S1-YXZE16C Hino 300 Manual

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1 MENU
FOREWORD
This supplement has been prepared to provide information covering general service repairs for HINO 300
Series which underwent changes in October, 2006.
WU300, 302, 340, 410, 412, 420, 422 series

Applicable models XZU303, 306, 307, 343, 347, 405, 407, 413, 415, 417, 423, 425, 427,
435, 437 series
Please note that the publications below have also been prepared as relevant service manuals for the
components and system in these vehicles.
Manual Name Pub. No.

Workshop Manual (Electric wiring diagram) S1-YXZE16C EWD
Chassis Workshop Manual S1-YXZE05A
W04D-J Engine Workshop Manual S5-YW04E06B
M153 Manual Transmission Workshop Manual S1-YXZE08A
M550 Manual Transmission Workshop Manual S1-YXZE09B
All information in this manual is based on the latest product information at the time of publication.
However, specifications and procedures are subject to change without notice.
If you find any failures in this manual, you are kindly requested to inform us by using the report form on the
next page.
Hino Motors, Ltd.
Copyright (C) 2007 HINO Motors, Ltd.

All rights reserved. This book may not be reproduced or copied, in whole or
in part, without the written permission of Hino Motors, Ltd.
First Printing: Sep. 2007
A122290E06
Repair Manual Quality Report
Att.) Service Manager, Your Distributor
Pub. No. Issue Date
Name of Dealer Name of Reporter
Subject
Problem Description
Correction Proposal
A114682E01
CAUTION
This contents does not include all the necessary items about repair and service. This manual is made for
the use of persons who have special techniques and certifications. If non-specialized or uncertified
technicians perform repairs or service only using this manual or without proper equipment or tools, this
may cause severe injury to you or other persons nearby and also cause damage to your customer's
vehicle.
In order to prevent dangerous operation and damage to your customer's vehicle, be sure to follow the
instructions shown below.
– This contents must be read thoroughly. It is especially important to have a good understanding of all
the contents written in the PRECAUTION of "INTRODUCTION" section.
– The service method written in this manual is very effective to perform repair and service. When
performing the operations following the procedures using this manual, be sure to use tools specified
and recommended. If using non-specified or tools other than recommended tools and service
methods, be sure to confirm the safety of the technicians and that there is no possibility of causing
personal injury or damage to the customer's vehicle before starting the operation.
– If part replacement is necessary, the part must be replaced with the same part number or equivalent
part. Do not replace it with an inferior quality part.
– It is important to note that this manual contains various "Cautions" and "Notices" that must be carefully
observed in order to reduce the risk of personal injury during service or repair, or reduce the possibility
that improper service or repair may damage the vehicle or render it unsafe. It is also important to
understand that these "Cautions" and "Notices" are not exaggerations and are possible hazardous
consequences that might result from failure to follow these instructions.
INTRODUCTION INTRODUCTION IN
PREPARATION PREPARATION PP
SERVICESPECIFCATION SERVICE SPECIFICATION SS
N04C-TR,TS,T ,TU,TV,TWENGINECONTROLSYSTEM N04C-TR,TS,TT,TU,TV,TW ENGINE CONTROL SYSTEM ES
W04D-J,TM,TNENGINECONTROLSYSTEM W04D-J,TM,TN ENGINE CONTROL SYSTEM ES
N04C-TR,TS,T ,TU,TV,TWENGINEMECHANICAL N04C-TR,TS,TT,TU,TV,TW ENGINE MECHANICAL EM
W04D-J,TM,TNENGINEMECHANICAL W04D-J,TM,TN ENGINE MECHANICAL EM
N04C-TR,TS,T ,TU,TV,TWFUEL N04C-TR,TS,TT,TU,TV,TW FUEL FU
W04D-J,TM,TNFUEL W04D-J,TM,TN FUEL FU
N04C-TR,TS,T EMIS IONCONTROL N04C-TR,TS,TT EMISSION CONTROL EC
N04C-TU,TVEMIS IONCONTROL N04C-TU,TV EMISSION CONTROL EC
N04C-TWEMIS IONCONTROL N04C-TW EMISSION CONTROL EC
W04D-J,TM,TNEMIS IONCONTROL W04D-J,TM,TN EMISSION CONTROL EC
N04C-TR,TS,T INTAKE N04C-TR,TS,TT INTAKE IT
N04C-TU,TV,TWINTAKE N04C-TU,TV,TW INTAKE IT
W04D-TM,TNINTAKE W04D-TM,TN INTAKE IT
N04C-TR,TS,T EXHAUST N04C-TR,TS,TT EXHAUST EX
N04C-TU,TVEXHAUST N04C-TU,TV EXHAUST EX
N04C-TWEXHAUST N04C-TW EXHAUST EX
W04D-TMEXHAUST W04D-TM EXHAUST EX
W04D-TNEXHAUST W04D-TN EXHAUST EX
N04C-TR,TS,T ,TU,TV,TWCO LING N04C-TR,TS,TT,TU,TV,TW COOLING CO
W04D-TM,TNCO LING W04D-TM,TN COOLING CO
N04C-TR,TS,T ,TU,TV,TWLUBRICATION N04C-TR,TS,TT,TU,TV,TW LUBRICATION LU
W04D-TM,TNLUBRICATION W04D-TM,TN LUBRICATION LU
N04C-TR,TS,T ,TU,TV,TWSTARTING N04C-TR,TS,TT,TU,TV,TW STARTING ST
W04D-TM,TNSTARTING W04D-TM,TN STARTING ST
N04C-TR,TS,T ,TU,TV,TWCHARGING N04C-TR,TS,TT,TU,TV,TW CHARGING CH
W04D-TM,TNCHARGING W04D-TM,TN CHARGING CH
CLUTCH CLUTCH CL
A860EAUTOMATICTRANSMIS ION A860E AUTOMATIC TRANSMISSION AT
M153MANUALTRANSMIS ION M153 MANUAL TRANSMISSION MT
M5 0MANUALTRANSMIS ION M550 MANUAL TRANSMISSION MT
MY 5AMANUALTRANSMIS ION MYY5A MANUAL TRANSMISSION MT
MY 6SMANUALTRANSMIS ION MYY6S MANUAL TRANSMISSION MT
PROPEL ERSHAFT PROPELLER SHAFT PR
FRONTSUSPENSION(IFS) FRONT SUSPENSION (IFS) FS
FRONTSUSPENSION(LEAFSPRING) FRONT SUSPENSION (LEAF SPRING) FS
DIF ERENTIAL DIFFERENTIAL DF
AXLE AXLE AH
TIREANDWHE L TIRE AND WHEEL TW
BRAKECONTROL BRAKE CONTROL BC
BRAKE BRAKE BR
PARKINGBRAKE PARKING BRAKE PB
POWERSTE RING POWER STEERING PS
AIRCONDITONI G AIR CONDITIONING AC
METER METER ME
SUP LEMENTALRESTRAINTSYSTEM SUPPLEMENTAL RESTRAINT SYSTEM RS
AUDIO/VISUAL AUDIO / VISUAL AV
POWERSOURCE/WIRING POWER SOURCE / WIRING PW
HORN HORN HO
INSTRUMENTPANEL/METER INSTRUMENT PANEL / METER ID
ENGINEHO D/DO R ENGINE HOOD / DOOR ED
EXTERIOR EXTERIOR ET
POWERTAKE-OF POWER TAKE-OFF PT
BODY BODY BO
INTRODUCTION
INTRODUCTION
HOW TO USE THIS MANUAL IN

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN-1
IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION AND SERIAL NUMBERS. . . . . . . . . . . . . . IN-4
REPAIR INSTRUCTION
PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN-6
VEHICLE LIFT AND SUPPORT LOCATIONS . . . . . . . . . . . . . . . . . . . . IN-15
DIAGNOSIS USING THE PC (PERSONAL COMPUTER)
DIAGNOSIS TOOL WITH INTERFACE
HOW TO PROCEED WITH TROUBLESHOOTING
ELECTRONIC CIRCUIT INSPECTION PROCEDURE . . . . . . . . . . . . . . IN-25
TERMS
ABBREVIATIONS USED IN MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . IN-31
INTRODUCTION – HOW TO USE THIS MANUAL IN–1
HOW TO USE THIS MANUAL

GENERAL INFORMATION
1. GENERAL DESCRIPTION
(a) Repair operations can be separated mainly in the
following 3 processes: IN
(1) Diagnosis
(2) Removing/Installing, Replacing, Disassembling/
Reassembling, Checking and Adjusting
(3) Final Inspection
(b) The following procedures are omitted from this
manual. However, these procedures must be
performed.
(1) Use a jack or lift to perform operations
(2) Clean all removed parts
(3) Perform a visual check
2. INDEX
(a) An alphabetical INDEX section is provided at the
end of the manual as a reference to help you find
the item to be repaired.
3. PREPARATION
(a) Use of Special Service Tools (SST) and Special
Service Materials (SSM) may be required,
depending on the repair procedure. Be sure to use
SST and SSM when they are required and follow
the working procedure properly. A list of SST and
SSM is in the "Preparation" section of this manual.
4. REPAIR PROCEDURES
(a) A component illustration is placed under the title
where necessary.
IN–2 INTRODUCTION – HOW TO USE THIS MANUAL
(b) Non-reusable parts, grease application areas,

precoated parts and torque specifications are noted
in the component illustrations.
Following illustration is example
Example: FILTER CAP CLEVIS PIN

IN
FLOAT RESERVOIR TANK CLIP
GASKET
GROMMET WASHER
SLOTTED
SPRING PIN 12 (120, 9) CLEVIS
LOCK NUT
15 (155, 11)
PUSH ROD BOOT
CYLINDER
PISTON
SNAP RING
N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part

N017080E13
(c) Torque specifications, grease application areas and

non-reusable parts are emphasized in the
procedures.
HINT:
There are cases where such information can only
be explained by using an illustration. In these cases,
torque, oil and other information are described in the
illustration.
(d) Only items with key points are described in the text.
What to do and other details are explained using
illustrations next to the text. Both the text and
illustrations are accompanied by standard values
and notices.
Illustration What to do and where to do
Task heading What work will be performed
How to perform the task
Explanation text Also has information such as specifications and warnings, which are
written in boldface text
(e) Illustrations of similar vehicle models are sometimes

used. In these cases, minor details may be different
from the actual vehicle.
(f) Procedures are presented in a step-by-step format.
5. SERVICE SPECIFICATIONS
(a) SPECIFICATIONS are presented in boldface text
throughout the manual. The specifications are also
found in the "Service Specifications" section for
reference.
INTRODUCTION – HOW TO USE THIS MANUAL IN–3
6. TERMS DEFINITION
CAUTION Possibility of injury to you or other people.
NOTICE Possibility of damage to components being repaired.
HINT Provides additional information to help you perform repairs.
7. INTERNATIONAL SYSTEM OF UNITS

(a) The units used in this manual comply with the IN
International System of Units (SI UNIT) standard.
Units from the metric system and the English
system are also provided.
Example is as follow.
Torque: 30 N*m (310 kgf*cm, 22 ft.*lbf)
IN–4 INTRODUCTION – IDENTIFICATION INFORMATION
IDENTIFICATION INFORMATION
B
C VEHICLE IDENTIFICATION AND
SERIAL NUMBERS
IN 1. VEHICLE IDENTIFICATION NUMBER
(a) The vehicle identification number is stamped on the
A right frame, as shown in the illustration. This number
D101729E01
has also been stamped on the manufacture's plate.
A:
Vehicle Identification Number
B:
Manufacturer's Plate
C:
Manufacturer's Plate (Regular cab LHD)
2. ENGINE SERIAL NUMBER
A (a) The engine serial number is stamped on the
cylinder block, as shown in the illustration.
A:
W04D-J, W04D-TM, W04D-TN, N04C-TR, TS,
TT, TU, TV, TW
D101636E01
INTRODUCTION – IDENTIFICATION INFORMATION IN–5
3. TRANSMISSION SERIAL NUMBER

A (a) The transmission serial number is stamped on the
transmission, as shown in the illustration.
A:
M153
B:
M550 IN
C:
MYY5A, MYY6S
D:
A860E
D101732E01
IN–6 INTRODUCTION – REPAIR INSTRUCTION
REPAIR INSTRUCTION
PRECAUTION
1. BASIC REPAIR HINT
(a) HINTS ON OPERATIONS
IN
3
6
4
D020200E01
• Always wear a clean uniform.

1 Attire
• Hat and safety shoes must be worn.
2 Prepare a grille cover, fender cover, seat cover and floor mat before starting the
Vehicle protection
operation.
• When working with 2 or more persons, be sure to check safety for one another.
• When working with the engine running, make sure to provide ventilation for exhaust
fumes in the workshop.
• If working on high temperature, high pressure, rotating, moving, or vibrating parts,
3 Safe operation wear appropriate safety equipment and take extra care not to injure yourself or
others.
• When jacking up the vehicle, be sure to support the specified location with a safety
stand.
• When lifting up the vehicle, use appropriate safety equipment.
Preparation of tools and
4 Before starting operation, prepare a tool stand, SST, gauge, oil and parts for replacement.
measuring gauge
• Diagnose with a thorough understanding of proper procedures and of the reported
problem.
• Before removing the parts, check the general condition of the assembly and for
deformation and damage.
Removal and installation,
• When the assembly is complicated, take notes. For example, note the total number of
5 disassembly and assembly
electrical connections, bolts, or hoses removed. Add matchmarks to insure
operations
reassembly of components in the original positions. Temporarily mark hoses and their
fittings if needed.
• Clean and wash the removed parts if necessary and assemble them after a thorough
check.
• Place the removed parts in a separate box to avoid mixing them up with the new parts
or contaminating the new parts.
6 Removed parts • For non-reusable parts such as gaskets, O-rings, and self-locking nuts, replace them
with new ones as instructed in this manual.
• Retain the removed parts for customer inspection, if requested.
INTRODUCTION – REPAIR INSTRUCTION IN–7
(b) JACKING UP AND SUPPORTING VEHICLE

(1) Care must be taken when jacking up and
supporting the vehicle. Be sure to lift and
support the vehicle at the proper locations.
(c) PRECOATED PARTS
(1) Precoated parts are bolts and nuts that are
coated with a seal lock adhesive at the factory. IN
(2) If a precoated part is retightened, loosened or
moved in any way, it must be recoated with the
specified adhesive.
(3) When reusing a precoated part, clean off the old
adhesive and dry the part with compressed air.
Seal Lock Adhesive
Then apply new seal lock adhesive appropriate
Z011554E03 to that part.
(4) Some seal lock agents harden slowly. You may
have to wait for the seal lock adhesive to
harden.
(d) GASKETS
(1) When necessary, use a sealer on gaskets to
prevent leaks.
(e) BOLTS, NUTS AND SCREWS
(1) Carefully follow all the specifications for
tightening torques. Always use a torque wrench.
(f) FUSES
INCORRECT CORRECT (1) When inspecting a fuse, check that the wire of
the fuse is not broken.
(2) When replacing fuses, be sure that the new fuse
has the correct amperage rating. Do not exceed
the rating or use one with a lower rating.
V035007E01
Illustration Symbol Part Name Abbreviation
FUSE FUSE
Illustration Symbol Part Name Abbreviation
MEDIUM CURRENT FUSE M-FUSE

IN
HIGH CURRENT FUSE H-FUSE
FUSIBLE LINK FL
CIRCUIT BREAKER CB
(g) CLIPS
(1) The removal and installation methods of typical
clips used for vehicle body parts are shown in
the table below.
HINT:
If clips are damaged during a procedure, always
replace the damaged clip with a new clip.
Shape (Example) Illustration Procedures
1. Remove clips with clip remover or pliers. IN
1. Remove the clips with clip remover or

screwdriver.
1. Remove clips with wide scraper to

prevent panel damage.
1. Remove clips by pushing center pin

through and prying out the shell.
IN 1. Remove clips by unscrewing the center

pin and prying out the shell.
1. Remove clips by prying out the pin and

then prying out the shell.
(h) CLAWS
(1) The removal and installation methods of typical
claws used for vehicle body parts are shown in
the table below.
HINT:
If claws are damaged during a procedure,
always replace the damaged claws with new
caps or covers.
1. Using a screwdriver, detach the claws

and remove the cap or covers.


IN
(i) REMOVAL AND INSTALLATION OF VACUUM

HOSES
INCORRECT CORRECT (1) To disconnect a vacuum hose, pull and twist
from the end of the hose. Do not pull from the
middle of the hose as this may cause damage.
D031750E01
(2) When disconnecting vacuum hoses, use tags to

identify where they should be reconnected.
(3) After completing any hose related repairs,
double check that the vacuum hoses are
properly connected. The label under the hood
shows the proper layout.
(4) When using a vacuum gauge, never force the
hose onto a connector that is too large. If a hose
has been stretched, it may leak air. Use a step-
D025064E01 down adapter if necessary.
(j) TORQUE WHEN USING TORQUE WRENCH

L1 L2 WITH EXTENSION TOOL
D002612E02
(1) Use the formula below to calculate special

L1 L2 torque values for situations where SST or an
extension tool is combined with the torque
wrench.
Formula:
T' = L2/(L1 + L2) * T
IN Reading of torque wrench {N*m
T'
(kgf*cm, ft.*lbf)}
T Torque {N*m (kgf*cm, ft.*lbf)}
D001201E01
Length of SST or extension tool {cm
L1
(in.)}
L2 Length of torque wrench {cm (in.)}
NOTICE:
If an extension tool or SST is combined with
a torque wrench and the wrench is used to
tighten to a torque specification in this
manual, the actual torque will be excessive
and parts will be damaged.
2. ELECTRONIC CONTROL
Negative (-) (a) REMOVAL AND INSTALLATION OF BATTERY
Cable TERMINAL
NOTICE:
Certain systems need to be initialized after
Negative (-) disconnecting and reconnecting the cable from
Battery Terminal the negative (-) battery terminal.
(1) Before performing electronic work, disconnect
the cable from the negative (-) battery terminal to
D033608E02 prevent component and wire damage caused by
accidental short circuits.
(2) When disconnecting the cable, turn the engine
switch and headlight dimmer switch OFF and
loosen the cable nut completely. Perform these
operations without twisting or prying the cable.
Then disconnect the cable.
(3) Clock settings, radio settings, audio system
memory, DTCs and other data are erased when
the cable is disconnected from the negative (-)
battery terminal. Write down any necessary data
before disconnecting the cable.
(b) HANDLING OF ELECTRONIC PARTS
(1) Do not open the cover or case of the ECU
unless absolutely necessary. If the IC terminals
are touched, the IC may be rendered inoperative
by static electricity.
(2) Do not pull the wires when disconnecting
INCORRECT
electronic connectors. Pull the connector itself.
(3) Be careful not to drop electronic components,
such as sensors or relays. If they are dropped
D031751E01 on a hard surface, they should be replaced.
(4) When cleaning the engine with steam, protect
the electronic components, air filter and
emission-related components from water.
(5) Never use an impact wrench to remove or install

temperature switches or temperature sensors.
(6) When measuring the resistance of a wire
connector, insert the tester probe carefully to
prevent terminals from bending.
3. REMOVAL AND INSTALLATION OF FUEL CONTROL
PARTS IN
(a) PLACE FOR REMOVING AND INSTALLING FUEL
SYSTEM PARTS
(1) Work in a location with good air ventilation that
does not have welders, grinders, drills, electric
motors, stoves, or any other ignition sources.
(2) Never work in a pit or near a pit as vaporized
fuel will collect in those places.
(b) REMOVING AND INSTALLING FUEL SYSTEM
PARTS
(1) Prepare a fire extinguisher before starting the
operation.
(2) To prevent static electricity, install a ground wire
to the fuel changer, vehicle and fuel tank, and do
not spray the surrounding area with water. Be
careful when performing work in this area, as the
work surface will become slippery. Do not clean
up gasoline spills with water, as this may cause
the gasoline to spread, and possibly create a fire
hazard.
(3) Avoid using electric motors, working lights and
other electric equipment that can cause sparks
or high temperatures.
(4) Avoid using iron hammers as they may create
sparks.
(5) Dispose of fuel-contaminated cloth separately
using a fire resistant container.
4. REMOVAL AND INSTALLATION OF ENGINE INTAKE
PARTS
(a) If any metal particles enter inlet system parts, this
may damage the engine.
(b) When removing and installing inlet system parts,
cover the openings of the removed parts and engine
openings. Use gummed tape or other suitable
materials.
(c) When installing inlet system parts, check that no
D001563E01 metal particles have entered the engine or the
installed parts.
5. HANDLING OF HOSE CLAMPS

Spring Type Clamp
(a) Before removing the hose, check the clamp position
so that it can be reinstalled in the same position.
(b) Replace any deformed or dented clamps with new
ones.
(c) When reusing a hose, attach the clamp on the
IN clamp track portion of the hose.
Clamp Track (d) For a spring type clamp, you may want to spread
the tabs slightly after installation by pushing in the
B107182E01 direction of the arrows as shown in the illustration.
6. FOR VEHICLES EQUIPPED WITH MOBILE

COMMUNICATION SYSTEMS
(a) Install the antenna far away from the ECU and
sensors of the vehicle electronic systems as
possible.
(b) Install an antenna feeder at least 20 cm (7.87 in.)
away from the ECU and sensors of the vehicle
electronic systems. For details about ECU and
sensors locations, refer to the section on the
D020199E01 applicable components.
(c) Keep the antenna and feeder separate from other
wirings as much as possible. This will prevent
signals from the communication equipment from
affecting vehicle equipment and vice-versa.
(d) Check that the antenna and feeder are correctly
adjusted.
(e) Do not install any high-powered mobile
communication system.
7. FOR VEHICLES EQUIPPED WITH CATALYTIC
CONVERTER
CAUTION:
If a large amount of unburned gasoline or gasoline
vapors flow into the converter, it may cause
overheating and create a fire hazard. To prevent this,
observe the following precautions.
(a) Use only unleaded gasoline.
(b) Avoid idling the engine for more than 20 minutes.
(c) Avoid performing unnecessary spark jump tests.
(1) Perform a spark jump test only when absolutely
necessary. Perform this test as rapidly as
possible.
(2) While testing, never race the engine.
(d) Avoid a prolonged engine compression
measurement. Engine compression measurements
must be performed as rapidly as possible.
(e) Do not run the engine when the fuel tank is nearly
empty. This may cause the engine to misfire and
create an extra load on the converter.
VEHICLE LIFT AND SUPPORT

LOCATIONS
1. NOTICE ABOUT VEHICLE CONDITION WHEN
JACKING UP THE VEHICLE
(a) As a rule, vehicle must be unloaded condition and
never jack up or lift up the vehicle with things of IN
heavy weight.
(b) If removing any things of heavy weight like the
engine and transmission, the center of gravity of the
vehicle moves. Therefore place a balance weight so
as to keep it from rolling, or hole the jacking support
location using the mission hack.
2. NOTICE FOR USING 4 POST LIFT
(a) Follow the instruction manual for a safety operation.
(b) Do not damage tires or wheels with a free wheel
beam.
(c) Using a wheel stopper, fix the vehicle.
3. NOTICE FOR USING JACK AND SAFETY STAND
(a) Work in the flat place using a wheel stopper all the
time.
(b) Support the specified location a jack and safety
stand accurately.
(c) Do not work or leave the vehicle with a support only
by a jack. Be sure to support the vehicle together
with a safety stand.
(d) Be careful and accurate in jacking up and down the
vehicle.
FRONT (IFS) REAR
IN
FRONT (RFS)
SUPPORT POSITION
JACK POSITION
SCREW JACK POSITION
Front (Auxiliary menber)
Rear (U-bolt seat)
D101692E01
INTRODUCTION – DIAGNOSIS USING THE PC (PERSONAL COMPUTER) DIAGNOSIS
TOOL WITH INTERFACE IN–17
DIAGNOSIS USING THE PC (PERSONAL COMPUTER)

INTRODUCTION
DIAGNOSIS TOOL WITH INTERFACE

GENERAL INFORMATION
1. DIAGNOSIS TOOL IN
• Trouble diagnosis can be performed using the PC
diagnosis tool. By connection to the diagnosis
connector, the trouble location is indicated.
SST:
Communication interface assembly (09993-E090)
Cable communication (09042-1220)
HINO-DX SAPH04Z000000069
Diagnosis software: HINO Diagnostic Explorer (DX)
Reprogramming software: HINO Reprog Manager
NOTICE:
Only ECU reprogramming can be performed by
authorized HINO dealer.
2. CONNECT THE PC DIAGNOSIS TOOL
(a) Turn the starter switch toi the “LOCK” position.
(b) Connect the diagnosis cable between diagnosis
connector and interface.
(c) Connect the interface to the PC.
(d) Turn the starter switch to the “ON” position.
(e) The opening menu will be displayed on the PC
screen.
DLC3
(MTM MODEL)
(ATM MODEL)
Hino-Bowie
Intelligent tester
HINO-DX A154337E01
INTRODUCTION
IN–18 INTRODUCTION – HOW TO PROCEED WITH TROUBLESHOOTING
HOW TO PROCEED WITH

TROUBLESHOOTING
GENERAL INFORMATION
IN 1. OPERATION FLOW
HINT:
Perform troubleshooting in accordance with the
procedures below. The following is an outline of basic
troubleshooting procedures. Confirm the troubleshooting
procedures for the circuit you are working on before
beginning troubleshooting.
1 VEHICLE BROUGHT TO WORKSHOP
NEXT
2 INSPECT BATTERY VOLTAGE
Standard voltage:
11 to 14 V
If the voltage is below 11 V, recharge or replace the
battery before proceeding.
NEXT
3 SYMPTOM CONFIRMATION AND DTC (AND FREEZE FRAME DATA) CHECK
(a) Visually check the wire harnesses, connectors and fuses

for open and short circuits.
(b) Warm up the engine to the normal operating
temperature.
(c) Confirm the problem symptoms and conditions, and
check for DTCs
Result
Result Proceed to
DTC is output A
DTC is not output B
B Go to step 6
4 DTC CHART
(a) Check the results obtained in step 3. Then find the

output DTC in the DTC chart. Look at the "Trouble Area"
column for a list of potentially malfunctioning circuits and
/ or parts.
INTRODUCTION – HOW TO PROCEED WITH TROUBLESHOOTING IN–19
NEXT Go to step 7
5 PROBLEM SYMPTOMS CHART
(a) Check the results obtained in step 3. Then find the

problem symptoms in the problem symptoms table. Look
IN
at the "Suspected Area" column for a list of potentially
malfunctioning circuits and / or parts.
NEXT
6 CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Confirm the malfunctioning circuit or part.

NEXT
7 ADJUST, REPAIR OR REPLACE
(a) Adjust, repair or replace the malfunctioning circuit or

parts.
NEXT
8 CONFIRMATION TEST
(a) After the adjustment, repairs or replacement, confirm

that the malfunction no longer exists. If the malfunction
does not reoccur, perform a confirmation test under the
same conditions and in the same environment as when
the malfunction occurred the first time.
NEXT
END
2. CUSTOMER PROBLEM ANALYSIS
HINT:
• In troubleshooting, confirm that the problem
symptoms have been accurately identified.
Preconceptions should be discarded in order to make
an accurate judgment. To clearly understand what the
problem symptoms are, it is extremely important to
ask the customer about the problem and the
conditions at the time the malfunction occurred.
• Gather as much information as possible for reference.
Past problems that seem unrelated may also help in
some cases.
• The following 5 items are important points in the
problem analysis:
What Vehicle model, system name

When Date, time, occurrence frequency
Where Road conditions
Under what conditions? Running conditions, driving conditions, weather conditions
How did it happen? Problem symptoms
IN 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC

TROUBLE CODE
HINT:
The diagnostic system in the HINO 300 Series has
various functions.
• The first function is the Diagnostic Trouble Code
(DTC) check. A DTC is a code stored in the ECU
memory whenever a malfunction in the signal circuits
to the ECU occurs. In a DTC check, a previous
malfunction's DTC can be checked by a technician
during troubleshooting.
• Another function is the Input Signal Check, which
checks if the signals from various switches are sent to
the ECU correctly. By using these functions, the
problem areas can be narrowed down and
troubleshooting is more effective. Diagnostic
functions are incorporated in the following system in
the HINO 300 Series.
Sensor Check/Test
(EXAMPLE) DTC Check (Normal DTC Check (Check
Mode (Input Signal Data List Active Test
System Mode) Mode)
Check)
N04C-TT ECD
{ { - { {
SYSTEM
• In the DTC check, it is very important to determine

whether the problem indicated by the DTC is either: 1)
still occurring, or 2) occurred in the past but has since
returned to normal. In addition, the DTC should be
compared to the problem symptom to see if they are
related. For this reason, DTCs should be checked
before and after confirmation of symptoms (i.e.,
whether or not problem symptoms exist) to determine
current system conditions, as shown in the flowchart
below.
• Never skip the DTC check. Failing to check DTCs
may, depending on the case, result in unnecessary
troubleshooting for systems operating normally or
lead to repairs not related to the problem. Follow the
procedures listed in the flowchart in the correct order.
• The following flowchart show how to proceed with
troubleshooting using the DTC check. Directions from
the flowchart will indicate how to proceed either to
DTC troubleshooting or to the troubleshooting of each
problem symptom.
1 DTC CHECK
NEXT
IN
2 MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR THE MEMORY
NEXT
3 SYMPTOM CONFIRMATION
Result:
Result Proceed to
No symptoms exist A
Symptoms exist B
a Go to step 5
4 SIMULATION TEST USING THE SYMPTOM SIMULATION METHODS
NEXT
5 DTC CHECK
Result:
Result Proceed to
DTC is not output A
DTC is output B
B Troubleshooting of problem indicated by

DTC
6 SYMPTOM CONFIRMATION
Result:
Result Proceed to
Symptoms exist A
No symptoms exist B
If a DTC was displayed in the initial DTC check, the problem

may have occurred in a wire harness or connector in that
circuit in the past. Check the wire harness and connectors
(See page IN-25).
B System normal
TROUBLESHOOTING OF EACH PROBLEM SYMPTOM

IN
The problem is still occurring in a place other than the
diagnostic circuit (the DTC displayed first is either for a past
problem or a secondary problem).
4. SYMPTOM SIMULATION
HINT:
The most difficult case in troubleshooting is when no
problem symptoms occur. In such a case, a thorough
problem analysis must be carried out. A simulation of the
same or similar conditions and environment in which the
problem occurred in the customer's vehicle should be
carried out. No matter how much skill or experience a
technician has, troubleshooting without confirming the
problem symptoms will lead to important repairs being
overlooked and mistakes or delays.
For example:
With a problem that only occurs when the engine is
cold or as a result of vibration caused by the road
during driving, the problem can never be determined if
the symptoms are being checked on a stationary
vehicle or a vehicle with a warmed-up engine.
Vibration, heat or water penetration (moisture) is
difficult to reproduce. The symptom simulation tests
below are effective substitutes for the conditions and
can be applied on a stationary vehicle. Important
points in the symptom simulation test: In the
symptom simulation test, the problem symptoms as
well as the problem area or parts must be confirmed.
First, narrow down the possible problem circuits
according to the symptoms. Then, connect the tester
and carry out the symptom simulation test, judging
whether the circuit being tested is defective or normal.
Also, confirm the problem symptoms at the same
time. Refer to the problem symptoms table for each
system to narrow down the possible causes.
(a) VIBRATION METHOD: When malfunction seems to

Vibrate Slightly occur as a result of vibration.
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of
the sensor suspected to be the cause of the
problem, and check whether or not the
malfunction occurs. IN
NOTICE:
Applying strong vibration to relays may open
relays
(2) CONNECTORS
Slightly shake the connector vertically and
horizontally.
Shake Slightly (3) WIRE HARNESS
Slightly shake the wire harness vertically and
horizontally.
HINT:
The connector joint and fulcrum of the vibration
Vibrate are the major areas that should be checked
Slightly thoroughly.
B071602E01 (b) HEAT METHOD: When a malfunction seems to
occur when the area in question is heated.
(1) Heat the component that is the possible cause of
the malfunction with a hair dryer or similar
device. Check if the malfunction occurs.
NOTICE:
• Do not heat to more than 60°C (140°F).
Exceeding this temperature may damage
components.
• Do not apply heat directly to the parts in
the ECU.
(c) WATER SPRINKLING METHOD: When a
malfunction seems to occur on a rainy day or in
high-humidity.
(1) Sprinkle water onto the vehicle and check if the
malfunction occurs.
NOTICE:
• Never sprinkle water directly into the
engine compartment. Indirectly change
the temperature and humidity by spraying
D020197J01 water onto the front of the radiator.
• Never apply water directly onto the
electronic components.
HINT:
If the vehicle has or had a water leakage
problem, the leakage may have damaged the
ECU or connections. Look for evidence of
corrosion or short circuits. Proceed with caution
during water tests.
(d) HIGH ELECTRICAL LOAD METHOD: When a

ON malfunction seems to occur when electrical load is
excessive.
(1) Turn on the heater blower, headlight, rear
window defogger and all other electrical loads.
Check if the malfunction reoccurs.
IN 5. DIAGNOSTIC TROUBLE CODE CHART
Look for output Diagnostic Trouble Codes (DTCs) (from
the DTC checks) in the appropriate section's Diagnostic
B002389E01 Trouble Code Chart. Use the chart to determine the
trouble area and the proper inspection procedure. A
description of each of the chart's columns are below.
Item Description
DTC No. Indicates the diagnostic trouble code
Detection Item Indicates the system or details of the problem
Trouble Area Indicates the suspect areas of the problem
Indicates the page where the inspection procedures for each circuit is
See Page
to be found, or gives instruction for checking and repairs.
6. PROBLEM SYMPTOMS TABLE

When a "Normal" code is output during a DTC check but
the problem is still occurring, use the Problem Symptoms
Table. The suspected areas (circuits or parts) for each
problem symptoms are in the table. The suspected areas
are listed in order of probability. A description of each of
the chart's columns are below.
HINT:
In some cases, the problem is not detected by the
diagnostic system even though a problem symptom is
present. It is possible that the problem is occurring
outside the detection range of the diagnostic system, or
that the problem is occurring in a completely different
system.
Item Description
Problem Symptom -
Circuit Inspection, Inspection Order Indicates the order in which the circuits need to be checked
Circuit or Part Name Indicates the circuit or part which needs to be checked
See Page Indicates the page where the flowchart for each circuit is located
7. CIRCUIT INSPECTION
A description of the main areas of each circuit inspection
is below.
Item Description
The major role, operation of the circuit and its component parts are
Circuit Description
explained.
Indicates the diagnostic trouble codes, diagnostic trouble code
Diagnostic Trouble Code No. and Detection item
settings and suspected areas for a problem
Item Description
This shows a wiring diagram of the circuit. Use this diagram together
with ELECTRICAL WIRING DIAGRAM to thoroughly understand the
circuit. Wire colors are indicated by an alphabetical code.
B = Black
L = Blue
R = Red
BR = Brown IN
LG = Light Green
V = Violet
Wiring diagram
G = Green
O = Orange
W = White
GR = Gray
P = Pink
Y = Yellow
SB = Sky Blue
The first letter indicates the basic wire color and the second letter
indicates the color of the stripe.
Inspection Procedures Use the inspection procedures to determine if the circuit is normal or
abnormal. If abnormal, use the inspection procedures to determine
whether the problem is located in the sensors, actuators, wire
harnesses or ECU.
Connector being checked is connected. Connections of tester are
indicated by (+) or (-) after the terminal name. Connector being
Indicates the condition of the connector of the ECU during the check checked is disconnected. The inspections between a connector and
body ground, information about the body ground is not shown in the
illustration.
ELECTRONIC CIRCUIT INSPECTION

PROCEDURE
1. BASIC INSPECTION
(a) WHEN MEASURING RESISTANCE OF
ELECTRONIC PARTS
(1) Unless otherwise stated, all resistance
measurements should be made at an ambient
temperature of 20°C (68°F). Resistance
measurements may be inaccurate if measured
at high temperatures, i.e. immediately after the
vehicle has been running. Measurements should
be made after the engine has cooled down.
(b) HANDLING CONNECTORS

(1) When disconnecting a connector, first squeeze
the mating halves tightly together to release the
lock, and then press the lock claw and separate
the connector.
(2) When disconnecting a connector, do not pull on
IN the harnesses. Grasp the connector directly and
separate it.
(3) Before connecting a connector, check that there
are no deformed, damaged, loose or missing
terminals.
INCORRECT (4) When connecting a connector, press firmly until
it locks with a "click" sound.
INCORRECT (5) If checking a connector with a electrical tester,
check the connector from the backside (harness
side) using a mini test lead.
NOTICE:
• As a waterproof connector cannot be
CORRECT checked from the backside, check it by
connecting a sub-harness.
D032092E01 • Do not damage the terminals by moving
the inserted tester needle.
(c) CHECKING CONNECTORS
Looseness of Core Wire (1) Checking when a connector is disconnected:
Crimping
Squeeze the connector together to confirm that
they are fully connected and locked.
(2) Checking when a connector is disconnected:
Check by pulling the wire harness lightly from
Terminal the backside of the connector. Look for
Deformation unlatched terminals, missing terminals, loose
Pull Lightly crimps or broken conductor wires. Check
D025087E03 visually for corrosion, metallic or foreign matter
and water, and bent, rusted, overheated,
contaminated, or deformed terminals.
NOTICE:
When testing a gold-plated female terminal,
always use a gold-plated male terminal.
(3) Checking the contact pressure of the terminal:
Prepare a spare male terminal. Insert it into a
female terminal, and check for ample tension
when inserting and after full engagement.
NOTICE:
When testing a gold-plated female terminal,
always use a gold-plated male terminal.
D025088E02
(d) REPAIR METHOD OF CONNECTOR TERMINAL

INCORRECT (1) If there is any foreign matter on the terminal,
CORRECT
clean the contact point using an air gun or cloth.
Never rub the contact point using sandpaper as
the plating may come off.
(2) If there is abnormal contact pressure, replace
the female terminal. If the male terminal is gold- IN
plated (gold color), use a gold-plated female
terminal; if it is silver-plated (silver color), use a
D032093E01 silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals
should be replaced. If the terminal does not lock
into the housing, the housing may have to be
replaced.
(e) HANDLING OF WIRE HARNESS
INCORRECT INCORRECT
(1) If removing a wire harness, check the wiring and
clamping before proceeding so that it can be
restored in the same way.
(2) Never twist, pull or slacken the wire harness
more than necessary.
(3) The wire harness should never come into
contact with a high temperature part, or rotating,
moving, vibrating or sharp-edged parts. Avoid
INCORRECT
D032094E01 contact with panel edges, screw tips and other
sharp items.
(4) When installing parts, never pinch the wire
harness.
(5) Never cut or break the cover of the wire harness.
If it is cut or broken, replace it or repair it with
vinyl tape.
2. CHECK FOR OPEN CIRCUIT
Fig. 1 ECU (a) For an open circuit in the wire harness in Fig. 1,
C OPEN B A check the resistance or voltage, as described below.
1 1 1 1
2 2 2 2
SENSOR
Z017004E02
(b) Check the resistance.

Fig. 2
(1) Disconnect connectors A and C and measure
ECU the resistance between them.
Standard resistance (Fig. 2)
Tester Connection Specified Condition
1 1 1
Connector A terminal 1 - Connector 10 kΩ or higher
2 2 2 C terminal 1
A Below 1 Ω
SENSOR C B Connector A terminal 2 - Connector
C terminal 2
Z017005E02
HINT:
Measure the resistance while lightly shaking the
wire harness vertically and horizontally. If the
results match the examples above, an open
circuit exists between terminal 1 of connector A
and terminal 1 of connector C.
IN (2) Disconnect connector B and measure the
Fig. 3 resistance between the connectors.
ECU Standard resistance (Fig. 3)
SENSOR Tester Connection Specified Condition
Connector A terminal 1 - Connector Below 1 Ω
B1 terminal 1
Connector B2 terminal 1- Connector 10 kΩ or higher
1 1 1 1 C terminal 1
2 2 2 2
C B2 B1 A
B004722E03
If the results match the examples above, an
open circuit exists between terminal 1 of
connector B2 and terminal 1 of connector C.
(c) Check the voltage.
Fig. 4
(1) In a circuit in which voltage is applied to the ECU
connector terminal, an open circuit can be
ECU
checked by conducting a voltage check. With
5V
SENSOR 0 V each connector still connected, measure the
5V 1 voltage between the body ground and these
1 1
2 2 2 2 terminals (in this order): 1) terminal 1 of
connector A, 2) terminal 1 of connector B, and 3)
C B A terminal 1 of connector C.
Z017007E02 Standard voltage (Fig. 4)
Connector A terminal 1 - Body 5V
ground
Connector B terminal 1 - Body 5V
ground
Connector C terminal 1 - Body Below 1 V
ground
If the results match the examples above, an

open circuit exists in the wire harness between
terminal 1 of connector B and terminal 1 of
connector C.
3. CHECK FOR SHORT CIRCUIT
Fig. 5 ECU
SHORT (a) If the wire harness is ground shorted (Fig. 5), locate
the section by conducting a resistance check with
1 1 1 the body ground (below).
2 2 2
C B A
Z017008E02
(b) Check the resistance with the body ground.

Fig. 6
(1) Disconnect connectors A and C and measure
the resistance.
ECU Standard resistance (Fig. 6)
SENSOR
1 1 1 Connector A terminal 1 - Body Below 1 Ω
2 2 2 ground IN
C A Connector A terminal 2 - Body 10 kΩ or higher
B
ground
Z017009E02
HINT:
Measure the resistance while lightly shaking the
wire harness vertically and horizontally. If your
results match the examples above, an short
circuit exists between terminal 1 of connector A
(2) Disconnect connector B and measure the
Fig. 7
resistance.
Standard resistance (Fig. 7)
ECU Tester Connection Specified Condition
SENSOR Connector A terminal 1 - Body 10 kΩ or higher
ground
1 1 1 1
Connector B2 terminal 1- Body Below 1 Ω
2 2 2 2 ground
C B2 B1 A
Z017808E02
If the results match the examples above, a short
circuit exists between terminal 1 of connector B2
4. CHECK AND REPLACE ECU
NOTICE:
• The connector should not be disconnected from
the ECU. Perform the inspection from the
backside of the connector on the wire harness
side.
• When no measuring condition is specified,
perform the inspection with the engine stopped
and the ignition switch ON.
• Check that the connectors are fully seated. Check
for loose, corroded or broken wires.
(a) First, check the ECU ground circuit. If it is faulty,
Example:
repair it. If it is normal, the ECU could be faulty.
Temporarily replace the ECU with a normally
Ground functioning one and check if the symptoms occur. If
the trouble symptoms disappear, replace the
original ECU.
(1) Measure the resistance between the ECU
ground terminal and body ground.
Standard resistance:
IN00383E02 Below 1 Ω
(2) Disconnect the ECU connector. Check the

ECU Side
ground terminal on the ECU side and wire
harness side for bending, corrosion or foreign
matter. Lastly, check the contact pressure of the
Wire Harness Side Ground female terminals.
W/H Side
IN Ground
IN00384E03
INTRODUCTION – TERMS IN–31
TERMS
ABBREVIATIONS USED IN MANUAL
Abbreviations Meaning
ABS Anti-Lock Brake System
A/C Air Conditioner
IN
AC Alternating Current
ACC Accessory
ACIS Acoustic Control Induction System
ACM Active Control Engine Mount
ACSD Automatic Cold Start Device
A.D.D Automatic Disconnecting Differential
A/F Air-Fuel Ratio
AHC Active Height Control Suspension
ALR Automatic Locking Retractor
ALT Alternator
AMP Amplifier
ANT Antenna
APPROX. Approximately
ASSY Assembly
A/T, ATM Automatic Transmission (Transaxle)
ATF Automatic Transmission Fluid
AUTO Automatic
AUX Auxiliary
AVG Average
AVS Adaptive Variable Suspension
B+ Battery Voltage
BA Brake Assist
BACS Boost Altitude Compensation System
BAT Battery
BDC Bottom Dead Center
B/L Bi-Level
B/S Bore-Stroke Ratio
BTDC Before Top Dead Center
BVSV Bimetallic Vacuum Switching Valve
CAN Controller Area Network
CB Circuit Breaker
CCo Catalytic Converter For Oxidation
CCV Canister Closed Valve
CD Compact Disc
CF Cornering Force
CG Center Of Gravity
CH Channel
CKD Complete Knock Down
COMB. Combination
CPE Coupe
CPS Combustion Pressure Sensor
CPU Central Processing Unit
CRS Child Restraint System
CTR Center
IN–32 INTRODUCTION – TERMS
C/V Check Valve
CV Control Valve
CW Curb Weight
DC Direct Current
DEF Defogger
IN
DFL Deflector
DIFF. Differential
DIFF. LOCK Differential Lock
D/INJ Direct Injection
DLC Data Link Connector
DLI Distributorless Ignition
DOHC Double Overhead Camshaft
DP Dash Pot
DPR Diesel Particulate active Reduction system
DS Dead Soak
DSP Digital Signal Processor
DTC Diagnostic Trouble Code
DVD Digital Versatible Disc
EBD Electric Brake Force Distribution
EC Electrochromic
ECAM Engine Control And Measurement System
ECD Electronically Controlled Diesel
ECDY Eddy Current Dynamometer
ECT Electronic Controlled Automatic Transmission
ECU Electronic Control Unit
ED Electro-Deposited Coating
EDU Electronic Driving Unit
EDIC Electric Diesel Injection Control
EFI Electronic Fuel Injection
E/G Engine
EGR Exhaust Gas Recirculation
EGR-VM EGR-Vacuum Modulator
ELR Emergency Locking Retractor
EPS Electric Power Steering
ENG Engine
ES Easy & Smooth
ESA Electronic Spark Advance
ETCS-i Electronic Throttle Control System-intelligent
EVAP Evaporative Emission Control
EVP Evaporator
E-VRV Electric Vacuum Regulating Valve
EX Exhaust
FE Fuel Economy
FF Front-Engine-Front-Wheel-Drive
F/G Fuel Gauge
FIPG Formed In Place Gasket
FL Fusible Link
F/P Fuel Pump
FPU Fuel Pressure Up
FR Front
F/W Flywheel
FW/D Flywheel Damper
FWD Front-Wheel-Drive
GAS Gasoline
IN
GND Ground
GPS Global Positioning System
GSA Gear Shift Actuator
HAC High Altitude Compensator
H/B Hatchback
H-FUSE High Current Fuse
HI High
HID High Intensity Discharge (Headlight)
HPU Hydraulic Power Unit
HSG Housing
HT Hard Top
HV Hybrid Vehicle
HWS Heated Windshield System
IC Integrated Circuit
IDI Indirect Diesel Injection
IFS Independent Front Suspension
IG Ignition
IIA Integrated Ignition Assembly
IN Intake (Manifold, Valve)
INT Intermittent
I/P Instrument Panel
IRS Independent Rear Suspension
ISC Idle Speed Control
J/B Junction Block
J/C Junction Connector
KD Kick-Down
LAN Local Area Network
LB Liftback
LCD Liquid Crystal Display
LED Light Emitting Diode
LH Left-Hand
LHD Left-Hand Drive
L/H/W Length, Height, Width
LLC Long-Life Coolant
LNG Liquified Natural Gas
LO Low
LPG Liquified Petroleum Gas
LSD Limited Slip Differential
LSP & BV Load Sensing Proportioning and Bypass Valve
LSPV Load Sensing Proportioning Valve
MAP Manifold Absolute Pressure
MAX. Maximum
MIC Microphone
MIL Malfunction Indicator Light
MIN. Minimum
MG1 Motor Generator No. 1
MG2 Motor Generator No. 2
MMT Multi-mode Manual Transmission
MP Multipurpose
IN
MPI Multipoint Electronic Injection
MPX Multiplex Communication System
M/T, MTM Manual Transmission (Transaxle)
MT Mount
MTG Mounting
N Neutral
NA Natural Aspiration
NO. Number
O2S Oxygen Sensor
OC Oxidation Catalyst
OCV Oil Control Valve
O/D Overdrive
OEM Original Equipment Manufacturing
OHC Overhead Camshaft
OHV Overhead Valve
OPT Option
ORVR On-board Refueling Vapor Recovery
O/S Oversize
P & BV Proportioning and Bypass Valve
PBD Power Back Door
PCS Power Control System
PCV Positive Crankcase Ventilation
PKB Parking Brake
PPS Progressive Power Steering
PROM Programmable Read Only Memory
PS Power Steering
PSD Power Slide Door
PTO Power Take-Off
PZEV Partial Zero Emission Vehicle
P/W Power Window
R&P Rack and Pinion
RAM Random Access Memory
R/B Relay Block
RBS Recirculating Ball Type Steering
R/F Reinforcement
RFS Rigid Front Suspension
RH Right-Hand
RHD Right-Hand Drive
RLY Relay
ROM Read Only Memory
RR Rear
RRS Rigid Rear Suspension
RSE Rear Seat Entertainment
RWD Rear-Wheel Drive
SC Supercharger
SCV Swirl Control Valve
SDN Sedan
SEN Sensor
SICS Starting Injection Control System
IN
SOC State Of Charge
SOHC Single Overhead Camshaft
SPEC Specification
SPI Single Point Injection
SRS Supplemental Restraint System
SSM Special Service Materials
SST Special Service Tools
STD Standard
STJ Cold-Start Fuel Injection
SW Switch
SYS System
T/A Transaxle
TACH Tachometer
TBI Throttle Body Electronic Fuel Injection
TC Turbocharger
TCCS TOYOTA Computer-Controlled System
TCV Timing Control Valve
TDC Top Dead Center
TEMP. Temperature
TFT TOYOTA Free-Tronic
TIS Total Information System For Vehicle Development
T/M Transmission
TMC TOYOTA Motor Corporation
TMMIN PT. TOYOTA Motor Manufacturing Indonesia
TMMK TOYOTA Motor Manufacturing Kentucky, Inc.
TMT TOYOTA Motor Thailand Co. Ltd.
TRAC/TRC Traction Control System
TURBO Turbocharge
TWC Three-Way Catalyst
U/D Underdrive
U/S Undersize
VCV Vacuum Control Valve
VENT Ventilator
VIM Vehicle Interface Module
VGRS Variable Gear Ratio Steering
VIN Vehicle Identification Number
VPS Variable Power Steering
VSC Vehicle Stability Control
VSV Vacuum Switching Valve
VTV Vacuum Transmitting Valve
VVT-i Variable Valve Timing-intelligent
W/ With
WGN Wagon
W/H Wire Harness
W/O Without
1ST First
2ND Second
2WD Two Wheel Drive Vehicle (4 x 2)
3RD Third
IN
4TH Fourth
4WD Four Wheel Drive Vehicle (4 x 4)
4WS Four Wheel Steering System
5TH Fifth
PREPARATION
PREPARATION
N04C-TR, TS, TT, TU, TV, TW ENGINE CONTROL SYSTEM

SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-1
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-1
PP
W04D-TM, TN ENGINE CONTROL SYSTEM
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-2
N04C-TR, TS, TT, TU, TV, TW ENGINE MECHANICAL
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-3
RECOMMENDED TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-7
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-7
SSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-8
W04D-TM, TN ENGINE MECHANICAL
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-9
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-11
SSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-12
N04C-TR, TS, TT, TU, TV, TW FUEL
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-13
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-13
SSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-13
W04D-J, TM, TN FUEL
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-14
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-16
SSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-16
N04C-TU, TV, TW EMISSION CONTROL
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-17
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-17
N04C-TR, TS, TT, TU, TV, TW INTAKE
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-18
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-18
W04D-TM, TN INTAKE
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-19
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-19
N04C-TR, TS, TT, TU, TV, TW EXHAUST
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-20
W04D-TM, TN EXHAUST
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-21
N04C-TR, TS, TT, TU, TV, TW COOLING
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-22
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-22
SSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-22
W04D-TM, TN COOLING
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-23
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-23
SSM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-23
N04C-TR, TS, TT, TU, TV, TW LUBRICATION
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-24
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-24
PP LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-24
SSM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-24
W04D-TM, TN LUBRICATION
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-25
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-25
LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-25
SSM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-25
N04C-TR, TS, TT, TU, TV, TW STARTING
RECOMMENDED TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-26
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-26
W04D-TM, TN STARTING
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-27
N04C-TR, TS, TT, TU, TV, TW CHARGING
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-28
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-29
W04D-TM, TN CHARGING
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-30
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-30
CLUTCH
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-31
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-31
LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-31
SSM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-31
A860E AUTOMATIC TRANSMISSION
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-32
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-32
LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-32
M153 MANUAL TRANSMISSION
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-33
LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-33
SSM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-33
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-34
LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-34
SSM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-34
MYY5A MANUAL TRANSMISSION
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-35
LUBRICANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-35
SSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-35
MYY6S MANUAL TRANSMISSION
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-36
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-39
LUBRICANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-39 PP
SSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-39
PROPELLER SHAFT
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-41
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-41
FRONT SUSPENSION
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-42
DIFFERENTIAL
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-43
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-47
LUBRICANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-47
SSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-47
AXLE
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-48
TIRE AND WHEEL
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-50
BRAKE CONTROL
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-51
BRAKE
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-52
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-52
LUBRICANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-52
PARKING BRAKE
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-53
POWER STEERING
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-54
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-55
LUBRICANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-55
AIR CONDITIONING
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-56
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-56
LUBRICANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-56
METER
SUPPLEMENTAL RESTRAINT SYSTEM
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-58
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-59
AUDIO / VISUAL
POWER SOURCE / WIRING
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-61
PP
HORN
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-62
ENGINE HOOD / DOOR
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-63
EXTERIOR
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-64
POWER TAKE-OFF
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-65
SSM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP-65
PREPARATION – N04C-TR, TS, TT, TU, TV, TW ENGINE CONTROL SYSTEM PP–1

PREPARATION
SST
09042-1220 Cable
PP
09993-E090 Interface Box (HINO-DX)
09843-18040 Diagnosis Check Wire No.2
EQUIPMENT
Torque wrench
Voltmeter
Ohmmeter
19mm deep socket wrench
Intelligent tester
Battery
PP–2 PREPARATION – W04D-TM, TN ENGINE CONTROL SYSTEM
W04D-TM, TN ENGINE CONTROL SYSTEM

PREPARATION
EQUIPMENT
Torque wrench
Ohmmeter
Vernier calipers
PP
PREPARATION – N04C-TR, TS, TT, TU, TV, TW ENGINE MECHANICAL PP–3

PREPARATION
SST
09042-1220 Cable
PP
S0948-21530 Front Oil Seal Press
S0948-21540 Rear Oil Seal Press
09023-12901 Union Nut Wrench 19 mm
09032-00100 Oil Pan Seal Cutter
09201-10000 Valve Guide Bushing Remover &

Replacer Set
(09201-01050) Valve Guide Bushing Remover &

Replacer 5
(09201-01070) Valve Guide Bushing Remover &

Replacer 7
09202-00020 Attachment
(09202-01020) Set Bolt

PP–4 PREPARATION – N04C-TR, TS, TT, TU, TV, TW ENGINE MECHANICAL
(90154-80004) Screw
09202-70020 Valve Spring Compressor
PP
(09202-01010) Arm
09215-00013 Crankshaft Bearing Remover &

Replacer Set B
(09215-00021) Gate B
(09215-00461) Camshaft Bearing Remover &

Replacer
09215-00101 Camshaft Bearing Remover &

Replacer Set A
(09215-00130) Bolt
(09215-00141) Nut
(09215-00150) Shaft A
(09215-00161) Pin
09223-78010 Crankshaft Oil Seal Replacer

09260-69015 Injection Nozzle Seat Tool Set
09268-06010 Ball
PP
09268-06020 Nozzle Seat Replacer
09843-18040 Diagnosis Check Wire No. 2
09910-00015 Puller Set
(09911-00011) Puller Clamp
(09912-00010) Puller Slide Hammer
09950-40011 Puller B Set
(09951-04010) Hanger 150
(09952-04010) Slide Arm
(09953-04020) Center Bolt 150
(09954-04010) Arm 25
(09955-04051) Claw No.5
09950-60010 Replacer Set
PP
(09951-00250) Replacer 25
(09951-00300) Replacer 30
(09951-00320) Replacer 32
(09951-00360) Replacer 36
(09952-06010) Adapter
09950-70010 Handle Set
(09951-07100) Handle 100
09992-00025 Cylinder Compression Check Gauge

Set
S0940-21450 Press Sub-Assembly
S0940-21470 Spindle
S0942-01460 Cylinder Liner Puller
S0947-22210 Bar
PP
S0948-11130 Guide
S0948-11140 Guide
S9191-08252 Bolt
S9233-10360 Wing Nut
RECOMMENDED TOOLS
09011-4C100 Socket Wrench
46mm
EQUIPMENT
Compression gauge
Feeler gauge
V-block
Magnet base
Dial gauge
Precision straight edge
Steel square
Vernier caliper
Micrometer
Caliper gauge
Brass block
Hammer
Wooden block
Pin punch 5
Valve guide bushing brush
Carbide cutter
Heater
TORX socket wrench E10
TORX socket wrench E8
Engine lifter
Protective tape
Shop rag or pice of cloth
Torch
PP Brass bar
Plastic-faced hammer
Cylinder gauge
Press
Torque wrench
MP grease
Piston ring compressor
Chain block
Engine sling device
Snap ring pliers
HINT:
TORX is registered trademark of Textron Inc.
SSM
HINO Genuine Seal Packing Black, Three Bond 1207B or equivalent -
PREPARATION – W04D-TM, TN ENGINE MECHANICAL PP–9
W04D-TM, TN ENGINE MECHANICAL

PREPARATION
SST
09032-00100 Oil Pan Seal Cutter
PP
09201-41020 Valve Stem Oil Seal Replacer
09202-70020 Valve Spring Compressor
(09202-00030) Attachment
09215-00013 Crankshaft Bearing Remover &

Replacer Set B
(09215-00461) Camshaft Bearing Remover &

Replacer
09303-35011 Input Shaft Front Bearing Puller
09304-12012 Input Shaft Front Bearing

Replacer
09950-60020 Replacer Set No. 2
(09951-00750) Replacer 75
PP–10 PREPARATION – W04D-TM, TN ENGINE MECHANICAL
(09951-07100) Handle 100
PP
09992-00025 Cylinder Compression Check Gauge
Set
(09992-00211) Gauge Assembly
S0940-81041 Press Gauge Adaptor
S0942-01460 Cylinder Liner Puller
S0944-41630 Gauge
S0947-21620 Tool
S0948-11130 Guide
S0948-11140 Guide
PREPARATION – W04D-TM, TN ENGINE MECHANICAL PP–11
S0948-11340 Guide
S0955-21070 Compression Gauge Adaptor
PP
S9001-24262 Check Bolt
S9191-08252 Bolt
S9233-10360 Wing Nut
EQUIPMENT
Compression gauge
Feeler gauge
V-block
Magnet base
Dial gauge
Precision straight edge
Steel square
Vernier caliper
Micrometer
Caliper gauge
Brass block
Hammer
Wooden block
Pin punch 5
Valve guide bushing brush
Carbide cutter
Heater
Engine lifter
Protective tape
Shop rag or pice of cloth
Torch
Brass bar
Plastic-faced hammer
Cylinder gauge
Press
MP grease
Piston ring compressor
PP–12 PREPARATION – W04D-TM, TN ENGINE MECHANICAL
Chain block
Engine sling device
Snap ring pliers
46 mm socket wrench
Torque wrench
SSM
PP HINO Genuine Seal Packing Black, Three Bond 1207B or equivalent
HINO Genuine Adhesive 1324, Three Bond 1324 or equivalent
PREPARATION – N04C-TR, TS, TT, TU, TV, TW FUEL PP–13

PREPARATION
SST
09042-1220 Cable
PP
RECOMMENDED TOOLS
09082-00040 Electrical Tester
EQUIPMENT
Ohmmeter
Vinyl tape
Torque wrench
SSM
HINO Genuine Seal Packing Black, Three Bond 1207B or equivalent -
PP–14 PREPARATION – W04D-J, TM, TN FUEL
W04D-J, TM, TN FUEL

PREPARATION
SST
09228-34010 Fuel Filter Wrench
PP
S0951-21150 Camshaft Clearance Gauge
S0951-21320 Wrench,Governor Round Nut
S0951-21620 Tweezers,INJ.
S0951-21670 Wrench,Governor Spring Nut
S0951-21790 Wrench,INJ.BOX
S0951-22200 Holder,Timer
S0951-22210 Timer Wrench
S0951-22260 Governor Camshaft Bushing

Extractor
S0951-22311 Press,Timer Weight Spring
S0951-22330 Puller,Outer Race

PREPARATION – W04D-J, TM, TN FUEL PP–15
S0951-22340 Rail,Injector Guide
S0951-22350 Tool,Bearing Driving
PP
S0951-22360 Puller, Injection Pump
Camshaft Bearring
S0951-22370 Pliers,INJ. Circlip
S0951-22380 Remover,Delivery Valve Holder
S0951-22390 Support,Injentor Setting
S0951-22400 Remover,INJ.Control Sleeve
S0951-22410 Compressor,Injector Spring
S0951-22420 Pressor,Oil Seal
S0951-22430 Extractor,Timer
S0951-22450 Setting,Timing
S0951-22510 Bit
PP–16 PREPARATION – W04D-J, TM, TN FUEL
S0951-22520 Driver-chuck
RECOMMENDED TOOLS
PP
EQUIPMENT
Ohmmeter
Vernier calipers
Spring tension gauge
Dial indicator
Angle gauge
Hexagon wrench
Injection nozzle tester
Brass brush
Battery
Vinyl tape
Torque wrench
SSM
HINO Genuine Adhesive 1324, Three Bond 1324 or equivalent
PREPARATION – N04C-TU, TV, TW EMISSION CONTROL PP–17

PREPARATION
SST
09042-1220 Cable
PP
09950-E9010 Air Nozzle Sub-Assembly
09992-00242 Turbocharger Pressure Gauge
EQUIPMENT
Torque wrench
Voltmeter
Ohmmeter
Intelligent tester
Union nut wrench (14mm)
PP–18 PREPARATION – N04C-TR, TS, TT, TU, TV, TW INTAKE

PREPARATION
SST
PP
EQUIPMENT
Torque wrench
Voltmeter
Ohmmeter
Dial indication
PREPARATION – W04D-TM, TN INTAKE PP–19
W04D-TM, TN INTAKE
PREPARATION
SST
PP
EQUIPMENT
Torque wrench
Dial indication
PP–20 PREPARATION – N04C-TR, TS, TT, TU, TV, TW EXHAUST
N04C-TR, TS, TT, TU, TV, TW EXHAUST

PREPARATION
EQUIPMENT
Torque wrench
PP
PREPARATION – W04D-TM, TN EXHAUST PP–21
W04D-TM, TN EXHAUST
PREPARATION
EQUIPMENT
Torque wrench
PP
PP–22 PREPARATION – N04C-TR, TS, TT, TU, TV, TW COOLING

PREPARATION
EQUIPMENT
Radiator cap tester
Vernier caliper
thermometer
PP torque wrench
COOLANT
Item Capacity Classification
Use only "HINO genuine LLC", or similar high
quality ethylene glycol based non-silicate,
non-amine, non-nitrite, and non-borate
coolant with long-life hybrid organic acid
Engine coolant 14.7 liters (15.5 US qts, 12.9 lmp. qts)
technology (coolant with long-life hybrid
organic acid technology consists of a
combination of low phosphates and organic
acids).
SSM
HINO Genuine Seal Packing Black
Three Bond 1207B or equivalent
PREPARATION – W04D-TM, TN COOLING PP–23
W04D-TM, TN COOLING
PREPARATION
EQUIPMENT
Radiator cap tester
Vernier caliper
thermometer
torque wrench
PP
COOLANT
Use only "HINO genuine LLC", or similar high
quality ethylene glycol based non-silicate,
non-amine, non-nitrite, and non-borate
coolant with long-life hybrid organic acid
Engine coolant 12.5 liters (13.3 US qts, 10.9 lmp. qts)
technology (coolant with long-life hybrid
organic acid technology consists of a
combination of low phosphates and organic
acids).
SSM
PP–24 PREPARATION – N04C-TR, TS, TT, TU, TV, TW LUBRICATION

PREPARATION
SST
09228-78010 Oil Filter Wrench
PP
09910-00015 Puller Set
(09911-00011) Puller Clamp
(09912-00010) Puller Slide Hammer
EQUIPMENT
Oil pressure gauge
Dial indicator
Torque wrench
Engine oil
LUBRICANT
w/ Oil filter change 7.2 litters (7.6 US qts, 6.3 imp. API CD, CE, CF, CH-4, or CI-4
qts) (You may also use API CE, or
Drain and refill CD.)
w/o Oil filter change 6.2 litters (6.6 US qts, 5.5 imp.
qts)
8.9 litters (9.4 US qts, 7.8 imp.
Dry fill
qts)
SSM
PREPARATION – W04D-TM, TN LUBRICATION PP–25
PREPARATION
SST
S0955-31030 Filter Wrench Sub-Assy
PP
EQUIPMENT
Oil pressure gauge
Dial indicator
Torque wrench
Engine oil
LUBRICANT
w/ Oil filter change 8.7 litters (9.1 US qts, 7.7 imp. API CD, CE, CF, CH-4, or CI-4
qts) (You may also use API CE, or
Drain and refill CD.)
w/o Oil filter change 7.5 litters (7.9 US qts, 6.6 imp.
qts)
10.8 litters (11.4 US qts, 9.5 imp.
Dry fill
qts)
SSM
PP–26 PREPARATION – N04C-TR, TS, TT, TU, TV, TW STARTING

PREPARATION
RECOMMENDED TOOLS
PP
EQUIPMENT
Aluminum protection plate
Service wire harness
Torque wrench
Battery
PREPARATION – W04D-TM, TN STARTING PP–27
PREPARATION
RECOMMENDED TOOLS
PP
EQUIPMENT
Aluminum protection plate
Service wire harness
Torque wrench
Dial gauge
Vernier calipers
Sandpaper (No. 400)
Spring scale
Battery
PP–28 PREPARATION – N04C-TR, TS, TT, TU, TV, TW CHARGING

PREPARATION
SST
09820-63010 Alternator Pulley Set Nut Wrench
Set
PP
(09820-06010) Alternator Rotor Shaft Wrench
(09820-06020) Alternator Pulley Set Nut 22 mm

Wrench
RECOMMENDED TOOLS
09011-2C590 Socket Wrench
30mm
95720-00051 Bearing Pullar set

(DENSO Parts No.)
(95720-10030) Crow A
(DENSO Parts No.)
(95720-10050) Hanger
(DENSO Parts No.)
(95720-10060) Lock nut

(DENSO Parts No.)
(95720-10070) Bushing bolt

(DENSO Parts No.)
PREPARATION – N04C-TR, TS, TT, TU, TV, TW CHARGING PP–29
(95720-10080) Pin
(DENSO Parts No.)
EQUIPMENT
Torque wrench
PP
Vernier caliper
Sandpaper (No. 400)
PP–30 PREPARATION – W04D-TM, TN CHARGING
PREPARATION
SST
09213-87211 TOOL,CRANKSHAFT PULLEY
HOLDING
PP
09238-47012 Water Pump Bearing Remover &
Replacer
09285-76010 Injection Pump Camshaft Bearing

Cone Replacer
(09309-03620) Plate
09309-36100 Transmission Bearing Replacer

Set
09950-00020 Bearing Remover
RECOMMENDED TOOLS
EQUIPMENT
27 mm socket wrench
Vernier calipers
Torque wrench
Soldering iron
PREPARATION – CLUTCH PP–31
CLUTCH
PREPARATION
SST
PP
09301-00120 Clutch Guide Tool
09303-35011 Input Shaft Front Bearing Puller
09304-12012 Input Shaft Front Bearing

Replacer
09333-00013 Universal Joint Bearing Remover

& Replacer
EQUIPMENT
Torque wrench
Vernier calipers
Dial gauge
Dial indicator
LUBRICANT
Brake fluid - SAE J1703 or FMVSS No. 116 DOT 3
SSM
HINO Genuine Release Hub Grease or equivalent
HINO Genuine Clutch Spline Grease or equivalent
PP–32 PREPARATION – A860E AUTOMATIC TRANSMISSION

PREPARATION
SST
PP
EQUIPMENT
Transmission jack
Torque wrench
LUBRICANT
Transmission oil 12.0 liters (12.7 US qts, 10.5 lmp. qts) Toyota genuine ATF Type T-IV
(ATF JWS3309)
PREPARATION – M153 MANUAL TRANSMISSION PP–33

PREPARATION
EQUIPMENT
Transmission jack
Torque wrench
Chisel
32 mm socket wrench
PP
LUBRICANT
Transmission oil 3.2 liters (3.4 US qts, 2.8 lmp. qts) API GL-4 or 5
SAE 75W-90
SSM
PP–34 PREPARATION – M550 MANUAL TRANSMISSION

PREPARATION
EQUIPMENT
Transmission jack
Torque wrench
Chisel
PP 32 mm socket wrench
LUBRICANT
Transmission oil 2.8 liters (3.0 US qts, 2.5 lmp. qts) API GL-4 or 5
SAE 75W-90
SSM
PREPARATION – MYY5A MANUAL TRANSMISSION PP–35

PREPARATION
RECOMMENDED TOOLS
09924-12361 Deep socket Wrench 36
PP
EQUIPMENT
Transmission jack
Torque wrench
Chisel
LUBRICANT
Engine oil 2.8 liters (3.0 US qts, 2.5 lmp. qts) SAE 10W-30 or 10W-40
SAE 15W-40
SAE 30
SAE 40
SSM
PP–36 PREPARATION – MYY6S MANUAL TRANSMISSION

PREPARATION
SST
09226-10010 Crankshaft Front & Rear Bearing
Replacer
PP
09308-00010 Oil Seal Puller
09308-14010 Replacer Pipe A
09309-14010 Remover & Replacer A
09310-35010 Countershaft Bearing Replacer
09319-60020 Output Shaft Needle Roller

Bearing Remover
09517-12010 Rear Axle Shaft Oil Seal

Replacer
09608-06041 Front Hub Inner Bearing Cone

Replacer
09608-10010 Steering Knuckle Oil Seal

Replacer

PREPARATION – MYY6S MANUAL TRANSMISSION PP–37
(09951-04020) Hanger 200
PP
(09952-04010) Slide Arm
(09953-04020) Center Bolt 150
(09954-04010) Arm 25
(09955-04031) Claw No.3
(09951-00200) Replacer 20
(09951-00210) Replacer 21
(09951-00280) Replacer 28
(09951-00310) Replacer 31
(09951-00320) Replacer 32
(09951-00470) Replacer 47
PP
(09951-00550) Replacer 55
(09951-00620) Replacer 62
(09952-06010) Adapter
(09951-07100) Handle 100
(09951-07150) Handle 150
09960-10010 Variable Pin Wrench Set
(09963-00700) Pin 7
RECOMMENDED TOOLS
09013-1C150 "TORX" Socket Wrench
T50
PREPARATION – MYY6S MANUAL TRANSMISSION PP–39
09051-1C410 Pin Punch

5
09904-00010 Expander Set
PP
(09904-00020) No. 1 Claw
(09904-00050) No. 4 Claw
09905-00012 Snap Ring No. 1 Expander
09924-12361 Deep socket Wrench 36
EQUIPMENT
Transmission jack
Torque wrench
Chisel
Micrometer
Vernier calipers
Bearing remover
Cylinder gauge
Dial gauge
V-block
Wooden block
Protection tape
LUBRICANT
Engine oil 3.5 liters (3.7 US qts, 3.0 lmp. qts) SAE 10W-30 or 10W-40
SAE 15W-40
SAE 30
SAE 40
SSM
HINO Genuine Seal Packing 1281, Three Bond 1281 or equivalent
HINO Genuine Loctite 242 or equivalent
PP
PREPARATION – PROPELLER SHAFT PP–41
PROPELLER SHAFT
PREPARATION
SST
09309-37010 Transmission Bearing Replacer
PP
09309-60010 Extension Pipe
09316-12010 Transfer Bearing Replacer
09710-28021 Front Suspension Bushing Tool

Set
(09710-08031) Base
09930-00010 Drive Shaft Nut Chisel
RECOMMENDED TOOLS
09905-00013 Snap Ring Pliers
EQUIPMENT
Torque wrench
Dial indicator with magnetic base
Spring tension gauge
Chisel
Micrometer
Caliper gauge
PP–42 PREPARATION – FRONT SUSPENSION
FRONT SUSPENSION
PREPARATION
SST
09722-30010 Tire Clamp Compensator
PP
(09951-04010) Hanger 150
(09952-04010) Slide Arm
(09953-04020) Senter Bolt 150
(09954-04010) Arm 25
(09955-04031) Claw NO.3
(09958-04011) Holder
PREPARATION – DIFFERENTIAL PP–43
DIFFERENTIAL
PREPARATION
SST
PP
09315-00022 Clutch Release Bearing Remover

& Replacer
09316-20011 Transfer Bearing Replacer
09316-60011 Transmission & Transfer Bearing

Replacer
(09316-00011) Replacer Pipe
(09316-00071) Replacer F
09330-00021 Companion Flange Holding Tool
09504-00011 Differential Side Bearing

Adjusting Nut Wrench
09506-35010 Differential Drive Pinion Rear

Bearing Replacer
09518-36020 Rear Axle Hub Oil Seal Replacer

PP–44 PREPARATION – DIFFERENTIAL
09527-17011 Rear Axle Shaft Bearing Remover
09556-22010 Drive Pinion Front Bearing

Remover
PP
09930-00010 Drive Shaft Nut Chisel
09950-00030 Bearing Remover Attachment
09950-30012 Puller A Set
(09951-03010) Upper Plate
(09953-03010) Center Bolt
(09954-03010) Arm
(09955-03030) Lower Plate 130
(09956-03040) Adapter 22

(09951-04020) Hanger 200
(09952-04010) Slide Arm
PP
(09953-04030) Center Bolt 200
(09954-04010) Arm 25
(09955-04061) Claw No. 6
(09958-04011) Holder
(09951-00480) Replacer 48
(09951-00500) Replacer 50
(09951-00610) Replacer 61
(09951-00640) Replacer 64
PP–46 PREPARATION – DIFFERENTIAL
(09951-00650) Replacer 65
09950-60020 Replacer Set No. 2
PP
(09951-00680) Replacer 68
(09951-00780) Replacer 78
(09951-01030) Replacer 103
(09951-07100) Handle 100
(09951-07150) Handle 150
S0964-01022 Gauge Assembly
RECOMMENDED TOOLS
09031-00030 Pin Punch
09905-00012 Snap Ring No. 1 Expander

EQUIPMENT
Dial indicator Brass bar
Micrometer Chain block
Vernier calipers Press
Hammer Tire lever
Torque wrench
PP
LUBRICANT
Rear differential oil (SH12) 5.2 liters (5.5 US qts, 4.6 Imp. qts.) Hypoid gear oil API GL-5 or equivalent
SAE 90
Rear differential oil (SH13) 3.7 liters (3.9 US qts, 3.3 Imp. qts.) Hypoid gear oil API GL-5 or equivalent
SAE 90
Rear differential oil (B265) 3.4 liters (3.6 US qts, 3.0 Imp. qts.) Hypoid gear oil API GL-5 or equivalent
SAE 90
SSM
Three Bond 1360 or Equivalent Three Bond 1344 or Equivalent
Three Bond 1215 or Equivalent Three Bond 1216 or Equivalent
PP–48 PREPARATION – AXLE
AXLE
PREPARATION
SST
09214-76011 Crankshaft Pully Replacer
PP
09513-36020 Rear Axle Bearing Lock Nut Wrench
09513-36040 Rear Axle Bearing Replacer
09518-36030 Rear Axle Hub Oil seal Replacer
09527-17011 Rear Axle Shaft Bearing Remover
09608-36010 Front Axle Hub Oil Seal Replacer
09650-2120 Hub Bearing Puller
09849-2001 Handle

PREPARATION – AXLE PP–49
(09951-07150) Handle 150
PP
09951-01000 Replacer 100
S0983-99401 Socket Wrench

PP–50 PREPARATION – TIRE AND WHEEL
TIRE AND WHEEL

PREPARATION
EQUIPMENT
Tire pressure gauge
Wheel balancer
PP Torque wrench
PREPARATION – BRAKE CONTROL PP–51
BRAKE CONTROL
PREPARATION
SST
PP
PP–52 PREPARATION – BRAKE
BRAKE
PREPARATION
SST
PP
09608-04031 Front Hub Inner Bearing Cone
Replacer
09709-29018 LSPV Gauge Set
EQUIPMENT
Ruler
Micrometer
Torque wrench
LUBRICANT
Brake fluid - SAE J1703 or FMVSS No. 116 DOT3
PREPARATION – PARKING BRAKE PP–53
PARKING BRAKE
PREPARATION
RECOMMENDED TOOLS
PP
EQUIPMENT
Torque wrench
PP–54 PREPARATION – POWER STEERING
POWER STEERING
PREPARATION
SST
PP
09610-20012 Pitman Arm Puller
09640-10010 Power Steering Pressure Gauge

Set
(09641-01010) Gauge Assy
(09641-01020) Attachment A
(09641-01030) Attachment B
(09641-01040) Attachment C
(09641-01050) Attachment D
09922-10010 Variable Open Wrench
(09951-04020) Hanger 200

PREPARATION – POWER STEERING PP–55
(09952-04010) Slide Arm
(09953-04020) Center Bolt 150
PP
(09954-04010) Arm 25
(09955-04031) Claw No.3
(09958-04011) Holder
EQUIPMENT
Torque wrench
LUBRICANT
Power steering fluid (Total) 2.0 liters (2.1 US qts, 1.8 Imp. qts) ATF DEXRON II or III or equivalent
PP–56 PREPARATION – AIR CONDITIONING
AIR CONDITIONING
PREPARATION
SST
07112-76060 Magnetic Clutch Stopper
PP
07114-84020 Snap Ring Pliers
RECOMMENDED TOOLS
(09083-00150) Test Lead Set
EQUIPMENT
Vinyl tape
Battery (24V)
Torque wrench
LUBRICANT
Compressor oil - ND-OIL 8 or equivalent
PREPARATION – METER PP–57
METER
PREPARATION
RECOMMENDED TOOLS
09082-00050 Electrical Tester Set
PP

PP–58 PREPARATION – SUPPLEMENTAL RESTRAINT SYSTEM
SUPPLEMENTAL RESTRAINT SYSTEM

PREPARATION
SST
09082-00700 SRS Airbag Deployment Tool HORN BUTTON ASSEMBLY
PP
09082-00760 Airbag Deployment Wire HORN BUTTON ASSEMBLY
Subharness No.4
09843-18040 Diagnosis Check Wire No.2 SUPPLEMENTAL RESTRAINT

SYSTEM
09950-50013 Puller C Set SPIRAL CABLE

AIRBAG SENSOR ASSEMBLY
(09951-05010) Hanger 150 SPIRAL CABLE

(09952-05010) Slide Arm SPIRAL CABLE

(09953-05020) Center Bolt 150 SPIRAL CABLE

(09954-05021) Claw No.2 SPIRAL CABLE

PREPARATION – SUPPLEMENTAL RESTRAINT SYSTEM PP–59
RECOMMENDED TOOLS
09042-00010 Torx Socket T30 SPIRAL CABLE SUB ASSEMBLY
HORN BUTTON ASSEMBLY
AIR BAG SENSOR ASSEMBLY NO.2
09042-00020 Torx Socket T40 AIR BAG SENSOR ASSEMBLY NO.2

PP
EQUIPMENT
Torque wrench
Tire Width:185 mm (7.28 in.) Inner diam.: 360 mm (14.17 in.) Airbag disposal
Tire with disc wheel Width:185 mm (7.28 in.)
Airbag disposal
Inner diam.: 360 mm (4.7 in.)
Vinyl bag Airbag disposal
PP–60 PREPARATION – AUDIO / VISUAL
AUDIO / VISUAL
PREPARATION
RECOMMENDED TOOLS
PP
PREPARATION – POWER SOURCE / WIRING PP–61

PREPARATION
RECOMMENDED TOOLS
PP
EQUIPMENT
Torque wrench
PP–62 PREPARATION – HORN
HORN
PREPARATION
EQUIPMENT
Torque wrench
PP
PREPARATION – ENGINE HOOD / DOOR PP–63
ENGINE HOOD / DOOR

PREPARATION
RECOMMENDED TOOLS
09041-00020 "TORX" Driver T25
PP
09042-00010 "TORX" Socket T30
HINT:
TORX is a registered trademark of Textron Inc.
EQUIPMENT
Torque wrench
MP grease
Protective tape
PP–64 PREPARATION – EXTERIOR
EXTERIOR
PREPARATION
RECOMMENDED TOOLS
09070-20010 Moulding Remover
PP
EQUIPMENT
Protective tape To avoid surface damage
Heat light
PREPARATION – POWER TAKE-OFF PP–65
POWER TAKE-OFF
PREPARATION
RECOMMENDED TOOLS
PP
EQUIPMENT
Torque wrench
Protective tape
SSM
Three Bond 1215 or equivalent
SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS
STANDARD BOLT
HOW TO DETERMINE BOLT STRENGTH. . . . . . . . . . . . . . . . . . . . . . . SS-1
SPECIFIED TORQUE FOR STANDARD BOLTS . . . . . . . . . . . . . . . . . . SS-2
HOW TO DETERMINE NUT STRENGTH. . . . . . . . . . . . . . . . . . . . . . . . SS-3 SS
SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-4
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-4
W04D-J, TM, TN ENGINE CONTROL SYSTEM
SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-5
SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-6
W04D-J, TM, TN ENGINE MECHANICAL
SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-12
SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-17
W04D-TM, TN FUEL
SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-18
W04D-J FUEL
SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-19
SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-21
SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-22
W04D-TM, TN INTAKE
SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-23
N04C-TR, TS, TT, TU, TV EXHAUST
N04C-TW EXHAUST
W04D-TM EXHAUST
W04D-TN EXHAUST
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-27
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-28
W04D-TM, TN COOLING
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-29
SS N04C-TR, TS, TT, TU, TV, TW LUBRICATION
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-30
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-31
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-32
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-33
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-35
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-36
CLUTCH
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-37
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-38
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-43
PROPELLER SHAFT
SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-46
FRONT SUSPENSION
SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-47
DIFFERENTIAL
SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-51
AXLE
SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-56
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-56 SS
TIRE AND WHEEL
SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-57
BRAKE
SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-60
PARKING BRAKE
SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-67
POWER STEERING
SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-68
AIR CONDITIONING
SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SS-70
SUPPLEMENTAL RESTRAINT SYSTEM (FOR PASSENGER)
HORN
ENGINE HOOD / DOOR
POWER TAKE-OFF
SERVICE SPECIFICATIONS – STANDARD BOLT SS–1
STANDARD BOLT
HOW TO DETERMINE BOLT
STRENGTH
Bolt Type
Hexagon Head Bolt Stud Bolt Weld Bolt Class
Normal Recess Bolt Deep Recess Bolt
No Mark No Mark No Mark 4T
SS
5T
w/ Washer w/ Washer 6T
7T
8T
9T
10T
11T
SS–2 SERVICE SPECIFICATIONS – STANDARD BOLT
SPECIFIED TORQUE FOR STANDARD

BOLTS
Class Diameter Pitch Specified torque
(mm) (mm)
Hexagon head bolt Hexagon flange bolt
N*m kgf*cm ft.*lbf N*m kgf*cm ft.*lbf
4T 6 1 5 55 48 in.*lbf 6 60 52 in.*lbf
8 1.25 12.5 130 9 14 145 10
10 1.25 26 260 19 29 290 21
SS 12 1.25 47 480 35 53 540 39
14 1.5 74 760 55 84 850 61
16 1.5 115 1,150 83 - - -
5T 6 1 6.5 65 56 in.*lbf 7.5 75 65 in.*lbf
8 1.25 15.5 160 12 17.5 175 13
10 1.25 32 330 24 36 360 26
12 1.25 59 600 43 65 670 48
14 1.5 91 930 67 100 1,050 76
16 1.5 140 1,400 101 - - -
6T 6 1 8 80 69 in.*lbf 9 90 78 in.*lbf
8 1.25 19 195 14 21 210 15
10 1.25 39 400 29 44 440 32
12 1.25 71 730 53 80 810 59
14 1.5 110 1,100 80 125 1,250 90
16 1.5 170 1,750 127 - - -
7T 6 1 10.5 110 8 12 120 9
8 1.25 25 260 19 28 290 21
10 1.25 52 530 38 58 590 43
12 1.25 95 970 70 105 1,050 76
14 1.5 145 1,500 108 165 1,700 123
16 1.5 230 2,300 166 - - -
8T 8 1.25 29 300 22 33 330 24
10 1.25 61 620 45 68 690 50
12 1.25 110 1,100 80 120 1,250 90
9T 8 1.25 34 340 25 37 380 27
10 1.25 70 710 51 78 790 57
12 1.25 125 1,300 94 140 1,450 105
10T 8 1.25 38 390 28 42 430 31
10 1.25 78 800 58 88 890 64
12 1.25 140 1,450 105 155 1,600 116
11T 8 1.25 42 430 31 47 480 35
10 1.25 87 890 64 97 990 72
12 1.25 155 1,600 116 175 1,800 130
SERVICE SPECIFICATIONS – STANDARD BOLT SS–3
HOW TO DETERMINE NUT STRENGTH

Nut Type
Present Standard Hexagon Nut Old Standard Hexagon Nut Class
Cold Forging Nut Cutting Processed Nut
No Mark 4N
No Mark (w/ Washer) No Mark (w/ Washer) No Mark 5N (4T)

SS
6N
7N (5T)
8N
No Mark 10N (7T)
11N
12N
HINT:
• *: Nut with 1 or more marks on one side surface of the nut.
• Use a nut with the same nut strength classification number
(or greater) as the bolt strength classification number
when tightening parts with a bolt and nut.
Example:
• Bolt = 4T
• Nut = 4N or more
SS–4 SERVICE SPECIFICATIONS – N04C-TR, TS, TT, TU, TV, TW ENGINE CONTROL SYSTEM
N04C-TR, TS, TT, TU, TV, TW

ENGINE CONTROL SYSTEM
SERVICE DATA
Resistance:
Crankshaft position sensor 1 (NE+) - 2 (NE-) 1,630 to 2,740 Ωat -10 to 50°C (14 to 122°F)
2,065 to 3,225 Ωat 50 to 100°C (122 to 212°F)
Resistance:
SS Engine coolant temperature sensor 1 (E2) - 2 (THW) 2.32 to 2.59 kΩ at 20°C (68°F)
0.310 to 0.326 kΩ at 80°C (176°F)
Resistance:
Intake air temperature sensor
2.21 to 2.65 kΩ at 20°C (68°F)
Diesel throttle body Resistance:
2-3
(N04C-TR, TS, TT less) 2 to 10 kΩ
10 kΩ or higher
3-5
EDU relay (battery voltage not applied)
(Resistance) Below 1 Ω
3-5
(battery voltage applied to terminals 1 and 2)
Accelerator pedal is released:
0.4 to 1.4 V
Accel Position No. 1
Accelerator pedal is depressed:
3.0 to 4.6 V
Accelerator pedal
Accelerator pedal is released:
0.9 to 2.3 V
Accel Position No. 2
Accelerator pedal is depressed:
3.4 to 5.5 V
TORQUE SPECIFICATIONS
Part Tightened N*m kgf*cm ft.*lbf
Camshaft position sensor x Timing chain cover 5.0 51 44 in.*lbf
Crankshaft position sensor x Timing chain cover 8.0 82 71 in.*lbf
Engine coolant temperature sensor x Cylinder head sub-assembly 29 296 21
Intake air temperature sensor x No. 1 intake air pipe 34 350 25
Diesel throttle body x Intake manifold 29 291 21
ECM x Body air conditioning unit 5.5 56 49 in. *lbf
Accelerator pedal assembly x Body 5.5 56 49 in. *lbf
SERVICE SPECIFICATIONS – W04D-J, TM, TN ENGINE CONTROL SYSTEM SS–5
W04D-J, TM, TN ENGINE

CONTROL SYSTEM
SERVICE DATA
1-2 2.32 to 2.59 kΩ 20°C (68°F)
1-2 0.310 to 0.326 kΩ 80°C (176°F)
Water temperature sender gage assembly
3 - body 79 - 92 Ω 75°C (167°F)
3 - body 35.5 - 41.5 Ω 100°C (212°F) SS
Engine coolant temperature sensor 1 - body 82 to 92 Ω 75°C (167°F)
pedal play:
Accelerator pedal play
1.5 to 4.0 mm (0.06 to 0.16 in.)
Part tightened N*m kgf*cm ft.*lbf
Water temperature sender gage assembly x Cylinder
29 300 22
head sub-assembly
Engine coolant temperature sensor x Cylinder head
7.4 75 65in.*lbf
sub-assembly
Accelerator pedal rod cover x Accelerator link assembly 5.5 56 49in.*lbf
Accelerator pedal x Floor 5.5 56 49in.*lbf
SS–6 SERVICE SPECIFICATIONS – N04C-TR, TS, TT, TU, TV, TW ENGINE MECHANICAL

ENGINE MECHANICAL
SERVICE DATA
Idle speed 550 to 650 rpm
Maximum speed 3600 to 3700 rpm
Standard 3200 kpa (33 kgf/cm 464 psi)
SS Compression Pressure
Minimum 2700 kpa (27 kgf/cm 392 psi)
Difference between each
290 kpa (3 kgf/cm 42 psi)
cylinder
New belt 10.5 to 12.5 mm (0.41 to 0.49 in.)
Fan and generator V belt Deflection
Used belt 12.5 to 16.0 mm (0.49 to 0.63 in.)
No. 1 V (cooler compressor to crankshaft New belt 8.5 to 10.0 mm (0.33 to 0.39 in.)
Deflection
pulley) belt Used belt 10.0 to 12.0 mm (0.39 to 0.47 in.)
Intake valve Clearance Cold 0.30 mm (0.0118 in.)
Exhaust valve Clearance Cold 0.45 mm (0.0177 in.)
Circle
Maximum 0.06 mm (0.0024 in.)
runout
Intake 50.66 to 50.86 mm (1.9944 to 2.0023 in.)
Camshaft Standard
Cam lobe Exhaust 49.36 to 49.56 mm (1.9432 to 1.9511 in.)
height Intake 50.20 mm (1.9764 in.)
Minimum
Exhaust 48.95 mm (1.9272 in.)
Cylinder
block side
Intake
manifold
Cylinder head sub-assembly Warpage Maximum 0.10 mm (0.0039 in.)
side
Exhaust
manifold
side
Deviation Maximum 2.0 mm (0.0787 in.)
Compression spring Standard 85.1 mm (3.350 in.)
Length
Maximum 82.1 mm (3.232 in.)
Overall
Standard 129.8 mm (5.1102 in.)
length
Intake valve
Stem
Standard 6.957 to 6.972 mm (0.2739 to 0.2745 in.)
diameter
Overall
length
Exhaust valve
Stem
diameter
Intake 0.8 to 1.0 mm (0.0315 to 0.0394 in.)
Standard
Exhaust 1.8 to 2.0 mm (0.070 to 0.078 in.)
Intake valve Sink
Intake 1.1 mm (0.0433 in.)
Maximum
Exhaust 2.1 mm (0.082 in.)
Inside
Valve guide bush (cylinder head side) Standard 13.000 to 13.018 mm (0.5118 to 0.5125 in.)
diameter
SERVICE SPECIFICATIONS – N04C-TR, TS, TT, TU, TV, TW ENGINE MECHANICAL SS–7
Inside
diameter
Protrusion
height
Valve guide bush Intake 0.014 to 0.029 mm (0.0006 to 0.0011 in.)
Standard
Oil Exhaust 0.053 to 0.083 mm (0.0021 to 0.0033 in.)
clearance Intake 0.12 mm (0.0047 in.)
Maximum
Exhaust 0.15 mm (0.0059 in.)
Protrusion
Injection nozzle seat Standard 2.45 to 2.95 mm (0.0964 to 0.1161 in.)
height
Cylinder A 36.00 to 36.015 mm (1.4173 to 1.4179 in.)
SS
head Standard
dimension B 8.4 to 8.6 mm (0.3307 to 0.3386 in.)
Valve seat
Intake 0.7 to 1.1 mm (0.0276 to 0.0433 in.)
Pressure Standard
Thrust Standard 0.103 to 0.164 mm (0.0040 to 0.0064 in.)

clearance Maximum 0.30 mm (0.0118 in.)
Backlash
Maximum 0.30 mm (0.0118 in.)
Idle gear Standard 50.000 to 50.025 mm (1.9685 to 1.9695 in.)
No. 2 idle gear and shaft inside
diameter Maximum 50.05 mm (1.9704 in.)

shaft
diameter Minimum 49.95 mm (1.9665 in.)
Oil Standard 0.0125 to 0.0375 mm (0.0005 to 0.0014 in.)

Camshaft timing gear Backlash
Maximum 0.30 mm (0.0118 in.)
Oil pump gear Backlash
Maximum 0.30 mm (0.0118 in.)

Backlash
Maximum 0.30 mm (0.0118 in.)
No. 1 idle gear and shaft inside
diameter Maximum 50.05 mm (19704 in.)

shaft


Connecting rod
Big end Standard 61.991 to 62.022 mm (2.4406 to 2.4418 in.)

inside

Connecting rod bearing Standard 61.94 to 61.96 mm (2.4386 to 2.4394 in.)
Under size U/S 0.25 61.69 to 61.71 mm (2.4287 to 2.4295 in.)

bearing U/S 0.50 61.44 to 61.46 mm (2.4189 to 2.4197 in.)
diameter
U/S 0.75 61.19 to 61.21 mm (2.4090 to 2.4098 in.)
SS U/S 1.00 60.94 to 60.96 mm (2.3992 to 2.4000 in.)

Crankshaft pin 3.50 to 4.00 mm (0.1378 to 0.1575 in.)
Inside Standard 37.035 to 37.045 mm (1.4581 to 1.4585 in.)

Connecting rod bush
Flywheel sub-assembly runout Maximum 0.15 mm (0.0059 in.)
Flywheel ring gear Clearance Standard 0.25 mm (0.0098 in.) or less
Diameter
Maximum 36.96 mm (1.4551 in.)
Piston pin
Oil Standard 0.035 to 0.056mm (0.0014 to 0.0022 in.)
Inside Standard 36.987 to 37.003 mm (1.4562 to 1.4568 in.)

Piston pin hole
Oil Standard 0.013 to 0.014 mm (-0.0005 to 0.0005 in.)
Journal No. 1 56.95 to 56.97 mm (2.2421 to 2.2429 in.)

outside No. 2 56.75 to 56.77 mm (2.2343 to 2.2350 in.)
diameter
No. 3 56.55 to 56.57 mm (2.2264 to 2.2272 in.)
Journal No. 1 57.035 to 57.135 mm (2.2455 to 2.2494 in.)

Camshaft
inside No. 2 56.835 to 56.935 mm (2.2376 to 2.2415 in.)
diameter
No. 3 56.635 to 56.735 mm (2.2297 to 2.2337 in.)

No. 1 57.0 mm (2.2441 in.)
Inside
No. 2 56.8 mm (2.2362 in.)
diameter
No. 3 56.6 mm (2.2283 in.)
Camshaft bearing
No. 1 60.0 mm (2.3622 in.)
Outside
No. 2 59.8 mm (2.3543 in.)
diameter
No. 3 59.6 mm (2.3465 in.)
Bush inside Standard 22.023 to 22.052 mm (0.8670 to 0.8681 in.)

Shaft Standard 21.959 to 21.980 mm (0.8645 to 0.8653 in.)

Valve rocker arm and shaft

Circle
Valve push rod Maximum 0.30 mm (0.0118 in.)
runout
Cylinder head set bolt Length Maximum 129 mm (5.07 in.)
Connecting rod bolt Length
Symbol A 106.982 to 106.989 mm (4.2119 to 4.2122 in.)

Outside
Symbol B 106.990 to 106.995 mm (4.2122 to 4.2124 in.)
diameter
Symbol C 106.996 to 107.004 mm (4.2124 to 4.2128 in.)
Cylinder liner Inside Standard 104.012 to 104.036 mm (4.0950 to 4.0959 in.)
Protrusion
Maximum 0.08 mm (0.0031 in.)
Symbol A 107.000 to 107.008 mm (4.2126 to 4.2129 in.)
Inside
Symbol B 107.008 to 107.014 mm (4.2129 to 4.2131 in.)
Cylinder block diameter
Symbol C 107.014 to 107.022 mm (4.2131 to 4.2135 in.)
SS
Warpage Maximum 0.10 mm (0.0039 in.)
Pin A 6.0 mm (0.236 in.)
Protrusion Pin B 13.0 mm (0.512 in.)

Straight pin (cylinder block)
height Pin C 16.0 mm (0.630 in.)
Pin D 6.0 mm (0.236 in.)
Diameter Standard 103.936 to 103.952 mm (4.0920 to 4.0926 in.)
Oil
clearance
1st 0.11 to 0.15 mm (0.0043 to 0.0059 in.)
Ring groove 2nd 0.07 to 0.11 mm (0.0028 to 0.0043 in.)

clearance Oil 0.02 to 0.06 mm (0.0008 to 0.0024 in.)
Maximum 0.30 mm (0.0118 in.)
1st 2.58 to 2.60 mm (0.1016 to 0.1024 in.)
Standard 2nd 2.06 to 2.08 mm (0.0811 to 0.0819 in.)
Piston Ring groove Oil 4.01 to to 4.03 mm (0.1579 to 0.1587 in.)

width 1st 3.10 mm (0.1220 in.)
Maximum 2nd 2.20 mm (0.0866 in.)
Oil 4.08 mm (0.1606 in.)
1st 2.47 to 2.49 mm (0.0972 to 0.0980 in.)
Ring Oil 4.97 to to 4.99 mm (0.1957 to 0.1965 in.)

thickness 1st 2.32 mm (0.0913 in.)
Minimum 2nd 1.82 mm (0.0717 in.)
Oil 4.95 mm (0.1949 in.)

Runout Maximum 0.04 mm (0.0016 in.)
Main New 72.74 mm (2.8638 in.)
journal Minimum
outside Old 71.76 mm (2.8252 in.)
diameter Maximum taper and out-
0.01 mm (0.0004 in.)
of-round
Crankshaft
Crankshaft New 61.74 mm (2.4307 in.)

Minimum
pin outside Old 60.76 mm (2.3921 in.)
diameter
Maximum taper and out-
0.01 mm (0.0004 in.)
of-round
Crankshaft Standard 34.00 to 34.08 mm (1.3386 to 1.3417 in.)
No. 4
journal Maximum 34.48 mm (1.3574 in.)
dimension

Crankshaft bearing cap set bolt Length
Maximum 95.00 mm (3.7401 in.)
Bearing cap Standard 77.985 to 78.00 mm (3.0703 to 3.0709 in.)
inside
Bearing Standard 73.01 to 73.04 mm (2.8744 to 2.8756 in.)

inside

Crankshaft bearing cap clearance Maximum 0.20 mm (0.0078 in.)
SS Standard 72.94 to 72.96 mm (2.8717 to 2.8724 in.)
U/S 0.25 72.69 to 72.71 mm (2.8618 to 2.8626 in.)
Under size
bearing U/S 0.50 72.44 to 72.46 mm (2.8520 to 2.8528 in.)
diameter
U/S 0.75 72.19 to 72.21 mm (2.8421 to 2.8429 in.)
U/S 1.00 71.94 to 71.96 mm (2.8323 to 2.8330 in.)
Main crankshaft journal 3.00 to 3.50 mm (0.1181 to 0.1378 in.)
Exhaust manifold x Cylinder head sub-assembly 60 610 44
Exhaust manifold heat insulator x Exhaust manifold 29 290 21
Intake manifold x Cylinder head sub-assembly 29 290 21
Union Bolt 25 250 18
Water by-pass pipe sub-assembly x Cylinder block
Bolt 29 290 21
Cylinder head cover sub-assembly x Cylinder head sub-assembly 29 290 21
No. 2 cylinder head cover sub-assembly x Cylinder head sub-assembly 29 290 21
Water by-pass pipe sub-assembly x Timing gear case 29 290 21
Radiator pipe x Timing gear case 18 184 21
Water pipe sub-assembly x Timing gear case 29 290 21
Fuel support x Cylinder block 29 290 21
Bolt x Glow plug hole 23 229 17
Idle pulley bracket x Timing gear case 55 561 41
Timing gear case x Cylinder block 29 290 21
Oil pan sub-assembly x Cylinder block 29 290 21
for M14 bolt 132 1350 97
Fly wheel housing stay RH x Cylinder block
for M12 bolt 97 990 72
for M14 bolt 132 1350 98
Fly wheel housing stay LH x Cylinder block
for M12 bolt 97 990 72
Crankshaft pulley x Crankshaft 519 5300 380
Vacuum pump assembly x Timing gear case 55 560 41
Vacuum pump oil pipe sub-assembly x Vacuum pump assembly 13 130 10
Vacuum pipe x vacuum pump assembly 13 130 10
Vane pump x Timing gear case 47 480 35
No. 3 Nozzle leakage pipe sub-assembly x Engine assembly 13 130 10
Bolt A 44 450 33
Idler pulley assembly x Timing gear case
Bolt B 5.9 60 53
Bolt A 25 250 18
Stud bolt x Cylinder head sub-assembly
Bolt B 51 520 38
No. 1 valve rocker shaft sub-assembly x Cylinder head sub-assembly 69 700 51
Water outlet housing x Cylinder head sub-assembly 29 290 21
Water outlet sub-assembly x Water outlet housing 29 290 21

Generator bracket sub-assembly x Timing gear case 55 560 41
Generator belt adjusting bar x Cylinder block 125 1275 21
No. 1 compressor mounting bracket x Cylinder block assembly 55 561 41
Crankshaft position sensor x Timing gear case 8.0 82 71 in.
Camshaft position sensor x Cylinder block 5.0 51 44
Water temperature sensor x Cylinder head sub-assembly 29 300 22
No. 1 engine mounting bracket x Cylinder block 69 700 51
Engine mounting insulator x Engine mounting bracket 98 1000 72
Intake air hose x Timing gear case 18 184 13
SS
Cooler compressor assembly x No. 1 compressor mounting bracket 25 250 18
Fan x Water pump assembly 29 291 21
Adjusting screw x Rocker arm 29 296 21
Bolt A 29 291 18
Generator bracket x Generator Bolt B 55 561 38
Bolt C 5.9 60 53
1st 60 610 44
Crankshaft bearing cap x Cylinder block 2nd 60° 60° 60°
3rd 60° 60° 60°
No. 1 Oil nozzle sub-assembly x Cylinder block 29 290 21
Oil check valve sub-assembly x Cylinder block 69 700 51
for M14 bolt 132 1350 98
Flywheel housing x Cylinder block
for M8 bolt 29 290 21
Flywheel sub-assembly x Crankshaft 186 1900 137
Front end plate x Cylinder block 29 290 21
Oil pump assembly x Cylinder block 29 290 21
No. 1 Idle gear shaft x Cylinder block 136 1390 100
Camshaft x Cylinder block 29 290 21
No. 2 Idle gear shaft x Lock plate 55 560 41
No. 2 Idle gear thrust plate x No. 2 Idle gear shaft 55 560 41
Oil separator assembly x Cylinder block 55 560 41
Oil strainer sub-assembly x Cylinder block 29 290 21
1st 60 612 44
Cylinder head sub-assembly x Cylinder block (1 to 18 head
2nd 90° 90° 90°
bolt)
3rd 90° 90° 90°
Cylinder head sub-assembly x Cylinder block (19 to 22 head bolt) 55 560 41
Piston with connecting rod x Bearing cap 30 55 22
Engine hunger x Cylinder head 108 1100 80
Pressure feed hose x Hose bracket 44 450 21
No. 3 cab mounting bracket sub-assembly x body 120 1224 89
Air hose assembly x Engine assembly 18 184 13
Air cleaner case x Air cleaner stay 18 184 13
Radiator reserve tank assembly x Body 12 120 10
SS–12 SERVICE SPECIFICATIONS – W04D-J, TM, TN ENGINE MECHANICAL
W04D-J, TM, TN ENGINE

MECHANICAL
SERVICE DATA
Idle speed 650 to 750 rpm
Maximum speed 3520 to 3620 rpm
Standard 3540 to 3820 kpa (36 to 39 kgf/cm 512 to 554 psi)
SS Compression Pressure
Minimum 2750 kpa (28 kgf/cm 399 psi)
Difference between each
290 kpa (3 kgf/cm 42 psi)
cylinder
New nozzle 22.06 to 22.94 MPa (225 to 234 kgf/cm2, 3199 to

3326 psi)
Injection nozzles Opening pressure
Reused nozzle 22.06 to 22.94 MPa (225 to 234 kgf/cm2, 3199 to
3326 psi)
Deflection 10.0 to 15.0 mm (0.394 to 0.591 in.)
Fan and generator V belt New belt 374 to 471 N (38 to 48 kg, 84 to 106 lbf)
Tension
Used belt 275 to 373 N (28 to 38 kg, 62 to 84 lbf)
New belt 9.0 to 10.5 mm (0.35 to 0.41 in.)
No. 1 v (cooler compressor to Deflection
crankshaft pulley) belt Used belt 10.5 to 12.0 mm (0.41 to 0.47 in.)
(W04D-TM less)
Tension 383 to 481 N (39 to 49 kg, 86 to 108 lbf)
Intake valve Clearance 0.35 mm (0.014 in.)
Exhaust valve Clearance 0.55 mm (0.022 in.)
Intake manifold Warpage Maximum 0.20 mm (0.0079 in.)
Exhaust manifold Warpage Maximum 0.20 mm (0.0079 in.)
Circle runout Maximum 0.05 mm (0.0020 in.)
Intake 49.435 mm (1.9463 in.)
Standard
Exhaust 49.493 mm (1.9485 in.)
Cam lobe height
Intake 48.90 mm (1.9252 in.)
Minimum
Exhaust 48.95 mm (1.9272 in.)
Thrust clearance
Maximum 0.30 mm (0.0118 in.)
Camshaft No. 1 56.95 to 56.97 mm (2.2421 to 2.2429 in.)
Standard No. 2 56.75 to 56.77 mm (2.2342 to 2.2350 in.)
No. 3 56.55 to 56.57 mm (2.2264 to 2.2272 in.)
Journal diameter
No. 1 56.85 mm (2.2382 in.)
Minimum No. 2 56.65 mm (2.2303 in.)
No. 3 56.45 mm (2.2224 in.)
Oil clearance
Maximum 0.15 mm (0.0059 in.)
Cylinder block side
Intake manifold
Cylinder head sub-assembly Warpage Maximum side 0.10 mm (0.0039 in.)
Exhaust manifold
side
SERVICE SPECIFICATIONS – W04D-J, TM, TN ENGINE MECHANICAL SS–13
Deviation Maximum 2.0 mm (0.079 in.)

Inner 61.0 mm (2.402 in.)
Length
Outer 60.2 mm (2.370 in.)
Compression spring Inner 43.0 mm (1.693 in.)
Setting Height
Outer 45.5 mm (1.791 in.)
Inner 86.0 N (8.8 kgf, 19.3 lbf)
Tension
Outer 269.0 N (27.4 kgf, 60.5 lbf)
Intake valve Stem diameter
Minimum 8.90 mm (0.3504 in.)
SS
Exhaust valve Stem diameter
Minimum 8.80 mm (0.3465 in.)
Intake 0.15 to 0.45 mm (0.0059 to 0.0177 in.)
Standard
Valve Sink
Intake 0.55 mm (0.0217 in.)
Maximum
Exhaust 0.87 mm (0.0342 in.)
Protrusion height Standard 15 mm (0.59 in.)
Intake 0.035 to 0.068 mm (0.0014 to 0.0027 in.)
Standard
Valve guide bush A & B 0.12 mm (0.0039 in.)
Oil clearance Intake
C 0.18 mm (0.0071 in.)
Maximum
A & B 0.12 mm (0.0047 in.)
Exhaust
C 0.20 mm (0.0079 in.)
Injection nozzle seat Protrusion height
Maximum 3.05 mm (0.1201 in.)
A: 46.500 to 46.516 mm (1.8307 to 1.8313 in.)
Intake
Cylinder head B: 8.800 to 9.000 mm (0.3465 to 0.3543 in.)
Standard
dimension A: 41.000 to 41.016 mm (1.6142 to 1.6148 in.)
Exhaust
B: 7.200 to 7.300 mm (1.2835 to 0.2874 in.)
Valve seat
C: 46.585 to 46.600 mm (1.8341 to 1.8346 in.)
Intake
Valve seat D: 7.500 to 7.700 mm (0.2953 to 0.3031 in.)
Standard
dimension C: 41.130 to 41.145 mm (1.6193 to 1.6199 in.)
Exhaust
D: 6.000 to 6.200 mm (0.2362 to 0.2441 in.)
Injection pump drive gear Backlash
Maximum 0.30 mm (0.0118 in.)
Camshaft timing gear Backlash
Maximum 0.30 mm (0.0118 in.)
Oil pump gear Backlash
Maximum 0.30 mm (0.0118 in.)
Thrust clearance
Maximum 0.15 mm (0.0059 in.)
Backlash (for Standard 0.068 to 0.194 mm (0.0027 to 0.0076 in.)
Crankshaft timing
gear) Maximum 0.30 mm (0.0118 in.)
No. 1 idle gear and shaft Idle gear inside

diameter
Idle gear shaft
diameter
Oil clearance
Maximum 0.10 mm (0.0039 in.)
Lifter diameter Standard 26.95 to 26.97 mm (1.0610 to 1.0618 in.)

Lifter bore
Valve lifter diameter
Oil clearance
Maximum 0.10 mm (0.0039 in.)
Thrust clearance
Maximum 0.60 mm (0.0236 in.)
Connecting rod
Bend Maximum 0.10 mm (0.0039 in.) per 200 mm (7.87 in.)
Twist Maximum 0.10 mm (0.0039 in.) per 200 mm (7.87 in.)
SS Big end inside Standard 61.985 to 62.000 mm (2.4403 to 2.4409 in.)
Connecting rod bearing Standard 0.031 to 0.082 mm (0.0012 to 0.0032 in.)
Oil clearance
Maximum 0.12 mm (0.0047 in.)
Crankshaft pin 3.50 to 4.00 mm (0.1378 to 0.1575 in.)
Connecting rod bush Inside diameter
Maximum 37.10 mm (1.4606 in.)
runout Maximum 0.15 mm (0.0059 in.)
Flywheel sub-assembly Maximum deflection 0.04 mm (0.0016 in.)
Grind limit 1.00 mm (0.0394 in.)
Diameter
Maximum 36.96 mm (1.4551 in.)
Piston pin
Standard 0.035 to 0.056mm (0.0014 to 0.0022 in.)
Oil clearance
Maximum 0.08 mm (0.0031 in.)
Inside diameter
Maximum 37.05 mm (1.4587 in.)
Piston pin hole
Standard 0.013 to 0.014 mm (-0.0005 to 0.0005 in.)
Oil clearance
Maximum 0.05 mm (0.0020 in.)
No. 1 57.00 to 57.07 mm (2.2441 to 2.2468 in.)
Camshaft bearing Inside diameter No. 2 56.80 to 56.87 mm (2.2362 to 2.2390 in.)
No. 3 56.60 to 56.67 mm (2.2238 to 2.2311 in.)
Bush inside Standard 19.020 to 19.045 mm (0.7488 to 0.7498 in.)

Valve rocker arm and shaft Shaft diameter
Minimum 18.95 mm (0.7461 in.)
Oil clearance
Maximum 0.10 mm (0.0039 in.)
Bolt No. 1 to 13 117.5 mm (4.63 in.)
Cylinder head set bolt Length Maximum
Bolt No. 14 to 18 164.5 mm (6.48 in.)
Connecting rod bolt Length
Maximum 60.00 mm (2.3622 in.)
Inside diameter
Maximum 104.15 mm (4.1004 in.)
Cylinder liner
Protrusion
Maximum 0.08 mm (0.0031 in.)
Standard 0.05 mm (0.0020 in.) or less
Cylinder block Warpage
Maximum 0.10 mm (0.0039 in.)
SERVICE SPECIFICATIONS – W04D-J, TM, TN ENGINE MECHANICAL SS–15
Diameter Standard 103.912 to 103.928 mm (4.0910 to 4.0917 in.)

Minimum 103.902 mm (4.0906 in.)
Oil clearance Standard 0.0140 to 0.0172 mm (0.0006 to 0.0007 in.)
1st Not easily measured
Ring groove 2nd 0.07 to 0.11 mm (0.0028 to 0.0043 in.)

clearance Oil 0.02 to 0.06 mm (0.0008 to 0.0024 in.)
Maximum 0.30 mm (0.0118 in.)
Oil 4.01 to to 4.03 mm (0.1579 to 0.1587 in.)
SS
Ring groove width
Maximum 2nd 2.20 mm (0.0866 in.)
Piston Oil 4.08 mm (0.1606 in.)
Oil 4.97 to to 4.99 mm (0.1957 to 0.1965 in.)
Ring thickness
Minimum 2nd 1.82 mm (0.0717 in.)
Oil 4.95 mm (0.1949 in.)
No. 1 0.30 to to 0.42 mm (0.0118 to 0.0165 in.)
Standard No. 2 0.50 to to 0.65 mm (0.0197 to 0.0255 in.)
No. 3 0.15 to to 0.30 mm (0.0059 to 0.0118 in.)
End gap
No. 1 1.2 mm (0.0472 in.)
Maximum No. 2 1.2 mm (0.0472 in.)
No. 3 1.0 mm (0.0394 in.)
Thrust clearance
Maximum 0.40 mm (0.0157 in.)
Runout Maximum 0.04 mm (0.0016 in.)
Crankshaft Main journal
New 72.74 mm (2.8638 in.)
outside diameter Minimum
Old 71.76 mm (2.8252 in.)
Crankshaft pin Standard 61.940 to 61.960 mm (2.4386 to 2.4394 in.)

outside diameter Minimum 60.76 mm (2.3921 in.)
Crankshaft bearing cap set bolt Length
Maximum 95.20 mm (3.7480 in.)
Bearing cap inside Standard 77.985 to 78.00 mm (3.0703 to 3.0709 in.)

Bearing inside Standard 73.000 mm (2.8740 in.)

Crankshaft bearing cap diameter Maximum 73.30 mm (2.8858 in.)
Oil clearance
Maximum 0.13 mm (0.0051 in.)
Main crankshaft journal 3.00 to 3.50 mm (0.1181 to 0.1378 in.)
Intake manifold x Cylinder head sub-assembly 29 291 21
Cylinder head cover sub-assembly x Cylinder head sub-assembly 25 250 18
Dust cover x Flywheel housing 29 291 21
Drain plug x Oil pan sub-assembly 41 420 30

Oil pan sub-assembly x Cylinder block 29 291 21
Crankshaft pulley x Crankshaft 515 5250 380
Bolt A 25 255 18
Stud bolt x Cylinder head sub-assembly
Bolt B 47 479 35
No. 1 valve rocker shaft sub-assembly x Cylinder head sub-assembly 69 700 51
1st 59 600 43
No. 1 valve rocker shaft sub-assembly x Cylinder head sub-
2nd 900 900 900
assembly
3rd 900 900 900
SS Nozzle holder x Cylinder head sub-assembly 15 150 11
Generator bracket sub-assembly x Cylinder block 55 561 41
Engine mounting bracket x Cylinder block 41 418 30
Engine mounting insulator x Engine mounting bracket 98 1000 72
Crankshaft bearing cap x Cylinder block 147 1500 109
Oil pipe sub-assembly x Cylinder block 22 220 16
Connecting rod bearing cap x Connecting rod sub-assembly 123 1250 90
Flywheel housing x Cylinder block 118 1200 87
Flywheel sub-assembly x Crankshaft 186 1900 137
No. 1 Idle gear shaft x Cylinder block 137 1400 101
Camshaft x Cylinder block 25 250 18
Bearing holder case x Timing gear cover assembly 29 291 21
Seat plate x Cylinder block 29 291 21
Oil strainer sub-assembly x Cylinder block 29 291 21
1st 59 600 43
Cylinder head sub-assembly x Cylinder block (1 to 18 head
2nd 90° 90° 90°
bolt)
3rd 90° 90° 90°
Cylinder head sub-assembly x Cylinder block (19 to 22 head bolt) 59 600 43
Engine hunger x Cylinder head 108 1100 80
No. 3 cab mounting bracket sub-assembly x body 120 1224 89
Radiator reserve tank assembly x Fender side apron sub-assembly 12 120 9
Timing gear cover assembly x Cylinder block 29 291 21
Fan spacer x Water pump 29 291 21
Fan x Fan spacer 29 291 21
Fan clutch x Water pump 29 291 21
Engine mounting insulator x Body 98 1000 72
Air cleaner pipe x Cylinder head cover 29 291 21
Valve clearance adjusting screw 25 250 18
Side bolt 25 255 18
Water outlet housing x Cylinder head sub-assembly
Upper bolt 51 520 38
Oil level gauge guide x Cylinder block 29 291 21
Oil cooler assembly x Cylinder block 33 337 24
Water outlet sub-assembly x Water outlet housing 25 255 18
Turbo charger sub-assembly x Exhaust manifold 56 571 41
No. 2 intake manifold x Intake manifold 29 291 21
Water temperature sender gauge assembly x Water outlet housing 29 291 21
Idler pulley bracket x Timing gear cover assembly (W04D-TM less) 69 700 51
No. 1 compressor mounting bracket x Cylinder block (W04D-TM less) 69 700 51
Crankshaft pulley (air conditioning) x Crankshaft pulley (W04D-TM less) 32 320 23
SERVICE SPECIFICATIONS – N04C-TR, TS, TT, TU, TV, TW FUEL SS–17

SERVICE DATA
Fuel injector assembly Resistance : 0.35 to 0.55 Ω at 20 °C (68 °F)
Suction control valve (Injection or supply pump Resistance : 7.6 to 8.2 Ω at 20 °C (68 °F)
assembly)
Fuel temperature sensor (Injection or supply pump Resistance : 2.21 to 2.69 kΩ at 20 °C (68 °F)
assembly)
Common rail assembly 2 - 3 : Resistance 16.4 kΩ or less at 20 °C (68 °F)
5 - 4 : Resistance 16.4 kΩ or less at 20 °C (68 °F) SS
1 - 2 : Resistance 3 kΩ or less at 20 °C (68 °F)
6 - 5 : Resistance 3 kΩ or less at 20 °C (68 °F)
Level warning switch Specified condition :
Switch ON (Upper end of float) Below 1 Ω
Switch OFF (Lower end of float) 10 kΩ or higher
Nozzle holder clamps x Cylinder head 25 255 18
Nozzle leakage pipe x Injector 13 133 10
EGR valve bracket x Intake manifold 29 291 21
EGR valve bracket x EGR valve assembly 29 291 21
Cylinder head cover sub-assembly x Cylinder head 29 291 21
Timer cover x Injection or supply pump assembly 29 291 21
Injection pump drive gear x Injection or supply pump assembly 64 650 47
Injection or supply pump assembly x Timing gear case 29 291 21
Holder clip x Injection or supply pump assembly 29 291 21
Fuel filter to injection pump fuel pipe x Injection or supply pump assembly
44 449 33
(Union nuts)
Common rail x Fuel filter to injection pump fuel pipe (Union nuts) 44 449 33
Fuel return pipe sub-assembly x Injection or supply pump assembly (Union
25 250 18
bolt)
No. 4 fuel pipe sub-assembly x Common rail (M10 union bolt) 20 204 15
No. 4 fuel pipe sub-assembly x Fuel return pipe sub-assembly (M12 union
25 250 18
bolt)
Fuel delivery pipe x Injection or supply pump assembly (Union bolt) 25 250 18
Common rail assembly x Engine unit 29 291 21
Injector x Injection pipe sub-assembly (Union nuts) 44 449 33
Injection pipe sub-assembly x Common rail assembly (Union nuts) 44 449 33
Intake pipe x Intake manifold 29 291 21
Fuel sedimenter filter assembly x Fuel filter bracket 18 180 13
Fuel filter assembly x Fuel filter bracket 44 449 33
Injector driver x Injector driver bracket 2.0 20 18 in.*lbf
Injector driver assembly x No. 3 cab mounting bracket sub-assembly 20 200 14
Fuel tank vent tube sub-assembly x Fuel tank 3.5 36 31 in.*lbf
Fuel cut off valve assembly x Fuel tank 1.5 15 13 in.*lbf
Fuel sender gauge assembly x Fuel tank 1.5 15 13 in.*lbf
Fuel tank stay x Body 61 622 45
Fuel tank band x Fuel tank stay 13 133 10
SS–18 SERVICE SPECIFICATIONS – W04D-TM, TN FUEL
W04D-TM, TN FUEL
SERVICE DATA
Injection pump Camshaft protruding length 16 to 17 mm (0.63 to 0.66 in.)
(Overhaul)
Camshaft end play 0.03 to 0.05 mm (0.0012 to 0.0019 in.)
Protruction of adjusting nut A -0.4 to 0.2 mm (-0.015 to 0.007 in.)
Damper thrust clearance 0.02 to 0.10 mm (0.0008 to 0.0039 in.)
Bearing bolt STD free play 1.5 to 2.0 mm (0.060 to 0.078 in.)
SS Fitting dimension 49.7 to 50.1 mm (1.957 to 1.972 in.)
Thrust clearance B 0.08 to 0.12 mm (0.0032 to 0.0047 in.)
Timer hub screw Oil volume 190 to 210 cm3 (11.60 to 12.82 cu in.)
Injection pump Governor adjustment L1 = L2 23.5 mm (0.925 in.)
(Adjustment) Injection timing Injection interval 89°45' to 90°15'
Injection order 1-3-4-2
Camshaft center bearing setting screw 6.9 to 8.8 70 to 90 5.1 to 6.5
Bearing cover x Pump body 16 160 12
Governor housing x Governor cover assembly 19 190 14
Delivery valve holder x Injection pump element 88 900 65
Injection pump element x Pump body 19 195 14
Driving flange x Timer cover 319 3250 235
Timer hub screw 14 140 10
Timer assembly x Injection pump 137 1400 101
Timer cover fitting bolt 29 291 21
Fuel filter assembly (for engine side) x Engine 47 480 35
Fuel pipes x Fuel filter assembly 25 255 18
Fuel pipes x Injection pump 17 173 13
Nozzle retaining nut 64 650 47
Nozzle holder x Cylinder head 15 153 11
Injection pipe x Injection nozzle 12 122 9
Injection pipe x Injection pump 29 296 21
Injection pipe x Engine 17 173 13
Injection pipe x Injection nozzle 34 347 25
Injection pipe x Injection pump 34 347 25
Injection pipe x Pipe clamp 29 296 21
Fuel filter assembly (for fuel tank side) x Body 44 449 32
Fuel pipe x fuel filter assembly (for fuel tank side) 25 255 18
SERVICE SPECIFICATIONS – W04D-J FUEL SS–19
W04D-J FUEL
SERVICE DATA
Injection pump Camshaft end play STD 0.03 - 0.05 mm (0.00 12 - 0.00 19 in.)
(Overhaul) Service limit 0.10 mm (0.0039 in.)
Protruction of adjusting nut A -0.4 -0.2 mm (-0.0015 -0.007 in.)
Damper thrust clearance STD 0.02 - 0.10 mm (0.0008 - 0.0039 in.)
Bearing bolt STD free play 1 .5 - 2.0 mm (0.060 - 0.078 in.)
Fitting dimension 49.7 - 50.1 mm (1.957 - 1 .972 in.)
Thrust clearance B 0.08 - 0.1 2 mm (0.0032 - 0.0047 in.) SS
Timer cover clearance Cover side 0.12 - 0.22 mm (0.00472 - 0.00866 in.)
Gear side 0.02 - 0.12 mm (0.00079 - 0.00472 in.)
Injection pump Governor adjustment L1 = L2 23.5 mm (0.925 in.)
(Adjustment) Preparations of pump tester
Test nozzle type 12SD12
Test nozzle opening pressure 17.160 MPa (175 kgf/cm2, 2,489 psi)
Injection pipe
Outside diameter 6.0 mm (0.24 in.)
Inside diameter 2.0 mm (0.08 in.)
Length 600 mm (23.6 in.)
Injection timing Injection interval 89°45' - 90°15'
Tappet top clearance More than 0.2 mm (0.0079 in.)
INJECTION PUMP CALIBRATION

W04D-J
INJECTION PUMP NUMBER: 22010 -9050, 20010-9060
Engine model W04D-J
Injection pump part 22010-9050, 22010-9060
INJECTION PUMP
SPECI PUMP Injection pump type ND-PES4A95D321R
SPECI-FICATION Governor type R801
FICATION
Timer type ND/SB0/1000-1600/3.5R
Feed pump type ND-FP/KS22AC
Test nozzle type ND-DN 12SD12A
Test nozzle opening pressure 17.16 - 17.65 MPa {175 - 180 kgf/cm2, 2,489 - 2,560 lbf/in.2}
Outer diameter 6.0 mm {0.24 in.}
Injection pipe Inner diameter 2.0 mm {0.08in.}
TEST CONDITION Lenght 600 mm {23.6 in.}
Type of fuel SAE J967C JISD3603
Calibration
Fuel temperature 40 - 45°C {1 04 - 11 3°F}
Fuel feed pressure 196 kpa {2.0 kgf/cm2, 28.4 lbf/in.2}
Overflow valve opening pressure 157 kpa {1.6 kgf/cm2, 22.8 lbf/in.2}
Rotation Clockwise viewed from driver side
INJECTION Injection order 1-3-4-2

TIMING Injection interval 89°45' - 90°15
Pre - stroke 2.97 - 3.03 mm {0.11 69 - 0.11 93 in.}
Rack position Pump revolution Injection volume cc
Measuring strokes Variation limit cc {cu.in}
mm (in) {r/min} {cu.in}
INJECTION 29.5 - 31.5 {1 ,800 - 1

9.45 {0.372} 1 ,000 500 1.5 {0.092} or less
VOLUME ,922}
ADJUSTMEN 27.75 - 30.75 {1.693 -
9.2 {0.362} 1,600 500 2.5 {0.1 53} or less
1.876}
8.3 {0.327} 350 500 5.5 - 6.5 {0.335 - 0.396} 1.5 {0.092} or less
SS–20 SERVICE SPECIFICATIONS – W04D-J FUEL
Adjusting lever position Pump speed r/minx Advance angle

3/4 load 1 ,000 0.3° or less
TIMER ADVANCE
4/4 load 1,550 3.5°±0.3°
4/4 load 1,600 3.5°±0.3°
GOVERNOR ADJUSTMENT
Adjusting item Adjusting lever position Pump speed r/min Cntrol rack position mm {in.}
Idling speed Idling 100 12.7±0.2 {0.500±0.007}
control -22.5° - -12.5°
150 12.5 {0.492} or more
SS 200 12.0 {0.472} or less

350 8.3±0.1 {0.327±0.003}
1,000 4.9±0.2 {0.1 93±0.007}
Medium speed Full load Full load 400 10.5±10.2 {0.413±0.007}
control 35° - 41° Between idling and
650 9.9±0.2 {0.390±0.007}
full-load
800 9.7±0.2 {0.382±0.007}
1,000 9.45±0.2 {0.372±0.007}
1,600 9.2±0.2 {0.362±0.007}
1,675 9.2±0.2 {0.362±0.007}
Maximum speed Full load Full load 1,850 Rw1+0.5 {0.020} or more
control 35° - 41° Between idling and
1,850 7.8±0.2 {0.307±0.007}=Rw1
full-load
2,000 5.0 {0.197} or less
MEASURE THE INJECTION VOLUME

Adjusting lever posi-tion Pump speed r/min Measuring stroke Injection volume cm3 {cu. in.} Adjusting position
650 24.0 - 26.5 {1,464 - 1,617}
Full Load Full Load 1,000 500 29.5 - 31.5 {1,800 - 1,922} Full - load stopper
1,600 27.75 - 30.75 {1,693 - 1,876}
Adjusting lever position Pump speed r/min Measuring stroke Control rack postion Adjusting position
Engine starting 100 - Rw=16.7±0.3
TORQUE
W04D-J
Fuel filter assembly x Intake manifold 47 480 35
Fuel pipe x Fuel filter assembly 24.5 250 18
Fuel filter drain bolt 6.9 70 61 in.*lbf
Injection pump air bleeder 5.9 60 52 in.*lbf
Nozzle holdr and nozzle set x Cylinder head 15 150 11
Injection pipe set x Injector 19.6 200 14.5
Injection pump x Timing gear case 29.42 - 34.32 300 - 500 22 - 25
Fuel tank bent tube x Fuel tank assembly 5.0 50 44 in.*lbf
Fuel sender gauge x Fuel tank assembly 1.5 15 13 in.*lbf
SERVICE SPECIFICATIONS – N04C-TU, TV, TW EMISSION CONTROL SS–21
N04C-TU, TV, TW EMISSION

CONTROL
SERVICE DATA
Resistance 1 (EGR) - 5 (+B) 25.5 to 29.5 Ω
EGR valve assembly Resistance 3 (VC) - 2 (E2) 2.45 to 4.55 Ω
Resistance 4 (EGLS) - 2 (E2) 2.45 to 4.55 Ω
0 kPa 0.75 V SS
2
20 kPa (0.2 kgf/cm , 2.9 1.53 V
Voltage
Differential pressure sensor psi)
B27 (PEX) - A28 (E2)
100 kPa (1.0 kgf/cm2, 14.5 4.65 V
psi)
Exhaust gas temperature sensor (front side) Resistance (1 - 2) 82 to 137 kΩ at 50°C (122°F)
Exhaust gas temperature sensor (rear side) Resistance (1 - 2) 82 to 137 kΩ at 50°C (122°F)
EGR valve assembly x Intake pipe 29 291 21
EGR bracket x EGR valve assembly 29 291 21
Cylinder head sub-assembly x No. 2 EGR pipe 24 245 18
Water by-pass pipe sub-assembly x Cylinder Union Bolt 25 255 18

block Bolt 29 291 21
Monolithic converter assembly x With catalyst converter assembly 35 357 26
Monolithic converter assembly x Center exhaust pipe sub-assembly 35 357 26
No. 5 exhaust pipe clamp x Support bracket 18 184 13
Center exhaust pipe assembly x Body 50 510 37
Front exhaust pipe assembly x Exhaust retarder assembly x Center exhaust
30 306 22
pipe assembly
Tail exhaust pipe assembly x Center exhaust pipe assembly 24 245 18
Oil separator bracket x Oil separator 29 291 21
Oil separator assembly x Intake manifold 29 291 21
Harness bracket x Oil separator assembly 18 178 13
Differential pressure sensor x Body 19 194 14
Exhaust gas temperature sensor x Center without union nut wrench 30 306 22
exhaust pipe assembly with union nut wrench 27 275 20
No. 2 exhaust gas temperature sensor x Center without union nut wrench 30 306 22
exhaust pipe assembly with union nut wrench 27 275 20
SS–22 SERVICE SPECIFICATIONS – N04C-TR, TS, TT, TU, TV, TW INTAKE

INTAKE
SERVICE DATA
Standard pressure:
Turbocharging pressure
40 to 70 kPa (0.40 to 0.71 kgf/cm2, 5.8 to 10.2 psi)
SS TORQUE SPECIFICATIONS
Part tightened N*m kgf*cm ft*lbf
Turbocharger sub-assembly x Exhaust manifold 70 714 52
Turbo oil outlet pipe x Turbocharger sub-assembly 29 296 21
Turbo oil outlet pipe x Cylinder head sub-assembly 29 296 21
No. 2 water by-pass pipe sub-assembly x Turbocharger Union bolt 25 255 18

sub-assembly Bolt 18 184 13
No. 1 turbo insulator x Turbocharger sub-assembly 29 291 21
Intake pipe x Turbocharger sub-assembly 28 286 21
No. 1 turbo water pipe sub-assembly x Turbocharger Union bolt 25 255 18

sub-assembly Bolt 29 291 21
Turbo oil inlet pipe sub-assembly x Turbocharger sub- Union bolt 25 255 18
assembly Bolt 25 250 18
Intake air connector bracket. x Turbocharger sub-assembly 29 291 21
Bolt 18 184 13
No. 2 intake pipe x Cylinder head sub-assembly
Bolt 29 291 21
No. 1 intake air pipe with No. 4 air hose x Body 18 184 13
Intercooler assembly x Radiator assembly 7.5 77 66 in.*lbf
SERVICE SPECIFICATIONS – W04D-TM, TN INTAKE SS–23
W04D-TM, TN INTAKE
SERVICE DATA
Standard play:
0.05 to 0.13 mm (0.0020 to 0.0051 in.)
Radial ball bearing clearance
Maximum play:
0.13 mm (0.0051 in.)
Standard play:
0.01 to 0.10 mm (0.0004 to 0.0039 in.)
Turbocharger
Axial bearing clearance
Maximum play: SS
0.10 mm (0.0039 in.)
Rod movement:
0.38 mm (0.015 in.)
Waste gate performance Air pressure:
106.9 to 112.3kPa (1.08 to 1.14 kg/cm2 15 to
16 psi)
Part tightened N*m kgf*cm ft*lbf
Turbocharger sub-assembly x Exhaust manifold 56 570 41
Water by-pass pipe sub-assembly x Turbocharger sub-assembly 25 250 18
Water by-pass pipe sub-assembly x Cylinder block 25 250 18
Water inlet pipe assembly X Turbocharger sub-assembly 25 250 18
Water inlet pipe clamp X Turbocharger sub-assembly 18 184 13
Turbo oil outlet pipe x Turbocharger sub-assembly 29 290 21
Turbo oil outlet pipe x Cylinder block 29 290 21
Turbo oil inlet pipe sub-assembly x Turbocharger sub-assembly 25 250 18
Turbo oil inlet pipe sub-assembly x Cylinder block 25 250 18
Turbo oil inlet pipe clamp x Turbocharger sub-assembly 18 184 13
Turbine outlet elbow X Turbocharger sub-assembly 30 301 22
Intake pipe x Turbocharger sub-assembly 29 290 21
Intake air connector pipe x Cylinder head cover sub-assembly 29 290 21
Intercooler assembly X Radiator assembly 7.5 77 66 in.*lbf
SS–24 SERVICE SPECIFICATIONS – N04C-TR, TS, TT, TU, TV EXHAUST
N04C-TR, TS, TT, TU, TV EXHAUST

Part Tightened N*m kgf*cm ft*lbf
Exhaust manifold cover x Exhaust manifold 29 290 21
Exhaust manifold x Cylinder head 60 610 44
Front exhaust pipe assembly x Turbo charger sub-assembly 70 714 52
Exhaust pipe clamp bolt 25 259 19
SS Center exhaust pipe assembly x Exhaust retarder assembly x Front exhaust pipe assembly 30 301 22
Center exhaust pipe assembly x No. 1 exhaust pipe support bracket 24 245 18
No. 1 exhaust pipe support bracket x Frame 50 510 37
No. 1 lower exhaust pipe support bracket x Exhaust pipe bracket 24 245 18
No. 1 lower exhaust pipe support bracket x Frame 24 245 18
Nut 31 313 23
Exhaust pipe support sub-assembly
Nut 50 510 37
Exhaust pipe support sub-assembly x No. 1 lower exhaust pipe support bracket 24 245 18
No. 4 exhaust pipe support bracket x No. 1 Exhaust pipe support 24 245 18
Exhaust pipe support bolt x No. 1 Exhaust pipe support 24 245 18
No. 5 exhaust pipe support bracket x No. 1 Exhaust pipe support 24 245 18
SERVICE SPECIFICATIONS – N04C-TW EXHAUST SS–25
N04C-TW EXHAUST
Exhaust manifold cover x Exhaust manifold 25 255 18
Front exhaust pipe assembly x Turbocharger 70 714 52
Front exhaust pipe assembly x Bracket 25 255 18
Center exhaust pipe assembly x Body 50 516 37 SS
Front exhaust pipe assembly x Exhaust retarder assembly x Center exhaust
30 306 22
pipe assembly
Tail exhaust pipe sub-assembly x Center exhaust pipe assembly 24 245 18
Tail exhaust pipe assembly x Tail exhaust pipe sub-assembly 24 245 18
SS–26 SERVICE SPECIFICATIONS – W04D-TM EXHAUST
W04D-TM EXHAUST
Center exhaust pipe assembly x Exhaust retarder assembly x Front exhaust pipe assembly 30 301 22
SS Center exhaust pipe assembly x No. 1 exhaust pipe support bracket 24 245 18
SERVICE SPECIFICATIONS – W04D-TN EXHAUST SS–27
W04D-TN EXHAUST
Center exhaust pipe assembly x Exhaust retarder assembly x Front exhaust pipe assembly 30 301 22
Center exhaust pipe assembly x No. 1 exhaust pipe support bracket 24 245 18 SS
31 313 23
Exhaust pipe support sub-assembly Nut
50 510 37
Exhaust pipe support sub-assembly x No. 1 lower exhaust pipe support bracket 24 245 18
Tail exhaust pipe assembly x Exhaust pipe bracket 25 259 19
No. 4 exhaust pipe support bracket x Exhaust pipe bracket 24 245 18
No. 5 exhaust pipe support bracket x Exhaust pipe bracket 24 245 18
31 313 23
Exhaust pipe support sub-assembly Nut
50 510 37
Exhaust pipe support sub-assembly x Rear muffler bracket 24 245 18
Rear muffler bracket x Frame 24 245 18
Rear muffler bracket x Rear cab mount member 50 510 37
Rear muffler bracket x Exhaust pipe support sub-assembly 58 591 43
No. 1 exhaust pipe heat insulator x Exhaust pipe support sub-assembly 24 245 18
No. 4 exhaust pipe support bracket sub-assembly x Frame 58 591 43
No. 4 exhaust pipe support bracket x Exhaust pipe support sub-assembly 58 591 43
Exhaust pipe support sub-assembly x No. 2 exhaust support cushion 25 250 18
Tail exhaust pipe assembly x No. 2 exhaust support cushion 25 250 18
SS–28 SERVICE SPECIFICATIONS – N04C-TR, TS, TT, TU, TV, TW COOLING

COOLING
SERVICE DATA
Valve opening temperature 80 to 84°C (176 to 183°F)
Thermostat
Valve lift 10 mm (0.394 in.) or more at 95°C (203°F)
Standard valve (for brand new cap) 93 to 123 kPa (0.95 to 1.25 kgf/cm2, 13.5 to
SS Radiator cap sub-assembly 17.8 psi)
Minimum standard valve (after using cap) 78 kPa (0.8 kgf/cm2, 11.4 psi)
Water pump assembly x Cylinder block 29 290 21
Water outlet x Water outlet housing 29 290 21
Radiator side plate x Radiator tank upper 13 130 9
Radiator side plate x Radiator tank lower 13 130 9
No. 1 radiator to support seal x Radiator side plate 7.5 77 66 in.*lbf
Fan shroud x Radiator side plate 5.0 51 44 in.*lbf
No. 3 radiator bracket x Radiator assembly 18 184 13
Heater hose x Radiator assembly 20 204 15
SERVICE SPECIFICATIONS – W04D-TM, TN COOLING SS–29
W04D-TM, TN COOLING
SERVICE DATA
Valve opening temperature 80 to 84°C (176 to 183°F)
Thermostat
Valve lift 10 mm (0.394 in.) or more at 95°C (203°F)
Standard valve (for brand new cap) 93 to 123 kPa (0.95 to 1.25 kgf/cm2, 13.5 to
Radiator cap sub-assembly 17.8 psi)
Minimum standard valve (after using cap) 78 kPa (0.8 kgf/cm2, 11.4 psi)
SS
Water pump assembly x Cylinder block 29 290 21
Vacuum switching valve hose bracket x Water outlet
29 290 21
(W04D-TN less)
Water outlet x Water outlet housing 25 250 18
Radiator air guide x Radiator assembly 7.5 77 66 in.*lbf
Fan shroud x Radiator assembly 5.0 51 44 in.*lbf
No. 3 radiator bracket x Radiator mounting insulator 18 184 13
No. 4 radiator bracket x Radiator mounting insulator 18 184 13
No. 1 radiator support x Radiator assembly: Bolt(A) 7.5 77 66 in.*lbf
No. 1 radiator support x Radiator assembly: Bolt(B) 18 184 13
No. 2 intake pipe x Radiator assembly 18 184 13
No. 3 intake pipe x Radiator assembly 18 184 13
SS–30 SERVICE SPECIFICATIONS – N04C-TR, TS, TT, TU, TV, TW LUBRICATION

LUBRICATION
SERVICE DATA
Oil pressure When idling 190 kPa (1.9 kgf/cm2, 27.6 psi)
Standard backlash (for oil pump gear) 0.065 to 0.215 mm (0.0026 to 0.0084 in.)
Maximum backlash (for oil pump gear) 0.3 mm (0.0118 in.)
SS Standard width 27.02 to 27.04 mm (1.0638 to 1.0646 in.)
Standard depth 27.03 to 27.07 mm (1.0642 to 1.0657 in.)
Standard clearance 0.05 to 0.13 mm (0.002 to 0.0051 in.)
Maximum clearance 0.17 mm (0.0067 in.)
Standard backlash (for drive gear) 0.091 to 0.217 mm (0.0036 to 0.0085 in.)
Maximum backlash (for drive gear) 0.30 mm (0.0118 in.)
Standard shaft diameter (for drive gear
18.088 to 18.106 mm (0.7121 to 0.7128 in.)
shaft)
Oil pump assembly Standard bush inside diameter (for drive
18.146 to 18.173 mm (0.7144 to 0.7155 in.)
gear bush)
Maximum bush inside diameter (for drive
18.20 mm (0.7165 in.)
gear bush)
Standard shaft diameter (for driven gear
17.979 to 17.997 mm (0.7078 to 0.7085 in.)
shaft)
Standard bush inside diameter (for
18.037 to 18.054 mm (0.7101 to 0.7108 in.)
driven gear bush)
Install the oil pressure switch by hand, then further tighten it by
Oil pressure switch x Oil filter bracket sub-assembly
20 to 40°
No. 1 idle gear sub-assembly x Cylinder block 137 1397 101
Oil cooler assembly x Oil filter bracket sub-assembly 12 125 9.0
Oil cooler assembly with oil filter bracket x Cylinder block 29 290 21
SERVICE SPECIFICATIONS – W04D-TM, TN LUBRICATION SS–31
SERVICE DATA
At idling 137 kPa (1.4 kgf/cm2, 19.7 psi)
Oil pressure
At 2500 rpm 363 kPa (3.7 kgf/cm2, 51 psi)
Standard backlash (for drive gear) 0.091 to 0.217 mm (0.0036 to 0.0085 in.)
Maximum backlash (for drive gear) 0.30 mm (0.0118 in.)
Standard shaft diameter (for drive gear
shaft)
18.088 to 18.106 mm (0.7121 to 0.7128 in.) SS
Minimum shaft diameter (for drive gear
18.062 mm (0.7111 in.)
shaft)
Standard bush inside diameter (for drive
18.146 to 18.173 mm (0.7144 to 0.7155 in.)
gear bush)
Maximum bush inside diameter (for drive
18.20 mm (0.7165 in.)
gear bush)
Oil pump assembly
Standard shaft diameter (for driven gear
17.979 to 17.997 mm (0.7078 to 0.7085 in.)
shaft)
Minimum shaft diameter (for driven gear
17.97 mm (0.7075 in.)
shaft)
Standard bush inside diameter (for
18.037 to 18.054 mm (0.7101 to 0.7108 in.)
driven gear bush)
Maximum bush inside diameter (for
18.707 mm (0.7114 in.)
driven gear bush)
Install the oil pressure switch by hand, then further tighten it by
Oil pressure switch x Oil filter bracket sub-assembly
20 to 40°
No. 1 idle gear x Cylinder block 137 1397 101
Oil cooler assembly x Oil filter bracket sub-assembly 12 125 9.0
Oil cooler assembly with oil filter bracket x Cylinder block 29 291 21
SS–32 SERVICE SPECIFICATIONS – N04C-TR, TS, TT, TU, TV, TW STARTING

STARTING
SERVICE DATA
Starter assembly Specified current 180 A or less at 23 V
10 kΩ or higher
Starter relay assembly Resistance L -B Below 1 Ω (When battery voltage applied
to terminals S8-SW and S8-G)
SS LOCK: Between all
10 kΩ or higher
terminals
ACC: I6-4 (ACC) - I6-9
Below 1 Ω
(AM1)
ON: I6-4 (ACC) - I6-9
Below 1 Ω
(AM1) - I6-10 (IG1)
Ignition switch assembly Resistance
ON: I6-5 (AM2) - I6-8
Below 1 Ω
(IG2)
START: I6-3 (ST1) - I6-9
Below 1 Ω
(AM1) - I6-10 (IG1)
START: I6-5 (AM2) - I6-8
Below 1 Ω
(IG2)
Lead wire x Terminal M Nut 14 138 10
Starter assembly x Engine assembly Bolt, Nut 154 1570 114
Wire harness clamp bracket x Manual transmission assembly Bolt 18 179 13
Starter wire x Terminal B Nut 14 138 10
Starter wire x Terminal C Bolt 2.5 25 22 in.*lbf
Clutch flexible hose bracket x Body Bolt 27 275 20
Starter relay assembly x No. 2 relay block Nut 8.0 82 71 in.*lbf
Lead wire x Starter relay assembly Nut 4.7 48 42 in.*lbf
SERVICE SPECIFICATIONS – W04D-TM, TN STARTING SS–33
SERVICE DATA
Starter assembly Specified current 90 A or less at 23 V
Open circuit Below 1 Ω
Commutator resistance
Ground 10 kΩ or higher
Commutator diameter
Starter armature assembly Minimum 35.0 mm (1.38 in.)
Standard 0.7 mm (0.028 in.) SS
Commutator undercut depth
Minimum 0.2 mm (0.008 in.)
Commutator circle runout Minimum 0.05 mm (0.0020 in.)
Open circuit Below 1 Ω
Starter yoke assembly Field coil resistance
Ground 10 MΩ or higher
Starter brush Brush length
Starter brush holder assembly Resistance Positive - Negative 10 MΩ or higher
Standard 36 N (3.6 kgf, 8.0 lbf)
Stater brush spring spring installed load
Minimum 13 N (1.3 kgf, 2.9 lbf)
Pull-in coil resistance Open circuit Below 1 Ω
Starter magnetic switch assembly
Hold-in coil resistance Open circuit Below 1.5 Ω
Glow plug assembly Resistance 20°C(68°F) 2.7 to 3.5 Ω
10 kΩ or higher
Starter relay assembly Resistance L-B Below 1 Ω (When battery voltage applied
to terminals S8-SW and S8-G)
10 kΩ or higher
Glow relay assembly Resistance 3-5 Below 1 Ω (When battery voltage applied
to terminals 1 and 2)
LOCK: All combinations of
10 kΩ or higher
all terminals
ACC: I6-4 (ACC) - I6-9
Below 1 Ω
(AM1)
ON: I6-4 (ACC) - I6-9
Below 1 Ω
Ignition switch assembly (with Tilt (AM1) - I6-10 (IG1)
Resistance
steering column ON: I6-5 (AM2) - I6-8
Below 1 Ω
(IG2)
START: I6-3 (ST1) - I6-9
Below 1 Ω
(AM1) - I6-10 (IG1)
START: I6-5 (AM2) - I6-8
Below 1 Ω
(IG2)
LOCK: All combinations of
10 kΩ or higher
all terminals
ACC: I6-4 (ACC) - I6-9
Below 1 Ω
(AM1)
ON: I6-4 (ACC) - I6-9
Below 1 Ω
Ignition switch assembly (without (AM1) - I6-10 (IG1)
Resistance
Tilt steering column ON: I6-5 (AM2) - I6-8
Below 1 Ω
(IG2)
START: I6-3 (ST1) - I6-9
Below 1 Ω
(AM1) - I6-10 (IG1)
START: I6-5 (AM2) - I6-8
Below 1 Ω
(IG2) - I6-1 (ST2)
SS–34 SERVICE SPECIFICATIONS – W04D-TM, TN STARTING
Glow plug assembly x Cylinder head 25 255 18
Glow plug connector x Glow plug assembly Nut 1.3 13 12 in.*lbf
Bolt
Starter assembly x Engine assembly 154 1570 114
Nut
Starter wire x Terminal B Nut 21 215 16
Starter wire x Terminal C Nut 24 245 18
SS End cover x Starter brush holder assembly Screw 3.6 37 32 in.*lbf

End cover x Starter housing Bolt 9.3 95 82 in.*lbf
Starter lead wire x Starter magnetic switch Screw 3.6 37 32 in.*lbf
Starter housing x Starter magnetic switch Bolt 9.3 95 82 in.*lbf
Starter relay assembly x No. 2 Relay block Nut 8.0 82 71 in.*lbf
Starter relay assembly x Wire harness Nut 4.7 48 42 in.*lbf
SERVICE SPECIFICATIONS – N04C-TR, TS, TT, TU, TV, TW CHARGING SS–35

CHARGING
SERVICE DATA
Electrolyte volume 1.25 to 1.29 at 20°C (68°F)
Battery
Voltage 24.0 to 25.0 V at 20°C (68°F)
Current 10 A or less
Charging circuit without load.
Voltage 25.0 to 26.0 V SS
Charging circuit with load. Current 30 A or more
Below 1 Ω (When the probes are
Terminal B to Terminal P1, connected one way)
P2, P3, P4 10 kΩ or higher (When the probes are
reversed)
Generator holder with rectifier Resistance
Below 1 Ω (When the probes are
Terminal E to Terminal P1, connected one way)
P2, P3, P4 10 kΩ or higher (When the probes are
reversed)
Generator brush holder assembly Exposed brush length
Open circuit 10.6 to 11.4 Ω at 20°C (68°F)
Resistance
Ground 10 MΩ or higher at 20°C (68°F)
Generator rotor assembly
Slip ring diameter
P1, P2, P4 and Drive end
10 kΩ or higher
Stator coil Resistance frame
P1, P2 and P3 1.5 Ω or lower
SST (A) x SST (B) 39 400 29
Rectifier end frame x Drive end frame Nut 4.5 46 40 in.*lbf
Generator holder with rectifier x Drive end frame Screw 2.9 30 26 in.*lbf
Generator regulator assembly x Rectifier end frame Screw 2.0 20 18 in.*lbf
Generator brush holder assembly x Rectifier end frame Screw 2.0 20 18 in.*lbf
Bolt 3.9 39 35 in.*lbf
Terminal plate x Rear end cover x Rectifier end frame
Nut 4.4 45 38 in.*lbf
Terminal insulator x Generator holder with rectifier Nut 3.6 37 32 in.*lbf
No. 2 generator rear end cover x Rectifier end frame Nut 4.4 45 38 in.*lbf
Generator pulley x Generator rotor assembly Nut 133 1351 98
Generator belt adjusting bar x Engine assembly Bolt 125 1275 92
Generator assembly x Generator belt adjusting bar Bolt 29 291 21
Generator assembly x Generator bracket Bolt 55 561 41
Wire harness x Terminal B Nut 10 102 7
SS–36 SERVICE SPECIFICATIONS – W04D-TM, TN CHARGING
SERVICE DATA
Electrolyte volume 1.25 to 1.29 at 20°C (68°F)
Battery
Voltage 24.0 to 25.0 V at 20°C (68°F)
Current 10 A or less
Charging circuit without load.
Voltage 27.5 to 28.5 V
Charging circuit with load. Current 30 A or more
SS Standard 21.0 mm (0.827 in.)
Generator brush holder assembly Exposed brush length
Open circuit 12.5 Ω at 20°C (68°F)
Resistance
Ground 1 MΩ or higher
Generator rotor assembly
Slip ring diameter
Front bracket x Rear bracket Bolt 7.4 75 65 in.*lbf
Generator pulley x Generator rotor assembly Nut 112 1138 82
Cover x Rear bracket Bolt 2.2 22 19 in.*lbf
Wire harness clamp bracket x Rear bracket Bolt 2.2 22 19 in.*lbf
Vacuum pump housing x Vacuum pump cover Bolt 3.8 39 34 in.*lbf
Vacuum pump assembly x Union Bolt 32 326 23
Oil inlet hose x Vacuum pump assembly Bolt 22 225 16
Wire harness x Generator body Bolt 3.8 39 34 in.*lbf
Wire harness x Terminal B Nut 10 102 7.4
Fan belt adjusting bar x Engine assembly Bolt 125 1275 92
Fan belt adjusting bar x Generator body Bolt 47 479 34
Generator assembly x Engine assembly Nut 47 479 34
SERVICE SPECIFICATIONS – CLUTCH SS–37
CLUTCH
SERVICE DATA
Pedal height from floor (for LHD) Standard body 186.2 to 196.2 mm (7.731 to 7.724 in.)
Wide body 181 to 191 mm (7.126 to 7.520 in.)
Pedal height from floor (for RHD) Standard body 187.2 to 197.2 mm (.7.370 to 7.764 in.)
Wide body 197.4 to 207.4 mm (7.772 to 8.165 in.)
Pedal free play - 5.0 to 10.0 mm (0.197 to 0.394 in.)
Push rod play at pedal top - 0.25 to 0.5 mm (0.01 to 0.02 in.)
SS
Clutch release point from pedal full stroke end position - 25 mm (0.98 in.) or more
Pedal stroke - 153 to 163 mm (6.024 to 6.417 in.)
Clutch disc rivet depth Minimum 0.3 mm (0.012 in.)
Clutch disc runout Maximum 1.0 mm (0.039 in.)
Diaphragm spring fingerwear Maximum depth 0.6 mm (0.024 in.)
Maximum width 5.0 mm (0.197 in.)
Flywheel runout Maximum 0.1 mm (0.004 in.)
Diaphragm spring tip misalignment Maximum 0.5 mm (0.020 in.)
Clutch pedal stopper bolt x Lock nut 25 255 18
Clutch master cylinder push rod clevis lock nut 12 120 9
Release cylinder bleeder plug x Clutch release cylinder 11 110 8
Clutch release cylinder set bolt 12 120 9
Clutch hose x Clutch release cylinder (for N04C-TT) 21 (23) 213 (235) 15 (17)
Clutch tube x Clutch hose (for N04C-TT) 22 (24) 222 (245) 16 (18)
Clutch line x Clutch hose (for W04D-J, W04D-TM, W04D-TN) 22 (24) 222 (245) 16 (18)
Clutch cover assembly x Flywheel sub-assembly 43 440 32
Release fork support x Manual transmission 47 480 35
(): For use without SST

SS–38 SERVICE SPECIFICATIONS – A860E AUTOMATIC TRANSMISSION
A860E AUTOMATIC
TRANSMISSION
SERVICE DATA
Time lag N→D range Less than 1.2 seconds
N→R range Less than 1.5 seconds
Engine stall revolution N04C-TU 1900 ± 150 rpm

SS N04C-TV 2000 ± 150 rpm
Line pressure (Wheel locked) D range 1.66 - 2.01 MPa {17.0 - 20.5 kgf/cm2, 242-292 psi}
AT stall
R range 1.66 - 2.01 MPa {17.0 - 20.5 kgf/cm2, 242-292 psi}
D range 1.00 - 2.01 MPa {10.2 - 20.5 kgf/cm2, 145-291 psi}

AT idle
R range 1.00 - 2.01 MPa {10.2 - 20.5 kgf/cm2, 145-291 psi}
1. Vehicle with NO4C-TU engine (standard cab)
DIFF
D-RANGE .
RATIO RANGE RANGE
THROTTLE RANGE THROTTLE RANGE THROTTLE RANGE
FULL OPEN FULL OPEN

Exhaust Brake: off C154314
2. Vehicle with N04C-TV engine (wide cab)
D-RANGE .
DIFF
RATIO RANGE RANGE
FULL OPEN FULL OPEN


SERVICE SPECIFICATIONS – A860E AUTOMATIC TRANSMISSION SS–39
Test plug x ATM case 27 275 20
Adapter x ATM case 27 275 20
Oil pressure gauge cap 34 350 25
Drain plug x Oil pan 27 275 20
Hose clamp x ATM case 18 184 13
Oil cooler tube clamp x ATM case 36 367 27
Engine mounting bracket x ATM case 65 663 50 SS
ATM assy x Engine assy 43 439 32
Torque converter set bolt 54 551 40
Dust cover bolt 18 184 13
Flywheel housing dust seal 10 102 7
Transmission service hole cover 5 51 44 in.*lbf
Connector tube x ATM case 27 275 20
Oil filler tube x ATM case 18 184 13
Transmission control cable bracket 37 377 27
Transmission control cable nut 12 122 9
Oil cooler outlet tube 69 704 50
Oil cooler inlet tube 69 704 50
Heat insulator x ATM case 36 367 27
Oil tube clamp x Body A bolt 7 71 62 in.*ibf
B bolt 18 184 13
Parking brake plate x Extension housing 95 969 70
Exhaust pipe support NO.1 50 510 37
Transmission flower shift 18 184 13

SS–40 SERVICE SPECIFICATIONS – M153 MANUAL TRANSMISSION

Filler plug x Manual transmission case 37 379 27
Drain plug x Manual transmission case 37 379 27
Transmission control cable lock nut 12 122 9
Transmission control select cable x Shift lever assembly 12 122 9
SS Transmission control select cable x Select lever 28 280 20
Transmission control shift cable x Shift lever 28 280 20
Transmission control cable clamp x Body 18 184 13
Transmission control cable bracket x Body 18 184 13
Shift lever assembly x Body 18 184 13
Selecting bellcrank x Shift lever retainer 12 122 9
Floor shift shift lever sub-assembly x Select lever 15 150 11
Floor shift control lever stopper x Shift lever retainer 7.5 76 66 in.*lbf
Release fork support x Transmission assembly 47 480 35
Transmission assembly x Engine 43 440 32
No. 1 engine mounting bracket x Transmission assembly 65 663 48
No. 1 engine mounting bracket x Body 65 663 48
Clutch release cylinder x Transmission assembly 12 120 9
Clutch tube x Engine 27 275 20
Parking brake plate x Transmission assembly 47 475 34
Transmission output shaft rear set nut x Transmission 127 1300 94
assembly
No. 1 exhaust pipe support bracket x Transmission 50 510 37
assembly
SERVICE SPECIFICATIONS – M550 MANUAL TRANSMISSION SS–41

Transmission control select cable x Shift lever assembly 12 122 9
Transmission control select cable x Select lever 28 280 20 SS
Selecting bellcrank x Shift lever retainer 12 122 9
Floor shift shift lever sub-assembly x Select lever 15 150 11
Floor shift control lever stopper x Shift lever retainer 7.5 76 66 in.*lbf
No. 1 transmission control cable bracket x Transmission 37 377 27
assembly
Clutch tuber x Engine 27 275 20
assembly
assembly
SS–42 SERVICE SPECIFICATIONS – MYY5A MANUAL TRANSMISSION

Transmission control cable x Shift lever assembly 12 122 9
SS Transmission control select cable x Select lever 28 280 20
Speedometer driven gear x Transmission assembly 19 196 14
Clutch tube x Engine 27 275 20
Parking brake dust cover x Parking brake drum 8.2 84 73 in.*lbf
assembly
assembly
Exhaust retarder assembly x Front exhaust pipe 30 306 22
assembly
SERVICE SPECIFICATIONS – MYY6S MANUAL TRANSMISSION SS–43

SERVICE DATA
Manual transmission extension housing oil - 2.5 mm (0.0984 in.)
seal drive in depth
Gear shift fork claw thickness No. 1 Standard 9.60 to 9.85 mm (0.3780 to 0.3878 in.)
No. 2 Standard 9.60 to 9.85 mm (0.3780 to 0.3878 in.)
No. 3 Standard
Maximum
9.60 to 9.85 mm (0.3780 to 0.3878 in.)
9.0 mm (0.3543 in.)
SS
No. 4 Standard 9.60 to 9.85 mm (0.3780 to 0.3878 in.)
9.60 to 9.85 mm (0.3780 to 0.3878 in.)
9.3 mm (0.3661 in.)
Counter gear shaft bearing setting shim Measured depth: Thickness:
thickness 3.34 to 3.39 mm (0.1315 to 0.1335 in.) 3.19 mm (0.126 in.)
3.28 to 3.33 mm (0.1291 to 0.1311 in.) 3.13 mm (0.123 in.)
3.22 to 3.27 mm (0.1268 to 0.1287 in.) 3.07 mm (0.121 in.)
3.16 to 3.21 mm (0.1244 to 0.1264 in.) 3.01 mm (0.119 in.)
3.10 to 3.15 mm (0.1220 to 0.1240 in.) 2.95 mm (0.116 in.)
3.04 to 3.11 mm (0.1197 to 0.1224 in.) 2.89 mm (0.114 in.)
2.98 to 3.03 mm (0.1173 to 0.1193 in.) 2.83 mm (0.111 in.)
2.92 to 2.97 mm (0.1150 to 0.1169 in.) 2.77 mm (0.109 in.)
2.86 to 2.91 mm (0.1126 to 0.1146 in.) 2.71 mm (0.107 in.)
2.80 to 2.85 mm (0.1102 to 0.1122 in.) 2.65 mm (0.104 in.)
2.74 to 2.79 mm (0.1079 to 0.1098 in.) 2.59 mm (0.102 in.)
2.68 to 2.73 mm (0.1055 to 0.1075 in.) 2.53 mm (0.100 in.)
2.62 to 2.67 mm (0.1031 to 0.1051 in.) 2.47 mm (0.097 in.)
2.56 to 2.61 mm (0.1008 to 0.1028 in.) 2.41 mm (0.095 in.)
2.50 to 2.55 mm (0.0984 to 0.1004 in.) 2.35 mm (0.093 in.)
2.44 to 2.49 mm (0.0961 to 0.0980 in.) 2.29 mm (0.090 in.)
2.38 to 2.43 mm (0.0937 to 0.0957 in.) 2.23 mm (0.088 in.)
2.32 to 2.37 mm (0.0913 to 0.0933 in.) 2.17 mm (0.085 in.)
2.26 to 2.31 mm (0.0890 to 0.0909 in.) 2.11 mm (0.083 in.)
Shaft snap ring thickness White 1.7 mm (0.0669 in.)
- 1.8 mm (0.0709 in.)
Blue 1.9 mm (0.0748 in.)
Counter gear 6th inner diameter Standard 50.009 to 50.025 mm (1.9689 to 1.9695 in.)
Maximum 50.065 mm (1.9711 in.)
5th gear inner diameter Standard 44.009 to 44.025 mm (1.7326 to 1.7333 in.)
Maximum 44.065 mm (1.7348 in.)
4th gear inner diameter Standard 44.009 to 44.025 mm (1.7326 to 1.7333 in.)
Maximum 44.065 mm (1.7348 in.)
3rd gear inner diameter Standard 63.010 to 63.029 mm (2.4807 to 2.4815 in.)
Maximum 63.069 mm (2.4830 in.)
2nd gear inner diameter Standard 63.010 to 63.029 mm (2.4807 to 2.4815 in.)
Maximum 63.069 mm (2.4830 in.)
1st gear inner diameter Standard 63.010 to 63.029 mm (2.4807 to 2.4815 in.)
Maximum 63.069 mm (2.4830 in.)
Reverse gear inner diameter Standard 63.010 to 63.029 mm (2.4807 to 2.4815 in.)
Maximum 63.069 mm (2.4830 in.)
Output shaft runout Standard 0.015 mm (0.0006 in.)
Synchronizer ring back and reverse gear Standard 1.30 to 2.60 mm (0.0512 to 0.1024 in.)
spline end clearance Minimum 0.5 mm (0.0197 in.)
Synchronizer ring back and 6th gear spline Standard 1.30 to 2.60 mm (0.0512 to 0.1024 in.)
end clearance Minimum 0.5 mm (0.0197 in.)
Synchronizer ring back and 4th gear spline Standard 1.30 to 2.60 mm (0.0512 to 0.1024 in.)
Synchronizer ring back and 3rd gear spline Standard 1.00 to 2.50 mm (0.394 to 0.0984 in.)
SS–44 SERVICE SPECIFICATIONS – MYY6S MANUAL TRANSMISSION
Synchronizer ring back and 2nd gear spline Standard 1.00 to 2.50 mm (0.394 to 0.0984 in.)
Synchronizer ring back and 1st gear spline Standard 1.00 to 2.50 mm (0.394 to 0.0984 in.)
No. 2 transmission clutch hub backlash Standard 0 to 0.05 mm (0 to 0.002 in.)
No. 3 synchromesh shifting key and No. 3 Standard 3.46 to 3.76 mm (0.1362 to 0.148 in.)
synchronizer ring groove clearance
No. 3 synchromesh shifting key and sleeve Standard 0.01 to 0.21 mm (0.0004 to 0.0083 in.)
and hub assembly clearance
SS Synchronizer ring and No. 2 transmission Standard 4.30 to 4.70 mm (0.1693 to 0.1850 in.)
clutch hub clearance
Synchronizer ring and No. 1 transmission Standard 4.30 to 4.70 mm (0.1693 to 0.1850 in.)
clutch hub clearance
Snap ring C/FT thickness Blue 1.9 mm (0.0748 in.)
Yellow 2.1 mm (0.0827 in.)
Pink 2.3 mm (0.0906 in.)
Transmission control cable x Shift lever assembly 12 122 9
Transmission control select cable x Select lever 28 280 20
Speedometer driven gear x Transmission assembly 19 196 14
Clutch tuber x Engine 27 275 20
Parking brake dust cover x Parking brake drum 8.2 84 73 in.*lbf
assembly
assembly
Exhaust retarder assembly x Front exhaust pipe 30 306 22
assembly
Propeller shaft assembly x Propeller intermediate shaft 75 760 55
assembly
Propeller shaft assembly x Differential flange 75 760 55
Clutch housing x Transmission case 46 470 34
Output shaft bearing retainer x Transmission case 26 265 19
Manual transmission power take-off cover setting bolt 37 380 28
Shift lever shaft housing x Transmission case 27 275 20
SERVICE SPECIFICATIONS – MYY6S MANUAL TRANSMISSION SS–45

Detent assembly x Transmission case 28 286 21
Back up light switch assembly x Transmission case 39 400 29
Manual transmission case plug 39 400 29
Detent assembly x Shift lever shaft housing 28 286 21
Exhaust brake neutral switch assembly x Shift lever shaft 34 347 25
housing
SS
SS–46 SERVICE SPECIFICATIONS – PROPELLER SHAFT
PROPELLER SHAFT
SERVICE DATA
Propeller shaft runout Standard 0 to 0.6 mm (0 to 0.0236 in.)
Universal joint spider Standard rotating torque (initial) of the flange 15 to 52 N (1.5 to 5.3 kgf, 3.3 to 12.0 lbf)
yoke that is connected to the MYY5 and
MYY6 manual transmission
Standard rotating torque (initial) of the flange 18 to 63 N (1.8 to 6.4 kgf, 4.0 to 14.2 lbf)
SS yokes that is connected to a transmission
other than the MYY5 and MYY6 manual
transmission
Spider bearing Standard clearance 0.022 to 0.061 mm (0.0009 to 0.0024 in.)
Universal joint sleeve yoke Standard free play 0.185 to 0.393 mm (0.0073 to 0.0155 in.)
Maximum free play 0.63 mm (0.0248 in.)
Retainer ring thickness 1.50 (0.0591 in.)
1.53 (0.0602 in.)
1.56 (0.0614 in.)
1.59 (0.0626 in.)
1.62 (0.0638 in.)
1.65 (0.0650 in.)
1.68 (0.0661 in.)
Intermediate shaft assembly x Parking brake drum (for M153, M550 and 75 760 55
A860E)
Intermediate shaft assembly x Parking brake drum (for MYY5 and MYY6) 103 1050 76
Center support bearing x Frame crossmember 52 525 38
Propeller shaft assembly x Intermediate shaft assembly 75 760 55
Propeller shaft assembly x Parking brake drum 75 760 55
Propeller shaft assembly x Differential carrier assembly 75 760 55
Spider journal x Grease fitting 6.4 65 57 in.*lbf
Sliding yoke x Grease fitting 6.4 65 57 in.*lbf
Cushion rubber x Bearing plate 27 270 20
Intermediate shaft x Lock nut 687 7000 506
SERVICE SPECIFICATIONS – FRONT SUSPENSION SS–47
FRONT SUSPENSION
SERVICE DATA
IFS
Tire Size Tire Inflation Pressure (kPa (kgf*cm2, psi))
Model
Front Rear Front Rear
XZU306-MQMMBQ3 195/75 R15 195/75 R15 600 (6.0, 87) 600 (6.0, 87)
Tire runout 3.0 mm (0.118 in.) or less SS
Tire size Toe-in (Total)

Toe-in
195/75 R15 2 ± 2 mm (0.078 ± 0.078 in.)
0° ± 45°
Camber
Left - right error 45’ or less
Front wheel alignment 3°05’ ± 45’
Caster
Left - right error 45’ or less
King pin inclination 12° 50’ (reference)
Inside wheel 40° 50’ - 43° 50’
Wheel angle
Outside wheel 38° 40’ (reference)
Front suspension Upper ball joint turning torque (During rotation) 6 N*m (60 kgf*cm, 4.4 ft*lbf) or less
LEAF SPRING
Regular Cab Model Front Tire Tie rod Knuckle Inside Outside Caster Camber Caster Steering
Size end type stopper (Refere Wedge Axis
bolt type nce) Inclination
XZU303R -HBMLAT3 7.50-15-12 A A 31°30’ - 34°30’ 26°36’ With 0°30’±1° 2°30’±1° 7°30’±1°
XZU303R -HBMMBT3 7.50-16-10 A A 37° - 40° 29°30’ With 0°30’±1° 2°30’±1° 7°30’±1°
XZU343R -HKMQBT3
WU300R -HBMLS3 7.00-16-10 A A 33° - 36° 27°30’ With 0°30’±1° 1°00’±1° 7°30’±1°
WU300L -HBMLS 7.00R-16-10
WU300L -HBMLS3
WU302L -HBMLA
WU302L -HBMLA3
XZU303L -HBMLA
XZU303L -HBMLA3
WU300L -HBMMS 7.00-16-10 A A
WU300L -HBMMS3 7.00R-16-12
WU340L -HKMMS 7.00R-16-10
WU340L -HKMMS3 7.00-16-10 A A
WU302L -HBMMB3 7.00-16-12
XZU343L -HKMMA3 7.00R-16-10
7.00R-16-12
XZU307R -HKTLBQ3 185/85R 16 A A 36° - 39° 29° With 0°30’±1° 2°30’±1° 7°30’±1°
XZU307R -HKMMBQ3
XZU347R -HKMMBQ3
XZU307R -HKMMBQ3 LP 195/75R 15 A A 42° - 45° 31°30’
SS–48 SERVICE SPECIFICATIONS – FRONT SUSPENSION
Wide Cab Model Front Tire Tie rod Knuckle Inside Outside Caster Camber Caster Steering
XZU407R -HKMMDQ3 195/85R 16 B A 46° - 49° 35° With 0°30’±1° 2°30’±1° 7°30’±1°
XZU417R -HKMMDQ3
XZU417R -HKTMDQ3
XZU415R -HKMMBW3 195/75R 16 A A 48° - 51° 36°
195/85R 16
WU410R -HKMMS3 7.00-16-10 A A 48° - 51° 36° With 0°30’±1° 1°30’±1° 7°30’±1°
WU412R -HKMMB3 7.00R-16-10
XZU413R -HKMMB3
SS XZU423R -HKMMB3
WU410L -HKMQSV 7.00-16-10 A A 48° - 51° 36° With 0°30’±1° 2°30’±1° 7°30’±1°
WU410L -HKMQSV3 7.00R-16-10
7.00R-16-12
WU412L -HKMMB 7.00-16-10 A A
WU412L -HKMMB3 7.00R-16-10
XZU413L -HKMMD3 7.00-16-10 A A
7.00R-16-10
7.50-16-12
XZU413R -HKMTBT3 7.50-16-14 A B 47°30’ - 50°30’ 36°30’ Without 1°00’±1° 2°00’±1° 7°00’±1°
XZU423R -HKMTBT3 7.50R-16-14
XZU417R -HKFQDQ3 205/85R 16 A B
XZU417R -HKFRDQ3 215/85R 16 A B
XZU417R -HKTRDQ3
XZU427R -HKFRDQ3
XZU427R -QKFRDQ3
XZU415R -HKFQDW3 215/75R17.5 A B
XZU425R -HKFQDW3
XZU415R -HKFRDW3 215/75R17.5 A B
XZU425R -HKFRDW3
XZU435R -HKFRDW3
WU410R -HKMQS3 7.50-16-10 A B
7.50R-16-10
WU420R -HKMRS3 7.50-16-14 A B
7.50-16-12
7.50R-16-12
7.50R-16-14
WU422R -HKMRB3 7.50-16-12 A B 47°30’ - 50°30’ 36°30’ Without 1°00’±1° 2°00’±1° 7°00’±1°
7.50-16-14
7.50R-16-12
7.50R-16-14
XZU423R -HKMRD3 7.50-16-12 A B
7.50R-16-12
XZU405R -HKFQD3 215/85R 16 A B
XZU415R -HKFQD3
XZU415R -QKFQD3
XZU415R -HKFTD3
XZU425R -HKFQD3 215/75R 17.5 A B
XZU425R -HKFTD3
SERVICE SPECIFICATIONS – FRONT SUSPENSION SS–49
WU420L -HKMQSV 7.50-16-10 A B 47°30’ - 50°30’ 36°30’ Without 1°00’±1° 2°00’±1° 7°00’±1°
WU420L -HKMQSV3 7.50R-16-10
WU412L -HKMRBV3 7.50-16-12 A B
7.50-16-14
7.50R-16-12
7.50R-16-14
WU412L -HKMRBV 7.50-16-12 A B
WU422L -HKMRBV 7.50R-16-12
WU422L -HKMRBV3 SS
WU412L -HKFTBV 7.50-16-14 A B
WU412L -HKFTBV3 7.50R-16-14
WU422L -HKFTBV
WU422L -HKFTBV3
WU412L -HKMQB 7.50-16-10 A B
WU412L -HKMQB3 7.50R-16-10
WU412L -HKMRB3 7.50-16-12 A B
WU422L -HKMRB3 7.50-16-14
7.50R-16-12
7.50R-16-14
WU412L -HKMRB 7.50-16-12 A B
WU422L -HKMRB 7.50R-16-12
XZU423L -HKMQD3
WU422L -HKFTB 7.50-16-14 A B
WU422L -HKFTB3 7.50R-16-14
XZU423L -HKMRD3
WU412L -HKFTB
WU412L -HKFTB3
XZU413L -HKMQD3 7.50-16-10 A B
7.50-16-12
7.50R-16-10
XZU427R -HKFTDQ3 225/80R 17.5 A B 42° - 45° 34°30’ Without 1°00’±1° 2°00’±1° 7°00’±1°
XZU437R -HKFTDQ3
A+B 0° - 0° 09’ (0° - 0.15°)

All models Toe-in (Total)
C-D 0 - 2 mm (0 - 0.08 in.)
IFS
Upper arm x suspension member 88 897 65
Intake pipe or hose stay x suspension member 18 183 13
Engine side cover lock bolt 11.5 117 8.5
Hub nut 515 5249 380
Tie-rod end lock nut 137 1396 101
Knuckle stopper lock nut 43 438 31.7
Stabilizer bracket lock nut 17.5 178 13
Stabilizer bracket cover lock nut 25 255 18
Speed sensor clip x member 19 194 14
Caster adjustment plate lock bolt 88 897 65
Front axle assy x lower arm No.1 (Nut) 206 2100 152
Front axle assy x upper arm (Nut) 152 1549 112
Disc brake cylinder assy lock bolt 60 612 44
SS–50 SERVICE SPECIFICATIONS – FRONT SUSPENSION

Lower arm No.1 x member (Bolt A) 155 2100 152
(Bolt B) 206 2100 152
Battery minus terminal 3.9 40 35 in.*lbf
Head taper screw plug x Upper arm shaft 7.8 79 70 in.*lbf
Upper arm bushing 343 3496 253
Tie-rod end ball joint lock nut 90 917 66
Bumper No.1 x lower arm No.1 64 652 47
SS (): For use without SST

LEAF SPRING

Type A: 137 1,400 101
Tie rod end lock nut
Type B: 37 377 27
Type A: 43 440 32
Steering knuckle stopper bolt
Type B: 74 760 55
SERVICE SPECIFICATIONS – DIFFERENTIAL SS–51
DIFFERENTIAL
SERVICE DATA
Differential (SH12)
Rear differential ring gear backlash Reduction ratio 5.375: 0.18 to 0.23 mm (0.0072 to 0.0092 in.)
Reduction ratio 4.333, 4.625, 4.875, 5.125, 5.571, 6.167, 6.500: 0.20
to 0.28 mm (0.0079 to 0.0110 in.)
Reduction ratio 5.833: 0.25 to 0.33 mm (0.0099 to 0.0130 in.)
Side gear backlash Standard: 0.2 to 0.6 mm (0.0079 to 0.0236 in.)
Maximum: 0.9 mm (0.0354 in.)
SS
Side bearing preload (New bearing) Reduction ratio 4.333: 0.34 to 0.45 N*m (3.5 to 4.6 kgf*cm, 3.0 to 3.9
in.*lbf)
Reduction ratio 4.625: 0.32 to 0.42 N*m (3.3 to 4.3 kgf*cm, 2.8 to 3.7
in.*lbf)
in.*lbf)
in.*lbf)
in.*lbf)
in.*lbf)
in.*lbf)
in.*lbf)
in.*lbf)
Side bearing preload (Reused bearing) Reduction ratio 4.333: 0.23 to 0.35 N*m (2.5 to 3.6 kgf*cm, 2.0 to 3.1
in.*lbf)
in.*lbf)
in.*lbf)
in.*lbf)
in.*lbf)
in.*lbf)
in.*lbf)
in.*lbf)
in.*lbf)
Drive pinion preload (Start torque) (New bearing) 1.47 to 1.96 N*m (15 to 20 kgf*cm, 13 to 17 in.*lbf)
Drive pinion preload (Start torque) (Reused bearing) 0.98 to 1.47 N*m (10 to 15 kgf*cm, 9 to 13 in.*lbf)
Total preload (Drive pinion preload plus) (New bearing) Reduction ratio 4.333: 1.81 to 2.41 N*m (18.5 to 24.6 kgf*cm, 16.0 to
20.9 in.*lbf)
Reduction ratio 4.625: 1.79 to 2.38 N*m (18.3 to 24.3 kgf*cm, 15.8 to
20.7 in.*lbf)
20.5 in.*lbf)
20.3 in.*lbf)
20.2 in.*lbf)
20.1 in.*lbf)
19.9 in.*lbf)
19.7 in.*lbf)
19.7 in.*lbf)
SS–52 SERVICE SPECIFICATIONS – DIFFERENTIAL
Total preload (Drive pinion preload plus) (Reused bearing) Reduction ratio 4.333: 1.21 to 1.82 N*m (12.5 to 18.6 kgf*cm, 11.0 to
16.1 in.*lbf)
15.7 in.*lbf)
15.6 in.*lbf)
15.5 in.*lbf)
15.4 in.*lbf)
15.3 in.*lbf)
SS Reduction ratio 5.833: 1.15 to 1.72 N*m (11.7 to 17.6 kgf*cm, 10.5 to
15.2 in.*lbf)
15.0 in.*lbf)
14.9 in.*lbf)
Inner diameter of the pinion - Outer diameter of the spider Standard: 0.140 to 0.261 mm (0.0055 to 0.0103 in.)
Maximum: 0.4 mm (0.0157 in.)
Pinion gear thrust washer thickness Standard: 1.5 to 1.7 mm (0.059 to 0.0669 in.)
Minimum: 1.3 mm (0.0512 in.)
Side gear thrust washer thickness Standard: 1.9 to 2.1 mm (0.0748 to 0.0827 in.)
Minimum: 1.7 mm (0.0669 in.)
Drive pinion bearing spacer thickness mm (in.) 14.400 (0.5669)
14.425 (0.5679)
14.450 (0.5689)
14.475 (0.5699)
14.500 (0.5709)
14.525 (0.5718)
14.550 (0.5728)
14.575 (0.5738)
14.600 (0.5748)
14.625 (0.5758)
14.650 (0.5768)
14.675 (0.5778)
14.700 (0.5787)
14.725 (0.5797)
14.750 (0.5807)
14.775 (0.5817)
14.800 (0.5827)
14.825 (0.5837)
14.850 (0.5846)
14.875 (0.5856)
Drive pinion cage shim thickness mm (in.) 0.30 (0.0118)
0.40 (0.0157)
0.45 (0.0177)
0.50 (0.0197)
Differential (SH13)
Rear differential ring gear backlash Reduction ratio 4.875, 5.142, 5.571: 0.25 to 0.33 mm (0.0099 to
0.0129 in.)
Reduction ratio 5.875, 6.428: 0.20 to 0.28 mm (0.0079 to 0.0110 in.)
Side gear backlash Standard: 0.2 to 0.6 mm (0.0079 to 0.0236 in.)
Maximum: 0.9 mm (0.0354 in.)
Side bearing preload (New bearing) Reduction ratio 4.875: 0.41 to 0.60 N*m (4.2 to 6.1 kgf*cm, 3.6 to 5.3
in.*lbf)
in.*lbf)
in.*lbf)
in.*lbf)
in.*lbf)
Side bearing preload (Reused bearing) Reduction ratio 4.875: 0.31 to 0.50 N*m (3.1 to 5.1 kgf*cm, 2.8 to 4.4
in.*lbf)
in.*lbf)
in.*lbf)
in.*lbf)
in.*lbf)
Drive pinion preload (Start torque) (New bearing) 1.97 to 2.94 N*m (20 to 30 kgf*cm, 17 to 26 in.*lbf)
Drive pinion preload (Start torque) (Reused bearing) 1.48 to 2.45 N*m (15 to 25 kgf*cm, 13 to 22 in.*lbf) SS
Total preload (Drive pinion preload plus) (New bearing) Reduction ratio 4.875: 2.38 to 3.54 N*m (24.2 to 36.1 kgf*cm, 20.6 to
31.3 in.*lbf)
31.0 in.*lbf)
30.6 in.*lbf)
30.4 in.*lbf)
30.4 in.*lbf)
Total preload (Drive pinion preload plus) (Reused bearing) Reduction ratio 4.875: 1.79 to 2.95 N*m (18.1 to 30.1 kgf*cm, 15.8 to
26.4 in.*lbf)
26.1 in.*lbf)
25.8 in.*lbf)
25.6 in.*lbf)
25.4 in.*lbf)
Inner diameter of the pinion - Outer diameter of the spider Standard: 0.140 to 0.261 mm (0.0055 to 0.0103 in.)
Maximum: 0.4 mm (0.0157 in.)
Pinion gear thrust washer thickness Standard: 1.5 to 1.7 mm (0.059 to 0.0669 in.)
Minimum: 1.3 mm (0.0512 in.)
Side gear thrust washer thickness Standard: 1.9 to 2.1 mm (0.0748 to 0.0827 in.)
Minimum: 1.7 mm (0.0669 in.)
Drive pinion bearing spacer thickness mm (in.) 13.900 (0.5472)
13.925 (0.5482)
13.950 (0.5492)
13.975 (0.5502)
14.000 (0.5512)
14.025 (0.5522)
14.050 (0.5531)
14.075 (0.5541)
14.100 (0.5551)
14.125 (0.5561)
14.150 (0.5571)
14.175 (0.5581)
14.200 (0.5591)
14.225 (0.5600)
14.250 (0.5610)
14.275 (0.5620)
14.300 (0.5630)
14.325 (0.5640)
14.350 (0.5650)
14.375 (0.5659)
Drive pinion cage shim thickness mm (in.) 0.30 (0.0118)
0.40 (0.0157)
0.45 (0.0177)
0.50 (0.0197)
Differential (B265)
Rear differential ring gear backlash 0.15 to 0.20 mm (0.0059 to 0.0079 in.)
Side gear backlash 0.02 to 0.20 mm (0.0008 to 0.0079 in.)
SS–54 SERVICE SPECIFICATIONS – DIFFERENTIAL
Drive pinion preload (Start torque) (New bearing) 2.00 to 5.39 N*m (20.4 to 55.0 kgf*cm, 17.7 to 47.7 in.*lbf)
Drive pinion preload (Start torque) (Reused bearing) 1.00 to 2.76 N*m (10.2 to 28.2 kgf*cm, 8.6 to 24.4 in.*lbf)
Total preload (Drive pinion preload plus) (New bearing) 2.20 to 5.78 N*m (22.4 to 59.0 kgf*cm, 19.4 to 51.2 in.*lbf)
Total preload (Drive pinion preload plus) (Reused bearing) 1.20 to 3.15 N*m (12.2 to 32.2 kgf*cm, 10.3 to 27.9 in.*lbf)
Inner diameter of the pinion - Outer diameter of the spider 0.041 to 0.142 mm (0.0016 to 0.0056 in.)
Pinion gear thrust washer thickness 1.5 to 1.7 mm (0.059 to 0.0669 in.)
Companion flange runout Maximum: 0.11 mm (0.0043 in.)
Companion flange lateral runout Maximum: 0.15 mm (0.0059 in.)
Ring gear runout Maximum: 0.10 mm (0.0039 in.)
SS Drive pinion bearing shim thickness mm (in.) 1.040 to 1.060 mm (0.0409 to 0.0417 in.)
1.065 to 1.085 mm (0.0419 to 0.0427 in.)
1.090 to 1.110 mm (0.0429 to 0.0437 in.)
1.115 to 1.135 mm (0.0439 to 0.0447 in.)
1.140 to 1.160 mm (0.0449 to 0.0457 in.)
1.165 to 1.185 mm (0.0459 to 0.0467 in.)
1.190 to 1.210 mm (0.0469 to 0.0476 in.)
1.215 to 1.235 mm (0.0478 to 0.0486 in.)
1.240 to 1.260 mm (0.0488 to 0.0496 in.)
1.265 to 1.285 mm (0.0498 to 0.0506 in.)
1.290 to 1.310 mm (0.0508 to 0.0516 in.)
1.315 to 1.335 mm (0.0518 to 0.0526 in.)
1.340 to 1.360 mm (0.0528 to 0.0535 in.)
1.365 to 1.385 mm (0.0537 to 0.0545 in.)
1.390 to 1.410 mm (0.0547 to 0.0555 in.)
1.415 to 1.435 mm (0.0557 to 0.0565 in.)
1.440 to 1.460 mm (0.0567 to 0.0575 in.)
1.465 to 1.485 mm (0.0577 to 0.0584 in.)
1.490 to 1.510 mm (0.0587 to 0.0594 in.)
1.515 to 1.535 mm (0.0596 to 0.0604 in.)
1.540 to 1.560 mm (0.0606 to 0.0614 in.)
Side gear thrust washer thickness mm (in.) 1.55 (0.0610)
1.60 (0.0629)
1.65 (0.0650)
1.70 (0.0670)
1.75 (0.0690)
1.80 (0.0709)
1.85 (0.0728)
1.90 (0.0748)
1.95 (0.0768)
2.00 (0.0784)
2.05 (0.0807)
2.10 (0.0827)
Shim A thickness mm (in.) 1.89 to 1.91 (0.0744 to 0.0752)
1.99 to 2.01 (0.0783 to 0.0791)
2.09 to 2.11 (0.0823 to 0.0831)
2.19 to 2.21 (0.0862 to 0.0870)
2.29 to 2.31 (0.0902 to 0.0909)
2.39 to 2.41 (0.0940 to 0.0949)
2.49 to 2.51 (0.0980 to 0.0988)
2.59 to 2.61 (0.1020 to 0.1028)
2.69 to 2.71 (0.1059 to 0.1067)
2.79 to 2.81 (0.1098 to 0.1106)
2.89 to 2.91 (0.1138 to 0.1146)
2.99 to 3.01 (0.1177 to 0.1185)
Shim B thickness mm (in.) 1.792 to 1.808 (0.0705 to 0.0712)
1.802 to 1.818 (0.0709 to 0.0716)
1.812 to 1.828 (0.0713 to 0.0720)
1.822 to 1.838 (0.0717 to 0.0724)
1.832 to 1.848 (0.0721 to 0.0728)
1.842 to 1.858 (0.0725 to 0.0731)
1.852 to 1.868 (0.0729 to 0.0735)
1.862 to 1.878 (0.0733 to 0.0739)
1.872 to 1.888 (0.0737 to 0.0743)
1.882 to 1.898 (0.0741 to 0.0747)
Differential (SH12)
Drain plug 50 510 37
Filler plug 50 510 37
Rear drive pinion companion flange sub-assembly x Rear differential carrier 435 4437 321
Differential case LH x Differential case RH 190 1938 141
Differential case x Ring gear 190 1938 141
Bearing retainer (pilot bearing outer race) x Differential carrier 22 225 16
SS
Drive pinion bearing cage x Rear differential carrier 74 760 55
Bearing cap x Rear differential carrier 210 2150 156
Adjusting nut lock x Bearing cap 22 225 16
Rear differential carrier x Rear axle housing 52 530 38
Propeller shaft x Rear differential carrier 75 760 55
Differential (SH13)
Differential case LH x Differential case RH 270 2754 199
Bearing retainer (pilot bearing outer race) x Differential carrier 22 225 16
Drive pinion bearing cage x Rear differential carrier 74 760 55
Adjusting nut lock x Bearing cap 22 225 16
Bolt A 130 1326 96
Rear differential carrier x Rear axle housing
Bolt B 96 979 71
Differential (B265)
Differential case LH x Differential case RH 78.5 800 58
Adjusting nut lock x Bearing cap 12.7 130 9.4
Rear differential carrier x Rear axle housing 52 530 38
SS–56 SERVICE SPECIFICATIONS – AXLE
AXLE
SERVICE DATA
STEERING KNUCKLE LH (INS / 2WD DRIVE)
Lower ball joint rotation condition 6.6 N*m {67 kgf*cm, 58in.ibf} or lower (during rotation)
REAR AXLE HUB LH

Pre-load (at starting, GVWR: 5.5 t, 7.5 t or less) 9.8-29.4 N {1.0-3.0 kgf, 2.2-6.6 lbf}
Pre-load (at rotaing, GVWR: Over 5.5 t, 8 t) 35-53 N {3.6-5.4 kgf, 7.9-11.9 lbf}
SS Axial play 0.10 mm {0.0039 in.} or less
STEERING KNUCKLE LH (IFS / 2WD DRIVE)
Steering knuclke x Front suspension lower arm 206 2100 152
Steering knuckle x Front suspension lower arm 152 1549 112
Front disc brake dust cover 19 194 14
Speed sensor clamp x Bolt 19 194 14
Speed sensor x Bolt 8 82 71 in.*lbf
Front tire 515 5250 380
REAR AXLE HUB LH (WIDE CAB / REAR BRAKE TYPE)

Rear disk rotor 200 2040 147
Rear skid control rotor 14 143 10
Rear axle bearing lock nut (GVWR: 5.5 t) 56 575 42
Rear axle bearing lock nut (GVWR: Over 5.5 t) 539 5500 397
Rear axle lock nut plate (GVWR: 5.5 t) 5.5 56 49 in.*lbf
Rear axle lock nut plate (GVWR: Over 5.5 t) 9.6 98 85 in.*lbf
Rear wheel 515 5250 380
REAR AXLE HUB LH (STANDARD CAB / REAR BRAKE TYPE: DISC)

Rear disk rotor 200 2040 147
Rear skid control rotor 14 143 10
Rear axle bearing lock nut (GVWR: 7.5 t or less) 56 575 42
Rear axle bearing lock nut (GVWR: 8 t) 539 5500 397
Rear axle lock nut plate (GVWR: 7.5 t or less) 5.5 56 49 in.*lbf
Rear axle lock nut plate (GVWR: 8 t) 9.6 98 85 in.*lbf
Rear wheel 515 5250 380
SERVICE SPECIFICATIONS – TIRE AND WHEEL SS–57
TIRE AND WHEEL

SERVICE DATA
Cold tire inflation pressure
for Australia and Newzealand (Standard cab))
Model
XZU307R-HKTLBQ3 185/85R16 215/85R16 600(6.0, 87) 600(6.0, 87)
XZU306R-HQMMBQ3 195/75R 15 195/75R 15 600(6.0, 87) 600(6.0, 87) SS
XZU347R-HKMMBQ3
185/85R 16 185/85R 16 600(6.0, 87) 600(6.0, 87)
XZU307R-HKMMBQ3

for Australia and Newzealand (Wide cab)
Model
XZU407R-HKMMDQ3
XZU417R-HKMMDQ3 195/85R 16 195/85R 16 600(6.0, 87) 600(6.0, 87)
XZU417R-HKTMDQ3
XZU417R-HKFQDQ3 205/85R 16 205/85R 16 600(6.0, 87) 600(6.0, 87)
XZU417R-HKFRDQ3
XZU417R-HKTRDQ3
215/85R 16 215/85R 16 600(6.0, 87) 600(6.0, 87)
XZU427R-HKFRDQ3
XZU427R-QKFRDQ3
XZU427R-HKFTDQ3
225/80R 17.5 225/80R 17.5 700(7.0, 102) 700(7.0, 102)
XZU437R-HKFTDQ3

for Thailand (Standard cab)
Model
XZU303R-HBMLAT3 7.50-15-12 7.50-15-12 300(3.0, 44) 600(6.0, 87)
XZU303R-HBMMBT3
7.50-16-10 7.50-16-10 525(5.3, 76) 525(5.3, 76)
XZU343R-HKMQBT3

for Thailand (Wide cab)
Model
XZU413R-HKMTBT3 7.50-16-14 7.50-16-14 650(6.5, 94) 650(6.5, 94)

XZU423R-HKMTBT3 7.50R16-14 7.50R16-14 700(7.0, 102) 700(7.0, 102)
SS–58 SERVICE SPECIFICATIONS – TIRE AND WHEEL

for G.C.C (Wide cab)
Model
7.00-16-10 7.00-16-10 500(5.0, 73) 500(5.0, 73)
WU410L-HKMQSV
7.00R16-10 7.00R16-10 525(5.3, 76) 525(5.3, 76)
WU410L-HKMQSV3
7.00R16-12 7.00R16-12 600(6.0, 87) 600(6.0, 87)
WU420L-HKMQSV 7.50-16-10 7.50-16-10 525(5.3, 76) 525(5.3, 76)

WU420L-HKMQSV3 7.50R16-10 7.50R16-10 575(5.8, 83) 575(5.8, 83)
SS 7.50-16-12 7.50-16-12 600(6.0, 87) 600(6.0, 87)
7.50-16-14 7.50-16-14 650(6.5, 94) 650(6.5, 94)
WU412L-HKMRBV3
7.50R16-12 7.50R16-12 650(6.5, 94) 650(6.5, 94)
7.50R16-14 7.50R16-14 700(7.0, 102) 700(7.0, 102)
WU412L-HKMRBV 7.50-16-12 7.50-16-12 600(6.0, 87) 600(6.0, 87)
WU422L-HKMRBV
WU422L-HKMRBV3 7.50R16-12 7.50R16-12 650(6.5, 94) 650(6.5, 94)
WU412L-HKFTBV 7.50-16-14 7.50-16-14 650(6.5, 94) 650(6.5, 94)

WU412L-HKFTBV3
WU422L-HKFTBV 7.50R16-14 7.50R16-14 700(7.0, 102) 700(7.0, 102)
WU422L-HKFTBV3

for HongKong (Wide cab)
Model
XZU405R-HKFQD3
XZU415R-HKFQD3
215/85R 16 215/85R 16 600(6.0, 87) 600(6.0, 87)
XZU415R-QKFQD3
XZU425R-HKFQD3
XZU425R-HKFTD3
215/75R17.5 215/75R17.5 700(7.0, 102) 700(7.0, 102)
XZU415R-HKFTD3

for General (Standard cab)
Model
WU300R-HBMLS3 7.00-16-10 7.00-16-12 500(5.0, 73) 575(5.8, 83)
WU300L-HBMLS
WU300L-HBMLS3
WU302L-HBMLA
WU302L-HBMLA3 7.00R16-10 7.00R16-12 525(5.3, 76) 600(6.0, 87)
XZU303L-HBMLA
XZU303L-HBMLA3
WU300L-HBMMS 7.00-16-10 7.00-16-10 500(5.0, 73) 500(5.0, 73)

WU300L-HBMMS3 7.00-16-12 7.00-16-12 575(5.8, 83) 575(5.8, 83)
WU340L-HKMMS3
7.00R16-10 7.00R16-10 525(5.3, 76) 525(5.3, 76)
7.00-16-10 7.00-16-10 500(5.0, 73) 500(5.0, 73)
WU340L-HKMMS 7.00-16-12 7.00-16-12 575(5.8, 83) 575(5.8, 83)
WU302L-HBMMB3
XZU343L-HKMMA3 7.00R16-10 7.00R16-10 525(5.3, 76) 525(5.3, 76)
7.00R16-12 7.00R16-12 600(6.0, 87) 600(6.0, 87)
XZU405R-HKFQD3
XZU415R-HKFQD3
215/85R 16 600(6.0, 87) 600(6.0, 87)
XZU415R-QKFQD3
XZU425R-HKFQD3
XZU425R-HKFTD3
215/75R17.5 700(7.0, 102) 700(7.0, 102)
XZU415R-HKFTD3
SERVICE SPECIFICATIONS – TIRE AND WHEEL SS–59

for General (Wide cab)
Model
WU410R-HKMMS3 7.00-16-10 7.00-16-10 500(5.0, 73) 500(5.0, 73)
WU412R-HKMMB3
WU412L-HKMMB
WU412L-HKMMB3 7.00R16-10 7.00R16-10 525(5.3, 76) 525(5.3, 76)
XZU423R-HKMMB3
XZU413R-HKMMB3
WU410R-HKMQS3
WU412L-HKMQB
7.50-16-10 7.50-16-10 525(5.3, 76) 525(5.3, 76) SS
WU412L-HKMQB3 7.50R16-10 7.50R16-10 575(5.8, 83) 575(5.8, 83)
7.50-16-14 7.50-16-14 650(6.5, 94) 650(6.5, 94)

7.50-16-12 7.50-16-12 600(6.0, 87) 600(6.0, 87)
WU420R-HKMRS3
7.50R16-12 7.50R16-12 650(6.5, 94) 650(6.5, 94)
7.50R16-14 7.50R16-14 700(7.0, 102) 700(7.0, 102)
7.50-16-12 7.50-16-12 600(6.0, 87) 600(6.0, 87)
WU412L-HKMRB3 7.50-16-14 7.50-16-14 650(6.5, 94) 650(6.5, 94)
WU422L-HKMRB3
WU422R-HKMRB3 7.50R16-12 7.50R16-12 650(6.5, 94) 650(6.5, 94)
7.50R16-14 7.50R16-14 700(7.0, 102) 700(7.0, 102)
WU412L-HKMRB 7.50-16-12 7.50-16-12 600(6.0, 87) 600(6.0, 87)
XZU423R-HKMRD3
WU422L-HKMRB 7.50R16-12 7.50R16-12 650(6.5, 94) 650(6.5, 94)
XZU423L-HKMQD3
WU422L-HKFTB 7.50-16-14 7.50-16-14 650(6.5, 94) 650(6.5, 94)
WU422L-HKFTB3
XZU423L-HKMRD3
WU412L-HKFTB 7.50R16-14 7.50R16-14 700(7.0, 102) 700(7.0, 102)
WU412L-HKFTB3
7.50-16-10 7.50-16-10 525(5.3, 76) 525(5.3, 76)
XZU413L-HKMQD3 7.50-16-12 7.50-16-12 600(6.0, 87) 600(6.0, 87)
7.50R16-10 7.50R16-10 575(5.8, 83) 575(5.8, 83)
7.00-16-10 7.00-16-10 500(5.0, 73) 500(5.0, 73)
XZU413L-HKMMD3 7.00R16-10 7.00R16-10 525(5.3, 76) 525(5.3, 76)
7.50-16-12 7.50-16-12 600(6.0, 87) 600(6.0, 87)

for Ireland (Wide cab)
Model
195/75R 16 195/75R 16 525(5.3, 76) 525(5.3, 76)
XZU415R-HKMMDW3
195/85R 16 195/85R 16 600(6.0, 87) 600(6.0, 87)
XZU415R-HKFQDW3
215/75R 17.5 215/75R 17.5 700(7.0, 102) 700(7.0, 102)
XZU425R-HKFQDW3
XZU425R-HKFRDW3
XZU435R-HKFRDW3 215/75R 17.5 215/75R 17.5 700(7.0, 102) 700(7.0, 102)
XZU415R-HKFRDW3
SS–60 SERVICE SPECIFICATIONS – BRAKE
BRAKE
SERVICE DATA
Pad lining thickness Wide Cab with 6 Hub Bolts
Front brake Standard 40.0 mm (1.575 in.)
Disc thickness Wide Cab with 6 Hub Bolts
Disc runout Wide Cab with 6 Hub Bolts Maximum 0.1 mm (0.0039 in.)
SS Standard 14.0 mm (0.551 in.)
for 5 Hub Bolt
Pad lining thickness
for 6 Hub Bolt
Rear brake for 5 Hub Bolt
Disc thickness
for 6 Hub Bolt
for 5 Hub Bolt Maximum 0.1 mm (0.0039 in.)
Disc runout
for 6 Hub Bolt Maximum 0.1 mm (0.0039 in.)
Rear axle load (including vehicle weight):

Standard body type
Model Front brake Rear axle load kg (lb)
WU300L-HBMLS
WU300L-HBMLS3
WU302L-HBMLA
WU302L-HBMLA3 Drum 1300 (2867)
WU300R-HBMLS3
XZU303L-HBMLA
XZU303L-HBMLA3
WU300L-HBMMS
WU300L-HBMMS3 Drum 1600 (3528)
WU302L-HBMMB3
WU300L-HBMMS
Disk 1250 (2756)
WU300L-HBMMS3
WU302L-HBMMB3 Disk 1200 (2646)
WU340L-HKMMS
WU340L-HKMMS3 Drum 1600 (3528)
XZU343L-HKMMA3
WU340L-HKMMS
WU340L-HKMMS3 Disk 1150 (2536)
XZU343L-HKMMA3
SERVICE SPECIFICATIONS – BRAKE SS–61
Wide body type

Model Front brake Rear axle load kg (lb)
WU410L-HKMQSV
WU410L-HKMQSV3
WU410R-HKMMS3
WU412R-HKMMB3
WU412L-HKMMB Drum 1550 (3418)
WU412L-HKMMB3
XZU423R-HKMMB3
XZU413L-HKMMD3
SS
XZU413R-HKMMB3
WU410R-HKMQS3
WU412L-HKMQB
WU412L-HKMQB3
XZU413L-HKMQD3 Drum 1730 (3815)
WU420L-HKMQSV
WU420L-HKMQSV3
XZU423L-HKMQD3
WU412L-HKMRBV
WU412L-HKMRBV3
WU412L-HKMRB
WU412L-HKMRB3
WU422L-HKMRBV
WU422L-HKMRBV3
Drum 1650 (3638)
WU420R-HKMRS3
WU422R-HKMRB3
WU422L-HKMRB
WU422L-HKMRB3
XZU423R-HKMRD3
XZU423L-HKMRD3
WU412L-HKFTBV
WU412L-HKFTBV3
Drum 1730 (3815)
WU412L-HKFTB
WU412L-HKFTB3
WU422L-HKFTBV
WU422L-HKFTBV3
Drum 1650 (3638)
WU422L-HKFTB
WU422L-HKFTB3
XZU405R-HKFQD3
XZU415R-HKFQD3 Disk 1730 (3815)
XZU425R-HKFQD3
Rear brake fluid pressure table

Rear brake pressure
Model
MPa (kgf/cm2, psi)
5.6 +/- 0.49
Standard body type
(57 +/- 5, 812 +/- 71)
5.4 +/- 0.49
Wide body type
(55 +/- 5, 783 +/- 71)
ABC point data table for the WU series:

A B C
Model Front Brake kPa (kgf/ kPa (kgf/ kPa (kgf/
kgf (lb) kgf (lb) kgf (lb)
cm2, psi) cm2, psi) cm2, psi)
1009 490 1015 600 2497 9200
WU300L-HBMLS Drum
(2224) (5.0, 71) (2238) (6.1, 87) (5506) (93.8, 1330)
1009 490 1015 600 2497 9200
WU300L-HBMLS3 Drum
(2224) (5.0, 71) (2238) (6.1, 87) (5506) (93.8, 1330)
1009 490 1015 600 2497 9200
WU302L-HBMLA Drum
(2224) (5.0, 71) (2238) (6.1, 87) (5506) (93.8, 1330)
SS 1009 490 1015 600 2497 9200
WU302L-HBMLA3 Drum
(2224) (5.0, 71) (2238) (6.1, 87) (5506) (93.8, 1330)
1009 490 1015 600 2497 9200
WU300R-HBMLS3 Drum
(2224) (5.0, 71) (2238) (6.1, 87) (5506) (93.8, 1330)
925 490 1839 6370 3589 13900
WU300L-HBMMS Drum
(2040) (5.0, 71) (4055) (65, 925) (7914) (141.8, 2020)
WU300L-HBMMS 925 490 1839 6370 3589 13000
Drum
Reinforced rear spring (2040) (5.0, 71) (4055) (65, 925) (7914) (132.6, 1890)
925 490 1839 6370 3589 13900
WU300L-HBMMS3 Drum
(2040) (5.0, 71) (4055) (65, 925) (7914) (141.8, 2020)
WU300L-HBMMS3 925 490 1839 6370 3589 13000
Drum
925 490 1839 6370 3589 13900
WU302L-HBMMB3 Drum
(2040) (5.0, 71) (4055) (65, 925) (7914) (141.8, 2020)
WU302L-HBMMB3 925 490 1839 6370 3589 13000
Drum
925 490 1839 8630 3589 16160
WU300L-HBMMS Disc
(2040) (5.0, 71) (4055) (88, 1250) (7914) (169.8, 2340)
WU300L-HBMMS 575 490 1839 8630 3589 15260
Disc
925 490 1839 8630 3589 16160
WU300L-HBMMS3 Disc
(2040) (5.0, 71) (4055) (88, 1250) (7914) (169.8, 2340)
WU300L-HBMMS3 575 490 1839 8630 3589 15260
Disc
925 490 1839 8630 3589 16160
WU302L-HBMMB3 Disc
(2040) (5.0, 71) (4055) (88, 1250) (7914) (169.8, 2340)
WU302L-HBMMB3 575 490 1839 8630 3589 15260
Drum
925 490 1839 6370 3374 13000
WU340L-HKMMS Drum
(2040) (5.0, 71) (4055) (65, 925) (7440) (132.6, 1890)
WU340L-HKMMS 925 490 1839 6370 3374 12220
Drum
925 490 1839 6370 3374 13000
WU340L-HKMMS3 Drum
(2040) (5.0, 71) (4055) (65, 925) (7440) (132.6, 1890)
WU340L-HKMMS3 925 490 1839 6370 3374 12220
Drum
475 490 1839 9320 3374 15900
WU340L-HKMMS Disc
(1047) (5.0, 71) (4055) (95, 1350) (7440) (162.2, 2310)
WU340L-HKMMS 475 490 1839 9280 3374 15120
Disc
Reinforced rear spring (1047) (5.0, 71) (4055) (94.6, 1350) (7440) (154.2, 2190)
475 490 1839 9320 3374 15900
WU340L-HKMMS3 Disc
(1047) (5.0, 71) (4055) (95, 1350) (7440) (162.2, 2310)
WU340L-HKMMS3 475 490 1839 9280 3374 15120
Disc
1031 490 2047 8090 3264 9250
WU410L-HKMQSV Drum
(2273) (5.0, 71) (4514) (82.5, 1170) (7197) (94.3, 1340)
WU410L-HKMQSV 1135 490 2289 8340 4168 14140
Drum
A B C
1031 490 2047 8090 3264 9250
WU410L-HKMQSV3 Drum
(2273) (5.0, 71) (4514) (82.5, 1170) (7197) (94.3, 1340)
WU410L-HKMQSV3 1135 490 2289 8340 4168 14140
Drum
1031 490 2047 8090 3264 9250
WU410R-HKMMS3 Drum
(2273) (5.0, 71) (4514) (82.5, 1170) (7197) (94.3, 1340)
WU410R-HKMMS3 1135 490 2289 8340 4168 14140
Reinforced rear spring
Drum
(2503) (5.0, 71) (5047) (85, 1180) (9190) (144.2, 2050) SS
1031 490 2047 8090 3264 9250
WU412R-HKMMB3 Drum
(2273) (5.0, 71) (4514) (82.5, 1170) (7197) (94.3, 1340)
WU412R-HKMMB3 1135 490 2289 8340 4168 14140
Drum
1031 490 2047 8090 3264 9250
WU412L-HKMMB Drum
(2273) (5.0, 71) (4514) (82.5, 1170) (7197) (94.3, 1340)
WU412L-HKMMB 1135 490 2289 8340 4168 14140
Drum
1031 490 2047 8090 3264 9250
WU412L-HKMMB3 Drum
(2273) (5.0, 71) (4514) (82.5, 1170) (7197) (94.3, 1340)
WU412L-HKMMB3 1135 490 2289 8340 4168 14140
Drum
1211 490 2136 7400 4168 10870
WU410R-HKMQS3 Drum
(2670) (5.0, 71) (4710) (75.5, 1070) (9190) (110.8, 1580)
WU410R-HKMQS3 1135 490 2289 8340 4168 14140
Drum
1211 490 2136 7400 4168 10870
WU412L-HKMQB Drum
(2670) (5.0, 71) (4710) (75.5, 1070) (9190) (110.8, 1580)
WU412L-HKMQB 1135 490 2289 8340 4168 14140
Drum
1211 490 2136 7400 4168 10870
WU412L-HKMQB3 Drum
(2670) (5.0, 71) (4710) (75.5, 1070) (9190) (110.8, 1580)
WU412L-HKMQB3 1135 490 2289 8340 4168 14140
Drum
1211 490 2136 7400 4168 10870
WU420L-HKMQSV Drum
(2670) (5.0, 71) (4710) (75.5, 1070) (9190) (110.8, 1580)
WU420L-HKMQSV 1135 490 2289 8340 4168 14140
Drum
1211 490 2136 7400 4168 10870
WU420L-HKMQSV3 Drum
(2670) (5.0, 71) (4710) (75.5, 1070) (9190) (110.8, 1580)
WU420L-HKMQSV3 1135 490 2289 8340 4168 14140
Drum
1060 490 2296 8960 4969 16330
WU412L-HKMRBV Drum
(2337) (5.0, 71) (5063) (91.4, 1300) (10957) (166.5, 2370)
WU412L-HKMRBV 1060 490 2216 8400 4696 14610
Drum
Reinforced rear spring (2337) (5.0, 71) (4886) (85.7, 1220) (10960) (149, 2120)
1060 490 2296 8960 4969 16330
WU412L-HKMRBV3 Drum
(2337) (5.0, 71) (5063) (91.4, 1300) (10957) (166.5, 2370)
WU412L-HKMRBV3 1060 490 2216 8400 4696 14610
Drum
1060 490 2296 8960 4969 16330
WU412L-HKMRB Drum
(2337) (5.0, 71) (5063) (91.4, 1300) (10957) (166.5, 2370)
WU412L-HKMRB 1060 490 2216 8400 4696 14610
Drum
1060 490 2296 8960 4969 16330
WU412L-HKMRB3 Drum
(2337) (5.0, 71) (5063) (91.4, 1300) (10957) (166.5, 2370)
WU412L-HKMRB3 1060 490 2216 8400 4696 14610
Drum
A B C
1060 490 2296 8960 4969 16050
WU422L-HKMRBV Drum
(2337) (5.0, 71) (5063) (91.4, 1300) (10957) (163.7, 2330)
WU422L-HKMRBV 1060 490 2216 8400 4905 14420
Drum
1060 490 2296 8960 4969 16050
WU422L-HKMRBV3 Drum
(2337) (5.0, 71) (5063) (91.4, 1300) (10957) (163.7, 2330)
WU422L-HKMRBV3 1060 490 2216 8400 4905 14420
SS Reinforced rear spring
Drum
(2337) (5.0, 71) (4886) (85.7, 1220) (10820) (147, 2090)
1060 490 2296 8960 4969 16050
WU420R-HKMRS3 Drum
(2337) (5.0, 71) (5063) (91.4, 1300) (10957) (163.7, 2330)
WU420R-HKMRS3 1060 490 2216 8400 4905 14420
Drum
1060 490 2296 8960 4969 16050
WU422R-HKMRB3 Drum
(2337) (5.0, 71) (5063) (91.4, 1300) (10957) (163.7, 2330)
WU422R-HKMRB3 1060 490 2216 8400 4905 14420
Drum
1060 490 2296 8960 4969 16050
WU422L-HKMRB Drum
(2337) (5.0, 71) (5063) (91.4, 1300) (10957) (163.7, 2330)
WU422L-HKMRB 1060 490 2216 8400 4905 14420
Drum
1060 490 2296 8960 4969 16050
WU422L-HKMRB3 Drum
(2337) (5.0, 71) (5063) (91.4, 1300) (10957) (163.7, 2330)
WU422L-HKMRB3 1060 490 2216 8400 4905 14420
Drum
1060 490 2250 8630 5742 15950
WU412L-HKFTBV Drum
(2337) (5.0, 71) (4961) (88, 1250) (12661) (162.6, 2310)
1060 490 2250 8630 5742 15950
WU412L-HKFTBV3 Drum
(2337) (5.0, 71) (4961) (88, 1250) (12661) (162.6, 2310)
1060 490 2250 8630 5742 15950
WU412L-HKFTB Drum
(2337) (5.0, 71) (4961) (88, 1250) (12661) (162.6, 2310)
1060 490 2250 8630 5742 15950
WU412L-HKFTB3 Drum
(2337) (5.0, 71) (4961) (88, 1250) (12661) (162.6, 2310)
1060 490 2250 8630 5742 15950
WU422L-HKFTBV Drum
(2337) (5.0, 71) (4961) (88, 1250) (12661) (162.6, 2310)
1060 490 2250 8630 5742 15950
WU422L-HKFTBV3 Drum
(2337) (5.0, 71) (4961) (88, 1250) (12661) (162.6, 2310)
1060 490 2250 8630 5742 15950
WU422L-HKFTB Drum
(2337) (5.0, 71) (4961) (88, 1250) (12661) (162.6, 2310)
1060 490 2250 8630 5742 15950
WU422L-HKFTB3 Drum
(2337) (5.0, 71) (4961) (88, 1250) (12661) (162.6, 2310)
ABC point data table for the XZU series:

A B C
1009 490 1015 600 2497 9200
XZU303L-HBMLA Drum
(2224) (5.0, 71) (2238) (6.1, 87) (5506) (93.8, 1330)
1009 490 1015 600 2497 9200
XZU303L-HBMLA3 Drum
(2224) (5.0, 71) (2238) (6.1, 87) (5506) (93.8, 1330)
925 490 1839 6370 3374 13000
XZU343L-HKMMA3 Drum
(2040) (5.0, 71) (4055) (65, 925) (7440) (132.6, 1890)
XZU343L-HKMMA3 925 490 1839 6370 3374 12220
Drum
475 490 1839 9320 3374 15900
XZU343L-HKMMA3 Disc
(1047) (5.0, 71) (4055) (95, 1350) (7440) (162.2, 3310)
A B C
XZU343L-HKMMA3 475 490 1839 9280 3374 15120
Drum
1031 490 2047 8090 3264 9250
XZU413R-HKMMB3 Drum
(2273) (5.0, 71) (4514) (82.5, 1170) (7197) (94.3, 1340)
XZU413R-HKMMB3 1135 490 2289 8340 4168 14140
Drum
1031 490 2047 8090 3264 9250
XZU413L-HKMMD3 Drum
(2273) (5.0, 71) (4514) (82.5, 1170) (7197) (94.3, 1340) SS
XZU413L-HKMMD3 1135 490 2289 8340 4168 14140
Drum
1031 490 2047 8090 3264 9250
XZU423R-HKMMB3 Drum
(2273) (5.0, 71) (4514) (82.5, 1170) (7197) (94.3, 1340)
XZU423R-HKMMB3 1135 490 2289 8340 4168 14140
Drum
1211 490 2136 7400 4168 10870
XZU413L-HKMQD3 Drum
(2670) (5.0, 71) (4710) (75.5, 1070) (9190) (110.8, 1580)
XZU413L-HKMQD3 1135 490 2289 8340 4168 14140
Drum
1211 490 2136 7400 4168 10870
XZU423L-HKMQD3 Drum
(2670) (5.0, 71) (4710) (75.5, 1070) (9190) (110.8, 1580)
XZU423L-HKMQD3 1135 490 2289 8340 4168 14140
Drum
1060 490 2296 8960 4905 16050
XZU423R-HKMRD3 Drum
(2337) (5.0, 71) (5063) (91.4, 1300) (10957) (163.7, 2230)
XZU423R-HKMRD3 1060 490 2216 8400 4950 14420
Drum
1060 490 2296 8960 4905 16050
XZU423L-HKMRD3 Drum
(2337) (5.0, 71) (5063) (91.4, 1300) (10957) (163.7, 2230)
XZU423L-HKMRD3 1060 490 2216 8400 4950 14420
Drum
Parts tightened N*m kgf*cm ft.*lbf
Vacuum pump gear lock nut 110 1120 81
Vacuum pump end cover x Vacuum pump housing 7.8 80 69 in.*lbf
Vacuum check valve sub-assembly x Vacuum pump assembly 74 750 54
Vacuum pump assembly x Engine assembly 55 560 41
Vacuum pipe x Vacuum pump 13 130 10
No. 3 nozzle leakage pipe sub-assembly x Engine assembly 13 130 10
Oil level gauge sub-assembly x Engine assembly 13 130 10
Vacuum pump oil pipe sub-assembly x Vacuum pump 13 130 10
Vacuum pump oil pipe sub-assembly x Engine assembly 20 200 15
Fuel filter to injection pump fuel pipe x Fuel filter 40 (44) 407 (448) 29 (32)
Fuel filter to injection pump fuel pipe x Injection pump 40 (44) 407 (448) 29 (32)
Vacuum pump housing x Vacuum pump cover 3.8 39 34 in.*lbf
Vacuum pump assembly x Union 32 326 23
Oil inlet hose x Vacuum pump assembly 22 225 16
Wire harness x Generator body 3.8 39 34 in.*lbf
Wire harness x Terminal B 10 102 7.4
Fan belt adjusting bar x Engine assembly 125 1275 92
Fan belt adjusting bar x Generator body 47 479 34

Generator assembly x Engine assembly 47 479 34
Front disc brake cylinder mounting bolt Wide Cab with 6 Hub Bolts 265 2700 195
Front disc brake cylinder assembly x Front disc brake
Wide Cab with 6 Hub Bolts 125 1270 92
cylinder mounting
Front disc brake cylinder assembly x Flexible hose 31 316 23
Front wheel nut 515 5250 380
for 5 Hub Bolts 200 2040 147
Rear disc brake cylinder mounting bolt
for 6 Hub Bolts 265 2700 195
SS Rear disc cylinder assembly x Rear flexible hose 31 316 23
Rear wheel nut 515 5250 380
Load sensing proportioning valve x Body 12.5 130 9

SERVICE SPECIFICATIONS – PARKING BRAKE SS–67
PARKING BRAKE
SERVICE DATA
Parking brake lever travel at 245 N (25 kgf, 55 lbf) 6 to 10 notches
Parking Brake Switch

Tester Connection Condition Specified Condition
1 - Body ground Parking brake switch ON (Switch pin free) Below 1 Ω
Parking brake switch OFF (Switch pin pushed
1 - Body ground
in)
10 kΩ or higher SS

Parking Brake Lever
18 184 13
Assembly x Body
Parking Brake Lever Screw A 1.5 15.3 13.3 in.*lbf
Assembly x Parking Brake
switch Screw B 0.24 2.4 2.1 in.*lbf
Parking Brake lever x Lock

5.0 51 44 in.*lbf
Nut
No. 2 Parking Brake Cable
18 184 13
x Body
No. 2 Parking Brake Cable
18 184 13
x Bracket
No. 2 Control Cable
18 184 13
Bracket x Body
No. 2 Control Cable
Bracket x No. 2 Control 18 184 13
Cable Bracket
No. 2 Control Cable
Bracket x Power Steering 18 184 13
Gear Assembly
SS–68 SERVICE SPECIFICATIONS – POWER STEERING
POWER STEERING
SERVICE DATA
POWER STEERING FLUID
Fluid level rise (Maximum) 6 mm (0.24 in.)
POWER STEERING FLUID (N04C-TR, TS, TT)

Barcode
Color Fluid Pressure
No.
SS 309 Yellow 8300 to 8800 kPa (85 to 90 kgf/cm2, 1203 to 1276 psi)
Fluid pressure at idle speed with valve closed 307 Orange 9300 to 10000 kPa (95 to 102 kgf/cm2, 1348 to 1450 psi)
322 Green 10900 to 11800 kPa (111 to 120 kgf/cm2, 1581 to 1711 psi)
309 Yellow 8300 to 8800 kPa (85 to 90 kgf/cm2, 1203 to 1276 psi)
Fluid pressure at idle speed with valve fully open
and turn the steering wheel to the full lock 307 Orange 9300 to 10000 kPa (95 to 102 kgf/cm2, 1348 to 1450 psi)
position
322 Green 10900 to 11800 kPa (111 to 120 kgf/cm2, 1581 to 1711 psi)
POWER STEERING FLUID (for W04D Engine Series Steel type Vane Pump)
Fluid pressure at idle speed with valve closed 9300 to 9800 kPa (95 to 100 kgf/cm2, 1349 to 1421 psi)
Fluid pressure at idle speed with valve fully open and turn the steering
wheel to the full lock position 9300 to 9800 kPa (95 to 100 kgf/cm2, 1349 to 1421 psi)
POWER STEERING FLUID (for W04D Engine Series Aluminum type Vane Pump)
Fluid pressure at idle speed with valve closed 10900 to 11800 kPa (111 to 120 kgf/cm2, 1581 to 1712 psi)
Fluid pressure at idle speed with valve fully open and turn the steering
wheel to the full lock position 10900 to 11800 kPa (111 to 120 kgf/cm2, 1581 to 1712 psi)
STEERING WHEEL
Steering effort at idle speed (Reference) 6.0 N*m (61 kgf*cm, 53 in.*lbf)
VANE PUMP (for N04C-TR, TS, TT)
Oil pump to gear box tube x Pressure feed hose 30 (44) 306 (448) 22 (32)
Oil pump to gear box tube x No. 1 hose support bracket (nut) 44 448 32
Oil pump to gear box tube x No. 1 hose support bracket (bolt) 18 183 13
Oil pump to gear box tube x Timing gear case 18 183 13
Oil pump to gear box tube x Vane pump assembly (union bolt) 49 499 36
Radiator pipe with radiator hose outlet x Timing gear case 18 183 13
Radiator pipe with radiator hose outlet x Radiator assembly 3.5 36 31 in.*lbf
Power steering suction port union x Vane pump assembly 29 296 21
Power steering suction port union set bolt 29 296 21
Vane pump assembly set bolt 47 480 35
( ): For use without SST

VANE PUMP (for W04D Engine Series Steel type Vane Pump)
Oil pump to gear box tube set nut 29 296 21
Oil pump to gear box tube set bolt 29 296 21
Power steering suction port union x Vane pump assembly 7.6 78 67in.*lbf
SERVICE SPECIFICATIONS – POWER STEERING SS–69
VANE PUMP (for W04D Engine Series Aluminum type Vane Pump)
Oil pump to gear box tube set nut 29 296 21
Oil pump to gear box tube set bolt 29 296 21
Power steering suction port union x Vane pump assembly 29 296 21
POWER STEERING GEAR SS

Steering main shaft assembly x Power steering gear assembly 35 357 26
Power steering gear assembly x Steering gear outlet return tube 44(40) 448(408) 32(29)
Power steering gear assembly x Pressure feed hose 44(40) 448(408) 32(29)
for Standard Body 150 1529 110
for Wide Body (except
195 1987 143
Steering drag link assembly x Pitman arm XZU413L-TKMMD3)
for Wide Body (XZU413L-
150 1529 110
TKMMD3)
Pitman arm x Power steering gear assembly 320 3261 235
Power steering gear assembly x Side frame 180 1835 132
Steering gear housing x Stud bolt 10 102 7
Transmission control cable clamp set nut for RHD 18 183 13
No. 2 transmission control cable bracket bolt for RHD 18 183 13
( ): For use without SST

RACK AND PINION GEAR
Steering rack end x Power steering rack 137 1397 101
Steering rack end x Power steering rack (Use torque wrench) 118 1200 87
A bolt 155 1580 114
Steering gear box x Crossmenber
B bolt 206 2100 152
Steering rack bousing bracket x Bolt 155 1580 114
Pressure feed hose union bolt x Power steering assembly 42 428 32
Steering gear outlet return tube x Power steering link assembly 44 448 32
Steering torque shaft x Bolt 35 360 26
Steering gear housing bracket x Bolt 39 400 29
Transmission control cable bracket x Bolt 18 184 13
Tie rod end x Castle nut 90 930 66
Steering main shaft assembly x Bolt 35 360 26
POWER STEERING LINK

Steering arm nuts (for standard body) 390 3975 287
Steering arm nuts (for wide body) 685 6981 503
Tie rod end lock nuts (for standard body) 137 1396 101
Tie rod end lock nuts (for wide body) 175 1784 129
Tie rod nuts x left knuckle arm (for standard body) 150 1529 110
Tie rod nuts x left knuckle arm (for wide body) 195 1987 143
Front wheel 515 5249 379
SS–70 SERVICE SPECIFICATIONS – AIR CONDITIONING
AIR CONDITIONING
SERVICE DATA
Refrigerant charge volume (Standard:) 550 +- 50 g (19.4 +- 1.8 oz.)
Magnetic clutch clearance 0.35 to 0.60 mm (0.014 to 0.024 in.)
SS Part tightened N*m kgf*cm ft*lbf
COMPRESSOR AND MAGNETIC CLUTCH
Magnet clutch hub x Cooler compressor assembly 18 184 13
Compressor and magnetic clutch x Engine 25 255 18
No. 1 cooler refrigerant discharge hose x Compressor and magnetic
9.8 100 87 in.*lbf
clutch
No. 1 cooler refrigerant suction hose x Compressor and magnetic clutch 9.8 100 87 in.*lbf
SERVICE SPECIFICATIONS – SUPPLEMENTAL RESTRAINT SYSTEM (FOR PASSEN-
GER) SS–71
SUPPLEMENTAL RESTRAINT
SYSTEM (FOR PASSENGER)
Instrument panel passenger airbag assembly x Body 20 200 14
SS
SS–72 SERVICE SPECIFICATIONS – POWER SOURCE / WIRING

Voltage converter sub-assembly x Body 15 153 11
SS
SERVICE SPECIFICATIONS – HORN SS–73
HORN
Low pitched horn assembly x Body 20 204 15
SS
SS–74 SERVICE SPECIFICATIONS – ENGINE HOOD / DOOR
ENGINE HOOD / DOOR

FRONT DOOR
Door check arm bracket x Body 5.0 51 44 in.*lbf
Door check x Door panel 5.0 51 44 in.*lbf
Door lock x Door panel 5.0 51 44 in.*lbf
SS Power window regulator motor x Window regulator 5.4 55 48 in.*lbf
Window regulator x Door panel 5.0 51 44 in.*lbf
Door glass x Window regulator 5.0 51 44 in.*lbf
Door outside handle x Door panel 5.0 51 44 in.*lbf
SERVICE SPECIFICATIONS – POWER TAKE-OFF SS–75
POWER TAKE-OFF
POWER TAKE-OFF ASSEMBLY (for Power Take Off Elctric Type)
Power take-off assembly x Manual transmission assembly 36 370 27
POWER TAKE-OFF ASSEMBLY (for Power Take Off Vacuum Type)
POWER TAKE-OFF ASSEMBLY (for Power Take Off Manual Lever Type) SS
Power take-off control lever x Power take-off assembly 37 377 27
Power take-off control cable stay x Power take-off assembly 37 377 27
Push pull cable assembly x Power take-off control lever 7.5 77 66 in.*lbf
Push pull cable clamp x Power take-off control cable stay 7.5 77 66 in.*lbf
POWER TAKE-OFF CONTROL UNIT
Power take-off control unit x Body 19 194 14
Tool box sub-assembly x Body 61 622 45
ENGINE

ENGINE CONTROL SYSTEM
NOTICE:
*E1: N04C-TU, TV, TW
*E2: N04C-TW
*E3: N04C-TU, TV
No mark: N04C-TR, TS, TT, TU, TV, TW
ECD SYSTEM
PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-1 ES
FUNCTION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-2
SUPPLY PUMP SPECIFICATION LEARNING AT THE TIME OF PUMP
REPLACEMENT (INITIALIZATION) . . . . . . . . . . . . . . . . . . . . . . . . . . ES-3
INJECTOR COMPENSATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-7
INITIALIZATION OF THE INJECTOR (SUPPLY) PUMP . . . . . . . . . . . . ES-7
FUNCTION EXPLANATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-9
PARTS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-10
SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-12
HOW TO PROCEED WITH TROUBLESHOOTING . . . . . . . . . . . . . . . . ES-16
BASIC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-18
DPR FORCIBLE REGENERATION PROCEDURE *E2 . . . . . . . . . . . . . ES-20
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-21
TERMINALS OF ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-24
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-28
DIAGNOSIS USING THE PC (PERSONAL COMPUTER) DIAGNOSIS
TOOL WITH INTERFACE (Hino-DX) . . . . . . . . . . . . . . . . . . . . . . . . . ES-28
DTC CHECK / CLEAR (WITH Hino-DX) . . . . . . . . . . . . . . . . . . . . . . . . . ES-29
DTC DHECK / CLEAR (NOT USING Hino-DX) . . . . . . . . . . . . . . . . . . . . ES-30
FREEZE-FRAME DATA/DTC DETAIL INFORMATION (WITH Hino-DX) ES-32
FAIL-SAFE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-32
DATA LIST / ACTIVE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-36
DIAGNOSTIC TROUBLE CODE CHART . . . . . . . . . . . . . . . . . . . . . . . . ES-41
P0045/34 *E1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-48
P0087/49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-52
P0190/49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-52
P0192/49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-52
P0193/49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-52
P0088/78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-55
P0627/78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-55
P1229/78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-55
P0093/78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-61
P0095/23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-67
P0097/23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-67
P0098/23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-67
P0100/31 *E1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-72
P0102/31 *E1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-72
P0103/31 *E1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-72
P0101/31 *E1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-77
P0105/35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-79
P0107/35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-79
P0108/35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-79
P0106/31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-83
P0110/24 *E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-84
P0112/24 *E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-84
P0113/24 *E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-84
P0115/22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-89
P0117/22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-89
P0118/22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-89
P0116/22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-94
P0120/41 *E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-96
P0122/41 *E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-96
P0123/41 *E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-96
P0168/39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-100
ES P0180/39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-100
P0182/39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-100
P0183/39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-100
P0200/97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-105
P0234/34 *E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-112
P0299/34 *E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-112
P1251/34 *E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-112
P0335/12, 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-115
P0339/13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-115
P0340/12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-119
P0400/71 *E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-123
P0405/96 *E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-126
P0406/96 *E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-126
P0488/15 *E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-130
P0500/42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-133
P0504/51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-137
P0544/A3 *E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-143
P0545/A3 *E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-143
P0546/A3 *E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-143
P0560/96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-149
P0606 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-151
P0607/54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-151
P0617/43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-152
P0630/89 *E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-155
P0863/17 *E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-156
P1133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-159
P1238/78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-162
P1425/A4 *E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-166
P1427/A4 *E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-166
P1428/A4 *E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-166
P1426/A4 *E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-170
P1530/92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-173
P1601/89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-174
P1611/17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-176
P1674/36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-177
P2002/94 *E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-180
P2031/A3 *E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-186
P2032/A3 *E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-186
P2033/A3 *E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-186
P2120/19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-191
P2121/19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-191
P2122/19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-191
P2123/19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-191
P2125/19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-191
P2127/19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-191
P2128/19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-191
P2138/19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-191
P2226/A5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-197
P2228/A5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-197
P2229/A5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-197
P2227/A5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-199
U1123/A2 *E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-200
Engine Difficult to Start or Stalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-203
Black Smoke Emitted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-214
Pre-heating Control Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-227 ES
Rough Idling or Excessive Engine Vibrations . . . . . . . . . . . . . . . . . . . . . ES-239
Engine Knocking or Rattling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-251
Lack of Power or Hesitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-264
ECM Power Source Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-280
EDU Power Source Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-290
VC Output Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-297
Starter Signal Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-304
MIL Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-309
DPR Manual Forced Regeneration Procedure *E2 . . . . . . . . . . . . . . . . . ES-312
DPR Switch and Buzzer Circuit *E2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-314
Clogging by DPR Catalytic Converter *E2 . . . . . . . . . . . . . . . . . . . . . . . . ES-320
Abnormal Temperature Detection by Exhaust Temperature Sensor
(Upstream) *E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-332
(Downstream) *E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-335
Exhaust Brake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-337
DIESEL THROTTLE BODY*1
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-344
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-345
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-345
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-345
ECM
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-347
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-347
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-348
ACCELERATOR PEDAL ROD
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-350
ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-351
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-352
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-352
MASS AIR FLOW METER *E1
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-354
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-354
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-355
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-355
CAMSHAFT POSITION SENSOR
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-356
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-356
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-357
CRANKSHAFT POSITION SENSOR
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-358
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-358
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-359
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-359
ENGINE COOLANT TEMPERATURE SENSOR
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-360
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-360
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-361
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-361
ES INTAKE AIR TEMPERATURE SENSOR
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-363
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-363
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-364
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-364
EDU RELAY
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-365
N04C-TR, TS, TT, TU, TV, TW ENGINE CONTROL SYSTEM – ECD SYSTEM ES–1
ECD SYSTEM
PRECAUTION
CAUTION:
• Approximately 110V is generated for the injector drive
actuation system. For this reason, electrical shock
may result if the injector drive circuit is touched
directly by hand. Turn the starter switch to the LOCK
position if it is necessary to check or repair the
computer, harnesses, or connectors.
1. BE CAREFUL NOT TO LET DIRT OR DUST GET ES
INSIDE THE ACTUATOR OR MAGNETIC VALVES.
2. HARNESS WIRE CONNECTOR.
(a) Multi-contact connectors suitable for the small
electrical signals of electronic circuitry are used for
wiring connections to the sensors, actuator and
control unit. Be very careful when handling them.
• Before disconnecting any connectors, make sure
that the starter switch is in the "LOCK" position.
• When disconnecting connectors, try to pull them
out in a straight line, disengaging the lock and
holding onto the housing.
• Do not try to disconnect connectors by gripping
the wires or twisting them, as this could bend the
contacts.
• Do not disconnect connectors unnecessarily.
• When using a circuit tester, apply the tester
probe to the harness wire side only. Never stick
the tester probe into the holes on the connector
terminal side, as this could cause poor contacts
when the connector is reconnected.
SHTS161110200005
• Do not let water, oil or dust get on the connector

when it is disconnected, as this could cause poor
contacts when the connector is reconnected.
• Do not open the control unit cover. It could
malfunction if dust or water gets inside.
• Take care to ensure that water, oil or dust do not
get on or inside parts.
• When connecting in connectors, push them in all
the way and make sure that the lock engages.
ES–2 N04C-TR, TS, TT, TU, TV, TW ENGINE CONTROL SYSTEM – ECD SYSTEM
3. ERASING THE MALFUNCTION MEMORY STORED IN

THE PAST, CHECK THE CURRENT MALFUNCTION
BY PERFORMING A DIAGNOSIS OF THE PRESENT
MALFUNCTION AGAIN.
4. AFTER COMPLETING THE MALFUNCTION
ANALYSIS, ERASE THE MALFUNCTION MEMORY
STORED IN THE PAST. OTHERWISE, THE
MALFUNCTION CODES IN THE DISPLAY WILL
REMAIN INDICATED.
5. CONNECTOR DRAWING, ALL OF WHICH HAS A
VIEW TO BE SEEN FROM THE CONNECTION SIDE,
ES INSERT THE TESTING LEAD FROM THE BACKSIDE.
6. USING A CIRCUIT TESTER
• Use a circuit tester with an internal resistance of 100
kΩ or greater in the voltage measuring range.
FUNCTION INSPECTION
1. DIESEL THROTTLE BODY ASSEMBLY
(a) Function inspection
SST (Hino-DX) 09993-E9070, 09042-1220
NOTICE:
A function inspection must be performed at the
time of diesel throttle body replacement and
after parts have been removed and reinstalled.
(1) Confirm an operation sound from the diesel
throttle when the ignition switch is set to ON.
Also confirm that there is no interference.
(2) Connect the SST (Hino-DX) to DLC3 and delete
the diagnostic code. (See page ES-29)
(3) Start the engine and confirm that the check
warning lamp does not light.
(4) After engine warm-up, confirm that the engine
speed is within the reference value.
Standard:
Engine speed Measuring conditions
• Neutral position
500 to 650 r/min • P, N range (ATM)
• Air conditioner OFF
HINT:
ECM Perform without electric load.
(5) After throttle body function inspection, perform a
E22 E23
running test and confirm that there is no
abnormal feeling.
(b) Check Voltage (throttle position sensor)
(1) Use an electrical tester to measure the voltage
between ECM terminals E23-20 (VLU) and E22-
E2 VLU 28 (E2). (See page ES-24 for the terminal
A101463E51 layout.)
Standard:
ECM Condition Standard
E23-20 (VLU) - Throttle closed (70% open) 1.4 to 1.8 V

E22-28 (E2) Throttle open (0% open) 2.6 to 3.0 V
2. ACCELERATOR PEDAL ROD ASSEMBLY

(a) Connect the SST (Hino-DX) to DLC3.
SST 09993-E9070, 09042-1220
(b) Set the ignition switch to ON and set the [Data
display] - [Data monitor] to confirm that the
numerical value of "Accelerator pedal position
sensor No. 1" is within the reference value.
Standard:
Inspection terminal
Inspection condition Standard
ECM data monitor
Accelerator pedal
12 - 20%
closed ES
Accelerator pedal Accelerator pedal
56 - 72%
position sensor No. 1 open
Accelerator pedal
Continuous change
closed to open
SUPPLY PUMP SPECIFICATION

LEARNING AT THE TIME OF PUMP
REPLACEMENT (INITIALIZATION)
NOTICE:
• This work (supply pump specification learning) must
be performed after replacement of injection (supply)
pump or engine control computer.
• When the ECM has been replaced, perform supply
pump specification learning after injector
compensation has been performed.
1. SUPPLY PUMP SPECIFICATION LEARNING WITH

THE Hino-DX
Supply pump difference learning

Initial screen
Engine cooling water temperature: Initial value
Fuel temperature: Initial value
Pump unit difference learning completion flag:
Value [before learning]
Note 1:
ES Perform warm-up operation
Engine cooling water temperature: 60ºC or more
Confirm that the following diagnostic codes
are not present.
Fuel temperature: 30ºC or more · P0191, P0192, P0193
Press the [Diagnosis confirmation] button (Note 1) · P0500, P0501 EP0628, P0629
· P1211, P1212, P1214, P1215
Press the "Next" button · P0201 - P0206
Initialization start
Note 2:
(1) Stop the engine · Gear in neutral position
(2) Set the gear to neutral position · Parking brake securely applied
(3) Set the starter key to ON · PTO OFF
Press the "Next" button
Note 3: ·
Initialization completion · Gear in neutral position
(1) Start the engine (note 2) · Parking brake securely applied
(2) Stop the engine after 5 sec · PTO OFF EAutomatic idle status
(3) Wait for 10 seconds or more and set · Exhaust brake warm-up cancelled
the starter key to ON
Press the "Next" button
Pump unit difference learning

(1) Start the engine (note 3)
(2) Supply pump specification learning If completion is not reached
completion flag: Value [learning completion] even after one minute has
passed, press the stop
Press the "Next" button button and do it again.
Writing
(1) Set the starter key to LOCK
(2) Wait for 10 sec
(3) Completion of registration to the ECM
End
ASM3-758

SST 09993-E9070, 09042-1220
(b) Set the ignition switch to ON.
NOTICE:
Do not operate the engine.
(c) Follow the SST (Hino-DX) screen display and select

[Function confirmation] → [Supply pump
specification learning].
Supply pump specification learning
Supply pump specification learning

Data View
Item Value Unit Stop (S)
Engine coolant temperature 4
Fuel temperature 4
Flag of having learned specific value of c.. [Pre-Learning] Next (N)
ES
Check DTC (D)
Explanation
Warm up the Engine till the coolant temperature is more than 60ºC [140ºF] and
the fuel temperature is more than 30ºC [86ºF]
Attention
Confirm following diagnostic trouble codes are not detected.
· P0627, P1229, P0093 (Supply pump malfunction)
· P0263, P0266, P0269, P0272, P200 (Injector abnormal)
Help (F1) End (C)
ASM3-759
(d) Perform warm-up operation until the water

temperature is 60°C (140°F) or more and the fuel
temperature is 30°C (86°F) or more. The value on
the [Data display] screen changes with rising
temperature.
NOTICE:
Press the [Check DTC] button and confirm that
the following diagnostic codes are not output.
• P0191, P0192/49, P0193/49 (PC sensor
system abnormal)
• P0500/42, P0501 (vehicle speed sensor
system abnormal)
• P0628, P0629 (Pump abnormal)
• P1211, P1212, P1214, P1215, PP0201-P0206
(injector system abnormal)
After completion of warm-up, press the [Next]
button.
(e) As the [Explanation] display changes, perform the

following work following [Explanation].
Explanation
Initialize supply pump learning value. Stop the engine. Shift into neutral of the Transmission
and turn the starter key on "ON" position
Attention
Without attention
ES
ASM3-760
• Stop the engine.

• Set the gear to the neutral position.
• Set the starter key to ON.
Press the [Next] button.
(f) Start the engine. Stop the engine after five seconds,
wait for 10 seconds, and set the starter key to ON.
Explanation
Confirm neutral gear position of the transmission, parking brake engagement and its
efficiency and PTO off, then start the Engine.
· Stop the engine after 30 seconds. Leave the engine more than 10 seconds as it is,
then turn the starter key on "ON" position.
Attention
Without attention
ASM3-761
NOTICE:
• Gear in neutral position
• Parking brake securely applied
• PTO OFF
Press the [Next] button.
(g) Start the engine.
Explanation
Confirm neutral gear position of the transmission, parking brake engagement and its
efficiency, PTO off, auto idle condition and cancel of exhaust brake warning brake switch,
then start the Engine.When the leaning is complete, click the [Next] button.
Attention
In case it is not completed after 1 minutes, click [Stop] button and execute leaning step again.
ASM3-762
NOTICE:
• Gear in neutral position
• Parking brake securely applied
• PTO OFF
• Automatic idle status

• Exhaust brake function cancelled
Press the [Next] button when the value of [Data
display] - [Supply pump specification learning
completion flag] has reached [Learning has
completed].
(h) Set the starter key to LOCK and wait for 10 sec.
Explanation
Supply pump specification learning is completed. To be programmed the leaning data to
ECM, turn the starter key on "LOCK" position and leave it more than 10 seconds.
ES
Caution Items
Without attention
ASM3-763
(i) [Supply pump specification learning] end.
INJECTOR COMPENSATION
NOTICE:
When the engine control computer has been replaced,
perform difference training at the time of pump
replacement after injector compensation has been
performed.
1. Procedure
SST 09993-E9070, 09042-1220
NOTICE:
[Settings] - [Injector compensation].
(d) Refer to “Help” of the Hino-DX for details in regard
to injector compensation.
INITIALIZATION OF THE INJECTOR

(SUPPLY) PUMP
1. INITIALIZATION WITH HINO-DX
SST 09993-E9070, 09042-1220
CAUTION:
[Work support] - [ECD] - [Supply pump learning
value initialization].
(d) Confirm the display contents and then perform

initialization.
CAUTION:
Execute with ignition ON and stopped engine.
(e) If an error occurs during initialization, repeat from
(c).
(f) Start the engine and perform warm-up to confirm
completion of initialization.
CAUTION:
Do not let the engine race directly after engine
start.
ES NOTICE:
• If the engine does not start, repeat from (c).
• The engine warm-up status represents a
water temperature of 60°C or more and a fuel
temperature of 20°C or more.
(1) Use [ECU data monitor] - [Engine cooling water
temperature] of SST (Hino-DX) to confirm the
water temperature.
SST 09993-E9070, 09042-1220
Reference value:
60°C or more
(2) Use [ECU data monitor] - [Fuel temperature] of
SST (Hino-DX) to confirm the fuel temperature.
SST 09993-E9070, 09042-1220
Reference value:
20°C or more
NOTICE:
If the fuel temperature does not rise because
of the measuring environment etc., raise the
engine speed gradually to a steady state of
approx. 3,000 r/min and raise the
temperature. Sudden racing must be
avoided.
(g) Perform idling for one minute or more in the status
after engine warm-up.
(h) Initialization completion.
2. INITIALIZATION BY DLC3 SHORT-CIRCUIT
DLC3 (a) Set the ignition switch to OFF (LOCK).
TC (b) Use diagnostic check wire No. 2 to short-circuit
between terminals 4 (CG) and 13 (TC) of DLC3.
16 15 14 13 12 1110 9 SST 09843-18040
(c) Set the ignition switch to ON.
8 7 6 5 4 3 2 1
CAUTION:
Do not start the engine.
CG
(d) After 3 minutes, set the ignition switch to OFF
A146915J01 (LOCK).
(e) Cancel the DLC3 short-circuit.
(f) Start the engine and perform warm-up to confirm
completion of initialization.
CAUTION:
Do not let the engine race directly after engine
start.
NOTICE:
• If the engine does not start, repeat from the
beginning.
• The engine warm-up status represents a
water temperature of 60°C or more and a fuel
temperature of 20°C or more.
(1) Use SST (Electrical Tester) and confirm water
ENGINE CONTROL COMPUTER temperature and fuel temperature from the
THW voltage between the terminals of the engine
control computer. (See page ES-24 for the
terminal layout.)
SST 09082-00040, 09083-00150 ES
THF E2
A101463J77
Reference value:
Inspection terminal Inspection condition Reference value
Engine control computer
THW(A19)←→E2(A28) Cooling water temperature 0.1 to 1.0 V
60 to 120°C
THF(A29)←→E2(A28) Fuel temperature 2.0 V or lower
20°C or more
NOTICE:
If the fuel temperature does not rise because
of the measuring environment etc., raise the
engine speed gradually to a steady state of
approx. 3,000 r/min and raise the
temperature. Sudden racing must be
avoided.
(g) Perform idling for one minute or more in the status
after engine warm-up.
(h) Initialization completion.
FUNCTION EXPLANATION
1. WHAT IS AN ID CORD
In order to optimize the injection characteristics of the
injector assembly, the engine control computer uses
different injection timing compensation for each
assembly. These compensation data are stamped as a
30-digit alphanumeric ID code on the head of the injector
assembly.
At the time of replacement of injector assembly or engine
control computer, registration of the ID code (injector
A076781E03 compensation) is required.
CAUTION:
Abnormal noise etc. may be caused when ID code is
not registered correctly.
PARTS LOCATION
FUEL INJECTOR TURBOCHARGER
DIESEL THROTTLE BODY

ACCELERATOR PEDAL ROD (THROTTLE CONTROL MOTOR) *E1
(ACCEL POSITION SENSOR)
(THROTTLE CONTROL SENSOR)
ENGINE COOLANT
ES TEMPERATURE
SENSOR
EXHAUST GAS
TEMPERATURE
SENSOR
EGR VALVE (UPSTREAM)
*E2
EXHAUST GAS
TEMPERATURE
SENSOR
(DOWNSTREAM)
*E2
DIFFERENTIAL
PRESSURE SENSOR
*E2
INJECTOR DRIVER
CAMSHAFT
POSITION
SENSOR
MASS AIR FLOW METER
*E1
CRANKSHAFT NO. 2 RELAY BLOCK

POSITION SENSOR TURBO PRESSURE
SENSOR
COMMON RAIL
(FUEL PRESSURE SENSOR)
INTAKE AIR TEMPERATURE
SENSOR FUEL SUPPLY PUMP
(SUCTION CONTROL VALVE FUEL TEMPERATURE SENSOR)
A154124E01
LHD MODELS
COMBINATION METER DPR SWITCH *E2
ES
NO. 1 RELAY BLOCK

DLC3 ECM
COMBI METER
RHD MODELS
DLC3
(ATM MODEL)
DLC3
(MTM MODEL)
ECM DPR SWITCH *E2
No.1 RELAY BLOCK

ASM3-734
SYSTEM DIAGRAM
*E1: N04C-TU,TV,TW
*E2: N04C-TW +B
No mark: N04C-TR,TS,TT,TU,TV,TW
MREL
ENG-3
STP
ES HEAD STOP
ST1-
Stop Light Switch
HSW
ENG Warm Up Switch *E1
CLSW
Exhaust Brake Clutch Switch
OUT1
EXSW
OUT2 Exhaust Brake
Combination Switch
+24V OUTM BATT

DC/DC
Converter
IGSW
DC-DC1 ENG-2
AM2 AM2 IG2

GAUGE
AM1 RGSW
AM1 ST1 W2
STA Ignition Switch DPR Switch
*E2
Battery STA
STA
STARTER
Starter
Battery ECM
ASM3-735
TC TC
VCPA VCPA
CAN CAN
VPA VPA
CANH CANH
EPA EPA
DLC3
VCP2 VCP2
ES
VPA2 VPA2 CAN
+B
EPA2 EPA2 CANH
Accelerator Pedal Position Sensor GND
Turbo Actuator *E1
to ENG-3 Relay
VA VPA1
VC VCP1
EXB
E2 EP1
VSV (Exhaust Brake)
Accelerator Position Sensor
PCV- E2R
LUSL VTAR
VGR
PCV+
Idle Speed Control Volume
Suction Control Valve No.1
THA THA +B
VG VG
to Diode (A/C No. 2) AC
EVG E2G E2
to A/C Amplifier ACT Mass Air Flow Meter
*E1
NE- +B
EGLS EGLS
VC
NE+ EGRS EGRS
E2
Crank Shaft Position Sensor EGR Valve Position Sensor
*E1
A B C
ECM
ASM3-736
A B C
VCC VCG VC
PIM PIM
EZ
OUT G+ Turbo Pressure Sensor
GND G- VC
VLU VTA
E2
Camshaft Position Sensor
Throttle Position Sensor
ES *E1
VC
SPD PCR1 VP
GND
PTO Fuel Pressure Sensor
Combination
Meter
W THIA
TAC Intake Air Temperature Sensor
GIND THF
Fuel Temperature Sensor
THW
to GLOW Fuse
Engine Coolant Temperature Sensor
VC
PEX PEX
E2
SREL Differential Pressure Sensor *E2
GLOW MAIN
THCI
Exhaust Gas Temperature Sensor
E1
(Bank 1 Sensor 1) *E2
E01
THCO
E02
E2
Glow Plug VC
EC
NUSW
Neutral Position Switch
D
ECM
ASM3-737
D
INJ1#
COM1
#1 IJT#1 No. 1 Fuel Injector
#2 IJT#2
INJ2#
ES
COM2
#3 IJT#3 No. 2 Fuel Injector
#4 IJT#4 INJ3#
INJF IJF No. 3 Fuel Injector
INJ4#
+B
No. 4 Fuel Injector

GND
EDU
to ENG Fuse
IREL
EDU
ECM
ASM3-738
HOW TO PROCEED WITH

TROUBLESHOOTING
HINT:
• Use the following procedures to troubleshoot the ECD
system.
• The Hino-DX should be used in steps 3, 7,and 10.
ES NEXT
2 CUSTOMER PROBLEM ANALYSIS
NEXT
3 CHECK DTC AND FREEZE FRAME DATA
1. Check DTC and freeze-frame data (See page ES-32).

2. Clear DTC and freeze-frame data
3. DTC reconfirmation
(a) To A in case of DTC output
(b) To B in case of no DTC output
B Go to step 5
4 TROUBLESHOOTING BY DIAGNOSTIC TROUBLE CODE CHART (TROUBLE AREA) OR

BY INDIVIDUAL CODE
Result
Result Proceed to
Malfunction occurs A
Malfunction does not occur B
A Go to step 10
B Go to step 7
5 PROBLEM SYMPTOMS TABLE
Problem symptoms table (See page ES-21).

Result
Result Proceed to
A Go to step 10
6 BASIC INSPECTION
Basic inspection (See page ES-18).

Result
Result Proceed to
ES
A Go to step 10
7 INSPECTION WITH Hino-DX
Perform ECU data monitoring and active test.

Result
Result Proceed to
A Go to step 10
8 CHECK VOLTAGE OF ECM TERMINALS AND CIRCUITS
ECM terminals voltage (See page ES-24)

NEXT
9 ADJUST AND/OR REPAIR OR REPLACE
NEXT
10 DTC CONFIRMATION
DTC confirmation (See page ES-29).

NEXT
END
BASIC INSPECTION
When a malfunction cannot be confirmed by checking DTCs,
troubleshooting should be performed on all circuits that are
possible causes of the problem. However, in most cases,
performing the basic engine check shown below can help you
find the problem quickly and efficiently. Always perform this
check first when troubleshooting the engine.
1 CHECK BATTERY VOLTAGE
ES NOTICE:
Check the battery voltage with the engine stopped and
the ignition switch off.
Standard voltage
OK NG
Voltage 22 V or more Less than 22 V
NG CHARGE OR REPLACE BATTERY
OK
2 CHECK IF ENGINE CRANKS
NG PROCEED TO PROBLEM SYMPTOMS

TABLE
OK
3 CHECK AIR FILTER
(a) Visually check that the air filter is not excessively

contaminated with dirt or oil.
NG CLEAN OR REPLACE AIR FILTER
OK
4 CHECK FUEL QUALITY
(a) Check that only diesel fuel is present.

(b) Check that the fuel does not contain any impurities.
NG DRAIN AND REFILL FUEL
OK
5 CHECK FUEL SYSTEM FOR AIR
NG BLEED AIR FROM FUEL SYSTEM

OK
6 CHECK FUEL PIPES AND HOSES
(a) Check that the fuel pipes and fuel hoses are not blocked,
damaged, disconnected or bent.
NG REPAIR OR REPLACE
OK
ES
7 CHECK FUEL FILTER FOR BLOCKAGE
NG CLEAN OR REPLACE
OK
8 CHECK ENGINE OIL
NG ADD OR DRAIN AND REFILL
OK
9 CHECK ENGINE COOLANT
NG ADD OR DRAIN AND REFILL ENGINE

COOLANT
OK
10 CHECK IDLE SPEED AND MAXIMUM ENGINE SPEED
NG REPLACE SUPPLY PUMP ASSEMBLY
OK
11 CHECK FUEL PRESSURE (WITH Hino-DX)
NG REPLACE COMMON RAIL ASSEMBLY
OK
12 CHECK DIAGNOSTIC CIRCUIT
NG REPAIR OR REPLACE
OK
13 CHECK VACUUM PUMP
NG REPAIR OR REPLACE VACUUM PUMP
OK
PROCEED TO PROBLEM SYMPTOMS TABLE

ES
DPR FORCIBLE REGENERATION

PROCEDURE *E2
1. DPR FORCIBLE REGENERATION PROCEDURE
(a) Park the vehicle in a safe location.
NOTICE:
Do not leave combustible materials around the
exhaust pipe because the temperature of the
DPR catalytic converter increases during the
forcible regeneration.
(b) Shift the lever to the neutral position.
(c) Securely apply the parking brake.
(d) Warm up the engine.
(e) Accelerate the engine speed to the maximum rpm
with no load 20 times.
(f) Connect the Hino-DX to the DLC3.
(g) Follow the Hino-DX screen display and select items:
Work support/ECD/Work related to filter (Forcible
regeneration drive.)
HINT:
When the DPR indicator light is blinking, the forcible
regeneration function can be performed by pressing
the DPR switch.
(h) Check that the idling speed increases and the
exhaust brake operates.
HINT:
• If the exhaust gas temperature (OUT) exceeds
800°C (1,472°F), cease the forcible regeneration
function immediately.
• If DTC P2002/94 recurs during the forcible
regeneration, catalyst degradation may occur.
• If the exhaust brake opens and closes
repetitively or does not close, check the exhaust
system. Also, check for friction within the
alternator and the air conditioning compressor
because the engine load may be abnormally
high.
• It takes 15 to 20 minutes to complete the forcible
regeneration function.
(i) Check that the engine speed decreases, the

exhaust brake is released, and the forcible
regeneration function is completed.
(j) After the forcible regeneration is completed, allow
the engine to idle for at least 5 minutes.
(k) Follow the Hino-DX screen display and set the ECU
data monitor - DPR/DPNR differential pressure.
(l) Check the differential pressure when the exhaust
gas temperature sensor indicates 200°C (392°F) or
less.
Standard:
15 kPa or less. ES
HINT:
• If the exhaust gas temperature is high, the
differential pressure cannot be measured
correctly.
• If the differential pressure is outside the normal
range, the monolithic converter assembly may
have deteriorated or the monolithic converter
assembly may be clogged with PM.
• Fully depress the accelerator pedal and when the
engine speed becomes stable, promptly read the
differential pressure.
(m) Check the amount of engine oil.
(n) If the amount of engine oil is more than the specified
level, replace the engine oil.
(o) DPR FORCIBLE REGENERATION is complete.
PROBLEM SYMPTOMS TABLE

Use the table below to help determine the cause of the
problem symptom. The potential causes of the symptoms are
listed in order of probability in the "Suspected Area" column
of the table. Check each symptom by checking the suspected
areas in the order they are listed. Replace parts as
necessary.
NOTICE:
*E2: N04C-TW
*No mark: N04C-TR, TS, TT, TU, TV, TW
ECD SYSTEM
Symptom Suspected Area See chapter or see
page
Starter ST
Engine does not crank (does not start) ST relay ST
ECT sensor ES-360

page
Engine difficult to start or stalling ES-203
Starter signal circuit ES-304
Injector FU
Fuel filter FU
Compression EM
Supply pump FU
Fuel pressure sensor FU
Difficult to start with cold engine
Diesel throttle body assembly *E1 ES-344
EDU (relay) ES-365
ES Battery deteriorated CH
Fuel with low cetane number used -
Fuel frozen -
Air mixed into fuel pipe -
ECM ES-347
Injector FU
Fuel filter FU
Compression EM
Supply pump FU
Difficult to start with warm engine
EDU (relay) ES-365
Battery deteriorated CH
ECM ES-347
Fuel filter FU
Injector FU
ECM power source circuit ES-280
Engine stalls soon after starting Supply pump FU
ECM ES-347
Engine stalls (not including the condition listed above) Engine difficult to start or stalling ES-203
Rough idling or excessive engine vibration ES-239
Fuel filter FU
Injector FU
Supply pump FU
Abnormal initial idling (poor idling) Fuel pressure sensor FU
Fuel with low cetane number used -
A/C signal circuit to ECM open and generator signal circuit to -
ECM open
ECM ES-347

page
A/C signal circuit -
Injector FU
High engine idling speed (poor idling) Supply pump FU
Speed sensor circuit open -
Accelerator pedal ES-350
ECM ES-347
ES
A/C signal circuit -
Injector FU
EGR system *E1 EC
Compression EM
Low engine idling speed (poor idling)
Fuel line (air bleeding) -
Supply pump FU
Diesel throttle body *E1 ES-344
ECM ES-347
Rough idling (poor idling) Rough idling or excessive engine vibration ES-239
Injector FU
Compression EM
Hunting with hot engine (poor idling)
Supply pump FU
ECM ES-347
Injector FU
Compression EM
Hunting with cold engine (poor idling)
Supply pump FU
ECM ES-347
Lack of power or hesitation ES-264
Injector FU
Fuel filter FU
EGR system *E1 EC
Compression EM
Hesitation/Poor acceleration (poor driveability) Supply pump FU
Diesel throttle body assembly ES-344
Accelerator pedal ES-350
Turbocharger system IT
ECM ES-347
Knocking (poor driveability) Engine knocking or rattling ES-251

page
Black smoke emitted ES-214
EGR system *E1 EC
Black smoke emitted (poor driveability)
Injector FU
Accumulation in exhaust system -
EGR system *E1 EC
Injector FU
Fuel filter FU
Supply pump FU
White smoke emitted (poor driveability)
ES Diesel throttle body ES-344
Low quality fuel -
ECM ES-347
Injector FU
Supply pump FU
Surging/Hunting (poor driveability) Fuel pressure sensor FU
Turbocharger system (VN turbo system) *E1 IT
ECM ES-347
DPR switch indicator does not come on while the DPR DPR switch and buzzer circuit *E2 ES-314
warning buzzer is sounding ECM ES-347
DPR switch and buzzer circuit *E2 ES-314
DPR forcible regeneration does not end Clogging by DPR catalytic converter *E2 ES-320
ECM ES-347
TERMINALS OF ECM
E22 E23 E24 E25
A066714E53
HINT:
Each ECM terminal's standard voltage is shown in the table
below.
In the table, first follow the information under "Condition".
Lock under "Terminal No. (Symbols)" for the terminals to be
inspected. The standard voltage between the terminals is
shown under "Specified Condition".
Use the illustration above as a reference for the ECM
terminals.
Specified
Terminal No. (Symbols) Wiring Color Terminal Description Condition
Condition
Battery (for measuring
E24-2 (BATT) - E23-7 (E1) L-R - BR battery voltage and for ECM Constant 11 to 14 V
memory)
Ignition switch in the ON
E25-16 (IGSW) - E23-7 (E1) GR - BR Ignition switch 11 to 14 V
position
E25-1 (+B) - E23-7 (E1) B-R - BR Power source of ECM 11 to 14 V
position
E25-13 (MREL) - E23-7 (E1) GR-R - BR MAIN relay 11 to 14 V
position
5 seconds pass after ignition
E25-13 (MREL) - E23-7 (E1) GR-R - BR MAIN relay 0 to 2 V
switch off ES
Power source of sensor (a Ignition switch in the ON
E22-18 (VC) - E23-7 (E2) L-B - BR 4.5 to 5.5 V
specific voltage) position
Accelerator pedal position
E25-22 (VPA) - E25-28 (EPA) BR-R - LG-B position, accelerator pedal 0.6 to 1.0 V
sensor (for engine control)
fully released
Accelerator pedal position
E25-22 (VPA) - E25-28 (EPA) BR-R - LG-B position, accelerator pedal 2.8 to 3.6 V
sensor (for engine control)
fully depressed
Accelerator pedal position Ignition switch in the ON
E25-23 (VPA2) - E25-29 (EPA2) R-W - GR-G sensor (for sensor position, accelerator pedal 1.4 to 1.8 V
malfunction detection) fully released
Accelerator pedal position Ignition switch in the ON
E25-23 (VPA2) - E25-29 (EPA2) R-W - GR-G sensor (for sensor position, accelerator pedal 3.6 to 4.4 V
malfunction detection) fully depressed
Power source of accelerator
E25-20 (VCPA) - E25-28 (EPA) B-O - LG-B pedal position sensor (for 4.5 to 5.5 V
position
VPA)
Power source of accelerator
E25-21 (VCP2) - E25-29 (EPA2) G-W - GR-G pedal position sensor (for 4.5 to 5.5 V
position
VPA2)
E23-24 (VG) - E23-32 (EVG) G - V-R MAF meter *E1 Engine is warmed up: Idling 1.5 to 1.9 V
Engine is warmed up: engine
E23-24 (VG) - E23-32 (EVG) G - V-R MAF meter 2.8 to 3.9 V
speed holt at 3000 r/min
IAT sensor (built in MAF Engine is warmed up: Idling,
E22-31 (THA) - E22-28 (E2) V-G - R-B 0.5 to 3.4 V
meter) *E1 IAT at 0 to 80°C (32 to 176°F)
IAT sensor (after Engine is warmed up: Idling,
E22-20 (THIA) - E22-28 (E2) Y-R - R-B 0.5 to 3.4 V
turbocharged) *E1 IAT at 0 to 80°C (32 to 176°F)
Idling, ECT at 80 to 120°C
E22-19 (THW) - E22-28 (E2) G-R - R-B ECT sensor 0.4 to 1.0 V
(176 to 248°F)
E23-18 (STA) - E23-7 (E1) B-W - BR Starter signal Cranking 6.0 V or more
E22-24 (#1) - E23-7 (E1) P-L - BR
E22-23 (#2) - E23-7 (E1) LG - BR Pulse generation
Injector Engine is warmed up: Idling
E22-22 (#3) - E23-7 (E1) LG-B - BR (See page ES-110)
E22-21 (#4) - E23-7 (E1) GR - BR
Pulse generation
E23-23 (G+) - E23-31 (G-) R-G Camshaft position sensor Engine is warmed up: Idling
(See page ES-120)
Pulse generation
E22-27 (NE+) - E22-34 (NE-) B-W Crankshaft position sensor Engine is warmed up: Idling
(See page ES-116)
E25-18 (STP) - E23-7 (E1) V - BR Stop light switch position, brake pedal 18 to 27 V
depressed
E25-18 (STP) - E23-7 (E1) V - BR Stop light switch position, brake pedal 0 to 2 V
released
Stop light switch (opposite to
E25-8 (ST1-) - E23-7 (E1) V-Y - BR Brake pedal depressed 0 to 2 V
STP)
Specified
Condition
Stop light switch (opposite to
E25-8 (ST1-) - E23-7 (E1) V-Y - BR Brake pedal released 18 to 27 V
STP)
E25-17 (TC) - E23-7 (E1) R-B - BR Terminal TC of DLC3 18 to 27 V
position
Short the terminals of DLC3
E25-17 (TC) - E23-7 (E1) R-B - BR Terminal TC of DLC3 0 to 2 V
between 13 (TC) - 4 (CG)
E23-18 (STA) - E23-7 (E1) B-W - BR Starter signal Cranking 6 V or higher
E25-6 (TAC) - E23-7 (E1) P - BR Engine speed Idling Pulse generation
E25-9 (W) - E23-7 (E1) Y-R - BR MIL MIL illuminated 0 to 2 V
E25-9 (W) - E23-7 (E1) Y-R - BR MIL MIL not illuminated 18 to 27 V
ES
Speed signal from
E25-19 (SPD) - E23-7 (E1) R - BR position, driving wheel slowly Pulse generation
combination meter
rotated
Turbo pressure sensor Applied negative pressure of
E23-28 (PIM) - E22-28 (E2) P-G - R-Y (manifold absolute pressure 93 kPa (697 mmHg, 27.5 0.25 to 0.4 V
sensor) in.Hg)
Turbo pressure sensor Applied positive pressure of
E23-28 (PIM) - E22-28 (E2) P-G - R-B (manifold absolute pressure 150 kPa (1,128 mmHg, 44.2 1.0 to 1.4 V
sensor) in.Hg)
E24-17 (CANH) - E23-7 (E1) W - BR Turbocharger operation *E1 Idling Pulse generation
E24-28 (CANL) - E23-7 (E1) B - BR Turbocharger status *E1 Idling Pulse generation
E25-14 (IREL) - E23-7 (E1) R - BR EDU relay Ignition switch OFF 0 to 2 V
E25-14 (IREL) - E23-7 (E1) R - BR EDU relay Idling 11 to 14 V
Idling (Approximately 30 MPa
E22-26 (PCR1) - E22-28 (E2) L-W - R-Y Fuel pressure sensor 1.3 to 1.7 V
(306 kgf/cm2, 4,351 psi))
E22-29 (THF) - E22-28 (E2) Y - R-Y Fuel temperature sensor 1.2 to 1.6 V
position
E23-22 (VCG) - E23-31 (G-) L-R - G Camshaft position sensor 4.5 to 5.5 V
position
Pulse generation
E22-2 (PCV+) - E22-1 (PCV-) L - L-Y Suction control valve Idling
(See page ES-59)
E23-33 (EGLS) - E22-28 (E2) G-Y - R-Y EGR position sensor *E1 3.8 to 4.2 V
position
E23-33 (EGLS) - E22-28 (E2) G-Y - R-Y EGR position sensor *E1 Engine is warmed up, Idling 3.0 to 3.5 V
E23-3 (EGRS) - E23-7 (E1) G - BR EGR valve *E1 0 to 2 V
position
Engine is warmed up, Engine
E23-3 (EGRS) - E23-7 (E1) G - BR EGR valve *E1 Pulse generation
speed 1500 rpm
Pulse generation
E22-25 (INJF) - E23-7 (E1) B - BR EDU Idling
(See page ES-110)
E23-20 (VLU) - E22-28 (E2) Y-B - R-Y Throttle position sensor *E1 Accelerator pedal depressed 2.6 to 3.0 V
E23-20 (VLU) - E22-28 (E2) Y-B - R-Y Throttle position sensor *E1 Accelerator pedal released 1.4 to 1.8 V
Accelerator pedal released
Throttle control motor duty → Accelerator pedal
E23-4 (LUSL) - E23-7 (E1) W - BR Pulse generation
signal *E1 depressed (when throttle
motor is operating)
Exhaust gas temperature
E23-1 (THCO) - E22-28 (E2) W-L - R-Y Engine is warmed up, Idling 4.5 to 4.9 V
sensor *E2
Exhaust gas temperature
E23-2 (THCI) - E22-28 (E2) R-B - R-Y Engine is warmed up, Idling 4.5 to 4.9 V
sensor *E2
Differential pressure sensor
E23-27 (PEX) - E22-28 (E2) P-L - R-Y Engine is warmed up, Idling 0.5 to 1.0 V
*E2
E24-15 (RGSW) - E23-7 (E1) P-L - BR DPR switch signal *E2 DPR switch on 18 to 27 V
E24-15 (RGSW) - E23-7 (E1) P-L - BR DPR switch signal *E2 DPR switch off 0 to 2 V
E23-8 (EXB) - E23-7 (E1) P-L - BR Exhaust brake Exhaust brake operating 18 to 27 V
Specified
Condition
DPR indicator on (ignition
E25-10 (W2) - E23-7 (E1) B - BR DPR indicator *E2 0 to 2 V
switch in the ON position)
E25-10 (W2) - E23-7 (E1) B - BR DPR indicator *E2 DPR indicator off (idling) 18 to 27 V
E23-16 (PMB) - E23-7 (E1) B - BR DPR warning buzzer *E2 Buzzer off 18 to 27 V
E23-16 (PMB) - E23-7 (E1) B - BR DPR warning buzzer *E2 Buzzer on 0 to 2 V
E24-16 (NUSW) - E23-7 (E1) B-W - BR Neutral position switch position, shift position is 11 to 14 V
neutral
E24-16 (NUSW) - E23-7 (E1) B-W - BR Neutral position switch position, shift position is not 0 to 2 V
neutral ES
E24-9 (CLSW) - E23-7 (E1) O - BR Exhaust brake clutch switch Clutch pedal depressed 0 to 2 V
E24-9 (CLSW) - E23-7 (E1) O - BR Exhaust brake clutch switch Clutch pedal released 18 to 27 V
E24-13 (EXSW) - E23-7 (E1) L - W - BR Combination switch Exhaust brake switch on 18 to 27 V
E24-13 (EXSW) - E23-7 (E1) L - W - BR Combination switch Exhaust brake switch off 0 to 2 V
E24-11 (HSW) - E23-7 (E1) BR-W - BR Warm up switch *E1 Warm up switch on 18 to 27 V
E24-11 (HSW) - E23-7 (E1) BR-W - BR Warm up switch *E1 Warm up switch off 0 to 2 V
E24-17 (CANH) - E23-7 (E1) W - BR CAN communication line Pulse generation
position
E24-28 (CANL) - E23-7 (E1) B - BR CAN communication line Pulse generation
position
E23-7 (E1) - Body ground BR - - Ground Always Below 1 Ω
E22-28 (E2) - Body ground R-Y - - Ground Always Below 1 Ω
E23-19 (EC) - Body ground BR - - Ground Always Below 1 Ω
Accelerator for works (for
E23-26 (VPA1) - E23-34 (EP1) B - R-Y Accelerator full open 0.7 to 1.0 V
installation)
Accelerator for works (for
E23-26 (VPA1) - E23-34 (EP1) B - R-Y Accelerator full close 3.3 to 3.9 V
installation)
Accelerator for works (for Engine stopped, ignition
E23-35 (VCP1) - E23-34 (EP1) L-R - R-Y 4.5 to 5.5 V
installation) switch in the ON position
E25-15 (SREL) - E23-7 (E1) R-L - BR Glow relay drive signal position, glow indicator is 11 to 14 V
lighting
E25-15 (SREL) - E23-7 (E1) R-L - BR Glow relay drive signal Engine is warmed up: Idling 0 to 2 V
E25-11 (GIND) - E23-7 (E1) Y-G - GR Glow indicator position, glow indicator is 0 to 2 V
lighting
E25-11 (GIND) - E23-7 (E1) Y-G - GR Glow indicator Engine is warmed up: Idling 18 to 27 V
Air conditioner signal (MG
E24-21 (AC) - E23-7 (E1) V-W - BR Air conditioner is operating 18 to 27 V
relay)
Air conditioner signal (MG Air conditioner das not
E24-21 (AC) - E23-7 (E1) V-W - BR 0 to 2 V
relay) operating
E24-19 (ACT) - E23-7 (E1) G - BR Air conditioner cut signal 18 to 27 V
position
Air conditioner cut engauged
(running 30km/h or less,
E24-19 (ACT) - E23-7 (E1) G - BR Air conditioner cut signal 0 to 2 V
accelerator pedal fully
depressed for 5 minutes)
Idle-up switch (for works on
E22-17 (IDUP) - E23-7 (E1) W - BR Idle-up switch on 18 to 27 V
installation)
Idle-up switch (for works on
E22-17 (IDUP) - E23-7 (E1) W - BR Idle-up switch off 0 to 2 V
installation)
Specified
Condition
Emergency stop (for works
E22-16 (STOP) - E23-7 (E1) V - BR Emergency stop switch on 18 to 27 V
on installation)
INSPECTION
1. CHECK ENGINE LIGHT STATUS
(a) INSPECTION PROCEDURE
(1) Turn the starter switch to "ON" position (Do not
start the engine) and confirm that the check
ES engine light in the indicator area lights up.
(2) Start the engine.
(3) If the engine is normal, the check engine light
goes out.
(4) If the check engine light does not go out, the
system is abnormal. Check the system
SHTS161110200010 according to diagnosis on the following page.
2. CHECK ENGINE LIGHT ILLUMINATION PATTERN
START
STARTER ON
SWITCH
LOCK
RUNNING
ENGINE
STOP
CHECK
ON
ENGINE
LIGHT OFF
SHTS161110200011
DIAGNOSIS USING THE PC

(PERSONAL COMPUTER) DIAGNOSIS
TOOL WITH INTERFACE (Hino-DX)
1. DIAGNOSIS TOOL
• Trouble diagnosis can be performed using the PC
diagnosis tool (Hino-DX). By connection to the
diagnosis connector (DLC3), the trouble location is
indicated.
SST Communication interface assembly (09993-
E9070), Cable communication (09042-1220),
Diagnosis software: HINO Diagnostic explorer
(DX), Reprogramming software: HINO Reprog
SHTS161110200017 Manager
NOTICE:
Only ECU reprogramming can be performed by
authorized HINO dealer.
2. CONNECT THE PC DIAGNOSIS TOOL.
(a) Turn the starter switch to "LOCK" position.
(b) Connect the diagnosis cable between diagnosis
connector and interface.
(c) Connect the interface to the PC.
(d) Turn the starter switch to "ON" position.
(e) The opening menu will be displayed on the PC
screen.
ES
(LEFT-HAND DRIVE) (RIGHT-HAND DRIVE)
AMT
MTM MODEL
MODEL
DLC3 DLC3
INTER FACE
ASM3-739
DTC CHECK / CLEAR (WITH Hino-DX)

1. INSPECTION PREPARATIONS
(a) Set the shift position to N-range or P-range.
(b) Switch off the air conditioner.
2. CHECK DTC (READING WITH Hino-DX)
SST 09993-E9070, 09042-1220
(b) Follow the screen display, display [Data display] -
[Trouble information] screen, and confirm the DTC.
NOTICE:
• If the DTC is not displayed (the lamp does not
flash), a wire break in the TC terminal system
or a computer defect can be assumed.
• If the check engine warning lamp is lit
continuously, short-circuit of the wire
harness (catching etc.) or a computer defect
can be assumed.
• If a meaningless DTC is put out, a computer

defect can be assumed.
• If the check engine warning lamp lights at
1000 rpm or higher and no DTC is put out, set
the ignition switch once to OFF and then
check again.
3. CLEAR DTC (CLEAR WITH Hino-DX)
(a) Follow the screen display, display [Data display] -
[Trouble information] screen, and clear DTC.
SST 09993-E9070, 09042-1220
NOTICE:
ES • If deletion is not possible, set the ignition
switch once to OFF and then try again.
• Do not delete a diagnostic code with Hino-DX
until the cause has been clarified.
4. CLEAR DTC (Clear by fuse pulling)
R/B NO.2 DC-DC1 Fuse (a) Remove the DC-DC1 fuse (30 A) and insert it again
after at least 15 seconds have passed.
NOTICE:
• After inspection or repair of the ECD system,
the DTC memory must be cleared once, and
then normal code output must be confirmed.
• Until clarification of the DTC, do not clear a
DTC by battery clearing (fuse pulling).
A153091E01 5. CONFIRMATION OF THE DTC JUDGMENT RESULT
(CONFIRMATION WITH Hino-DX)
SST 09993-E9070, 09042-1220
NOTICE:
Confirm the diagnostic output after repair of the
trouble system by diagnostic output or at the time of
a repeatability test after diagnostic code deletion etc.
(a) Follow the screen display, display the [Diagnostic
judgment result] screen and select [Confirmation by
DTC] from the menu.
(b) At the next screen, enter the DTC to be entered.
(c) After execution (confirmation start), perform a
repeat test for the corresponding DTC and confirm
the DTC judgment result.
DTC DHECK / CLEAR (NOT USING

Hino-DX)
1. Not using the hand-held tester:
CHECK DTC
(a) Turn the ignition switch ON.
(b) Using SST, connect between terminals 13 (TC) and
4 (CG) of the DLC3.
SST 09843-18040
A97716
(c) Read DTC by observing the MIL. If any DTC is not

detected, the MIL blinks as shown in the illustration.
A96649
(d) Example ES
If DTCs 12 and 31 are detected,the MIL flashes
once (for 0.52 seconds) and flashes twice after the
1.5 seconds interval, then flashes 3 times after a 2.5
seconds interval from the previous DTC and flashes
once.
If the interval between the previous DTC and the
next DTC is 4.5 seconds, it means the previous
DTC is the last one of the multiple string DTCs.The
BR3589 MIL repeats the indication of DTCs from the initial
cycle (refer to the illustration on the left).
(e) Check the details of the malfunction using the DTC
chart on page ES-41.
(f) After completing the check, disconnect terminals 13
(TC) and 4 (CG) and turn off the display.
HINT:
If 2 or more DTCs are detected, the MIL will
illuminate the smaller number DTC first.
2. Not using the hand-held tester:
R/B NO.2 DC-DC1 Fuse
CLEAR DTC
(a) Disconnect the battery terminal or remove the DC-
DC1 fuse from the R/B No.2 for more than 60
seconds.
A153091E01
FREEZE-FRAME DATA/DTC DETAIL

INFORMATION (WITH Hino-DX)
1. FREEZE-FRAME DATA CONFIRMATION (READING
WITH Hino-DX)
(a) Use the SST (Hino-DX), operate according to the
screen display, display [Data display] - [Trouble
information display] screen, and select the DTC (F-
display) memorizing the freeze data.
SST 09993-E9070, 09042-1220
NOTICE:
ES • The freeze data can be used to confirm the
engine status (ECU data) before and after
diagnostic code detection.
• Use of time series freeze data can be helpful
to troubleshoot when the phenomena cannot
be reproduced.
Item name Abbreviation
Engine speed ESPD
Engine load CALO
FAIL-SAFE CHART
1. FAIL-SAFE CHART
If any of the following DTCs are set, the ECM enters fail-
safe mode to allow the vehicle to be driven temporarily.
NOTICE:
*E2: N04C-TW
Fail-safe Deactivation
DTC No. Detection Item Fail-safe Operation
Condition
Fuel Rail / System Pressure - Too Low
P0087/49 Limits engine power Ignition switch on
[Fuel pressure sensor system malfunction]
Fuel Rail / System Pressure - Too High
P0088/78 Limits engine power Ignition switch on
[Common rail system malfunction]
Fuel System Leak Detected - Large Leak Limits engine power for 1 minute and
P0093/78 Ignition switch on
[Fuel leaks in common rail system] then stalls engine
Intake air (intake manifold) temperature
P0095/23 Intake Air Temperature Sensor 2 Circuit Normal condition is restored.
is fixed at 90°C (130°F)
P0097/23 Intake Air Temperature Sensor 2 Circuit Low Normal condition is restored.
P0098/23 Intake Air Temperature Sensor 2 Circuit High Normal condition is restored.
P0100/31 Mass or Volume Air Flow Circuit *E1 Limits engine power Normal condition is restored.
Mass or Volume Air Flow Meter Circuit Low
P0102/31 Limits engine power Normal condition is restored.
Input *E1
Mass or Volume Air Flow Meter Circuit High
Input *E1
Manifold Absolute Pressure / Barometric
P0105/35 Pressure Circuit Turbo pressure is fixed at specified value Normal condition is restored.
[Intake air pressure sensor]
P0107/35 Pressure Circuit Low Input Turbo pressure is fixed at specified value Normal condition is restored.
[Intake air pressure sensor low input]
Condition
P0108/35 Pressure Circuit High Input Turbo pressure is fixed at specified value Normal condition is restored.
[Intake air pressure sensor high input]
Intake Air Temperature Circuit Normal condition is restored
P0110/24 Limits engine power *1
[Intake air temperature sensor] *2
Intake Air Temperature Circuit Intake air temperature is fixed at
P0110/24 Normal condition is restored.
[Intake air temperature sensor] specified value
Intake Air Temperature Circuit Low Input Normal condition is restored
[Intake air temperature sensor low input] *2
Intake Air Temperature Circuit Low Input Intake air temperature is fixed at
[Intake air temperature sensor low input] specified value ES
Intake Air Temperature Circuit High Input Normal condition is restored
[Intake air temperature sensor high input] *2
Intake Air Temperature Circuit High Input Intake air temperature is fixed at
[Intake air temperature sensor high input] specified value
Engine Coolant Temperature Circuit Normal condition is restored
[Engine coolant temperature sensor] *2
Engine coolant temperature sensor
Engine Coolant Temperature Circuit
P0115/22 output is fixed at specified value (fixed Normal condition is restored.
[Engine coolant temperature sensor]
value varies depending on conditions)
Engine Coolant Temperature Circuit Range /
Normal condition is restored
P0116/22 Performance Problem Limits engine power *1
*2
[Engine coolant temperature sensor]
Engine Coolant Temperature Circuit Low
Normal condition is restored
P0117/22 Input Limits engine power *1
*2
[Engine coolant temperature sensor low input]
Engine Coolant Temperature Circuit Low Engine coolant temperature sensor
P0117/22 Input output is fixed at specified value (fixed Normal condition is restored.
[Engine coolant temperature sensor low input] value varies depending on conditions)
Engine Coolant Temperature Circuit High
Input Normal condition is restored
[Engine coolant temperature sensor high *2
input]
Engine Coolant Temperature Circuit High
Engine coolant temperature sensor
Input
P0118/22 output is fixed at specified value (fixed Normal condition is restored.
[Engine coolant temperature sensor high
value varies depending on conditions)
input]
Throttle / Pedal Position Sensor / Switch "A"
P0120/41 Circuit Limits engine power Ignition switch off
[Throttle position sensor] *E1
P0122/41 Circuit Low Input Limits engine power Ignition switch off
[Throttle position sensor low input] *E1
P0123/41 Circuit High Input Limits engine power Ignition switch off
[Throttle position sensor high input] *E1
Fuel Temperature Too High
[Fuel temperature sensor rationality]
Fuel Temperature Sensor "A" Circuit Fuel temperature is fixed at specified
[Fuel temperature sensor] value
Fuel Temperature Sensor "A" Circuit Low
Fuel temperature is fixed at specified
P0182/39 Input Normal condition is restored.
value
[Fuel temperature sensor low input]
Fuel Temperature Sensor "A" Circuit High
Fuel temperature is fixed at specified
P0183/39 Input Normal condition is restored.
value
[Fuel temperature sensor high input]
Fuel Rail Pressure Sensor Circuit
P0190/49 Limits engine power Ignition switch off
[Fuel pressure sensor]
Condition
Fuel Rail Pressure Sensor Circuit Low Input
[Fuel pressure sensor low input]
Fuel Rail Pressure Sensor Circuit High Input
[Fuel pressure sensor high input]
When one injector circuit is
Injector Circuit / Open malfunctioning, engine power is limited;
P0200/97 Ignition switch on
[EDU system for injector malfunction] when 2 or more ignition circuits are
malfunctioning, engine is stopped
P0234/34 Turbo/Supercharger Overboost Condition Limits engine power Ignition switch off
P0299/34 Turbocharger / Supercharger Underboost Limits engine power Ignition switch off
ES P0335/12, 13
Crankshaft Position Sensor "A" Circuit
Engine stopped Normal condition is restored.
[Crankshaft position sensor]
P0400/71 Exhaust Gas Recirculation Flow *E1 Limits engine power Ignition switch off
Exhaust Gas Recirculation Sensor "A" Circuit
Low *E1
High *E1
Exhaust Gas Recirculation Throttle Position
P0488/15 Control Range / Performance Limits engine power Ignition switch off
[Intake shutter] *E1
Vehicle Speed Sensor "A"
P0500/42 Vehicle speed is fixed at 0 km/h (0 mph) Normal condition is restored.
[Vehicle speed sensor]
Exhaust Gas Temperature Sensor Circuit
P0544/A3 Limits engine power Ignition switch off
(Bank1 Sensor 1) *E2
Exhaust Gas Temperature Sensor Circuit Low
(Bank1 Sensor 1) *E2
High (Bank1 Sensor 1) *E2
Fuel Pump Control Circuit / Open
P0627/78 Engine stopped Ignition switch off
Fuel Pump System
Turbo/Super Charger Overboost Condition
(Too High)
Differential pressure is fixed at specified
P1425/A4 Differential Pressure Sensor Circuit *E2 Ignition switch off
value
P1427/A4 Differential Pressure Sensor Circuit Low *E2 Ignition switch off
value
P1428/A4 Differential Pressure Sensor Circuit High *E2 Ignition switch off
value
RUN PULSE
P1611/17 Engine stopped Ignition switch off
[ECM]
Solenoid for Exhaust Brake Circuit
P1674/36 Exhaust brake stop operation Pass condition defected
Malfunction
Particulate Trap Efficiency Below Threshold
P2002*/94 Limits engine power Ignition switch off
(Bank 1)
P2031/A3
P2033/A3
High (Bank 1 Sensor 2) *E2
Throttle / Pedal Position Sensor / Switch "D"
[Accelerator pedal position sensor (sensor 1)]
Condition
Circuit Range / Performance
P2121/19 Limits engine power Normal condition is restored
[Accelerator pedal position sensor rationality
(sensor 1)]
Circuit Low Input
[Accelerator pedal position sensor low input
(sensor 1)]
Circuit High Input
[Accelerator pedal position sensor high input
(sensor 1)] ES
Throttle / Pedal Position Sensor / Switch "E"
[Accelerator pedal position sensor (sensor 2)]
Circuit Low Input
[Accelerator pedal position sensor low input
(sensor 2)]
Throttle/Pedal Position Sensor/Switch "E"
Circuit High Input
[Accelerator pedal position sensor high input
(sensor 2)]
Throttle / Pedal Position Sensor / Switch "D" /
"E" Voltage Correlation
[Accelerator pedal position sensor
malfunction]
Barometric Pressure Circuit Atmospheric pressure is fixed at
P2226/A5 Normal condition is restored.
[ECM] specified value
Barometric Pressure Circuit Low Input Atmospheric pressure is fixed at
Barometric Pressure Circuit High Input Atmospheric pressure is fixed at
MIL stays on or goes off

MIL remains blinking and engine
output limiting control starts
*1 *2
MIL starts blinking MIL is blinking
50 hours
IG ON IG ON
IG OFF IG OFF
Malfunction is Vehicle returns to Normal condition Idle signal

detected Idle signal is input
normal condition is determined is input
*1: Engine output limiting control is being enabled *2: Engine output limiting control stops A175196E01
HINT:
*1: The ECM will start measuring the time elapsed after
the malfunction is detected at the same time the MIL
starts blinking. If an idle signal is input after 50 hours
have elapsed and the MIL is still blinking, 75% of engine
output will be limited.
*2: If an idle signal is input after the MIL stops blinking,
the engine output limiting control will stop. After the ECM
determines that the vehicle has returned to normal
condition is 3 successive trips, the MIL will stop blinking.
If the MIL is blinking, the DTC cannot be cleared using
ES the tester.
*3: Fail-safe operation is not performed when a DTC is
detected because of deterioration of the DPR catalyst.
DATA LIST / ACTIVE TEST

1. READ DATA LIST
HINT:
Using the Hino-DX's Data List allows switch, sensor,
actuator, and other item values to be read without
removing any parts. Reading the Data List early in
troubleshooting is one way to save time.
NOTICE:
In the table below, the values listed under "Normal
Condition" are reference values. Do not depend
solely on these reference values when deciding
whether a part is faulty or not.
(a) Warm up the engine.
(b) Turn the ignition switch off.
(c) Connect the Hino-DX to the DLC3.
(d) Turn the ignition switch to the ON position.
(e) Follow the Hino-DX screen display and set the Data
display.
(f) Read the Data List.
NOTICE:
*E2: N04C-TW
Tester Display Measurement Item/Range Normal Condition Diagnostic Notes
Idling: 10 to 25%
Calculated load by ECM/
Calculate Load Running without load (2,500 rpm): 7.5 to -
Min.: 0%, Max.: 100%
14.5%
0 g/sec: Mass air flow
sensor power source
Air flow rate from Mass Air Flow (MAF) Idling: 5.0 to 20.0 g/sec
circuit is open or VG
MAF *E1 sensor/ Running without load (3,000 rpm): 70 to 90
circuit is open/shorted
Min.: 0 g/sec, Max.: 655.35 g/sec g/sec
160 g/sec or more: E2G
circuit is open
Absolute pressure inside intake • Idling: 90 to 100 kPa
MAP manifold/ • Engine running at 3,000 rpm: 110 to -
Min.: 0 kPa, Max.: 255 kPa 140 kPa
Engine speed/
Engine Speed Idling: 550 to 650 rpm After warming-up engine
Min.: 0 rpm, Max.: 16383.75 rpm
Vehicle speed/ Speed indicated on
Vehicle Speed Actual vehicle speed
Min.: 0 km/h, Max.: 255 km/h speedometer

If value is -40°C (-40°F)
Engine coolant temperature/ After warming up engine: 80 to 100°C (176 or 140°C (284°F),
Coolant Temp
Min.: -40°C (-40°F), Max.: 140°C (284°F) to 212°F) sensor circuit open or
shorted
If value is -40°C (-40°F)
Intake air temperature/ Equivalent to temperature at intake or 140°C (284°F),
Intake Air
Min.: -40°C (-40°F), Max.: 140°C (284°F) manifold sensor circuit open or
shorted
Fuel Temperature (Fuel Fuel temperature/
Actual fuel temperature -
Temp) Min.: -40°C (-40°F), Max.: 140°C (284°F)
Fuel pressure/
Fuel Press Idling: 25000 to 35000 kPa -
Min.: 0 kPa, Max.: 655350 kPa
EGR position/
ES
EGR Position *E1 Idling: 35 to 45% -
Min: 0%, Max: 100%
• Accelerator pedal released: 12 to 20%
Accelerator position No. 1/
Accelerator Position No. 1 • Accelerator pedal depressed: 56 to -
Min.: 0%, Max.: 100%
72%
• Accelerator pedal released: 28 to 36%
Accelerator position No. 2/
Accelerator Position No. 2 • Accelerator pedal depressed: 72 to -
Min.: 0%, Max.: 100%
88%
Throttle actuator output /
Throttle Motor *E1 Idling after warming up engine: 30 to 50% -
Min.: 0%, Max.: 100%
Accel sensor position (for power take
When power take off operating: 27 to
Accel Sensor Position off)/ -
100%
Max.: 100%, Min.: 0%
Accel sensor voltage (for power take off)/ When power take off operating: 0.6 to 3.7
Accel Sensor Voltage -
Max.: 5 V, Min.: 0 V V
Initial Engine Coolant Initial engine coolant temperature/
ECT when engine starts -
Temp Min.: -40°C (-40°F), Max.: 120°C (248°F)
Initial intake air temperature/
Initial Intake Air Temp IAT when engine starts -
Min.: -40°C (-40°F), Max.: 120°C (248°F)
Exhaust temperature sensor for IN/ Idling: 50 to 150°C (122 to 302°F)
Initial Exhaust Temp (In) Min.: 0°C (32°F), Max.: 1000°C Idling after driving: 80 to 400°C (176 to -
(1,832°F) 752°F)
Exhaust temperature sensor for OUT/ Idling: 50 to 150°C (122 to 302°F)
Initial Exhaust Temp (Out) Min.: 0°C (32°F), Max.: 1000°C Idling after driving: 80 to 400°C (176 to -
(1,832°F) 752°F)
Intake air temperature (Turbo)/
Intake Air Temp (Turbo) 65°C (149°F) or less -
Min.: -40°C (-40°F) to 140°C (284°F)
DPR Differential Pressure DPR differential pressure/
-3 kPa to 3 kPa -
*E2 Min.: -5 kPa, Max.: 100 kPa
EGR lift position/
EGR Lift Position *E1 Idling 70 to 90% -
Max.: 100%, Min.:0%
EGR Close Learning EGR close learning value/
3.5 to 4.5 V -
Value *E1 Min.: 0 V, Max.: 5 V
Throttle Valve Fully Throttle valve fully closed/
- -
Closed *E1 Min.: 0 deg, Max.: 84 deg
Target Common Rail Target common rail pressure/
Idling: 35 to 45 MPa -
Pressure Min.: 0 kPa, Max.: 655350 kPa
VN turbo type/
VNT Type *E1 0: Not AVI, 1: Commo, 2: Vacuum, 3: 1: Commo -
CAN Commo
VN turbo maximum angle /
VNT Max angle *E1 100% -
Min.: 0%, Max.: 100%
VN turbo minimum angle /
VNT Min angle *E1 7.5% -
Min.: 0%, Max.: 100%
Injection Pressure Injection pressure correction/
-400 to 400 mm3/st -
Correction Min.: -500 mm3/st, Max.: 780 mm3/st

Differential Pressure FB Differential pressure correction/
Idling: -1.5 to 1.5 kPa -
*E2 Min.: -10 kPa, , Max.: 246 kPa
Result of DPR catalyst regeneration
(PM)/
DPR Status Reju (PM) *E2 OFF -
$00: Stand by, $01: Ready, $02:
Operate, $03: Compl
• Accelerator pedal released: Read value with ignition
Accelerator pedal position sensor No. 1
0.6 to 1.0 V switch in the ON
Accel Position 1 voltage/
• Accelerator pedal depressed: position
Min.: 0 V, Max.: 5 V
2.8 to 3.6 V (do not start engine)
• Accelerator pedal released: Read value with ignition
Accelerator pedal position sensor No. 2
1.4 to 1.8 V switch in the ON
ES Accel Position 2 voltage/
• Accelerator pedal depressed: position
Min.: 0 V, Max.: 5 V
3.6 to 4.4 V (do not start engine)
Read value with ignition
• Accelerator pedal released: 0%
Accelerator position status/Min.: 0%, switch in the ON
Accel Position • Accelerator pedal depressed: 68 to
Max.: 100% position (do not start
99.6%
engine)
Diesel throttle Angle Diesel throttle angle/
Idling after warmed-up engine: 81 to 95%
(Diesel Thrtl Ang) *E1 Min.: -20%, Max.: 120%
VN turbo command/
VNT Command *E1 - -
Min.: 0%, Max.: 100%
Pump open current value/
Pump VCM Angle Idling: 900 to 1100 mA ECD freeze frame data
Min.: 0 mA, Max.: 4000 mA
IDL stable control/
IDL Stable Control -10 to 10 mm3/st ECD freeze frame data
Min.: -80mm3/st, Max.: 79mm3/st
Common rail pressure (sensor 2)/ Idling: 25000 to 35000 kPa 2000 rpm:
Common Rail Pres Sens 2 -
Max.: 655350 kPa, Min.: 0 kPa 95000 to 105000 kPa
Pilot 1 Injection/
Pilot 1 Injection Idling after warming up engine: 0 µs -
Min.: 0 µs, Max.: 65535 µs
Pilot 2 Injection/
Pilot 2 Injection Idling: 500 to 600 µs -
Min.: 0 µs, Max.: 65535 µs
Main Injection/
Main Injection Idling: 650 to 800 µs -
Min.: 0 µs, Max.: 65535 µs
After Injection/
After Injection - -
Min.: 0 µs, Max.: 65535 µs
Pilot 1 Injection/
Pilot 1 Injection - -
Min.: -70°CA, Max.: 20°CA
Pilot 2 Injection/
Pilot 2 Injection Idling: -8 to -6°CA -
Main Injection/
Main Injection Idling: -1 to 1°CA -
After Injection/
After Injection - -
Injection volume feedback learning
Injection Feedback Value value/ Idling: -0.4 to 1.0 mm3 -
Min.: -10 mm3, Max.: 9.92 mm3
Injection volume correction for cylinder 1/
Injection Feedback Val #1 Idling: -2.0 to 2.0 mm3 -
Min.: -10 mm3, Max.: 10 mm3
Min.: -10 mm3, Max.: 10 mm3
Min.: -10 mm3, Max.: 10 mm3
Min.: -10 mm3, Max.: 10 mm3
Injection volume/
Injection Volume Idling: 5.0 to 15.0 mm3 -
Min.: 0 mm3/st, Max.: 1279.98 mm3/st

DPR operation/
DPR No Activate *E2 No Active -
0: Active, 1: No Active
DPR PM Block/
DPR PM Block *E2 No blocked -
0: No blocked, 1: Blocked
Target engine speed/Max.: 5000 rpm,
Target Engine Speed Idling: 600 to 700 rpm -
Min.: 0 rpm
Target Common Rail Target common rail pressure/Max.: 256
Idling: 30 to 32 MPa -
Press MPa, Min.: 0 MPa
Catalyst Warm Up Catalyst warm up malfunction/ON or
OFF -
Malfunction *E1 OFF
Manual Catalyst Manual catalyst regeneration status/ON
Regeneration *E1 or OFF
OFF -
ES
Supply pump control model/PCV, DUTY,
Pump Mode - -
IG OFF, STOP or Undef
Catalyst malfunction (differential
Catalyst Malfunction *E1 OFF -
pressure detection)/ON or OFF
Clogged catalyst (differential pressure
Clogged Catalyst *E1 OFF -
detection)/ON or OFF
Catalyst temperature malfunction/ON or
Heat Catalyst *E1 OFF -
OFF
Clogged Catalyst Warning Clogged catalyst warning/SAFE or
SAFE -
*E1 Warning
Clogged Catalyst Warning Clogged catalyst warning/SAFE or
SAFE -
*E1 Danger
Clogged catalyst warning/00: SAFE, 01:
Clogged Catalyst Warning SAFE -
Danger, 10: Warning, 11: Danger
DPNR Catalyst
DPR catalyst deteriorate/0: OFF, 1: ON OFF -
Deteriorate
Exhaust fuel addition malfunction/0:
Exhaust Fuel Addition OFF -
OFF, 1: ON
DPR model/Undef, Normal, N/EGR,
DPR Mode *E2 Normal -
Warm, Warm/Idl, PM, PM/Idl or S Dchg
Injection Pump Learning Injection pump learning status/Incompl
Compl -
Status or Compl
PCV Open Duty SCV open duty/Max.: 100%, Min.: 0% 45 to 55% -
PCV open current feedback volume/
PCV Open Current FB Val -400 to 400 mA -
Max.: 6000 mA, Min.: -6000 mA
Diesel Throttle Learn Diesel throttle learning status/
OK -
Status *E1 0: NG, 1: OK
EGR learning status/
EGR Learning Status *E1 OK -
OK or NG
Intake Water History Intake the water in history/ON or OFF OFF -
Engine Overspeed History Engine overspeed history/ ON or OFF OFF -
Starter signal/
Starter Signal ON: Cranking -
ON or OFF
A/C signal/
A/C Signal ON: A/C ON -
ON or OFF
Stop light switch/ • ON: Brake pedal depressed
Stop Light Switch -
ON or OFF • OFF: Brake pedal released
Catalyst Regeneration Catalyst regeneration switch status/ON
ON: Catalyst regeneration switch ON -
Switch *E1 or OFF
Exhaust Brake Switch Exhaust brake switch status/ON or OFF ON: Exhaust brake operated -
PTO Switch PTO switch status/ON or OFF ON: PTO switch ON -
Clutch Switch Clutch switch status/ON or OFF ON: Clutch switch ON -
Diagnosis Switch Diagnosis switch status/ON or OFF ON: Diagnosis switch ON -
Engine Warm Up Switch Engine warm up switch status/ON or
ON: Engine warm up switch ON -
*E1 OFF

Battery voltage/
Battery Voltage Idling: 18 to 27 V -
Min.: 0 V Max.: 65.535 V
Atmospheric pressure value/
Atmosphere Pressure Min.: 0 kPa (0 mmHg, 0 in.Hg), Max.: Actual atmospheric pressure -
255 kPa (1,912.6 mmHg, 75.3 in.Hg)
ACT VSV ACT VSV status/ON or OFF - -
TC and TE1 terminal of DLC3
TC and TE1 - -
ON or OFF
#Code/ Number of detected
#Codes -
Min.: 0, Max.: 255 DTCs
Check Mode Check mode/ ON or OFF ON: Check mode ON -
ES SPD Test SPD test/0: COMPL, 1: INCMPL 0: COMPL -
MIL MIL status/ON or OFF ON: MIL ON -
MIL ON Run Distance/
MIL ON Run Distance Distance after DTC detected -
Min.: 0 km, Max.: 65535 km
Running Time from MIL Running Time from MIL ON/
Equivalent running time after MIL was ON -
ON Min.: 0 minute, Max.: 65535 minutes
Engine run time/
Engine Run Time Time after engine started Service data
Min.: 0 second Max.: 65535 seconds
Time after DTC cleared/
Time After DTC Cleared Equivalent to time after DTCs were erased -
Min.: 0 minute Max.: 65535 minutes
Distance from DTC Distance after DTC cleared/ Equivalent to drive distance after DTCs
-
Cleared Min.: 0 km, Max.: 65535 km were erased
Warmup Cycle Cleared Warm up cycle after DTC cleared/ Number of warm up
-
DTC *E1 Min.: 0 Max.: 255 cycles after DTC cleared
OBD Requirements Identifying OBD requirement Euro-OBD -
Number of Emission DTC (Number of emission DTC) - -
EGR Monitor *E1 EGR monitor/0: NOT AVL, 1: AVAIL - EGR monitor
Identifying model code:
Model Code Model code -
XZU41
Identifying engine type:
Engine Type Engine type -
N04CTQ
Identifying cylinder number/Min.: 0, Identifying cylinder
Cylinder Number -
Max.: 255 number: 4
Identifying transmission
Transmission Type Transmission type -
type: MT
Identifying destination:
Destination Destination -
W
Identifying model year/ Min.: 1900, Max.: Identifying model year:
Model Year -
2155 200#
Identifying engine
System Identification Identifying engine system -
system: Diesel
HINT:
Normal Condition: If no idling conditions are
specified, the shift lever is in the neutral position,
and the A/C switch and all accessory switches are
off.
2. PERFORM ACTIVE TEST
HINT:
Performing Active Test using the Hino-DX allows relays,
VSVs, actuators and other items to be operated without
removing any parts. Performing the Active Test early in
troubleshooting is one way to save time. The Data List
can be displayed during the Active Test.
(a) Connect the Hino-DX to the DLC3.
(b) Turn the ignition switch to the ON position.

(c) Follow the Hino-DX screen display to set Active test.
(d) Perform the Active Test.
Tester Display Test Part Control Range Diagnostic Notes
Control the A/C Cut Signal Control the A/C cut signal ON/OFF -
Connect the TC and TE1 Turn on TC and TE1 connection ON/OFF -
DPR catalyst regeneration (PM) raises
Activate the DPR Regeneration
temperature of DPR to more than 600°C ON/OFF -
(PM)
(1,112°F) by adding fuel intermittently.
Test the Turbo Charger Step
Control the turbocharger motor 0 to 100% -
Motor
• Fuel pressure inside common rail ES
pressurized to specified value and
Pressurize common rail internal fuel engine speed increased to 2,000
Test the Fuel Leak Stop/Start
pressure, and checks for fuel leaks rpm when ON is selected
• Above conditions preserved while
test is ON
Activate the VSV for Exhaust
Activate the VSV for exhaust brake ON/OFF -
Brake
Increase and decrease of EGR valve EGR valve opening increases and
EGR 0 to 100%
opening decreases with 1% step
DIAGNOSTIC TROUBLE CODE CHART

HINT:
Parameters listed in the chart may be different from your
readings depending on the type of instruments and other
factors.
If any DTCs are displayed during a check mode, check the
circuit for the DTCs listed in the chart below. For details of
each DTC, refer to the page indicated.
NOTICE:
*E2: N04C-TW
*E3: N04C-TU, TV
ECD SYSTEM:
DTC Code Detection Item Trouble Area MIL Memory See page
1. Open or short in VN turbo control
circuit
Turbocharger / Supercharger Boost
P0045/34 2. Turbocharger Comes on DTC stored ES-48
Control Solenoid Circuit / Open *E1
3. Turbocharger actuator
4. ECM
1. Open or short in fuel pressure sensor
circuit
P0087/49 Fuel Rail / System Pressure - Too Low Comes on DTC stored ES-52
2. Fuel pressure sensor
3. ECM
1. Supply pump (suction control valve)
2. Open or short in supply pump (suction
P0088/78 Fuel Rail / System Pressure - Too High control valve) circuit Comes on DTC stored ES-55
3. Common rail
4. ECM
1. Fuel leak (supply pump to common rail
P0093/78 Fuel System Leak Detected - Large Leak to injector) Comes on DTC stored ES-61
2. Injector
1. Open or short in IAT sensor (after
turbocharged) circuit
P0095/23 Intake Air Temperature Sensor 2 Circuit Comes on DTC stored ES-67
2. IAT sensor (after turbocharged)
3. ECM
Intake Air Temperature Sensor 2 Circuit turbocharged) circuit
P0097/23 Comes on DTC stored ES-67
Low 2. IAT sensor (after turbocharged)
3. ECM
Intake Air Temperature Sensor 2 Circuit turbocharged) circuit
High 2. IAT sensor (after turbocharged)
3. ECM
1. Open or short in MAF meter circuit
2. MAF meter
P0100/31 Mass or Volume Air Flow Circuit *E1 Comes on DTC stored ES-72
3. Voltage converter
4. ECM
ES Mass Air Flow Circuit Range /
P0101/31 Mass air flow meter Comes on DTC stored ES-77
Performance Problem *E1
Mass or Volume Air Flow Circuit Low 2. MAF meter
Input *E1 3. Voltage converter
4. ECM
Mass or Volume Air Flow Circuit High 2. MAF meter
Input *E1 3. Voltage converter
4. ECM
1. Open or short in turbo pressure
Manifold Absolute Pressure / Barometric sensor circuit
Pressure Circuit 2. Turbo pressure sensor
3. ECM
P0106/31 Pressure Circuit Range / Performance Manifold absolute pressure sensor Comes on DTC stored ES-83
Problem
Pressure Circuit Low Input 2. Turbo pressure sensor
3. ECM
Pressure Circuit High Input 2. Turbo pressure sensor
3. ECM
1. Open or short in IAT sensor circuit
Comes on
P0110/24 Intake Air Temperature Circuit 2. IAT sensor (built in MAF meter) DTC stored ES-84
Blinking*E2
3. ECM
Comes on
P0112/24 Intake Air Temperature Circuit Low Input 2. IAT sensor (built in MAF meter) DTC stored ES-84
Blinking*E2
3. ECM
Comes on
P0113/24 Intake Air Temperature Circuit High Input 2. IAT sensor (built in MAF meter) DTC stored ES-84
Blinking*E2
3. ECM
1. Open or short in ECT sensor circuit
Comes on
P0115/22 Engine Coolant Temperature Circuit 2. ECT sensor DTC stored ES-89
Blinking*E2
3. ECM
Engine Coolant Temperature Circuit Comes on
P0116/22 Engine coolant temperature sensor DTC stored ES-94
Range / Performance Problem Blinking*E2
Engine Coolant Temperature Circuit Low Comes on
P0117/22 2. ECT sensor DTC stored ES-89
Input Blinking*E2
3. ECM
Engine Coolant Temperature Circuit High Comes on
P0118/22 2. ECT sensor DTC stored ES-89
Input Blinking*E2
3. ECM
1. Open or short in throttle position
Throttle / Pedal Position Sensor / Switch sensor circuit
"A" Circuit *E1 2. Throttle position sensor
3. ECM
"A" Circuit Low Input *E1 2. Throttle position sensor
3. ECM
"A" Circuit High Input *E1 2. Throttle position sensor
3. ECM
1. Open or short in fuel temperature
sensor circuit
P0168/39 Fuel Temperature Too High Comes on DTC stored ES-100
2. Fuel temperature sensor
3. ECM
1. Open or short in fuel temperature ES
sensor circuit
P0180/39 Fuel Temperature Sensor "A" Circuit Comes on DTC stored ES-100
2. Fuel temperature sensor
3. ECM
Fuel Temperature Sensor "A" Circuit Low sensor circuit
Input 2. Fuel temperature sensor
3. ECM
Fuel Temperature Sensor "A" Circuit sensor circuit
High Input 2. Fuel temperature sensor
3. ECM
circuit
P0190/49 Fuel Rail Pressure Sensor Circuit Comes on DTC stored ES-52
2. Fuel pressure sensor
3. ECM
Fuel Rail Pressure Sensor Circuit Low circuit
Input 2. Fuel pressure sensor
3. ECM
Fuel Rail Pressure Sensor Circuit High circuit
Input 2. Fuel pressure sensor
3. ECM
1. Open or short in EDU circuit
2. Injector
P0200/97 Injector Circuit / Open Comes on DTC stored ES-105
3. EDU
4. ECM
Turbocharger / Supercharger Overboost 2. Open or short in supply pump (suction
P0234/34 Condition VN Turbocharger Open Side control valve) circuit Comes on DTC stored ES-112
Malfunction *E1 3. Common rail
4. ECM
1. Supply pump (suction control valve) Comes on
Turbocharger / Supercharger 2. Open or short in supply pump (suction *E2
P0299/34 Underboost VN Turbocharger Close Side control valve) circuit Does not DTC stored ES-112
Malfunction *E1 3. Common rail comes on
4. ECM *E3
1. Open or short in crankshaft position
sensor circuit
P0335/12,
Crankshaft Position Sensor "A" Circuit 2. Crankshaft position sensor Comes on DTC stored ES-115
13
3. Crankshaft angle sensor plate
4. ECM
1. Open or short in crankshaft position
sensor circuit
Crankshaft Position Sensor "A" Circuit Does not
P0339/13 2. Crankshaft position sensor DTC stored ES-115
Intermittent come on
3. Crankshaft angle sensor plate
4. ECM
1. Open or short in camshaft position
sensor circuit
Camshaft Position Sensor "A" Circuit
P0340/12 2. Camshaft position sensor Comes on DTC stored ES-119
(Bank 1 or Single Sensor)
3. Camshaft drive gear
4. ECM
1. Open or short in EGR valve circuit
P0400/71 Exhaust Gas Recirculation Flow *E1 2. EGR valve Comes on DTC stored ES-123
3. ECM
1. Open in EGR valve position sensor
Exhaust Gas Recirculation Sensor "A" circuit
Circuit Low *E1 2. EGR valve
3. ECM
ES Comes on
1. Short in EGR valve position sensor
*E2
Exhaust Gas Recirculation Sensor "A" circuit
P0406/96 Does not DTC stored ES-126
Circuit High *E1 2. EGR valve
comes on
3. ECM
*E3
Comes on
1. Open or short in throttle control motor
Exhaust Gas Recirculation Throttle *E2
circuit
P0488/15 Position Control Range / Performance Does not DTC stored ES-130
2. Throttle control motor
*E1 comes on
3. ECM
*E3
1. Open or short in vehicle speed sensor
circuit
2. Vehicle speed sensor Comes on
P0500/42 Vehicle Speed Sensor "A" DTC stored ES-133
3. Combination meter Blinking *E2
4. Tachograph
5. ECM
1. Short in stop light switch signal circuit
Does not
P0504/51 Brake Switch "A" / "B" Correlation 2. Stop light switch DTC stored ES-137
come on
3. ECM
1. Open or short in exhaust gas
temperature sensor (on upstream) circuit
Exhaust GAS Temperature Sensor
P0544/A3 2. Exhaust gas temperature sensor (on Comes on DTC stored ES-143
Circuit (Bank 1 Sensor 1) *E2
upstream)
3. ECM
Low (Bank 1 Sensor 1) *E2
upstream)
3. ECM
High (Bank 1 Sensor 1) *E2
upstream)
3. ECM
1. Open in back-up power source circuit
P0560/96 System Voltage 2. Low battery voltage Comes on DTC stored ES-149
3. ECM
Does not
P0606 ECM / PCM Processor ECM DTC stored ES-151
come on
P0607/54 Control Module Performance ECM Comes on DTC stored ES-151
1. Starter relay circuit
P0617/43 Starter Relay Circuit High 2. Ignition switch Comes on DTC stored ES-152
3. ECM
P0627/78 Fuel Pump Control Circuit / Open control valve) circuit Comes on DTC stored ES-55
3. Common rail
4. ECM
VIN not Programmed or Mismatch - ECM
P0630/89 ECM Comes on DTC stored ES-155
/ PCM *E2
1. Wire harness and connector (serial
communication signal circuit Does not
P0863/17 EFI - ECT Communication Error DTC stored ES-156
2. Transmission control ECU come on
3. ECM
1. Short in accelerator sensor circuit
Power Take-off Accelerator Position Does not
P1133 2. Accelerator position sensor DTC stored ES-159
Sensor Circuit High come on
3. ECM
P1229/78 Fuel Pump System control valve) circuit Comes on DTC stored ES-55
3. Common rail
4. ECM
Main: ES
1.Injector
2.EDU (P200 is set simultaneously)
3.Open or short in engine wire harness
(P200 is simultaneously)
P1238/78 Injector Malfunction 4.Connector connection (P200 is set Comes on DTC stored ES-162
simultaneously)
5.Compression pressure
Related:
1.Valve timing
2.ECM
1. Open or short in VN turbo control
circuit
Turbocharger / Supercharger Overboost 2. Turbocharger
Condition (Too High) 3. Turbocharger actuator
4. EGR valve assembly
5. ECM
1. Open or short in differential pressure
sensor circuit
2. Incorrect differential pressure sensor
P1425/A4 Differential Pressure Sensor Circuit *E2 Comes on DTC stored ES-166
hose routing
3. Differential pressure sensor
4. ECM
1. Incorrect arrangement differential
pressure sensor hose piping
2. Differential pressure sensor vacuum
Differential Pressure Sensor Installation hose is clogged
P1426/A4 Comes on DTC stored ES-170
Error *E2 3. Blockage in vacuum transmitting pipe
subassembly
5. ECM
sensor circuit
Differential Pressure Sensor Circuit Low 2. Incorrect differential pressure sensor
*E2 hose routing
4. ECM
sensor circuit
Differential Pressure Sensor Circuit High 2. Incorrect differential pressure sensor
*E2 hose routing
4. ECM
1. Emergency halt switch circuit
Does not
P1530/92 Engine Emergency Halt Switch 2. Emergency halt switch DTC stored ES-173
come on
3. ECM
Injector Correction Circuit Malfunction 1. Injector compensation code
(EEPROM) 2. ECM
P1611/17 IC Circuit Malfunction ECM Comes on DTC stored ES-176
1. Open or short in exhaust brake
Solenoid for Exhaust Brake Circuit solenoid circuit
Malfunction 2. Exhaust brake solenoid
3. ECM
1. Exhaust gas temperature sensor
3. DPR manifold converter
Particulate Trap Efficiency Below 4. Open or short in differential pressure
Threshold (Bank1) *E2 sensor circuit
temperature sensor circuit
6. ECM
ES 1. Open or short in exhaust gas
temperature sensor (on downstream)
Exhaust Gas Temperature Sensor Circuit circuit
(Bank 1 Sensor 2) *E2 2. Exhaust gas temperature sensor (on
downstream)
3. ECM
Low (Bank 1 Sensor 2) *E2 2. Exhaust gas temperature sensor (on
downstream)
3. ECM
High (Bank 1 Sensor 2) *E2 2. Exhaust gas temperature sensor (on
downstream)
3. ECM
1. Open or short in accelerator pedal
Throttle / Pedal Position Sensor / Switch position sensor circuit
"D" Circuit 2. Accelerator pedal position sensor
3. ECM
"D" Circuit Range / Performance 2. Accelerator pedal position sensor
3. ECM
"D" Circuit Low Input 2. Accelerator pedal position sensor
3. ECM
"D" Circuit High Input 2. Accelerator pedal position sensor
3. ECM
"E" Circuit 2. Accelerator pedal position sensor
3. ECM
"E" Circuit Low Input 2. Accelerator pedal position sensor
3. ECM
"E" Circuit High Input 2. Accelerator pedal position sensor
3. ECM
"D" / "E" Voltage Correlation 2. Accelerator pedal position sensor
3. ECM
P2226/A5 Barometric Pressure Circuit ECM Comes on DTC stored ES-197
Barometric Pressure Circuit Range /
P2227/A5 ECM Comes on DTC stored ES-199
Performance
P2228/A5 Barometric Pressure Circuit Low Input ECM Comes on DTC stored ES-197
P2229/A5 Barometric Pressure Circuit High Input ECM Comes on DTC stored ES-197
1. Open or short in turbo actuator circuit
Lost Communication with Variable Come on
U1123/A2 2. Turbocharger sub-assembly DTC stored ES-200
Nozzle Type Turbo Charger Module DTC stored
3. ECM
ES
Turbocharger / Supercharger Boost Control

DTC P0045/34
Solenoid Circuit / Open *E1
DESCRIPTION
The turbocharger system is comprised of the Variable Nozzle (VN) type turbocharger, turbo motor driver
and ECM.
The turbocharger has a nozzle vane which opens and closes to control the volume of the exhaust gas
flowing into the turbine. This, in turn, controls the boost pressure. When the nozzle vane moves towards
the closing direction, the pressure increases. When the vane moves towards the opening direction, the
pressure decreases.
ES The turbocharger actuator built on the turbine side activates the nozzle vane. The nozzle vane position
sensor built on the actuator detects the opening angle of the nozzle vane. The nozzle vane position
sensor signal is sent via the turbo motor driver to the ECM. Then, based on the signal, the ECM actuates
the actuator.
The ECM sends a target nozzle vane position signal to the turbo motor driver to obtain the nozzle vane
position for the optimal boost pressure in accordance with the driving conditions.
DTC No. DTC Detection Condition Trouble Area
• Open or short in VN turbo control circuit
Open or short in VN turbo control circuit for 1 second or • Turbocharger
P0045/34
more (1 trip detection logic) • Turbocharger actuator
• ECM
WIRING DIAGRAM
1 17
CANH E24 CANH
4 28
CANL E24 CANL
6
GND
3
+B ES
X19 Turbo Charger Actuator
2
+24V OUT1
8 5 3
DC-DC1 OUT2
ENG
13
X17 Voltage Converter 2 1
E25 MREL
ENG-3
Battery
Battery ECM
A162400E1
INSPECTION PROCEDURE
NOTICE:
After replacing the ECM, the ECM needs supply pump specification learning (See page ES-3) and
injector compensation (See page ES-7).
HINT:
Read freeze frame data using the Hino-DX. The ECM records vehicle and driving condition information as
freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be helpful in
determining whether the vehicle was running or stopped, whether the engine was warmed up or not,
whether the air fuel ratio was lean or rich, as well as other data recorded at the time of a malfunction.
1 CHECK TURBOCHARGER POWER SOURCE VOLTAGE
(a) Disconnect the ECM connector.

Wire Harness Side: (b) Disconnect the turbocharger actuator connector.
(c) Set the starter switch to ON position.
(d) Measure the voltage according to the value(s) in the
Turbocharger Actuator Connector
table below.
Standard voltage
ES X19 T8-3 (+B) - Body ground

Ignition switch in
9 to 14 V
the ON position
Front View (e) Measure the resistance according to the value(s) in the
table below.
Standard resistance
E24 Tester Connection Condition Specified Condition
T8-6 (GND) - Body ground Always 1 Ω or less
ECM Connector CANH NG CHECK POWER SOURCE CIRCUIT
CANL
ASM3-740
OK
2 INSPECT TURBOCHARGER SUB-ASSEMBLY
(a) Inspect the turbocharger sub-assembly (See chapter IT)

NG REPLACE TURBOCHARGER SUB-
ASSEMBLY
OK
3 REPLACE ECM
(a) Replace the ECM (See page ES-347)
NEXT
4 REPLACE WHETHER DTC OUTPUT RECURS
(a) Connect the intelligent tester to the DLC3.

(c) Turn the tester on.
(d) Enter the following menu items: Powertrain / Engine and
ECT / DTC.
(e) Read the DTCs.
Result
Display (DTC output) Proceed to
No output A
P0045 B
B REPLACE TURBOCHARGER SUB-

ASSEMBLY
5 CHECK HARNESS OR CONNECTOR (TURBOCHARGER - BODY GROUND) ES

(a) Disconnect the turbocharger connector.
Wire Harness Side:
(b) Measure the resistance according to the value(s) in the
table below.
Turbocharger Connector Standard resistance
X19-6 (GND) - Body ground Always Below 1 Ω
X19 (c) Reconnect the turbocharger.
GND A164233E06
NG REPAIR OR REPLACE HARNESS OR
CONNECTOR (TURBOCHARGER - BODY
GROUND)
OK
REPAIR OR REPLACE HARNESS OR CONNECTOR (TURBOCHARGER - ENG-3 RELAY)

DTC P0087/49 Fuel Rail / System Pressure - Too Low
DTC P0190/49 Fuel Rail Pressure Sensor Circuit
DTC P0192/49 Fuel Rail Pressure Sensor Circuit Low Input
DTC P0193/49 Fuel Rail Pressure Sensor Circuit High Input

DESCRIPTION
ES The fuel pressure sensor, mounted on the common rail, converts the fuel pressure into an electric signal
and outputs the signal to the ECM. Based on the signal from the fuel pressure sensor, the ECM controls
the injection (supply) pump (suction control valve) and keeps the internal fuel pressure of the common rail
at the target fuel pressure.
Conditions (a), (b) and (c) are met 10 times with engine
speed 600 rpm or more:
• Open or short in fuel pressure sensor circuit
(a) Battery voltage: 16 V or more
P0087/49 • Fuel pressure sensor
(b) Fuel quantify: 5 mm/st or more
• ECM
(c) Amount of change in fuel pressure applied to
common rail: 0.1 Mpa or less
Conditions (a) and (b) continue for 1 second or more: • Open or short in fuel pressure sensor circuit
P0190/49 (a) Ignition switch in the ON position • Fuel pressure sensor
(b) Open or short in fuel pressure sensor circuit • ECM
Condition (a) continues for 1 second: • Open or short in fuel pressure sensor circuit
P0192/49 (a) Fuel pressure sensor output voltage is 0.55 V or • Fuel pressure sensor
less • ECM
Condition (a) continues for 1 second: • Open or short in fuel pressure sensor circuit
P0193/49 (a) Fuel pressure sensor output voltage is 4.9 V or • Fuel pressure sensor
more • ECM
HINT:
• If the vehicle runs out of fuel, the ECM determines the fuel pressure has decreased, and DTC P0192/
49 may be output.
• When DTC P0087/49, P0190/49, P0192/49 and/or P0193/49 is set, check the internal fuel pressure of
the common rail by the Hino-DX.
Fuel Pressure Malfunction
• Short in PCR and E2 terminal
Approx. 0 Mpa (0 kg/cm2, 0 psi) or more • Open in VC circuit
• Short in PCR and VC circuit
Approx. 190 Mpa (1,937 kg/cm2, 27,556 psi) or more • Open in PCR circuit
• Open in E2 circuit
WIRING DIAGRAM
18
3
VC1 E22 VC
26
2
PCR1 E22 PCR1 ES
1 28
E1 E22 E2
Fuel Pressure Sensor

ECM
ASM3-744
NOTICE:
injector compensation (See page ES-7) .
HINT:
• Read freeze frame data using the Hino-DX. The ECM records vehicle and driving condition information
as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can be
helpful in determining whether the vehicle was running or stopped, whether the engine was warmed up
or not, whether the air fuel ratio was lean or rich, as well as other data recorded at the time of a
malfunction.
• If different DTCs that are related to a different system are output simultaneously while terminal E2 is
used as a ground terminal, terminal E2 may be open.
1 INSPECT ECM (OUTPUT VOLTAGE)
(a) Turn the ignition switch to the ON position.

(b) Measure the voltage according to the value(s) in the
E22 table below.
Standard voltage
Ignition switch to the ON
E22-18 (VC) - E22-28 (E2) 4.5 to 5.5 V
position
E2 ECM Connector
VC
NG CHECK ECM POWER SOURCE CIRCUIT
A153569E08
OK
2 INSPECT ECM (PCR VOLTAGE)
(a) Start the engine.

E22
table below.
Standard voltage
E22-26 (PCR1) - E22-28 (E2) Idling 1.3 to 1.7 V
PCR1 E2
ECM Connector
ES NG Go to step
ASM3-745
OK
REPLACE ECM
3 CHECK HARNESS AND CONNECTOR (ECM - FUEL PRESSURE SENSOR)

Wire Harness Side: (b) Disconnect the fuel pressure sensor connector.
(c) Measure the resistance according to the value(s) in the
table below.
E22 Standard resistance:
Check for open
PCR1
VC ECM Connector E22-26 (PCR1) - 2 (PCR1) Always Below 1 Ω
E22-18 (VC) - 3 (VC1) Always Below 1 Ω
E22-28 (E2) - 1 (E1) Always Below 1 Ω
E2
Check for short
Fuel Pressure Sensor Connector
E22-26 (PCR1) or 2 (PCR1) -
Always 10 kΩ or higher
Body ground
E22-18 (VC) or 3 (VC1) - Body
ground
E22-28 (E2) or 1 (E1) - Other
terminal
E1 PCR1 VC1
(d) Reconnect the fuel pressure sensor connector.
ASM3-741
(e) Reconnect the ECM connector.
CONNECTOR (ECM - FUEL PRESSURE
SENSOR)
OK
REPLACE COMMON RAIL ASSEMBLY (FUEL PRESSURE SENSOR)

DTC P0088/78 Fuel Rail / System Pressure - Too High
DTC P0627/78 Fuel Pump Control Circuit / Open
DTC P1229/78 Fuel Pump System

DESCRIPTION
The injection (supply) pump is a single-type pump and has a circuit for fuel suction that achieves high
pressure force feed and reduction of driving torque, and for force feed process. The ECM controls the
suction control valve, which operates fuel suction by the plunger in the process of suction. ES
When the internal fuel pressure of the common rail exceeds the target pressure, the pressure limiter on
the common rail starts operating to control the internal fuel pressure of the common rail.
Conditions (a) and (b) are met 2 times or more: • Supply pump (suction control valve)
(a) Ignition switch in the ON position • Open or short in supply pump (suction control
P0088/78 valve) circuit
(b) Internal fuel pressure of the common rail: 180 MPa
• Common rail
(1,835 kg/cm2, 25,106 psi) or more
• ECM
• Supply pump (suction control valve)
• Open or short in supply pump (suction control
Open or short in suction control valve circuit for more
P0627/78 valve) circuit
than 0.5 seconds
• Common rail
• ECM
• Supply pump (suction control valve)
Fuel over-feed: • Open or short in supply pump (suction control
P1229/78 Internal fuel pressure is beyond target fuel pressure valve) circuit
despite ECM closing suction control valve • Common rail
• ECM
WIRING DIAGRAM
Suction Control Valve ECM
2
SCV+ 1
E22 PCV+
1
SCV- 2
E22 PCV-
7
E34 E1
ASM3-771
NOTICE:
• After replacing the injection (supply) pump, the injection (supply) pump needs supply pump
specification learning (See page ES-3).
• After replacing the ECM, the ECM needs supply pump specification learning (See page ES-3)
and injector compensation (See page ES-7).
HINT:
1 CHECK OTHER DTC OUTPUT

(c) Follow the Hino-DX screen display and set the Data
ES display.
(d) Rear the DTCs.
Result
P0180/39, P0182/39, P0183/39, P0190/49, P0192/49, P0193/49 or P0200/97 is not output A
P0180/39, P0182/39, P0183/39, P0190/49, P0192/49, P0193/49 or P0200/97 is output B
B GO TO DTC CHART
2 INSPECT INJECTION OR SUPPLY PUMP ASSEMBLY (SUCTION CONTROL VALVE)
(a) Disconnect the suction control valve connector.

Suction Control (b) Measure the resistance according to the value(s) in the
Valve table below.
Standard resistance
1-2 20°C (68°F) 1.9 to 2.3 Ω
(c) Reconnect the suction control valve connector.
ASM3-772
NG REPLACE INJECTION OR SUPPLY PUMP
ASSEMBLY
OK
3 CHECK DTC OUTPUT

display.
(d) Rear the DTCs.
Result
P0088/78 and/or P1229/78 A
P0627/78 B
B Go to step 8
(a) Disconnect the suction control valve connector and then

start the engine.
OK:
Engine does not start.
ASSEMBLY ES
OK
5 READ VALUE OF Hino-DX (PCV OPEN CURRENT)

(b) Start the engine.
(c) Follow the Hino-DX screen display and set the ECU data
monitor.
(d) Read the value.
Standard
Engine Speed Result
Idling 1,050 to 1,150 mA

ASSEMBLY
OK
6 READ VALUE OF Hino-DX (FUEL PRESSURE)

monitor.
(d) Check that the internal fuel pressure of the common rail
is within the specification below.
Standard
Engine Speed Fuel Pressure
Idling Approximately 25 to 35 MPa
3,000 rpm (No engine load) Approximately 80 to 90 MPa
OK Go to step 8
NG
7 CHECK HARNESS AND CONNECTOR (SUCTION CONTROL VALVE - ECM)

Wire Harness Side: (b) Disconnect the ECM connector.
table below.
Suction Control Valve
Check for open
ES E22-2 (PCV+) - 1 Always Below 1 Ω

E22-1 (PCV-) - 2 Always Below 1 Ω
Front View Check for short

E22-2 (PCV+) or 1 - Body ground Always 10 kΩ or higher
E22 E22-1 (PCV-) or 2 - Body ground Always 10 kΩ or higher
(d) Reconnect the suction control valve connector.

PCV- ECM Connector
CONNECTOR (SUCTION CONTROL VALVE -
PCV+ ECM)
ASM3-773
OK

monitor.
(d) Wiggle the fuel pressure sensor connector and check
that the fuel pressure reading does not change.
OK:
The fuel pressure reading does not change.
OK
REPLACE INJECTION OR SUPPLY PUMP ASSEMBLY


table below.
Check for open
E22-2 (PCV+) - 1 Always Below 1 Ω ES


PCV- ECM Connector
PCV+ ECM)
ASM3-773
OK
10 CHECK ECM TERMINAL VOLTAGE (PCV+ AND PCV- TERMINAL)
(a) While cranking or idling the engine, check the waveform

of the ECM connector using an oscilloscope.
Standard
Tester Specified
Condition Tool Setting
E22 E23 Connection Condition
Correct
Idling or
E22-2 (PCV+) - 10 V/DIV., 5 waveform
cranking with
E23-7 (E1) msec./DIV. appears as
warm engine
shown
Correct
PCV+ Idling or
PCV- E1 E22-1 (PCV-) - 1 V/DIV., 5 msec./ waveform
cranking with
E23-7 (E1) DIV. appears as
warm engine
shown
NG REPLACE ECM
PCV+ 10 V/DIV.
PCV- 1 V/DIV.
5 msec./DIV.
A151976E04
OK
11 PERFORM INITIALIZATION (INJECTION OR SUPPLY PUMP)
(a) Perform initialization (See page ES-3).
NEXT
12 CHECK WHETHER DTC OUTPUT RECURS

ES (b) Turn the ignition switch to the ON position.
(c) Clear the DTCs.
(d) Follow the Hino-DX screen display and set the Data
display
(e) Rear the DTCs.
Result
P0088/78, P0627/78 or P1229/78 is output A
P0088/78, P0627/78 or P1229/78 is not output B
B SYSTEM IS OK

DTC P0093/78 Fuel System Leak Detected - Large Leak

DESCRIPTION
Refer to DTC P0087/49 (See page ES-52).
DTC is output when following conditions (a), (b) and (c)
are all met and if difference of common rail pressure
that fuel pressure sensor detects before and after fuel
• Fuel leak (supply pump to common rail to injector)
injection varies greatly from difference of value that
• Injector
ECM calculates before and after fuel injection, ECM
P0093/78 determines that there may be fuel leaks.
•
•
Supply pump (suction control valve)
Wire harness and connector
ES
(a) Engine RPM is 1,500 rpm or higher.
• Common rail
(b) Fuel pressure sensor is normal (P0190/49, P0192/
• ECM
49, and P0193/49 are not detected).
(c) Suction control valve is normal (P0088/78, P0627/
78 and P1229/78 are not detected).
WIRING DIAGRAM
NOTICE:
• After replacing the injector, the injector needs compensation (See page ES-7).
HINT:

display.
(d) Rear the DTCs.
Result
P0087/49, P0190/49, P0192/49, P0193/49, P0200/97, P0088/78, P0627/78 or P1229/78 is output A
No output B
A GO TO DTC CHART
B
2 PERFORM ACTIVE TEST BY Hino-DX (TEST THE FUEL LEAK)
HINT:
By performing this Active Test, the engine speed is
maintained at 2,000 rpm and the common rail internal fuel
pressure is raised to the maximum operating pressure. As a
result, a fuel leak check can be conducted while retaining the
high common rail pressure.
ES (c) Follow the Hino-DX screen display to set Active test.
(d) Visually check the supply pump, injector and fuel line
located between the supply pump and common rail for
fuel leaks and fuel pressure leaks. Also, perform the
same check on the fuel line between the common rail
and the injector.
HINT:
There may be fuel leaks inside the components, such as
the supply pump.
OK:
No leakage.
NG REPAIR OR REPLACE FUEL LEAKAGE
POINT
OK

Valve table below.
Standard resistance
1-2 20°C (68°F) 1.9 to 2.3 Ω
(c) Reconnect the suction control valve connector.
ASM3-772
ASSEMBLY
OK
(a) Disconnect the suction control valve connector and then

start the engine.
OK:
Engine does not start.
ASSEMBLY
OK
5 READ VALUE OF Hino-DX (PCV OPEN CURRENT)

monitor.
(d) Read the value.
Standard
Engine Speed Result
ES

ASSEMBLY
OK

monitor.
Standard
OK Go to step 11
NG
7 CHECK HARNESS AND CONNECTOR (ECM - FUEL PRESSURE SENSOR)

table below.
Check for open
PCR1
ES VC ECM Connector E22-26 (PCR1) - 2 (PCR1) Always Below 1 Ω

E22-28 (E2) - 1 (E1) Always Below 1 Ω
E2
Check for short
E22-26 (PCR1) or 2 (PCR1) -
Body ground
E22-18 (VC) or 3 (VC1) - Body
ground
E22-28 (E2) or 1 (E1) - Other
terminal
E1 PCR1 VC1
(d) Reconnect the fuel pressure sensor connector.
ASM3-741
CONNECTOR (ECM - FUEL PRESSURE
SENSOR)
OK

monitor.
(d) Wiggle the fuel pressure sensor connector and check
that the fuel pressure reading does not change.
OK:
The fuel pressure reading does not change.
OK
9 PERFORM INITIALIZATION (INJECTION OR SUPPLY PUMP)
(a) Perform initialization (See page ES-3).
NEXT
10 CHECK WHETHER DTC OUTPUT RECURS (P0093/78)
(a) Clear the DTC (See page ES-29).

(b) Warm up the engine.
(c) Drive the vehicle by 1,500 rpm or more for 5 minutes.
display.
(e) Read the DTC.
Result
Display (DTC output) Proceed to ES
No DTC output A
P0093/78 B
B REPLACE INJECTION OR SUPPLY PUMP

ASSEMBLY
SYSTEM OK

table below.
Check for open
E22-2 (PCV+) - 1 Always Below 1 Ω


PCV- ECM Connector
PCV+ ECM)
ASM3-773
OK
12 INSPECT ECM (PCR VOLTAGE)

E22
table below.
Standard voltage
PCR1 E2
ECM Connector
ES NG REPLACE COMMON RAIL ASSEMBLY
ASM3-746
OK
REPLACE INJECTOR ASSEMBLY

DTC P0095/23 Intake Air Temperature Sensor 2 Circuit
DTC P0097/23 Intake Air Temperature Sensor 2 Circuit Low
DTC P0098/23 Intake Air Temperature Sensor 2 Circuit High

DESCRIPTION
The Intake Air Temperature (IAT) sensor (after turbocharged), built into the intake pipe, senses the
turbocharged air temperature. A thermistor built in the sensor changes the resistance value according to
the IAT. The lower the IAT is the greater the thermistor resistance value becomes, and the higher the IAT ES
is the lower the thermistor resistance value becomes (see Fig. 1).
The IAT sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the IAT
sensor from terminal THIA via a resistor R. The resistor R and IAT sensor are connected in series. When
the resistance value of the IAT sensor changes in accordance with changes in the IAT, the voltage at
terminal THIA also changes. Based on this signal, the ECM increases the fuel injection volume to improve
driveability during cold engine operation.
(Figure 1)
Resistance kΩ
Acceptable
Temperature °C (°F)
A056276E06
DTC No. Proceed to DTC Detection Condition Trouble Area

Open or short in IAT sensor (after • Open or short in IAT sensor (after turbocharged) circuit
P0095/23 Step 1 turbocharged) circuit for 0.5 seconds (1 • IAT sensor (after turbocharged)
trip detection logic) • ECM
• Open or short in IAT sensor (after turbocharged) circuit
Short in IAT sensor (after turbocharged)
P0097/23 Step 4 • IAT sensor (after turbocharged)
circuit for 0.5 seconds
• ECM
• Open or short in IAT sensor (after turbocharged) circuit
Open in IAT sensor (after turbocharged)
P0098/23 Step2 • IAT sensor (after turbocharged)
circuit for 0.5 seconds
• ECM
HINT:
When any of DTCs are set, check the IAT by the Hino-DX.
Temperature Displayed Malfunction
-40°C (-40°F) Open circuit

140°C (284°F) or more Short circuit
WIRING DIAGRAM
ECM
I9
Intake Air Temperature Sensor
5V
ES 20
THIA
E22
2
28
E2
E22
1
A110952E07
NOTICE:
HINT:
• If DTCs that are related to different systems are output simultaneously while terminal E2 is used as a
ground terminal, terminal E2 may have an open circuit.
malfunction.
1 READ VALUE OF Hino-DX (INTAKE AIR TEMPERATURE)

monitor.
(d) Read the value.
Standard:
Same value as the actual inlet air temperature.
Result
Temperature Display Proceed to
-40°C (-40°F) A
140°C (284°F) or more B
OK (same as air temperature near intake manifold) C
HINT:
• If there is an open circuit, the Hino-DX indicates -40°C
(-40°F).
• If there is a short circuit, the Hino-DX indicates 140°C

(284°F) or more.
B Go to step 4
C CHECK FOR INTERMITTENT PROBLEMS
2 READ VALUE OF Hino-DX (CHECK FOR OPEN IN WIRE HARNESS)
(a) Disconnect the IAT sensor connector. ES

ECM
(b) Connect terminals 1 and 2 of the IAT sensor harness
side connector.
IAT Sensor (c) Connect the Hino-DX to the DLC3.
I9 (d) Turn the ignition switch to the ON position.
(e) The engine is stopped.
THIA
(f) Follow the Hino-DX screen display and set the ECU data
E2 monitor.
(g) Read the value.
Standard:
140°C (284°F) or more
Wire Harness Side: (h) Reconnect the IAT sensor connector.
IAT Sensor Connector NG Go to step 3
I9
Front View
A153587E01
OK
REPLACE INTAKE AIR TEMPERATURE SENSOR

3 READ VALUE OF Hino-DX (CHECK FOR OPEN IN ECM)
(a) Disconnect the IAT sensor connector.

ECM
(b) Connect terminals THIA and E2 of the ECM connector.
HINT:
IAT Sensor Before checking, do a visual and contact pressure check
I9 for the ECM connector.
THIA (d) Turn the ignition switch to the ON position.
ES E2
monitor.
ECM Connector (g) Read the value.
Standard:
140°C (284°F) or more
E22 (h) Reconnect the IAT sensor connector.
NG REPLACE ECM
THIA E2
A153588E13
OK
REPAIR OR REPLACE HARNESS OR CONNECTOR (ECM - INTAKE AIR TEMPERATURE

SENSOR)
4 READ VALUE OF Hino-DX (CHECK FOR SHORT IN WIRE HARNESS)
(a) Disconnect the IAT sensor connector.

ECM (b) Connect the Hino-DX to the DLC3.
IAT Sensor (c) Turn the ignition switch to the ON position.
I9 (d) The engine is stopped.
THIA (e) Follow the Hino-DX screen display and set the ECU data
monitor.
E2 (f) Read the value.
Standard:
-40°C (-40°F)
A076591E07 (g) Reconnect the IAT sensor connector.
NG Go to step 5
OK
REPLACE INTAKE AIR TEMPERATURE SENSOR

5 CHECK INTAKE AIR TEMPERATURE SENSOR (CHECK FOR SHORT IN ECM)

(b) Connect the Hino-DX to the DLC3.
ECM
(c) Turn the ignition switch to the ON position.
IAT Sensor (d) The engine is stopped.
I9 (e) Follow the Hino-DX screen display and set the ECU data
monitor.
THIA (f) Read the value.
Standard:
E2
-40°C (-40°F)
ES
(g) Reconnect the ECM connector.
ECM Connector NG REPLACE ECM
E22
THIA
E2
A153589E12
OK
REPAIR OR REPLACE HARNESS OR CONNECTOR (ECM - INTAKE AIR TEMPERATURE

SENSOR)
DTC P0100/31 Mass or Volume Air Flow Circuit *E1
DTC P0102/31 Mass or Volume Air Flow Circuit Low Input *E1
DTC P0103/31 Mass or Volume Air Flow Circuit High Input *E1
DESCRIPTION
The Mass Air Flow (MAF) meter uses a platinum hot wire. The hot wire MAF meter consists of a platinum
hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire MAF meter works on
ES the principle that the hot wire and thermistor located in the intake air bypass of the housing detect any
changes in the IAT.
The hot wire is maintained at the set temperature by controlling current flow through the hot wire. This
current flow is then measured as the output voltage of the MAF meter.
The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit with the
power transistor controlled so that the potential of A and B remains equal to maintain the set temperature.
Temperature Sensor Mass Air Flow Meter

(Thermistor) +B
Platinum Hot Wire
A Platinum Hot Wire

B
Output Voltage
Temperature Sensor (Thermistor)

A153590E01

• Open or short in MAF meter circuit
Open or short in MAF meter circuit for more than 3 • MAF meter
P0100/31
seconds with engine speed at 4,000 rpm or less • Voltage converter
• ECM
Open in MAF meter circuit for more than 3 seconds with • MAF meter
P0102/31
engine speed at 4,000 rpm or less • Voltage converter
• ECM
Short in MAF meter circuit for more than 3 seconds with • MAF meter
P0103/31
engine speed at 4,000 rpm or less • Voltage converter
• ECM
HINT:
When DTC P0100/31, P0102/31 or P0103/31 is detected, check the mass air flow ratio by the Hino-DX.
Air Flow Value Malfunction
• Open in MAF meter power source circuit
Approx. 0.0 gm/sec.
• Open
170.1 gm/sec. or more Open in EVG circuit
WIRING DIAGRAM
32
2
E2G E23 EVG
1 2 5 3 1
+24V OUT1 +B
ENG 24
3
8 2 1
VG E23 VG ES
DC-DC1 OUT2
ENG-3 A20 Mass Air (*1)
D8 Voltage Converter Flow Meter
13
E25 MREL
Battery
Battery
*1:Shielded ECM
A162406E01
NOTICE:
HINT:
1 READ VALUE OF Hino-DX (MAF RATE)

monitor.
(d) Read the value.
Result
Air Flow Rate Proceed to
0.0 gm/sec. A
170.1 gm/sec. or more B
Between 1.6 and 170.0* gm/sec. C
HINT:
*: The value should change when the throttle valve is
opened or closed.
B Go to step 4
2 CHECK MASS AIR FLOW METER (POWER SOURCE)

ES
(a) Disconnect the MAF meter connector.
Wire Harness Side: (b) Turn the ignition switch to the ON position.
(c) Measure the voltage according to the value(s) in the
Mass Air Flow Meter Connector table below.
Standard voltage
A20 Tester Connection Condition Specified Condition
A20-1 (+B) - Body ground Always 11 to 14 V
+B (+) Front View (d) Reconnect the MAF meter connector.

A084809E11
NG Go to step 5
OK
3 INSPECT ECM (VG VOLTAGE)

E23 table below.
Standard voltage
E23-24 (VG) - E23-32
Engine is idling 1.8 to 2.6 V
(EVG)
EVG VG ECM Connector E23-24 (VG) - E23-32 Engine speed at 3,000
3.0 to 4.0 V
(EVG) rpm
A153569E10
HINT:
The A/C switch should be turned off.
NG Go to step 4
OK
REPLACE ECM
4 CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - ECM)

Mass Air Flow Meter Connector table below.
Check for open
A20 Tester Connection Condition Specified Condition
Front View
A20-3 (VG) - E23-24 (VG) Always Below 1 Ω ES
A20-2 (E2G) - E23-32 (EVG) Always Below 1 Ω
E2G VG
Check for short
A20-3 (VG) or E23-24 (VG) - Body
ground
E23
(d) Reconnect the MAF meter connector.
ECM Connector
VG CONNECTOR (MASS AIR FLOW METER -
EVG ECM)
A096607E07
OK
REPLACE MASS AIR FLOW METER

5 CHECK HARNESS AND CONNECTOR (VOLTAGE CONVERTER - MASS AIR FLOW

METER)
(a) Disconnect the voltage converter connector.

(b) Disconnect the MAF meter connector.
Wire Harness Side:
table below.
Voltage Converter Connector
Check for open
ES
V8-2 (OUT1) - A20-1 (+B) Always Below 1 Ω
OUT1
D8-8 (OUT2) - A20-1 (+B) Always Below 1 Ω
D8
OUT2 Check for short
D8-2 (OUT1), D8-8 (OUT2) or A20-
1 (+B) - Body ground
Mass Air Flow Meter Connector
(d) Reconnect the MAF meter connector.
(e) Reconnect the voltage converter connector.
A20
CONNECTOR (VOLTAGE CONVERTER -
+B Front View MASS AIR FLOW METER)
ASM3-742
OK
6 INSPECT VOLTAGE CONVERTER ASSEMBLY (VIM VOLTAGE)

Wire Harness Side: (b) Disconnect the voltage converter connector.
Voltage Converter Connector (c) Measure the voltage according to the value(s) in the
table below.
Standard voltage
+24V Tester Connection Condition Specified Condition
D8 D8-1 (+24V) - Body Ignition switch in the
18 to 27 V
ground ON position
ASM3-743
(d) Reconnect the voltage converter connector.
NG CHECK VOLTAGE CONVERTER CIRCUIT
OK
REPLACE VOLTAGE CONVERTER

Mass Air Flow Circuit Range / Performance

DTC P0101/31
Problem *E1
DESCRIPTION
The Mass Air Flow (MAF) meter uses a platinum hot wire. The hot wire MAF meter consists of a platinum
hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire MAF meter works on
the principle that the hot wire and thermistor located in the intake air bypass of the housing detect any
changes in the IAT.
The hot wire is maintained at the set temperature by controlling current flow through the hot wire. This
current flow is then measured as the output voltage of the MAF meter.
The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit with the ES
power transistor controlled so that the potential of A and B remains equal to maintain the set temperature.
Temperature Sensor Mass Air Flow Meter

(Thermistor) +B
Platinum Hot Wire
A Platinum Hot Wire

B
Output Voltage
Temperature Sensor (Thermistor)

A153590E01

Test value calculated with engine load and fuel trim are
out of specified threshold under the following conditions
(2 trip detection logic):
P0101/31 Mass air flow meter
• Engine load is 30% or more and constant
• Engine coolant temperature is 70°C (158°F) or
higher
HINT:

display.
(d) Read the DTCs.
Result
P0101/31 A
P0101/31 and other DTCs B
B GO TO DTC CHART

ES
Manifold Absolute Pressure / Barometric Pres-

DTC P0105/35
sure Circuit

DTC P0107/35
sure Circuit Low Input

DTC P0108/35
sure Circuit High Input
ES
DESCRIPTION
By a built-in sensor unit, the turbo pressure sensor (manifold absolute pressure sensor) detects the intake
manifold pressure as a voltage. The ECM then determines the basic injection duration and basic ignition
advance angle based on this voltage.
Since the turbo pressure sensor does not use the atmospheric pressure as a criterion, but senses the
absolute pressure inside the intake manifold (the pressure in proportion to the preset absolute vacuum 0),
it is not influenced by fluctuations in the atmospheric pressure due to high altitude and other factors. This
permits it to control the air fuel ratio at the proper level under all conditions.
Voltage
V
4.5
0.345
kPa
93 370
mmHg
697.6 2,775
(27.5) Air Pressure (109) (in.Hg)
A006532E05

After engine is started, condition (a) continues for more
• Open or short in turbo pressure sensor circuit
than 2.0 seconds
P0105/35 • Turbo pressure sensor
(a) Open or short in turbo pressure sensor circuit for 0.5
• ECM
seconds or more
than 2.0 seconds
(a) Short in turbo pressure sensor circuit for 0.5
• ECM
seconds or more
than 2.0 seconds
(a) Open in turbo pressure sensor circuit for 0.5
• ECM
seconds or more
HINT:
When DTC P0105/35, P0107/35 or P0108/35 is detected, check the intake manifold pressure by the Hino-
DX.
Intake Manifold Pressure Malfunction
Approximately 0 kPa Short in PIM circuit
Intake Manifold Pressure Malfunction

• Open or short in VC circuit
370 kPa or more • Open in PIM circuit
• Open in E2 circuit
WIRING DIAGRAM
T2
Turbo Pressure Sensor
ECM
ES
18
3
VC E22 VC
28
2
PIM E23 PIM
28
1
E2 E22 E2
ASM3-747
NOTICE:
HINT:
malfunction.
1 READ VALUE OF Hino-DX (MANIFOLD ABSOLUTE PRESSURE)

(c) The engine is stopped.
(d) Follow the Hino-DX screen display and set the ECU data
monitor.
(e) Read the value.
Result
Pressure Displayed Proceed to
130 kPa A
0 kPa B
OK (same as atmospheric pressure near to intake manifold) C
B Go to step 3
2 CHECK ECM (VC VOLTAGE)

E22 VC (+) table below.
Standard voltage
Tester Connection Condition Specified Condition ES
E22-18 (VC) - E22-28 (E2) 4.5 to 5.5 V
position
E2 (-) ECM Connector
NG REPLACE ECM
A153569E01
OK
3 CHECK ECM (PIM VOLTAGE)

E22 E23 table below.
Standard voltage
Negative pressure of 93
E23-28 (PIM) - E22-28
kPa (698 mmHg, 27.5 0.25 to 0.4 V
(E2)
in.Hg) applied
ECM Connector
E2 (-) PIM (+) Positive pressure of 150
E23-28 (PIM) - E22-28
kPa (1,125 mmHg, 44 1.0 to 1.4 V
A153569E02 (E2)
in.Hg) applied
NG REPLACE ECM
OK
4 CHECK HARNESS AND CONNECTOR (TURBO PRESSURE SENSOR - ECM)
(a) Disconnect the turbo pressure sensor connector.

table below.
Check for open
T2 Front View
ES T2-2 (PIM) - E23-28 (PIM) Always Below 1 Ω
T2-3 (VC) - E22-18 (VC) Always Below 1 Ω
T2-1 (E2) - E22-28 (E2) Always Below 1 Ω
E2 PIM VC
Check for short
T2-2 (PIM) or E23-28 (PIM) - Body
E22 E23 Always 10 kΩ or higher
ground
T2-3 (VC) or E22-18 (VC) - Body
ground
ECM Connector
(d) Reconnect the turbo pressure sensor connector.
VC E2 PIM ASM3-748
CONNECTOR (TURBO PRESSURE SENSOR
- ECM)
OK
REPLACE TURBO PRESSURE SENSOR


DTC P0106/31
sure Circuit Range / Performance Problem
DESCRIPTION
By a built-in sensor unit, the turbo pressure sensor (manifold absolute pressure sensor) detects the intake
manifold pressure as a voltage. The ECM then determines the basic injection duration and basic ignition
advance angle based on this voltage.
Since the turbo pressure sensor does not use the atmospheric pressure as a criterion, but senses the
absolute pressure inside the intake manifold (the pressure in proportion to the preset absolute vacuum 0),
it is not influenced by fluctuations in the atmospheric pressure due to high altitude and other factors. This
permits it to control the air fuel ratio at the proper level under all conditions. ES
Voltage output of the manifold absolute pressure
P0106/31 sensor is out of the standard range (2 trip detection Manifold absolute pressure sensor
logic)
HINT:
If DTCs P0105/35, P0107/35, and P0108/35 are output simultaneously, the manifold absolute pressure
sensor circuit may be open or shorted. Perform troubleshooting for those DTCs first.

display.
(d) Read the DTCs.
Result
P0106/31 A
B GO TO DTC CHART

DTC P0110/24 Intake Air Temperature Circuit *E1
DTC P0112/24 Intake Air Temperature Circuit Low Input *E1
DTC P0113/24 Intake Air Temperature Circuit High Input *E1

DESCRIPTION
The Intake Air Temperature (IAT) sensor is built into the Mass Air Flow (MAF) meter and senses the
atmospheric temperature. A thermistor built in the sensor changes the resistance value according to the
ES intake air temperature. The lower the atmospheric temperature is, the greater the thermistor resistance
value is, and the higher the atmospheric temperature is, the lower the thermistor resistance value is (see
Fig. 1).
The IAT sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the IAT
sensor from terminal THA via a resistor R. The resistor R and the IAT sensor are connected in series.
When the resistance value of the IAT sensor changes in accordance with changes in the IAT, the voltage
at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to
improve driveability during cold engine operation.
(Figure 1)
Resistance kΩ
Acceptable
A056276E06

• Open or short in IAT sensor circuit
Open or short in IAT sensor circuit for 0.5
P0110/24 Step 1 • IAT sensor (built in MAF meter)
seconds
• ECM
Short in intake IAT sensor circuit for 0.5
seconds
• ECM
Open in IAT sensor circuit for 0.5
seconds
• ECM
HINT:
When DTC P0110/24, P0112/24 or P0113/24 is detected, check the intake air temperature by the Hino-
DX.
WIRING DIAGRAM
ECM
A20 ES
Intake Air Temperature Sensor (Built in Mass Air Flow Meter)
5V
31
THA 5 THA
E22
28
E2 4 E2
E22
A110952E08
NOTICE:
HINT:
malfunction.
1 READ VALUE OF Hino-DX (INTAKE AIR TEMPERATURE)

monitor.
(e) Read the value.
Standard:
Same value as the actual inlet air temperature.
Result
-40°C (-40°F) A
140°C (284°F) or more B

HINT:
(-40°F).
(284°F) or more.
B Go to step 4

ES
A

ECM (b) Connect terminals 4 and 5 of the MAF meter wire
harness side connector.
MAF Meter (c) Connect the Hino-DX to the DLC3.
A20 (d) Turn the ignition switch to the ON position and the
engine is stopped.
THA (e) Follow the Hino-DX screen display and set the ECU data
monitor.
Standard:
140°C (284°F) or more
Wire Harness Side: (g) Reconnect the MAF meter connector.
Mass Air Flow Meter Connector NG Go to step 3
A20 Front View
THA
E2
A153594E01
OK


ECM (b) Connect terminals THA and E2 of the ECM connector.
HINT:
MAF Meter Before checking, perform a visual and contact pressure
A20 check on the ECM connector.
THA (d) Turn the ignition switch to the ON position.
E2 (f) Follow the Hino-DX screen display and set the ECU data
ES
monitor.
(g) Read the value.
ECM Connector
Standard:
140°C (284°F) or more
E22 (h) Reconnect the MAF meter connector.
NG REPLACE ECM
THA E2
A153595E01
OK
REPAIR OR REPLACE HARNESS OR CONNECTOR (ECM - MASS AIR FLOW METER)

MAF Meter
A20
(d) The engine is stopped.
(e) Follow the Hino-DX screen display and set the ECU data
THA monitor.
(f) Read the value.
E2 Standard:
-40°C (-40°F)
A083863E39 (g) Reconnect the MAF meter connector.
NG Go to step 5
OK

5 READ VALUE OF Hino-DX (CHECK FOR SHORT IN ECM)

(b) Disconnect the ECM connector.
ECM
MAF Meter (d) Turn the ignition switch to the ON position.
A20 (e) The engine is stopped.
THA monitor.
(g) Read the value.
ES E2 Standard:
-40°C (-40°F)
(h) Reconnect the MAF meter connector.
ECM Connector (i) Reconnect the ECM connector.
NG REPLACE ECM
E22
E2
THA A153596E01
OK
REPAIR OR REPLACE HARNESS OR CONNECTOR (ECM - MASS AIR FLOW METER)

DTC P0115/22 Engine Coolant Temperature Circuit
DTC P0117/22 Engine Coolant Temperature Circuit Low Input
DTC P0118/22 Engine Coolant Temperature Circuit High Input

DESCRIPTION
A thermistor is built into the Engine Coolant Temperature (ECT) sensor and changes its resistance value
according to the ECT.
The structure of the sensor and connection to the ECM is the same as the Intake Air Temperature (IAT) ES
sensor.
• Open or short in ECT sensor circuit
Open or short in ECT sensor circuit for
P0115/22 Step 1 • ECT sensor
0.5 seconds
• ECM
Short in ECT sensor circuit for 0.5
seconds
• ECM
Open in ECT sensor circuit for 0.5
seconds
• ECM
HINT:
When DTC P0115/22, P0117/22 and/or P0118/22 is detected, check the engine coolant temperature by
entering the following menus on the tester: Powertrain / Engine and ECT / Data List / Coolant Temp.
WIRING DIAGRAM
ECM
W5
5V
19
1 THW
E22
28
2 E2
E22
A110952E09
NOTICE:
HINT:
malfunction.
1 READ VALUE OF Hino-DX (COOLANT TEMPERATURE)

ES (a) Connect the Hino-DX to the DLC3.
(b) Turn the ignition switch to the ON position and the
engine is stopped.
monitor.
(d) Read the value.
Standard:
Same value as the actual engine coolant
temperature.
Result
-40°C (-40°F) A
140°C (284°F) or more B
HINT:
(-40°F).
(284°F) or more.
B Go to step 4
A
(a) Disconnect the ECT sensor connector.

ECM (b) Connect terminals 1 and 2 of the ECT sensor wire
ECT Sensor harness side connector.
W5 (c) Connect the Hino-DX to the DLC3.
THW (f) Follow the Hino-DX screen display and set the ECU data
monitor.
E2
(g) Read the value.
ES
Standard:
Wire Harness Side: 140°C (284°F) or more
(h) Reconnect the ECT sensor connector.
Connector
NG Go to step 3
W5 Front View
THW E2
A153599E01
OK
REPLACE ENGINE COOLANT TEMPERATURE SENSOR


ECM (b) Connect terminals THW and E2 of the ECM connector.
HINT:
ECT Sensor
W5 Before checking, perform a visual and contact pressure
check for the ECM connector.
THW (d) Turn the ignition switch to the ON position.
ES E2
monitor.
Standard:
140°C (284°F) or more
E22 (h) Reconnect the ECT sensor connector.
NG REPLACE ECM
THW E2
A153588E02
OK
REPAIR OR REPLACE HARNESS OR CONNECTOR (ECM - ENGINE COOLANT TEMPERATURE

SENSOR)

ECT Sensor
W5
THW
(e) Follow the Hino-DX screen display and set the ECU data
monitor.
Standard:
-40°C (-40°F)
A075766E25 (g) Reconnect the ECT sensor connector.
NG Go to step 5
OK


ECM
ECT Sensor (d) The engine is stopped.
W5 (e) Follow the Hino-DX screen display and set the ECU data
monitor.
THW (f) Read the value.
Standard:
E2
-40°C (-40°F)
ES
(g) Reconnect the ECT sensor connector.
E22
THW
E2
A153589E02
OK

SENSOR)
Engine Coolant Temperature Circuit Range /

DTC P0116/22
Performance Problem
DESCRIPTION
A thermistor is built into the Engine Coolant Temperature (ECT) sensor and it changes its resistance value
according to the engine coolant temperature.
The structure of the sensor and connection to the ECM is the same as the intake air temperature sensor.
If the engine coolant temperature was between -40°C (-40°F)
and 60°C (140°F) at engine start, and conditions (a) and (b)
ES are met:
(2 trip detection logic)
(a) Vehicle is driven at varying speeds (accelerating and
decelerating)
(b) Engine coolant temperature remains within 3°C (37°F) of
P0116/22 the engine starting temperature Engine coolant temperature sensor
If the engine coolant temperature was more than 60°C (140°F)
at engine start, and conditions (a) and (b) are met:
(2-trip detection logic)
(a) Vehicle is driven at varying speeds (accelerating and
decelerating)
(b) Engine coolant temperature remains within 1°C (34°F) of
the engine starting temperature.
HINT:
If DTCs P0115/22, P0116/22, P0117/22, and P0118/22 are output simultaneously, the engine coolant
temperature sensor circuit may be open or shorted. Perform troubleshooting for those DTCs first.

display.
(d) Read the DTCs.
Result
P0116/22 A
B GO TO DTC CHART
2 INSPECT THERMOSTAT
(a) Remove the thermostat (See chapter CO).

(b) Check the valve opening temperature of the thermostat
(See chapter CO).
Standard:
80 to 84°C (176 to 183°F)
HINT:
In addition to the above check, confirm that the valve is
completely closed when the temperature is below the
standard.
(c) Reinstall the thermostat (See chapter CO).
NG REPLACE THERMOSTAT
OK

ES

DTC P0120/41
Circuit *E1

DTC P0122/41
Circuit Low Input *E1

DTC P0123/41
Circuit High Input *E1
ES
DESCRIPTION
The throttle position sensor is mounted in the throttle body and detects the throttle valve (intake shutter)
opening angle.
When the throttle valve is fully closed, a voltage of approximately 0.7 V is applied to terminal VLU of the
ECM. The voltage applied to terminal VLU of the ECM increases in proportion to the opening angle of the
throttle valve and becomes approximately 3.5 to 4.0 V when the throttle valve is fully opened. The ECM
judges the vehicle driving conditions from these signals input from terminal VLU, and uses them as one of
the conditions for deciding the air fuel ratio correction, power increase correction and fuel cut control, etc.
Throttle Position Sensor ECM
Magnet Hall IC
5V
VC VC
VTA VLU
E2 E2
Magnet
G037167E07
DTC Detection Condition
DTC No. Condition (a) of DTC P0120/41, P0122/41 or P0123/ Trouble Area
41 continues for 0.5 second (open or short in
throttle position sensor circuit)
• Open or short in throttle position sensor circuit
Open or short in throttle position sensor circuit for 1
P0120/41 • Throttle position sensor
second.
• ECM
• Open in throttle position sensor circuit
P0122/41 Open in throttle position sensor circuit for 1 second. • Throttle position sensor
• ECM
• Short in throttle position sensor circuit
P0123/41 Short in throttle position sensor circuit for 1 second. • Throttle position sensor
• ECM
WIRING DIAGRAM
T7
Throttle Position Sensor ECM
18 5V
1
VC E22 VC
20
3 VLU
VTA E23
ES
28
2 E2
E2 E22
E1
ASM3-774
NOTICE:
HINT:
malfunction.
1 CHECK ECM (VC VOLTAGE)

E22 VC (+) table below.
Standard voltage
E22-18 (VC) - E22-28 (E2) Always 4.5 to 5.5 V
E2 (-) ECM Connector

NG REPLACE ECM
A153569E01
OK
2 CHECK ECM (VLU VOLTAGE)

Standard voltage
Accelerator Pedal
Condition
E23-20 (VLU) - E22-28
Released 2.6 to 3.0 V
(E2)
ES E2 (-) VLU (+)
ECM Connector
E23-20 (VLU) - E22-28
Depressed 1.4 to 1.8 V
A153569E03
(E2)
E23-20 (VLU) - E22-28 Voltage changes
Released → Depressed
(E2) constantly
NG Go to step 3
OK
REPLACE ECM
3 INSPECT THROTTLE POSITION SENSOR
(a) Disconnect the throttle position sensor connector.

Component Side: (b) Measure the resistance according to the value(s) in the
table below.
Throttle Position Sensor Standard resistance
Tester Connection Throttle Valve Condition Specified Condition
T7-3 (VTA) - T7-2 (E2) Fully closed 0.2 to 5.7 kΩ
T7-3 (VTA) - T7-2 (E2) Fully open 2.0 to 10.2 kΩ
T7
(c) Reconnect the throttle position sensor connector.
VTA E2 ASM3-775
NG REPLACE DIESEL THROTTLE BODY
OK
4 CHECK HARNESS AND CONNECTOR (ECM - THROTTLE POSITION SENSOR)
(a) Disconnect the turbo ECM connectors.

Wire Harness Side: (b) Disconnect the throttle position sensor connector.
ECM Connector table below.
Check for open
E22 E23 Tester Connection Condition Specified Condition
T7-1 (VC) - E22-18 (VC) Always Below 1 Ω ES
T7-3 (VTA) - E23-20 (VLU) Always Below 1 Ω
T7-2 (E2) - E22-28 (E2) Always Below 1 Ω
Check for short

VC E2 VLU
T7-1 (VC) or E22-18 (VC) - Body
Throttle Position Sensor Connector Always 10 kΩ or higher
ground
E2 T7-3 (VTA) or E23-20 (VLU) -
Body ground
T7 (d) Reconnect the throttle position sensor connector.

VC Front View VTA
A153603E01
CONNECTOR (ECM - THROTTLE POSITION
SENSOR)
OK
5 CHECK DTC OUTPUT

display.
(d) Read the DTCs.
Result
P0120/41, P0122/41 and/or P0123/41 A
No output B
NG CHECK FOR INTERMITTENT PROBLEMS
OK
REPLACE ECM
DTC P0168/39 Fuel Temperature Too High
DTC P0180/39 Fuel Temperature Sensor "A" Circuit
DTC P0182/39 Fuel Temperature Sensor "A" Circuit Low Input
DTC P0183/39 Fuel Temperature Sensor "A" Circuit High Input

DESCRIPTION
ES The fuel temperature sensor senses the fuel temperature. A thermistor built into the sensor changes its
resistance value according to the fuel temperature. The lower the fuel temperature is, the greater the
thermistor resistance becomes, and the higher the fuel temperature is, the lower the thermistor resistance
becomes (see Fig. 1).
The fuel temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is
applied to the fuel temperature sensor from terminal THF via resistor R. The resistor R and the fuel
temperature sensor are connected in series. When the resistance value of the fuel temperature sensor
changes in accordance with the fuel temperature, the voltage at terminal THF also changes. Based on
this signal, the ECM corrects the pressure control compensation of the supply pump and an error.
(Figure 1)
Resistance kΩ
Acceptable
A056276E06

After engine is warmed up, conditions (a), (b) and (c)
continue for more than 1 second: • Open or short in fuel temperature sensor circuit
P0168/39 (a) Engine speed: 1,000 rpm or more • Fuel temperature sensor
(b) Vehicle speed: 10 km/h (6 mph) or more • ECM
(c) Fuel temperature: 96°C (205°F) or more
• Open or short in fuel temperature sensor circuit
Open or short in fuel temperature sensor circuit for 0.5
P0180/39 • Fuel temperature sensor
seconds
• ECM
P0182/39 Short in fuel temperature sensor circuit for 0.5 seconds • Fuel temperature sensor
• ECM

P0183/39 Open in fuel temperature sensor circuit for 0.5 seconds • Fuel temperature sensor
• ECM
HINT:
When DTC P0180/39, P0182/39 or P0183/39 is detected, check the fuel temperature by selecting the
following menus on the Hino-DX: Powertrain / Engine and ECT / Data List / Fuel Temperature.
ES
WIRING DIAGRAM
ECM
Fuel Temperature Sensor

5V
F10
2 29
THF
E22
1 28
E2
E22
ASM3-776
NOTICE:
HINT:
malfunction.
1 READ VALUE OF Hino-DX (FUEL TEMPERATURE)

monitor.
(e) Read the value.
Standard:
Same value as the actual fuel temperature.
Result
Temperature Displayed Proceed to
-40°C (-40°F) A
140°C (284°F) or more B
OK (same as actual fuel temperature) C
HINT:
(-40°F).
ES • If there is a short circuit, the Hino-DX indicates 140°C
(284°F) or more.
B Go to step 4
(a) Disconnect the fuel temperature sensor connector.

Wire Harness Side: (b) Connect terminals 1 and 2 of the wire harness side
Fuel Temperature Sensor Connector
connector.
F10 (f) Follow the Hino-DX screen display and set the ECU data
monitor.
Front View (g) Read the value.
Standard:
Fuel Temperature 140°C (284°F) or more
Sensor ECM
(h) Reconnect the fuel temperature sensor connector.
F10 NG Go to step 3
THF
E2
ASM3-777
OK
REPLACE COMMON RAIL ASSEMBLY (FUEL TEMPERATURE SENSOR)


ECM (b) Connect terminals THF and E2 of the ECM connector.
Fuel Temperature Sensor HINT:
Before checking, do a visual and contact pressure check
F10 for the ECM connector.
THF (d) Turn the ignition switch to the ON position.
E2
ES
monitor.
Standard:
140°C (284°F) or more
E22 (h) Reconnect the fuel temperature sensor connector.
NG REPLACE ECM
THF E2
ASM3-778
OK
REPAIR OR REPLACE HARNESS OR CONNECTOR (ECM - FUEL TEMPERATURE SENSOR)

Fuel Temperature Sensor ECM (b) Connect the Hino-DX to the DLC3.
F10
THF (e) Follow the Hino-DX screen display and set the ECU data
monitor.
Standard:
-40°C (-40°F)
ASM3-779 (g) Reconnect the fuel temperature sensor connector.
NG Go to step 5
OK
REPLACE COMMON RAIL ASSEMBLY (FUEL TEMPERATURE SENSOR)


Fuel Temperature Sensor (b) Connect the Hino-DX to the DLC3.
ECM
F10 (e) Follow the Hino-DX screen display and set the ECU data
monitor.
THF (f) Read the value.
Standard:
ES E2
-40°C (-40°F)
(g) Reconnect the ECM connector.
E22
E2
THF ASM3-780
OK
REPAIR OR REPLACE HARNESS OR CONNECTOR (ECM - FUEL TEMPERATURE SENSOR)

DTC P0200/97 Injector Circuit / Open

DESCRIPTION
The EDU has been adopted to drive the injector at high speeds. The EDU has realized high-speed driving
under high fuel pressure conditions through the use of a DC/DC converter that provides a high-voltage,
quick-charging system.
The ECM constantly monitors the EDU and stops the engine if an abnormal condition is detected.
Open or short in EDU or injector circuit. After engine is • Open or short in EDU circuit
started, there is no injection confirmation signal (IJF) • Injector
P0200/97
from EDU to ECM despite ECM sending injection
command signal (IJT) to EDU
•
•
EDU
ECM
ES
WIRING DIAGRAM
EDU ECM
6 24
IJT#1 E27 E22 #1
3 23
IJT#2 E27 E22 #2
2 22
ES IJT#3 E27 E22 #3
5 21
IJT#4 E27 E22 #4
7 25
IJF E27 E22 INJF
4 (*1)
INJ#1 E26
5
COM1 E26
1 2
(*1) 2 No. 1 Injector
3
INJ#4 E26
1 2
2
INJ#2 E26
6
COM2 E26
1 2
1
INJ#3 E26
1 2
4 No. 3 Injector
1
GND E27
*1: Shielded
ASM3-781
8
+B E26
EDU
ENG 5 3
14
E25 IREL
1 2 ES
EDU
2 5 3
OUT1
1 13
+24V 2 1
DC-DC1 8 E25 MREL
OUT2
ENG-3 7
X17 Voltage Converter E23 E1
Battery
Battery
ECM A162396E03
NOTICE:
HINT:
1 CHECK EDU (+B VOLTAGE)
(a) Disconnect the EDU connectors.

EDU Connector table below.
Standard voltage
E26-8 (+B) - E27-1 Ignition switch in the
E26 18 to 27 V
(GND) ON position
ES
+B (+) (d) Reconnect the EDU connectors.
Front View
NG CHECK EDU POWER SOURCE CIRCUIT
EDU Connector
E27
GND (-)
Front View
A153605E01
OK
2 CHECK EDU (INJECTOR RESISTANCE)
(a) Disconnect the EDU connector.

Wire Harness Side: (b) Measure the resistance according to the value(s) in the
table below.
EDU Connector Standard resistance
E26-4 (INJ#1) - E26-5 (COM1) 20°C (68°F) 0.35 to 0.55 Ω
E26-2 (INJ#2) - E26-6 (COM2) 20°C (68°F) 0.35 to 0.55 Ω
INJ#4 INJ#1 COM1
E26-1 (INJ#3) - E26-6 (COM2) 20°C (68°F) 0.35 to 0.55 Ω
COM2
E26 E26-3 (INJ#4) - E26-5 (COM1) 20°C (68°F) 0.35 to 0.55 Ω
INJ#3 (c) Reconnect the EDU connector.

INJ#2 OK Go to step 4
Front View
A153606E01
NG
3 INSPECT INJECTOR ASSEMBLY
(a) Disconnect the injector connectors.

Component Side: (b) Measure the resistance of the injector assemblies INJ1
to INJ4 according to the value(s) in the table below.
Standard resistance
INJ1, INJ2, Tester Connection Condition Specified Condition
INJ3, INJ4 1-2 20°C (68°F) 0.35 to 0.55 Ω
(c) Reconnect the injector connectors.

Injector Assembly ES
ASM3-782
NG REPLACE INJECTOR ASSEMBLY
OK
REPAIR OR REPLACE HARNESS OR CONNECTOR (EDU - INJECTOR ASSEMBLY)
4 CHECK HARNESS AND CONNECTOR (EDU - ECM)

EDU Connector table below.
Check for open
E27-6 (IJT#1) - E22-24 (#1) Always Below 1 Ω
IJT#3 IJF E27-3 (IJT#2) - E22-23 (#2) Always Below 1 Ω

IJT#2 IJT#4 IJT#1 E27-2 (IJT#3) - E22-22 (#3) Always Below 1 Ω
E27-5 (IJT#4) - E22-21 (#4) Always Below 1 Ω
Front View
E27-7 (IJF) - E22-25 (INJF) Always Below 1 Ω
Check for short

E22
E27-6 (IJT#1) or E22-24 (#1) -
#1 #3 Body ground
ECM Connector E27-3 (IJT#2) or E22-23 (#2) -
#4 Body ground
E27-2 (IJT#3) or E22-22 (#3) -
INJF #2 Always 10 kΩ or higher
A153607E01 Body ground
E27-5 (IJT#4) or E22-21 (#4) -
Body ground
E27-7 (IJF) or E22-25 (INJF) -
Body ground
(d) Reconnect the EDU connector.

CONNECTOR (EDU - ECM)
OK
5 CHECK ECM (OUTPUT VOLTAGE)
(a) While idling the engine, check the waveform of the ECM
ECM Connector connectors using an oscilloscope.
Standard
E22 E23 Tester Connection Specified Condition
E22-24 (#1) - E23-7 (E1) Correct waveform appears as shown
ES
#4 E1 E22-25 (INJF) - E23-7 (E1) Correct waveform appears as shown
#2
#1 #3
Result
INJF
Signal Waveform Result Proceed to
#1 to #4 is normal INJF is abnormal A
#1 to #4 is abnormal INJF is normal B
#1
#3 5 V/DIV. B REPLACE ECM
#4
#2
20 msec./DIV.
INJF
2 V/DIV.
1 msec./DIV. A151977E04
REPLACE EDU
NEXT
6 CLEAR DTC
(a) Connect the Hino-DX to the DL3.

(b) Turn the ignition switch ON.
display.
(d) Clear the DTC.
NEXT
7 CONFIRM DTC

(b) Follow the Hino-DX screen display and set the Data
display.
(c) Read the DTC.
DTC is displayed A
ES
DTC is displayed again B
B REPLACE ECM
SYSTEM OK
Turbocharger / Supercharger Overboost Condi-

DTC P0234/34 tion VN Turbocharger Open Side Malfunction
*E1
Turbocharger / Supercharger Underboost VN

DTC P0299/34
Turbocharger Close Side Malfunction *E1
Turbocharger / Supercharger Overboost Condi-

ES DTC P1251/34 tion (Too High) VN Turbocharger Circuit
Momentary Open *E1
DESCRIPTION
• Turbocharger
• Turbocharger actuator
Actual turbocharger pressure is deviated 100 kPa (750 • EGR valve assembly
P0234/34 mmHg, 29.5 in.Hg) or more from the simulated target • MAF meter
pressure for 60 seconds • Turbo pressure sensor
• Vacuum hose
• Exhaust system is clogged
• ECM
• Turbocharger
• Turbocharger actuator
Actual turbocharger pressure is deviated -50 kPa (-375
• EGR valve assembly
mmHg, -14.8 in.Hg) to -100 kPa (-750 mmHg, -29.5
P0299/34 • MAF meter
in.Hg) or more from the simulated target pressure for 50
• Turbo pressure sensor
seconds
• Exhaust system and intake system are modified or
clogged
• ECM
Actual turbocharger pressure is deviated 40 kPa (300 • Turbocharger
P1251/34 mmHg, 11.8 in.Hg) or more from the simulated target • Turbocharger actuator
pressure for 0.5 seconds • EGR valve assembly
• ECM
WIRING DIAGRAM
NOTICE:
1 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P0234/34, P0299/34 AND/OR P1251/
34)

display.
(d) Read the DTCs.
Result
Display (DTC Output) Proceed to
P0234/34, P0299/34 and/or P1251/34 A
Other DTCs B
B GO TO DTC CHART
2 CHECK INTAKE AND EXHAUST SYSTEM

ES
(a) Check the intake and exhaust systems modifications.
OK:
No modifications.
NG REPAIR OR REPLACE INTAKE AND
EXHAUST SYSTEM
OK
3 CHECK CONNECTION OF VACUUM HOSE
(a) Check the vacuum hoses of turbocharger system

connections.
NG REPAIR OR REPLACE VACUUM HOSE
OK
(a) Check the turbocharger sub-assembly (See chapter IT).

ASSEMBLY
OK
5 INSPECT EGR VALVE ASSEMBLY
(a) Check the EGR valve assembly (See chapter EC).

NG REPLACE EGR VALVE ASSEMBLY
OK
6 INSPECT MASS AIR FLOW METER
(a) Check the mass air flow meter (See page ES-354).
NG REPLACE MASS AIR FLOW METER
OK
REPLACE ECM
ES
P0335/12,
DTC Crankshaft Position Sensor "A" Circuit
13
Crankshaft Position Sensor "A" Circuit Inter-

DTC P0339/13
mittent
DESCRIPTION
The crankshaft position sensor (NE signal) consists of a magnet, iron core and pickup coil.
The crankshaft angle sensor plate has 32 teeth and is installed on the injection pump drive gear. The NE
signal sensor generates 32 signals of every engine revolution. The ECM detects the standard crankshaft ES
angle based on the G signal from the camshaft position sensor, and the actual crankshaft angle and the
engine speed by the NE signal.
One of the following conditions is met:
• Open or short in crankshaft position sensor circuit
(a) No crankshaft position sensor signal to ECM while
• Crankshaft position sensor
P0335/12, 13 cranking for 4.7 seconds or more
• Crankshaft angle sensor plate
(b) No crankshaft position sensor signal to ECM after
• ECM
cranking (Engine revolution 600 rpm or more)
In conditions (a), (b) and (c), no crankshaft position
sensor (NE) signal is input for 0.05 seconds or more. • Open or short in crankshaft position sensor circuit
(a) Engine revolution is 1,000 rpm or more • Crankshaft position sensor
P0339/13
(b) NE signal is OFF • Crankshaft angle sensor plate
(c) 3 seconds or more has lapsed after STA signal is • ECM
switched from ON to OFF
WIRING DIAGRAM
ECM
27
1
E22 NE+
34
2
E22 NE-
Crankshaft Position Sensor (*)

22
E23 VCG
23
1
OUT E23 G+
3
VCC 31
2
GND E23 G-
C1 Camshaft Position Sensor

(*): Shielded
ASM3-783
NOTICE:
HINT:
ES 1 CHECK CRANKSHAFT POSITION SENSOR
Standard
E22-27 (NE+) - E22-34 (NE-) Correct waveform appears as shown
NE+ E22 E23
E23-23 (G+) - E23-31 (G-) Correct waveform appears as shown
NG Go to step 2
NE- G- G+
G+ and NE Signal Waveforms
5 V/DIV.
G+
NE
20 msec./DIV. (Idling)
A153609E01
OK
CHECK FOR INTERMITTENT PROBLEMS

2 INSPECT CRANKSHAFT POSITION SENSOR (RESISTANCE)
(a) Disconnect the crankshaft position sensor connector.

table below.
Standard resistance
1-2 Cold 1630 to 2740 Ω
1-2 Hot 2065 to 3225 Ω
Crankshaft Position Sensor
NOTICE:
ES
ASM3-784 In the above table, the terms "Cold" and "Hot" refer
to the temperature of the coils. "Cold" means
approximately -10 to 50°C (14 to 122°F). "Hot" means
approximately 50 to 100°C (122 to 212°F).
(c) Reconnect the crankshaft position sensor connector.
NG REPLACE CRANKSHAFT POSITION
SENSOR
OK
3 CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM)

Crankshaft Position Sensor Connector table below.
Check for open
1 - E22-27 (NE+) Always Below 1 Ω
Front View 2 - E22-34 (NE-) Always Below 1 Ω
Check for short

ECM Connector
1 or E22-27 (NE+) - Body ground Always 10 kΩ or higher
E22 2 or E22-34 (NE-) - Body ground Always 10 kΩ or higher
(d) Reconnect the crankshaft position sensor connector.

NE+ (e) Reconnect the ECM connector.
CONNECTOR (CRANKSHAFT POSITION
NE- SENSOR - ECM)
ASM3-785
OK
4 CHECK CRANKSHAFT POSITION SENSOR (SENSOR INSTALLATION)
OK:
The crankshaft position sensor is installed properly.
NG SECURELY REINSTALL CRANKSHAFT
POSITION SENSOR
ES Clearance
OK NG
BR03795E40
OK
5 CHECK CRANKSHAFT POSITION SENSOR PLATE
(a) Check the teeth of the crankshaft angle sensor plate.

SENSOR PLATE
OK
REPLACE ECM
Camshaft Position Sensor "A" Circuit (Bank 1

DTC P0340/12
or Single Sensor)
DESCRIPTION
The camshaft position sensor (G signal) consists of a magnet and MRE element.
The camshaft drive gear has 5 teeth on its inner circumference. When the camshaft gear rotates, air gap
changes between the protrusion on the gear and the pickup coil. The change affects the magnetic field
and results in change in the resistance of the MRE element. The crankshaft angle sensor plate has 32
teeth and output 32 signals every engine revolution. The ECM detects the standard crankshaft angle
based on the G signal and actual crankshaft angle and engine speed by NE signal.
ES
STA ON:
No camshaft position sensor signal to ECM while • Open or short in camshaft position sensor circuit
cranking for 4 seconds or more • Camshaft position sensor
P0340/12
STA OFF: • Camshaft drive gear
No camshaft position sensor signal to ECM with engine • ECM
speed 650 to 3,000 rpm 20 times or more
WIRING DIAGRAM
Refer to DTC P0335/12, 13 (See page ES-115).
NOTICE:
HINT:
1 CHECK CAMSHAFT POSITION SENSOR
Standard
E22-27 (NE+) - E22-34 (NE-) Correct waveform appears as shown
NE+ E22 E23
E23-23 (G+) - E23-31 (G-) Correct waveform appears as shown
ES OK Go to step 7
NE- G- G+
G+ and NE Signal Waveforms
5 V/DIV.
G+
NE
20 msec./DIV. (Idling)
A153609E01
NG
2 CHECK ECM (VCG VOLTAGE)

E23 table below.
Standard voltage
E23-22 (VCG) - E23-31 Ignition switch in the ON
4.5 to 5.5 V
(G-) position
G- (-) ECM Connector
VCG (+) NG REPLACE ECM

A153569E04
OK
3 CHECK HARNESS AND CONNECTOR (CAMSHAFT POSITION SENSOR - ECM)
(a) Disconnect the camshaft position sensor connector.

Camshaft Position Sensor Connector (c) Measure the resistance according to the value(s) in the
table below.
Check for open
C1 Tester Connection Condition Specified Condition
1 (OUT) - E23-23 (G+) Always Below 1 Ω ES
2 (GND) - E23-31 (G-) Always Below 1 Ω
3 (VCC) - E23-22 (VCG) Always Below 1 Ω
OUT GND VCC
1 (OUT) or E23-23 (G+) - Body
E23 Always 10 kΩ or higher
ground
2 (GND) or E23-31 (G-) - Body
ground
ECM Connector 3 (VCC) or E23-22 (VCG) - Body
ground
G+ G- VCG (d) Reconnect the camshaft position sensor connector.

ASM3-750
CONNECTOR (CAMSHAFT POSITION
SENSOR - ECM)
OK
4 CHECK CAMSHAFT POSITION SENSOR (SENSOR INSTALLATION)
OK:
The camshaft position sensor is installed properly.
NG SECURELY REINSTALL CAMSHAFT
POSITION SENSOR
Clearance
OK NG
BR03795E40
OK
5 INSPECT CAMSHAFT TIMING GEAR
(a) Check the teeth of the camshaft timing gear.

NG REPLACE CAMSHAFT TIMING GEAR
OK
6 REPLACE CAMSHAFT POSITION SENSOR
(a) Replace the camshaft position sensor (See page ES-

356).
NEXT
ES 7 CLEAR DTC

display.
(d) Clear the DTC.
NEXT
8 CHECK DTC OUTPUT

monitor.
(d) Read the value.
Result
P0340/12 is output A
No DTC is output B
B SYSTEM IS OK
REPLACE ECM
DTC P0400/71 Exhaust Gas Recirculation Flow *E1

DESCRIPTION
The EGR system recirculates exhaust gases, in order to suit every driving condition. The recirculated gas
mingles with the intake air, therefore the EGR system can slow combustion speed and keep the
combustion temperature down. This helps reduce NOx emissions.
In order to increase EGR circulation efficiency, the ECM adjusts the lift amount of the EGR valve and
intake shutter valve angle (throttle valve).
• Open or short in EGR valve circuit
P0400/71 Open or short in EGR valve circuit • EGR valve ES
• ECM
WIRING DIAGRAM
18
3
VC E22 VC
33
4
EGLS E23 EGLS
28
2
E2 E22 E2
3
1
EGR E23 EGRS
5
+B
E17 EGR Valve Position Sensor
2 5 3
1 OUT1
+24V ENG
DC-DC1 13
2 1
8 E25 MREL
OUT2
ENG-3
D8 Voltage Converter
Battery
Battery ECM
A164703E01
NOTICE:
1 INSPECT EGR VALVE ASSEMBLY (RESISTANCE)
(a) Disconnect the EGR valve connector.

EGR table below.
ES Standard resistance
E17 E17-1 (EGR) - E17-5 (+B) 20°C (68°F) 25.5 to 29.5 Ω
(c) Reconnect the EGR valve connector.

+B
EGR Valve
A101433E04
NG REPLACE EGR VALVE ASSEMBLY (See
chapter EC)
OK
2 CHECK EGR VALVE ASSEMBLY (EGR VALVE POWER SOURCE)

Wire Harness Side:
EGR Valve Connector (c) Measure the voltage according to the value(s) in the
+B table below.
Standard voltage
E17-5 (VC) - Body ground 11 to 14 V
Front View position
A101429E04
(d) Reconnect the EGR valve connector.
CONNECTOR (EGR VALVE POSITION
SENSOR - MAIN RELAY)
OK
3 CHECK HARNESS AND CONNECTOR (EGR VALVE - ECM)
(a) Disconnect the EGR valve position sensor.

EGR Valve Connector table below.
Check for open
E23-3 (EGRS) - E17-1 (EGR) Always Below 1 Ω ES
EGR
E23-3 (EGRS) or E17-1 (EGR) -
ECM Connector Always 10 kΩ or higher
Body ground

E23
CONNECTOR (EGR VALVE - ECM)
EGRS
A151975E02
OK
REPLACE ECM

DTC P0405/96
Low *E1

DTC P0406/96
High *E1
DESCRIPTION
The EGR valve position sensor is mounted on the EGR valve and used for detecting the lift amount of the
valve. The lift amount detected by the sensor is provided to the ECM as feedback. The ECM then
ES regulates the lift amount of the valve in accordance with engine running conditions.
• Open in EGR valve position sensor circuit
P0405/96 Open in EGR valve position sensor circuit • EGR valve
• ECM
• Short in EGR valve position sensor circuit
P0406/96 Short in EGR valve position sensor circuit • EGR valve
• ECM
WIRING DIAGRAM
NOTICE:
1 CHECK EGR OPENING RATIO WITH Hino-DX

(b) Read the EGR opening ratio.
Result
Test Condition Reference Trouble Area
Engine idling speed (warmed up, air • EGR valve assembly
45 - 55%
conditioner OFF, T/M N position) • ECM
OK CHECK FOR INTERMITTENT PROBLEMS
NG
2 CHECK EGR VALVE ASSEMBLY (POSITION SENSOR POWER SOURCE)

Wire Harness Side:
EGR Valve Connector (c) Measure the voltage according to the value(s) in the
table below.
E2 VC
Standard voltage
E17-3 (VC) - E17-2 (E2) 4.5 to 5.5 V
position
Front View ES
A101429E01
NG Go to step 5
OK
3 INSPECT EGR VALVE ASSEMBLY (POSITION SENSOR RESISTANCE)

table below.
Standard resistance
E17 E17-3 (VC) - E17-2 (E2) 20°C (68°F) 2.45 to 4.45 kΩ
E17-4 (EGLS) - E17-2 (E2) 20°C (68°F) 2.45 to 4.45 kΩ
EGLS VC E2
EGR Valve
(c) Reconnect the EGR valve connector.
A101433E01
OK
4 CHECK ECM (EGLS VOLTAGE)

Standard voltage
E23-33 (EGLS) - E22-28
Idling 2.7 to 3.0 V
(E2)
ECM Connector E23-33 (EGLS) - E22-28 Engine running at
3.3 to 3.6 V
E2 EGLS (E2) 3.000rpm
A153569E73
OK REPLACE ECM
NG
5 CHECK HARNESS AND CONNECTOR (ECM - EGR VALVE POSITION SENSOR)

EGR Valve Connector
table below.
Check for open
ES E17 E23-33 (EGLS) - E17-4 (EGLS) Always Below 1 Ω
E2 E22-28 (E2) - E17-2 (E2) Always Below 1 Ω

Front View EGLS
Check for short
E23-33 (EGLS) or E17-4 (EGLS) -
Body ground
E22 E23
E22-28 (E2) or E17-2 (E2) - Body
ground

ECM Connector
E2 EGLS A154597E01
CONNECTOR (ECM - EGR VALVE)
OK
REPLACE ECM
6 CHECK ECU

E22 (b) Measure the voltage according to the value(s) in the
VC table below.
Standard voltage
E22-18 (VC) - E22-28 Ignition switch in the
4.5 to 5.5 V
(FC) ON position
E2
NG REPLACE ECM
A101463E56
OK
7 CHECK HARNESS AND CONNECTOR (ECM - EGR VALVE)

table below.
EGR Valve Connector
Check for open
E17 E22-18 (VC) - E17-3 (VC) Always Below 1 Ω ES
E22-28 (E2) - E17-2 (E2) Always Below 1 Ω
E2 VC
E22-18 (VC) or E17-3
(VC) - Body ground
E22 E22-28 (E2) or E17-2
(E2) - Body ground

ECM Connector (e) Reconnect the ECM connector.
VC
E2 A154598E01
CONNECTOR (ECM - EGR VALVE)
OK
REPLACE ECM
Exhaust Gas Recirculation Throttle Position

DTC P0488/15
Control Range / Performance *E1
DESCRIPTION
The throttle control motor opens and closes the throttle valve according to a duty-cycle (signal) from the
ECM.
Condition (a) or (b) continues for more than 1 second
(a) Battery voltage: 18.5 V or more • Open or short in throttle control motor circuit
P0488/15 • Throttle motor's activation duty is out of the normal • Throttle control motor
ES range (Activation duty: 10 to 90) • ECM
(b) Open, short or stuck in throttle sensor
WIRING DIAGRAM
4
1 2 5 3 2 1
+24V OUT1 VCR VTAR E23 LUSL
ENG
1 2 3
DC-DC1 8 E2R
OUT2
ENG-3
D8 Voltage Converter I12 Throttle Control Motor
Battery 13
E25 MREL
Battery
ECM
A162405E01
NOTICE:
HINT:
1 CHECK THROTTLE CONTROL MOTOR (+B VOLTAGE)

Wire Harness Side: (b) Disconnect the throttle control motor connector.
table below.
Throttle Control Motor Connector Standard voltage
VCR I12-2 (VCR) - Body Ignition switch in the

11 to 14 V
ground ON position
ES
I12 (d) Reconnect the throttle control motor connector.
NG Go to step 3
Front View
ASM3-751
OK
2 INSPECT THROTTLE CONTROL MOTOR (RESISTANCE)
(a) Disconnect the throttle control motor connector.

Component Side: table below.
Standard resistance
I12-2 (VCR) - I12-3
Always 2 to 10 kΩ
Throttle Control Motor (E2R)
(c) Reconnect the throttle control motor connector.

I12 ASSEMBLY (THROTTLE CONTROL MOTOR)
E2R VCR
ASM3-752
OK
3 CHECK HARNESS AND CONNECTOR (THROTTLE CONTROL MOTOR - ECM)
(a) Disconnect the throttle control motor connector.

Throttle Control Motor Connector table below.
Check for open
I12
ES I12-1 (VTAR) - E23-4 (LUSL) Always Below 1 Ω
E2R I12-3 (E2R) - Body ground Always Below 1 Ω

VTAR Front View
Check for short
I12-1 (VTAR) or E23-4 (LUSL) -
Body ground
E23
(d) Reconnect the throttle control motor connector.
ECM Connector NG REPAIR OR REPLACE HARNESS OR
CONNECTOR (THROTTLE CONTROL
LUSL MOTOR - ECM)
ASM3-753
OK
REPLACE ECM
DTC P0500/42 Vehicle Speed Sensor "A"

DESCRIPTION
The vehicle speed sensor outputs on 8-pulse signal every revolution of the rotor shaft, which is rotated by
the transmission output shaft via the driven gear. After this signal is converted into a more precise
rectangular waveform by the waveform shaping circuit inside the tachograph, it is then transmitted to the
ECM. The ECM determines the vehicle speed, based on the frequency of these pulse signals.
8-pulse 4-pulse ES
Vehicle Speed Sensor Tachograph ECM
ASM3-754

All conditions below are detected continuously for 8
seconds or more: • Open or short in vehicle speed sensor circuit
(a) Vehicle speed signal: 0 km/h (0 mph) • Vehicle speed sensor
P0500/42 (b) Engine speed: 1,500 to 2,500 rpm • Combination meter
(c) Engine coolant temp.: 70°C (158°F) or more • Tachograth
(d) ECT sensor, accelerator pedal position sensor, and • ECM
MAF meter are all normal
WIRING DIAGRAM
ECM
C5 Combination Meter
37 19
SPD
S4P2 E25
ES
7
E23 E1
ASM3-755
NOTICE:
HINT:
1 READ VALUE OF INTELLIGENT TESTER (VEHICLE SPEED)
(a) Drive the vehicle and check whether the operation of the
speedometer in the combination meter is normal.
HINT:
• The vehicle speed sensor is operating normally if the
speedometer reading is normal.
• If the speedometer does not operate, check it by
following the procedure described in speedometer
malfunction.
NG Go to step 2
OK
REPAIR OR REPLACE HARNESS OR CONNECTOR (TACHOGRAPH - ECM)

2 CHECK ECM (SPD VOLTAGE)
(a) Drive the vehicle.

ECM Connector (b) Measure the voltage of the ECM connectors as the
wheel is turned slowly.
E23 E25 Standard voltage
E25-19 (SPD) - E23-7 (E1) Generated intermittently
HINT:
The output voltage should fluctuate up and down
ES
E1 SPD
similarly to the diagram when the wheel is turned slowly.
NG Go to step 3
4.5 to 5.5 V
0V
Wheel Turned
A154964E02
OK
REPLACE ECM
NEXT
3 CHECK HARNESS AND CONNECTOR (ECM - COMBINATION METER ASSEMBLY)
(a) Disconnect the combination meter connector.

Combination Meter table below.
Check for short
C5
ES E25-19 (PSD) or C5-37 (S4P2) -
Always 10 Ω or higher
Body ground
S4P2 Check for open

E25-19 (PSD) - C5-37 (S4P2) Always below 1 Ω
E25
CONNECTOR (ECM - COMBINATION METER
ECM Connector ASSEMBLY)
SPD
ASM3-756
OK
REPLACE ECM
DTC P0504/51 Brake Switch "A" / "B" Correlation

DESCRIPTION
In this system, signals of the stop light switch are used to judge whether the brake system is abnormal or
not.
The stop light switch has a duplex system (signals STP and ST1-) to memorize the abnormality when the
signals of depressing and releasing the brake pedal are detected simultaneously.
HINT:
Normal condition is as shown in the table below.
Signal Brake Pedal Released In Transition Brake Pedal Depressed
STP OFF ON ON ES
ST1- ON ON OFF

Conditions (a) and (b) continue for 0.5 seconds or
• Short in stop light switch signal circuit
more:
P0504/51 • Stop light switch
(a) Ignition switch in the ON position
• ECM
(b) Open or short in stop light switch signal circuit
WIRING DIAGRAM
18
E25 STP
STOP 2 1
HEAD
8
E25 ST1-
9 10 ECU-IG 4 3
AM1 IG1 S15 Stop Light Switch

AM1
I6 Ignition Switch
MAIN5
Battery
Battery
ECM
A169288
NOTICE:
HINT:
malfunction.
• STP signal conditions can be checked using the Hino-DX.
ES (a)Connect the Hino-DX to the DLC3.
(b)Turn the ignition switch to the ON position.
(c) Follow the Hino-DX screen display and set the ECU data monitor.
(d)Check the STP signal when the brake pedal is depressed and released.
Result
Brake Pedal Operation Specified Condition
Depressed STP signal ON
Released STP signal OFF
1 CHECK STOP LIGHT SWITCH ASSEMBLY (TERMINAL VOLTAGE)
(a) Disconnect the stop light switch connector.

(c) Measure the voltage between the terminals according to
Stop Light Switch Connector the value(s) in the table below.
Standard voltage
S15 Ignition switch in the
Front View S15-4 - Body ground 18 to 27 V
ON position
A154599E02
(d) Reconnect the stop light switch connector.
NG Go to step 4
OK
2 CHECK STOP LIGHT SWITCH ASSEMBLY (TERMINAL VOLTAGE)
(a) Disconnect the stop light switch assembly connector.

Wire Harness Side: (b) Measure the voltage according to the value(s) in the
table below.
Stop Light Switch Connector Standard voltage
S15-2 - Body ground Always 18 to 27 V
S15
Front View (c) Reconnect the stop light switch assembly connector.
A154599E02
NG Go to step 5
OK
3 CHECK ECM (STP AND ST1- VOLTAGE)

E25 (c) Measure the voltage according to the value(s) in the
table below.
Standard voltage
ECM Connector Tester Connection Condition Specified Condition
E25-8 (ST1-) - Body Depressed Below 2 V
ST1- STP
ground Released 18 to 27 V ES
E25-18 (STP) - Body Depressed 18 to 27 V
A154601E01
ground Released Below 2 V
(d) Reconnect the ECM connector.

CONNECTOR (STOP LIGHT SWITCH - ECM)
OK
REPLACE ECM
4 INSPECT FUSE (ECU-IG)
(a) Remove the GAUGE fuse from the No. 1 relay block.
table below.
Standard resistance
1-2 Always Below 1 Ω
(c) Reinstall the GAUGE fuse.

NG REPLACE FUSE (GAUGE FUSE)
OK
5 CHECK HARNESS AND CONNECTOR (STOP LIGHT SWITCH ASSEMBLY - IGNITION

SWITCH ASSEMBLY)
(a) Disconnect the stop light switch assembly connector.

(b) Disconnect the ignition switch assembly.
Wire Harness Side: (c) Measure the resistance according to the value(s) in the
table below.
Stop Light Switch Connector Standard resistance:
Check for open
ES
S15 S15-4 - I6-10 Always Below 1 Ω
(d) Reconnect the stop light switch assembly connector.

(e) Reconnect the ignition switch assembly connector.
Ignition Switch Connector CONNECTOR (STOP LIGHT SWITCH
ASSEMBLY - IGNITION SWITCH ASSEMBLY)
I6
IG1
A175214E01
OK
6 INSPECT IGNITION SWITCH ASSEMBLY
(a) Disconnect the ignition switch assembly connector.

table below.
Standard resistance
Ignition Switch
ACC I6 All terminal LOCK 10 kΩ or higher
LOCK I6-9 (AM1) - I6-10 (IG1) ON Below 1 Ω
ON
(c) Reconnect the ignition switch assembly connector.
START NG REPLACE IGNITION SWITCH ASSEMBLY
IG1
AM1
A153627E07
OK
7 INSPECT FUSE (AM1 FUSE)
(a) Remove the AM1 fuse from the No.2 relay block.
No. 2 Relay Block:
table below.
Standard resistance
(c) Reinstall the AM1 fuse.

AM1 fuse ES
NG REPLACE FUSE (AM1 FUSE)
A155013E01
OK
REPAIR OR REPLACE HARNESS OR CONNECTOR (IGNITION SWITCH ASSEMBLY - BATTERY)
8 INSPECT FUSE (STOP FUSE)
(a) Remove the STOP fuse from the No.1 relay block.
No. 1 Relay Block (b) Measure the resistance according to the value(s) in the
table below.
Standard resistance
(c) Reinstall the STOP fuse.

STOP Fuse
NG REPLACE FUSE (STOP FUSE)
A164149E01
OK
9 INSPECT FUSE (HEAD FUSE)
(a) Remove the HEAD fuse from the No.2 relay block.
No. 2 Relay Block
table below.
Standard resistance
(c) Reconnect the HEAD fuse.

ES
HEAD Fuse NG REPLACE FUSE (HEAD FUSE)
A175215E01
OK
REPAIR OR REPLACE HARNESS OR CONNECTOR (STOP LIGHT SWITCH ASSEMBLY -

BATTERY)
Exhaust GAS Temperature Sensor Circuit

DTC P0544/A3

DTC P0545/A3
Exhaust Gas Temperature Sensor Circuit High

DTC P0546/A3
ES
DESCRIPTION
Exhaust Gas Temperature

Sensor (Bank 1 Sensor1)
Exhaust Gas Temperature Sensor:
ECM Exhaust Gas Temperature

Exhaust
Gas
Property of Output Voltage: DPR Catalytic Converter
Exhaust Gas Temperature Sensor °C (°F)

1,000 (1,832)
960 (1,760)
760 (1,400)
P0546 or P0233 detected
560 (1,040)
360 (680)
160 (320)
-40 (-40)
0 0.2 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 4.95 5.0
Exhaust Gas Temperature Sensor Voltage (V)
A164232E01
The exhaust gas temperature sensors are installed in front of and behind the DPR (*1) catalytic converter
to sense the exhaust gas temperature.
A thermistor built into the sensor changes its resistance value according to the exhaust gas temperature.
The lower the exhaust gas temperature is, the greater the thermistor resistance value becomes. The
exhaust gas temperature becomes, the lower the thermistor resistance value becomes.
The exhaust gas temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM
is applied to the exhaust gas temperature sensor from terminals THCI (bank 1 sensor 1) and THCO (bank
1 sensor 2) via resistor R.
The resistor R and the exhaust gas temperature sensor are connected in series. When the resistance
value of the exhaust gas temperature sensor changes in accordance with changes in the exhaust gas
temperature, the voltage at terminals THCI (bank 1 sensor 1) and THCO (bank 1 sensor 2) also changes.
Based on these signals, when DPR catalyst regeneration is needed, the ECM operates the injector to
obtain target upstream temperature of the DPR catalytic converter as mentioned through sensor 1. In
addition, the ECM monitors the rate of DPR catalytic converter temperature increase using sensor 2.
*1: Diesel Particulate active Reduction system
• Open or short in exhaust gas temperature sensor
Sensor 1 output is less than 0.2 V or more than 4.95 V (on upstream) circuit
P0544/A3
for 8 seconds or more (1 trip detection logic) • Exhaust gas temperature sensor (on upstream)
• ECM
ES
Sensor 1 output is less than 0.2 V for 8 seconds or (on upstream) circuit
P0545/A3
more (1 trip detection logic) • Exhaust gas temperature sensor (on upstream)
• ECM
Sensor 1 output is more than 4.95 V for 8 seconds or (on upstream) circuit
P0546/A3
more (1 trip detection logic) • Exhaust gas temperature sensor (on upstream)
• ECM
HINT:
• Sensor 1 represents a sensor located upstream on the DPR catalytic converter.
• Sensor 2 represents a sensor located downstream on the DPR catalytic converter.
• After confirming DTC P0544/A3, P0545/A3, P0546/A3, P2031/A3, P2032/A3, and P2033/A3, check
the upstream and downstream exhaust gas temperature by selecting the following menus on the
tester: Powertrain / Engine and ECT / Initial Exhaust Temp (In) and Initial Exhaust Temp (Out).
Result
Condition Exhaust Gas Temperature
Condition
Constant at 50 to 700°C (122 to 1,292°F) Normal
Idling after warm-up 0°C (32°F) Short circuit
1,000°C (1,832°F) Open circuit
WIRING DIAGRAM
E28
ECM
(bank 1 sensor 2)
2 1 1
E23 THCO ES
2 1 2
E23 THCI
E28
(bank 1 sensor 1)
28
E22 E2
ASM3-786
NOTICE:
1 READ VALUE OF Hino-DX (EXHAUST GAS TEMPERATURE)

monitor.
Standard:
Same as the actual exhaust gas temperature (50 to
700°C [122 to 1,292°F] during idling after warm-up),
and varies after an engine speed of 3,000 rpm is
maintained for 1 minute.
(e) Read the valve.
Result
1,000°C (1,832°F) A
0°C (32°F) (After warming up the engine) B

OK: Same as the actual exhaust gas temperature (50 to 700°C [122 to 1,292°F] during idling
after warm-up), and varies after maintaining the engine speed of 3,000 rpm for 1 minute after C
accelerating the engine from idling to 3,000 rpm
HINT:
• If there is a short circuit, the Hino-DX will indicate 0°C
(32°F).
• If there is an open circuit, the Hino-DX will indicate
1,000°C (1,832°F).
B Go to step 4
ES
2 READ VALUE OF Hino-DX (OPEN IN WIRE HARNESS)
(a) Disconnect the exhaust gas temperature sensor

connector.
ECM (b) Connect terminals 1 and 2 of the exhaust gas
temperature sensor wire harness side connector.
E28 (c) Connect the Hino-DX to the DLC 3.
THCO (e) The engine is stopped.
E2 monitor.
(g) Read the value.
Standard:
Exhaust Gas Temperature Sensor 0°C (32°F)
Connector (h) Reconnect the exhaust gas temperature sensor
connector.
NG Go to step 3
E28
Front View
ASM3-791
OK
REPLACE EXHAUST GAS TEMPERATURE SENSOR

3 READ VALUE OF Hino-DX (OPEN IN ECM)

connector.
ECM (b) Connect terminals THCI and E2 of the ECM connectors.
HINT:
E28 Before checking, do a visual and contact pressure check
on the ECM connector.
THCI
E2
ES
Exhaust Gas Temperature Sensor monitor.
(g) Read the value.
ECM Connector Standard:
E22 E23 0°C (32°F)
(h) Reconnect the exhaust gas temperature sensor
connector.
NG REPLACE ECM
E2 THCI
A099842E32
OK
REPAIR OR REPLACE HARNESS OR CONNECTOR (ECM - EXHAUST GAS TEMPERATURE

SENSOR)
4 READ VALUE OF Hino-DX (SHORT IN WIRE HARNESS)

Exhaust Gas Temperature Sensor connector.
E28 (c) Turn the ignition switch to the ON position.
THCI (e) Follow the Hino-DX screen display and set the ECU data
monitor.
Standard:
A083863E54 1,000°C (1,832°F)
(g) Reconnect the exhaust gas temperature sensor
connector.
OK REPLACE EXHAUST GAS TEMPERATURE
SENSOR
NG
5 READ VALUE OF Hino-DX (SHORT IN ECM)

ECM (c) Connect the Hino-DX to the DLC3.
E28 (d) Turn the ignition switch to the ON position.
THCI (f) Follow the Hino-DX screen display and set the ECU data
monitor.
ES E2 (g) Read the value.
Standard:
ECM Connector 1,000°C (1,832°F)
connector.
(i) Reconnect the ECM connector.
E23
NG REPLACE ECM
THCI
A116781E03
OK

SENSOR)
DTC P0560/96 System Voltage

DESCRIPTION
While the ignition switch is off, battery voltage is supplied to terminal BATT of the ECM for storing DTCs
and fuel injection feedback learning values.
Condition (a) or (b) continues: • Open in back-up power source circuit
(a) Significant decrease in battery voltage • Low battery voltage
P0560/96
(b) Open in back-up power source circuit (1 trip • Voltage converter
detection logic) • ECM
HINT: ES
If DTC P0560/96 appears, the ECM does not store other DTCs.
WIRING DIAGRAM
7 2 BATT
1
+24V OUTM E24
D8
DC-DC 1 Voltage Converter
7
Battery E23 E1
ECM
Battery
A164420E01
NOTICE:
1 CHECK HARNESS AND CONNECTOR (ECM - VOLTAGE CONVERTER)
(a) Disconnect the voltage converter connector.

ES table below.
ECM Connector Standard resistance:
Check for open
E24 E24-2 (BATT) - D8-7 (OUTM) Always Below 1 Ω
Check for short

E24-2 (BATT) or D8-7 (OUTM) -
BATT Always 10 kΩ or higher
Body ground

(e) Reconnect the voltage converter connector.
Voltage Converter Connector
CONNECTOR (ECM - BATTERY)
D8
OUTM A164421E02
OK
2 READ VALUE OF Hino-DX (BATTERY VOLTAGE)
(a) Disconnect the Hino-DX to the DLC3.

(b) Turn the ignition switch to the On position.
monitor.
(d) Read the values.
Standard voltage:
11 to 14 V
Reconnect the ECM connector.
NG CHECK VOLTAGE CONVERTER SYSTEM
OK
REPLACE ECM
DTC P0606 ECM / PCM Processor
DTC P0607/54 Control Module Performance

DESCRIPTION
P0606 ECM internal error (1 trip detection logic) ECM
P0607/54 ECM internal error (1 trip detection logic) ECM
ES
NOTICE:
1 CHECK DTC OUTPUT
(a) Clear the DTCs (See page ES-29).

(b) Turn the ignition switch off.
(c) Disconnect the negative battery terminal and wait for 1
minute.
(d) Connect the negative battery terminal.
(e) Turn the ignition switch to the ON position.
(f) Follow the Hino-DX screen display and set the Data
display.
(g) Read the DTCs.
Result
P0606 and/or P0607/54 A
No DTC output B
B CHECK FOR INTERMITTENT PROBLEMS
REPLACE ECM
DTC P0617/43 Starter Relay Circuit High

DESCRIPTION
While the engine is being cranked, positive battery voltage is applied to terminal STA of the ECM.
If the ECM detects the starter control (STA) signal while the vehicle is being driven, it determines that
there is a malfunction in the STA circuit. The ECM then illuminates the MIL and sets the DTC.
This monitor runs when the vehicle has been driven at 20 km/h (12.4 mph) for more than 20 seconds.
When conditions (a), (b) and (c) are met, positive (+B)
battery voltage of 10.5 V or more is applied to ECM for
• Starter relay circuit
ES P0617/43
20 seconds (1 trip detection logic):
(a) Vehicle speed is more than 20 km/h (12.4 mph)
• Ignition switch
• ECM
(b) Engine speed is more than 1,000 rpm
(c) STA signal is ON
WIRING DIAGRAM
9 AM1 ST1 3 ST
I6
Ignition Switch
18 ES
E23 STA
13 5
S6 S7
1 2
S8 S8
Starter
AM1
STA
GLOW
FL MAIN
1
1 S5
S4
Starter
Battery
Battery
ECM
A154226E01
NOTICE:
HINT:
• The following troubleshooting flowchart is based on the premise that the engine is cranked normally. If
the engine does not crank, proceed to the problem symptoms table (See page ES-21).
malfunction.
1 READ VALUE OF Hino-DX (STARTER SIGNAL)

ES monitor.
(d) Check the value displayed on the monitor when the
ignition switch is turned to the ON position and START
position.
OK
Ignition Switch Condition ON START
Starter Signal OFF ON
NG Go to step 2
OK
REPLACE ECM
(a) Disconnect the ignition switch connector.

table below.
Standard resistance
Ignition Switch
Tester Connection Ignition Switch Position Specified Condition
ACC I6 All terminals LOCK 10 kΩ or higher
LOCK I6-9 (AM1) - I6-3 (ST1) START Below 1 Ω
ON
NG REPLACE IGNITION SWITCH ASSEMBLY

START
AM1 ST1
A153627E04
OK
REPAIR OR REPLACE HARNESS OR CONNECTOR (ECM - IGNITION SWITCH)

VIN not Programmed or Mismatch - ECM / PCM

DTC P0630/89
*E2
DESCRIPTION
DTC P0630/89 is set when the Vehicle Identification Number (VIN) is not stored in the Engine Control
Module (ECM) or the input VIN is not accurate. Input the VIN with the Hino-DX.
• VIN not stored in ECM
P0630/89 ECM
• Input VIN in ECM not accurate
ES
1 CHECK DTC OUTPUT

display.
(d) Read the DTCs.
Result
P0630/89 A
If any DTCs other than P0630/89 are output,

troubleshoot those DTCs first.
NOTICE:
If P0630/89 is set, the VIN must be input to the ECM
using the Hino-DX. However, all DTCs are cleared
automatically by the tester when inputting the VIN. If
DTCs other than P0630/89 are set, check them first.
B GO TO DTC CHART (See page ES-41)
2 INPUT VIN WITH Hino-DX
(a) Input the VIN code (Refer to the help of the Hino-DX).
NEXT
END
DTC P0863/17 EFI - ECT Communication Error *E3

DESCRIPTION
The ECM transmits accelerator opening signal and idle signal etc. to the transmission control ECU. The
ECM receives rockup signal and sift range signal etc. on the one hand from the transmission control ECU.
All conditions below are detected continuously for 5
• Wire harness and connector (serial communication
seconds or more:
signal circuit)
P0863/17 (a) Ignition switch ON
• Transmission control ECU
(b) Communication error between ECM and
• ECM
transmission control ECU
ES
ECM Transmission control ECU
D31 B24
EFI+ EFI+
D30 B23
EFI- EFI-
D25 B21
ECT+ ECT+
D24 B20
ECT- ECT-
C072184E01
NOTICE:
HINT:
1 CHECK HARNESS AND CONNECTOR (ECM - TRANSMISSION CONTROL ECU)

Transmission control ECU (b) Disconnect the transmission control connector.
table below.
Check for open
EFI- ECT+
EFI+
E25-24 (ECT-) - B20 (ECT-) Always Below 1 Ω ES
ECT- E25-25 (ECT+) - B21 (ECT+) Always Below 1 Ω
E25-30 (EFI-) - B23 (EFI-) Always Below 1 Ω
Connector B
E25-31 (EFI+) - B24 (EFI+) Always Below 1 Ω
ECU
ECT- Check for short
E25-24 (ECT-) or B20 (ECT-) -
EFI- Body ground
ECT+ E25-25 (ECT+) or B21 (ECT+) -

Body ground
EFI+ E25-30 (EFI-) or B23 (EFI-) - Body
ground
C073611E02 E25-31 (EFI+) or B24 (EFI+) -
Body ground

CONNECTOR (ECM - TRANSMISSION
CONTROL ECU)
OK
2 REPLACE TRANSMISSION CONTROL ECU
NEXT
3 CLEAR DTC

(b) Set the starter switch to ON position.
(c) Follow the Hino-DX screen display, clear the DTC.
NEXT
4 CONFIRM DTC
(a) Set the starter switch to ON position.

(b) Follow the Hino-DX screen display, confirm the DTC.
Result
No output A

P0863/17 B
B REPLACE ECM
SYSTEM OK
ES
Power Take-off Accel Position Sensor Circuit

DTC P1133
High
DESCRIPTION
The outer accel position sensor, mounted on the accel bellcrank, is used to control the PTO. The sensor
converts the opening degrees of the accelerator pedal into voltage of 0 to 5 V and output it to the ECM.
• Short in accel position sensor circuit
Short in accel position sensor circuit for more than 1
P1133 • Accel position sensor
second
• ECM
ES
WIRING DIAGRAM
35
VC 1
E23 VCP
26
VA 2
E23 VPA
34
E2 3
E23 E2P
A4
Accel Position Sensor ECM
A163952E01
NOTICE:
1 CHECK ECM (VCP VOLTAGE)

E23 table below.
Standard voltage
Tester Connection Switch Condition Specified Condition
E23-35 (VCP) - E23-34 Ignition switch in the
4.5 to 5.5 V
(E2P) ON position
VCP E2P
ES ECM Connector
NG REPLACE ECM
A153569E74
OK
2 CHECK ECM (VCP VOLTAGE)

E23 table below.
Standard voltage
Tester Connection PTO Switch Condition Specified Condition
E23-26 (VPA) - E23-34
Fully closed 0.7 to 1.0 V
(E2P)
E2P VPA E23-26 (VPA) - E23-34
Fully open 3.3 to 3.9 V
ECM Connector (E2P)
A153569E79 E23-26 (VPA) - E23-34 Fully closed → Fully Voltage changes
(E2P) open constantly
NG Go to step 3
OK
REPLACE ECM
3 INSPECT ACCEL BELLCRANK ASSEMBLY (ACCEL POSITION SENSOR)
(a) Disconnect the accel position sensor connector.

Accel Position Sensor Connector table below.
Standard resistance
VA VC A4-1 (VC) - A4-3 (E2) Always 1.6 to 2.4 kΩ
Resistance changes
A4 A4-2 (VA) - A4-3 (E2) Released → Depressed
constantly
E2 A163821E03 (c) Reconnect the accel position sensor connector.

NG REPLACE ACCEL BELLCRANK ASSEMBLY
(ACCEL POSITION SENSOR)
OK
4 CHECK HARNESS AND CONNECTOR (ACCEL POSITION SENSOR - ECM)
(a) Disconnect the accel position sensor connector.

Accel Position Sensor Connector table below.
Standard resistance (Check for open)
VC VA Tester Connection Condition Specified Condition
E23-35 (VCP) - A4-1
ES
A4 Always Below 1 Ω
(VC)
E23-26 (VPA) - A4-2 (VA) Always Below 1 Ω
E2
E23-34 (E2P) - A4-3 (E2) Always Below 1 Ω
Standard resistance (Check for short)

E23-35 (VCP) - A4-1
(VC) - Body ground
E23-26 (VPA) - A4-2 (VA)
- Body ground
E23-34 (E2P) - A4-3 (E2)
VPA ECM Connector Always 10 kΩ or higher
- Body ground
VCP E2P (d) Reconnect the accel position sensor connector.

A163822E03
CONNECTOR (ACCEL POSITION SENSOR -
ECM)
OK
REPLACE ECM
DTC P1238/78 Injector Malfunction

DESCRIPTION
The ECM detects combustion deterioration for a specific cylinder.
HINT:
• A cylinder which has an injection volume compensation value that varies from other cylinders may be
malfunctioning.
• If DTC P0093/78 (Fuel leaks in high-pressure area) is present simultaneously, a leakage malfunction of
the injector for the affected cylinder probably has occurred.
• If DTC P0200/97 (Open or short in EDU or injector circuit) is present simultaneously, there probably is
ES a fault in the circuit between the ECM and the injector. This fault may also be as a result of the EDU.
• If only DTC P1238/78 (Injector malfunction) is present, the probable cause is an injector mechanical
malfunction or insufficient compression (valve etc), not an open or short malfunction of the ECM, EDU
and injector circuit.
• Solenoid valve of the injector is the same type as that of the pressure discharge valve.
DTC No. DTC Detection Condition Main Trouble Area Related Trouble Area
• Injector
• EDU (P0200/97 is set
simultaneously)
• Open or short in engine wire
Engine speed fluctuation is large when harness (P0200/97 is set • Valve timing
P1238/78
idling (2 trip detection logic) simultaneously) • ECM
• Connector connection (P0200/
97 is set simultaneously)
• Compression pressure
• Valve clearance
HINT:
After confirming DTC P1238/78, check the internal fuel pressure in "Powertrain / Engine and ECT / Data
List / Fuel Press" using the Hino-DX.
Reference:
Engine Speed Fuel Pressure (MPa)
Idling Approximately 27 to 37
2,500 rpm (No engine load) Approximately 63 to 71
MONITOR DESCRIPTION
P1238/78 (Injection malfunction, except open or short in injector circuit):
This DTC will be set if the engine speed fluctuation between each cylinder is large. The ECM monitors
changes in the crankshaft rotation speed using the crankshaft position sensor in order to detect improper
combustion. The camshaft position sensor also plays a role in determining which cylinder has the
problem. The fluctuation counter increments when irregular crankshaft rotation speed variation exceeds
the threshold with the engine idling. Therefore, if any one of the cylinders is operating poorly (rough idle),
the ECM sets this DTC.
NOTICE:
After replacing an injector, the injector needs compensation (See page ES-7).
HINT:
• After clearing the DTC, let the engine idle for 10 minutes after warm-up, and then confirm that P1238/
78 is not present again.
• If DTCs other than P1238/78 are present simultaneously, first perform troubleshoot those DTCs.
1 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P1238/78)

display.
(d) Read DTCs.
Result
P1238/78 A ES
HINT:
If codes other than P1238/78 are output, perform
troubleshooting for those DTCs first.
B GO TO DTC CHART
2 CHECK HARNESS AND CONNECTOR (ENGINE WIRE HARNESS)
HINT:
Check the wire harness and connector connections.
CONNECTOR
OK
3 READ VALUE OF INJECTION VOLUME (COMPENSATION OF INJECTION VOLUME

BETWEEN CYLINDERS)

monitor.
(d) Read the injection compensation volume #1 to #4.
Standard
Result Compensatory Injection Volume (mm3)
Standard -4.9 to 4.9 or less
HINT:
• If the injector is malfunctioning, the compensatory
injection volume remains at -5.0 mm3 or 5.0 mm3.
• The compensatory injection volume is usually
between -2.0 mm3 and 2.0 mm3.
(e) Cylinders that have a compensation value which is more
than the value specified above are considered to be
faulty. Use the following steps to inspect and repair the
cylinder.
Result
Result Proceed to
Faulty cylinder is not identified A
Faulty cylinder is identified B
B Go to step 5
4 PERFORM ACTIVE TEST BY Hino-DX (INJECTION CUT FOR IDENTIFYING

ES MALFUNCTION CYLINDER)

(c) Follow the Hino-DX screen display to set Active test
power balance, and perform one of #1 to #4.
(d) Check the four cylinders in sequence to identify a faulty
cylinder by performing the power-balance inspection.
HINT:
If the engine idle does not change when an injector is
disabled, the cylinder being tested is malfunctioning.
NEXT
5 CHECK CYLINDER COMPRESSION PRESSURE OF MALFUNCTIONING CYLINDER
(a) Check the cylinder compression pressure (See chapter

EM).
Standard:
2,700 kPa (27.5 kgf/cm2, 392 psi)
Minimum pressure:
2,200 kPa (22.4 kgf/cm2, 319 psi)
Difference between each cylinder:
500 kPa (5.1 kgf/cm2, 73 psi)
NG CHECK ENGINE TO DETERMINE CAUSE OF
LOW COMPRESSION
OK
6 CHECK IF DTC OUTPUT RECURS (DTC P1238/78)
HINT:
After clearing the DTC, let the engine idle for 10 minutes after
warm-up, and then confirm that P1238/78 is not present
again.
NG
7 REPLACE INJECTOR ASSEMBLY
NEXT
CHECK IF DTC OUTPUT RECURS (DTC P1238/78)
ES
DTC P1425/A4 Differential Pressure Sensor Circuit *E2
DTC P1427/A4 Differential Pressure Sensor Circuit Low *E2
DTC P1428/A4 Differential Pressure Sensor Circuit High *E2

DESCRIPTION
ES
Property of Output Voltage:
Differentail Pressure Sensor Voltage (V)
5,000
ECM 4,800
Differential Pressure
Sensor 4,700 P1425/A4 or P1428/A4
detected
P1425/A4 or
1,530 P1427/A4
0.750 detected
0.530
Exhaust
Gas 0.400
0
-0.5 0 20.0 100.0
Exhaust Gas Differential Pressure (kPa)
DPR Catalytic Converter
A164231E01
The two sensing chambers of the differential pressure sensor are mounted to monitor the pressure before
and after the DPR (*2) catalytic converter. The sensor itself is not located on the engine assembly in order
to reduce the influence of vibration. The sensor is a semiconductor-type that is not influenced by exhaust
gases.
The ECM compares the exhaust gas pressure before and after DPR catalytic converter by monitoring the
pressure using the upstream and downstream sensing chambers of the differential pressure sensor. If the
difference between the pressure before and after the catalytic converter exceeds a predetermined level,
the ECM judges that the catalytic converter has clogged with particulate matter (PM). When the ECM
judges that a partially clogged condition exists, the ECM begins to perform DPR catalyst regeneration.
When the output voltage of the sensor deviates from the normal operating range, the ECM interprets this
as a malfunction of the sensor circuit, and sets DTC P1425/A4, P1427/A4, or P1428/A4 and illuminates
the MIL.

HINT:
If the vacuum hoses of the differential pressure sensor are incorrectly connected (crossed), the ECM
interprets this as abnormal pressure difference, DTC P1426/A4 (Differential Pressure Sensor
[Installation]) will be set and the MIL will be illuminated.
• Open or short in differential pressure sensor
circuit
Differential pressure sensor output voltage is less than 0.4 V, or • Incorrect differential pressure sensor hose
P1425/A4
more than 4.8 V for 1 seconds or more (1 trip detection logic) routing
• Differential pressure sensor
• ECM
• Open or short in differential pressure sensor ES
circuit
Differential pressure sensor output voltage is less than 0.4 V • Incorrect differential pressure sensor hose
P1427/A4
for 1 seconds or more (1 trip detection logic) routing
• ECM
• Open or short in differential pressure sensor
circuit
Differential pressure sensor output voltage is more than 4.8 V • Incorrect differential pressure sensor hose
P1428/A4
for 1 seconds or more (1 trip detection logic) routing
• ECM
HINT:
• "A" in the above table indicates that the MIL flashes 10 times.
• DTC P1426/A4 (Differential pressure sensor [installation]) will be present if there is incorrect vacuum
hose routing to the differential pressure sensor.
• After confirming DTC P1425/A4, P1427/A4 and P1428/A4, check the differential pressure by selecting
the following menus on the tester: Powertrain / Engine and ECT / Data List / DPNR Differential
Pressure.
Result
Condition Differential Pressure Output Sensor Condition
Ignition Switch in the ON Position Approximately 0 kPa Normal
Always -5 kPa or 100 kPa Open or short circuit
3,000 rpm (No engine load) Negative output Incorrect arrangement of hose piping
WIRING DIAGRAM
D14 Differential Pressure Sensor
ECM
18
3
VC E22 VC
27
2
PEX E23 PEX
28
1
E2 E22 E2
ASM3-787
NOTICE:
1 READ VALUE OF Hino-DX (DIFFERENTIAL PRESSURE)

ES (d) Follow the Hino-DX screen display and set the ECU data
monitor.
(e) Check that differential pressure is within the specification
below.
Result
Condition Differential Pressure Proceed to
-5 kPa or less A
Always -1 to 1 kPa B
100 kPa C
C Go to step 3
2 CHECK CONNECTION OF VACUUM HOSE (DIFFERENTIAL PRESSURE SENSOR -

CATALYST CONVERTER)
(a) Check if the vacuum hose routing between the

differential pressure sensor and the catalyst converter is
correct.
(b) Check that there is no exhaust gas leakage between the
differential pressure sensor and the catalyst converter.
NG RECONNECT TO VACUUM HOSE
OK
3 CHECK BLOCKAGE OF VACUUM HOSE AND CATALYST CONVERTER
CAUTION:
Be careful of being burned by exhaust gases during the
following inspection.
(a) Disconnect the vacuum hose (both upstream and
downstream) on the differential pressure sensor.
(c) Check if there are exhaust gas pulsations from both
vacuum hoses during idling.
NG REPLACE CLOGGED PARTS
OK
4 CHECK HARNESS AND CONNECTOR (DIFFERENTIAL PRESSURE SENSOR - ECM)
(a) Disconnect the differential pressure sensor connector.

Wire Harness Side: (b) Disconnect the ECM connectors.
Differential Pressure Sensor Connector table below.
Check for open
Specified
ES
Tester Connection Condition
D14 Condition
PEX (E23-27) - PEX (D14-2) Always Below 1 Ω
VC (E22-18) - VC (D14-3) Always Below 1 Ω
E2 PEX VC E2 (E22-28) - E2 (D14-1) Always Below 1 Ω

Specified
E22 E23 Tester Connection Condition
Condition
PEX (E23-27) or PEX (D14-2) - Body
ground
VC ECM Connector VC (E22-18) or VC (D14-3) - Body
ground
PEX
(d) Reconnect the differential pressure sensor connector.
E2 ASM3-788
(e) Reconnect the ECM connectors.
CONNECTOR (DIFFERENTIAL PRESSURE
SENSOR - ECM)
OK
REPLACE DIFFERENTIAL PRESSURE SENSOR ASSEMBLY

Differential Pressure Sensor Installation Error

DTC P1426/A4
*E2
DESCRIPTION
ES Property of Output Voltage:
Differentail Pressure Sensor Voltage (V)
5,000
ECM 4,800
Differential Pressure
Sensor 4,700 P1425/A4 or P1428/A4
detected
P1425/A4 or
1,530 P1427/A4
0.750 detected
0.530
Exhaust
Gas 0.400
0
-0.5 0 20.0 100.0
Exhaust Gas Differential Pressure (kPa)
DPR Catalytic Converter
A164231E01
The two sensing chambers of the differential pressure sensor are mounted to monitor the pressure before
and after the DPR (*2) catalytic converter. The sensor itself is not located on the engine assembly in order
to reduce the influence of vibration. The sensor is a semiconductor-type that is not influenced by exhaust
gases.
The ECM compares the exhaust gas pressure before and after DPR catalytic converter by monitoring the
pressure using the upstream and downstream sensing chambers of the differential pressure sensor. If the
difference between the pressure before and after the catalytic converter exceeds a predetermined level,
the ECM judges that the catalytic converter has clogged with particulate matter (PM). When the ECM
judges that a partially clogged condition exists, the ECM begins to perform DPR catalyst regeneration.
HINT:
If the vacuum hoses of the differential pressure sensor are incorrectly connected (crossed), the ECM
interprets this as abnormal pressure difference, DTC P1426/A4 (Differential Pressure Sensor
[Installation]) will be set and the MIL will be illuminated.

• Incorrect arrangement differential pressure sensor
hose piping
• Differential pressure sensor vacuum hose is
When output voltage from the differential pressure
clogged
P1426/A4 sensor indicates positive pressure as negative pressure
• Blockage in vacuum transmitting pipe sub-
(and vice versa) (1 trip detection logic)
assembly
• ECM
HINT:
• DTC P1425/A4 (Differential pressure sensor circuit), DTC P1427/A4 (Differential pressure sensor
circuit low) and/or DTC P1428/A4 (Differential pressure sensor high) will be present if there is an open
or short in the differential pressure sensor circuit. ES
• After confirming DTC P1426/A4, check the differential pressure by selecting the following menus on
the tester: Powertrain / Engine and ECT / Data List / DPNR Differential Pressure.
Result
Always 3 kPa Open or short circuit
1 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P1426/A4)

display.
(e) Read the DTCs.
Result
P1426/A4 A
P1426/A4 and other DTCs B
HINT:
If codes other than P1426/A4 are output, perform
troubleshooting for those DTCs first.
B GO TO DTC CHART

CATALYST CONVERTER)
(a) Check if vacuum hose routing between the differential

pressure sensor and the catalyst converter is correct.
NG RECONNECT TO VACUUM HOSE
OK
3 CHECK BLOCKAGE OF VACUUM HOSE AND CATALYST CONVERTER
CAUTION:
Be careful of being burned by exhaust gases during the
following inspection.
(a) Disconnect the vacuum hose (both upstream and
downstream) on the differential pressure sensor.
ES (c) Check if there are exhaust gas pulsations from both
vacuum hoses during idling.
NG REPLACE CLOGGED PARTS
OK

(b) Turn the ignition switch to the ON position and the
engine is stopped.
monitor.
(d) Check that differential pressure is within the specification
below.
Result
Always -5 kPa or 100 kPa Open or short circuit
NG
REPLACE DIFFERENTIAL PRESSURE SENSOR ASSEMBLY

DTC P1530/92 Engine Emergency Halt Switch

DESCRIPTION
Some vehicles are equipped with an emergency halt switch due to the conversion of the vehicle. In this
case, this DTC is set if a vehicle speed signal and emergency halt switch ON signal are input to the ECM
simultaneously. If this DTC is set, inspect and repair the emergency halt switch circuit.
HINT:
Different types of emergency halt switches may be used according to the type of vehicle conversion.
Either of the following condition (a) or (b) is met:
(a) Both of the following conditions (1) and (2) are met: ES
(1) Engine cranking • Emergency halt switch circuit
P1530/92 (2) STOP signal on • Emergency halt switch
(b) Both of the following conditions (3) and (4) are met • ECM
(3) Engine speed 10 km/h (6.3 mph) or more
(4) STOP signal on
Injector ID Codes Abnormal or Not Registrated

DTC P1601/89
(EEPROM)
DESCRIPTION
When either condition below is met:
• Injection ID code is not registered (1 trip detection
• Injector ID code
P1601/89 logic)
• ECM
• Injection ID code is registered (1 trip detection
logic)
ES NOTICE:
• When an injector is replaced, the injector's compensation code must be input into the ECM.
When the ECM is changed, all of the existing injector compensation codes must be input into
the new ECM.
• Injector compensation codes are unique, 30-digit, alphanumeric values printed on the head
portion of each injector. If an incorrect injector compensation code is input into the ECM, the
engine assembly may rattle or engine idling may become rough. In addition, engine failure may
occur and the life of the engine may be shortened.
1. When replacing the ECM with a new one, input all the injector's compensation codes into the
new ECM as follows:
(a) Prior to replacing the ECM, use the intelligent tester to read and save each injector's
compensation code from the original ECM.
(b) After installing a new ECM, input the saved compensation codes into the new ECM using the
tester.
(c) Turn the ignition switch off and then turn the tester off.
(d) Wait for at least 30 seconds.
(e) Turn the ignition switch to the ON position and then turn the tester on.
(f) Clear DTC P1601 stored in the ECM using the tester.
HINT:
• Each injector has different fuel injection characteristics. In order to optimize the fuel
injections, the ECM uses the compensation codes to balance the different fuel injections
between each injector.
• When you first turn the ignition switch to the ON position after replacing the ECM or an
injector(s), DTC P1601 is set. If an injector was replaced, the compensation code for the new
injector will need to be registered in the ECM. If the ECM was replaced, the compensation
codes for the injector must be registered to the new ECM. Manually clear the DTCs upon
completion of compensation code registration.
NOTICE:
After replacing the ECM, the new ECM needs registration (See page ES-3) and initialization (See
page ES-3).
HINT:
Read freeze frame data using the intelligent tester. The ECM records vehicle and driving condition
information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data
can be helpful in determining whether the vehicle was running or stopped, whether the engine was
warmed up or not, whether the air fuel ratio was lean or rich, as well as other data recorded at the time of
a malfunction.
1 CHECK INJECTOR COMPENSATION CODE
(a) Read the injector compensation code (See page ES-7).

OK:
Injector ID codes stored in the ECM match injector
ID codes of the installed injectors.
NG PERFORM REGISTRATION INJECTOR ID
CODE
OK
REPLACE ECM
ES
DTC P1611/17 IC Circuit Malfunction

DESCRIPTION
P1611/17 ECM inside error ECM
NOTICE:
ES injector compensation (See page ES-7).

(c) Clear the DTCs (See page ES-29).
(d) Turn the ignition switch off.
(f) Follow the Hino-DX screen display and set the Data
display.
(g) Read the DTCs.
Result
P1611/17 A
No DTC output B
REPLACE ECM
DTC P1674/36 Solenoid for Exhaust Brake Circuit Malfunction

DESCRIPTION
The exhaust brake VSV, mounted on the exhaust retarder, opens and closes according to the signals from
the ECM. The ECM receives the signals from the clutch switch and exhaust retarder switch. Through the
brake VSV, the ECM controls the negative pressure applied to the diaphragm in the retarder.
• Open or short in exhaust brake solenoid circuit
Open or short in exhaust brake solenoid circuit for more
P1674/36 • Exhaust brake solenoid
than 3 seconds with clutch pedal released
• ECM
ES
WIRING DIAGRAM
ECM
E3
Exhaust Brake Solenoid
8
1
E23 EXB
7
2
E23 E1
ASM3-789
NOTICE:
HINT:
1 CHECK ECM (EXB VOLTAGE)

E23 table below.
Standard voltage
Exhaust brake is
E23-8 (EXB) - E23-7 (E1) 11 to 14 V
operating
ES E1 EXB
ECM Connector
NG Go to step 2
A153569E11
OK
REPLACE ECM
2 INSPECT EXHAUST BRAKE VALVE ASSEMBLY
(a) Remove the exhaust brake solenoid.

(b) Check operation of the exhaust brake solenoid.
B Result
C Port Connection Specified Condition
A-B Air does not flow
1 (+)
Air flows
A-B
(when battery voltage is applied to terminals 1 and 2)
A A-C Air flows
2 (-)
Air does not flow
A-C
A153620E01 (when battery voltage is applied to terminals 1 and 2)
NG REPLACE EXHAUST BRAKE VALVE

ASSEMBLY
OK
3 CHECK HARNESS AND CONNECTOR (ECM - EXHAUST BRAKE VALVE ASSEMBLY)
(a) Disconnect the exhaust brake solenoid connector.

Exhaust Brake Solenoid Connector table below.
Check for open
E3
E3-1 - E23-8 (EXB) Always Below 1 Ω ES
ECM Connector
E3-1 or E23-8 (EXB) - Body
ground
E23 (d) Reconnect the exhaust brake solenoid connector.

CONNECTOR (ECM - EXHAUST BRAKE
EXB VALVE ASSEMBLY)
ASM3-799
OK
REPLACE ECM
Particulate Trap Efficiency Below Threshold

DTC P2002/94
(Bank1) *E2
DESCRIPTION
A DPR (Diesel Particulate active Reduction system) catalyst is located in the exhaust pipe. A wall-flow
type DPR catalyst, which filters all exhaust gas through ceramic walls with high heat resistance, is used to
allow the exhaust gas to be organized by the catalyst when flowing through the porous ceramic structure,
reducing PM (Particulate Matter) drastically.
Oxidation Catalyst
ES
Exhaust
Gas Exhaust
Catalyst Converter Gas
A154780E01

• Differential pressure sensor detects abnormally
high differential pressure while vehicle is running.
• Exhaust gas temperature sensor detects
• Exhaust gas temperature sensor
abnormally high temperature while vehicle is
running.
• DPR manifold converter
• Vehicle is driven continuously without performing
P2002/94 • Open or short in differential pressure sensor circuit
forcible regeneration function although DPR switch
light is blinking, and amount of accumulated PM
circuit
exceeds specified value.
• ECM
• During forcible regeneration function, temperature
of monolithic converter assembly does not increase
although injection volume is as specified.
NOTICE:
HINT:
malfunction.
• If the amount of accumulated PM exceeds the specified value, DTC P2002/94 is set and the system
enters fail-safe mode, in which the system limits the engine power.
• Check the amount of engine oil after troubleshooting is finished.
• If the amount of engine oil is more than the specified level, replace the engine oil.
1 INSPECT DPR SWITCH
(a) Use the table below to troubleshoot each problem

symptom.
Result
Condition Proceed to
DPR switch light is not blinking A
DPR switch light is blinking B
B Go to step 5 ES
A

display.
(d) Read the DTCs.
Result
P2002/94 A
B GO TO DTC CHART
3 READ VALUE OF FREEZE FRAME DATA (EXHAUST GAS TEMPERATURE)

monitor.
(d) Read the value.
Result
Item Exhaust Temperature Proceed to
Initial Exhaust Temp (IN) Less than 740°C (1,364°F) A
Initial Exhaust Temp (OUT) Less than 940°C (1,724°F) A
Initial Exhaust Temp (IN) 740°C (1,364°F) or more B
Initial Exhaust Temp (OUT) 940°C (1,724°F) or more C
HINT:
When troubleshooting abnormal temperature detection
by exhaust temperature sensor (upstream), check that
the hose between the turbocharger and the intake
manifold is connected properly.
B GO TO ABNORMAL TEMPERATURE
DETECTION BY EXHAUST TEMPERATURE
SENSOR (DOWNSTREAM)
C GO TO ABNORMAL TEMPERATURE
DETECTION BY EXHAUST TEMPERATURE
SENSOR (UPSTREAM)
ES 4 READ VALUE OF FREEZE FRAME DATA (DIFFERENTIAL PRESSURE)

monitor.
(d) Read the value.
Result
Item Differential Pressure Proceed to
DPR Differential Pressure 15 kPa or less A
DPR Differential Pressure 15 kPa or more B
B GO TO CLOGGING BY DPR CATALYTIC

CONVERTER
GO TO CLOGGING BY DPR CATALYTIC CONVERTER (GO TO STEP 8)
(a) Allow the engine to idle for at least 5 minutes.

monitor - DPR/DPNR differential pressure.
HINT:
• Perform initialization with the engine warmed up
(engine coolant temperature is 60°C (140°F) or more
and fuel temperature is 20°C (60°F) or more).
• If the exhaust gas temperature is high, the differential
pressure cannot be measured correctly.
• If the differential pressure is outside the normal range,
the monolithic converter assembly may have
deteriorated or the monolithic converter assembly
may be clogged with PM.
Result
Engine Speed (no engine load) Differential Pressure Proceed to
3,500 to 3,600 rpm (Exhaust gas
temperature (up stream) is 200°C (392°F) 30 kPa or more A
or less)
temperature (up stream) is 200°C (392°F) 30 kPa or less B
or less)
B Go to step 9
A
ES
6 CLEAN EXHAUST SYSTEM
(a) Clean the catalytic converter and monolithic converter

(See chapter EC).
NEXT

HINT:
Result
temperature (up stream) is 200°C (392°F) 30 kPa or less A
or less)
temperature (up stream) is 200°C (392°F) 30 kPa or more B
or less)
B REPLACE MONOLITHIC CONVERTER

ASSEMBLY
A
(a) Perform the forcible regeneration function (See page ES-

20).
(b) After the forcible regeneration is completed, allow the
engine to idle for at least 5 minutes.
(d) Check the differential pressure when the exhaust gas
temperature sensor indicates 200°C (392°F) or less.
ES HINT:
Result
or less)
or less)

ASSEMBLY
END
(a) Perform the forcible regeneration function (See page ES-

20).
(b) After the forcible regeneration is completed, allow the
(d) Check the differential pressure when the exhaust gas
HINT:

Result
or less) ES
or less)

ASSEMBLY
END
Exhaust Gas Temperature Sensor Circuit (Bank

DTC P2031/A3
1 Sensor 2) *E2

DTC P2032/A3
Exhaust Gas Temperature Sensor Circuit High

DTC P2033/A3
ES
DESCRIPTION
Exhaust Gas Temperature

Exhaust Gas Temperature Sensor:
ECM Exhaust Gas Temperature

Exhaust
Gas
Property of Output Voltage: DPR Catalytic Converter
Exhaust Gas Temperature Sensor °C (°F)

1,000 (1,832)
960 (1,760)
760 (1,400)
560 (1,040)
360 (680)
160 (320)
-40 (-40)
0 0.2 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 4.95 5.0
Exhaust Gas Temperature Sensor Voltage (V)
A164232E01
The exhaust gas temperature sensors are installed in front of and be hind the DPR (*1) catalytic converter
to sense the exhaust gas temperature.
A thermistor built into the sensor changes its resistance value according to the exhaust gas temperature.
The lower the exhaust gas temperature, the greater the thermistor resistance value. The higher exhaust
gas temperature, the lower the thermistor resistance value.
The exhaust gas temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM
is applied to the exhaust gas temperature sensor from terminals THCI (bank 1 sensor 1) and THCO (bank
1 sensor 2) via resistor R.
The resistor R and the exhaust gas temperature sensor are connected in series. When the resistance
value of the exhaust gas temperature sensor changes in accordance with changes in the exhaust gas
temperature, the voltage at terminals THCI (bank 1 sensor 1) and THCO (bank 1 sensor 2) also changes.
Based on these signals, when DPR catalyst regeneration is needed, the ECM operates the injector to
obtain target upstream temperature of the DPR catalytic converter as mentioned through sensor 1. In
addition, the ECM monitors the rate of DPR catalytic converter temperature increase using sensor 2.
*1: Diesel Particulate Active Reduction System
Sensor 2 output is less than 0.2 V or more than 4.95 V (on downstream) circuit
P2031/A3
for 8 seconds or more (1 trip detection logic) • Exhaust gas temperature sensor (on downstream)
• ECM
ES
Sensor 2 output is less than 0.2 V for 8 seconds or
(on downstream) circuit
P2032/A3 more
• Exhaust gas temperature sensor (on downstream)
• ECM
Sensor 2 output is more than 4.95 V for 8 seconds or
(on downstream) circuit
P2033/A3 more
• Exhaust gas temperature sensor (on downstream)
• ECM
HINT:
• "A" in the above table indicates that the MIL flashes 10 times.
• Sensor 1 represents a sensor located upstream on the DPR catalytic converter.
• Sensor 2 represents a sensor located downstream on the DPR catalytic converter.
• After confirming DTC P2031/A3, P2032/A3, and P2033/A3, check the upstream and downstream
exhaust gas temperature by selecting the following menus on the tester: Powertrain / Engine and ECT
/ Initial Exhaust Temp (In) and Initial Exhaust Temp (Out).
Result
Condition Exhaust Gas Temperature
Condition
Constant at 50 to 700°C (122 to 1,292°F) Normal
Idling after warm-up 0°C (32°F) Short circuit
1,000°C (1,832°F) Open circuit
WIRING DIAGRAM
Refer to DTC P0544/A3 (See page ES-143).
NOTICE:
1 READ VALUE OF Hino-DX (EXHAUST GAS TEMPERATURE)

monitor.
(e) Read the value of exhaust gas temperature.
Standard:
Same as the actual exhaust gas temperature (50 to
700°C [122 to 1,292°F] during idling after warm-up),
and varies after an engine speed of 3,000 rpm is
maintained for 1 minute.
Result
1,000°C (1,832°F) A
0°C (32°F) (After warming up the engine) B
OK: Same as the actual exhaust gas temperature (50 to 700°C [122 to 1,292°F] during idling
after warm-up), and varies after maintaining the engine speed of 3,000 rpm for 1 minute after C
ES accelerating the engine from idling to 3,000 rpm
HINT:
• If there is a short circuit, the Hino-DX will indicate 0°C
(32°F).
• If there is an open circuit, the Hino-DX will indicate
1,000°C (1,832°F).
B Go to step 4
2 READ VALUE OF Hino-DX (OPEN IN WIRE HARNESS)

connector.
ECM (b) Connect terminals 1 and 2 of the exhaust gas
temperature sensor wire harness side connector.
E28 (c) Connect the Hino-DX to the DLC 3.
THCO (e) The engine is stopped.
E2 monitor.
(g) Read the value of exhaust gas temperature.
Standard:
Exhaust Gas Temperature Sensor 0°C (32°F)
Connector (h) Reconnect the exhaust gas temperature sensor
connector.
NG Go to step 3
E28
Front View
ASM3-791
OK
REPLACE EXHAUST GAS TEMPERATURE SENSOR

3 READ VALUE OF Hino-DX (OPEN IN ECM)

connector.
ECM (b) Connect terminals THCO and E2 of the ECM
connectors.
E28 HINT:
Before checking, do a visual and contact pressure check
THCO on the ECM connector.
E2
ES
monitor.
(g) Read the value of exhaust gas temperature.
E22 E23 Standard:
0°C (32°F)
connector.
THCO
NG REPLACE ECM
E2
ASM3-793
OK

SENSOR)
4 READ VALUE OF Hino-DX (SHORT IN WIRE HARNESS)

connector.
E28 (c) Turn the ignition switch to the ON position.
THCO (e) Follow the Hino-DX screen display and set the ECU data
monitor.
E2 (f) Read the value of exhaust gas temperature.
Standard:
ASM3-794 1,000°C (1,832°F)
(g) Reconnect the exhaust gas temperature sensor
connector.
NG Go to step 5
OK
5 READ VALUE OF Hino-DX (SHORT IN ECM)

ECM (c) Connect the Hino-DX to the DLC3.
E28 (d) Turn the ignition switch to the ON position.
THCO (f) Follow the Hino-DX screen display and set the ECU data
monitor.
ES E2 (g) Read the value of exhaust gas temperature.
Standard:
ECM Connector 1,000°C (1,832°F)
connector.
(i) Reconnect the ECM connector.
E23
NG REPLACE ECM
THCO
ASM3-795
OK

SENSOR)

DTC P2120/19
Circuit

DTC P2121/19
Circuit Range / Performance

DTC P2122/19
Circuit Low Input
ES
DTC P2123/19
Circuit High Input

DTC P2125/19
Circuit

DTC P2127/19
Circuit Low Input

DTC P2128/19
Circuit High Input
Throttle / Pedal Position Sensor / Switch "D" /

DTC P2138/19
"E" Voltage Correlation
DESCRIPTION
HINT:
This is the repair procedure for the accelerator pedal position sensor.
• This electrical throttle system does not use a throttle cable.
• This accelerator pedal position sensor is non-contact type.
The accelerator pedal position sensor is mounted on the accelerator pedal and detects the opening angle
of the accelerator pedal. Since this sensor is electronically controlled with Hall-effect elements, accurate
control and reliability can be obtained. It has 2 sensors to detect the accelerator position and a
malfunction of the accelerator position sensor.
In the accelerator pedal position sensor, the voltage applied to pedal terminals VPA and VPA2 of the ECM
changes between 0 V and 5 V, in proportion to the opening angle of the accelerator pedal. The VPA is a
signal to indicate the actual accelerator pedal opening angle which is used for engine control, and the
VPA2 is a signal to indicate the information about the opening angle which is used for detecting a
malfunction.
The ECM judges the current opening angle of the accelerator pedal from these signals input from
terminals VPA and VPA2, and the ECM controls the throttle motor based on these signals.
Accelerator Pedal Position

Sensor Output Voltage (V)
*1 *2
Accelerator Pedal
Position Sensor
5
VPA2
Magnet 3.6 to 4.4
ECM
VPA
ES IC No. 1 2.8 to 3.6
EPA VPA
VCPA 1.4 to 1.8
VPA2 0.6 to 1.0
EPA2
Usable Range
0 15.9
IC No. 2 VCP2
Accelerator Pedal Turning Angle (deg.)
Magnet
*1: Accelerator Pedal Fully Released
*2: Accelerator Pedal Fully Depressed
A165160E01

• Open or short in accelerator pedal position sensor
Condition (a) continues for 1 second or more:
circuit
P2120/19 (a) VPA less than 0.2 V and VPA2 greater than 2.7 deg,
• Accelerator pedal position sensor
or VPA greater than 4.8 V
• ECM
Conditions (a) and (b) continue for 1 second or more: • Open or short in accelerator pedal position sensor
(a) Difference between VPA and VPA2 exceeds the circuit
P2121/19
threshold • Accelerator pedal position sensor
(b) IDL is OFF • ECM
Conditions (a) and (b) continue for 1 second or more:
circuit
P2122/19 (a) VPA less than 0.2 V
(b) VPA2 greater than 2.7 deg
• ECM
Condition (a) continues for 2 seconds or more: circuit
P2123/19
(a) VPA greater than 4.8 V • Accelerator pedal position sensor
• ECM
Condition (a) continues for 1 second or more: • Open or short in accelerator pedal position sensor
(a) VPA2 less than 0.5 V and VPA greater than 2.7 deg, circuit
P2125/19
or VPA2 greater than 4.8 V and VPA greater than 0.2 V • Accelerator pedal position sensor
but less than 3.45 V • ECM
Conditions (a) and (b) continue for 1 second or more:
circuit
P2127/19 (a) VPA2 less than 0.5 V
(b) VPA greater than 2.7 deg
• ECM

Conditions (a) and (b) continue for 2 seconds or more:
circuit
P2128/19 (a) VPA2 greater than 4.8 V
(b) VPA greater than 0.2 V but less than 3.45 V
• ECM
Condition (a) or (b) continues for 2 seconds or more:
circuit
P2138/19 (a) Difference between VPA and VPA2 less than 0.02 V
(b) VPA less than 0.2 V and VPA2 less than 0.5 V
• ECM
HINT:
When DTC P2120/19, P2122/19, P2123/19, P2125/19, P2127/19, P2128/19 or P2138/19 is detected,
check the output voltage of the accelerator pedal position sensor following to the Hino-DX screen display,
set ECU Data Monitor / Data List / Accelerator Position No. 1 and Accelerator Position No. 2. ES
Accelerator pedal position expressed as voltage output
Trouble Area Accelerator pedal released Accelerator pedal depressed
ACCEL POS #1 ACCEL POS #2 ACCEL POS #1 ACCEL POS #2
VC circuit open 0 to 0.2 V 0 to 0.2 V 0 to 0.2 V 0 to 0.2 V
VPA1 circuit open or ground short 0 to 0.2 V 1.4 to 1.8 V 0 to 0.2 V 3.6 to 4.4 V
VPA2 circuit open or ground short 0.6 to 1.0 V 0 to 0.2 V 2.8 to 3.6 V 0 to 0.2 V
EPA circuit open 4.5 to 5.5 V 4.5 to 5.5 V 4.5 to 5.5 V 4.5 to 5.5 V
WIRING DIAGRAM
A11
Accelerator Pedal Position Sensor ECM
21
1
VCP2 E25 VCP2
29
2
EP2 E25 EPA2
23
3
VPA2 E25 VPA2
20
4
VCP1 E25 VCPA
28
5
EP1 E25 EPA
22
6
VPA1 E25 VPA
A154456E01
NOTICE:
HINT:
1 READ VALUE OF Hino-DX (ACCELERATOR POSITION)

(c) Following to the Hino-DX screen display, set ECU Data
Monitor / Data List / Accelerator Position No. 1 and
Accelerator Position No. 2.
(d) Read the value.
Standard
ES Accelerator Pedal
Condition
Accelerator Position
No. 1
Accelerator Position
No. 2
Depressed Released
FI07052E07 Released 0.6 to 1.0 V 1.4 to 1.8 V
Depressed 2.8 to 3.6 V 3.6 to 4.4 V
NG Go to step 5
OK
2 CHECK HARNESS AND CONNECTOR (ECM - ACCELERATOR PEDAL POSITION

SENSOR)
(a) Disconnect the accelerator pedal position sensor

Wire Harness Side: connector.
Accelerator Pedal Position Sensor
Connector
table below.
Check for open
A11
A11-1 (VCP2) - E25-21 (VCP2) Always Below 1 Ω
VCP2 EP2 VPA2 VCP1 EP1 VPA1 A11-2 (EP2) - E25-29 (EPA2) Always Below 1 Ω
Front View A11-3 (VPA2) - E25-23 (VPA2) Always Below 1 Ω

A11-4 (VCP1) - E25-20 (VCPA) Always Below 1 Ω
A11-5 (EP1) - E25-28 (EPA) Always Below 1 Ω
E25 A11-6 (VPA1) - E25-22 (VPA) Always Below 1 Ω
VPA Check for short

ECM Connector VPA2
A11-1 (VCP2) or E25-21 (VCP2) -
EPA2 Always 10 kΩ or higher
Body ground
EPA VCPA A11-2 (EP2) or E25-29 (EPA2) -
VCP2 A163601E01 Always 10 kΩ or higher
Body ground
A11-3 (VPA2) or E25-23 (VPA2) -
Body ground
A11-4 (VCP1) or E25-20 (VCPA) -
Body ground
A11-5 (EP1) or E25-28 (EPA) -
Body ground
A11-6 (VPA1) or E25-22 (VPA) -
Body ground
(d) Reconnect the accelerator pedal position sensor.


CONNECTOR (ECM - ACCELERATOR
PEDAL POSITION SENSOR)
OK
3 CHECK ECM (VCPA AND VCP2 VOLTAGE)

connector.
A11
(b) Turn the ignition switch to the ON position. ES
Accelerator Pedal (c) Measure the voltage according to the value(s) in the
Position Sensor table below.
Connector Standard voltage
E25-20 (VCPA) - E25-28 Ignition switch in the ON
4.5 to 5.5 V
(EPA) position
E25-21 (VCP2) - E25-29 Ignition switch in the ON
4.5 to 5.5 V
(EPA2) position
ECM Connector
(d) Reconnect the accelerator pedal position sensor.
VCP2 E25 NG REPLACE ECM
EPA2 VCPA
EPA
A096639E08
OK
4 REPLACE ACCELERATOR PEDAL
(a) Replace the accelerator pedal assembly (See page ES-

350).
NEXT

(c) Clear the DTCs (See page ES-29).
(e) Start the engine.
(f) Drive the engine at idle for 15 seconds or more.
(g) Follow the Hino-DX screen display and set the Data
display.
(h) Read the DTCs.
Result
P2120/19, P2121/19, P2122/19, P2123/19, P2125/19, P2127/19, P2128/19 or P2138/19 is output A
No output B
B SYSTEM IS OK
REPLACE ECM
ES
DTC P2226/A5 Barometric Pressure Circuit
DTC P2228/A5 Barometric Pressure Circuit Low Input
DTC P2229/A5 Barometric Pressure Circuit High Input

DESCRIPTION
The atmospheric pressure sensor, built into the ECM, detects the atmospheric pressure. According to the
value of the atmospheric pressure, the ECM corrects the injection timing, the injection volume and the
amount of common rail internal fuel pressure for an optimum combustion. ES
Open or short in atmospheric pressure sensor circuit for
P2226/A5 ECM
more than 0.5 seconds (ECM internal malfunction)
Short in atmospheric pressure sensor circuit for more
P2228/A5 ECM
than 0.5 seconds (ECM internal malfunction)
Open in atmospheric pressure sensor circuit for more
P2229/A5 ECM
than 0.5 seconds (ECM internal malfunction)
HINT:
"A" in the above table indicates that the MIL flashes 10 times.
NOTICE:
1 CLEAR DTC

(a) Turn the ignition switch to the OFF position and wait for
15 seconds or more.
display.
(e) Read the DTCs.
Result
P2226/A5, P2228/A5 or P2229/A5 and other DTCs are output A
P2226/A5, P2228/A5 or P2229/A5 is output B
B REPLACE ECM
GO TO DTC CHART
ES
Barometric Pressure Circuit Range / Perfor-

DTC P2227/A5
mance
DESCRIPTION
The atmospheric pressure sensor, built into the ECM, detects the atmospheric pressure.
According to the value of the atmospheric pressure, the ECM corrects the injection timing, the injection
volume and the amount of common rail internal fuel pressure for an optimum combustion.
Atmospheric pressure sensor malfunction (The MIL is
P2227/A5 illuminated as well as a DTC being set immediately ECM
malfunction is detected) ES
HINT:
DTC P2227/A5 is set when the ignition switch is in the ON position.

display.
(d) Read the DTCs.
Result
P2227/A5 A
P2227/A5 and other DTC B
HINT:
If any DTCs other than P2227/A5 are output,
troubleshoot those DTCs first.
B GO TO DTC CHART
REPLACE ECM
Lost Communication with Variable Nozzle Type

DTC U1123/A2
Turbo Charger Module *E1
DESCRIPTION
The CAN (Controller Area Network) is a serial data communication system for real time application. It is a
multiplex communication system designed for on-vehicle use that provides a superior communication
speed of 500 kbps and a capability to detect malfunctions. Through the combination of the CANH and
CANL bus lines, the CAN is able to maintain communication based on differential voltage.
HINT:
• Malfunctions in the CAN bus (communication line) can be checked from the DLC3 connector. (except
ES when the sub bus line of the DLC3 is open.)
• Diagnostics codes (DTCs) related to CAN communication can be checked by using the Hino-DX.
• The DLC3 is connected to the CAN communication line, but the CAN communication line cannot
detect malfunctions in the DLC3 sub bus line.
Both of the following conditions are met:
• Open or short in turbo actuator circuit
(a) Ignition switch in the ON position
U1123/A2 • Turbocharger sub-assembly
(b) No communication between ECM and turbocharger
• ECM
actuator for 0.7 seconds
WIRING DIAGRAM
NOTICE:
1 CLEAR DTC

NOTICE:
When DTC is cleared, because also frame freeze
data is cleared. Before clearing DTC, be sure to save
frame freeze data.
2 CHECK WHETHER DTC OUTPUT RECURS (U1123/A2)
(a) Turn the ignition switch off.

(b) Ignition switch to the ON position.
display.
(d) Read the DTCs.
Result
Result Proceed to
DTC U1123/A2 is output A
No DTC output B
3 CHECK HARNESS AND CONNECTOR (CAN BUS LINE)

table below.
Turbocharger Actuator Connector Standard resistance
CANH T8-1 (CANH) - T8-4
Always 105 to 135 Ω
(CANL)
T8
CANL (c) Reconnect the turbocharger connector.

A164233E03
CONNECTOR (CAN BUS LINE)
OK
4 CHECK TURBOCHARGER SUB-ASSEMBLY (POWER SOURCE)

Turbocharger Actuator Connector table below.
Standard voltage
+B Tester Connection Condition Specified Condition
T8 T8-3 (+B) - T8-6 (GND) Ignition switch on 18 to 27 V
GND (d) Reconnect the turbocharger connector.

A164233E01
NG Go to step 4
OK
REPLACE TURBOCHARGER SUB-ASSEMBLY
5 CHECK HARNESS AND CONNECTOR (TURBOCHARGER - BODY GROUND)

table below.
Turbocharger Actuator Connector Standard resistance
T8-6 (GND) - Body
Always Below 1 Ω
ground
T8
GND (c) Reconnect the turbocharger connector.
A164233E04

CONNECTOR (TURBOCHARGER - BODY
GROUND)
OK
REPAIR OR REPLACE HARNESS OR CONNECTOR (TURBOCHARGER - ENG-3 RELAY)
ES
Engine Difficult to Start or Stalling

NOTICE:
HINT:
• Specified values in the following troubleshooting flowchart are for reference only. Variations in the Data
List values may occur depending on the measuring conditions or the vehicle's age. Do not assume the ES
vehicle is normal when the Data List outputs standard values. There may be concealed factors of the
malfunction.
• If the vehicle runs out of fuel while the engine is operating, there is a chance that the engine may be
difficult to restart after fuel is refilled.
1 CHECK OUTPUT DTC (RELATED TO ENGINE)

display.
(d) Read the DTCs.
Result
No output A
DTCs related to engine B
B GO TO DTC CHART
2 CHECK FUEL FILTER ASSEMBLY
(a) Check that the fuel filter is not clogged.

OK:
Fuel filter is not clogged.
NG REPLACE FUEL FILTER ASSEMBLY
OK
3 CHECK INJECTOR ID CORD
(a) Check injector ID cord (See page ES-7).

OK:
ID cord is registered.
NG REGISTER INJECTOR ID CORD
OK
4 CHECK ENGINE CRANKING CONDITION
(a) Check the engine cranking condition.

(b) Compare the cranking condition with that of a normal
engine of the same model, and carefully check if there is
any difference between them.
OK:
Engine cranking condition is normal.
NG CHECK AND REPLACE BATTERY,
ES CHARGING SYSTEM, STARTER ASSEMBLY
AND STARTING SYSTEM
OK
5 READ VALUE OF FUEL PRESSURE SENSOR

monitor.
(d) Read the value.
Standard
Item Inspection Condition Reference Value
Cranking, and engine coolant temperature
Fuel Press 30 MPa or higher
0°C (32°F) or more
NG BLEED AIR FROM FUEL SYSTEM
OK
6 CHECK IF INITIAL COMBUSTION OCCURS
(a) Check if initial combustion occurs.

Result
Result Proceed to
No initial combustion (Cold) A
No initial combustion (Warmed up) B
Initial combustion occurs C
B Go to step 7
C Go to step 9
7 CHECK PRE- HEATING SYSTEM
(a) Check preheating system (See chapter ST).

NG REPAIR OR REPLACE GLOW SYSTEM
OK
8 CHECK FUEL FORCED FEED
(a) Loosen the flare nut of the high-pressure pipe of injection

(supply) pump.
(b) Confirm fuel is spilled out when cranking
NG Go to step 9
OK ES
9 CHECK IF FUEL IS BEING SUPPLIED TO SUPPLY PUMP
(a) Disconnect the inlet hose from the supply pump.

(b) Operate the priming pump and check that fuel is being
supplied to the supply pump.
OK:
Fuel is properly supplied to the supply pump when
the priming pump is operated.
OK Go to step 12
NG
CHECK AND REPLACE FUEL PIPE CLOGGING (INCLUDING FUEL FREEZING) (FUEL TANK -
SUPPLY PUMP)
10 CHECK AIR INTAKE SYSTEM AND EXHAUST SYSTEM
(a) Inspect the engine condition (See chapter EC).

NG REPAIR OR REPLACE LOCATIONS WHERE
MALFUNCTIONS EXIST
OK
11 INSPECT EXHAUST RETARDER ASSEMBLY
(a) Inspect exhaust retarder assembly.

NG REPLACE EXHAUST RETARDER
ASSEMBLY
OK
12 READ VALUE OF FUEL PRESSURE SENSOR AND INJECTOR

monitor.
(d) Select the following menu items in order and read the
values.
• Fuel Press
• Injection Volume
Standard
Item Engine Speed * Reference Value
Fuel Press Idling 25 to 35 MPa
Fuel Press 2,000 rpm (No engine load) 80 to 90 MPa
Fuel Press 3,000 rpm (No engine load) 100 to 110 MPa
ES Injection Volume Idling 5 to 12 mm3
Injection Volume 2,000 rpm (No engine load) 8 to 15 mm3
Injection Volume 3,000 rpm (No engine load) 13 to 20 mm3
main Injection Timing Idling -1 to 1° CA
main Injection Timing 2,000 rpm (No engine load) -4 to -3° CA
main Injection Timing 3,000 rpm (No engine load) -10 to -6° CA
HINT:
*: If no idling conditions are specified, the shift lever
should be in the neutral position, and the A/C switch and
all accessory switches should be OFF.
NG Go to step 17
OK
13 CHECK CYLINDER COMPRESSION PRESSURE

EM).
LOW COMPRESSION
OK
14 CHECK HARNESS AND CONNECTOR (INJECTOR - EDU)
(a) Check the wire harness between the injector and injector
Wire Harness Side: driver (INJ terminal).
(1) Disconnect the injector connectors.
Injector Connector (2) Disconnect the EDU connector.
(3) Measure the resistance according to the value(s) in
the table below.
INJ1, INJ2 Check for open
INJ3, INJ4 Front View ES
INJ1-2 - E26-4 (INJ#1) Always Below 1 Ω
EDU Connector INJ3-2 - E26-1 (INJ#3) Always Below 1 Ω
INJ#4 INJ#1 INJ4-2 - E26-3 (INJ#4) Always Below 1 Ω
INJ1-1 - E26-5 (COM1) Always Below 1 Ω
E26 Front View INJ3-1 - E26-6 (COM2) Always Below 1 Ω
INJ#3 COM2
INJ#2 COM1 Check for short
ASM3-796
INJ1-2 or E26-4 (INJ#1) - Body
ground
ground
ground
ground
INJ1-1 or E26-5 (COM1) - Body
ground
ground
ground
ground
(4) Reconnect the injector connectors.

(5) Reconnect the EDU connector.
CONNECTOR (INJECTOR - EDU)
OK

(b) Disconnect the connectors for the No. 1 through No. 4
injectors in this order.
(c) Check the engine idling condition during the fuel injection
of each cylinder.
Result
Engine Idling Condition Proceed to
Becomes unstable A
Does not change B
HINT:
Replace the injector mounted on the cylinder that causes
no significant idle speed change.
(d) Clear the DTCs (See page ES-29).
ES B REPLACE INJECTOR ASSEMBLY
REPLACE INJECTOR DRIVER ASSEMBLY
16 CHECK ECM TERMINAL VOLTAGE (THW TERMINAL)

(b) Measure the voltage of the ECM connector.
E22 Standard voltage
Specified
Tester Connection Condition
Condition
Idling, engine coolant
E22-19 (THW) - E22-28
temperature between 80 and 0.4 to 1.0 V
(E2)
120°C (140 and 248°F)
THW (+) E2 (-) ECM Connector
A153569E05 NG Go to step 21
OK
17 INSPECT ENGINE COOLANT TEMPERATURE SENSOR
(a) Remove the engine coolant temperature sensor.

Ohmmeter table below.
Standard resistance
W5-1 - W5-2 20°C (68°F) 2.21 to 2.69 kΩ
W5-1 - W5-2 80°C (176°F) 0.29 to 0.354 kΩ
kΩ W5-3 - Body ground 75°C (167°F) 79 to 93 Ω ES
30
W5-3 - Body ground 100°C (212°F) 35.5 to 41.5 Ω
20
10 NOTICE:
W5 When checking the sensor in water, keep the
5
terminals dry. After the check, wipe the sensor dry.
3
2 ECT Sensor HINT:
1
Alternative procedure: Connect an ohmmeter to the
installed ECT sensor and read the resistance. Use an
0.5 Acceptable infrared thermometer to measure the engine
0.3
0.2 temperature in the immediate vicinity of the sensor.
°C 0.1 -20 0 20 40 80 100
Compare these values against the resistance/
(°F) (-4) (32)(68)(104)(176)(212) temperature graph. Change the engine temperature
A126612E02 (warm up or cool down) and repeat the test.
(c) Reinstall the engine coolant temperature sensor.
NG REPLACE ENGINE COOLANT
TEMPERATURE SENSOR
OK

SENSOR)
18 INSPECT CRANKSHAFT POSITION SENSOR

table below.
Standard resistance
1-2 Cold 1,630 to 2,740 Ω
1-2 Hot 2,065 to 3,225 Ω
NOTICE:
ASM3-784 In the table above, the terms "cold" and "hot" refer
to the temperature of the coils in the sensors. "Cold"
means approximately -10° to 50°C (14° to 122°F).
"Hot" means approximately 50° to 100°C (122° to
212°F).
(c) Reconnect the crankshaft position sensor.

SENSOR
OK
19 CHECK HARNESS AND CONNECTOR (CRANK POSITION SENSOR - ECM)
(a) Disconnect the connector of ECM and crank position

ECM sennsor.
ES E22 table below.
Check for open
E22-27 (NE+) - 1 (NE+) Always 1 Ω or less
E22-34 (NE-) - 2 (NE-) Always 1 Ω or less
Check for short

Crank Position Sensor Tester Connection Condition Specified Condition
E22-27 (NE+) or 1 (NE+) - Body
ground
E22-34 (NE-) or 2 (NE-) - Body
ground

CONNECTOR (CRANK POSITION SENSOR -
NE+ NE- ECM)
Front View A101632E01
OK
20 CHECK HARNESS AND CONNECTOR (STARTER RELAY - ECM)

Wire Harness Side: (Refer to Pub. No. S1-YXZE16C EWD for the relay and
fuse location of each vehicle)
(b) Disconnect the starter relay connector.
STARTER Relay (c) Measure the resistance according to the value(s) in the
table below.
S8 Standard resistance
S8-1 - E23-18 (STA) Always Below 1 Ω
S8-1 or E23-18 (STA) -
Body ground
No. 2 Relay Block (d) Reinstall the starter relay.

ECM Connector
CONNECTOR (STARTER RELAY - ECM)
E23
STA
A154705E01
OK
21 CHECK ECM TERMINAL VOLTAGE (PCR1 TERMINAL)

E22 table below.
Standard voltage
PCR1 (+) E2 (-) ECM Connector

OK REPLACE ECM
A153569E06
NG
22 INSPECT COMMON RAIL ASSEMBLY (FUEL PRESSURE SENSOR)
(a) Disconnect the fuel pressure sensor connector.

Component Side: table below.
Standard resistance
Fuel Pressure Sensor Connector Tester Connection Specified Condition
2 (PCR1) - 3 (VC1) 3 kΩ or less
Front View 1 (E2) - 2 (PCR1) 16.4 kΩ or less
ES (c) Reconnect the fuel pressure sensor connector.
VC1 E2
PCR1
ASM3-797
OK
23 CHECK HARNESS AND CONNECTOR (FUEL PRESSURE SENSOR - ECM)

table below.
Check for open
PCR1
VC ECM Connector E22-18 (VC) - 3 (VC1) Always Below 1 Ω
E22-26 (PCR1) - 2 (PCR1) Always Below 1 Ω
E2 E22-28 (E2) - 1 (E1) Always Below 1 Ω
Check for short

E22-18 (VC) or F8-3 (VC1) - Body
ground
E22-26 (PCR1) - 2 (PCR1) - Body
ground
E22-28 (E2) - 1 (E1) - Body
ground
E1 PCR1 VC1
(d) Reconnect the ECM connectors.
ASM3-741
(e) Reconnect the fuel pressure sensor connector.
CONNECTOR (FUEL PRESSURE SENSOR -
ECM)
OK
24 REPLACE ECM
(a) Replace the ECM. (See page ES-347)

NOTICE:
After replacing the ECM, the new ECM needs
registration (See page ES-3) and initialization (See
page ES-3).
(b) Check if the engine starts smoothly or if the engine stalls.
OK:
The engine starts smoothly and does not stall.
ES
OK
END
Black Smoke Emitted

NOTICE:
HINT:
ES Specified values in the following troubleshooting flowchart are for reference only. Variations in the Data
List values may occur depending on the measuring conditions or the vehicle's age. Do not assume the
vehicle to be normal when the Data List outputs standard values. There may be concealed factors of the
malfunction.
1 CHECK OUTPUT DTC (RELATED TO ENGINE)

display.
(d) Read the DTCs.
Result
No output A
DTCs related to the engine B
B GO TO DTC CHART
2 CHECK INJECTION ID CORD
(a) Check injection ID cord (See page ES-7).

OK:
Injector ID cord is registered.
NG REGISTER INJECTOR ID CORD
OK
3 READ VALUE OF INJECTOR ASSEMBLY (INJECTION VOLUME AND INJECTION FEED

BACK VAL #1 TO #4)

monitor.
values.
• Injection Feedback Val #1, #2, #3, and #4
Standard
Item Engine Speed* Reference Value
Idling (No engine load) 5 to 12 mm3
Injection Volume 2,000 r/min (No engine load) 8 to 15 mm3
(No engine load) 13 to 20 mm3
Injection Feedback Val (#1) Idling (No engine load) -3 to 3 mm3
HINT: ES
*: If no idling conditions are specified, the shift lever
should be in the neutral position, and the A/C switch and
all accessory switches should be off.
NG Go to step 13
OK
4 PERFORM ENGINE RPM ACCELERATION
HINT:
If the exhaust gas contains excessive black smoke, perform
the following operations:
(a) Accelerate the engine speed to the maximum rpm with
no load 20 times.
(b) Check the volume of black smoke in the exhaust gas.
Result
Result Proceed to
Black smoke is not present OK
Black smoke remains in the exhaust gas NG
HINT:
Soot deposits in the exhaust system may cause
excessive black smoke.
NG Go to step 5
OK
END
5 CHECK AIR INTAKE SYSTEM AND EXHAUST SYSTEM
(a) Remove the air filter.

(b) Accelerate the engine speed to maximum rpm with no
load.
(c) Check the diesel throttle valve becomes full opening.
Standard:
Diesel throttle valve becomes full opening.
NG CHECK AND REPLACE LOCATIONS WHERE

MALFUNCTIONS EXIST
OK
6 CHECK INTAKE AIR FLOW METER SUB-ASSEMBLY
HINT:
*: If no idling condition is specified, the shift lever should be in
neutral position, and the A/C switch and all accessory
ES switches should be off.
(c) Follow the Hino-DX screen display and select the ECU
data monitor.
(d) Read the intake air volume.
Standard

Idling (No engine load) 8 to 12 g/s
Intake Air Volume
3,000 r/min (No engine load) 80 to 90 g/s
NG REPLACE INTAKE AIR FLOW METER SUB-

ASSEMBLY
OK
7 CHECK TURBOCHARGER SUB-ASSEMBLY (PRESSURE)
(a) Check the turbocharger pressure. (See chapter IT)

ASSEMBLY
OK
OK END
NG
9 PERFORM ACTIVE TEST BY FUEL PRESSURE SENSOR AND INJECTOR ASSEMBLY

monitor.
values.
• Fuel Pressure
• Main Injection
• Pilot 2 Injection
Result
Fuel Pressure Idling 25 to 35 MPa
Fuel Pressure 2,000 rpm (no engine load) 80 to 90 MPa
Injection Volume Idling 5.0 to 12.0 mm3
Injection Volume 2,000 rpm (no engine load) 8.0 to 15.0 mm3 ES
Injection Volume 3,000 rpm (no engine load) 13.0 to 20.0 mm3
Main Injection Idling 500 to 700 µs
Main Injection Idling -1 to 1° CA
Main Injection 2,000 rpm (no engine load) -4 to -3° CA
Main Injection 3,000 rpm (no engine load) -10 to -6° CA
Pilot 2 Injection Idling 500 to 600 µs
Pilot 1 Injection Idling 0 µs
Injection Feedback Val #1 Idling -3.0 to 3.0 mm3
HINT:
If no idling conditions are specified, the shift lever should
be in the neutral position, and the A/C switch and all
accessory switches should be OFF.
Result
Result Proceed to
Within reference value A
One of Injection Feedback Val #1 to #4 is not within reference value B
Other result C
B REPLACE INJECTOR ASSEMBLY
C Go to step 13

EM).
LOW COMPRESSION
OK
11 CHECK HARNESS AND CONNECTOR (INJECTOR ASSEMBLY - EDU)
(a) Disconnect the injector connectors.

Wire Harness Side:
(b) Disconnect the EDU connectors.
table below.
Injector Connector Standard resistance:
Check for open
INJ1, INJ2
ES INJ3, INJ4 Front View
EDU Connector INJ1-1 - E26-5 (COM1) Always Below 1 Ω
INJ#1 INJ2-1 - E26-6 (COM2) Always Below 1 Ω

INJ#4
E26 Front View
Check for short
INJ#3 COM2 Tester Connection Condition Specified Condition
INJ#2 COM1 INJ1-2 or E26-4 (INJ#1) - Body

ground
ASM3-798
ground
ground
ground
ground
ground
ground
ground

(e) Reconnect the injector connectors.
CONNECTOR (INJECTOR ASSEMBLY - EDU)
OK
12 PERFORM ACTIVE TEST WITH Hino-DX

(c) Follow the Hino-DX screen display.
(d) Check the engine speed.
HINT:
Perform this to all cylinders.
Result
Engine Idling Condition Proceed to
Becomes unstable A
Does not change B
HINT:
Replace the injector mounted on the cylinder that causes
no significant idle speed change.
(e) Clear the DTCs (See page ES-29).
A ES
REPLACE EDU
13 CHECK ECM TERMINAL VOLTAGE (THW TERMINAL)

E22 table below.
Standard voltage
Idling, engine coolant
E22-19 (THW) - E22-28
temperature between 80 0.4 to 1.0 V
(E2)
to 120°C (176 to 248°F)
THW E2 ECM Connector
A153569E12
NG Go to step 15
OK

Standard resistance
W5-1 - W5-2 20°C (68°F) 2.21 to 2.69 kΩ
W5-1 - W5-2 80°C (176°F) 0.29 to 0.354 kΩ
ES kΩ W5-3 - Body ground 75°C (167°F) 79 to 93 Ω
30
W5-3 - Body ground 100°C (212°F) 35.5 to 41.5 Ω
20
10 NOTICE:
W5 When checking the ECT sensor in water, keep the
5
3
2 ECT Sensor HINT:
1
installed ECT sensor and read the resistance. Use an
0.5 Acceptable infrared thermometer to measure the engine
0.3
°C 0.1 -20 0 20 40 80 100
Compare these values against the resistance/
A126612E02 (warm up or cool down) and repeat the test.
TEMPERATURE SENSOR
OK
REPAIR OR REPLACE HARNESS OR CONNECTOR (INJECTOR ASSEMBLY - EDU)
15 CHECK ECM TERMINAL VOLTAGE (PIM TERMINAL)

Standard voltage
Applied negative
E23-28 (PIM) - E22-28
pressure of 93 kPa (700 0.25 to 0.4 V
(E2)
mmHg, 27.5 in.Hg)
ECM Connector
E2 PIM Applied positive
E23-28 (PIM) - E22-28
pressure of 150 kPa 1.0 to 1.4 V
A153569E13 (E2)
(1,125 mmHg, 44 in.Hg)
OK Go to step 17
OK
16 CHECK HARNESS AND CONNECTOR (MANIFOLD ABSOLUTE PRESSURE SENSOR -

ECM)
(a) Disconnect the manifold absolute pressure sensor

(b) Disconnect the ECM connectors.
table below.
Check for open
T2 Front View Tester Connection Condition Specified Condition
ES
E23-28 (PIM) - T2-2 (PIM) Always Below 1 Ω
E22-18 (VC) - T2-3 (VC) Always Below 1 Ω
E2 PIM VC E22-28 (E2) - T2-1 (E2) Always Below 1 Ω
Check for short

E22 E23
E23-28 (PIM) or T2-2 (PIM) - Body
ground
E22-18 (VC) or T2-3 (VC) - Body
ECM Connector ground
E22-28 (E2) or T2-1 (E2) - Body
ground
VC E2 PIM ASM3-748
(d) Reconnect the manifold absolute pressure sensor.
(e) Reconnect the ECM connectors.
CONNECTOR (MANIFOLD ABSOLUTE
PRESSURE SENSOR - ECM)
OK
17 INSPECT CRANKSHAFT POSITION SENSOR

table below.
Standard resistance
1-2 Cold 1,630 to 2,740 Ω
1-2 Hot 2,065 to 3,225 Ω
NOTICE:
ASM3-784 In the table above, the terms "cold" and "hot" refer
to the temperature of the coils in the sensors. "Cold"
means approximately -10 to 50°C (14 to 122°F). "Hot"
means approximately 50 to 100°C (122 to 212°F).

SENSOR
OK
REPAIR OR REPLACE HARNESS OR CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM)
18 CHECK HARNESS AND CONNECTOR (CRANK POSITION SENSOR - ECM)

ES (a) Disconnect the connector of the ECM and crank position
ECM sensor.
E22 table below.
Check for open
E22-27 (NE+) - 1 (NE+) Always 1 Ω or less
E22-34 (NE-) - 2 (NE-) Always 1 Ω or less
Check for short

Crank Position Sensor Tester Connection Condition Specified Condition
E22-27 (NE+) or 1 (NE+) - Body
ground
E22-34 (NE-) or 2 (NE-) - Body
ground

CONNECTOR (CRANK POSITION SENSOR -
NE+ NE- ECM)
OK
19 CHECK ECM TERMINAL VOLTAGE (VPA AND VPA2 TERMINALS)

E25 table below.
Standard voltage
Accelerator Pedal
Tester Condition Specified Condition
Condition
E25-22 (VPA) - E25-28 (EPA) Released 0.6 to 1.0 V
ECM Connector VPA2 VPA E25-22 (VPA) - E25-28 (EPA) Depressed 2.8 to 3.6 V
EPA2 EPA E25-23 (VPA2) - E25-29
Released 1.4 to 1.8 V
A153569E14 (EPA2)
E25-23 (VPA2) - E25-29
Depressed 3.6 to 4.4 V
(EPA2)
NG Go to step 21
OK
20 CHECK HARNESS AND CONNECTOR (ACCELERATOR PEDAL POSITION SENSOR -

ECM)

Connector
table below.
Standard resistance: ES
Check for open
A11
A11-1 (VCP2) - E25-21 (VCP2) Always Below 1 Ω
VCP2 EP2 VPA2 VCP1 EP1 VPA1 A11-2 (EP2) - E25-29 (EPA2) Always Below 1 Ω
Front View A11-3 (VPA2) - E25-23 (VPA2) Always Below 1 Ω

A11-4 (VCP1) - E25-20 (VCPA) Always Below 1 Ω
A11-5 (EP1) - E25-28 (EPA) Always Below 1 Ω
E25 A11-6 (VPA1) - E25-22 (VPA) Always Below 1 Ω
VPA Check for short

ECM Connector VPA2
A11-1 (VCP2) or E25-21 (VCP2) -
EPA2 Always 10 kΩ or higher
Body ground
EPA VCPA A11-2 (EP2) or E25-29 (EPA2) -
VCP2 A163601E01 Always 10 kΩ or higher
Body ground
A11-3 (VPA2) or E25-23 (VPA2) -
Body ground
A11-4 (VCP1) or E25-20 (VCPA) -
Body ground
A11-5 (EP1) or E25-28 (EPA) -
Body ground
A11-6 (VPA1) or E25-22 (VPA) -
Body ground
(d) Reconnect the accelerator pedal position sensor

connector.
CONNECTOR (ACCELERATOR PEDAL
POSITION SENSOR - ECM)
OK
REPLACE ACCELERATOR PEDAL (ACCELERATOR PEDAL POSITION SENSOR)

21 CHECK ECM TERMINAL VOLTAGE (THA TERMINAL)

E22 table below.
Standard voltage
Idling, intake air
E22-31 (THA) - E22-28
temperature at 20°C 0.5 to 3.4 V
(E2)
(68°F)
ES THA E2 ECM Connector
A153569E15
NG Go to step 23
OK
22 INSPECT INTAKE AIR FLOW METER
(a) Remove the intake air flow meter.

Air table below.
Standard resistance
4 (THA) - 5 (E2) -20°C (-4°F) 12.5 to 16.9 kΩ
4 (THA) - 5 (E2) 20°C (68°F) 2.19 to 2.67 kΩ
4 (THA) - 5 (E2) 60°C (140°F) 0.50 to 0.68 kΩ
Intake Air Flow Meter S/A NOTICE:

When checking the sensor in water, keep the
NG REPLACE INTAKE AIR TEMPERATURE
FLOR METER
(-4) (32) (68) (104)(140)(176) (212)

[ºC] (ºF) A098859E05
OK
REPAIR OR REPLACE HARNESS OR CONNECTOR (INTAKE AIR FLOW METER - ECM)

23 CHECK ECM TERMINAL VOLTAGE (PCR1 TERMINAL)

E22
table below.
Standard voltage
PCR1 E2
ECM Connector
OK REPLACE ECM ES
ASM3-745
NG

Component Side:
Fuel Pressure Sensor Connector table below.
Standard resistance
2 (PCR1) - 3 (VC1) 3 kΩ or less
1 (E2) - 2 (PCR1) 16.4 kΩ or less
VC1 E2
PCR1 (c) Reconnect the fuel pressure sensor connector.
OK
25 CHECK HARNESS AND CONNECTOR (FUEL PRESSURE SENSOR - ECM)
(a) Disconnect the ECM connectors.

table below.
Check for open
PCR1
ES VC ECM Connector E22-26 (PCR1) - 2 (PV1) Always Below 1 Ω

E2 E22-28 (E2) - 1 (E1) Always Below 1 Ω
Check for short

E22-26 (PCR1) or 2 (PV1) - Body
ground
E22-18 (VC) or 3 (VC1) - Body
ground
E22-28 (E2) or 1 (E1) - Body
ground
E1 PCR1 VC1
(d) Reconnect the ECM connectors.
ASM3-741
(e) Reconnect the fuel pressure sensor connector.
CONNECTOR (INJECTOR ASSEMBLY - EDU)
OK
26 REPLACE ECM
(a) Replace the ECM.

NOTICE:
After replacing the ECM, the ECM needs supply
pump specification learning (See page ES-3) and
(b) Check the volume of black smoke in the exhaust gas.
OK:
Black smoke is not present.
OK
END
Pre-heating Control Circuit

DESCRIPTION
The glow plug is mounted inside the engine combustion chamber. To ensure efficient engine starting with
a cold engine, the ECM calculates a time interval of the current that needs to flow through the glow plug
depending on the starting engine coolant temperature when the ignition switch is turned to the ON
position. The ECM then turns on the GLOW relay and permits the current to flow through the glow plug
based on the ECM's calculated time. The GLOW relay is then heated, and enhances fuel combustion with
a cold engine.
This DTC will be set if the glow plug or the circuit is open.
ES
Glow System Wiring Diagram
ECM
GLOW
From
Battery SREL
5 2
GLOW MAIN Relay
3 1
Glow Plug
G034667E05
HINT:
• These troubleshooting procedures are for: 1) difficult starting engine in cold weather, and 2) difficult
driving/vehicle malfunctions in cold weather immediately after the engine is started.
• After the engine is started, the ECM performs an "after-glow" for a certain period of time. In proportion
to the actual engine coolant temperature, the time period varies. The after-glow reduces diesel engine
knocking, white smoke emissions and engine noises when the engine is cold.
Pre-heating System:
Indicator Light Operation

After-glow Time
Second Second
120
1 1
0 0
-20 8 20 28 55 80 100 -40 -20 0 20 40 60 80 100

(-4) (47) (68)(83) (131) (176) (212) (-40) (-4) (32) (68) (104)(140)(176)(212)
Engine Coolant Temperature °C Engine Coolant Temperature °C
(°F) (°F) A162402E01
WIRING DIAGRAM
11
9 AM1 IG1 10 28 3
E25 GIND
GAUGE
I6
ES Ignition Switch C5
Combination Meter
AM1
15
2 1
E25 SREL
3 5
GLOW
GLOW MAIN
ALT
ECM
1
G4
Glow Plug
Battery
Battery
A164422E01
1 CHECK GLOW INDICATOR LIGHT (ILLUMINATED)

(b) Check if the glow indicator is illuminated.
OK:
Glow indicator light is illuminated for 0.5 seconds
or more.
NG Go to step 11
OK
2 CHECK GLOW INDICATOR LIGHT (ILLUMINATED TIME)

(b) Check the period that the glow indicator light is
illuminated.
Indicator Light Operation ES

Second
1
0
-20 8 20 28 55 80 100
(-4) (47) (68)(83) (131) (176) (212)
Engine Coolant Temperature °C
(°F) A162403E01
OK:
The glow indicator light is illuminated according to
the engine coolant temperature as shown in the
graph.
HINT:
Glow plug operation varies depending on the engine
coolant temperature.
NG Go to step 17
OK
3 CHECK ECM (SREL VOLTAGE)

E25 table below.
SREL
ECM Connector
A153569E77
After-glow Time
Second
120
ES
1
0
-40 -20 0 20 40 60 80 100

(-40) (-4) (32) (68) (104)(140)(176)(212)
Engine Coolant Temperature °C
(°F) A162404E01
Standard voltage
E25-15 (SREL) - Body Engine idling and after
11 to 14 V
ground glow on
E25-15 (SREL) - Body Engine idling and after
0 to 2 V
ground glow off
OK:
The after-glow operated according to the engine
coolant temperature as shown in the graph.
HINT:
After-glow operation varies depending on the engine
coolant temperature.
NG Go to step 17
OK
4 INSPECT GLOW MAIN RELAY
(a) Remove the GLOW MAIN relay from the No. 2 relay
block.
table below.
Standard resistance
3-5 Normal 10 kΩ or higher
Battery voltage applied
3-5 between terminal 1 and Below 1 Ω
B016200 2
(c) Reinstall the GLOW MAIN relay.

NG REPLACE GLOW MAIN RELAY
OK
5 INSPECT GLOW PLUG ASSEMBLY
(a) Remove the glow plug connector.

table below.
Standard resistance
Glow Plug Tester Connection Condition Specified Condition ES
Assembly Glow plug terminal -
20°C (68°F) 2.7 to 3.5 Ω
Body ground
(c) Reinstall the glow plug connector.

A101682E01
NG REPLACE GLOW PLUG ASSEMBLY
OK
6 CHECK GLOW PLUG ASSEMBLY (INSTALLATION)
(a) Check the glow plug installation (See chapter ST).

OK:
The glow plugs are installed securely.
NG SECURELY REINSTALL GLOW PLUG
ASSEMBLY
OK
7 CHECK GLOW MAIN RELAY (POWER SOURCE)
No. 2 Relay Block:
block. (Refer to Pub. No. S1-YXZE16C EWD for the
relay and fuse location of each vehicle)
table below.
Standard voltage
GLOW MAIN relay
terminal 3 - Body Always 18 to 27 V
GLOW MAIN Relay ground

NG Go to step 18
A155011E01
OK
8 CHECK HARNESS AND CONNECTOR (GLOW MAIN RELAY - GLOW PLUG ASSEMBLY)
(b) Remove the glow plug connector.
Wire Harness Side: (c) Measure the resistance according to the value(s) in the
table below.
Standard resistance (check for open)
Glow Plug Connector
ES Tester Connection Condition Specified Condition
GLOW MAIN relay
Always Below 1 Ω
terminal 5 - G4-1
G4 Standard resistance (check for short)

GLOW MAIN relay
terminal 5 or G4-1 - Always 10 kΩ or higher
No. 2 Relay Block Body ground
(d) Reinstall the glow plug connector.

(e) Reinstall the GLOW MAIN relay.
CONNECTOR (GLOW MAIN RELAY - GLOW
PLUG ASSEMBLY)
GLOW MAIN
Relay
A163997E01
OK
9 CHECK HARNESS AND CONNECTOR (GLOW MAIN RELAY - ECM)
Wire Harness Side: block. (Refer to Pub. No. S1-YXZE16C EWD for the
No. 2 Relay Block relay and fuse location of each vehicle)
table below.
GLOW MAIN relay
terminal 1 - E25-15 Always Below 1 Ω
(SREL)
GLOW MAIN
Relay Standard resistance (check for short)
GLOW MAIN relay
terminal 1 or E25-15 Always 10 kΩ or higher
(SREL) - Body ground

E25
CONNECTOR (GLOW MAIN RELAY - ECM)
ECM Connector
SREL
A164423E01
OK
10 CHECK HARNESS AND CONNECTOR (GLOW MAIN RELAY - BODY GROUND)
No. 2 Relay Block:
table below.
Standard resistance
GLOW MAIN relay
terminal 2 - Body Always Below 1 Ω
GLOW MAIN Relay ground

CONNECTOR (GLOW MAIN RELAY - BODY
A155011E01
GROUND)
OK
PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE
11 CHECK HARNESS AND CONNECTOR (ECM - COMBINATION METER)

Wire Harness Side: (b) Disconnect the combination meter connector.
ES
Combination Meter Connector table below.
E25-11 (GIND) - C5-3 Always Below 1 Ω
C5
Standard resistance (check for short)
E25-11 (GIND) or C5-3 -
Body ground
(d) Reconnect the combination meter connector.

E25 (e) Reinstall the ECM connector.
CONNECTOR (ECM - COMBINATION
ECM Connector
METER)
SREL
A164236E03
OK
12 INSPECT FUSE (GAUGE FUSE)
(a) Remove the GAUGE fuse from the No. 1 relay block.
(Refer to Pub. No. S1-YXZE16C EWD for the relay and
No. 1 Relay Block
table below.
Standard resistance
GAUGE
(c) Reinstall the GAUGE fuse.
NG REPLACE FUSE (GAUGE FUSE)
A164424E01
OK
13 CHECK HARNESS AND CONNECTOR (COMBINATION METER - IGNITION SWITCH)

Wire Harness Side (b) Disconnect the ignition switch connector.
Combination Meter Connector table below.
C5-28 - I6-10 (IG1) Always Below 1 Ω
C5
ES
C5-28 or I6-10 (IG1) -
Body ground
Ignition Switch Connector
(d) Reconnect the combination meter connector.
(e) Reinstall the ignition switch connector.
I6 CONNECTOR (COMBINATION METER -
IGNITION SWITCH)
IG1
A164426E01
OK

Component Side:
table below.
Ignition Switch
Standard resistance
LOCK
I6-9 (AM1) - I6-10 (IG1) ON Below 1 Ω
ON
(c) Reconnect the ignition switch connector.
IG1
AM1
A153627E07
OK
(a) Remove the AM1 fuse from the No. 2 relay block.
No. 2 Relay Block:
table below.
Standard resistance
AM1 fuse
ES 1-2 Always Below 1 Ω

A155013E01
OK
16 CHECK IGNITION SWITCH ASSEMBLY (AM1 VOLTAGE)

table below.
Ignition Switch Connector
Standard voltage
I6-9 (AM1) - Body
Always 18 to 27 V
ground
I6
(c) Reinstall the ignition switch connector.
AM1
A164425E01
CONNECTOR (IGNITION SWITCH -
BATTERY)
OK
REPLACE COMBINATION METER ASSEMBLY


Standard resistance
W5-1 - W5-2 20°C (68°F) 2.32 to 2.59 kΩ
W5-1 - W5-2 80°C (176°F) 0.31 to 0.326 kΩ
30
kΩ
NOTICE:
ES
20 When checking the sensor in water, keep the
10 terminals dry. After the check, wipe the sensor dry.
W5 HINT:
5
3
2 ECT Sensor installed ECT sensor and read the resistance. Use an
1 infrared thermometer to measure the engine
temperature in the immediate vicinity of the sensor.
0.5 Acceptable
0.3 Compare these values with the resistance/ temperature
0.2 graph. Change the engine temperature (warm up or cool
°C 0.1 -20 0 20 40 80 100 down) and repeat the test.
(°F) (-4) (32)(68)(104)(176)(212) (c) Reinstall the engine coolant temperature sensor.
A126612E02
TEMPERATURE SENSOR
OK
REPLACE ECM
18 INSPECT FUSE (GLOW FUSE)
(a) Remove the GLOW fuse from the No. 2 relay block.
No. 2 Relay Block (Refer to Pub. No. S1-YXZE16C EWD for the relay and
table below.
Standard resistance
(c) Reinstall the GLOW fuse.

NG REPLACE FUSE (GLOW FUSE)
GLOW Fuse
A155012E01
OK
19 INSPECT FUSE (ALT FUSE)
(a) Remove the ALT fuse from the No. 2 relay block.
table below.
Standard resistance
(c) Reinstall the ALT fuse.
ALT Fuse NG REPLACE FUSE (ALT FUSE)
A155014E01
OK
REPAIR OR REPLACE HARNESS OR CONNECTOR (GLOW MAIN RELAY BATTERY)

Rough Idling or Excessive Engine Vibrations

DESCRIPTION
Malfunction Condition Main Trouble Areas Related Trouble Areas
• Injector compensation code
• Fuel leak
• Engine mounting insulator
• Intake air system leakage
1. Injector malfunctions
• Intake air system blockage
– Injector sliding malfunction
• EGR system
– Injector stuck closed
• Rough idling or shuddering due to • Throttle valve system
– Injector stuck open
abnormal combustion • Supply pump
• Shuddering when vehicle starting due to
– Deposit in injector
• Pressure limiter
ES
– Injector circuit malfunction
clutch system malfunctions • Fuel pressure sensor
2. Clutch system malfunctions
• EDU (P0200/97 set simultaneously)
– Clutch system (shuddering when
• Low quality fuel
starting)
• Vehicle modifications
• Fuel filter air bleed problem
• Accessory problem (A/C, generator, etc.)
• ECM
HINT:
• Rough idling and excessive engine vibrations are checked in this troubleshooting procedure.
List result values may occur depending on the measuring conditions or the vehicle's age. Do not judge
the vehicle to be normal even when the Data List values indicate a standard level. There are possibly
some concealed factors of the malfunction.
• Check that the vehicle has not been modified in any way prior to the vehicle inspection.
NOTICE:
• After replacing the supply pump, the ECM needs initialization (See page ES-3).
• After replacing the injector, the ECM needs registration (See page ES-3).
HINT:
Before troubleshooting, conduct the following:
(a) Check the fuel quality.
(b) Check the fuel for air.
(c) Check the fuel system for blockages.
(d) Check the air filter.
(e) Check the engine oil.
(f) Check the engine coolant.
(g) Check the engine idling speed and the maximum engine speed.
(h) Check the vacuum pump.
1 CHECK HARNESS AND CONNECTOR IN ENGINE COMPARTMENT
(a) Check the wire harness and connector connections of

the common rail system components.
HINT:
Check the following components and systems:
• Sensors
• Supply pump
• Common rail
• Injectors
• EDU
• Turbocharger system
• Intake and exhaust system

OK:
The wire harnesses and connectors are
connected securely.
CONNECTOR
OK
2 PERFORM CONFIRMATION DRIVING PATTERN

ES
HINT:
Drive the vehicle according to the driving pattern below to
allow the ECM to set DTCs relating to malfunctions of the fuel
system, EGR system, and throttle valve. If DTCs are set,
problem areas can be identified.
(a) Start the engine (Procedure "A").
(b) Stop the engine and wait for at least 10 seconds
(Procedure "B").
(c) Perform steps "A" (See procedure "A") and "B" (See
procedure "B") described above (to allow the ECM to set
pressure discharge valve malfunction DTCs again).
(d) Enter CHECK MODE.
(e) Fully warm up the engine.
(f) Allow the engine to idle for 5 minutes or more.
(g) Drive the vehicle at more than 40 km/h (25 mph) for 1
minute or more (Procedure "C").
(h) Decelerate and stop the vehicle (Procedure "D").
(i) Repeat steps "C" (See procedure "C") and "D" (See
procedure "D") 4 times or more.
(j) Stop the engine and wait for at least 10 seconds
(Procedure "E").
(k) Repeat steps "C" (See procedure "C") and "E" (See
procedure "E") described above (to set DTCs relating to
the EGR system and throttle valve)
(l) Drive the vehicle at more than 70 km/h (43 mph) for at
least 1 minute (to set DTCs relating to the supply pump).
NEXT
3 CHECK OUTPUT DTC (RELATING TO ENGINE)

(d) Select the following menu item: Powertrain / Engine and
ECT / DTC.
(e) Read pending DTCs.
Result
No DTCs A
Engine related DTCs B
B GO TO DTC CHART
4 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (FUEL LEAK TEST)
HINT:
result, a fuel leak check can be conducted while retaining the ES
ECT / Active Test / Test the Fuel Leak.
(e) Visually check the supply pump, injector, and fuel line
and the injector.
HINT:
the supply pump.
OK:
No fuel leakage.
PARTS
OK
5 READ VALUE OF INTELLIGENT TESTER

(b) Start the engine and warm it up.
ECT / Data List.
(e) Select the following menu items in order and read the
values.
• MAP
• MAF
• Fuel Press
Standard
Item Engine Speed *1 Standard Range Description
Same as atmospheric pressure
position (engine stopped)
Intake manifold internal
90 to 105 kPa (675 to 788
MAP Idling pressure detected by manifold
mmHg, 26.57 to 31.00 in.Hg)
absolute pressure sensor
110 to 140 kPa (825 to 1,050
3,000 rpm (no engine load)
mmHg, 32.48 to 41.35 in.Hg)

0g/s
Intake air volume detected by
MAF
Idling 8 to 12g/s mass air flow meter
3,000 rpm (no engine load) 80 to 90 g/s
Idling 25 to 35 MPa
Common rail internal fuel
pressure
3,000 rpm (no engine load) 100 to 110 MPa
Result
Item Result Proceed to
ES MAP, MAF and Fuel press Standard range A
MAP and MAF Outside standard range B
Only MAP Outside standard range C
Only MAF Outside standard range D
Only Fuel Press Outside standard range E
HINT:
*1: The A/C switch and all accessory switches should be
off with a fully-warmed engine.
B Go to step 12
C GO TO DTC P0105, P0107, AND P0108

(RELATED TO MANIFOLD ABSOLUTE
PRESSURE SENSOR)
D GO TO DTC P0100, P0102, AND P0103

(RELATED TO MAF METER)
E Go to step 25
6 READ VALUE OF INJECTOR (INJECTION FEEDBACK VAL AND INJECTION VOLUME)
(a) Select the following menu items in order and read the
values.
NOTICE:
Be sure to use the 24 V DLC3 cable when connecting
the intelligent tester to the DLC3. Using the normal
DLC3 cable (12 V specification) will cause damage to
the tester.
Standard
Item Engine Speed* Standard Range Description
Injection Feedback Val #1 Idling -3.0 to 3.0 mm 3 Value of injector fuel injection volume
compensates for differences in combustion
Injection Feedback Val #2 Idling -3.0 to 3.0 mm3 condition of cylinders
• Positive values indicate control which
corrects combustion degradation
• Negative values indicate control which
corrects excessive combustion pressure
• If problems exist, "Injection Feedback Val"
may deviate from the -3.0 and 3.0 mm range

Fuel injection volume value controlled by ECU
• Controls NE signal, fuel temperature, engine
coolant temperature, intake air temperature,
Injection Volume Idling 5.0 to 12.0 mm3 boost pressure, atmospheric pressure, and
EGR volume.
• If problems exist, "Injection Volume" may be
outside the standard range
Result
Result Proceed to
Standard range A
Injection Feedback Val #1 to #4 and/or Injection Volume outside standard range B
ES
HINT:
*: The A/C switch and all accessory switches should be off
with a fully-warmed engine.
B Go to step 15
(a) Read the injector compensation code (See page ES-7).

HINT:
If the injector compensation code is not correctly
registered, it may cause malfunctions (See page ES-7).
(b) Check the injector compensation code.
OK:
Compensation code of the installed injector is the
same as the code registered in the ECM.
NG PERFORM REGISTRATION INJECTOR
COMPENSATION CODE
OK
8 RESET ECM
(a) Disconnect the cable from the negative (-) battery

terminal for at least 2 minutes.
(b) Reconnect the cable to the negative (-) battery terminal.
(c) Check whether the malfunction has been successfully
repaired by performing a driving test using the freeze
frame data recorded at the time the malfunction
occurred.
OK:
Malfunction has been repaired successfully.
NG
9 CHECK ENGINE MOUNTING INSULATOR
(a) Visually check that the engine mounting insulator is

installed correctly and is not crooked or twisted.
OK:
No abnormalities.
NG REPAIR OR REPLACE ENGINE MOUNTING
INSULATOR
ES OK
10 CHECK INTAKE SYSTEM
(a) Check for air leaks and blockage between the air cleaner
and turbocharger.
(b) Check for air leaks and blockage between the
turbocharger and intake manifold.
OK:
No air leaks or blockage.
NG REPAIR OR REPLACE INTAKE SYSTEM
OK
(a) Inspect the exhaust retarder assembly.

ASSEMBLY
OK
12 CHECK EGR VALVE ASSEMBLY

NG REPLACE ELECTRIC EGR CONTROL VALVE
ASSEMBLY
OK
13 INSPECT DIESEL THROTTLE BODY ASSEMBLY

(b) Turn the ignition switch to the ON position and tester on.
(c) Enter the following menu items: Powertrain / Engine and
ECT / Diesel Throttle Angle.
(d) Read the value.
Standard:
Ignition switch in the ON position:
0%
Idling (Warmed up engine):
70%
Accelerator pedal fully depressed:
0%
OK Go to step 17
NG
REPLACE DIESEL THROTTLE BODY ASSEMBLY

ES
14 IDENTIFY MALFUNCTIONING CYLINDER INJECTOR
(a) Follow the instructions in the table below according to

the check result of the intelligent tester.
HINT:
This operation is based on the premise that the common
rail pressure is normal.
Standard
Injection Feedback Val #1 to #4 Idling -3.0 to 3.0 mm3
HINT:
*: The A/C switch and all accessory switches should be
off, and the engine should be fully warmed up.
Result
Injection volume
Injection Feedback Val #1 to #4 Between 5.0 and 15.0 mm3
Less than 5.0 mm3 More than 15.0 mm3
(Normal)
3.0 mm3 or more, -3.0 mm3 or A B B

less
Between -3.0 and 3.0 mm3 - Normal C*
Proceed to Inspection Areas Descriptions

Inspect and repair cylinder injector with
revised injection volume of less than -2.0
mm3:
Abnormal value cylinder injector injects
A • Perform power balance inspection and
excessively large quantity of fuel
identify malfunctioning cylinder
• Replace malfunctioning cylinder
injector
Identify malfunctioning cylinders by • Fuel injection volume too low due to
conducting power balance inspection: injector nozzle being blocked by
• Perform power balance inspection to deposits
B
identify malfunctioning cylinders • Abnormal value cylinder injector
• Clean malfunctioning cylinder injector, compression decreases
then check and repair it • Abnormal value cylinder injector
injects excessively large quantity of
fuel

All cylinder injectors inject excessively
Inspect and repair all cylinder injectors: small quantity of fuel:
C Clean all cylinder injectors, inspect, and Fuel injection volume too low due to all
repair them cylinder injector nozzles being blocked by
deposits
HINT:
*: When the Injection Volume displayed on the intelligent
tester is large despite the Fuel Press and Injection
Feedback Val #1 to #4 in the Data List being normal, the
injector may be clogged. In this case, there may be
ES deposits inside or outside the tip of the injector.
• Despite the injector functioning normally, the indicated
Injection Feedback Val #1 to #4 value may be outside
the normal operating range due to compensation for
other problems (such as low compression).
• Injection Feedback Val #1 to #4 is the value used to
correct the fuel injection volumes of each cylinder, in
order to optimize (compensate for the unevenness
between) all the cylinder combustion conditions. If
any of the cylinders malfunction, the fuel injection
volumes for the normal cylinders are corrected
simultaneously. As a result, the Injection Feedback
Val #1 to #4 may deviate from the standard range.
B Go to step 17
C Go to step 22

(b) Disconnect the connectors for the No.1 through No.4
of each cylinder.
NEXT
REPLACE INJECTOR OF MALFUNCTIONING CYLINDER
16 PERFORM ACTIVE TEST BY INJECTOR ASSEMBLY

ECT / Active Test / Control the Cylinder #1, #2, #3, and
#4 Fuel Cut.
(e) Check the four cylinders in sequence to identify any

faulty cylinders by performing the power balance
inspection.
HINT:
• If the engine idle does not change when an injector is
disabled, the cylinder being tested is malfunctioning.
• If the cylinder being tested is normal, there will be a
significant change in idle speed when the fuel
injection is stopped for that cylinder.
NEXT
ES
(a) Check the cylinder compression pressure. (See chapter

EM)
LOW COMPRESSION
OK
18 CHECK MALFUNCTIONING CYLINDER'S INJECTOR FOR DEPOSITS
HINT:
If an injector is contaminated with deposits, the fuel injection
volume deviates from the standard range. This may cause
malfunctions.
(a) Check the injector for any deposits.
Result
Injector Condition Proceed to
Deposits A
No deposits B
B REPLACE INJECTOR OF MALFUNCTIONING

CYLINDER
19 CLEAN INJECTOR ASSEMBLY
(a) Wipe away deposits from the tips of the injectors.

HINT:
• Solvent or carbon removal agents help remove
deposits easily.
• Exercise extreme care not to damage the injectors
while wiping off the deposits.
NEXT
20 READ VALUE OF INJECTOR ASSEMBLY (INJECTION FEEDBACK VAL AND INJECTION

VOLUME)
(a) Reinstall the injector to the cylinder head.

(b) Connect the intelligent tester to the DLC3.
(d) Turn the tester on.
(e) Start the engine and warm it up.
(f) Enter the following menu items: Powertrain / Engine and
ECT / Data List.
ES (g) Select the following menu items in order and read the
values.
Standard
HINT:
off, and the engine should be fully warmed up. When the
values are outside the standard range, deposits inside
the injector may be causing the problem.
OK:
Values are within the standard range.
NG REPLACE INJECTOR OF MALFUNCTIONING
CYLINDER
OK
END
21 CHECK INJECTORS FOR DEPOSITS (EXCEPT FUEL ADDITION INJECTOR)
HINT:
malfunctions.
Result
Deposits A
No deposits B
A

HINT:
deposits easily.
NEXT
ES

(f) Turn the tester on.
(g) Enter the following menu items: Powertrain / Engine and
ECT / Data List.
(h) Select the following menu items in order and read the
values.
Standard
HINT:
off, and the engine should be fully warmed up. When the
values are outside the standard range, deposits inside
the injector may be causing the problem.
OK:
OK
END

Component Side:
table below.
Standard resistance
F8-2 (VP) - F8-1 (GND) 16.4 kΩ or less
F8-5 (VP) - F8-3 (VC) 3 kΩ or less
F8 3 2 1
VC VP GND
A160890E02
OK
25 INSPECT SUPPLY PUMP ASSEMBLY

Valve table blow.
Standard resistance
S9
1-2 20°C (68°F) 1.9 to 2.3 Ω

A160890E02
OK
CHECK AND REPLACE COMMON RAIL ASSEMBLY (PRESSURE DISCHARGE VALVE)

Engine Knocking or Rattling

DESCRIPTION
• Injector compensation codes
1. Injector malfunctions • Fuel leakage
– Injector sliding malfunction • Intake air system leakage
– Injector stuck closed • Intake air system blockage
– Injector stuck open • EGR system
• Knocking and abnormal sound due to – Deposits in injector • Throttle valve system
extremely rich combustion – Injector circuit malfunction • Fuel pressure sensor
• Abnormal sound due to friction between 2. Abnormal common rail pressure • Manifold absolute pressure sensor
parts – Supply pump • Atmosphere air pressure sensor (built into
ES
– Fuel pulsation sound ECM)
– Air in fuel • Vehicle modifications
3. Friction between parts • Low quality fuel
4. Compression pressure • Lack of fuel
• ECM
HINT:
List values may occur depending on the measuring conditions or the vehicle's age. Do not judge the
vehicle to be normal even when the Data List values indicate a standard level. There are possibly
NOTICE:
• After replacing an injector, the ECM needs registration (See page ES-3).
HINT:
• This troubleshooting procedure checks for knocking and rattling.
• Knocking is most likely to occur while the engine is idling.
1 CHECK SOUND AREA
(a) Find source of the abnormal sound using a mechanic's

stethoscope.
Result
Result Proceed to
Sound from supply pump A
Sound from parts other than supply pump B
B REPAIR OR REPLACE MALFUNCTION

PARTS
2 CHECK WIRE HARNESS IN ENGINE COMPARTMENT
(a) Check the wire harness connections.

OK:
Wire harnesses are connected securely.

CONNECTOR
OK
HINT:
ES system, EGR system and throttle valve. If DTCs are set,
(a) Enter CHECK MODE.
(b) Fully warm up the engine.
(c) Allow the engine to idle for 5 minutes or more.
(d) Drive the vehicle at more than 40 km/h (25 mph) for 1
minute or more (Procedure "A").
(e) Decelerate and stop the vehicle (Procedure "B").
(f) Repeat steps "A" (See procedure "A") and "B" (See
procedure "B") 4 times or more.
(g) Stop the engine and wait for at least 10 seconds
(Procedure "C").
(h) Repeat steps "A" (See procedure "A") and "C" (See
procedure "C") described above (to set DTCs relating to
the EGR system and throttle valve).
(i) Drive the vehicle at more than 70 km/h (43 mph) for at
NEXT
4 READ OUTPUT DTC (RELATING TO ENGINE)

ECT / DTC.
(e) Read pending DTC.
Result
No output A
B GO TO DTC CHART
A
5 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (TEST THE FUEL LEAK)
HINT:
maintained. As a result, a fuel leak check can be conducted
while retaining the high common rail pressure.
ES
(e) Visually check the supply pump, injector, and fuel line
and the injector.
HINT:
the supply pump.
OK:
No fuel leakage.
POINT
OK

(b) Start the engine, and warm it up.
ECT / Data List.
values.
• MAP
• MAF
• Fuel Press
Standard
90 to 105 kPa (675 to 788
mmHg, 26.57 to 31.00 in.Hg)
110 to 140 kPa (825 to 1,050
mmHg. 32.48 to 41.35 in.Hg)
0 g/s
position (engine stopped) Intake air volume detected by
MAF
Idling 8 to 12 g/s mass air flow meter

Idling 25 to 35 MPa
pressure
Result
MAP, MAF and Fuel press Standard range A
ES Only Fuel Press Outside standard range E
HINT:
B Go to step 10
C GO TO DTC P0105, P0107 AND P0108

PRESSURE SENSOR)
D GO TO DTC P0100, P0102 AND P0103

E Go to step 27
7 READ VALUE OF INJECTOR ASSEMBLY (INJECTION FEED BACK VAL AND INJECTION
VOLUME)
values.
Standard
Injection Feedback Val #1 Idling -3.0 to 3.0 mm3 Value of injector fuel injection
volume compensates for
Injection Feedback Val #2 Idling 3
-3.0 to 3.0 mm differences in combustion
condition of cylinders
• Positive values indicate
control which corrects
combustion degradation
• Negative values indicate
control which corrects
Injection Feedback Val #4 Idling -3.0 to 3.0 mm3 excessive combustion
pressure
• If problems exist, Injection
Feedback Val may deviate
from -3.0 and 3.0 mm range

Fuel injection volume value
controlled by ECU
• Controls NE signal, fuel
temperature, engine
coolant temperature, intake
Injection Volume Idling 5.0 to 12.0 mm3 air temperature, boost
pressure, atmospheric
pressure, and EGR volume.
• If problems exist, Injection
Volume may be outside
standard range
Result
ES
Result Proceed to
Standard range A
Injection Feedback Val #1 to #4 and/or Injection Volume outside
B
standard range
HINT:
*: The A/C switch and all accessory switches should be off,
and the engine should be fully warmed up.
B Go to step 20
HINT:
If the injector compensation code is not correctly registered, it
may cause malfunctions (See page ES-7).
OK:
Compensation code of the installed injector is the same
as the code registered in the ECM.
NG REGISTER INJECTOR COMPENSATION
CODE
OK
9 RESET ECM
(a) Disconnect the cable from the negative battery terminal

for at least 2 minutes.
(b) Reconnect the cable to the negative battery terminal.
occurred.
OK:
OK END
NG
and turbocharger.
OK:
No air leakage or blockage.
NG REPAIR OR REPLACE MALFUNCTION
ES PARTS
OK

ASSEMBLY
OK

OK

(e) Read the value.
Standard:
0%
70%
0%
ASSEMBLY
OK
14 CHECK COMBUSTION SOUND
(a) Confirm type of sound emitted.

Result
Result Proceed to
Knocking A
Mechanical sound other than knocking B
B Go to step 25
ES
A

of each cylinder.
NEXT

EM).
LOW COMPRESSION
OK
HINT:
malfunctions.
Result
Result Proceed to
Deposits A
No deposits B
B REPLACE INJECTOR ASSEMBLY OF

MALFUNCTIONING CYLINDER
A

HINT:
deposits easily.
NEXT
ES
19 READ VALUE OF INJECTOR ASSEMBLY (INJECTION FEEDBACK VAL AND INJECTION
VOLUME)

ECT / Data List.
(g) Select the following menu items in order and read the
values.
Standard
HINT:
• *: The A/C switch and all accessory switches should
be off, and the engine should be fully warmed up.
• When the values are outside the standard range,
deposits inside the injector may be causing the
problem.
OK:
NG REPLACE INJECTOR ASSEMBLY OF
OK
END

HINT:
Standard
HINT:
Result ES
Injection Volume Injection Volume
Between 5.0 and 15.0 mm3

Injection Feedback Val #1 to #4 Less than 5.0 mm3 More than 15.0 mm3
(Normal)
2.0 mm3 or more, -2.0 mm3 or

A B B
less
Between -2.0 to 2.0 mm3 - Normal C*

mm3 :
injector
excessively large quantity of fuel:
B
then check and repair it • Abnormal value cylinder injector
fuel
C Clean all cylinder injectors, and then Fuel injection volume too low due to all
inspect and repair them cylinder injector nozzles being blocked by
deposits
HINT:
tester is large despite the Fuel Press and Injection Feedback
Val #1 to #4 in the Data List being normal, the injector may be
clogged. In this case, there may be deposits inside or outside
the injector.
Injection Feedback Val #1 to #4 values may be outside the
normal operating range due to compensation for other
problems (such as low compression).

correct the fuel injection volumes of each cylinder, in order
to optimize (compensate for the unevenness between) all
the cylinder combustion conditions. If any of the cylinders
malfunction, the fuel injection volumes for the normal
cylinders are corrected simultaneously. As a result, the
Injection Feedback Val #1 to #4 may deviate from the
standard range.
B Go to step 17
C Go to step 22
ES
A

of each cylinder.
NEXT
REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER
HINT:
malfunctions.
Result
Deposits A
No deposits B

HINT:
deposits easily.
NEXT

ECT / Data List. ES
values displayed on the intelligent tester respectively.
Standard

HINT:
When the values are outside the standard range,
deposits inside the injector may be causing the problem.
OK:
OK
END
25 BLEED AIR FROM FUEL SYSTEM
(a) To bleed air from the priming pump, pump the priming
pump until it becomes hard and cannot be pumped any
more.
NEXT
26 CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED
(a) Check whether the knocking has been successfully

repaired by performing a driving test.
OK:
NEXT
END

(b) Measure the resistance between each terminal of the
Component Side:
fuel pressure sensor connector.
ES
Standard resistance
(c) Reconnect the fuel pressure sensor connector.

F8 3 2 1
VC VP GND
A160890E02
OK
(a) Measure the resistance between the suction control

Suction Control valve terminals.
Valve Standard resistance
S9 S9-1 - S9-2 20°C (68°F) 1.9 to 2.3 Ω
A160890E02
OK
29 READ VALUE OF INTELLIGENT TESTER (PCV OPEN CURRENT FB VAL)

ECT / Data List / PCV Open Current FB Val.
(e) Read the value.
Standard
Engine Speed Result
OK
REPAIR OR REPLACE COMMON RAIL ASSEMBLY (PRESSURE DISCHARGE VALVE)
ES
Lack of Power or Hesitation

DESCRIPTION
• Pressure limiter
• Intake air system leakage
1. Injector malfunctions
• Intake air system blockage
– Injector sliding malfunction
• EGR system
– Injector stuck closed
• Lack of power caused by abnormal fuel • Fuel filter element is clogged
– Injector stuck open
injection volume (supply pump • Throttle valve
– Deposits in injector
malfunction or injector malfunction) • Compression pressure
– Injector circuit malfunction
• Lack of power caused by intake air • Injector compensation code
ES volume shortage (turbocharger
2. Abnormal common rail pressure
• Fuel leak
– Supply pump
malfunction, front exhaust pipe or exhaust • Fuel pressure sensor
3. Abnormal intake air volume
manifold converter blocked) • EDU (P0200/97 set simultaneously)
– Turbocharger
• Vehicle modifications
– Front exhaust pipe blockage
• Low quality fuel
– Exhaust manifold converter blockage
• Frozen fuel
• ECM
HINT:
List values may occur depending on the measuring conditions or the vehicle's age. Do not judge the
vehicle to be normal even when the Data List values indicate a standard level. There are possibly
• This troubleshooting procedure checks for the cause of an obvious lack of engine power (the vehicle
speed does not reach the target speed in the high speed range) while the vehicle is being driven.
NOTICE:
• After replacing the injector, the ECM needs registration (See page ES-3).
HINT:
Before troubleshooting, conduct the following:
(a) Check the fuel quality.
(b) Check the fuel for air.
(c) Check the fuel system for blockages.
(d) Check the air filter.
(e) Check the engine oil.
(f) Check the engine coolant.
(g) Check the engine idling speed and the maximum engine speed.
(h) Check the vacuum pump.
1 CHECK HARNESS AND CONNECTOR IN ENGINE ROOM
(a) Check the wire harness and connector connections of

the common rail system components.
HINT:
Check the following components and systems:
• Sensors
• Supply pump
• Common rail
• Injectors
• EDU
• Turbocharger system
• Intake and exhaust system

OK:
The wire harnesses and connectors are
connected securely.
CONNECTOR
OK

ES
HINT:
system, EGR system, and throttle valve. If DTCs are set,
(a) Start the engine (Procedure "A").
(b) Stop the engine and wait for at least 10 seconds
(Procedure "B").
(c) Perform steps "A" (See procedure "A") and "B" (See
procedure "B") again described above (to allow the ECM
to set pressure discharge valve malfunction DTCs).
(d) Enter CHECK MODE.
(e) Fully warm up the engine.
(f) Allow the engine to idle for 5 minutes or more.
(g) Drive the vehicle at more than 40 km/h (25 mph) for 1
minute or more (Procedure "C").
(h) Decelerate and stop the vehicle (Procedure "D").
(i) Repeat steps "C" (See procedure "C") and "D" (See
procedure "D") 4 times or more.
(j) Stop the engine and wait for at least 10 seconds
(Procedure "E").
(k) Repeat steps "C" (See procedure "C") and "E" (See
procedure "E") described above (to set DTCs relating to
the EGR system and throttle valve).
(l) Drive the vehicle at more than 70 km/h (43 mph) for at
NEXT
3 READ OUTPUT DTC (RELATING TO ENGINE)
(a) Read pending DTCs.

Result
No DTCs A
B GO TO DTC CHART
A
4 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (TEST THE FUEL LEAK)
HINT:
result, a fuel leak check can be conducted while retaining the
ES (c) Turn the tester on.
(e) Visually check the supply pump, injector and fuel line
and the injector.
HINT:
the supply pump.
OK:
No leakage.
POINT
OK
5 CHECK WHITE SMOKE
(a) Rev up the engine from idling to 3,000 rpm several times
to check whether white smoke is emitted from the
exhaust pipe.
(b) Check that the intake system pipes and hoses are not
excessively contaminated with oil. If white smoke is
emitted from the intake system, its pipes and hoses are
excessively contaminated with oil. If the presence of
white smoke in the exhaust gas is confirmed, there is a
high possibility of mechanical problems in the
turbocharger or engine.
Result
Result Proceed to
No problems described above A
White smoke emitted, or intake system pipes and hoses excessively contaminated with oil B
B Go to step 26
A

(b) Start the engine and warm it up. Turn the intelligent
tester on.
(c) Enter the following menu items: Powertrain / Engine and
ECT / Data List.
values.
• MAP
• MAF
ES
• Fuel Press
Standard
Item Engine Speed*1 Standard Range Description
90 to 105 kPa (675 to 788
mmHg, 26.57 to 31.00 in.Hg)
110 to 140 kPa (825 to 1,050
mmHg, 32.48 to 41.35 in.Hg)
0 g/s
MAF
Idling 25 to 35 MPa
pressure
Result
MAP, MAF, and Fuel press Standard range A
Only Fuel Press Outside standard range E
HINT:
B Go to step 23
C GO TO DTC P0105, P0107, AND P0108

PRESSURE SENSOR)
D GO TO DTC P0100, P0102, AND P0103

E Go to step 32
A
7 READ VALUE OF INJECTOR (INJECTION FEED BACK VAL AND INJECTION VOLUME)
values.
Standard
Injection Feedback Val #1 Idling -3.0 to 3.0 mm3 Value of injector fuel injection volume compensates for
differences in combustion condition of cylinders
ES Injection Feedback Val #2 Idling -3.0 to 3.0 mm3 • Positive values indicate control which corrects
combustion degradation
• Negative values indicate control which corrects
excessive combustion pressure
Injection Feedback Val #4 Idling -3.0 to 3.0 mm3 • If problems exist, "Injection Feedback Val" may
deviate from the -2.0 and 2.0 mm range
Fuel injection volume value controlled by ECU
• Controls NE signal, fuel temperature, engine coolant
temperature, intake air temperature, boost pressure,
atmospheric pressure, and EGR volume.
• If problems exist, "Injection Volume" may be outside
the standard range
Result
Result Proceed to
Standard range A
Injection Feedback Val #1 to #4 and/or Injection Volume outside standard range B
HINT:
B Go to step 13
(a) Read the injector compensation code. (See page ES-7)

HINT:
If the injector compensation code is not correctly
registered, it may cause malfunctions (See page ES-7).
(b) Check the injector compensation code.
OK:
Compensation code of the installed injector is the
same as the one registered in the ECM.
NG REGISTER INJECTOR COMPENSATION
CODE
OK
9 RESET ECM
(a) Disconnect the cable from the negative battery terminal

for at least 2 minutes.
(b) Reconnect the cable to the negative battery terminal.
occurred.
OK:
ES
NG
10 BLEED AIR FROM FUEL SYSTEM
(a) To bleed air from the priming pump, pump the priming
pump until it becomes hard and cannot be pumped any
more.
NEXT
11 CONFIRM WHETHER LACK OF POWER HAS BEEN SUCCESSFULLY REPAIRED
(a) Check whether the lack of power has been successfully

repaired by performing a driving test. Use the freeze
occurred.
OK:
OK END
NG
and turbocharger.
OK:
No leakage or blockage.
NEXT
END

HINT:
Standard
ES Injection Feedback Val #1 to #4 Idling -3.0 to 3.0 mm3

HINT:
Result
Injection Volume Injection Volume
Between 5.0 and 15.0 mm3

Injection Feedback Val #1 to #4 Less than 5.0 mm3 More than 15.0 mm3
(Normal)
2.0 mm3 or more, -2.0 mm3 or A B B

less
Between -2.0 to 2.0 mm3 - Normal C*

mm3:
injector
excessively small quantity of fuel:
B
check, and repair it • Abnormal value cylinder injector
fuel
C Clean all cylinder injectors, inspect, and Fuel injection volume too low due to all
repair them cylinder injector nozzles being blocked by
deposits
HINT:
tester is large despite the Fuel Pressure and Injection
Feedback Val #1 to #4 in the Data List being normal, the
injector may be clogged. In this case, there may be
deposits inside or outside the tip of the injector.

Injection Feedback Val #1 to #4 value may be outside
the normal operating range due to compensation for
other problems (such as low compression).
correct the fuel injection volumes of each cylinder, in
order to optimize (compensate for the unevenness
between) all the cylinder combustion conditions. If
any of the cylinders malfunction, the fuel injection
volumes for the normal cylinders are corrected
simultaneously. As a result, the Injection Feedback
Val #1 to #4 may deviate from the standard range. ES
B Go to step 15
C Go to step 22

of each cylinder.
NEXT
REPLACE INJECTOR ASSEMBLY OF MALFUNCTIONING CYLINDER

of each cylinder.
NEXT

EM).
LOW COMPRESSION
OK
HINT:
malfunctions.
Result
Result Proceed to
ES Deposits A
No deposits B
B REPLACE INJECTOR ASSEMBLY OF


HINT:
deposits easily.
NEXT

ECT / Data List.
values.
Standard
HINT:
• The A/C switch and all accessory switches should be

deposits inside the injector may be causing the
problem.
OK:
NG REPLACE INJECTOR ASSEMBLY OF
OK
END ES
HINT:
malfunctions.
Result
Deposits A
No deposits B

HINT:
deposits easily.
NEXT

ECT / Data List.
values.

Standard
Injection Volume #1 to #4 Idling 5.0 to 12.0 mm3
HINT:
• *: The A/C switch and all accessory switches should
be off with a fully-warmed engine.
ES deposits inside the injector may be causing the
problem.
OK:
OK
END

OK

(b) Turn the ignition switch in the ON position.
(e) Read the value.
Standard:
0%
95%
0%
ASSEMBLY
OK
and turbocharger.
OK:
No leakage or blockage.
NG REPAIR OR REPLACE MALFUNCTIONING
PARTS ES
OK

ASSEMBLY
OK
(a) Check the turbocharger (See chapter IT).

ASSEMBLY
OK

ECT / Data List.
values.
• MAP
• MAF
• Fuel Press
Standard
90 to 105 kPa (675 to 788
mmHg, 26.57 to 31.00 in.Hg)
110 to 140 kPa (825 to 1,050
mmHg, 32.48 to 41.35 in.Hg)

0 g/s
MAF
HINT:
OK:
The values are within the standard range.
ES OK END
NG
29 REPLACE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
NEXT

ECT / Data List.
values.
• MAP
• MAF
• Fuel Press
Standard
90 to 105 kPa (675 to 788
mmHg, 26.57 to 31.00 in.Hg)
110 to 140 kPa (825 to 1,050
mmHg, 32.48 to 41.35 in.Hg)
0 g/s
position (engine stopped) Intake air volume detected by
MAF
HINT:
OK:
ASSEMBLY
OK
END
31 CHECK AND REPLACE FUEL FILTER ASSEMBLY
NEXT
ES
(a) Replace the normal DLC3 cable (12 V specification) for

the intelligent tester with the 24 V DLC3 cable.
NOTICE:
Be sure to use the 24 V DLC3 cable when connecting
the intelligent tester to the DLC3. Using the normal
DLC3 cable (12 V specification) will cause damage to
the tester.
(c) Start the engine and warm it up.
(e) Enter the following menu items: Powertrain / Engine and
ECT / Data List.
(f) Select the following menu item and read the values.
• Fuel Press
Standard
Item Engine Speed *1 Reference Value
Fuel Press Idling 25 to 35 MPa
Fuel Press 2,000 rpm (no engine load) 80 to 90 MPa
Fuel Press 3,000 rpm (no engine load) 100 to 110 MPa
HINT:
OK:
OK END
NG

(b) Measure the resistance between each terminal of the
Component Side:
fuel pressure sensor connector.
Standard resistance
F8 3 2 1
VC VP GND
A160890E02
OK

Suction Control valve terminals.
Valve Standard resistance
S9 S9-1 - S9-2 20°C (68°F) 1.9 to 2.3 Ω
A160890E02
OK
35 READ VALUE OF INTELLIGENT TESTER (PCV OPEN CURRENT FB VAL)

ECT / Data List / PCV Open Current FB Val.
(e) Read the value.
Standard
Engine Speed Result

OK
CHECK AND REPLACE COMMON RAIL ASSEMBLY (PRESSURE DISCHARGE VALVE)
ES
ECM Power Source Circuit

DESCRIPTION
When the ignition switch is turned to the ON position, battery positive voltage is applied to the coil, closing
the contacts of the MAIN relay and supplying power to terminal +B of the ECM.
WIRING DIAGRAM
ES 3 5
16
E25 IGSW
5 8 1 2
AM1 AM2 IG2
I6 Ignition Switch ENG-2
1
5 3
E25 +B
HEAD 13
2 1
E25 MREL
ENG
ENG-3
1
+24V OUT1 2
DC-DC1
8 7
OUT2
Battery E23 E1
D8 Voltage Converter
Battery
ECM
A162397E02
1 CHECK ECM (+B VOLTAGE)

Standard voltage
E25-1 (+B) - E23-7 (E1) Always 11 to 14 V
ECM Connector +B
E1 NG Go to step 3
A153569E16
OK
PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE
2 CHECK HARNESS AND CONNECTOR (ECM - BODY GROUND)
(a) Disconnect ECM connector.

table below.
ECM Connector ES
Standard resistance
E23-7 (E1) - Body ground Always Below 1 Ω
E23 (c) Reconnect the ECM connector.

CONNECTOR (ECM - BODY GROUND)
E1
A154709E01
OK
3 CHECK ECM (MREL VOLTAGE)

ECM Connector
E25 table below.
Standard voltage
E25-13 (MREL) - Body Ignition switch in the
11 to 14 V
ground ON position
MREL
NG Go to step 10
A153569E17
OK
4 INSPECT FUSE (ENG FUSE)
(a) Remove the ENG fuse from the No. 1. (Refer to Pub. No.
No. 1 Relay Block
S1-YXZE16C EWD for the relay and fuse location of
each vehicle)
table below.
Standard resistance

ENG Fuse
(c) Reinstall the ENG fuse.
NG REPLACE FUSE (ENG FUSE)
ASM3-768
OK
5 INSPECT ENG-3 RELAY
(a) Remove the ENG-3 relay from the No. 1.

table below.
Standard resistance
Battery voltage is not applied
3-5 10 kΩ or higher
to terminals 1 and 2
Battery voltage is applied to
3-5 Below 1 Ω
terminals 1 and 2
B016200E02
(c) Reinstall the ENG-3 relay.
NG REPLACE ENG-3 RELAY
OK
6 CHECK HARNESS AND CONNECTOR (ENG-3 RELAY - ECM)
(a) Remove the ENG-3 relay from the No. 1. (Refer to Pub.
No. 1 Relay Block No. S1-YXZE16C EWD for the relay and fuse location of
each vehicle)
table below.
Check for open
ES
ENG-3 Relay
ENG-3 relay terminal 3 - E25-1
Always Below 1 Ω
(+B)
Check for short

ENG-3 relay terminal 3 or E25-1
(+B) - Body ground
(d) Reinstall the ENG-3 relay.

E25
CONNECTOR (ENG-3 RELAY - ECM)
ECM Connector
+B
A164240E01
OK
7 CHECK HARNESS AND CONNECTOR (ENG-3 RELAY - BODY GROUND)
(a) Remove the ENG-3 relay from the No. 1 relay block.
No. 1 Relay Block
table below.
Standard resistance
ENG-3 Relay ENG-3 relay terminal 2 - Body
Always Below 1 Ω
ground

CONNECTOR (ENG-3 RELAY - BODY
GROUND)
A164152E01
OK
8 CHECK HARNESS AND CONNECTOR (ECM - ENG-3 RELAY)
table below.
Check for open
ES
ENG-3 Relay
E25-13 (MREL) - ENG-3 relay
Always Below 1 Ω
terminal 1
Check for short

E25-13 (MREL) or ENG-3 relay
terminal 1 - Body ground

E25
CONNECTOR (ECM - ENG-3 RELAY)
ECM Connector
MREL
A164240E02
OK
9 CHECK HARNESS AND CONNECTOR (ENG-3 RELAY - BATTERY)
No. 1 Relay Block
(b) Disconnect the negative battery terminal.
(c) Disconnect the positive battery terminal.
(d) Measure the resistance according to the value(s) in the
table below.
ENG-3 Relay Standard resistance:
Check for open
ENG-3 relay terminal 5 - Battery
Always Below 1 Ω
positive terminal
Check for short

A164152E01
ENG-3 relay terminal 5 or Battery
positive terminal - Body ground
(e) Reinstall the ENG-3 relay.

(f) Reconnect the positive battery terminal.

(g) Reconnect the negative battery terminal.
CONNECTOR (ENG-3 RELAY - BATTERY)
OK
10 CHECK ECM (IGSW VOLTAGE)

ECM Connector
(b) Measure the voltage according to the value(s) in the ES
E25 table below.
Standard voltage
E25-16 (IGSW) - Body Ignition switch in the
11 to 14 V
ground ON position
IGSW
NG Go to step 11
A153569E18
OK
CHECK VOLTAGE CONVERTER SYSTEM
table below.
Standard resistance
AM1 Fuse (c) Reinstall the AM2 fuse.

ASM3-769
OK
12 INSPECT ENG-2 RELAY
table below.
Standard resistance
3-5 Always 10 kΩ or higher
below 1 Ω
ES 3-5 Always (when battery voltage is applied
to terminals 1 and 2)
A154711
NG REPLACE ENG-2 RELAY
OK
13 CHECK HARNESS AND CONNECTOR (ENG-2 RELAY - ECM)
No. 1 Relay Block fuse location of each vehicle)
table below.
Check for open
ENG-2 relay terminal 5 - E25-16
Always Below 1 Ω
(IGSW)
ENG-2 Relay
Check for short
ENG-2 relay terminal 5 or E25-16
(IGSW) - Body ground

E25
CONNECTOR (ENG-2 RELAY - ECM)
ECM Connector
IGSW
A164242E01
OK
14 CHECK HARNESS AND CONNECTOR (ENG-2 RELAY - BATTERY)
table below.
Check for open
ES
ENG-2 relay terminal 3 - Battery
Always Below 1 Ω
ENG-2 Relay positive terminal
Check for short

A164155E01
ENG-2 relay terminal 3 or Battery
positive terminal - Body ground

CONNECTOR (ENG-2 RELAY - BATTERY)
OK
15 CHECK HARNESS AND CONNECTOR (ENG-2 RELAY - BODY GROUND)
table below.
Standard resistance
ENG-2 relay terminal 2 - Body
Always Below 1 Ω
ground

ENG-2 Relay NG REPAIR OR REPLACE HARNESS OR
CONNECTOR (ENG-2 RELAY - BODY
GROUND)
A164155E01
OK

Component Side:
table below.
Ignition Switch
Standard resistance
ACC I6 I6-5 (AM2) - I6-8 (IG2) LOCK 10 kΩ or higher
LOCK
I6-5 (AM2) - I6-8 (IG2) ON Below 1 Ω
ON
ES (c) Reconnect the ignition switch connector.
AM1 IG2
A153627E06
OK
17 CHECK HARNESS AND CONNECTOR (ENG-2 RELAY - IGNITION SWITCH)
No. 1 Relay Block
(b) Disconnect the ignition switch connector.
table below.
Check for open
ENG-2 relay terminal 1 - I6-8 (IG2) Always Below 1 Ω
Check for short

ENG-2 Relay
ENG-2 relay terminal 1 or I6-8
(IG2) - Body ground

Ignition Switch Connector (e) Reconnect the ignition switch connector.
CONNECTOR (ENG-2 RELAY - IGNITION
SWITCH)
I6
IG2
A164263E01
OK
REPAIR OR REPLACE HARNESS OR CONNECTOR (IGNITION SWITCH - BATTERY)
ES
EDU Power Source Circuit

DESCRIPTION
An injector driver has been adopted to drive the injectors at high speeds. The injector driver has realized
high-speed driving under high fuel pressure conditions through the use of a voltage converter that
provides a high-voltage, quick-charging system. The ECM constantly monitors the injector driver and
stops the engine or cuts off fuel supply to some cylinders if an abnormal condition is detected.
WIRING DIAGRAM
ES
5 3
ENG 14
1 2 E25 IREL
DC/DC1
EDU
1 E26 8
+24V +B
2
OUT1 1
ENG E27 GND
8
OUT2 5 3
EDU
13
X17 Voltage Converter 2 1
E25 MREL
ENG-3
16
3 5
MAIN5 E25 IGSW
2 1
ENG-2
Battery
5 8
AM2 AM2 IG2
Battery I6 Ignition Switch
ECM
A169286
NOTICE:
1 CHECK EDU (POWER SOURCE)

EDU Connector table below. ES
Standard voltage
E26 E26-8 (+B) - E27-1 (GND) 18 to 27 V
position
+B (+) (d) Reconnect the EDU connector.

Front View
NG Go to step 2
EDU Connector
E27
GND (-)
Front View
A153605E01
OK
REPLACE EDU
2 INSPECT EDU RELAY
(a) Remove the EDU relay from the No. 2 relay block.
table below.
Standard resistance
3-5 Battery voltage not applied 10 kΩ or higher
Battery voltage applied to
3-5 Below 1 Ω
terminals 1 and 2
B016200E02 (c) Reinstall the EDU relay.

NG REPLACE EDU RELAY
OK
3 INSPECT FUSE (ENG FUSE)
(a) Remove the ENG fuse from the No. 1 relay block. (Refer
No. 1 Relay Block
to Pub. No. S1-YXZE16C EWD for the relay and fuse
location of each vehicle)
table below.
Standard resistance

ENG Fuse
(c) Reinstall the ENG fuse.
NG REPLACE FUSE (ENG FUSE)
ASM3-768
OK
4 CHECK HARNESS AND CONNECTOR (EDU RELAY - BATTERY)
No. 2 Relay (Refer to Pub. No. S1-YXZE16C EWD for the relay and
Block fuse location of each vehicle)
table below.
Check for open
EDU relay terminal 5 - Positive
EDU Relay Always Below 1 Ω
battery terminal
Check for short

EDU relay terminal 5 or Positive
battery terminal - Body ground
No. 2 Relay Block (e) Reinstall the EDU relay.

CONNECTOR (EDU RELAY - BATTERY)
EDU Relay
A164156E01
OK
5 CHECK HARNESS AND CONNECTOR (EDU RELAY - ENG-3 RELAY)
(b) Remove the ENG-3 relay from the No. 1 relay block.
table below.
Standard resistance: ES
Check for open
EDU relay terminal 1 - ENG-3
Always Below 1 Ω
relay terminal 3
ENG-3 Relay
Check for short
EDU relay terminal 1 or ENG-3
relay terminal 3 - Body ground
(d) Reinstall the EDU relay.

No. 2 Relay Block
CONNECTOR (EDU RELAY - ENG-3 RELAY)
EDU Relay
No. 2 Relay Block
EDU Relay
A164272E01
OK
6 CHECK HARNESS AND CONNECTOR (EDU RELAY - ECM)
No. 2 Relay Block
table below.
ES Standard resistance:
Check for open
EDU relay terminal 2 - E25-14
Always Below 1 Ω
(IREL)
Check for short

EDU Relay Tester Connection Condition Specified Condition
EDU relay terminal 2 or E25-14
(IREL) - Body ground

(e) Reinstall the EDU relay.
No. 2 Relay Block CONNECTOR (EDU RELAY - ECM)
EDU Relay
E25
ECM Connector
IREL
A164273E01
OK
7 CHECK HARNESS AND CONNECTOR (EDU RELAY - EDU)
(a) Disconnect the EDU relay from the No. 2 relay block.
No. 2 Relay Block fuse location of each vehicle)
(b) Disconnect the EDU connector.
table below.
Check for open
ES
EDU relay terminal 3 - E26-8 (+B) Always Below 1 Ω
Check for short

EDU relay terminal 3 or E26-8
EDU Relay Always 10 kΩ or higher
(+B) - Body ground

(e) Reinstall the EDU relay.
CONNECTOR (EDU RELAY - EDU)
EDU Connector
E26
A164274E01
OK
8 CHECK HARNESS AND CONNECTOR (EDU - BODY GROUND)

table below.
EDU Connector Standard resistance
E27-1 (GND) - Body ground Always Below 1 Ω
E27 (c) Reconnect the EDU connector.
GND A154955E01
CONNECTOR (EDU - BODY GROUND)
OK
9 CHECK ECM (IREL VOLTAGE)

ECM Connector
E25 table below.
Standard voltage
E25-14 (IREL) - Body Ignition switch in the ON
ES ground position
11 to 14 V
IREL
NG CHECK ECM POWER SOURCE CIRCUIT
A153569E19
OK
REPLACE ECM
VC Output Circuit
DESCRIPTION
The ECM constantly uses 5 V from the battery voltages supplied to the +B (BATT) terminal to operate the
microprocessor. The ECM also provides this power to the sensors through the VC output circuit.
When the VC circuit is short-circuited, the microprocessor in the ECM and sensors that obtain power
through the VC circuit are deactivated because power is not supplied from the VC circuit. Under this
condition, the system does not start up and the MIL is not illuminated even if the system malfunctions.
HINT:
Under normal conditions, the MIL is illuminated for several seconds when the ignition switch is first turned
to the ON position. The MIL goes off when the engine is started. ES
ECM
BATT
From EFI MAIN Fuse 5 V Constant Voltage Circuit
+B
From EFI Relay
Microprocessor
Throttle Position Sensor, Accelerator
Pedal Position Sensor, etc. (Sensors VC
which have IC)
Engine Coolant Temperature Sensor,

R
Intake Air Temperature Sensor, etc.
A116143E14
WIRING DIAGRAM
ECM
1 28
GND 2
3 PB E23 PIM
VC
T2
ES 18
E22 VC
2 20
E2 3
1 Y1A E23 VLU
VC
T7
Throttle Position Sensor *E1
2 33
E2 4
3 EGLS E23 EGLS
VC
E17
EGR Valve Position Sensor *E1
1 27
GND 2
3 VP E23 PEX
VC
D14
Differential Pressure Sensor *E2
26
2
1 PFUEL E22 PCR1
GND
3
VC

28
E22 E2
ASM3-804
ECM
22
3
VCC E23 VCG
1 23
OUT E23 G+
2 31
GND E23 G-
ES
Camshaft Position Sensor1
20
4
VCP1 E25 VCPA
22
6
VPA1 E25 VPA
28
5
EP1 E25 EPA
21
1
VCP2 E25 VCP2
23
3
VPA2 E25 VPA2
29
2
EP2 E25 EPA2
A11
A154228E01
NOTICE:
1 CHECK MIL
(a) Check that the Malfunction Indicator Lamp (MIL) lights

up when turning the ignition switch to the ON position.
OK:
MIL lights up.
OK GO TO MIL CIRCUIT (See page ES-309)
NG
2 CHECK CONNECTION BETWEEN Hino-DX AND ECM

(b) Turn the ignition switch to the ON position and tester on.
(c) Check the communication between the Hino-DX and
ECM.
Result
Result Proceed to
ES Communication is possible A
Communication is not possible B
A GO TO MIL CIRCUIT (See page ES-309)
3 CHECK DIESEL THROTTLE BODY (CHECK MIL ILLUMINATED)

(c) Check the MIL.
Result
Result Proceed to
MIL is illuminated A
MIL is not illuminated B
(d) Reconnect the throttle position sensor connector.

A REPLACE DIESEL THROTTLE BODY
ASSEMBLY
4 CHECK ACCELERATOR PEDAL (CHECK MIL ILLUMINATED)

connector.
(c) Check the MIL.
Result
Result Proceed to
(d) Reconnect the accelerator pedal position sensor

connector.
A REPLACE ACCELERATOR PEDAL
ASSEMBLY
5 CHECK CAMSHAFT POSITION SENSOR (CHECK MIL ILLUMINATED)
(a) Disconnect the connector from the camshaft position

sensor.
(c) Check the MIL.
Result
Result Proceed to
ES
(d) Reconnect the connector to the camshaft position

sensor.
A REPLACE CAMSHAFT POSITION SENSOR
6 CHECK TURBO PRESSURE SENSOR (CHECK MIL ILLUMINATED)
(a) Disconnect the connector from the turbo pressure

sensor.
(c) Check the MIL.
Result
Result Proceed to
(d) Reconnect the connector to the turbo pressure sensor.

A REPLACE TURBO PRESSURE SENSOR
7 CHECK EGR VALVE POSITION SENSOR (CHECK MIL ILLUMINATED) *E1
(a) Disconnect the connector from the EGR valve position

sensor.
(c) Check the MIL.
Result
Result Proceed to
(d) Reconnect the connector to the EGR valve position

sensor.
A REPLACE EGR VALVE ASSEMBLY (EGR
VALVE POSITION SENSOR)
8 CHECK DIFFERENTIAL PRESSURE SENSOR (CHECK MIL ILLUMINATED) *E2
(a) Disconnect the connector from the differential pressure

sensor.
(c) Check the MIL.
Result
Result Proceed to
ES MIL is illuminated A
(d) Reconnect the connector from the differential pressure

sensor.
A REPLACE DIFFERENTIAL PRESSURE
SENSOR
9 CHECK HARNESS AND CONNECTOR

Wire Harness Side: (b) Disconnect the accelerator pedal position sensor
connector.
ECM Connector (c) Disconnect the connector from the camshaft position
sensor.
(d) Disconnect the connector from the turbo pressure
E22 sensor.
E23 E25
(e) Disconnect the connector from the EGR valve position
sensor.
(f) Disconnect the connector from the differential pressure
sensor.
(g) Disconnect the ECM connector.
VCP2 (h) Measure the resistance according to the value(s) in the
VC VCG
VCPA table below.
A154967E01
Check for short
Tester Connections Condition Specified Conditions
E25-21 (VCP2) - Body ground Always 10 kΩ or higher
E25-20 (VCPA) - Body ground Always 10 kΩ or higher
E23-22 (VCG) - Body ground Always 10 kΩ or higher
E22-18 (VC) - Body ground Always 10 kΩ or higher
(i) Reconnect the ECM connectors.

(j) Reconnect the connector to the differential pressure
sensor.
(k) Reconnect the connector to the EGR valve position
sensor.
(l) Reconnect the connector to the turbo pressure sensor.
(m) Reconnect the connector to the camshaft position
sensor.
(n) Reconnect the accelerator pedal position sensor.

(o) Reconnect the throttle position sensor connector.
CONNECTOR
OK
REPLACE ECM (See page ES-347)
ES
Starter Signal Circuit

DESCRIPTION
When the engine is being cranked, the intake air flow is slow, so fuel vaporization is poor. A rich mixture is
therefore necessary in order to achieve good startability. While the engine is being cranked, the battery
positive voltage is applied to terminal STA of the ECM. The starter signal is mainly used to increase the
fuel injection volume for starting injection control and after-start injection control.
WIRING DIAGRAM
ES
NOTICE:
After replacing the ECM, the ECM pump needs supply pump specification learning (See page ES-
3) and injector compensation (See page ES-7).
HINT:
This diagnosis procedure is based on the precondition that the engine in normal status can be cranked by
the starter. If cranking by the starter is not possible, first perform inspection of the respective parts
according to the symptoms table (See page ES-21).
1 READ Hino-DX DATA (STARTER SIGNAL)

(c) Follow the SST (Hino-DX) screen display to display the
ECU data monitor, and read the starter signal at the time
of starter operation.
Result
Ignition switch position Display contents
ON OFF
START ON
Inspection Result Proceed to

OK for MTM vehicle A
OK for ATM vehicle B
NG C
B Go to step 6
C TO RELATED CIRCUIT INSPECTION IN THE

SYMPTOM TABLE
A
2 INSPECT NEUTRAL POSITION SWITCH
(a) Disconnect the neutral position switch connector.

Neutral Position Switch (b) Measure the resistance according to the value(s) in the
table below.
NSW+ NSW- Standard resistance
Terminal Condition Condition Specified Conditions

N1
Neutral Position 10 kΩ or higher
N1-1 (NSW-) - N2-2 (NSW+) Other than
Neutral Position
Bellow 10 kΩ ES
ASM3-767
NG REPLACE NEUTRAL POSITION SWITCH
OK
3 INSPECT WIRE HARNESS AND CONNECTOR (NEUTRAL SWITCH - ECM)
(a) Disconnect connector E24 of the ECM.

ECU (b) Disconnect the neutral switch connector.
E24 table below.
Standard resistance :
Check for open
Terminal Condition Condition Specified Condition
NUSW E24-16 (NUSW) - N1-2 (NUSW+) Always Below 1 Ω
A160083E04
Check for short

Neutral Switch Terminal Condition Condition Specified Condition
E24-16 (NUSW) or N1-2 (NUSW+)
- Body ground
N1
NG REPAIR OR REPLACE HARNESS AND
CONNECTOR
NSW- NSW+
A160058E01
OK
4 INSPECT WIRE HARNESS AND CONNECTOR (NEUTRAL SWITCH - BODY GROUND)
(a) Disconnect the neutral switch connector.

table below.
Check for open
N1-1 (NUSW-) - Body ground Always Below 1 Ω
Check for short

N1-1 (NUSW-) or Body ground -
Other terminals

CONNECTOR
OK
ES 5 INSPECT WIRE HARNESS AND CONNECTOR (STARTER RELAY - ECM)
(a) Disconnect connector E23 of the engine control

ECU computer.
E23
STA
A101460E02
(b) Disconnect the starter relay connector on the coil side.

Harness Side: (c) Measure the resistance according to the value(s) in the
Starter Relay (Coil) table below.
Check for open
S8 E23-18 (STA) - S8-2 (+S) Always Below 1 Ω
Check for short

A153105E01
E23-18 (STA) or S8-2 (+S) - Body
ground

CONNECTOR
OK
REPLACE ECM
6 INSPECT NEUTRAL START SWITCH ASSY
(a) Disconnect the neutral start switch connector.

table below.
Standard resistance
4 (C) - 5 (PL) P range Below 1 Ω
6 (N) - 10 (B) P range Below 1 Ω
4 (C) - 9 (RL) R range Below 1 Ω ES
4 (C) - 1 (NL) N range Below 1 Ω
C073045E02
6 (N) - 10 (B) N range Below 1 Ω
4 (C) - 8 (DL) D range Below 1 Ω
4 (C) - 2 (3L) 4 range Below 1 Ω
4 (C) - 7 (2L) L-2 range Below 1 Ω
NG REPLACE NEUTRAL START SWITCH
OK
7 INSPECT WIRE HARNESS AND CONNECTOR (STARTER RELAY - ECM)

ECU computer.
E24 (c) Measure the resistance according to the value(s) in the
table below.
Check for open
NSW Terminal Condition Condition Specified Condition
E24-10 (NSW) - S8-2 (+S) N or P range Below 1 Ω
A160083E01
Check for short

Harness Side:
Starter Relay (Coil) E24-10 (NSW) or S8-2 (+S) - Body
N or P range 10 kΩ or higher
ground

S8 CONNECTOR
A153105E01
OK
8 INSPECT WIRE HARNESS AND CONNECTOR (STARTER RELAY - ECM)

ECU computer.
E23
table below.
Standard resistance :
Check for open
STA
ES Terminal Condition Condition Specified Condition
E23-18 (STA) - S8-2 (+S) N or P range Below 1 Ω
A101460E02
Check for short

Harness Side:
Starter Relay (Coil) E23-18 (STA) or S8-2 (+S) - Body
N or P range 10 kΩ or higher
ground

S8 CONNECTOR
A153105E01
OK
REPLACE ECM
MIL Circuit
DESCRIPTION
If the ECM detects a malfunction, the MIL will be illuminated. The ECM then records the DTC in its
memory.
WIRING DIAGRAM
ES
28 23 9
C5 C6 E25 W
GAUGE
Check Engine
Combination Meter
AM1 9 AM1 IG1 10

I6
FL MAIN Ignition Switch
Battery
Battery
ECM
A154347E01
NOTICE:
1 CHECK MIL CONDITION
(a) Use the table below to troubleshoot each problem

symptom.
Result
Condition Proceed to
MIL remains ON A
B Go to step 4
2 CHECK DTC OUTPUT

ES
display.
(d) Read the pending DTCs.
Result
No DTCs A
A GO TO DTC CHART
3 CHECK HARNESS AND CONNECTOR

(c) Check that the MIL is not illuminated.
E25
OK:
MIL is not illuminated.
CONNECTOR (COMBINATION METER -
A065748E55
ECM)
OK
REPLACE ECM
4 CHECK IF MIL IS ILLUMINATED

(b) Using a service wire, connect W (E9-12) of the ECM and
body ground.
E25
(c) Check if the MIL is illuminated when the ignition switch is
turned to the ON position.
OK:
MIL is illuminated.
W ES
A065748E56
NG Go to step 5
OK
REPLACE ECM
5 CHECK COMBINATION METER ASSEMBLY (MIL CIRCUIT)
(a) Check the combination meter circuit (See chapter ME).

OK:
Combination meter circuit is normal.
NG REPAIR OR REPLACE COMBINATION
METER ASSEMBLY
OK
REPAIR OR REPLACE HARNESS OR CONNECTOR (COMBINATION METER - ECM)

DPR Manual Forced Regeneration Procedure *E2

1 DPR MANUAL FORCED REGENERATION PROCEDURE
SST 09993-E9070, 09042-1220 (Hino-DX)

(a) Stop the car at a safe location.
CAUTION:
ES Do not keep any easily inflammable objects near the
exhaust pipes as the DPR catalyst becomes very hot
at the time of DPR forced regeneration.
(b) Set the transmission to the neutral position and apply the
parking brake securely.
(c) Perform forced regeneration drive.
(1) Perform complete engine warm-up.
HINT:
Complete engine warm-up means that the cooling
water temperature (outlet) is 75°C (167°F) or higher
and that the engine water temperature is stable.
(2) Follow the SST (Hino-DX) screen display and
execute [Work support] - [ECD] - [Filter-related work
(forced regeneration drive)]. When the DPR
indicator lamp is flashing, manual forced
regeneration also is possible by pressing the DPR
switch.
(3) Confirm that the idling speed increases and that the
exhaust brake operates.
HINT:
• If the exhaust temperature (OUT) should exceed
800°C (1470°F) during forced regeneration,
immediately stop forced regeneration.
• If P2002/94 is put out again during forced
regeneration, catalyst deterioration can be
considered.
• If the exhaust brake repeats opening and closing
during forced regeneration or does not close,
inspect the exhaust brake system and also
inspect in regard to an abnormally high engine
load (friction of alternator, cooler compressor,
etc.).
• Execution of forced regeneration takes 15 to 25
minutes from start to completion.
(d) Confirm that the engine speed drops, that the exhaust
brake is released (meter indicator OFF), and that forced
regeneration has ended.
(e) After completion of forced regeneration, wait for at least
five minutes in idling status.
(f) Follow the SST (Hino-DX) screen display and with

securely depressed brake pedal at [ECU data monitor] -
[DPR/DPNR differential pressure] quickly read the center
value for the differential pressure while the accelerator
pedal is fully depressed (the no-load engine speed
becomes approximately 3,650 r/min).
HINT:
When the exhaust temperature is high, the DPR
differential pressure cannot be measured correctly.
Read the DPR differential pressure as soon as possible
after the accelerator pedal has been depressed fully and
the engine speed has stabilized. ES
Standard:
15 kPa or lower
(g) Check the engine oil quantity.
HINT:
Replace the engine oil when the engine oil exceeds the
level gauge inspection upper mark (X-mark: Normal level
gauge upper mark + 25 mm (1 in.)).
NEXT
END
DPR Switch and Buzzer Circuit *E2

DESCRIPTION
The DPR (Diesel Particulate active Reduction system) is controlled by the ECM to activate the forcible
regeneration function automatically. However, depending on driving conditions, the forcible regeneration
function may not be activated. In such a case, the indicator light on the combination meter and the DPR
switch light blink to inform the driver. When the DPR switch is pressed with the vehicle stopped, RGSW
signals will be input into the ECM and the forcible regeneration function will activate.
If the vehicle continues to be driven without performing forcible regeneration while the indicator light is
ON, a buzzer intermittently sounds to inform the driver.
ES HINT:
If the buzzer intermittently sounds, the brake vacuum warning switch may have been turned on.
In this case, inspect the brake vacuum warning switch circuit first.
Buzzer Sounding Pattern:
When the forcible

regeneration function ON
is not conducted even
if the DPF switch light OFF
is blinking:
ON
When the brake
warning switch is
turned on: OFF
A160152E01
WIRING DIAGRAM
15
E24 RGSW
1 2 10
E25 W2
ES
X4 DPR Switch 3
ECU-IG
D18 Diode (DPR)
28 10
C5 C6
GAUGE DPF
Combination Meter
16
4 1 1 2 1 2
E23 PMB
P7 Parking Brake B6 Vacuum
Warning Buzzer X2 VCM
WRN DIODE
B2 Brake Vacuum Warning Switch
ECM
10 IG1 AM1 9
I6 Ignition Switch
Battery MAIN5 AM1
Battery
ASM3-800-2
1 CHECK BUZZER OPERATION
(a) Check the buzzer sounds.

Result
Sounds Proceed to
The buzzer sounds intermittently A
The buzzer sounds continuously B
B CHECK BRAKE VACUUM WARNING

BUZZER CIRCUIT
ES 2 CHECK DPR SWITCH (POWER SOURCE)
(a) Disconnect the DPR switch connector.

table below.
DPR Switch Connector
Standard voltage
X4 D13-6 - Body ground 18 to 27 V
position
D13-2 - Body ground 18 to 27 V
ASM3-765 position

(e) Reconnect the DPR switch.
NG Go to step 4
OK
3 INSPECT DPR SWITCH ASSEMBLY (RESISTANCE)

table below.
Standard resistance
DPR Switch Tester Connection Condition Specified Condition
D13-6 - D13-7 DPR switch on Below 1 Ω
D13-6 - D13-7 DPR switch off 10 kΩ or higher
(c) Reconnect the DPR switch connector.

X4
NG INSPECT IGNITION SWITCH ASSEMBLY
ASM3-801
OK
4 INSPECT DPR SWITCH ASSEMBLY (ILLUMINATED)
(a) Remove the DPR switch.

Component Side: (b) Check that the illumination comes on.
Result
Connector Connection Condition Illumination
DPR Switch Apply the battery voltage
Always Comes on
terminal D13-2 (+) and D13-3 (-)
(c) Reinstall the DPR switch.

ES
X4
CONNECTOR (IGNITION SWITCH -
BATTERY)
ASM3-801
OK
5 CHECK HARNESS AND CONNECTOR (DPR SWITCH - ECM)

table below.
DPR Switch Connector
Check for open
D13-7 - E24-15 (RGSW) Always Below 1 Ω
X4
D13-3 - E25-10 (W2) Always Below 1 Ω
Check for short

D13-7 or E24-15 (RGSW) -
Body ground
E24
D13-3 or E25-10 (W2) - Body
ground
(d) Reconnect the DPR switch.

ECM Connector
NG REPLACE DPR SWITCH ASSEMBLY
RGSW ASM3-802
OK
REPLACE DPR SWITCH ASSEMBLY

6 INSPECT FUSE (ECU-IG FUSE)
(a) Remove the ECU-IG fuse from the No. 1 relay block and
No. 1 junction block. (Refer to Pub. No. S1-YXZE16C
EWD for the relay and fuse location of each vehicle)
No. 1 Relay Block and No. 1 Juction Block table below.
Standard resistance
ECU-IG Fuse (c) Reinstall the ECU-IG fuse.

CONNECTOR (DPR SWITCH - ECM)
A154957E01
OK
7 CHECK HARNESS AND CONNECTOR (DPR SWITCH - IGNITION SWITCH)

Wire Harness Side: (b) Disconnect the ignition switch connector.
table below.
DPR Switch Connector Standard resistance:
Check for open
X4 D13-6 - I6-10 (IG1) Always Below 1 Ω

D13-2 - I6-10 (IG1) Always Below 1 Ω
Check for short

Ignition Switch Connector D13-6 or I6-10 (IG1) -

Body ground
D13-2 or I6-10 (IG1) -
Body ground
I6 (d) Reconnect the DPR switch connector.

(e) Reconnect the ignition switch connector.
NG PROCEED TO NEXT CIRCUIT INSPECTION
IG1 ASM3-803
SHOWN IN PROBLEM SYMPTOMS TABLE
OK

Ignition Switch (b) Measure the resistance according to the value(s) in the
table below.
Standard resistance
Tester Connection Ignition Switch Position Specified Condition
LOCK ON I6-9 (AM1) - I6-10 (IG1) ON Below 1 Ω
(c) Reconnect the ignition switch connector.

ES
START NG REPLACE FUSE (ECU-IG FUSE)
IG1 AM1
A153627E03
OK
9 INSPECT FUEL (AM1 FUSE)
(a) Remove the AM1 fuse.

table below.
Standard resistance

AM1 Fuse
A175381E01
OK
REPAIR OR REPLACE HARNESS OR CONNECTOR (IGNITION SWITCH ASSEMBLY - BATTERY)

Clogging by DPR Catalytic Converter *E2

DESCRIPTION
The differential pressure sensor is mounted on the exhaust pipe. It measures the pressure before and
after the DPR catalytic converter (monolithic converter assembly), converts the difference in pressure into
a voltage signal, and outputs it to the ECM. Based on this signal, the ECM determines whether the DPR
catalytic converter is clogged. If the DPR catalytic converter is clogged, the ECM activates the forcible
regeneration function of the DPR catalytic converter. In some cases, the forcible regeneration function
may not be conducted depending on the driving conditions. In such cases, the indicator light in the
combination meter and the DPR switch light blink to inform the driver that the converter is clogged. When
ES the driver presses the DPR switch, the forcible regeneration function signal (RGSW) is transmitted to the
ECM, and the forcible regeneration function starts. If the vehicle is driven continuously without performing
the forcible regeneration function when the indicator lights are blinking, PM (Particulate Matter)
accumulates and DTC P2002/94 is set. If the forcible regeneration function is activated when the amount
of PM accumulation is too high, the temperature in the DPR catalytic converter rises beyond normal
operating conditions, (it may reach 800°C (1,472°F) or higher), and the DPR catalytic converter may melt
down. Therefore, if the forcible regeneration function is activated with DTC P2002/94 set, the differential
pressure when the engine is running at near the maximum no-load speed (3550 r/m) must be checked. If
the pressure exceeds the threshold, the DPR catalytic converter must be cleaned.
Threshold
Differential Pressure (kPa)
60
50
40
30
Differential Pressure Limit Value
20
10
0
0 50 100 150 200 250
MAF (g/s)
A160134E01
Engine Speed Standard Differential Pressure MAF

3,500 to 3,600 rpm 15 kPa or less 100 to 110 g/s
NOTICE:
1 PERFORM ENGINE RPM ACCELERATION
(a) Warm up the engine. ES

(b) Disconnect the negative battery terminal and wait for at
least 1 minute.
(c) Reconnect the negative battery terminal.
(d) Initialize the learning values of the supply pump (See
page ES-7).
HINT:
Perform initialization with the engine warmed up (engine
coolant temperature 60°C (140°F) or more and fuel
temperature 20°C (68°F) or more).
(e) Initialize the leaning values of the diesel throttle body
(See page ES-3).
(f) Accelerate the engine speed to the maximum rpm with
no load 20 times.
(g) Check the volume of black smoke in the exhaust gas.
HINT:
• If DTC P2002/94 is set, the engine speed cannot be
raised to the high-speed range because the engine
output limiting control is performed.
• If DTC P2002/94 is set, be sure to clear the DTCs.
Result
Result Proceed to
Black smoke remains in the exhaust gas A
Black smoke is not present B
B Go to step 9
2 CHECK AIR FILTER ELEMENT
(a) Inspect the air filter element.

NG REPAIR OR CLEAN AIR FILTER ELEMENT
OK
(a) Check for air leakage from the intake system and check
that the intake system is installed properly.

PARTS, COMPONENT AND AREA
OK
4 CHECK FUEL FILTER ASSEMBLY
(a) Inspect the fuel filter assembly (See chapter FU).

NG REPLACE FUEL FILTER ASSEMBLY
ES OK

monitor.
Standard

OK
6 INSPECT FOR ENGINE OIL LEAK
(a) Check that the intake system pipes and hoses are not
excessively contaminated with oil.
OK

CATALYST CONVERTER)
(a) Check if the vacuum hose routing between the

differential pressure sensor and the catalyst converter is
correct.
OK
8 CLEAR DTC
(a) Connect to Hino-DX to the DLC3.

(c) Follow the Hino-DX screen display to clear DTC.
NOTICE:
When clearing DTC, be sure to use Hino-DX. Never
clear DTC by battery terminal disconnect.
ES

HINT:
Result
or less)
or less)
B Go to step 16
10 READ VALUE OF Hino-DX (EXHAUST GAS TEMP DURING FORCIBLE REGENERATION

FUNCTION)

(c) Perform the forcible regeneration function (See page ES-
20).
monitor.
(e) Select the following menu items, and read the value
every minute during the forcible regeneration function.
• Initial Exhaust Temp (In)

• Initial Exhaust Temp (Out)
• Engine Speed
Result
Initial Exhaust Temp (OUT) Proceed to
800°C (1,472°F) or less A
800°C (1,472°F) or more B
NOTICE:
If Initial Exhaust Temp (Out) exceeds 800°C
(1,472°F), cease the forcible regeneration function
ES immediately.
B Go to step 16
11 READ VALUE OF Hino-DX (ENGINE SPEED DURING FORCIBLE REGENERATION

FUNCTION)
(a) Read the engine speed during the forcible regeneration

function.
Standard
Condition Engine Speed
During forcible regeneration function 1,200 rpm or more
NG Go to step 18
OK

FUNCTION)
(a) Read the exhaust gas temperature after at least 5

minutes have elapsed since the forcible regeneration
function was started.
Standard
Condition Initial Exhaust Temp (IN)
During forcible regeneration function 220°C (428°F) or more
NG Go to step 21
OK

FUNCTION)
(a) Read the exhaust gas temperature just before the

forcible regeneration function is completed.
Standard
Condition Initial Exhaust Temp (IN)
NG Go to step 25
OK
(a) After the forcible regeneration is completed, allow the

(d) Follow the Hino-DX screen display and set the ECU data ES
(e) Check the differential pressure when the exhaust gas
HINT:
Standard
Engine Speed (no engine load) Differential Pressure
3,500 to 3,600 rpm 15 kPa or less
NG REPLACE MONOLITHIC CONVERTER

ASSEMBLY
OK
15 INSPECT ENGINE OIL LEVEL
(a) Inspect the engine oil level.

NG REPLACE ENGINE OIL
OK
END
16 CLEAN EXHAUST SYSTEM
(a) Clean the catalytic converter and monolithic converter

(See chapter EC).
NEXT

(e) Read the value.
HINT:
ES pressure cannot be measured correctly.
Result
or less)
or less)
B Go to step 10
REPLACE MONOLITHIC CONVERTER ASSEMBLY
18 READ VALUE OF Hino-DX (INJECTION VOLUME)
(a) Cease the forcible regeneration function.

(c) Start the engine.
monitor.
(e) Read the value.
Standard
Condition Injection Volume
Idling 5.0 to 12 mm3
NG Go to step 19
OK
(a) Replace the injector assembly (See chapter FU).
NEXT
PERFORM DPF FORCIBLE REGENERATION PROCEDURE
20 ADJUST EXHAUST RETARDER ASSEMBLY ES
(a) Adjust the exhaust retarder gap (widen the gap).

Cross section of valve (1) While holding bolt A, loosen nut B.
(viewed from the lever side) (2) Using SST, turn adjusting bolt A to adjust the valve
body clearance.
Clearence
Standard clearance:
0.2 to 0.3 mm (0.0079 to 0.0118 in.)
(3) While holding bolt A, tighten nut B.
Torque:
7.4 N*m (75 kgf*cm 65 in*lbf)
Clearence
A151981E02
NEXT
PERFORM DPF FORCIBLE REGENERATION PROCEDURE

21 ADJUST EXHAUST RETARDER ASSEMBLY

body clearance.
Clearence
Standard clearance:
0.2 to 0.3 mm (0.0079 to 0.0118 in.)
Torque:
ES 7.4 N*m (75 kgf*cm 65 in*lbf)
Clearence
A151981E02
NEXT
PERFORM DPR FORCIBLE REGENERATION PROCEDURE

FUNCTION)
(a) Read the exhaust gas temperature during the forcible

Standard
Condition Initial Exhaust Temp (OUT)
NG Go to step 23
OK
REPLACE EXHAUST TEMPERATURE SENSOR (DOWN STREAM)

23 READ VALUE OF Hino-DX (INJECTION VOLUME DURING FORCIBLE REGENERATION

FUNCTION)
(a) Read the injection volume during the forcible

Standard
During forcible regeneration function 18 to 24 mm3
NG Go to step 25 ES
OK
24 CHECK FOR EXHAUST GAS LEAK
(a) Check the exhaust gas leak.

NEXT

body clearance.
Clearence
Standard clearance:
0.2 to 0.3 mm (0.0079 to 0.0118 in.)
Torque:
Clearence
A151981E02
NEXT
26 READ VALUE OF INTELLIGENT TESTER (INJECTION VOLUME DURING FORCIBLE

REGENERATION FUNCTION)
(a) Read the injection volume during the forcible

ES Standard
During forcible regeneration function 5.0 to 12 mm3
B Go to step 29
(a) Cease the forcible regeneration function.

monitor.
(e) Check that the internal fuel pressure of the common rail
Standard
NG REPAIR OR REPLACE FUEL SYSTEM
OK
28 INSPECT INJECTION OR SUPPLY PUMP ASSEMBLY
(a) Inspect the injection or supply pump assembly (See

chapter FU).
OK Go to step 16
NG


body clearance.
Clearence
Standard clearance:
0.2 to 0.3 mm (0.0079 to 0.0118 in.)
Torque:
ES
Clearence
A151981E02
NEXT


(Upstream) *E2
NOTICE:
HINT:
• If the exhaust temperature sensor detects an abnormally high temperature, conduct the following
inspection.
ES • Check the amount of engine oil after troubleshooting is finished.

display.
(d) Read the DTCs.
Result
P2002/94 A
B GO TO DTC CHART
2 INSPECT FUEL SYSTEM

(b) Disconnect the negative battery terminal and wait for at
least 1 minute.
(c) Reconnect the negative battery terminal.
(d) Initialize the learning values of the supply pump (See
page ES-7).
HINT:
Perform initialization with the engine warmed up (engine
coolant temperature 60°C (140°F) or more and fuel
temperature is 20°C (68°F) or more).
(e) Initialize the leaning values of the diesel throttle body
(See page ES-3).
(f) Connect the intelligent tester to the DLC3.
(g) Start the engine and turn the tester ON.
(h) Select the following menu items: Powertain / Engine and
(i) Perform the active test.
NEXT
HINT:
• If the pipes or hoses are contaminated with oil, clean
them.
• If pipes or hoses are contaminated with a large
amount of oil, repair or replace the parts and areas
where the engine oil is leaking from.
(b) Check if the engine oil is leaking from the turbocharger.
ES
NEXT
(a) Clear the DTCs (See page ES-29).

(b) Perform the forcible regeneration function (See page ES-
20).
(c) After the forcible regeneration is completed, allow the
(d) Connect the Hino-DX to the DLC3.
(g) Check the differential pressure when the exhaust gas
HINT:
Result
temperature (up stream) is 200°C (392°F) 15 kPa or less (MIL is not illuminated) A
or less)
temperature (up stream) is 200°C (392°F) 15 kPa or more (MIL is not illuminated) C
or less)
Result
Engine Speed (no engine load) Result Proceed to
temperature (up stream) is 200°C (392°F) MIL remains ON B
or less)
B GO TO DPR FORCIBLE REGENERATION

PROCEDURE
C REPLACE MONOLITHIC CONVERTER

ASSEMBLY
END
ES

(Downstream) *E2
HINT:
• If the exhaust temperature sensor detects an abnormally high temperature, conduct the following
inspection.
• Check the amount of engine oil after troubleshooting is finished.
ES

display.
(d) Read the DTCs.
Result
P2002/94 A
B GO TO DTC CHART
2 INSPECT FUEL SYSTEM

(c) Follow the Hino-DX screen display to set Active test.
(d) Perform the active test.
(e) Visually check the supply pump, injector and fuel line
and the injector.
(f) Check that the fuel filter is not clogged.
NEXT
HINT:
• If the pipes or hoses are contaminated with oil, clean
them.
• If pipes or hoses are contaminated with a large
amount of oil, repair or replace the parts and areas
where the engine oil is leaking from.
(b) Check if the engine oil is leaking from the turbocharger.
NEXT
(a) Clear the DTCs.

(b) Perform the forcible regeneration function (See page ES-
20).
(c) After the forcible regeneration is completed, allow the
ES (d) Connect the Hino-DX to the DLC3.
(g) Check the differential pressure when the exhaust gas
HINT:
Result
temperature (up stream) is 200°C (392°F) 15 kPa or less (MIL is not illuminated) A
or less)
temperature (up stream) is 200°C (392°F) 15 kPa or more (MIL is not illuminated) C
or less)
Result
Engine Speed (no engine load) Result Proceed to
temperature (up stream) is 200°C (392°F) MIL remains ON B
or less)
B GO TO DPR FORCIBLE REGENERATION

PROCEDURE
C REPLACE MONOLITHIC CONVERTER

ASSEMBLY
END
Exhaust Brake System

HINT:
Execute inspection below if the exhaust brake das not operate.
1 READ DTC

(b) Turn the ignition switch to the ON position. ES
(c) Follow the SST (Hino-DX) screen display to read the
DTC (See page ES-29).
HINT:
If a DTC is put out, prohibition of the exhaust brake
system can be considered.
Result
No DTC output A
DTC output B
B GO TO DTC CHART
2 INSPECT ECM (VOLTAGE)
(a) Measure the voltage according to the value(s) in the

ECM table below.
Standard voltage
EXB
E1 E23 E24
At the time of
E23-8 (EXB) - E23-7 (E1) exhaust brake 11 to 14 V
operation
HINT:
Exhaust brake operation conditions
A101463E73
• Exhaust brake operation switch ON
• Accelerator pedal not operated
• Specified vehicle speed or higher (3 km/h or higher)
• Other than N or P range
• ABS not operating
OK Go to step 12
NG

ECM (b) Measure the voltage according to the value(s) in the
table below.
EXSW Standard voltage
E1
E23 E24 Terminal Condition Condition Specified Condition
Exhaust brake
switch position 0 to 2 V
OFF
ES E24-13 (EXSW) - E23-7 (E1)
Exhaust brake
A101463E74
switch position 18 to 27 V
ON
Result
NG A
OK for AT vehicle B
OK for MT vehicle C
B Go to step 6
C Go to step 8
4 INSPECT TURN SIGNAL SWITCH ASSEMBLY (EXHAUST BRAKE SWITCH)
(a) Disconnect the connector of the turn signal switch

Turn signal Switch assembly.
L table below.
Standard resistance
C8
Exhaust brake
B switch position 1kΩ or higher
OFF
C8-11 (B) - C8-3 (L)
A153107E01 Exhaust brake
switch position Bellow 1Ω
ON
NG REPLACE TURN SIGNAL SWITCH

ASSEMBLY
OK
5 INSPECT FUSE (ECU-IG)
(a) Remove ECU-IG (10 A) from the relay block.

No. 1 Relay Block and No. 1 Juction Block table below.
Standard resistance
ECU-IG Fuse Always Below 1 Ω ES
ECU-IG Fuse (c) Reinstall the ECU-IG fuse.
NG REPLACE FUSE
A154957E01
OK
REPAIR OR REPLACE HARNESS AND CONNECTOR

ECM
NSW table below.
Standard voltage
E1 E23 E24
Ignition ON
Shift lever other 11 to 14 V
than N range
E24-10 (NSW) - E23- 7 (E1)
Ignition ON
A101463E75
Shift lever in N 0 to 2 V
range
OK Go to step 14
NG
7 INSPECT NEUTRAL START SWITCH ASSY
(a) Disconnect the neutral start switch connector.

table below.
Standard resistance
4 (C) - 5 (PL) P range Below 1 Ω
6 (N) - 10 (B) P range Below 1 Ω
ES 4 (C) - 9 (RL) R range Below 1 Ω
4 (C) - 1 (NL) N range Below 1 Ω
C073045E02
6 (N) - 10 (B) N range Below 1 Ω
4 (C) - 8 (DL) D range Below 1 Ω
4 (C) - 2 (3L) 4 range Below 1 Ω
4 (C) - 7 (2L) L-2 range Below 1 Ω
NG REPLACE NEUTRAL START SWITCH
OK

ECM
table below.
NUSW
Standard resistance
E1 E23 E24
Ignition ON
Shift lever in N 11 to 14 V
range
E24-16 (NUSW) - E23-7 (E1)
Ignition ON
A101463E81
Shift lever other 0 to 2 V
than N range
OK Go to step 10
NG
9 INSPECT NEUTRAL POSITION SWITCH
(a) Disconnect connector of the neutral position switch.

Neutral Position Switch (b) Measure the resistance according to the value(s) in the
table below.
NSW+ NSW- Standard resistance
N1 Other than N
Bellow 10 kΩ
1 (NSW-) - N1-2 (NSW+) range
N range 10 kΩ or higher
ES
ASM3-767 (c) Reconnect the starter relay connector.
NG REPLACE NEUTRAL POSITION SWITCH
OK

ECM
table below.
CLSW
Standard voltage
E1 E23 E24
Ignition ON
Clutch pedal 11 to 14 V
released
E24-9 (CLSW) - E23-7 (E1)
Ignition ON
A101463E80
Clutch pedal 0 to 2 V
depressed
OK Go to step 14
NG
11 INSPECT CLUTCH SWITCH
(a) Disconnect the connector of the clutch switch assembly.

Clutch Switch (b) Measure the resistance according to the value(s) in the
table below.
Standard resistance
L Terminal Condition Condition Specified Conditions
E9 Ignition ON
Clutch pedal Bellow 1 kΩ
B released
E9-1 (L) - E9-2 (B)
Ignition ON
A160059E01
Clutch pedal 10 kΩ or higher
depressed
NG REPLACE CLUTCH SWITCH
OK
12 INSPECT EXHAUST BRAKE SOLENOID ASSEMBLY
(a) Remove the exhaust brake solenoid assembly.

ES (b) Inspect air passage
Exhaust Brake Solenoid (1) Check for air passage between the ports when
battery voltage (12 V) is applied between the
terminals.
Standard air passage
Air passage between
Energized
ports
1-2
No air passage
Not energized
between ports
NG REPLACE EXHAUST BRAKE SOLENOID

ASSEMBLY
A153112E01
OK
(a) Remove the exhaust retarder assembly.

(b) Confirm that the butterfly valve is at a right angle to the
flange (fully open).
F042342
(c) Use a vacuum pump and a vacuum gauge, confirm that

the butterfly valve is completely closed and the indication
does not drop when a negative pressure of
approximately 67 kPa {500 mm Hg} is applied to the
exhaust brake chamber.
F042340
(d) Use a thickness gauge and inspect the clearance of the

butterfly valve in a status where the indication does not
drop.
Standard:
0.2 to 0.3 mm (0.0079 to 0.0118 in.)
A126628
Result
ES
Inspect Result Proceed to
Normal A
Butterfly valve is not fully open B
Indication drops when negative pressure is applied C
Indication does not drop, but clearance is outside standard D
HINT:
If the inspection result is normal, perform trouble-
shooting for black smoke. In the flow chart, omit steps
where the inspection already has been performed and
go to the next step. (See page ES-214)
B ADJUST OR REPLACE EXHAUST
RETARDER ASSEMBLY
C REPLACE EXHAUST BRAKE CHAMBER

ASSEMBLY
D ADJUST CLEARANCE
INSPECT, REPAIR OR REPLACE VACUUM SYSTEM (HOSES, PIPING)
14 REPLACE ECM
(a) Replace the ECM (See page ES-347).

(b) Perform injector compensation (See page ES-7).
(c) Perform supply pump specification leaning at the time of
pump replacement (See page ES-3).
NEXT
END
N04C-TR, TS, TT, TU, TV, TW ENGINE CONTROL SYSTEM – DIESEL THROTTLE BODY
ES–344 *E1
DIESEL THROTTLE BODY *E1

ENGINE
COMPONENTS
ES DIESEL THROTTLE BODY
29 (290, 21)
x2
x2
29 (291, 21)
NO. 4 AIR HOSE
N*m (kgf*cm, ft.*lbf) : Specified torque

A152381E01
*E1 ES–345
REMOVAL
1. REMOVE NO. 4 AIR HOSE
(a) Loosen the 2 clamps and remove the No. 4 air hose.
A152401E02
2. REMOVE DIESEL THROTTLE BODY ES

(a) Disconnect the 2 diesel throttle body connectors.
A152755
(b) Remove the 2 bolts, 2 nuts and diesel throttle body.
A152756
INSPECTION
1. REMOVE DIESEL THROTTLE BODY
(a) Check the resistance of the throttle control motor.
(1) Using an ohmmeter, measure the resistance
between the terminals.
Standard resistance
2-3 2 to 10 kΩ
A101854
If the result is not as specified, replace the
diesel throttle body.
INSTALLATION
1. INSTALL DIESEL THROTTLE BODY
(a) Remove any seal packing material from the contact
surface.
ES–346 *E1
70 mm (2.75 in.)
(b) Apply a continuous bead of seal packing (width: 1.5
to 2.5 mm (0.06 to 0.10 in.)) as shown in the
illustration.
HINT:
• Remove any oil from the contact surface.
• Apply seal packing to the inner side of the bolt
holes.
• Install the diesel throttle body assembly within 3
minutes of applying the seal packing.
: Seal Packing
A146656E01 • Do not run the engine for at least 2 hours after
installing.
ES (c) Install the diesel throttle body with the 2 bolts and 2
nuts.
A152756
(d) Connect the 2 diesel throttle body connectors.
A152755
2. INSTALL NO. 4 AIR HOSE

(a) Install the No. 4 air hose and tighten the 2 hose
clamps.
A152401E02
N04C-TR, TS, TT, TU, TV, TW ENGINE CONTROL SYSTEM – ECM ES–347
ECM
ENGINE
COMPONENTS
ES
ECM
A158141E01
REMOVAL
1. CHECK FOR COMPENSATION CODE
NOTICE:
• When the ECM is replaced, all of the existing
injector compensation codes must be input into
the new ECM and the learned value of the supply
pump assembly must be input.
ES–348 N04C-TR, TS, TT, TU, TV, TW ENGINE CONTROL SYSTEM – ECM
(a) Using the Hino-DX, check that the ID codes

registered in the injector assemblies installed on
each cylinder match the ECM (See page ES-7).
If the codes do not match, correct the registered
data and recheck the problem symptom by following
the steps below.
(1) Using SST, manually correct the registered ID
code.
(2) Check if the same symptom occurs when the
vehicle was brought in.
HINT:
ES If the symptom does not occur, the problem
may be caused by misregistration of an ID
code.
2. REMOVE ECM
(a) Disconnect the 4 ECM connectors.
A152758
(b) Remove the 4 bolts and the ECM cover.
A152757
INSTALLATION
1. INSTALL ECM
(a) Install the ECM cover with the 4 bolts.
NOTICE:
Do not use an ECM that was dropped or
received strong impact.
Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf)
A152757
N04C-TR, TS, TT, TU, TV, TW ENGINE CONTROL SYSTEM – ECM ES–349
(b) Connect the 4 ECM connectors until they are

locked.
2. REGISTER ID CODE
3. CHECK ID CODE
4. INITIALIZE THE LEARNED VALUE OF THE SUPPLY
PUMP ASSEMBLY
(a) Perform initialization procedures.
NOTICE:
A152758
Certain systems need to be initialized after
reconnecting the cable to the negative (-) battery
terminal. ES
ES–350 N04C-TR, TS, TT, TU, TV, TW ENGINE CONTROL SYSTEM – ACCELERATOR PEDAL ROD

ENGINE
COMPONENTS
EXAMPLE: LHD
ES
ACCELERATOR LINK ASSEMBLY
5.5 (56, 49 in.*lbf)

A155969E03
N04C-TR, TS, TT, TU, TV, TW ENGINE CONTROL SYSTEM – ACCELERATOR PEDAL ROD ES–351
EXAMPLE: RHD
ES
5.5 (56, 49 in.*lbf)
ACCELERATOR PEDAL

A153236E03
ON-VEHICLE INSPECTION
1. INSPECT ACCELERATOR PEDAL ROD ASSEMBLY
(a) Inspect the voltage.
(1) Connect the Hino-DX to the DLC3.
(2) Turn the ignition switch to the ON position.
(3) Follow the Hino-DX screen display and set the
ECU data monitor - Accelerator Position No.1,
Accelrator Position No.2.
ES–352 N04C-TR, TS, TT, TU, TV, TW ENGINE CONTROL SYSTEM – ACCELERATOR PEDAL ROD
(4) When depressing and releasing the accelerator

pedal, check that the values of the accelerator
position No.1 and accelerator position No. 2
are within the specification.
Accelerator Position No. 1 standard voltage
Condition Specified Condition
Accelerator pedal is released 0.4 to 1.4 V
Accelerator pedal is depressed 3.0 to 4.6 V
Accelerator Position No. 2 standard voltage

ES Accelerator pedal is released 0.9 to 2.3 V
Accelerator pedal is depressed 3.4 to 5.5 V
If the result is not as specified, check the

accelerator pedal, wire harness, and ECM.
REMOVAL
1. REMOVE ACCELERATOR LINK ASSEMBLY
(a) Disconnect the accelerator pedal connector.
(b) Remove the 2 nuts and accelerator pedal.
LHD
NOTICE:
• Avoid physical shock to the accelerator
pedal.
• Do not disassemble the accelerator pedal
assembly.
A152759E01
RHD
A154062E01
INSTALLATION
1. INSTALL ACCELERATOR LINK ASSEMBLY
NOTICE:
• Avoid physical shock to the accelerator pedal.
• Do not disassemble the accelerator pedal
assembly.
N04C-TR, TS, TT, TU, TV, TW ENGINE CONTROL SYSTEM – ACCELERATOR PEDAL ROD ES–353
(a) Install the accelerator pedal with the 2bolts.

LHD
(b) Connect the accelerator pedal connector.
A152759E01
RHD ES
A154062E02
N04C-TR, TS, TT, TU, TV, TW ENGINE CONTROL SYSTEM – MASS AIR FLOW METER
ES–354 *E1
MASS AIR FLOW METER *E1

ENGINE
COMPONENTS
EXAMPLE
INTAKE AIR FLOW METER SUB-ASSEMBLY
ES
A152384E01
REMOVAL
1. REMOVE INTAKE AIR FLOW METER SUB-
ASSEMBLY
(a) Disconnect the mass air flow meter connector.
(b) Remove the 2 screws and mass air flow meter.
A152753
N04C-TR, TS, TT, TU, TV, TW ENGINE CONTROL SYSTEM – MASS AIR FLOW METER
*E1 ES–355
INSPECTION
Platinum
Hot Wire 1. INSPECT MASS AIR FLOW METER
(heater) (a) Using a work light, check that the platinum filament
(heater portion) in the mass air flow meter has no
foreign matter attached.
Standard:
No foreign matter attached.
If the result is not as specified, replace the mass air
flow meter.
ES
A146798E01
INSTALLATION
1. INSTALL INTAKE AIR FLOW METER SUB-
ASSEMBLY
(a) Install the mass air flow meter with the 2 screws.
(b) Connect the mass air flow meter connector.
A152753
N04C-TR, TS, TT, TU, TV, TW ENGINE CONTROL SYSTEM – CAMSHAFT POSITION SEN-
ES–356 SOR

ENGINE
COMPONENTS
ES
5.0 (50, 44 in.*lbf)
A154054E01
REMOVAL
1. REMOVE CAMSHAFT POSITION SENSOR
(a) Disconnect the camshaft position sensor connector.
N04C-TR, TS, TT, TU, TV, TW ENGINE CONTROL SYSTEM – CAMSHAFT POSITION SEN-
SOR ES–357
(b) Remove the bolt and camshaft position sensor.
INSTALLATION
1. INSTALL CAMSHAFT POSITION SENSOR
(a) Apply a light coat of engine oil to the O-ring of the
camshaft position sensor.
A146644
(b) Install the camshaft position sensor with the bolt. ES

(c) Connect the camshaft position sensor connector.
2. INSPECT FOR OIL LEAK
A146644
N04C-TR, TS, TT, TU, TV, TW ENGINE CONTROL SYSTEM – CRANKSHAFT POSITION
ES–358 SENSOR

ENGINE
COMPONENTS
ES
8.0 (82, 71 in.*lbf)
CRANK POSITION SENSOR
A152386E01
REMOVAL
1. REMOVE CRANK POSITION SENSOR
(a) Disconnect the crank position sensor connector.
N04C-TR, TS, TT, TU, TV, TW ENGINE CONTROL SYSTEM – CRANKSHAFT POSITION
SENSOR ES–359
(b) Remove the bolt and crank position sensor.
A146645
INSPECTION ES
1. INSPECT CRANKSHAFT POSITION SENSOR
NE- NE+
(a) Measure the resistance between the terminals.
Standard resistance
Temperature Specified Condition
Cold 1630 to 2740 Ω
Hot 2065 to 3225 Ω
A165187E01
HINT:
In the table above, the terms "cold" and "hot" refer
to the temperature of the coils. "Cold" means
approximately -10 to 50°C (14 to 122°F). "Hot"
means approximately 50 to 100°C (122 to 212°F).
If the resistance is not as specified, replace the
sensor.
INSTALLATION
1. INSTALL CRANK POSITION SENSOR
(a) Apply a light coat of engine oil to the O-ring of the
sensor.
(b) Install the crank position sensor with the bolt.
(c) Connect the crank position sensor connector.
A146645
N04C-TR, TS, TT, TU, TV, TW ENGINE CONTROL SYSTEM – ENGINE COOLANT TEM-
ES–360 PERATURE SENSOR

ENGINE
COMPONENTS
ES RADIATOR HOSE INLET
GASKET
29 (296, 21)
Non-reusable part
A152387E01
REMOVAL
1. REMOVE GENERATOR ASSEMBLY
(See chapter CH)
2. DRAIN ENGINE COOLANT (See chapter CO)
3. DISCONNECT RADIATOR HOSE INLET (See chapter
CO)
PERATURE SENSOR ES–361
4. REMOVE ENGINE COOLANT TEMPERATURE

SENSOR
(a) Disconnect the engine coolant temperature sensor
connector.
(b) Using a 19 mm deep socket wrench, remove the
engine coolant temperature sensor and gasket.
INSPECTION
1. INSPECT ENGINE COOLANT TEMPERATURE
SENSOR
(a) Check the resistance. ES
A152754E01
Resistance kΩ 30
20
Ohmmeter 10
5 Acceptable
3
2
1
0.5
0.3
0.2
0.1
Temperature °C (°F) -20 0 20 40 60 80 100

(-4) (32) (68) (104) (140)(176) (212)
A108624E03
(b) Measure the resistance between the terminals.

Standard resistance
1 (E2) - 2 (THW) 2.32 to 2.59 kΩ at 20°C (68°F)
1 (E2) - 2 (THW) 0.310 to 0.326 kΩ at 80°C (176°F)
NOTICE:
When checking the intake air temperature
sensor in the water, keep the terminals dry. After
the check, wipe the sensor dry.
If the result is not as specified, replace the engine
coolant temperature sensor.
INSTALLATION
1. INSTALL ENGINE COOLANT TEMPERATURE
SENSOR
(a) Install a new gasket to the engine coolant
temperature sensor.
A124979
ES–362 PERATURE SENSOR
(b) Using a 19 mm deep socket wrench, tighten the

engine coolant temperature sensor.
2. CONNECT RADIATOR HOSE INLET (See chapter CO)
3. ADD ENGINE COOLANT (See chapter CO)
4. INSPECT FOR COOLANT LEAK (See chapter CO)
5. INSTALL GENERATOR ASSEMBLY
A152754E01 (See chapter CH)
ES
N04C-TR, TS, TT, TU, TV, TW ENGINE CONTROL SYSTEM – INTAKE AIR TEMPERATURE
SENSOR ES–363
INTAKE AIR TEMPERATURE SENSOR

ENGINE
COMPONENTS
INTAKE AIR TEMPERATURE SENSOR
ES
34 (350, 25)

A152388E01
REMOVAL
1. REMOVE INTAKE AIR TEMPERATURE SENSOR
(a) Disconnect the intake air temperature sensor
connector.
(b) Remove the intake air temperature sensor and
gasket.
A158148
N04C-TR, TS, TT, TU, TV, TW ENGINE CONTROL SYSTEM – INTAKE AIR TEMPERATURE
ES–364 SENSOR
Ohmmeter
INSPECTION
1. INSPECT INTAKE AIR TEMPERATURE SENSOR
(a) Using an ohmmeter, measure the resistance
Resistance kΩ Standard resistance:
2.21 to 2.65 kΩ at 20°C (68°F)
NOTICE:
When checking the intake air temperature
sensor in the water, keep the terminals dry. After
Acceptable the check, wipe the sensor dry.
If the result is not as specified, replace the sensor.
ES
INSTALLATION
1. INSTALL INTAKE AIR TEMPERATURE SENSOR
(a) Install a new gasket to the intake air temperature
Temperature °C (°F) sensor.
Z017274E05
(b) Install the intake air temperature sensor.

(c) Connect the intake air temperature sensor
connector.
A152404
N04C-TR, TS, TT, TU, TV, TW ENGINE CONTROL SYSTEM – EDU RELAY ES–365
EDU RELAY
INSPECTION
1. INSPECT EDU RELAY
(a) Measure the resistance according to the value(s) in
the table below.
Standard resistance
B016200E02 Tester connection Condition Specified Condition

Battery voltage not
3-5 10 kΩ or higher
applied
ES
Battery voltage applied
3-5 Below 1 Ω
to terminals 1 and 2
ENGINE
W04D-J, TM, TN ENGINE CONTROL

SYSTEM

COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-1
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-2
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-5
ES
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-9
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ES-11
W04D-J, TM, TN ENGINE CONTROL SYSTEM – ACCELERATOR PEDAL ROD ES–1

ENGINE
COMPONENTS
EXAMPE: LHD Models
THROTTLE CONTROL CABLE KNOB
THROTTLE NUT
ACCELERATOR FLEXIBLE WIRE ASSEMBLY
ES
ACCELERATOR LINK ASSEMBLY
5.5 (56, 49 in.*lbf)

x2
5.5 (56, 49 in.*lbf)
5.5 (56, 49 in.*lbf)

x2
ACCELERATOR PEDAL
HOLD PIN
ACCEL CONTROL WITH THROTTLE CABLE ASSEMBLY
CLIP
N*m (kgf*cm, ft.*lbf) :Specified torque

A165706E01
ES–2 W04D-J, TM, TN ENGINE CONTROL SYSTEM – ACCELERATOR PEDAL ROD
REMOVAL
1. REMOVE ACCELERATOR PEDAL
(a) Remove the 2 bolts and accelerator pedal.
A165707
2. REMOVE THROTTLE CONTROL CABLE KNOB

(a) Using a screwdriver, release the lock and remove
ES the throttle control cable knob.
A155960
3. REMOVE THROTTLE NUT

(a) Remove the throttle nut.
A155959E01
4. REMOVE ACCELERATOR LINK ASSEMBLY

(a) Remove the 2 bolts, nut and disconnect the
accelerator link assembly.
A166087
(b) Remove the clamp.
A155957E01
(c) Disconnect the accel control with throttle cable

assembly and remove the accelerator link
assembly.
A155955
5. REMOVE ACCEL CONTROL WITH THROTTLE

CABLE ASSEMBLY
(a) Pull out the accel control with throttle cable ES
assembly with throttle assembly to the outside of the
vehicle.
A165709
(b) Remove the clip, hold pin, bolt, 4 clamps and accel
control with throttle cable assembly.
Standard body:
ES
Wide body:
A166430E01
6. REMOVE ACCELERATOR FLEXIBLE WIRE

ASSEMBLY
(a) Remove the accelerator flexible wire assembly and
throttle wire clamp from the accelerator link
assembly.
Stopper bolt
ADJUSTMENT
1. ADJUST OUTLINE
(a) When the accelerator pedal is fully depressed, the
governor speed control lever should come into
contact with the stopper bolt.
Speed control lever

A163422E01
2. ADJUST ACCELERATOR PEDAL PLAY

(a) Adjust the pedal play.
Pedal play: ES
1.0 to 3.0 mm (0.04 to 0.12 in.)
NOTICE:
When the pedal is returned the exhaust brake
switch should be pushed in.
A163423
3. ADJUST ACCELERATOR CONTROL CABLE

(a) Pinch the locks of clip A of the accelerator cable on
the side of the accelerator link assembly as shown
Clip A in the left frame (1) and pull down the clip A.
(1) (1)
A163424E01
(b) Turn the nut of the cable and adjust the play of the
Clip A accelerator pedal.
(1) Turn the nut clockwise when pedal play is
insufficient (the wire will become looser).
Nut
(2) Turn the nut counterclockwise when pedal play
is excessive (the wire will become tighter).
Clip B
A163425E01
(c) After adjustment of the pedal play, fix clip A to clip B.
INSTALLATION
1. INSTALL ACCELERATOR FLEXIBLE WIRE
ASSEMBLY
Clip B (a) Install the accelerator flexible wire assembly from
the accelerator link assembly.
Clip A
A163426E01
2. INSTALL ACCEL CONTROL WITH THROTTLE

CABLE ASSEMBLY
(a) Install the accel control with throttle cable assembly
with the 4 clamps, bolt, hold pin and clip.
Standard body:
ES
Wide body:
A166430E01

(b) Insert the accel control with throttle cable assembly
to the inside of the vehicle.
A165709
3. INSTALL ACCELERATOR LINK ASSEMBLY

(a) Connect the accel control with throttle cable
assembly to the accelerator link assembly.
A155955
(b) Install the clamp.
ES
A155957E01
(c) Install the accelerator link assembly and accelerator

pedal rod cover with the 2 bolts and nut.
A166087
4. INSTALL THROTTLE NUT

(a) Install the throttle nut.
A155959E02
5. INSTALL THROTTLE CONTROL CABLE KNOB

(a) Install the throttle control cable knob.
HINT:
Make sure that the throttle control cable knob is
locked.
A163378
6. INSTALL ACCELERATOR PEDAL

(a) Install the acceleration pedal with the 2 bolts.
A165707
ES
W04D-J, TM, TN ENGINE CONTROL SYSTEM – ENGINE COOLANT TEMPERATURE
SENSOR ES–9

ENGINE
COMPONENTS
29 (300, 22)
WATER TEMPERATURE SENDER GAGE ASSEMBLY
ES
7.4 (75, 65 in.*lbf)

ENGINE COOLANT
TEMPERATURE SENSOR
A166043E01
REMOVAL
2. REMOVE WATER TEMPERATURE SENDER GAGE
ASSEMBLY
(a) Disconnect the water temperature sender gage
assembly connector.
ES–10 SENSOR
(b) Using a 19 mm deep socket wrench, remove the

water temperature sender gage assembly.
3. REMOVE ENGINE COOLANT TEMPERATURE
SENSOR
connector.
A165512E01
(b) Using a 19 mm spana, remove the engine coolant

temperature sensor.
ES
A165511E01
INSPECTION
1. INSPECT WATER TEMPERATURE SENDER GAGE
Ohmmeter ASSEMBLY
(a) Check the pre-heating circuit resistance.
Standard resistance
1-2 20°C (68°F) 2.32 to 2.59 kΩ
1-2 80°C (176°F) 0.310 to 0.326 kΩ
Wate temperature sender gage assembly NOTICE:

• When checking the water temperature
sender gage assembly in the water,
• keep the terminals dry.
• After the check, wipe the sensor dry.
A165514E01
SENSOR ES–11
(b) Check the water temperature gage circuit

resistance.
Ohmmeter between the terminals.
Standard resistance
3 - body 75°C (167°F) 79 - 92 Ω
3 - body 100°C (212°F) 35.5 - 41.5 Ω
NOTICE:
• When checking the water temperature
sender gage assembly in the water,
Wate temperature sender gage assembly
• After the check, wipe the sensor dry. ES
A165513E01
2. INSPECT ENGINE COOLANT TEMPERATURE

SENSOR
Ohmmeter (a) Using an ohmmeter, measure the resistance
Standard resistance
1 - body 75°C (167°F) 82 to 92 Ω
NOTICE:
A165515E01 • When checking the engine coolant
temperature sensor in the water,
• After the check, wipe the sensor dry.
If the result is not as specified, replace the engine
coolant temperature sensor.
INSTALLATION
1. INSTALL WATER TEMPERATURE SENDER GAGE
ASSEMBLY
(a) Using a 19 mm deep socket wrench, tighten the
(b) Connect the water temperature sender gage
assembly connector.
A165512E01
ES–12 SENSOR
2. INSTALL ENGINE COOLANT TEMPERATURE

SENSOR
(a) Using a 19 mm spana, tighten the engine coolant
temperature sensor.
(b) Connect the engine coolant temperature sensor
connector.
A165511E01 4. INSPECT FOR COOLANT LEAK (See chapter CO)
ES
ENGINE

ENGINE MECHANICAL
ENGINE
ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-1
DRIVE BELT
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-5 EM
VALVE CLEARANCE
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-6
CAMSHAFT
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-18
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-21
CYLINDER HEAD GASKET
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-47
CYLINDER HEAD
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-51
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-52
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-53
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-56
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-63
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-65
CYLINDER BLOCK
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-66
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-67
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-70
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-83
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-84
ENGINE FRONT OIL SEAL
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-91
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-92
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-92
ENGINE REAR OIL SEAL
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-93
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-94
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-95
ENGINE ASSEMBLY
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-96
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-127
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-138
ENGINE UNIT
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-151
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-154
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-160
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-163
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-165
EM
N04C-TR, TS, TT, TU, TV, TW ENGINE MECHANICAL – ENGINE EM–1
ENGINE
1. INSPECT ENGINE COOLANT (See chapter CO)
2. INSPECT ENGINE OIL (See chapter LU)
3. INSPECT BATTERY (See chapter CH)
4. INSPECT AIR CLEANER FILTER ELEMENT SUB-
ASSEMBLY
5. INSPECT DRIVE BELT
Fan Pulley (a) Check the fan and generator V belt deflection.
HINT:
The specified deflection values per belt are shown
Generator in the following table. EM
Deflection
Item Specified Condition
Crankshaft Pulley New belt 10.5 to 12.5 mm (0.41 to 0.49 in.)
A153408E01
NOTICE:
• Check the V belt deflection at the specified
point.
• When inspecting a belt which has been used
for over 5 minutes, apply the used belt
specifications.
(b) Check the No. 1 V (cooler compressor to crankshaft
pulley) belt deflection. (N04C-TR, TS, TT, TV)
Idler Pulley HINT:
The specified deflection values per belt are shown
in the following table.
Deflection
A/C Compressor Crankshaft Pulley New belt 8.5 to 10.0 mm (0.33 to 0.39 in.)
A153409E01
NOTICE:
• Check the V belt deflection at the specified
point.
• When inspecting a belt which has been used
for over 5 minutes, apply the used belt
specifications.
6. CHECK TAPPET FOR ABNORMAL NOISE
7. CHECK IDLE SPEED AND MAXIMUM SPEED
NOTICE:
Turn all the electrical systems and the A/C OFF.
(a) Warm up and stop the engine.
EM–2 N04C-TR, TS, TT, TU, TV, TW ENGINE MECHANICAL – ENGINE
(b) When using the HINO-DX:

(1) Connect the HINO-DX to the DLC3.
(c) Select the following menu items: Powertrain /
Engine and ECT / Data List
HINT:
Refer to the HINO-DX operator's manual for further
information regarding the selection of Data List.
DLC3 (1) Inspect the engine idling speed.
(MTM MODEL)
(ATM MODEL)
Idling speed:
550 to 650 rpm
(d) Fully depress the accelerator pedal.
(e) Check the maximum speed.
Maximum speed:
3600 to 3700 rpm
EM Hino-Bowie (f) Turn the ignition switch off.
(g) Disconnect the HINO-DX from the DLC3.
(h) When not using the HINO-DX:
Intelligent tester
(1) Install SST to terminal TAC of the DLC3, then
HINO-DX connect a tachometer.
A154337E01
SST 09843-18040
NOTICE:
Examine the terminal number before
connecting SST. Connecting to the wrong
terminal can damage the engine.
(3) Inspect the engine idling speed.
Idling speed:
550 to 650 rpm
(4) Fully depress the accelerator pedal.
(5) Check the maximum speed.
Maximum speed:
3600 to 3700 rpm
(6) Turn the ignition switch off.
(7) Disconnect the tachometer.
(8) Remove SST from terminal TAC.
8. INSPECT COMPRESSION
(b) Remove the 4 bolts from the glow plug hole.
(c) Remove the oil filler cap.
(d) Remove the 2 bolts, then remove the No. 2 cylinder
head cover sub-assembly.
(e) Disconnect all connectors from the 4 injectors.
(f) Crank the engine to remove foreign matter before
SST
measuring the compression.
(g) Install SST into the glow plug hole.
SST 09992-00025
(h) Connect a compression gauge to SST.
SST 09992-00025
A101588E01
N04C-TR, TS, TT, TU, TV, TW ENGINE MECHANICAL – ENGINE EM–3
(i) While cranking the engine, measure the

compression pressure.
Compression pressure:
3200 kPa (33 kgf/cm2, 464 psi)
Minimum pressure:
2700 kPa (27 kgf/cm2, 392 psi)
290 kPa (3 kgf/cm2, 42 psi)
NOTICE:
• Use a fully-charged battery so that the engine
speed can be increased to 250 rpm or more.
• Inspect the other cylinders in the same way.
• Measure the compression pressure in as
short a time as possible.
If the cylinder compression is low, pour a small EM
amount of engine oil into the cylinder through the
glow plug hole, then inspect it again.
HINT:
• If adding oil increases the compression, the
piston rings and/or cylinder bore may be worn or
damaged.
• If the pressure stays low, a valve may be stuck or
seated improperly, or there may be leakage from
the gasket.
(j) Remove the compression gauge and SST.
(k) Disconnect the cable from the negative battery
terminal.
(l) Connect all connectors to the 4 injectors.
(m) Install the No. 2 cylinder head cover sub-assembly
with the 2 bolts.
(n) Install the 4 bolts to the glow plug hole.
9. INSPECT DIESEL SMOKE
Standard (Black smoke):
10% or less
EM–4 N04C-TR, TS, TT, TU, TV, TW ENGINE MECHANICAL – DRIVE BELT
DRIVE BELT
ENGINE
COMPONENTS
FAN AND GENERATOR V BELT
EM
NO. 1 V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT
(N04C-TR, TS, TT, TV, with Air Conditioning System)

A153168E01
REMOVAL
1. REMOVE FAN AND GENERATOR V BELT
(a) Loosen bolts A and B.
A (b) Loosen bolt C, then remove the fan and generator V
C belt.
B
A152864E01
2. REMOVE NO. 1 V (COOLER COMPRESSOR TO

B CRANKSHAFT PULLEY) BELT (N04C-TR, TS, TT, TV,
with Air Conditioning System)
(a) Loosen bolts A.
(b) Loosen bolt B, then remove the No. 1 V belt.
A155642E01
N04C-TR, TS, TT, TU, TV, TW ENGINE MECHANICAL – DRIVE BELT EM–5
INSPECTION
1. INSPECT V BELT
(a) Check the belt for wear, cracks and other signs of
damage.
If any defects are found, replace the V belt.
HINT:
Replace the drive belt if any of the following defects
are found:
• The belt is worn out and the wire is exposed.
• The cracks reach the wire in more than one
place.
(b) Check that the belt fits properly into the grooves.
HINT:
Confirm by hand that the belt has not slipped out of
the grooves on the bottom of the pulley. EM
INSTALLATION
1. INSTALL NO. 1 V (COOLER COMPRESSOR TO
CRANKSHAFT PULLEY) BELT (with Air Conditioning
System)
(a) Install the belt.
2. ADJUST NO. 1 V (COOLER COMPRESSOR TO
B CRANKSHAFT PULLEY) BELT (N04C-TR, TS, TT, TV,
with Air Conditioning System)
(a) Turn bolt B to adjust the tension of the V belt.
(b) Tighten bolt A.
A (c) Tighten bolt B.
3. INSTALL FAN AND GENERATOR V BELT
A155642E01
(a) Install the belt.
4. ADJUST FAN AND GENERATOR V BELT
(a) Turn bolt C to adjust the tension of the V belt.
(b) Tighten bolts A and B.
Torque: Bolt A
A 29 N*m (290 kgf*cm, 18 ft.*lbf)
C
Bolt B
55 N*m (560 kgf*cm, 38 ft.*lbf)
(c) Tighten bolt C.
B
A152864E01
5. INSPECT DRIVE BELT (See page EM-1)
EM–6 N04C-TR, TS, TT, TU, TV, TW ENGINE MECHANICAL – VALVE CLEARANCE
VALVE CLEARANCE
ADJUSTMENT
1. REMOVE INJECTOR ASSEMBLY
HINT:
(See chapter FU)
2. CHECK VALVE CLEARANCE
Timing Mark (a) Set the No. 1 cylinder to TDC/compression.
EM
A146510E01
(b) Check the valve clearance of the No. 1 cylinder

intake valve and the No. 3 cylinder exhaust valve.
Valve clearance (Cold):
Intake:
0.30 mm (0.0118 in.)
Exhaust:
No. 1
No. 3 0.45 mm (0.0177 in.)
IN
EX NOTICE:
Do not apply excessive force to the valve
A146508E01 adjusting screw.
HINT:
If the clearance is not as specified, record the out-
of-specification measurement, then adjust the valve
clearance.
(c) Check the valve clearance of the No. 1 cylinder
exhaust valve and the No. 2 cylinder intake valve.
Intake:
0.30 mm (0.0118 in.)
Exhaust:
No. 1
No. 2 0.45 mm (0.0177 in.)
EX
IN NOTICE:
HINT:
clearance.
(d) Turn the crankshaft by a further 360° clockwise.
N04C-TR, TS, TT, TU, TV, TW ENGINE MECHANICAL – VALVE CLEARANCE EM–7
(e) Set the No. 4 cylinder to TDC/compression.

Timing Mark
A146510E01
(f) Check the valve clearance of the No. 2 cylinder

exhaust valve and the No. 4 cylinder intake valve.
Intake:
0.30 mm (0.0118 in.) EM
Exhaust:
No. 2 No. 4 0.45 mm (0.0177 in.)
EX IN NOTICE:
HINT:
clearance.
(g) Check the valve clearance of the No. 3 cylinder
intake valve and the No. 4 cylinder exhaust valve.
Intake:
0.30 mm (0.0118 in.)
Exhaust:
No. 4 0.45 mm (0.0177 in.)
No. 3
EX NOTICE:
IN
HINT:
clearance.
EM–8 N04C-TR, TS, TT, TU, TV, TW ENGINE MECHANICAL – VALVE CLEARANCE
3. ADJUST VALVE CLEARANCE

No. 1 and No. 4 Cylinder (a) Turn the crankshaft clockwise to align the
matchmark on the crankshaft pulley with the pointer
on the timing gear case.
HINT:
If not, turn the crankshaft 1 revolution (360°) to align
the matchmark.
Matchmark
No. 2 and No. 3 Cylinder
EM
Matchmark
A151511E01
(b) With the No. 1 piston positioned at TDC on the

Adjusting Screw
compression stroke, using a feeler gauge, adjust
each valve clearance.
Intake:
0.30 mm (0.0118 in.)
Exhaust:
Feeler Gauge 0.45 mm (0.0177 in.)
Lock nut HINT:
A151512E01 The feeler gauge should move with a very slight
pull.
(c) Loosen the lock nut on the valve rocker arm and
loosen the adjusting screw.
(d) Insert a 0.30 mm (0.012 in.) feeler gauge for the
intake or a 0.45 mm (0.018 in.) feeler gauge for the
exhaust between the adjusting screw on the valve
rocker arm and the valve bridge.
(e) Turn the adjusting screw on the valve rocker arm
until the feeler gauge slides with a very slight drag,
and lock the adjusting screw with the lock nut.
4. INSTALL INJECTOR ASSEMBLY
HINT:
(See chapter FU)
5. BLEED AIR FROM FUEL SYSTEM (See chapter FU)
6. INSPECT FOR FUEL LEAK (See chapter FU)
N04C-TR, TS, TT, TU, TV, TW ENGINE MECHANICAL – CAMSHAFT EM–9
CAMSHAFT
ENGINE
COMPONENTS
OIL PUMP TO GEAR BOX TUBE
44 (450, 32) 44 (450, 32)
PRESSURE FEED HOSE
NO. 1 HOSE SUPPORT BRACKET

EM
x2
POWER STEERING
18 (180, 13) 18 (180, 13) SUCTION PORT UNION
NO. 2 OIL RESERVOIR

TO PUMP HOSE
GASKET
49 (490, 36)
UNION BOLT
O-RING
VANE PUMP ASSEMBLY
O-RING
x2
CLIP
x2 18 (180, 13)
29 (290, 21)
x2
47 (480, 35) 29 (290, 21)
O-RING
3.5 (35, 31 in.*lbf) RADIATOR PIPE
Non-reusable part
Power Steering Fluid

C151629E03
EM–10 N04C-TR, TS, TT, TU, TV, TW ENGINE MECHANICAL – CAMSHAFT
EXAMPLE: N04C-TR, TS, TT, TU, TV
VACUUM PIPE
GASKET
EM
VACUUM PUMP ASSEMBLY 13 (130, 10)
GASKET
O-RING
13 (130, 10)
55 (560, 41) x3
x2
GASKET
VACUUM PUMP OIL PIPE SUB-ASSEMBLY
NO. 3 NOZZLE LEAKAGE PIPE SUB-ASSEMBLY
GASKET
13 (130, 10)
35 (360, 26)
FUEL FILTER TO INJECTION PUMP FUEL PIPE
29 (290, 21)
FUEL PIPE SUPPORT
35 (360, 26)
29 (290, 21)
Non-reusable part
A165805E01
EXAMPLE: N04C-TW
VACUUM PIPE
GASKET
EM
GASKET
O-RING
13 (130, 10)
x2 x3
55 (560, 41)
VACUUM PUMP OIL PIPE

SUB-ASSEMBLY
NO. 4 FUEL PIPE SUB-ASSEMBLY
GASKET
20 (200, 15)
GASKET
25 (250, 18)
44 (450, 33)
Non-reusable part
A164412E01
EXAMPLE: N04C-TR, TS, TT, TV
GASKET
20 (200, 15)
GASKET
20 (200, 15)
NO. 4 FUEL PIPE

SUB-ASSEMBLY
EM
FUEL RETURN PIPE
SUB-ASSEMBLY
x2
29 (290, 21)
FUEL PIPE SUB-ASSEMBLY
25 (250, 18)
GASKET
INJECTION OR SUPPLY PUMP ASSEMBLY
29 (290, 21)
x2
29 (290, 21)
O-RING
HOLDER CLAMP
29 (290, 21)
Non-reusable part
A163605E01
EXAMPLE: N04C-TW
FUEL RETURN PIPE SUB-ASSEMBLY GASKET
25 (250, 18)
20 (204, 15)
GASKET
25 (250, 18)
NO. 1 FUEL HOSE

NO. 4 FUEL PIPE
RETURN TUBE
SUB-ASSEMBLY EM
GASKET
x2
25 (250, 18)
29 (290, 21)
INJECTION PUMP TO FUEL
FILTER FUEL HOSE OR PIPE
FUEL DELIVERY PIPE SUB-ASSEMBLY
29 (290, 21)
x2
29 (290, 21)
O-RING
HOLDER CLAMP
29 (290, 21)
Non-reusable part
A163950E01
EXAMPLE: N04C-TR,System:
with Air Conditioning TS, TT, TV with Air Conditioning System
EM
55 (561, 41)
25 (250, 18) x4
x3
NO. 1 COMPRESSOR MOUNTING BRACKET
55 (561, 41)
x2
IDLE PULLEY BRACKET
A160489E02
29 (300, 21)
60 (610, 44) EXHAUST MANIFOLD
x3
x7
EXHAUST MANIFOLD HEAT INSULATOR
GASKET

EM
O-RING
WATER PUMP ASSEMBLY
29 (290, 21)
12 (120, 9)
x8
INTAKE MANIFOLD
WATER PIPE SUB-ASSEMBLY
29 (290, 21)
x6
WATER BY-PASS PIPE x8

SUB-ASSEMBLY 29 (290, 21)
x3
29 (290, 21)
O-RING
12 (120, 9)
O-RING
Non-reusable part
A160429E01
69 (700, 51)
NO. 1 VALVE ROCKER SHAFT x5

SUB-ASSEMBLY
VALVE BRIDGE
VALVE PUSH ROD x8 x8

x 16
VALVE LIFTER
x 16
EM 1st: 60 (610, 44)
x 18
2nd: turn 90° CYLINDER HEAD SUB-ASSEMBLY
55 (560, 41)
3rd: turn 90°
x4
SPACER
519 (5300, 380)
CRANKSHAFT PULLEY
Non-reusable part
A155645E01
CAMSHAFT
29 (290, 21)
x2
TIMING GEAR CASE

29 (290, 21)
x 15
EM
97 (990, 72)
TIMING CHAIN OR BELT
COVER OIL SEAL
FLYWHEEL HOUSING STAY RH
132 (1350, 97)
FLYWHEEL HOUSING STAY LH

132 (1350, 97)
97 (990, 72)
OIL PAN SUB-ASSEMBLY

GASKET

41 (420, 30)
x 26 OIL PAN DRAIN PLUG
Non-reusable part
29 (290, 21)
Grease
A155646E01
REMOVAL
1. REMOVE ENGINE UNDER COVER
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
3. DRAIN ENGINE OIL (See chapter LU)
5. DRAIN POWER STEERING FLUID
6. REMOVE CYLINDER HEAD GASKET
HINT:
(See page EM-44)
7. REMOVE COMPRESSOR AND MAGNETIC CLUTCH
EM (N04C-TR, TS, TT, TV, with Air Conditioning System)
(See page EM-129)
8. DISCONNECT NO. 2 OIL RESERVOIR TO PUMP
HOSE (See page EM-130)
9. REMOVE PRESSURE FEED HOSE (See page EM-
130)
10. REMOVE VANE PUMP ASSEMBLY (See page EM-
133)
11. REMOVE IDLE PULLEY BRACKET (N04C-TR, TS, TT,
TV, with Air Conditioning System) (See page EM-133)
12. REMOVE NO. 1 COMPRESSOR MOUNTING
BRACKET (N04C-TR, TS, TT, TV, with Air
Conditioning System) (See page EM-134)
13. REMOVE WATER PUMP ASSEMBLY (See chapter
CO)
14. REMOVE INTAKE MANIFOLD (See page EM-137)
15. REMOVE EXHAUST MANIFOLD (See page EM-134)
16. REMOVE CRANKSHAFT POSITION SENSOR (See
page EM-135)
17. REMOVE CAMSHAFT POSITION SENSOR (See page
EM-135)
18. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See
page EM-46)
19. REMOVE VACUUM PIPE (See page EM-136)
20. REMOVE VACUUM PUMP OIL PIPE SUB-ASSEMBLY
(See page EM-136)
21. REMOVE VACUUM PUMP ASSEMBLY (See page EM-
137)
22. REMOVE FUEL PIPE SUB-ASSEMBLY (See chapter
FU)
23. REMOVE FUEL FILTER TO INJECTION PUMP FUEL
PIPE (N04C-TV, TW, See chapter FU)
24. REMOVE NO. 3 NOZZLE LEAKAGE PIPE SUB-

ASSEMBLY (See page EM-137)
25. REMOVE COMMON RAIL ASSEMBLY (N04C-TU, TV,
See chapter FU)
26. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY (See
chapter FU)
27. REMOVE FUEL DELIVERY PIPE (N04C-TW, See
chapter FU)
28. REMOVE FUEL RETURN PIPE SUB-ASSEMBLY
(N04C-TW, See chapter FU)
29. REMOVE INJECTION OR SUPPLY PUMP ASSEMBLY
(See chapter FU)
30. REMOVE CRANKSHAFT PULLEY (See page EM-92) EM
31. REMOVE FLYWHEEL HOUSING STAY LH
(a) Remove the 4 bolts and flywheel housing stay LH.
32. REMOVE FLYWHEEL HOUSING STAY RH
(a) Remove the 4 bolts and flywheel housing stay RH.
33. REMOVE OIL PAN SUB-ASSEMBLY
(a) Remove the 26 bolts.
(b) Insert the blade of SST between the crankcase and
oil pan. Cut through the applied sealer and remove
SST the oil pan.
SST 09032-00100
NOTICE:
SST
Do not damage the contact surface of the
cylinder block and oil pan.
A101612E01
34. REMOVE TIMING GEAR CASE

(b) Using a screwdriver with its tip wrapped in
protective tape, pry out the timing gear case.
NOTICE:
Do not damage the contact surfaces of the
timing gear case, cylinder block and cylinder
head.
A151471
35. REMOVE TIMING CHAIN OR BELT COVER OIL SEAL

(a) Using a screwdriver with its tip wrapped in
protective tape, pry out the oil seal.
Protective Tape
A152900E01
36. REMOVE CAMSHAFT

(a) Remove the 2 bolts and remove the camshaft.
EM
A146589
INSPECTION
1. INSPECT CAMSHAFT
(a) Inspect the camshaft for circle runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial gauge, measure the circle runout
at the center journal.
Maximum circle runout:
0.06 mm (0.0024 in.)
A151553
If the circle runout is greater than the
maximum, replace the camshaft.
(b) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake:
50.66 to 50.86 mm (1.9944 to 2.0023 in.)
Exhaust:
49.36 to 49.56 mm (1.9432 to 1.9511 in.)
Minimum cam lobe height:
Intake:
50.20 mm (1.9764 in.)
Exhaust:
48.95 mm (1.9272 in.)
If the lobe height is less than the minimum, replace
the camshaft.
INSTALLATION
1. INSTALL CAMSHAFT
(a) Apply engine oil to the camshaft journal and
bearing.
(b) Align the matchmarks of the camshaft timing gear
and oil pump gear and install the camshaft.
Alignment Mark
Alignment Mark
A151500E03
EM
(c) Install the thrust plate with the 2 bolts.
A146589
2. INSTALL TIMING CHAIN OR BELT COVER OIL SEAL

(a) Using SST and a hammer, tap in the oil seal to the
timing gear case so that the oil seal is flush with the
timing gear edge.
SST 09223-78010
NOTICE:
• Be careful not to tap the oil seal at an angle.
SST
556 • Keep the gap between the gear case edge
and the oil seal free of foreign matter.
A101615E01 (b) Apply MP grease to the oil seal lip.
3. INSTALL TIMING GEAR CASE

(a) Remove any oil packing material from the contact
surface.
(b) Apply seal packing in a continuous line (width: 3 to 4
mm (0.11 to 0.15 in.)) as shown in the illustration.
Seal packing:
Seal
Toyota Genuine Seal Packing Black, Three
Packing
Bond 1207B or equivalent
NOTICE:
A151504E01 • Remove any oil from the contact surface.
• Install the belt cover within 3 minutes of
applying the seal packing.
• Do not expose the seal packing to engine oil
for at least 2 hours after installing.
(c) Install the timing gear case with the 15 bolts.

A151471
4. INSTALL OIL PAN SUB-ASSEMBLY

surface.
(b) Apply seal packing in a continuous line (width: 3 to 4
EM mm (0.11 to 0.15 in.)) as shown in the illustration.
Seal packing:
Seal Packing
NOTICE:
for at least 2 hours after installing.
(c) Install the oil pan with the 26 bolts.
5. INSTALL FLYWHEEL HOUSING STAY LH
(a) Install the flywheel housing stay LH with the 4 bolts.
Torque: for M14 bolt
Seal Packing 132 N*m (1350 kgf*cm, 97 ft.*lbf)
A146590E01
for M12 bolt
97 N*m (990 kgf*cm, 72 ft.*lbf)
6. INSTALL FLYWHEEL HOUSING STAY RH
(a) Install the flywheel housing stay RH with the 4 bolts.
Torque: for M14 bolt
132 N*m (1350 kgf*cm, 97 ft.*lbf)
for M12 bolt
97 N*m (990 kgf*cm, 72 ft.*lbf)
7. INSTALL CRANKSHAFT PULLEY (See page EM-92)
8. INSTALL CYLINDER HEAD GASKET
HINT:
(See page EM-47)
9. INSTALL INJECTION OR SUPPLY PUMP ASSEMBLY
(See chapter FU)
10. INSTALL FUEL RETURN PIPE SUB-ASSEMBLY
11. INSTALL FUEL DELIVERY PIPE (N04C-TW, See
chapter FU)
12. INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY (See
chapter FU)
13. INSTALL COMMON RAIL ASSEMBLY (N04C-TU, TV,

See chapter FU)
14. INSTALL NO. 3 NOZZLE LEAKAGE PIPE SUB-
15. INSTALL FUEL FILTER TO INJECTION PUMP FUEL
PIPE (N04C-TV, TW, See chapter FU)
16. INSTALL FUEL PIPE SUB-ASSEMBLY (See chapter
FU)
17. INSTALL VACUUM PUMP ASSEMBLY (See page EM-
139)
18. INSTALL VACUUM PUMP OIL PIPE SUB-ASSEMBLY
(See page EM-139)
19. INSTALL VACUUM PIPE (See page EM-139) EM
20. INSTALL CAMSHAFT POSITION SENSOR (See page
EM-140)
21. INSTALL CRANKSHAFT POSITION SENSOR (See
page EM-140)
22. INSTALL EXHAUST MANIFOLD (See page EM-141)
23. INSTALL INTAKE MANIFOLD (See page EM-138)
24. INSTALL WATER PUMP ASSEMBLY (See chapter
CO)
25. INSTALL NO. 1 COMPRESSOR MOUNTING
26. INSTALL IDLE PULLEY BRACKET (with Air
27. INSTALL VANE PUMP ASSEMBLY (See page EM-143)
28. CONNECT PRESSURE FEED HOSE (See page EM-
146)
29. CONNECT NO. 2 OIL RESERVOIR TO PUMP HOSE
(See page EM-147)
30. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
(See page EM-147)
31. INSTALL NEGATIVE BATTERY TERMINAL
32. ADD ENGINE OIL (See chapter LU)
34. ADD POWER STEERING FLUID
36. INSPECT FOR ENGINE OIL LEAK
37. INSPECT FOR ENGINE COOLANT LEAK (See
chapter CO)
38. BLEED POWER STEERING SYSTEM (See chapter

PS)
39. INSPECT FOR POWER STEERING FLUID LEAK
40. INSPECT FOR EXHAUST GAS LEAK
42. INSTALL ENGINE UNDER COVER
EM
N04C-TR, TS, TT, TU, TV, TW ENGINE MECHANICAL – CYLINDER HEAD GASKET EM–25

ENGINE
COMPONENTS
N04C-TR, TS, TT, TV, TW N04C-TU
EM
ENGINE SIDE COVER SUB-ASSEMBLY RH ENGINE SIDE COVER SUB-ASSEMBLY RH
NO. 1 V (COOLER COMPRESSOR TO

CRANKSHAFT PULLEY) BELT
(N04C-TR, TS, TT, TV with Air Conditioning System)

ENGINE SIDE COVER SUB-ASSEMBLY LH ENGINE SIDE COVER SUB-ASSEMBLY LH
A160488E032
EM–26 N04C-TR, TS, TT, TU, TV, TW ENGINE MECHANICAL – CYLINDER HEAD GASKET
RADIATOR RESERVE TANK ASSEMBLY
12 (120, 9)
FENDER SIDE APRON SUB-ASSEMBLY RH
VACUUM RESERVOIR
SUB-ASSEMBLY NO. 3 CAB MOUNTING
BRACKET SUB-ASSEMBLY
EM
27 (275, 20)
120 (1224, 89)

x4
x4
120 (1224, 89)
20 (200, 15)
x2
INJECTOR DRIVER ASSEMBLY
12 (120, 9) FENDER SIDE APRON SUB-ASSEMBLY LH
A161412E02
EXAMPLE: N04C-TR, TS, TT

GENERATOR BRACKET SUB-ASSEMBLY
GENERATOR BELT ADJUSTING BAR

x3
55 (560, 41)
GENERATOR ASSEMBLY
125 (1275, 92) WATER HOSE
x2
29 (290, 18)
55 (560, 38) EM
FUEL HOSE
WATER HOSE
x2
98 (1000, 72)
WATER HOSE
29 (291, 21)
INTAKE AIR CONNECTOR BRACKET
29 (291, 21) x2 x2
x2
CLAMP
CLAMP
NO. 2 INTAKE PIPE 18 (184, 13)

x2
NO. 1 AIR HOSE
AIR CLEANER CASE
AIR CLEANER STAY 18 (184, 13)

x4
65 (663, 48)
x4
A166650E01
EXAMPLE: N04C-TU

x3
55 (560, 41)
GENERATOR ASSEMBLY
125 (1275, 92) WATER HOSE
x2
29 (290, 18)
EM 55 (560, 38)
FUEL HOSE
WATER HOSE
x2
98 (1000, 72)
WATER HOSE
18 (184, 13) NO. 2 INTAKE PIPE

x2
CLAMP
CLAMP
NO. 1 AIR HOSE
CLAMP
A166044E01
EXAMPLE: N04C-TV, TW

x3
55 (560, 41)
GENERATOR ASSEMBLY
125 (1275, 92) WATER HOSE
x2
29 (290, 18)
55 (560, 38)
EM
FUEL HOSE
WATER HOSE
x2
98 (1000, 72)
WATER HOSE

x2
CLAMP
CLAMP
18 (184, 13)
x2
NO. 1 AIR HOSE
AIR CLEANER CASE

x4
65 (663, 48)
N*m (kgf*cm, ft.*lbf) : Specified torque x4
A164411E01
EXAMPLE: N04C-TR, TS, TT, TV, TW
NO. 2 AIR HOSE
EM
7.5 (77, 66 in.*lbf)
7.5 (77, 66 in.*lbf)
INTERCOOLER ASSEMBLY
18 (184, 13)
NO. 1 INTAKE AIR PIPE WITH NO. 4 AIR HOSE

A155410E02
EXAMPLE: N04C-TU, TW
NO. 2 AIR HOSE WITH NO. 1 AIR HOSE
13 (133, 10)
x2
EM
7.5 (77, 66 in.*lbf)
7.5 (77, 66 in.*lbf)
18 (184, 13)
18 (184, 13)
18 (184, 13)
18 (184, 13)
N*m (kgf*cm, ft.*lbf) : Specified torque NO. 1 INTAKE AIR PIPE WITH NO. 4 AIR HOSE
A152382E06
29 (290, 21) N04C-TW

x4
20 (199, 14) FAN PULLEY

FAN NO. 3 RADIATOR BRACKET
RADIATOR HOSE
INLET
NO. 5 RADIATOR HOSE
EM RADIATOR HOSE OUTLET
20 (199, 14) HEATER HOSE
N04C-TW
18 (184, 13)
18 (184, 13)
x3 x3
NO. 4 RADIATOR BRACKET
7.5 (77, 66 in.*lbf) RADIATOR ASSEMBLY

NO. 1 RADIATOR SUPPORT
20 (199, 14) 18 (184, 13)
x3
HEATER HOSE
7.5 (77, 66 in.*lbf) HEATER HOSE

20 (199, 14)
N*m (kgf*cm, ft.*lbf) : Specified torque 20 (199, 14)
A165981E01
EXAMPLE: N04C-TU
29 (290, 21)
20 (199, 14)
x4
HEATER HOSE
FAN PULLEY
RADIATOR HOSE INLET

EM
FAN
18 (184, 13)
NO. 5 RADIATOR HOSE

18 (184, 13)
RADIATOR ASSEMBLY
NO. 3 RADIATOR
BRACKET
RADIATOR HOSE OUTLET
7.5 (77, 66 in.*lbf)
x2 HEATER HOSE

18 (184, 13)
20 (199, 14) 18 (184, 13)
x3
20 (199, 14)
HEATER HOSE
RADIATOR AIR GUIDE

x2
7.5 (77, 66 in.*lbf)
A165997E01
EGR VALVE BRACKET
EM
x4
29 (291, 21)
VENTURI ASSEMBLY
x2
x4
29 (291, 21)
29 (291, 21)

A165654E01
EXAMPLE: N04C-TU, TV
GASKET
69 (700, 51)
x2
x2
SCREW GROMMET
55 (560, 41)
x2
GASKET
1.5 (15, 13 in.*lbf)
EGR COOLER SUB-ASSEMBLY
EM
GLOW PLUG GROUND WIRE
25 (255, 18)
GLOW PLUG ASSEMBLY
EGR VALVE BRACKET
29 (290, 21)
VENTURI ASSEMBLY
29 (290, 21)

x2
29 (290, 21)
x2
WATER BY-PASS PIPE SUB-ASSEMBLY
25 (250, 18) 29 (290, 21)
GASKET 25 (250, 18)

Non-reusable part
A155568E01
EXAMPLE: N04C-TW
GASKET
69 (700, 51)
x2
x2
55 (560, 41)
x2
GASKET

EM
EGR VALVE
BRACKET
29 (290, 21)
VENTURI ASSEMBLY
29 (290, 21)

x2
29 (290, 21)
x2
25 (250, 18)
29 (290, 21)
N*m (kgf*cm, ft.*lbf) : Specified torque GASKET
25 (250, 18)
Non-reusable part
A165071E01
29 (290, 21)
x6
EM
x3
29 (290, 21) WATER BY-PASS PIPE SUB-ASSEMBLY
O-RING O-RING
18 (180, 13)
x2
RADIATOR PIPE
GASKET
FRONT EXHAUST PIPE ASSEMBLY
70 (714, 52)
VACUUM HOSE
x3
25 (259, 19)
x4
30 (306, 22)
GASKET
EXHAUST RETARDER ASSEMBLY

Non-reusable part
A165684E01
EXAMPLE: N04C-TU, TV, TW
EM 29 (290, 21)
x6
x3
29 (290, 21) WATER BY-PASS PIPE SUB-ASSEMBLY
O-RING O-RING
18 (180, 13)
x2
RADIATOR PIPE
70 (714, 52)
25 (259, 19)
GASKET
30 (306, 22)

Non-reusable part FRONT EXHAUST PIPE ASSEMBLY
A164222E01
NO. 1 TURBO WATER PIPE
BRACKET
25 (250, 18)
GASKET
O-RING
29 (291, 21) 29 (291, 21)
NO. 1 TURBO INSULATOR
29 (291, 21)
x2 EM
TURBOCHARGER GASKET GASKET
SUB-ASSEMBLY
36 (367, 27)
x5
GASKET
TURBINE OUTLET ELBOW

INTAKE PIPE 28 (286, 21)
69 (704, 51)
x4
CLAMP x2
GASKET
5.0 (51, 44 in.*lbf) x2 TURBO OIL OUTLET PIPE
x2
29 (291, 21) 29 (291, 21)
GASKET
TURBO OIL INLET PIPE SUB-ASSEMBLY
25 (250, 18) 25 (250, 18) GASKET
GASKET
29 (291, 21)
29 (291, 21)
29 (291, 21)
GASKET
25 (250, 18)
GASKET NO. 2 TURBO WATER PIPE
GASKET
Non-reusable part
A165653E01
25 (255, 18) NO. 1 TURBO WATER

PIPE SUB-ASSEMBLY
GASKET
O-RING
29 (296, 21)
70 (714, 52)
GASKET
EM 25 (255, 18)
GASKET
70 (714, 52)
25 (255, 18)
18 (184, 13)
TURBOCHARGER SUB-ASSEMBLY
GASKET
GASKET
TURBO OIL INLET PIPE

SUB-ASSEMBLY
x2
29 (296, 21) GASKET

GASKET
x2
29 (296, 21)
25 (255, 18)
x2
TURBO OIL OUTLET PIPE SUB-ASSEMBLY
INTAKE PIPE
GASKET
25 (255, 18)
NO. 2 WATER BY-PASS PIPE
SUB-ASSEMBLY
29 (296, 21) 29 (296, 21)

25 (255, 18)
GASKET
Non-reusable part
A158150E02
EXAMPLE: N04C-TW
EM
29 (291, 21)
VENTILATION PIPE
SUB-ASSEMBLY
x2
OIL SEPARATOR BRACKET
29 (291, 21)
x4
29 (291, 21)
x2
18 (184, 13)
OIL SEPARATOR x2
ASSEMBLY
HARNESS BRACKET
HOSE
A157925E01
OIL FILLER CAP SUB-ASSEMBLY
29 (290, 21)
CYLINDER HEAD COVER SUB-ASSEMBLY
x2
NO. 1 NOZZLE LEAKAGE PIPE

WIRE HARNESS
29 (290, 21)
x2
13 (133, 10) x5 CUSHION x2
SPACER x2
EM
GASKET x5
NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY
GASKET
x4
25 (255, 18) x4 NOZZLE HOLDER CLAMP

GASKET
x4 INJECTOR ASSEMBLY
NOZZLE HOLDER OIL LEVEL GAUGE
CLAMP BOLT
x4 NOZZLE HOLDER SEAL
x4
O-RING x4
GASKET x4
x2
35 (360, 26)
x2
INJECTION PIPE CLAMP
OIL LEVEL GAUGE GUIDE
O-RING
Non-reusable part
A152847E05
69 (700, 51)
NO. 1 VALVE ROCKER SHAFT

SUB-ASSEMBLY x5
VALVE BRIDGE
x 16 x8
VALVE PUSH ROD x8
VALVE LIFTER
x 16 EM
1st: 60 (610, 44)
55 (560, 41)
2nd: turn 90° x 18 CYLINDER HEAD SUB-ASSEMBLY
3rd: turn 90°
x4
Non-reusable part
A155668E01
REMOVAL
2. REMOVE CABLE FROM NEGATIVE BATTERY
TERMINAL
5. REMOVE ENGINE SIDE COVER SUB-ASSEMBLY LH
6. REMOVE ENGINE SIDE COVER SUB-ASSEMBLY RH
7. REMOVE RADIATOR RESERVE TANK ASSEMBLY
(See page EM-127)
8. REMOVE FENDER SIDE APRON SUB-ASSEMBLY LH
EM
9. REMOVE FENDER SIDE APRON SUB-ASSEMBLY RH
10. REMOVE VACUUM RESERVOIR SUB-ASSEMBLY
11. REMOVE INJECTOR DRIVER ASSEMBLY (N04C-TR,
TS, TT, TU, TV, See chapter FU)
12. REMOVE SPILL VALVE CONTROL DRIVER
ASSEMBLY (N04C-TW, See chapter FU)
13. REMOVE NO. 2 INTAKE PIPE (See chapter IT)
14. REMOVE NO. 3 CAB MOUNTING BRACKET SUB-
15. REMOVE INTAKE AIR CONNECTOR BRACKET
(N04C-TR, TS, TT, See page )
16. REMOVE NO. 1 INTAKE AIR PIPE WITH NO. 4 AIR
HOSE (See chapter IT)
17. REMOVE NO. 2 AIR HOSE (See chapter IT)
18. REMOVE INTERCOOLER ASSEMBLY (See chapter
IT)
19. REMOVE FAN (See page EM-128)
20. REMOVE FAN PULLEY (See page EM-129)
CRANKSHAFT PULLEY) BELT (N04C-TR, TS, TT, TV,
with Air Conditioning System) (See page EM-4)
22. DISCONNECT RADIATOR HOSE INLET (See page
EM-129)
23. SEPARATE RADIATOR HOSE OUTLET (See page
EM-129)
24. SEPARATE HEATER HOSE (See chapter CO)
25. SEPARATE NO. 4 RADIATOR BRACKET (See chapter
CO)
CO)
27. REMOVE RADIATOR ASSEMBLY (See chapter CO)
28. REMOVE GENERATOR ASSEMBLY (See chapter CH)

29. REMOVE EXHAUST RETARDER ASSEMBLY (See
chapter MT)
30. REMOVE FRONT EXHAUST PIPE ASSEMBLY (See
chapter EX)
31. DISCONNECT FUEL HOSE (See page EM-130)
32. DISCONNECT WIRE HARNESS (See page EM-130)
33. REMOVE EGR COOLER SUB-ASSEMBLY (See page
EM-131)
34. REMOVE OIL FILLER CAP SUB-ASSEMBLY (See
page EM-131)
35. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY EM
(See page EM-131)
36. REMOVE NO. 2 CYLINDER HEAD COVER SUB-
37. REMOVE DIESEL THROTTLE BODY (N04C-TU, TV,
TW, See chapter ES)
38. REMOVE VENTURI ASSEMBLY (N04C-TU, TV, TW,
See page EM-133)
39. SEPARATE WIRE HARNESS AND CONNECTORS
(N04C-TU, TV, TW, See chapter EC)
40. REMOVE VENTILATION PIPE SUB-ASSEMBLY
41. REMOVE EGR VALVE BRACKET (See page EM-132)
42. REMOE OIL SEPARATOR ASSEMBLY (N04C-TW, See
chapter FU)
43. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY
(See page EM-133)
44. REMOVE VENTURI ASSEMBLY (N04C-TR, TS, TT,
See chapter FU)
45. REMOVE INJECTION PIPE CLAMP (See chapter FU)
46. REMOVE OIL LEVEL GAUGE GUIDE (See page EM-
133)
47. REMOVE INJECTOR ASSEMBLY (See chapter FU)
48. REMOVE GENERATOR BELT ADJUSTING BAR (See
page EM-133)
49. REMOVE GENERATOR BRACKET SUB-ASSEMBLY
(See page EM-134)
50. REMOVE RADIATOR PIPE (See page EM-134)
51. REMOVE GLOW PLUG GROUND WIRE (N04C-TU,
TV, See chapter ST)
52. REMOVE GLOW PLUG ASSEMBLY (See chapter ST)
53. REMOVE TURBOCHARGER SUB-ASSEMBLY

HINT:
(See chapter IT)
54. REMOVE WATER PIPE SUB-ASSEMBLY (See page
EM-136)
(See page EM-136)
56. SET NO. 1 CYLINDER TO TDC/COMPRESSION
Timing Mark (a) Turn the crankshaft pulley until the grooves of the
crankshaft damper and timing gear are aligned.
EM
A146510E01
57. REMOVE NO. 1 VALVE ROCKER SHAFT SUB-

Adjusting Screw ASSEMBLY
(a) Loosen the lock nuts at the top of the rocker arms
and wind up the adjusting screws completely.
NOTICE:
If the adjusting screws are left unwound, the
rocker shaft may bend when the rocker arm
support bolts are loosened.
Lock Nut
A151464E01
(b) Loosen the rocker arm support bolts in the order

shown in the illustration.
1 3 5 4 2
58. REMOVE VALVE PUSH ROD
HINT:
Organize the parts so that each part location can be
remembered for reassembly.
59. REMOVE VALVE BRIDGE
HINT:
A151465E01 Organize the parts so that each part location can be
60. REMOVE CYLINDER HEAD SUB-ASSEMBLY
2 4 3 1 (a) Remove the cylinder head bolts in the order shown
in the illustration.
7 15 22 14 6 (b) Lift and remove the cylinder head from the cylinder
block.
11 19 18 10 61. REMOVE CYLINDER HEAD GASKET
8 16 21 13 5
12 20 17 9
A151469E01
INSTALLATION
1. INSTALL CYLINDER HEAD GASKET
(a) Install a new cylinder head gasket.
NOTICE:
Always use a new cylinder head gasket after
cleaning the surface of the cylinder head,
cylinder block and head gasket and keep them
free of dirt, water and grease.
2. INSPECT CYLINDER HEAD SET BOLT
(a) Measure the length of the M12 head bolts (No. 1 to
No. 18).
Maximum length:
129 mm (5.07 in.)
Length If the length is greater than the maximum, replace
the bolts. EM
3. INSTALL CYLINDER HEAD SUB-ASSEMBLY
(a) Install the cylinder head over the dowels on the
A151514E01
cylinder block.
HINT:
Since the cylinder head bolts are unique to this
engine, do not substitute them with ordinary bolts.
(b) Uniformly install and tighten the cylinder head bolts
21 19 20 22 (1 to 18) in the order shown in the illustration.
16 8 1 9 17
12 4 5 13
15 7 2 10 18
11 3 6 14
A151469E02
(c) Mark the front side of each cylinder head bolt with
paint as shown in the illustration.
(d) Retighten the cylinder head bolts by 90° in the same
90° 90° order as step (b).
(e) Perform step (d) again.
(f) Check that each painted mark is now at a 180°
angle to the front.
Front
Paint
A151508E01
(g) Uniformly install and tighten the cylinder head bolts

21 19 20 22 (19 to 22) in the order shown in the illustration.
16 8 1 9 17
4. INSTALL VALVE BRIDGE
NOTICE:
12 4 5 13 Be sure to install the removed valve bridge to its
original position.
15 7 2 10 18 5. INSTALL VALVE PUSH ROD
11 3 6 14
A151469E02
NOTICE:
Be sure to install the removed push rod to its
original position.
6. INSTALL NO. 1 VALVE ROCKER SHAFT SUB-
ASSEMBLY
EM (a) Install the rocker shaft to the cylinder head.
(b) Apply engine oil to the rocker arm and push rod.
(c) Install the bolts in the order shown in the illustration.
NOTICE:
Make sure that the push rod does not interfere
with the adjusting screw.
A101622
7. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
(See page EM-139)
8. INSTALL WATER PIPE SUB-ASSEMBLY (See page
EM-139)
9. INSTALL TURBOCHARGER SUB-ASSEMBLY
HINT:
(See chapter IT)
10. INSTALL GLOW PLUG ASSEMBLY (N04C-TU, TV,
See chapter ST)
11. INSTALL GLOW PLUG GROUND WIRE (N04C-TU, TV,
See chapter ST)
12. INSTALL RADIATOR PIPE (See page EM-142)
13. INSTALL GENERATOR BRACKET SUB-ASSEMBLY
(See page EM-142)
14. INSTALL GENERATOR BELT ADJUSTING BAR (See
page EM-143)
15. INSTALL INJECTOR ASSEMBLY (See chapter FU)
16. INSTALL OIL LEVEL GAUGE GUIDE (See page EM-
143)
17. INSTALL INJECTION PIPE CLAMP (See chapter FU)
18. INSTALL VENTURI ASSEMBLY (N04C-TR, TS, TT,
See chapter FU)
(See page EM-139)
20. INSTALL OIL SEPARATOR ASSEMBLY (N04C-TW,
See chapter FU)
21. INSTALL EGR VALVE BRACKET (See page EM-144)

22. INSTALL VENTILATION PIPE SUB-ASSEMBLY
23. CONNECT WIRE HARNESS AND CONNECTORS
24. INSTALL VENTURI ASSEMBLY (N04C-TU, TV, TW,
See page EM-143)
25. INSTALL DIESEL THROTTLE BODY (N04C-TU, TV,
TW, See chapter ES)
26. INSTALL NO. 2 CYLINDER HEAD COVER SUB-
27. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(See page EM-145) EM
28. INSTALL OIL FILLER CAP SUB-ASSEMBLY (See
page EM-145)
29. INSTALL EGR COOLER SUB-ASSEMBLY (See page
EM-145)
30. INSTALL WIRE HARNESS (See page EM-146)
31. CONNECT FUEL HOSE (See page EM-146)
32. INSTALL FRONT EXHAUST PIPE ASSEMBLY (See
chapter EX)
33. INSTALL EXHAUST RETARDER ASSEMBLY (See
chapter MT)
34. INSTALL GENERATOR ASSEMBLY (See chapter CH)
35. INSTALL RADIATOR ASSEMBLY (See chapter CO)
36. INSTALL NO. 3 RADIATOR BRACKET (See chapter
CO)
CO)
38. INSTALL HEATER HOSE (See chapter CO)
39. CONNECT RADIATOR HOSE OUTLET (See page EM-
147)
40. CONNECT RADIATOR HOSE INLET (See page EM-
147)
42. INSTALL FAN PULLEY (See page EM-148)
43. INSTALL FAN (See page EM-148)
45. INSTALL INTERCOOLER ASSEMBLY (See chapter
IT)
46. INSTALL NO. 2 AIR HOSE (See chapter IT)
47. INSTALL NO. 1 INTAKE AIR PIPE WITH NO. 4 AIR

48. INSTALL INTAKE AIR CONNECTOR BRACKET
(N04C-TT, See chapter EM-148)
49. INSTALL NO. 3 CAB MOUNTING BRACKET SUB-
50. INSTALL NO. 2 INTAKE PIPE (See chapter IT)
51. INSTALL SPILL VALVE CONTROL DRIVER
ASSEMBLY (N04C-TW, See chapter FU)
52. INSTALL INJECTOR DRIVER ASSEMBLY (N04C-TR,
TS, TT, TU, TV, See chapter FU)
53. INSTALL VACUUM RESERVOIR SUB-ASSEMBLY
EM
54. INSTALL FENDER SIDE APRON SUB-ASSEMBLY LH
55. INSTALL FENDER SIDE APRON SUB-ASSEMBLY RH
56. INSTALL RADIATOR RESERVE TANK ASSEMBLY
(See page EM-149)
57. INSTALL ENGINE SIDE COVER SUB-ASSEMBLY LH
58. INSTALL ENGINE SIDE COVER SUB-ASSEMBLY RH
60. INSTALL NEGATIVE BATTERY TERMINAL
chapter CO)
N04C-TR, TS, TT, TU, TV, TW ENGINE MECHANICAL – CYLINDER HEAD EM–51
CYLINDER HEAD
ENGINE
COMPONENTS
VALVE SPRING RETAINER LOCK
x8
VALVE SPRING RETAINER

x8
x8 EM
x8
INNER COMPRESSION SPRING x8
x8
VALVE STEM OIL SHIELD x8
x8
EXHAUST VALVE
INTAKE VALVE GUIDE BUSH x8 GUIDE BUSH
x8
INJECTION NOZZLE SEAT O-RING
x2 CYLINDER HEAD
SUB-ASSEMBLY
51 (520, 38)
STUD BOLT x8
25 (255, 18)
EXHAUST VALVE SEAT STUD BOLT

INTAKE VALVE SEAT
EXHAUST VALVE
INTAKE VALVE
Non-reusable part
A155116E01
EM–52 N04C-TR, TS, TT, TU, TV, TW ENGINE MECHANICAL – CYLINDER HEAD
SST
DISASSEMBLY
1. REMOVE INTAKE VALVE
(a) Using SST, remove the retainer lock, then remove
the retainer, compression spring and valve.
SST 09202-70020 (09202-01010, 09202-00020,
09202-01020, 90154-80004)
HINT:
Keep the removed parts in the correct order so that
A146605E01
they can be returned to their original positions when
reassembled.
2. REMOVE EXHAUST VALVE
SST
(a) Using SST, remove the retainer lock, then remove
the retainer, compression spring and valve.
SST 09202-70020 (09202-01010, 09202-00020,
EM 09202-01020, 90154-80004)
HINT:
Keep the removed parts in the correct order so that
they can be returned to their original positions when
reassembled.
A146605E01
3. REMOVE VALVE STEM OIL SHIELD
(a) Using needle-nose pliers, remove the oil shield.
INSPECTION
1. INSPECT CYLINDER HEAD FOR FLATNESS
(a) Using a precision straight edge and feeler gauge,
measure the warpage on the cylinder block side and
the intake and exhaust manifold sides.
Maximum warpage:
0.10 mm (0.0039 in.)
2. INSPECT CYLINDER HEAD FOR CRACKS
(a) Using a dye penetrant, check the cylinder head for
cracks.
Cylinder Block Side:
EM
Intake Manifold Side:
Exhaust Manifold Side:
A146579E01
3. INSPECT INNER COMPRESSION SPRING

(a) Using a steel square, measure the deviation of the
Deviation
compression spring.
Maximum deviation:
2.0 mm (0.0787 in.)
If the deviation is greater than the maximum,
replace the inner compression spring.
A137173E01
(b) Using vernier calipers, measure the free length of

the compression spring.
Standard free length:
85.1 mm (3.350 in.)
Maximum free length:
82.1 mm (3.232 in.)
If the free length is not as specified, replace the
inner compression spring.
EM00801E01
4. INSPECT INTAKE VALVE

(a) Visually check the valves for damage, burns, carbon
or warpage, and check the valve heads, valve
stems and valve stem grooves for cracks.
If excessive wear, burns, warpage or cracks are
Width present, replace the valves.
(b) Check the valve seating condition.
(1) Lightly apply prussian blue marking compound
to the valve face.
A146585E01 (2) Tapping the valve against the seat, check the
seating condition.
Width:
1.24 mm (0.049 in.) or more
If the prussian blue mark is not concentric or
the compound is scattered all around the valve
EM face or seat, repair the valve face or the valve
seat.
(c) Using vernier calipers, measure the overall length of
the intake valve.
Standard overall length:
129.8 mm (5.1102 in.)
Overall
Length If the overall length is not as specified, replace the
exhaust valve.
A137169E01
(d) Using a micrometer, measure the diameter of the

valve stem.
Valve stem diameter:
6.957 to 6.972 mm (0.2739 to 0.2745 in.)
A137170
5. INSPECT EXHAUST VALVE

(a) Visually check the valves for damage, burns, carbon
or warpage, and check the valve heads, valve
stems and valve stem grooves for cracks.
If excessive wear, burns, warpage or cracks are
Width present, replace the valves.
(1) Lightly apply prussian blue marking compound
to the valve face.
A146585E01 (2) Tapping the valve against the seat, check the
seating condition.
Width:
1.24 mm (0.049 in.) or more
If the prussian blue mark is not concentric or

the compound is scattered all around the valve
face or seat, repair the valve face or the valve
seat.
(c) Using vernier calipers, measure the overall length of
the exhaust valve.
Standard overall length:
128.8 mm (5.0709 in.)
Overall
Length If the overall length is not as specified, replace the
exhaust valve.
A137169E01
EM
(d) Using a micrometer, measure the diameter of the
valve stem.
Valve stem diameter:
6.932 to 6.947 mm (0.2729 to 0.2735 in.)
A137170
6. INSPECT VALVE GUIDE BUSH OIL CLEARANCE

(a) Using a caliper gauge, measure the internal
diameter of the valve guide bush.
Inside diameter:
7.000 to 7.015 mm (0.2756 to 0.2762 in.)
If the bore diameter is not as specified, replace the
valve guide bush.
(b) Subtract the valve stem diameter measurement
from the bore diameter measurement of the valve
A146578 guide bush to calculate the oil clearance.
Standard oil clearance
Intake 0.03 to 0.04 mm (0.0013 to 0.0017 in.)
7. INSPECT INTAKE VALVE SINK

(a) Using vernier calipers, measure the valve sink.
Standard:
0.8 to 1.0 mm (0.0315 to 0.0394 in.)
Maximum:
1.1 mm (0.0433 in.)
If the sink is greater than the maximum, replace the
valve and valve seat.
NOTICE:
• If the valve heads are protruding from the
cylinder head surface, the valve heads may
hit the pistons when the engine is running.
• When replacing the valve and valve seat,
always recheck the seating condition.
EM A146577
8. INSPECT EXHAUST VALVE SINK

(a) Using vernier calipers, measure the valve sink.
Standard:
1.8 to 2.0 mm (0.070 to 0.078 in.)
Maximum:
2.1 mm (0.082 in.)
If the sink is greater than the maximum, replace the
valve and valve seat.
NOTICE:
cylinder head surface, the valve heads may
hit the pistons when the engine is running.
A146577
REPLACEMENT
Brass Block 1. REPLACE INTAKE VALVE SEAT
Valve Seat (a) As shown in the illustration, grind the 3 points on the
circumference of an unwanted valve and weld it to
the valve seat.
NOTICE:
To protect the lower surface of the cylinder head
Valve from welding spatters, be sure to apply grease
to the cylinder head before welding.
Grind these (b) Place a brass block on the top of the valve stem and
Points with a strike it with a hammer to remove the valve seat.
Grinder CAUTION:
Weld Application Point When striking, metal shards may fly off on
impact. Wear safety glasses to protect your
A146573E02 eyes.
(c) Using a caliper gauge and vernier calipers, measure

the dimensions of the valve seat installation holes.
Intake valve seat dimensions:
A:
36.00 to 36.015 mm (1.4173 to 1.4179 in.)
B:
8.4 to 8.6 mm (0.3307 to 0.3386 in.)
If the result is not specified, replace the cylinder
B
head.
A A146563E01 (d) Heat the cylinder head up to 80 to 100°C (176 to
212°F).
(e) Using SST and a hammer, lightly tap the valve seats
into the cylinder head.
SST 09950-60010 (09951-00300, 09951-00360,
SST 09952-06010), 09950-70010 (09951-07100)
SST 1
EM
SST 1 09951-07100
SST 2 SST 2 09952-06010
SST 3 SST 3 09951-00360
SST 4 09951-00300
SST 4
SST 2 (f) Using SST and a hammer, completely tap in the
valve seats.
SST 09950-60010 (09951-00300, 09951-00360,
09952-06010), 09950-70010 (09951-07100)
A146564E02
2. REPLACE EXHAUST VALVE SEAT

(a) As shown in the illustration, grind the 3 points on the
Brass Block circumference of an unwanted valve and weld it to
Valve Seat the valve seat.
NOTICE:
To protect the lower surface of the cylinder head
from welding spatters, be sure to apply grease
Valve
to the cylinder head before welding.
(b) Place a brass block on the top of the valve stem and
strike it with a hammer to remove the valve seat.
Grind these CAUTION:
Points with a
When striking, metal shards may fly off on
Grinder
Weld Application Point
eyes.
A146573E02
(c) Using a caliper gauge and vernier calipers, measure

the dimensions of the valve seat installation holes.
Exhaust valve seat dimensions:
A:
36.00 to 36.015 mm (1.4173 to 1.4179 in.)
B:
8.4 to 8.6 mm (0.3307 to 0.3386 in.)
If the result is not specified, replace the cylinder
B
head.
A A146559E02
(d) Heat the cylinder head up to 80 to 100°C (176 to

212°F).
(e) Using SST and a hammer, lightly tap the valve seats
into the cylinder head.
SST 09950-60010 (09951-00250, 09951-00320,
SST 09952-06010), 09950-70010 (09951-07100)
SST 1
SST 1 09951-07100
SST 2
SST 2 09952-06010
SST 3
SST 3 09951-00360
SST 4
SST 4 09951-00300
SST 2
(f) Using SST and a hammer, completely tap in the
valve seats.
SST 09950-60010 (09951-00250, 09951-00320,
EM 09952-06010), 09950-70010 (09951-07100)
3. REPLACE INTAKE VALVE GUIDE BUSH
A146560E02 (a) Heat the cylinder head up to 80 to 100°C (176 to
212°F).
(b) Using SST and a hammer, tap the valve guide bush.
SST 09201-10000 (09201-01070), 09950-70010
SST (09951-07100)
A146575E01
(c) Using a caliper gauge, measure the inside diameter

of the guide bush.
Bush inside diameter:
13.000 to 13.018 mm (0.5118 to 0.5125 in.)
HINT:
If the bush bore diameter of the cylinder head is
greater than 13.02 mm (0.5125 in.), replace the
cylinder head.
A146571 212°F).
(e) Using SST, tap in a new valve guide bush to the

specified protrusion height.
SST 09201-10000 (09201-01070), 09950-70010
SST (09951-07100)
Protrusion height:
26.4 to 26.8 mm (1.039 to 1.055 in.)
NOTICE:
26.4 to Do not tap in the guide bush excessively.
26.8 mm (f) Using a reamer, ream the inside of the valve guide
bush to the specified oil clearance between the
valve guide bush and valve stem.
Standard oil clearance:
0.014 to 0.029 mm (0.0006 to 0.0011 in.)
Maximum oil clearance:
0.12 mm (0.0047 in.)
A146570E01 EM
4. REPLACE EXHAUST VALVE GUIDE BUSH
(a) Heat the cylinder head up to 80 to 100°C (176 to
212°F).
(b) Using SST and a hammer, tap the valve guide bush.
SST 09201-10000 (09201-01070), 09950-70010
SST (09951-07100)
A146576E01
(c) Using a caliper gauge, measure the inside diameter

of the guide bush.
Bush inside diameter:
13.000 to 13.018 mm (0.5118 to 0.5125 in.)
HINT:
If the bush bore diameter of the cylinder head is
greater than 13.02 mm (0.5125 in.), replace the
cylinder head.
A146571 212°F).
(e) Using SST, tap in a new valve guide bush to the

specified protrusion height.
SST SST 09201-10000 (09201-01070), 09950-70010
(09951-07100)
Protrusion height:
26.4 to 26.8 mm (1.039 to 1.055 in.)
26.4 to NOTICE:
26.8 mm Do not tap in the guide bush excessively.
(f) Using a reamer, ream the inside of the valve guide
bush to the specified oil clearance between the
valve guide bush and valve stem.
0.053 to 0.083 mm (0.0021 to 0.0033 in.)
0.15 mm (0.0059 in.)
EM A146572E01
5. REPLACE INJECTION NOZZLE SEAT

(a) Using SST, remove the injection nozzle seat.
SST 09201-10000 (09201-01050), 09950-70010
(09951-07100)
(b) Remove the O-ring from the cylinder head sub-
assembly.
SST
A146574E01
(c) Apply a light coat of engine oil to new O-rings, and

install them into to the cylinder head.
Cylinder Head
NOTICE:
Be sure to install new O-rings. Reusing O-rings
may cause water or gas leakage and lead to
overheating or a cracked cylinder head.
O-Ring
Nozzle Seat
A146565E01
(d) Apply seal packing to new nozzle seats.

Seal packing:
NOTICE:
• Remove any oil from the installation surface
of the cylinder head and nozzle seats.
• Be sure to install new nozzle seats. Reusing
nozzle seats may cause water or gas leakage
and lead to overheating or a cracked cylinder
head.
Seal Packing
A146566E01 EM
(e) Using SST, install the nozzle seats onto to the
SST cylinder head.
SST 09260-69015, 09268-06020
Nozzle Seat
A146567E01
(f) Using SST, stake the nozzle seats.

SST SST 09260-69015, 09268-06010
NOTICE:
Put a container under the cylinder head to
prevent the steel balls from being lost.
Nozzle Seat (g) Install the injectors onto the cylinder head. Using
vernier calipers, measure the protrusion of the
SST (Steel Ball)
injectors from the lower surface of the cylinder head.
Standard:
A146561E01 2.45 to 2.95 mm (0.0964 to 0.1161 in.)
6. REPLACE STUD BOLT
(a) Remove the stud bolts.
(b) Using "TORX" socket wrench E8 and E10, install

the stud bolts.
Intake Manifold Side: Exhaust Manifold Side:
B B B B
A A
B B B B
EM
19.5 mm (0.767 in.)
18.0 mm (0.708 in.) 52.5 mm

(2.066 in.)
32.5 mm
(1.279 in.)
10.5 mm (0.413 in.) 12.0 mm (0.472 in.)
A (M8) B (M10)
A146556E02
Torque: Bolt A
25 N*m (255 kgf*cm, 18 ft.*lbf)
Bolt B
51 N*m (520 kgf*cm, 38 ft.*lbf)
REASSEMBLY
1. INSTALL VALVE STEM OIL SHIELD
(a) Apply a light coat of engine oil to the valve guide
SST bush.
(b) Using SST, install the valve stem oil shield.
SST S0947-22210
HINT:
After pressing in the oil seal, check that the height of
the valve stem oil seal is as illustrated.
2. INSTALL INTAKE VALVE
(a) Apply engine oil to the valve tip.
EM
29 to 29.5 mm
(1.142 to 1.161 in.)
A146554E01
(b) Install the valve, inner compression spring and

SST valve spring retainer.
NOTICE:
Install the parts to their original locations.
(c) Using SST, compress the inner compression spring
and place the 2 valve spring retainer locks around
the valve stem.
SST 09202-70020 (09202-01010, 09202-00020,
09202-01020, 90154-80004)
A146584E01
(d) Using a 5 mm pin punch, lightly tap the valve stem

tip to ensure a proper fit.
NOTICE:
Be careful not to damage the valve stem tip.
3. INSTALL EXHAUST VALVE
(a) Apply engine oil to the valve tip.
A146553
(b) Install the valve, inner compression spring and

SST valve spring retainer.
NOTICE:
Install the parts to their original locations.
(c) Using SST, compress the inner compression spring
and place the 2 valve spring retainer locks around
the valve stem.
SST 09202-70020 (09202-01010, 09202-00020,
09202-01020, 90154-80004)
A146584E01
(d) Using a 5 mm pin punch, lightly tap the valve stem

tip to ensure a proper fit.
NOTICE:
Be careful not to damage the valve stem tip.
EM
A146553
REPAIR
1. REPAIR VALVE SEAT
CAUTION:
When grinding, wear safety glasses to protect your
eyes from metal shards.
NOTICE:
Gradually release the seat cutter pressure to make
the valve seat surface smoother.
(a) If the seating is too high on the valve face, use 30°
Intake side: and 45° cutters to correct the seat.
Standard
30°
Intake 0.7 to 1.1 mm (0.0276 to 0.0433 in.)
Exhaust 1.7 to 2.1 mm (0.0669 to 0.0827 in.) EM
Exhaust side:
45°
A146557E02
EM–66 N04C-TR, TS, TT, TU, TV, TW ENGINE MECHANICAL – CYLINDER BLOCK
CYLINDER BLOCK
ENGINE
COMPONENTS
PISTON
PISTON PIN PISTON RING SET
PISTON PIN HOLE PISTON PIN HOLE SNAP RING

SNAP RING
CONNECTING ROD
SMALL END BUSH CONNECTING ROD SUB-ASSEMBLY
EM CONNECTING ROD BEARING
CONNECTING ROD BEARING CAP

CYLINDER LINER
1st: 30 (300, 22)
2nd: Turn 60° STRAIGHT PIN

x2
3rd: Turn 60°
NO. 3 CAMSHAFT BEARING
STRAIGHT PIN
x2
NO. 2 CAMSHAFT BEARING
x3 NO. 1 OIL NOZZLE SUB-ASSEMBLY

STRAIGHT PIN
CRANKSHAFT THRUST WASHER SET

NO. 1 CAMSHAFT BEARING 29 (290, 21)
CRANKSHAFT THRUST WASHER SET

CRANKSHAFT BEARING SET
CRANKSHAFT TIMING GEAR KEY CRANKSHAFT THRUST

WASHER SET
CRANKSHAFT ASSEMBLY
CRANKSHAFT THRUST WASHER SET CRANKSHAFT BEARING SET
CRANKSHAFT BEARING CAP
1st: 60 (610, 44)

2nd: Turn 60°
Non-reusable part 3rd: Turn 60°
A153258E01
N04C-TR, TS, TT, TU, TV, TW ENGINE MECHANICAL – CYLINDER BLOCK EM–67
DISASSEMBLY
1. REMOVE PISTON WITH CONNECTING ROD
(a) Remove the piston with connecting rod from the
cylinder block.
2. REMOVE CONNECTING ROD BEARING
3. REMOVE CYLINDER LINER
HINT:
Before removing the cylinder liner, put matchmarks on
the cylinder liner and cylinder block.
NOTICE:
When reusing the cylinder liner, misalignment with
the cylinder block may concentrate stress on the
thin part of the cylinder liner and the cylinder liner
Matchmark
may break. EM
A151515E06
(a) Using SST, remove the cylinder liner.

SST S0942-01460
NOTICE:
SST Organize the parts so that each part location can
be remembered for reassembly.
A151516E01
4. REMOVE CRANKSHAFT ASSEMBLY

4 8 10 6 2 (a) Remove the 10 bearing cap bolts in the order shown
(b) Using a plastic-faced hammer, tap the bearing caps
to remove them.
NOTICE:
Be careful not to damage the thrust washers and
bearings.
(c) Remove the crankshaft.
3 7 9 5 1A151520E01
5. REMOVE CRANKSHAFT THRUST WASHER SET
NOTICE:
6. REMOVE CRANKSHAFT BEARING SET
NOTICE:
7. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY
(a) Remove the bolt and the No. 1 oil nozzle.
8. REMOVE PISTON RING SET

(a) Using a piston ring expander, remove the piston
rings.
HINT:
Arrange the piston rings in the correct order.
A151521
9. REMOVE PISTON PIN HOLE SNAP RING

(a) Using snap ring pliers, remove the snap rings.
EM
A151522
10. REMOVE PISTON

(a) Gradually heat the piston to approximately 50°C
(122°F).
A151523
(b) Using a plastic-faced hammer and brass bar, lightly

tap out the piston pin and remove the connecting
rod.
HINT:
• The piston and pin are a set.
• Arrange the pistons, pins, rings, connecting rods
and bearings in the correct order.
A151524
11. REMOVE CONNECTING ROD SMALL END BUSH

(a) Prepare SST.
SST S0940-21450, S0948-11130, S9233-10360
SST
(1) Assemble the guide and press sub-assembly
(Guide)
by inserting its pin into the guide, then secure
them with the wing nut.
HINT:
Orient the letter W, stamped on the guide,
above the pin.
SST (Press Sub-assembly)
SST (Wing Nut)
A151666E01 EM
(2) Make sure to align both supporting surfaces of
the guide and press sub-assembly flatly on an
Connecting Rod
even plane.
(b) Using SST, remove the bush.
(1) Set the connecting rod assembled without the
crankshaft bearing on the guide and press sub-
assembly.
Guide Press Sub-assembly

A151536E01
(2) Using SST, install the spindle into the bush.

SST S0940-21470
HINT:
Groove Spindle
Align the groove of the spindle with the oil hole
of the bush.
Bush
Connecting
Oil Hole Rod
Press Sub-assembly
A151537E01
(3) Using a press, remove the bush.

Press HINT:
Spindle Always operate the press slowly and smoothly.
Connecting Rod
A151538E01
12. REMOVE CAMSHAFT BEARING

Front (a) Using SST, remove the camshaft bearings in the
No. 1 No. 2 No. 3 directions indicated by the arrow marks in the
illustration.
SST 09215-00101 (09215-00130, 09215-00141,
09215-00150, 09215-00161), 09215-00013
(09215-00021, 09215-00461)
SST
NOTICE:
Remove the No. 1, No. 2 and No. 3 camshaft
A151660E01 bearings in order.
INSPECTION
1. INSPECT CONNECTING ROD THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance
while moving the connecting rod back and forth.
EM
Standard thrust clearance:
0.200 to 0.520 mm (0.0079 to 0.0205 in.)
Maximum thrust clearance:
0.60 mm (0.0236 in.)
A151513
If the thrust clearance is greater than the maximum,
replace the connecting rod. If necessary, replace
the crankshaft.
2. INSPECT CRANKSHAFT THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance
while prying the crankshaft back and forth with a
screwdriver.
0.050 to 0.220 mm (0.0019 to 0.0086 in.)
0.40 mm (0.0157 in.)
A151519 replace the crankshaft or thrust washers as a set.
3. INSPECT CONNECTING ROD BOLT

(a) Using vernier calipers, measure the length of the
connecting rod bolt.
Standard bolt length:
59.00 mm (2.3228 in.)
Length Maximum bolt length:
61.5 mm (2.421 in.)
If the length is greater than the maximum, replace
the connecting rod bolt.
A151514E01
4. INSPECT CYLINDER LINER

(a) Using a micrometer, measure the outside diameter
of the cylinder liner.
Standard
Symbol Symbols Outside Diameter
A 106.982 to 106.989 mm (4.2119 to 4.2122 in.)
B 106.990 to 106.995 mm (4.2122 to 4.2124 in.)
C 106.996 to 107.004 mm (4.2124 to 4.2128 in.)
A151517E01
If the diameter is less than the standard, replace the

cylinder liner.
(b) Using a cylinder gauge, measure the inside
Cylinder Block Side: diameter of the cylinder block.
Standard
Symbols Inside Diameter
A 107.000 to 107.008 mm (4.2126 to 4.2129 in.)
B 107.008 to 107.014 mm (4.2129 to 4.2131 in.)
C 107.014 to 107.022 mm (4.2131 to 4.2135 in.)
Symbol
If the diameter is greater than the standard, replace
the cylinder block.
Intake Manifold Side:
Symbol
EM
A151518E02
5. INSPECT CYLINDER BLOCK FOR WARPAGE

HINT:
Before the measurement, remove carbon deposits from
the upper end inside the cylinder liner with a scraper or
emery paper (recommended: No. 150), working in a
circular direction. Make sure that there are no scratches
inside the cylinder liner.
A151525
(a) Using a precision straight edge and feeler gauge,

measure the warpage of the surface in contact with
cylinder head.
Maximum warpage:
0.10 mm (0.0039 in.)
If the warpage is greater than the maximum, replace
the cylinder block.
(b) Visually check the cylinders for vertical scratches.
If deep scratches are found, rebore all 4 cylinders. If
necessary, replace the cylinder block.
EM
A151526
6. INSPECT CYLINDER BORE

(a) Using a cylinder gauge, measure the cylinder liner
inside diameter at the 4 points in the piston boss
and thrust direction, as shown in the illustration.
Standard inside diameter:
104.012 to 104.036 mm (4.0950 to 4.0959 in.)
Maximum inside diameter:
104.15 mm (4.1004 in.)
If the diameter is greater than the maximum, replace
the cylinder liner with a new one.
80 mm (3.15 in.)
A151527E01
7. INSPECT PISTON
(a) Using a micrometer, measure the piston diameter at
the points in the illustration.
Standard piston diameter:
103.936 to 103.952 mm (4.0920 to 4.0926 in.)
If the diameter is less than the standard, replace the
piston with a new one.
8. INSPECT PISTON OIL CLEARANCE
(a) Subtract the piston diameter measurement from the
cylinder liner inside diameter measurement.
0.06 to 0.1 mm (0.0024 to 0.0039 in.)
Diameter
If the clearance is greater than the standard, replace
the cylinder liner and/or piston with a new one.
HINT: EM
Apply the value measured at the most worn point to
20 mm (0.78 in.) the cylinder liner inside diameter.
A151528E01
9. INSPECT PISTON PIN OIL CLEARANCE

(a) Using a micrometer, measure the piston pin
diameter.
Standard piston pin diameter:
36.989 to 37.000 mm (1.4563 to 1.4567 in.)
Minimum piston pin diameter:
36.96 mm (1.4551 in.)
If the diameter is less than the minimum, replace the
piston pin with a new one.
A151531 HINT:
Never grind the piston pin, because the surface is
coated with a special material.
(b) Using a cylinder gauge, measure the connecting rod
bush inside diameter.
Standard bush inside diameter:
37.035 to 37.045 mm (1.4581 to 1.4585 in.)
Maximum bush inside diameter:
37.10 mm (1.4606 in.)
If the inside diameter is greater than the maximum,
replace the connecting rod bush with a new one.
(c) Subtract the diameter measurement of the piston
A151532 pin from the inside diameter measurement of the
connecting rod bush.
0.035 to 0.056 mm (0.0014 to 0.0022 in.)
0.08 mm (0.0031 in.)
If the oil clearance is greater than the maximum,
replace the piston with a new one.
(d) Using a cylinder gauge, measure the piston pin

boss inside diameter while turning the gauge by
90°.
Standard piston pin hole inside diameter:
36.987 to 37.003 mm (1.4562 to 1.4568 in.)
Maximum piston pin hole inside diameter:
37.05 mm (1.4587 in.)
90q If the piston pin hole inside diameter is greater than
the maximum, replace the piston with a new one.
A151533E01 (e) Subtract the diameter measurement of the piston
pin from the inside diameter measurement of the
piston pin hole.
-0.013 to 0.014 mm (-0.0005 to 0.0005 in.)
EM 0.05 mm (0.0020 in.)
HINT:
If the clearance is greater than the maximum,
replace the piston or piston pin.
10. INSPECT RING GROOVE CLEARANCE
(a) Insert the piston ring into the piston ring groove.
(b) Using a feeler gauge, measure the clearance
between the piston ring and piston ring groove.
Standard groove clearance
Item Clearance
1st 0.11 to 0.15 mm (0.0043 to 0.0059 in.)
2nd 0.07 to 0.11 mm (0.0028 to 0.0043 in.)
Oil 0.02 to 0.06 mm (0.0008 to 0.0024 in.)
A151529
Maximum groove clearance:

0.30 mm (0.0118 in.)
measure the width of the piston ring and piston ring
groove individually and replace any parts that do not
meet the limit with new ones.
(c) Using a feeler gauge, measure the dimension of
each groove.
Standard groove width
Item Width
1st 2.58 to 2.60 mm (0.1016 to 0.1024 in.)
2nd 2.06 to 2.08 mm (0.0811 to 0.0819 in.)
Oil 4.01 to 4.03 mm (0.1579 to 0.1587 in.)
Maximum groove width

Item Width
1st 3.10 mm (0.1220 in.)
2nd 2.20 mm (0.0866 in.)
Oil 4.08 mm (0.1606 in.)
If the dimension is greater than the maximum,

replace the piston and piston rings as a set.
(d) Using a micrometer, measure the piston ring

thickness.
Standard ring thickness
Item Thickness
1st 2.47 to 2.49 mm (0.0972 to 0.0980 in.)
2nd 1.97 to 1.99 mm (0.0776 to 0.0783 in.)
Oil 4.97 to 4.99 mm (0.1957 to 0.1965 in.)
Minimum ring thickness

A151530
Item Thickness
1st 2.32 mm (0.0913 in.)
2nd 1.82 mm (0.0717 in.)
Oil 4.95 mm (0.1949 in.)
If the thickness is less than the minimum, replace EM

the piston ring.
11. INSPECT CONNECTING ROD SUB-ASSEMBLY
(a) Check that there is no clogging in the lubrication
passage to the connecting rod small end.
If there is any clogging, blow air through the
lubrication passage using an air gun, or clean by
inserting a wire.
A151534
12. INSPECT CRANKSHAFT ASSEMBLY

HINT:
Air Gun Before the inspection, clean the crankshaft with a
commercial cleaning agent and clean the lubrication
passages using an air gun.
(a) Performing the dye penetrant test, check the
crankshaft for cracks.
HINT:
Pay special attention to the finished section and oil
A151539E01 hole of the crankshaft journal and crankshaft pin.
(b) Visually check the condition of the crankshaft
journal and pin for damage or wear.
If any damage is found, replace the crankshaft with
a new one.
(c) Inspect for runout.
(1) Place the crankshaft on V-blocks.
of the crankshaft at the center journal.
Maximum runout:
0.04 mm (0.0016 in.)
maximum, replace the crankshaft with a new
one.
A151540
(d) Using a micrometer, measure the main journal

outside diameter.
Standard journal diameter:
72.94 to 72.96 mm (2.8717 to 2.8724 in.)
Minimum journal diameter
Item Journal Diameter
New 72.74 mm (2.8638 in.)
Old 71.76 mm (2.8252 in.)
A151541 If the diameter is less than the minimum, replace the

crankshaft with a new one.
(e) Check each main journal for taper and out-of-round.
Maximum taper and out-of-round:
0.01 mm (0.0004 in.)
If the taper and out-of-round is greater than the
EM maximum, replace the crankshaft.
(f) Using a micrometer, measure the crankshaft pin
outside diameter.
Standard crankshaft pin diameter:
61.94 to 61.96 mm (2.4386 to 2.4394 in.)
Minimum crankshaft pin diameter
Item crankshaft pin Diameter
New 61.74 mm (2.4307 in.)
Old 60.76 mm (2.3921 in.)
A151542 If the diameter is less than the minimum, replace the

crankshaft with a new one.
(g) Check each crankshaft pin for taper and out-of-
round.
Maximum taper and out-of-round:
0.01 mm (0.0004 in.)
If the taper and out-of-round is greater than the
maximum, replace the crankshaft.
(h) Using vernier calipers, measure the dimension of
the crankshaft No. 4 journal.
Standard journal dimension:
34.00 to 34.08 mm (1.3386 to 1.3417 in.)
Maximum journal dimension:
34.48 mm (1.3574 in.)
If the dimension is greater than the maximum,
replace the crankshaft.
(i) Visually check if there are any cracks on the
A151543 crankshaft.
(j) Check if the oil holes of the crankshaft are blocked.
If any blockage is found, replace the crankshaft.
13. INSPECT CRANKSHAFT BEARING CAP SET BOLT

(a) Using vernier calipers, measure the bearing cap bolt
length.
Standard bolt length:
92.80 to 93.80 mm (3.6535 to 3.6929 in.)
Length Maximum bolt length:
95.00 mm (3.7401 in.)
If the length is longer than the maximum, replace
the bolt.
A151514E01
14. INSPECT CRANKSHAFT BEARING CAP

(a) Install the bearing caps to the cylinder block.
(b) Apply a light coat of engine oil to the threads of the
Front Mark bearing cap bolts.
EM
Journal No.
A151544E01
(c) Uniformly tighten the 10 bolts in the order shown in

10 6 2 4 8 the illustration.
9 5 1 3 7 A151545E01
(d) Mark the front side of the bolts with paint.

(e) Retighten the bolts by 60° in the same order as step
60°
(c).
(f) Perform step (e) again.
60° (g) Check that each painted mark is now at a 120°
Front angle to the front.
Paint Mark
A151546E01
(h) Using a cylinder gauge, measure the crankshaft

bearing cap inside diameter at 3 points (X, Y, Z in
the illustration).
Standard crankshaft bearing cap inside
diameter:
77.985 to 78.00 mm (3.0703 to 3.0709 in.)
Maximum crankshaft bearing cap inside
diameter:
78.20 mm (3.0787 in.)
carry out boring after overlay welding or replace the
cylinder block with a new one.
HINT:
45° 45° When installing the main bearing caps, make sure
to return them to their original locations according to
EM XYZ the number stamped on the caps.
15. INSPECT CRANKSHAFT OIL CLEARANCE
HINT:
The upper bearings have an oil groove and oil hole,
however, the lower bearings do not.
A151547E01
(a) Align the key of the bearing with the keyway of the
cylinder block, and push in the upper bearing.
NOTICE:
Do not apply engine oil to the bearing and its
contact surface.
Oil Hole
A151548E01
(b) Align the key of the bearing with the keyway of the
main bearing cap, and push in the lower bearing.
NOTICE:
Do not apply engine oil to the bearing and its
contact surface.
A151549
(c) Install the bearing cap onto the cylinder block.

(d) Apply a light coat of engine oil to the threads of the
bearing cap bolt.
Front Mark
Journal No.
A151544E01 EM
(e) Uniformly tighten the 10 bolts in the order shown in
10 6 2 4 8 the illustration.
9 5 1 3 7 A151545E01
(f) Mark the front side of the bolts with paint.

(g) Retighten the bolts by 60° in the same order as step
60°
(e).
(h) Perform step (g) again.
60° (i) Check that each painted mark is now at a 120°
Front angle to the front.
Paint Mark
A151546E01
(j) Using a cylinder gauge, measure the crankshaft

bearing inside diameter at 3 points (X, Y, Z in the
illustration).
Standard crankshaft bearing inside diameter:
73.01 to 73.04 mm (2.8744 to 2.8756 in.)
Maximum crankshaft bearing inside diameter:
73.30 mm (2.8858 in.)
NOTICE:
Do not damage the crankshaft bearing.
replace the bearing with a new one.
HINT:
When installing the bearing caps, make sure to
45° 45° return them to their original locations according to
the number stamped on the caps.
EM XYZ (k) Subtract the crankshaft journal diameter
measurement from the bearing inside diameter
measurement.
0.051 to 0.102 mm (0.0020 to 0.004 in.)
A151547E01 Maximum oil clearance:
0.20 mm (0.0078 in.)
use an undersize bearing and correct or regrind the
crankshaft so that the oil clearance becomes 0.20
mm (0.0078 in.) or less.
Undersize bearing diameter
Item Diameter
STD 72.94 to 72.96 mm (2.8717 to 2.8724 in.)
U/S 0.25 72.69 to 72.71 mm (2.8618 to 2.8626 in.)
U/S 0.50 72.44 to 72.46 mm (2.8520 to 2.8528 in.)
U/S 0.75 72.19 to 72.21 mm (2.8421 to 2.8429 in.)
U/S 1.00 71.94 to 71.96 mm (2.8323 to 2.8330 in.)
HINT:
Make sure to replace the upper and lower main
bearings as one set.
(1) Machined dimension of fillet radius
Main crankshaft journal:
3.00 to 3.50 mm (0.1181 to 0.1378 in.)
CORRECT INCORRECT
A151550E01
16. INSPECT CONNECTING ROD OIL CLEARANCE

Claw (a) Align the claw of the bearing with the claw grooves
of the connecting rod and connecting cap.
NOTICE:
Clean the back side of the bearing and the
bearing surface of the connecting rod. The
surface should be free of dust and oil.
(b) Tighten the connecting rod bolts.
(1) Install the bearing cap.
A151551E01 NOTICE:
Be careful of the installation direction of the
bearing cap.
(2) Uniformly tighten the bolts several times.
(3) Retighten the connecting rod bolts.
(4) Mark the front side of the bolts with paint. EM
(c) Retighten the bolts by 60° in the same order as step
(b-2).
60°
(d) Perform step (c) again.
60°
Front
Paint Mark
A151546E01
(e) Using a cylinder gauge, measure the connecting rod

big end inside diameter.
Standard big end inside diameter (with bearing):
61.991 to 62.022 mm (2.4406 to 2.4418 in.)
Maximum big end inside diameter (with
bearing):
62.06 mm (2.4433 in.)
If the result is greater than the maximum, replace
the connecting rod bearing.
(f) Subtract the inside diameter measurement of the
connecting rod from the diameter measurement of
the crankshaft pin.
Standard clearance:
0.031 to 0.082 mm (0.0012 to 0.0032 in.)
0.20 mm (0.0079 in.)
If the result is greater than the maximum, use an
undersize bearing and correct or regrind the
crankshaft so that the oil clearance becomes 0.2
mm (0.0079 in.) or less.
A151552 Undersize bearing diameter
Item Diameter
STD 61.94 to 61.96 mm (2.4386 to 2.4394 in.)
U/S 0.25 61.69 to 61.71 mm (2.4287 to 2.4295 in.)
U/S 0.50 61.44 to 61.46 mm (2.4189 to 2.4197 in.)
U/S 0.75 61.19 to 61.21 mm (2.4090 to 2.4098 in.)
U/S 1.00 60.94 to 60.96 mm (2.3992 to 2.4000 in.)
(1) Machined dimension of fillet radius

Crankshaft pin:
3.50 to 4.00 mm (0.1378 to 0.1575 in.)
CORRECT INCORRECT
A151550E01
17. INSPECT CAMSHAFT OIL CLEARANCE

(a) Measure the oil clearance of the camshaft journal.
(1) Using a micrometer, measure the camshaft
journal outside diameter.
EM Journal outside diameter
Item Diameter
No. 1 56.95 to 56.97 mm (2.2421 to 2.2429 in.)
No. 2 56.75 to 56.77 mm (2.2343 to 2.2350 in.)
No. 3 56.55 to 56.57 mm (2.2264 to 2.2272 in.)
A151658
If the outside diameter is less than the

standard, replace the camshaft.
(2) Using a cylinder gauge, measure the camshaft
bearing inside diameter.
Inside diameter
Item Diameter
No. 1 57.035 to 57.135 mm (2.2455 to 2.2494 in.)
No. 2 56.835 to 56.935 mm (2.2376 to 2.2415 in.)
No. 3 56.635 to 56.735 mm (2.2297 to 2.2337 in.)
If the inside diameter is greater than the

A151659 standard, replace the camshaft bearing.
(3) Subtract the outside diameter measurement of
the camshaft journal from the inside diameter
measurement of the camshaft bearing.
0.030 to 0.120 mm (0.0012 to 0.0047 in.)
0.15 mm (0.0059 in.)
If the oil clearance is greater than the
maximum, replace the camshaft or camshaft
bearing.
REPLACEMENT
1. REPLACE STRAIGHT PIN
NOTICE:
It is not necessary to remove the straight pins
unless they are being replaced.
(a) Remove the 7 straight pins.
(b) Using a plastic-faced hammer, install 7 new straight
pins.
Standard protrusion height
A 6.0 mm (0.236 in.)
B 13.0 mm (0.512 in.)
C 16.0 mm (0.630 in.)
D 6.0 mm (0.236 in.)
EM
Front Side: Rear Side: Cylinder Head Side:
A B
C
8 mm (0.31 in.) 12 mm (0.47 in.)

8 mm (0.31 in.)
5 mm (0.19 in.)
10 mm 24 mm 24 mm 16 mm
(0.39 in.) (0.94 in.) (0.94 in.) (0.62 in.)
A
D
B C
Protrusion Height
A151663E02
REASSEMBLY
Notch No. 3
Notch 1. INSTALL CAMSHAFT BEARING
(a) Be sure to face the notches of the No. 1 and No. 2
camshaft bearings and the oil holes of the No. 3
camshaft bearing in the correct direction.
Oil Hole
No. 2
No. 1
A151662E01
(b) Using SST, install new camshaft bearings in the

Front direction indicated by the arrow marks in the
No. 1 No. 2 No. 3 illustration.
SST 09215-00101 (09215-00130, 09215-00141,
EM 09215-00150, 09215-00161), 09215-00013
(09215-00021, 09215-00461)
Journal bearing diameter
SST Journal No. Inside diameter Outside diameter
No. 1 57.0 mm (2.2441 in.) 60.0 mm (2.3622 in.)
A151661E01
No. 2 56.8 mm (2.2362 in.) 59.8 mm (2.3543 in.)
No. 3 56.6 mm (2.2283 in.) 59.6 mm (2.3465 in.)
NOTICE:
Install the No. 2, No. 1 and No. 3 camshaft
bearings in order.
2. INSTALL CONNECTING ROD SMALL END BUSH
(a) Uniformly chamfer one edge of the bush hole at the
small end of the connecting rod.
HINT:
• Incorrect chamfering can cause the bush to run
out-of-round, which may result in jamming during
insertion.
• Remove dust from the inner surface of the
connecting rod hole.
A151664
(b) Mount the bush on the spindle.

SST (Spindle) SST S0940-21470, S0948-11140, S9191-08252
Oil Hole Groove HINT:
Align the oil holes in the bush with both grooves of
Bush the spindle and guide, and make sure that oil holes
SST (Guide)
Groove will meet with the oil path in the connecting rod led
from the big end bore in the rod.
SST (Bolt) (1) Apply fresh engine oil around the bush and
A151665E01 guide.
(c) Prepare SST.

SST S0940-21450, S0948-11130, S9233-10360
SST
by inserting its pin into the guide, then secure
(Guide)
HINT:
Orient the letter W, stamped on the guide,
above the pin.
SST (Press Sub-assembly)
SST (Wing Nut)
A151666E01 EM
(2) Make sure to align both supporting surfaces of
the guide and press sub-assembly on an even
Connecting Rod
plane.

A151536E01
(d) Install the bush into the connecting rod. Position the
spindle and bush so that the oil holes align with the
oil path through the connecting rod.
HINT:
Before installing, fully coat the bore in the
Groove connecting rod with fresh engine oil.
Oil Hole
A151667E01
(e) Inspect the bush position after installation.

(1) Make sure that the oil hole of the bush and the
oil path of the connecting rod are suitably
aligned, allowing a 6 mm (0.23 in.) diameter rod
to penetrate.
HINT:
Misalignment can lead to insufficient
lubrication, which may result in piston seizure.
(2) With a new piston pin inserted in the piston,
A151534 make sure that the pin can be rotated by hand
without looseness.
3. INSTALL PISTON PIN HOLE SNAP RING

(a) Using snap ring pliers, install a new snap ring on
one side of the piston hole.
4. INSTALL PISTON
HINT:
Before assembling the piston with the connecting rod,
check whether the piston is specified for this engine.
Check should be performed using the engine compatible
identification code on the top of the piston.
A151668
Engine compatible identification code:
95
(a) Assemble the piston and connecting rod.
(1) Gradually heat the piston to approximately
50°C (122°F).
EM CAUTION:
Never touch the piston by hand while it is
hot.
A151669
(2) Coat the piston pin with engine oil.

Notch (3) Install the piston to the connecting rod with the
notch of the piston facing in the same direction
as the matchmark of the rod. Then, insert the
piston pin.
Matchmark
A151670E01
(4) Check that the piston and piston pin fit

securely.
HINT:
Try to move the piston back and forth.
A151671
(5) Using snap ring pliers, install a new snap ring

on the other side of the piston pin hole.
A151672
5. INSTALL PISTON RING SET

(a) Face the identification marks on the piston ring up,
then using a piston ring expander, install them in the
following order: the oil ring, 2nd ring and 1st ring.
HINT:
• Never change the combination of the coil and oil
ring.
• Connect the joint of the coil expander for the oil
ring and install it inside the oil ring. Align the
A153788 expander joint 180° opposite to the gap of the
ring.
6. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY
(a) Install the No. 1 oil nozzle with the bolt.
NOTICE: EM
• If an oil nozzle has been dropped impacted,
replace the nozzle with a new one.
• Replace any deformed nozzle with a new one.
7. INSTALL CRANKSHAFT BEARING SET
(a) Align the oil groove of the bearing with the oil hole of
the cylinder block, and push in the 5 upper bearings.
NOTICE:
Keep the back side of the bearing and the
bearing surface free of foreign matter.
Oil Hole
A151548E01
(b) Align the bearing with the crankshaft bearing cap,

and push in the 5 lower bearings.
NOTICE:
Keep the back side of the bearing and the
bearing surface free of foreign matter.
(c) Install the crankshaft.
A151549
(d) Insert the thrust washer into the clearance between

the cylinder block and crankshaft with the oil groove
facing outward.
(e) Install the main bearing cap to the cylinder block.
(f) Apply a light coat of engine oil to the threads and
under the cap bolt.
NOTICE:
Be sure to install the removed thrust washer to
Groove
its original position.
A151674E01
(g) Temporarily tighten the bolts in several steps, in the

10 6 2 4 8 sequence shown in the illustration.
(h) Tighten the bolts to the specified torque.
9 5 1 3 7 A151545E01
(i) Mark the front of the bearing cap bolts with paint.
(j) Retighten the bolts by 60° and then an additional
60°
60° as shown in the illustration.
EM 60°
Front
Paint Mark
A151546E01
8. INSTALL CYLINDER LINER

HINT:
• When assembling the cylinder liner in the cylinder
block, clearance can be set to 3 levels.
• The upper surface and side surface of the cylinder
block are stamped A, B or C. When using a new
cylinder liner, insert a matching cylinder liner having
the same symbol.
Position of (a) Apply engine oil to the cylinder block inside bore.
Mark A, B or C
Position of
Mark A, B or C
A151675E01
(b) Align the marks of the cylinder liner and cylinder

block.
HINT:
When reusing the cylinder liner, install it according
Mark to the marks made during the removal. When
reusing the cylinder liner, misalignment with the
cylinder block may concentrate stress on the thin
part of the cylinder liner and the cylinder liner may
break.
A151676E01
(c) Install the cylinder liner.

NOTICE:
Make sure to install the cylinder liner to its
original location.
9. INSPECT PROTRUSION OF CYLINDER LINER
SST (a) Install SST onto the cylinder block.
SST S0942-01460
(b) Tighten the center bolt to the specified torque below
to set the SST in the proper installation position.
Torque: 9.8 N*m (100 kgf*cm, 7.2 ft.*lbf)
A151677E01
EM
(c) Using a dial indicator, measure the protrusion of the
Pressure: 4903 N (500 kgf, 1100 lbf) cylinder liner.
Standard protrusion:
Protrusion 0.01 to 0.08 mm (0.0004 to 0.0031 in.)
Maximum protrusion:
0.08 mm (0.0031 in.)
If the protrusion is greater than the maximum,
replace the cylinder liner.
A151678E03
10. INSTALL CONNECTING ROD BEARING

NOTICE:
• When reusing the bearing, make sure to
reassemble the removed bearing as it was
originally installed.
• Install the bearing with the oil hole on the
connecting rod side and install the bearing
without the oil hole on the cap side.
• Match the bearing protrusion with the notch of the
A151679 connecting rod or cap.
• Keep the back side of the bearing and bearing
surface of the bearing cap free of foreign matter.
11. INSTALL PISTON SUB-ASSEMBLY WITH
2nd Ring Mark CONNECTING ROD
HINT:
Position the piston ring end gaps an even distance apart
from each other as shown in the illustration. Do not align
Top Ring the ring end gaps.
95
Oil Ring
A151680E01
(a) Using a piston ring compressor and a hammer

handle, insert the piston with connecting rod
assembly into the cylinder block.
HINT:
• Before installation, apply engine oil to the piston
pin, piston ring, cylinder liner and connecting rod
bearing.
• Recheck the gap of each piston ring.
• Do not damage the inside of the liner.
A151681
(1) Make sure that the mark on the piston is at the

tappet chamber side.
(b) Install the bearing cap to the connecting rod with the
front mark facing in the correct direction.
EM (c) Uniformly install and tighten the bolts to the
specified torque in several steps.
Mark
Tappet Chamber
A151682E01
(d) Mark the front side of the bolt head with paint as
60°
(e) Retighten the bolts by 60°.
60°
(g) Check that each painted mark is now at a 120°
angle to the front.
Front
Paint
A151683E01
N04C-TR, TS, TT, TU, TV, TW ENGINE MECHANICAL – ENGINE FRONT OIL SEAL EM–91

ENGINE
COMPONENTS
EM
SPACER
519 (5300, 380)
TIMING CHAIN OR BELT COVER OIL SEAL
CRANKSHAFT PULLEY
Non-reusable part
A155669E01
EM–92 N04C-TR, TS, TT, TU, TV, TW ENGINE MECHANICAL – ENGINE FRONT OIL SEAL
REMOVAL
1. REMOVE RADIATOR ASSEMBLY
(See chapter CO)
2. REMOVE CRANKSHAFT PULLEY
(a) Using a 46 mm socket wrench, remove the nut,
spacer and pulley.
HINT:
Insert a screwdriver through the inspection hole of
the flywheel housing into the ring gear of the
flywheel to keep it from turning together with the
crankshaft.
A151470
EM 3. REMOVE TIMING CHAIN OR BELT COVER OIL SEAL

Protective Tape
A152900E01
INSTALLATION
timing gear edge.
SST 09223-78010
NOTICE:
SST
A154138E01
• Keep the gap between the gear case edge
(b) Apply MP grease to the oil seal lip.
2. INSTALL CRANKSHAFT PULLEY
(a) Install the pulley and spacer to the crankshaft.
HINT:
Align the pulley set key with the key groove of the
pulley.
(b) Using a 46 mm socket wrench, tighten the nut.
HINT:
A151470 the flywheel housing into the ring gear of the
crankshaft.
3. INSTALL RADIATOR ASSEMBLY
(See chapter CO)
N04C-TR, TS, TT, TU, TV, TW ENGINE MECHANICAL – ENGINE REAR OIL SEAL EM–93

ENGINE
COMPONENTS
REAR ENGINE OIL SEAL 186 (1900, 137)
x6
EM
FLYWHEEL SUB-ASSEMBLY
CLUTCH COVER ASSEMBLY
CLUTCH DISC ASSEMBLY
x8
43 (439, 32)

Non-reusable part
A164271E01
EM–94 N04C-TR, TS, TT, TU, TV, TW ENGINE MECHANICAL – ENGINE REAR OIL SEAL
REMOVAL
1. REMOVE MANUAL TRANSMISSION ASSEMBLY
HINT:
(See chapter MT)
2. REMOVE CLUTCH COVER ASSEMBLY (See chapter
CL)
3. REMOVE CLUTCH DISC ASSEMBLY (See chapter
CL)
4. REMOVE FLYWHEEL SUB-ASSEMBLY
(a) Uniformly loosen and remove the 6 bolts in the
order shown in the illustration.
(b) Remove the flywheel.
HINT:
EM

crankshaft.
A101644
5. REMOVE REAR ENGINE OIL SEAL

Cut Position ಾᢿ▎ᚲ
(a) Using a knife, cut off the lip of the oil seal.
Tape
଻⼔࠹࡯ࡊ A101645E01
N04C-TR, TS, TT, TU, TV, TW ENGINE MECHANICAL – ENGINE REAR OIL SEAL EM–95
SST INSTALLATION
4 mm 1. INSTALL REAR ENGINE OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal until
it is 4 mm (0.16 in.) below the upper edge of the
flywheel housing.
SST 09223-78010
NOTICE:
A101646E01
• Keep the gap between the rear oil seal
retainer edge and the oil seal free of foreign
matter.
2. INSTALL FLYWHEEL SUB-ASSEMBLY
(a) Insert the flywheel slowly until it contacts the collar
knock in order to prevent impact on the guide bar. EM
Adjust the position, then insert it completely.
NOTICE:

The flywheel is heavy. When removing, be

careful not to drop it on your feet.
HINT:
crankshaft.
(b) Apply clean engine oil to the threads of the flywheel
bolts and the flywheel bolt seats.
(c) Tighten the flywheel bolts in the order shown in the
illustration.
3. INSTALL CLUTCH DISC ASSEMBLY (See chapter CL)
4. INSTALL CLUTCH COVER ASSEMBLY (See chapter
A101644 CL)
5. INSTALL MANUAL TRANSMISSION ASSEMBLY
HINT:
(See chapter MT)
EM–96 N04C-TR, TS, TT, TU, TV, TW ENGINE MECHANICAL – ENGINE ASSEMBLY
ENGINE ASSEMBLY
ENGINE
COMPONENTS
EM
ENGINE SIDE COVER SUB-ASSEMBLY RH ENGINE SIDE COVER SUB-ASSEMBLY RH

(N04C-TR, TS, TT, TV with Air Conditioning System)

ENGINE SIDE COVER SUB-ASSEMBLY LH ENGINE SIDE COVER SUB-ASSEMBLY LH
A160488E032
N04C-TR, TS, TT, TU, TV, TW ENGINE MECHANICAL – ENGINE ASSEMBLY EM–97
12 (120, 9)
VACUUM RESERVOIR
SUB-ASSEMBLY NO. 3 CAB MOUNTING
BRACKET SUB-ASSEMBLY
EM
27 (275, 20)
120 (1224, 89)

x4
x4
120 (1224, 89)
20 (200, 15)
x2
12 (120, 9) FENDER SIDE APRON SUB-ASSEMBLY LH
A161412E02


x3
55 (560, 41)
GENERATOR ASSEMBLY
125 (1275, 92) WATER HOSE
x2
29 (290, 18)
EM 55 (560, 38)
FUEL HOSE
WATER HOSE
x2
98 (1000, 72)
WATER HOSE 12 (120, 9)

x2
STARTER ASSEMBLY
29 (291, 21)
29 (291, 21) x2
x2 INTAKE AIR CONNECTOR BRACKET
x2
CLAMP
CLAMP

x2
NO. 1 AIR HOSE
AIR CLEANER CASE

x4
65 (663, 48)
x4
A166651E01
EXAMPLE: N04C-TU

x3
55 (560, 41)
GENERATOR ASSEMBLY
125 (1275, 92)
x2 WATER HOSE
29 (290, 18)
55 (560, 38)
EM
FUEL HOSE
WATER HOSE
x2
98 (1000, 72)

x2
STARTER ASSEMBLY

x2
CLAMP
CLAMP
NO. 1 AIR HOSE
CLAMP
A165818E01
EXAMPLE: N04C-TV, TW

x3
55 (560, 41)
GENERATOR ASSEMBLY
125 (1275, 92) WATER HOSE
x2
29 (290, 18)
EM 55 (560, 38)
FUEL HOSE
WATER HOSE
x2
98 (1000, 72)

x2
STARTER ASSEMBLY

x2
CLAMP
CLAMP
18 (184, 13)
x2
NO. 1 AIR HOSE
AIR CLEANER CASE

x4
65 (663, 48)
x4
A153576E01
NO. 2 AIR HOSE
EM
7.5 (77, 66 in.*lbf)
7.5 (77, 66 in.*lbf)
18 (184, 13)

A155410E02
NO. 2 AIR HOSE WITH NO. 1 AIR HOSE
13 (133, 10)
x2
EM
7.5 (77, 66 in.*lbf)
7.5 (77, 66 in.*lbf)
18 (184, 13)
18 (184, 13)
18 (184, 13)
18 (184, 13)
A152382E06
29 (290, 21) N04C-TW

x4
20 (199, 14) FAN PULLEY

FAN NO. 3 RADIATOR BRACKET
RADIATOR HOSE
INLET
NO. 5 RADIATOR HOSE

EM
20 (199, 14) HEATER HOSE
N04C-TW
18 (184, 13)
18 (184, 13)
x3 x3
7.5 (77, 66 in.*lbf) RADIATOR ASSEMBLY

20 (199, 14) 18 (184, 13)
x3
HEATER HOSE
7.5 (77, 66 in.*lbf) HEATER HOSE

20 (199, 14)
A165981E01
EXAMPLE: N04C-TU
29 (290, 21)
20 (199, 14)
x4
HEATER HOSE
FAN PULLEY
RADIATOR HOSE INLET

EM
FAN
18 (184, 13)
NO. 5 RADIATOR HOSE

18 (184, 13)
RADIATOR ASSEMBLY
NO. 3 RADIATOR
BRACKET
7.5 (77, 66 in.*lbf)
x2 HEATER HOSE

18 (184, 13)
20 (199, 14) 18 (184, 13)
x3
20 (199, 14)
HEATER HOSE
RADIATOR AIR GUIDE

x2
7.5 (77, 66 in.*lbf)
A165997E01
EXAMPLE:
for M550: N04C-TR, TS, TT, TU, for M550
2 Joint Type (Propeller shaft):
B265 Type: 75 (760, 55)
x4
x4
75 (760, 55)
x4
EM
x4
75 (760, 55)
PROPELLER SHAFT ASSEMBLY
3 Joint Type (Propeller shaft): B265 Type: 75 (760, 55)
x4
x4
75 (760, 55)
x4
x4
75 (760, 55)
C162595E02
x4
75 (760, 55)
x4
103 (1050, 76)
x4
PROPELLER INTERMEDIATE SHAFT ASSEMBLY
CENTER SUPPORT BEARING COVER

EM
x4
52 (525, 38)
B265 Type:
75 (760, 55)
x4
x4
75 (760, 55)
x4
x4
75 (760, 55)
C162825E01
EXAMPLE:
for MYY5A: N04C-TU, for MYY5A
103 (1050, 76)
x4
EM
x4
75 (760, 55)
3 Joint Type (Propeller shaft): 75 (760, 55)
x4
x4
75 (760, 55)
C162596E03
EXAMPLE:
for MYY5A: N04C-TU, for MYY5A
3 Joint Type (Intermediate shaft):
EM
75 (760, 55)
x4
75 (760, 55)
x4
x4 CENTER SUPPORT BEARING COVER
52 (525, 38)
C162970E01
18 (184, 13)
28 (280, 20)
x2
WIRE HARNESS
TRANSMISSION
CONTROL SHIFT
CABLE NO. 3 ENGINE MOUNTING BRACKET
103 (1050, 76)
x3
TRANSMISSION x3
CONTROL
SELECT CABLE
NO. 1 ENGINE MOUNTING
BRACKET 103 (1050, 76) EM
x3 x3
64 (653, 47)
39 (400, 29) 289 (2947, 213)
DRAIN PLUG MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT
GASKET
39 (400, 29) 43 (440, 32) O-RING
GASKET x 12
COMPANION FLANGE
8.2 (84, 73 in.*lbf)
PARKING BRAKE
127 (1290, 93) x4
DUST COVER
PARKING BRAKE PLATE

SUB-ASSEMBLY PARKING BRAKE DRUM
SUB-ASSEMBLY
CLUTCH RELEASE
CYLINDER ASSEMBLY

12 (120, 9)
x2
Non-reusable part
Clutch spline grease
A165791E01
EXAMPLE: N04C-TR, TS, TT, TU, for M550

for M550: WIRE HARNESS
NO. 1 ENGINE MOUNTING BRACKET
CLIP 28 (280, 20)
57 (585, 42)
CLIP
x4
SHIFT AND SELECT TRANSMISSION 64 (653, 47)

CONTROL CABLE
57 (585, 42)
EM x4
127 (1300, 94)

MANUAL TRANSMISSION OUTPUT
SHAFT REAR SET NUT
37 (380, 27) 43 (440, 32)

FILLER PLUG
GASKET
MANUAL TRANSMISSION ASSEMBLY
x 12
O-RING
PARKING BRAKE DRUM

SUB-ASSEMBLY
27 (275, 20) x4
GASKET 95 (964, 70)

PARKING BRAKE PLATE
37 (380, 27) SUB-ASSEMBLY
DRAIN PLUG
CLUTCH RELEASE CYLINDER ASSEMBLY 27 (275, 20)
x2
Non-reusable part
MP grease
A165651E01
x8
43 (439, 32)
EM
GASKET
70 (714, 52)
VACUUM HOSE
x3
25 (259, 19)
x4
30 (306, 22)
GASKET
Non-reusable part
A165652E01
x8
43 (439, 32)
EM
70 (715, 52)
25 (259, 19) EXHAUST RETARDER ASSEMBLY
GASKET 30 (306, 22)
Non-reusable part
A165792E01

BRACKET
25 (250, 18)
GASKET
O-RING
29 (291, 21) 29 (291, 21)
29 (291, 21)
x2
TURBOCHARGER GASKET GASKET EM
SUB-ASSEMBLY
36 (367, 27)
x5
GASKET

69 (704, 51)
x4
CLAMP x2
GASKET
5.0 (51, 44 in.*lbf) x2 TURBO OIL OUTLET PIPE
x2
29 (291, 21) 29 (291, 21)
GASKET
25 (250, 18) 25 (250, 18) GASKET
GASKET
29 (291, 21)
29 (291, 21)
29 (291, 21)
GASKET
25 (250, 18)
GASKET NO. 2 TURBO WATER PIPE
GASKET
Non-reusable part
A165653E01
25 (255, 18) NO. 1 TURBO WATER

PIPE SUB-ASSEMBLY
GASKET
O-RING
29 (296, 21)
70 (714, 52)
GASKET
EM 25 (255, 18)
GASKET
70 (714, 52)
25 (255, 18)
18 (184, 13)
TURBOCHARGER SUB-ASSEMBLY
GASKET
GASKET

SUB-ASSEMBLY
x2
29 (296, 21) GASKET

GASKET
x2
29 (296, 21)
25 (255, 18)
x2
TURBO OIL OUTLET PIPE SUB-ASSEMBLY
INTAKE PIPE
GASKET
25 (255, 18)
SUB-ASSEMBLY
29 (296, 21) 29 (296, 21)

25 (255, 18)
GASKET
Non-reusable part
A158150E02
EGR VALVE BRACKET
EM
x4
29 (291, 21)
VENTURI ASSEMBLY
x2
x4
29 (291, 21)
29 (291, 21)

A165654E01
GASKET
69 (700, 51)
x2
x2
SCREW GROMMET
55 (560, 41)
x2
GASKET
1.5 (15, 13 in.*lbf)
EM
25 (255, 18)
GLOW PLUG ASSEMBLY
EGR VALVE BRACKET
29 (290, 21)
VENTURI ASSEMBLY
29 (290, 21)

x2
29 (290, 21)
x2
25 (250, 18) 29 (290, 21)
GASKET 25 (250, 18)

Non-reusable part
A155568E01
EXAMPLE: N04C-TW
GASKET
69 (700, 51)
x2
x2
55 (560, 41)
x2
GASKET

EM
EGR VALVE
BRACKET
29 (290, 21)
VENTURI ASSEMBLY
29 (290, 21)

x2
29 (290, 21)
x2
25 (250, 18)
29 (290, 21)
N*m (kgf*cm, ft.*lbf) : Specified torque GASKET
25 (250, 18)
Non-reusable part
A165071E01
EXAMPLE: N04C-TR,System:
with Air Conditioning TS, TT, TV with Air Conditioning System
EM
55 (561, 41)
25 (250, 18) x4
x3
NO. 1 COMPRESSOR MOUNTING BRACKET
55 (561, 41)
x2
IDLE PULLEY BRACKET
A160489E02
OIL PUMP TO GEAR BOX TUBE
44 (450, 32) 44 (450, 32)
PRESSURE FEED HOSE
NO. 1 HOSE SUPPORT BRACKET
x2
POWER STEERING EM
18 (180, 13) 18 (180, 13) SUCTION PORT UNION
NO. 2 OIL RESERVOIR

TO PUMP HOSE
GASKET
49 (490, 36)
UNION BOLT
O-RING
VANE PUMP ASSEMBLY
O-RING
x2
CLIP
x2 18 (180, 13)
29 (290, 21)
x2
47 (480, 35) 29 (290, 21)
O-RING
3.5 (35, 31 in.*lbf) RADIATOR PIPE
Non-reusable part
Power Steering Fluid

C151629E03
EXAMPLE: N04C-TW
EM
29 (291, 21)
VENTILATION PIPE
SUB-ASSEMBLY
x2
29 (291, 21)
x4
29 (291, 21)
x2
18 (184, 13)
OIL SEPARATOR x2
ASSEMBLY
HARNESS BRACKET
HOSE
A157925E01
VACUUM PIPE
GASKET
EM
GASKET
O-RING
13 (130, 10)
55 (560, 41) x3
x2
GASKET
VACUUM PUMP OIL PIPE SUB-ASSEMBLY
NO. 3 NOZZLE LEAKAGE PIPE SUB-ASSEMBLY
FUEL PIPE SUPPORT
COMMON RAIL ASSEMBLY
GASKET
FUEL HOSE
13 (130, 10)
35 (360, 26)
55 (560, 41)
x2
29 (290, 21)
FUEL PIPE SUPPORT
35 (360, 26)
29 (290, 21)
Non-reusable part
A155566E01
EXAMPLE: N04C-TW
VACUUM PIPE
GASKET
EM
GASKET
O-RING
13 (130, 10)
x2 x3
55 (560, 41)
VACUUM PUMP OIL PIPE

SUB-ASSEMBLY
NO. 4 FUEL PIPE

SUB-ASSEMBLY
GASKET
20 (200, 15)
GASKET
COMMON RAIL ASSEMBLY 25 (250, 18)
NO. 3 INJECTION PIPE BRACKET

x2
29 (290, 21)
44 (450, 33)
Non-reusable part
A163947E01
GASKET
20 (200, 15)
GASKET
20 (200, 15)
NO. 4 FUEL PIPE

SUB-ASSEMBLY
EM
FUEL RETURN PIPE
SUB-ASSEMBLY
x2
29 (290, 21)
25 (250, 18)
GASKET
29 (290, 21)
x2
29 (290, 21)
O-RING
HOLDER CLAMP
29 (290, 21)
Non-reusable part
A163605E01
EXAMPLE: N04C-TW
FUEL RETURN PIPE SUB-ASSEMBLY
GASKET
25 (250, 18)
GASKET
NO. 1 FUEL HOSE

EM RETURN TUBE
GASKET
x2
25 (250, 18)
29 (290, 21)
INJECTION PUMP TO FUEL
FILTER FUEL HOSE OR PIPE
FUEL DELIVERY PIPE
29 (290, 21)
x2
29 (290, 21)
O-RING
HOLDER CLAMP
29 (290, 21)
Non-reusable part
A164294E01
29 (290, 21)
x2

WIRE HARNESS
29 (290, 21)
x2
13 (133, 10) x5 CUSHION x2
SPACER x2
EM
GASKET x5
NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY
GASKET
x4

GASKET
CLAMP BOLT
x4
O-RING x4
GASKET x4
x2
35 (360, 26)
x2
O-RING
Non-reusable part
A152847E05
EXHAUST MANIFOLD HEAT INSULATOR
29 (300, 21)
29 (290, 21) 60 (610, 44)
x3 EXHAUST MANIFOLD
THERMOSTAT
WATER OUTLET x7
SUB-ASSEMBLY x3
WATER OUTLET
HOUSING
29 (300, 21)
GASKET
EM WATER TEMPERATURE
SENDER GAUGE ASSEMBLY
GASKET CAMSHAFT POSITION SENSOR
ENGINE OIL PRESSURE

O-RING
SWITCH ASSEMBLY
29 (290, 21)
GASKET
x 15
5.0 (51, 44 in.*lbf)
29 (290, 21)
OIL COOLER ASSEMBLY
x8
WATER PUMP ASSEMBLY

INTAKE MANIFOLD
29 (290, 21)
x6
WATER BY-PASS PIPE x8

8.0 (82, 71 in.*lbf)
SUB-ASSEMBLY
x3
29 (290, 21)
O-RING
12 (120, 9)
O-RING
Non-reusable part
A153169E02
REMOVAL
TERMINAL
(a) Remove the bolt and 3 nuts.
(b) Remove the radiator reserve tank assembly. EM
10. REMOVE FENDER SIDE APRON SUB-ASSEMBLY RH
12. REMOVE INJECTOR DRIVER ASSEMBLY (See
A153578 chapter FU)
ASSEMBLY
(a) Disconnect the connector. (with Cab tilt warning)
A155100
(b) Remove the 4 nuts and remove the air cleaner

case.
A154077
(c) Remove the 2 clamps and remove the No. 1 air

hose assembly (N04C-TU).
A165819
(d) Remove the 2 bolts and remove the No. 1 air hose
assembly.
EM
A153054
(e) Remove the 8 bolts and remove the No. 3 cab

mounting bracket.
A152861

(N04C-TR, TS, TT)
(a) Remove the 2 bolts and intake air connector
bracket.
A153278
IT)
19. REMOVE FAN
(a) Loosen the 4 nuts.
(b) Remove the fan and generator V belt (See page
EM-4).
(c) Remove the 4 nuts and fan.
20. REMOVE FAN PULLEY

(a) Remove the fan pulley.
22. DISCONNECT RADIATOR HOSE INLET
(a) Disconnect the radiator hose inlet.
23. DISCONNECT RADIATOR HOSE OUTLET
A146459
(a) Remove the radiator hose outlet.
24. SEPARATE HEATER HOSE (See chapter CO)
CO)
26. SEPARATE NO. 3 RADIATOR BRACKET (See chapter EM
CO)
(a) Disconnect the connector.
(b) Remove the 4 bolts and separate the compressor
and magnetic clutch.
HINT:
Secure the compressor and hoses off to the side
instead of discharging the A/C system.
30. REMOVE STARTER ASSEMBLY (See chapter ST)
A160490
31. DISCONNECT HEATER HOSE

chapter MT)
chapter EX)
34. REMOVE PROPELLER SHAFT ASSEMBLY (See
chapter MT)
35. REMOVE PROPELLER INTERMEDIATE SHAFT
ASSEMBLY (See chapter PR)
36. SEPARATE CLUTCH RELEASE CYLINDER
ASSEMBLY (See chapter MT)
37. DISCONNECT TRANSMISSION CONTROL SELECT
CABLE (See chapter MT)
38. DISCONNECT TRANSMISSION CONTROL SHIFT

HOSE
(a) Disconnect the No. 2 oil reservoir to pump hose.
A154301

HOSE (N04C-TU)
(a) Disconnect the No. 2 oil reservoir to pump hose.
EM
A154074
41. REMOVE PRESSURE FEED HOSE

(a) Using SST, separate the pressure feed hose.
SST 09023-12901
(b) Remove the gasket from the pressure feed hose.
A154073
42. DISCONNECT FUEL HOSE

(a) Disconnect the 2 fuel hoses.
43. DISCONNECT WIRE HARNESS
(a) Disconnect the wire harness.
44. REMOVE MANUAL TRANSMISSION OUTPUT SHAFT
REAR SET NUT (See chapter MT)
45. REMOVE PARKING BRAKE DRUM SUB-ASSEMBLY
(See chapter MT)
A153056
46. SEPARATE PARKING BRAKE PLATE SUB-

ASSEMBLY (See chapter MT)
47. SUPPORT TRANSMISSION ASSEMBLY (See chapter
MT)
48. DISCONNECT NO. 3 ENGINE MOUNTING BRACKET
(See chapter MT)
(See chapter MT)
50. SUPPORT ENGINE ASSEMBLY

(a) Install the engine hanger with the 2 bolts.
A154075
(b) Attach the sling device and the engine with the
chain block.
51. REMOVE MANUAL TRANSMISSION ASSEMBLY (See
chapter MT) EM
CL)
CL)
A152866
54. REMOVE ENGINE ASSEMBLY

(a) Remove the 2 nuts and engine from the engine
mounting brackets.
(b) Remove the engine hanger.
55. REMOVE EGR COOLER SUB-ASSEMBLY (N04C-TU,
TV)
(a) Separate the water by-pass hose.
(b) Remove the 6 bolts and remove the EGR cooler.
56. REMOVE OIL FILLER CAP SUB-ASSEMBLY
(a) Remove the oil filler cap sub-assembly.
A146428
57. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

(a) Remove the 2 bolts and remove the cylinder head
cover sub-assembly.
A146429

ASSEMBLY
(a) Remove the wire harness.
(b) Remove the cylinder head cover cushion rubber.
(c) Remove the 2 bolts and remove the No. 2 cylinder
head cover sub-assembly.
59. REMOVE EGR VALVE BRACKET (N04C-TR, TS, TT,
See chapter FU)
60. REMOVE VENTURI ASSEMBLY (N04C-TR, TS, TT,
See chapter FU)
61. REMOVE INJECTION PIPE CLAMP (N04C-TR, TS, TT,
See chapter FU)
62. REMOVE OIL LEVEL GAUGE GUIDE
EM A155150
(a) Remove the oil level gauge guide.
63. REMOVE INJECTOR ASSEMBLY (N04C-TR, TS, TT,
See chapter FU)
64. REMOVE DIESEL THROTTLE BODY (N04-TU, TV, TW,
See chapter ES)
(N04-TU, TV, TW, See chapter EC)
(N04C-TE, See chapter FU)
67. REMOVE EGR VALVE BRACKET (N04C-TU, TV)
(a) Remove the 4 bolts and bracket.
A162712
68. REMOVE EGR VALVE BRACKET (N04C-TW)

N04C-TW
69. REMOVE OIL SEPARATOR ASSEMBLY (N04C-TW,
See chapter FU)
A146672

N04C-TR, TS, TT, TU, TV
(N04C-TU, TV)
(a) Remove the 3 bolts and 2 union bolts.
(b) Remove the water by-pass pipe.
71. REMOVE VENTURI ASSEMBLY
(a) Remove the 4 bolts, 2 nuts and venturi from the
intake manifold.
72. REMOVE INJECTION PIPE CLAMP (See chapter FU)
A160129
74. REMOVE INJECTOR ASSEMBLY (See chapter FU)
N04C-TW
EM
A154072
75. REMOVE VANE PUMP ASSEMBLY

(a) Remove the 2 bolts and remove the vane pump
assembly.
(b) Remove the vane pump O-ring from the vane pump
assembly.
76. REMOVE GENERATOR BELT ADJUSTING BAR
(N04C-TU, TV)
(a) Remove the 2 bolts and remove the generator belt
adjusting bar.
C101991E03
77. REMOVE IDLE PULLEY BRACKET (N04C-TR, TS, TT,

TV, with Air Conditioning System)
(a) Remove the 3 bolts and remove the idler pulley
assembly.
A153276

Conditioning System)
(a) Remove the 3 bolts and remove the No. 1
compressor mounting bracket.
A160491

(a) Remove the 3 bolts and remove the generator
bracket.
EM
A153275
80. REMOVE RADIATOR PIPE

(a) Remove the 2 bolts and remove the radiator pipe.
HINT:
(See chapter IT)
A154224
82. REMOVE EXHAUST MANIFOLD

(a) Remove the 3 bolts and remove the exhaust
manifold heat insulator sub-assembly.
A160130
(b) Remove the 8 nuts and remove the exhaust

manifold.
83. REMOVE GLOW PLUG GROUND WIRE (N04C-TU,
TV, See chapter ST)
84. REMOVE GLOW PLUG ASSEMBLY (N04C-TU, TV,
See chapter ST)
A146437
85. REMOVE ENGINE OIL PRESSURE SWITCH

ASSEMBLY
(a) Remove the engine oil pressure switch assembly.
86. REMOVE OIL COOLER ASSEMBLY (See chapter LU) EM
A146439
87. REMOVE CRANKSHAFT POSITION SENSOR

(a) Remove the bolt and remove the crankshaft position
sensor.
A146479
88. REMOVE CAMSHAFT POSITION SENSOR

(a) Remove the bolt and remove the camshaft position
sensor.
A146480
89. REMOVE WATER OUTLET SUB-ASSEMBLY

Remove the 3 bolts and remove the water outlet sub-
assembly.
90. REMOVE THERMOSTAT (See chapter CO)
A146606
91. REMOVE WATER TEMPERATURE SENDER GAUGE

ASSEMBLY
(b) Remove the water temperature sender gauge
assembly.
A146478
92. REMOVE WATER OUTLET HOUSING

(a) Remove the 3 bolts and remove the water outlet
housing.
EM
A146582
93. REMOVE WATER PIPE SUB-ASSEMBLY

(a) Remove the 3 bolts and remove the water pipe sub-
assembly.
(a) Remove the 6 bolts and remove the water by-pass
pipe sub-assembly.
CO)
A153279
96. REMOVE VACUUM PIPE
(a) Remove the union bolt and bolt and remove the
vacuum pipe.
97. REMOVE VACUUM PUMP OIL PIPE SUB-ASSEMBLY
(a) Remove the 3 bolts and remove the vacuum pump
oil pipe sub-assembly.
A146492
98. REMOVE VACUUM PUMP ASSEMBLY

(a) Remove the 2 nuts and remove the vacuum pump
assembly.
99. REMOVE FUEL PIPE SUB-ASSEMBLY (N04C-TR, TS,
TT, TU, TV, See chapter FU)
PIPE (See chapter FU)
101. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY (N04C-
A146493
TW, See chapter FU)
PIPE (N04C-TW, See chapter FU)
103. REMOVE COMMON RAIL ASSEMBLY (N04C-TW, See
chapter FU) EM
104. REMOVE FUEL DELIVERY PIPE (N04C-TW, See
chapter FU)
107. REMOVE NO. 3 NOZZLE LEAKAGE PIPE SUB-
ASSEMBLY (N04C-TR, TS, TT, TU, TV)
(a) Remove the nut and the fuel pipe clamp.
(b) Remove the 2 union bolts, the 4 gaskets and the
No. 3 nozzle leakage pipe sub-assembly.
108. REMOVE COMMON RAIL ASSEMBLY (N04C-TR, TS,
109. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY (N04C-
A155370 TR, TS, TT, TU, TV, See chapter FU)
(N04C-TR, TS, TT, TU, TV, See chapter FU)
111. REMOVE INTAKE MANIFOLD
(a) Remove the 8 bolts and 2 nuts and remove the
intake manifold.
A146498
INSTALLATION
1. INSTALL INTAKE MANIFOLD
(a) Apply seal packing in a continuous line (width: 1.5 to
2.5 mm (0.06 to 0.10 in.)) as shown in the
illustration.
Seal packing:
Seal Packing Bond 1207B or equivalent
A146603E01
NOTICE:
• Install the timing chain cover within 3
minutes, and tighten the bolts within 15
(b) Install the intake manifold with the 8 bolts and 2
EM nuts.
(See chapter FU)
3. INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY (N04C-
TR, TS, TT, TU, TV, See chapter FU)
4. INSTALL COMMON RAIL ASSEMBLY (N04C-TR, TS,
5. INSTALL INJECTON OR SUPPLY PUMP ASSEMBLY
7. INSTALL FUEL DELIVERY PIPE (N04C-TW, See
chapter FU)
8. INSTALL COMMON RAIL ASSEMBLY (N04C-TW, See
chapter FU)
9. INSATLL NO. 4 FUEL PIPE SUB-ASSEMBLY (N04C-
TW, See chapter FU)
10. INSTALL NO. 3 NOZZLE LEAKAGE PIPE SUB-
ASSEMBLY (N04C-TR, TS, TT, TU, TV)
(a) Install 4 new gaskets and the No. 3 nozzle leakage
pipe with the 2 union bolts.
(b) Install the fuel pipe clamp with the nut. Tighten the
nut until the clamp's edges make contact with the
engine side clamp's edges.
A155370
PIPE (See chapter FU)
12. INSTALL FUEL PIPE SUB-ASSEMBLY (N04C-TR, TS,
13. INSTALL VACUUM PUMP ASSEMBLY

(a) Install the vacuum pump assembly with a new O-
ring and the 2 nuts.
A146493
14. INSTALL VACUUM PUMP OIL PIPE SUB-ASSEMBLY

(a) Install the vacuum pump oil pipe sub-assembly with
a new gasket and the 3 union bolts.
EM
15. INSTALL VACUUM PIPE
(a) Install the vacuum pipe with 2 new gaskets, the
union bolt, and the bolt.
A146492 16. INSTALL WATER PUMP ASSEMBLY (See chapter
CO)
2.5 mm (0.06 to 0.10 in.)) as shown in the
illustration.
Seal packing:
Seal Packing Toyota Genuine Seal Packing Black, Three
NOTICE:
A146599E01 • Install the water by-pass pipe sub-assembly
within 3 minutes, and tighten the bolts within
15 minutes of applying the seal packing.
(b) Install the water by-pass pipe sub-assembly with the
clamp and the 6 bolts.
18. INSTALL WATER PIPE SUB-ASSEMBLY
(a) Install the water pipe sub-assembly with a new O-
ring and the 3 bolts.
A153279
19. INSTALL WATER OUTLET HOUSING

(a) Install the water outlet sub-assembly with the 3
bolts.
A146582
20. INSTALL WATER TEMPERATURE SENDER GAUGE

ASSEMBLY
(a) Install the water temperature sender gauge
assembly with a new gasket.
EM Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf)
21. INSTALL THERMOSTAT (See chapter CO)
A146478
22. INSTALL WATER OUTLET SUB-ASSEMBLY

bolts.
A146606
23. INSTALL CAMSHAFT POSITION SENSOR

(a) Install the camshaft position sensor with a new O-
ring and the bolt.
A146480
24. INSTALL CRANKSHAFT POSITION SENSOR

(a) Install the crankshaft position sensor with a new O-
ring and the bolt.
25. INSTALL OIL COOLER ASSEMBLY (See chapter LU)
A146479
26. INSTALL ENGINE OIL PRESSURE SWITCH

20 to 30°
ASSEMBLY
(a) Install the oil pressure switch.
(1) Install the oil pressure switch with a new O-ring
by hand, then further tighten it by 20 to 30° as
(b) Connect the oil pressure switch connector.
27. INSTALL GLOW PLUG ASSEMBLY (N04C-TU, TV,
See chapter ST)
A147513E02
28. INSTALL GLOW PLUG GROUND WIRE (N04C-TU, TT,

See chapter ST)
29. INSTALL EXHAUST MANIFOLD
(a) Install a new gasket to the cylinder head as shown
CORRECT INCORRECT in the illustration. EM
A161408E01
(b) Temporarily install the exhaust manifold. Uniformly

and temporarily tighten the 8 nuts in the order
8 4 2 6 HINT:
The stud bolts should contact the exhaust manifold
as shown in the illustration
7 3 1 5
Contact Contact
A166690E01
(c) Tighten the exhaust manifold with the 8 nuts.

Uniformly and tighten the 8 nuts in the order shown
8 4 2 6 Torque: 60 N*m (610 kgf*cm, 44 ft.*lbf)
7 3 1 5
A166691E01
(d) Install the exhaust manifold heat insulator sub-

assembly with the 3 bolts.
EM 30. INSTALL TURBOCHARGER SUB-ASSEMBLY

HINT:
(See chapter IT)
A160130
31. INSTALL RADIATOR PIPE

(a) Install the radiator pipe with a new gasket and the 2
bolts.
A154224

(a) Install the generator bracket with the 3 bolts.
A153275

BRACKET (N04C-TR, TS, TT, TU, with Air
(a) Install the No. 1 compressor mounting bracket with
the 3 bolts.
A160491
34. INSTALL IDLE PULLEY BRACKET (N04C-TR, TS, TT,

TU, with Air Conditioning System)
(a) Install the idle pulley assembly with bracket with the
3 bolts.
Torque: 55 N*m (561 kgf*cm, 41 ft.*lbf) EM
35. INSTALL GENERATOR BELT ADJUSTING BAR
(N04C-TU, TV)
(a) Install the generator belt adjusting bar with the 2
bolts.
A153276
36. INSTALL VANE PUMP ASSEMBLY
(a) Coat a new O-ring with power steering fluid and
install it to the vane pump.
(b) Install the vane pump assembly with the 2 bolts.
37. INSTALL INJECTOR ASSEMBLY (See chapter FU)
38. INSTALL OIL LEVEL GAUGE GUIDE
(a) Install the oil level gauge guide with a new O-ring.
39. INSTALL INJECTION PIPE CLAMP (See chapter FU)
C101991
40. INSTALL VENTURI ASSEMBLY

Seal 2.5 mm (0.06 to 0.10 in. )) as shown in the
Packing
illustration.
Seal packing:
NOTICE:
A146604E01 • Install the intake pipe with EGR valve within 3
minutes, and tighten the bolts within 15
(b) Install the venturi assembly with the 4 bolts.
N04C-TU, TV 41. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY

(N04C-TU, TV, TW)
(a) Install the water by-pass pipe sub-assembly with the
3 bolts and 2 union bolts.
Torque: Union bolt
25 N*m (250 kgf*cm, 18 ft.*lbf)
Bolt
29 N*m (290 kgf*cm, 21 ft.*lbf)
Gasket
A160128E01
N04C-TW 42. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY

(a) Install the water by-pass pipe sub-assembly with the
3 bolts and 2 union bolts.
Torque: Union bolt
EM 25 N*m (250 kgf*cm, 18 ft.*lbf)
Bolt
29 N*m (290 kgf*cm, 21 ft.*lbf)
GASKET
A154071E01
N04C- 43. INSTALL EGR VALVE BRACKET (N04C-TU, TV, TW)

TU, TV (a) Install the EGR valve bracket with 4 bolts.
44. INSTALL OIL SEPARATOR ASSEMBLY (N04C-TW,
See chapter FU)
A162712
47. INSTALL DIESEL THROTTLE BODY (N04C-TU, TV,
TW, See chapter ES)
N04C-TW 48. INSTALL EGR VALVE BRACKET
(a) Install the EGR valve bracket with 4 bolts.
49. INSTALL OIL SEPARATOR ASSEMBLY (See chapter
EC)
50. INSTALL VENTILATION PIPE SUB-ASSEMBLY (See
chapter FU)
A146672
(See chapter EC)
52. INSTALL DIESEL THROTTLE BODY (See chapter ES)

ASSEMBLY
(a) Install a new cylinder head cover gasket onto the
No. 2 cylinder head cover.
(b) Install the No. 2 cylinder head cover sub-assembly
with the 2 bolts.
(c) Install the cylinder head cover cushion rubber.
(d) Connect the ventilation hose.
A155150 EM
(a) Install the cylinder head cover sub-assembly with a
new gasket and the 2 bolts.
A146429
55. INSTALL OIL FILLER CAP SUB-ASSEMBLY

(a) Install the oil filler cap sub-assembly.
56. INSTALL EGR COOLER SUB-ASSEMBLY
(a) Install the EGR cooler with a new gasket and the 2
bolts.
Torque: Flange
55 N*m (560 kgf*cm, 41 ft.*lbf)
Engine
69 N*m (700 kgf*cm, 51 ft.*lbf)
A146428
(b) Connect the water by-pass hose.
57. INSTALL ENGINE ASSEMBLY
A154075
(b) Install the engine to the engine mounting brackets

with the 2 nuts.
(c) Remove the engine hanger.
CL)
60. INSTALL MANUAL TRANSMISSION ASSEMBLY (See
A152866
chapter MT)
61. INSTALL NO. 1 ENGINE MOUNTING BRACKET (See
chapter MT)
62. INSTALL NO. 3 ENGINE MOUNTING BRACKET (See
EM chapter MT)
63. INSTALL PARKING BRAKE PLATE SUB-ASSEMBLY
(See chapter MT)
64. INSTALL PARKING BRAKE DRUM SUB-ASSEMBLY
(See chapter MT)
65. INSTALL MANUAL TRANSMISSION OUTPUT SHAFT
REAR SET NUT (See chapter MT)
66. INSTALL WIRE HARNESS
(a) Install the wire harness.
67. CONNECT FUEL HOSE
(a) Connect the 2 fuel hoses.
68. CONNECT PRESSURE FEED HOSE
(a) Install the pressure feed hose with a new gasket.
A153056
(b) Using SST, install the pressure feed hose.

SST 09023-12901
A154073

(N04C-TR, TS, TT)
(a) Connect the No. 2 oil reservoir to pump hose.
A154074

(a) Connect the No. 2 oil reservoir to pump hose.
71. CONNECT TRANSMISSION CONTROL SHIFT CABLE
(See chapter MT) EM
72. CONNECT TRANSMISSION CONTROL SELECT
73. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY
(See chapter MT)
A154301

75. INSTALL PROPELLER SHAFT ASSEMBLY (See
chapter MT)
chapter EX)
chapter MT)
78. CONNECT HEATER HOSE
79. INSTALL STARTER ASSEMBLY (See chapter ST)
(a) Install the compressor and magnetic clutch with the
4 bolts.
(b) Connect the connector.
A160490
CO)
CO)
85. INSTALL HEATER HOSE (See chapter CO)
86. CONNECT RADIATOR HOSE OUTLET
(a) Install the radiator hose outlet.
87. CONNECT RADIATOR HOSE INLET
(a) Install the radiator hose inlet.

CRANKSHAFT PULLEY) BELT (N04C-with Air
89. INSTALL FAN PULLEY
(a) Install the fan pulley.
90. INSTALL FAN
(a) Temporarily install the fan with the 4 nuts.
(b) Install the fan and generator V belt (See page EM-
5).
(c) Holding the V belt, tighten the 4 nuts completely to
install the fan pulley and fan properly.
A146459

EM 92. INSTALL INTERCOOLER ASSEMBLY (See chapter
IT)
(N04C-TR, TS, TT)
(a) Install the intake air connector bracket with the 2
bolts.
A153278

ASSEMBLY
(a) Install the No. 3 cab mounting bracket with the 8
bolts.
A152861
(b) Install the No. 1 air hose assembly with the 2 bolts.
A153054
(c) Install the No. 1 air hose assembly with the 2

clamps (N04C-TU).
A165819
(d) Install the air cleaner case with the 4 bolts (N04C-
TR, TS, TT, TV).
EM
A154077
(e) Connect the connector. (with Cab tilt warning)

98. INSTALL INJECTOR DRIVER ASSEMBLY (See
chapter FU)
A155100

(a) Install the radiator reserve tank assembly with the
bolt and 3 nuts.
105. CONNECT NEGATIVE BATTERY TERMINAL
A153578 106. ADD ENGINE OIL (See chapter LU)
chapter CO)
112. BLEED POWER STEERING SYSTEM (See chapter
PS)

EM
N04C-TR, TS, TT, TU, TV, TW ENGINE MECHANICAL – ENGINE UNIT EM–151
ENGINE UNIT
ENGINE
COMPONENTS
29 (290, 21) OIL FILLER CAP SUB-ASSEMBLY
x2
CYLINDER HEAD x2 NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY
COVER STAY
CYLINDER HEAD COVER CUSHION RUBBER
29 (290, 21)
CYLINDER HEAD x2 CYLINDER HEAD COVER SUB-ASSEMBLY EM

COVER CUSHION x2
CYLINDER HEAD
COVER SPACER FLYWHEEL HOUSING STAY RH
x2 97 (990, 72) FLYWHEEL HOUSING

CYLINDER HEAD DUST SEAL
COVER GASKET
x2
FLYWHEEL
132 (1350, 98) RING GEAR
69 (700, 51)
x4 x2
29 (290, 21)
x6
x 10
FRONT NO. 1 ENGINE
MOUNTING BRACKET x4 186 (1900, 137)
RH
ENGINE REAR
OIL SEAL
132 (1350, 98)
O-RING
SPACER
FLYWHEEL HOUSING
29 (290, 21)
FLYWHEEL HOUS-
CRANKSHAFT PULLEY x2 ING STAY LH
132 (1350, 98)
97 (990, 72) x2
519 (5300, 380) 29 (290, 21)
x2
OIL STRAINER
N*m (kgf*cm, ft.*lbf) : Specified torque SUB-ASSEMBLY 69 (700, 51)
Non-reusable part x4
GASKET FRONT NO. 1 ENGINE
Apply MP grease 41 (420, 30)
MOUNTING BRACKET LH
DRAIN PLUG
29 (290, 21) x 26
A153255E03
EM–152 N04C-TR, TS, TT, TU, TV, TW ENGINE MECHANICAL – ENGINE UNIT
NO. 2 VALVE ROCKER SUPPORT NO. 1 VALVE ROCKER ARM
29 (300, 21) VALVE ROCKER ARM BUSH

VALVE ADJUSTING
NUT NO. 2 VALVE ROCKER ARM
NO. 1 VALVE ROCKER

VALVE ADJUSTING SUPPORT
SCREW
x5 NO. 1 VALVE ROCKER SHAFT
SUB-ASSEMBLY
69 (704, 51)
VALVE PUSH ROD
NO. 2 VALVE x8 x4
x4
EM ROCKER VALVE BRIDGE
SUPPORT x 18
x8
55 (560, 41)
x4
VALVE LIFTER
1st: 60 (612, 44)
2nd: Turn 90°

CYLINDER HEAD
3rd: Turn 90° SUB-ASSEMBLY
69 (700, 51)
OIL CHECK VALVE

SUB-ASSEMBLY
GASKET
Non-reusable part
A155119E01
CAMSHAFT
OIL PUMP ASSEMBLY

29 (290, 21)
x2
GASKET
29 (290, 21)
OIL PUMP DRIVEN GEAR
x7
NO. 1 IDLE GEAR SUB-ASSEMBLY
NO. 1 IDLE GEAR SHAFT
NO. 1 IDLE GEAR
137 (1400, 101) THRUST PLATE
TIMING GEAR
CASE
CRANKSHAFT TIMING EM
GEAR OR SPROCKET
x 15 55 (560, 41)
29 (290, 21) x5
55 (560, 41) LOCK PLATE

x2
TIMING CHAIN NO. 2 IDLE GEAR O-RING

OR BELT COVER THRUST PLATE
OIL SEAL
NO. 2 IDLE GEAR
NO. 2 IDLE GEAR SHAFT SUB-ASSEMBLY
55 (560, 41)
x3
OIL SEPARATOR ASSEMBLY
O-RING
O-RING
55 (560, 41)
x2
x4
GASKET
29 (290, 21)
FRONT END PLATE
Non-reusable part
Apply MP grease
A153257E03
DISASSEMBLY
ASSEMBLY
(a) Remove the 2 bolts and the No. 2 cylinder head
cover.
3. REMOVE CYLINDER HEAD COVER CUSHION
RUBBER
(a) Remove the cylinder head cover cushion rubber
from the No. 2 cylinder head cover.
4. REMOVE CYLINDER HEAD COVER STAY
(a) Remove the 2 cylinder head cover stays from the
No. 2 cylinder head cover.
EM
(a) Remove the 2 bolts and cylinder head cover.
(b) Remove the 2 cylinder head cover spacers from the
cylinder head cover.
6. REMOVE CYLINDER HEAD COVER CUSHION
(a) Remove the 2 cylinder head cover cushions from
the cylinder head cover.
7. REMOVE CYLINDER HEAD COVER GASKET
(a) Remove the cylinder head cover gasket from the
8. REMOVE NO. 1 VALVE ROCKER SHAFT SUB-
Adjusting Screw ASSEMBLY
(a) Loosen the lock nut at the top of the rocker arms,
then loosen the adjusting screws completely.
NOTICE:
If the adjusting screws are not loosened, the
rocker shaft may bend when the rocker arm
support bolts are loosened.
Lock Nut
A151464E01
(b) Loosen the 5 rocker arm support bolts in the order

1 3 5 4 2 (c) Remove the bolts and the No. 1 valve rocker shaft.
9. REMOVE VALVE PUSH ROD
NOTICE:
10. REMOVE VALVE BRIDGE
A151465E01 NOTICE:
11. REMOVE CYLINDER HEAD SUB-ASSEMBLY

(a) Remove the cylinder head bolts in the order shown
2 4 3 1 (b) Lift and remove the cylinder head from the cylinder
7 15 22 14 6 block.
(c) Remove the cylinder head gasket.
12. REMOVE VALVE LIFTER
11 19 18 10 NOTICE:
8 16 21 13 5 remembered for reassembly.
12 20 17 9
A151469E01 EM
spacer and pulley.
HINT:
crankshaft.
14. REMOVE FLYWHEEL HOUSING STAY RH
A151470
(a) Remove the 4 bolts and the flywheel housing stay.
15. REMOVE FLYWHEEL HOUSING STAY LH
(a) Remove the 4 bolts and the flywheel housing stay.
16. REMOVE FRONT NO. 1 ENGINE MOUNTING
BRACKET RH
(a) Remove the 4 bolts and the front No. 1 engine
mounting bracket.
17. REMOVE FRONT NO. 1 ENGINE MOUNTING
BRACKET LH
(a) Remove the 4 bolts and the front No. 1 engine
mounting bracket.
(a) Remove the 26 bolts from the oil pan.
SST oil pan. Cut through the applied sealer and remove
the oil pan.
SST 09032-00100
NOTICE:
SST Do not damage the contact surfaces of the
19. REMOVE OIL STRAINER SUB-ASSEMBLY
(a) Remove the 3 bolts and strainer.
A000019E05
(b) Remove the O-ring.
20. REMOVE OIL SEPARATOR ASSEMBLY

(a) Remove the 5 bolts and the oil separator from the
timing gear case.
(b) Remove the 2 O-rings.
21. REMOVE TIMING GEAR CASE
(b) Using a screwdriver with its tip wrapped with
protective tape, pry off the timing gear case.
NOTICE:
timing gear case, cylinder block and cylinder
head.
A151471
EM
(a) Using a screwdriver with its tip wrapped with
Protective Tape protective tape, pry out the oil seal.
HINT:
Use wooden blocks and a shop rag or piece of cloth
to prevent damage to the timing gear case.
Wooden
Shop Rag or
Block
Piece of Cloth
A151472E03
23. INSPECT NO. 2 IDLE GEAR THRUST CLEARANCE

(a) Using a feeler gauge, measure the thrust clearance
between the No. 2 idle gear thrust plate and No. 2
idle gear.
0.103 to 0.164 mm (0.0040 to 0.0064 in.)
0.30 mm (0.0118 in.)
A151473 replace the No. 2 idle gear thrust plate and No. 2
idle gear.
24. INSPECT NO. 2 IDLE GEAR BACKLASH
(a) Using a dial indicator, measure the backlash
between the No. 1 idle gear and No. 2 idle gear.
Standard backlash:
0.036 to 0.227 mm (0.0014 to 0.0089 in.)
Maximum backlash:
0.30 mm (0.0118 in.)
If the backlash is greater than the maximum,
replace the No. 1 idle gear and No. 2 idle gear.
A151474
25. REMOVE NO. 2 IDLE GEAR THRUST PLATE
(a) Remove the 2 bolts and No. 2 idle gear thrust plate.
26. REMOVE NO. 2 IDLE GEAR SUB-ASSEMBLY

27. REMOVE NO. 2 IDLE GEAR SHAFT
(a) Remove the 2 bolts and No. 2 idle gear shaft.
(b) Remove the O-ring.
28. REMOVE LOCK PLATE
(a) Remove the 3 bolts and plate from the end plate.
29. INSPECT CAMSHAFT TIMING GEAR BACKLASH
between the camshaft timing gear and No. 1 idle
gear.
Standard backlash:
0.069 to 0.203 mm (0.0027 to 0.0079 in.)
Maximum backlash:
0.30 mm (0.0118 in.) EM
A151477 replace the camshaft timing gear and No. 1 idle
gear.
30. REMOVE CAMSHAFT
(a) Remove the 2 bolts, thrust plate and camshaft.
31. INSPECT OIL PUMP GEAR BACKLASH
between the oil pump gear and No. 1 idle gear.
Standard backlash:
0.065 to 0.215 mm (0.0025 to 0.0084 in.)
Maximum backlash:
0.30 mm (0.0118 in.)
replace the pump and No. 1 idle gear.
A151478

(a) Using a feeler gauge, measure the thrust clearance
between the No. 1 idle gear thrust plate and No. 1
idle gear.
0.103 to 0.164 mm (0.0040 to 0.0064 in.)
0.30 mm (0.0118 in.)
A151479 replace the No. 1 idle gear thrust plate and No. 1
idle gear.
33. INSPECT NO. 1 IDLE GEAR BACKLASH
between the crankshaft timing gear and No. 1 idle
gear.
Standard backlash:
0.035 to 0.193 mm (0.0014 to 0.0075 in.)
Maximum backlash:
0.30 mm (0.0118 in.)
A151480 replace the crankshaft timing gear and No. 1 idle
gear.

(a) Remove the bolt.
(b) Using SST, remove the No. 1 idle gear shaft.
SST 09910-00015 (09911-00011, 09912-00010)
NOTICE:
When removing the gear shaft, hold the No. 1
idle gear by hand to prevent the No. 1 gear and
No. 1 idle gear thrust plate from falling.
SST 35. REMOVE NO. 1 IDLE GEAR SUB-ASSEMBLY
A151481E01
36. REMOVE NO. 1 IDLE GEAR THRUST PLATE

37. REMOVE CRANKSHAFT TIMING GEAR OR
SPROCKET
(a) Using SST, remove the crankshaft timing gear or
EM
SST sprocket.
Hold SST 09950-40011 (09951-04010, 09952-04010,
09953-04020, 09954-04010, 09955-04051)
38. REMOVE OIL PUMP ASSEMBLY
(a) Remove the 7 bolts and oil pump.
Turn Clockwise
A151484E01 39. REMOVE OIL PUMP COVER GASKET
(a) Remove the gasket from the oil pump.
40. REMOVE FRONT END PLATE
(a) Remove the 4 bolts and front end plate.
41. REMOVE FRONT END PLATE GASKET
(a) Remove the front end plate gasket from the front
end plate.
A151485

(a) Temporarily install 4 bolts in the positions of the
cylinder block shown in the illustration to prevent the
cables from sliding toward the center of the block.
(b) Attach 2 cables to the cylinder block.
HINT:
The cables must be attached outside the installed
bolts.
(c) Using a chain block and an engine sling device,
A151486 remove the cylinder block from the engine stand.
(d) Place the cylinder block on wooden blocks on a

Flywheel workbench.
Housing (e) Remove the 4 bolts from the cylinder block.
Wooden Block
A151487E01 EM
(f) Insert a screwdriver through the inspection hole of
crankshaft.
A151470
(g) Uniformly loosen and remove the 6 bolts in the

(h) Remove the flywheel.
NOTICE:
1 The flywheel is heavy. When removing, be
6 3
4 5 careful not to drop it.
2
A151488E01
43. REMOVE FLYWHEEL RING GEAR

(a) Using a torch, heat the ring gear evenly to
approximately 200°C (392°F).
NOTICE:
Be careful not to overheat the ring gear.
CAUTION:
Do not touch the ring gear and flywheel while
they are hot.
A151489
(b) Using a brass bar and hammer, uniformly strike all

around the ring gear and remove the gear.
CAUTION:
After removing, allow the ring gear to cool
before handling.
44. REMOVE FLYWHEEL HOUSING
(a) Remove the 14 bolts from the cylinder block.
(b) Using a screwdriver with its tip wrapped with
protective tape, pry off the flywheel housing.
A151490
45. REMOVE ENGINE REAR OIL SEAL

Protective Tape
protective tape, pry out the engine rear oil seal.
HINT:
EM Use wooden blocks and a shop rag or piece of cloth
to prevent damage to the flywheel housing.
46. REMOVE OIL CHECK VALVE SUB-ASSEMBLY
(a) Remove the bolt, the oil check valve and gasket.
Shop Rag or
Piece of Cloth
Wooden Block
A151491E02
INSPECTION
1. INSPECT VALVE ROCKER ARM OIL CLEARANCE
(a) Using a caliper gauge, measure the inside diameter
of the rocker arm bush.
22.023 to 22.052 mm (0.8670 to 0.8681 in.)
22.08 mm (0.8693 in.)
A151466
replace the bush.
NOTICE:
When installing a bush into the rocker arm, align
the bush correctly with the 2 oil holes of the
rocker arm.
(b) Using a micrometer, measure the outside diameter
of the rocker arm shaft.
Standard shaft diameter:
21.959 to 21.980 mm (0.8645 to 0.8653 in.)
Minimum shaft diameter:
21.92 mm (0.8630 in.)
If the outside diameter is less than the minimum,
replace the rocker arm shaft and rocker arm.
A151467
(c) Subtract the valve rocker arm inside diameter

measurement from the valve rocker shaft outside
diameter measurement.
0.043 to 0.093 mm (0.0017 to 0.0036 in.)
0.15 mm (0.0059 in.)
replace the rocker arm shaft and rocker arm bush.
2. INSPECT VALVE PUSH ROD
(a) Place the push rod on V-blocks.
(b) Using a dial indicator, measure the circle runout at
the center of the push rod.
0.30 mm (0.0118 in.) EM
If the circle runout is greater than the maximum,
replace the push rod.
A151468

(a) Measure the length of the M12 head bolts (No. 1 to
No. 18).
Maximum length:
129 mm (5.07 in.)
Length If the length is greater than the maximum, replace
the bolts.
A151514E01
4. INSPECT NO. 2 IDLE GEAR OIL CLEARANCE

(a) Using a cylinder gauge, measure the inside
diameter of the No. 2 idle gear.
Standard idle gear inside diameter:
50.000 to 50.025 mm (1.9685 to 1.9695 in.)
Maximum idle gear inside diameter:
50.05 mm (1.9704 in.)
the No. 2 idle gear.
A151475
(b) Using a micrometer, measure the diameter of the

No. 2 idle gear shaft.
49.950 to 49.975 mm (1.9665 to 1.9675 in.)
Minimum idle gear shaft diameter:
49.95 mm (1.9665 in.)
A151476
(c) Subtract the No. 2 idle gear inside diameter

measurement from the No. 2 idle gear shaft
0.0125 to 0.0375 mm (0.0005 to 0.0014 in.)
0.10 mm (0.0039 in.)
replace the No. 2 idle gear and No. 2 idle gear shaft.
5. INSPECT NO. 1 IDLE GEAR OIL CLEARANCE
diameter of the No. 1 idle gear.
Standard idle gear inside diameter:
50.000 to 50.025 mm (1.9685 to 1.9695 in.)
EM Maximum idle gear inside diameter:
50.05 mm (1.9704 in.)
the No. 1 idle gear.
A151482
(b) Using a micrometer, measure the diameter of the

Standard idle gear shaft diameter:
49.950 to 49.975 mm (1.9665 to 1.9675 in.)
Minimum idle gear shaft diameter:
49.95 mm (1.9665 in.)
(c) Subtract the No. 1 idle gear inside diameter
A151483 measurement from the No. 1 idle gear shaft outside
0.0125 to 0.0370 mm (0.0005 to 0.0014 in.)
0.10 mm (0.0039 in.)
replace the No. 1 idle gear and No. 1 idle gear shaft.
REPLACEMENT
HINT:
There are 2 methods to replace the timing chain or belt cover
oil seal.
1. REPLACE TIMING CHAIN OR BELT COVER OIL
SEAL
Protective Tape (a) If the timing gear case is removed from the cylinder
block:
(1) Using a screwdriver with its tip wrapped in
HINT:
Use wooden blocks and a shop rag or piece of
cloth to prevent damage to the timing gear
case.
EM
Wooden
Shop Rag or
Block
Piece of Cloth
A151472E03
(2) Using SST and a hammer, tap in the oil seal to

the timing gear case so that oil seal is flush with
the timing gear edge.
SST 09223-78010
NOTICE:
• Be careful not to tap the oil seal at an
angle.
• Keep the gap between the gear case
SST
edge and the oil seal free of foreign
A151503E01 matter.
(3) Apply MP grease to the oil seal lip.
(b) If the timing gear case is installed to the cylinder
block:
(1) Using a 46 mm socket wrench, remove the nut,
spacer and crankshaft pulley.
HINT:
Insert a screwdriver through the inspection hole
of the flywheel housing into the ring gear of the
flywheel to keep it from turning together with
the crankshaft.
A151470
(2) Using a screwdriver with its tip wrapped with

Protective Tape
A152900E01
(3) Using SST and a hammer, tap in the oil seal to

the timing gear case so that oil seal is flush with
the timing gear edge.
SST 09223-78010
NOTICE:
• Be careful not to tap the oil seal at an
angle.
• Keep the gap between the gear case
edge and the oil seal free of foreign
matter.
(4) Apply MP grease to the oil seal lip.
SST
EM A152899E01
(5) Install the pulley and spacer to the crankshaft.

HINT:
Align the pulley set key with the key groove of
the pulley.
(6) Using a 46 mm socket wrench, tighten the nut.
HINT:
Insert a screwdriver through the inspection hole
of the flywheel housing into the ring gear of the
A151470 flywheel to keep it from turning together with
the crankshaft.
2. REPLACE ENGINE REAR OIL SEAL
Protective Tape
Shop Rag or
Piece of Cloth
Wooden Block
A151491E02
(b) Using SST and a hammer, tap in a new oil seal until
SST flywheel housing.
SST 09223-78010
NOTICE:
4 mm matter.
(c) Apply MP grease to the oil seal lip.
A151492E01 EM
REASSEMBLY
1. INSTALL OIL CHECK VALVE SUB-ASSEMBLY
(a) Install a new gasket and the oil check valve with the
bolt.
2. INSTALL ENGINE REAR OIL SEAL
(a) Using SST and a hammer, tap in a new engine rear
SST oil seal until it is 4 mm (0.16 in.) below the upper
edge of the flywheel housing.
SST 09223-78010
NOTICE:
4 mm
matter.
A151492E01
3. INSTALL FLYWHEEL HOUSING

(a) Remove any oil or packing material from the contact
surface.
(b) Apply a continuous bead of seal packing (diameter:
1.5 to 2.5 mm (0.06 to 0.10 in.)) as shown in the
illustration.
Seal packing:
NOTICE:
• Install the flywheel housing within 3 minutes
of applying the seal packing.
Seal Packing
for at least 2 hours after installing flywheel
A151493E01
housing.
(c) Install the flywheel housing with the 14 bolts.

Torque: 132 N*m (1350 kgf*cm, 98 ft.*lbf) for bolt
(M14)
29 N*m (290 kgf*cm, 21 ft.*lbf) for bolt
(M8)
4. INSTALL FLYWHEEL RING GEAR
0.25 mm or less (a) Using a torch, heat the ring gear evenly to
Chamfer
approximately 200°C (392°F).
NOTICE:
Ring Gear
Flywheel (b) Using a brass bar, strike the ring gear onto the
flywheel with its chamfered gear teeth facing the
block.
Standard clearance:
EM A153717E01 0.25 mm (0.0098 in.) or less
CAUTION:
After installing the ring gear, allow it to cool
before handling.
(a) Insert the flywheel slowly until it contacts the collar
knock in order to prevent impact with the guide bar.
NOTICE:
The flywheel is heavy. When installing the
flywheel, be careful not to drop it.
(b) Apply clean engine oil to the threads of the flywheel
bolts and the flywheel bolt seats.
(c) Insert a screwdriver through the inspection hole of
crankshaft.
A151470
(d) Tighten the flywheel bolts in several steps in the

1
6 3
4 5
2
A151488E01
(e) Using a dial indicator, measure the runout of the

flywheel.
Maximum runout:
0.15 mm (0.0059 in.)
If the runout is greater than the maximum, resurface
the sliding surface.
A151495
(f) Temporarily install 4 bolts in the positions of the

cylinder block shown in the illustration to prevent the
cables from sliding toward the center of the block.
(g) Attach 2 cables to the cylinder block.
HINT: EM
The cables must be attached outside the installed
bolts.
(h) Using a chain block and an engine sling device,
install the cylinder block to the engine stand.
A151486 (i) Remove the 4 bolts from the cylinder block.
6. INSTALL FRONT END PLATE

(a) Install the front end plate with a new gasket and the
4 bolts.
(b) Using a cutter, cut the gasket so that it is flush with
the lower surface of the cylinder block.
A151485
7. INSTALL OIL PUMP ASSEMBLY

(a) Apply engine oil to the oil pump case of the cylinder
block and bearing.
NOTICE:
Engine Oil If engine oil is not applied, an oil suction
malfunction will occur when starting the engine.
The malfunction will cause seizure or abnormal
wear to the engine.
(b) Install a new gasket and the oil pump with the 7
A151496E01 bolts.
(c) Check that the oil pump rotates smoothly by hand
after installation.
8. INSTALL CRANKSHAFT TIMING GEAR OR

No. 1, No. 4 Cylinder: SPROCKET
(a) Turn the crankshaft clockwise, and align the
alignment mark on the flywheel with the alignment
mark between the 2 numbers on the edge of the
flywheel housing to set the No. 1 cylinder to TDC.
(b) Align the set key on the crankshaft with the key
groove of the crankshaft timing gear.
(c) Using a hammer, tap in the crankshaft timing gear.
Alignment
Mark
EM A151497E02
9. INSTALL NO. 1 IDLE GEAR SUB-ASSEMBLY

(a) Install the idle gear and idle gear thrust plate to the
idle gear shaft.
Oil Hole
A151498E01
(b) With the idle gear shaft oil hole facing down, match
Alignment
Mark
the alignment marks for each gear, and insert the
shaft into the cylinder block.
NOTICE:
If the oil hole is not facing down, it will cause oil
burning or abnormal engine wear.
(c) Tighten the bolt.
Alignment Torque: 137 N*m (1400 kgf*cm, 100 ft.*lbf)
Mark
Alignment Mark
A153732E01
10. INSTALL CAMSHAFT

(a) Apply engine oil to the camshaft journal and
Alignment Mark bearing.
(b) Match the alignment marks of the camshaft timing
gear and oil pump gear and install the camshaft.
Alignment Mark
A151500E05
11. INSTALL NO. 2 IDLE GEAR SHAFT

(a) Install the lock plate to the end plate with the 3 bolts.
(b) Install a new O-ring to the idle gear shaft.
(c) With the idle gear shaft oil hole facing down, install
the gear shaft to the lock plate with the 2 bolts.
NOTICE:
Oil Hole If the oil hole is not facing down, it will cause oil
A151501E01 burning or abnormal engine wear.

(a) Match the alignment marks of the No. 1 and No. 2
idle gears and install the No. 2 idle gear.
Alignment Mark
13. INSTALL NO. 2 IDLE GEAR THRUST PLATE EM
(a) Install the thrust plate with the 2 bolts.
Alignment Mark
A151502E03

timing gear edge.
SST 09223-78010
NOTICE:
SST
15. INSTALL TIMING GEAR CASE

surface.
3 to 4 mm (0.11 to 0.15 in.)) as shown in the
illustration.
Seal
Seal packing:
Packing
A151504E01 NOTICE:
• Install the timing gear case within 3 minutes
of applying the seal packing.
for at least 2 hours after installing the timing
gear case.
(c) Install the timing gear case with the 15 bolts.

A151471

HINT:
EM pulley.
HINT:
crankshaft.
17. INSTALL OIL SEPARATOR ASSEMBLY
(a) Install 2 new O-rings to the timing gear case.
(b) Install the oil separator with the 5 bolts.
18. INSTALL OIL STRAINER SUB-ASSEMBLY
(a) Install a new O-ring to the cylinder block.
(b) Install the strainer with the 3 bolts.
surface.
Seal Packing 3 to 4 mm (0.11 to 0.15 in.)) as shown in the
illustration.
Seal packing:
A151505E01 NOTICE:
• Install the oil pan within 3 minutes of applying
the seal packing.
for at least 2 hours after installing the oil pan.

20. INSTALL FLYWHEEL HOUSING STAY RH
(a) Install the stay with the 4 bolts.
(M14)
(M12)
Seal Packing
A151506E01 21. INSTALL FLYWHEEL HOUSING STAY LH
(a) Install the stay with the 4 bolts.
(M14)
(M12)
EM
22. INSTALL FRONT NO. 1 ENGINE MOUNTING
BRACKET RH
(a) Install the bracket with the 4 bolts.
23. INSTALL FRONT NO. 1 ENGINE MOUNTING
BRACKET LH
(a) Install the bracket with the 4 bolts.
24. INSTALL VALVE LIFTER
NOTICE:
Be sure to install the removed push rods to their
original position.
NOTICE:
Always install a new cylinder head gasket after
cleaning the surface of the cylinder head and
cylinder block.
(b) Install the cylinder head over the dowels on the
cylinder block.
HINT:
A151507 Since the cylinder head bolts are unique to this
engine, do not substitute them with ordinary bolts.
(c) Uniformly install and tighten the cylinder head bolts

(1 to 18) in several steps in the order shown in the
illustration.
16 8 1 9 17
12 4 5 13
15 7 2 10 18
11 3 6 14
EM A151469E02
(d) Mark the front side of each cylinder head bolt head
with paint as shown in the illustration.
(e) Retighten the cylinder head bolts by 90° in the same
90° 90° order as step (c).
(g) Check that each painted mark is now at a 180°
angle to the front.
Front
Paint
A151508E01
(h) Uniformly install and tighten the cylinder head bolts

(19 to 22) in several steps in the order shown in the
illustration.
16 8 1 9 17 26. INSTALL VALVE BRIDGE
NOTICE:
Be sure to install the removed valve bridge to its
12 4 5 13 original location.
15 7 2 10 18
27. INSTALL VALVE PUSH ROD
11 3 6 14 NOTICE:
Be sure to install the removed push rods to their
original location.
28. INSTALL NO. 1 VALVE ROCKER SHAFT SUB-
A151469E02 ASSEMBLY
(a) Lubricate the rocker arm shaft and bush.
NOTICE:
Confirm that oil hole of the rocker arm No. 1
support aligns with the shaft oil hole. Improper
installation will result in burning of the entire
valve.
(b) Install the No. 1 and No. 2 valve rocker arms, No. 1
and No. 2 valve rocker supports, and the rocker arm
bushes to the No. 1 valve rocker shaft.
NOTICE:
When installing, face the hole on the cylinder
head side of the No. 1 valve rocker shaft as
No. 1 Valve Rocker Arm No. 1 Valve

Rocker Support
Valve Rocker Arm Bush
No. 2 Valve Rocker Arm
Front
EM
Cylinder Head Cover Side
No. 2 Valve Rocker Support
No. 1 Valve Rocker Shaft
No. 1 Valve Rocker Support No. 2 Valve Rocker Support

Cylinder Head Side
A151509E02
(c) Install the rocker shaft to the cylinder head.

(d) Apply engine oil to the rocker arm and push rod.
5 3 1 2 4 (e) Install the bolts in the order shown in the illustration.
NOTICE:
Be careful that the push rod does not interfere
with the adjusting screw.
A151465E02

No. 1 and No. 4 Cylinder: (a) Flywheel housing side:
Turn the crankshaft clockwise to align the alignment
mark on the flywheel with the alignment mark
between the 2 numbers on the edge on the flywheel
housing.
Alignment
Mark
No. 2 and No. 3 Cylinder:
EM
Alignment
Mark
A151510E03
(b) Crankshaft pulley side:

No. 1 and No. 4 Cylinder: Pointer Turn the crankshaft clockwise to align the alignment
mark on the crankshaft pulley with the pointer on the
timing gear case.
HINT:
If not, turn the crankshaft 1 revolution (360°) to align
the matchmark with the pointer.
Alignment
Mark
No. 2 and No. 3 Cylinder: Pointer
Alignment Mark
A151511E02
(c) With the No. 1 piston positioned at TDC on the

Adjusting Screw
compression stroke, adjust each valve clearance
using a feeler gauge.
Valve clearance (Cold)
Intake 0.30 mm (0.0118 in.)
Exhaust 0.45 mm (0.0177 in.)
Feeler Gauge HINT:

Lock Nut The feeler gauge should move with a very slight
A151512E02 pull.
(d) Loosen the lock nut on the valve rocker arm and
loosen the adjusting screw.
(e) Insert a 0.30 mm (0.012 in.) feeler gauge for the
intake or a 0.45 mm (0.018 in.) feeler gauge for the
exhaust between the adjusting screw on the valve
rocker arm and the valve bridge.
(f) Turn the adjusting screw on the valve rocker arm
until the feeler gauge slides with a very slight drag,
and lock the adjusting screw with the lock nut.
(g) Recheck the clearance.
(h) Adjust the other valves.
(1) Turn the crankshaft 1 revolution (360°)
clockwise.
(2) Adjust the valve clearance for each cylinder in
the firing order. EM
Firing order:
1-3-4-2
(The number of a cylinder is counted from
the timing gear side)
30. INSTALL CYLINDER HEAD COVER GASKET
31. INSTALL CYLINDER HEAD COVER CUSHION
(a) Install the 2 cylinder head cover spacers and 2
cylinder head cover cushions onto the cylinder head
cover.
(a) Install the cylinder head cover with the 2 bolts.
33. INSTALL CYLINDER HEAD COVER STAY
(a) Install the 2 cylinder head cover stays onto the No. 2
34. INSTALL CYLINDER HEAD COVER CUSHION
RUBBER
(a) Install the cylinder head cover cushion rubber onto
the No. 2 cylinder head cover.
ASSEMBLY
(a) Install the No. 2 cylinder head cover with the 2 bolts.
(a) Install the oil filler cap onto the No. 2 cylinder head
cover.
ENGINE
ENGINE
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-1
ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-2
DRIVE BELT
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-6
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-7
VALVE CLEARANCE
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-9 EM
CAMSHAFT
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-12
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-16
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-22
CYLINDER HEAD
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-24
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-25
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-25
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-29
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-32
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-33
CYLINDER BLOCK
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-34
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-35
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-37
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-48
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-53
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-60
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-60
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-61
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-62
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-62
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-63
ENGINE ASSEMBLY
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-64
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-83
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-88
ENGINE UNIT
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-97
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-101
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-103
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-109
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM-110
EM
W04D-J, TM, TN ENGINE MECHANICAL – ENGINE EM–1
ENGINE
ENGINE:
Symptom Suspected Area See chapter or page
1. Starter ST
Engine does not crank (Does not start) 2. Starter relay ST
3. Starter Circuit ST
1. Starter Circuit ST
2. Injector FU
Difficult to start 3. Fuel filter FU
4. Compression EM-4
5. Injection pump FU
1. Fuel filter FU
Engine stalls soon after starting 2. Injector FU
EM
1. Fuel filter FU
Abnormal initial idling (Poor idling) 2. Injector FU
1. Injector FU
High engine idling speed (Poor idling) 2. Starter circuit ST
1. Injector FU
2. Compression EM-4
Low engine idling speed (Poor idling) 3. Valve clearance EM-9
4. Fuel line (bleeding) FU
1. Injector FU
2. Fuel line (bleeding) FU
Rough idling (Poor idling) 3. Compression EM-4
4. Valve clearance EM-9
1. Injector FU
2. Compression EM-4
Hunting (Poor idling) 3. Fuel line (bleeding) FU
4. Valve clearance EM-9
1. Injector FU
2. Fuel filter FU
3. Compression EM-4
Hesitation/ Poor acceleration (Poor driveability)
5. Turbocharger IT
6. Injector FU
1. Injector FU
Knocking (Poor driveability)
1. Injector FU
Black smoke emitted (Poor driveability) 2. Injection pump FU
3. Fuel filter FU
EM–2 W04D-J, TM, TN ENGINE MECHANICAL – ENGINE
Symptom Suspected Area See chapter or page

1. Injector FU
White smoke emitted (Poor driveability) 2. Fuel filter FU
1. Injector FU
Surging/ Hunting (Poor driveability) 2. Injection pump FU
3. Fuel filter FU
1. INSPECT ENGINE COOLANT (See chapter CO)
2. INSPECT ENGINE OIL (See chapter LU)
3. INSPECT BATTERY (See chapter CH)
4. INSPECT AIR CLEANER FILTER ELEMENT SUB-
ASSEMBLY
EM
5. INSPECT V BELT
(a) Visually check the belt for cracks, oiliness or wear.
Check that the belt does not touch the bottom of the
pulley groove.
If necessary, replace the belts as a set.
Clearance
CORRECT INCORRECT
A160887E01
(b) Check the fan and generator V belt deflection.

Fan Pulley
(1) Measure the belt deflection by pressing on the
belt at the points indicated in the illustration
with 98 N (10 kgf, 22 lbf) of pressure.
Generator Deflection:
10.0 to 15.0 mm (0.394 to 0.591 in.)
(2) Reference:
Using a belt tension gauge, measure the belt
Crankshaft Pulley tension.
A160891E01 Tension
New belt 374 to 471 N (38 to 48 kgf, 84 to 106 lbf)
Used belt 275 to 373 N (28 to 38 kgf, 62 to 84 lbf)
HINT:
• New belt refers to a belt which has been
used for less than 5 minutes on a running
engine.
• Used belt refers to a belt which has been
used on a running engine for 5 minutes or
more.
• After installing a new belt, run the engine for
about 5 minutes and recheck the belt
tension.
(c) Check the No. 1 V (cooler compressor to crankshaft

pulley) belt deflection. (W04D-J, TN, w/ Air
Idler Pulley Crankshaft Pulley Conditioning System)
(1) Measure the belt deflection by pressing on the
belt at the points indicated in the illustration
with 98 N (10 kgf, 22 lbf) of pressure.
Deflection
Air Conditioning Pulley New belt 9.0 to 10.5 mm (0.35 to 0.41 in)
A165246E01
Used belt 10.5 to 12.0 mm (0.41 to 0.47 in)
(2) Reference:
Using a belt tension gauge, measure the belt
tension.
Tension:
383 to 481 N (39 to 49 kgf, 86 to 108 lbf)
HINT: EM
• New belt refers to a belt which has been
used for less than 5 minutes on a running
engine.
• Used belt refers to a belt which has been
used on a running engine for 5 minutes or
more.
• After installing a new belt, run the engine for
about 5 minutes and recheck the belt
tension.
6. CHECK IDLE SPEED AND MAXIMUM SPEED
(b) Connect the tachometer.
(c) Inspect the engine idling speed.
Idling speed:
650 to 750 rpm
(d) Fully depress the accelerator pedal.
(e) Check the maximum speed.
Maximum speed:
3520 to 3620 rpm
(f) Turn the ignition switch off.
(g) Disconnect the tachometer.
7. ADJUST INJECTION PRESSURE
(a) Connect the nozzle holder with a nozzle tester and
move the lever at the rate of about 50 to 60 times
per minute.
1st opening pressure (with new parts):
22.06 to 22.94 MPa
(225 to 234 kgf/cm2, 3199 to 3327 psi)
1st opening pressure (with reused parts):
22.06 to 22.94 MPa
(225 to 234 kgf/cm2, 3199 to 3327 psi)
A158329
EM–4 W04D-J, TM, TN ENGINE MECHANICAL – ENGINE
NOTICE:
• Diesel fuel is flammable.
This nozzle adjusting should be done in a
well ventilated room and away from any open
flames or electric sparks.
• The spray must always be covered. Keep
your face and body away from the spray. This
is because of the risk of fuel oil getting in
your eyes or passing into your body.
If the injection pressure is not as specified, change
the shim.
8. INSPECT COMPRESSION
HINT:
If the power is short, the oil consumption is excessive,
and the fuel economy is poor, measure the compression
pressure.
EM (a) Allow the engine to warm up to the normal operating
temperature.
(b) Remove the injection pipe set.
(c) Check the compression pressure.
A161535
NOTICE:
When measuring each compression pressure,
the other 3 injection nozzles must be installed in
the cylinder head.
(1) Remove the nozzle holder and nozzle set.
(2) Install the gasket and SST (attachment) to the
injection nozzle hole with the adapter and bolt.
SST S0940-81041, S0955-21070
(3) Connect SST (compression gauge) to the SST
(attachment).
SST 09992-00025 (09992-00211)
(4) While cranking the engine, measure the
compression pressure.
HINT:
Always use a fully charged battery to obtain the
engine revolution of 280 rpm or more.
(5) Repeat steps (2) through (4) for each cylinder.
A165242 NOTICE:
This measurement must be done as short a
time as possible.
Compression pressure:
3540 to 3820 kPa (36 to 39 kgf/cm2, 512 to
554 psi)
Minimum pressure:
2750 kPa (28 kgf/cm2, 399 psi)
290 kPa (3.0 kgf/cm2, 43 psi)
(6) If the cylinder compression in one or more

cylinders is low, pour a small amount of engine
oil into the cylinder through the injector hole
and repeat steps (2) through (4) for the cylinder
with low compression.
• If the compression becomes high by adding
oil, it shows that the piston rings and/or
cylinder bore are worn or damaged.
• If the pressure remains low, a valve may be
sticking or seating improperly, or there may
be leakage through the gasket.
(7) Remove the compression gauge and SST.
(8) Install the injector.
(d) Install the nozzle holder and nozzle set.
(e) Start the engine and inspect for fuel leak.
EM
EM–6 W04D-J, TM, TN ENGINE MECHANICAL – DRIVE BELT
DRIVE BELT
ENGINE
COMPONENTS
EM
W04D-J, TN, with Air Conditioning System:

A165243E012
REMOVAL
B
CRANKSHAFT PULLEY) BELT (W04D-J, TN, w/ Air
(a) Loosen nut A.
A (b) Loosen bolt B, then remove the No. 1 V (cooler
compressor to crankshaft pulley) belt.
A165249E01
W04D-J, TM, TN ENGINE MECHANICAL – DRIVE BELT EM–7
2. REMOVE FAN AND GENERATOR V BELT

(a) Loosen bolt A and bolt B.
A
(b) Remove the fan and generator V belt.
B
A160892E01
INSPECTION
1. INSPECT V BELT
damage.
Clearance If any defects are found, replace the V belt.
HINT: EM
Replace the drive belt if any of the following defects
CORRECT INCORRECT are found:
A160887E01
• The belt is worn out and the wire is exposed.
• The cracks reach the wire in more than one
place.
(b) Check that the belt fits properly into the grooves.
HINT:
Confirm by hand that the belt has not slipped out of
the grooves on the bottom of the pulley.
INSTALLATION
1. INSTALL FAN AND GENERATOR V BELT
(a) Install the fan and generator V belt.
2. ADJUST FAN AND GENERATOR V BELT
(a) Insert a bar between the generator and the engine.
A Pull the bar toward the front of the vehicle and
adjust the tension.
(b) Tighten the fixing bolt A and bolt B.
Torque: Bolt A
47 N*m (479 kgf*cm, 34 ft.*lbf)
Bolt B
B
47 N*m (479 kgf*cm, 34 ft.*lbf)
A161495E01
(a) Install the No. 1 V (cooler compressor to crankshaft
pulley) belt.
EM–8 W04D-J, TM, TN ENGINE MECHANICAL – DRIVE BELT

B CRANKSHAFT PULLEY) BELT (W04D-J, TN, w/ Air
(a) Turn bolt B to adjust the tension of the No. 1 V
(cooler compressor to crankshaft pulley) belt.
(b) Tighten bolt A.
A Torque: Bolt A
41 N*m (418 kgf*cm, 30 ft.*lbf)
5. INSPECT V BELT (See page EM-2)
A165249E01
EM
W04D-J, TM, TN ENGINE MECHANICAL – VALVE CLEARANCE EM–9
VALVE CLEARANCE
ADJUSTMENT
(See page EM-21)
Flywheel (a) Set the No. 1 piston to top dead center on
compression stroke.
Flywheel
Housing
Pointer
TDC
A155729E01
EM
(b) With the No. 1 piston positioned at top dead center
on compression stroke, adjust the No. 1 valve
clearance using a thickness gauge.
(c) The thickness gauge should move with a very slight
pull.
(d) Adjust the clearance with the adjusting screw of the
rocker arm.
Tighten the lock nut.
Valve clearance
Item Valve clearance
Intake 0.35 mm (0.014 in.)
Exhaust 0.55 mm (0.022 in.)
(e) Adjust the other valves.

Valve Clearance Turn the crankshaft counterclockwise 180° viewed
from flywheel side. Adjust the valve clearance for
each cylinder in the firing order.
Firing order:
1 - 3 - 4 - 2 (The number of each cylinder is to
A155730E01 be counted in order from the timing gear side)
3. INSPECT INJECTION TIMING

INSPECTION HOLE
(a) Turn the crankshaft counterclockwise viewed from
FLYWHEEL the flywheel side to align the injection timing mark
on the flywheel or crankshaft pulley damper at A°
before top dead center for No. 1 cylinder on
TURNING compression stroke with the pointer.
DIRECTION Injection timing A°:
9°
POINTER
A161490E01
EM–10 W04D-J, TM, TN ENGINE MECHANICAL – VALVE CLEARANCE
(b) Check that the injection timing mark (the scribe line,
not the notch) on the timer housing is aligned with
TIMER COVER the pointer (the scribe line) timing plate on the pump
housing.
POINTER If not, adjust the injection timing.
MARK
A161491E01
4. ADJUST NO. 1 CYLINDER TO TDC / COMPRESSION

NOTICE:
• Turning the crankshaft, align the mark 1 to 4 on
the flywheel with the pointer on the flywheel
housing.
EM • In this position either the No. 1 or No. 4 piston is
at the top dead center on compression stroke.
(a) If both the No. 1 intake and exhaust rocker arms can
be moved easily by hand, the No. 1 piston is at top
A161492 dead center on compression stroke.
(b) If the injection timing mark is nearly aligned with the

pointer, the No. 1 piston is at top dead center on
TIMER COVER compression stroke.
If not, turn the crankshaft 1 complete revolution and
POINTER align marks as above.
MARK
A161491E01
(c) While locking at the push rods of No. 1 and No. 4

pistons, turn the crankshaft counterclockwise and
clockwise about 30° to 40° (see left figure).
If the piston whose exhaust and inlet push rods do
not move during the interval, it is at the top dead
center on compression stroke.
If the piston whose push rods have moved, it is at
PUSH RODS: MOVE PUSH RODS: STANDING
the compression of the exhaust and beginning of
(COMPRESSION STROKE) (OVERLAPPING STROKE) the intake stroke (overlapping stroke).
30°to 40°
A161493E01
W04D-J, TM, TN ENGINE MECHANICAL – CAMSHAFT EM–11
CAMSHAFT
ENGINE
COMPONENTS
VALVE ROCKER SHAFT 1st: 59 (600, 43)
SUB-ASSEMBLY
2nd: turn 90°
x5
3rd: turn 90°
44 (450, 32)
x8
1st: 59 (600, 43)
2nd: turn 90°
3rd: turn 90°
VALVE ADJUSTING SCREW CYLINDER HEAD SUB-ASSEMBLY
PUSH ROD
x5
1st: 59 (600, 43) EM
x8 x 13
x4 2nd: turn 90°
59 (600, 43) x8
3rd: turn 90°

VALVE LIFTER x8
CRANKSHAFT PULLEY
515 (5250, 380)

SPACER
Non-reusable part
MP grease
A156044E02
EM–12 W04D-J, TM, TN ENGINE MECHANICAL – CAMSHAFT
CAMSHAFT
x2
25 (250, 18)
29 (291, 21)
x 12
REVOLUTION DETECTOR
ASSEMBLY
x2
29 (291, 21) TIMING GEAR COVER ASSEMBLY
EM
PIPE
29 (291, 21)
GASKET
PIPE
GASKET
20 (200, 15)

GASKET
x 26 41 (420, 30)
29 (291, 21)
Non-reusable part
A156045E01
REMOVAL
TERMINAL

4. DRAIN POWER STEERING FLUID (W04D-J, TN)
5. REMOVE AIR HOSE ASSEMBLY (W04D-J, TN, for
Standard Body) (See page EM-83)
6. REMOVE AIR HOSE ASSEMBLY (W04D-J, TN, for
Wide Body) (See page EM-83)
7. REMOVE AIR CLEANER PIPE (See page EM-83)
8. REMOVE NO. 1 AIR HOSE (See page EM-83)
EM
EM-84)
14. DISCONNECT RADIATOR HOSE OUTLET (See page
EM-84)
15. REMOVE INTERCOOLER ASSEMBLY
HINT:
(See chapter IT)
chapter EX)
(W04D-J, TN, w/ Air Conditioning System) (See page
EM-84)
20. DISCONNECT POWER STEERING SUCTION PORT
UNION (See chapter PS)
21. DISCONNECT OIL PUMP TO GEAR BOX TUBE (See
chapter PS)
22. REMOVE VANE PUMP ASSEMBLY (See chapter PS)
(See page EM-21)
25. REMOVE INJECTION PIPE SET (See chapter FU)
26. REMOVE FUEL PIPE SET (See chapter FU)
27. REMOVE DIESEL FUEL FILTER ASSEMBLY (See
chapter FU)

(See chapter FU)
29. REMOVE NOZZLE HOLDER AND NOZZLE SET (See
chapter FU)
86)
31. REMOVE FAN BELT ADJUSTING BAR
BRACKET (W04D-J, TN, w/ Air Conditioning System)
(See page EM-87)
34. REMOVE IDLER PULLEY BRACKET (W04D-J, TN, w/
Air Conditioning System) (See page EM-87)
EM 35. REMOVE REVOLUTION DETECTOR ASSEMBLY
(W04D-J, TN, w/ Tachometer) (See page EM-87)
36. REMOVE WATER OUTLET SUB-ASSEMBLY (See
page EM-87)
37. REMOVE THERMOSTAT (See page EM-87)
38. REMOVE WATER OUTLET HOUSING (See page EM-
87)
CO)
HINT:
(See chapter IT)
43. SET NO. 1 CYLINDER TO TDC / COMPRESSION (See
page EM-22)
44. REMOVE VALVE ROCKER ARM ASSEMBLY (See
page EM-101)
45. REMOVE CYLINDER HEAD SUB-ASSEMBLY (See
page EM-101)
46. REMOVE CYLINDER HEAD GASKET
(a) Remove cylinder head gasket.
47. REMOVE VALVE LIFTER (See page EM-101)
48. REMOVE CRANKSHAFT PULLEY (See page EM-60)

oil pan. Cut through the applied sealer and remove
SST the oil pan.
SST 09032-00100
NOTICE:
SST
Do not damage the contact surface of the
A101612E01
50. REMOVE TIMING GEAR COVER ASSEMBLY

protective tape, pry out the timing gear cover
assembly.
NOTICE: EM
timing gear cover assembly, cylinder block and
cylinder head.
A161520

Protective Tape
A161494E01
52. REMOVE CAMSHAFT

(a) Remove the 2 bolts and camshaft.
NOTICE:
Pull out the camshaft by slowly turning it, so as
not to damage the bearings.
A146589
INSPECTION
1. INSPECT CAMSHAFT
(a) Inspect the camshaft for circle runout.
(1) Place the camshaft on V-blocks.
at the center journal.
0.05 mm (0.0020 in.)
A151553
maximum, replace the camshaft.
(b) Using a micrometer, measure the cam lobe height.

Standard cam lobe height:
Intake:
49.435 mm (1.9463 in.)
Exhaust:
49.493 mm (1.9485 in.)
Minimum cam lobe height:
Intake:
48.90 mm (1.925 in.)
Exhaust:
48.95 mm (1.9272 in.)
the camshaft.
INSTALLATION
1. INSTALL CAMSHAFT
EM (a) Apply engine oil to the camshaft journal and
bearing.
(b) Match the matchmarks of the camshaft timing gear
and oil pump gear and install the camshaft.
Alignment Mark NOTICE:
Insert the camshaft while slowly turning it so
that the bearing will not be damaged.
Alignment Mark
A151500E06

timing gear case so that oil seal is flush with the
timing gear edge.
SST 09223-78010
NOTICE:
SST and the oil seal free of foreign matter.
3. INSTALL TIMING GEAR COVER ASSEMBLY

Seal (a) Remove any oil packing material from the contact
Packing
surface.
illustration.
Seal packing:
A165241E01 NOTICE:
• Do not expose the seal packing engine oil for

at least 2 hours after installing.
(c) Install the timing gear cover assembly with the 12
bolts.
A161520

surface.
(b) Apply a continuous bead of seal packing (diameter: EM
illustration.
Seal Packing
Seal packing:
NOTICE:
• Do not expose the seal packing engine oil for
at least 2 hours after installing.
6. INSTALL VALVE LIFTER (See page EM-113)
Seal Packing
A146590E01
7. INSTALL CYLINDER HEAD AND VALVE ROCKER
ARM ASSEMBLY (See page EM-113)
8. INSTALL CYLINDER HEAD SUB-ASSEMBLY (See
page EM-114)
HINT:
(See chapter IT)
12. INSTALL REVOLUTION DETECTOR ASSEMBLY
(W04D-J, TN, w/ Tachometer) (See page EM-90)
CO)
14. INSTALL WATER OUTLET HOUSING (See page EM-
90)
15. INSTALL THERMOSTAT (See page EM-90)
16. INSTALL WATER OUTLET SUB-ASSEMBLY (See

page EM-91)
18. INSTALL IDLER PULLEY BRACKET (W04D-J, TN, w/
(See page EM-91)
20. INSTALL FAN BELT ADJUSTING BAR
(See chapter FU)
91)
EM 23. INSTALL DIESEL FUEL FILTER ASSEMBLY (See
chapter FU)
24. INSTALL NOZZLE HOLDER AND NOZZLE SET (See
chapter FU)
25. INSTALL FUEL PIPE SET (See chapter FU)
26. INSTALL INJECTION PIPE SET (See chapter FU)
27. INSTALL GLOW PLUG ASSEMBLY (See chapter ST)
28. ADJUST VALVE CLEARANCE (See chapter EM-9)
(See page EM-23)
30. INSTALL VANE PUMP ASSEMBLY (W04D-J, TN, See
chapter PS)
31. CONNECT OIL PUMP TO GEAR BOX TUBE (W04D-J,
TN, See chapter PS)
32. CONNECT POWER STEERING SUCTION PORT
UNION (W04D-J, TN, See chapter PS)
(W04D-J, TN, w/ Air Conditioning System) (See page
EM-93)
chapter EX)
37. INSTALL INTERCOOLER ASSEMBLY
HINT:
(See chapter IT)
94)
94)

42. ADJUST FAN AND GENERATOR V BELT (See page
EM-7)
45. INSTALL NO. 4 AIR HOSE (See page EM-95)
47. INSTALL AIR CLEANER PIPE (See page EM-95)
48. INSTALL AIR HOSE ASSEMBLY (for Standard Body) EM
(See page EM-95)
49. INSTALL AIR HOSE ASSEMBLY (for Wide Body) (See
page EM-95)
53. ADD POWER STEERING FLUID (W04D-J, TN)
54. BLEED FUEL LINE
55. BLEED POWER STEERING SYSTEM (W04D-J, TN)
56. INSPECT FOR OIL LEAK (See chapter LU)
(W04D-J, TN)
EM–20 W04D-J, TM, TN ENGINE MECHANICAL – CYLINDER HEAD GASKET

ENGINE
COMPONENTS
x6 25 (250, 18)
CYLINDER HEAD COVER

SUB-ASSEMBLY
GASKET
1st: 59 (600, 43)
VALVE ROCKER SHAFT 2nd: turn 90°

x5
EM SUB-ASSEMBLY 3rd: turn 90°
44 (450, 32)
x8 1st: 59 (600, 43)
2nd: turn 90°
x5 3rd: turn 90°

VALVE ADJUSTING SCREW
x 13
PUSH ROD
x8
x8 CYLINDER HEAD SUB-ASSEMBLY
59 (600, 43) x4
VALVE LIFTER x8
Non-reusable part
A156046E02
W04D-J, TM, TN ENGINE MECHANICAL – CYLINDER HEAD GASKET EM–21
REMOVAL
TERMINAL
4. REMOVE AIR HOSE ASSEMBLY (for Standard Body)
(See page EM-83)
5. REMOVE AIR HOSE ASSEMBLY (for Wide Body)
(See page EM-83)
6. REMOVE AIR CLEANER PIPE (See page EM-83)
9. REMOVE NO. 1 V (COOLER COMPRESSOR TO EM
EM-84)
13. DISCONNECT RADIATOR HOSE OUTLET (See page
EM-84)
chapter EX)
(a) Remove the 6 bolts and cylinder head cover sub-
assembly.
A161526 chapter FU)
21. REMOVE INSPECTION OR SUPPLY PUMP
ASSEMBLY (W04S-TM, See chapter FU)
chapter FU)
86)
HINT:
(See page IT)
EM–22 W04D-J, TM, TN ENGINE MECHANICAL – CYLINDER HEAD GASKET

27. REMOVE WATER OUTLET SUB-ASSEMBLY (See
page EM-87)
28. REMOVE THERMOSTAT (See page EM-87)
29. REMOVE WATER OUTLET HOUSING (See page EM-
87)
30. SET NO. 1 CYLINDER TO TDC / COMPRESSION
Flywheel (a) Set the No. 1 piston to DTC on the compression
stroke.
Flywheel
Housing 31. REMOVE VALVE ROCKER SHAFT SUB-ASSEMBLY
Pointer (See page EM-101)
32. REMOVE CYLINDER HEAD SUB-ASSEMBLY (See
TDC page EM-101)
EM 33. REMOVE CYLINDER HEAD GASKET (See page EM-
A155729E01
14)
INSTALLATION
ARM ASSEMBLY (See page EM-113)
2. INSTALL CYLINDER HEAD SUB-ASSEMBLY (See
page EM-114)
3. INSTALL WATER OUTLET HOUSING (See page EM-
90)
4. INSTALL THERMOSTAT (See page EM-90)
5. INSTALL WATER OUTLET SUB-ASSEMBLY (See
page EM-91)
HINT:
(See chapter IT )
91)
chapter FU)
(W04D-TM, See chapter FU-)
12. INSTALL DIESEL FUEL FILTER ASSEMBLY (See
chapter FU)
16. ADJUST VALVE CLEARANCE (See page EM-9)
W04D-J, TM, TN ENGINE MECHANICAL – CYLINDER HEAD GASKET EM–23

(b) Install the cylinder head cover sub-assembly with
the 6 bolts.
chapter EX)
94)
A161526

94)
EM
EM-7)
25. INSTALL NO. 1 V (W04D-J, TN, COOLER
COMPRESSOR TO CRANKSHAFT PULLEY) BELT
(See page EM-7)
26. ADJUST NO. 1 V (W04D-J, TN, COOLER
COMPRESSOR TO CRANKSHAFT PULLEY) BELT
(See page EM-8)
29. INSTALL AIR CLEANER PIPE (See page EM-95)
30. INSTALL AIR HOSE ASSEMBLY (for Standard Body)
(See page EM-95)
page EM-95)
35. BLEED FUEL LINE
EM–24 W04D-J, TM, TN ENGINE MECHANICAL – CYLINDER HEAD
CYLINDER HEAD
ENGINE
COMPONENTS
VALVE SPRING RETAINER LOCK
VALVE SPRING RETAINER
INNER COMPRESSING SPRING
OUTER COMPRESSION SPRING

25 (255, 18)
EM STUD BOLT
VALVE STEM OIL
VALVE SPRING SEAT TIGHT PLUG
VALVE GUIDE BUSH
47 (479, 35)
STUD BOLT
TIGHT PLUG
TIGHT PLUG
TIGHT PLUG
VALVE SEAT
Non-reusable part
VALVE
Precoated part
A157449E01
W04D-J, TM, TN ENGINE MECHANICAL – CYLINDER HEAD EM–25
DISASSEMBLY
SST
1. REMOVE VALVE
(a) Using SST, compress the compression springs and
remove the 2 keepers.
SST 09202-70020 (09202-00030)
(b) Remove the spring retainer, 2 compression springs
and valve.
(c) Remove the oil seal and spring seat.
A155712E01
HINT:
Arrange the valves, compression springs, spring
seats and spring retainers in the correct order.
2. REMOVE VALVE STEM OIL
(a) Remove the oil seal and spring seat.
HINT:
Arrange the valves, compression springs, spring
seats and spring retainers in the correct order. EM
3. REMOVE VALVE GUIDE BUSH (See page EM-30)
4. REMOVE VALVE SEAT (See page EM-29)
5. REMOVE TIGHT PLUG (See page EM-30)
6. REMOVE STUD BOLT (See page EM-31)
INSPECTION
1. INSPECT CYLINDER HEAD SUB-ASSEMBLY
(a) Inspect for cracks.
(1) Using a dye penetrant, check the combustion
chamber, intake ports, exhaust ports and
cylinder block surface for cracks.
If any of them have cracks, replace the cylinder
head.
A155827
(b) Inspect the flatness.

(1) Using a precision straight edge and feeler
gauge, measure the surfaces contacting the
cylinder block and the manifolds for warpage.
Standard warpage
Item Warpage
Longitudinal direction 0.05 mm (0.0020 in.) or less
Lateral direction 0.05 mm (0.0020 in.) or less
Maximum warpage:
0.10 mm (0.0039 in.)
If the warpage is greater than the maximum,
regrind the cylinder head.
6
3 2
1
4
EM 5
A155828E01
2. CLEAN VALVE
(a) Using a gasket scraper, chip off any carbons from
the valve head.
(b) Using a wire brush, thoroughly clean the valve.
A053867
3. INSPECT VALVE
(a) Visually check the valves for damage, burns,
carbons or warpage, and check the valve heads,
valve stems and valve stem grooves for cracks.
If wear, burns, warpage or cracks are excessive,
Width replace the valve.
(1) Lightly apply red lead marking compound to the
valve face. Tapping and rotating the valve
A146585E01 against the seat, check the seating condition.
If the red lead mark is not concentric or the
compound is scattered all around the valve
face or seat, correct the valve face or the valve
seat.
4. INSPECT VALVE SINK

(a) Inspect the valve sink.
(1) Using a precision straight edge and feeler
gauge, measure the valve sink.
Valve Seat Standard dimension
Item Dimension
Valve Sink Intake 0.15 to 0.45 mm (0.0059 to 0.0177 in.)
Dimension Exhaust 0.47 to 0.77 mm (0.0185 to 0.0303 in.)
Cylinder Head Valve
A155831E01 Maximum dimension
Item Dimension
Intake 0.55 mm (0.0217 in.)
Exhaust 0.87 mm (0.0342 in.)
HINT:
cylinder head surface, the valve heads may EM
hit against the pistons while the engine is
running.
If the sink is greater than the maximum, replace
the valve and valve seat.
5. INSPECT VALVE STEM AND VALVE GUIDE
(a) Using a micrometer, measure the diameter of the
stem.
Standard valve stem diameter
Item Valve stem diameter
Intake 8.95 to 8.97 mm (0.3524 to 0.3531 in.)
Minimum valve stem diameter

A137170
Item Valve stem diameter
Intake 8.90 mm (0.3504 in.)
Exhaust 8.80 mm (0.3465 in.)
If the stem diameter is less than the minimum,

replace the valve.
diameter of the valve guide.
A
90 ° (c) Subtract the diameter measurement of the valve
C stem from the inside diameter measurement of the
B valve guide.
Standard oil clearance
Item Oil clearance
A: 5 mm (0.197 in.)
B: 25 mm (0.984 in.) Intake 0.035 to 0.068 mm (0.0014 to 0.0027 in.)
C: 45 mm (1.771 in.) Exhaust 0.050 to 0.083 mm (0.0020 to 0.0033 in.)
A155832E01
Maximum oil clearance

Item Measurement Oil clearance
A&B 0.10 mm (0.0039 in.)
Intake
C 0.18 mm (0.0071 in.)
Item Measurement Oil clearance

A&B 0.12 mm (0.0047 in.)
Exhaust
C 0.20 mm (0.0079 in.)

replace the valve or valve guide.
6. INSPECT COMPRESSION SPRING
Deviation (a) Using a steel square, measure the deviation of the
spring.
Maximum deviation:
2.0 mm (0.079 in.)
If the deviation is greater than the maximum,
replace the spring.
A053807E03
EM
(b) Using vernier calipers, measure the free length of
the spring.
Free length
Item Length
Inner 61.0 mm (2.402 in.)
Outer 60.2 mm (2.370 in.)
If the free length is not as specified, replace the

spring.
EM00801
(c) Using a spring tester, measure the tension of the

valve spring at the specified installed length.
Installed tension
Item Setting Height Tension
Inner 43.0 mm (1.693 in.) 86.0 N (8.8 kgf, 19.3 lbf)
Outer 45.5 mm (1.791 in.) 269.0 N (27.4 kgf, 60.5 lbf)
If the installed tension is not as specified, replace

the spring.
EM00281
7. INSPECT VALVE SPRING SEAT

(a) Visually check the contact surface of the upper and
lower valve spring seats.
If damage such as wear and scratches is excessive,
replace the valve spring seat.
8. INSPECT CYLINDER HEAD COOLANT GALLERY
FOR LEAK
(a) Close all coolant holes, and apply air pressure of
A155719
about 2.5 kg/cm2 (36 lb/sq.in.) from one of the
coolant holes. Immerse the cylinder head into the
water, then check for air leakage.
If any leakage is found, replace the cylinder head.
REPLACEMENT
1. REPLACE VALVE STEM OIL
(a) Replace the stem seal when the valve guide is
replaced or the seal clearance is excessive or the
stem seal has been worn or damaged.
(b) Install the lower spring seat and valve to the cylinder
head (for guide of SST), then apply engine oil to the
lip of the stem seal and drive the guide with SST.
SST 09201-41020
SST CAUTION:
When striking, a metal tip may fly off on impact.
Wear safety glasses to protect your eyes.
A155717E01
HINT: EM
• After installing the valve stem seal, make sure
Coat Oil that there are gaps (A) and (B) as shown in the
illustration.
• Do not use SST if its surface contacting the valve
spring lower seat is deformed.
B
• Check that the seal has not been deformed or
A cracked after the installation.
A155718E01
2. REPLACE VALVE SEAT

Block Brass
Valve Seat (a) Cut the 3 places on the circumference of an
Electric welding
unwanted valve and weld it to the valve seat.
applied NOTICE:
Valve To protect the lower surface of the cylinder head
from welding spatters, be sure to apply grease
Grind this point
before welding.
with a grinder
(b) Place a block brass on the top of the valve stem and
strike it with a hammer to remove the valve seat.
A153759E01 CAUTION:
(c) Machine the valve seat according to the specified
Intake Exhaust
valve seat dimensions.
Cylinder head dimension:
Item Measurement Dimension
B B
46.500 to 46.516 mm (1.8307 to
A
30° 45° 1.8313 in.)
A A Intake
8.800 to 9.000 mm (0.3465 to
C C B
0.3543 in.)
D D
Intake 45° Exhaust 41.000 to 41.016 mm (1.6142 to
30° A
A155715E01 1.6148 in.)
Exhaust
7.200 to 7.300 mm (0.2835 to
B
0.2874 in.)
Valve seat dimension:

Item Measurement Dimension
46.585 to 46.600 mm (1.8341 to
C
1.8346 in.)
Intake
7.500 to 7.700 mm (0.2953 to
D
0.3031 in.)
41.130 to 41.145 mm (1.6193 to
C
1.6199 in.)
Exhaust
6.000 to 6.200 mm (0.2362 to
D
0.2441 in.)
(d) Heat the cylinder head to 80 to 100°C (176 to

212°F) with hot water. Cool the valve seat with dry
ice for approximately 30 minutes.
(e) Hold the valve seat with pincers and place it into the
heated cylinder head. Lightly hitting the valve seat
can easily fit them.
EM CAUTION:
• Never touch the cooled valve seat with your
bare hands.
A155830 • When hitting, a metal tip may fly off on
eyes.
HINT:
When valve grinding the valve, always recheck the
seating condition.
3. REPLACE VALVE GUIDE BUSH
(a) Using a brass bar and a hammer, strike out the
valve guide out.
CAUTION:
A155833
(b) Press-fit a new valve guide straight allowing it to

protrude, as shown in the illustration.
C Protrusion height (C):
15 mm (0.59 in.)
HINT:
B Apply engine oil lightly to the valve guide outer
A circumference before the installation.
4. REPLACE TIGHT PLUG
A: 33 mm (1.30 in.) C: 15 mm (0.59 in.) NOTICE:
B: 74 mm (2.91 in.) A155716E01
If water leaks from the tight plug or the plug
corrodes, replace it.
(a) Remove the tight plugs.
(b) Apply adhesive around 17 new tight plugs.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond
1324 or equivalent
(c) Install the tight plugs to the cylinder head as shown

Intake Side:
Rear Side:
Upper Side: A
EM
Exhaust Side:
9.0 to 9.5 mm
(0.35 to 0.37 in.)
Lower Side:
A-A
A163505E01
HINT:
When installing the plugs, do not allow them to
project from the machined surface of the cylinder
head.
5. REPLACE STUD BOLT
NOTICE:
If the stud bolt is deformed or the threads are
damaged, replace it.
(a) Remove the stud bolts.

(b) Apply adhesive to the threads of the stud bolts.
Adhesive:
1324 or equivalent
HINT:
Apply Three Bond to stud bolts A before installing
them.
(c) Install the stud bolts.
Upper Side: Exhaust Side:

B
EM
B B
A A
A
17.7 mm (0.70 in.) B
18.5 mm (0.73 in.)

69.95 mm (2.75 in.) 51 mm (2.01 in.)
11 mm (0.43 in.)
11.25 mm (0.44 in.)
A163506E01
Torque: Bolt A
25 N*m (255 kgf*cm, 18 ft.*lbf)
Bolt B
47 N*m (479 kgf*cm, 35 ft.*lbf)
REASSEMBLY
1. INSTALL STUD BOLT (See page EM-31)
2. INSTALL TIGHT PLUG (See page EM-30)
3. INSTALL VALVE SEAT (See page EM-29)
4. INSTALL VALVE GUIDE BUSH (See page EM-30)
5. INSTALL VALVE STEM OIL (See page EM-29)
6. INSTALL VALVE
HINT:
If parts are reused, be sure to install them to their original
position.
(a) Install the spring seat and a new oil seal.

SST (b) Apply engine oil to the valve stem. Then insert them
into the valve guide installed in the cylinder head.
(c) Install the valve, the inner and outer springs and
spring retainer.
(d) Using SST, press-fit the spring retainer, then
securely fit the 2 keepers.
SST 09202-70020 (09202-00030)
A155712E01
NOTICE:
• Be sure to apply engine oil to the contact
surface of the parts before the assembly.
• Be sure to place each valve in its original
position.
• When the valve spring is compressed, be
careful that the upper seat will not damage to EM
the stem seal.
• Since this valve spring is evenly pitched, it
A155725 can be installed with either end up.
REPAIR
1. REPAIR VALVE SEAT
(a) Grind the valve and seat.
HINT:
• Grinding of valves should only be performed
when hand-lapping does not result in proper
seating.
• When hand-lapping always recheck the seating
condition.
CAUTION:
When grinding, a metal tip may fly off on impact.
Valve seat angle
Item Valve seat angle
Intake 29° 00' to 30° 00'
30° 45° Exhaust 44° 00' to 45° 15'
Valve face angle

Item Valve face angle
A155829E01 Intake 29° 45' to 30° 15'
Exhaust 44° 45' to 45° 15'
(b) Hand-lap the valve and valve seat.

(1) Lightly apply lapping compound to the valve
face.
Tap and rotate the valve against the seat.
HINT:
• After hand-lapping, clean off any lapping
compound on the valves and valve seats.
• When hand-lapping, always recheck the
seating condition.
A155714
EM–34 W04D-J, TM, TN ENGINE MECHANICAL – CYLINDER BLOCK
CYLINDER BLOCK
ENGINE
COMPONENTS
TIGHT PLUG
STRAIGHT PIN
CYLINDER LINER TIGHT PLUG
STRAIGHT PIN
TIGHT PLUG
CAMSHAFT BEARING
TIGHT PLUG
OIL PUMP
EM COVER BUSH
CYLINDER BLOCK
STRAIGHT PIN
HOLE PLUG OIL PIPE SUB-ASSEMBLY CRANKSHAFT
BEARING SET
O-RING
x4
PISTON RING (1ST) 22 (220, 16)
x4
PISTON RING PISTON RING (2ND)
SET CRANKSHAFT
PISTON RING (OIL) THRUST WASHER
PISTON
PISTON PIN HOLE SNAP RING
PISTON PIN CONNECTING ROD SUB-ASSEMBLY
CONNECTING ROD 123 (1250, 90)

SMALL END BUSH COLLAR
CONNECTING ROD BEARING x8
CONNECTING ROD CAP CRANKSHAFT
KEY
CRANKSHAFT BEARING CAP
x 10
Non-reusable part
147 (1500, 109)
Precoated part
A163317E01
W04D-J, TM, TN ENGINE MECHANICAL – CYLINDER BLOCK EM–35
DISASSEMBLY
1. REMOVE PISTON AND CONNECTING ROD
(a) Remove the connecting rod bearing cap mounting
bolts and pull out the pistons along with the
connecting rods from the cylinder block upper side.
HINT:
• Before pulling out the pistons, remove carbon
deposits from the upper end inside the cylinder
A151525
liner with a scraper or an emery paper
(recommended: No. 150), working in a circular
direction.
• When pulling out the pistons, be careful that the
insides of the cylinder liners are not damaged by
the connecting rod big ends.
• When pulling out the pistons, be careful not to
drop the connecting rod bearings from the
connecting rod big ends, which may cause EM
deformation or damage.
• Arrange the removed parts in order of the
cylinder numbers. Be careful not to change the
combination of the connecting rod and cap.
• 2 pistons can be removed at a time (Nos. 1 and
4, Nos. 2 and 3).
2. REMOVE CONNECTING ROD BEARING
(a) Remove the connecting rod bearings.
HINT:
Arrange the removed parts in the correct order.
3. REMOVE CYLINDER LINER
(a) Before removing the cylinder liner, put matchmarks
on the cylinder liner and cylinder block.
HINT:
Before removing the piston, put matchmarks on the
cylinder liner and cylinder is bent by "run-in". When
Matchmark
reusing the cylinder liner, misalignment with the
cylinder block may concentrate stress on the thin
part of the cylinder liner and it may break.
A155767E01
4. REMOVE CRANKSHAFT BEARING SET

(a) Remove the bearing cap mounting bolts.
Turn Clockwise
A155765E01
(b) Remove the crankshaft.

(c) Remove the 5 upper main bearings from the
cylinder block.
HINT:
Arrange the bearings in the correct order.
(d) Remove the 5 lower main bearings from the 5 main
bearing caps.
HINT:
Arrange the bearings in the correct order.
A155766 (e) Remove the crankshaft thrust washers.
5. REMOVE PISTON RING SET

(a) Using a piston ring expander, remove the piston
ring.
HINT:
• Handle the piston rings carefully because they
EM are made of a special casting which is easily
broken.
• Arrange the piston rings in the order of the
cylinder numbers.
A155770
6. REMOVE CONNECTING ROD SUB-ASSEMBLY

(a) Using snap ring pliers, remove the retainer rings
from both ends of the piston pin.
CAUTION:
Removing the retainer rings may cause the
retainer rings to fly up. Be sure to wear
protective goggles.
(b) Using a hammer, apply the reinforcing plate to the
piston pin and punch out the piston pin.
A155769 HINT:
If it is difficult to punch out the piston pin, first
immerse the piston and piston pin in hot water (80 to
90°C (176 to 194°F)) for approximately 5 minutes to
facilitate removal.
CAUTION:
Never touch the piston with your bare hands
when it is hot.
7. REMOVE CONNECTING ROD SMALL END BUSH
(See page EM-48)
8. REMOVE CAMSHAFT BEARING (See page EM-50)
9. REMOVE OIL PIPE SUB-ASSEMBLY
(a) Remove the 4 check valves and 4 oil pipes.
10. REMOVE TIGHT PLUG (See page EM-50)
11. REMOVE STRAIGHT PIN (See page EM-51)
12. REMOVE HOLE PLUG (See page EM-52)
13. REMOVE OIL PUMP COVER BUSH (See page EM-52)
A163621
INSPECTION
1. INSPECT CONNECTING ROD THRUST CLEARANCE
(a) Install the connecting rod cap (See page EM-58).
between the connecting rod and crankshaft pin end
surface.
0.20 to 0.52 mm (0.0079 to 0.0205 in.)
0.60 mm (0.0236 in.)
replace the connecting rod.
A155808
2. INSPECT CONNECTING ROD BOLT

(a) Measure the length of the bolts.
EM
Standard length (A):
59.00 mm (2.3228 in.)
Maximum length (A):
A 60.00 mm (2.3622 in.)
them with new bolts.
(b) Apply clean engine oil to the nut seat surface and
A153702E01 bolt thread of the connecting rod cap.
3. CLEAN CYLINDER BLOCK
(a) Rinse the cylinder block in a hot commercial alkaline
solution, and remove oil from the cylinder block.
(b) Remove the alkaline solution from the cylinder block
using a steam cleaner.
(c) If the water jacket is dirty, clean it as follows.
(1) Rinse the cylinder block in a commercial acid
solution.
(2) After rinsing the cylinder block for a while,
immerse it in the solution for approximately 30
minutes.
(3) Pull out the cylinder block. After the solution
has drained off, re-immerse the cylinder block
in the solution and leave it for approximately 10
minutes.
(4) Repeat step 3 until deposits are removed.
(5) Remove the acid solution with hot water.
(6) Immerse the cylinder block in the alkaline
solution to neutralize the acid.
(7) Finish by cleaning with a steam cleaner.
(d) When the cooling water passage and oil passage
are cleaned completely, dry the cylinder block,
press-fit a new blank cap and apply seal packing.
4. INSPECT CRANKSHAFT THRUST CLEARANCE
(a) Install the main bearing cap (See page EM-55).
(b) Using a dial gauge, measure the crankshaft thrust

clearance.
0.05 to 0.22 mm (0.0020 to 0.0087 in.)
0.40 mm (0.0157 in.)
replace the thrust bearing.
A155797
5. INSPECT CYLINDER BLOCK

(a) Remove the water gallery plug, and visually check
the condition of the worn hole.
If the wear is excessive, replace the part with a new
one. Also inspect the inside of the cylinder block,
EM and clean the cylinder block main body with a
commercial cleaning agent as required.
(b) Check the cylinder for cracks.
Check the cylinder block for cracks and perform the
dye penetrant test.
If any cracks are found, replace the cylinder block
with a new one.
E F G (c) Check the flatness of the cylinder block upper
B A
surface.
C C
Using a straight edge and feeler gauge, measure
the warpage of the surfaces contacting the cylinder
head.
D D Standard warpage:
A E F G B 0.05 mm (0.0020 in.) or less
Maximum warpage:
A155785E01 0.10 mm (0.0039 in.)
the cylinder block with a new one.
6. INSPECT PISTON AND CYLINDER LINER
HINT:
Before the measurement, remove carbon deposits from
the upper end inside the cylinder liner with a scraper or
an emery paper (recommended: No. 150), working in a
circular direction.
Make sure that there is no scratches inside the cylinder
liner.
A151525
(a) Using a micrometer, measure the piston diameter at

the points in the illustration.
Standard piston diameter:
103.908 mm (4.0909 in.)
Minimum piston diameter:
103.902 mm (4.0906 in.)
If the piston diameter is less than the minimum,
Diameter
15 mm EM
(0.59 in.)
A155778E01
(b) Using a cylinder gauge, measure the cylinder liner

inside diameter at the 4 points in the piston boss
and thrust direction, as shown in the illustration.
104.003 to 104.018 mm (4.0946 to 4.0952 in.)
Maximum inside diameter:
104.15 mm (4.1004 in.)
replace the cylinder liner with a new one.
HINT:
• Apply the value measured at the most worn point
to the cylinder liner inside diameter.
• If the cylinder liner is heavily worn or if only the
piston ring must be replaced, correct the
corrugation at the top of the cylinder liner.
(c) Subtract the piston diameter measurement from the
80 mm (3.15 in.) cylinder liner inside diameter measurement.
0.0140 to 0.0172 mm (0.0006 to 0.0007 in.)
If the clearance is greater than the standard, replace
A155779E01 the cylinder liner and/or piston with a new one.
HINT:
Apply the value measured at the most worn point to
the cylinder liner inside diameter.
7. INSPECT PISTON RING AND PISTON RING GROOVE

(a) Insert the piston ring into the piston ring groove.
A155781

between the piston ring and piston ring groove.
Standard groove clearance
Item Groove clearance
EM 2nd 0.07 to 0.11 mm (0.0028 to 0.0043 in.)
Oil 0.02 to 0.06 mm (0.0008 to 0.0024 in.)
Maximum groove clearance:

A151530 0.30 mm (0.0118 in.)
measure the width of the piston ring and piston ring
groove individually and replace any parts that do not
meet the limit with new ones.
Standard groove width
Item Groove width
2nd 2.06 to 2.08 mm (0.0811 to 0.0819 in.)
Oil 4.01 to 4.03 mm (0.1579 to 0.1587 in.)

Item Groove width
2nd 2.20 mm (0.0866 in.)
Oil 4.08 mm (0.1606 in.)
Standard ring thickness

Item Ring thickness
2nd 1.97 to 1.99 mm (0.0776 to 0.0783 in.)
Oil 4.97 to 4.99 mm (0.1957 to 0.1965 in.)

Item Groove width
2nd 1.82 mm (0.0717 in.)
Oil 4.95 mm (0.1949 in.)
8. INSPECT PISTON RING END GAP

(a) Fit the piston ring into the cylinder liner.
(b) Using a feeler gauge, measure the end gap of the
piston ring matching point.
Standard end gap
Item Ring thickness
1st 0.30 to 0.42 mm (0.0118 to 0.0165 in.)
2nd 0.50 to 0.65 mm (0.0197 to 0.0255 in.)
Oil 0.15 to 0.30 mm (0.0059 to 0.0118 in.)
A155782
Maximum end gap

Item Groove width
1st 1.2 mm (0.0472 in.)
2nd 1.2 mm (0.0472 in.)
Oil 1.0 mm (0.0394 in.)
If the end gap is greater than the maximum, replace EM

the piston ring with a new one.
9. INSPECT CONNECTING ROD SMALL END BUSH
(a) Using a cylinder gauge, measure the connecting rod
bush inside diameter.
37.035 to 37.045 mm (1.4581 to 1.4585 in.)
37.10 mm (1.4606 in.)
replace the connecting rod bush with a new one.
A155775 (b) Subtract the diameter measurement of the piston
connecting rod bush.
0.035 to 0.056 mm (0.0014 to 0.0022 in.)
0.08 mm (0.0031 in.)
10. INSPECT PISTON PIN
(a) Using a micrometer, measure the piston pin
diameter.
Standard piston pin diameter:
36.989 to 37.000 mm (1.4563 to 1.4567 in.)
Minimum piston pin diameter:
36.96 mm (1.4551 in.)
piston pin with a new one.
A155774 HINT:
Never grind the piston pin because the surface is
coated with a special material.
11. INSPECT PISTON PIN BOSS

(a) Using a cylinder gauge, measure the piston pin
boss inside diameter.
Standard piston pin boss inside diameter:
36.987 to 37.003 mm (1.4562 to 1.4568 in.)
Maximum piston pin boss inside diameter:
37.05 mm (1.4587 in.)
If the piston pin boss inside diameter is greater than
90° the maximum, replace the piston with a new one.
A155780E01 (b) Subtract the diameter measurement of the piston
piston pin boss.
0.013 (T) to 0.014 (L) mm (0.00051 (T) to
0.00055 (L) in.)
EM 0.05 mm (0.0020 in.)
HINT:
T = tightening allowance, L = clearance
replace the piston or piston pin.
12. INSPECT CONNECTING ROD SUB-ASSEMBLY
(a) After tightening the connecting rod cap without
bearing, using a cylinder gauge, measure the inside
diameter of the connecting rod big end to calculate
the roundness.
Standard big end inside diameter (without
Bearing):
65.985 to 66.000 mm (2.5978 to 2.5984 in.)
Maximum big end inside diameter (without
Bearing):
66.06 mm (2.6008 in.)
HINT:
For tightening of the connecting rod cap, see step
29.
A155776
(b) Using dye penetrant test or magnetic test, check the

connecting rod for cracks or damage.
If there are any cracks or damage, replace the
connecting rod with a new one.
A155771
(c) Check that there is no clogging in the lubrication

passage to the connecting rod small end.
If there is any clogging, blow air through the
lubrication passage using an air gun, or clean by
inserting a wire.
A153798
(d) Using a rod aligner and feeler gauge, check the

connecting rod alignment.
(1) Check for bend.
Maximum bend:
0.10 mm (0.0039 in.) per 200 mm (7.87 in.)
If the bend is greater than the maximum, EM
replace the connecting rod with a new one.
A155772
(2) Check for twist.

Maximum twist:
0.10 mm (0.0039 in.) per 200 mm (7.87 in.)
If the twist is greater than the maximum,
replace the connecting rod with a new one.
13. INSPECT CRANKSHAFT
HINT:
Before the inspection, clean the crankshaft with a
commercial cleaning agent and clean the lubrication
A155773
passage using an air gun.
(a) Performing the dye penetrant test, and check the
crankshaft for cracks.
Air Gun HINT:
Pay special attention to the finished R section and
oil hole of the crankshaft journal and crankshaft pin.
(b) Visually check the condition of the crankshaft
journal and pin for damage or wear.
If any damages are found, replace the crankshaft
with a new one.
A151539E01
(c) Inspect for bend.

(2) Using a dial gauge, measure the bend of the
crankshaft at the center journal.
Maximum bend:
0.04 mm (0.0016 in.)
If the bend is greater than the maximum,
replace the crankshaft with a new one.
A155783
14. INSPECT CRANKSHAFT BEARING CAP

(a) After tightening the main bearing caps without
bearing, using a cylinder gauge, measure the bore
diameter of the main bearing caps to calculate the
roundness.
Standard bore diameter (without Bearing):
77.985 to 78.000 mm (3.0703 to 3.0709 in.)
Maximum bore diameter (without Bearing):
78.20 mm (3.0787 in.)
If the bore diameter is greater than the maximum,
carry out boring after overlay welding or replace the
cylinder block with a new one.
HINT:
45° 45° • When installing the main bearing caps, make
sure to return them to the original position
XYZ according to the number stamped on the caps.
EM The main bearing caps together with the cylinder
block are round.
• For tightening of the main bearing caps, see step
23.
A151547E01
15. INSPECT CRANKSHAFT JOURNAL AND BEARING

(a) Using a micrometer, measure the main journal
outside diameter.
Standard journal diameter:
72.94 to 72.96 mm (2.8716 to 2.8724 in.)
Minimum journal diameter
Item Journal diameter
Repair 72.74 mm (2.8638 in.)
Use 71.76 mm (2.8252 in.)
If the diameter is less than the minimum for use,

X
X replace the crankshaft with a new one.
Y
Y Y
X
Y
A155784E01
(b) After installing and tightening the bearing caps,

using a cylinder gauge, measure the bearing inside
diameter.
Standard bearing inside diameter:
73.000 mm (2.8740 in.)
Maximum bearing inside diameter:
73.30 mm (2.8858 in.)
replace the bearing with a new one.
HINT:
• When installing the bearing caps, make sure to
return them to the original position according to
the number stamped on the caps. The bearing
45° 45° caps together with the cylinder block are round.
• For tightening of the bearing cap, see step 23.
XYZ (c) Subtract the crankshaft journal diameter
measurement from the bearing inside diameter EM
measurement.
0.039 to 0.090 mm (0.0015 to 0.0035 in.)
A151547E01 Maximum oil clearance:
0.13 mm (0.0051 in.)
HINT:
Undersize machining dimension: 4 sizes below
• 0.25 mm (0.0098 in.)
• 0.50 mm (0.0197 in.)
• 0.75 mm (0.0295 in.)
• 1.00 mm (0.0394 in.)
replace the bearing with a correct one.
HINT:
• Make sure to replace the top and bottom main
bearings as one set. The top and bottom main
bearings must be round.
R • Machined dimension of filet R
Main crankshaft journal:
3.00 to 3.50 mm (0.1181 to 0.1378 in.)
CORRECT WRONG
A151550E02
16. INSPECT CRANKSHAFT PIN AND BEARING

(a) Using a micrometer, measure the crankshaft pin
diameter.
Standard pin diameter:
61.940 to 61.960 mm (2.4386 to 2.4394 in.)
Minimum pin diameter:
60.76 mm (2.3921 in.)
Y Y
X
EM
A155777E01
(b) Using a cylinder gauge, measure the connecting rod

big end inside diameter.
Standard big end inside diameter (with Bearing):
61.985 to 62.000 mm (2.4403 to 2.4409 in.)
Maximum big end inside diameter (with
Bearing):
62.06 mm (2.4433 in.)
(c) Subtract the diameter measurement of the
crankshaft pin from the inside diameter
measurement of the connecting rod big end.
Standard clearance:
0.031 to 0.082 mm (0.0012 to 0.0032 in.)
Maximum clearance:
0.12 mm (0.0047 in.)
replace the connecting rod bearing with the correct
one.
HINT:
Undersize machining dimension: 4 sizes below
• 0.25 mm (0.0098 in.)
A151552 • 0.50 mm (0.0197 in.)
• 0.75 mm (0.0295 in.)
• 1.00 mm (0.0394 in.)
HINT:
Machined dimension of filet R
Crankshaft pin:
3.50 to 4.00 mm (0.1378 to 0.1575 in.)
R
CORRECT WRONG
A151550E02
17. INSPECT CRANKSHAFT BEARING CAP SET BOLT

(a) Measure the length of the bearing cap bolts.
94.00 mm (3.7008 in.)
Maximum length (A):
95.20 mm (3.7480 in.) EM
A
them with new bolts.
(b) Apply clean engine oil to the bolt seat and bolt
A153807E01 threads.
18. INSPECT PROTRUSION OF CYLINDER LINER

SST (a) Install SST onto the cylinder block.
SST S0942-01460
(b) Tighten the center bolt to the specified torque below
to set the cylinder liner in the normal installation
condition.
A155792E01
(c) Using a dial gauge, measure the protrusion of the

Pressure: 4903 N (500 kgf, 1100 lbf) cylinder liner.
Standard protrusion:
Protrusion 0.01 to 0.08 mm (0.0004 to 0.0031 in.)
Maximum protrusion:
0.08 mm (0.0031 in.)
replace the cylinder liner.
A151678E02
19. INSPECT OIL PIPE SUB-ASSEMBLY

(a) Using a wooden stick, push the valve and check if it
is stuck.
If stuck, replace the check valve.
A163622
20. INSPECT OIL CHECK VALVE SUB-ASSEMBLY

(a) Check the oil jet for damage or clogging.
If necessary, replace the oil jet.
A163623
REPLACEMENT
Guide 1. REPLACE CONNECTING ROD SMALL END BUSH
(a) Prepare SST.
Wing Nut
SST S0940-21450, S0948-11130, S9233-10360
EM by inserting its pin into the guide, then secure
HINT:
Press Sub-assembly • Bring the lever W punched on the guide
A153799E01
above the pin.
• Make sure to align both supporting surfaces
of the guide and press sub-assembly flatly
on a plane.
(b) Using SST, remove the bush.
(1) Set the connecting rod assembled without
Connecting Rod
crankshaft pin bore bearing on the guide and
press sub-assembly.

A151536E01
(2) Using SST, install the spindle into the bush.

SST S0940-21460
HINT:
Groove Spindle
Align the groove of the spindle with the oil hole
of the bush.
Bush
Connecting
Oil Hole Rod
Press Sub-assembly
A151537E01
(3) Using a press, remove the bush.

Press
HINT:
Spindle Always operate the press slowly and smoothly.
Connecting Rod
A153802E01
(c) Assemble the bush.

C (1) Uniformly chamfer one edge of the bush hole at
the small end of the connecting rod by C (0.5 to
1.0 mm (0.0196 to 0.0393 in.)).
HINT:
Irregular chamfering can cause out-of- EM
roundness of the pressed bush, which may
result in jamming during the insertion. Remove
Connecting Rod dust from the inner surface of the smaller hole.
A155786E01
(d) Mount the bush on the spindle.

Spindle SST S0940-21460, S0948-11140, S9191-08252
(1) Set the bush and guide on the spindle, then
Groove secure them with the bolt.
Oil Hole (B) Torque: 6.0 N*m (60 kgf*cm, 52 in.*lbf)
Bush
HINT:
Bush Align oil hole (A) in the bush with both groove
Oil Hole (A) or the spindle and guide, and make sure that oil
Guide Bolt Guide hole (B) will meet with oil path in the connecting
A155787E01 rod led from the big end bore in the rod.
(2) Apply fresh engine oil around the bush and

Press Spindle
guide.
Groove (e) Install the bush in the connecting rod. Position the
Oil Hole
bush tool assembly so that the oil hole (B) aligns
with the oil path through the connecting rod.
HINT:
Before installing, fully coat the bore in the
connecting rod with fresh engine oil.
Connecting Rod
A155788E01
(f) Inspect the bush position after the installation.

(1) Make sure that the oil hole of the bush and the
oil path of the connecting rod are suitably
aligned allowing a 3 mm (0.12 in.) diameter rod
to penetrate.
HINT:
Misalignment can lead to insufficient
lubrication, which may result in seizure.
(2) With a new piston pin inserted in the piston pin,
A155789 make sure that the bush can be rotated by
hand without rattling.
(g) Check that there is no clogging in the lubrication

passage to the connecting rod small end. If there is
any clogging, blow air through the lubrication
passage using an air gun, or clean by inserting a
wire.
A153798
2. REPLACE CAMSHAFT BEARING

Front (a) Using SST, remove the bearings.
SST 09215-00013 (09215-00461)
No. 1 No. 2 No. 3
HINT:
• Pull out the No. 1 bearing toward the front.
EM • Pull out the No. 2 bearing toward the front.
• Pull out the No. 3 bearing toward the rear.
SST
A153821E01
(b) Using SST, install new bearings.

(1) No. 3 bearing only:
Align the oil holes of the bearing with the oil
holes of the cylinder block.
No. 3
No. 2
No. 1
A155758E01
(2) Using SST, install the bearings.

Front SST 09215-00013 (09215-00461)
HINT:
No. 1 No. 2 No. 3
• Push in the No. 3 bearing from the rear.
• Push in the No. 2 bearing from the front.
• Push in the No. 1 bearing from the front.
(c) Recheck the camshaft oil clearance (See page EM-
107).
3. REPLACE TIGHT PLUG
A153823E01
NOTICE:
If water leaks from the tight plug or the plug
corrodes, replace it.
(a) Remove the tight plugs.
(b) Apply adhesive around 16 new tight plugs.
NOTICE:
Do not apply Three Bond to the 4 tight plugs on
the lower side.
Adhesive:
1324 or equivalent
(c) Install the tight plugs to the cylinder block as shown

Front Side: Rear Side: LH Side:
EM
RH Side: Upper Side:

0.5 to 1.0 mm
(0.020 to 0.039 in.)
A163508E01
4. REPLACE STRAIGHT PIN

NOTICE:
It is not necessary to remove a straight pin unless it
is being replaced.
(a) Remove the straight pins.
(b) Using a plastic-faced hammer, install 7 new straight

pins.
Front Side: Rear Side: Upper Side:
A B D D
EM
8 mm (0.32 in.) 12 mm (0.47 in.) 8 mm (0.32 in.)
5 mm (0.20 in.)
16 mm
24 mm (0.95 in.) 24 mm (0.95 in.) 10 mm (0.39 in.) (0.63 in.)
C D
A B
Install the straight pin until the pin

reaches the bottom of the hole
A163507E01
5. REPLACE HOLE PLUG

NOTICE:
It is not necessary to remove a hole plug unless it is
being replaced.
(a) Remove the hole plug and O-ring.
(b) Install a new O-ring and hole plug to the cylinder
block as shown in the illustration.
6. REPLACE OIL PUMP COVER BUSH
NOTICE:
It is not necessary to remove a hole plug unless it is
being replaced.
(a) Remove the oil pump cover bush.
A163509
(b) Install the oil pump cover bush to the cylinder block
as shown in the illustration.
REASSEMBLY
1. INSTALL OIL PUMP COVER BUSH (See page EM-52)
2. INSTALL HOLE PLUG (See page EM-52)
3. INSTALL STRAIGHT PIN (See page EM-51)
4. INSTALL TIGHT PLUG (See page EM-50)
28 mm
(1.10 in.)
EM
A163510E01
5. ADJUST OIL PIPE SUB-ASSEMBLY

(a) Align the pin of the jet with the pin hole of the
Oil Jet cylinder block.
(b) Using SST, install the jet with SST.
SST S9001-24262
SST
(c) Connect a commercial oil pump (hydraulic pressure:
2 kgf/cm2 (28 psi.)) to SST using a hose.
Oil Hose
A163624E02
(d) Set SST on the cylinder block upper surface against

the dowel pin.
SST SST S0944-41630
Cylinder Block
A163625E01
(e) Start the oil pump, let the engine oil spray out the oil
jet to check that the center of the jet flow is within
the φ 7 mm (φ 0.27 in.) reference line of the gauge
Spray Target as well as to judge whether the jet flow is normal as
NOTICE:
• Use new engine oil.
• Engine oil is flammable.
INCORRECT CORRECT • This spray test should be performed in a well
ventilated room and away from any open
Spray Pattern flames or electric sparks.
If the center of the jet flow is out of the φ 7 mm (φ
0.27 in.) reference line of the gauge, adjust the jet
Spray
sight using SST.
EM 1 2 3 4
Oil Jet
INCORRECT
A163626E01
(f) Remove the checking bolt after the inspection.

SST S0947-21620
6. INSTALL OIL PIPE SUB-ASSEMBLY
(a) Align the pin of the jet with the pin hole of the
SST cylinder block.
(b) Install the jet with the check valve.
NOTICE:
• Always install the soft washer.
A163627E01
• When installing the piston, make sure that the
oil jet is not struck by the piston when at
bottom dead center.
7. INSTALL CAMSHAFT BEARING (See page EM-50)
8. INSTALL CONNECTING ROD SMALL END BUSH
(See page EM-48)
9. INSTALL CONNECTING ROD SUB-ASSEMBLY
φ 5 mm Gap (a) Install a new retainer ring onto one end of the piston
boss.
HINT:
Installing the retainer ring may cause it to fly up. Be
Alignment sure to wear protective goggles.
Mark (b) Immerse the piston in hot water (80 to 90°C (176 to
194°F)) for approximately 5 minutes.
(c) Assemble the piston with the φ 5 mm (0.20 in.) gap
A155798E01 being opposite to the connecting rod alignment
mark.
CAUTION:
Never touch the piston with your bare hands
while it is hot.
(d) Insert the piston pin into the piston.

HINT:
Insert the piston pin from the piston boss attached
to the retainer ring so that the ring groove is not
damaged.
(e) Install a new retainer ring to the other end of the
piston boss.
CAUTION:
Installing the retainer ring may cause it to fly up.
A155799 Be sure to wear protective goggles.
HINT:
• When using an oversized piston, hone the liner
so that the clearance between the cylinder liner
and the piston becomes the standard value.
• Prevent parts from damage by wrapping them in
a cloth while they are being installed onto the
cylinder block. EM
10. INSTALL PISTON RING SET
Identification Mark (a) Facing the identification marks on the piston ring
upper surface, using a piston ring expander, install
them in the order of the oil ring, 2nd ring and 1st
ring.
HINT:
• Never change the combination of the coil and oil
Ring Upper Face ring.
• Connect the joint of the coil expander for the oil
Oil Ring ring and install it inside the piston ring. Assemble
1st Ring 2nd Ring
the ring with the joint 180° opposite to the
matching point of the ring.
Joint
Gap
A155800E01
11. INSTALL CRANKSHAFT BEARING SET

(a) Install the main bearings onto the cylinder block and
main bearing caps.
HINT:
• When reusing a bearing, make sure to
• Install the bearing with the oil hole on the block
side and install the bearing without the oil hole on
A155793 the cap side.
• Match the bearing protrusion with the notch of
the block or cap.
• After the installation, apply engine oil to the
journal surfaces of the bearings.
(b) Install the thrust washers onto the 4 points of the

No. 2 journal of the cylinder block and either side of
the bearing caps.
A155794
EM (c) Install the crankshaft onto the cylinder block.

HINT:
• When reusing a bearing, make sure to
• Install the thrust washers with the groove side
(front) toward the crankshaft arm and with the
part number stamp (back) toward the main
bearing cap or cylinder block.
A155766 • Apply engine oil or grease to the back of the
bearing to prevent looseness during the
installation.
• Fit the bearing to the mounting groove of the
block and cap side.
(d) Install the bearing cap.
Arrow Mark HINT:
Facing the arrow mark stamped on the cap forward,
install it in the order of the stamped numbers.
Timing Gear Side

A155795E01
(1) Measure the length of the bearing cap bolts.

94.00 mm (3.7008 in.)
Maximum length (A):
95.20 mm (3.7480 in.)
If the length is greater than the maximum,
A
replace them with new bolts.
(2) Apply clean engine oil to the bolt seat and bolt
threads.
A153807E01
(3) Tighten the bolts in the order shown in the

illustration.
Tightening order:
3-2-4-1-5
HINT:
When adding torque, never untighten the nuts
even if they have been over-tightened.
(4) After tightening, using a plastic-faced hammer,
A155796 tap the front and back ends of the crankshaft to
make a complete fit.
(5) Check the crankshaft thrust clearance (See
page EM-37).
12. INSTALL CYLINDER LINER
(a) Install the cylinder liner.
HINT:
• When assembling the cylinder liner with the EM
cylinder block, clearance can be set to three
levels.
• When using a new cylinder liner, the upper
surface and side surface of the cylinder block are
Position of Mark A, B or C
stamped A, B or C.
Insert a matching cylinder liner having the same
symbol.
Position of
Mark A, B or C
A155790E01
(b) Align the marks of the cylinder liner and cylinder

block.
HINT:
Matchmark When reusing a cylinder liner, install it according to
the matchmarks made during the removal. The
cylinder liner is bent by "run-in". When reusing the
cylinder liner, misalignment with the cylinder block
may concentrate stress on the thin part of the
cylinder liner and it may be broken.
A155791E01 (c) Check the protrusion of the cylinder liner (See page
EM-47).
13. INSTALL CONNECTING ROD BEARING

(a) Install the connecting rod bearing to the connecting
rod and bearing cap.
NOTICE:
• When reusing the bearing, make sure to
• Install the bearing with the oil hole on the
connecting rod side and install the bearing
A155802 without the oil hole on the cap side.
• Match the bearing protrusion with the notch
of the connecting rod or cap.
(b) Position the piston rings so that the ring ends are as
Oil Ring φ 5 mm Gap shown in the illustration.
HINT:
Position the matching points of the piston ring at an
EM even distance. Be careful not to position at the
1st Ring piston boss.
2nd Ring
A155801E01
14. INSTALL PISTON AND CONNECTING ROD

(a) Using a piston ring compressor and a hammer
handle, insert the piston through the connecting rod
assembly into the cylinder block.
A155803
HINT:
• Before the installation, apply engine oil to the
piston pin, piston ring, cylinder liner and
connecting rod bearing.
• Recheck the matching point of each piston ring.
A155804
• Make sure that the φ 5 mm (0.20 in.) gap on the

piston is at the tappet chamber side.
• Do not damage the inside of the liner.
φ 5 mm Gap
Tappet Chamber
A155805E01
(b) Install the connecting rod cap.
A155806
(c) Tighten the connecting rod nut in the order shown in

the illustration to the specified torque below.
(1) Tighten the connecting rod nuts 1 and 2
temporarily, dividing into small amount.
HINT: EM
When adding torque, never untighten the nuts
even if they have been over-tightened.
1 2
(2) Check the connecting rod thrust clearance
A155807E01 (See page EM-37).
EM–60 W04D-J, TM, TN ENGINE MECHANICAL – ENGINE FRONT OIL SEAL

ENGINE
COMPONENTS
EM
CRANKSHAFT PULLEY
SPACER
515 (5250, 380)

Non-reusable part
MP grease
A156048E01
REMOVAL
HINT:
(See chapter CO)
spacer and pulley.
HINT:
crankshaft.
A151470
W04D-J, TM, TN ENGINE MECHANICAL – ENGINE FRONT OIL SEAL EM–61

Protective Tape
A161494E01
INSTALLATION
SST 09950-60020 (09951-00750), 09950-70010
(09951-07100)
(a) Using SST and a hammer, tap in the oil seal to the EM
timing gear case so that oil seal is flush with the
timing gear edge.
NOTICE:
SST
A161497E01

HINT:
pulley.
HINT:
crankshaft.
HINT:
(See chapter CO)
EM–62 W04D-J, TM, TN ENGINE MECHANICAL – ENGINE REAR OIL SEAL

ENGINE
COMPONENTS
REAR ENGINE OIL SEAL
186 (1900, 137)
EM x6
N*m (kgf*cm, ft.*lbf): Specified torque

Non-reusable part
MP grease
A156047E01
REMOVAL
HINT:
• for M550 (See chapter MT)
• for MYY6S (See chapter MT)
CL)
CL)
4. REMOVE FLYWHEEL SUB-ASSEMBLY (See page
EM-103)
W04D-J, TM, TN ENGINE MECHANICAL – ENGINE REAR OIL SEAL EM–63
5. REMOVE REAR ENGINE OIL SEAL

Cut Position ಾᢿ▎ᚲ
(a) Using a knife, cut off the lip of the oil seal.
Tape
଻⼔࠹࡯ࡊ A101645E01
SST INSTALLATION
4 mm 1. INSTALL REAR ENGINE OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal until
flywheel housing.
SST 09223-78010 EM
NOTICE:
A101646E01
matter.
2. INSTALL FLYWHEEL SUB-ASSEMBLY (See page EM-
111)
CL)
HINT:
• for M550 (See chapter MT)
• for MYY6S (See chapter MT)
EM–64 W04D-J, TM, TN ENGINE MECHANICAL – ENGINE ASSEMBLY
ENGINE ASSEMBLY
ENGINE
COMPONENTS
for Standard Body: for Wide Body: for Standard Body: for Wide Body:
12 (120, 9)
12 (120, 9)
12 (120, 9)
12 (120, 9)
EM ENGINE SIDE COVER SUB-ASSEMBLY RH

27 (275, 20)
VACUUM RESERVOIR SUB-ASSEMBLY x4

120 (1224, 89)
x4
120 (1224, 89)
NO. 3 CAB MOUNTING BRACKET SUB-ASSEMBLY
for Standard Body: for Wide Body: for Standard Body: for Wide Body:
12 (120, 9)
12 (120, 9) 12 (120, 9)
12 (120, 9)
ENGINE SIDE COVER SUB-ASSEMBLY LH

FENDER SIDE APRON SUB-ASSEMBLY LH
A165252E01
W04D-J, TM, TN ENGINE MECHANICAL – ENGINE ASSEMBLY EM–65
for Standard Body: (W04D-TM, TN)
NO. 1 AIR HOSE
EM
CLAMP
x2
18 (184, 13)
CLAMP
NO. 2 INTAKE PIPE
NO. 2 AIR HOSE

CLAMP
CLAMP
x4 NO. 4 AIR HOSE
7.5 (77, 66 in.*lbf)

CLAMP
NO. 3 INTAKE PIPE
x2
18 (184, 13)
NO. 3 AIR HOSE
EXHAUST RETARDER
GASKET ASSEMBLY
FRONT EXHAUST PIPE ASSEMBLY 25 (259, 19)
x3
x4
70 (714, 52)
Non-reusable part GASKET

A161540E012
for Wide Body: (W04D-TN)
NO. 1 AIR HOSE
EM
18 (184, 13)
CLAMP
NO. 2 INTAKE PIPE
CLAMP
NO. 2 AIR HOSE CLAMP
CLAMP INTERCOOLER ASSEMBLY
NO. 4 AIR HOSE

x4 CLAMP
NO. 3 INTAKE PIPE
7.5 (77, 66 in.*lbf)
18 (184, 13)
NO. 3 AIR HOSE
EXHAUST RETARDER
GASKET ASSEMBLY
x3
x4
70 (714, 52)
GASKET
Non-reusable part
A161541E012
for Standard Body: (W04D-TM, TN)

29 (291, 21)
x4
FAN PULLEY
FAN

CLAMP
CLAMP
EM
NO. 1 RADIATOR
SUPPORT FAN SHROUD ASSEMBLY
CLAMP
RADIATOR HOSE INLET
18 (184, 13)
18 (184, 13)
18 (184, 13)
7.5 (77, 66 in.*lbf)
x3 CLAMP
NO. 3 RADIATOR BRACKET x4
7.5 (77, 66 in.*lbf)

NO. 1 RADIATOR BRACKET x4
18 (184, 13)
x3
18 (184, 13)
7.5 (77, 66 in.*lbf) RADIATOR ASSEMBLY NO. 2 RADIATOR BRACKET

RADIATOR AIR GUIDE

A165251E012
for Wide Body: with out Fan Clutch: with Fan Clutch:
(W04D-TN)
29 (291, 21) 29 (291, 21)
x4 x4
FAN PULLEY FAN PULLEY
FAN FAN
CLAMP
CLAMP
EM
NO. 3 RADIATOR BRACKET RADIATOR HOSE INLET

CLAMP
FAN SHROUD ASSEMBLY
18 (184, 13)
18 (184, 13)
x3 x3
NO. 1 RADIATOR CLAMP

BRACKET
18 (184, 13) x4
18 (184, 13) 7.5 (77, 66 in.*lbf)
x3 NO. 4 RADIATOR BRACKET

RADIATOR SUPPORT LH
x3
RADIATOR ASSEMBLY 18 (184, 13)
18 (184, 13)
RADIATOR SUPPORT LH
A161543E012
(W04D-TM, TN) for Wide Body:

AIR HOSE ASSEMBLY
CLAMP
29 (291, 21) CLAMP
x2
18 (184, 13)
x2 x2
for Standard Body:

CLAMP
CLAMP
AIR CLEANER PIPE EM

CLAMP
GENERATOR BELT 47 (479, 34)
ADJUSTING BAR
AIR HOSE ASSEMBLY
125 (1275, 92)

FUEL HOSE
47 (479, 34)
GENERATOR ASSEMBLY 154 (1570, 114)
FR ENGINE MOUNTING BRACKET RH

STARTER ASSEMBLY
x4
41 (418, 30)
21 (215, 16)
98 (1000, 72)
FR ENGINE MOUNTING BRACKET LH
98 (1000, 72)
ENGINE MOUNTING
ENGINE MOUNTING
98 (1000, 72) STABILIZER
STABILIZER
x4
41 (418, 30)
FR ENGINE MOUNTING
FR ENGINE MOUNTING 41 (418, 30) INSULATOR
INSULATOR
98 (1000, 72)
A161539E012
GASKET
VENTILATION PIPE SUB-ASSEMBLY
20 (200, 15)
GASKET
GASKET
20 (200, 15)
GASKET
DIESEL FUEL FILTER

ASSEMBLY
25 (250, 18)
EM 29 (291, 21)
29 (291, 21) x2
GASKET
NO. 3 FUEL PIPE GASKET
25 (250, 18)
NO. 4 FUEL PIPE
20 (200, 15)
GASKET x2
GASKET
17 (173, 13) 29 (290, 21)
PIPE NO. 2 FUEL PIPE
GASKET 17 (170, 13)

29 (291, 21)
GASKET
20 (200, 15)
GASKET
PIPE
20 (200, 15) 29 (291, 21) x2

60 (612, 44)
GASKET
29 (291, 21)
INJECTION OR SUPPLY PUMP ASSEMBLY 17 (170, 13)
GASKET
29 (291, 21)
N*m (kgf*cm, ft.*lbf) : Specified torque NO. 1 FUEL PIPE
29 (291, 21)
Non-reusable part
A156052E01
29 (291, 21)
x4
12 (122, 9) x2
x2
NO. 1 NOZZLE LEAKAGE PIPE x2
x2 x2
GASKET
x4 x2
x2 x2
15 (153, 11)
NOZZLE HOLDER AND 17 (173, 13) INJECTION PIPE

NOZZLE SET SUB-ASSEMBLY
EM
34 (347, 25)
OIL LEVEL GAUGE
29 (291, 21)
N*m (kgf*cm, ft.*lbf) : Specified torque OIL LEVEL GAUGE GUIDE
Non-reusable part O-RING
A165230E01
(W04D-TM, TN) 25 (250, 18)
OIL PIPE
GASKET
25 (250, 18)
25 (250, 18)
GASKET
GASKET
TURBOCHARGER
COOLANT PIPE SUB-ASSEMBLY
25 (250, 18)
GASKET
GASKET
EM 25 (250, 18)
GASKET GASKET
29 (291, 21)
29 (291, 21)
25 (250, 18) x2 OIL PIPE
29 (291 21)
COOLANT PIPE
GASKET
GASKET
Non-reusable part
A156055E012
(W04D-TM, TN) WATER OUTLET SUB-ASSEMBLY

GROMMET
x3
25 (250, 18)
51 (520, 38)
1.3 (13, 12 in.*lbf)
GASKET x3
EXHAUST MANIFOLD
THERMOSTAT
GLOW PLUG CONNECTOR
WATER OUTLET
HOUSING 56 (571, 41)
x4
47 (479, 35)
25 (250, 18)
x8 23 (235, 17)
GLOW PLUG ASSEMBLY
x4
GASKET EM
GASKET OIL PRESSIOR GASKET

SWITCH
x 15
29 (291, 21)
OIL COOLER ASSEMBLY

REVOLUTION DETECTOR
ASSEMBLY
29 (291, 21)
x2
GASKET
INTAKE MANIFOLD
x7
29 (290, 21)
29 (291, 21)
WATER PUMP ASSEMBLY x2

GASKET
x8
x4
29 (291, 21)
29 (291, 21)
NO. 2 INTAKE MANIFOLD
Non-reusable part
A165245E012
(W04D-TM)
OIL PUMP TO
GEAR BOX TUBE
EM
29 (296, 21)
O-RING
x2
55 (561, 41)
VANE PUMP
ASSEMBLY
29 (296, 21)
O-RING
GASKET
29 (296, 21)
49 (499, 36) x2 POWER STEERING SUCTION

PORT UNION
7.6 (78, 67 in.*lbf)
Non-reusable part
Power steering fluid

C153692E012
(W04D-TN)
OIL PUMP TO
GEAR BOX TUBE
EM
O-RING
29 (296, 21)
x2 VANE PUMP
ASSEMBLY
55 (561, 41)
29 (296, 21)
GASKET
29 (296, 21)
O-RING
49 (499, 36)
POWER STEERING
SUCTION PORT
x2 UNION
29 (296, 21)
Non-reusable part
Power steering fluid
C156391E012
EXAMPLE, with Air Conditioning System: (W04D-J, TM)
IDLER PULLEY BRACKET
x3
69 (700, 51)
EM
x6
32 (320, 23)
CRANKSHAFT PULLEY ASSEMBLY
x2
69 (700, 51)
69 (700, 51)
x2
NO. 1 COMPRESSOR
MOUNTING BRACKET
25 (255, 18)
x4
A165244E012
ACCELERATOR FLEXIBLE WIRE ASSEMBLY
PIN
CLIP
x2
18 (184, 13)
7.5 (77, 66 in.*lbf) CLUTCH DISC ASSEMBLY
EM
x8
43 (440, 32)
Non-reusable part
A165250E01
(W04D-TM)
75 (760, 55)
x4
x4
x4
EM
75 (760, 55)
C162780E022
EXAMPLE.
2 Joint Type (Propeller shaft): (W04D-TN)
75 (760, 55)
x4
x4
75 (760, 55)
EM
3 Joint Type (Propeller shaft): (W04D-TN)
75 (760, 55)
x4
x4
75 (760, 55)
C162781E012
EXAMPLE,
3 Joint Type (Intermediate shaft): (W04D-TN)
x4
for M550: 75 (760, 55)
75 (760, 55)
for MYY6S: 103 (1050, 76)

x4
EM
x4
x4
52 (525, 38)
C162599E042
for MYY6S : (W04D-TN) 18 (184, 13)

x2
WIRE HARNESS
28 (280, 20)
TRANSMISSION CONTROL
SHIFT CABLE
103 (1050, 76)
x3
x3
SELECT CABLE
NO. 1 ENGINE
MOUNTING BRACKET 103 (1050, 76)
x3 x3 EM
64 (653, 47) 289 (2947, 213)
39 (400, 29)
MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT
DRAIN PLUG
43 (440, 32)
COMPANION FLANGE O-RING
GASKET
39 (400, 29)
FILLER PLUG GASKET x 12 PARKING BRAKE PLATE
SUB-ASSEMBLY
x4 8.2 (84, 73 in.*lbf)

127 (1290, 93)
PARKING BRAKE
DUST COVER
PARKING BRAKE
DRUM SUB-ASSEMBLY
27 (275, 20)
12 (120, 9)
Clutch spline grease CLUTCH RELEASE CYLINDER ASSEMBLY

C162782E012
for M550: (W04D-TM, TN) WIRE HARNESS

CLIP 28 (280, 20)
57 (585, 42)
CLIP
x4
SHIFT AND SELECT TRANSMISSION CONTROL CABLE 64 (653, 47)
NO. 3 ENGINE
37 (377, 27) NO. 1 TRANSMISSION MOUNTING BRACKET
57 (585, 42)
CONTROL CABLE BRACKET x4
x3 127 (1300, 94)
EM MANUAL TRANSMISSION
OUTPUT SHAFT REAR SET
NUT
37 (380, 27) 43 (440, 32)
FILLER PLUG
GASKET
MANUAL TRANSMISSION
ASSEMBLY
x 12
O-RING
PARKING BRAKE DRUM

SUB-ASSEMBLY
x4
GASKET 95 (964, 70)

PARKING BRAKE
37 (380, 27) PLATE SUB-ASSEMBLY
DRAIN PLUG
27 (275, 20)
12 (120, 9)
Non-reusable part
x2
CLUTCH RELEASE CYLINDER ASSEMBLY
MP grease
C162783E022
REMOVAL
TERMINAL
(a) Remove the bolt and 3 nuts.
(b) Remove the radiator reserve tank assembly.
9. REMOVE FENDER SIDE APRON SUB-ASSEMBLY RH EM
ASSEMBLY
(a) Remove the 8 bolts and No. 3 cab mounting
bracket.
(a) Loosen the 2 hose clamps and remove the air hose
assembly.
A152861 (a) Loosen the 2 hose clamps.
(b) Remove the 2 bolts and air hose assembly.
14. REMOVE AIR CLEANER PIPE
(b) Loosen the hose clamp and remove the air cleaner
pipe.
(a) Loosen the 2 hose clamps and remove the No. 1 air
hose.
(a) Loosen the 2 hose clamps and remove the No. 4 air
hose.
17. DISCONNECT ACCELERATOR FLEXIBLE WIRE
ASSEMBLY
(a) Remove the bolt, clip, holed pin, and accelerator
flexible wire assembly.
18. REMOVE NO. 1 V (W04D-J, TN, COOLER
COMPRESSOR TO CRANKSHAFT PULLEY) BELT (w/
19. REMOVE FAN
(a) Remove the 4 nuts.
(b) Remove the fan and fan spacer. (w/o fan clutch)
(c) Remove the fan and fan clutch. (w/ fan clutch)
20. REMOVE FAN PULLEY

(a) Remove the fan pulley.
(b) Remove the fan and generator V belt.
(a) Disconnect the radiator inlet hose.
(a) Disconnect the radiator outlet hose.
23. DISCONNECT NO. 3 AIR HOSE
24. DISCONNECT NO. 2 AIR HOSE
HINT:
(See chapter IT)
26. REMOVE NO. 3 INTAKE PIPE (for Wide Body) (See
chapter CO)
EM
27. REMOVE NO. 2 INTAKE PIPE (for Wide Body) (See
chapter CO)
28. REMOVE NO. 1 RADIATOR SUPPORT (for Standard
Body) (See chapter CO)
29. SEPARATE NO. 3 RADIATOR BRACKET (for
Standard Body) (See chapter CO)
30. SEPARATE NO. 3 RADIATOR BRACKET (for Wide
Standard Body) (See chapter CO)
32. SEPARATE NO. 4 RADIATOR BRACKET (for Wide
33. DISCONNECT HEATER HOSE
(a) Disconnect the heater hose.
35. DISCONNECT POWER STEERING SUCTION PORT
36. DISCONNECT OIL PUMP TO GEAR BOX TUBE (See
chapter PS)
(W04D-J, TN, w/ Air Conditioning System)
(b) Remove the 4 bolts and separate the compressor
and magnetic clutch.
HINT:
Secure the compressor and hoses off to the side
instead of discharging the A/C system.
39. REMOVE STARTER ASSEMBLY (See chapter ST)
A165256
40. REMOVE EXHAUST RETARDER ASSEMBLY


chapter EX)
42. DISCONNECT PROPELLER SHAFT ASSEMBLY
(W04D-TM)
(a) Place matchmarks on the propeller shaft flange and
Matchmark differential.
(b) Remove the 4 nuts, 4 bolts and 4 washers.
(c) Separate the propeller shaft from the differential
carrier.
HINT:
• Engage the parking brake.
C152531E01 • When the flange connection is difficult to
separate, temporarily install one nut and evenly
tap the propeller shaft flange part with a brass
bar and hammer to separate.
(d) Place matchmarks on the propeller shaft flange and
parking brake drum. EM
(e) Remove the 4 nuts and 4 washers.
(f) Slide the slide yoke towards the rear of the vehicle
and remove the propeller shaft assembly.
HINT:
Matchmark When the flange connection is difficult to separate,
temporarily install one nut and evenly tap the
propeller shaft flange part with a brass bar and
C152789E01 hammer to separate.
43. REMOVE PROPELLER SHAFT ASSEMBLY
HINT:
(See chapter PR)
ASSEMBLY (for M550) (See chapter MT)
ASSEMBLY (for MYY6S) (See chapter MT)
46. DISCONNECT FUEL HOSE
47. DISCONNECT WIRE HARNESS
(a) Disconnect the wire harness.
48. DISCONNECT SHIFT AND SELECT TRANSMISSION
CONTROL CABLE (for M550) (See chapter MT)
CABLE (for MYY6S) (See chapter MT)
A153056

REAR SET NUT (for M550) (See chapter MT)
REAR SET NUT (for MYY6S) (See chapter MT)
(for M550) (See chapter MT)

(for MYY6S) (See chapter MT)
ASSEMBLY (for M550) (See chapter MT)
ASSEMBLY (for MYY6S) (See chapter MT)
57. SUPPORT TRANSMISSION ASSEMBLY (for M550)
(See chapter MT)
58. SUPPORT TRANSMISSION ASSEMBLY (for MYY6S)
(See chapter MT)
EM
(a) Attach the sling device and the engine with the
chain block.
64. REMOVE MANUAL TRANSMISSION ASSEMBLY (for
M550) (See chapter MT)
65. REMOVE MANUAL TRANSMISSION ASSEMBLY (for
MYY6S) (See chapter MT)
A161519
CL)
CL)
68. REMOVE ENGINE ASSEMBLY
(a) Remove the 2 nuts and engine from the engine
mounting brackets.
(b) Remove the engine hanger.
69. REMOVE VANE PUMP ASSEMBLY (See chapter PS)
chapter FU)
chapter FU)

(See chapter FU)
77. REMOVE FAN BELT ADJUSTING BAR
(a) Remove the 4 bolts and No. 1 compressor mounting
bracket.
A165247
79. REMOVE IDLER PULLEY BRACKET (W04D-J, TN, w/

Air Conditioning System)
(a) Remove the 3 bolts and idler pulley bracket.
EM
(a) Remove the 3 bolts and alternator bracket.
ASSEMBLY (See chapter LU)
82. REMOVE OIL COOLER ASSEMBLY (See chapter LU)
A165248
83. REMOVE WATER OUTLET SUB-ASSEMBLY

(a) Remove the 3 bolts and water outlet sub-assembly.
84. REMOVE THERMOSTAT
(a) Remove the thermostat from the water outlet
housing.
(b) Remove the gasket from the thermostat.
A161536
85. REMOVE WATER OUTLET HOUSING

(a) Remove the 7 bolts and water by-pass pipe sub-
assembly.
CO)
87. REMOVE REVOLUTION DETECTOR ASSEMBLY (w/
Tachometer)
(a) Remove the 2 bolts and revolution detector
A161537 assembly.
HINT:
(See chapter IT)

(a) Remove the 8 nuts and exhaust manifold.
A161518
90. REMOVE INTAKE MANIFOLD

(a) Remove the 8 bolts, 2 nuts, and intake manifold.
Nut Nut
EM
A161516E01
INSTALLATION
1. INSPECT INTAKE MANIFOLD
HINT:
Clean the intake manifold with a commercial cleaning
agent before the inspection.
(a) Using a dye penetrant, check the intake manifold for
cracks.
If cracks are found, replace the manifold.
A161524
(b) Using a precision straight edge and feeler gauge,

measure the surface contacting the cylinder head
for warpage.
Maximum warpage:
0.20 mm (0.0079 in.)
the intake manifold.
(c) Visually check the seal surface of the intake
manifold for deformation or wear.
A161525 If damage such as deformation and wear is
excessive, replace the manifold.
2. INSPECT EXHAUST MANIFOLD
HINT:
Clean the exhaust manifold with a commercial cleaning
agent before the inspection.
(a) Using a dye penetrate, check the exhaust manifold

for cracks.
If cracks are found, replace the manifold.
A161527
(b) Using a precision straight edge and feeler gauge,

measure the surface contacting the cylinder head
for warpage.
Maximum warpage:
0.20 mm (0.0079 in.)
If the warpage is greater than the maximum, correct EM
the exhaust manifold by grinding it so that the
warpage is within 0.1 mm (0.004 in.) per 2 flanges
or 0.1 mm (0.004 in.) per flange.
A161528 If damage such as deformation and wear is
excessive, replace the manifold.
3. INSTALL INTAKE MANIFOLD
(a) Apply a continuous bead of seal packing (width: 1.5
illustration.
Seal packing:
NOTICE:
Seal Packing • Remove any oil from the contact surface.
A161517E01 • Install the timing chain cover within 3
minutes, and tighten the bolts within 15 of
(b) Install the intake manifold with the 8 bolts and 2
nuts.
4. INSTALL OIL COOLER ASSEMBLY (See chapter LU)
ASSEMBLY (See chapter LU)
(a) Install 4 new gaskets onto the exhaust manifold.
(b) Install the manifold with the 8 bolts. Uniformly,
tighten the 8 nuts in the order shown in the
illustration.
8 4 2 6
HINT:
7 3 1 5 (See chapter IT)
A165257E01 (See chapter FU)
9. INSTALL REVOLUTION DETECTOR ASSEMBLY (w/

Tachometer)
(a) Install the revolution detector assembly with the 2
bolts.
CO)
11. INSTALL WATER OUTLET HOUSING
(a) Apply seal packing to the water outlet housing and
install it onto the cylinder head within 20 minutes.
Seal packing:
Toyota Genuine Seal Packing, Three Bond
1282B or equivalent
Coating width:
1.5 to 2.5 mm (0.059 to 0.098 in.)
EM HINT:
• If more than 20 minutes have passed since the
seal packing is applied, do not assemble the
parts. After removing the seal packing
completely, reapply it to assemble them.
• Do not start the engine for 2 hours after the
installation.
(b) Tighten the 4 side ones of the water outlet housing
mounting bolts.
(c) Tighten the 3 upper ones of the water outlet housing
bolts.
12. INSTALL WATER TEMPERATURE SENDER GAUGE
ASSEMBLY
(a) Install the water temperature sender gauge
A161537
assembly with a new gasket.
13. INSTALL THERMOSTAT
(a) Install a new gasket to the thermostat.
(b) Install the thermostat with the jiggle valve upward.
A163487
14. INSTALL WATER OUTLET SUB-ASSEMBLY

bolts.
A161536
16. INSTALL IDLER PULLEY BRACKET (W04D-J, TN, w/

Air Conditioning System)
(a) Install the idler pulley bracket with the 3 bolts.
EM
A165248

(a) Install the No. 1 compressor mounting bracket with
the 4 bolts.
18. INSTALL FAN BELT ADJUSTING BAR
19. INSTALL DIESEL FUEL FILTER ASSEMBLY (See
chapter FU)
A165247
chapter FU)
24. INSTALL OIL LEVEL GAUGE GUIDE
(a) Install the oil level gauge guide with a new O-ring.
25. INSTALL VANE PUMP ASSEMBLY (See chapter PS)
28. INSTALL ENGINE ASSEMBLY
(b) Install the engine to the engine mounting brackets

with the 2 nuts.
(c) Remove the engine hanger.
CL)
31. INSTALL MANUAL TRANSMISSION ASSEMBLY (for
A161519
32. INSTALL MANUAL TRANSMISSION ASSEMBLY (for
33. INSTALL NO. 1 ENGINE MOUNTING BRACKET (for
EM MYY6S) (See chapter MT)
REAR SET NUT (for M550) (See chapter MT)
REAR SET NUT (for MYY6S) (See chapter MT)
43. INSTALL SHIFT AND SELECT TRANSMISSION
CONTROL CABLE (for M550) (See chapter MT)
44. INSTALL TRANSMISSION CONTROL SHIFT CABLE
45. INSTALL TRANSMISSION CONTROL SELECT
46. INSTALL WIRE HARNESS
(a) Install the wire harness.
47. CONNECT FUEL HOSE

(a) Connect the 2 fuel hoses.
A153056
50. INSTALL PROPELLER SHAFT ASSEMBLY (W04D-

TM)
(a) Align the matchmarks on the propeller shaft flange
and parking brake drum down or flange.
(b) Install the 4 nuts and 4 washers.
Torque: 75 N*m (760 kgf*cm, 55 ft.*lbf) EM
Matchmark
C152789E01
(c) Align the matchmarks on the yoke and differential

flange.
(d) Install the 4 bolts, 4 washers and 4 nuts.
Matchmark Torque: 75 N*m (760 kgf*cm, 55 ft.*lbf)
51. INSTALL PROPELLER SHAFT ASSEMBLY
HINT:
(See chapter PR)
C152531E01 chapter EX)
53. INSTALL EXHAUST RETARDER ASSEMBLY
(W04D-J, TN, w/ Air Conditioning System)
(a) Install the compressor and magnetic clutch with the
4 bolts.
57. CONNECT OIL PUMP TO GEAR BOX TUBE (See
A165256 chapter PS)
59. CONNECT HEATER HOSE
(a) Connect the heater hose.
60. CONNECT OIL PUMP TO GEAR BOX TUBE (W04D-
TM, See chapter PS)
UNION (W04D-TM, See chapter PS)

63. INSTALL NO. 4 RADIATOR BRACKET (for Standard
64. INSTALL NO. 4 RADIATOR BRACKET (for Wide
66. INSTALL NO. 3 RADIATOR BRACKET (for Wide
67. INSTALL NO. 1 RADIATOR SUPPORT (for Standard
68. INSTALL NO. 3 INTAKE PIPE (for Wide Body) (See
chapter CO)
EM 69. INSTALL NO. 2 INTAKE PIPE (for Wide Body) (See
chapter CO)
HINT:
(See chapter IT)
71. CONNECT NO. 2 AIR HOSE
72. CONNECT NO. 3 AIR HOSE
(a) Install the radiator hose outlet.
75. INSTALL FAN PULLEY
(a) Install the fan pulley.
76. INSTALL FAN
(a) Install the fan and fan spacer temporarily with the 4
nuts. (w/o fan clutch)
(b) Install the fan and fan clutch temporarily with the 4
nuts. (w/ fan clutch)
(c) Install the fan and generator V belt.
(d) Holding the V belt, tighten the 4 nuts completely to
install the fan pulley and fan spacer properly. (w/o
fan clutch)
(e) Holding the V belt, tighten the 4 nuts completely to
install the fan pulley and fan clutch properly. (w/ fan
clutch)
EM-7)

80. CONNECT ACCELERATOR FLEXIBLE WIRE
ASSEMBLY
(a) Connect the accelerator flexible wire assembly, bolt,
hold pin and clip.
(a) Install the No. 4 air hose.
(b) Tighten the 2 air hose clamps.
(b) Tighten the 2 air hose clamps.
83. INSTALL AIR CLEANER PIPE
(a) Install the air cleaner pipe with the 4 bolts.
EM
(b) Tighten the air cleaner pipe clamp.
(a) Install the air hose assembly.
(b) Tighten the 2 hose clamps.
85. INSTALL AIR HOSE ASSEMBLY (for Wide Body)
(a) Install the air hose assembly.
(b) Tighten the 2 hose clamps and 2 bolts.
ASSEMBLY
(a) Install the No. 3 cab mounting bracket with the 8
bolts.
A152861

(a) Install the radiator reserve tank assembly with the
bolt and 3 nuts.
97. BLEED FUEL LINE
98. BLEED POWER STEERING SYSTEM
99. INSPECT POWER STEERING FLUID LEVEL

EM
W04D-J, TM, TN ENGINE MECHANICAL – ENGINE UNIT EM–97
ENGINE UNIT
ENGINE
COMPONENTS
25 (250, 18)
x6
x5
OIL FILLER CAP
SUB-ASSEMBLY
EM
x 13
1st: 59 (600, 43)
2nd: turn 90°
3rd: turn 90°
CYLINDER HEAD
GASKET SET BOLT
59 (600, 43) x4
CYLINDER HEAD CYLINDER HEAD
ADDITIONAL BOLT SUB-ASSEMBLY
Non-reusable part
A155836E01
EM–98 W04D-J, TM, TN ENGINE MECHANICAL – ENGINE UNIT
COLLAR
VALVE ROCKER ARM ASSEMBLY
1st: 59 (600, 43) 44 (450, 32)

VALVE ROCKER SUPPORT
2nd: turn 90°
3rd: turn 90°

x5
EM
VALVE ROCKER SHAFT
VALVE ADJUSTING SCREW x8
PUSH ROD x8
VALVE LIFTER
x8
A155837E01
CAMSHAFT TIMING GEAR
NO. 1 IDLE GEAR
INJECTION PUMP DRIVE GEAR
REAR END PLATE
CAMSHAFT
25 (250, 18)
OIL PUMP DRIVE
GEAR
x2
CRANKSHAFT TIMING GEAR
OIL PUMP DRIVE GEAR
EM
GASKET
GASKET
OIL PUMP ASSEMBLY
x5 THRUST PLATE
TIMING GEAR COVER 29 (291, 21) x2

ASSEMBLY
INJECTION PUMP
DRIVE GEAR
137 (1400, 101) BUSH

29 (291, 21) NO. 1 IDLE GEAR
x 12 CRANKSHAFT TIMING GEAR

TIMING CHAIN COVER
OIL SEAL NO. 1 IDLE GEAR SHAFT
O-RING
29 (291, 21) RETAINER RING
x3 BALL BEARING
BEARING HOLDER CASE
Non-reusable part
A165762E01
CRANKSHAFT PULLEY
INPUT SHAFT BEARING
SPACER
515 (5250, 380) 186 (1900, 137)

x6
DUST COVER 29 (291, 21) FLYWHEEL
SUB-ASSEMBLY
x2
FLYWHEEL RING GEAR
29 (291, 21)
EM REAR ENGINE OIL SEAL
29 (291, 21)
SEAT PLATE
118 (1200, 87)
O-RING
FLYWHEEL HOUSING
O-RING
OIL STRAINER
SUB-ASSEMBLY
29 (291, 21)
OIL PAN SUB-

29 (291, 21)
ASSEMBLY
SOFT WASHER
x 26
29 (291, 21)
DRAIN PLUG
Non-reusable part
A165227E01
DISASSEMBLY
(See page EM-21)
3. REMOVE VALVE ROCKER ARM ASSEMBLY
2 4 3 1
5 4 2
(a) Loosen the cylinder head additional bolts and rocker
1 3
arm support bolts in the order as shown in the
illustration.
A155709E01
4. REMOVE CYLINDER HEAD SUB-ASSEMBLY EM

Exhaust Side (a) Loosen the cylinder head bolts little in 3 stages, in
the order as shown in the illustration.
* * *
*
3 7 11 18 6 2
15 14 10
12 16 17
4 8
13 9 1
5
Intake Side
A155710E01
(b) Lift the cylinder head from the dowels on the

cylinder block, and place the cylinder head on
wooden blocks on a bench.
Pry
If the cylinder head is difficult to be lifted, insert a
screwdriver between the cylinder head and block to
pry it up.
NOTICE:
Cylinder Block
Be careful not to damage the contact surfaces
between the cylinder head and block.
A155711E01
(c) Using a gasket scraper, remove all the gasket

material from the cylinder block contact surface.
NOTICE:
Be careful not to scratch the cylinder block
contact surface.
(d) Using a wire brush, remove all the carbons from the
combustion chambers.
5. REMOVE VALVE LIFTER
(a) Remove the valve lifters.
A155713
HINT:
Arrange the valve lifters in the correct order.
6. REMOVE BEARING HOLDER CASE

(a) Remove the 3 bolts, O-ring and bearing holder
case.
(b) Remove the retainer ring and bearing.
7. REMOVE CRANKSHAFT PULLEY (See page EM-60)
8. REMOVE OIL PAN SUB-ASSEMBLY (See page EM-
14)
9. REMOVE OIL STRAINER SUB-ASSEMBLY
A163314
(a) Remove the 3 bolts, O-ring and oil strainer.
10. REMOVE TIMING GEAR COVER ASSEMBLY (See
page EM-15)
11. REMOVE TIMING CHAIN COVER OIL SEAL (See
page EM-109)
EM (a) Using a sliding hammer, drive out the idle gear
shaft.
A155747
13. REMOVE CAMSHAFT

Seal Plate (a) Remove the 2 bolts, seal plate and O-ring.
A155757E01
(b) Remove the thrust plate set bolts, and pull out the
camshaft together with the gear.
NOTICE:
Pull out the camshaft by slowly turning it, so as
not to damage the bearings.
14. REMOVE OIL PUMP ASSEMBLY (See chapter LU)
15. REMOVE CRANKSHAFT TIMING GEAR
16. REMOVE INPUT SHAFT BEARING (See page EM-
A155748
109)
17. REMOVE REAR ENGINE OIL SEAL (See page EM-
109)

(a) Remove the flywheel mounting bolts.
(b) Hold a copper rod through the starter hole against
the flywheel, and strike the rod lightly with a
hammer to remove the flywheel from the crankshaft
while rotating the crankshaft.
NOTICE:
The flywheel is heavy. When removing, be
A155732
19. REMOVE FLYWHEEL HOUSING EM

(a) Remove the rear mounting bolts of the flywheel
housing.
(b) Using a plastic-faced hammer, remove the flywheel
housing by striking it lightly.
CAUTION:
The flywheel housing is heavy. When removing,
be careful not to drop it on your feet.
A155733
20. REMOVE FLYWHEEL RING GEAR

(a) Using a torch, heat the ring gear evenly to about
200°C (392°F).
(b) Using a metal rod as a pad, uniformly strike all
around the ring gear in a uniform manner and
remove the gear.
CAUTION:
A155737
INSPECTION
1. INSPECT OIL CLEARANCE BETWEEN VALVE
ROCKER ARM AND SHAFT
diameter of the rocker arm bush.
19.020 to 19.045 mm (0.7488 to 0.7498 in.)
A155834
19.06 mm (0.7504 in.)
replace the bush.
HINT:
When installing a bush into the rocker arm, align the
bush with the oil holes of the rocker arm.
(b) Using a micrometer, measure the outside diameter

of the rocker arm shaft.
18.966 to 18.984 mm (0.7467 to 0.7474 in.)
18.95 mm (0.7461 in.)
rocker arm.
(c) Subtract the diameter measurement of the rocker
A153679 arm shaft from the inside diameter measurement of
the rocker arm bush.
0.036 to 0.079 mm (0.0014 to 0.0031 in.)
0.10 mm (0.0039 in.)
EM replace the rocker arm bush.
2. INSPECT OTHER VALVE SYSTEM PARTS
(a) Visually check the contact condition between the
rocker arm and valve bridge.
Replace the rocker arm and the valve bridge if
damage such as wear and scratches is excessive. If
there is only a minimal amount of wear, correct the
surface with a resurfacer.
A155723
(b) Visually check the adjusting screw and push rod.

HINT:
Replace the adjusting screw if damage such as
wear and scratches is excessive.
A155724
3. INSPECT OIL CLEARANCE BETWEEN VALVE

LIFTER AND LIFTER BORE
(a) Using a micrometer, measure the lifter diameter.
Standard lifter diameter:
26.95 to 26.97 mm (1.0610 to 1.0618 in.)
A155721
(b) Using a cylinder gauge, measure the lifter bore

diameter.
Standard lifter bore diameter:
27.00 to 27.02 mm (1.0630 to 1.0638 in.)
(c) Subtract the lifter diameter measurement from the
lifter bore diameter measurement.
0.025 to 0.071 mm (0.0010 to 0.0028 in.)
A155722 0.10 mm (0.0039 in.)
replace the lifter.
(a) Preparation
(1) Measure the length of the M12 head bolts.
Maximum bolt length (A)
Bolt No. Length (A)
EM
A 1 to 13 117.5 mm (4.63 in.)
14 to 18 164.5 mm (6.48 in.)

A153682E01 replace them with new bolts.
(2) Make sure that no dirt or scratch is on the
tightening surface of the cylinder head bolt.
5. INSPECT TIMING GEAR BACKLASH
(a) Using a dial gauge, measure the backlash between
the gears.
Standard backlash
Item Backlash
0.068 to 0.194 mm (0.0027 to 0.0076
Crankshaft timing gear x Idle gear
in.)
0.065 to 0.232 mm (0.0026 to 0.0091
Idle gear x Injection pump drive gear
in.)
A155764 0.068 to 0.194 mm (0.0027 to 0.0076
Idle gear x Oil pump drive gear
in.)
Camshaft timing gear x Oil pump 0.069 to 0.203 mm (0.0027 to 0.0079
drive gear in.)
Maximum backlash:
0.30 mm (0.0118 in.)
replace the gear.
(a) Using a feeler gauge, measure the clearance
between the idle gear and thrust bearing.
0.115 to 0.170 mm (0.0045 to 0.0067 in.)
0.15 mm (0.0059 in.)
replace the thrust bearing.
A155763
7. INSPECT OIL CLEARANCE BETWEEN IDLE GEAR

AND SHAFT
(a) Using a micrometer, measure the diameter of the
idle gear shaft.
49.950 to 49.975 mm (1.9665 to 1.9675 in.)
A155750

diameter of the idle gear bush.
50.000 to 50.025 mm (1.9685 to 1.9695 in.)
(c) Subtract the diameter measurement of the idle gear
EM shaft from the inside diameter measurement of the
isle gear bush.
0.025 to 0.075 mm (0.0010 to 0.0030 in.)
A155751 Maximum oil clearance:
0.10 mm (0.0039 in.)
replace the idle gear shaft or idle gear bush.
8. INSPECT CRANKSHAFT PULLEY
HINT:
• Clean the torsional damper with a commercial
cleaning agent before inspection.
• Use a cleaning agent that does not damage gum.
(a) Check if there are any cracks in the damper rubber
section.
If the cracks are excessive, replace the pulley.
A155734
9. INSPECT FLYWHEEL SUB-ASSEMBLY

(a) Check the friction surface for damage.
(b) Check the friction surface for distortion.
(1) Grinding and replacement should be performed
as necessary.
Maximum deflection:
0.04 mm (0.0016 in.)
Grind limit:
1.00 mm (0.0394 in.)
A155735 If the flywheel is ground over the limit, replace it
with a new one.
10. INSPECT INPUT SHAFT BEARING

(a) Rotate the bearing lightly by hand, and check
whether there is any abnormal noise or clatter and
whether the balls run smoothly.
If there is any fault, replace the pilot bearing.
11. INSPECT FLYWHEEL RING GEAR
(a) Visually check the flywheel ring gear.
If damage such as wear and scratches is excessive,
replace the part.
A155736
12. INSPECT NOZZLE HOLDER AND NOZZLE SET

(a) Install the nozzle to the cylinder head. Using vernier
calipers, measure the protrusion of the nozzle from
the lower surface of the cylinder head.
Standard protrusion (A):
2.55 to 3.05 mm (0.1004 to 0.1201 in.) EM
Maximum protrusion (A):
A Cylinder Head 3.05 mm (0.1201 in.)
A155720E01 replace the nozzle.
13. INSPECT CAMSHAFT

(a) Inspect for bend.
(2) Using a dial gauge, measure the bend of the
crankshaft at the center journal.
Maximum bend:
0.04 mm (0.0016 in.)
If the bend is greater than the maximum,
replace the crankshaft with a new one.
A155755
(b) Inspect the camshaft thrust clearance.

(1) Using a feeler gauge, measure the clearance
between the camshaft and thrust plate.
0.10 to 0.18 mm (0.0039 to 0.0071 in.)
0.30 mm (0.0118 in.)
If the thrust clearance is greater than the
maximum, replace the thrust bearing and/or
A155756 gear.
(c) Visually check the camshaft surface for wear and

scratches.
A155753
(d) Using a micrometer, measure the cam lobe height.

Standard cam lobe height
Item Cam lobe height
Intake 49.435 mm (1.9463 in.)
Exhaust 49.493 mm (1.9485 in.)
Minimum cam lobe height

Item Cam lobe height
Intake 48.90 mm (1.9252 in.)
EM02011
Exhaust 48.95 mm (1.9272 in.)

the camshaft.
(e) Measure the oil clearance of the camshaft journal.
(1) Using a micrometer, measure the journal
diameter of the camshaft.
EM Standard journal diameter
No. 1 56.95 to 56.97 mm (2.2421 to 2.2429 in.)
No. 2 56.75 to 56.77 mm (2.2342 to 2.2350 in.)
No. 3 56.55 to 56.57 mm (2.2264 to 2.2272 in.)
EM02538 Minimum journal diameter

No. 1 56.85 mm (2.2382 in.)
No. 2 56.65 mm (2.2303 in.)
No. 3 56.45 mm (2.2224 in.)
If the diameter is less than the minimum,

replace the camshaft bearing.
(2) Using a cylinder gauge, measure the inside
diameter of the camshaft bearing.
Standard inside diameter
Item Inside diameter
No. 1 57.00 to 57.07 mm (2.2441 to 2.2468 in.)
No. 2 56.80 to 56.87 mm (2.2362 to 2.2390 in.)
No. 3 56.60 to 56.67 mm (2.2283 to 2.2311 in.)

A155754 maximum, replace the camshaft or camshaft
bearing.
(f) Subtract the journal diameter measurement of the
camshaft from the inside diameter measurement of
the camshaft bearing.
(1) Calculate the oil clearance from the above
measurement.
0.030 to 0.120 mm (0.0012 to 0.0047 in.)
0.15 mm (0.0059 in.)
maximum, replace the camshaft or camshaft
bearing.
REPLACEMENT
1. REPLACE REAR ENGINE OIL SEAL
(a) Using a screwdriver, pry out the oil seal.
(b) Apply a small amount of clean engine oil on the
outer periphery of the oil seal.
(c) Using SST and a hammer, tap in oil seal to the
flywheel housing, checking that it is flush with the
SST
end of the flywheel housing.
SST 09223-78010
NOTICE:
Make sure that the lip of the oil seal is coated
with the oil seal lubricating grease (lithium-
based).
2. REPLACE TIMING CHAIN COVER OIL SEAL
A155739E01
(a) Using a screwdriver, pry out the oil seal.
EM
(b) Using SST and a hammer, tap in a new oil seal.
SST 09950-60020 (09951-00750), 09950-70010
(09951-07100)
SST
A155759E01
3. REPLACE INPUT SHAFT BEARING

SST
(a) Using SST, remove the input shaft bearing.
SST 09303-35011
C153744E01
(b) Using SST and a hammer, install a new input shaft

bearing.
SST 09304-12012
HINT:
SST After assembling the input shaft bearing to the hub,
make sure that it rotates smoothly.
C153749E01
REASSEMBLY
Seal Packing
1. INSTALL FLYWHEEL HOUSING
(a) Clean the rear end plate mounting surface of the
flywheel housing.
(b) Apply seal packing to the flywheel housing, then
install it to the rear end plate within 20 minutes.
Seal packing:
A155740E01
Coating width:
1.5 to 2.5 mm (0.059 to 0.098 in.)
If left more than 20 minutes, clean off the seal
packing completely and reapply the seal packing.
NOTICE:
Before installing the flywheel, be sure to tighten
EM the bolt A, apply seal packing to the flywheel
housing, and be sure to assemble the stud bolt
on the block side.
CAUTION:
The flywheel is heavy. When installing, be
2. INSTALL FLYWHEEL RING GEAR
(a) Using a torch, heat the ring gear evenly to about
200°C (392°F).
(b) Using a metal rod, strike the ring gear onto the the
flywheel with its chamfered gear teeth facing the
block.
NOTICE:
A155738

(a) Make sure that there are no burns or dirt on the
contact surface or in the threaded hole of the
SST crankshaft or flywheel.
(b) Insert SST onto the crankshaft.
SST S0948-11340
HINT:
Place one guide bar on one side of the collar knock
and another on the opposite side of the collar knock.
(c) Insert the flywheel slowly until it contacts the collar
knock in order to prevent impact on the guide bar.
CAUTION:
The flywheel is heavy. When installing, be
EM
A155741E01
(d) Apply clean engine oil to the threads of the flywheel

Crankshaft Collar bolt and the flywheel bolt seat. Be sure to tighten 2
1 or 3 threads provisionally by hand. Then, tighten the
5
4 flywheel bolts with a low-torque impact wrench.
3 (e) Pull out the guide bar and tighten the remaining 2
flywheel bolts provisionally as in step (d).
4 (f) Tighten the flywheel bolts in the order shown in the
6 illustration.
2 Torque: 186 N*m (1900 kgf*cm, 137 ft.*lbf)
A155742E01
(g) Measure the sliding surface play of the flywheel.

(1) Using a dial gauge, measure the runout of the
flywheel.
Maximum runout:
0.15 mm (0.0059 in.)
If the runout is greater than the maximum,
resurface the sliding surface.
4. INSTALL REAR ENGINE OIL SEAL (See page EM-
109)
A151495
5. INSTALL INPUT SHAFT BEARING (See page EM-109)

6. INSTALL CRANKSHAFT TIMING GEAR
7. INSTALL OIL PUMP ASSEMBLY (See chapter LU)
8. INSTALL CAMSHAFT
(a) Lubricate all the journals of the camshaft.
(b) Insert the camshaft into the cylinder block.
NOTICE:
Insert the camshaft while slowly turning it so
that the bearing will not be damaged.
(c) Tighten the 2 bolts of the thrust plate.
A155748
(d) Install a new O-ring and the seal plate with the 2
Seal Plate bolts.
EM
A155757E01
9. INSTALL NO. 1 IDLE GEAR SHAFT

(a) Install the idle gear.
HINT:
• Apply engine oil to the contact surface of the idle
gear and idle gear shaft before the installation.
• Be sure that the timing marks of the crankshaft
timing gear, camshaft timing gear, injection pump
drive gear and idle gear are aligned correctly.
A155762
(b) Install the idle gear shaft through the thrust plate so
that the lubrication hole faces downward.
(c) Tighten the mounting bolts of the idle gear shaft.
10. INSTALL TIMING CHAIN COVER OIL SEAL (See page
EM-109)
11. INSTALL TIMING GEAR COVER ASSEMBLY (See
page EM-16)
A163313
12. INSTALL OIL STRAINER SUB-ASSEMBLY
(a) Install a new O-ring and oil pump with the 3 bolts.
13. INSTALL OIL PAN SUB-ASSEMBLY (See page EM-17)
15. INSTALL BEARING HOLDER CASE
(a) Install the bearing and retainer ring to the 2 bearing
holder cases.
(b) Install a new O-ring and bearing holder case with
the 3 bolts.
16. INSTALL VALVE LIFTER

(a) Apply engine oil to the valve lifter face and valve
lifter guide.
(b) Install the valve lifters in the cylinder block in the
correct order.
17. INSTALL VALVE ROCKER ARM ASSEMBLY
No. 5 Support (a) Lubricate the rocker arm shaft and bush.
NOTICE:
Timing Gear Side Confirm that oil hole of the rocker arm assembly
No. 5 support aligns with the shaft oil hole.
Improper installation will result in burning of the
entire valve assembly.
Arrow Mark
Intake Exhaust
Arrow Mark
Oil Hole
EM
Rocker Arm Shaft

No. 5 Support
A155726E01

ARM ASSEMBLY
NOTICE:
Always use a new cylinder head gasket after
cleaning the surface of the cylinder head,
cylinder block and head gasket and keep them
free of all dirt, water and grease.
(b) Install the cylinder head over the dowels on the
A151507 cylinder block.
(c) Insert the push rods in the correct order after

applying engine oil to both ends.
(d) Mount the rocker arm assembly on the cylinder
head, and make sure that the push rods interlock
with the adjusting screws.
NOTICE:
Always loosen the lock nuts, and raise the
adjusting screws fully to the top.
A155727

(a) Preparation
(1) Measure the length of the M12 head bolts.
Maximum bolt length (A)
Bolt No. Length (A)
A 1 to 13 118 mm (4.65 in.)
14 to 18 165 mm (6.50 in.)

A153682E01 replace them with new bolts.
(2) Make sure that no dirt or scratch is on the
tightening surface of the cylinder head bolt.
(3) Apply clean engine oil to the bolt surface and
bolt threads.
HINT:
Since the cylinder head bolts are unique to this
EM engine, do not substitute ordinary bolts for
them.
(b) Tighten the cylinder head bolt.
Exhaust Side (1) Tighten M12 bolts No. 1 to No. 18 in the order
*
*
8
* * Torque: 59 N*m (600 kgf*cm, 43 ft.*lbf)
16 12 4 1
9 17 (2) After tightening bolt No. 18, check the torque
5 13
7 2 again all through the bolts from No. 1 to No. 18.
15 11 6 HINT:
3 10 18
14 When adding torque, never untighten the nuts
even if they have been overtightened.
Intake Side
A157615E01
(3) Mark each cylinder head bolt in the same spot

180° or direction with paint.
(4) Tighten No. 1 to No. 18 cylinder head bolts in
the same sequence as 2. above.
90° 90°
(5) Repeat step 4. above so that each bolt is given
a total of 1/2 a turn (180°) but not to exceed
200°.
(6) Make sure that paint marks are all in the same
direction.
Paint Mark
A163616E01
(7) Make sure that the cylinder head top surface

and the rocker arm support bottom are free of
dust, chips, or other foreign matter.
(8) Apply engine oil to the rocker arm ends and
adjusting screws.
(9) Mount the rocker arm assembly on the cylinder
head; make sure that the push rods interlock
with the adjusting screws.
NOTICE:
A163617 Always loosen the lock nut and raise the
adjusting screws fully to the top. If the
adjusting screws are too low, the piston and
valves may strike each other during valve
clearance adjustment.
(10) Tighten No. 1 to No. 5 cylinder head and rocker

arm support bolts in the order as shown in the
illustration.
5 3 1 2 4
A163618E01
(11) Mark each cylinder head and rocker arm

support bolt in the same spot or direction with
180° paint.
(12) Tighten No. 1 to No. 5 cylinder head and rocker
90° 90° arm support bolts in the same sequence as 10.
above. EM
(13) Repeat step 12. above so that each bolt is
given a total of 1/2 turn (180°) but not to exceed
Paint Mark
200°.
A163619E01 (14) Make sure that paint marks are all in the same
direction.
(15) Tighten the cylinder head additional bolts and
3 1 2 4
5 6 8
rocker arm support bolts little in 3 stages and in
9 7
the numerical order as shown in the illustration.
Torque: Tightening Order 1 to 4
59 N*m (600 kgf*cm, 43 ft.*lbf)
Tightening Order 5 to 9
25 N*m (250 kgf*cm, 18 ft.*lbf)
20. ADJUST VALVE CLEARANCE (See page EM-9)
A155709E02 21. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
(See page EM-23)
ENGINE
FUEL SYSTEM
PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-1
PARTS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-2
SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-3
ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-7
FUEL INJECTOR
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-8
REMOVAL (N04C-TR, TS, TT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-14
REMOVAL (N04C-TU, TV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-16
REMOVAL (N04C-TW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-18
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-20
INSTALLATION (N04C-TR, TS, TT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-20 FU
INSTALLATION (N04C-TU, TV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-24
INSTALLATION (N04C-TW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-27
FUEL SUPPLY PUMP
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-31
REMOVAL (N04C-TW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-41
INSPECTION (N04C-TR, TS, TT, TU, TV) . . . . . . . . . . . . . . . . . . . . . . . FU-43
INSPECTION (N04C-TW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-44
INSTALLATION (N04C-TR, TS, TT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-44
COMMON RAIL
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-56
REMOVAL (N04C-TW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-64
INSPECTION (N04C-TR, TS, TT, TU, TV) . . . . . . . . . . . . . . . . . . . . . . . FU-66
INSPECTION (N04C-TW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-66
FUEL FILTER
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-73
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-76
REPLACEMENT (N04C-TR, TS, TT, TV) . . . . . . . . . . . . . . . . . . . . . . . . FU-76
REPLACEMENT (N04C-TU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-82
REPLACEMENT (N04C-TW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-87
INJECTOR DRIVER
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-92
REMOVAL (N04C-TU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-97
INSTALLATION (N04C-TU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-98
REMOVAL (N04C-TV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-98
INSTALLATION (N04C-TV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-98
REMOVAL (N04C-TW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-99
INSTALLATION (N04C-TW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-100
FUEL TANK
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-101
REMOVAL (N04C-TR, TS, TT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-104
INSTALLATION (N04C-TR, TS, TT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-106
REMOVAL (N04C-TU, TV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-107
INSTALLATION (N04C-TU, TV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-108
REMOVAL (N04C-TW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-110
INSTALLATION (N04C-TW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-112
FU
N04C-TR, TS, TT, TU, TV, TW FUEL – FUEL SYSTEM FU–1
FUEL SYSTEM
PRECAUTION
CAUTION:
• Before inspecting and repairing the fuel system,
disconnect the negative battery cable.
• Do not smoke or work near fire when handling the fuel
system.
HINT:
Keep diesel fuel away from rubber or leather parts.
1. INSPECT FOR FUEL LEAK
(a) Check that there are no fuel leaks anywhere in the
fuel system after completing maintenance (See
page FU-7).
FU
FU–2 N04C-TR, TS, TT, TU, TV, TW FUEL – FUEL SYSTEM
PARTS LOCATION
EXAMPLE
FUEL INJECTOR
COMMON RAIL
FU
FUEL FILTER
FUEL SEDIMENT FILTER
FUEL SUPPLY PUMP
INJECTOR DRIVER
A164962E01
SYSTEM DIAGRAM
• By storing fuel at high-pressure, the common rail system
provides fuel at stable fuel injection pressures.
3 6 24
E26 INJ#4 IJT#1 E27 E22 #1
2 1
I5 Injector No. 4 (*1) 3 23

IJT#2 E27 E22 #2
1
E26 INJ#3
FU
2 1
2 22
I4 Injector No. 3 (*1) IJT#3 E27 E22 #3
2
E26 INJ#2
6 5 21
2 1 IJT#4 E27 E22 #4
E26 COM2
I3 Injector No. 2 (*1)
4
E26 INJ#1 7 25
IJF E27 E22 INJF
5
2 1
E26 COM1
I2 Injector No. 1 (*1)
1 8
E27 GND +B E26
(*1) EDU
(*1)
(*1)
(*1)
*1: Shielded
ECM
A154202E01
5 3
ENG
14
1 2
1 8 E25 IREL
+24V OUT2
DC-DC1 EDU 1
2 5 3
OUT1 E25 +B
ENG
13
D8 DC/DC Converter 2 1
E25 MREL
ENG-3
16
3 5
E25 IGSW
FU
5 8 1 2
HEAD AM2 AM2 IG2
ENG-2
I6 Ignition Switch
29
1 2
E22 THF
F10 Fuel Temperature Sensor
28
1
GND E22 E2
26
2
VP E22 PCR1
18
3
VC E22 VC
F8 Fuel Pressure Sensor
Battery 7
E22 E01
6
E22 E02
Battery 7
E23 E1
ECM
A166555E01
EXAMPLE: N04C-TW
5
2 1
E26 COM1
6 24
I2 Injector No. 1
IJT#1 E27 E22 #1
4
E26 INJ#1
3 23
(*1)
IJT#2 E27 E22 #2
6
2 1
E26 COM2
I3 Injector No. 2 2 22
IJT#3 E27 E22 #3
2
E26 INJ#2
5 21
FU
(*1) IJT#4 E27 E22 #4
1
E26 INJ#3
2 1 7 25
IJF E27 E22 INJF
I4 Injector No. 3 3
E26 INJ#4
8
+B E26
(*1) 1
E27 GND
2 1
EDU
I5 Injector No. 4
7
E22 E01
6
(*1) (*1) E22 E02
(*1)
(*1) 7
(*1) E23 E1
*1 : Shielded ECM
A154556E01
EXAMPLE: N04C-TW
5 3
1 2 14
E25 IREL
EDU
5 3
13
E25 MREL
1 2
E/G MAIN
FU 16
3 5
E25 IGSW
IGN
5 8 1 2
AM2 IG2
IG2
I6 Ignition Switch
AM2 29
1 2
E22 THF
F10 Fuel Temperature Sensor
28
E22 E2
18
3 1
FL MAIN A-GND A-VCC E22 VC
4 6
A-GND A-VCC
26
2 5
PFUEL PFUEL E22 PCR1
Battery
F8 Fuel Pressure Sensor
33
E22 PCR2
Battery
ECM
A154557E01
1. INSPECT FOR FUEL PRESSURE
(a) Read the Data List.
(1) Warm up the engine.
(5) Turn the HINO-DX on.
(6) Select the following menu items: Powertrain /
Engine / Data List.
(7) Read the Data List.
SST S0904-21220 Cable
S0912-11040 Interface Box
Intelligent Tester Display Measurement: Range (Display) Normal Condition
Fuel Press Fuel pressure/Min.: 0 kPa, Max.: 655350 kPa 25000 to 35000 kPa: Idling

(a) Perform the Active Test.
FU
(3) Turn the HINO-DX on.
(4) Select the following menu items: Powertrain /
Engine / Active Test.
(5) Perform the Active Test.
Intelligent Tester Display Test Details Control Range Diagnostic Notes
• Fuel pressure inside common
rail pressurized to specified
Pressurize common rail internal value and engine speed
Test the Fuel Leak fuel pressure, and checks for fuel Stop/Start increased to 2000 rpm when
leaks ON is selected.
• Above conditions preserved
while test is ON.
FU–8 N04C-TR, TS, TT, TU, TV, TW FUEL – FUEL INJECTOR
FUEL INJECTOR
ENGINE
COMPONENTS
29 (291, 21)
29 (291, 21)
x2 x2

18 (184, 13)
FU
EGR VALVE BRACKET

NO. 1 AIR HOSE
29 (291, 21)
x4
x4 x2
VENTURI ASSEMBLY
29 (291, 21)
29 (291, 21)
NO. 4 AIR HOSE
A166450E01
N04C-TR, TS, TT, TU, TV, TW FUEL – FUEL INJECTOR FU–9
69 (699, 51)
GASKET
29 (291, 21) 29 (291, 21)
x2
x2
55 (560, 41)
x2
GASKET
18 (184, 13)
EGR COOLER SUB-ASSEMBLY x2
NO. 2 INTAKE PIPE
NO. 1 AIR HOSE
EGR VALVE BRACKET FU
29 (291, 21)
x4
VENTURI ASSEMBLY 29 (290, 21)

x2
DIESEL THROTTLE BODY x2

29 (291, 21)
WATER BY-PASS PIPE
NO. 4 AIR HOSE SUB-ASSEMBLY
29 (291, 21)
25 (250, 18)
25 (250, 18)
GASKET
Non-reusable part
A150373E02
EXAMPLE: N04C-TW
18 (184, 13)
18 (184, 13)
NO. 2 INTAKE PIPE
FU
HOSE
29 (291, 21)
x4 HOSE
29 (291, 21)
x2
18 (184, 13)

x2
HARNESS BRACKET
HOSE
A164416E01
EXAMPLE: N04C-TW
69 (699, 51)
GASKET
x2
x2
55 (560, 41)
x2
GASKET
EGR VALVE BRACKET
FU
29 (290, 21)
x4
VENTURI ASSEMBLY x4
29 (290, 21)
x2
x2
29 (290, 21)
WATER BY-PASS PIPE
SUB-ASSEMBLY
25 (250, 18)
29 (290, 21)
x3
18 (184, 13)
25 (250, 18)
18 (184, 13)
GASKET
INTAKE AIR PIPE NO. 1 WITH AIR HOSE NO. 4
Non-reusable part
A157508E01

29 (291, 21)
x2

WIRE HARNESS
29 (291, 21)
x2
13 (130, 9) x5 CUSHION x2
SPACER x2
GASKET x5
NO. 2 CYLINDER HEAD COVER
FU SUB-ASSEMBLY
GASKET
x4

GASKET
CLAMP BOLT
x4
O-RING x4
35 (360, 26)
GASKET x4 INJECTION PIPE
SUB-ASSEMBLY x2
x2
O-RING
Non-reusable part
A152847E06
EXAMPLE: N04C-TW
OIL FILLER CAP
SUB-ASSEMBLY
29 (290, 21)
CYLINDER HEAD COVER

SUB-ASSEMBLY x2
INJECTOR CONNECTOR
29 (290, 21)
CUSHION x2
13 (133, 10) x5
x2
STAY
x2
NO. 2 CYLINDER HEAD
GASKET x5 COVER SUB-ASSEMBLY
FU
GASKET x4
GASKET
25 (255, 18)
x4
NOZZLE HOLDER CLAMP
x4
INJECTOR ASSEMBLY
OIL LEVEL DIPSICK
x4
x4
O-RING x4 NOZZLE HOLDER SEAL
GASKET x4
x2
44 (449, 32)
x2
INJECTION PIPE
OIL LEVEL
DIPSICK GUIDE O-RING
Non-reusable part
A157515E01
REMOVAL (N04C-TR, TS, TT)

1. INSPECT INJECTOR COMPENSATION CODE
(a) Check that the injection compensation code
registered in the injector assembly installed on each
cylinder matches the one registered in the ECM
(See chapter ES).
(b) If any of the codes do not match, follow the
procedures below to correct the registration details
and recheck the symptom.
(1) Correct the registration details by following the
procedures in "Register injection compensation
code" (See chapter ES).
(2) After correcting the registration details, check if
the same symptom occurs as when the vehicle
was brought in.
HINT:
If it does not occur, the symptom may be
FU caused by errors in injection compensation
code registration.
TERMINAL
4. REMOVE INTAKE AIR CONNECTOR BRACKET (See
chapter EM)
(a) Loosen the clamp.
(b) Remove the 2 bolts and the No. 1 air hose.
(a) Loosen the clamp.
(b) Remove the No. 4 air hose.
7. REMOVE EGR VALVE BRACKET
(a) Disconnect the wire harness from EGR valve
bracket.
(b) Remove the 4 bolts, then remove the EGR valve
bracket.
A166094 8. REMOVE VENTURI ASSEMBLY (See page FU-63)
chapter EM)
(See chapter EM)
ASSEMBLY (See chapter EM)
12. REMOVE INJECTION PIPE CLAMP

(b) Remove the oil level gauge guide and O-ring, then
remove the 2 injection pipe clamps.
13. REMOVE INJECTION PIPE SUB-ASSEMBLY (See
page FU-63)
A101559

(a) Remove the union bolt, the 5 hollow screws, the 5
gaskets and then remove the nozzle leakage pipe.
NOTICE:
After removing the nozzle leakage pipe, put it in
a plastic bag to prevent foreign matter from
contaminating the injectors.
FU
A101560
(b) Using a small screwdriver, remove the 4 holder

seals.
A101561E01
(c) Remove the 4 bolts and the 4 nozzle holder clamps.

NOTICE:
Arrange the holder clamps and bolts in the
correct order.
(d) Remove the 4 injectors.
NOTICE:
Arrange the injectors in the correct order.
(e) Remove the No. 2 cylinder head cover gasket from
each injector.
A101562
(f) Remove the O-ring from each injector.

(g) Remove the 4 gaskets from the cylinder head.
1࡝ࡦࠣ
O-ring
A101565E01
REMOVAL (N04C-TU, TV)

1. CHECK ID CODE
cylinder matches the ones registered in the ECM
(See chapter ES).
(b) If any of the codes do not match, follow the
procedures below to correct the registration details
and recheck the symptom.
procedures in "register injection compensation
was brought in.
HINT:
FU caused by errors in injection compensation
code registration.
TERMINAL
(a) Remove the 2 bolts and 2 hose clamps, then
remove the No. 1 air hose.
(a) Loosen the 2 clamps.
(b) Remove the No. 4 air hose.
7. REMOVE DIESEL THROTTLE BODY (See chapter
ES)
(See chapter EM)
9. REMOVE EGR COOLER SUB-ASSEMBLY (See
A166094
chapter EM)
10. REMOVE EGR VALVE BRACKET (See chapter EM)
11. REMOVE VENTURI ASSEMBLY (See page FU-63)
chapter EM)
(See chapter EM)

A101559

(a) Using SST, loosen the 8 union nuts and remove the
injection pipe sub-assembly.
SST 09023-12701
FU
A154205
(b) Remove the 5 hollow screws and 5 gaskets, then

remove the nozzle leakage pipe.
HINT:
After removing the nozzle leakage pipe, put it in a
plastic bag to prevent foreign matter from
contaminating the injectors.
A101560
(c) Using a small screwdriver, remove the 4 holder

seals.
A101561
(d) Remove the 4 bolts and the 4 nozzle holder clamps.

NOTICE:
correct order.
(e) Remove the 4 injectors.
NOTICE:
(f) Remove the No. 2 cylinder head cover gasket from
each injector.
A101562
(g) Remove the O-ring from each injector.

(h) Remove the 4 injection nozzle seats from the
cylinder head.
1࡝ࡦࠣ
O-ring
A101565E01
REMOVAL (N04C-TW)
1. INSPECT INJECTOR COMPENSATION CODE
cylinder matches the one registered in the ECM
(See chapter ES).
(b) If they do not match, follow the procedures below to
FU correct the registration details and recheck the
symptom.
procedures in "Resister injection compensation
was brought in.
HINT:
caused by errors in injection compensation
code registration.
TERMINAL
5. REMOVE VENTILATION PIPE SUB-ASSEMBLY (See
page FU-64)
6. REMOVE INTAKE AIR PIPE NO. 1 WITH AIR HOSE
NO. 4 (See chapter IT)
ES)
8. DISCONNECT WIRE HARNESS AND CONNECTORS
(See chapter EC)
(See chapter EC)
chapter EM)

chapter EM)
A146672

(a) Disconnect the ventilation hose.
(b) Disconnect the 5 connectors and remove the wire
harness.
(c) Remove the cylinder head cover cushion rubber.
(d) Remove the 2 bolts, the 2 cushions, and the
(e) Remove the gasket from the cylinder head cover. FU
A146731

(b) Remove the oil level dipstick guide and O-ring, then
17. REMOVE INJECTION PIPE SUB-ASSEMBLY (See
page FU-65)
A101559

(a) Remove the union bolt, the 4 hollow screws, the 5
gaskets and the nozzle leakage pipe.
NOTICE:
After removing the nozzle leakage pipe, put it in
a plastic bag to prevent foreign matter from
contaminating its injector.
A101560
(b) Using a small screwdriver, move the 4 holder seals.
A101561E01
(c) Remove the 4 bolts and the 4 nozzle holder clamps.

NOTICE:
correct order.
(d) Remove the 4 injectors.
NOTICE:
(e) Remove the No. 2 cylinder head cover gasket from
each injector.
A101562
(f) Remove the O-ring from each injector.

(g) Remove the 4 injection nozzle seats from the
cylinder head.
1࡝ࡦࠣ
O-ring
FU
A101565E01
INSPECTION
1. INSPECT INJECTOR ASSEMBLY
(a) Check the resistance.
according to the value(s) in the table below.
Standard resistance
Terminals Condition Resistance
1-2 20°C (68°F) 0.35 to 0.55 Ω
A101541
HINT:
The temperature indicated in "Condition" refers
to the temperature of the injector assembly.
injector assembly.
INSTALLATION (N04C-TR, TS, TT)
(a) Register compensation code.
NOTICE:
Register the injector compensation code of a
new fuel injector in the ECM when replacing the
fuel injector. Register the injector compensation
Injector Compensation Code code in advance so that it can be installed in the
A146720E01
correct position. (See chapter ES)
(b) Attach tags to identify the cylinder (#1 to #4) to the

new injector assemblies so that each injector
assembly can be inserted into the correct cylinder
during installation.
(c) Install 4 new gaskets to the cylinder head.
(d) Apply a light amount of clean engine oil to 4 new O-
rings.
A101564
(e) Install an O-ring to each injector as shown in the

illustration.
(f) Install a new No. 2 cylinder head cover gasket to
1࡝ࡦࠣ each injector.
O-ring
(g) Referring to the tags (that show the cylinder
number) attached to the fuel injector assemblies,
insert the fuel injector assembly, nozzle holder
clamp, and nozzle holder clamp bolt for each FU
cylinder.
A101565E01 NOTICE:
• Check that the tip of the fuel injector has no
• When reusing the fuel injectors, reinstall
them to the same cylinder they were removed
from. Otherwise, it could cause the engine to
malfunction.
• Carefully insert the fuel injector so that the O-
ring is not caught between the cylinder head
and the injector.
(h) Temporarily install the 4 nozzle holder clamps with
the 4 clamp bolts.
NOTICE:
Be sure to install the holder clamps and bolts in
their original positions.
A101562
(i) Install the 4 holder seals.

NOTICE:
Securely insert the tip of the holder seal into the
fuel injector.
A101561E01
(j) Temporarily install the nozzle leakage pipe

assembly through 5 new gaskets by hand with the
union bolts and the 4 hollow screws.
A101566
(k) Temporarily tighten the union nuts of injection pipes

No. 1, No. 2, No. 3 and No. 4 by hand.
FU
A146738
(l) Tighten the 4 nozzle holder clamp bolts.

NOTICE:
After tightening the nozzle holder clamp bolts,
check that the fuel injector and the nozzle holder
clamp do not interfere with the valve spring.
A164225
(m) Tighten the 4 hollow screws and union bolt.

NOTICE:
Do not reuse a nozzle leakage pipe assembly
that has been tightened to more than the
specified torque.
2. INSTALL INJECTION PIPE SUB-ASSEMBLY (See
page FU-67)
A146732 3. INSTALL INJECTION PIPE CLAMP
(a) Install a new O-ring to oil level gauge guide.
NOTICE:
Apply a light amount of clean engine oil to the
new O-ring.
(b) Temporarily install the 2 pipe clamps and oil level

gauge guide to the intake manifold.
(c) Install the 2 injection pipe clamps with the 2 nuts.
Tighten the 2 nuts until the clamps' edges make
contact with the engine side clamps' edges.
A101559 (See chapter EM)
chapter EM)
7. INSTALL VENTURI ASSEMBLY (See page FU-67)
8. INSTALL EGR VALVE BRACKET
(b) Install the wire harness clamp.
FU
(a) Install the No. 4 air hose with the clamp.
(a) Install the No. 1 air hose with the 2 bolts and the
clamp.
Torque: Bolt
18 N*m (184 kgf*cm, 13 ft.*lbf)
11. INSTALL INTAKE AIR CONNECTOR BRACKET (See
A166094 chapter EM)
13. BLEED AIR FROM FUEL SYSTEM
HINT:
(See chapter FU-81).
14. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
15. REGISTER INJECTOR COMPENSATION CODE
(a) Register the injector compensation code (See
chapter ES).
16. INSPECT FOR INJECTOR COMPENSATION CODE
17. INSPECT FOR FUEL LEAK (See page FU-7)
INSTALLATION (N04C-TU, TV)

NOTICE:
Register the injector compensation code of a new
fuel injector in the ECM when replacing the fuel
injector. Register the injector compensation code in
advance so that it can be installed in the correct
Injector Compensation Code position (See chapter ES).
A146720E01
(a) Attach tags to identify the cylinder (#1 to #4) to the

new injector assemblies so that each injector
assembly can be inserted into the correct cylinder
during installation.
(b) Install 4 new gaskets to the cylinder head.
(c) Apply a light amount of clean engine oil to 4 new O-
rings.
FU
A101564
(d) Install an O-ring to each injector as shown in the

illustration.
(e) Install a new No. 2 cylinder head cover gasket to
O-ring
(f) Referring to each cylinder number identification tag
attached to the fuel injector assemblies, insert the
fuel injector assembly, nozzle holder clamp, and
nozzle holder clamp bolt for each cylinder.
NOTICE:
A101565E01 • Check that the tip of the fuel injector has no
• When reusing the fuel injectors, reinstall
them to the same cylinder they were removed
from. Otherwise, it could cause the engine to
malfunction.
and the injector.
(g) Temporarily install the 4 nozzle holder clamps with
the 4 clamp bolts.
NOTICE:
A101562
(h) Install the 4 new holder seals.

NOTICE:
fuel injector.
A101561
(i) Temporarily install the nozzle leakage pipe

union bolt and the 4 hollow screws.
NOTICE:
Make sure that the hollow screws and nozzle
leakage pipe assembly are not deformed or
damaged.
FU
A101566
(j) Temporarily tighten the union nuts of injection pipes

NOTICE:
If an injector has been replaced, the
corresponding injector pipe must also be
replaced.
(k) Tighten the 4 nozzle holder clamp bolts.
NOTICE:
A154205 After tightening the nozzle holder clamp bolts,
(l) Tighten the 5 hollow screws.
NOTICE:
Do not reuse a nozzle leakage pipe assembly
that has been tightened to more than the
specified torque.
(m) Using SST, tighten the 8 union nuts.
SST 09023-12701
NOTICE:
Refer to the torque above when not using SST,
when using SST, calculate the torque in
accordance with the lengths of SST and the
torque wrench (See chapter IN).
2. INSTALL INJECTION PIPE CLAMP
A154205
(a) Install a new O-ring to the oil level gauge guide.
NOTICE:
Apply a light amount of clean engine oil to the
new O-ring.

gauge guide to the intake manifold.
A101559 (See chapter EM)
chapter EM)
7. INSTALL EGR VALVE BRACKET (See chapter EM)
8. INSTALL EGR COOLER SUB-ASSEMBLY (See
chapter EM)
FU 9. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
(See chapter EM)
(a) Install the No. 4 air hose with the 2 clamps.
(a) Install the 2 bolts and 2 hose clamps, then install the
No. 1 air hose.
A166094

TERMINAL
chapter ES).
18. BLEED AIR FROM FUEL SYSTEM (See page FU-86)
chapter CO)
INSTALLATION (N04C-TW)
NOTICE:
Register the injector compensation code of a new
fuel injector in the ECM when replacing the fuel
injector. Register the injector compensation code in
advance so that it can be installed in the correct
position. (See chapter ES)
(a) Install 4 new injection nozzle seats to the cylinder
head.
(b) Apply a light amount of clean engine oil to 4 new O-
rings.
Injector Compensation Code
A146720E01 FU
(c) Install an O-ring to each injector as shown in the
illustration.
(d) Install a new No. 2 cylinder head cover gasket to
O-ring
(e) Insert the 4 injectors into the cylinder head.
NOTICE:
• Check that the insertion part of the fuel
injector has no foreign matter attached.
• When reusing a fuel injector, install the same
A101565E01 fuel injector that was removed. Otherwise, it
could cause the engine to malfunction.
and the injector.
(f) Temporarily install the 4 nozzle holder clamps with
the 4 clamp bolts.
NOTICE:
A101562
(g) Install the 4 holder seals.

NOTICE:
fuel injector.
A101561E01
(h) Temporarily install the nozzle leakage pipe

union bolt and the 4 hollow screws.
FU
A101566
(i) Temporarily tighten the union nuts of injection pipes

A146738
(j) Tighten the 4 nozzle holder clamp bolts.

NOTICE:
After tightening the nozzle holder clamp bolts,
A164225
(k) Tighten the 4 hollow screws and union bolt.

2. INSTALL INJECTION PIPE SUB-ASSEMBLY (See
page FU-71)
(a) Install the new O-ring to oil level dipstick guide.
NOTICE:
Apply a light amount of clean engine oil to new
A146732 O-ring.

dipstick guide to intake manifold.
A101559
(b) Install the cylinder head cover and the 2 cushions

with the 2 bolts.
(c) Install the cylinder head cover cushion rubber.
(d) Install the wire harness and connect the 5
connectors.
(e) Connect the ventilation hose.
5. INSTALL NO. 2 CYLINDER HEAD COVER SUB- FU
A146731

chapter EM)
chapter EM)
(See chapter EC)
11. INSTALL WIRE HARNESS AND CONNECTORS (See
A146672
chapter EC)
13. INSTALL INTAKE AIR PIPE NO. 1 WITH AIR HOSE
HINT:
See page FU-91.
TERMINAL
chapter ES).

FU
N04C-TR, TS, TT, TU, TV, TW FUEL – FUEL SUPPLY PUMP FU–31
FUEL SUPPLY PUMP

ENGINE
COMPONENTS
FU
18 (184, 13)
18 (184, 13)
A166034E01
FU–32 N04C-TR, TS, TT, TU, TV, TW FUEL – FUEL SUPPLY PUMP
69 (699, 51)
GASKET
29 (290, 21) 29 (291, 21)

x2
x2
55 (560, 41)
x2
NO. 2 INTAKE PIPE
GASKET
18 (184, 13)
x2
NO. 1 AIR HOSE
FU EGR VALVE BRACKET
29 (291, 21)
x4
x2
NO. 1 INTAKE AIR PIPE
WITH NO. 4 AIR HOSE
x2
29 (291, 21)
WATER BY-PASS PIPE
SUB-ASSEMBLY
29 (291, 21)
18 (184, 13) 25 (250, 18)
18 (184, 13)
25 (250, 18)
GASKET
Non-reusable part
A154208E02
EXAMPLE: N04C-TW
29 (291, 21)
VENTILATION PIPE
SUB-ASSEMBLY
x2 FU
29 (291, 21)
x4
29 (291, 21)
x2 18 (184, 13)
x2
OIL SEPARATOR
ASSEMBLY HARNESS BRACKET
HOSE
18 (184, 13)
A164989E01
35 (360, 26)
35 (360, 26)
GASKET
20 (200, 14)
20 (200, 14)
FUEL RETURN PIPE

FU SUB-ASSEMBLY
GASKET
x2
29 (291, 21)
25 (250, 18)
GASKET
SUPPLY PUMP ASSEMBLY
O-RING
29 (291, 21)
TIMER COVER x2
O-RING
HOLDER CLIP
64 (650, 47)
29 (291, 21) 29 (291, 21) 12 (120, 9)
CRANKSHAFT ANGLE SENSOR PLATE
INJECTION PUMP DRIVE GEAR CRANKSHAFT POSITION SENSOR
Non-reusable part
A154210E02
EXAMPLE: N04C-TW
12 (122, 9)
CRANK POSITION SENSOR

FU
HOLDER CLIP
29 (291, 21)
FUEL FILTER TO INJECTION

PUMP FUEL PIPE
44 (449, 33)
GASKET

25 (250, 18)
20 (204, 15)
GASKET
25 (250, 18)
GASKET
FUEL RETURN PIPE SUB-ASSEMBLY
FUEL RETURN HOSE
GASKET
25 (250, 18)
FUEL DELIVERY PIPE
Non-reusable part
A157926E01
EXAMPLE: N04C-TW
TIMER COVER
FU
29 (291, 21)
O-RING
INJECTION OR SUPPLY
PUMP ASSEMBLY
CRANKSHAFT ANGLE
PLATE x2
29 (291, 21)
64 (650, 47)
29 (291, 21)
O-RING
INJECTION PUMP DRIVE GEAR
Non-reusable part
A157927E01
REMOVAL(N04C-TR, TS, TT)

TERMINAL
chapter EM)
5. DISCONNECT FUEL HOSE (See chapter EM)
6. REMOVE FUEL PIPE SUB-ASSEMBLY
(a) Remove the 2 bolts and nut, then remove the 3 fuel
pipe clamps.
(b) Remove the union bolt, then remove the fuel pipe
sub-assembly.
PIPE FU
(a) Disconnect the wire harness connector.
(b) Separate the 2 wire harness clamps.
A155368
(c) Remove the nut and the fuel pipe clamp.

(d) Using SST, loosen the 2 union nuts.
SST 09023-12701
(e) Remove the fuel filter to injection pump fuel pipe.
A159431
8. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY

(a) Remove the 2 union bolts, the 5 gaskets and the
No. 4 fuel pipe sub-assembly.
chapter EM)
A160263
10. REMOVE SUPPLY PUMP ASSEMBLY

(a) Disconnect the 2 connectors.
(b) Remove the bolt, then separate the holder clip.
A146745
(c) Remove the 6 bolts and the supply pump assembly.

(d) Remove the O-ring from the timer cover.
FU
A146746
11. REMOVE INJECTION PUMP DRIVE GEAR

(a) Clamp the supply pump in a soft jaw vise.
(b) Remove the nut, injection pump drive gear and
crankshaft angle sensor plate.
A146747
(c) Remove the 2 bolts and the timer cover.

A146748

TERMINAL
chapter EM)
(a) Remove the 2 bolts and 2 hose clamps, then
remove the No. 1 air hose.
9. REMOVE DIESEL THROTTLE BODY (See chapter FU
ES)
(See chapter EM)
chapter EM)
14. DISCONNECT FUEL HOSE (See chapter EM)
15. REMOVE FUEL PIPE SUB-ASSEMBLY
(a) Remove the 2 bolts and nut, then remove the 3
injection pipe clamps.
(b) Remove the union bolt and clip, then remove the
fuel pipe sub-assembly.
PIPE
(a) Separate the wire harness connector.
A155368
(c) Remove the fuel pipe clamp with the nut.

(d) Using SST, loosen the 2 union nuts.
SST 09023-12701
(e) Remove the fuel filter to injection pump fuel pipe.
A159431

(a) Using SST, loosen the 2 union bolts.
SST 09023-12701
(b) Remove the No. 4 fuel pipe sub-assembly.
chapter EM)
FU
A160263
19. REMOVE SUPPLY PUMP ASSEMBLY

(a) Separate the 2 connectors.
(b) Remove the bolt, then separate the injection pump
stay.
(c) Remove the 6 bolts and the supply pump assembly.
(a) Clamp the injection pump assembly in a vise.
A146745
(b) Remove the nut, injection pump drive gear and

crankshaft angle sensor plate.
A146747

A146748
REMOVAL (N04C-TW)
TERMINAL
chapter EM)
(See chapter EC)
5. REMOVE VENTILATION PIPE SUB-ASSEMBLY (See
page FU-64)
6. REMOVE OIL SEPARATOR ASSEMBLY (See page
FU-65)
7. DISCONNECT FUEL RETURN HOSE
(a) Move the clamp and disconnect the fuel hose.
FU
A146795
8. REMOVE FUEL DELIVERY PIPE

(a) Remove the union bolt, the 2 gaskets and the fuel
delivery pipe.
A146741

(a) Remove the 2 union bolts, the 4 gaskets and the
No. 4 fuel pipe sub-assembly.
A146742

(b) Remove the union bolt, the gasket and the fuel
return pipe sub-assembly.
A146743

PIPE
(b) Using SST, loosen the union nuts and remove the
fuel filter to injection pump fuel pipe.
SST 09023-12901
12. REMOVE CRANK POSITION SENSOR (See chapter
FU ES)
A146744

(b) Remove the bolt and the holder clip.
A146745
(c) Remove the 4 bolts and the injection or supply

pump assembly.
A146746

(a) Clamp the injection pump in a soft jaw vise.
(b) Remove the nut, the injection pump drive gear and
the crankshaft angle sensor plate.
A146747

A146748
2
INSPECTION (N04C-TR, TS, TT, TU,TV)
1 1. INSPECT SUPPLY PUMP ASSEMBLY
valve terminals.
Standard resistance
1-2 20°C (68°F) 1.9 to 2.3 Ω
FU
A159437E01
HINT:
The temperature indicated in "Condition" refers to
the temperature of the suction control valve.
If the result is not as specified, replace the supply
pump assembly.
(b) Measure the resistance between the fuel
temperature sensor terminals.
Standard resistance
2 1
1-2 20°C (68°F) 2.21 to 2.69 kΩ
1-2 80°C (176°F) 0.287 to 0.349 kΩ
If the result is not as specified, replace the supply

pump assembly.
Resistance
Temperature
A159436E01
INSPECTION (N04C-TW)
1. INSPECT INJECTION OR SUPPLY PUMP ASSEMBLY
valve terminals.
7.6 to 8.2 Ω at 20°C (68°F)
If the resistance is not as specified, replace the fuel
supply pump.
A146749
(b) Measure the resistance between the fuel

temperature sensor terminals.
2.21 to 2.69 kΩ at 20°C (68°F)
If the resistance is not as specified, replace the fuel
supply pump.
FU
A146750

1. INSTALL INJECTION PUMP DRIVE GEAR
(a) Install a new O-ring onto the timer cover.
(b) Install the timer cover onto the supply pump with the
2 bolts.
A146748
(c) Install the crankshaft angle sensor plate and the

injection pump drive gear with the nut.
A146747
2. INSTALL SUPPLY PUMP ASSEMBLY

Matchmark (a) Turn the drive gear and align the hole with the
matchmark as shown in the illustration.
Hole (b) Install a new O-ring onto the timer cover.
A146751E01
(c) Align the matchmarks of the timer cover and the

front end plate, then install the supply pump
assembly.
Matchmark
FU
A165097E01
(d) When the crankshaft position sensor's installation

hole can be accessed directly:
(1) Check that the knock pin of the injection pump
drive gear is at the center of the hole.
If not, perform steps (b) and (c) again. Then,
proceed to step (f).
A101551
(e) When the crankshaft position sensor's installation

hole cannot be accessed directly:
(1) Tape the screwdriver as shown in the
36 mm (1.42 in.) illustration.
6 mm
Vinyl Tape (0.24 in.)
A146792E01
(2) Remove the service plug from the timing chain

cover sub-assembly.
A146793
(3) Insert the screwdriver into the service plug

Timing Chain Cover hole.
(4) Check that the tape end and timing chain cover
Screwdriver
are aligned as shown in the illustration.
If not, perform steps (b) and (c) again.
0 to 2 mm (5) Install the service plug hole.
(0 to 0.08 in.)
FU
Drive Gear
A146794E01
(f) Install the holder clip with the bolt.

(g) Connect the 2 connectors.
chapter EM)
A146745
4. INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY

(a) Temporarily install the No. 4 fuel pipe sub-assembly
with the 2 union bolts and 5 new gaskets.
(b) Tighten the 2 union bolts.
PIPE
NOTICE:
If the supply pump or common rail has been
A160263
replaced, the fuel filter to injection pump fuel pipe
must also be replaced.
(a) Temporarily install the fuel filter to injection pump

fuel pipe with the 2 union nuts.
(b) Using SST, tighten the 2 union nuts.
SST 09023-12701
NOTICE:
Refer to the torque above when not using SST.
When using SST, calculate the torque in
A159431 torque wrench. (See chapter IN)
(c) Install the injection pipe clamp with the nut. Tighten
the nut until the clamp's edges make contact with
the engine side clamp's edges.
(d) Connect the 2 wire harness clamps.
(e) Connect the wire harness connector.
6. INSTALL FUEL PIPE SUB-ASSEMBLY
(a) Install the fuel pipe sub-assembly with the union bolt
and 2 new gaskets. FU
(b) Install the 3 injection pipe clamps with the 2 bolts
and nut. Tighten the 2 nuts and bolt until the clamp's
edges make contact with the engine side clamp's
A155368
edges.
7. CONNECT FUEL HOSE (See chapter EM)
HINT:
(See page FU-81).
TERMINAL
14. INITIALIZE FUEL PUMP
HINT:
(See chapter ES).

(b) Install the timer cover onto the supply pump with the
2 bolts.
A146748

drive gear with the nut.
FU
A146747
2. INSTALL SUPPLY PUMP ASSEMBLY

A146751E01

front end plate, then install the supply pump
assembly.
Matchmark
FU
A165097E01
(d) When the crank position sensor's installation hole

can be accessed directly:
drive gear is at the center of the hole. If not,
perform steps (b) and (c) again. Then, proceed
to step (f).
A101551

hole cannot be accessed directly:
6 mm
A146792E01

cover sub-assembly.
A146793

(4) Check that the tape end and timing chain cover
Screwdriver
sub-assembly are aligned as shown in the
illustration. If not, perform steps (b) and (c)
0 to 2 mm again.
(0 to 0.08 in.) (5) Install the service plug hole.
Drive Gear
A146794E01
(f) Install the holder clip with the bolt.

(g) Connect the 2 connectors.
chapter EM)
FU
A146745

(a) Temporarily install the No. 4 fuel pipe sub-assembly
with the 2 union bolts and 5 new gaskets.
(b) Tighten the 2 union bolts.
A160263

PIPE
(a) Using SST, install the fuel filter to injection pump
fuel pipe with the 2 union nuts.
SST 09023-12701
NOTICE:
A159431 accordance with the lengths of SST and the
torque wrench. (See chapter IN)
nut until the clamp's edge makes contact with the
engine side clamp's edge.
(c) Connect the 2 wire harness clamps.

(d) Connect the wire harness connector.
6. INSTALL FUEL PIPE SUB-ASSEMBLY
(a) Install the fuel pipe sub-assembly with the union bolt
and 2 new gaskets.
(b) Install the 3 fuel pipe clamps with the 2 bolts and
nut. Tighten the 2 bolts and nut until the clamps'
edges make contact with the engine side clamps'
A155368
edges.
7. CONNECT FUEL HOSE (See chapter EM)
chapter EM)
11. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY FU
(See chapter EM)
(a) Install the No. 1 air hose with the 2 bolts and 2 hose
clamps.
TERMINAL
HINT:
(See page FU-86).
chapter CO)
24. SUPPLY PUMP INITIALIZATION
HINT:
(See chapter ES).
(b) Install the timer cover onto the injection or supply
pump with the 2 bolts.
A146748

drive gear with the nut.
FU
A146747

A146751E01

front end plate, then install the supply pump.
Matchmark
A146752E01
(d) When the crankshaft position sensor's installation

hole can be accessed directly:
drive gear is at the center of the hole. Then,
proceed to step (f).
If not, perform steps (b) and (c) again.
A101551

hole can not be accessed directly:
6 mm
FU
A146792E01

or belt cover sub-assembly.
A146793

(4) Check that the tape end and timing chain or
Screwdriver
belt cover sub-assembly are aligned as shown
0 to 2 mm If not, perform steps (b) and (c) again.
(0 to 0.08 in.) (5) Install the service plug hole.
Drive Gear
A146794E01
(f) Install the injection or supply pump with the 4 bolts.

A146746
(g) Install the holder clip with the bolt.

(h) Connect the 2 connectors.
3. INSTALL CRANK POSITION SENSOR (See chapter
ES)
A146745

PIPE
(a) Temporarily install the fuel pipe with the union nuts.
(b) Using SST, tighten the union nuts.
NOTICE:
FU When using SST, calculate the torque in
(c) Install the pipe clamp with the nut. Tighten the nut
until the clamp's edges make contact with the
(a) Install a new gasket and the fuel return pipe with the
union bolt.
nut until the clamp's edges make contact with the
A146743

(a) Install 4 new gaskets and the No. 4 fuel pipe with
the 2 union bolts.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) for M10
bolt
25 N*m (250 kgf*cm, 18 ft.*lbf) for M12
bolt
A146742
7. INSTALL FUEL DELIVERY PIPE

(a) Install 2 new gaskets and the fuel delivery pipe with
the union bolt.
A146741
8. CONNECT FUEL RETURN HOSE

(a) Connect the fuel hose.
EC)
10. INSTALL VENTILATION PIPE SUB-ASSEMBLY (See
page FU-72)
11. INSTALL WIRE HARNESS AND CONNECTORS (See FU
chapter EC)
A146795

HINT:
See page FU-91.
TERMINAL
17. INITIALIZE FUEL PUMP
HINT:
See chapter ES.
FU–56 N04C-TR, TS, TT, TU, TV, TW FUEL – COMMON RAIL
COMMON RAIL
ENGINE
COMPONENTS
EGR VALVE BRACKET
29 (291, 21)
29 (291, 21)
x2
x4
FU
VENTURI ASSEMBLY
x4
29 (291, 21)
18 (184, 13)
18 (184, 13)
A166033E01
N04C-TR, TS, TT, TU, TV, TW FUEL – COMMON RAIL FU–57
69 (699, 51)
GASKET
29 (291, 21) 29 (291, 21)
x2
x2
55 (560, 41)
x2
GASKET
18 (184, 13)
NO. 2 INTAKE PIPE
NO. 1 AIR HOSE
EGR VALVE BRACKET FU
29 (291, 21)
x4

x2
DIESEL THROTTLE BODY x2

29 (291, 21)
WATER BY-PASS PIPE
NO. 4 AIR HOSE SUB-ASSEMBLY
29 (291, 21)
25 (250, 18)
25 (250, 18)
GASKET
Non-reusable part
A150373E02
EXAMPLE: N04C-TW
29 (291, 21)
FU VENTILATION PIPE
SUB-ASSEMBLY
x2
29 (291, 21)
x4
29 (291, 21)
x2
18 (184, 13)
OIL SEPARATOR x2
ASSEMBLY
HARNESS BRACKET
HOSE
A157925E01
EXAMPLE: N04C-TW
69 (699, 51)
GASKET
x2
x2
55 (560, 41)
x2
GASKET
EGR VALVE BRACKET
FU
29 (290, 21)
x4
VENTURI ASSEMBLY x4
29 (290, 21)
x2
x2
29 (290, 21)
WATER BY-PASS PIPE
SUB-ASSEMBLY
25 (250, 18)
29 (290, 21)
x3
18 (184, 13)
25 (250, 18)
18 (184, 13)
GASKET
Non-reusable part
A157508E01
INJECTION PIPE
SUB-ASSEMBLY
35 (360, 26) OIL LEVEL GAUGE
35 (360, 26)
FU O-RING
COMMON RAIL ASSEMBLY
FUEL HOSE
55 (560, 41) 35 (360, 26)
29 (291, 21)
FUEL FILTER TO INJECTION

PUMP FUEL PIPE
x2
x2
FUEL PIPE SUPPORT 35 (360, 26)
Non-reusable part
A159438E02
EXAMPLE: N04C-TW
29 (291, 21)
VENTILATION PIPE FU
SUB-ASSEMBLY
x2
29 (291, 21)
x4
29 (291, 21)
x2
18 (184, 13)
OIL SEPARATOR x2
ASSEMBLY
HARNESS BRACKET
HOSE
A157925E01

TERMINAL
3. REMOVE EGR VALVE BRACKET (See page FU-14)
(a) Remove the 4 bolts and 2 nuts then remove the
intake pipe.
A160476
FU
A154204
6. REMOVE INJECTION PIPE SUB-ASSEMBLY

4 injection pipes.
SST 09023-12701
PIPE (See page FU-37)
A154205
8. REMOVE COMMON RAIL ASSEMBLY

(b) Loosen the clip, disconnect the fuel hose.
(c) Remove the 2 bolts and the common rail assembly.
A154206

TERMINAL
chapter EM)
6. REMOVE NO. 1 AIR HOSE (See page FU-16)
7. REMOVE NO. 4 AIR HOSE (See page FU-16)
ES)
(See chapter EM)
FU
chapter EM)
(a) Remove the 4 bolts and 2 nuts, then remove the
venturi assembly with EGR valve assembly.
A154204

injection pipe sub-assembly.
SST 09023-12701
PIPE
(a) Separate the wire harness connector.
A154205

(c) Remove the fuel pipe clamp with the nut.
A155368
(d) Using SST, loosen the 2 union nuts and remove the
SST 09023-12701
FU
A155283

(a) Separate the fuel pressure sensor connector.
(b) Loosen the clip and separate the fuel hose.
(c) Remove the common rail assembly with the 2 bolts.
A154206
REMOVAL (N04C-TW)
TERMINAL
ES)
(See chapter EC)
(See chapter EC)
chapter EM)
(b) Disconnect the 3 hoses and remove the ventilation
pipe sub-assembly.
9. REMOVE EGR VALVE BRACKET (See page FU-19)

(a) Move the clamp and disconnect the hose.
(b) Remove the 2 bolts and the oil separator assembly.
A164430

(a) Remove the 4 bolts and the intake pipe with EGR
valve.
FU
A146755

(a) Remove the 2 nuts, oil level dipstick guide and the 2
pipe clamps.
A165074

(a) Using SST, loosen the union nuts and remove the 4
injection pipe sub-assemblies.
SST 09023-12901
14. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY (See
page FU-41)
A146757

PIPE
(b) Using SST, loosen the union nuts and remove the
SST 09023-12901
A146744

(b) Remove the 2 bolts, the No. 3 injection pipe bracket
and the common rail assembly.
FU
A146758
INSPECTION (N04C-TR, TS, TT, TU, TV)

1. COMMON RAIL ASSEMBLY
(a) Check the fuel pressure sensor.

A103229
Standard resistance
Terminal Condition Resistance
2 (PR) - 3 (E2) 20°C (68°F) 16.4 kΩ or less
1 (VC) - 2 (PR) 20°C (68°F) 3 kΩ or less
1. INSPECT COMMON RAIL ASSEMBLY
(a) Check the fuel pressure sensor.
Standard resistance
2-3 16.4 kΩ or less at 20°C (68°F)
A101542 5-4 16.4 kΩ or less at 20°C (68°F)
1-2 3 kΩ or less at 20°C (68°F)
6-5 3 kΩ or less at 20°C (68°F)

common rail assembly.

1. INSTALL COMMON RAIL ASSEMBLY
(a) Install the common rail assembly with the 2 bolts.
(b) Connect the fuel hose with the clip.
(c) Connect the fuel pressure sensor connector.
PIPE (See page FU-46)
A154206
3. INSTALL INJECTION PIPE SUB-ASSEMBLY
NOTICE:
• If the common rail has been replaced, the
injection pipes must also be replaced.
• If an injector has been replaced, the
corresponding injection pipe must also be
replaced.
(a) Temporarily install the 4 injection pipes with the 8
union nuts. FU
SST 09023-12701
NOTICE:
(a) Apply a light amount of clean engine oil to the new
O-ring.
(b) Install the O-ring to oil level gauge guide.
(c) Temporarily install the 2 injection pipe clamps and
oil level gauge guide with the 2 nuts.
(d) Tighten the nuts until the clamp's edges make
contact with the engine side clamp's edges.
A154204

surface.
illustration.
Seal packing:
: Seal Packing Bond 1207B or equivalent
A146760E02 NOTICE:
• Apply seal packing to the inner side of the

bolt holes.
• Install the intake pipe with EGR valve within 3
• Do not run the engine for at least 2 hours
after installing.
(c) Install the intake pipe with the 4 bolts and 2 nuts.
6. INSTALL EGR VALVE BRACKET (See page FU-23)
HINT:
(See page FU-72).
A160476

TERMINAL
FU
(a) Install the common rail assembly with the 2 bolts.
(b) Connect the fuel hose and tighten the clip.
(c) Connect the fuel pressure sensor connector.
A154206

PIPE
(a) Temporarily install the fuel pipe with the 2 union
nuts.
SST 09023-12701
NOTICE:
A155283 when using SST, calculate the torque in
until the clamp's edge makes contact with the
engine side clamp's edge.
(d) Connect the 2 wire harness clamps and wire

harness connector.
A155368

(a) Temporarily install a new injection pipe sub-
assembly with the 8 union nuts.
NOTICE:
If the common rail has been replaced, the
injection pipes must also be replaced.
SST 09023-12701 FU
A154205 NOTICE:
(a) Apply a light amount of clean engine oil to a new O-
ring.
(b) Install the O-ring to the oil level gauge guide.
(c) Temporarily install the 2 injection pipe clamps and
oil level gauge guide.
(d) Install the 2 injection pipe clamps with the 2 nuts.
Tighten the nuts until the clamp's edges make
A154204

surface.
illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond
: Seal Packing 1207B or equivalent
A146760E02 NOTICE:
bolt holes.

after installing.
(c) Install the 4 bolts and 2 nuts, then install the venturi
assembly to intake manifold.
chapter EM)
(See chapter EM)
10. INSTALL NO. 4 AIR HOSE (See page FU-26)
11. INSTALL NO. 1 AIR HOSE (See page FU-26)
FU 12. INSTALL NO. 2 INTAKE PIPE (See chapter IT)
TERMINAL
HINT:
(See page FU-86).
chapter CO)
19. SUPPLY PUMP INITIALIZATION
HINT:
(See chapter ES).
(a) Install the common rail assembly and the No. 3
injection pipe bracket with the 2 bolts.
(b) Connect the fuel pressure sensor connector.
A146758

PIPE
(a) Temporarily install the fuel pipe with the union nuts.
SST 09023-12901
NOTICE:
until the clamp's edges make contact with the
3. INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY (See
page FU-54)
(a) Temporarily install the 4 injection pipes with the FU
union nuts.
SST 09023-12901
NOTICE:
(a) Apply a light coat of engine oil to the O-ring of oil
level dipstick guide.
(b) Temporarily install the 2 injection pipe clamps and
oil level dipstick guide with the 2 nuts.
(c) Tighten the nut until the clamp's edges make
A165074

surface.
illustration.
Seal packing:
: Seal Packing Bond 1207B or equivalent
A146760E02 NOTICE:

bolt holes.
after installing.
(c) Install the intake pipe with EGR valve with the 4
bolts.
7. INSTALL EGR VALVE BRACKET (See page FU-29)
17)
(a) Install the ventilation pipe sub-assembly with the 2
A146755
bolts.
(b) Connect the 3 hoses.
FU 10. INSTALL EGR COOLER SUB-ASSEMBLY (See
chapter EM)
(See chapter EC)
(See chapter EC)
HINT:
See page FU-86.
16. ADD COOLANT
TERMINAL
N04C-TR, TS, TT, TU, TV, TW FUEL – FUEL FILTER FU–73
FUEL FILTER
ENGINE
COMPONENTS
FUEL SEDIMENT
FILTER ASSEMBLY
FU
x2
44 (449, 33)
18 (180, 13)
x2
FUEL FILTER ASSEMBLY
A164966E01
FU–74 N04C-TR, TS, TT, TU, TV, TW FUEL – FUEL FILTER
EXAMPLE: N04C-TU
18 (180, 13)
44 (449, 33)
FU
FUEL SEDIMENT FILTER ASSEMBLY
A165016E01
EXAMPLE: N04C-TW
FUEL FILTER CAP
FU
O-RING
FUEL FILTER ELEMENT

SUB-ASSEMBLY
FUEL FILTER COVER
Non-reusable part
A164967E01
INSPECTION
1. INSPECT FUEL FILTER ASSEMBLY
(a) Inspect for level warning switch.
(1) Measure the resistance between the terminals.
Standard resistance
Upper end of float Below 1 Ω
Lower end of float 10 kΩ or higher
If the result is not as specified, replace the fuel

filter case.
A160465
REPLACEMENT (N04C-TR, TS, TT, TV)

FU HINT:
If only replacing the fuel filter element sub-assembly, steps 3
through 6 are not necessary.
TERMINAL
2. REMOVE FUEL FILTER ELEMENT SUB-ASSEMBLY
(a) Disconnect the level warning switch connector.
(b) Place a drain pan under the filter.
A160466E01
(c) Loosen the drain plug and the air bleed plug as
shown in the illustration. Drain the fuel.
NOTICE:
• Do not use any tools.
• Do not spill any fuel.
• If any fuel is spilt on any part of the engine,
wipe it clean with a shop rag or a piece of
cloth.
FU
A160467
(d) When fuel stops draining from the drain plug, tighten
the drain plug and air bleed plug.
A160468
(e) Disengage the claw. Then, remove the cover by

turning it counterclockwise approximately 120°.
Cover
Claw
Turn
A160469E01
(f) Remove the fuel filter element sub-assembly.

Fuel Filter Element (g) Remove the O-ring from the fuel filter cover.
FU Sub-assembly
O-ring
A160106E01
3. REMOVE FUEL FILTER ASSEMBLY

A160470
(b) Remove the 2 bolts and the fuel filter assembly.
A165904
4. REMOVE FUEL SEDIMENT FILTER ASSEMBLY

(a) Loosen the drain plug as shown in the illustration.
Drain the fuel.
(b) When fuel stops draining from the drain plug, tighten
the drain plug.
A158067
(c) Disconnect the 2 fuel hoses.
FU
A155378
(d) Remove the 2 bolts and the fuel sediment filter

assembly.
A155379
5. INSTALL FUEL SEDIMENT FILTER ASSEMBLY

(a) Install the sediment filter assembly with the 2 bolts.
A155379
(b) Connect the 2 fuel hoses.
A155378
6. INSTALL FUEL FILTER ASSEMBLY

(a) Install the fuel filter assembly with the 2 bolts.
A165904
FU
A160470
7. INSTALL FUEL FILTER ELEMENT SUB-ASSEMBLY

Fuel Filter Element (a) Install the fuel filter element sub-assembly to the
Sub-assembly
fuel filter cover.
(b) Install the O-ring to the fuel filter cover.
O-ring
A160106E02
(c) Install the fuel filter cover by turning it clockwise until

the claw is engaged.
Cover
Claw
Turn
A160469E02
(d) Connect the level warning switch connector.
A160466E01

(a) Loosen the fuel filter's air bleed plug.
FU
A160471
(b) While covering the drain pipe with a shop rag or a

piece of cloth, press and release the priming pump
until the fuel from the drain pipe does not have any
bubbles.
A160472
(c) Tighten the air bleed plug.

NOTICE:
Do not use any tools.
TERMINAL
A160473
REPLACEMENT (N04C-TU)
HINT:
TERMINAL
(b) Place a drain pan under the filter.
A165017
FU (c) Loosen the drain plug and the air bleed plug as
NOTICE:
cloth.
A160467
(d) When fuel stops draining from the drain plug, tighten
FU
A160468
(e) Disengage the claw. Remove the cover by turning it

counterclockwise approximately 120°.
Cover
Claw
Turn
A160469E01
(f) Remove the fuel filter element sub-assembly.

Fuel Filter Element (g) Remove the O-ring from the fuel filter cover.
Sub-assembly
O-ring
A160106E01

A165018
FU
A165904

Drain the fuel.
the drain plug.
A165019
A165020

assembly.
A165021

(a) Install the fuel sediment filter assembly with the 2
bolts.
A165021
FU
A165020

A165904
A165018

Sub-assembly
fuel filter cover.
O-ring
A160106E02

Cover
Claw
Turn
A160469E01

FU
A165017

A160471

bubbles.
A160472

NOTICE:
TERMINAL
A160473
REPLACEMENT (N04C-TW)
HINT:
TERMINAL
2. REMOVE FUEL FILTER ELEMENT SUB-ASSEMBLY FU
A160466E01
(b) Loosen the drain plug and the air bleed plug as
NOTICE:
cloth.
A160467
(c) When fuel stops draining from the drain plug, tighten
FU
A160468
(d) Disengage the claw. Then, remove the cover by

turning it counterclockwise approximately 120°.
Cover
Claw
Turn
A160469E01
(e) Remove the fuel filter element sub-assembly.

Fuel Filter Element (f) Remove the O-ring from the fuel filter cover.
Sub-assembly
O-ring
A160106E01

A160470

Drain the fuel.
the drain plug.
FU
A158067
A155378

assembly.
A155379

(a) Install the fuel sediment filter assembly with the 2
bolts.
A155379

A155378
FU
A160470

Sub-assembly
fuel filter cover.
O-ring
A160106E01

Cover
Claw
Turn
A160469E02
A160466E01

FU
A160471

bubbles.
A160472

NOTICE:
TERMINAL
A160473
FU–92 N04C-TR, TS, TT, TU, TV, TW FUEL – INJECTOR DRIVER
INJECTOR DRIVER
ENGINE
COMPONENTS
FU
20 (200, 14)
x2
A164964E01
N04C-TR, TS, TT, TU, TV, TW FUEL – INJECTOR DRIVER FU–93
EXAMPLE: N04C-TU
FU
20 (200, 14)
x2
A165085E02
EXAMPLE: N04C-TV
FU
20 (200, 14)
x2
A165102E01
EXAMPLE: N04C-TW
FU
20 (200, 14)
x2
2.0 (20, 18 in.*lbf)

x4 INJECTOR DRIVER
BRACKET
A157487E01

TERMINAL
2. REMOVE INJECTOR DRIVER ASSEMBLY
(a) Disconnect the 2 injector driver connectors.
FU A164965E01
(b) Remove the 2 bolts and remove the injector driver.
A150371E01

1. INSTALL INJECTOR DRIVER ASSEMBLY
(a) Install the injector driver assembly with the 2 bolts.
A150371E01
(b) Connect the 2 injector driver connectors.

TERMINAL
A164965E01
REMOVAL (N04C-TU)
1. DISCONNECT CABLE FROM NEGATIVE BATTERY FU
TERMINAL
(a) Separate the 2 injector driver connectors.
(b) Separate the wire harness clamp from the injector
driver assembly.
(c) Remove the injector driver assembly with the 2
bolts.
A159428
INSTALLATION (N04C-TU)
(b) Connect the wire harness clamp to the injector
driver assembly.
(c) Connect the 2 injector driver connectors.
TERMINAL
A159428
REMOVAL (N04C-TV)
FU 1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
(a) Separate the 2 injector driver connectors.
(b) Separate the wire harness clamp from the injector
driver assembly.
(c) Remove the injector driver assembly with the 2
bolts.
A159429
INSTALLATION (N04C-TV)
(b) Connect the wire harness clamp to the injector
driver assembly.
(c) Connect the 2 injector driver connectors.
TERMINAL
A159429
REMOVAL (N04C-TW)
TERMINAL
(a) Disconnect the 2 injector driver connectors.
A157484
(b) Remove the 2 bolts and remove the injector driver.
FU
A157485E01
3. REMOVE INJECTOR DRIVER

(a) Remove the 4 screws and the injector driver
bracket.
A157486
1. INSTALL INJECTOR DRIVER
(a) Install the injector driver bracket with the 4 screws.
A157486

FU
A157485E01
(b) Connect the 2 injector driver connectors.

TERMINAL
A157484
N04C-TR, TS, TT, TU, TV, TW FUEL – FUEL TANK FU–101
FUEL TANK
ENGINE
COMPONENTS
NO. 2 MAIN TUBE 1.5 (15, 13 in.*lbf)
FUEL HOSE
x5
1.5 (15, 13 in.*lbf)
NO. 2 RETURN
TUBE FUEL HOSE
x5 GASKET
GASKET
FUEL TANK VENT TUBE
SUB-ASSEMBLY FUEL CUT OFF VALVE ASSEMBLY
FUEL TANK SUPPORT TUBE PLATE FU
1.5 (15, 13 in.*lbf)

x5
GASKET
FUEL SENDER
GAUGE ASSEMBLY
FUEL TANK GASKET
FUEL TANK ASSEMBLY
x4
FUEL TANK BAND 61 (622, 45)
x4
PIN x4
61 (622, 45)
x4
FUEL TANK STAY PIN
FUEL TANK BAND
13 (130, 9)
FUEL TANK STAY
13 (130, 9)
Non-reusable part
A151443E01
FU–102 N04C-TR, TS, TT, TU, TV, TW FUEL – FUEL TANK
EXAMPLE: N04C-TU
NO. 2 MAIN TUBE 1.5 (15, 13 in.*lbf)

FUEL HOSE
x5
1.5 (15, 13 in.*lbf)
NO. 2 RETURN
TUBE FUEL HOSE
x5 GASKET
GASKET
FUEL TANK VENT TUBE
FUEL TANK SUPPORT TUBE PLATE
FU 1.5 (15, 13 in.*lbf)

x5
GASKET
FUEL SENDER
GAUGE ASSEMBLY
GASKET
FUEL TANK CAP
FUEL TANK
SUB-ASSEMBLY
x4
x4
x4
PIN
61 (622, 45)
x4
FUEL TANK STAY
FUEL TANK BAND PIN
13 (130, 9)
FUEL TANK STAY
13 (130, 9)
Non-reusable part
A165101E01
EXAMPLE: N04C-TW
EVAPORATION HOSE
FUEL EVAPORATIVE
SEPARATOR FUEL HOSE
1.5 (15, 13 in.*lbf)

x5
1.5 (15, 13 in.*lbf) x5
FUEL TANK VENT
FUEL SENDER
TUBE SUB-ASSEMBLY
GAUGE ASSEMBLY
1.5 (15, 13 in.*lbf)
1.5 (15, 13 in.*lbf) x5
GASKET x5
GASKET GASKET GASKET FU

FUEL CUT OFF
FUEL CUT OFF
VALVE ASSEMBLY FUEL TANK
VALVE ASSEMBLY
CAP
FUEL TANK SUPPORT

TUBE PLATE
FUEL TANK ASSEMBLY FUEL TANK BAND
FUEL TANK BAND

PIN
PIN
x4
x4
x4
13 (130, 9) 61 (622, 45)
x4
N*m (kgf*cm, ft.*lbf) : Specified torque FUEL TANK STAY
13 (130, 9)
61 (622, 45)
Non-reusable part
FUEL TANK STAY
A155380E01

TERMINAL
2. DRAIN FUEL
(a) Remove the fuel drain plug, and drain the fuel from
the fuel tank.
NOTICE:
Collect the fuel in a container.
(b) Wipe the fuel tank and drain plug.
(c) Install a new gasket and the drain plug.
3. DISCONNECT FUEL SENDER GAUGE CONNECTOR
(a) Disconnect the fuel sender gauge connector.
(b) Disconnect the 2 wire harness clamps.
FU
A150380E01
4. DISCONNECT FUEL EMISSION HOSE

(a) Loosen the clip and disconnect the fuel emission
hose.
A157739
5. DISCONNECT NO. 2 MAIN TUBE FUEL HOSE

(a) Loosen the clip and clamp, and disconnect the No.
2 main tube fuel hose.
6. REMOVE NO. 2 RETURN TUBE FUEL HOSE
(a) Loosen the clip and clamp, and disconnect the No.
2 return tube fuel hose.
A156512E01
7. REMOVE FUEL TANK ASSEMBLY

(a) Remove the 4 nuts and 2 fuel tank bands.
(b) Remove the fuel tank.
A150379E01
8. REMOVE FUEL SENDER GAUGE ASSEMBLY

(a) Remove the 5 screws, fuel sender gauge assembly,
and gasket.
FU
A150375E01
9. REMOVE FUEL CUT OFF VALVE ASSEMBLY

(a) Remove the 5 screws, fuel cut off valve assembly,
the fuel tank support tube plate, and the gaskets.
A150377E01
10. REMOVE FUEL TANK VENT TUBE SUB-ASSEMBLY

(a) Remove the 5 bolts, fuel tank vent tube sub-
assembly and gasket.
A156516

1. INSTALL FUEL TANK VENT TUBE SUB-ASSEMBLY
(a) Install the fuel tank vent tube sub-assembly and a
new gasket with the 5 bolts.
A156516
2. INSTALL FUEL CUT OFF VALVE ASSEMBLY

(a) Install the fuel tank support tube plate, the fuel cut
off valve assembly and the new gaskets with the 5
screws.
FU
A150377E01
3. INSTALL FUEL SENDER GAUGE ASSEMBLY

(a) Install the fuel sender gauge assembly and a new
gasket with the 5 screws.
4. INSTALL FUEL TANK ASSEMBLY
(a) While supporting the fuel tank, install the fuel tank
assembly to the fuel tank stays.
A150375E01
(b) Install the 2 fuel tank bands with the 4 nuts.

A150379E01
5. CONNECT NO. 2 RETURN TUBE FUEL HOSE

(a) Install the No. 2 return tube fuel hose with the clip.
6. CONNECT NO. 2 MAIN TUBE FUEL HOSE
(a) Install the No. 2 main tube fuel hose with the clip.
A156512E01
7. CONNECT FUEL EMISSION HOSE

(a) Connect the fuel emission hose with the clip.
A157739
8. CONNECT FUEL SENDER GAUGE CONNECTOR

(a) Connect the 2 wire harness clamps.
(b) Connect the fuel sender gauge connector.
9. ADD FUEL
TERMINAL FU
A150380E01 12. INSPECT FOR FUEL LEAK (See page FU-7)

TERMINAL
2. DRAIN FUEL
(a) Loosen the drain bolt and drain the fuel.
(b) Tighten the drain bolt with new gasket.
3. SEPARATE FUEL SENDER GAUGE CONNECTOR
(a) Separate the fuel sender gauge connector, then
separate the 2 wire harness clamps.
A150380J01
4. SEPARATE NO. 2 MAIN TUBE FUEL HOSE

(a) Loosen the clip, then separate the No. 2 main tube
fuel hose.
5. SEPARATE NO. 2 RETURN TUBE FUEL HOSE
(a) Loosen the clip, then separate the No. 2 return tube
fuel hose.
6. SEPARATE FUEL EMISSION HOSE
(a) Loosen the clip, then separate the fuel emission
A150376J01 hose.
7. REMOVE FUEL TANK SUB-ASSEMBLY

(a) Remove the 4 nuts, then remove the 2 fuel tank
bands.
(b) Remove the fuel tank sub-assembly.
A150379J01

(a) Remove the 5 screws, then remove the fuel sender
gauge assembly.
FU
A150375J01

(a) Remove the 5 screws, then remove the fuel cut off
valve assembly.
A150377J01

(a) Remove the 5 screws, then remove the fuel tank
vent tube sub-assembly.
A150378J01

new gasket with the 5 screws.
A150378J01

(a) Install the fuel cut off valve assembly and new
gaskets with the 5 screws.
A150377J01

FU
A150375J01
4. INSTALL FUEL TANK SUB-ASSEMBLY

(a) Set the fuel tank sub-assembly to the fuel tank
stays.
(b) Install the fuel tank band and the fuel tank stays with
the 4 nuts.
(a) Connect the fuel emission hose with the clip.
A150379J01 6. CONNECT NO. 2 RETURN TUBE FUEL HOSE
(a) Connect the No. 2 return tube fuel hose with the
clip.
(a) Connect the No. 2 main tube fuel hose with the clip.
A150376J01

(a) Connect the fuel sender gauge connector and 2
wire harness clamps.
9. ADD FUEL
HINT:
(See page FU-86).
A150380J01
TERMINAL
REMOVAL (N04C-TW)
TERMINAL
2. DRAIN FUEL
FU 3. DISCONNECT NO. 2 MAIN TUBE FUEL HOSE
(a) Loosen the clip and disconnect the No. 2 main tube
fuel hose.
A157476
4. DISCONNECT NO. 2 RETURN TUBE FUEL HOSE

(a) Loosen the clip and disconnect the No. 2 return tube
fuel hose.
A157477
5. DISCONNECT FUEL EVAPORATIVE SEPARATOR

FUEL HOSE
(a) Loosen the clip and clamp, and disconnect the fuel
evaporative separator fuel hose.
A157478

(a) While supporting the fuel tank, remove the 12 nuts,
8 bolts, fuel tank band, and fuel tank stay.
(b) Disconnect the fuel sender gauge connector and
remove the fuel tank.
A A157479E01

(a) Remove the 5 screws, fuel sender gauge assembly,
and gasket.
FU
A157480

(a) Loosen the 2 clips and 3 clamps, and disconnect the
evaporation hose.
A157481
(b) Remove the 10 screws, 2 fuel cut off valve

assemblies, the fuel tank support tube plate, and the
2 gaskets.
A157482

(a) Remove the 5 bolts, and remove the fuel tank vent
tube sub-assembly and gasket.
A157483
FU
A157483

(a) Install the 2 fuel tank support tube plates, the 2 fuel
cut off valve assemblies and the 4 new gaskets with
the 10 screws.
A157482
(b) Install the evaporation hose with the 2 clips and

clamp.
A157481

A157480

(a) While supporting the fuel tank, connect the fuel
sender gauge connector.
(b) Install the fuel tank band and the fuel tank stay with
the 12 nuts and 8 bolts.
13 N*m (133 kgf*cm, 10 ft.*lbf) for nut A
A A157479E01
5. CONNECT FUEL EVAPORATIVE SEPARATOR FUEL

HOSE
(a) Install the fuel evaporative separator fuel hose with
FU
the clip and clamp.
A157478

(a) Install the No. 2 return tube fuel hose with the clip.
A157477

(a) Install the No. 2 main tube fuel hose with the clip.
8. ADD FUEL
TERMINAL
A157476
ENGINE
W04D-J, TM, TN FUEL
FUEL SYSTEM
PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-1
PARTS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-2
SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-3
ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-4
FUEL INJECTION PUMP
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-16
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-17
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-24
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-51
FUEL INJECTION NOZZLE
FU
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-53
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-55
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-56
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-57
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-58
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-59
FUEL FILTER
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-61
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-63
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-64
FUEL TANK
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-69
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-70
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU-71
W04D-J, TM, TN FUEL – FUEL SYSTEM FU–1
FUEL SYSTEM
PRECAUTION
CAUTION:
• Before inspecting and repairing the fuel system,
disconnect the negative battery cable.
• Do not smoke or work near fire when handling the fuel
system.
HINT:
Keep diesel fuel away from rubber or leather parts.
(a) Check that there are no fuel leaks anywhere on the
fuel system after completing maintenance (See
page FU-4).
FU
FU–2 W04D-J, TM, TN FUEL – FUEL SYSTEM
PARTS LOCATION
FU
FUEL FILTER
VACUUM SWITCHING VALVE
A165107E01
SYSTEM DIAGRAM
1 2 5 8
AM2 IG2
HEAD
AM2
I6 Ignition Switch
FL MAIN
Battery V3 VSV
2
Battery
FU
A166039E01
FU–4 W04D-J, TM, TN FUEL – FUEL SYSTEM
Vacuum Switching Valve
Intake Manifold
Injection Nozzle
Fuel Filter
FU Injection Pump
Fuel Filter
Fuel Tank
A158826E01
(a) Check that there are no leaks from any part of the
fuel system when the engine stops.
If there is fuel leakage, replace those parts.
(b) While cranking or starting the engine, check that
there are no leaks from any part of the fuel system.
If there is fuel leakage, replace those parts.
(c) Disconnect the return hose from the injection pump.
(d) While cranking the engine, check fuel leakage from

the return pipe.
(e) Check that there are no leaks from any part of the
fuel system.
NOTICE:
If the leakage from the return pipe is less than 10
cc (0.6 cu in.) in a minute, it is acceptable.
2. INSPECT VACUUM SWITCHING VALVE ASSEMBLY
Standard resistance
2 1 Tester Connection Condition Specified Condition
1-2 20°C (68°F) 11 to 13 Ω

Port B vacuum switching valve.
Standard resistance FU
Port A Tester Connection Condition Specified Condition
A163444E01 1 - Body ground Always 10 kΩ or higher

2 - Body ground Always 10 kΩ or higher

vacuum switching valve.
(b) Check the air tightness.
(1) Apply a vacuum to the port A.
(2) Check that the needle of the vacuum pump
indicates decrease of 66.7 kPa (500 mmHg,
19.7 in.Hg) or less.
If the air tightness is not as specified, replace
the vacuum switching valve.
(c) Check the operation.
(1) Apply battery voltage across the terminals.
(2) Check that the needle does not move when a
vacuum is applied to the port A.
If the operation is not as specified, replace the
vacuum switching valve.
FU–6 W04D-J, TM, TN FUEL – FUEL INJECTION PUMP
FUEL INJECTION PUMP

W04D-J, TM, TN FUEL
ENGINE
COMPONENTS
29 (296, 21)
x4
12 (122, 9) x2
x2
x2 x2
GASKET
x4
x2
x2
FU
29 (296, 21) INJECTION PIPE
SUB-ASSEMBLY
GASKET
34 (347, 25)
OIL LEVEL GAUGE
29 (290, 21)
N*m (kgf*cm, ft.*lbf) : Specified torque O-RING
Non-reusable part
A163406E03
W04D-J, TM, TN FUEL – FUEL INJECTION PUMP FU–7
EXAMPLE: W04D-TM, TN GASKET
VENTILATION PIPE SUB-ASSEMBLY
20 (204, 15)
GASKET
GASKET
20 (204, 15)
GASKET
DIESEL FUEL FILTER

ASSEMBLY
25 (255, 18)
29 (290, 21)
29 (296, 21) x2
GASKET
FU
NO. 3 FUEL PIPE GASKET
25 (255, 18)
NO. 4 FUEL PIPE
GASKET x2
17 (173, 13) 29 (296, 21)
NO. 2 FUEL PIPE
17 (173, 13)
29 (290, 21)
GASKET
60 (612, 44)
x2
55 (561, 41)
x2
INJECTION OR SUPPLY PUMP ASSEMBLY 60 (612, 44)
29 (296, 21)
17 (173, 13)
GASKET
29 (296, 21)
N*m (kgf*cm, ft.*lbf) : Specified torque NO. 1 FUEL PIPE
29 (296, 21)
Non-reusable part
A165976E01
DELIVERY VALVE HOLDER

PLUNGER UPPER SPRING SEAT
O-RING PLUNGER SPRING

88 (900, 65)
DELIVERY VALVE PLUNGER LOWER SPRING SEAT

SPRING
SHIM BEARING RETAINER
DELIVERY VALVE CAMSHAFT

PLUNGER SHIM PLATE
GASKET
SHIM
CAMSHAFT
INJECTION PUMP ADJUSTING RING
ELEMENT
TAPPET BEARING
O-RING
CONTROL RACK JOINT BOLT
FU CONTROL SLEEVE
O-RING SOFT WASHER
TAPPET ADJUSTING JOINT BOLT
SHIM SCREW
CAMSHAFT ADJUSTING RING RACK GUIDE SCREW
O-RING
16 (160, 12)
OIL SEAL PUMP BODY

JOINT BOLT
CAMSHAFT
SOFT WASHER
BEARING COVER
CAMSHAFT SHIM PLATE
OVERFLOW VALVE
BEARING
SOFT WASHER JOINT BOLT
O-RING

KEY
Non-reusable part TIMER ROUND NUT

A151328E05
FULL LOAD STOPPER HOUSING SUB-ASSEMBLY
FU
with ANEROID COMPENSATOR:
ANEROID COMPENSATOR
GASKET
8.3 (85, 6.2)
x2
GOVERNOR HOUSING
GASKET
FUEL CUT ACTUATOR
N*m (kgf*cm, ft*lbf) : Specified torque
Non-reusable part
A165091E01
GOVERNOR COVER ASSEMBLY O-RING
RETURN SPRING
FU
ADJUSTING LEVER
FLYWEIGHT SUB-ASSEMBLY
RETURN SPRING
FLOATING LEVER ASSEMBLY

SHACKLE
SUB-ASSEMBLY
SUPPORT LEVER
START SPRING
ARM SUB-ASSEMBLY
SUPPORT LEVER SHAFT
Non-reusable part
A151330E02
DRIVING FLANGE
OIL SEAL
FLANGE
WASHER
23 (222, 16)
FU
TIMER SPRING SUPPORT
TIMER WEIGHT O-RING
DRIVING PLATE
14 (140, 10)
TIMER HUB
TIMER HUB SCREW
OIL SEAL
TIMER COVER
SPRING SEAT
O-RING
SHIM
TIMER SUB SPRING
SPRING SEAT
RETAINER RING

Non-reusable part
A151331E03
for Feed Pump (KD-Type) :
JOINT BOLT PRIMING PUMP
SPECIAL WASHER
GASKET
ADAPTER
PLUG ADAPTER
GASKET
FU SPRING
GASKET
CHECK VALVE ROLLER

SPRING
RETAINER RING
CHECK VALVE
PIN
PUSH ROD SLIDING BLOCK

PISTON
TAPPET
PISTON SPRING
FEED PUMP
PISTON SPRING HOUSING 17 (175, 13)
JOINT BOLT
CONNECTOR
FILTER

Non-reusable part
A151332E03
for Feed Pump (KS-Type)
PRIMING PUMP JOINT BOLT 17.2 (175, 13)

44.1 (450, 33)
WASHER
CONNECTOR
O- RING 51.5 (525, 38)
CHECK VALVE SPRING WASHER RETAINER RING
CHECK VALVE TAPPET
ROLLER
PIN
PISTON SLIDING
SPRING TAPPET ASSY BLOCK
GASKET
FEED PUMP HOUSING

WASHER FU
PLUG
83.4 (850, 61) JOINT BOLT
17.2 (175, 13)
N·m (kgf·cm, ft·lbf) : Specified torque

Non resuable part
A720652
FULL-LOAD STOPPER HOUSING
SHACKLE
FLOATING ARM
SLIDING PLATE
FULL-LOAD STOPPER
ADAPTER SCREW
ADAPTER SCREW
CONTROL LEVER
STOP CAM
RETURN SPRING
CONTROL ROD
FLOATING ARM SPRING
STOP LEVER
FU CAM PLATE
CONNECTING BOLT
GUIDE SHAFT
STOPPER ARM
SLIDING BLOCK
START SPRING
FLOATING LEVER
SCREW PLUG FLYWEIGHT HOLDER
SPRING SEAT
STEERING LEVER
FLYWEIGHT
JOINTING BOLT ADJUSTING LEVER SHAFT
BELL CRANK SHAFT BEARING BOLT
SUPPORTING SHAFT
SLIDER
SUPPORTING LEVER
A156248E02
CAP
LOCK NUT
STOP SCREW
THRUST WASHER COVER
DIAPHRAGM FU
SPRING UPPER SEAT
SPRING
CLAMP PLATE
GUIDE BUSHING
HOUSING
PLATE WASHER
SCREW PLUG
PUSH ROD
SCREW
Non-reusable part
A151333E01
REMOVAL
TERMINAL
2. DRAIN FUEL
3. REMOVE OIL LEVEL GAUGE GUIDE (See chapter
EM)
4. REMOVE NO. 4 AIR HOSE (See chapter EM)
5. REMOVE INJECTION PIPE SET (See page FU-55)
6. REMOVE FUEL PIPE SET
(a) Remove the illustrated fuel pipe.
(1) Remove the 4 union bolts and 8 gaskets.
(2) Remove the 2 nuts and the fuel pipe clamp,
then remove the 2 fuel pipes.
7. REMOVE DIESEL FUEL FILTER ASSEMBLY
(a) Remove the 2 bolts and fuel filter assembly.
FU A156102

Flywheel Housing Flywheel (a) Disconnect the fuel lines, oil lines and engine
control lines.
(b) Turn the crankshaft counterclockwise viewed from
the flywheel side to align the injection timing marks
on the flywheel at A° before top dead center for No.
A° BTDC
1 cylinder on compression stroke.
Injection timing A° 8°
Pointer
A156114E01
(c) Remove the timing inspection hole plug.

(d) Check that the injection timing mark on the
Timer Cover automatic timer is aligned with timer cover pointer.
Pointer
Mark
A156233E03
(e) Rotate the drive gear cover clockwise to align the

injection timing and then tighten the drive gear fitting
bolts.
If not, remove the timing gear cover and then loosen
the drive gear fitting bolts.
NOTICE:
Do not remove the drive gear fitting bolts.
A156234
(f) Lock the automatic timer with SST.

SST S0951-22450
SST
(g) Remove the 2 bolts and the nut, then remove the
pump stay.
Timer Cover
Timer
A156235E02
(h) Loosen the bolts (A) and timer cover fitting bolts (B)
and then remove the injection pump with timer
cover.
NOTICE: FU
B Do not loosen the injection pump body fitting
A C nuts (C).
A165088E01
DISASSEMBLY
1. REMOVE AUTOMATIC TIMER ASSEMBLY
(a) Using SST, remove the timer round nut.
SST S0951-22430
(b) Remove the timer assembly from the injection
pump.
(c) Remove the injection pump drive gear and flange.
SST
A156237E01
2. REMOVE TIMER COVER

(a) Fix SST in a vise.
Screw SST S0951-22200
(b) Remove the 2 timer hub screws.
SST
A156238E01
(c) Install SST on the cover, and fix with the nut.
SST S0951-22210
Shorter Longer NOTICE:
Do not tighten the nut but leave loosened.
for SA1, Unused Nut

SB1 TYPE (for SA1,
SB1 TYPE
SST
A156239E02
(d) Set the extension bar on the timer wrench, then

loosen and remove the timer cover.
FU
A156240
3. REMOVE TIMER WEIGHT

(a) Remove the timer weight (with spring, timer weight
Large Cam rod, etc.).
NOTICE:
Leave timer cams on timer hub.
Small Cam
Timer Hub
A156241E01
(b) Using SST, compress the time spring, then remove

the retainer ring.
Retainer Ring SST S0951-22311
4. REMOVE TIMER CAMS AND TIMER HUB
(a) Remove the timer cams and timer hub.
NOTICE:
Remember the position of timer cams.
SST
A156242E01
5. REMOVE OIL SEAL

(a) Using a screwdriver, remove the oil seals from the
timer cover and driving flange.
6. REMOVE GOVERNOR COVER SUB-ASSEMBLY
(a) Remove the 2 bolts, then remove the aneroid
compensator. (with aneroid compensator)
A156243
(b) With the adjusting lever held in its "idling" position,

detach the governor cover by lifting it up in such as
way that the sliding block can slide out of the slit in
the floating lever.
NOTICE:
• Disconnecting the special bolts or crimp caps
by anyone other than HINO or pump
manufacture authorized service stations to
make these adjustment will void the warranty.
A151334 • If problems with the fuel pump or governor FU
are suspected, consult only HINO or pump
manufacture authorized service stations,
where the problem can be corrected and the
injection pump lead seals and crimp caps can
be reinstalled as required.
• Before lifting the governor cover, be sure to
pull up the supporting lever as shown by
dotted lines in the figure, so that its lower end
Floating Lever may not obstruct the lifting of the governor
cover.
Slider
Pull Up The
Supporting
Lever
Lever End Obstructs
The Governor Cover
Lift The Governor Cover
A151335E02
7. REMOVE FLYWEIGHT ROUND NUT

(a) Using SST, remove the flyweight round nut.
SST SST S0951-21320
NOTICE:
Use the holding spanner to keep the camshaft
from rotating.
A151336E01
8. REMOVE FLYWEIGHT SUB-ASSEMBLY

(a) Remove the flyweight sub-assembly using a
screwdriver to pull it out slowly.
A151337
(b) Using SST, remove the camshaft bushing.

SST S0951-22260
SST
FU A151338E01
(c) Remove the damper from the flyweight sub-

assembly.
Damper
A151339E01
(d) Remove the flyweight.

SST
(1) Using SST, remove the adjusting nut and
disassemble the inner parts of the flyweight
sub-assembly.
SST S0951-21670
NOTICE:
• Disconnecting the special bolts or crimp
caps by anyone other than HINO or pump
manufacture authorized service stations
A151340E01 to make these adjustments will void the
warranty.
• If problems with the fuel pump or
governor are suspected, consult only
HINO or pump manufacture authorized
service stations, where the problem can
be corrected and the injection pump lead
seals and crimp caps can be reinstalled
as required.
• Measure and record the fuel delivery
characteristics of the pump before
disassembling it.
• Keep the parts for each cylinder in

separate groups and in an orderly
arrangement. Parts to be replaced and
parts to be used again must be kept
separately.
9. REMOVE DELIVERY VALVE GROUP
(a) Using SST, remove the nut that secures the
cylinder.
SST S0951-21790
SST
A151341E02
(b) Turn the guide until the clearance between the

washer and the handle is approximately. 1 to 2 mm
Approximately Handle (0.039 to 0.078 in.), to set SST.
1 to 2 mm SST S0951-22380
FU
Washer NOTICE:
The guide of SST is left-hand threaded.
Guide
SST
A151342E02
(c) Turn the handle clockwise into the deliver valve

Turn Clockwise holder. Continue until the O-ring in the cylinder
comes off the pump housing.
Cylinder
O-Ring
A151343E01
(d) Pull SST upward to remove the delivery valve

assembly.
SST
Delivery Valve
Group
A151344E01
(e) Remove the rack guide screw.
A151345
(f) Remove the control sleeve.

(1) Pull the control rack to the left (viewed from the
feed pump) as far as it goes.
(2) Hook the end of SST onto the groove of the
SST control sleeve and remove it.
SST S0951-22400
NOTICE:
Set the camshaft at bottom dead center
before removing the control sleeve.
FU
Sleeve
A151346E03
(g) Remove the plunger.

Lower Spring Plunger Foot Bring the camshaft of the cylinder to top dead
Seat Hole center.
NOTICE:
• Do not mix up the plungers since they must
be put back into the same cylinders.
• Handle the plunger very gently, in order not to
damage it.
• Keep the removed plungers in a pan
containing clean diesel fuel.
Lower Spring
Seat
A151347E01
(h) Using SST, remove the upper spring seat.

SST Pushing the handle down to push in the plunger
spring, turn the guide lever 90° (in either direction)
to remove the upper spring seat from the stopper
pin.
Guide SST S0951-22410
Lever
NOTICE:
First bring the cam of the cylinder to bottom
dead center.
A151348E01 (i) Remove the upper seat and plunger spring.
(j) Using SST, remove the lower spring seat.

SST S0951-21620
SST
Lower Spring Seat
A151349E01
(k) Remove the tappet.

Use SST to pull out the tappet.
SST S0951-22370
SST NOTICE:
The tappet can be removed more easily when
the cam of the cylinder is at top dead center.
Tappet
A151350E01 FU
(l) Remove the camshaft from the injection pump body.
(1) Remove the center bearing two set screws.
(2) Loosen the bearing cover set screws.
(3) Lightly tap the camshaft with a plastic hammer
from the governor side and remove the
camshaft and bearing cover at the same time.
Center Bearing
A151351E01
(m) Disassemble the delivery valve group.

Mount the delivery valve assembly in SST, and
SST remove the delivery valve holder.
SST S0951-22390
A151352E01
(n) Remove the taper bearing from the camshaft.

Remove the taper roller bearing from the drive end
of the camshaft using SST.
SST S0951-22360
Guide
(1) Use the guide to remove the bearing at the
governor side.
SST
Guide
A151353E01
(2) Using SST, tap out the outer race in the bearing
cover.
SST S0951-22330
FU Bearing Cover SST
10. REMOVE PRIMING PUMP AND CHECK VALVES
(a) Unscrew the priming pump and remove the spring
and inlet check valve.
(b) Remove the outlet check valve and spring.
11. REMOVE PISTON
A151354E01 (a) Remove the piston and spring in the hausing and
screw on the chamber plug with a gasket.
12. REMOVE TAPPET
(a) Remove the retainer ring and pull out the tappet.
13. REMOVE FILTER FROM INLET PIPE JOINT
(a) Remove the filter from the inlet pipe joint.
(b) Clean the filter with clean diesel fuel.
A151355
Control Rack ADJUSTMENT

1. PREPARATION
Joint Bolt
(a) Connect the rack measuring device to the control
Nut
rack and set to "0".
(b) Connect the fuel line.
(c) Refill the camshaft chamber with engine oil.
(d) Install the angle gauge on the adjusting lever.
(e) Using SST, remove the full-load stopper housing
A151408E01
cover.
SST S0951-22510, S0951-22520
(f) Connect the boost line to the boost compensator

To Pressure Gauge
port from the vacuum pump on a test bench via a
"T" connection to a pressure gauge.
To Vacuume
Pump
A156247E01
2. STEPS IN GOVERNOR ADJUSTMENT

Full-load Stopper (a) Perform governor testing and adjustment in the
Adapter Screw (A) following sequence.
(1) Preliminary adjustment of stop cam
Guide Bushing (2) Adjustment of idle speed control
(3) Preliminary adjustment of maximum speed
Stop Screw
control
(4) Adjustment of medium speed control
Maximum
(5) Adjustment of maximum speed control
Speed Screw
(6) Adjustment of fuel injection volume under full- FU
load
(7) Inspection of stop lever operation
Adjusting
Lever
Idle Adjusting
Screw
Adjusting Nut
A151385E02
(b) Preliminary adjustment of stop cam.

L1 = L2 :
23.5 mm (0.925 in.)
L2 L1
A151386E01
(c) Adjustment of idling speed control.

Screw Out NOTICE:
Rack
The adjusting lever should always be in the
Position
(mm)
"IDLING" position during adjustment of the idle
speed control.
Screw In
Pump Speed (rpm)

A151388E01
(W04D-TM, TN)
Adjust lever position Pump speed r/min Control rack position mm {in.}
Idling 100 10.6 to 11.0 {0.417 to 0.433}
-31.5° to -21.5° 280 9.45 to 9.85 {0.372 to 0.387}
350 7.70 to 7.90 {0.303 to 0.311}
460 6.05 to 6.45 {0.2382 to 0.2539}
800 4.20 to 4.60 {0.1654 to 0.1811}
1100 2.00 to 2.60 {0.0787 to 0.1024}
(1) At a pump speed of Na rpm, measure the

control rack position Ra mm.
Rack Na and Ra refer to CALIBRATION ( See step 9
Position ).
(mm) If not within specification, adjust with the idle
Ra
adjusting screw.
NOTICE:
Na The idle adjusting screw will change the
Pump Speed (rpm) governor charcteristics as shown in the
A151387E01 illustration.
FU
(2) At a pump speed of Nb rpm, measure the
Rb
control rack position Rb mm.
Rack Nb and Rb refer to CALIBRATION ( See step 9
Position ).
(mm)
Nb
Pump Speed (rpm)
A151389E01
(3) At a pump speed Nc rpm, measure the control

Idle Outer Spring rack position Rc mm.
Rack Position (mm) Nb and Rb refer to CALIBRATION ( See step 9
).
Adjusting
Nut If not within specification, replace the idle outer
spring.
NOTICE:
Rc A Protrusion of the adjusting nut should be
within -0.4 mm (-0.015 in.) to 0.2 mm (0.007
in.).
Nc
Pump Speed (rpm)
A151390E01
(4) At a pump speed of Nd rpm, measure the

control rack position Rd mm.
Washer (A) For Nd and Rd, refer to CALIBRATION ( See
step 9 ).
If not within specification, replace the washer
(A).
Rack
Position
(mm)
Pump Speed (rpm)

A165089E01
FU
(5) At a pump speed of Ne rpm, measure the

control rack position Re mm.
Washer (B) Ne and Re refer to CALIBRATION ( See step 9
).
If not within specification, replace the washer
(B).
Rack
Position
(mm)
Pump Speed (rpm)

A165090E01
(d) Preliminary adjusting of maximum speed control.
Rack Position (mm)
Maximum Speed
Adjusting Screw
Rj
Nj
Pump Speed (r/min)
A151393E01
(W04D-TM, TN)
Full-load 1785 9.0 to 9.4 {0.3543 to 0.3701}
34.5° to 40.5°
1950 5.8 {0.228} or less
FU Between idling and full-load
(1) Apply a 93.3 kPa (700 mmHg) boost pressure

to the boost compensator.
(2) The adjusting lever should be in the "FULL-
SPEED" position.
(3) At the pump speed of Nj rpm, measure the
control rack position Rj mm.
For Nj and Rj, refer to CALIBRATION ( See
step9 ).
If not within specification, adjust with the
maximum speed adjusting screw.
(e) Adjustment of medium speed control.
NOTICE:
• The adjusting lever should always be in the
"FULL- SPEED" position during adjustment
of the medium speed control.
• Apply a 93.3 kPa (700 mmHg) boost pressure
to the boost compensator.
(W04D-TN)
Full-load 600 12.40 to 12.80 {0.4882 to 0.539} = RW3
34.5° to 40.5°
900 12.45 to 12.85 {0.4902 to 0.5059}
Between idling and full-load
1250 13.65 to 14.05 {0.5374 to 0.5531} = RW1
1400 RW1 + 0.15 {0.0059} or less
1680 13.15 to 13.55 {0.5177 to 0.5335}
(W04D-TM)
Full-load 400 10.85 to 11.25 {0.4272 to 0.4429} = RW3
34.5° to 40.5°
900 11.05 to 11.45 {0.435 to 0.4508}
1250 12.25 to 12.65 {0.4823 to 0.498} = RW1
1400 12.95 to 13.35 {0.5098 to 0.5256}
1680 RW1 + 0.3 {0.0118} or less
(1) At a pump speed of Nf rpm, measure the

Full-load Stopper control rack position Rf mm.
If not within specification, adjust by turning the
full-load stopper.
A151394E03
(2) At a pump speed of Ng rpm, measure the

control rack position Rg mm.
Adapter screw (A)
adapter screw (A).
A151396E03 FU
(3) At a pump speed of Nh rpm, measure the
Adapter Screw control rack position Rh mm.
(A) (B)
adapter screws (A) and (B).
(4) Confirm the rack position Ri mm with at a pump
speed of Nj rpm.
A151396E02
(f) Adjustment of maximum speed control

Rack Position (mm) NOTICE:
• The adjusting lever should always be in the
"FULL- LOAD" position.
Maximum Speed • Apply a 93.3 kPa (700 mmHg) boost pressure
Adjusting Screw to the boost compensator.
Rj
Nj
Pump Speed (r/min)
A151397E01
(W04D-TM, TN)
Full-load 1785 9.0 to 9.4 {0.3543 to 0.3701}
34.5° to 40.5°
1950 5.8 {0.228} or less
(1) At a pump speed of Nj rpm, measure the

control rack position Rj mm.
For Nj and Rj, refer to CALIBRATION ( See
step 9 ).
maximum speed adjusting screw.
(2) Confirm the rack position Rm and Rn mm, with
at a pump speed Nm and Nn rpm.
For each speed and rack position, refer to
CALIBRATION ( See step 9 ).
(g) Adjustment of the boost compensator
NOTICE:
The adjusting lever should be in the "FULL-
LOAD" position during adjustment of the boost
Stop Screw compensator.
FU A151398E01
(W04D-TN)
Adjust lever position Pump speed r/min Boost pressure kPa Control rack position mm {in.}
{mmHg}
Full-load 100 0 {0} 12.65 to 13.45 {0.4980 to 0.5295}
34.5° to 40.5°
400 0 {0} 9.75 {0.3839} = RW2
Between idling and full-
load 400 17.7 {133} (RW2+0.2) +/- 0.1
400 93.3 {700} 12.4 to 12.8 {0.4882 to 0.5039}
(W04D-TM)
Adjust lever position Pump speed r/min Boost pressure kPa Control rack position mm {in.}
{mmHg}
Full-load 100 0 {0} 12.65 to 13.45 {0.4980 to 0.5295}
34.5° to 40.5°
400 0 {0} 9.75 {0.3839} = RW2
Between idling and full-
load 400 19.5 {146} (RW2+0.2) +/- 0.1
400 93.3 {700} 10.85 to 11.25 {0.4272 to 0.4429}
HINT:
For control rack position and boost pressure, refer
to CALIBRATION ( See step 10 )
(1) Without boost pressure, at a pump speed of
300 rpm, measure the injection volume and
read the rack position.
If not within specification, adjust the volume
with the stop screw.
(2) Using hexagon wrench (10 mm), remove the
screw plug.
(3) Apply a boost pressure to the boost

compensator.
At a pump speed of 300 rpm, adjust with the
guide bushing to adjust the rack position.
(4) Using hexagon wrench(10 mm), install the
screw plug.
(5) Apply a boost pressure to the boost
compensator.
At a pump speed of 300 rpm, confirm the rack
A151399 position.
(h) Adjustment of fuel injection volume under "FULL-

LOAD".
Measure the injection volume in the "FULL-LOAD"
position.
Apply a P mmHg boost pressure to the boost
compensator.
If the average injection volume is not at standard
value, using hexagon wrench (3 mm), adjust with
the "FULL-LOAD" stopper.
A151418
Boost pressure P 93.3kPa {700mmHg}
FU
(i) Inspection of stop lever operation.

(1) Adjusting lever at "IDLING" position and pump
speed at "0" rpm, the control rack position
should be Rq mm.
Control rack position Rq 7.1 mm {0.2795 in.}
3. INSTALL FULL-LOAD STOPPER HOUSING COVER

AND FULL-ROAD STOPPER CAP
(a) Using SST, install the full-load stopper housing
A151400 cover.
SST S0951-22510, S0951-22520
4. GOVERNOR EXTERNAL CRIMP CAPS
Full-load Stopper NOTICE:
Adapter Screw (A) All adjusting devices on the fuel injection pump
governor, except the low idle adjustment screw, are
Guide Bushing wired and crimp capped as a protection for the
customer. This is to prevent unauthorized
Stop Screw
readjustment which may cause engine malfunction
and/or engine failure.
Maximum
Periodically check to ensure that these seals are not
Speed Screw
broken as this will void the warranty.
Adjusting
Lever
Idle Adjusting
Screw
Adjusting Nut
A151385E02
5. PRE-ADJUSTMENT OF BOOST COMPENSATOR

Push Rod (a) Before installing the boost compensator on the full-
Stop load stopper housing, pre-adjustment of the boost
Screw
Screw compensator should be done as follows.
Guide Bushing
A151402E01
(b) Turn the guide bushing with a screw driver inserted

through the screw plug hole and set the "A"
clearance to zero.
Guide Screw
A
FU A151403E01
(c) Tighten the stop screw until it comes in contact with

Stop the push rod end, then further tighten the stop screw
Screw by 1/2 turn.
Push Rod
A151404E01
(d) Set length "B" by turning the screw indicated in the

illustration.
Screw
Length "B":
14.8 mm (0.582 in.)
A151405E01
(e) Check screw traveling length "E" while applying

Screw 133.3 kPa (1000 mmHg) boost pressure to port "D".
Traveling length "E":
4 to 5 mm (0.158 to 0.196 in.)
(D)
(f) Check the boost compensator air seal. While
applying 133.3 kPa (1,000 mmHg) boost pressure
to port "D", the time required for pressure to drop to
130.7 kPa (980 mmHg) should be more than 10
E
seconds.
A151406E01
6. PREPARATION
(a) Mount the injection pump correctly on the pump
tester.
A151407
(b) Attach a rack position measuring device to the

Control Rack
control rack and set to zero.
Joint Bolt Part No. 95091-00170 (DENSO) for models
Nut equipped with R901 governor.
(c) Install the calibration nozzles and lines.
A151408E01 FU
(d) Fill the pump camshaft chamber with engine oil.
Vernier Scale
Lock Screw
Main Scale
A151409E01
7. ADJUST INJECTION TIMING

Fuel Hose (a) Preparation of the pre-stroke
(1) Remove the screw plug from the pre-stroke
measuring hole of the first cylinder.
Blind Plug (2) Remove the overflow valve, attach the inlet
adaptor and connect the fuel hose of the pump
tester. Close the fuel port of the injection pump
with a blind plug.
(3) Install a pre-stroke measuring instrument. Bring
the tappet of the first cylinder to its bottom dead
center, and set the pointer tip on the tappet.
Plunger
(b) Measure the pre-stroke (No. 1 plunger)
Spring
(1) Set the control rack at full-load position.
(2) Loosen the overflow screw of each nozzle
holder.
Pointer Tappet
A151410E01
(3) Operate the high-pressure pump of the pump

Overflow Pipe tester and let fuel run out of the overflow line.
High Pressure
A151411E01
(4) Move the angle dial to set the first cylinder of

Angle Dial the pump to bottom dead center and adjust the
pre-stroke gauge to zero.
NOTICE:
Bottom dead center is the point at which the
pointer of the dial gauge does not move
even when the angle dial is rotated while
fuel is flowing from the overflow line.
FU A151412E01
(5) Turn the camshaft clockwise the angle dial and

Angle Dial read the dial gauge when the fuel stops running
out of the overflow line. This reading is the pre-
stroke value of the pump.
If the pre-stroke value is not within
specification, change the shims between the
cylinder flange and the pump housing.
A151412E01
(c) Adjust the pre-stroke.

(1) Use SST to lift the cylinder and install the
SST proper shim.
SST S0951-22380
NOTICE:
Shim
• Insert a pair of shims of the same
thickness to the cylinder (If different
thickness shims are used, the rack will
not move smoothly and hunting and
other problems will result).
• Use only one shim on each side.
• Always install the shims with the
φ2.5 mm
thickness marking facing up.
Marked Thickness
A158705E01
(d) Adjust the injection interval.

Angle Dial
(1) Using the No. 1 cylinder injection starting point
as a base, inspect and adjust the injection
Pointer interval in the order of injection.
Injection interval 89° 45' to 90° 15'
(2) If the injection intervals are not within

specification, adjust by using the same
A151415E01 procedure as for pre-stroke adjustment.
(3) After adjustment, make sure that the injection
timing is correct.
(e) Measur and adjust the injection volume
SST
(1) Connect the fuel line and the overflow valve in
Shim
their correct positions.
FU
A151413E01
(f) Measure the injection volume for each control rack

Volume Variation position and pump revolution.
(1) To adjust the injection volume, loosen the
delivery valve holder tightening nut and rotate
the delivery valve holder.
A151416E01
(2) After adjustment has been completed, tighten

the nuts alternately to torque.
Delivery Valve Holder Torque: 19 N*m (195 kgf*cm, 14 ft.*lbf)
8. INSPECT TIMER ADVANCE
(a) Set a stroboscope on a pump tester.
(b) Check the timer advance.
If the angle is not within specification, adjust with an
appropriate shim.
Shim
A151417E01
9. GOVERNOR CHARACTERISTIC DIAGRAM
(W04D-TM)
GOVERNOR SPECIALITY
Control
Rack
Position
Idle Spring Intersection
Np = (540) rpm Lan
FU
Pump Revolution
Idle Spring Intersection Idle Spring Intersection
Np = 290 +/- 10 rpm Lan Np = 385 +/- 20 rpm Lan
A165200E01
10. BOOST COMPENSATOR CHARACTERISTIC

DIAGRAM
BOOST COMPENSATOR SET (Np = 400 rpm)
Control
Rack
Position
Boost Pressure
A165104E01
(W04D-TN)
GOVERNOR SPECIALITY
Control
Rack
Position
Idle Spring Intersection
Np = (540) rpm Lan
FU
Pump Revolution
Idle Spring Intersection Idle Spring Intersection
Np = 290 +/- 10 rpm Lan Np = 385 +/- 20 rpm Lan
A165198E01
12. BOOST COMPENSATOR CHARACTERISTIC

DIAGRAM
BOOST COMPENSATOR SET (Np = 400 rpm)
Control
Rack
Position
Boost Pressure
A165103E01
(W04D-J) 22010-9050
22010-9060
GOVERNOR SPECIALITY
Control
Rack
Position
FU
3WC11-D-1
14. ANEROID COMPENSATOR CHARACTERISTIC

DIAGRAM
22010-9060 Only
3WC11-D-2
REASSEMBLY
1. INSTALL TAPPET
(a) Install the tappet and retainer ring.
2. INSTALL PISTON
(a) Insert the piston and spring in the housing and
screw on the chamber plug with a new gasket.
3. INSTALL PRIMING PUMP AND CHECK VALVES
(a) Install the outlet check valve.
(b) Tighten the priming pump and install the spring and
inlet check valve.
4. INSPECT CAMSHAFT PROTRUDING LENGTH
(a) Measure the distance from the surface of the end of
the pump housing to the surface of the end of the
SST (where the tapered section of the camshaft
starts).
SST S0951-22340
Standard length 16 to 17 mm (0.63 to 0.66 in.)
SST
FU
A151356E01
(b) If the specification is not met, use appropriate shim

plates at the governor end of the camshaft until the
specification is met.
Shim Plate
Governor End
A151357E01
5. INSPECT CAMSHAFT END PLAY

Guide (a) Using SST, measure the thrust clearance of the
SST camshaft with a dial gauge.
SST S0951-21150
Standard end play 0.03 to 0.05 mm (0.0012 to 0.0019 in.)
A151358E01
(b) If the specification is not met, use an appropriate

shim at the plates drive end of the camshaft until the
specification is met.
Bearing Cover
Shim Plate
(Drive End)
A151359E01
6. INSPECT SLIDING RESISTANCE OF CONTROL

RACK
(a) After the pump body has been assembled, attach a
FU spring scale to the control rack and check that the
control rack slides smoothly through its entire
stroke.
Assembly standard Less than 0.98 N (100 gf, 3.52 ozf)
NOTICE:
A151360
• Wash all parts with clean diesel fuel before
installing them, and any defective or
damaged parts must be replaced.
• Do not allow dust or other foreign particles to
enter the pump during assembly.
• Apply grease to O-rings and oil seals before
installing them.
• Assemble the parts in the correct order and to
correct tightening torques, assembled
dimensions etc.
• Reassembly takes place in the reverse order
of disassembly.
7. INSTALL BEARING
Hand Press (a) Put SST on the bearing outer race, and press-fit it
into the bearing cover using a hand press.
SST SST S0951-22350
Outer Race
A151361E02
(b) Install the adjustment ring, shim and taper roller

Shim
bearing, in that order, on the camshaft.
NOTICE:
SST Put a round nut on the other end of the camshaft
to protect the threads.
Adjusting Ring
A151362E01
8. INSTALL CAMSHAFT
(a) Place the center bearing on the camshaft and insert
the camshaft into the pump housing, and tighten the
center bearing setting screws.
Torque:
6.9 to 8.8 N*m (70 to 90 kgf*cm, 61 to 78
in.*lbf)
Center Bearing 9. INSTALL BEARING COVER AND GOVERNOR
HOUSING FU
A151351E01
Torque: Bearing cover
16 N*m (160 kgf*cm, 12 ft.*lbf)
Governor housing
19 N*m (190 kgf*cm, 14 ft.*lbf)
10. INSTALL TAPPET
(a) Using SST, install the tappet.
SST S0951-22370
SST NOTICE:
Position the groove provided in the tappet in the
axial direction of the camshaft, and position it
Tappet accurately so that the tappet is retained in
position by the tappet retainer pin which is
driven inside the pump housing.
A151350E01
11. INSTALL LOWER SPRING SEAT

(a) Using SST, install the lower spring seat.
SST S0951-21620
Lower
Spring Seat
NOTICE:
• Be sure that the plunger of the lower spring
seat is accurately seated in the groove of the
tappet.
SST • This is very important since an inaccurately
positioned seat may cause damage to the
pump.
A151363E01
12. INSTALL UPPER SPRING SEAT

SST (a) Using SST, insert the upper spring seat with the
projected part of the seat facing at the drive end of
the housing.
SST S0951-21620
Projected Part
A151364E01
(b) Using SST, attach the upper spring extractor, and fit
SST the guide groove on the extractor to the projected
part of the upper spring seat.
SST S0951-22410
Guide
Lever
FU A151348E01
(c) Push the handle down to compress the plunger

spring, turn the guide lever 90° towards you, and
Depress
Handle
Extractor install the upper spring seat underneath the stopper
pin which is driven inside the pump housing.
Housing
Guide
Groove
Stopper
Pin
90°
Plunger Spring
A151365E01
NOTICE:
• First bring the cam of the cylinder to bottom
Toward The Rack dead center.
• Check that the spring is accurately retained
Projected by the stopper pin.
Part • Check that the projected part of the upper
spring seat faces away from the rack.
Upper Spring
Stopper Pin
Seat
Pump Plunger Spring

Housing
A151366E01
13. INSTALL PLUNGER

Lower Spring Plunger Foot (a) Put the flange of the plunger leg through the hole
Seat Hole provided in the lower spring seat, with the part
number marking facing the spill side (away from the
feed pump), then turn it clockwise 90°.
NOTICE:
• The plunger can be installed more easily if
the cam of the cylinder is at top dead center.
• Grip the plunger at the top, and pull up to
check that it does not come out.
14. INSTALL PLUNGER CONTROL SLEEVE
Lower Spring
Seat
(a) Iinsert the control rack.
A151347E01
(b) Using SST, install the control sleeve.

SST S0951-22400
NOTICE:
Position the flanges of the control sleeve and FU
SST the plunger, and the projected part of the upper
spring seat correctly before inserting the control
sleeve.
Sleeve
A151346E03
Control
Rack
Ball
Control Stopper
Sleeve Pin
Upper Spring Seat
A151367E01
(c) Move the control rack until the ball in the control
sleeve is accurately inside the groove provided in
the control rack.
Plunger
NOTICE:
FU • The plunger may slip out of its position
Control
Rack Upper during installation. Check the following for a
Spring second time.
Seat • The vertical groove of the plunger must face
the spill side.
• The plunger must not come out when it is
Control
Sleeve
pulled up.
Plunger
Spring
A151368E01
15. INSTALL DELIVERY VALVE GROUP

Valve Holder (a) Install the valve gasket, delivery valve, valve spring,
shim, and the valve holder in that order inside the
Shim cylinder.
NOTICE:
Valve Spring • Apply grease to each O-ring first to protect it
from damage. Install O-rings (a) and (b) in
O-Ring that order.
• Use new valve gaskets and O-rings. Never
reuse them.
O-Ring
Delivery Valve
(b)
Valve Gasket
O-Ring
(a) Cylinder
A151369E01
(b) Using SST, put the delivery valve, and tighten the
delivery valve on the delivery valve group.
SST S0951-22390
SST
A151370E02
(c) Apply a small amount of grease to the O-rings and

Mark Line the outside of the cylinder, position the cylinder with
the marked line on its flange facing the spill side of
the feed pump, slip the cylinder over the plunger,
moving the control rack in and out, and insert the
delivery valve group inside the pump body.
NOTICE:
• Install the cylinder in the correct position.
This is very important since, otherwise, the
A151371E01 relative position of the feed hole and the spill FU
port will be reversed and the characteristics
of the injection volume will be different.
• Each time a cylinder is inserted, move the
control rack to check that it slides smoothly.
(d) Put pair of shims under the flange of the cylinder.
NOTICE:
• Use a pair of shims of the same thickness at
the sides of each cylinder.
• Install the shims with the thickness marking
facing up. (They cannot be installed upside
down since the valve holder cover will be in
the way).
• Push each shim completely in until it touches
the cylinder.
φ 2.5 mm
Marked Thickness
A151372E02
(e) Tighten the nuts finger tight. Then, tighten the nuts
alternately to their specified torque.
SST S0951-21790
NOTICE:
SST • Wash all parts with clean diesel fuel before
installing them, and any defective or
damaged parts must be replaced.
• Do not allow dust or other foreign matter to
A151373E02 enter the pump during assembly.
• Apply grease to O-rings and oil seals before
installing them.
• Assemble the parts in the correct order and
correct tightening torque, assembled
dimensions etc.
• Assembly takes place in the reverse order of
disassembly.
16. INSTALL STOP LEVER
(a) Install the stop lever as shown.
FU
Stop Lever Spring Cover (b) Measure the thrust clearance of the stop arm.
Thrust clearance 0.05 to 0.10 mm (0.0020 to 0.0039 in.)
0.05 to 0.10 mm
O-Ring NOTICE:
Return Spring The O-ring should be coated with grease before
Bolt being fitted.
Washer Stop Arm
17. INSTALL FLYWEIGHT SUB-ASSEMBLY
NOTICE:
Shim Be sure to install the spring inner seat correctly so
Governor that its "LAPPED" surface should face downwards.
Housing
A151374E01
(a) Tighten the adjusting nut with SST.

SST
SST S0951-21670
A151340E01
(b) Measure the protrusion of the adjusting nut.

A
Protrusion of adjusting nut A -0.4 to 0.2 mm (-0.015 to 0.007 in.)
A160477E01
FU
(c) Install the woodruff key and spring washer on the

camshaft. then install and secure the flyweight
SST assembly by tightening the round nut with SST
SST S0951-21320
A165192E01
18. ADJUST DAMPER THRUST CLEARANCE (IF

EQUIPPED WITH DAMPER)
(a) This provides a clearance between the flyweight
and the camshaft bushing.
(1) Temporarily install the camshaft bushing on the
camshaft.
(2) Install the flyweight without the dampers.
(3) Temporarily fit the governor round nut.
Camshaft Bearing
A151377E01
(4) Apply a dial gauge to the end face of the

Flyweight flyweight, and measure the thrust clearance.
Thrust clearance 0.02 to 0.10 mm (0.0008 to 0.0039 in.)
If not within specification, adjust the clearance

by inserting shims between the camshaft
bushing and the governor round nut.
A151378E01
19. INSTALL BEARING BOLT

1.5 to 2.0 mm (a) Measure the free play of the joint bolt along its axis.
Joint Bolt
Standard free play 1.5 to 2.0 mm (0.059 to 0.078 in.)
NOTICE:
Nut
Make sure that the bearing bolt can be moved
smoothly through the guide bushing.
Lock Washer
Washer
Bearing Bolt
A151379E02
(b) Measure the fitting dimension of the bearing bolt.

Bearing Bolt (1) While pulling on the bearing bolt, measure the
dimension "L" with calipers.
FU Sliding Block Fitting dimension 49.7 to 50.1 mm (1.957 to 1.972 in.)
Adapter Plate
Vernier
Calipers
Housing
A151380E01
20. INSTALL GOVERNOR COVER SUB-ASSEMBLY

E-Ring (a) Install the cam plate on the governor cover and
shim with E-ring.
NOTICE:
Shim A about 0.5 mm (0.02 in.) in thickness
Shim A should be installed with the E-ring.
B
0.08 to 0.12 mm
A151381E02
(b) Measure the cam plate thrust clearance B.
Thrust clearance B 0.08 to 0.12 mm (0.0031 to 0.0047 in.)
(c) Install the 2 bolts and aneroid compensator. (with

Cam Plate Governor aneroid compensator)
Cover Torque: 8.3 N*m (85 kgf*cm, 74 in.*lbf)
A151382E01
21. INSTALL OIL SEAL

(a) Using SST, push the oil seals into the timer cover
SST and driving flange.
SST S0951-22420
NOTICE:
The oil seals must be replaced with new ones.
A151383E01
22. INSTALL TIMER CAMS AND TIMER HUB

(a) Install the timer hub and timer cams to the driving
Large Cam flange as shown in the illustration.
Small Cam
FU
Timer Hub
A156241E01
23. INSTALL TIMER SPRING TO TIMER WEIGHT

A
A<B (a) Install the timer spring to the timer weight.
B
NOTICE:
Take care of the spring seat direction.
Retainer Ring
SST
A160484E01
24. INSTALL TIMER COVER

NOTICE:
Nut
The O-ring must be replaced with a new one.
SST (a) Install SST on the cover and fix with the nut.
SST S0951-22210
NOTICE:
• Do not tighten the nut but leave it loosened.
• Since a new timer cover is coated with
adhesive, it is unnecessary to apply fresh
A156245E01 adhesive to a new timer cover when
replacing.
• If reusing the timer cover, apply 4 to 6 dots of

adhesive to 2 or 3 threads of the screw of the
flange.
Adhesive:
Part No. 08833-00070, Three Bond 1342 or
equivalent
• Since the timer cover is attached with
adhesive, a torque of approximately 70 kgf/m
is necessary when removing it.
• Fully remove the adhesive on the threads of
the screw when overhauling. If too much
adhesive is applied, excess adhesive will
stick to the O-ring, resulting in oil leakage.
(b) Hook a spring balancer between the two socket
bolts at the end of the extension bar, then pull the
spring balancer until it shows 196.14 to 228.49 N
1.5 m (59 in.) (20 to 23.3 kgf, 45 to 51 lbf) to tighten up the timer
cover.
Torque: 319 N*m (3250 kgf*cm, 235.1 ft.*lbf)
FU
A156246E01
25. FILL PUMP TIMER OIL INTO TIMER THEN TIGHTEN

Timer Hub TIMER HUB SCREWS
Screws
SST S0951-22200
Oil grade SAE 90
Oil volume 190 to 210 cc (11.60 to 12.82 cu.in.)
SST
26. INSTALL TIMER ASSEMBLY ON THE INJECTION
PUMP
A156238E03
(a) Install the injection pump drive gear and flange.
(b) Mount the timer assembly on the injection pump.
Flywheel Housing Flywheel

INSTALLATION
(a) Check that the injection timing mark on the flywheel
is aligned with the flywheel housing pointer.
A° BTDC Injection timing A° 8°
Pointer
A156114E01
(b) Check that the injection timing mark on the

automatic timer is aligned with the timer cover
Timer Cover pointer.
If not, adjust the injection timing.
Pointer
Mark
A156233E03
FU
(c) Lock the automatic timer with SST.

SST S0951-22450
SST
Timer Cover
Timer
A156235E02
(d) Tighten the bolts (A) and 3 timer cover fitting bolts
(B).
(e) Install the 2 bolts and nut, then install the pump stay.
B Torque: bolt
A C 55 N*m (561 kgf*cm, 41 ft.*lbf)
Torque: nut
60 N*m (612 kgf*cm, 44 ft.*lbf)
(f) Install the timing inspection hole plug.
A165088E01 (g) Connect the fuel lines, oil lines and engine control
lines.
2. INSTALL DIESEL FUEL FILTER ASSEMBLY
(a) Tighten the fuel filter assembly with the 2 bolts.
3. INSTALL FUEL PIPE SET

A
(a) Install the fuel pipes.
A
(1) Install the 2 union bolts and 4 new gaskets (bolt
A).
(2) Install the 2 union bolts and 4 new gaskets (bolt
B).
B B
4. INSTALL INJECTION PIPE SET (See page FU-59)
A156102E01
5. INSTALL NO. 4 AIR HOSE (See chapter EM)

6. INSTALL OIL LEVEL GAUGE GUIDE (See chapter
EM)
7. ADD FUEL
8. BLEED FUEL (See page FU-67)
TERMINAL
FU
W04D-J, TM, TN FUEL – FUEL INJECTION NOZZLE FU–53
FUEL INJECTION NOZZLE

W04D-J, TM, TN FUEL
ENGINE
COMPONENTS
29 (296, 21)
12 (122, 9)
x4 x2
x3
x3 x2
GASKET
x4
x3
17 (173, 13)
x2
15 (153, 11) x2 FU
INJECTOR ASSEMBLY INJECTION PIPE
SUB-ASSEMBLY
x3
GASKET
29 (296, 21)
34 (347, 25)
Non-reusable part
A163404E02
FU–54 W04D-J, TM, TN FUEL – FUEL INJECTION NOZZLE
NOZZLE HOLDER CAP NUT

GASKET
ADJUSTING SCREW
PRESSURE SPRING
FU NOZZLE HOLDER
PRESSURE PIN
NOZZLE HOLDER BODY
NOZZLE ASSEMBLY
NOZZLE RETAINING
NUT 64 (650, 47)
Non-reusable part
A157577E03
REMOVAL
TERMINAL
2. DRAIN FUEL
3. REMOVE INJECTION PIPE SET
(a) Loosen the 8 union nuts from the 4 nozzle holders
and nozzle set.
A156098
NOTICE:
If foreign matter is allowed to enter the
combustion chamber, engine trouble may result.
FU
A156099
(b) Remove the 5 nuts, then remove the injection pipe

set.
A160479
NOTICE:
Cover open ends of the pipes and fuel injection
pump to prevent entry of dirt.
A156111
(c) Remove the 4 joint bolts (A) and 4 gaskets.

(d) Remove the union bolt (B) and 3 gaskets.
(e) Remove the 2 bolts and fuel return pipe.
A
A
A
A
C
C
B
A156100E01
4. REMOVE NOZZLE HOLDER AND NOZZLE SET

(a) Remove the 8 nuts, 4 nozzle holders and 4 nozzle
sets.
FU (b) Remove the 4 shims, 4 ring packings and 4 gaskets
from the cylinder head.
A156101
(c) Use special tools if the nozzle is difficult to remove

by hand.
NOTICE:
After removal of the nozzle holder, cover the
nozzle holder with cloth. Also cover the cylinder
head with a cloth to prevent dust from getting in.
A156112
DISASSEMBLY
1. REMOVE NOZZLE ASSEMBLY
(a) Using a retaining nut wrench, unscrew the retaining
nut.
Part No. 95092-10500 (DENSO made)
NOTICE:
When disassembling the nozzle, be careful not
to drop the inner parts.
A156103
(b) Remove the pressure spring, adjusting shim,

pressure pin, distance piece and the nozzle
assembly.
2. CLEAN NOZZLE ASSEMBLY
(a) Using a wooden stick and brass brush, clean the
nozzle.
Wash them in clean diesel fuel before cleaning.
NOTICE:
Do not touch the nozzle mating surfaces with
your fingers.
(b) Using a wooden stick, remove the carbon adhering
to the nozzle needle tip.
A156104
(c) Using a brass brush, remove the carbon from the

exterior of the nozzle body (except lapped surface).
(d) Check the nozzle body for burns or corrosion.
(e) Check the nozzle needle tip for damage or
corrosion.
If any of these are found, replace the nozzle
FU
assembly.
A156105
ADJUSTMENT
1. ADJUST INJECTION PRESSURE
(a) Connect the nozzle holder with a nozzle tester and
move the lever at the rate of about 50 to 60 times
per minute.
A158329
1st opening pressure (with new parts) 22.06 to 22.94 MPa

(225 to 234 kgf/cm2, 3199 to 3326 psi)
1st opening pressure (with reused parts) 22.06 to 22.94 MPa
(225 to 234 kgf/cm2, 3199 to 3326 psi)
NOTICE:
• Diesel fuel is flammable.
This nozzle adjusting should be done in a
well ventilated room and away from any open
flames or electric sparks.
• The spray must always be covered. Keep
your face and body away from the spray. This
is because of the risk of fuel oil getting in
your eyes or passing into your body.
If the injection pressure is not as specified, change
the shim.
REASSEMBLY
1. INSPECT NOZZLE ASSEMBLY
(a) Wash the nozzle in clean diesel fuel.
NOTICE:
Do not touch the nozzle mating surfaces with
your fingers.
60° (b) Tilt the nozzle body about 60° and pull the needle
out about one-third of its length.
A156106E01
(c) Check that the needle falls into the body vent
smoothly by its own weight when released.
(d) Repeat this test, rotating the needle slightly every
time.
If the needle does not fall smoothly, replace the
nozzle assembly.
FU A156107
2. INSTALL NOZZLE ASSEMBLY

(a) Assemble the nozzle holder body, adjusting shim,
pressure spring, pressure pin, distance piece,
nozzle assembly and nozzle retaining nut, and
tighten the nozzle body nut with your finger.
(b) Using a retaining nut wrench, tighten the retaining
nut.
Part No. 95092-10500 (DENSO made)
HINT:
Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.).
A158324
3. INSPECT NOZZLE HOLDER AND NOZZLE SET

(a) Check for leaks.
(1) While maintaining pressure at about 981 to
1961 kPa (10 to 20 kgf/cm2, 142 to 284 psi)
below opening pressure (adjust it by the tester
handle), check that there is no dripping from
the injection hole or around the retaining nut for
10 seconds.
If there is dripping within 10 seconds, replace
A156108
or clean and overhaul the nozzle holder and
nozzle set.
(b) Check the spray pattern.

(1) The injection nozzle should shudder at a
certain pumping speed between 15 to 60 times
(old nozzle) or 30 to 60 times (new nozzle) per
minute.
(2) Check the spray pattern while shuddering.
If the spray pattern is not correct, replace or
clean the nozzle.
A156109
INSTALLATION
1. INSTALL NOZZLE HOLDER AND NOZZLE SET
(a) Install a new gasket, the packing ring and shim into
the groove of the cylinder head, and then insert the
nozzle holder and nozzle set.
Tightening (b) Insert the nozzle and holder assemblies into the
Torque nozzle sleeves with their inlet connectors toward the
Nozzle
Holder injection pump.
NOTICE:
15 N*m
• Do not let dust fall into the nozzle holder. FU
Carefully fit it over the top end of the sleeve.
• Do not damage the ring packing when
installing the nozzle holder. If damaged, entry
Ring of oil and dust makes removal of the nozzle
Packing difficult.
Gasket (c) Assemble the injection pipe temporarily, and tighten
the installation nuts of the nozzle holder.
Nozzle
A156113E03
2. INSTALL INJECTION PIPE SET

(a) Temporarily install the fuel leakage pipe with 4 new
gaskets and 4 new joint bolts (A).
(b) Temporarily install the union bolt (B) and 3 gaskets.
A (c) Install the 2 bolts (C), tighten the 4 joint bolts (A) and
A
A the union bolt (B).
A Torque: Bolt A
12 N*m (122 kgf*cm, 9 ft.*lbf)
Bolt B
29 N*m (296 kgf*cm, 21 ft.*lbf)
C Bolt C
C 17 N*m (173 kgf*cm, 13 ft.*lbf)
B
A160478E01
(d) Tighten the 8 union nuts to the 4 injection pipes.

A156098
(e) Install the 5 nuts (D), then install the clamp onto the
injection pipe set.
D
D
3. ADD FUEL
D 4. BLEED FUEL (See page FU-67)
D
FU A160480E01
W04D-J, TM, TN FUEL – FUEL FILTER FU–61
FUEL FILTER
W04D-J, TM, TN FUEL
ENGINE
COMPONENTS
for Fuel Tank Side:
44 (449, 32)
x2 FU
x2
25 (255, 18)
A165108E01
FU–62 W04D-J, TM, TN FUEL – FUEL FILTER
for Fuel Tank Side:
FUEL FILTER COVER
FUEL FILTER ELEMENT
FU
FUEL FILTER CASE
A155233E04
for Engine Room Side:
FUEL FILTER ELEMENT SUB-ASSEMBLY FU
A163603E02
INSPECTION
1. INSPECT LEVEL WARNING SWITCH
(a) Inspect level warning switch
(1) Measure the resistance between the terminals.
Standard resistance
Upper end of float Below 100 Ω
Lower end of float 220 kΩ or higher
If the result is not as specified, replace the fuel

filter case.
A163661
REPLACEMENT
1. DRAIN FUEL
(a) Loosen the drain bolt, and drain the fuel from the
fuel filter.
NOTICE:
• If any fuel is on any part of the engine, wipe it
clean with a shop rag or a piece of cloth.
A155372E01
the drain plug.
2. REMOVE DIESEL FUEL FILTER ASSEMBLY (for Fuel
Tank Side)
FU A155373
(b) Remove the 2 union bolts and 4 gaskets, and

separate the 2 fuel pipes.
A155374E01
(c) Remove the 2 bolts, 2 nuts and fuel filter assembly.
A155375
3. REMOVE FUEL FILTER ELEMENT (for Fuel Tank

Side)
(a) Remove the nut at the top of fuel filter cover, then
remove the filter case.
(b) Remove the fuel filter element.
Fuel Filter
Element
Fuel Filter
Case FU
A155371E02

(for Engine Room Side)
(a) Using SST, remove the fuel filter element.
SST 09228-34010
(for Engine Room Side)
SST (a) Remove the dust on the installation surface.
(b) Apply a light coat of fuel to the gasket of new fuel
filter.
A156110E01
(c) Install the fuel filter by turning it slightly to the right
by hand until it comes in contact with the surface of
the fuel filter cover.
NOTICE:
Do not use SST in tightening the element by
hand.
(d) Using SST, tighten the fuel filter about 252° (7/10
turn).
SST 09228-34010
NOTICE:
• Replace with a new gasket.
• Do not reuse the element.
• Be careful not to damage the gasket.

6. INSTALL FUEL FILTER ELEMENT (for Fuel Tank
Side)
(a) Remove the dust on installation surface.
(b) Install the fuel filter element into the fuel filter case.
(c) Tighten the nut at the top of fuel filter cover.
Fuel Filter
Element
FU
Fuel Filter
Case
A155371E02
7. INSTALL DIESEL FUEL FILTER ASSEMBLY (for Fuel

Tank Side)
(a) Tighten the fuel filter assembly with the 2 bolts and 2
nuts.
A155375
(b) Using a new gasket, install the fuel pipe to the fuel
filter assembly with the union bolts.
A155374E01
(c) Connect the level warning switch connector.

8. BLEED FUEL
CAUTION:
At the time of air bleeding, pay attention to the
following items.
• Pay attention to fuel spilling from the supply
pump air bleeder and the fuel filter drain pipe at
the time of air bleeding.
Apply rags etc. to the respective parts being FU
A155373
worked on and take care to prevent spilling of fuel
onto the surroundings.
• If starting is difficult or if the engine stops some
time after starting, the air has not been bled
sufficiently and should be repeated.
(a) Loosen the priming pump knob of the injection
pump by hand and pull out the knob.
(b) Push the knob by hand and move it up and down for
pumping.
(c) When pushing the knob becomes harder, loosen the
Drain Bolt Drain Pipe fuel filter drain bolt and bleed the air through the
drain pipe.
(d) Tighten the fuel filter drain bolt temporarily.
(e) Repeat steps (b) to (d) until air no longer comes
from the drain pipe and then tighten the drain bolt to
the specified torque.
(f) Move the priming pump knob of the injection pump
A165087E01 up and down for pumping.
(g) When pushing the knob becomes harder, loosen the
air bleeder of the supply pump and bleed the air.
(h) Tighten the air bleeder temporarily.
(i) Repeat steps (f) to (h). When air no longer comes
out from the air bleeder, tighten the air bleeder to
the specified torque.
(j) Perform pumping until pushing the knob becomes
harder, and finally lock the knob by tightening it in
the pushed condition.
(k) Confirm the tightening of all parts and then start the
engine.
NOTICE:
• When starting the engine, do not use the
starter for 15 seconds continuously to
prevent it from being burned out. Take an
interval of 30 seconds before re-starting to
protect the battery.
• For the above reason, do not bleed the air by
cranking the engine with the starter.
FU
W04D-J, TM, TN FUEL – FUEL TANK FU–69
FUEL TANK
W04D-J, TM, TN FUEL
ENGINE
COMPONENTS
EXAMPLE NO. 2 MAIN TUBE 1.5 (15, 13 in.*lbf)
FUEL HOSE
x5
1.5 (15, 13 in.*lbf)
NO. 2 RETURN
TUBE FUEL HOSE
x5 GASKET
GASKET
FUEL TANK VENT TUBE
1.5 (15, 13 in.*lbf)

x5
FU
GASKET
FUEL SENDER
GAUGE ASSEMBLY
FUEL TANK GASKET
FUEL TANK ASSEMBLY
x4
x4
PIN x4
61 (622, 45)
x4
FUEL TANK STAY PIN
FUEL TANK BAND
13 (130, 9)
FUEL TANK STAY
13 (130, 9)
Non-reusable part
A151443E01
FU–70 W04D-J, TM, TN FUEL – FUEL TANK
REMOVAL
1. DRAIN FUEL
(a) Loosen the drain bolt and drain the fuel.
(b) Tighten the drain bolt with new gasket.
2. REMOVE FUEL SENDER GAUGE CONNECTOR
(a) Separate the fuel sender gauge connector, then
separate the 2 wire harness clamps.
3. REMOVE FUEL EMISSION HOSE
(a) Loosen the clip, then separate the fuel emission
hose.
A150380J01
4. REMOVE NO. 2 MAIN TUBE FUEL HOSE

(a) Loosen the clip, then separate the No. 2 main tube
fuel hose.
FU
5. REMOVE NO. 2 RETURN TUBE FUEL HOSE
(a) Loosen the clip, then separate the No. 2 return tube
fuel hose.
A150376J01

(a) Remove the 4 nuts, then remove the 2 fuel tank
bands.
(b) Remove the fuel tank.
A150379J01

(a) Remove the 5 screws, then remove the fuel sender
gauge assembly.
A150375J01
W04D-J, TM, TN FUEL – FUEL TANK FU–71

(a) Remove the 5 screws, then remove the fuel cut off
valve assembly.
A150377J01

(a) Remove the 5 screws, then remove the fuel tank
vent tube sub-assembly.
A150378J01 FU
INSTALLATION
A150378J01

(a) Install the fuel cut off valve assembly and a new
gasket with the 5 bolts.
A150377J01

gasket with the 5 bolts.
A150375J01
FU–72 W04D-J, TM, TN FUEL – FUEL TANK

(a) Set the fuel tank sub-assembly to the fuel tank stay.
(b) Install the fuel tank band and the fuel tank stay with
the 4 nuts.
(a) Connect the No. 2 return tube fuel hose with the
clamp.
A150379J01

(a) Connect the No. 2 main tube fuel hose with the
clamp.
(a) Connect the fuel emission hose with the clamp.
FU A150376J01

(a) Connect the fuel sender gauge connector.
9. ADD FUEL
10. BLEED FUEL LINE (See page FU-67)
A150380J01
ENGINE
N04C-TR, TS, TT EMISSION CONTROL
EMISSION CONTROL SYSTEM

ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-1
FUEL TANK CAP
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-2
EC
N04C-TR, TS, TT EMISSION CONTROL – EMISSION CONTROL SYSTEM EC–1

1. VISUALLY CHECK HOSES, CONNECTIONS AND
GASKETS
(a) Check the appearance.
(1) Check if there are any cracks, damage, or
leaks on the indicted portions of the engine
A101567 assembly.
NOTICE:
• Detachment or other problems with the
engine oil dipstick, filler cap, PCV hose
and other components may cause the
engine to run improperly.
• Air suction caused by disconnections,
looseness or cracks in the parts of the air
induction system between the throttle
body and cylinder head will cause engine
failure or engine malfunction.
If the result is not as specified, replace the parts
as necessary.
EC
EC–2 N04C-TR, TS, TT EMISSION CONTROL – FUEL TANK CAP
FUEL TANK CAP

INSPECTION
1. INSPECT FUEL TANK CAP
(a) Check that there is no deformation or damage to the
fuel tank cap and gasket.
Gasket
If necessary, replace the fuel tank cap.
A157541E01
EC
ENGINE
N04C-TU, TV EMISSION CONTROL

PARTS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-1
SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-2
ELECTRIC EGR CONTROL VALVE
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-5
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-6
FUEL TANK CAP
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-8
EC
N04C-TU, TV EMISSION CONTROL – EMISSION CONTROL SYSTEM EC–1

ENGINE
PARTS LOCATION
EC
A166010E01
EC–2 N04C-TU, TV EMISSION CONTROL – EMISSION CONTROL SYSTEM
SYSTEM DIAGRAM
EGR Valve Position Sensor

ECM
VC VC
1
EGLS 3 EGLS
E2 E2
2
MAIN Relay
From Battery
Throttle Body Assembly +B
VRV (EGR)
+B EGR
1 2
EC
DUTY LUSL
VAF VLU
E1
A110732E01
HINT:
In a malfunction where the EGR system is always on, black
or white smoke may emit from the exhaust pipe.
1. CHECK SEATING OF EGR VALVE
(a) Start the engine. Check that the engine starts and
then idles.
2. INSPECT ENGINE CONDITION
(a) Connect the HINO-DX to the DLC3.
(b) Start the engine, then run it at idle.
(c) Warm up the engine.
The coolant temperature should be between 75°C
(167°F) and 90°C (194°F).
(d) Turn the HINO-DX on.
(e) Select the following menu items: Powertrain /
Engine and ECT / Data List / EGR Position.
N04C-TU, TV EMISSION CONTROL – EMISSION CONTROL SYSTEM EC–3
(f) Check that the value of EGR position is within the

specification.
SST S0904-21220, S0912-11040
Standard
EGR valve opening position
Engine condition
expressed as percentage
During idling 40 to 60%
If the result is not as specified, refer to the

INSPECTION section (See chapter EM).
GASKETS
leaks on the indicated portions of the engine
assembly.
NOTICE:
A101567 and other components may cause the
induction system between the throttle EC
failure or engine malfunctions.
as necessary.
EC–4 N04C-TU, TV EMISSION CONTROL – ELECTRIC EGR CONTROL VALVE

ENGINE
COMPONENTS
18 (184, 13)
18 (184, 13) x2
NO. 2 INTAKE PIPE
18 (184, 13)
NO. 2 INTAKE PIPE
NO. 4 AIR HOSE
EC
EGR VALVE ASSEMBLY
29 (296, 21)
x2
x4
EGR VALVE BRACKET

x2
GASKET WATER BY-PASS PIPE

SUB-ASSEMBLY
29 (296, 21)
GASKET 29 (296, 21)
25 (250, 18)
25 (250, 18)
GASKET
Non-reusable part
A166008E01
N04C-TU, TV EMISSION CONTROL – ELECTRIC EGR CONTROL VALVE EC–5
REMOVAL
2. REMOVE NO. 4 AIR HOSE (See chapter ES)
4. REMOVE WIRE HARNESS AND CONNECTORS
A155554

(a) Remove the 4 bolts and EGR valve bracket.
EC
A146672

(a) Disconnect the 2 hoses from the EGR valve
assembly.
A146753
(b) Remove the 3 bolts and 2 union bolts, 4 gaskets

and separate the water by-pass pipe sub-assembly.
A160129
EC–6 N04C-TU, TV EMISSION CONTROL – ELECTRIC EGR CONTROL VALVE
7. REMOVE EGR VALVE ASSEMBLY

(a) Remove the 2 bolts, 2 nuts, EGR valve assembly
and gasket.
A146673
INSPECTION
1. INSPECT EGR VALVE ASSEMBLY
+B
$ EGLS
').5 VC
8% E2
' EGR
')4
(a) Inspect the EGR solenoid valve.
(1) Measure the resistance.
Standard resistance

1 (EGR) - 5 (+B) 25.5 to 29.5 Ω
A101578E01
If the result is not as specified, replace the EGR
valve.
(b) Inspect the EGR valve lift sensor.
EC EGLS VC E2 Standard resistance
+B
$ ').5 8% ' EGR
')4
2 (E2) - 3 (VC) 2.45 to 4.55 Ω
2 (E2) - 4 (EGLS) 2.45 to 4.55 Ω
A101578E01
INSTALLATION
1. INSTALL EGR VALVE ASSEMBLY
(a) Install a new gasket and the EGR valve assembly
with the 2 bolts and 2 nuts.
A146673

(a) Install 4 new gaskets and water by-pass pipe sub-
assembly with the 2 union bolts and 3 bolts.
Torque: Union Bolt
25 N*m (250 kgf*cm, 18 ft.*lbf)
Bolt
29 N*m (291 kgf*cm, 21 ft.*lbf)
A160129
N04C-TU, TV EMISSION CONTROL – ELECTRIC EGR CONTROL VALVE EC–7
(b) Connect the 2 hoses to the EGR valve assembly.
A146753

(a) Install the EGR valve bracket with the 4 bolts.
A146672
4. INSTALL WIRE HARNESS AND CONNECTORS

(a) Connect the 3 connectors. EC
6. INSTALL NO. 4 AIR HOSE (See chapter ES)
A155554
EC–8 N04C-TU, TV EMISSION CONTROL – FUEL TANK CAP
FUEL TANK CAP

INSPECTION
Gasket fuel tank cap and gasket.
A157541E01
EC
ENGINE
N04C-TW EMISSION CONTROL

PARTS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-1
SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-2
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-7
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-8
OIL SEPARATOR
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-11
DPR SWITCH
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-13
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-14 EC
DIFFERENTIAL PRESSURE SENSOR
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-16
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-16
EXHAUST GAS TEMPERATURE SENSOR
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-19
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-20
FUEL TANK CAP
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-22
N04C-TW EMISSION CONTROL – EMISSION CONTROL SYSTEM EC–1

ENGINE
PARTS LOCATION
EXAMPLE
DIFFERENTIAL PRESSURE SENSOR ASSEMBLY
EC
DPR SWITCH
A158143E01
EC–2 N04C-TW EMISSION CONTROL – EMISSION CONTROL SYSTEM
SYSTEM DIAGRAM
EGR Valve Position Sensor

ECM
VC VC
1
EGLS 3 EGLS
E2 E2
2
MAIN Relay
From Battery
Throttle Body Assembly +B
VRV (EGR)
+B EGR
1 2
EC DUTY LUSL
VAF VLU
E1
A110732E01
HINT:
In a malfunction where the EGR system is always on, black
or white smoke may emit from the exhaust pipe.
1. CHECK SEATING OF EGR VALVE
(a) Start the engine. Check that the engine starts and
then idles.
2. INSPECT FOR ENGINE CONDITION
(b) Start the engine, then run it at idle.
The coolant temperature should be between 75°C
(167°F) and 90°C (194°F).
(d) Turn the Hino-DX ON.
(e) Select the following menu items: Powertrain /
Engine and ECT / Data List / EGR Position.
(f) Check that the value of EGR position is within the

specification.
SST S0904-21220, S0902-11040
Standard
EGR valve opening position
Engine condition
expressed as percentage
During idling 40 to 60%
If the result is not as specified, refer to the

INSPECTION section.
GASKETS
(a) Inspect hose and hose connection part for cracks,
leakage, and damage.
A101567
(b) Check the DPR pressure difference sensor for hose

disconnection, mistaken piping, cracks, leaks, and
damage.
EC
A155967
4. DPR MANUAL FORCED REGENERATION PROCEDURE

(a) Stop the car at a safe location.
CAUTION:
As the DPR catalyst becomes very hot at the time of forced regeneration, do not place
any easily inflammable objects near the exhaust pipe.
(b) Set the transmission to the neutral position and apply the parking brake securely.
(c) Perform forced regeneration drive.
(1) Perform complete engine warm-up.
NOTICE:
Complete engine warm-up means that that the cooling water temperature (outlet) is
75°C or higher and that the engine water temperature is stable.
(2) Follow the screen display of the SST (Hino-DX) and perform [Work support] - [ECD] - [Filter-
related work (forced regeneration drive)]. When the DPR indicator lamp is flashing, manual
forced regeneration also is possible by pressing the DPR switch.
SST
S0904-21220
S0912-11040
(3) Confirm that the idling speed increases and that the exhaust brake operates.
NOTICE:
• If the exhaust temperature (OUT) should exceed 800°C during forced regeneration,
immediately stop forced regeneration.
EC–4 N04C-TW EMISSION CONTROL – EMISSION CONTROL SYSTEM
• If P2002/94 is put out again during forced regeneration, catalyst deterioration can
be assumed.
• If the exhaust brake repeatedly opens and closes during forced regeneration drive
or if it does not close, inspect the exhaust system and check for an abnormally
high engine load (friction of alternator, cooler compressor, etc.).
• Execution of forced regeneration takes 15 to 25 minutes from start to completion.
(d) Confirm that the engine speed drops, that the exhaust brake is released (meter indicator OFF),
and that forced regeneration has ended.
(e) After completion of forced regeneration, wait for at least five minutes in idling status.
(f) Follow the screen display of the SST (Hino-DX) and with a securely depressed brake pedal at
[ECU data monitor] - [DPR/DPNR differential pressure] quickly read the center value for the
differential pressure while the accelerator pedal is fully depressed (the no-load engine speed
becomes approximately 3650 rpm).
SST
S0904-27220
S0912-11040
Standard : 15 kPa (0.15 kgf*cm, 2.1psi)
NOTICE:
When the exhaust temperature is high, the DPR differential pressure cannot be measured
correctly. Read the DPR differential pressure as soon as possible after the accelerator
pedal has been depressed fully and the engine speed has stabilized.
(g) Check the engine oil quantity.
NOTICE:
If the engine oil exceeds the upper level of the inspection gauge (X-mark: Normal lever
gauge upper mark + 25 mm), replace the engine oil.
EC
5. AIR BLOWING WORK
NOTICE:
Air blowing work is performed at the time of no-load
high-speed when the DPR difference pressure
widely exceeds the reference value. (At this time, it
can be considered that a large quantity of PM (soot)
has accumulated in the DPR.)
(a) Remove the plug near the center of the of the center
Exhaust Gas pipe.
Temperature
Sensor CAUTION:
As the center pipe may be hot, confirm that the
temperature has dropped before the work is
started.
Plug NOTICE:
Perform the work without removing the center
pipe.
EC-4-1 (b) Remove the exhaust gas temperature sensor
installed near the center of the center pipe.
(Close the boss hole of the sensor with packing tape
or similar.)
(c) Perform air blowing.

(1) Connect the air hose to the SST.
(Set the air valve of the SST to the closed
position.)
Closed Position
EC4-3-9
(2) Insert the air hole of the SST into the plug hole
in the direction towards the vehicle front.
Vehicle Front Air Hole
SST 09950-E9010
NOTICE:
The air hole is located at the top of the
pentagonal part at the root of the SST.
Plug Hole
Air Open & Shut Valve

EC
Air Hole
Direction
of Air Hole Open Position
EC-4-2
(3) Open the air valve, move the SST in the

indicated range while keeping the tip in contact
Vehicle Front with the inner wall of the DPR, and perform air
blowing repeatedly for approximately five
minutes.
Rotation
Range Close the valve after completion of air blowing.
CAUTION:
• Perform the work taking care that the
SST does not touch the catalyst.
• Never perform air blowing towards the
rear of the vehicle.
(4) Remove the SST.
(5) Disconnect the air hose.
(d) Install the plug.
Rotation Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf)
Range
(e) Remove the rubber tape from the sensor boss hole,
remove any foreign matter from inside the boss, and
install the exhaust gas temperature sensor.
SST Plug Hole Torque: 30 N*m (300 kgf*cm, 22 ft.*lbf)
EC-4-3
EC–6 N04C-TW EMISSION CONTROL – ELECTRIC EGR CONTROL VALVE

ENGINE
COMPONENTS
EXAMPLE 18 (184, 13)
18 (184, 13)
NO. 2 INTAKE PIPE
EC
NO. 4 AIR HOSE
29 (296, 21)
EGR VALVE x2
ASSEMBLY
29 (296, 21)
x4
x2
29 (296, 21)
GASKET
29 (296, 21)
GASKET
x3
25 (255, 18)
WATER BY-PASS PIPE SUB-
ASSEMBLY
25 (255, 18)

GASKET
Non-reusable part
A158144E01
N04C-TW EMISSION CONTROL – ELECTRIC EGR CONTROL VALVE EC–7
REMOVAL
1. DRAIN ENGINE COOLANT
3. REMOVE NO. 2 INTAKE PIPE
4. REMOVE WIRE HARNESS AND CONNECTORS
A155554

(a) Disconnect the hoses from the EGR valve
assembly.
EC
A146753
(b) Remove the 3 bolts and 2 union bolts, and separate

the water by-pass pipe sub-assembly.
A146754
6. REMOVE EGR VALVE ASSEMBLY

A146672
EC–8 N04C-TW EMISSION CONTROL – ELECTRIC EGR CONTROL VALVE
(b) Remove the 2 bolts, 2 nuts, EGR valve assembly

and gasket.
A146673
INSPECTION
1. INSPECT EGR VALVE ASSEMBLY
+B
$ EGLS
').5 VC
8% E2
' EGR
')4
(a) Inspect the EGR solenoid valve.
Standard resistance

1 (EGR) - 5 (+B) 25.5 to 29.5 Ω
A101578E01
If the result is not as specified, replace the EGR
valve.
(b) Inspect the EGR valve lift sensor.
+B
$ EGLS
').5 VC
8% E2
' EGR
')4 Standard resistance
EC Tester Connection Specified Condition
2 (E2) - 3 (VC) 2.45 to 4.55 Ω
2 (E2) - 4 (EGLS) 2.45 to 4.55 Ω
A101578E01
INSTALLATION
1. INSTALL EGR VALVE ASSEMBLY
(a) Install a new gasket and the EGR valve with 2 bolts
and 2 nuts.
A146673
(b) Install the EGR valve bracket with the 4 bolts.

A146672
N04C-TW EMISSION CONTROL – ELECTRIC EGR CONTROL VALVE EC–9

(a) Install 4 new gaskets and water by-pass pipe sub-
assembly with the 2 union bolts and 3 bolts.
Torque: for Union Bolt
25 N*m (250 kgf*cm, 18 ft.*lbf)
for Bolt
29 N*m (291 kgf*cm, 21 ft.*lbf)
(b) Connect the 2 hoses to the EGR valve.
A146754
3. INSTALL WIRE HARNESS AND CONNECTORS

(a) Connect the 3 connectors.
4. INSTALL NO. 4 AIR HOSE (See chapter ES)
A155554
EC
EC–10 N04C-TW EMISSION CONTROL – OIL SEPARATOR
OIL SEPARATOR
ENGINE
COMPONENTS
EC
29 (290, 21) HOSE
29 (290, 21)
29 (290, 21)
HARNESS BRACKET
HOSE
A152392E03
N04C-TW EMISSION CONTROL – OIL SEPARATOR EC–11
REMOVAL
(a) Remove the 2 bolts and separate the harness
bracket from the oil separator.
A146670
(b) Remove the 2 bolts and separate the oil separator

assembly.
(c) Disconnect the 3 hoses and remove the oil
separator assembly.
A155976
(d) Remove the 4 bolts and the oil separator bracket.
x4
EC
A155971E01
INSTALLATION
1. INSTALL OIL SEPARATOR ASSEMBLY
x4 (a) Install the oil separator bracket with the 4 bolts onto
the oil separator.
A155971E01
(b) Connect the 3 hoses.

(c) Install the oil separator assembly with the 2 bolts.
A155976
EC–12 N04C-TW EMISSION CONTROL – OIL SEPARATOR
(d) Install the harness bracket with the 2 bolts onto the
oil separator.
A146670
EC
N04C-TW EMISSION CONTROL – DPR SWITCH EC–13
DPR SWITCH
ENGINE
COMPONENTS
EC
CONNECTOR
DPR SWITCH ASSEMBLY
A152393E01
A154060J02
REMOVAL
1. REMOVE CENTER INSTRUMENT CLUSTER FINISH
PANEL SUB-ASSEMBLY
EC–14 N04C-TW EMISSION CONTROL – DPR SWITCH
2. REMOVE DPR SWITCH ASSEMBLY

(a) Disconnect the DPR switch assembly connector.
(b) Remove the DPR switch assembly.
A158146
INSPECTION
DPR SWITCH ASSEMBLY: 1. INSPECT DPR SWITCH ASSEMBLY
(a) Inspect the resistance.
Standard resistance
Tester Connection Switch Connection Specified Condition
2-3 Switch OFF Below 1 Ω
EC 6-7 Switch OFF 10 kΩ or higher
6-7 Switch ON Below 1 Ω
6 2
7 3
A157531E01
A157531E01
INSTALLATION
1. INSTALL DPR SWITCH ASSEMBLY
(a) Install the DPR switch assembly.
(b) Connect the DPR switch assembly connector.
2. INSTALL CENTER INSTRUMENT CLUSTER FINISH
PANEL SUB-ASSEMBLY
A163434
N04C-TW EMISSION CONTROL – DIFFERENTIAL PRESSURE SENSOR EC–15
DIFFERENTIAL PRESSURE SENSOR

ENGINE
COMPONENTS
EXAMPLE
DIFFERENTIAL PRESSURE SENSOR ASSEMBLY
19 (194, 14)
HOSE HOSE
EC

A152394E01
EC–16 N04C-TW EMISSION CONTROL – DIFFERENTIAL PRESSURE SENSOR
REMOVAL
1. REMOVE DIFFERENTIAL PRESSURE SENSOR
ASSEMBLY
(a) Disconnect the 2 differential pressure sensor
assembly hoses.
(b) Disconnect the differential pressure sensor
assembly connector.
A154024E01
(c) Remove the 2 bolts and differential pressure sensor

assembly.
INSPECTION
1. INSPECT DIFFERENTIAL PRESSURE SENSOR
ASSEMBLY
(a) Disconnect the differential pressure sensor
assembly hose.
(b) Connect SST to the differential pressure sensor
A158145
assembly.
SST 09992-00242
ECM :
EC table below.
Standard voltage
0 kPa 0.75 V
20 kPa (0.2 kgf/cm2, 2.8

1.53 V
B27 (PEX) - A28 (E2) psi)
100 kPa (1.0 kgf/cm2,

4.65 V
E2 PEX 14 psi)
A125012E02
(e) Disconnect SST from the differential pressure

sensor assembly.
(f) Connect the differential pressure sensor assembly
hose.
INSTALLATION
1. INSTALL DIFFERENTIAL PRESSURE SENSOR
ASSEMBLY
(a) Install the differential pressure sensor with the 2
bolts.
(b) Connect the differential pressure sensor connector.
A158145
N04C-TW EMISSION CONTROL – DIFFERENTIAL PRESSURE SENSOR EC–17
(c) Connect the 2 differential pressure sensor hoses.

HINT:
Be sure to connect the hoses correctly.
A154024E01
EC
EC–18 N04C-TW EMISSION CONTROL – EXHAUST GAS TEMPERATURE SENSOR

ENGINE
COMPONENTS
30 (306, 22)
27 (275, 20)*
30 (306, 22)
27 (275, 20)*
EC
NO. 2 EXHAUST GAS TEMPERATURE SENSOR
* For use with UNION NUT WRENCH A152395E01

N04C-TW EMISSION CONTROL – EXHAUST GAS TEMPERATURE SENSOR EC–19
REMOVAL
1. REMOVE EXHAUST GAS TEMPERATURE SENSOR
connector.
A154028E01
(b) Using a union nut wrench (14 mm), loosen the union
nut and remove the exhaust gas temperature
sensor.
A154027E01
2. REMOVE NO. 2 EXHAUST GAS TEMPERATURE

SENSOR
(a) Disconnect the No. 2 exhaust gas temperature
sensor connector. EC
A154025
(b) Using a union nut wrench (14 mm), loosen the union
nut and remove the No. 2 exhaust gas temperature
sensor.
A154026E01
INSPECTION
1. INSPECT EXHAUST GAS TEMPERATURE SENSOR
(a) Measure the resistance of the exhaust gas
temperature sensor (front side).
Standard resistance

1-2 82 to 137 kΩ at 50°C (122°F)
A101574
EC–20 N04C-TW EMISSION CONTROL – EXHAUST GAS TEMPERATURE SENSOR
(b) Measure the resistance of the exhaust gas

temperature sensor (rear side).
Standard resistance
1-2 82 to 137 kΩ at 50°C (122°F)

A101574
INSTALLATION
1. INSTALL EXHAUST GAS TEMPERATURE SENSOR
(a) Using a union nut wrench (14 mm), install the
exhaust gas temperature sensor onto the center
exhaust pipe assembly.
Torque: without union nut wrench
30 N*m (306 kgf*cm, 22 ft.*lbf)
with union nut wrench
A154027E01
27 N*m (275 kgf*cm, 20 ft.*lbf)
HINT:
• Refer to the torque above when not using a union
nut wrench. When not using a union nut wrench,
calculate the torque in accordance with the
lengths of union nut wrench and the torque
EC wrench.
• Do not damage the exhaust gas temperature
sensor.
(b) Connect the exhaust gas temperature sensor
connector.
A154028J01
2. INSTALL NO. 2 EXHAUST GAS TEMPERATURE

SENSOR
(a) Using a union nut wrench (14 mm), install the No. 2
exhaust gas temperature sensor onto the center
Torque: without union nut wrench
30 N*m (306 kgf*cm, 22 ft.*lbf)
with union nut wrench
27 N*m (275 kgf*cm, 20 ft.*lbf)
A154026E01 HINT:
• Refer to the torque above when not using a union
nut wrench. When not using a union nut wrench,
calculate the torque in accordance with the
lengths of union nut wrench and the torque
wrench.
N04C-TW EMISSION CONTROL – EXHAUST GAS TEMPERATURE SENSOR EC–21
• Do not damage the exhaust gas temperature

sensor.
(b) Connect the No. 2 exhaust gas temperature sensor
connector.
A154025
EC
EC–22 N04C-TW EMISSION CONTROL – FUEL TANK CAP
FUEL TANK CAP

INSPECTION
A157541E01
EC
ENGINE
W04D-J, TM, TN EMISSION CONTROL

FUEL TANK CAP
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EC-2
EC
W04D-J, TM, TN EMISSION CONTROL – EMISSION CONTROL SYSTEM EC–1

GASKETS
leaks on the indicted portions of the engine
A101567 assembly.
NOTICE:
and other components may cause the
induction system between the throttle
failure or engine malfunction.
as necessary.
EC
EC–2 W04D-J, TM, TN EMISSION CONTROL – FUEL TANK CAP
FUEL TANK CAP

INSPECTION
A157541E01
EC
ENGINE
N04C-TR, TS, TT INTAKE
INTAKE SYSTEM
PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT-1
ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT-2
TURBOCHARGER
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT-4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT-5
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT-8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT-9
INTERCOOLER
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT-12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT-13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT-14
IT
N04C-TR, TS, TT INTAKE – INTAKE SYSTEM IT–1
INTAKE SYSTEM
PRECAUTION
1. MAINTENANCE PRECAUTION
(a) Do not stop the engine immediately after towing a
trailer, or after high-speed or uphill driving. Idle the
engine for 20 to 120 seconds depending on how
hard the vehicle has been driven.
(b) Avoid sudden acceleration or racing the engine
immediately after starting a cold engine.
(c) If the turbocharger is found to be defective and must
be replaced, check the following items and repair or
replace as necessary:
(1) Engine oil level and quality
(2) Conditions under which the turbocharger was
used
(3) Oil lines leading to the turbocharger
(d) Be careful when removing and reinstalling the
turbocharger. Do not drop or strike the turbocharger.
Also, do not grasp or apply pressure to fragile areas
of the turbocharger (for example, the vane
activation link).
(e) Before removing the turbocharger, plug the intake
port, exhaust port and oil inlet to protect them from
dirt and other foreign matter.
A164974
IT
(f) If replacing the turbocharger, check for
Oil Pipe accumulation of sludge particles in the oil pipes.
Sludge
If necessary, replace the oil pipes.
(g) Completely remove the gasket adhered to the
lubrication oil pipe flange and turbocharger oil
flange.
(h) When replacing the bolts or nuts, use only
authorized replacement parts to prevent breakage
or deformation.
A146683E01
(i) If replacing the turbocharger, put 20 cm3 (1.2 cu in.)

of fresh oil into the turbocharger oil inlet hole and
turn the turbine wheel by hand to spread oil to the
bearing.
(j) If overhauling or replacing the engine, cut the fuel
supply after installing the engine and crank the
engine for 30 seconds to distribute oil throughout
the engine. Then allow the engine to idle for 60
seconds.
A164975
IT–2 N04C-TR, TS, TT INTAKE – INTAKE SYSTEM
(k) If the engine is running without the air cleaner, case

cover and hose installed, entry of foreign particles
will damage the turbocharger.
A164976
1. CHECK TURBOCHARGER PRESSURE
(b) Using a 3-way connector, connect SST
(turbocharger pressure gauge) to the hose between
the turbo pressure sensor and the No. 1 air hose.
SST 09992-00242
(c) Depress the clutch pedal, and then fully depress the
SST
A154053E01
accelerator pedal. Measure the turbocharging
pressure at maximum speed (approximately 3500 to
3600 rpm).
Standard pressure:
40 to 70 kPa (0.40 to 0.71 kgf/cm2, 5.8 to 10.2
psi)
If the pressure is less than the minimum, check the
intake air and exhaust system for leakage. If the
result is not as specified, replace the turbocharger.
IT
2. INSPECT TURBO PRESSURE SENSOR
(a) Inspect the power source voltage.
(1) Disconnect the sensor connector.
(3) Measure the voltage between terminals T7-3
(VC) and T7-1 (E) of the wire harness side
connector.
Standard voltage:
4.5 to 5.5 V
If the result is not as specified, inspect the wire
harness or ECM (See chapter ES ).
(5) Connect the sensor connector.
N04C-TR, TS, TT INTAKE – INTAKE SYSTEM IT–3
(b) Check the power supply.

(2) Disconnect the vacuum hose from the sensor.
ECM (3) Connect a voltmeter to terminals E34-28 (PIM
(+)) and E33-28 (E2 (-)) of the ECM.
E33 E34
E2 (-) PIM (+)
G039061E06
(4) Using SST (a turbocharger pressure gauge),

apply the following amount of pressure.
SST 09992-00242
Measure the voltage.
Standard voltage
Applied Pressure kPa (kgf/cm2, psi) Specified condition
93.0 (0.95, 13.5) 0.25 to 0.40 V IT
150 (1.53, 21.8) 1.0 to 1.4 V
SST
A154053E01
turbo pressure sensor.
(6) Connect the vacuum hose.
IT–4 N04C-TR, TS, TT INTAKE – TURBOCHARGER
TURBOCHARGER
ENGINE
COMPONENTS
18 (184, 13)
NO. 2 INTAKE PIPE
29 (291, 21)
x2
x2
ENGINE SIDE COVER RH
RADIATOR RESERVOIR TANK
x6
12 (117, 8)
12 (117, 8)
x2
FRONT MUDGUARD RH
IT
GASKET EXHAUST PIPE ASSEMBLY FRONT
EXHAUST RETARDER
70 (714, 52)
x4
x3
30 (306, 22)
GASKET
Non-reusable part
A166595E01
N04C-TR, TS, TT INTAKE – TURBOCHARGER IT–5
NO. 1 TURBO WATER PIPE SUB-ASSEMBLY

25 (250, 18)
GASKET
O-RING
29 (291, 21) 29 (291, 21)

GASKET
29 (291, 21)
x2
70 (714, 52)
x2
TURBOCHARGER GASKET
SUB-ASSEMBLY
36 (367, 27)
x5
GASKET

70 (714, 52)
x2
CLAMP x2
GASKET
x2 TURBO OIL OUTLET PIPE
x2
29 (291, 21) 29 (291, 21)
NO. 1 AIR HOSE

GASKET IT
25 (250, 18) 25 (250, 18) GASKET
GASKET
18 (184, 13) NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY
18 (184, 13)
25 (250, 18)
GASKET
25 (250, 18)
GASKET
GASKET

Non-reusable part
A166596E01
REMOVAL
2. REMOVE ENGINE SIDE COVER RH

4. REMOVE FRONT MUDGUARD RH
(a) Remove the 4 bolts, loosen the 2 bands, and
remove the No. 2 intake pipe.
6. REMOVE NO. 1 AIR HOSE WITH NO. 2 AIR HOSE
(a) Remove the 2 hose bands, 2 nuts and No. 1 air
hose with No. 2 air hose.
chapter EX)
9. REMOVE TURBINE OUTLET ELBOW
(a) Remove the 5 nuts, gasket and turbine outlet elbow.
(a) Remove the 2 bolts and intake air connector
bracket.
A164980
11. REMOVE NO. 1 TURBO INSULATOR

IT (a) Remove the 2 bolts and No. 1 turbo insulator.
A164982
12. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY

(b) Remove the 2 union bolts, 4 gaskets and turbo oil
inlet pipe sub-assembly.
A155555
13. REMOVE TURBO OIL OUTLET PIPE

(a) Remove the 4 bolts, 2 gaskets and turbo oil outlet
pipe.
A155557J01
14. REMOVE NO. 1 TURBO WATER PIPE SUB-

ASSEMBLY IT
(a) Remove the 2 union bolts, bolt, O-ring, gasket and
No. 1 turbo water pipe sub-assembly.
A153234
15. REMOVE NO. 2 WATER BY-PASS PIPE SUB-

ASSEMBLY
(a) Remove the bolt, separate the water by-pass pipe
sub-assembly bracket.
(b) Remove the 2 union bolts, 4 gaskets and water by-
pass pipe sub-assembly.
16. REMOVE INTAKE PIPE
(a) Remove the 2 bolts, gasket and intake pipe.
A155556

(a) Remove the 4 nuts, gasket and turbocharger sub-
assembly.
A162710
INSPECTION
1. CHECK TURBINE SHAFT ROTATION
(a) Check the turbine shaft.
(1) Hold the nut on the turbine shaft with your
fingers and check that there is no remarkable
looseness in the radial and axial directions.
HINT:
If the fins of the impeller and the turbine wheel
A103067
are in contact with the housing because of the
looseness, replace the turbocharger assembly.
(2) Turn the turbine charger with your fingers and
check that it turns smoothly.
HINT:
If the turbine shaft does not turn smoothly,
replace the turbocharger assembly.
(b) Check the turbine housing.
(1) Visually check the turbine housing and
IT compressor housing for damage or breaks.
HINT:
If any damage or breaks are found in the
housings, replace the turbocharger assembly.
(2) Visually check the fins of the impeller and
turbine wheel for damage or breaks.
2. INSPECT AXIAL PLAY OF TURBINE SHAFT
(a) Using a dial indicator, insert the needle of the dial
indicator into the exhaust side of the turbine shaft.
(b) Move the turbine shaft in an axial direction and
measure the axial play of the turbine shaft.
Maximum axial play:
0.008 mm (0.00031 in.)
If the axial play is greater than the maximum,
replace the turbocharger.
A099566
3. INSPECT RADIAL PLAY OF TURBINE SHAFT

indicator into the oil outlet hole, and set it in the
center of the turbine shaft.
(b) Move the turbine shaft in a radial direction and
measure the radial play of the turbine shaft.
Maximum radial play:
0.11 mm (0.0043 in.)
If the radial play is greater than the maximum,
A099567 replace the turbocharger.
4. INSPECT ACTUATOR AND WASTE GATE VALVE

SST OPERATION
(a) Disconnect the actuator hose from the compressor
housing.
(b) Using SST, apply pressure to the actuator.
SST 09992-00242
Standard:
114 kPa (1.16 kgf/cm2, 16.5 psi)
NOTICE:
Never apply more than 147 kPa (1.50 kgf/cm2,
A099568E01
21.3 psi) of pressure to the actuator.

(c) Check that the actuator push rod moves and that
the waste gate valve opens.
If the rod does not move, replace the actuator or
turbocharger.
(d) Connect the actuator hose to the compressor
housing.
INSTALLATION IT
(a) Install a new gasket and the turbocharger with 2
bolts and 2 nuts.
2. INSTALL INTAKE PIPE
(a) Install a new gasket and the intake pipe with the 2
bolts.
A162710 Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
3. INSTALL NO. 2 WATER BY-PASS PIPE SUB-

ASSEMBLY
(a) Install 4 new gaskets and No. 2 water by-pass pipe
sub-assembly, temporarily tighten the 2 union bolts.
(b) Temporarily tighten the No. 2 water by-pass pipe
sub-assembly bracket with the bolt.
(c) Tighten the 2 union bolts.
(d) Tighten the bolt.
4. INSTALL NO. 1 TURBO WATER PIPE SUB-

ASSEMBLY
(a) Install a new O-ring onto the No. 1 turbo water pipe
sub-assembly.
(b) Install 2 new gaskets and the No. 1 turbo water pipe
sub-assembly with the union bolt and bolt.
Torque: Union Bolt
25 N*m (250 kgf*cm, 18 ft.*lbf)
Bolt
A153234 29 N*m (291 kgf*cm, 21 ft.*lbf)
5. INSTALL TURBO OIL OUTLET PIPE

(a) Install 2 new gaskets and the turbo oil outlet pipe
with the 4 bolts.
IT
A155557J01
6. INSTALL TURBO OIL INLET PIPE SUB-ASSEMBLY

(a) Install 4 new gaskets and turbo oil inlet pipe sub-
assembly, temporarily tighten the 2 union bolts.
(b) Temporarily tighten the turbo oil inlet pipe sub-
assembly bracket with the bolt.
A155555
7. INSTALL NO. 1 TURBO INSULATOR

(a) Install the No. 1 turbo insulator with the 2 bolts.
A164982

(a) Install the intake pipe or hose stay with the 2 bolts.
9. INSTALL TURBINE OUTLET ELBOW
(a) Install a new gasket and the turbine outlet elbow
with the 5 nuts.
A164980 chapter EX)
12. INSTALL NO. 1 AIR HOSE WITH NO. 2 AIR HOSE
(a) Install the No. 2 air hose with the 2 hose bands and
2 nuts.
13. INSTALL NO. 2 INTAKE PIPE
(a) Install the No. 2 intake pipe with the 4 bolts and 2 IT
bands.
Torque: Side bolt
29 N*m (291 kgf*cm, 21 ft.*lbf)
Upper bolt
18 N*m (184 kgf*cm, 13 ft.*lbf)
14. INSTALL FRONT MUDGUARD RH
16. INSTALL ENGINE SIDE COVER RH
IT–12 N04C-TR, TS, TT INTAKE – INTERCOOLER
INTERCOOLER
ENGINE
COMPONENTS
EXAMPLE
NO. 2 AIR HOSE
7.5 (77, 66 in.*lbf)
IT
7.5 (77, 66 in.*lbf)
18 (184, 13)

A155410E01
N04C-TR, TS, TT INTAKE – INTERCOOLER IT–13
REMOVAL
HOSE
(a) Disconnect hose band.
A160165
(b) Remove the bolt.
A160157
(c) Disconnect the turbo pressure sensor connector,

wire harness clamp, remove the bolt.
IT
A160158
(d) Disconnect the intake air temperature sensor

connector, remove the bolt.
A160163
(e) Disconnect the hose band, remove the No. 1 intake

air pipe with No. 4 air hose.
A155408

(a) Disconnect the 2 hose bands and No. 2 air hose.
A152406E01

(a) Remove the 4 bolts and intercooler assembly.
IT
A152407E01
INSTALLATION
(a) Install the intercooler assembly with the 4 bolts.
A152407E01
N04C-TR, TS, TT INTAKE – INTERCOOLER IT–15

(a) Install the No. 2 air hose with the 2 hose bands.
A152406E01

HOSE
(a) Install the No. 1 intake air pipe with No.4 air hose
with the hose band.
A155408
(b) Connect the intake air temperature sensor

connector.
IT
A160163
(c) Install the bolt, connect the turbo pressure sensor

connector and wire harness clamp.
A160158
(d) Install the bolt.

A160157
(e) Install the hose band.
A160165
IT
ENGINE
N04C-TU, TV, TW INTAKE
INTAKE SYSTEM
PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT-1
SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT-2
TURBOCHARGER
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT-8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT-10
INSPECTION (N04C-TW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT-12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT-14
INTERCOOLER
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT-17
REMOVAL (N04C-TU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT-19
INSTALLATION (N04C-TU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT-20
REMOVAL (N04C-TV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT-22
INSTALLATION (N04C-TV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT-23
REMOVAL (N04C-TW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT-25
INSTALLATION (N04C-TW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT-26
IT
N04C-TU, TV, TW INTAKE – INTAKE SYSTEM IT–1
INTAKE SYSTEM
PRECAUTION
1. MAINTENANCE PRECAUTION
(a) Do not stop the engine immediately after towing a
trailer, or after high-speed or uphill driving. Idle the
engine for 20 to 120 seconds depending on how
hard the vehicle has been driven.
(b) Avoid sudden acceleration or racing the engine
immediately after starting a cold engine.
(c) If the turbocharger is found to be defective and must
be replaced, check the following items and repair or
replace as necessary:
(1) Engine oil level and quality
(2) Conditions under which the turbocharger was
used
(3) Oil lines leading to the turbocharger
(d) Be careful when removing and reinstalling the
INCORRECT turbocharger. Do not drop or strike the turbocharger.
Also, do not grasp or apply pressure to fragile areas
of the turbocharger (for example, the vane
activation link).
(e) Before removing the turbocharger, plug the intake
port, exhaust port and oil inlet to protect them from
dirt and other foreign matter.
A146682E01
(f) If replacing the turbocharger, check for

Oil Pipe accumulation of sludge particles in the oil pipes. IT
Sludge
If necessary, replace the oil pipes.
(g) Completely remove the gasket adhered to the
lubrication oil pipe flange and turbocharger oil
flange.
(h) When replacing the bolts or nuts, use only
authorized replacement parts to prevent breakage
or deformation.
A146683E01
(i) If replacing the turbocharger, put 20 cm3 (1.2 cu in.)

of fresh oil into the turbocharger oil inlet hole and
turn the turbine wheel by hand to spread oil to the
bearing.
(j) If overhauling or replacing the engine, cut the fuel
supply after installing the engine and crank the
engine for 30 seconds to distribute oil throughout
the engine. Then allow the engine to idle for 60
seconds.
A146684 (k) If the engine is running without the air cleaner, case
cover and hose installed, entry of foreign particles
will damage the turbocharger.
IT–2 N04C-TU, TV, TW INTAKE – INTAKE SYSTEM
SYSTEM DIAGRAM
• The turbocharger system is comprised of the Variable
Nozzle (VN) type turbocharger, turbocharger control
actuator incorporated into the turbocharger and ECM.
• The turbocharger has a nozzle vane which opens and
closes to control the volume of the exhaust gas flowing
into the turbine. This, in turn, controls the boost pressure.
When the nozzle vane moves towards the closing
direction, the pressure increases. When the vane moves
towards the opening direction, the pressure decreases.
• The turbocharger actuator built on the turbine side
activates the nozzle vane. The nozzle vane position
sensor built on the actuator detects the opening angle of
the nozzle vane. The nozzle vane position sensor signal is
sent via the turbocharger control actuator to the ECM.
Then, based on the signal, the ECM actuates the actuator.
• The ECM sends a target nozzle vane position signal to the
turbocharger control actuator to obtain the nozzle vane
position for the optimal pressure in accordance with the
driving conditions.
IT
Turbochager Control
Actuator
ECD MAIN
+B
VNTO
VNTI
GND
ECD
ECM
(*2) VNTI
(*1)
VNTO
FL MAIN
MREL
MAIN IT
VC VC
E2
PIM PIM
E2
E1
*1: for TMC Made
*2: for Salvador Caetano Made
A146801E03
1. CHECK TURBOCHARGER PRESSURE
(b) Using a 3-way connector, connect SST
(turbocharger pressure gauge) to the hose between
the turbo pressure sensor and the No. 1 air hose.
SST 09992-00242
(c) Depress the clutch pedal, and then fully depress the
SST
A154053E01
accelerator pedal. Measure the turbocharging
pressure at maximum speed (approximately 3500 to
3600 rpm).
Standard pressure:
40 to 70 kPa (0.40 to 0.71 kgf/cm2, 5.8 to 10.2
psi)
If the pressure is less than the minimum,
check the intake air and exhaust system for
leakage. If there is no leakage, perform the
"check motor for turbocharger control
operation" procedures below. If the result is
not as specified, replace the turbocharger.
2. INSPECT TURBO PRESSURE SENSOR
(a) Inspect the power source voltage.
(1) Disconnect the sensor connector.
(3) Measure the voltage between terminals T7-3
(VC) and T7-1 (E) of the wire harness side
connector.
Standard voltage:
4.5 to 5.5 V
IT If the result is not as specified, inspect the wire
harness or ECM (See chapter ES).
(5) Connect the sensor connector.
(b) Check the power supply.

(2) Disconnect the vacuum hose from the sensor.
ECM (3) Connect a voltmeter to terminals E34-28 (PIM
(+)) and E33-28 (E2 (-)) of the ECM.
E33 E34
E2 (-) PIM (+)
G039061E06
(4) Using SST (a turbocharger pressure gauge),

apply the following amount of pressure.
SST 09992-00242
Measure the voltage.
Standard voltage
Applied Pressure kPa (kgf/cm2, psi) Specified condition
93.0 (0.95, 13.5) 0.25 to 0.40 V
150 (1.53, 21.8) 1.0 to 1.4 V
IT
A154053
turbo pressure sensor.
3. CHECK MOTOR FOR TURBOCHARGER CONTROL
OPERATION
(a) Remove the No. 1 turbo insulator (See page IT-10).
(b) Check the stroke.
NOTICE:
Make sure that the DC motor connectors are
properly installed.
(1) Turn the ignition switch ON and off.
(2) Check the turbocharger control actuator (DC
motor) operation. Check that the actuator rod
stroke is as shown in the illustration below.
NOTICE:
Never loosen or tighten the fully closed
stopper lock nut.
A B C D
Lock Nut
Motor Rod Stroke
(mm (in.))
Fully Cosed Stopper
9 (0.35) Motor Rod
5 (0.20)
Fully Closed Stopper Contact
0
0 1 2 3
Ignition Switch off Time (sec.)
A146688E02
If the result is not as specified, check the ECM

(See chapter ES) and turbocharger control
actuator.
4. INSPECT TURBOCHARGER CONTROL ACTUATOR
+B (a) Check the voltage of the turbocharger control
actuator.
T9 (1) Turn the ignition switch to the ON position.
(2) Measure the voltage of the actuator.
IT Standard voltage
T9-3 (+B) - Body ground 16 to 32 V
A146689E01 If the voltage is not as specified, check the wire

harness and connector.
(b) Check the resistance of the wire harness side
Wire Harness Side:
connector.
(2) Disconnect the T9 turbocharger control
T9 actuator connector.
GND
Standard resistance
T9-6 (GND) - Body ground Below 1 Ω
A146690E01
If the resistance is not as specified, check the

wire harness and connector.
(c) Connect the T9 turbocharger control actuator
connector.
(d) Check the turbo motor signal.
(1) Connect an oscilloscope to the terminals of the
ECM.
(2) While idling the engine, check the waveform of

the ECM.
Standard condition
ECM Terminal (a) Between E34-21 (VNTO) and E34-7
(E1)
(b) Between E34-29 (VNTI) and E34-7
(E1)
Tester Range 5 V/Division, 20 msec./Division
Specified Condition Idling with warm engine

turbocharger assembly.
HINT:
The waveform varies depending on the
turbocharger operation.
ECM
E34
5 V/Division
(a) VNTO
(32 msec.)
E1
(b) VNTI
VNTO
(128 msec.)
20 msec./Division (Idling)
IT
VINTI
A146691E01
IT–8 N04C-TU, TV, TW INTAKE – TURBOCHARGER
TURBOCHARGER
ENGINE
COMPONENTS
GASKET
GASKET
69 (700, 51)
69 (700, 51)
30 (305, 22)
x3 69 (700, 51)
x2
x4
69 (700, 51)
69 (700, 51)
GASKET 29 (296, 21)

INTAKE PIPE OR HOSE STAY
x2
IT
18 (184, 13)
x3
NO. 1 AIR HOSE
FRONT MUDGUARD RH ENGINE SIDE COVER RH
Non-reusable part
NO. 2 INTAKE PIPE
A158149E01
N04C-TU, TV, TW INTAKE – TURBOCHARGER IT–9
25 (255, 18) TURBO OIL INLET PIPE

SUB-ASSEMBLY
GASKET
29 (296, 21)
70 (714, 52)
GASKET
25 (255, 18)
x2
GASKET
70 (714, 52)
25 (255, 18)
29 (296, 21)
GASKET TURBOCHARGER SUB-ASSEMBLY

SUB-ASSEMBLY
x2
IT
29 (296, 21) GASKET
GASKET
x2
29 (296, 21)
25 (255, 18)
x2
TURBO OIL OUTLET PIPE
INTAKE PIPE
GASKET
25 (255, 18)

29 (296, 21)
18 (184, 13)
25 (255, 18)
GASKET
Non-reusable part
A158150E01
REMOVAL
2. REMOVE ENGINE SIDE COVER RH
3. REMOVE FRONT MUDGUARD RH
(a) Remove the 3 bolts, loosen the 2 bands, and
remove the No. 2 intake pipe.
(a) Remove the 2 bands, 2 bolts and No. 1 air hose.
chapter EX)
A155552
chapter EX)
8. REMOVE EGR COOLER SUB-ASSEMBLY
(a) Disconnect the 3 water by-pass hoses.
(b) Remove the 6 bolts and EGR cooler sub-assembly.
(c) Remove the 2 gaskets.
9. REMOVE INTAKE PIPE OR HOSE STAY
(a) Remove the 2 bolts and intake pipe or hose stay.
IT A152399E01
10. REMOVE NO. 1 TURBO INSULATOR

(a) Remove the 2 bolts and No. 1 turbo insulator.
A163435
11. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY

(a) Remove the bolt, and separate the turbo oil inlet
pipe sub-assembly bracket.
(b) Remove the 2 union bolts, 4 gaskets and turbo oil
inlet pipe sub-assembly.
A155555
12. REMOVE TURBO OIL OUTLET PIPE

(a) Remove the 4 bolts, 2 gaskets and turbo oil outlet
pipe.
A155557J01

ASSEMBLY
(a) Remove the union bolt, bolt, O-ring, 2 gaskets and
IT
No. 1 turbo water pipe sub-assembly.
A153234
14. REMOVE NO. 2 WATER BY-PASS PIPE SUB-

ASSEMBLY
(a) Remove the nut, and separate the water by-pass
pipe sub-assembly bracket.
(b) Remove the 2 union bolts, 4 gaskets and water by-
pass pipe sub-assembly.
(a) Remove the 2 bolts, gasket and intake pipe.
A155556 16. REMOVE TURBOCHARGER SUB-ASSEMBLY
(b) Remove the 4 nuts, gasket and turbocharger sub-

assembly.
A162710
(c) Remove the 7 stud bolts.
IT
A162711
1. CHECK TURBINE SHAFT ROTATION
(a) Check the turbine shaft.
(1) Hold the nut on the turbine shaft with your
fingers and check that there is no remarkable
looseness in the radial and axial directions.
HINT:
If the fins of the impeller and the turbine wheel
A103067
are in contact with the housing because of the
looseness, replace the turbocharger assembly.
(2) Turn the turbine charger with your fingers and
check that it turns smoothly.
HINT:
If the turbine shaft does not turn smoothly,
replace the turbocharger assembly.
(b) Check the turbo housing.
(1) Visually check the turbine housing and
compressor housing for damage or breaks.
HINT:
If any damage or breaks are found in the
housings, replace the turbocharger assembly.
(2) Visually check the fins of the impeller and

turbine wheel for damage or breaks.
2. INSPECT AXIAL PLAY OF TURBINE SHAFT
indicator into the exhaust side of the turbine shaft.
(b) Move the turbine shaft in an axial direction and
measure the axial play of the turbine shaft.
Maximum axial play:
0.008 mm (0.00031 in.)
If the axial play is greater than the maximum,
replace the turbocharger.
A099566
3. INSPECT RADIAL PLAY OF TURBINE SHAFT

indicator into the oil outlet hole, and set it in the
center of the turbine shaft.
(b) Move the turbine shaft in a radial direction and
measure the radial play of the turbine shaft.
Maximum radial play:
0.11 mm (0.0043 in.)
If the radial play is greater than the maximum,
A099567 replace the turbocharger.
4. INSPECT ACTUATOR AND WASTE GATE VALVE

SST OPERATION
(a) Disconnect the actuator hose from the compressor
housing.
(b) Using SST, apply pressure to the actuator.
SST 09992-00242
Standard: IT
114 kPa (1.16 kgf/cm2, 16.5 psi)
NOTICE:
Never apply more than 147 kPa (1.50 kgf/cm2,
A099568E01
21.3 psi) of pressure to the actuator.

(c) Check that the actuator push rod moves and that
the waste gate valve opens.
If the rod does not move, replace the actuator or
turbocharger.
(d) Connect the actuator hose to the compressor
housing.
INSTALLATION
(a) Install the 7 stud bolts.
A162711
(b) Install a new gasket and the turbocharger with 4

new nuts.
(c) Connect the connector.
bolts.
IT
A162710
3. INSTALL NO. 2 WATER BY-PASS PIPE SUB-

ASSEMBLY
(a) Install 4 new gaskets and No. 2 water by-pass pipe
sub-assembly, temporarily tighten the 2 union bolts.
(b) Temporarily tighten the No. 2 water by-pass pipe
sub-assembly bracket with the bolt.
(d) Tighten the nut.

ASSEMBLY
(a) Install a new O-ring onto the No. 2 turbo water pipe.
(b) Install 2 new gaskets and the No. 2 turbo water pipe
sub-assembly with the union bolt and bolt.
Torque: Union Bolt
25 N*m (255 kgf*cm, 18 ft.*lbf)
Bolt
29 N*m (296 kgf*cm, 21 ft.*lbf)
A153234
5. INSTALL TURBO OIL OUTLET PIPE

(a) Install 2 new gaskets and the turbo oil outlet pipe
with the 4 bolts.
A155557J01
6. INSTALL TURBO OIL INLET PIPE SUB-ASSEMBLY

(a) Install the 4 new gaskets and turbo oil inlet pipe sub-
assembly, temporarily tighten the 2 union bolts.
IT
(b) Temporarily tighten the turbo oil inlet pipe sub-
assembly bracket with the bolt.
A155555
7. INSTALL NO. 1 TURBO INSULATOR

(a) Install the No. 1 turbo insulator with the 2 bolts.
A163435
8. INSTALL INTAKE PIPE OR HOSE STAY

(a) Install the intake pipe or hose stay with the 2 bolts.
9. INSTALL EGR COOLER SUB-ASSEMBLY
(a) Install the EGR cooler sub-assembly with the 6
bolts.
(b) Connect the 3 water by-pass hoses.
A152399J01 10. INSTALL FRONT EXHAUST PIPE ASSEMBLY (See
chapter EX)
chapter EX)
(a) Install the No.1 air hose with the 2 bands and 2
bolts.
Torque: Bolt
13 N*m (133 kgf*cm, 10 ft.*lbf)
13. INSTALL NO. 2 INTAKE PIPE
(a) Install the No. 2 intake pipe with the 3 bolts and 2
bands.
14. INSTALL FRONT MUDGUARD RH
15. INSTALL ENGINE SIDE COVER RH
A155552 17. INSPECT FOR COOLANT LEAK (See chapter CO)
IT
N04C-TU, TV, TW INTAKE – INTERCOOLER IT–17
INTERCOOLER
ENGINE
COMPONENTS
EXAMPLE: N04C-TV
NO. 2 AIR HOSE
7.5 (77, 66 in.*lbf)
IT
7.5 (77, 66 in.*lbf)
18 (184, 13)

A155410E02
IT–18 N04C-TU, TV, TW INTAKE – INTERCOOLER
NO. 1 AIR HOSE
13 (133, 10)
7.5 (77, 66 in.*lbf)
7.5 (77, 66 in.*lbf)
IT
18 (184, 13)
18 (184, 13)
18 (184, 13)
18 (184, 13)
A152382E04
REMOVAL (N04C-TU)
HOSE
(a) Disconnect the hose band.
A160165
(b) Remove the 2 bolts and bracket.
A152402E01
(c) Disconnect the turbo pressure sensor connector

and wire harness clamp, and remove the bolt.
IT
A152403E01

connector, and remove the bolt.
A158151
(e) Disconnect the hose band, and remove the No. 1

intake air pipe with No. 4 air hose.
(a) Disconnect the 2 hose bands, 2 nuts and No. 2 air
hose.
A155407

A152407E01
2. INSTALL NO. 2 AIR HOSE WITH NO. 1 AIR HOSE
(a) Install the No. 2 air hose with the 2 hose bands and
bolts.
IT
A152407E01

HOSE
(a) Install the No. 1 intake air pipe with No. 4 air hose
with the hose band.
A155407E01
(b) Install the bolt, and connect the intake air

temperature sensor connector.
A158151
(c) Install the bolt, and connect the turbo pressure

sensor connector and wire harness clamp.
A152403E02
(d) Install the bracket with the 2 bolts.

IT
A152402E01
A160165
REMOVAL (N04C-TV)
HOSE
A160165
A160157

IT
A160158

A160163

A155408

A152407E01
INSTALLATION (N04C-TV)
IT
A152407E01

HOSE
with the hose band.
A155408

A160163

A160158
(d) Install the bracket with the bolt.

IT
A160157
A160165
REMOVAL (N04C-TW)
HOSE
A152401E01
A152402E01

IT
A152403J01

A158151

A152405E01

A152406E01

IT
A152407E01
A152407E01

A152406E01

HOSE
with the hose band.
A152405E01

IT
A158151

A152403E01
(d) Install the bracket with the 2 bolts.

A152402E01
A152401E01
IT
ENGINE
W04D-TM, TN INTAKE
INTERCOOLER
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT-1
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT-2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT-3
TURBOCHARGER ASSEMBLY
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT-4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT-7
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT-8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT-10
IT
W04D-TM, TN INTAKE – INTERCOOLER IT–1
INTERCOOLER
W04D-TM, TN INTAKE
ENGINE
COMPONENTS
NO. 2 AIR HOSE
x4
7.5 (77, 66 in.*lbf) IT
NO. 3 AIR HOSE
A165996E01
IT–2 W04D-TM, TN INTAKE – INTERCOOLER
REMOVAL
(a) Remove the No. 2 air hose.
A155952

(a) Remove the No. 3 air hose.
A155951
IT
A152407J01
W04D-TM, TN INTAKE – INTERCOOLER IT–3
INSTALLATION
A152407J01

A155952
IT
A155951
IT–4 W04D-TM, TN INTAKE – TURBOCHARGER ASSEMBLY
TURBOCHARGER ASSEMBLY
W04D-TM, TN INTAKE
ENGINE
COMPONENTS
x5
30 (301, 22)
GASKET
x3
EXHAUST RETARDER
IT GASKET
GASKET
30 (306, 22)
25 (259, 19)
x3
70 (714, 52)
GASKET
N*m (kgf*cm, ft.*lbf) : Specified torque FRONT EXHAUST PIPE ASSEMBLY
Non-reusable part
A163436E01
W04D-TM, TN INTAKE – TURBOCHARGER ASSEMBLY IT–5

GASKET
18 (184, 13)
GASKET
GASKET
25 (250, 18) TURBOCHARGER
SUB-ASSEMBLY
WATER OUTLET PIPE
SUB-ASSEMBLY
29 (290, 21)
STUD BOLT
25 (250, 18) STUD BOLT x5 56 (570, 41)
GASKET x2
x2
x2
GASKET x2 STUD BOLT
INTAKE PIPE GASKET

x2
25 (250, 18)
56 (570, 41) GASKET
GASKET
GASKET GASKET 29 (290, 21)
29 (290, 21)
18 (184, 13) TURBO OIL
OUTLET PIPE
x2
WATER INLET PIPE GASKET

ASSEMBLY
IT
GASKET 29 (290, 21)

25 (250, 18)
x2
INTAKE AIR CONNECTOR PIPE
INTAKE AIR CONNECTOR PIPE
Non-reusable part
A163437E01
1. INSPECT TURBOCHARGER EXTERIOR AND
INSTALLATION
(a) Visually check for missing or loose nuts and bolts.
(b) Visually check for loose or damaged intake and
exhaust pipes.
(c) Visually check for damaged oil supply and drain
lines.
(d) Visually check for cracked or deteriorating
turbocharger housings.
(e) Visually check for external oil or coolant leakage.
Repair any problems found during installation. If any
turbocharger parts are damaged, overhaul the unit
after completing the remaining troubleshooting
procedures.
CAUTION:
Operation of the engine without the intake pipe
and air cleaner connected can result in foreign
objects entering the turbocharger, which can
lead to personal injury or mechanical damage.
2. INSPECT TURBINE WHEEL AND HOUSING
(a) Remove the turbine outlet elbow from the turbine
outlet. Using a flashlight, check for rubbing between
the turbine wheel and housing, evidence of leaks, or
foreign object damage. Foreign object damage is
usually not visible on the turbine outlet unless it is
severe.
(1) Check for rubbing between the turbine wheel
and housing.
A163429 If the turbine wheel rubs against the housing
while both components are securely installed,
IT the turbocharger may be damaged internally
and must be overhauled.
(2) Check for oil leakage.
If oil deposits are found, determine whether the
oil has come from the engine exhaust or the
turbocharger center housing. If the oil has
come from the engine, refer to the ENGINE
MECHANICAL section (See chapter ME) and
repair the problem. If heavy oil deposits are
found on the turbine wheel, then the
turbocharger should be disassembled, cleaned,
and overhauled as necessary.
(3) Check for damage due to foreign objects.
If the turbine is obviously damaged due to
foreign objects, the turbocharger must be
overhauled. Such damage destroys the wheel's
balance and causes internal damage to the
seal bores and journal bearings. Be sure to find
the source of the foreign objects. In many
cases, the object has come from the engine,
and the engine may have damage as well.
3. INSPECT COMPRESSOR WHEEL AND HOUSING

(a) Remove the ducting from the compressor inlet.
Using a flashlight, check for rubbing between the
compressor wheel and housing, evidence of oil
leakage and damage due to foreign objects.
(1) Check for rubbing between the compressor
wheel and housing.
If the compressor wheel rubs against the
housing while both components are securely
A163430 installed, the turbocharger may be damaged
internally and must be overhauled.
(2) Check for oil leakage.
Oil leakage into the compressor can be caused
by long periods of idling with a restricted oil
drain line, a restricted air intake system, or
frequent engine braking. In this case, there is
nothing wrong with the engine or turbocharger.
However, frequent cleaning of the compressor
wheel and housing is recommended if the oil
drain line and air intake system are normal.
(3) Check for damage due to foreign objects.
If the compressor wheel has been damaged by
foreign objects, overhaul the turbocharger.
4. INSPECT ROTATING ASSEMBLY FOR NOISE OR
EXCESSIVE PLAY
(a) If no damage is visible in the turbine and
compressor areas, spin the rotating assembly by
hand. It should spin freely without drag or any
grinding noise.
REMOVAL
1. DRAIN ENGINE COOLANT (See chapter CO) IT
A163431

3. REMOVE FENDER SIDE APRON SUB-ASSEMBLY
4. REMOVE NO. 2 AIR HOSE (See page IT-2)
chapter EX)
6. REMOVE INTAKE AIR CONNECTOR PIPE
(a) Remove the 4 bolts and intake air connect pip.
A155946

(a) Remove the 2 nuts and intake pipe.
(b) Remove the gasket.
A155947
8. REMOVE TURBINE OUTLET ELBOW

(a) Remove the 5 nuts and turbine outlet elbow.
A155948

(a) Remove the clamp bolt, 2 union bolts, 4 gaskets and
turbo oil inlet pipe sub-assembly.
(b) Remove the 4 bolts, 2 gaskets and turbo oil outlet
pipe.
(c) Remove the clamp bolt, 2 union bolts, 4 gaskets and
water inlet pipe assembly.
(d) Remove the 2 union bolts, 4 gaskets and water
outlet pipe sub-assembly.
A155949
IT
(e) Remove the 2 bolts, 2 nuts and turbocharger sub-
assembly.
INSPECTION
1. INSPECT RADIAL BALL BEARING CLEARANCE
(a) Remove the 3 bolts of the actuator and hose.
(b) Remove the retainer and measure it.
(c) Attach a turbocharger gauge set to the unit so that
the dial indicator plunger extends through the oil
A155950
drain port and contacts the shaft of the turbine
wheel assembly.
(d) Using the dial indicator, check the radial play of the
turbine rotor.
Standard play:
0.05 to 0.13 mm (0.0020 to 0.0051 in.)
Maximum play:
0.13 mm (0.0051 in.)
If the radial play is greater than the maximum, the
turbocharger is worn or damaged internally and
must be overhauled.
2. INSPECT AXIAL BEARING CLEARANCE

(a) Using the dial indicator, check the axial play of the
turbine rotor (exhaust side).
Standard play:
0.01 to 0.10 mm (0.0004 to 0.0039 in.)
Maximum play:
0.10 mm (0.0039 in.)
If the axial play is greater than the maximum, the
turbocharger is worn or damaged internally and
A163427 must be overhauled.
3. INSPECT WASTE GATE PERFORMANCE

(a) Remove the waste gate sensing hose.
(b) Attach a dial indicator set to the turbocharger so that
the dial indicator is set on the end of the actuator
rod in the same plane as the rod as shown in the
illustration.
(c) Set the dial indicator to 0.
(d) While gently tapping the turbine housing with a soft
mallet, use SST to apply air pressure so that the dial
A163428 indicator pointer shows the following value
(Procedure "A").
SST 09992-00242
Rod movement:
0.38 mm (0.015 in.)
(e) Make sure that air pressure is within the specified
range (Procedure "B").
Air pressure:
106.9 to 112.3 kPa (1.08 to 1.14 kgf/cm2, 15 to
16 psi)
(f) Release the air pressure at the sensing port. Note
that the dial indicator pointer returns exactly to 0
(Procedure "C").
IT
(g) Repeat procedures "A" through "C" several times to
make sure that the air pressure has been accurately
measured.
If the air pressure is not within the specified range,
replace the turbine housing assembly or actuator
assembly.
NOTICE:
Operation of the engine with the waste gate
calibrated to some values other than that
specified can result in reduced performance or
severe engine damage.
(h) Reinstall the waste gate sensing hose.
INSTALLATION
(a) Install a new gasket and the turbocharger sub-
assembly with the 2 nuts and 2 bolts.
A155950E01
(b) Install 4 new gaskets and the turbo oil outlet pipe
with the 2 union bolts.
(c) Install 4 new gaskets and the water inlet pipe
assembly with the 2 union bolts and clamp bolt.
Torque: Union bolt
25 N*m (250 kgf*cm, 18 ft.*lbf)
Clamp bolt
18 N*m (184 kgf*cm, 13 ft.*lbf)
A155949 (d) Install 2 new gaskets and the water outlet pipe sub-
(e) Install 4 new gaskets and the turbo oil inlet pipe sub-
assembly with the 2 union bolts and clamp bolt.
Torque: Union bolt
25 N*m (250 kgf*cm, 18 ft.*lbf)
Clamp bolt
18 N*m (184 kgf*cm, 13 ft.*lbf)
2. INSTALL TURBINE OUTLET ELBOW
(a) Install a new gasket and the turbine outlet elbow
with the 5 nuts.
IT
A155948

nuts.
A155947
4. INSTALL INTAKE AIR CONNECTOR PIPE

(a) Install the intake air connector pipe with the 4 bolts.
chapter EX)
6. INSTALL NO. 2 AIR HOSE (See page IT-3)
7. INSTALL FENDER SIDE APRON SUB-ASSEMBLY
A155946 8. INSTALL ENGINE SIDE COVER SUB-ASSEMBLY RH
IT
ENGINE
N04C-TR, TS, TT EXHAUST
EXHAUST MANIFOLD
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-1
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-2
EXHAUST PIPE
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-10
EX
N04C-TR, TS, TT EXHAUST – EXHAUST MANIFOLD EX–1
EXHAUST MANIFOLD
ENGINE
COMPONENTS
EXHAUST MANIFOLD COVER
29 (290, 21) 60 (610, 44) EXHAUST MANIFOLD
x3
x8
GASKET
GASKET
EX
Non-reusable part
A165808E01
REMOVAL
HINT:
(See chapter IT)
EX–2 N04C-TR, TS, TT EXHAUST – EXHAUST MANIFOLD

(a) Remove the 3 bolts and exhaust manifold cover.
A155964
(b) Remove the 8 nuts and exhaust manifold.

A155965
INSTALLATION
CORRECT INCORRECT 1. INSTALL EXHAUST MANIFOLD
(a) Install a new gasket to the cylinder head as shown
A161408E01

EX and temporarily tighten the 8 nuts in the order
8 4 2 6 HINT:
7 3 1 5
Contact Contact
A166690E01
N04C-TR, TS, TT EXHAUST – EXHAUST MANIFOLD EX–3

7 3 1 5
A166691E01
(d) Install the exhaust manifold heat insulator sub-

HINT:
(See chapter IT)
A155964
EX
EX–4 N04C-TR, TS, TT EXHAUST – EXHAUST PIPE
EXHAUST PIPE
ENGINE
COMPONENTS
Exhaust pipe short tail:
NO. 1 LOWER EXHAUST PIPE

SUPPORT BRACKET
HOLDER PLATE
HOLDER PLATE
NO. 2 EXHAUST PIPE SUPPORT CUSHION 24 (245, 18)

24 (245, 18)
EXHAUST PIPE
x2 BRACKET
50 (510, 37)
GASKET
x2
24 (245, 18)
NO. 1 EXHAUST PIPE SUPPORT BRACKET
70 (714, 52) VACUUM HOSE

x3 25 (259, 19)
25 (259, 19)
x4
EX 30 (301, 22)
CENTER EXHAUST
PIPE ASSEMBLY
GASKET GASKET
Non-reusable part
A164454E10
N04C-TR, TS, TT EXHAUST – EXHAUST PIPE EX–5
EXAMPLE: Exhaust
Exhaust pipe longpipe
tail:long tail
GASKET CENTER EXHAUST PIPE ASSEMBLY
VACUUM HOSE
70 (714, 52)
x3
25 (259, 19)
30 (301, 22)
x4
GASKET
GASKET
TAIL EXHAUST PIPE SUB-ASSEMBLY
EX
TAIL EXHAUST PIPE ASSEMBLY
Non-reusable part
A163443E05
EXAMPLE:
Exhaust Exhaust
pipe longpipe
tail:long tail HOLDER PLATE
NO. 2 EXHAUST PIPE 24 (245, 18)
NO. 2 EXHAUST PIPE SUPPORT CUSHION
SUPPORT CUSHION
x2
50 (510, 37)
NO. 1 EXHAUST PIPE

SUPPORT BRACKET
NO. 1 LOWER EXHAUST PIPE 24 (245, 18)

HOLDER PLATE
SUPPORT BRACKET
24 (245, 18)
x2
HOLDER PLATE
50 (510, 37)
NO. 1 LOWER EXHAUST PIPE

SUPPORT BRACKET
24 (245, 18) 24 (245, 18)
31 (313, 23)
x2
EXHAUST PIPE SUPPORT
SUB-ASSEMBLY
50 (510, 37)
50 (510, 37)
31 (313, 23) x2
HOLDER PLATE 24 (245, 18)
EX
NO. 1 EXHAUST PIPE SUPPORT
EXHAUST PIPE SUPPORT
HOLDER PLATE x2
25 (259, 19)
NO. 1 EXHAUST PIPE SUPPORT x2
24 (245, 18)
NO. 5 EXHAUST
x2 PIPE SUPPORT
NO. 4 EXHAUST PIPE BRACKET
SUPPORT BRACKET
EXHAUST PIPE SUPPORT BOLT
A164455E05
REMOVAL
1. REMOVE TAIL EXHAUST PIPE ASSEMBLY
(a) Exhaust pipe long tail
(1) Remove the 2 nuts and 2 holder plates.
A164764
(2) Remove the 2 nuts and tail exhaust pipe

assembly.
(3) Remove the bolt, 2 nuts, 2 No. 1 exhaust pipe
supports and exhaust pipe support bolt.
EX
A165145
A165144
(4) Remove the 2 bolts, nut, exhaust pipe support

sub-assembly, exhaust pipe bracket and holder
plate.
A165143
(5) Remove the 2 nuts and tail exhaust pipe sub-

assembly.
A165146

sub-assembly, exhaust pipe bracket and holder
plate.
EX
A165143
2. REMOVE CENTER EXHAUST PIPE ASSEMBLY

(a) Exhaust pipe short tail
(1) Disconnect the vacuum hose.
A164456
(2) Remove the 4 bolts and exhaust retarder

assembly.
(3) Remove the 2 gaskets.
A152398E01
(4) Remove the 2 nuts, 2 holder plates, 4 exhaust

pipe support cushions and center exhaust pipe
assembly.
(5) Remove the 2 bolts and 2 No. 1 exhaust pipe
support bracket.
(6) Remove the 2 bolts and 2 No. 1 lower exhaust
pipe support bracket.
(7) Remove the bolt and exhaust pipe bracket from
the center exhaust pipe assembly.
A164458
(b) Exhaust pipe long tail

A164456

assembly. EX
A152398E01
(4) Remove the nut, holder plate, 2 exhaust pipe

support cushions and center exhaust pipe
assembly.
(5) Remove the 2 bolts and exhaust pipe bracket.
A165010
3. REMOVE FRONT EXHAUST PIPE ASSEMBLY

A154032E01
(b) Remove the 3 nuts and front exhaust pipe

assembly.
(c) Remove the gasket.
A164459
INSTALLATION
1. INSTALL FRONT EXHAUST PIPE ASSEMBLY
(a) Install a new gasket and front exhaust pipe
assembly and temporarily tighten the 3 nuts.
A164459
(b) Temporarily tighten the bolt.

EX (c) Tighten the 3 nuts.
2. INSTALL CENTER EXHAUST PIPE ASSEMBLY
(a) Exhaust pipe short tail
(1) Install the No. 1 exhaust pipe support bracket
with the 2 bolts
A154032E01
(2) Install the No. 1 lower exhaust pipe support
bracket with the 2 bolts
(3) Install the exhaust pipe bracket with the bolt to
the center exhaust pipe assembly.
(4) Install the center exhaust pipe assembly, 2

exhaust pipe support cushions and 2 holder
plates with the 2 nuts.
A164458
(5) Install 2 new gaskets and the exhaust retarder

A152398E01

with the 2 bolts
A164456
(2) Install the center exhaust pipe assembly, 2

exhaust pipe support cushions and holder plate EX
with the nut.
A165010
(3) Install 2 new gaskets and the exhaust retarder

A152398E01

3. INSTALL TAIL EXHAUST PIPE SUB-ASSEMBLY AND
(a) Exhaust pipe long tail
(1) Install the No. 5 exhaust pipe bracket to the
frame with the 2 bolts.
(2) Install the 2 exhaust pipe brackets and No. 4
exhaust pipe support bracket to the frame with
A164456
the 6 bolts.
(3) Install the 2 exhaust pipe support sub-
assemblies, 2 No. 1 exhaust pipe supports and
4 holder plates to the brackets.
Temporarily tighten the 4 nuts.
(4) Install the tail exhaust pipe sub-assembly and
the tail exhaust pipe assembly.
(5) Temporarily tighten the exhaust pipe support
bolt, 2 nuts and bolt.
EX
A166605
(6) Tighten the 6 nuts.
C C
A A
B B
A166689E01
Torque: A
50 N*m (510 kgf*cm, 37 ft.*lbf)
B
31 N*m (313 kgf*cm, 23 ft.*lbf)
C
24 N*m (245 kgf*cm, 18 ft.*lbf)
HINT:
Make sure to tighten the upper bolt first and the
lower bolt last.
(7) Tighten the 5 nuts.
Torque: D
D D E 25 N*m (250 kgf*cm, 18 ft.*lbf)
E
24 N*m (245 kgf*cm, 18 ft.*lbf)
F
25 N*m (259 kgf*cm, 19 ft.*lbf)
HINT: EX
Make sure to tighten the upper bolt first and the
lower bolt last.
A164764E01
5. INSPECT CENTER EXHAUST PIPE ASSEMBLY

105 to 111 mm (4.13 to 4.37 in) (a) Exhaust pipe short tail
Bellows (1) Check that the exhaust center pipe assembly
bellows pipe is installed as shown in the
illustration.
Below 5 mm
(0.19 in)
157 mm (6.18 in) A155409E09

121 to 127 mm (4.76 to 5.00 in) (1) Check that the exhaust center pipe assembly
Bellows bellows pipe is installed as shown in the
illustration.
Below 5 mm
(0.19 in)
175 mm (6.89 in) A155409E10
EX
ENGINE
N04C-TU, TV EXHAUST
EXHAUST MANIFOLD
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-1
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-2
EXHAUST PIPE
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-13
EX
N04C-TU, TV EXHAUST – EXHAUST MANIFOLD EX–1
EXHAUST MANIFOLD
N04C-TU, TV EXHAUST
ENGINE
COMPONENTS
EXHAUST MANIFOLD COVER
x3
x8
GASKET
GASKET
EX
Non-reusable part
A152769E01
REMOVAL
HINT:
(See chapter IT)
EX–2 N04C-TU, TV EXHAUST – EXHAUST MANIFOLD

A155964

(c) Remove the 4 gasket.
A155965
INSTALLATION
CORRECT INCORRECT 1. INSTALL EXHAUST MANIFOLD
(a) Install 4 new gaskets to the cylinder head as shown
A161408E01

EX 8 4 2 6 HINT:
7 3 1 5
Contact Contact
A166690E01
N04C-TU, TV EXHAUST – EXHAUST MANIFOLD EX–3

7 3 1 5
A166691E01
(d) Install the exhaust manifold heat insulator

subassembly with the 3 bolts.
HINT:
(See chapter IT)
A155964
EX
EX–4 N04C-TU, TV EXHAUST – EXHAUST PIPE
EXHAUST PIPE
N04C-TU, TV EXHAUST
ENGINE
COMPONENTS
Short wheelbase (high frame):
x2
50 (510, 37) NO. 2 EXHAUST PIPE SUPPORT
CUSHION
Long wheelbase, short wheelbase (high frame),

semi-long wheelbase:
x2 24 (245, 18)
HOLDER PLATE
50 (510, 37)
NO. 2 EXHAUST PIPE

SUPPORT CUSHION
EXHAUST RETARDER
70 (714, 52)
x3 ASSEMBLY
GASKET 25 (259, 19)
CENTER EXHAUST
x4 PIPE ASSEMBLY
FRONT EXHAUST 30 (301, 22)
EX PIPE ASSEMBLY GASKET
Non-reusable part
A165210E06
N04C-TU, TV EXHAUST – EXHAUST PIPE EX–5
EXAMPLE: Long wheelbase

Long wheelbase:

25 (259, 19)
50 (510, 37)
HOLDER PLATE
HOLDER PLATE
NO. 1 LOWER EXHAUST 50 (510, 37)

PIPE SUPPORT BRACKET
24 (245, 18) x2
x2
24 (245, 18) x2
NO. 5 EXHAUST PIPE
24 (245, 18) SUPPORT BRACKET
HOLDER PLATE
x2 NO. 1 EXHAUST PIPE
x2 SUPPORT
EXHAUST PIPE SUPPORT BOLT

24 (245, 18) 31 (313, 23)
50 (510, 37) 50 (510, 37)
31 (313, 23)
EXHAUST PIPE SUPPORT SUB-ASSEMBLY

NO. 5 EXHAUST PIPE EX
EXHAUST PIPE SUPPORT SUB-ASSEMBLY SUPPORT BRACKET
NO. 1 LOWER EXHAUST PIPE SUPPORT BRACKET
A165882E09
EXAMPLE: Short wheelbase

Short wheelbase (low frame),
(low frame), semi-long
semi-long wheelbase
wheelbase):
25 (259, 19)
24 (245, 18)
HOLDER PLATE
25 (259, 19) 50 (510, 37)
x2
x2 x2
NO. 5 EXHAUST
HOLDER PLATE
24 (245, 18)
PIPE SUPPORT BRACKET
x2
24 (245, 18)
24 (245, 18)
NO. 1 LOWER EXHAUST PIPE EXHAUST PIPE SUPPORT BOLT

SUPPORT BRACKET
50 (510, 37)
EXHAUST PIPE SUPPORT 31 (313, 23)
SUB-ASSEMBLY
EXAMPLE: Short wheelbase (high frame)

Short wheelbase (high frame):
HOLDER PLATE
HOLDER PLATE
24 (245, 18)
NO. 4 EXHAUST PIPE

x2
SUPPORT BRACKET 24 (245, 18) NO. 1 EXHAUST
EX 24 (245, 18)
25 (259, 19) PIPE SUPPORT
24 (245, 18) x2
HOLDER PLATE
TAIL EXHAUST x2
x2
PIPE ASSEMBLY 24 (245, 18)
NO. 1 LOWER EXHAUST

24 (245, 18) 50 (510, 37) PIPE SUPPORT BRACKET
31 (313, 23)
NO. 1 LOWER EXHAUST
PIPE SUPPORT BRACKET EXHAUST PIPE SUPPORT BOLT

A165883E08
EX
ASM3-733
REMOVAL
(a) Short wheelbase (low frame), semi-long wheelbase
and long wheelbase
assembly.
A165218E01
Semi-long wheelbase: Short wheelbase (low frame),

long wheelbase:
EX
A166659E01

A165568
(4) Remove the 2 bolts and No. 4 exhaust pipe

support.
support bracket.
sub-assembly, No. 1 lower exhaust pipe
support bracket and holder plate.
(b) Short wheelbase (high frame)
EX
A165221

assembly.
A165220
A165569

support bracket.
(5) Remove the 2 bolts and No. 1 lower exhaust
EX pipe support bracket.
subassembly, exhaust pipe bracket and holder
plate.
A166603
2. REMOVE TAIL EXHAUST PIPE SUB-ASSEMBLY

Long wheelbase: (a) Long wheelbase
assembly.
subassembly, exhaust pipe bracket and holder
plate.
A166660E01

and long wheelbase
A164456

assembly.
(3) Remove the 2 gaskets. EX
A152398E01
(4) Remove the nut, 2 No. 2 exhaust pipe support

cushions, holder plate and center exhaust pipe
assembly.
A165214

A164456

assembly.
EX
A152398E01
(4) Remove the nut, 2 No. 2 exhaust pipe support

cushions, holder plate and center exhaust pipe
assembly.
A165219

A154032E01

assembly.
A152396E01
INSTALLATION
assembly, and temporarily tighten the 3 nuts.
A152396E01

(c) Tighten the 3 nuts.
(d) Tighten the bolt. EX
and long wheelbase
A154032E01
bracket with the 2 bolts.
(2) Install the center exhaust pipe assembly, holder

plate and 2 No. 2 exhaust pipe support
cushions with the nut.
A165214
(3) Install the 2 new gaskets and exhaust retarder

A152398E01

(b) Short wheelbase (low frame), semi-long wheelbase
and long wheelbase
EX
A164456
(2) Install the center exhaust pipe assembly, holder

plate and 2 No. 2 exhaust pipe support
cushions with the nut.
A165219
(3) Install 2 new gaskets and exhaust retarder

A152398E01

3. INSTALL TAIL EXHAUST PIPE SUB-ASSEMBLY
(a) Long wheel base
(1) Install the exhaust pipe support sub-assembly
and No. 1 lower exhaust pipe support bracket
and holder plate with the 2 bolts and nut.
A164456
(b) Install the tail exhaust pipe assembly with the 2

Long wheelbase: nuts.
Torque: A
50 N*m (510 kgf*cm, 37 ft.*lbf)
B
31 N*m (313 kgf*cm, 23 ft.*lbf)
HINT:
Make sure to tighten the bolt A first and the bolt B
last.
4. INSTALL TAIL EXHAUST PIPE ASSEMBLY
A and long wheelbase
bracket and No. 4 exhaust pipe support bracket EX
to the frame with 4 bolts.
B
to the frame with 2 bolts.
(3) Install the exhaust pipe support sub-assembly,
A166660E02
2 No. 1 exhaust pipe supports and 3 holder
plates to the brackets. Temporarily tighten the 3
nuts.
(4) Install the tail exhaust pipe assembly.

bolt, 2 nuts and bolt.
A166593
EX
(6) Tighten 7 nuts and bolt.
Short wheelbase (low frame),

Semi-long: long wheelbase:
C
C
A
A
B
B
Semi-long, short wheelbase (low frame),

long wheelbase: D DC
EX
C
A166662E01
Torque: A
50 N*m (510 kgf*cm, 37 ft.*lbf)
B
31 N*m (313 kgf*cm, 23 ft.*lbf)
C
24 N*m (245 kgf*cm, 18 ft.*lbf)
D, E
25 N*m (259 kgf*cm, 19 ft.*lbf)
HINT:
Make sure to tighten the bolt A first and the bolt
B last.
(1) Install the 2 No. 1 lower exhaust pipe support
bracket and No. 4 exhaust pipe support bracket
to frame with 6 bolts.
(2) Install the exhaust pipe support sub-assembly,
2 No. 1 exhaust pipe supports and 3 holder
plate to brackets. Temporarily tighten the 3
nuts.
(3) Install the exhaust pipe assembly.
bolts, 2 nuts and bolt.
A165569
(5) Tighten 7 nuts and bolt.
EX
C
DD
C
A E
B
A166604E01
Torque: A
50 N*m (510 kgf*cm, 37 ft.*lbf)
B
31 N*m (313 kgf*cm, 23 ft.*lbf)
C
24 N*m (245 kgf*cm, 18 ft.*lbf)
D
25 N*m (249 kgf*cm, 19 ft.*lbf)
HINT:
B last.
5. INSPECT FOR CENTER EXHAUST PIPE ASSEMBLY
136 to 142 mm (5.35 to 5.59 in) (a) Check that the exhaust center pipe assembly
Bellows bellows pipe is installed as shown in the illustration.
Below 5 mm
188 mm (7.40 in) (0.19 in)
A155409E11
EX
ENGINE
N04C-TW EXHAUST
EXHAUST MANIFOLD
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-1
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-2
EXHAUST PIPE
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-7
EX
N04C-TW EXHAUST – EXHAUST MANIFOLD EX–1
EXHAUST MANIFOLD
N04C-TW EXHAUST
ENGINE
COMPONENTS
GASKET
GASKET
EX
Non-reusable part
A152769E01
REMOVAL
HINT:
(See chapter IT)
EX–2 N04C-TW EXHAUST – EXHAUST MANIFOLD

A155964

(c) Remove the 4 gasket.
A155965
INSTALLATION
CORRECT INCORRECT
(a) Install 4 new gaskets to the cylinder head as shown
A161408E01

8 4 2 6 HINT:
EX as shown in the illustration
7 3 1 5
Contact Contact
A166690E01
N04C-TW EXHAUST – EXHAUST MANIFOLD EX–3

7 3 1 5
A166691E01
(d) Install the exhaust manifold heat insulator

subassembly with the 3 bolts.
HINT:
(See chapter IT)
A155964
EX
EX–4 N04C-TW EXHAUST – EXHAUST PIPE
EXHAUST PIPE
N04C-TW EXHAUST
ENGINE
COMPONENTS
EXAMPLE:
CENTER EXHAUST PIPE ASSEMBLY
50 (516, 37)
50 (516, 37)
30 (306, 22)
27 (275, 20)*
70 (714, 52)
NO. 2 EXHAUST GAS
x3 TEMPERATURE SENSOR
25 (255, 18)
30 (306, 22)
27 (275, 20)*
x4
EXHAUST GAS TEMPERATURE
GASKET SENSOR
30 (306, 22)
EX
24 (245, 17)
x2
x2
24 (245, 17)
Non-reusable part
* For use with union nut wrench

A152379E03
N04C-TW EXHAUST – EXHAUST PIPE EX–5
REMOVAL
(a) Remove the 2 nuts and tail exhaust pipe assembly.
2. REMOVE TAIL EXHAUST PIPE SUB-ASSEMBLY
(a) Remove the 2 nuts and tail exhaust pipe assembly.
A154029E01

(a) Disconnect the vacuum hose.
A152397E01
(b) Remove the 4 bolts and exhaust retarder assembly.

4. REMOVE EXHAUST GAS TEMPERATURE SENSOR
(See chapter EC)
5. REMOVE NO. 2 EXHAUST GAS TEMPERATURE
SENSOR (See chapter EC)
A152398E01
6. REMOVE CENTER EXHAUST PIPE ASSEMBLY EX

(a) Disconnect the 2 differential pressure sensor hoses.
A154024E01
(b) Remove the 3 nuts, 6 cushions and center exhaust

pipe assembly.
A155977

EX A154032E01

assembly.
A152396E01
N04C-TW EXHAUST – EXHAUST PIPE EX–7
INSTALLATION
assembly, and temporarily tighten the 3 nuts.
A152396E01

(c) Torque:70 N*m (714 kgf*cm, 52 ft.*lbf)
Tighten the 3 nuts.
A154032E01

(a) Install the center exhaust pipe assembly with 3 new
nuts and 6 cushion.
EX
A155977
(b) Connect the 2 differential pressure sensor hoses.

3. INSTALL EXHAUST GAS TEMPERATURE SENSOR
(See chapter EC)
4. INSTALL NO. 2 EXHAUST GAS TEMPERATURE
SENSOR (See chapter EC)
A154024E01

(a) Install 2 new gaskets and exhaust retarder
A152398E01
(b) Connect the vacuum hose.
A152397E01
6. INSTALL TAIL EXHAUST PIPE SUB-ASSEMBLY

(a) Install a new gasket and tail exhaust pipe sub-
assembly with the 2 nuts.
EX 7. REMOVE TAIL EXHAUST PIPE ASSEMBLY
(a) Install the tail exhaust pipe assembly with the 2
nuts.
A154029E01 8. INSPECT FOR EXHAUST GAS LEAK
9. INSPECT FOR CENTER EXHAUST PIPE ASSEMBLY

161 mm ± 3 mm (a) Check if the exhaust center pipe assembly bellows
Bellows pipe is installed as shown in the illustration.
5 mm
(210 mm)
A155409E01
ENGINE
W04D-TM EXHAUST
EXHAUST MANIFOLD
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-1
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-2
EXHAUST PIPE
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-4
EX
W04D-TM EXHAUST – EXHAUST MANIFOLD EX–1
EXHAUST MANIFOLD
W04D-TM EXHAUST
ENGINE
COMPONENTS
EXHAUST MANIFOLD
47 (479, 35)
x8
GASKET
EX
Non-reusable part
A165957E01
REMOVAL
HINT:
(See chapter IT)
EX–2 W04D-TM EXHAUST – EXHAUST MANIFOLD

(b) Remove the 4 gaskets.
INSTALLATION
A161518

illustration.
8 4 2 6
HINT:
A165257E01
EX
W04D-TM EXHAUST – EXHAUST PIPE EX–3
EXHAUST PIPE
W04D-TM EXHAUST
ENGINE
COMPONENTS
NO. 1 LOWER EXHAUST PIPE HOLDER PLATE

SUPPORT BRACKET
HOLDER PLATE
24 (245, 18)
NO. 2 EXHAUST PIPE SUPPORT CUSHION 24 (245, 18) EXHAUST PIPE

BRACKET
x2
50 (510, 37)
GASKET
x2
24 (245, 18)

x3 25 (259, 19)
25 (259, 19)
x4
30 (301, 22)
CENTER EXHAUST
PIPE ASSEMBLY
GASKET GASKET
EX
Non-reusable part
A166652E01
EX–4 W04D-TM EXHAUST – EXHAUST PIPE
REMOVAL
A164456

A152398E01
(d) Remove the 2 nuts, 2 holder plates, 2 exhaust pipe

assembly.
(e) Remove the bolt and exhaust pipe bracket from the
center exhaust pipe.
(f) Remove the 2 bolts and No. 1 lower exhaust pipe
support bracket.
(g) Remove the 2 bolts and No. 1 exhaust pipe support
bracket.
A164458

EX
A154032E01

assembly.
INSTALLATION
(a) Install a new gasket.
A164459
W04D-TM EXHAUST – EXHAUST PIPE EX–5
(b) Install the front exhaust pipe assembly and

temporarily tighten the 3 nuts.
A163421
(c) Temporarily tighten the bolt.

(d) Tighten the 3 nuts.
(e) Tighten the bolt.
(a) Install the No. 1 lower exhaust pipe support bracket
with the 2 bolts.
A154032
(b) Install the No. 1 exhaust pipe support bracket with
the 2 bolts.
(c) Install the exhaust pipe bracket with bolt to the
center exhaust pipe assembly.
(d) Install the center exhaust pipe assembly, No. 2
exhaust pipe support cushions and 2 holder plates
with the 2 nuts.
(e) Install 2 new gaskets.
A164458
(f) Install the exhaust retarder assembly with the 4

bolts. EX
A152398E01
EX–6 W04D-TM EXHAUST – EXHAUST PIPE
(g) Connect the vacuum hose.
A164456

105 to 111 mm (4.13 to 4.37 in) (a) Check if the exhaust center pipe assembly bellows
Bellows pipe is installed as shown in the illustrations.
Below 5 mm
(0.19 in)
157 mm (6.18 in) A155409E09
EX
ENGINE
W04D-TN EXHAUST
EXHAUST MANIFOLD
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-1
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-2
EXHAUST PIPE
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EX-9
EX
W04D-TN EXHAUST – EXHAUST MANIFOLD EX–1
EXHAUST MANIFOLD
W04D-TN EXHAUST
ENGINE
COMPONENTS
EXHAUST MANIFOLD
47 (479, 35)
x8
GASKET
Non-reusable part
A165957E01
EX
REMOVAL
HINT:
(See chapter IT)
EX–2 W04D-TN EXHAUST – EXHAUST MANIFOLD

(b) Remove the 4 gaskets.
INSTALLATION
A161518

illustration.
HINT:
A165257E01
EX
W04D-TN EXHAUST – EXHAUST PIPE EX–3
EXHAUST PIPE
W04D-TN EXHAUST
ENGINE
COMPONENTS
Exhaust short tail pipe (standard body): Exhaust short tail pipe (wide body):
24 (245, 18) 24 (245, 18)
NO. 1 LOWER NO. 1 LOWER
EXHAUST PIPE EXHAUST PIPE
SUPPORT BRACKET SUPPORT BRACKET HOLDER PLATE
HOLDER x2
PLATE
x2
24 (245, 18)
24 (245, 18)
EXHAUST PIPE BRACKET EXHAUST PIPE BRACKET
HOLDER PLATE
24 (245, 18)
50 (510, 37)
GASKET
x2
NO. 1 EXHAUST PIPE
SUPPORT BRACKET
70 (714, 52)
VACUUM HOSE
x3 25 (259, 19)
25 (259, 19)
x4
30 (301, 22)
CENTER EXHAUST
GASKET GASKET
PIPE ASSEMBLY
EX
Non-reusable part
A165483E03
EX–4 W04D-TN EXHAUST – EXHAUST PIPE
Exhaust stack tail pipe:
HOLDER PLATE HOLDER PLATE

EXHAUST PIPE
BRACKET NO. 4 EXHAUST PIPE
SUPPORT BRACKET
NO. 5 EXHAUST PIPE
SUPPORT BRACKET
24 (245, 18)
x2
24 (245, 18)
24 (245, 18)
EXHAUST PIPE
BRACKET
24 (245, 18)
25 (259, 19)
x2
25 (259, 19)
NO. 1 LOWER EXHAUST PIPE SUPPORT BRACKET
HOLDER PLATE
NO. 2 EXHAUST PIPE SUPPORT CUSHION 24 (245, 18) 24 (245, 18)

x2
HOLDER PLATE
GASKET 50 (510, 37) x2
NO. 1 EXHAUST PIPE SUPPORT BRACKET 50 (510, 37)
31 (313, 23)
EXHAUST PIPE
x3
SUPPORT
CENTER EXHAUST
x4 PIPE ASSEMBLY
EX GASKET 30 (301, 22)
GASKET
Non-reusable part
A164452E06
Exhaust stack tail pipe: NO. 4 EXHAUST PIPE SUPPORT BRACKET
NO. 2 EXHAUST PIPE

SUPPORT CUSHION
x2
25 (250, 18)
x2
25 (250, 18) 58 (591, 43) x2
x3
NO. 1 EXHAUST PIPE
HEAT INSULATOR
x3
24 (245, 18)
REAR MUFFLER
BRACKET
x2
58 (591, 43)
58 (591, 43) 58 (591, 43)
x2
50 (510, 37)
x2 x2
24 (245, 18) 58 (591, 43)
x3
x3 24 (245, 18)
50 (510, 37)
HOLDER
PLATE
REAR MUFFLER
31 (313, 23)
BRACKET
50 (510, 37)
EXHAUST PIPE EX
x2 SUPPORT
REAR MUFFLER BRACKET SUB-ASSEMBLY TAIL EXHAUST
PIPE ASSEMBLY
24 (245, 18)
Non-reusable part
A164988E04
REMOVAL
(a) Exhaust stack tail pipe
(1) Remove the 3 nut, 2 No. 2 exhaust pipe
support cushions and tail exhaust pipe
assembly.
(2) Remove the nut, holder plate, 2 No. 2 exhaust
pipe support cushions and exhaust pipe
support sub-assembly.
(3) Remove the 2 bolts and rear muffler bracket.
A165149
EX
A165147
(4) Remove the 8 nuts and No. 4 exhaust pipe

support bracket.
(5) Remove the 4 nuts and exhaust pipe support
sub-assembly and then remove the 3 bolts and
No. 1 exhaust pipe heat insulator from the
exhaust pipe support sub-assembly.

(1) Remove the 4 nuts, 2 holder plate and tail
A165148
(2) Remove the nut, holder plate, exhaust pipe

support sub-assembly and then remove the 2
bolts and No. 1 lower exhaust pipe bracket.
support bracket.
support bracket. EX
(5) Remove the 2 bolts and 2 exhaust pipe bracket
to the tail exhaust pipe assembly.
A165143

(a) Exhaust short tail pipe
A164456

assembly.
A152398E01
(4) Remove the 2 nuts, 2 holder plates, 2 exhaust

pipe support cushions and center exhaust pipe
assembly.
(5) Remove the bolt and exhaust pipe bracket from
the center exhaust pipe.
support bracket.
A164458
(b) Exhaust stack tail pipe

EX
A164456

assembly.
A152398E01
(4) Remove the nut, holder plate, 2 exhaust pipe

assembly.
support bracket.
A165010

A154032E01

assembly.
INSTALLATION
(a) Install a new gasket.
A164459
(b) Install the front exhaust pipe assembly and

temporarily tighten the 3 nuts.
EX
A163421
(c) Temporarily tighten the bolt.

(d) Tighten the 3 nuts.
(e) Tighten the bolt.
(a) Exhaust short tail pipe
A154032

with the 2 bolts.
(3) Install the exhaust pipe bracket with bolt to the
center exhaust pipe assembly.
(4) Install the center exhaust pipe assembly, No. 2
exhaust pipe support cushions and 2 holder
plates with the 2 nuts.
(5) Install 2 new gaskets.
A164458
(6) Install the exhaust retarder assembly with the 4

bolts.
A152398E01

with the 2 bolts.
A164456
(2) Install the center exhaust pipe assembly, No. 2

EX exhaust pipe support cushion and holder plate
with the nut.
(3) Install 2 new gaskets.
A165010
(4) Install the exhaust retarder assembly with the 4

bolts.
A152398E01
A164456

Nut Bolt (1) Install the exhaust pipe support sub-assembly
and No. 1 lower exhaust pipe support bracket
with the 2 bolts and nut.
Torque: Bolt
Bolt 24 N*m (245 kgf*cm, 18 ft.*lbf)
Nut
24 N*m (245 kgf*cm, 18 ft.*lbf)
A165143E01 (2) Install the No. 4 exhaust pipe support bracket
with the 2 bolts.
with the 2 bolts.
(4) Install the 2 holder plate and tail exhaust pipe
Torque: A
50 N*m (510 kgf*cm, 37 ft.*lbf)
B
EX
31 N*m (313 kgf*cm, 23 ft.*lbf)
C
24 N*m (245 kgf*cm, 18 ft.*lbf)
A
B
A165148E01
HINT:
B last.
(1) Install the rear muffler bracket with the 3 bolts.
Torque: A
50 N*m (510 kgf*cm, 37 ft.*lbf)
EX
F
B
C
E
A A165147E01

Torque: B
50 N*m (510 kgf*cm, 37 ft.*lbf)
C
24 N*m (245 kgf*cm, 18 ft.*lbf)
(3) Install the No. 1 exhaust pipe heat insulator
with the 3 bolts to the exhaust pipe support
sub-assembly, and then install the exhaust pipe
support sub-assembly with the 4 nuts.
Torque: D
24 N*m (245 kgf*cm, 18 ft.*lbf)
E
58 N*m (591 kgf*cm, 43 ft.*lbf)
(4) Install the No. 4 exhaust pipe support bracket EX
with the 8 nuts.
Torque: F
58 N*m (591 kgf*cm, 43 ft.*lbf)

Torque: G
24 N*m (245 kgf*cm, 18 ft.*lbf)
(6) Install the 2 No. 2 exhaust pipe support cushion
and exhaust pipe support sub-assembly with
the 2 nut.
Torque: H
I I
25 N*m (250 kgf*cm, 18 ft.*lbf)
(7) Install the tail exhaust pipe assembly with the 2
nuts.
H H Torque: I
25 N*m (250 kgf*cm, 18 ft.*lbf)
(8) Install the 4 nuts.
Torque: J
50 N*m (510 kgf*cm, 37 ft.*lbf)
K
31 N*m (313 kgf*cm, 23 ft.*lbf)
HINT:
G
Make sure to tighten the bolt J first and the bolt
K
J K last.
A165149E01

105 to 111 mm (a) Exhaust short tail pipe
Bellows (1) Check if the exhaust center pipe assembly
bellows pipe is installed as shown in the
illustrations.
Below 5 mm
157 mm
A155409E04

158 to 164 mm (1) Check if the exhaust center pipe assembly
Bellows bellows pipe is installed as shown in the
illustrations.
EX 210 mm
Below 5 mm
A155409E07
ENGINE
COOLANT
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-1
WATER PUMP
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-3
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-4
THERMOSTAT
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-5
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-6
RADIATOR
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-8
ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-14
ON-VEHICLE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-14
REMOVAL (N04C-TR, TS, TT, TV, TW) . . . . . . . . . . . . . . . . . . . . . . . . . CO-14
REMOVAL (N04C-TU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-16
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-18
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-19
INSTALLATION (N04C-TR, TS, TT, TV, TW) . . . . . . . . . . . . . . . . . . . . . CO-22
INSTALLATION (N04C-TU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-24
COOLING SYSTEM
CO
N04C-TR, TS, TT, TU, TV, TW COOLING – COOLANT CO–1
COOLANT
REPLACEMENT
CAUTION:
Do not remove the radiator cap sub-assembly while
the engine and radiator are still hot. Pressurized, hot
engine coolant and steam may be released and
cause serious burns.
(a) Loosen the radiator drain cock plug and engine
drain plug.
Radiator Cap (b) Remove the radiator cap, then drain the coolant.
(c) Close the radiator drain cock plug.
(d) Tighten the engine drain plug.
Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) for the
engine drain plug
2. ADD ENGINE COOLANT
(a) Add engine coolant.
Specified capacity:
14.7 liters (15.5 US qts, 12.9 lmp. qts)
HINT:
• HINO vehicles are filled with HINO genuine LLC
at the factory. In order to avoid damage to the
Radiator Drain Plug engine cooling system and other technical
problems, only use HINO genuine LLC or similar
high quality ethylene glycol based non-silicate,
non-amine, non-nitrite, non-borate coolant with
Engine Drain Plug long-life hybrid organic acid technology (coolant
with long-life hybrid organic acid technology
A159713E01
consists of a combination of low phosphates and
organic acids).
• Contact your HINO dealer for further details.
(b) Check the coolant level inside the radiator by
squeezing the inlet and outlet radiator hoses several
times by hand. If the coolant level goes down, add
coolant.
(c) Install the radiator cap.
(d) Slowly pour coolant into the radiator reservoir until it
reaches the FULL line.
(e) Bleed air from the cooling system.
(1) Warm up the engine until the thermostat opens. CO
While the thermostat is open, circulate the
coolant for several minutes.
(2) Press the inlet and outlet radiator hoses
several times by hand to bleed air.
NOTICE:
• Be careful as the radiator hoses are hot.
• Keep your hands away from the radiator
fan.
(f) Stop the engine and wait until the coolant cools
down.
(g) Remove the radiator cap and check the coolant
level.
CO–2 N04C-TR, TS, TT, TU, TV, TW COOLING – COOLANT
(h) If the coolant level has dropped, add coolant.

(i) Check the coolant level inside the radiator reservoir
tank again. If it is below the full level, add coolant.
3. INSPECT FOR COOLANT LEAK (See page CO-26)
CO
N04C-TR, TS, TT, TU, TV, TW COOLING – WATER PUMP CO–3
WATER PUMP
ENGINE
COMPONENTS
RADIATOR HOSE INLET
29 (290, 21)
x4
FAN PULLEY
FAN
29 (290, 21)
x8
WATER PUMP ASSEMBLY
CO
A153066E04
REMOVAL
1. REMOVE RADIATOR HOSE INLET (See chapter CH)
2. REMOVE FAN (See chapter EM)
3. REMOVE FAN PULLEY (See chapter EM)
CO–4 N04C-TR, TS, TT, TU, TV, TW COOLING – WATER PUMP
4. REMOVE WATER PUMP ASSEMBLY

(a) Remove the 8 bolts and water pump assembly.
A101937
INSPECTION
1. INSPECT WATER PUMP ASSEMBLY
(a) Turn the pulley and check that the water pump
bearing moves smoothly and quietly.
If necessary, replace the water pump assembly.
A147500
1.5 to 2.5 INSTALLATION

mm (0.06 1. INSTALL WATER PUMP ASSEMBLY
to 0.10 in.) (a) Apply a continuous bead of seal packing (diameter
illustration.
Seal packing:
A147499E01
NOTICE:
• Install the water pump within 3 minutes of
• Do not start the engine for at least 2 hours
after the installation.
(b) Install the water pump assembly with the 8 bolts.
2. INSTALL FAN PULLEY (See chapter EM)
3. INSTALL FAN (See chapter EM)
4. INSPECT DRIVE BELT (See chapter EM)
CO
5. INSTALL RADIATOR HOSE INLET (See chapter CH)
A101937
N04C-TR, TS, TT, TU, TV, TW COOLING – THERMOSTAT CO–5
THERMOSTAT
ENGINE
COMPONENTS
WATER OUTLET
29 (290, 21)
THERMOSTAT
x3
GASKET
RADIATOR HOSE INLET
Non-reusable part
A153065E04
REMOVAL
(a) Loosen the clip and disconnect the radiator hose
inlet.
CO
A153298
CO–6 N04C-TR, TS, TT, TU, TV, TW COOLING – THERMOSTAT
(a) Remove the 3 bolts and water outlet.
(b) Remove the thermostat from the cylinder block.
(c) Remove the gasket from the thermostat.
A147505
INSPECTION
1. INSPECT THERMOSTAT
HINT:
The valve opening temperature is inscribed on the
thermostat.
A147506
(a) Immerse the thermostat in water and gradually heat

the water.
(b) Check the valve opening temperature of the
thermostat.
Valve opening temperature:
80 to 84°C (176 to 183°F)
If the valve opening temperature is not as
specified, replace the thermostat.
A147507
(c) Check the valve lift.

Valve lift:
10 mm (0.394 in.) or more at 95°C (203°F)
If the valve lift is not as specified, replace the
thermostat.
(d) Check that the valve is fully closed when the
thermostat is at low temperatures (below 40°C
Valve Iift (104°F))
If not fully closed, replace the thermostat.
A147508E01
CO
INSTALLATION
(a) Apply a continuous bead of seal packing (diameter
illustration.
Seal packing:
1.5 to 2.5 mm
(0.06 to 0.10 in.)
Bond 1207B or equivalent.
A147509E01
NOTICE:
N04C-TR, TS, TT, TU, TV, TW COOLING – THERMOSTAT CO–7
• Install the water pump within 3 minutes of

(b) Install a new gasket onto the thermostat.
(c) Align the jiggle valve to the position shown in the
illustration and install the thermostat.
A147510
(d) Install the water outlet with the 3 bolts.

A153044

(a) Connect the radiator hose inlet with the clip.
A153298
CO
CO–8 N04C-TR, TS, TT, TU, TV, TW COOLING – RADIATOR
RADIATOR
ENGINE
COMPONENTS
NO. 2 AIR HOSE
7.5 (77, 66 in.*lbf)
7.5 (77, 66 in.*lbf)
18 (184, 13)
CO
A155410E02
N04C-TR, TS, TT, TU, TV, TW COOLING – RADIATOR CO–9
NO. 1 AIR HOSE
13 (133, 10)
7.5 (77, 66 in.*lbf)
7.5 (77, 66 in.*lbf)
18 (184, 13)
18 (184, 13)
18 (184, 13)
18 (184, 13)
A152382E04
CO

FAN PULLEY
29 (290, 21)
x4
20 (204, 15)
FAN
RADIATOR HOSE INLET
NO. 5 RADIATOR HOSE
HEATER HOSE
18 (184, 13)
x3
18 (184, 13)
7.5 (77, 66 in.*lbf)
RADIATOR ASSEMBLY
x3
20 (204, 15) NO. 4 RADIATOR BRACKET

HEATER HOSE
CO
20 (204, 15)
HEATER HOSE

7.5 (77, 66 in.*lbf)
A165064E01
EXAMPLE: N04C-TU
20 (199, 14)
29 (290, 21)
HEATER HOSE x4
RADIATOR HOSE INLET

FAN PULLEY
FAN
NO. 5 RADIATOR HOSE

18 (184, 13)
18 (184, 13)
RADIATOR ASSEMBLY
x3
NO. 3 RADIATOR
BRACKET RADIATOR HOSE OUTLET
7.5 (77, 66 in.*lbf) FAN AND GENERATOR V BELT
x2 HEATER HOSE
20 (199, 14)
18 (184, 13)
18 (184, 13) x3
20 (199, 14)
HEATER HOSE CO
RADIATOR AIR GUIDE
7.5 (77, 66 in.*lbf)
x2
A165948E01

NO. 1 RADIATOR TO SUPPORT SEAL
x4
5.0 (51, 44 in.*lbf)
7.5 (77, 66 in.*lbf)
x4
FAN SHROUD
x4
RADIATOR TANK UPPER
13 (130, 9)
O-RING
RADIATOR SIDE PLATE
13 (130, 9)
CORE SUB-ASSEMBLY
13 (130, 9)
RADIATOR COLLAR
RADIATOR BUSHING
RADIATOR BUSHING
13 (130, 9)
CO RADIATOR COLLAR
O-RING
RADIATOR SIDE PLATE
RADIATOR DRAIN PLUG
O-RING

RADIATOR TANK LOWER
Non-reusable part
A163819E01
EXAMPLE: N04C-TU
5.0 (51, 44 in.*lbf)
FAN SHROUD
x4
RADIATOR TANK UPPER
13 (130, 9)
O-RING
RADIATOR SIDE PLATE
13 (130, 9)
CORE SUB-ASSEMBLY
13 (130, 9)
RADIATOR COLLAR
RADIATOR BUSHING
RADIATOR BUSHING
13 (130, 9)
O-RING RADIATOR COLLAR

O-RING
RADIATOR DRAIN PLUG RADIATOR SIDE PLATE
Non-reusable part
RADIATOR TANK LOWER A165974E01
CO
1. INSPECT RADIATOR CAP SUB-ASSEMBLY
(a) Measure the valve opening pressure.
(1) If there are water stains or foreign matter on
1 rubber seals 1, 2 or 3, clean the parts with
water and finger scouring.
2
(2) Check that rubber seals 1, 2 and 3, are not
4 deformed, cracked or swollen.
3
A138101
(3) Check that rubber seals 3 and 4 are not stuck
together.
(4) Apply engine coolant to rubber seals 2 and 3
before using the radiator cap tester.
(5) When using the cap tester, tilt it to more than
30 degrees upwards.
Radiator Cap Tester (6) Pump the cap tester several times, and check
the maximum pressure *1.
Pumping speed:
30° or more 1 pump per second.
*1: Even if the cap cannot maintain the
Radiator Cap maximum pressure, it is not defective.
Judgement criteria
Z000570E05
Standard value (for brand new cap) 93 to 123 kPa (0.95 to 1.25 kgf*cm2,
13.5 to 17.8 psi)
Minimum standard value (for used 78 kPa (0.8 kgf*cm2, 11.4 psi)
cap)
If the maximum pressure is less than the

specified pressure for the minimum standard
value, replace the radiator cap sub-assembly.
ON-VEHICLE CLEANING
1. CHECK FIN FOR BLOCKAGE
(a) If the fins are clogged, wash them with water or a
steam cleaner, then dry them with compressed air.
NOTICE:
• If the steam cleaner is too close to the core,
there is a possibility of damaging the fins, so
keep to the following injection distances.
A073603 Injection Pressure Injection Distance
kPa (kgf*cm2, psi) mm (in.)
CO 2942 to 4903
(30 to 50, 427 to 711)
300 (11.811)
4903 to 7845
500 (19.685)
(50 to 80, 711 to 1138)
• If the fins are bent, straighten them with a

screwdriver or pliers.
• Do not expose electronic components to
water.
REMOVAL (N04C-TR, TS, TT, TV, TW)

1. DRAIN ENGINE COOLANT (See page CO-1)

(a) Loosen the 2 clips and disconnect the radiator hose
inlet and No. 5 radiator hose.
A153297

outlet.
IT)
A153296

9. SEPARATE HEATER HOSE
(a) Remove the 5 bolts and separate the heater hose.
CO
A155551
10. SEPARATE NO. 4 RADIATOR BRACKET

(a) Remove the 3 bolts and separate the No. 4 radiator
bracket.
(b) Remove the bolt and radiator support No. 2.
A155592

bracket.
(b) Remove the bolt and No. 1 radiator support.
(a) Remove the radiator assembly with fan shroud.
A155591
13. REMOVE FAN SHROUD

(a) Remove the 4 bolts and fan shroud.
14. REMOVE NO. 1 RADIATOR TO SUPPORT SEAL
(a) Remove the 4 bolts, 4 clips and the No. 1 radiator to
support seal.
A155589
REMOVAL (N04C-TU)
(a) Loosen the 2 clips and disconnect the radiator hose
inlet and No. 5 radiator hose.
CO
A153297

outlet.
(See chapter IT)
6. REMOVE INTERCOOLER ASSEMBLY (Seechapter IT)
A153296

9. SEPARATE HEATER HOSE
(a) Remove the bolt and separate the heater hose.
A153292
(b) Remove the 3 bolts and separate the No. 4 radiator

bracket.
A165509
(b) Remove the nut and separate the No. 3 radiator

bracket.
CO
A158458

(a) Remove the 2 bolts and radiator air guide.
(b) Remove the radiator assembly with fan shroud.
(c) Remove the 3 bolts and the No. 3 radiator bracket
from the radiator assembly.
A153290

A155589
DISASSEMBLY
1. REMOVE RADIATOR SIDE PLATE
(a) Remove the all square head M8 (4 or 8) bolts to
remove the left and the right side plates.
(b) Remove the side seal and radiator packing.
(c) Remove the drain cock and O-ring.
Radiator Side Plate
A156561E01
2. REMOVE RADIATOR TANK UPPER

(a) Adjust dimension B show in the illustration using a
stopper bolt so that it is 0.2 to 0.3 mm when the
handle of the SST touches the stopper bolt.
SST 09230-01010 (09231-01010, 09231-01030)
NOTICE:
If the stopper bolt is not adjusted, the claw may
Dimension B
be damaged.
Stopper Bolt
CO
Claw SST
A113337E05
(b) As the aluminum radiator adopts an integral

crimping construction by the core plate, remove the
Tank
upper and the lower tanks by lifting up the core plate
in such a way that the latter may not be damaged.
Release the crimping by using the SST and by
gripping it until it hits the stopper bolt of the handle
Core Plate as shown on the illustration.
SST 09230-01010 (09231-01010, 09231-01030)
SST NOTICE:
Do not lift up the core plate more than 90°.
SST
A163978E01
(c) Remove the upper and lower tanks by lightly

tapping the radiator hose fitting position.
NOTICE:
• Remember the mounting direction of the core
sub-assembly.
• Remount it in such a way that the original
direction can be maintained.
3. REMOVE RADIATOR TANK LOWER
HINT:
A156564
The removal procedure of the radiator tank lower is the
same as that of the radiator tank upper.
REASSEMBLY
Part A 1. INSTALL RADIATOR TANK UPPER
(a) Install the punch assembly to the overhaul handle,
inserting it in the hole in part A as shown in the
illustration.
SST 09230-01010 (09231-01010, 09231-01020),
Dimension B 09231-14010
Stopper Bolt (b) While gripping the handle, adjust the stopper bolt so
that dimension B is as specified below.
Dimension B:
7.4 to 7.8 mm (0.29 to 0.30 in.)
SST CO
Punch Assembly Overhaul Handle
A120276E02
(c) Check that there are no foreign objects in the core

plate groove, and install a new O-ring. Make sure
the O-ring is not twisted.
NOTICE:
When cleaning the core plate groove, lightly rub
it with sandpaper without scratching it.
Normal
Twisted
O-Ring
Twisted
A156567E01
(d) Tap the lock plate with a plastic-faced hammer so

that there is no gap between the lock plate and the
Tank tank.
Core Plate
Gap
A156569E02
(e) Lightly press the crimping tool against the core plate
in the order shown in the illustration. After repeating
this a few times, fully crimp the core plate by
5 11 3 9 7 squeezing the handle until stopped by the stopper
bolt.
1 2 NOTICE:
6 8 • For positions where the crimping tool is not
12 4 10 usable, crimp by using pliers.
• Crimp according to the order shown in the
CO illustration.
Press
Against Core Plate
A164226E01
(f) Check the dimension D after crimping.

Tank
Standard dimension:
7.4 to7.8 mm (0.29 to 0.30 in.)
(g) In the event that the dimension D does not fall within
the standard limit, adjust the stopper bolt of the
handle once again and recrimp.
Dimension D NOTICE:
Core Plate Check the dimensions at both ends of the core
plate as well as around the central portion where
O-Ring
A164234E01 the crimping has not been performed (under the
pipe, etc.).
(h) Others:
Mark for the first repair for the second repair at a
well visible place in the upper tank.
NOTICE:
The radiator can only be recrimped twice. After
the second time, the radiator core must be
replaced.
2. INSTALL RADIATOR TANK LOWER
HINT:
The installation procedure of the radiator tank lower is
the same as that of the radiator tank upper.
3. INSPECT FOR COOLANT LEAK
(a) Assemble the plug handle as shown in the
Washer (Small) illustration and tighten the nut until the washer, the
Handle
plug and the handle are in light contact with each
other.
Nut
Washer (Large) Plug
A156573E01
(b) Using SST, plug the inlet and outlet pipes of the
radiator.
SST 09230-01010 (09231-00030, 09231-00050)
(c) Using a radiator cap tester, apply pressure to the
radiator.
Test pressure:
118 kPa (1.2 kgf/cm2, 17 psi)
SST
CO
A156574E01
HINT:
Tank On radiators with resin tanks, there is a clearance
between the core plate and tank plate where a
minute amount of air will remain, giving the
appearance of an air leak when the radiator is
submerged in water. Therefore, before performing
Core Plate
the water leak test, first swirl the radiator around in
O-Ring the water until all air bubbles disappear.
A156575E02
4. INSTALL RADIATOR SIDE PLATE

(a) Install the all square head bolts to install the left and
the right side plates.
INSTALLATION (N04C-TR, TS, TT, TV,

TW)
1. INSTALL NO. 1 RADIATOR TO SUPPORT SEAL
(a) Install the radiator to No. 1 support seal with the 4
bolts and 4 clips.
2. INSTALL FAN SHROUD
(a) Install the fan shroud with the 4 bolts.
(a) Install the radiator assembly with fan shroud.
A155589
4. INSTALL NO. 3 RADIATOR BRACKET

(a) Install the No. 3 radiator bracket with the 3 bolts.
(b) Install the No. 1 radiator support with the bolt.
A155591

(b) Install the radiator support No. 2 with the bolt.
CO
A155592
6. INSTALL HEATER HOSE

(a) Install the heater hose with the 5 bolts.
IT)
A155551

(a) Connect the radiator hose outlet with the clip.
A153296

(a) Connect the radiator hose inlet and radiator hose
No. 5 with the 2 clips.
15. ADD ENGINE COOLANT (See page CO-1) CO
A153297
(b) Install the radiator assembly with fan shroud.
A155589
(c) Install the radiator air guide with the 2 bolts.

A153290

(a) Install the No. 3 radiator bracket with the nut.
(b) Install the heater hose with the bolt.
A158458

(b) Install the heater hose with the bolt.
CO A165509
5. INSTALL HEATER HOSE

(a) Install the heater hose with the bolt.
9. INSTALL INTERCOOLER ASSEMBLY (See chapter IT
A153292

A153296

(a) Connect the radiator hose inlet and radiator hose
No. 5 with the 2 clips.
14. ADD ENGINE COOLANT (See page CO-1)
A153297
CO
CO–26 N04C-TR, TS, TT, TU, TV, TW COOLING – COOLING SYSTEM
COOLING SYSTEM
(a) Remove the radiator cap.
CAUTION:
Do not remove the radiator cap while the engine
and radiator are still hot. Pressurized, hot
(b) Fill the radiator with coolant and attach a radiator
cap tester.
(d) Using a radiator cap tester, increase the pressure
inside the radiator to 137 kPa (1.4 kgf/cm2, 19.9
psi), and check that the pressure does not drop.
If the pressure drops, check the hoses, radiator and
water pump for leaks. If no external leaks are found,
Radiator Cap Tester
check the heater core, cylinder block and cylinder
A101647E01
head.
(e) Install the radiator cap.
2. CHECK COOLANT LEVEL OF RESERVOIR
(a) Check that the engine coolant level is between the
LOW and FULL lines when the engine is cold.
If the engine coolant level is low, check for leaks and
add "TOYOTA Super Long Life Coolant" or similar
high quality ethylene glycol based non-silicate, non-
amine, non-nitrite and non-borate coolant with long-
life hybrid organic acid technology to the FULL line.
3. CHECK ENGINE COOLANT QUALITY
CAUTION:
(b) Check if there are any excessive deposits of rust or
scales around the radiator cap and radiator filler
hole. Also, the coolant should be free of oil.
If excessively dirty, clean the coolant passage and
CO replace the coolant.
ENGINE
W04D-TM, TN COOLING
COOLANT
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-1
WATER PUMP
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-4
THERMOSTAT
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-6
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-8
RADIATOR
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-9
ON-VEHICLE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-13
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-15
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CO-19
COOLING SYSTEM
CO
W04D-TM, TN COOLING – COOLANT CO–1
COOLANT
REPLACEMENT
CAUTION:
Do not remove the radiator cap sub-assembly while
the engine and radiator are still hot. Pressurized, hot
(a) Loosen the radiator drain cock plug.
(b) Remove the radiator cap, then drain the coolant.
(c) Close the radiator drain cock plug.
2. ADD ENGINE COOLANT
(a) Add engine coolant.
Specified capacity:
NOTICE:
Do not substitute plain water for engine coolant.
HINT:
• HINO vehicles are filled with HINO genuine LLC
at the factory. In order to avoid damage to the
engine cooling system and other technical
problems, only use HINO genuine LLC or similar
high quality ethylene glycol based non-silicate,
non-amine, non-nitrite, non-borate coolant with
long-life hybrid organic acid technology (coolant
with long-life hybrid organic acid technology
consists of a combination of low phosphates and
organic acids).
• Contact your HINO dealer for further details.
(b) Check the coolant level inside the radiator by
squeezing the inlet and outlet radiator hoses several
times by hand. If the coolant level goes down, add
coolant.
(d) Slowly pour coolant into the radiator reservoir until it
reaches the FULL line.
(e) Bleed air from the cooling system.
(1) Warm up the engine until the thermostat opens.
While the thermostat is open, circulate the
coolant for several minutes.
(2) Press the inlet and outlet radiator hoses
several times by hand to bleed air. CO
NOTICE:
• Be careful as the radiator hoses are hot.
• Keep your hands away from the radiator
fan.
(f) Stop the engine and wait until the coolant cools
down.
(g) Remove the radiator cap and check the coolant
level.
(h) If the coolant level has dropped, add coolant.
CO–2 W04D-TM, TN COOLING – COOLANT
(i) Check the coolant level inside the radiator reservoir

tank again. If it is below the full level, add coolant.
CO
W04D-TM, TN COOLING – WATER PUMP CO–3
WATER PUMP
ENGINE
W04D-TM, TN COOLING
COMPONENTS
with
withFan
FanClutch:
Clutch:W04D-TN
FAN
x4
FAN PULLEY

RADIATOR HOSE INLET
29 (290, 21) with Air

with Air Conditioning
Conditioning System:
System:
W04D-TN
x4
FAN PULLEY
NO. 1 V (COOLER COMPRESSOR

FAN TO CRANKSHAFT PULLEY) BELT
29 (290, 21)
x7
CO
WATER PUMP ASSEMBLY
A165853E01
CO–4 W04D-TM, TN COOLING – WATER PUMP
REMOVAL
2. REMOVE RADIATOR HOSE INLET
(a) Remove the radiator inlet hose.
CRANKSHAFT PULLEY) BELT (W04D-TN, w/ Air
Conditioning System) (See chapter EM)
6. REMOVE WATER PUMP ASSEMBLY
(a) Remove the 7 bolts and the water pump assembly.
A158452
INSPECTION
1. INSPECT WATER PUMP ASSEMBLY
(a) Turn the pulley and check that the water pump
bearing moves smoothly and quietly.
If necessary, replace the water pump assembly.
A147500
INSTALLATION
Seal Packing
1. INSTALL WATER PUMP ASSEMBLY
(a) Apply seal packing to the illustrated position.
Seal packing:
NOTICE:
Clean the installation surface.
A158453E01
CO (b) Install the water pump assembly with the 7 bolts.

4. ADJUST FAN AND GENERATOR V BELT (See
chapter EM)
A158452 CRANKSHAFT PULLEY) BELT (W04D-TN, w/ Air
W04D-TM, TN COOLING – WATER PUMP CO–5

7. INSTALL RADIATOR HOSE INLET
CO
CO–6 W04D-TM, TN COOLING – THERMOSTAT
THERMOSTAT
W04D-TM, TN COOLING
ENGINE
COMPONENTS
WATER OUTLET CAP SUB-ASSEMBLY
25 (250, 18)
x3
RADIATOR HOSE INLET
WATER OUTLET
29 (290, 21)
x2
THERMOSTAT
VACUUM SWITCHING VALVE

HOSE BRACKET
GASKET
Non-reusable part
A158832E02
CO REMOVAL
(a) Remove the water outlet cap sub-assembly.
W04D-TM, TN COOLING – THERMOSTAT CO–7
(b) Loosen the clip and disconnect the radiator hose

inlet.
(c) Loosen the clip and disconnect the water by-pass
hose.
A158517
(a) Remove the 2 bolts and vacuum switching valve
hose bracket.
A158518
(b) Remove the 3 bolts and water outlet.

(c) Remove the thermostat from the water outlet
housing.
(d) Remove the gasket from the thermostat.
A158512
INSPECTION
1. INSPECT THERMOSTAT
HINT:
The valve opening temperature is inscribed on the
thermostat.
A147506
(a) Immerse the thermostat in water and gradually heat CO

the water.
(b) Check the valve opening temperature of the
thermostat.
Valve opening temperature:
80 to 84°C (176 to 183°F)
If the valve opening temperature is not as
specified, replace the thermostat.
A147507
CO–8 W04D-TM, TN COOLING – THERMOSTAT
(c) Check the valve lift.

Valve lift:
10 mm (0.394 in.) or more at 95°C (203°F)
If the valve lift is not as specified, replace the
thermostat.
(d) Check that the valve is fully closed when the
thermostat is at low temperatures (below 40°C
Valve Iift (104°F))
If not fully closed, replace the thermostat.
A147508E01
INSTALLATION
(a) Install a new gasket to the thermostat.
(b) Install the thermostat with the jiggle valve upward.
A163487
(c) Install the water outlet with the 3 bolts.

A158512

(a) Connect the radiator hose inlet.
(b) Connect the water by-pass hose.
A158517
CO (c) Install the vacuum switching valve hose bracket with

the 2 bolts.
(d) Install the water outlet cap sub-assembly.
A158518
W04D-TM, TN COOLING – RADIATOR CO–9
RADIATOR
ENGINE
W04D-TM, TN COOLING
COMPONENTS
NO. 2 AIR HOSE
x4
7.5 (77, 66 in.*lbf)
NO. 3 AIR HOSE

CO
A155945E01
CO–10 W04D-TM, TN COOLING – RADIATOR
EXAMPLE:
for Standardfor Standard Body
Body:
29 (290, 21)
18 (184, 13)
18 (184, 13) x4
18 (184, 13)
FAN PULLEY
FAN
x2
FAN SHROUD
NO. 3 RADIATOR BRACKET 5.0 (51, 44 in.*lbf)
RADIATOR HOSE INLET x4
7.5 (77, 66 in.*lbf) FAN AND GENERATOR V BELT
x2
RADIATOR ASSEMBLY
18 (184, 13)
x3
18 (184, 13) NO. 1 RADIATOR SUPPORT
7.5 (77, 66 in.*lbf) RADIATOR AIR GUIDE

x2
CO
A165151E02
for Wide Body: with

with Fan
Fan Clutch:
clutch: W04D-TN
29 (290, 21)
FAN PULLEY
FAN
RADIATOR HOSE INLET

29 (290, 21)
x4
18 (184, 13)
FAN SHROUD FAN PULLEY
FAN
x3

7.5 (77, 66 in.*lbf)
x4
18 (184, 13)

NO. 3 INTAKE PIPE
7.5 (77, 66 in.*lbf)
RADIATOR ASSEMBLY with Air

Conditioning System:
System:
W04D-TN
18 (184, 13)
NO. 2 INTAKE PIPE

NO. 1 RADIATOR SUPPORT 18 (184, 13)

x3
NO. 1 V (COOLER COMPRESSOR
NO. 2RADIATOR SUPPORT TO CRANKSHAFT PULLEY) BELT
CO
N*m (kgf*cm, ft.*lbf) : Specified torque 7.5 (77, 66 in.*lbf)
A165152E01
RADIATOR TANK UPPER
13 (130, 9)
O-RING
RADIATOR SIDE PLATE
13 (130, 9)
CORE SUB-ASSEMBLY
13 (130, 9)
RADIATOR COLLAR
RADIATOR BUSHING
RADIATOR BUSHING
13 (130, 9)
RADIATOR COLLAR
O-RING
RADIATOR SIDE PLATE
RADIATOR DRAIN PLUG
O-RING

RADIATOR TANK LOWER
Non-reusable part
A165564E01
CO ON-VEHICLE INSPECTION
1. INSPECT RADIATOR CAP SUB-ASSEMBLY
(a) Measure the valve opening pressure.
(1) If there are water stains or foreign matter on
1 rubber packings 1, 2 or 3, clean the parts with
water and finger scouring.
2
(2) Check that rubber packings 1, 2 and 3, are not
4 deformed, cracked or swollen.
3
A138101
(3) Check that rubber packings 3 and 4 are not
stuck together.
(4) Apply engine coolant to rubber packings 2 and

3 before using the radiator cap tester.
(5) When using the cap tester, tilt it to more than
30 degrees.
Radiator Cap Tester (6) Pump the cap tester several times, and check
the maximum pressure *1.
Pumping speed:
30° or more 1 pump per second
*1: Even if the cap cannot maintain the
Radiator Cap maximum pressure, it is not a defect.
Judgement criteria
Z000570E05
Standard value (for brand new cap) 93 to 123 kPa (0.95 to 1.25 kgf*cm2,
13.5 to 17.8 psi)
Minimum standard value (for used 78 kPa (0.8 kgf*cm2, 11.4 psi)
cap)
If the maximum pressure is less than the

specified pressure for the minimum standard
value, replace the radiator cap sub-assembly.
ON-VEHICLE CLEANING
1. CHECK FIN FOR BLOCKAGE
(a) If the fins are clogged, wash them with water or a
steam cleaner, then dry them with compressed air.
NOTICE:
• If the steam cleaner is too close to the core,
there is a possibility of damaging the fins, so
keep the following injection distances.
A073603 Injection Pressure Injection Distance
kPa (kgf*cm2, psi) mm (in.)
2942 to 4903
300 (11.811)
(30 to 50, 427 to 711)
4903 to 7845
500 (19.685)
(50 to 80, 711 to 1138)
• If the fins are bent, straighten them with a

screwdriver or pliers.
• Do not expose electronic components to
water.
REMOVAL
CO
IT)
5. REMOVE NO. 3 INTAKE PIPE (for Wide Body)
(a) Remove the bolt and No. 3 intake pipe.
6. REMOVE NO. 2 INTAKE PIPE (for Wide Body)
(a) Remove the bolt and No. 2 intake pipe.

inlet.
A165507

outlet.
A165508
12. REMOVE NO. 1 RADIATOR SUPPORT (for Standard

Body)
(a) Remove the 3 bolts and No. 1 radiator support.
A163537

Standard Body)
(a) Disconnect the 2 clamps and wire harness.
A158457
CO (b) Remove the nut and separate the No. 3 radiator

bracket.
A158458
14. SEPARATE NO. 3 RADIATOR BRACKET (W04D-TN

W04D-TN
for Wide Body)
bracket.
(b) Remove the bolt and separate the No. 1 radiator
support.
A155592

Standard Body)
bracket.
16. SEPARATE NO. 4 RADIATOR BRACKET (W04D-TN
for Wide Body)
(a) Disconnect the clamp and accelerator wire.
A165509
(b) Remove the 3 bolts and separate the No. 4 radiator

W04D-TN bracket.
(c) Remove the bolt and separate the No. 2 radiator
support.
(a) Remove the radiator assembly with the fan shroud.
(b) for standard body
(1) Remove the 2 bolts and nut, No. 3 radiator
bracket from the radiator assembly.
A155591
(2) Remove the 2 bolts and radiator air guide.
A155589
DISASSEMBLY CO
1. REMOVE RADIATOR SIDE PLATE
(a) Remove the all square head M8 (4 or 8) bolts to
remove the left and the right side plates.
(b) Remove the side seal and radiator packing.
(c) Remove the drain cock and O-ring.
Radiator Side Plate
A156561E01
2. REMOVE RADIATOR TANK UPPER

(a) Adjust dimension B shown in the illustration using a
stopper bolt so that it is 0.2 to 0.3 mm when the
handle of SST touches the stopper bolt.
SST 09230-01010 (09231-01010, 09231-01030)
NOTICE:
If the stopper bolt is not adjusted, the claw may
Dimension B
be damaged.
Stopper Bolt
Claw SST
A113337E05
(b) As the aluminum radiator adopts an integral

crimping construction by the core plate, remove the
Tank
upper and the lower tanks by lifting up the core plate
in such a way that the latter may not be damaged.
Release the crimping by using SST and by gripping
it until it hits the stopper bolt of the handle as shown
Core Plate the illustration.
SST 09230-01010 (09231-01010, 09231-01030)
SST NOTICE:
Do not lift up the core plate more than 90°.
SST
A163978E01
(c) Remove the upper and lower tanks by lightly

tapping the radiator hose fitting position.
NOTICE:
• Remember the mounting direction of the core
sub-assembly.
• Remount it in such a way that the original
direction can be maintained.
3. REMOVE RADIATOR TANK LOWER
HINT:
A156564
The removal procedure of the radiator tank lower is the
CO same as that of the radiator tank upper.
REASSEMBLY
Part A 1. INSTALL RADIATOR TANK UPPER
(a) Install the punch assembly to the overhaul handle,
inserting it in the hole in part A as shown in the
illustration.
SST 09230-01010 (09231-01010, 09231-01020),
Dimension B 09231-14010
Stopper Bolt (b) While gripping the handle, adjust the stopper bolt so
that dimension B is as specified below.
Dimension B:
7.4 to 7.8 mm (0.29 to 0.30 in.)
SST
Punch Assembly Overhaul Handle
A120276E02
(c) Check that there are no foreign objects in the core

plate groove, and install a new O-ring. Make sure
that the O-ring is not twisted.
NOTICE:
When cleaning the core plate groove, lightly rub
it with sandpaper without scratching it.
Normal
Twisted
O-Ring
Twisted
A156567E01
(d) Tap the lock plate with a plastic-faced hammer so

that there is no gap between the lock plate and the
Tank tank.
Core Plate
Gap
CO
A156569E02
(e) Lightly press the crimping tool against the core plate
in the order shown in the illustration. After repeating
this a few times, fully crimp the core plate by
5 11 3 9 7 squeezing the handle until stopped by the stopper
bolt.
1 2 NOTICE:
6 8 • For positions where the crimping tool is not
12 4 10 usable, crimp by using pliers.
• Crimp according to the order shown in the
illustration.
Press
Against Core Plate
A164226E01
(f) Check dimension D after crimping.

Tank
Standard dimension:
7.4 to 7.8 mm (0.29 to 0.30 in.)
(g) In the event that dimension D does not fall within the
standard limit, adjust the stopper bolt of the handle
once again and recrimp.
Dimension D NOTICE:
Core Plate Check the dimensions at both ends of the core
plate as well as around the central portion where
O-Ring
A164234E01 the crimping has not been performed (under the
pipe, etc.).
(h) Others:
Mark for the first repair for the second repair at a
well visible place in the upper tank.
NOTICE:
The radiator can only be recrimped twice. After
the second time, the radiator core must be
replaced.
2. INSTALL RADIATOR TANK LOWER
HINT:
The installation procedure of the radiator tank lower is
CO the same as that of the radiator tank upper.

(a) Assemble the plug handle as shown in the
Washer (Small) illustration and tighten the nut until the washer, the
Handle
plug and the handle are in light contact with each
other.
Nut
Washer (Large) Plug
A156573E01
(b) Using SST, plug the inlet and outlet pipes of the
radiator.
SST 09230-01010 (09231-00030, 09231-00050)
(c) Using a radiator cap tester, apply pressure to the
radiator.
Test pressure:
118 kPa (1.2 kgf/cm2, 17 psi)
SST
A156574E01
HINT:
Tank On radiators with resin tanks, there is a clearance
between the core plate and tank plate where a
minute amount of air will remain, giving the
appearance of an air leak when the radiator is
submerged in water. Therefore, before performing
Core Plate
the water leak test, first swirl the radiator around in
O-Ring the water until all air bubbles disappear.
4. INSTALL RADIATOR SIDE PLATE
A156575E02
(a) Install the all square head bolts to install the left and
the right side plates.
INSTALLATION
(a) for standard body
(1) Install the No. 3 radiator bracket to the radiator
assembly with the 2 bolts and nut. CO
(2) Install the radiator air guide to the radiator
(b) Install the radiator assembly with the fan shroud.

Body)
4. INSTALL NO. 4 RADIATOR BRACKET (W04D-TN for
Wide Body)
(a) Connect the accelerator wire with the clamp.
A165509
(b) Install the No. 4 radiator bracket with the 3 bolts.

W04D-TN Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
(c) Install the No. 2 radiator support with the bolt.
A155591
5. INSTALL NO. 3 RADIATOR BRACKET (W04D-TN for

Standard Body)
(a) Install the No. 3 radiator bracket with the nut.
A158458
(b) Connect the wire harness with the 2 clamps.
A158457
CO 6. INSTALL NO. 3 RADIATOR BRACKET (W04D-TN for

W04D-TN
Wide Body)
(b) Install the No. 1 radiator support with the bolt.
A155592
7. INSTALL NO. 1 RADIATOR SUPPORT (for Standard

Body)
(a) Install the No. 1 radiator support with the 3 bolts.
Torque: Bolt (A)
7.5 N*m (77 kgf*cm, 66 in.*lbf)
Bolt (B)
(B) 18 N*m (184 kgf*cm, 13 ft.*lbf)
(A) 8. INSTALL FAN PULLEY (See chapter EM)
(A) A163537E01 9. INSTALL FAN (See chapter EM)
chapter EM)
A165508

(a) Connect the radiator hose inlet with the clip.
IT)
18. INSTALL NO. 3 INTAKE PIPE (W04D-TN, for Wide
A165507 Body)
(a) Install the No. 3 intake pipe with the bolt.
19. INSTALL NO. 2 INTAKE PIPE (W04D-TN, for Wide
Body) CO
(a) Install the No. 2 intake pipe with the bolt.
CO–22 W04D-TM, TN COOLING – COOLING SYSTEM
COOLING SYSTEM
CAUTION:
(b) Fill the radiator with coolant and attach a radiator
cap tester.
(d) Using a radiator cap tester, increase the pressure
inside the radiator to 137 kPa (1.4 kgf/cm2, 19.9
psi), and check that the pressure does not drop.
If the pressure drops, check the hoses, radiator and
water pump for leaks. If no external leaks are found,
check the heater core, cylinder block and cylinder
A158454
head.
(e) Install the radiator cap.
2. CHECK COOLANT LEVEL OF RESERVOIR
(a) Check that the engine coolant level is between the
LOW and FULL lines when the engine is cold.
If the engine coolant level is low, check for leaks and
add "HINO genuine Long Life Coolant" or similar
high quality ethylene glycol based non-silicate, non-
amine, non-nitrite and non-borate coolant with long-
life hybrid organic acid technology to the FULL line.
3. CHECK ENGINE COOLANT QUALITY
CAUTION:
(b) Check if there are any excessive deposits of rust or
scales around the radiator cap and radiator filler
hole. Also, the coolant should be free of oil.
If excessively dirty, clean the coolant passage and
replace the coolant.
CO (c) Install the radiator cap.
4. MAINTAIN AND INSPECT FAN AND FAN CLUTCH
(a) During maintenance and inspection, be careful not
to drop or strike the fan coupling or fan itself. The
resulting damage may lower the performance of the
fan. Also, note that the fan is made of plastic and
may become damaged or deformed if force is
applied to it.
W04D-TM, TN COOLING – COOLING SYSTEM CO–23
(b) Do not replace the fan unless it is faulty. When

replacing the fan, replace it with the same type as
the one which was removed.
If the fan is replaced with one of a larger capacity
due to overheating, or conversely is replaced with
one of a smaller capacity due to over cooling, the
cooling performance may be in fact reduced and
durability may be jeopardized.
(c) Check the temperature detector (bimetal) to see if
there is any mud or dust on it.
If the bimetal is covered with mud or dust, the fan
performance will be erratic, and may result in
overheating or over cooling.
(d) In such case, carefully remove mud and dust
adhering to the surface of the bimetal, using a wire
brush, or the like.
(e) Take particular care not to apply excessive force. Do
not paint the fan or fan clutch.
(f) Do not place any paint or other reagents which are
likely to dissolve plastic in contact with the fan.
CO
ENGINE
OIL AND OIL FILTER

COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-1
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-2
OIL PUMP
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-4
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-5
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-5
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-7
ENGINE OIL COOLER
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-10
LUBRICATION SYSTEM
ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-12
LU
N04C-TR, TS, TT, TU, TV, TW LUBRICATION – OIL AND OIL FILTER LU–1
OIL AND OIL FILTER

ENGINE
COMPONENTS
GASKET
41 (418, 30)
20 (200, 14) DRAIN PLUG
OIL FILTER SUB-ASSEMBLY
LU
Non-reusable part
A158431E03
LU–2 N04C-TR, TS, TT, TU, TV, TW LUBRICATION – OIL AND OIL FILTER
REPLACEMENT
CAUTION:
• Prolonged and repeated contact with engine oil will
cause the loss of natural oils from the skin, leading to
dryness, irritation and dermatitis. In addition, used
engine oil contains potentially harmful contaminants
that may cause skin cancer.
• Precautions should be taken when replacing engine
oil to minimize the risk of your skin making contact
with used engine oil. Wear protective clothing and
gloves. Wash your skin thoroughly with soap and
water, or use a waterless hand cleaner to remove any
used engine oil. Do not use gasoline, thinners or
solvents.
• For environmental protection, used oil and used oil
filters must be disposed of at designated disposal
sites.
1. DRAIN ENGINE OIL
(b) Remove the drain plug from the oil pan and drain
engine oil into a container.
(c) Clean the drain plug.
(d) Install the drain plug with a new gasket.
2. REMOVE OIL FILTER SUB-ASSEMBLY
(a) Using SST, remove the oil filter.
SST 09228-78010
3. INSTALL OIL FILTER SUB-ASSEMBLY
(a) Clean the oil filter installation surface.
(b) Apply engine oil to the oil filter gasket.
(c) Lightly screw the oil filter to the engine until the oil
filter does not turn.
(d) Using SST, tighten the oil filter an additional 2/3
turn.
SST 09228-78010
4. ADD ENGINE OIL
(a) Add fresh oil and install the oil filler cap sub-
assembly.
Engine oil
Oil Grade Oil Viscosity (SAE)
• API: CD, CE, CF, CH-4, CI-4 or CJ-4*1 • 10W-30

• 20W-20
JASO: DH-1 or DH-2*1
LU ACEA: E-3, E-4, E-5 or E-6*1
•
•
15W-40
30
*1
:HINO recommends these oil to the EURO4 regulation countries. • 40
Capacity
Item Fill amount
Drain and refill with oil filter change 7.1 liters (7.5 US qts, 6.2 Imp. qts)
Drain and refill without oil filter change 5.9 liters (6.2 US qts, 5.2 Imp. qts)
Dry fill 7.6 liters (8.0 US qts, 6.7 Imp. qts)
N04C-TR, TS, TT, TU, TV, TW LUBRICATION – OIL AND OIL FILTER LU–3

(a) Warm up the engine and check for engine oil leaks.
6. CHECK OIL LEVEL (See page LU-12)
LU
LU–4 N04C-TR, TS, TT, TU, TV, TW LUBRICATION – OIL PUMP
OIL PUMP
ENGINE
COMPONENTS
29 (290, 21)
x7 GASKET
OIL PUMP ASSEMBLY
137 (1397, 101)
NO. 1 IDLE GEAR SUB-ASSEMBLY
LU Non-reusable part
A164662E01
REMOVAL
1. REMOVE CAMSHAFT
(See chapter EM)
N04C-TR, TS, TT, TU, TV, TW LUBRICATION – OIL PUMP LU–5
2. REMOVE NO. 1 IDLE GEAR SUB-ASSEMBLY

(a) Remove the bolt from the No. 1 idle gear sub-
assembly.
(b) Using SST, remove the No. 1 idle gear shaft.
SST 09910-00015 (09911-00011, 09912-00010)
(c) Remove the No. 1 idle gear sub-assembly.
(a) Remove the 7 bolts and oil pump assembly.
SST
A147518E01
DISASSEMBLY
1. REMOVE OIL PUMP DRIVEN GEAR
(a) Remove the driven gear from the oil pump.
NOTICE:
Since the driven gear is a press-fit type, it can
not be disassembled.
A153842E01
INSPECTION
1. INSPECT OIL PUMP ASSEMBLY
between the oil pump gear and No. 1 idle gear sub-
assembly.
Standard backlash:
0.065 to 0.215 mm (0.0026 to 0.0085 in.)
Maximum backlash:
A147521
0.30 mm (0.0118 in.)
replace the oil pump assembly and No. 1 idle gear
sub-assembly.
(b) Using vernier calipers, measure the width of the
drive gear.
Standard width:
27.02 to 27.04 mm (1.0638 to 1.0646 in.)
A153843
LU
(c) Using vernier calipers, measure the depth of the

pump chamber on the cylinder block.
Standard depth:
27.03 to 27.07 mm (1.0642 to 1.0657 in.)
(d) Calculate the difference between the width of the
drive gear and the depth of the pump chamber on
the cylinder block. (Gasket thickness: 0.06 to 0.08
mm)
Standard clearance:
A153844 0.05 to 0.13 mm (0.002 to 0.0051 in.)
Maximum clearance:
0.17 mm (0.0067 in.)
HINT:
If the difference exceeds the limit, replace the oil
pump assembly or cylinder block.
(e) Inspect the backlash between the drive gear and
driven gear.
(1) Using a vise, fix the oil pump assembly.
(2) Using a dial gauge, measure the backlash
between the drive gear and driven gear.
Standard backlash:
0.091 to 0.217 mm (0.0036 to 0.0085 in.)
Maximum backlash:
0.30 mm (0.0118 in.)
A153845
(f) Inspect the clearance between the drive gear shaft

and driven gear bush.
(1) Using a micrometer, measure the diameter of
the drive gear shaft.
18.088 to 18.106 mm (0.7121 to 0.7128 in.)
A153846
(g) Using a dial gauge, measure the inside diameter of

the drive gear bush.
18.146 to 18.173 mm (0.7144 to 0.7155 in.)
LU 18.20 mm (0.7165 in.)
(h) Subtract the diameter measurement of the drive
gear shaft from the inside diameter measurement of
the drive gear bush.
A153847 Standard clearance:
0.040 to 0.085 mm (0.0016 to 0.0033 in.)
Maximum clearance:
0.10 mm (0.0039 in.)
N04C-TR, TS, TT, TU, TV, TW LUBRICATION – OIL PUMP LU–7

replace the oil pump assembly or drive gear bush.
(i) Inspect the clearance between the driven gear shaft
the driven gear shaft.
17.979 to 17.997 mm (0.7078 to 0.7085 in.)
A153848
(j) Using a dial gauge, measure the inside diameter of

the driven gear bush.
18.037 to 18.054 mm (0.7101 to 0.7108 in.)
(k) Subtract the diameter measurement of the driven
gear shaft from the inside diameter measurement of
the driven gear bush.
Standard clearance:
0.040 mm to 0.075 mm (0.0016 to 0.0030 in.)
A153849 Maximum clearance:
0.13 mm (0.0051 in.)
replace the drive gear shaft or the driven gear.
REASSEMBLY
1. INSTALL OIL PUMP DRIVEN GEAR
(a) Install the driven gear to the oil pump.
A153842E01
INSTALLATION
Apply
Engine Oil 1. INSTALL OIL PUMP ASSEMBLY
(a) Apply engine oil to the pump case of the cylinder
block and the bearing.
NOTICE:
Failure to apply engine oil to the pump may
cause poor lubrication, resulting in burning
engine oil or abnormal engine wear.
A147519E01
(b) Install the new gasket. LU
(c) Install the oil pump assembly with the 7 bolts.

Matchmark (a) With the oil hole of the No. 1 idle gear sub-assembly
facing down, align the matchmarks of each gear and
insert the No. 1 idle gear sub-assembly into the
cylinder block.
NOTICE:
Face the oil hole downward to avoid burning
Matchmark engine oil or abnormal engine wear.
(b) Install the No. 1 idle gear sub-assembly with the
bolt.
3. INSTALL CAMSHAFT
Matchmark (See chapter EM)
A164986E01
LU
N04C-TR, TS, TT, TU, TV, TW LUBRICATION – ENGINE OIL COOLER LU–9
ENGINE OIL COOLER

ENGINE
COMPONENTS
ENGINE OIL PRESSURE SWITCH ASSEMBLY
O-RING
29 (290, 21)
12 (125, 9.0)
x 15
x4
OIL FILTER BRACKET SUB-ASSEMBLY
GASKET
GASKET
OIL COOLER ASSEMBLY
20 (200, 14)
OIL FILTER ASSEMBLY
LU
Non-reusable part
A147514E05
LU–10 N04C-TR, TS, TT, TU, TV, TW LUBRICATION – ENGINE OIL COOLER
REMOVAL
(See chapter IT)
2. REMOVE OIL FILTER ASSEMBLY (See page LU-2)
ASSEMBLY
(a) Disconnect the oil pressure switch connector.
(b) Remove the oil pressure switch.
4. REMOVE OIL COOLER ASSEMBLY
(a) Remove the 15 bolts and oil cooler assembly with
bracket.
A146518
(b) Remove the 4 nuts and oil cooler assembly.

A147515
INSTALLATION
1. INSTALL OIL COOLER ASSEMBLY
(a) Install the oil cooler assembly and 2 new gaskets to
the oil filter bracket sub-assembly with the 4 nuts.
A147515
(b) Apply a continuous bead of seal packing (diameter

1.5 to 2.5 mm (0.06 to 0.10 in.) illustration.
LU Seal packing:
Bond 1207B or equivalent.
NOTICE:
• Install the oil cooler within 3 minutes of
A147516E01 applying the seal packing.
N04C-TR, TS, TT, TU, TV, TW LUBRICATION – ENGINE OIL COOLER LU–11
(c) Install the oil cooler assembly with oil filter bracket
with the 15 bolts.
A146518

20 to 40°
ASSEMBLY
(a) Install the oil pressure switch.
3. INSTALL OIL FILTER ASSEMBLY (See page LU-2)
A147513E01 4. INSTALL TURBOCHARGER SUB-ASSEMBLY
(See chapter IT)
LU
LU–12 N04C-TR, TS, TT, TU, TV, TW LUBRICATION – LUBRICATION SYSTEM
LUBRICATION SYSTEM
1. CHECK ENGINE OIL LEVEL
(a) Warm up the engine, then stop the engine and wait
Full 5 minutes. Check that the engine oil level is
between the Low and Full level marks.
Low If low, check for leakage and add oil up to the full
A164448E01 level mark.
NOTICE:
• Do not add engine oil above the Full mark.
• If the oil level is 25 mm (0.98 in.) above the
Full mark, replace engine oil.
2. INSPECT OIL PRESSURE
(c) Install the union and 2 new gaskets to the oil cooler
bracket with the union bolt.
Hint
Union bolt 90034-01011
Oil Pressure Switch Union 90404-10024
(d) Install the oil pressure gauge.

(e) Warm up the engine.
(f) Inspect the oil pressure.
Union Bolt Gasket Oil pressure
Engine condition Specification
Union When Idling 190 kPa (1.9 kgf*cm2, 27.6 psi)
Adapter D (g) Remove the oil pressure gauge.

(h) Remove the union and union bolt.
Gasket
A147512E01
(i) Install the oil pressure switch.

20 to 40°
(j) Connect the oil pressure switch connector.
(k) Inspect for engine oil leaks.
LU
A147513E01
ENGINE
OIL AND OIL FILTER

COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-1
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-1
OIL PUMP
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-3
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-4
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-5
ENGINE OIL COOLER
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-7
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-8
LUBRICATION SYSTEM
ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LU-10
LU
W04D-TM, TN LUBRICATION – OIL AND OIL FILTER LU–1
OIL AND OIL FILTER

ENGINE
COMPONENTS
GASKET
OIL FILTER
DRAIN PLUG
Non-reusable part
A165084E01
REPLACEMENT
CAUTION:
• Prolonged and repeated contact with engine oil will
cause the loss of natural oils from the skin, leading to
dryness, irritation and dermatitis. In addition, used
engine oil contains potentially harmful contaminants
that may cause skin cancer.
• Precautions should be taken when replacing engine
oil to minimize the risk of your skin making contact
with used engine oil. Wear protective clothing and LU
gloves. Wash your skin thoroughly with soap and
water, or use a waterless hand cleaner to remove any
used engine oil. Do not use gasoline, thinners or
solvents.
LU–2 W04D-TM, TN LUBRICATION – OIL AND OIL FILTER
• For environmental protection, used oil and used oil

filters must be disposed of at designated disposal
sites.
1. DRAIN ENGINE OIL
(b) Remove the drain plug from the oil pan and drain
the engine oil into a container.
(c) Clean the drain plug.
(d) Install the drain plug with a new gasket.
2. REMOVE OIL FILTER SUB-ASSEMBLY
(a) Using SST, remove the oil filter.
SST S0955-31030
3. INSTALL OIL FILTER SUB-ASSEMBLY
(a) Clean the oil filter installation surface.
(b) Apply engine oil to the oil filter gasket.
(c) Lightly screw the oil filter to the engine until the oil
filter does not turn.
(d) Using SST, tighten the oil filter an additional 2/3
turn.
SST S0955-31030
4. ADD ENGINE OIL
(a) Add fresh oil and install the oil filler cap sub-
assembly.
Engine oil
Oil Grade Oil Viscosity (SAE)
• API: CD, CE, CF, CH-4 or CI-4 • 10W-30
JASO: DH-1 • 20W-20
ACEA: E-3 or E-4 • 5W-30
• 30
• 40
Capacity
Item Fill amount
Drain and refill with oil filter change 8.9 liters (9.4 US qts, 7.8 Imp. qts)
Drain and refill without oil filter change 7.5 liters (7.9 US qts, 6.6 Imp. qts)
Dry fill 9 liters (9.5 US qts, 7.9 Imp. qts)

(a) Warm up the engine and check for engine oil leaks.
6. CHECK OIL LEVEL (See page LU-10)
LU
W04D-TM, TN LUBRICATION – OIL PUMP LU–3
OIL PUMP
ENGINE
COMPONENTS
OIL PUMP ASSEMBLY
29 (291, 21)
x5
29 (291, 21)
GASKET
x2
137 (1397, 101)
NO. 1 IDLE GEAR

Non-reusable part
A165203E01
REMOVAL
1. REMOVE CAMSHAFT
(See chapter EM)
2. REMOVE NO. 1 IDLE GEAR (See chapter EM)
(a) Remove the 7 bolts and remove the oil pump
assembly.
LU
A158461
LU–4 W04D-TM, TN LUBRICATION – OIL PUMP
DISASSEMBLY
1. REMOVE OIL PUMP DRIVEN GEAR
(a) Remove the driven gear from the oil pump.
NOTICE:
Since the driven gear is a press-fit type, it can
not be disassembled.
INSPECTION
A163412 1. INSPECT OIL PUMP ASSEMBLY
(a) Visually check each part of the oil pump for damage
or wear.
If damage or wear is excessive, replace the oil
pump assembly with a new one.
(b) Inspect the backlash between the drive gear and
driven gear.
(1) Using a vise, fix the oil pump assembly.
(2) Using a dial gauge, measure the backlash
between the drive gear and driven gear.
Standard backlash:
0.091 to 0.217 mm (0.0036 to 0.0085 in.)
Maximum backlash:
0.30 mm (0.0118 in.)
A163413 If the backlash is greater than the maximum,
replace the oil pump assembly with a new one.
(c) Inspect the clearance between the drive gear shaft
the drive gear shaft.
18.088 to 18.106 mm (0.7121 to 0.7128 in.)
18.062 mm (0.7111 in.)
A163414
(2) Using a dial gauge, measure the inside

diameter of the drive gear bush.
18.146 to 18.173 mm (0.7144 to 0.7155 in.)
18.20 mm (0.7165 in.)
(3) Subtract the diameter measurement of the
drive gear shaft from the inside diameter
measurement of the drive gear bush.
LU 0.040 to 0.085 mm (0.0016 to 0.0033 in.)
Maximum clearance:
0.10 mm (0.0039 in.)
replace the oil pump assembly or drive gear
bush.
W04D-TM, TN LUBRICATION – OIL PUMP LU–5
(d) Inspect the clearance between the driven gear shaft

the driven gear shaft.
17.979 to 17.997 mm (0.7078 to 0.7085 in.)
17.97 mm (0.7075 in.)
A163416
(2) Using a dial gauge, measure the inside

diameter of the driven gear bush.
18.037 to 18.054 mm (0.7101 to 0.7108 in.)
18.07 mm (0.7114 in.)
(3) Subtract the diameter measurement of the
driven gear shaft from the inside diameter
measurement of the driven gear bush.
0.040 to 0.075 mm (0.0016 to 0.0030 in.)
Maximum clearance:
0.10 mm (0.0039 in.)
replace the drive gear shaft or the driven gear.
REASSEMBLY
1. INSTALL OIL PUMP DRIVEN GEAR
(a) Install the driven gear to the oil pump.
INSTALLATION
1. INSTALL OIL PUMP ASSEMBLY
(a) Apply engine oil to the pump case of the cylinder
block and the bearing.
A163412 NOTICE:
Failure to apply engine oil to the pump may
cause poor lubrication, resulting in burning or
abnormal wear.
(b) Install a new gasket.
(c) Install the oil pump assembly with the 7 bolts.
LU
A158461
LU–6 W04D-TM, TN LUBRICATION – OIL PUMP
(d) Confirm smooth rotation of the oil pump.

2. INSTALL NO. 1 IDLE GEAR (See chapter EM)
3. INSTALL CAMSHAFT
(See chapter EM)
A163418
LU
W04D-TM, TN LUBRICATION – ENGINE OIL COOLER LU–7
ENGINE OIL COOLER

ENGINE
COMPONENTS
25 (255, 18)
UNION BOLT
OIL OUTLET HOSE
GASKET UNION
ENGINE OIL PRESSURE

SWITCH ASSEMBLY
29 (291, 21)
GASKET
GASKET
x 15
GASKET GASKET
OIL FILTER BRACKET

SUB-ASSEMBLY x4 OIL COOLER ASSEMBLY
12 (125, 9.0)
OIL FILTER ASSEMBLY
Non-reusable part
A158833E01
REMOVAL
(See chapter IT)
2. REMOVE OIL FILTER ASSEMBLY (See page LU-2) LU
ASSEMBLY
LU–8 W04D-TM, TN LUBRICATION – ENGINE OIL COOLER
4. REMOVE OIL COOLER ASSEMBLY

(a) Remove the union bolt, oil outlet hose, union and 3
gaskets.
(b) Remove the 15 bolts and remove the oil cooler
assembly with bracket.
A153304E01
(c) Remove the 4 nuts and remove the oil cooler

assembly.
(d) Remove the 2 gaskets.
INSPECTION
1. INSPECT OIL COOLER ASSEMBLY
NOTICE:
• Be sure to clean the oil cooler element and oil
passage, using a commercial cleaning agent.
A154306E01
• Clean the metal parts, using treated oil.
(a) Carry out a pneumatic test for the oil cooler
element.
Test pressure:
6 kg/cm2 (85.3 lb/sq.in.)
Test time:
1 min.
If defective, replace the oil cooler element with a
new one.
(b) Visually check each part for damage or wear.
If the damage or wear is excessive, replace the
safety valve with a new one.
If the spring is flattened, replace the safety valve
with a new one.
INSTALLATION
1. INSTALL OIL COOLER ASSEMBLY
(a) Install the oil cooler assembly and 2 new gaskets to
the oil filter bracket sub-assembly with the 4 nuts.
LU A154306E01
W04D-TM, TN LUBRICATION – ENGINE OIL COOLER LU–9
(b) Apply a continuous bead of seal packing (diameter

1.5 to 2.5 mm illustration.
Seal packing:
NOTICE:
• Install the oil cooler within 3 minutes of
A147516E03 applying the seal packing.
(c) Install the oil cooler assembly with oil filter bracket
with the 15 bolts.
(d) Install the oil outlet hose, union and 3 gaskets with
the union bolt.
A153304E01

ASSEMBLY
20 to 40° (a) Install the oil pressure switch.
(1) Install the oil pressure switch, then further
tighten it by 20 to 40° as shown in the
illustration.
3. INSTALL OIL FILTER ASSEMBLY (See page LU-2)
A163396E01 4. INSTALL TURBOCHARGER SUB-ASSEMBLY
(See chapter IT)
LU
LU–10 W04D-TM, TN LUBRICATION – LUBRICATION SYSTEM
LUBRICATION SYSTEM
1. CHECK ENGINE OIL LEVEL
(a) Warm up the engine, then stop the engine and wait
for 5 minutes.
(b) Check that the engine oil level is between the low
level and full level marks on the level gauge.
If low, check for leakage and add oil up to the full
level mark.
NOTICE:
Do not add engine oil to above the full level
mark.
2. INSPECT OIL PRESSURE
(c) Install the oil pressure gauge.
Oil Pressure Gauge Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf)
(d) Warm up the engine.
(e) Inspect the oil pressure.
Oil pressure
Engine condition Specification
At idle 137 kPa (1.4 kgf*cm2, 19.7 psi) or
higher
At 2500 rpm 363 kPa (3.7 kgf*cm2, 51 psi) or
higher
(f) Remove the oil pressure gauge.

Oil Pressure Switch (g) Remove the union and union bolt.
A158467E01
(h) Install the oil pressure switch.

(1) Install the oil pressure switch, then further
20 to 40° tighten it by 20 to 40° as shown in the
illustration.
(i) Connect the oil pressure switch connector.
(j) Inspect for engine oil leaks.
A163396E01
LU
ENGINE
STARTING SYSTEM
PARTS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-1
SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-2
PRE-HEATING SYSTEM (N04C-TU, TV)
ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-4
GLOW PLUG (N04C-TU, TV)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-8
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-8
STARTER
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-10
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-14
STARTER RELAY (N04C-TR, TS, TT, TU, TV)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-15
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-16
STARTER RELAY (N04C-TW)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-17
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-18
GLOW RELAY (N04C-TU, TV)
IGNITION SWITCH
ST
N04C-TR, TS, TT, TU, TV, TW STARTING – STARTING SYSTEM ST–1
STARTING SYSTEM
ENGINE
PARTS LOCATION
EXAMPLE
NO. 2 RELAY BLOCK

- STARTER RELAY
- AM FUSE
- GLOW FUSE
STARTER
LHD:
NO. 1 RELAY BLOCK

- ST FUSE
ECM
IGNITION SWITCH
RHD:
NO. 1 RELAY BLOCK

- ST FUSE
ST
ECM
IGNITION SWITCH
A165314E01
ST–2 N04C-TR, TS, TT, TU, TV, TW STARTING – STARTING SYSTEM
SYSTEM DIAGRAM
EXAMPLE
9 AM1 ST1 3 ST
I6 Ignition Switch
18
E23 STA
1 1
S6 S7
1 2
S8 S8
Starter
AM1
GLOW
FL MAIN
FL MAIN (N04C-TR,TS,TT)
S5 1
1
S4
Battery
Starter
Battery
ECM
A160569E01
ST
N04C-TR, TS, TT, TU, TV, TW STARTING – PRE-HEATING SYSTEM (N04C-TU, TV) ST–3
PRE-HEATING SYSTEM (N04C-TU, TV)

ENGINE
PARTS LOCATION
EXAMPLE
GLOW PLUG
NO. 2 RELAY BLOCK

- GLOW RELAY
- AM1 FUSE
- ALT FUSE
- GLOW FUSE
COMBINATION METER
LHD:
- GLOW INDICATOR LIGHT
NO. 1 RELAY BLOCK

- GAUGE FUSE
ECM
IGNITION SWITCH
RHD: COMBINATION METER

NO. 1 RELAY BLOCK

- GAUGE FUSE ST
ECM
IGNITION SWITCH A165154E01
ST–4 N04C-TR, TS, TT, TU, TV, TW STARTING – PRE-HEATING SYSTEM (N04C-TU, TV)
SYSTEM DIAGRAM
9 AM1 IG1 10 11
E25 GIND
GAUGE Glow
I6 Ignition Switch
AM1
2 1 15
E25 SREL
3 5
GLOW
GLOW MAIN
ALT
ECM
Battery
G4 Glow Plug
Battery
A165190E01
NOTICE:
Turn the ignition switch off for 60 seconds before
performing the following inspections.
ST
N04C-TR, TS, TT, TU, TV, TW STARTING – PRE-HEATING SYSTEM (N04C-TU, TV) ST–5
1. INSPECT ILLUMINATION DURATION OF GLOW

Light Illumination Duration INDICATOR LIGHT
(sec.) (a) Turn the ignition switch to the ON position and
measure the duration of time that the light remains
6 illuminated.
Light illumination duration:
Refer to the graph and the table
3
If the result is not as specified, check the ECM,
1 engine coolant temperature sensor, glow plug and
0 glow plug relay.
-40 -20 8 28 55 80 100 (°C)
-40 -4 46.4 82.4 131176 212 (°F)
Engine Coolant Temperature
A165184E01
2. INSPECT PRE-HEATING
Pre-heating (a) Turn the ignition switch to the ON position and
Time (sec.) measure the length of time that battery voltage is
applied to the glow plugs.
10
24
Battery Voltage (V)
A165185E01
Pre-heating time
Engine coolant temperature
Pre-heating time
°C (°F)
40 (104) or more 1 sec.
Refer to the graph
40 (104) or less
(15 sec. at the longest)

engine coolant temperature sensor, glow plug and
glow plug relay.
(b) Disconnect all connectors from the 4 injectors.
(c) Turn the ignition switch to the START position.
Check that battery voltage is applied to the glow
plugs.
(d) While cranking the engine, measure how long it
takes for battery voltage to be applied to the glow
plugs.
Pre-heating time ST
Pre-heating time
°C (°F)
40 (104) or more 1 sec.
ST–6 N04C-TR, TS, TT, TU, TV, TW STARTING – PRE-HEATING SYSTEM (N04C-TU, TV)

Pre-heating time
°C (°F)
Refer to the graph
40 (104) or less
(15 sec. at the longest)

glow plug relay.
3. INSPECT AFTERGLOW TIME
(a) Measure the length of time that battery voltage is
applied to the glow plugs.
(b) After the engine starts, measure the length of time
Afterglow that battery voltage is applied to the glow plugs.
Time Afterglow time:
(sec.) Refer to the graph and the table
120
glow plug relay.
1
0
20 40 (°C)
68 104 (°F)
Engine Coolant Temperature
A165186E01
ST
N04C-TR, TS, TT, TU, TV, TW STARTING – GLOW PLUG (N04C-TU, TV) ST–7
GLOW PLUG (N04C-TU, TV)

ENGINE
COMPONENTS
NO. 1 TURBO WATER PIPE SUB-ASSEMBLY
25 (255, 18) SCREW GROMMET

GASKET
1.5 (15, 13 in.*lbf)

29 (296, 21)
O-RING
x2 55 (560, 41)
69 (700, 51) x2
x2
18 (184, 13)
EGR COOLER
x2 x2 25 (255, 18)
SUB-ASSEMBLY GASKET
GLOW PLUG ASSEMBLY
NO. 2 INTAKE PIPE
EXHAUST RETARDER
ASSEMBLY
70 (715, 52)
x3 25 (259, 19)
GASKET
x4
30 (306, 22)
FRONT EXHAUST
N*m (kgf*cm, ft.*lbf) : Specified torque PIPE ASSEMBLY
GASKET ST
Non-reusable part
A165523E01
ST–8 N04C-TR, TS, TT, TU, TV, TW STARTING – GLOW PLUG (N04C-TU, TV)
REMOVAL
TERMINAL
chapter MT)
chapter EX)
ASSEMBLY (See chapter IT)
chapter IT)
8. REMOVE GLOW PLUG GROUND WIRE
(a) Remove the 4 screw grommets.
(b) Remove the 4 nuts and 3 glow plug ground wires.
9. REMOVE GLOW PLUG ASSEMBLY
(a) Using a 12 mm deep socket wrench, remove the 4
glow plugs.
INSPECTION
1. INSPECT GLOW PLUG ASSEMBLY
between the glow plug terminal and ground.
Standard resistance
Tester Connection Condition Specified condition
Glow plug terminal -
20°C (68°F) 0.55 to 0.68 Ω
Ground
A101682
If the result is not as specified, replace the glow plug
assembly.
INSTALLATION
1. INSTALL GLOW PLUG ASSEMBLY
(a) Using a 12 mm deep socket wrench, install the 4
glow plugs.
ST
N04C-TR, TS, TT, TU, TV, TW STARTING – GLOW PLUG (N04C-TU, TV) ST–9
2. INSTALL GLOW PLUG GROUND WIRE

Glow Plug Ground Wire (a) Install the 3 ground wires so that they overlap as
shown in the illustration. Make sure that the ground
wire on the front side of the engine is installed first.
NOTICE:
If the ground wires are not installed in the
correct order, they may deform when the nuts
are tightened.
(b) Install the wire harness onto the No. 4 glow plug.
(c) Install the 4 nuts.
Wire Harness NOTICE:
Check that the ground wires do not interfere
Engine Front Side with the cylinder head or intake manifold.
(d) Install the 4 screw grommets.
A155675E02

chapter IT)
ASSEMBLY (See chapter IT)
chapter EX)
chapter MT)
TERMINAL
ST
ST–10 N04C-TR, TS, TT, TU, TV, TW STARTING – STARTER
STARTER
ENGINE
COMPONENTS
154 (1570, 114)
WIRE HARNESS
CLAMP BRACKET
18 (179, 13)
STARTER ASSEMBLY
14 (138, 10)
154 (1570, 114)
2.5 (25, 22 in.*lbf)
27 (275, 20)
CLUTCH FLEXIBLE HOSE BRACKET
A158413E01
REMOVAL
TERMINAL
ST
N04C-TR, TS, TT, TU, TV, TW STARTING – STARTER ST–11
2. SEPARATE CLUTCH FLEXIBLE HOSE BRACKET

(a) Remove the bolt and separate the clutch flexible
hose bracket.
A153321
3. REMOVE STARTER ASSEMBLY

(a) Disconnect the 2 wire harness clamps.
(b) Remove the bolt and the wire harness clamp
bracket.
(c) Pull off the terminal cap and remove the bolt, and
disconnect the starter wire from terminal B.
(d) Pull off the terminal cap and remove the nut, and
disconnect the starter wire from terminal C.
A153324
(e) Remove the nut, bolt and the starter assembly.
INSPECTION
1. INSPECT STARTER ASSEMBLY
NOTICE:
These tests must be performed within 3 to 5 seconds
to prevent the coil from burning out. Use a thick
cable for carrying a large electric current.
A149610
(a) Perform pull-in/holding test.

(1) Pull off the dust protector cap.
(2) Remove the nut and disconnect the lead wire
from terminal M.
Terminal M
A101668E01
ST
(3) Connect the battery to the magnetic switch as

shown in the illustration. Then check that the
clutch pinion gear moves outward.
Terminal C
Terminal M
A158520E01
(4) Disconnect the negative (-) lead from terminal

M. Check that the pinion gear remains out.
Terminal C
Terminal M
A158521E01
ST
N04C-TR, TS, TT, TU, TV, TW STARTING – STARTER ST–13
(5) Disconnect the negative (-) lead from the

starter body. Check that the clutch pinion gear
returns inward.
If the result is not as specified, repair or replace
the starter motor housing assembly.
Terminal C
Terminal M
A158522E01
(b) Perform operation test without load.

(1) Connect the lead wire to terminal M.
(2) Using a vise and aluminum protection plates,
fix the starter assembly.
Terminal M
A101668E01
(3) Connect the battery and an ammeter to the

starter with terminal C disconnected, as shown
NOTICE:
Terminal C Do not connect terminal C to the battery in
step (3).
(4) Connect terminal C to the battery and check
that the starter rotates smoothly and steadily
while the pinion gear is out. Then measure the
current.
Standard current:
180 A or less at 23 V
Terminal B starter assembly.
A158523E01
ST
INSTALLATION
1. INSTALL STARTER ASSEMBLY
(a) Install the starter assembly with the bolt and nut.
A149610
(b) Install the starter wire to terminal C with the bolt,

and install the terminal cap.
(c) Install the starter wire to terminal B with the nut, and
install the terminal cap.
(d) Install the wire harness clamp bracket with the bolt.
A153324
2. INSTALL CLUTCH FLEXIBLE HOSE BRACKET

(a) Install the clutch flexible hose bracket with the bolt.
TERMINAL
A153321
ST
N04C-TR, TS, TT, TU, TV, TW STARTING – STARTER RELAY (N04C-TR, TS, TT, TU, TV) ST–15
STARTER RELAY (N04C-TR, TS, TT, TU, TV)

ENGINE
COMPONENTS
RELAY BLOCK COVER
4.7 (48, 42 in.*lbf)
STARTER RELAY ASSEMBLY x2
x2
8.0 (82, 71 in.*lbf)

A161888E01
REMOVAL
1. REMOVE STARTER RELAY ASSEMBLY
(a) Remove the relay block cover.
(b) Remove the 2 nuts and disconnect the 2 lead wires.
(c) Disconnect the connector.
(d) Remove the 2 nuts and the starter relay assembly.
A161889
ST
ST–16 N04C-TR, TS, TT, TU, TV, TW STARTING – STARTER RELAY (N04C-TR, TS, TT, TU, TV)
INSPECTION
L B 1. INSPECT STARTER RELAY ASSEMBLY
Standard resistance
Battery voltage is not
L-B applied to terminals S8- 10 kΩ or higher
SW and S8-G
L B
Battery voltage is
L-B applied to terminals S8- Below 1 Ω
SW and S8-G
SW If the result is not as specified, replace the starter

relay assembly.
G
S8 G SW
A154066E02
INSTALLATION
1. INSTALL STARTER RELAY ASSEMBLY
(a) Install the starter relay assembly with the 2 nuts.
(c) Connect the 2 lead wires with the 2 nuts to the
starter relay assembly.
A161889
(d) Install the relay block cover.
ST
N04C-TR, TS, TT, TU, TV, TW STARTING – STARTER RELAY (N04C-TW) ST–17
STARTER RELAY (N04C-TW)

ENGINE
COMPONENTS
STARTER RELAY
ASSEMBLY
x2
8.0 (82, 71 in.*lbf)

x2
4.7 (48, 42 in.*lbf)
RELAY BLOCK COVER
A158416E01
REMOVAL
A153323
ST
ST–18 N04C-TR, TS, TT, TU, TV, TW STARTING – STARTER RELAY (N04C-TW)
INSPECTION
Standard resistance
SW and S8-G
L B
Battery voltage is
SW and S8-G
SW If the result is not as specified, replace the starter

relay assembly.
G
S8 G SW
A154066E02
INSTALLATION
(c) Connect the 2 lead wires with the 2 nuts to the
A153323
ST
N04C-TR, TS, TT, TU, TV, TW STARTING – GLOW RELAY (N04C-TU, TV) ST–19
GLOW RELAY (N04C-TU, TV)

1. INSPECT GLOW PLUG RELAY ASSEMBLY
Standard resistance
A101683
3-5 applied to terminals 1 10 kΩ or higher
and 2
Battery voltage (12 V) is
3-5 applied to terminals 1 Below 1 Ω
and 2
If the resistance is not as specified, replace the glow

plug relay assembly.
ST
ST–20 N04C-TR, TS, TT, TU, TV, TW STARTING – IGNITION SWITCH
IGNITION SWITCH
LOCK
ACC 1. INSPECT IGNITION SWITCH ASSEMBLY
ON
Standard resistance
START
Component Side:
Between all terminals LOCK 10 kΩ or higher
I6-4 (ACC) - I6-9 (AM1) ACC Below 1 Ω
ST1
ACC I6-4 (ACC) - I6-9 (AM1) -
I6-10 (IG1) ON Below 1 Ω
AM2 I6-5 (AM2) - I6-8 (IG2)
I6-3 (ST1) - I6-9 (AM1) -
I6 I6-10 (IG1) START Below 1 Ω
I6-5 (AM2) - I6-8 (IG2)
IG1
AM1 IG2 If the result is not specified, replace the ignition
switch assembly.
A163318E02
ST
ENGINE
STARTING SYSTEM
Engine does not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-4
PRE-HEATING SYSTEM
Pre-heating Control Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-14
PRE-HEATING TIMER
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-28
GLOW PLUG
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-29
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-29
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-31
STARTER
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-32
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-34
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-34
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-36
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-43
STARTER RELAY
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-44
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-44
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-45
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST-45
GLOW RELAY
IGNITION SWITCH (w/ Tilt Steering Column)
IGNITION SWITCH (w/o Tilt Steering Column)
ST
W04D-TM, TN STARTING – STARTING SYSTEM ST–1
STARTING SYSTEM
ENGINE
PARTS LOCATION
Standard Body:
NO. 2 RELAY BLOCK

- STARTER RELAY
- HEAD FUSE
Wide Body: - AM1 FUSE

STARTER
- STA FUSE
STARTER
NO. 2 RELAY BLOCK

- STARTER RELAY
- HEAD FUSE
- AM1 FUSE
- STA FUSE ST
A163548E01
ST–2 W04D-TM, TN STARTING – STARTING SYSTEM
LHD:
NO. 1 RELAY BLOCK
- STA FUSE
- AM2 FUSE
IGNITION SWITCH
RHD:
NO. 1 RELAY BLOCK
- STA FUSE
- AM2 FUSE
IGNITION SWITCH
A163550E01
ST
SYSTEM DIAGRAM
9 3
AM1 ST1
AM1
I6 Ignition Switch
STA
STA
FL MAIN
1 1 1 1
S4 S5 S7 S6
2 1
Battery S8 S8
STARTER
Starter
Battery
A165822E01
ST
Engine does not Start

WIRING DIAGRAM
9 3
AM1 AM1 ST1
I6 Ignition Switch
STA
STA
FL MAIN
1 1
S7 S6
2 1
S8 S8
Battery STARTER
1 S5 1
S4
Starter
Battery
A163840E04
1 CHECK IGNITION SWITCH ASSEMBLY

table below.
Ignition Switch Connector Standard voltage
I6-9 (AM1) - Body
Always 18 to 27 V
ground
I6
ST (c) Reconnect the ignition switch connector.
AM1
A163683E01
NG Go to step 3
OK

LOCK (b) Measure the resistance according to the value(s) in the
table below.
Standard resistance
ACC Tester Connection Condition Specified Condition
All combinations of all
LOCK 10 kΩ or higher
ON terminals
I6-9 (AM1) - I6-3 (ST1) START Below 1 Ω
START (c) Reconnect the ignition switch connector.

Component Side:
ST1
I6
IG1
AM1
A163318E03
OK
3 INSPECT FUSE (STA FUSE)
(a) Remove the STA fuse from the No. 1 relay block.
No. 1 Relay Block
table below.
Standard resistance
(c) Reinstall the STA fuse.

NG REPLACE FUSE (STA FUSE)
STA Fuse
A165202E01
OK
ST
4 CHECK HARNESS AND CONNECTOR (IGNITION SWITCH - STARTER RELAY)

Wire Harness Side: (b) Disconnect the starter relay connector.
table below.
Ignition Switch Connector Standard resistance (check for open)
I6-3 (ST1) - S8-1 Always Below 1 Ω

I6
ST1 Tester Connection Condition Specified Condition
I6-3 (ST1) or S8-1 - Body
ground
Starter Relay Connector (d) Reconnect the ignition switch connector.

(e) Reconnect the starter relay connector.
CONNECTOR (IGNITION SWITCH - STARTER
S8
RELAY)
A163684E01
OK
5 INSPECT STARTER RELAY
(a) Inspect the starter relay (See page ST-45).

NG REPLACE STARTER RELAY
OK
6 CHECK HARNESS AND CONNECTOR (STARTER RELAY - BODY GROUND)
(a) Disconnect the starter relay connector.

table below.
Starter Relay Connector Standard resistance
S8-2 - Body ground Always Below 1 Ω
S8
(c) Reconnect the starter relay connector.
A163685E01
CONNECTOR (STARTER RELAY - BODY
GROUND)
ST
OK
No. 2 Relay Block
table below.
Standard resistance

STA Fuse
A163665E01
OK
8 CHECK HARNESS AND CONNECTOR (STARTER RELAY - BATTERY)
(a) Disconnect the negative battery terminal.

Wire Harness Side: (b) Disconnect the positive battery terminal.
(c) Disconnect the starter relay connector.
Starter Relay Connector (d) Measure the resistance according to the value(s) in the
table below.
S6
S6-1 - Positive battery
Always Below 1 Ω
terminal
A163273E03

S6-1 or Positive battery
terminal - Body ground
(e) Reconnect the starter relay connector.

CONNECTOR (STARTER RELAY - BATTERY)
OK
ST
9 CHECK HARNESS AND CONNECTOR (STARTER RELAY - STARTER)

Wire Harness Side: (b) Disconnect the starter relay connector.
(c) Disconnect the starter connector.
table below.
Starter Relay Connector Tester Connection Condition Specified Condition
S7-1 - S5-1 Always Below 1 Ω
S7 Standard resistance (check for short)

S7-1 or S5-1 - Body
ground
Starter Connector
(e) Reconnect the starter connector.
(f) Reconnect the starter relay connector.
S5 NG REPAIR OR REPLACE HARNESS OR
CONNECTOR (STARTER RELAY - STARTER)
A163686E01
OK
10 CHECK HARNESS AND CONNECTOR (STARTER - BATTERY)

Wire Harness Side:
(b) Disconnect the positive battery terminal.
Starter Connector (c) Disconnect the starter connector.
table below.
S4
Always Below 1 Ω
terminal
A163687E02

terminal
(e) Reconnect the starter connector.

CONNECTOR (STARTER - BATTERY)
ST
OK
REPLACE STARTER ASSEMBLY
No. 2 Relay Block:
table below.
Standard resistance
AM1 fuse
A155013E01
OK
ST
ST–10 W04D-TM, TN STARTING – PRE-HEATING SYSTEM
PRE-HEATING SYSTEM
ENGINE
PARTS LOCATION
ENGINE COOLANT
Standard Body: TEMPERATURE
SENSOR
GLOW PLUG
NO. 2 RELAY BLOCK:
- GLOW RELAY
- ALT FUSE
Wide Body: - GLOW FUSE
- AM1 FUSE
ENGINE COOLANT
TEMPERATURE
SENSOR
NO. 2 RELAY BLOCK:
- GLOW RELAY
- ALT FUSE
- GLOW FUSE
GLOW PLUG
- AM1 FUSE
ST
A162022E01
W04D-TM, TN STARTING – PRE-HEATING SYSTEM ST–11
LHD:
COMBINATION METER
NO. 1 RELAY BLOCK

- AM2 FUSE
PREHEATING TIMER - STA FUSE
- HEAD FUSE
IGNITION SWITCH - IG1 FUSE
RHD:
COMBINATION METER
NO. 1 RELAY BLOCK

- AM2 FUSE
- STA FUSE PREHEATING TIMER
- HEAD FUSE
- IG1 FUSE IGNITION SWITCH A162023E01

ST
SYSTEM DIAGRAM
9 10 3
ST
AM1 IG1 STA
3 11
B
ST1 IG1
5 8 3
8 19
C6 C5 WRN
AM2 IG2 Glow
AM1
I6 Ignition Switch
AM2
10
RLY1
HEAD 1 2 2 1 14
TMP+
3 5 W4 Engine Coolant
ALT Temperature Sensor
GLOW
GLOW MAIN
FL MAIN
22
E
Battery 1
G5 Glow Plug
P15 Preheating Timer
Battery
A165363E01
ST
1. INSPECT PRE-HEATING
(a) Check that the glow indicator light and glow relay
operate as shown below:
Engine Coolant Temperature Below 0°C (32°F) Engine Coolant

Temperature 0°C
(32°F) or higher
8.5 Sec. or less 8.5 Sec. or more
START
Ignition
Switch ON
Condition
OFF
Engine High
Coolant 0°C (32°F)
Temperature Low
8.5 Sec.
ON
Glow Relay
OFF
3.2 Sec. 3.2 Sec.
Max 0.1
3.2 Sec. Sec. 1 Sec.
5 Sec.
Glow ON
Indicator
Light OFF
5 Sec.
98.5 Sec.
A162035E01
HINT:
When the engine coolant temperature is 0°C (32°F),
voltage between terminals J11 (TEP+) and J51 (E)
of the preheating timer is 3.28 V.
ST
Pre-heating Control Circuit

DESCRIPTION
The glow plug is mounted inside the engine combustion chamber. To ensure efficient engine starting with
a cold engine, the ECM calculates a time interval that the current needs to flow through the glow plug
depending on the engine coolant temperature when the ignition switch is turned to the START position.
The ECM then turns on the glow relay and permits the current to flow through the glow plug based on the
ECM's calculated time. The glow plug is then heated, enhancing fuel combustion with a cold engine.
HINT:
• These troubleshooting procedures are for: 1) difficulty in starting the engine in cold weather, and 2)
difficulty in driving/vehicle malfunctions in cold weather immediately after the engine is started.
• After the engine is started, the ECM performs an "after-glow" for a certain period of time. The time
period varies in proportion to the actual engine coolant temperature. The after-glow reduces diesel
engine knocking, white smoke emissions and engine noise when the engine is cold.
Engine Coolant Temperature Below 0°C (32°F) Engine Coolant

Temperature 0°C
(32°F) or higher
8.5 Sec. or less 8.5 Sec. or more
START
Ignition
Switch ON
Condition
OFF
Engine High
Coolant 0°C (32°F)
Temperature Low
8.5 Sec.
ON
Glow Relay
OFF
3.2 Sec. 3.2 Sec.
Max 0.1
3.2 Sec. Sec. 1 Sec.
5 Sec.
Glow ON
Indicator
Light OFF
5 Sec.
ST 98.5 Sec.
A162035E01
WIRING DIAGRAM
9 10 3
ST
AM1 IG1 STA
3 11
B
ST1 IG1
5 8 3
8 19
C6 C5 WRN
AM2 IG2 Glow
AM1
I6 Ignition Switch
AM2
10
RLY1
HEAD 1 2 2 1 14
TMP+
3 5 W4 Engine Coolant
ALT Temperature Sensor
GLOW
GLOW MAIN
FL MAIN
22
E
Battery 1
G5 Glow Plug
P15 Preheating Timer
Battery
A165363E01
ST
1 CHECK GLOW MAIN RELAY (VOLTAGE)
No. 2 Relay Block:
block.
table below.
Standard voltage
GLOW MAIN relay
ground
GLOW MAIN Relay
NG Go to step 14
A155011E01
OK
2 INSPECT GLOW MAIN RELAY
block.
table below.
Standard resistance
3-5 applied between 10 kΩ or higher
terminals 1 and 2
A163540 Battery voltage is
3-5 applied between Below 1 Ω
terminals 1 and 2

NG REPLACE GLOW MAIN RELAY
OK
ST
3 CHECK HARNESS AND CONNECTOR (GLOW MAIN RELAY - GLOW PLUG ASSEMBLY)
Wire Harness Side: block.
(b) Disconnect the glow plug connector.
Glow Plug Connector table below.
GLOW MAIN relay
Always Below 1 Ω
G5 terminal 5 - G5-1

No. 2 Relay Block GLOW MAIN relay
terminal 5 or G5-1 - Always 10 kΩ or higher
Body ground
(d) Reconnect the glow plug connector.

CONNECTOR (GLOW MAIN RELAY - GLOW
PLUG ASSEMBLY)
GLOW MAIN
Relay
A163997E01
OK
4 INSPECT GLOW PLUG ASSEMBLY (RESISTANCE)
(a) Remove the glow plug connector.

table below.
Standard resistance
20°C (68°F) 2.7 to 3.5 Ω
Body ground
HINT:
A101682
If any of the glow plugs has an open circuit, the engine
power is insufficient only when the engine is cold.
NOTICE:
• Exercise extreme care not to damage the glow
plug pipes. Damaging them could cause an open
circuit, or shorten the life of the glow plugs.
• Keep the glow plugs free of oil and fuel while ST
cleaning.
• Wipe any oil off of the terminal and Bakelite
washer with a clean, dry cloth during inspection.
(c) Reinstall the glow plug connector.

NG REPLACE GLOW PLUG ASSEMBLY
OK
5 CHECK GLOW PLUG ASSEMBLY (INSTALLATION)
(a) Check the glow plug installation.

OK:
Glow plugs are installed securely.
NG RETIGHTEN GLOW PLUG ASSEMBLY
OK
6 CHECK HARNESS AND CONNECTOR (GLOW MAIN RELAY - PREHEATING TIMER)
Wire Harness Side: block.
(b) Disconnect the preheating timer connector.
No. 2 Relay Block table below.
GLOW MAIN relay
terminal 1 - P15-10 Always Below 1 Ω
(RLY1)

GLOW MAIN Relay GLOW MAIN relay
terminal 1 or P15-10 Always 10 kΩ or higher
(RLY1) - Body ground
(d) Reinstall the GLOW MAIN relay.

(e) Reconnect the preheating timer connector.
Preheating Timer Connector CONNECTOR (GLOW MAIN RELAY -
PREHEATING TIMER)
P15
RLY1
A163663E03
OK
ST
7 CHECK HARNESS AND CONNECTOR (GLOW MAIN RELAY - BODY GROUND)
No. 2 Relay Block:
block.
table below.
Standard resistance
GLOW MAIN relay
terminal 2 - Body Always Below 1 Ω
ground
GLOW MAIN Relay
CONNECTOR (GLOW MAIN RELAY - BODY
GROUND)
A155011E01
OK

Standard resistance
W4-1 - W4-2 20°C (68°F) 2.32 to 2.59 Ω
W4-1 - W4-2 80°C (176°F) 3.10 to 3.26 Ω
Ω
30 NOTICE:
20 • When checking the ECT sensor in water, keep the
10 terminals dry.
W4 • After the check, wipe the sensor dry.
5
3
HINT:
2 ECT Sensor • Alternative procedure: Connect an ohmmeter to the
1 installed engine coolant temperature sensor and read
the resistance.
0.5 Acceptable
0.3 • Use an infrared thermometer to measure the engine
°C 0.1 -20 0 20 40 80 100 • Compare these values against the resistance/
A126612E08 (warm up or cool down the engine) and repeat the
test.
TEMPERATURE SENSOR
ST
OK
9 CHECK HARNESS AND CONNECTOR (PREHEATING TIMER - ENGINE COOLANT

TEMPERATURE SENSOR)
(a) Disconnect the preheating timer connector.

Wire Harness Side: (b) Disconnect the engine coolant temperature sensor
connector.
ECT Sensor Connector table below.
P15-14 (TMP+) - W4-1 Always Below 1 Ω
W4
P15-14 (TMP+) or W4-1 -
Preheating Timer Connector Body ground
(d) Reconnect the preheating timer connector.

(e) Reconnect the engine coolant temperature sensor
connector.
P15 NG REPAIR OR REPLACE HARNESS OR
CONNECTOR (PREHEATING TIMER -
TMP+ ENGINE COOLANT TEMPERATURE
A163667E02
SENSOR)
OK
10 CHECK HARNESS AND CONNECTOR (ENGINE COOLANT TEMPERATURE SENSOR

CONNECTOR - BODY GROUND)

table below.
ECT Sensor Connector
Standard resistance
W4-1 - Body ground Always Below 1 Ω
W4
(c) Reconnect the engine coolant temperature sensor.
A163668E01
CONNECTOR (ENGINE COOLANT
TEMPERATURE SENSOR - BODY GROUND)
OK
ST
11 CHECK PREHEATING TIMER (VOLTAGE)

table below.
Standard voltage
P15 P15-11 (B) - Body Ignition switch in the
18 to 27 V
B ground ON position
Preheating Timer Connector (c) Reconnect the preheating timer connector.

A155015E05
NG Go to step 16
OK
12 CHECK PREHEATING TIMER (VOLTAGE)

table below.
Standard voltage
P15 P15-3 (ST) - Body
Engine cranking 18 to 27 V
ground
ST
Preheating Timer Connector (c) Reconnect the preheating timer connector.
A155015E06
NG Go to step 18
OK
13 CHECK HARNESS AND CONNECTOR (PREHEATING TIMER - BODY GROUND)

table below.
Standard resistance
P15 P15-22 (E) - Body
Always Below 1 Ω
ground
Preheating Timer Connector E

(c) Reconnect the preheating timer connector.
A155015E08
CONNECTOR (PREHEATING TIMER - BODY
GROUND)
OK
ST
REPLACE PREHEATING TIMER ASSEMBLY
14 INSPECT FUSE (GLOW FUSE)
(a) Remove the GLOW fuse from the No. 2 relay block.
table below.
Standard resistance
(c) Reinstall the GLOW fuse.

NG REPLACE FUSE (GLOW FUSE)
GLOW Fuse
A155012E01
OK
15 INSPECT FUSE (ALT FUSE)
(a) Remove the ALT fuse from the No. 2 relay block.
table below.
Standard resistance
(c) Reinstall the ALT fuse.

NG REPLACE FUSE (ALT FUSE)
ALT Fuse
A155014E01
OK
REPAIR OR REPLACE HARNESS OR CONNECTOR (GLOW MAIN RELAY - BATTERY)
ST
16 INSPECT FUSE (IG1 FUSE)
(a) Remove the IG1 fuse from the No. 1 relay block.
No. 1 Relay Block
table below.
Standard resistance
(c) Reinstall the IG1 fuse.

NG REPLACE FUSE (IG1 FUSE)
IG1 Fuse
A163664E01
OK
17 CHECK HARNESS AND CONNECTOR (PREHEATING TIMER - IGNITION SWITCH)

Wire Harness SIde: (b) Disconnect the ignition switch connector.
table below.
Ignition Switch Connector Standard resistance (Check for open)
P15-11 (B) - I6-10 (IG1) Always Below 1 Ω
I6 Standard resistance (Check for short)

IG1
P15-11 (B) or I6-10 (IG1)
- Body ground
Preheating Timer Connector (d) Reconnect the preheating timer connector.

Result
Result Proceed to
P15 NG A
B OK B
A163669E04
B Go to step 20
REPAIR OR REPLACE HARNESS OR CONNECTOR (PREHEATING TIMER - IGNITION SWITCH)

ST
No. 1 Relay Block
table below.
Standard resistance

STA Fuse
A165202E01
OK
19 CHECK HARNESS AND CONNECTOR (PREHEATING TIMER - IGNITION SWITCH)

Wire Harness SIde: (b) Disconnect the ignition switch connector.
table below.
Ignition Switch Connector Standard resistance (Check for open)
P15-3 (ST) - I6-3 (ST1) Always Below 1 Ω
I6 Standard resistance (Check for short)

ST1 Tester Connection Condition Specified Condition
P15-3 (ST) or I6-3 (ST1) -
Body ground
Preheating Timer Connector (d) Reconnect the preheating timer connector.

CONNECTOR (PREHEATING TIMER -
P15
IGNITION SWITCH)
ST
A163669E05
OK
ST

LOCK (b) Measure the resistance according to the value(s) in the
table below.
Standard resistance
ACC Tester Connection Switch Condition Specified Condition
All combinations of all
LOCK 10 kΩ or higher
ON terminals
I6-9 (AM1) - I6-10 (IG1) ON Below 1 Ω
START I6-9 (AM1) - I6-3 (ST1) START Below 1 Ω
Component Side: (c) Reconnect the ignition switch connector.

ST1
I6
IG1
AM1
A163318E03
OK
No. 2 Relay Block:
table below.
Standard resistance
AM1 fuse (c) Reinstall the AM1 fuse.

A155013E01
OK

ST
ST–26 W04D-TM, TN STARTING – PRE-HEATING TIMER
PRE-HEATING TIMER
ENGINE
COMPONENTS
EXAMPLE: LHD
PREHEATING TIMER
ASSEMBLY
x2
x2
LOWER NO. 2
INSTRUMENT COVER
x2
LOWER INSTRUMENT COVER
for Wide Body:
LOWER NO. 3
INSTRUMENT COVER
x2
ST
A162034E01
W04D-TM, TN STARTING – PRE-HEATING TIMER ST–27
EXAMPLE: RHD
PREHEATING TIMER
ASSEMBLY
x2
x2
LOWER NO. 2
INSTRUMENT COVER
x2
LOWER INSTRUMENT COVER
for Wide Body:
LOWER NO. 3
INSTRUMENT COVER
x2
ASM14-075
ST
ST–28 W04D-TM, TN STARTING – PRE-HEATING TIMER
REMOVAL
TERMINAL
2. REMOVE LOWER INSTRUMENT COVER (for Wide
Body)
HINT:
See Pub. No. S1-YXZE05A, chapter 71.
3. REMOVE LOWER INSTRUMENT COVER (for
Standard Body)
HINT:
4. REMOVE LOWER NO. 3 INSTRUMENT COVER (for
Wide Body)
HINT:
Wide Body)
HINT:
Standard Body)
HINT:
7. REMOVE PREHEATING TIMER ASSEMBLY
(b) Remove the 2 screws and preheating timer
assembly.
A162036
INSTALLATION
1. INSTALL PREHEATING TIMER ASSEMBLY
(a) Install the preheating timer assembly with the 2
screws.
2. INSTALL LOWER NO. 2 INSTRUMENT COVER
3. INSTALL LOWER NO. 3 INSTRUMENT COVER (for
Wide Body)
A162036
4. INSTALL LOWER INSTRUMENT COVER

TERMINAL
ST
W04D-TM, TN STARTING – GLOW PLUG ST–29
GLOW PLUG
ENGINE
COMPONENTS
EXAMPLE: for Wide Body:
1.3 (13, 12 in.*lbf)

AIR HOSE ASSEMBLY
GLOW PLUG CONNECTOR

18 (184, 13)
GROMMET
for Standard Body:
25 (255, 18) AIR HOSE ASSEMBLY

GLOW PLUG ASSEMBLY
A165984E01
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY ST
TERMINAL
(See chapter EM)
ST–30 W04D-TM, TN STARTING – GLOW PLUG

(See chapter EM)
4. REMOVE GLOW PLUG ASSEMBLY
(a) Remove the 4 grommets.
(b) Remove the 4 nuts and glow plug connector.
(c) Remove the 4 glow plugs.
A162030
INSPECTION
1. INSPECT GLOW PLUG ASSEMBLY
between the glow plug terminal and ground.
Standard resistance
20°C (68°F) 2.7 to 3.5 Ω
Ground
A101682
NOTICE:
• Do not damage the glow plug pipes as this
could cause an open circuit or shorten the life
of the glow plugs.
• Prevent oil and fuel from spraying onto the
glow plugs when cleaning.
• Wipe any oil off the terminal and the Bakelite
washer with a dry cloth if the terminal is
stained with oil during the inspection.
If the result is not as specified, replace the glow
plug.
ST
W04D-TM, TN STARTING – GLOW PLUG ST–31
Glow Plug Wire Glow Plug Connector

INSTALLATION
1. INSTALL GLOW PLUG ASSEMBLY
(a) Install the 4 glow plugs.
NOTICE:
• Install the glow plug wire tilted within
approximately 15°as shown in the illustration.
• Make sure that the glow plug wire does not
interfere with other parts.
• Connect the glow plug connector with the
white identification paint facing upward.
(b) Install the glow plug connector with the 4 nuts.
15°
Paint Torque: 1.3 N*m (13 kgf*cm, 12 in.*lbf)
(c) Install the 4 grommets.
A166009E01
(See chapter EM)
chapter EM)
TERMINAL
ST
ST–32 W04D-TM, TN STARTING – STARTER
STARTER
ENGINE
COMPONENTS
154 (1570, 114)
STARTER ASSEMBLY
21 (215, 16)
A158326E01
ST
W04D-TM, TN STARTING – STARTER ST–33
RETURN SPRING
STEEL BALL
STARTER LEAD WIRE

STARTER CLUTCH SUB-ASSEMBLY
3.6 (37, 32 in.*lbf)
x3
9.3 (95, 82 in.*lbf)
STARTER HOUSING
IDLE GEAR
BEARING
PLATE WASHER
STARTER MAGNETIC SWITCH
24 (245, 18)
3.6 (37, 32 in.*lbf)
9.3 (95, 82 in.*lbf) x2 STARTER ARMATURE ASSEMBLY
STARTER YOKE ASSEMBLY

x2
STARTER BRUSH HOLDER ASSEMBLY
END COVER

ST
Grease
A158318E01
REMOVAL
TERMINAL
2. REMOVE STARTER ASSEMBLY
(a) Remove the nut and disconnect the wire harness.
(b) Disconnect the starter connector.
A158162
(c) Remove the bolt, nut, and starter assembly.
A158161
DISASSEMBLY
1. REMOVE STARTER LEAD WIRE
(a) Remove the screw and lead wire from the terminal
50.
A158163
2. REMOVE STARTER YOKE ASSEMBLY

(a) Remove the nut and disconnect the lead wire from
the magnetic switch terminal.
A158171
ST
(b) Remove the 2 through bolts.

(c) Pull out the starter yoke together with the armature.
(d) Remove the felt washer and lock plate.
A158295
3. REMOVE STARTER CLUTCH SUB-ASSEMBLY

(a) Remove the 3 screws.
(b) Remove the starter housing, clutch sub-assembly,
return spring, idle gear, bearing and plate washer
from the magnetic switch.
A158319
4. REMOVE STEEL BALL

(a) Using a magnetic pick-up tool, remove the steel ball
from the clutch shaft hole.
A160493
5. REMOVE STARTER BRUSH HOLDER ASSEMBLY

(a) Remove the 2 screws and end cover from the
starter yoke.
A158297
(b) Using a screwdriver, hold the brush springs back,

disconnect the 4 brushes from the brush holder, and
remove the holder.
6. REMOVE STARTER ARMATURE ASSEMBLY
(a) Remove the starter armature assembly from the
starter yoke assembly.
ST
A158298
INSPECTION
1. INSPECT STARTER ASSEMBLY
NOTICE:
The following tests must be completed within 5
seconds to prevent the coil from burning out.
(a) Perform a pull-in test:
(1) Disconnect the field coil lead wire from terminal
C.
A158171
(2) Connect the battery to the magnetic switch as

shown in the illustration. Check that the clutch
pinion gear moves outward.
If the clutch pinion gear does not move
Terminal 50 outward, replace the magnetic switch.
Terminal C
A158172E01
(b) Perform a hold-in test:

(1) Disconnect the negative (-) terminal lead from
terminal C with the conditions specified in (a)
being maintained. Check that the pinion gear
remains out.
If the clutch pinion gear moves inward, replace
the magnetic switch.
Terminal C
A158173E01
ST
(c) Inspect clutch pinion gear return:

(1) Disconnect the negative (-) lead from the
starter body. Check that the clutch pinion gear
moves inward.
If the clutch pinion gear does not move inward,
replace the magnetic switch.
A158174
(d) Perform a no-load performance test:

(1) Connect the field coil wire to terminal C with the
nut. Make sure that the lead is not grounded.
(2) Clamp the starter in a vise.
(3) Connect the battery and an ammeter to the
starter as shown in the illustration.
Terminal 50 (4) Check that the starter rotates smoothly and
steadily with the clutch pinion gear remaining
out. Check that the ammeter indicates the
specified current.
Terminal 30
Specified current:
90 A or less at 23 V
If the current is not as specified, replace the
starter.
A158175E01
2. INSPECT STARTER ARMATURE ASSEMBLY

If the surface of the commutator is dirty or burned, polish
the part with sandpaper (#400).
(a) Check the commutator for an open circuit.
between the segments of the commutator.
Standard resistance
Segment - Segment - Below 1 Ω
A160494

armature.
ST
(b) Check the commutator for a short circuit to ground.

between the commutator and armature core.
Standard resistance
Commutator - Armature
- 10 kΩ or higher
core

A160495
armature.
(c) Check the commutator circle runout.

0.05 mm (0.0020 in.)
If the circle runout is greater than the maximum,
correct it using a lathe.
A158299
(d) Check the commutator diameter.

(1) Using vernier calipers, measure the
commutator diameter.
Standard diameter:
36.0 mm (1.42 in.)
Minimum diameter:
35.0 mm (1.38 in.)
If the diameter is less than the minimum,
replace the armature assembly.
A158300
(e) Measure the undercut depth of the commutator.

(1) Check that the undercut depth is clean and free
of foreign materials. Smooth out the edge.
Standard undercut depth:
0.7 mm (0.028 in.)
Minimum undercut depth:
0.2 mm (0.008 in.)
If the undercut depth is less than the minimum,
correct it with a hacksaw blade.
A158301 (f) Check the starter armature bearings smoothly
rotate.
If the bearings are rough or worn, replace the
armature assembly.
ST
3. INSPECT STARTER YOKE ASSEMBLY

(a) Inspect the resistance of the field coil.
between the lead wire and brush lead.
Standard resistance
Lead wire - Brush lead - Below 1 Ω

A158302 yoke assembly.

between the brush lead and body.
Standard resistance
Body - Brush lead - 10 MΩ or higher

yoke assembly.
A158303
4. INSPECT STARTER BRUSH

Brush Holder Side: (a) Using vernier calipers, measure the brush length.
Standard length:
20.5 mm (0.807 in.)
Minimum length:
11.0 mm (0.433 in.)
If the length is less than the minimum, replace the
brush holder assembly and starter yoke assembly.
Length
Field Frame Side:
Length
A158304E02
5. INSPECT STARTER BRUSH HOLDER ASSEMBLY

(a) Inspect the resistance.
between the positive (+) and negative (-) brush
holders.
Standard resistance
ST
Positive brush holder -
- 10 MΩ or higher
Negative brush holder
A158305

brush holder.
(b) Inspect the brush spring load.
(1) Take the pull scale reading the instant the
brush spring separates from the brush.
Standard installed load:
36 N (3.6 kgf, 8.0 lbf)
Minimum installed load:
13 N (1.3 kgf, 2.9 lbf)
If the installed load is less than the minimum,
replace the brush springs.
A158306
6. INSPECT STARTER CLUTCH SUB-ASSEMBLY

(a) With the clutch fixed, turn only the inner sleeve right
Free
and left.
(b) Check that the inner sleeve turns lightly in the arrow
mark direction but does not turn in the opposite
Lock direction.
If the starter clutch does not operate, replace it with
a new one.
A158307E01
7. INSPECT STARTER MAGNETIC SWITCH ASSEMBLY

Terminal C (a) Inspect the resistance of the pull-in coil.
Terminal 50
between terminals 50 and C.
Standard resistance
Terminal 50 - Terminal C - Below 1 Ω

A158308E02 starter magnetic switch.
(b) Inspect the resistance of the hold-in coil.

Terminal 50 between terminal 50 and the switch body.
Standard resistance
Terminal 50 - Body - Below 1.5 Ω

starter magnetic switch.
A158309E02
ST
REASSEMBLY
1. INSTALL STARTER ARMATURE ASSEMBLY
(a) Install the armature to the starter yoke.
A158310
2. INSTALL STARTER BRUSH HOLDER ASSEMBLY

(a) Place the brush holder in position on the armature.
(b) Using a screwdriver, hold the brush springs back.
Then, connect the 4 brushes to the brush holder.
A158298
(c) Install the end cover with the 2 screws.

A158297
3. INSTALL STEEL BALL

(a) Apply grease to the steel ball.
(b) Insert the steel ball into the clutch shaft hole.
A158311
4. INSTALL STARTER CLUTCH SUB-ASSEMBLY

(a) Place the plate washer in position on the magnetic
switch assembly, as shown in the illustration.
ST
A158312
(b) Apply grease to the bearing (1) and idle gear (2).
(c) Place the bearing (1), idle gear (2), return spring (3)
and clutch sub-assembly (4) in position on the
starter magnetic switch.
(1)
(2)
(3)
(4) A158313E01
(d) Assemble the starter housing and magnetic switch

with the 3 screws.
A158319
5. INSTALL STARTER YOKE ASSEMBLY

(a) Align the cutout of the starter magnetic switch with
the protrusion of the starter yoke.
A158315
(b) Install the starter yoke and armature with the 2

through bolts.
A158295
(c) Connect the lead wire to the magnetic switch

terminal with the nut.
ST
A158171
6. INSTALL STARTER LEAD WIRE

(a) Install the lead wire with the screw.
A158163
INSTALLATION
1. INSTALL STARTER ASSEMBLY
(a) Install the starter assembly with the bolt and nut.
A158161
(b) Connect the starter connector.

(c) Install the wire harness with the nut.
TERMINAL
A158162
ST
ST–44 W04D-TM, TN STARTING – STARTER RELAY
STARTER RELAY
ENGINE
COMPONENTS
RELAY BLOCK COVER
4.7 (48, 42 in.*lbf)
STARTER RELAY ASSEMBLY x2
x2
8.0 (82, 71 in.*lbf)

A161888E01
REMOVAL
A161889
ST
W04D-TM, TN STARTING – STARTER RELAY ST–45
INSPECTION
Standard resistance
SW and S8-G
L B
Battery voltage is
SW and S8-G
SW If the resistance is not as specified, replace the

G
S8 G SW
A154066E02
INSTALLATION
(c) Connect the 2 lead wires to the starter relay
A161889
ST
ST–46 W04D-TM, TN STARTING – GLOW RELAY
GLOW RELAY
1. INSPECT GLOW PLUG RELAY ASSEMBLY
Standard resistance
A163540
3-5 applied to terminals 1 10 kΩ or higher
and 2
Battery voltage is
3-5 applied to terminals 1 Below 1 Ω
and 2
If the resistance is not as specified, replace the glow

plug relay assembly.
ST
W04D-TM, TN STARTING – IGNITION SWITCH (w/ Tilt Steering Column) ST–47
IGNITION SWITCH (w/ Tilt Steering

LOCK
Column)
ACC ON-VEHICLE INSPECTION
1. INSPECT IGNITION SWITCH ASSEMBLY
ON (a) Check the resistance.
START between the terminals.
Component Side: Standard resistance
ST1 All combinations of all
ACC LOCK 10 kΩ or higher
terminals
AM2 I6-4 (ACC) - I6-9 (AM1) ACC Below 1 Ω
I6-4 (ACC) - I6-9 (AM1) -
I6 I6-10 (IG1) ON Below 1 Ω
I6-5 (AM2) - I6-8 (IG2)
IG1 I6-3 (ST1) - I6-9 (AM1) -
AM1 IG2 I6-10 (IG1) START Below 1 Ω
I6-5 (AM2) - I6-8 (IG2)
A163318E02
If the result is not specified, replace the ignition
switch assembly.
ST
ST–48 W04D-TM, TN STARTING – IGNITION SWITCH (w/o Tilt Steering Column)
IGNITION SWITCH (w/o Tilt

LOCK
Steering Column)
ACC ON-VEHICLE INSPECTION
1. INSPECT IGNITION SWITCH ASSEMBLY
ON
START between the terminals.
Component Side: Standard resistance
ST1 All combinations of all
ACC LOCK 10 kΩ or higher
ST2 terminals
AM2 I6-4 (ACC) - I6-9 (AM1) ACC Below 1 Ω
I6-4 (ACC) - I6-9 (AM1) -
I6 I6-10 (IG1) ON Below 1 Ω
I6-5 (AM2) - I6-8 (IG2)
IG1 I6-3 (ST1) - I6-9 (AM1) -
AM1 IG2 I6-10 (IG1)
START Below 1 Ω
I6-5 (AM2) - I6-8 (IG2) -
A163318E01 I6-1 (ST2)
If the result is not specified, replace the ignition

switch assembly.
ST
ENGINE
CHARGING SYSTEM CH
PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-1
PARTS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-2
SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-4
ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-6
GENERATOR
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-12
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-12
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-15
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-19
N04C-TR, TS, TT, TU, TV, TW CHARGING – CHARGING SYSTEM CH–1
CHARGING SYSTEM
PRECAUTION
1. Check that the battery cables are connected to the
correct terminals.
2. Disconnect the battery cables when the battery is CH
quickly charged.
3. Do not perform tests using a high voltage insulation
resistance tester.
4. Never disconnect the battery cables while the engine
is running.
5. Check that the charging cable nut is tightly installed
in terminal B of the generator and the fuse box.
CH–2 N04C-TR, TS, TT, TU, TV, TW CHARGING – CHARGING SYSTEM
PARTS LOCATION
CH
NO. 2 RELAY BLOCK

- ALT FUSE
- ALT-S FUSE
GENERATOR - HEAD FUSE
COMBINATION METER
LHD:
- CHARGE WARNING LIGHT
NO. 1 RELAY BLOCK

- AM2 FUSE
IGNITION SWITCH
RHD: COMBINATION METER

NO. 1 RELAY BLOCK

- AM2 FUSE

CH
NO. 2 RELAY BLOCK

- ALT FUSE
- ALT-S FUSE
- IGN FUSE
- AM2 FUSE
GENERATOR - IG2 RELAY
LHD: COMBINATION METER

IGNITION SWITCH
COMBINATION METER
RHD:

SYSTEM DIAGRAM
CH
AM2 5 AM2 IG2 8 1 2
I6 Ignition Switch 3 5
IG2
IGN
7 8
Charge
ALT-S
1 3 2 1
ALT A6 A7 A7 A7
B S IG L
FL MAIN B
F
Battery
E
Battery
Generator
A165811E01
HEAD AM2 5 AM2 IG2 8

CH
I6 Ignition Switch
7 8
Charge
ALT-S
ALT A6 1 A7 3 A7 2 A7 1
B S IG L
P
Regulator
F
Battery
Battery
Generator
A165231E01
EXAMPLE: N04C-TW
AM2 5 AM1 IG2 8 1 2

CH
I6 Ignition Switch 3 5
IG2
IGN
7 8
Charge
ALT-S
ALT B S IG L
FL MAIN B
F
Battery
E
Battery
Generator
A157929E01
CAUTION:
If the battery is weak or if the engine is difficult to start,
recharge the battery and perform inspections again
before returning the vehicle to the customer.
1. CHECK BATTERY CONDITION

(a) Check the battery for damage and deformation. If
severe damage, deformation or leakage is found,
replace the battery.
(b) Check the volume of electrolyte in each cell (for
maintenance-free batteries).
(1) If the electrolyte volume is below the lower line, CH
add distilled water to each cell or replace the
battery.
A149663
(c) Check the volume of electrolyte in each cell (for

non-maintenance-free batteries).
(1) If the electrolyte volume is below the lower line,
add distilled water to each cell. Then, recharge
the battery and check the electrolyte specific
gravity.
Standard electrolyte specific gravity:
1.25 to 1.29 at 20°C (68°F)
If the result is not as specified, recharge or
A001259 replace the battery.
(d) Measure the battery voltage.

(1) If it has been less than 20 minutes since you
stopped driving the vehicle or since the engine
was stopped, turn the ignition switch and
electrical systems (headlight, blower motor,
rear defogger etc.) to the ON position for 20
seconds. This will remove the surface charge
on the battery.
A149664 (3) Turn the electrical systems to OFF.
(4) Using a voltmeter, measure the battery voltage
between the positive (+) and negative (-)
terminals of the battery.
Standard voltage:
24.0 to 25.0 V at 20°C (68°F)
2. CHECK FUSES
(a) Measure the resistance of the ALT fuse, ALT-S fuse,
IGN fuse and AM2 fuse.
Below 1 Ω
If the result is not as specified, replace the fuses as
necessary.
3. CHECK DRIVE BELT

damage.
If any defects are found, replace the drive belts as a
set.
CH
A101818
(b) Check that the belt does not touch the bottom of the
CORRECT INCORRECT
pulley groove.
If the result is not as specified, replace the drive
belts as a set.
4. VISUALLY CHECK GENERATOR WIRING
(a) Check that the generator wiring is in good condition.
Clearance If the condition is not good, repair or replace the
generator wire.
P003788E03 5. LISTEN FOR ABNORMAL NOISES FROM
GENERATOR
(a) Check that there is no abnormal noise from the
generator while the engine is running.
If there is abnormal noise, replace the pulley or
generator.
6. CHECK CHARGE WARNING LIGHT CIRCUIT
(a) Turn the ignition switch to the ON position. Check
that the charge warning light comes on.
(b) Start the engine and check that the light goes off.
If the light does not operate as specified,
troubleshoot the charge warning light circuit.
7. CHECK CHARGING CIRCUIT WITHOUT LOAD
(a) According to the following procedure, connect an
Ammeter Terminal B ammeter and voltmeter as shown in the illustration.
(1) Disconnect the wire from terminal B of the
A
generator and connect it to the negative (-) lead
of the ammeter.
(2) Connect the positive (+) lead of the ammeter to
terminal B of the generator.
(3) Connect the positive (+) lead of the voltmeter to
V
the positive (+) terminal of the battery.
Generator (4) Ground the negative (-) lead of the voltmeter.
(b) Check the charging circuit.
Battery
Voltmeter (1) While keeping the engine speed at 2000 rpm,
check the readings on the ammeter and
voltmeter.
A125200E02
Standard amperage:
10 A or less
Standard voltage:
25.0 to 26.0 V
If the results are not as specified, replace the
generator assembly.
HINT:
If the battery is not fully charged, the ammeter
reading may be more than the standard
amperage.
8. CHECK CHARGING CIRCUIT WITH LOAD
(a) Keep the engine speed at 2000 rpm, turn on the
high beam headlights, and turn the heater blower CH
switch to the "HI" position.
(b) Check the reading on the ammeter.
Standard amperage:
30 A or more
If the ammeter reading is less than the standard
amperage, replace the generator assembly.
HINT:
If the battery is fully charged, the ammeter reading
may be less than the standard amperage. In this
case, increase electrical load by operating devices
such as the wiper motor and rear window defogger.
Then, recheck the reading on the ammeter.
CH–10 N04C-TR, TS, TT, TU, TV, TW CHARGING – GENERATOR
GENERATOR
ENGINE
COMPONENTS
CH
NO. 1 AIR HOSE
13 (133, 10)
TERMINAL CAP
10 (102, 7)
GENERATOR BELT
ADJUSTING BAR
GENERATOR ASSEMBLY
29 (291, 21)
x2
55 (561, 41)
125 (1275, 92)
RADIATOR HOSE INLET
A158450E01
N04C-TR, TS, TT, TU, TV, TW CHARGING – GENERATOR CH–11
CH
GENERATOR WASHER
GENERATOR ROTOR ASSEMBLY
RUBBER INSULATOR
4.5 (46, 40 in.*lbf)

DRIVE END FRAME x4
x4
GENERATOR RECTIFIER END FRAME
x4 2.9 (30, 26 in.*lbf)
GENERATOR BRUSH HOLDER ASSEMBLY

133 (1351, 98) GENERATOR PULLEY
GENERATOR BRUSH COVER
GENERATOR REAR END COVER
NO. 2 GENERATOR REAR

END COVER
GENERATOR TERMINAL
3.6 (37, 32 in.*lbf)
INSULATOR
x3
x2
x2
x3
2.0 (20, 18 in.*lbf)
4.4 (45, 38 in.*lbf)
2.0 (20, 18 in.*lbf)

3.9 (39, 35 in.*lbf)
GENERATOR REGULATOR
ASSEMBLY TERMINAL PLATE
PLATE SEAL
GENERATOR HOLDER WITH RECTIFIER

A158451E01
REMOVAL
TERMINAL
3. REMOVE RADIATOR HOSE INLET
CH (a) Loosen the 2 clips and remove the radiator hose
inlet.
5. REMOVE FAN AND GENERATOR V BELT (See
chapter EM)
A153322

(a) Remove the terminal cap and the nut, disconnect
the wire harness from terminal B.
(b) Disconnect the connector from the generator.
(c) Disconnect the 3 wire harness clamps.
A153282
(d) Remove the 4 bolts, generator bracket and

generator assembly.
A158434
DISASSEMBLY
SST 1-A
SST 1-B 1. REMOVE GENERATOR PULLEY
SST 09820-63010 (09820-06010, 09820-06020)
HINT:
Hold SST 1-A and 1-B 09820-06010
SST 2 09820-06020
Turn (a) Hold SST 1-A with a torque wrench, and tighten
A153905E01
SST 1-B clockwise to the specified torque.
NOTICE:
Check that SST is securely fitted onto the
generator rotor shaft.
(b) Mount SST 2 in a vise.

(c) Insert SST 1-A and B into SST 2, and attach the
generator pulley nut to SST 2.
(d) To loosen the generator pulley nut, turn SST 1-A in
the direction shown in the illustration.
SST 2
CH
Turn
A156064E01
(e) Remove the generator from SST 2.

SST 1-A
(f) Turn SST 1-B, and remove SST 1-A and 1-B.
SST 1-B
(g) Remove the generator pulley nut and the generator
Turn pulley.
Hold
A153907E01
2. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY

(a) Place the generator on the generator pulley.
(b) Remove the 3 nuts and the No. 2 generator rear end
Pulley cover.
A150491E01
(c) Remove the nut and the terminal insulator.
A150492
(d) Remove the bolt, 2 nuts, terminal plate, and the rear
end cover.
Terminal Plate
A150493E01
(e) Remove the generator brush cover.
CH
A150494
(f) Remove the 2 screws and generator brush holder

assembly.
3. REMOVE GENERATOR REGULATOR ASSEMBLY
(a) Remove the 3 screws and the generator regulator
assembly.
(b) Remove the plate seal from the rectifier end frame.
A150495
4. REMOVE GENERATOR HOLDER WITH RECTIFIER

(a) Remove the 4 screws and the generator holder with
rectifier.
A150498
5. REMOVE GENERATOR ROTOR ASSEMBLY

(a) Remove the 4 rubber insulators.
A150499
(b) Remove the 4 nuts.
A150500
(c) Using a bearing puller, remove the rectifier end

frame.
Turn
Hold
CH
A150501E01
(d) Remove the generator washer.
A150502
(e) Remove the generator rotor assembly.
A150503
(f) If the generator rotor assembly is difficult to remove,

position the drive end frame horizontally and lightly
tap it using a plastic hammer to remove the
generator rotor assembly.
NOTICE:
Do not drop the generator rotor assembly.
(g) Remove the generator washer.
A153908
INSPECTION
1. INSPECT GENERATOR ROTOR ASSEMBLY
(a) Check the rotor for open circuit.
between the slip rings.
10.6 to 11.4 Ω at 20°C (68°F)
A150506
(b) Check the rotor for ground.

between the slip ring and rotor.
10 MΩ or higher at 20°C (68°F)
CH generator rotor assembly.
A150507
(c) Using vernier calipers, measure each slip ring

diameter.
Standard diameter:
14.2 to 14.4 mm (0.559 to 0.567 in.)
Minimum diameter:
12.8 mm (0.504 in.)
If either diameter is less than the minimum, replace
the generator rotor assembly.
(d) Check that each slip ring is not rough or scorched.
A150508 If rough or scorched, restore them with sandpaper
(No. 400) or replace the generator rotor assembly.
2. INSPECT GENERATOR HOLDER WITH RECTIFIER
B
(a) Using an ohmmeter, check the continuity among
P1 P2 P3 P4 terminals P1, P2, P3, P4 and B, and among P1, P2,
B P3, P4 and E.
E E Standard:
When the positive and negative poles among
P1 P4 terminals P1, P2, P3, P4 and B are exchanged,
there is continuity in one direction but no
continuity in the other direction. When the
P2 P3 A153912E01 positive and negative poles among terminals
P1, P2, P3, P4 and E are exchanged, there is
continuity in one direction but no continuity in
the other direction.
generator holder with rectifier.
3. INSPECT GENERATOR BRUSH HOLDER ASSEMBLY
Length (a) Using a vernier caliper, measure the exposed brush
length.
Standard exposed brush length:
9.5 to 11.5 mm (0.374 to 0.453 in.)
Minimum exposed brush length:
1.5 mm (0.059 in.)
If the exposed brush length is less than the
minimum, replace the generator brush holder
A153913E01 assembly.
4. INSPECT STATOR COIL

P2 P3 (a) Inspect the stator for ground.
P1 P4 (1) Using an ohmmeter, check the resistance
between the P1,P2,P4 and drive end frame.
10 MΩ or higher
If the result is not as specified, replace the CH
generator assembly.
(b) Check the stator coil for open circuits.
A153914E01 (1) Using an ohmmeter, check the resistance
between the P1,P4 and P3.
1.5 Ω or lower
generator assembly.
REASSEMBLY
1. INSTALL GENERATOR ROTOR ASSEMBLY
(a) Install the generator rotor assembly to the drive end
frame.
HINT:
If the generator rotor is engaged firmly, lightly tap it
using a plastic hammer.
(b) Place the generator washer on the rotor.
(c) Using a 30 mm socket wrench and press, slowly
30 mm Socket
Wrench
press in the rectifier end frame.
A153918E01
(d) Install the 4 nuts.

A153919
(e) Install the 4 rubber insulators on the lead wires.

NOTICE:
Make sure each rubber insulator is oriented as
2. INSTALL GENERATOR HOLDER WITH RECTIFIER
(a) Place the generator holder with rectifier on the
CH rectifier end frame.
(b) Push the generator holder with rectifier down and
install it with the 4 screws.
A150519
3. INSTALL GENERATOR REGULATOR ASSEMBLY
(a) Place the plate seal on the generator holder with
rectifier.
(b) Install the generator regulator assembly with the 3
screws.
Upward
4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
(a) Install the generator brush holder assembly with the
2 screws.
NOTICE:
Be careful of the holder installation direction.
A153921E01
(b) Place the generator brush cover on the generator
brush holder assembly.
(c) Install the rear end cover and the terminal plate with
the 2 nuts and bolt.
Torque: Bolt
3.9 N*m (39 kgf*cm, 35 in.*lbf)
Nut
4.4 N*m (45 kgf*cm, 39 in.*lbf)
Terminal Plate
A150493E01
(d) Install the terminal insulator with the nut.

(e) Install the No. 2 generator rear end cover with the 3
nuts.
A150492
5. INSTALL GENERATOR PULLEY

SST 1-A SST 09820-63010 (09820-06010, 09820-06020)
SST 1-B HINT:
SST 1-A and 1-B 09820-06010
SST 2 09820-06020
Hold
(a) Install the generator pulley onto the rotor shaft by CH
tightening the generator pulley nut by hand.
Turn
(b) Hold SST 1-A with a torque wrench, and tighten
A153905E01 SST 1-B clockwise to the specified torque.
NOTICE:
Check that SST is secured to the rotor shaft.
(c) Mount SST 2 in a vise.
(d) Insert SST 1-A and B into SST 2, and attach the
generator pulley nut to SST 2.
(e) Tighten the generator pulley nut by turning SST 1-A
in the direction shown in the illustration.
SST 2 Torque: 133 N*m (1351 kgf*cm, 98 ft.*lbf)
Turn
A153906E01
(f) Remove the generator from SST 2.

SST 1-A
(g) Turn SST 1-B, and remove SST 1-A and B.
SST 1-B
(h) Turn the generator pulley, and check that the
Turn generator pulley moves smoothly.
Hold
A153907E01
B
INSTALLATION
C (a) Temporarily install the generator assembly with bolt
A.
(b) Temporarily install the generator bracket to the
C
generator assembly with bolt B.
(c) Install the generator bracket with 2 bolts C.
A A153283E01
(d) Connect the 3 wire harness clamps.
(e) Connect the connector to the generator.
(f) Install the wire harness to terminal B with the nut,
and install the terminal cap.
2. INSTALL FAN AND GENERATOR V BELT (See
chapter EM)
chapter EM)

6. INSTALL RADIATOR HOSE INLET
(a) Connect the radiator hose inlet with the 2 clips.
TERMINAL
CH 8. ADD ENGINE COOLANT (See chapter CO)
A153322
ENGINE
CHARGING SYSTEM
PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-1
PARTS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-2
CH
SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-4
ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-4
GENERATOR
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-10
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-11
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-14
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CH-18
W04D-TM, TN CHARGING – CHARGING SYSTEM CH–1
CHARGING SYSTEM
PRECAUTION
1. Check that the battery cables are connected to the
correct terminals.
2. Disconnect the battery cables when the battery is
quickly charged.
CH
3. Do not perform tests using a high voltage insulation
resistance tester.
4. Never disconnect the battery cables while the engine
is running.
5. Check that the charging cable nut is tightly installed
in terminal B of the generator and the fuse box.
CH–2 W04D-TM, TN CHARGING – CHARGING SYSTEM
PARTS LOCATION
EXAMPLE:
Standard Body:
CH
NO. 2 RELAY BLOCK:
GENERATOR - AL
- HEAD FUSE
Wide Body:
T FUSE
NO. 2 RELAY BLOCK:
- ALT FUSE
GENERATOR - HEAD FUSE
A161890E01
LHD
COMBINATION METER
CH
NO. 1 RELAY BLOCK
- AM2 FUSE
IGNITION SWITCH
RHD
COMBINATION METER
NO. 1 RELAY BLOCK
- AM2 FUSE
IGNITION SWITCH
A161892E01
SYSTEM DIAGRAM
5 AM2 IG2 8
I6 Ignition Switch
CH
AM2
4 2
Charge
HEAD
ALT 1 2 1
A6 A7 A7
B IG L
FL MAIN
Battery L R
F
Regulator
E
Battery
Generator
A161885E01
CAUTION:
If the battery is weak or if the engine is difficult to start,
recharge the battery and perform inspections again
before returning the vehicle to the customer.
1. CHECK BATTERY CONDITION
(a) Check the battery for damage and deformation. If
severe damage, deformation or leakage is found,
(b) Check the volume of electrolyte in each cell (for

maintenance-free batteries).
add distilled water to each cell or replace the
battery.
CH
A149663
(c) Check the volume of electrolyte in each cell (for

non-maintenance-free batteries).
add distilled water to each cell. Then, recharge
the battery and check the electrolyte specific
gravity.
Standard electrolyte specific gravity:
1.25 to 1.29 at 20°C (68°F)
A001259 replace the battery.
(d) Measure the battery voltage.

(1) If it has been less than 20 minutes since the
vehicle was stopped or the engine was
stopped, turn the ignition switch to the ON
position and turn electrical systems (headlight,
blower motor, rear defogger etc.) on for 20
seconds. This will remove the surface charge
on the battery.
A149664 (3) Turn the electrical systems off.
(4) Using a voltmeter, measure the battery voltage
between the positive (+) and negative (-)
terminals of the battery.
Standard voltage:
24.0 to 25.0 V at 20°C (68°F)
2. CHECK BATTERY TERMINAL
(a) Check that the battery terminals are not loose or
corroded.
If the terminals are corroded, clean the terminals.
3. CHECK FUSES
(a) Measure the resistance of the AM2 fuse, HEAD fuse
and ALT fuse.
Below 1 Ω
If the result is not as specified, replace the AM2
fuse, MEAD fuse and ALT fuse.
4. CHECK DRIVE BELT

(a) Check the belts for wear, cracks and other signs of
damage.
If any defects are found, replace the drive belts as a
set.
CH
A101818
(b) Check that the belt does not touch the bottom of the
pulley groove.
If the result is not as specified, replace the drive
belts as a set.
Clearance 5. VISUALLY CHECK GENERATOR WIRING
(a) Check that the wiring is in good condition.
6. LISTEN FOR ABNORMAL NOISES FROM
CORRECT INCORRECT GENERATOR
A160887E01 (a) Check that the generator does not emit any
abnormal noise while the engine is running.
7. CHECK CHARGE WARNING LIGHT CIRCUIT
(a) Turn the ignition switch to the ON position. Check
that the charge warning light turns on.
(b) Start the engine and check that the light turns off. If
the light does not operate as specified, troubleshoot
the charge warning light circuit.
8. CHECK CHARGING CIRCUIT WITHOUT LOAD
(a) Connect a voltmeter and an ammeter to the
Disconnect Wire charging circuit as follows.
Ammeter from Terminal B (1) Disconnect the wire from terminal B of the
generator and connect it to the negative (-) lead
of the ammeter.
(2) Connect the ammeter positive (+) lead to
terminal B of the generator.
(3) Connect the voltmeter positive (+) lead to
positive (+) terminal of the battery.
Battery
Generator (4) Ground the voltmeter negative (-) lead.
(b) Check the charging circuit.
Voltmeter (1) Keep the engine speed at 2000 rpm and check
the reading on the ammeter and voltmeter.
Standard current:
A118255E02
10 A or less
Standard voltage:
27.5 to 28.5 V
generator assembly.
HINT:
If the battery is not fully charged, the ammeter
reading will sometimes be more than the
standard current.
9. CHECK CHARGING CIRCUIT WITH LOAD

(a) With the engine running at 2000 rpm, turn on the
high beam headlights and turn the heater blower
switch to the HI position.
(b) Check the reading on the ammeter.
Standard current:
30 A or more
If the ammeter reading is less than the standard
current, replace the generator assembly. CH
HINT:
If the battery is fully charged, the ammeter reading
will sometimes be less than the standard current.
In this case, operate the wiper motor and the
window defogger to increase the load and then
check the charging circuit again.
CH–8 W04D-TM, TN CHARGING – GENERATOR
GENERATOR
ENGINE
COMPONENTS
EXAMPLE
VACUUM HOSE 32 (326, 23) VACUUM HOSE
CH 47 (479, 34)
TERMINAL CAP
10 (102, 7.4)
UNION
3.8 (39, 34 in.*lbf)
GASKET
125 (1275, 92) GASKET

FAN BELT
ADJUSTING BAR 22 (225, 16)
OIL INLET HOSE
GENERATOR ASSEMBLY
OIL OUTLET HOSE

GASKET
47 (479, 34)
UNION
for Wide Body:
32 (326, 23)
NO. 1 AIR HOSE
FAN AND
GENERATOR
V BELT
for Standard Body:

NO. 1 AIR HOSE
System:
Non-reusable part
A166655E01
W04D-TM, TN CHARGING – GENERATOR CH–9
GENERATOR ROTOR BEARING
GENERATOR ROTOR ASSEMBLY
FRONT BRACKET
CH
PLATE
7.4 (75, 65 in.*lbf)
x3
GENERATOR FAN
2.2 (22, 19 in.*lbf) GENERATOR PULLEY
x3 x2 COLLAR 112 (1138, 82)
WASHER
COVER 2.2 (22, 19 in.*lbf)
GENERATOR REGULATOR
ASSEMBLY
REAR BRACKET
GENERATOR BRUSH
HOLDER ASSEMBLY
3.8 (39, 34 in.*lbf) x3
HOUSING x4
BLADE
VACUUM PUMP
ROTOR
ASSEMBLY
O-RING
COVER
Non-reusable part
A160863E01
REMOVAL
TERMINAL
2. REMOVE NO. 1 AIR HOSE (See chapter EM)
CRANKSHAFT PULLEY) BELT (w/ Air Conditioning
CH System) (See chapter EM)
4. REMOVE FAN AND GENERATOR V BELT (See
chapter EM)
(a) Remove the terminal cap.
(b) Remove the nut and disconnect the wire harness
from terminal B.
(c) Remove the bolt and disconnect the wire harness
from the generator body.
(d) Disconnect the generator connector.
(e) Disconnect the 2 vacuum hoses.
(f) Disconnect the oil outlet hose.
(g) Remove the union bolt and 2 gaskets, and
disconnect the oil inlet hose.
A158164
(h) Remove the 3 bolts, nut, fan belt adjusting bar and
generator assembly.
A158165
(i) Remove the bolt, union and 2 gaskets.
A158167
(j) Remove the bolt, union and 2 gaskets.
CH
A158166
DISASSEMBLY
1. REMOVE VACUUM PUMP ASSEMBLY
(a) Remove the 3 bolts and the vacuum pump housing
from the vacuum pump cover.
A158348
(b) Remove the 4 vacuum pump blades and vacuum

pump rotor from the generator rotor shaft.
A158349
(c) Remove the vacuum pump cover from the rear

bracket.
(d) Remove the O-ring from the vacuum pump cover.
A158350
2. REMOVE GENERATOR REGULATOR ASSEMBLY

(a) Remove the 4 bolts, clamp bracket and cover.
A158351
(b) Unsolder the 4 lead wires from the generator

regulator.
CH
A158352
3. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY

(a) Remove the 2 screws and the brush holder
assembly.
A158353
4. REMOVE GENERATOR PULLEY

(a) Mount the generator assembly in a vise.
SST NOTICE:
Hold Do not overtighten the vise.
(b) Using SST, hold the generator pulley.
SST 09213-87211
Turn (c) Using a 27 mm socket wrench, loosen the nut.
HINT:
Loosen the nut until the generator pulley rotates
A158354E02 freely.
(d) While holding the generator rotor shaft with pliers,

remove the nut.
NOTICE:
Hold
Cover the generator rotor shaft with a shop rag
Shop or piece of cloth to prevent it from being
Rag damaged.
(e) Remove the washer, generator pulley and generator
fan.
Turn
A158359E03
5. REMOVE GENERATOR ROTOR ASSEMBLY

(a) Remove the 3 through bolts.
CH
A158355
(b) Using a press, remove the front bracket from the

A158356
(c) Remove the 2 collars from the front bracket.
A158392
(d) Using a plastic hammer, remove the generator rotor

assembly from the rear bracket.
NOTICE:
• If the shaft is beaten, the serration jointed
with the vacuum pump assembly would be
bended and collapsed.
• Pull it out by beating the frame.
A158357
(e) Using SST and a press, remove the generator rotor

bearing and plate from the generator rotor
assembly.
Bearing Plate SST 09950-00020
CH SST
A160855E01
INSPECTION
Slip Ring
1. INSPECT GENERATOR ROTOR ASSEMBLY
(a) Check the rotor for an open circuit.
between the slip rings.
Standard resistance
Slip ring - Slip ring Approx. 20°C (68°F) 12.5 Ω
A158363E01
If the resistance is not within the specified
range, replace the rotor assembly.
(b) Check the rotor for a short to ground.
Rotor Core (1) Using an ohmmeter, measure the resistance
between the slip ring and rotor.
Standard resistance
Silp Ring Slip ring - Rotor - 1 MΩ or higher
If the resistance is not within the specified

range, replace the rotor assembly.
A158362E01
(c) Check that the slip rings are not rough or scored.
If rough or scored, replace the rotor.
(d) Using vernier calipers, measure the slip ring
diameter.
Standard diameter:
34.5 mm (1.358 in.)
Minimum diameter:
33.5 mm (1.319 in.)
A158365 rotor assembly.
2. INSPECT GENERATOR BRUSH HOLDER ASSEMBLY

(a) Using vernier calipers, measure the length of the
exposed brushes.
Standard exposed length:
21.0 mm (0.827 in.)
Minimum exposed length:
7.0 mm (0.276 in.)
If the exposed length is less than the minimum,
replace the brush holder assembly. CH
A158364
REASSEMBLY
1. INSTALL GENERATOR ROTOR ASSEMBLY
(a) Using SST and a press, install the generator rotor
Bearing bearing and plate to the generator rotor.
SST
SST 09309-36100, 09285-76010 (09309-03620)
NOTICE:
Plate
The plate is installed in the direction of the
illustration.
A160860E01
(b) Install the 2 collars to the front bracket.
A158392
(c) Using a press, install the generator rotor assembly

to the front bracket.
Collar
A158393E01
(d) Using SST and a press, install the rear bracket to

the rotor assembly with front bracket.
SST 09238-47012
SST
CH
A158394E01
(e) Install the 3 through bolts.

2. INSTALL GENERATOR PULLEY
(a) Install the washer, generator pulley and generator
fan to the generator rotor shaft.
A158355
(b) Mount the generator assembly in a vise.

NOTICE:
Do not overtighten the vise.
Hold
(c) While holding the generator rotor shaft with pliers,
Shop temporarily tighten the nut.
Rag NOTICE:
Cover the generator rotor shaft with a shop rag
or piece of cloth to prevent it from being
damaged.
Turn
A158359E02
(d) Using SST, hold the generator pulley.

Hold SST 09213-87211
SST (e) Using a 27 mm socket wrench, tighten the nut.
Turn
A158360E02
3. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

(a) Install the brush holder assembly and 2 wire
harnesses with the 2 screws.
CH
A158353
4. INSTALL GENERATOR REGULATOR ASSEMBLY

(a) Solder the 4 lead wires to the generator regulator.
A158352
(b) Install the cover and clamp bracket with the 4 bolts.
5. INSTALL VACUUM PUMP ASSEMBLY
(a) Install the new O-ring to the vacuum pump cover.
A158351
(b) Install the new vacuum pump cover to the rear

bracket.
A158350
(c) Install the 4 new vacuum pump blades and vacuum

pump rotor to the generator rotor shaft.
CH
A158349
(d) Install the vacuum pump housing with the 3 bolts.

A158348
INSTALLATION
(a) Install 2 new gaskets and the union.
A158166
(b) Install 2 new gaskets and the union.

A158167
(c) Temporarily install the generator with bolt A and the

nut.
B
(d) Temporarily install the fan belt adjusting slider with
bolt B and bolt C.
C
(e) Move the generator assembly toward the cylinder
block and tighten bolt B.
A
A158888E01
(f) Install the oil inlet hose with the union bolt and 2
gaskets.
(g) Connect the oil outlet hose.
(h) Connect the 2 vacuum hoses.
(i) Connect the generator connector.
(j) Install the wire harness to the generator body with
the bolt.
Torque: 3.8 N*m (39 kgf*cm, 34 in.*lbf) CH
(k) Connect the wire harness to terminal B with the nut.
(l) Install the terminal cap.
2. INSTALL FAN AND GENERATOR V BELT (See
chapter EM)
A158164
chapter EM)
System) (See chapter EM)
System) (See chapter EM)
6. INSPECT V BELT (See chapter EM)
7. INSTALL NO. 1 AIR HOSE (See chapter EM)
TERMINAL
TRANSMISSION
CLUTCH
CLUTCH PEDAL SUB-ASSY (W / BOOSTER)

ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-1
CLUTCH PEDAL SUB-ASSY (W / O BOOSTER)
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-3 CL
CLUTCH RELEASE CYLINDER
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-6
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-7
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-8
CLUTCH UNIT
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-12
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-14
CLUTCH – CLUTCH PEDAL SUB-ASSY (W / BOOSTER) CL–1
CLUTCH PEDAL SUB-ASSY (W /

BOOSTER)
ADJUSTMENT
1. INSPECT AND ADJUST CLUTCH PEDAL HEIGHT
Pedal Height
(a) Turn back the floor carpet.
Adjust Point (b) Check that the pedal height is correct.
Pedal height from floor (LHD)
CL
Body type Pedal height: mm (in.)
Standard body 183 to 193 (7.205 to 7.598)
Wide body 163.8 to 173.8 (6.450 to 6.843)
Push Rod
Play and Pedal height from floor (RHD)
Free Play Body type Pedal height: mm (in.)
Pedal Height
Adjust Point
Standard body 179 to 189 (7.047 to 7.441)
Wide body 179 to 189 (7.047 to 7.441)
Floor (c) Loosen the lock nut and turn the stopper bolt until
C155062E01 the correct height is obtained.
(d) Tighten the lock nut.
2. INSPECT CLUTCH PEDAL FREE PLAY AND PUSH
ROD PLAY
(a) Fully depress the clutch pedal several times while
the engine is stopped to remove the vacuum from
the clutch booster.
(b) Check that pedal free play and push rod play are
correct.
(1) Depress the pedal until the beginning of clutch
resistance is felt.
Push Rod Play
Pedal free play:
5.0 to 10.0 mm (0.197 to 0.394 in.)
(2) Gently depress the pedal until resistance
begins to increase a little.
Pedal Free Play Push rod play at pedal top:
C102627E01 0.25 to 0.5 mm (0.01 to 0.02 in.)
(c) If necessary, adjust the pedal free play and push rod
play.
(1) Loosen the lock nut and turn the push rod until
correct free play and push rod play are
obtained.
(2) Tighten the lock nut.
(3) After adjusting the pedal free play, check the
pedal height.
CL–2 CLUTCH – CLUTCH PEDAL SUB-ASSY (W / BOOSTER)
3. INSPECT CLUTCH RELEASE POINT

(a) Check the clutch release point.
(1) Pull the parking brake lever and install wheel
chocks.
(2) Start the engine and run it at idle.
25 mm or more (3) Without depressing the clutch pedal, slowly
move the shift lever into reverse until the gears
Release Point contact.
(4) Gradually depress the clutch pedal and
measure the stroke distance from the point that
CL the gear noise stops (release point) up to the
full stroke end position.
Pedal Stroke
Standard distance:
Full Stroke End Position 25 mm (0.98 in.) or more (from pedal
stroke end position to release point)
C156453E01
Pedal stroke:
143 to 153 mm (5.630 to 6.024 in.)
If the distance is not as specified, perform the
following procedures:
• Check the pedal height.
• Check the push rod play and pedal free play.
• Bleed the clutch line.
• Check the clutch cover and disc.
CLUTCH – CLUTCH PEDAL SUB-ASSY (W / O BOOSTER) CL–3
CLUTCH PEDAL SUB-ASSY (W / O

BOOSTER)
ADJUSTMENT
1. INSPECT AND ADJUST CLUTCH PEDAL HEIGHT
(a) Turn back the floor carpet.
Pedal Height (b) Check that the pedal height is correct.
Adjust Point Pedal height from floor (LHD)
CL
Body type Pedal height: mm (in.)
Standard body 186.2 to 196.2 (7.731 to 7.724)
Wide body 181 to 191 (7.126 to 7.520)
Push Rod
Play and Pedal height from floor (RHD)
Free Play Pedal Height Body type Pedal height: mm (in.)
Adjust Point
Standard body 187.2 to 197.2 (7.370 to 7.764)
Wide body 197.4 to 207.4 (7.772 to 8.165)
Floor
(c) Loosen the lock nut and turn the stopper bolt until
C159118E01 the correct height is obtained.
(d) Tighten the lock nut.
2. INSPECT CLUTCH PEDAL FREE PLAY AND PUSH
ROD PLAY
(a) Fully depress the clutch pedal several times while
the engine is stopped to remove the vacuum from
the clutch booster.
(b) Check that pedal free play and push rod play are
correct.
(1) Depress the pedal until the beginning of clutch
resistance is felt.
Push Rod Play
Pedal free play:
5.0 to 10.0 mm (0.197 to 0.394 in.)
(2) Gently depress the pedal until resistance
begins to increase a little.
Pedal Free Play Push rod play at pedal top:
C102627E01 0.25 to 0.5 mm (0.01 to 0.02 in.)
(c) If necessary, adjust the pedal free play and push rod
play.
(1) Loosen the lock nut and turn the push rod until
correct free play and push rod play are
obtained.
(2) Tighten the lock nut.
(3) After adjusting the pedal free play, check the
pedal height.
CL–4 CLUTCH – CLUTCH PEDAL SUB-ASSY (W / O BOOSTER)
3. INSPECT CLUTCH RELEASE POINT

(a) Check the clutch release point.
(1) Pull the parking brake lever and install wheel
chocks.
(2) Start the engine and run it at idle.
25 mm or more (3) Without depressing the clutch pedal, slowly
move the shift lever into reverse until the gears
Release Point contact.
(4) Gradually depress the clutch pedal and
measure the stroke distance from the point that
CL the gear noise stops (release point) up to the
full stroke end position.
Pedal Stroke
Standard distance:
Full Stroke End Position 25 mm (0.98 in.) or more (from pedal
stroke end position to release point)
C156453E01
Pedal stroke:
153 to 163 mm (6.024 to 6.417 in.)
If the distance is not as specified, perform the
following procedures:
• Check the pedal height.
• Check the push rod play and pedal free play.
• Bleed the clutch line.
• Check the clutch cover and disc.
CLUTCH – CLUTCH RELEASE CYLINDER CL–5
CLUTCH RELEASE CYLINDER

CLUTCH
TRANSMISSION
COMPONENTS
for
forN04C series:
N04C-TT:
CL
24 (245, 18)
22 (222, 16)*
11 (110, 8)
RELEASE CYLINDER BLEEDER PLUG
CLIP BLEEDER PLUG CAP
PUSH ROD
BOOT
PISTON
SPRING
23 (235, 17)
21 (213, 15)* x2
12 (120, 9)
CLUTCH HOSE
CLUTCH RELEASE CYLINDER BODY
* For use with SST
Non-reusable part
Lithium soap base glycol grease

C155059E02
CL–6 CLUTCH – CLUTCH RELEASE CYLINDER
for
forW04D series:
W04D-J, W04D-TM, W04D-TN:
CL 11 (110, 8)
RELEASE CYLINDER BLEEDER PLUG
BLEEDER PLUG CAP
PUSH ROD
BOOT
24 (245, 18)
PISTON
22 (222, 16)*
SPRING
CLUTCH LINE
12 (120, 9)
x2
CLUTCH RELEASE CYLINDER BODY
* For use with SST
Non-reusable part
Lithium soap base glycol grease

C153739E02
REMOVAL
A 1. REMOVE CLUTCH RELEASE CYLINDER ASSEMBLY
B (for N04C series)
(a) Using SST, disconnect the clutch tube (Procedure
A).
SST 09023-38201
HINT:
C Use a container to catch the fluid.
C156443E01
(b) Remove the clip (Procedure B).
(c) Using SST, remove the clutch hose (Procedure C).
SST 09023-12701
HINT:
Use a container to catch the fluid.
(d) Remove the 2 bolts and clutch release cylinder.
C155060
CL
2. REMOVE CLUTCH RELEASE CYLINDER ASSEMBLY
(for W04D series)
(a) Using SST, disconnect the clutch line.
SST 09023-00101
HINT:
Use a container to catch the fluid.
(b) Remove the 2 bolts and clutch release cylinder.
SST DISASSEMBLY
C153741E01
1. REMOVE RELEASE CYLINDER BLEEDER PLUG
(a) Remove the bleeder plug cap from the bleeder plug.
(b) Remove the bleeder plug from the cylinder body.
2. REMOVE CLUTCH RELEASE CYLINDER KIT
(a) Remove the boot from the cylinder body.
(b) Remove the push rod from the cylinder body.
(c) Remove the piston and spring from the cylinder
body.
NOTICE:
Do not damage the inside of the cylinder body.
Spring
Piston
Push Rod
Boot
C155090E02
REASSEMBLY
1. INSTALL CLUTCH RELEASE CYLINDER KIT
(a) Coat a new piston with lithium soap base glycol
grease, as shown in the illustration.
CL00672
CL–8 CLUTCH – CLUTCH RELEASE CYLINDER
(b) Install the piston and a new spring to the cylinder

body.
NOTICE:
Do not damage the inside of the cylinder body.
HINT:
Install the smaller end of the spring to the piston.
(c) Install a new boot to the push rod.
(d) Install the push rod to the cylinder body.
Spring
2. INSTALL RELEASE CYLINDER BLEEDER PLUG
CL Piston (a) Install the bleeder plug to the cylinder body.
Push Rod Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf)
(b) Install the bleeder plug cap to the bleeder plug.
Boot
C155090E02
INSTALLATION
(for N04C series)
(a) Install the clutch release cylinder with the 2 bolts.
C155060
(b) Using SST, install the clutch hose to the clutch

release cylinder (Procedure A).
C SST 09023-12701
B Torque: without SST
23 N*m (235 kgf*cm, 17 ft.*lbf)
with SST
21 N*m (213 kgf*cm, 15 ft.*lbf)
NOTICE:
A • Use a torque wrench with a fulcrum length of
C156443E02 300 mm (11.81 in.).
• This torque value is effective when SST is
parallel to a torque wrench.
(c) Connect the clutch hose to the bracket with a new
clip (Procedure B).
(d) Using SST, connect the clutch tube to the clutch
hose (Procedure C).
SST 09023-38201
Torque: without SST
24 N*m (245 kgf*cm, 18 ft.*lbf)
with SST
22 N*m (222 kgf*cm, 16 ft.*lbf)
NOTICE:
• Use a torque wrench with a fulcrum length of
300 mm (11.81 in.).

(for W04D series)
(a) Install the clutch release cylinder with the 2 bolts.
(b) Using SST, connect the clutch line to the clutch
release cylinder.
SST 09023-00101
Torque: without SST
SST 24 N*m (245 kgf*cm, 18 ft.*lbf)
with SST
C153741E01
22 N*m (222 kgf*cm, 16 ft.*lbf)

CL
NOTICE:
300 mm (11.81 in.).
3. BLEED CLUTCH LINE
HINT:
See Pub. No. S1-YXZE05A, page 42-2.
4. INSPECT FOR FLUID LEAK
5. INSPECT FLUID LEVEL IN RESERVOIR
HINT:
CL–10 CLUTCH – CLUTCH UNIT
CLUTCH UNIT
CLUTCH
TRANSMISSION
COMPONENTS
for
forN04C series:
N04C-TT (Wide body):
CL
INPUT SHAFT BEARING
x 10
43 (440, 32)
CLUTCH RELEASE
BEARING ASSEMBLY
CLUTCH RELEASE FORK

SUB-ASSEMBLY
RELEASE
BEARING
HUB CLIP
47 (480, 35)
RELEASE FORK SUPPORT
CLUTCH RELEASE FORK BOOT
Non-reusable part
Release hub grease

C153738E02
CLUTCH – CLUTCH UNIT CL–11
for W04D
except series: (Wide Body):
N04C-TT
INPUT SHAFT BEARING

CL
x8
43 (440, 32)
CLUTCH RELEASE
BEARING ASSEMBLY
CLUTCH RELEASE FORK

SUB-ASSEMBLY
RELEASE
BEARING
HUB CLIP
47 (480, 35)
RELEASE FORK SUPPORT
CLUTCH RELEASE FORK BOOT
Non-reusable part
Release hub grease

C156452E02
REMOVAL
1. REMOVE MANUAL TRANSMISSION UNIT
ASSEMBLY
HINT:
• M153 manual transmission (See chapter MT).
• MYY5S manual transmission (See chapter MT).
2. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY
CL (a) Remove the clutch release fork with the clutch
release bearing from the transmission unit.
C152315
(b) Remove the release bearing and clip from the clutch
release fork.
3. REMOVE CLUTCH RELEASE FORK BOOT
(a) Remove the clutch release fork boot from the
transmission unit.
C152316
4. REMOVE RELEASE FORK SUPPORT

(a) Remove the release fork support from the
transmission unit.
C152317
5. REMOVE CLUTCH COVER ASSEMBLY (for N04C

Matchmark series)
(a) Put matchmarks on the clutch cover assembly and
the flywheel sub-assembly.
(b) Loosen each set bolt one turn at a time until spring
tension is released.
(c) Remove the 10 bolts, and pull off the clutch cover
assembly.
NOTICE:
C156445E01 Do not drop the clutch disc assembly.
6. REMOVE CLUTCH COVER ASSEMBLY (W04D

Matchmark
series)
(a) Put matchmarks on the clutch cover assembly and
the flywheel sub-assembly.
(b) Loosen each set bolt one turn at a time until spring
tension is released.
(c) Remove the 8 bolts, and pull off the clutch cover
assembly.
NOTICE:
Do not drop the clutch disc assembly.
C153742E01
CL
7. REMOVE CLUTCH DISC ASSEMBLY
NOTICE:
Keep the lined part of the clutch disc assembly, the
pressure plate and the surface of the flywheel sub-
assembly away from oil and foreign matter.
(a) Turn the bearing by hand while applying force in the
direction of the rotation.
If the bearing is stuck or difficult to turn, replace the
input shaft bearing.
HINT:
The bearing is permanently lubricated and requires
no cleaning or lubrication.
C153743
9. REMOVE INPUT SHAFT BEARING

SST
(a) Using SST, remove the input shaft bearing.
SST 09303-35011
C153744E01
INSPECTION
1. INSPECT CLUTCH DISC ASSEMBLY
(a) Using vernier calipers, measure the rivet head
depth.
Minimum rivet depth:
0.3 mm (0.012 in.)
If the result is less than the minimum, replace the
clutch disc assembly.
C153745
(b) Install the clutch disc assembly to the transmission

unit.
NOTICE:
Take care not to insert the clutch disc assembly
in the wrong direction.
(c) Using a dial indicator, check the clutch disc
assembly runout.
Maximum runout:
1.0 mm (0.039 in.)
If the runout exceeds the maximum, replace the
CL C114037
clutch disc assembly.

2. INSPECT CLUTCH COVER ASSEMBLY
Width (a) Using vernier calipers, inspect the diaphragm spring
for the depth and width of wear.
Maximum
Depth Depth Width
0.6 mm (0.024 in.) 5.0 mm (0.197 in.)
If the result exceeds the maximum, replace the

clutch cover assembly.
C153746E01
3. INSPECT FLYWHEEL SUB-ASSEMBLY

(a) Using a dial indicator, inspect the flywheel sub-
assembly runout.
Maximum runout:
0.1 mm (0.004 in.)
If the runout exceeds the maximum, replace the
flywheel sub-assembly.
C153747
4. INSPECT CLUTCH RELEASE BEARING ASSEMBLY

(a) Check that the clutch release bearing assembly
moves smoothly without abnormal resistance by
turning the sliding parts of the clutch release bearing
assembly (contact surfaces with the clutch cover)
while applying force in the axial direction.
(b) Inspect the clutch release bearing assembly for
damage or wear.
HINT:
C153748 Replace the release bearing assembly as
necessary.
INSTALLATION
1. INSTALL INPUT SHAFT BEARING
(a) Using SST and a hammer, install a new input shaft
SST bearing.
SST 09304-12012
HINT:
After installing the input shaft bearing to the hub,
make sure that it rotates smoothly.
C153749E01
2. INSTALL CLUTCH DISC ASSEMBLY

(a) Insert SST into the clutch disc assembly, then insert
them into the flywheel sub-assembly.
SST 09301-00120
NOTICE:
Take care not to insert the clutch disc assembly
in the wrong direction.
SST
CL
Flywheel Side
C153750E01
3. INSTALL CLUTCH COVER ASSEMBLY (for N04C

Matchmark 4 1
5 series)
(a) Align the matchmark on the clutch cover assembly
9
7 with the one on the flywheel sub-assembly.
(b) In the order shown in the illustration, tighten the 10
8
SST bolts starting from the bolt located near the knock
pin on the top.
10
HINT:
3 • Evenly tighten the bolts by following the order
6 2 C156444E01

• Tighten the bolts after checking that the disc is
centered by lightly moving SST up and down, left
and right.
SST 09301-00120
1
4. INSTALL CLUTCH COVER ASSEMBLY (for W04D
4 series)
5 (a) Align the matchmark on the clutch cover assembly
7 with the one on the flywheel sub-assembly.
SST (b) In the order shown in the illustration, tighten the 8
bolts starting from the bolt located near the knock
Match- pin on the top.
8
mark Torque: 43 N*m (440 kgf*cm, 32 ft.*lbf)
6 HINT:
3
2 C153751E01 • Evenly tighten the bolts by following the order
• Tighten the bolts after checking that the disc is
centered by lightly moving SST up and down, left
and right.
SST 09301-00120
5. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY

(a) Using a dial indicator with a roller instrument, check
the diaphragm spring tip alignment.
SST
Maximum misalignment:
0.5 mm (0.020 in.)
(b) If alignment is not as specified, adjust the
diaphragm spring tip alignment using SST.
SST 09333-00013
6. INSTALL CLUTCH RELEASE FORK BOOT
CL C153752E01
(a) Install the clutch release fork boot.
7. INSTALL RELEASE FORK SUPPORT
(a) Install the clutch release fork support to the
transmission unit.
C152317
8. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY

(a) Apply release hub grease to the release fork as
Grease:
Part No. 08887-01806, Release Hub Grease or
equivalent
C152314E01
(b) Apply clutch spline grease to the input shaft spline.

Grease:
Part No. 08887-01706, Clutch Spline Grease or
equivalent
C153754E01
(c) Install the release bearing to the clutch release fork

with the clip.
C152316
(d) Install the clutch release fork assembly to the

transmission unit.
NOTICE:
After installation, move the fork back and forth
to check that the release bearing slides
smoothly.
9. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY
HINT:
C152315
• M550 manual transmission (See chapter MT). CL
FRONT SUSPENSION (IFS)
AUTOMATIC TRANSMISSION ASSY (A860E)

COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-1
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-12
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-22
AT
SHIFT LEVER ASSY (A860E)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-27
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-29
TRANSMISSION CONTROL CABLE (A860E)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-36
DIAGNOSIS OF ELECTRONIC CONTROLLED AUTOMATIC
TRANSMISSION [ECT] (A860)
FUNCTION EXPLANATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-41
TROUBLE-SHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . AT-42
INTERVIEW TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-44
PREINSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-45
DIAGNOSIS CODE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-54
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-57
ECU TERMINAL LAYOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-59
SYMTOM TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT-66
A860E AUTOMATIC TRANSMISSION – AUTOMATIC TRANSMISSION ASSY (A860E) AT–1
AUTOMATIC TRANSMISSION ASSY (A860E)

COMPONENTS
2-JOINT TYPE, WITH STANDARD CAB
75 (760, 55)
AT
75 (760, 55)
Propeller Shaft Assy
3-JOINT TYPE, WITH WIDE CAB
75 (760, 55)
75 (760, 55)
Intermediate Shaft Assy
75 (760, 55)
Propeller Shaft Assy
Center Support
52 (525, 38)

ASM91-005
AT–2 A860E AUTOMATIC TRANSMISSION – AUTOMATIC TRANSMISSION ASSY (A860E)
WITH WIDE CAB: WITH STANDARD CAB:
18 (184, 13)
18 (184, 13)
18 (184, 13)
O-RING
AT
O-RING
OIL LEV EL GAUGE TRANSMISSION

OIL FILLER TUBE OIL LEV EL GAUGE TRANSMISSION
OIL FILLER TUBE
18 (184, 13)
50 (510, 37) X2
X2 CONNECTOR
EXHAUST PIPE SUPPORT BRACKET NO.1
43 (439, 32) TRANSMISSION CASE

DUST COV ER
54 (551, 40) X 12
TORQUE CONV ERTER SET BOLT
X6
PARKING BRAKE
DRUM
GASKET
27 (275, 20)
TORQUE CONV ERTER ASSY DRAIN PLUG
X4
N*m (kgf*cm, ft*lbf) : Specified Torque
Non-reusable part 190 (1937, 140)

PARKING BRAKE PLATE 95 (969, 70) OUTPUT SHAFT SET NUT
Apply Adhesive 1344
Apply TOYOTA Authorized Auto Fluid TYPE T-IV

C153456J03
OIL COOLER OUTLET TUBE NO.1
OIL TUBE CLAMP 18 (184, 13)
36 (367, 27)
18 (184, 13)
OIL COOLER CLAMP
18 (184, 13)
TRANSMISSION OIL COOLER FLEXIBLE HOSE CLAMP NO.1 AT

TUBE CLAMP NO.1
69 (704, 51)
OIL COOLER INLET TUBE NO.1
7.0 (71, 5.2)
OIL TUBE CLAMP
7.0 (71, 5.2)

OIL TUBE CLAMP 18 (184, 13)
OIL TUBE CLAMP
CONNECTOR 24 (245, 18)

36 (367, 27)
70 (714, 52)
HEAT INSULATOR X2
X3
25 (259, 18)
30 (305, 22)
X4
GASKET
EXHAUST RETARDER ASSY
EXHAUST PIPE ASSY FR

FLYWHEEL HOUSING DUST SEAL
N*m (kgf*cm, ft*lbf) : Specified Torque 10 (102, 7)
Non-reusable part C153482J01

WITH WIDE CAB: WITH STANDARD CAB:
ENGINE MOUNTING
X2 X2
BRACKET RR
X2
X2
AT 65 (663, 48) 65 (663, 48) X4
65 (663, 48)
X4
65 (663, 48)
ENGINE MOUNTING BRACKET RR
TRANSMISSION CONTROL CABLE ASSY

CLIP
12 (122, 9)
TRANSMISSION
BREATHER SKIRT
CLAMP
37 (377, 27) X2
CABLE BRACKET NO.1
27 (275, 20)

INTAKE MANIFOLD (V ACUUM PUMP)
TO CONNECTOR
Non-reusable part
C153457J01
REMOVAL
1. DISCONNECT THE BATTERY MINUS CABLE
2. DRAIN THE AUTOMATIC TRANSMISSION FLUID
(a) Remove the drain plug and the gasket and drain the
fluid.
(b) Install the drain plug with a new gasket.
Torque: T = 27 N*m (275 kgf*cm, 20 ft*lbf)
3. REMOVE THE REAR PROPELLER SHAFT ASSY
4. REMOVE THE PROPELLER INTERMEDIATE SHAFT
ASSY (OTHER THAN EXTREMELY LONG BODY AT
SHAPE)
5. REMOVE THE CTR PROPELLER SHAFT ASSY
(EXTREMELY LONG BODY SHAPE)
6. REMOVE THE PROPELLER INTERMEDIATE SHAFT
ASSY (EXTREMELY LONG BODY SHAPE)
7. REMOVE THE EXHAUST RETARDER ASSY
8. REMOVE THE FRONT EXHAUST PIPE ASSY
9. REMOVE EXHAUST PIPE SUPPORT BRACKET NO. 1
(a) Remove the two bolts and remove exhaust support
bracket No. 1.
10. REMOVE THE OUTPUT SHAFT SET NUT
11. REMOVE THE PARKING BRAKE DRUM
C154971
12. REMOVE THE PARKING BRAKE PLATE

Vehicle front (a) Remove the four bolts and remove the parking
brake plate.
NOTICE:
Use a string or similar to suspend the parking
brake plate from the vehicle.
C151691J01
13. DISCONNECT OIL COOLER INLET TUBE NO. 1

Vehicle front (a) Remove the five bolts and the five oil cooler tube
plugs.
C151692J02
(b) Remove the bolt and the heat insulator.
Vehicle front
C151693J01
AT (c) Use a 22 mm spanner to unscrew the nut of the oil

cooler inlet tube No. 1 and separate the oil cooler
inlet tube from the transmission assy.
Vehicle front C151694J01
14. DISCONNECT OIL COOLER OUTLET TUBE NO. 1

(a) Use a 22 mm spanner to unscrew the nut of oil
cooler outlet tube No. 1 and separate the oil cooler
outlet tube from the transmission assy.
Vehicle front
C151695J01
15. REMOVE THE TRANSMISSION CONTROL CABLE

ASSY
Vehicle front (a) Remove the nut and the clip and disconnect the
control cable assy from the control shaft lever and
the control cable bracket.
C151696J03
16. REMOVE TRANSMISSION CONTROL CABLE

BRACKET NO. 1
(a) Remove the two bolts and remove transmission
control cable bracket No. 1.
C154970J01
17. REMOVE THE TRANSMISSION OIL FILLER TUBE

(STANDARD CAB BODY SHAPE)
(a) Remove the oil level gauge from the oil filler tube.
(b) Remove the two bolts and remove the oil filler tube
from the transmission assy.
(c) Remove the O-ring from the oil filler tube.
AT
O-ring
C151697J01

(WIDE CAB BODY SHAPE)
(a) Remove the oil level gauge from the oil filler tube.
(b) Remove the bolt and remove the oil filler tube from
the transmission assy.
(c) Remove the O-ring from the oil filler tube.
O-ring
C151698J01
19. DISCONNECT THE INTAKE MANIFOLD (VACUUM

PUMP) 2-CONNECTOR TUBE
(a) Remove the bolt and disconnect the intake manifold
(vacuum pump) to connector tube from the
transmission assy.
C153467
20. DISCONNECT CONNECTOR

(a) Disconnect the temperature sensor connector.
Vehicle front C153467

(b) Disconnect the neutral start switch connector, the

two transmission wire connectors, the speedometer
driven gear connector, and the speed sensor
connector.
Vehicle front
C151701J01
AT (c) Disconnect the speed sensor (turbine sensor)

connector.
Vehicle front
C151702J01
(d) Disconnect the wire harness clamp from flexible

hose clamp No. 1.
C154972
(e) Remove the two bolts and disconnect the wire

harness clamp bracket from the transmission assy.
C154973
21. REMOVE THE TRANSMISSION SERVICE HOLE

COVER (VAN BODY SHAPE)
(a) Remove the 12 bolts and the service hole cover.
C151703
22. REMOVE THE FLYWHEEL HOUSING DUST SEAL AT

(a) Remove the two bolts and the flywheel housing dust
seal.
C154974
23. REMOVE THE TRANSMISSION CASE DUST COVER

Vehicle front (a) Remove the two screws and the transmission case
dust cover.
C151705J01
24. REMOVE THE TORQUE CONVERTER SET BOLTS

Vehicle front (a) Remove the six set bolts from the dust cover hole.
NOTICE:
Turn the drive plate from the dust seal hole.
C153448J01
25. SUPPORT ENGINE ASSY

(a) Support the engine assy with a jack via a piece of
wood.
C153453
26. SUPPORT AUTOMATIC TRANSMISSION ASSY

(a) Support the automatic transmission assy with the
transmission jack.
C153449
AT 27. DISCONNECT REAR ENGINE MOUNTING BRACKET

Vehicle left side: (STANDARD CAB BODY SHAPE)
(a) Remove the four bolts and disconnect rear
mounting bracket from the automatic transmission
assy.
Vehicle front
Vehicle right side:
Vehicle front
C153450J01
28. DISCONNECT REAR ENGINE MOUNTING BRACKET

Vehicle left side: (WIDE CAB BODY SHAPE)
(a) Remove the four bolts and disconnect rear
mounting bracket from the automatic transmission
assy.
Vehicle front
Vehicle right side:

AT
Vehicle front
C153451J01
29. REMOVE THE AUTOMATIC TRANSMISSION ASSY

(a) Remove the 12 bolts and the automatic
transmission assy.
CAUTION:
• Do not drop the torque converter.
• Do not damage the housing.
• The breather skirt is tightened at the same
time.
Breather skirt
C153452J01
30. REMOVE TRANSMISSION AND BREATHER SKIRT.

(a) Slide the clamp and disconnect the breather skirt
from the breather hose.
31. REMOVE TRANSMISSION OIL COOLER TUBE

CLAMP NO. 1
(a) Remove the bolt and the oil cooler tube clamp.
C153465
AT 32. REMOVE FLEXIBLE HOSE CLAMP NO. 1

(a) Remove the bolt and the clamp of flexible hose No. 1.
C153466
33. REMOVE THE TORQUE CONVERTER ASSY

(a) Remove the torque converter assy from the
automatic transmission assy.
INSTALLATION
1. INSTALL THE TORQUE CONVERTER ASSY
(a) Clean the drive plate converter set bolt installation
hole.
(b) Use vernier calipers and a ruler and measure
dimension A from the transmission installation plane
to the drive plate converter installation plane. [*1]
Standard: A = 66.7 mm (2.63 in.)
NOTICE:
The thickness of the ruler must be measured.
A
C153454
(c) Use vernier calipers and a ruler to measure

dimension A from the housing edge to the converter
plate installation plane and confirm that it is smaller
than dimension A of step [*1].
Standard: Dimension A - 1 mm (0.04 in.) or
smaller
NOTICE:
The thickness of the ruler must be measured.
A-1 mm or
smaller
C153455J01
2. INSTALL FLEXIBLE HOSE CLAMP NO. 1

(a) Install flexible hose clamp No. 1 with a bolt to the
Torque: 18 N*m (184 kgf*cm, 13 ft*lbf)
C153466
3. INSTALL TRANSMISSION OIL COOLER TUBE AT

CLAMP NO.1
(a) Install the oil cooler tube clamp with a bolt to the
C153465
4. SUPPORT AUTOMATIC TRANSMISSION ASSY

(a) Support the automatic transmission assy with the
transmission jack.
C153449
5. INSTALLATION AUTOMATIC TRANSMISSION ASSY

(a) Install the breather skirt with a clamp to the breather
hose.
(b) Confirm that a knock pin is installed on the engine
side.
(c) Bring the engine assy and the transmission assy to
level condition and match the knock pin and the
knock pin hole.
(d) Install the transmission assy with 12 bolts to the

engine assy.
CAUTION:
• The breather skirt is tightened at the same
time.
• Confirm that the torque converter can be
turned by hand.
• Do not twist the transmission assy
excessively.
AT
Breather skirt
C153452J01
6. INSTALL REAR ENGINE MOUNTING BRACKET

Vehicle left side: (STANDARD CAB BODY SHAPE)
(a) Install the rear engine mounting bracket with eight
bolts to the automatic transmission assy.
Vehicle front
Vehicle right side:
Vehicle front
C153450J01
7. INSTALL REAR ENGINE MOUNTING BRACKET

Vehicle left side: (WIDE CAB BODY SHAPE)
(a) Install engine mounting bracket with eight bolts to
the automatic transmission assy.
Vehicle front
Vehicle right side:

AT
Vehicle front
C153451J01
8. INSTALL THE TORQUE CONVERTER SET BOLTS

Vehicle front (a) Install the six set bolts from the dust cover hole to
the drive plate.
CAUTION:
• Install the set bolts from the location with
identifying paint (pink).
• Tighten the six set bolts uniformly.
NOTICE:
C153448J01 Turn the drive plate from the dust seal hole.
9. INSTALL THE TRANSMISSION CASE DUST COVER

Vehicle front (a) Install the dust cover with two bolts.
C151705J01
10. INSTALL THE FLYWHEEL HOUSING DUST SEAL

(a) Install the dust seal with two bolts.
C154974
11. INSTALL THE TRANSMISSION SERVICE HOLE

COVER (VAN BODY SHAPE)
(a) Install the service hole cover with 12 bolts.
C151703
AT 12. CONNECT CONNECTOR

(a) Install the wire harness clamp bracket with two bolts
to the transmission assy.
C154973
(b) Connect the wire harness clamp to flexible hose

clamp No. 1.
C154972
(c) Connect the speed sensor connector.
Vehicle front
C151702J01
(d) Connect the neutral start switch connector, the two

transmission wire connectors, the speedometer
driven gear connector, and the speed sensor
connector.
Vehicle front
C151701J01
(e) Connect the temperature sensor connector. AT
13. INSTALL THE INTAKE MANIFOLD (VACUUM PUMP)

2-CONNECTOR TUBE
(a) Install the intake manifold (vacuum pump) 2-
connector tube with a bolt to the transmission assy.
C153467
14. INSTALL THE TRANSMISSION OIL FILLER TUBE

(STANDARD CAB BODY SHAPE)
(a) Apply ATF to a new O-ring and install the O-ring to
the oil filler tube.
(b) Install the oil filler tube with two bolts to the
transmission assy.
AT
O-ring
C151697J01
(c) Install the oil level gauge to the oil filler tube.
(a) Apply ATF to a new O-ring and install the O-ring to
the oil filler tube.
(b) Install the oil filler tube with a bolt to the
transmission assy.
O-ring
C151698J01
(c) Install the oil level gauge to the oil filler tube.
16. INSTALL TRANSMISSION CONTROL CABLE
BRACKET NO. 1
(a) Install the transmission control cable bracket No. 1
with two bolts.
C154970J01
17. INSTALL THE TRANSMISSION CONTROL CABLE

ASSY
(a) Confirm that shift lever and outer lever are at the N-
position.
(b) Install the transmission control cable assy with a
new clip to the control cable bracket.
Vehicle front
AT
C151696J02
(c) Provisionally tighten the cable end with the

adjusting nut to the outer lever.
Vehicle front
C151696J01
(d) Push the cable end lightly towards the vehicle front
(in direction of range L-3), release it, and tighten the
adjusting nut with the specified torque.
CAUTION:
Tighten the adjusting nut after taking your hand
once completely off.
18. INSTALL OIL COOLER OUTLET TUBE NO. 1
(a) Use a 22 mm spanner and install the oil cooler
outlet tube No. 1 to the transmission assy.
Vehicle front
C151695J01
19. INSTALL OIL COOLER INLET TUBE NO. 1

(a) Use a 22 mm spanner and install oil cooler inlet tube
No. 1 to the transmission assy.

(b) Install the heat insulator with a bolt to the

transmission assy.
Vehicle front
C151693J01
AT (c) Install the five oil tube clamps with five bolts.
Vehicle front Torque:
Bolt A 7.0 N*m (71 kgf*cm, 5.2 ft*lbf)
B Bolt B 18 N*m (184 kgf*cm, 13 ft*lbf)
B
A
A B C151692J01
20. INSTALL THE PARKING BRAKE PLATE

(a) Clean the parking plate bolts and bolt holes,
degrease the bolt threads, and apply adhesive
1344.
(b) Install the parking brake plate with four bolts to the
Vehicle front extension housing.
C151691J01
21. INSTALL THE PARKING BRAKE DRUM

22. ADJUST PARKING BRAKE SHOE GAP
23. INSPECT THE PARKING BRAKE LEVER PULL
SLACK
24. ADJUST THE PARKING BRAKE LEVER PULL
SLACK
25. TIGHTEN THE OUTPUT SHAFT SET NUT
26. INSTALL EXHAUST PIPE SUPPORT BRACKET NO. 1

(a) Install the exhaust pipe support bracket No. 1 with
two bolts.
C154971
27. INSTALL FRONT EXHAUST PIPE ASSY AT

28. INSTALL THE EXHAUST RETARDER ASSY
29. INSTALL THE PROPELLER INTERMEDIATE SHAFT
ASSY (EXTREMELY LONG BODY SHAPE)
30. INSTALL THE PROPELLER INTERMEDIATE SHAFT
ASSY (OTHER THAN EXTREMELY LONG BODY
SHAPE)
31. INSTALL CTR PROPELLER SHAFT ASSY
(EXTREMELY LONG BODY SHAPE)
32. INSTALL THE REAR PROPELLER SHAFT ASSY
33. REPLENISH GREASE
34. CONNECT THE BATTERY MINUS TERMINAL
35. REPLENISH THE AUTOMATIC TRANSMISSION
FLUID
36. INSPECT THE AUTOMATIC TRANSMISSION FLUID
QUANTITY
37. INSPECT EXHAUST GAS LEAKAGE
38. INSPECT SHIFT LEVER POSITION (SEE PAGE AT-30)
39. ADJUST SHIFT LEVER POSITION (SEE PAGE AT-30)
40. INITIALIZE AT LEARNING VALUE
ADJUSTMENT
1. PREPARATIONS BEFORE THE WORK
(a) Switch off air conditioner, headlights, and other
OIL TEMPERATURE LAMP electric loads, as well as the PTO.
Lit (b) Use the parking brake and wheel chocks to securely
lock the wheels.
Not (c) Confirm that the AT oil level is within the specified
lit range.
(d) Execute warm-up operation in idle condition for 5
"A/T OIL TEMP" lamp lighting specification
minutes.
AT ASM7-051 (e) Repeat N→D, N→R shift operation three to five
times.
2. TRANSITION TO ADJUSTMENT MODE
OIL TEMPERATURE LAMP (a) Bring the vehicle to the following status.
Adjustment mode
• Vehicle stopped
0.2 sec • Diagnostic terminals: Short-circuited
Lit • Shift brake: ON
• AT oil pan oil temperature: 40 to 90°C (104 to
Not 194°F)
lit • Engine speed: 500 rpm or higher
0.2 sec • O/D cut switch: OFF
When transition to adjustment mode was possible, (b) For transition to adjust mode, perform
flashing occurs in intervals of 0.2 sec. D→4→D→4→D→4→D shift operation within 10
When transition to adjustment mode was not seconds in the above status (a).
possible, not lit or lit.
ASM7-052
NOTICE:
• When transition to adjustment mode is not
possible and the "A/T OIL TEMP" lamp is not
lit, start again from No. 2 "Transition to
adjustment mode".
• When transition to adjustment mode is not
possible and the "A/T OIL TEMP" lamp is lit,
switch off the ignition once, and because the
AT oil pan oil temperature condition is not
met, perform warm-up operation or cooling,
and then start again from No. 1 "Preparations
before the work".
3. EXECUTION OF ADJUST {1}
OIL TEMPERATURE LAMP (a) Bring the vehicle to the following status.
During adjust {1} execution • Shift position: D-range
0.2 sec 0.2 sec
0.5 sec • Shift brake: ON
Lit • Throttle opening: 0%
• Engine speed: Stable within the idle speed range
Not
(b) To start adjust {1}, switch the O/D cut switch from
lit OFF to ON in the above status (a).
0.2 sec 0.5 sec 0.2 sec NOTICE:
• During execution of adjust {1}, the above
During execution of adjust {1}, flashing occurs
in intervals of 0.5 sec, after completion flashing
status (a) shall be maintained.
occurs in intervals of 0.2 sec. • If adjustment fails (the "A/T OIL TEMP" lamp
Lit in case of failure. lights), start again from No. 3 "Execution of
ASM7-053 adjust {1}".

OIL TEMPERATURE LAMP
During execution
(a) When adjust {1} has been completed, depress the
During adjust
{1} execution of adjust {2} accelerator within 30 seconds after the "A/T OIL
0.2 sec 0.5 sec TEMP" lamp flashes in intervals of 0.2 sec to obtain
Lit
an engine speed of 1000 to 1500 rpm.
Until completion of adjust {2} ("A/T OIL TEMP" lamp
lit or not lit), do not change the throttle opening as
Not
lit far as possible to maintain an engine speed of 1000
0.2 sec 0.5 sec to 1500 rpm.
(b) When adjust {2} has been completed ("A/T OIL
During execution of adjust {2}, flashing in
intervals of 0.5 sec, not lit after completion. TEMP" lamp lit or not lit), return the accelerator to
Lit in case of failure.
the idle position. AT
ASM7-054
(c) Switch the O/D cut switch from ON to OFF.
NOTICE:
• During execution of adjust {2}, keep the D-
range as the shift position and the shift brake
in ON condition.
• If the adjustment has failed ("A/T OIL TEMP"
lamp lit), start again from No. 3 "Execution of
adjust {1}".
During adjust {3} execution (a) Bring the vehicle to the following status.
0.5 sec 0.2 sec • Shift position: R-range
• Shift brake: ON
Lit
• Throttle opening: 0%
• Engine speed: Stable within the idle speed range
Not (b) To start adjust {3}, switch the O/D cut switch from
lit
OFF to ON in the above status (a).
0.5 sec 0.2 sec
NOTICE:
• During execution of adjust {3}, the above
Flashing in intervals of 0.5 sec during execution of
adjust {3} and in intervals of 0.2 sec after status (a) shall be maintained.
completion. • If adjustment fails (the "A/T OIL TEMP" lamp
Lights in case of failure. lights), start again from No. 5 "Execution of
ASM7-055
adjust {3}".
During execution
(a) When adjust {3} has been completed, depress the
of adjust {3} During execution of adjust {4} accelerator within 30 seconds after the "A/T OIL
TEMP" lamp flashes in intervals of 0.2 sec to obtain
0.2 sec 0.5 sec
an engine speed of 1000 to 1500 rpm.
Lit
2 sec Until completion of adjust {4} ("A/T OIL TEMP" lamp
repeating not lit for 2 sec and lit for 1 sec or lit), do
Not
lit
not change the throttle opening as far as possible to
0.5 sec 1 sec maintain an engine speed of 1000 to 1500 rpm.
0.2 sec
(b) When adjust {4} has been completed ("A/T OIL
Flashing in intervals of 0.5 sec during execution of TEMP" lamp repeating not lit for 2 sec and lit for 1
adjust {4} and repetition of not lit for 2 sec and lit for
1 sec in case of successful completion of adjust {4}. sec), return the accelerator to the idle position.
Lights in case of failure. NOTICE:
ASM7-056
• During execution of adjust {4}, keep the R-
range as the shift position and the shift brake
in ON condition.
• If adjustment fails (the "A/T OIL TEMP" lamp
lights), start again from No. 5 "Execution of
adjust {3}"
7. ADJUSTMENT COMPLETION
OIL TEMPERATURE LAMP (a) End adjustment with the vehicle in the following
Lit condition.
2 sec
• Shift position: P-range
Not
• Diagnostic terminals: Not short-circuited
lit • Ignition: OFF
1 sec
Ignition OFF
Repetition of not lit for 2 sec and lit for 1 sec
until ignition OFF
ASM7-057
NOTICE:
AT • If normal completion is not possible even with several
executions, confirm the diagnostic code, as parts
1 sec
failure etc. must be considered.
Lit • If the "A/T OIL TEMP" lamp repeats "lit for 2 sec → not
lit for 1 sec" after transition to adjustment mode (from
2 sec
No. 2 on), it is judged that the vehicle has been moved.
Not
lit Stop adjustment once, set the ignition to OFF, confirm
that the vehicle is stopped, and start again from No. 1
ASM7-058 "Preparations before the work".
A860E AUTOMATIC TRANSMISSION – SHIFT LEVER ASSY (A860E) AT–25
SHIFT LEVER ASSY (A860E)

COMPONENTS
TRANSMISSION CONTROL CABLLE ASSY
STEERING COLUMN LOWER COV ER
AT
18 (184, 13)
X3
TRANSMISSION FLOOR SHIFT ASSY
CLIP
POSITION INDICATOR HOUSING COV ER
WITH WIDE CAB

INSTRUMENT COV ER LWR NO. 3
INSTRUMENT COV ER LWR
: Non- reusable part
C153463J01
AT–26 A860E AUTOMATIC TRANSMISSION – SHIFT LEVER ASSY (A860E)
REMOVAL
1. REMOVE LOWER INSTRUMENT COVER
2. REMOVE LOWER INSTRUMENT COVER NO. 3 (WIDE
CAB BODY SHAPE)
3. REMOVE LOWER INSTRUMENT COVER NO. 2
4. REMOVE STEERING COLUMN LOWER COVER
(a) Remove the four screws and the clip and take off
the steering column lower cover.
AT
C154969J01
5. REMOVE POSITION INDICATOR HOUSING COVER

(a) Remove the clip and the three retaining tabs.
C153458
(b) Remove the position indicator housing cover as

shown.
C153459
6. REMOVE THE TRANSMISSION FLOOR SHIFT ASSY

(a) Set the shift lever to the N-range position.
(b) Disconnect the connector.
C154967
(c) Remove the three bolts and the transmission floor

shift assy.
C153460
7. DISCONNECT THE TRANSMISSION CONTROL AT

CABLE ASSY
(a) Disconnect the cable end and the clip and
disconnect the transmission control cable assy from
the transmission floor shift assy.
C153461J01
INSTALLATION
ASSY
(b) Connect the cable end and install the transmission
control cable assy with a new clip to the
transmission floor shift lever.
C153461J01
2. INSTALL THE TRANSMISSION FLOOR SHIFT ASSY

(a) Install the transmission floor shift assy with three
bolts.
C153460
AT–28 A860E AUTOMATIC TRANSMISSION – SHIFT LEVER ASSY (A860E)
C154967
AT 3. INSTALL POSITION INDICATOR HOUSING COVER

(a) Insert the position indicator housing cover as
shown.
C153462
(b) Install the position indicator housing cover with a

clip and three retaining tabs.
CAUTION:
In order to confirm that the position indicator
housing cover has been installed securely,
confirm that shift lock release is possible from
the service hole of the position indicator
housing cover.
Service hole
C153458J01
4. INSTALL STEERING COLUMN LOWER COVER

(a) Install the steering column lower cover with four
screws and a clip.
C154969J01
5. INSTALL LOWER INSTRUMENT COVER NO. 2

6. INSTALL LOWER INSTRUMENT COVER NO. 3 (WIDE
CAB BODY SHAPE)
7. INSTALL LOWER INSTRUMENT COVER
9. ADJUST SHIFT LEVER POSITION (SEE PAGE AT-30)
ADJUSTMENT
1. ADJUST SHIFT LEVER POSITION
(b) Remove the adjusting nut of the control shaft lever.
Vehicle front
AT
C151696J01
(c) Push the control shaft lever to the rear of the vehicle
until it stops, and then return it by two notches.
C153464
(d) Push the cable end lightly towards the vehicle front
(in direction of range L3), release it, and tighten the
Vehicle front adjusting nut with the specified torque.
CAUTION:
NOTICE:
After installation, confirm that the starter
C151696J01 operates only when the shift lever is in the P-
range or the N-range position.
2. INSPECT SHIFT LEVER POSITION
(a) Set the ignition switch to ON and depress the brake
pedal.
(b) Confirm that the shift lever moves smoothly when it
is shifted to each range and shifting to each range
can be satisfactorily accomplished.
(c) Start the engine and confirm that the vehicle moves
forward with shifting from N-range to D-range and
moves back with shifting from N-range to R-range.
AT–30 A860E AUTOMATIC TRANSMISSION – TRANSMISSION CONTROL CABLE (A860E)
TRANSMISSION CONTROL CABLE (A860E)

COMPONENTS
TRANSMISSION CONTROL CABLLE ASSY
STEERING COLUMN LOWER COV ER
AT
18 (184, 13)
X3
TRANSMISSION FLOOR SHIFT ASSY
CLIP
POSITION INDICATOR HOUSING COV ER
WITH WIDE CAB

INSTRUMENT COV ER LWR
C153463J01
A860E AUTOMATIC TRANSMISSION – TRANSMISSION CONTROL CABLE (A860E) AT–31
WITH STANDARD CAB:
RADIATOR GRILLE ASSY
CABLE INSULATOR
AT
18 (184, 13)
18 (184, 13)
CABLE BRACKET NO. 3
CABLE BRACKET NO. 3
CABLE BRACKET NO. 4
18 (184, 13)
CLIP
18 (184, 13)
12 (122, 9)
WASHER
(SELECT USE)
18 (184, 9) CABLE CLAMP
CABLE CLAMP
7.5 (77, 5.5) OUTER LEV ER
18 (184, 13)
CABLE BRACKET NO. 3

C153483J01
WITH WIDE CAB:

RADIATOR GRILLE ASSY
AT
CLIP
GROMMET WASHER (SELECT USE)
7.5 (77, 5.5)

12 (122, 9)
18 (184, 13)
CLAMP
OUTER LEV ER
CLAMP
CABLE BRACKET NO. 2
18 (184, 9)
CABLE BRACKET NO. 2
CABLE CLAMP
C155841J01
REMOVAL
1. REMOVE THE LOWER INSTALLMENT COVER
2. REMOVE THE LOWER INSTRUMENT COVER NO. 3
3. REMOVE THE LOWER INSTRUMENT COVER NO. 2
4. REMOVE STEERING COLUMN LOWER COVER (SEE
PAGE AT-26)
5. REMOVE POSITION INDICATOR HOUSING COVER
(SEE PAGE AT-26)
AT
6. REMOVE THE RADIATOR GRILL ASSY (STANDARD
CAB BODY SHAPE)
7. REMOVE THE RADIATOR GRILLE ASSY (WIDE CAB
BODY SHAPE)
8. REMOVE THE TRANSMISSION FLOOR SHIFT ASSY
(SEE PAGE AT-26)
9. DISCONNECT THE TRANSMISSION CONTROL
CABLE ASSY
(b) Disconnect the cable end and the clip and
the transmission floor shift assy.
C153461J01
(c) Remove the adjusting nut and the clip and

Vehicle front the outer lever and the transmission control bracket.
C151696J03
(d) Remove the grommet from the floor panel.
C154968
(e) Standard cab vehicle
AT
(*) Washer
(*) Install the washer when the holding force

of the clamp is not sufficient.
High-power vehicle (RFS):
C153484J01
(1) Remove the seven clamps and the

transmission control cable assy.
(f) Wide-cab vehicle
AT
(*) Washer
(*) Install the washer when the holding force of the clamp is not sufficient.
C155842J02
(1) Remove the six clamps and the transmission

control cable assy.
NOTICE:
The plastic clamp on the radiator side is
destroyed when it is removed.
INSTALLATION
ASSY
(a) Standard cab vehicle
NUT BOLT B
BOLT B
AT
BOLT A
PLASTIC CLAMP
(*) WASHER BOLT B
BOLT B
(*) Install the washer when the holding force

HIGH POWER V EHICLE (RFS) of the clamp is not sufficient.
NUT
C153484J02
(1) Install the transmission control cable assy with

a new plastic clamp.
NOTICE:
Install a washer when the holding force of
the plastic clamp is not sufficient.
six clamps.
Torque:
Bolt B 18 N*m (184 kgf*cm, 13 ft*lbf)
Nut 18 N*m (184 kgf*cm, 13 ft*lbf) AT
(b) Wide cab vehicle
BOLT B
NUT
AT BOLT A
PLASTIC CLAMP PLASTIC CLAMP
(*) WASHER
NUT
(*) Install the washer when the holding force of the clamp is not sufficient.
C155842J01

two new plastic clamps.
NOTICE:
Install a washer when the holding force of
the plastic clamp is not sufficient.

four clamps.
Torque:
Bolt B 18 N*m (184 kgf*cm, 13 ft*lbf)
Nut 18 N*m (184 kgf*cm, 13 ft*lbf)
(c) Install the grommet on the floor panel.
AT
C154968
(d) Confirm that the shift lever and the outer lever are
set to the N-range.
(e) Install the cable end and install the transmission
control cable assy with a new clip to the shift lever
assy.
2. INSTALL THE TRANSMISSION FLOOR SHIFT ASSY
(SEE PAGE AT-27)
3. INSTALL POSITION INDICATOR HOUSING COVER
(SEE PAGE AT-29)
4. INSTALL STEERING COLUMN LOWER COVER (SEE
C153461J01
PAGE AT-29)
5. INSTALL THE LOWER INSTRUMENT COVER NO. 2
6. INSTALL THE LOWER INSTRUMENT COVER NO. 3
(WIDE BODY CAB SHAPE)
7. INSTALL THE LOWER INSTRUMENT COVER
8. INSTALL THE RADIATOR GRILLE ASSY (STANDARD
CAB BODY SHAPE)
9. INSTALL THE RADIATOR GRILLE ASSY (WIDE CAB
BODY SHAPE)
10. CONNECT THE TRANSMISSION CONTROL CABLE
ASSY
Vehicle front (a) Install the transmission control cable assy with a
new clip to the transmission control cable bracket.
C151696J02
(b) Provisionally tighten the cable end with the

adjusting nut to the outer lever.
Vehicle front (c) Push the cable end lightly towards the vehicle front
(in direction of range L-3), release it, and tighten the
adjusting nut with the specified torque.
CAUTION:
C151696J01
AT 12. ADJUST SHIFT LEVER POSITION (SEE PAGE AT-30)

A860E AUTOMATIC TRANSMISSION – DIAGNOSIS OF ELECTRONIC CONTROLLED
AUTOMATIC TRANSMISSION [ECT] (A860E) AT–41
DIAGNOSIS OF ELECTRONIC CONTROLLED AUTOMATIC

TRANSMISSION [ECT] (A860E)
1. DIAGNOSIS FUNCTION
(a) When trouble has occurred in the ECT system, the O/D OFF indicator lamp flashes and the
check AT indicator lamp lights.
NOTICE:
• Flashing of the O/D OFF indicator lamp and
lighting of the check AT indicator lamp differs
AT
according to the diagnostic code. (Refer to
the diagnostic code table AT-45 for the lamp
correspondence.)
• The O/D OFF indicator lamp does not flash when the trouble item has been reset
normally.
• The check AT indicator lamp does not light when the trouble item has been reset
normally.
HINT:
The check AT indicator lamp lights for 3 sec after the ignition switch has been set to ON and then
goes out.
2. FAILSAFE FUNCTION
(a) In case of a short-circuit or a wire break of one of the solenoid valve systems, the transmission
control computer ASSY switches the other solenoids ON or OFF. In case of failure of all
solenoids, the hydraulic circuit becomes completely mechanical and manual shifting is done. (In
case of a wire break or a short-circuit, the transmission control computer ASSY stops energizing
the failed solenoid.)
AT–42 AUTOMATIC TRANSMISSION [ECT] (A860E)
TROUBLE-SHOOTING PROCEDURE
1 MOVE VEHICLE INTO THE SHOP
2 CONFIRM INTERVIEW AND PHENOMENON (REFER TO AT-44 FOR THE OUTLINE)
AT
No code (go to step 4)
3 CONFIRM DIAGNOSTIC CODE (REFER TO AT-54 FOR THE OUTLINE)
(a) Confirm the diagnostic code.

(1) Record the diagnostic code.
(b) Erase the diagnostic code.
(c) Reconfirm the diagnostic code.
(1) Reproduce the trouble phenomenon based on the diagnostic code and confirm that the diagnostic
code is put out again.
HINT:
At the time of diagnostic code output, refer to "Diagnostic code table (AT-54)".
There is a code (go to step 7).
No code, the phenomenon could not be

confirmed or reproduced [to trouble
simulation].
No code, the phenomenon could be confirmed or reproduced [to step 5].
4 MANUAL RUNNING TEST (REFER TO AT-45 FOR THE OUTLINE)
5 SYMPTOM LIST (REFER TO AT-66 FOR THE OUTLINE)
Correspondence by symptom (to step 7)
No correspondence by symptom (to step 6)

6 PERFORM TROUBLE-SHOOTING ACCORDING TO THE FOLLOWING METHOD BASED

ON THE TROUBLE PHENOMENON.
(a) Pre-inspection (refer to AT-45 for the outline)

(1) Before trouble-shooting
(2) Perform a manual driving test.
(b) ECU terminal layout (refer to AT-59 for the outline)
AT
7 ADJUSTMENT, REPAIR, OR REPLACEMENT
8 CONFIRMATION TEST
END
INTERVIEW TABLE
AT CONTROL SYSTEM Inspection

CHECK SHEET Inspector: Date:
Mr. Registration No.

Customer Mrs.
Name Initial Registration
Ms.
date
Vehicle Model Frame No.
AT
Date Vehicle km
Brought in Trip Distance
miles
Trouble (Engine: Cold period Warm period)
Occurrence date
Occurrence
Frequency Continuous Intermittent ( times a day)
Running impossible ( All gears Specific gear position [gear ])
No up-shifting 1st → 2nd 2nd → 3rd 3rd → 4th

4th → 5th 5th → 6th
No down-shifting 6th → 5th 5th → 4th 4th → 3rd

3rd → 2nd 2nd → 1st
Defective lock-up
Symptom
Bad gear shift point
Large gear-shift shock ( N → D·R Lock-up At the time of shifting)
No acceleration (slipping etc.)
Abnormal noise/vibrations
Others
O/D OFF Indicator Lamp Status Flashing ( ) Not lit
Check AT Indicator Lamp Status Lit ( ) Not lit
First Time Normal code Trouble code

Diagnosis Code
Confirmation
Second Time Normal code Trouble code
C73310
PREINSPECTION
1. BEFORE TROUBLE-SHOOTING
(a) Use the electrical tester to check the battery voltage.
Standard: :
20 to 32 V (with stopped engine)
(b) Check the locations where visual confirmation is possible for blown fuses, wire harness breaks
or short-circuits, bad connector connections, etc.
2. CONFIRM DIAGNOSTIC CODE WITH THE O/D OFF
INDICATOR LAMP
(a) Use the SST and short-circuit between terminals 13
(TC) and 4 (CG) of DLC3. AT
SST 09843-18040
CAUTION:
Only short-circuit at the correct location as
otherwise defects may be caused.
C72197
(c) Read the diagnostic code (O/D OFF indicator lamp

flashing count).
HINT:
• Normally, lit for 0.25 sec and not lit for 0.25 sec is
repeated.
• In case of a single diagnostic code, the same
code is put out in intervals of 4.5 sec.
• In case of multiple diagnostic codes, different
codes are put out in intervals of 25 sec, and once
C73241 all codes have been put out, the output is
repeated after 4.5 sec.
• When two or more code numbers are put out,
display is made from the smaller code numbers.
(d) Set the ignition switch to OFF.
(e) Remove the short-circuit between terminals 13 (TC)
and 4 (CG) of DLC3.
3. DELET DIAGNOSTIC CODE MEMORY USING THE O/
D OFF INDICATOR LAMP
(a) Set the ignition switch to ON.
(b) After repair of the defective locations, short-circuit
for at least 3 sec between terminals 13 (TC) and 4
(CG) of DLC3.
SST 09843-18040
CAUTION:
C72197 otherwise defects may be caused.
(c) Set the transmission control switch to ON (O/D

permission). (The O/D OFF indicator lamp goes
out.)
(d) Remove the short-circuit between terminals 13 (TC)
and 4 (CG) of DLC3.
(e) Set the ignition switch to OFF.
(f) Set the transmission control switch to OFF (O/D
prohibition). (The O/D OFF indicator lamp lights.)
(g) Use the SST and short-circuit between terminals 13
C72200 (TC) and 4 (CG) of DLC3.
SST 09843-18040
AT (h) Set the ignition switch to ON.
(i) Check normal code output.
NOTICE:
If an abnormal code is put out, perform repair
again according to the code.
C72201
4. INSPECT TIME LAG

CAUTION:
• Always perform after engine inspection and
adjustment.
• Perform with normal running oil temperature (50
to 80°C, 122 to 176°F).
• Perform with the air condition switched off.
(a) Apply the parking brake and lock the wheels.
(c) With depressed brake pedal, shift at idle speed from
N-range to D-range or R-range and measure the
time until a light shock is felt.
Standard:
N-range → D-range less than 1.2 sec
N-range → R-range less than 1.5 sec
CAUTION:
• Measure several times and obtain the average
value.
• In case of consecutive measuring, use
intervals of 1 minute.
5. INSPECT STALL REVOLUTION
CAUTION:
adjustment.
to 80°C, 122 to 176°F).
• Perform with the air condition switched off.
• Do not perform continuously for longer than 5
seconds.
• Perform at a location with high µ (friction

coefficient) like on asphalt etc., so that the tires
do not slip.
(c) Strongly depress the brake pedal with the left foot,
shift to D-range, and quickly read the max. engine
speed when the accelerator pedal is depressed fully
with the right foot.
Standard:
ENGINE TYPE TRANSMISSION TYPE STALL REVOLUTION [r/min]
N04C-TU A860E 1900±150 AT
N04C-TV A860E 2000±150
6. INSPECT LINE PRESSURE

CAUTION:
adjustment.
to 80°C, 122 to 176°F).
• Perform with the air conditioner switched off.
• Do not continue for longer than 5 seconds at the
time of stall.
(b) Install oil pressure gauge (vehicles without PTO)
(1) Remove the test plug, install the automatic
transmission oil pressure gauge and the
adapter, and start the engine.
Torque:
Adapter
27 N*m (275 kgf*cm, 20 ft*lbf) (test plug)
27 N*m (275 kgf*cm, 20 ft*lbf) (adapter)
CAUTION:
Clean the instrument and the hoses with
C073309J01 white gasoline or similar before and after
measuring.
(c) Install oil pressure gauge (vehicles with PTO)
(1) Loosen flare nut B of the PTO tube, disconnect
union A, and install the cap.
(2) Tighten flare nut B.
Cap Torque: 34 N*m (350 kgf*cm, 25 ft*lbf)
C158742J01
(3) Disconnect the elbow, install the adapter and

the gauge, and start the engine.
(d) Strongly depress the brake pedal with the left foot,
shift to D-range or R-range, and check the oil
pressure at the time of idle speed and at the time of
Adapter stall speed.
C158743J01
Standard:
AT TRANSMISSION TYPE AT IDLEING TIME AT STALL TIME
SHIFT POSITION
(ENGINE TYPE) [MPa (kgf/cm2, psi)] [MPa (kgf/cm2, psi)]
1.00-2.01 1.66-2.01
D renge
A860E (10.2-20.5, 145-291) (17.0-20.5, 241-291)
(N04C-TU, TV) 1.00-2.01 1.66-2.01
R renge
(10.2-20.5, 145-291) (17.0-20.5, 241-291)
7.
SHIFTING TABLE
CAUTION:
adjustment.
to 80°C, 122 to 176°F).
• Perform with air condition off.
NOTICE:
• The gear will not shift to the 6th gear when the
transmission control switch is set to the OFF
position (O/D OFF).
• The 6 th gear lock-up system will not operate
when the transmission controll switch is turned
off (O/D OFF).
• The gear will not shift to the 5th or 6th when the
ATF temperature is below 5°C (41°F).
• The gear will not shift to the 6th when the ATF
temperature is below 25°C (77°F).
• *1: Indicates that the exhaust brake switch is OFF.
(a) Vehicle with NO4C-TU engine (standard cab)
1. Automatic shifting point: Each shift point is within the range listed in the following diagram.
2. Shift point: (km/h)
DIFF
D-RANGE .
RATIO RANGE RANGE
FULL OPEN FULL OPEN


(b) Vehicle with N04C-TV engine (wide cab)

1. Automatic shifting point: Each shift point is within the range listed in the following diagram.
2. Shift point: (km/h)
D-RANGE .
DIFF
RATIO RANGE RANGE
FULL OPEN FULL OPEN


AT
8. AT INITIAL LEARNING
NOTICE:
• AT initial learning must be performed after the
automatic transmission ASSY or the transmission
control computer ASSY has been replaced.
• If the AT oil temperature warning lamp repeats
lighting for 2 sec and going out for 1 sec during
AT initial learning, set the ignition switch to OFF,
confirm that the vehicle has completely stopped,
and then start the work again from the beginning.
(a) Set the air conditioner, the headlights, other electric
loads, and the PTO switch to OFF.
(b) Apply the parking brake and lock the wheels.
NOTICE:
Lock the wheels securely.
(c) Start the engine and perform warm-up by idling for 5
minutes.
(d) Move the shift lever five times each from N to D and
from N to R.
(e) Perform operation in AT initialization mode.
(1) Check the AT oil temperature.
Standard :
40-90°C (104-194°F)
(2) Use the SST and short-circuit between
terminals 13 (TC) and 4 (CG) of DLC3.
SST 09843-18040
CAUTION:
otherwise defects may be caused.
(3) Confirm that the transmission control switch is
set to ON (O/D permission). (O/D OFF indicator
lamp not lit)
C72197 (4) With the brake pedal depressed, raise the
engine speed to 500 r/min or higher and
operate the shift lever from D → 4 → D → 4 → D
→ 4 → D within 10 seconds.
(5) Confirm rapid flashing of the AT oil temperature

warning lamp of the combination meter ASSY
in intervals of 0.2 seconds.
HINT:
• Rapid flashing of the AT oil temperature
warning lamp in intervals of 0.2 sec
indicates that transition to AT initial learning
mode has been done.
• If the AT oil temperature warning lamp is lit,
C73552 the AT oil temperature is outside the
conditions for transition to AT initial learning
AT mode. Set the ignition switch to OFF and
start again from (a).
• If the AT oil temperature warning lamp is not
lit, start again from (1).
(f) Perform AT initial learning 1.
NOTICE:
Keep the shift lever in D range and the brake
pedal depressed while performing AT initial
learning 1 and AT initial learning 2.
(1) Check the idling speed.
Standard :
600-700 r/min
(2) Move the shift lever to D range while keeping
the brake pedal depressed.
(3) Change the transmission control switch from
ON (O/D permission) to OFF (O/D prohibition).
(The O/D OFF indicator lamp lights.)
(4) Confirm slow flashing of the AT oil temperature
warning lamp in intervals of 0.5 seconds.
NOTICE:
During AT initial learning 1, keep the shift
lever in D range and the brake pedal
depressed.
HINT:
Slow flashing of the AT oil temperature warning
lamp in intervals of 0.5 sec indicates execution
C73553 of AT initial learning 1.
(5) Confirm that the AT oil temperature warning
lamp changes from slow flashing in intervals of
0.5 seconds to rapid flashing in intervals of 0.2
seconds.
HINT:
• Change of the AT oil temperature warning
lamp to rapid flashing in intervals of 0.2
seconds indicates that AT initial learning 1
has been completed.
• If AT initial learning 1 has not been
completed, the AT oil temperature warning
lamp lights and the work must be started
again from (1).
(g) Perform AT initial learning 2.

NOTICE:
Keep the shift lever in D range and the brake
(1) Within 30 seconds of completing AT initial
learning 1, bring the engine speed to between
1000 and 1500 r/min.
(2) Maintain the engine speed at 1000 to 1500 r/
min and confirm rapid flashing of the AT oil
temperature warning lamp in intervals of 0.5
seconds. AT
NOTICE:
• During AT initial learning 2, keep the shift
C73790 lever in D range and the brake pedal
depressed.
• When maintaining the engine speed,
maintain a constant speed and avoid
rapid throttle changes.
HINT:
Rapid flashing of the AT oil temperature
warning lamp in intervals of 0.5 seconds
indicates execution of AT initial learning 2.
(3) Return to idling status after the AT oil
temperature warning lamp remains lit or not lit.
HINT:
• The AT oil temperature warning lamp goes
out when AT initial learning 2 has been
completed.
lamp lights and the work must be repeated
from AT initial learning 1.
OFF (O/D prohibition) to ON (O/D permission).
(The O/D OFF indicator lamp goes out.)
(h) Perform AT initial learning 3.
NOTICE:
Keep the shift lever in R range and the brake
(1) Check the idling speed.
Standard :
600-700 r/min
(2) Move the shift lever to R range while keeping
the brake pedal depressed.
ON (O/D permission) to OFF (O/D prohibition).
(The O/D OFF indicator lamp lights.)
(4) Confirm slow flashing of the AT oil temperature

warning lamp in intervals of 0.5 seconds.
NOTICE:
During AT initial learning 3, keep the shift
lever in R range and the brake pedal
depressed.
HINT:
C73791 indicates execution of AT initial learning 3.
(5) Confirm that the AT oil temperature warning
AT lamp changes from slow flashing in intervals of
0.5 seconds to rapid flashing in intervals of 0.2
seconds.
HINT:
• Change of the AT oil temperature warning
lamp to rapid flashing in intervals of 0.2
seconds indicates that AT initial learning 3
has been completed.
from AT initial learning (1).
(i) Perform AT initial learning 4.
(1) After completion of AT initial learning 3, bring
the engine speed to between 1000 and 1500 r/
min.
(2) Maintain the engine speed at 1000 to 1500 r/
min and confirm rapid flashing of the AT oil
temperature warning lamp in intervals of 0.5
seconds.
NOTICE:
• During AT initial learning 4, keep the shift
C73792 lever in R range and the brake pedal
depressed.
• When maintaining the engine speed,
maintain a constant speed and avoid
rapid throttle changes.
HINT:
indicates execution of AT initial learning 4.
(3) Bring the engine to idle status after the AT oil
temperature warning lamp remains lit or goes
out for two seconds and lights for 1 second.
HINT:
• When AT initial learning 4 has been
lamp repeats lighting for two seconds and
going out for one second.
C73793 completed, the AT oil temperature warning
from AT initial learning 3.
(j) Move the shift lever to P range.

(k) Remove the short-circuit between terminals 13 (TC)
and 4 (CG) of DLC3.
(l) Stop the engine.
9. RUNNING TEST
CAUTION:
Perform the test while paying sufficient attention to road safety.
NOTICE:
• Always perform this test after engine inspection and adjustment.
• Perform this test with the oil temperature of normal running condition (50 to 80°C, 122 to
176°F).
• Perform this test with the air conditioner switched off. AT
HINT:
Running test table
Inspection item Inspection and confirmation outline
Inspect gear 1 ↔ gear 2 ↔ gear 3 ↔ gear 4 ↔ gear 5 ↔ gear 6 shifting with normal
D range shift function
driving (driving on general city streets).
Shift shock level while running in D range Check the shock level each time the gear is shifted up during normal driving.
In the range of gear 6, move the transmission control switch between ON and OFF
Operation of the transmission control switch
and check shifting between gear 6 and gear 5.
• Perform kick-down for each gear and check that down-shifting is performed.
Kick-down function
• Check the shock level at the time of kick-down.
• While driving with gear 5 in the D range (approximately 55 to 65 km/h), shift
from D range to range 4 and check the engine brake operation with gear 4.
Engine brake operation
• While driving with gear 4 in range 4 (approximately 30 to 40 km/h), shift from D
range to L-3 range and check the engine brake operation with gear 3.
Start driving in D range with fully depressed accelerator pedal and check that the
Shifting point with fully open accelerator pedal
up-shift speed from gear 1 to gear 2 is suitable for the shifting point
While driving on a level road at a constant speed in the lock-up speed range,
Lock-up function confirm that the engine speed does not change much when the accelerator pedal is
depressed lightly.
Stop the vehicle on a slope (approximately 5( or more), shift to P range, and confirm
P range operation
that the vehicle does not move when the parking brake is released.
Abnormal noise, vibrations Inspect for abnormal noise and vibrations while driving and shifting.
Oil leakage After the running test, inspect all parts for oil leakage.
10. MANUAL DRIVING TEST

(a) Disconnect the two connectors of the transmission wire.
(b) While driving, check that shifting to the suitable gear is done in each range.
Standard:
Shift lever position Position
D range gear 3
Range 4 gear 3
L-3 range gear 3
(c) Delete the diagnostic code after the manual driving test.
DIAGNOSIS CODE TABLE

O/D OFF Check AT
DTC No. Diagnosis item Code
Inspection part indicator indicator
(listed page) [terminal symbol] memory
lamp lamp
Vehicle speed sensor • Wire harness and connector (SP1 signal system)
P0500/42 O
system • Combination meter ASSY O O
(AT-68) *1
[SP1] • Transmission control computer ASSY
Power supply line • ECY +B fuse
P0562/11
abnormal • Wire harness and connector (+B signal system) O O O
(AT-71)
[+B] • Transmission control computer ASSY
• Wire harness and connector (P, R, N, D, 4, 3 signal
Shift position SW
P0705/43 system)
AT (AT-73)
system
[P, N]
• Neutral start switch ASSY
O O O
• Transmission control computer ASSY
D range pressure • Wire harness and connector (PSW8 signal system)
P0706/44
abnormal • Automatic transmission ASSY (PSW8) O O O
(AT-77)
[PSW8] • Transmission control computer ASSY
• Wire harness and connector (oil temperature sensor
P0710/38 Oil temperature system signal system)
X X O
(AT-80) [ATF+] • Temperature sensor (in the valve body)
NCO speed sensor • Wire harness and connector (NT signal system)
P0715/12
system • Speed sensor (NT) O O O
(AT-83)
[S-B, NT-] • Transmission control computer ASSY
Vehicle speed sensor • Wire harness and connector (SP2 signal system)
P0720/61 O
No. 2 system • Speed sensor (SP2) O O
(AT-86) *1
[S-B, NO-] • Transmission control computer ASSY
NE communication line • Wire harness and connector (NE signal system)
P0725/86
system • Engine control computer O O O
(AT-89)
[NE+] • Transmission control computer ASSY
• Transmission solenoid ASSY (S1)
P0730/37 • Transmission solenoid ASSY (S3)
Gear ratio trouble O O O
(AT-92) • Transmission solenoid ASSY (SL1)
• Transmission solenoid ASSY (SL2)
• Automatic transmission ASSY
• Wire harness and connector (PSW1 signal system)
P0746/31 Control valve 1 system • Automatic transmission ASSY (PSW1)
O O O
(AT-96) [PSW1] • Transmission solenoid ASSY (SL1)
Linear solenoid 1 • Wire harness and connector (SL1 signal system)
P0748/25
trouble • Transmission solenoid ASSY (SL1) O O O
(AT-101)
[SL1+, SL1-] • Transmission control computer ASSY
P0751/45 Shift valve 1 system • Automatic transmission ASSY (PSW3)
O O O
(AT-105) [PSW3] • Transmission solenoid ASSY (S1)
P0756/46 Shift valve 2 system • Automatic transmission ASSY (PSW4)
O O O
(AT-105) [PSW4] • Transmission solenoid ASSY (S2)
P0761/47 Shift valve 3, 4 system • Automatic transmission ASSY (PSW5)
O O O
(AT-105) [PSW 5] • Transmission solenoid ASSY (S3)
P0761/48 Shift valve 3, 4 system • Automatic transmission ASSY (PSW6)
O O O
(AT-105) trouble [PSW6] • Transmission solenoid ASSY (S3)
O O O
O/D OFF Check AT

DTC No. Diagnosis item Code
Inspection part indicator indicator
(listed page) [terminal symbol] memory
lamp lamp
P0778/26
(AT-101)
EFI communication • Wire harness and connector (Communication signal
P0863/88 trouble system)
O X O
(AT-110) [EFI+, EFI-, ECT+, • Engine control computer
ECT-] • Transmission control computer ASSY
Shift solenoid 1 system • Wire harness and connector (S1 signal system)
P0973/62
(Low) • Transmission solenoid ASSY (S1) O O O
(AT-113)
[S1] • Transmission control computer ASSY
Shift solenoid 1 system • Wire harness and connector (S1 signal system) AT
P0974/62
(High) • Transmission solenoid ASSY (S1) O O O
(AT-113)
P0976/63
(AT-113)
P0977/63
(AT-113)
P0979/64
(AT-113)
P0980/64
(AT-113)
Hydraulic pressure • Wire harness and connector (S4 signal system)
P0985/65
solenoid system (Low) • Transmission solenoid ASSY (S4) O X O
(AT-117)
Hydraulic pressure • Wire harness and connector (S4 signal system)
P0986/65
solenoid system (High) • Transmission solenoid ASSY (S4) O X O
(AT-117)
Exhaust brake
P1604/24 • Accelerator position sensor
operation signal trouble O X O
(AT-120) • Transmission control computer ASSY
[EFI+, EFI-]
Exhaust brake • Wire harness and connector (serial communication signal
P1604/54
operation signal trouble system) O X O
(AT-122)
[EXBK] • Transmission control computer ASSY
PTO solenoid system • Wire harness and connector (POS signal system)
P1911/51
(Low) • PTO solenoid X X O
(AT-124)
[POS] • Transmission control computer ASSY
Pressure control • Wire harness and connector (S4 signal system)
P2716/28
solenoid system • Line pressure control solenoid (SL4) O O O
(AT-127)
• Wire harness and connector (oil temperature sensor
Oil temperature sensor
P2740/17 signal system)
No. 2 system O X O
(AT-130) • Temperature sensor (transmission body)
[TC+]
O O O
P2759/27
(AT-132)
• Torque converter ASSY
P2764/36 Lock-up trouble
• Transmission solenoid ASSY (SL3) X X O
(AT-135) [SL3+, SL3-]
• Transmission valve body ASSY
NOTICE:
*1...The check AT indicator lamp lights only at the time of simultaneous output of PO500/42
(vehicle sensor system) and PO720/61 (vehicle sensor system).
AT
COMPONENTS
AT
C73308
AT
ATM75-001
ECU TERMINAL LAYOUT
AT
C73314
1. Transmission control computer [A860E]
AT
C73031
Terminal layout
Terminal symbol
I/O Item Measuring condition Reference value
[terminal No.]
S1 ↔ GND1
Output Voltage Shift lever P range (pressure switch 3 OFF) 0-3V
[A1 ↔ B8]
S1 ↔ GND1
Output Voltage Shift lever R range (pressure switch 3 ON) 15-32V
[A1 ↔ B8]
S2 ↔ GND1
Output Voltage Shift lever P range (pressure switch 4 ON) 15-32V
[A2 ↔ B8]
S2 ↔ GND1
Output Voltage Running with gear 2 (pressure switch 4 OFF) 0-3V
[A2 ↔ B8]
S3 ↔ GND1
Output Voltage Shift lever P range (pressure switch 6 ON) 15-32V
[A3 ↔ B8]
S3 ↔ GND1
Output Voltage Running with gear 2 (pressure switch 6 OFF) 0-3V
[A3 ↔ B8]
SL3+ ↔ SL3-
Output Waveform Engine at idle speed Waveform 1
[A5 ↔ A4]
SL2+ ↔ SL2-
[A7 ↔ A6]
SL1+ ↔ SL1-
[A9 ↔ A8]
BK ↔ GND1
Input Voltage Brake pedal depressed (switch ON) 15-32V
[A10 ↔ B8]
BK ↔ GND1
Input Voltage Brake pedal released (switch OFF) 0-3V
[A10 ↔ B8]
PSW7 ↔ GND1
Input Voltage Shift lever D range, vehicle stopped (pressure switch 7 ON) 0-3V
[A11 ↔ B8]
PSW7 ↔ GND1
Input Voltage Shift lever P range, vehicle stopped (pressure switch 7 OFF) 12-32V
[A11 ↔ B8]
SPD1 ↔ GND1
Input Waveform Running with vehicle speed 20 km/h Waveform 4
[A12 ↔ B8]
CPTO ↔ GND1
Output Voltage PTO switch ON 15-32V
[A13 ↔ B8]
CPTO ↔ GND1
Output Voltage PTO switch OFF 0-3V
[A13 ↔ B8]
L ↔ GND1
Input Voltage Shift lever L-3 range 15-32V
[A17 ↔ B8]
L ↔ GND1
Input Voltage Shift lever other than L-3 range 0-3V
[A17 ↔ B8]
2 ↔ GND1
Input Voltage Shift lever 4 range 15-32V
[A18 ↔ B8]
2 ↔ GND1
Input Voltage Shift lever other than 4 range 0-3V
[A18 ↔ B8]
Terminal symbol
[terminal No.]
D ↔ GND1
Input Voltage Shift lever D range 15-32V
[A19 ↔ B8]
D ↔ GND1
Input Voltage Shift lever other than D range 0-3V
[A19 ↔ B8]
P ↔ GND1
Input Voltage Shift lever P range 15-32V
[A20 ↔ B8]
P ↔ GND1
Input Voltage Shift lever other than P range 0-3V
[A20 ↔ B8]
SL4+ ↔ SL4-
[A21 ↔ A31]
BFC ↔ GND1
Input Voltage Exhaust brake switch OFF 0-3V
AT
[A22 ↔ B8]
BFC ↔ GND1
Input Voltage Exhaust brake switch ON 15-32V
[A22 ↔ B8]
APTO ↔ GND1
Input Voltage Engine stopped, ignition switch ON 15-32V
[A25 ↔ B8]
PSW8 ↔ GND1
Input Voltage Shift lever P range (pressure switch 8 OFF) 12-32V
[A26 ↔ B8]
PSW8 ↔ GND1
Input Voltage Shift lever D range (pressure switch 8 ON) 0-3V
[A26 ↔ B8]
E2 ↔ Body earth
- Conductivity Always Conductivity
[B8]
N ↔ GND1
Input Voltage Shift lever N range 15-32V
[A29 ↔ B8]
N ↔ GND1
Input Voltage Shift lever other than N range 0-3V
[A29 ↔ B8]
R ↔ GND1
Input Voltage Shift lever R range 15-32V
[A30 ↔ B8]
R ↔ GND1
Input Voltage Shift lever other than R range 0-3V
[A30 ↔ B8]
SP2+ ↔ GND1
Input Voltage Engine at idle speed 7-9V
[B1 ↔ B8]
SP2- ↔ GND1
Input Waveform Running with vehicle speed 20 km/h Waveform 6
[B2 ↔ B8]
IG2 ↔ GND1
[B3 ↔ B8]
IG1 ↔ GND1
[B4 ↔ B8]
S4 ↔ GND1 Shift lever P range, engine at idle speed (pressure switch 8
Output Voltage 15-32V
[B5 ↔ B8] OFF)
S4 ↔ GND1
Output Voltage Running with gear 2 (pressure switch 8 ON) 0-3V
[B5 ↔ B8]
PTOS ↔ GND1
Output Voltage PTO switch ON 15-32V
[B6 ↔ B8]
PTOS ↔ GND1
Output Voltage PTO switch OFF 0-3V
[B6 ↔ B8]
+B ↔ GND1
[B7 ↔ B8]
GND1 ↔ Body earth
- Conductivity Always Conductivity
[B8]
POS ↔ GND1
[B10 ↔ B8]
DG ↔ GND1
Input Voltage DLC3 TC-CG short-circuited 0-3V
[B13 ↔ B8]
DG ↔ GND1
Input Voltage DLC3 TC-CG open 12-32V
[B13 ↔ B8]
Terminal symbol
[terminal No.]
OD2 ↔ GND1
Input Voltage Transmission control switch ON (gear 4 permitted) 12-32V
[B14 ↔ B8]
OD2 ↔ GND1
Input Voltage Transmission control switch OFF (gear 4 prohibited) 0-3V
[B14 ↔ B8]
OIL ↔ E2
Input Voltage Engine stopped, ignition switch ON 0.1-4.9V
[B15 ↔ A28]
OIL2 ↔ E2
Input Voltage Engine stopped, ignition switch ON 0.4-4.9V
[B16 ↔ A28]
GND2 ↔ Body earth
- Voltage Always Conductivity
[B17]
AT OILW ↔ GND1
Output Voltage AT oil temperature warning lamp lit 0-3V
[B19 ↔ B8]
OILW ↔ GND1
Output Voltage AT oil temperature warning lamp not lit 15-32V
[B19 ↔ B8]
ECT- ↔ GND1
[B20 ↔ B8]
ECT+ ↔ GND1
[B21 ↔ B8]
EFI- ↔ GND1
Input Waveform Engine at idle speed Waveform 7
[B23 ↔ B8]
EFI+ ↔ GND1
[B24 ↔ B8]
NT- ↔ GND1
[C1 ↔ B8]
DGLP ↔ GND1
Input Voltage Transmission control switch ON (gear 4 permitted) 0-3V
[C2 ↔ B8]
DGLP ↔ GND1
Input Voltage Transmission control switch OFF (gear 4 prohibited) 15-32V
[C2 ↔ B8]
PSW4 ↔ GND1
Input Voltage Shift lever P range, engine stopped (pressure switch 4 ON) 0-3V
[C5 ↔ B8]
PSW4 ↔ GND1
Input Voltage Running with gear 2 (pressure switch 4 OFF) 12-32V
[C5 ↔ B8]
PSW1 ↔ GND1
Input Voltage Shift lever P range, engine stopped (pressure switch 1 OFF) 12-32V
[C6 ↔ B8]
PSW1 ↔ GND1
Input Voltage Running with gear 2 (pressure switch 1 ON) 0-3V
[C6 ↔ B8]
NE ↔ GND1
[C7 ↔ B8]
WGLP ↔ GND1
Output Voltage For 3 seconds after ignition switch ON (when the lamp is lit) 0-3V
[C10 ↔ B8]
WGLP ↔ GND1 For 3 seconds after ignition switch ON (when the lamp is not
Output Voltage 15-32V
[C10 ↔ B8] lit)
PSW5 ↔ GND1
Input Voltage Shift lever P range, engine stopped (pressure switch 5 ON) 0-3V
[C11 ↔ B8]
PSW5 ↔ GND1
[C11 ↔ B8]
PSW2 ↔ GND1
Input Voltage Shift lever R range (pressure switch 2 ON) 0-3V
[C12 ↔ B8]
PSW2 ↔ GND1
Input Voltage Shift lever D range (pressure switch 2 OFF) 15-32V
[C12 ↔ B8]
SIL ↔ GND1
Output Waveform When the SST is connected to DLC3 Waveform 11
[C13 ↔ B8]
PSW6 ↔ GND1
Input Voltage Shift lever P range, vehicle stopped (pressure switch 6 ON) 0-3V
[C16 ↔ B8]
PSW6 ↔ GND1
[C16 ↔ B8]
Terminal symbol
[terminal No.]
PSW3 ↔ GND1
Input Voltage Shift lever P range (pressure switch 3 OFF) 12-32V
[C17 ↔ B8]
PSW3 ↔ GND1
Input Voltage Shift lever R range (pressure switch 3 ON) 0-3V
[C17 ↔ B8]
(a) Waveform 1 (SL3)

Item Contents
Measuring terminal SL3+ ↔ SL3-
Instrument setting 10V/DIV, 500µs/DIV
Measuring condition Engine at idle speed
AT
C73540
(b) Waveform 2 (SL2)

Item Contents
Measuring condition Shift lever P range, engine at idle speed
C73541
(c) Waveform 3 (SL1)

Item Contents
Measuring condition Shift lever P range, engine at idle speed
C73540
(d) Waveform 4 (speed sensor SP1)

Item Contents
Measuring terminal SPD1 ↔ GND1
Instrument setting 2V/DIV, 20ms/DIV
Measuring condition Running with vehicle speed of 20 km/h
HINT:
The waveform cycle becomes shorter with
increasing vehicle speed.
C72206
(e) Waveform 5 (line pressure control solenoid ASSY

(SL4))
Item Contents
HINT:
The waveform duty ratio decreases with increasing
C72189 throttle opening.
AT (f) Waveform 6 (speed sensor (SP2))

Item Contents
Measuring terminal SP2- ↔ GND1
Instrument setting 500mv/DIV, 2ms/DIV
HINT:
C73543
(g) Waveform 7 (communication line)

Item Contents
Measuring terminal EFI- ↔ GND1, ECT- ↔ GND1
C72207
(h) Waveform 8 (communication line)

Item Contents
Measuring terminal EFI+ ↔ GND1, ECT+ ↔ GND1
C72208
(i) Waveform 9 (speed sensor (NT-))

Item Contents
Measuring terminal NT- ↔ GND1
Instrument setting 500mv/DIV, 500µs/DIV
HINT:
C73544
(j) Waveform 10 (speed sensor (NE))

Item Contents
Measuring terminal NE ↔ GND1
HINT:
C62234
(k) Waveform 11 (communication line) AT

Item Contents
Measuring terminal SIL ↔ GND1
Measuring condition SST connected, communication established
HINT:
C31918
SYMPTOM TABLE
ELECTRONIC CONTROL SYSTEM
See chapter or see
Symptom Inspection range
page
1. Transmission solenoid ASSY (S2, S3) 1. AT-92
No shifting up (from gear 1 to gear 2) 2. Transmission solenoid ASSY (SL1) 2. AT-92
3. Transmission control computer ASSY 3. AT-59
1. Transmission solenoid ASSY (S1) 1. AT-92
No shifting up (from gear 2 to gear 3) 2. Transmission solenoid ASSY (SL1, SL2) 2. AT-92
AT No shifting up (from gear 3 to gear 4) 2. Transmission solenoid ASSY (SL1, SL2)
3. Transmission control computer ASSY
2. AT-92
3. AT-59
No shifting up (from gear 4 to gear 5) 2. Transmission solenoid ASSY (SL1, SL2) 2. AT-92
1. Transmission solenoid ASSY (SL1, SL2) 1. AT-92
No shifting up (from gear 5 to gear 6) 2. Transmission control switch system 2. AT-139
No shifting down (from gear 6 to gear 5) 2. Transmission control switch system 2. AT-139
No shifting down (from gear 5 to gear 4) 2. Transmission control switch system (SL1, SL2) 2. AT-92
1. Transmission solenoid ASSY (S2, S3) 1. AT-92
No shifting down (from gear 2 to gear 1) 2. Transmission control switch system (SL1) 2. AT-92
1. Transmission solenoid ASSY (SL3) 1. AT-135
2. Speed sensor (NT) system 2. AT-83
Lock-up does not switch ON or OFF 3. Stop lamp switch ASSY system 3. AT-137
4. Temperature sensor (in the valve body) 4. AT-80
1. Accelerator position sensor system (NO4C) 1. ES
3. Speed sensor (SP2) system 3. AT-86
Bad shifting point
5. Neutral start switch ASSY system 5. AT-73
7. Temperature sensor (in the transmission body) 7. AT-130
Shifting to gear 4 in the shift position L-3 range
Shifting to gear 5 in the shift position 4 range
Shifting up to gear 5 or 6 while the transmission is cold
Large shifting shock (N → D)
1. Accelerator position sensor system (NO4C) 1. ES
Large shifting shock (at any gear change)
See chapter or see

Symptom Inspection range
page
2. Speed sensor (SP2) system 2. AT-86
Large shock at the time of lock-up
Bad acceleration
The engine stops when going into D or R range after 1. Transmission solenoid ASSY (SL3) 1. AT-135
engine start or when the vehicle is stopped. 2. Transmission control computer ASSY 2. AT-59
AT
DTC P0500/42 VEHICLE SPEED SENSOR SYSTEM

Control of shift and lock-up is performed by input of the vehicle speed signal from the combination meter
ASSY to the transmission control computer ASSY.
1. Diagnosis conditions
2. Trouble status
DTC No. Inspection part
3. Trouble length
4. Others
1. While running other than in P or N range (SP2 normal)
2. No input of the SP1 signal during input of the SP2 • Wire harness and connector (SP1 signal system)
AT P0500/42 signal • Combination meter ASSY
3. Consecutively 500 times established • Transmission control computer ASSY
4. 2 trips
CIRCUIT DIAGRAM
4P OUT SPD1
Transmission
Combination
control
meter
computer
ASSY
ASSY
C73586
1 INSPECT TRANSMISSION CONTROL COMPUTER ASSY BY ITSELF (SPD1)
(a) Connect an oscilloscope between connector terminals

A12 (SPD1) and B8 (GND1) of the transmission control
computer ASSY.
AT
C73587
(b) Inspect the waveform between the terminals of the

transmission control computer ASSY.
Standard:
Item Contents
Measuring terminal SPD1 ↔ GND1
HINT:
C72206 The waveform cycle becomes shorter with increasing
vehicle speed.
OK Inspect and replace the transmission control
computer ASSY.
NG
2 INSPECT WIRE HARNESS AND CONNECTOR (COMBINATION METER ASSY -

TRANSMISSION CONTROL COMPUTER ASSY)
(a) Conductivity inspection

(1) Disconnect connector A of the transmission control
computer ASSY and connector A of the combination
meter ASSY.
(2) Check the conductivity between the connector on
the wire harness side of the transmission control
computer ASSY and the connector on the wire
AT harness side of the combination meter ASSY. (Refer
to AT-59 for the terminal layout.)
Standard:
Terminal No. (terminal symbol)
Conductivity
(Transmission computer↔meter)
A12 (SPD1) ↔ A38 (4P OUT) Yes
(b) Insulation inspection

(1) Check the insulation between the connector on the
wire harness side of the transmission control
computer ASSY and body earth. (Refer to AT-59 for
the terminal layout.)
Standard:
Conductivity
(Transmission computer)
A12 (SPD1) ↔ Body earth No
C73588
NG Repair or replace wire harness and

connector.
OK
Inspect and replace the combination meter ASSY.

DTC P0562/11 POWER SUPPLY LINE ABNORMAL

The battery voltage is applied at the +B terminal when the ignition switch is ON.
When trouble has occurred in this +B voltage signal system, the transmission control computer ASSY
puts out a diagnostic code.
Detection condition 1
2. Trouble status
3. Trouble length
4. Others
1. For 0.2 sec after ignition switch OFF AT
• ECU +B fuse
2. Wire break or short-circuit of the +B terminal circuit
P0562/11 • Wire harness and connector (+B signal system)
3. None
4. 2 trips
DTC No. 2. Trouble status Inspection part
3. Trouble length
1. Ignition switch OFF
• ECU +B fuse
2. The engine does not stop within 15 sec after ignition
P0562/11 • Wire harness and connector (+B signal system)
switch OFF
3. None
CIRCUIT DIAGRAM
ECU +B fuse Transmission

+B
control
computer ASSY
C73297
1 INSPECT FUSE (ECU +B)
(a) Check for continuity between the terminals.

Standard:
Conductivity
NG Replace the fuse (ECU +B)
OK
AT
2 INSPECT TRANSMISSION CONTROL COMPUTER ASSY BY ITSELF (INSPECT VOLTAGE)

(b) Check the voltage between the terminals of the
transmission control computer ASSY. (Refer to AT-59 for
Standard:
Terminal No. (terminal symbol) Voltage [V]
B7 (+B) ↔ B8 (GND1) 20-32
C73589
connector.
OK
Inspect and replace the transmission control computer ASSY.

DTC P0705/43 SHIFT POSITION SW SYSTEM

Shift position detection is performed by input of the signal from the neutral start switch ASSY to the
transmission control computer ASSY. In case of abnormalities for the P, R, N, D, 4, and 3 signals of the
neutral start switch ASSY, the transmission control computer ASSY puts out a diagnostic code.
3. Trouble length
1. At the time of engine start • Wire harness and connector (P, R, N, D, 4, 3 signal
2. Input of an R, D, 4, 3 signal at the time of P or N signal system) AT
P0705/43
input • Neutral start switch ASSY system
3. None • Transmission control computer ASSY
3. Trouble length
1. None
2. Input of the OFF signal of the hydraulic pressure
system)
P0705/43 switch 8 when there is no input of P, R, N, D, 4, and 3
• Neutral start switch ASSY system
signals (all switches OFF)
3. None
3. Trouble length
1. None • Wire harness and connector (P, R, N, D, 4, 3 signal
2. Input of none of the P, R, N, D, 4, and 3 signals (all system)
P0705/43
switches OFF) • Neutral start switch ASSY system
3. 30 sec or more • Transmission control computer ASSY
3. Trouble length
1. None
• Wire harness and connector (SP1 signal system)
2. Input of D, 4, or 3 signal during input of the OFF signal
P0705/43 • Combination meter ASSY
of hydraulic switch
3. Three times in a row
3. Trouble length
1. At the time of shift lever R ↔ D operation
system)
P0705/43 2. No N signal input
3. Trouble length
1. At the time of shift lever P ↔ N operation
system)
P0705/43 2. No R signal input
3. Trouble length
1. None • Wire harness and connector (P, R, N, D, 4, 3 signal
2. Simultaneous output of two or more signals out of P, system)
P0705/43
R, N, D, 4, and 3 • Neutral start switch ASSY system
3. 0.5 sec or more • Transmission control computer ASSY
3. Trouble length
AT 1. None • Wire harness and connector (P, R, N, D, 4, 3 signal
2. Input of P, R, or N signal during input of the ON signal system)
P0705/43
of hydraulic switch 8 • Neutral start switch ASSY system
3. None • Transmission control computer ASSY
CIRCUIT DIAGRAM
C73319
1 INSPECT WIRE HARNESS AND CONNECTOR (POWER SUPPLY SYSTEM)
(a) Disconnect the connector of the neutral start switch

ASSY.
(b) Check the connector terminal voltage on the wire
harness side.
Standard:
10 (B) ↔ Body earth 15-32 AT
C73046
NG Inspect the power supply system.
OK
2 INSPECT NEUTRAL START SWITCH ASSY BY ITSELF
(a) Disconnect the connector of the neutral start switch

ASSY.
(b) Check for continuity between the terminals.
Standard:
Terminal No.
Shift position Conductivity
(terminal symbol)
P range 4 (RB) ↔ 5 (PL) Yes
P range 6 (L) ↔ 10 (B) Yes
R range 4 (RB) ↔ 9 (RL) Yes
C73045
N range 4 (RB) ↔ 1 (NL) Yes
N range 6 (L) ↔ 10 (B) Yes
D range 4 (RB) ↔ 8 (DL) Yes
4 range 4 (RB) ↔ 2 (2L) Yes
L-3 range 4 (RB) ↔ 7 (LL) Yes
NG Replace the neutral start switch ASSY.
OK
3 INSPECT WIRE HARNESS AND CONNECTOR (NEUTRAL START SWITCH ASSY -

(a) Connect the connector of the neutral start switch ASSY.

(b) Disconnect connector A of the transmission control
computer ASSY.
(c) Set the ignition switch to ON and check the voltage
between the terminals. (Refer to AT-59 for the terminal
layout.)
Standard:
AT Terminal No.
Shift position Voltage [V]
(terminal symbol)
C73590 P range A20 (P) ↔ B8 (GND1) 15-32
Other than P range A20 (P) ↔ B8 (GND1) 0-3
R range A30 (R) ↔ B8 (GND1) 15-32
Other than R range A30 (R) ↔ B8 (GND1) 0-3
N range A29 (N) ↔ B8 (GND1) 15-32
Other than N range A29 (N) ↔ B8 (GND1) 0-3
D range A19 (D) ↔ B8 (GND1) 15-32
Other than D range A19 (D) ↔ B8 (GND1) 0-3
4 range A18 (2) ↔ B8 (GND1) 15-32
Other than 4 range A18 (2) ↔ B8 (GND1) 0-3
L-3 range A17 (L) ↔ B8 (GND1) 15-32
Other than L-3 range A17 (L) ↔ B8 (GND1) 0-3

connector.
OK

DTC P0706/44 D RANGE PRESSURE TROUBLE

Eight pressure switches are installed in the valve body. The oil passages in the valve body are switched
according to the operation status of each solenoid, each shift valve, and each control valve etc., and the
pressure switches are switched ON or OFF. Pressure switch 8 operates according to the status of the D
range pressure. If trouble occurs in this PSW8 signal system or in the valve body system, the
transmission control computer ASSY puts out a diagnostic code.
DTC No. 2. Trouble status
3. Trouble length
Inspection part
AT
1. At the time of D, 4, L-3 range • Wire harness and connector (PSW8 signal system)
P0706/44 2. Hydraulic pressure switch 8 OFF • Automatic transmission ASSY (PSW8)
3. 0.5 sec or longer three times in a row • Transmission control computer ASSY
3. Trouble length
1. Engine rotating in P, R, or N range • Wire harness and connector (PSW8 signal system)
P0706/44 2. Hydraulic pressure switch 8 ON • Automatic transmission ASSY (PSW8)
3. Continuously for 0.5 seconds or longer • Transmission control computer ASSY
CIRCUIT DIAGRAM
Automatic transmission ASSY
Pressure switch 8
PSW8 PSW8 Transmission
control
computer ASSY
C73300

(b) Check the terminal voltage the transmission control
computer ASSY. (Refer to AT-59 for the terminal layout.)
Standard:
Terminal No.
Measuring condition Voltage [V]
(terminal symbol)
AT A26 (PSW8) ↔ B8 (GND1)

P range
12-32
(pressure switch 8 OFF)
D range
A26 (PSW8) ↔ B8 (GND1) 0-3
C73591
(Pressure switch 8 ON)
NG Inspect and replace the transmission control

computer ASSY.
OK
2 INSPECT WIRE HARNESS AND CONNECTOR (TRANSMISSION CONTROL COMPUTER

ASSY - TRANSMISSION WIRE)
(a) Disconnect connector B of the transmission wire.

(c) Check the voltage between the terminals of the
connector on the wire harness side of the transmission
wire and the connector on the body earth side.
Standard:
Terminal No.
(terminal symbol)
P range
A26 (PSW8) ↔ Body earth 12-32
C73592 (pressure switch 8 OFF)

connector.
OK
3 INSPECT TRANSMISSION WIRE BY ITSELF
(a) Disconnect the transmission wire.

Standard:
Terminal No. (terminal symbol) Conductivity
B6 (PSW8) ↔ PSW8 Yes
AT
C73047
NG Repair or replace the transmission wire.
OK
Replace the automatic transmission ASSY.

DTC P0710/38 OIL TEMPERATURE SENSOR SYSTEM

An oil temperature sensor is installed in the valve body, it detects the oil temperature in the transmission
hydraulic pressure circuit, and it provides a signal corresponding to the oil temperature to the transmission
control computer ASSY.
3. Trouble length
1. None • Wire harness and connector (oil temperature sensor
2. Oil temperature sensor resistance below 90 Ω or 310 signal system)
AT P0710/38
kΩ or higher • Temperature sensor (in the valve body)
CIRCUIT DIAGRAM
ATF+ OIL
Transmission
Temperature sensor control
(in the valve body) computer ASSY
ATF– E2
C73593
1 INSPECT TRANSMISSION WIRE (OIL TEMPERATURE SENSOR)

(b) Check the resistance between the terminals.
Standard:
Terminal No. Oil temperature
Resistance value [kΩ]
(terminal symbol) [°C (°F)]
B3 (ATF+) ↔ B8 (ATF-) 10 (50) 6.445±0.645
B3 (ATF+) ↔ B8 (ATF-) 110 (230) 0.247±0.016 AT
(c) Check the insulation of the terminals.
C73594 Standard:
Terminal No. (terminal symbol) Resistance value [kΩ]
B3 (ATF+) ↔ Body earth 1 MΩ or more
NG To step 3
OK
2 INSPECT WIRE HARNESS AND CONNECTOR (TRANSMISSION WIRE - TRANSMISSION

CONTROL COMPUTER ASSY)
(a) Connect connector B of the transmission wire.

(b) Disconnect connector A and connector B of the
(c) Check the resistance between the terminals.
Standard:
B15 (OIL) ↔ A28 (E2) 10 (50) 6.445±0.645
B15 (OIL) ↔ A28 (E2) 110 (230) 0.247±0.016
C73595

connector.
OK

3 INSPECT TEMPERATURE SENSOR BY ITSELF
(a) Remove the temperature sensor.

(b) Immerse the sender part of the temperature sensor into a vessel filled with original Toyota Auto Fluid
Type T-IV.
(c) Heat the fluid and check the resistance between the terminals.
Standard:
Oil temperature [°C (°F)] Resistance value [kΩ]
10 (50) 6.445±0.645
AT 110 (230) 0.247±0.016
NOTICE:
Take care not to heat the oil excessively, as the oil may catch fire.
NG Replace the automatic transmission ASSY.
OK
Repair or replace the transmission wire.

DTC P0715/12 NC0 SPEED SENSOR SYSTEM

This is provided as signal input from the turbine speed sensor (NT) to the engine control computer. The
turbine speed sensor (NT) signal and the vehicle speed sensor (SP2) signal are used to control engine
torque and shift timing. Also, lock-up control is performed based on the engine speed signal.
2. Trouble status
3. Trouble length
4. Others
1. Driving
2. No input of the turbine speed
• Wire harness and connector (NT signal system) AT
P0715/12 • Speed sensor (NT)
3. Continuously for 0.5 seconds or longer
4. 2 trips
CIRCUIT DIAGRAM
B1
NIN+ S–B
Transmission
Speed sensor (NT) control
computer ASSY
C1
NIN– NT–
C73321

(b) Check the voltage between the terminals off the
transmission control computer.
Standard:
Terminal No.
(terminal symbol)
AT B1 (SP2+) ↔ B8 (GND1) Engine at idle speed 7-9
NG To step 3
C73785
OK
2 INSPECT TRANSMISSION CONTROL COMPUTER ASSY BY ITSELF (INSPECT

WAVEFORM)
(a) Connect an oscilloscope between terminals C1 (NT-)

and B8 (GND1) of the transmission control computer
ASSY.
C73788

Standard:
Item Contents
Measuring terminal NT- ↔ GND1
Instrument setting 500mv/DIV, 500µs/DIV
HINT:
vehicle speed.
computer ASSY.
NG
3 INSPECT WIRE HARNESS AND CONNECTOR (SPEED SENSOR (NT) - TRANSMISSION

(a) Inspect conductivity

(1) Disconnect the connector of the speed sensor (NT)
and connectors B and C of the transmission control
computer ASSY.
harness side of the speed sensor (NT). (Refer to AT- AT
59 for the terminal layout.)
Standard:
Conductivity
(Transmission computer ↔ speed sensor)
B1 (SP2+) ↔ 1 (NIN+) Yes
C1 (NT-) ↔ 2 (NIN-) Yes
(b) Inspect insulation

Standard:
C73786

Conductivity
B1 (SP2+) ↔ Body earth No
C1 (NT-) ↔ Body earth No

connector.
OK
Replace speed sensor (NT).

DTC P0720/61 VEHICLE SPEED SENSOR NO. 2 SYSTEM

This is provided as an input signal from the vehicle speed sensor (SP2) to the transmission control
computer ASSY. The turbine speed sensor (NT) signal and the vehicle speed sensor (SP2) signal are
used to control engine torque and shift timing.
2. Trouble status
3. Trouble length
4. Others
1. Running (other than P or N range)
AT 2. No input of 1 pulse of the SP2 signal during 4 pulses • Wire harness and connector (SP2 signal system)
P0720/61 of the SPD1 sensor signal • Speed sensor (SP2)
3. Consecutively 500 times established • Transmission control computer ASSY
4. 2 trips
CIRCUIT DIAGRAM
SP2+ B1
SP2+
Transmission
Speed sensor (SP2) control
computer ASSY
SP2– B2
SP2–
C73322

transmission control computer.
Standard:
Terminal No.
(terminal symbol)
B1 (SP2+) ↔ B8 (GND1) Engine at idle speed 7-9 AT
NG To step 3
C73785
OK
2 INSPECT TRANSMISSION CONTROL COMPUTER ASSY BY ITSELF (INSPECT

WAVEFORM)
(a) Connect an oscilloscope between terminals B2 (SP2-)

and B8 (GND1) of the transmission control computer
ASSY.
C73787

Standard:
Item Contents
Measuring terminal SP2- ↔ GND1
Instrument setting 500mv/DIV, 2ms/DIV
HINT:
vehicle speed.
computer ASSY.
NG
3 INSPECT WIRE HARNESS AND CONNECTOR (SPEED SENSOR (SP2) - TRANSMISSION


(1) Connect the connector of the speed sensor (SP2)
and disconnect connector B of the transmission
AT harness side of the speed sensor (SP2). (Refer to
AT-59 for the terminal layout.)
Standard:
Conductivity
(Transmission computer ↔ speed sensor)
B1 (SP2+) ↔ 1 (SP2+) Yes
C1 (NT-) ↔ 2 (SP2-) Yes
(b) Inspect Insulation

(1) Ceck the insulation between the connector on the
Standard:
C73789

Conductivity
B1 (SP2+) ↔ Body earth No
C1 (NT-) ↔ Body earth No

connector.
OK
Replace the speedsensor (SP2).

DTC P0725/86 NE COMMUNICATION LINE SYSTEM

The engine speed signal is provided as input from the engine control computer to the transmission control
computer ASSY. The transmission control computer ASSY puts out a diagnostic code when the engine
speed signal is abnormal.
2. Trouble status
3. Trouble length
4. Others
1. Other than P or N range
2. Engine speed signal (NE) below 300 r/min
• Wire harness and connector (NE signal system) AT
P0725/85 • Engine control computer
3. Continuously for 4 seconds or longer
4. 2 trips
CIRCUIT DIAGRAM
TACH NE
Transmission
Engine control
control
computer
computer ASSY
C73323
1 CONFIRM DIAGNOSTIC CODE
(a) Confirm that DTC P0335/12 and 13 [crank angle sensor system] and P0339/13 [crank angle sensor
system (intermittent discontinuity)] of the ECD system are put out in addition to DTC P0725/85.
Standard:
Inspection result Step
Only output of DTC P0725/85 To step A
Output of DTC P0725/85 and other diagnostic codes To step B
AT
HINT:
When a diagnostic code other than DTC P0725/85 is put out, perform trouble-shooting first for that
diagnostic code.
B To the related diagnostic code chart [refer to
chapter ES (NO4C)]
2 INSPECT TRANSMISSION CONTROL COMPUTER ASSY BY ITSELF (NE)
(a) Connect an oscilloscope between connector terminals

C7 (NE) and B8 (GND1) of the transmission control
computer ASSY. (Refer to AT-59 for the terminal layout.)
C73597

Standard:
Item Contents
Measuring terminal NE ↔ GND1
HINT:
vehicle speed.
computer ASSY.
NG
3 INSPECT WIRE HARNESS AND CONNECTOR (ENGINE CONTROL COMPUTER -


(1) Disconnect connector C of the transmission control
computer ASSY and the connector D of the engine
control computer.
harness side of the engine control computer. (Refer AT
to AT-59 for the terminal layout.)
Standard:
Conductivity
(Transmission computer↔meter)
C7 (NE) ↔ D6 (TAC) Yes

Standard:
Conductivity
C73598
C7 (NE) ↔ Body earth No

connector.
OK
Inspect and replace the engine control computer.

DTC P0730/37 GEAR RATIO TROUBLE

The transmission control computer ASSY detects the gear position from the signals from turbine speed
sensor (NT) and output speed sensor (SP2).
When the detected gear position differs from the specified gear position, the transmission control
computer ASSY judges this as mechanical trouble of a solenoid or in the automatic transmission and puts
out a diagnostic code.
2. Trouble status
AT 3.
4.
Trouble length
Others
1. At the time of D, 4, or L-3 range • Transmission solenoid ASSY (S2)
2. The clutch slip (turbine speed - output speed/gear • Transmission solenoid ASSY (S3)
P0730/37
ratio) is larger than specified. • Transmission solenoid ASSY (SL1)
3. Continuously for 0.5 seconds or longer • Transmission solenoid ASSY (SL2)
• Automatic transmission ASSY
(a) Confirm that a diagnostic code other than DTC P0730/37 is put out.
Standard:
Only output of P0730/37 To step A
Output of P0730/37 and other diagnostic codes To step B
HINT: AT
When a diagnostic code other than P0730/37 is put out, perform trouble-shooting first for that
diagnostic code.
B To the related diagnostic code chart (refer to
AT-54 for the outline)
2 INSPECT TRANSMISSION SOLENOID ASSY (S1) BY ITSELF
(a) Inspect operation

(1) Confirm that the valve in the solenoid operates when battery (24 V) plus is connected to the
terminal of the transmission solenoid ASSY (S1) and battery (24 V) minus is connected to the
body.
Standard:
Operation (operation sound)
(b) Inspect resistance
(1) Check the resistance between solenoid terminal and body.
Standard:
40-46Ω (20°C, 68°F)
OK Replace the automatic transmission ASSY.
NG

body.
Standard:
AT Standard:
40-46Ω (20°C, 68°F)
OK

body.
Standard:
Standard:
40-46Ω (20°C, 68°F)
OK
5 INSPECT TRANSMISSION SOLENOID ASSY (SL1) BY ITSELF

(1) Confirm that the valve in the solenoid operates
when battery (12 V) plus is connected to terminal 2
of the transmission solenoid ASSY (SL1) and
battery (12 V) minus is connected to terminal 1.
Standard:
(1) Check the resistance between terminals 1 and 2.
AT
C73754 Standard:
5.0-6.0Ω (20°C, 68°F)
OK

(1) Confirm that the valve in the solenoid operates
when battery (12 V) plus is connected to terminal 2
of the transmission solenoid ASSY (SL2) and
battery (12 V) minus is connected to terminal 1.
Standard:
(1) Check the resistance between terminals 1 and 2.
C53442 Standard:
5.0-6.0Ω (20°C, 68°F)
OK

DTC P0746/31 CONTROL VALVE 1 SYSTEM

AT pressure switches are switched ON or OFF. Pressure switch 1 operates according to the status of
solenoid SL1 and control valve No. 1, pressure switch 2 operates according to the status of solenoid SL2
and control valve No. 2, and pressure switch 7 operates according to the status of solenoid SL3 and
control valve No. 3. The transmission control computer ASSY puts out diagnostic codes when trouble
occurs in this PSW1 signal system, PSW2 signal system, PSW7 signal system or in the solenoid or
control valve system.
3. Trouble length
1. Engine rotating in D, 4, or L-3 range
2. Hydraulic pressure switch 1 does not become OFF
• Automatic transmission ASSY (PSW1)
P0746/31 during output of C1 clutch, C2 clutch, and B1 brake
inactive signal.
3. 0.3 seconds or more
2. Hydraulic pressure switch 2 does not become OFF
P0776/32 during output of C3 clutch and B2 brake inactive
signal.
1. Shifting from N to D or N to R during engine rotation • Wire harness and connector (PSW7 signal system)
2. Pressure switch 7 does not become ON at the time of • Automatic transmission ASSY (PSW7)
P2757/33
shifting from N to D or N to R. • Transmission solenoid ASSY (SL3)
3. 0.3 seconds or more • Transmission control computer ASSY
3. Trouble length
2. Hydraulic pressure switch 1 does not become ON
P0746/31 during output of C1 clutch, C2 clutch, and B1 brake
operation signal.
P0776/32 during output of C3 clutch and B3 brake operation
signal.
P2757/33 during output of C1 clutch and C3 clutch operation
signal.
CIRCUIT DIAGRAM
Pressure switch 1
PSW1 PSW1
Pressure switch 2
PSW2 PSW2 Transmission
control
computer ASSY
AT
Pressure switch 7
PSW7 PSW7
C73299
(a) Confirm output of P0748/25 (SL1 solenoid system), P0778/26 (SL2 solenoid system), and P2759/27
(lock-up solenoid system) in addition to DTC P0746/31, P0776/32 and P2757/33.
Standard:
Only output of DTC P0746/31, P0776/32 and P2757/33 To step A
Output of DTC 0746/31, P0776/32, P2757/33 and other diagnostic codes To step B
HINT:
In case of output of a diagnostic code other than DTC P0746/31, P0776/32 and P2757/27, perform
trouble-shooting for that diagnostic code first.
A

Standard:
Terminal No.
(terminal symbol)
P range
AT C6 (PSW1) ↔ B8 (GND1)
(Pressure switch 1 OFF)
12-32
C73599 D range
C12 (PSW2) ↔ B8 (GND1) 12-32
P range
A11 (PSW7) ↔ B8 (GND1) 12-32

computer ASSY.
NG

(a) Disconnect connectors A and B of the transmission wire.

(c) Check the terminal voltage between the connector on
the wire harness side of the transmission wire and body
earth.
Standard:
Terminal No.
(terminal symbol)
Measuring condition Voltage [V] AT
P range
D range
P range
B1 (PSW7) ↔ Body earth 12-32
C73600

connector.
OK
4 INSPECT TRANSMISSION WIRE BY ITSELF (PSW1, PSW2, PSW7)
(a) Disconnect the two transmission wires.

(b) Check for conductivity between the terminals.
Standard:
A1 (PSW1) ↔ PSW1 Yes
AT
C73601
OK

DTC P0748/25 LINEAR SOLENOID 1 TROUBLE

The transmission control computer ASSY performs shifting from gear 1 to gear 6 according to the
combination of solenoids SL1, SL2, SL3, S1, S2, and S3. In case of a short-circuit or a wire break of one
of the solenoid valve systems, the transmission control computer ASSY switches the other solenoids ON
or OFF as a failsafe function. In case of failure of all solenoid valves, the circuit becomes just a
mechanical hydraulic circuit and manual shifting is performed. (In case of a wire break or a short-circuit,
the transmission control computer ASSY stops energizing the failed solenoid.) AT
3. Trouble length
1. None • Wire harness and connector (SL1 signal system)
P0748/25 2. SL1 solenoid resistance: 100 kΩ or more • Transmission solenoid ASSY (SL1)
3. Trouble length
P0748/25 2. SL1 solenoid current: 4 A or more • Transmission solenoid ASSY (SL1)
3. Continuously for 0.1 second or longer • Transmission control computer ASSY
CIRCUIT DIAGRAM
SL1+ SL1+
SL1
SL1– SL1–
Transmission
control
SL2+ SL2+ computer ASSY
SL1
SL2– SL2–
C73324
1 INSPECT TRANSMISSION WIRE BY ITSELF (SL1/SL2)

Standard:
Terminal No. (terminal symbol) Resistance value [Ω]
B5 (SL1+) ↔ B10 (SL-) 5.0-6.0 (20°C, 68°F)
A6 (SL2+) ↔ A12 (SL2-) 5.0-6.0 (20°C, 68°F)
AT
(c) Use the SST (electrical tester) and check the insulation
of the terminals.
Standard:
B5 (SL1+) ↔ Body earth 1 MΩ or more
A6 (SL2+) ↔ Body earth 1 MΩ or more
Inspection result
Status Step
SL1 trouble To step A
SL2 trouble To step B
Normal To OK
C73604
NG (A) To step 3
NG (B) To step 4
OK

(a) Connect connectors A and B of the transmission wire

and disconnect connector A of the transmission control
computer ASSY.
(b) Check the resistance between the terminals. (Refer to
Standard:
AT
A9 (SL1+) ↔ A8 (SL1-) 5.0-6.0 (20°C, 68°F)
A7 (SL2+) ↔ A6 (SL2-) 5.0-6.0 (20°C, 68°F)
C73605
OK Repair or replace wire harness and

connector.
NG
(a) Disconnect the connector of the transmission solenoid ASSY (SL1)

(b) Check the resistance between terminals 1 and 2.
Standard:
5.0-6.0Ω (20°C, 68°F)
OK

(a) Disconnect the connector of the transmission solenoid ASSY (SL2)

(b) Check the resistance between terminals 1 and 2.
Standard:
5.0-6.0Ω (20°C, 68°F)
OK
AT
Repair or replace the transmission wire
DTC P0751/45 SHIFT VALVE 1 SYSTEM
DTC P0756/46 SHIFT VALVE 2 SYSTEM
DTC P0761/47 SHIFT VALVE 3, 4 SYSTEM
DTC P0761/48 SHIFT VALVE 3, 4 SYSTEM

AT
pressure switches are switched ON or OFF. Pressure switch 3 operates according to the status of
solenoid S1 and shift valve No. 1, pressure switch 4 operates according to the status of solenoid S2 and
shift valve No. 2, pressure switch 5 operates according to the status of solenoid S3 and shift valve No. 3,
and pressure switch 6 operates according to the status of solenoid S3 and shift valve No. 4. The
transmission control computer ASSY puts out diagnostic codes when trouble occurs in this PSW3 signal
system, PSW4 signal system, PSW5 signal system, PSW6 signal system, or in the solenoid or shift valve
system.
3. Trouble length
1. Engine rotating • Wire harness and connector (PSW3 signal system)
2. The hydraulic switch (PSW3) does not become ON • Automatic transmission ASSY (PSW3)
P0751/45
although solenoid S1 becomes ON. • Transmission solenoid ASSY (S1)
P0756/46
P0761/47
P0761/48
CIRCUIT DIAGRAM
Pressure switch 3
PSW3 PSW3
Pressure switch 4
PSW4 PSW4
Transmission
AT Pressure switch 5
control
computer ASSY
PSW5 PSW5
Pressure switch 6
PSW6 PSW6
C73298
(a) Confirm output of P0973/62 [shift solenoid 1 trouble (Low)], P0974/62 [shift solenoid 1 trouble
(High)], P0976/63 [shift solenoid 2 trouble (Low)], P0977/63 [shift solenoid 2 trouble (High)], P0979/
64 [shift solenoid 3 trouble (Low)], P0980/64 [shift solenoid 3 trouble (High)], P0985/65 [shift solenoid
4 trouble (Low)] and P0986/65 [shift solenoid 4 trouble (High)] in addition to DTC P0751/54, P0756/
46, P0761/47 and P0761/48.
Standard:
Only output of DTC P0751/45, P0756/46, P0761/47 and P0761/48 To step A
Output of DTC P0751/45, P0756/46, P0761/47, and P0761/48, as well as other diagnostic
To step B
codes.
HINT:
In case of output of a diagnostic code other than DTC P0751/45, P0756/46, P0761/47 and P0761/48,
perform trouble-shooting for that diagnostic code first.
A

Standard:
Terminal No.
(terminal symbol)
P range
C17 (PSW3) ↔ B8 (GND1)
12-32 AT
C73606 Driving with gear 2
C5 (PSW4) ↔ B8 (GND1) 12-32
Driving with gear 2
C11 (PSW5) ↔ B8 (GND1) 12-32
Driving with gear 2
C16 (PSW6) ↔ B8 (GND1) 12-32

connector.
OK


(c) Check the voltage between the terminals of the
connector on the wire harness side of the transmission
wire and body earth.
Standard:
Terminal No.
AT (terminal symbol)
P range
Driving with gear 2
Driving with gear 2
Driving with gear 2
C73607

connector.
OK
4 INSPECT TRANSMISSION WIRE BY ITSELF (PSW3, PSW4, PSW5, PSW6)
(a) Disconnect the two transmission wires.

Standard:
A2 (PSW6) ↔ PSW6 Yes AT
C73608
OK

DTC P0863/88 EFI COMMUNICATION TROUBLE

The transmission control computer ASSY receives accelerator opening signal, idle signal, and other
information from the engine control computer and sends lock-up status, shift range position, and other
information to the engine control computer.
3. Trouble length
1. Engine speed 500 rpm or higher • Wire harness and connector (serial communication
2. Communication trouble with the engine control signal system)
AT P0863/88
computer • Engine control computer.
3. 5 seconds or more • Transmission control computer ASSY
CIRCUIT DIAGRAM
EFI+ EFI+
EFI– EFI–
Transmission
Engine control
control
computer
computer ASSY
ECT+ ECT+
ECT– ECT–
C72184
1 INSPECT TRANSMISSION CONTROL COMPUTER ASSY BY ITSELF
(a) Connect the SST between terminals B23 (EFI-) and B8

(GND1) and between B24 (EFI+) and B8 (GND1) of the
AT
C73610
(b) Inspect the waveform between terminals B23 (EFI-) and

B8 (GND1) of the transmission control computer ASSY.
Standard:
ITEM CONTENTS
Measuring terminal EFI- ↔ GND1
C72207
(c) Inspect the waveform between terminals B24 (EFI+) and

B8 (GND1) of the transmission control computer ASSY.
Standard:
ITEM CONTENTS
Measuring terminal EFI+ ↔ GND1
C72208 OK Inspect and replace the transmission control

computer ASSY.
NG

ASSY - ENGINE CONTROL COMPUTER)

(1) Disconnect connector B of the transmission control
computer ASSY and connector D of the engine
control computer.
(2) Check the conductivity between the terminals of the
connector on the wire harness side of the
transmission control computer ASSY and the
AT connector on the wire harness side of the engine
control computer. (Refer to AT-59 for the terminal
layout.)
Standard:
Terminal No. (terminal symbol) (Transmission
Conductivity
computer ↔ engine control computer)
B20 (ECT-) ↔ D24 (ECT-) Yes
B21 (ECT+) ↔ D25 (ECT+) Yes
B23 (EFI-) ↔ D30 (EFI-) Yes
B24 (EFI+) ↔ D31 (EFI+) Yes

C73611
Standard:
B20 (ECT-) ↔ Body earth No
B21 (ECT+) ↔ Body earth No
B23 (EFI-) ↔ Body earth No
B24 (EFI+) ↔ Body earth No

connector.
NG
Inspect and replace the engine control computer.

DTC P0973/62 SHIFT SOLENOID 1 SYSTEM (LOW)
DTC P0974/62 SHIFT SOLENOID 1 SYSTEM (HIGH)
DTC P0976/63 SHIFT SOLENOID 2 SYSTEM (LOW)
DTC P0979/64 SHIFT SOLENOID 3 SYSTEM (LOW) AT

The transmission control computer ASSY performs shifting from gear 1 to gear 6 according to the
combination of solenoids SL1, SL2, SL3, S1, S2, and S3. In case of a short-circuit or a wire break of one
of the solenoid valve systems, the transmission control computer ASSY switches the other solenoids ON
or OFF as a failsafe function. In case of failure of all solenoid valves, the circuit becomes just a
mechanical hydraulic circuit and manual shifting is performed. (In case of a wire break or a short-circuit,
the transmission control computer ASSY stops energizing the failed solenoid.)
3. Trouble length
1. None • Wire harness and connector (S1 signal system)
P0973/62 2. S1 solenoid current: 4 A or more • Transmission solenoid ASSY (S1)
P0974/62 2. S1 solenoid resistance: 100 kΩ or more • Transmission solenoid ASSY (S1)
P0977/63 2. SL2 solenoid resistance: 100 kΩ or more • Transmission solenoid ASSY (S2)
P0980/64 2. S3 solenoid resistance: 100 kΩ or more • Transmission solenoid ASSY (S3)
CIRCUIT DIAGRAM
S1 S1 S1
S2 S2 S2 Transmission
control
computer ASSY
AT
S3 S3 S3
C73538
1 INSPECT TRANSMISSION WIRE BY ITSELF (S1/S2/S3)
(a) Disconnect connector A of the transmission wire.

Standard:
A10 (S1) ↔ Body earth 40-46 (20°C, 68°F)
A3 (S2) ↔ Body earth 40-46 (20°C, 68°F)
A9 (S3) ↔ Body earth 40-46 (20°C, 68°F)
Inspection result
C73612 Status Step
S1 trouble To step A
S2 trouble To step B
S3 trouble To step C
Normal To OK
NG (A) To step 3
NG (B) To step 4
NG (C) To step 5
OK

(a) Connect connector A of the transmission wire and

disconnect connector A of the transmission control
computer ASSY.
Standard:
AT
A1 (S1) ↔ B8 (GND1) 40-46 (20°C, 68°F)
A2 (S2) ↔ B8 (GND1) 40-46 (20°C, 68°F)
C73613
A3 (S3) ↔ B8 (GND1) 40-46 (20°C, 68°F)

connector.
OK
(a) Disconnect the connector of the transmission solenoid ASSY (S1).

(b) Check the resistance between solenoid terminal and body earth.
Standard:
40-46Ω (20°C, 68°F)
OK


Standard:
40-46Ω (20°C, 68°F)
OK
AT

Standard:
40-46Ω (20°C, 68°F)
OK

HYDRAULIC PRESSURE SOLENOID SYSTEM

DTC P0985/65
(LOW)
HYDRAULIC PRESSURE SOLENOID SYSTEM

DTC P0986/65
(HIGH)
The S4 solenoid controls the pressure switching valve by signals from the transmission control computer
ASSY, and it switches the output pressure from control valve No. 1 and control valve No. 2 to the line
pressure. This line pressure operates clutch and brake. In case of a wire break or short-circuit in the S4 AT
solenoid system, the transmission control computer ASSY puts out a diagnostic code.
3. Trouble length
P0986/65 2. SL4 solenoid resistance: 100 kΩ or more • Transmission solenoid ASSY (S4)
CIRCUIT DIAGRAM
S4 S4 S4 Transmission
control
computer ASSY
C73539
1 INSPECT TRANSMISSION WIRE BY ITSELF (S4)

Standard:
A4 (S4) ↔ Body earth 40-46 (20°C, 68°F)
AT NG To step 3
C73614
OK


computer ASSY.
Standard:
A4 (SL3-) ↔ B8 (GND1) 40-46 (20°C, 68°F)
C73615
connector.
OK

(a) Disconnect the connector of the transmission solenoid ASSY (S4)

Standard:
40-46Ω (20°C, 68°F)
OK
AT
EXHAUST BRAKE OPERATION SIGNAL

DTC P1604/24
ABNORMAL
The accelerator position sensor is installed on the accelerator pedal and detects the accelerator pedal
opening. The engine control computer judges the present opening of the accelerator pedal and controls
the throttle motor. The engine control computer sends a trouble detection signal to the transmission
control computer ASSY when it detects accelerator position sensor trouble. When the transmission
control computer ASSY receives this signal, it puts out a diagnostic code.
AT DTC No. 2. Trouble status Inspection part
3. Trouble length
1. None
2. Reception of the accelerator position sensor trouble • Accelerator position sensor
P1604/24
signal from the engine control computer. • Transmission control computer ASSY
3. None
CIRCUIT DIAGRAM
EFI+ EFI+
EFI– EFI–
Transmission
Engine control
control
computer
computer ASSY
ECT+ ECT+
ECT– ECT–
C72184
(a) Output of an ECD system accelerator position sensor trouble code other than DTC P1604/24, {DTC
P2120/19 [accelerator sensor wire break], P2121/19 [accelerator sensor (outside the range)], P2122/
19 [accelerator sensor No. 1 wire break (Low)], P2123/19 [accelerator sensor No. 1 wire break
(High)], P2125/19 [accelerator sensor No. 2 wire break], P2127/19 [accelerator sensor No. 2 wire
break (Low)], P2128/19 [accelerator sensor No. 2 wire break (High)], and P2138/19 [accelerator
sensor wire break]} is checked.
Standard: AT
Output of DTC P1604/24 To step A
Output of DTC P1604/24 and other diagnostic codes To step B
HINT:
diagnostic code.
B To the related diagnostic code chart [refer to
chapter ES (NO4C) for the outline]

EXHAUST BRAKE OPERATION SIGNAL

DTC P1604/54
ABNORMAL
When neutral status is judged by the transmission control computer ASSY at the time of exhaust brake
switch ON signal input, an exhaust brake cut request signal is sent as serial communication to the engine
control computer. A diagnostic code is put out when an exhaust brake operating signal is received during
transmission of this exhaust brake cut request signal transmission.
AT 3. Trouble length
1. None
• Wire harness and connector (serial communication
2. Reception of an exhaust brake operating signal during
P1604/54 signal system)
transmission of exhaust brake cut-off request signal
3. Continuously for 0.5 seconds or longer
CIRCUIT DIAGRAM
EFI+ EFI+
EFI– EFI–
Transmission
Engine control
control
computer
computer ASSY
ECT+ ECT+
ECT– ECT–
C72184
1 CONFIRMAT DIAGNOSTIC CODE
(a) Confirm output of P0863/88 (serial communication trouble) in addition to DTC P1604/54.
Standard:
Output of P1604/54 and P0863/88 To step B
HINT:
AT
diagnostic code.

DTC P1911/51 PTO SOLENOID SYSTEM (LOW)

The PTO solenoid becomes ON and the PTO operates by the PTO operation signal from the transmission
control computer ASSY. In case of a wire break in this PTO solenoid system, the transmission control
computer ASSY puts out a diagnostic code.
3. Trouble length
1. None • Wire harness and connector (POS signal system)
P1911/51 2. PTO solenoid current: 4 A or more • PTO solenoid
AT 3. 0.1 second or more • Transmission control computer ASSY
HINT:
There is not diagnostic code detection for a wire break of the PTO solenoid system.
CIRCUIT DIAGRAM
PTO solenoid
Transmission POS
control
computer ASSY
C73315
1 INSPECT TRANSMISSION CONTROL COMPUTER ASSY (POS)

Standard:
B10 (POS) ↔ B8 (GND1) 12-32
AT
NG Inspect and replace the transmission control
C73637
computer ASSY.
OK

ASSY - PTO SOLENOID)
(a) Inspect insulation

(1) Disconnect connector B of the transmission control
computer ASSY and the connector of the PTO
solenoid.
Standard:
C73638
Conductivity
B10 (POS) ↔ Body earth No

connector.
OK
3 INSPECT PTO SOLENOID BY ITSELF
(a) Check the resistance between terminal 1 (B) and body

earth.
Standard:
46-54Ω (20°C, 68°F)
AT
C73534
NG Replace the PTO solenoid.
OK

DTC P2716/28 PRESSURE CONTROL SOLENOID SYSTEM

Based on the signal from the throttle position sensor, the transmission control computer ASSY controls
the line pressure solenoid to a predetermined duty ratio. By this, the line pressure is adjusted to a
pressure fitting the throttle opening and the engine output.
3. Trouble length
P2716/28 2. SL4 solenoid resistance: 100 kΩ or more • Line pressure control solenoid (SL4) AT
3. Trouble length
P2716/28 2. SL4 solenoid current: 4 A or more • Line pressure control solenoid (SL4)
CIRCUIT DIAGRAM
SL4+ SL4+
Transmission
SL4 control
computer ASSY
SL4– SL4–
C73326
1 INSPECT TRANSMISSION WIRE BY ITSELF (SL4)

Standard:
A5 (SL4+) ↔ A11 (SL4-) 5.0-6.0 (20°C, 68°F)
AT (c) Check the insulation of the terminals.

Standard:
C73041
A5 (SL4+) ↔ Body earth 1 MΩ or more
NG To step 3
OK


computer ASSY.
Standard:
A21 (SL4+) ↔ A31 (SL4-) 5.0-6.0 (20°C, 68°F)
C73639
connector.
OK

3 INSPECT LINE PRESSURE CONTROL SOLENOID (SL4) BY ITSELF
(a) Disconnect the connector of the line pressure control solenoid (SL4).
Standard:
5.0-6.0Ω (20°C, 68°F)
OK
AT
DTC P2740/17 OIL TEMPERATURE SENSOR NO. 2 SYSTEM

The oil temperature sensor is installed on the transmission case, the oil temperature in the torque
converter is detected, and a signal corresponding to the oil temperature is given as input to the
transmission control computer ASSY. When the oil temperature of the torque converter rises to 145°C
(293°F) or higher, the AT OIL TEMP lamp in the meter lights, and when it drops to -40°C (-40°F) or lower,
the AT OIL TEMP lamp flashes.
AT DTC No. 2. Trouble status
3. Trouble length
Inspection part
1. None • Wire harness and connector (oil temperature sensor

2. Oil temperature sensor resistance: Below 90 Ω or 470 signal system)
P2740/17
kΩ or higher • Temperature sensor (transmission body)
CIRCUIT DIAGRAM
Temperature sensor (transmission body)
OIL2 OIL2
Transmission
control
computer ASSY
GND E2
C73327
1 INSPECT TEMPERATURE SENSOR BY ITSELF
(a) Remove the temperature sensor.

(b) Immerse the sender part of the temperature sensor into
a vessel filled with original Toyota Auto Fluid Type T-IV.
(c) Heat the fluid and check the resistance between the
terminals.
Standard:
Oil temperature [°C (°F)] Resistance value [kΩ] AT
115 (239) 657.1-726.3
120 (248) 584.8-646.4
C73044
145 (293) 340.8-375.3
155 (311) 277.9-307.1
NOTICE:
Take care not to heat the oil excessively, as the oil
may catch fire.
NG Replace the temperature sensor.
OK
2 INSPECT WIRE HARNESS AND CONNECTOR (TEMPERATURE SENSOR -

(a) Install the temperature sensor.

(b) Connect the connector of the temperature sensor.
(c) Disconnect connectors A and B of the transmission
(d) Check the resistance between the terminals. (Refer to
Standard:
C73640 B16 (OIL2) ↔ A28 (E2) 115 (239) 657.1-726.3
B16 (OIL2) ↔ A28 (E2) 120 (248) 584.8-646.4
B16 (OIL2) ↔ A28 (E2) 145 (293) 340.8-375.3
B16 (OIL2) ↔ A28 (E2) 155 (311) 277.9-307.1

connector.
OK


The transmission control computer ASSY controls the lock-up control solenoid to a predetermined duty
ratio and performs lock-up.
3. Trouble length
AT 3. Continuously for 0.065 seconds or longer • Transmission control computer ASSY
3. Trouble length
CIRCUIT DIAGRAM
SL3+ SL3+
Transmission
SL3 control
computer ASSY
SL3– SL3–
C73328
1 INSPECT TRANSMISSION WIRE BY ITSELF (SL3)

Standard:
B4 (SL3+) ↔ B9 (SL3-) 5.0-6.0 (20°C, 68°F)
(c) Check the insulation of the terminals. AT

Standard:
C73641
B4 (SL3+) ↔ Body earth 1 MΩ or more
NG To step 3
OK

(a) Connect connector B of the transmission wire and

computer ASSY.
Standard:
Terminal No.
Resistance value [Ω]
(terminal symbol)
A5 (SL3+) ↔ A4 (SL3-) 5.0-6.0 (20°C, 68°F)
C73642

connector.
NG

(a) Disconnect the connector of the transmission solenoid ASSY (SL3).

Standard:
5.0-6.0Ω (20°C, 68°F)
OK
AT
DTC P2764/36 LOCK-UP TROUBLE

The transmission control computer ASSY calculates the duty ratio from vehicle speed, throttle opening,
etc. and operates the transmission solenoid ASSY (SL3). During lock-up operation, the slippage status is
confirmed from engine speed and turbine speed signal, and control is performed for optimal slippage.
When engine speed and turbine speed do not coincide during output of the lock-up operation signal, the
transmission control computer ASSY puts out a diagnostic code.
3. Trouble length
AT
1. During output of the lock-up operation signal • Torque converter ASSY
P2764/36 2. Engine speed and turbine speed do not coincide • Transmission solenoid ASSY (SL3)
3. Continuously for 5 seconds or longer • Transmission valve body ASSY
(a) Check for output of 2759/27 (lock-up solenoid system) in addition to DTC P2764/36.
Standard:
Output of P2764/36 and other diagnostic codes To step B
HINT:
When a diagnostic code other than P2764/36 is put out, perform trouble-shooting first for that
diagnostic code.
B To the related diagnostic chart (refer to AT-
54 for the outline)
A

(1) Connect battery (12 V) plus to terminal 2 of the
transmission solenoid ASSY (SL3), connect battery
(12 V) minus to terminal 1, and confirm that the
valve in the solenoid operates.
Standard:
AT (1) Check the resistance between terminals 1 and 2.
C73754 Standard:
5.0-6.0Ω (20°C, 68°F)
OK Replace the automatic transmission ASSY.
NG
3 INSPECT TORQUE CONVERTER ASSY BY ITSELF (REFER TO AT-12 FOR THE OUTLINE)
OK Replace the torque converter ASSY.
NG

STOP LAMP SWITCH SYSTEM

The signal from the stop lamp switch ASSY is given as input to the transmission control computer ASSY
to detect the operation status of the brake. The signal of the stop lamp switch ASSY is used for shift-down
and lock-up ON or OFF when driving downhill.
CIRCUIT DIAGRAM
Stop lamp switch ASSY

AT
STOP STP
fuse
(7.5 A) Transmission
control
computer ASSY
Stop lamp
C72223
1 INSPECT STOP LAMP LIGHTING
(a) Confirm that the stop lamp lights when the brake pedal is depressed and goes out when the brake
pedal is released.
NG Inspect the stop lamp system.
OK
2 INSPECT WIRE HARNESS AND CONNECTOR (STOP LAMP SWITCH ASSY -

(a) Disconnect connector A of the transmission control

computer ASSY.
(b) Set the ignition switch to ON and check the voltage
between the terminals. (Refer to AT-59 for the terminal
layout.)
Standard:
Terminal No.
AT (terminal symbol)
Stop lamp switch ASSY Voltage [V]
OFF
A10 (BK) ↔ B8 (GND1) 0-3
C73644 (brake pedal released)
ON
A10 (BK) ↔ B8 (GND1) (brake pedal 15-32
depressed)

connector.
NG

TRANSMISSION CONTROL SWITCH SYSTEM

Switching between gear 5 and gear 6 is performed by input of the signal from the transmission control
switch to the transmission control computer ASSY.
CIRCUIT DIAGRAM
AT
Transmission control switch
OD2 Transmission
control
computer ASSY
C73329
1 INSPECT TRANSMISSION CONTROL SWITCH BY ITSELF
(a) Disconnect the connector of the transmission control switch.

(b) Check for conductivity between the terminals.
Standard:
Transmission control switch Standard
Pressed Conductivity
Released No conductivity
NG Replace the transmission control switch.
OK
2 INSPECT WIRE HARNESS AND CONNECTOR (TRANSMISSION CONTROL SWITCH -

(a) Connect the connector of the transmission control switch

and disconnect connector B of the transmission control
computer ASSY.
(b) Check for conductivity between the terminals. (Refer to
Standard:
Terminal No. Transmission control
Standard
(terminal symbol) switch
B14 (OD2) ↔ B8 (GND1) Pressed Conductivity
C73643
B14 (OD2) ↔ B8 (GND1) Released No conductivity

connector.
OK
AT
TRANSMISSION
MANUAL TRANSMISSION SYSTEM

PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-1
MANUAL TRANSMISSION OIL
ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-2
SHIFT AND SELECT TRANSMISSION CONTROL CABLE (for Stan-
dard Body)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-3
MT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-5
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-10
SHIFT AND SELECT TRANSMISSION CONTROL CABLE (for Wide
Body)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-18
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-22
SHIFT LEVER ASSEMBLY (for LHD)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-29
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-30
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-34
SHIFT LEVER ASSEMBLY (for RHD)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-38
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-39
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-48
M153 MANUAL TRANSMISSION – MANUAL TRANSMISSION SYSTEM MT–1
MANUAL TRANSMISSION
SYSTEM
Use the table below to help you find the cause of the problem.
The numbers indicate the ranked order of probability of each
of the possible causes. Check each part in order. Replace
parts as necessary.
MANUAL TRANSMISSION SYSTEM:
Symptom Suspected Area See page
Oil level (low) MT-2
Oil (wrong) MT-2 MT
Abnormal noise
Gears (worn or damaged) (*1)
Bearing (worn or damaged) (*1)
Oil level (high) MT-2
Oil leak Gasket (damaged) (*1)
Oil seal (worn or damaged) (*2)
Control cable (Faulty) MT-3
Hard shifting or will not shift Synchronizer ring (worn or damaged) (*1)
Shift key spring (damaged) (*1)
Shift detent spring (damaged) (*1)
Shift fork (worn) (*1)
Jumps out of gear
Gear (worn or damaged) (*1)
*1 : See Pub. No. S1-YXZE09B, page 41-1.

MT–2 M153 MANUAL TRANSMISSION – MANUAL TRANSMISSION OIL

1. CHECK TRANSMISSION OIL
(a) Park the vehicle in a level place.
(b) Remove the transmission filler plug and gasket.
(c) Check that the oil surface is within 5 mm (0.20 in.)
0 to 5 mm
(0 to 0.20 in.) below the lowest point of the transmission filler plug
D025304E01 opening.
Oil grade:
GL-4 or 5
Viscosity:
MT SAE 75W-90
NOTICE:
• Problems may occur when the oil level is too
high or too low.
• After replacing the oil, drive the vehicle and
check the oil level again.
(d) Check for oil leakage if the oil level is low.
(e) Install the transmission filler plug and a new gasket.
M153 MANUAL TRANSMISSION – SHIFT AND SELECT TRANSMISSION CONTROL
CABLE (for Standard Body) MT–3
SHIFT AND SELECT TRANSMISSION CONTROL CABLE (for

TRANSMISSION
Standard Body)
COMPONENTS
for LHD:
SHIFT LEVER KNOB SUB-ASSEMBLY
MT
SHIFTING HOLE COVER
SUB-ASSEMBLY
x3
SHIFT LEVER BOOT COVER
PARKING BRAKE
CLIP HOLE COVER
WASHER
12 (122, 9)
CLIP
18 (184, 13)
SHIFT AND SELECT

18 (184, 13)
TRANSMISSION CONTROL TRANSMISSION
CABLE BRACKET CONTROL CABLE
TRANSMISSION
CONTROL CABLE
CLAMP
CLIP
18 (184, 13) 28 (280, 20)

18 (184, 13) 18 (184, 13)
18 (184, 13)
TRANSMISSION CONTROL CABLE BRACKET

28 (280, 20)
Non-reusable part TRANSMISSION CONTROL CABLE BRACKET

C161589E01
MT–4 CABLE (for Standard Body)
for RHD:
SHIFTING HOLE COVER

SUB-ASSEMBLY
MT
x3
PARKING BRAKE
HOLE COVER
WASHER
CLIP 12 (122, 9)
CLIP with POWER without POWER

STEERING: STEERING:
x2
18 (184, 13) SHIFT AND SELECT
18 (184, 13) TRANSMISSION
18 (184, 13)
CONTROL CABLE
TRANSMISSION
CONTROL CABLE
CLAMP TRANSMISSION CONTROL CABLE BRACKET
CLIP
18 (184, 13)
18 (184, 13) 18 (184, 13)
28 (280, 20)
18 (184, 13)

28 (280, 20)

C161579E01
REMOVAL
1. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY
(a) Turn the shift lever knob counterclockwise and
remove the shift lever knob sub-assembly.
C151315
2. REMOVE PARKING BRAKE HOLE COVER

for LHD: (a) Remove the screw and the parking brake hole
cover. MT
for RHD:
C162828E01
3. REMOVE SHIFTING HOLE COVER SUB-ASSEMBLY

(a) Disengage the 6 claws, and then remove the
shifting hole cover sub-assembly.
C152349
4. REMOVE SHIFT LEVER BOOT COVER

(a) Remove the 3 clips and shift lever boot cover.
C161588
5. REMOVE SHIFT AND SELECT TRANSMISSION

CONTROL CABLE
(a) Remove the nut and disconnect the transmission
control shift cable from the shift lever assembly.
(b) Remove the clip and washer and disconnect the
transmission control select cable from the shift lever
assembly.
HINT:
For LHD vehicles, the configuration is opposite to
C161576 RHD vehicles.
(c) Remove the 2 clips and disconnect the shift and

select transmission control cables from the shift
MT lever retainer.
C152466
(d) Remove the 2 nuts and disconnect the shift and

lever and select lever.
(e) Remove the 2 clips and disconnect the shift and
select transmission control cables from the No. 1
transmission control cable bracket.
Select
Lever
Shift Lever
C161590E01
(f) Remove the nut and transmission control cable

bracket.
C149958
(g) Remove the nut and transmission control cable

bracket.
C151313
(h) for LHD:

(1) Remove the nut and transmission control cable
bracket.
C161571
(2) Remove the 2 nuts, bolt, and 2 transmission

control cable brackets.
MT
C161570
(i) for RHD (with power steering):

bracket.
C152323
(2) Remove the bolt and transmission control cable

clamp.
C161582

bracket.
C158797
(j) for RHD (without power steering):

bracket.
C152323
(2) Remove the 2 bolts and transmission control

cable bracket.
MT
C151314

bracket.
C158797
(k) Remove the bolt and transmission control cable

clamp.
(l) Pull out the shift and select transmission control
cables from the engine side.
ADJUSTMENT
1. INSPECT AND ADJUST SHIFT LEVER POSITION (for
LHD)
(a) When the shift lever is in the neutral position, check
C158791
that the shift lever is perpendicular to the installation
surface of the shift lever assembly.

control select cable from the shift lever assembly.
(c) Remove the nut and disconnect the control shift
cable from the shift lever assembly.
C161585
(d) Loosen the lock nuts and adjust the shift lever
Lock Nut position by turning the ball joints.
MT
Lock Nut
C162047E01
(e) Connect the control select cable to the shift lever

assembly with the washer and clip.
(f) Install the control shift cable to the shift lever
assembly with the nut.
C161585
(g) Tighten the lock nuts.

(h) After adjustment, check the following:
(1) When the shift lever is in the neutral position,
check that the shift lever is perpendicular to the
installation surface of the shift lever assembly.
(2) Shifting into each position can be done
correctly.
(3) When selecting or shifting the shift positions, no
C162052 abnormal force is required.
(4) The shift lever returns to the neutral position
smoothly.
(5) No abnormal noise is heard during operation.
RHD)

C161576
position by turning the ball joints.
MT Lock Nut
Lock Nut
C161599E01

C161576

correctly.
C162051 excessive force is required.
smoothly.
INSTALLATION
CONTROL CABLE
(a) Pass the shift and select transmission control
cables from the engine side to the cabin side.
(b) Install the shift and select transmission control

cables to the No. 1 transmission control cable
bracket with 2 new clips.
(c) Install the transmission control shift cable to the shift
lever with the nut.
(d) Install the transmission control select cable to the
select lever with the nut.
Select
Lever
Shift Lever
MT
C161590E01
(e) Install the transmission control cable clamp with the

bolt.
C158791
(f) for LHD:

(1) Install the 2 transmission control cable brackets
with the 2 nuts and bolt.
C161570
(2) Install the transmission control cable bracket

with the nut.
C161571
(g) for RHD (with power steering):

with the bolt.
C158797

with the bolt.
MT Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
C161582

with the nut.
C152323
(h) for RHD (without power steering):

with the bolt.
C158797

with the 2 bolts.
C151314

with the nut.
C152323
(i) Install the transmission control cable bracket with

the nut.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) MT
C151313
(j) Install the transmission control cable bracket with

the nut.
C149958
(k) Install the shift and select transmission control

cables to the shift lever retainer with 2 new clips.
C152466
(l) Install the transmission control select cable to the

shift lever assembly with the washer and clip.
(m) Install the transmission control shift cable to the shift
lever assembly with the nut.
HINT:
• The nut should be fully tightened after the shift
lever position has been adjusted.
• For LHD vehicles, the configuration is opposite to
C161576 RHD vehicles.
2. INSPECT AND ADJUST SHIFT LEVER POSITION

See page MT-8.
3. INSTALL SHIFT LEVER BOOT COVER
(a) Install the shift lever boot cover with the 3 clips.
C161588
MT 4. INSTALL SHIFTING HOLE COVER SUB-ASSEMBLY

(a) Engage the 6 claws, and install the shifting hole
cover sub-assembly.
C152349
5. INSTALL PARKING BRAKE HOLE COVER

for LHD: (a) Install the parking brake hole cover with the screw.
for RHD:
C162828E01
6. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY

(a) Turn the shift lever knob clockwise and install the
shift lever knob sub-assembly.
C151316
MT
MT–16 CABLE (for Wide Body)

TRANSMISSION
Wide Body)
COMPONENTS
for LHD:
MT
SHIFTING HOLE COVER SUB-ASSEMBLY

x3 PARKING BRAKE
HOLE COVER
SHIFT AND SELECT
TRANSMISSION
CONTROL CABLE
CLIP
WASHER
CLIP
CABLE BRACKET
12 (122, 9)
18 (184, 13)
CLIP
TRANSMISSION CONTROL CABLE
WASHER 18 (184, 13)
TRANSMISSION 18 (184, 13)

CONTROL CLIP
CABLE CLAMP
TRANSMISSION
28 (280, 20)
CONTROL
CABLE CLAMP
18 (184, 13)
CABLE BRACKET 18 (184, 13)
CABLE BRACKET
Non-reusable part
C161591E01
CABLE (for Wide Body) MT–17
for RHD:

x3 PARKING BRAKE MT
HOLE COVER
SHIFT AND SELECT
TRANSMISSION
CONTROL CABLE
SCREW
12 (122, 9)
CLIP
WASHER
CLIP CABLE BRACKET
CLIP 18 (184, 13)

TRANSMISSION CONTROL CABLE
18 (184, 13) CLAMP
WASHER
18 (184, 13)
CLIP
TRANSMISSION
CONTROL
CABLE CLAMP
18 (184, 13)
TRANSMISSION
TRANSMISSION CONTROL CONTROL
CABLE BRACKET CABLE CLAMP 18 (184, 13)
28 (280, 20)

CABLE BRACKET
Non-reusable part
C161592E01
REMOVAL
C159400

for LHD: (a) Remove the screw and the parking brake hole
MT cover.
for RHD:
C162828E01

C159402

C159403

CONTROL CABLE
(a) Remove the nut and disconnect the control shift
(b) Remove the clip and washer, and disconnect the
HINT:
For RHD vehicles, the configuration is opposite to
LHD vehicles.
C161585

lever retainer. MT
C161586

Select
Lever
Shift Lever
C161590E01
(f) Remove the 2 nuts and 2 transmission control cable

brackets.
(g) Remove the transmission control cable clamp from
the transmission control cable bracket.
Bracket
Clamp
C160011E01
(h) Remove the transmission control cable clamp.
C152476
(i) Remove the nut and transmission control cable

bracket.
C152475
(j) Remove the bolt and transmission control cable

bracket.
MT
C152479
(k) for LHD:

clamp.
C156185
(l) for RHD:

clamp.
(m) Pull out the shift and select transmission control
ADJUSTMENT
LHD)
C158792
(b) Remove the nut and disconnect the control shift
(c) Remove the clip and washer, and disconnect the

C161585
(e) Connect the control select cable to the shift lever MT
Lock Nut
C162047E01

C161585

the shift lever is perpendicular to the installation
correctly.
smoothly.
RHD)

C161576
position by turning the ball joints.
MT Lock Nut (e) Connect the control select cable to the shift lever
Lock Nut
C161599E01

C161576

correctly.
smoothly.
INSTALLATION
CONTROL CABLE

(c) Install the control shift cable to the shift lever with
the nut.
(d) Install the control select cable to the select lever
with the nut.
Select
Lever
Shift Lever
MT
C161590E01
(e) for LHD:

(1) Install the transmission control cable clamp
with the bolt.
C156185
(f) for RHD:

(1) Install the transmission control cable clamp
with the bolt.
C158792
(g) Install the transmission control cable bracket with

the bolt.
C152479
(h) Install the transmission control cable bracket with

the nut.
C152475
(i) Install a new transmission control cable clamp.

HINT:
MT If the clamp cannot fully secure the cables, a
washer should be used for support.
C152476
(j) Install a new transmission control cable clamp to the

transmission control cable.
(k) Install the 2 transmission control cable brackets with
the 2 nuts.
Bracket
Clamp
C160011E01
(l) Install the shift and select transmission control

C161586
(m) Connect the control select cable to the shift lever

(n) Install the control shift cable to the shift lever
HINT:
• The nut should be fully tightened after the shift
lever position has been adjusted.
• For RHD vehicles, the configuration is opposite
C161585 to LHD vehicles.

See page MT-20.
C159403
4. INSTALL SHIFTING HOLE COVER SUB-ASSEMBLY MT

cover sub-assembly.
C159402

for LHD: (a) Install the parking brake hole cover with the screw.
for RHD:
C162828E01

C162050
MT
M153 MANUAL TRANSMISSION – SHIFT LEVER ASSEMBLY (for LHD) MT–27
SHIFT LEVER ASSEMBLY (for LHD)

TRANSMISSION
COMPONENTS

MT
x3
PARKING BRAKE
HOLE COVER
18 (184, 13)
WASHER
CLIP x4
CLIP
12 (122, 9)
SHIFT LEVER ASSEMBLY
CLIP
NO. 1 CONTROL SHIFT LEVER

RETAINER GROMMET
SHIFT AND SELECT x4
TRANSMISSION
CONTROL CABLE x4 SHIFT LEVER
RETAINER BUSHING
Non-reusable part
C160012E01
MT–28 M153 MANUAL TRANSMISSION – SHIFT LEVER ASSEMBLY (for LHD)
FLOOR SHIFT SHIFT LEVER

SUB-ASSEMBLY
SELECT LEVER TORSION SPRING
MT 12 (122, 9)
CUSHION
SNAP RING
WASHER
15 (150, 11)
SELECTING
BELLCRANK BUSHING
x2
COLLAR
7.5 (76, 66 in.*lbf)
BUSHING FLOOR SHIFT CONTROL

LEVER STOPPER
SELECT LEVER
NO. 1 FLOOR
BUSHING SHIFT BUSHING
SELECT LEVER
COLLAR
FLOOR SHIFT CONTROL

SHIFT LEVER RETAINER
SUB-ASSEMBLY
MP grease
C160013E02
REMOVAL
1. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (See
page MT-18)
(a) Remove the screw and the parking brake hole
cover.
(See page MT-18)
4. REMOVE SHIFT LEVER BOOT COVER (See page MT-
18)
C159401 MT
5. SEPARATE SHIFT AND SELECT TRANSMISSION
CONTROL CABLE
cables from the shift lever assembly.
C161585

select transmission control cable from the shift lever
retainer.
C161586
6. REMOVE SHIFT LEVER ASSEMBLY

(a) Remove the 4 bolts and shift lever assembly.
C161587
DISASSEMBLY
1. REMOVE FLOOR SHIFT CONTROL LEVER STOPPER
(a) Remove the 2 bolts and control lever stopper.
(b) Remove the washer from the control lever stopper.
C161580
(c) Using snap ring pliers, remove the snap ring from
the control lever stopper.
MT
C161598
2. REMOVE FLOOR SHIFT CONTROL SHIFT LEVER

RETAINER SUB-ASSEMBLY
(a) Remove the shift lever retainer.
C161595
(b) Remove the bushing from the shift lever retainer.

Bushing
C158794E01
3. REMOVE FLOOR SHIFT SHIFT LEVER SUB-

ASSEMBLY
(a) Remove the nut, bolt, and shift lever from the select
lever.
C161573
4. REMOVE SELECT LEVER COLLAR

(a) Remove the 2 bushings and collar from the select
lever. MT
Collar
Bushing
Bushing
C161574E01
5. REMOVE SELECT LEVER TORSION SPRING

(a) Remove the torsion spring from the select lever.
C161575
6. REMOVE NO. 1 FLOOR SHIFT BUSHING

(a) Remove the bushing and cushion from the select
Cushion
lever.
Bushing
C158795E01
7. REMOVE SELECTING BELLCRANK

(a) Remove the nut, bolt, and selecting bellcrank from
the shift lever retainer.
(b) Remove the collar from the selecting bellcrank.
C161596
8. REMOVE NO. 1 CONTROL SHIFT LEVER RETAINER

GROMMET
(a) Remove the 4 grommets and 4 bushings from the
shift lever retainer.
C161597
REASSEMBLY
1. INSTALL NO. 1 CONTROL SHIFT LEVER RETAINER
MT GROMMET
(a) Install the 4 bushings and 4 grommets to the shift
lever retainer.
C161597
2. INSTALL SELECTING BELLCRANK

(a) Apply MP grease to the outside of the collar.
(b) Install the selecting bellcrank to the shift lever
retainer with the bolt and nut.
C161596E01
3. INSTALL NO. 1 FLOOR SHIFT BUSHING

(a) Apply MP grease to the inside and outside of the
bushing.
(b) Install the cushion and bushing to the select lever.
C091114
4. INSTALL SELECT LEVER TORSION SPRING

(a) Apply MP grease to the torsion spring.
(b) Install the torsion spring to the select lever.
C161575E01
5. INSTALL SELECT LEVER COLLAR

(b) Apply MP grease to both sides of the 2 bushings.
(c) Install the collar and 2 bushings to the select lever.
C161574E02
6. INSTALL FLOOR SHIFT SHIFT LEVER SUB-

ASSEMBLY
(a) Install the shift lever to the select lever with the bolt MT
and nut.
C161573
(b) Apply MP grease to the outside of the shift lever.
C161584
7. INSTALL FLOOR SHIFT CONTROL SHIFT LEVER

bushing.
(b) Install the bushing to the shift lever retainer.
C091115
(c) Install the floor shift lever sub-assembly to the shift

lever retainer.
MT
C161595
8. INSTALL FLOOR SHIFT CONTROL LEVER STOPPER

(a) Using snap ring pliers, install the snap ring to the
control lever stopper.
(b) Install the washer to the control lever stopper.
C161598
(c) Install the control lever stopper with the 2 bolts.

C161580
INSTALLATION
1. INSTALL SHIFT LEVER ASSEMBLY
(a) Install the shift lever assembly with the 4 bolts.
C161587

CONTROL CABLE
(a) Install the shift and select transmission control
C161586
(b) Install the transmission control select cable to the

(c) Install the control shift cable to the shift lever MT
HINT:
The nut should be fully tightened after the shift lever
position has been adjusted.
C161585
(See page MT-20)
4. INSTALL SHIFT LEVER BOOT COVER (See page MT-
25)
5. INSTALL SHIFTING HOLE COVER SUB-ASSEMBLY
(See page MT-25)
(a) Install the parking brake hole cover with the screw.
7. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (See
page MT-26)
C159401
MT–36 M153 MANUAL TRANSMISSION – SHIFT LEVER ASSEMBLY (for RHD)
SHIFT LEVER ASSEMBLY (for RHD)

TRANSMISSION
COMPONENTS

MT
x3
18 (184, 13)
12 (122, 9) x4
WASHER PARKING BRAKE HOLE COVER
CLIP
CLIP
SHIFT AND SELECT TRANSMISSION CONTROL CABLE
Non-reusable part
C161572E01
M153 MANUAL TRANSMISSION – SHIFT LEVER ASSEMBLY (for RHD) MT–37
REMOVAL
page MT-5)
cover.
(See page MT-5)
5)
C152348 MT
CONTROL CABLE
(a) Remove the nut, and disconnect the control shift
C161576

lever retainer.
C152466

(a) Remove the 4 bolts and remove the shift lever
assembly.
C161577
MT–38 M153 MANUAL TRANSMISSION – SHIFT LEVER ASSEMBLY (for RHD)
INSTALLATION
C161577

CONTROL CABLE
MT (a) Install the shift and select transmission control cable
to the shift lever retainer with 2 new clips.
C152466

HINT:
C161576
(See page MT-8)
14)
(See page MT-14)
page MT-15)
C152348
M153 MANUAL TRANSMISSION – MANUAL TRANSMISSION ASSEMBLY MT–39

TRANSMISSION
COMPONENTS
B265 Type: 75 (760, 55)
x4
MT
M153, M550, A860E Type: x4
75 (760, 55)
MYY5, MYY6 Type: 103 (1050, 76) x4
x4
75 (760, 55)
x4
x4
75 (760, 55)
x4
x4
75 (760, 55)
ASM91-003
MT–40 M153 MANUAL TRANSMISSION – MANUAL TRANSMISSION ASSEMBLY
MT
75 (760, 55)
x4
x4
x4
75 (760, 55)

ASM91-001
Propeller Shaft:
6.4 (65, 57 in.*lbf)

GREASE FITTING
UNIVERSAL JOINT SPIDER
ASSEMBLY
UNIVERSAL JOINT SLEEVE YOKE
THRUST WASHER
x4
x4
MT
FLANGE YOKE SPIDER BEARING
x4
RETAINER RING
SPIDER BEARING
x4
THRUST WASHER
x4
6.4 (65, 57 in.*lbf)
GREASE FITTING FLANGE YOKE
RETAINER RING x4

ASSEMBLY
DUST SEAL
SLIDING YOKE
6.4 (65, 57 in.*lbf)
GREASE FITTING
Non-reusable part
MP Grease
C153112E01

x4
M153, M550, A860E Type:
75 (760, 55)
75 (760, 55)
x4
MYY5, MYY6 Type: 103 (1050, 76)
x4
MT
x4
52 (525, 38)
CENTER PROPELLER SHAFT ASSEMBLY

x4
4 Joint Type (Intermediate shaft

and center propeller shaft): x4
75 (760, 55)
x4
MYY6 Type: 103 (1050, 76)
x4 CENTER SUPPORT
BEARING COVER
CENTER SUPPORT x4
BEARING COVER
52 (525, 38)
x4
PROPELLER INTERMEDIATE SHAFT
ASSEMBLY 52 (525, 38)
75 (760, 55)
x4
ASM91-002
3 and
3 and 4
4 Joint
Joint Type
Type (Intermediate
(Intermediate shaft
shaft and
and Propeller
Center propeller shaft):
shaft center):
NO. 1 CENTER SUPPORT BEARING ASSEMBLY
DUST DEFLECTOR
MT
SPIDER BEARING x4
INTERMEDIATE SHAFT
THRUST WASHER x4
6.4 (65, 57 in.*lbf)
GREASE FITTING
UNIVERSAL JOINT
687 (7000, 506)
SPIDER ASSEMBLY
FLANGE YOKE x4
6.4 (65, 57 in.*lbf)
GREASE FITTING
RETAINER RING
27 (270, 20) x4
UNIVERSAL JOINT FLANGE

CUSHION RUBBER SUB-ASSEMBLY
x4 DUST DEFLECTOR
BEARING PLATE
Non-reusable part
MP Grease
C161496E02

CLIP
65 (663, 48)
CLIP 28 (280, 20)

x4
65 (663, 48)

NO. 3 ENGINE
MT MOUNTING BRACKET 65 (663, 48)
x4
PARKING BRAKE PLATE 127 (1300, 94)

SUB-ASSEMBLY MANUAL TRANSMISSION
OUTPUT SHAFT REAR
SET NUT
37 (379, 27)
GASKET
DRAIN PLUG
43 (440, 32)
37 (379, 27) O-RING
FILLER PLUG
x 12
CLUTCH
RELEASE
FORK GASKET
PARKING BRAKE
37 (379, 27) DRUM SUB-ASSEMBLY
x4
47 (480, 35) 47 (475, 34)
RELEASE FORK SUPPORT 27 (275, 20)

CLUTCH RELEASE
BEARING ASSEMBLY
BOOT CLUTCH RELEASE
CYLINDER ASSEMBLY
Release hub grease
MP grease
C162829E01
REMOVAL
TERMINAL
2. REMOVE EXHAUST PIPE ASSEMBLY

HINT:
3. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET
(a) Remove the 2 bolts and No. 1 exhaust pipe support
bracket.
See chapter PR.
MT
C154971

REAR SET NUT
(a) Using a chisel and hammer, unstake the
transmission output shaft rear set nut.
(b) Fully apply the parking brake and shift into reverse.
C156176
(c) Using a 32 mm socket wrench, remove the

(d) Using a screwdriver, remove the O-ring.
(a) Release the parking brake.
(b) Remove the parking brake drum sub-assembly.
C152470
(c) If the brake drum cannot be removed easily, turn the

shoe adjuster clockwise until the drum turns freely.
C156872

ASSEMBLY
(a) Remove the 4 bolts and disconnect the parking
brake plate sub-assembly.
HINT:
Use wire or an equivalent tool to prevent the parking
brake plate sub-assembly from hanging down by
the parking brake cable.
C158272

CONTROL CABLE
MT (a) Remove the 2 nuts, and disconnect the shift and
(b) Remove the 2 clips and disconnect the shift and
Select select transmission control cables from the No. 1
Lever
Shift Lever
C161590E01

ASSEMBLY
(a) Remove the 2 bolts and disconnect the clutch tube.
C149953
(b) Remove the 2 bolts and disconnect the clutch

release cylinder.
10. SUPPORT TRANSMISSION ASSEMBLY
(a) Support the transmission assembly with a
transmission jack.
C149947

(a) Remove the nut.
C152340
(b) Remove the 4 bolts and disconnect the No. 3

engine mounting bracket.
C158268

(a) Remove the nut.
MT
C152341
(b) Remove the 4 bolts and disconnect the No. 1

engine mounting bracket.
(a) Support the engine assembly with a transmission
jack.
NOTICE:
Do not tilt the engine and transmission
assembly more than necessary.
C158269

(b) Remove the transmission assembly.
NOTICE:
Do not apply excessive force to the
transmission assembly as this will break the
input shaft.
C158266
15. REMOVE CLUTCH RELEASE BEARING ASSEMBLY

(a) Separate the clutch release fork from the release
fork support.
(b) Remove the clutch release fork with the clutch
release bearing assembly from the transmission
assembly.
(c) Remove the boot.
C156177
(d) Disconnect the release bearing assembly from the

release fork.
C152316

(a) Remove the release fork support.
MT
C156178
INSTALLATION
(a) Install the release fork support to the transmission
assembly.
C156178
2. INSTALL CLUTCH RELEASE BEARING ASSEMBLY

Grease:
equivalent
Grease
C162058E01
(b) Install the release bearing assembly to the release

fork.
C152316
(c) Apply clutch spline grease to the input shaft spline.

Grease:
equivalent
Grease (d) Install the boot.
(e) Install the clutch release fork assembly to the
transmission assembly.
C152312E01
(f) Install the release fork to the release fork support.

NOTICE:
After installation, move the fork back and forth MT
smoothly.
C156177

(a) Support the manual transmission with a
transmission jack.
(b) Install the transmission assembly.
NOTICE:
input shaft.
(c) Install the 12 bolts.
C158266 Torque: 43 N*m (440 kgf*cm, 32 ft.*lbf)
4. INSTALL NO. 1 ENGINE MOUNTING BRACKET

(a) Install the No. 1 engine mounting bracket with the 4
bolts.
C158269
(b) Install the nut.

C152341

bolts.
C158269

MT
C152340

(a) Install the clutch release cylinder assembly with the
2 bolts.
C149947
(b) Install the clutch tube with the 2 bolts.

C149953

CONTROL CABLE
Select cables to the shift lever and select lever with the 2
Lever
nuts.
Shift Lever Torque: 28 N*m (280 kgf*cm, 20 ft.*lbf)
C161590E01

(a) Install the parking brake plate sub-assembly with
the 4 bolts.
(a) Install the parking brake drum sub-assembly.
REAR SET NUT
C158272 (a) Apply MP grease to a new O-ring, and install it to
the companion flange.
(b) Fully apply the parking brake and shift into 1st gear.
(c) Using a 32 mm socket wrench, install a new
transmission output shaft rear set nut. MT
C152470
(d) Using a chisel and hammer, stake the transmission

output shaft rear set nut.
See chapter PR.
C156176
12. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET

(a) Install the No. 1 exhaust pipe support bracket with
the 2 bolts.
13. INSTALL EXHAUST PIPE ASSEMBLY
HINT:
C154971 TERMINAL
15. ADJUST PARKING BRAKE SHOE CLEARANCE
HINT:
16. INSPECT AND ADJUST MANUAL TRANSMISSION
OIL LEVEL
HINT:
TRANSMISSION

SHIFT AND SELECT TRANSMISSION CONTROL CABLE (for Stan-
dard Body)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-4 MT
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-7
SHIFT AND SELECT TRANSMISSION CONTROL CABLE (for Wide
Body)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-12
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-15
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-21
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-21
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-26
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-39
M550 MANUAL TRANSMISSION – MANUAL TRANSMISSION SYSTEM MT–1
MANUAL TRANSMISSION
SYSTEM
parts as necessary.
Oil (wrong) MT-2
Abnormal noise
Gears (worn or damaged) (*1)
MT
Oil leak Gasket (damaged) (*1)
Oil seal (worn or damaged) (*2)
Hard shifting or will not shift Synchronizer ring (worn or damaged) (*1)
Shift key spring (damaged) (*1)
Shift detent spring (damaged) (*1)
Shift fork (worn) (*1)
Jumps out of gear
Gear (worn or damaged) (*1)

MT–2 M550 MANUAL TRANSMISSION – MANUAL TRANSMISSION OIL

1. CHECK TRANSMISSION OIL
0 to 5 mm
D025304E01 opening.
Oil grade:
GL-4 or 5
Viscosity:
SAE 75W-90
NOTICE:
MT • Problems may occur when the oil level is too
high or too low.
(d) Check for oil leakage if the oil level is low.

TRANSMISSION
Standard Body)
COMPONENTS
SHIFTING HOLE COVER

SUB-ASSEMBLY MT
x3
PARKING BRAKE
CLIP HOLE COVER
WASHER
12 (122, 9)
TRANSMISSION
CONTROL CABLE
CLIP BRACKET
SHIFT AND SELECT

18 (184, 13) TRANSMISSION
18 (184, 13)
CONTROL CABLE
TRANSMISSION
CONTROL CABLE
CLAMP
CLIP
18 (184, 13)
18 (184, 13) 18 (184, 13)
28 (280, 20)
x2 18 (184, 13)

C161593E01
REMOVAL
C159400

cover.
MT
C159401

C159402

C159403

CONTROL CABLE
assembly.
C161585

lever retainer.
C161586

MT
Select Shift
Lever Lever
C149941E01

C149942
(f) Remove the nut and transmission control cable

bracket.
C149958
(g) Remove the nut and transmission control cable

bracket.
C151313
(h) Remove the nut and transmission control cable

bracket.
C161571
(i) Remove the 2 nuts, bolt, and 2 transmission control

cable brackets.
MT
C161570

clamp.
(k) Pull out the shift and select transmission control
ADJUSTMENT
C158791
C161585
Lock Nut
C162047E01

C161585

check that the shift lever is perpendicular to the MT
correctly.
smoothly.
INSTALLATION
CONTROL CABLE
C149942
(c) Install the shift and select transmission control cable

to the shift lever and select lever with the 2 nuts.
Select Shift
Lever Lever
C149941E01
(d) Install the transmission control cable clamp with the

bolt.
C158791
(e) Install the 2 transmission control cable brackets with

the 2 nuts and bolt.
MT
C161570
(f) Install the transmission control cable bracket with

the nut.
C161571

the nut.
C151313
(h) Install the transmission control cable bracket with

the nut.
C149958
(i) Install the shift and select transmission control

C161586
(j) Install the control select cable to the shift lever

(k) Install the control shift cable to the shift lever
HINT:
C161585
See page MT-6.
C159403

cover sub-assembly.
C159402

C159401

C162050
MT

TRANSMISSION
Wide Body)
COMPONENTS

MT

x3 PARKING BRAKE
HOLE COVER
SHIFT AND SELECT
TRANSMISSION
CONTROL CABLE
CLIP
WASHER
CLIP
CABLE BRACKET
12 (122, 9)
18 (184, 13)
CLIP
TRANSMISSION CONTROL CABLE CLAMP
WASHER 18 (184, 13)

CONTROL CLIP
CABLE CLAMP
TRANSMISSION
CONTROL
CABLE CLAMP 28 (280, 20)
18 (184, 13)
CABLE BRACKET
Non-reusable part
C161594E01
REMOVAL
C159400

cover.
MT
C159401

C159402

C159403

CONTROL CABLE
C161585

lever retainer.
C161586

select transmission control cable from the shift lever
and select lever.
MT
Select Shift
Lever Lever
C149941E01

C149942
(f) Remove the 2 nuts and 2 transmission control cable

brackets.
(g) Remove the transmission control cable clamp from
Bracket
Clamp
C160011E01
C152476
(i) Remove the nut and transmission control cable

bracket.
C152475

bracket.
MT
C152479

clamp.
(l) Pull out the shift and select transmission control
ADJUSTMENT
C156185
C161585
(d) Loosen the lock nuts and adjust the shift lever range
Lock Nut by turning the ball joints.
Lock Nut
C162047E01

C161585

check that the shift lever is perpendicular to the MT
correctly.
smoothly.
INSTALLATION
CONTROL CABLE
C149942
(c) Install the shift and select transmission control

cables to the shift lever and select lever with the 2
nuts.
Select Shift
Lever Lever
C149941E01
(d) Install the transmission control cable clamp with the

bolt.
C156185
(e) Install the transmission control cable bracket with

the bolt.
MT
C152479

the nut.
C152475
(g) Install a new transmission control cable clamp.

HINT:
If the clamp cannot fully secure the cables, a
C152476
(h) Install a new transmission control cable clamp to the

transmission control cable.
(i) Install the 2 transmission control cable brackets with
the 2 nuts.
Bracket
Clamp
C160011E01
(j) Install the shift and select transmission control

C161586
(k) Connect the control select cable to the shift lever

(l) Install the control shift cable to the shift lever
HINT:
C161585
See page MT-14.
C159403

cover sub-assembly.
C159402

C159401

C162050
MT
M550 MANUAL TRANSMISSION – SHIFT LEVER ASSEMBLY MT–19

TRANSMISSION
COMPONENTS
MT
x3
PARKING BRAKE
HOLE COVER
18 (184, 13)
WASHER
CLIP x4
CLIP
12 (122, 9)
CLIP

RETAINER GROMMET
SHIFT AND SELECT x4
TRANSMISSION
RETAINER BUSHING
Non-reusable part
C160012E01
MT–20 M550 MANUAL TRANSMISSION – SHIFT LEVER ASSEMBLY

SUB-ASSEMBLY
12 (122, 9)
CUSHION
MT
SNAP RING
WASHER
15 (150, 11)
SELECTING
BELLCRANK BUSHING
x2
COLLAR
7.5 (76, 66 in.*lbf)

LEVER STOPPER
SELECT LEVER
NO. 1 FLOOR
SELECT LEVER
COLLAR
FLOOR SHIFT CONTROL

SUB-ASSEMBLY
MP grease
C160013E02
REMOVAL
page MT-4)
2. REMOVE PARKING BRAKE HOLE COVER (See page
MT-4)
(See page MT-4)
4)
CONTROL CABLE
cable from the shift lever assembly. MT
C161585

lever retainer.
C161586

C161587
DISASSEMBLY
C161580
C161598

MT
C161595

Bushing
C158794E01

ASSEMBLY
lever.
C161573

lever.
Collar
Bushing
Bushing
C161574E01

MT
C161575

Cushion
lever.
Bushing
C158795E01

C161596

GROMMET
(a) Remove the 4 grommets and 4 bushings from the
C161597
REASSEMBLY
GROMMET
(a) Install the 4 bushings and 4 grommets to the shift
lever retainer.
C161597

MT Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
C161596E01

bushing.
C091114

C161575E01

(b) Apply MP grease to both sides of 2 bushings.
C161574E02

ASSEMBLY
(a) Install the shift lever to the select lever with the bolt
and nut.
C161573
MT
C161584

bushing.
C091115

lever retainer.
C161595

C161598

MT
C161580
INSTALLATION
C161587

CONTROL CABLE
C161586

(c) Install the control shift cable to the shift lever
HINT:
C161585
(See page MT-6)

9)
(See page MT-9)
6. INSTALL PARKING BRAKE HOLE COVER (See page
MT-9)
page MT-10)
MT

TRANSMISSION
COMPONENTS
B265 Type: 75 (760, 55)
x4
M153, M550, A860E Type: x4

MT 75 (760, 55)
MYY5, MYY6 Type: 103 (1050, 76) x4
x4
75 (760, 55)
x4
x4
75 (760, 55)
x4
x4
75 (760, 55)
ASM91-003
75 (760, 55)
MT
x4
x4
x4
75 (760, 55)

ASM91-001
Propeller Shaft:
6.4 (65, 57 in.*lbf)

GREASE FITTING
ASSEMBLY
THRUST WASHER
x4
x4
MT
x4
RETAINER RING
SPIDER BEARING
x4
THRUST WASHER
x4
6.4 (65, 57 in.*lbf)
RETAINER RING x4

ASSEMBLY
DUST SEAL
SLIDING YOKE
6.4 (65, 57 in.*lbf)
GREASE FITTING
Non-reusable part
MP Grease
C153112E01

x4
M153, M550, A860E Type:
75 (760, 55)
75 (760, 55)
x4
MYY5, MYY6 Type: 103 (1050, 76)
x4

MT
x4
52 (525, 38)

x4

75 (760, 55)
x4
MYY6 Type: 103 (1050, 76)
x4 CENTER SUPPORT
BEARING COVER
CENTER SUPPORT x4
BEARING COVER
52 (525, 38)
x4
ASSEMBLY 52 (525, 38)
75 (760, 55)
x4
ASM91-002
3 and
3 and 4
4 Joint
Joint Type
Type (Intermediate
(Intermediate shaft
shaft and
and Propeller
shaft center):
DUST DEFLECTOR
MT SPIDER BEARING x4
INTERMEDIATE SHAFT
THRUST WASHER x4
6.4 (65, 57 in.*lbf)
GREASE FITTING
UNIVERSAL JOINT
687 (7000, 506)
SPIDER ASSEMBLY
FLANGE YOKE x4
6.4 (65, 57 in.*lbf)
GREASE FITTING
RETAINER RING
27 (270, 20) x4

x4 DUST DEFLECTOR
BEARING PLATE
Non-reusable part
MP Grease
C161496E02

GASKET
50 (510, 37)
NO. 1 EXHAUST PIPE
VACUUM HOSE
SUPPORT BRACKET
x3
25 (259, 19)
50 (510, 37)
30 (306, 22)
x2 x4
GASKET
GASKET
MT
EXHAUST RETARDER
ASSEMBLY
Non-reusable part
C162830E01
WIRE HARNESS
CLIP 28 (280, 20)
57 (585, 42)
CLIP
x4
SHIFT AND SELECT TRANSMISSION CONTROL CABLE 64 (653, 47)
NO. 3 ENGINE
37 (377, 27) NO. 1 TRANSMISSION MOUNTING BRACKET
57 (585, 42)
CONTROL CABLE BRACKET x4
MT x3 127 (1300, 94)
MANUAL TRANSMISSION
OUTPUT SHAFT REAR SET
NUT
37 (380, 27) 43 (440, 32)
FILLER PLUG
GASKET
MANUAL TRANSMISSION
ASSEMBLY
CLUTCH x 12
RELEASE
FORK
O-RING
PARKING BRAKE DRUM

SUB-ASSEMBLY
x4
GASKET
95 (964, 70)
CLUTCH
47 (480, 35) 37 (380, 27) PARKING BRAKE
RELEASE
BEARING RELEASE FORK SUPPORT DRAIN PLUG PLATE SUB-ASSEMBLY
ASSEMBLY
for
for W04D series:
W04D-TM, W04D-TN: for N04C series:
for N04C-TT:
BOOT
CLUTCH RELEASE
N*m (kgf*cm, ft.*lbf) : Specified torque CYLINDER ASSEMBLY

12 (120, 9)
Clutch spline grease 12 (120, 9)
Release hub grease x2 x2
MP grease CLUTCH RELEASE CYLINDER ASSEMBLY

C162070E01
REMOVAL
TERMINAL

chapter EX)
bracket.
(See chapter PR)
C154971

REAR SET NUT MT
C156176

(b) Remove the parking brake drum sub-assembly and
companion flange.
C152470
(c) for Standard cab 2.0 t and 3.0 t, wide cab 2.0 t:
HINT:
If the brake drum cannot be removed easily, turn the
shoe adjuster clockwise until the drum turns freely.
C156872
(d) for Wide cab over 2.0 t (200 mm type):

HINT:
If the brake drum cannot be removed easily, remove
the rubber plug, and turn the shoe adjuster in the
direction of the illustrated arrow mark until the drum
turns freely.
C162824

Standard Cab 2.0 t and 3.0 t ASSEMBLY
Wide Cab 2.0 t: (a) Remove the 4 bolts and disconnect the parking
MT HINT:
Wide Cab Over 2.0 t (200 mm Type):
C162823E01

CONTROL CABLE
(a) Remove the 2 nuts and disconnect the shift and
Select Shift
Lever Lever
C149941E01
(b) Remove the 2 clips and disconnect the shift and

select transmission control cables from the
C149942

ASSEMBLY
(a) for N04C series:
(1) Remove the 2 bolts and disconnect the clutch
release cylinder. MT
C152310
(b) for W04 series:

tube.
C149953

release cylinder.
transmission jack.
C149947

(a) Remove the nut and 4 bolts and disconnect the No.
Nut
3 engine mounting bracket.
C149944E01

(a) Remove the nut and 4 bolts and disconnect the No.
Nut 1 engine mounting bracket.
jack.
NOTICE:
C149945E01

(a) Disconnect the connector and clamp.
(b) Remove the 12 bolts.
(c) Remove the transmission assembly.
MT NOTICE:
input shaft.
C152313E01
15. REMOVE NO. 1 TRANSMISSION CONTROL CABLE

BRACKET
(a) Remove the 3 bolts and No. 1 transmission control
cable bracket.
C149946

fork support.
assembly.
C156177

release fork.
C152316

MT
C156178
INSTALLATION
assembly.
C156178

Grease:
equivalent
Grease
C162058E01

fork.
C152316

Grease:
equivalent
(e) Install the clutch release fork to the transmission
assembly.
C152312E01

NOTICE:
MT smoothly.
C156177
3. INSTALL NO. 1 TRANSMISSION CONTROL CABLE

BRACKET
(a) Install the No. 1 transmission control cable bracket
with the 3 bolts.
C149946

transmission jack.
(b) Install the transmission assembly.
NOTICE:
input shaft.
C152313E01 Torque: 43 N*m (440 kgf*cm, 32 ft.*lbf)
(d) Connect the connector and clamp.
Nut bolts.
C149945E01

Nut
bolts.
C149944E01

(a) for N04C series:
(1) Install the clutch release cylinder assembly with
the 2 bolts.
C152310
(b) for W04D series:

(1) Install the clutch release cylinder assembly with
the 2 bolts.
C149947
(2) Install the clutch tube with the 2 bolts.

C149953

CONTROL CABLE
(a) Install the No. 1 transmission control cable bracket
with 2 new clips.
C149942
(b) Install the shift lever and select lever with the 2 nuts.
Select Shift
Lever Lever
C149941E01

Standard Cab 2.0 t and 3.0 t (a) Install the parking brake plate sub-assembly with
Wide Cab 2.0 t: the 4 bolts.
MT
(a) Install the parking brake drum sub-assembly.
REAR SET NUT
(a) Apply MP grease to a new O-ring, and install it to
the companion flange.
Wide Cab Over 2.0 t (200 mm Type):
C162823E01

C152470

(See chapter PR)
C156176

the 2 bolts.
MT
chapter EX)
TERMINAL
C154971
HINT:
OIL LEVEL
HINT:
See page MT-2.
TRANSMISSION

COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-4
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-7
MT
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-13
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-13
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-18
SPEEDOMETER SENSOR
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-21
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-32
MYY5A MANUAL TRANSMISSION – MANUAL TRANSMISSION SYSTEM MT–1
MANUAL TRANSMISSION
SYSTEM
parts as necessary.
Oil (wrong) MT-2
Abnormal noise
Gears (worn or damaged) -
Bearing (worn or damaged) -
Oil level (high) MT-2 MT
Oil leak Gasket (damaged) -
Oil seal (worn or damaged) -
Hard shifting or will not shift Synchronizer ring (worn or damaged) -
Shift key spring (damaged) -
Detent spring (damaged) -
Shift fork (worn) -
Jumps out of gear
Gear (worn or damaged) -
Bearing (worn or damaged) -
MT–2 MYY5A MANUAL TRANSMISSION – MANUAL TRANSMISSION OIL

1. CHECK MANUAL TRANSMISSION OIL
0 to 5 mm
D025304E01 opening.
Oil grade:
API CD, CE, CF, CH-4 or Cl-4
Viscosity:
SAE 10W-30 or 10W-40
SAE 15W-40
SAE 30
MT SAE 40
NOTICE:
high or too low.
(d) Check for oil leaks if the oil level is low.
MYY5A MANUAL TRANSMISSION – SHIFT AND SELECT TRANSMISSION CONTROL
CABLE MT–3

TRANSMISSION
COMPONENTS
SHIFTING HOLE COVER

SUB-ASSEMBLY
x3
PARKING BRAKE
MT
HOLE COVER
SCREW
SHIFT AND SELECT

WASHER
TRANSMISSION
CONTROL CABLE CLIP
TRANSMISSION
CONTROL CABLE
12 (122, 9) BRACKET TRANSMISSION CONTROL
CABLE INSULATOR
CLIP
18 (184, 13)
18 (184, 13)
18 (184, 13)
CABLE CLAMP x2
TRANSMISSION
CONTROL CABLE
CLAMP
WASHER CLIP
28 (280, 20)
18 (184, 13)
x2 18 (184, 13) 18 (184, 13)
N*m (kgf*cm, ft.*lbf) : Specified torque TRANSMISSION CONTROL 28 (280, 20)

CABLE BRACKET
Non-reusable part
C162055E01
MT–4 CABLE
REMOVAL
C159400

cover.
MT
C159401

C159402

C159403

CONTROL CABLE
(a) Remove the nut and disconnect the transmission
control shift cable from the shift lever assembly.
assembly.
C161585
CABLE MT–5

lever retainer.
C161586

Select Lever lever and select lever.
select transmission control cables from the
transmission control cable bracket. MT
Shift Lever
C156174E01
(f) Remove the 2 bolts and transmission control cable

insulator.
C162827
(g) Remove the bolt and transmission control cable

bracket.
C152345
MT–6 CABLE
C152480
(i) Remove the bolt and transmission control cable

clamp.
MT
C162053
(j) Remove the nut and transmission control cable

bracket.
C161571
(k) Remove the 2 nuts, bolt, and 2 transmission control

cables brackets.
C161570
(l) Remove the bolt and transmission control cable

clamp.
ADJUSTMENT
C158791
CABLE MT–7

C161585
Lock Nut
MT
C162047E01

C161585

correctly.
C162052 abnormal force is required.
smoothly.
INSTALLATION
CONTROL CABLE
MT–8 CABLE

lever with the nut.
Select Lever Torque: 28 N*m (280 kgf*cm, 20 ft.*lbf)
(d) Install the transmission control select cable to the
select lever with the nut.
Shift Lever
MT
C156174E01

bolt.
C158791
(f) Install the 2 transmission control cable brackets with

2 nuts and bolt.
C161570

the nut.
C161571
CABLE MT–9
(h) Install the transmission control cable clamp with the

bolt.
C162053
(i) Install a new transmission control cable clamp.

HINT:
MT
C152480
(j) Install the transmission control cable bracket with

the bolt.
C152345
(k) Install the transmission control cable insulator with

the 2 bolts.
C162827
(l) Install the shift and select transmission control

C161586
MT–10 CABLE
(m) Install the transmission control select cable to the

(n) Install the transmission control shift cable to the shift
HINT:
C161585
See page MT-6.
MT
C159403

cover sub-assembly.
C159402

C159401

C162050
MYY5A MANUAL TRANSMISSION – SHIFT LEVER ASSEMBLY MT–11

TRANSMISSION
COMPONENTS
MT
x3
PARKING BRAKE
HOLE COVER
18 (184, 13)
WASHER
CLIP x4
CLIP
12 (122, 9)
CLIP

RETAINER GROMMET
SHIFT AND SELECT x4
TRANSMISSION
RETAINER BUSHING
Non-reusable part
C160012E01
MT–12 MYY5A MANUAL TRANSMISSION – SHIFT LEVER ASSEMBLY

SUB-ASSEMBLY
12 (122, 9)
CUSHION
SNAP RING
MT
WASHER
15 (150, 11)
SELECTING
BELLCRANK BUSHING
x2
COLLAR
7.5 (76, 66 in.*lbf)

LEVER STOPPER
SELECT LEVER
NO. 1 FLOOR
SELECT LEVER
COLLAR
FLOOR SHIFT CONTROL

SUB-ASSEMBLY
MP grease
C160013E02
REMOVAL
page MT-4)
MT-4)
(See page MT-4)
4)
CONTROL CABLE
control select cable from the shift lever assembly. MT
C161585

lever retainer.
C161586

C161587
DISASSEMBLY
C161580
C161598

MT
C161595

Bushing
C158794E01

ASSEMBLY
lever.
C161573

lever.
Collar
Bushing
Bushing
C161574E01

MT
C161575

Cushion
lever.
Bushing
C158795E01

C161596

GROMMET
(a) Remove the 4 grommets and bushings from the
C161597
REASSEMBLY
GROMMET
(a) Install the 4 bushings and grommets to the shift
lever retainer.
C161597

MT
C161596E01

bushing.
C091114

C161575E01

(b) Apply MP grease to both sides of 2 the bushings.
C161574E02

ASSEMBLY
(a) Install the shift lever to the select lever with the bolt
and nut.
C161573
MT
C161584

bushing.
C091115

lever retainer.
C161595

C161598

MT
C161580
INSTALLATION
C161587

CONTROL CABLE
C161586

HINT:
C161585
See page MT-6.

10)
(See page MT-10)
MT-10)
page MT-10)
MT
MT–20 MYY5A MANUAL TRANSMISSION – SPEEDOMETER SENSOR
SPEEDOMETER SENSOR
TRANSMISSION
COMPONENTS
SPEEDOMETER SLEEVE LOCK PLATE
MT
19 (196, 14)
SPEEDOMETER DRIVEN (MTM)

GEAR SUB-ASSEMBLY
C152492E01
REMOVAL
1. REMOVE SPEEDOMETER DRIVEN (MTM) GEAR
SUB-ASSEMBLY
MYY5A MANUAL TRANSMISSION – SPEEDOMETER SENSOR MT–21
(b) Remove the bolt and plate, and remove the

speedometer driven gear sub-assembly.
Identification groove Number of teeth Identification paint

Left side 1 15 / 4 White
NOTICE:
• Installing the speedometer driven gear into
the manual transmission improperly will
result in inaccurate readings of the
speedometer. Check the painted number of
teeth of the speedometer driven gear before
reinstalling.
• If the identification paint cannot be identified,
Identification Groove
refer to the identification groove on the
speedometer driven gear and the table above
to determine the number of teeth before
3 3 3 3 3 3 reinstalling. MT
Left Side Right Side
Number of Teeth
Identification
Paint
Lock Plate
C158289E01
INSTALLATION
1. INSTALL SPEEDOMETER DRIVEN (MTM) GEAR
SUB-ASSEMBLY
(a) Coat the O-ring with engine oil.
(b) Positioning the painted number of teeth and the lock
plate as shown in the illustration, install the
O-ring speedometer driven gear with the bolt.
Number of Teeth NOTICE:
refer to the identification groove on the gear
Identification and the table above to determine the number
Paint
of teeth and position the appropriate number
of teeth as shown in the illustration when
Lock Plate
installing the speedometer driven gear.
• Make sure that the number of teeth can be
seen after installing the gear.
C152320E01
MT–22 MYY5A MANUAL TRANSMISSION – MANUAL TRANSMISSION ASSEMBLY

TRANSMISSION
COMPONENTS
B265 Type: 75 (760, 55)
x4
M153, M550, A860E Type: x4

75 (760, 55)
MT
MYY5, MYY6 Type: 103 (1050, 76) x4
x4
75 (760, 55)
x4
x4
75 (760, 55)
x4
x4
75 (760, 55)
ASM91-003
MYY5A MANUAL TRANSMISSION – MANUAL TRANSMISSION ASSEMBLY MT–23
75 (760, 55)
x4 MT
x4
x4
75 (760, 55)

ASM91-001
Propeller Shaft:
6.4 (65, 57 in.*lbf)

GREASE FITTING
ASSEMBLY
THRUST WASHER
x4
x4

MT
x4
RETAINER RING
SPIDER BEARING
x4
THRUST WASHER
x4
6.4 (65, 57 in.*lbf)
RETAINER RING x4

ASSEMBLY
DUST SEAL
SLIDING YOKE
6.4 (65, 57 in.*lbf)
GREASE FITTING
Non-reusable part
MP Grease
C153112E01

x4
M153, M550, A860E Type:
75 (760, 55)
75 (760, 55)
x4
MYY5, MYY6 Type: 103 (1050, 76)
x4
x4 MT
52 (525, 38)

x4

75 (760, 55)
x4
MYY6 Type: 103 (1050, 76)
x4 CENTER SUPPORT
BEARING COVER
CENTER SUPPORT x4
BEARING COVER
52 (525, 38)
x4
ASSEMBLY 52 (525, 38)
75 (760, 55)
x4
ASM91-002
3 and
3 and 4
4 Joint
Joint Type
Type (Intermediate
(Intermediate shaft
shaft and
and Propeller
shaft center):
DUST DEFLECTOR
SPIDER BEARING x4
INTERMEDIATE SHAFT
MT
THRUST WASHER x4
6.4 (65, 57 in.*lbf)
GREASE FITTING
UNIVERSAL JOINT
687 (7000, 506)
SPIDER ASSEMBLY
FLANGE YOKE x4
6.4 (65, 57 in.*lbf)
GREASE FITTING
RETAINER RING
27 (270, 20) x4

x4 DUST DEFLECTOR
BEARING PLATE
Non-reusable part
MP Grease
C161496E02
GASKET

50 (510, 37)
NO. 1 EXHAUST PIPE

SUPPORT BRACKET x3 VACUUM HOSE
25 (259, 19)
50 (510, 37)
30 (306, 22)
x2 x4
GASKET
GASKET MT
EXHAUST RETARDER
ASSEMBLY
Non-reusable part
C162833E01
18 (184, 13)
28 (280, 20) x2
WIRE HARNESS
SHIFT CABLE
103 (1050, 76)
x3
x3
SELECT CABLE
NO. 1 ENGINE
MT x3 x3
64 (653, 47)
39 (400, 29) 289 (2947, 213)
DRAIN PLUG MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT
GASKET
39 (400, 29) 43 (440, 32) O-RING
FILLER PLUG GASKET x 12
COMPANION FLANGE
47 (480, 35)
RELEASE FORK
SUPPORT
RELEASE FORK
8.2 (84, 73 in.*lbf)
PARKING BRAKE
127 (1290, 93) x4
DUST COVER
PARKING BRAKE PLATE

CLUTCH RELEASE SUB-ASSEMBLY PARKING BRAKE
BEARING ASSEMBLY DRUM SUB-ASSEMBLY
BOOT
CLUTCH RELEASE
CYLINDER ASSEMBLY
12 (120, 9)
Non-reusable part
x2
Release hub grease

C162835E01
REMOVAL
TERMINAL

A164456

chapter EX)
MT
A152398E01

bracket.
(See chapter PR)
C154971

REAR SET NUT
C152469

C152470

(a) Remove the bolt and dust cover from the parking
brake drum.
(b) Release the parking brake.
(c) Remove the parking brake drum sub-assembly and
companion flange.
C156869
(d) If the brake drum cannot be removed easily, turn the

shoe adjuster in the direction of the illustrated arrow
mark until the drum turns freely.
MT
C162048

ASSEMBLY
(a) Remove the 4 nuts and disconnect the parking
HINT:
C156871

CABLE
(a) Remove the nut and control select cable from the
select lever.
Select Lever
C152328E01

CABLE
Shift Lever (a) Remove the nut and control shift cable from the shift
lever.
C152311E01

ASSEMBLY
(a) Remove the 2 bolts and disconnect the clutch
release cylinder.
transmission jack.
C152310

(a) Remove the nut.
MT
C152340
(b) Remove the 3 bolts and 3 washers and disconnect

the No. 3 engine mounting bracket.
C152339

(a) Remove the nut.
C152341

jack.
NOTICE:
C152338 16. REMOVE MANUAL TRANSMISSION ASSEMBLY

NOTICE:
input shaft.
C152313E01

fork support.
MT assembly.
C152315

release fork.
C152316

C152317
INSTALLATION
assembly.
C152317

Grease:
equivalent
Grease
C162058E01

fork.
MT
C152316

Grease:
equivalent
assembly.
C152312E01

NOTICE:
smoothly.
C152315

transmission jack.
(b) Install the transmission.
NOTICE:
input shaft.

bolts and 3 washers.
C152338

MT
C152341

C152339

C152340

2 bolts.
C152310

(a) Install the control shift cable to the shift lever with
Shift Lever the nut.
C152311E01

CABLE
(a) Install the control select cable to the select lever
with the nut.
MT
Select Lever
C152328E01

the 4 nuts.
(a) Install the companion flange.
C156871
(b) Install the parking brake dust cover to the parking

brake drum sub-assembly with the bolt.
(c) Install the parking brake drum sub-assembly.
REAR SET NUT
(a) Apply engine oil to a new O-ring, and install it to the
companion flange.
(b) Fully apply the parking break and shift into 1st gear.
C156869

C152470

(See chapter PR)
C152469

the 2 bolts.
MT chapter EX)
C154971

(a) Install the 2 new gaskets and exhaust retarder
A152398E01

TERMINAL
HINT:
OIL LEVEL (See page MT-2)
A164456

TRANSMISSION

MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-4
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-7 MT
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-10
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-16
SPEEDOMETER SENSOR
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-18
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-30
MANUAL TRANSMISSION UNIT
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-36
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-40
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-45
INPUT SHAFT
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-56
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-56
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-57
OUTPUT SHAFT
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-59
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-60
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-63
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-65
COUNTER GEAR AND REVERSE IDLER GEAR
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-72
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-72
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-74
SHIFT LEVER SHAFT HOUSING
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-77
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-78
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MT-79
MT
MYY6S MANUAL TRANSMISSION – MANUAL TRANSMISSION SYSTEM MT–1
MANUAL TRANSMISSION
SYSTEM
parts as necessary.
Oil (wrong) MT-2
Gears (worn or damaged) MT-40
- MT-56
- MT-60
Abnormal noise
- MT-72
Bearing (worn or damaged) MT-40 MT
- MT-56
- MT-60
- MT-72
Oil leak Gasket (damaged) MT-40
Oil seal (worn or damaged) MT-3
Synchronizer ring (worn or damaged) MT-40
- MT-56
Hard shifting or will not shift
- MT-60
Shift key spring (damaged) MT-40
- MT-60
Detent spring (damaged) MT-40
- MT-78
Shift fork (worn) MT-40
Gear (worn or damaged) MT-40
- MT-56
Jumps out of gear - MT-60
- MT-72
Bearing (worn or damaged) MT-40
- MT-56
- MT-60
- MT-72
MT–2 MYY6S MANUAL TRANSMISSION – MANUAL TRANSMISSION OIL

1. CHECK MANUAL TRANSMISSION OIL
0 to 5 mm
D025304E01 opening.
Oil grade:
API: CD, CE, CF, CH-4, Cl-4 or CJ-4
JASO: DH-1 or DH-2
ACEA: E-3, E-4, E-5 or E-6
Viscosity:
SAE 10W-30 or 10W-40
SAE 15W-40
SAE 30
MT SAE 40
NOTICE:
high or too low.
(d) Check for oil leaks if the oil level is low.
MYY6S MANUAL TRANSMISSION – MANUAL TRANSMISSION EXTENSION HOUSING
OIL SEAL MT–3
MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL

TRANSMISSION
COMPONENTS
MANUAL TRANSMISSION
EXTENSION HOUSING
39 (400, 29) OIL SEAL
GASKET
DRAIN PLUG
GASKET
39 (400, 29)
FILLER PLUG
MT
COMPANION O-RING
FLANGE
127 (1290, 93)
289 (2947, 213)

MANUAL TRANSMISSION
x4 OUTPUT SHAFT REAR SET NUT
PARKING BRAKE DRUM

PARKING SUB-ASSEMBLY
BRAKE PLATE
SUB-ASSEMBLY
Non-reusable part
MP grease
C161581E01
REMOVAL
1. DRAIN MANUAL TRANSMISSION OIL
(a) Remove the filler plug and gasket.
(b) Remove the drain plug and gasket, and then drain
the manual transmission oil.
(c) Install a new gasket and the drain plug.
2. REMOVE PROPELLER SHAFT ASSEMBLY (See page
MT-26)
MT–4 OIL SEAL

REAR SET NUT (See page MT-27)
(See page MT-27)
6. REMOVE PARKING BRAKE PLATE SUB-ASSEMBLY
(See page MT-28)
7. REMOVE MANUAL TRANSMISSION EXTENSION
SST
HOUSING OIL SEAL
(a) Using SST, remove the oil seal.
SST 09308-00010
INSTALLATION
1. INSTALL MANUAL TRANSMISSION EXTENSION
HOUSING OIL SEAL
MT (a) Coat the outside of the oil seal with engine oil.
C156881E01
(b) Using SST and a hammer, install a new oil seal to

SST
the extension housing.
SST 09226-10010, 09309-14010
Drive in depth:
2.5 mm (0.0984 in.)
(c) Coat the lip of the oil seal with MP grease.
(See page MT-33)
(See page MT-33)
REAR SET NUT (See page MT-34)
SST
5. INSTALL PROPELLER INTERMEDIATE SHAFT
C156882E01
6. INSTALL PROPELLER SHAFT ASSEMBLY (See page
MT-34)
HINT:
8. ADD MANUAL TRANSMISSION OIL
(a) Add the manual transmission oil.
(b) Install the filler plug and a new gasket.
OIL SEAL MT–5
10. INSPECT TRANSMISSION OIL LEVEL (See page MT-

2)
MT
MYY6S MANUAL TRANSMISSION – SHIFT AND SELECT TRANSMISSION CONTROL
MT–6 CABLE

TRANSMISSION
COMPONENTS

x3
MT PARKING BRAKE
HOLE COVER
SHIFT AND SELECT
TRANSMISSION
CONTROL CABLE
CLIP
WASHER
CLIP
CABLE BRACKET
12 (122, 9)
18 (184, 13)
CLIP
TRANSMISSION CONTROL CABLE CLAMP
WASHER 18 (184, 13)

CONTROL CLIP
CABLE CLAMP
TRANSMISSION
28 (280, 20)
CONTROL
CABLE CLAMP
18 (184, 13)
CABLE BRACKET
Non-reusable part
C161591E02
CABLE MT–7
REMOVAL
C159400

cover.
MT
C159401

C159402

C159403

CONTROL CABLE
C161585
MT–8 CABLE

lever retainer.
C161586
(d) Remove the nut and disconnect the control shift

cable from the shift lever.
Select Lever (e) Remove the nut and disconnect the control select
cable from the select lever.
(f) Remove the 2 clips and disconnect the shift and
Shift Lever transmission control cable bracket.
MT
C156174E01
(g) Remove the 2 nuts and 2 transmission control cable

brackets.
(h) Remove the transmission control cable clamp from
Bracket
Clamp
C160011E01
(i) Remove the transmission control cable clamp.
C152476
CABLE MT–9
(j) Remove the nut and transmission control cable

bracket.
C152475

bracket.
MT
C152479
(l) Remove the bolt and transmission control cable

clamp.
ADJUSTMENT
C156185
C161585
Lock Nut
C162047E01
MT–10 CABLE

C161585

MT correctly.
smoothly.
INSTALLATION
CONTROL CABLE
(b) Install the control shift cable to the shift lever with
the nut.
Select Lever Torque: 28 N*m (280 kgf*cm, 20 ft.*lbf)
(c) Install the control select cable to the select lever
with the nut.
Shift Lever (d) Install 2 new clips to the No. 1 transmission control
cable bracket.
C156174E01
CABLE MT–11

bolt.
C156185

the bolt.
MT
C152479

the nut.
C152475
(h) Install a new transmission control cable clamp.

HINT:
C152476
(i) Install a new transmission control cable clamp to the

(j) Install the 2 transmission control cable brackets with
the 2 nuts.
Bracket
Clamp
C160011E01
MT–12 CABLE
(k) Install the shift and select transmission control

C161586
(l) Connect the control select cable to the shift lever

(m) Install the control shift cable to the shift lever
HINT:
MT position has been adjusted.
C161585
See page MT-9.
C159403

cover sub-assembly.
C159402

C159401
CABLE MT–13

C162050
MT
MT–14 MYY6S MANUAL TRANSMISSION – SHIFT LEVER ASSEMBLY

TRANSMISSION
COMPONENTS
MT
x3
SHIFT LEVER ASSEMBLY 18 (184, 13)
x4
CLIP
WASHER
PARKING BRAKE HOLE COVER
CLIP
12 (122, 9) NO. 1 CONTROL SHIFT LEVER

RETAINER GROMMET
SHIFT AND SELECT x4

CLIP
TRANSMISSION
CONTROL CABLE x4
SHIFT LEVER RETAINER BUSH
Non-reusable part
C162049E01
MYY6S MANUAL TRANSMISSION – SHIFT LEVER ASSEMBLY MT–15
REMOVAL
page MT-7)
MT-7)
(See page MT-7)
7)
CONTROL CABLE
MT
C161585

lever retainer.
C161586

C161587

GROMMET
(a) Remove the 4 No. 1 control shift lever retainer
grommets and 4 shift lever retainer bushes from the
shift lever assembly.
C156889
MT–16 MYY6S MANUAL TRANSMISSION – SHIFT LEVER ASSEMBLY
INSTALLATION
GROMMET
(a) Install the 4 No. 1 control shift lever retainer
grommets and 4 shift lever retainer bushes to the
shift lever assembly.
C156889

MT
C161587

CONTROL CABLE
C161586
(b) Connect the control select cable to the shift lever

See page MT-9.
C161585 12)
(See page MT-12)
MT-12)
page MT-13)
MYY6S MANUAL TRANSMISSION – SPEEDOMETER SENSOR MT–17
SPEEDOMETER SENSOR
TRANSMISSION
COMPONENTS
SPEEDOMETER SLEEVE LOCK PLATE
MT
19 (196, 14)
SPEEDOMETER DRIVEN (MTM)

GEAR SUB-ASSEMBLY
C152492E01
REMOVAL
1. REMOVE SPEEDOMETER DRIVEN (MTM) GEAR
SUB-ASSEMBLY
MT–18 MYY6S MANUAL TRANSMISSION – SPEEDOMETER SENSOR
(b) Remove the bolt and plate, and remove the

speedometer driven gear sub-assembly.
Identification groove Number of teeth Identification paint

Right side 1 16 / 4 White
NOTICE:
• Installing the speedometer driven gear into
the manual transmission improperly will
result in inaccurate readings of the
Identification Groove speedometer. Check the painted number of
teeth of the speedometer driven gear before
reinstalling.
3 3 3 3 3 3 refer to the identification groove on the
MT Left Side Right Side speedometer driven gear and the table above
to determine the number of teeth before
reinstalling.
Number of Teeth
Identification
Paint
Lock Plate
C158289E01
INSTALLATION
1. INSTALL SPEEDOMETER DRIVEN (MTM) GEAR
SUB-ASSEMBLY
(a) Coat the O-ring with engine oil.
(b) Positioning the painted number of teeth and the lock
plate as shown in the illustration, install the
O-ring speedometer driven gear with the bolt.
Number of Teeth NOTICE:
• If the identification painted cannot be
identified, refer to the identification groove on
Identification the gear and the table above to determine the
Paint
number of teeth and position the appropriate
number of teeth as shown in the illustration
Lock Plate
when installing the speedometer driven gear.
• Make sure that the number of teeth can be
seen after installing the gear.
C152320E01
MYY6S MANUAL TRANSMISSION – MANUAL TRANSMISSION ASSEMBLY MT–19

TRANSMISSION
COMPONENTS
B265 Type: 75 (760, 55)
x4
M153, M550, A860E Type: x4

75 (760, 55)
MYY5, MYY6 Type: 103 (1050, 76) x4

MT
x4
75 (760, 55)
x4
x4
75 (760, 55)
x4
x4
75 (760, 55)
ASM91-003
MT–20 MYY6S MANUAL TRANSMISSION – MANUAL TRANSMISSION ASSEMBLY
75 (760, 55)
x4
x4
MT
x4
75 (760, 55)

ASM91-001
Propeller Shaft:
6.4 (65, 57 in.*lbf)

GREASE FITTING
ASSEMBLY
THRUST WASHER
x4
x4
x4
MT
RETAINER RING
SPIDER BEARING
x4
THRUST WASHER
x4
6.4 (65, 57 in.*lbf)
RETAINER RING x4

ASSEMBLY
DUST SEAL
SLIDING YOKE
6.4 (65, 57 in.*lbf)
GREASE FITTING
Non-reusable part
MP Grease
C153112E01

x4
M153, M550, A860E Type:
75 (760, 55)
75 (760, 55)
x4
MYY5, MYY6 Type: 103 (1050, 76)
x4
x4
MT 52 (525, 38)

x4

75 (760, 55)
x4
MYY6 Type: 103 (1050, 76)
x4 CENTER SUPPORT
BEARING COVER
CENTER SUPPORT x4
BEARING COVER
52 (525, 38)
x4
ASSEMBLY 52 (525, 38)
75 (760, 55)
x4
ASM91-002
3 and
3 and 4
4 Joint
Joint Type
Type (Intermediate
(Intermediate shaft
shaft and
and Propeller
shaft center):
DUST DEFLECTOR
SPIDER BEARING x4
INTERMEDIATE SHAFT
THRUST WASHER x4 MT
6.4 (65, 57 in.*lbf)
GREASE FITTING
UNIVERSAL JOINT
687 (7000, 506)
SPIDER ASSEMBLY
FLANGE YOKE x4
6.4 (65, 57 in.*lbf)
GREASE FITTING
RETAINER RING
27 (270, 20) x4

x4 DUST DEFLECTOR
BEARING PLATE
Non-reusable part
MP Grease
C161496E02

GASKET
NO. 1 EXHAUST PIPE 70 (714, 52)

SUPPORT BRACKET
x3
25 (259, 19)
50 (510, 37)
30 (306, 22)
x2 x4
MT
GASKET
GASKET
EXHAUST RETARDER
ASSEMBLY
Non-reusable part
C162831E01
18 (184, 13)
x2
WIRE HARNESS
SHIFT CABLE NO. 3 ENGINE MOUNTING BRACKET
28 (280, 20)
103 (1050, 76)
x3
x3
SELECT CABLE
NO. 1 ENGINE
x3 x3
64 (653, 47)
39 (400, 29)
289 (2947, 213)
MT
MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT
DRAIN PLUG
43 (440, 32)
COMPANION FLANGE O-RING
GASKET
39 (400, 29)
FILLER PLUG GASKET x 12 PARKING BRAKE PLATE
SUB-ASSEMBLY
47 (480, 35)
RELEASE FORK
SUPPORT
RELEASE FORK
x4 8.2 (84, 73 in.*lbf)
127 (1290, 93)
PARKING BRAKE
DUST COVER
PARKING BRAKE
DRUM SUB-ASSEMBLY
CLUTCH RELEASE
BEARING ASSEMBLY for W04D-TN:
for W04D: for N04C-TT:
for N04C:
BOOT
CLUTCH RELEASE
CYLINDER ASSEMBLY
27 (275, 20)
Non-reusable part
12 (120, 9)
12 (120, 9)
Clutch spline grease x2 x2
Release hub grease CLUTCH RELEASE CYLINDER ASSEMBLY
C162069E01
REMOVAL
TERMINAL

A164456

chapter EX)
MT
A152398E01

bracket.
C154971

differential.
Matchmark (b) Remove the 4 nuts, 4 bolts and 4 washers separate
the propeller shaft from the differential carrier.
HINT:
• When the flange connection is difficult to
C152531E01 tap the propeller shaft flange part with a brass
(c) Place matchmarks on the propeller shaft flange and
intermediate shaft.
(d) Remove the 4 nuts and 4 washers.
(e) Slide the slide yoke towards the rear of the vehicle
and remove the propeller shaft assembly.
HINT:
When the flange connection is difficult to separate,
Matchmark temporarily install one nut and evenly tap the
C152532E01 hammer to separate.

REAR SET NUT
C152469

MT
C152470

(a) Remove the bolt and dust cover from the parking
brake drum.
(b) Release the parking brake.
(c) Remove the parking brake drum sub-assembly and
companion flange.
C156869
(d) If the brake drum cannot be removed easily, turn the

shoe adjuster in the direction of the illustrated arrow
mark until the drum turns freely.
C162048

ASSEMBLY
(a) Remove the 4 nuts and disconnect the parking
HINT:
C156871

CABLE
(a) Remove the nut and control select cable from the
select lever.
MT
Select Lever
C152328E01

CABLE
(a) Remove the nut and control shift cable from the shift
lever.
Shift Lever
C160009E01

ASSEMBLY (for N04C series)
(a) Remove the 2 bolts and disconnect the clutch
release cylinder.
C152310

ASSEMBLY (for W04D series)
(a) Remove the 2 bolts and disconnect the clutch tube.
C149953
(b) Remove the 2 bolts and disconnect the clutch

release cylinder.
transmission jack.
C149947

(a) Remove the nut.
MT
C152340

C152339

(a) Remove the nut.
C152341

jack.
NOTICE:
C152338 18. REMOVE MANUAL TRANSMISSION ASSEMBLY

NOTICE:
input shaft.
C152313E01

fork support.
assembly.
MT
C152315

release fork.
C152316

C152317
INSTALLATION
assembly.
C152317

Grease:
equivalent
Grease
C162058E01

fork.
MT
C152316

Grease:
equivalent
assembly.
C152312E01

NOTICE:
smoothly.
C152315

transmission jack.
(b) Install the transmission.
NOTICE:
input shaft.

C152338

MT
C152341

C152339

C152340

(for N04C series)
2 bolts.
C152310

(for W04D series)
2 bolts.
C149947
(b) Install the clutch tube with the 2 bolts.

MT
C149953

(a) Install the control shift cable to the shift lever with
the nut.
Shift Lever
C160009E01

CABLE
(a) Install the control select cable to the select lever
with the nut.
Select Lever
C152328E01

the 4 nuts.
(a) Install the companion flange.
C156871
(b) Install the parking brake dust cover to the parking

brake drum sub-assembly with the bolt.
(c) Install the parking brake drum sub-assembly.
REAR SET NUT
(a) Apply engine oil to a new O-ring, and install it to the
companion flange.
C156869

MT
C152470

C152469

(a) Align the matchmarks on the propeller shaft
assembly and the intermediate shaft, and
temporarily install the 4 washers and 4 nuts.
(b) Tighten the nut.
Matchmark
C152532E01

flange.
(d) Install the 4 bolts, 4 washers and 4 nuts.
Matchmark Torque: 75 N*m (760 kgf*cm, 55 ft.*lbf)
C152531E01

the 2 bolts.
chapter EX)
C154971

(a) Install 2 new gaskets and the exhaust retarder
MT
A152398E01

TERMINAL
HINT:
OIL LEVEL (See page MT-2)
A164456

MT–36 MYY6S MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT
MANUAL TRANSMISSION UNIT

TRANSMISSION
COMPONENTS
NO. 2 GEAR SHIFT FORK SHAFT

SHIFT ARM BUSHING
CLUTCH HOUSING BUSHING
NO. 3 GEAR SHIFT FORK
SHIFT ARM BUSHING
NO. 3 GEAR SHIFT HEAD
SLOTTED SPRING PIN
MT
CLUTCH HOUSING BUSHING
NO. 1 GEAR SHIFT FORK SHAFT

CLUTCH HOUSING
SLOTTED SPRING PIN
NO. 3 GEAR SHIFT HEAD

TRANSMISSION
ADAPTER NO. 1 GEAR
STRAIGHT PIN SHIFT FORK
SHIFT ARM BUSHING
TRANSMISSION MAGNET
SLOTTED SPRING PIN
COUNTER GEAR FRONT

BEARING OR ROLLER
TRANSMISSION FRONT
BEARING RETAINER OIL SEAL
Non-reusable part
Engine oil
MP grease
C152473E01
MYY6S MANUAL TRANSMISSION – MANUAL TRANSMISSION UNIT MT–37

27 (275, 20)
BLEEDER HOSE
O-RING
x4 x2 27 (275, 20)
DETENT ASSEMBLY
TRANSMISSION OIL FILTER PLATE
39 (400, 29)
MANUAL TRANSMISSION
39 (400, 29) CASE PLUG
BACK UP LIGHT SWITCH ASSEMBLY
27 (275, 20)
46 (470, 34) DETENT ASSEMBLY MT

O-RING
39 (400, 29)
x 13
TRANSMISSION
DRAIN PLUG
O-RING
8.0 (82, 71 in.*lbf)
GASKET
MANUAL TRANSMISSION CASE
x6
37 (380, 28) 23 (235, 17) REVERSE IDLER GEAR SUB-ASSEMBLY
x6
NO. 2 CLUTCH
HOUSING COVER
MANUAL TRANSMISSION
POWER TAKE-OFF COVER
REVERSE IDLER
GEAR SHAFT
REVERSE IDLER GEAR BEARING
Non-reusable part
Engine oil
Precoated part
C159407E02
SLOTTED
SPRING PIN
OUTPUT SHAFT REAR BEARING RETAINER
NO. 2 SHIFT
LEVER INNER
44 (445, 32)
SLOTTED SPRING PIN

27 (275, 20)
DETENT ASSEMBLY
NO. 4 GEAR SHIFT
26 (265, 19) FORK SHAFT
27 (275, 20)
DETENT ASSEMBLY x 10
COUNTER GEAR REAR
BEARING OR ROLLER
MT
COUNTER GEAR SHAFT BEARING SETTING SHIM
SPEEDOMETER
OUTPUT SHAFT BEARING SHAFT SNAP RING DRIVE GEAR
SPEEDOMETER
DRIVE GEAR SPACER
RADIAL BALL BEARING
NO. 3 SYNCHROMESH
SHIFTING KEY
COUNTER GEAR 6TH

6TH SLEEVE AND
HUB ASSEMBLY
NO. 3 SYNCHROMESH SHIFTING KEY
REAR TRANSMISSION STOPPER

CASE PLATE 6TH
46 (470, 34)
x 10
NO. 3 SYNCHROMESH
SHIFTING KEY SPRING SHAFT SNAP RING
46 (470, 34) TRANSMISSION REAR BEARING RETAINER OIL SEAL

x2
O-RING NEEDLE ROLLER BEARING
39 (400, 29)
Non-reusable part MANUAL TRANSMISSION CASE PLUG
Engine oil
MP grease
Precoated part
C152483E01
INPUT SHAFT
OUTPUT SHAFT MT
COUNTER GEAR
C152485E01
DISASSEMBLY
NOTICE:
• The transmission case and clutch housing are made
of aluminum. Be careful not to damage them.
• Pay special attention not to damage the ribs of the
transmission case and clutch housing. If the ribs are
damaged, the strength of the case will be reduced.
• Use caution when handling heavy parts such a
transmission case or gears.
1. REMOVE MANUAL TRANSMISSION CASE PLUG
(a) Remove the manual transmission case plug and O-
ring.
2. REMOVE BACK UP LIGHT SWITCH ASSEMBLY
Oil Filter Plate (a) Remove the back up light switch assembly.
3. REMOVE DETENT ASSEMBLY
(a) Remove the 2 detent assemblies.
MT 4. REMOVE SHIFT LEVER SHAFT HOUSING
(a) Remove the 6 bolts, shift lever shaft housing and
Shift Lever transmission oil filter plate.
Shaft Housing
Detent Back Up
Assembly Light
Switch
Assembly
Detent
Assembly
Detent Assembly
C151320E01
5. REMOVE MANUAL TRANSMISSION POWER TAKE-

OFF COVER
Power Take-off Cover (a) Remove the 6 bolts, manual transmission power
take-off cover and gasket.
(b) Remove the 6 bolts and No. 2 clutch housing cover.
6. REMOVE REAR TRANSMISSION CASE
(a) Remove the 12 bolts and rear transmission case.
7. REMOVE NEEDLE ROLLER BEARING
(a) Using a screwdriver, remove the transmission rear
bearing retainer oil seal from the transmission rear
case.
HINT:
No. 2 Clutch Housing Cover Inspect the transmission rear bearing retainer oil
seal. If it is worn or damaged, replace it.
C151321E01
(b) Using SST and a hammer, remove the needle roller

bearing from the transmission rear case.
SST
SST 09950-60010 (09951-00620), 09950-70010
(09951-07150)
C162010E01
8. REMOVE NO. 2 SHIFT LEVER INNER

No. 2 Shift Lever Inner (a) Remove the 2 bolts and No. 2 shift lever inner.
9. REMOVE NO. 4 GEAR SHIFT FORK SHAFT
(a) Using a pin punch (5 mm (0.20 in.)) and a hammer,
remove the shift head set slotted spring pin and No.
4 gear shift fork shaft from the No. 4 gear shift fork.
MT
Slotted
Spring Pin
No. 4 Gear
Shift Fork Shaft
No. 4 Gear
Shift Fork
C151322E01
10. REMOVE COUNTER GEAR 6TH

(a) Using a snap ring expander, remove the shaft snap
ring.
C161689
(b) Using SST, remove the 6th sleeve and hub

assembly, radial ball bearing and 6th counter gear
SST from the counter gear.
SST 09950-40011 (09951-04020, 09952-04010,
09953-04020, 09954-04010, 09955-04031,
09957-04010)
C151323E01
11. REMOVE STOPPER PLATE 6TH

(a) Remove the stopper plate 6th from the 6th sleeve
and hub assembly.
HINT:
The arrow in the illustration shows the front side of
the transmission.
Front Side
C151324E01
12. REMOVE 6TH SLEEVE AND HUB ASSEMBLY

(a) Remove the 2 No. 3 synchromesh shifting key
Shifting Key Spring
springs, 3 No. 3 synchromesh shifting keys and
clutch hub from the hub sleeve.
13. REMOVE SPEEDOMETER DRIVE GEAR
(a) Remove the speedometer drive gear and
Shifting Key speedometer drive gear spacer.
MT
14. REMOVE OUTPUT SHAFT REAR BEARING
RETAINER
(a) Using a "TORX" socket wrench (T50), remove the
10 "TORX" screws and output shaft rear bearing
retainer from the manual transmission case.
C151325E01
15. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY

Idler Gear Shaft (a) Remove the reverse idler gear shaft, reverse idler
gear sub-assembly and reverse idler gear bearing.
Idler Gear Bearing
Idler Gear
G025891E01
16. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP

RING
(a) Using a snap ring expander, remove the output
shaft bearing shaft snap ring from the output shaft
rear bearing.
(b) Remove the gear shaft bearing setting shim.
C161690
17. REMOVE SNAP RING

(a) Using a snap ring expander, remove the snap ring.
18. REMOVE MANUAL TRANSMISSION CASE
(a) Remove the 13 bolts and manual transmission case
from the clutch housing.
C161691
19. REMOVE COUNTER GEAR REAR BEARING

(a) Remove the counter gear rear bearing or roller
(outer race) from the manual transmission case.
MT
G025893

(a) Using a pin punch (5 mm (0.20 in.)) and hammer,
tap out the slotted spring pin.
NOTICE:
Place a brass bar on the opposite side of the No.
2 gear shift fork shaft to prevent damage to
other parts.
(b) Remove the No. 2 gear shift fork shaft and No. 3
gear shift head.
G032369

(a) Using a pin punch (5 mm (0.20 in.)) and hammer,
tap out the slotted spring pin.
NOTICE:
Place a brass bar on the opposite side of the No.
1 gear shift fork shaft to prevent damage to
other parts.
(b) Remove the No. 1 shift fork shaft, No. 1 gear shift
fork, No. 2 gear shift fork and No. 3 gear shift head.
G032370
22. INSPECT SHIFT ARM BUSHING

(a) Using SST, remove the shift arm bushing from the
No. 3 gear shift fork.
SST 09319-60020
NOTICE:
B Do not damage the inner surface of the No. 3
SST
A gear shift fork.
(b) Using SST, remove the shift arm bushing from the
No. 2 gear shift fork.
C151326E01 SST 09319-60020
NOTICE:
Do not damage the inner surface of the No. 2
gear shift fork.
23. REMOVE TRANSMISSION MAGNET
(a) Remove the transmission magnet from the clutch
housing.
24. REMOVE OUTPUT SHAFT ASSEMBLY
(a) Using 2 straps with a ratcheting function such as tie
down straps, securely bind the output shaft
assembly, counter gear, and input shaft assembly at
2 places.
G025899
MT (b) Install SST to the output shaft assembly with the

output shaft rear set nut. Hang the assembly with
SST cables.
SST 09950-00020
C161692E01
(c) While expanding the front bearing shaft snap ring

using a snap ring expander, remove the input shaft
assembly, output shaft assembly, and counter gear
as a unit from the clutch housing.
G025917
25. REMOVE CLUTCH HOUSING BUSHING

(a) Using SST, remove the clutch housing bushing from
B the clutch housing.
A SST 09319-60020
NOTICE:
Do not damage the inner surface of the clutch
housing.
HINT:
SST Inspect the clutch housing bushing. If it is worn or
C151327E01 damaged, replace it.
26. REMOVE COUNTER GEAR FRONT BEARING

(a) Using SST, remove the counter gear front bearing
(outer race) from the clutch housing.
SST 09308-10010, 09950-60010 (09951-00470),
09950-40011 (09957-04010)
HINT:
SST Inspect the counter gear front bearing. If it is worn or
damaged, replace it.
27. REMOVE TRANSMISSION FRONT BEARING
C151328E01
RETAINER OIL SEAL
(a) Using a screwdriver, remove the transmission front
bearing retainer oil seal from the clutch housing.
HINT:
Inspect the transmission front bearing retainer oil
seal. If it is worn or damaged, replace it.
28. INSPECT GEAR SHIFT FORK
(a) Using a micrometer, measure the thickness of the
claw part of each gear shift fork. MT
Standard
Standard Thickness Minimum Thickness
Inspection Part
(mm) (mm)
9.60 to 9.85 (0.3780 to
No. 1 gear shift fork 9.0 (0.3543)
0.3878)
9.60 to 9.85 (0.3780 to
0.3878)
9.60 to 9.85 (0.3780 to
0.3878)
9.60 to 9.85 (0.3780 to
0.3878)
If the thickness is less than the minimum, replace

the gear shift fork.
(b) Visually check each gear shift fork.
If any wear, damage, or other problem is found,
replace the gear shift fork.
(c) Inspect each part of the shift mechanism.
If any damage, bending, or uneven wear is found,
replace the part.
29. INSPECT NO. 3 SYNCHROMESH SHIFTING KEY
(a) Using vernier calipers, measure the clearance
between the No. 3 synchromesh shifting key and
No. 3 synchronizer ring groove.
Standard clearance:
3.46 to 3.76 mm (0.1362 to 0.1480 in.)
If the clearance is not within the specified range,
replace the No. 3 synchromesh shifting key and No.
3 synchronizer ring.
REASSEMBLY
1. INSTALL TRANSMISSION FRONT BEARING
RETAINER OIL SEAL
(a) Apply engine oil to the outer circumference of a new
transmission front bearing retainer oil seal.
(b) Using SST, install a new transmission front bearing

retainer oil seal to the clutch housing.
SST SST 09517-12010
NOTICE:
Do not damage the lip of the oil seal.
(c) Coat the lip of the oil seal with MP grease.
C161693E01
2. INSTALL COUNTER GEAR FRONT BEARING

(a) Using SST and a press, install a new counter gear
front bearing (outer race).
SST SST 09608-10010, 09950-70010 (09951-07100)
MT
C161694E01
3. INSTALL CLUTCH HOUSING BUSHING

(a) Using SST, install a new clutch housing bushing.
SST NOTICE:
Check that the bushing is installed in the
direction shown in the illustration.
Bashing
C162354E01
4. INSTALL OUTPUT SHAFT ASSEMBLY

(a) Using 2 straps with a ratcheting function such as tie
down straps, securely bind the output shaft
assembly, counter gear, and input shaft assembly at
2 places.
(b) Install SST to the output shaft assembly with the
output shaft rear set nut. Hang the assembly with
cables.
NOTICE:
G025899 Be careful not to drop the input shaft assembly.
(c) Place the input shaft assembly, output shaft

assembly, and counter gear on a support stand with
the input shaft assembly facing up.
(d) Apply protective tape to the input shaft assembly.
Vinyl Tape (e) Apply a small amount of MP grease to the contact
surfaces of the lip of the transmission front bearing
retainer oil seal and the input shaft assembly.
Apply MP Grease
MT
C151329E01
(f) While expanding the front bearing shaft snap ring

using a snap ring expander, insert the input shaft
assembly, counter gear, and output shaft assembly
as a unit into the clutch housing.
NOTICE:
• Check that the snap ring is securely installed.
• Carefully perform this operation to prevent
damage to the transmission front bearing
retainer oil seal.
G026109
5. INSTALL TRANSMISSION MAGNET
(a) Install the transmission magnet to the clutch
housing.
6. INSTALL SHIFT ARM BUSHING

(a) Using SST and a press, install a new shift arm
bushing of the No. 3 gear shift fork.
SST NOTICE:
Check that the bushing is installed in the correct
direction and at the correct angle as shown in
the illustration.
(b) Using SST and a press, install a new shift arm
bushing of the No. 2 gear shift fork.
NOTICE:
Check that the bushing is installed in the correct
direction and at the correct angle as shown in
the illustration.
MT
C162355E01
(c) Stake each bushing at 3 points other than the

opening of the bushing and the previous staked
points.
15°
C161697E01
7. INSTALL NO. 1 GEAR SHIFT FORK SHAFT

(a) Install the No. 3 gear shift head, No. 2 gear shift fork
and No. 1 gear shift fork to the No. 1 gear shift fork
No. 1 Fork Shaft shaft.
(b) Align the holes for the 2 shift head slotted spring
pins and tap in the slotted spring pins using a
No. 1 Fork
hammer.
No. 2 Fork NOTICE:
When tapping in the slotted spring pins, place a
brass bar on the opposite side of the No. 1 gear
Slotted shift fork shaft to prevent damage to other parts.
Pin
No. 3 Gear Shift Head
MT
C151330E01

(a) Install the No. 3 gear shift fork and No. 3 gear shift
No. 2 Shaft head to the No. 2 gear shift fork shaft.
(b) Align the holes for the shift head slotted spring pin
and tap in the slotted spring pin using a hammer.
NOTICE:
No. 3 Gear Shift Head
When tapping in the slotted spring pin, place a
brass bar on the opposite side of the No. 2 gear
shift fork shaft to prevent damage to other parts.
9. INSTALL MANUAL TRANSMISSION CASE
(a) Clean the seal packing attached on the manual
transmission case and clutch housing using a
No. 3 Fork scraper and wire brush. Then remove the oil with
non-residue type solvent or equivalent.
NOTICE:
Do not scratch the fitting surface.
Slotted Pin
C151331E01
(b) Apply FIPG to the manual transmission case as

NOTICE:
Before applying FIPG, remove any moisture,
grease, and oil from the sealing surface. FIPG
FIPG should be applied in a continuous line (width of
2 mm (0.079 in.) or more).
FIPG:
Toyota Genuine Seal Packing 1281, Three
C151332E01 Bond 1281 or equivalent
(c) Install the 13 bolts and manual transmission case.

10. INSTALL COUNTER GEAR REAR BEARING
(a) Install the counter gear rear bearing (outer race) to
the transmission case.
11. INSTALL SNAP RING
(a) Using a snap ring expander, install the snap ring.
NOTICE:
• If the snap ring is deformed or damaged,
replace it with a new one.
12. ADJUST COUNTER GEAR BEARING PRELOAD
(a) Install the counter gear shaft bearing setting shim.
(b) Move the shift lever to the N position.
C161691
(c) Place the transmission assembly with the clutch
housing facing down.
(d) Turn the counter gear 30 times or more to settle the
MT bearing.
(e) Measure the depth from the rear end face of the
transmission case to the outer end face of the
counter gear rear bearing at 3 points at 120-degree
intervals. Calculate the average value.
(f) Based on the average value, select the appropriate
shim from the table below.
Measured depth mm (in.) Thickness mm (in.)
3.34 to 3.39 (0.1315 to 0.1335) 3.19 (0.126)
3.28 to 3.33 (0.1291 to 0.1311) 3.13 (0.123)
3.22 to 3.27 (0.1268 to 0.1287) 3.07 (0.121)
3.16 to 3.21 (0.1244 to 0.1264) 3.01 (0.119)
3.10 to 3.15 (0.1220 to 0.1240) 2.95 (0.116)
3.04 to 3.11 (0.1197 to 0.1224) 2.89 (0.114)
2.98 to 3.03 (0.1173 to 0.1193) 2.83 (0.111)
2.92 to 2.97 (0.1150 to 0.1169) 2.77 (0.109)
2.86 to 2.91 (0.1126 to 0.1146) 2.71 (0.107)
2.80 to 2.85 (0.1102 to 0.1122) 2.65 (0.104)
2.74 to 2.79 (0.1079 to 0.1098) 2.59 (0.102)
2.68 to 2.73 (0.1055 to 0.1075) 2.53 (0.100)
C158778
2.62 to 2.67 (0.1031 to 0.1051) 2.47 (0.097)
2.56 to 2.61 (0.1008 to 0.1028) 2.41 (0.095)
2.50 to 2.55 (0.0984 to 0.1004) 2.35 (0.093)
2.44 to 2.49 (0.0961 to 0.0980) 2.29 (0.090)
2.38 to 2.43 (0.0937 to 0.0957) 2.23 (0.088)
2.32 to 2.37 (0.0913 to 0.0933) 2.17 (0.085)
2.26 to 2.31 (0.0890 to 0.0909) 2.11 (0.083)
13. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP

RING
(a) Using a snap ring expander, install the output shaft
bearing shaft snap ring to the output shaft rear
bearing.
C161690
14. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY

(a) Coat the reverse idler gear bearing with engine oil
and install it to the reverse idler gear.
Front Side MT
C151333E01
(b) Install the reverse idler gear shaft to the reverse

idler gear shaft.
15. INSTALL OUTPUT SHAFT REAR BEARING
RETAINER
(a) Using a "TORX" socket wrench T50, install the
output shaft rear bearing retainer to the
transmission case with 10 new "TORX" bolts.
NOTICE:
G025891
Remove any sealing material from the threads of
the transmission case.
16. INSTALL SPEEDOMETER DRIVE GEAR
(a) Install the speedometer drive gear spacer and
speedometer drive gear.
17. INSTALL 6TH SLEEVE AND HUB ASSEMBLY
No. 3 Shifting Key (a) Securely install the 3 No. 3 synchromesh shifting
keys into the grooves on the No. 1 synchronizer
ring.
6th Sleeve
No. 3 Key Spring

6th Hub
C151335E01
(b) Install the 2 No. 3 synchromesh shifting key springs

to the No. 3 synchromesh shifting keys.
NOTICE:
• When installing the No. 3 synchromesh
shifting key springs, leave an equal amount
of excess space at both ends of each spring
to prevent interference with the inside of the
clutch hub.
• Do not allow the openings of the No. 3
synchromesh shifting key springs to overlap.
MT
C162356
(c) Check that the clutch hub and hub sleeve slide
Hub Sleeve smoothly.
18. INSTALL STOPPER PLATE 6TH
(a) Install a new stopper plate 6th to the 6th sleeve and
hub assembly.
Clutch Hub
19. INSTALL COUNTER GEAR 6TH
(a) Apply engine oil to the radial ball bearing and the
inside of the No. 1 synchronizer ring.
C151334E01
(b) Install the counter gear 6th, radial ball bearing, and
No. 1 synchronizer ring.
(c) Align the No. 1 synchronizer ring with the groove on
the 6th sleeve and hub assembly. Using SST and a
SST hammer, install the 6th sleeve and hub assembly.
SST 09308-14010
C161750E01
(d) Using a snap ring expander, install the shaft snap

ring.
SST (1) Select the thickest shaft snap ring that can be
installed from the following 3 types.
Thickness mm (in.) Identification Color
1.7 (0.0669) White
1.8 (0.0709) -
1.9 (0.0748) Blue
C161689E01
NOTICE:
• If the shaft snap ring is deformed or
damaged, replace it with a new one.
• Check that the snap ring is securely
installed.
(a) Apply engine oil to the No. 4 gear shift fork shaft
installation hole on the manual transmission case.
(b) Install the No. 4 gear shift fork and No. 4 gear shift
No. 2 Shift Lever Inner fork shaft.
(c) Align the holes for the shift head slotted spring pin
and tap in the slotted spring pin using a hammer.
21. INSTALL NO. 2 SHIFT LEVER INNER
(a) Install the No. 2 shift lever inner with the 2 bolts.
22. INSTALL TRANSMISSION REAR BEARING
RETAINER OIL SEAL MT
(a) Apply MP grease to the inside of the needle bearing
and apply engine oil to the needle bearing contact
Slotted surface of the transmission rear case.
Spring Pin
No. 4 Gear
Shift Fork Shaft
No. 4 Gear
Shift Fork
C151322E01
(b) Using SST and a hammer, tap the needle bearing

SST into the transmission rear case from the inside with
the inscribed mark facing outward.
SST
SST 09950-60010 (09951-00550, 09951-00620,
09952-06010), 09950-70010 (09951-07150)
(c) Apply engine oil to the outer circumference of a new
transmission rear bearing retainer oil seal.
C161751E01
(d) Using SST, install a new transmission rear bearing

retainer oil seal to the rear transmission case.
SST 09310-35010
NOTICE:
SST Do not damage the lip of the transmission rear
bearing retainer oil seal.
(e) Coat the lip of the oil seal with MP grease.
23. INSTALL REAR TRANSMISSION CASE
C161752E01
transmission case and rear transmission case with
a scraper and wire brush. Then remove the oil with

NOTICE:
should be applied in a continuous line (width of
2 mm (0.079 in.) or more).
FIPG:
MT
FIPG
G032379E01
(c) Install the 12 bolts and rear transmission case.

NOTICE:
The 2 bolts indicated by the arrows in the
illustration are precoated bolts (coated with
Loctite). Remove any sealing material from the
threads of the transmission case and install new
precoated bolts.
24. INSTALL NO. 2 CLUTCH HOUSING COVER
G032380
transmission case and No. 2 clutch housing cover
with a scraper and wire brush. Then remove the oil
with non-residue type solvent or equivalent.
NOTICE:
FIPG should be applied in a continuous line (width of
2 mm (0.079 in.) or more).
FIPG:
G025916E01 (c) Install the 6 bolts and No. 2 clutch housing cover.
25. INSTALL MANUAL TRANSMISSION POWER TAKE-
OFF COVER
(a) Install a new gasket and transmission power take-
off cover with 6 new bolts.
NOTICE:
The bolts are precoated bolts (coated with
precoated bolts.
26. INSTALL SHIFT LEVER SHAFT HOUSING
transmission case and shift lever shaft housing with
a scraper and wire brush. Then remove the oil with
(b) Move the shift lever to the N position.
(c) Apply FIPG to the manual transmission case as
NOTICE:
FIPG
should be applied in a continuous line (width of
2 mm (0.079 in.) or more). MT
FIPG:
G025918E01 (d) Install the transmission oil filter plate and shift lever
shaft housing with 6 new bolts.
NOTICE:
The bolts are precoated bolts (coated with
precoated bolts.
27. INSTALL DETENT ASSEMBLY
Oil Filter Plate (a) Remove any sealing material from the threads of
the detent assembly. Then apply sealant to the
threads of the detent assembly.
Sealant:
Loctite 242 or equivalent
(b) Install it to the manual transmission case.
Shift Lever Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf)
Shaft Housing
28. INSTALL BACK UP LIGHT SWITCH ASSEMBLY
(a) Apply sealant to the threads of the back up light
switch assembly.
Back Up
Detent Sealant:
Assembly Light
Switch Loctite 242 or equivalent
Assembly (b) Install it to the manual transmission case.
29. INSTALL MANUAL TRANSMISSION CASE PLUG
(a) Apply engine oil to the O-ring.
Detent
Assembly
(b) Install the manual transmission case plug and O-
Detent Assembly ring.
MT–56 MYY6S MANUAL TRANSMISSION – INPUT SHAFT
INPUT SHAFT
TRANSMISSION
COMPONENTS
FRONT BEARING SHAFT SNAP RING
INPUT SHAFT FRONT BEARING
INPUT SHAFT
MT
INPUT SHAFT BEARING
NO. 3 SYNCHRONIZER RING
Engine oil
C152486E01
DISASSEMBLY
1. REMOVE NO. 3 SYNCHRONIZER RING
(a) Remove the No. 3 synchronizer ring from the input
shaft assembly.
2. REMOVE INPUT SHAFT BEARING
(a) Remove the input shaft bearing from the input shaft
assembly.
NOTICE:
The input shaft bearing is a separate type. When
removing the input shaft bearing, be careful not
to drop or damage the rollers.
MYY6S MANUAL TRANSMISSION – INPUT SHAFT MT–57
3. REMOVE FRONT BEARING SHAFT SNAP RING

(a) Using a snap ring expander, remove the front
bearing shaft snap ring.
C161753
4. REMOVE INPUT SHAFT FRONT BEARING

(a) Using SST and a press, remove the input shaft front
bearing.
SST 09950-00020
SST
5. INSPECT INPUT SHAFT
(a) Inspect the gear tooth surfaces, splines, and sliding
surfaces at the tip of the input shaft for damage or
wear. If any damage or wear is found, replace the MT
input shaft.
C161754E01

(a) Inspect the input shaft bearing for the following
items. If any problem is found, replace the bearing.
(1) Smooth rotation
(2) Abnormal noise
(3) Visible problems such as damage or rust
(4) Abnormal looseness in the thrust direction
(5) Discoloration, excessive wear, or pitching of the
rolling part or the rolling surface of the input
shaft bearing
7. INSPECT NO. 3 SYNCHRONIZER RING
(a) Inspect the No. 3 synchronizer ring. If any wear,
damage, or other problem is found, replace the No.
3 synchronizer ring.
REASSEMBLY
1. INSTALL INPUT SHAFT FRONT BEARING
(a) Using SST and a press, install the input shaft front
bearing.
SST
C161755E01
MT–58 MYY6S MANUAL TRANSMISSION – INPUT SHAFT
2. INSTALL FRONT BEARING SHAFT SNAP RING

(a) Using a snap ring expander, install the front bearing
shaft snap ring.
3. INSTALL INPUT SHAFT BEARING
(a) Install the input shaft bearing to the input shaft
assembly.
4. INSTALL NO. 3 SYNCHRONIZER RING
(a) Apply a sufficient amount of engine oil to the inside
C161753 of the No. 3 synchronizer ring and install it to the
input shaft assembly.
MT
MYY6S MANUAL TRANSMISSION – OUTPUT SHAFT MT–59
OUTPUT SHAFT
TRANSMISSION
COMPONENTS
NEEDLE ROLLER HOLE SNAP RING
SLEEVE AND HUB ASSEMBLY
NO. 3 SHIFTING KEY
4TH GEAR
4TH GEAR NEEDLE ROLLER BEARING

NO. 3 SHIFTING KEY SPRING
3RD GEAR NEEDLE
GEAR THRUST WASHER SHAFT SNAP RING ROLLER BEARING MT
3RD GEAR THRUST WASHER
3RD AND 2ND INSIDE RING 3RD GEAR
3RD AND 2ND OUTSIDE RING
NO. 3 SYNCHRONIZER RING SET
SHIFTING KEY BALL
NO. 2 SHIFTING KEY
COMPRESSION SPRING
NO. 2 SYNCHRONIZER RING SET
NO. 2 TRANSMIOSSION HUB SLEEVE

3RD AND 2ND INSIDE RING
NO. 2 TRANSMISSION CLUTCH HUB
3RD AND 2ND OUTSIDE RING
2ND GEAR
2ND GEAR NEEDLE ROLLER BEARING
OUTPUT SHAFT
Engine oil
C152487E01
MT–60 MYY6S MANUAL TRANSMISSION – OUTPUT SHAFT
1ST GEAR NEEDLE ROLLER BEARING
1ST GEAR
LOW AND REV

INSIDE RING
OUTPUT SHAFT
LOW AND REV
OUTSIDE RING
MT
NO. 1 TRANSMISSION HUB SLEEVE
SHIFTING KEY BALL

NO. 1 SHIFTING KEY
COMPRESSION SPRING
REVERSE GEAR
NO. 1 TRANSMISSION CLUTCH HUB REVRSE GEAR BEARING

INNER RACE
6TH GEAR
REVERSE GEAR BEARING
OUTPUT SHAFT SPACER
OUTPUT SHAFT REAR BEARING
Engine oil
C152488E01
DISASSEMBLY
1. REMOVE 6TH GEAR SUB-ASSEMBLY
(a) Remove the 6th gear sub-assembly.
2. REMOVE 1ST GEAR

(a) Using a bearing remover and press, remove the
following parts:
• Output shaft rear bearing
• Output shaft spacer
• Reverse gear bearing inner race
• Reverse gear
• Reverse gear bearing
• No. 2 synchronizer ring
G025923 • No. 1 transmission clutch hub assembly
• No. 1 transmission hub sleeve
• No. 1 synchronizer ring
• Outside low and rev ring
• Low and reverse inside ring
• 1st gear
• First gear needle roller bearing
3. REMOVE NO. 1 TRANSMISSION HUB SLEEVE
(a) Disassemble the No. 1 transmission clutch hub and
Compression Spring
No. 1 transmission hub sleeve. MT
No. 1 Clutch Hub
No. 1 Shifting Key
Shifting Key
No. 1 Hub Sleeve
C151336E01
4. REMOVE NEEDLE ROLLER HOLE SNAP RING

(a) Using a snap ring expander, remove the needle
roller hole snap ring.
C161756
5. REMOVE 4TH GEAR

(a) Using a bearing remover and press, remove the
sleeve and hub assembly, No. 3 synchronizer ring,
4th gear and 4th gear needle roller bearing.
G025925
6. REMOVE NO. 3 SYNCHROMESH SHIFTING KEY

(a) Disassemble the sleeve and hub assembly.
Shifting Key Spring
Shifting Key
MT
C151325E01
7. REMOVE GEAR THRUST WASHER SHAFT SNAP

RING
(a) Using a snap ring expander, remove the gear thrust
washer shaft snap ring.
C161757
8. REMOVE 2ND GEAR

(a) Using a press, remove the following parts from the
output shaft:
• 3rd gear thrust washer
• 3rd gear
• 3rd gear needle roller bearing
• 3rd and 2nd inside ring
• 3rd and 2nd outside ring
• No. 3 synchronizer ring set
G025927 • No. 2 transmission clutch hub
• No. 2 transmission hub sleeve
• No. 2 synchronizer ring set
• 2nd gear
• 2nd gear needle roller bearing
9. REMOVE NO. 2 TRANSMISSION HUB SLEEVE

(a) Disassemble the No. 2 transmission clutch hub and
Compression Spring
No. 2 transmission hub sleeve.
(1) Inspect each part. If any wear, damage, or
No. 2 Clutch Hub other problem is found, replace the part.
(b) Inspect each bearing for the following items. If any
problem is found, replace the bearing.
(1) Smooth rotation
(2) Abnormal noise
No. 2 Shifting Key
Shifting Key
Ball
No. 2 Hub Sleeve MT

C151336E02
INSPECTION
1. INSPECT GEAR
diameter of the gear.
G025929
Standard
Gear Type Standard: mm (in.) Maximum: mm (in.)
Counter gear 6th 50.009 to 50.025 (1.9689 to 1.9695) 50.065 (1.9711)
5th gear 44.009 to 44.025 (1.7326 to 1.7333) 44.065 (1.7348)
4th gear 44.009 to 44.025 (1.7326 to 1.7333) 44.065 (1.7348)
3rd gear 63.010 to 63.029 (2.4807 to 2.4815) 63.069 (2.4830)
2nd gear 63.010 to 63.029 (2.4807 to 2.4815) 63.069 (2.4830)
1st gear 63.010 to 63.029 (2.4807 to 2.4815) 63.069 (2.4830)
Reverse gear 63.010 to 63.029 (2.4807 to 2.4815) 63.069 (2.4830)
If the inside diameter exceeds the maximum,

replace the gear.
2. INSPECT OUTPUT SHAFT

(a) Using a dial gauge and 2 V-blocks, check the output
shaft runout.
Standard runout:
0.015 mm (0.0006 in.)
Maximum runout:
0.1 mm (0.0039 in.)
G025930
3. INSPECT SYNCHRONIZER RING

(a) Inspect the synchromesh mechanism.
(1) Inspect each part of the synchromesh
mechanism. If uneven wear or damage is
found, replace the synchronizer ring or
synchronizer ring set.
(b) Inspect the clearance between the synchronizer ring
MT and the tapered part.
(1) Using a thickness gauge, measure the
G025931 clearance between the synchronizer ring and
the tapered part.
Standard
Gear Type Standard Clearance: mm (in.) Minimum Clearance: mm (in.)
4th, 6th, Reverse 1.30 to 2.60 (0.0512 to 0.1024) 0.5 (0.0197)
1st, 2nd, 3rd 1.00 to 2.50 (0.394 to 0.0984) 0.5 (0.0197)
If the clearance is less than the minimum,

replace the gear.
4. INSPECT NO. 2 TRANSMISSION CLUTCH HUB
(a) Check the sliding parts, splines, keys, and key
grooves of the No. 2 transmission clutch hub and
No. 2 transmission hub sleeve for wear or damage.
(b) Measure the backlash in the spline rotational
direction on the outer circumference of the clutch
hub.
G025934
Standard
Standard Backlash: mm (in.) Maximum Backlash: mm (in.)
0 to 0.05 (0 to 0.002) 0.3 (0.0118)
If the backlash exceeds the maximum, replace the

clutch hub.
5. INSPECT NO. 3 SYNCHROMESH SHIFTING KEY

(a) Using vernier calipers, measure the clearance
No. 3 synchronizer ring groove.
Standard clearance:
3.46 to 3.76 mm (0.1362 to 0.148 in.)
If the clearance is not as specified, replace the No. 3
synchromesh shifting key and No. 3 synchronizer
ring.
G025935
6. INSPECT TOP-OD SLEEVE AND HUB ASSEMBLY

(a) Using a thickness gauge, measure the clearance
the sleeve and hub assembly (clutch hub).
Standard clearance:
0.01 to 0.21 mm (0.0004 to 0.0083 in.)
If the clearance is not as specified, replace the
sleeve and hub assembly. MT
G025936
7. INSPECT TRANSMISSION CLUTCH HUB

A
Clutch Hub Synchronizer Ring (a) Using a thickness gauge, measure clearance A
between the synchronizer ring and the transmission
clutch hub.
C151338E01
Standard
Gear Type Standard Clearance: mm (in.)
No. 2 transmission clutch hub 4.30 to 4.70 (0.1693 to 0.1850)
No. 1 transmission clutch hub 4.30 to 4.70 (0.1693 to 0.1850)
If the clearance is not as specified, replace the

synchronizer ring and transmission clutch hub.
REASSEMBLY
1. INSTALL NO. 2 TRANSMISSION HUB SLEEVE
HINT:
• Thoroughly clean each part.
• Secure the output shaft in a vise with the longer
splines down. Be careful not to damage the polished
surface.
(a) Install the 3 No. 2 synchromesh shifting keys and 3

compression springs to the No. 2 transmission
clutch hub.
G025938
(b) Install the No. 2 transmission hub sleeve onto the

No. 2 Hub Shifting Key Ball No. 2 transmission clutch hub until the hub sleeve is
Sleeve
in light contact with the No. 2 synchromesh shifting
keys.
HINT:
No. 2 Shifting There are 3 grooves inside the No. 2 transmission
Key
hub sleeve. Assemble the parts so that the
MT synchromesh shifting key balls can be positioned at
the center of each groove.
Compression No. 2 Clutch (c) While pressing in the 3 synchromesh shifting key
Spring Hub balls, No. 2 synchromesh shifting keys, and
compression springs, completely install the No. 2
transmission hub sleeve until the shifting key balls
are fitted in the grooves on the hub sleeve.
C151339E01 2. INSTALL 2ND GEAR
(a) Apply engine oil to the 2nd gear needle roller
bearing, the thrust surface of the 2nd gear, and the
tapered part of the synchronizer ring.
(b) Install the 2nd gear and 2nd gear needle roller
bearing to the output shaft.
(c) Install the 3rd and 2nd inside ring, 3rd and 2nd
outside ring, and No. 2 synchronizer ring so that the
claws on the outside ring are fitted in the holes on
the 2nd gear.
HINT:
Apply engine oil to both sides of the 3rd and 2nd
inside and outside rings and the inside of the No. 2
synchronizer ring set.
(d) Using SST and a press, install the No. 2

No. 2 Clutch Hub transmission clutch hub and No. 2 transmission hub
sleeve so that the 6 claws on the 3rd and 2nd inside
ring are fitted in the 6 holes on the hub.
No. 2 Synchronizer
Ring Set 3. INSTALL 3RD GEAR
(a) Install the No. 3 synchronizer ring set, 3rd and 2nd
outside ring, and 3rd and 2nd inside ring so that the
Outside Ring 6 claws on the inside ring are fitted in the 6 holes on
3rd and 2nd the hub.
HINT:
Inside Ring Apply a sufficient amount of engine oil to the inside
3rd and 2nd of the 3rd and 2nd inside and outside rings and No.
3 synchronizer ring set.
(b) Apply engine oil to the 3rd gear needle roller
2nd Gear bearing, the thrust surface of the 3rd gear, and the
MT
C151340E01
(c) Using SST and a press, install the 3rd gear, 3rd
gear needle roller bearing, and 3rd gear thrust
Snap Ring washer so that the claws on the 3rd and 2nd outside
Thrust Washer ring are fitted in the holes on the 3rd gear.
3rd Gear
Needle Roller Bearing

Inside Ring 3rd and 2nd
Outside Ring
3rd and 2nd
No. 3 Synchronizer
Ring Set
C151341E01
4. INSTALL GEAR THRUST WASHER SHAFT SNAP

RING
(a) Using a snap ring expander, install the gear thrust
washer shaft snap ring.
NOTICE:
C161757
5. INSTALL NO. 3 SYNCHROMESH SHIFTING KEY

(a) Securely install the 3 No. 3 synchromesh shifting
keys into the grooves on the No. 3 synchronizer
ring.
(b) Install the 2 No. 3 synchromesh shifting key springs
to the No. 3 synchromesh shifting keys.
NOTICE:
• When installing the No. 3 synchromesh
shifting key springs, leave an equal amount
of excess space at both ends of each spring
to prevent interference with the inside of the
clutch hub.
• Do not allow the openings of the No. 3
synchromesh shifting key springs to overlap.
MT
C162356
(c) Check that the clutch hub and hub sleeve slide
smoothly.
Front Side
C151342E01
6. INSTALL 4TH GEAR

No. 3 Shifting Key (a) Apply a sufficient amount of engine oil to the 4th
gear needle roller bearing, the thrust surface of the
4th gear, and the tapered part of the synchronizer
ring.
(b) Install the 4th gear and 4th gear needle roller
bearing.
(c) Apply engine oil to the No. 3 synchronizer ring and
install it.
No. 3 Shifting
TOP-OD Sleeve and Key Spring
Hub Assembly
C151335E02
(d) Using SST and a press, install the sleeve and hub
assembly with the oil groove facing down so that the
Snap Ring sleeve and hub assembly is fitted in the groove on
the No. 3 synchronizer ring.
TOP-OD Sleeve and
Hub Assembly
No. 3 Synchronizer
Ring
Needle Roller Bearing
4th Gear
MT
C152302E01
7. INSTALL NEEDLE ROLLER HOLE SNAP RING

(a) Using a snap ring expander, install the needle roller
hole snap ring.
NOTICE:
8. INSTALL NO. 1 TRANSMISSION HUB SLEEVE
(a) Install the 3 No. 1 synchromesh shifting keys and 3
C161756
compression springs to the No. 1 transmission hub
sleeve.
(b) Install the No. 1 transmission hub sleeve onto the
No. 1 transmission clutch hub until the hub sleeve is
in light contact with the No. 1 synchromesh shifting
keys.
HINT:
There are 3 grooves inside the No. 1 transmission
hub sleeve. Assemble the parts so that the
synchromesh shifting key balls can be positioned at
the center of each groove.
G025938
(c) While pressing in the 3 synchromesh shifting key

No. 1 Hub Shifting Key Ball balls, No. 1 synchromesh shifting keys, and
Sleeve
compression springs, completely install the No. 1
transmission hub sleeve until the shifting key balls
are fitted in the grooves on the hub sleeve.
No. 1 Shifting
Key 9. INSTALL 1ST GEAR
(a) Apply engine oil to the 1st gear needle roller
bearing, the thrust surface of the 1st gear, and the
Compression No. 1 Clutch
Spring Hub (b) Install the 1st gear and 1st gear needle roller
bearing.
(c) Install the low and reverse inside ring, low and
reverse outside ring, and No. 1 synchronizer ring in
this order so that the claws on the outside ring are
C151339E02 fitted in the holes on the 1st gear.
(d) Using SST and a press, install the No. 1

transmission hub sleeve so that the 6 claws on the
MT No. 1 Clutch Hub low and reverse inside ring are fitted in the 6 holes
on the hub.
No. 1
Synchronizer 10. INSTALL REVERSE GEAR
Ring (a) Apply a sufficient amount of engine oil to the No. 2
synchronizer ring.
(b) Install the No. 2 synchronizer ring so that the No. 1
Outside Ring transmission clutch hub and No. 1 transmission hub
LOW and REV sleeve are fitted in the grooves on the No. 2
synchronizer ring.
1st Gear (c) Apply engine oil to the reverse gear bearing, the
Inside Ring thrust surface of the reverse gear, and the tapered
LOW and REV part of the synchronizer ring.
(d) Using SST and a press, install the reverse gear,
Needle Roller reverse gear bearing, and reverse gear bearing
Bearing inner race so that the claws on the low and reverse
inside ring are fitted in the holes on the synchronizer
ring.
C152303E01
(e) Install the output shaft spacer.

Reverse Gear
Bearing Inner Race
Reverse Gear
Reverse Gear Bearing
No. 2 Synchronizer Ring
MT
C152304E01
11. INSTALL OUTPUT SHAFT REAR BEARING

(a) Using SST and a press, install the output shaft rear
Inscribed Surface A bearings with inscribed surface A facing up and
inscribed surface B facing down.
12. INSTALL 6TH GEAR SUB-ASSEMBLY
(a) Install the 6th gear sub-assembly.
Output Shaft HINT:
Rear Bearing Check that the convex part is facing down.
Inscribed
Surface B
Output Shaft
Spacer
C152305E01
MT–72 MYY6S MANUAL TRANSMISSION – COUNTER GEAR AND REVERSE IDLER GEAR
COUNTER GEAR AND REVERSE IDLER GEAR

TRANSMISSION
COMPONENTS
SNAP RING C/FT
COUNTER GEAR FRONT BEARING
ANTI-LASH SNAP RING
ANTI-LASH PLATE
ANTI-LASH PLATE PIN
MT
ANTI-LASH
PLATE SPRING
COUNTER GEAR
COUNTER GEAR REAR BEARING

THRUST 6TH WASHER
COLLAR 6TH COUNTER
Non-reusable part
C152489E01
DISASSEMBLY
1. REMOVE SNAP RING C/FT
(a) Using a snap ring expander, remove the snap ring
C/FT.
C161758
MYY6S MANUAL TRANSMISSION – COUNTER GEAR AND REVERSE IDLER GEAR MT–73
2. REMOVE COUNTER GEAR FRONT BEARING

(a) Using SST, remove the counter gear front bearing
SST (inner race).
SST SST 09950-00020, 09950-60010 (09951-00320),
09950-70010 (09951-07100)
C161759E01
3. REMOVE ANTI-LASH SNAP RING

(a) Using a snap ring expander, remove the anti-lash
snap ring.
4. REMOVE ANTI-LASH PLATE
(a) Using SST, remove the anti-lash plate.
SST 09960-10010 (09963-00700)
(b) Remove the 3 anti-lash plate springs from the 5th
gear. MT
C161996
(c) Remove the 3 anti-lash plate pin from the 5th gear.
SST
C161997E01
5. REMOVE COLLAR 6TH COUNTER

(a) Using SST, remove the collar 6th counter and thrust
SST 6th washer.
SST
SST 09950-00020, 09950-60010 (09951-00320),
09950-70010 (09951-07100)
C161998E01
6. REMOVE COUNTER GEAR REAR BEARING

(a) Using SST, remove the counter gear rear bearing
SST (inner race).
SST SST 09950-00020, 09950-60010 (09951-00320),
09950-70010 (09951-07100)
7. INSPECT COUNTER GEAR
(a) Inspect the counter gear.
If any crack, damage, or wear is found, replace the
counter gear.
C161999E01
8. INSPECT COUNTER GEAR FRONT BEARING

(a) Inspect the counter gear front bearing for the
following items. If any problem is found, replace the
bearing.
(1) Smooth rotation
(2) Abnormal noise
9. INSPECT COUNTER GEAR REAR BEARING
(a) Inspect the counter gear rear bearing for the
following items. If any problem is found, replace the
bearing.
(1) Smooth rotation
(2) Abnormal noise
REASSEMBLY
MT 1. INSTALL COUNTER GEAR REAR BEARING
SST (a) Using SST and a press, install the counter gear rear
bearing (inner race).
SST 09608-06041
C162000E01
2. INSTALL COLLAR 6TH COUNTER

(a) Using SST and a press, install the collar 6th counter
SST and thrust 6th washer.
SST 09608-06041
C162006E01
3. INSTALL ANTI-LASH PLATE

(a) Install the 3 anti-lash plate pins so that the
protruding amount is within the range indicated in
the illustration.
2.74 to 2.8 mm
(0.1079 to
0.1102 in.)
C152306E01
MYY6S MANUAL TRANSMISSION – COUNTER GEAR AND REVERSE IDLER GEAR MT–75
(b) Install the 3 anti-lash plate springs in the grooves on

the side of the 5th gear so that the springs are
positioned on the left of the pins respectively when
viewed from the center of the gear.
G025956
(c) Place the anti-lash plate so that the anti-lash plate

SST springs are positioned between the bent portions of
the anti-lash plate and the anti-lash plate pins.
Aligning the holes on the anti-lash plate with the
holes on the 5th gear, install the plate using SST.
SST 09960-10010 (09963-00700)
MT
C161997E01
4. INSTALL ANTI-LASH SNAP RING

(a) Using an snap ring expander, install the anti-lash
snap ring.
NOTICE:
C161996
5. INSTALL COUNTER GEAR FRONT BEARING

(a) Using SST and a press, install a new counter gear
front bearing (inner race).
SST SST 09608-06041
C162007E01
6. INSTALL SNAP RING C/FT

(a) Using a snap ring expander, install the snap ring C/
SST
FT.
(1) Select the thickest snap ring C/FT that can be
installed from the following 3 types.
NOTICE:
• Check that the snap ring is securely
C161758E01 installed.
Thickness: mm (in.) Identification Color

1.9 (0.0748) Blue
2.1 (0.0827) Yellow
2.3 (0.0906) Pink
MT
MYY6S MANUAL TRANSMISSION – SHIFT LEVER SHAFT HOUSING MT–77

TRANSMISSION
COMPONENTS
with Exhaust Brake Neutral Switch Assembly:
34 (347, 25)
EXHAUST BRAKE NEUTRAL
SWITCH ASSEMBLY
NO. 1 SHIFT OUTER LEVER
SELECT OUTER LEVER MT
SHIFT LEVER NO. 2 SHAFT OIL SEAL

WASHER
SHIFT LEVER NO. 2 LEVER SPRING
SHAFT OIL SEAL SPRING SEAT
SHIFT AND SELECT LEVER
SPRING SEAT
NO. 1 LEVER SPRING
28 (286, 21)
SPACER DETENT ASSEMBLY
SELECT LEVER SHAFT
SELECT OUTER LEVER LOCK PIN
STOPPER RING
STOPPER RING SPRING PIN
SHIFT LEVER SHAFT SPRING PIN
Non-reusable part
C159127E01
MT–78 MYY6S MANUAL TRANSMISSION – SHIFT LEVER SHAFT HOUSING
DISASSEMBLY
Exhaust Brake Neutral
Switch Assembly 1. REMOVE DETENT ASSEMBLY
(a) Remove the detent assembly and spacer.
(b) with Exhaust brake neutral switch assembly:
(1) Remove the exhaust brake neutral switch
assembly.
Spacer
Detent Assembly
C159120E01
2. REMOVE SELECT LEVER SHAFT

(a) Using a pin punch (5 mm) and hammer, remove the
MT select outer lever lock pin.
G025960
(b) Remove the select lever shaft, select outer lever,

Select Outer Lever select outer lever lock pin and washer.
3. REMOVE NO. 1 SHIFT OUTER LEVER
Washer (a) Using the pliers, remove the stopper ring spring pin
and shift lever shaft spring pin.
Select Lever Shaft
Select Outer Lever Lock Pin

C159121E01
(b) Remove the No. 1 shift outer lever, stopper ring, No.
Shift Lever Shaft Spring Pin 2 shift and select lever spring, shift and select lever,
2 spring seats and No. 1 shift and select lever
No. 1 Shift Outer Lever
spring.
4. REMOVE SHIFT LEVER SHAFT OIL SEAL
(a) Using a screwdriver, remove the shift lever shaft oil
seal from the shift lever shaft housing.
5. REMOVE SHIFT LEVER NO. 2 SHAFT OIL SEAL
(a) Using a screwdriver, remove the shift lever No. 2
shaft oil seal.
No. 2 Lever Spring
Spring Seat
Shift and Select Lever
Spring Seat
No. 1 Lever Spring
MT
Stopper Ring
Stopper Ring Spring Pin C159122E01
REASSEMBLY
1. INSTALL SHIFT LEVER NO. 2 SHAFT OIL SEAL
SST
(a) Using SST and a hammer, install a new shift lever
No. 2 shaft oil seal.
SST 09950-60010 (09951-00210, 09951-00310,
09952-06010), 09950-70010 (09951-07100)
C162008E01
2. INSTALL SHIFT LEVER SHAFT OIL SEAL

(a) Using SST and a hammer, install a new shift lever
SST shaft oil seal.
SST 09950-60010 (09951-00200, 09951-00280,
09952-06010), 09950-70010 (09951-07100)
C162009E01
MT–80 MYY6S MANUAL TRANSMISSION – SHIFT LEVER SHAFT HOUSING
3. INSTALL NO. 1 SHIFT OUTER LEVER

Shift Lever Shaft Spring Pin (a) Install the No. 1 shift and select lever spring, 2
spring seats, shift and select lever, No. 2 shift and
No. 1 Shift Outer Lever
select lever spring, stopper ring and No. 1 shift outer
lever.
(b) Install a new stopper ring spring pin and a new shift
lever shaft spring pin.
No. 2 Lever Spring

Spring Seat
Shift and Select Lever
Spring Seat
No. 1 Lever Spring
MT
Stopper Ring
Stopper Ring Spring Pin C159122E01
4. INSTALL SELECT LEVER SHAFT

Select Outer Lever (a) Insert the select outer lever and washer into the shift
lever shaft housing and install the select lever shaft.
(b) Tap in a new select outer lever shaft lock pin.
Washer
Select Lever Shaft
Select Outer Lever Lock Pin

C159121E01
5. INSTALL DETENT ASSEMBLY

Exhaust Brake Neutral (a) Install a new detent assembly and spacer to the shift
Switch Assembly lever shaft housing.
NOTICE:
A detent is precoated with Loctite. Completely
remove any sealing material from the threads on
the case and install a new detent assembly.
(b) with Exhaust brake neutral switch assembly:
(1) Remove any sealing material from the threads
of the exhaust brake neutral switch assembly.
Then apply sealant to the threads of the
Spacer
exhaust brake neutral switch assembly.
Detent Assembly Sealant:
Loctite 242 or equivalent
C159120E01
(2) Install the exhaust brake neutral switch

assembly.
MT
DRIVE LINE
PROPELLER SHAFT

COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PR-1
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PR-6
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PR-7
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PR-11
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PR-12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PR-16
PR
PROPELLER SHAFT – PROPELLER SHAFT ASSEMBLY PR–1

DRIVE LINE SHAFT
PROPELLER
COMPONENTS
B265 Type: 75 (760, 55)
x4
M153, M550, A860E Type: x4

75 (760, 55)
MYY5, MYY6 Type: 103 (1050, 76) x4
x4 PR
75 (760, 55)
x4
x4
75 (760, 55)
x4
x4
75 (760, 55)
ASM91-003
PR–2 PROPELLER SHAFT – PROPELLER SHAFT ASSEMBLY
75 (760, 55)
x4
x4
x4
PR
75 (760, 55)

ASM91-001
Propeller Shaft:
6.4 (65, 57 in.*lbf)

GREASE FITTING
ASSEMBLY
THRUST WASHER
x4
x4
x4
RETAINER RING
SPIDER BEARING PR
x4
THRUST WASHER
x4
6.4 (65, 57 in.*lbf)
RETAINER RING x4

ASSEMBLY
DUST SEAL
SLIDING YOKE
6.4 (65, 57 in.*lbf)
GREASE FITTING
Non-reusable part
MP Grease
C153112E01

x4
M153, M550, A860E Type:
75 (760, 55)
75 (760, 55)
x4
MYY5, MYY6 Type: 103 (1050, 76)
x4
x4
52 (525, 38)
PR
x4

75 (760, 55)
x4
MYY6 Type: 103 (1050, 76)
x4 CENTER SUPPORT
BEARING COVER
CENTER SUPPORT x4
BEARING COVER
52 (525, 38)
x4
ASSEMBLY 52 (525, 38)
75 (760, 55)
x4
ASM91-002
3 and
3 and 44 Joint
Joint Type
Type (Intermediate
(Intermediate shaft
shaft and
and Propeller
shaft center):
DUST DEFLECTOR
SPIDER BEARING x4
INTERMEDIATE SHAFT
THRUST WASHER x4
6.4 (65, 57 in.*lbf)
GREASE FITTING PR
UNIVERSAL JOINT
687 (7000, 506)
SPIDER ASSEMBLY
FLANGE YOKE x4
6.4 (65, 57 in.*lbf)
GREASE FITTING
RETAINER RING
27 (270, 20) x4

x4 DUST DEFLECTOR
BEARING PLATE
Non-reusable part
MP Grease
C161496E02
REMOVAL
Matchmark
differential.
(b) SH12, SH13 Type:
(1) Remove the 4 nuts and 4 washers.
(c) B265 Type:
(1) Remove the 4 nuts, 4 bolts and 4 washers.
C152531E01
(d) Separate the propeller shaft from the differential
carrier.
HINT:
• When the flange connection is difficult to
(e) 2 Joint Type:
(1) Place matchmarks on the propeller shaft flange
and parking brake drum.
PR (2) Remove the 4 nuts and 4 washers.
(3) Slide the slide yoke towards the rear of the
vehicle and remove the propeller shaft
Matchmark assembly.
HINT:
When the flange connection is difficult to
C152789E01 separate, temporarily install one nut and evenly
(f) 3, 4 Joint Type:
(1) Place matchmarks on the propeller shaft flange
and intermediate shaft.
(2) Remove the 4 nuts and 4 washers.
(3) Slide the slide yoke towards the rear of the
vehicle and remove the propeller shaft
assembly.
Matchmark HINT:
When the flange connection is difficult to
C152532E01 separate, temporarily install one nut and evenly
2. REMOVE CENTER PROPELLER SHAFT ASSEMBLY
(for 4 Joint Type)
(a) Holding the center support bearing cover bolts,
remove the 4 nuts and 4 washers.
C159158
(b) Place matchmarks on the propeller shaft center

flange and intermediate shaft.
(c) Remove the 4 nuts and 4 washers.
(d) Remove the propeller shaft center.
Matchmark
C159157E01

ASSEMBLY (for 3, 4 Joint Type)
(a) Secure the center support bearing cover bolts and
remove the 4 nuts.
C159158 PR
(b) Place matchmarks on the intermediate shaft flange
and parking brake drum.
(c) Remove the 4 nuts and 4 washers.
(d) Remove the intermediate shaft.
HINT:
When the flange connection is difficult to separate,
Matchmark temporarily install one nut and evenly tap the
hammer to separate.
C152789E01
DISASSEMBLY
1. REMOVE UNIVERSAL JOINT SLEEVE YOKE
(a) Place matchmarks on the universal joint sleeve
yoke and propeller shaft.
(b) Remove the universal joint sleeve yoke from the
propeller shaft.
Matchmark (c) Remove the grease fitting.
C153117E01
2. REMOVE DUST SEAL

(a) Grip the lip of the dust seal with pliers and pull up
the dust seal.
C158710
(b) Insert a screwdriver into the gap made between the

dust seal and dust cover to remove the dust seal.
NOTICE:
• When removing the dust cover, do not deform
it.
• If the dust cover has been deformed, replace
with a new propeller shaft assembly.
3. REMOVE SPIDER BEARING
(a) Place matchmarks on the flange yoke and sliding
C158711
yoke.
(b) Using snap ring pliers, remove the retainer ring.
PR C153119
(c) Using a press, extrude the spider bearing just until

the spider and yoke come into contact.
HINT:
Disassembly is easier if you remove the grease
fitting in advance, because it will allow you to have
more extruding area.
(d) Remove the spider bearing on the opposite side
using the same procedures.
4. REMOVE UNIVERSAL JOINT SPIDER ASSEMBLY
C153120
(a) Remove the universal joint spider assembly.
5. INSPECT UNIVERSAL JOINT SLEEVE YOKE
(a) Securing the sliding yoke horizontally with a vise,
place a dial indicator onto the yoke of the sleeve
yoke to measure the free play.
HINT:
Place the dial indicator 50 mm (1.96 in.) away from
the center of the sleeve yoke.
C153121
Standard free play:

50 mm 0.185 to 0.393 mm (0.0073 to 0.0155 in.)
Maximum free play:
0.63 mm (0.0248 in.)
(b) If the free play is greater than the maximum, replace
the sleeve yoke.
C153122E01
6. INSPECT SPIDER BEARING

(a) If there are any scratches or cracks in the spider
journal area or on the spider bearing, replace the
spider or spider bearing.
(b) If there are any scratches or cracks on the thrust
washer or bearing case lip, replace the spider
bearing.
C153123
(c) Measure the clearance of the spider bearing.

(1) Using a caliper gauge, measure the bore
diameter (A) of the bearing case of the spider
bearing.
(A)
C157068E01 PR
(2) Using a micrometer, measure the thickness (B)
of a needle roller.
(B)
C153125E01
(3) Using a micrometer, measure the diameter (C)

of the journal of the spider.
(C)
C153126E01
(d) Calculate the clearance between the spider journal

and spider bearing as follows: Subtract the outside
(B) diameter of the needle roller (B x 2) from the inside
diameter of the bearing case (A), then subtract the
outside diameter of the spider journal (C).
(A) (C)
Standard clearance (mm) Maximum clearance (mm)
0.022 to 0.061 mm (0.0009 to 0.0024
0.1 mm (0.0039 in.)
in.)
(B)
C153127E01
(e) If the clearance is greater than the maximum,
change the spider journal or the spider bearing.
7. REMOVE UNIVERSAL JOINT FLANGE SUB-

(a) Secure the flange coupling at the center bearing
section with a vice.
(b) Using SST and a hammer, loosen the staked part of
the lock nut.
SST 09930-00010
SST
NOTICE:
There are 2 staked portions.
C153138E01
(c) Place matchmarks on the intermediate shaft and

Matchmark
flange coupling.
(d) Using a socket wrench (41 mm), remove the lock
nut and flange coupling from the intermediate shaft.
NOTICE:
PR
Check that the staked nut is completely
unstaked before removing as the shaft can get
damaged.
C153139E01
8. REMOVE NO. 1 CENTER SUPPORT BEARING

(a) Secure the bolts, remove the 4 nuts respectively,
and then remove the center bearing plate and
center bearing cushion rubber.
(b) Using a brass bar and hammer, tap evenly around
the outside of the center bearing to remove it.
C153140
9. REMOVE DUST DEFLECTOR (for 3, 4 Joint Type)

(a) Using a screwdriver and a hammer, tap out the dust
deflectors from the universal joint flange and
intermediate shaft.
INSPECTION
1. INSPECT PROPELLER SHAFT ASSEMBLY
(a) Check the shaft tube for wear or damage.
C153141
PR
(b) Set the propeller shaft on V-blocks. Using a dial

indicator, measure the runout of the center of the
propeller shaft.
Standard runout:
0 to 0.6 mm (0 to 0.024 in.)
Maximum runout:
1.0 mm (0.039 in.)
(c) If the shaft runout is greater than the maximum,
replace the shaft assembly.
C153115
2. INSPECT UNIVERSAL JOINT SPIDER ASSEMBLY

(a) Shake the spider in the axial direction and lateral
direction strongly with both hands, and check that
there is no looseness in the spider and spider
bearing.
NOTICE:
If there is deformation or damage, replace the
spider or spider bearing.
C153116
3. INSPECT NO. 1 CENTER SUPPORT BEARING

ASSEMBLY (for 3 Joint Type)
(a) Check that the center bearing rotates smoothly
when the bearing is rotated by hand and check if
there are any cracks or damage. If there are any
malfunctions, replace the bearing.
(b) If there is any damage on the lip of the center
bearing case, replace it.
NOTICE:
C153142 Do not soak the center bearing in cleaner.
(c) If there are any scratches or cracks on the surface

of the cushion rubber or if the bearing plates are
damaged, replace them.
C153217
REASSEMBLY
1. INSTALL SPIDER BEARING
(a) Install the grease fitting onto the spider section.
(b) Apply a sufficient amount of MP grease to the spider
journal section.
(c) Remove the old grease from the bearing case and
needle rollers and apply a sufficient amount of MP
grease.
PR C153128E02
(d) Apply MP grease to the bearing case lip and both
sides of the thrust washers.
(e) Insert the thrust washers and needle rollers into the
bearing case.
C153129
(f) Measure the size of groove (A) of the retainer ring of

the yoke.
(g) After inserting the thrust washers and spider
bearings into the spider journal section, measure
the size of the universal joint (B).
A B HINT:
Size (B) should be measured with the universal joint
secured to the vice, because the spider and spider
bearing will become stuck.
C153130E01 NOTICE:
Do not overtighten the vice.
(h) Select the thickness of the retainer ring to make

sizes (A) and (B) equal.
Thickness of the retainer ring:
Part No. Thickness mm (in.) Identification (Color)
90035-21044 1.50 (0.0591) White
90035-21043 1.53 (0.0602) Red
90035-21042 1.56 (0.0614) Green
90035-21041 1.59 (0.0626) Blue
Identification Paint
90035-21040 1.62 (0.0638) Yellow
C153131E01
90035-21039 1.65 (0.0650) Pink
90035-21038 1.68 (0.0661) Orange
2. INSTALL UNIVERSAL JOINT SPIDER ASSEMBLY

(a) Insert the spider into the yoke. Using a vice, press
the spider bearing into the end of the retainer ring.
(b) Press in the spider bearing on the other side using
the same procedures.
NOTICE:
Be careful not to damage the spider bearing lip
while pressing.
PR
C153132
(c) Using snap ring pliers, install new retainer rings.
C153119
3. INSPECT UNIVERSAL JOINT FLANGE

(a) Using a spring tension gauge, hang the hook of the
B spring tension gauge on the bolt hole of the flange
yoke and measure the rotating torque.
A Standard rotating torque (initial) of the flange
yoke that is connected to the MYY5 and MYY6
Flange Yoke manual transmission:
15 to 52 N (1.5 to 5.3 kgf, 3.3 to 12.0 lbf)
End Yoke Standard rotating torque (initial) of the flange
C161607E01 yokes that is connected to a transmission other
than the MYY5 and MYY6 manual transmission :
18 to 63 N (1.8 to 6.4 kgf, 4.0 to 14.2 lbf)
NOTICE:
Measure the rotating torque at 2 positions of the
universal joint in direction A (flange yoke side)
and direction B (flange yoke side).
(b) When the rotating torque is less than the standard,

use a thicker retainer ring, when it is greater, use a
thinner retainer ring.
Thickness of the retainer ring:
Part No. Thickness mm (in.) Identification (Color)
90035-21044 1.50 (0.0591) White
90035-21043 1.53 (0.0602) Red
90035-21042 1.56 (0.0614) Green
Identification Paint
90035-21041 1.59 (0.0626) Blue
C153131E01
90035-21040 1.62 (0.0638) Yellow
90035-21039 1.65 (0.0650) Pink
90035-21038 1.68 (0.0661) Orange
4. INSTALL DUST SEAL

(a) Place the outside of the dust seal on the gap of the
dust seal cover and push in the seal.
NOTICE:
• Install the seal so that the lip faces outside.
• After installing check that the outside of the
dust seal contacts the dust cover.
PR
C158712
(b) Apply grease to the dust seal oil lip.

Dust Seal
5. INSTALL UNIVERSAL JOINT SLEEVE YOKE
(a) Remove the old grease on the spline and sliding
sections.
(b) Remove any rust and dirt on the spline sections.
(c) Apply bearing grease to the spline and sliding
sections.
Dust Cover
C158713E01
(d) Align the matchmarks of the propeller shaft and

sleeve yoke, and insert the sleeve yoke.
NOTICE:
Phase marks are imprinted on each yoke. Install
the sleeve yoke so that the matchmarks of the
propeller shaft and sleeve yoke are aligned.
(e) Install the grease fitting.
Matchmark
C153117E01
(f) Check that the directions of the phase marks of

each joint are installed as shown in the illustration.
Phase Mark
C161891E01
6. INSTALL DUST DEFLECTOR (for 3, 4 Joint Type)

(a) Using SST and a hammer, tap in a new dust
deflector to the intermediate shaft.
SST SST 09316-12010
NOTICE:
Do not deform the dust cover.
(b) Using SST and a hammer, tap in a new dust
deflector to the universal joint flange.
SST 09309-37010, 09316-12010, 09710-28021
(09710-08031) PR
SST
C162101E01
7. INSTALL NO. 1 CENTER SUPPORT BEARING

(a) Apply MP grease to the inside of the center bearing.
C153219
(b) Using SST and a hammer, tap in the center bearing.

SST 09309-60010
NOTICE:
SST
When tapping in the center bearing, pay
attention not to damage it.
(c) Install the bearing plate and cushion rubber.
C153220E01
(d) Secure the bolts and install the 4 nuts.

C153140
8. INSTALL UNIVERSAL JOINT FLANGE SUB-

Matchmark
(a) Align the matchmarks on the companion flange and
the intermediate shaft to install the flange.
PR C153139E01
HINT:
Install the flange so that the phase marks of the
flange and the shaft are aligned.
(b) Using a socket wrench (41 mm), tighten a new lock
nut.
Phase Mark
C153221E01
(c) Using a chisel and hammer, stake the lock nut.

NOTICE:
Stake the lock nut, aligning them with the
cutouts of the shaft.
C153222
INSTALLATION
(a) Align the matchmarks on the intermediate shaft
flange and parking brake drum.
(b) Install the 4 nuts and 4 washers.
Matchmark Torque:
M153, M550 and A860E Type:
C152789E01
75 N*m (760 kgf*cm, 55 ft.*lbf)
MYY5 and MYY6 Type:
103 N*m (1050 kgf*cm, 76 ft.*lbf)
HINT:
Engage the parking brake.
(c) Secure the bolts and install the intermediate shaft
assembly to the body with the 4 nuts.
C159158
2. INSTALL CENTER PROPELLER SHAFT ASSEMBLY

(for 4 Joint Type)
(a) Align the matchmarks on the propeller shaft center
flange and the intermediate shaft, and install the 4
washers and 4 nuts.
PR
Matchmark
C159157E01
(b) Secure the bolts and install the propeller shaft

center to the body with the 4 nuts and 4 washers.
C159158

(a) 2 Joint Type:
(1) Align the matchmarks on the propeller shaft
flange and parking brake drum.
(2) Install the 4 nuts and 4 washers.
Torque:
Matchmark M153, M550 and A860E Type:
75 N*m (760 kgf*cm, 55 ft.*lbf)
MYY5 and MYY6 Type:
C152789E01 103 N*m (1050 kgf*cm, 76 ft.*lbf)
(b) 3, 4 Joint Type:

(1) Align the matchmarks on the propeller shaft
assembly and the intermediate shaft, and
temporarily install the 4 washers and 4 nuts.
(2) Tighten the nuts.
Matchmark
C152532E01

flange.
(d) SH12, SH13 Type:
Matchmark (1) Install the 4 washers and 4 nuts.
PR C152531E01
(e) B265 Type:

(1) Install the 4 bolts, 4 washers and 4 nuts.
Washer
4. APPLY GREASE
(a) Apply MP grease from the grease fitting of the joint
Nut section.
(b) Apply MP grease from the grease fitting of the
Bolt sleeve yoke.
C162598E01
FRONTO SUSPENSION SYSTEM (IFS, COIL SPRING TYPE)

PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS-1
FRONT WHEEL ALIGNEMT (IFS)
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS-1
FRONT SHOCK ABSORBER WITH COIL SPRING (IFS/2WD DRIVE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS-10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS-13
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS-17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS-17
DISCARDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS-21
FRONT SUSPENSION UPPER ARM ASSY LH (IFS/2WD DRIVE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS-22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS-23
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS-26
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS-27 FS
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS-28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS-29
FRONT SUSPENSION LOWER ARM ASSY LH (IFS/2WD DRIVE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS-32
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS-35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS-36
FRONT STABILIZER BAR (IFS/2WD DRIVE)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS-37
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS-38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS-39
FRONT SUSPENSION (IFS) – FRONT SUSPENSION SYSTEM (IFS, COIL SPRING TYPE) FS–1
FRONT SUSPENSION SYSTEM (IFS, COIL SPRING TYPE)

SUSPENSION

Use the table below to help determine the cause of the problem. The number indicate the priority of the
likely cause of the problem. Check each part in order. If necessary, replace these parts.
BRAKE SYSTEM (with Disc Brake)
Tire (Worn or improperly inflated) FS-1
Wheel alignment (Incorrect) FS-2
Hub bearing (Worn) -
Wander/pulls
Front shock abcorber w/coil spring. FS-10
Rear spring assy (Leaf spring) -
Rear shock absorber -
Vehicle (Overloaded) -
Bottoming Front shock abcorber w/coil spring. FS-10
Rear shock abcorber w/coil spring. -
Front stabilizer FS-38
Sways/pitches
Front shock abcorber w/coil spring. FS-10
Rear spring assy (Leaf spring) -
FS
Wheel (Out of balance) FS-2
Front wheel shimmy Front shock abcorber w/coil spring. FS-10
Suspension upper arm FS-22
Suspension lower arm FS-32
Hub bearing (Worn) -
Abnormal tire wear Wheel (Out of balance) FS-2
FRONT WHEEL ALIGNMENT (IFS)

ADJUSTMENT
NOTICE:
IFS (Independant front suspension) is installed for only
following vehicle model.
XZU306-HQMMBQ3
1. INSPECT TIRE
(a) Check the tires for wear and proper inflation
pressure.
Cold tire inflation pressure:
Tire size Inflation pressure kPa (kgf/cm2, psi)
Model
XZU306-HQMMBQ3 195/75R15 195/75R15 600 (6.0, 87) 600 (6.0, 87)
FS–2 FRONT SUSPENSION (IFS) – FRONT WHEEL ALIGNMENT (IFS)
(b) Check the damage for the suspension parts.

(c) Check the tire runout.
Tire runout: 3.0mm (0.118in.) or less
AP011043
2. INSPECTION OF CAMBER, CASTER, AND KINGPIN

ANGLE
(a) Jack-up the vehicle at a level location.
(b) Install SST (tire clamp compensator).
SST 09722-30010
(1) Turn the clamp dial of the SST (tire clamp
compensator) and open the tire clamp arm.
CAUTION:
When the tire clamp arm is opened too much,
the body etc. may be damaged; therefore
caution is required.
FS
(2) Turn the dial, match the two lower claws to the
position of the corresponding wheel size, bring
them into contact with the lower part of the wheel
rim, and secure in the position where the upper
claw is in contact with the wheel rim.
CAUTION:
Install so that no claw touches a balance
weight and that the air valve of the wheel
preferably is on the upper side.
C156602
C156602
(3) Turn the clamp dial to contract the tire clamp

arm and to clamp the tire.
CAUTION:
The tire clamp arm should engage a tire
groove and the SST (tire clamp
compensator) should be pressed securely
against the wheel.
(4) Install the drop prevention wire on the air valve
of the wheel.
C156603
C156603
(c) Correct the SST (tire clamp compensator).

(1) Turn the correction dial of the SST (tire clamp
compensator) and match it to the range of the
Mech
mechanical zero line (red line).

anica
l zero
line
C107541
C107541
FRONT SUSPENSION (IFS) – FRONT WHEEL ALIGNMENT (IFS) FS–3
(2) Install the camber, caster, kingpin gauge on the

Match mark mounting plate of the SST (tire clamp
compensator) and match the match marks.
C107542J04
C107542J04
(3) Turn the wheel a little, match so that the

horizontal air bubble of the camber, caster,
Horizontal air bubble kingpin gauge comes to the center, and adjust
the caster air bubble with the adjustment screw
of the camber, caster, kingpin gauge to 0°.
Caster air bubble

C107543J04
(4) Rotate the wheel 180°, match the match marks FS

of camber, caster, kingpin gauge and SST (tire
clamp compensator) and match the horizontal
air bubble. (*1)
Match
mark Horizontal
air bubble
C156604J01
(5) Read the caster air bubble in the above

condition and turn the correction dial of the SST
Correction dial (tire clamp compensator) so that the scale
becomes one half of this value. (*2)
CAUTION:
Do not move the adjustment screw of the
camber, caster, kingpin gauge.
(6) Repeat the above steps (*1) and (*2). Setting of
Caster air bubble the camber, caster, kingpin gauge has been
C C107545J03 completed when the scale position of the caster
air bubble remains constant even when the
wheel is rotated 180° forward and back.
(d) Set the turning radius gauge and lower the vehicle.
CAUTION:
Level the vehicle on a stand with the same
height as the turning radius gauge.
(e) Move the vehicle corners strongly up and down, and
inspect camber, caster, and kingpin angle after the
suspension has settled down.
Camber, caster and king pin inclination:
Camber Caster King pin inclination
0°00’ ± 45’ 3°05’ ± 45’ 12°50’
CAUTION:
• Inspect with the vehicle in empty state (no
spare tire and tools).
• The left/right limit degree for camber and
caster is within 45' (0.75°).
3. CAMBER ADJUSTMENT (SUSPENSION FORM: COIL
SUSPENSION)
(a) Jack-up the vehicle and remove the front tires.
(b) Remove the three bolts and engine side cover (LH).
C154229
C154229
(c) Remove the four bolts and engine side cover (RH).
FS
C151580
(d) Remove the two bolts and the clamp and remove
the intake pipe or hose stay.
Clamp position
C151587J01
(e) Loosen the two upper arm mounting bolts.
C154213
C154213
(f) Adjust the camber by increasing or decreasing the

quantity of camber adjustment shims.
Types of camber adjustment shims
Chopping mark Part No. Camber change valve
t 0.8 90565-12016 6.4’ (0.11°)
Vehicle outside
t 1.2 90565-12015 9.6’ (0.16°)
t 2.0 90565-12014 16’ (0.27°)
t 4.0 90565-12013 32’ (0.53°)
CAUTION:
• Camber adjustment shims are installed
between upper arm and suspension member.
• Install camber adjustment shims with the
Camber adjustment shim marking towards the outside of the vehicle.
• The total thickness of the camber adjustment
C154219J02
C154219J02
shims shall be within 8 mm.
• Adjust to be within the reference value.
NOTICE:
The change by 1 mm of camber adjustment shim
is 8' (0.13°).
(g) Tighten the two upper arm mounting bolts.
Torque: 88 N*m (897 kgf*cm, 64.9 ft*lbf) FS
C154213
C154213
(h) Install the intake pipe or hose stay with two bolts.
Torque: 18 N*m (183 kgf*cm, 13.3 ft*lbf)
Clamp position
C151587J01
(i) Install the wire harness clamp to the intake pipe or

hose stay.
(j) Install engine side cover (LH) with two bolts.
Torque: 11.5 N*m (117 kgf*cm, 8.5 ft*lbf)
C154229
C154229
(k) Install engine side cover (RH) with four bolts.

C151580
(l) Install the front tires.

(m) Jack-down the vehicle, shake it several times up
and down, and let the suspension settle down.
(n) Inspect the camber again.
Camber: 0°00' ± 45'
CAUTION:
• The left/right limit degree is 45' (0.75°).
4. CASTER ADJUSTMENT (SUSPENSION FORM: COIL
FS SUSPENSION)
(a) Jack-up the vehicle and remove the front tires.
(b) Loosen the two upper arm mounting bolts.
C154213
C154213
(c) Adjust the caster by turning the caster adjustment

bolt installed on the caster adjustment plate.
(1) Turn the caster adjustment bolt until there is no
more play between caster adjustment bolt and
suspension member.
(2) Turn the caster adjustment bolt only as much as
required.
NOTICE:
• When the adjustment bolt is turned
clockwise as seen from the rear of the
vehicle, the caster angle increases, and it
decreases with counterclockwise turning.
• A change of dimension A by 1 mm causes
A a change by 8' (0.13°).
C158624J01
C158624J01
(d) Tighten the two upper arm mounting bolts.

Torque: 88 N*m (897 kgf*cm, 64.9 ft*lbf)
(e) Install the front tires.
(f) Jack-down the vehicle, shake it several times up
and down, and let the suspension settle down.
(g) Inspect the caster again.
Caster: 3°05' ± 45'
CAUTION:
C154213
C154213 • Inspect with the vehicle in empty state (no
• The left/right limit degree is 45' (0.75°).
5. SIDE SLIP INSPECTION
(a) Inspect the side slip with a side slip tester.
Side slip: 0 ± 5 mm (every 1 m)
CAUTION:
• Drive into the side slip tester driving straight
at walking speed (about 4 km/h) and inspect
in neutral condition.
• Do not apply the brake on the side slip tester.
• Do not perform steering operation on the side
slip tester. FS
(b) Inspect the wheel alignment if outside the reference
value.
6. INSPECT TOE-IN
(a) Move the vehicle corners strongly up and down, and
inspect the toe-in after the suspension has settled
down.
(b) Push the vehicle straight forward for 5 m.
CAUTION:
If the vehicle has been moved back, it must be
moved forward for the same distance.
(c) Match the height of the toe-in needle with the center
Dimension B of the front wheel track and place it at the rear of the
tire.
(d) Mark the tread center at the rear of each front tire
and measure the distance (dimension B) between
the marks.
Toe-in gauge (e) Push the vehicle slowly forward and rotate the front
wheels 180°.
CAUTION:
ZD09137J01
ZD09137J01 Take care not to exceed 180°, and if 180° is
exceeded, start again from setting the toe-in
gauge.
(f) Measure the distance (dimension A) between the

marks at the front of the vehicle.
(g) Obtain the toe-in.
V ehicle front Standard:
Toe-in 0-4 mm (0-0.15 in.)
Dimension NOTICE:
A
Toe-in = Dimension B - dimension A
7. ADJUST TOE-IN
Toe-in gauge CA00067J01
1
(a) Measure the length of the thread part on left and
right rack end.
Standard: Left/right difference within 3 mm
(0.11 in.)
(b) Remove the clip of the rack boot.
(c) Loosen the lock nut of the tie rod end.
(d) Perform adjustment if the left/right difference is
outside the reference value.
(1) If the toe-in measuring value is off on the toe-in
side, adjust the rack end with the shorter
dimension in extension direction.
(2) If the toe-in measuring value is off on the toe-out
side, adjust the rack end with the longer
FS dimension in extension direction.
(3) Inspect the toe-in again.
(e) Turn the left and the right rack end for the same
amount in opposite directions and adjust so that the
toe-in is within the reference value.
Standard:
Toe-in 0-4 mm (0-0.15 in.)
(f) Secure the hexagonal parts of the steering rack

ends so that the steering rack ends do not turn, and
tighten the lock nuts provisionally.
(g) Secure the flats of the tie rod end and tighten the
lock nut.
(h) Use pliers and install a clamp on the steering rack
boot.
CAUTION:
• If the rack boot is twisted, correct the
twisting.
• Orient the grip of the clip to the upside of the
vehicle.
8. INSPECT WHEEL ANGLE
Inside Outside Outside Inside (a) Set the turning radius gauge.
CAUTION:
Front
Set a stand with the same height as the turning
radius gauge to the opposite tire.
ZE05765J01
ZE05765J01
(b) Inspect the wheel deflection angle.

Standard:
Model Front tire size Inside Out side (Reference)
XZU306-HQMMBQ3 195/75R15 43°50’ + 0°, -3° 38°40’
CAUTION:
• Perform inspection in empty condition and
with the foot brake applied for example by
use of brake pedal pressure etc.
• Perform the inspection with removed stop
lamp fuse so that the stop lamp does not
light.
• Left/right limit degree within 30' (0.5°).
9. ADJUST WHEEL ANGLE
CAUTION:
Perform adjustment of the wheel deflection angle
after completion of alignment adjustment.
(a) Loosen the lock nut and adjust the length of the
Lock nut knuckle stopper bolt.
A: 15-17.5 mm (0.59-0.68 in.) FS
(b) Secure the knuckle stopper bolt and tighten the lock
nut.
A Torque: 43 N*m (438 kgf*cm, 31.7 ft*lbf)
(c) Confirm that the wheel deflection angle is within the
reference value.
(d) If the left/right difference after adjustment of the
wheel deflection angle exceeds 30' (0.5°), adjust by
turning left and right tie rod for the same amount in
the same direction.
Knuckle stopper bolt
C154217J01
C154217J01
FRONT SUSPENSION (IFS) – FRONT SHOCK ABSORBER WITH COIL SPRING (IFS/2WD
FS–10 DRIVE)
FRONT SHOCK ABSORBER WITH COIL SPRING (IFS/2WD

DRIVE)
COMPONENTS
With Front Stabilizer
FS Front Stabilizer Bracket
Front Stabilizer Bar x2
17.5 (178, 13)
x2
Front Stabilizer Bracket Cover

17.5 (178, 13)
x2
Front Stabilizer Bracket
25 (255, 18)
25 (255, 18) x2
C156477J01
C156477J01
DRIVE) FS–11
Installation Position RH Side: Installation Position LH Side:
11.5 (122, 8.5)

x4
x3
11.5 (122, 8.5)
Engine Side Cover RH Engine Side Cover LH
Front Suspension Upper Arm LH 18 (183, 13)
Intake Pipe or Hose Stay FS
Camber Adjustment Shim

18 (183, 13)
Caster Adjustment Bolt
19 (194, 14)
Speed Sensor FR LH 88 (897, 65)
152 (1549, 112)

Cotter Pin
Caster Adjustment Plate LH
Non-reusable part
C152272J01
C152272J01
FS–12 DRIVE)
Lock nut
Shock Absorber Cushon Retainer
Shock Absorber Cushon
Front Coil Spring Insulator UPR LH
Front Coil Spring LH

Front Suspension Support LH
FS
Front Shock Absorber Assy LH
155 (1580, 114)
Cotter Pin
206 (2100,152) 206 (2100, 152)
Front Axle Assy LH Front Suspension

Cotter Pin
Lower Arm NO.1 LH
90 (917, 66)
60 (612, 44)
Tie-Rod End LH
N*m (kgf*cm, ft*lbf) : Specified Torque Front Disc Brake Cylinder Assy LH
Non-reusable part
C152273J01
C152273J01
DRIVE) FS–13
REMOVAL
2. REMOVE FRONT TIRE
3. REMOVE ENGINE SIDE COVER (LH) (INSTALLATION
POSITION: LEFT SIDE)
(a) Remove the three bolts and engine side cover (LH).
C154229
C154229
4. REMOVE THE ENGINE SIDE COVER (RH)

(INSTALLATION POSITION: RIGHT SIDE)
(a) Remove the four bolts and engine side cover (RH).
5. REMOVE THE FRONT STABILIZER BRACKET
COVER (WITH FRONT STABILIZER) (SEE FS-38)
6. REMOVE THE FRONT STABILIZER BRACKET (WITH FS
FRONT STABILIZER) (SEE FS-38)
7. REMOVE THE FRONT STABILIZER BAR (WITH
C151580
8. DISCONNECT THE SPEED SENSORS (FR, LH)
(a) Disconnect the connectors of the front and left
speed sensors.
(b) Remove the bolts and separate the front and left
speed sensors from the suspension member assy.
9. DISCONNECT TIE ROD END (LH)
C155576
C155576
10. DISCONNECT THE FRONT DISK BRAKE CYLINDER

ASSY (LH)
(a) Secure the slide pin with a spanner, remove the two
Move
bolts, and disconnect the front disk brake cylinder
assy (LH).
CAUTION:
Suspend the disconnected front disk brake
cylinder assy (LH) with a wire.
Hold
C156594J01
C156594J01
FS–14 DRIVE)
11. REMOVE THE FRONT AXLE ASSY (LH)

(a) Support the front axle assy (LH) with a jack via a
piece of wood.
CAUTION:
• Apply the piece of wood to the front axle hub.
• When it is possible that the front axle assy
(LH) will drop during the following work, the
vehicle must be supported wit jacks to
prevent damage.
C151584
C151584
(b) Remove the cotter pin and the castle nut.

FS
C151585
C151585
(c) Use SST and separate the front axle assy (LH) from
the front suspension upper arm (LH).
SST 09950-40011 (09951-04010, 09953-04020,
09952-04010, 09954-04010, 09955-04031,
09958-04011)
CAUTION:
• Before separating the front axle assy (LH),
confirm that SST does not clamp the dust
boot.
• Perform the work while suspending the front
axle assy (LH) with a jack.
• As the front axle assy (LH) is heavy, take
sufficient care not to drop it.
Boot
SST
SST
C156593J01
C156593J01
DRIVE) FS–15
(d) Remove the cotter pin and the castle nut.

CAUTION:
• Do not apply excessive force to the lower ball
joint.
C151606
C151606
(e) Use the special tool and remove the front axle assy
(LH) from the front suspension lower arm No. 1
(LH).
SST 09950-40011 (09951-04010, 09953-04020,
09952-04010, 09954-04010, 09955-04031,
SST
09958-04011)
CAUTION:
• Before separating the front axle assy (LH),
confirm that the special tool does not clamp
the dust boot.
FS
SST
12. REMOVE THE INTAKE PIPE OR HOSE STAY (SEE
FS-25)
13. REMOVE THE FRONT SUSPENSION UPPER ARM
Boot
(LH) (SEE FS-25)
C156671J01
C156671J01
14. REMOVE THE FRONT SUSPENSION LOWER ARM

NO. 1 (LH)
(a) Loosen the bolt and the two nuts.
(1) Support the front suspension lower arm No. 1
(LH) with a jack via a piece of wood.
C154225
C154225
FS–16 DRIVE)
(2) Remove the lock nut.

(3) Lower the jack slowly until the spring has
extended completely.
(4) Remove the two bolts and the two nuts.
C160386
C160386
(5) Lower the jack slowly and remove the front

suspension lower arm No. 1 (LH) and the front
shock absorber assy (LH)
CAUTION:
Take sufficient care not to drop the parts.
FS NOTICE:
First disconnect the front suspension lower
arm No. 1 (LH) and the suspension member
assy side.
C151604
C151604 (6) Remove the shock absorber cushion retainer
and the front shock absorber cushion.
15. REMOVE OF THE FRONT COIL SPRING INSULATOR
(UPPER LEFT)
(a) Separate the front coil spring insulator (upper left)
from the front coil spring (LH).
16. REMOVE OF THE FRONT COIL SPRING (LH)
(a) Remove the front coil spring (LH) from the front
shock absorber assy (LH).
17. REMOVE THE FRONT SUSPENSION SUPPORT (LH)
(a) Remove the front suspension support (LH) from the
front shock absorber assy (LH).
18. REMOVE THE FRONT SHOCK ABSORBER ASSY
(LH)
(a) Remove the bolt and remove the front shock
absorber assy (LH) from the front suspension lower
arm No. 1 (LH).
C158849
DRIVE) FS–17
INSPECTION
1. INSPECT THE FRONT SHOCK ABSORBER ASSY
(LH)
(a) Operation inspection for the front shock absorber
assy (LH)
(1) Repeat the operation of pushing the front shock
absorber assy (LH) to the lowest end and
letting it extend naturally at least four times.
(2) Inspect the front shock absorber assy (LH).
Standard: When expansion and
C154218
C154218 contraction is done at constant speed, the
load shall be uniform over the entire
stroke and there shall be no abnormal
response or abnormal noise.
The return at the time of expansion and
contraction shall be at constant speed and
without abnormal noise.
INSTALLATION
1. INSTALL THE FRONT SHOCK ABSORBER ASSY
(LH) FS
V ehicle front
(a) Install the front shock absorber assy (LH) with a bolt
provisionally to the front suspension lower arm No.
1 (LH).
CAUTION:
Install so that the stopper of the front shock
absorber assy (LH) points to the vehicle front.
Stopper
C151598J01
C151598J01
2. INSTALL THE FRONT SUSPENSION SUPPORT (LH)

(a) Install the front suspension support (LH) to the front
shock absorber assy (LH).
C151597
C151597
FS–18 DRIVE)
3. INSTALL THE FRONT COIL SPRING (LH)

Flat part (a) Install the front coil spring (LH) to the front shock
absorber assy (LH).
CAUTION:
• Install the coil spring so that it is in contact
with the stopper.
• Install the coil with the flat end up.
4. INSTALL THE FRONT COIL SPRING INSULATOR
(UPPER LEFT)
(a) Install the front coil spring insulator (upper left) to
the front coil spring (LH).
Stopper
C151599J01
C151599J01
FS
5. INSTALL THE FRONT SUSPENSION LOWER ARM
NO. 1 (LH)
(a) Install the shock absorber cushion retainer and the
shock absorber cushion to the suspension member
assy.
NOTICE:
Installation is not possible after installation of
the front suspension lower arm No. 1 (LH) and
the front shock absorber assy (LH).
C151608
C151608 (b) Support the front suspension lower arm No. 1 (LH)
and the front shock absorber assy (LH) with a jack.
(c) Adjust the jack and install the front suspension
lower arm No. 1 (LH) and the front shock absorber
assy (LH) to the suspension member assy.
CAUTION:
Take sufficient care not to drop the parts.
1. Pass the piston rod of the front shock
absorber assy (LH) through the mounting
hole of the suspension member assy.
Bolt installation direction 2. Pass the piston rod of the front shock
C156114J01
C156114J01 absorber assy (LH) through the holes of the
shock absorber cushion retainer and the
shock absorber cushion.
3. Provisionally install the front suspension
lower arm No. 1 (LH) with two bolts and two
nuts as shown in the figure to the suspension
member assy.
DRIVE) FS–19
(d) Raise the front suspension lower arm No. 1 (LH)

with a jack until the suspension support engages the
mounting hole of the suspension member assy.
CAUTION:
Confirm that the suspension support has
engaged the mounting hole of the suspension
member assy securely.
C156605
C156605
(e) Install a new lock nut.

FS
(1) Tighten the lock nut until dimension A is within
the range of the standard value.
A: 35-39 mm (1.38-1.53 in)
6. INSTALL THE FRONT SUSPENSION UPPER ARM
(LH) (SEE FS-29)
7. INSTALL THE INTAKE PIPE OR HOSE STAY (SEE
A
FS-30)
C160387J01
C160387J01
8. INSTALL THE FRONT AXLE ASSY (LH)

(a) Install the front axle assy (LH) with a castle nut to
the front suspension lower arm No. 1.
CAUTION:
• Use sufficient care as the front axle assy (LH)
is heavy.
C151606
C151606 • Do not apply excessive force to the lower ball
joint.
• Perform matching of the cotter pin hole after
tightening the castle nut by additional
tightening within 30°.
(b) Install a new cotter pin.
FS–20 DRIVE)
(c) Install the front axle assy (LH) with a castle nut to
the front suspension upper arm (LH).
CAUTION:
Perform matching of the cotter pin hole after
tightening the castle nut by additional tightening
within 30°.
(d) Install a new cotter pin.
C151585
C151585
9. CONNECT THE FRONT DISK BRAKE CYLINDER

ASSY (LH)
(a) Secure the slide pin with a spanner and install the
Move
front disk brake cylinder assy (LH) with two bolts.
10. CONNECT THE TIE ROD END (LH)
Hold
C156594J01
C156594J01
FS 11. CONNECT THE FRONT SPEED SENSOR (LH)

(a) Install the front speed sensor (LH) with a bolt to the
suspension member assy.
(b) Connect the connector of the front speed sensor
(LH).
12. INSTALL THE FRONT STABILIZER BAR (WITH
C155576
C155576 13. INSTALL THE FRONT STABILIZER BRACKET (WITH
14. INSTALL THE FRONT STABILIZER BRACKET
15. INSTALL THE ENGINE SIDE COVER (LH)
(INSTALLATION POSITION: LEFT SIDE)
(a) Install the engine side cover (LH) with three bolts.
C154229
C154229
DRIVE) FS–21
16. INSTALL THE ENGINE SIDE COVER (RH)

(INSTALLATION POSITION: RIGHT SIDE)
(a) Install the engine side cover (RH) with four bolts.
17. INSTALL FRONT TIRE
18. VEHICLE SETTLING DOWN
(a) Jack-down the vehicle, shake it several times up
C151580 and down, and let the front suspension settle down.
19. FINAL TIGHTENING OF THE FRONT SUSPENSION

LOWER ARM NO. 1 (LH)
(a) Tighten the bolt and the two nuts.
Torque:
Bolt A 155 N*m (1580 kgf*cm, 114 ft*lbf)
Nut B 206 N*m (2100 kgf*cm, 152 ft*lbf)
20. CONNECT THE BATTERY MINUS TERMINAL
Nut B
21. INSPECT AND ADJUST THE FRONT WHEEL
ALIGNMENT (SEE FS-1)
SST 09722-30010 FS
22. INSPECT ON THE TEST MODE (INSPECT SPEED
SENSOR SYSTEM)
Nut B
Bolt A
C154225J01
C154225J01
DISCARDING
1. DISCARD THE FRONT SHOCK ABSORBER ASSY
A B (LH)
(a) Place the assy horizontally with extended piston rod
and use a metal saw or similar to open a hole
between A and B in the figure to release the gas.
CAUTION:
• The vented gas has no color, no smell, and is
C154227J01
not harmful.
C154227J01
• As it is to be feared that the escaping gas
may propel cutting chips etc., place rags or
similar over the metal saw when opening the
hole.
FRONT SUSPENSION (IFS) – FRONT SUSPENSION UPPER ARM ASSY LH (IFS/2WD
FS–22 DRIVE)
FRONT SUSPENSION UPPER ARM ASSY LH (IFS/2WD

DRIVE)
COMPONENTS
11.5 (122, 8.5)

x4
x3
11.5 (122, 8.5)
FS
Intake Pipe or Hose Stay

18 (183, 13)
19 (194, 14)
152 (1549, 112)

Cotter Pin
Non-reusable part
C152272J08
C152272J08
DRIVE) FS–23
7.8 (79, 69 in.*lbf)

Head Taper Screw Plug
343 (3496, 283)

Front Suspension Upper Arm Shaft LH
Front Suspension Upper Arm Bushing LH
343 (3496, 283)

Front Suspension Upper Arm Bushing LH
FS
Front Suspension Upper Arm Pivot Dust Seal LH
7.8 (79, 69 in.*lbf)

Head taper screw plug
Upper Arm LH
Hino Ausolized Blue Ribbon Chassis Grease

C152271J03
C152271J03
REMOVAL
3. REMOVE THE ENGINE SIDE COVER (LH)
(INSTALLATION POSITION: LEFT SIDE) (SEE FS-13)
(INSTALLATION POSITION: RIGHT SIDE) (SEE FS-21)
FS–24 DRIVE)
5. DISCONNECT THE FRONT SPEED SENSOR (LH)

(SEE FS-13)
6. LOOSEN THE FRONT SUSPENSION UPPER ARM
BUSHING (LH)
NOTICE:
When the front suspension upper arm (LH) is not to
be disassembled, do not loosen the front
suspension upper arm bushing.
(a) Loosen the two front suspension upper arm
bushings (LH).
C154943
C154943
7. DISCONNECT THE FRONT SUSPENSION UPPER

ARM (LH)
FS (a) Support the front axle assy (LH) with a jack via a
piece of wood.
CAUTION:
• Apply the piece of wood to the front axle hub.
• When it is possible that the front axle assy
(LH) will drop during the following work, the
vehicle must be supported wit jacks to
prevent damage.
C151584
C151584
(b) Remove the cotter pin and the castle nut.
C151585
C151585
DRIVE) FS–25
(c) Use SST and separate the front suspension upper

arm (LH) from the steering knuckle.
SST 09950-40011 (09951-04010, 09953-04020,
09952-04010, 09954-04010, 09955-04031,
09958-04011)
CAUTION:
• Before separating the front suspension upper
arm (LH), confirm that the dust boot is not
clamped by the SST.
Boot
SST
SST
C156593J01
C156593J01
8. REMOVE THE INTAKE PIPE OR HOSE STAY FS

(a) Remove the two bolts and the clamp and remove
the intake pipe or hose stay.
Clamp position
C151587J01

(LH)
(a) Measure the projection (A) of the caster adjustment
bolt.
CAUTION:
Record the value of the projection (A) because it
is required at the time of installation.
C158624J01
C158624J01
FS–26 DRIVE)
(b) Loosen the two bolts.
C151588
C151588
(c) Remove the camber adjustment shim.
C151589
C151589
FS (d) Remove the two bolts and remove the caster

adjustment plate (LH) and the front suspension
upper arm (LH) from the suspension member assy.
C151590
C151590
DISASSEMBLY
1. REMOVE THE HEAD TAPER SCREW PLUG
(a) Secure the front suspension upper arm (LH) with a
vice via aluminum plates.
(b) Remove the two head taper screw plugs from the
front suspension upper arm bushing (LH).
C152268
C152268
DRIVE) FS–27

BUSHING (LH)
(a) Remove the two front suspension upper arm
bushings (LH) from the front suspension upper arm
(LH).
C152269
C152269

SHAFT (LH)
(a) Remove the front suspension upper arm shaft (LH)
from the upper arm (LH) as shown in the figure.
PIVOT DUST SEAL (LH)
(a) Remove the two front suspension upper arm pivot
dust seals (LH) from the upper arm shaft.
C152270J01
C152270J01
FS
INSPECTION
1. INSPECT THE FRONT UPPER BALL JOINT
(a) Secure the front suspension upper arm (LH) with a
(b) Inspect the front upper ball joint (LH) rotation
condition
(1) Install the nut on the stud.
(2) After moving the stud five times in oscillation
direction and back, rotate it continuously with a
speed of 2 to 4 seconds per revolution and
C154228
C154228 measure the rotation torque at the fifth time.
Torque: 6.0 N*m or lower {60 kgf*cm, 4.4
ft*lbf or lower} (during rotation)
(3) Rotate the stud.
Standard: No abnormal sticking or
looseness during rotation
(c) Inspect dust boot
(1) Check that the dust boot is free of cracks and
that there is no grease leakage.
(d) Inspect ball joint looseness
(1) Move the stud of the ball joint in axis direction
and check that there is no looseness.
Standared: No looseness shall be felt.
NOTICE:
In case of abnormalities during the above
inspections (2) to (4), replace the front
suspension upper arm (LH).
C158708
C158708
FS–28 DRIVE)
ASSEMBLY
PIVOT DUST SEAL (LH)
(a) Apply original Hino Blue Ribbon chassis grease to
the inside of the front suspension upper arm pivot
dust seal (LH).
(b) Apply original Hino Blue Ribbon chassis grease to
the thread part of the front suspension upper arm
shaft (LH).
(c) Install the front suspension upper arm pivot dust
seal (LH) to the front suspension upper arm shaft
(LH).
SHAFT (LH)
(a) Secure the front suspension upper arm (LH) in a
C152274
C152274
(b) Install the front suspension upper arm shaft (LH) as
shown in the figure.
FS
C152270J02
C152270J02
3. PROVISIONALLY TIGHTEN THE FRONT

SUSPENSION UPPER ARM BUSHING (LH)
(a) Provisionally tighten the two front suspension upper
arm bushings (LH) until they contact the front
suspension upper arm (LH).
CAUTION:
After provisional tightening, confirm that the
seat surface of the upper arm bushing is in
contact with the front suspension upper arm
C152269
C152269 (LH) end surface.
(b) Fill up with original Hino Blue Ribbon chassis
grease through the two head taper screw plug
mounting holes.
(c) Confirm that the front suspension upper arm shaft
(LH) moves smoothly.
C154429
C154429
DRIVE) FS–29
4. INSTALL HEAD TAPER SCREW PLUG

(a) Install the two head taper screw plugs.
C152268
C152268
INSTALLATION
O mark (LH)
(a) Move the front suspension upper arm shaft so that
the mark (ο) of the front suspension upper arm shaft
on the vehicle outside comes to opposite the mark
(x) on the vehicle inside.
FS
C151602J01
C151602J01
(b) Provisionally tighten the front suspension upper arm

(LH) and the caster adjustment plate (LH) with two
bolts to the suspension member assy.
C151590
C151590
(c) Install the camber adjustment shim between the

front suspension upper arm (LH) and the
suspension member assy.
CAUTION:
Install camber adjustment shims with the
V ehicle outside marking towards the outside of the vehicle.
Camber adjustment shim
C154219J01
C154219J01
FS–30 DRIVE)
(d) Adjust the projection (A) of the caster adjustment

bolt to the dimension measured at the time of
removal.
C158624J01
C158624J01
(e) Tighten the two bolts.

FS
C151588
C151588
2. INSTALL THE INTAKE PIPE OR HOSE STAY

(a) Install the intake pipe or hose stay with two bolts.
(b) Install the wire harness clamp to the intake pipe
stay.
Clamp position
C151587J01
3. CONNECT THE FRONT SUSPENSION UPPER ARM

(LH)
(a) Connect the front suspension upper arm (LH) to the
steering knuckle and install it with a castle nut.
CAUTION:
Perform matching of the cotter pin hole after
tightening the castle nut by additional tightening
C151585
C151585 within 30°.
4. FINALLY TIGHTEN THE FRONT SUSPENSION
UPPER ARM BUSHING (LH)
NOTICE:
This final tightening is not performed when the front
suspension upper arm (LH) is not disassembled.
DRIVE) FS–31
(a) Tighten the two front suspension upper arm

bushings (LH).
WARNING:
After tightening, confirm that the upper arm
bushing seat surface is in contact with the
upper arm (LH) end surface.
5. CONNECT THE FRONT SPEED SENSOR (LH) (SEE
FS-20)
C154943
C154943
8. INSTALL FRONT TIRE (SEE FS-21)
9. SETTLING DOWN VEHICLE (SEE FS-21)
10. CONNECT THE BATTERY MINUS TERMINAL (SEE
FS-21)
SENSOR SYSTEM) FS
FRONT SUSPENSION (IFS) – FRONT SUSPENSION LOWER ARM ASSY LH (IFS/2WD
FS–32 DRIVE)
FRONT SUSPENSION LOWER ARM ASSY LH (IFS/2WD

DRIVE)
COMPONENTS
With Front Stabilizer
FS Front Stabilizer Bracket
Front Stabilizer Bar x2
17.5 (178, 13)
x2

17.5 (178, 13)
x2
25 (255, 18)
25 (255, 18) x2
C156477J01
C156477J02
DRIVE) FS–33
11.5 (122, 8.5)

x4
x3
11.5 (122, 8.5)
Intake Pipe or Hose Stay FS

18 (183, 13)
19 (194, 14)
152 (1549, 112)

Cotter Pin
Non-reusable part
C152272J09
C152272J01
FS–34 DRIVE)
Lock nut
Shock Absorber Cushon Retainer
Shock Absorber Cushon
Front Coil Spring Insulator UPR LH
Front Coil Spring LH

FS
Front Shock Absorber Assy LH
155 (1580, 114)
Cotter Pin
206 (2100,152) 206 (2100, 152)
Front Axle Assy LH

Front Suspension
Cotter Pin
Lower Arm NO.1 LH
90 (917, 66)
60 (612, 44)
Tie-Rod End LH
N*m (kgf*cm, ft*lbf) : Specified Torque Front Disc Brake Cylinder Assy LH
Non-reusable part
C154776J01
C152273J01
DRIVE) FS–35
REMOVAL
3. REMOVE THE ENGINE SIDE COVER (LH)
6. REMOVE THE FRONT STABILIZER BRACKET (WITH
7. REMOVE THE FRONT STABILIZER BAR (WITH
8. DISCONNECT SPEED SENSOR FRONT (LH) (SEE
FS-13)
10. DISCONNECT THE FRONT DISK BRAKE CYLINDER
ASSY (LH) FS
11. REMOVE THE FRONT AXLE ASSY (LH) (SEE FS-14)
12. REMOVE THE INTAKE PIPE OR HOSE STAY (SEE
FS-25)
(LH) (SEE FS-25)
14. REMOVE THE FRONT SUSPENSION LOWER ARM
NO. 1 (LH) (SEE FS-15)
15. REMOVE THE UPPER FRONT COIL SPRING
INSULATOR (LH) (SEE FS-16)
16. REMOVE THE FRONT COIL SPRING (LH) (SEE FS-16)
17. REMOVE THE FRONT SUSPENSION SUPPORT (LH)
(SEE FS-16)
18. REMOVE THE FRONT SHOCK ABSORBER ASSY
(LH) (SEE FS-16)
19. REMOVE THE FRONT SPRING BUMPER NO. 1 (LH)
(a) Remove the bolt and remove the front spring
bumper No. 1 (LH) from the front suspension lower
arm No. 1 (LH).
C151594
C151594
FS–36 DRIVE)
INSTALLATION
1. INSTALL THE FRONT SPRING BUMPER NO. 1 (LH)
(a) Install the front spring bumper No. 1 (LH) with a bolt
to the front suspension lower arm No. 1 (LH).
2. INSTALL THE FRONT SHOCK ABSORBER ASSY
(LH) (SEE FS-16)
3. INSTALL THE FRONT SUSPENSION SUPPORT (LH)
C151594
C151594
(SEE FS-17)
4. INSTALL THE FRONT COIL SPRING (LH) (SEE FS-18)
5. INSTALL THE UPPER FRONT COIL SPRING
INSULATOR (LH) (SEE FS-18)
6. INSTALL THE FRONT SUSPENSION LOWER ARM
NO. 1 (LH) (SEE FS-18)
(LH) (SEE FS-29)
8. INSTALL THE INTAKE PIPE OR HOSE STAY (SEE
FS-30)
FS
9. INSTALL THE FRONT AXLE ASSY (LH) (SEE FS-19)
10. CONNECT THE FRONT DISK BRAKE CYLINDER
ASSY (LH) (SEE FS-20)
11. CONNECT THE TIE ROD END (LH) (SEE FS-20)
12. CONNECT THE FRONT SPEED SENSOR (LH) (SEE
FS-20)
13. INSTALL THE FRONT STABILIZER BAR (WITH
14. INSTALL THE FRONT STABILIZER BRACKET (WITH
18. FRONT TIRE INSTALLATION (SEE FS-21)
19. VEHICLE SETTLING DOWN (SEE FS-21)
20. FINALLY TIGHTEN THE FRONT SUSPENSION
LOWER ARM NO. 1 (LH) (SEE FS-21)
21. CONNECT THE BATTERY MINUS TERMINAL (SEE
FS-21)
22. INSPECT AND ADJUST THE FRONT WHEEL
ALIGNMENT (SEE FS-1)
SENSOR SYSTEM)
FRONT SUSPENSION (IFS) – FRONT STABILIZER BAR (IFS/2WD DRIVE) FS–37
FRONT STABILIZER BAR (IFS/2WD DRIVE)

COMPONENTS
Lock Nut
Front Suspension Support RH
Lock Nut
Front Stabilizer Link
FS
Front Stabilizer Bar Bushing NO.1
Front Stabilizer Bar 17.5 (178, 13) x2

Front Stabilizer Link
Front Stabilizer Bar Bushing NO.1
17.5 (178, 13) x2

Front Stabilizer Bar Bushing No.2
x2 Front Stabilizer Bracket

25 (255, 18)
Front Stabilizer Bushing NO.2

x2 Front Stabilizer Bracket Cover
25 (255, 18)
Non-reusable part
C153731J07
C153731J07
FS–38 FRONT SUSPENSION (IFS) – FRONT STABILIZER BAR (IFS/2WD DRIVE)
REMOVAL
Vehicle
left side COVER
(a) Remove the four bolts and remove the two front
stabilizer bracket covers.
Vehicle
right side
FS
C154780J02
C154780J02

(a) Remove the four bolts and remove the two front
stabilizer brackets.
4. REMOVE THE FRONT STABILIZER BAR
(a) Remove the front stabilizer bar.
5. REMOVE THE FRONT STABILIZER BAR BUSHING
NO. 1
(a) Remove the two front stabilizer bar bushings No. 1
C154781
C154781 from the front stabilizer bar.
6. REMOVE THE FRONT STABILIZER BAR BUSHING
NO. 2
(a) Remove the two front stabilizer bar bushings No. 2
from the front stabilizer bar.
7. REMOVE THE FRONT STABILIZER LINK
(a) Remove the lock nut and remove the two front
suspension supports (LH) and the front stabilizer
link.
C154786
C154786
FRONT SUSPENSION (IFS) – FRONT STABILIZER BAR (IFS/2WD DRIVE) FS–39
INSTALLATION
1. INSTALL THE FRONT STABILIZER LINK
(a) Provisionally install the front stabilizer link and the
two front suspension supports (LH) with a new lock
nut to the suspension member assy.
CAUTION:
Confirm that the two front suspension supports
(LH) have engaged the mounting hole of the
suspension member assy securely.
2. INSTALL THE FRONT STABILIZER BAR BUSHING
C156606
C156606
NO. 2
(a) Install the two front stabilizer bar bushings No. 2 to
the front stabilizer bar.
3. INSTALL THE FRONT STABILIZER BAR BUSHING
Vehicle outside Vehicle outside NO. 1
Vehicle front
(a) Install the two front stabilizer bar bushings No. 2 to
the front stabilizer bar.
NOTICE:
Install the bushings so that the stabilizer bar
side slip prevention stopper comes to the
vehicle inside. FS
Stopper
C154791J01
C154791J01
4. INSTALL THE FRONT STABILIZER BAR

(a) Install the front stabilizer bar so to the front stabilizer
Identification paint link that the identification paint is on the right side of
the vehicle.
Vehicle right side
C156607J01
C156607J01

(a) Install the two front stabilizer brackets with four nuts.
Torque: 17.5 N*m (178 kgf*cm, 13 ft*lbf)
C154781
C154781
FS–40 FRONT SUSPENSION (IFS) – FRONT STABILIZER BAR (IFS/2WD DRIVE)

Vehicle
left side
COVER
(a) Tighten the two bolts A provisionally.
(b) Tighten the two bolts B securely.
(c) Tighten the two bolts A securely.
Bolt B
Bolt A
Vehicle
right side
Bolt B
Bolt A
C154781
C154780J01
FS
7. TIGHTEN THE FRONT STABILIZER LINK
(a) Tighten the lock nut until the projection amount (A)
A of the threaded part of the front stabilizer link
becomes the standard value.
A: 2-4 pitch
C156073J01
C156073J01
FRONT SUSPENSION (LEAF SPRING)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS-1
FRONT WHEEL ALIGNMENT
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS-2
FS
FRONT SUSPENSION (LEAF SPRING) – TROUBLESHOOTING FS–1
TROUBLESHOOTING
SUSPENSION

Use the table below to help you find a cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
Symptom Suspected Area See Page
3. Tire (Worn or improperly inflated) TW-1
4. Wheel alignment (Incorrect) FS-2
5. Steering linkage (Loose or worn) (*1)
6. Hub bearing (Worn) (*2)
Wander/pulls
(*3)
(*4)
7. Steering gear (Out of adjustment or broken) (*5)
8. Suspension parts (Worn) -
1. Vehicle (Overloaded) -
2. Spring (Weak) (*6)
Bottoming
(*7)
3. Shock absorber (Worn) (*8)
Sways/pitches
2. Wheel (Out of balance) TW-1 FS
Front wheel shimmy 5. Hub bearing (Worn) (*2)
(*3)
(*4)
6. Steering linkage (Loose or worn) (*1)
7. Steering gear (Out of adjustment or broken) (*5)
Abnormal tire wear
4. Suspension parts (Worn) -
*1: See Pub. No. S1-YXZE05A, page 51-54.

FS–2 FRONT SUSPENSION (LEAF SPRING) – FRONT WHEEL ALIGNMENT
FRONT WHEEL ALIGNMENT

INSPECTION
1. INSPECT TIRE (See page TW-1)
2. INSPECT CAMBER, CASTER AND STEERING AXIS
Camber (a) Put the vehicle on a turning radius gauge.
Caster (b) Using a screwdriver, remove the hub grease cap.
Turning King Pin (c) Remove the cotter pin and adjusting lock cap.
Radius Gauge Gauge (d) Install a camber-caster-king pin gauge.
HINT:
For the details of equipments, follow the
manufacturers instructions.
(e) Measure the camber, caster and steering axis
Z03382 inclination.
Standard: See page FS-4
If the results are not as specified, check and replace
the suspension part.
HINT:
GVWR over 5.5 t and Hong kong 5.5 t are without
the caster wedge.
3. INSPECT TOE-IN
FS A B (a) Check that the toe-in is with in the specified range.
D
Standard:
Front A+B 0° - 0° 09’ (0° - 0.15°)
Toe-in (Total)
C-D 0 - 2 mm (0 - 0.08 in.)
If the toe-in is not as specified, proceed to the next

step.
C
SA3213
4. ADJUST TOE-IN
(a) Loosen the tie rod end lock nut.
(b) Using a pipe wrench, turn the tie rod by an equal
Type A amount to adjust the toe-in.
HINT:
Adjust the toe-in to the intermediate value of the
specified range.
(c) Tighten the tie rod end lock nut.
Torque:
137 N*m (1,400 kgf*cm, 101 ft*lbf) for type A
Type B
37 N*m (377 kgf*cm, 27 ft*lbf) for type B
C94171
FRONT SUSPENSION (LEAF SPRING) – FRONT WHEEL ALIGNMENT FS–3
5. INSPECT WHEEL ANGLE A

A B B A (a) Fully steer the steering wheel and measure the
turning
Front Wheel angle: See page FS-4
If the right and left inside wheel angles differ from
the specified values, check the length of the right
and left tie rod ends.
A: Inside
B: Outside
SA0028
6. ADJUST WHEEL ANGLE

Type A (a) Fixing the knuckle stopper bolt, loosen the nut.
(b) Adjust the knuckle stopper bolt length.
(c) Fixing the knuckle stopper bolt, tighten the nut.
Torque:
43 N*m (440 kgf*cm, 32 ft*lbf) for type A
74 N*m (760 kgf*cm, 55 ft*lbf) for type B
HINT:
When the steering wheel is fully turned, make sure
that the wheel is not touching the body or brake
flexible hose.
Type B
FS
C60789
Regular Cab Model Front Tire Tie rod Knuckle Inside Outside Caster Camber Caster Steering
XZU303R -HBMLAT3 7.50-15-12 A A 31°30’ - 34°30’ 26°36’ With 0°30’±1° 2°30’±1° 7°30’±1°
XZU303R -HBMMBT3 7.50-16-10 A A 37° - 40° 29°30’ With 0°30’±1° 2°30’±1° 7°30’±1°
XZU343R -HKMQBT3
WU300R -HBMLS3 7.00-16-10 A A 33° - 36° 27°30’ With 0°30’±1° 1°00’±1° 7°30’±1°
WU300L -HBMLS 7.00R-16-10
WU300L -HBMLS3
WU302L -HBMLA
WU302L -HBMLA3
XZU303L -HBMLA
XZU303L -HBMLA3
WU300L -HBMMS 7.00-16-10 A A
WU300L -HBMMS3 7.00R-16-12
WU340L -HKMMS 7.00R-16-10
WU340L -HKMMS3 7.00-16-10 A A
WU302L -HBMMB3 7.00-16-12
XZU343L -HKMMA3 7.00R-16-10
7.00R-16-12
XZU307R -HKTLBQ3 185/85R 16 A A 36° - 39° 29° With 0°30’±1° 2°30’±1° 7°30’±1°
XZU307R -HKMMBQ3
XZU347R -HKMMBQ3
XZU307R -HKMMBQ3 LP 195/75R 15 A A 42° - 45° 31°30’
FS
FRONT SUSPENSION (LEAF SPRING) – FRONT WHEEL ALIGNMENT FS–5
XZU407R -HKMMDQ3 195/85R 16 B A 46° - 49° 35° With 0°30’±1° 2°30’±1° 7°30’±1°
XZU417R -HKMMDQ3
XZU417R -HKTMDQ3
XZU415R -HKMMBW3 195/75R 16 A A 48° - 51° 36°
195/85R 16
WU410R -HKMMS3 7.00-16-10 A A 48° - 51° 36° With 0°30’±1° 1°30’±1° 7°30’±1°
WU412R -HKMMB3 7.00R-16-10
XZU413R -HKMMB3
XZU423R -HKMMB3
WU410L -HKMQSV 7.00-16-10 A A 48° - 51° 36° With 0°30’±1° 2°30’±1° 7°30’±1°
WU410L -HKMQSV3 7.00R-16-10
7.00R-16-12
WU412L -HKMMB 7.00-16-10 A A
WU412L -HKMMB3 7.00R-16-10
XZU413L -HKMMD3 7.00-16-10 A A
7.00R-16-10
7.50-16-12
XZU413R -HKMTBT3 7.50-16-14 A B 47°30’ - 50°30’ 36°30’ Without 1°00’±1° 2°00’±1° 7°00’±1°
XZU423R -HKMTBT3 7.50R-16-14
XZU417R -HKFQDQ3 205/85R 16 A B
XZU417R -HKFRDQ3 215/85R 16 A B
XZU417R -HKTRDQ3
XZU427R -HKFRDQ3
XZU427R -QKFRDQ3 FS
XZU415R -HKFQDW3 215/75R17.5 A B
XZU425R -HKFQDW3
XZU415R -HKFRDW3 215/75R17.5 A B
XZU425R -HKFRDW3
XZU435R -HKFRDW3
WU410R -HKMQS3 7.50-16-10 A B
7.50R-16-10
WU420R -HKMRS3 7.50-16-14 A B
7.50-16-12
7.50R-16-12
7.50R-16-14
WU422R -HKMRB3 7.50-16-12 A B 47°30’ - 50°30’ 36°30’ Without 1°00’±1° 2°00’±1° 7°00’±1°
7.50-16-14
7.50R-16-12
7.50R-16-14
XZU423R -HKMRD3 7.50-16-12 A B
7.50R-16-12
XZU405R -HKFQD3 215/85R 16 A B
XZU415R -HKFQD3
XZU415R -QKFQD3
XZU415R -HKFTD3
XZU425R -HKFQD3 215/75R 17.5 A B
XZU425R -HKFTD3
WU420L -HKMQSV 7.50-16-10 A B 47°30’ - 50°30’ 36°30’ Without 1°00’±1° 2°00’±1° 7°00’±1°
WU420L -HKMQSV3 7.50R-16-10
WU412L -HKMRBV3 7.50-16-12 A B
7.50-16-14
7.50R-16-12
7.50R-16-14
WU412L -HKMRBV 7.50-16-12 A B
WU422L -HKMRBV 7.50R-16-12
WU422L -HKMRBV3
WU412L -HKFTBV 7.50-16-14 A B
WU412L -HKFTBV3 7.50R-16-14
WU422L -HKFTBV
WU422L -HKFTBV3
WU412L -HKMQB 7.50-16-10 A B
WU412L -HKMQB3 7.50R-16-10
WU412L -HKMRB3 7.50-16-12 A B
WU422L -HKMRB3 7.50-16-14
7.50R-16-12
7.50R-16-14
WU412L -HKMRB 7.50-16-12 A B
WU422L -HKMRB 7.50R-16-12
XZU423L -HKMQD3
WU422L -HKFTB 7.50-16-14 A B
FS WU422L -HKFTB3
XZU423L -HKMRD3
7.50R-16-14
WU412L -HKFTB
WU412L -HKFTB3
XZU413L -HKMQD3 7.50-16-10 A B
7.50-16-12
7.50R-16-10
XZU427R -HKFTDQ3 225/80R 17.5 A B 42° - 45° 34°30’ Without 1°00’±1° 2°00’±1° 7°00’±1°
XZU437R -HKFTDQ3
DRIVE LINE
DIFFERENTIAL
DIFFERENTIAL SYSTEM
PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-1
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-1
DIFFERENTIAL OIL (for SH12)
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-3
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-4
DIFFERENTIAL OIL (for B265)
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-5
REAR DIFFERENTIAL CARRIER OIL SEAL (for SH12)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-8
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-12 DF
REAR DIFFERENTIAL CARRIER OIL SEAL (for B265)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-16
REAR DIFFERENTIAL CARRIER ASSEMBLY (for SH12)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-21
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-22
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-28
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-42
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-44
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-47
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-48
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-55
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-62
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-71
REAR DIFFERENTIAL CARRIER ASSEMBLY (for B265)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-72
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-74
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-75
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-80
REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-89
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DF-94
DIFFERENTIAL – DIFFERENTIAL SYSTEM DF–1
DIFFERENTIAL SYSTEM
PRECAUTION
1. Before overhaul, clean the outside of the differential
assembly to prevent sand or mud from entering
inside the differential carrier during overhaul.
2. Always arrange the disassembled parts in order and
protect them from dust.
3. Before installation, thoroughly clean and dry each
part and then apply hypoid gear oil to it. Do not use
alkaline cleaner for aluminum or rubber parts and
ring gear set bolts. Also, do not clean the rubber
parts, such as O-rings and oil seals with a non
residue solvent.
4. Coat all the sliding surfaces and rotating parts with
hypoid gear oil.
5. When holding a component part with a vise, be sure
to place an aluminum sheet under the part. Do not
put it directly on the vise.
6. Be careful not to damage the contact surfaces of the
case. Such damage may cause oil leakage.
7. Before applying sealant, remove the deposits of the
oil sealant and clean the part to be sealed using a
non residue solvent. DF
8. Do not supply oil immediately after installing the
sealed parts. Wait at least an hour.
9. Damage to the surface being contact with an oil seal,
O-ring and gasket may cause oil leakage. Special
attention should be paid.
10. When press-fitting an oil seal, be careful not to
damage the oil seal lip and outside periphery.
11. When replacing a bearing, replace the inner and
outer races as a set.

HINT:
Use the table below to help determine the cause of a
problem. The likely causes of the problem are indicated in
descending order. Check each suspected area in order.
Repair or replace faulty parts or perform adjustments as
necessary.
1. Oil level (Excessively high) DF-3
2. Rear differential carrier oil seal (Worn or damaged) DF-8
Oil leak from rear differential (SH 12)
3. Drive pinion bearing cage (O-ring) DF-38
4. Rear differential carrier gasket DF-22
2. Rear differential carrier oil seal (Worn or damaged) DF-12
Oil leak from rear differential (SH 13)
3. Drive pinion bearing cage (O-ring) DF-65
4. Seal packing (Differential carrier assembly - Axle housing) DF-71
DF–2 DIFFERENTIAL – DIFFERENTIAL SYSTEM

Oil leak from rear differential (B265) 2. Rear differential carrier oil seal (Worn or damaged) DF-16
3. Rear differential carrier gasket DF-75
DF
DIFFERENTIAL – DIFFERENTIAL OIL (for SH12) DF–3

REPLACEMENT
NOTICE:
• New gaskets must be used for the filler plug and the
drain plug.
• Confirm that there is no oil leak.
1. DRAIN DIFFERENTIAL OIL
(a) Using a socket wrench (21 mm), remove the filler
Filler Plug plug and gasket.
(b) Remove the drain plug and gasket, and drain the oil.
(c) Install the drain plug with a new gasket.
2. ADD DIFFERENTIAL OIL
(a) Add oil.
Capacity:
Oil grade:
Hypoid gear oil API GL-5 or equivalent
Drain Plug
Recommended oil viscosity:
SAE 90
C162158E01
3. INSPECT DIFFERENTIAL OIL DF

(a) Check that the oil surface is within 5 mm (0.20 in.) of
Filler Plug the lowest position of the inner surface of the
differential filler plug opening.
NOTICE:
• Excessively large or small amounts of oil may
cause trouble.
• After replacing oil, drive the vehicle and
check the oil level.
HINT:
If necessary, fill the rear differential carrier with
hypoid gear oil.
Max.: 5 mm (0.20 in.) (b) Check for oil leakage when the oil level is low.
(c) Using a socket wrench (21 mm), install the
differential filler plug with a new gasket.
C151423E04
DF–4 DIFFERENTIAL – DIFFERENTIAL OIL (for SH13)

REPLACEMENT
NOTICE:
drain plug.
(a) Add oil.
Capacity:
Oil grade:
Drain Plug
SAE 90
C162158E01
DF 3. INSPECT DIFFERENTIAL OIL

NOTICE:
cause trouble.
HINT:
hypoid gear oil.
C151423E04
DIFFERENTIAL – DIFFERENTIAL OIL (for B265) DF–5
DIFFERENTIAL OIL (for B265)

REPLACEMENT
NOTICE:
drain plug.
(a) Add oil.
Capacity:
Oil grade:
Drain Plug
SAE 90
C162158E01
3. INSPECT DIFFERENTIAL OIL DF

NOTICE:
cause trouble.
HINT:
hypoid gear oil.
C151423E04
DF–6 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER OIL SEAL (for SH12)

DRIVE LINE
DIFFERENTIAL
COMPONENTS
DF
x4
x4 REAR DIFFERENTIAL
75 (760, 55) CARRIER OIL SEAL
REAR DRIVE PINION COMPANION

FLANGE SUB-ASSEMBLY
435 (4437, 321)
REAR DRIVE PINION NUT

Non-reusable part
MP grease
C157986E01
REMOVAL
1. DRAIN DIFFERENTIAL OIL (See page DF-3)
DIFFERENTIAL – REAR DIFFERENTIAL CARRIER OIL SEAL (for SH12) DF–7
2. SEPARATE PROPELLER SHAFT ASSEMBLY

(a) Put matchmarks on the flanges.
(b) Remove the 4 nuts and 4 bolts, and separate the
Matchmark propeller shaft assembly.
NOTICE:
Hang the propeller shaft using wire. Be careful
not to apply excessive force to the joint of the
propeller shaft.
HINT:
If the flange is engaged firmly, lightly tap it to
remove using a plastic hammer.
C154098E01
3. REMOVE REAR DRIVE PINION NUT

SST (a) Using SST and a hammer, unstake the staked part
of the rear drive pinion nut.
SST 09930-00010 DF
NOTICE:
• Be sure to use SST with the tapered end
facing the shaft.
• Do not grind SST tip with a grinder, etc.
C153515E01
(b) Temporarily install the 2 nuts to the bolts on the rear

drive pinion companion flange sub-assembly.
(c) Fix the rear drive pinion companion flange sub-
assembly with the tire lever. Using a deep socket
wrench (41 mm), remove the rear drive pinion nut.
NOTICE:
• Ensure that the rear drive pinion nut is
completely unstaked when removing it.
• Ensure to install the nuts so as not to break
C153519 the bolt of the rear drive pinion companion
flange sub-assembly.
(d) Remove the 2 nuts and the 2 bolts.
4. REMOVE REAR DRIVE PINION COMPANION
FLANGE SUB-ASSEMBLY
(a) Remove the rear drive pinion companion flange
sub-assembly.
NOTICE:
Lightly tap the flange using a plastic hammer if it
is engaged firmly into the spline.
5. REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL

SST (a) Using SST, remove the rear differential carrier oil
seal.
SST 09308-10010
C151427E01
INSTALLATION
1. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL
(a) Apply MP grease to the lip of a new rear differential
carrier oil seal.
(b) Using a brass bar and hammer, tap in the rear
differential carrier oil seal.
Oil seal drive in depth:
0 mm (0 in.)
C151428
NOTICE:
Be sure to tap the rear differential carrier oil seal
uniformly so that it is not installed at an angle.
2. INSTALL REAR DRIVE PINION COMPANION FLANGE
SUB-ASSEMBLY
DF (a) Install the companion flange sub-assembly on the
differential drive pinion.
wrench (41 mm), install a new rear drive pinion nut.
NOTICE:
Ensure to install the 2 nuts so as not to break
the bolt of the rear drive pinion companion
C153523 flange sub-assembly.
3. INSTALL REAR DRIVE PINION NUT

SST (a) Using SST and a hammer, stake a new rear drive
pinion nut.
SST 09930-00010
NOTICE:
• Ensure that there is no crack on the staked
part of the rear drive pinion nut.
• Stake the nut completely as shown in the
illustration.
C153525E01

(a) Align the matchmarks and install the propeller shaft
assembly to the rear drive pinion companion flange
Matchmark sub-assembly with the 4 nuts and 4 bolts. DF
5. ADD DIFFERENTIAL OIL (See page DF-3)
C154098E01

DRIVE LINE
DIFFERENTIAL
COMPONENTS
DF
x4 CARRIER OIL SEAL
75 (760, 55)
REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY
435 (4437, 321)


Non-reusable part
MP grease
C154541E02
REMOVAL

NOTICE:
Hang the propeller shaft assembly using wire.
Be careful not to apply excessive force to the
joint of the propeller shaft assembly.
HINT:
C154098E01

(a) Using SST and a hammer, unstake the staked part
SST of the rear drive pinion nut.
SST 09930-00010 DF
NOTICE:
facing the shaft.
• Do not grind SST tip with a grinder etc.
C154533E01

wrench (41 mm), remove the rear drive pinion nut.
NOTICE:
• Ensure that the rear drive pinion nut is
• Ensure to install the nuts so as not to break
C154536 the bolt of the rear drive pinion companion
FLANGE SUB-ASSEMBLY
sub-assembly.
NOTICE:

SST (a) Using SST, remove the differential carrier oil seal.
SST 09308-10010
C154537E01
INSTALLATION
carrier oil seal.
(b) Using a brass bar and hammer, tap in the rear
differential carrier oil seal.
0 mm (0 in.)
C154538
NOTICE:
SUB-ASSEMBLY
DF (a) Install the rear drive pinion companion flange sub-
assembly on the differential drive pinion.
wrench (41 mm), install a new rear drive pinion nut.
NOTICE:
Ensure to install the 2 nuts so as not to break
the bolt of the rear drive pinion companion
C154539 flange sub-assembly.

pinion nut.
SST 09930-00010
NOTICE:
illustration.
C153526E01

C154098E01
DF–14 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER OIL SEAL (for B265)
REAR DIFFERENTIAL CARRIER OIL SEAL (for B265)

DRIVE LINE
DIFFERENTIAL
COMPONENTS
304 (3100, 224)

DF
CARRIER OIL SEAL
x4
75 (760, 55)
PLATE WASHER
REAR DRIVE PINION COMPANION

FLANGE SUB-ASSEMBLY
Non-reusable part
MP grease
C157209E01
REMOVAL
DIFFERENTIAL – REAR DIFFERENTIAL CARRIER OIL SEAL (for B265) DF–15

NOTICE:
Hang the propeller shaft assembly using wire.
Be careful not to apply excessive force to the
joint of the propeller shaft assembly.
HINT:
C157149E01

(a) Using SST and a hammer, unstake the staked part
SST of the rear drive pinion nut.
SST 09930-00010
NOTICE:
facing the shaft.
• Do not grind SST tip with a grinder etc.
DF
C157227E01
(b) Using SST, hold the rear drive pinion companion

flange sub-assembly, remove the rear drive pinion
nut and the plate washer.
SST 09330-00021
SST
C157150E01

SST FLANGE SUB-ASSEMBLY
(a) Using SST, remove the rear drive pinion companion
SST 09950-30012 (09951-03010, 09953-03010,
09954-03010, 09955-03030, 09956-03040)
NOTICE:
C157151E01
DF–16 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER OIL SEAL (for B265)

(a) Using SST, remove the rear differential carrier oil
SST seal.
SST 09308-10010
INSTALLATION
carrier oil seal.
C157152E01
(b) Using SST and a hammer, tap in the rear differential

carrier oil seal.
SST 09223-78010
Rear differential carrier oil seal drive in depth:
0 mm (0 in.)
SST
NOTICE:
C157153E01

SST
SUB-ASSEMBLY
(a) Using SST, install the rear drive pinion companion
DF flange sub-assembly on the differential drive pinion.
SST 09950-30012 (09951-03010, 09953-03010,
09954-03010, 09955-03030, 09956-03040)
(b) Apply a light coat of gear oil on the threads of a new
rear drive pinion nut and the plate washer.
C158807E01
(c) Using SST, hold the flange and tighten the rear drive
pinion nut.
SST
C157154E01
DIFFERENTIAL – REAR DIFFERENTIAL CARRIER OIL SEAL (for B265) DF–17

pinion nut.
SST 09930-00010
NOTICE:
illustration.
C153525E01

C157149E01
DF–18 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY (for SH12)

DRIVE LINE
DIFFERENTIAL
COMPONENTS
for 6 Hub Bolts: for 5 Hub Bolts: REAR AXLE SHAFT RH

x 10 x8
x8
x 10 x8
97 (985, 71) 60 (612, 44)
REAR DIFFERENTIAL CARRIER GASKET
GASKET
50 (510, 37)
DF FILLER PLUG
52 (530, 38)
x4
x4
GASKET
x4 x4
50 (510, 37)
75 (760, 55)
x8 DRAIN PLUG
52 (530, 38)
REAR DIFFERENTIAL CARRIER ASSEMBLY

REAR AXLE SHAFT LH
for 6 Hub Bolts: for 5 Hub Bolts:
x 10 x8
x8
N*m (kgf*cm, ft.*lbf) : Specified torque x 10 x8
Non-reusable part 97 (985, 71) 60 (612, 44)

C157987E01
DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY (for SH12) DF–19
PILOT BEARING OUTER RACE
BEARING RETAINER
REAR DIFFERENTIAL BEARING

ADJUSTING NUT LOCK 22 (225, 16)
22 (225, 16)
210 (2150, 156)

x2
REAR DIFFERENTIAL CARRIER
x2
22 (225, 16)

BEARING RETAINER ADJUSTING NUT LOCK
DF
DIFFERENTIAL BEARING CAP
Non-reusable part
C151548E05
PILOT BEARING INNER RACE
DIFFERENTIAL DRIVE PINION
REAR DRIVE PINION REAR TAPERED ROLLER BEARING
REAR BEARING OUTER RACE
REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
DIFFERENTIAL DRIVE PINION CAGE SHIM

BEARING CAGE
74 (760, 55)
SNAP RING
x6
DF x4
O-RING
FRONT BEARING OUTER RACE
REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
REAR DIFFERENTIAL CARRIER OIL SEAL
REAR DIFFERENTIAL DUST DEFLECTOR
435 (4437, 321)

Non-reusable part
MP grease
C151549E05
REAR DIFFERENTIAL BEARING ADJUSTING NUT
SIDE BEARING OUTER RACE
SIDE BEARING INNER RACE
DIFFERENTIAL CASE RH
REAR DIFFERENTIAL SIDE GEAR THRUST WASHER
REAR DIFFERENTIAL PINION THRUST WASHER
REAR DIFFERENTIAL SPIDER
REAR DIFFERENTIAL PINION DF

190 (1938, 141)
REAR DIFFERENTIAL SIDE GEAR
x 16
DIFFERENTIAL RING GEAR
DIFFERENTIAL CASE LH x8
190 (1938, 141)
Precoated part
C151550E06
REMOVAL
2. REMOVE REAR AXLE SHAFT

HINT:
REAR AXLE SHAFT (See Pub. No. S1-YXZE05A)
3. SEPARATE PROPELLER SHAFT ASSEMBLY (See
page DF-7)
4. REMOVE REAR DIFFERENTIAL CARRIER
ASSEMBLY
(a) Using a jack, support the differential carrier
Screw Hole assembly.
NOTICE:
As it is heavy, support the differential securely
with a jack.
(b) Remove the 8 bolts, 4 nuts and 4 washers, and
tighten the 2 bolts (M10 x P1.25) into the 2 screw
holes evenly to remove the differential carrier
assembly.
NOTICE:
Screw Hole Be careful not to damage the installation
surface.
C151431E01 5. REMOVE REAR DIFFERENTIAL CARRIER GASKET
(a) Remove the rear differential carrier gasket.
DISASSEMBLY
1. FIX REAR DIFFERENTIAL CARRIER ASSEMBLY
DF (a) Fix the differential carrier assembly to the overhaul
attachment.
C151432
2. REMOVE REAR DIFFERENTIAL BEARING

ADJUSTING NUT LOCK
(a) Remove the 2 bolts and 2 rear differential bearing
adjusting nut locks.
C151433

ADJUSTING NUT
(a) Put matchmarks on the differential bearing cap and
rear differential carrier.
(b) Remove the 4 bolts, 2 bearing caps and 2 rear
differential bearing adjusting nuts.
NOTICE:
Do not swap bearing caps and carriers as they
are manufactured as units.
Matchmark
C151434E01
(c) Tag the removed parts to show the location for

installation.
L R
DF
C151435E01
4. REMOVE REAR DIFFERENTIAL CASE SUB-

ASSEMBLY
(a) Using a chain block, remove the differential case
from the rear differential carrier.
(b) Remove the 2 side bearing outer races.
HINT:
Tag the removed parts.
C151436
5. REMOVE DRIVE PINION SUB-ASSEMBLY

x6 (a) Remove the 6 bolts.
(b) Remove the differential drive pinion sub-assembly,
drive pinion cage shim(s) and O-ring from the rear
differential carrier.
HINT:
For easy removal, use a brass bar and hammer.
C151437E02
6. REMOVE PILOT BEARING OUTER RACE

(a) Remove the bolt, nut and 2 bearing retainers.
(b) Remove the pilot bearing outer race from the rear
C151438
7. REMOVE SIDE BEARING INNER RACE

SST (a) Using SST, remove the 2 side bearing inner races
from the differential case.
SST 09950-60020 (09951-00680), 09950-40011
(09957-04010), 09950-00020, 09950-00030
If reusing the bearings, arrange them so that the
right and left bearings can be distinguished.
C151529E01
8. REMOVE DIFFERENTIAL RING GEAR

(a) Put matchmarks on the differential ring gear and
differential case LH.
DF (b) Using a press to hold the differential case, remove
the 16 bolts.
(c) Using a plastic hammer, remove the differential ring
gear to separate it from the differential case.
Matchmark NOTICE:
Be careful not to drop the ring gear.
C151439E01
9. REMOVE DIFFERENTIAL CASE

(a) Put matchmarks on the differential case LH and
differential case RH.
Matchmark
C151440E01
(b) Using a press to hold the differential case, remove

the 8 bolts.
NOTICE:
Be careful as the bolts are tightened firmly.
(c) Using a plastic hammer, separate the differential
case LH and differential case RH.
C151441
10. REMOVE REAR DIFFERENTIAL SPIDER

(a) Remove the rear differential side gear thrust washer
and the rear differential side gear.
C151442
(b) Remove the 4 rear differential pinion thrust washers,

4 rear differential pinions and rear differential spider.
(c) Remove the rear differential side gear thrust washer
and rear differential side gear. DF
C151443
11. REMOVE PILOT BEARING INNER RACE

NOTICE:
When removing the snap ring, use a cloth or
equivalent to prevent the snap ring from flying
off.
C151444
(b) Using SST, remove the pilot bearing inner race from
the differential drive pinion.
SST 09950-00030, 09950-00020
SST
C151445E01

(a) Hold the rear drive pinion companion flange sub-
assembly in a vise with aluminum plates in between.
C153535
(b) Using SST and a hammer, unstake the rear drive

pinion nut.
SST 09930-00010
NOTICE:
facing the shaft.
SST
C153534E01
(c) Using a deep socket wrench (41 mm), remove the

rear drive pinion nut.
NOTICE:
DF Ensure that the rear drive pinion nut is
FLANGE SUB-ASSEMBLY
sub-assembly from the differential drive pinion.
C153533
HINT:
If the rear drive pinion companion flange sub-
assembly is engaged firmly, lightly tap it to remove
14. REMOVE REAR DIFFERENTIAL DUST DEFLECTOR
SST (a) Using SST and a press, remove the rear differential
dust deflector.
SST 09950-60010 (09951-00610), 09950-70010
(09951-07100), 09950-00020
NOTICE:
• If it is not necessary to replace, do not
remove the rear differential dust deflector.
• Replace the rear differential dust deflector if it
C151449E01 is cracked, damaged, or deformed.
• Be careful not to drop the rear drive pinion
companion flange sub-assembly when
removing the rear differential dust deflector.

seal.
SST SST 09308-10010
C151450E01
16. REMOVE DIFFERENTIAL DRIVE PINION

(a) Using a press, remove the differential drive pinion
from the differential drive pinion bearing cage.
NOTICE:
Be careful not to drop the drive pinion.
(b) Remove the rear drive pinion front tapered roller
bearing from the differential drive pinion bearing
cage.
C151451
17. REMOVE REAR DIFFERENTIAL DRIVE PINION

BEARING SPACER
(a) Remove the rear differential drive pinion bearing
spacer from the differential drive pinion. DF
C151452
18. REMOVE REAR DRIVE PINION FRONT TAPERED

ROLLER BEARING
(a) Using SST and a press, remove the rear drive
SST
pinion rear tapered roller bearing.
SST 09950-00020
C151453E01
19. REMOVE FRONT BEARING OUTER RACE

(a) Using a brass bar and a hammer, tap out the front
bearing outer race.
NOTICE:
Do not damage the inner surface of the cage.
C151454
20. REMOVE REAR BEARING OUTER RACE

(a) Using a brass bar and a hammer, tap out the rear
bearing outer race.
NOTICE:
Do not damage the inner surface of the drive
pinion cage.
C151455
INSPECTION
1. INSPECT CLEARANCE BETWEEN REAR
DIFFERENTIAL SPIDER AND REAR DIFFERENTIAL
PINION
(a) Using a micrometer, measure the outer diameter at
4 points of the rear differential spider.
(b) Using a caliper gauge, measure the inner diameter
of the 4 pinions.
C151456
(c) Calculate the clearance by subtracting the outer
diameter of the rear differential spider from the inner
diameter of the pinion.
Clearance:
Standard Maximum
0.140 to 0.261 mm (0.0055 to 0.0103 in.) 0.40 mm (0.0157 in.)
DF
replace the parts.
2. INSPECT REAR DIFFERENTIAL SIDE GEAR THRUST
WASHER AND REAR DIFFERENTIAL PINION
THRUST WASHER
(a) Using vernier calipers, measure the thicknesses of
the rear differential side gear thrust washer and the
rear differential pinion thrust washer.
Thickness of side gear thrust washer:
Standard Maximum
1.9 to 2.1 mm (0.0748 to 0.0827 in.) 1.7 mm (0.0669 in.)
C151457
Thickness of pinion thrust washer:

Standard Maximum
1.5 to 1.7 mm (0.0590 to 0.0669 in.) 1.3 mm (0.0512 in.)
If the value is less than the minimum, replace the

rear differential side gear thrust washer or rear
differential pinion thrust washer.
3. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH

(a) Install the rear differential side gear thrust washer
on the rear differential side gear.
C151458
(b) Install the 4 rear differential pinions and 4 rear

differential pinion thrust washers to the rear
differential spider.
(c) Install the rear differential spider with the rear
differential pinions facing the differential case LH.
C151443
(d) Using a dial indicator, measure the differential side

gear backlash.
Backlash:
Standard Maximum DF
0.20 to 0.60 mm (0.0079 to 0.0236 in.) 0.90 mm (0.0354 in.)

replace the parts.
HINT:
Measure the backlash when the side gear and the
pinion are as shown in the illustration.
C153607
4. INSPECT CONICAL DISTANCE

Differential Drive Pinion Front View:
(a) Before installing the differential pinion, record the
Machining Error Dimension machining error dimension stamped at the pinion tip
and use it for calculation of the conical distance.
(b) Using SST, confirm the depth from the side bearing
mounting surface to the drive pinion tip (this is the
standard conical distance).
-20
Gear Set No.
C153543E04
Rear Differential Carrier

SST
SST
DF
Conical Distance
Drive Pinion
C162500E01
SST S0964-01370
Standard:
27 mm (1.063 in.) + machining error dimension
NOTICE:
• The conical distance is the standard
dimension at the time of adjustment of the
drive pinion and ring gear. The best tooth
contact will be obtained when this dimension
is used for adjustment. Due to machining
considerations, a machining error dimension
is provided for compensation of the normal
pinion dimension. The combination of normal
pinion dimension and machining error
dimension are referred to as the standard
dimension.
• If the tip of SST does not touch the drive

pinion, select a thinner shim and reconfirm
the drive pinion depth.
• When the machining error dimension
stamped at the end of the pinion is -20, the
machining error dimension is -0.20 mm (-
0.008 in.).
• The purpose of SST is not to recheck the
position of a correctly installed pinion. The
purpose of SST is initial shim selection.
(c) Based on the conical distance and the SST reading,
Drive Pinion Cage Shims adjust the bearing cage shim thickness.
Shim thickness to be adjusted:
Standard (27.0 mm (1.063 in.) + machining
error dimension) - (27.0 mm (1.063 in.) (size of
SST) - SST reading)
HINT:
For example, if the machining error dimension
stamped at the pinion tip reads -20, the standard
machining error dimension is -0.20 mm (-0.008 in.):
Standard conical distance = 27 mm (1.063 in.) + (-
0.20 mm (-0.008 in.)) = 26.80 mm (1.055 in.).
When SST reads 0, the conical distance is 27 mm
(1.063 in.). Subtract the SST reading from 27 mm
(1.063 in.) to find the measured conical distance.
C161672E01
For example, when SST reads 0.1 mm (0.004 in.):
DF
Calculated conical distance = 27 mm (1.063 in.) -
0.1 mm (0.004 in.) = 26.90 mm (1.059 in.).
Subtract the standard conical distance from the
measured conical distance to find the correct shim
thickness. 26.8 mm (1.055 in.) - 26.9 mm (1.059 in.)
= -0.1 mm (-0.004 in.) Use a shim that is 0.1 mm
(0.004 in.) thicker.
In order to use SST to check conical distance, it is
necessary to ensure that the tip of SST touches the
drive pinion. To do this, it may be necessary to
temporarily select a shim which is too thin, in order
to allow SST to be used to select the correct shim.
If the conical distance cannot be adjusted to
specification, replace the ring gear set.
Shim thickness:
Part No. Thickness
S4112-34950 0.30 mm (0.0118 in.)
S4112-34960 0.40 mm (0.0157 in.)
S4112-34970 0.45 mm (0.0177 in.)
S4112-34980 0.50 mm (0.0197 in.)
(d) Using a punch, stake the 2 portions of the pilot

bearing lock nut.
C151514
5. INSPECT TOOTH CONTACT BETWEEN RING GEAR

AND DRIVE PINION
(a) Coat 3 or 4 teeth at 3 different positions on the ring
gear with Prussian blue.
(b) Turn the companion flange in both directions to
inspect the ring gear for proper tooth contact.
C151519
DF Heel Contact Face Contact

Proper Contact
Select an adjusting washer that brings the drive pinion closer to the ring gear.
Toe Contact Flank Contact
Select an adjusting washer that shifts the drive pinion away from the ring gear.
SA01653E11
If the teeth are not properly contacting, use the table

below to select a proper shim (drive pinion cage
shim) for correction.
Shim thickness:
Part No. Thickness
S4112-34950 0.30 mm (0.0118 in.)
S4112-34960 0.40 mm (0.0157 in.)
S4112-34970 0.45 mm (0.0177 in.)
S4112-34980 0.50 mm (0.0197 in.)
HINT:
Use one or more shims for adjustment.
6. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
(a) Install the rear drive pinion companion flange sub-
assembly and rear drive pinion nut to the drive
pinion. Hold the drive pinion companion flange sub-
C153535
(b) Using a deep socket wrench (41 mm), tighten the

C153541
(c) Using a torque wrench, measure the preload at the

rear drive pinion nut part. DF
Preload:
New bearing Reused bearing
1.47 to 1.96 N*m 0.98 to 1.47 N*m
(15 to 20 kgf*cm, 13 to 17 in.*lbf) (10 to 15 kgf*cm, 9 to 13 in.*lbf)
NOTICE:
• Do not install an oil seal before preload
measurement.
C153540
• When either of the bearings is new, use the
preload for a new bearing.
(d) When the measured value is not within the specified
range, select the drive pinion bearing spacer
thickness to adjust the preload.
Spacer thickness:
Part No. Thickness
S4123-14080 14.400 mm (0.5669 in.)
S4123-14090 14.425 mm (0.5679 in.)
S4123-14100 14.450 mm (0.5689 in.)
S4123-14110 14.475 mm (0.5699 in.)
C151506
S4123-14120 14.500 mm (0.5709 in.)
S4123-14130 14.525 mm (0.5718 in.)
S4123-14140 14.550 mm (0.5728 in.)
S4123-14150 14.575 mm (0.5738 in.)
S4123-14160 14.600 mm (0.5748 in.)
S4123-14170 14.625 mm (0.5758 in.)
S4123-14180 14.650 mm (0.5768 in.)
S4123-14190 14.675 mm (0.5778 in.)
Part No. Thickness

S4123-14200 14.700 mm (0.5787 in.)
S4123-14210 14.725 mm (0.5797 in.)
S4123-14220 14.750 mm (0.5807 in.)
S4123-14230 14.775 mm (0.5817 in.)
S4123-14240 14.800 mm (0.5827 in.)
S4123-14250 14.825 mm (0.5837 in.)
S4123-14260 14.850 mm (0.5846 in.)
S4123-14270 14.875 mm (0.5856 in.)
7. INSPECT TOTAL PRELOAD

(a) Using a deep socket wrench (41 mm) and torque
wrench, measure the total preload.
(b) Calculate the side bearing preload by subtracting
the drive pinion preload (starting torque after
installing the oil seal) from the total preload. Check
that the side bearing preload is within the
specification.
Side bearing preload (new bearing):
C151521 Reduction ratio Standard
4.333 0.34 to 0.45 N*m (3.5 to 4.6 kgf*cm, 3.0 to 3.9 in.*lbf)
DF 5.375 0.28 to 0.36 N*m (2.8 to 3.7 kgf*cm, 2.5 to 3.2 in.*lbf)
Side bearing preload (reused bearing):

Reduction ratio Standard
HINT:
• Total preload = Drive pinion preload + Side
bearing preload
• When replacing both or either side bearings, use
the standard of the side bearing preload (new
bearing).
(c) If the result is not as specified, then turn the left/right

adjusting nuts using SST to adjust the preload.
SST 09504-00011
NOTICE:
When adjusting with the adjusting nuts, turn
SST
them by an equal amount so that the backlash
will not be incorrect.
C151516E01
(d) Tighten the 2 bearing caps with the 4 bolts.

(e) Recheck the total preload.
C151524
(f) Recheck the ring gear backlash.

Backlash:
Reduction ratio Backlash
5.375 0.18 to 0.23 mm (0.0072 to 0.0092 in.) DF
4.333, 4.625, 4.875, 5.125, 5.571,
0.20 to 0.28 mm (0.0079 to 0.0110 in.)
6.167, 6.500
5.833 0.25 to 0.33 mm (0.0099 to 0.0130 in.)
C151518
REASSEMBLY
1. INSTALL FRONT BEARING OUTER RACE
(a) Using SST and a press, press in the front bearing
outer race onto the differential drive pinion bearing
SST
Outer Race cage.
SST 09518-36020
HINT:
Apply gear oil to the front bearing outer race.
C151501E01
2. INSTALL REAR BEARING OUTER RACE

(a) Using SST and a press, press in the rear bearing
cage.
SST
SST 09223-78010
Outer Race HINT:
Apply gear oil to the rear bearing outer race.
C151502E01
3. INSTALL PILOT BEARING INNER RACE

(a) Using SST and a press, press in the pilot bearing
inner race onto the differential drive pinion.
SST 09316-60011 (09316-00011, 09316-00071)
SST HINT:
Apply gear oil to the inner race.
DF
C151503E01
(b) Using a snap ring expander, install a new snap ring

in the groove on the differential drive pinion tip.
NOTICE:
When installing the snap ring, use a cloth or
off.
C151504
4. INSTALL REAR DRIVE PINION REAR TAPERED

ROLLER BEARING
(a) Using SST and a press, install the rear drive pinion
SST rear tapered roller bearing onto the differential drive
pinion.
SST 09315-00022
HINT:
C151505E01
5. INSTALL REAR DIFFERENTIAL DRIVE PINION

BEARING SPACER
(a) Install the rear differential drive pinion bearing
spacer.
C151506
6. INSTALL REAR DRIVE PINION FRONT TAPERED

ROLLER BEARING
(a) Using SST and a press, install the differential drive
SST pinion bearing cage and front tapered roller bearing
onto the differential drive pinion.
SST 09316-60011
(See page DF-33)
C151507E01

(a) After preload adjustment, remove the companion
flange sub-assembly and use a brass bar and
hammer to tap in a new rear differential carrier oil DF
seal into the differential drive pinion bearing cage.
0 mm (0 in.)
NOTICE:
Tap the oil seal uniformly to drive it in.
C151510 (b) Apply MP grease to the oil seal lip.
9. INSTALL REAR DIFFERENTIAL DUST DEFLECTOR

SST (a) Using SST and a press, install a new rear
differential dust deflector to the rear drive pinion
companion flange sub-assembly.
SST 09950-60010 (09951-00610), 09950-70010
(09951-07100), 09527-17011
NOTICE:
Perform this procedure only when the dust
deflector has been removed.
C153539E01

SUB-ASSEMBLY
(a) Apply MP grease to the rear differential dust
deflector lip.
(b) Install the rear drive pinion companion flange sub-
assembly, and tighten a new rear drive pinion nut
using a deep socket wrench (41 mm).
C153541
(c) Using a deep socket wrench (41 mm) and torque

wrench, measure the drive pinion preload (starting
torque) with the oil seal installed.
HINT:
The measured value should be used to calculate the
side bearing preload after installing the drive pinion
assembly to the differential carrier.
C153540
(d) Using SST and a hammer, stake a new rear drive

pinion nut completely while aligning the 2 shaft
grooves.
SST 09930-00010
SST
NOTICE:
illustration.
part of the nut.
11. INSTALL O-RING
(a) Using a scraper, clean off dust on the connecting
surfaces of the bearing cage, differential carrier and
shim(s).
NOTICE:
DF Be careful not to damage the installation
surface.
(b) Apply MP grease to a new O-ring.
(c) Install the O-ring to the differential drive pinion
bearing cage.
NOTICE:
C153538E01
Be careful not to damage the O-ring.
12. INSTALL DIFFERENTIAL CASE
(a) Apply hypoid gear oil to the sliding surfaces of the
rear differential side gear thrust washer, rear
differential side gear and differential case LH.
(b) Install the rear differential side gear thrust washer
(c) Apply hypoid gear oil to the sliding surfaces of the
differential spider, differential pinions, thrust
washers and differential case LH.
C151458
(d) Install the 4 rear differential pinions and thrust

washers to the spider.
(e) Install the spider with the differential pinions and
thrust washers on the differential case LH.
C151443
(f) Install the rear differential side gear and rear

differential side gear thrust washer to the differential
case RH.
(g) Apply gear oil to each part.
C151442
(h) Align the matchmarks on the differential case LH

and differential case RH.
(i) Using a press, fix the differential case.
Matchmark
DF
C151440E01
(j) Apply adhesive to the threads of the 8 bolts and

install them.
Adhesive:
Three bond 1360K or equivalent
C151441
13. INSTALL DIFFERENTIAL RING GEAR

Boiling Water (a) Clean the contact surfaces of the differential case
and ring gear.
(b) Clean the differential ring gear set bolt hole.
(c) Heat the ring gear approximately. 100°C (212°F) in
boiling water.
CAUTION:
Use thick gloves to protect your hands as the
ring gear is hot.
SA01143E01 (d) Carefully take the ring gear out of the boiling water.
(e) Hold the differential case in a vise with aluminum
plates in between.
NOTICE:
(f) Align the matchmarks on the ring gear and the

(g) Apply adhesive to the threads of the 16 bolts and
install them.
Adhesive:
Matchmark
C151439E01
14. INSTALL SIDE BEARING INNER RACE

(a) Using SST and a press, install the 2 side bearing
inner races to the differential case.
SST 09950-60010 (09951-00640, 09951-00650)
NOTICE:
SST Be careful not to apply load to the bearing
retainers when installing.
Bearing Retainer
DF
C151513E01
15. INSTALL PILOT BEARING OUTER RACE

(a) Install the pilot bearing outer race with the 2
retainers, bolt and a new nut.
16. INSPECT CONICAL DISTANCE (See page DF-30)
C151438
17. INSTALL DRIVE PINION SUB-ASSEMBLY

x6 (a) Install the drive pinion sub-assembly and the drive
pinion cage shim(s) to the rear differential carrier
assembly.
NOTICE:
Be careful not to damage the O-ring when
installing.
C153846E02
(b) Tighten the 6 bolts to the drive pinion sub-assembly

Corner of Spotted Portion with the rear differential carrier assembly.
C154683E02
18. INSTALL REAR DIFFERENTIAL CASE SUB-

ASSEMBLY
(a) Place the 2 bearing outer races on the 2 side
bearings.
NOTICE:
Check that the left and right outer races are not
interchanged.
(b) Using a chain block, install the rear differential case
sub-assembly.
DF
C151436 HINT:
Tilting the differential case, install the differential
carrier.
(c) Install the 2 adjusting nuts on the carrier. Make sure
that they are properly engaged.
HINT:
Making the 2 adjusting nuts horizontal to the side
bearing, insert them from the top of the differential
carrier.
(d) Align the matchmarks on the differential bearing cap
and rear differential carrier. Temporarily install the
side bearing caps with the 2 bolts.
HINT:
If the bearing cap does not tightly fit the carrier, the
adjusting nuts may not be properly engaged.
Reinstall the adjusting nuts if necessary.
Matchmark
C151515E01
19. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

(a) Using SST, fully tighten the adjusting nut on the ring
gear side. Loosen the nut by a 1/4 revolution.
SST 09504-00011
(b) Use the same procedures on the other side.
SST
C151516E01
(c) Using a plastic hammer, lightly tap the top of the

side bearing cap so that the bearing fits.
C151517
(d) Using a dial indicator, measure the backlash.

Backlash:
DF 5.375 0.18 to 0.23 mm (0.0072 to 0.0092 in.)
4.333, 4.625, 4.875, 5.125, 5.571,
0.20 to 0.28 mm (0.0079 to 0.0110 in.)
6.167, 6.500
5.833 0.25 to 0.33 mm (0.0099 to 0.0130 in.)
HINT:
C151518
Perform the measurement at 3 or more positions
around the circumference of the ring gear, and
adjust the side bearing preload as necessary.
(e) The backlash should be adjusted by turning the left
and right adjusting nuts by equal amounts. For
example, if loosening the nut on the left side one
notch, torque the nut on the right side one notch.
AND DRIVE PINION (See page DF-32)
21. INSPECT TOTAL PRELOAD (See page DF-34)
22. INSTALL REAR DIFFERENTIAL BEARING
ADJUSTING NUT LOCK
(a) Install the 2 rear differential bearing adjusting nut
locks on the 2 bearing caps.
INSTALLATION
1. INSTALL REAR DIFFERENTIAL CARRIER
ASSEMBLY
C151525
(a) Remove dust and oil on the connecting surfaces of
the carrier assembly and axle housing.
(b) Apply sealant to both sides of a new rear differential

carrier gasket.
Sealant:
Three bond 1344 or equivalent
HINT:
Install the bolt within 20 minutes after applying
adhesive.
(c) Install the rear differential carrier gasket to the axle
housing
(d) Apply adhesive to the differential carrier installation
bolt.
Adhesive:
HINT:
• Be sure to apply enough adhesive to the threads
• Install the bolt within 20 minutes after applying
Three bond 1215 or equivalent adhesive.
C151526E03 (e) Using a jack, install the rear differential carrier
assembly to the axle housing.
NOTICE:
Be sure to install the carrier assembly with the
ring gear teeth facing the right side of the
vehicle when setting on a jack.
(f) Temporarily tighten the 4 nuts and 4 washers, and DF
jack down.
C151527
(g) Install the 8 bolts, and tighten the rear differential

carrier assembly installation bolts and nuts evenly.
DF-9)
3. INSTALL REAR AXLE SHAFT
HINT:
C151528

DRIVE LINE
DIFFERENTIAL
COMPONENTS
x 10
REAR AXLE SHAFT RH
x 10
97 (985, 71)
GASKET
98 (1000, 72)
FILLER PLUG
DF
130 (1326, 96) x4
GASKET
x4 x4
75 (760, 55) 98 (1000, 72)
x8 DRAIN PLUG
96 (979, 71)
REAR DIFFERENTIAL CARRIER ASSEMBLY
PROPELLER SHAFT ASSEMBLY 97 (985, 71)
x 10
x 10
REAR AXLE SHAFT LH
Non-reusable part
C162220E01
PILOT BEARING OUTER RACE
BEARING RETAINER

ADJUSTING NUT LOCK 22 (225, 16)
22 (225, 16)
210 (2150, 156)

x2
x2
22 (225, 16)

BEARING RETAINER ADJUSTING NUT LOCK
DF
DIFFERENTIAL BEARING CAP
Non-reusable part
C153512E03
PILOT BEARING INNER RACE
REAR BEARING OUTER RACE
REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
DIFFERENTIAL DRIVE PINION CAGE SHIM

BEARING CAGE
74 (760, 55)
SNAP RING
x6
DF x4
O-RING
FRONT BEARING OUTER RACE
435 (4437, 321)
Non-reusable part
MP grease
C151549E07
SIDE BEARING OUTER RACE
SIDE BEARING INNER RACE
SIDE BEARING SPACER (*1)
REAR DIFFERENTIAL PINION THRUST
REAR DIFFERENTIAL PINION x 12

270 (2754, 199) DF
x8
DIFFERENTIAL RING GEAR x 12
DIFFERENTIAL CASE LH 270 (2754, 199)
SIDE BEARING SPACER (*2)
N*m (kgf*cm, ft.*lbf) : Specified torque *1: Reduction Ratio 6.428

*2: Reduction Ratio 4.875, 5.142, 5.571, 5.857
Precoated part
C157993E01
REMOVAL

HINT:
page DF-11)
ASSEMBLY
Screw Hole assembly.
NOTICE:
with a jack.
(b) Remove the 12 bolts, and tighten the 2 bolts (M12 x
P1.5) into the 2 screw holes evenly to remove the
differential carrier assembly.
NOTICE:
Screw Hole Be careful not to damage the installation
surface.
C154534E01
DISASSEMBLY
DF (a) Fix the differential carrier assembly to the overhaul
attachment.
C151432

ADJUSTING NUT LOCK
C151433

ADJUSTING NUT
(a) Put matchmarks on the differential bearing cap and
(b) Remove the 4 bolts, 2 bearing caps and 2 adjusting
nuts.
NOTICE:
Matchmark
C151434E01

installation.
L R
DF
C151435E01

ASSEMBLY
(a) Using a chain block, remove the differential case
from the rear differential carrier.
HINT:
C151436
5. REMOVE DRIVE PINION SUB-ASSEMBLY

x6 (a) Remove the 6 bolts.
(b) Remove the drive pinion sub-assembly, differential
drive pinion cage shim(s) and O-ring from the rear
HINT:
For easy removal, use a brass bar and hammer.
C151437E02
6. REMOVE PILOT BEARING OUTER RACE

(a) Remove the bolt, nut and 2 bearing retainers.
(b) Remove the pilot bearing outer race from the rear
C153549
7. REMOVE SIDE BEARING INNER RACE

SST (a) Using SST, remove the 2 side bearing inner races
from the differential case.
SST 09950-60020 (09951-00680), 09950-40011
(09957-04010), 09950-00020, 09950-00030
If reusing the bearings, arrange them so that the
right and left bearings can be distinguished.
(b) Remove the side bearing spacer.
(1) Remove the side bearing spacer from the
C151529E01 differential case RH.
(for reduction ratio 6.428)
(2) Remove the side bearing spacer from the
(for reduction ratio 4.875, 5.142, 5.571, 5.857)
DF

(a) Put matchmarks on the differential ring gear and the
the 12 bolts and 12 nuts.
(c) Using a plastic hammer, remove the differential ring
gear to separate it from the differential case.
Differential Case NOTICE:
Nut
Ring Gear Bolt
DF
Matchmark
C154944E01

(a) Put matchmarks on the differential case LH and
differential case RH.
Matchmark
C153531E01

the 8 bolts.
NOTICE:
Be careful as the bolts are tightened firmly.
(c) Using a plastic hammer, separate the differential
case LH and differential case RH.
C153514

and the rear differential side gear.
C153530

4 rear differential pinions and rear differential spider.
DF and rear differential side gear.
C153529
11. REMOVE PILOT BEARING INNER RACE

NOTICE:
When removing the snap ring, use a cloth or
off.
C151444
(b) Using SST, remove the pilot bearing inner race from
the differential drive pinion.
SST 09950-00030, 09950-00020
SST
C151445E01

(a) Hold the rear drive pinion companion flange sub-
C153535
(b) Using SST and a hammer, unstake the rear drive

pinion nut.
SST 09930-00010
NOTICE:
facing the shaft.
SST
C153534E01
(c) Using a deep socket wrench (41 mm), remove the

NOTICE:
Ensure that the rear drive pinion nut is DF
FLANGE SUB-ASSEMBLY
sub-assembly from the differential drive pinion.
C153533
HINT:
If the rear drive pinion companion flange sub-
assembly is engaged firmly, lightly tap it to remove
SST (a) Using SST and a press, remove the rear differential
dust deflector.
SST 09950-60010 (09951-00610), 09950-70010
(09951-07100), 09950-00020
NOTICE:
• If it is not necessary to replace, do not
remove the rear differential dust deflector.
• Replace the rear differential dust deflector if it
C151449E01 is cracked, damaged, or deformed.
• Be careful not to drop the rear drive pinion
companion flange sub-assembly when
removing the rear differential dust deflector.

seal.
SST SST 09308-10010
C151450E01
16. REMOVE DIFFERENTIAL DRIVE PINION

(a) Using a press, remove the differential drive pinion
from the differential drive pinion bearing cage.
NOTICE:
Be careful not to drop the drive pinion.
(b) Remove the rear drive pinion front tapered roller
bearing from the bearing cage.
C151451
17. REMOVE REAR DIFFERENTIAL DRIVE PINION

BEARING SPACER
(a) Remove the rear differential drive pinion bearing
DF spacer from the differential drive pinion.
C151452
18. REMOVE REAR DRIVE PINION REAR TAPERED

ROLLER BEARING
(a) Using SST and a press, remove the rear drive
SST
pinion rear tapered roller bearing.
SST 09950-00020
C151453E01
19. REMOVE FRONT BEARING OUTER RACE

(a) Using a brass bar and a hammer, tap out the front
bearing outer race.
NOTICE:
Do not damage the inner surface of the cage.
C151454
20. REMOVE REAR BEARING OUTER RACE

(a) Using a brass bar and a hammer, tap out the rear
bearing outer race.
NOTICE:
Do not damage the inner surface of the drive
pinion bearing cage.
C151455
INSPECTION
PINION
4 points of the rear differential spider.
of the 4 rear differential pinions.
C151456
diameter of the spider from the inner diameter of the
pinion.
Clearance:
Standard Maximum
0.140 to 0.261 mm (0.0055 to 0.0103 in.) 0.40 mm (0.0157 in.)
DF
replace the parts.
2. INSPECT REAR DIFFERENTIAL SIDE GEAR THRUST
WASHER AND REAR DIFFERENTIAL PINION
THRUST WASHER
the rear differential side gear thrust washer and the
rear differential pinion thrust washer.
Thickness of side gear thrust washer:
Standard Maximum
1.9 to 2.1 mm (0.0748 to 0.0827 in.) 1.7 mm (0.0669 in.)
C151457
Thickness of pinion thrust washer:

Standard Maximum
1.5 to 1.7 mm (0.0590 to 0.0669 in.) 1.3 mm (0.0512 in.)

rear differential side gear thrust washer or rear
differential pinion thrust washer.

(a) Install the rear differential side gear thrust washer
C153528
(b) Install the 4 rear differential pinions and 4 rear

differential pinion thrust washers to the rear
differential spider.
(c) Install the rear differential spider with the rear
differential pinions facing the differential case LH.
C153529
(d) Using a dial indicator, measure the rear differential

side gear backlash.
Backlash:
DF Standard Maximum
0.20 to 0.60 mm (0.0079 to 0.0236 in.) 0.90 mm (0.0354 in.)

replace the parts.
HINT:
Measure the backlash when the side gear and the
pinion are as shown in the illustration.
C153607
4. INSPECT CONICAL DISTANCE

Differential Drive Pinion Front View:
(a) Before installing the differential pinion, record the
Machining Error Dimension machining error dimension stamped at the pinion tip
and use it for calculation of the conical distance.
(b) Using SST, confirm the depth from the side bearing
mounting surface to the drive pinion tip (this is the
standard conical distance).
-20
Gear Set No.
C153543E04
Rear Differential Carrier

SST
SST
DF
Conical Distance
Drive Pinion
C162500E01
SST S0964-01022
Standard:
21.5 mm (0.846 in.) + machining error
dimension
NOTICE:
• The conical distance is the standard
dimension at the time of adjustment of the
drive pinion and ring gear. The best tooth
contact will be obtained when this dimension
is used for adjustment. Due to machining
considerations, a machining error dimension
is provided for compensation of the normal
pinion dimension. The combination of normal
pinion dimension and machining error
dimension are referred to as the standard
dimension.
• If the tip of SST does not touch the drive

pinion, select a thinner shim and reconfirm
the drive pinion depth.
• When the machining error dimension
stamped at the end of the pinion is -20, the
machining error dimension is -0.20 mm (-
0.008 in.).
• The purpose of SST is not to recheck the
position of a correctly installed pinion. The
purpose of SST is initial shim selection.
(c) Based on the conical distance and the SST reading,
Drive Pinion Cage Shims adjust the bearing cage shim thickness.
Shim thickness to be adjusted:
Standard (21.5 mm (0.846 in.) + machining
error dimension) - (21.5 mm (0.846 in.) (size of
SST) - SST reading)
HINT:
For example, if the machining error dimension
stamped at the pinion tip reads -20, the standard
machining error dimension is -0.20 mm (-0.008 in.):
Standard conical distance = 21.5 mm (0.846 in.) + (-
0.20 mm (-0.008 in.)) = 21.30 mm (0.839 in.).
When SST reads 0, the conical distance is 21.5 mm
(0.846 in.). Subtract the SST reading from 21.5 mm
(0.846 in.) to find the measured conical distance.
DF C161672E01
For example, when SST reads 0.1 mm (0.004 in.):
Calculated conical distance = 21.5 mm (0.846 in.) -
0.1 mm (0.004 in.) = 21.4 mm (0.843 in.).
Subtract the standard conical distance from the
measured conical distance to find the correct shim
thickness. 21.3 mm (0.839 in.) - 21.4 mm (0.843 in.)
= -0.1 mm (-0.004 in.) Use a shim that is 0.1 mm
(0.004 in.) thicker.
In order to use SST to check conical distance, it is
necessary to ensure that the tip of SST touches the
drive pinion. To do this, it may be necessary to
temporarily select a shim which is too thin, in order
to allow SST to be used to select the correct shim.
If the conical distance cannot be adjusted to
specification, replace the ring gear set.
Shim thickness:
Part No. Thickness
S4112-34910 0.30 mm (0.0118 in.)
S4112-34920 0.40 mm (0.0157 in.)
S4112-34930 0.45 mm (0.0177 in.)
S4112-34940 0.50 mm (0.0197 in.)
(d) Using a punch, stake the 2 portions of the pilot

bearing lock nut.
C151514

AND DRIVE PINION
gear with Prussian blue.
C151519
Heel Contact Face Contact

DF
Proper Contact
SA01653E11
If the teeth are not properly contacting, use the table

below to select a proper shim (drive pinion cage
shim) for correction.
Shim thickness:
Part No. Thickness
S4112-34910 0.30 mm (0.0118 in.)
S4112-34920 0.40 mm (0.0157 in.)
S4112-34930 0.45 mm (0.0177 in.)
S4112-34940 0.50 mm (0.0197 in.)
HINT:
(a) Install the rear drive pinion companion flange sub-
assembly and rear drive pinion nut to the differential
drive pinion. Hold the drive pinion companion flange
sub-assembly in a vise with aluminum plates in
between.
C153535
(b) Using a deep socket wrench (41 mm), tighten the

lock nut.
C153541
(c) Using a torque wrench, measure the preload at the

DF lock nut part.
Preload:
1.97 to 2.94 N*m 1.48 to 2.45 N*m
(20 to 30 kgf*cm, 17 to 26 in.*lbf) (15 to 25 kgf*cm, 13 to 22 in.*lbf)
NOTICE:
• Do not install an oil seal before preload
measurement.
C153540
• When either of the bearings is new, use the
preload for a new bearing.
(d) When the measured value is not within the specified
range, select the drive pinion bearing spacer
thickness to adjust the preload.
Spacer thickness:
Part No. Thickness
S4123-13880 13.900 mm (0.5472 in.)
S4123-13890 13.925 mm (0.5482 in.)
S4123-13900 13.950 mm (0.5492 in.)
S4123-13910 13.975 mm (0.5502 in.)
C151506
S4123-13920 14.000 mm (0.5512 in.)
S4123-13930 14.025 mm (0.5522 in.)
S4123-13940 14.050 mm (0.5531 in.)
S4123-13950 14.075 mm (0.5541 in.)
S4123-13960 14.100 mm (0.5551 in.)
S4123-13970 14.125 mm (0.5561 in.)
S4123-13980 14.150 mm (0.5571 in.)
S4123-13990 14.175 mm (0.5581 in.)
Part No. Thickness

S4123-14000 14.200 mm (0.5591 in.)
S4123-14010 14.225 mm (0.5600 in.)
S4123-14020 14.250 mm (0.5610 in.)
S4123-14030 14.275 mm (0.5620 in.)
S4123-14040 14.300 mm (0.5630 in.)
S4123-14050 14.325 mm (0.5640 in.)
S4123-14060 14.350 mm (0.5650 in.)
S4123-14070 14.375 mm (0.5659 in.)

(a) Using a deep socket wrench (41 mm) and torque
wrench, measure the total preload.
(b) Calculate the side bearing preload by subtracting
the drive pinion preload (starting torque after
installing the oil seal) from the total preload. Check
that the side bearing preload is within the
specification.
Side bearing preload (new bearing)
C151521 Reduction ratio Standard
6.428 0.31 to 0.45 N*m (3.2 to 4.6 kgf*cm, 2.7 to 4.0 in.*lbf) DF
Side bearing preload (reused bearing)
Reduction ratio Standard
HINT:
bearing preload
the standard of the side bearing preload (new
bearing).
(c) If the result is not as specified, then turn the left/right
SST 09504-00011
NOTICE:
SST When adjusting with the adjusting nuts, turn
C153536E01
(d) Tighten the 2 bearing caps with the 4 bolts.

(e) Recheck the total preload.
C151524
(f) Recheck the ring gear backlash.

Backlash:
4.875, 5.142, 5.571 0.25 to 0.33 mm (0.0099 to 0.0129 in.)
5.857, 6.428 0.20 to 0.28 mm (0.0079 to 0.0110 in.)
C151518
REASSEMBLY
1. INSTALL FRONT BEARING OUTER RACE
DF (a) Using SST and a press, press in the front bearing
SST
Outer Race cage.
SST 09518-36020
HINT:
Apply gear oil to the front bearing outer race.
C151501E01
2. INSTALL REAR BEARING OUTER RACE

(a) Using SST and a press, press in the rear bearing
cage.
SST
SST 09223-78010
Outer Race HINT:
Apply gear oil to the rear bearing outer race.
C151502E01
3. INSTALL PILOT BEARING INNER RACE

(a) Using SST and a press, press in the pilot bearing
inner race onto the differential drive pinion.
SST 09316-60011 (09316-00011, 09316-00071)
SST HINT:
Apply gear oil to the pilot bearing inner race.
C151503E01
(b) Using a snap ring expander, install a new snap ring

in the groove on the differential drive pinion tip.
NOTICE:
When installing the snap ring, use a cloth or
off.
C151504

ROLLER BEARING
(a) Using SST and a press, install the rear drive pinion
SST rear tapered roller bearing onto the differential drive DF
pinion.
SST 09315-00022
HINT:
Apply gear oil to the rear drive pinion rear tapered
roller bearing .
C151505E01
5. INSTALL REAR DIFFERENTIAL DRIVE PINION

BEARING SPACER
(a) Install the rear differential drive pinion bearing
spacer.
C151506
6. INSTALL REAR DRIVE PINION FRONT TAPERED

ROLLER BEARING
(a) Using SST and a press, install the differential drive
SST pinion bearing cage and front tapered roller bearing
onto the differential drive pinion.
SST 09316-60011
(See page DF-60)
C151507E01

(a) After preload adjustment, remove the companion
flange sub-assembly and use a brass bar and
hammer to tap in a new rear differential carrier oil
seal into the differential drive pinion bearing cage.
0 mm (0 in.)
NOTICE:
Tap the oil seal uniformly to drive it in.
C151510 (b) Apply MP grease to the oil seal lip.

SST (a) Using SST and a press, install a new rear
differential dust deflector to the rear drive pinion
SST 09950-60010 (09951-00610), 09950-70010
(09951-07100), 09527-17011
NOTICE:
Perform this procedure only when the dust
deflector has been removed.
C153539E01

SUB-ASSEMBLY
(a) Apply MP grease to the rear differential dust
DF deflector lip.
(b) Install the rear drive pinion companion flange sub-
assembly, and tighten a new rear drive pinion nut
using a deep socket wrench (41 mm).
C153541
(c) Using a deep socket wrench (41 mm) and torque

wrench, measure the drive pinion preload (starting
torque) with the oil seal installed.
HINT:
The measured value should be used to calculate the
side bearing preload after installing the drive pinion
assembly to the differential carrier.
C153540
(d) Using SST and a hammer, stake a new rear drive

pinion nut completely while aligning the 2 shaft
grooves.
SST 09930-00010
SST
NOTICE:
illustration.
part of the nut.
11. INSTALL O-RING
(a) Using a scraper, clean off dust on the connecting
surfaces of the bearing cage, differential carrier and
shim(s).
NOTICE:
Be careful not to damage the installation
surface.
(b) Apply MP grease to a new O-ring.
(c) Install the O-ring to the differential drive pinion
bearing cage.
NOTICE:
C153538E01
Be careful not to damage the O-ring.
(a) Apply gear oil to the sliding surfaces of the rear
differential side gear thrust washer, rear differential
side gear and differential case LH. DF
(b) Install the thrust washer on the rear differential side
gear.
(c) Apply gear oil to the sliding surfaces of the
differential spider, differential pinions, rear
differential pinion thrust washers and differential
C153528 case LH.
(d) Install the 4 rear differential pinions and the rear

differential pinion thrust washers to the spider.
(e) Install the rear differential spider with the differential
pinions and rear differential pinion thrust washers
on the differential case LH.
C153529
(f) Install the rear differential side gear and thrust rear
differential side gear washer to the differential case
RH.
C153530
(h) Align the matchmarks on the differential case LH

and differential case RH.
(i) Using a press, fix the differential case.
Matchmark
C153531E01
(j) Apply adhesive to the threads of the 8 bolts and

install them.
Adhesive:
DF
C153514

and ring gear.
(c) Heat the ring gear approximately. 100°C (212°F) in
boiling water.
CAUTION:
ring gear is hot.
plates in between.
NOTICE:
(f) Align the matchmarks on the ring gear and the

(g) Apply adhesive to the threads of the 12 bolts.
Adhesive:
(h) Install the 12 bolts and 12 nuts to the differential
case.
Differential Case Torque: 270 N*m (2754 kgf*cm, 199 ft.*lbf)
Nut
Ring Gear Bolt
DF
Matchmark
C154944E01
14. INSTALL SIDE BEARING INNER RACE

for Reduction Ratio 6.428: (a) Install the side bearing spacer.
(1) Install the side bearing spacer from the
Bearing Inner Race differential case RH. (for reduction ratio 6.428)
(2) Install the side bearing spacer from the
differential case LH. (for reduction ratio 4.875,
SST
5.142, 5.571, 5.857)
(b) Using SST and a press, install the 2 side bearing
inner races to the differential case.
SST 09950-60010 (09951-00640, 09951-00650)
Side Bearing NOTICE:
Seacer Be careful not to apply load to the bearing
retainers when installing.
Bearing Retainer
for Reduction Ratio 4.875, 5.142,

5.571, 5.857:
Bearing Inner Race
DF
SST
Side Bearing
Seacer
Bearing Retainer
C158302E01
15. INSTALL PILOT BEARING OUTER RACE

(a) Install the pilot bearing outer race with the 2 bearing
retainers, bolt and a new nut.
16. INSPECT CONICAL DISTANCE (See page DF-57)
17. INSTALL DRIVE PINION SUB-ASSEMBLY
(a) Clean the differential carrier fitting face of the drive
pinion sub-assembly so that oil, dust and other
C153549 foreign particles are removed.
(b) Install the drive pinion sub-assembly and the drive

x6 pinion cage shim(s) to the rear differential carrier
assembly.
NOTICE:
Be careful not to damage the O-ring when
installing.
C153846E02
(c) Tighten the 6 bolts to the drive pinion sub-assembly

Corner of Spotted Portion
with the rear differential carrier assembly.
DF
C154682E03

ASSEMBLY
(a) Place the 2 bearing outer races on the 2 side
bearings.
NOTICE:
interchanged.
(b) Using a chain block, install the rear differential case
sub-assembly.
C151436 HINT:
Tilting the differential case, install the differential
carrier.
(c) Install the 2 adjusting nuts on the carrier. Make sure
they are properly engaged.
HINT:
Making the 2 adjusting nuts horizontal to the side
bearing, insert them from the top of the differential
carrier.
(d) Align the matchmarks on the cap and carrier.

Temporarily install the side bearing caps with the 2
bolts.
HINT:
If the bearing cap does not tightly fit the carrier, the
adjusting nuts may not be properly engaged.
Reinstall the adjusting nuts if necessary.
Matchmark
C151515E01
19. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

(a) Using SST, fully tighten the adjusting nut on the ring
gear side. Loosen the nut by a 1/4 revolution.
SST 09504-00011
SST (b) Use the same procedures on the other side.
C153536E01
(c) Using a plastic hammer, lightly tap the top of the

differential bearing cap so that the bearing fits.
DF
C151517
(d) Using a dial indicator, measure the backlash.

Backlash:
4.875, 5.142, 5.571 0.25 to 0.33 mm (0.0099 to 0.0129 in.)
5.857, 6.428 0.20 to 0.28 mm (0.0079 to 0.0110 in.)
HINT:
Perform the measurement at 3 or more positions
around the circumference of the ring gear, and
C151518 adjust the side bearing preload as necessary.
(e) The backlash should be adjusted by turning the left
example, if loosening the nut on the left side one
notch, torque the nut on the right side one notch.
22. INSTALL REAR DIFFERENTIAL BEARING

ADJUSTING NUT LOCK
(a) Install the 2 bearing adjusting nut locks on the 2
bearing caps.
INSTALLATION
ASSEMBLY
C151525
(a) Clean the rear differential carrier fitting face of the
rear axle housing so that oil, dust and other foreign
particles are removed.
(b) Apply seal packing to the fitting face of the housing.
Seal packing:
4 mm (0.16 in.)
Three bond 1215, 1216 or equivalent
3 mm NOTICE:
• Seal packing shall be applied with thickness
3 mm (0.12 in.).
• Start and end of the applied packing shall be
overlapped.
4 mm (0.16 in.) • Seal packing shall be applied without break.
C153548E02 • The differential carrier shall be installed
within 20 minutes after applying the seal
packing.
(c) Using a jack, install the rear differential carrier DF
assembly to the axle housing.
NOTICE:
• Be sure to install the carrier assembly with
the ring gear teeth facing the right side of the
• Be careful not to damage the contacting
portions between the gears and the axle.
(d) Temporarily tighten the 2 upper bolts and 2 lower
C154579 bolts, and lower the jack.
(e) Install the 8 bolts, and tighten the rear differential

carrier assembly installation bolts evenly.
Torque: BOLT A
A 130 N*m (1326 kgf*cm, 96 ft.*lbf)
BOLT B
96 N*m (979 kgf*cm, 71 ft.*lbf)
B B DF-13)
HINT:
A
C155130E02
DF–72 DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY (for B265)
REAR DIFFERENTIAL CARRIER ASSEMBLY (for B265)

DRIVE LINE
DIFFERENTIAL
COMPONENTS
x6
x6 REAR AXLE SHAFT RH
x6
60 (612, 44)
AXLE SHAFT GASKET
REAR DIFFERENTIAL CARRIER GASKET
GASKET
50 (510, 37)
FILLER PLUG
DF
52 (530, 38) x4
x4
x4 GASKET
x4 50 (510, 37)
75 (760, 55) x8
DRAIN PLUG
52 (530, 38)

ASSEMBLY AXLE SHAFT GASKET
PROPELLER SHAFT ASSEMBLY 60 (612, 44)
x6 x6
x6
REAR AXLE SHAFT LH

Non-reusable part
C157191E02
DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY (for B265) DF–73
DRIVE PINION
304 (3100, 224)
REAR DRIVE PINION NUT SHIM
DRIVE PINION BEARING SPACER

ADJUSTING NUT LOCK
SHIM B x2 x2
12.7 (130, 9.4)

x4
SHIM A DF
196 (2000, 145)
BEARING CAP
OIL SLINGER
NUT LOCK TYPE

REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY x2
NO. 2
PLATE WASHER
Non-reusable part NO. 1

MP grease
C158337E02
REAR DIFFERENTIAL SIDE BEARING
78.5 (800, 58)
x 12 REAR DIFFERENTIAL PINION THRUST WASHER
LOCK PLATE
DF x6
x 12
REAR DIFFERENTIAL PINION
162 (1650, 119)
DIFFERENTIAL RING GEAR
DIFFERENTIAL CASE LH
Non-reusable part
C157193E01
REMOVAL

HINT:
page DF-7)
ASSEMBLY
assembly.
NOTICE:
with a jack.
(b) Remove the 8 bolts, 4 nuts and 4 washers to
remove the differential carrier assembly.
C157232 NOTICE:
Be careful not to damage the installation
surface.
5. REMOVE REAR DIFFERENTIAL CARRIER GASKET
(a) Remove the rear differential carrier gasket.
DISASSEMBLY
(a) Fix the differential carrier assembly to the overhaul
attachment.
DF
C151432

ADJUSTING NUT LOCK
C158735

ADJUSTING NUT
(a) Put matchmarks on the bearing cap and rear
differential carrier assembly.
(b) Remove the 4 bolts, 2 bearing caps and 2 rear
differential bearing adjusting nuts.
NOTICE:
Matchmark
C151434E01

installation.
L R
DF
C151435E01

ASSEMBLY
(a) Remove the differential case from the rear
HINT:
C157182

FLANGE SUB-ASSEMBLY
SST (a) Using SST and a hammer, unstake the rear drive
pinion nut.
SST 09930-00010
NOTICE:
facing the shaft.
C157227E01
(b) Using SST, hold the rear drive pinion companion

flange sub-assembly and remove the rear drive
SST pinion nut.
(c) Remove the plate washer from the differential
carrier.
SST 09330-00021
C157162E01
(d) Using SST, remove the rear drive pinion companion

flange sub-assembly from the differential carrier.
SST 09950-30012 (09951-03010, 09953-03010,
SST 09954-03010, 09955-03030, 09956-03040)
C162974E01

SST seal from the differential carrier.
SST 09308-10010 DF
(b) Remove the oil slinger from the differential carrier.
C157164E01
7. REMOVE REAR DRIVE PINION FRONT TAPERED

ROLLER BEARING
(a) Using SST, remove the rear drive pinion front
SST tapered roller bearing from the drive pinion.
SST 09556-22010
NOTICE:
If the front bearing is damaged or worn, replace
the bearing.
C157165E01
(b) Remove the shim A and B.

(c) Remove the drive pinion bearing spacer.
Oil Slinger
Front Tapered
Roller Bearing
Shim A
Shim B
Drive Pinion
Bearing Spacer
DF
C162230E01
8. REMOVE REAR DRIVE PINION REAR TAPERED

ROLLER BEARING
(a) Using SST and a press, press out the rear drive
SST
pinion rear tapered roller bearing from the drive
pinion.
SST 09950-00020
HINT:
If the drive pinion or ring gear is damaged, replace
them as a set.
C157167E01 (b) Remove the shim(s) from the drive pinion.
(c) Using a brass bar and hammer, tap out the front
bearing outer race and the rear bearing outer race.
Front Rear
C157168E01

SST (a) Using SST and a press, press out the rear
differential dust deflector from the rear drive pinion
SST 09950-60010 (09951-00480), 09950-70010
(09951-07150)
C157171E01

(a) Put matchmarks on the ring gear and differential
case LH.
(b) Using a screwdriver, unstake the lock plates.
(c) Remove the 12 bolts and 6 lock plates.
Matchmark (d) Using a plastic hammer, remove the ring gear to
separate it from the differential case.
NOTICE:
DF
C157169E01

SST (a) Using SST, remove the 2 side bearings from the
differential case.
SST 09950-40011 (09951-04020, 09952-04010,
09953-04030, 09954-04010, 09955-04061,
09957-04010, 09958-04011), 09950-60010
(09951-00480)
C151529E01
(b) Put matchmarks on the differential case LH and

Matchmark differential case RH.
(c) Protect the ring gear attaching face with a piece of
cloth and secure it in a vise. Then remove the 12
bolts.
(d) Using a plastic hammer, separate the LH and RH
cases.
C157170E01

and rear differential side gear.
C153530

4 rear differential pinions and the rear differential
spider.
and rear differential side gear.
C153529
INSPECTION
DF PINION
4 points of the spider.
of the 4 pinions.
C151456
diameter of the spider from the inner diameter of the
pinion.
Clearance:
Standard
0.041 to 0.142 mm (0.0016 to 0.0056 in.)

replace the parts.
2. INSPECT REAR DIFFERENTIAL PINION THRUST
WASHER
the pinion gear thrust washer.
Thickness of pinion gear thrust washer:
Standard
1.5 to 1.7 mm (0.0590 to 0.0669 in.)

C151457
pinion gear thrust washer.

(a) Using a dial indicator, measure the side gear
backlash.
Backlash:
Standard
0.02 to 0.20 mm (0.0008 to 0.0079 in.)
HINT:
• Measure the backlash at the case RH and case
LH.
• Use the thrust washer with the same thickness
on both the right and left sides.
(b) When the measured value is not within the specified
range, select the rear differential side gear thrust
washer thickness to adjust the preload.
Washer thickness:
Part No. Thickness
41361-60480 1.55 mm (0.0610 in.)
41361-60011 1.60 mm (0.0629 in.)
41361-60490 1.65 mm (0.0650 in.)
C153607 41361-60500 1.70 mm (0.0670 in.)
41361-60021 1.75 mm (0.0690 in.)
41361-60510 1.80 mm (0.0709 in.)
41361-60520 1.85 mm (0.0728 in.)
41361-60031 1.90 mm (0.0748 in.)
DF
41361-60530 1.95 mm (0.0768 in.)
41361-60540 2.00 mm (0.0784 in.)
41361-60041 2.05 mm (0.0807 in.)
41361-60550 2.10 mm (0.0827 in.)
4. INSPECT COMPANION FLANGE RUNOUT

38 mm (1.50 in.) (a) Using a dial indicator, measure the longitudinal
runout.
Maximum longitudinal runout:
0.11 mm (0.0043 in.)
C157157E01
(b) Using a dial indicator, measure the lateral runout.

Maximum lateral runout:
0.15 mm (0.0059 in.)
If the runout is greater than the maximum, replace
the rear drive pinion companion flange sub-
assembly.
C157158
5. INSPECT DIFFERENTIAL RING GEAR

(a) Using a dial indicator, measure the ring gear runout.
Maximum runout:
0.10 mm (0.0039 in.)
If the runnot is greater than the maximum, replace
the ring gear.
C157159
(b) Using a dial indicator, measure the ring gear

backlash.
Backlash:
0.15 to 0.20 mm (0.0059 to 0.0079 in.)
HINT:
Perform the measurements at 3 or more positions
around the circumference of the ring gear.
If the backlash is not as specified, adjust the side
bearing preload as necessary.
C157160

AND DRIVE PINION
DF gear with prussian blue.
C151519
Heel Contact Face Contact

Proper Contact
SA01653E11
(c) If the teeth are not properly contacting, use the

following chart to select a proper shim for correction.
NOTICE:
• When the gear is a straight cut gear type and
the tooth has face contact or flank contact,
replace the ring gear and the drive pinion as a
set.
• In the case of face contact or flank contact,
Shim the gear may be able to be adjusted within the
C157188E01 specified range of backlash.
Shim thickness:
Part No. Thickness
1.040 to 1.060 mm (0.0409 to 0.0417
90564-40004
in.)
1.065 to 1.085 mm (0.0419 to 0.0427
90564-40006
in.)
1.090 to 1.110 mm (0.0429 to 0.0437
90564-40007
in.)
1.115 to 1.135 mm (0.0439 to 0.0447
90564-40008
in.)
1.140 to 1.160 mm (0.0449 to 0.0457
90564-40009
in.)
1.165 to 1.175 mm (0.0459 to 0.0463
90564-40010
in.)
1.190 to 1.210 mm (0.0469 to 0.0476
90564-40011
in.)
90564-40012
1.215 to 1.235 mm (0.0478 to 0.0486 DF
in.)
1.240 to 1.260 mm (0.0488 to 0.0496
90564-40013
in.)
1.265 to 1.285 mm (0.0498 to 0.0506
90564-40014
in.)
1.290 to 1.310 mm (0.0508 to 0.0516
90564-40015
in.)
1.315 to 1.335 mm (0.0518 to 0.0526
90564-40016
in.)
1.340 to 1.360 mm (0.0528 to 0.0535
90564-40017
in.)
1.365 to 1.385 mm (0.0537 to 0.0545
90564-40018
in.)
1.390 to 1.410 mm (0.0547 to 0.0555
90564-40019
in.)
1.415 to 1.435 mm (0.0557 to 0.0565
90564-40020
in.)
1.440 to 1.460 mm (0.0567 to 0.0575
90564-40021
in.)
1.465 to 1.485 mm (0.0577 to 0.0584
90564-40022
in.)
1.490 to 1.510 mm (0.0587 to 0.0594
90564-40023
in.)
1.515 to 1.535 mm (0.0596 to 0.0604
90564-40024
in.)
1.540 to 1.560 mm (0.0606 to 0.0614
90564-40025
in.)
HINT:
7. INSPECT DRIVE PINION PRELOAD

HINT:
When reusing the drive pinion bearings, skip step (g), (h)
and (i).
(a) Instal the drive pinion to the rear differential carrier.
(b) Install the rear differential drive pinion spacer to the
rear differential carrier.
Oil Slinger (c) Install the shims A and B, front drive pinion tapered
roller bearing, and oil slinger.
HINT:
• When replacing the drive pinion bearings, install
Front Tapered the thickest shim A and B.
Roller Bearing • Assemble and install the oil seal after adjusting
the total preload.
Shim A:
Shim A 90564-35035
Shim B:
90564-35040
Shim B
Drive Pinion
Bearing Spacer
DF
C162230E01
(d) Using SST, install the rear differential companion

SST 09950-30012 (09951-03010, 09953-03010,
SST 09954-03010, 09955-03030, 09956-03040)
(e) Install a new rear drive pinion nut and plate washer.
HINT:
Coat the threads of the rear drive pinion nut.
C157179E01
(f) Using SST, hold the rear differential companion

flange and tighten the rear drive pinion nut.
SST SST 09330-00021
C157180E01
(g) Using a dial indicator, measure the drive pinion axial

play and make a note of it.
(h) Calculate the value "T".
T = 4.89 mm (0.1925 in.) - Drive pinion axial play
(i) Select shims A and B so that the sum of the 2 shims
is closest to value "T".
Shim A thickness:
Part No. Thickness (shim A)
90564-35024 1.89 to 1.91 mm (0.0744 to 0.0752 in.)
C157181 90564-35025 1.99 to 2.01 mm (0.0783 to 0.0791 in.)
90564-35026 2.09 to 2.11 mm (0.0823 to 0.0831 in.)
90564-35027 2.19 to 2.21 mm (0.0862 to 0.0870 in.)
90564-35028 2.29 to 2.31 mm (0.0902 to 0.0909 in.)
90564-35029 2.39 to 2.41 mm (0.0940 to 0.0949 in.)
90564-35030 2.49 to 2.51 mm (0.0980 to 0.0988 in.)
90564-35031 2.59 to 2.61 mm (0.1020 to 0.1028 in.)
90564-35032 2.69 to 2.71 mm (0.1059 to 0.1067 in.)
90564-35033 2.79 to 2.81 mm (0.1098 to 0.1106 in.)
90564-35034 2.89 to 2.91 mm (0.1138 to 0.1146 in.)
90564-35035 2.99 to 3.01 mm (0.1177 to 0.1185 in.)
Shim B thickness:
Part No. Thickness (shim B)
1.792 to 1.808 mm (0.0705 to 0.0712
90564-35019
in.)
DF
1.802 to 1.818 mm (0.0709 to 0.0716
90564-35036
in.)
1.812 to 1.828 mm (0.0713 to 0.0720
90564-35020
in.)
1.822 to 1.838 mm (0.0717 to 0.0724
90564-35037
in.)
1.832 to 1.848 mm (0.0721 to 0.0728
90564-35021
in.)
1.842 to 1.858 mm (0.0725 to 0.0731
90564-35038
in.)
1.852 to 1.868 mm (0.0729 to 0.0735
90564-35022
in.)
1.862 to 1.878 mm (0.0733 to 0.0739
90564-35039
in.)
1.872 to 1.888 mm (0.0737 to 0.0743
90564-35023
in.)
1.882 to 1.898 mm (0.0741 to 0.0747
90564-35040
in.)
(j) Remove the companion flange, front oil slinger, front

bearing and 2 shims.
(k) Install the selected shims, front oil slinger and
companion flange (see steps (b) to (f)).
(l) Using a torque wrench, measure the drive pinion

preload.
Preload:
2.00 to 5.39 N*m (20.4 to 55.0 kgf*cm, 1.00 to 2.76 N*m (10.2 to 28.2 kgf*cm,
17.7 to 47.7 in.*lbf) 8.6 to 24.4 in.*lbf)
HINT:
Measure the preload after snagging the bearing
down by rotating it left and right several times.
C157161
If the preload is not as specified, adjust by
increasing or decreasing the thickness of shims.
Shim A thickness:
Part No. Thickness (shim A)
90564-35024 1.89 to 1.91 mm (0.0744 to 0.0752 in.)
90564-35025 1.99 to 2.01 mm (0.0783 to 0.0791 in.)
90564-35026 2.09 to 2.11 mm (0.0823 to 0.0831 in.)
90564-35027 2.19 to 2.21 mm (0.0862 to 0.0870 in.)
90564-35028 2.29 to 2.31 mm (0.0902 to 0.0909 in.)
90564-35029 2.39 to 2.41 mm (0.0940 to 0.0949 in.)
90564-35030 2.49 to 2.51 mm (0.0980 to 0.0988 in.)
90564-35031 2.59 to 2.61 mm (0.1020 to 0.1028 in.)
90564-35032 2.69 to 2.71 mm (0.1059 to 0.1067 in.)
90564-35033 2.79 to 2.81 mm (0.1098 to 0.1106 in.)
90564-35034 2.89 to 2.91 mm (0.1138 to 0.1146 in.)
DF
90564-35035 2.99 to 3.01 mm (0.1177 to 0.1185 in.)
Shim B thickness:
Part No. Thickness (shim B)
1.792 to 1.808 mm (0.0705 to 0.0712
90564-35019
in.)
1.802 to 1.818 mm (0.0709 to 0.0716
90564-35036
in.)
1.812 to 1.828 mm (0.0713 to 0.0720
90564-35020
in.)
1.822 to 1.838 mm (0.0717 to 0.0724
90564-35037
in.)
1.832 to 1.848 mm (0.0721 to 0.0728
90564-35021
in.)
1.842 to 1.858 mm (0.0725 to 0.0731
90564-35038
in.)
1.852 to 1.868 mm (0.0729 to 0.0735
90564-35022
in.)
1.862 to 1.878 mm (0.0733 to 0.0739
90564-35039
in.)
1.872 to 1.888 mm (0.0737 to 0.0743
90564-35023
in.)
1.882 to 1.898 mm (0.0741 to 0.0747
90564-35040
in.)
8. INSPECT SIDE BEARING PRELOAD

(a) Tighten the 4 bearing cap bolts to the specified
torque, and then loosen them to the point where the
rear differential bearing adjusting nuts can be turned
using SST.
SST 09504-00011
(b) Fully tighten the 4 bearing cap bolts by hand.
C157184
(c) Using SST, tighten the rear differential bearing

adjusting nut on the ring gear side until the ring has
a backlash of approximately 0.18 mm (0.007 in.).
SST 09504-00011
SST
C157185E01
(d) While turning the ring gear, use SST to fully tighten
the adjusting nut on the drive pinion side.
SST 09504-00011
(e) After the bearings are settled, loosen the adjusting DF
nut on the drive pinion side.
SST C157186E01
(f) Place a dial indicator on the top of the bearing inner

SST race on the ring gear side.
(g) Adjust the side bearing for zero preload by
tightening the other adjusting nut until the pointer on
the indicator begins to move.
C157187E01
(h) Using SST, tighten the adjusting nut 1 to 1.5

notches from the zero preload position.
SST C157186E01
(i) Using a dial indicator, adjust the ring gear backlash

so that it will be within the specification.
Backlash:
0.15 to 0.20 mm (0.0059 to 0.0079 in.)
HINT:
The backlash should be adjusted by turning the left
example, loosen the nut on the left side one notch
and torque the nut on the right side one notch.
C157160
(j) Tighten the 4 bearing cap bolts.

C157184

(a) Using a torque wrench, measure the total preload.
Total preload:
DF Drive pinion preload + (0.2 to 0.39 N*m (2 to 4
kgf*cm, 1.7 to 3.5 in.*lbf))
HINT:
bearing preload
C157161 the standard of the side bearing preload (new
bearing).
(b) If the result is not as specified, then turn the left/right
SST 09504-00011
NOTICE:
SST When adjusting with the adjusting nuts, turn
C153536E01
(c) Tighten the 2 bearing caps with the 4 bolts.

(d) Recheck the total preload.
C151524
(e) Recheck the ring gear backlash.

Backlash:
0.15 to 0.20 mm (0.0059 to 0.0079 in.)
C157160
REASSEMBLY
1. INSTALL FRONT AND REAR BEARING OUTER
RACE
Front Rear
(a) Using SST and a press, press in the front outer race
and rear outer race.
SST 09950-60020 (09951-00780), 09950-70010
SST
(09951-07150), 09950-60020 (09951-
SST 01030), 09950-70010 (09951-07150)
C157176E01 DF
(a) Using a press, press a new rear differential dust
deflector into the rear drive pinion companion flange
sub-assembly.
C157172
3. INSTALL REAR DIFFERENTIAL SPIDER

(a) Apply gear oil to the sliding surfaces of the rear
differential side gear thrust washer, differential side
gear and differential case LH.
(b) Install the rear differential side gear thrust washer
on the differential slide gear.
(c) Apply gear oil to the sliding surfaces of the
differential spider, differential pinions, rear
differential pinion thrust washers and differential
C153528 case LH.
(d) Install the 4 differential pinions and rear differential

pinion thrust washers to the rear differential spider.
(e) Install the rear differential spider with the differential
pinion and the rear differential pinion thrust washers
on the differential case LH.
(f) Install the side gear and rear differential side gear
thrust washer to the differential case RH.
C153529
(See page DF-81)
(a) Align the matchmarks on the differential case LH
Matchmark and differential case RH.
(b) Using a press, fix the differential case.
C153531E01
(c) Using a torque wrench, install the 12 bolts.

Matchmark Torque: 78.5 N*m (800 kgf*cm, 58 ft.*lbf)
DF
C157170E01

and ring gear.
(c) Heat the ring gear approximately 100°C (212°F) in
boiling water).
CAUTION:
ring gear is hot.
plates in between.
NOTICE:
(f) Install 6 new lock plates and temporarily install the

12 bolts so that the bolt holes in the ring gear and
differential case are not misaligned.
NOTICE:
The ring gear set bolts should not be tightened
Matchmark until the ring gear has sufficiently cooled down.
(g) After the ring gear has sufficiently cooled down,
tighten the ring gear set bolts.
C157169E01
(h) Using SST and a hammer, stake the lock plates.

SST 09930-00010
HINT:
Stake one claw flush with the flat surface of the nut.
Since the claw touches the protruding portion of the
nut, stake the half of it on the tightening side.
SST
DF
C157175E01
7. INSTALL REAR DIFFERENTIAL SIDE BEARING

(a) Using SST and a press, install the 2 side bearing
SST inner races to the differential case.
SST 09316-20011, 09950-60010 (09951-00500)
SST
C157174E02

ROLLER BEARING
(a) Install the shim to the drive pinion.
Shim
C157188E01
(b) Using SST and a press, press in the rear tapered

roller bearing onto the drive pinion.
SST 09506-35010
HINT:
SST
9. INSPECT DRIVE PINION PRELOAD (See page DF-84)
C157177E01

ASSEMBLY
(a) Place the bearing outer races on their respective
bearings.
NOTICE:
interchanged.
(b) Install the differential case.
HINT:
C157182 Check that there is backlash between the ring gear
and drive pinion.
(c) Install the 2 rear differential bearing adjusting nuts
on the differential carrier, marking sure that the nuts
are properly threaded.
DF (d) Align the matchmarks on the cap and differential
carrier. Screw in the 2 bearing cap bolts 2 or 3 turns
and press down the bearing cap by hand.
HINT:
If the bearing cap does not tightly fit the differential
carrier, the rear differential bearing adjusting nuts
may not be properly threaded. Reinstall the rear
differential bearing adjusting nuts if necessary.
11. INSPECT SIDE BEARING PRELOAD (See page DF-
87)
12. INSPECT DIFFERENTIAL RING GEAR (See page DF-
Matchmark 82)
Matchmark
C157183E01
(a) After preload adjustment, remove the rear drive
pinion companion flange.
(b) Apply MP grease to the lip of a new rear differential
carrier oil seal.
(c) Using SST and a hammer, tap in the rear differential

SST carrier oil seal.
SST 09223-78010
0 mm (0 in.)
C158737E01

SUB-ASSEMBLY
(a) Using SST, install the rear drive pinion companion
SST flange sub-assembly.
(b) Install a new rear drive pinion nut and the plate
washer.
SST 09950-30012 (09951-03010, 09953-03010,
09954-03010, 09955-03030, 09956-03040)
C157179E01
(c) Using SST, hold the rear drive pinion companion

flange sub-assembly and tighten the rear drive
pinion nut.
SST SST 09330-00021 DF
C157180E01
(d) Check the drive pinion preload.

(1) Using a torque wrench, measure the maximum
torque within the backlash between the drive
pinion and ring gear when the companion
flange begins to rotate.
Preload
New Bearing Reused Bearing
2.00 to 5.39 N*m (20.4 to 55 kgf*cm, 1.00 to 2.76 N*m (10.2 to 28 kgf*cm,
17.7 to 47.7 in.*lbf) 8.6 to 24.4 in.*lbf)
C157161
HINT:
• If the preload is excessive, replace the drive
pinion bearing spacer.
• If the preload is insufficient, further tighten
the drive pinion nut by 5 to 10 degrees at a
time and measure the preload again.
Repeat this operation until the preload
satisfies the standard.
• If the threads are not worn, install an
appropriate spacer, coat the threads with
hypoid gear oil and repeat the above
operation.
(e) Check the total preload.

(1) Using a torque wrench, measure the maximum
torque without the backlash between the drive
pinion and ring gear when the companion
flange begins to rotate.
Total preload:
Drive pinion preload + 0.2 to 0.39 N*m (2 to 4
kgf*cm, 1.7 to 3.5 in.*lbf)
17. INSPECT COMPANION FLANGE RUNOUT (See page
DF-81)
18. INSTALL ADJUSTING NUT LOCK
(a) Install 2 new rear differential bearing adjusting nut
locks on the 2 bearing caps.
HINT:
It additionally selects it from No. 1 and No. 2 in the
ditch of adjusting nut lock.
C157189
19. STAKE DRIVE PINION NUT

(a) Using SST and a hammer, stake a new rear drive
pinion nut.
DF SST 09930-00010
SST
INSTALLATION
ASSEMBLY
(a) Remove dust and oil on the connecting surfaces of
C157190E01
the carrier assembly and axle housing.
(b) Apply adhesive to both sides of a new rear
differential carrier gasket.
Adhesive:
(c) Install the rear differential carrier gasket to the axle
housing.
(d) Apply adhesive to the differential carrier installation
bolt.
Adhesive:
HINT:
• Be sure to apply enough adhesive to the threads
• Install the bolt within 20 minutes after applying
Three bond 1215 or equivalent adhesive.
C151526E03
(e) Using a jack, install the differential carrier assembly

to the axle housing.
NOTICE:
Be sure to install the carrier assembly with the
ring gear teeth facing the right side of the
(f) Temporarily tighten the 4 nuts and 4 washers, and
lower the jack.
C151527
(g) Install the 8 bolts, and tighten the differential carrier

assembly installation bolts and nuts evenly.
DF-9)
HINT:
C157231
DF
AXLE
AXLE
STEERING KNUCKLE LH (IFS/2WD DRIVE)

COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AH-1
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AH-2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AH-5
REAR AXLE HUB LH (WIDE CAB / REAR BRAKE TYPE: DISC)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AH-7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AH-9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AH-11
REAR AXLE HUB LH (STANDARD CAB / REAR BRAKE TYPE:
DISC)
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AH-17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AH-19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AH-21
AH
AXLE – STEERING KNUCKLE LH (IFS/2WD DRIVE) AH–1
STEERING KNUCKLE LH (IFS/2WD DRIVE)

AXLE
COMPONENTS
Speed Sensor FR LH
19 (194, 14)
Front Suspension Upper Arm LH
60 (612, 44)
8.0 (82, 71 in.*lbf) x2
Steering Knucle LH
Cotter Pin
Front Dise Brake Cylinder Assy LH
206 (2100, 152) 265 (2700, 195)
Front Disc Brake Pad

152
(1549, 112)
Front Suspension
Louwer Arm No1 LH
Cotter Pin
AH
Front Disc Brake
Cotter Pin
Cylinder Mounying LH
90 (917, 66)
Tie Rod End LH
Axle Hub With Disc 19 (194, 14)
x4
Front Disc Brake Dust Cover LH
Front Axle Outer Bearing Inner Race
Cotter Pin
Washier
N*m (kgf*cm, ft*lbf) : Specified Torque Front Axle Hub Nut LH
Lock Cap
Non-reasable part Front Axle Hub Grease Cap LH
Hino Ausolized Blue Ribbon Chassis Grease
C153231J01
C153231E01
AH–2 AXLE – STEERING KNUCKLE LH (IFS/2WD DRIVE)
REMOVAL
2. REMOVE FRONT AXLE HUB GREASE CAP (LH)
3. REMOVE FRONT DISK BRAKE CYLINDER
ASSEMBLY (LH)
4. REMOVE FRONT DISK BRAKE PAD
5. REMOVE FRONT DISK BRAKE CYLINDER
MOUNTING (LH)
6. REMOVE FRONT AXLE HUB NUT (LH)
7. REMOVE AXLE HUB AND DISK
9. DISCONNECT SPEED SENSOR (FR LH)
(a) Remove the bolt and separate the speed sensor
from the steering knuckle.
10. REMOVE FRONT STABILIZER LINK ASSEMBLY
C153228
C153228
11. REMOVE FRONT DISK BRAKE DUST COVER (LH)

AH (a) Remove the four bolts and remove the brake dust
cover.
C153230
C153230
12. REMOVE STEERING KNUCKLE (LH)

(a) Remove the cotter pin and the castle nut of the
upper ball joint.
C151585
C151585
(b) Use the special tool and disconnect the steering

knuckle from the front suspension upper arm (LH).
SST 09950-40011 (09952-04010, 09951-04010,
09953-04020, 09954-04010, 09955-04031,
09957-04010, 09958-04011)
CAUTION:
• Before disconnecting the front suspension
upper arm (LH), confirm that the dust boot is
not clamped by the special tool.
• Suspend the upper arm with a rope or similar.
Boot
SST
SST
C156593J01
C156593E01
(c) Remove the cotter pin and the castle nut of the
lower ball joint.
AH
C1515606
C151606
(d) Use the special tool and disconnect the steering

knuckle from the front suspension lower arm No. 1
(LH).
SST 09950-40011 (09951-04010, 09952-04010,
09953-04020, 09954-04010, 09955-04031,
SST
09957-04010, 09958-04011)
CAUTION:
Before disconnecting the steering knuckle,
confirm that the dust boot is not clamped by the
special tool.
SST
Boot
C156671J01
C156671E01
13. INSPECT LOWER BALL JOINT ASSEMBLY (ONE

SIDE)
(a) Inspection of the ball joint rotation condition
(1) Install a nut on the joint, move the stud five
times in sliding direction and back, and then
AH rotate it continuously with a speed of 2 - 4 sec/
revolution and confirm that the rotation is
smooth.
Torque: T = 6.6 N*m (67 kgf*cm, 58 in.*lbf)
C153229
C153229
or lower (during rotation)
(b) Inspection dust cover
(1) Check that the dust cover is free of cracks and
that there is no grease leakage.
(c) Inspection ball joint looseness
(1) Move the ball joint stud part in axial direction of
the stud and check that there is no looseness.
Standard: No looseness shall be felt.
In case of abnormalities with the above
inspections (a) to (c), replace the lower ball
joint assembly.
C158717
C158717
INSTALLATION
1. INSTALL STEERING KNUCKLE (LH)
(a) Connect the steering knuckle to the front
suspension lower arm No. 1 (LH) and install it with a
castle nut.
CAUTION:
Do not apply oil or grease to the taper part of the
ball joint.
C151606
C151606
(c) Connect the steering knuckle to the front

suspension upper arm (LH) and install it with a
castle nut.
CAUTION:
Do not apply oil or grease to the taper part of the
ball joint.
(d) Install a new cotter pin.
CAUTION:
C151585
C151585
Matching of the cotter pin hole after tightening
of the castle nut shall be done within 30° in
tightening direction.
2. INSTALL FRONT DISK BRAKE DUST COVER (LH)
(a) Install the brake dust cover with four bolts. AH
3. INSTALL FRONT STABILIZER LINK ASSEMBLY
C153230
C153230
4. INSTALL SPEED SENSOR (FR LH)

(a) Install the speed sensor with a bolt to the steering
knuckle.
(b) Install the speed sensor to the steering knuckle.
Torque: T = 8.0 N*m (82 kgf*cm, 71 in.*lbf)
CAUTION:
• Do not damage the core part of the sensor tip
when installing the sensor body.
C153228
C153228
• After the installation, there shall be no gap
between the sensor stay part and the
mounting surface.
• Do not catch any foreign matter.
• Do not twist the sensor wire at the time of
installation.
5. CONNECT TIE ROD END (LH)
6. INSTALL AXLE HUB AND DISK
7. INSTALL FRONT AXLE HUB NUT (LH)

8. ADJUST PRELOAD
9. INSPECT HUB BEARING FOR LOOSENESS IN AXIAL
DIRECTION OF THE FRONT AXLE
10. INSTALL FRONT DISK BRAKE CYLINDER
MOUNTING (LH)
11. INSTALL FRONT DISK BRAKE PAD
12. INSTALL FRONT DISK BRAKE CYLINDER
ASSEMBLY (LH)
13. INSTALL FRONT AXLE HUB GREASE CAP (LH)
INSTALLATION
14. INSTALL FRONT TIRE INSTALLATION
15. ADJUST FRONT WHEEL ALIGNMENT
AH
AXLE – REAR AXLE HUB LH (WIDE CAB / REAR BRAKE TYPE: DISC) AH–7
REAR AXLE HUB LH (WIDE CAB / REAR BRAKE TYPE:

AXLE
DISC)
COMPONENTS
GVWR: 5.5 t (5 HUB BOLTS) 60 (612, 44)
x2
REAR DISC BRAKE
x4 CYLINDER ASSY LH
200 (2040, 147)

REAR DISC BRAKE CYLINDER
MOUNTING LH
14 (138, 10)
x4
REAR DISC BRAKE PAD

REAR SKID CONTROL ROTOR
REAR AXLE HUB INNER

REAR AXLE SHAFT BEARING LH (INNER RACE)
OIL SEAL LH
REAR AXLE HUB INNER BEARING

OUTER RACE LH AH
515 (5250, 380)
x5
x5
REAR AXLE OUTER BEARING OUTER RACE
REAR DISC ROTOR
REAR AXLE OUTER BEARING (INNER RACE)
REAR AXLE HUB LH
200 (2040, 147)
x5
REAR AXLE SHAFT
REAR AXLE BEARING LOCK NUT OIL SEAL
REAR AXLE LOCK NUT PLATE
REAR AXLE SHAFT

5.5 (56, 49 in.*lbf)
x2
REAR AXLE SHAFT GASKET LH

x8
MP grease 60 (612, 44) C154271E03
AH–8 AXLE – REAR AXLE HUB LH (WIDE CAB / REAR BRAKE TYPE: DISC)
GVWR: OVER 5.5 t (6 HUB BOLTS)

125 (1270, 92)
x2
x4 ASSEMBLY
265 (2700, 195)

REAR DISC BRAKE
CYLINDER MOUNTING
14 (143, 10)
x4
REAR DISC BRAKE PAD

REAR AXLE SHAFT OIL SEAL LH
REAR AXLE OIL SEAL GUIDE
REAR AXLE HUB INNER

BEARING OUTER RACE
515 (5250, 380)
x6
AH
x6
200 (2040, 147)
x6 REAR AXLE OUTER BEARING OUTER RACE

REAR DISC ROTOR
REAR AXLE HUB
REAR AXLE OUTER BEARING REAR AXLE BEARING LOCK NUT
REAR AXLE SHAFT OIL SEAL

x3
x 10
REAR AXLE SHAFT
Non-reusable part x 10
97 (989, 72)
MP grease C162160E01
REMOVAL
1. REMOVE REAR WHEEL
HINT:
3. REMOVE REAR AXLE SHAFT OIL SEAL
HINT:
4. REMOVE REAR DISC BRAKE CYLINDER ASSEMBLY
(See chapter BR)
5. REMOVE REAR DISC BRAKE PAD (See chapter BR)
6. REMOVE REAR DISC BRAKE CYLINDER MOUNTING
(See chapter BR)
7. REMOVE REAR AXLE LOCK NUT PLATE
GVWR: 5.5 t (a) GVWR: 5.5 t
(1) Remove the 2 screws from the lock nut plate.
(2) Remove the lock nut plate.
(b) GVWR: Over 5.5 t
(1) Remove the 3 bolts from the lock nut plate.
GVWR: OVER 5.5 t AH
C156274E02
8. REMOVE REAR 5.5 t AXLE BEARING LOCK NUT

(1) Using SST, remove the lock nut.
SST 09513-36020
SST
SST S0983-99401
9. REMOVE REAR AXLE HUB AND DISC ASSEMBLY
GVWR: OVER 5.5 t (a) Pull on the rear axle hub and disc assembly and
remove the rear axle outer bearing.
SST (b) Remove the rear axle hub and disc assembly.
NOTICE:
• Be careful not to drop the outer bearing.
• Be sure to securely hold the rear axle hub
and disc assembly because it is heavy.
C156277E02
10. REMOVE REAR AXLE OIL SEAL GUIDE (GVWR:

OVER 5.5 t)
(a) Using SST, remove the oil seal guide and inner
bearing from the rear axle housing.
SST 09650-2120, 09849-2001
C152175E01
11. REMOVE REAR AXLE SHAFT OIL SEAL LH (GVWR:

5.5 t)
SST (a) Using SST, drive out the oil seal.
SST 09308-00010
(b) Remove the inner bearing.
C152180E01

OVER 5.5 t)
SST 09308-36010
AH
13. REMOVE REAR AXLE HUB OUTER BEARING
OUTER RACE
(a) Remove the grease from the axle hub.
C152180E01
(b) Using a brass bar and hammer, tap out the outer
race for the outer bearing.
NOTICE:
• Apply the brass bar to the cut out of the axle
hub to hit the outer race.
• Do not damage the rear disc.
• Remove the bearing outer race only when
replacing the bearing.
C158715
14. REMOVE REAR AXLE HUB INNER BEARING OUTER

RACE
(a) Remove the MP grease from the axle hub.
race for the inner bearing.
NOTICE:
C158716 • Remove the bearing outer race only when
15. REMOVE REAR SKID CONTROL ROTOR

(a) Using a hexagon wrench (5 mm), remove the rear
skid control rotor.
C152178
16. REMOVE REAR DISC ROTOR

(a) Place matchmarks on the disc and axle hub.
(b) Remove the 6 bolts and separate the brake disc and
axle hub.
NOTICE:
GVWR: 5.5 t; 5 Bolts
GVWR: Over 5.5 t; 6 Bolts
Matchmark
C152179E01
INSTALLATION
1. INSTALL REAR DISC ROTOR
(a) Align the matchmarks of the brake disc and the rear
axle hub and then install them with the 6 bolts.
NOTICE:
AH
GVWR: 5.5 t; 5 Bolts
Matchmark GVWR: Over 5.5 t; 6 Bolts
C152179E01
2. INSTALL REAR SKID CONTROL ROTOR

(a) Using a hexagon wrench (5 mm), install the rear
skid control rotor.
C152178
3. INSTALL REAR AXLE HUB INNER BEARING OUTER

SST RACE
(a) GVWR: 5.5 t
(1) Using SST and a press, press in a new rear
axle inner bearing outer race until it contacts
the installation surface.
SST 09608-36010, 09950-70010 (09951-
07150)
NOTICE:
C154265E01 • Do not damage the bearing outer race.
• Slowly and evently install the bearing

outer reace.
SST (1) Using SST and a press, press in a new rear
SST 09518-36030, 09950-70010 (09951-
07150)
NOTICE:
• Do not damage the bearing outer race.
C154265E01 outer reace.
4. INSTALL REAR AXLE OUTER BEARING OUTER

RACE
SST (a) GVWR: 5.5 t
axle outer bearing outer race until it contacts
SST 09527-17011, 09951-01000, 09950-
70010 (09951-07150)
NOTICE:
• Slowly and evenly install the bearing
outer race.
(1) Using a brass bar and hammer, install the outer
AH race until it contacts the installation surface.
NOTICE:
outer race.
5. INSTALL REAR AXLE SHAFT OIL SEAL LH (GVWR:
5.5 t)
(a) Using SST and a press, press in a new rear axle
SST
shaft oil seal until it contact the installation surface.
SST 09518-36030, 09608-36010, 09950-70010
(09951-07150)
NOTICE:
• Slowly and evenly install the oil seal.
• Do not damage the oil seal.
C158714E01 (b) Coat the lip of the oil seal with MP grease.

OVER 5.5 t)
(a) Using a brass bar and hammer, tap in the oil seal
until its surface is flush with the axle hub.
NOTICE:
Clean the surface where the oil seal comes.
(b) Coat the lip of the oil seal with MP grease.
C152523
7. APPLY GREASE
GVWR: 5.5 t (a) Apply some MP grease into the illustrated portion of
the axle hub.
NOTICE:
Be sure not to mix the different kinds of grease,
MP grease as the grease will deteriorate and bearing failure
may result. Do not allow foreign objects or dirt
to enter the grease, as this may also cause
bearing failure.
GVWR: OVER 5.5 t
MP grease
C154264E03
8. INSTALL REAR AXLE OIL SEAL GUIDE (GVWR:

OVER 5.5 t)
(a) Using SST and a hammer, install the oil seal guide
and inner bearing.
SST 09513-36040 AH
(b) Apply a sufficient amount of MP grease to the roller
SST
of the rear axle hub inner bearing.
C158709E01
9. INSTALL REAR AXLE HUB AND DISC ASSEMBLY

(a) Fill MP grease so that there should be no gap in the
space between the oil seal and rear axle hub inner
bearing.
(b) Clean the rear axle hub and disc assembly contact
surface of the rear axle housing. Apply a light coat
of grease to the contact surface.
(c) Install the rear axle hub and disc assembly on the
MP grease rear axle housing.
C152526E01 NOTICE:
• Be careful not to damage the oil seal.
(d) GVWR: 5.5 t
(1) Install (tap in) the outer bearing to the rear axle
housing.
(e) GVWR: Over 5.5 t
(1) Using SST and a hammer, tap in the outer
bearing to the rear axle housing.
SST 09214-76011
NOTICE:
Be careful not to damage the outer bearing.
SST
C152527E01
AH
10. INSTALL REAR AXLE BEARING LOCK NUT
SST
(1) Using SST, turn the rear axle hub and disc
assembly to tighten the rear axle housing lock
nut.
SST 09513-36020
(1) Install the lock nut plate.
GVWR: OVER 5.5 t
nut.
SST
SST S0983-99401
11. ADJUST PRELOAD
(a) Using a plastic hammer, tap the rear axle hub. Turn
the rear wheel hub in both directions 2 or 3 times to
C154273E02 settle the bearing into position.
(b) GVWR: 5.5 t
(1) Using SST, loosen the bearing lock nut until the
rear axle hub can be lightly turned.
SST 09513-36020
(c) GVWR: Over 5.5 t
SST S0983-99401
HINT:
The bearing lock nut should not be loosened
enough to be turned by hand.
(d) GVWR: 5.5 t
(1) Using a spring tension gauge, measure the
turning torque of the rear axle hub.
Pre-load (at starting): 9.8-29.4 N (1.0-3.0 kgf,
2.2-6.6 lbf)
NOTICE:
• Make sure that there is no brake drag.
• After adjusting the rear axle bearing lock
nut, be sure to tap the rear axle hub with
C159336 a plastic hammer to settle the bearing
into position.
• Measure the turning torque in both
clockwise and counterclockwise
directions.
(e) GVWR: Over 5.5 t
Pre-load (at rotating): 35-53 N (3.6-5.4 kgf,
7.9-11.9 lbf)
NOTICE:
C152529 a plastic hammer to settle the bearing AH
into position.
directions.
12. INSPECT BEARING AXIAL PLAY
(a) Check the bearing for play in the axial direction near
the inner circumference of the rear axle hub.
Axial play: 0.10 mm (0.0039 in.) or less
C157069
13. INSTALL REAR AXLE LOCK NUT PLATE

(2) Secure the lock nut plate and rear axle bearing
lock nut with the 2 lock nut screw.
NOTICE:
Align the bolt installation holes on the lock
nut plate and rear axle bearing lock nut by
tightening the lock nut by the minimum
possible amount.
GVWR: OVER 5.5 t
lock nut with the 3 bolts.
NOTICE:
C156274E02
possible amount.
14. FILL UP GREASE
(a) Fill the rear axle hub with grease up to the center of
the thickness of the lock nut.
15. INSTALL REAR DISC BRAKE CYLINDER MOUNTING
(See chapter BR)
AH
16. INSTALL REAR DISC BRAKE PAD (See chapter BR)
17. INSTALL REAR DISC BRAKE CYLINDER ASSEMBLY
MP grease
(See chapter BR)
C152530E01
18. INSTALL REAR AXLE SHAFT OIL SEAL

HINT:
HINT:
20. INSTALL REAR WHEEL
21. CHECK ABS SPEED SENSOR SIGNAL
HINT:
(See chapter BC)
AXLE – REAR AXLE HUB LH (STANDARD CAB / REAR BRAKE TYPE: DISC) AH–17
REAR AXLE HUB LH (STANDARD CAB / REAR BRAKE

AXLE
TYPE: DISC)
COMPONENTS
GVWR: 7.5 t or LESS (5 HUB BOLTS) 60 (612, 44)
x2
REAR DISC BRAKE
x4 CYLINDER ASSY LH
200 (2040, 147)

MOUNTING LH
14 (138, 10)
x4
REAR DISC BRAKE PAD
REAR AXLE HUB INNER

REAR AXLE SHAFT BEARING LH (INNER RACE)
OIL SEAL LH

GVWR: 4.8-5.1 t
REAR AXLE
OUTER RACE LH AH
HUB BOLT
x5 515 (5250, 380)
x5 x5
REAR AXLE OUTER BEARING OUTER RACE
REAR DISC ROTOR
REAR AXLE OUTER BEARING (INNER RACE)
REAR AXLE HUB LH
200 (2040, 147)
x5
REAR AXLE SHAFT
REAR AXLE BEARING LOCK NUT OIL SEAL
REAR AXLE SHAFT

5.5 (56, 49 in.*lbf)
x2
REAR AXLE SHAFT GASKET LH

x8
MP grease 60 (612, 44) ASM90-001
AH–18 AXLE – REAR AXLE HUB LH (STANDARD CAB / REAR BRAKE TYPE: DISC)
GVWR: 8 t (6 HUB BOLTS)

125 (1270, 92)
x2
x4 ASSEMBLY
265 (2700, 195)

REAR DISC BRAKE
CYLINDER MOUNTING
14 (143, 10)
x4
REAR DISC BRAKE PAD

REAR AXLE SHAFT OIL SEAL LH
REAR AXLE OIL SEAL GUIDE
REAR AXLE HUB INNER

BEARING OUTER RACE
515 (5250, 380)
x6
AH
x6
200 (2040, 147)
x6 REAR AXLE OUTER BEARING OUTER RACE

REAR DISC ROTOR
REAR AXLE HUB
REAR AXLE OUTER BEARING REAR AXLE BEARING LOCK NUT
REAR AXLE SHAFT OIL SEAL

x3
x 10
REAR AXLE SHAFT
Non-reusable part x 10
97 (989, 72)
MP grease ASM90-002
REMOVAL
1. REMOVE REAR WHEEL
HINT:
3. REMOVE REAR AXLE SHAFT OIL SEAL
HINT:
4. REMOVE REAR DISC BRAKE CYLINDER ASSEMBLY
(See chapter BR)
5. REMOVE REAR DISC BRAKE PAD (See chapter BR)
6. REMOVE REAR DISC BRAKE CYLINDER MOUNTING
(See chapter BR)
7. REMOVE REAR AXLE LOCK NUT PLATE
GVWR: 7.5 t or LESS (a) GVWR: 7.5 t or less
(1) Remove the 2 screws from the lock nut plate.
(b) GVWR: 8 t
(1) Remove the 3 bolts from the lock nut plate.
GVWR: 8 t AH
ASM90-003
8. REMOVE REAR 5.5 t AXLE BEARING LOCK NUT

SST S09513-36020
(b) GVWR: 8 t
SST
SST S0983-99401
9. REMOVE REAR AXLE HUB AND DISC ASSEMBLY
GVWR: OVER 8 t (a) Pull on the rear axle hub and disc assembly and
remove the rear axle outer bearing.
SST (b) Remove the rear axle hub and disc assembly.
NOTICE:
• Be careful not to drop the outer bearing.
ASM90-004
10. REMOVE REAR AXLE OIL SEAL GUIDE (GVWR: 8 t)

(a) Using SST, remove the oil seal guide and inner
bearing from the rear axle housing.
SST 09650-2120, 09849-2001
C152175E01

7.5 t or LESS)
SST 09308-00010
C152180E01

8 t)
SST 09308-36010
AH
13. REMOVE REAR AXLE HUB OUTER BEARING
OUTER RACE
(a) Remove the grease from the axle hub.
C152180E01
race for the outer bearing.
NOTICE:
• Remove the bearing outer race only when
C158715
14. REMOVE REAR AXLE HUB INNER BEARING OUTER

RACE
(a) Remove the MP grease from the axle hub.
race for the inner bearing.
NOTICE:
C158716 • Remove the bearing outer race only when
15. REMOVE REAR SKID CONTROL ROTOR

(a) Using a hexagon wrench (5 mm), remove the rear
skid control rotor.
C152178
16. REMOVE REAR DISC ROTOR

(a) Place matchmarks on the disc and axle hub.
(b) Remove the 6 bolts and separate the brake disc and
axle hub.
NOTICE:
GVWR: 7.5 t or less; 5 Bolts
GVWR: 8 t; 6 Bolts
Matchmark
C152179E01
17. REMOVE REAR AXLE HUB BOLT LH (GVWR: 4.8-5.1

t)
(a) Using a press, remove hub bolts.
AH
C154267
INSTALLATION
1. INSTALL REAR AXLE HUB BOLT LH (GVWR: 4.8-5.1 t)
(a) Using a press, install hub bolts.
C154268
2. INSTALL REAR DISC ROTOR

(a) Align the matchmarks of the brake disc and the rear
axle hub and then install them with the 6 bolts.
NOTICE:
GVWR: 7.5 t or less; 5 Bolts
GVWR: 8 t; 6 Bolts
Matchmark
C152179E01
3. INSTALL REAR SKID CONTROL ROTOR

(a) Using a hexagon wrench (5 mm), install the rear
skid control rotor.
C152178
4. INSTALL REAR AXLE HUB INNER BEARING OUTER

SST RACE
(a) GVWR: 7.5 t or less
SST 09608-36010, 09950-70010 (09951-
07150)
NOTICE:
outer reace.
(b) GVWR: 8 t
SST (1) Using SST and a press, press in a new rear
AH SST 09518-36030, 09950-70010 (09951-
07150)
NOTICE:
C154265E01 outer reace.
5. INSTALL REAR AXLE OUTER BEARING OUTER

RACE
SST (a) GVWR: 7.5 t or less
axle outer bearing outer race until it contacts
SST 09527-17011, 09951-01000, 09950-
70010 (09951-07150)
NOTICE:
outer race.
(b) GVWR: 8 t
(1) Using a brass bar and hammer, install the outer
race until it contacts the installation surface.
NOTICE:
outer race.

7.5 t or LESS)
(a) Using SST and a press, press in a new rear axle
SST
shaft oil seal until it contact the installation surface.
SST 09518-36030, 09608-36010, 09950-70010
(09951-07150)
NOTICE:
• Slowly and evenly install the oil seal.
• Do not damage the oil seal.
C158714E01 (b) Coat the lip of the oil seal with MP grease.
7. INSTALL REAR AXLE SHAFT OIL SEAL LH (GVWR: 8

t)
(a) Using a brass bar and hammer, tap in the oil seal
until its surface is flush with the axle hub.
NOTICE:
Clean the surface where the oil seal comes.
(b) Coat the lip of the oil seal with MP grease.
C152523
8. APPLY GREASE
GVWR: 7.5 t or LESS (a) Apply some MP grease into the illustrated portion of
the axle hub.
NOTICE:
Be sure not to mix the different kinds of grease,
MP grease as the grease will deteriorate and bearing failure AH
may result. Do not allow foreign objects or dirt
to enter the grease, as this may also cause
bearing failure.
GVWR: 8 t
MP grease
ASM90-005
9. INSTALL REAR AXLE OIL SEAL GUIDE (GVWR: 8 t)

(a) Using SST and a hammer, install the oil seal guide
and inner bearing.
SST 09513-36040
(b) Apply a sufficient amount of MP grease to the roller
of the rear axle hub inner bearing.
SST
C158709E01
10. INSTALL REAR AXLE HUB AND DISC ASSEMBLY

(a) Fill MP grease so that there should be no gap in the
space between the oil seal and rear axle hub inner
bearing.
(b) Clean the rear axle hub and disc assembly contact
AH surface of the rear axle housing. Apply a light coat
of grease to the contact surface.
(c) Install the rear axle hub and disc assembly on the
MP grease rear axle housing.
C152526E01 NOTICE:
• Be careful not to damage the oil seal.
(d) GVWR: 7.5 t or less
(1) Install (tap in) the outer bearing to the rear axle
housing.
(e) GVWR: 8 t
(1) Using SST and a hammer, tap in the outer
bearing to the rear axle housing.
SST 09214-76011
NOTICE:
Be careful not to damage the outer bearing.
SST
C152527E01
11. INSTALL REAR AXLE BEARING LOCK NUT

SST
nut.
SST 09513-36020
(b) GVWR: 8 t
GVWR: 8 t
nut.
SST
SST S0983-99401
12. ADJUST PRELOAD
(a) Using a plastic hammer, tap the rear axle hub. Turn
the rear wheel hub in both directions 2 or 3 times to
ASM90-006 settle the bearing into position.
(b) GVWR: 7.5 t or less
SST 09513-36020
(c) GVWR: 8 t
SST S0983-99401
HINT: AH
The bearing lock nut should not be loosened
enough to be turned by hand.
(d) GVWR: 7.5 t or less
Pre-load (at starting): 9.8-29.4 N (1.0-3.0 kgf,
2.2-6.6 lbf)
NOTICE:
C159336 a plastic hammer to settle the bearing
into position.
directions.
(e) GVWR: Over 8 t
Pre-load (at rotating): 35-53 N (3.6-5.4 kgf,
7.9-11.9 lbf)
NOTICE:
C152529

a plastic hammer to settle the bearing
into position.
directions.
13. INSPECT BEARING AXIAL PLAY
(a) Check the bearing for play in the axial direction near
the inner circumference of the rear axle hub.
Axial play: 0.10 mm (0.0039 in.) or less
C157069
14. INSTALL REAR AXLE LOCK NUT PLATE

lock nut with the 2 lock nut screw.
NOTICE:
AH nut plate and rear axle bearing lock nut by
possible amount.
GVWR: 8 t
(b) GVWR: 8 t
lock nut with the 3 bolts.
NOTICE:
ASM90-003
possible amount.
15. FILL UP GREASE
(a) Fill the rear axle hub with grease up to the center of
the thickness of the lock nut.
16. INSTALL REAR DISC BRAKE CYLINDER MOUNTING
(See chapter BR)
17. INSTALL REAR DISC BRAKE PAD (See chapter BR)
18. INSTALL REAR DISC BRAKE CYLINDER ASSEMBLY
MP grease
(See chapter BR)
C152530E01
19. INSTALL REAR AXLE SHAFT OIL SEAL

HINT:

HINT:
21. INSTALL REAR WHEEL
22. CHECK ABS SPEED SENSOR SIGNAL
HINT:
(See chapter BC)
AH
SUSPENSION & AXLE
TIRE AND WHEEL
TIRE AND WHEEL SYSTEM

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TW-1
TW
TIRE AND WHEEL – TIRE AND WHEEL SYSTEM TW–1
TIRE AND WHEEL SYSTEM

INSPECTION
1. INSPECT TIRES
(a) Check the tires for wear and proper inflation
pressure.
for Australia and Newzealand (Standard cab))
Model
XZU307R-HKTLBQ3 185/85R16 215/85R16 600(6.0, 87) 600(6.0, 87)
XZU306R-HQMMBQ3 195/75R 15 195/75R 15 600(6.0, 87) 600(6.0, 87)
XZU347R-HKMMBQ3
185/85R 16 185/85R 16 600(6.0, 87) 600(6.0, 87)
XZU307R-HKMMBQ3

for Australia and Newzealand (Wide cab)
Model
XZU407R-HKMMDQ3
XZU417R-HKMMDQ3 195/85R 16 195/85R 16 600(6.0, 87) 600(6.0, 87)
XZU417R-HKTMDQ3
XZU417R-HKFQDQ3 205/85R 16 205/85R 16 600(6.0, 87) 600(6.0, 87)
XZU417R-HKFRDQ3
XZU417R-HKTRDQ3
215/85R 16 215/85R 16 600(6.0, 87) 600(6.0, 87)
XZU427R-HKFRDQ3
XZU427R-QKFRDQ3
XZU427R-HKFTDQ3
225/80R 17.5 225/80R 17.5 700(7.0, 102) 700(7.0, 102)
XZU437R-HKFTDQ3 TW
for Thailand (Standard cab)
Model
XZU303R-HBMLAT3 7.50-15-12 7.50-15-12 300(3.0, 44) 600(6.0, 87)
XZU303R-HBMMBT3
7.50-16-10 7.50-16-10 525(5.3, 76) 525(5.3, 76)
XZU343R-HKMQBT3

for Thailand (Wide cab)
Model
XZU413R-HKMTBT3 7.50-16-14 7.50-16-14 650(6.5, 94) 650(6.5, 94)

XZU423R-HKMTBT3 7.50R16-14 7.50R16-14 700(7.0, 102) 700(7.0, 102)
TW–2 TIRE AND WHEEL – TIRE AND WHEEL SYSTEM

for G.C.C (Wide cab)
Model
7.00-16-10 7.00-16-10 500(5.0, 73) 500(5.0, 73)
WU410L-HKMQSV
7.00R16-10 7.00R16-10 525(5.3, 76) 525(5.3, 76)
WU410L-HKMQSV3
7.00R16-12 7.00R16-12 600(6.0, 87) 600(6.0, 87)
WU420L-HKMQSV 7.50-16-10 7.50-16-10 525(5.3, 76) 525(5.3, 76)

WU420L-HKMQSV3 7.50R16-10 7.50R16-10 575(5.8, 83) 575(5.8, 83)
7.50-16-12 7.50-16-12 600(6.0, 87) 600(6.0, 87)
7.50-16-14 7.50-16-14 650(6.5, 94) 650(6.5, 94)
WU412L-HKMRBV3
7.50R16-12 7.50R16-12 650(6.5, 94) 650(6.5, 94)
7.50R16-14 7.50R16-14 700(7.0, 102) 700(7.0, 102)
WU412L-HKMRBV 7.50-16-12 7.50-16-12 600(6.0, 87) 600(6.0, 87)
WU422L-HKMRBV
WU422L-HKMRBV3 7.50R16-12 7.50R16-12 650(6.5, 94) 650(6.5, 94)
WU412L-HKFTBV 7.50-16-14 7.50-16-14 650(6.5, 94) 650(6.5, 94)

WU412L-HKFTBV3
WU422L-HKFTBV 7.50R16-14 7.50R16-14 700(7.0, 102) 700(7.0, 102)
WU422L-HKFTBV3

for HongKong (Wide cab)
Model
XZU405R-HKFQD3
XZU415R-HKFQD3
215/85R 16 215/85R 16 600(6.0, 87) 600(6.0, 87)
XZU415R-QKFQD3
XZU425R-HKFQD3
TW XZU425R-HKFTD3
215/75R17.5 215/75R17.5 700(7.0, 102) 700(7.0, 102)
XZU415R-HKFTD3

for General (Standard cab)
Model
WU300R-HBMLS3 7.00-16-10 7.00-16-12 500(5.0, 73) 575(5.8, 83)
WU300L-HBMLS
WU300L-HBMLS3
WU302L-HBMLA
WU302L-HBMLA3 7.00R16-10 7.00R16-12 525(5.3, 76) 600(6.0, 87)
XZU303L-HBMLA
XZU303L-HBMLA3
WU300L-HBMMS 7.00-16-10 7.00-16-10 500(5.0, 73) 500(5.0, 73)

WU300L-HBMMS3 7.00-16-12 7.00-16-12 575(5.8, 83) 575(5.8, 83)
WU340L-HKMMS3
7.00R16-10 7.00R16-10 525(5.3, 76) 525(5.3, 76)
7.00-16-10 7.00-16-10 500(5.0, 73) 500(5.0, 73)
WU340L-HKMMS 7.00-16-12 7.00-16-12 575(5.8, 83) 575(5.8, 83)
WU302L-HBMMB3
XZU343L-HKMMA3 7.00R16-10 7.00R16-10 525(5.3, 76) 525(5.3, 76)
7.00R16-12 7.00R16-12 600(6.0, 87) 600(6.0, 87)
XZU405R-HKFQD3
XZU415R-HKFQD3
215/85R 16 600(6.0, 87) 600(6.0, 87)
XZU415R-QKFQD3
XZU425R-HKFQD3
XZU425R-HKFTD3
215/75R17.5 700(7.0, 102) 700(7.0, 102)
XZU415R-HKFTD3
TIRE AND WHEEL – TIRE AND WHEEL SYSTEM TW–3

for General (Wide cab)
Model
WU410R-HKMMS3 7.00-16-10 7.00-16-10 500(5.0, 73) 500(5.0, 73)
WU412R-HKMMB3
WU412L-HKMMB
WU412L-HKMMB3 7.00R16-10 7.00R16-10 525(5.3, 76) 525(5.3, 76)
XZU423R-HKMMB3
XZU413R-HKMMB3
WU410R-HKMQS3 7.50-16-10 7.50-16-10 525(5.3, 76) 525(5.3, 76)
WU412L-HKMQB
WU412L-HKMQB3 7.50R16-10 7.50R16-10 575(5.8, 83) 575(5.8, 83)
7.50-16-14 7.50-16-14 650(6.5, 94) 650(6.5, 94)

7.50-16-12 7.50-16-12 600(6.0, 87) 600(6.0, 87)
WU420R-HKMRS3
7.50R16-12 7.50R16-12 650(6.5, 94) 650(6.5, 94)
7.50R16-14 7.50R16-14 700(7.0, 102) 700(7.0, 102)
7.50-16-12 7.50-16-12 600(6.0, 87) 600(6.0, 87)
WU412L-HKMRB3 7.50-16-14 7.50-16-14 650(6.5, 94) 650(6.5, 94)
WU422L-HKMRB3
WU422R-HKMRB3 7.50R16-12 7.50R16-12 650(6.5, 94) 650(6.5, 94)
7.50R16-14 7.50R16-14 700(7.0, 102) 700(7.0, 102)
WU412L-HKMRB 7.50-16-12 7.50-16-12 600(6.0, 87) 600(6.0, 87)
XZU423R-HKMRD3
WU422L-HKMRB 7.50R16-12 7.50R16-12 650(6.5, 94) 650(6.5, 94)
XZU423L-HKMQD3
WU422L-HKFTB 7.50-16-14 7.50-16-14 650(6.5, 94) 650(6.5, 94)
WU422L-HKFTB3
XZU423L-HKMRD3
WU412L-HKFTB 7.50R16-14 7.50R16-14 700(7.0, 102) 700(7.0, 102)
WU412L-HKFTB3
7.50-16-10 7.50-16-10 525(5.3, 76) 525(5.3, 76)
TW
XZU413L-HKMQD3 7.50-16-12 7.50-16-12 600(6.0, 87) 600(6.0, 87)
7.50R16-10 7.50R16-10 575(5.8, 83) 575(5.8, 83)
7.00-16-10 7.00-16-10 500(5.0, 73) 500(5.0, 73)
XZU413L-HKMMD3 7.00R16-10 7.00R16-10 525(5.3, 76) 525(5.3, 76)
7.50-16-12 7.50-16-12 600(6.0, 87) 600(6.0, 87)

for Ireland (Wide cab)
Model
195/75R 16 195/75R 16 525(5.3, 76) 525(5.3, 76)
XZU415R-HKMMDW3
195/85R 16 195/85R 16 600(6.0, 87) 600(6.0, 87)
XZU415R-HKFQDW3
215/75R 17.5 215/75R 17.5 700(7.0, 102) 700(7.0, 102)
XZU425R-HKFQDW3
XZU425R-HKFRDW3
XZU435R-HKFRDW3 215/75R 17.5 215/75R 17.5 700(7.0, 102) 700(7.0, 102)
XZU415R-HKFRDW3
TW–4 TIRE AND WHEEL – TIRE AND WHEEL SYSTEM
(b) Using a dial indicator, check the runout of the tires.

Tire runout:
3.0 mm (0.12 in.) or less
C137874
TW
BRAKE
BRAKE CONTROL
ANTI-LOCK BRAKE SYSTEM

PARTS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-1
HOW TO PROCEED WITH TROUBLESHOOTING . . . . . . . . . . . . . . . . BC-4
TEST MODE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-5
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-13
TERMINALS OF ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-14
DIAGNOSIS SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-17
DIAGNOSTIC TROUBLE CODE CHART . . . . . . . . . . . . . . . . . . . . . . . . BC-19
C0200/31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-22
C0205/32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-22
C1271/71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-22
C1272/72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-22
C0210/33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-29
C0215/34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-29
C1273/73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-29
C1274/74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-29
C0226/21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-36
C0236/22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-36
C0246/23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-36
C0256/24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-36
C1227/27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-36
C0273/13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-42
C0274/14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-42
C0278/11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-50
C0279/12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-50 BC
C1225/25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-57
C1235/35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-60
C1236/36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-60
C1238/38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-60
C1239/39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-60
C1275/75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-60
C1276/76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-60
C1277/77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-60
C1278/78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-60
C1241/41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-68
C1246/46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-72
C1281/81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-72
C1249/49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-78
C1251/51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-87
C1265/65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-90
C1285/85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-90
C1266/66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-96
ABS Warning Light Remains ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-100
ABS Warning Light does not Come ON. . . . . . . . . . . . . . . . . . . . . . . . . . BC-105
Brake Warning Light Remains ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-108
Brake Warning Light does not Come ON. . . . . . . . . . . . . . . . . . . . . . . . . BC-117
TC and CG Terminal Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-120
TS and CG Terminal Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-123
BRAKE ACTUATOR
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-126
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-127
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-129
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-129
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-129
EASY & SMOOTH STARTING SYSTEM (N04C)
HOW TO PROCEED WITH TROUBLESHOOTING . . . . . . . . . . . . . . . . . BC-132
CUSTOMER PROBLEM ANALYSIS CHECK . . . . . . . . . . . . . . . . . . . . . . BC-134
PRE-CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-135
DIAGNOSTIC TROUBLE CODE CHART . . . . . . . . . . . . . . . . . . . . . . . . . BC-140
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-141
TERMINALS OF ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-142
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-144
C1382/112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-145
C1383/111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-148
C1384/113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-151
C1386/116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-153
C1387/115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-156
C1388/117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-159
C1389/118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-160
C1390/42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-163
ES STARTING SYSTEM DOES NOT OPERATE. . . . . . . . . . . . . . . . . . . BC-166
ES BUZZER CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-171
PARKING BRAKE SWITCH CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-173
BC
BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM BC–1
ANTI-LOCK BRAKE SYSTEM

BRAKE CONTROL
PARTS LOCATION
MASTER CYLINDER PRESSURE SENSOR

(OIL PRESSURE SENSOR (RHD) )
BRAKE ACTUATOR
(ABS ACTUATOR)
REAR SPEED SENSOR
BC
REAR SPEED SENSOR ROTOR
NO. 2 RELAY BLOCK

FRONT SPEED SENSOR
- ABS MTR MAIN RELAY
- ABS SOL MAIN RELAY
- ABS FUSE
FRONT SPEED SENSOR ROTOR
- ABS SOL FUSE
- STOP FUSE
ASM77-013
BC–2 BRAKE CONTROL – ANTI-LOCK BRAKE SYSTEM
R/B No.1 AND J/B No.1
COMBINATION METER ASSY

ABS WARNING LAMP
PARKING BRAKE WARNING LAMP
GAUGE FUSE BRAKE FLUID LEVEL

WARNING SWITCH ASSY
ECU-IG FUSE
VACUUM SENSOR
BC
STOP LAMP SWITCH ASSY
SKID CONTROL ECU ASSY
PARKING BRAKE SWITCH ASSY
ASM77-014
RHD WITH ATM
NO. 1 RELAY BLOCK COMBINATION METER
BC
SKID CONTROL
ECU ASSY
ECM
DLC3
STOP LIGHT SWITCH
ASM77-015
HOW TO PROCEED WITH

TROUBLESHOOTING
NEXT
2 CUSTOMER PROBLEM ANALYSIS
(a) Interview the customer and confirm the trouble (See

chapter IN).
NEXT
3 CHECK DTC
(a) Check and record a DTC.

(b) Clear the DTC (See Pub. No. S1-YXZE05A, page 05-
98).
(c) Reconfirm the DTC.
(1) Reconfirm the DTC based on the recorded DTC
(See Pub. No. S1-YXZE05A, page 05-98).
Result
Result Proceed to
DTC is output A
BC DTC is not output (Problem symptom does not occur) B

DTC is not output (Problem symptom occurs) C
B GO TO STEP 5
C GO TO STEP 6
4 DIAGNOSTIC TROUBLE CODE CHART
(a) Proceed to Diagnostic Trouble Code Chart (See page

BC-19).
NEXT
GO TO STEP 7
5 SYMPTOM SIMULATION
(a) Proceed to Diagnosis System (See page BC-17).

NEXT
6 PROBLEM SYMPTOMS TABLE
(a) Proceed to Problem Symptoms Table (See page BC-13).

NEXT
7 CIRCUIT INSPECTION
NEXT
8 IDENTIFICATION OF PROBLEM
NEXT
9 REPAIR OR REPLACEMENT
NEXT
10 CONFIRMATION TEST
NEXT
BC
END
TEST MODE PROCEDURE

ABS Warning Brake Warning 1. WARNING LIGHT INITIAL CHECK
Light: Light: (a) Release the parking brake.
NOTICE:
Before releasing the parking brake, set chocks
to hold the vehicle for safety.
HINT:
When the parking brake is applied, the level of the
C143718E03
brake fluid is low or the vacuum is low, the brake
warning light comes on.
(b) When the ignition switch is turned to the ON
position, check that the ABS and brake warning
lights come on for approximately 3 seconds.
HINT:
If the ECU stores a DTC, the ABS and brake
warning lights will come on.
If the indicator remains on or does not come on,

proceed to troubleshooting for the light circuits listed
below.
Trouble Area See procedure
ABS warning light circuit (Remains on) BC-100
ABS warning light circuit (Does not come on) BC-105
Brake warning light circuit (Remains on) BC-108
Brake warning light circuit (Does not come on) BC-117
2. SENSOR CHECK USING TEST MODE (SIGNAL

CHECK) (for Using an SST Check Wire)
HINT:
If the ignition switch is turned from ON to ACC or LOCK
during Test Mode (signal check), DTCs of the signal
check function will be erased.
(a) Procedure to enter Test Mode.
(1) Start the engine
HINT:
Idle the engine for 20 seconds or more to ensure
high vacuum in the vacuum booster.
HINT:
When the ignition switch is off, to prevent
vacuum loss, do not depress the brake pedal.
(3) Check that the steering wheel is centered and
DLC3:
CG apply the parking brake.
(4) Using SST, connect terminals TS and CG of the
DLC3.
SST 09843-18040
BC
(6) After the ABS warning light comes on for several
seconds (initial valve check), check that ECU
code is output.
TS
G022987E07 (7) Check that the ABS warning light starts to blink
after ECU code is indicated. This transition
shows that the Test Mode is activated.
ECU code table:
Vehicle Type Code
Short body w/o ES start system 6
Long body w/o ES start system 9
Short body w/ ES start system 7
Long body w/ ES start system 10
(8) A blinking pattern of the ABS warning light

(transition from ECU code 3 to Test Mode) is
shown below as an example.
Ignition Switch:
ON
OFF
Blinking Pattern of ABS Warning Light (Example Code 3):
When vacuum is enough:
0.125 sec. 0.5 sec.
0.5 sec.
0.13 sec.
3 sec.
0.13 sec.
ON
0.5 sec.
OFF
ECU Code 3 TEST MODE Display

BC
When vacuum is not enough:
0.125 sec. 0.5 sec.
0.5 sec.
0.13 sec.
3 sec.
0.13 sec.
ON
Engine
0.5 sec. Start
OFF
ECU Code 3 TEST MODE Display
C156341E01
NOTICE:
• Do not depress the brake pedal until the
entry of the Test Mode is confirmed.
• If the ABS warning light remains on even

after the ECU code is output, start the
engine. Then, check that Test Mode is
entered after several seconds. The
indication of the warning light after the
ECU code is output depends on vacuum
of the vacuum booster. When the vacuum
is high enough, Test Mode is entered.
When the vacuum is not high enough, the
warning light remains on.
(9) Check that the ABS warning light is blinking in
Blinking Pattern in Test Mode:
Test Mode.
HINT:
0.13 sec. 0.13 sec. If the ABS warning light does not blink, inspect
ON the TS and CG terminal circuit and ABS warning
light circuit.
TS and CG terminal circuit BC-123
OFF
ABS warning light circuit (Does not come on) BC-105
BR03904E69
(10)Check the ABS sensor.

HINT:
Check that the ABS warning light is blinking in
Test Mode and perform the check.
3. MASTER CYLINDER PRESSURE SENSOR CHECK
(for Using an SST Check Wire)
HINT:
If the engine is running, stop the engine once and then
turn the ignition switch to the ON position.
(a) Leave the vehicle stationary condition and release
BC
the brake pedal for 1 second or more, and depress
the brake pedal with a force of 186 N (19 kgf, 42 lbf)
or more.
(b) Check that the ABS warning light comes on.
(c) Depress the brake pedal for 1 second with the ABS
warning light illuminated and release it.
(d) Check that the blinking pattern of the ABS warning

light returns to the pattern shown in Test Mode.
Brake Pedal Depression Force:
186 N (19 kgf, 42 lbf)
0 N (0 kgf, 0 lbf)
Blinking Pattern of ABS Warning Light:

1 sec. or more
ON
OFF
C151816E01
NOTICE:
• Do not depress the brake pedal several times.
• If the ABS warning light does not come on
although the brake pedal is depressed, the
master cylinder pressure sensor may be
defective.
4. VACUUM SENSOR CHECK (for Using an SST Check BC
Wire)
HINT:
If the engine is running, stop the engine once and then
turn the ignition switch to the ON position.
(a) Depress the brake pedal several times.
(b) Check that the ABS warning light comes on.
Brake Pedal Depression Force:
186 N (19 kgf, 42 lbf)
0 N (0 kgf, 0 lbf)
Blinking Pattern of ABS Warning Light:
ON
OFF
C151817E01
NOTICE:
• If the ABS warning light does not come on
after depressing the brake pedal
continuously, the vacuum sensor may be
defective.
• When the parking brake is released, the
vacuum warning buzzer may sound.
BC • Soon after the warning light changes from
blinking to staying on, stop the pumping
operation.
5. SPEED SENSOR CHECK (for Using an SST Check
Wire)
(a) Drive the vehicle straight ahead.
Accelerate the vehicle to a speed of 45 km/h (28
mph) or more for several seconds and check that
the ABS warning light goes off.
HINT:
The sensor check may not be completed if
wheelspin occurs.
(b) Stop the vehicle.
NOTICE:
• The speed sensor check may not be
completed if the speed sensor check is
started while turning the steering wheel or
spinning the wheels.
• If the vehicle speed exceeds 80 km/h (50
mph) after the ABS warning light goes off, a
sensor check code will be stored again.
Complete the check before the speed reaches
80 km/h (50 mph).
• If the sensor check has not been completed,

the ABS warning light blinks while driving
and the ABS does not operate.
HINT:
When the sensor check has been completed, the
ABS warning light goes off while driving and blinks
in the Test Mode pattern while stationary.
6. END OF SENSOR CHECK (for Using an SST Check
Blinking Pattern in Test Mode:
Wire)
(a) If the sensor check is completed, the ABS warning
0.13 sec. 0.13 sec. light blinks (Test Mode) when the vehicle stops and
ON the ABS warning light is off while the vehicle is
driving.
NOTICE:
• When the master cylinder pressure sensor,
OFF vacuum sensor, and speed sensor checks are
BR03904E69 completed, the sensor check is completed.
• If the sensor check is not completed, the ABS
warning light blinks even while the vehicle is
driving and the ABS does not operate.
7. READ DTC OF SIGNAL CHECK FUNCTION (for Using
DLC3: CG an SST Check Wire)
(a) Using SST, connect terminals TC and CG of the
DLC3.
SST 09843-18040
TS TC
G022988E01
BC
(b) Count the number of blinks of the ABS and VSC

warning lights.
Blinking Pattern for Normal System Code:
0.25 sec. 0.25 sec.
ON
OFF
Blinking Pattern for Trouble Code (Example Codes 71 and 72):
0.5 sec. 2.5 sec.

1.5 sec. 4 sec.
0.5 sec.
Repeat
ON
OFF
Code 71 Code 72
C132876E04
NOTICE:
BC • If only the DTCs are displayed, repair the
malfunction area and clear the DTCs.
• If the DTCs or Test Mode codes (DTC of
signal check function) are displayed, repair
the malfunction area, clear the DTCs and
perform the Test Mode inspection.
HINT:
• If more than 1 malfunction is detected at the
same time, the lowest numbered code will be
displayed first.
• See the list of DTC (See procedure "A").
(c) After performing the check, disconnect the SST
from terminals TS and CG, and TC and CG of the
DLC3 and turn the ignition switch off.
HINT:
• If the ignition switch is not turned to the ON
position after the SST is removed from the DLC3,
the previous Test Mode will continue.
• If the ignition switch is turned to the ON position
with terminals TS and CG shorted, the previous
Test Mode will continue.
8. DTC OF TEST MODE (SIGNAL CHECK) FUNCTION

(Procedure "A")
ABS sensor:
DTC Code Detection Item Trouble Area
• Front speed sensor RH
C1271/71 Low output signal of front speed sensor RH • Sensor installation
• Speed sensor rotor
• Front speed sensor LH
C1272/72 Low output signal of front speed sensor LH • Sensor installation
• Rear speed sensor RH
C1273/73 Low output signal of rear speed sensor RH • Sensor installation
• Rear speed sensor LH
C1274/74 Low output signal of rear speed sensor LH • Sensor installation
Abnormal change in output signal of front speed sensor • Front speed sensor RH
C1275/75
RH • Speed sensor rotor
Abnormal change in output signal of front speed sensor • Front speed sensor LH
C1276/76
LH • Speed sensor rotor
Abnormal change in output signal of rear speed sensor • Rear speed sensor RH
C1277/77
RH • Speed sensor rotor
Abnormal change in output signal of rear speed sensor • Rear speed sensor LH
C1278/78
LH • Speed sensor rotor
• Stop light switch
C1281/81 Master cylinder pressure sensor output malfunction
• Master cylinder pressure sensor
C1285/85 Vacuum sensor output malfunction Vacuum sensor
HINT:
The codes in this table are output only in Test Mode
(signal check).
PROBLEM SYMPTOMS TABLE BC

Use the table below to help determine the cause of a
problem. The likely causes of the problem are indicated in
descending order. Check each suspected area in order.
Repair or replace faulty parts or perform adjustments as
necessary.
NOTICE:
When replacing the skid control ECU, sensor, etc., turn
the ignition switch off.
HINT:
• Inspect the fuse and relay before investigating the
suspected areas as shown in the table below.
• Inspect each malfunction circuit in order for the
corresponding symptom.
Anti-lock Brake System:

Check the DTC again and make sure that the normal system
(*1)
code is output.
IG power source circuit BC-68
Front speed sensor circuit BC-22
ABS and/or EBD does not operate Rear speed sensor circuit BC-29
Check the brake actuator assembly. If abnormal, check the
BC-126
hydraulic circuit for leakage.
If the symptoms still occur even after the above circuits in
suspected areas have been inspected and proved to be (*1)
normal, replace the skid control ECU.
(*1)
code is output.
Front speed sensor circuit BC-22
Rear speed sensor circuit BC-29
ABS and/or EBD does not operate efficiently Stop light switch circuit BC-78
Check the brake actuator assembly. If abnormal, check the
BC-126
hydraulic circuit for leakage.
If the symptoms still occur even after the above circuits in
suspected areas have been inspected and proved to be (*1)
normal, replace the skid control ECU.
(*1)
code is output.
TC and CG terminal circuit BC-120
ABS sensor DTC check cannot be done
If the symptoms still occur even after the above circuit in
suspected areas has been inspected and proved to be normal, (*1)
replace the skid control ECU.
ABS warning light circuit BC-100
ABS warning light abnormal (Remains on)
Skid control ECU (*1)
ABS warning light circuit BC-105
ABS warning light abnormal (Does not come on)
BC Skid control ECU (*1)
Vacuum sensor circuit BC-90
Brake warning light abnormal (Remains on) Brake warning light circuit BC-108
Brake warning light circuit BC-117
Brake warning light abnormal (Does not come on)
TS and CG terminal circuit BC-123
Sensor check cannot be done
(*1): See Pub. No. S1-XYZE05A
TERMINALS OF ECU
1. CHECK BATTERY VOLTAGE
(a) Check the battery voltage.
Standard voltage:
20 to 32 V
2. INSPECT SKID CONTROL ECU
(a) Measure the voltage between each terminal and the
body ground.
(b) Using an oscilloscope, check that the pulse

generates between each terminal and the body
ground.
NOTICE:
Inspection should be performed from the back
of the connector with the connector connected
to the skid control ECU.
Skid Control ECU:
S14 S13 S12 S11
9 8 7 6 5 4 3 2 1 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1 7 6 5 4 3 2 1
21 20 19 18 17 16 15 14 13 12 11 10 16 15 14 13 12 11 10 9 8 19 18 17 16 15 14 13 12 11 10 15 14 13 12 11 10 9 8
31 30 29 28 27 26 25 24 23 22 24 23 22 21 20 19 18 17 28 27 26 25 24 23 22 21 20 22 21 20 19 18 17 16
C151809E01
HINT:
Inspect the ECU from the wire harness side while
the connector is connected.
Terminal No. (Symbols) Wiring Color Terminal Description Condition Specified Condition
S11-1 (SRLR) - Body Rear decrease solenoid Approx. 3 seconds after
R-Y - Body ground 20 to 32 V
ground LH output turning ignition switch ON
S11-2 (SM1-) - Body
ground
W-R - Body ground
Front linear solenoid (-)
output
Approx. 3 seconds after
turning ignition switch ON
Below 3 V BC
S11-3 (SM1+) - Body Front linear solenoid (+) Approx. 3 seconds after
B-Y - Body ground Below 3 V
ground output turning ignition switch ON
S11-4 (SM2-) - Body Rear linear solenoid (-) Approx. 3 seconds after
W-L - Body ground Below 3 V
S11-5 (SM2+) - Body Rear linear solenoid (+) Approx. 3 seconds after
W-G - Body ground Below 3 V
S11-6 (AST) - Body Approx. 3 seconds after
BR-B - Body ground Solenoid relay test input 20 to 32 V
ground turning ignition switch ON
S11-7 (SRLH) - Body Rear holding solenoid LH Approx. 3 seconds after
L-O - Body ground 20 to 32 V
S11-8 (SFRR) - Body Front decrease solenoid Approx. 3 seconds after
R-W - Body ground 20 to 32 V
ground RH output turning ignition switch ON
S11-14 (GND4) - Body
W-B - Body ground Skid control ECU ground 4 Always Below 1 Ω
ground
ground
S11-16 (SFRH) - Body Front holding solenoid RH Approx. 3 seconds after
Y - Body ground 20 to 32 V
S12-10 (PIM) - Body
W - Body ground Vacuum sensor input Engine idling 0.5 to 4 V
ground
S12-11 (E4) - Body ground R - Body ground Vacuum sensor ground Always Below 1 Ω
S12-12 (ISS2) - Body Vacuum sensor 2 shielded
Shielded - Body ground Always Below 1 Ω
ground ground
S12-13 (E3) - Body
V - Body ground Vacuum sensor 2 ground Always Below 1 Ω
ground
S12-14 (PSS) - Body Master cylinder pressure
ground sensor shielded ground
S12-15 (E2) - Body Master cylinder pressure
R - Body ground Always Below 1 Ω
ground sensor ground
S12-20 (VSS2) - Body Vacuum sensor shielded
ground ground
S12-21 (VCP) - Body Vacuum sensor power
B - Body ground Ignition switch ON 4.75 to 5.25 V
ground supply output
S12-22 (VCP2) - Body Vacuum sensor 2 power
O - Body ground Ignition switch ON 4.75 to 5.25 V
ground supply output
S12-23 (PIM2) - Body
LG - Body ground Vacuum sensor 2 input Engine idling 0.5 to 4 V
ground
Master cylinder pressure
S12-24 (VCM) - Body
B - Body ground sensor power supply Ignition switch ON 4.75 to 5.25 V
ground
output
S12-25 (PMC1) - Body Master cylinder pressure Ignition switch ON, brake
W - Body ground 0.3 to 0.7 V
ground sensor input pedal released
Stop light switch ON →
S13-1 (STP) - Body
V - Body ground Stop light switch input OFF (Brake pedal 16 to 32 V → Below 3 V
ground
depressed → released)
7 to 18 V for approx. 3
S13-6 (WA) - Body ground R-Y - Body ground ABS warning light output Ignition switch off → ON
seconds → Below 3 V
S13-7 (IG) - Body ground B-R - Body ground IG1 power supply Ignition switch ON 20 to 32 V
S13-10 (EXO) - Body Exhaust brake request
V-R - Body ground Ignition switch ON 18 to 32 V
ground output
S13-14 (BRL) - Body 7 to 25 V for approx. 3
P-B - Body ground Brake warning light output Ignition switch off → ON
ground seconds → Below 2 V
S13-15 (RR-) - Body Rear wheel speed sensor
BR - Body ground Ignition switch off Below 1 Ω
ground RH (-) input
S13-16 (RR+) - Body Rear wheel speed sensor Pulse generation
Y - Body ground Vehicle speed input
ground RH (+) input (see waveform 1)
BC S13-18 (TS) - Body Sensor check activation

Ignition switch ON,
terminals TS and CG of
P-L - Body ground Below 3 V → 10 to 32 V
ground input DLC3 connected →
disconnected
Ignition switch ON,
S13-19 (TC) - Body terminals TC and CG of
R-B - Body ground Diagnosis activation input Below 3 V → 20 to 32 V
ground DLC3 connected →
disconnected
Ignition switch ON,
S13-21 (PKB1) - Body Parking brake switch 1
B-L - Body ground parking brake switch ON Below 3 V → 10 to 32 V
ground input
→ OFF
S13-22 (RL+) - Body Rear wheel speed sensor Pulse generation
P - Body ground Vehicle speed input
ground LH (+) input (see waveform 1)
S13-23 (RL-) - Body Rear wheel speed sensor
L - Body ground Ignition switch off Below 1 Ω
ground LH (-) input
S13-24 (RSS) - Body Rear wheel speed sensor
ground shielded ground
S14-1 (R+) - Body ground V-G - Body ground Relay power supply Ignition switch ON 20 to 32 V
S14-2 (GND1) - Body
ground
S14-3 (GND2) - Body
ground
S14-6 (SRM1) - Body Approx. 3 seconds after
B-W - Body ground SRM1 solenoid output 20 to 32 V
S14-8 (SFLH) - Body Front holding solenoid LH Approx. 3 seconds after
LG-B - Body ground 20 to 32 V
S14-9 (SFLR) - Body Front decrease solenoid Approx. 3 seconds after
R-G - Body ground 20 to 32 V
ground LH output turning ignition switch ON
S14-12 (MR) - Body Approx. 3 seconds after
B-O - Body ground Motor relay output 20 to 32 V
S14-13 (D/G) - Body Diagnosis tester
W-L - Body ground Using intelligent tester Communication possible
ground communication line
S14-18 (MT) - Body Approx. 3 seconds after
BR-W - Body ground Motor relay test input Below 1.7 V
S14-20 (SRRH) - Body Rear holding solenoid RH Approx. 3 seconds after
P-G - Body ground 20 to 32 V
S14-21 (SRM2) - Body Approx. 3 seconds after
B-R - Body ground SRM2 solenoid output 20 to 32 V
S14-24 (SR) - Body Approx. 3 seconds after
R-G - Body ground Solenoid relay output Below 3 V
S14-25 (FR-) - Body Front wheel speed sensor
W - Body ground Ignition switch off Below 1 Ω
ground RH (-) input
S14-26 (FR+) - Body Front wheel speed sensor Pulse generation
B - Body ground Vehicle speed input
ground RH (+) input (see waveform 1)
S14-27 (FL+) - Body Front wheel speed sensor Pulse generation
R - Body ground Vehicle speed input
ground LH (+) input (see waveform 1)
S14-28 (FL-) - Body Front wheel speed sensor
G - Body ground Ignition switch off Below 1 Ω
ground LH (-) input
S14-29 (FSS) - Body Front wheel speed sensor
ground shielded ground
S14-30 (SRRR) - Body Rear decrease solenoid Approx. 3 seconds after
LG - Body ground 20 to 32 V
(c) Waveform 1 (Reference): Using an oscilloscope:
Item Condition
Tool setting 1 V/DIV., 2 ms/DIV.
Vehicle condition While driving at approximately 30 km/h (18 mph).
GND
HINT:
As the vehicle speed (tire rotating speed) becomes BC
faster, the cycle becomes shorter and output
voltage larger.
F047509E01
DIAGNOSIS SYSTEM
1. DIAGNOSIS
(a) If the skid control ECU detects a malfunction, the
ABS Warning Brake Warning
ABS warning and the brake warning lights will come
Light: Light:
on to warn the driver.
The table below indicates which lights will come on
when there is a malfunction in a particular function.
C143718E03
Item / Trouble Area ABS EBD

ABS warning light { {
Brake warning light - {
{: Light ON
-: Light OFF
• The DTCs are simultaneously stored in the
memory. The DTCs can be read by connecting
the SST between terminals TC and CG of the
DLC3 and observing the blinking pattern of the
ABS warning light, or by connecting the
intelligent tester.
• This system has a Test Mode (signal check)
function (See page BC-5).
The DTC can be read by connecting the
intelligent tester and observing the blinking
pattern of the ABS warning light.
2. WARNING LIGHT INITIAL CHECK
ABS Warning Brake Warning
NOTICE:
Light: Light:
When releasing the parking brake, set chocks to
hold the vehicle for safety.
HINT:
When the parking brake is applied, the level of the
brake fluid is low or the vacuum is low, the brake
warning light comes on.
C143718E03 (b) When the ignition switch is turned to the ON
position, check that the ABS and brake warning
lights come on for approximately 3 seconds.
HINT:
If the warning light and indicator light check result is
not normal, proceed to troubleshooting for the ABS
and brake warning light circuits.
If the indicator remains on, proceed to
BC troubleshooting for the light circuit below.
ABS warning light circuit (Remains on) BC-100
Brake warning light circuit (Remains on) BC-108
3. SYMPTOM SIMULATION
HINT:
The most difficult case in troubleshooting is when no
symptoms occur. In such cases, a thorough customer
problem analysis must be carried out. Then the same or
similar conditions and environment in which the problem
occurred in the customer's vehicle should be
reproduced. No matter how experienced or skilled a
technician may be, if he proceeds to troubleshooting
without confirming the problem symptoms, he will likely
overlook something important and make a wrong guess
at some points in the repair operation. This leads to a
standstill in troubleshooting.
(a) Vibration method: When vibration seems to be the

major cause.
HINT:
Vibrate Slightly Perform the simulation method only during the
primary check period (for approximately 6 seconds
after the ignition switch is turned to the ON position).
(1) Slightly vibrate the part of the sensor considered
to be the problem cause with your fingers and
check whether the malfunction occurs.
(2) Slightly shake the connector vertically and
horizontally.
HINT:
Shaking the relays too strongly may result in
open relays.
(3) Slightly shake the wire harness vertically and
horizontally. The connector joint and fulcrum of
Shake Slightly the vibration are the major areas to be checked
thoroughly.
DIAGNOSTIC TROUBLE CODE CHART

NOTICE:
Turn the ignition switch off before removing parts.
• If no abnormality is found when inspecting parts, inspect
Vibrate Slightly the skid control ECU and ground points for poor contact.
• If a trouble code is displayed during the DTC check, check
C159239E02 the circuit indicated by the DTC. For details of each code,
refer to the page for the respective "DTC Code" in the DTC
chart.
• When 2 or more DTCs are detected, perform circuit
inspection one by one until the problem is identified.
• Inspect the fuse and relay before investigating the trouble
BC
areas as shown in the table below.
DTC chart of ABS:
DTC Code Detection Item Trouble Area See page
1. Front speed sensor RH
2. Speed sensor circuit
C0200/31 (*1) Front Speed Sensor RH Circuit 3. Speed sensor rotor BC-22
4. Sensor installation
5. Skid control ECU
1. Front speed sensor LH
C0205/32 (*1) Front Speed Sensor LH Circuit 3. Speed sensor rotor BC-22
5. Skid control ECU
1. Rear speed sensor RH
C0210/33 (*1) Rear Speed Sensor RH Circuit 3. Speed sensor rotor BC-29
5. Skid control ECU
1. Rear speed sensor LH
C0215/34 (*1) Rear Speed Sensor LH Circuit 3. Speed sensor rotor BC-29
5. Skid control ECU
1. Brake actuator assembly
C0226/21 SFR Solenoid Circuit 2. SFRH or SFRR circuit BC-36
3. Skid control ECU

C0236/22 SFL Solenoid Circuit 2. SFLH or SFLR circuit BC-36
3. Skid control ECU
C0246/23 SRR Solenoid Circuit 2. SRRH or SRRR circuit BC-36
3. Skid control ECU
C0256/24 SRL Solenoid Circuit 2. SRLH or SRLR circuit BC-36
3. Skid control ECU
1. ABS fuse
2. ABS MTR MAIN relay
C0273/13 Open in ABS Motor Relay Circuit 3. ABS MTR MAIN relay circuit BC-42
5. Skid control ECU
1. ABS fuse
2. ABS MTR MAIN relay
Short to B+ in ABS Motor Relay
C0274/14 3. ABS MTR MAIN relay circuit BC-42
Circuit
5. Skid control ECU
1. ABS SOL fuse
Open in ABS Solenoid Relay 2. ABS SOL MAIN relay
C0278/11 BC-50
Circuit 3. ABS SOL MAIN relay circuit
4. Skid control ECU
1. ABS SOL fuse
Short to B+ in ABS Solenoid 2. ABS SOL MAIN relay
C0279/12 BC-50
Relay Circuit 3. ABS SOL MAIN relay circuit
4. Skid control ECU
C1225/25 SMC Solenoid Circuit 2. SMC1 or SMC2 circuit BC-57
3. Skid control ECU
C1227/27 SRM Solenoid Circuit 2. SRM1 or SRM2 circuit BC-36
3. Skid control ECU
BC C1235/35
Foreign Object is Attached on Tip 2. Speed sensor rotor
BC-60
of Front Speed Sensor RH 3. Sensor installation
4. Skid control ECU
C1236/36 BC-60
of Front Speed Sensor LH 3. Sensor installation
4. Skid control ECU
C1238/38 BC-60
of Rear Speed Sensor RH 3. Sensor installation
4. Skid control ECU
C1239/39 BC-60
of Rear Speed Sensor LH 3. Sensor installation
4. Skid control ECU
1. ECU-IG fuse
2. Battery
3. Charging system
C1241/41 Low Battery Positive Voltage BC-68
4. Power source circuit
5. Internal power supply circuit of
the skid control ECU
1. Master cylinder pressure
sensor
Master Cylinder Pressure Sensor 2. Master cylinder pressure
C1246/46 BC-72
Malfunction sensor circuit
3. Stop light switch circuit
4. Skid control ECU

1. STOP fuse
2. Stop light switch
C1249/49 Open in Stop Light Switch Circuit BC-78
3. Stop light switch circuit
4. Skid control ECU
(Ground circuit)
C1251/51 Open in Pump Motor Circuit 2. Brake actuator assembly BC-87
(Motor circuit)
3. Skid control ECU
1. Vacuum sensor
C1265/65 Vacuum Sensor Malfunction 2. Vacuum sensor circuit BC-90
3. Skid control ECU
1. EXO circuit
Exhaust Retarder Prevention
C1266/66 2. ECM BC-96
Signal Circuit
3. Skid control ECU
(*1): Even after the trouble areas are repaired, the ABS
warning light will not go off unless the following operations
are performed:
1. Drive the vehicle at 20 km/h (12 mph) for 30 seconds or
more and check that the ABS warning light goes off.
2. Clear the DTC.
Test Mode DTC of ABS:
Low Output Signal of Front Speed
C1271/71 2. Sensor installation BC-22
Sensor RH (Test Mode DTC)
3. Speed sensor rotor
Low Output Signal of Front Speed
Sensor LH (Test Mode DTC)
Low Output Signal of Rear Speed
Sensor RH (Test Mode DTC)
BC
Low Output Signal of Rear Speed
Sensor LH (Test Mode DTC)
Abnormal Change in Output
C1275/75 Signal of Front Speed Sensor RH BC-60
(Test Mode DTC)
C1276/76 Signal of Front Speed Sensor LH BC-60
(Test Mode DTC)
C1277/77 Signal of Rear Speed Sensor RH BC-60
(Test Mode DTC)
C1278/78 Signal of Rear Speed Sensor LH BC-60
(Test Mode DTC)
Master Cylinder Pressure Sensor 1. Stop light switch
C1281/81 Output Malfunction (Test Mode 2. Master cylinder pressure BC-72
DTC) sensor
Vacuum Sensor Output
C1285/85 Vacuum sensor BC-90
Malfunction (Test Mode DTC)
DTC C0200/31 Front Speed Sensor RH Circuit
DTC C0205/32 Front Speed Sensor LH Circuit
Low Output Signal of Front Speed Sensor RH

DTC C1271/71
(Test Mode DTC)
Low Output Signal of Front Speed Sensor LH

DTC C1272/72
(Test Mode DTC)
DESCRIPTION
The speed sensors detect wheel speed and transmit the signals to the ECU. These signals are used for
control of the ABS control system. Each of the front and rear rotors has 48 serrations. When the rotors
rotate, the magnetic filed generated by the permanent magnet in the speed sensor induces an AC
voltage.
Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the
frequency is used by the ECU to detect the speed of each wheel.
DTCs C1271/71 and C1272/72 can be deleted when the speed sensor sends a wheel speed signal or the
Test Mode ends. DTCs C1271/71 and C1272/72 are output only in the Test Mode.
Speed Sensor
Rotor N S Magnet
Coil
To ECU
BC Low speed
High speed
+V
-V
F000010E20
DTC Code DTC Detection Condition Trouble Area

When any of the following is detected:
1. At a vehicle speed of 10 km/h (6 mph) or more, an open
or short in the sensor signal circuit continues for 15
seconds or more.
2. Momentary interruption of the sensor signal from the • Front speed sensor RH/LH
abnormal wheel occurs 7 times or more. • Speed sensor circuit
C0200/31
3. An open in the speed sensor signal circuit continues for • Speed sensor rotor
C0205/32
0.5 seconds or more. • Sensor installation
4. When the following condition occurs 4 or more times after • Skid control ECU
the ignition switch is turned off:
The speeds of the front wheels are lower than the rear
wheel speed by 20 km/h (12 mph) or more for 20 seconds
or more.
• Front speed sensor RH/LH
C1271/71
Detected only during Test Mode. • Sensor installation
C1272/72
HINT:
• DTCs C0200/31 and C1271/71 are for the front speed sensor RH.
• DTCs C0205/32 and C1272/72 are for the front speed sensor LH.
WIRING DIAGRAM
26
2 1
S14 FR+
A3 Front Speed Sensor RH
25
S14 FR-
Shielded
29
S14 FSS
27
2 1
S14 FL+
A2 Front Speed Sensor LH
28
S14 FL-
Shielded
Skid Control ECU
BC
C135886E01
1 PERFORM TEST MODE (SIGNAL CHECK)
(a) Perform sensor check in the Test Mode procedure (See

page BC-5).
OK:
All Test Mode DTCs are not output.
NG Go to step 3
OK
2 RECONFIRM DTC

(b) Clear the DTC (See Pub. No. S1-XYZE05A, page 05-
108).
(d) Drive the vehicle at the speed of 20 km/h (12 mph) or

more for at least 30 seconds.
(e) Check if the same DTC is recorded (See Pub. No. S1-
XYZE05A, page 05-108).
Result
Result Proceed to
DTCs (C0200/31 and/or C0205/32) are not output A
DTCs (C0200/31 and/or C0205/32) are output B
HINT:
If troubleshooting has been carried out according to the
Problem Symptoms Table, refer back to the table and
proceed to the next step (See page BC-13).
B Go to step 5
CHECK FOR INTERMITTENT PROBLEMS (SYMPTOM SIMULATION) (See page BC-17)
3 CHECK FRONT SPEED SENSOR INSTALLATION

Front Speed Sensor: (b) Check the speed sensor installation.
OK:
8.0 N*m There is no clearance between the sensor and the
front steering knuckle.
The installation bolt is tightened properly.
BC
NG INSTALL FRONT SPEED SENSOR
CORRECTLY
No clearance
OK NG
C144929E02
OK
4 CHECK FRONT SPEED SENSOR TIP
(a) Remove the front speed sensor (See Pub. No. S1-
(b) Check the speed sensor tip.
OK:
No scratches or foreign matter on the sensor tip.
NOTICE:
Check the speed sensor signal after cleaning or
replacement (See page BC-5).
NG CLEAN OR REPLACE FRONT SPEED

SENSOR
OK
5 INSPECT FRONT SPEED SENSOR

Front Speed Sensor: (b) Install the front speed sensor.
(c) Disconnect the front speed sensor connector.
table below.
1 2
for RH
0.9 to 1.3 kΩ at 20°C
1 (FR+) - 2 (FR-) Always
(68°F)
1 (FR+) - Body ground Always 10 kΩ or higher
2 (FR-) - Body ground Always 10 kΩ or higher
for LH
C151810E01
0.9 to 1.3 kΩ at 20°C
1 (FL+) - 2 (FL-) Always
(68°F)
1 (FL+) - Body ground Always 10 kΩ or higher
2 (FL-) - Body ground Always 10 kΩ or higher
NOTICE:
Check the speed sensor signal after replacement
(See page BC-5). BC
NG REPLACE FRONT SPEED SENSOR
OK
6 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - FRONT SPEED SENSOR)
(a) Disconnect the skid control ECU connector.

Skid Control ECU
Wire Harness View: table below.
for RH
S14-26 (FR+) - A3-1 (FR+) Always Below 1 Ω
S14-26 (FR+) - Body ground Always 10 kΩ or higher
S14-25 (FR-) - A3-2 (FR-) Always Below 1 Ω
S14-25 (FR-) - Body ground Always 10 kΩ or higher
S14-25 (FR-) for LH

S14-26 (FR+) S14-27 (FL+) - A2-1 (FL+) Always Below 1 Ω
S14-27 (FL+) - Body ground Always 10 kΩ or higher
S14-28 (FL-) S14-27 (FL+) S14-28 (FL-) - A2-2 (FL-) Always Below 1 Ω
S14-28 (FL-) - Body ground Always 10 kΩ or higher
Front Speed Sensor Harness Side NG REPAIR OR REPLACE HARNESS OR

Connector Front View:
CONNECTOR
A3 A2
BC
FR- FR+ FL- FL+
C153317E01
OK
7 CHECK SPEED SENSOR AND SPEED SENSOR ROTOR SERRATIONS
(a) Reconnect the skid control ECU connector and the front
speed sensor connector.
Skid Control ECU
Wire Harness View: (b) Connect the oscilloscope to the front speed sensor
terminal of the skid control ECU.
(c) Check that a waveform is output by each sensor circuit
when the tires are rotated.
S14-28 (FL-) S14-25 (FR-) OK:
The same waveform is output from all the 4 wheels
and there is no noise or interference in the
waveform.
HINT:
• As the vehicle speed (wheel revolution speed)
increases, a cycle of the waveform narrows and the
S14-27 (FL+) S14-26 (FR+) output voltage becomes greater.
• When noise is identified in the waveform on the
oscilloscope, the erratic signals are generated due to
speed sensor rotor's scratches, looseness or foreign
Normal Signal Waveform: matter attached to it.
NOTICE:
NG CLEAN OR REPLACE SPEED SENSOR OR
SPEED SENSOR ROTOR
GND
BC
1 V/Division, 2 ms./Division
C153318E01
OK
8 RECONFIRM DTC

108).
Result
Result Proceed to
HINT:
B REPLACE SKID CONTROL ECU
BC
DTC C0210/33 Rear Speed Sensor RH Circuit
DTC C0215/34 Rear Speed Sensor LH Circuit
Low Output Signal of Rear Speed Sensor RH

DTC C1273/73
(Test Mode DTC)
Low Output Signal of Rear Speed Sensor LH

DTC C1274/74
(Test Mode DTC)
DESCRIPTION
control of the ABS control system. Each of the front and rear rotors has 48 serrations.
When the rotors rotate, the magnetic field generated by the permanent magnet in the speed sensor
induces an AC voltage.
DTCs C1273/73 and C1274/74 can be deleted when the speed sensor sends a wheel speed signal or the
Test Mode ends. DTCs C1273/73 and C1274/74 are output only in the Test Mode.
Speed Sensor
Rotor N S Magnet
Coil
To ECU
Low speed BC
High speed
+V
-V
F000010E20

1. At a vehicle speed of 10 km/h (6 mph) or more, an open
• Rear speed sensor RH/LH
or short in the sensor signal circuit continues for 15
• Speed sensor circuit
C0210/33 seconds or more.
C0215/34 2. Momentary interruption of the sensor signal from the
• Sensor installation
abnormal wheel occurs 7 times or more.
• Skid control ECU
3. An open in the speed sensor signal circuit continues for
0.5 seconds or more.
• Rear speed sensor RH/LH
C1273/73
Detected only during Test Mode. • Sensor installation
C1274/74
HINT:
• DTCs C0210/33 and C1273/73 are for the rear speed sensor RH.
• DTCs C0215/34 and C1274/74 are for the rear speed sensor LH.
WIRING DIAGRAM
16
2 1
S13 RR+
A16 Rear Speed Sensor RH
15
S13 RR-
Shielded
24
S13 RSS
22
2 1
S13 RL+
A15 Rear Speed Sensor LH
23
S13 RL-
Shielded
Skid Control ECU
C135886E02
BC INSPECTION PROCEDURE
1 PERFORM TEST MODE (SIGNAL CHECK)
(a) Perform sensor check in the Test Mode procedure (See

page BC-5).
OK:
All Test Mode DTCs are not output.
NG Go to step 3
OK
2 RECONFIRM DTC

108).
Result
Result Proceed to
HINT:
B Go to step 6
3 CHECK REAR SPEED SENSOR INSTALLATION

Rear Speed Sensor: (b) Check the speed sensor installation.
OK:
rear axle carrier.
NG INSTALL REAR SPEED SENSOR
CORRECTLY
BC
No clearance
OK NG
C144929E03
OK
4 CHECK REAR SPEED SENSOR TIP
(a) Remove the rear speed sensor (See Pub. No. S1-
OK:
NOTICE:
NG CLEAN OR REPLACE REAR SPEED
SENSOR
OK
5 INSPECT REAR SPEED SENSOR

Rear Speed Sensor: (b) Install the rear speed sensor.
(c) Disconnect the rear speed sensor connector.
table below.
1 2
for RH
1.4 to 1.8 kΩ at 20°C
1 (RR+) - 2 (RR-) Always
(68°F)
1 (RR+) - Body ground Always 10 kΩ or higher
2 (RR-) - Body ground Always 10 kΩ or higher
for LH
C151810E02
1.4 to 1.8 kΩ at 20°C
1 (RL+) - 2 (RL-) Always
(68°F)
1 (RL+) - Body ground Always 10 kΩ or higher
2 (RL-) - Body ground Always 10 kΩ or higher
NOTICE:
(See page BC-5).
NG REPLACE REAR SPEED SENSOR
OK
BC
6 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - REAR SPEED SENSOR)

Skid Control ECU
table below.
Wire Harness View:
for RH
S13-16 (RR+) - A16-1 (RR+) Always Below 1 Ω
S13-16 (RR+) - Body ground Always 10 kΩ or higher
S13-15 (RR-) - A16-2 (RR-) Always Below 1 Ω
S13-15 (RR-) - Body ground Always 10 kΩ or higher
S13-15 (RR-) for LH

S13-22 (RL+) S13-22 (RL+) - A15-1 (RL+) Always Below 1 Ω
S13-16 (RR+) S13-23 (RL-) S13-22 (RL+) - Body ground Always 10 kΩ or higher
S13-23 (RL-) - A15-2 (RL-) Always Below 1 Ω
S13-23 (RL-) - Body ground Always 10 kΩ or higher
Rear Speed Sensor Harness Side
CONNECTOR
A16 A15
BC
RR- RR+ RL- RL+
C153319E01
OK
(a) Reconnect the skid control ECU connector and the rear
Skid Control ECU speed sensor connector.
Wire Harness View: (b) Connect the oscilloscope to the rear speed sensor
terminal of the skid control ECU.
(c) Check that waveform is output by each sensor circuit
S13-16 (RR+) S13-15 (RR-) OK:
The same waveform is output from all the 4 wheels
and there is no noise or interference in the
waveform.
HINT:
S13-23 (RL-) S13-22 (RL+) output voltage becomes greater.
speed sensor rotor's scratches, looseness or foreign
matter attached to it.
Normal Signal Waveform: NOTICE:
NG CLEAN OR REPLACE SPEED SENSOR OR
SPEED SENSOR ROTOR
GND
BC
C153318E02
OK
8 RECONFIRM DTC

108).
Result
Result Proceed to
HINT:
BC
DTC C0226/21 SFR Solenoid Circuit
DTC C0236/22 SFL Solenoid Circuit
DTC C0246/23 SRR Solenoid Circuit
DTC C0256/24 SRL Solenoid Circuit
DTC C1227/27 SRM Solenoid Circuit

DESCRIPTION
These solenoids turn on when signals are received from the skid control ECU and control the pressure
acting on the wheel cylinders to control the braking force.
C0226/21
C0236/22 • Brake actuator assembly
When AST terminal voltage is 20 to 32 V, an open or short in the
C0246/23 • Solenoid circuit
solenoid circuit continues for 0.05 seconds or more.
C0256/24 • Skid control ECU
C1227/27
BC
WIRING DIAGRAM
3
20
S11 SM1+
SMC1+
2
13
S11 SM1-
SMC1-
5
21
S11 SM2+
SMC2+
4
8
S11 SM2-
SMC2-
6
10
S11 AST
AST
16
18
S11 SFRH
SFRH
8
7
S11 SFRR
SFRR
6
8 BC
S14 SFLH
SFLH
9
12
S14 SFLR
SFLR
20
19
S14 SRRH
SRRH
C135891E01
30
14
S14 SRRR
SRRR
7
22
S11 SRLH
SRLH
1
15
S11 SRLR
SRLR
6
5
S14 SRM1
SRM1
21
23
S14 SRM2
SRM2
16
BS
S22 Brake Actuator
1 2 1 2 1 2 5 3
ALT ABS ABS SOL
1
FL MAIN 1 2
S14 R+
ABS SOL MAIN

BC
Battery 24
S14 SR
Battery
Skid Control ECU
C135893E01
HINT:
When C0278/11 and/or C0279/12 is output together with C0226/21, C0236/22, C0246/23, C0256/24, and/
or C1227/27, inspect and repair the trouble areas indicated by C0278/11 and/or C0279/12 first (See page
BC-50).
1 INSPECT BRAKE ACTUATOR ASSEMBLY
(a) Disconnect the brake actuator connector.

Brake Actuator: (b) Measure the resistance according to the value(s) in the
table below.
Standard resistance
SRLR SFRR SFLH SRM1 BS
31.7 to 35.7 Ω at 25°C
16 (BS) - 18 (SFRH) Always
(77°F)
18 (SFRH) - Body
ground
31.7 to 35.7 Ω at 25°C
16 (BS) - 6 (SFLH) Always
(77°F)
6 (SFLH) - Body ground Always 10 kΩ or higher
31.7 to 35.7 Ω at 25°C
16 (BS) - 19 (SRRH) Always
SFRH (77°F)
SRRR
SRM2 SRLH SFLR SRRH 19 (SRRH) - Body
C135895E01 ground
31.7 to 35.7 Ω at 25°C
16 (BS) - 22 (SRLH) Always
(77°F)
22 (SRLH) - Body
ground
15.9 to 17.9 Ω at 25°C
16 (BS) - 7 (SFRR) Always
(77°F)
7 (SFRR) - Body ground Always 10 kΩ or higher
15.9 to 17.9 Ω at 25°C
16 (BS) - 12 (SFLR) Always
(77°F)
12 (SFLR) - Body
ground
15.9 to 17.9 Ω at 25°C
16 (BS) - 14 (SRRR) Always
(77°F)
BC
14 (SRRR) - Body
ground
15.9 to 17.9 Ω at 25°C
16 (BS) - 15 (SRLR) Always
(77°F)
15 (SRLR) - Body
ground
20.5 to 23.5 Ω at 25°C
16 (BS) - 5 (SRM1) Always
(77°F)
5 (SRM1) - Body ground Always 10 kΩ or higher
20.5 to 23.5 Ω at 25°C
16 (BS) - 23 (SRM2) Always
(77°F)
23 (SRM2) - Body
ground
NG REPLACE BRAKE ACTUATOR ASSEMBLY

(See page BC-127)
OK
2 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - BRAKE ACTUATOR)
(a) Disconnect the skid control ECU connectors.

Skid Control ECU (b) Measure the resistance according to the value(s) in the
Standard resistance
S11-16 (SFRH) - S22-18
Always Below 1 Ω
(SFRH)
S11-16 (SFRH) - Body
ground
S14-9 S11-1
S11-8 (SFRR) - S22-7
(SFLR) S14-6 (SRLR) Always Below 1 Ω
(SRM1) (SFRR)
S11-8 S11-8 (SFRR) - Body

S14-21 S14-8 Always 10 kΩ or higher
(SFRR) ground
(SMR2) (SFLH)
S14-8 (SFLH) - S22-6
S14-20 S11-7 Always Below 1 Ω
S14-30 S11-16 (SFLH)
(SRRR) (SRRH) (SRLH) (SFRH)
S14-8 (SFLH) - Body
ground
Brake Actuator Harness Side S14-9 (SFLR) - S22-12
Always Below 1 Ω
Connector Front View: (SFLR)
S14-9 (SFLR) - Body
ground
S14-20 (SRRH) - S22-19
Always Below 1 Ω
SFLR SRM1 SFLH SFRR SRLR (SRRH)
S22 S14-20 (SRRH) - Body
ground
S14-30 (SRRR) - S22-14
Always Below 1 Ω
(SRRR)
S14-30 (SRRR) - Body
BC ground
S11-7 (SRLH) - S22-22

Always Below 1 Ω
(SRLH)
SFRH SRRH SRLH SRM2 SRRR S11-7 (SRLH) - Body

ground
C153320E01 S11-1 (SRLR) - S22-15
Always Below 1 Ω
(SRLR)
S11-1 (SRLR) - Body
ground
S14-6 (SRM1) - S22-5
Always Below 1 Ω
(SRM1)
S14-6 (SRM1) - Body
ground
S14-21 (SRM2) - S22-23
Always Below 1 Ω
(SRM2)
S14-21 (SRM2) - Body
ground

CONNECTOR
OK
3 RECONFIRM DTC
(a) Reconnect the skid control ECU connectors and the

brake actuator connector.
108).
(d) Drive the vehicle at a speed of 20 km/h (12 mph) or more
for 30 seconds or more.
Result
Result Proceed to
DTCs (C0226/21, C0236/22, C0246/23, C0256/24 and/or C1227/27) are not output A
DTCs (C0226/21, C0236/22, C0246/23, C0256/24 and/or C1227/27) are output B
HINT:
• If a speed signal of 6 km/h (4 mph) or more is input to
the skid control ECU, with the ignition switch ON and
the stop light switch off, the ECU performs self
diagnosis of the motor and solenoid circuits.
• If the normal system code is output (the trouble code
is not output), slightly jiggle the connectors, wire
harness, and fuses of the skid control ECU and brake
actuator assembly. Make sure that no DTCs are
output.
• If any DTCs are output while jiggling a connector or
wire harness of the skid control ECU and brake
actuator assembly, inspect and repair the connector BC
or wire harness.
• It is suspected that the DTCs were output due to a
bad connection of the connector terminal.

DTC C0273/13 Open in ABS Motor Relay Circuit
DTC C0274/14 Short to B+ in ABS Motor Relay Circuit

DESCRIPTION
While the ABS is operating, the skid control ECU turns the ABS MTR MAIN relay on and activates the
pump motor in the brake actuator.
These codes may be stored if the motor relay (BM) voltage becomes lower than a specified level due to
insufficient output from the battery or alternator.
When either of the following is detected:
• ABS fuse
1. When IG1 terminal voltage is 20 to 32 V, the relay contact
• ABS MTR MAIN relay
is OFF (MT terminal voltage is less than 2 V) for 0.2
C0273/13 • ABS MTR MAIN relay circuit
seconds or more.
• Brake actuator assembly
2. IG1 terminal voltage lowers due to turning the relay ON,
and the relay contact is not ON for 0.2 seconds or more.
When either of the following is detected: • ABS fuse
1. When the relay is OFF, the relay contact is ON (MT • ABS MTR MAIN relay
C0274/14 terminal voltage is 2 V or more) for 4 seconds or more. • ABS MTR MAIN relay circuit
2. When the relay is OFF, an open in the MT terminal • Brake actuator assembly
continues for 4 seconds or more. • Skid control ECU
BC
WIRING DIAGRAM
2 3 5
BM 12
1 2
S14 MR
ABS MTR MAIN 2

ABS
1
1
S14 R+
2
ALT
1
18
3
S14 MT
MT
FL MAIN
Battery
1
GND BC
Battery
S22 Brake Actuator

Skid Control ECU
C135892E01
1 INSPECT ABS FUSE
(a) Remove the ABS fuse from the No. 2 relay block.
No. 2 Relay Block: (b) Measure the resistance according to the value(s) in the
table below.
Standard resistance
ABS (50 A) fuse Always Below 1 Ω
NG REPLACE ABS FUSE
ABS Fuse
C151806E01
OK
2 INSPECT ABS MOTOR RELAY (ABS MTR MAIN)
(a) Install the ABS fuse.

ABS MTR MAIN Relay: (b) Remove the ABS MTR MAIN relay.
table below.
BC Standard resistance
Voltage is not applied
3-5 between terminals 1 10 kΩ or higher
and 2
Apply the battery
3-5 voltage between Below 1 Ω
terminals 1 and 2
NG REPLACE ABS MOTOR RELAY (ABS MTR

MAIN)
C144829E04
OK
3 INSPECT NO. 2 RELAY BLOCK (POWER SOURCE TERMINAL)

table below.
No. 2 Relay Block:
Standard voltage
ABS MTR MAIN relay
ground

CONNECTOR (POWER SOURCE CIRCUIT)
ABS MTR MAIN Relay

C153587E01
OK

table below.
Standard resistance
MT BM
2 (BM) - 3 (MT) Always 31.3 to 34.7 Ω BC
3 (MT) - Body ground Always 10 kΩ or higher

(See page BC-127)
C135895E02
OK
5 CHECK HARNESS AND CONNECTOR (BRAKE ACTUATOR - NO. 2 RELAY BLOCK)
(a) Measure the resistance according to the value(s) in the

Brake Actuator Harness Side table below.
Connector Front View: Standard resistance
S22-2 (BM) - ABS MTR
Always Below 1 Ω
MAIN relay terminal 3
S22 S22-2 (BM) - Body
ground

CONNECTOR
BM
No. 2 Relay Block:
BC
ABS MTR MAIN Relay
C153333E01
OK

Skid Control ECU
Standard resistance
S14-18 (MT) - S22-3 (MT) Always Below 1 Ω
S14-18 (MT) - Body
ground

CONNECTOR
S14-18 (MT)
Brake Actuator Harness Side

S22
BC
MT
C153321E01
OK
7 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - NO. 2 RELAY BLOCK)

table below.
Skid Control ECU
Wire Harness View:
Standard resistance
S14-12 (MR) - ABS MTR
Always Below 1 Ω
S14-12 (MR) - Body ground Always 10 kΩ or higher
S14-1 (R+) - ABS MTR MAIN
Always Below 1 Ω
relay terminal 1
S14-1 (R+) - Body ground Always 10 kΩ or higher
S14-1 (R+) NG REPAIR OR REPLACE HARNESS OR

CONNECTOR
S14-12 (MR)
No. 2 Relay Block:
BC
ABS MTR MAIN Relay
C153334E01
OK
8 RECONFIRM DTC
(a) Clear the DTC (See Pub. No. S1-XYZE05A, page 05-
108).
(c) Drive the vehicle at a speed of 20 km/h (12 mph) or more
(d) Check if the same DTC is recorded (See Pub. No. S1-
HINT:
Reinstall the relays, connectors, etc. and restore the
vehicle to its prior condition before rechecking for DTCs.
Result
Result Proceed to
HINT:
output.
actuator assembly, inspect and repair the connector
or wire harness.
BC
DTC C0278/11 Open in ABS Solenoid Relay Circuit
DTC C0279/12 Short to B+ in ABS Solenoid Relay Circuit

DESCRIPTION
The ABS solenoid relay supplies power to the ABS solenoid.
The solenoid relay is turned on 1.5 seconds after the ignition switch is turned to the ON position, and is
turned off if an open or short in the solenoid is detected by self diagnosis performed when the vehicle
starts running.
HINT:
If a speed signal of 6 km/h (4 mph) or more is input to the skid control ECU, with the ignition switch ON
and the stop light switch off, the ECU performs self diagnosis of the motor and solenoid circuits.
• ABS SOL fuse
1. When IG1 terminal voltage is 20 to 32 V, the relay contact is OFF
• ABS SOL MAIN relay
C0278/11 (AST terminal voltage is less than 4.8 V) for 0.2 seconds or more.
• ABS SOL MAIN relay circuit
2. IG1 terminal voltage lowers due to turning the relay ON, and the
relay contact is not ON for 0.2 seconds or more.
• ABS SOL fuse
Immediately after the ignition switch is turned to the ON position, the
• ABS SOL MAIN relay
C0279/12 solenoid relay contact is closed (AST terminal voltage is 4.8 V or
• ABS SOL MAIN relay circuit
more) for 0.2 seconds when the relay is turned off.
WIRING DIAGRAM
Refer to DTCs C0226/21, C0236/22, C0246/23, C0256/24 and C1227/27 (See page BC-37).
BC 1 INSPECT ABS SOL FUSE
(a) Remove the ABS SOL fuse from the No. 2 relay block.
table below.
Standard resistance
ABS SOL (30 A) fuse Always Below 1 Ω
NG REPLACE ABS SOL FUSE
ABS SOL Fuse
C151806E02
OK
2 INSPECT ABS SOLENOID RELAY (ABS SOL MAIN)
(a) Install the ABS SOL fuse.

ABS SOL MAIN Relay: (b) Remove the ABS SOL MAIN relay.
table below.
Standard resistance
Voltage is not applied
3-5 between terminals 1 10 kΩ or higher
and 2
Apply the battery
3-5 voltage between Below 1 Ω
terminals 1 and 2
NG REPLACE ABS SOLENOID RELAY (ABS SOL

MAIN)
C144829E05
OK
3 INSPECT NO. 2 RELAY BLOCK (POWER SOURCE TERMINAL)

No. 2 Relay Block: table below.
Standard voltage
ABS SOL MAIN relay
terminal 5 - Body Always 20 to 32 V BC
ground

ABS SOL MAIN Relay

C153599E01
OK

table below.
Standard resistance
16 (BS) - 10 (AST) Always Below 1 Ω
10 (AST) - Body ground Always 10 kΩ or higher

(See page BC-127)
AST BS
C135895E03
OK
BC
5 CHECK HARNESS AND CONNECTOR (BRAKE ACTUATOR - NO. 2 RELAY BLOCK)

Brake Actuator Harness Side table below.
Connector Front View: Standard resistance
S22-16 (BS) - ABS SOL
Always Below 1 Ω
S22 S22-16 (BS) - Body
ground

CONNECTOR
BS
No. 2 Relay Block:
BC
ABS SOL MAIN Relay
C153336E01
OK

Skid Control ECU
table below.
Wire Harness View:
Standard resistance
S11-6 (AST) - S22-10
Always Below 1 Ω
(AST)
S11-6 (AST) - Body
ground

CONNECTOR
S11-6 (AST)
Brake Actuator Harness Side

S22
BC
AST
C153323E01
OK
7 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - NO. 2 RELAY BLOCK)

Standard resistance
S14-1 (R+) - ABS SOL
Always Below 1 Ω
S14-1 (R+) - Body
ground
S14-24 (SR) - ABS SOL
Always Below 1 Ω
S14-1 (R+) S14-24 (SR) - Body
ground
S14-24 (SR)
CONNECTOR
No. 2 Relay Block:
BC
ABS SOL MAIN Relay
C153322E01
OK
8 RECONFIRM DTC
(a) Clear the DTC (See Pub. No. S1-XYZE05A, page 05-
108).
HINT:
Reinstall the relays, connectors, etc. and restore the
vehicle to its prior condition before rechecking for DTCs.
Result
Result Proceed to
HINT:
output.
or wire harness.
BC
DTC C1225/25 SMC Solenoid Circuit

DESCRIPTION
1. When AST terminal voltage is 34 V or less, overcurrent
continues for 0.05 seconds or more.
2. While outputting solenoid OFF, an open circuit continues for
3. When AST terminal voltage is 19 V or more and current does
• Brake actuator assembly
not fluctuate, there is a difference in operation between SMC1
C1225/25 • SMC1 or SMC2 circuit
and SMC2 for 0.2 seconds or more.
4. When AST terminal voltage is 19 V or more, a short in the
SMC1 or SMC2 solenoid circuit continues for 0.1 second or
more.
5. When AST terminal voltage is 19 V or more and current that
exceeds a specified level is applied, current that is lower than
the specified level is monitored for 0.1 second.
WIRING DIAGRAM
Refer to DTCs C0226/21, C0236/22, C0246/23, C0256/24 and C1227/27 (See page BC-37).

table below.
Standard resistance
SMC2- SMC1- AST
BC
16 (BS) - 10 (AST) Always Below 1 Ω
10 (AST) - Body ground Always 10 kΩ or higher
31.7 to 35.7 Ω at 25°C
20 (SMC1+) - 13 (SMC1-) Always
(77°F)
13 (SMC1-) - Body
ground
31.7 to 35.7 Ω at 25°C
21 (SMC2+) - 8 (SMC2-) Always
(77°F)
BS 8 (SMC2-) - Body
SMC2+ SMC1+ ground
C135895E04

(See page BC-127)
OK

Skid Control ECU
table below.
Wire Harness View:
Standard resistance
S11-6 (AST) - S22-10
Always Below 1 Ω
(AST)
S11-6 (AST) - Body
ground
S11-3 (SM1+) - S22-20
Always Below 1 Ω
(SMC1+)
S11-6 (AST)
S11-2 S11-3 (SM1+) - Body
(SM1-) ground
S11-5 (SM2+)
S11-2 (SM1-) - S22-13
Always Below 1 Ω
(SMC1-)
S11-4 (SM2-) S11-3 (SM1+)
S11-2 (SM1-) - Body
ground
S11-5 (SM2+) - S22-21
Brake Actuator Harness Side Always Below 1 Ω
(SMC2+)
S11-5 (SM2+) - Body
ground
SMC1- SMC2- S11-4 (SM2-) - S22-8

Always Below 1 Ω
(SMC2-)
S22
S11-4 (SM2-) - Body
ground
S11-3 (SM1+) - S11-2
(SM1-)
S11-3 (SM1+) - S11-4
BC (SM2-)
S11-5 (SM2+) - S11-2

(SM1-)
S11-5 (SM2+) - S11-4
AST SMC1+ SMC2+ Always 10 kΩ or higher
(SM2-)
C153323E02 S11-3 (SM1+) - S11-5
(SM2+)
S11-2 (SM1-) - S11-4
(SM2-)

CONNECTOR
OK
3 RECONFIRM DTC
(a) Reconnect the skid control ECU connector and the brake
actuator connector.
108).
(d) Drive the vehicle at a speed of 20 km/h (12 mph) or more
Result
Result Proceed to
DTC (C1225/25) is not output A
DTC (C1225/25) is output B
HINT:
output.
or wire harness.

BC
Foreign Object is Attached on Tip of Front

DTC C1235/35
Speed Sensor RH
Foreign Object is Attached on Tip of Front

DTC C1236/36
Speed Sensor LH
Foreign Object is Attached on Tip of Rear

DTC C1238/38
Speed Sensor RH
Foreign Object is Attached on Tip of Rear

DTC C1239/39
Speed Sensor LH
Abnormal Change in Output Signal of Front

DTC C1275/75
Speed Sensor RH (Test Mode DTC)
Abnormal Change in Output Signal of Front

DTC C1276/76
Speed Sensor LH (Test Mode DTC)
Abnormal Change in Output Signal of Rear

DTC C1277/77
Speed Sensor RH (Test Mode DTC)
Abnormal Change in Output Signal of Rear

DTC C1278/78
BC Speed Sensor LH (Test Mode DTC)
DESCRIPTION
control of the ABS control system. Each of the front and rear rotors has 48 serrations. When the rotors
rotate, the magnetic field generated by the permanent magnet in the speed sensor induces an AC
voltage.
When foreign matter adheres to the speed sensor tip or speed sensor rotor, or the rotor teeth are chipped,
these DTCs are output. An abnormal waveform input from the sensor determines these conditions.
These DTCs may be detected when a malfunction occurs in the connector terminals or wire harness of
the speed sensor circuit.
DTCs C1275/75 to C1278/78 can be deleted when the speed sensor sends a vehicle speed signal or the
Test Mode ends. DTCs from C1275/75 to C1278/78 are output only in the Test Mode.
Speed Sensor
Rotor N S Magnet
Coil
To ECU
Low speed
High speed
+V
-V
F000010E20

1. At a vehicle speed of 20 km/h (12 mph) or more, noise
C1235/35 • Speed sensor
occurs in the sensor signal from the abnormal wheel for
C1236/36 • Speed sensor rotor
5 seconds or more.
C1238/38 • Sensor installation
2. When the vehicle starts off, the condition that the speed
C1239/39 • Skid control ECU
of any wheel is 7 km/h (4.3 mph) or more occurs 3 times
or more.
C1275/75
C1276/76 • Speed sensor
Detected only during Test Mode.
C1277/77 • Speed sensor rotor
C1278/78
HINT:
• DTCs C1235/35 and C1275/75 are for the front speed sensor RH.
• DTCs C1236/36 and C1276/76 are for the front speed sensor LH.
• DTCs C1238/38 and C1277/77 are for the rear speed sensor RH. BC
• DTCs C1239/39 and C1278/78 are for the rear speed sensor LH.
WIRING DIAGRAM
26
2 1
S14 FR+
A3 Front Speed Sensor RH
25
S14 FR-
Shielded
29
S14 FSS
27
2 1
S14 FL+
A2 Front Speed Sensor LH
28
S14 FL-
Shielded
16
2 1
S13 RR+
A16 Rear Speed Sensor RH
15
S13 RR-
Shielded
24
BC S13 RSS
22
2 1
S13 RL+
A15 Rear Speed Sensor LH
23
S13 RL-
Shielded
Skid Control ECU
C135887E01
HINT:
When C0200/31, C0205/32, C0210/33, and/or C0215/34 is output together with C1235/35, C1236/36,
C1238/38, and/or C1239/39, inspect and repair the trouble areas indicated by C0200/31, C0205/32,
C0210/33, and/or C0215/34 first (See page BC-22 for front, or BC-29 for rear).
(a) Connect the oscilloscope to each speed sensor terminal

of the skid control ECU.
Skid Control ECU
Wire Harness View: (b) Check that a waveform is output by each sensor circuit
OK:
S14-26 S14-25 S13-16 S13-15 The same waveform is output from all the 4 wheels
(FR+) (FR-) (RR+) (RR-) and there is no noise or waveform.
(c) Check that the waveform does not change while jiggling
a connector or a wire harness.
OK:
The waveform does not change.
HINT:
S14-28 S14-27 S13-23 S13-22
(FL-) (FL+) (RL-) (RL+) output voltage becomes greater.
Normal Signal Waveform: speed sensor rotor's scratches, looseness or foreign
matter attached to it.
NG Go to step 3
GND
BC
C153318E03
OK
2 RECONFIRM DTC

108).
Result
Result Proceed to
DTCs (C1235/35, C1236/36, C1238/38 and/or C1239/39) are not output A
DTCs (C1235/35, C1236/36, C1238/38 and/or C1239/39) are output B
3 INSPECT EACH SPEED SENSOR

Speed Sensor: (b) Disconnect each speed sensor connector.
table below.
for RH
1 2
0.9 to 1.3 kΩ at 20°C
1 (FR+) - 2 (FR-) Always
(68°F)
1 (FR+) - Body ground Always 10 kΩ or higher
2 (FR-) - Body ground Always 10 kΩ or higher
1.4 to 1.8 kΩ at 20°C
1 (RR+) - 2 (RR-) Always
(68°F)
1 (RR+) - Body ground Always 10 kΩ or higher
C151810E04
2 (RR-) - Body ground Always 10 kΩ or higher
for LH
0.9 to 1.3 kΩ at 20°C
1 (FL+) - 2 (FL-) Always
BC (68°F)
1 (FL+) - Body ground Always 10 kΩ or higher
2 (FL-) - Body ground Always 10 kΩ or higher
1.4 to 1.8 kΩ at 20°C
1 (RL+) - 2 (RL-) Always
(68°F)
1 (RL+) - Body ground Always 10 kΩ or higher
2 (RL-) - Body ground Always 10 kΩ or higher
NOTICE:
(See page BC-5).
NG REPLACE EACH SPEED SENSOR
OK
4 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - EACH SPEED SENSOR)
(a) Disconnect the skid control ECU connectors.

Skid Control ECU Wire Harness View:
table below.
for RH
S14-26 (FR+) - A3-1 (FR+) Always Below 1 Ω
S13-16 (RR+)
S14-26 (FR+) - Body ground Always 10 kΩ or higher
S13-15 (RR-) S14-25 (FR-) - A3-2 (FR-) Always Below 1 Ω
S13-22 (RL+) S14-25 (FR-) - Body ground Always 10 kΩ or higher

S13-16 (RR+) - A16-1 (RR+) Always Below 1 Ω
S13-23 (RL-)
S13-16 (RR+) - Body ground Always 10 kΩ or higher
S14-28 (FL-) S14-25 (FR-)
S13-15 (RR-) - A16-2 (RR-) Always Below 1 Ω
S14-27 (FL+) S14-26 (FR+) S13-15 (RR-) - Body ground Always 10 kΩ or higher
Front Speed Sensor Harness Side
for LH
S14-27 (FL+) - A2-1 (FL+) Always Below 1 Ω
A3 A2 S14-27 (FL+) - Body ground Always 10 kΩ or higher

S14-28 (FL-) - A2-2 (FL-) Always Below 1 Ω
S14-28 (FL-) - Body ground Always 10 kΩ or higher
S13-22 (RL+) - A15-1 (RL+) Always Below 1 Ω
S13-22 (RL+) - Body ground Always 10 kΩ or higher
FR- FR+ FL- FL+ S13-23 (RL-) - A15-2 (RL-) Always Below 1 Ω
S13-23 (RL-) - Body ground Always 10 kΩ or higher
Rear Speed Sensor Harness Side BC
CONNECTOR
A16 A15
RR- RR+ RL- RL+

C153325E01
OK
5 RECONFIRM DTC

speed sensor connector.
108).
Result
Result Proceed to
DTCs (C1235/35, C1236/36, C1238/38 and/or C1239/39) are output A
DTCs (C1235/35, C1236/36, C1238/38 and/or C1239/39) are not output B

(SYMPTOM SIMULATION) (See page BC-17)
6 CHECK EACH SPEED SENSOR INSTALLATION

Speed Sensor: (b) Check the speed sensor installation.
OK:
front steering knuckle (for front) or rear axle carrier
(for rear).
NG INSTALL EACH SPEED SENSOR
CORRECTLY
No clearance
OK NG
BC C144929E05
OK
7 CHECK EACH SPEED SENSOR TIP
(a) Remove each speed sensor (See Pub. No. S1-

XYZE05A, page 32-91 for front, or 32-92 for rear).
OK:
NOTICE:
NG CLEAN OR REPLACE EACH SPEED
SENSOR
OK
8 CHECK EACH SPEED SENSOR ROTOR

(b) Remove each speed sensor rotor (See Pub. No. S1-
XYZE05A, page 30-34 for front, or chapter AH for rear).
(c) Check the speed sensor rotor.
OK:
No scratches, missing teeth, or foreign matter on
the rotors.
NOTICE:
NG CLEAN OR REPLACE EACH SPEED
SENSOR ROTOR
OK
9 RECONFIRM DTC
(a) Install the speed sensor and the speed sensor rotor.
108).
Result
Result Proceed to
DTCs (C1235/35, C1236/36, C1238/38 and/or C1239/39) are not output A
DTCs (C1235/35, C1236/36, C1238/38 and/or C1239/39) are output B
BC

DTC C1241/41 Low Battery Positive Voltage

DESCRIPTION
If a malfunction is detected in the power supply circuit, the skid control ECU stores this DTC and the fail
safe function prohibits ABS operation.
This DTC is stored when the IG1 terminal voltage deviates from the DTC detection condition due to a
malfunction in the power supply or charging circuit such as the battery or alternator circuit, etc.
The DTC is cancelled when the IG1 terminal voltage returns to normal.
1. At a vehicle speed of 3 km/h (2 mph) or more, the IG1
terminal voltage is 19 V or less for 10 seconds or more.
2. IG1 terminal voltage is 34 V or more for 1.2 seconds or • ECU-IG fuse
more. • Battery
C1241/41 3. When IG1 terminal voltage is 19 V or less, the detection • Charging system
condition for an open in the solenoid relay or motor relay • Power source circuit
is met. • Internal power supply circuit of the skid control ECU
4. When AST terminal voltage is 19 V or less, the detection
condition for a solenoid malfunction is met for 0.5
seconds or more.
WIRING DIAGRAM
7
1 2 9 10 1 2
S13 IG1
AM1 AM1 IG1 ECU-IG
BC I6 Ignition Switch
2
S14 GND1
FL MAIN
3
S14 GND2
15
S11 GND3
Battery 14
S11 GND4
Battery
Skid Control ECU
C151227E01
1 INSPECT ECU-IG FUSE
(a) Remove the ECU-IG fuse from the No. 1 relay block.
table below.
Standard resistance
ECU-IG (15 A) fuse Always Below 1 Ω
NG REPLACE ECU-IG FUSE
ECU-IG Fuse
C151807E01
OK
2 CHECK BATTERY
(a) Install the ECU-IG fuse.

(b) Check the battery voltage.
Standard voltage:
20 to 32 V BC
NG CHECK OR REPLACE CHARGING SYSTEM
OR BATTERY (See chapter CH)
OK
3 INSPECT SKID CONTROL ECU (IG1 TERMINAL)

Skid Control ECU
Wire Harness View:
table below.
Standard voltage
S13-7 (IG1) - Body
Ignition switch ON 20 to 32 V
ground

CONNECTOR (IG1 CIRCUIT)
S13-7 (IG)
C135876E01
OK
4 INSPECT SKID CONTROL ECU (GND TERMINAL)

Skid Control ECU (b) Disconnect the skid control ECU connectors.
Wire Harness View: (c) Measure the resistance according to the value(s) in the
table below.
Standard resistance
BC Tester Connection Condition Specified Condition
S14-2 (GND1) - Body
Always Below 1 Ω
ground
S14-3 (GND2) - Body
Always Below 1 Ω
ground
Always Below 1 Ω
ground
S14-3 S14-2 S11-15 S11-14 Always Below 1 Ω
ground
(GND2) (GND1) (GND3) (GND4)
C135878E01
CONNECTOR (GND CIRCUIT)
OK
5 RECONFIRM DTC
(a) Reconnect the skid control ECU connectors.

108).
(c) Drive the vehicle at the speed of 3 km/h (2 mph) or more
Result
Result Proceed to
HINT:
BC
DTC C1246/46 Master Cylinder Pressure Sensor Malfunction
Master Cylinder Pressure Sensor Output Mal-

DTC C1281/81
function (Test Mode DTC)
DESCRIPTION
DTC C1281/81 can be deleted when the master cylinder pressure sensor sends a master cylinder
pressure signal or the Test Mode ends. DTC C1281/81 is output only in the Test Mode.
1. When IG1 terminal voltage is 20 to 32 V, VCM terminal
voltage is not between 4.3 and 5.8 V for 1.2 seconds or
more.
2. PMC terminal voltage is not between 0.14 and 4.75 V for
3. With the stop light switch off, either of the following
continues for 5 seconds or more:
• Master cylinder pressure sensor circuit
C1246/46 – Vehicle speed is 10 km/h (6 mph) or more and PMC
• Stop light switch circuit
voltage is 0.86 V or more.
– PMC voltage is less than 0.3 V.
4. At a vehicle speed of 7 km/h (4.3 mph) or more, PMC
terminal voltage does not change by 0.01 V or more for
30 seconds or more.
5. At a vehicle speed of 10 km/h (6 mph) or more, noise
occurs in PMC terminal voltage at least 7 times for 5
seconds.
• Stop light switch
C1281/81 Detected only during Test Mode.
BC
WIRING DIAGRAM
24
3
VCM S12 VCM
25
2
PMC S12 PMC1
15
1
E2 S12 E2
14
S12 PSS
Shielded
M1 Master Cylinder
Pressure Sensor
1
1 2 2 1
From Battery S13 STP
STOP
S15 Stop Light Switch
Skid Control ECU BC
C151237E01
1 CHECK STOP LIGHT OPERATION
(a) Check that the stop light comes on when the brake pedal
is depressed, and goes off when the brake pedal is
released.
OK
Condition Illumination Condition
Brake pedal depressed ON
Brake pedal released OFF
NG INSPECT STOP LIGHT CIRCUIT
OK
2 RECONFIRM DTC

108).
(d) At a speed of 10 km/h (6 mph) or more, drive the vehicle
and perform braking test (decelerate the vehicle by
depressing the brake pedal).
Result
Result Proceed to
3 INSPECT MASTER CYLINDER PRESSURE SENSOR

Master Cylinder Pressure Sensor: table below.
BC Standard voltage
3 (VCM) - 1 (E2) Ignition switch ON 4.75 to 5.25 V
VCM
(b) Install the hydro LSPV gauge (SST) and bleed air.
PMC table below.
Standard voltage
Fluid Pressure
E2 MPa (kgf/cm2, psi)
2 (PMC) - 1 (E2) 0 (0, 0) 0.5 V
C151814E01 2 (PMC) - 1 (E2) 9.8 (100, 1422) 2.5 V

2 (PMC) - 1 (E2) 19.6 (200, 2844) 4.5 V
NOTICE:
Check the master cylinder pressure sensor signal
after replacement (See page BC-5)
NG REPLACE MASTER CYLINDER PRESSURE
SENSOR
OK
4 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - MASTER CYLINDER

PRESSURE SENSOR)

Skid Control ECU (b) Disconnect the skid control ECU connector and the
Wire Harness View: master cylinder pressure sensor connector.
table below.
Standard resistance
S12-24 (VCM) - M1-3 (VCM) Always Below 1 Ω
S12-24 (VCM) - Body ground Always 10 kΩ or higher
S12-25 (PMC1) - M1-2 (PMC) Always Below 1 Ω
S12-25 (PMC1) - Body
ground
S12-15 (E2)
S12-25 (PMC1) S12-15 (E2) - M1-1 (E2) Always Below 1 Ω
S12-15 (E2) - Body ground Always 10 kΩ or higher
S12-24 (VCM)

Master Cylinder Pressure Sensor
CONNECTOR
Harness Side Connector Front View:
M1 BC
C153330E02
OK
5 INSPECT SKID CONTROL ECU (SENSOR INPUT)
(a) Reconnect the skid control ECU connector.

Skid Control ECU (b) Turn the ignition switch to the ON position.
Wire Harness View: (c) Measure the voltage according to the value(s) in the
table below.
Standard voltage
S12-24 (VCM) - Body
Ignition switch ON 4.75 to 5.25 V
ground
NG REPLACE SKID CONTROL ECU
S12-24 (VCM)
C135872E01
OK
6 INSPECT SKID CONTROL ECU (SENSOR OUTPUT)

Skid Control ECU (b) Reconnect the master cylinder pressure sensor
Wire Harness View: connector.
BC table below.
Standard voltage
S12-25 (PMC1) - Body Ignition switch ON, brake
0.3 to 0.7 V
ground pedal released
NOTICE:
S12-25 (PMC1) Check the master cylinder pressure sensor signal
after replacement (See page BC-5)
C135872E02 NG REPLACE MASTER CYLINDER PRESSURE

SENSOR
OK
7 RECONFIRM DTC

108).
(d) At a speed of 10 km/h (6 mph) or more, drive the vehicle
depressing the brake pedal).
Result
Result Proceed to
8 INSPECT SKID CONTROL ECU (STP TERMINAL)

Skid Control ECU (b) Disconnect the skid control ECU connector.
table below.
Standard voltage
Specified
Tester Connection Switch Condition
Condition
S13-1 (STP) - Body Stop light switch ON (Brake
16 to 32 V
ground pedal depressed)
S13-1 (STP) - Body Stop light switch OFF (Brake
Below 3 V
ground pedal released)
NG REPAIR OR REPLACE HARNESS OR BC

S13-1 (STP) CONNECTOR (STP CIRCUIT)
C135876E02
OK
REPLACE SKID CONTROL ECU

DTC C1249/49 Open in Stop Light Switch Circuit

DESCRIPTION
The skid control ECU inputs the stop light switch signal and the condition of brake operation.
The skid control ECU has an open detection circuit, which outputs this DTC when detecting an open in the
stop light input line while the stop light switch is OFF.
• STOP fuse
When IG1 terminal voltage is 20 to 32 V, an open circuit of the • Stop light switch
C1249/49
stop light switch continues for 0.3 seconds or more. • Stop light switch circuit
BC
WIRING DIAGRAM
7
1 2
From Ignition Switch S13
ECU-IG IG
1 2
D15 Diode
Open
1 Direction
2 1 Circuit
S13
STP
2 1 2 BC
STOP
1
D16 Diode
From Battery
C135889E01
2 1
STOP
R3 Rear Combination Light LH
2 1
STOP
R4 Rear Combination Light RH
2
S14
GND1
BC 3
S14
GND2
15
S11
GND3
14
S11
GND4
Skid Control ECU
C135890E01
1 INSPECT STOP FUSE
(a) Remove the STOP fuse from the No. 2 relay block.
table below.
Standard resistance
STOP (7.5 A) fuse Always Below 1 Ω
NG REPLACE STOP FUSE
STOP Fuse
C151806E03
OK
(a) Install the STOP fuse.

(b) Check that the stop light comes on when the brake pedal
released.
OK BC
NG Go to step 7
OK

Skid Control ECU (b) Measure the voltage according to the value(s) in the
Standard voltage
Stop light switch ON
S13-1 (STP) - Body
(Brake pedal 16 to 32 V
ground
depressed)
S13-1 (STP) - Body Stop light switch OFF
Below 3 V
ground (Brake pedal released)

CONNECTOR (STP CIRCUIT)
S13-1 (STP)
C135876E02
OK

Skid Control ECU
Wire Harness View: (b) Measure the voltage according to the value(s) in the
table below.
Standard voltage
BC S13-7 (IG) - Body
ground

CONNECTOR (IG CIRCUIT)
S13-7 (IG)
C135876E01
OK

table below.
Standard resistance
S14-2 (GND1) - Body
Always Below 1 Ω
ground
S14-3 (GND2) - Body
Always Below 1 Ω
ground
Always Below 1 Ω
ground
ground
C135878E01
OK
6 RECONFIRM DTC
(a) Reconnect the skid control ECU connectors.

108).
(d) Depress the brake pedal several times to test the stop BC
light circuit.
Result
Result Proceed to
HINT:

7 INSPECT STOP LIGHT SWITCH (POWER SOURCE TERMINAL)
(a) Disconnect the stop light switch connector.

Stop Light Switch Harness Side (b) Measure the voltage according to the value(s) in the
Connector Front View: table below.
Standard voltage
S15-2 - Body ground Always 20 to 32 V

S15
C142000E05
OK
8 INSPECT STOP LIGHT SWITCH

Stop Light Switch: table below.
Standard resistance
1-2 Switch pin free Below 1 Ω
BC 1-2 Switch pin pushed in 10 kΩ or higher
NG REPLACE STOP LIGHT SWITCH
Free Pushed in
C135883E01
OK
9 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - STOP LIGHT SWITCH)

Skid Control ECU
Standard resistance
S13-1 (STP) - S15-1 Always Below 1 Ω
S13-1 (STP) - Body
ground

CONNECTOR
S13-1 (STP)
Stop Light Switch Harness Side

S15 BC
C153326E01
OK
10 RECONFIRM DTC
(a) Reconnect the skid control ECU connector and the stop
light switch connector.
108).
(d) Depress the brake pedal several times to test the stop
light circuit.
Result
Result Proceed to
Result Proceed to
HINT:
INSPECT LIGHTING SYSTEM (STOP LIGHT CIRCUIT)
BC
DTC C1251/51 Open in Pump Motor Circuit

DESCRIPTION
• Brake actuator assembly (Ground circuit)
C1251/51 Actuator pump motor does not operate properly. • Brake actuator assembly (Motor circuit)
WIRING DIAGRAM
Refer to DTCs C0273/13 and C0274/14 (See page BC-43).
HINT:
When C0273/13 and/or C0274/14 is output together with C1251/51, inspect and repair the trouble areas
indicated by C0273/13 and/or C0274/14 first (See page BC-42).
1 INSPECT BRAKE ACTUATOR ASSEMBLY (GND TERMINAL)

Brake Actuator Harness Side (b) Disconnect the brake actuator connector.
Connector Front View: (c) Measure the resistance according to the value(s) in the
table below.
Standard resistance
S22 Tester Connection Condition Specified Condition
S22-1 (GND) - Body ground Always Below 1 Ω

CONNECTOR (GND CIRCUIT) BC
GND
C135896E01
OK

table below.
Standard resistance
MT BM
2 (BM) - 3 (MT) Always 31.3 to 34.7 Ω
3 (MT) - Body ground Always 10 kΩ or higher

(See page BC-127)
C135895E02
OK
3 RECONFIRM DTC

(b) Reconnect the brake actuator connector.
(c) Clear the DTC (See Pub. No. S1-XYZE05A, page 05-
108).
(d) Start the engine.
BC (e) Drive the vehicle at a speed of 20 km/h (12 mph) or more
(f) Check if the same DTC is recorded (See Pub. No. S1-
Result
Result Proceed to
HINT:
output.
or wire harness.
BC
DTC C1265/65 Vacuum Sensor Malfunction
Vacuum Sensor Output Malfunction (Test Mode

DTC C1285/85
DTC)
DESCRIPTION
DTC C1285/85 can be deleted when the vacuum sensor sends a vacuum signal or the Test Mode ends.
DTC C1285/85 is output only in the Test Mode.
1. When IG1 terminal voltage is 20 to 32 V, VCM
terminal voltage is not between 4.3 and 5.8 V for
2. Either PIM or PIM2 terminal voltage is not between
0.4 and 4.5 V for 1.2 seconds or more.
3. After the stop light switch is turned off with PMC • Vacuum sensor
C1265/65 terminal voltage 1 V or more, either PIM or PIM2 • Vacuum sensor circuit
terminal voltage does not change by 0.01 V in 1 • Skid control ECU
second.
4. Noise occurs in either PIM or PIM2 terminal voltage
at least 7 times for 5 seconds.
5. Difference between PIM and PIM2 terminal
voltages is 344 mV or more for 10 seconds or
more.
C1285/85 Detected only during Test Mode. Vacuum sensor
BC
WIRING DIAGRAM
11
1
E2 S12 E4
10
2
PIM S12 PIM
21
3
VC S12 VCP
20
S12 VSS2
Shielded
V1 No. 1 Vacuum Sensor
13
1
E2 S12 E3
23
2
PIM S12 PIM2
22
3
VC S12 VCP2
BC
12
S12 ISS2
Shielded
V2 No. 2 Vacuum Sensor
1
From Battery 1 2 2 1
S13 STP
STOP

Skid Control ECU
C135894E01
(a) Check that the stop light comes on when the brake pedal
released.
OK
NG INSPECT STOP LIGHT CIRCUIT
OK
2 CHECK VACUUM HOSE

(b) Check the vacuum hose.
OK:
No cracks or damage on the vacuum hoses.
NG REPLACE VACUUM HOSE
OK
3 INSPECT VACUUM SENSOR
(a) Remove the No. 1 and No. 2 vacuum sensors.

Vacuum Sensor: (b) Connect 3 dry batteries of 1.5 V in series.
(c) Connect the VC terminal to the battery's positive (+)
terminal and the E2 terminal to the battery's negative (-)
terminal. Then apply about 4.5 V between the VC and E2
(-)
terminals.
NOTICE:
BC Do not apply 6 V or more to terminals VC and E2.
(d) Connect a voltmeter to terminals PIM and E2 of the
(+) PIM (-) sensor, and measure the output voltage at atmospheric
VC pressure.
(e) Apply a vacuum to the vacuum sensor in 20 kPa (0.2 kgf/
E2
cm2, 2.9 psi) in increments to 100 kPa (1.02 kgf/cm2,
14.51 psi).
(+) (f) Measure the voltage according to the value(s) in the
table below.
Standard voltage
Front Brake Pressure
kPa (kgf/cm2, psi)
2 (PIM) - 1 (E2) 20 (0.2, 2.9) 0.5 V
C151812E02
2 (PIM) - 1 (E2) 60 (0.61, 8.7) 2.4 V
2 (PIM) - 1 (E2) 100 (1.02, 14.51) 3.6 V
(g) Check the difference of voltage between the vacuum

sensors.
OK:
Difference is 340 mV or more.
NOTICE:
Check the vacuum sensor signal after replacement
(See page BC-5)
NG REPLACE VACUUM SENSOR
OK
4 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - VACUUM SENSOR)
(a) Install the vacuum sensor.

Skid Control ECU (b) Disconnect the skid control ECU connector and the
Wire Harness View: vacuum sensor connector.
table below.
S12-12 (ISS2) Standard resistance
S12-11 (E4)
S12-11 (E4) - V1-1 (E2) Always Below 1 Ω
S12-11 (E4) - Body
ground
S12-10 (PIM)
S12-13 (E3) S12-10 (PIM) - V1-2 (PI
Always Below 1 Ω
S12-20 (VSS2) M)
S12-23 (PIM2)
S12-10 (PIM) - Body
S12-22 (VCP2) S12-21 (VCP) ground
S12-21 (VCP) - V1-3
Always Below 1 Ω
(VC)
S12-21 (VCP) - Body
ground
Vacuum Sensor Harness Side
Connector Front View: S12-13 (E3) - V2-1 (E2) Always Below 1 Ω
S12-13 (E3) - Body
ground
S12-23 (PIM2) - V2-2
Always Below 1 Ω
(PIM)
S12-23 (PIM2) - Body
ground
Always 10 kΩ or higher BC
S12-22 (VCP2) - V2-3
Always Below 1 Ω
(VC)
V1 S12-22 (VCP2) - Body
V2 ground

CONNECTOR
C153330E01
OK
5 INSPECT SKID CONTROL ECU (SENSOR INPUT)
(a) Reconnect the skid control ECU connector.

Skid Control ECU (b) Turn the ignition switch to the ON position.
table below.
Standard voltage
S12-21 (VCP) - Body
ground
S12-22 (VCP2) - Body
ground
S12-22 (VCP2) S12-21 (VCP) NG REPLACE SKID CONTROL ECU
C135872E03
OK
6 RECONFIRM DTC
(a) Reconnect the vacuum sensor.

108).
(c) At a speed of 10 km/h (6 mph) or more, drive the vehicle
BC depressing the brake pedal).
Result
Result Proceed to
HINT:


Skid Control ECU (b) Disconnect the skid control ECU connector.
table below.
Standard voltage
Stop light switch ON
S13-1 (STP) - Body
(Brake pedal 16 to 32 V
ground
depressed)
S13-1 (STP) - Body Stop light switch OFF
Below 3 V
ground (Brake pedal released)
HINT:
S13-1 (STP) Problem Symptoms Table, refer back to the table and
C135876E02 proceed to the next step (See page BC-13).
CONNECTOR (STP CIRCUIT)
OK
BC
DTC C1266/66 Exhaust Retarder Prevention Signal Circuit

DESCRIPTION
1. When exhaust brake request is ON, the monitor is
• EXO circuit
OFF for 0.3 seconds or more.
C1266/66 • ECM
2. When vehicle speed is 6 km/h (4 mph) or more and
exhaust brake request is OFF, the monitor is ON for
WIRING DIAGRAM
10
30
ABS S13 EXO
Skid Control ECU

BC E24 ECM
C151238E01
1 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - ECM)
(a) Disconnect the skid control ECU connector and the ECM
Skid Control ECU connector.
Wire Harness View: (b) Measure the resistance according to the value(s) in the
table below.
Standard resistance
S13-10 (EXO) - E24-30
Always Below 1 Ω
(ABS)
S13-10 (EXO) - Body
ground
S13-10 (EXO) NG REPAIR OR REPLACE HARNESS OR

CONNECTOR
ECM Wire Harness View:
BC
E24-30 (ABS)
C153331E01
OK
2 INSPECT ECM (ECU INPUT)
(a) Reconnect the ECM connector.

ECM Wire Harness View:
table below.
Standard voltage
E24-30 (ABS) - Body
ground
NG REPLACE ECM (See Chapter ES)
E24-30 (ABS)
E113314E03
BC
OK
3 INSPECT SKID CONTROL ECU (ECM INPUT)

Skid Control ECU (b) Reconnect the skid control ECU connector.
Wire Harness View: (c) Turn the ignition switch to the ON position.
table below.
Standard voltage
S13-10 (EXO) - Body
ground
NG REPLACE SKID CONTROL ECU

S13-10 (EXO)
C135872E04
OK
4 RECONFIRM DTC

108).
Result
Result Proceed to
BC
ABS Warning Light Remains ON

DESCRIPTION
If any of the following is detected, the ABS warning light remains on:
• The skid control ECU connectors are disconnected from the skid control ECU.
• There is a malfunction in the skid control ECU internal circuit.
• There is an open in the harness between the combination meter and the skid control ECU.
HINT:
In some cases, the intelligent tester cannot be used when the skid control ECU is abnormal.
WIRING DIAGRAM
6
40
S13 WA
ESC
7
1 2
S13 IG
ECU-IG
From Ignition Switch
28 2 1
IG+ GAUGE
ABS
BC
2
S14 GND1
3
S14 GND2
15
S11 GND3
14
S11 GND4
C5 Combination Meter Skid Control ECU
C135871E02
1 CHECK IF SKID CONTROL ECU CONNECTOR IS SECURELY CONNECTED
(a) Check if the skid control ECU connector is securely

connected.
OK:
The connector should be securely connected.
NG CONNECT CONNECTOR TO ECU
CORRECTLY
OK
2 CHECK BATTERY

Standard voltage:
20 to 32 V
OR BATTERY (See chapter CH)
OK

Skid Control ECU
(c) Measure the voltage according to the value(s) in the BC
Wire Harness View:
table below.
Standard voltage
S13-7 (IG) -Body ground Ignition switch ON 20 to 32 V

S13-7 (IG)
C135876E01
OK

table below.
Standard resistance
S14-2 (GND1) - Body
Always Below 1 Ω
ground
S14-3 (GND2) - Body
Always Below 1 Ω
ground
Always Below 1 Ω
ground
ground
C135878E01
OK
BC
5 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - COMBINATION METER)

Standard resistance
S13-6 (WA) - C5-40
Always Below 1 Ω
(ESC)
S13-6 (WA) - Body
ground

CONNECTOR
S13-6 (WA)
Combination Meter Wire Harness View:
C5-40 (ESC)
BC
C152017E03
OK
6 INSPECT COMBINATION METER ASSEMBLY

combination meter connector.
(b) Check the combination meter.
OK:
The combination meter is normal.
HINT:
NG REPLACE COMBINATION METER
ASSEMBLY
OK
BC
ABS Warning Light does not Come ON

WIRING DIAGRAM
Refer to ABS Warning Light Remains ON (See page BC-100).
1 CHECK ABS WARNING LIGHT

(c) Check that the ABS warning light comes on.
OK:
The ABS warning light comes on.
HINT:
proceed to the next step before replacing the part (See
page BC-13).
NG Go to step 2
OK
BC

Skid Control ECU (b) Disconnect the combination meter connector.
table below.
Standard resistance
S13-6 (WA) - C5-40
Always Below 1 Ω
(ESC)
S13-6 (WA) - Body
ground

CONNECTOR
S13-6 (WA)
BC C5-40 (ESC)
C152017E03
OK
(a) Reconnect the skid control ECU connector and the

OK:
HINT:
page BC-13).
ASSEMBLY
OK
BC
Brake Warning Light Remains ON

DESCRIPTION
If any of the following is detected, the brake warning light remains on:
• The skid control ECU connector is disconnected from the skid control ECU.
• The brake fluid level is insufficient.
• The parking brake is applied.
• EBD operation is not possible.
• The vacuum created by the vacuum pump is below the standard level.
BC
WIRING DIAGRAM
14
19
S13 BRL
PKBI
7
1 2
S13 IG
ECU-IG
28 2 1
Brake IG+ GAUGE
16 2 1
PKB
B5 Brake Fluid Level
Warning Switch
3 2 2 1
21 BC
S13 PKB1
P7 Parking Brake D11 Diode

Switch
C135880E01
20
S12 VSS2
11
1
E2 S12 E4
10
2
PIM S12 PIM
21
3
VC S12 VCP
V1 No. 1 Vacuum Sensor Shielded

12
S12 ISS2
13
1 S12 E3
E2
23
2 S12 PIM2
PIM
22
3 S12 VCP2
VC
V2 No. 2 Vacuum Sensor Shielded

2
S14 GND1
3
S14 GND2
BC
15
S11 GND3
14
S11 GND4
Skid Control ECU
C135881E01
1 CHECK DTC
(a) Check if the ABS DTC is output (See Pub. No. S1-
Result
Result Proceed to
DTC is not output A
DTC is output B
B REPAIR CIRCUIT INDICATED BY OUTPUT

DTC (See page BC-19)
2 CHECK IF SKID CONTROL ECU CONNECTOR IS SECURELY CONNECTED
(a) Check if the skid control ECU connector is securely

connected.
OK:
The connector should be securely connected.
NG CONNECT CONNECTOR TO ECU
CORRECTLY
OK
3 CHECK BATTERY

Standard voltage:
20 to 32 V
OR BATTERY (See chapter CH) BC
OK

Skid Control ECU
Wire Harness View:
table below.
Standard voltage
S13-7 (IG) - Body
ground

S13-7 (IG)
C135876E01
OK

table below.
Standard resistance
S14-2 (GND1) - Body
Always Below 1 Ω
ground
S14-3 (GND2) - Body
Always Below 1 Ω
ground
Always Below 1 Ω
ground
ground
C135878E01
OK
6 INSPECT BRAKE FLUID LEVEL WARNING SWITCH

Brake Fluid Level Warning Switch: (b) Remove the reservoir filler cap and strainer.
BC (c) Disconnect the brake fluid level warning switch
connector.
table below.
MAX HINT:
A float is located inside the reservoir. Its position can be
MIN changed by increasing or decreasing the level of brake
fluid.
Standard resistance
1-2 Switch OFF (Float up) 1.9 to 2.1 kΩ
1-2 Switch ON (Float down) Below 1 Ω
C135885E01
HINT:
If there is no problem after finishing the above check,
adjust the brake fluid level to the MAX level.
NG REPLACE BRAKE MASTER CYLINDER
RESERVOIR SUB-ASSEMBLY (BRAKE
FLUID LEVEL WARNING SWITCH)
OK
7 CHECK HARNESS AND CONNECTOR (COMBINATION METER - BRAKE FLUID LEVEL

WARNING SWITCH)

Combination Meter Wire Harness View: (b) Measure the resistance according to the value(s) in the
table below.
Standard resistance
C5-16 (PKB) - B5-2 Always Below 1 Ω
C5-16 (PKB) - Body
ground
B5-1 - Body ground Always Below 1 Ω
C5-16 (PKB) NG REPAIR OR REPLACE HARNESS OR

CONNECTOR
Brake Fluid Level Warning Switch

Harness Side Connector Front View:
B5 1 BC
2
C152018E02
OK

Standard resistance
S13-14 (BRL) - C5-19
Always Below 1 Ω
(PKBI)
S13-14 (BRL) - Body
ground

CONNECTOR
S13-14 (BRL)
BC C5-19 (PKBI)
C152017E04
OK
(a) Check the combination meter.

OK:
HINT:
• Reinstall the connectors and restore the vehicle to its
prior condition before checking the combination
meter.
• If troubleshooting has been carried out according to
the Problem Symptoms Table, refer back to the table
and proceed to the next step before replacing the part
(See page BC-13).

ASSEMBLY
OK
10 INSPECT PARKING BRAKE SWITCH

Parking Brake Switch: (b) Disconnect the parking brake switch connector.
table below.
Standard resistance
Parking brake switch
2-3 ON Below 1 Ω
(Switch pin free)
Parking brake switch
2-3 OFF 10 kΩ or higher
(Switch pin pushed in)
Free Pushed in
NG REPLACE PARKING BRAKE SWITCH
C135882E01
OK
BC
11 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - PARKING BRAKE SWITCH)

Standard resistance
S13-21 (PKB1) - P7-2 Always Below 1 Ω
S13-21 (PKB1) - Body
ground
P7-3 - Body ground Always Below 1 Ω
HINT:
S13-21 (PKB1)
CONNECTOR
Parking Brake Switch Harness

Side Connector Front View:
BC P7
C153690E01
OK

Brake Warning Light does not Come ON

WIRING DIAGRAM
Refer to Brake Warning Light Remains ON (See page BC-109).
1 CHECK BRAKE WARNING LIGHT

(c) Check that the brake warning light comes on.
OK:
The brake warning light comes on.
HINT:
page BC-13).
NG Go to step 2
OK
BC

Skid Control ECU (b) Disconnect the combination meter connector.
table below.
Standard resistance
S13-14 (BRL) - C5-19
Always Below 1 Ω
(PKBI)
S13-14 (BRL) - Body
ground

CONNECTOR
S13-14 (BRL)
BC C5-19 (PKBI)
C152017E04
OK
(a) Reconnect the skid control ECU connector and the

OK:
HINT:
ASSEMBLY
OK
BC
TC and CG Terminal Circuit

DESCRIPTION
Connecting terminals TC and CG of the DLC3 causes the skid control ECU to display the DTC by blinking
the ABS warning light.
HINT:
When the warning lights continue to blink, a ground short in the wiring of terminal TC of the DLC3 or an
internal ground short in one or more ECU is suspected.
WIRING DIAGRAM
19
13
TC S13 TC
4
CG
D3 DLC3 Skid Control ECU
BC
C146759E02
1 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - TC of DLC3)

Skid Control ECU
table below.
Wire Harness View:
Standard resistance
S13-19 (TC) - D3-13
Always Below 1 Ω
(TC)

CONNECTOR
S13-19 (TC)
DLC3:
BC
D3
TC
C153394E01
OK
2 CHECK HARNESS AND CONNECTOR (CG of DLC3 - BODY GROUND)

DLC3: table below.
CG
Standard resistance
D3-4 (CG) - Body
Always Below 1 Ω
ground
D3

CONNECTOR
G022986E44
OK
3 CHECK HARNESS AND CONNECTOR (TC of DLC3 - BODY GROUND)

DLC3:
table below.
Standard resistance
D3-13 (TC) - Body
ground
D3 HINT:
TC G022987E42
page BC-13).
NG REPAIR OR REPLACE WIRE HARNESS OR
EACH ECU
OK
BC
TS and CG Terminal Circuit

DESCRIPTION
In the Test Mode (signal check), a malfunction of the speed sensor that cannot be detected when the
vehicle is stopped can be detected while driving.
Transition to the sensor check mode can be performed by connecting terminals TS and CG of the DLC3
and turning the ignition switch from off to ON.
WIRING DIAGRAM
18
12
TS S13 TS
4
CG
D3 DLC3 Skid Control ECU
C146759E03
BC
1 CHECK HARNESS AND CONNECTOR (SKID CONTROL ECU - TS of DLC3)

Skid Control ECU
table below.
Wire Harness View:
Standard resistance
S13-18 (TS) - D3-12 (TS) Always Below 1 Ω

CONNECTOR
S13-18 (TS)
DLC3:
BC
D3
TS
C153394E02
OK
2 CHECK HARNESS AND CONNECTOR (CG of DLC3 - BODY GROUND)

DLC3: table below.
CG
Standard resistance
D3-4 (CG) - Body ground Always Below 1 Ω
D3
CONNECTOR
G022986E44
OK
3 CHECK HARNESS AND CONNECTOR (TS of DLC3 - BODY GROUND)

DLC3:
table below.
Standard resistance
D3-12 (TS) - Body ground Always 10 kΩ or higher
HINT:
D3
TS G022987E38 proceed to the next step before replacing the part (See
page BC-13).
CONNECTOR
OK
BC
BC–126 BRAKE CONTROL – BRAKE ACTUATOR
BRAKE ACTUATOR
BRAKE CONTROL
COMPONENTS
15 (153, 11)
14 (143, 10)*
BC
CONNECTOR
BRAKE ACTUATOR WITH BRACKET
N*m (kgf*cm, ft.*lbf) : Specified torque 29 (296, 21) x3
* For use with SST

C152080E01
BRAKE CONTROL – BRAKE ACTUATOR BC–127
BRAKE ACTUATOR
5.4 (55, 48 in.*lbf)
x3
BRAKE ACTUATOR BRACKET
C153489E01
REMOVAL
1. DRAIN BRAKE FLUID BC
TERMINAL
3. REMOVE BRAKE ACTUATOR WITH BRACKET
(a) Pull the lock lever.
(b) Disconnect the brake actuator connector.
NOTICE:
Be careful not to allow brake fluid to enter the
removed connector.
C152084
(c) Using SST, disconnect the 6 brake lines.

SST 09023-00101
SST
C152082E01
(d) Use tags or make a memo to identify the places to

reconnect.
• *1: To front wheel cylinder RH
• *2: To front wheel cylinder LH
*6 • *3: To rear wheel cylinder RH
*2 • *4: To rear wheel cylinder LH
*3 • *5: From master cylinder (Rear side)
*1 • *6: From master cylinder (Front side)
*4
*5
BC
C152085E01
(e) Remove the 3 bolts and the brake actuator with

bracket.
NOTICE:
Do not damage the brake lines or wire harness.
C152081
DISASSEMBLY
1. REMOVE BRAKE ACTUATOR
(a) Remove the 3 nuts and the brake actuator from the
brake actuator bracket.
C152079
REASSEMBLY
1. INSTALL BRAKE ACTUATOR
(a) Install the brake actuator to the brake actuator
bracket with the 3 nuts.
NOTICE:
Do not remove the hole plug before installing a
new brake actuator because the brake actuator
is filled with brake fluid.
BC
C152079
INSTALLATION
1. INSTALL BRAKE ACTUATOR WITH BRACKET
(a) Install the brake actuator with bracket to the body
with the 3 bolts.
NOTICE:
Do not damage the brake lines or wire harness.
C152081
(b) Temporarily tighten each brake line to the correct

positions of the brake actuator with bracket as
HINT:
*6 • *1: To front wheel cylinder RH
*2 • *2: To front wheel cylinder LH
*3 • *3: To rear wheel cylinder RH
*1 • *4: To rear wheel cylinder LH
• *5: From master cylinder (Rear side)
*4
• *6: From master cylinder (Front side)
*5
C152085E01
(c) Using SST, fully tighten the 6 brake lines.

Fulcrum Length SST 09023-00101
Torque: without SST
15 N*m (153 kgf*cm, 11 ft.*lbf)
with SST
14 N*m (143 kgf*cm, 10 ft.*lbf)
NOTICE:
SST 250 mm (9.84 in.).
BC
C152083E01
(d) Connect the brake actuator connector.

NOTICE:
Make sure that the connector is locked securely.
2. FILL RESERVOIR WITH BRAKE FLUID
HINT:
See Pub. No. S1-XYZE05A, page 32-4.
3. BLEED BLAKE LINE
HINT:
4. INSPECT FOR BRAKE FLUID LEAK
HINT:
5. INSPECT FLUID LEVEL IN RESERVOIR
C153735
HINT:
TERMINAL
7. CHECK BRAKE ACTUATOR

HINT:
(See page BC-127).
BC
BC–132 BRAKE CONTROL – EASY & SMOOTH STARTING SYSTEM (N04C)
EASY & SMOOTH STARTING SYSTEM (N04C)

HOW TO PROCEED WITH TROUBLESHOOTING
HINT:
Use this procedure to troubleshoot the easy &smooth starting system (ES starting system).
2 CUSTOMER PROBLEM ANALYSIS CHECK AND PROBLEM SYMPTOM CHECK (See page
BC-134)
3 CHECK AND CLEAR DTCS (See page BC-135)
4 PROBLEM SYMPTOM CONFIRMATION
(a) If the symptom does not occur, proceed to A.

(b) If the symptom occurs, proceed to B.
BC B Go to step 6
5 SYMPTOM SIMULATION (See chapter IN)
6 CHECK FOR DTC
(a) Check for DTCs and note any codes that are output.
(b) Clear the DTC.
(c) Recheck for DTCs. Based on the DTC output in (a), try to force output of the ABS & BA system or ES
starting system DTC by simulating the operation indicated by the DTC.
(1) If the DTC does not reoccur, proceed to A.
(2) If the ABS &BA system DTC reoccurs, proceed to B.
(3) If the ES starting system DTC reoccurs, proceed to C.
B Go to ABS &BA SYSTEM (See page BC-4)
C Go to step 9
BRAKE CONTROL – EASY & SMOOTH STARTING SYSTEM (N04C) BC–133
7 PROBLEM SYMPTOMS TABLE (See page BC-144)
(a) If the fault is not listed on the problem symptoms table, proceed to A.
(b) If the fault is listed on the problem symptoms table, proceed to B.
B Go to step 9
8 OVERALL ANALYSIS AND TROUBLESHOOTING
(a) PRE-CHECK (See page BC-135)

(b) Terminals of ECU (See page BC-142)
9 ADJUST,REPAIR OR REPLACE
10 CONFIRMATION TEST
BC
END
BC–134 BRAKE CONTROL – EASY & SMOOTH STARTING SYSTEM (N04C)
CUSTOMER PROBLEM ANALYSIS CHECK
EASY &SMOOTH STARTING SYSTEM Check Sheet Inspector's

name :
VIN
Customer's Name Production Date / /
License Plate No.
Date Vehicle km
/ / Odometer Reading
Brought in miles
Date Problem First Occurred / /
Frequency Problem Occurs Constant Intermittent ( times a day)

'(
Only once
Fine Cloudy Rainy Snowy

Weather
Weather Conditions Various/Others
When Problem
Occurred Outdoor Hot Warm Cool
Temperature Cold (Approx. ºC ( ºF)
ES starting system does not operate
BC ES starting system does not operate efficiently

Symptoms
Brake pressure increase function does not operate
ES Start Indicator Remains ON Does not turn ON

Lamp Abnormal
1st Time Normal Code Malfunction Code (Code )

DTC Check
2nd Time Normal Cod Malfunction Code (Code )
BRAKE CONTROL – EASY & SMOOTH STARTING SYSTEM (N04C) BC–135
PRE-CHECK
1. SELF-CHECK
(b) Check the buzzer and ES start indicator lamp on the combination meter.
OK: The buzzer emits a beep and the ES start indicator lamp turns on for 3 seconds.
NOTICE:
• If only the ES start indicator lamp turns on, perform the clutch stroke sensor
adjustment or cancel position in

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■■■■■■■■

WU300, 302, 340, 410, 412, 420, 422 series

Manual Name Pub. No.

Hino Motors, Ltd.

Copyright (C) 2007 HINO Motors, Ltd.

Att.) Service Manager, Your Distributor

Pub. No. Issue Date

Name of Dealer Name of Reporter

HOW TO USE THIS MANUAL IN

HOW TO USE THIS MANUAL

(b) Non-reusable parts, grease application areas,

Example: FILTER CAP CLEVIS PIN

N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part

(c) Torque specifications, grease application areas and

(e) Illustrations of similar vehicle models are sometimes

7. INTERNATIONAL SYSTEM OF UNITS

3. TRANSMISSION SERIAL NUMBER

• Always wear a clean uniform.

(b) JACKING UP AND SUPPORTING VEHICLE

Illustration Symbol Part Name Abbreviation

Illustration Symbol Part Name Abbreviation

MEDIUM CURRENT FUSE M-FUSE

HIGH CURRENT FUSE H-FUSE

Shape (Example) Illustration Procedures

1. Remove clips with clip remover or pliers. IN

1. Remove the clips with clip remover or

1. Remove clips with wide scraper to

1. Remove clips by pushing center pin

Shape (Example) Illustration Procedures

IN 1. Remove clips by unscrewing the center

1. Remove clips by prying out the pin and

1. Using a screwdriver, detach the claws

1. Using a screwdriver, detach the claws

Shape (Example) Illustration Procedures

1. Using a screwdriver, detach the claws

(i) REMOVAL AND INSTALLATION OF VACUUM

(2) When disconnecting vacuum hoses, use tags to

(j) TORQUE WHEN USING TORQUE WRENCH

(1) Use the formula below to calculate special

(5) Never use an impact wrench to remove or install

5. HANDLING OF HOSE CLAMPS

6. FOR VEHICLES EQUIPPED WITH MOBILE

VEHICLE LIFT AND SUPPORT

FRONT (IFS) REAR

SCREW JACK POSITION

Front (Auxiliary menber)

Rear (U-bolt seat)

DIAGNOSIS USING THE PC (PERSONAL COMPUTER)

DIAGNOSIS TOOL WITH INTERFACE

HOW TO PROCEED WITH

1 VEHICLE BROUGHT TO WORKSHOP

2 INSPECT BATTERY VOLTAGE

3 SYMPTOM CONFIRMATION AND DTC (AND FREEZE FRAME DATA) CHECK

(a) Visually check the wire harnesses, connectors and fuses

(a) Check the results obtained in step 3. Then find the

5 PROBLEM SYMPTOMS CHART

(a) Check the results obtained in step 3. Then find the

6 CIRCUIT INSPECTION OR PARTS INSPECTION

(a) Confirm the malfunctioning circuit or part.

7 ADJUST, REPAIR OR REPLACE

Nm (kgfcm, ft.*lbf) : Specified torque Non-reusable part