12MY L200 (EU) Workshop Manual

00-1
GROUP 00
GENERAL
CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00
GENERAL <ELECTRICAL> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00E

00-1
GROUP 00
GENERAL
CONTENTS
HOW TO USE THIS MANUAL. . . . . . 00-3 PRECAUTIONS BEFORE SERVICE . 00-36

SERVICING COMMON RAIL ENGINE . . . . 00-36
HOW TO USE TROUBLESHOOTING/ CAUTIONS FOR AIR CONDITIONER STARITING
INSPECTION SERVICE POINTS. . . . 00-6 ...................................... 00-36
CONTENTS OF TROUBLESHOOTING . . . 00-6 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
DIAGNOSIS FUNCTION. . . . . . . . . . . . . . . 00-8 ...................................... 00-37
HOW TO USE THE INSPECTION PROCEDURES SERVICING ELECTRICAL SYSTEM . . . . . 00-37
...................................... 00-9 IN ORDER TO PREVENT VEHICLES FROM FIRE
CONNECTOR MEASUREMENT SERVICE POINTS ...................................... 00-37
...................................... 00-12 MULTI USE TESTER (M.U.T.-III) SUB ASSEMBLY
CONNECTOR INSPECTION SERVICE POINTS ...................................... 00-38
...................................... 00-13 HOW TO PERFORM CHASSIS NUMBER (Chassis
INSPECTION SERVICE POINTS FOR A BLOWN No.) WRITING . . . . . . . . . . . . . . . . . . . . . . . 00-38
FUSE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-14 PRE-INSPECTION CONDITION . . . . . . . . . 00-42
HOW TO COPE WITH INTERMITTENT ENGINE OILS . . . . . . . . . . . . . . . . . . . . . . . 00-42
MALFUNCTIONS . . . . . . . . . . . . . . . . . . . . 00-14 WHAT THE COMMON RAIL ENGINE LEARNS
HOW TO TREAT PAST TROUBLE . . . . . . 00-15 ...................................... 00-43
INJECTOR IDENTIFICATION CODE REGISTRATION
VEHICLE IDENTIFICATION . . . . . . . 00-15 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 00-43
MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-15 SMALL INJECTION QUANTITY LEARNING
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 00-45
VEHICLE IDENTIFICATION NUMBER (CHASSIS
NUMBER) . . . . . . . . . . . . . . . . . . . . . . . . . . 00-18 SUPPLY PUMP CORRECTION LEARNING
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 00-45
VEHICLE INFORMATION CODE PLATE. . 00-19
INITIALISATION PROCEDURE FOR LEARNING
VEHICLE IDENTIFICATION NUMBER (VIN) PLATE
VALUE IN DIESEL PARTICULATE FILTER (DPF)
<VEHICLES FOR RHD>. . . . . . . . . . . . . . . 00-19
SYSTEM <Euro5> . . . . . . . . . . . . . . . . . . . . 00-46
MANUFACTURER PLATE . . . . . . . . . . . . . 00-20
BATTERY CURRENT SENSOR CALIBRATION
ENGINE MODEL STAMPING. . . . . . . . . . . 00-20 <Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-46
HOW TO USE THE THROTTLE CONTROLLER
GENERAL DATA AND SPECIFICATIONS ...................................... 00-47
................................. 00-21 APPLICATION OF ANTI-CORROSION AGENTS AND
GENERAL DATA AND SPECIFICATIONS UNDERCOATS . . . . . . . . . . . . . . . . . . . . . . 00-47
<VEHICLES FOR EUROPE> . . . . . . . . . . . 00-21 VEHICLE WASHING . . . . . . . . . . . . . . . . . . 00-48
GENERAL DATA AND SPECIFICATIONS PRECAUTIONS FOR INSTALLATION OF ON-
<VEHICLES FOR RUSSIA (EASTERN EUROPE VEHICLE RADIO TRANSMISSION EQUIPMENT
COUNTRIES)> . . . . . . . . . . . . . . . . . . . . . . 00-32 ...................................... 00-48
GENERAL DATA AND SPECIFICATIONS
<VEHICLES FOR MOROCCO> . . . . . . . . . 00-35 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
................................. 00-48
00-2
SRS SERVICE PRECAUTIONS . . . . 00-50 SUPPORT LOCATIONS FOR LIFTING AND

JACKING . . . . . . . . . . . . . . . . . . . . . . 00-54
GENERAL
HOW TO USE THIS MANUAL
00-3
M1001000103302
SCOPE OF MAINTENANCE, REPAIR AND REFERENCE VALUE

SERVICING EXPLANATIONS Indicates the adjustment value prior to starting the
work (presented in order to facilitate assembly and
This manual provides explanations, etc. concerning
adjustment procedures, and so they can be com-
procedures for the inspection, maintenance, repair
pleted in a shorter time).
and servicing of the subject model. Note, however,
that for engine and transmission-related component DANGER, WARNING, AND CAUTION
parts, this manual covers only on-vehicle inspec- DANGER, WARNING, and CAUTION call special
tions, adjustments, and the removal and installation attention to a necessary action or to an action that
procedures for major components. For detailed infor- must be avoided. The differences among DANGER,
mation concerning the inspection, checking, adjust- WARNING, and CAUTION are as follows:
ment, disassembly and reassembly of the engine, • If a DANGER is not followed, the result is severe
transmission and major components after they have bodily harm or even death.
been removed from the vehicle, please refer to sepa- • If a WARNING is not followed, the result could be
rate manuals covering the engine and the transmis- bodily injury.
sion. • If a CAUTION is not followed, the result could be
ON-VEHICLE SERVICE damage to the vehicle, vehicle components or
"On-vehicle Service" is procedures for performing service equipment.
inspections and adjustments of particularly important
locations with regard to the construction and for INDICATION OF TIGHTENING TORQUE
maintenance and servicing, but other inspection (for Tightening torques (units: N⋅m) are set to take into
looseness, play, cracking, damage, etc.) must also account the central value and the allowable toler-
be performed. ance. The central value is the target value, and the
allowable tolerance provides the checking range for
INSPECTION
tightening torques. If bolts and nuts are not provided
Under this title are presented inspection and check-
with tightening torques.
ing procedures to be performed by using special
tools and measuring instruments and by feeling, but,
for actual maintenance and servicing procedures,
MODEL INDICATIONS
visual inspections should always be performed as The following abbreviations are used in this manual
well. for identification of model types.
2500:Indicates an engine with the 2,477mL <4D56>
DEFINITION OF TERMS diesel engine.
2WD:Indicates the 2-wheel drive vehicles.
STANDARD VALUE 4WD:Indicates the 4-wheel drive vehicles.
Indicates the value used as the standard for judging A/C:Indicates the air conditioner.
the quality of a part or assembly on inspection or the A/T:Indicates the automatic transmission.
value to which the part or assembly is corrected and DOHC: Indicates an engine with the double over-
adjusted. It is given by tolerance. head camshaft.
LIMIT M/T:Indicates the manual transmission.
Shows the standard for judging the quality of a part
or assembly on inspection and means the maximum
or minimum value within which the part or assembly
must be kept functionally or in strength. It is a value
established outside the range of standard value.
00-4 GENERAL
EXPLANATION OF MANUAL CONTENTS
Indicates the
Denotes tightening torque. section title.
For bolts and nuts which do
not have a tightening torque
listed, refer to the "Standard Indicates the Indicates the
Parts tightening-torque Table" group title. group number.
35A-19 Indicates the page number.
Indicates procedures to be performed be-

fore the work in that section is started, and
procedures to be performed after the work
in that section is finished.
Component diagram
A diagram of the component parts is pro-
vided near the front of each section in order
to give the reader a better understanding of
the installed condition of component parts.
Mark N denotes nonreusable part.
Repair kit or parts sets are shown.

(Only very frequently used parts are shown.)
>>A<<
>>B<<
Maintenance and servicing procedures

The numbers provided within the diagram indicate the Installation steps :
sequence for maintenance and servicing procedures. Specified in case installation is impossible in
Removal steps : reverse order of removal steps. Omitted if
The part designation number corresponds to installation is possible in reverse order of re-
the number in the illustration to indicate remov- moval steps.
al steps. Reassembly steps :
Disassembly steps : Specified in case installation is impossible in
The part designation number corresponds to reverse order of removal steps. Omitted if
the number in the illustration to indicate disas- reassembly is possible in reverse order of dis-
sembly steps. assembly steps.
AC311238 AE
GENERAL
00-5
Classifications of major maintenance / service points

When there are major points relative to maintenance and servicing procedures (such as essential maintenance
and service points, maintenance and service standard values, information regarding the use of special tools, etc.).
These are arranged together as major maintenance and service points and explained in detail.
<<A>> : Indicates that there are essential points for removal or disassembly.
>>A<< : Indicates that there are essential points for installation or reassembly.
35A-21
Operating procedures,
cautions, etc. on removal,
installation, disassembly and
reassembly are described
BRAKE CALIPER ASSEMBLY
The title of the page

(following the page on which
the diagram of component
parts is presented) indicating
the locations of lubrication and
sealing procedures.
Indicates (by symbols) where

lubrication is necessary.
Symbols for lubrication, sealants and adhesives
Symbols are used to show the locations for lubrication : Grease

and for application of sealants and adhesives. (Multi-purpose grease unless there is a brand
These symbols are included in the diagram of compo- or type specified)
nent parts or on the page following the component : Sealant or adhesive
parts page. The symbols do not always have accomp- : Automatic transmission fluid, brake fluid, power
anying text to support that symbol. steering fluid or air conditioning compressor oil
: Engine oil or gear oil
: Adhesive tape or butyl rubber tape
AC509265AF
00-6 GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE

POINTS
CONTENTS OF TROUBLESHOOTING
M1001013300794
CAUTION
During diagnosis, a diagnosis code associated
with other system may be set when the ignition
switch is turned on with connector(s) discon-
nected. On completion, confirm all systems for
diagnosis code(s). If diagnosis code(s) are set,
erase them all.
WARNING
Since the radiator fan rotates during CAN
bus line diagnostics, make sure that no one
is servicing the engine compartment before
diagnosing the CAN bus line. Since the CAN
communication stops when diagnosing the
CAN bus line, the ETACS-ECU detects the
time-out of the engine-ECU, and activates
the radiator fan to prevent overheating as
fail-safe.
Troubleshooting of electronic control systems for
which the M.U.T.-III can be used follows the basic
outline described below. Even in systems for which
the M.U.T.-III cannot be used, some of these sys-
tems still follow this outline.
1. STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING

Troubleshooting sections are based on the diagnostic flow as below. If the diagnostic flow is different from
that given below, or if additional explanation is required, the details of such differences or additions will also
be listed.
GENERAL
00-7
Diagnosis method
Gathering information
from the customer.
Reoccurs Does not reoccur

Check trouble symptom.
NG
CAN bus diagnosis* 1 CAN bus diagnosis chart* 2
OK
Diagnosis code Diagnosis code
Read the diagnosis code. displayed. displayed. Read the diagnosis code.
(Current trouble)* 3 (Current trouble)* 3
No diagnosis code Diagnosis code After taking note of the Diagnosis code No diagnosis
or communication displayed. malfunction code, erase the displayed. code.
with M.U.T.-III not (Past trouble)* 3 diagnosis code memory. (Past trouble)* 3
possible
How to treat past Recheck trouble symptom. How to treat past

trouble* 4 trouble* 4
Read the diagnosis codes. No diagnosis

Diagnosis code code.
displayed.
Refer to the INSPECTION CHART Refer to the INSPECTION CHART INTERMITTENT MALFUNCTIONS* 5
FOR TROUBLE SYMPTOMS FOR DIAGNOSIS CODES
(Refer to applicable group). (Refer to applicable group).
AC501888
1
• * : For how to diagnose CAN bus lines, refer to GROUP 54C .
• *2: For the CAN bus diagnosis chart, refer to GROUP 54C .
• *3: When the M.U.T.-III detects a diagnosis code, its display informs users whether a mechanical problem
currently exists or whether it existed before. The message for the former state identifies it as a "Active"
and the message for the latter identifies it as a "Stored".
• *4: For how to treat past trouble, refer to P.00-15.
• *5: For how to cope with intermittent malfunctions, refer to P.00-14.
2. SYSTEM OPERATION AND SYMPTOM 5. DIAGNOSIS CODE PROCEDURES

VERIFICATION TESTS Indicates the inspection procedures corresponding to
If verification of the symptom(s) is difficult, proce- each diagnosis code (Refer to How to Use Inspection
dures for checking operation and verifying symptoms Procedures P.00-9).
are shown.
6. TROUBLE SYMPTOM CHART
3. DIAGNOSIS FUNCTION If there are trouble symptoms even though the
Details specific to individual systems are described. M.U.T.-III does not find any diagnosis codes, Inspec-
tion procedures for each trouble symptom will be
4. DIAGNOSIS CODE CHART found by means of this chart.
Diagnosis codes and diagnostic items are shown.
00-8 GENERAL
7. SYMPTOM PROCEDURES HOW TO READ DIAGNOSIS CODE

Indicates the inspection procedures corresponding to CAUTION
each symptoms classified in the Symptom Chart Before connecting or disconnecting the M.U.T.-
(Refer to How to Use Inspection Procedures P.00-9). III, turn the ignition switch to the "LOCK" (OFF)
position.
8. SERVICE DATA REFERENCE TABLE
<LH drive vehicles>
Inspection items and normal judgment values have
been provided in this chart as reference information.
9. ACTUATOR TEST TABLE

The Actuator Test item numbers, inspection items,
and judgment values have been provided in this Diagnosis
chart as reference information. connector
10. CHECK AT ECU TERMINALS MB991910

Terminal numbers for the ECU connectors, inspec-
tion items, and judgment values have been provided MB991824
in this chart as reference information.
11. INSPECTION PROCEDURE BY USING

AN OSCILLOSCOPE
When there are inspection procedures using an
oscilloscope, these are described here.
DIAGNOSIS FUNCTION MB991827 AC509179AB

M1001013400865
The diagnosis function retrieves diagnosis code and <RH drive vehicles> Diagnosis
service data by M.U.T.-III and enables the perform- connector
ance of the actuator test.
• DIAGNOSIS CODE
• Service data sent
• Actuator test
• Diagnosis deletion using M.U.T.-III
• Freeze frame data MB991910
• Status indication by diagnosis code
• ECU information display
NOTE: If a diagnosis code is set, the "status indica- MB991824
tion by diagnosis code" informs users whether a
mechanical problem currently exists (current trouble)
or whether it existed before but normal operation has
been restored (past trouble).
MB991827 AC501413AC
Connect the M.U.T.-III to the 16-pin diagnosis con-

nector, and read the diagnosis code.
NOTE: For details on how to use the M.U.T.-III, refer
to the "M.U.T.-III operation manual."
1. Ensure that the ignition switch is at the "LOCK"
(OFF) position.
2. Start up the personal computer.
GENERAL
00-9
3. Connect special tool M.U.T.-III USB cable NOTE: When storing the diagnosis code as refer-
MB991827 to V.C.I. (MB991824) and the personal ence information, the freeze frame data obtains the
computer. data when the diagnosis code is confirmed, and then
4. Connect special tool M.U.T.-III main harness A stores the ECU status of that time. By analysing
(MB991910) to the V.C.I. each data using M.U.T.-III, troubleshooting can be
carried out efficiently.
5. Connect the M.U.T.-III main harness A to the
diagnosis connector of the vehicle. 9. Disconnecting the M.U.T.-III is the reverse of the
connecting sequence, making sure that the
6. Turn the V.C.I. power switch to the "ON" position.
ignition switch is at the "LOCK" (OFF) position.
NOTE: When the V.C.I. is energized, the V.C.I.
indicator lamp will be illuminated in a green col- ERASING DIAGNOSIS CODE
our.
CAUTION
7. Start the M.U.T.-III system on the personal
Before connecting or disconnecting the M.U.T.-
computer and turn the ignition switch to the "ON"
III, turn the ignition switch to the "LOCK" (OFF)
position.
position.
8. Read the diagnosis code. Connect the M.U.T.-III to the diagnosis connector,
and erase the diagnosis code. The procedure is the
same as "How to Read Diagnosis Code ."
HOW TO USE THE INSPECTION

PROCEDURES
M1001013500345
The causes of many of the problems occurring in electric circuitry are generally the connectors, components,
the ECU, the wiring harnesses between connectors, in that order. These inspection procedures follow this
order. They first try to discover a problem with a connector or a defective component.
00-10 GENERAL
Relevant circuit(s) of the component which

the Code No. indicates are described.
Grey
AC301964AC
GENERAL
00-11
Start of diagnosis Describes

Explains about the basic
procedure inspection
operation of the components.
procedure.
M.U.T.-III data list
Explains about
technical details.
Describes the
conditions for that
diagnosis code being
set.
Describes possible
causes(s) for that
diagnosis code.
AC313955AC
CURRENT TROUBLE HARNESS CHECK

Indicates that the status is "Active" and the trouble is Check for an open or short circuit in the harness
currently present. Carry out troubleshooting as between the terminals which are faulty according to
described in the applicable inspection procedure. the connector measurements. Carry out this inspec-
tion while referring to the Electrical Wiring Manual.
PAST TROUBLE Here, "Check the wiring harness between the power
Indicates that the status is "Stored" and the trouble is supply and terminal xx" also includes checking for
historic. Since the trouble may still be present, set blown fuse. For inspection service points when there
the vehicle to the diagnosis code detection condition is a blown fuse, refer to "Inspection Service Points
and check that the status changes to "Active". If the for a Blown Fuse P.00-14."
status does not change from "Stored", observe the
applicable inspection procedure with particular MEASURES TO TAKE AFTER REPLAC-
emphasis on connector(s) and wiring harness. ING THE ECU
If the trouble symptoms have not disappeared even
after replacing the ECU, repeat the inspection proce-
dure from the beginning.
00-12 GENERAL
CONNECTOR MEASUREMENT SERVICE Inspect by inserting a test probe from the harness
POINTS side. If the connector is too small to insert a test
M1001013600386 probe (e.g. control unit connector), do not insert it
CAUTION forcibly. Use special tool extra fine probe
During diagnosis, a diagnosis code associated (MB992006).
with other system may be set when the ignition IF INSPECTING WITH THE CONNECTOR
switch is turned on with connector(s) discon- DISCONNECTED <WHEN INSPECTING A
nected. On completion, confirm all systems for FEMALE PIN>
diagnosis code(s). If diagnosis code(s) are set,
erase them all. CAUTION
Turn the ignition switch to the "LOCK" (OFF) position • Use special tool inspection harness
when connecting and disconnecting the connectors. (MB991219). If the test bar is inserted forcibly,
Turn the ignition switch to "ON" when measuring, it will cause a poor contact.
unless there are instructions to the contrary. • If the connector is disconnected, a diagnosis
IF INSPECTING WITH THE CONNECTOR code may be stored for the system to be
CONNECTED <WATERPROOF CONNECTORS> checked or other systems.
CAUTION MB991219
Never insert a test probe from the harness side,
as this will reduce the waterproof performance
and result in corrosion.
AC105599 AB
Use inspection harness (MB991219) of special tool

Special tool harness set (MB991223).
IF INSPECTING WITH THE CONNECTOR

AC105597AB
DISCONNECTED <WHEN INSPECTING A MALE
Use the special tools such as test harness, harness PIN>
connector or check harness.
CAUTION
IF INSPECTING WITH THE CONNECTOR • Be careful not to short the connector pins
CONNECTED <ORDINARY (NON-WATERPROOF) with the test bars. To do so may damage the
CONNECTORS> circuits inside the ECU.
• If the connector is disconnected, a diagnosis
code may be stored for the system to be
checked or other systems.
MB992006
AC105598AH
AC105600
Touch the pin directly with the test bar.

GENERAL
00-13
CONNECTOR INSPECTION SERVICE • Low contact pressure between male and female
POINTS terminals
M1001013700275 • Low connection pressure due to rusted terminals
VISUAL INSPECTION or foreign matter lodged in terminals
•
Connector disconnected or CONNECTOR PIN INSPECTION

improperly connected
Stretched or broken wires AC300898
If the connector pin stopper is damaged, the terminal

connections (male and female pins) will not be per-
fect even if the connector body is connected, and the
pins may pull out of the reverse side of the connec-
tor. Therefore, gently pull the harnesses one by one
to make sure that no pins pull out of the connector.
CONNECTOR ENGAGEMENT INSPECTION
Harness wire breakage MB991219

at terminal section
Low contact
pressure
Good
Bad
AC300899AB
Use special tool inspection harness (MB991219)

AC300896AB (connector pin connection pressure inspection har-
Connector is disconnected or improperly connected ness of the inspection harness set) to inspect the
• Connector pins are pulled out engagement of the male pins and female pins. (Pin
• Due to harness tension at terminal section drawing force: 1 N or more)
00-14 GENERAL
INSPECTION SERVICE POINTS FOR A HOW TO COPE WITH INTERMITTENT

BLOWN FUSE MALFUNCTIONS
M1001013800250 M1001013900257
CAUTION
A diagnosis code may be stored due to a blown
fuse.
Battery
Fuse
Short-circuit
Load occurrence
switch section
Load
AC300900AB
Remove the blown fuse and measure the resistance

between the load side of the blown fuse and the
earth. Close the switches of all circuits which are
connected to this fuse. If the resistance is almost 0 Ω
at this time, there is a short somewhere between
these switches and the load. If the resistance is not 0
Ω, there is no short at the present time, but a AC300901
momentary short has probably caused the fuse to
Intermittent malfunctions often occur under certain
blow.
conditions, and if these conditions can be ascer-
The main causes of a short circuit are the following.
tained, determining the cause becomes simple. In
• Harness being clamped by the vehicle body
order to ascertain the conditions under which an
• Damage to the outer casing of the harness due to
intermittent malfunction occurs, first ask the cus-
wear or heat
tomer for details about the driving conditions,
• Water getting into the connector or circuitry
weather conditions, frequency of occurrence and
• Human error (mistakenly shorting a circuit, etc.)
trouble symptoms, and then try to recreate the trou-
ble symptoms. Next, ascertain whether the reason
why the trouble symptom occurred under these con-
ditions is due to vibration, temperature or some other
factor. If vibration is thought to be the cause, carry
out the following checks with the connectors and
components to confirm whether the trouble symptom
occurs. The objects to be checked are connectors
and components which are indicated by inspection
procedures or given as probable causes (which gen-
erates diagnosis codes or trouble symptoms).
GENERAL
VEHICLE IDENTIFICATION
00-15
• Gently shake the connector up, down and to the HOW TO TREAT PAST TROUBLE
left and right. M1001014100243
• Gently shake the wiring harness up, down and to Since the trouble may still be present even the status
the left and right. is "Stored", set the vehicle to the diagnosis code
• Gently rock each sensor and relay, etc. by hand. detection condition and check that the status
• Gently shake the wiring harness at suspensions changes to "Active". If the status does not change
and other moving parts. from "Stored", carry out the following procedure.
1. Establish from the customer whether a fuse or
NOTE: If determining the cause is difficult, the drive
connector has been replaced or disconnected.
recorder function of the M.U.T.-III can also be used.
(For details on how to use the M.U.T.-III, refer to the 2. If yes, erase the diagnosis code, and then check
"M.U.T.-III operation manual). that no diagnostic code is reset. If no diagnosis
code is reset, the diagnosis is complete.
3. If no, follow the applicable Diagnostic Trouble
Code Chart. Then check the wiring harness and
connector, and refer to "How to Cope with
Intermittent Malfunction P.00-14 ."
MODELS
M1001000306510
VEHICLES FOR EUROPE
<SINGLE CAB>
Model code Engine model Transmission model Fuel supply system
KA4T NENMZL6 4D56 (2,477 mL) R5MB1 (Rear wheel drive Common rail fuel
DOHC DI-D (Direct Injection- 2WD, 5M/T) injection (Electrical
KB4T NENMZL6/R6 Diesel) engine with V5MB1 (Easy select 4WD, fuel injection)
intercooled turbocharger 5M/T)
<CLUB CAB>
KB4T NCNUZL6/R6 4D56 (2,477 mL) V5MB1 (Easy select 4WD, Common rail fuel
DOHC DI-D (Direct Injection- 5M/T) injection (Electrical
GCNXZL6 Diesel) engine with V5MB1 (Super select fuel injection)
intercooled turbocharger 4WD, 5M/T)
GCNXZPL6 4D56 (2,477 mL)
DOHC DI-D (Direct Injection-
Diesel) high-power engine
with intercooled turbocharger
00-16 GENERAL
<DOUBLE CAB>
KA4T NJNUZL6 4D56 (2,477 mL) R5MB1 (Rear wheel drive Common rail fuel
HJNUZL6 DOHC DI-D (Direct Injection- 2WD, 5M/T) injection (Electrical
Diesel) engine with fuel injection)
HJRUZL6 intercooled turbocharger R4A5A (Rear wheel drive
2WD, 4A/T)
KB4T NJNUZL6/R6 V5MB1 (Easy select 4WD,
5M/T)
NJRUZL6 V4A5A (Easy select 4WD,
4A/T)
GJNXZL6 V5MB1 (Super select
4WD, 5M/T)
GJRXZR6 V4A5A (Super select 4WD,
4A/T)
GJNXZPL6/R6 4D56 (2,477 mL) V5MB1 (Super select
DOHC DI-D (Direct Injection- 4WD, 5M/T)
GJYXZPL6/R6 Diesel) high-power engine
V5A5A (Super select 4WD,
with intercooled turbocharger
5A/T)
VEHICLES FOR RUSSIA (EASTERN EUROPE COUNTRIES)
KB4T NJNUZL6Z 4D56 (2,477 mL) V5MB1 (Easy select 4WD, Common rail fuel
DOHC DI-D (Direct Injection- 5M/T) injection (Electrical
GJNXZL6Z Diesel) engine with V5MB1 (Super select fuel injection)
intercooled turbocharger 4WD, 5M/T)
GJRXZL6Z V4A5A (Super select 4WD,
4A/T)
MODEL CODE <VEHICLES FOR EUROPE AND RUSSIA (EASTERN EUROPE COUNTRIES)>
B L 6Z
1 2 3 4 5 6 7 8 9 10 11
AC407365AK
No. Item Content

1 Development K L200
2 Drive system A 2WD
B 4WD
3 Engine type 4 2.5L diesel engine (4D56)
4 Sort T Truck
5 Vehicle width G Wide fender
H High rider
N Standard
6 Body style E Single cab
C Club cab
J Double cab
GENERAL
00-17
No. Item Content
7 Transmission type N 5-speed manual transmission
R 4-speed automatic transmission
Y 5-speed automatic transmission
8 Vehicle grade M GL
U GLX
X GLS
9 Engine specification Z Common rail (intercooled turbocharger)
ZP Common rail (intercooled turbocharger high power engine)
10 Steering wheel location L Left hand
R Right hand
11 Destination 6 Vehicles for Europe
6Z Vehicles for Russia (Eastern Europe countries)
VEHICLES FOR MOROCCO
KA4T NENMZ6BA 4D56 (2,477 mL) R5MB1 (Rear wheel drive Common rail fuel
DOHC DI-D (Direct Injection- 2WD, 5M/T) injection (Electrical
Diesel) engine with fuel injection)
intercooled turbocharger
MODEL CODE <VEHICLES FOR MOROCCO>
E M 6BA
1 2 3 4 5 6 7 8 9 10
ACA00801AC
No. Item Content

1 Development K L200
3 Engine type 4 2.5L diesel engine (4D56)
4 Sort T Truck
5 Vehicle width N Standard
6 Body style E Single cab
8 Vehicle grade M GL
9 Engine specification Z Common rail (intercooled turbocharger)
10 Destination 6BA Vehicles for Morocco
00-18 GENERAL
VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the

M1001005602547 side wall of the frame near the rear wheel (right side).
Frame
AC501503AB
C 0 00001
1 2 3 4 5 6 7 8 9 10 11 12 13
AC804908 AD
No. Item Content

1 Country M Thailand
2 Make M MITSUBISHI MOTORS (Thailand) Co., Ltd.
3 Register C Europe (including Russia)
4 Body type E Single cab
C Club cab
J Double cab
R 4-speed automatic transmission
Y 5-speed automatic transmission
6 Vehicle line K MITSUBISHI L200
B 4WD
8 Engine 4 2.5L diesel engine (4D56)
9 MMTh internal purpose 0 No meaning
10 Model year C 2012 year
11 Plants D Laemchabang-2 (Thailand motor vehicle works)
F Laemchabang-1 (Thailand motor vehicle works)
12 Emission step 0 Euro-4 <Vehicles for Morocco>, Euro-5
9 Euro-4 <Vehicles for Turkey>
Z Euro-3, Euro-4 <Vehicles for Russia (Eastern Europe countries) >
13 Serial number 00001 to 99999
GENERAL
00-19
VEHICLE INFORMATION CODE PLATE
M1001005402792
The vehicle identification number (VIN) is located on
a plate attached to the left top side of the instrument
panel.
AC508917AB
The information code plate is riveted to the cowl top 1 2 3 4 5 6 7 8 9 10 11 12 13

outer panel in the engine compartment.
AC804910AD
No. Item Content

1 Country M Thailand
MODEL 1
2 Make M MITSUBISHI MOTORS
ENGINE 2 (Thailand) Co., Ltd.
TRANS
AXLE 3 3 Register C Europe
COLOR,TRIM
4 5 6
OPT
4 Body type E Single cab
AC507828AB
C Club cab
J Double cab
No. Item Example Content
5 Transmission N 5-speed manual
1 MODEL KB4T Vehicle model type transmission
GJRXZL6 Model series R 4-speed automatic
2 ENGINE 4D56 Engine model transmission
3 TRANS V4A5A Transmission model Y 5-speed automatic
AXLE 4100 and final gear ratio transmission
4 COLOUR W32 Body colour code 6 Vehicle line K MITSUBISHI L200
5 TRIM 10X Interior code 7 Drive system B 4WD
6 OPT S31 Option code 8 Engine 4 2.5L diesel engine (4D56)
9 MMTh internal 0 No meaning
VEHICLE IDENTIFICATION NUMBER (VIN) purpose
PLATE <VEHICLES FOR RHD> 10 Model year C 2012
M1001005501945
11 Plants D Laemchabang-2 (Thailand
motor vehicle works)
F Laemchabang-1 (Thailand
motor vehicle works)
12 Emission step 0 Euro-5
13 Serial number 00001 to 99999
AC507971AB
00-20 GENERAL
MANUFACTURER PLATE No. Content

M1001017600399
4 Gross axle weight front
5 Gross axle weight rear
6 or 7 NTA No. (National type approval number)
ENGINE MODEL STAMPING

M1001005700861
AC508918AB
The manufacturer plate is riveted to the cowl top

outer panel in the engine compartment.
6 Front suspension upper arm <left side>

1 AC507123AD
2 The engine model is stamped on the cylinder block.
3
4
This engine model numbers is as shown as follow.
5
Engine model Engine displacement
7 4D56 2,477 mL
AC511709AB
The engine serial number is stamped near the
engine model number.
No. Content Engine serial number AA0201 to YY9999
1 Chassis No. (Vehicle identification number)
2 Gross vehicle weight
3 Gross combination weight
GENERAL
00-21
<VEHICLES FOR EUROPE>
M1001000906642
SINGLE CAB
11
10 12
8
13
1 3 4 5 7
2 6 9
AC805672
Item KA4T KB4T

NENMZL6 NENMZL6/NENMZR6
Vehicle Front track 1 1,505 1,505
dimension mm Overall width 2 1,750 1,750
Front overhang 3 830 830
Wheel base 4 3,000 3,000
Rear overhang 5 1,210 1,210
Overall length 6 5,040 5,040
Ground clearance (unladen) 7 200 200
Overall height (unladen) 8 1,655 1,775
Rear track 9 1,500 1,500
Cargo bed interior length 10 2,220 2,220
Cargo bed interior width 11 1,470 1,470
Cargo bed interior height 12 405 405
Cargo floor height (unladen) 13 715 845
Vehicle weight Kerb Without optional parts 1,565 1,780 <LHD>
kg weight 1,770 <RHD>
With full optional parts 1,595 1,840 <LHD>
1,810 <RHD>
Max. gross vehicle weight 2,630 2,850 <LHD>
2,890 <RHD>
Max. axle weight rating-front 1,030 1,260
Max. axle weight rating-rear 1,700 1,800
Max. towable With brake 1,800 2,700
weight Without brake 750 750
Max. trailer-nose weight 77 115
Max. gross combination weight 4,400 5,500 <LHD>
5,540 <RHD>
00-22 GENERAL
Item KA4T KB4T

NENMZL6 NENMZL6/NENMZR6
Seating capacity (including a driver) 2 2
Engine Model code 4D56 4D56
Total displacement mL 2,477 2,477
Type DOHC diesel DOHC diesel
Intercooled, Intercooled,
Turbocharger Turbocharger
Max. output kW/rpm (EEC net) 94/4,000 100/4,000
Max. torque N⋅m/rpm (EEC net) 240/1,500 − 3,500 314/2,000
Transmission Model code R5MB1 V5MB1
Type 5M/T 5M/T
Drive system Rear wheel drive 2WD Easy select 4WD
Fuel system Fuel supply system Electrical fuel injection Electrical fuel injection
Turning radius Body 6.1 6.3
m Wheel 5.7 5.9
NOTE: .
• Trailer specifications indicate the manufacturer’s recommendation.
• When loading luggage and/or towing a trailer, make sure not to exceed any of the above maximum
weights all the time.
CLUB CAB
11
10 12
13
1 3 4 5 7
2 6 9
AC805455
GENERAL
00-23
Item KB4T
NCNUZL6/NCNUZR6 GCNXZL6
Wheel base 4 3,000 3,000
Rear Without rear bumper 5 1,325 1,325
overhang With rear bumper 1,400 1,400
Overall Without rear bumper 6 5,120 5,120
length With rear bumper 5,195 5,195
Overall height (unladen) 8 1,775/1,790* 1,780
Rear track 9 1,500 1,515
Cargo bed interior length 10 1,805 1,805
Cargo bed interior height 12 460 460
Vehicle weight Kerb Without optional parts 1,800 1,815
kg weight With full optional parts 1,900 <LHD> 1,910
1,880 <RHD>
Max. gross vehicle weight 2,850 2,850
Max. gross combination weight 5,500 5,500
Max. torque N⋅m/rpm (EEC net) 314/2,000 314/2,000
Transmission Model code V5MB1 V5MB1
Type 5M/T 5M/T
Drive system Easy select 4WD Super select 4WD
m Wheel 5.9 5.9
00-24 GENERAL
NOTE: .
• *:Vehicles with rear body ground frame.
Item KB4T
GCNXZPL6
Vehicle Front track 1 1,520
dimension mm Overall width 2 1,815
Front overhang 3 795
Wheel base 4 3,000
Rear Without rear bumper 5 1,325
overhang With rear bumper 1,400
Overall Without rear bumper 6 5,120
length With rear bumper 5,195
Ground clearance (unladen) 7 205
Overall height (unladen) 8 1,780
Rear track 9 1,515
Cargo bed interior length 10 1,805
Cargo bed interior width 11 1,470
Cargo bed interior height 12 460
Cargo floor height (unladen) 13 860
Vehicle weight Kerb Without optional parts 1,825
kg weight With full optional parts 1,920
Max. gross vehicle weight 2,850
Max. axle weight rating-front 1,260
Max. axle weight rating-rear 1,800
Max. towable With brake 2,700
weight Without brake 750
Max. trailer-nose weight 115
Max. gross combination weight 5,500
Seating capacity (including a driver) 4
Engine Model code 4D56
Total displacement mL 2,477
Type DOHC High-power diesel Intercooled,
Turbocharger
Max. output kW/rpm (EEC net) 131/3,750
Max. torque N⋅m/rpm (EEC net) 400/2,000 − 2,850
Transmission Model code V5MB1
Type 5M/T
Drive system Super select 4WD
GENERAL
00-25
Item KB4T
GCNXZPL6
Fuel system Fuel supply system Electrical fuel injection
Turning radius Body 6.3
m Wheel 5.9
NOTE: .
DOUBLE CAB
11
10
12
8
13
1 3 4 5 7
2 6 9
AC809340 AB
<2WD>
Item KA4T
NJNUZL6 HJNUZL6
Wheel base 4 3,000 3,000
Rear Without rear bumper 5 1,210/1,390* 1,210/1,390*
overhang With rear bumper − 1,285/1,465*
Overall Without rear bumper 6 5,040/5,220 5,005/5,185*
length With rear bumper − 5,080/5,260*
Overall height (unladen) 8 1655 1,775
Rear track 9 1,500 1,500
Cargo bed interior length 10 1,325/1,505* 1,325/1,505*
Cargo bed interior height 12 405/460* 405/460*
00-26 GENERAL
Item KA4T
NJNUZL6 HJNUZL6
kg weight With full optional parts 1,735 1,900
Max. torque N⋅m/rpm (EEC net) 240/1,500 − 3,500 314/2,000
Transmission Model code R5MB1 R5MB1
Type 5M/T 5M/T
Drive system Rear wheel drive 2WD Rear wheel drive 2WD
m Wheel 5.7 5.9
NOTE: .
• *:Vehicles with long cargo bed.
GENERAL
00-27
Item KA4T
HJRUZL6
Wheel base 4 3,000
Rear Without rear bumper 5 1,210/1,390*
overhang With rear bumper 1,285/1,465*
Overall Without rear bumper 6 5,005/5,185*
length With rear bumper 5,080/5,260*
Rear track 9 1,500
Cargo bed interior length 10 1,325/1,505*
Cargo bed interior height 12 405/460*
Type DOHC diesel Intercooled, Turbocharger
Max. torque N⋅m/rpm (EEC net) 314/2,000
Transmission Model code R4A5A
Type 4A/T
Drive system Rear wheel drive 2WD
m Wheel 5.9
00-28 GENERAL
NOTE: .
<4WD>
Item KB4T
NJNUZL6/NJNUZR6 NJRUZL6
Wheel base 4 3,000 3,000
overhang With rear bumper 1,285/1,465* 1,285/1,465*
Overall Without rear bumper 6 5,005/5,185* 5,005/5,185*
length With rear bumper 5,080/5,260* 5,080/5,260*
Rear track 9 1,500 1,500
Vehicle weight Kerb Without optional parts 1,870 <LHD> 1,880
kg weight 1,850 <RHD>
With full optional parts 2,000 <LHD> 2,010
1,980 <RHD>
Max. gross vehicle weight 2,850 <LHD> 2,850
2,900 <RHD>
Max. gross combination weight 5,500 <LHD> 5,500
5,550 <RHD>
GENERAL
00-29
Item KB4T
NJNUZL6/NJNUZR6 NJRUZL6
Transmission Model code V5MB1 V4A5A
Type 5M/T 4A/T
Drive system Easy select 4WD Easy select 4WD
m Wheel 5.9 5.9
NOTE: .
Item KB4T
GJNXZL6 GJRXZR6
Wheel base 4 3,000 3,000
Rear track 9 1,515 1,515
00-30 GENERAL
Item KB4T
GJNXZL6 GJRXZR6
Type 5M/T 4A/T
Drive system Super select 4WD Super select 4WD
m Wheel 5.9 5.9
NOTE: .
GENERAL
00-31
Item KB4T
GJNXZPL6/GJNXZPR6 GJYXZPL6/GJYXZPR6
Wheel base 4 3,000 3,000
Rear track 9 1,515 1,515
Vehicle weight Kerb Without optional parts 1,900 <LHD> 1,915 <LHD>
kg weight 1,885 <RHD> 1,900 <RHD>
With full optional parts 2,040 <LHD> 2,045
2,030 <RHD>
Max. gross vehicle weight 2,850 <LHD> 2,850 <LHD>
2,930 <RHD> 2,945 <RHD>
Max. gross combination weight 5,500 <LHD> 5,500 <LHD>
5,580 <RHD> 5,595 <RHD>
Type DOHC High-power DOHC High-power
diesel Intercooled, diesel Intercooled,
Max. torque N⋅m/rpm (EEC net) 400/2,000 − 2,850 350/1,800 − 3,500
Type 5M/T 5A/T
Drive system Super select 4WD Super select 4WD
00-32 GENERAL
Item KB4T
GJNXZPL6/GJNXZPR6 GJYXZPL6/GJYXZPR6
m Wheel 5.9 5.9
NOTE: .

<VEHICLES FOR RUSSIA (EASTERN
EUROPE COUNTRIES)>
M1001000906653
11
10
12
13
1 3 4 5 7
2 6 9
AC502186AB
GENERAL
00-33
Item KB4T
NJNUZL6Z GJNXZL6Z
Wheel base 4 3,000 3,000
Rear Without rear bumper 5 1,210/1,390*1 1,210/1,390*1
overhang
With rear bumper 1,285/1,465*1 1,285/1,465*1
Overall Without rear bumper 6 5,040/5,220*1 5,040/5,220*1
length
With rear bumper 5,115/5,295*1 5,115/5,295*1
Rear track 9 1,500 1,515
Cargo bed interior length 10 1,325/1,505*1 1,325/1,505*1
Cargo bed interior height 12 405/460*1 405/460*1
Transmission Model code V5MB1 V5MB1
Type 5M/T 5M/T
Drive system Easy select 4WD Super select 4WD
m Wheel 5.9 5.9
00-34 GENERAL
Item KB4T
GJRXZL6Z
Wheel base 4 3,000
Rear Without rear bumper 5 1,210/1,390*1
overhang
With rear bumper 1,285/1,465*1
Overall Without rear bumper 6 5,040/5,220*1
length
With rear bumper 5,115/5,295*1
Rear track 9 1,515
Cargo bed interior length 10 1,325/1,505*1
Cargo bed interior height 12 405/460*1
Type DOHC diesel
Intercooled, Turbocharger
Max. torque N⋅m/rpm (EEC net) 314/2,000
Transmission Model code V4A5A
Type 4A/T
Drive system Super select 4WD
m Wheel 5.9
GENERAL
00-35
NOTE: .
• *1: Vehicle with extended cargo bed (optional)

<VEHICLES FOR MOROCCO>
M1001000906675
11
10 12
8
13
1 3 4 5 7
2 6 9
AC805672
Item KA4T
NENMZ6BA
Vehicle dimension Front track 1 1,505
mm Overall width 2 1,750
Wheel base 4 3,000
Rear overhang 5 1,210/1,385*1
Overall length 6 5,040/5,215*1
Rear track 9 1,500
Cargo bed interior length 10 2,220
Cargo bed interior height 12 405
Vehicle weight kg Kerb weight Without optional parts 1,550
With full optional parts 1,600
00-36 GENERAL
PRECAUTIONS BEFORE SERVICE
Item KA4T
NENMZ6BA
Type DOHC diesel
Intercooled, Turbocharger
Max. torque N⋅m/rpm (EEC net) 240/1,500 − 3,500
Transmission Model code R5MB1
Type 5M/T
Drive system Rear wheel drive 2WD
Turning radius m Body 6.1
Wheel 5.7
NOTE: .
• *1: Vehicles with rear step bumper assembly.

SERVICING COMMON RAIL ENGINE VEHICLES WITH SEMI AUTOMATIC AIR
M1001016400154
CONDITIONER STARTING
DANGER M1001011300077
• The working near to a naked flame or CAUTION
sparks must be avoided. Never start the engine with the refrigerant system
• Attention during engine running: empty as it will damage the A/C compressor.
a. Do not work on the high pressure fuel
circuit.
b. Always remain out of the way of possi-
ble fuel jet that may result in serious
injuries.
c. Do not place your hand near the high
pressure fuel circuit.
• Attention before service:
a. After turning the ignition switch to the
"LOCK" (OFF) position, wait for 30 sec-
onds before starting any repair
work.This period of time is required so
that the high pressure fuel circuit pres-
sure can get back to the atmospheric
pressure.
b. After turning the ignition switch to the
"LOCK" (OFF) position, wait 10 min-
utes before disconnecting the fuel
return pipe from diesel injectors.
GENERAL
00-37
SUPPLEMENTAL RESTRAINT SYSTEM seat belt pre-tensioner.
(SRS) AND SEAT BELT WITH PRE- • SRS-ECU, air bag modules, clock spring
and impact sensors: 93° C or more
TENSIONER
M1001011601695 • Seat belt with pre-tensioner: 90°C or more
CAUTION
Items to review when servicing SRS: SERVICING ELECTRICAL SYSTEM
M1001011900303
1. Be sure to read GROUP 52B − Supplemental CAUTION
Restraint System (SRS). For safe operation, Before connecting or disconnecting the negative
please follow the directions and heed all (−) cable, be sure to turn off the ignition switch
warnings. and the lighting switch (If this is not done, there
2. Wait at least 60 seconds after disconnecting is the possibility of semiconductor parts being
the battery cable before doing any further damaged).
work. The SRS system is designed to retain
enough voltage to deploy the air bag even
after the battery has been disconnected. Seri-
ous injury may result from unintended air bag
deployment if work is done on the SRS sys-
tem immediately after the battery cable is dis-
connected.
3. Warning/Caution labels must be heeded when
servicing or handling SRS components.
Warning labels can be found in the following
locations. (Refer to WARNING/CAUTION AC300693
LABELS .) Before replacing a component related to the electri-

4. Always use the designated special tools and cal system and before undertaking any repair proce-
test equipment. dures involving the electrical system, be sure to first
5. Store components removed from the SRS in a disconnect the negative (−) cable from the battery in
clean and dry place. The air bag module order to avoid damage caused by short-circuiting.
should be stored on a flat surface and placed
so that the pad surface is facing upward. Do
IN ORDER TO PREVENT VEHICLES
not place anything on top of it. FROM FIRE
M1001011100147
6. Never attempt to disassemble or repair the "Improper installation of electrical or fuel related parts
SRS components (SRS-ECU, air bag module could cause a fire. In order to retain the high quality
and clock spring). and safety of the vehicle, it is important that any
7. Whenever you finish servicing the SRS, check accessories that may be fitted or modifications/
the SRS warning lamp operation to make sure repairs that may be carried out which involve the
that the system functions properly. electrical or fuel systems, must be carried out in
8. Be sure to deploy the air bag before dispos- accordance with MMC's information/Instructions".
ing of the air bag module or disposing of a
vehicle equipped with an air bag (Refer to
GROUP 52B − Air Bag Module Disposal Pro-
cedures).
Observe the following when carrying out opera-
tions on places where SRS components are
installed, including operations not directly
related to the SRS air bag.
1. When removing or installing parts, do not
allow any impact or shock to the SRS compo-
nents.
2. If heat damage may occur during paint work,
remove the SRS-ECU, the air bag module,
clock spring, the front impact sensor, and the
00-38 GENERAL
MULTI USE TESTER (M.U.T.-III) SUB CAUTION

ASSEMBLY Turn the ignition switch to the "LOCK" (OFF)
M1001012400215 position before connecting or disconnecting the
Multi use tester (M.U.T.-III) M.U.T.-III.
sub assembly <LH drive vehicles>
Vehicle communication interface (V.C.I.)
Diagnosis
MB991824 connector
M.U.T.-III USB cable
MB991910
MB991824
MB991827
M.U.T.-III main harness A
MB991910 MB991827 AC509179AB
<RH drive vehicles> Diagnosis

M.U.T.-III main harness B connector
Do not use
MB991911
M.U.T.-III measurement adapter MB991910
MB991824
MB991825
M.U.T.-III trigger harness
MB991827 AC501413AC
MB991826
AC305090AK
Connect the M.U.T.-III to the diagnosis connector as
Refer to the "M.U.T.-III OPERATION MANUAL" for shown in the illustration.
instructions on handling the M.U.T.-III.
HOW TO PERFORM CHASSIS NUMBER
(CHASSIS NO.) WRITING
M1001015200715
Write the Chassis Number (Chassis No.) of immobi-
liser system as following procedure.
GENERAL
00-39
The Chassis Number (Chassis No.) is stored in the No. malfunction) is shown. When the engine-ECU or
engine-ECU or ETACS-ECU by the vehicle manufac- ETACS-ECU is replaced, and entry of the Chassis
ture. If the Chassis No. to be stored in the engine- No. necessary due to diagnosis code No. P0630
ECU or ETACS-ECU is eliminated fraudulently, the (Chassis No. malfunction). Enter the Chassis No. in
engine warning lamp illuminates and Diagnostic accordance with the procedure as follows:
Trouble Code (diagnosis code) No.P0630 (Chassis
SCREEN FLOW OF M.U.T.-III
System choice IMMOBILIZER
Special Function Coding

Engine Key Code
Chassis No. Writing Chassis No. Information
Reg. & Chassis No.
Writing
Key Code Registration to Engine-ECU IMMOBILIZER & Chassis No. Chassis No. Information
Writing
Key Code Registration Completed

Writing confirmation
Engine Key Code Reg. &

Chassis No. Writing Chassis No. Writing
Chassis No. Writing

Confirmation of Chassis No. writing
Completed
execution
Writing Result Display

Chassis No. Writing
Chassis No. Writing Completed
Result of Chassis No. Writing
AC510087AE
00-40 GENERAL
CHASSIS NUMBER REGISTRATION PRO- Connect the M.U.T.-III to the 16-pin diagnosis con-
CEDURE FOR ENGINE-ECU nector, and read the diagnosis code.
CAUTION
• Check that diagnosis code No.P0603 (EEP-
ROM malfunction) is not set. If diagnosis
(OFF) position.
code No.P0603 (EEPROM malfunction) is set,
entered Chassis No. cannot be stored. There- 2. Start up the personal computer.
fore, carry out troubleshooting and repair the 3. Connect special tool M.U.T.-III USB cable
malfunction when this code is set. (MB991827) to V.C.I. (MB991824) and the
<LH drive vehicles>
•
personal computer.
4. Connect special tool M.U.T.-III main harness A
(MB991910) to the V.C.I.
diagnosis connector.
6. Turn the V.C.I. power switch to the "ON" position.
Diagnosis
connector NOTE: When the V.C.I. is energized, the V.C.I.
indicator lamp will be illuminated in a green col-
MB991910 our.
7. Start the M.U.T.-III system on the personal
MB991824
position.
MB991827 AC509179AB

connector
AC510062
8. Select "IMMOBILIZER" in the "System Select"

tag. Select the model year and push the OK
button (Check each model if there is an option).
Select "Special Function" on the next screen, and
MB991910 select "Engine Key Code Reg. & Chassis No.
Writing" on the further screen.
MB991824
OK button
AC510063AB
MB991827 AC501413AC
To prevent damage to M.U.T.-III, always turn the 9. Push the OK button after "Key Code Registration"
ignition switch to the "LOCK" (OFF) position is displayed.
before connecting or disconnecting M.U.T.-III.
GENERAL
00-41
10.Push the OK button after "Completed. Press the CHASSIS NUMBER REGISTRATION PRO-
OK button and move to Chassis No. writing CEDURE FOR ETACS-ECU.
function." is displayed.
<LH drive vehicles>
*****************
*****************
Diagnosis
connector
MB991910
AC510064AB
MB991824
11.Enter the Chassis No. of registering vehicle and
push the OK button.
12.Push the OK button after "Chassis No. Writing will
start. Are you sure?" is displayed.
13.Return to the previous screen and "In Progress" is
displayed at the lower-left corner on the screen.
14.Push the OK button after "Completed." is
displayed. MB991827 AC509179AB

IMMOBILIZER Special Functio Engine Key Code Reg. Chassis No. Writing
connector
Result of Writing
Item Current Before Writing
Chassis No. ***************** *****************
MB991910
AC510065AB
15.Chassis No. writing result is displayed. MB991824

16.Select "Chassis No. Information" on the "Coding"
screen after the Chassis No. writing is completed,
and check that the Chassis No. is changed.
17.Complete the M.U.T.-III.
18.Disconnecting the M.U.T.-III is the reverse of the
connecting sequence, making sure that the
ignition switch is at the "LOCK" (OFF) position.
MB991827 AC501413AC
Connect the M.U.T.-III to the 16-pin diagnosis con-

nector, and read the diagnosis code.
(OFF).
2. Start up the personal computer.
3. Connect M.U.T.-III USB cable (MB991827) to
special tool Vehicle Communication Interface
(V.C.I.) (MB991824) and the personal computer.
00-42 GENERAL
4. Connect M.U.T.-III main harness A (MB991910) to

the V.C.I.
diagnosis connector.
6. Turn the V.C.I. power switch to the "ON" position. *****************
NOTE: When the V.C.I. is energized, the V.C.I.
indicator lamp will be illuminated in a green col-
our.
7. Start the M.U.T.-III system on the personal AC510067AB
position. 13.Chassis No. writing result is displayed.
14.Select "Chassis No. Information" on the "Coding"
screen after the Chassis No. writing is completed,
and check that the Chassis No. is changed.
15.Resister the other ID code.(Refer to GROUP 54A,
Immobilizer system − On-vehicle service )
PRE-INSPECTION CONDITION
M1001012100388
"Pre-inspection condition" refers to the condition that
the vehicle must be in before proper engine inspec-
AC510062
tion can be carried out. If you see the words "Set the
8. Select "IMMOBILIZER" in the "System Select" vehicle to the pre-inspection condition" in this man-
tag. Select the model year and push the OK ual. It means to set the vehicle to the following condi-
button (Check each model if there is an tion.
option).Select "Coding" on the next screen, and • Engine coolant temperature 80 to 90°C
select "Chassis No. Writing" on the further screen. • Lamps, electric cooling fan and all accessories:
OFF
• M/T: Neutral
***************** • A/T: P range
ENGINE OILS
M1001011200155
HEALTH WARNING
OK button Prolonged and repeated contact with mineral oil will
result in the removal of natural fats from the skin,
leading to dryness, irritation and dermatitis. In addi-
AC510066 AC tion, used engine oil contains potentially harmful con-
taminants which may cause skin cancer. Adequate
9. Enter the Chassis No. of registering vehicle and
means of skin protection and washing facilities must
push the OK button.
be provided.
10.Push the OK button after "Chassis No. Writing will
start. Are you sure?" is displayed. RECOMMENDED PRECAUTIONS
11.Return to the previous screen and "In Progress" is The most effective precaution is to adapt working
displayed at the lower-left corner on the screen. practices which prevent, as far as practicable, the
12.Push the OK button after "Completed." is risk of skin contact with mineral oils, for example by
displayed. using enclosed systems for handling used engine oil
and by degreasing components, where practicable,
before handling them.
Other precautions:
• Avoid prolonged and repeated contact with oils,
particularly used engine oils.
GENERAL
00-43
• Wear protective clothing, including impervious • Obtain first aid treatment immediately for open
gloves where practicable. cuts and wounds.
• Avoid contaminating clothes, particularly under- • Wash regularly with soap and water to ensure all
pants, with oil. oil is removed, especially before meals (skin
• Do not put oily rags in pockets, the use of overalls cleansers and nail brushes will help). After clean-
without pockets will avoid this. ing, the application of preparations containing
• Do not wear heavily soiled clothing and oil- lanolin to replace the natural skin oils is advised.
impregnated foot-wear. Overalls must be cleaned • Do not use petrol, kerosine, diesel fuel, gas oil,
regularly and kept separately from personal cloth- thinners or solvents for cleaning skin.
ing. • Use barrier creams, applying them before each
• Where there is a risk of eye contact, eye protec- work period, to help the removal of oil from the
tion should be worn, for example, chemical gog- skin after work.
gles or face shields; in addition an eye wash • If skin disorders develop, obtain medical advice
facility should be provided. without delay.
WHAT THE COMMON RAIL ENGINE LEARNS

M1001012500018
After fuel-related parts are replaced, the common rail NOTE: When the engine-ECU is replaced, collect in
engine must register their identification codes with advance the injector identification code from the cur-
the engine-ECU and execute learning. rent engine-ECU. Doing it makes registration easy.
The table below shows what should be registered Correspondence table
and learned after each type of operation.
Registration and learning item Operation type
Injector Supply pump Engine-ECU
replacement replacement replacement
Injector identification code registration applicable − applicable
Small injection quantity learning applicable − applicable
Supply pump correction learning − applicable −
REGISTRATION AND LEARNING PROCE- Small injection quantity learning

DURE Refer to P.00-45, SMALL INJECTION QUANTITY
LEARNING PROCEDURE.
Injector identification code registration
Refer to P.00-43, INJECTOR IDENTIFICATION Supply pump correction learning
CODE REGISTRATION PROCEDURE. Refer to P.00-45, SUPPLY PUMP CORRECTION
LEARNING PROCEDURE.
INJECTOR IDENTIFICATION CODE REGISTRATION PROCEDURE

M1001012600015
CAUTION
1. If the injector identification code is not regis- Identification code
tered, the engine warning lamp goes on and
diagnosis code No. P1626 is logged.
2. Failure to register the injector identification
code correctly will cause rough idling, abnor-
mal noise, and emission deterioration.
PURPOSE
AK501491 AB
Because individual injectors have different injection

characteristics, the engine-ECU corrects injection
time for each cylinder to improve injection accuracy.
00-44 GENERAL
For this reason, when the injector or engine-ECU is 6. If the injector has been replaced or data has not
replaced, injector correction data must be registered been read from the current engine-ECU, register
afterwards in the engine-ECU using the Multi Use the injector identification code as follows:
Tester III (M.U.T.-III). (1) Select Write Injector ID Code from the
Correction data is converted into an identification SPECIAL FUNCTION menu.
code consisting of 30 alphanumeric characters and (2) If the injector was replaced, specify whether to
printed on the injector connector. write to every cylinder or a specific cylinder.
REGISTRATION PROCEDURE Frame 1 Frame 2
(4 digits) (4 digits)
1. When replacing the engine-ECU, connect the
current engine-ECU to the body harness. Frame 3 Frame 4
NOTE: This operation is purposed to read the injec- (4 digits) (4 digits)
tor identification code stored in the engine-ECU. Frame 5 Frame 6
Reading the identification code in this way before (4 digits) (4 digits)
replacement can eliminate manual input of the identi-
Frame 7 Frame 8
fication code after replacement. (4 digits) (2 digits)
2. After the ignition switch is in "LOCK" (OFF) AK501492 AB
position, connect the M.U.T.-III to the diagnosis
(3) Select the write mode from the menu, enter
connector.
the identification code printed on the injector,
3. Turn the ignition switch to "ON" position. and execute writing.
4. Select SPECIAL FUNCTION from the function
CAUTION
menu.
Even if the number of the cylinder to be regis-
5. When the current engine-ECU is still mounted, tered does not match the actual injector mount-
read and register the injector identification code ing location, registration ends normally. Specify
as follows: the cylinder number correctly.
(1) Select Read Injector ID Code (for engine-ECU
NOTE: The identification code is displayed in order
replacement) from the SPECIAL FUNCTION
of the frame numbers when it is read.
menu.
7. Makes sure that the engine warning lamp that is
(2) Select Write and Save Injector ID Code from
on changes to blinking, indicating the registration
the menu to read data from the current engine-
is complete.
ECU and save the data if it could be read
normally. NOTE: When the injector is replaced, executing the
write operation also clears the values of small injec-
(3) Mount the new engine-ECU on the vehicle.
tion quantity learning.
(4) Select SPECIAL FUNCTION from the function
8. Execute small injection quantity learning.
menu.
(5) Select Write Injector ID Code (for engine-ECU Refer to P.00-45, the SMALL INJECTION
replacement) from the SPECIAL FUNCTION QUANTITY LEARNING PROCEDURE for the
menu. learning procedure.
(6) Select SAVED INJECTOR ID WRITING from 9. Confirm that the engine warning lamp is off.
the Write Injector ID Code menu to write the Confirm also that the diagnosis code is not stored.
data, which was saved previously, to the
engine-ECU.
GENERAL
00-45
SMALL INJECTION QUANTITY LEARNING PROCEDURE
M1001014300322
CAUTION NOTE: The engine sound may change or idling

1. If small injection quantity learning has not engine speeds may increase during injection learn-
been executed, the engine warning lamp ing. These are not abnormalities.
blinks.
2. When the requirements for learning are satis- LEARNING PROCEDURE
fied by operation after replacement of the 1. After the ignition switch is in "LOCK" (OFF)
engine-ECU, learning is automatically exe- position, connect the M.U.T.-III to the diagnosis
cuted even if no instruction is given from the connector.
M.U.T.-III. Accordingly, the malfunction indica- 2. Put the vehicle in the following idling stable
tor lamp goes off. However, the learning thus conditions:
executed is tentative and limited. Be sure to • Engine coolant temperature: 80 − 90°C
complete leaning using the M.U.T.-III. • Fuel temperature: 30 − 100°C
• Intake air temperature: −30 to 100°C
PURPOSE • Barometric pressure: 70 kPa or more
To keep emission and noise level at adequate levels, • Automatic transmission fluid temperature: 60°C
the engine-ECU must learn injector fuel injection in or higher
idle mode. • Lamps, A/C condenser fan and all accessories:
During learning, the engine-ECU calculates actual OFF
injection from each cylinder based on changes in • Transmission: Neutral <M/T>, "P" range <A/T>
engine speeds and corrects pilot injection control. It • Power steering: Static state
then keeps records of this amount of correction as a 3. Select SPECIAL FUNCTION from the function
learned value. menu.
For this reason, after the engine-ECU or injector is 4. Select LEARNING from the SPECIAL FUNCTION
replaced, learning must be executed using the menu.
M.U.T.-III.
5. Select Item No. 1 Small injection quantity learning
NOTE: Engine friction changes or injector deteriora- to execute learning.
tion over time may cause fluctuation in pilot injection.
CAUTION
After use over time, it may prevent injection of an
If the vehicle conditions go out of the learning
accurate amount of fuel according to the indication
conditions during idling, learning is interrupted.
by the engine-ECU. This is why learning must be
executed again periodically. To reexecute learning, the ignition switch
For this reason, the engine-ECU periodically leans must once be turned off.
injection according to the cumulative mileage. 6. Continue idling for about 3 minutes before
Note that making the M.U.T.-III learn again resets the learning is completed.
cumulative mileage. 7. Confirm that the engine warning lamp is off. If it
still blinks, reexecute learning.
SUPPLY PUMP CORRECTION LEARNING PROCEDURE

M1001014400299
PURPOSE Re-learning is executed when the engine is idling

The engine-ECU learns the relation between the after the learning value in the engine-ECU has been
suction control valve (linear solenoid valve) of the reset by the M.U.T.-III.
supply pump drive current and the fuel injection vol-
ume. LEARNING PROCEDURE
The learning value is calculated from the suction After the ignition switch is in "LOCK" (OFF) position,
control valve drive current and the rail pressure sen- connect the M.U.T.-III to the diagnosis connector.
sor output voltage. 1. Turn the ignition switch to "ON" position. (Do not
When the supply pump is replaced, therefore, this start the engine.)
learning must be executed. 2. Select SPECIAL FUNCTION from the function
menu.
00-46 GENERAL
3. Select INITIALIZATION from SPECIAL Service Item Item

FUNCTION menu. No.
4. Select and initialize Item No. 21 Supply pump At replacing DPF 40 DPF exchange service
exchange service.
At replacing 41 DPF differential
5. After initializing, run the engine at idle in the
exhaust differential pressure sensor
following conditions.
pressure sensor exchange service
• Accelerator pedal: OFF
• Engine coolant temperature: 60°C or higher At replacing 42 DPF system
• Fuel temperature: 30°C or higher catalytic converter malfunction service
6. Confirm that the item No. 65 High pressure pump
learned status on M.U.T.-III Service Data is "2". BATTERY CURRENT SENSOR
NOTE: "2" indicates that the learning has completed. CALIBRATION <Euro5>
M1001018600240
INITIALIZATION PROCEDURE FOR PURPOSE

The engine-ECU carries out the electrical generation
LEARNING VALUE IN DIESEL
control according to the charge level of the battery,
PARTICULATE FILTER (DPF) SYSTEM based on the battery current sensor signal. To
<Euro5> improve the effect of reducing the fuel consumption
M1001015600069
by the electrical generation control, it is necessary to
PURPOSE accurately detect the charge level of the battery. For
The engine-ECU stores the change of the DPF sys- this, if the following services are performed, carry out
tem caused by the various driving conditions as the the battery current sensor calibration.
learning value and uses it for assumption of the PM • Replacing the battery current sensor
accumulated amount or for the acceptance/rejection • Replacing the engine-ECU
criteria of the DPF system. For this reason, the learn-
ing value is necessary to be initialized when the parts LEARNING PROCEDURE
related to the DPF system are replaced.
1. After the ignition switch is in "LOCK" (OFF)
INITIALISATION PROCEDURE position, disconnect the battery cable from the
1. After the ignition switch is in "LOCK" (OFF) negative battery terminal.
position, connect M.U.T.-III with the diagnosis
connector.
2. Ignition switch is in "ON" position.
3. Select the "SPECIAL FUNCTION" from the
"FUNCTION MENU" on the M.U.T.-III.
4. Select the INITIALIZATION from the SPECIAL
FUNCTION. Battery current
5. Select the item on the screen of the initialization sensor
for learning, and perform the initialization.
AKB00261AB
2. Remove the battery current sensor from the

battery cable (Do not disconnect the battery
current sensor connector).
3. Connect the battery cable without the battery
current sensor to the negative battery terminal.
GENERAL
00-47
<LH drive vehicles> 9. Select "Battery current SNSR.calibration" from
Learning Screen.
10.Start the calibration by pressing the "OK" button.
11.Confirm that the M.U.T.-III data list item No. 452
Battery current sensor calibration is "Completed".
Diagnosis
12.After the ignition switch is in "LOCK" (OFF)
connector position, disconnect the M.U.T.-III.
13.Install the battery current sensor.
MB991910
HOW TO USE THE THROTTLE
MB991824
CONTROLLER
M1001009300036
As for a vehicle with the electronic control throttle
valve*, engine operations such as racing can not be
performed from outside the vehicle. Thus, the throttle
valve controller (MB991791) is provided as a special
tool to enable the engine operation from outside the
vehicle.
MB991827 AC509179AB NOTE: *: A vehicle with the accelerator pedal posi-
tion sensor (APS) installed to the accelerator pedal
<RH drive vehicles> Diagnosis THE THROTTLE CONTROLLER CONNECTION
connector
APS harness
side connector
MB991894
MB991910
MB991791
MB991824 AC103781AC
1. Disconnect the accelerator pedal position sensor

(APS) connector installed to the accelerator
pedal, and connect the 6-pin connector of throttle
controller adaptor (MB991894) to the vehicle
harness-side connector.
2. Connect the throttle controller (MB991791) to the
MB991827 8-pin connector of throttle controller adaptor
AC501413AC
(MB991894).
4. Connect the M.U.T.-III to the diagnosis connector
(But do not start the engine). APPLICATION OF ANTI-CORROSION
5. Turn the ignition switch to the ON position. AGENTS AND UNDERCOATS
M1001011000247
6. Select "MPI/GDI/DIESEL" from System select If oil or grease gets onto the oxygen sensor, it will
Screen of the M.U.T.-III. cause a drop in the performance of the sensor.
7. Select "Special Function" from MPI/GDI/DIESEL Cover the oxygen sensor with a protective cover
Screen. when applying anti-corrosion agents and undercoats.
8. Select "Learning" from Special Function Screen.
00-48 GENERAL
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
VEHICLE WASHING • Because radio wave is radiated from the coaxial

M1001012000723 cables of the antenna for radio transmission
equipment, do not route the cables in parallel with
the vehicle wiring harness.
Approximately • Install only radio transmission equipment with the
40 cm or more frequencies, output, and radio wave types
described in the table.
FREQUENCY, OUTPUT, AND RADIO WAVE
TYPE OF THE RADIO TRANSMISSION
EQUIPMENT
AC300832AC
Frequency Maximum Modulation
(MHz) output power
If high-pressure car-washing equipment or steam
(W)
car-washing equipment is used to wash the vehicle,
be sure to note the following information in order to 3.5 50 CW, FM, AM,
avoid damage to plastic components, etc. 7 SSB
• Spray nozzle distance: Approx. 40 cm or more 14
• Spray pressure: 3,900 kPa or less
• Spray temperature: 82°C or less 21
• Time of concentrated spray to one point: within 28
30 sec. 50
PRECAUTIONS FOR INSTALLATION OF 144
ON-VEHICLE RADIO TRANSMISSION 430
EQUIPMENT 1,260 2
M1001015500095 •
The computers (control unit) for various on-vehicle

electronic equipment are provided with sufficient pro-
tective measures against external radio wave inter-
ference. However, because the on-vehicle radio
transmission equipment may affect adversely the
computers (control unit), pay attention to the follow-
ing precautions for installation.
• Install radio transmission equipment and antenna
(including coaxial cables) 200 mm or more away Antenna attachment position
from the computers (control unit) for on-vehicle AC709451AB
electronic equipment. Install the antenna for radio transmission equipment
only to the position shown in the figure.

M1001009801120
The driver’s and passenger’s air bag and seat belt The Supplemental Restraint System (SRS) consists
with pre-tensioner is designed to supplement the of air bag modules, SRS air bag control unit (SRS-
driver's and front passenger's seat belts to help ECU), front impact sensors, side impact sensor, SRS
reduce the risk or severity of injury to the driver and warning lamp, clock spring, passenger’s air bag cut
front passenger by activating and deploying both off switch, passenger’s air bag cut off indicator lamp
front air bags in certain frontal collisions. The side-air and seat belt with pre-tensioner. Front air bags are
bag and the curtain air bag are activated when an located in the centre of the steering wheel and above
impact exceeds the threshold upon a side collision, the glove box. Side-airbags are located inside the
and inflates to protect the heads of the occupants in front seatback assemblies. The curtain air bag mod-
the front and rear seats. ule is installed in the roof side sections (from the
GENERAL
00-49
driver's and the passenger's front pillars to the rear installed in the steering column. The passenger’s air
pillars). Each air bag is made up of a folded air bag bag cut off switch is located above inside the glove
and an inflator unit. The SRS-ECU is mounted on the box. The passenger’s air bag cut off indicator lamp is
front of the floor console and has a front air bag saf- located above the centre upper panel. The seat belt
ing G-sensor, front air bag analogue G-sensor. The pre-tensioner is built into the driver's and passen-
front impact sensor is installed out side of the head- ger's front seat belt retractor.
lamp support panel. The side impact sensor is Only authorized service personnel should do work on
installed in the lower parts of the centre pillars. The or around the SRS components. Those service per-
warning lamp on the instrument panel indicates the sonnel should read this manual carefully before start-
operational status of the SRS. The clock spring is ing any such work.
<A/T> Driver's air bag Passenger's air bag

SRS warning lamp module cut off indicator lamp
Passenger's (front)
air bag module
Clock spring
<M/T> SRS warning lamp
Passenger's air bag
cut off switch
SRS-ECU
Side-airbag module
Curtain air bag module
SRS-ECU
Side impact sensor

Front impact sensor
Seat belt pre-tensioner
AC900651AB
00-50 GENERAL
SRS SERVICE PRECAUTIONS

M1001006001006
DANGER CAUTION
In order to avoid injury to yourself or others SRS-ECU connector
from accidental deployment of the air bag <Vehicles without side-airbag and curtain air bag>
during servicing, read and carefully follow all
the precautions and procedures described in
this manual.
CAUTION <Vehicles with side-airbag and curtain air bag>
Do not use any electrical test equipment on or
near SRS components, except those specified on
.
AC800836 AB
CAUTION
Never attempt to repair the following compo- Do not attempt to repair the wiring harness con-
nents: nectors of the SRS. If a defective wiring harness
1. SRS-ECU is found, repair or replace it by referring to the
table below.
2. Front impact sensor
3. Clock spring
4. Driver's and passenger's (front) air bag mod-
ules
5. Seat belt with pre-tensioner
6. Side impact sensor
7. Front seatback assembly incorporating side-
airbag module
8. Curtain air bag module
NOTE: If any of these components are diagnosed as
faulty, they should only be replaced, in accordance
with the INDIVIDUAL COMPONENTS SERVICE pro-
cedures in this manual, starting at page .
<Vehicle without side-airbag and curtain air bag>
SRS-ECU terminal No. Destination of harness Remedy
1, 2 Instrument panel wiring harness → Correct or replace each wiring harness.
Front wiring harness → Front impact
sensor (RH)
sensor (LH)
8 Instrument panel wiring harness → Correct or replace the Instrument panel
SRS warning lamp wiring harness.
9, 10 Instrument panel wiring harness → Correct or replace the instrument panel
Passenger's air bag cut off switch → wiring harness.
Passenger's (front) air bag module
11, 12 Instrument panel wiring harness → Correct or replace instrument panel
Clock spring → Driver's air bag module wiring harness. Replace the clock
spring.
13 Instrument panel wiring harness → Correct or replace the instrument panel
Junction block (fuse No.21) wiring harness.
GENERAL
00-51
Earth wiring harness.
Diagnosis connector wiring harness.
Floor wiring harness → Seat belt pre-
tensioner (passenger’s side)
Floor wiring harness → Seat belt pre-
tensioner (driver’s side)
<Vehicle with side-airbag and curtain air bag>

1, 2 Floor wiring harness → Instrument Correct or replace each wiring harness.
panel wiring harness → roof wiring
harness → curtain air bag module (LH)
3, 4 Floor wiring harness → side-airbag Correct or replace the floor wiring
module (LH) harness.
5, 6 Floor wiring harness → Seat belt pre-
tensioner (passenger’s side)
15, 16 Floor wiring harness → side impact
sensor (LH)
21, 22 Instrument panel wiring harness → Correct or replace the instrument panel
Passenger's air bag cut off switch → wiring harness.
Passenger's (front) air bag module
27, 28 Instrument panel wiring harness → Correct or replace instrument panel
Clock spring → Driver's air bag module wiring harness. Replace the clock
spring.
sensor (LH)
35, 36 Instrument panel wiring harness →
sensor (RH)
38 Instrument panel wiring harness →
Diagnosis connector
SRS warning lamp
Earth
Junction block (fuse No.21)
00-52 GENERAL

51, 52 Floor wiring harness → Seat belt pre- Correct or replace the floor wiring
tensioner (driver’s side) harness.
53, 54 Floor wiring harness → side-airbag
module (RH)
55, 56 Floor wiring harness → Instrument Correct or replace each wiring harness.
panel wiring harness → roof wiring
harness → curtain air bag module (RH)
61, 62 Floor wiring harness → side impact Correct or replace the floor wiring
sensor (RH) harness.
DANGER retain enough voltage to deploy the air bag
Insulating tape
Battery
Battery cable
AC300580AB
After disconnecting the battery cable, wait 60

seconds or more before proceeding with the
following work. In addition, insulate the neg-
ative battery terminal with a tape. The con-
denser inside the SRS-ECU is designed to
GENERAL
00-53
for a short time even after the battery has touched directly by the probe, the plating may
been disconnected, so serious injury may break, which will cause drops in reliability.
result from unintended air bag deployment if
work is done on the SRS system immediately
after the battery cables are disconnected.
CAUTION
The SRS components and seat belt with pre-ten-
sioner should not be subjected to heat, so
remove the SRS-ECU, driver’s and passenger’s
(front) air bag modules, clock spring, front
impact sensor, seat belt with pre-tensioner
before drying or baking the vehicle after painting.
• SRS-ECU, air bag modules, clock spring and
impact sensors: 93° C or more
• Seat belt with pre-tensioner: 90°C or more
CAUTION
Whenever you finish servicing the SRS, always
erase the diagnosis code and check warning
lamp operation to make sure that the system
functions properly.
CAUTION
SRS-harness connector
MB992006
SRS-ECU harness connector (rear side)

<Vehicles without side-airbag and curtain air bag>
<Vehicles with side-airbag and curtain air bag>
AC801105AB
If checks are carried out by using the SRS-ECU

harness connector, observe the following proce-
dures: Insert the special tool extra fine probe
(MB992006) into connector from harness side
(rear side), and connect the tester to this probe. If
any tool than special tool is used, damage to the
harness and other components will result. Never
insert the probe directly to the terminals from the
front of the connector. The terminals are plated
to increase their conductivity, so that if they are
00-54 GENERAL
SUPPORT LOCATIONS FOR LIFTING AND JACKING

M1001000701160
SUPPORT POSITIONS FOR A GARAGE JACK AND AXLE STANDS

CAUTION
Do not support the vehicles at locations other than specified supporting points. Doing so will cause
damage, etc.
AXLE STANDS
<Front> <Rear> <Rear>
AC502650 AC502651 AC502647
GARAGE JACK
<Front> <Rear>
crossmember
AC502069 AC502070
AC502553AF
GENERAL
00-55
SUPPORT POSITIONS FOR A SINGLE-POST LIFT OR DOUBLE-POST LIFT
CAUTION
When service procedures require removing rear suspension, spare tyre and rear bumper, place addi-
tional weight on rear end of vehicle or anchor vehicle to hoist to prevent tipping of centre of gravity
changes.
<Front> <Rear>
AC505968 AC502653
AC502572 AC
00E-1
GROUP 00E
GENERAL
<ELECTRICAL>
CONTENTS
HOW TO READ WIRING DIAGRAMS 00E-2 HOW TO READ CIRCUIT DIAGRAMS . . . . 00E-4
COMPOSITION AND CONTENTS OF WIRING MARKINGS FOR CONNECTOR AND EARTHING
DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . 00E-2 ...................................... 00E-5
HOW TO READ CONFIGURATION DIAGRAMS WIRE COLOUR CODES . . . . . . . . . . . . . . . 00E-7
...................................... 00E-2 ABBREVIATION SYMBOLS . . . . . . . . . . . . 00E-8
00E-2 GENERAL <ELECTRICAL>
HOW TO READ WIRING DIAGRAMS

COMPOSITION AND CONTENTS OF
WIRING DIAGRAMS
M1001012800150
In each section, all specifications are listed, including optional specifications. Accordingly, some specifica-
tions may not be applicable for individual vehicles.
Section Basic contents

Component Locations are shown for each point of relays, ECUs, sensors, solenoid valves,
locations inspection connectors, fusible links, fuses, etc. In the part’s lists, parts are listed in
alphabetical order.
Configuration Connector locations and harness wiring configurations on actual vehicles are
diagrams illustrated.
Circuit diagrams Circuits from power source to earth are shown completely, classified according to
system. There is a main division into power source circuits and circuits classified by
system.
• Junction block
The entire circuit for the junction block is described, because only the part of the
junction block needed is normally shown in each circuit diagram.
• Joint connectors
The internal circuits for all joint connectors are described, because only the part
needed is shown in each circuit diagram.
• Power source circuits
Circuits from the battery to fusible link, fuse, ignition switch, etc are shown.
• Circuits classified by system
For each system, the circuits are shown from fuse to earth, excluding the power
source sections.
HOW TO READ CONFIGURATION

DIAGRAMS
M1001006400227
The wiring harness diagrams clearly show the connector locations and harness routings at each site on
actual vehicles.
GENERAL <ELECTRICAL>
00E-3
Denotes connector No.

The same connector No. is used throughout the circuit diagrams to facilitate connector location search.
The first alphabetical symbol indicates the location site of the connector and a number that follows is the unique number.
Numbers are usually assigned to part in clockwise order on the diagram.
Example: A-19
Number specific to connector (serial number)
Connector location site symbol

A: Engine compartment
B: Transmission
C: Instrument panel
D: Floor and roof
E: Door
F: Frame
A-19
Denotes earth point.
Same earth number is used throughout circuit
diagrams to facilitate search of earth point.
Refer to GROUP 70 COMPONENT LOCATIONS
- EARTH MOUNTING LOCATIONS 1
for details of earth points.
Front
wiring
harness
(RH)
Denotes harness name.
A-18
Denotes a section covered by a

corrugated tube. A-17
The mark shows the

standard mounting position
of wiring harness.
Denotes the colour of the corrugated A-16

tube (If not specified, it is black.)
R: Red
Y: Yellow Y
The number of connector pins and the connector colour

(except milk white)* are shown for ease of retrieval. A-15
Example: (2-B)
Connector colour
(milk white if no colour is indicated) A-15 (2) Fog lamp (RH)
A-16 (2-GR) Horn (LO)
Number of connector pins A-17 (2-B) Headlamp (RH)
A-18 (2-B) Windshield washer motor
*: Typical connector colours A-19 (2-GR) Dual pressure switch
B: Black BR: Brown
Y: Yellow V: Violet
L: Blue O: Orange
G: Green GR: Grey Indicates the device to which the
R: Red None: Milk white connector is connected.
AC208446 AP
HOW TO READ CIRCUIT DIAGRAMS

M1001006500194
The circuit of each system from the fuse (or fusible link) to earth is shown. The power source is shown at the
top and the earth at the bottom to facilitate understanding of how the current flows. The circuit diagrams show
the state when switches are not operated.
Indicates power source. Indicates connector number. Indicates input/output Indicates a wiring connector which is inside
The same numbers are used in the to/from control unit the equipment and which is not shown in
wiring harness diagram. (current flow direction). the wiring harness configuration diagram.
Connector and connector numbers
are shown at the lower part of the Input Output Input/ Example C-15-2 Indicates a connector
Indicates that terminal is conne- output
cted via a plate in the relay box. page. which is inside the
Connector numbers not enclosed equipment, numbered Indicates that the diagram comes
by frame indicate the device incor- in order starting from 1. from which belongs to the
porated into wiring harness. block in the same circuit.
Indicates the connector number shown in
Each circuit diagram consists of the wiring harness configuration diagram.
block(s).
Indicates that these connectors
are the same intermediate
connectors.
Indicates harness junction point
numbers for another system.
The number corresponds to the
junction point number indicated
on another circuit diagram. Indicates terminal number.
Indicates the circuit name to be In case two or more connectors

connected. The arrow indicates are connected to the same
the current flow direction. device, markings indicating the
same connector are connector
by a broken line.
Indicates the power supply in Bi-directional arrow indicates

the control unit. If no voltage is that current flows in both
displayed, this indicates battery directions due to control by an
positive voltage. ECU.
An "X" at the end of a connector Indicates harness junction where

number indicates that the conn- wire diameter or colour changes.
ector is connected to a central-
ized junction that is shown in the
section "Centralized Junction." Indicates intersections at
which the lead wires are
not connected.
Indicates that the diagram contin-
ues at which belongs to the Indicates intersections at
block in the same circuit. which the lead wires are
connected.
Indicates the connector symbol. Indicates representative vehicle

Connectors in the circuit diagram body earth point. (Same number
are indicated in numerical order. as that of earth point in
EARTHING LOCATION).
Indicates that the terminal is a

Indicates the operating conditions Indicates shield wire. One-directional arrow indicates spare one if the device (sensor
of the engine coolant switch, etc. that current flows upwards. in this case) is not provided.
AC502479AB
AC502479
00E-5
MARKINGS FOR CONNECTOR AND
EARTHING
M1001007900162
IGNITION FUSIBLE
SWITCH (IG1) LINK 1
SOLENOID
VALVE 5
1
8 ECU
4
SENSOR
MOTOR
INSPECTION
CONNECTOR
AC208460 AB
7
2
Item No. Connector/Earthing Symbol Contents

Connector 1 Male terminal The male and female terminals
and terminal Male connector are indicated as shown. The
marking connector with male terminal(s)
is called as male connector and
indicated by two connector
ACX01252AD
contour lines, while the
Male connector
connector with female
terminal(s) is called as female
connector and indicated by
Male terminal single connector contour line.
ACX01253 AI
ACX01251AE
Female terminal
Female connector
ACX01255AD
Female connector
Female terminal
ACX01256 AH
ACX01254 AD
Connector 2 Device The symbol indicates the

symbol connector is viewed as shown.
marking At a device connection, the
connector symbol on the device
side is shown. For an
ACX01253 intermediate connector, the
ACX01257AD male connector symbol is
shown. For spare connectors
Intermediate connector
and check connectors, no
device is connected, and so the
harness-side connector symbol
is shown for these connectors.
However, a diagnosis connector
ACX01258AD is exceptional.
Spare connector, check connector
ACX01256
ACX01816 AD
00E-7
Item No. Connector/Earthing Symbol Contents
Connector 3 Direct connection type Connection between a device
connection and the harness is either by
marking direct insertion in the device
(direct connection type) or by
connection with a harness
connector furnished on the
ACX01261
ACX01260 AD device side (harness
connection type). The two types
4 Harness connection type are indicated as illustrated.
ACX01263
ACX01262 AD
5 Intermediate connector
ACX01265
ACX01264AD
Earth 6 Body earth Earthing is either by body earth,

marking device earth or control unit
interior earth. These are
indicated as illustrated.
AC208448AB ACX01274
7 Device earth
AC208449AB ACX01276
8 Earth in control unit
ACX01278
AC208450AB
WIRE COLOUR CODE

M1001008000195
Wire colours are identified by the following colour
codes.
Code Wire colour Code Wire colour Code Wire colour Code Wire colour
B Black L Blue PU Purple V Violet
BR Brown LG Light green R Red W White
G Green O Orange SB Sky blue Y Yellow
GR Grey P Pink SI Silver − −
If a cable has two colours, the first of the two colour
code characters indicates the basic colour (colour of
Example: <F> 1.25 G B
the cable coating) and the second indicates the
1 2 3 4 marking colour.
ACX01279 AE
No. Meaning
1 <F>: Flexible wire
<T>: Twisted wire
2 Wire size (mm2)*
3 Basic colour (colour of the cable coating)
4 Marking colour
NOTE: ABBREVIATION SYMBOLS
2
*: No code indicates 0.5 mm . Cable colour code in M1001008101593
parentheses indicates 0.3 mm2.

The abbreviation symbols used in wiring diagrams are defined below.
1. FOR SYSTEM NAME
Abbreviation Meaning Abbreviation Meaning
symbol symbol
ABS Anti-skid braking system LHD Left hand drive vehicles
ASTC Active stability and traction control MMCS Mitsubishi multi-communication
system system
CAN Controller area network PTC Positive temperature coefficient
ELC-4A/T Electronic controlled 4-speed RHD Right hand drive vehicles
automatic transmission
ELC-5A/T Electronic controlled 5-speed RV Recreation vehicle
automatic transmission
J/B Junction block SRS Supplemental restraint system
J/C Joint connector USB Universal serial bus
00E-9
2. FOR COMBINATION METERS
symbol symbol
4WD 4-wheel drive indicator lamp GLOW Diesel preheat indicator lamp
A/T TEMP Automatic transmission fluid LCD Liquid crystal display
temperature warning lamp
ABS Anti-skid braking system warning ODO Odometer
lamp
ASTC ASTC indicator lamp OD OFF Overdrive off indicator lamp
ASTC OFF ASTC OFF indicator lamp OIL Engine oil pressure warning lamp
BEAM High beam indicator lamp REAR DIFF Rear differential lock indicator lamp
LOCK
BRAKE Brake warning lamp REAR FOG Rear fog lamp indicator lamp
C/D LOCK Centre differential lock indicator REAR Rear wheel indicator lamp
lamp WHEEL
CHECK Check engine warning lamp SEAT BELT Seat belt warning lamp
ENGINE
CHG Charging warning lamp SPEED Speedometer
CPU Central processing unit SRS Supplemental restraint system
warning lamp
CRUISE Cruise control indicator lamp T/GA Engine coolant temperature gauge
DOOR Door-ajar warning lamp TACHO Tachometer
DPF Diesel particulate filter warning lamp
F/GA Fuel gauge TRIP Tripmeter
FRONT FOG Front fog lamp indicator lamp TURN (LH) Turn-signal indicator lamp and
FRONT Front wheel indicator lamp TURN (RH) hazard warning indicator lamp
WHEEL
FUEL Low fuel warning lamp WATER Fuel filter warning lamp
SEPARATOR
3. FOR SWITCHES AND RELAYS

Name of switches Abbreviation Operation
and relays symbol
Blower switch LO Blower operates at low speed
ML Blower operates at medium low speed
MH Blower operates at medium high speed
HI Blower operates at high speed
Cruise control switch ON/OFF Cruise control system ON/OFF
RES/ACC Set the vehicle speed
SET/CST
CANCEL Cancel the driving at a constant speed
Door lock actuator LOCK Door locked
UNLOCK Door unlocked

and relays symbol
Headlamp levelling 0, 1, 2, 3, 4 Lower the optical axis of the headlamp (LO) in steps at each
switch position
Heated seat switch LO Normal heating
HI Rapid heating
Ignition switch LOCK When turned to the LOCK position, no circuits will start
ACC When turned to the ACC (ACCESSORY) or ON position, the
power circuit will start
IG2 When at the ST (START) position, the power circuit will not start
functioning
IG1 Even when at the ST (START) position, the power circuit will start
ST Only when turned to the ST (START) position, the power circuit
will start
Inhibitor switch P Selector lever is at the P (PARKING) position
R Selector lever is at the R (REVERSE) position
N Selector lever is at the N (NEUTRAL) position
D Selector lever is at the D (DRIVE) position
2 Selector lever is at the 2 (SECOND) position
L Selector lever is at the L (LOW) position
Lighting switch LO Low beams ON
HI High beams ON
PASS High beams ON
TAIL Tail, position, licence plate and illumination lamps ON
HEAD Headlamps ON
AUTO Headlamps or tail lamps automatically illuminate by sensing
ambient brightness.
FOG Front, rear fog lamps ON
Others ON Switched ON
OFF Switched OFF
Power window switch UP Window closes
DOWN Window opens
AUTO UP Window is easily closed with one action
AUTO DOWN Window is easily opened with one action
LOCK Prevents all switches other than the main switch from operating
the power windows
UNLOCK Every switch can open or close the respective window
Power seat switch FR Seat is moved forwards or seat back is stood upright
RR Seat is moved forwards or seat back is leaned backward
UP Seat cushion is tilted up
DOWN Seat cushion is tilted down
00E-11
and relays symbol
Rear panel power UP Window closes
window switch DOWN Window opens
FULL UP Window is easily closed with one action
FULL DOWN Window is easily opened with one action
Remote controlled LH LH mirror operates
mirror switch RH RH mirror operates
Room lamp DOOR Room lamp ON when a door is open
Steering wheel audio MODE Switches the mode
remote control switch CH UP Changes the radio frequency or the music number in the CD
CH DOWN
VOL UP Increases the sound volume
VOL DOWN Decreases the sound volume
Sunroof switch OPEN Sunroof slides to open
CLOSE Sunroof slides to close
Turn-signal lamp LH LH turn-signal lamps ON
switch RH RH turn-signal lamps ON
Windshield intermittent SLOW Pause time for intermittent operation lengthens
wiper interval adjusting FAST Pause time for intermittent operation shortens
knob
Windshield rain − Lowers the sensitivity of the lighting control sensor to the amount
sensitive wiper function of rainfall.
adjusting knob + Raises the sensitivity of the lighting control sensor to the amount
of rainfall.
Windshield wiper MIST Windshield wiper operates once
switch AUTO The windshield wiper operates depending on the amount of
rainfall.
INT Windshield wiper operates intermittently
LO Windshield wiper operates at low speed
HI Windshield wiper operates at high speed
4. FOR OTHERS
symbol symbol
2WD 2 wheel-drive vehicles HI High
4WD 4 wheel-drive vehicles IC Integrated circuit
A/C Air conditioner ILL Illumination lamp
A/T Automatic transmission IND Indicator lamp
CPU Central processing unit LIN Local interconnect network
D.C Direct current LH Left hand
ECU Electronic control unit LO Low

symbol symbol
EEPROM Electrical erasable and M/T Manual transmission
programmable read only memory
ETACS Electronic time and alarm control M.U.T. Multi-use tester
system
EGR Exhaust gas recirculation RH Right hand
GND Earthing
11-1
GROUP 11
ENGINE
CONTENTS
ENGINE MECHANICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B

11A-1
GROUP 11A
ENGINE
MECHANICAL
CONTENTS
GENERAL INFORMATION . . . . . . . . 11A-2 OIL PAN AND OIL STRAINER. . . . . . 11A-27

OIL PAN AND OIL STRAINER REMOVAL AND
SERVICE SPECIFICATIONS. . . . . . . 11A-2 INSTALLATION <2WD (except high rider)> 11A-27
OIL PAN AND OIL STRAINER REMOVAL AND
SEALANTS AND ADHESIVES . . . . . 11A-3 INSTALLATION <2WD (high rider) and 4WD>
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-30
OIL PAN AND OIL STRAINER INSPECTION
SPECIAL TOOLS. . . . . . . . . . . . . . . . 11A-4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-32
ON-VEHICLE SERVICE. . . . . . . . . . . 11A-7 CRANKSHAFT OIL SEAL . . . . . . . . . 11A-33

ALTERNATOR AND POWER STEERING OIL PUMP
CRANKSHAFT OIL SEAL REMOVAL AND
DRIVE BELT TENSION CHECK AND ADJUSTMENT
INSTALLATION <M/T> . . . . . . . . . . . . . . . . 11A-33
...................................... 11A-7
CRANKSHAFT OIL SEAL REMOVAL AND
A/C COMPRESSOR DRIVE BELT TENSION CHECK
INSTALLATION <A/T> . . . . . . . . . . . . . . . . 11A-36
AND ADJUSTMENT . . . . . . . . . . . . . . . . . . 11A-7
AUTO-TENSIONER CHECK . . . . . . . . . . . 11A-9
CYLINDER HEAD GASKET . . . . . . . . 11A-39
VALVE CLEARANCE CHECK AND ADJUSTMENT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-12 CYLINDER HEAD GASKET REMOVAL AND
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 11A-39
IDLE SPEED CHECK . . . . . . . . . . . . . . . . . 11A-13
COMPRESSION PRESSURE CHECK. . . . 11A-14
TIMING BELT . . . . . . . . . . . . . . . . . . . 11A-43
TIMING BELT B TENSION ADJUSTMENT 11A-15
TIMING BELT REMOVAL AND INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-43
CRANKSHAFT PULLEY . . . . . . . . . . 11A-17
CRANKSHAFT PULLEY REMOVAL AND VACUUM PUMP . . . . . . . . . . . . . . . . . 11A-50
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 11A-17
VACUUM PUMP REMOVAL AND INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-50
CAMSHAFT AND VALVE STEM SEAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-20 ENGINE ASSEMBLY . . . . . . . . . . . . . 11A-52
CAMSHAFT AND VALVE STEM SEAL REMOVAL ENGINE ASSEMBLY REMOVAL AND INSTALLATION
AND INSTALLATION . . . . . . . . . . . . . . . . . 11A-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-52
11A-2 ENGINE MECHANICAL
GENERAL INFORMATION
GENERAL INFORMATION
M1111000102222
Item Euro 5 Except Euro 5

Bore × Stroke mm 91.1 × 95.0
Compression ratio 16.5 17
Combustion chamber Direct injection type
Camshaft arrangement DOHC
Number of valve Inlet 8
Exhaust 8
Valve timing Inlet Opening BTDC 13° BTDC 20°
Closing ABDC 30° ABDC 40°
Exhaust Opening BBDC 38°
Closing ATDC 22°
Fuel system Common rail fuel injection
Rocker arm Double roller type
SERVICE SPECIFICATIONS
M1111000302118
Item Standard value Limit

A/C compressor drive belt tension Vibration frequency Hz 222.5 − 251.0 −
(When checked) Tension N 363 − 462 −
Deflection mm (Reference) 6.8 − 8.0 −
(When adjusted) Tension N 363 − 462 −
(When replaced) Tension N 495 − 660 −
Alternator and power steering oil Vibration frequency Hz 107 − 151 −
pump drive belt tension <Except (Reference)
Euro5> Tension N (Reference) 196 − 392 −
Alternator and power steering oil Vibration frequency Hz 87 − 123 −
pump drive belt tension <Euro5> (Reference)
Tension N (Reference) 196 − 392 −
Valve clearance (at cold) [indicates Intake valve 0.09 −
clearance between cam and roller] Exhaust valve 0.14 −
mm
ENGINE MECHANICAL
SEALANTS
11A-3
Idle speed r/min Euro 5-M/T 600 ± 50 −
Euro 5-A/T 650 ± 50 −
Except Euro 5-2WD-except 650 ± 50 −
high rider
Except Euro 5-high rider and 700 ± 50 −
4WD
Compression pressure (at engine Euro 5 2,400 Minimum
speed of 250 r/min) kPa 1,650
Except Euro 5 2,500 Minimum
1,750
Compression pressure difference of all cylinder kPa − Maximum 300
Timing belt B tension mm 4−5
Timing belt auto tensioner rod protrusion amount mm 2.3 − 7.6
SEALANTS
M1111000500956
Item Specified Sealant Remark

Semi-circular packing 3M ATD Part No. 8660 or exact equivalent Semi-drying sealant
Front left camshaft bearing cap
Oil seal case assembly ThreeBond 1207F (Mitsubishi Genuine Part
No. 1000A992) or exact equivalent
SPECIAL TOOLS
SPECIAL TOOLS
M1111000602799
Tool Number Name Use

MB992080 Belt tension meter set Drive belt tension check
a
a: MB992081 a: Belt tension meter
b: MB992082 b: Microphone assembly
b
B992080
MB991955 M.U.T.-III sub assembly CAUTION

a
a: MB991824 a: Vehicle communication For vehicles with CAN
b: MB991827 interface (V.C.I.) communication, use M.U.T.-III
c: MB991910 b: M.U.T.-III USB cable main harness A to send
d: MB991911 c: M.U.T.-III main harness simulated vehicle speed. If
MB991824 e: MB991825 A (Vehicles with CAN you connect M.U.T.-III main
b f: MB991826 communication system) harness B instead, the CAN
d: M.U.T.-III main harness communication does not
B (Vehicles without CAN function correctly.
communication system) • Checking the idle speed
MB991827 e: M.U.T.-III adapter • Erasing diagnosis code
c
harness
f: M.U.T.-III trigger harness
MB991910
DO NOT USE
MB991911
MB991825
MB991826
MB991955
MB992046 Valve adjusting socket Adjustment of valve clearance
MB992046
ENGINE MECHANICAL
SPECIAL TOOLS
11A-5
MB991800 Pulley holder Holding the crankshaft pulley
MB991800
MB992100 Crank pulley holder • Holding the crankshaft pulley

• Crankshaft pulley removal
B992100
MB992099 Crank pulley puller Crankshaft pulley removal
B992099
MD998772 Valve spring compressor Compressing valve spring
MD998772
MB991999 Valve stem seal installer Valve stem seal installation
MD998713 Camshaft oil seal installer Camshaft oil seal installation
D998713
MD998727 Oil pan FIPG cutter Oil pan removal
D998727
MB991883 Flywheel stopper • Supporting the flywheel

assembly <M/T>
• Supporting the inertia ring
assembly <A/T>
MB991883
SPECIAL TOOLS

MB990767 Front hub and flange yoke Holding the camshaft sprocket
holder
B990767
MD998719 Pin
D998719
MB992147 Oil seal installer Crankshaft rear oil seal

installation
MD998383 Crankshaft front oil seal Crankshaft front oil seal

guide installation
D998383
MD998382 Crankshaft front oil seal

installer
D998382
MD998051 Cylinder head bolt wrench Removal and installation of

cylinder head bolt
MB991683 Sling chain set Removal and installation of

engine assembly
B991683
ENGINE MECHANICAL
ON-VEHICLE SERVICE
11A-7
ON-VEHICLE SERVICE
ALTERNATOR AND POWER STEERING WHEN THE VIBRATION FREQUENCY IS
OIL PUMP DRIVE BELT TENSION CHECK MEASURED (SPECIAL TOOL MB992080 IS
M1111001200033 USED): RECOMMENDATION
CAUTION NOTE: The vibration frequency measuring method is
Check the drive belt tension after turning the recommended for check and adjustment of the drive
crankshaft clockwise one turn or more. belt tension.
Belt tension meter set (MB992080)
A
MB992081
Indicator mark
MB992082
Auto tensioner
AC501803AB AC507219AB
1. Make sure that the indicator mark is within the 1. Connect special tool microphone assembly
area marked with A in the illustration. (MB992082) to special tool belt tension meter
2. If the mark is out of the area, replace the drive (MB992081) of special tool belt tension meter set
belt. (Refer to P.11A-17). (MB992080).
NOTE: The drive belt tension check is not neces- 2. Press the "POWER" button to turn on the power
sary as auto tensioner is adopted. supply.
3. Press the numeral key of "1" and check that
A/C COMPRESSOR DRIVE BELT "No.1" appears on the upper left of the display.
TENSION CHECK AND ADJUSTMENT NOTE: This operation is to temporarily set the
M1111001000363
preset data such as the belt specifications,
Check the drive belt tension by the following proce- because if the measurement is taken without input
dures. of the belt specifications, conversion to tension
STANDARD VALUE: value (N) cannot be made, resulting in judgement
Item When When When of error.
checked adjusted replaced 4. Press "Hz" button twice to change the display to
Vibration 222.5 − 222.5 − 259.8 − the frequency display (Hz).
frequency Hz 251.0 251.0 300.0
Tension N 363 − 462 363 − 462 495 − 660
Deflection 6.8 − 8.0 6.8 − 8.0 5.1 − 6.4
mm
(Reference)
ON-VEHICLE SERVICE
CAUTION WHEN USING THE TENSION GAUGE

• The temperature of the surface of the belt Tensioner pulley
should be as close to normal temperature as
possible.
• Do not let any contaminants such as water or
Tension
oil get onto the microphone. gauge
• If strong gusts of wind blow against the
microphone or if there are any loud sources
of noise nearby, the values measured by the
microphone may not correspond to actual Crankshaft A/C compressor pulley
values. pulley AC506003AB
• If the microphone is touching the belt while Use a belt tension gauge in the middle of the belt
the measurement is being made, the values between the pulleys shown in the figure (at the place
measured by the microphone may not corre- indicated by the arrow) to check that the belt tension
spond to actual values. is within the standard value.
• Do not take the measurement while the vehi-
cle's engine is running. BELT DEFLECTION CHECK
10 – 15 mm 15˚
Tensioner pulley Tensioner pulley
Approximately
15˚ 100N
MB992080
(Microphone)
Deflection
Crankshaft A/C compressor pulley Crankshaft A/C compressor pulley
pulley AC903689 AB pulley AC506004AB
5. Hold special tool MB992080 to the middle of the Apply approximately 100 N of pressure against the
belt between the pulleys (at the place indicated by location between the pulleys shown by the arrow in
arrow) where it does not contact the belt the illustration and then measure the deflection.
(approximately 10 − 15 mm away from the rear When the belt tension is adjusted by measuring the
surface of the belt) so that it is perpendicular to belt deflection, adjust it with a tool for vibration fre-
the belt (within an angle of ± 15 °). quency measurement or tension measurement after-
6. Press the "MEASURE" button. ward.
7. Gently tap the middle of the belt between the
BELT TENSION ADJUSTMENT
pulleys (the place indicated by the arrow) with
If not within the standard value, adjust the belt ten-
your finger as shown in the illustration, and check
sion by the following procedure.
that the vibration frequency of the belt is within the
standard value.
Adjusting bolt
NOTE: To take the measurement repeatedly, fillip Tensioner pulley
the belt again. Locking nut
AC505988AB
1. Loosen the locking nut of the tensioner pulley.

ENGINE MECHANICAL
ON-VEHICLE SERVICE
11A-9
2. Use the adjusting bolt to adjust the belt tension. FUNCTION CHECK
The tension will increase when turning the You can verify if the auto tensioner is defective or not
adjusting bolt clockwise, and decrease when by checking the drive belt tension.
turning anti-clockwise. When the vibration frequency is measured
3. Tighten the locking nut. (Special tool MB992080 is used):
4. Tighten the adjusting bolt. Recommendation
CAUTION 1. Check the drive belt tension (Refer to P.11A-7).
When checking the belt tension, turn the crank- 2. Measure the drive belt tension vibration frequency
shaft clockwise one turn or more. by the following procedures:
5. Check the belt tension, and readjust if necessary. Belt tension meter set (MB992080)
AUTO-TENSIONER CHECK MB992081

M1111003003216
OPERATION CHECK
1. Turn off the engine from the idle state then check
to see that the drive belt is not protruding from the
pulley width of the auto tensioner.
MB992082
2. Remove the drive belt (Refer to P.11A-17).
AC507219AB
AC501804
Auto tensioner (1) Connect special tool microphone assembly
(MB992082) to special tool belt tension meter
(MB992081) of special tool belt tension meter
set (MB992080).
(2) Press the "POWER" button to turn on the
power supply.
(3) Press the numeral key of "1" and check that
"No.1" appears on the upper left of the display.
AC507703AB NOTE: This operation is to temporarily set the
preset data such as the belt specifications,
3. Install the tool to the auto tensioner, and check
because if the measurement is taken without
that no binding is present by turning the auto
input of the belt specifications, conversion to
tensioner in the left and right directions.
tension value (N) cannot be made, resulting in
4. If there are any problems in the procedure 1 or 3, judgement of error.
replace the auto tensioner (Refer to P.11A-43).
(4) Press "Hz" button twice to change the display
5. Install the drive belt (Refer to P.11A-17). to the frequency display (Hz).
ON-VEHICLE SERVICE
CAUTION <Except Euro5>

• The temperature of the surface of the belt MB992080
Power steering (Microphone)
should be as close to normal temperature as 15˚
oil pump pulley
possible.
• Do not allow any contaminants such as water 15˚
or oil to get onto the microphone.
• If strong gusts of wind blow against the 10 – 15 mm
microphone or if there are any loud sources Gentry tap
of noise nearby, the values measured by the with your
microphone may not correspond to actual finger
values.
• If the microphone is touching the belt while
the measurement is being made, the values
measured by the microphone may not corre-
spond to actual values.
• Do not take the measurement while the vehi-
cle's engine is running.
Water pump pulley
AC805802AF
<Euro5>
Power steering
10 – 15 mm
oil pump pulley
15˚
Gentry tap
with your finger
15˚
MB992080
(Microphone)
Alternator pulley
AC805654AG
(5) Hold special tool MB992080 to the middle of

the belt between the pulleys (at the place
indicated by arrow) where it does not contact
the belt (approximately 10 − 15 mm away from
the rear surface of the belt) so that it is
perpendicular to the belt (within an angle of ±
15 °).
(6) Press the "MEASURE" button.
ENGINE MECHANICAL
ON-VEHICLE SERVICE
11A-11
(7) Gently tap the middle of the belt between the
pulleys (the place indicated by the arrow) with <Except Euro5>
your finger as shown in the illustration, and Power steering
oil pump pulley
check that the vibration frequency of the belt is Belt tension
within the standard value. gauge
Standard value (Reference):
<Except Euro5> 107 − 151 Hz
<Euro5> 87 − 123 Hz
NOTE: To take the measurement repeatedly,
fillip the belt again.
3. If not within the standard value, replace the auto
tensioner (Refer to P.11A-43).
When using the tension gauge

1. Check the drive belt tension (Refer to P.11A-7).
Water pump pulley
AC805803AE
<Euro5>
Power steering
Belt tension oil pump pulley
gauge
Alternator pulley
AC805655AF
2. Use a belt tension gauge in the middle of the belt

between the pulleys shown in the figure (at the
place indicated by the arrow) to check that the belt
tension is within the standard value.
Standard value (Reference): 196 − 392 N
3. If not within the standard value, replace the auto
tensioner (Refer to P.11A-43).
ON-VEHICLE SERVICE
VALVE CLEARANCE CHECK AND 7. Measure the valve clearance.

ADJUSTMENT If the valve clearance is not as specified, loosen
M1111001502096
the rocker arm lock nut and adjust the clearance
NOTE: The valve clearance check and adjustment using a thickness gauge between the cam shaft
should be done when the engine is cold. and the roller while turning the adjusting screw.
1. Remove the engine air intake pipe. Standard value (cold engine):
2. Remove the inlet manifold. Inlet valve: 0.09 mm
3. Remove the injection pipe. Exhaust valve: 0.14 mm
CAUTION
Leaked fuel on parts causes a decrease in func-
tion and burning. Therefore, Place waste to
absorb leaked fuel.
4. Remove the timing belt cover. MB992046
5. Remove the rocker cover.
Timing marks
Thickness gauge
Camshaft
sprocket AK500381 AC
8. While holding the adjusting screw with a

screwdriver to prevent it from turning, tighten the
lock nut to the specified torque using a valve
adjusting socket. (MB992046)
Tightening torque: 15 ± 3 N⋅m
CAUTION
Timing marks Pay special attention that the tightening torque is
not beyond this valve. If the tightening torque is
beyond the valve, the valve stem would possibly
Crank shaft bend.
pulley
9. Turn the crankshaft 360° clockwise to bring No. 4
cylinder to the top dead centre position.
Exhaust valve side
AK500379 AB
6. Align the camshaft sprocket timing marks and set

the No. 1 cylinder at top dead centre.
CAUTION
The crankshaft should always be turned in a
clockwise direction.
Exhaust valve side
Inlet valve side AK500380 AE
10.Measure the valve clearances at the places

indicated by arrows in the illustration. If the
clearance is not within the standard value, repeat
steps 7 and 8 above.
Inlet valve side AK500380 AD

ENGINE MECHANICAL
ON-VEHICLE SERVICE
11A-13
CAUTION
• The reinstallation histories of the removed
injection pipe are up to five times. To count
how many times the injection pipe is rein-
stalled, record the number of the reinstalla-
tion histories on the service booklet by
adding this latest number of the histories,
which is usually "1", to the previous one. Use
a new injection pipe when the total reinstalla-
AK202860AB tion history numbers reach five times, or
when the injector or common rail is replaced.
10 mm
In this case, record " a new injector pipe, the
number of the reinstallation histories is zero"
on the service booklet.
• When the injection pipe is reinstalled, confirm
there is no foreign material on the seal sur-
face or in the pipe and then install it not to
10 mm deviate from the axis, fitting the seal surface.
Semicircular 15.Install the inlet manifold.
packing Cylinder head AK304411AB
NOTE: Install a new gasket
16.Install the engine air intake pipe.
11.Apply specified sealant to the section of the semi- 17.After the ignition switch is in "LOCK" (OFF)
circular packing shown in the illustration. position, connect the M.U.T.-III to the diagnosis
Specified sealant: 3M ATD Part No. 8660 or connector.
equivalent 18.Start the engine, and let it run at idle.
12.Install the rocker cover. 19.Select SPECIAL FUNCTION from the function
13.Install the timing belt cover. menu.
14.Install the injection pipe, the injection pipe to the 20.Select FUEL LEAKAGE CHECK from SPECIAL
specified torque. FUNCTION menu to execute the test.
Tightening torque: 35 ± 5 N⋅m NOTE: During the test, the engine speed and the fuel
pressure is 2, 000 r/min and 180Mpa for 20 seconds
respectively.
21.Confirm there is no fuel leak from the joint for the
injection pipe.
IDLE SPEED CHECK

M1111003503277
1. Set the vehicle to the pre-inspection condition.
ON-VEHICLE SERVICE
<LH drive vehicles> 5. If the idle speed is not within the standard value,
inspect the diesel system (Refer to GROUP 13A −
Troubleshooting − Inspection Chart for Diagnosis
Code P.13A-429).
COMPRESSION PRESSURE CHECK

M1111002604058
Diagnosis
connector 1. Before inspection, check that the engine oil,
starter and battery are normal. In addition, set the
MB991910
vehicle to the pre-inspection condition.
2. Remove the engine air intake pipe.
MB991824 3. Remove the inlet manifold.
4. Remove all of the glow plugs.
MB991827
<RH drive vehicles> Diagnosis Crank angle
connector sensor connector
AK500382 AB
5. Disconnect the crank angle sensor connector.

NOTE: Doing this will prevent carrying out fuel
injection.
MB991910 6. Cover the glow plug hole with a shop towel etc.,
and after the engine has been cranked, check that
no foreign material is adhering to the shop towel.
MB991824 CAUTION
• Keep away from the glow plug hole when
cranking.
• If compression is measured with water, oil,
fuel, etc., that has come from cracks inside
the cylinder, these materials will become
heated and will gush out from glow plug hole,
which is dangerous.
MB991827 AK600277AB
Compression
2. Turn the ignition switch to "LOOK" (OFF) position, gauge
and connect the diagnosis connector to the
M.U.T.-III.
3. Start the engine, and let it run at idle.
4. Check the idle speed.
Standard value:
600 ± 50 r/min <Euro 5-M/T>
650 ± 50 r/min <Euro 5-A/T> AK500383AB
650 ± 50 r/min <Except Euro 5-2WD-except
high rider> 7. Set compression gauge to one of the glow plug
700 ± 50 r/min <Except Euro 5-high rider and holes.
4WD> 8. Crank the engine and measure the compression
pressure.
ENGINE MECHANICAL
ON-VEHICLE SERVICE
11A-15
Standard value (at engine speed of 250 r/ <LH drive vehicles>
min):
2,400 kPa <Euro 5>
2,500 kPa <Except Euro 5>
Limit (at engine speed of 250 r/min):
Minimum 1,650 kPa <Euro 5>
Diagnosis
Minimum 1,750 kPa <Except Euro 5> connector
9. Measure the compression pressure for all the
cylinders, and check that the pressure differences MB991910
of the cylinders are below the limit.
Limit: Maximum 300 kPa MB991824
10.If there is a cylinder with compression or a
compression difference that is outside the limit,
pour a small amount of engine oil through the
glow plug hole, and repeat the operations in steps
(8) and (9).
(1) If the compression increases after oil is added,
the cause of the malfunction is a worn or
damaged piston ring and/or cylinder inner MB991827
surface. <RH drive vehicles> Diagnosis
connector
(2) If the compression does not rise after oil is
added, the cause is a burnt or defective valve
seat, or pressure is leaking from the gasket.
11.Connect the crank angle sensor connector.
12.Install the glow plugs.
MB991910
13.Install the inlet manifold.
NOTE: Install a new gasket.
14.Install the engine air intake pipe. MB991824
MB991827 AK600277AB
15.Use the M.U.T.-III to erase the diagnosis codes.

NOTE: This will erase the diagnosis code result-
ing from the crank angle sensor connector being
disconnected.
TIMING BELT B TENSION ADJUSTMENT

M1111004900031
1. Remove timing belt upper cover.
2. Turn the crankshaft in the clockwise direction and
check the timing belt around its entire
circumference for abnormalities.
ON-VEHICLE SERVICE
4. Remove the access cover.

Timing marks
Camshaft
sprocket
Pivot side bolt
Slot side bolt
AK500385 AB
Timing marks
5. Loosen the tensioner pivot side bolt 1 turn and
slot side nut 1 or 2 turns.
Crank shaft NOTE: These works will allow the tensioner
pulley
spring to tension timing belt B automatically.
6. First tighten tensioner slot side nut, and then
tighten pivot side bolt to the specified torque.
AK500379 AB
Tightening torque:
3. Align the timing marks on the sprockets with the Pivot side bolt 23 ± 3 N⋅m
timing mark on the front upper case. Slot side bolt 20 ± 4 N⋅m
CAUTION
When aligning the timing mark, be sure not to
turn the crankshaft in the anti-clockwise direc-
tion as this can cause improper belt tension.
Access cover
AK500386AB
Access cover
7. Install the access cover.
8. Install the timing belt upper cover.
AK500384 AB
ENGINE MECHANICAL
CRANKSHAFT PULLEY
11A-17
CRANKSHAFT PULLEY
REMOVAL AND INSTALLATION
M1112001602814
Pre-removal Operation Post-installation Operation

• Under Skid Plate and Engine Room Under Cover • Alternator and Power Steering Oil Pump Drive Belt Ten-
Removal (Refer to GROUP 51 − Under Cover P.51-32). sion Check (Refer to P.11A-7).
• A/C Compressor Drive Belt Tension Check and Adjust-
ment (Refer to P.11A-7).
• Under Skid Plate and Engine Room Under Cover Installa-
tion (Refer to GROUP 51 − Under Cover P.51-32).
5
265 N·m to 0 N·m
to 275 N·m
4
3
1
(Engine oil)
AC501821AB
Removal steps Removal steps (Continued)

<<A>> 1. A/C compressor drive belt <<C>> >>A<< 3. Crankshaft pulley bolt
<> 2. Alternator and power steering oil <<C>> >>A<< 4. Crankshaft pulley washer
pump drive belt <<C>> >>A<< 5. Crankshaft pulley
CRANKSHAFT PULLEY
REMOVAL SERVICE POINTS

<<A>> A/C COMPRESSOR DRIVE BELT <<C>> CRANKSHAFT PULLEY BOLT/
REMOVAL CRANKSHAFT PULLEY WASHER/CRANKSHAFT
PULLEY REMOVAL
Adjusting bolt
Tensioner pulley
Locking nut MB992100
Crankshaft pulley
MB991800
AC505988AB
AC501824 AB
1. Loosen the locking nut of the tensioner pulley.
1. Use the following special tools to hold the
CAUTION crankshaft pulley.
To reuse the drive belt, draw an arrow indicating • Pulley holder (MB991800)
the rotating direction (clockwise) on the back of • Crank pulley holder (MB992100)
the belt using chalk, etc.
2. Loosen the crankshaft pulley bolt and remove the
2. Rotate the adjusting bolt to the anti-clockwise crankshaft pulley washer and crankshaft pulley.
direction (to the left), and remove the drive belt. 3. If the crankshaft pulley cannot be removed from
the crankshaft, follow the procedure below.
<> ALTERNATOR AND POWER STEERING (1) Install the crankshaft pulley bolt and
OIL PUMP DRIVE BELT REMOVAL crankshaft pulley washer to the crankshaft
AC501823
L-shaped
pulley. At this time, the crankshaft pulley bolt
hexagon wrench must be loosened by 3 to 4 turns from the
completely tightened state.
MB992099
Auto tensioner
AC507702 AB
The following operations will be needed due to the

introduction of the serpentine drive system with the MB992100
auto tensioner. AC501870AB
1. Set the tool to the pulley bolt of auto tensioner, (2) Using the special tools below, remove the
and then turn the auto tensioner clockwise. crankshaft pulley.
CAUTION • Crank pulley puller (MB992099)
To reuse the drive belt, draw an arrow indicating • Crank pulley holder (MB992100)
the rotating direction (clockwise) on the back of
the belt using chalk, etc.
2. Insert an L-shaped hexagon wrench, etc. into the
hole to fix and then remove the drive belt.
ENGINE MECHANICAL
CRANKSHAFT PULLEY
11A-19
INSTALLATION SERVICE POINT 2. Install the crankshaft pulley.
>>A<< CRANKSHAFT PULLEY/CRANKSHAFT 3. Apply an appropriate quantity of new engine oil to
PULLEY WASHER/CRANKSHAFT PULLEY BOLT the thread of crankshaft pulley bolt.
INSTALLATION
Engine front : Clean MB992100

: Apply engine oil
: Degrease
Crankshaft pulley
washer Crankshaft pulley
Crankshaft
Crankshaft pulley MB991800
pulley bolt
Degrease
AC501824 AB
4. In the same way as for removing, using the

special tools below, support the crankshaft pulley.
• Pulley holder (MB991800)
• Crank pulley holder (MB992100)
Clean Clean 5. Tighten the crankshaft pulley bolt according to the
Clean
(Engine oil) procedure below.
Crankshaft
(1) Tighten the crankshaft pulley bolt to the
specified torque.
Tightening torque: 265 N⋅m
AC501871AB
(2) Loosen the crankshaft pulley bolt fully.
1. Clean the screw hole of the crankshaft, the (3) Tighten the crankshaft pulley bolt to the
crankshaft pulley, the crankshaft pulley bolt and specified torque again.
the crankshaft pulley washer. Tightening torque: 275 N⋅m

M1112006602262
CAUTION
* Remove and assemble the marked parts in each cylinder unit.
Pre-removal and Post-installation Operation
• Inlet Manifold Removal and Installation (Refer to GROUP
15 − Inlet Manifold P.15-15).
11 ± 1 N·m 16 11 ± 1 N·m
Apply engine oil to all
moving parts before 17 N 5
installation. 20 ± 1 N·m
18
6N
15 18
7
20 ± 1 N·m
4
19
21
20
22 21
24 11 13 24 20
23 13
25* 9 22
18 ± 2 N·m 8 14 25* 23
12 18 ± 2 N·m
26*
10 26*
27*
N 28 27*
29* 28 N
2 N 3 29*
88 ± 10 N·m
10 ± 2 N·m AC501908AD
Inlet camshaft removal steps Inlet camshaft removal steps

• Timing belt (Refer to P.11A-43). >>H<< 8. Inlet camshaft assembly
• Rocker cover (Refer to GROUP >>G<< 9. Snap ring
13A − Fuel Injector P.13A-598). >>G<< 10. Wave washer
• Valve clearance check and >>G<< 11. Sub gear
adjustment (Refer to P.11A-12). >>G<< 12. C-spring
<<A>> >>K<< 1. Camshaft sprocket >>G<< 13. Dowel pin
2. Timing belt rear cover >>G<< 14. Inlet camshaft
>>J<< 3. Camshaft oil seal
<> >>I<< 4. Front left camshaft bearing cap
>>I<< 5. Inlet oil pipe assembly
>>I<< 6. O-ring
<> >>I<< 7. Left camshaft bearing cap
ENGINE MECHANICAL
11A-21
Exhaust camshaft removal 1. Use the following special tools to hold the
steps camshaft sprocket.
• Rocker cover (Refer to GROUP • Front hub and flange yoke holder (MB990767)
13A − Fuel Injector P.13A-598). • Pin (MD998719)
• Valve clearance check and
adjustment (Refer to P.11A-12). 2. Loosen the camshaft sprocket mounting bolt and
<> >>F<< 15. Front right camshaft bearing cap remove the camshaft sprocket.
>>F<< 16. Exhaust oil pipe assembly
>>F<< 17. O-ring <> FRONT LEFT CAMSHAFT BEARING CAP/
<> >>F<< 18. Right camshaft bearing cap LEFT CAMSHAFT BEARING CAP/FRONT RIGHT
>>E<< 19. Exhaust camshaft assembly CAMSHAFT BEARING CAP/RIGHT CAMSHAFT
Valve stem seal removal steps BEARING CAP REMOVAL
• Timing belt (Refer to P.11A-43).
• Rocker cover (Refer to GROUP Engine front
13A − Fuel Injector P.13A-598). Front right camshaft
• Valve clearance check and bearing cap
adjustment (Refer to P.11A-12).
<<A>> >>K<< 1. Camshaft sprocket Right camshaft bearing cap
2. Timing belt rear cover
>>J<< 3. Camshaft oil seal
<> >>I<< 4. Front left camshaft bearing cap 8 10 6 4
>>I<< 5. Inlet oil pipe assembly 2
>>I<< 6. O-ring 1 7 9 5 3
<> >>I<< 7. Left camshaft bearing cap
>>H<< 8. Inlet camshaft assembly 1 7 9 5 3
<> >>F<< 15. Front right camshaft bearing cap 2
>>F<< 16. Exhaust oil pipe assembly 8 10 6 4
>>F<< 17. O-ring
<> >>F<< 18. Right camshaft bearing cap
>>E<< 19. Exhaust camshaft assembly
>>D<< 20. Rocker arm assembly Left camshaft bearing cap
>>D<< 21. Nut
Front left camshaft
>>D<< 22. Adjusting screw
bearing cap
23. Pivot bolt
>>C<< 24. Stem end cap
<<C>> >>B<< 25. Valve spring retainer lock
AC501909AB
26. Valve spring retainer Loosen the mounting bolts of the front camshaft
27. Valve spring bearing cap and camshaft bearing cap in the order
>>A<< 28. Valve stem seal shown in the figure. Then, remove the front camshaft
29. Valve spring seat bearing cap and camshaft bearing caps.
<<A>> CAMSHAFT SPROCKET REMOVAL
MD998719
MB990767
AC507554AB
<<C>> VALVE SPRING RETAINER LOCK >>B<< VALVE SPRING RETAINER LOCK
REMOVAL INSTALLATION
CAUTION
When removing valve spring retainer lock, leave MD998772
the piston of each cylinder in the TDC (Top Dead
Centre) position. The valve may fall into the cylin-
der if the piston is not properly in the TDC posi-
tion.
MD998772
AC501910AB
Use special tool valve spring compressor

(MD998772) to compress the valve spring and then
install the valve spring retainer lock in the same man-
ner as removal.
AC501910AB >>C<< STEM END CAP INSTALLATION

Use special tool valve spring compressor
(MD998772) to compress the valve spring and then
remove the valve spring retainer lock. Inlet valve or Stem end cap
exhaust valve
INSTALLATION SERVICE POINTS

>>A<< VALVE STEM SEAL INSTALLATION
1. Apply a small amount of engine oil to the valve
stem seal.
CAUTION
AC501911AB
• Do not re-use the valve stem seal.
• Special tool valve stem seal installer Install the stem end cap. Make sure that the stem
(MB991999) must be used to install the valve end cap is in close contact with the stem end faces of
stem seal. Improper installation could result the inlet and exhaust valve.
in oil leaking past the valve guide.
>>D<< ADJUSTING SCREW/NUT/ROCKER ARM
ASSEMBLY INSTALLATION
MB991999
Valve
Nut
Rocker arm
Valve stem assembly
seal
Valve guide
AC308654AC
5.5 – 6.5 mm
Adjusting screw
2. Use the special tool valve stem seal installer AC501912AB
(MB991999) to fill a new valve stem seal in the
valve guide using the valve stem area as a guide. 1. Screw the adjusting screw into the rocker arm
assembly, and then temporarily assemble using a
nut so that the adjusting screw protrusion
becomes the dimension shown in the figure.
2. Apply the engine oil to the sliding surface of the
parts below.
ENGINE MECHANICAL
11A-23
• Roller and valve-side sliding area of the rocker
Engine front
arm assembly
• Concave spherical surface of pivot bolt or spheri-
cal surface of adjusting screw Front right camshaft
bearing cap
Stem end cap Rocker arm assembly Right camshaft bearing cap
3 1 5 7
9
10 4 2 6 8
Pivot
bolt
AC501913 AB
3. Place the rocker arm assembly onto the pivot bolt

and the stem end cap as shown in the figure.
>>E<< EXHAUST CAMSHAFT ASSEMBLY

INSTALLATION
1. Apply the engine oil to the cam face, journal AC501915AB
section, thrust face, and gear teeth face of

exhaust camshaft. 3. Tighten the mounting bolts of the right camshaft
bearing cap and front right camshaft bearing cap
Exhaust camshaft to the specified torque in the order shown in the
figure. Then, fix the right camshaft bearing cap,
Timing mark exhaust oil pipe assembly, and front right
camshaft bearing cap to the cylinder head.
Tightening torque:
11 ± 1 N⋅m (Right camshaft bearing cap mount-
ing bolts)
20 ± 1 N⋅m (Front right camshaft bearing cap
mounting bolts)
AC501914AB
2. Set the timing mark of the exhaust camshaft in the >>G<< INLET CAMSHAFT/DOWEL PIN/C-
position shown in the figure. SPRING/SUB GEAR/WAVE WASHER/SNAP RING
INSTALLATION
>>F<< RIGHT CAMSHAFT BEARING CAP/O-
RING/EXHAUST OIL PIPE ASSEMBLY/FRONT
RIGHT CAMSHAFT BEARING CAP
Inlet camshaft
INSTALLATION
1. Place the right camshaft bearing cap onto the
camshaft journal section.
2. Apply the engine oil to the O-ring section of
exhaust oil pipe assembly, and insert the tip of
exhaust oil pipe assembly into the cylinder head.
Then, place the pipe section onto the right AC501916AB
camshaft bearing cap.
1. Fix the inlet camshaft hexagonal area using a vice
or other devices.
>>H<< INLET CAMSHAFT ASSEMBLY

Inlet camshaft
2.3 – 2.8 mm INSTALLATION
Inlet camshaft
2.3 – 2.8 mm
Dowel pin
Sub gear Dowel pin AC501917AB
2. Press fit the dowel pin into the inlet camshaft and AC501919 AB
sub gear so that the dimension becomes as
shown in the figure. 1. Fix the hexagonal area of inlet camshaft assembly
using a vice or other devices.
C-spring Dowel pin
CAUTION
Avoid turning the sub gear than necessary.
Hole of sub gear (M8) Thread hole of
camshaft (M6)
Screwdriver
Inlet camshaft AC501918AB
3. After contacting the C-spring with the dowel pin as

shown in the figure, set to the inlet camshaft.
A Flange bolts (M6 × 20) AC501920AB
Dowel pin C-spring
2. Set the flange bolts (M6 x 20) to 2 locations of sub
gear. Then, using a screwdriver, turn the sub gear
clockwise until the sub gear hole (M8) and the
threaded hole (M6) of inlet camshaft gear match
as shown in the figure.
Bolt (M6 × 20)
Inlet camshaft AC501918AC
4. Set the sub gear to the inlet camshaft so that the

sub gear dowel pin is inside the A range between
the C-spring and inlet camshaft dowel pin as
shown in the figure.
5. Assemble the wave washer and the snap ring to
the inlet camshaft.
AC501921AB
3. Temporarily fix the sub gear using the bolt (M6 x

20). At this time, screw in until the bolt head is in
contact with the sub gear.
4. Remove the 2 flange bolts (M6 x 20) installed in
the step 2.
ENGINE MECHANICAL
11A-25
5. Remove from the vice or other devices the inlet NOTE: Install the front left camshaft bearing cap
camshaft assembly to which the sub gear being immediately after applying sealant.
temporarily fixed. Then, apply the engine oil to the
cam face, journal section, thrust face, and gear Engine front
teeth face of inlet camshaft assembly.
Exhaust Inlet camshaft
camshaft Timing mark
10 4 2 6 8
9
3 1 5 7
AC501922AB
6. Set the timing mark of the inlet camshaft

assembly and exhaust camshaft in the position Left camshaft bearing cap
shown in the illustration.
Front left camshaft
>>I<< LEFT CAMSHAFT BEARING CAP/O-RING/ bearing cap
INLET OIL PIPE ASSEMBLY/FRONT LEFT
CAMSHAFT BEARING CAP INSTALLATION AC501924AB
1. Place the left camshaft bearing cap onto the

camshaft journal. 4. Tighten the mounting bolts of the left camshaft
bearing cap and front left camshaft bearing cap to
2. Apply the engine oil to the O-ring of the inlet oil
the specified torque in the order shown in the
pipe assembly, and insert the tip of the inlet oil
figure. Then, fix the left camshaft bearing cap,
pipe assembly into the cylinder head. Then, place
inlet oil pipe assembly, and front left camshaft
the pipe onto the left camshaft bearing cap.
bearing cap to the cylinder head.
CAUTION Tightening torque:
After the installation, until a sufficient period of 11 ± 1 N⋅m (Left camshaft bearing cap mount-
time (one hour or more) elapses, do not apply the ing bolts)
oil or water to the sealant application area or 20 ± 1 N⋅m (Front left camshaft bearing cap
start the engine. mounting bolts)
5. Remove the bolt (M6 x 20) used to temporarily fix
Cylinder head
assembly
the sub gear of inlet camshaft assembly.
>>J<< CAMSHAFT OIL SEAL INSTALLATION

Camshaft oil seal
Front left
camshaft
bearing cap AC501923AB
(Engine oil)
3. Apply specified sealant to the matching area of
the cylinder head assembly and the front left
camshaft bearing cap as shown, and install the
left camshaft bearing cap to the cylinder head MD998713 AC102323AC
assembly.
1. Apply engine oil to the entire inner diameter of the
Specified sealant: 3M ATD Part No.8660 oil seal lip.
2. Use special tool camshaft oil seal installer 1. Use the following special tool as during removal to
(MD998713) to press-fit the oil seal as shown. hold the camshaft sprocket.
• Front hub and flange yoke holder (MB990767)
>>K<< CAMSHAFT SPROCKET INSTALLATION • Pin (MD998719)
2. Tighten the camshaft sprocket mounting bolt to
the specified torque.
MD998719
MB990767
AC507554AB
ENGINE MECHANICAL
OIL PAN AND OIL STRAINER
11A-27
REMOVAL AND INSTALLATION <2WD
(EXCEPT HIGH RIDER)>
M1112008301004
CAUTION
At the time of factory shipment or when the engine is overhauled, liquid gasket is used for the engine
oil pan gasket. Use the replacement engine oil pan gasket since the sealed surface may interfere with
surrounding parts, causing engine oil leak when the engine oil pan is installed on the vehicle using
the liquid gasket.
• Engine Room Under Cover Removal (Refer to GROUP 51 • Engine Oil Refilling (Refer to GROUP 12 − On-vehicle
− Under Cover P.51-32). Service, Engine Oil Replacement P.12-4).
• Engine Oil Draining (Refer to GROUP 12 − On-vehicle • Engine Room Under Cover Installation (Refer to GROUP
Service, Engine Oil Replacement P.12-4). 51 − Under Cover P.51-32).
48 ± 6 N·m
11 2N (Engine oil)
19 ± 3 N·m
N 10
3
19 ± 3 N·m 9.0 ± 1.0 N·m

11 ± 1 N·m
19 ± 3 N·m
9
N5
8N 6
39 ± 5 N·m
4 7
9.0 ± 3.0 N·m
AC506493 AC

1. Engine oil level gauge and guide 4. Engine oil pan drain plug
assembly >>B<< 5. Engine oil pan drain plug gasket
2. O-ring
3. Bell housing cover
Removal steps (Continued)

<<A>> • Steering column assembly and <<C>> ENGINE OIL PAN AND ENGINE OIL PAN
steering shaft joint assembly STRAINER ASSEMBLY REMOVAL
connection
1. Remove the engine oil pan mounting bolts.
<> • Power steering gear & link
assembly mounting bolt CAUTION
<> • Return tube clamp Do not use special tool oil pan FIPG cutter
<> • Pressure tube clamp (MD998727) in area A of the engine oil pan. Using
<<C>> 6. Engine oil pan and engine oil pan the special tool (MD998727) in area A may cause
strainer assembly deformation of the cylinder block case assembly
>>A<< 7. Engine oil pan front lower because the cylinder block case
>>A<< 8. Engine oil pan gasket assembly front lower is made of aluminium.
>>A<< 9. Engine oil pan strainer
>>A<< 10. Engine oil pan strainer gasket
11. Stiffener
B
<<A>> STEERING COLUMN ASSEMBLY AND
A
STEERING SHAFT JOINT ASSEMBLY DISCON-
NECTION
Steering column
assembly and
steering shaft AC504256AB
joint assembly
MD998727 MD998727
connecting bolt
18 ± 2 N·m
Front suspension
upper arm (LH)
AC600311AF
Disconnect the steering column assembly and the

steering shaft joint assembly. (Refer to GROUP 37 −
Steering Column Shaft Assembly P.37-18). AC104547AC
2. Tap special tool (MD998727) into the range B

<> POWER STEERING GEAR & LINK between the cylinder block assembly and the
ASSEMBLY MOUNTING BOLT/RETURN TUBE engine oil pan, and then slide the tool sideways.
CLAMP/PRESSURE TUBE CLAMP REMOVAL
NOTE: If any surrounding parts interfere with the
removal, there is no need to use the special tool.
3. With the engine oil pan separated from the
cylinder block assembly, remove the engine oil
pan strainer mounting bolts, and then remove the
engine oil pan together with the engine oil pan
strainer.

>>A<< ENGINE OIL PAN STRAINER GASKET/
AC502231AB
ENGINE OIL PAN STRAINER/ENGINE OIL PAN
Remove the mounting bolts of the power steering GASKET/ENGINE OIL PAN INSTALLATION
gear & link assembly and of the tube clamps, and 1. Remove sealant from the engine oil pan and
hung the power steering gear & link assembly using cylinder block assembly surfaces.
a wire or other similar material. (Refer to GROUP 37
− Power Steering Gear Box and Linkage P.37-22,
and Power Steering Hoses P.37-40).
ENGINE MECHANICAL
11A-29
2. Place the engine oil pan strainer into the engine Tightening torque: 9.0 ± 3.0 N⋅m
oil pan. Then, insert the engine oil pan and engine
oil pan gasket into the clearance between the >>B<< ENGINE OIL PAN DRAIN PLUG GASKET
cylinder block assembly and the power steering INSTALLATION
gear & link assembly.
3. Set the engine oil pan strainer gasket and the
engine oil pan strainer in the engine oil pan to the Engine oil pan side
cylinder block assembly, and tighten the engine oil
pan strainer mounting bolts to the specified
torque.
4. Set the engine oil pan gasket and engine oil pan
to the cylinder block assembly, and tighten the AC102325 AI
engine oil pan mounting bolts to the specified
torque. Replace the gasket with a new gasket. Install the
new gasket in the direction shown in the illustration.

(HIGH RIDER) AND 4WD>
M1112008301015
CAUTION
At the time of factory shipment or when the engine is overhauled, liquid gasket is used for the engine
oil pan gasket. Use the replacement engine oil pan gasket since the sealed surface may interfere with
surrounding parts, causing oil leak when the engine oil pan is installed on the vehicle using the liquid
gasket.
• Under Skid Plate and Engine Room Under Cover • Power Steering Gear Box and Linkage Assembly Installa-
Removal (Refer to GROUP 51 − Under Cover P.51-32). tion (Refer to GROUP 37 − Power Steering Gear Box and
• Engine Oil Draining (Refer to GROUP 12 − On-vehicle Linkage P.37-22).
Service, Engine Oil Replacement P.12-4). • Front Differential Carrier Assembly Installation (Refer to
• Differential Gear Oil Draining (Refer to GROUP 26 − On- GROUP 26 − Differential Carrier and Freewheel Clutch
vehicle Service, Gear Oil Replacement P.26-11) <4WD>. P.26-33) <4WD>.
• Front Differential Carrier Assembly Removal (Refer to • Differential Gear Oil Refilling (Refer to GROUP 26 − On-
GROUP 26 − Differential Carrier and Freewheel Clutch vehicle Service, Gear Oil Replacement P.26-11) <4WD>.
P.26-33) <4WD>. • Engine Oil Refilling (Refer to GROUP 12 − On-vehicle
• Power Steering Gear Box and Linkage Assembly Service, Engine Oil Replacement P.12-4).
Removal (Refer to GROUP 37 − Power Steering Gear • Under Skid Plate and Engine Room Under Cover Installa-
Box and Linkage P.37-22). tion (Refer to GROUP 51 − Under Cover P.51-32).
ENGINE MECHANICAL
11A-31
48 ± 6 N·m
10 2N (Engine oil)
19 ± 3 N·m
N9 8 3
19 ± 3 N·m 9.0 ± 1.0 N·m

19 ± 3 N·m
11 ± 1 N·m
7N
6
9.0 ± 3.0 N·m
5N
4
39 ± 5 N·m
AC506494AC

1. Engine oil level gauge and guide 9. Engine oil pan strainer gasket
assembly 10. Stiffener
2. O-ring
3. Bell housing cover REMOVAL SERVICE POINT
4. Engine oil pan drain plug <<A>> ENGINE OIL PAN REMOVAL
>>C<< 5. Engine oil pan drain plug gasket
1. Remove the engine oil pan mounting bolts.
<<A>> >>B<< 6. Engine oil pan
>>A<< 7. Engine oil pan gasket
8. Engine oil pan strainer
CAUTION INSTALLATION SERVICE POINTS

Do not use special tool oil pan FIPG cutter >>A<< ENGINE OIL PAN GASKET INSTALLATION
(MD998727) in area A of the engine oil pan. Using Install the engine oil pan gasket so that its fluorine-
the special tool MD998727 in area A may cause coated surface faces the cylinder block side.
deformation of the front case because the front
case is made of aluminium. >>B<< ENGINE OIL PAN INSTALLATION
1. Remove sealant from the engine oil pan and
cylinder block surfaces.
B 2. Install the engine oil pan.
3. Tighten the engine oil pan bolts to the specified
torque.
A Tightening torque: 9.0 ± 3.0 N⋅m
>>C<< ENGINE OIL PAN DRAIN PLUG GASKET

INSTALLATION
AC504256AB
MD998727 MD998727
Engine oil pan side
AC102325 AI
AC104547AC Replace the gasket with a new gasket. Install the

new gasket in the direction shown in the illustration.
2. Tap special tool MD998727 into the range (B)
between the cylinder block and the engine oil pan, INSPECTION
and then slide the special tool MD998727 M1112008400138
sideways. • Check the engine oil pan for cracks.

• Check the engine oil pan sealant-coated surface
NOTE: If any surrounding parts interfere with the
for damage and deformation.
removal, there is no need to use the special tool
• Check the engine oil pan strainer for cracked,
MD998727.
clogged or damaged wire net and pipe.
3. Remove the engine oil pan.
ENGINE MECHANICAL
CRANKSHAFT OIL SEAL
11A-33
CRANKSHAFT OIL SEAL
REMOVAL AND INSTALLATION <M/T>
M1112003104219
<Except high power engine>

5 4 133 ± 4 N·m
6 132 ± 5 N·m
<High power engine>
11 ± 1 N·m
10
7
9 8
11 N
3 11
3N
1
(Lip section) (Lip section)
Engine oil
AC903691AC
Crankshaft front oil seal removal Crankshaft rear oil seal removal
steps steps <Except high power
• Timing belt, timing belt B (Refer to engine>
P.11A-43) • Transmission assembly (Refer to
>>F<< 1. Crankshaft B sprocket GROUP 22A − Transmission
2. Crankshaft key Assembly P.22A-9) <2WD>
>>E<< 3. Crankshaft front oil seal • Transmission assembly (Refer to
GROUP 22A − Transmission
Assembly P.22A-10) <4WD>
CRANKSHAFT OIL SEAL
Crankshaft rear oil seal removal 1. Use special tool flywheel stopper (MB991883) to
steps <Except high power secure the flywheel assembly.
engine> (Continued)
2. Remove the flywheel bolts.
• Clutch cover and clutch disc (Refer
to GROUP 21B − Clutch P.21B-3)
<> >>D<< 4. Flywheel bolt INSTALLATION SERVICE POINTS
5. Flywheel assembly >>A<< CRANKSHAFT REAR OIL SEAL INSTAL-
>>B<< 10. Oil seal case assembly LATION
>>A<< 11. Crankshaft rear oil seal 1. Apply a small amount of engine oil to the entire
Crankshaft rear oil seal removal
inner diameter of the oil seal lip.
steps <High power engine>
<<A>> • Transmission assembly (Refer to
Assembly P.22A-10) <4WD>
• Clutch cover and clutch disc (Refer MB992147
to GROUP 21B − Clutch P.21B-3)
8.5 mm
<> >>D<< 6. Flywheel bolt Oil seal
>>C<< 7. Adapter
8. Flywheel assembly
9. Crankshaft adapter
>>B<< 10. Oil seal case assembly Oil seal case
>>A<< 11. Crankshaft rear oil seal AK503243AB
REMOVAL SERVICE POINTS 2. Use special tool oil seal installer (MB992147) to
press-fit the crankshaft rear oil seal.
<<A>> TRANSMISSION ASSEMBLY REMOVAL
3. Press-fit the crankshaft rear oil seal into the oil
CAUTION seal case assembly to have the dimension shown
AC300897 in the illustration.
>>B<< CRANKSHAFT REAR OIL SEAL CASE

Engine front ASSEMBLY INSTALLATION
1. Remove completely old sealant remaining on the
Flywheel
assembly crankshaft rear oil seal case assembly and
Flywheel cylinder block.
bolt
Crankshaft
AC308604 AB
rear oil seal
Do not remove the flywheel bolt. If this bolt is case assembly
removed, the flywheel assembly will become out
of balance and damaged.
<> FLYWHEEL BOLT REMOVAL
MB991883 AC503164 AD
2. Apply a continuous bead of the specified sealant

to the crankshaft rear oil seal case assembly
mating surface as shown.
Specified sealant: ThreeBond 1207F
NOTE: Install the crankshaft rear oil seal case
assembly immediately applying sealant.
AC802013AB
ENGINE MECHANICAL
CRANKSHAFT OIL SEAL
11A-35
CAUTION 1. Apply a small amount of engine oil to the outer
After the installation, until a sufficient period of diameter of special tool crankshaft front oil seal
time (one hour or more) elapses, do not apply the guide (MD998383) and install it to the crankshaft.
oil or water to the sealant application area or 2. Apply a small amount of engine oil to the entire
start the engine. inner diameter of the oil seal lip.
3. Applying an appropriate amount of engine oil to 3. Use special tool crankshaft front oil seal installer
the entire circumference of its crankshaft oil seal (MD998382) to press-fit the crankshaft front oil
rear lip portion, and then set the crankshaft rear seal.
oil seal case assembly to the cylinder block and
tighten the mounting bolts to the specified torque. >>F<< CRANKSHAFT B SPROCKET
Tightening torque: 11 ± 1 N⋅m INSTALLATION
: Clean
>>C<< ADAPTER INSTALLATION : Clean and degrease
Install the adapter to the flywheel so that the identifi-
cation mark (φ4 mm) faces the transmission side.
>>D<< FLYWHEEL BOLT INSTALLATION Crankshaft B sprocket
MB991883
Crankshaft
AC802014AB
Front case
1. Use special tool flywheel stopper (MB991883) to
secure the flywheel assembly in the same manner
as removal. Engine front
AC502148AB
2. Tighten the flywheel bolts to the specified torque.
Tightening torque: 1. Clean or degrease the oil pump case, the
<Except high power engine> 133 ± 4 N⋅m crankshaft and the crankshaft B sprocket as
<High power engine> 132 ± 5 N⋅m shown.
NOTE: Also clean the degreased surfaces.
>>E<< CRANKSHAFT FRONT OIL SEAL 2. Install the crankshaft B sprocket in the direction
INSTALLATION shown in the illustration.
Crankshaft MD998382
(Engine oil)
MD998383 Crankshaft
(Oil applied to the front oil seal
circumference) AC102329AI
CRANKSHAFT OIL SEAL
REMOVAL AND INSTALLATION <A/T>

M1112003104220
4
6 135 ± 5 N·m
11 ± 1 N·m
5
8
9N
2 3 9
3N (Lip section) (Lip section)

1 Engine oil
ACB00630 AB
Crankshaft front oil seal removal Crankshaft rear oil seal removal
steps steps (Continued)
• Timing belt, timing belt B (Refer to >>B<< 8. Oil seal case assembly
P.11A-43) >>A<< 9. Crankshaft rear oil seal
>>E<< 1. Crankshaft B sprocket
2. Crankshaft key REMOVAL SERVICE POINT
>>D<< 3. Crankshaft front oil seal <<A>> DRIVE PLATE BOLT REMOVAL
Crankshaft rear oil seal removal
steps
• Transmission assembly (Refer to MB991883
Assembly P.23A-135) <4A/T>
• Transmission assembly (Refer to
Assembly P.23A-139) <5A/T>
<<A>> >>C<< 4. Drive plate bolt
5. Adapter plate
6. Drive plate
AC802013AB
7. Inertia ring assembly
ENGINE MECHANICAL
CRANKSHAFT OIL SEAL
11A-37
1. Use special tool flywheel stopper (MB991883) to CAUTION
secure the inertia ring assembly. After the installation, until a sufficient period of
2. Remove the drive plate bolts. time (one hour or more) elapses, do not apply the
oil or water to the sealant application area or
INSTALLATION SERVICE POINTS start the engine.
>>A<< CRANKSHAFT REAR OIL SEAL INSTAL- 3. Applying an appropriate amount of engine oil to
LATION the entire circumference of its crankshaft oil seal
1. Apply a small amount of engine oil to the entire rear lip portion, and then set the crankshaft rear
inner diameter of the oil seal lip. oil seal case assembly to the cylinder block and
tighten the mounting bolts to the specified torque.
MB992147
>>C<< DRIVE PLATE BOLT INSTALLATION
8.5 mm Oil seal
MB991883
Oil seal case

AK503243AB
2. Use special tool oil seal installer (MB992147) to

press-fit the crankshaft rear oil seal.
3. Press-fit the crankshaft rear oil seal into the oil
AC802014AB
seal case assembly to have the dimension shown
in the illustration. 1. Use special tool flywheel stopper (MB991883) to
secure the inertia ring assembly in the same
>>B<< CRANKSHAFT REAR OIL SEAL CASE manner as removal.
ASSEMBLY INSTALLATION 2. Tighten the drive plate bolts to the specified
1. Remove completely old sealant remaining on the torque.
crankshaft rear oil seal case assembly and Tightening torque: 135 ± 5 N⋅m
cylinder block.
>>D<< CRANKSHAFT FRONT OIL SEAL
Crankshaft INSTALLATION
rear oil seal
case assembly Crankshaft MD998382
(Engine oil)
AC503164 AD
MD998383 Crankshaft
2. Apply a continuous bead of the specified sealant (Oil applied to the front oil seal
circumference)
to the crankshaft rear oil seal case assembly AC102329AI
mating surface as shown.

1. Apply a small amount of engine oil to the outer
Specified sealant: ThreeBond 1207F diameter of special tool crankshaft front oil seal
NOTE: Install the crankshaft rear oil seal case guide (MD998383) and install it to the crankshaft.
assembly immediately applying sealant. 2. Apply a small amount of engine oil to the entire
inner diameter of the oil seal lip.
3. Use special tool crankshaft front oil seal installer
(MD998382) to press-fit the crankshaft front oil
seal.
CRANKSHAFT OIL SEAL
1. Clean or degrease the oil pump case, the

>>E<< CRANKSHAFT B SPROCKET crankshaft and the crankshaft B sprocket as
INSTALLATION shown.
NOTE: Also clean the degreased surfaces.
: Clean
: Clean and degrease 2. Install the crankshaft B sprocket in the direction
Crankshaft B sprocket
Crankshaft
Front case
Engine front
AC502148AB
ENGINE MECHANICAL
CYLINDER HEAD GASKET
11A-39
M1112004005081

• Engine Oil Draining (Refer to GROUP 12 − On-vehicle • Timing Belt Installation (Refer to P.11A-43).
Service, Engine Oil Replacement P.12-4). • Turbocharger Assembly and Exhaust Manifold Installation
• Fuel Injector Removal (Refer to GROUP 13A − Fuel Injec- (Refer to GROUP 15 − Turbocharger Assembly P.15-19)
tor P.13A-598). <Except Euro5>.
• Common Rail Assembly Removal (Refer to GROUP 13A • Turbocharger Assembly and Exhaust Manifold Installation
− Common Rail and Supply Pump P.13A-604). (Refer to GROUP 15 − Turbocharger Assembly P.15-21)
• Turbocharger Assembly and Exhaust Manifold Removal <Euro5>.
(Refer to GROUP 15 − Turbocharger Assembly P.15-19) • Common Rail Assembly Installation (Refer to GROUP
<Except Euro5>. 13A − Common Rail and Supply Pump P.13A-604).
• Turbocharger Assembly and Exhaust Manifold Removal • Fuel Injector Installation (Refer to GROUP 13A − Fuel
(Refer to GROUP 15 − Turbocharger Assembly P.15-21) Injector P.13A-598).
<Euro5>. • Engine Oil Refilling (Refer to GROUP 12 − On-vehicle
• Timing Belt Removal (Refer to P.11A-43). Service, Engine Oil Replacement P.12-4).
9 78 ± 2 N·m to 0 N·m to 29 ± 2 N·m to +90˚ to +90˚

(Cold engine)
8 10 3
(Engine oil)
24 ± 4 N·m
5
7 11
6
5.0 ± 1.0 N·m

<Except Euro5>
4
2
10 ± 2 N·m
1
88 ± 10 N·m
AC502177AE

1. Engine coolant temperature sensor <> >>C<< 6. Camshaft sprocket
connector 7. Timing belt rear cover
2. Engine coolant temperature gauge <<C>> 8. Power steering oil pump assembly
unit connector <<D>> >>B<< 9. Cylinder head bolt
3. Control wiring harness connection 10. Cylinder head assembly
<<A>> >>D<< 4. Radiator upper hose connection >>A<< 11. Cylinder head gasket
5. Oil hose connection
REMOVAL SERVICE POINTS <<D>> CYLINDER HEAD BOLT REMOVAL

<<A>> RADIATOR UPPER HOSE DISCONNEC- CAUTION
TION
Punch mark
Head of cylinder
head bolt
Mating marks
AC502181AB
AC606081AE
Provide one punch mark on the head of the cylin-
Make mating marks on the radiator hose and hose der head bolt each time the bolt is tightened.
clamp as shown to install them in the original posi- Replace the bolt that already has five punch
tion. Then, remove them. marks (the evidence of having been tightened
five times)
<> CAMSHAFT SPROCKET REMOVAL
Engine front
6 14 16 8
2 10 18 12 4
MD998719
1 9 17 11 3
5 13 15 7
MB990767 AC502179 AB
AC507554AB
Loosen the cylinder head bolts in two or three steps
1. Use the following special tools to hold the in the order of the numbers shown in the illustration.
camshaft sprocket.
• Front hub and flange yoke holder (MB990767) INSTALLATION SERVICE POINTS
• Pin (MD998719) >>A<< CYLINDER HEAD GASKET INSTALLA-
2. Loosen the camshaft sprocket mounting bolt and TION
remove the camshaft sprocket. CAUTION
Do not allow any foreign materials get into the
<<C>> POWER STEERING OIL PUMP ASSEMBLY
coolant passages, oil passages and cylinder.
REMOVAL
1. With the hose installed, remove the power 1. Degrease the cylinder head gasket mounting
steering oil pump assembly from the bracket. surface.
2. After removing the power steering oil pump
assembly, secure it with a cord in the location
where the removal and installation of the cylinder
head assembly cannot be hindered.
ENGINE MECHANICAL
11A-41
CAUTION >>B<< CYLINDER HEAD BOLTS INSTALLATION
The thickness of the original cylinder head gas- CAUTION
ket is selected according to protrusion amount of • Before installing the cylinder head bolt, check
the piston. Therefore, If the cylinder block, pis- the number of punch marks on its head. (the
ton, connecting rod or crankshaft is replaced, the bolt is reusable if it is four or less.) The
protrusion amount may be changed. Always number of punch marks corresponds to that
select a correct gasket by measuring the protru- to times the bolt has been tightened to the
sion amount (Refer to GROUP 11B − Cylinder plastic area. If the bolt has five punch marks,
Head and Valves P.11B-46). replace it.
Identification mark 1. Set the cylinder head bolt washer with its shear
Timing belt side
droop toward the bolt head.
Cylinder head gasket 2. Apply a small amount of engine oil to the thread of
the bolts and to the washers.
Engine front
13 5 3 11
17 9 1 7 15
AC502182AB
2. When replacing the cylinder head gasket only, 18 10 2 8 16

confirm the gasket identification mark, and then 14 6 4 12
select a replacement part according to the
following table. AC502179 AC
<Except Euro5> 3. Tighten the cylinder head bolts in the following

Specification Identification Thickness of procedures.
mark (fitted selected gasket (1) Tighten the bolts to 78 ± 2 N⋅m in the order
thickness (when tightened) shown.
mm) mm (2) Loosen the bolts fully in the reverse sequence
A D5−205 0.95 ± 0.04 to that shown.
B D5−206 1.00 ± 0.04 (3) Tighten the bolts to 29 ± 2 N⋅m in the order
shown.
C D5−207 1.05 ± 0.04
Step (4) Step (5)
<Euro5>
Specification Identification Thickness of 90˚ 90˚
mark (fitted selected gasket
thickness (when tightened)
mm) mm
A D5 − 819 1.07 ± 0.04
D5 − 996 Paint marking Paint marking
B D5 − 997 1.12 ± 0.04 AC102331AB
C D5 − 998 1.17 ± 0.04
(4) Apply a paint mark to the heads of the cylinder
head bolts and cylinder head, then tighten 90°
as shown.
CAUTION 1. Use the following special tools as during removal

• The bolt is not tightening sufficiently if the to hold the camshaft sprocket.
tightening angle is less than a 90°. • Front hub and flange yoke holder (MB990767)
• If the tightening angle exceeds the standard • Pin (MD998719)
specification, remove the bolt and start over 2. Tighten the camshaft sprocket mounting bolt to
from step (1). the specified torque.
(5) Tighten in a 90° as shown in the instructions of Tightening torque: 88 ± 10 N⋅m
the illustration, then check to see that the paint
mark on the head of the cylinder head bolts >>D<< RADIATOR UPPER HOSE CONNECTION
and the paint mark on the cylinder head is on a
linear line. Projection
>>C<< CAMSHAFT SPROCKET INSTALLATION
MD998719 Pipe, fitting, or etc. Mating marks
AC606082 BA
1. Insert radiator hose as far as the projection of the

MB990767 cooling water outlet hose fitting.
AC507554AB
2. Align the mating marks on the radiator hose and
hose clamp, and then connect the radiator hose.
ENGINE MECHANICAL
TIMING BELT
11A-43
TIMING BELT
M1112004302889

• Water Pump Pulley Removal and Installation (Refer to
GROUP 14 − Radiator Fan P.14-6).
• Crankshaft Pulley Removal and Installation (Refer to
P.11A-17).
<Except Euro5>
3.0 ± 0.5 N·m
10
3
4 10 ± 2 N·m
48 ± 6 N·m
9
7
42 ± 8 N·m 44 ± 10 N·m
2 10
44 ± 10 N·m
23 ± 3 N·m
6
10 ± 2 N·m
5 AC805880 AB

1. Engine cover 6. Timing belt lower cover
2. Harness bracket >>D<< 7. Auto tensioner
3. Timing belt upper cover <<A>> >>D<< 8. Timing belt
4. Auto tensioner >>D<< 9. Tensioner arm assembly
5. Harness bracket 10. Idler pulley
TIMING BELT
23 ± 3 N·m
16
15
14
20 ± 4 N·m
13
11 12
AC502913 AE

>>C<< 11. Crankshaft sprocket >>A<< 15. Tensioner B spring
>>C<< 12. Flange >>A<< 16. Timing belt B tensioner assembly
<> >>B<< 13. Timing belt B
>>A<< 14. Tensioner B spacer
ENGINE MECHANICAL
TIMING BELT
11A-45
<Euro5>
3.0 ± 0.5 N·m
11
5 10 ± 2 N·m 4
48 ± 6 N·m
42 ± 8 N·m
10
8
44 ± 10 N·m
2
10 ± 2 N·m 11
44 ± 10 N·m
3 23 ± 3 N·m
7
10 ± 2 N·m
10 ± 2 N·m 6
AC805668 AB

1. Engine cover 6. Harness bracket
2. Harness bracket 7. Timing belt lower cover
3. Solenoid valve and harness bracket >>D<< 8. Auto tensioner
assembly <<A>> >>D<< 9. Timing belt
4. Timing belt upper cover >>D<< 10. Tensioner arm assembly
5. Auto tensioner 11. Idler pulley
TIMING BELT
23 ± 3 N·m
17
16
15
20 ± 4 N·m
14
12 13
AC502913 AF
Removal steps REMOVAL SERVICE POINTS

>>C<< 12. Crankshaft sprocket <<A>> TIMING BELT REMOVAL
>>C<< 13. Flange
<> >>B<< 14. Timing belt B CAUTION
>>A<< 15. Tensioner B spacer Never turn the crankshaft anti-clockwise.
>>A<< 16. Tensioner B spring
>>A<< 17. Timing belt B tensioner assembly Timing mark
Camshaft
sprocket
Timing mark
Timing
mark Injection pump
sprocket
Crankshaft
sprocket AC502914AB
1. Turn the crankshaft clockwise, align each timing

mark to set No.1 cylinder to TDC of its
compression stroke.
ENGINE MECHANICAL
TIMING BELT
11A-47
CAUTION INSTALLATION SERVICE POINTS
To reuse the timing belt, draw an arrow indicating >>A<< TIMING BELT B TENSIONER ASSEMBLY/
the rotating direction (clockwise) on the back of TENSIONER B SPRING/TENSIONER B SPACER
the belt using chalk, etc. INSTALLATION
Timing belt B
Timing belt tensioner
assembly
Flange
bolt
Water
AC502915AB
pump
2. Remove the timing belt.
Hexagon
socket
<> TIMING BELT B REMOVAL head bolt
CAUTION Tensioner B
To reuse the timing belt B, draw an arrow indicat- spacer
Front lower case
ing the rotating direction on the back of the belt
using chalk, etc.
Washer
Tensioner B spring AC502918AB
1. Install the timing belt B tensioner assembly,

tensioner B spring and tensioner B spacer.
Timing NOTE: Be sure to install the tensioner B spring
belt B with its shorter end toward the water pump.
2. Move timing belt B tensioner assembly toward
AC502917AB
water pump and tighten mounting bolts.
1. Loosen the timing belt B tensioner assembly >>B<< TIMING BELT B INSTALLATION
mounting bolts.
Balancer
2. Push the timing belt B tensioner assembly to Timing mark shaft
water pump side and tighten the timing belt B sprocket
Timing mark
tensioner assembly mounting bolts.
Timing mark
3. Remove the timing belt B.
Timing belt B
Crankshaft
Balancer sprocket B
shaft sprocket AC502919AB
1. Align timing marks on the crankshaft sprocket B,

and balancer shaft sprockets with their timing
marks.
2. Install balancer timing belt B onto sprockets and
ensure that its tension side is not slack.
TIMING BELT
Timing belt B NOTE: Also clean the degreased surfaces.

tensioner
assembly Flange Timing mark
bolt
Flange
Hexagon socket
head bolt
AC502920AB
AC502923 AB
3. Loosen timing belt B tensioner assembly
mounting flange bolt, one to two turns. 2. Assemble the flange by aligning the timing mark
4. Tighten the timing belt B tensioner assembly of the front lower case and the timing mark of the
mounting hexagon socket head bolt. flange.
5. timing belt B tensioner assembly mounting flange
bolt. >>D<< TENSIONER ARM ASSEMBLY/TIMING
BELT/AUTO TENSIONER INSTALLATION
NOTE: If the bolt is tightened first, the timing belt
B tensioner assembly should be turned together, 1. To reuse the auto tensioner, bleed the air
resulting in reduced timing belt B tensioner according to the procedure below, and then set
assembly. the rod to the auto tensioner.
CAUTION
Balancer shaft
sprocket • If a horizontal press such as a vice is used,
the air entrainment may occur. Thus, a verti-
cal press must be used.
• If the compression is too fast, the procedure
Belt may damage the rod. Make sure to compress
deflection slowly and thoroughly.
• To prevent a damage to the auto tensioner, do
Crankshaft
sprocket B not push down the rod exceeding the bottom
AC502921AB end (a position where the rod protrusion is at
0.5 mm from the auto tensioner).
6. Ensure that the deflection is as specified when the
timing belt B is pushed by the index finger at the
position indicated by an arrow. Press Rod
Belt deflection: 4 − 5 mm
>>C<< FLANGE/CRANKSHAFT SPROCKET Auto tensioner

INSTALLATION
Crankshaft
Crankshaft sprocket B
Flange AC502924 AB
sprocket
Crankshaft
(1) Set the auto tensioner to the vertical press,
and then slowly compress the rod to the
bottom end (a position where the rod
protrusion is at 0.5 mm from the auto
tensioner). Perform this operation 2 to 3 times.
(2) With the rod protruding (a position where the
AC502922AB rod protrusion is at 5 mm from the auto
tensioner), check that there is a rigidity when
1. Clean or degrease the crankshaft, the flange and the rod is pushed with a load (100 to 200 N).
crankshaft sprocket as shown.
ENGINE MECHANICAL
TIMING BELT
11A-49
(3) If the rod rigidity is not obtained by repeating
the operations of (1) and (2), replace the auto Camshaft Timing mark
tensioner. sprocket
B
Rod
A Timing mark
Auto tensioner
AC502924 AC
(4) Compress the rod slowly, and then align the

set hole A of the rod with the set hole B of the Timing
auto tensioner body. mark Injection pump
sprocket
Wire or pin
Crankshaft
sprocket AC502916AB
Auto tensioner
4. Align the timing mark of each sprocket.
Crankshaft Crankshaft
sprocket Slide sprocket B
Crankshaft
AC502925AB
(5) Insert a wire or pin in the aligned set hole. Key top end
NOTE: When the auto tensioner is replaced
with a new part, the auto tensioner is set with a
pin.
Notched area AC502926AB
2. Install the auto tensioner in position. Leave the
wire or pin installed until the auto tensioner is 5. In the order below, install the timing belt without
completely installed. slack.
3. Install the tensioner arm assembly. NOTE: When installing the timing belt into the
crankshaft sprocket, slide the crankshaft sprocket
to near the tip of the key, and then install the tim-
ing belt. (When installing the timing belt, be care-
ful not to damage the belt by the cut-out of
crankshaft sprocket.) After that, install the crank-
shaft sprocket to the correct position.
(1) Crankshaft sprocket
(2) Idler pulley
(3) Injection pump sprocket
(4) Idler pulley
(5) Camshaft sprocket
(6) Tensioner pulley
6. Check that the timing marks on sprockets are at
the correct positions.
7. Remove the wire or pin of the auto tensioner.
VACUUM PUMP
8. Turn the crankshaft 2 turns clockwise, and then 9. Check again that the timing marks on sprockets
measure the protrusion of auto tensioner rod. are at the correct positions.
Standard value: 2.3 − 7.6 mm
VACUUM PUMP
M1112005200458

• A/C Compressor Drive Belt, Alternator and Power Steer-
ing Oil Pump Drive Belt Removal and Installation (Refer to
P.11A-17).
• Air Duct Removal and Installation (Refer to GROUP 15 −
Air Cleaner P.15-6).
<Except Euro5>
3.0 ± 0.5 N·m
1
9
7
8
10
24 ± 3 N·m
11 ± 1 N·m
6
2 4
23 ± 3 N·m 5
20 ± 4 N·m
24 ± 4 N·m 3
AC805886 AC

1. Engine cover 7. Vacuum hose connection
<<A>> 2. Power steering oil pump assembly 8. Vacuum pump assembly
3. Power steering oil pump bracket A 9. O-ring
4. Oil hose 10. O-ring
5. Oil hose
6. Oil pipe
ENGINE MECHANICAL
VACUUM PUMP
11A-51
<Euro5>
3.0 ± 0.5 N·m
1
8 9 11
10
12
24 ± 3 N·m 11 ± 1 N·m
2 7
5
23 ± 3 N·m
6
20 ± 4 N·m
24 ± 4 N·m
4
50 ± 5 N·m
AC805665 AC
Removal steps REMOVAL SERVICE POINT

1. Engine cover <<A>> POWER STEERING OIL PUMP ASSEMBLY
<<A>> 2. Power steering oil pump assembly REMOVAL
3. Power steering oil pump bracket A
4. Idler pulley 1. With the hose installed, remove the power
5. Oil hose steering oil pump assembly from the bracket.
6. Oil hose 2. After removing the power steering oil pump
7. Oil pipe assembly, secure it with a cord in the location
8. Vacuum hose connection where the removal and installation of the vacuum
9. Vacuum hose connection pump assembly cannot be hindered.
10. Vacuum pump assembly
11. O-ring
12. O-ring
ENGINE ASSEMBLY
ENGINE ASSEMBLY
M1112001006784

• Hood Removal (Refer to GROUP 42 − Hood P.42-6). • Cowl Top Panel Front Installation
• Engine Oil Draining (Refer to GROUP 12 − On-vehicle • Windshield Wiper Assembly Installation (Refer to GROUP
Service, Engine Oil Replacement P.12-4). 51 − Windshield Wiper P.51-68).
• Air Cleaner Assembly Removal (Refer to GROUP 15 − Air • Radiator Installation (Refer to GROUP 14 − Radiator
Cleaner P.15-6). P.14-16).
• Battery Removal • Cooling Fan and Fan Clutch Assembly Installation (Refer
• Cooling Fan and Fan Clutch Assembly Removal (Refer to to GROUP 14 − Cooling Fan P.14-6).
GROUP 14 − Cooling Fan P.14-6). • Battery Installation
• Radiator Removal (Refer to GROUP 14 − Radiator P.14- • Air Cleaner Assembly Installation (Refer to GROUP 15 −
16). Air Cleaner P.15-6).
• Windshield Wiper Assembly Removal (Refer to GROUP • Engine Oil Refilling (Refer to GROUP 12 − On-vehicle
51 − Windshield Wiper P.51-68). Service, Engine Oil Replacement P.12-4).
• Cowl Top Panel Front Removal • Air Bleeding from Fuel Line (Refer to GROUP 13A − On-
vehicle Service, Evacuation of Air from Fuel Line P.13A-
589).
• Hood Installation (Refer to GROUP 42 − Hood P.42-6).
ENGINE MECHANICAL
ENGINE ASSEMBLY
11A-53
3.0 ± 0.5 N·m
1 3
5.0 ± 1.0 N·m

<Except Euro5>
11 ± 1 N·m
14 ± 4 N·m
5.0 ± 1.0 N·m

2 11
10 9
23 ± 3 N·m
8
12
23 ± 3 N·m 48 ± 7 N·m
7
13
22 ± 4 N·m
14
AC903710 AC

1. Engine cover <> 6. A/C compressor assembly
2. Earth cable connection 7. Brake booster vacuum hose
3. Control wiring harness connection connection
4. Battery wiring harness connection 8. Boost sensor vacuum hose
<<A>> 5. Power steering oil pump assembly connection
ENGINE ASSEMBLY
Removal steps (Continued) Refer to GROUP 22A − Transmission Assembly

9. Heater piping hose connection P.22A-10 <4WD>.
10. Free-wheeling hub solenoid valve
vacuum hose connection <4WD>
<<D>> ENGINE ASSEMBLY REMOVAL
11. Fuel hose D connection
12. Fuel return hose connection 1. Check that all cables, hoses and wiring harness
<<C>> • Transmission assembly <M/T>. connectors are disconnected from the engine
Assembly P.23A-135) <4A/T>. MB991683
Assembly P.23A-139) <5A/T>.
13. Front engine mounting insulator
mounting bolt
<<D>> >>A<< 14. Engine assembly
REMOVAL SERVICE POINTS AC502542AB
<<A>> POWER STEERING OIL PUMP ASSEMBLY 2. Lift the special tool sling chain set (MB991683)
REMOVAL and chain block slowly to remove the engine
1. With the hose installed, remove the power assembly upwards from the engine compartment.
steering oil pump assembly from the bracket.
2. After removing the power steering oil pump INSTALLATION SERVICE POINT
assembly, secure it with a cord in the location >>A<< ENGINE ASSEMBLY INSTALLATION
where the removal and installation of the engine
assembly cannot be hindered.
<> A/C COMPRESSOR ASSEMBLY MB991683

REMOVAL
1. With the hose installed, remove the A/C
compressor assembly from the bracket.
2. After removing the A/C compressor assembly,
secure it with a cord in the location where the
removal and installation of the engine assembly
cannot be hindered. AC502542AB
<<C>> TRANSMISSION ASSEMBLY REMOVAL 1. Use special tool sling chain set (MB991683) and
<M/T> chain block to lift the engine assembly in the same
manner as removal.
CAUTION
2. Install the engine assembly, being careful not to
AC300897
pinch the cables, hoses or wiring harness
connectors.
Engine front
Flywheel
assembly
Flywheel
bolt
AC308604 AB
Do not remove the flywheel bolt. If this bolt is

removed, the flywheel assembly will become out
of balance and damaged <High power engine>.
Refer to GROUP 22A − Transmission Assembly
P.22A-9 <2WD>.
11B-1
GROUP 11B
ENGINE OVERHAUL
CONTENTS
GENERAL SPECIFICATIONS . . . . . . 11B-2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 11B-35
SERVICE SPECIFICATIONS. . . . . . . 11B-2 WATER HOSE AND PIPE . . . . . . . . . 11B-39

WATER HOSE AND PIPE REMOVAL AND
REWORK DIMENSIONS . . . . . . . . . . 11B-4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 11B-39
TORQUE SPECIFICATIONS . . . . . . . 11B-4 ROCKER ARMS AND CAMSHAFT . . 11B-42

ROCKER ARMS AND CAMSHAFT REMOVAL AND
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 11B-42
SEALANTS . . . . . . . . . . . . . . . . . . . . 11B-8
ROCKER ARMS AND CAMSHAFT INSPECTION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B-45
SPECIAL TOOLS. . . . . . . . . . . . . . . . 11B-9
CYLINDER HEAD AND VALVES. . . . 11B-46
ALTERNATOR . . . . . . . . . . . . . . . . . . 11B-13
CYLINDER HEAD AND VALVES REMOVAL AND
ALTERNATOR REMOVAL AND INSTALLATION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 11B-46
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B-13
CYLINDER HEAD AND VALVES INSPECTION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B-49
INLET MANIFOLD . . . . . . . . . . . . . . . 11B-16
INLET MANIFOLD REMOVAL AND INSTALLATION OIL PAN AND OIL PUMP. . . . . . . . . . 11B-52
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B-16
OIL PAN AND OIL PUMP REMOVAL AND
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 11B-52
EXHAUST MANIFOLD. . . . . . . . . . . . 11B-19 OIL PAN AND OIL PUMP INSPECTION. . . 11B-57
EXHAUST MANIFOLD REMOVAL AND
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 11B-19
PISTON AND CONNECTING ROD . . 11B-58
PISTON AND CONNECTING ROD REMOVAL AND
TIMING BELT. . . . . . . . . . . . . . . . . . . 11B-22 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 11B-58
TIMING BELT REMOVAL AND INSTALLATION
PISTON AND CONNECTING ROD INSPECTION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B-22
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B-61
TIMING BELT INSPECTION. . . . . . . . . . . . 11B-27
CRANKSHAFT AND CYLINDER BLOCK
COMMON RAIL AND SUPPLY PUMP 11B-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B-63
COMMON RAIL AND SUPPLY PUMP REMOVAL AND
CRANKSHAFT AND CYLINDER BLOCK REMOVAL
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 11B-30
AND INSTALLATION . . . . . . . . . . . . . . . . . 11B-63
ROCKER COVER AND INJECTOR . 11B-35 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-67
ROCKER COVER AND INJECTOR REMOVAL AND
11B-2 ENGINE OVERHAUL
GENERAL SPECIFICATIONS
M1113000203046
Description Specifications
Bore × Stroke mm 91.1 × 95
Compression ratio 17 <Except Euro5>,
16.5 <Euro5>
Compression chamber Vortex chamber type
Camshaft arrangement DOHC
Number of valve Intake 2
Exhaust 2
Valve timing Intake valve Open 20° BTDC <Except Euro5>,
13° BTDC <Euro5>
Close 40° BTDC <Except Euro5>,
30° BTDC <Euro5>
Exhaust valve Open 38° BBDC
Close 22° ATDC
Rocker arm End pivot type
Lubrication system Pressure feed, full-flow filtration
Oil pump Trochoid type
Fuel system Common rail type injection pump
Turbocharger Water-cooled
Cooling system Water-cooled
Water pump type Centrifugal impeller type
M1113000303601
Item Standard Limit

Timing belt
Auto-tensioner rod extension length 2.3 − 7.6 −
(with timing belt installed) mm
Auto-tensioner rod extension length (when free) mm 14.5 −
Auto-tensioner rod retraction length Less than 1 −
(when pressed with force of 100 − 200 N⋅m) mm
Rocker arm and camshaft
Valve clearance mm Intake 0.09 −
Exhaust 0.14 −
Cam height mm Intake Except Euro5 35.47 34.97
Euro5 35.42 34.92
Exhaust 35.41 34.91
Cylinder head and valves
ENGINE OVERHAUL
11B-3
Item Standard Limit
Flatness of gasket surface mm 0.03 *0.2
*Grinding is not suitable for correction.
Cylinder head overall height mm 129.9 − 130.1 −
Valve thickness of valve head mm (margin) Intake 1.3 0.8
Exhaust 1.5 1.0
Valve length mm Intake 107.58 107.08
Exhaust 107.98 107.48
Valve spring free height mm 54.3 53.3
Valve spring cut-of-squareness 2° or less Max. 4°
Valve seat contact width mm 1.1 − 1.5 −
Valve stem-to guide clearance mm Intake 0.020 − 0.047 0.10
Exhaust 0.035 − 0.062 0.15
Valve guide protrusion 18.3 − 18.9 −
Oil pan and oil pump
Balancer shaft oil clearance mm Front Right 0.02 − 0.05 −
Left 0.02 − 0.06 −
Rear 0.06 − 0.10 −
Oil pump tip clearance mm 0.11 − 0.24 −
Oil pump side clearance mm 0.04 − 0.10 −
Oil pump body clearance mm 0.10 − 0.18 0.35
Piston and connecting rod
Piston ring end gap mm No. 1 ring Except Euro5 0.30 − 0.45 0.8
Euro5 0.20 − 0.30 0.8
No. 2 ring Except Euro5 0.30 − 0.45 0.8
Euro5 0.20 − 0.35 0.8
Oil ring 0.25 − 0.45 0.8
Piston ring-to-ring groove clearance mm No. 1 ring 0.07 − 0.10 0.15
No. 2 ring 0.05 − 0.06 0.15
Oil ring 0.02 − 0.06 0.10
Oil clearance at crankshaft pins mm 0.02 − 0.05 0.10
Connecting rod big end side clearance mm 0.10 − 0.25 0.40
Crankshaft and cylinder block
Crankshaft end play mm 0.05 − 0.25 0.45
Oil clearance at crankshaft journal mm 0.02 − 0.03 0.10
Cylinder block gasket surface warp mm 0.05 0.10
Cylinder I.D. mm 91.10 − 91.13 −
Cylindricity mm − 0.02
NOTE: O.D.: Outer diameter
I.D.: Inner diameter
REWORK DIMENSIONS
REWORK DIMENSIONS
M1113024301728
Item Standard value

Cylinder head oversize valve guide hole diameter mm 0.05 O.S. 11.050 − 11.068
Cylinder head oversize valve seat hole diameter, intake mm 0.30 O.S. 33.300 − 33.325
Cylinder head oversize valve seat hole diameter, exhaust mm 0.30 O.S. 29.300 − 29.321
TORQUE SPECIFICATIONS
M1113023405274
Item N⋅m
Alternator
Cooling fan bolt 11 ± 1
Fan clutch bolt 11 ± 1
Crankshaft bolt 265 → 0 → 275
Idler pulley bolt <Euro5> 50 ± 5
Power steering pump bracket "A" bolt (Bolt, washer assembly) 20 ± 4
Power steering pump bracket "A" bolt (Flange bolt) 24 ± 4
Power steering pump bracket "B" bolt (M8 × 30) 23 ± 2
Power steering pump bracket "B" bolt (M8 × 90) 24 ± 4
Alternator pivot nut 44 ± 10
Oil level gauge bolt 48 ± 6
Inlet manifold
Vacuum pump pipe "B" bolt 24 ± 3
Air temperature sensor 14 ± 1
EGR pipe "B" bolt (EGR valve side) 49 ± 6
EGR pipe "B" bolt (EGR cooler side) 17 ± 2
EGR pipe "A" heat protector bolt 11 ± 1
EGR pipe "A" bolt and nut 17 ± 2
EGR valve bolt 48 ± 6
Throttle body bolt 13 ± 2
Fuel inlet pipe bolt 20 ± 4
Inlet manifold stay bolt 24 ± 3
Inlet manifold bolt 24 ± 3
Inlet manifold nut 20 ± 2
Exhaust manifold
<Except Euro5>
Engine hanger bolt 24 ± 3
Eye bolt (oil pipe) 17 ± 2
Oil pipe bolt 9.0 ± 1.0
ENGINE OVERHAUL
11B-5
Item N⋅m
Eye bolt (water pipe) 53 ± 7
Water pipe bolt 11 ± 1
Oil return pipe bolt 9.0 ± 1.0
Turbocharger nut 59 ± 10
Exhaust manifold heat protector bolt 14 ± 1
Exhaust manifold nut (M8) 18 ± 2
<Euro5>
Engine hanger bolt 24 ± 3
Eye bolt 17 ± 2
Oil pipe bolt 24 ± 3
Heat protector bolt 9.0 ± 1.0
Heat protector bracket bolt (M6) 9.0 ± 1.0
Heat protector bracket bolt (M8) 24 ± 3
Turbocharger water pipe bolt (M6) 11 ± 1
Turbocharger water pipe bolt (M8) 24 ± 3
Vacuum pipe and hose bolt 23 ± 6
Connector bracket bolt 9.5 ± 1.5
E-VRV bolt 9.5 ± 2.5
Oil return pipe bolt 9.0 ± 1.0
Turbocharger heat protector bolt 14 ± 1
Turbocharger bolt and nut 59 ± 10
Exhaust manifold heat protector A bolt 14 ± 1
Exhaust manifold heat protector B bolt 14 ± 1
Timing belt
Oil pipe bolt 11 ± 1
Vacuum pump bolt 24 ± 3
Vacuum pump pipe "A" bolt 24 ± 3
Cover bolt 11 ± 1
Crank angle sensor bolt 11 ± 1
Timing belt cover bolt 10 ± 2
Glow plug plate nut 1.8 ± 0.2
Glow plug 9.0 ± 1.0 → +30° to 40°
Tensioner arm bolt 48 ± 6
Auto tensioner bolt 23 ± 3
Pump sprocket nut 64 ± 5
Idler pulley bolt 44 ± 10
Hexagon socket head bolt 20 ± 4
Item N⋅m
Timing belt tensioner "B" bolt 23 ± 3
Balancer shaft sprocket bolt and nut 36 ± 3
Common rail and supply pump
EGR cooler bracket bolt 24 ± 3
EGR cooler bolt 24 ± 3
Supply pump bolt 24 ± 4
EGR cooler nut 28 ± 4
Suction control valve kit bolt 8.9 ± 1.9
Fuel supply pump pipe flare nut 35 ± 5
Fuel supply pump pipe bolt 10 ± 2
Fuel supply pump pipe bracket bolt 10 ± 2
Bracket bolt <Euro5> 20 ± 4
Fuel injection pipe flare nut 35 ± 5
Fuel injection pipe bolt 10 ± 2
Common rail bolt 24 ± 4
Fuel return pipe bolt 10 ± 2
Eyebolt (Cylinder head side) <Except Euro5> 17 ± 2
Eyebolt (Cylinder head side) <Euro5> 20 ± 2
Eyebolt (Common rail side) 20 ± 2
Rocker cover and injector
Rocker cover bolt 3.0 ± 1.0 → 10 ± 2
Injector holder bolt 10 ± 1 → +120° to 125°
Eye bolt 15 ± 2
Camshaft sprocket bolt 88 ± 10
Timing belt rear cover bolt 10 ± 2
Water hose and pipe
Water pipe "A" bolt <Except Euro5> 24 ± 3
Water pipe bolt (M6) 11 ± 1
Water pipe bolt (M8) 24 ± 3
Water pipe "D" flare nut 54 ± 4
Water pipe "D" bolt 24 ± 3
Joint 39 ± 5
Front upper case stiffener bolt 50 ± 5
Engine coolant temperature gauge unit 11 ± 1
Engine coolant temperature sensor 29 ± 10
Water outlet fitting bolt and nut 24 ± 3
Water inlet fitting bolt 24 ± 3
Plate bolt 10 ± 2
Water pump bolt 24 ± 3
Rocker arm and camshaft
ENGINE OVERHAUL
11B-7
Item N⋅m
Cam position sensor bolt 11 ± 1
Camshaft bearing cap bolt (M6) 11 ± 1
Camshaft bearing cap bolt (M8) 20 ± 1
Pivot bolt 18 ± 2
Cylinder head bolt 78 ± 2 → 0 → 29 ± 2 → +90° → +90°
Oil pan and oil pump
Oil filter 22 ± 2
Oil pressure switch 10 ± 2
Oil cooler bolt 39 ± 5
Heat protector bolt <Except Euro5> 10 ± 2
Oil filter bracket bolt 24 ± 4
Harness bracket bolt 9.5 ± 2.5
Oil drain plug 39 ± 5
Oil pan bolt 9.0 ± 3.0
Oil screen bolt 19 ± 3
Stiffener bolt 19 ± 3
Front upper case bolt 24 ± 4
Plug cap 23 ± 3
Balancer shaft driven gear bolt 37 ± 3
Front lower case bolt 24 ± 4
Plug 37 ± 7
Oil pump cover screw 12 ± 2
Balancer shaft gear cover bolt 23 ± 4
Piston and connecting rod
Connecting rod cap nut 27 ± 2 → +90° to 94°
Crankshaft and cylinder block
Drive plate bolt (A/T) 135 ± 5
Flywheel bolt (M/T) 132 ± 5
Rear plate bolt 9.0 ± 1.0
Bell housing cover bolt 9.0 ± 1.0
Oil seal case bolt 11 ± 1
Bearing cap bolt 40 ± 2 → +35° to 39°
Check valve 32 ± 2
Engine support bracket bolt 54 ± 5
SEALANTS
SEALANTS
M1113000503531
Item Specified sealant

Cover Three bond 1207C, Three bond 1207D, Three bond
1207F (Mitsubishi Part No. 1000A992), Three bond
1217G (Mitsubishi Part No. 1000A923), Three bond
1227D
Cover seal bolt Three bond 2310 or equivalent
Rocker cover Three bond 1212D, Three bond 1217G (Mitsubishi
Part No. 1000A923)
Semi-circular packing Three bond 1212D, Three bond 1217G (Mitsubishi
Part No. 1000A923)
Coolant temperature gauge unit Three bond 2310 or equivalent
Coolant temperature sensor Three bond 1324N, LOCTITE 262
Camshaft bearing cap, front left Three bond 1212D or equivalent
Oil pressure switch Three bond 1141J, Three bond 1215, Three bond
1212D, Three bond 1207F (Mitsubishi Part No.
100A992), Three bond 1207C
Oil pan Three bond 1227D, Three bond 1217G (Mitsubishi
Part No. 1000A923), LOCTITE 5970, LOCTITE 5900
Oil seal case Three bond 1207C, Three bond 1207D, Three bond
1207F (Mitsubishi Part No. 1000A992), Three bond
1217G (Mitsubishi Part No. 1000A923), Three bond
1227D
NOTE: *: Part to be sealed with a form-in-place gas- Surface Preparation
ket (FIPG) Thoroughly remove all substances deposited on the
FIPG application surface, using a gasket scraper.
FORM-IN-PLACE GASKET (FIPG) Make sure that the FIPG application surface is flat
This engine has several areas where the form-in- and smooth. Also make sure that the surface is free
place gasket (FIPG) is used for sealing. To ensure from oils, greases and foreign substances. Do not fail
that the FIPG fully serves its purpose, it is necessary to remove old FIPG that may remain in the fastener
to observe some precautions when applying it. fitting holes.
Bead size, continuity and location are of paramount
importance. Too thin a bead could cause leaks. Too FIPG Application
thick a bead, on the other hand, could be squeezed Applied FIPG bead should be of the specified size
out of location, causing blocking or narrowing of fluid and free of any break. FIPG can be wiped away
passages. To prevent leaks or blocking of passages, unless it has completely hardened. Install the mating
therefore, it is absolutely necessary to apply the parts in position while the FIPG is still wet (in less
FIPG evenly without a break, while observing the than 15 minutes after application). Do not allow FIPG
correct bead size. to spread beyond the sealing areas during installa-
FIPG hardens as it reacts with the moisture in the tion. Avoid operating the engine or letting oils or
atmospheric air, and it is usually used for sealing water come in contact with the sealed area before a
metallic flange areas. time sufficient for FIPG to harden (approximately one
hour) has passed. FIPG application method may
Disassembly vary from location to location. Follow the instruction
Parts sealed with a FIPG can be easily removed for each particular case described later in this man-
without need for the use of a special method. In ual.
some cases, however, the FIPG in joints may have to
be broken by tapping parts with a mallet or similar
tool.
ENGINE OVERHAUL
SPECIAL TOOLS
11B-9
SPECIAL TOOLS
M1113000603271

MD998781 Flywheel stopper Holding flywheel and drive plate
D998781
MB992099 Crank pulley puller • Removal of crankshaft pulley (Use

with MB992100)
• Removal of pump sprocket (Use
with MB992098)
B992099
MB992100 Crank pulley holder Removal of crankshaft pulley (Use with

MB992099)
B992100
MB992048 Injection pump Holding pump sprocket

sprocket holder
B992048
MB992098 Injection pump Removal of pump sprocket (Use with

sprocket puller MB992099)
B992098
MD998778 Crankshaft sprocket Removal of crankshaft sprocket

puller
MB990784 Ornament remover Clean of cylinder head (Injector insert

hole)
MB990784
MB992188 Fuel injection pipe Installation of fuel injection pipe

wrench
SPECIAL TOOLS

MD998713 Camshaft oil seal Installation of camshaft oil seal
installer
D998713
MD998051 Cylinder head bolt Removal and installation of cylinder

wrench head bolt
MD998772 Valve spring Compression of valve spring

compressor
MB992046 Valve adjusting socket Adjustment of valve clearance
MB992046
MD998775 Valve stem seal Installation of valve stem seal

installer
D998775
MD998727 Oil pan sealer cutter Removal of oil pan
D998727
MD998380 Bearing installer Guide for removal and installation of

stopper silent shaft right rear bearing
D998380
MD998251 Balancer shaft bearing Removal of silent shaft rear bearing

puller
D998251
ENGINE OVERHAUL
SPECIAL TOOLS
11B-11
MD998250 Balancer shaft bearing Installation of silent shaft rear bearing
installer
D998250
MD998385 Balancer shaft drive Installation of silent shaft drive oil seal
gear oil seal guide
D998385
MD998383 Crankshaft front oil Installation of crankshaft front oil seal

seal guide
D998383
MD998382 Crankshaft front oil Guide for installation of crankshaft front

seal installer oil seal
D998382
MD998012 Oil pressure switch Removal and installation of oil pressure

wrench switch
MB991614 Angle gauge Installation of bearing cap bolt and

injector holder bolt and connecting rod
cap nut
MB991614
MB992010 Bolt guide Removal and installation of piston and

connecting rod assembly
MB992147 Oil seal installer Removal and installation of rear oil seal
ALTERNATOR
ALTERNATOR
M1113027600684
<Except Euro5>
20 ± 4 N·m
10
7 9
44 ± 10 N·m
8 11
24 ± 4 N·m
23 ± 2 N·m 3
24 ± 4 N·m 48 ± 6 N·m
2
1
12
13
5 6
11 ± 1 N·m 4
265 N·m
11 ± 1 N·m 0 N·m
275 N·m
AK502994AC

1. Cooling fan 8. Power steering pump bracket "B"
2. Fan clutch 9. Alternator
3. Water pump pulley 10. Oil level gauge
<<A>> >>A<< 4. Crankshaft bolt 11. O-ring
<<A>> >>A<< 5. Crankshaft pulley washer 12. Oil level gauge guide
<> >>A<< 6. Crankshaft pulley 13. O-ring
7. Power steering pump bracket "A"
ENGINE OVERHAUL
ALTERNATOR
11B-13
<Euro5>
7
50 ± 5 N·m
20 ± 4 N·m
44 ± 10 N·m
10
11
9
12
24 ± 4 N·m
23 ± 2 N·m
24 ± 4 N·m
3
48 ± 6 N·m
2
1
13
14
5 6
11 ± 1 N·m 4
265 N·m
11 ± 1 N·m 0 N·m
275 N·m
AKB00328AB

1. Cooling fan <<A>> CRANKSHAFT BOLT / CRANKSHAFT
2. Fan clutch PULLEY WASHER REMOVAL
3. Water pump pulley
<<A>> >>A<< 4. Crankshaft bolt
<<A>> >>A<< 5. Crankshaft pulley washer
<> >>A<< 6. Crankshaft pulley
7. Idler pulley
8. Power steering pump bracket "A"
9. Power steering pump bracket "B"
10. Alternator
11. Oil level gauge
12. O-ring
13. Oil level gauge guide MD998781
AK402854AB
14. O-ring
1. Use the special tool Flywheel stopper
(MD998781), hold the flywheel.
2. Remove the crankshaft bolt and washer.
ALTERNATOR
<> CRANKSHAFT PULLEY REMOVAL

: Wipe clean with a rag.
: Wipe clean with a rag and degrease.
Crankshaft
MB992100 pulley : Wipe clean with a rag, degrease and
apply a small amount of engine oil.
MB992099
Crankshaft pulley
Crankshaft sprocket
Crankshaft bolt
Crankshaft bolt
MB992100 AK502851AB
1. Screw securely the crankshaft bolt into the

crankshaft.
2. Use the special tool, remove the crankshaft
pulley. Crankshaft Crankshaft
pulley washer
• Crank pulley puller (MB992099)
• Crank pulley holder (MB992100)
3. Remove the crankshaft bolt.
Engine front
INSTALLATION SERVICE POINTS AK603656 AB
2. Wipe the dirt on the crankshaft pulley washer

>>A<< CRANKSHAFT BOLT / CRANKSHAFT using a rag.
PULLEY WASHER / CRANKSHAFT PULLEY 3. Using a rag, wipe the dirt on the crankshaft pulley,
INSTALLATION the crankshaft sprocket, the thread hole of the
crankshaft and then remove the grease.
NOTE: Degreasing is necessary to prevent
decrease in the friction between contacting sur-
faces.
4. Install the front flange and crankshaft pulley.
5. Apply an appropriate and minimum amount of
engine oil to the threads of crankshaft bolt and
lower part of the flange.
MD998781 6. Install the crankshaft pulley washer to the
AK402854AB
crankshaft bolt.
1. Use the special tool Flywheel stopper 7. Tighten the crankshaft bolt to the specified torque
(MD998781), hold the flywheel. of 265 N⋅m.
8. Loosen the bolt completely.
9. Tighten the crankshaft bolt again to the specified
torque of 275 N⋅m.
ENGINE OVERHAUL
INLET MANIFOLD
11B-15
INLET MANIFOLD
M1113026101258
<Except Euro5>
1
14 ± 1 N·m
3 24 ± 3 N·m
20 ± 2 N·m 4
2
24 ± 3 N·m
12
13
18 48 ± 6 N·m
15 24 ± 3 N·m
14 19
16
17
13 ± 2 N·m 20 20 ± 4 N·m
17 ± 2 N·m
17 ± 2 N·m
9
11 11 ± 1 N·m
10 5
8
49 ± 6 N·m
7 17 ± 2 N·m
AK801103AB

1. Vacuum hose >>D<< 11. EGR pipe gasket
2. Vacuum pump pipe "B" 12. EGR valve
3. Air temperature sensor >>C<< 13. EGR valve gasket
4. Gasket 14. Throttle body
5. EGR pipe "B" >>B<< 15. Throttle body gasket
6. EGR pipe gasket 16. Fuel inlet pipe
7. EGR pipe gasket 17. Inlet manifold stay
8. EGR pipe heat protector >>A<< 18. Inlet manifold
9. EGR pipe "A" 19. Herical gasket
10. EGR pipe gasket 20. Tangential gasket
INLET MANIFOLD
<Euro5>
1
14 ± 1 N·m
24 ± 3 N·m
3
20 ± 2 N·m 2
24 ± 3 N·m
12
13
18
48 ± 6 N·m
15 24 ± 3 N·m 5
17 ± 2 N·m
14 19
6 4
7
16
17
13 ± 2 N·m 20 20 ± 4 N·m
49 ± 6 N·m
8 17 ± 2 N·m
17 ± 2 N·m
11
9
17 ± 2 N·m
10
AKB00325 AB

1. Vacuum hose >>D<< 11. EGR pipe gasket
2. Vacuum pump pipe "B" 12. EGR valve
3. Air temperature sensor >>C<< 13. EGR valve gasket
4. EGR pipe fitting "B" 14. Throttle body
5. EGR pipe gasket >>B<< 15. Throttle body gasket
6. EGR pipe gasket 16. Fuel inlet pipe
7. EGR pipe "B" 17. Inlet manifold stay
8. EGR pipe gasket >>A<< 18. Inlet manifold
9. EGR pipe "A" 19. Herical gasket
10. EGR pipe gasket 20. Tangential gasket
ENGINE OVERHAUL
INLET MANIFOLD
11B-17
INSTALLATION SERVICE POINTS Position the projection as shown in the illustration.
>>A<< INLET MANIFOLD INSTALLATION
>>C<< EGR VALVE GASKET INSTALLATION
B side
A side
AK500701AB
Projection
AK500703AB
1. As shown in the illustration, temporarily tighten to
Position the projection as shown in the illustration.
6.0 ± 1.0 N⋅m the bolts located at side "A."
2. As shown in the illustration, tighten to the >>D<< EGR PIPE GASKET INSTALLATION
specified torque of 24 ± 3 N⋅m the bolts located at
side "B" Tighten nuts to the specified torque of 20
± 2 N⋅m.
3. As shown in the illustration, tighten to the
specified torque of 24 ± 3 N⋅m the bolts located at
side "A."
>>B<< THROTTLE BODY GASKET

INSTALLATION Projection
AK500704AB
Projection Position the projection as shown in the illustration.
AK500702AB
EXHAUST MANIFOLD
EXHAUST MANIFOLD
M1113011901195
<Except Euro5>
17 ± 2 N·m 17 ± 2 N·m
53 ± 7 N·m
11 ± 1 N·m 2 4
7 9.0 ± 1.0 N·m
5
59 ± 10 N·m 3
8 6
14 ± 1 N·m
9 11 ± 1 N·m
18
12
16
14
17
11 10
53 ± 7 N·m
20
9.0 ± 1.0 N·m
19 21
13
15
18 ± 2 N·m
24 ± 3 N·m
30 ± 2 N·m
AK801104AB

1. Engine hanger 12. Water pipe "B"
>>C<< 2. Eyebolt (Oil pipe) 13. Oil return pipe
>>C<< 3. Gasket 14. Oil return pipe gasket
>>C<< 4. Eyebolt (Oil pipe) >>B<< 15. Oil return pipe gasket
>>C<< 5. Gasket 16. Turbocharger
>>C<< 6. Oil pipe >>A<< 17. Turbocharger gasket
7. Eyebolt (Water pipe) 18. Exhaust manifold heat protector
8. Gasket 19. Engine hanger
9. Water pipe "C" 20. Exhaust manifold
10. Eyebolt (Water pipe) 21. Exhaust manifold gasket
11. Gasket
ENGINE OVERHAUL
EXHAUST MANIFOLD
11B-19
<Euro5>
17 ± 2 N·m 17 ± 2 N·m
24 ± 3 N·m
2 4
6
3 5
14 ± 1 N·m
59 ± 10 N·m 9.0 ± 1.0 N·m
7
20 9.0 ± 1.0 N·m
19 8
24 ± 3 N·m
18 14 ± 1 N·m
21
17 23
9.0 ± 1.0 N·m 16
59 ± 10 N·m
22 24
11 ± 1 N·m
25
26
12 11
14 ± 1 N·m
9 23 ± 6 N·m
34 ± 3 N·m
24 ± 3 N·m
24 ± 3 N·m
62 ± 10 N·m
10
13
9.5 ± 2.5 N·m

1
15
14
9.5 ± 1.5 N·m
AKB00327AB

1. Engine hanger 14. Connector bracket
>>C<< 2. Eyebolt (Oil pipe) 15. E-VRV
>>C<< 3. Gasket 16. Oil return hose
>>C<< 4. Eyebolt (Oil pipe) 17. Oil return pipe
>>C<< 5. Gasket 18. Oil return pipe gasket
>>C<< 6. Oil pipe 19. Turbocharger heat protector
7. Heat protector 20. Turbocharger
8. Heat protector bracket >>A<< 21. Turbocharger gasket
9. Water hose 22. Exhaust manifold heat protector A
10. Water hose 23. Exhaust manifold heat protector B
11. Turbocharger water pipe 24. Engine hanger
>>D<< 12. Turbocharger water pipe gasket 25. Exhaust manifold
13. Vacuum pipe and hose 26. Exhaust manifold gasket
EXHAUST MANIFOLD
INSTALLATION SERVICE POINTS Position the projection as shown in the illustration.

>>A<< TURBOCHARGER GASKET INSTALLA-
TION >>C<< EYE BOLT / GASKET / OIL PIPE
INSTALLATION
<Except Euro5>
1. Temporarily tighten the oil pipe with eye bolt.
NOTE: At this time, always install the gasket.
A
2. Tighten the eye bolt temporarily tightened to the
specified torque of 17 ± 2 N⋅m.
NOTE: Ensure there is neither torsion nor cam-
ber.
A
Projection
3. Tighten the flange bolt to the specified torque of
A–A
24 ± 3 N⋅m.
AK500739 AF
<Euro5>
>>D<< TURBOCHARGER WATER PIPE GASKET
INSTALLATION
Projection
Projection
Projection
AK801164AE

AK801165AB
>>B<< OIL RETURN PIPE GASKET Position the projection as shown in the illustration.
INSTALLATION
Projection
AK500740AB
ENGINE OVERHAUL
TIMING BELT
11B-21
TIMING BELT
M1113001902164
9 24 ± 3 N·m
10 ± 2 N·m
4
24 ± 3 N·m 5
10
11 ± 1 N·m
3 1.8 ± 0.2 N·m

13
1 11
44 ± 10 N·m 2
17
10 ± 2 N·m
48 ± 6 N·m
12
15 14 9.0 ± 1.0 N·m

+30˚ to 40˚
23 ± 3 N·m
19
18
6
16 44 ± 10 N·m
25 36 ± 3 N·m
23 ± 3 N·m
26
24
64 ± 5 N·m 23 11 ± 1 N·m
28
27 7
8
22 36 ± 3 N·m 11 ± 1 N·m
20 ± 4 N·m
29
20 21 AK801106AB

1. Oil hose <<C>> >>H<< 16. Pump sprocket
2. Oil hose 17. Idler pulley
3. Oil pipe 18. Idler pulley
4. Vacuum pump <<D>> >>G<< 19. Crankshaft sprocket
5. Vacuum pump pipe "A" >>G<< 20. Flange
>>K<< 6. Cover <<E>> >>F<< 21. Timing belt "B"
7. Crank angle sensor 22. Hexagon socket head bolt
8. O-ring 23. Tensioner spacer "B"
9. Timing belt upper cover 24. Tensioner spring "B"
10. Timing belt lower cover >>E<< 25. Timing belt tensioner "B"
>>J<< 11. Glow plug plate <<F>> >>D<< 26. Balancer shaft sprocket, right
>>J<< 12. Glow plug <<G>> >>C<< 27. Balancer shaft sprocket, left
<<A>> >>J<< 13. Timing belt >>B<< 28. Spacer
14. Tensioner arm <<H>> >>A<< 29. Crankshaft sprocket "B"
<> >>I<< 15. Auto tensioner
TIMING BELT
REMOVAL SERVICE POINTS 3. Use the special tool remove the pump sprocket.
<<A>> TIMING BELT REMOVAL • Injection pump sprocket puller (MB992098)
• Crank pulley puller (MB992099)
<<D>> CRANKSHAFT SPROCKET REMOVAL
AK500721
1. Using chalk, etc., mark an arrow on the back of

MD998778
the timing belt to indicate the direction of rotation. AK404172 AB
This is to ensure correct installation of the belt in Use the special tool Crankshaft sprocket puller
case it is reused. (MD998778), if the sprocket is stuck and hard to
remove.
<> AUTO TENSIONER REMOVAL
Keep the auto-tensioner longitudinal. If it were kept <<E>> TIMING BELT "B" REMOVAL
lateral, it would possibly cause aeration.
<<C>> PUMP SPROCKET REMOVAL
AK404168
MB992048
Using chalk, etc., mark an arrow on the back of the
timing belt to indicate the direction of rotation. This is
AK502995 AC
to ensure correct installation of the belt in case it is
1. Use the special tool Injection pump sprocket reused.
holder (MB992048), hold the pump sprocket. NOTE: Water or oil on the belt shortens its life drasti-
CAUTION cally, so the removed timing belt, sprocket, and ten-
Never strike the shaft or sprocket to remove the sioner must be free from oil and water. Do not
sprocket. This may cause malfunction in the immerse parts in cleaning solvent.
injection pump. Be sure to use a puller to remove NOTE: If there is oil or water on any part, check front
the sprocket. case oil seals, camshaft oil seal and water pump for
2. Remove the pump sprocket nut. leaks.
MB992098
MB992099
AK503162AB
ENGINE OVERHAUL
TIMING BELT
11B-23
<<F>> BALANCER SHAFT, RIGHT REMOVAL INSTALLATION SERVICE POINTS
Right side >>A<< CRANKSHAFT SPROCKET "B" INSTAL-
LATION
Remove this
plug and insert
a screwdriver Crankshaft sprocket "B"
Crankshaft
AK500724AB
1. Remove the plug at the right side of the cylinder Degrease

block. AK500726AB
2. Insert a Phillips screwdriver [shank diameter 8 Clean and then degrease the front face of the oil
mm] through the plug hole and lock the balancer pump gear drive shaft, crankshaft sprocket "B" and
shaft. crankshaft surface on which sprocket "B" is attached.
3. Loosen the balancer shaft sprocket nut. NOTE: Degreasing is necessary to prevent decrease
in the friction between contacting surfaces.
<<G>> BALANCER SHAFT, LEFT REMOVAL
>>B<< SPACER INSTALLATION
Left side
Oil seal
Insert bar Spacer
Balancer
shaft
AK500725AB Chamfered
Sharp edge
AK402871 AB
1. Insert a wrench extension bar or similar rod and
lock the balancer shaft. Install the spacer with its chamfered end toward the
2. Loosen the balancer shaft sprocket bolt. oil seal.
<<H>> CRANKSHAFT SPROCKET "B" REMOVAL >>C<< BALANCER SHAFT SPROCKET, LEFT
INSTALLATION
Left side
Insert bar
MD998778 AK404167AB
AK500725AB
Use the special tool Crankshaft sprocket puller
(MD998778), if the sprocket is stuck and hard to 1. Lock the balancer shaft in the same way as used
remove. in the removal procedure.
2. Install the balancer shaft sprocket and tighten the
bolt to the specified torque of 36 ± 3 N⋅m.
TIMING BELT
>>D<< BALANCER SHAFT SPROCKET, RIGHT >>F<< TIMING BELT "B" INSTALLATION
INSTALLATION
Timing mark
Right side
Remove this Timing mark
plug and insert
a screwdriver
Timing belt "B"

Crankshaft
sprocket "B"
AK500728AB
AK500724AB
1. Align timing marks on the crankshaft sprocket "B",
1. Lock the balancer shaft in the same way as used and silent shaft sprockets with their timing marks.
in the removal procedure. 2. Install timing belt "B" onto sprockets and ensure
2. Install the balancer shaft sprocket and tighten the that its tension side is not slack.
nut to the specified torque of 36 ± 3 N⋅m.
>>E<< TIMING BELT TENSIONER "B"

INSTALLATION Flange
bolt
Water pump
Tensioner "B"
Hexagon socket
head bolt
AK500729AB
Flange 3. Loosen tensioner "B" mounting flange bolt, one to

bolt
two turns.
4. Tighten the tensioner "B" attaching hexagon
socket head bolt.
Hexagon
socket 5. Tighten the tensioner "B" attaching flange bolt.
head bolt
NOTE: If the bolt is tightened first, the tensioner
"B" should be turned together, resulting in
Spacer Front lower case reduced timing belt "B" tension.
Washer
Blancer shaft
sprocket
Spring Tensioner "B" AK500727AB

Belt
1. Install the tensioner, tensioner spring and spacer. deflection
NOTE: Be sure to install the tensioner spring with Crankshaft

its shorter end toward the water pump. sprocket "B"
AK500730AB
2. Move tensioner "B" toward water pump and
tighten mounting bolt. 6. Ensure that the deflection is as specified when the
belt is pushed by the index finger at the position
indicated by an arrow.
Belt deflection: 4 − 5 mm
ENGINE OVERHAUL
TIMING BELT
11B-25
>>G<< FLANGE / CRANKSHAFT SPROCKET >>H<< PUMP SPROCKET INSTALLATION
INSTALLATION
sprocket Flange sprocket "B"
Crankshaft
MB992048
AK502995 AC
AK500731 AB
1. Use the special tool Injection pump sprocket
1. Clean and then degrease the following surfaces holder (MB992048) to prevent the pump sprocket
and parts: Sprocket mounting surface of from rotating.
crankshaft, flange, and crankshaft sprocket. 2. Tighten the pump sprocket nut to the specified
NOTE: Degreasing is necessary to prevent torque of 64 ± 5 N⋅m.
decrease in the friction between contacting sur-
faces. >>I<< AUTO TENSIONER INSTALLATION
2. Clean the crankshaft contacting surface of the CAUTION
crankshaft sprocket. Always bleed the auto-tensioner of air before
3. Install the flange, aligning a timing mark on a front installing the auto-tensioner. (Refer to auto ten-
lower case with that on the flange. sioner inspection P.11B-27 .)
>>J<< TIMING BELT INSTALLATION
Timing mark
(on timing belt rear cover)
Timing mark
(on camshaft procket)
Timing mark
(on front
upper case)
Timing mark Timing mark

(on front (on pump sprocket)
lower case)
Timing belt
Timing mark
(on crankshaft
sprocket "B")
AK500734AB
1. Align the timing marks on each sprocket. crankshaft sprocket → idler pulley → pump
2. In accordance with the following procedure, install sprocket → idler pulley → camshaft sprocket →
a timing belt not to be slack. tensioner pulley
TIMING BELT
>>K<< COVER INSTALLATION

sprocket True position sprocket "B"
Crankshaft
Slide
Key top end
Oil pump
Notched area AK500735 AB

AK500654AB
NOTE: When the timing belt is installed into the
crankshaft sprocket, install the timing belt after 1. Clean both mating surfaces of cover and cylinder
sliding the crankshaft sprocket to around the key block.
end. (Pay attention to the notch on the crankshaft 2. Apply a 2.3 ± 1.0 mm wide bead of sealant to the
sprocket not to be damaged at the timing belt cylinder block.
installation.) And then, install the crankshaft
Specified sealant:
sprocket in position.
Three bond 1217G or equivalent
3. Confirm the timing marks on each sprocket are in
position.
CAUTION
Check that the glow plugs, glow plug mounting
threads and plug seating surfaces of cylinder
head are dry.
4. When installing the glow plug, screw in one thread
or more with fingers and then tighten with a tool.
5. Tighten the glow plugs to 9.0 ± 1.0 N⋅m.
AK500657AB
3. Coat the bolt with sealant, then install and tighten

MB991614 it.
Specified sealant:
Three bond 2310 or equivalent
INSPECTION
M1113002001428
30 to 40˚
TIMING BELTS
AK501273AC
The timing belts must be checked closely. Should the
6. Using the special tool Angle gauge (MB991614), following defects be evident, replace the belt with a
tighten the glow plug to a further 30° to 40°. new one.
7. Install a glow plug plate to the glow plug, and then
tighten them to the specified torque of 1.8 ± 0.2
N⋅m.
8. Pull out the set pin of an auto tensioner.
9. Turn the crankshaft twice in a clockwise direction
and measure the protrusion height of the auto
tensioner.
10.Confirm the timing marks on each sprocket are in AK202794
position.
1. Hardened back surface rubber.
ENGINE OVERHAUL
TIMING BELT
11B-27
Glossy, non-elastic, and so hard that no mark is Canvas on load side tooth flank worn (Fluffy canvas
produced even when scratched by fingernails. fibers, rubber gone and color changed to white, and
unclear canvas texture)
Cracks Cracks Last stage:
Canvas on load side tooth flank worn down and rub-
ber exposed (tooth width reduced)
8. Missing tooth.
Peeling of canvas
Cracks in sides
AUTO-TENSIONER
1. Check the auto-tensioner for leaks from the
sealed sections.
Cracks in tooth roots AK202793 AB Replace it if leaky.
2. Cracked back surface rubber. 2. Check the rod end for wear and other damage.
3. Cracked or separated canvas. Replace the auto-tensioner if the rod is badly
4. Cracked tooth bottom. worn or damaged.
5. Cracked side.
Rounded edge 14.5 mm
AK500737AB
Abnormal wear
(Fluffy strand)
AK202795 AB
3. Measure the extension length of the rod.
6. Abnormal wear on side. If it is not within the standard value range, replace
NOTE: Normal belt should have clear-cut sides as the auto-tensioner.
if cut by a sharp knife. Standard value: 14.5 mm
4. Measure the amount of the retraction when the
Canvas lost and rod is pressed with the force of 100 − 200 N. If it
rubber exposed deviates from the standard value, replace the auto
tensioner.
Missing Standard value: within 1.0 mm
Tooth
AIR BLEEDING PROCEDURE OF AUTO-

TENSIONER
When the auto tensioner is not kept with its rod
AK202796 AB
upward, or when the set pin having φ2 mm is pulled
7. Abnormal wear in teeth. out before the installation to the engine, carry out the
Initial stage: air bleeding as follows.
TIMING BELT
CAUTION 1. Set the auto tensioner to the longitudinal type

• If the lateral type press is used, the appropri- press as shown in the illustration.
ate air bleeding is not carried out. Always use 2. Slowly press down the rod, two or three times, to
longitudinal type press. the cylinder end plane.
• To prevent damage to the auto tensioner, do 3. When the rod protrusion has approximately 5 mm,
not apply the load of 5,000 N or more. apply the load of 100 − 200 N. Check whether the
• To prevent damage to the auto tensioner, do auto tensioner has sufficient stiffness.
not push down the rod from the cylinder end 4. If the auto tensioner does not have sufficient
plane by 0.5 mm or less. stiffness, replace the auto tensioner.
5. Slowly pressing down the rod, insert the set pin
100 – 200 N having φ2mm through the hole to fix the auto
tensioner.
CAUTION
5 mm
To prevent the air from being incorporated, keep
the auto tensioner with its rod upward after the
air bleeding. Do not keep the auto tensioner with
60° or more tilt.
AK801061AB
ENGINE OVERHAUL
COMMON RAIL AND SUPPLY PUMP
11B-29
M1113029200239
<Except Euro5>
5
2
6
8.9 ± 1.9 N·m
24 ± 4 N·m
17 ± 2 N·m
15
14
12
18 10 ± 2 N·m
11
16 10
9
10 ± 2 N·m
17
1
20 ± 2 N·m
8
35 ± 5 N·m
10 ± 2 N·m
24 ± 3 N·m 7
13
3 35 ± 5 N·m
4 24 ± 4 N·m
24 ± 3 N·m
AKB00337AB

1. Fuel return hose >>A<< 10. Fuel injection No.2 pipe
2. Fuel inlet hose >>A<< 11. Fuel injection No.3 pipe
>>B<< 3. EGR cooler bracket >>A<< 12. Fuel injection No.4 pipe
4. EGR cooler >>A<< 13. Common rail
>>B<< 5. Suction control valve kit *1 >>A<< 14. Eye bolt (Cylinder head side)
>>B<< 6. Supply pump >>A<< 15. Fuel return gasket
7. Fuel supply pump pipe bracket >>A<< 16. Eye bolt (Common rail side)
>>B<< 8. Fuel supply pump pipe >>A<< 17. Fuel return gasket
>>A<< 9. Fuel injection No.1 pipe >>A<< 18. Fuel return pipe
CAUTION
*1: Unless replaced, do not remove the sensor.
<Euro5>
6
2
7
8.9 ± 1.9 N·m
24 ± 4 N·m
10
20 ± 4 N·m
20 ± 2 N·m
17
16
14
20 13 10 ± 2 N·m
18
12
11
10 ± 2 N·m
19
1
20 ± 2 N·m
24 ± 3 N·m 9
35 ± 5 N·m
5
10 ± 2 N·m
8
15
35 ± 5 N·m
24 ± 3 N·m 24 ± 4 N·m
4
3
24 ± 3 N·m
AKB00324 AB

1. Fuel return hose 11. Fuel injection No.1 pipe
2. Fuel inlet hose >>A<< 12. Fuel injection No.2 pipe
>>B<< 3. EGR cooler brackct assenbly "B" >>A<< 13. Fuel injection No.3 pipe
>>B<< 4. EGR cooler brackct assenbly "A" >>A<< 14. Fuel injection No.4 pipe
>>B<< 5. EGR cooler >>A<< 15. Common rail
6. Suction control valve kit *1 >>A<< 16. Eye bolt (Cylinder head side)
>>B<< 7. Supply pump >>A<< 17. Fuel return gasket
>>B<< 8. Fuel supply pump pipe bracket >>A<< 18. Eye bolt (Common rail side)
>>A<< 9. Fuel supply pump pipe >>A<< 19. Fuel return gasket
>>A<< 10. Bracket >>A<< 20. Fuel return pipe
ENGINE OVERHAUL
11B-31
CAUTION 1. Temporarily tighten the fuel return pipe with bolts.
*1: Unless replaced, do not remove the sensor.

>>A<< BRACKET / FUEL INJECTION PIPE / COM-
MON RAIL / EYE BOLT / FUEL RETURN GASKET /
FUEL RETURN PIPE INSTALLATION
CAUTION Hatched
Cylinder
• The reinstallation histories of the removed port
injection pipe are up to five times. To count Bracket
how many times the injection pipe is rein- AK801174 AB
stalled, record the number of the reinstalla-

2. Slightly put the hatched area of the bracket to the
tion histories on the service booklet by
cylinder port and tighten it to the specified torque
adding this latest number of the histories,
of 20 ± 2 N⋅m. <Euro5>
which is usually "1", to the previous one. Use
a new injection pipe when the total reinstalla- 3. Tighten to the specified torque of 20 ± 2 N⋅m the
tion history numbers reach five times, or eye bolt and the fuel return gasket located at the
when the injector or common rail is replaced. cylinder head side.
In this case, record "a new injection pipe, the 4. Temporarily tighten the common rail with bolts,
number of the reinstallation histories is zero" holding the common rail body.
on the service booklet.
• If a fuel leak is present in the fuel injection
pipe and fuel injection pipe set once, do not Pressure limiter Pressure sensor
reuse it and replace with a new one.
• If the fuel injector assembly, common rail
assembly or supply pump assembly is
replaced, the contact surface (seal surface)
between the fuel injection pipe and fuel injec- Common rail
tion pipe set, and the other side component is
changed, do not reuse the fuel injection pipe AK500706AB
and fuel supply pump pipe and replace with a
new one. NOTE: At this time, do not hold the pressure lim-
• When the injection pipe is reinstalled, confirm iter or pressure sensor of the common rail.
there is no foreign material on the seal sur- NOTE: Before the installation, confirm there is
face or in the pipe and then install it not to neither foreign material nor a rust on the threads
deviate from the axis, fitting the seal surface. and the sealing surface of a high-pressure pipe.
5. Align the fuel injection pipe centre axis with the
other side components (fuel injector assembly
and common rail assembly) centre axis to install
the fuel injection pipe. Then, tighten the flare nut
temporarily until the tip of pipe (seal surface)
contacts with the other side components.
NOTE: When the fuel injection pipe is installed,
tighten the flare nut while shaking the pipe lightly
to align the centre axis of both components.
AK500705
>>B<< EGR COOLER / EGR COOLER BRACKET /

SUPPLY PUMP / FUEL SUPPLY PUMP PIPE /
FUEL SUPPLY PUMP PIPE BRACKET
INSTALLATION
MB992188 CAUTION
• The reinstallation histories of the removed
fuel supply pump pipe are up to five times. To
count how many times the fuel supply pump
pipe is reinstalled, record the number of the
AK600656 AB reinstallation histories on the service booklet
by adding this latest number of the histories,
6. Using special tool Fuel injection pipe wrench which is usually "1", to the previous one. Use
(MB992188), install injection pipe assembly No.1 a new fuel supply pump pipe when the total
to No.4. reinstallation history numbers reach five
Tighten to the specified torque of 35 ± 5 N⋅m the times, or when the supply pump or common
flare nuts of the fuel injection pipe No.1 to No.4 at rail is replaced. In this case, record "a new
injector side. fuel supply pump pipe, the number of the
reinstallation histories is zero" on the service
booklet.
• If a fuel leak is present in the fuel injection
pipe and fuel injection pipe set once, do not
reuse it and replace with a new one.
• If the fuel injector assembly, common rail
assembly or supply pump assembly is
replaced, the contact surface (seal surface)
between the fuel injection pipe and fuel injec-
MB992188
tion pipe set, and the other side component is
AK600668 AB changed, do not reuse the fuel injection pipe
and fuel supply pump pipe and replace with a
7. Using special tool Fuel injection pipe wrench
new one.
(MB992188), install injection pipe assembly No.1
to No.4. • When the fuel supply pump pipe is rein-
stalled, confirm there is no foreign material on
Tighten to the specified torque of 35 ± 5 N⋅m the the seal surface or in the pipe and then install
flare nuts of the fuel injection pipe No.1 to No.4 at it not to deviate from the axis, fitting the seal
common rail side. surface.
8. Tighten the common rail to the specified torque of 1. Align the fuel supply pump pipe centre axis with
24 ± 4 N⋅m. the other side components (common rail
9. Tighten to the specified torque of 20 ± 2 N⋅m the assembly and supply pump assembly) centre axis
eye bolt and the fuel return gasket located at the to install the fuel supply pump pipe. Then, tighten
common rail side. the flare nut temporarily until the tip of pipe (seal
10.Tighten the fuel return pipe to the specified torque surface) contacts with the other side components.
of 10 ± 2 N⋅m. NOTE: When the fuel supply pump pipe is
11.Tighten to the specified torque of 10 ± 2 N⋅m the installed, tighten the flare nut while shaking the
bolts of the fuel injection pipe No.1 to No.4. pipe lightly to align the centre axis of both compo-
nents.
2. Temporarily tighten the supply pump with bolts.
3. Temporarily tighten the fuel supply pump pipe
flare nuts.
4. Tighten to the specified torque of 35 ± 5 N⋅m the
flare nuts of the fuel supply pump pipe together
with the supply pump and common rail.
ENGINE OVERHAUL
11B-33
5. Tighten the supply pump to the specified torque of 6. Tighten the EGR cooler to the specified torque of
24 ± 4 N⋅m. 24 ± 3 N⋅m.
<Except Euro5> NOTE: The arrow position shown in the illustra-
tion is tightened together with the fuel supply
Tightened together pump pipe bracket.
with the fuel supply
pump pipe bracket
Bracket
AK801189AC
<Euro5>
Fuel supply pump pipe
AK801190AB
Tightened together 7. Tighten the EGR cooler bracket to the specified

with the fuel supply torque of 24 ± 3 N⋅m.
pump pipe bracket
8. Tighten to the specified torque of 10 ± 2 N⋅m the
installation fuel supply pump pipe bolts together
with the fuel supply pump pipe bracket.
AKB00339AB
ROCKER COVER AND INJECTOR

M1113028500282
2 7
3.0 ± 1.0 N·m 10 ± 2 N·m
1
8
3 4
9 6
15 ± 2 N·m 5
13 10 ± 1 N·m
15 ± 2 N·m 10 +120˚ to 125˚
12 14
13 11
15
16
14
17
10 ± 2 N·m 20
19
88 ± 10 N·m
18
AK801108AB

1. Breather hose >>B<< 11. Injector holder
2. Oil filler cap >>B<< 12. Fuel leakage pipe
>>F<< 3. Rocker cover >>B<< 13. Eye bolt
4. Gasket "A" >>B<< 14. Fuel leak-off gasket
5. Gasket "B" 15. Pivot boss
6. Gasket "C" 16. Injector
>>E<< 7. Oil seal 17. Nozzle gasket
>>D<< 8. Oil seal >>A<< 18. Camshaft sprocket bolt
>>C<< 9. Semi-circular packing <<A>> >>A<< 19. Camshaft sprocket
>>B<< 10. Injector holder bolt 20. Timing belt rear cover
ENGINE OVERHAUL
11B-35
REMOVAL SERVICE POINTS CAUTION
<<A>> CAMSHAFT SPROCKET REMOVAL Do not clean the injection part of the nozzle with
a resin spatula.
Fuel injector
A: Nozzle side face
AK500708
Injection part of the nozzle AC900270 AB
Remove the camshaft sprocket holding the hexago-
nal area of the camshaft with a wrench. (1) Using a resin spatula, scrape off the carbon
deposit on the fuel injector nozzle side face
INSTALLATION SERVICE POINTS ("A" shown in the figure).
>>A<< CAMSHAFT SPROCKET INSTALLATION
Fuel injector
AC900203 AB
AK500708 (2) Spray the carburetor cleaner (MZ100139) or

equivalent to the nozzle side face ("A" shown
Tighten the camshaft sprocket to the specified torque
in the figure).
of 88 ± 10 N⋅m holding the hexagonal area of the
camshaft with a wrench. CAUTION
Do not touch the injection part of the nozzle with
>>B<< INJECTOR / PIVOT BOSS / FUEL LEAK- hand or wipe it with a rag.
OFF GASKET / EYE BOLT / FUEL LEAKAGE PIPE (3) Leave the injection part for a while until the
/ INJECTOR HOLDER / INJECTOR HOLDER BOLT carbon deposit melts down, and then blow air
INSTALLATION to the injection part.
1. Clean the fuel injector assembly (nozzle) and the
cylinder head (fuel injector insertion hole) by
following the procedure below.
Cylinder head
MB990784
AC900204AB
(4) Insert the special tool ornament remover

(MB990784) to the cylinder head (fuel injector
insertion hole) with turning the special tool as
shown, and scrape off the carbon deposit.
CAUTION CAUTION
In order to prevent carbon from adhering to the • When the tightening angle is smaller than the
inner surface of the cylinder, blow air with the specified tightening angle, the appropriate
piston in the TDC position. tightening capacity cannot be secured.
(5) Remove the special tool MB990784, and blow • When the tightening angle is larger than the
off the carbon deposit on the cylinder head specified tightening angle, remove the bolt to
(fuel injector insertion hole) by air. start from the beginning again according to
(6) Check that there is no carbon deposit the procedure.
remaining on the contact surface of the fuel
injector nozzle gasket.
NOTE: Repeat step 4 to step 6 several times
until the carbon deposit is completely removed. MB991614
Injector holder bolt
Fuel injector
Injector supporter
AK500711AB
Pivot boss
8. Using the special tool Angle gauge (MB991614),
tighten the injector holder bolt in the illustrated
Nozzle sequence by a further 120 to 125°.
gasket
AC502872 AB
>>C<< SEMI-CIRCULAR PACKING

2. Install the nozzle gasket, fuel injector, pivot boss,
INSTALLATION
and injector supporter to the cylinder head as
3. Apply a small amount of engine oil to the seat
surface and thread of injector holder bolt, and
then temporarily tighten the bolt to the cylinder
head.
4. Set the fuel leak-off gasket to the fuel leakage
pipe, and temporarily tighten to the fuel injector
and to the cylinder head using the eye bolt.
5. Tighten the eye bolt of the fuel injector side to the AK202860AB
specified torque.
Apply specified sealant to portions indicated in illus-
Tightening torque: 15 ± 2 N⋅m tration.
6. Tighten the eye bolt of the cylinder head side to Specified sealant:
the specified torque. Three bond 1217G or equivalent
7. Tighten the injector holder bolt to the specified >>D<< OIL SEAL INSTALLATION
torque.
Tightening torque: 10 ± 1 N⋅m Socket wrench
Rocker cover
Oil seal
AK500713AB
ENGINE OVERHAUL
11B-37
Using a proper socket wrench, the oil seal is pressed Specified sealant:
and fit into the rocker cover. Three bond 1217G or equivalent
>>E<< OIL SEAL INSTALLATION Rocker cover

Oil seal lip
Socket wrench
Rocker cover
Oil seal Connector
Injector
AK603148AB
AK500712AB
Using a proper socket wrench, the oil seal is pressed

and fit into the rocker cover.
>>F<< ROCKER COVER INSTALLATION
10 mm
AK603149AB
CAUTION
Pay attention that the connector does not dam-
10 mm
age the seal lip when inserting the rocker cover.
Semicircular 2. Slightly press the oil seal lip to the place in the
packing Cylinder head opposite direction of the connector, shown in the
AK304411AB
illustration.
Rocker cover 3. Leave enough clearance for the connector to
avoid touching the seal lip.
Gasket "A"
10 mm
AK603150AB
10 mm 10 mm AK800029AB 4. Slowly get the seal lip through not making contact
with the connector.
1. Apply specified sealant to portions indicated in
illustration. 5. Put the rocker cover down to the installation
location.
WATER HOSE AND PIPE
2
6 9 3
Injector seal face

7
8
4 10 1 5
AK603151AB AK500741AB
6. Check that the injector-sealing surface has the 7. In accordance with the tightening order shown in
seal lip. the illustration, tighten bolts to 3.0 ± 1.0 N⋅m.
8. Again, in accordance with the tightening order
shown in the illustration, tighten bolts to the
WATER HOSE AND PIPE

M1113010201007
<Except Euro5>
39 ± 5 N·m
54 ± 4 N·m 24 ± 3 N·m
9
2
8 5 1
24 ± 3 N·m
3
7 24 ± 3 N·m
11 ± 1 N·m
6
4 10
24 ± 3 N·m 50 ± 5 N·m
18 19
20
21
11
15
17
12
10 ± 2 N·m
22
16
24 ± 3 N·m 24 ± 3 N·m
14 13
29 ± 10 N·m 11 ± 1 N·m
AK403582 AB
ENGINE OVERHAUL
WATER HOSE AND PIPE
11B-39
1. Water hose 12. Water hose
2. Water pipe "A" >>C<< 13. Coolant temperature gauge unit
3. Water hose >>B<< 14. Coolant temperature sensor
4. Water hose 15. Water outlet fitting
>>E<< 5. Water pipe 16. Water outlet fitting gasket
>>E<< 6. O-ring 17. Water inlet fitting
7. Water hose >>A<< 18. Thermostat
8. Water pipe "D" 19. Plate
9. Joint 20. Gasket
>>D<< 10. Front upper case stiffener 21. Water pump
11. Water hose 22. Water pump gasket
<Euro5>
39 ± 5 N·m
54 ± 4 N·m
6
5 2
24 ± 3 N·m
4 24 ± 3 N·m
11 ± 1 N·m
3
1 7
24 ± 3 N·m 50 ± 5 N·m
15 16
17
18 8
12
14
9
10 ± 2 N·m
19
13
24 ± 3 N·m 24 ± 3 N·m
11 10
29 ± 10 N·m 11 ± 1 N·m
AK801109 AB

1. Water hose >>C<< 10. Coolant temperature gauge unit
>>E<< 2. Water pipe >>B<< 11. Coolant temperature sensor
>>E<< 3. O-ring 12. Water outlet fitting
4. Water hose 13. Water outlet fitting gasket
5. Water pipe "D" 14. Water inlet fitting
6. Joint >>A<< 15. Thermostat
>>D<< 7. Front upper case stiffener 16. Plate
8. Water hose 17. Gasket
9. Water hose
WATER HOSE AND PIPE
Removal steps (Continued) Apply the specified sealant to the threads.

18. Water pump Specified sealant:
19. Water pump gasket Three bond 2310 or equivalent
>>D<< FRONT UPPER CASE STIFFENER
>>A<< THERMOSTAT INSTALLATION
INSTALLATION
Front upper case stiffener

"A"
"B"
"B"
Manufacturing "A"
Valve opening year and month
tenperature Manufacturer
mark AK801125AB
AK500675AB
1. Check that the rubber ring is undamaged and

1. Temporarily tighten the front upper case stiffener
seated correctly in the thermostat flange.
with bolts.
2. Install the thermostat as shown in the illustration.
2. Tighten to the specified torque of 50 ± 5 N⋅m Bolt
"A" located at the front upper case side.
>>B<< COOLANT TEMPERATURE SENSOR
3. Next, tighten to the specified torque of 50 ± 5 N⋅m
INSTALLATION
Bolt "B" located at the cylinder block side.
>>E<< WATER PIPE / O-RING INSTALLATION

CAUTION
Keep the O-ring free of oil or grease.
AK400587AD
When reusing the sensor, apply the specified sealant

to the threads.
Specified sealant:
Three bond 1324N, LOCTITE 262 or equiva- O-ring
AK400406 AC
lent
1. Attach a new O-ring to each end of the water pipe.
>>C<< COOLANT TEMPERATURE GAUGE UNIT 2. Wet the O-ring with water.
INSTALLATION 3. Insert the rear end of the pipe into the thermostat
housing.
AK400588AD
ENGINE OVERHAUL
ROCKER ARMS AND CAMSHAFT
11B-41
M1113005402042
11 ± 1 N·m
11 ± 1 N·m 3 7
4
8
20 ± 1 N·m
20 ± 1 N·m 10
6 10
6 10
5 6 10
6 9
11 17 12
16
15
14 19
13
21 18
19 21 20
18
20 22
23
23 18 ± 2 N·m
18 ± 2 N·m 22 1
11 ± 1 N·m
2
AK503039AB

1. Camshaft position sensor >>C<< 13. Snap ring
>>F<< 2. Camshaft oil seal >>C<< 14. Wave washer
>>E<< 3. Exhaust oil pipe >>C<< 15. Sub gear
>>E<< 4. O-ring >>C<< 16. C-spring
>>E<< 5. Camshaft bearing cap, front right 17. Inlet camshaft
>>E<< 6. Camshaft bearing cap, right >>B<< 18. Rocker arm assembly
>>E<< 7. Inlet oil pipe 19. Nut
>>E<< 8. O-ring 20. Adjusting screw
>>E<< 9. Camshaft bearing cap, front left 21. Rocker arm
>>E<< 10. Camshaft bearing cap, left >>A<< 22. Stem end cap
>>D<< 11. Exhaust camshaft 23. Pivot bolt
>>D<< 12. Inlet camshaft assembly

Camshaft
2.3 – 2.8 mm
>>A<< STEM END CAP INSTALLATION
Stem end cap

Dowel pin 2.3 – 2.8 mm
Valve
Sub gear Dowel pin

AK500651AB
2. Press and fit a dowel pin into the inlet camshaft

AK500648AB
and sub gear to be the dimension shown in the
Install the stem end cap securely to attach the stem illustration.
end surfaces of the intake and exhaust valves.
Dowel pin C-spring
>>B<< ROCKER ARM ASSEMBLY INSTALLATION
Adjusting screw
Nut
Rocker arm
Camshaft AK500652AB
Protrusion 3. Place the c-spring adjoining the dowel pin which

is pressed and fit into the inlet camshaft.
AK500649AB
Temporarily install the adjusting screw to the rocker A

arm with screw nut. Dowel pin C-spring
Protrusion: 5.5 − 6.5 mm
>>C<< SNAP RING / WAVE WASHER / SUB GEAR

/ C SPRING INSTALLATION
Camshaft AK500652AC
4. Within the area "A" between the c-spring and inlet

camshaft, place the dowel pin which is pressed
and fitted into the sub gear.
5. Install the wave washer and snap ring.
Hole of sub gear (Ø8) Thread hole of
AK500650 camshaft (M6)
1. Fix the camshaft using the hexagonal area of the Driver

inlet camshaft.
Flange bolt (M6 × 20) AK500655AB

ENGINE OVERHAUL
11B-43
6. Set two flange bolts (M6 × 20) to two places on 1. Apply specified sealant to portions indicated in
the sub gear. As shown in the illustration, turn the illustration.
sub gear in a clockwise direction so that the sub Specified sealant:
gear hole (φ8) can align with the inlet camshaft Three bond 1212D or equivalent
thread hole (M6).
2. Installation the bearing cap.
CAUTION
• Do not turn the sub gear excessively.
Front mark
• Do not press the snap ring strongly with a
driver.
7. Screw the bolts to attach the bolt heads to the sub
gear. Temporarily fix the sub gear.
Cap No.
8. After the temporary installation of the sub gear,
remove two flange bolts (M6 × 20) described in Symbol identifying
No. 6. intake or exhaust
AK404134AB
>>D<< INLET CAMSHAFT ASSEMBLY/ EXHAUST
CAMSHAFT INSTALLATION NOTE: Install the camshaft bearing cap in numeri-
cal order in accordance with "cap No." stamped
on the upper surface of the bearing cap.
Timing mark Timing mark
3. Installation the O-ring and oil pipe.
4 2 6 8
10
9 3 1 5 7
10 4 2 6 8
AK500656 AB
1. Install the camshaft so that each timing mark can 9 3 1 5 7

be in position as shown in the illustration. AK501386AB
NOTE: Carefully install the camshaft because a
rocker arm assembly is easily dropped at the 4. In accordance with the tightening order shown in
camshaft installation. the illustration, tighten the bearing cap bolt to the
specified torque.
2. Confirm all the stem end caps are installed.
3. Confirm the rocker arm assembly is straightly
>>F<< CAMSHAFT OIL SEAL INSTALLATION
mounted on the pivot bolts and stem end caps.
>>E<< OIL PIPE / O-RING / CAMSHAFT BEARING MD998713

CAP FRONT LEFT / CAMSHAFT BEARING CAP
INSTALLATION
AK500659AB
1. Apply oil to the oil seal lips.

2. Using the special tool Camshaft oil seal installer
(MD998713), press-fit a new camshaft oil seal into
AK500658AB the front left bearing cap.
INSPECTION 1. Measure the valve clearance.

M1113005501660
If the valve clearance is not as specified, loosen
CAMSHAFT
the rocker arm lock nut and adjust the clearance
using a thickness gauge between the cam shaft
and the roller while turning the adjusting screw.
Standard value (cold engine):
Intake valve: 0.09 mm
Exhaust valve: 0.14 mm
screwdriver
Thickness gauge
MB992046
AK500660
Adjusting
Measure the cam height. screw
Standard value: Nut
Intake:
35.47 mm <Except Euro5>
35.42 mm <Euro5> AK500662AB
exhaust: 35.41 mm
2. While holding the adjusting screw with a
Limit:
screwdriver to prevent it from turning, tighten the
Intake:
lock nut to the specified torque using a special
34.97 mm <Except Euro5>
tool Valve adjusting socket (MB992046).
34.92 mm <Euro5>
exhaust: 34.91 mm Tightening torque: 15 ± 3 N⋅m
3. Turn the crankshaft 360° clockwise to bring No. 4
cylinder to the top dead centre position.
VALVE CLEARANCE ADJUSTMENT
Turn the crankshaft clockwise to bring No. 1 cylinder
to the top dead centre position.
No. 1 No. 2 No. 3 No. 4
No. 1 No. 2 No. 3 No. 4

AK500661AC
4. Adjust the valve clearance at points shown in the

illustration.
AK500661AB
5. Repeat steps 3 to 5 to adjust the valve clearance
of remaining valves.
ENGINE OVERHAUL
CYLINDER HEAD AND VALVES
11B-45
M1113006903407
78 ± 2 N·m 0 N·m
29 ± 2 N·m +90˚ +90˚
1
2
9
21 10
5 11
6 15
7 16
13 18
14
20
17
12
19
8
3
Apply engine oil to

all moving parts
before installation.
AK600424AB

<<A>> >>D<< 1. Cylinder head bolt 12. Exhaust valve
2. Cylinder head bolt washer >>A<< 13. Valve stem seal
3. Cylinder head assembly 14. Spring seat
>>C<< 4. Cylinder head gasket >>A<< 15. Valve stem seal
<> >>B<< 5. Valve spring retainer lock 16. Spring seat
6. Valve spring retainer 17. Intake valve guide
7. Valve spring 18. Exhaust valve guide
8. Intake valve 19. Exhaust valve seat
<> >>B<< 9. Valve spring retainer lock 20. Intake valve seat
10. Valve spring retainer 21. Cylinder head
11. Valve spring
REMOVAL SERVICE POINTS 2. Relieve the spring tension and remove the valve,
<<A>> CYLINDER HEAD BOLTS REMOVAL retainer, spring, etc. Store removed valves,
springs, and other parts, tagged to indicate their
cylinder no. and location for assembly.

>>A<< VALVE STEM SEAL INSTALLATION
CAUTION
Do not reuse removed valve stem seals.
MD998775
AK404126
Using a 14 mm − 12 points socket wrench, loosen

the cylinder head bolt. Loosen each bolt evenly, little
by little, by two or three steps.
Punch mark
AK404135AB
1. Install the valve spring seat.

2. The special tool Valve stem seal installer
(MD998775) must be used to install the valve
stem seal. Improper installation could result in oil
consumption through valve guide.
AK500581AB
CAUTION >>B<< VALVE SPRING RETAINER LOCK

provide one punch mark on the head of the cylin- INSTALLATION
der head bolt each time the bolt is tightened.
replace the bolt that already has five punch MD998772
marks (the evidence of having been tightened
five times)
<> VALVE SPRING RETAINER LOCK

REMOVAL
MD998772
AK404133AB
CAUTION
The valve spring, if excessively compressed,
causes the bottom end of the retainer to be in
contact with, and damage, the stem seal.
Compress the valve spring using the special tool
Valve spring compressor (MD998772), them install
AK404133AB
the retainer lock.
1. Set special tool Valve spring compressor
(MD998772) as illustrated to compress the valve
spring. Remove the retainer lock.
>>C<< CYLINDER HEAD GASKET
INSTALLATION
ENGINE OVERHAUL
11B-47
Timing belt side

2. In case any of the cylinder block, piston,
Identification tab connecting rod and crankshaft have been
replaced, reselect and install the gasket in
accordance with the following procedure.
(1) With each piston held at the top dead center,
measure its protrusion from the upper block
surface at the locations shown in the
illustration at left (total of eight locations). Be
sure to take measurements on the crankshaft
Rank A Rank B Rank C AK801812 AB center line.
1. In case any of the cylinder block, piston,

connecting rod and crankshaft has not been
replaced, install the gasket of the same rank as
before which can be identified by the identification
tab shown in the illustration at left.
Protrusion
1 2 3 4 5 6 7 8
AK402940 AB
(2) Using the average of the eight measurements,

select the gasket rank (A, B or C) in
Reference for measurement accordance with the table given below. If,
Protrusion measuring locations however, the maximum protrusion at any one
(with each piston at top dead center) location exceeds the protrusion tolerance
AK402939 AB
shown for any rank in the following table, use
the gasket one rank higher that rank.
<Except Euro5>
Rank Average value of Protrusion tolerance Thickness of selected Identification tab
piston protrusions for each rank mm gasket (when
mm tightened) mm
A 0.06 − 0.12 0.17 0.95 ± 0.04 Non-equipped
B 0.12 − 0.18 0.23 1.00 ± 0.04
C 0.18 − 0.24 − 1.05 ± 0.04
<Euro5>
Rank Average value of Protrusion tolerance Thickness of selected Identification tab
piston protrusions for each rank mm gasket (when
mm tightened) mm
A 0.16 − 0.22 0.17 1.07 ± 0.04 Equipped
B 0.22 − 0.28 0.23 1.12 ± 0.04
C 0.28 − 0.34 − 1.17 ± 0.04
NOTE: If the piston projection exceeds the tolerance,
replace the piston, connecting rod, crankshaft or cyl-
inder block and check again.
>>D<< CYLINDER HEAD BOLT INSTALLATION 6. Make paint marks on each bolt’s head and on the
CAUTION cylinder head.
Before installing the cylinder head bolt, check CAUTION
the number of punch marks on its head. (the bolt • When the tightening angle is smaller than the
is reusable if it is four or less.) the number of specified tightening angle, the appropriate
punch marks corresponds to that to times the tightening capacity cannot be secured.
bolt has been tightened to the plastic area. if the • When the tightening angle is larger than the
bolt has five punch marks, replace it. specified tightening angle, remove the bolt to
1. Set the cylinder head bolt washer with its shear start from the beginning again according to
droop toward the bolt head. the procedure.
2. Apply engine oil to the bolt threads and washers. 7. Turn the bolts 90° in the tightening direction and in
the indicated sequence.
8. Give another 90° turn in the tightening direction to
each bolt, making sure that the paint mark on the
bolt head and that on the cylinder head are on the
same line.
INSPECTION
M1113007002987
CYLINDER HEAD
AK404127
NOTE: Using a 14 mm − 12 points socket wrench.

Timing belt side
13 5 3 11
17 9 1 7 15
AK404142
18 10 2 8 16
14 6 4 12 Check the cylinder head gasket surface for flatness
by using a straightedge in the directions of illustra-
AK500584AB tion.
Standard value: 0.03 mm
3. Tighten the bolts to 78 ± 2 N⋅m in the indicated
Limit: 0.2 mm
sequence.
4. Loosen all the bolts completely.
VALVE
5. Tighten the bolts again to a torque of 29 ± 2 N⋅m
in the indicated sequence. After that, confirm all
bolts are reached to the specified torque, and then
go to the next process. Contact
(Should be at
centre of face)
Margin
90˚ 90˚
AK300593AB
1. Check the valve face for correct contact. If

Paint mark Paint mark incorrect, reface using valve refacer. Valve seat
AK500582AB contact should be maintained uniform at the
center of valve face.
ENGINE OVERHAUL
11B-49
2. If the margin is smaller than the service limit, VALVE GUIDE
replace the valve.
Standard value:
Intake: 1.3 mm
Exhaust: 1.5 mm
Limit: Valve
Intake: 0.8 mm guide
Exhaust: 1.0 mm
Stem diameter
Guide inside diameter AK300168 AE
Measure the clearance between the valve guide and

valve stem. If the limit is exceeded, replace the valve
guide or valve, or both.
Standard value:
Intake: 0.020 − 0.047 mm
Total length Exhaust: 0.035 − 0.062 mm
AK304590AB Limit:
Intake: 0.10 mm
3. Measure the valves total length. If the Exhaust: 0.15 mm
measurement is less than the limit, replace the
valve.
VALVE SEAT
Standard value:
Intake: 107.58 mm
Exhaust: 107.98 mm
Limit:
Intake: 107.08 mm
Contact width Valve seat
Exhaust: 107.48 mm
VALVE SPRING
AK600918AB
Out of square
Assemble the valve, then measure the contact width.
If the measurement exceeds the specified limit,
replace the valve seat.
Free height Standard value: 1.1 − 1.5 mm
VALVE SEAT RECONDITIONING PROCEDURE

AK300594 AB
m
m
1. Measure the free height of spring and if it is

5
1.
smaller than the limit, replace.

-
1
75˚
1.
Standard value: 54.3 mm

Limit: 53.3 mm
30˚
2. Measure the squareness of the spring and, if the
limit is exceeded, replace. 43.5˚ - 44˚
Standard value: 2° or less
Limit: Max. 4° AK500585AB
1. Before correcting the valve seat, check for 4. Using valve seat cutter, correct the valve seat to
clearance between the valve guide and valve and, the specified width and angle.
if necessary, replace the valve guide. See "VALVE SEAT RECONDITIONING
2. Using the seat grinder, correct to obtain the PROCEDURE."
specified seat width and angle.
3. After correction, valve and valve seat should be VALVE GUIDE REPLACEMENT PROCEDURE
lapped with a lapping compound. 1. Force out the valve guide toward the cylinder
block using a press.
VALVE SEAT REPLACEMENT PROCEDURE CAUTION
Do not use a replacement valve guide of the
0.5 - 1 mm
same size as the removed one.
2. Machine the valve guide hole in the cylinder head
to the size matched to the selected oversize valve
guide.
Cut away
Valve guide hole diameter:
0.5 - 1 mm
0.05 O.S.: 11.050 − 11.068 mm
NOTE: Do not install a valve guide of the same
size again.
AK400379 AC
1. Cut the valve seat to be replaced from the inside

to thin the wall thickness. Then, remove the valve
Protrusion Protrusion
seat.
Valve seat
height
AK500586AB
3. Press-fit the valve guide until it remains protruded

Oversize hole diameter above the cylinder head by the amount indicated
AK400380AD
in the illustration.
Protrusion: 18.3 − 18.9 mm
2. Rebore the valve seat hole in cylinder head to the NOTE: Press the valve guide from above the cyl-
oversize valve seat diameter. inder head.
Intake valve seat hole diameter: NOTE: The valve guides for the intake valves are
0.30 O.S.: 33.300 − 33.325 mm different in length from those for the exhaust
Exhaust valve seat hole diameter: valves (45.2 mm for intake valves; 48.2 mm for
0.30 O.S.: 29.300 − 29.321 mm exhaust valves)
3. When the valve sheet is a press fit, engine oil is 4. After installing the valve guide, insert a new valve
applied to the valve sheet or the cylinder head not in it to check for smooth movement.
to damage the inside diameter of the cylinder
head.
ENGINE OVERHAUL
OIL PAN AND OIL PUMP
11B-51
M1113008102244
10 ± 2 N·m
10 ± 2 N·m
22 ± 2 N·m 1
2 10 ± 2 N·m
3 38
7 37
8
9.5 ± 2.5 N·m 9
Apply engine oil to
all moving parts
24 ± 4 N·m
5 6 36
4
39 ± 5 N·m
23 ± 4 N·m
33 17
34 18
23 35
24 ± 4 N·m 24
37 ± 3 N·m 24 ± 4 N·m
12 ± 2 N·m
22 30 19 9.5 ± 2.5 N·m
21 32 16
31
13
20 26
23 ± 3 N·m 29 19 ± 3 N·m
25 28
27 37 ± 7 N·m
15
14 12
19 ± 3 N·m
9.0 ± 3.0 N·m 10 39 ± 5 N·m

11
AK801110AB

>>M<< 1. Oil filter 14. Oil screen
<<A>> >>L<< 2. Oil pressure switch <Except Euro5> 15. Oil screen gasket
>>K<< 3. Oil pressure switch <Euro5> 16. Stiffener
4. O-ring 17. Front upper case
>>J<< 5. Oil cooler 18. Front upper case gasket
6. O-ring >>G<< 19. Front upper case oil seal
7. Heat protector <Except Euro5> 20. Plug cap
8. Oil filter bracket 21. O-ring
9. Oil filter bracket gasket <<C>> >>F<< 22. Flange bolt
10. Oil drain plug 23. Front lower case
>>I<< 11. Oil drain plug gasket 24. Front lower case gasket
<> >>H<< 12. Oil pan >>E<< 25. Crankshaft front oil seal
>>H<< 13. Oil pan gasket* >>D<< 26. Balancer shaft oil seal
27. Plug
Removal steps (Continued) <<C>> FLANGE BOLT REMOVAL

28. Relief spring
29. Relief plunger
30. Oil pump cover
<<D>> >>C<< 31. Inner rotor
<<D>> >>C<< 32. Outer rotor
33. Balancer shaft gear cover
>>B<< 34. Balancer shaft driven gear
>>B<< 35. Balancer shaft drive gear
36. Balancer shaft, left
37. Balancer shaft, right
<<E>> >>A<< 38. Balancer shaft bearing AK404131
NOTE: *:Use either an oil pan gasket or a sealant for
installing the oil pan. 1. Remove the plug on the right side of cylinder
block.
REMOVAL SERVICE POINTS 2. Insert a Phillips screwdriver into the plug hole to
<<A>> OIL PRESSURE SWITCH REMOVAL lock the silent shaft in position.
3. Remove the flange bolt.
<<D>> OUTER ROTOR / INNER ROTOR

MD998012 REMOVAL
AK404158AB
Using special tool Oil pressure switch socket wrench

(MD998012), removal the oil pressure switch. Alignment mark
AK404136AB
<> OIL PAN REMOVAL
Put alignment marks on the outer and inner rotors for
reference in reassembly.
MD998727
<<E>> BALANCER SHAFT BEARING REMOVAL
MD998380
AK404130AB
1. Knock the special tool Oil pan sealer cutter

(MD998727) deeply between the oil pan and the
cylinder block. AK500587AB
2. Hitting the side of the special tool Oil pan sealer
cutter (MD998727), slide the special tool along 1. Install the special tool Bearing installer stopper
the oil pan to remove it. (MD998380) to the cylinder block. This is used to
hold the special tool.
ENGINE OVERHAUL
11B-53
2. Install the balancer shaft drive and driven gears to
MD998251 Bearing the front lower case. Make sure that the alignment
marks are in line.
>>C<< INNER ROTOR / OUTER ROTOR

INSTALLATION
MD998380
(Right side only)
AK402949AB
2. Pull out the rear bearing from the cylinder block

using the special tool Balancer shaft bearing
puller (MD998251).
Alignment mark
AK404136AB
>>A<< BALANCER SHAFT BEARING INSTALLA-
TION Install the outer rotor in the same direction as before
noting the mark put at the time of removal. Apply
MD998250 Bearing engine oil to the entire rotor surface.
>>D<< OIL SEAL INSTALLATION

1. Apply engine oil to the oil seal outer surface.
Oil seal
Apply
engine Balancer shaft
MD998380 drive gear
(Right side only) oil
AK402958AB
Using the special tools, press-fit the bearing into the

cylinder block.
Before press-fitting the bearing, apply an ample MD998385
amount of engine oil to the bearing surfaces as well
as bearing hole in the cylinder block. Front lower case AK500588AB
• Balance shaft bearing installer (MD998250)

2. Using the special tool Balancer shaft drive gear oil
• Bearing installer stopper (MD998380)
seal guide (MD998385), drive in with a socket
wrench.
>>B<< BALANCER SHAFT DRIVE GEAR /
BALANCER SHAFT DRIVEN GEAR
>>E<< CRANKSHAFT FRONT OIL SEAL
INSTALLATION
INSTALLATION
1. Apply engine oil to the balancer shaft drive and
driven gears. Oil seal Front
lower
Crankshaft case
Alignment
mark
MD998383
MD998382
(Apply oil to outer surface) AK500589AB
AK404137AB
1. Attach the special tool Crankshaft front oil seal

guide (MD998383) to the crankshaft and apply
engine oil to the outer surface of the tool.
2. Using the special tool Crankshaft front oil seal
installer (MD998382), install the front oil seal into
the front lower case.
Bolt
>>F<< FLANGE BOLT INSTALLATION Groove hole
portion portion
AK503041AB
1. Clean both mating surfaces of oil pan and cylinder

block.
2. Apply a 4 mm wide bead of sealant to the entire
circumference of the oil pan flange.
Specified sealant:
AK404132 3. The oil pan should be installed in 15 minutes after
the application of sealant.
1. Insert a Phillips screwdriver into the plug hole to
block the balancer shaft.
<GASKET>
2. Install the flange bolt and tighten to the
Clean both mating surfaces of oil pan and cylinder
specification.
block.
3. Remove the screwdriver and install the plug.
>>I<< OIL DRAIN PLUG GASKET INSTALLATION
>>G<< FRONT UPPER CASE OIL SEAL
INSTALLATION
Drain plug
Socket wrench
Oil seal
Oil pan
AK500590AB Gasket Oil pan

side
Apply engine oil to the oil seal outer surface and
drive in with a socket wrench.
>>H<< OIL PAN / OIL PAN GASKET

INSTALLATION
Use either an oil pan gasket or a sealant for installing
the oil pan. Install the oil pan in accordance with the
following procedure respectively.
<SEALANT> AK300601AB
Replace the gasket with a new one and install it in

the direction shown in the illustration.
ENGINE OVERHAUL
11B-55
>>J<< OIL COOLER SWITCH INSTALLATION CAUTION
This area shall be free from oil (antirust oil etc.)
for switch output shall be adversely affected.
Tab
1 mm 5 mm
AK404160AB
Position the tab as shown in the illustration.

AK503747 AB
>>K<< OIL PRESSURE SWITCH INSTALLATION
CAUTION
Use care not to allow the sealant to plug the oil
1 mm 5 mm passage.
1. Apply sealant to the threads of the switch.
Specified sealant:
Three bond 1207F or equivalent
AK600888AB
CAUTION
Use care not to allow the sealant to plug the oil
passage.
Apply sealant to the threads of the switch.
Specified sealant: MD998012 AK404159AB
Three bond 1207F or equivalent
2. Using special tool Oil pressure switch socket
>>L<< OIL PRESSURE SWITCH INSTALLATION wrench (MD998012), tighten the oil pressure
switch to the specified torque.
>>M<< OIL FILTER INSTALLATION
Bracket
side
AK503746 AB
AK400405AC
1. Clean the filter mounting surface of the oil filter

bracket.
2. Apply engine oil to the O-ring of the oil filter.
Standard value
Front:
General service tool
Right 0.02 − 0.05 mm
Left 0.02 − 0.06 mm
Rear: 0.06 − 0.10 mm
OIL PUMP
AK404129AB
3. Using general service tool Oil filter wrench, Install

the oil filter to the bracket and tighten it to the
specified torque.
4. If a torque wrench cannot be used use the
following procedure. AK404139
(1) Screw in the oil filter until its o-ring contacts
the oil filter bracket. 1. Install the inner and outer rotors in the front case.
(2) Tighten the oil filter 3/4 turn. 2. Check the tip clearance using a thickness gauge.
INSPECTION
M1113008200568
FRONT LOWER CASE
1. The front case parts must be free from damage
and cracks.
2. Install the oil pump rotor or gear into the front case
and make sure that the rotor or gear turns
smoothly with no excessive play in it.
3. The front case and oil pump cover surfaces in
contact with the pump rotor or gear side face must
AK404138
be free from ridge wear.
3. Check the side clearance using a straight edge
BALANCER SHAFT and a thickness gauge.
Oil hole
AK404141AB
1. Check oil holes must be free from clogging. AK404140
2. Check journal for size, damage, and contact with 4. Check the body clearance using a thickness
bearing. If defects are evident, replace the gauge.
balancer shaft, bearing, or front case assembly.
3. Check the balancer shaft oil clearance. If wear is Limit: 0.35 mm
excessive, replace the balancer shaft bearing,
balancer shaft or front case assembly.
ENGINE OVERHAUL
PISTON AND CONNECTING ROD
11B-57
M1113008403840
6
Apply engine oil to
7
all moving parts 8 12
4
10 11
13
9
14
3
2
27 ± 2 N·m +90˚ to 94˚
1
AK403589 AC

>>E<< 1. Connecting rod cap nut >>B<< 8. Oil ring
<<A>> >>E<< 2. Connecting rod cap >>A<< 9. Snap ring
3. Connecting rod bearing >>A<< 10. Piston pin
<> >>D<< 4. Piston and connecting rod assembly >>A<< 11. Piston
5. Connecting rod bearing >>A<< 12. Snap ring
>>C<< 6. Piston ring No. 1 13. Bolt
>>C<< 7. Piston ring No. 2 >>A<< 14. Connecting rod
REMOVAL SERVICE POINTS Cylinder bore size Piston size mark

<<A>> CONNECTING ROD CAP REMOVAL A A
B None
C C
Cylinder NOTE: The piston size mark shows on the top of
number
the piston.
2. Set the snap ring into one side of the piston pin
hole.
<Except Euro 5>

AK404150 AB Front mark
Mark the cylinder number on the side of the connect-
ing rod big end for correct reassembly.
Front mark
<> PISTON AND CONNECTING ROD
ASSEMBLY REMOVAL
D5
<Euro 5>
MB992010 Front mark
AK801093AD
3. With the front mark of the connecting rod and that

Crank pin
of the piston located on the same side, insert the
AK402310 AC
piston pin.
1. Not to damage the crank pin, attach a special tool NOTE: It is difficult to fit the piston pin into the pis-
Bolt guide (MB992010), to the connecting rod ton when they have a different temperature,
bolt. Therefore, fit the piston pin into the piston when
2. Remove the piston and connecting rod assembly they have the same temperature.
from the cylinder block. 4. Set the snap ring into the other side of the piston
pin hole.
INSTALLATION SERVICE POINTS 5. Check that the piston moves smoothly.
>>A<< CONNECTING ROD / SNAP RING / PISTON
PIN / PISTON INSTALLATION >>B<< OIL RING INSTALLATION
Timing belt side
Expander coil Oil ring
No.1 No.2 No.3 No.4
AK500593AB AK500591AB
1. When replacing the piston pin, read off the Install the expander coil and oil ring in the piston ring
cylinder bore size mark on the cylinder block as groove.
illustrated, and select a piston according to the
following table.
ENGINE OVERHAUL
11B-59
>>C<< PISTON RING NO. 1 / PISTON RING NO. 2
INSTALLATION Bolt
MB992010
Connecting rod
AK402300AC
AK404152 4. Not to damage the crank pin, attach a special tool

Bolt guide (MB992010), to the connecting rod
Identification mark bolt.
Size marks
No. 1
No. 2
AK202807 AB
Use a piston ring expander to install the No.1 and AK404153

No.2 piston rings. The ring identification mark should
face upwards. 5. Use suitable thread protectors on connecting rod
Identification marks bolts before inserting piston and connecting rod
No. 1 ring: 1R assembly into cylinder block. Care must be taken
No. 2 ring: 2R not to nick crank pin.
6. Using a suitable piston ring compressor tool,
install piston and connecting rod assembly into
>>D<< PISTON AND CONNECTING ROD
cylinder block.
CAUTION
Insert with the front mark on the piston head
No. 1
Side rail directed toward the engine front (timing belt
side).
Piston pin >>E<< CONNECTING ROD CAP / CONNECTING

ROD CAP NUT INSTALLATION
No. 2 Side rail

AK202553 AC
Cylinder
1. Liberally coat engine oil on the circumference of number
the piston, piston ring, and oil ring.
2. Arrange the piston ring and oil ring gaps (side rail
and spacer) as shown in the figure.
3. Rotate crankshaft so that crank pin is on center of
cylinder bore. AK404150 AB
1. Verifying the mark made during disassembly, 7. Make sure that connecting rod big end side
install the bearing cap to the connecting rod. If the clearance meets the specification.
connecting rod is new with no index mark, make Standard value: 0.10 − 0.25 mm
sure that the bearing locking notches come on the Limit: 0.40 mm
same side as shown.
2. The connecting rod cap bolts and nuts are INSPECTION
M1113008502651
tightened using the torque-to-yield method. For
this reason, each bolt to be reused must be PISTON RING
checked for elongation before installation. Piston Thickness gauge
Whether or not the bolt has been elongated can
be determined by running a nut with fingers
through all the threads of the bolt. If the nut does
not turn smoothly over all the threads, the bolt has
been elongated and must be replaced.
3. Apply engine oil to the threads and bearing
surface of each nut before installation.
4. Finger-tighten the nuts on the bolts, then tighten
the nuts alternately and repeatedly to install the AK402966AB
cap properly.
5. Tighten the nuts to a torque of 27 ± 2 N⋅m. No.1 oil ring groove
MB991614
Ring carrier
AK402967AB
AK500742 AB
1. Check for side clearance. If the limit is exceeded,
replace the ring or piston, or both.
6. Using the special tool Angle gauge (MB991614), NOTE: In cases of keystone type, measure the
tighten the connecting rod cap nut in the ring to groove clearance as shown.
illustrated sequence by a further 90° to 94°. Standard value:
CAUTION No. 1: 0.07 − 0.10 mm
• When the tightening angle is smaller than the No. 2: 0.05 − 0.06 mm
specified tightening angle, the appropriate Oil: 0.02 − 0.06 mm
tightening capacity cannot be secured.
Limit:
• When the tightening angle is larger than the
No. 1: 0.15 mm
specified tightening angle, remove the bolt to
No. 2: 0.15 mm
start from the beginning again according to
Oil: 0.10 mm
the procedure.
Force ring down

with piston
Piston ring End gap AK202788 AB

AK404156
ENGINE OVERHAUL
11B-61
2. Insert the piston ring into cylinder bore. Force it 2. Cut a piece of plastigage whose length is
down with a piston, its crown being in contact with equivalent to the width of the bearing and place it
the ring, to correctly position it at right angles to on the crankshaft pin in parallel with its axis.
the cylinder wall. Then, measure the end gap with 3. Install the connecting rod cap carefully and tighten
a thickness gauge. If the end gap is excessive, the nuts according to INSTALLATION SERVICE
replace piston ring. POINTS >>E<<P.11B-58.
Item Standard value Limit 4. Remove the nuts, then remove the connecting rod
mm mm cap carefully.
No.1 Except Euro5 0.30 − 0.45 0.8
Euro5 0.20 − 0.30 0.8
No.2 Except Euro5 0.30 − 0.45 0.8
Euro5 0.20 − 0.35 0.8
Oil 0.25 − 0.45 0.8
CRANKSHAFT PIN OIL CLEARANCE

(PLASTIGAGE METHOD)
AK404155
1. Wipe off oil from the crankshaft pin and
connecting rod bearing. 5. Measure the largest width of the crushed
plastigage using the ruler printed on the bag of the
Plastigage plastigage.
Limit: 0.1 mm
AK404154AB

M1113008704208
CAUTION
On the flexible flywheel equipped engines, do not remove any of the bolts "A" of the flywheel shown
in the illustration. The balance of the flexible flywheel is adjusted in an assembled condition. Remov-
ing the bolt, therefore, can cause the flexible flywheel to be out of balance giving and resulting in
damage.
2
Apply engine oil to
all moving parts 13
1
54 ± 5 N·m 15 133 ± 4 N·m

29
27 16 3
9.0 ± 1.0 N·m
133 ± 4 N·m
11 ± 1 N·m 14 4
9.0 ± 1.0 N·m 6
28
26 5
24
54 ± 5 N·m
25 23
32 ± 2 N·m 135 ± 5 N·m

8 A
22 7
9
12
21
10
18
18
11
17 40 ± 2 N·m +35˚ to 39˚
20
19 AKB00336AB

1. Flywheel bolt (M/T−2WD) 10. Adapter plate (A/T)
2. Ball bearing (M/T−2WD) 11. Drive plate (A/T)
3. Flywheel (M/T−2WD) 12. Inertiar ring(A/T)
4. Flywheel bolt (M/T−4WD) 13. Rear plate
5. Ball bearing (M/T−4WD) 14. Bell housing cover
6. Adapter (M/T−4WD) >>E<< 15. Oil seal case
7. Flexible flywheel (M/T−4WD) >>D<< 16. Oil seal
8. Crankshaft adapter (M/T−4WD) >>C<< 17. Bearing cap bolt
9. Drive plate bolt (A/T) >>C<< 18. Bearing cap
ENGINE OVERHAUL
11B-63
Place of journal diameter class
>>C<< 19. Bearing cap No.3
>>C<< 20. Bearing cap No.4
>>B<< 21. Crankshaft bearing, lower
22. Crankshaft
>>B<< 23. Crankshaft bearing, upper
>>B<< 24. Crankshaft thrust bearing
>>A<< 25. Check valve No.5
>>A<< 26. Oil jet No.4
27. Engine support bracket, right No.3
No.2
28. Engine support bracket, left No.1
29. Cylinder block
Ident mark and color location
INSTALLATION SERVICE POINTS ( Using both ID mark and color or either one )
No.3
>>A<< OIL JET INSTALLATION
No.2
No.1, 3 No.2, 4
Cylinder Cylinder
No.4
No.1 No.5
AK503244 AB
(1) Measure the crankshaft journal diameter and

Oil jet Oil jet
(for No.1, 3) (for No.2, 4) confirm its classification from the following
table. In the case of a crankshaft supplied as a
service part, identification colors and marks of
its journals and painted at the positions shown
Cylinder block Knock pin
Timing belt side
No.1
No.2
Check valve Oil jet
No.3
No.4
AK402957AB
No.5
There are two types of oil jets installed.
one for No.1 and 3 and the other for N0.2 and 4. AK402986AB
Make sure that the correct one is installed with cor-
rect direction as shown. (2) The cylinder block bore diameter identification
marks are stamped at the position shown in
the illustration from front to rear beginning at
>>B<< CRANKSHAFT BEARING INSTALLATION
No.1.
1. When the bearing needs replacing, select a
proper bearing by the following procedure. Identification For upper
NOTE: If the crankshaft is machined to an under- color
sized, bearings for undersized crankshaft should
be used and therefore the following selection pro- Identification mark
cedure is unnecessary.
Identification mark
Identification
For lower color
AK503245AB
(3) Select proper bearings from the below table b. Next, check the cylinder block bearing bore iden-
on the basis of the identification data tification mark stamped on the cylinder block. If it
confirmed under Items (1) and (2). is "A" read the "Bearing identification mark" col-
umn to find the identification mark of the bearing
Example
to be used. In this case, it is "1" or "Green"
a. If the measured value of a crankshaft journal
outer diameter is 65.997 mm, the journal is clas-
sified as "1" or "Yellow" in the table. In case the
crankshaft is also replaced by a spare part, check
the identification colors of the journals painted on
the new crankshaft.
Combination of crankshaft journal diameter and cylinder block bearing bore Bearing
diameter identification mark
Crankshaft journal Classification Cylinder block bearing
Identification color or mark O.D. mm bore diameter
Using both ID (mark and color) or identification mark
either one
1 Yellow 65.994 − 66.000 A 1 or Green
B 2 or Yellow
C 3 or None
2 None 65.988 − 65.994 A 2 or Yellow
B 3 or None
C 4 or Blue
3 White 65.982 − 65.988 A 3 or None
B 4 or Blue
C 5 or Red
For upper
Groove
Groove
For lower
AK503246AB AK301467AD
2. Crankshaft bearing 3. Crankshaft thrust bearing installation

(1) Install the bearings having an oil groove to the (1) Install the two thrust bearing in the number 3
cylinder block. bearing bore in the cylinder block. For easier
NOTE: The No. 3 bearing integrated with thrust installation, apply engine oil to the bearings;
bearing has no oil groove. this will help hold them in position.
(2) Install the bearings having no oil groove to the (2) The thrust bearings must be installed with their
bearing cap. groove side toward the crankshaft web.
>>C<< BEARING CAP / BEARING CAP BOLT

INSTALLATION
ENGINE OVERHAUL
11B-65
Front mark Limit: 0.45 mm
>>D<< OIL SEAL INSTALLATION
Press
Cap No. MB992147
AK404143AB
1. Install according to the front mark and cap No.

2. Apply engine oil to the threaded portion and
seating face of the bolt. Oil seal Oil seal case
AK600423 AB
3. Tighten the bearing cap bolts in the illustrated
sequence to 40 ± 2 N⋅m. 1. Apply oil to oil seal lips.
2. Using the special tool Oil seal installer
(MD992147), Press and fit the oil seal into the oil
seal case to have the dimension shown in the
MB991614
illustration.
>>E<< OIL SEAL CASE INSTALLATION

1. Remove completely old FIPG remaining on the
rear oil seal case and cylinder block.
AK500598AB
CAUTION
• When the tightening angle is smaller than the
specified tightening angle, the appropriate
tightening capacity cannot be secured.
• When the tightening angle is larger than the
specified tightening angle, remove the bolt to
start from the beginning again according to
the procedure. AK500580AB
4. Using the special tool Angle gauge (MB991614), 2. Apply a bead of FIPG to the surface of the rear oil
tighten the bearing cap bolts in the illustrated seal case as shown in the drawing.
sequence by a further 35° to 39°.
Specified sealant:
NOTE: Be sure to install the case quickly while
the sealant is wet (within 15 minutes).
3. Install the oil seal into the cylinder block after
applying an appropriate amount of engine oil to
the entire circumference of its lip portion.
4. Install the rear oil seal case by tightening its bolts
to 11 ± 1 N⋅m.
AK404157 NOTE: After installation, keep the sealed area away
from the oil for approximately one hour.
5. After installing the bearing caps, make sure that
the crankshaft turns smoothly and the end play is
correct. If the end play exceeds the limit, replace
crankshaft bearings.
INSPECTION
M1113008802759
OIL JET / CHECK VALVE
Engine oil
Oil jet AK404149
Check valve assembly 6. Measure the width of the smashed plastigage at

AK402951 AB its widest section by using a scale printed on the
plastigage bag.
The inspection procedure for this oil jet is the same
as for the conventional oil jet.
Limit: 0.1 mm
CRANKSHAFT OIL CLEARANCE (PLASTIGAGE
METHOD) CYLINDER BLOCK
The crankshaft oil clearance can be measured easily
by using a plastigage, as follows.
Plastigage
AK404145
1. Using a straightedge and thickness gauge, check

AK404148AB
the block top surface for warpage. Make sure that
1. Remove oil and grease and any other foreign the surface is free from gasket chips and other
matters from crankshaft journal and bearing inner objects.
surface. Standard value: 0.05 mm
2. Install the crankshaft. Limit: 0.1 mm
3. Cut the plastigage to the same length as the width 2. If the distortion is excessive, replace the cylinder
of bearing and place it on journal in parallel with block.
its axis.
4. Gently place the crankshaft bearing cap over it
and tighten the bolts to the specified torque.
5. Remove the bolts and gently remove the
crankshaft bearing cap.
12 mm
AK404146 AB
3. Check cylinder walls for scratches and size. If

defects are evident, replace the cylinder block.
ENGINE OVERHAUL
11B-67
4. Using cylinder gauge, measure the cylinder bore, Standard value:
and cylindricity. If worn badly, replace the cylinder Cylinder I.D. 91.10 − 91.13 mm
block. Measurement points are shown in Cylindricity 0.02 mm
illustration.
12-1
GROUP 12
ENGINE
LUBRICATION
CONTENTS
GENERAL INFORMATION . . . . . . . . 12-2 ENGINE OIL CHANGE . . . . . . . . . . . . . . . . 12-4

ENGINE OIL FILTER REPLACEMENT. . . . 12-5
SERVICE SPECIFICATIONS. . . . . . . 12-2 OIL PRESSURE CHECK . . . . . . . . . . . . . . 12-6
SEALANTS OR ADHESIVES . . . . . . 12-2 ENGINE OIL PRESSURE SWITCH . . 12-6

ENGINE OIL PRESSURE SWITCH REMOVAL AND
LUBRICANTS . . . . . . . . . . . . . . . . . . 12-3 INSTALLATION <Except Euro5> . . . . . . . . 12-6
ENGINE OIL PRESSURE SWITCH REMOVAL AND
SPECIAL TOOLS. . . . . . . . . . . . . . . . 12-3 INSTALLATION <Euro5> . . . . . . . . . . . . . . 12-8
ON-VEHICLE SERVICE. . . . . . . . . . . 12-4 ENGINE OIL COOLER . . . . . . . . . . . . 12-10

ENGINE OIL COOLER REMOVAL AND
ENGINE OIL CHECK . . . . . . . . . . . . . . . . . 12-4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 12-10
12-2 ENGINE LUBRICATION
GENERAL INFORMATION
GENERAL INFORMATION
M1121000101242
The lubrication method is a fully force-fed, full-flow fil- • Avoid contaminating clothes, particularly under-
tration type. Water-cooled oil cooler built into the oil pants, with oil.
filter bracket have been adopted. • Do not put oily rags in pockets, the use of overalls
without pockets will avoid this.
ENGINE OILS • Do not wear heavily soiled clothing and oil-
HEALTH WARNING impregnated foot-wear. Overalls must be cleaned
Prolonged and repeated contact with mineral oil will regularly and kept separate from personal cloth-
result in the removal of natural fats from the skin, ing.
leading to dryness, irritation and dermatitis. In addi- • Where there is a risk of eye contact, eye protec-
tion, used engine oil contains potentially harmful con- tion should be worn, for example, chemical gog-
taminants which may cause skin cancer. Adequate gles or face shields; in addition an eye wash
means of skin protection and washing facilities must facility should be provided.
be provided. • Obtain first aid treatment immediately for open
cuts and wounds.
RECOMMENDED PRECAUTIONS • Wash regularly with soap and water to ensure all
The most effective precaution is to adapt working oil is removed, especially before meals (skin
practices which prevent, as far as practicable, the cleansers and nail brushes will help). After clean-
risk of skin contact with mineral oils, for example by ing, the application of preparations containing
using enclosed systems for handling used engine oil lanolin to replace the natural skin oils is advised.
and by degreasing components, where practicable, • Do not use petrol, kerosine, diesel fuel, gas oil,
before handling them. Other precautions: thinners or solvents for cleaning skin.
• Avoid prolonged and repeated contact with oils, • Use barrier creams, applying them before each
particularly used engine oils. work period, to help the removal of oil from the
• Wear protective clothing, including impervious skin after work.
gloves where practicable. • If skin disorders develop, obtain medical advice
without delay.
SERVICE SPECIFICATION
M1121000300414
Item Standard value

Oil pressure kPa at idle 29 or more
at 3,500 r/min 294 − 686
SEALANT
M1121000501262

Engine oil pressure switch Three bond 1141J, Three bond 1215, Three bond 1212D, Three bond 1207F
(Mitsubishi Part No. 1000A992), Three bond 1207C or equivalent
ENGINE LUBRICATION
LUBRICANT
12-3
LUBRICANT
M1121000402923
Item Vehicles without DPF Vehicles with DPF

Engine oil ACEA classification A1/B1, A3/B3, A3/B4 or C1, C2, C3 or C4
A5/B5
Engine oil API classification CF-4 −
Engine oil JASO classification − DL-1
Engine oil 2WD with 15 inch tyres Oil pan 6.5
quantity L Oil filter 0.8
Oil cooler 0.1
Total 7.4
2WD with 16 inch tyres, Oil pan 5.5
4WD Oil filter 0.8
Oil cooler 0.1
Total 6.4
SPECIAL TOOLS
M1121000602433

MH061590 Oil filter wrench Removal and installation of engine
oil filter
MH061590
MD998012 Oil pressure switch Removal and installation of engine

wrench oil pressure switch <Except Euro5>
MB992118 Oil pressure switch Removal and installation of engine

wrench oil pressure switch <Euro5>
MB992118
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
ENGINE OIL CHECK 4. Install a new drain plug gasket so that it faces in
M1121000901475 the direction shown in the illustration, and then
CAUTION tighten the drain plug to the specified torque.
NOTE: Install the drain plug gasket so it faces in
"X" mark 5. Refill with specified quantity of oil.
Specified Engine Oil
• ACEA classification: "For service A1/B1,
A3/B3, A3/B4 or A5/B5"
• API classification: "For service CF-4"
Maximum Minimum
Total quantity (Includes volume inside oil fil-
ACB00687 AB
ter and oil cooler):
When burning away and removing soot accumu- <2WD with 15 inch tyres> 7.4L
lated in the DPF, fuel can mix with the engine oil <2WD with 16 inch tyres, 4WD> 6.4L
and an increase in the engine oil level may occur. NOTE:
This does not indicate an abnormality. However,
if the engine oil level is at or over the "X" mark on
the engine oil level gauge, change the engine oil
<Vehicles with diesel particulate filter (DPF)>.
1. Pull out the engine oil level gauge slowly and
check that the engine oil level is in the illustrated
range.
2. Check that the engine oil is not excessively dirty,
that there is no engine coolant or fuel mixed in,
and that it has sufficient viscosity. AC903479
Select engine oil of the proper SAE viscosity

ENGINE OIL REPLACEMENT number according to the atmospheric tempera-
M1121001003608
ture.
<Vehicles without diesel particulate filter 6. Install the engine oil filler cap.
(DPF)> 7. Check oil level.
1. Start the engine and allow it to warm up until the
temperature of the coolant reaches 80 °C to 90 <Vehicles with diesel particulate filter
°C. (DPF)>
2. Remove the engine oil filler cap. 1. Start the engine and allow it to warm up until the
WARNING temperature of the coolant reaches 80 °C to 90
Use care as oil could be hot. °C.
3. Remove the drain plug to drain oil. 2. Remove the engine oil filler cap.
WARNING
Engine oil pan Use care as oil could be hot.
drain plug
3. Remove the drain plug to drain oil.
Engine oil
pan side
AC502277AC
ENGINE LUBRICATION
ON-VEHICLE SERVICE
12-5
2. Remove the engine oil filler cap.
Engine oil pan WARNING
drain plug
Use care as oil could be hot.
3. Remove the drain plug to drain oil.
4. Remove the under cover.
Engine oil
pan side
AC502277AC
MH061590
4. Install a new drain plug gasket so that it faces in
the direction shown in the illustration, and then
tighten the drain plug to the specified torque.
AC000093AN
NOTE: Install the drain plug gasket so it faces in
5. Use the special tool oil filter wrench (MH061590)
5. Refill with specified quantity of oil.
to remove the engine oil filter.
Specified Engine Oil 6. Clean the filter bracket side mounting surface.
• ACEA classification: "For service C1, C2,
C3 or C4"
• JASO classification: "For service DL-1"
Total quantity (Includes volume inside oil fil-
ter and oil cooler):
<2WD with 15 inch tyres> 7.4L
<2WD with 16 inch tyres, 4WD> 6.4L
NOTE:
O-ring
AC103250AD
7. Apply a small amount of engine oil to the O-ring of

the new oil filter.
8. Once the O-ring of the oil filter is touching the
flange, use the special tool oil filter wrench
(MH061590) to tighten to the specified torque.
ACA00381AB Tightening torque: Approximately 3/4 turn
Select engine oil of the proper SAE viscosity (22 ± 2 N⋅m)
number according to the atmospheric tempera- 9. Install the drain plug and refill the engine oil (Refer
ture. to P.12-4).
6. Install the engine oil filler cap. 10.Race the engine 2−3 times, and check to be sure
7. Check oil level. that no engine oil leaks from installation section of
the oil filter.
ENGINE OIL FILTER REPLACEMENT
M1121001100703
1. Start the engine and allow it to warm up until the
temperature of the coolant reaches 80 °C to 90
°C.
ENGINE OIL PRESSURE SWITCH
OIL PRESSURE CHECK 1. Check engine oil quantity.

M1121002302472
2. Remove the engine oil pressure switch (Refer to
<Except high power engine vehicles> engine oil pressure switch removal and
installation ).
Engine oil pressure switch
3. Install the oil pressure gauge.
NOTE: Use an adapter of PT 1/8 thread.
4. Run the engine to warm it.
5. After the engine has been warmed up, check that
oil pressure is within the standard value.
Standard value:
AK403473AM
At idle: 29 kPa or more
At 3,500 r/min: 294 − 686 kPa
<High power engine vehicles>
6. Remove the oil pressure gauge.
7. Install the engine oil pressure switch (Refer to
Oil pressure switch engine oil pressure switch removal and
installation ).
AK802450AG

REMOVAL AND INSTALLATION <Except Euro5>
M1121002502078

• Under Skid Plate and Engine Room Under Cover • Engine Oil Check (Refer to P.12-4).
Removal (Refer to GROUP 51 − Under Cover P.51-32). • Under Skid Plate and Engine Room Under Cover Installa-
AK403473
Engine oil filter
3
10 ± 2 N·m
2
1
3.5 ± 0.4 N·m
AC804274AC

1. Engine oil pressure switch >>B<< 2. Engine oil pressure switch terminal
connector connection <<A>> >>A<< 3. Engine oil pressure switch
ENGINE LUBRICATION
12-7
REMOVAL SERVICE POINT 1. Apply sealant to the engine oil pressure switch
<<A>> ENGINE OIL PRESSURE SWITCH thread.
REMOVAL Specified sealant: Three bond 1215 or equiv-
CAUTION alent
The sealant is applied to the bolt. Remove the NOTE: Install the engine oil pressure switch
bolt with care not to break it. immediately after applying sealant.
CAUTION
After the installation, until a sufficient period of
time (one hour or more) elapses, do not apply the
start the engine.
MD998012
AC503935 AG
Use special tool oil pressure switch wrench

(MD998012) to remove the engine oil pressure
switch.
MD998012
INSTALLATION SERVICE POINTS AC503935 AG
>>A<< ENGINE OIL PRESSURE SWITCH INSTAL- 2. In the same manner as removal, use special tool
LATION oil pressure switch wrench (MD998012) to tighten
CAUTION the engine oil pressure switch to the specified
torque.
>>B<< ENGINE OIL PRESSURE SWITCH

TERMINAL INSTALLATION
Engine front
Engine oil filter
AC804286AB
Do not get any oil (rust prevention oil etc.) on the

area as shown in the figure to prevent the influ- 15˚
ence of switch function. 15˚
Engine oil pressure
switch terminal AC711376 AD
1 mm 5 mm
1. Install the engine oil pressure switch terminal in

2. Tighten the engine oil pressure switch terminal
mounting screw to the specified torque.
Tightening torque: 3.5 ± 0.4 N⋅m
AC611856AL
REMOVAL AND INSTALLATION <Euro5>

M1121002502089

• Under Skid Plate and Engine Room Under Cover • Engine Oil Check (Refer to P.12-4).
Removal (Refer to GROUP 51 − Under Cover P.51-32). • Under Skid Plate and Engine Room Under Cover Installa-
Engine oil filter

10 ± 2 N·m
2
1
AC903779
AC903864 AB
Removal steps Use special tool oil pressure switch wrench

1. Engine oil pressure switch (MB992118) to remove the engine oil pressure
connector connection switch.
<<A>> >>A<< 2. Engine oil pressure switch
INSTALLATION SERVICE POINT
REMOVAL SERVICE POINT
>>A<< ENGINE OIL PRESSURE SWITCH INSTAL-
<<A>> ENGINE OIL PRESSURE SWITCH LATION
REMOVAL
CAUTION 1 mm 5 mm
The sealant is applied to the bolt. Remove the
bolt with care not to break it.
AK402699AC
1. Apply sealant to the engine oil pressure switch

MB992118
thread.
AK502606 AD Specified sealant: Three bond 1215 or equiv-
alent
NOTE: Install the engine oil pressure switch
immediately after applying sealant.
ENGINE LUBRICATION
12-9
CAUTION 2. In the same manner as removal, use special tool
After the installation, until a sufficient period of oil pressure switch wrench (MB992118) to tighten
time (one hour or more) elapses, do not apply the the engine oil pressure switch to the specified
oil or water to the sealant application area or torque.
start the engine. Tightening torque: 10 ± 2 N⋅m
MB992118
AK502606 AD
ENGINE OIL COOLER
ENGINE OIL COOLER

M1121001300923

• Under Skid Plate and Engine Room Under Cover • Alternator Installation (Refer to GROUP 16 − Charging
Removal (Refer to GROUP 51 − Under Cover P.51-32). System, Alternator P.16-13).
• Engine Coolant Draining (Refer to GROUP 14 − On-vehi- • Engine Coolant Refilling (Refer to GROUP 14 − On-vehi-
cle Service, Engine Coolant Replacement P.14-4). cle Service, Engine Coolant Replacement P.14-4).
• Engine Oil Draining (Refer to P.12-4). • Engine Oil Refilling (Refer to P.12-4).
• Alternator Removal (Refer to GROUP 16 − Charging Sys- • Under Skid Plate and Engine Room Under Cover Installa-
tem, Alternator P.16-13). tion (Refer to GROUP 51 − Under Cover P.51-32).
1
N6
5
4N
3
2
39 ± 5 N·m
AC806119AB
Removal steps INSTALLATION SERVICE POINT

1. Water hose >>A<< ENGINE OIL COOLER INSTALLATION
2. Water hose
3. Engine oil cooler bolt
4. O-ring
>>A<< 5. Engine oil cooler
6. O-ring
Tab
Engine oil cooler AC502935 AB
Position the tab as shown in the illustration.

13-1
GROUP 13
FUEL
CONTENTS
DIESEL FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A
FUEL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B

13A-1
GROUP 13A
DIESEL FUEL
CONTENTS
GENERAL INFORMATION . . . . . . . . 13A-6 INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-68

CODE NO. P0103 AIR FLOW SENSOR CIRCUIT
SERVICE SPECIFICATIONS. . . . . . . 13A-10 HIGH INPUT . . . . . . . . . . . . . . . . . . . . . . . . 13A-75
CODE NO. P0106 MANIFOLD ABSOLUTE
PRESSURE SENSOR RANGE/PERFORMANCE
SEALANTS OR ADHESIVES . . . . . . 13A-10
PROBLEM . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-78
CODE NO. P0107 MANIFOLD ABSOLUTE
SPECIAL TOOLS. . . . . . . . . . . . . . . . 13A-11 PRESSURE SENSOR CIRCUIT LOW INPUT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-83
TROUBLESHOOTING . . . . . . . . . . . . 13A-12 CODE NO. P0108 MANIFOLD ABSOLUTE
DIAGNOSIS TROUBLESHOOTING FLOW 13A-12 PRESSURE SENSOR CIRCUIT HIGH INPUT
DIAGNOSIS FUNCTION. . . . . . . . . . . . . . . 13A-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-91
DIAGNOSIS CODE CHART . . . . . . . . . . . . 13A-21 CODE NO. P0112 EGR GAS TEMPERATURE
SENSOR CIRCUIT LOW INPUT <Euro5> . 13A-94
DIAGNOSIS CODE PROCEDURES . . . . . 13A-26
CODE NO. P0112 INTAKE AIR TEMPERATURE
CODE NO. P0003 SUCTION CONTROL VALVE SENSOR NO.1 CIRCUIT LOW INPUT <Except Euro5>
OPEN <Euro5> . . . . . . . . . . . . . . . . . . . . . . 13A-26
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-99
CODE NO. P0004 SUCTION CONTROL VALVE
CODE NO. P0113 EGR GAS TEMPERATURE
BATTRY SHORT <Euro5> . . . . . . . . . . . . . 13A-29
SENSOR CIRCUIT HIGH INPUT <Euro5> . 13A-104
CODE NO. P0016 CRANKSHAFT/CAMSHAFT
CODE NO. P0113 INTAKE AIR TEMPERATURE
POSITION SENSOR PHASE PROBLEM . . 13A-32 SENSOR NO.1 CIRCUIT HIGH INPUT <Except
CODE NO. P0047 VARIABLE GEOMETRY Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-109
SOLENOID VALVE LOW <Euro5> . . . . . . . 13A-34 CODE NO. P0117 ENGINE COOLANT
CODE NO. P0048 VARIABLE GEOMETRY TEMPERATURE SENSOR CIRCUIT LOW INPUT
SOLENOID VALVE HIGH <Euro5> . . . . . . 13A-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-113
CODE NO. P0072 NO.1 INTAKE AIR TEMPERATURE CODE NO. P0118 ENGINE COOLANT
SENSOR CIRCUIT LOW INPUT <Euro5> . 13A-43 TEMPERATURE SENSOR CIRCUIT HIGH INPUT
CODE NO. P0072 INTAKE AIR TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-119
SENSOR NO.2 CIRCUIT LOW INPUT <Except Euro5> CODE NO. P0122 THROTTLE POSITION SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-48 CIRCUIT LOW INPUT . . . . . . . . . . . . . . . . . 13A-124
CODE NO. P0073 NO.1 INTAKE AIR TEMPERATURE CODE NO. P0123 THROTTLE POSITION SENSOR
SENSOR CIRCUIT HIGH INPUT <Euro5>. 13A-53 CIRCUIT HIGH INPUT . . . . . . . . . . . . . . . . 13A-131
CODE NO. P0073 INTAKE AIR TEMPERATURE CODE NO. P0182 FUEL TEMPERATURE SENSOR
SENSOR NO.2 CIRCUIT HIGH INPUT <Except CIRCUIT LOW INPUT . . . . . . . . . . . . . . . . . 13A-134
Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-57 CODE NO. P0183 FUEL TEMPERATURE SENSOR
CODE NO. P0088 COMMON RAIL HIGH PRESSURE CIRCUIT HIGH INPUT . . . . . . . . . . . . . . . . 13A-139
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . 13A-60 CODE NO. P0191 RAIL PRESSURE SENSOR
CODE NO. P0089 SUCTION CONTROL VALVE RANGE/PERFORMANCE PROBLEM . . . . 13A-143
STUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-63 CODE NO. P0192 RAIL PRESSURE SENSOR
CODE NO. P0093 FUEL LEAK PROBLEM 13A-64 CIRCUIT LOW INPUT . . . . . . . . . . . . . . . . . 13A-147
CODE NO. P0102 AIR FLOW SENSOR CIRCUIT LOW CODE NO. P0193 RAIL PRESSURE SENSOR
13A-2
CIRCUIT HIGH INPUT . . . . . . . . . . . . . . . . 13A-155 TEMPERATURE SENSOR CIRCUIT LOW INPUT

CODE NO. P0201 NO.1 INJECTOR CIRCUIT <Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-231
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . 13A-158 CODE NO. P0428 NO. 2 EXHAUST GAS
CODE NO. P0202 NO.2 INJECTOR CIRCUIT TEMPERATURE SENSOR CIRCUIT HIGH INPUT
MALFUNCTION <Euro5> . . . . . . . . . . . . . . 13A-161 <Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-234
CODE NO. P0202 NO.2 INJECTOR CIRCUIT CODE NO. P0489 EGR VALVE POSITION SENSOR
MALFUNCTION <Except Euro5> . . . . . . . . 13A-164 CIRCUIT LOW INPUT <Euro5> . . . . . . . . . 13A-240
CODE NO. P0203 NO.3 INJECTOR CIRCUIT CODE NO. P0490 EGR VALVE POSITION SENSOR
MALFUNCTION <Euro5> . . . . . . . . . . . . . . 13A-167 CIRCUIT HIGH INPUT <Euro5> . . . . . . . . . 13A-248
CODE NO. P0203 NO.3 INJECTOR CIRCUIT CODE NO. P0502 VEHICLE SPEED SENSOR LOW
MALFUNCTION <Except Euro5> . . . . . . . . 13A-170 INPUT <2WD-M/T and 4WD vehicles> . . . . 13A-251
CODE NO. P0204 NO.4 INJECTOR CIRCUIT CODE NO. P0513 IMMOBILIZER MALFUNCTION
MALFUNCTION <Euro5> . . . . . . . . . . . . . . 13A-173 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-254
CODE NO. P0204 NO.4 INJECTOR CIRCUIT CODE NO. P0515 BATTERY TEMPERATURE
MALFUNCTION <Except Euro5> . . . . . . . . 13A-176 SENSOR SYSTEM <Euro5> . . . . . . . . . . . . 13A-255
CODE NO. P0219 ENGINE OVERSPEED CODE NO. P0545 NO. 1 EXHAUST GAS
CONDITION . . . . . . . . . . . . . . . . . . . . . . . . 13A-178 TEMPERATURE SENSOR CIRCUIT LOW INPUT
<Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-260
CODE NO. P0234 TURBOCHARGER OVERBOOST
CONDITION <Except Euro5> . . . . . . . . . . . 13A-179 CODE NO. P0546 NO. 1 EXHAUST GAS
TEMPERATURE SENSOR CIRCUIT HIGH INPUT
CODE NO. P0299 TURBOCHARGER UNDER BOOST
<Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-263
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-180
CODE NO. P0551 POWER STEERING FLUID
CODE NO. P0301 NO. 1 CYLINDER INJECTOR
PRESSURE SWITCH SYSTEM . . . . . . . . . 13A-268
MALFUNCTION (NO INJECTION) . . . . . . . 13A-180
CODE NO. P0603 EEP ROM MALFUNCTION <Except
Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-270
CODE NO. P0604 RANDOM ACCESS MEMORY
(RAM) MALFUNCTION . . . . . . . . . . . . . . . . 13A-271
CODE NO. P0605 READ ONLY MEMORY (FLASH
ROM) MALFUNCTION . . . . . . . . . . . . . . . . 13A-271
CODE NO. P0606 ENGINE-ECU (MAIN CPU)
CODE NO. P0335 CRANK ANGLE SENSOR SYSTEM
MALFUNCTION. . . . . . . . . . . . . . . . . . . . . . 13A-272
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-184
CODE NO. P0607 ENGINE-ECU (SUB CPU)
CODE NO. P0336 CRANK ANGLE SENSOR RANGE/
MALFUNCTION. . . . . . . . . . . . . . . . . . . . . . 13A-272
PERFORMANCE PROBLEM . . . . . . . . . . . 13A-190
CODE NO. P0620 ALTERNATOR CONTROL
CODE NO. P0340 CAMSHAFT POSITION SENSOR
CIRCUIT <Euro5> . . . . . . . . . . . . . . . . . . . . 13A-273
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-192
CODE NO. P0341 CAMSHAFT POSITION SENSOR
OPEN <Except Euro5> . . . . . . . . . . . . . . . . 13A-276
RANGE/PERFORMANCE PROBLEM . . . . 13A-198
CODE NO. P0381 GLOW PLUG OPEN/SHORT
BATTERY SHORT <Except Euro5> . . . . . . 13A-279
MALFUNCTION <Euro5> . . . . . . . . . . . . . . 13A-200
CODE NO. P062F EEPROM MALFUNCTION <Euro5>
CODE NO. P0401 EGR FLOW INSUFFICIENT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-282
<Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-204
CODE NO. P0630 CHASSIS NUMBER NOT
CODE NO. P0402 EGR FLOW EXCESSIVE <Euro5>
PROGRAMMED . . . . . . . . . . . . . . . . . . . . . 13A-282
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-209
CODE NO. P0638 THROTTLE VALVE CONTROL
CODE NO. P0403 EGR VALVE DC MOTOR
SERVO STUCK . . . . . . . . . . . . . . . . . . . . . . 13A-284
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . 13A-215
CODE NO. P0642 ANALOG SENSOR REFERENCE
CODE NO. P0405 EGR VALVE POSITION SENSOR
VOLTAGE NO.1 TOO LOW . . . . . . . . . . . . 13A-286
CIRCUIT LOW INPUT <Except Euro5> . . . 13A-219
CODE NO. P0406 EGR VALVE POSITION SENSOR
VOLTAGE NO.1 TOO HIGH . . . . . . . . . . . . 13A-287
CIRCUIT HIGH INPUT <Except Euro5> . . . 13A-227
CODE NO. P064C GLOW CONTROL UNIT
CODE NO. P0420 CATALYST MALFUNCTION
<Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-229
CODE NO. P0427 NO. 2 EXHAUST GAS
VOLTAGE NO.2 TOO LOW . . . . . . . . . . . . 13A-290
13A-3
CODE NO. P0653 ANALOG SENSOR REFERENCE SENSOR (MAIN) CIRCUIT HIGH INPUT . . 13A-341
VOLTAGE NO.2 TOO HIGH . . . . . . . . . . . . 13A-291 CODE NO. P2124 ACCELERATOR PEDAL POSITION
CODE NO. P0683 GLOW CONTROL UNIT SENSOR (MAIN) CIRCUIT HIGH INPUT
COMMUNICATION ABNORMALITY <Euro5> INTERMITTENT . . . . . . . . . . . . . . . . . . . . . 13A-345
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-292 CODE NO. P2127 ACCELERATOR PEDAL POSITION
CODE NO. P1203 CAPACITOR INSUFFICIENT SENSOR (SUB) CIRCUIT LOW INPUT . . . 13A-349
CHARGING. . . . . . . . . . . . . . . . . . . . . . . . . 13A-296 CODE NO. P2128 ACCELERATOR PEDAL POSITION
CODE NO. P1204 CAPACITOR EXCESSIVE SENSOR (SUB) CIRCUIT HIGH INPUT . . . 13A-357
CHARGING. . . . . . . . . . . . . . . . . . . . . . . . . 13A-296 CODE NO. P2138 ACCELERATOR PEDAL POSITION
CODE NO. P1272 PRESSURE LIMITER SENSOR (MAIN AND SUB) RANGE/PERFORMANCE
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . 13A-297 PROBLEM . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-360
CODE NO. P1273 SUPPLY PUMP INSUFFICIENT CODE NO. P2146 INJECTOR COMMON 1
FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-300 (CYLINDER NO.1 AND NO.4) CIRCUIT OPEN
CODE NO. P1274 SUPPLY PUMP PROTECTION <Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-368
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-301 CODE NO. P2146 INJECTOR COMMON 1
CODE NO. P1275 SUPPLY PUMP EXCHANGE (CYLINDER NO.1 AND NO.4) CIRCUIT OPEN
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-302 <Except Euro5> . . . . . . . . . . . . . . . . . . . . . . 13A-371
CODE NO. P1276 FUEL FILTER EXCHANGE CODE NO. P2147 INJECTOR COMMON 1
<Vehicles with fuel filter pressure switch> . 13A-304 (CYLINDER NO. 1 AND NO. 4) CIRCUIT EARTH
SHORT <Euro5> . . . . . . . . . . . . . . . . . . . . . 13A-374
CODE NO. P1277 FUEL FILTER FREEZE <Vehicles
with fuel filter pressure switch> . . . . . . . . . . 13A-307 CODE NO. P2147 INJECTOR COMMON CIRCUIT
GND SHORT <Except Euro5> . . . . . . . . . . 13A-378
CODE NO. P1298 VARIABLE GEOMETRY
TURBOCHARGER CONTROL SYSTEM CODE NO. P2148 INJECTOR COMMON 1
MALFUNCTION (HIGH PRESSURE) <Euro5> (CYLINDER NO. 1 AND NO. 4) CIRCUIT BATTERY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-308 SHORT <Euro5> . . . . . . . . . . . . . . . . . . . . . 13A-383
CODE NO. P1299 VARIABLE GEOMETRY CODE NO. P2148 INJECTOR COMMON CIRCUIT
TURBOCHARGER CONTROL SYSTEM BATTERY SHORT <Except Euro5> . . . . . . 13A-387
MALFUNCTION (LOW PRESSURE) <Euro5> CODE NO. P2149 INJECTOR COMMON 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-308 (CYLINDER NO.2 AND NO.3) CIRCUIT OPEN
CODE NO. P1427 NO. 3 EXHAUST GAS <Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-392
TEMPERATURE SENSOR CIRCUIT LOW INPUT CODE NO. P2149 INJECTOR COMMON 2
<Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-310 (CYLINDER NO.2 AND NO.3) CIRCUIT OPEN
CODE NO. P1428 NO. 3 EXHAUST GAS <Except Euro5> . . . . . . . . . . . . . . . . . . . . . . 13A-396
TEMPERATURE SENSOR CIRCUIT HIGH INPUT CODE NO. P2150 INJECTOR COMMON 2(CYLINDER
<Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-313 NO. 2 AND NO. 3) CIRCUIT EARTH SHORT <Euro5>
CODE NO. P1497 DPF SYSTEM MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-399
<Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-319 CODE NO. P2151 INJECTOR COMMON 2(CYLINDER
CODE NO. P1498 EXCESSIVE PM ACCUMULATED NO. 2 AND NO. 3) CIRCUIT BATTERY SHORT
IN DPF <Euro5> . . . . . . . . . . . . . . . . . . . . . 13A-320 <Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-403
CODE NO. P1499 ABNORMALLY HIGH DPF CODE NO. P2228 BAROMETRIC PRESSURE
TEMPERATURE <Euro5> . . . . . . . . . . . . . 13A-320 SENSOR CIRCUIT LOW INPUT . . . . . . . . . 13A-406
CODE NO. P1608 BATTERY CURRENT SENSOR CODE NO. P2229 BAROMETRIC PRESSURE
SYSTEM <Euro5>. . . . . . . . . . . . . . . . . . . . 13A-322 SENSOR CIRCUIT HIGH INPUT . . . . . . . . 13A-407
CODE NO. P1625 INJECTION QUANTITY CODE NO. P2413 EGR SYSTEM PERFORMANCE
COMPENSATION VALUE ERROR . . . . . . 13A-327 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-408
CODE NO. P1626 INJECTION QUANTITY CODE NO. P2454 EXHAUST DIFFERENTIAL
COMPENSATION VALUE ERROR NOT CODING PRESSURE SENSOR CIRCUIT LOW INPUT <Euro5>
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-411
CODE NO. P2118 THROTTLE VALVE CONTROL DC CODE NO. P2455 EXHAUST DIFFERENTIAL
MOTOR CURRENT MALFUNCTION . . . . . 13A-329 PRESSURE SENSOR CIRCUIT HIGH INPUT <Euro5>
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-417
CODE NO. P2122 ACCELERATOR PEDAL POSITION
SENSOR (MAIN) CIRCUIT LOW INPUT . . 13A-333 CODE NO. P252F ENGINE OIL LEVEL
CODE NO. P2123 ACCELERATOR PEDAL POSITION
13A-4
CODE NO. U1073 BUS OFF . . . . . . . . . . . 13A-420 4LLC SWITCH SYSTEM <M/T-High power engine
CODE NO. U1101 A/T-ECU TIME-OUT <A/T> vehicle> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-505
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-421 CONDENSER FAN RELAY SYSTEM <Vehicles with A/
CODE NO. U1102 ASTC-ECU TIME-OUT <Except C condenser fan> . . . . . . . . . . . . . . . . . . . . 13A-507
vehicles for Morocco> . . . . . . . . . . . . . . . . . 13A-422 A/C SWITCH SYSTEM . . . . . . . . . . . . . . . . 13A-509
CODE NO. U1109 ETACS TIME-OUT . . . . 13A-424 A/C COMPRESSOR RELAY SYSTEM . . . . 13A-512
CODE NO. U1110 A/C-ECU TIME-OUT <Euro5> POWER STEERING FLUID PRESSURE SWITCH
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-425 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-514
CODE NO. U1117 ETACS-ECU (IMMOBILIZER-ECU) GLOW SYSTEM <Except Euro5> . . . . . . . . 13A-520
TIME-OUT. . . . . . . . . . . . . . . . . . . . . . . . . . 13A-427 PTC HEATER RELAY SYSTEM . . . . . . . . . 13A-525
CODE NO. U1190 THE NETWORK SYSTEM BLOWER SWITCH SYSTEM <Euro5> . . . . 13A-528
DIAGNOSIS CODE OUTPUT PERMITTED SIGNAL
REAR WINDOW DEFOGGER SYSTEM <Euro5>
CANNOT BE RECEIVED . . . . . . . . . . . . . . 13A-428
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-533
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 13A-429
DPF LAMP SYSTEM <Euro5> . . . . . . . . . . 13A-537
CHECK CHART CLASSIFIED BY PROBLEM
DATA LIST REFERENCE TABLE . . . . . . . . 13A-542
SYMPTOMS . . . . . . . . . . . . . . . . . . . . . . . . 13A-432
ACTUATOR TEST REFERENCE TABLE . . 13A-574
SYMPTOM PROCEDURES . . . . . . . . . . . . 13A-433
CHECK AT THE ENGINE-ECU TERMINALS
COMMUNICATION WITH ENGINE-ECU IS NOT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-576
POSSIBLE . . . . . . . . . . . . . . . . . . . . . . . . . 13A-433
INSPECTION PROCEDURE USING AN
THE ENGINE WARNING LAMP DOES NOT
OSCILLOSCOPE . . . . . . . . . . . . . . . . . . . . 13A-586
ILLUMINATE RIGHT AFTER THE IGNITION SWITCH
IS TURNED TO THE "ON" POSITION . . . . 13A-438
THE ENGINE WARNING LAMP REMAINS ON-VEHICLE SERVICE . . . . . . . . . . . 13A-589
ILLUMINATING AND NEVER GOES OUT OR IS EVACUATION OF WATER FROM FUEL FILTER
BLINKING . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-441 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-589
STARTING IMPOSSIBLE (NO INITIAL FUEL LINE AIR-BLEEDING . . . . . . . . . . . . 13A-589
COMBUSTION) <M/T> . . . . . . . . . . . . . . . . 13A-445 FUEL FILTER CARTRIDGE REPLACEMENT
STARTING IMPOSSIBLE (NO INITIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-589
COMBUSTION) <A/T> . . . . . . . . . . . . . . . . 13A-453 FUEL LINE LEAK CHECK. . . . . . . . . . . . . . 13A-590
STARTING IMPOSSIBLE (STARTER OPERATIVE COMPONENT LOCATION . . . . . . . . . . . . . 13A-591
BUT NO INITIAL COMBUSTION). . . . . . . . 13A-462
ENGINE CONTROL RELAY CONTINUITY CHECK
IMPROPER STARTING (LONG TIME TO START) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-594
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-464
ENGINE COOLANT TEMPERATURE SENSOR
IMPROPER IDLING . . . . . . . . . . . . . . . . . . 13A-466 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-594
THE ENGINE STALLS WHEN DECELERATING INJECTOR CHECK . . . . . . . . . . . . . . . . . . . 13A-595
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-468
INTAKE AIR TEMPERATURE SENSOR NO.1 CHECK
POOR ACCELERATION. . . . . . . . . . . . . . . 13A-471 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-595
A LARGE AMOUNT OF FUEL CONSUMPTION INTAKE AIR TEMPERATURE SENSOR NO.2 CHECK
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-473 <Except Euro5> . . . . . . . . . . . . . . . . . . . . . . 13A-595
KNOCKING, ABNORMAL NOISE. . . . . . . . 13A-475 SUCTION CONTROL VALVE CHECK . . . . 13A-596
WHITE SMOKE. . . . . . . . . . . . . . . . . . . . . . 13A-477 FUEL TEMPERATURE SENSOR CHECK . 13A-596
BLACK SMOKE . . . . . . . . . . . . . . . . . . . . . 13A-479 COMMON RAIL CHECK . . . . . . . . . . . . . . . 13A-596
BATTERY RUNDOWN <Euro5>. . . . . . . . . 13A-481 THROTTLE VALVE CONTROL SERVO CHECK
BATTERY RUNDOWN <Except Euro5>. . . 13A-486 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-596
OVERHEATING . . . . . . . . . . . . . . . . . . . . . 13A-487
ENGINE-ECU POWER SUPPLY SYSTEM 13A-488 FUEL INJECTOR . . . . . . . . . . . . . . . . 13A-598
ENGINE-ECU BATTERY BACK-UP SYSTEM FUEL INJECTOR REMOVAL AND INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-493 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-598
1ST AND 2ND RAIL SWITCH SYSTEM <M/T>
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-497 COMMON RAIL AND SUPPLY PUMP13A-604
BACK-UP LAMP SWITCH SYSTEM <M/T> 13A-501 COMMON RAIL AND SUPPLY PUMP REMOVAL AND
13A-5
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 13A-604 CAMSHAFT POSITION SENSOR . . . 13A-613

CAMSHAFT POSITION SENSOR REMOVAL AND
SUCTION CONTROL VALVE . . . . . . 13A-610 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 13A-613
SUCTION CONTROL VALVE REMOVAL AND
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 13A-610 CRANK ANGLE SENSOR . . . . . . . . . 13A-613
CRANK ANGLE SENSOR REMOVAL AND
THROTTLE BODY ASSEMBLY . . . . 13A-612 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 13A-613
THROTTLE BODY ASSEMBLY REMOVAL AND
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 13A-612 ENGINE-ECU . . . . . . . . . . . . . . . . . . . 13A-614
ENGINE-ECU REMOVAL AND INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-614
13A-6 DIESEL FUEL
GENERAL INFORMATION
GENERAL INFORMATION
M1133000101089
The common rail fuel injection system consists of ECU. The engine-ECU carries out activities such as
sensors which detect the condition of the diesel fuel injection control and idle speed control. In addi-
engine, an engine electronic control unit (engine- tion, the engine-ECU is equipped with several self-
ECU) which controls the system based on signals diagnosis functions which make troubleshooting eas-
from these sensors, and actuators which operate ier in the event that a problem develops.
according to control commands from the engine-
FUEL INJECTION CONTROL
The injector drive time, the injection timing and the
fuel pressure are controlled so that the appropriate
quantities of fuel are supplied to the engine in
response to engine conditions which can change fre-
quently. A single injector is mounted at each cylinder.
The supply pump increases the fuel pressure to the
pressure which is required for high-pressure injec-
tion, and then send the fuel each injector.
IDLE SPEED CONTROL

The idle speed is kept at the optimum speed by con- The engine-ECU drives the fuel injector to keep the
trolling the fuel injection quantity in accordance with engine running at the pre-set idle target speed in
changes in idling conditions and engine load during accordance with the engine coolant temperature and
idling. A/C and other electrical load.
SELF-DIAGNOSIS FUNCTION
• When an abnormality is detected in any of the • The RAM data relating to the sensors and actua-
sensors or actuators, the engine warning lamp tors which is stored in the engine-ECU can be
illuminates to warn the driver. read using the M.U.T.-III. In addition, the actuator
• When an abnormality is detected in any of the can be force-driven under certain conditions.
sensors or actuators, a diagnosis code number
corresponding to the problem which occurred is
output.
OTHER CONTROL FUNCTIONS

1. Power Supply Control Controls the condenser fan motor relay based on the
When the ignition switch ON signal is input by the A/C switch, A/C load signal, engine coolant tem-
ignition switch, the engine-ECU turns ON the perature and vehicle speed input signals.
power transistor for controlling the engine control 6. PTC Heater Relay Control <Vehicle with PTC
relay. As a result, current flows through the coil in heater>
the engine control relay, causing the relay switch The PTC heater is turned ON is accordance with the
to turn ON and supply power to the sensors and A/C operation at the engine cold state.
actuators. 7. DPF System Control <Euro5>
2. Glow Control [Refer to GROUP 17 − Emission Control − Diesel
Refer to GROUP 16 Particulate Filter (DPF) System <Euro5> − Gen-
(Refer to , GROUP 16 − Glow System). eral Information (DPF system) ].
3. EGR Control 8. Variable Geometry Turbocharger Control
Refer to GROUP 17 <Euro5>
[Refer to , GROUP 17 − Engine And Emission Con- Performing the duty control over the variable geome-
trol − Exhaust Gas Recirculation (EGR) System]. try control solenoid valve, the engine-ECU opens
4. A/C Relay Control and closes the nozzle vane located in the turbo-
Turns the compressor clutch of the A/C ON and OFF. charger assembly. This allows the boost pressure
5. Condenser Fan Motor Relay Control to be obtained in accordance with the engine
operation.
9. Alternator Output Current Control <Euro5>
DIESEL FUEL
GENERAL INFORMATION
13A-7
Prevents the alternator output current from increas-
ing suddenly and the idle speed from varying
such as when the headlamp is turned on.
13A-8 DIESEL FUEL
GENERAL INFORMATION
FUEL INJECTION SYSTEM DIAGRAM

<Euro5>
1 Air flow sensor Accelerator pedal Engine- 1 Suction control Engine control relay
2 Crank angle sensor position sensor ECU valve A/C relay
3 Camshaft position (main) Barometric 2 Throttle valve
pressure Condenser fan relay
sensor Accelerator pedal control servo
sensor (DC motor) Glow control unit
4 Engine coolant position sensor
(sub) 3 Injector PTC heater relay
temperature sensor <Vehicles with
5 Rail pressure sensor Power steering 4 EGR valve PTC heater>
fluid pressure (DC motor)
6 Intake air temperature switch Glow indicator lamp
sensor No. 1 5 Variable geometry
Vehicle speed sensor control solenoid Engine warning lamp
7 EGR gas temperature valve
sensor Power supply Tachometer
8 Manifold absolute Ignition switch-IG Alternator G terminal
pressure sensor Ignition switch-ST CAN communication
9 Fuel temperature (output signal)
A/C switch
sensor
10 Throttle position A/C load signal
sensor Back-up lamp
11 EGR valve switch <M/T>
position sensor 1st and 2nd rail switch
12 No. 1 exhaust gas <M/T>
temperature sensor 4LLC switch <M/T>
13 No. 2 exhaust gas PTC heater control
temperature sensor signal <Vehicles
(catalyst temperature) with PTC heater>
14 No. 3 exhaust gas Battery current sensor
temperature sensor Battery temperature
(DPF temperature) sensor
15 Exhaust differential Glow diagnosis signal 10 Throttle position sensor
pressure sensor
CAN communication 2 Throttle valve control servo (DC motor)
(input signal)
8 Manifold absolute pressure sensor
11 EGR valve position sensor
1 Air flow sensor 4 EGR valve (DC motor)
Air 6 Intake air temperature
sensor No. 1
7 EGR gas temperature
sensor
5 Rail pressure sensor

To brake system
To fuel tank
5 Variable geometry 3 Camshaft
control solenoid valve position Supply
sensor pump
3 Injector
Variable geometry
actuator 9 Fuel
temperature
sensor
4 Engine coolant
temperature sensor 1 Suction control
valve
Catalytic 2 Crank angle sensor
converter
12
No. 1 exhaust
gas temperature Catalytic From fuel
sensor DPF
converter 15 Exhaust differential pressure sensor Fuel filter tank
13
No. 2 exhaust gas 14 No. 3 exhaust gas temperature sensor
temperature sensor (catalyst temperature) (DPF temperature) AKB00240 AB
DIESEL FUEL
GENERAL INFORMATION
13A-9
<Except Euro5>
1 Air flow sensor Accelerator pedal Engine- 1 Suction control Engine control relay
position sensor ECU valve
2 Crank angle sensor (main) A/C relay
3 Camshaft position Barometric 2 Throttle valve Glow plug relay
Accelerator pedal pressure control servo
sensor position sensor PTC heater relay
sensor (DC motor)
4 Engine coolant (sub) <Vehicles with PTC
temperature sensor Power steering fluid 3 Injector heater>
5 Rail pressure sensor pressure switch 4 EGR valve Glow indicator lamp
6 Intake air temperature Vehicle speed (DC motor) Engine warning lamp
sensor No. 1 sensor Tachometer
7 Intake air temperature Power supply CAN communication
sensor No. 2 Ignition switch-IG (output signal)
8 Manifold absolute Ignition switch-ST
pressure sensor A/C switch
9 Fuel temperature A/C load signal
sensor Back-up switch
10 Throttle postion <M/T>
sensor 1st and 2nd rail
11 EGR valve position switch <M/T>
sensor PTC heater control
12 Fuel filter pressure signal <Vehicles
switch with PTC heater>
<Vehicles for Russia CAN
and Morocco> communication
(input signal)
7 Intake air temperature sensor No. 2

10 Throttle position sensor
2 Throttle valve control servo (DC motor)
11 EGR valve position sensor
1 Air flow sensor 4 EGR valve (DC motor)
6 Intake air temperature
Air sensor No. 1
8 Manifold absolute
pressure sensor
5 Rail pressure sensor

To brake system
To fuel tank
3 Camshaft
position
sensor Supply
pump
Turbocharger 3 Injector
9 Fuel
temperature
4 Engine coolant sensor
temperature sensor 1 Suction control
2 Crank angle sensor valve
Catalytic
Waste gate converter
actuator
12 Fuel filter pressure switch From fuel
<Vehicles for Russia and Morocco> Fuel filter tank
AKB00239AB
13A-10 DIESEL FUEL
M1133000300488
Items Specifications
Engine coolant temperature Engine coolant temperature at − 14 − 17
sensor resistance kΩ 20°C
Engine coolant temperature at 5.1 − 6.5
0°C
20°C
40°C
60°C
80°C
Intake air temperature sensor Intake air temperature at −20°C 13 − 17
No.1 resistance kΩ Intake air temperature at 0°C 5.4 − 6.6
Intake air temperature at 20°C 2.3 − 3.0
Intake air temperature sensor Intake air temperature at −20°C 13 − 18
No.2 resistance kΩ <Except Intake air temperature at 0°C 5.1 − 6.9
Euro5>
Injector coil resistance Ω (at 20°C) Approximately 0.45
Suction control valve resistance Ω (at 20°C) Approximately 2.1
Fuel temperature resistance kΩ (at 20°C) 2.0 − 3.0
Throttle valve control servo resistance (at 20°C) Ω 0.3 − 100
SEALANTS
M1133000500385

Engine coolant temperature sensor threaded portion 3M Nut Locking Part No. 4171 or equivalent
Semi-circular packing Three bond 1212D, Three bond 1217G (Mitsubishi
Cylinder head Part No. 1000A923) or equivalent
DIESEL FUEL
SPECIAL TOOLS
13A-11
SPECIAL TOOLS
M1133000600746

a a: MB991824 a: Vehicle communication For vehicles with CAN
b: MB991827 interface (V.C.I.) communication, use M.U.T.-III
c: MB991910 b: M.U.T.-III USB cable main harness A to send
d: MB991911 c: M.U.T.-III main harness simulated vehicle speed. If
MB991824 e: MB991825 A (Vehicles with CAN you connect M.U.T.-III main
d: M.U.T.-III main harness communication does not
B (Vehicles without CAN function correctly.
communication system) • Reading diagnosis code
MB991827 e: M.U.T.-III adapter • Diesel system inspection
harness • Measurement of fuel
c
f: M.U.T.-III trigger harness pressure
• Fuel line leak check
MB991910
DO NOT USE
MB991911
MB991825
MB991826
MB991955
MB991658 Test harness • Measurement of voltage

during troubleshooting
• Inspection using an
oscilloscope
MB991658
MB991709 Test harness • Measurement of voltage

during Troubleshooting
• Inspection using an
oscilloscope
13A-12 DIESEL FUEL
TROUBLESHOOTING

MB992188 Fuel injection pipe wrench Removal and installation of fuel
injection pipe
MB992042 Engine coolant Removal and installation of the

temperature sensor wrench engine coolant temperature
sensor
MB992042
MB990784 Ornament remover Carbon deposit cleaning
MB990784
MB991614 Angle gauge Installation of injector holder bolt
MB991614
MB992048 Sprocket holder Injection pump sprocket bolt

removal and installation
B992048
MB992098 Injection pump sprocket Injection pump sprocket removal

puller
B992098
MB992099 Crank pulley puller
B992099
TROUBLESHOOTING
DIAGNOSIS TROUBLESHOOTING FLOW
M1133003700430
Refer to , GROUP 00 − How to Use Troubleshooting/ shooting.
Inspection Service Points − Contents of Trouble-
DIESEL FUEL
TROUBLESHOOTING
13A-13
WARNING DIAGNOSIS FUNCTION
M1133003800954
A high-tension voltage is flowing between
the engine-ECU and the injectors while the ENGINE WARNING LAMP (CHECK
engine is running. Handle them carefully to ENGINE LAMP)
avoid receiving electric shocks from the volt-
age.
CAUTION
After replacing the engine-ECU, register the Engine warning lamp
injector identification code and learn fuel injec-
20engine lamp)
(Check
tion. (Refer to GROUP 00 − Precautions Before

Service − What The Common Rail Engine Learns
)
CAUTION
AK500611 AB
After replacing the injector, register the injector
identification code and learn fuel injection. (Refer When the abnormal condition occurs with respect to
to GROUP 00 − Precautions Before Service − the items of electronically controlled fuel injection
What The Common Rail Engine Learns ). system shown in the table, the engine warning lamp
is illuminated. When the lamp remains illuminated
CAUTION
after the engine start, or when the lamp is illuminated
After replacing the supply pump, learn the supply
while the engine is running, check the diagnosis
pump. (Refer to GROUP 00 − Precautions Before
code output. There are two methods for checking the
Service − What The Common Rail Engine Learns
indicator lamp burn out: When the ignition switch is in
).
ON position, the indicator lamp is illuminated, and
CAUTION then extinguished few seconds later. When the igni-
The vehicle equipped with the DPF shall initialize tion switch is in ON position and the engine starts,
the learning value after the following parts are the indicator lamp is extinguished.
replaced (Refer to GROUP 00 − Precautions
Before Service − Initialization Procedure for
Learning Value in Diesel Particulate Filter (DPF)
System <Euro5> ).
• DPF
• Exhaust differential pressure sensor
• Catalytic converter
• Engine oil
ENGINE WARNING LAMP INSPECTION ITEMS

CAUTION
The engine warning lamp continuously illuminates when the engine-ECU malfunctions.
Code No. Diagnosis item

− Engine-ECU
P0003* Suction control valve open <Euro5>
P0004* Suction control valve battery short <Euro5>
P0016* Crank angle sensor/camshaft position sensor phase problem
P0047* Variable geometry control solenoid valve circuit low input <Euro5>
P0048* Variable geometry control solenoid valve circuit high input <Euro5>
P0072 Intake air temperature sensor No.1 circuit low input <Euro5>
P0072 Intake air temperature sensor No. 2 circuit low input <Except Euro5>
P0073 Intake air temperature sensor No.1 circuit high input <Euro5>
13A-14 DIESEL FUEL
TROUBLESHOOTING

P0073 Intake air temperature sensor No. 2 circuit high input <Except Euro5>
P0088* Common rail pressure malfunction
P0089* Suction control valve stuck
P0093* Fuel leak problem
P0102 Air flow sensor circuit low input
P0103 Air flow sensor circuit high input
P0106* Manifold absolute pressure sensor range/performance problem
P0107* Manifold absolute pressure sensor circuit low input
P0108* Manifold absolute pressure sensor circuit high input
P0112 EGR gas temperature sensor circuit low input <Euro5>
P0112 Intake air temperature sensor No. 1 circuit low input <Except Euro5>
P0113 EGR gas temperature sensor circuit high input <Euro5>
P0113 Intake air temperature sensor No. 1 circuit high input <Except Euro5>
P0117 Engine coolant temperature sensor circuit low input
P0118 Engine coolant temperature sensor circuit high input
P0122 Throttle position sensor circuit low input
P0123 Throttle position sensor circuit high input
P0182 Fuel temperature sensor circuit low input
P0183 Fuel temperature sensor circuit high input
P0191* Rail pressure sensor range/performance problem
P0192* Rail pressure sensor low input
P0193* Rail pressure sensor high input
P0201* No. 1 Injector circuit malfunction
P0234* Turbocharger overboost condition <Except Euro5>
P0299* Turbocharger under boost condition
P0301* No. 1 cylinder injector malfunction (No injection)
P0335* Crank angle sensor system
P0336* Crank angle sensor range/performance problem
P0340* Camshaft position sensor system
P0341* Camshaft position sensor range/performance problem
P0381 Glow plug open/short malfunction <Euro5>
P0401 EGR flow insufficient <Euro5>
P0403 EGR valve (DC motor) malfunction
P0405 EGR valve position sensor circuit low input <Except Euro5>
DIESEL FUEL
TROUBLESHOOTING
13A-15
P0406 EGR valve position sensor circuit high input <Except Euro5>
P0420* Catalyst malfunction <Euro5>
P0427* No. 2 exhaust gas temperature sensor (catalyst temperature) circuit low input <Euro5>
P0428* No. 2 exhaust gas temperature sensor (catalyst temperature) circuit high input <Euro5>
P0489 EGR valve position sensor circuit low input <Euro5>
P0490 EGR valve position sensor circuit high input <Euro5>
P0502 Vehicle speed sensor low input
P0513* Immobilizer malfunction
P0545* No. 1 exhaust gas temperature sensor circuit low input <Euro5>
P0546* No. 1 exhaust gas temperature sensor circuit high input <Euro5>
P0551 Power steering fluid pressure switch system
P0603 EEPROM malfunction <Except Euro5>
P0604 Random access memory (RAM) malfunction
P0605* Read only memory (FLASH ROM) malfunction
P0606* Engine-ECU (main CPU) malfunction
P0607* Engine-ECU (sub CPU) malfunction
P0628* Suction control valve open <Except Euro5>
P0629* Suction control valve battery short <Except Euro5>
P062F EEPROM malfunction <Euro5>
P0630* Chassis number not programmed
P0638 Throttle valve control servo stuck
P0642* Analog sensor reference voltage No. 1 too low
P0643* Analog sensor reference voltage No. 1 too high
P064C Glow control unit malfunction <Euro5>
P0652* Analog sensor reference voltage No. 2 too low
P0653* Analog sensor reference voltage No. 2 too high
P0683 Glow control unit communication abnormality <Euro5>
P1203* Capacitor insufficient charging
P1204* Capacitor excessive charging
P1272 Pressure limiter malfunction
P1273* Supply pump insufficient flow
P1274* Supply pump protection
P1275* Supply pump exchange
P1276 Fuel filter exchange <Except Euro5>
P1298* Variable geometry turbocharger control system malfunction (high pressure)
<Euro5>
P1299* Variable geometry turbocharger control system malfunction (low pressure)
<Euro5>
P1427* No. 3 exhaust gas temperature sensor (DPF temperature) circuit low input <Euro5>
P1428* No. 3 exhaust gas temperature sensor (DPF temperature) circuit high input <Euro5>
P1497* DPF system malfunction <Euro5>
13A-16 DIESEL FUEL
TROUBLESHOOTING

P1498* Excessive PM accumulated in DPF <Euro5>
P1499* Abnormally high DPF temperature <Euro5>
P1608* Battery current sensor system <Euro5>
P1625* Injection quantity compensation valve error
P1626* Injection quantity compensation valve not coding
P2118 Throttle valve control (DC motor) current malfunction
P2122* Accelerator pedal position sensor (main) circuit low input
P2123* Accelerator pedal position sensor (main) circuit high input
P2127* Accelerator pedal position sensor (sub) circuit low input
P2128* Accelerator pedal position sensor (sub) circuit high input
P2138* Accelerator pedal position sensor (main and sub) range/performance problem
P2146* Injector common 1 (cylinder No. 1 and No. 4) circuit open
P2147* Injector common circuit earth short
P2148* Injector common circuit battery short
P2149* Injector common 2 (cylinder No. 2 and No. 3) circuit open
P2150* Injector common 2 circuit earth short <Euro5>
P2151* Injector common 2 circuit battery short <Euro5>
P2228 Barometric pressure sensor circuit low input
P2229 Barometric pressure sensor circuit high input
P2413 EGR system performance
P2454* Exhaust differential pressure sensor circuit low input <Euro5>
P2455* Exhaust differential pressure sensor circuit high input <Euro5>
NOTE: .
• After the engine-ECU has detected a malfunction, the engine warning lamp illuminates when the engine is
next turned on and the same malfunction is re-detected. However, for items marked with a "*" in the diag-
nosis code number column, the engine warning lamp illuminates only on the first detection of the malfunc-
tion.
• When the fuel runs out, the engine warning lamp would illuminate possibly. Supplying the fuel turns off the
engine warning lamp, but the diagnosis code No. P1272 and P1273 are stored.
METHOD OF READING AND ERASING 2. After repairing, re-check using the M.U.T.-III and
DIAGNOSIS CODES check that the abnormal input and output have
Refer to , GROUP 00 − How to Use Troubleshooting/ returned to normal as a result of the repairs.
Inspection Service Points − How to Cope with Inter- 3. Erase the diagnosis code memory.
mittent Malfunctions. 4. Remove the M.U.T.-III, and then start the engine
again and carry out a road test to confirm that the
INSPECTION USING M.U.T.-III DATA LIST problem has disappeared.
AND ACTUATOR TESTING
1. Carry out inspection by means of the data list and
the actuator test function, if there is an
abnormality, check and repair the chassis harness
and components.
DIESEL FUEL
TROUBLESHOOTING
13A-17
PROVISIONAL DIAGNOSIS CODE CON- 2. Turn the ignition switch to the "ON" position.
FIRMED 3. Select "MPI/GDI/DIESEL" from System select
If detecting the malfunction during the first drive Screen of the M.U.T.-III.
cycle, the engine-ECU temporarily stores the diagno- 4. Select "Special Function" from MPI/GDI/DIESEL
sis code as the provisional diagnosis code. If detect- Screen.
ing the same malfunction during the next drive cycle, 5. Select "Provisional DTCs" from Special Function
the engine-ECU determines that the malfunction Screen.
exists. The engine-ECU outputs the diagnosis code.
On the M.U.T.-III it is possible to display the stored FREEZE FRAME DATA
provisional diagnosis code which the engine-ECU When the engine-ECU detects a malfunction and
had detected during the first drive cycle. This makes stores a diagnosis code, it also stores a current sta-
it possible to confirm in one drive cycle whether the tus of the engine. This function is called "Freeze
malfunction could happen again after the repair. frame data". By analyzing this "Freeze frame" data
CONFIRMATION METHOD with the M.U.T.-III, an effective troubleshooting can
1. After the ignition switch is in "LOCK" (OFF) be performed.
position, connect the M.U.T.-III to the diagnosis The display items of freeze frame data are shown
connector. below.
DISPLAY ITEM LIST

Item No. Data Unit
2 Ignition cycle −
4 Accumulated minute *1 min
500*2 Air flow sensor g/s
501*2 Throttle position sensor (main) %
507*2 Target exhaust gas recirculation valve %
508*2 Barometric pressure sensor kPa
509*2 Relative throttle position sensor %
511*2 Accelerator pedal position sensor (main) %
512*2 Accelerator pedal position sensor (sub) %
516*2 Engine coolant temperature sensor °C

525*2 Manifold absolute pressure sensor kPa
526*2 Crank angle sensor r/min
527*2 Vehicle speed km/h
529*2 Intake air temperature sensor °C

530*2 Time since engine running*3 sec
537*2 Power supply voltage V
541*2 Throttle valve control servo %
560*2 Rail pressure sensor kPa
573*2 Exhaust gas recirculation error %

NOTE: *1: Accumulated time of current malfunction from time point when malfunction is detected.
NOTE: *2: The items of Freeze Frame Data can be seen by selecting "Freeze Frame Data (OBD)" on "Self-
diagnosis" screen of M.U.T.-III. When system malfunctions are detected, the first detected malfunction data
only is stored.
13A-18 DIESEL FUEL
TROUBLESHOOTING
NOTE: *3: Time between engine start and malfunction detection.
FAIL-SAFE FUNCTION REFERENCE TABLE

When the diagnostic function detects a sensor or actuator fault or an abnormality in the control condition, the
vehicle is controlled by means of the pre-set control logic to maintain safe conditions for driving.
Malfunctioning item Control contents during malfunction

Accelerator pedal position • The accelerator pedal opening is controlled as 0%.
sensor • Idle rotations are 1,300 r/min (both main and sub are faulty or have a
characteristic error).
Accelerator pedal position The amount of depression of the accelerator pedal is detected with using the
sensor (main) accelerator pedal position sensor (sub) signal, which is calculated by taking
half of the normal value.
Accelerator pedal position The amount of depression of the accelerator pedal is detected with using the
sensor (sub) accelerator pedal position sensor (main) signal, which is calculated by taking
half of the normal value.
Throttle position sensor Power to the throttle valve control servo is interrupted.
Crank angle sensor The engine is stopped (fuel injection and pump pressure feed are stopped).
Camshaft position sensor • Rail pressure is controlled in the range from 50 to 100 MPa.
• Fuel injection is restricted (output restriction).
• The open angle of the accelerator pedal is controlled.
• The engine is stopped when a characteristic error of the crank angle
sensor occurs (fuel injection and pump pressure feed are stopped).
Engine coolant temperature • Engine coolant temperature is controlled as 80 °C (−25 °C at startup).
sensor • EGR control is stopped (fully closed).
Rail pressure sensor • Rail pressure is controlled in the range from 50 to 100 MPa.
• The throttle valve is shut (opening fixed)
• EGR control is stopped (fully closed).
Fuel temperature sensor Fuel temperature is controlled as 45 °C (−25 °C at startup).
Air flow sensor • EGR control is stopped (fully closed).
• Control is performed using the previous value.
Manifold absolute pressure • Manifold absolute pressure is controlled as 100 kPa.
sensor • EGR control is stopped (fully closed).
Barometric pressure sensor • Barometric pressure is controlled as 100 kPa.
Intake air temperature • Intake air temperature is controlled as 50 °C.
sensor No. 1 • EGR control is stopped (fully closed).
Intake air temperature • Intake air temperature is controlled as 50 °C.
sensor No. 2 <Except • EGR control is stopped (fully closed).
Euro5>
EGR valve position sensor EGR control is stopped (fully closed).
No. 1 exhaust gas • The throttle valve is shut (fully closed).
temperature sensor <Euro5> • Exhaust gas recirculation control is stopped (fully closed).
• DPF regeneration prohibited
temperature sensor (catalyst • Exhaust gas recirculation control is stopped (fully closed).
temperature) <Euro5> • DPF regeneration prohibited
DIESEL FUEL
TROUBLESHOOTING
13A-19
temperature sensor (DPF • Exhaust gas recirculation control is stopped (fully closed).
temperature) <Euro5> • DPF regeneration prohibited
Exhaust differential pressure • The throttle valve is shut (fully closed).
sensor <Euro5> • Exhaust gas recirculation control is stopped (fully closed).
• DPF regeneration prohibited
Injector EGR control is stopped (fully closed).
Suction control valve • Rail pressure is controlled in the range from 50 to 100 MPa.
EGR valve (DC motor) EGR control is stopped (fully closed).
Throttle valve control servo Power to the throttle valve control servo is interrupted.
Rail pressure too high • The throttle valve is shut (opening fixed)
• The engine is stopped (fuel injection and pump pressure feed are
stopped).
Fuel leak The engine is stopped (fuel injection and pump pressure feed are stopped).
Engine overrun • The throttle valve is shut (opening fixed)
• The engine is stopped (fuel injection and pump pressure feed are
stopped).
Boost pressure too high • Fuel injection is restricted (output restriction).
Engine-ECU (RAM error) The engine is stopped (fuel injection and pump pressure feed are stopped).
Engine-ECU (sensor power • The accelerator pedal opening is controlled as 0%.
error) • Idle rotations are 1,300 r/min.
Engine-ECU (flash ROM • Rail pressure is controlled in the range from 50 to 100 MPa.
error, CPU error) • Fuel injection is restricted (output restriction).
Engine-ECU (insufficient • Rail pressure is controlled in the range from 50 to 100 MPa.
charging of capacitor for • Fuel injection is restricted (output restriction).
injector) • The open angle of the accelerator pedal is controlled.
Engine-ECU (excessive The engine is stopped. (The fuel injection and pump delivery pressure are
charging of capacitor for stopped).
injector)
Injector drive circuit error The engine is stopped. (The fuel injection and pump delivery pressure are
stopped).
Pressure limiter open valve • Rail pressure is controlled in the range from 50 to 100 MPa.
error • Fuel injection is restricted (output restriction).
13A-20 DIESEL FUEL
TROUBLESHOOTING

Supply pump error • Rail pressure is controlled in the range from 50 to 60 MPa
• A/C is cut <Except the driving condition that the fuel pressure exceeds the
seizure resistance>
• The throttle valve is shut (fully closed) <Except the driving condition that
the fuel pressure exceeds the seizure resistance>
• Exhaust gas recirculation control is stopped (fully closed).
• When the burn-in limit is exceeded, the engine is stopped gradually
Injector correction data • Rail pressure is controlled in the range from 50 to 100 MPa.
(Error data, unwritten) • Fuel injection is restricted (output restriction).
Variable geometry control • Rail pressure is controlled in the range from 50 to 100 MPa. <Except
solenoid valve error <Euro5> when the malfunction of battery short circuit exists>
• Fuel injection is restricted (output restriction). <Except when the
malfunction of battery short circuit exists>
• The open angle of the accelerator pedal is controlled. <Except when the
malfunction of battery short circuit exists>
• The throttle valve is shut (fully closed).
Catalytic converter <Euro5> • The throttle valve is shut (fully closed).
• DPF regeneration prohibited.
DPF <Euro5> • The throttle valve is shut (fully closed).
• DPF regeneration prohibited.
INSPECTION CHART FOR DIAGNOSIS

CODES
M1133004000962
Diagnosis Diagnosis item Reference page

code No.
P0003 Suction control valve open <Euro5> P.13A-26
P0004 Suction control valve battery short <Euro5> P.13A-29
P0016 Crank angle sensor/camshaft position sensor phase problem P.13A-32
P0047 Variable geometry control solenoid valve circuit low input <Euro5> P.13A-48
P0048 Variable geometry control solenoid valve circuit high input <Euro5> P.13A-57
P0072 Intake air temperature sensor No. 1 circuit low input <Euro5> P.13A-43
P0072 Intake air temperature sensor No. 2 circuit low input <Except Euro5> P.13A-48
P0073 Intake air temperature sensor No. 1 circuit high input <Euro5> P.13A-53
P0073 Intake air temperature sensor No. 2 circuit high input <Except Euro5> P.13A-57
P0088 Common rail high pressure malfunction P.13A-60
P0089 Suction control valve stuck P.13A-63
DIESEL FUEL
TROUBLESHOOTING
13A-21
code No.
P0093 Fuel leak problem P.13A-64
P0102 Air flow sensor circuit low input P.13A-68
P0103 Air flow sensor circuit high input P.13A-75
P0106 Manifold absolute pressure sensor range/performance problem P.13A-78
P0107 Manifold absolute pressure sensor circuit low input P.13A-83
P0108 Manifold absolute pressure sensor circuit high input P.13A-91
P0112 EGR gas temperature sensor circuit low input <Euro5> P.13A-94
P0112 Intake air temperature sensor No. 1 circuit low input <Except Euro5> P.13A-99
P0113 EGR gas temperature sensor circuit high input <Euro5> P.13A-104
P0113 Intake air temperature sensor No. 1 circuit high input <Except Euro5> P.13A-109
P0117 Engine coolant temperature sensor circuit low input P.13A-113
P0118 Engine coolant temperature sensor circuit high input P.13A-119
P0122 Throttle position sensor circuit low input P.13A-124
P0123 Throttle position sensor circuit high input P.13A-131
P0182 Fuel temperature sensor circuit low input P.13A-134
P0183 Fuel temperature sensor circuit high input P.13A-139
P0191 Rail pressure sensor range/performance problem P.13A-143
P0192 Rail pressure sensor circuit low input P.13A-147
P0193 Rail pressure sensor circuit high input P.13A-155
P0201 No. 1 injector circuit malfunction P.13A-158
P0202 No. 2 injector circuit malfunction <Euro5> P.13A-161
P0202 No. 2 injector circuit malfunction <Except Euro5> P.13A-164
P0219 Engine overspeed condition P.13A-178
P0234 Turbocharger overboost condition <Except Euro5> P.13A-179
P0299 Turbocharger under boost condition P.13A-180
P0301 No. 1 Cylinder injector malfunction (No injection) P.13A-180
P0335 Crank angle sensor system P.13A-184
P0336 Crank angle sensor range/performance problem P.13A-190
P0340 Camshaft position sensor system P.13A-192
13A-22 DIESEL FUEL
TROUBLESHOOTING

code No.
P0341 Camshaft position sensor range/performance problem P.13A-198
P0381 Glow plug open/short malfunction <Euro5> P.13A-200
P0401 EGR flow insufficient <Euro5> P.13A-204
P0402 EGR flow excessive <Euro5> P.13A-209
P0403 EGR valve (DC motor) malfunction P.13A-215
P0405 EGR valve position sensor circuit low input <Except Euro5> P.13A-219
P0406 EGR valve position sensor circuit high input <Except Euro5> P.13A-227
P0420 Catalyst malfunction <Euro5> P.13A-229
P0427 No. 2 exhaust gas temperature sensor (catalyst temperature) circuit P.13A-231
low input <Euro5>
P0428 No. 2 exhaust gas temperature sensor (catalyst temperature) circuit P.13A-234
high input <Euro5>
P0489 EGR valve position sensor circuit low input <Euro5> P.13A-240
P0490 EGR valve position sensor circuit high input <Euro5> P.13A-248
P0502 Vehicle speed sensor low input <2WD-M/T and 4WD vehicles> P.13A-251
P0513 Immobilizer malfunction P.13A-254
P0515 Battery temperature sensor system <Euro5> P.13A-255
P0545 No. 1 exhaust gas temperature sensor circuit low input <Euro5> P.13A-260
P0546 No. 1 exhaust gas temperature sensor circuit high input <Euro5> P.13A-263
P0551 Power steering fluid pressure switch system P.13A-268
P0603 EEPROM malfunction <Except Euro5> P.13A-270
P0604 Random access memory (RAM) malfunction P.13A-271
P0605 Read only memory (FLASH ROM) malfunction P.13A-271
P0606 Engine-ECU (main CPU) malfunction P.13A-272
P0607 Engine-ECU (sub CPU) malfunction P.13A-272
P0620 Alternator control circuit <Euro5> P.13A-273
P0628 Suction control valve open <Except Euro5> P.13A-276
P0629 Suction control valve battery short <Except Euro5> P.13A-279
P062F EEPROM malfunction <Euro5> P.13A-282
P0630 Chassis number not programmed P.13A-282
P0638 Throttle valve control servo stuck P.13A-284
P0642 Analog sensor reference voltage No. 1 too low P.13A-286
P0643 Analog sensor reference voltage No. 1 too high P.13A-287
P064C Glow control unit malfunction <Euro5> P.13A-288
P0652 Analog sensor reference voltage No. 2 too low P.13A-290
P0653 Analog sensor reference voltage No. 2 too high P.13A-291
P0683 Glow control unit communication abnormality <Euro5> P.13A-292
DIESEL FUEL
TROUBLESHOOTING
13A-23
code No.
P1203 Capacitor insufficient charging P.13A-296
P1204 Capacitor excessive charging P.13A-296
P1272 Pressure limiter malfunction P.13A-297
P1273 Supply pump insufficient flow P.13A-300
P1274 Supply pump protection P.13A-301
P1275 Supply pump exchange P.13A-302
P1276 Fuel filter exchange <Vehicles with fuel filter pressure switch> P.13A-304
P1277 Fuel filter freeze <Vehicles with fuel filter pressure switch> P.13A-307
P1298 Variable geometry turbocharger control system malfunction (high P.13A-327
pressure) <Euro5>
P1299 Variable geometry turbocharger control system malfunction (low P.13A-328
pressure) <Euro5>
P1427 No. 3 exhaust gas temperature sensor (DPF temperature) circuit low P.13A-310
input <Euro5>
P1428 No. 3 exhaust gas temperature sensor (DPF temperature) circuit P.13A-313
high input <Euro5>
P1497 DPF system malfunction <Euro5> P.13A-319
P1498 Excessive PM accumulated in DPF <Euro5> P.13A-320
P1499 Abnormally high DPF temperature <Euro5> P.13A-320
P1608 Battery current sensor system <Euro5> P.13A-322
P1625 Injection quantity compensation value error P.13A-327
P1626 Injection quantity compensation value not coding P.13A-328
P2118 Throttle valve control (DC motor) current malfunction P.13A-329
P2122 Accelerator pedal position sensor (main) circuit low input P.13A-333
P2123 Accelerator pedal position sensor (main) circuit high input P.13A-341
P2124 Accelerator pedal position sensor (main) circuit high input intermittent P.13A-345
P2127 Accelerator pedal position sensor (sub) circuit low input P.13A-349
P2128 Accelerator pedal position sensor (sub) circuit high input P.13A-357
P2138 Accelerator pedal position sensor (main and sub) range/performance P.13A-360
problem
P2146 Injector common 1 (cylinder No. 1 and No. 4) circuit open <Euro5> P.13A-368
P2146 Injector common 1 (cylinder No. 1 and No. 4) circuit open <Except P.13A-371
Euro5>
P2147 Injector common 1 (cylinder No. 1 and No. 4) circuit earth short P.13A-374
<Euro5>
P2147 Injector common circuit earth short <Except Euro5> P.13A-378
P2148 Injector common 1 (cylinder No. 1 and No. 4) circuit battery short P.13A-383
<Euro5>
P2148 Injector common circuit battery short <Except Euro5> P.13A-387
13A-24 DIESEL FUEL
TROUBLESHOOTING

code No.
P2149 Injector common 2 (cylinder No. 2 and No. 3) circuit open <Euro5> P.13A-392
P2149 Injector common 2 (cylinder No. 2 and No. 3) circuit open <Except P.13A-396
Euro5>
P2150 Injector common 2 circuit earth short <Euro5> P.13A-399
P2151 Injector common 2 circuit battery short <Euro5> P.13A-403
P2228 Barometric pressure sensor circuit low input P.13A-406
P2229 Barometric pressure sensor circuit high input P.13A-407
P2413 EGR system performance P.13A-408
P2454 Exhaust differential pressure sensor circuit low input <Euro5> P.13A-411
P2455 Exhaust differential pressure sensor circuit high input <Euro5> P.13A-417
P252F Engine oil level malfunction <Euro5> P.13A-419
U1073 Bus off P.13A-420
U1101* A/T-ECU time-out <A/T> P.13A-421
U1102* ASTC-ECU time-out <Except vehicles for Morocco> P.13A-422
U1109* ETACS-ECU time-out P.13A-424
U1110* A/C-ECU time-out <Euro5> P.13A-425
U1117* ETACS-ECU (Immobilizer- ECU) time-out P.13A-427
U1190 The network system diagnosis code output permitted signal can not P.13A-428
be received
NOTE: *:When the diagnosis codes relating to the CAN communication error are output, make sure of the
vehicle equipment. When the vehicle is not equipped with the system the engine-ECU communicates to, the
diagnosis code is always output. This is not abnormal.
DIESEL FUEL
TROUBLESHOOTING
13A-25
DIAGNOSIS CODE PROCEDURES
Code No. P0003: Suction Control Valve Open <Euro5>
Suction Control Valve Circuit
1
A-47
(MU802768) Suction
control
1 2 valve
P
2
SB
C-103
146 131
103104105106107108109110 111112113 114115
101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
Wire colour code

B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Grey
R: Red P: Pink V: Violet PU: Purple SI: Silver
AKA00106 AB
OPERATION • 2 seconds later after the ignition switch has been

• The voltage is applied from the engine-ECU (ter- in "ON" position or the engine has started up.
minal No. 131) to the suction control valve (termi- • The supply pump and injector are being normally
nal No. 1) via the power transistor in the engine- controlled.
ECU. • The fuel injection rate is 4 mm3/st or more.
• The voltage is earthed to the engine-ECU (termi-
nal No. 146) from the suction control valve (termi- Judgment Criterion
nal No. 2). • When the driving duty ratio of the suction control
valve is higher than the specified value, the driv-
FUNCTION ing current is lower than the specified value.
• The engine-ECU performs duty control over the
suction control valve. PROBABLE CAUSES
• The engine-ECU checks whether the amount of • Failed suction control valve
current for driving duty is adequate. • Open/short circuit or harness damage in suction
control valve circuit or loose connector contact
TROUBLE JUDGMENT • Failed engine-ECU
Check Conditions
• Battery positive voltage is 8 − 16 V
13A-26 DIESEL FUEL
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 3. Connector check: C-103 engine-ECU

connector
STEP 1. Connector check: A-47 suction control Connector: C-103
valve connector <L.H. drive vehicles>
Connector: A-47
2 1
Harness side
connector
A-47 (GR)
C-103 (B)
<R.H. drive vehicles>
AK503644 AB
Q: Is the check result normal?

YES : Go to Step 2 .
NO : Repair or replace the connector.
C-103 (B)
STEP 2. Check suction control valve itself.
• Check suction control valve itself (Refer to P.13A- 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
596). 117 116
143 142 141 140 139138 137 136 135 134 133 132 131
145 144
Q: Is the check result normal? 158 157156 155 154 153 152 151 150 149 148 147 146
YES : Go to Step 3 . Harness side connector AKA00090 AB

NO : Replace the suction control valve.
DIESEL FUEL
TROUBLESHOOTING
13A-27
STEP 4. Check harness between C-103 (terminal STEP 5. Check harness between C-103 (terminal
No. 131) engine-ECU connector and A-47 No. 146) engine-ECU connector and A-47
(terminal No. 1) suction control valve connector. (terminal No. 2) suction control valve connector.
• Check power supply line for open/short circuit Connector: C-103
and damage. <L.H. drive vehicles>
Connector: C-103
<L.H. drive vehicles>
C-103 (B)
C-103 (B) <R.H. drive vehicles>
C-103 (B)
C-103 (B) 115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
130 129 128 127 126 125 124 123 122 121120 119 118
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
115 114 113 112 111 110 109 108 107 106 105 104 103 145 144
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 158 157156 155 154 153 152 151 150 149 148 147 146
117 116
143 142 141 140 139138 137 136 135 134 133 132 131 Harness side connector AKA00090 AB
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Harness side connector AKA00090 AB

Connector: A-47
2 1
Connector: A-47 Harness side
2 1 connector
Harness side A-47 (GR)
connector
A-47 (GR)
AK503644 AB
• Check earthing line for open/short circuit and

AK503644 AB
damage.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 5 . YES : Go to Step 6 .
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
STEP 6. M.U.T.-III diagnosis code

• Reconfirmation of diagnosis code.
Q: Is the diagnosis code set?
13A-28 DIESEL FUEL
TROUBLESHOOTING
YES : Replace the engine-ECU. When the engine-

ECU is replaced, write the chassis number
(Refer to GROUP 00 − Precautions Before
Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU,
register the injector identification code and
learn fuel injection (Refer to GROUP 00 −
Precautions Before Service − What The
Common Rail Engine Learns ). After
registering the injector identification code,
carry out the forcible DPF regeneration.
(Refer to GROUP 17 − Emission Control −
Diesel Particulate Filter (DPF) System −
Forcible DPF Regeneration ).
NO : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/
Inspection Service Points − How to Cope
with Intermittent Malfunctions ).
Code No. P0004: Suction Control Valve Battery Short <Euro5>
1
A-47
(MU802768) Suction
control
1 2 valve
P
2
SB
C-103
146 131
103104105106107108109110 111112113 114115
101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
Wire colour code

AKA00106 AB
OPERATION ECU.
• The voltage is applied from the engine-ECU (ter- • The voltage is earthed to the engine-ECU (termi-
minal No. 131) to the suction control valve (terminal No. 146) from the suction control valve (termi-
nal No. 1) via the power transistor in the engine- nal No. 2).
DIESEL FUEL
TROUBLESHOOTING
13A-29
FUNCTION YES : Go to Step 2.
• The engine-ECU performs duty control over the NO : Repair or replace the connector.
suction control valve.
• The engine-ECU checks whether the amount of STEP 2. Check suction control valve itself.
current for driving duty is adequate. • Check suction control valve itself (Refer to P.13A-
596).
TROUBLE JUDGMENT
Check Conditions YES : Go to Step 3.
• Battery positive voltage is 8 − 16 V NO : Replace the suction control valve.
• 2 seconds later after the ignition switch has been
in "ON" position or the engine has started up
• The supply pump and injector are being normally STEP 3. Connector check: C-103 engine-ECU
controlled. connector
• The fuel injection rate is 4 mm3/st or more. Connector: C-103
Judgment Criterion
• When the driving duty ratio of the suction control
valve is lower than the specified value, the driving
current is higher than the specified value.
PROBABLE CAUSES
• Failed suction control valve C-103 (B)
• Short circuit in suction control valve circuit or
loose connector contact <R.H. drive vehicles>
• Failed engine-ECU
DIAGNOSIS PROCEDURE
STEP 1. Connector check: A-47 suction control

valve connector C-103 (B)
Connector: A-47
2 1 115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
130 129 128 127 126 125 124 123 122 121120 119 118
117 116
Harness side 143 142 141 140 139138 137 136 135 134 133 132 131
connector 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
A-47 (GR) Harness side connector AKA00090 AB

YES : Go to Step 4.
AK503644 AB

13A-30 DIESEL FUEL
TROUBLESHOOTING
Connector: C-103 Connector: C-103
<L.H. drive vehicles> <L.H. drive vehicles>
C-103 (B) C-103 (B)
<R.H. drive vehicles> <R.H. drive vehicles>
C-103 (B) C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 117 116

143 142 141 140 139138 137 136 135 134 133 132 131 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Harness side connector AKA00090 AB Harness side connector AKA00090 AB
Connector: A-47 Connector: A-47

2 1 2 1
Harness side Harness side

connector connector
A-47 (GR) A-47 (GR)
AK503644 AB AK503644 AB
• Check power supply line for short circuit. • Check earthing line for short circuit.
YES : Go to Step 5. YES : Go to Step 6.
STEP 6. M.U.T.-III diagnosis code.

DIESEL FUEL
TROUBLESHOOTING
13A-31
Code No. P0016: Crank Angle Sensor/Camshaft Position Sensor Phase Problem
OPERATION PROBABLE CAUSES

• Refer to Code No. P0335: Crank Angle Sensor • Failed crank angle sensor
System P.13A-184 • Failed camshaft position sensor
• Refer to Code No. P0340: Camshaft Position • Failed timing chain
Sensor System P.13A-192 • Failed engine-ECU
FUNCTION DIAGNOSTIC PROCEDURE

• The engine-ECU monitors the signals input from
the crank angle sensor and camshaft position
sensor. STEP 1. M.U.T.-III diagnosis code.
• The engine-ECU compares these input pulse sig- Q: Is any other diagnosis code than P0016 output?
nals to check the position relations for validity. YES : Inspection chart for diagnosis codes (Refer
to P.13A-21).
TROUBLE JUDGMENT NO : Go to Step 2 .
Check Conditions
• Battery positive voltage is 8 − 16 V STEP 2. Check the timing chain.
• One of the following two is true. • See the timing marks to check for skipped gear
1. 2 seconds have passed after the ignition teeth.
switch is turned on, the crank angle sensor
and camshaft position sensor output signals
are normal, and the engine rotation speed is
NO : Repair.
1,200 r/min or lower.
2. Cranking is in progress, the engine rotation
speed is 350 r/min or faster, and the engine STEP 3. Check crankshaft sensing vane.
coolant temperature is −30°C or higher. Q: Is the check result normal?
Judgment Criterion
NO : Replace the crankshaft sprocket.
• The phase shift angle between the crank and
camshaft position sensor signals exceeds its
threshold value. STEP 4. Check camshaft sensing vane.
YES : Go to Step 5 . NO : Replace the camshaft.
13A-32 DIESEL FUEL
TROUBLESHOOTING

• After clearing the diagnosis code through M.U.T.-
III, start the engine and confirm whether the diag-
nosis code is output.
Q: Is the diagnosis code set? register the injector identification code and
the vehicle equipped with the DPF carries
out the forcible DPF regeneration. (Refer to
GROUP 17 − Emission Control − Diesel
Particulate Filter (DPF) System − Forcible
DPF Regeneration ).
DIESEL FUEL
TROUBLESHOOTING
13A-33
Code No. P0047: Variable Geometry Control Solenoid Valve Circuit Low Input <Euro5>
Variable geometry control solenoid valve circuit
Fusible link 23
W-R
10 Relay
20A box
W-B A-115
3
W-B W-B
A-20X 4 1
1 2
3 Engine control relay
4 OFF ON
3 2
To engine-ECU
R
2
A-56
Variable geometry
1 2 control solenoid valve
W-R
C-105 17
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00128 AD
• The engine-ECU (terminal No. 17) makes the

OPERATION power transistor in the unit be in "ON" position,
• Power is supplied to the variable geometry con- and that makes currents go on the variable
trol solenoid valve (terminal No. 2) from the geometry control solenoid valve (terminal No. 1).
engine control relay (terminal No. 3).
13A-34 DIESEL FUEL
TROUBLESHOOTING
FUNCTION YES : Go to Step 3 .

• The variable geometry control solenoid valve NO : Repair or replace the connector.
controls the vacuum pressure introduced into the
variable geometry actuator, using the signal from STEP 3. Perform resistance measurement at A-56
the engine-ECU. This allows the boost pressure variable geometry control solenoid valve
to be adequate for the driving conditions. connector.
TROUBLE JUDGMENT Connector: A-56
Check Conditions A-56 (BR)

• Battery positive voltage is 8 − 16 V.
• 2 seconds later after the engine has started up.
Judgment Criterion
• Variable geometry control solenoid valve output
voltage is 0.4 V or less (driving current is abnor- 2 1
mally low). Harness side
connector AK900982AC
PROBABLE CAUSES
• Disconnect connector, and measure at solenoid
• Failed variable geometry control solenoid valve
valve side.
• Open/short circuit or harness damage in variable
• Resistance between terminal No. 1 and No. 2.
geometry control solenoid valve circuit or loose
connector contact OK: 10 − 14 Ω (at 20°C)
• Failed engine-ECU Q: Is the check result normal?
DIAGNOSIS PROCEDURE NO : Replace the variable geometry control
solenoid valve.
STEP 1. M.U.T.-III actuator test
• Item 36: Variable geometry control solenoid valve STEP 4. Perform voltage measurement at A-56
OK: The variable geometry actuator is oper- variable geometry control solenoid valve
ated connector.
Connector: A-56
YES : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/ A-56 (BR)
NO : Go to Step 2 .
2 1
STEP 2. Connector check: A-56 variable
Harness side
geometry control solenoid valve connector connector AK900982AC
Connector: A-56
• Disconnect connector, and measure at harness
side.
A-56 (BR)
• Ignition switch: ON
• Voltage between terminal No. 2 and earth.
OK: System voltage
2 1 YES : Go to Step 6 .
Harness side NO : Go to Step 5 .

DIESEL FUEL
TROUBLESHOOTING
13A-35
STEP 5. Connector check: A-20X engine control STEP 6. Perform voltage measurement at C-105
relay connector engine-ECU connector.
Connector: A-20X Connector: C-105
A-20X
2 1
3
4 C-105 (B)
Relay box's side
connector AK501321 AC
Connector: A-56
A-56 (BR)
C-105 (B)
2 1
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Harness side
connector AK900982AC 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Q: Is the check result normal? Harness side connector AKA00089 AB

YES : Check and repair harness between A-56
(terminal No. 2) variable geometry control • Disconnect connector, and measure at harness
solenoid valve connector and A-20X side.
(terminal No. 3) engine control relay • Ignition switch: ON
connector. • Voltage between terminal No. 17 and earth.
• Check power supply line open/short OK: System voltage
circuit
NO : Go to Step 7 .
13A-36 DIESEL FUEL
TROUBLESHOOTING

STEP 7. Connector check: C-105 engine-ECU
(terminal No. 1) variable geometry control
connector
solenoid valve connector and C-105
Connector: C-105 (terminal No. 17) engine-ECU connector.
• Check output line for open/short
circuit.

connector
C-105 (B)
Connector: C-105
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-56
C-105 (B)
A-56 (BR)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

2 1
Harness side Q: Is the check result normal?
connector AK900982AC YES : Go to Step 9 .
DIESEL FUEL
TROUBLESHOOTING
13A-37
STEP 9. Check harness between A-56 (terminal
NO : Repair the damaged harness wire.
No. 1) variable geometry control solenoid valve
connector and C-105 (terminal No. 17) engine-
ECU connector. STEP 10. Check harness between A-56 (terminal
Connector: A-56
connector and A20X (terminal No. 3) engine
A-56 (BR)
control relay connector.
Connector: A-56
A-56 (BR)
2 1
Harness side
2 1
Connector: C-105
<L.H. drive vehicles> Harness side
Connector: A-20X
A-20X
C-105 (B)
2 1
3
<R.H. drive vehicles> 4
Relay box's side
• Check power supply line for damage.

C-105 (B) NO : Repair the damaged harness wire.
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 • Item 36: Variable geometry control solenoid valve
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
OK: The variable geometry actuator is oper-
Harness side connector AKA00089 AB ated
• Check output line for damage. Q: Is the check result normal?
13A-38 DIESEL FUEL
TROUBLESHOOTING

NO : Replace the engine-ECU. When the engine-
DIESEL FUEL
TROUBLESHOOTING
13A-39
Code No. P0048: Variable Geometry Control Solenoid Valve Circuit High Input <Euro5>
Variable geometry control solenoid valve circuit
Fusible link 23
W-R
10 Relay
20A box
W-B A-115
3
W-B W-B
A-20X 4 1
1 2
3 Engine control relay
4 OFF ON
3 2
To engine-ECU
R
2
A-56
Variable geometry
1 2 control solenoid valve
W-R
C-105 17
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00128 AD
• The engine-ECU (terminal No. 17) makes the

OPERATION power transistor in the unit be in "ON" position,
• Power is supplied to the variable geometry con- and that makes currents go on the variable
trol solenoid valve (terminal No. 2) from the geometry control solenoid valve (terminal No. 1).
engine control relay (terminal No. 3).
13A-40 DIESEL FUEL
TROUBLESHOOTING
FUNCTION DIAGNOSIS PROCEDURE

• The variable geometry control solenoid valve
controls the vacuum pressure introduced into the
variable geometry actuator, using the signal from STEP 1. Connector check: A-56 variable
the engine-ECU. This allows the boost pressure geometry control solenoid valve connector, C-
to be adequate for the driving conditions. 105 engine-ECU connector
Connector: A-56
TROUBLE JUDGMENT
Check Conditions A-56 (BR)
• 2 seconds later after the engine has started up.
Judgment Criterion
• Variable geometry control solenoid valve output 2 1
voltage is 4.5 V or more (driving current is abnor-
Harness side
mally high). connector AK900982AC
PROBABLE CAUSES Connector: C-105

• Short circuit in variable geometry control solenoid <L.H. drive vehicles>
valve circuit or loose connector contact
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Q: Are the check results normal?

DIESEL FUEL
TROUBLESHOOTING
13A-41
ECU connector. STEP 3. M.U.T.-III diagnosis code
Connector: A-56
Q: Is diagnosis code set?
A-56 (BR) YES : Replace the engine-ECU. When the engine-
2 1 register the injector identification code and
Harness side
connector AK900982AC Precautions Before Service − What The
Connector: C-105 registering the injector identification code,
C-105 (B) Inspection Service Points − How to Cope
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Check output line for short circuit.

13A-42 DIESEL FUEL
TROUBLESHOOTING
Code No. P0072: Intake Air Temperature Sensor No. 1 Circuit Low Input <Euro5>
Intake Air Temperature Sensor No. 1 Circuit
A-135 Intake air temperature

sensor No. 1 (integrated in
1 2 3 4 5 air flow sensor)
1 2
B-L Y-L
86 62
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 5V
Wire colour code

B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
AKA00356 AB
OPERATION TROUBLE JUDGMENT

• A power voltage of 5 V is applied to the intake air
Check Conditions
temperature sensor No. 1 output terminal (termi-
nal No. 2) from the engine-ECU (terminal No. 62).
• The power voltage is earthed to the engine-ECU
in "ON" position or the engine has started up.
(terminal No. 86) from the intake air temperature
sensor No. 1 (terminal No. 1). Judgment Criterion
• The intake air temperature sensor No. 1 output
FUNCTION voltage is 0.09 V or less for 0.5 second.
• The intake air temperature sensor No. 1 converts
the intake air temperature into a voltage and PROBABLE CAUSES
inputs the voltage signal to the engine-ECU. • Failed intake air temperature sensor No. 1
• In response to the signal, the engine-ECU cor- • Short circuit or harness damage in intake air tem-
rects the fuel injection amount, etc. perature sensor No.1 circuit or loose connector
• The intake air temperature sensor No. 1 is a kind contact
of resistor, which has characteristics to reduce its • Failed engine-ECU
resistance as the intake air temperature rises.
Therefore, the sensor output voltage varies with
the intake air temperature, and becomes lower as
the intake air temperature rises.
DIESEL FUEL
TROUBLESHOOTING
13A-43
DIAGNOSIS PROCEDURE STEP 4. Perform Voltage measurement at A-135
air flow sensor connector.
STEP 1. M.U.T.-III data list Connector: A-135
• Item 43: Intake air temperature sensor No. 1
OK: At ambient temperature (atmospheric
temperature) or equivalent.
with Intermittent Malfunctions ). Harness side A-135 (B)
connector AKA00399AB
NO : Go to Step 2 .
side.
STEP 2. Connector check: A-135 air flow sensor
connector
Connector: A-135
OK: 4.5 − 4.9 V
NO : Go to Step 5 .

connector
Harness side A-135 (B) Connector: C-105
connector AKA00399AB <L.H. drive vehicles>

STEP 3. Check intake air temperature sensor No.

C-105 (B)
1 itself.
• Check intake air temperature sensor No. 1 itself
(Refer to P.13A-595). <R.H. drive vehicles>
NO : Replace the air flow sensor.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-44 DIESEL FUEL
TROUBLESHOOTING
STEP 6. Check harness between A-135 (terminal STEP 7. M.U.T.-III data list
No. 2) air flow sensor connector and C-105 • Item 43: Intake air temperature sensor No. 1
(terminal No. 62) engine-ECU connector. OK: At ambient temperature (atmospheric
Connector: A-135 temperature) or equivalent.
Harness side A-135 (B) (Refer to GROUP 00 − Precautions Before
connector AKA00399AB Service − How to Perform Chassis Number
Connector: C-105
<L.H. drive vehicles> register the injector identification code and
C-105 (B) Diesel Particulate Filter (DPF) System −
STEP 8. Perform resistance measurement at A-
135 air flow sensor connector.
Connector: A-135
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side A-135 (B)

Harness side connector AKA00089 AB connector AKA00399AB
• Check output line for short circuit. • Disconnect connector, and measure at harness
Q: Is the check result normal? side.
YES : Go to Step 7 . • Resistance between terminal No. 1 and earth.
NO : Repair the damaged harness wire. OK: Continuity (2 Ω or less)
NO : Go to Step 9 .
DIESEL FUEL
TROUBLESHOOTING
13A-45
STEP 9. Connector check: C-105 engine-ECU STEP 10. Check harness between A-135 (terminal
connector No. 1) air flow sensor connector and C-105
Connector: C-105
(terminal No. 86) engine-ECU connector.
<L.H. drive vehicles> • Check earthing line for damage.
Connector: A-135
C-105 (B)

Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-46 DIESEL FUEL
TROUBLESHOOTING
Connector: C-105
<L.H. drive vehicles> Connector: A-135
C-105 (B)

<R.H. drive vehicles> connector AKA00399AB
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Check output line for damage.

DIESEL FUEL
TROUBLESHOOTING
13A-47
Code No. P0072: Intake Air Temperature Sensor No. 2 Circuit Low Input <Except Euro5>
A-136
(MU802409)
Intake air temperature
sensor No. 2
1 2
2 1
B-P L-R
C-105 32 38
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00091 AB

Check Conditions
sensor (terminal No. 2). Judgment Criterion
FUNCTION voltage is 0.05 V or less (the intake air tempera-
• The intake air temperature sensor No. 2 converts ture is above 150°C or equivalent) for 0.5 second.
the intake air temperature into a voltage and
inputs the voltage signal to the engine-ECU. PROBABLE CAUSES
• In response to the signal, the engine-ECU cor- • Failed intake air temperature sensor No. 2
rects the fuel injection amount, etc. • Short circuit or harness damage in intake air tem-
• The intake air temperature sensor No. 2 is a kind perature sensor No. 2 circuit or loose connector
of resistor, which has characteristics to reduce its contact
resistance as the intake air temperature rises. • Failed engine-ECU
the fuel temperature, and becomes lower as the
intake air temperature rises.
13A-48 DIESEL FUEL
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 4. Perform voltage measurement at A-136

intake air temperature sensor No. 2 connector.
temperature) or equivalent. A-136 (B)

2 1
with Intermittent Malfunctions ). Harness side
connector
NO : Go to Step 2 . AK501317 AB

side.
STEP 2. Connector check: A-136 intake air
temperature sensor No. 2 connector
Connector: A-136
OK: 4.5 − 4.9 V
A-136 (B) YES : Go to Step 8 .
NO : Go to Step 5 .

2 1 connector
Harness side Connector: C-105
connector AK501317 AB <L.H. drive vehicles>


C-105 (B)
2 itself.
NO : Replace the intake air temperature sensor
No. 2.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-49
No. 1) intake air temperature sensor No. 2 • Item 8: Intake air temperature sensor No. 2
connector and C-105 (terminal No. 38) engine- OK: At ambient temperature (atmospheric
ECU connector. temperature) or equivalent.
Connector: A-136 Q: Is the check result normal?
A-136 (B) Inspection Service Points − How to Cope
2 1 (Refer to GROUP 00 − Precautions Before
Harness side Service − How to Perform Chassis Number
connector AK501317 AB Writing ). After replacing the engine-ECU,
Connector: C-105
<L.H. drive vehicles> learn fuel injection (Refer to GROUP 00 −
Common Rail Engine Learns ).

136 intake air temperature sensor No. 2
C-105 (B) connector.
Connector: A-136
A-136 (B)
2 1
C-105 (B) Harness side
connector AK501317 AB
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 • Disconnect connector, and measure at harness
side.
• Resistance between terminal No. 2 and earth.
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector AKA00089 AB OK: Continuity (2 Ω or less)

• Check output line for short circuit. Q: Is the check result normal?
NO : Go to Step 9 .
13A-50 DIESEL FUEL
TROUBLESHOOTING
connector No. 2) intake air temperature sensor No. 2
Connector: C-105
<L.H. drive vehicles> ECU connector.
Connector: A-136
A-136 (B)
C-105 (B)
2 1
Harness side
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Check earthing line for damage.

DIESEL FUEL
TROUBLESHOOTING
13A-51
Connector: C-105
Connector: A-136
A-136 (B)
C-105 (B)
2 1
Harness side
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-52 DIESEL FUEL
TROUBLESHOOTING
Code No. P0073: Intake Air Temperature Sensor No. 1 Circuit High Input <Euro5>

1 2
B-L Y-L
86 62
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 5V
Wire colour code

AKA00356 AB

Check Conditions
temperature sensor No.1 output terminal (termi-
nal No. 2) of air flow sensor connector from the
engine-ECU (terminal No. 62).
(terminal No. 86) from the intake air temperature Judgment Criterion
sensor No. 1 (terminal No. 1). • The intake air temperature sensor No. 1 output
voltage is 4.87 V or more for 0.5 second.
FUNCTION
• The intake air temperature sensor No. 1 converts PROBABLE CAUSES
the intake air temperature into a voltage and • Failed intake air temperature sensor No. 1
inputs the voltage signal to the engine-ECU. • Open circuit or harness damage in intake air tem-
• In response to the signal, the engine-ECU cor- perature sensor No. 1 circuit or loose connector
rects the fuel injection amount, etc. contact
• The intake air temperature sensor No. 1 is a kind • Failed engine-ECU
of resistor, which has characteristics to reduce its
DIESEL FUEL
TROUBLESHOOTING
13A-53
air flow sensor No. 1 connector.
• Refer to Data List Reference Table P.13A-542.
a. Item 43: Intake air temperature sensor No. 1
Harness side
Inspection Service Points − How to Cope connector
A-135 (B)
AKA00399AB
NO : Go to Step 2 . • Disconnect connector, and measure at harness
side.
connector
OK: 4.5 − 4.9 V
Connector: A-135
NO : Go to Step 5 .

connector
Connector: C-105
Harness side A-135 (B) <L.H. drive vehicles>

C-105 (B)
1 itself.
• Check intake air temperature sensor No. 1 itself <R.H. drive vehicles>
(Refer to P.13A-595).
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-54 DIESEL FUEL
TROUBLESHOOTING
Connector: C-105
C-105 (B) Diesel Particulate Filter (DPF) System −
Connector: A-135
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

Harness side connector AKA00089 AB connector AKA00399AB
• Check output line for open circuit. • Disconnect connector, and measure at harness
NO : Go to Step 9 .
DIESEL FUEL
TROUBLESHOOTING
13A-55
Connector: C-105
<L.H. drive vehicles> • Check earthing line open circuit and damage.
Connector: A-135
C-105 (B)

Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-56 DIESEL FUEL
TROUBLESHOOTING
Code No. P0073: Intake Air Temperature Sensor No. 2 Circuit High Input <Except Euro5>
A-136
(MU802409)
sensor No. 2
1 2
2 1
B-P L-R
C-105 32 38
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00091 AB

Check Conditions
FUNCTION voltage is 4.9 V or more (the intake air tempera-
• The intake air temperature sensor No. 2 converts ture is below −40°C or equivalent) for 0.5 second.
the intake air temperature into a voltage and
inputs the voltage signal to the engine-ECU. PROBABLE CAUSES
• In response to the signal, the engine-ECU cor- • Failed intake air temperature sensor No. 2
rects the fuel injection amount, etc. • Open circuit in intake air temperature sensor No.
• The intake air temperature sensor No. 2 is a kind 2 circuit or loose connector contact
the fuel temperature, and becomes lower as the
intake air temperature rises.
DIESEL FUEL
TROUBLESHOOTING
13A-57
intake air temperature sensor No. 2 connector.
temperature) or equivalent. A-136 (B)

2 1
connector

side.
STEP 2. Connector check: A-136 intake air
temperature sensor No. 2 connector
Connector: A-136
OK: 4.5 − 4.9 V
A-136 (B) YES : Go to Step 8 .
NO : Go to Step 5 .

2 1 connector


C-105 (B)
2 itself.
NO : Replace the intake air temperature sensor
No. 2.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-58 DIESEL FUEL
TROUBLESHOOTING
No. 1) intake air temperature sensor No. 2 • Item 8: Intake air temperature sensor No. 2
connector and C-105 (terminal No. 38) engine- OK: At ambient temperature (atmospheric
ECU connector. temperature) or equivalent.
2 1 (Refer to GROUP 00 − Precautions Before
Connector: C-105

136 intake air temperature sensor No. 2
C-105 (B) connector.
Connector: A-136
A-136 (B)
2 1
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
side.
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

• Check output line for open circuit. Q: Is the check result normal?
NO : Go to Step 9 .
DIESEL FUEL
TROUBLESHOOTING
13A-59
Connector: C-105
Connector: A-136
A-136 (B)
C-105 (B)
2 1
Harness side
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Check earthing line for open circuit.

Code No. P0088: Common Rail High Pressure Malfunction
OPERATION • Sensor signals are input from the rail pressure

• 5 V power is supplied from the engine-ECU (ter- sensor (terminal No. 2) to the engine-ECU (termi-
minal No. 70) to the rail pressure sensor (terminal nal No. 64).
No. 1).
• The rail pressure sensor (terminal No. 3) is FUNCTION
earthed to the engine-ECU (terminal No. 88). • The engine-ECU monitors the signals input from
the rail pressure sensor.
13A-60 DIESEL FUEL
TROUBLESHOOTING
• Based on The input signals, the engine-ECU STEP 3. Connector check: C-105 engine-ECU
checks whether the fuel pressure in the common connector and A-47 suction control valve
rail exceeds the maximum withstand pressure of connector.
the system.
Connector: C-105
TROUBLE JUDGMENT <L.H. drive vehicles>
Check Conditions
• Rail pressure sensor is normal
Judgment Criterion
• The rail pressure exceeds the threshold value of C-105 (B)
an abnormal high pressure for 3 seconds (contin-
uous or accumulated).
PROBABLE CAUSES
• Failed suction control valve
• Failed rail pressure sensor
DIAGNOSIS PROCEDURE
C-105 (B)
STEP 1. M.U.T.-III diagnosis code 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Q: Is any other diagnosis code than P0088 output? 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49

YES : Inspection chart for diagnosis codes (Refer 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
to P.13A-21). Harness side connector AKA00089 AB

NO : Go to Step 2 .
Connector: A-47
STEP 2. Check suction control valve itself 2 1
• Check suction control valve itself (Refer to P.13A- Harness side
596). connector
Q: Is the check result normal? A-47 (GR)

NO : Replace the suction control valve. After
replacing the suction control valve, learn the
supply pump (Refer to GROUP 00 − AK503644 AB
Common Rail Engine Learns ). Q: Are the check results normal?
DIESEL FUEL
TROUBLESHOOTING
13A-61
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

2 1 2 1

connector connector
A-47 (GR) A-47 (GR)
AK503644 AB AK503644 AB
• Check output line for open/short circuit and dam- • Check output line for open/short circuit and dam-
age. age.
13A-62 DIESEL FUEL
TROUBLESHOOTING
STEP 6. Perform output wave pattern STEP 7. Replace the common rail assembly and
measurement at A-47 suction control valve fuel injection tubes.
(Using an oscilloscope). • After replacing the common rail assembly and
fuel injection tubes, re-check the trouble symp-
Connector: A-47
2 1
toms
Harness side
Q: Does trouble symptom persist?
connector YES : Replace the engine-ECU. When the engine-
A-47 (GR) (Refer to GROUP 00 − Precautions Before
AK503644 AB learn fuel injection (Refer to GROUP 00 −
• Engine: Idling Precautions Before Service − What The
• Connect the oscilloscope special patterns pickup Common Rail Engine Learns ). After
to engine-ECU terminal No. 146 and earth. registering the injector identification code,
OK: The waveform should show a pattern out the forcible DPF regeneration. (Refer to
similar to the illustration of inspection proce- GROUP 17 − Emission Control − Diesel
dure using an oscilloscope (Refer to P.13A- Particulate Filter (DPF) System − Forcible
586). DPF Regeneration ).
Q: Is the check result normal? NO : The check is end.
supply pump (Refer to GROUP 00 −
Code No. P0089: Suction Control Valve Stuck
OPERATION • 2 seconds later after the ignition switch has been

• Battery power is supplied from the engine-ECU in "ON" position or the engine has started up
(terminal No. 131) to the suction control valve
Judgment Criterion
(terminal No. 1).
• The actual rail pressure remains higher than the
• The engine-ECU (terminal No. 146) turns on the
objective rail pressure by 10 MPa or more for a
power transistor to flow current to the suction
certain interval.
control valve (terminal No. 2).
PROBABLE CAUSES
FUNCTION
the rail pressure sensor.
• The engine-ECU monitors the difference between
DIAGNOSIS PROCEDURE
the target fuel pressure and actual fuel pressure
to check whether the suction control valve is
open or fixed. STEP 1. M.U.T.-III actuator test.
• Refer to Actuator Test Table P.13A-574.
TROUBLE JUDGMENT a. Item 19: Suction control valve
Check Conditions Q: Is the check result normal?
• Battery positive voltage is 8 − 16 V YES : Go to Step 2 .
NO : Go to Step 4 .
DIESEL FUEL
TROUBLESHOOTING
13A-63
STEP 2. Make a check on the following items. STEP 4. Replace the suction control valve.
• Check for foreign matters (water, kerosene, etc.) • After the suction control valve, learn the supply
in fuel and replace if necessary. pump. (Refer to GROUP 00 − Precautions Before
• Check fuel filter itself. Service − What The Common Rail Engine Learns
).
YES : Go to Step 3 . • After learning the supply pump assembly, re-
NO : Make a repair or replacement for items check the trouble symptoms
whose checking results are abnormal. Q: Does trouble symptom persist?
STEP 3. M.U.T.-III diagnosis code. ECU is replaced, write the chassis number
• Reconfirmation of diagnosis code (Refer to GROUP 00 − Precautions Before
Q: Is the diagnosis code set? Writing ). After replacing the engine-ECU,
YES : Replace the engine-ECU. When the engine- register the injector identification code and
ECU is replaced, write the chassis number learn fuel injection (Refer to GROUP 00 −
(Refer to GROUP 00 − Precautions Before Precautions Before Service − What The
Service − How to Perform Chassis Number Common Rail Engine Learns ). After
Writing ). After replacing the engine-ECU, registering the injector identification code,
register the injector identification code and the vehicle equipped with the DPF carries
learn fuel injection (Refer to GROUP 00 − out the forcible DPF regeneration. (Refer to
Precautions Before Service − What The GROUP 17 − Emission Control − Diesel
Common Rail Engine Learns ). After Particulate Filter (DPF) System − Forcible
registering the injector identification code, DPF Regeneration ).
the vehicle equipped with the DPF carries NO : The check is end.
DPF Regeneration ).
Code No. P0093: Fuel Leak Problem

• Refer to Code No. P0192: Rail Pressure Sensor
Check Conditions
Circuit Low Input P.13A-147.
FUNCTION • 2 seconds later after the ignition switch has been
• The engine-ECU monitors the signals input from in "ON" position or the engine has started up
the rail pressure sensor. • The engine speed is 600 r/min or more
• The engine-ECU controls the suction control • Rail pressure sensor is normal
valve so that necessary fuel pressure can be Judgment Criterion
obtained before fuel injection. • The fuel discharge rate of the supply pump con-
• The engine-ECU compares the fuel pressure tinues to exceed its threshold value against the
immediately before fuel injection and the fuel fuel injection rate.
pressure after injection to check whether. The
pressure drop greatly exceeds the expected PROBABLE CAUSES
range determined based on fuel consumption. • Fuel leakage or fuel line blocked
The engine-ECU detects fuel leaks in this way. • Failed injector
13A-64 DIESEL FUEL
TROUBLESHOOTING
• Failed rail pressure sensor. STEP 4. Connector check: A-44 rail pressure
• Harness damage in rail pressure sensor circuit or sensor connector and C-105 engine-ECU
loose connector contact. connector.
Connector: A-44
DIAGNOSTIC PROCEDURE

Q: Is any other diagnosis code than P0093 set?
YES : Inspection chart for diagnosis codes (Refer
to P.13A-21). 3 2 1
NO : Go to Step 2 . A-44 (B)
Harness side
STEP 2. Detection of fuel line leakage Connector: C-105

• Check whether fuel is leaking from a high-pres- <L.H. drive vehicles>
sure fuel line.
NO : Replace the parts of an abnormal location.
C-105 (B)
STEP 3. Release the air from the fuel line.
• After releasing the air from the fuel line, continue
idle operation for about five minutes and recheck <R.H. drive vehicles>
for trouble symptoms.
Q: Does the trouble symptom persist?
NO : The check is end.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-65
STEP 5. Check harness between A-44 (terminal STEP 6. Check harness between A-44 (terminal
No. 1) rail pressure sensor connector and C-105 No. 2) rail pressure sensor connector and C-105
(terminal No. 70) engine-ECU connector. (terminal No. 64) engine-ECU connector.
3 2 1 3 2 1
A-44 (B) A-44 (B)
connector AK501327 AB connector AK501327 AB

C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
NOTE: Before checking harness, check intermediate NOTE: Before checking harness, check intermediate
connector A-131, and repair if necessary. connector A-131, and repair if necessary.
• Check power supply line for damage. • Check output line for damage.
13A-66 DIESEL FUEL
TROUBLESHOOTING
No. 3) rail pressure sensor connector and C-105
STEP 8. Detection of fuel leakage from injector
Connector: A-44
body
• Remove the injector. Check whether there is the
evidence of the fuel leakage from the injector
body.
3 2 1 NO : Replace the abnormal injector. After
A-44 (B) replacing the injector, register the injector
Harness side
connector AK501327 AB identification code and learn fuel injection.
Connector: C-105 Service − What The Common Rail Engine
Learns ).
STEP 9. Replace the common rail assembly and

fuel injection tubes.
• After replacing the common rail assembly and
C-105 (B)
toms.
<R.H. drive vehicles> YES : Replace the engine-ECU. When the engine-
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 registering the injector identification code,
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector AKA00089 AB GROUP 17 − Emission Control − Diesel
NOTE: Before checking harness, check intermediate DPF Regeneration ).
connector A-131, and repair if necessary. NO : The check is end.
DIESEL FUEL
TROUBLESHOOTING
13A-67
Code No. P0102: Air flow Sensor Circuit Low Input
Air Flow Sensor Circuit
Fusible link 23
W-R
10 Relay
box
20A
W-B A-115
3
W-B W-B
4 1
A-20X
1 2 Engine
3 OFF control
ON relay
4
3 2
R To engine-ECU
A-135
1 2 3 4 5 Heat
sensitizing Air flow sensor
resistance
3 4
W-R BR-B
C-103 140 155
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
5V
Wire colour code

AKA00355 AB
OPERATION • The air flow sensor (terminal No. 3) outputs a

• Power is supplied by the engine control relay (ter- sensor signal, which is input into the engine-ECU
minal No. 3) to the air flow sensor (terminal No. (terminal No. 140).
5), and the air flow sensor (terminal No. 4) is
earthed through the engine-ECU (terminal No.
155).
13A-68 DIESEL FUEL
TROUBLESHOOTING
FUNCTION STEP 3. Perform voltage measurement at A-135

• The air flow sensor outputs pulse signal that var- air flow sensor connector.
ies in accordance with the intake air volume.
• In response to the signal, the engine-ECU con- Connector: A-135
trols EGR control, etc.
TROUBLE JUDGMENT
Check Conditions
Judgment Criterion connector AKA00399AB
• The air flow sensor output voltage is 0.50 V or
less.
side.
PROBABLE CAUSES • Ignition switch: ON
• Failed air flow sensor • Voltage between terminal No. 5 and earth.
• Open/short circuit or harness damage in air flow OK: System voltage
sensor circuit or loose connector contact Q: Is the check result normal?
• Failed engine-ECU YES : Go to Step 5 .
NO : Go to Step 4 .
DIAGNOSIS PROCEDURE
STEP 4. Connector check: A-20X engine control
STEP 1. M.U.T.-III data list relay connector
Connector: A-20X
a. Item 114: Air flow sensor
Q: Is the check result normal? A-20X
Inspection Service Points − How to Cope 2 1
with Intermittent Malfunctions ). 3
NO : Go to Step 2 . 4
Relay box's side
connector
STEP 2. Connector check: A-135 air flow sensor AK501321 AC
connector Connector: A-135

Connector: A-135

DIESEL FUEL
TROUBLESHOOTING
13A-69
YES : Check and repair harness between A-20X
(terminal No. 3) engine control relay
connector
connector and A-135 (terminal No. 5) air
flow sensor connector. Connector: C-103
• Check power supply for open/short <L.H. drive vehicles>
circuit.

C-103 (B)
Connector: A-135
Harness side A-135 (B) C-103 (B)

• Disconnect connector, and measure at harness 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
side. 117 116
• Resistance between terminal No. 4 and earth. 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
OK: Continuity (2 Ω or less) Harness side connector AKA00090 AB

YES : Go to Step 9 . Q: Is the check result normal?
NO : Go to Step 6 . YES : Go to Step 7 .
13A-70 DIESEL FUEL
TROUBLESHOOTING
No. 4) air flow sensor connector and C-103 Connector: A-135
Connector: A-135


connector AKA00399AB Connector: C-103
Connector: C-103
C-103 (B)
C-103 (B)
C-103 (B) 115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
130 129 128 127 126 125 124 123 122 121120 119 118
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
115 114 113 112 111 110 109 108 107 106 105 104 103 145 144
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 158 157156 155 154 153 152 151 150 149 148 147 146
117 116
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

DIESEL FUEL
TROUBLESHOOTING
13A-71
YES : Intermittent malfunction (Refer to GROUP YES : Go to Step 12 .
00 − How to Use Troubleshooting/ NO : Go to Step 10 .
with Intermittent Malfunctions ). STEP 10. Connector check: C-103 engine-ECU
connector
(Refer to GROUP 00 − Precautions Before Connector: C-103
registering the injector identification code, C-103 (B)
out the forcible DPF regeneration. (Refer to <R.H. drive vehicles>
DPF Regeneration ).
STEP 9. Perform voltage measurement at A-135

C-103 (B)
Connector: A-135
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

Harness side
connector
A-135 (B) NO : Repair or replace the connector.
AKA00399AB

side.
OK: 4.9 − 5.1 V
13A-72 DIESEL FUEL
TROUBLESHOOTING
STEP 11. Check harness between A-135 (terminal STEP 12. Perform voltage measurement at C-103
No. 3) air flow sensor connector and C-103 engine-ECU connector.
(terminal No. 140) engine-ECU connector. Connector: C-103
Connector: A-135 <L.H. drive vehicles>
C-103 (B)
Harness side A-135 (B) <R.H. drive vehicles>

Connector: C-103
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
C-103 (B) 117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Connector: A-135
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 Harness side A-135 (B)
Harness side connector AKA00090 AB • Measure engine-ECU terminal voltage.
• Check output line for short circuit. • Disconnect A-135 air flow sensor connector.
YES : Replace the air flow sensor. • Voltage between terminal No. 140 and earth.
NO : Repair the damaged harness wire. OK: 4.9 − 5.1 V
NO : Go to Step 13 .
DIESEL FUEL
TROUBLESHOOTING
13A-73
(terminal No. 3) air-flow sensor connector
connector
and C-103 (terminal No. 140) engine-ECU
Connector: C-103 connector.
<L.H. drive vehicles> • Check output line for open circuit.

connector
Connector: C-103
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
C-103 (B)
Connector: A-135
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

Harness side YES : Go to Step 8 .
A-135 (B)
connector AKA00399AB NO : Repair or replace the connector.

13A-74 DIESEL FUEL
TROUBLESHOOTING
Code No. P0103: Air Flow Sensor Circuit High Input
Air Flow Sensor Circuit
Fusible link 23
W-R
10 Relay
box
20A
W-B A-115
3
W-B W-B
4 1
A-20X
1 2 Engine
3 OFF control
ON relay
4
3 2
R To engine-ECU
A-135
1 2 3 4 5 Heat
sensitizing Air flow sensor
resistance
3 4
W-R BR-B
C-103 140 155
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
5V
Wire colour code

AKA00355 AB
OPERATION • The air flow sensor (terminal No. 3) outputs a

• Power is supplied by the engine control relay (ter- sensor signal, which is input into the engine-ECU
minal No. 3) to the air flow sensor (terminal No. (terminal No. 140).
5), and the air flow sensor (terminal No. 4) is
earthed through the engine-ECU (terminal No.
155).
DIESEL FUEL
TROUBLESHOOTING
13A-75
FUNCTION STEP 3. Perform resistance measurement at A-
• The air flow sensor outputs pulse signal that var- 135 air flow sensor connector.
ies in accordance with the intake air volume.
• In response to the signal, the engine-ECU con- Connector: A-135
trols EGR control, etc.
TROUBLE JUDGMENT
Check Conditions
Judgment Criterion connector AKA00399AB
• The air flow sensor output voltage is 4.72 V or
more.
side.
PROBABLE CAUSES • Resistance between terminal No. 4 and earth.
• Failed air flow sensor OK: Continuity (2 Ω or less)
• Open circuit in air flow sensor circuit or loose Q: Is the check result normal?
connector contact YES : Go to Step 7 .
• Failed engine-ECU NO : Go to Step 4 .
DIAGNOSIS PROCEDURE
connector
STEP 1. M.U.T.-III data list Connector: C-103
• Refer to Data List Reference Table P.13A-542. <L.H. drive vehicles>
with Intermittent Malfunctions ). C-103 (B)
NO : Go to Step 2 .
connector
Connector: A-135
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
connector AKA00399AB Harness side connector AKA00090 AB

NO : Repair or replace the connector. NO : Repair or replace the connector.
13A-76 DIESEL FUEL
TROUBLESHOOTING
No. 4) air flow sensor connector and C-103
STEP 6. M.U.T.-III data list
Connector: A-135
Harness side NO : Replace the engine-ECU. When the engine-
A-135 (B)
connector AKA00399AB ECU is replaced, write the chassis number
Connector: C-103 Service − How to Perform Chassis Number
C-103 (B) the vehicle equipped with the DPF carries
<R.H. drive vehicles> GROUP 17 − Emission Control − Diesel
DPF Regeneration ).

C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103 YES : Intermittent malfunction (Refer to GROUP
102 101
130 129 128 127 126 125 124 123 122 121120 119 118
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 Inspection Service Points − How to Cope
Harness side connector AKA00090 AB NO : Replace the air flow sensor.
DIESEL FUEL
TROUBLESHOOTING
13A-77
Code No. P0106: Manifold Absolute Pressure Sensor Range/Performance Problem
Manifold Absolute Pressure Sensor Circuit
A-105 Manifold
absolute
1 2 3 pressure
sensor
3 2 1
LG-B G-L GR
C-105 31 37 72
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

R: Red P: Pink V:Violet PU: Purple SI:Silver
AKA00093 AB
OPERATION • The following 3 conditions are formed:

• A power voltage of 5 V is applied to the manifold 1. The engine cooling water temperature is from
absolute pressure sensor power terminal (termi- −5 to 80 °C.
nal No. 1) from the engine-ECU (terminal No. 72) 2. The air intake temperature is from −5 to 80
and earthed to the engine-ECU (terminal No. 31)
°C.
from the manifold absolute pressure sensor (ter-
3. The atmospheric pressure is from 76 to 120
minal No. 3).
kPa.
• The sensor signal is inputted to the engine-ECU
(terminal No. 37) from the manifold absolute Judgment Criterion
pressure sensor output terminal (terminal No. 2). • When an idle state and an engine rotation speed
of 2,000 r/min continue for three seconds, mani-
FUNCTION fold absolute pressures are read and the differ-
• The manifold absolute pressure sensor converts ence between them goes under 800 Pa for 1
the manifold absolute pressure into a voltage sig- second.
nal and inputs the signal to the engine-ECU.
• In response to the signal, the engine-ECU cor- PROBABLE CAUSES
rects the fuel injection amount, etc. • Failed manifold absolute pressure sensor
• Manifold absolute pressure sensor circuit har-
TROUBLE JUDGMENT ness damage or loose connector contact.
Check Conditions • EGR cooler clogged.
• Battery positive voltage is 8 − 16 V • EGR pipe (A, B) clogged.
• 2 seconds later after the ignition switch has been • Failed engine-ECU
13A-78 DIESEL FUEL
TROUBLESHOOTING
DIAGNOSIS PROCEDURE YES : Go to Step 5.

NO : Go to Step 4.

• Refer to Data List Reference Table P.13A-542. STEP 4. Connector check: C-105 engine-ECU
connector
a. Item 6: Manifold absolute pressure sensor
Connector: C-105
Q: Is the check result normal? <L.H. drive vehicles>
YES : Go to Step 10.
NO : Go to Step 2.
STEP 2. Connector check: A-105 manifold

absolute pressure sensor connector
Connector: A-105 C-105 (B)
3 2 1
Harness side
A-105 (L) connector <R.H. drive vehicles>
AK900797 AB C-105 (B)
Q: Is the check result normal? 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

YES : Go to Step 3. 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
NO : Repair or replace the connector. 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49

96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector

STEP 3. Perform voltage measurement at A-105 AKA00089 AB
manifold absolute pressure sensor connector.

Connector: A-105
Connector: A-105 3 2 1
3 2 1 Harness side
Harness side A-105 (L) connector
A-105 (L) connector
AK900797 AB
AK900797 AB
• Use special tool test harness (MB991709) to con- YES : Check and repair harness between A-105
nect connector, and measure at pick-up harness. (terminal No. 1) manifold absolute pressure
• Ignition switch: ON sensor connector and C-105 (terminal No.
• Voltage between terminal No. 1 and earth. 72) engine-ECU connector.
OK: 4.9 − 5.1 V • Check power supply line for damage.
Q: Is the check result normal? NO : Repair or replace the connector.
DIESEL FUEL
TROUBLESHOOTING
13A-79
STEP 5. Perform voltage measurement at A-105 STEP 6. Connector check: C-105 engine-ECU
manifold absolute pressure sensor connector. connector
Connector: A-105 Connector: C-105
3 2 1 <L.H. drive vehicles>
Harness side
A-105 (L) connector
C-105 (B)
AK900797 AB
• Use special tool harness (MB991709) to connect
connector, and measure at pick-up harness.
OK: 0.5 V or less
Q: Is the check result normal? C-105 (B)
YES : Go to Step 7.
NO : Go to Step 6. 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-105
3 2 1
Harness side
A-105 (L) connector
AK900797 AB

(terminal No. 3) manifold absolute pressure
sensor connector and C-105 (terminal No.
31) engine-ECU connector.
13A-80 DIESEL FUEL
TROUBLESHOOTING
STEP 7. Perform voltage measurement at A-105 STEP 8. Perform voltage measurement at C-105
manifold absolute pressure sensor connector. engine-ECU connector.
3 2 1 <L.H. drive vehicles>
Harness side
A-105 (L) connector
C-105 (B)
AK900797 AB
OK: The voltage should be 0.7 − 1.2 V. When
the accelerator pedal is quickly depressed
from the idling state, the voltage temporarily C-105 (B)
rises.
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
YES : Go to Step 8. 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
NO : Replace the manifold absolute pressure

96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
sensor. Harness side connector AKA00089 AB
Connector: A-105
3 2 1
Harness side
A-105 (L) connector
AK900797 AB
• Measure engine-ECU terminal voltage.

OK: The voltage should be 0.7 − 1.2 V. When
the accelerator pedal is quickly depressed
from the idling state, the voltage temporarily
rises.
YES : Go to Step 9.
NO : Check and repair harness between A-105
DIESEL FUEL
TROUBLESHOOTING
13A-81
NO : Replace the EGR cooler.
connector
Connector: C-105
<L.H. drive vehicles> STEP 11. Check on clogged EGR pipe (A, B).
• Check whether the EGR pipe (A, B) is being
clogged or not.
NO : Replace the EGR pipe (A, B).
C-105 (B)
C-105 (B) NO : Replace the engine-ECU. When the engine-
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 (Refer to GROUP 00 − Precautions Before
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 Writing ). After replacing the engine-ECU,
Q: Is the check result normal? Precautions Before Service − What The
YES : Go to Step 10. Common Rail Engine Learns ). After
NO : Repair or replace the connector. registering the injector identification code,
STEP 10. Check on clogged EGR cooler. out the forcible DPF regeneration. (Refer to
NOTE: When checking the clogged EGR cooler,
make a visual check or use an air blower.
DPF Regeneration ).
• Check whether the EGR cooler is being clogged
or not.
13A-82 DIESEL FUEL
TROUBLESHOOTING
Code No. P0107: Manifold Absolute Pressure Sensor Circuit Low Input
A-105 Manifold
absolute
1 2 3 pressure
sensor
3 2 1
LG-B G-L GR
C-105 31 37 72
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKA00093 AB
OPERATION Judgment Criterion

• A power voltage of 5 V is applied to the manifold • The manifold absolute pressure sensor output
absolute pressure sensor power terminal (termi- voltage should is lower than 0.28 V for 0.5 sec-
nal No. 1) from the engine-ECU (terminal No. 72) onds.
and earthed to the engine-ECU (terminal No. 31)
from the manifold absolute pressure sensor (ter- PROBABLE CAUSES
minal No. 3). • Failed manifold absolute pressure sensor
• The sensor signal is inputted to the engine-ECU • Open/short or harness damage circuit in manifold
(terminal No. 37) from the manifold absolute absolute pressure sensor circuit or loose connec-
pressure sensor output terminal (terminal No. 2). tor contact
FUNCTION
• The manifold absolute pressure sensor converts DIAGNOSIS PROCEDURE
the manifold absolute pressure into a voltage sig-
• In response to the signal, the engine-ECU cor-
rects the fuel injection amount, etc.
TROUBLE JUDGMENT Q: Is the check result normal?
Check Conditions YES : Intermittent malfunction (Refer to GROUP
• Battery positive voltage is 8 − 16 V 00 − How to Use Troubleshooting/
• 2 seconds later after the ignition switch has been Inspection Service Points − How to Cope
in "ON" position or the engine has started up with Intermittent Malfunctions ).
NO : Go to Step 2 .
DIESEL FUEL
TROUBLESHOOTING
13A-83
NO : Go to Step 4 .
Connector: A-105
3 2 1 STEP 4. Perform voltage measurement at C-105
Harness side engine-ECU connector.
A-105 (L) connector
Connector: C-105
AK900797 AB
C-105 (B)
NO : Repair or replace the connector. <R.H. drive vehicles>

Connector: A-105
3 2 1
Harness side C-105 (B)
A-105 (L) connector
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
AK900797 AB • Measure engine-ECU terminal voltage.

• Use special tool test harness (MB991709) to con- • Voltage between terminal No. 72 and earth.
nect connector, and measure at pick-up harness.
• Ignition switch: ON OK: 4.9 − 5.1 V
• Voltage between terminal No. 1 and earth. Q: Is the check result normal?
OK: 4.9 − 5.1 V YES : Go to Step 8 .
NO : Go to Step 5 .
13A-84 DIESEL FUEL
TROUBLESHOOTING
connector No. 1) manifold absolute pressure sensor
Connector: C-105
Connector: A-105
3 2 1
Harness side
A-105 (L) connector
C-105 (B)
AK900797 AB
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Check power supply line for short circuit.


DIESEL FUEL
TROUBLESHOOTING
13A-85
connector
with Intermittent Malfunctions ). Connector: A-105
3 2 1
Harness side
ECU is replaced, write the chassis number A-105 (L) connector
Common Rail Engine Learns ). After AK900797 AB

Connector: C-105
the vehicle equipped with the DPF carries <L.H. drive vehicles>
DPF Regeneration ).
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

• Check power supply line for open
circuit and damage.
13A-86 DIESEL FUEL
TROUBLESHOOTING
105 manifold absolute pressure sensor
connector.
Connector: A-105
3 2 1 No. 3) manifold absolute pressure sensor
Harness side connector and C-105 (terminal No. 31) engine-
A-105 (L) connector ECU connector.
Connector: A-105
3 2 1
Harness side
A-105 (L) connector
AK900797 AB

side.
AK900797 AB
OK: Continuity (2 Ω or less)
Connector: C-105

connector
Connector: C-105 C-105 (B)
C-105 (B)
<R.H. drive vehicles> C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B) • Check earthing line for damage.

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 YES : Go to Step 7 .
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-87
Connector: A-105
3 2 1 STEP 14. Check harness between A-105 (terminal
Harness side No. 2) manifold absolute pressure sensor
A-105 (L) connector connector and C-105 (terminal No. 37) engine-
ECU connector.
Connector: A-105
3 2 1
Harness side
A-105 (L) connector
AK900797 AB
• Use special tool test harness (MB991709) to con-

AK900797 AB
OK: 0.7 − 1.2 V
Connector: C-105

connector
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B) • Check output line for short circuit.

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 YES : Replace the manifold absolute pressure
sensor.
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 NO : Repair the damaged harness wire.

13A-88 DIESEL FUEL
TROUBLESHOOTING
STEP 15. Perform voltage measurement at C-105 STEP 16. Connector check: C-105 engine-ECU
engine-ECU connector. connector
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

Connector: A-105
• Ignition switch: ON 3 2 1
• Voltage between terminal No. 37 and earth. Harness side
A-105 (L) connector
OK: 0.7 − 1.2 V
AK900797 AB

YES : Check and repair check harness between
A-105 (terminal No. 2) manifold absolute
pressure sensor connector and C-105
• Check output line for open circuit and
damage.
DIESEL FUEL
TROUBLESHOOTING
13A-89
connector
Connector: C-105
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-90 DIESEL FUEL
TROUBLESHOOTING
Code No. P0108: Manifold Absolute Pressure Sensor Circuit High Input
A-105 Manifold
absolute
1 2 3 pressure
sensor
3 2 1
LG-B G-L GR
C-105 31 37 72
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKA00093 AB

• A power voltage of 5 V is applied to the manifold • The manifold absolute pressure sensor output
absolute pressure sensor power terminal (termi- voltage should exceed 4.72 V for 0.5 seconds.
nal No. 1) from the engine-ECU (terminal No. 72)
and earthed to the engine-ECU (terminal No. 31) PROBABLE CAUSES
from the manifold absolute pressure sensor (ter- • Failed manifold absolute pressure sensor
minal No. 3). • Open circuit in manifold absolute pressure sensor
• The sensor signal is inputted to the engine-ECU circuit or loose connector contact
(terminal No. 37) from the manifold absolute • Failed engine-ECU
pressure sensor output terminal (terminal No. 2).
DIAGNOSIS PROCEDURE
FUNCTION
• The manifold absolute pressure sensor converts
the manifold absolute pressure into a voltage sig-
• In response to the signal, the engine-ECU cor- a. Item 6: Manifold absolute pressure sensor
rects the fuel injection amount, etc. Q: Is the check result normal?
TROUBLE JUDGMENT 00 − How to Use Troubleshooting/
Check Conditions Inspection Service Points − How to Cope
• Battery positive voltage is 8 − 16 V with Intermittent Malfunctions ).
• 2 seconds later after the ignition switch has been NO : Go to Step 2 .
DIESEL FUEL
TROUBLESHOOTING
13A-91
NO : Go to Step 4 .
Connector: A-105
3 2 1 STEP 4. Connector check: C-105 engine-ECU
A-105 (L) connector
Connector: C-105
AK900797 AB
C-105 (B)

105 manifold absolute pressure sensor
connector.
Connector: A-105
3 2 1 C-105 (B)
Harness side
A-105 (L) connector 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

AK900797 AB YES : Go to Step 5 .
• Disconnect connector, and measure at harness NO : Repair or replace the connector.
side.
13A-92 DIESEL FUEL
TROUBLESHOOTING
No. 3) manifold absolute pressure sensor
ECU connector. STEP 6. M.U.T.-III data list
Connector: A-105
3 2 1 a. Item 6: Manifold absolute pressure sensor
A-105 (L) connector
AK900797 AB (Refer to GROUP 00 − Precautions Before
Connector: C-105 Writing ). After replacing the engine-ECU,
C-105 (B) out the forcible DPF regeneration. (Refer to
DPF Regeneration ).

C-105 (B) Q: Is the check result normal?
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
NO : Replace the manifold absolute pressure
Harness side connector AKA00089 AB sensor.
DIESEL FUEL
TROUBLESHOOTING
13A-93
Code No. P0112: EGR Gas Temperature Sensor Circuit Low Input <Euro5>
EGR Gas Temperature Sensor Circuit
A-157
EGR gas temperature
sensor
1 2
1 2
B-P L-R
C-105 30 36
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKB00262 AB

• A power voltage of 5 V is applied to the EGR gas
Check Conditions
temperature sensor output terminal (terminal No.
2) from the engine-ECU (terminal No. 36).
(terminal No. 30) from the EGR gas temperature
• The EGR gas temperature sensor output voltage
FUNCTION is 0.11 V or less (the EGR gas temperature is
• The EGR gas temperature sensor converts the above 500°C or equivalent).
EGR gas temperature into a voltage and inputs
the voltage signal to the engine-ECU. PROBABLE CAUSES
• The EGR gas temperature sensor is a kind of • Failed EGR gas temperature sensor
resistor, which has characteristics to reduce its • Short circuit or harness damage in EGR gas tem-
resistance as the EGR gas temperature rises. perature sensor circuit or loose connector contact
Therefore, the sensor output voltage varies with • Failed engine-ECU
the EGR gas temperature, and becomes lower as
the EGR gas temperature rises.
13A-94 DIESEL FUEL
TROUBLESHOOTING

EGR gas temperature sensor connector.
• Refer to Data List Reference Table P.13A-542
A-157 (B)
a. Item 8: EGR gas temperature sensor
with Intermittent Malfunctions ). 2 1
NO : Go to Step 2 . Harness side
connector AKB00263 AB
STEP 2. Connector check: A-157 EGR gas • Disconnect connector, and measure at harness
temperature sensor connector side.
Connector: A-157 • Voltage between terminal No. 2 and earth.
A-157 (B) OK: 4.5 − 4.9 V
NO : Go to Step 5 .
2 1 STEP 5. Connector check: C-105 engine-ECU

Connector: C-105
STEP 3. Check EGR gas temperature sensor

itself.
• Check EGR gas temperature sensor itself (Refer C-105 (B)
to GROUP 17 − Emission Control − Exhaust Gas
Recirculation (EGR) System − EGR Gas Temper- <R.H. drive vehicles>
ature Sensor Check ).
NO : Replace the EGR gas temperature sensor.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-95
No. 2) EGR gas temperature sensor connector • Refer to Data List Reference Table P.13A-542
and C-105 (terminal No. 36) engine-ECU a. Item 8: EGR gas temperature sensor
connector.
Connector: A-157 YES : Intermittent malfunction (Refer to GROUP
A-157 (B)
2 1 Service − How to Perform Chassis Number
Harness side Writing ). After replacing the engine-ECU,
connector AKB00263 AB register the injector identification code and
Connector: C-105
C-105 (B)

<R.H. drive vehicles> 157 EGR gas temperature sensor connector.
Connector: A-157
A-157 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
2 1
Harness side
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 connector AKB00263 AB
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector • Disconnect connector, and measure at harness

AKA00089 AB
side.
• Check output line for short circuit. • Resistance between terminal No. 1 and earth.
Q: Is the check result normal? OK: Continuity (2 Ω or less)
NO : Go to Step 9 .
13A-96 DIESEL FUEL
TROUBLESHOOTING
connector No. 1) EGR gas temperature sensor connector
Connector: C-105
<L.H. drive vehicles> connector.
Connector: A-157
A-157 (B)
C-105 (B)
2 1
Harness side
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-97
Connector: C-105
Connector: A-157
A-157 (B)
C-105 (B)
2 1
Harness side
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-98 DIESEL FUEL
TROUBLESHOOTING
Code No. P0112: Intake Air Temperature Sensor No. 1 Circuit Low Input <Except Euro5>

1 2
B-L Y-L
86 62
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 5V
Wire colour code

AKA00356 AB

Check Conditions
FUNCTION voltage is 0.09 V or less for 0.5 second.
• The intake air temperature sensor No. 1 converts
the intake air temperature into a voltage and PROBABLE CAUSES
inputs the voltage signal to the engine-ECU. • Failed intake air temperature sensor No. 1
• In response to the signal, the engine-ECU cor- • Short circuit or harness damage in intake air tem-
rects the fuel injection amount, etc. perature sensor No.1 circuit or loose connector
• The intake air temperature sensor No. 1 is a kind contact
DIESEL FUEL
TROUBLESHOOTING
13A-99
DIAGNOSIS PROCEDURE STEP 4. Perform Voltage measurement at A-135
with Intermittent Malfunctions ). Harness side A-135 (B)
NO : Go to Step 2 .
side.
connector
Connector: A-135
OK: 4.5 − 4.9 V
NO : Go to Step 5 .

connector
Harness side A-135 (B) Connector: C-105
connector AKA00399AB <L.H. drive vehicles>


C-105 (B)
1 itself.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-100 DIESEL FUEL
TROUBLESHOOTING
Connector: C-105

C-105 (B) 135 air flow sensor connector.
Connector: A-135
C-105 (B) Harness side A-135 (B)

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
side.
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

• Check output line for short circuit. Q: Is the check result normal?
NO : Go to Step 9 .
DIESEL FUEL
TROUBLESHOOTING
13A-101
Connector: C-105
Connector: A-135
C-105 (B)

Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-102 DIESEL FUEL
TROUBLESHOOTING
Connector: C-105
C-105 (B)

<R.H. drive vehicles> connector AKA00399AB
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-103
Code No. P0113: EGR Gas Temperature Sensor Circuit High Input <Euro5>
EGR Gas Temperature Sensor Circuit
A-157
EGR gas temperature
sensor
1 2
1 2
B-P L-R
C-105 30 36
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKB00262 AB

• A power voltage of 5 V is applied to the EGR gas
Check Conditions
temperature sensor output terminal (terminal No.
2) from the engine-ECU (terminal No. 36).
(terminal No. 30) from the EGR gas temperature
• The EGR gas temperature sensor output voltage
FUNCTION is 4.96 V or more (the EGR gas temperature is
• The EGR gas temperature sensor converts the below −50°C or equivalent).
EGR gas temperature into a voltage and inputs
the voltage signal to the engine-ECU. PROBABLE CAUSES
• The EGR gas temperature sensor is a kind of • Failed EGR gas temperature sensor
resistor, which has characteristics to reduce its • Open circuit in EGR gas temperature sensor cir-
resistance as the EGR gas temperature rises. cuit or loose connector contact
Therefore, the sensor output voltage varies with • Failed engine-ECU
the EGR gas temperature, and becomes lower as
the EGR gas temperature rises.
13A-104 DIESEL FUEL
TROUBLESHOOTING

EGR gas temperature sensor connector.
A-157 (B)
a. Item 8: EGR gas temperature sensor
with Intermittent Malfunctions ). 2 1
NO : Go to Step 2 . Harness side
STEP 2. Connector check: A-157 EGR gas • Disconnect connector, and measure at harness
temperature sensor connector side.
Connector: A-157 • Voltage between terminal No. 2 and earth.
A-157 (B) OK: 4.5 − 4.9 V
NO : Go to Step 5 .
2 1 STEP 5. Connector check: C-105 engine-ECU

Connector: C-105
STEP 3. Check EGR gas temperature sensor

itself.
• Check EGR gas temperature sensor itself (Refer C-105 (B)
to GROUP 17 − Emission Control − Exhaust Gas
Recirculation (EGR) System − EGR Gas Temper- <R.H. drive vehicles>
ature Sensor Check ).
NO : Replace the EGR gas temperature sensor.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-105
No. 2) EGR gas temperature sensor connector • Refer to Data List Reference Table P.13A-542
and C-105 (terminal No. 36) engine-ECU a. Item 8: EGR gas temperature sensor
connector.
A-157 (B)
Connector: C-105
C-105 (B)

<R.H. drive vehicles> 157 EGR gas temperature sensor connector.
Connector: A-157
A-157 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
2 1
Harness side
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 connector AKB00263 AB
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector • Disconnect connector, and measure at harness

AKA00089 AB
side.
• Check output line for open circuit. • Resistance between terminal No. 1 and earth.
NO : Go to Step 9 .
13A-106 DIESEL FUEL
TROUBLESHOOTING
Connector: C-105
Connector: A-157
A-157 (B)
C-105 (B)
2 1
Harness side
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-107
Connector: C-105
Connector: A-157
A-157 (B)
C-105 (B)
2 1
Harness side
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-108 DIESEL FUEL
TROUBLESHOOTING
Code No. P0113: Intake Air Temperature Sensor No. 1 Circuit High Input <Except Euro5>

1 2
B-L Y-L
86 62
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 5V
Wire colour code

AKA00356 AB

Check Conditions
temperature sensor No.1 output terminal (termi-
nal No. 2) of air flow sensor connector from the
(terminal No. 86) from the intake air temperature Judgment Criterion
sensor No. 1 (terminal No. 1). • The intake air temperature sensor No. 1 output
FUNCTION
• The intake air temperature sensor No. 1 converts PROBABLE CAUSES
the intake air temperature into a voltage and • Failed intake air temperature sensor No. 1
inputs the voltage signal to the engine-ECU. • Open circuit or harness damage in intake air tem-
• In response to the signal, the engine-ECU cor- perature sensor No. 1 circuit or loose connector
rects the fuel injection amount, etc. contact
• The intake air temperature sensor No. 1 is a kind • Failed engine-ECU
of resistor, which has characteristics to reduce its
DIESEL FUEL
TROUBLESHOOTING
13A-109
air flow sensor No. 1 connector.
a. Item 43: Intake air temperature sensor No. 1
Harness side
Inspection Service Points − How to Cope connector
A-135 (B)
AKA00399AB
NO : Go to Step 2 . • Disconnect connector, and measure at harness
side.
connector
OK: 4.5 − 4.9 V
Connector: A-135
NO : Go to Step 5 .

connector
Connector: C-105
Harness side A-135 (B) <L.H. drive vehicles>

C-105 (B)
1 itself.
• Check intake air temperature sensor No. 1 itself <R.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-110 DIESEL FUEL
TROUBLESHOOTING
Connector: C-105

C-105 (B) 135 air flow sensor connector.
Connector: A-135
C-105 (B) Harness side A-135 (B)

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
side.
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

• Check output line for open circuit. Q: Is the check result normal?
NO : Go to Step 9 .
DIESEL FUEL
TROUBLESHOOTING
13A-111
Connector: C-105
<L.H. drive vehicles> • Check earthing line open circuit and damage.
Connector: A-135
C-105 (B)

Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-112 DIESEL FUEL
TROUBLESHOOTING
Code No. P0117: Engine Coolant Temperature Sensor Circuit Low Input
Engine Coolant Temperature Sensor Circuit
A-107
(MU802406) Engine coolant
temperature sensor
1 2
2 1
LG V
C-105 87 63
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00095 AB
OPERATION • The engine coolant temperature sensor is a kind

• A power voltage of 5 V is applied to the engine of resistor, which has characteristics to reduce its
coolant temperature sensor output terminal (ter- resistance as the engine coolant temperature
minal No. 1) from the engine-ECU (terminal No. rises. Therefore, the sensor output voltage varies
63). with the engine coolant temperature, and
• The power voltage is earthed to the engine-ECU becomes lower as the engine coolant tempera-
(terminal No. 87) from the engine coolant temper- ture rises.
ature sensor (terminal No. 2).
TROUBLE JUDGMENT
FUNCTION
Check Conditions
• The engine coolant temperature sensor converts
the engine coolant temperature into a voltage sig-
nal, and inputs the voltage to the engine-ECU.
• In response to the signal, the engine-ECU con-
trols the fuel infection amount and the fast idle Judgment Criterion
speed when the engine is cold state. • The engine coolant temperature sensor output
voltage is 0.15 V or less for 0.5 second.
PROBABLE CAUSES
• Failed engine coolant temperature sensor
DIESEL FUEL
TROUBLESHOOTING
13A-113
• Short circuit or harness damage in engine cool- STEP 3. Perform resistance measurement at A-
ant temperature sensor circuit or loose connector 107 engine coolant temperature sensor
contact connector.
Connector: A-107
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-III data list A-107 (B)

• Item 7: Engine coolant temperature sensor
OK:
Engine cold state: At ambient temperature 2 1
(atmospheric temperature) or equivalent. Harness side
Engine hot state: At 80 − 120°C connector AK501323 AB
Q: Is the check result normal? • Disconnect connector, and measure at sensor

YES : Intermittent malfunction (Refer to GROUP side.
00 − How to Use Troubleshooting/ • Resistance between terminal No. 1 and No. 2.
Inspection Service Points − How to Cope OK:
with Intermittent Malfunctions ). Engine coolant temperature at −20°C: 14 − 17
NO : Go to Step 2 . kΩ
Engine coolant temperature at 0°C: 5.1 − 6.5
STEP 2. Connector check: A-107 engine coolant kΩ
temperature sensor connector Engine coolant temperature at 20°C: 2.1 − 2.7
kΩ
Connector: A-107
kΩ
Engine coolant temperature at 60°C: 0.48 −
0.68 kΩ
A-107 (B)
0.36 kΩ
2 1 Q: Is the check result normal?
Harness side
connector AK501323 AB NO : Replace the engine coolant temperature
sensor.
STEP 4. Perform voltage measurement at A-107 • Voltage between terminal No. 1 and earth.
engine coolant temperature sensor connector. OK: 4.5 − 4.9 V
NO : Go to Step 5 .
A-107 (B)
2 1
Harness side

side.
13A-114 DIESEL FUEL
TROUBLESHOOTING
connector No. 1) engine coolant temperature sensor
ECU connector.
Connector: C-105
A-107 (B)
C-105 (B)
2 1
Harness side
<R.H. drive vehicles> connector AK501323 AB
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


OK:
Engine cold state: At ambient temperature
(atmospheric temperature) or equivalent.
Engine hot state: At 80 − 120 °C
DIESEL FUEL
TROUBLESHOOTING
13A-115
connector
DPF Regeneration ).

107 engine coolant temperature sensor
connector. C-105 (B)
Connector: A-107 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-107 (B) Harness side connector AKA00089 AB

2 1
Harness side

side.
13A-116 DIESEL FUEL
TROUBLESHOOTING
No. 2) engine coolant temperature sensor
ECU connector. STEP 11. Connector check: C-105 engine-ECU
connector
Connector: A-107
Connector: C-105
A-107 (B)
2 1
Connector: C-105 <R.H. drive vehicles>

C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25

72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-117
ECU connector.
Connector: A-107
A-107 (B)
2 1
Harness side
Connector: C-105
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-118 DIESEL FUEL
TROUBLESHOOTING
Code No. P0118: Engine Coolant Temperature Sensor Circuit High Input
Engine Coolant Temperature Sensor Circuit
A-107
(MU802406) Engine coolant
temperature sensor
1 2
2 1
LG V
C-105 87 63
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00095 AB
OPERATION • The engine coolant temperature sensor is a kind

• A power voltage of 5 V is applied to the engine of resistor, which has characteristics to reduce its
coolant temperature sensor output terminal (ter- resistance as the engine coolant temperature
minal No. 1) from the engine-ECU (terminal No. rises. Therefore, the sensor output voltage varies
63). with the engine coolant temperature, and
• The power voltage is earthed to the engine-ECU becomes lower as the engine coolant tempera-
(terminal No. 87) from the engine coolant temper- ture rises.
ature sensor (terminal No. 2).
TROUBLE JUDGMENT
FUNCTION
Check Conditions
• The engine coolant temperature sensor converts
the engine coolant temperature into a voltage sig-
nal, and inputs the voltage to the engine-ECU.
trols the fuel infection amount and the fast idle Judgment Criterion
speed when the engine is cold state. • The engine coolant temperature sensor output
PROBABLE CAUSES
• Failed engine coolant temperature sensor
• Open circuit in engine coolant temperature sensor circuit or loose connector contact
DIESEL FUEL
TROUBLESHOOTING
13A-119
• Failed engine-ECU STEP 3. Perform resistance measurement at A-
DIAGNOSIS PROCEDURE connector.
Connector: A-107
OK:
Engine cold state: At ambient temperature A-107 (B)
Engine hot state: At 80 − 120°C
Q: Is the check result normal? 2 1
YES : Intermittent malfunction (Refer to GROUP Harness side
connector
00 − How to Use Troubleshooting/ AK501323 AB
Inspection Service Points − How to Cope • Disconnect connector, and measure at sensor
with Intermittent Malfunctions ). side.
NO : Go to Step 2 . • Resistance between terminal No. 1 and No. 2.
OK:
STEP 2. Connector check: A-107 engine coolant Engine coolant temperature at −20°C: 14 − 17
temperature sensor connector kΩ
Connector: A-107
kΩ
kΩ
A-107 (B)
kΩ
0.68 kΩ
2 1
Harness side 0.36 kΩ
Q: Is the check result normal? YES : Go to Step 4 .
YES : Go to Step 3 . NO : Replace the engine coolant temperature
NO : Repair or replace the connector. sensor.

engine coolant temperature sensor connector. NO : Go to Step 5 .
Connector: A-107
A-107 (B)
2 1
Harness side

side.
OK: 4.5 − 4.9 V
13A-120 DIESEL FUEL
TROUBLESHOOTING
connector No. 1) engine coolant temperature sensor
ECU connector.
Connector: C-105
A-107 (B)
C-105 (B)
2 1
Harness side
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Check output line for open circuit.


OK:
Engine cold state: At ambient temperature
Engine hot state: At 80 − 120 °C
DIESEL FUEL
TROUBLESHOOTING
13A-121
connector
DPF Regeneration ).

connector. C-105 (B)
Connector: A-107 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-107 (B) Harness side connector AKA00089 AB

2 1
Harness side

side.
13A-122 DIESEL FUEL
TROUBLESHOOTING
ECU connector.
Connector: A-107
A-107 (B)
2 1
Harness side
Connector: C-105
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-123
Code No. P0122: Throttle Position Sensor Circuit Low Input
Throttle Position Sensor Circuit
A-132
(MU805200) Hall IC
Electronic-controlled
throttle valve
1 2 3 4 5 6
2 1 4
W R B
B
93 40 34
Engine-ECU
5V
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00096 AB
OPERATION FUNCTION
• A power voltage of 5 V is applied to the elec- • The throttle position sensor converts the throttle
tronic-controlled throttle valve (terminal No. 2) valve position into voltage and inputs it into the
from the engine-ECU (terminal No. 93). engine-ECU.
• The power voltage is earthed to the engine-ECU • The engine-ECU control the throttle valve posi-
(terminal No. 34) from the electronic-controlled tion.
throttle valve (terminal No. 4).
• The sensor signal is inputted to the engine-ECU TROUBLE JUDGMENT
(terminal No. 40) from the electronic-controlled Check Conditions
throttle valve output terminal (terminal No. 1). • Battery positive voltage is 8 − 16 V
• 2 seconds later after the ignition switch has been in "ON" position or the engine has started up
13A-124 DIESEL FUEL
TROUBLESHOOTING
Judgment Criterion STEP 3. Perform voltage measurement at A-132

• The throttle position sensor output voltage is 0.15 electronic-controlled throttle valve connector.
V or less for 0.5 second.
Connector: A-132
PROBABLE CAUSES
• Failed throttle position sensor
• Open/short circuit or harness damage in throttle
position sensor circuit or loose connector contact
A-132 (B)
DIAGNOSIS PROCEDURE 6 5 4 3 2 1
Harness side
• Refer to Data List Reference Table P.13A-542. • Disconnect connector, and measure at harness
a. Item 45: Throttle position sensor side.
Q: Is the check result normal? • Voltage between terminal No. 2 and earth.
00 − How to Use Troubleshooting/ OK: 4.9 − 5.1 V
Inspection Service Points − How to Cope Q: Is the check result normal?
with Intermittent Malfunctions ). YES : Go to Step 7 .
NO : Go to Step 2 . NO : Go to Step 4 .
STEP 2. Connector check: A-132 electronic- STEP 4. Connector check: C-105 engine-ECU
controlled throttle valve connector connector
A-132 (B)
6 5 4 3 2 1 C-105 (B)
Harness side
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-125
No. 2) electronic-controlled throttle valve • Refer to Data List Reference Table P.13A-542.
connector and C-105 (terminal No. 93) engine- a. Item 45: Throttle position sensor
ECU connector.
A-132 (B)
6 5 4 3 2 1 Service − How to Perform Chassis Number
connector AK604705 AB register the injector identification code and
Connector: C-105
C-105 (B) DPF Regeneration ).
<R.H. drive vehicles> STEP 7. Perform resistance measurement at A-

132 electronic-controlled throttle valve
connector.
Connector: A-132
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
A-132 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 6 5 4 3 2 1
Harness side
Harness side connector AKA00089 AB connector AK604705 AB
• Check power supply line for open/short circuit. • Disconnect connector, and measure at harness
NO : Go to Step 8 .
13A-126 DIESEL FUEL
TROUBLESHOOTING
connector No. 4) electronic-controlled throttle valve
Connector: C-105
Connector: A-132
C-105 (B)
A-132 (B)
<R.H. drive vehicles> 6 5 4 3 2 1
Harness side
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-127
connector
Connector: C-105
<L.H. drive vehicles> STEP 12. Connector check: C-105 engine-ECU
connector
Connector: C-105
C-105 (B)

C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49

electronic-controlled throttle valve connector.
Connector: A-132
A-132 (B)
6 5 4 3 2 1
Harness side

OK: 3.7 V or higher.
13A-128 DIESEL FUEL
TROUBLESHOOTING
No. 1) electronic-controlled throttle valve No. 2) electronic-controlled throttle valve
connector and C-105 (terminal No. 40) engine- connector and C-105 (terminal No. 93) engine-
ECU connector. ECU connector.
A-132 (B) A-132 (B)

6 5 4 3 2 1 6 5 4 3 2 1

C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Check output line for short circuit. • Check power supply line for damage.
YES : Go to Step 14 . YES : Replace the electronic-controlled throttle
NO : Repair the damaged harness wire. valve.
DIESEL FUEL
TROUBLESHOOTING
13A-129
No. 1) electronic-controlled throttle valve
ECU connector.
Connector: A-132
A-132 (B)
6 5 4 3 2 1
Harness side
Connector: C-105
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Check output line for open circuit and damage.

13A-130 DIESEL FUEL
TROUBLESHOOTING
Code No. P0123: Throttle Position Sensor Circuit High Input
Throttle Position Sensor Circuit
A-132
(MU805200) Hall IC
throttle valve
1 2 3 4 5 6
2 1 4
W R B
B
93 40 34
Engine-ECU
5V
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00096 AB
OPERATION FUNCTION
• A power voltage of 5 V is applied to the elec- • The throttle position sensor converts the throttle
tronic-controlled throttle valve (terminal No. 2) valve position into voltage and inputs it into the
from the engine-ECU (terminal No. 93). engine-ECU.
• The power voltage is earthed to the engine-ECU • The engine-ECU control the throttle valve posi-
(terminal No. 34) from the electronic-controlled tion.
throttle valve (terminal No. 4).
• The sensor signal is inputted to the engine-ECU TROUBLE JUDGMENT
(terminal No. 40) from the electronic-controlled Check Conditions
throttle valve output terminal (terminal No. 1). • Battery positive voltage is 8 − 16 V
• 2 seconds later after the ignition switch has been in "ON" position or the engine has started up
DIESEL FUEL
TROUBLESHOOTING
13A-131
Judgment Criterion STEP 3. Perform resistance measurement at A-
• The throttle position sensor output voltage is 4.85 132 electronic-controlled throttle valve
V or more for 0.5 second. connector.
PROBABLE CAUSES Connector: A-132
• Failed throttle position sensor
• Open circuit or harness damage in throttle posi-
tion sensor circuit or loose connector contact
DIAGNOSIS PROCEDURE A-132 (B)

6 5 4 3 2 1
STEP 1. M.U.T.-III data list Harness side
a. Item 45: Throttle position sensor • Disconnect connector, and measure at harness
side.
Q: Is the check result normal? • Resistance between terminal No. 4 and earth.
00 − How to Use Troubleshooting/ OK: Continuity (2 Ω or less)
Inspection Service Points − How to Cope Q: Is the check result normal?
with Intermittent Malfunctions ). YES : Go to Step 7 .
NO : Go to Step 2 . NO : Go to Step 4 .
STEP 2. Connector check: A-132 electronic- STEP 4. Connector check: C-105 engine-ECU
controlled throttle valve connector connector
A-132 (B)
6 5 4 3 2 1 C-105 (B)
Harness side
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-132 DIESEL FUEL
TROUBLESHOOTING
No. 4) electronic-controlled throttle valve • Refer to Data List Reference Table P.13A-542.
connector and C-105 (terminal No. 34) engine- a. Item 45: Throttle position sensor
ECU connector.
A-132 (B)
6 5 4 3 2 1 Service − How to Perform Chassis Number
connector AK604705 AB register the injector identification code and
Connector: C-105
C-105 (B) DPF Regeneration ).
<R.H. drive vehicles> STEP 7. Replace the electronic-controlled

throttle valve assembly
• After replacing the electronic-controlled throttle
valve assembly, re-check the trouble symptoms.
YES : Check end.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector AKA00089 AB learn fuel injection (Refer to GROUP 00 −
• Check earthing line for open circuit and damage. Precautions Before Service − What The
Q: Is the check result normal? registering the injector identification code,
DPF Regeneration ).
DIESEL FUEL
TROUBLESHOOTING
13A-133
Code No. P0182: Fuel Temperature Sensor Circuit Low input
Fuel Temperature Sensor Circuit
A-46
(MU802406)
Fuel temperature sensor
1 2
2 1
BR Y-B
79 55
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 5V
Wire colour code

AKA00097AB

• A power voltage of 5 V is applied to the fuel tem-
Check Conditions
perature sensor output terminal (terminal No. 1)
from the engine-ECU (terminal No. 55).
(terminal No. 79) from the fuel temperature sen-
sor (terminal No. 2). Judgment Criterion
• The fuel temperature sensor output voltage is
FUNCTION 0.10 V or less for 0.5 second.
• The fuel temperature sensor converts the fuel
temperature into a voltage and inputs the voltage PROBABLE CAUSES
signal to the engine-ECU. • Failed fuel temperature sensor
• In response to the signal, the engine-ECU cor- • Short circuit or harness damage in fuel tempera-
rects the fuel injection amount, etc. ture sensor circuit or loose connector contact
• The fuel temperature sensor is a kind of resistor, • Failed engine-ECU
which has characteristics to reduce its resistance
as the fuel temperature rises. Therefore, the sen-
sor output voltage varies with the fuel tempera-
ture, and becomes lower as the fuel temperature
rises.
13A-134 DIESEL FUEL
TROUBLESHOOTING

fuel temperature sensor connector.
• Item 21: Fuel temperature sensor
OK: At ambient temperature (fuel tempera-
ture) or equivalent.
YES : Intermittent malfunction (Refer to GROUP A-46 (B)
NO : Go to Step 2 .
side.
STEP 2. Connector check: A-46 fuel temperature
sensor connector
Connector: A-46
OK: 4.5 − 4.9 V
NO : Go to Step 5 .
A-46 (B)
2 1 connector

STEP 3. Check fuel temperature sensor itself.

C-105 (B)
• Check fuel temperature sensor itself (Refer to
P.13A-596).
NO : Replace the fuel temperature sensor.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-135
No. 1) fuel temperature sensor connector and C- • Item 21: Fuel temperature sensor
105 (terminal No. 55) engine-ECU connector. OK: At ambient temperature (fuel tempera-
Connector: A-46 ture) or equivalent.
A-46 (B)
2 1 ECU is replaced, write the chassis number
Harness side (Refer to GROUP 00 − Precautions Before
connector AK501326 AB Service − How to Perform Chassis Number
Connector: C-105
C-105 (B) GROUP 17 − Emission Control − Diesel
<R.H. drive vehicles> DPF Regeneration ).
STEP 8. Perform resistance measurement at A-46

Connector: A-46
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 A-46 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
2 1
Harness side
• Check output line for short circuit. connector AK501326 AB
Q: Is the check result normal? • Disconnect connector, and measure at harness

YES : Go to Step 7 . side.
NO : Repair the damaged harness wire. • Resistance between terminal No. 2 and earth.
NO : Go to Step 9 .
13A-136 DIESEL FUEL
TROUBLESHOOTING
connector No. 2) fuel temperature sensor connector and C-
Connector: C-105
105 (terminal No. 79) engine-ECU connector.
Connector: A-46
C-105 (B)
A-46 (B)
2 1
Harness side
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-137
Connector: C-105
Connector: A-46
A-46 (B)
C-105 (B)
2 1
<R.H. drive vehicles> Harness side

Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-138 DIESEL FUEL
TROUBLESHOOTING
Code No. P0183: Fuel Temperature Sensor Circuit High Input
Fuel Temperature Sensor Circuit
A-46
(MU802406)
1 2
2 1
BR Y-B
79 55
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 5V
Wire colour code

AKA00097AB

• A power voltage of 5 V is applied to the fuel tem-
Check Conditions
perature sensor output terminal (terminal No. 1)
of the air flow sensor connector from the engine-
ECU (terminal No. 55).
(terminal No. 79) from the fuel temperature sen- Judgment Criterion
sor (terminal No. 2). • The fuel temperature sensor output voltage is
4.95 V or more for 0.5 second.
FUNCTION
• The fuel temperature sensor converts the intake PROBABLE CAUSES
air temperature into a voltage and inputs the volt- • Failed fuel temperature sensor
age signal to the engine-ECU. • Open circuit or harness damage in fuel tempera-
• In response to the signal, the engine-ECU cor- ture sensor circuit or loose connector contact
rects the fuel injection amount, etc. • Failed engine-ECU
• The fuel temperature sensor is a kind of resistor,
which has characteristics to reduce its resistance
as the intake air temperature rises. Therefore, the
sensor output voltage varies with the fuel temper-
ature, and becomes lower as the fuel tempera-
ture rises.
DIESEL FUEL
TROUBLESHOOTING
13A-139
• Item 21: Fuel temperature sensor
OK: At ambient temperature (fuel tempera-
ture) or equivalent.
YES : Intermittent malfunction (Refer to GROUP A-46 (B)
NO : Go to Step 2 .
side.
STEP 2. Connector check: A-46 fuel temperature
sensor connector
Connector: A-46
OK: 4.5 − 4.9 V
NO : Go to Step 5 .
A-46 (B)
2 1 connector

STEP 3. Check fuel temperature sensor itself.

C-105 (B)
• Check fuel temperature sensor itself (Refer to
P.13A-596).
NO : Replace the fuel temperature sensor.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-140 DIESEL FUEL
TROUBLESHOOTING
No. 1) fuel temperature sensor connector and C- • Item 21: Fuel temperature sensor
105 (terminal No. 55) engine-ECU connector. OK: At ambient temperature (fuel tempera-
Connector: A-46 ture) or equivalent.
A-46 (B)
Harness side (Refer to GROUP 00 − Precautions Before
connector AK501326 AB Service − How to Perform Chassis Number
Connector: C-105

Connector: A-46
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 A-46 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
2 1
Harness side
• Check output line for open circuit. connector AK501326 AB

NO : Go to Step 9 .
DIESEL FUEL
TROUBLESHOOTING
13A-141
Connector: C-105
<L.H. drive vehicles> • Check earthing line for open circuit and damage.
Connector: A-46
C-105 (B)
A-46 (B)
2 1
Harness side
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-142 DIESEL FUEL
TROUBLESHOOTING
Code No. P0191: Rail Pressure Sensor Range/Performance Problem
Rail Pressure Sensor Circuit
A-44
(MU802408)
Rail pressure
3 2 1 sensor
2 1 3
W R B
A-131
5 6 4
W R B B
C-105 64 70 88
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

R: Red P: Pink V:Violet PU: Purple SI: Silver
AKA00196 AD

• 5 V power is supplied from the engine-ECU (ter- • A difference between the objective and actual rail
minal No. 70) to the rail pressure sensor (terminal pressures exceeds 15 MPa for 0.5 second, and
No. 1). the rail pressure sensor has an output voltage
• The rail pressure sensor (terminal No. 3) is variation of 0.01 V or less.
earthed to the engine-ECU (terminal No. 88).
• Sensor signals are input from the rail pressure PROBABLE CAUSES
sensor (terminal No. 2) to the engine-ECU (termi- • Failed rail pressure sensor
nal No. 64). • Failed suction control valve
• Fuel line blocked
FUNCTION • Failed engine-ECU
the rail pressure sensor. DIAGNOSIS PROCEDURE
• Based on these signals, the engine-ECU checks
the rail pressure sensor for errors.
TROUBLE JUDGMENT • Check suction control valve itself (Refer to P.13A-
596).
Check Condition
• Engine is running. Q: Is the check result normal?
DIESEL FUEL
TROUBLESHOOTING
13A-143
NO : Replace the suction control valve. After NO : Repair or replace the connector.
supply pump (Refer to GROUP 00 − STEP 4. Check harness between A-44 (terminal
Precautions Before Service − What The No. 3) rail pressure sensor connector and C-105
Common Rail Engine Learns ). (terminal No. 88) engine-ECU connector.
Connector: A-44
STEP 2. Connector check: A-44 rail pressure
sensor connector.
Connector: A-44
3 2 1
A-44 (B)
Harness side
3 2 1
A-44 (B) Connector: C-105
Harness side <L.H. drive vehicles>

YES : Go to Step 3.
STEP 3. Connector check: C-105 engine-ECU C-105 (B)

connector
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
NOTE: Before checking harness, check intermediate

connector A-131, and repair if necessary.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 YES : Go to Step 5.
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-144 DIESEL FUEL
TROUBLESHOOTING
No. 1) rail pressure sensor connector and C-105 No. 2) rail pressure sensor connector and C-105
3 2 1 3 2 1
A-44 (B) A-44 (B)

C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
DIESEL FUEL
TROUBLESHOOTING
13A-145
rail pressure sensor connector.
Connector: A-44 Service − How to Perform Chassis Number
3 2 1 the vehicle equipped with the DPF carries
A-44 (B)
Harness side out the forcible DPF regeneration. (Refer to
connector AK501327 AB GROUP 17 − Emission Control − Diesel
• Use special tool test harness (MB991658) to con- Particulate Filter (DPF) System − Forcible
nect connector, and measure at pick-up harness. DPF Regeneration ).
• Engine: Idling (after warning up) NO : Replace the common rail assembly and fuel
• Voltage between terminal No. 2 and earth. injection tubes.
OK: 1.15 − 1.75 V
13A-146 DIESEL FUEL
TROUBLESHOOTING
Code No. P0192: Rail Pressure Sensor Circuit Low Input
A-44
(MU802408)
Rail pressure
3 2 1 sensor
2 1 3
W R B
A-131
5 6 4
W R B B
C-105 64 70 88
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKA00196 AD

• A power voltage of 5 V is applied to the rail pres-
Check Conditions
sure sensor power terminal (terminal No. 1) from
the engine-ECU (terminal No. 70) and earthed to
the engine-ECU (terminal No. 88) from the rail
pressure sensor (terminal No. 3).
• The sensor signal is inputted to the engine-ECU Judgment Criterion
(terminal No. 64) from the rail pressure sensor • The rail pressure sensor output voltage is 0.70 V
output terminal (terminal No. 2). or less for 0.5 second.
FUNCTION PROBABLE CAUSES

• The rail pressure sensor converts the rail pres- • Failed rail pressure sensor
sure into a voltage signal and inputs the signal to • Open/short circuit or harness damage in rail pres-
the engine-ECU. sure sensor circuit or loose connector contact
• In response to the signal, the engine-ECU cor- • Failed engine-ECU
rects the fuel injection quantity.
DIESEL FUEL
TROUBLESHOOTING
13A-147
DIAGNOSIS PROCEDURE YES : Go to Step 9 .
NO : Go to Step 4 .

• Refer to Data List Reference Table P.13A-542. STEP 4. Perform voltage measurement at C-105
engine-ECU connector.
a. Item 63: Rail pressure sensor
Connector: C-105
NO : Go to Step 2 .
C-105 (B)
sensor connector
Connector: A-44
C-105 (B)
3 2 1
A-44 (B)
Harness side 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
rail pressure sensor connector. OK: 4.9 − 5.1 V
NO : Go to Step 5 .
3 2 1
A-44 (B)
Harness side

OK: 4.9 − 5.1 V
13A-148 DIESEL FUEL
TROUBLESHOOTING
connector No. 1) rail pressure sensor connector and C-105
Connector: C-105
Connector: A-44
C-105 (B)
3 2 1
A-44 (B)
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


DIESEL FUEL
TROUBLESHOOTING
13A-149
connector
with Intermittent Malfunctions ). Connector: C-105
learn fuel injection (Refer to GROUP 00 − C-105 (B)
DPF Regeneration ).
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-44
3 2 1
A-44 (B)
Harness side

YES : Check intermediate connector A-131, and
repair if necessary. If intermediate
connector is normal, check and repair
harness between A-44 (terminal No. 1) rail
circuit and damage.
13A-150 DIESEL FUEL
TROUBLESHOOTING
Connector: A-44
Connector: C-105
3 2 1
A-44 (B)
Harness side

C-105 (B)
side.
OK: Continuity (2 Ω or less) <R.H. drive vehicles>


connector C-105 (B)
Connector: C-105
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
<L.H. drive vehicles> 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-44
C-105 (B)
3 2 1
A-44 (B)
Harness side
C-105 (B) NOTE: Before checking harness, check intermediate

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 Q: Is the check result normal?
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector AKA00089 AB NO : Repair the damaged harness wire.

DIESEL FUEL
TROUBLESHOOTING
13A-151
Connector: A-44
Connector: C-105
3 2 1
A-44 (B)
Harness side

C-105 (B)
• Engine: Idle (after warning up)
• Voltage between terminal No. 2 and earth. <R.H. drive vehicles>
OK: 1.15 − 1.75 V
STEP 13. Connector check: C-105 engine-ECU C-105 (B)

connector
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Connector: C-105 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25

72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-44
C-105 (B)
3 2 1
A-44 (B)
Harness side

C-105 (B) connector A-131, and repair if necessary.
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
YES : Replace the common rail assembly.
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-152 DIESEL FUEL
TROUBLESHOOTING
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

Connector: A-44
• Engine: Idle (after warning up)
OK: 1.15 − 1.75 V
3 2 1
A-44 (B)
Harness side

connector is normal, check and repair check
harness between A-44 (terminal No. 2) rail
damage.
DIESEL FUEL
TROUBLESHOOTING
13A-153
connector
Connector: C-105
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-154 DIESEL FUEL
TROUBLESHOOTING
Code No. P0193: Rail Pressure Sensor Circuit High Input
A-44
(MU802408)
Rail pressure
3 2 1 sensor
2 1 3
W R B
A-131
5 6 4
W R B B
C-105 64 70 88
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKA00196 AD

• A power voltage of 5 V is applied to the rail pres-
Check Conditions
sure sensor power terminal (terminal No. 1) from
the engine-ECU (terminal No. 70) and earthed to
the engine-ECU (terminal No. 88) from the rail
pressure sensor (terminal No. 3).
(terminal No. 64) from the rail pressure sensor • The rail pressure sensor output voltage is 4.85 V
output terminal (terminal No. 2). or more for 0.5 second.

• The rail pressure sensor converts the rail pres- • Failed rail pressure sensor
sure into a voltage signal and inputs the signal to • Open circuit in rail pressure sensor circuit or
the engine-ECU. loose connector contact
• In response to the signal, the engine-ECU cor- • Failed engine-ECU
rects the fuel injection quantity.
DIESEL FUEL
TROUBLESHOOTING
13A-155
NO : Go to Step 4 .

connector
Connector: C-105
NO : Go to Step 2 .
C-105 (B)
sensor connector
Connector: A-44
C-105 (B)
3 2 1
A-44 (B)
Harness side 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 3. Perform resistance measurement at A-44 NO : Repair or replace the connector.
Connector: A-44
3 2 1
A-44 (B)
Harness side

side.
13A-156 DIESEL FUEL
TROUBLESHOOTING
Connector: A-44
3 2 1 with Intermittent Malfunctions ).
Harness side
A-44 (B) NO : Replace the engine-ECU. When the engine-
connector AK501327 AB ECU is replaced, write the chassis number
C-105 (B) the vehicle equipped with the DPF carries
DPF Regeneration ).

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 YES : Intermittent malfunction (Refer to GROUP
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector AKA00089 AB NO : Replace the common rail assembly.
DIESEL FUEL
TROUBLESHOOTING
13A-157
Code No. P0201: No. 1 Injector Circuit Malfunction
No. 1 Injector Circuit
A-42
No. 1
1 2 injector G
1 2
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00099 AJ
OPERATION • Battery positive voltage is 8 V or more.

• Driving power is supplied from the engine-ECU • Except during the engine cranking period
(terminal No. 1) to the No. 1 injector (terminal No. • When an engine-ECU internal capacitor is
2). allowed to be charged
• The engine-ECU (terminal No. 2) turn on the
Judgment Criterion
power transistor to flow current to the No. 1 injec-
• When the peak current of the No. 1 injector circuit
tor (terminal No. 1).
is not detected, the circuit is judged to be open.
FUNCTION
PROBABLE CAUSES
• The engine-ECU monitors peak current during
• Failed No. 1 injector
injector drive control to detect disconnection in
• Open/short circuit or harness damage in No. 1
the injector No. 1 circuit.
injector circuit or loose connector contact
Check Conditions
• Ignition switch is in ON position
13A-158 DIESEL FUEL
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 3. Check harness between No. 1 injector

CAUTION connector and engine-ECU connector.
A high-tension voltage is flowing between the Connector: A-42
engine-ECU and the injectors while the engine is
running. Handle them carefully to avoid receiving
electric shocks from the voltage.
A-42 (GR)
STEP 1. Connector check: A-42 No. 1 injector

connector
1 2
Connector: A-42
Harness side
connector AKA00186 AB
Connector: C-105
A-42 (GR) <L.H. drive vehicles>
1 2
Harness side
C-105 (B)
STEP 2. Check No. 1 injector itself.

• Check No. 1 injector itself (Refer to P.13A-595).
NO : Replace the No. 1 injector. After replacing C-105 (B)
the Injector, register the injector
identification code and learn fuel injection 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Service − What The Common Rail Engine 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49

96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Learns ).
Check harness between A-42 (terminal No. 1) No. 1

injector connector and C-105 (terminal No. 2)
damage.
DIESEL FUEL
TROUBLESHOOTING
13A-159
STEP 4. Check harness between A-42 (terminal STEP 5. Connector check: C-105 engine-ECU
No. 2) No. 1 injector connector and C-105 connector
A-42 (GR)
C-105 (B)
1 2
Harness side
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
C-105 (B) 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


C-105 (B) STEP 6. M.U.T.-III diagnosis code

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 Q: Is the diagnosis code set?
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Check power supply line for open/short circuit Writing ). After replacing the engine-ECU,
and damage. register the injector identification code and
Q: Is the check result normal? learn fuel injection (Refer to GROUP 00 −
YES : Go to Step 5 . Precautions Before Service − What The
NO : Repair or replace the connector. Common Rail Engine Learns ). After
DPF Regeneration ).
13A-160 DIESEL FUEL
TROUBLESHOOTING
Code No. P0202: No. 2 Injector Circuit Malfunction <Euro5>
A-41
No. 2
1 2 injector R-L
P-B
73 75
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00099 AN

(terminal No. 73) to the No. 2 injector (terminal • When an engine-ECU internal capacitor is
No. 2). allowed to be charged
Judgment Criterion
FUNCTION
PROBABLE CAUSES
Check Conditions
DIESEL FUEL
TROUBLESHOOTING
13A-161
A-41 (GR)
connector
1 2
Connector: A-41
Harness side
Connector: C-105
A-41 (GR)
1 2
Harness side
C-105 (B)


48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25

96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Learns ).

damage.
13A-162 DIESEL FUEL
TROUBLESHOOTING
A-41 (GR)
C-105 (B)
1 2
Harness side
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
C-105 (B) 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73



24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
DIESEL FUEL
TROUBLESHOOTING
13A-163
Code No. P0202: No. 2 Injector Circuit Malfunction <Except Euro5>
A-41
No. 2
1 2 injector R-L
W-L
25 75
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00099 AK

Judgment Criterion
FUNCTION
PROBABLE CAUSES
Check Conditions
13A-164 DIESEL FUEL
TROUBLESHOOTING

A-41 (GR)
connector
1 2
Connector: A-41
Harness side
Connector: C-105
A-41 (GR)
1 2
Harness side
C-105 (B)


48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25

96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Learns ).

damage.
DIESEL FUEL
TROUBLESHOOTING
13A-165
A-41 (GR)
C-105 (B)
1 2
Harness side
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
C-105 (B) 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73



24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
NO : Repair or replace the connector. Common Rail Engine Learns ).
13A-166 DIESEL FUEL
TROUBLESHOOTING
A-130
No. 3
1 2 injector L-O
W-L
49 50
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00099 AP

Judgment Criterion
FUNCTION
PROBABLE CAUSES
Check Conditions
DIESEL FUEL
TROUBLESHOOTING
13A-167
STEP 1. Connector check: A-130 No. 3 injector A-130 (GR)

connector
1 2
Connector: A-130
Harness side
Connector: C-105
A-130 (GR)
1 2
Harness side
C-105 (B)


48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25

96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Learns ).

damage.
13A-168 DIESEL FUEL
TROUBLESHOOTING
A-130 (GR)
C-105 (B)
1 2
Harness side
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
C-105 (B) 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73



24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
DIESEL FUEL
TROUBLESHOOTING
13A-169
A-130
No. 3
1 2 injector L-O
W-L
25 50
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00099 AL

Judgment Criterion
FUNCTION
PROBABLE CAUSES
Check Conditions
13A-170 DIESEL FUEL
TROUBLESHOOTING

STEP 1. Connector check: A-130 No. 3 injector A-130 (GR)

connector
1 2
Connector: A-130
Harness side
Connector: C-105
A-130 (GR)
1 2
Harness side
C-105 (B)


48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25

96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Learns ).

damage.
DIESEL FUEL
TROUBLESHOOTING
13A-171
A-130 (GR)
C-105 (B)
1 2
Harness side
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
C-105 (B) 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73



24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
13A-172 DIESEL FUEL
TROUBLESHOOTING
A-129
No. 4
1 2 injector Y-G
R-Y
25 27
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00099 AO

Judgment Criterion
FUNCTION
PROBABLE CAUSES
Check Conditions
DIESEL FUEL
TROUBLESHOOTING
13A-173
A-129 (GR)
connector
1 2
Connector: A-129
Harness side
Connector: C-105
1 2
Harness side
C-105 (B)


48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25

96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Learns ).

damage.
13A-174 DIESEL FUEL
TROUBLESHOOTING
A-129 (GR)
C-105 (B)
1 2
Harness side
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
C-105 (B) 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73



24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
DIESEL FUEL
TROUBLESHOOTING
13A-175
A-129
No. 4
1 2 injector Y-G
1 27
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00099 AM

(terminal No. 1) to the No. 4 injector (terminal No. • When an engine-ECU internal capacitor is
2). allowed to be charged
Judgment Criterion
FUNCTION
PROBABLE CAUSES
Check Conditions
13A-176 DIESEL FUEL
TROUBLESHOOTING

A-129 (GR)
connector
1 2
Connector: A-129
Harness side
Connector: C-105
1 2
Harness side
C-105 (B)


48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25

96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Learns ).

damage.
DIESEL FUEL
TROUBLESHOOTING
13A-177
A-129 (GR)
C-105 (B)
1 2
Harness side
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
C-105 (B) 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73



24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Code No. P0219: Engine Overspeed Condition
OPERATION
• Refer to Code No. P0335: Crank Angle Sensor
System P.13A-184.
13A-178 DIESEL FUEL
TROUBLESHOOTING
FUNCTION YES : Inspection chart for diagnosis codes (Refer

• The engine-ECU monitors the engine speeds to P.13A-21).
based on the signals from the crank angle sen- NO : Replace the engine-ECU. When the engine-
sor. ECU is replaced, write the chassis number
• The engine-ECU checks whether the engine (Refer to GROUP 00 − Precautions Before
speeds are too high. Service − How to Perform Chassis Number
TROUBLE JUDGMENT register the injector identification code and
Check Condition learn fuel injection (Refer to GROUP 00 −
• Ignition switch is in ON position Precautions Before Service − What The
Judgment Criterion registering the injector identification code,
• Engine speed is 5,500 r/min or more the vehicle equipped with the DPF carries
PROBABLE CAUSE
DPF Regeneration ).
DIAGNOSIS PROCEDURE

Q: Is any other diagnosis code than P0219 output?
Code No. P0234: Turbocharger Overboost Condition <Except Euro5>
FUNCTION NO : Replace the waste gate actuator.
• The engine-ECU checks whether the boost pres-
sure is not higher than the specified value. STEP 2. M.U.T.-III diagnosis code
TROUBLE JUDGMENT
Check Condition YES : Replace the engine-ECU. When the engine-
• Engine is running ECU is replaced, write the chassis number
Judgement Criterion (Refer to GROUP 00 − Precautions Before
• The boost pressure exceeds the abnormality Service − How to Perform Chassis Number
determination value for 3 seconds. Writing ). After replacing the engine-ECU,
PROBABLE CAUSES learn fuel injection (Refer to GROUP 00 −
• Failed the waste gate actuator Precautions Before Service − What The
• Failed the engine-ECU Common Rail Engine Learns ). After
DIAGNOSIS carry out the forcible DPF regeneration.
STEP 1. Check waste gate actuator itself. Forcible DPF Regeneration ).
• Check waste gate actuator itself (Refer to NO : Intermittent malfunction (Refer to GROUP
GROUP 15 − On-vehicle Service − Waste Gate 00 − How to Use Troubleshooting/
Actuator Check ). Inspection Service Points − How to Cope
Q: Is the check result normal? with Intermittent Malfunctions ).
DIESEL FUEL
TROUBLESHOOTING
13A-179
Code No. P0299: Turbocharger Under Boost Condition

• The engine-ECU checks whether the boost pres- NO : Repair.
sure is not lower than the specified value.
STEP 3. Check turbocharger supercharging
TROUBLE JUDGMENT
pressure..
Check Condition • Check turbocharger supercharging pressure
• Engine is running (Refer to GROUP 15 − On-vehicle − Turbo-
Judgment Criterion charger Supercharging Pressure Check ).
• The opening degree of accelerator pedal is 23% Q: Is the check result normal?
for 3 seconds and the boost pressure is not lower YES : Go to Step 4 .
than the specified value. NO : Repair.
PROBABLE CAUSES
• Intercooler air hose disconnected or damaged
• Vacuum hose of manifold absolute pressure sen-
sor disconnected or damaged Q: Is the check result normal?
• Failed manifold absolute pressure sensor YES : Replace the engine-ECU. When the engine-
• Failed engine-ECU ECU is replaced, write the chassis number
DIAGNOSIS Service − How to Perform Chassis Number
STEP 1. Check on intercooler air hose. learn fuel injection (Refer to GROUP 00 −
• Check whether the intercooler air hose is discon- Precautions Before Service − What The
nected or damaged. Common Rail Engine Learns ). After
YES : Go to Step 2 . the vehicle equipped with the DPF carries
NO : Repair. out the forcible DPF regeneration. (Refer to
STEP 2. Check on vacuum hose of manifold DPF Regeneration ).
absolute pressure sensor. NO : Intermittent malfunction (Refer to GROUP
• Check whether the vacuum hose of manifold 00 − How to Use Troubleshooting/
absolute pressure sensor is disconnected or Inspection Service Points − How to Cope
damaged. with Intermittent Malfunctions ).
Code No. P0301: No. 1 Cylinder Injector Malfunction (No Injection)
FUNCTION • Crank angle sensor is normal.

• The Engine-ECU, by monitoring the variation in
Judgment Criterion
the engine revolution, detects the non-fuel injec-
• The variation in the engine revolution is more
tion state.
than the specified value.
TROUBLE JUDGMENT
PROBABLE CAUSES
Check Conditions • Failed No. 1 injector
• During the normal engine operation • No. 1 fuel injection pipe clogged
• Engine coolant temperature is 80°C or higher. • Failed Engine-ECU
13A-180 DIESEL FUEL
TROUBLESHOOTING
DIAGNOSIS PROCEDURE YES : Clean or replace the No. 1 fuel injection

pipe.
CAUTION NO : Replace the No.1 injector. After replacing
A high-tension voltage is flowing between the the injector, register the injector
engine-ECU and the injectors while the engine is identification code and learn fuel injection
running. Handle them carefully to avoid receiving (Refer to GROUP 00 − Precautions Before
electric shocks from the voltage. Service − What The Common Rail Engine
Learns ). Then go to Step 3 .
• After erasing the diagnosis code through M.U.T.- STEP 3. M.U.T.-III diagnosis code
III, operate the engine in the warm-up state and • After erasing the diagnosis code through M.U.T.-
confirm and confirm whether the diagnosis code III, operate the engine in the warm-up state and
is output confirm and confirm whether the diagnosis code
Q: Is the diagnosis code set? is output.
00 − How to Use Troubleshooting/ ECU is replaced, write the chassis number
Inspection Service Points − How to Cope (Refer to GROUP 00 − Precautions Before
with Intermittent Malfunctions ). Service − How to Perform Chassis Number
STEP 2. Check for No.1 fuel injection pipe register the injector identification code and
clogged learn fuel injection (Refer to GROUP 00 −
• Remove the No.1 fuel injection pipe. Precautions Before Service − What The
• Check whether No.1 fuel injection pipe is clogged Common Rail Engine Learns ). After
or not. registering the injector identification code,
Q: Is it clogged?
DPF Regeneration ).
FUNCTION • No. 2 fuel injection pipe clogged

• The Engine-ECU, by monitoring the variation in • Failed Engine-ECU
tion state. DIAGNOSIS PROCEDURE
TROUBLE JUDGMENT CAUTION
A high-tension voltage is flowing between the
Check Conditions engine-ECU and the injectors while the engine is
• During the normal engine operation running. Handle them carefully to avoid receiving
• Engine coolant temperature is 80°C or higher. electric shocks from the voltage.
• Crank angle sensor is normal.
Judgment Criterion STEP 1. M.U.T.-III diagnosis code
• The variation in the engine revolution is more • After erasing the diagnosis code through M.U.T.-
than the specified value. III, operate the engine in the warm-up state and
confirm and confirm whether the diagnosis code
PROBABLE CAUSES is output
DIESEL FUEL
TROUBLESHOOTING
13A-181
• After erasing the diagnosis code through M.U.T.-
III, operate the engine in the warm-up state and
is output.
STEP 2. Check for No. 2 fuel injection pipe
clogged
• Remove the No. 2 fuel injection pipe.
• Check whether No. 2 fuel injection pipe is
clogged or not.
Q: Is it clogged? register the injector identification code and
YES : Clean or replace the No. 2 fuel injection learn fuel injection (Refer to GROUP 00 −
pipe. Precautions Before Service − What The
NO : Replace the No. 2 injector. After replacing Common Rail Engine Learns ). After
the injector, register the injector registering the injector identification code,
identification code and learn fuel injection the vehicle equipped with the DPF carries
(Refer to GROUP 00 − Precautions Before out the forcible DPF regeneration. (Refer to
Service − What The Common Rail Engine GROUP 17 − Emission Control − Diesel
Learns ). Then go to Step 3 . Particulate Filter (DPF) System − Forcible
DPF Regeneration ).

• The Engine-ECU, by monitoring the variation in
CAUTION
A high-tension voltage is flowing between the
tion state.
TROUBLE JUDGMENT running. Handle them carefully to avoid receiving
Check Conditions
• During the normal engine operation
• Engine coolant temperature is 80°C or higher. STEP 1. M.U.T.-III diagnosis code
• Crank angle sensor is normal. • After erasing the diagnosis code through M.U.T.-
Judgment Criterion confirm and confirm whether the diagnosis code
• The variation in the engine revolution is more is output
than the specified value.
PROBABLE CAUSES YES : Go to Step 2 .
• Failed No. 3 injector NO : Intermittent malfunction (Refer to GROUP
• No. 3 fuel injection pipe clogged 00 − How to Use Troubleshooting/
• Failed Engine-ECU Inspection Service Points − How to Cope
STEP 2. Check for No. 3 fuel injection pipe

clogged
• Remove the No. 3 fuel injection pipe.
• Check whether No. 3 fuel injection pipe is
clogged or not.
Q: Is it clogged?
13A-182 DIESEL FUEL
TROUBLESHOOTING
YES : Clean or replace the No. 3 fuel injection YES : Replace the engine-ECU. When the engine-
pipe. ECU is replaced, write the chassis number
NO : Replace the No. 3 injector. After replacing (Refer to GROUP 00 − Precautions Before
the injector, register the injector Service − How to Perform Chassis Number
identification code and learn fuel injection. Writing ). After replacing the engine-ECU,
(Refer to GROUP 00 − Precautions Before register the injector identification code and
Service − What The Common Rail Engine learn fuel injection (Refer to GROUP 00 −
Learns ). Then go to Step 3 . Precautions Before Service − What The
STEP 3. M.U.T.-III diagnosis code registering the injector identification code,
• After erasing the diagnosis code through M.U.T.- the vehicle equipped with the DPF carries
III, operate the engine in the warm-up state and out the forcible DPF regeneration. (Refer to
confirm and confirm whether the diagnosis code GROUP 17 − Emission Control − Diesel
is output. Particulate Filter (DPF) System − Forcible
DPF Regeneration ).
Q: Is the diagnosis code set? NO : The check is end.

• The Engine-ECU, by monitoring the variation in NO : Intermittent malfunction (Refer to GROUP
the engine revolution, detects the non-fuel injec- 00 − How to Use Troubleshooting/
tion state. Inspection Service Points − How to Cope
TROUBLE JUDGMENT
Check Conditions STEP 2. Check for No.4 fuel injection pipe
• During the normal engine operation clogged
• Engine coolant temperature is 80°C or higher. • Remove the No. 4 fuel injection pipe.
• Crank angle sensor is normal. • Check whether No.4 fuel injection pipe is clogged
Judgment Criterion or not.
• The variation in the engine revolution is more Q: Is it clogged?
than the specified value. YES : Clean or replace the No. 4 fuel injection
pipe.
PROBABLE CAUSES NO : Replace the No. 4 injector. After replacing
• Failed No. 4 injector the injector, register the injector
• No. 4 fuel injection pipe clogged identification code and learn fuel injection
• Failed Engine-ECU (Refer to GROUP 00 − Precautions Before
Service − What The Common Rail Engine
DIAGNOSIS PROCEDURE Learns ). Then go to Step 3 .
CAUTION
A high-tension voltage is flowing between the STEP 3. M.U.T.-III diagnosis code
engine-ECU and the injectors while the engine is • After erasing the diagnosis code through M.U.T.-
running. Handle them carefully to avoid receiving III, operate the engine in the warm-up state and
electric shocks from the voltage. confirm and confirm whether the diagnosis code
is output.
STEP 1. M.U.T.-III diagnosis code Q: Is the diagnosis code set?
is output
DIESEL FUEL
TROUBLESHOOTING
13A-183
DPF Regeneration ).
Code No. P0335: Crank Angle Sensor System
Crank Angle Sensor Circuit
A-07
MU802337
Crank
angle
sensor
1 2 3
3 2 1
R G-R B-W
3 2 1
A-133
P G-R B-Y
C-105 68 67 91
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V 5V
Wire colour code

AKA00100 AB
13A-184 DIESEL FUEL
TROUBLESHOOTING
OPERATION STEP 2. Connector check: A-07 crank angle

• A power voltage of 5 V is applied to the crank sensor connector
angle sensor power terminal (terminal No. 3)
from the engine-ECU (terminal No. 68) and Connector: A-07
earthed to engine-ECU (terminal No. 91) from the
crank angle sensor (terminal No. 1).
(terminal No. 67) from the crank angle sensor
A-07 (B)
output terminal (terminal No. 2).
FUNCTION 3 2 1
• The crank angle sensor detects the crank angle Harness side
(position) and inputs a pulse signal to the engine- connector AK501329 AB
ECU.
• In response to the signal, the engine ECU detects Q: Is the check result normal?
the engine speed, controls the fuel injection tim- YES : Go to Step 3 .
ing and fuel injection quantity, etc. NO : Repair or replace the connector.
TROUBLE JUDGMENT STEP 3. Perform voltage measurement at A-07

Check Condition crank angle sensor connector.
• Battery positive voltage is 6 − 16 V. Connector: A-07
Judgment Criterion
• The number of output pulses from the crank
angle sensor per engine rotation is one or less.
A-07 (B)
PROBABLE CAUSES
• Failed crank angle sensor
• Open/short circuit in crank angle sensor circuit or 3 2 1
loose connector contact Harness side
• Failed engine-ECU connector AK501329 AB

DIAGNOSIS PROCEDURE nect connector, and measure at pick-up harness.
STEP 1. M.U.T.-III data list • Voltage between terminal No. 2 and earth.
• Refer to Data List Reference Table OK: 4.9 − 5.1 V
a. Item 2: Engine revolution Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP NO : Go to Step 4 .
NO : Go to Step 2 .
DIESEL FUEL
TROUBLESHOOTING
13A-185
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-07 (B) A-07 (B)
3 2 1 3 2 1
• Measure engine-ECU terminal voltage. Q: Is the check result normal?

• Disconnect A-07 crank angle sensor connector. YES : Check intermediate connector A-133, and
• Ignition switch: ON repair if necessary. If intermediate
• Voltage between terminal No. 67 and earth. connector is normal, check and repair
OK: 4.9 − 5.1 V harness between A-07 (terminal No. 2)
Q: Is the check result normal? crank angle sensor connector and C-105
YES : Go to Step 5 . (terminal No. 67) engine-ECU connector.
NO : Go to Step 6 . • Check output line for open circuit and
damage.
13A-186 DIESEL FUEL
TROUBLESHOOTING
connector No. 2) crank angle sensor connector and C-105
Connector: C-105
Connector: A-07
A-07 (B)
C-105 (B)
3 2 1
Harness side
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


• Refer to Data List Reference Table
a. Item 2: Engine revolution
DIESEL FUEL
TROUBLESHOOTING
13A-187
connector
DPF Regeneration ).
C-105 (B)
crank angle sensor connector. 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Connector: A-07 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-07
A-07 (B)
3 2 1
• Use special tool test harness (MB991709) to con- 3 2 1

Harness side
• Ignition switch: ON connector AK501329 AB
OK: 4.9 − 5.1 V Q: Is the check result normal?
harness between A-07 (terminal No. 3)
crank angle sensor connector and C-105
• Check power supply line for open/
short circuit and damage.
13A-188 DIESEL FUEL
TROUBLESHOOTING
07 crank angle sensor connector.
Connector: A-07
No. 1) crank angle sensor connector and C-105
Connector: A-07
A-07 (B)
3 2 1

3 2 1
side.
• Resistance between terminal No. 1 and earth. Harness side
Connector: C-105

connector
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
• Check earthing line for open circuit and damage.
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-189
STEP 14. Perform output wave pattern
measurement at A-07 crank angle sensor (Using
an oscilloscope).
STEP 15. Check the crankshaft sensing blade.
Connector: A-07
NO : Replace the crankshaft sensing blade
A-07 (B)
STEP 16. M.U.T-III data list
• Refer to Data List Reference Table
3 2 1
a. Item 2: Engine revolution
Harness side
connector AK501329 AB Q: Is the check result normal?
• Use special tool test harness (MB991709) to con- 00 − How to Use Troubleshooting/
nect connector, and measure at pick-up harness. Inspection Service Points − How to Cope
• Engine: Idling with Intermittent Malfunctions ).
• Transmission: Neutral <M/T> or P range <A/T> NO : Replace the crank angle sensor
OK: Waveforms should be displayed on
Inspection procedure using an oscilloscope
(Refer to P.13A-586), its maximum value
should be 4.8 V or more, and its minimum
valve should be 0.6 V or less with no noise in
waveform.
Code No. P0336: Crank Angle Sensor Range/Performance Problem

• Refer to Code No. P0335: Crank Angle Sensor • Failed crank angle sensor
System P.13A-184. • Open/short circuit in crank angle sensor circuit or
loose connector contact
• The crank angle sensor detects the crank angle
(position) and inputs a pulse signal to the engine- DIAGNOSIS PROCEDURE
ECU.
• In response to the signal, the engine-ECU
detects the engine speed, controls the fuel injec- STEP 1. Installation check of crank angle sensor
tion timing and fuel injection quantity, etc • Check whether the crank angle sensor is cor-
rectly installed.
TROUBLE JUDGMENT
Check Conditions YES : Go to Step 2 .
• Battery positive voltage is 6 − 16 V. NO : Repair or replace the crank angle sensor.
• Engine speed is 350 r/min or more
Judgment Criterion STEP 2. M.U.T.-III diagnosis code
• The number of pulses from the crank shaft posi- • Reconfirmation of diagnosis code.
tion sensor per engine rotation is abnormal. Q: Is the diagnosis code set?
13A-190 DIESEL FUEL
TROUBLESHOOTING

DPF Regeneration ).
DIESEL FUEL
TROUBLESHOOTING
13A-191
Code No. P0340: Camshaft Position Sensor System
Camshaft Position Sensor Circuit
A-43
MU802337 Camshaft
position
sensor
1 2 3
3 2 1
R-B L-Y B-W
1 2 3
A-131
R-B L-Y B-W
C-105 69 66 90
1 2 3 4 5 6 7 8 9 10 10 11
111213141516171819
12 13 14 15 16 17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V 5V
Wire colour code

AKA00197AB

• A power voltage of 5 V is applied to the camshaft
Check Condition
position sensor power terminal (terminal No. 3)
from the engine-ECU (terminal No. 69) and
earthed to engine-ECU (terminal No. 90) from the Judgment Criterion
camshaft position sensor (terminal No. 1). • The number of output pulses from the camshaft
• The sensor signal is inputted to the engine-ECU position sensor per engine rotation is one or less.
(terminal No. 66) from the camshaft position sen-
sor output terminal (terminal No. 2). PROBABLE CAUSES
• Failed camshaft position sensor
FUNCTION • Open/short circuit or harness damage in cam-
• The camshaft position sensor detects the top shaft position sensor circuit or loose connector
dead center on the compression stroke of the No. contact
1 cylinder and inputs a pulse signal to the engine- • Failed engine-ECU
ECU.
13A-192 DIESEL FUEL
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 3. Perform voltage measurement at C-105

STEP 1. Connector check: A-43 camshaft Connector: C-105
position sensor connector <L.H. drive vehicles>
Connector: A-43
C-105 (B)
A-43 (B)
3 2 1
Harness side

C-105 (B)
camshaft position sensor connector. 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Connector: A-43 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-43
A-43 (B)
3 2 1
Harness side
• Use special tool harness (MB991709) to connect A-43 (B)

3 2 1
• Ignition switch: ON Harness side
connector
• Voltage between terminal No. 2 and earth. AK501330 AB
OK: 4.9 − 5.1 V • Measure engine-ECU terminal voltage.

• Disconnect A-43 camshaft position sensor con-
Q: Is the check result normal? nector.
NO : Go to Step 3 .
OK: 4.9 − 5.1 V
NO : Go to Step 5 .
DIESEL FUEL
TROUBLESHOOTING
13A-193
connector
Connector: C-105 harness between A-43 (terminal No. 2)
camshaft sensor connector and C-105
damage.
C-105 (B)
connector
<R.H. drive vehicles> Connector: C-105
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25

72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-43
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
A-43 (B) 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
3 2 1 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side Harness side connector AKA00089 AB

13A-194 DIESEL FUEL
TROUBLESHOOTING
STEP 6. Check harness between A-43 (terminal STEP 7. M.U.T.-III diagnosis code
No. 2) camshaft position sensor connector and • Reconfirmation of diagnosis code.
C-105 (terminal No. 66) engine-ECU connector. Q: Is the diagnosis code set?
Connector: A-43 YES : Replace the engine-ECU. When the engine-
A-43 (B)
3 2 1 Precautions Before Service − What The
Harness side Common Rail Engine Learns ). After
connector AK501330 AB registering the injector identification code,
Connector: C-105 out the forcible DPF regeneration. (Refer to
DPF Regeneration ).
C-105 (B) with Intermittent Malfunctions ).
<R.H. drive vehicles> STEP 8. Perform voltage measurement at A-43

camshaft position sensor connector.
Connector: A-43
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 A-43 (B)
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
3 2 1
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side
NOTE: Before checking harness, check intermediate connector, and measure at pick-up harness.
connector A-131, and repair if necessary. • Ignition switch: ON
• Check output line for short circuit. • Voltage between terminal No. 3 and earth.
Q: Is the check result normal? OK: 4.9 − 5.1 V
NO : Repair the damaged harness wire. YES : Go to Step 11 .
NO : Go to Step 9 .
DIESEL FUEL
TROUBLESHOOTING
13A-195
connector No. 3) camshaft position sensor connector and
Connector: C-105
C-105 (terminal No. 69) engine-ECU connector.
C-105 (B) A-43 (B)

3 2 1
Harness side
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

• Check power supply line for short circuit and
damage.
13A-196 DIESEL FUEL
TROUBLESHOOTING
43 camshaft position sensor connector.
Connector: A-43
No. 1) camshaft position sensor connector and
Connector: A-43
A-43 (B)
3 2 1
Harness side
• Disconnect connector, and measure at harness A-43 (B)

3 2 1
side.
• Resistance between terminal No. 1 and earth. Harness side
Connector: C-105

connector
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-197
NO : Replace the camshaft position sensor.
measurement at A-43 camshaft position sensor
(Using an oscilloscope).
Connector: A-43
A-43 (B)
3 2 1
Harness side

• Engine: Idling
• Transmission: Neutral <M/T> or P range <A/T>
OK: Waveforms should be displayed on
Inspection procedure using an oscilloscope
(Refer to P.13A-586), its maximum value
should be 4.8 V or more, and its minimum
valve should be 0.6 V or less with no noise in
waveform.
Code No. P0341: Camshaft Position Sensor Range/Performance Problem

• Refer to Code No. P0340: Camshaft Position • Failed camshaft position sensor
Sensor System P.13A-192. • Open/short circuit in camshaft position sensor cir-
cuit or loose connector contact
• The camshaft position sensor detects the top
dead center on the compression stroke of the No. DIAGNOSIS PROCEDURE
1 cylinder and inputs a pulse signal to the engine-
ECU.
STEP 1. Installation check of camshaft position
TROUBLE JUDGMENT sensor
• Check whether the camshaft position sensor is
Check Conditions
correctly installed.
• Engine speed is 350 r/min or more. Q: Is the check result normal?
Judgment Criterion NO : Repair or replace the camshaft position
• The number of output pulses from the camshaft sensor.
position sensor every two engine rotations (from
when one excessive tooth is detected to when
another is detected) is not five. STEP 2. M.U.T.-III diagnosis code
13A-198 DIESEL FUEL
TROUBLESHOOTING

DPF Regeneration ).
DIESEL FUEL
TROUBLESHOOTING
13A-199
Code No. P0381: Glow Plug Open/Short Malfunction <Euro5>
Glow System Circuit
Fusible link 23 Fusible link 24
W-R
10 Relay
20A box
W-B A-115
3
W-B W-B W
A-20X 1 4
1 2
3 OFF Engine control relay
4 ON
2 3
A-151
To engine-ECU
R
6 10 Glow control unit
GND
1 9 7 1 2 3 4
Y BR-Y G-R L-B
LG-R GR-R B A-150
2 1 4 3
Y L G R
120 126 1 1 1 1
A-153 A-154 A-155 A-156
1 1 1 1
Engine-
ECU
No.1 No.2 No.3 No.4
Glow plug Glow plug Glow plug Glow plug
C-103
Wire colour code

AKB00259 AB
13A-200 DIESEL FUEL
TROUBLESHOOTING
OPERATION DIAGNOSTIC PROCEDURE

• The electrical current source is supplied from the
engine control relay (terminal No.3) to the glow
control unit (terminal No.6). Also, it is supplied STEP 1. Connector check: A-151 glow control
from the glow control unit (terminal No.7) to the unit connector
body earth. Connector: A-151
• The request signal of operating the glow plug is
input into the glow control unit (terminal No. 1)
from the engine-ECU (terminal No.120).
• The voltage for the glow plug is applied from the
battery to the glow control unit (terminal No.10).
• The voltage is applied from the glow control unit 4 3 2 1
8 7 6 5
(terminal No.1, 2, 3 and 4) to each glow plug. 11 10 9 A-151 (B)
• The diagnosis signal is output from the glow con- Harness side
trol unit (terminal No.9) to the engine-ECU (termi- connector AKB00264 AB
nal No.126).
• The voltage applied to the glow control unit (ter- NO : Repair or replace the connector.
minal No.10) from the battery is applied to each
glow plug in the duty ratio according to the signal
STEP 2. Connector check: A-153 No. 1 glow plug
from the engine ECU.
connector, A-154 No. 2 glow plug connector, A-
TROUBLE JUDGMENT 155 No. 3 glow plug connector and A-156 No. 4
glow plug connector.
Check Conditions
• While the engine is running Connectors: A-153, A-154, A-155 and A-156
• The electrical continuity duty to the glow plug is
17 − 83 %.
Judgment Criterion A-156 (B)
• The information that the glow is abnormal is A-155 (B)
received from the glow control unit.
A-154 (B)
PROBABLE CAUSES 1
A-153 (B)
• Failed glow plug Harness side
• Failed glow control unit
• Open/short circuit or harness damage in glow Q: Is the check result normal?
plug circuit or loose connector contact. YES : Go to Step 3 .
• Failed engine-ECU NO : Repair or replace the connector.
DIESEL FUEL
TROUBLESHOOTING
13A-201
No.1) glow control unit connector and A-153 No. 2) glow control unit connector and A-154
(terminal No.1) No.1 glow plug connector. (terminal No. 1) No.2 glow plug connector.
4 3 2 1 4 3 2 1
8 7 6 5 8 7 6 5
11 10 9 A-151 (B) 11 10 9 A-151 (B)
connector AKB00264 AB connector AKB00264 AB
A-154 (B)
1 1
Harness side A-153 (B) Harness side
age. age.
13A-202 DIESEL FUEL
TROUBLESHOOTING
No. 3) glow control unit connector and A-155 No. 4) glow control unit connector and A-156
(terminal No. 1) No.3 glow plug connector. (terminal No. 1) No.4 glow plug connector.
4 3 2 1 4 3 2 1
8 7 6 5 8 7 6 5
11 10 9 A-151 (B) 11 10 9 A-151 (B)
A-156 (B)
A-155 (B)
1 1
age. age.
STEP 7. Replace the glow control unit.

• After replacing the glow control unit, reconfirm
whether the diagnosis code is set.
NO : Check is end.
DIESEL FUEL
TROUBLESHOOTING
13A-203
Code No. P0401: EGR Flow Insufficient <Euro5>
OPERATION STEP 2. Connector check: A-45 EGR valve

• Refer to Code No. P0102: Air Flow Sensor Circuit assembly connector
Low Input P.13A-68.
• Refer to Code No. P0403: EGR Valve (DC Motor) Connector: A-45
Malfunction P.13A-215.
• Refer to Code No. P0489: EGR Valve Position
Sensor Circuit Low Input <Euro5> P.13A-240. A-45 (GR)
FUNCTION
• The engine-ECU monitors the EGR flow rate. 3 2 1
6 5 4
TROUBLE JUDGMENT
Harness side
Check Conditions connector AK501331 AB
• Engine is running.
• Normal running (vehicle speed: 65 − 75 km/h,
transmission: 5th <M/T>, D range <A/T>).
• The intake air temperature is from 20 to 40 °C.
STEP 3. Connector check: C-103 and C-105
Judgment Criterion engine-ECU connectors
• The EGR flow rate is larger than target EGR flow
rate by the rate that is more than the specified Connectors: C-103, C-105
value.
PROBABLE CAUSES
• Failed EGR passage (leakage and clogged EGR
passage)
• Harness damage in EGR valve circuit or loose
connector contact C-103 (B) C-105 (B)
• Failed EGR valve operation
• Harness damage in air flow sensor circuit or
• Failed air flow sensor (abnormal output charac-
teristics)
C-103 (B) C-105 (B)

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Q: Is the diagnosis code P0403 or P2413 set? 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
YES : Inspection chart for diagnosis codes (Refer 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
to P.13A-21).
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
NO : Go to Step 2 . C-105 Harness side connector
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
C-103 Harness side connector

AKB00270 AB

YES : Go to Step 4 . NO : Repair or replace the connector.
13A-204 DIESEL FUEL
TROUBLESHOOTING
(terminal No. 6) EGR valve assembly connector. (terminal No. 4) EGR valve assembly connector.
C-103 (B) C-103 (B)
C-103 (B) C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 117 116

143 142 141 140 139138 137 136 135 134 133 132 131 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
A-45 (GR) A-45 (GR)
3 2 1 3 2 1
6 5 4 6 5 4
• Check output line for damage. • Check output line for damage.
STEP 6. Check harness between C-105 (terminal

No. 81) engine-ECU connector and A-45 (terminal
No. 2) EGR valve assembly connector.
DIESEL FUEL
TROUBLESHOOTING
13A-205
Connector: C-105 STEP 7. Check harness between C-105 (terminal
<L.H. drive vehicles> No. 71) engine-ECU connector and A-45 (terminal
Connector: C-105
C-105 (B)

C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
Connector: A-45 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-45 (GR) Connector: A-45
3 2 1
A-45 (GR)
6 5 4
Harness side
3 2 1
• Check earthing line for damage. 6 5 4
Q: Is the check result normal? Harness side
connector
YES : Go to Step 7 . AK501331 AB
NO : Repair the damaged harness wire. • Check power supply line for damage.
13A-206 DIESEL FUEL
TROUBLESHOOTING
STEP 9. Check EGR valve itself.
Connector: C-105
<L.H. drive vehicles> • Check EGR valve itself [Refer to GROUP 17 −
Emission Control − Exhaust Gas Recirculation
(EGR) System − EGR Valve (DC motor) Check ].
NO : Replace the EGR valve assembly.
C-105 (B)
STEP 10. Check EGR passage for deposits.
• Check the EGR valve, the EGR pipe and the
inside of the EGR cooler for deposits. (Refer to
GROUP 17 − Emission Control − EGR Valve And
EGR Cooler − Removal And Installation ).
NO : Cleaning or replace the EGR valve, EGR
C-105 (B) pipe and EGR cooler.
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 connector.
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-135
Connector: A-45
A-45 (GR)

3 2 1 connector AKA00399AB
6 5 4
• Check output line for damage. NO : Repair or replace the connector.
DIESEL FUEL
TROUBLESHOOTING
13A-207
No. 4) air flow sensor connector and C-103 No. 3) air flow sensor connector and C-103
Harness side A-135 (B) Harness side A-135 (B)

connector AKA00399AB connector AKA00399AB

C-103 (B) C-103 (B)
C-103 (B) C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 117 116

143 142 141 140 139138 137 136 135 134 133 132 131 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
• Check earthing line for damage. • Check output line for damage.
STEP 14. Replace the air flow sensor.

• After replacing the air flow sensor, re-check the
trouble symptoms.
13A-208 DIESEL FUEL
TROUBLESHOOTING

Code No. P0402: EGR Flow Excessive <Euro5>
OPERATION • Failed air flow sensor (abnormal output charac-

• Refer to Code No. P0102: Air Flow Sensor Circuit teristics)
Low Input P.13A-68. • Failed engine-ECU
• Refer to Code No. P0403: EGR Valve (DC Motor)
Malfunction P.13A-215. DIAGNOSTIC PROCEDURE
• Refer to Code No. P0489: EGR Valve Position
Sensor Circuit Low Input <Euro5> P.13A-240.
FUNCTION Q: Is the diagnosis code P0403 or P2413 set?
• The engine-ECU monitors the EGR flow rate. YES : Inspection chart for diagnosis codes (Refer
to P.13A-21).
TROUBLE JUDGMENT NO : Go to Step 2 .
Check Conditions
• Engine is running STEP 2. Connector check: A-45 EGR valve
• Battery positive voltage is 8 − 16 V. assembly connector
• Vehicle is stopped (transmission: Neutral <M/T>,
Connector: A-45
P range <A/T>)
Judgment Criterion
• The EGR flow rate is smaller than target EGR
A-45 (GR)
flow rate by the rate that is more than the speci-
fied value.
3 2 1
PROBABLE CAUSES
6 5 4
• Failed EGR passage (air suction)
• Harness damage in EGR valve circuit or loose Harness side
connector contact
• Failed EGR valve operation Q: Is the check result normal?
• Harness damage in air flow sensor circuit or YES : Go to Step 3 .
loose connector contact NO : Repair or replace the connector.
DIESEL FUEL
TROUBLESHOOTING
13A-209
STEP 3. Connector check: C-103 and C-105 STEP 4. Check harness between C-103 (terminal
engine-ECU connectors No. 115) engine-ECU connector and A-45
Connectors: C-103, C-105
(terminal No. 6) EGR valve assembly connector.
<L.H. drive vehicles> Connector: C-103
C-103 (B) C-105 (B)

C-103 (B)
C-103 (B) C-105 (B)

C-103 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 Connector: A-45

143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

AKB00270 AB
A-45 (GR)
3 2 1
6 5 4
Harness side

13A-210 DIESEL FUEL
TROUBLESHOOTING
No. 130) engine-ECU connector and A-45 No. 81) engine-ECU connector and A-45 (terminal
(terminal No. 4) EGR valve assembly connector. No. 2) EGR valve assembly connector.
C-103 (B) C-105 (B)
C-103 (B) C-105 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
102 101
130 129 128 127 126 125 124 123 122 121120 119 118 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
117 116
143 142 141 140 139138 137 136 135 134 133 132 131 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-45 (GR) A-45 (GR)
3 2 1 3 2 1
6 5 4 6 5 4
• Check output line for damage. • Check earthing line for damage.
DIESEL FUEL
TROUBLESHOOTING
13A-211
No. 71) engine-ECU connector and A-45 (terminal No. 57) engine-ECU connector and A-45 (terminal
No. 3) EGR valve assembly connector. No. 1) EGR valve assembly connector.
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-45 (GR) A-45 (GR)
3 2 1 3 2 1
6 5 4 6 5 4
STEP 9. Check EGR valve itself.

• Check EGR valve itself [Refer to GROUP 17 −
Emission Control − Exhaust Gas Recirculation
(EGR) System − EGR Valve (DC motor) Check ].
13A-212 DIESEL FUEL
TROUBLESHOOTING
STEP 10. Check EGR passage for air suction. STEP 12. Check harness between A-135 (terminal
• Check the EGR valve, the EGR pipe and the No. 4) air flow sensor connector and C-103
EGR cooler for the air suction. (terminal No. 155) engine-ECU connector.
Q: Is the check result normal? Connector: A-135
NO : Cleaning or replace the EGR valve, EGR
pipe and EGR cooler.

connector
Connector: A-135
Connector: C-103

C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

DIESEL FUEL
TROUBLESHOOTING
13A-213
No. 3) air flow sensor connector and C-103
STEP 14. Replace the air flow sensor.
Connector: A-135
• After replacing the air flow sensor, re-check the
trouble symptoms.
Harness side
A-135 (B)
connector AKA00399AB ECU is replaced, write the chassis number
<L.H. drive vehicles> Writing ). After replacing the engine-ECU,
C-103 (B) carry out the forcible DPF regeneration.
<R.H. drive vehicles> Diesel Particulate Filter (DPF) System −
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

13A-214 DIESEL FUEL
TROUBLESHOOTING
Code No. P0403: EGR Valve (DC Motor) Malfunction
EGR Valve (DC motor) Circuit
A-45
(MU802056)
M
EGR valve assembly
1 2 3
4 5 6
6 4
V Y-B
C-103 115 130
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
Wire colour code

AKA00102 AB

• The electric current from the engine-ECU (termi-
Check Condition
nal No. 130 and No. 115) to the EGR valve (DC
• Ignition switch is in "ON" position
motor) (terminal No. 4 and No. 6).
Judgment Criterion
FUNCTION • An overcurrent cut-off signal from the EGR valve
• The engine-ECU performs duty control over the drive control integrated circuit (IC) is detected for
EGR valve (DC motor). 0.5 second.
• The engine-ECU performs feedback control over
the EGR valve based on the signals from the PROBABLE CAUSES
EGR position sensor. • Failed EGR valve
• Open/short circuit or harness damage in EGR
DIESEL FUEL
TROUBLESHOOTING
13A-215
connector
STEP 1. Connector check: A-45 EGR valve Connector: C-103
assembly connector <L.H. drive vehicles>
Connector: A-45
A-45 (GR)
C-103 (B)
3 2 1
6 5 4 <R.H. drive vehicles>
Harness side

C-103 (B)
STEP 2. Check EGR valve itself
• Check EGR valve itself [Refer to GROUP 17 − 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
Exhaust Gas Recirculation (EGR) System − EGR 117 116
valve (DC motor) check ]. 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

NO : Replace the EGR valve assembly. Q: Is the check result normal?
13A-216 DIESEL FUEL
TROUBLESHOOTING
(terminal No. 6) EGR valve assembly connector. (terminal No. 4) EGR valve connector.
C-103 (B) C-103 (B)
C-103 (B) C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 117 116

143 142 141 140 139138 137 136 135 134 133 132 131 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
A-45 (GR) A-45 (GR)
3 2 1 3 2 1
6 5 4 6 5 4
age. age.

DIESEL FUEL
TROUBLESHOOTING
13A-217
DPF Regeneration ).
13A-218 DIESEL FUEL
TROUBLESHOOTING
Code No. P0405: EGR Valve Position Sensor Circuit Low Input <Except Euro5>
EGR valve Position Sensor Circuit
A-45
(MU802056)
EGR valve assembly
1 2 3
4 5 6
3 1 2
SB G-B BR-B
C-105 71 57 81
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKA00103 AB

• A power voltage of 5 V is applied to the EGR
Check Conditions
valve assembly power terminal (terminal No. 3)
earthed to the engine-ECU (terminal No. 81) from
the EGR valve assembly (terminal No. 2).
(terminal No. 57) from the EGR valve assembly • The EGR valve position sensor output voltage is
output terminal (terminal No. 1). 0.20 V or less for 0.5 second.

• The EGR valve assembly detects the position of • Failed EGR valve position sensor
the EGR valve and sends the signal to the • Open/short circuit or harness damage in EGR
engine-ECU. valve position sensor circuit or loose connector
• Based on the signal, the engine-ECU performs contact
the feedback control of the EGR valve. • Failed engine-ECU
DIESEL FUEL
TROUBLESHOOTING
13A-219
NO : Go to Step 4 .

a. Item 16: EGR valve position sensor
Connector: C-105
NO : Go to Step 2 .
C-105 (B)
STEP 2. Connector check: A-45 EGR valve
assembly connector
Connector: A-45
A-45 (GR)
3 2 1 C-105 (B)
6 5 4
Harness side 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
EGR valve assembly connector. OK: 4.9 − 5.1 V
NO : Go to Step 5 .
A-45 (GR)
3 2 1
6 5 4
Harness side

side.
OK: 4.9 − 5.1 V
13A-220 DIESEL FUEL
TROUBLESHOOTING
connector No. 3) EGR valve assembly connector and C-105
Connector: C-105
A-45 (GR)
C-105 (B) 3 2 1
6 5 4
Harness side
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


DIESEL FUEL
TROUBLESHOOTING
13A-221
YES : Intermittent malfunction (Refer to GROUP YES : Check and repair harness between A-45
00 − How to Use Troubleshooting/ (terminal No. 3) EGR valve assembly
Inspection Service Points − How to Cope connector and C-105 (terminal No. 71)
with Intermittent Malfunctions ). engine-ECU connector.
NO : Replace the engine-ECU. When the engine- • Check power supply line for open
ECU is replaced, write the chassis number circuit and damage.
(Refer to GROUP 00 − Precautions Before NO : Repair or replace the connector.
Writing ). After replacing the engine-ECU, STEP 9. Perform resistance measurement at A-45
register the injector identification code and EGR valve assembly connector.
Precautions Before Service − What The Connector: A-45
STEP 8. Connector check: C-105 engine-ECU A-45 (GR)

connector
Connector: C-105 3 2 1
6 5 4
Harness side

side.
C-105 (B) • Resistance between terminal No. 2 and earth.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-45
A-45 (GR)
3 2 1
6 5 4
Harness side

13A-222 DIESEL FUEL
TROUBLESHOOTING
Connector: C-105
A-45 (GR)
C-105 (B) 3 2 1
6 5 4
Harness side
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-223
EGR valve assembly connector.
Connector: A-45
No. 1) EGR valve assembly connector and C-105
A-45 (GR)
Connector: A-45
3 2 1
6 5 4 A-45 (GR)
Harness side

nect connector and measure at pick-up harness. 6 5 4
• Engine: Idling (after warning up) Harness side
connector
AK501331 AB
OK: 2.0 V or higher Connector: C-105


connector
C-105 (B)
Connector: C-105
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

YES : Replace the EGR valve assembly.
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-224 DIESEL FUEL
TROUBLESHOOTING
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Measure engine-ECU terminal voltage. Connector: A-45

• Engine: Idling (after warning up)
OK: 2.0 V or higher
A-45 (GR)
NO : Go to Step 16 . 3 2 1
6 5 4
Harness side

(terminal No. 1) EGR valve assembly
connector and C-105 (terminal No. 57)
damage.
DIESEL FUEL
TROUBLESHOOTING
13A-225
connector
Connector: C-105
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-226 DIESEL FUEL
TROUBLESHOOTING
Code No. P0406: EGR Valve Position Sensor Circuit High Input <Except Euro5>
A-45
(MU802056)
EGR valve assembly
1 2 3
4 5 6
3 1 2
SB G-B BR-B
C-105 71 57 81
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKA00103 AB

Check Conditions
output terminal (terminal No. 1). 4.80 V or more for 0.5 second.

the EGR valve and sends the signal to the • Open circuit in EGR valve position sensor circuit
engine-ECU. or loose connector contact
• Based on the signal, the engine-ECU performs • Failed engine-ECU
the feedback control of the EGR valve.
DIESEL FUEL
TROUBLESHOOTING
13A-227
NO : Go to Step 4 .

connector
Connector: C-105
NO : Go to Step 2 .
C-105 (B)
assembly connector
Connector: A-45
A-45 (GR)
3 2 1 C-105 (B)
6 5 4
Harness side 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-45
A-45 (GR)
3 2 1
6 5 4
Harness side

side.
13A-228 DIESEL FUEL
TROUBLESHOOTING
Connector: A-45
A-45 (GR) Q: Is the check result normal?

3 2 1 Inspection Service Points − How to Cope
C-105 (B)
<R.H. drive vehicles> a. Item 16: EGR valve position sensor
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

Code No. P0420: Catalyst Malfunction <Euro5>
FUNCTION TROUBLE JUDGMENT

• The engine-ECU injects the fuel with the slower
Check Condition
timing than usual (post injection), so that the oxy-
• On DPF regeneration
gen and HC of exhaust gas burn in the catalyst,
and the exhaust gas temperature raises up to the Judgement Criteria
level which enables the DPF regeneration. • The conditions below continues for 30 seconds.
• The engine-ECU monitors the signals from the • The fuel injection amount exceeds the specified
No. 2 exhaust gas temperature sensor (catalyst value.
temperature) to detect the catalyst inactivation. • The engine speed exceeds the specified value.
DIESEL FUEL
TROUBLESHOOTING
13A-229
• The No. 1 exhaust gas temperature sensor is STEP 2. Forcible DPF regeneration execution
350°C or higher. • Initialise the DPF-related parts, and then delete
• The No. 2 exhaust gas temperature sensor (cata- the diagnosis code (Refer to GROUP 00 − Pre-
lyst temperature) is 450°C or below. cautions before Service − Initialisation Procedure
PROBABLE CAUSES for Learning Value in Diesel Particulate Filter
• Failed No. 1 exhaust gas temperature sensor (DPF) System ).
• Failed No. 2 exhaust gas temperature sensor a. Item 42: DPF system malfunction service
(catalyst temperature) • Carry out the forcible DPF regeneration (Refer to
• Catalytic converter inactive GROUP 17 − Emission Control − Diesel Particu-
late Filter (DPF) System − Forcible DPF Regen-
DIAGNOSIS PROCEDURE eration ).
Q: Is the diagnosis code P0420 or P1497 output?
YES : Replace the catalytic converter. When the
STEP 1. M.U.T.-III data list.
catalytic converter is replaced, initialise the
learning value. (Refer to GROUP 00 −
a. Item 117: No. 1 exhaust gas temperature sen- Precautions before Service − Initialisation
sor Procedure for Learning Value in Diesel
b. Item 118: No. 2 exhaust gas temperature sen- Particulate Filter (DPF) System .) On
sor (catalyst temperature) completion, carry out the forcible DPF
Q: Are the check results normal? regeneration (Refer to GROUP 17 −
YES : Go to Step 2 . Emission Control − Diesel Particulate Filter
NO : Perform the diagnosis code classified check (DPF) System − Forcible DPF Regeneration
procedure for the sensor that has shown an ).
abnormal data value (Refer to Inspection NO : Replace the engine-ECU. When the engine-
Chart for Diagnosis Code P.13A-21). ECU is replaced, write the chassis number
13A-230 DIESEL FUEL
TROUBLESHOOTING
Code No. P0427: No. 2 Exhaust Gas Temperature Sensor (catalyst temperature) Circuit Low Input
<Euro5>
No. 2 Exhaust Gas Temperature Sensor (catalyst temperature) Circuit
A-159
MU802601
No. 2 exhaust gas
temperature sensor
1 2 (catalyst temperature)
2 1
BR-G R-B
A-28
2 8
O-B GR-R
C-105 83 59
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKB00271 AB
OPERATION • The No. 2 exhaust gas temperature sensor (cata-

• A power voltage of 5 V is applied to the No. 2 lyst temperature) is a kind of resistor, which has
exhaust gas temperature sensor (catalyst tem- characteristics to reduce its resistance as the cat-
perature) output terminal (terminal No. 1) from alyst temperature rises. Therefore, the sensor
the engine-ECU (terminal No. 59). output voltage varies with the catalyst tempera-
• The power voltage is earthed to the engine-ECU ture, and becomes lower as the catalyst tempera-
(terminal No. 83) from the No. 2 exhaust gas tem- ture rises.
perature sensor (catalyst temperature) (terminal
No. 2). TROUBLE JUDGMENT
Check Conditions
FUNCTION
• The No. 2 exhaust gas temperature sensor (cata-
lyst temperature) converts the catalyst tempera-
ture into a voltage and inputs the voltage signal to
the engine-ECU. Judgment Criterion
• Engine-ECU uses this voltage output for DPF • The No. 2 exhaust gas temperature sensor (cata-
regeneration control. lyst temperature) output voltage is 0.255 V or
less.
DIESEL FUEL
TROUBLESHOOTING
13A-231
PROBABLE CAUSES STEP 3. Check No. 2 exhaust gas temperature
• Failed No. 2 exhaust gas temperature sensor sensor (catalyst temperature) itself.
(catalyst temperature) • Check No. 2 exhaust gas temperature sensor
• Short circuit in No. 2 exhaust gas temperature (catalyst temperature) itself (Refer to GROUP 17
sensor (catalyst temperature) circuit or loose con-
− Emission Control − Diesel Particulate Filter
nector contact
(DPF) System − No. 2 Exhaust Gas Temperature
Sensor (catalyst temperature) Check ).
DIAGNOSTIC PROCEDURE Q: Is the check result normal?
NO : Replace the No. 2 exhaust gas temperature
STEP 1. M.U.T.-III data list sensor (catalyst temperature). After
• Refer to Data List Reference Table P.13A-542. replacing the No. 2 exhaust gas
a. Item 118: No. 2 exhaust gas temperature sensor temperature sensor (catalyst temperature),
(catalyst temperature) carry out the forcible DPF regeneration.
Q: Is the check result normal? (Refer to GROUP 17 − Emission Control −
YES : Intermittent malfunction (Refer to GROUP Diesel Particulate Filter (DPF) System −
00 − How to Use Troubleshooting/ Forcible DPF Regeneration ).
NO : Go to Step 2 . connector
Connector: C-105
STEP 2. Connector check: A-159 No. 2 exhaust <L.H. drive vehicles>
gas temperature sensor (catalyst temperature)
connector
Connector: A-159
C-105 (B)
2 1 A-159 (B)
Harness side
connector
C-105 (B)
No. 2 exhaust gas

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
temperature sensor 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
(catalyst temperature)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
AKB00272 AB
YES : Go to Step 3 . NO : Repair or replace the connector.
13A-232 DIESEL FUEL
TROUBLESHOOTING
No. 1) No. 2 exhaust gas temperature sensor
(catalyst temperature) connector and C-105
(terminal No. 59) engine-ECU connector. STEP 6. M.U.T.-III data list
Connector: A-159
a. Item 118: No. 2 exhaust gas temperature sensor
A-159 (B) with Intermittent Malfunctions ).
2 1
Harness side
connector ECU is replaced, write the chassis number
No. 2 exhaust gas learn fuel injection (Refer to GROUP 00 −
temperature sensor
(catalyst temperature) Precautions Before Service − What The
AKB00272 AB (Refer to GROUP 17 − Emission Control −
Connector: C-105 Forcible DPF Regeneration ).
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
NOTE: Before checking harness, check intemediate

DIESEL FUEL
TROUBLESHOOTING
13A-233
Code No. P0428: No. 2 Exhaust Gas Temperature Sensor (catalyst temperature) Circuit High Input
<Euro5>
No. 2 Exhaust Gas Temperature Sensor (catalyst temperature) Circuit
A-159
MU802601
No. 2 exhaust gas
temperature sensor
1 2 (catalyst temperature)
2 1
BR-G R-B
A-28
2 8
O-B GR-R
C-105 83 59
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKB00271 AB
OPERATION • The No. 2 exhaust gas temperature sensor (cata-

• A power voltage of 5 V is applied to the No. 2 lyst temperature) is a kind of resistor, which has
exhaust gas temperature sensor (catalyst tem- characteristics to reduce its resistance as the cat-
perature) output terminal (terminal No. 1) from alyst temperature rises. Therefore, the sensor
the engine-ECU (terminal No. 59). output voltage varies with the catalyst tempera-
• The power voltage is earthed to the engine-ECU ture, and becomes lower as the catalyst tempera-
(terminal No. 83) from the No. 2 exhaust gas tem- ture rises.
perature sensor (catalyst temperature) (terminal
No. 2). TROUBLE JUDGMENT
Check Conditions
FUNCTION
• The No. 2 exhaust gas temperature sensor (cata-
lyst temperature) converts the catalyst tempera-
ture into a voltage and inputs the voltage signal to
• Vehicle speed is 20 km/h or higher.
the engine-ECU.
• Engine-ECU uses this voltage for DPF regenera- Judgment Criterion
tion control. • The No. 2 exhaust gas temperature sensor (cata-
lyst temperature) output voltage is 4.95 V or
more.
13A-234 DIESEL FUEL
TROUBLESHOOTING
PROBABLE CAUSES STEP 3. Check No. 2 exhaust gas temperature

• Failed No. 2 exhaust gas temperature sensor sensor (catalyst temperature) itself.
(catalyst temperature) • Check No. 2 exhaust gas temperature sensor
• Open circuit or harness damage in No. 2 exhaust (catalyst temperature) itself (Refer to GROUP 17
− Emission Control − Diesel Particulate Filter
circuit or loose connector contact
(DPF) System − No. 2 Exhaust Gas Temperature
Sensor (catalyst temperature) Check ).
DIAGNOSTIC PROCEDURE Q: Is the check result normal?
STEP 1. M.U.T.-III data list sensor (catalyst temperature). After
• Refer to Data List Reference Table P.13A-542 replacing the No. 2 exhaust gas
a. Item 118: No. 2 exhaust gas temperature sensor temperature sensor (catalyst temperature),
(catalyst temperature) carry out the forcible DPF regeneration.
YES : Intermittent malfunction (Refer to GROUP Diesel Particulate Filter (DPF) System −
00 − How to Use Troubleshooting/ Forcible DPF Regeneration ).
with Intermittent Malfunctions ). STEP 4. Perform voltage measurement at A-159
NO : Go to Step 2 . No. 2 exhaust gas temperature sensor (catalyst
temperature) connector.
STEP 2. Connector check: A-159 No. 2 exhaust Connector: A-159
connector
Connector: A-159
2 1 A-159 (B)
Harness side
connector
2 1 A-159 (B)
Harness side
connector
No. 2 exhaust gas

temperature sensor
No. 2 exhaust gas

temperature sensor
AKB00272 AB

side.
AKB00272 AB • Ignition switch: ON
YES : Go to Step 3 . OK: 4.5 − 4.9 V
NO : Repair or replace the connector. Q: Is the check result normal?
NO : Go to Step 5 .
DIESEL FUEL
TROUBLESHOOTING
13A-235
connector. No. 1) No. 2 exhaust gas temperature sensor
Connector: C-105
<L.H. drive vehicles> (terminal No. 59) engine-ECU connector.
Connector: A-159
C-105 (B)
<R.H. drive vehicles> 2 1 A-159 (B)

Harness side
connector
No. 2 exhaust gas

C-105 (B) temperature sensor
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
AKB00272 AB
Connector: C-105
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-236 DIESEL FUEL
TROUBLESHOOTING
159 No. 2 exhaust gas temperature sensor
(catalyst temperature) connector.
Connector: A-159
Inspection Service Points − How to Cope A-159 (B)
2 1
Harness side
NO : Replace the engine-ECU. When the engine- connector
register the injector identification code and No. 2 exhaust gas
temperature sensor
learn fuel injection (Refer to GROUP 00 − (catalyst temperature)
carry out the forcible DPF regeneration. AKB00272 AB
(Refer to GROUP 17 − Emission Control − • Disconnect connector, and measure at harness
Diesel Particulate Filter (DPF) System − side.
Forcible DPF Regeneration ). • Resistance between terminal No. 2 and earth.
NO : Go to Step 9 .
DIESEL FUEL
TROUBLESHOOTING
13A-237
connector No. 2) No. 2 exhaust gas temperature sensor
Connector: C-105
<L.H. drive vehicles> (terminal No. 83) engine-ECU connector.
Connector: A-159
C-105 (B)

Harness side
connector
No. 2 exhaust gas

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
AKB00272 AB
Connector: C-105
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-238 DIESEL FUEL
TROUBLESHOOTING
STEP 11. Connector check: C-105 engine-ECU (terminal No. 59) engine-ECU connector.
connector.
Connector: A-159
Connector: C-105
2 1 A-159 (B)
C-105 (B)
Harness side
connector
No. 2 exhaust gas

temperature sensor
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AKB00272 AB
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
Connector: C-105
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 <L.H. drive vehicles>

C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-239
Code No. P0489: EGR Valve Position Sensor Circuit Low Input <Euro5>
A-45
(MU802056)
EGR valve assembly
1 2 3
4 5 6
3 1 2
SB G-B BR-B
C-105 71 57 81
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKA00103 AB

Check Conditions
output terminal (terminal No. 1). 0.20 V or less for 0.5 second.

the EGR valve and sends the signal to the • Open/short circuit or harness damage in EGR
engine-ECU. valve position sensor circuit or loose connector
• Based on the signal, the engine-ECU performs contact
the feedback control of the EGR valve. • Failed engine-ECU
13A-240 DIESEL FUEL
TROUBLESHOOTING

NO : Go to Step 4 .

Connector: C-105
NO : Go to Step 2 .
C-105 (B)
assembly connector
Connector: A-45
A-45 (GR)
3 2 1 C-105 (B)
6 5 4
Harness side 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
EGR valve assembly connector. OK: 4.9 − 5.1 V
NO : Go to Step 5 .
A-45 (GR)
3 2 1
6 5 4
Harness side

side.
OK: 4.9 − 5.1 V
DIESEL FUEL
TROUBLESHOOTING
13A-241
Connector: C-105
A-45 (GR)
C-105 (B) 3 2 1
6 5 4
Harness side
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


13A-242 DIESEL FUEL
TROUBLESHOOTING

connector
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-45
A-45 (GR)
3 2 1
6 5 4
Harness side

circuit and damage.
DIESEL FUEL
TROUBLESHOOTING
13A-243
Connector: A-45
A-45 (GR)
Connector: A-45
3 2 1
6 5 4 A-45 (GR)
Harness side
• Disconnect connector, and measure at harness 3 2 1

side. 6 5 4
• Ignition switch: ON Harness side
connector
AK501331 AB
OK: Continuity (2 Ω or less) Connector: C-105


connector
C-105 (B)
Connector: C-105
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-244 DIESEL FUEL
TROUBLESHOOTING
Connector: A-45
A-45 (GR)
Connector: A-45
3 2 1
6 5 4 A-45 (GR)
Harness side

nect connector and measure at pick-up harness. 6 5 4
• Engine: Idling (after warning up) Harness side
connector
AK501331 AB
OK: 2.0 V or higher Connector: C-105


connector
C-105 (B)
Connector: C-105
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

YES : Replace the EGR valve assembly.
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-245
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Measure engine-ECU terminal voltage. Connector: A-45

• Engine: Idling (after warning up)
OK: 2.0 V or higher
A-45 (GR)
NO : Go to Step 16 . 3 2 1
6 5 4
Harness side

damage.
13A-246 DIESEL FUEL
TROUBLESHOOTING
connector
Connector: C-105
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-247
Code No. P0490: EGR Valve Position Sensor Circuit High Input <Euro5>
A-45
(MU802056)
EGR valve assembly
1 2 3
4 5 6
3 1 2
SB G-B BR-B
C-105 71 57 81
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKA00103 AB

Check Conditions
output terminal (terminal No. 1). 4.80 V or more for 0.5 second.

the EGR valve and sends the signal to the • Open circuit in EGR valve position sensor circuit
engine-ECU. or loose connector contact
• Based on the signal, the engine-ECU performs • Failed engine-ECU
the feedback control of the EGR valve.
13A-248 DIESEL FUEL
TROUBLESHOOTING

NO : Go to Step 4 .

connector
Connector: C-105
NO : Go to Step 2 .
C-105 (B)
assembly connector
Connector: A-45
A-45 (GR)
3 2 1 C-105 (B)
6 5 4
Harness side 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-45
A-45 (GR)
3 2 1
6 5 4
Harness side

side.
DIESEL FUEL
TROUBLESHOOTING
13A-249
Connector: A-45

3 2 1 Inspection Service Points − How to Cope
C-105 (B) carry out the forcible DPF regeneration.

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 00 − How to Use Troubleshooting/
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-250 DIESEL FUEL
TROUBLESHOOTING
Code No. P0502: Vehicle Speed Sensor Low Input <2WD-M/T and 4WD vehicles>
Vehicle Speed Sensor Circuit
Fusible link 23
W-R
Relay 10
box 20A Engine-ECU
C-103
5V
W-B 103104105106107108109110 111112113 114115
101 102 118119120121122123124125126127128 129130
A-115
3 116 117
131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
W-B
W-B
141
W-L
1 4 C-53*¹
A-20X
or
1 2 Engine C-35*²
11
3 control
ON relay W-L
4 OFF
22
2 3
J/C (2)
R C-127
A-28
10 21
W-L
To engine-ECU
R C-30
C-29
2 4
R W-L
1 3
B-01
(MU802723)
Vehicle speed sensor
1 2 3
B
NOTE
*1: L.H. drive vehicles
*2: R.H. drive vehicles
Wire colour code
AKA00104 AB
DIESEL FUEL
TROUBLESHOOTING
13A-251
OPERATION STEP 2. M.U.T.-III data list
• A power voltage of 5 V is applied to the vehicle • Refer to Data list reference table P.13A-542.
speed sensor (terminal No. 3) from the engine-
a. Item 4: Vehicle speed sensor
FUNCTION YES : Intermittent malfunction (Refer to GROUP
• The vehicle speed sensor converts the vehicle 00 − How to Use Troubleshooting/
speed to the voltage, and then input it into the Inspection Service Points − How to Cope
engine-ECU with Intermittent Malfunctions ).
NO : Go to Step 3 .
TROUBLE JUDGMENT
Check Conditions STEP 3. Connector check: C-103 engine-ECU
• Engine is running connector
• Engine coolant temperature is 80°C or higher
Connector: C-103
• The last fuel injection rate exceeds the specified <L.H. drive vehicles>
value.
• Engine speed is 2,900 r/min or more.
Judgment Criterion
• Vehicle speed is 5 km/h or lower for 2 seconds.
PROBABLE CAUSES
• Failed vehicle speed sensor C-103 (B)
• Open/short circuit or harness damage in vehicle
speed sensor circuit or loose connector contact <R.H. drive vehicles>
DIAGNOSIS PROCEDURE
STEP 1. Check the speed meter

C-103 (B)
NO : Check the speed meter (Refer to GROUP 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
54A −Combination Meter − On-vehicle 117 116
Service − Speedometer Check ).

143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

13A-252 DIESEL FUEL
TROUBLESHOOTING
No. 114) engine-ECU connector and B-01
(terminal No. 3) Vehicle speed sensor connector.
Connector: C-103
<L.H. drive vehicles> • Reconfirmation of diagnosis code.
C-103 (B)
C-103 (B) Particulate Filter (DPF) System − Forcible
DPF Regeneration ).
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101

117 116
143 142 141 140 139138 137 136 135 134 133 132 131
145 144
158 157156 155 154 153 152 151 150 149 148 147 146
Connector: B-01
<2WD>
B-01 (B)
<4WD>
B-01 (B)
3 2 1
Harness side

connectors C-30, C-35 <R. H. drive vehicles>, C-53
<L. H. drive vehicles> and C-127, and repair if nec-
essary.
DIESEL FUEL
TROUBLESHOOTING
13A-253
Code No. P0513: Immobilizer Malfunction

• Engine-ECU sends or receives the control sig-
nals to or from ETACS-ECU to certify the ignition
key. STEP 1. M.U.T.-III other system diagnosis code.
• Confirm whether the diagnosis codes are output
NOTE: . from ETACS-ECU.
• If the registered ignition keys are close each
other when starting the engine, radio interfer- Q: Is the diagnosis code output?
ence may cause this code to be displayed. YES : Perform the troubleshooting of immobilizer
• This code may be displayed when registering system (Refer to GROUP 54A − Immobilizer
the key encrypted code. System − Check Chart for Diagnosis Code ).
NO : If diagnosis code P0513 output again after
TROUBLE JUDGMENT the MPI diagnosis code has been erased,
replace the engine-ECU. When the engine-
Check Condition
• Ignition switch is in "ON" position.
Judgment Criterion Service − How to Perform Chassis Number
• The check result of the ETACS-ECU is not suita- Writing ). After replacing the engine-ECU,
ble for that of the engine-ECU. register the injector identification code and
PROBABLE CAUSES Precautions Before Service − What The
• Open/short circuit in immobilizer system circuit or Common Rail Engine Learns ). After
loose connector contact registering the injector identification code,
• Failed ETACS-ECU the vehicle equipped with the DPF carries
• Failed engine-ECU out the forcible DPF regeneration. (Refer to
DPF Regeneration ).
13A-254 DIESEL FUEL
TROUBLESHOOTING
Code No. P0515: Battery Temperature Sensor System <Euro5>
Battery Temperature Sensor Circuit
A-152
Battery temperature
1 2 sensor (integrated in
battery current sensor)
3 4
3 2
BR-B GR-L
155 39
Engine-ECU
5V
C-103 C-105
103104105106107108109110 111112113 114115 1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24

101 102 118119120121122123124125126127128 129130 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
116 117
131132133134135136137138139140 141142143 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
144 145 146147148149150151152153154155156 157158 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKB00273AB
OPERATION • The battery temperature sensor is a kind of resis-

• A power voltage of 5 V is applied to the battery tor, which has characteristics to reduce its resist-
temperature sensor output terminal (terminal No. ance as the battery temperature rises. Therefore,
2) from the engine-ECU (terminal No. 39). the sensor output voltage varies with the battery
• The power voltage is earthed to the engine-ECU temperature, and becomes lower as the battery
(terminal No. 155) from the battery temperature temperature rises.
sensor (terminal No. 3).
TROUBLE JUDGMENT
FUNCTION
Check Condition
• The battery temperature sensor converts the bat-
tery temperature into a voltage and inputs the sig-
nal to the engine-ECU.
trols charging and discharging. Judgment Criterion
• The battery temperature sensor output voltage is
more than 4.88 V.
or
DIESEL FUEL
TROUBLESHOOTING
13A-255
• The battery temperature sensor output voltage is STEP 4. Perform voltage measurement at A-152
less than 0.99 V. battery current sensor connector.
PROBABLE CAUSES Connector: A-152
• Failed battery temperature sensor 2 1
4 3
• Open/short circuit or harness damage in battery
temperature sensor circuit or loose connector Harness side
connector
contact
DIAGNOSIS PROCEDURE
A-152 (GR)
AKB00274 AB
• Item No. 402: Battery temperature sensor • Disconnect connector and measure at harness
side.
temperature) of battery temperature sensor,
or equivalent
OK: 4.5 − 4.9 V
YES : Intermittent malfunction (Refer to GROUP Q: Is the check result normal?
00 − How to Use Troubleshooting/ YES : Go to Step 8 .
Inspection Service Points − How to Cope NO : Go to Step 5 .
NO : Go to Step 2 . STEP 5. Connector check: C-105 engine-ECU
connector
STEP 2. Connector check: A-152 battery current Connector: C-105
sensor connector <L.H. drive vehicles>
Connector: A-152
2 1
4 3
Harness side
connector
C-105 (B)

A-152 (GR)
AKB00274 AB

C-105 (B)
STEP 3. Check battery temperature sensor itself.
• Check battery temperature sensor itself (Refer to 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
GROUP 54A − Battery − Inspection − Battery

48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Current Sensor Check ). 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49

96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

NO : Replace the battery current sensor. Q: Is the check result normal?
13A-256 DIESEL FUEL
TROUBLESHOOTING
No. 2) battery current sensor connector and C- • Item No. 402: Battery temperature sensor
105 (terminal No. 39) engine-ECU connector. OK: At ambient temperature (atmospheric
Connector: A-152 temperature) of battery temperature sensor,
2 1 or equivalent
4 3
Harness side YES : Intermittent malfunction (Refer to GROUP
connector
A-152 (GR) ECU is replaced, write the chassis number
AKB00274 AB (Refer to GROUP 00 − Precautions Before
Connector: C-105
<L.H. drive vehicles> Writing ). After replacing the engine-ECU,
C-105 (B) (Refer to GROUP 17 − Emission Control −
<R.H. drive vehicles> Forcible DPF Regeneration ).

152 battery current sensor connector.
Connector: A-152
2 1
4 3
C-105 (B)
Harness side
connector
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector AKA00089 AB A-152 (GR)

• Check output line for open/short circuit. AKB00274 AB
Q: Is the check result normal? • Disconnect connector and measure at harness

NO : Go to Step 9 .
DIESEL FUEL
TROUBLESHOOTING
13A-257
connector No. 3) battery current sensor connector and C-
Connector: C-103
2 1
4 3
Harness side
connector
C-103 (B)
A-152 (GR)
AKB00274 AB
Connector: C-103
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
C-103 (B)
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

13A-258 DIESEL FUEL
TROUBLESHOOTING
Connector: C-105
Connector: A-152
2 1
4 3
Harness side
connector
C-105 (B)
A-152 (GR)
AKB00274 AB
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-259
Code No. P0545: No.1 Exhaust Gas Temperature Sensor Circuit Low Input <Euro5>
No. 1 Exhaust Gas Temperature Sensor Circuit
A-149
MU802601
No. 1 exhaust gas
temperature sensor
1 2
2 1
BR-L O-G
C-105 82 58
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKB00275 AB
OPERATION • The No.1 exhaust gas temperature sensor is a

• A power voltage of 5 V is applied to the No.1 kind of resistor, which has characteristics to
exhaust gas temperature sensor output terminal reduce its resistance as the exhaust gas temper-
(terminal No. 1) from the engine-ECU (terminal ature rises. Therefore, the sensor output voltage
No. 58). varies with the exhaust gas temperature, and
• The power voltage is earthed to the engine-ECU becomes lower as the exhaust gas temperature
(terminal No. 82) from the No.1 exhaust gas tem- rises.
perature sensor (terminal No. 2).
TROUBLE JUDGMENT
FUNCTION
Check Conditions
• The No.1 exhaust gas temperature sensor con-
verts the exhaust gas temperature into a voltage
and inputs the voltage signal to the engine-ECU.
• Engine-ECU uses this voltage output for DPF
regeneration control. Judgment Criterion
• The No.1 exhaust gas temperature sensor output
voltage is 0.255 V or less.
PROBABLE CAUSES
• Failed No.1 exhaust gas temperature sensor
• Short circuit in No.1 exhaust gas temperature sensor circuit or connector damage
13A-260 DIESEL FUEL
TROUBLESHOOTING

NO : Replace the No.1 exhaust gas temperature
DIAGNOSTIC PROCEDURE sensor. After replacing the No.1 exhaust
gas temperature sensor, carry out the
forcible DPF regeneration. (Refer to
STEP 1. M.U.T.-III data list GROUP 17 − Emission Control − Diesel
• Refer to Data List Reference Table P.13A-542. Particulate Filter (DPF) System − Forcible
a. Item 117: No.1 exhaust gas temperature sensor DPF Regeneration ).
YES : Intermittent malfunction (Refer to GROUP STEP 4. Connector check: C-105 engine-ECU
00 − How to Use Troubleshooting/ connector
NO : Go to Step 2 .
STEP 2. Connector check: A-149 No.1 exhaust

gas temperature sensor connector
Connector: A-149
C-105 (B)
A-149 (B)
2 1
Harness side
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 3. Check No.1 exhaust gas temperature
sensor itself. AKA00089 AB
• Check No.1 exhaust gas temperature sensor

itself (Refer to GROUP 17 − Emission Control −
Diesel Particulate Filter (DPF) System − No.1
exhaust gas temperature sensor Check ).
DIESEL FUEL
TROUBLESHOOTING
13A-261
Connector: A-149
a. Item 117: No.1 exhaust gas temperature sensor
2 1
Harness side ECU is replaced, write the chassis number
connector AKB00276 AB (Refer to GROUP 00 − Precautions Before
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-262 DIESEL FUEL
TROUBLESHOOTING
Code No. P0546: No. 1 exhaust gas temperature sensor Circuit High Input <Euro5>
No. 1 Exhaust Gas Temperature Sensor Circuit
A-149
MU802601
No. 1 exhaust gas
temperature sensor
1 2
2 1
BR-L O-G
C-105 82 58
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKB00275 AB
OPERATION • The No. 1 exhaust gas temperature sensor is a

• A power voltage of 5 V is applied to the No. 1 kind of resistor, which has characteristics to
exhaust gas temperature sensor output terminal reduce its resistance as the exhaust gas temper-
(terminal No. 1) from the engine-ECU (terminal ature rises. Therefore, the sensor output voltage
No. 58). varies with the exhaust gas temperature, and
• The power voltage is earthed to the engine-ECU becomes lower as the exhaust gas temperature
(terminal No. 82) from the No. 1 exhaust gas tem- rises.
perature sensor (terminal No. 2).
TROUBLE JUDGMENT
FUNCTION
Check Conditions
• The No. 1 exhaust gas temperature sensor con-
verts the exhaust gas temperature into a voltage
and inputs the voltage signal to the engine-ECU.
• Engine-ECU uses this voltage for DPF regenera-
tion control.
Judgment Criterion
• The No. 1 exhaust gas temperature sensor out-
put voltage is 4.95 V or more.
PROBABLE CAUSES
• Failed No. 1 exhaust gas temperature sensor
DIESEL FUEL
TROUBLESHOOTING
13A-263
• Open circuit or harness damage in No. 1 exhaust STEP 4. Perform voltage measurement at A-149
gas temperature sensor circuit or loose connector No. 1 exhaust gas temperature sensor connector.
contact
• Failed engine-ECU Connector: A-149

• Refer to Data List Reference Table P.13A-542 A-149 (B)
a. Item 117: No. 1 exhaust gas temperature sensor 2 1
YES : Intermittent malfunction (Refer to GROUP connector AKB00276 AB
00 − How to Use Troubleshooting/ • Disconnect connector, and measure at harness

Inspection Service Points − How to Cope side.
with Intermittent Malfunctions ). • Ignition switch: ON
NO : Go to Step 2 . • Voltage between terminal No. 1 and earth.
OK: 4.5 − 4.9 V
STEP 2. Connector check: A-149 No. 1 exhaust Q: Is the check result normal?
gas temperature sensor connector YES : Go to Step 8 .
Connector: A-149 NO : Go to Step 5 .

connector.
Connector: C-105
A-149 (B)
2 1
Harness side

YES : Go to Step 3 . C-105 (B)

STEP 3. Check No. 1 exhaust gas temperature
sensor itself.
• Check No. 1 exhaust gas temperature sensor
itself (Refer to GROUP 17 − Emission Control −
Diesel Particulate Filter (DPF) System − No. 1
exhaust gas temperature sensor Check ).
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
sensor. After replacing the No. 1 exhaust 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49

gas temperature sensor, carry out the 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
forcible DPF regeneration. (Refer to Harness side connector AKA00089 AB

Particulate Filter (DPF) System − Forcible Q: Is the check result normal?
DPF Regeneration ). YES : Go to Step 6 .
13A-264 DIESEL FUEL
TROUBLESHOOTING
No. 1) No. 1 exhaust gas temperature sensor • Refer to Data List Reference Table P.13A-542
connector and C-105 (terminal No. 58) engine- a. Item 117: No. 1 exhaust gas temperature sensor
ECU connector.
A-149 (B) (Refer to GROUP 00 − Precautions Before
Connector: C-105
C-105 (B)

<R.H. drive vehicles> 149 No. 1 exhaust gas temperature sensor
connector.
Connector: A-149
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 A-149 (B)
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
2 1
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 Harness side
AKA00089 AB
• Check output line for open circuit. side.

Q: Is the check result normal? • Resistance between terminal No. 2 and earth.
YES : Go to Step 7 . OK: Continuity (2 Ω or less)
NO : Go to Step 9 .
DIESEL FUEL
TROUBLESHOOTING
13A-265
Connector: C-105
Connector: A-149
C-105 (B)
A-149 (B)
<R.H. drive vehicles> 2 1

Harness side
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-266 DIESEL FUEL
TROUBLESHOOTING
Connector: C-105
Connector: A-149
C-105 (B)
A-149 (B)
<R.H. drive vehicles> 2 1

Harness side
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-267
Code No. P0551: Power Steering Fluid Pressure Switch System
Power steering fluid pressure switch circuit
C-103
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
127
B-R
A-115
5
B-R
A-27
8
B-R
A-134
(MU801211) Power steering fluid
pressure switch
1 OFF ON
Wire colour code

AKA00105 AB

• The battery voltage is applied to the power steer-
Check Condition
ing pressure switch (terminal No. 1) from the
• Within 5 seconds after the ignition switch is in the
engine-ECU (terminal No. 127)
"OFF" position.
FUNCTION Judgment Criterion
• It is detected whether a load is applied on the • For 2 seconds, the power steering fluid pressure
power steering fluid pump by steering or not, and switch is in the "ON" position and the engine con-
the signal is inputted to the engine-ECU. When tinuously stops.
the power steering fluid pressure switch "ON" sig-
nal (a large load on the power steering fluid PROBABLE CAUSES
pump) is inputted, the engine-ECU provides the • Failed power steering fluid pressure switch
idle-up control. • Short circuit in power steering fluid pressure
switch circuit or loose connector contact
DIAGNOSIS PROCEDURE
13A-268 DIESEL FUEL
TROUBLESHOOTING
STEP 1. M.U.T.-III data list. STEP 4. Check at A-134 power steering fluid
• Refer to Data List Reference Table P.13A-542. pressure switch connector.
a. Item 75: Power steering fluid pressure switch Connector: A-134
A-134 (B)
NO : Go to Step 2
1
STEP 2. Connector check: A-134 power steering Harness side
pressure switch connector
Connector: A-134
side.
• Voltage between terminal No.1 and earth.
A-134 (B) OK: System voltage
1 NO : Go to Step 5 .
Harness side
Q: Is the check result normal? connector
YES : Go to Step 3 . Connector: C-103
NO : Repair or replace the connector. <L.H. drive vehicles>
STEP 3. Check power steering pressure switch

itself.
• Disconnect A-134 power steering fluid pressure
switch connector.
• Continuity between terminal No.1 and earth. C-103 (B)
OK: No continuity
YES : Replace the power steering fluid pressure
switch.
NO : Go to Step 4 .
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

DIESEL FUEL
TROUBLESHOOTING
13A-269
No. 127) engine-ECU connector and A-134
(terminal No. 1) power steering fluid pressure
switch connector.
Connector: C-103 register the injector identification code and

a. Item 75: Power steering fluid pressure switch
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
145 144
158 157156 155 154 153 152 151 150 149 148 147 146
Harness side connector AKA00090 AB ECU is replaced, write the chassis number
Connector: A-134 Service − How to Perform Chassis Number
A-134 (B) learn fuel injection (Refer to GROUP 00 −
1 the vehicle equipped with the DPF carries
Harness side out the forcible DPF regeneration. (Refer to
connector AK501383 AB GROUP 17 − Emission Control − Diesel
NOTE: Before checking harness, check intermediate Particulate Filter (DPF) System − Forcible
connectors A-27 and A-115, and repair if necessary. DPF Regeneration ).
Code No. P0603: EEPROM Malfunction <Except Euro5>
TROUBLE JUDGMENT
FUNCTION Check Conditions
• To check whether the information such as the idle • Ignition switch is in ON position
learned value and so on is stored in the memory
of engine-ECU.
13A-270 DIESEL FUEL
TROUBLESHOOTING
Judgement Criterion YES : Replace the engine-ECU. When the engine-

• When the abnormal EEPROM memory data is ECU is replaced, write the chassis number
detected. (Refer to GROUP 00 − Precautions Before
PROBABLE CAUSE Writing ). After replacing the engine-ECU,
• Failed the engine-ECU register the injector identification code and
DIAGNOSIS Precautions Before Service − What The
STEP 1. Reconfirmation of diagnosis codes. 00 − How to Use Troubleshooting/
Q: Is the check result normal? Inspection Service Points − How to Cope
Code No. P0604: Random Access Memory (RAM) Malfunction
FUNCTION YES : Replace the engine-ECU. When the engine-

• The engine-ECU writes information to RAM or ECU is replaced, write the chassis number
reads information from RAM. (Refer to GROUP 00 − Precautions Before
• The engine-ECU performs an initial check to Service − How to Perform Chassis Number
detect errors in RAM. Writing ). After replacing the engine-ECU,
TROUBLE JUDGMENT learn fuel injection (Refer to GROUP 00 −
Check Condition Precautions Before Service − What The
• Ignition switch is in "ON" position. Common Rail Engine Learns ). After
Judgment Criterion the vehicle equipped with the DPF carries
• A destroyed RAM is detected by engine-ECU ini- out the forcible DPF regeneration. (Refer to
tial check. GROUP 17 − Emission Control − Diesel
PROBABLE CAUSE
DPF Regeneration ).
DIAGNOSIS PROCEDURE Inspection Service Points − How to Cope
III, ignition switch is "ON" position and confirm
whether the diagnosis code is output.
Code No. P0605: Read Only Memory (FLASH ROM) Malfunction

• The engine-ECU reads information from flash
Check Condition
ROM.
• The engine-ECU detects checksum errors.
Judgment Criterion
• In each inspection target area of a flash ROM, a
checksum mismatch is detected three times con-
secutively.
DIESEL FUEL
TROUBLESHOOTING
13A-271
PROBABLE CAUSE YES : Replace the engine-ECU. When the engine-
DIAGNOSIS PROCEDURE Service − How to Perform Chassis Number
STEP 1. M.U.T.-III diagnosis code learn fuel injection (Refer to GROUP 00 −
• After erasing the diagnosis code through M.U.T.- Precautions Before Service − What The
III, ignition switch is "ON" position and confirm Common Rail Engine Learns ). After
whether the diagnosis code is output. registering the injector identification code,
Q: Is the diagnosis code set? the vehicle equipped with the DPF carries
DPF Regeneration ).
Code No. P0606: Engine-ECU (main CPU) Malfunction

FUNCTION ECU is replaced, write the chassis number
• The engine-ECU check whether the microcom- (Refer to GROUP 00 − Precautions Before
puter, which performs the drive control of the Service − How to Perform Chassis Number
throttle valve, is normal. Writing ). After replacing the engine-ECU,
TROUBLE JUDGMENT learn fuel injection (Refer to GROUP 00 −
Check Condition
Judgment Criterion the vehicle equipped with the DPF carries
• The monitoring microcomputer detects a main out the forcible DPF regeneration. (Refer to
microcomputer error. GROUP 17 − Emission Control − Diesel
PROBABLE CAUSE DPF Regeneration ).
• Failed engine-ECU NO : Intermittent malfunction (Refer to GROUP
DIAGNOSIS Inspection Service Points − How to Cope
Code No. P0607: Engine-ECU (sub CPU) Malfunction
FUNCTION
• The main microcomputer detects errors in the
sub microcomputer used for monitoring.
13A-272 DIESEL FUEL
TROUBLESHOOTING
TROUBLE JUDGMENT YES : Replace the engine-ECU. When the engine-

Check Conditions
• Battery positive voltage is 10 V or more
Judgment Criterion learn fuel injection (Refer to GROUP 00 −
• The main microcomputer detects a main micro- Precautions Before Service − What The
computer error. Common Rail Engine Learns ). After
PROBABLE CAUSE the vehicle equipped with the DPF carries
DIAGNOSIS PROCEDURE Particulate Filter (DPF) System − Forcible
DPF Regeneration ).
STEP 1. M.U.T.-III diagnosis code NO : Intermittent malfunction (Refer to GROUP
• After erasing the diagnosis code through M.U.T.- 00 − How to Use Troubleshooting/
III, ignition switch is "ON" position and confirm Inspection Service Points − How to Cope
whether the diagnosis code is output. with Intermittent Malfunctions ).
Code No. P0620: Alternator Control Circuit <Euro5>
OPERATION or
• When the ignition switch is turned ON, the current • For 30 seconds, the battery backup voltage sub-
should be supplied from the combination meter tracted from the final target generation voltage
(terminal No. 52) to the alternator (terminal No. equals 1.9 V or more.
3). When the engine starts under those condi-
tions, the alternator should generate currents. PROBABLE CAUSES
• The engine-ECU checks the voltage of the bat- • Failed battery
tery backup terminal (terminal No. 103) to moni- • Failed drive belt
tor the electricity generation voltage of the • Loose connector contact
alternator. • Open/short circuit or harness damage in alterna-
tor G-terminal circuit
FUNCTION • Harness damage in battery backup circuit
• The engine-ECU compares the battery voltage • Failed alternator
with the voltage generated from the alternator to • Failed engine-ECU
check whether the electrical generation is normal.
DIAGNOSIS PROCEDURE
TROUBLE JUDGMENT
Check Conditions STEP 1. Checking engine start conditions
• Ignition switch is "ON" position. • Check whether the user uses the booster cable to
• The engine speed is 1 500 r/min or more. start the engine.
• The battery backup voltage is 13.5 V or more.
NOTE: This diagnosis code can be output due to the
• The G-terminal duty ratio is 10.2 % or more and
battery voltage drop.
89.8 % or less.
Q: Have you ever used the booster cable to start the
Judgement Criterion
engine?
• For 30 seconds, the final target generation volt- YES : Delete the diagnosis code and check end.
age subtracted from the battery backup voltage NO : Go to Step 2 .
equals 0.8 V or more.
DIESEL FUEL
TROUBLESHOOTING
13A-273
STEP 2. Battery check STEP 5. Perform voltage measurement at C-103
• Check the battery (Refer to GROUP 54A − Bat- engine-ECU connector.
tery − On-vehicle Service − Battery Test ). Connector: C-103
NO : Replace the battery.
STEP 3. Drive belt tension check

• Drive belt tension check (Refer to GROUP 11A −
On-vehicle Service − Alternator and Power Steer- C-103 (B)
ing Oil Pump Drive Belt Tension Check ).
NO : Replace the drive belt.

connector
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

C-103 (B)
side.
OK: System voltage
NO : Go to Step 6 .
C-103 (B)
STEP 6. Connector check: A-122 alternator
115 114 113 112 111 110 109 108 107 106 105 104 103
connector
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 Connector: A-122

143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

NO : Repair or replace the connector. M
4 3 2 1 A-122 (GR)
Harness side

13A-274 DIESEL FUEL
TROUBLESHOOTING
STEP 7. Check harness between C-103 (terminal STEP 8. Check harness between battery and C-
No. 121) engine-ECU connector and A-122 103 (terminal No. 103) engine-ECU connector.
(terminal No. 1) alternator connector. Connector: C-103
Connector: C-103 <L.H. drive vehicles>
C-103 (B)
C-103 (B)
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
115 114 113 112 111 110 109 108 107 106 105 104 103 117 116
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
143 142 141 140 139138 137 136 135 134 133 132 131
117 116 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Connector: A-122 connector A-115, and repair if necessary.
M STEP 9. M.U.T.-III diagnosis code

4 3 2 1 A-122 (GR) • Reconfirmation of diagnosis code.
Harness side
connector AKB00292 AB Q: Is diagnosis code set?
NOTE: Before checking harness, check intermediate NO : Intermittent malfunction (Refer to GROUP
connectors A-27 and A-115, and repair if necessary. 00 − How to Use Troubleshooting/
• Check output line for open/short circuit and dam- Inspection Service Points − How to Cope
age. with Intermittent Malfunctions ).
YES : Check the alternator. STEP 10. Replace the drive belt
NO : Repair the damaged harness wire. • After replacing the drive belt, reconfirm whether
the diagnosis code is set.
Q: Is diagnosis code set?
NO : Check end.
DIESEL FUEL
TROUBLESHOOTING
13A-275
STEP 11. Replace the alternator
• After replacing the alternator, reconfirm whether
the diagnosis code is set.
Q: Is diagnosis code set? Writing ). After replacing the engine-ECU,
NO : Check end.
Code No. P0628: Suction Control Valve Open <Except Euro5>
1
A-47
(MU802768) Suction
control
1 2 valve
P
2
SB
C-103
146 131
103104105106107108109110 111112113 114115
101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
Wire colour code

AKA00106 AB
OPERATION • The voltage is earthed to the engine-ECU (termi-

• The voltage is applied from the engine-ECU (ter- nal No. 146) from the suction control valve (termi-
minal No. 131) to the suction control valve (terminal No. 2).
nal No. 1) via the power transistor in the engine-
ECU. FUNCTION
• The engine-ECU performs duty control over the
suction control valve.
13A-276 DIESEL FUEL
TROUBLESHOOTING
• The engine-ECU checks whether the amount of YES : Go to Step 2 .

current for driving duty is adequate. NO : Repair or replace the connector.
TROUBLE JUDGMENT
Check Conditions • Check suction control valve itself (Refer to P.13A-
• Battery positive voltage is 8 − 16 V 596).
in "ON" position or the engine has started up. YES : Go to Step 3 .
• The supply pump and injector are being normally NO : Replace the suction control valve.
controlled.
• The fuel injection rate is 4 mm3/st or more.
Judgment Criterion connector
Connector: C-103
valve is higher than the specified value, the driv- <L.H. drive vehicles>
ing current is lower than the specified value.
PROBABLE CAUSES
• Open/short circuit or harness damage in suction
control valve circuit or loose connector contact
• Failed engine-ECU C-103 (B)
DIAGNOSIS PROCEDURE <R.H. drive vehicles>

valve connector
Connector: A-47
2 1
C-103 (B)
Harness side
connector
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
A-47 (GR)
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
AK503644 AB
DIESEL FUEL
TROUBLESHOOTING
13A-277
• Check power supply line for open/short circuit Connector: C-103
and damage. <L.H. drive vehicles>
Connector: C-103
C-103 (B)
C-103 (B)
C-103 (B) 115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
130 129 128 127 126 125 124 123 122 121120 119 118
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
115 114 113 112 111 110 109 108 107 106 105 104 103 145 144
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 158 157156 155 154 153 152 151 150 149 148 147 146
117 116
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

Connector: A-47
2 1
Connector: A-47 Harness side
2 1 connector
Harness side A-47 (GR)
connector
A-47 (GR)
AK503644 AB

AK503644 AB
damage.

13A-278 DIESEL FUEL
TROUBLESHOOTING

Code No. P0629: Suction Control Valve Battery Short <Except Euro5>
1
A-47
(MU802768) Suction
control
1 2 valve
P
2
SB
C-103
146 131
103104105106107108109110 111112113 114115
101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
Wire colour code

AKA00106 AB
OPERATION FUNCTION
• The voltage is applied from the engine-ECU (ter- • The engine-ECU performs duty control over the
minal No. 131) to the suction control valve (termi- suction control valve.
nal No. 1) via the power transistor in the engine- • The engine-ECU checks whether the amount of
ECU. current for driving duty is adequate.
• The voltage is earthed to the engine-ECU (termi-
nal No. 146) from the suction control valve (termi- TROUBLE JUDGMENT
nal No. 2). Check Conditions
DIESEL FUEL
TROUBLESHOOTING
13A-279
• 2 seconds later after the ignition switch has been STEP 2. Check suction control valve itself.
in "ON" position or the engine has started up • Check suction control valve itself (Refer to P.13A-
• The supply pump and injector are being normally 596).
controlled.
• The fuel injection rate is 4 mm3/st or more.
YES : Go to Step 3.
Judgment Criterion NO : Replace the suction control valve.
valve is lower than the specified value, the driving STEP 3. Connector check: C-103 engine-ECU
current is higher than the specified value. connector
PROBABLE CAUSES Connector: C-103
• Failed suction control valve <L.H. drive vehicles>
• Short circuit in suction control valve circuit or
DIAGNOSIS PROCEDURE
C-103 (B)
valve connector <R.H. drive vehicles>
Connector: A-47
2 1
Harness side
connector
A-47 (GR)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
AK503644 AB 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

YES : Go to Step 2.
YES : Go to Step 4.
13A-280 DIESEL FUEL
TROUBLESHOOTING
C-103 (B) C-103 (B)
C-103 (B) C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 117 116

143 142 141 140 139138 137 136 135 134 133 132 131 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 158 157156 155 154 153 152 151 150 149 148 147 146
145 144

2 1 2 1

connector connector
A-47 (GR) A-47 (GR)
AK503644 AB AK503644 AB
• Check power supply line for short circuit. • Check earthing line for short circuit.

DIESEL FUEL
TROUBLESHOOTING
13A-281
Code No. P062F: EEPROM Malfunction <Euro5>
FUNCTION YES : Replace the engine-ECU. When the engine-

• To check whether the information such as the idle ECU is replaced, write the chassis number
learned value and so on is stored in the memory (Refer to GROUP 00 − Precautions Before
of engine-ECU. Service − How to Perform Chassis Number
TROUBLE JUDGMENT register the injector identification code and
Check Conditions learn fuel injection (Refer to GROUP 00 −
• Ignition switch is in ON position Precautions Before Service − What The
Judgement Criterion registering the injector identification code,
• When the abnormal EEPROM memory data is carry out the forcible DPF regeneration.
detected. (Refer to GROUP 17 − Emission Control −
PROBABLE CAUSE
• Failed the engine-ECU
DIAGNOSIS Inspection Service Points − How to Cope
STEP 1. Reconfirmation of diagnosis codes.
Code No. P0630: Chassis Number not Programmed
FUNCTION PROBABLE CAUSE

• The chassis number is stored in the engine-ECU • The chassis number is not entered.
by the vehicle manufacturer. • Failed engine-ECU.
TROUBLE JUDGMENT DIAGNOSIS PROCEDURE

Check Condition
• Ignition switch is "ON" position. STEP 1. Check VIN information.
Judgment Criterion • Set M.U.T.-III to the coding mode for chassis
• The entered chassis number data history is not number information.
found. Q: Has VIN (current) been written?
YES : Go to Step 2 . NO : Write VIN. Go to Step 3
13A-282 DIESEL FUEL
TROUBLESHOOTING
STEP 2. M.U.T.-III diagnosis code. STEP 3. M.U.T.-III diagnosis code.

• Reconfirm whether the diagnosis code is output. • Reconfirm whether the diagnosis code is output.
1. Erase the diagnosis codes being output. 1. Erase the diagnosis codes being output.
2. Ignition switch: "LOOK" (OFF) to ON. 2. Ignition switch: "LOOK" (OFF) to ON.
3. Confirm whether the diagnosis code is output. 3. Confirm whether the diagnosis code is output.
Q: Is the diagnosis code output? Q: Is the diagnosis code output?
YES : Replace the engine-ECU. When the engine- YES : Replace the engine-ECU. When the engine-
ECU is replaced, write the chassis number ECU is replaced, write the chassis number
(Refer to GROUP 00 − Precautions Before (Refer to GROUP 00 − Precautions Before
Service − How to Perform Chassis Number Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU, Writing ). After replacing the engine-ECU,
register the injector identification code and register the injector identification code and
learn fuel injection (Refer to GROUP 00 − learn fuel injection (Refer to GROUP 00 −
Precautions Before Service − What The Precautions Before Service − What The
Common Rail Engine Learns ). After Common Rail Engine Learns ). After
registering the injector identification code, registering the injector identification code,
the vehicle equipped with the DPF carries the vehicle equipped with the DPF carries
out the forcible DPF regeneration. (Refer to out the forcible DPF regeneration. (Refer to
GROUP 17 − Emission Control − Diesel GROUP 17 − Emission Control − Diesel
Particulate Filter (DPF) System − Forcible Particulate Filter (DPF) System − Forcible
DPF Regeneration ). DPF Regeneration ).
NO : Intermittent malfunction (Refer to GROUP NO : The check is end.
DIESEL FUEL
TROUBLESHOOTING
13A-283
Code No. P0638: Throttle Valve Control Servo Stuck
Throttle valve control servo circuit
A-132
(MU805200)
1 2 3 4 5 6 throttle valve
5 6
G-B G
C-103 129 114
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
Wire colour code

AKA00107 AB
OPERATION • 2 seconds later after the ignition switch has

• The electric current from the engine- ECU (termi- been in "ON" position.
nal No. 129 and No. 114) to the throttle valve con- • The engine static state.
trol servo (terminal No. 5 and No. 6) is controlled.
Judgment Criterion
FUNCTION • The difference between the objective and real
• Engine- ECU checks the electronic-controlled openings is 10° or more for 0.5 second.
throttle system for abnormal conditions.
PROBABLE CAUSES
TROUBLE JUDGMENT • Failed throttle valve return spring
• Failed throttle valve operation
Check Conditions • Failed throttle valve control servo
The following conditions are met for 3 seconds. • Throttle valve control servo circuit harness dam-
• Battery positive voltage is 6 − 16 V. age or loose connector contact
13A-284 DIESEL FUEL
TROUBLESHOOTING

connector
STEP 1. Connector check: A-132 electronic- Connector: C-103
controlled throttle valve connector <L.H. drive vehicles>
Connector: A-132
C-103 (B)
A-132 (B)
6 5 4 3 2 1 <R.H. drive vehicles>
Harness side

C-103 (B)
STEP 2. Check throttle valve control servo itself.
• Check throttle valve control servo itself (Refer to 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
P.13A-596). 117 116

143 142 141 140 139138 137 136 135 134 133 132 131
145 144
158 157156 155 154 153 152 151 150 149 148 147 146

NO : Replace the electronic-controlled throttle
valve. Q: Is the check result normal?
DIESEL FUEL
TROUBLESHOOTING
13A-285
STEP 4. Check harness between electronic-
controlled throttle valve connector and engine-
ECU connector.
STEP 5. Replace the electronic-controlled
Connector: A-132
throttle valve assembly.
• After replace the electronic-controlled throttle
valve assembly, re-check the trouble symptoms.
A-132 (B)
6 5 4 3 2 1
Harness side
Connector: C-103 learn fuel injection (Refer to GROUP 00 −
<L.H. drive vehicles> Precautions Before Service − What The
C-103 (B) Particulate Filter (DPF) System − Forcible
DPF Regeneration ).
<R.H. drive vehicles> NO : Check end.
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
a. Check harness between A-132 (terminal No.5)

electronic-controlled throttle valve connector and
C-103 (terminal No.129) engine-ECU connector.
b. Check harness between A-132 (terminal No.6)
electronic-controlled throttle valve connector and
C-103 (terminal No.114) engine-ECU connector.
Code No. P0642: Analog Sensor Reference Voltage No. 1 Too Low
FUNCTION • The engine-ECU checks whether the supply volt-

• The engine-ECU applies 5 V to the accelerator age is within the specified range.
pedal position sensor (main).
13A-286 DIESEL FUEL
TROUBLESHOOTING

Check Conditions
• The detected voltage of analog sensor reference Precautions Before Service − What The
voltage No. 1 is 4.86 V or less for 0.5 second. Common Rail Engine Learns ). After
[Power supply for accelerator pedal position sen- registering the injector identification code,
sor (main)] the vehicle equipped with the DPF carries
PROBABLE CAUSE GROUP 17 − Emission Control − Diesel
• Failed engine-ECU Particulate Filter (DPF) System − Forcible
DPF Regeneration ).
DIAGNOSIS PROCEDURE NO : Intermittent malfunction (Refer to GROUP
STEP 1. M.U.T.-III diagnosis code Inspection Service Points − How to Cope
• After erasing the diagnosis code through M.U.T.- with Intermittent Malfunctions ).
Code No. P0643: Analog Sensor Reference Voltage No. 1 Too High

• The engine-ECU applies 5 V to the accelerator
pedal position sensor (main).
• The engine-ECU checks whether the supply volt- STEP 1. M.U.T.-III diagnosis code
age is within the specified range. • After erasing the diagnosis code through M.U.T.-
TROUBLE JUDGMENT whether the diagnosis code is output.
Check Conditions Q: Is the diagnosis code set?
• Battery positive voltage is 8 −16 V YES : Replace the engine-ECU. When the engine-
• 2 seconds later after the ignition switch has been ECU is replaced, write the chassis number
in "ON" position or the engine has started up (Refer to GROUP 00 − Precautions Before
Judgment Criterion Writing ). After replacing the engine-ECU,
• The detected voltage of analog sensor reference register the injector identification code and
voltage No. 1 is 5.14 V or more for 0.5 second. learn fuel injection (Refer to GROUP 00 −
[Power supply for accelerator pedal position sen- Precautions Before Service − What The
sor (main)] Common Rail Engine Learns ). After
PROBABLE CAUSE
DPF Regeneration ).
DIESEL FUEL
TROUBLESHOOTING
13A-287
Code No. P064C: Glow Control Unit Malfunction <Euro5>
Glow System Circuit
W-R
10 Relay
20A box
W-B A-115
3
W-B W-B W
A-20X 1 4
1 2
4 ON
2 3
A-151
To engine-ECU
R
GND
1 9 7 1 2 3 4
Y BR-Y G-R L-B
LG-R GR-R B A-150
2 1 4 3
Y L G R
120 126 1 1 1 1
A-153 A-154 A-155 A-156
1 1 1 1
Engine-
ECU
No.1 No.2 No.3 No.4
C-103
Wire colour code

AKB00259 AB
13A-288 DIESEL FUEL
TROUBLESHOOTING

engine control relay (terminal No. 3) to the glow
control unit (terminal No. 6). Also, it is supplied STEP 1. Connector check: A-151 glow control
from the glow control unit (terminal No. 7) to the unit connector
battery to the glow control unit (terminal No.10).
8 7 6 5
trol unit (terminal No. 9) to the engine-ECU (ter- connector AKB00264 AB
minal No.126).
glow control unit connector.
Check Conditions
• While the engine is running
17 − 83 %.
Judgment Criterion 4 3 2 1
• When a failure of the glow control unit body is 8 7 6 5
11 10 9 A-151 (B)
detected.
Harness side
PROBABLE CAUSES
• Failed glow control unit • Disconnect connector, and measure at harness
• Open/short circuit or harness damage in glow side.
plug power supply circuit or loose connector con- • Voltage between terminal No.10 and earth.
tact. OK: System voltage
(terminal No.10) glow control unit connector
and battery (fusible link 24).
short circuit.
DIESEL FUEL
TROUBLESHOOTING
13A-289
No. 10) glow control unit connector and battery
(fusible link 24).
Inspection Service points − How to Cope
Connector: A-151 with intermittent Malfunctions ).
STEP 5. Replace the glow control unit.

• After replacing the glow control unit, reconfirm
whether the diagnosis code is set.
4 3 2 1 Q: Is the diagnosis code set?
8 7 6 5
11 10 9
A-151 (B)
Harness side
connector AKB00264 AB (Refer to GROUP 00 − Precautions Before
• Check power supply line for damage. Writing ). After replacing the engine-ECU,
Q: Is the check result normal? register the injector identification code and
YES : Go to Step 4 . learn fuel injection (Refer to GROUP 00 −
NO : Repair the damaged harness wire. Precautions Before Service − What The
STEP 4. M.U.T.-III diagnosis code. registering the injector identification code,
• Reconfirmation of diagnosis code. carry out the forcible DPF regeneration.
Q: Is the diagnosis code set? Diesel Particulate Filter (DPF) System −
NO : Check is end.
Code No. P0652: Analog Sensor Reference Voltage No. 2 Too Low
FUNCTION PROBABLE CAUSE

• The engine-ECU applies 5 V to the sensors other • Failed engine-ECU
than the accelerator pedal position sensor (main)
• The engine-ECU checks whether the supply volt- DIAGNOSIS PROCEDURE
age is within the specified range.
TROUBLE JUDGMENT STEP 1. M.U.T.-III diagnosis code

Check Conditions III, ignition switch is "ON" position and confirm
• Battery positive voltage is 8 − 16 V whether the diagnosis code is output.
in "ON" position or the engine has started up Q: Is the diagnosis code set?
Judgment Criterion
• The detected voltage of analog sensor reference
voltage No. 2 is 4.86 V or less for 0.5 second.
[Power supply for other than accelerator pedal
position sensor (main)]
13A-290 DIESEL FUEL
TROUBLESHOOTING

DPF Regeneration ).
Code No. P0653: Analog Sensor Reference Voltage No. 2 Too High

• The engine-ECU applies 5 V to the sensors other
than the accelerator pedal position sensor (main).
• The engine-ECU checks whether the supply volt- STEP 1. M.U.T.-III diagnosis code
age is within the specified range. • After erasing the diagnosis code through M.U.T.-
TROUBLE JUDGMENT whether the diagnosis code is output.
Check Conditions Q: Is the diagnosis code set?
• Battery positive voltage is 8 − 16 V YES : Replace the engine-ECU. When the engine-
• 2 seconds later after the ignition switch has been ECU is replaced, write the chassis number
in "ON" position or the engine has started up (Refer to GROUP 00 − Precautions Before
Judgment Criterion Writing ). After replacing the engine-ECU,
• The detected voltage of analog sensor reference register the injector identification code and
voltage No. 2 is 5.14 V or more for 0.5 second. learn fuel injection (Refer to GROUP 00 −
[Power supply for other than accelerator pedal Precautions Before Service − What The
position sensor (main)] Common Rail Engine Learns ). After
PROBABLE CAUSE
DPF Regeneration ).
DIESEL FUEL
TROUBLESHOOTING
13A-291
Code No. P0683: Glow Control Unit Communication Abnormality <Euro5>
Glow System Circuit
W-R
10 Relay
20A box
W-B A-115
3
W-B W-B W
A-20X 1 4
1 2
4 ON
2 3
A-151
To engine-ECU
R
GND
1 9 7 1 2 3 4
Y BR-Y G-R L-B
LG-R GR-R B A-150
2 1 4 3
Y L G R
120 126 1 1 1 1
A-153 A-154 A-155 A-156
1 1 1 1
Engine-
ECU
No.1 No.2 No.3 No.4
C-103
Wire colour code

AKB00259 AB
13A-292 DIESEL FUEL
TROUBLESHOOTING

engine control relay (terminal No. 3) to the glow
control unit (terminal No. 6). Also, it is supplied STEP 1. Connector check: A-151 glow control
from the glow control unit (terminal No.7) to the unit connector
battery to the glow control unit (terminal No. 10).
8 7 6 5
trol unit (terminal No. 9) to the engine-ECU (ter- connector AKB00264 AB
minal No. 126).
glow control unit connector.
Check Conditions
• While the engine is running
17 − 83 %.
Judgment Criterion 4 3 2 1
• The diagnosis signal is not received from the 8 7 6 5
11 10 9 A-151 (B)
glow control unit for more than 5 seconds.
Harness side
PROBABLE CAUSES
• Failed glow control unit • Disconnect connector, and measure at harness
• Open/short circuit or harness damage in glow side.
control unit power supply/earth circuit or loose • Ignition switch: ON
connector contact. • Voltage between terminal No. 6 and earth.
• Loose connector contact; open/short circuit or OK: System voltage
harness damage of communication wire between
glow control unit and engine-ECU. Q: Is the check result normal?
NO : Go to Step 3 .
DIESEL FUEL
TROUBLESHOOTING
13A-293
STEP 3. Connector check: A-20X engine control
relay connector
(terminal No.7) glow control unit connector
Connector: A-20X and body earth.
• Check earthing line for open circuit
A-20X and damage.

2 1 No. 1) glow control unit connector and C-103
3
4
Relay box's side Connector: A-151
Connector: A-151
4 3 2 1
8 7 6 5
11 10 9 A-151 (B)
4 3 2 1
Harness side
8 7 6 5 connector AKB00264 AB
11 10 9 A-151 (B)
connector AKB00264 AB <L.H. drive vehicles>

(terminal No. 6) glow control unit connector
and A-20X (terminal No. 3) engine control
relay connector.
C-103 (B)
short circuit.

151 glow control unit connector.
Connector: A-151
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
4 3 2 1 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
8 7 6 5
11 10 9 A-151 (B) Harness side connector AKA00090 AB
Harness side
• Check signal line for open/short circuit and dam-
age.
side.
• Resistance between terminal No.7 and earth.
13A-294 DIESEL FUEL
TROUBLESHOOTING
No. 9) glow control unit connector and C-103 No. 6) glow control unit connector and A-20X
(terminal No. 126) engine-ECU connector. (terminal No. 3) engine control relay connector.
4 3 2 1 4 3 2 1
8 7 6 5 8 7 6 5
11 10 9 A-151 (B) 11 10 9 A-151 (B)
Connector: C-103 Connector: A-20X

A-20X
2 1
3
C-103 (B) 4
Relay box's side
C-103 (B) STEP 8. M.U.T.-III diagnosis code.

115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 Q: Is the diagnosis code set?
117 116 YES : Go to Step 9 .
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 NO : Intermittent malfunction (Refer to GROUP
Inspection Service points − How to Cope
• Check signal line for open/short circuit and dam- with intermittent Malfunctions ).
age.
Q: Is the check result normal? STEP 9. Replace the glow control unit.
YES : Go to Step 7 . • After replacing the glow control unit, reconfirm
NO : Repair the damaged harness wire. whether the diagnosis code is set.
DIESEL FUEL
TROUBLESHOOTING
13A-295
NO : Check is end.
Code No. P1203: Capacitor Insufficient Charging

• The engine-ECU monitors the charged state of
the capacitor in the injector drive circuit.
• The engine-ECU checks whether the injector STEP 1. M.U.T.-III diagnosis code
driving voltage is too low due to insufficient • After erasing the diagnosis code through M.U.T.-
charging of the capacitor. III, ignition switch is "ON" position and confirm
TROUBLE JUDGMENT Q: Is the diagnosis code set?
Check Conditions YES : Replace the engine-ECU. When the engine-
• Ignition switch is in "ON" position ECU is replaced, write the chassis number
• Except during the engine cranking period (Refer to GROUP 00 − Precautions Before
• Battery positive voltage is 8 V or more Service − How to Perform Chassis Number
Judgment Criterion register the injector identification code and
• A capacitor in low charge state (40 V or less) is learn fuel injection (Refer to GROUP 00 −
detected in an engine-ECU internal circuit. Precautions Before Service − What The
PROBABLE CAUSE
DPF Regeneration ).
Code No. P1204: Capacitor Excessive Charging
FUNCTION • The engine-ECU checks whether the injector

• The engine-ECU monitors the charged state of driving voltage is too high due to excessive
the capacitor in the injector drive circuit. charging of the capacitor.
13A-296 DIESEL FUEL
TROUBLESHOOTING

Check Conditions
• Except during the engine cranking period
• Battery positive voltage is 8 V or more
• A capacitor in overcharge state (100 V or higher) Precautions Before Service − What The
is detected in an engine-ECU internal circuit. Common Rail Engine Learns ). After
PROBABLE CAUSE the vehicle equipped with the DPF carries
DIAGNOSIS PROCEDURE Particulate Filter (DPF) System − Forcible
DPF Regeneration ).
STEP 1. M.U.T.-III diagnosis code NO : Intermittent malfunction (Refer to GROUP
• After erasing the diagnosis code through M.U.T.- 00 − How to Use Troubleshooting/
III, ignition switch is "ON" position and confirm Inspection Service Points − How to Cope
whether the diagnosis code is output. with Intermittent Malfunctions ).
Code No. P1272: Pressure Limiter Malfunction
TROUBLE JUDGMENT
OPERATION Check Conditions
• Refer to Code No. P0003: Suction Control Valve • Battery positive voltage is 8 − 16 V
Open P.13A-26. <Euro 5> • Engine speed is 600 r/min or more
• Refer to Code No. P0004: Suction Control Valve • 2 seconds later after the ignition switch has been
Battery Short P.13A-29. <Euro 5> in "ON" position or the engine has started up
• Refer to Code No. P0191: Rail Pressure Sensor • Rail pressure is normal
Range/Performance Problem P.13A-143.
• Refer to Code No. P0192: Rail Pressure Sensor Judgment Criterion
Circuit Low Input P.13A-147. • After a pressure higher than the pressure of the
• Refer to Code No. P0193: Rail Pressure Sensor pressure limiter opening valve is detected, fuel
Circuit High Input P.13A-155. leakage diagnosis (supply pump discharge rate
• Refer to Code No. P0628: Suction Control Valve excessive) is detected within the predetermined
Open P.13A-276. <Except Euro 5> time.
• Refer to Code No. P0629: Suction Control Valve
PROBABLE CAUSES
Battery Short P.13A-279. <Except Euro 5>
FUNCTION • Failed fuel system
• The engine-ECU controls the fuel discharge rate • Failed common rail assembly
using the suction control valve. • Open/short circuit or harness damage in suction
• The engine-ECU monitors the signals input from control valve circuit or loose connector contact
the rail pressure sensor. • Failed engine-ECU
• The engine-ECU checks whether the pressure
limiter valve is open, based on changes in the DIAGNOSIS PROCEDURE
signals input from the rail pressure sensor (rapid NOTE: This diagnosis code is outputted for an air
drop of pressure after it goes extremely high). penetration in the fuel line of the supply pump due to
lack of fuel. Therefore, bleed air from the fuel line
after the fuel supply, and delete the diagnosis code
through M.U.T.-III.
DIESEL FUEL
TROUBLESHOOTING
13A-297
STEP 1. M.U.T.-III diagnosis code STEP 5. Connector check: C-103 engine-ECU
Q: Is any other diagnosis code than P1272 output?
connector and A-47 suction control valve
YES : Inspection chart for diagnosis codes (Refer connector
to P.13A-21). Connector: C-103
NO : Go to Step 2 . <L.H. drive vehicles>
STEP 2. Check the fuel filter contamination

NO : Replace the fuel filter then replace the
common rail assembly and fuel injection C-103 (B)
tubes.
STEP 3. Release the air from the fuel line.

• After releasing the air from the fuel line, continue
idle operation for about five minutes and recheck
for abnormal symptoms.
YES : Replace the common rail assembly and C-103 (B)
common tubes.
NO : Go to Step 4 . 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
145 144
STEP 4. Check suction control valve itself 158 157156 155 154 153 152 151 150 149 148 147 146
• Check suction control valve itself (Refer to P.13A- Harness side connector AKA00090 AB
596).
Connector: A-47
2 1
NO : Replace the suction control valve. After Harness side
replacing the suction control valve, learn the connector
supply pump (Refer to GROUP 00 − A-47 (GR)
AK503644 AB

13A-298 DIESEL FUEL
TROUBLESHOOTING
C-103 (B) C-103 (B)
C-103 (B) C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 117 116

143 142 141 140 139138 137 136 135 134 133 132 131 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 158 157156 155 154 153 152 151 150 149 148 147 146
145 144

2 1 2 1

connector connector
A-47 (GR) A-47 (GR)
AK503644 AB AK503644 AB
age. age.
DIESEL FUEL
TROUBLESHOOTING
13A-299
NO : Replace the engine-ECU then replace the
measurement at A-47 suction control valve
common rail assembly and fuel injection
(Using an oscilloscope).
tubes. When the engine-ECU is replaced,
Connector: A-47 write the chassis number (Refer to GROUP
2 1 00 − Precautions Before Service − How to
Harness side Perform Chassis Number Writing ). After
connector replacing the engine-ECU, register the
injector identification code and learn fuel
A-47 (GR)
injection (Refer to GROUP 00 − Precautions
Before Service − What The Common Rail
Engine Learns ). After registering the
injector identification code, the vehicle
AK503644 AB equipped with the DPF carries out the
• Engine: Idling forcible DPF regeneration. (Refer to
• Connect the oscilloscope special patterns pickup GROUP 17 − Emission Control − Diesel
to engine-ECU terminal No. 131 and earth. Particulate Filter (DPF) System − Forcible
DPF Regeneration ).
OK: The waveform should show a pattern
similar to the illustration of Inspection proce-
dure using an oscilloscope (Refer to P.13A- STEP 9. Replace the common rail assembly and
586). fuel injection tubes.
common tubes, re-check the trouble symptoms
YES : Replace the suction control valve. After
Code No. P1273: Supply Pump Insufficient Flow
• The engine-ECU monitors changes in the fuel

OPERATION discharge rate at each injection to detect a fault in
• Refer to Code No. P0003: Suction Control Valve one of the two plungers in the supply pump.
Open P.13A-26. <Euro 5>
• Refer to Code No. P0004: Suction Control Valve TROUBLE JUDGMENT
Battery Short P.13A-29. <Euro 5> Check Condition
• Refer to Code No. P0335: Crank Angle Sensor • Vehicle in steady and stable state (the difference
System P.13A-184. from the last data of the objective common rail
• Refer to Code No. P0340: Camshaft Position pressure is less than 3 MPa and that from the last
Sensor System P.13A-192. data of the final fuel injection rate is less than 2
• Refer to Code No. P0628: Suction Control Valve mm3/st.
Open P.13A-276. <Except Euro 5>
• Refer to Code No. P0629: Suction Control Valve Judgment Criterion
Battery Short P.13A-279. <Except Euro 5> • The inter-cylinder difference in pressure feed
exceeds the predetermined value 500 times con-
FUNCTION secutively.
• The engine-ECU controls the fuel discharge rate
using the suction control valve. PROBABLE CAUSES
• Air penetration due to lack of fuel
13A-300 DIESEL FUEL
TROUBLESHOOTING
• Failed supply pump STEP 2. Replace the supply pump assembly.

• Failed engine-ECU • After the supply pump assembly, learn the sup-
ply pump (Refer to GROUP 00 − Precautions
DIAGNOSIS PROCEDURE Before Service − What The Common Rail Engine
NOTE: This diagnosis code is outputted for an air Learns ).
penetration in the fuel line of the supply pump due to • After learning the supply pump assembly, re-
lack of fuel. Therefore, bleed air from the fuel line check the trouble symptoms.
after the fuel supply, and delete the diagnosis code Q: Does trouble symptom persist?
through M.U.T.-III. YES : Replace the engine-ECU. When the engine-
STEP 1. M.U.T.-III diagnosis code (Refer to GROUP 00 − Precautions Before
• With the air released from the fuel line, supply Service − How to Perform Chassis Number
fuel if necessary. Writing ). After replacing the engine-ECU,
• Continue idle operation for about 5 minutes. register the injector identification code and
Q: Is the diagnosis code P1273 outputted again? Precautions Before Service − What The
YES : Go to Step 2 . Common Rail Engine Learns ). After
DPF Regeneration ).
Code No. P1274: Supply Pump Protection
PROBABLE CAUSES
OPERATION • Failed supply pump
• Refer to Code No. P0191: Rail Pressure Sensor • Failed common rail assembly
Range/Performance Problem P.13A-143. • Failed engine-ECU
Circuit Low Input P.13A-147. DIAGNOSIS PROCEDURE
Circuit High Input P.13A-155.
FUNCTION Q: Is any other diagnosis code than P1274 output?
• The engine-ECU monitors the signals input from YES : Inspection chart for diagnosis codes (Refer
the rail pressure sensor. to P.13A-21).
• Based on these input signals, the engine-ECU NO : Go to Step 2 .
checks whether the fuel pressure in the common
rail is abnormal.
STEP 2. Check suction control valve itself
TROUBLE JUDGMENT • Check suction control valve itself (Refer to P.13A-
596).
Check Conditions
• Engine is running Q: Is the check result normal?
• Rail pressure sensor is normal YES : Go to Step 3 .
Judgment Criterion replacing the supply pump, learn the supply
• For 1 seconds, the rail pressure stays in the criti- pump (Refer to GROUP 00 − Precautions
cal pressure range in which the supply pump is Before Service − What The Common Rail
burned out. Engine Learns ).
DIESEL FUEL
TROUBLESHOOTING
13A-301
STEP 3. Replace the supply pump assembly.
• After the supply pump assembly, learn the sup-
ply pump (Refer to GROUP 00 − Precautions
Before Service − What The Common Rail Engine
Learns ).
• After learning the supply pump assembly, re-
check the trouble symptoms.
Q: Does trouble symptom persist? Common Rail Engine Learns ). After
YES : Go to Step 4 . registering the injector identification code,
NO : The check is end. the vehicle equipped with the DPF carries
STEP 4. Replace the common rail assembly and GROUP 17 − Emission Control − Diesel
fuel injection tubes. Particulate Filter (DPF) System − Forcible
• After replacing the common rail assembly and DPF Regeneration ).
fuel injection tubes, re-check the trouble symp- NO : The check is end.
toms
Code No. P1275: Supply Pump Exchange
DIAGNOSIS PROCEDURE
OPERATION
Range/Performance Problem P.13A-143.
• Refer to Code No. P0192: Rail Pressure Sensor Q: Is any other diagnosis code than P1275 output?
Circuit Low Input P.13A-147. YES : Inspection chart for diagnosis codes (Refer
• Refer to Code No. P0193: Rail Pressure Sensor to P.13A-21).
Circuit High Input P.13A-155. NO : Go to Step 2 .
FUNCTION STEP 2. Check suction control valve itself

• The engine-ECU monitors the signals input from • Check suction control valve itself (Refer to P.13A-
the rail pressure sensor. 596).
• Based on these input signals, the engine-ECU
checks whether the fuel pressure in the common Q: Is the check result normal?
rail is abnormal. YES : Go to Step 3 .
TROUBLE JUDGMENT replacing the suction control valve, learn the
Check Conditions
• Engine is running
• Rail pressure sensor is normal
Judgment Criterion STEP 3. Replace the supply pump.
• The rail pressure continues to exceed the maxi- • After the supply pump assembly, learn the supply
mum operating pressure of the supply pump for pump. (Refer to GROUP 00 − Precautions Before
15 seconds. Service − What The Common Rail Engine Learns
PROBABLE CAUSES ).
• Failed supply pump • After learning the supply pump, re-check the trou-
• Failed rail pressure sensor ble symptoms.
• Failed engine-ECU Q: Does trouble symptom persist?
13A-302 DIESEL FUEL
TROUBLESHOOTING

STEP 4. Replace the common rail assembly and
fuel injection tubes.
toms.
Q: Does trouble symptom persist? learn fuel injection (Refer to GROUP 00 −
DPF Regeneration ).
DIESEL FUEL
TROUBLESHOOTING
13A-303
Code No. P1276: Fuel Filter Exchange <Vehicles with fuel filter pressure switch>
Fuel filter pressure switch circuit
C-103
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
99 100 101
116 117 110 111 Engine-ECU
128 141142143
131132133134135136137138139140 129 130
144 145 146147148149150151152153154155156 157158
110
A-143 Fuel filter

ON pressure switch
1 2 OFF
Wire colour code

R: Red P: Pink V: Violet PU: Purple
AKB00283 AB

• The battery voltage is applied to the fuel filter
Check Condition
pressure switch (terminal No. 1) from the engine-
• During steady driving after engine warm up.
Judgment Criterion
FUNCTION • Determination of clogged fuel filter.
• The engine-ECU detects the clogged fuel filter by
using the fuel filter pressure switch installed on PROBABLE CAUSES
the fuel filter assembly. • Failed fuel filter pressure switch
• Open/short circuit or harness damage in fuel filter
pressure switch circuit or loose connector contact
13A-304 DIESEL FUEL
TROUBLESHOOTING

NO : Go to Step 4 .
STEP 1. Connector check: A-143 fuel filter

pressure switch connector STEP 4. Connector check: C-103 engine-ECU
connector
Connector: A-143
Connector: C-103
A-143 (B) <L.H. drive vehicles>
2 1

STEP 2. Check the fuel filter pressure switch

itself.
Check the fuel filter pressure switch itself (Refer to C-103 (B)
GROUP 13B − Fuel Filter − Fuel Filter Inspection ).
115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
YES : Replace the fuel filter body. 117 116

143 142 141 140 139138 137 136 135 134 133 132 131
NO : Go to Step 3 . 158 157156 155 154 153 152 151 150 149 148 147 146
145 144

fuel filter pressure switch connector. Q: Is the check result normal?
Connector: A-143 NO : Repair or replace the connector.
A-143 (B)
2 1
Harness side

side.
OK: System voltage
DIESEL FUEL
TROUBLESHOOTING
13A-305
No. 1) fuel filter pressure switch connector and • Refer to Data List Reference Table P.13A-542.
C-103 (terminal No. 110) engine-ECU connector. a. Item 152: Fuel filter pressure switch
A-143 (B)
2 1
connector AK700919AC Writing ). After replacing the engine-ECU,
Connector: C-103

143 fuel filter pressure switch connector.
C-103 (B) Connector: A-143
A-143 (B)
2 1
Harness side
C-103 (B) connector AK700919AC

115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 side.
117 116 • Resistance between terminal No. 2 and earth.
143 142 141 140 139138 137 136 135 134 133 132 131

158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Harness side connector AKA00090 AB Q: Is the check result normal?

• Check output line for open/short circuit. YES : Go to Step 8 .
Q: Is the check result normal? (terminal No. 2) fuel filter pressure switch
YES : Go to Step 6 . connector and body earth.
• Check earthing line for open circuit
and damage.
13A-306 DIESEL FUEL
TROUBLESHOOTING
connector No. 1) fuel filter pressure switch connector and
Connector: C-103
A-143 (B)
C-103 (B) 2 1

Connector: C-103
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
C-103 (B)
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

YES : Replace the fuel filter.
Code No. P1277: Fuel Filter Freeze <Vehicles with fuel filter pressure switch>

• The engine-ECU estimates that the fuel filter is
Check Conditions
freezing, using the input signal from the each
• During steady driving
sensor.
• Fuel temperature is lower than specified temper-
• When storing this diagnosis code, the engine-
ature
ECU blinks the glow lamp.
• Engine coolant temperature is lower than speci-
fied temperature
DIESEL FUEL
TROUBLESHOOTING
13A-307
Judgment Criteria DIAGNOSIS PROCEDURE
• Determination of clogged fuel filter
• Fuel pressure hunting occurs more than certain
degree, or difference more than certain degree STEP 1. Reconfirmation of M.U.T.-III diagnosis
exists between target fuel pressure and actual code after warming up the engine
fuel pressure Q: Is any other diagnosis code than P1276 output?
YES : Inspection chart for diagnosis code (Refer
PROBABLE CAUSE to ).
• Fuel filter Freezing NO : Check end.
Code No. P1298: Variable Geometry Turbocharger Control System Malfunction (high pressure)
<Euro5>

• The engine-ECU controls the duty ratio of the NO : Repair the variable geometry turbocharger
variable geometry control solenoid valve so that control system.
the actual boost pressure can become the target
boost pressure. STEP 2. M.U.T.-III diagnosis code.
TROUBLE JUDGMENT
Check Condition nosis code is output.
Judgment Criterion YES : Replace the engine-ECU. When the engine-
• Actual boost pressure is higher than target boost ECU is replaced, write the chassis number
pressure by more than 6.7 kPa (Refer to GROUP 00 − Precautions Before
PROBABLE CAUSES Writing ). After replacing the engine-ECU,
• Failed variable geometry turbocharger control register the injector identification code and
system learn fuel injection (Refer to GROUP 00 −
• Failed engine-ECU Precautions Before Service − What The
DIAGNOSTIC PROCEDURE registering the injector identification code,
STEP 1. Check the turbocharger supercharging (Refer to GROUP 17 − Emission Control −
pressure. Diesel Particulate Filter (DPF) System −
• Check the turbocharger supercharging pressure Forcible DPF Regeneration ).
(refer to GROUP 15 − On-vehicle Service − Tur-
bocharger Supercharging Pressure Check ).
Q: Is the check result normal? with Intermittent Malfunctions ).
Code No. P1299: Variable Geometry Turbocharger Control System Malfunction (low pressure)
<Euro5>

• The engine-ECU controls the duty ratio of the
Check Condition
variable geometry control solenoid valve so that
the actual boost pressure can become the target
boost pressure.
13A-308 DIESEL FUEL
TROUBLESHOOTING
Judgment Criterion STEP 2. M.U.T.-III diagnosis code.

• Actual boost pressure is lower than target boost • After clearing the diagnosis code through M.U.T.-
pressure by less than 6.7 kPa III, start the engine and confirm whether the diag-
PROBABLE CAUSES nosis code is output.
• Failed variable geometry turbocharger control Q: Is the diagnosis code set?
system YES : Replace the engine-ECU. When the engine-
DIAGNOSTIC PROCEDURE Service − How to Perform Chassis Number
STEP 1. Check the turbocharger supercharging learn fuel injection (Refer to GROUP 00 −
pressure. Precautions Before Service − What The
• Check the turbocharger supercharging pressure Common Rail Engine Learns ). After
(refer to GROUP 15 − On-vehicle Service − Tur- registering the injector identification code,
bocharger Supercharging Pressure Check ). carry out the forcible DPF regeneration.
YES : Go to Step 2 . Diesel Particulate Filter (DPF) System −
NO : Repair the variable geometry turbocharger Forcible DPF Regeneration ).
control system. NO : Intermittent malfunction (Refer to GROUP
DIESEL FUEL
TROUBLESHOOTING
13A-309
Code No. P1427: No. 3 Exhaust Gas Temperature Sensor (DPF temperature) Circuit Low Input
<Euro5>
No. 3 Exhaust Gas Temperature Sensor (DPF temperature) Circuit
A-158
MU802661
No. 3 exhaust gas
temperature sensor
1 2 (DPF temperature)
1 2
B W
A-28
6 12
W-V BR-G
C-105 84 60
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKB00277 AB
OPERATION • The No. 3 exhaust gas temperature sensor (DPF

• A power voltage of 5 V is applied to the No. 3 temperature) is a kind of resistor, which has char-
exhaust gas temperature sensor (DPF tempera- acteristics to reduce its resistance as the DPF
ture) output terminal (terminal No. 2) from the temperature rises. Therefore, the sensor output
engine-ECU (terminal No. 60). voltage varies with the DPF temperature, and
• The power voltage is earthed to the engine-ECU becomes lower as the DPF temperature rises.
(terminal No. 84) from the No. 3 exhaust gas tem-
perature sensor (DPF temperature) (terminal No. TROUBLE JUDGMENT
1). Check Conditions
FUNCTION
• The No. 3 exhaust gas temperature sensor (DPF
temperature) converts the DPF temperature into
a voltage and inputs the voltage signal to the Judgment Criterion
engine-ECU. • The No. 3 exhaust gas temperature sensor (DPF
• Engine-ECU uses this voltage output for DPF temperature) output voltage is 0.255 V or less.
regeneration control.
PROBABLE CAUSES
(DPF temperature)
13A-310 DIESEL FUEL
TROUBLESHOOTING
• Short circuit in No. 3 exhaust gas temperature STEP 3. Check No. 3 exhaust gas temperature
sensor (DPF temperature) circuit or connector sensor (DPF temperature) itself.
damage • Check No. 3 exhaust gas temperature sensor
• Failed engine-ECU (DPF temperature) itself (Refer to GROUP 17 −
Emission Control − Diesel Particulate Filter (DPF)
DIAGNOSTIC PROCEDURE System − No. 3 exhaust gas temperature sensor
(DPF temperature) Check ).
STEP 1. M.U.T.-III data list Q: Is the check result normal?
• Refer to Data List Reference Table P.13A-542. YES : Go to Step 4 .
a. Item 119: No. 3 exhaust gas temperature sensor NO : Replace the No. 3 exhaust gas temperature
(DPF temperature) sensor (DPF temperature). After replacing
the No. 3 exhaust gas temperature sensor
YES : Intermittent malfunction (Refer to GROUP (DPF temperature), carry out the forcible
00 − How to Use Troubleshooting/ DPF regeneration. (Refer to GROUP 17 −
Inspection Service Points − How to Cope Emission Control − Diesel Particulate Filter
with Intermittent Malfunctions ). (DPF) System − Forcible DPF Regeneration
NO : Go to Step 2 . ).
STEP 2. Connector check: A-158 No. 3 exhaust STEP 4. Connector check: C-105 engine-ECU
gas temperature sensor (DPF temperature) connector
connector Connector: C-105
Connector: A-158
C-105 (B)
2 1 A-158 (B)
Harness side
connector
No. 3 exhaust gas

temperature sensor
(DPF temperature) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
AKB00278 AB 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-311
(DPF temperature) connector and C-105 (terminal
No. 60) engine-ECU connector. STEP 6. M.U.T.-III data list
Connector: A-158
(DPF temperature)
2 1
connector
No. 3 exhaust gas learn fuel injection (Refer to GROUP 00 −
temperature sensor Precautions Before Service − What The
(DPF temperature)
AKB00278 AB (Refer to GROUP 17 − Emission Control −
Connector: C-105 Forcible DPF Regeneration ).
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-312 DIESEL FUEL
TROUBLESHOOTING
Code No. P1428: No. 3 Exhaust Gas Temperature Sensor (DPF temperature) Circuit High Input
<Euro5>
No. 3 Exhaust Gas Temperature Sensor (DPF temperature) Circuit
A-158
MU802661
No. 3 exhaust gas
temperature sensor
1 2 (DPF temperature)
1 2
B W
A-28
6 12
W-V BR-G
C-105 84 60
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKB00277 AB
OPERATION • The No. 3 exhaust gas temperature sensor (DPF

• A power voltage of 5 V is applied to the No. 3 temperature) is a kind of resistor, which has char-
exhaust gas temperature sensor (DPF tempera- acteristics to reduce its resistance as the DPF
ture) output terminal (terminal No. 2) from the temperature rises. Therefore, the sensor output
engine-ECU (terminal No. 60). voltage varies with the DPF temperature, and
• The power voltage is earthed to the engine-ECU becomes lower as the DPF temperature rises.
(terminal No. 84) from the No. 3 exhaust gas tem-
perature sensor (DPF temperature) (terminal No. TROUBLE JUDGMENT
1). Check Conditions
FUNCTION
temperature) converts the DPF temperature into
a voltage and inputs the voltage signal to the
engine-ECU. Judgment Criterion
• Engine-ECU uses this voltage for DPF regenera- • The No. 3 exhaust gas temperature sensor (DPF
tion control. temperature) output voltage is 4.95 V or more.
PROBABLE CAUSES (DPF temperature)

DIESEL FUEL
TROUBLESHOOTING
13A-313
• Open circuit or harness damage in No. 3 exhaust STEP 3. Check No. 3 exhaust gas temperature
gas temperature sensor (DPF temperature) cir- sensor (DPF temperature) itself.
cuit or loose connector contact • Check No. 3 exhaust gas temperature sensor
• Failed engine-ECU (DPF temperature) itself (Refer to GROUP 17 −
Emission Control − Diesel Particulate Filter (DPF)
DIAGNOSTIC PROCEDURE System − No. 3 exhaust gas temperature sensor
(DPF temperature) Check ).
STEP 1. M.U.T.-III data list Q: Is the check result normal?
• Refer to Data List Reference Table P.13A-542 YES : Go to Step 4 .
a. Item 119: No. 3 exhaust gas temperature sensor NO : Replace the No. 3 exhaust gas temperature
(DPF temperature) sensor (DPF temperature). After replacing
the No. 3 exhaust gas temperature sensor
YES : Intermittent malfunction (Refer to GROUP (DPF temperature), carry out the forcible
00 − How to Use Troubleshooting/ DPF regeneration. (Refer to GROUP 17 −
Inspection Service Points − How to Cope Emission Control − Diesel Particulate Filter
with Intermittent Malfunctions ). (DPF) System − Forcible DPF Regeneration
NO : Go to Step 2 . ).
STEP 2. Connector check: A-158 No. 3 exhaust STEP 4. Perform voltage measurement at A-158
gas temperature sensor (DPF temperature) No. 3 exhaust gas temperature sensor (DPF
connector temperature) connector.
A-158 (B) 2 1 A-158 (B)

2 1
connector connector
No. 3 exhaust gas No. 3 exhaust gas

temperature sensor temperature sensor
(DPF temperature) (DPF temperature)
AKB00278 AB AKB00278 AB

OK: 4.5 − 4.9 V
NO : Go to Step 5 .
13A-314 DIESEL FUEL
TROUBLESHOOTING
Connector: C-105
<L.H. drive vehicles> No. 60) engine-ECU connector.
Connector: A-158
C-105 (B)
Harness side
connector
No. 3 exhaust gas

(DPF temperature)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
AKB00278 AB
Connector: C-105
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-315
158 No. 3 exhaust gas temperature sensor (DPF
temperature) connector.
Connector: A-158
(DPF temperature)
Inspection Service Points − How to Cope A-158 (B)
2 1
NO : Replace the engine-ECU. When the engine- Harness side
connector
register the injector identification code and No. 3 exhaust gas
learn fuel injection (Refer to GROUP 00 − temperature sensor
(DPF temperature)
carry out the forcible DPF regeneration. AKB00278 AB
(Refer to GROUP 17 − Emission Control − • Disconnect connector, and measure at harness
Diesel Particulate Filter (DPF) System − side.
Forcible DPF Regeneration ). • Resistance between terminal No. 1 and earth.
NO : Go to Step 9 .
13A-316 DIESEL FUEL
TROUBLESHOOTING
Connector: C-105
<L.H. drive vehicles> No. 84) engine-ECU connector.
Connector: A-158
C-105 (B)
Harness side
connector
No. 3 exhaust gas

(DPF temperature)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
AKB00278 AB
Connector: C-105
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-317
STEP 11. Connector check: C-105 engine-ECU No. 60) engine-ECU connector.
connector.
Connector: A-158
Connector: C-105
2 1 A-158 (B)
C-105 (B)
Harness side
connector
No. 3 exhaust gas

temperature sensor
(DPF temperature)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AKB00278 AB
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
Connector: C-105
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 <L.H. drive vehicles>

C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

YES : Go to Step 7 . NO : Repair the damaged harness wire.
13A-318 DIESEL FUEL
TROUBLESHOOTING
Code No. P1497: DPF System Malfunction <Euro5>
FUNCTION STEP 2. M.U.T.-III data list.

• The engine-ECU monitors the input signals from • Item 208: Short interval DPF regeneration count
sensors to check if the DPF regeneration is exe-
cuted normally. OK: 10 or more
Q: Is the short interval DPF regeneration counting 10
TROUBLE JUDGMENT or more?
Check Condition YES : Go to Step 4 .
• On DPF regeneration NO : Go to Step 3 .
Judgement Criterion
STEP 3. Forcible DPF regeneration execution
• The DPF regeneration status continues for 30
• Initialise the DPF-related parts, and then delete
minutes or more.
the diagnosis code (Refer to GROUP 00 − Pre-
Check Condition cautions before Service − Initialisation Procedure
• Ignition switch is in "ON" position for Learning Value in Diesel Particulate Filter
Judgement Criterion (DPF) System ).
• The regeneration with short interval continues for a. Item 42: DPF system malfunction service
specified times. • Carry out the forcible DPF regeneration (Refer to
GROUP 17 − Emission Control − Diesel Particu-
PROBABLE CAUSES late Filter (DPF) System − Forcible DPF Regen-
• Failed No. 2 exhaust gas temperature sensor eration ).
(catalyst temperature) Q: Is the diagnosis code P0420 or P1497 set?
• Failed No. 3 exhaust gas temperature sensor YES : Replace the catalytic converter. When the
(DPF temperature) catalytic converter is replaced, initialise the
• Failed exhaust differential pressure sensor learning value (Refer to GROUP 00 −
• Failed exhaust differential pressure sensor ambi- Precautions before Service − Initialisation
ent air temperature sensor Procedure for Learning Value in Diesel
• Catalytic converter inactive Particulate Filter (DPF) System ). On
• The engine oil-containing ash is loaded to the completion, carry out the forcible DPF
DPF inside. regeneration (Refer to GROUP 17 −
Emission Control − Diesel Particulate Filter
DIAGNOSIS PROCEDURE (DPF) System − Forcible DPF Regeneration
).
STEP 1. M.U.T.-III data list. NO : Replace the engine-ECU. When the engine-
• Refer to Data List Reference Table P.13A-542. ECU is replaced, write the chassis number
a. Item 118: No. 2 exhaust gas temperature sen- (Refer to GROUP 00 − Precautions Before
sor (catalyst temperature) Service − How to Perform Chassis Number
b. Item 119: No. 3 exhaust gas temperature sen-
sor (DPF temperature)
c. Item 120: Exhaust differential pressure sensor Precautions Before Service − What The
Q: Are the check results normal? Common Rail Engine Learns ). After
YES : Go to Step 2 . registering the injector identification code,
NO : Perform the diagnosis code classified check carry out the forcible DPF regeneration.
procedure for the sensor that has shown an (Refer to GROUP 17 − Emission Control −
abnormal data value (Refer to Inspection Diesel Particulate Filter (DPF) System −
Chart for Diagnosis Code P.13A-21). Forcible DPF Regeneration ).
DIESEL FUEL
TROUBLESHOOTING
13A-319
YES : Proceed to troubleshooting for black smoke
STEP 4. Forcible DPF regeneration execution
(Refer to Inspection Procedure 13 P.13A-
• Initialise the DPF-related parts, and then delete
479).
the diagnosis code (Refer to GROUP 00 − Pre-
NO : Replace the DPF. When the DPF is
cautions before Service − Initialisation Procedure
replaced, initialise the learning value (Refer
for Learning Value in Diesel Particulate Filter
to GROUP 00 − Precautions Before Service
(DPF) System ).
− Initialisation Procedure For Learning
a. Item 42: DPF system malfunction service
Value in Diesel Particulate Filter (DPF)
• Carry out the forcible DPF regeneration 2 times
System ).
(Refer to GROUP 17 − Emission Control − Diesel
Particulate Filter (DPF) System − Forcible DPF
Regeneration ).
NOTE: Carry out the DPF regeneration 2 times
because the assumption of the accumulated
amount of the DPF is not stable.
• M.U.T.-III data list
a. Item 156: Soot loading by differential pressure
OK: 3 g/L or less
Code No. P1498: Excessive PM Accumulated in DPF <Euro5>
FUNCTION Judgement Criterion

• The engine-ECU monitors the input signals from • Driving distance exceeds the specified value after
sensors to estimate the PM amount loaded to the the last DPF regeneration.
DPF inside.
• If the PM is loaded more than the specified PROBABLE CAUSE
amount, the DPF regeneration is automatically • The PM is abnormally loaded to the DPF inside.
executed under certain conditions in order to
eliminate the PM. DIAGNOSIS PROCEDURE
• If the PM is excessively loaded, the engine-ECU
does not execute the automatic DPF regenera- STEP 1. Forcible DPF regeneration execution
tion. It makes the engine warning lamp illuminate • Carry out the forcible DPF regeneration (Refer to
and the DPF lamp blink. GROUP 17 − Emission Control − Diesel Particu-
late Filter (DPF) System − Forcible DPF Regen-
TROUBLE JUDGMENT
eration ).
Check Condition
Q: Is the diagnosis code output?
to P.13A-21).
NO : Check end.
Code No. P1499: Abnormally high DPF temperature <Euro5>

• The DPF may be have melting damage if the
Check Condition
temperature exceeds the specified value.
• On DPF regeneration
• The engine-ECU monitors the signals from No. 3
exhaust gas temperature sensor (DPF tempera-
ture) to check if the DPF is under the specified
temperature.
13A-320 DIESEL FUEL
TROUBLESHOOTING
Judgement Criterion DIAGNOSIS PROCEDURE

temperature) detects the abnormally high temper-
ature. STEP 1. M.U.T.-III data list.
or • Refer to Data List Reference Table P.13A-542.
• The estimated DPF centre temperature exceeds a. Item 119: No. 3 exhaust gas temperature sen-
the specified value. sor (DPF temperature)
PROBABLE CAUSE YES : Replace the DPF. When the DPF is
• Damage by the DPF with high temperature replaced, initialise the learning value (Refer
to GROUP 00 − Precautions Before Service
− Initialisation Procedure For Learning
Value in Diesel Particulate Filter (DPF)
System ).
NO : Perform the diagnosis code classified check
procedure for the sensor that has shown an
abnormal data value (Refer to Inspection
Chart for Diagnosis Code P.13A-21).
DIESEL FUEL
TROUBLESHOOTING
13A-321
Code No. P1608: Battery Current Sensor System <Euro5>
Battery Current Sensor Circuit
A-152
Hall IC
1 2 Battery current sensor
3 4
1 4 3
R-B BR-Y BR-B
C-103 148 138 155
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
5V
Wire colour code

AKB00279 AB

• A power voltage of 5 V is supplied to the battery
Check Condition
current sensor (terminal No. 1) from the engine-
ECU (terminal No. 148) and is earthed to the
engine-ECU (terminal No. 155) from the battery Judgment Criterion
current sensor (terminal No. 3). • The battery current sensor output voltage is 0.2 V
• The battery current sensor (terminal No. 4) out- or less.
puts a sensor signal, which is input into the or
engine-ECU (terminal No. 138). • The battery current sensor output voltage is 4.8 V
or more.
FUNCTION
• The battery current sensor detects a battery cur- PROBABLE CAUSES
rent and inputs a signal into the engine-ECU. • Failed battery current sensor
• In response to the signal, the engine-ECU con- • Open/short circuit or harness damage in battery
trols charging and discharging. current sensor circuit or loose connector contact
13A-322 DIESEL FUEL
TROUBLESHOOTING

NO : Go to Step 4 .
STEP 1. Connector check: A-152 battery current

sensor connector STEP 4. Connector check: C-103 engine-ECU
connector
Connector: A-152
2 1 Connector: C-103
4 3 <L.H. drive vehicles>
Harness side
connector
A-152 (GR) C-103 (B)

AKB00274 AB
STEP 2. Check battery current sensor itself.

• Check battery current sensor itself (Refer to
GROUP 54A − Battery − Inspection − Battery C-103 (B)
Current Sensor Check ).
115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
YES : Go to Step 3 . 117 116

143 142 141 140 139138 137 136 135 134 133 132 131
NO : Replace the battery current sensor. 158 157156 155 154 153 152 151 150 149 148 147 146
145 144

battery current sensor connector.
Connector: A-152 NO : Repair or replace the connector.
2 1
4 3
Harness side
connector
A-152 (GR)
AKB00274 AB
• Disconnect connector and measure at harness

side.
OK: 4.9 − 5.1 V
DIESEL FUEL
TROUBLESHOOTING
13A-323
STEP 5. Check harness between A-152 (terminal STEP 6. M.U.T.-III diagnosis code
No. 1) battery current sensor connector and C- • Reconfirmation of diagnosis code.
103 (terminal No. 148) engine-ECU connector. Q: Is the diagnosis code set?
Connector: A-152 YES : Replace the engine-ECU. When the engine-
4 3
connector
A-152 (GR) Common Rail Engine Learns ). After
AKB00274 AB registering the injector identification code,
Connector: C-103 (Refer to GROUP 17 − Emission Control −
C-103 (B)
<R.H. drive vehicles> 152 battery current sensor connector.
Connector: A-152
2 1
4 3
Harness side
connector
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
130 129 128 127 126 125 124 123 122 121120 119 118
A-152 (GR)
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
145 144
AKB00274 AB
158 157156 155 154 153 152 151 150 149 148 147 146
• Disconnect connector and measure at harness

side.
• Check power supply line for open/short circuit. • Resistance between terminal No. 3 and earth.
NO : Repair the damaged harness wire. YES : Go to Step 10 .
NO : Go to Step 8 .
13A-324 DIESEL FUEL
TROUBLESHOOTING
Connector: C-103
2 1
4 3
Harness side
connector
C-103 (B)
A-152 (GR)
AKB00274 AB
Connector: C-103
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
C-103 (B)
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

DIESEL FUEL
TROUBLESHOOTING
13A-325
Connector: C-103
2 1
4 3
Harness side
connector
C-103 (B)
A-152 (GR)
AKB00274 AB
Connector: C-103
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
C-103 (B)
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

13A-326 DIESEL FUEL
TROUBLESHOOTING
No. 4) battery current sensor connector and C-
Connector: A-152
2 1
4 3
Harness side
connector
A-152 (GR)
AKB00274 AB
Connector: C-103
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
• Check output line for open/short circuit and dam-

age.
Code No. P1625: Injection Quantity Compensation Value Error
TROUBLE JUDGMENT
FUNCTION Check Condition
• Correction data of the injector built in the engine • Ignition switch is in "ON" position.
is written to the engine-ECU.
• The engine-ECU checks whether the correction Judgment Criterion
data thus written is valid. • An error is detected during three-side majority
decision check or upper/lower limit check of an
injector correction value.
DIESEL FUEL
TROUBLESHOOTING
13A-327
PROBABLE CAUSE STEP 2. Rewrite the injector identification code
• Failed engine-ECU data again.
• Rewrite the injector identification code data
DIAGNOSIS PROCEDURE (Refer to GROUP 00− Precautions Before Serv-
ice − Injector Identification Code Registration
STEP 1. Injector identification code data check Procedure ).
• Check whether injector identification code data is • After rewriting the injector identification code data
correctly written to the engine-ECU in M.U.T.-III. again, recheck for abnormal symptoms.
ECU is replaced, write the chassis number ECU is replaced, write the chassis number
(Refer to GROUP 00 − Precautions Before (Refer to GROUP 00 − Precautions Before
Service − How to Perform Chassis Number Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU, Writing ). After replacing the engine-ECU,
register the injector identification code and register the injector identification code and
learn fuel injection (Refer to GROUP 00 − learn fuel injection (Refer to GROUP 00 −
Precautions Before Service − What The Precautions Before Service − What The
Common Rail Engine Learns ). After Common Rail Engine Learns ). After
registering the injector identification code, registering the injector identification code,
the vehicle equipped with the DPF carries the vehicle equipped with the DPF carries
out the forcible DPF regeneration. (Refer to out the forcible DPF regeneration. (Refer to
GROUP 17 − Emission Control − Diesel GROUP 17 − Emission Control − Diesel
Particulate Filter (DPF) System − Forcible Particulate Filter (DPF) System − Forcible
DPF Regeneration ). DPF Regeneration ).
NO : Go to Step 2 .
Code No. P1626: Injection Quantity Compensation Value Not Coding
DIAGNOSIS PROCEDURE
FUNCTION
• The engine-ECU checks whether injector correc-
STEP 1. Write the injector identification code
tion data is written to the engine-ECU.
data.
TROUBLE JUDGMENT • Write the injector identification code data (Refer
to GROUP 00 − Precautions Before Service −
Check Condition Injector Identification Code Registration Proce-
• Ignition switch is in "ON" position. dure ).
Judgment Criterion • After writing the injector identification code data,
• No record of writing injector correction data recheck for abnormal symptoms.
PROBABLE CAUSE
YES : Replace the engine-ECU. When the engine- registering the injector identification code,
ECU is replaced, write the chassis number the vehicle equipped with the DPF carries
(Refer to GROUP 00 − Precautions Before out the forcible DPF regeneration. (Refer to
Service − How to Perform Chassis Number GROUP 17 − Emission Control − Diesel
Writing ). After replacing the engine-ECU, Particulate Filter (DPF) System − Forcible
register the injector identification code and DPF Regeneration ).
learn fuel injection (Refer to GROUP 00 − NO : The check is end.
13A-328 DIESEL FUEL
TROUBLESHOOTING
Code No. P2118: Throttle Valve Control (DC Motor) Current Malfunction
Throttle valve control servo circuit
A-132
(MU805200)
1 2 3 4 5 6 throttle valve
5 6
G-B G
C-103 129 114
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
Wire colour code

AKA00107 AB

• Current supplied from the engine-ECU (terminal
Check Condition
No. 129 and No. 114) to the throttle valve control
servo (terminal No. 5 and No. 6) is adjusted.
Judgment Criterion
FUNCTION • An overcurrent cut-off signal from the throttle
• The throttle valve control servo drive IC in the valve control servo drive integrated circuit (IC) is
engine-ECU monitors current flowing in the throt- repeatedly detected for 0.5 second.
tle control servo and cuts energization if it detects
overcurrent. PROBABLE CAUSES
• Failed throttle control servo
• Short circuit in throttle valve control servo circuit
or loose connector contact
DIESEL FUEL
TROUBLESHOOTING
13A-329
connector.
STEP 1. Connector check: A-132 electronic- Connector: C-103
controlled throttle valve connector. <L.H. drive vehicles>
Connector: A-132
C-103 (B)
A-132 (B)
6 5 4 3 2 1 <R.H. drive vehicles>
Harness side

C-103 (B)
STEP 2. Check throttle valve control servo itself
• Check throttle valve control servo itself (Refer to 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
P.13A-596). 117 116

143 142 141 140 139138 137 136 135 134 133 132 131
145 144
158 157156 155 154 153 152 151 150 149 148 147 146

NO : Replace the throttle body assembly.
13A-330 DIESEL FUEL
TROUBLESHOOTING
(terminal No. 6) electronic-controlled throttle (terminal No. 5) electronic-controlled throttle
valve connector. valve connector.
C-103 (B) C-103 (B)
C-103 (B) C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 117 116

143 142 141 140 139138 137 136 135 134 133 132 131 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
A-132 (B) A-132 (B)

6 5 4 3 2 1 6 5 4 3 2 1
• Check output line for short circuit. • Check output line for short circuit.

DIESEL FUEL
TROUBLESHOOTING
13A-331
DPF Regeneration ).
13A-332 DIESEL FUEL
TROUBLESHOOTING
Code No. P2122: Accelerator Pedal Position Sensor (main) Circuit Low Input
Accelerator Pedal Position Sensor (main) Circuit
(main)
Accelerator
C-115 Hall IC pedal
(MU805200) position
1 2 3 4 5 6 sensor
1 3 2
L-W GR BR-W
C-103 149 150 151
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
5V
Wire colour code

AKA00109 AB

• A power voltage of 5 V is applied to the accelera-
Check Conditions
tor pedal position sensor (terminal No. 1) from the
• Accelerator pedal position sensor (sub) is normal
(terminal No. 151) from the accelerator pedal Judgment Criterion
position sensor (terminal No. 2). • Accelerator pedal position sensor (main) output
• The sensor signal is inputted to the engine-ECU voltage is lower than 0.2 V for 0.3 seconds.
(terminal No. 150) from the accelerator pedal
position sensor output terminal (terminal No. 3). PROBABLE CAUSES
• Failed accelerator pedal position sensor
FUNCTION • Open/short circuit or harness damage in acceler-
• The accelerator pedal position sensor (main) out- ator pedal position sensor circuit or loose con-
puts voltage which corresponds to the accelera- nector contact
tor pedal depression. • Failed engine-ECU
• The engine-ECU checks whether the voltage is
within a specified range.
DIESEL FUEL
TROUBLESHOOTING
13A-333

accelerator pedal position sensor connector.
a. Item 9: Accelerator pedal position sensor
(main) Connector: C-115
NO : Go to Step 2 .
STEP 2. Connector check: C-115 accelerator

pedal position sensor connector
Connector: C-115
C-115 (B)
C-115 (B)
6 5 4 3 2 1
Harness side connector AK700804 AB

<R.H. drive vehicles> side.
OK: 4.9 − 5.1 V
C-115 (B) YES : Go to Step 7 .
NO : Go to Step 4 .
6 5 4 3 2 1

13A-334 DIESEL FUEL
TROUBLESHOOTING
STEP 4. Connector check: C-103 engine-ECU STEP 5. Check harness between C-115 (terminal
connector No. 1) accelerator pedal position sensor
Connector: C-103
Connector: C-115
C-103 (B)
C-115 (B)
C-103 (B)
C-115 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
6 5 4 3 2 1
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Connector: C-103
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
• Check power supply line for open/short circuit.

DIESEL FUEL
TROUBLESHOOTING
13A-335
NO : Go to Step 8 .
(main) STEP 8. Connector check: C-103 engine-ECU
connector
YES : Intermittent malfunction (Refer to GROUP Connector: C-103
Service − How to Perform Chassis Number C-103 (B)
register the injector identification code and <R.H. drive vehicles>
GROUP 17 − Emission Control − Diesel C-103 (B)
DPF Regeneration ). 115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
130 129 128 127 126 125 124 123 122 121120 119 118
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
STEP 7. Perform resistance measurement at C- 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
115 accelerator pedal position sensor connector. Harness side connector AKA00090 AB
Connector: C-115
<L.H. drive vehicles> Q: Is the check result normal?
C-115 (B)
C-115 (B)
6 5 4 3 2 1

side.
13A-336 DIESEL FUEL
TROUBLESHOOTING
No. 2) accelerator pedal position sensor
connector
Connector: C-115
C-115 (B)
C-103 (B)
C-115 (B)
C-103 (B)
6 5 4 3 2 1
Harness side connector AK700804 AB 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
Connector: C-103 143 142 141 140 139138 137 136 135 134 133 132 131
145 144
<L.H. drive vehicles> 158 157156 155 154 153 152 151 150 149 148 147 146

C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

DIESEL FUEL
TROUBLESHOOTING
13A-337
accelerator pedal position sensor connector. connector
C-115 (B)
C-103 (B)

C-115 (B)
C-103 (B)
6 5 4 3 2 1
115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
130 129 128 127 126 125 124 123 122 121120 119 118
117 116
• Use special tool test harness (MB991658) to con- 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

• Ignition switch: ON AKA00090 AB
OK: 0.7 − 1.3 V YES : Go to Step 13 .
13A-338 DIESEL FUEL
TROUBLESHOOTING
No. 3) accelerator pedal position sensor and C- No. 1) accelerator pedal position sensor
103 (terminal No. 150) engine-ECU connector. connector and C-103 (terminal No. 149) engine-
ECU connector.
Connector: C-115
C-115 (B)
C-115 (B)

C-115 (B)
C-115 (B)
6 5 4 3 2 1
Harness side connector 6 5 4 3 2 1
AK700804 AB
Connector: C-103
C-103 (B)
C-103 (B)
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
• Check output line for short circuit. AKA00090 AB

NO : Repair the damaged harness wire. YES : Replace the accelerator pedal position
sensor.
DIESEL FUEL
TROUBLESHOOTING
13A-339
ECU connector.
Connector: C-115
C-115 (B)
C-115 (B)
6 5 4 3 2 1
Connector: C-103
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

13A-340 DIESEL FUEL
TROUBLESHOOTING
Code No. P2123: Accelerator Pedal Position Sensor (main) Circuit High Input
(main)
Accelerator
C-115 Hall IC pedal
(MU805200) position
1 2 3 4 5 6 sensor
1 3 2
L-W GR BR-W
C-103 149 150 151
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
5V
Wire colour code

AKA00109 AB

Check Conditions
• Accelerator pedal position sensor (sub) is normal
• Accelerator pedal position sensor (sub) output
voltage is 0.125 V or higher and 1.4 V or lower.
position sensor (terminal No. 2).
• DTC No. P2124 is memorized.
position sensor output terminal (terminal No. 3). • Accelerator pedal position sensor (main) output
voltage exceeds 4.8 V for 0.25 seconds.
FUNCTION
• The accelerator pedal position sensor (main) out- PROBABLE CAUSES
puts voltage which corresponds to the accelera- • Failed accelerator pedal position sensor
tor pedal depression. • Open circuit in accelerator pedal position sensor
• The engine-ECU checks whether the voltage is circuit or loose connector contact
within a specified range. • Failed engine-ECU
DIESEL FUEL
TROUBLESHOOTING
13A-341

• Refer to Data List Reference Table P.13A-542. STEP 3. Perform resistance measurement at C-
115 accelerator pedal position sensor connector.
NO : Go to Step 2 .

Connector: C-115
C-115 (B)
C-115 (B)
6 5 4 3 2 1

C-115 (B) NO : Go to Step 4 .
6 5 4 3 2 1

13A-342 DIESEL FUEL
TROUBLESHOOTING
Connector: C-103
Connector: C-115
C-103 (B)
C-115 (B)
C-103 (B)
C-115 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
6 5 4 3 2 1
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Connector: C-103
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

DIESEL FUEL
TROUBLESHOOTING
13A-343
STEP 6. M.U.T.-III data list STEP 7. Replace the accelerator pedal position
• Refer to Data List Reference Table P.13A-542. sensor
a. Item 9: Accelerator pedal position sensor • After replacing the accelerator pedal position
(main) sensor, re-check the trouble symptoms.
YES : Intermittent malfunction (Refer to GROUP YES : The check is end.
00 − How to Use Troubleshooting/ NO : Replace the engine-ECU. When the engine-
Inspection Service Points − How to Cope ECU is replaced, write the chassis number
with Intermittent Malfunctions ). (Refer to GROUP 00 − Precautions Before
NO : Replace the engine-ECU. When the engine- Service − How to Perform Chassis Number
ECU is replaced, write the chassis number Writing ). After replacing the engine-ECU,
Service − How to Perform Chassis Number learn fuel injection (Refer to GROUP 00 −
Writing ). After replacing the engine-ECU, Precautions Before Service − What The
register the injector identification code and Common Rail Engine Learns ). After
learn fuel injection (Refer to GROUP 00 − registering the injector identification code,
Precautions Before Service − What The the vehicle equipped with the DPF carries
Common Rail Engine Learns ). After out the forcible DPF regeneration. (Refer to
registering the injector identification code, GROUP 17 − Emission Control − Diesel
the vehicle equipped with the DPF carries Particulate Filter (DPF) System − Forcible
out the forcible DPF regeneration. (Refer to DPF Regeneration ).
DPF Regeneration ).
13A-344 DIESEL FUEL
TROUBLESHOOTING
Code No. P2124: Accelerator Pedal Position Sensor (Main) Circuit High Input Intermittent
(main)
Accelerator
C-115 Hall IC pedal
(MU805200) position
1 2 3 4 5 6 sensor
1 3 2
L-W GR BR-W
C-103 149 150 151
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
5V
Wire colour code

AKA00109 AB
OPERATION • The engine-ECU checks whether the voltage is

• A power voltage of 5 V is applied to the accelera- within a specified range.
engine-ECU (terminal No. 149). TROUBLE JUDGMENT
• The power voltage is earthed to the engine-ECU Check Conditions
(terminal No. 151) from the accelerator pedal • Ignition switch is in "ON" position
position sensor (terminal No. 2). • Accelerator pedal position sensor (sub) is normal
position sensor output terminal (terminal No. 3). • Accelerator pedal position sensor (main) output
voltage exceeds 4.8 V for 0.05 seconds.
FUNCTION
• The accelerator pedal position sensor (main) out- PROBABLE CAUSES
puts voltage which corresponds to the accelera- • Failed accelerator pedal position sensor
tor pedal depression. • Open circuit in accelerator pedal position sensor
DIESEL FUEL
TROUBLESHOOTING
13A-345

NO : Go to Step 2 .

Connector: C-115
C-115 (B)
C-115 (B)
6 5 4 3 2 1

6 5 4 3 2 1

13A-346 DIESEL FUEL
TROUBLESHOOTING
Connector: C-103
Connector: C-115
C-103 (B)
C-115 (B)
C-103 (B)
C-115 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
6 5 4 3 2 1
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Connector: C-103
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

DIESEL FUEL
TROUBLESHOOTING
13A-347
a. Item 9: Accelerator pedal position sensor • After replacing the accelerator pedal position
(main) sensor, re-check the trouble symptoms.
DPF Regeneration ).
13A-348 DIESEL FUEL
TROUBLESHOOTING
Code No. P2127: Accelerator Pedal Position Sensor (sub) Circuit Low Input
Accelerator Pedal Position Sensor (sub) Circuit
(sub)
Accelerator
C-115 Hall IC pedal
(MU805200) position
1 2 3 4 5 6 sensor
4 6 5
Y-R L B-Y
C-103 134 135 136
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
5V
Wire colour code

AKA00110 AB

Check Conditions
• Accelerator pedal position sensor (main) is nor-
mal
position sensor (terminal No. 5). Judgment Criterion
• The sensor signal is inputted to the engine-ECU • Accelerator pedal position sensor (sub) output
(terminal No. 135) from the accelerator pedal voltage is lower than 0.125 V for 0.3 seconds.
position sensor output terminal (terminal No. 6).
PROBABLE CAUSES
FUNCTION • Failed accelerator pedal position sensor
• The accelerator pedal position sensor (sub) out- • Open/short circuit or harness damage in acceler-
puts voltage which corresponds to the accelera- ator pedal position sensor circuit or loose con-
tor pedal depression. nector contact
• The engine-ECU checks whether the voltage is • Failed engine-ECU
within a specified range.
DIESEL FUEL
TROUBLESHOOTING
13A-349

(sub) Connector: C-115
NO : Go to Step 2 .

Connector: C-115
C-115 (B)
C-115 (B)
6 5 4 3 2 1

OK: 4.9 − 5.1 V
C-115 (B) YES : Go to Step 7 .
NO : Go to Step 4 .
6 5 4 3 2 1

13A-350 DIESEL FUEL
TROUBLESHOOTING
Connector: C-103
Connector: C-115
C-103 (B)
C-115 (B)
C-103 (B)
C-115 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
6 5 4 3 2 1
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Connector: C-103
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

DIESEL FUEL
TROUBLESHOOTING
13A-351
NO : Go to Step 8 .
(sub) STEP 8. Connector check: C-103 engine-ECU
connector
YES : Intermittent malfunction (Refer to GROUP Connector: C-103
Service − How to Perform Chassis Number C-103 (B)
register the injector identification code and <R.H. drive vehicles>
GROUP 17 − Emission Control − Diesel C-103 (B)
DPF Regeneration ). 115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
130 129 128 127 126 125 124 123 122 121120 119 118
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
STEP 7. Perform resistance measurement at C- 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
115 accelerator pedal position sensor connector. Harness side connector AKA00090 AB
Connector: C-115
C-115 (B)
C-115 (B)
6 5 4 3 2 1

side.
13A-352 DIESEL FUEL
TROUBLESHOOTING
connector
Connector: C-115
C-115 (B)
C-103 (B)
C-115 (B)
C-103 (B)
6 5 4 3 2 1
Harness side connector AK700804 AB 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
Connector: C-103 143 142 141 140 139138 137 136 135 134 133 132 131
145 144

C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

DIESEL FUEL
TROUBLESHOOTING
13A-353
accelerator pedal position sensor connector. connector
C-115 (B)
C-103 (B)

C-115 (B)
C-103 (B)
6 5 4 3 2 1
115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
130 129 128 127 126 125 124 123 122 121120 119 118
117 116
• Use special tool test harness (MB991658) to con- 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

• Ignition switch: ON AKA00090 AB
OK: 0.2 − 0.8 V YES : Go to Step 13 .
13A-354 DIESEL FUEL
TROUBLESHOOTING
No. 6) accelerator pedal position sensor No. 4) accelerator pedal position sensor
connector and C-103 (terminal No. 135) engine- connector and C-103 (terminal No. 134) engine-
ECU connector. ECU connector.
C-115 (B) C-115 (B)
C-115 (B) C-115 (B)
6 5 4 3 2 1 6 5 4 3 2 1
Harness side connector AK700804 AB Harness side connector AK700804 AB

C-103 (B) C-103 (B)
C-103 (B) C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 117 116

143 142 141 140 139138 137 136 135 134 133 132 131 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
• Check output line for short circuit. • Check power supply line for damage.
YES : Go to Step 14 . YES : Replace the accelerator pedal position
NO : Repair the damaged harness wire. sensor.
DIESEL FUEL
TROUBLESHOOTING
13A-355
ECU connector.
Connector: C-115
C-115 (B)
C-115 (B)
6 5 4 3 2 1
Connector: C-103
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

13A-356 DIESEL FUEL
TROUBLESHOOTING
Code No. P2128: Accelerator Pedal Position Sensor (sub) Circuit High Input
Accelerator Pedal Position Sensor (sub) Circuit
(sub)
Accelerator
C-115 Hall IC pedal
(MU805200) position
1 2 3 4 5 6 sensor
4 6 5
Y-R L B-Y
C-103 134 135 136
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
5V
Wire colour code

AKA00110 AB

Check Conditions
• Accelerator pedal position sensor (main) is nor-
position sensor (terminal No. 5).
mal
• Accelerator pedal position sensor (main) output
voltage is 0.2 V or higher and 2.8 V or lower.
position sensor output terminal (terminal No. 6).
Judgment Criterion
FUNCTION • Accelerator pedal position sensor (main) output
• The accelerator pedal position sensor (sub) out- voltage exceeds 2.4 V for 0.3 seconds.
puts voltage which corresponds to the accelera-
tor pedal depression. PROBABLE CAUSES
• The engine-ECU checks whether the voltage is • Failed accelerator pedal position sensor
within a specified range. • Open circuit in accelerator pedal position sensor
DIESEL FUEL
TROUBLESHOOTING
13A-357

(sub) Connector: C-115
NO : Go to Step 2 .

Connector: C-115
C-115 (B)
C-115 (B)
6 5 4 3 2 1

6 5 4 3 2 1

13A-358 DIESEL FUEL
TROUBLESHOOTING
Connector: C-103
Connector: C-115
C-103 (B)
C-115 (B)
C-103 (B)
C-115 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
6 5 4 3 2 1
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Connector: C-103
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

DIESEL FUEL
TROUBLESHOOTING
13A-359
a. Item 10: Accelerator pedal position sensor • After replacing the accelerator position sensor,
(sub) re-check the trouble symptoms.
DPF Regeneration ).
Code No. P2138: Accelerator Pedal Position Sensor (Main and Sub) Range/Performance Problem
OPERATION Check Conditions

• Refer to Code No. P2122: Accelerator Pedal • Battery positive voltage is 6 − 16 V
Position Sensor (main) Circuit Low Input P.13A- • 2 seconds later after the ignition switch has been
333. in "ON" position or the engine has started up
• Refer to Code No. P2127: Accelerator Pedal • Engine speed is 600 r/min or more.
Position Sensor (sub) Circuit Low Input P.13A- • Accelerator pedal position sensor (main) output
349. voltage is 0.2 V or higher and 4.8 V or lower.
• Accelerator pedal position sensor (sub) output
FUNCTION voltage is 0.125 V or higher and 2.375 V or lower.
• Engine-ECU checks the accelerator pedal posi-
tion sensor output signal characteristics for Judgment Criterion
abnormal conditions. • When a change in the accelerator pedal position
sensor (sub) output voltage is less than the spec-
TROUBLE JUDGMENT ified value for 0.2 second, the difference between
the opening indicated by the accelerator pedal
Check Condition
position sensor (main) and that by the accelerator
pedal position sensor (sub) is 18 % or more of the
Judgment Criterion specified value.
• When an error is detected on the High side of the
accelerator pedal position (main) for 0.1 second, PROBABLE CAUSES
the accelerator pedal position sensor (sub) is • Failed accelerator pedal position sensor
faulty on the High/Low side. • Accelerator pedal position sensor circuit harness
damage or loose connector contact
13A-360 DIESEL FUEL
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 2. Perform resistance measurement at C-

STEP 1. Connector check: C-115 accelerator Connector: C-115
pedal position connector <L.H. drive vehicles>
Connector: C-115
C-115 (B)
C-115 (B)
C-115 (B)
C-115 (B) 6 5 4 3 2 1
6 5 4 3 2 1
Harness side connector AK700804 AB side.
YES : Go to Step 2 . OK: Continuity (2 Ω or less)
NO : Go to Step 3 .
DIESEL FUEL
TROUBLESHOOTING
13A-361
YES : Check and repair harness between C-115
(terminal No. 2) accelerator pedal position
connector
Connector: C-103 151) engine-ECU connector.
STEP 4. Perform resistance measurement at C-

Connector: C-115
C-103 (B)
C-115 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

C-115 (B)
Connector: C-115
<L.H. drive vehicles> 6 5 4 3 2 1

side.
C-115 (B) • Resistance between terminal No. 5 and earth.
<R.H. drive vehicles> NO : Go to Step 5 .
C-115 (B)
6 5 4 3 2 1

13A-362 DIESEL FUEL
TROUBLESHOOTING

connector
STEP 6. Perform voltage measurement at C-115

Connector: C-115
C-103 (B)
C-115 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

C-115 (B)
Connector: C-115
<L.H. drive vehicles> 6 5 4 3 2 1

C-115 (B) • Ignition switch: ON
OK: 4.9 − 5.1 V
<R.H. drive vehicles> YES : Go to Step 8 .
NO : Go to Step 7 .
C-115 (B)
6 5 4 3 2 1

DIESEL FUEL
TROUBLESHOOTING
13A-363
connector
<L.H. drive vehicles> • Check power supply line for damage.

C-115 (B) accelerator pedal position sensor connector.
Connector: C-115
C-115 (B)
C-115 (B)
6 5 4 3 2 1
Connector: C-103
C-115 (B)
6 5 4 3 2 1

C-103 (B) nect connector, and measure at pick-up harness.
<R.H. drive vehicles> • Voltage between terminal No. 4 and earth.
OK: 4.9 − 5.1 V
NO : Go to Step 9 .
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

13A-364 DIESEL FUEL
TROUBLESHOOTING

connector
<L.H. drive vehicles> • Check power supply line for damage.

Connector: C-103
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
C-103 (B)
Connector: C-115
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

C-115 (B)
OK: 0.7 − 1.3 V
C-115 (B)
6 5 4 3 2 1

DIESEL FUEL
TROUBLESHOOTING
13A-365
YES : Replace the accelerator pedal position
sensor.
ECU connector.
Connector: C-115
<L.H. drive vehicles> engine-ECU connector.
Connector: C-103
C-115 (B)
C-103 (B)
C-115 (B)
6 5 4 3 2 1
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
Connector: C-103 130 129 128 127 126 125 124 123 122 121120 119 118
117 116
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

C-103 (B) OK: 0.2 − 0.8 V
<R.H. drive vehicles> Q: Is the check result normal?

C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

13A-366 DIESEL FUEL
TROUBLESHOOTING
STEP 13. Check harness between C-115 (terminal STEP 14. Connector check: C-103 engine-ECU
No. 6) accelerator pedal position sensor connector
connector and C-103 (terminal No. 135) engine- Connector: C-103
ECU connector. <L.H. drive vehicles>
Connector: C-115
C-103 (B)
C-115 (B)
C-103 (B)
C-115 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
6 5 4 3 2 1 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Connector: C-103

C-103 (B) Q: Is the diagnosis code set?
<R.H. drive vehicles> ECU is replaced, write the chassis number
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 the vehicle equipped with the DPF carries
117 116 out the forcible DPF regeneration. (Refer to
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Harness side connector Particulate Filter (DPF) System − Forcible

AKA00090 AB
DPF Regeneration ).
• Check output line for damage. NO : Intermittent malfunction (Refer to GROUP
Q: Is the check result normal? 00 − How to Use Troubleshooting/
YES : Replace the accelerator pedal position Inspection Service Points − How to Cope
sensor. with Intermittent Malfunctions ).
DIESEL FUEL
TROUBLESHOOTING
13A-367
Code No. P2146: Injector Common 1 (cylinder No. 1 and No. 4) Circuit Open <Euro5>
OPERATION YES : Go to Step 2 .

• Refer to Code No. P0201: No. 1 Injector Circuit NO : Repair or replace the connector.
Malfunction P.13A-158.
• Refer to Code No. P0204: No. 4 Injector Circuit STEP 2. Check Injector itself
Malfunction P.13A-158. <Euro5> • Check No. 1 injector and No. 4 injector itself
FUNCTION
• The engine-ECU monitors peak current from the Q: Is the check result normal?
No. 1 and No. 4 injector drive circuits. YES : Go to Step 3 .
NO : Replace the injector. After replacing the
TROUBLE JUDGMENT Injector, register the injector identification
Check Conditions code and learn fuel injection (Refer to
• Ignition switch is in "ON" position. GROUP 00 − Precautions Before Service −
• Except during the engine cranking period What The Common Rail Engine Learns ).
• Battery positive voltage is 8 V or more.
Judgment Criterion
connector
• When the peak current is not detected in injector
circuits No. 1 and No. 4 Connector: C-105
PROBABLE CAUSES
• Open/short circuit in No. 1 and No. 4 injector cir-
cuit or loose connector contact
DIAGNOSIS PROCEDURE
WARNING
the engine-ECU and the injectors while the
engine is running. Handle them carefully to
age.
C-105 (B)
STEP 1. Connector check: A-42 No. 1 injector 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
connector and A-129 No. 4 injector connector 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
Connectors: A-42, A-129 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

A-42 (GR)
A-129 (GR)
1 2
Harness side

13A-368 DIESEL FUEL
TROUBLESHOOTING
No. 1) engine-ECU connector and A-42 (terminal No. 25) engine-ECU connector and A-129
No. 2) No. 1 injector connector. (terminal No. 2) No. 4 injector connector.
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-42 (GR) A-129 (GR)
1 2 1 2
connector AKA00186 AB connector AKA00189AB
• Check power supply line for open/short circuit. • Check power supply line for open/short circuit.

No. 1) No. 1 injector connector.
DIESEL FUEL
TROUBLESHOOTING
13A-369
Connector: C-105 STEP 7. Check harness between C-105 (terminal
<L.H. drive vehicles> No. 27) engine-ECU connector and A-129
(terminal No. 1) No. 4 injector connector.
Connector: C-105
C-105 (B)

C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
Connector: A-42 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-42 (GR) Connector: A-129
1 2
A-129 (GR)
Harness side
• Check earthing line for open/short circuit. 1 2

connector
YES : Go to Step 7 . AKA00189AB
NO : Repair the damaged harness wire. • Check earthing line for open circuit.

13A-370 DIESEL FUEL
TROUBLESHOOTING

Code No. P2146: Injector Common 1 (cylinder No. 1 and No. 4) Circuit Open <Except Euro5>
OPERATION DIAGNOSIS PROCEDURE

• Driving power is supplied from the engine-ECU
WARNING
(terminal No. 1) to the No. 1 injector terminal (ter-
minal No. 2) and No. 4 injector (terminal No. 2).
FUNCTION engine is running. Handle them carefully to
• The engine-ECU monitors peak current from the avoid receiving electric shocks from the volt-
No. 1 and No. 4 injector drive circuits. age.
TROUBLE JUDGMENT
Check Conditions connector and A-129 No. 4 injector connector
• Except during the engine cranking period Connectors: A-42, A-129
Judgment Criterion A-42 (GR)
circuits No. 1 and No. 4
A-129 (GR)
PROBABLE CAUSES 1 2
Harness side
• Failed No. 4 injector connector AKA00190 AB
• Open/short circuit in No. 1 and No. 4 injector cir-
cuit or loose connector contact Q: Are the check results normal?
STEP 2. Check Injector itself

• Check No. 1 injector and No. 4 injector itself
DIESEL FUEL
TROUBLESHOOTING
13A-371
Injector, register the injector identification
code and learn fuel injection (Refer to
GROUP 00 − Precautions Before Service − Connector: C-105
What The Common Rail Engine Learns ).

connector
Connector: C-105
C-105 (B)
C-105 (B)

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
Connector: A-42
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector A-42 (GR)

AKA00089 AB

YES : Go to Step 4 . 1 2
NO : Repair or replace the connector. Harness side

13A-372 DIESEL FUEL
TROUBLESHOOTING
No. 2) No. 4 injector connector. No. 1) No. 1 injector connector.
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-129 (GR) A-42 (GR)
1 2 1 2
connector AKA00189AB connector AKA00186 AB
• Check power supply line for open/short circuit. • Check earthing line for open/short circuit.
DIESEL FUEL
TROUBLESHOOTING
13A-373
Connector: C-105
<L.H. drive vehicles> • After erasing the diagnosis code through M.U.T.-
C-105 (B) (Refer to GROUP 00 − Precautions Before
<R.H. drive vehicles> register the injector identification code and
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-129
A-129 (GR)
1 2
Harness side

Code No. P2147: Injector Common 1 (Cylinder No. 1 and No. 4) Circuit Earth Short <Euro5>
OPERATION FUNCTION
• Refer to Code No. P0201: No. 1 Injector Circuit • The engine-ECU monitors voltage application to
Malfunction P.13A-158. the injector during no injector energization to
• Refer to Code No. P0204: No. 4 Injector Circuit detect errors in the No. 1 and No. 4 injector drive
Malfunction P.13A-173. <Euro5> circuit.
TROUBLE JUDGMENT
Check Conditions
13A-374 DIESEL FUEL
TROUBLESHOOTING
• Except during the engine cranking period YES : Go to Step 2 .

• Battery positive voltage is 8 V or more. NO : Repair or replace the connector.
• When an engine-ECU internal capacitor is
allowed to be charged STEP 2. Connector check: C-105 engine-ECU
Judgment Criterion connector.
• Short-circuit to the ground is detected in the injec- Connector: C-105
tor drive circuit. <L.H. drive vehicles>
PROBABLE CAUSES
• Short circuit in injector circuit or loose connector
contact
C-105 (B)
DIAGNOSIS PROCEDURE <R.H. drive vehicles>
WARNING
age. C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
STEP 1. Connector check: A-42 No. 1 injector 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
connector and A-129 No. 4 injector connector. 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49

96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connectors: A-42, A-129

A-129 (GR)
1 2
Harness side

DIESEL FUEL
TROUBLESHOOTING
13A-375
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-42 (GR) A-129 (GR)
1 2 1 2
• Check earthing line for short circuit. • Check earthing line for short circuit.
13A-376 DIESEL FUEL
TROUBLESHOOTING
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-42 (GR) A-129 (GR)
1 2 1 2
• Check power supply line for short circuit. • Check power supply line for short circuit.

NO : Replace the injector.
DIESEL FUEL
TROUBLESHOOTING
13A-377
nosis code is set.
Code No. P2147: Injector Common Circuit Earth Short <Except Euro5>

• The engine-ECU monitors voltage application to
WARNING
the injector during no injector energization to
detect errors in the injector drive circuit.
TROUBLE JUDGMENT engine is running. Handle them carefully to
Check Conditions
• Ignition switch is in "ON" position. age.
• Battery positive voltage is 8 V or more. STEP 1. Connector check: A-41, A-42, A-129 and
• When an engine-ECU internal capacitor is A-130 injector connectors
allowed to be charged
Connectors: A-41, A-42, A-129 and A-130
Judgment Criterion
• Short-circuit to earth is detected in the injector A-42 (GR)
drive circuit. A-41 (GR)
PROBABLE CAUSES A-130 (GR)

• Failed injector A-129 (GR)
• Short circuit in injector circuit or loose connector 1 2
contact Harness side
• Failed engine-ECU connector AKA00192 AB

YES : Go to Step 2.

• Check injector itself (Refer to P.13A-595).
13A-378 DIESEL FUEL
TROUBLESHOOTING
YES : Go to Step 3.

connector
Connector: C-105
C-105 (B)
C-105 (B)

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
Connector: A-42
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

AKA00089 AB

YES : Go to Step 4. 1 2
• Check earthing line for short circuit.

YES : Go to Step 5.
DIESEL FUEL
TROUBLESHOOTING
13A-379
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-41 (GR)
A-130 (GR)
1 2 1 2
13A-380 DIESEL FUEL
TROUBLESHOOTING
(terminal No. 1) No. 4 injector connector. No. 2) No. 1 injector connector.
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-129 (GR) A-42 (GR)
1 2 1 2
• Check earthing line for short circuit. • Check power supply line for short circuit.
DIESEL FUEL
TROUBLESHOOTING
13A-381
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-41 (GR)
A-130 (GR)
1 2 1 2
13A-382 DIESEL FUEL
TROUBLESHOOTING

Connector: C-105
nosis code is set.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-129
A-129 (GR)
1 2
Harness side

Code No. P2148: Injector Common 1 (Cylinder No. 1 and No. 4) Circuit Battery Short <Euro5>
OPERATION FUNCTION
Malfunction P.13A-158. the injector during no injector energization to
Malfunction P.13A-173. <Euro5> circuit.
TROUBLE JUDGMENT
Check Condition
DIESEL FUEL
TROUBLESHOOTING
13A-383
Judgment Criterion YES : Go to Step 2 .
• Short-circuit to the battery is detected in the injec- NO : Repair or replace the connector.
tor drive circuit.
PROBABLE CAUSES
connector.
contact Connector: C-105
DIAGNOSIS PROCEDURE
WARNING
C-105 (B)
engine is running. Handle them carefully to <R.H. drive vehicles>
age.

connector and A-129 No. 4 injector connector.
Connectors: A-42, A-129 C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
A-42 (GR)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

A-129 (GR)
1 2 Q: Is the check result normal?
Harness side YES : Go to Step 3 .
connector AKA00190 AB NO : Repair or replace the connector.

13A-384 DIESEL FUEL
TROUBLESHOOTING
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-42 (GR) A-129 (GR)
1 2 1 2
DIESEL FUEL
TROUBLESHOOTING
13A-385
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-42 (GR) A-129 (GR)
1 2 1 2

NO : Replace the injector.
13A-386 DIESEL FUEL
TROUBLESHOOTING

nosis code is set.
Code No. P2148: Injector Common Circuit Battry Short <Except Euro5>

• The engine-ECU monitors voltage application to
WARNING
detect errors in the injector drive circuit.
TROUBLE JUDGMENT engine is running. Handle them carefully to
Check Condition
• Ignition switch is in "ON" position. age.
Judgment Criterion
• Short-circuit to earth is detected in the injector STEP 1. Connector check: A-41, A-42, A-129 and
drive circuit. A-130 injector connectors
Connectors: A-41, A-42, A-129 and A-130
PROBABLE CAUSES
• Failed injector
A-42 (GR)
A-41 (GR)
contact
• Failed engine-ECU A-130 (GR)
A-129 (GR)
1 2
Harness side

YES : Go to Step 2.

DIESEL FUEL
TROUBLESHOOTING
13A-387
YES : Go to Step 3.

connector
Connector: C-105
C-105 (B)
C-105 (B)

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
Connector: A-42
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

AKA00089 AB

YES : Go to Step 4. 1 2

YES : Go to Step 5.
13A-388 DIESEL FUEL
TROUBLESHOOTING
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-41 (GR)
A-130 (GR)
1 2 1 2
DIESEL FUEL
TROUBLESHOOTING
13A-389
(terminal No. 1) No. 4 injector connector. No. 2) No. 1 injector connector.
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-129 (GR) A-42 (GR)
1 2 1 2
13A-390 DIESEL FUEL
TROUBLESHOOTING
No.25) engine-ECU connector and A-41 (terminal No. 25) engine-ECU connector and A-130
No. 2) No. 2 injector connector. (terminal No. 2) No. 3 injector connector
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-41 (GR)
A-130 (GR)
1 2 1 2
DIESEL FUEL
TROUBLESHOOTING
13A-391
Connector: C-105
nosis code is set.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-129
A-129 (GR)
1 2
Harness side

Code No. P2149: Injector Common 2 (cylinder No. 2 and No. 3) Circuit Open <Euro5>

• Refer to Code No. P0202: No. 2 Injector Circuit
Check Conditions
Malfunction P.13A-161. <Euro5>
FUNCTION • When an engine-ECU internal capacitor is
• The engine-ECU monitors peak current from the allowed to be charged
No. 2 and No. 3 injector drive circuits.
13A-392 DIESEL FUEL
TROUBLESHOOTING
Judgment Criterion STEP 2. Check Injector itself

• When the peak current is not detected in injector • Check No. 2 injector and No. 3 injector itself
circuits No. 2 and No. 3 (Refer to P.13A-595).
PROBABLE CAUSES Q: Is the check result normal?
• Failed No. 2 injector YES : Go to Step 3 .
• Failed No. 3 injector NO : Replace the injector. After replacing the
• Open/short circuit or harness damage in No. 2 Injector, register the injector identification
and No. 3 injector circuit or loose connector con- code and learn fuel injection (Refer to
tact GROUP 00 − Precautions Before Service −
• Failed engine-ECU What The Common Rail Engine Learns ).

WARNING connector
A high-tension voltage is flowing between Connector: C-105
the engine-ECU and the injectors while the <L.H. drive vehicles>
age.

C-105 (B)
connector and A-130 No. 3 injector connector
A-41 (GR)
A-130 (GR)
1 2
C-105 (B)
Harness side
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25

72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
NO : Repair or replace the connector. Harness side connector AKA00089 AB

DIESEL FUEL
TROUBLESHOOTING
13A-393
No. 2) No. 2 injector connector. No. 1) No. 2 injector connector.
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-41 (GR) A-41 (GR)
1 2 1 2
connector AKA00187AB connector AKA00187AB
• Check power supply line for open circuit and • Check earthing line for open/short circuit and
damage. damage.
13A-394 DIESEL FUEL
TROUBLESHOOTING
(terminal No. 2) No. 3 injector connector. (terminal No. 1) No. 3 injector connector.
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-130 (GR) A-130 (GR)
1 2 1 2
connector AKA00188 AB connector AKA00188 AB
• Check power supply line for open/short circuit • Check earthing line for open/short circuit and
and damage. damage.

DIESEL FUEL
TROUBLESHOOTING
13A-395
Code No. P2149: Injector Common 2 (cylinder No. 2 and No. 3) Circuit Open <Except Euro5>

Driving power is supplied from the engine-ECU (ter-
WARNING
minal No. 25) to the No. 2 injector (terminal No. 2)
and No. 3 injector (terminal No. 2).
FUNCTION engine is running. Handle them carefully to
• The engine-ECU monitors peak current from the avoid receiving electric shocks from the volt-
No. 2 and No. 3 injector drive circuits. age.
TROUBLE JUDGMENT
Check Conditions connector and A-130 No. 3 injector connector
• Except during the engine cranking period Connectors: A-41, A-130
• When an engine-ECU internal capacitor is
allowed to be charged A-41 (GR)
Judgment Criterion A-130 (GR)

circuits No. 2 and No. 3 1 2
Harness side
PROBABLE CAUSES connector AKA00191 AB
• Failed No. 3 injector Q: Are the check results normal?
• Open/short circuit or harness damage in No. 2 YES : Go to Step 2 .
and No. 3 injector circuit or loose connector con- NO : Repair or replace the connector.
tact
• Failed engine-ECU STEP 2. Check Injector itself
13A-396 DIESEL FUEL
TROUBLESHOOTING

connector
Connector: C-105
C-105 (B)
C-105 (B)

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
Connector: A-41
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector AKA00089 AB A-41 (GR)

YES : Go to Step 4 . 1 2
• Check power supply line for open circuit and

damage.
DIESEL FUEL
TROUBLESHOOTING
13A-397
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-41 (GR)
A-130 (GR)
1 2 1 2
• Check earthing line for open/short circuit and • Check power supply line for open/short circuit
damage. and damage.
13A-398 DIESEL FUEL
TROUBLESHOOTING
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-130
A-130 (GR)
1 2
Harness side

damage.
Code No. P2150: Injector Common 2 (Cylinder No. 2 and No. 3) Circuit Earth Short <Euro5>
OPERATION FUNCTION
Malfunction P.13A-161. <Euro5> the injector during no injector energization to
Malfunction P.13A-167. circuit.
TROUBLE JUDGMENT • Ignition switch is in "ON" position.

Check Conditions
DIESEL FUEL
TROUBLESHOOTING
13A-399
• When an engine-ECU internal capacitor is YES : Go to Step 2 .
allowed to be charged NO : Repair or replace the connector.
Judgment Criterion
• Short-circuit to the earth is detected in the injector STEP 2. Connector check: C-105 engine-ECU
drive circuit. connector.
Connector: C-105
PROBABLE CAUSES <L.H. drive vehicles>
contact
C-105 (B)
DIAGNOSIS PROCEDURE
WARNING
age.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

A-41 (GR)

1 2
Harness side

13A-400 DIESEL FUEL
TROUBLESHOOTING
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-41 (GR)
A-130 (GR)
1 2 1 2
DIESEL FUEL
TROUBLESHOOTING
13A-401
No. 2) No. 2 injector connector (terminal No. 2) No. 3 injector connector.
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-41 (GR)
A-130 (GR)
1 2 1 2

GROUP 00 − Precautions Before Service −
13A-402 DIESEL FUEL
TROUBLESHOOTING

nosis code is set.
Code No. P2151: Injector Common 2 (Cylinder No. 2 and No. 3) Circuit Battery Short <Euro5>

WARNING
Malfunction P.13A-167. <Euro5> the engine-ECU and the injectors while the
FUNCTION avoid receiving electric shocks from the volt-
• The engine-ECU monitors voltage application to age.
detect errors in the No. 2 and No. 3 injector drive
circuit.
TROUBLE JUDGMENT Connectors: A-41, A-130
Check Condition
A-41 (GR)
Judgment Criterion
• Short-circuit to the battery is detected in the injec- A-130 (GR)
tor drive circuit.
1 2
PROBABLE CAUSES
Harness side
• Short circuit in injector circuit or loose connector connector AKA00191 AB
contact
• Failed No. 2 injector Q: Are the check results normal?
• Failed No. 3 injector YES : Go to Step 2 .
• Failed engine-ECU NO : Repair or replace the connector.
DIESEL FUEL
TROUBLESHOOTING
13A-403
connector. No. 75) engine-ECU connector and A-41 (terminal
Connector: C-105
C-105 (B)
C-105 (B)

C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
YES : Go to Step 3 . Connector: A-41
A-41 (GR)
1 2
Harness side

13A-404 DIESEL FUEL
TROUBLESHOOTING
(terminal No. 1) No. 3 injector connector. No. 2) No. 2 injector connector
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-41 (GR)
A-130 (GR)
1 2 1 2
DIESEL FUEL
TROUBLESHOOTING
13A-405
Connector: C-105
<L.H. drive vehicles> • Check No. 2 injector and No. 3 injector itself
C-105 (B) code and learn fuel injection (Refer to
GROUP 00 − Precautions Before Service −

nosis code is set.
C-105 (B) YES : Replace the engine-ECU. When the engine-
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
Connector: A-130 Precautions Before Service − What The
A-130 (GR) Diesel Particulate Filter (DPF) System −
1 2 NO : Intermittent malfunction (Refer to GROUP
Harness side 00 − How to Use Troubleshooting/
connector AKA00188 AB Inspection Service Points − How to Cope
• Check power supply line for short circuit. with Intermittent Malfunctions ).
Code No. P2228: Barometric Pressure Sensor Circuit Low Input

• The barometric pressure sensor converts the bar-
Check Conditions
ometric pressure into a voltage signal and inputs
the signal to the engine-ECU.
• In response to the signal, the engine-ECU cor-
rects the fuel injection amount, etc.
Judgment Criterion
• The barometric pressure sensor output voltage is
1.60 V or less for 0.5 second.
13A-406 DIESEL FUEL
TROUBLESHOOTING
PROBABLE CAUSE YES : Intermittent malfunction (Refer to GROUP

• Failed barometric pressure sensor 00 − How to Use Troubleshooting/
DIAGNOSIS PROCEDURE with Intermittent Malfunctions ).
STEP 1. M.U.T.-III data list (Refer to GROUP 00 − Precautions Before
• Refer to Data List Reference Table P.13A-542. Service − How to Perform Chassis Number
a. Item 5: Barometric pressure sensor Writing ). After replacing the engine-ECU,
Q: Is the check result normal? register the injector identification code and
DPF Regeneration ).
Code No. P2229: Barometric Pressure Sensor Circuit High Input

• The barometric pressure sensor converts the bar-
ometric pressure into a voltage signal and inputs
the signal to the engine-ECU. STEP 1. M.U.T.-III data list
• In response to the signal, the engine-ECU cor- • Refer to Data List Reference Table P.13A-542.
rects the fuel injection amount, etc. a. Item 5: Barometric pressure sensor
TROUBLE JUDGMENT YES : Intermittent malfunction (Refer to GROUP
Check Conditions 00 − How to Use Troubleshooting/
• Battery positive voltage is 8 − 16 V Inspection Service Points − How to Cope
• 2 seconds later after the ignition switch has been with Intermittent Malfunctions .)
in "ON" position or the engine has started up NO : Replace the engine-ECU. When the engine-
Judgment Criterion (Refer to GROUP 00 − Precautions Before
• The barometric pressure sensor output voltage is Service − How to Perform Chassis Number
4.80 V or less for 0.5 second. Writing ). After replacing the engine-ECU,
PROBABLE CAUSE
• Failed barometric pressure sensor
DPF Regeneration ).
DIESEL FUEL
TROUBLESHOOTING
13A-407
Code No. P2413: EGR System Performance
OPERATION STEP 2. Check EGR valve itself

• System power is supplied from the engine-ECU • Check EGR valve itself [Refer to GROUP 17 −
(terminal No. 115) to the EGR valve (terminal No. Emission Control System − Exhaust Gas Recir-
6). culation (EGR) System − EGR valve check ].
• The engine-ECU (terminal No. 130) turns on the
power transistor to flow current to the EGR valve Q: Is the check result normal?
(terminal No. 4). YES : Go to Step 3 .
FUNCTION
• The engine-ECU performs duty control over the STEP 3. Connector check: C-105 engine-ECU
EGR valve (DC motor). connector
• The engine-ECU performs feedback control over
the EGR valve based on the signals from the Connector: C-105
EGR position sensor.
TROUBLE JUDGMENT
Check Condition
Judgment Criterion C-105 (B)
• The EGR valve in sticking state (a high duty state
continues for the predetermined time or more) is
repeatedly detected.
PROBABLE CAUSES
• Failed EGR valve
• Open/short circuit or harness damage in EGR
C-105 (B)
DIAGNOSIS PROCEDURE 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
STEP 1. M.U.T.-III diagnosis code 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49

96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Q: Is any other diagnosis code than P2413 output? Harness side connector AKA00089 AB
YES : Inspection chart for diagnosis codes (Refer
to P.13A-21). Q: Is the check result normal?
NO : Go to Step 2 . YES : Go to Step 4 .
13A-408 DIESEL FUEL
TROUBLESHOOTING
(terminal No. 6) EGR valve assembly connector. (terminal No. 4) EGR valve connector.
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-45 (GR) A-45 (GR)
3 2 1 3 2 1
6 5 4 6 5 4
age. age.

DIESEL FUEL
TROUBLESHOOTING
13A-409
DPF Regeneration ).
13A-410 DIESEL FUEL
TROUBLESHOOTING
Code No. P2454: Exhaust Differential Pressure Sensor Circuit Low Input <Euro5>
Exhaust Differential Pressure Sensor Circuit
A-148 Output signal

Exhaust differential
1 2 3 pressure sensor
Earth Power source
2 1 3
GR-B P-G B-O
C-105
80 56 94
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKB00280 AB

• A power voltage of 5 V is applied to the exhaust
Check Conditions
differential pressure sensor power terminal (ter-
minal No. 3) from the engine-ECU (terminal No.
94) and earthed to the engine-ECU (terminal No.
80) from exhaust differential pressure sensor (ter-
minal No. 2). Judgment Criterion
• The sensor signal is inputted to the engine-ECU • The exhaust differential pressure sensor output
(terminal No. 56) from the exhaust differential voltage is 0.49 V or less.
PROBABLE CAUSES
FUNCTION • Failed exhaust differential pressure sensor
• The exhaust differential pressure sensor outputs • Open/short circuit or harness damage in exhaust
the voltage to the engine-ECU in accordance with differential pressure sensor circuit or loose con-
the difference in the voltage between the DPF nector contact
upstream area and the DPF downstream area. • Failed engine-ECU
• The engine-ECU anticipates the amount of PM
accumulated in the DPF through this output volt-
age.
DIESEL FUEL
TROUBLESHOOTING
13A-411
DIAGNOSTIC PROCEDURE YES : Go to Step 9 .
NO : Go to Step 4 .

a. Item 120: exhaust differential pressure sensor
Connector: C-105
NO : Go to Step 2 .
C-105 (B)
STEP 2. Connector check: A-148 exhaust
differential pressure sensor connector
Connector: A-148
A-148 (B)
C-105 (B)
3 2 1
Harness side 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
connector AKB00281AB
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
exhaust differential pressure sensor connector. OK: 4.9 − 5.1 V
NO : Go to Step 5 .
A-148 (B)
3 2 1
Harness side

side.
OK: 4.9 − 5.1 V
13A-412 DIESEL FUEL
TROUBLESHOOTING
connector No. 3) exhaust differential pressure sensor
Connector: C-105
Connector: A-148
C-105 (B) A-148 (B)
3 2 1
Harness side
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


DIESEL FUEL
TROUBLESHOOTING
13A-413
connector
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-148
A-148 (B)
3 2 1
Harness side

(terminal No. 3) exhaust differential
circuit.
13A-414 DIESEL FUEL
TROUBLESHOOTING
connector No. 3) exhaust differential pressure sensor
Connector: C-105
Connector: A-148
C-105 (B) A-148 (B)
3 2 1
Harness side
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

DIESEL FUEL
TROUBLESHOOTING
13A-415
No. 1) exhaust differential pressure sensor
ECU connector. STEP 12. Replace the exhaust differential
pressure sensor
Connector: A-148
• After replacing the exhaust differential pressure
sensor, carry out the forcible DPF regeneration.
Particulate Filter (DPF) System − Forcible DPF
Regeneration ). After carrying out the forcible
A-148 (B) DPF regeneration, re-check the trouble symp-
toms.
3 2 1
connector AKB00281AB YES : Go to Step 7 .
NO : Check end.
Connector: C-105
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Check output line for open/short circuit and dam-

age.
13A-416 DIESEL FUEL
TROUBLESHOOTING
Code No. P2455: Exhaust Differential Pressure Sensor Circuit High Input <Euro5>
Exhaust Differential Pressure Sensor Circuit
A-148 Output signal

1 2 3 pressure sensor
Earth Power source
2 1 3
GR-B P-G B-O
C-105
80 56 94
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
Wire colour code

AKB00280 AB
OPERATION • The engine-ECU anticipates the amount of PM

• A power voltage of 5 V is applied to the exhaust accumulated in the DPF through this output volt-
differential pressure sensor power terminal (ter- age.
minal No. 3) from the engine-ECU (terminal No.
94) and earthed to the engine-ECU (terminal No. TROUBLE JUDGMENT
80) from the exhaust differential pressure sensor Check Conditions
(terminal No. 2). • Battery positive voltage is 8 − 16 V
• The sensor signal is inputted to the engine-ECU • 2 seconds later after the ignition switch has been
(terminal No. 56) from the exhaust differential in "ON" position or the engine has started up
Judgment Criterion
FUNCTION • The exhaust differential pressure sensor output
• The exhaust differential pressure sensor outputs voltage is 4.79 V or more.
the voltage to the engine-ECU in accordance with
the difference in the voltage between the DPF PROBABLE CAUSES
upstream area and the DPF down stream area. • Failed exhaust differential pressure sensor
• Open circuit in exhaust differential pressure sen-
sor circuit or loose connector contact
DIESEL FUEL
TROUBLESHOOTING
13A-417
DIAGNOSTIC PROCEDURE YES : Go to Step 7 .
NO : Go to Step 4 .

connector
Connector: C-105
NO : Go to Step 2 .
C-105 (B)
STEP 2. Connector check: A-148 exhaust
differential pressure sensor connector
Connector: A-148
A-148 (B)
C-105 (B)
3 2 1
Harness side 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 3. Perform resistance measurement at A- NO : Repair or replace the connector.
148 exhaust differential pressure sensor
connector.
Connector: A-148
A-148 (B)
3 2 1
Harness side

side.
13A-418 DIESEL FUEL
TROUBLESHOOTING
No. 2) exhaust differential pressure sensor
Connector: A-148
3 2 1 NO : Replace the engine-ECU. When the engine-
connector AKB00281AB (Refer to GROUP 00 − Precautions Before
STEP 7. Replace the exhaust differential

pressure sensor
• After replacing the exhaust differential pressure
sensor, Carry out the forcible DPF regeneration.
C-105 (B) Particulate Filter (DPF) System − Forcible DPF
Regeneration ). After carrying out the forcible
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 DPF regeneration, re-check the trouble symp-
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
toms.
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector AKA00089 AB YES : Go to Step 6 .
• Check earthing line for open circuit and damage. NO : Check end.
Code No. P252F: Engine Oil Level Malfunction <Euro5>

• The engine oil level may ascend if the fuel runs
Check Condition
into the engine oil on the DPF regeneration.
• The engine-ECU monitors the engine driving con-
ditions to estimate the ascend of engine oil level. Judgement Criterion
• The estimated increased amount of the engine oil
exceeds the 1,000 cc.
PROBABLE CAUSE • The engine oil is increased.

DIESEL FUEL
TROUBLESHOOTING
13A-419
DIAGNOSIS PROCEDURE YES : Replace the engine-ECU. When the engine-
STEP 1. Replace the engine oil. Service − How to Perform Chassis Number
• Replace the engine oil, When the engine oil is Writing ). After replacing the engine-ECU,
replaced, initialise the learning value (Refer to register the injector identification code and
GROUP 00 − Precautions before Service − Initial- learn fuel injection (Refer to GROUP 00 −
isation Procedure for Learning Value in Diesel Precautions Before Service − What The
Particulate Filter (DPF) System ). After initialising Common Rail Engine Learns ). After
the learning value, reconfirm diagnosis code. registering the injector identification code,
Q: Is the diagnosis code set? carry out the forcible DPF regeneration.
NO : Check end.
Code No. U1073: Bus Off
CAUTION STEP 2. M.U.T.-III diagnosis code

If diagnosis code U1073 is output from engine- • Reconfirm whether the diagnosis codes are out-
ECU surely perform CAN busline diagnosis. put from engine-ECU.
CAUTION 1. Erase the diagnosis codes being output.
Replace ECU after certainly confirming that the 2. Ignition switch: "LOCK" (OFF) to ON
communication circuits are normal. 3. Confirm whether the diagnosis codes are output.
TROUBLE JUDGMENT Q: Are the diagnosis codes output?
Check Condition YES : Replace the engine-ECU. When the
• All the time engine-ECU is replaced, write the chassis
number (Refer to GROUP 00 − Precautions
Judgment Criterion Before Service − How to Perform Chassis
• When the buss off error is detected. Number Writing ). After replacing the
COMMENT ON TROUBLE SYMPTOM engine-ECU, register the injector
• The failure is possibly caused by malfunction of identification code and learn fuel injection
the harness and connector in CAN busline or by (Refer to GROUP 00 − Precautions Before
malfunction in engine-ECU. Service − What The Common Rail Engine
Learns ). After registering the injector
PROBABLE CAUSE identification code, the vehicle equipped
• Failed engine-ECU with the DPF carries out the forcible DPF
regeneration. (Refer to GROUP 17 −
DIAGNOSIS PROCEDURE Emission Control − Diesel Particulate Filter
(DPF) System − Forcible DPF Regeneration
STEP 1. M.U.T.-III CAN bus diagnostics ). and then go to Step 3 .
• Using M.U.T.-III, perform CAN busline diagnosis.
Q: Is the check result normal? Inspection Service Points − How to Cope
YES : Go to Step 2 . with Intermittent Malfunctions ).
NO : Correct CAN busline (Refer to GROUP 54C
− Troubleshooting − Can Bus Diagnostics
Table ), and then go to Step 3 .
13A-420 DIESEL FUEL
TROUBLESHOOTING
• Reconfirm whether the diagnosis codes are out-
put from engine-ECU.
1. Erase the diagnosis codes being output.
2. Ignition switch: "LOCK" (OFF) to ON
3. Confirm whether the diagnosis codes are output.
Q: Are the diagnosis codes output?
Code No. U1101: A/T-ECU Time-out <A/T>
CAUTION NOTE: In case of Past trouble, M.U.T.-III CAN bus

If Diagnosis Code U1101 is output from engine- diagnosis cannot detect the failure even if there is
ECU surely perform CAN busline diagnosis. malfunction in CAN bus, so that check CAN
busline in the same way as Intermittent malfunc-
CAUTION tion (Refer to GROUP 00 − How to Use Trouble-
Replace ECU after certainly confirming that the shooting/Inspection Service Points − How to
communication circuits are normal. Cope with Intermittent Malfunctions ). The diag-
NOTE: When the diagnosis codes relating to the nosis codes being output to each ECU with CAN
CAN communication error are output, make sure of communication can narrow down the most sus-
the vehicle equipment. When the vehicle is not pected area (Refer to GROUP 54C − Trouble-
equipped with the system the engine-ECU communi- shooting − Can Bus Diagnostics Table ).
cates to, the diagnosis code is always output. This is
not abnormal. PROBABLE CAUSES
TROUBLE JUDGMENT • Failed of the harness and the connector
• Failed A/T-ECU
Check Conditions • Failed engine-ECU
• The diagnosis code setting enabled signal is
received from ETACS-ECU. DIAGNOSIS PROCEDURE
Judgment Criterion
• The signals cannot be received from A/T-ECU for STEP 1. M.U.T.-III CAN bus diagnosis
0.5 second or more. • Using M.U.T.-III, perform CAN busline diagnosis.
COMMENT ON TROUBLE SYMPTOM Q: Is the check result normal?
Current malfunction
NO : Correct CAN busline (Refer to GROUP 54C
• The failure is possibly caused by malfunction of
− Troubleshooting − CAN Bus Diagnostics
the harness and connector in CAN busline
between engine-ECU and A/T-ECU, by malfunc-
tion in the power supply system of A/T-ECU, in
combination meter itself, in engine-ECU. STEP 2. M.U.T.-III other system diagnosis codes.
Past malfunction
from A/T-ECU.
• Focus on diagnosing malfunction of the harness
and connector in CAN busline between engine- Q: Is the diagnosis code output?
ECU and A/T-ECU as well as malfunction in the YES : Perform the troubleshooting of A/T-ECU
power supply system of A/T-ECU. Refer to past (Refer to GROUP 23A − Check Chart for
trouble (Refer to GROUP 00 − How to Use Trou- Diagnosis Code ).
bleshooting/Inspection Service Points − How to NO : Go to Step 3 .
Treat Past Trouble ) for the diagnosis procedure.
DIESEL FUEL
TROUBLESHOOTING
13A-421
STEP 3. M.U.T.-III other system diagnosis codes.
• Confirm whether Diagnosis Code U1101: A/T-
ECU time out is output from the following ECU
having CAN communication with automatic trans-
mission.
a. ETACS-ECU
Q: Is the diagnosis code output? Precautions Before Service − What The
NO : Go to Step 5 . registering the injector identification code,
STEP 4. Reconfirmation of diagnosis codes out the forcible DPF regeneration. (Refer to
• Reconfirm whether the diagnosis codes are out- GROUP 17 − Emission Control − Diesel
put from engine-ECU Particulate Filter (DPF) System − Forcible
1. Erase the diagnosis codes being output. DPF Regeneration ). and then go to Step 6
.
NO : Intermittent malfunction in CAN busline
3. Confirm whether the diagnosis codes are output. between engine-ECU and A/T-ECU (Refer
Q: Is the diagnosis code output? to GROUP 00 − How to Use
YES : After replacing the A/T-ECU, go to Step 6 . Troubleshooting/Inspection Service Points −
NO : Intermittent malfunction in CAN busline How to Cope with Intermittent Malfunctions
between engine-ECU and A/T-ECU (Refer ).
to GROUP 00 − How to Use
Troubleshooting/Inspection Service Points −
STEP 6. Reconfirmation of diagnosis codes
How to Cope with Intermittent Malfunctions
).
put from engine-ECU
STEP 5. Reconfirmation of diagnosis codes 2. Ignition switch: "LOCK" (OFF) to ON
• Reconfirm whether the diagnosis codes are out- 3. Confirm whether the diagnosis codes are output.
put from engine-ECU
1. Erase the diagnosis codes being output. Q: Is the diagnosis code output?
Code No. U1102 ASTC-ECU Time-out <Except vehicles for Morocco>
CAUTION TROUBLE JUDGMENT

If Diagnosis Code U1102 is output from engine- Check Condition
ECU surely perform CAN busline diagnosis. • The diagnosis code setting enabled signal is
CAUTION received from ETACS-ECU.
Replace ECU after certainly confirming that the Judgment Criterion
communication circuits are normal. • The signals cannot be received from ASTC-ECU
NOTE: When the diagnosis codes relating to the for 65 second or more.
CAN communication error are output, make sure of
the vehicle equipment. When the vehicle is not
equipped with the system the engine-ECU communi-
cates to, the diagnosis code is always output. This is
not abnormal.
13A-422 DIESEL FUEL
TROUBLESHOOTING
COMMENT ON TROUBLE SYMPTOM STEP 2. M.U.T.-III other system diagnosis codes

Current malfunction • Confirm whether the diagnosis codes are output
• The failure is possibly caused by malfunction of from ASTC-ECU.
the harness and connector in CAN busline Q: Is the diagnosis code output?
between engine-ECU and ASTC-ECU, by mal- YES : Perform the troubleshooting of anti-skid
function in the power supply system of ASTC- braking system (Refer to GROUP 35B −
ECU, in ASTC-ECU itself, in engine-ECU. Troubleshooting − Check Chart for
Past malfunction Diagnosis Code ).
• Focus on diagnosing malfunction of the harness NO : Go to Step 3 .
and connector in CAN busline between engine-
ECU and ASTC-ECU as well as malfunction in STEP 3. M.U.T.-III diagnosis code
the power supply system of ASTC-ECU (Refer to • Reconfirm whether the diagnosis codes are out-
GROUP 00 − How to Use Troubleshooting/ put from engine-ECU
Inspection Service Points − How to Cope with 1. Erase the diagnosis codes being output.
Intermittent Malfunctions ). 2. Ignition switch: "LOCK" (OFF) to ON
NOTE: In case of Past trouble, M.U.T.-III CAN bus 3. Confirm whether the diagnosis codes are out-
diagnosis cannot detect the failure even if there is put.
malfunction in CAN bus, so that check CAN
busline in the same way as Intermittent malfunc- Q: Is the diagnosis code output?
tion (Refer to GROUP 00 − How to Use Trouble- YES : Go to Step 4 .
shooting/Inspection Service Points − How to
between engine-ECU and ASTC-ECU
Cope with Intermittent Malfunctions ). The diag-
(Refer to GROUP 00 − How to Use
nosis codes being output to each ECU with CAN
communication can narrow down the most sus-
How to Cope with Intermittent Malfunction ).
pected area. (Refer to GROUP 54C − Explana-
tion About The M.U.T.-III Can Bus Diagnostics ).
STEP 4. Replace the ASTC-ECU
PROBABLE CAUSE • After replacing the ASTC-ECU, re-check the
• Failed of the harness and the connector diagnosis code output.
• Failed ASTC-ECU Q: Is the diagnosis code output?
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-III CAN bus diagnostics Writing ). After replacing the engine-ECU,
• Using M.U.T.-III, perform CAN busline diagnosis. register the injector identification code and
NO : Correct CAN busline (Refer to GROUP 54C Common Rail Engine Learns ). After
− Diagnosis − Can Bus Diagnostic Chart ), registering the injector identification code,
and then go to Step 4 . the vehicle equipped with the DPF carries
DPF Regeneration ).
DIESEL FUEL
TROUBLESHOOTING
13A-423
Code No. U1109: ETACS-ECU Time-out
CAUTION PROBABLE CAUSES

If Diagnosis Code U1109 is output from engine- • Failed of the harness and the connector
ECU surely perform CAN busline diagnosis. • Failed ETACS-ECU
CAUTION
Replace ECU after certainly confirming that the DIAGNOSIS PROCEDURE
communication circuits are normal.
NOTE: When the diagnosis codes relating to the
CAN communication error are output, make sure of STEP 1. M.U.T.-III CAN bus diagnosis
the vehicle equipment. When the vehicle is not • Using M.U.T.-III, perform CAN busline diagnosis.
equipped with the system the engine-ECU communi- Q: Is the check result normal?
cates to, the diagnosis code is always output. This is YES : Go to Step 2 .
not abnormal. NO : Correct CAN busline (Refer to GROUP 54C
TROUBLE JUDGMENT − Troubleshooting − CAN Bus Diagnosis
Check Condition
• The diagnosis code setting enabled signal is
received from ETACS-ECU. STEP 2. M.U.T.-III other system diagnosis codes.
Judgment Criterion
from ETACS-ECU.
• The signals cannot be received from ETACS-
ECU for 0.5 second or more. Q: Is the diagnosis code output?
YES : Perform the troubleshooting of ETACS-ECU
COMMENT ON TROUBLE SYMPTOM (Refer to GROUP 54B − Diagnostic Code
Chart )
Current malfunction
NO : Go to Step 3 . <A/T>
• The failure is possibly caused by malfunction of
NO : Go to Step 5 . <M/T>
the harness and connector in CAN busline
between engine-ECU and ETACS-ECU by mal-
function in the power supply system of ETACS- STEP 3. M.U.T.-III other system diagnosis codes.
ECU, in ETACS-ECU itself, in engine-ECU. • Confirm whether Diagnosis Code U1109:
ETACS-ECU time out is output from the following
Past malfunction ECU having CAN communication with automatic
• Focus on diagnosing malfunction of the harness transmission.
a. A/T-ECU
ECU and ETACS-ECU as well as malfunction in
the power supply system of ETACS-ECU. Refer Q: Is the diagnosis code output?
to past trouble (Refer to GROUP 00 − How to YES : Go to Step 4 .
Use Troubleshooting/Inspection Service Points − NO : Go to Step 5 .
How to Treat Past Trouble ) for the diagnosis pro-
cedure. STEP 4. Reconfirmation of diagnosis codes
NOTE: In case of Past trouble, M.U.T.-III CAN bus • Reconfirm whether the diagnosis codes are out-
diagnosis cannot detect the failure even if there is put from engine-ECU
malfunction in CAN bus, so that check CAN 1. Erase the diagnosis codes being output.
busline in the same way as Intermittent malfunc- 2. Ignition switch: "LOCK" (OFF) to ON
tion (Refer to GROUP 00 − How to Use Trouble- 3. Confirm whether the diagnosis codes are output.
shooting/Inspection Service Points − How to
Cope with Intermittent Malfunctions ). The diag- Q: Is the diagnosis code output?
nosis codes being output to each ECU with CAN
communication can narrow down the most sus-
pected area (Refer to GROUP 54C − Can Bus
Diagnosis Table ).
13A-424 DIESEL FUEL
TROUBLESHOOTING
YES : After replacing the ETACS-ECU, go to Step YES : Replace the engine-ECU. When the engine-
6. ECU is replaced, write the chassis number
NO : Intermittent malfunction in CAN busline (Refer to GROUP 00 − Precautions Before
between engine-ECU and ETACS-ECU Service − How to Perform Chassis Number
(Refer to GROUP 00 − How to Use Writing ). After replacing the engine-ECU,
Troubleshooting/Inspection Service Points − register the injector identification code and
How to Cope with Intermittent Malfunctions learn fuel injection (Refer to GROUP 00 −
). Precautions Before Service − What The
STEP 5. Reconfirmation of diagnosis codes registering the injector identification code,
• Reconfirm whether the diagnosis codes are out- the vehicle equipped with the DPF carries
put from engine-ECU out the forcible DPF regeneration. (Refer to
2. Ignition switch: "LOCK" (OFF) to ON DPF Regeneration ). and then go to Step 6
3. Confirm whether the diagnosis codes are output. .
Q: Is the diagnosis code output? NO : Intermittent malfunction in CAN busline
between engine-ECU and ETACS-ECU
(Refer to GROUP 00 − How to Use
How to Cope with Intermittent Malfunctions
).

put from engine-ECU
Code No. U1110: A/C-ECU Time-out <Euro5>
CAUTION TROUBLE JUDGMENT

If Diagnosis Code U1110 is output from engine- Check Conditions
ECU surely perform CAN busline diagnosis. • Ignition switch is in "ON" position.
CAUTION Judgment Criterion
Replace ECU after certainly confirming that the • The signals cannot be received from A/C-ECU for
communication circuits are normal. 0.5 second or more.
NOTE: When the diagnosis codes relating to the
CAN communication error are output, make sure of COMMENT ON TROUBLE SYMPTOM
the vehicle equipment. When the vehicle is not Current malfunction
equipped with the system the engine-ECU communi- • The failure is possibly caused by malfunction of
cates to, the diagnosis code is always output. This is the harness and connector in CAN busline
not abnormal. between engine-ECU and A/C-ECU, by malfunc-
tion in the power supply system of A/C-ECU, in A/
C-ECU itself, in engine-ECU.
DIESEL FUEL
TROUBLESHOOTING
13A-425
Past malfunction YES : Go to Step 4 .
• Focus on diagnosing malfunction of the harness NO : Go to Step 5 .
ECU and A/C-ECU as well as malfunction in the STEP 4. Reconfirmation of diagnosis codes
power supply system of A/C-ECU. Refer to past • Reconfirm whether the diagnosis codes are out-
trouble (Refer to GROUP 00 − How to Use Trou- put from engine-ECU
bleshooting/Inspection Service Points − How to 1. Erase the diagnosis codes being output.
Treat Past Trouble ) for the diagnosis procedure.
NOTE: In case of Past trouble, M.U.T.-III CAN bus 3. Confirm whether the diagnosis codes are output.
diagnosis cannot detect the failure even if there is
malfunction in CAN bus, so that check CAN Q: Is the diagnosis code output?
busline in the same way as Intermittent malfunc- YES : After replacing the A/C-ECU, go to Step 6 .
tion (Refer to GROUP 00 − How to Use Trouble- NO : Intermittent malfunction in CAN busline
shooting/Inspection Service Points − How to between engine-ECU and A/C-ECU (Refer
Cope with Intermittent Malfunctions ). The diag- to GROUP 00 − How to Use
nosis codes being output to each ECU with CAN Troubleshooting/Inspection Service Points −
communication can narrow down the most sus- How to Cope with Intermittent Malfunctions
pected area (Refer to GROUP 54C − Trouble- ).
shooting − Can Bus Diagnostics Table ).
PROBABLE CAUSES • Reconfirm whether the diagnosis codes are out-
• Failed of the harness and the connector put from engine-ECU
• Failed A/C-ECU
DIAGNOSIS PROCEDURE 3. Confirm whether the diagnosis codes are output.
STEP 1. M.U.T.-III CAN bus diagnosis
Q: Is the check result normal? Service − How to Perform Chassis Number
YES : Go to Step 2 . Writing ). After replacing the engine-ECU,
NO : Correct CAN busline (Refer to GROUP 54C register the injector identification code and
− Troubleshooting − CAN Bus Diagnostics learn fuel injection (Refer to GROUP 00 −
Table ), and then go to Step 6 . Precautions Before Service − What The
STEP 2. M.U.T.-III other system diagnosis codes. registering the injector identification code,
• Confirm whether the diagnosis codes are output carry out the forcible DPF regeneration.
from A/C-ECU. (Refer to GROUP 17 − Emission Control −
Q: Is the diagnosis code output? Forcible DPF Regeneration ). and then go
YES : Perform the troubleshooting of A/C-ECU to Step 6 .
(Refer to GROUP 55B − Troubleshooting − NO : Intermittent malfunction in CAN busline
Diagnostics Chart ). between engine-ECU and A/C-ECU (Refer
NO : Go to Step 3 . to GROUP 00 − How to Use
STEP 3. M.U.T.-III other system diagnosis codes. How to Cope with Intermittent Malfunctions
• Confirm whether Diagnosis Code U1110: A/C- ).
ECU time out is output from the following ECU
having CAN communication with automatic trans-
mission.
a. ETACS-ECU
13A-426 DIESEL FUEL
TROUBLESHOOTING
put from engine-ECU
Code No. U1117 ETACS-ECU (Immobilizer-ECU) Time-out
CAUTION CAUTION
If Diagnosis Code U1117 is output from engine-
ECU surely perform CAN busline diagnosis. Acc position
On position
CAUTION
Range
Replace ECU after certainly confirming that the Lock (off) "A"
communication circuits are normal. position
NOTE: When the diagnosis codes relating to the Start
CAN communication error are output, make sure of position
the vehicle equipment. When the vehicle is not
equipped with the system the engine-ECU communi-
cates to, the diagnosis code is always output. This is AK503593 AB
not abnormal. When the ignition key is maintained within the

TROUBLE JUDGMENT range "A" (i.e., the ignition switch IG2 is in OFF
position but the cranking does not start) for more
Check Condition
than 1 second, engine-ECU stores diagnosis
code U1117 (the past trouble).
Judgment Criterion NOTE: In case of Past trouble, M.U.T.-III CAN bus
• The signal from the ETACS-ECU is not received diagnosis cannot detect the failure even if there is
for 0.5 second or more. malfunction in CAN bus, so that check CAN busline
in the same way as Intermittent malfunction (Refer to
COMMENT ON TROUBLE SYMPTOM
GROUP 00 − How to Use Troubleshooting/Inspec-
Current malfunction tion Service Points − How to Cope with Intermittent
• The failure is possibly caused by malfunction of Malfunctions ). The diagnosis codes being output to
the harness and connector in CAN busline each ECU with CAN communication can narrow
between engine-ECU and ETACS-ECU, by mal- down the most suspected area. (Refer to GROUP
function in the power supply system of ETACS- 54C − Explanation About The M.U.T.-III Can Bus
ECU, in ETACS-ECU itself, in engine-ECU. Diagnostics ).
Past malfunction PROBABLE CAUSE
• Focus on diagnosing malfunction of the harness • Failed of the harness and the connector
and connector in CAN busline between engine- • Failed engine-ECU
ECU and ETACS-ECU as well as malfunction in • Failed ETACS-ECU
the power supply system of ETACS-ECU (Refer
to GROUP 00 − How to Use Troubleshooting/
DIAGNOSIS PROCEDURE
Inspection Service Points − How to Cope with
Intermittent Malfunctions ).
STEP 1. M.U.T.-III CAN bus diagnostics
DIESEL FUEL
TROUBLESHOOTING
13A-427
YES : Go to Step 2 . YES : Replace the engine-ECU. When the engine-
NO : Correct CAN busline (Refer to GROUP 54C ECU is replaced, write the chassis number
− Diagnosis − Can Bus Diagnostic Chart ), (Refer to GROUP 00 − Precautions Before
and then go to Step 3 . Service − How to Perform Chassis Number
STEP 2. M.U.T.-III other system diagnosis codes
from ETACS-ECU.
Q: Is the diagnosis code output? registering the injector identification code,
YES : Perform the troubleshooting of immobilizer the vehicle equipped with the DPF carries
system (Refer to GROUP 54A − Immobilizer out the forcible DPF regeneration. (Refer to
System − Check Chart for Diagnosis Code ). GROUP 17 − Emission Control − Diesel
NO : Go to Step 3 . Particulate Filter (DPF) System − Forcible
DPF Regeneration ).
STEP 3. M.U.T.-III diagnosis code NO : Intermittent malfunction in CAN busline
• Reconfirm whether the diagnosis codes are out- between engine-ECU and ETACS-ECU
put from engine-ECU (Refer to GROUP 00 − How to Use
1. Erase the diagnosis codes being output. Troubleshooting/Inspection Service Points −
How to Cope with Intermittent Malfunction ).
3. Confirm whether the diagnosis codes are out-
put.
Code No.U1190: The Network System Diagnosis Code Output Permitted Signal Can Not Be Received
TROUBLE JUDGMENT DIAGNOSIS PROCEDURE

Check Condition
• Ignition switch is in "ON" position STEP 1. M.U.T.-III CAN bus diagnostics
Judgment Criterion • Using M.U.T.-III perform the CAN buslines diag-
• The diagnosis enable signal from the ETACS- nosis.
ECU about the abnormal CAN is not received at Q: Is the check result normal?
all for 5 seconds or more after the ignition switch YES : Go to Step 2 .
is on. NO : Repair the CAN busline (Refer to GROUP
54C − Troubleshooting Can Bus
Diagnostics Table ), and then go to Step 3 .
• The ETACS-ECU sends the permitted / not per-
mitted signals for detecting the diagnosis code
(U-code) to each ECU connected with the CAN STEP 2. M.U.T.-III diagnosis code.
busline. When the engine-ECU cannot receive • Reconfirm whether the diagnosis codes are out-
the permitted / not permitted signals for detecting put from engine-ECU.
the diagnosis code (U-code) for 5seconds, the 1. Erase the diagnosis codes being output.
diagnosis code No. U1190 is stored. 2. Ignition switch: "LOCK" (OFF) to "ON".
PROBABLE CAUSES
• Failed ETACS-ECU Q: Are the diagnosis codes output?
• Failed CAN bus YES : Replace the ETACS-ECU, and then go to
• Failed engine-ECU Step 3 .
NO : Check end.
13A-428 DIESEL FUEL
TROUBLESHOOTING
NO : Check end.
put from engine-ECU.
2. Ignition switch: "LOCK" (OFF) to "ON".
Q: Are the diagnosis codes output?
INSPECTION CHART FOR TROUBLE SYMPTOMS

M1133004100754
Items Trouble symptom Inspection

procedure
No.
Communication Communication with engine-ECU is not possible 1
with M.U.T.-III
Engine warning The engine warning lamp does not illuminate right after the ignition switch 2
lamp is turned the "ON" position
The engine warning lamp remains illuminating and never goes out or is 3
blinking
Starting The starter is impossible to operate. 4
Starting impossible The starter is operative and cranks 5
(Starter operative but no initial the engine, but none of initial
combustion) combustion is in the cylinders and
the engine is not started.
Starting improper It is long cranking to start the engine. 6
(Long time to start)
Improper idling The proper idling speed is not satisfied. 7
Engine stalls The engine stalls when The engine stalls at the deceleration. 8
decelerating
Driving Poor acceleration The engine cannot obtain the 9
acceleration corresponding to the
degree of throttle opening although
the engine is smooth at the constant
speed.
A large amount of fuel Compared with before, the fuel 10
consumption consumption is dramatically
increased.
Knocking, Knocking Sharp sound like a hammer striking 11
Abnormal noise on the cylinder walls during the
driving can be heard and wrongly
affects the driving.
Abnormal noise Abnormal noise during the engine
operation. (It is presumed that this is
caused by malfunction over the wide
range.)
DIESEL FUEL
TROUBLESHOOTING
13A-429
Items Trouble symptom Inspection
procedure
No.
Exhaust gas White smoke Exhaust gases are extraordinarily 12
white.
Black smoke Exhaust gases are extraordinarily 13
black.
Charging Battery rundown The battery is soon rundown or the 14
performance charging ability of battery is small.
Cooling Overheating The temperature of engine cooling 15
performance water is extremely high.
PROBLEM SYMPTOMS TABLE

Inspection Trouble symptom Reference page
procedure
No.
1 Communication with engine-ECU is not possible P.13A-433
2 The engine warning lamp does not illuminate right after the ignition P.13A-438
switch is turned the "ON" position
3 The engine warning lamp remains illuminating and never goes out or P.13A-441
is blinking
4 The starter is impossible to operate <M/T> P.13A-445
The starter is impossible to operate <A/T> P.13A-453
5 Starting impossible (Starter operative but no initial combustion) P.13A-462
6 Improper starting (Long time to start) P.13A-464
7 Improper idling P.13A-466
8 The engine stalls when decelerating P.13A-468
9 Poor acceleration P.13A-471
10 A large amount of fuel consumption P.13A-473
11 Knocking, Abnormal noise P.13A-475
12 White smoke P.13A-477
13 Black smoke P.13A-479
14 Battery rundown <Euro5> P.13A-481
Battery rundown <Except Euro5> P.13A-486
15 Overheating P.13A-487
16 Engine-ECU power supply system P.13A-488
17 Engine-ECU battery back-up system P.13A-493
18 1st and 2nd rail switch system <M/T> P.13A-497
19 Back-up lamp switch system <M/T> P.13A-501
20 4LLC switch system <M/T-high power engine vehicle> P.13A-505
21 Condenser fan relay system <Vehicles with A/C condenser fan> P.13A-507
22 A/C switch system P.13A-509
13A-430 DIESEL FUEL
TROUBLESHOOTING
Inspection Trouble symptom Reference page

procedure
No.
23 A/C compressor relay system P.13A-512
24 Power steering fluid pressure switch system P.13A-514
25 Glow system <Except Euro5> P.13A-520
26 PTC heater relay system <Vehicles with PTC heater> P.13A-525
27 Blower switch system <Euro5> P.13A-528
28 Rear window defogger system <Euro5> P.13A-533
29 DPF lamp system <Euro5> P.13A-537
DIESEL FUEL
TROUBLESHOOTING
13A-431
CHECK CHART CLASSIFIED BY PROBLEM SYMPTOMS
M1133604700134
Communication with engine-ECU is not possible
The engine warning lamp does not illuminate right after the
goes out or is blinking
The engine warning lamp remains illuminating and never
The starter is impossible to operate
Starting impossible (Starter operative but no initial combustion)
Starting impossible (Long time to start)
Improper idling
The engine stalls when decelerating
Poor acceleration
A large amount of fuel consumption
Knocking, Abnormal noise
White smoke
Black smoke
Battery rundown
Overheating
ignition switch is turned the "ON" position
Trouble symptoms
Probable causes
Diagnosis connector circuit

Engine warning lamp
Engine warning lamp circuit
Starter motor
Starter motor relay
Starting system related circuit
Battery
Inhibitor switch
Engine control relay
Engine-ECU power supply circuit
Engine-ECU
Glow system
Timing chain torn
Valve clearance
Compression pressure
Common rail assembly
Suction control valve
Supply pump
Supply pump correction learning
Fuel filter clogged
Fuel line leaking or clogged
Mixing of air with fuel
Improper fuel
Engine oil
Air cleaner clogged
Electronic-controlled throttle valve
EGR system
EGR port clogged
Turbocharger
Injector
Injector identification code registration
Small injection quantity learning
Crank angle sensor
Camshaft position sensor
Barometric pressure sensor
Engine coolant temperature sensor
Manifold absolute pressure sensor
Accelerator pedal position sensor
Throttle position sensor
Fuel pressure sensor
Engine cooling system
Alternator
AK503602
13A-432 DIESEL FUEL
TROUBLESHOOTING
SYMPTOM PROCEDURES
Inspection Procedure 1: Communication with Engine-ECU Is Not Possible

DIESEL FUEL
TROUBLESHOOTING
13A-433
CAN Communication Circuit
C-103
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
Engine-ECU
116 117
131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
Fusible link 20
108 109
R B W
9*¹ or 20*¹ or C-213

10*² 21*² 1
J/C (CAN 2) 12
C-01 J/B
15A
11 22 13
C-208
R B
C-53*¹ or
6 7 C-35*²
R B
W-B
11 22
J/C (CAN 1)
C-119
10 21
R-L B-L
C-22
MU803797 6 14 16
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
4 5
Diagnosis connector
B B
NOTE
Wire colour code
AKA00111AB

• The M.U.T.-III receives data from the engine-ECU • Damaged connector (Engine-ECU connector,
via the CAN bus line. diagnosis connector)
13A-434 DIESEL FUEL
TROUBLESHOOTING
• Damaged harness (Open or short circuit in the DIAGNOSIS PROCEDURE

engine-ECU power supply circuit, open circuit
between diagnosis connector and J/B connector,
and open circuit between diagnosis connector STEP 1. Check the V.C.I. indicator lamp
and earth) illuminates.
• Failed CAN bus line <L.H. drive vehicles>
• Failed M.U.T.-III
Diagnosis
connector
MB991910
MB991824
MB991827
<R.H. drive vehicles> Diagnosis
connector
MB991910
MB991824
MB991827 AK600277 AC
• Connect the M.U.T.-III to the diagnosis connector.

Q: Is the V.C.I. indicator lamp illuminates in a green
colour?
YES : CAN bus diagnosis (Refer to GROUP 54C −
Troubleshooting − Can Bus Diagnosis Table
).
NO : Go to Step 2 .
DIESEL FUEL
TROUBLESHOOTING
13A-435
STEP 2. Connector check: C-22 diagnosis STEP 3. Perform voltage measurement for open
connector circuit at C-22 diagnosis connector.
C-22 (B) C-22 (B)
C-22 (B) C-22 (B)
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
9 10111213 141516 9 10111213 141516
Harness side connector Harness side connector

AK700805 AB AK700805 AB

YES : Go to Step 3 . OK: System voltage
NO : Repair or replace. Q: Is the check result normal?
NO : Repair harness between C-22 (terminal No.
16) diagnosis connector and C-208
(terminal No. 13) J/B connector.
13A-436 DIESEL FUEL
TROUBLESHOOTING
YES : Refer to M.U.T.-III User’ s Manual −

STEP 4. Check for open circuit between
Troubleshooting Procedures.
diagnosis connector C-22 and earth.
NO : Repair harness between diagnosis
Connector: C-22 connector and body earth.
C-22 (B)
C-22 (B)
1 2 3 4 5 6 7 8
9 10111213 141516

AK700805 AB
• Disconnect connector.
• Check open circuit between terminal No. 4 and
earth also between terminal No. 5 and earth.
DIESEL FUEL
TROUBLESHOOTING
13A-437
Inspection Procedure 2: The Engine Warning Lamp Does Not Illuminate Right after the Ignition Switch
Is Turned the "ON" Position
Engine Warning Lamp (check engine lamp) Circuit
C-307
R LOCK
1 2 3 ST ACC Ignition switch
4 5 6 IG1 IG2
2
L-B
C-207
4
15
7.5A J/B
6
C-209
B-W
12
J/C (5)
C-132
15
B-W
C-112
C-112 36
31 32 33 34 35 36
37 38 39 40 41 42
Combination meter
C-111 Engine
MU801586 warning
lamp
51 52 53 54 55 56 57
58 59 60 61 62 63 64 63
C-111
R-W
C-53*¹ or
C-35*²
23
R-W
C-105 46
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
NOTE
Wire colour code
AKB00284 AB
13A-438 DIESEL FUEL
TROUBLESHOOTING
OPERATION STEP 3. Connector check: C-105 Engine-ECU

• Engine-ECU turn on engine warning lamp for 5 connector and C-111 combination meter
seconds to check for burnt-out bulb immediately connector.
after ignition switch is turned to ON.
Connector: C-105
• Damaged connector (Engine-ECU connector,
combination meter connector)
• Damaged harness (Open circuit between engine-
ECU and combination meter)
• Failed combination meter
DIAGNOSIS PROCEDURE
STEP 1. Check indicator illumination.

Q: Does an indicator other than the engine warning
lamp illuminate?
NO : Inspect combination meter and related
C-105 (B)
circuits (Refer to GROUP 54A −
Combination Meter − Check Chart for
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Trouble Symptoms ). 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
YES : Inspection chart for diagnosis code (Refer Connector: C-111
to P.13A-21). <L.H. drive vehicles>
NO : Go to Step 3 .
C-111
C-111
57 56 55 54 53 52 51
64 63 62 61 60 59 58

NO : Repair or replace.
DIESEL FUEL
TROUBLESHOOTING
13A-439
STEP 4. Perform resistance measurement for • Resistance between C-105 engine-ECU connec-
open circuit at between C-105 engine-ECU tor terminal No. 46 and C-111 combination con-
connector and C-111 combination meter nector terminal No. 63.
connector. OK: Continuity (2 Ω or less)
Connector: C-105 Q: Is the check result normal?
<L.H. drive vehicles> YES : Go to Step 5 .
NO : Check the intermediate connector C-53 <L.
H. drive vehicles>, C-35 <R. H. drive
vehicles>, and repair if necessary. If
intermediate connector is normal, repair the
harness wire.
C-105 (B)
STEP 5. Check the trouble symptoms.
<R.H. drive vehicles> Q: Does trouble symptom persist?
C-105 (B) learn fuel injection (Refer to GROUP 00 −
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector out the forcible DPF regeneration. (Refer to

AKA00089 AB
Connector: C-111 Particulate Filter (DPF) System − Forcible
<L.H. drive vehicles> DPF Regeneration ).
C-111 00 − How to Use Troubleshooting/
with Intermittent Malfunction ).
C-111
57 56 55 54 53 52 51
64 63 62 61 60 59 58
• Disconnect C-105 engine-ECU connector and C-

111 combination meter connector, and measure
resistance at the wiring harness.
13A-440 DIESEL FUEL
TROUBLESHOOTING
Inspection Procedure 3: The Engine Warning Lamp Remains Illuminating and Never Goes Out or Is
Blinking.
Engine Warning Lamp (check engine lamp) Circuit
C-307
R LOCK
1 2 3 ST ACC Ignition switch
4 5 6 IG1 IG2
2
L-B
C-207
4
15
7.5A J/B
6
C-209
B-W
12
J/C (5)
C-132
15
B-W
C-112
C-112 36
31 32 33 34 35 36
37 38 39 40 41 42
Combination meter
C-111 Engine
MU801586 warning
lamp
51 52 53 54 55 56 57
58 59 60 61 62 63 64 63
C-111
R-W
C-53*¹ or
C-35*²
23
R-W
C-105 46
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
NOTE
Wire colour code
AKB00284 AB
DIESEL FUEL
TROUBLESHOOTING
13A-441
OPERATION STEP 3. Connector check: C-105 engine-ECU
• Engine-ECU has detected failed sensor or failed connector and C-111 combination meter
actuator. Or failure is possibly caused by short connector
circuit or other faults.
Connector: C-105
combination meter connector)
• Damaged harness (Short circuit between engine-
ECU and combination meter)
DIAGNOSIS PROCEDURE
STEP 1. Check the illuminating condition of the

engine warning lamp.
Q: Is the engine warning lamp blinking?
YES : Carry out the small injection quantity
learning procedure (Refer to GROUP 00 −
C-105 (B)
Precautions Before Service − Small
Injection Quantity Learning Procedure ). 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
NO : Go to Step 2 . 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

YES : Inspection chart for diagnosis code (Refer Connector: C-111
to P.13A-21). <L.H. drive vehicles>
NO : Go to Step 3 .
C-111
C-111
57 56 55 54 53 52 51
64 63 62 61 60 59 58

13A-442 DIESEL FUEL
TROUBLESHOOTING
STEP 4. Check combination meter.
NO : Check combination meter (Refer to GROUP
Connector: C-111 54A − Combination Meter − Check Chart for
Trouble Symptoms ).
C-111
C-111
57 56 55 54 53 52 51
64 63 62 61 60 59 58
• Disconnect C-111 combination meter connector
Q: Does the engine warning lamp go out?
DIESEL FUEL
TROUBLESHOOTING
13A-443
STEP 5. Perform resistance measurement for OK: 1 kΩ or more
short circuit at C-105 engine-ECU connector. Q: Is the check result normal?
Connector: C-105
<L.H. drive vehicles> NO : Repair the harness wire.
STEP 6. Check injector identification code.

• Check injector identification code (Refer to
GROUP 00 − Precautions Before Service − Injec-
tor Identification code Registration Procedure ).
NO : Register the injector ID.
STEP 7. Small injection quantity learning.

• Carry out the small injection quantity learning
procedure (Refer to GROUP 00 − Precautions
Before Service − Small Injection Quantity Learn-
ing Procedure ).
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector AKA00089 AB Writing ). After replacing the engine-ECU,

Connector: C-111
C-111
DPF Regeneration ).
NO : The procedure is complete.
C-111
57 56 55 54 53 52 51
64 63 62 61 60 59 58

side.
• Disconnect C-111 combination meter connector.
13A-444 DIESEL FUEL
TROUBLESHOOTING
Inspection Procedure 4: Starting Impossible (No Initial Combustion) <M/T>
Starting Impossible (no initial combustion) <M/T>
Battery Fusible link 3 Ignition switch

C-307
LOCK
ACC
1 2 3
ST
IG1 IG2 4 5 6
R-B
C-207
2
4 J/B
7.5A
5
C-211
W
R-B
B-R A-115
11
A-115
10
B-Y
A-16X
4 2
1 2
3 OFF Starter
relay
4 ON
3 1
B
B-L
B-L
6
A-27 A-115
B-W 8
1 1 G-R C-103
OFF 111 103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
A-10 ON A-110
(MU801211) 116 117
1 131132133134135136137138139140 141142143
1 144 145 146147148149150151152153154155156 157158
Engine-ECU
Starter
Wire colour code

AKB00285 AB
DIESEL FUEL
TROUBLESHOOTING
13A-445
COMMENT ON TROUBLE SYMPTOM STEP 3. Connector check: A-16X starter relay
• Failure is possibly caused by failed starter itself connector
or failed related circuit.
Connector: A-16X
PROBABLE CAUSES
• Failed battery
• Failed starter motor
• Failed starter relay
• Open/short circuit in starter associated circuit or
A-16X
loose connector contact 2 1
• Failed engine-ECU 3
4
DIAGNOSIS PROCEDURE Relay box's side connector AK501014 AC

STEP 1. Check battery voltage. YES : Go to Step 4.
• Measure battery voltage at cranking. NO : Repair or replace.
OK: 8 V or higher
Q: Is the check result normal? STEP 4. Check starter relay.
YES : Go to Step 2. • Check starter relay (Refer to GROUP 16 − Start-
NO : Check battery (Refer to GROUP 54A − ing System − Starter Relay Check )
Battery − On-vehicle Service − Battery Test Q: Is the check result normal?
). YES : Go to Step 5.
NO : Replace the starter relay.
• Item 40: Starter switch STEP 5. Perform voltage measurement at A-16X
OK: starter relay connector.
ON (Ignition switch: ST)
Connector: A-16X
OFF (Ignition switch: ON)
NO : Go to Step 3.
A-16X
2 1
3
4
Relay box's side connector AK501014 AC
• Disconnect connector, and measure at the har-

ness side.
• Ignition switch: ST
OK: System voltage
YES : Go to Step 8.
NO : Go to Step 6.
13A-446 DIESEL FUEL
TROUBLESHOOTING
STEP 6. Connector check: C-307 ignition switch STEP 7. Check ignition switch.
connector
Connector: A-16X
Connector: C-307
A-16X
C-307 2 1
3
4
<R.H. drive vehicles> Connector: C-307

C-307
C-307
3 2 1 <R.H. drive vehicles>

6 5 4
Harness side connector AKB00286 AB

YES : Go to Step 7. C-307
3 2 1
6 5 4
• Check ignition switch (Refer to GROUP 54A −

Ignition Switch − Inspection ).
YES : Check intermediate connectors A-115, C-
207 and C-211, and repair if necessary. If
intermediate connectors are normal, check
and repair harness between A-16X (terminal
No. 2) starter relay connector and C-307
(terminal No. 5) ignition switch connector.
short circuit.
NO : Replace the ignition switch.
DIESEL FUEL
TROUBLESHOOTING
13A-447
STEP 8. Perform voltage measurement at A-16X STEP 10. Connector check: A-110 starter
starter relay connector. connector
Connector: A-16X Connector: A-110
A-110 (B)
A-16X
2 1
3
4 1
Relay box's side connector Harness side connector AK700920 AB
AK501014 AC
• Disconnect connector, and measure at the har- Q: Is the check result normal?
ness side. YES : Go to Step 11.
• Voltage between terminal No. 4 and earth. NO : Repair or replace.
OK: System voltage
Q: Is the check result normal? STEP 11. Check harness between A-110 (terminal
YES : Go to Step 9. No. 1) starter connector and A-16X (terminal No.
NO : Check and repair harness between A16X 3) starter relay connector.
(terminal No. 4) starter relay connector and
battery. Connector: A-110
• Check power supply line for open/ A-110 (B)
short circuit.

16X starter relay connector.
Connector: A-16X 1
Connector: A-16X
A-16X
2 1
3
4
Relay box's side connector AK501014 AC A-16X
2 1
• Disconnect connector, and measure at harness 3
side. 4
• Resistance between terminal No. 1 and earth. Relay box's side connector AK501014 AC
OK: Continuity (2Ω or less)
Q: Is the check result normal? connector A-27, and repair if necessary.
YES : Go to Step 10. • Check output line for open/short circuit.
NO : Check and repair harness between A16X
(terminal No. 1) starter relay connector and Q: Is the check result normal?
body earth.
• Check earth line for open circuit and
damage.
13A-448 DIESEL FUEL
TROUBLESHOOTING
STEP 12. Connector check: C-103 engine-ECU STEP 13. Connector check: A-110 starter
connector connector
Connector: C-103 Connector: A-110
A-110 (B)
C-103 (B) 1


C-103 (B) starter connector.
Connector: A-110
115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
130 129 128 127 126 125 124 123 122 121120 119 118
A-110 (B)
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Connector: A-16X
1

A-16X ness side.
2 1 • Ignition switch: ST
3
4
OK: System voltage
Q: Is the check result normal? YES : Go to Step 16.
YES : Check intermediate connector A-115, and NO : Go to Step 15.
harness between C-103 (terminal No. 111)
starter connector and A-16X (terminal No.
3) starter relay connector.
DIESEL FUEL
TROUBLESHOOTING
13A-449
STEP 15. Connector check: A-16X starter relay STEP 16. Connector check: A-10 starter
connector connector
A-10
A-16X
2 1
3
4 1
AK501014 AC

A-110 (B)

starter connector.
Connector: A-10
1
A-10

1
harness between A-16X (terminal No. 3)
stater relay connector and A-110 (terminal Harness side connector AK700921 AB
No. 1) starter connector. • Disconnect connector, and measure at the har-
• Check output line for open circuit and ness side.
damage. • Voltage between terminal No. 1 and earth.
OK: System voltage
(terminal No. 1) starter connector and
battery.
short circuit.
13A-450 DIESEL FUEL
TROUBLESHOOTING
STEP 18. Connector check: A-16X starter relay STEP 19. Check harness between C-307 (terminal
connector and C-307 Ignition switch connector No. 5) ignition switch connector and A-16X
(terminal No. 2) starter relay connector.
Connector: A-16X
Connector: C-307
A-16X
2 1 C-307
3
4

C-307
C-307
<R.H. drive vehicles> 3 2 1

6 5 4
Connector: A-16X
C-307
3 2 1 A-16X
2 1
6 5 4 3
4
YES : Go to Step 19. NOTE: Before checking harness, check intermediate
NO : Repair or replace. connectors A-115, C-207 and C-211, and repair if
necessary.
DIESEL FUEL
TROUBLESHOOTING
13A-451
STEP 20. Check harness between A-16X
battery
Connector: A-16X
No. 1) starter connector and battery.
Connector: A-110
A-110 (B)
A-16X
2 1
3
4
1
• Check power supply line for damage. Harness side connector AK700920 AB
NO : Repair the damaged harness wire. Q: Is the check result normal?
YES : Replace the starter.
(terminal No. 3) starter relay connector and A-110
(terminal No. 1) starter relay connector
Connector: A-16X
A-16X
2 1
3
4
Connector: A-110
A-110 (B)
1

13A-452 DIESEL FUEL
TROUBLESHOOTING
Inspection Procedure 4: Starting Impossible (No Initial Combustion) <A/T>
Starting Impossible (no initial combustion) <A/T>
Battery Fusible link 3 Ignition switch

C-307
LOCK
1 2 3
ST ACC 4 5 6
IG1 IG2
5
R-B
C-207
2
4
J/B
7.5A
C-211
5
R-B
A-115
11
W R-B
B-10
5
R-B
10 B-14
MU802645
B-R
Inhibitor P 1 2 3 4 5
switch
R 6 7 8 9 10
D N
9
B-Y
B-10
6
B-Y
A-115
10
A-16X B-Y
4 2
1 2
3 OFF Starter
ON
relay
4
3 1
B-L B
B-L
6 A-115
A-27 8
B-W
1 1 G-R C-103
111
103104105106107108109110 111112113 114115
A-110 101 102 118119120121122123124125126127128 129130
ON
A-10 OFF (MU801211) 116 117
1 1 131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
Engine-ECU
Starter
Wire colour code
R: Red P: Pink V: Violet PU: Purple AKB00287 AB
DIESEL FUEL
TROUBLESHOOTING
13A-453
COMMENT ON TROUBLE SYMPTOM STEP 4. Check starter relay
• Failure is possibly caused by failed starter itself • Check starter relay (Refer to GROUP 16 − Start-
or failed related circuit. ing System − Starter Relay Check ).
• Failed battery YES : Go to Step 5.
• Failed inhibitor switch NO : Replace the starter relay.
• Failed starter motor
• Failed starter relay STEP 5. Perform voltage measurement at A-16X
• Open/short circuit in starter associated circuit or starter relay connector.
• Failed engine-ECU Connector: A-16X
DIAGNOSIS PROCEDURE
STEP 1. Check battery voltage.

A-16X
• Measure battery voltage at cranking. 2 1
OK: 8 V or higher 3
4
Q: Is the check result normal? Relay box's side connector
YES : Go to Step 2. AK501014 AC
NO : Check battery (Refer to GROUP 54A − • Disconnect connector, and measure at the har-
Battery-On-vehicle Service − Battery Test ). ness side.
• Item 40: Starter switch OK: System voltage
OK: Q: Is the check result normal?
ON (Ignition switch: ST) YES : Go to Step 11.
OFF (Ignition switch: ON) NO : Go to Step 6.

YES : Go to Step 17. STEP 6. Connector check: B-14 inhibitor switch
NO : Go to Step 3. connector
Connector: B-14
5 4 3 2 1
STEP 3. Connector check: A-16X starter relay
10 9 8 7 6
connector
Harness side
Connector: A-16X connector
B-14 (B)
A-16X AK700823AB
2 1
3
4
YES : Go to Step 7.
Relay box's side connector AK501014 AC NO : Repair or replace.

YES : Go to Step 4. STEP 7. Check inhibitor switch
NO : Repair or replace. • Check inhibitor switch (Refer to GROUP 23A −
On-vehicle Service − Inhibitor Switch Continuity
Check ).
YES : Go to Step 8. NO : Replace the inhibitor switch.
13A-454 DIESEL FUEL
TROUBLESHOOTING
STEP 8. Perform voltage measurement at B-14 STEP 9. Connector check: C-307 ignition switch
inhibitor switch connector connector
Connector: B-14 Connector: C-307
5 4 3 2 1 <L.H. drive vehicles>
10 9 8 7 6
Harness side
connector
C-307
B-14 (B)
AK700823AB
Connector: A-16X
C-307
A-16X
2 1
3
4
Relay box's side connector AK501014 AC 3 2 1
• Disconnect connector, and measure at the har- 6 5 4
ness side. Harness side connector AKB00286 AB
OK: System voltage YES : Go to Step 10.
YES : Check intermediate connectors A-115 and
B-10, and repair if necessary. If starter relay
connector are normal, check and repair
starter relay connector and B-14 (terminal
No. 9) inhibitor switch connector.
short circuit.
NO : Go to Step 9.
DIESEL FUEL
TROUBLESHOOTING
13A-455
STEP 10. Check ignition switch STEP 11. Perform voltage measurement at A-16X
Connector: B-14
starter relay connector.
5 4 3 2 1
Connector: A-16X
10 9 8 7 6
Harness side
connector
A-16X
B-14 (B) 2 1
3
4
AK700823AB
Connector: C-307
<L.H. drive vehicles> • Disconnect connector, and measure at the har-
ness side.
OK: System voltage
C-307
NO : Check and repair harness between A-16X
battery.
<R.H. drive vehicles> • Check power supply line for open/
short circuit.

16X starter relay connector.
C-307
Connector: A-16X
3 2 1
6 5 4
A-16X
Harness side connector 2 1
AKB00286 AB
3
• Check ignition switch (Refer to GROUP 54A − 4
Ignition switch − Inspection ). Relay box's side connector AK501014 AC

YES : Check intermediate connectors A-115, B- side.
10, C-207 and C-211, and repair if • Resistance between terminal No. 1 and earth.
necessary. If starter relay connectors are
OK: Continuity (2Ω or less)
normal, check and repair harness between
B-14 (terminal No. 10) inhibitor switch Q: Is the check result normal?
connector and C-307 (terminal No. 5) YES : Go to Step 13.
ignition switch connector. NO : Check and repair harness between A-16X
• Check power supply line for open/ (terminal No. 1) starter relay connector and
short circuit. body earth.
NO : Replace the ignition switch. • Check earth line for open circuit and
damage.
13A-456 DIESEL FUEL
TROUBLESHOOTING
STEP 13. Connector check: A-16X starter relay STEP 15. Check harness between A-110 (terminal
connector No. 1) starter connector and A-16X (terminal No.
Connector: A-16X
Connector: A-110
A-110 (B)
A-16X
2 1
3
4
1
YES : Go to Step 14. Connector: A-16X
STEP 14. Connector check: A-110 starter

connector
A-16X
Connector: A-110 2 1
A-110 (B) 3
4

• Check output line for open/short circuit.
1
AK700920 AB YES : Go to Step 16.
DIESEL FUEL
TROUBLESHOOTING
13A-457
STEP 16. Connector check: C-103 engine-ECU STEP 17. Connector check: A-110 starter
connector. connector
Connector: C-105 Connector: A-110
A-110 (B)
C-105 (B)
1

C-105 (B) starter connector.
Connector: A-110
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 A-110 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-16X
1

A-16X ness side.
2 1 • Ignition switch: ST
3
4
OK: System voltage
YES : Check intermediate connector A-115, and NO : Go to Step 19.
starter connector and A-16X (terminal No.
13A-458 DIESEL FUEL
TROUBLESHOOTING
STEP 19. Connector check: A-16X starter relay STEP 20. Connector check: A-10 starter
connector connector
A-10
A-16X
2 1
3
4 1
AK501014 AC

A-110 (B)

starter connector.
Connector: A-10
1
A-10

1
starter relay connector and A-110 (terminal Harness side connector AK700921 AB
No. 1) starter connector. • Disconnect connector, and measure at the har-
• Check output line for open circuit and ness side.
damage. • Voltage between terminal No. 1 and earth.
OK: System voltage
(terminal No. 1) starter connector and
battery.
short circuit.
DIESEL FUEL
TROUBLESHOOTING
13A-459
STEP 22. Connector check: B-14 inhibitor switch STEP 23. Check harness between B-14 (terminal
connector and C-307 ignition switch connector No. 10) inhibitor switch connector and C-307
Connector: B-14
(terminal No. 5) ignition switch connector.
5 4 3 2 1 Connector: B-14
10 9 8 7 6 5 4 3 2 1
Harness side 10 9 8 7 6
connector Harness side
connector
B-14 (B)
B-14 (B)
AK700823AB
AK700823AB
Connector: C-307
C-307
C-307

C-307
C-307
3 2 1
6 5 4 3 2 1
Harness side connector 6 5 4
AKB00286 AB
YES : Go to Step 23. NOTE: Before checking harness, check starter relay
NO : Repair or replace. connectors A-115, C-207 and C-211, and repair if
necessary.
13A-460 DIESEL FUEL
TROUBLESHOOTING
STEP 24. Connector check: A-16X starter relay STEP 26. Check harness between A-16X
connector (terminal No. 3) starter relay connector and A-110
(terminal No. 1) starter connector
Connector: A-16X
Connector: A-16X
A-16X
2 1
A-16X
3 2 1
4 3
Relay box's side connector 4
AK501014 AC
YES : Go to Step 25. Connector: A-110
A-110 (B)

(terminal No. 2) starter relay connector and B-14
(terminal No. 9) inhibitor switch connector
Connector: A-16X
1
NOTE: Before checking harness, check starter relay

connectors A-27, and repair if necessary.
A-16X
2 1 • Check output line for damage.
3
4
Relay box's side connector AK501014 AC NO : Repair the damaged harness wire.
Connector: B-14
5 4 3 2 1 STEP 27. Check harness between A-10 (terminal
10 9 8 7 6 No. 1) starter connector and battery.
Harness side
connector Connector: A-10
A-10
B-14 (B)
AK700823AB
NOTE: Before checking harness, check starter relay 1

connectors A-115 and B-10, and repair if necessary. Harness side connector
• Check power supply line for damage. AK700921 AB

YES : Go to Step 26. Q: Is the check result normal?
NO : Repair the damaged harness wire. YES : Replace the starter.
DIESEL FUEL
TROUBLESHOOTING
13A-461
Inspection Procedure 5: Starting Impossible (Starter operative but no initial combustion)
PROBABLE CAUSES STEP 4. M.U.T.-III data list.

• Failed battery • Item 40: Starter switch
• Improper fuel used
• Fuel contaminated with foreign matter OK:
• Injector leaking or clogged ON (Ignition switch: ST)
• Failed injector OFF (Ignition switch: ON)
• Fuel injection learning failure Q: Is the check result normal?
• Fuel filter clogged YES : Go to Step 5 .
• Fuel line leaking or clogged NO : Check for starting impossible to operate
• Failed fuel pressure limiter valve (Refer to Inspection Procedure 4 P.13A-445
• Failed rail pressure sensor <M/T> or P.13A-453 <A/T>).
• Failed supply pump (suction control valve)
• Failed glow system STEP 5. Check timing belt for breakage.
• Timing belt broken
• Air cleaner clogged YES : Go to Step 6 .
NO : Replace the timing belt.
• Compression pressure low
DIAGNOSIS PROCEDURE STEP 6. Confirm the using fuel.

Q: Is the specified fuel being used?
STEP 1. Check battery voltage. YES : Go to Step 7 .
• Measure battery voltage at cranking. NO : Replace fuel.
OK: 8 V or more
STEP 7. Check glow system.
• Check glow system (Refer to Code No. P0381
NO : Check battery (Refer to GROUP 54A − P.13A-200 <Euro5> or Inspection Procedure 25
Battery − On-vehicle Service − Battery test P.13A-520 <Except Euro5>).
). Q: Is the check result normal?
STEP 2. M.U.T.-III diagnosis code. NO : Repair or replace the failed item.

YES : Inspection chart for diagnosis code (Refer STEP 8. Check fuel supply line.
to P.13A-21). • Check for fuel leakage and clogging
NO : Go to Step 3 . • Check fuel filter for clogging
STEP 3. Check injector identification code. YES : Go to Step 9 .
• Check injector identification code (Refer to NO : Repair or replace the failed item.
tor Identification code Registration Procedure ). STEP 9. Priming (air bleeding)
Q: Is the check result normal? • Bleed air
YES : Go to Step 4 . Q: Does trouble symptom persist?
NO : Register the injector ID. YES : Go to Step 10 .
13A-462 DIESEL FUEL
TROUBLESHOOTING
STEP 10. M.U.T.-III actuator test.
NO : Proceed to the diagnostic code procedure
• Refer to Actuator Test Reference Table P.13A-
for the sensor that does not output
574.
waveforms (Refer to Inspection Chart for
a. Item 19: Suction control valve Diagnosis Code P.13A-21).
STEP 15. Check compression pressure.
• Check compression pressure (Refer to GROUP
11A − On-vehicle Service − Compression Pres-
sure Check ).
Common Rail Engine Learns ). Q: Is the check result normal?
NO : Check and repair the engine itself.
STEP 11. Check suction control value itself.
• Check suction control value itself (Refer to
P.13A-596). STEP 16. Check injector itself.
NO : Replace the suction control valve. After YES : Go to Step 17 .
replacing the suction control valve, learn the NO : Replace the injector at the failed cylinder.
supply pump (Refer to GROUP 00 − After replacing the Injector, register the
Precautions Before Service − What The injector identification code and learn fuel
Common Rail Engine Learns ). injection (Refer to GROUP 00 − Precautions
Engine Learns ).
b. Item 64: Rail pressure target
a. Item 5: Barometric pressure sensor
Q: Are the check results normal? b. Item 7: Engine coolant temperature sensor
c. Item 8: EGR gas temperature sensor
<Euro5>
d. Item 8: Intake air temperature sensor No. 2
STEP 13. Replace the rail pressure sensor. <Except Euro5>
• Replace the common-rail assembly. e. Item 21: Fuel temperature sensor
Q: Does trouble symptom persist? f. Item 43: Intake air temperature sensor No. 1
STEP 14. Check the waveforms of crank angle procedure for the sensor that has shown an
sensor and camshaft position sensor. abnormal data value (Refer to Inspection
• Check the waveforms during cranking. Chart for Diagnosis Code P.13A-21).
Q: Are waveforms being output?
DIESEL FUEL
TROUBLESHOOTING
13A-463
DPF Regeneration ).
Inspection Procedure 6: Improper Starting (Long time to start)
PROBABLE CAUSES STEP 2. M.U.T.-III diagnosis code.

• Failed battery
• Improper fuel used Q: Is the diagnosis code set?
• Fuel contaminated with foreign matter YES : Inspection chart for diagnosis code (Refer
• Injector leaking or clogged to P.13A-21).
• Failed injector NO : Go to Step 3 .
• Fuel injection learning failure
• Fuel filter clogged STEP 3. M.U.T.-III data list.
• Fuel line leaking or clogged • Refer to Data List Reference Table (Refer to
• Failed fuel pressure limiter valve P.13A-542).
• Failed rail pressure sensor a. Item 5: Barometric pressure sensor
b. Item 7: Engine coolant temperature sensor
• Failed supply pump correction learning
c. Item 8: EGR gas temperature sensor
• Failed glow system
<Euro5>
• Failed EGR system operation
• Failed engine-ECU d. Item 8: Intake air temperature sensor No. 2
• Compression pressure low <Except Euro5>
e. Item 16: EGR valve position sensor
DIAGNOSIS PROCEDURE f. Item 17: EGR valve target position
g. Item 21: Fuel temperature sensor
h. Item 43: Intake air temperature sensor No. 1
• Measure battery voltage during cranking. Q: Are the check results normal?
OK: 8 V or more YES : Go to Step 4 .
Q: Is the check result normal? procedure for the sensor that has shown an
YES : Go to Step 2 . abnormal data value (Refer to Inspection
NO : Check battery (Refer to GROUP 54A − Chart for Diagnosis Code P.13A-21).
Battery − On-vehicle Service − Battery Test
).
13A-464 DIESEL FUEL
TROUBLESHOOTING
• Check injector identification code (Refer to
tor Identification code Registration Procedure ). STEP 11. M.U.T.-III actuator test.
574.
NO : Register the injector ID. a. Item 19: Suction control valve
STEP 5. Supply pump correction learning. YES : Go to Step 12 .
• Carry out the supply pump correction learning
(Refer to GROUP 00 − Precautions Before Serv- replacing the suction control valve, learn the
ice − Supply Pump Correction Learning ). supply pump (Refer to GROUP 00 −
Q: Does trouble symptom persist? Common Rail Engine Learns ).
STEP 6. Small injection quantity learning.
P.13A-596).
procedure (Refer to GROUP 00 − Precautions Q: Is the check result normal?
Before Service − Small Injection Quantity Learn- YES : Go to Step 13 .
ing Procedure ). NO : Replace the suction control valve. After
Q: Does trouble symptom persist? supply pump (Refer to GROUP 00 −
STEP 7. Confirm the using fuel.

Q: Is the specified fuel being used? • Refer to Data List Reference Table P.13A-542.
YES : Go to Step 8 . a. Item 63: Rail pressure sensor
NO : Replace fuel. b. Item 64: Rail pressure target
STEP 8. Check glow system. YES : Go to Step 15 .
• Check glow system (Refer to Code No. P0381 NO : Go to Step 14 .
P.13A-200 <Euro5> or Inspection Procedure 25
P.13A-520 <Except Euro5>).
STEP 14. Replace the rail pressure sensor.
Q: Is the check result normal? • Replace the common-rail assembly.
NO : Repair or replace the failed item.
STEP 9. Check fuel supply line.
• Check for fuel leakage and clogging.
STEP 15. Check the waveforms of crank angle
• Check fuel filter for clogging.
sensor and camshaft position sensor.
Q: Is the check result normal? • Check the output waveforms on an oscilloscope
YES : Go to Step 10 . (Refer to P.13A-586).
STEP 10. Priming (air bleeding) NO : Proceed to the inspection procedure by
• Bleed air. diagnosis code for the abnormal waveform
(Refer to Inspection Chart for Diagnosis
Code P.13A-21).
DIESEL FUEL
TROUBLESHOOTING
13A-465
STEP 16. Check compression pressure. STEP 18. Check the trouble symptoms.
• Check compression pressure (Refer to GROUP Q: Does trouble symptom persist?
11A − On-vehicle Service − Compression Pres- YES : Replace the engine-ECU. When the engine-
sure Check ). ECU is replaced, write the chassis number
Q: Is the check result normal? (Refer to GROUP 00 − Precautions Before
YES : Go to Step 17 . Service − How to Perform Chassis Number
NO : Check and repair the engine itself. Writing ). After replacing the engine-ECU,
STEP 17. Check injector itself. learn fuel injection (Refer to GROUP 00 −
• Check injector itself (Refer to P.13A-595). Precautions Before Service − What The
NO : Replace the injector at the failed cylinder. out the forcible DPF regeneration. (Refer to
After replacing the Injector, register the GROUP 17 − Emission Control − Diesel
injector identification code and learn fuel Particulate Filter (DPF) System − Forcible
injection (Refer to GROUP 00 − Precautions DPF Regeneration ).
Before Service − What The Common Rail NO : Intermittent malfunction (Refer to GROUP
Engine Learns ). 00 − How to Use Troubleshooting/
Inspection Procedure 7: Improper Idling
PROBABLE CAUSES STEP 2. Check injector identification code.

• Improper fuel used • Check injector identification code (Refer to
• Fuel contaminated with foreign matter GROUP 00 − Precautions Before Service − Injec-
• Injector leaking or clogged tor Identification code Registration Procedure ).
• Failed injector
• Fuel injection learning failure Q: Is the check result normal?
• Fuel filter clogged YES : Go to Step 3 .
• Fuel line leaking or clogged NO : Register the injector ID.
• Failed fuel pressure limiter valve
• Failed rail pressure sensor STEP 3. M.U.T.-III data list.
• Failed supply pump (suction control valve) • Refer to Data List Reference Table P.13A-542.
• Failed supply pump correction learning a. Item 16: EGR valve position sensor
• Failed EGR system operation b. Item 17: EGR valve target position
• Failed valve clearance adjustment
• Failed engine-ECU Q: Are the check results normal?
• Compression pressure low YES : Go to Step 4 .
DIAGNOSIS PROCEDURE procedure for the sensor that has shown an
Q: Is the diagnosis code set? STEP 4. Confirm the using fuel.
to P.13A-21).
NO : Go to Step 2 .
NO : Replace fuel.
13A-466 DIESEL FUEL
TROUBLESHOOTING
• Check the output waveforms on an oscilloscope
STEP 6. Priming (air bleeding)
• Bleed air.
NO : Proceed to the inspection procedure by
Q: Does trouble symptom persist? diagnosis code for the abnormal waveform
YES : Go to Step 7 . (Refer to Inspection Chart for Diagnosis
NO : The procedure is complete. Code P.13A-21).
STEP 7. M.U.T.-III actuator test. STEP 12. Check compression pressure.

• Refer to Actuator Test Reference Table P.13A- • Check compression pressure (Refer to GROUP
574. 11A On-vehicle Service − Compression Pressure
a. Item 19: Suction control valve Check ).
NO : Replace the suction control valve. After NO : Check and repair the engine itself.
STEP 13. Check valve clearance.
• Check valve clearance (Refer to GROUP 11A −
On-vehicle Service − Valve Clearance Check and
Adjustment ).
P.13A-596). NO : Adjust the valve clearance.
YES : Go to Step 9 . STEP 14. M.U.T.-III actuator test.
a. Item 15: Injector No. 1
Precautions Before Service − What The b. Item 16: Injector No. 2
Common Rail Engine Learns ). c. Item 17: Injector No. 3
d. Item 18: Injector No. 4
STEP 9. M.U.T.-III data list. Q: Are the check results normal?
NO : Replace the injector at the failed cylinder.
After replacing the Injector, register the
Q: Are the check results normal? injection (Refer to GROUP 00 − Precautions
YES : Go to Step 11 . Before Service − What The Common Rail
NO : Go to Step 10 . Engine Learns ).
STEP 10. Replace the rail pressure sensor. STEP 15. Check injector itself.
• Replace the common-rail assembly. • Check injector itself (Refer to P.13A-595).
Q: Does trouble symptom persist? Q: Is the check result normal?
DIESEL FUEL
TROUBLESHOOTING
13A-467
NO : Replace the injector at the failed cylinder. NO : Perform the diagnosis code classified check
After replacing the Injector, register the procedure for the sensor that has shown an
injector identification code and learn fuel abnormal data value (Refer to Inspection
injection (Refer to GROUP 00 − Precautions Chart for Diagnosis Code P.13A-21).
Engine Learns ). STEP 17. Check the trouble symptoms.
STEP 16. M.U.T.-III data list. YES : Replace the engine-ECU. When the engine-
• Refer to Data List Reference Table P.13A-542. ECU is replaced, write the chassis number
a. Item 5: Barometric pressure sensor (Refer to GROUP 00 − Precautions Before
b. Item 6: Manifold absolute pressure sensor Service − How to Perform Chassis Number
c. Item 7: Engine coolant temperature sensor Writing ). After replacing the engine-ECU,
d. Item 8: EGR gas temperature sensor register the injector identification code and
<Euro5> learn fuel injection (Refer to GROUP 00 −
e. Item 8: Intake air temperature sensor No. 2 Precautions Before Service − What The
<Except Euro5> Common Rail Engine Learns ). After
f. Item 9: Accelerator pedal position sensor registering the injector identification code,
g. Item 21: Fuel temperature sensor
h. Item 43: Intake air temperature sensor No. 1
i. Item 45: Throttle position sensor Particulate Filter (DPF) System − Forcible
Q: Are the check results normal? DPF Regeneration ).
Inspection Procedure 8: The Engine Stalls When Decelerating
PROBABLE CAUSES DIAGNOSIS PROCEDURE

• Fuel contaminated with foreign matter
• Injector leaking or clogged STEP 1. M.U.T.-III diagnosis code.
• Failed injector Q: Is the diagnosis code set?
• Fuel injection learning failure YES : Inspection chart for diagnosis code (Refer
• Fuel filter clogged to P.13A-21).
• Fuel line leaking or clogged NO : Go to Step 2 .
• Failed fuel pressure limiter valve
• Failed rail pressure sensor STEP 2. Check idling condition.
• Failed supply pump correction learning Q: Is the idling condition normal?
• Failed EGR system operation YES : Go to Step 3 .
NO : Proceed to troubleshooting for improper
• Failed engine-ECU idling (Refer to Inspection Procedure 7
• Compression pressure low P.13A-466).
• Air cleaner clogged
13A-468 DIESEL FUEL
TROUBLESHOOTING
STEP 3. M.U.T.-III data list. STEP 6. Small injection quantity learning.

• Refer to Data List Reference Table P.13A-542. • Carry out the small injection quantity learning
a. Item 5: Barometric pressure sensor procedure (Refer to GROUP 00 − Precautions
b. Item 6: Manifold absolute pressure sensor Before Service − Small Injection Quantity Learn-
c. Item 7: Engine coolant temperature sensor ing Procedure ).
d. Item 8: EGR gas temperature sensor Q: Does trouble symptom persist?
<Euro5> YES : Go to Step 7 .
e. Item 8: Intake air temperature sensor No. 2 NO : The procedure is complete.
<Except Euro5>
f. Item 9: Accelerator pedal position sensor STEP 7. Check air cleaner.
(main)
g. Item 10: Accelerator pedal position sensor YES : Go to Step 8 .
(sub) NO : Replace air cleaner.
h. Item 13: Accelerator pedal position sensor
(main) learned closed position
i. Item 16: EGR valve position sensor
j. Item 17: EGR valve target position Q: Is the specified fuel being used?
k. Item 21: Fuel temperature sensor
NO : Replace fuel.
l. Item 43: Intake air temperature sensor No. 1
m. Item 45: Throttle position sensor
n. Item 46: Throttle position sensor learned
closed position
Chart for Diagnosis Code P.13A-21). STEP 10. Priming (air bleeding)
• Bleed air.
STEP 4. Check injector identification code. Q: Does trouble symptom persist?
• Check injector identification code (Refer to YES : Go to Step 11 .
GROUP 00 − Precautions Before Service − Injec- NO : The procedure is complete.
Q: Is the check result normal? STEP 11. M.U.T.-III actuator test.
YES : Go to Step 5 . • Refer to Actuator Test Reference Table P.13A-
NO : Register the injector ID. 574.
a. Item 19: Suction control valve
STEP 5. Supply pump correction learning. Q: Is the check result normal?
• Carry out the supply pump correction learning YES : Go to Step 12 .
(Refer to GROUP 00 − Precautions Before Serv- NO : Replace the suction control valve. After
ice − Supply Pump Correction Learning ). replacing the suction control valve, learn the

P.13A-596).
DIESEL FUEL
TROUBLESHOOTING
13A-469
574.
Precautions Before Service − What The a. Item 15: Injector No. 1
Common Rail Engine Learns ). b. Item 16: Injector No. 2
c. Item 17: Injector No. 3
d. Item 18: Injector No. 4
• Refer to Data List Reference Table P.13A-542. Q: Are the check results normal?
a. Item 63: Rail pressure sensor YES : Go to Step 19 .
Q: Are the check results normal? injector identification code and learn fuel
YES : Go to Step 15 . injection (Refer to GROUP 00 − Precautions
NO : Go to Step 14 . Before Service − What The Common Rail
Engine Learns ).
• Replace the common-rail assembly. STEP 19. Check injector itself.
Q: Does trouble symptom persist? • Check injector itself (Refer to P.13A-595).
STEP 15. Check the waveforms of crank angle After replacing the Injector, register the
sensor and camshaft position sensor. injector identification code and learn fuel
• Check the output waveforms on an oscilloscope injection (Refer to GROUP 00 − Precautions
(Refer to P.13A-586). Before Service − What The Common Rail
Engine Learns ).
NO : Proceed to the inspection procedure by STEP 20. Check the trouble symptoms.
diagnosis code for the abnormal waveform
(Refer to Inspection Chart for Diagnosis YES : Replace the engine-ECU. When the engine-
Code P.13A-21). ECU is replaced, write the chassis number
STEP 16. Check compression pressure. Service − How to Perform Chassis Number
• Check compression pressure (Refer to GROUP Writing ). After replacing the engine-ECU,
11A − On-vehicle Service − Compression Pres- register the injector identification code and
sure Check ). learn fuel injection (Refer to GROUP 00 −
NO : Check and repair the engine itself. registering the injector identification code,
STEP 17. Check valve clearance. GROUP 17 − Emission Control − Diesel
• Check valve clearance (Refer to GROUP 11A − Particulate Filter (DPF) System − Forcible
On-vehicle Service − Valve Clearance Check and DPF Regeneration ).
Adjustment ). NO : Intermittent malfunction (Refer to GROUP
Q: Is the check result normal? 00 − How to Use Troubleshooting/
YES : Go to Step 18 . Inspection Service Points − How to Cope
NO : Adjust the valve clearance. with Intermittent Malfunction ).
13A-470 DIESEL FUEL
TROUBLESHOOTING
Inspection Procedure 9: Poor Acceleration
PROBABLE CAUSES STEP 4. M.U.T.-III data list.

• Failed boost pressure control system • Refer to Data List Reference Table P.13A-542.
• Failed turbocharger
a. Item 5: Barometric pressure sensor
• Fuel contaminated with foreign matter b. Item 6: Manifold absolute pressure sensor
• Injector leaking or clogged c. Item 7: Engine coolant temperature sensor
• Failed injector d. Item 8: EGR gas temperature sensor
• Fuel injection learning failure <Euro5>
• Fuel filter clogged e. Item 8: Intake air temperature sensor No. 2
• Fuel line leaking or clogged <Except Euro5>
• Failed fuel pressure limiter valve f. Item 9: Accelerator pedal position sensor
• Failed rail pressure sensor (main)
• Failed supply pump (suction control valve) g. Item 10: Accelerator pedal position sensor
• Failed supply pump correction learning (sub)
• Failed EGR system operation h. Item 13: Accelerator pedal position sensor
• Failed valve clearance adjustment (main) learned closed position
• Compression pressure low
j. Item 17: EGR valve target position
• Air cleaner clogged
DIAGNOSIS PROCEDURE l. Item 43: Intake air temperature sensor No. 1
closed position
to P.13A-21). NO : Perform the diagnosis code classified check
NO : Go to Step 2 .
STEP 2. Check idling condition. Chart for Diagnosis Code P.13A-21).
YES : Go to Step 3 . STEP 5. Supply pump correction learning.
NO : Proceed to troubleshooting for improper • Carry out the supply pump correction learning
idling (Refer to Inspection Procedure 7 (Refer to GROUP 00 − Precautions Before Serv-
P.13A-466). ice − Supply Pump Correction Learning ).
STEP 3. Check injector identification code. YES : Go to Step 6 .
• Check injector identification code (Refer to NO : The procedure is complete.
tor Identification code Registration Procedure ). STEP 6. Small injection quantity learning.
Q: Is the check result normal? • Carry out the small injection quantity learning
YES : Go to Step 4 . procedure (Refer to GROUP 00 − Precautions
NO : Register the injector ID. Before Service − Small Injection Quantity Learn-
ing Procedure ).

STEP 7. Check air cleaner.
DIESEL FUEL
TROUBLESHOOTING
13A-471
NO : Replace air cleaner. NO : Replace the suction control valve. After
STEP 8. Confirm the using fuel. supply pump (Refer to GROUP 00 −
Q: Is the specified fuel being used? Common Rail Engine Learns ).
NO : Replace fuel.
STEP 9. Checking the turbocharging pressure. a. Item 63: Rail pressure sensor
• Check the turbocharging pressure (Refer to
GROUP 15 − On-vehicle Service − Turbocharger
Supercharging Pressure Check ). Q: Are the check results normal?
• Replace the common-rail assembly.
• Check for fuel leakage and clogging. Q: Does trouble symptom persist?
• Check fuel filter for clogging. YES : Go to Step 20 .
NO : Repair or replace the failed item. STEP 16. Check the waveforms of crank angle
• Check the output waveforms on an oscilloscope
• Bleed air.
NO : Proceed to the inspection procedure by
(Refer to Inspection Chart for Diagnosis
STEP 12. M.U.T.-III actuator test. Code P.13A-21).
574.
a. Item 19: Suction control valve • Refer to Actuator Test Reference Table P.13A-
Q: Is the check result normal? 574.
YES : Go to Step 13 . a. Item 15: Injector No. 1
NO : Replace the suction control valve. After b. Item 16: Injector No. 2
c. Item 17: Injector No. 3
Precautions Before Service − What The d. Item 18: Injector No. 4
Common Rail Engine Learns ). Q: Are the check results normal?
P.13A-596). injection (Refer to GROUP 00 − Precautions
Q: Is the check result normal? Before Service − What The Common Rail
Engine Learns ).
13A-472 DIESEL FUEL
TROUBLESHOOTING
STEP 18. Check compression pressure. STEP 20. Check the trouble symptoms.
• Check compression pressure (Refer to GROUP Q: Does trouble symptom persist?
11A − On-vehicle Service − Compression Pres- YES : Replace the engine-ECU. When the engine-
sure Check ). ECU is replaced, write the chassis number
NO : Check and repair the engine itself. Writing ). After replacing the engine-ECU,
Inspection Procedure 10: A Large Amount of Fuel Consumption

• Injector leaking
• Failed injector STEP 1. M.U.T.-III diagnosis code.
• Fuel injection learning failure Q: Is the diagnosis code set?
• Fuel filter clogged YES : Inspection chart for diagnosis code (Refer
• Failed rail pressure sensor to P.13A-21).
• Failed supply pump (suction control valve) NO : Go to Step 2 .
• Failed EGR system operation STEP 2. Check whether other trouble symptoms
• Failed turbocharger are occurring.
• Failed thermostat
• Failed engine-ECU Q: Are other trouble symptoms occurring?
• Compression pressure low YES : Inspection Chart for Trouble Symptoms
• Air cleaner clogged (Refer to P.13A-429).
NO : Go to Step 3 .
DIESEL FUEL
TROUBLESHOOTING
13A-473
<Except Euro5>
f. Item 9: Accelerator pedal position sensor STEP 7. Check turbocharger itself.
(main)
(sub) NO : Replace the turbocharger.
STEP 8. Check the cooling system.
i. Item 16: EGR valve position sensor • Check how the engine coolant level rises.
j. Item 17: EGR valve target position
l. Item 43: Intake air temperature sensor No. 1 NO : Check the cooling system.
closed position
• Bleed air.
Chart for Diagnosis Code P.13A-21). STEP 10. M.U.T.-III actuator test.
574.
• Check injector identification code (Refer to a. Item 19: Suction control valve
GROUP 00 − Precautions Before Service − Injec- Q: Is the check result normal?
tor Identification code Registration Procedure ). YES : Go to Step 11 .
STEP 5. Supply pump correction learning.
• Carry out the supply pump correction learning
(Refer to GROUP 00 − Precautions Before Serv- STEP 11. Check suction control valve itself.
ice − Supply Pump Correction Learning ). • Check suction control value itself (Refer to
P.13A-596).
NO : The procedure is complete. YES : Go to Step 12 .
13A-474 DIESEL FUEL
TROUBLESHOOTING
a. Item 63: Rail pressure sensor injector identification code and learn fuel
b. Item 64: Rail pressure target injection (Refer to GROUP 00 − Precautions
Q: Are the check results normal? Before Service − What The Common Rail
YES : Go to Step 14 . Engine Learns ).
STEP 13. Replace the rail pressure sensor. Q: Does trouble symptom persist?
• Replace the common-rail assembly. YES : Replace the engine-ECU. When the engine-
Q: Does trouble symptom persist? ECU is replaced, write the chassis number
YES : Go to Step 16 . (Refer to GROUP 00 − Precautions Before
NO : The procedure is complete. Service − How to Perform Chassis Number
STEP 14. Check compression pressure. register the injector identification code and
• Check compression pressure (Refer to GROUP learn fuel injection (Refer to GROUP 00 −
11A − On-vehicle Service − Compression Pres- Precautions Before Service − What The
sure Check ). Common Rail Engine Learns ). After
Q: Is the check result normal? the vehicle equipped with the DPF carries
YES : Go to Step 15 . out the forcible DPF regeneration. (Refer to
NO : Check and repair the engine itself. GROUP 17 − Emission Control − Diesel
STEP 15. Check injector itself. DPF Regeneration ).
• Check injector itself (Refer to P.13A-595). NO : Intermittent malfunction (Refer to GROUP
Inspection Procedure 11: Knocking, Abnormal Noise

• Failed injector
• Fuel injection learning failure STEP 1. M.U.T.-III diagnosis code.
• Failed fuel pressure limiter valve Q: Is the diagnosis code set?
• Failed supply pump (suction control valve) YES : Inspection chart for diagnosis code (Refer
• Failed supply pump correction learning to P.13A-21).
• Failed EGR system operation NO : Go to Step 2 .
• Compression pressure low STEP 2. Check idling condition.
idling. (Refer to Inspection Procedure 7
P.13A-466).
DIESEL FUEL
TROUBLESHOOTING
13A-475
<Except Euro5>
f. Item 9: Accelerator pedal position sensor STEP 7. Priming (air bleeding)
(main) • Bleed air.
g. Item 10: Accelerator pedal position sensor Q: Does trouble symptom persist?
(sub) YES : Go to Step 8 .
h. Item 13: Accelerator pedal position sensor NO : The procedure is complete.
i. Item 16: EGR valve position sensor STEP 8. Check the waveforms of crank angle
j. Item 17: EGR valve target position sensor and camshaft position sensor.
k. Item 21: Fuel temperature sensor • Check the output waveforms on an oscilloscope
l. Item 43: Intake air temperature sensor No. 1 (Refer to P.13A-586).
m. Item 45: Throttle position sensor Q: Is the check result normal?
n. Item 46: Throttle position sensor learned YES : Go to Step 9 .
closed position NO : Proceed to the inspection procedure by
Q: Are the check results normal? diagnosis code for the abnormal waveform
YES : Go to Step 4 . (Refer to Inspection Chart for Diagnosis
NO : Perform the diagnosis code classified check Code P.13A-21).
abnormal data value (Refer to Inspection STEP 9. M.U.T.-III actuator test.
Chart for Diagnosis Code P.13A-21). • Refer to Actuator Test Reference Table P.13A-
574.
STEP 4. Check injector identification code. a. Item 15: Injector No. 1
• Check injector identification code (Refer to b. Item 16: Injector No. 2
GROUP 00 − Precautions Before Service − Injec- c. Item 17: Injector No. 3
tor Identification code Registration Procedure ). d. Item 18: Injector No. 4
Q: Is the check result normal? Q: Are the check results normal?
NO : Register the injector ID. NO : Replace the injector at the failed cylinder.
STEP 5. Supply pump correction learning. injector identification code and learn fuel
• Carry out the supply pump correction learning injection (Refer to GROUP 00 − Precautions
(Refer to GROUP 00 − Precautions Before Serv- Before Service − What The Common Rail
ice − Supply Pump Correction Learning ). Engine Learns ).
YES : Go to Step 6 . STEP 10. Check compression pressure.
NO : The procedure is complete. • Check compression pressure (Refer to GROUP
sure Check ).
NO : Check and repair the engine itself.
13A-476 DIESEL FUEL
TROUBLESHOOTING
STEP 11. Check valve clearance. STEP 13. Check the trouble symptoms.
• Check valve clearance (Refer to GROUP 11A − Q: Does trouble symptom persist?
On-vehicle Service − Valve Clearance Check and YES : Replace the engine-ECU. When the engine-
Adjustment ). ECU is replaced, write the chassis number
NO : Adjust the valve clearance. Writing ). After replacing the engine-ECU,
Inspection Procedure 12: White Smoke

• Injector leaking or clogged
• Failed injector STEP 1. M.U.T.-III diagnosis code.
• Fuel injection learning failure Q: Is the diagnosis code set?
• Fuel filter clogged YES : Inspection chart for diagnosis code (Refer
• Fuel line leaking or clogged to P.13A-21).
• Failed fuel pressure limiter valve NO : Go to Step 2 .
• Failed rail pressure sensor
• Failed supply pump (suction control valve) STEP 2. Check idling condition.
• Failed EGR system operation Q: Is the check result normal?
• Compression pressure low NO : Proceed to troubleshooting for improper
• Air cleaner clogged idling (Refer to Inspection Procedure 7
P.13A-466).
DIESEL FUEL
TROUBLESHOOTING
13A-477
<Except Euro5>
f. Item 9: Accelerator pedal position sensor STEP 7. Check air cleaner.
(main)
(sub) NO : Replace air cleaner.
j. Item 17: EGR valve target position Q: Is the specified fuel being used?
NO : Replace fuel.
l. Item 43: Intake air temperature sensor No. 1
closed position
Chart for Diagnosis Code P.13A-21). STEP 10. Priming (air bleeding)
• Bleed air.
STEP 4. Check injector identification code. Q: Does trouble symptom persist?
• Check injector identification code (Refer to YES : Go to Step 11 .
GROUP 00 − Precautions Before Service − Injec- NO : The procedure is complete.
Q: Is the check result normal? STEP 11. M.U.T.-III actuator test.
YES : Go to Step 5 . • Refer to Actuator Test Reference Table P.13A-
NO : Register the injector ID. 574.
a. Item 19: Suction control valve
STEP 5. Supply pump correction learning. Q: Is the check result normal?
• Carry out the supply pump correction learning YES : Go to Step 12 .
(Refer to GROUP 00 − Precautions Before Serv- NO : Replace the suction control valve. After
ice − Supply Pump Correction Learning ). replacing the suction control valve, learn the

P.13A-596).
13A-478 DIESEL FUEL
TROUBLESHOOTING

NO : Replace the suction control valve. After NO : Check and repair the engine itself.
supply pump (Refer to GROUP 00 − STEP 17. Check injector itself.
Precautions Before Service − What The • Check injector itself (Refer to P.13A-595).
STEP 13. M.U.T.-III data list. NO : Replace the injector at the failed cylinder.
• Refer to Data List Reference Table P.13A-542. After replacing the Injector, register the
a. Item 63: Rail pressure sensor injector identification code and learn fuel
b. Item 64: Rail pressure target injection (Refer to GROUP 00 − Precautions
Q: Are the check results normal? Before Service − What The Common Rail
YES : Go to Step 15 . Engine Learns ).
STEP 14. Replace the rail pressure sensor. Q: Does trouble symptom persist?
• Replace the common-rail assembly. YES : Replace the engine-ECU. When the engine-
Q: Does trouble symptom persist? ECU is replaced, write the chassis number
YES : Go to Step 18 . (Refer to GROUP 00 − Precautions Before
NO : The procedure is complete. Service − How to Perform Chassis Number
STEP 15. Check the waveforms of crank angle learn fuel injection (Refer to GROUP 00 −
sensor and camshaft position sensor. Precautions Before Service − What The
• Check the output waveforms on an oscilloscope Common Rail Engine Learns ). After
(Refer to P.13A-586). registering the injector identification code,
Q: Is the check result normal? the vehicle equipped with the DPF carries
YES : Go to Step 16 . out the forcible DPF regeneration. (Refer to
NO : Proceed to the inspection procedure by GROUP 17 − Emission Control − Diesel
diagnosis code for the abnormal waveform Particulate Filter (DPF) System − Forcible
(Refer to Inspection Chart for Diagnosis DPF Regeneration ).
Code P.13A-21). NO : Intermittent malfunction (Refer to GROUP
STEP 16. Check compression pressure. Inspection Service Points − How to Cope
• Check compression pressure (Refer to GROUP with Intermittent Malfunction ).
sure Check ).
Inspection Procedure 13: Black Smoke
PROBABLE CAUSES • Failed supply pump correction learning

• Improper fuel used • Failed EGR system operation
• Injector leaking or clogged • Failed glow system
• Failed injector • Failed engine-ECU
• Fuel injection learning failure • Compression pressure low
• Failed fuel pressure limiter valve • Failed turbocharger
• Failed rail pressure sensor • Improper engine oil volume or viscosity
DIESEL FUEL
TROUBLESHOOTING
13A-479

STEP 5. Supply pump correction learning.
Q: Is the diagnosis code set? • Carry out the supply pump correction learning
YES : Inspection chart for diagnosis code (Refer (Refer to GROUP 00 − Precautions Before Serv-
to P.13A-21). ice − Supply Pump Correction Learning ).
NO : Go to Step 2 .
STEP 2. Check idling condition. NO : The procedure is complete.
YES : Go to Step 3 . STEP 6. Small injection quantity learning.
idling (Refer to Inspection Procedure 7 procedure (Refer to GROUP 00 − Precautions
P.13A-466). Before Service − Small Injection Quantity Learn-
ing Procedure ).
STEP 3. M.U.T.-III data list. Q: Does trouble symptom persist?
a. Item 5: Barometric pressure sensor NO : The procedure is complete.
b. Item 6: Manifold absolute pressure sensor
c. Item 7: Engine coolant temperature sensor STEP 7. Confirm the using fuel.
d. Item 8: EGR gas temperature sensor
<Euro5>
e. Item 8: Intake air temperature sensor No. 2 NO : Replace fuel.
<Except Euro5>
f. Item 9: Accelerator pedal position sensor
STEP 8. Check engine oil.
(main)
g. Item 10: Accelerator pedal position sensor Q: Are the oil volume and viscosity normal?
(sub) YES : Go to Step 9 .
h. Item 13: Accelerator pedal position sensor NO : Replenish or change engine oil.
i. Item 16: EGR valve position sensor STEP 9. Check glow system.
j. Item 17: EGR valve target position • Check glow system (Refer to Code No. P0381
k. Item 21: Fuel temperature sensor P.13A-200 <Euro5> or Inspection Procedure 25
l. Item 43: Intake air temperature sensor No. 1 P.13A-520 <Except Euro5>).
m. Item 45: Throttle position sensor Q: Is the check result normal?
n. Item 46: Throttle position sensor learned YES : Go to Step 10 .
closed position NO : Repair or replace the failed item.

YES : Go to Step 4 . STEP 10. Check turbocharger itself.
procedure for the sensor that has shown an YES : Go to Step 11 .
abnormal data value (Refer to Inspection NO : Repair the turbocharger.

STEP 4. Check injector identification code. sensor and camshaft position sensor.
• Check injector identification code (Refer to • Check the output waveforms on an oscilloscope
GROUP 00 − Precautions Before Service − Injec- (Refer to P.13A-586).
13A-480 DIESEL FUEL
TROUBLESHOOTING

NO : Proceed to the inspection procedure by NO : The procedure is complete.
(Refer to Inspection Chart for Diagnosis STEP 16. Check compression pressure.
Code P.13A-21). • Check compression pressure (Refer to GROUP
STEP 12. M.U.T.-III actuator test. sure Check ).
• Refer to Actuator Test Reference Table P.13A- Q: Is the check result normal?
574. YES : Go to Step 17 .
a. Item 19: Suction control valve NO : Check and repair the engine itself.
YES : Go to Step 13 . STEP 17. Check injector itself.
NO : Replace the suction control valve. After • Check injector itself (Refer to P.13A-595).
supply pump (Refer to GROUP 00 − Q: Is the check result normal?
Precautions Before Service − What The YES : Go to Step 18 .
STEP 13. Check suction control valve itself. injection (Refer to GROUP 00 − Precautions
• Check suction control value itself (Refer to Before Service − What The Common Rail
P.13A-596). Engine Learns ).
YES : Go to Step 14 . STEP 18. Check the trouble symptoms.
STEP 14. M.U.T.-III data list. register the injector identification code and
• Refer to Data List Reference Table P.13A-542. learn fuel injection (Refer to GROUP 00 −
a. Item 63: Rail pressure sensor Precautions Before Service − What The
b. Item 64: Rail pressure target Common Rail Engine Learns ). After
STEP 15. Replace the rail pressure sensor. DPF Regeneration ).
• Replace the common-rail assembly. NO : Intermittent malfunction (Refer to GROUP
Q: Does trouble symptom persist? 00 − How to Use Troubleshooting/
Inspection Procedure 14: Battery rundown <Euro5>
COMMENT ON TROUBLE SYMPTOM PROBABLE CAUSES

• Failure is possibly caused by failed alternator, • Failed battery
failed generation control circuit or other faults. • Open/short circuit or harness damage in alterna-
tor L terminal circuit
• Short circuit in alternator G terminal
DIESEL FUEL
TROUBLESHOOTING
13A-481
• Failed alternator STEP 4. Perform voltage measurement at A-122
• Failed engine-ECU alternator connector.
DIAGNOSIS PROCEDURE Connector: A-122
STEP 1. Check battery.

• Check battery (Refer to GROUP 54A − Battery −
On-vehicle Service − Battery Test ).
Q: Is the check result normal? M
YES : Go to Step 2 . 4 3 2 1 A-122 (GR)
NO : Replace the battery. Harness side
STEP 2. M.U.T.-III diagnosis code. • Disconnect connector, and measure at harness

side.
to P.13A-21).
NO : Go to Step 3 . OK: System voltage
STEP 3. Connector check: A-122 alternator YES : Go to Step 7 .
connector NO : Go to Step 5 .
Connector: A-122
STEP 5. Connector check: C-111 combination
meter connector
Connector: C-111
C-111
M
4 3 2 1 A-122 (GR)
Harness side

C-111
57 56 55 54 53 52 51
64 63 62 61 60 59 58

13A-482 DIESEL FUEL
TROUBLESHOOTING
YES : Check the combination meter (Refer to

GROUP 54A − Combination Meter −
No. 3) alternator connector and C-111 (terminal
Trouble Symptom Chart ).
No. 52) combination meter connector.
Connector: A-122

connector
Connector: C-103
M
4 3 2 1 A-122 (GR)
Harness side
Connector: C-111
<L.H. drive vehicles> C-103 (B)
C-111 <R.H. drive vehicles>
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
145 144
C-111 158 157156 155 154 153 152 151 150 149 148 147 146

57 56 55 54 53 52 51
64 63 62 61 60 59 58

connectors A-27, C-14 <R.H. drive vehicles> and C-
54 <L.H. drive vehicles>, and repair if necessary.
DIESEL FUEL
TROUBLESHOOTING
13A-483
STEP 8. Perform voltage measurement at C-103 STEP 9. Check harness between C-103 (terminal
engine-ECU connector. No. 121) engine-ECU connector and A-122
Connector: C-103
(terminal No. 1) alternator connector.
C-103 (B)
C-103 (B)
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
• Disconnect connector, and measure at harness AKA00090 AB
side. Connector: A-122

OK: System voltage
NO : Go to Step 9 . M
4 3 2 1 A-122 (GR)
Harness side

connectors A-27 and A-115, and repair if necessary.
13A-484 DIESEL FUEL
TROUBLESHOOTING
STEP 10. Connector check: C-111 combination STEP 11. Check harness between A-122 (terminal
meter connector No. 3) alternator connector and C-111 (terminal
Connector: C-111 No. 52) combination meter connector.
Connector: A-122
C-111
M
4 3 2 1 A-122 (GR)
Harness side
<R.H. drive vehicles> connector AKB00292 AB
Connector: C-111
C-111
C-111
57 56 55 54 53 52 51
64 63 62 61 60 59 58
Harness side connector AK700806 AB <R.H. drive vehicles>

NO : Repair or replace the connector. C-111
57 56 55 54 53 52 51
64 63 62 61 60 59 58

connectors A-27, C-14 <R.H. drive vehicles> and C-
54 <L.H. drive vehicles>, and repair if necessary.
YES : Check the alternator.
DIESEL FUEL
TROUBLESHOOTING
13A-485
Connector: C-103 with Intermittent Malfunctions ).
<L.H. drive vehicles> NO : Replace the engine-ECU. When the engine-
<R.H. drive vehicles> Common Rail Engine Learns ). After
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

• Engine: Idling after warm-up
• Transmission: Neutral <M/T> or P range <A/T>
OK: The voltage increases when the head-
lamp switch and the rear window defogger
switch are turned ON from OFF.
Inspection Procedure 14: Battery Rundown <Except Euro5>

• Failed battery
• Failed alternator
• Damaged harness (Circuit related to charging STEP 1. Check battery.
system has an open circuit or is earthed) • Check battery (Refer to GROUP 54A − Battery −
• Damaged connector (Circuit related to charging On-vehicle Service − Battery Test ).
system) Q: Is the check result normal?
YES : Check charging system (Refer to GROUP
16 − Charging System − On-vehicle Service
− Output Current Test ).
NO : Replace the battery.
13A-486 DIESEL FUEL
TROUBLESHOOTING
Inspection Procedure 15: Overheating

• Failed cooling fan system
• Insufficient or deteriorated engine coolant
• Failed thermostat STEP 1. Check cooling system.
• Failed water pump • Check cooling fan system (Refer to GROUP 55A
• Failed radiator core − Troubleshooting − Symptom Procedures
<manual A/C>, Refer to GROUP 55B − Trouble-
shooting − Symptom Procedures <automatic A/
C>).
YES : Check cooling system.
DIESEL FUEL
TROUBLESHOOTING
13A-487
Inspection Procedure 16: Engine-ECU Power Supply System
Power Supply and Ignition Switch-IG Circuit
Fusible link 23
W-R
Ignition switch
C-307
LOCK
10 R
Relay
20A box ST ACC 1 2 3
IG1 IG2 4 5 6
W-B 2
A-115 L-B
3 C-207
4
9
J/B
W-B W-B 7.5A
4 1
A-20X 14
C-208
1 2 Engine
OFF control W
3 relay C-53*¹
ON
4 or
C-35*²
3 2 8
R
Y-G B-W
R R C-103
101 102 118 104 C-103
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
Power
source 116 117
131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
C-103 116 117 145 Engine-ECU
B B B
NOTE
Wire colour code
R: Red P: Pink V: Violet PU: Purple SI:Silver
AKB00288 AB
OPERATION sensor and actuator.

• When the ignition switch ON signal is input to the
engine-ECU, the engine-ECU places the engine PROBABLE CAUSES
control relay in the ON position. Accordingly, the • Failed battery
battery voltage is supplied to the engine-ECU, • Failed ignition switch
13A-488 DIESEL FUEL
TROUBLESHOOTING
• Failed engine control relay STEP 4. Perform voltage measurement at A-20X

• Damaged harness (Open circuit between engine- engine control relay connector.
ECU and engine control relay, engine control
relay and relay box, engine-ECU and earth, and Connector: A-20X
open circuit between engine-ECU and J/B)
• Damaged connector (Engine-ECU connector, A-20X
diagnosis connector)
2 1
DIAGNOSIS PROCEDURE 3
4
Relay box's side
STEP 1. Check battery voltage. connector AK501321 AC
• Measure battery voltage during cranking.
• Remove relay, and measure at harness side.
OK: 8 V or more • Voltage between terminal No. 1 and earth, also
Q: Is the check result normal? between terminal No. 4 and earth.
NO : Check battery (Refer to GROUP 54A −
Battery − On-vehicle Service − Battery test Q: Is the check result normal?
). YES : Go to Step 5 .
NO : Check intermediate connector A-115, and
STEP 2. Check engine control relay itself. connector is normal, check and repair
• Check engine control relay itself (Refer to P.13A- harness between A-20X (terminal No. 1 and
594). terminal No. 4) engine control relay
Q: Is the check result normal? connector and battery.
NO : Replace the engine control relay. STEP 5. Connector check: C-103 engine-ECU
connector.
STEP 3. Connector check: A-20X engine control Connector: C-103
relay connector <L.H. drive vehicles>
Connector: A-20X
A-20X
2 1 C-103 (B)
3
4 <R.H. drive vehicles>
Relay box's side

C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

DIESEL FUEL
TROUBLESHOOTING
13A-489
Connector: C-103
STEP 6. Perform voltage measurement at C-103 <L.H. drive vehicles>
engine-ECU connector
Connector: C-103
C-103 (B)

C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
C-103 (B) 117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 • Disconnect connector, and measure at harness
side.
• Short-circuit terminal No. 118 to earth.
• Disconnect connector, and measure at harness • Voltage between terminal No. 101 and earth also
side. between terminal No. 102 and earth.
• Voltage between terminal No. 118 and earth. OK: System voltage
OK: System voltage
YES : Go to Step 7 . NO : Repair the harness wire.
NO : Repair the harness wire.
13A-490 DIESEL FUEL
TROUBLESHOOTING
STEP 8. Check for open circuit between engine-
ECU connector C-103 and earth.
Connector: C-103
<L.H. drive vehicles> STEP 9. Connector check: C-103 engine-ECU
connector.
Connector: C-103
C-103 (B)

C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
C-103 (B)
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
Harness side connector AKA00090 AB 117 116
• Disconnect connector, and measure at harness 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
side.
• Check open circuit between terminal No. 145 and AKA00090 AB
earth. Q: Is the check result normal?

DIESEL FUEL
TROUBLESHOOTING
13A-491
STEP 10. Check for open circuit between engine- STEP 11. Perform voltage measurement at C-103
ECU connector C-103 and earth. engine-ECU connector.
C-103 (B) C-103 (B)
C-103 (B) C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 117 116

143 142 141 140 139138 137 136 135 134 133 132 131 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
• Disconnect connector. • Disconnect connector, and measure at harness

• Check open circuit between terminal No. 116 and side.
earth also between terminal No. 117 and earth. • Ignition switch: ON
NO : Repair the harness wire. Q: Is the check result normal?
NO : Check intermediate connector C-53 <L. H.
drive vehicles> or C-35 <R. H. drive
intermediate connector is normal, check and
repair harness between C-103 (terminal No.
104) engine-ECU connector and C-208 J/B
connector.

13A-492 DIESEL FUEL
TROUBLESHOOTING

DPF Regeneration ).
Inspection Procedure 17: Engine-ECU Battery Back-up System
Battery back-up circuit
Fusible link 23
W-R
10 Relay
20A box
W-B
A-115
3
W-B
C-103 103
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
Battery
116 117 backup Engine-ECU
131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
Wire colour code

AKA00116 AB
OPERATION engine-ECU from a battery.

• Backup power source is directly supplied to an
DIESEL FUEL
TROUBLESHOOTING
13A-493
PROBABLE CAUSES STEP 3. Connector check: C-103 engine-ECU
• Damaged harness (Open circuit between engine- connector and A-115 intermediate connector.
ECU and relay box)
• Damaged connector (Engine-ECU connector) Connector: C-103
DIAGNOSIS PROCEDURE

• Measure battery voltage during cranking.
C-103 (B)
OK: 8 V or more
Q: Is the check result normal? <R.H. drive vehicles>
NO : Check battery (Refer to GROUP 54A −
Battery − On-vehicle Service − Battery test
).

C-103 (B)
Connector: C-103 115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Connector: A-115
C-103 (B)
A-115

C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Harness side connector AKA00090 AB A-115

side.
OK: System voltage
1 2 3 4
Q: Is the check result normal? 5 6 7 8 9 10
YES : Go to Step 5 . Harness side connector

YES : Go to Step 4 . NO : Repair or replace.
13A-494 DIESEL FUEL
TROUBLESHOOTING

STEP 4. Check for open circuit between C-103
(terminal No. 103) engine-ECU connector and A- NO : Repair the harness wire.
115 (terminal No. 3) intermediate connector.
Connector: C-103
C-103 (B)
C-103 (B)
DPF Regeneration ).
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
145 144
158 157156 155 154 153 152 151 150 149 148 147 146
Connector: A-115
A-115
A-115
1 2 3 4
5 6 7 8 9 10
AK700922 AB
• Disconnect connector.
DIESEL FUEL
TROUBLESHOOTING
13A-495
Inspection Procedure 18: 1st and 2nd Rail Switch System <M/T>
1st and 2nd Rail Switch Circuit
Ignition switch (IG1)
L-B
C-207
4
21
J/B
7.5A
2
C-208
L-Y
C-30
10
L-Y
1
B-06
MU802662
ON 1st and 2nd rail switch
1 2 OFF
G-Y
C-29
4
G-Y
A-115
6
G-Y
C-105 11
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKB00289 AC
OPERATION • An engine-ECU controls an engine speed to be 3,

• The 1st and 2nd rail switches detect that a trans- 000 r/min or less so that an excessive load can-
mission is shifted into the 1st speed gear posi- not be applied to a drive train system due to a
tion. sudden start in the first gear position.
PROBABLE CAUSES • Failed 1st and 2nd rail switch

13A-496 DIESEL FUEL
TROUBLESHOOTING
• Damaged harness (Open circuit between 1st and YES : Go to Step 4 .

2nd rail switch and engine-ECU, and open circuit NO : Repair or replace.
between 1st and 2nd rail switch and J/B)
• Damaged connector (Engine-ECU connector, 1st STEP 4. Perform voltage measurement at B-06
and 2nd rail switch connector) 1st and 2nd rail switch connector.
Connector: B-06
DIAGNOSIS PROCEDURE

a. Item 72: 1st and 2nd rail switch B-06 (GR)
1 2
YES : Go to Step 7 . Harness side
NO : Go to Step 2 . connector AK503584AB

STEP 2. Check 1st and 2nd rail switch itself side.
• Check 1st and 2nd rail switch itself (Refer to • Ignition switch: ON
GROUP 22B − Transmission − Transmission • Voltage between terminal No. 1 and earth.
Inspection <2WD>, GROUP 22C − Transmission OK: System voltage
− Transmission Inspection <4WD>). Q: Is the check result normal?
YES : Go to Step 3 . NO : Check intermediate connector C-30, and
NO : Replace the 1st and 2nd rail switch. repair if necessary. If intermediate
harness between B-06 (terminal No. 1) 1st
STEP 3. Connector check: B-06 1st and 2nd rail and 2nd rail switch connector and C-208
switch connector (terminal No. 2) J/B connector.
Connector: B-06
B-06 (GR)
1 2
Harness side
connector AK503584AB

DIESEL FUEL
TROUBLESHOOTING
13A-497
STEP 5. Connector check: C-105 engine-ECU STEP 6. Perform voltage measurement at C-105
connector engine-ECU connector.
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

NO : Repair or replace. • Ignition switch: ON
OK:
System voltage (Shift lever position: 1st)
0 V (Shift lever position: Neutral)
NO : Check intermediate connectors A-115 and
C-29, and repair if necessary. If intermediate
connectors are normal, check and repair
engine-ECU connector and B-06 (terminal
No. 2) 1st and 2nd rail switch connector.

13A-498 DIESEL FUEL
TROUBLESHOOTING

DPF Regeneration ).
DIESEL FUEL
TROUBLESHOOTING
13A-499
Inspection Procedure 19: Back-up Lamp Switch System <M/T>
Back-up Lamp Switch Circuit
Ignition switch (IG1)
L-B
C-207
4
21
J/B
7.5A
2
C-208
L-Y
C-30
10
L-Y
2
B-02
MU802601
ON Back-up lamp switch
1 2 OFF
R-G
C-29
13
R-G
A-28
9
R-G
C-105 9
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKB00290AB
OPERATION • An engine-ECU controls an engine speed to be 3,

• A backup lamp switch detects that a transmission 000 r/min or less so that an excessive load can-
is shifted into a reverse gear position. not be applied to a drive train system due to a
sudden start in a reverse gear position.
PROBABLE CAUSES • Failed back-up lamp switch

13A-500 DIESEL FUEL
TROUBLESHOOTING
• Damaged harness (Open circuit between back- YES : Go to Step 4 .

up lamp switch and engine-ECU, and open circuit NO : Repair or replace.
between back-up lamp switch and J/B)
• Damaged connector (Engine-ECU connector, STEP 4. Perform voltage measurement at B-02
back-up lamp switch connector) back-up lamp switch connector.
Connector: B-02
DIAGNOSIS PROCEDURE

a. Item 73: Reverse shift switch
B-02 (B)
YES : Go to Step 7 . Harness side
NO : Go to Step 2 . connector AK501385AB

STEP 2. Check back-up lamp switch itself side.
• Check back-up lamp switch itself (Refer to • Ignition switch: ON
GROUP 22B − Transmission − Transmission • Voltage between terminal No. 2 and earth.
Inspection <2WD>, GROUP 22C − Transmission OK: System voltage
− Transmission Inspection <4WD>). Q: Is the check result normal?
YES : Go to Step 3 . NO : Check intermediate connector C-30, and
NO : Replace the back-up lamp switch. repair if necessary. If intermediate
harness between B-02 (terminal No. 2)
STEP 3. Connector check: B-02 back-up lamp back-up lamp switch connector and C-208
switch connector (terminal No. 2) connector.
Connector: B-02
B-02 (B)
2 1
Harness side
connector AK501385AB

DIESEL FUEL
TROUBLESHOOTING
13A-501
STEP 5. Connector check: C-105 engine-ECU STEP 6. Perform voltage measurement at C-105
connector engine-ECU connector.
C-105 (B) C-105 (B)
C-105 (B) C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

NO : Repair or replace. • Ignition switch: ON
OK:
System voltage (Shift lever position: Reverse)
0 V (Shift lever position: Neutral)
NO : Check intermediate connectors A-28 and C-
29, and repair if necessary. If intermediate
connectors are normal, check and repair
engine-ECU connector and B-02 (terminal
No. 1) back-up lamp switch connector.

13A-502 DIESEL FUEL
TROUBLESHOOTING

DPF Regeneration ).
DIESEL FUEL
TROUBLESHOOTING
13A-503
Inspection Procedure 20: 4LLC Switch System <M/T-High power engine vehicle>
4LLC Switch Circuit
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
13
L-B
A-115
7
L-R
C-29
5
L-R
B-05
MU802653 4LLC switch
OFF ON
1
Wire colour code

AKB00291 AB
OPERATION • Damaged connector (Engine-ECU connector,

• A 4LLC switch detects that a transmission is 4LLC switch connector)
shifted into a 4LLC position. • Failed engine-ECU
• An engine-ECU controls an engine speed to be 3,
000 r/min or less so that an excessive load can- DIAGNOSIS PROCEDURE
not be applied to a drive train system due to a
sudden start in a reverse gear position.
STEP 1. Check 4LLC switch itself
PROBABLE CAUSES • Check 4LLC switch itself (Refer to GROUP 22A −
• Failed 4LLC switch On-vehicle service − 4LLC detection switch conti-
• Damaged harness (Open circuit between 4LLC nuity check ).
switch and engine-ECU, and open circuit Q: Is the check result normal?
between 4LLC switch and J/B) YES : Go to Step 2 .
NO : Replace the 4LLC switch.
13A-504 DIESEL FUEL
TROUBLESHOOTING
STEP 2. Connectors check: B-05 4LLC switch STEP 3. check harness between C-105 (terminal
connector and C-105 engine-ECU connector No. 13) engine-ECU connector and B-05 (terminal
Connector: B-05
No. 1) 4LLC switch connector.
Connector: B-05
B-05
B-05
1
Harness side 1
connector
AK801710AB
AK801710AB
Connector: C-105
C-105 (B)
C-105 (B)

C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
YES : Go to Step 3 . NOTE: Before checking harness, check intermediate
NO : Repair or replace. connectors C-29 and A-115, and repair if necessary.
DIESEL FUEL
TROUBLESHOOTING
13A-505
DPF Regeneration ).
13A-506 DIESEL FUEL
TROUBLESHOOTING
Inspection Procedure 21: Condenser Fan Relay System <Vehicles with A/C condenser fan>
Condenser Fan Relay Circuit
Ignition switch
C-307
R LOCK
1 2 3 ST ACC
IG1 IG2
4 5 6
L-R
Fusible link 20
C-207
6
W
16 J/B
7.5A
5 Relay
20A box 9
C-210
L-R
4
1
A-14X
1 2
OFF Condenser fan relay
3
ON
4
2
3
L-B LG-R
A-115
A-120 2 1
MU802601
A/C condenser
1 2 M fan motor LG-R
21 C-105
1
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
B
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
B 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Engine-ECU
Wire colour code

AKB00293 AB

• The A/C condenser fan relay is controlled by turn- • Failed condenser fan relay
ing on and off the power transistor in the engine- • Failed condenser fan motor
ECU. • Damaged harness (Open or short circuit between
• In response to the A/C switch signal, A/C load engine-ECU and condenser fan relay, Open cir-
signal, vehicle speed and engine coolant temper- cuit between condenser fan motor and earth,
ature, the engine-ECU controls the condenser condenser fan relay and J/B, condenser fan relay
fan relay. and relay box, and open circuit between con-
denser fan relay and condenser fan motor)
DIESEL FUEL
TROUBLESHOOTING
13A-507
• Damaged connector (condenser fan relay con- YES : Go to Step 3 .
nector, condenser fan motor connector, Engine- NO : Check condenser fan system (Refer to
ECU connector) GROUP 55A − Troubleshooting − Trouble
• Failed engine-ECU Symptom Chart <Manual A/C>, GROUP
55B − Troubleshooting − Trouble Symptom
DIAGNOSIS PROCEDURE Chart <Automatic A/C>).
STEP 1. M.U.T.-III data list STEP 3. Connector check: C-105 engine-ECU

• Refer to Data List Reference Table P.13A-542. connector.
a. Item 26: A/C load signal Connector: C-105
NO : Check A/C system (Refer to GROUP 55A −
Troubleshooting − Check Chart for Trouble
Symptoms <Manual A/C>, GROUP 55B −
Troubleshooting − Trouble Symptom Chart
<Automatic A/C>). C-105 (B)
STEP 2. Check at C-105 engine-ECU connector. <R.H. drive vehicles>
Connector: C-105
C-105 (B)
C-105 (B) 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
<R.H. drive vehicles> 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

C-105 (B) Service − How to Perform Chassis Number
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 register the injector identification code and
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector Common Rail Engine Learns ). After

AKA00089 AB
• Disconnect connector, and measure at harness the vehicle equipped with the DPF carries
side. out the forcible DPF regeneration. (Refer to
• Ignition switch: ON GROUP 17 − Emission Control − Diesel
• Short-circuit terminal No. 21 to earth. Particulate Filter (DPF) System − Forcible
OK: Condenser fan motor rotates DPF Regeneration ).
13A-508 DIESEL FUEL
TROUBLESHOOTING
Inspection Procedure 22: A/C Switch System
A/C Switch circuit

A/C evaporator air outlet thermistor <Manual A/C> or
A/C-ECU <Automatic A/C>
BR-W
C-105
8
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Wire colour code

AKA00119 AF
OPERATION • Failed A/C system

• The battery voltage is applied to the engine-ECU • Open/short circuit in A/C circuit or loose connec-
(terminal No. 8) from the A/C switch module. tor contact
PROBABLE CAUSES
• Failed A/C
DIESEL FUEL
TROUBLESHOOTING
13A-509
connector
STEP 1. Perform voltage measurement at C-105 Connector: C-105
engine-ECU connector. <L.H. drive vehicles>
Connector: C-105
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
C-105 (B) 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25

72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector Q: Is the check result normal?

AKA00089 AB
• Measure engine-ECU terminal voltage. NO : Repair or replace.
• Engine: Idling
• A/C set temperature:
Maximum Cool when temperature in cabin is
• Item 25: A/C switch
25°C or more
a. Engine: Idling
Maximum Hot when temperature in cabin is 25°C
or less b. A/C set temperature:
• Voltage between terminal No. 8 and earth. Maximum Cool when temperature in cabin is
25°C or more
OK:
Maximum Hot when temperature in cabin is
System voltage (when A/C is ON)
25°C or less
0.5 V or less (when A/C is OFF)
OK:
Q: Is the check result normal? ON (when A/C is ON)
YES : Go to Step 2 . OFF (when A/C is OFF)
Troubleshooting − Check Chart for Trouble Q: Is the check result normal?
Symptoms <Manual A/C>, GROUP 55B −
Symptoms <Automatic A/C>).
13A-510 DIESEL FUEL
TROUBLESHOOTING

DPF Regeneration ).
DIESEL FUEL
TROUBLESHOOTING
13A-511
Inspection Procedure 23: A/C Compressor Relay System
A/C Compressor Relay Circuit
Ignition switch
C-307
LOCK
R
1 2 3 ST ACC
IG1 IG2
4 5 6
4
Fusible link 20
L-R
C-207
W 6
16 J/B
4 Relay
box 7.5A
10A
9
C-210
B-O L-R
A-115 A-28
4 7
B-O L-R
4 1
A-21X
1 2 OFF A/C compressor relay

3 ON
4
3 2
L-W
A-28
4
L-W O
A-27
5
L-W
C-105
1 19
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
A-33
MU802655
A/C 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
compressor 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
1 clutch assembly
Engine-ECU
A/C compressor and clutch assembly
Wire colour code

AKB00294 AB
13A-512 DIESEL FUEL
TROUBLESHOOTING
OPERATION STEP 2. Connector check: C-105 engine-ECU

• When the A/C switch "ON" signal is input to the connector
engine-ECU, the engine-ECU places the A/C
compressor relay in the "ON" position. Accord- Connector: C-105
ingly, the battery voltage supplied to the A/C com-
pressor operates the magnet clutch.
PROBABLE CAUSES
• Failed A/C compressor relay
• Failed A/C compressor assembly
• Damaged harness (Open circuit between A/C C-105 (B)
compressor relay and condenser fan relay, A/C
compressor relay and engine-ECU, A/C com-
pressor relay and A/C compressor, and open cir-
cuit between A/C compressor relay and relay
box)
• Damaged connector (A/C compressor relay con-
nector, A/C compressor connector, Engine-ECU
connector)
DIAGNOSIS PROCEDURE 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
STEP 1. M.U.T.-III data list 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Refer to Data List Reference Table P.13A-542. Harness side connector AKA00089 AB
a. Item 25: A/C switch
b. Item 26: A/C load signal Q: Is the check result normal?
c. Item 27: A/C relay YES : Go to Step 3.
YES : Go to Step 2.
NO : Check A/C system (Refer to GROUP 55A − STEP 3. Check the trouble symptoms.
Troubleshooting − Trouble Symptom Chart Q: Does trouble symptom persist?
<Manual A/C>, GROUP 55B − YES : Replace the engine-ECU. When the engine-
Troubleshooting − Trouble Symptom Chart ECU is replaced, write the chassis number
<Automatic A/C>). (Refer to GROUP 00 − Precautions Before
DPF Regeneration ).
DIESEL FUEL
TROUBLESHOOTING
13A-513
Inspection Procedure 24: Power Steering Fluid Pressure Switch System
Power steering fluid pressure switch circuit
C-103
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
127
B-R
A-115
5
B-R
A-27
8
B-R
A-134
(MU801211) Power steering fluid
pressure switch
1 OFF ON
Wire colour code

AKA00105 AB

• It is detected whether a load is applied on the
power steering fluid pump by steering or not, and
the signal is inputted to the engine-ECU. When STEP 1. Connector check: A-134 power steering
the power steering fluid pressure switch "ON" sig- fluid pressure switch connector
nal (a large load on the power steering fluid Connector: A-134
pump) is inputted, the engine-ECU provides the
idle-up control.
PROBABLE CAUSES A-134 (B)

• Failed power steering fluid pressure switch
• Damaged harness (Open or short circuit between
power steering fluid pressure switch and engine- 1
ECU)
Harness side
• Damaged connector (Engine-ECU connector, connector AK501383 AB
power steering fluid pressure switch connector)
13A-514 DIESEL FUEL
TROUBLESHOOTING
Connector: C-103
STEP 2. Perform voltage measurement at A-134 <L.H. drive vehicles>
power steering fluid pressure switch connector.
Connector: A-134
A-134 (B)
C-103 (B)

1
Harness side

side.
• Voltage between terminal No. 1 and earth. C-103 (B)
OK: System voltage
115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
117 116
YES : Go to Step 8 . 143 142 141 140 139138 137 136 135 134 133 132 131
145 144
NO : Go to Step 3 . 158 157156 155 154 153 152 151 150 149 148 147 146

OK: System voltage
NO : Go to Step 5 .
DIESEL FUEL
TROUBLESHOOTING
13A-515
YES : Check intermediate connectors A-27 and A-
115, and repair if necessary. If intermediate
connector
connector are normal, check and repair
Connector: C-103 harness between A-134 (terminal No. 1)
<L.H. drive vehicles> power steering fluid pressure switch
C-103 (B) STEP 5. Connector check: C-103 engine-ECU

connector
Connector: C-103
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 <R.H. drive vehicles>

143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Connector: A-134
C-103 (B)
A-134 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
1
Harness side Harness side connector AKA00090 AB
13A-516 DIESEL FUEL
TROUBLESHOOTING

No. 1) power steering fluid pressure switch
ECU connector.
Connector: A-134 ECU is replaced, write the chassis number
A-134 (B)
1 Common Rail Engine Learns ). After
Harness side registering the injector identification code,
connector AK501383 AB the vehicle equipped with the DPF carries
Connector: C-103
DPF Regeneration ).

C-103 (B) Connector: C-103
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
NOTE: Before checking harness, check intermediate C-103 (B)

• Check output line for short circuit. 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101

143 142 141 140 139138 137 136 135 134 133 132 131
YES : Go to Step 7 . 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
NO : Repair the harness wire. Harness side connector AKA00090 AB

STEP 7. M.U.T.-III data list • Engine: Idling
• Refer to Data List Reference Table P.13A-542. • Voltage between terminal No. 127 and earth.
a. Item 75: Power steering fluid pressure switch OK:
Q: Is the check result normal? System voltage (Steering wheel: Stationary)
1 V or less (Steering wheel: Turned)
DIESEL FUEL
TROUBLESHOOTING
13A-517
NO : Go to Step 9 .
No. 1) power steering fluid pressure switch
STEP 9. Connector check: C-103 engine-ECU ECU connector.
connector
Connector: A-134
Connector: C-103
A-134 (B)
1

Connector: C-103
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 <R.H. drive vehicles>

143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

YES : Replace the power steering fluid pressure
switch.
13A-518 DIESEL FUEL
TROUBLESHOOTING
connector
Connector: C-103
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

DIESEL FUEL
TROUBLESHOOTING
13A-519
Inspection Procedure 25: Glow System <Except Euro5>
Glow System Circuit
Fusible link 24 Engine control relay Ignition switch (IG1)
L-B
C-207
4
15
J/B 7.5A
6
W R C-209
B-W
12
J/C (5)
C-132
15
A-11 A-11 B-W
1 1 C-112
1 A-112 36
MU802601 C-112
Glow
plug 31 32 33 34 35 36
OFF 1 2
relay ON
37 38 39 40 41 42
A-111 C-111
1 Combination Glow MU801586
1 A-111 2 meter
51 52 53 54 55 56 57
51 58 59 60 61 62 63 64
L C-111
W-R B-R
C-53*¹ or
24 C-35*²
L
1 20 22
A-06
1 Glow
plugs Engine-ECU
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
NOTE
*1: L.H. drive vehicles C-105
Wire colour code
AKA00122 AB

• The engine-ECU controls the glow plug relay and • Failed glow control relay
glow indicator lamp based on the signal of the • Failed glow plug
engine coolant temperature sensor in order to
easily start the engine at the cool condition.
13A-520 DIESEL FUEL
TROUBLESHOOTING
• Damaged harness (Open or short circuit between STEP 2. Connector check: C-105 engine-ECU
engine-ECU and glow plug relay, and open or connector and C-111 combination meter
short circuit between glow plug relay and glow connector.
plug, Open circuit between engine control relay
and glow plug relay, engine control relay and fusi- Connector: C-105
ble link, and open circuit between engine-ECU
and combination meter)
glow plug relay connector, combination meter
connector)
C-105 (B)
DIAGNOSIS PROCEDURE
STEP 1. Check the glow indicator lamp
illuminates.
• Engine coolant temperature: 40°C or lower
Q: Is the glow indicator lamp illuminates?
YES : Go to Step 4 . C-105 (B)
NO : Go to Step 2 .
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: C-111
C-111
C-111
57 56 55 54 53 52 51
64 63 62 61 60 59 58

DIESEL FUEL
TROUBLESHOOTING
13A-521
STEP 3. Perform voltage measurement at C-105 STEP 4. Connector checks: A-11, A-111 and A-
engine-ECU connector. 112 glow plug relay connectors.
Connector: C-105 Connector: A-11, A-111 and A-112
AC501628
A-111 (GR)
A-11
C-105 (B) A-112 (B)

Fuel filter
1
A-11, A-111
<R.H. drive vehicles> Harness side connector
2 1
A-112 Harness side connector AK501004 AB

C-105 (B) NO : Repair or replace.
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 STEP 5. Check the glow plug relay itself.
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
• Check the glow plug relay itself (Refer to GROUP
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
16 − Glow System − On-vehicle Service − Glow
Harness side connector AKA00089 AB Plug Relay Check ).
• Disconnect connector, and measurement at har- Q: Is the check result normal?
ness side. YES : Go to Step 6 .
• Ignition switch: ON NO : Replace the glow plug relay.
OK: System voltage STEP 6. Perform voltage measurement at A-11
glow plug relay connector.
YES : Replace the engine-ECU. When the engine- Connector: A-11 AC501628
Writing ). After replacing the engine-ECU, A-11
Precautions Before Service − What The Fuel filter
Common Rail Engine Learns ). 1
NO : Check intermediate connector C-53 <L. H. Harness side connector AK501005 AB
drive vehicles> or C-35 <R. H. drive • Disconnect connector, and measurement at har-
vehicles>, and repair if necessary. If ness side.
intermediate connector is normal, check and • Voltage between terminal No. 1 and earth.
repair harness between C-111 (terminal No.
51) combination meter connector and C-105 OK: System voltage
(terminal No. 28) engine-ECU connector. Q: Is the check result normal?
NO : Check harness between fusible link No. 24
and A-11 (terminal No. 1) glow plug relay
connector.
13A-522 DIESEL FUEL
TROUBLESHOOTING
NO : Replace the glow plug.
glow plug relay connector.
Connector: A-112 AC501628
No. 1) glow plug relay connector and A-06
(terminal No. 1) glow plug connector.
Connector: A-111 AC501628
A-111 (GR)
A-112 (B)
Fuel filter
2 1
• Disconnect connector, and measurement at har-

ness side. Fuel filter
• Voltage between terminal No. 1 and earth. 1
OK: System voltage
Q: Is the check result normal? Connector: A-06
NO : Check harness between A-112 (terminal No.
1) glow plug relay connector and A-20X
(terminal No. 3) engine control relay A-06
connector.
STEP 8. Check glow plug itself. 1

• Check glow plug itself (Refer to GROUP 16 − Harness side connector AK700923 AB
Glow System − On-vehicle Service − Glow Plug
Check ). Q: Is the check result normal?
DIESEL FUEL
TROUBLESHOOTING
13A-523
connector No. 2) glow plug relay connector and C-105
Connector: C-105
<L.H. drive vehicles> Connector: A-112 AC501628
C-105 (B) A-112 (B)

Fuel filter
2 1
<R.H. drive vehicles> Harness side connector AK501006 AB
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73


C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

13A-524 DIESEL FUEL
TROUBLESHOOTING
Inspection Procedure 26: PTC Heater Relay System <Vehicle with PTC Heater>
PTC Heater Circuit
Fusible link 25 Ignition switch (IG2)
L-R C-207
6
16
J/B
7.5A
9
C-210
L-R
R R A-28
7
L-R
C-148
L-R 4
L-R
PTC heater 2 3 2 3 PTC heater
relay 1 relay 2
A-140X A-141X
ON ON
2 OFF OFF 2
1 3 1 3
4 4
4 1 4 1
B-L B-Y
2 2 A/C switch module <Manual A/C>
Y-G or A/C-ECU <Automatic A/C>
Y-L
C-149 C-150
PTC C-148 PTC C-148
Heater 1 2 Heater 2 1
1 2 1 2 L-W
1 1 C-52
3
B Y-GR B G-O
L-W
43 44 6
Engine-ECU
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
C-105
Wire colour code
AKB00307 AB
DIESEL FUEL
TROUBLESHOOTING
13A-525
OPERATION YES : Go to Step 2 .
• When the PTC heater operation request signal NO : Check PTC heater system (Refer to
(battery voltage) is input into the engine-ECU GROUP 55A − Troubleshooting − Trouble
(terminal No. 6) from the A/C switch module Symptom Chart <manual A/C>, GROUP
<manual A/C> or A/C-ECU <automatic A/C>, the 55B − Troubleshooting − Trouble Symptom
engine-ECU turns ON the PTC heater relay 1 and Chart <automatic A/C>).
2 after satisfying all the operation conditions.
Operation conditions of PTC heater relay 1 STEP 2. PTC heater 1 operation check
a. Engine coolant temperature is under 80°C Connector: C-105
b. 2 seconds later after the engine has start up. <L.H. drive vehicles>
c. The PTC heater request signal has been input
continuously 2 seconds or more
d. The battery voltage continues to be 12.3 V or
more for 12 seconds or more.
Operation conditions of PTC heater relay 2
a. Engine coolant temperature is under 75°C. C-105 (B)
b. The PTC heater 1 has been ON continuously
45 seconds or more. <R.H. drive vehicles>
c. Heater switch (warm up switch) is ON or vehi-
cle speed is 20km/h or more.
d. The battery voltage continues to be 12.9 V or
more for 12 seconds or more.
PROBABLE CAUSES
• Failed PTC heater relay C-105 (B)
• Failed PTC heater
• Damaged harness (Open circuit between PTC 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
heater relay and engine-ECU, PTC heater relay

and J/B, PTC heater relay and PTC heater, PTC
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
heater and body earth, and open circuit between Harness side connector AKA00089 AB
PTC heater relay and fusible link 25.
• Damaged connector (PTC heater relay connec- • Disconnect the C-105 connector.
tor, PTC heater connector, engine-ECU connec- • Using the jumper wire, connect terminal No. 43 to
tor). earth.
• Failed engine-ECU OK: The PTC heater 1 operates.
NO : Check PTC heater system (Refer to
STEP 1. M.U.T.-III data list GROUP 55A − Troubleshooting − Trouble
• Refer to Data List Reference Table P.13A-542. Symptom Chart <manual A/C>, GROUP
a. Item 76: PTC heater relay 1 55B − Troubleshooting − Trouble Symptom
Chart <automatic A/C>).
b. Item 77: PTC heater relay 2
13A-526 DIESEL FUEL
TROUBLESHOOTING
STEP 3. PTC heater 2 operation check. STEP 4. Connector check: C-105 engine-ECU
Connector: C-105
connector.
C-105 (B)
C-105 (B)

C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Disconnect the C-105 connector. AKA00089 AB
• Using the jumper wire, connect terminal No. 44 to Q: Is the check result normal?
earth. YES : Go to Step 5 .
OK: The PTC heater 2 operates. NO : Repair or replace.
YES : Go to Step 4 . STEP 5. Check the trouble symptoms.
NO : Check PTC heater system (Refer to
GROUP 55A − Troubleshooting − Trouble
Symptom Chart <manual A/C>, GROUP
55B − Troubleshooting − Trouble Symptom
Chart <automatic A/C>).
DPF Regeneration ).
DIESEL FUEL
TROUBLESHOOTING
13A-527
Inspection Procedure 27: Blower Switch System <Euro5>
Blower Switch Circuit
Blower switch
L-B
10
J/C (9)
C-10
3
L-B
C-52*¹ or
C-34*²
1*¹ or
4*²
G-Y
C-103 125
103104105106107108109110 111112113 114115

101 102 118119120121122123124125126127128 129130
116 117 Engine-ECU

131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
NOTE
Wire colour code
AKB00331 AB

• The battery voltage is applied to the engine-ECU • Failed A/C system
(terminal No. 125) from the blower switch. • Open/short circuit or harness damage in blower
switch circuit or loose connector contact
• When the blower fan is turned ON and the battery
voltage is applied to the engine-ECU, the engine-
ECU increases the idle speed.
13A-528 DIESEL FUEL
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 2. Perform voltage measurement at C-10

joint connector.
STEP 1. Connector check: C-10 joint connector. Connector: C-10
Connector: C-10 <L. H. drive vehicles>
<L. H. drive vehicles>
C-10 (GR)
C-10 (GR)
5 4 3 2 1
5 4 3 2 1 12 11 10 9 8 7 6 AB
12 11 10 9 8 7 6 AB Harness side connector

<R. H. drive vehicles>
C-10 (GR)
C-10 (GR)
AKB00330 AB
AKB00330 AB • Disconnect connector, and measure at the har-

ness side.
Q: Is the check result normal? • Ignition switch: ON
OK: System voltage
NO : Go to Step 3 .
DIESEL FUEL
TROUBLESHOOTING
13A-529
connector. No. 3) joint connector and C-103 (terminal No.
Connector: C-103
<L. H. drive vehicles>
C-10 (GR)
C-103 (B)
5 4 3 2 1
12 11 10 9 8 7 6 AB
C-10 (GR)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
145 144
AKB00330 AB
158 157156 155 154 153 152 151 150 149 148 147 146
Harness side connector Connector: C-103

AKA00090 AB
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

connector C-52 <L. H. drive vehicles>, C-34 <R. H.
drive vehicles>, and repair if necessary.
13A-530 DIESEL FUEL
TROUBLESHOOTING
YES : Replace the engine-ECU.

No. 3) joint connector and C-103 (terminal No.
Connector: C-10
connector. <L. H. drive vehicles>
Connector: C-103
C-10 (GR)
5 4 3 2 1
C-103 (B) 12 11 10 9 8 7 6 AB

C-10 (GR)
C-103 (B)
AKB00330 AB
115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
130 129 128 127 126 125 124 123 122 121120 119 118 Connector: C-103
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

YES : Go to Step 6.
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

drive vehicles>, and repair if necessary.
DIESEL FUEL
TROUBLESHOOTING
13A-531
YES : Go to Step 7. YES : Intermittent malfunction (Refer to GROUP
NO : Repair the damaged harness wire. 00 − How to Use Troubleshooting/
STEP 7. Perform voltage measurement at C-103 with Intermittent Malfunctions ).
Connector: C-103 Symptoms <Manual A/C>, GROUP 55B −
Symptoms <Automatic A/C>).
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144

• Engine: Idling
OK:
System voltage (when A/C is ON)
1 V or less (when A/C is OFF)
13A-532 DIESEL FUEL
TROUBLESHOOTING
Inspection Procedure 28: Rear Window Defogger System <Euro5>
Rear Window Defogger Circuit
Rear window
defogger relay
J/B
19
7.5A
10
C-208
*1 *2
L-O
10
L-O J/C (8)

C-08
11
L-O
C-53*¹ or
C-35*²
19
B-G
C-105 10
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
NOTE
Wire colour code
AKB00332 AB

• The battery voltage is applied to the engine-ECU • Failed rear window defogger system
(terminal No. 10) from the rear window defogger • Open/short circuit or harness damage in rear win-
relay. dow defogger relay circuit or loose connector
contact
• When the rear window defogger is turned ON and
the battery voltage is applied to the engine-ECU,
the engine-ECU increases the idle speed.
DIESEL FUEL
TROUBLESHOOTING
13A-533
STEP 1. Check the rear window defogger.

The rear defogger system should work normally STEP 3. Perform voltage measurement at C-105
(Refer to GROUP 54A, Printed Heater Lines Check ). engine-ECU connector.
Connector: C-105
NO : Check rear window defogger relay system
(Refer to GROUP 55A − Troubleshooting −
Check Chart for Trouble Symptoms
<Manual A/C>, GROUP 55B −
Symptoms <Automatic A/C>). C-105 (B)
STEP 2. Connector check: C-105 engine-ECU <R.H. drive vehicles>

connector.
Connector: C-105
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
<R.H. drive vehicles> Harness side connector AKA00089 AB

• Engine: Idling
OK:
System voltage (when rear window defogger
C-105 (B) is ON)
1 V or less (when rear window defogger is
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
OFF)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector AKA00089 AB NO : Go to Step 4 .

13A-534 DIESEL FUEL
TROUBLESHOOTING
STEP 4. Connector check: C-208 junction block STEP 5. Check harness between C-208 (terminal
connector. No. 10) junction block connector and C-105
Connector: C-208
<L. H. drive vehicles> Connector: C-208
Junction block (Front view) <L. H. drive vehicles>
C-208 Junction block (Front view)
C-208

Junction block <R. H. drive vehicles>
(Front view) Junction block
(Front view)
Harness side
connector
C-208
C-208
AKB00333 AB
AKB00333 AB
YES : Go to Step 5. Connector: C-105
NO : Repair or replace the connector. <L.H. drive vehicles>
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

drive vehicles> and C-35 <R. H. drive vehicles>, and
repair if necessary.
DIESEL FUEL
TROUBLESHOOTING
13A-535
YES : Replace the engine-ECU.
No. 10) junction block connector and C-105
STEP 6. Connector check: C-208 junction block
Connector: C-208
connector. <L. H. drive vehicles>
Junction block (Front view)
Connector: C-208
<L. H. drive vehicles> C-208
Junction block (Front view)
C-208

Junction block
<R. H. drive vehicles> (Front view)
Junction block
(Front view) Harness side
connector
Harness side
connector
C-208
C-208
AKB00333 AB
AKB00333 AB Connector: C-105

YES : Go to Step 7.
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73

drive vehicles> and C-35 <R. H. drive vehicles>, and
repair if necessary.
13A-536 DIESEL FUEL
TROUBLESHOOTING

Inspection Procedure 29: DPF Lamp System <Euro5>
DPF Lamp Circuit
C-113
Combination meter
1 2 3 4 5 6 7 8 9 10 11 12
DPF
13 14 15 16 17 18 19 20 21 22 23 24
lamp
1
C-113
G-R
C-53*¹ or
C-35*²
17
V-W
C-105 47
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
NOTE
Wire colour code
AKB00340 AB

• Engine-ECU turn on DPF lamp for 5 seconds to
check for burnt-out bulb immediately after ignition
switch is turned to ON. STEP 1. M.U.T.-III actuator test.
• Engine-ECU has detected failed DPF system. Or • Refer to Actuator Test Table P.13A-574.
failure is possibly caused by open or short circuit a. Item 44: DPF lamp
or other faults. Q: Is the check result normal?
PROBABLE CAUSES 00 − How to Use Troubleshooting/
• Damaged connector (Engine-ECU connector, Inspection Service Points − How to Cope
combination meter connector) with Intermittent Malfunction ).
• Damaged harness (Open or short circuit between NO : Go to Step 2 .
engine-ECU and combination meter)
• Failed engine-ECU STEP 2. Check indicator illumination.
Q: Does an indicator other than the DPF lamp
illuminate?
DIESEL FUEL
TROUBLESHOOTING
13A-537
STEP 4. Connector check: C-105 Engine-ECU
NO : Inspect combination meter and related
connector and C-113 combination meter
circuits (Refer to GROUP 54A −
connector.
Combination Meter − Check Chart for
Trouble Symptoms ). Connector: C-105

to P.13A-21).
NO : Go to Step 4 . C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: C-113
C-113
C-113
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
Harness side connector AKB00260AB

13A-538 DIESEL FUEL
TROUBLESHOOTING
STEP 5. Check combination meter.
NO : Check combination meter (Refer to GROUP
Connector: C-113 54A − Combination Meter − Check Chart for
Trouble Symptoms ).
C-113
C-113
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
• Disconnect C-113 combination meter connector
Q: Does the DPF lamp go out?
DIESEL FUEL
TROUBLESHOOTING
13A-539
STEP 6. Perform resistance measurement for OK: 1 kΩ or more
short circuit at C-105 engine-ECU connector. Q: Is the check result normal?
Connector: C-105
<L.H. drive vehicles> NO : Repair the harness wire.
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: C-113
C-113
C-113
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13

side.
• Disconnect C-113 combination meter connector.
13A-540 DIESEL FUEL
TROUBLESHOOTING
STEP 7. Perform resistance measurement for • Resistance between C-105 engine-ECU connec-
open circuit at between C-105 engine-ECU tor terminal No. 47 and C-113 combination con-
connector and C-113 combination meter nector terminal No. 1.
connector. OK: Continuity (2 Ω or less)
Connector: C-105 Q: Is the check result normal?
<L.H. drive vehicles> YES : Go to Step 8 .
NO : Check the intermediate connector C-53 <L.
H. drive vehicles>, C-35 <R. H. drive
intermediate connector is normal, repair the
harness wire.
C-105 (B)
<R.H. drive vehicles> Q: Does trouble symptom persist?
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector out the forcible DPF regeneration. (Refer to

AKA00089 AB
Connector: C-113 Particulate Filter (DPF) System − Forcible
<L.H. drive vehicles> DPF Regeneration ).
C-113
C-113
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
• Disconnect C-105 engine-ECU connector and C-

113 combination meter connector, and measure
resistance at the wiring harness.
DIESEL FUEL
TROUBLESHOOTING
13A-541
Data List Reference Table
M1133004201011
Item Check item Inspection conditions Value to be Code No. Reference

No. determined or page
as normal inspection
procedure
No.
1 Battery Ignition switch: ON System Procedure P.13A-488
voltage voltage No. 16
2 Engine • Engine: Cranking Compare engine Matched Code No. P.13A-184
revolution • Tachometer: speed on tachometer P0335
Connected with the value
displayed on M.U.T.-
III
• Engine: Idle When the engine 1,100 r/min
operation coolant temperature: <Euro5>
• Transmission: −20 °C 900 r/min
Neutral <M/T> or <Except
P range <A/T> Euro5>
• A/C switch: OFF
When the engine 1,100 r/min
coolant temperature: <Euro5>
0 °C
900 r/min *1
650 r/min
<Vehicles for
Morocco>
When the engine 700 r/min *2
coolant temperature:
25 °C 850 r/min *1
When the engine 600 r/min
coolant temperature: <Euro5-M/T>
40 °C
650 r/min *3
800 r/min *1
80 °C
650 r/min *4
700 r/min *5
13A-542 DIESEL FUEL
TROUBLESHOOTING

procedure
No.
3 Target Idle • Engine: Idle When the engine 1,100 r/min Code No. P.13A-184
speed operation coolant temperature: <Euro5> P0335
• Transmission: −20 °C 900 r/min
• A/C switch: OFF
0 °C
900 r/min *1
650 r/min
<Vehicles for
Morocco>
25 °C 850 r/min *1
40 °C
650 r/min *3
800 r/min *1
80 °C
650 r/min *4
700 r/min *5
4 Vehicle Drive 40 km/h Approximatel Code No. P.13A-251
speed y 40 km/h P0502
sensor
5 Barometric Ignition switch: ON Altitude 0 m 101 kPa Code No. P.13A-406,
pressure Altitude 600 m 95 kPa P2228, P.13A-407
sensor P2229
Altitude 1,200 m 88 kPa
Altitude 1,800 m 81 kPa
6 Manifold Ignition switch: ON Altitude: 0 m 101 kPa Code No. P.13A-78,
absolute or Idle operation Altitude: 600 m 95 kPa P0106, P.13A-83,
pressure P0107, P.13A-91
sensor Altitude: 1,200 m 88 kPa P0108
Altitude: 1,800 m 81 kPa
• Engine coolant When engine is The voltage in
temperature: 85 − suddenly raced. accordance
95°C with the boost
• Lights and all pressure in
accessories: OFF the inlet
• Transmission: manifold
Neutral <M/T> or
P range <A/T>
DIESEL FUEL
TROUBLESHOOTING
13A-543
procedure
No.
7 Engine Ignition switch: ON When the engine −20°C Code No. P.13A-113,
coolant or the engine coolant temperature P0117, P.13A-119
temperature running is −20°C P0118
sensor When the engine 0°C
coolant temperature
is 0°C
When the engine 20°C
coolant temperature
is 20°C
coolant temperature
is 40°C
coolant temperature
is 80°C
8 EGR gas Ignition switch: ON When the intake air −20°C Code No. P.13A-94,
temperature or the engine temperature is − P0112, P.13A-104
sensor running 20°C P0113
<Euro5> When the intake air 0°C
temperature is 0°C
When the intake air 20°C
temperature is 20°C
When the EGR is Varies
introduced depending on
the
temperature
in the inlet
manifold
8 Intake air Ignition switch: ON When the intake air −20°C Code No. P.13A-48,
sensor No. 2 running 20°C P0073
<Except When the intake air 0°C
Euro5> temperature is 0°C
13A-544 DIESEL FUEL
TROUBLESHOOTING

procedure
No.
9 Accelerator Ignition switch: ON Release the 700 − 1,300 Code No. P.13A-333,
pedal accelerator pedal mV P2122, P.13A-341,
position Depress the Increases in P2123, P.13A-345
sensor accelerator pedal response to P2124
(main) gradually the pedal
depression
stroke
Depress the 4,000 mV or
accelerator pedal more
fully
10 Accelerator Ignition switch: ON Release the 200 − 800 mV Code No. P.13A-349,
pedal accelerator pedal P2127, P.13A-357
position Depress the Increases in P2128
sensor (sub) accelerator pedal response to
gradually the pedal
depression
stroke
Depress the 2,000 mV or
accelerator pedal more
fully
11 Accelerator Ignition switch: ON Release the 0% Code No. P.13A-333,
pedal accelerator pedal P2122, P.13A-341,
(main) gradually the pedal
depression
stroke
Depress the 98 % or more
accelerator pedal
fully
12 Accelerator Ignition switch: ON Release the 20 % or Code No. P.13A-349,
pedal accelerator pedal below P2127, P.13A-357
position Depress the Increases in P2128
sensor (sub) accelerator pedal response to
gradually the pedal
depression
stroke
accelerator pedal
fully
15 Vehicle Drive 40 km/h Approximatel − −
speed y 40 km/h
sensor
DIESEL FUEL
TROUBLESHOOTING
13A-545
procedure
No.
16 EGR valve • Engine: After Idling 50 % or Code No. P.13A-240,
position warming up the more*6 P0489, P.13A-248
sensor engine P0490, <Euro5>
3,500 r/min or more 10 % or
• Transmission: <Euro5> P.13A-219,
below
Neutral <M/T> or P0405,
P.13A-227
P range <A/T> P0406
<Except
<Except
Euro5>
Euro5>
17 EGR valve • Engine: After Idling 50 % or more Code No. P.13A-240,
target warming up the 3,500 r/min or more 10 % or P0489, P.13A-248
position engine below P0490, <Euro5>
• Transmission: <Euro5> P.13A-219,
Neutral <M/T> or P0405,
P.13A-227
P range <A/T> P0406
<Except
<Except
Euro5>
Euro5>
21 Fuel Ignition switch: ON When the fuel −20°C Code No. P.13A-134,
sensor running 20°C P0183
When the fuel 0°C
temperature is 0°C
When the fuel 20°C
When the fuel 40°C
When the fuel 80°C
25 A/C switch Engine: Idling after A/C switch: OFF OFF Procedure P.13A-512
warming up the A/C switch: ON ON No. 22
engine (The A/C
compressor in
operation)
26 A/C load • Engine: Idling A/C compressor ON Procedure P.13A-507
signal after warming up clutch not in No. 23
<Vehicles the engine operation
with • A/C switch: ON When the A/C OFF
automatic A/ compressor clutch is
C> under high load
27 A/C relay Engine: Idling after A/C switch: OFF OFF Procedure P.13A-512
warming up the A/C switch: ON ON (A/C No. 23
engine compressor
clutch in
operation)
13A-546 DIESEL FUEL
TROUBLESHOOTING

procedure
No.
28 AT/MT Ignition switch: ON Vehicles with M/T M/T − −
switch Vehicles with A/T A/T
29 Condenser Ignition switch: ON A/C switch: OFF OFF Procedure P.13A-507
fan relay (engine coolant No. 21
<Vehicles temperature at 97°C
with A/C or lower)
condenser A/C switch: ON and ON
fan> vehicle speed is
lower than 50 km/h
30 Control relay Ignition switch: ON ON − −
33 Engine Ignition switch: "OFF" → "ON" "ON" → Procedure P.13A-438
check lamp "OFF" (after 5 No. 2
seconds have
elapsed)
35 Glow lamp • Ignition switch: "OFF" → "ON" "ON" → − −
• Engine coolant temperature: lower than "OFF" (After
60 °C several
seconds have
elapsed)
36 Glow plug Ignition switch: Engine coolant ON − −
relay "OFF" → "ON" temperature: lower
than 60 °C
Engine coolant OFF
temperature: higher
than 60 °C
38 Ignition Ignition switch: ON ON − −
switch
40 Starter Ignition switch: ON Engine: Except OFF − −
switch cranking
Engine: Cranking ON
42 Neutral Ignition switch: ON Selector lever: N or N or P − −
switch <A/ P range
T> Selector lever: D or R
Except N or P range
DIESEL FUEL
TROUBLESHOOTING
13A-547
procedure
No.
43 Intake air Ignition switch: ON Intake air −20°C Code No. P.13A-43,
temperature temperature: −20°C P0072, P.13A-53
sensor No. 1 Intake air 0°C P0073, <Euro5>
temperature: 0°C <Euro5> P.13A-99,
P0112,
Intake air 20°C P.13A-57
P0113
temperature: 20°C <Except
<Except
Euro5>
Intake air 40°C Euro5>
temperature: 40°C
Intake air 80°C
temperature: 80°C
45 Throttle • Remove the Fully close the 300 − 700 mV Code No. P.13A-124,
position intake air hose at throttle valve with P0122, P.13A-131
sensor the throttle body your finger P0123
• Disconnect the Fully open the 4,000 mV or
connector of the throttle valve with higher
electronic- your finger
controlled throttle
valve
• With the special
tool test harness
(MB991658)
bridge only the
mating terminals
of No. 1, No. 2,
and No. 4 of the
disconnected
connectors
• Ignition switch:
ON (engine
stopped)
13A-548 DIESEL FUEL
TROUBLESHOOTING

procedure
No.
47 Throttle • Remove the Fully close the 0 − 5 deg Code No. P.13A-124,
position intake air hose at throttle valve with P0122, P.13A-131
sensor the throttle body your finger P0123
• Disconnect the Fully open the 73 deg or
connector of the throttle valve with higher
electronic- your finger
controlled throttle
valve
tool test harness
(MB991658)
bridge only the
mating terminals
of No. 1, No. 2,
and No. 4 of the
disconnected
connectors
ON (engine
stopped)
DIESEL FUEL
TROUBLESHOOTING
13A-549
procedure
No.
56 Engine • Engine: Cranking Compare engine Matched − −
revolution • Tachometer: speed on tachometer
Connected with the value
displayed on M.U.T.-
III
• Engine: Idle When the engine 1,100 r/min
operation coolant temperature: <Euro5>
• Transmission: −20°C 900 r/min
• A/C switch: OFF
0°C
900 r/min *1
650 r/min
<Vehicles for
Morocco>
25°C 850 r/min *1
40°C
650 r/min *3
800 r/min *1
80°C
650 r/min *4
700 r/min *5
63 Rail • Engine coolant Idling Rail pressure Code No. P.13A-143,
pressure temperature: 85 − target ± 10 P0191, P.13A-147,
sensor 95°C MPa P0192, P.13A-155
• Lights and all Depress the Rail pressure P0193
accessories: OFF accelerator pedal target ± 15
• Transmission: gradually MPa
Neutral <M/T> or
P range <A/T>
64 Rail • Engine coolant Idling 20 − 35 MPa Code No. P.13A-143,
pressure temperature: 85 − Depress the Increases in P0191, P.13A-147,
target 95°C accelerator pedal response to P0192, P.13A-155
• Lights and all gradually the pedal P0193
accessories: OFF depression
• Transmission: stroke
Neutral <M/T> or
P range <A/T>
13A-550 DIESEL FUEL
TROUBLESHOOTING

procedure
No.
66 Supply Ignition switch: ON −300 to 300 − −
pump mA
learned
value
67 Supply • Engine coolant Idling 1,700 − 1,900 − −
pump target temperature: 85 − mA
value 95°C Depress the Decreases in
• Lamps and all accelerator pedal response to
accessories: OFF gradually the pedal
• Transmission: depression
Neutral <M/T>, P stroke
range <A/T>
72 1st and 2nd Ignition switch: ON Shift position: 1st or ON Procedure P.13A-497
rail switch 2nd No. 18
<M/T> Shift position: except OFF
1st or 2nd
73 Reverse Ignition switch: ON Shift position: ON Procedure P.13A-501
shift switch reverse No. 19
<M/T> Shift position: except OFF
reverse
75 Power Engine: Idle Steering wheel OFF Procedure P.13A-514
steering fluid operation stationary No. 24
pressure Steering wheel ON
switch turning
76 PTC heater • Engine coolant temperature: lower than ON Procedure P.13A-525
relay 1 75°C No. 26
<Vehicles • Heater temperature setting: Maximum
with PTC • Blower fan: ON
heater> • 2 seconds later after the engine has
start up
Other than the above OFF
77 PTC heater • Engine coolant temperature: lower than ON
relay 2 75°C
<Vehicles • Heater switch (warm up switch) is ON or
with PTC vehicle speed is 20 km/h or more
heater> • Heater temperature setting: Maximum
• Blower fan: ON
• 2 seconds later after the engine has
start up
• The PTC heater 1 has been ON
Other than the above OFF
DIESEL FUEL
TROUBLESHOOTING
13A-551
procedure
No.
114 Air flow • Engine coolant Idle operation 725 − 935 Code No. P.13A-68,
sensor temperature: 85 − mg/cyl P0102, P.13A-75,
95°C P0103
• Lights and all
accessories: OFF
• Transmission:
Neutral <M/T> or
P range <A/T>
117 No. 1 Engine: Idling after When the exhaust 150°C Code No. P.13A-260,
exhaust gas warming up the gas temperature is P0545, P.13A-263
temperature engine 150°C P0546
sensor When the exhaust 300°C
<Euro5> gas temperature is
300°C
When the exhaust 450°C
gas temperature is
450°C
gas temperature is
600°C
gas temperature is
750°C
118 No. 2 Engine: Idling after When the catalyst 150°C Code No. P.13A-231,
exhaust gas warming up the temperature is P0427, P.13A-234
sensor When the catalyst 300°C
(catalyst temperature is
temperature 300°C
) <Euro5>
When the catalyst 450°C
temperature is
450°C
temperature is
600°C
temperature is
750°C
13A-552 DIESEL FUEL
TROUBLESHOOTING

procedure
No.
119 No. 3 Engine: Idling after When the DPF 150°C Code No. P.13A-310,
exhaust gas warming up the temperature is P1427, P.13A-313
sensor (DPF When the DPF 300°C
temperature temperature is
) <Euro5> 300°C
When the DPF 450°C
temperature is
450°C
When the DPF 600°C
temperature is
600°C
When the DPF 750°C
temperature is
750°C
120 Exhaust • Remove the Release the both −2.5 to 2.5 Code No. P.13A-411,
differential pressure hoses, nipples to the open kPa P2454, P.13A-417
pressure which are air. P2455
sensor connected to the Connect the manual Changes
<Euro5> both nipple of the pump (pressure- depending on
exhaust application type) to the pressure.
differential the one of the
pressure sensor. nipples, and
• Ignition switch: pressurise it.
ON
• Exhaust
differential
pressure sensor
ambient air
temperature: 0 −
85°C
131 Clutch Ignition switch: ON Depress the clutch OFF − −
switch <M/ pedal
T> Release the clutch ON
pedal
135 Brake lamp Ignition switch: ON Release the brale OFF − −
switch pedal
Deplesse the brale ON
pedal
DIESEL FUEL
TROUBLESHOOTING
13A-553
procedure
No.
142 Variable • Engine coolant Idling 45 − 55 % − −
geometry temperature: 85 − When engine is Increases
control 95°C suddenly raced
solenoid • Lamps and all
valve duty accessories: OFF
before • Transmission:
compensati Neutral <M/T>, P
on <Euro5> range <A/T>
143 Variable • Engine coolant Idling Variable − −
geometry temperature: 85 − geometry
control 95°C control
solenoid • Lamps and all solenoid
valve duty accessories: OFF valve duty
after • Transmission: before
compensati Neutral <M/T>, P compensation
on <Euro5> range <A/T> ±10 %
When engine is Variable
suddenly raced geometry
control
solenoid
valve duty
before
compensation
±10 %
152 Fuel filter Ignition switch: ON OFF Code No. P.13A-304
pressure • Engine: Idling ON P1276
switch • Squeeze the fuel hose with one's fingers
<Vehicles at the inlet side of the fuel filter
for Russia
and
Morocco>
214 DPF lamp Ignition switch: ON When DPF lamp is OFF − −
<Euro5> not illuminated
When DPF lamp is ON
illuminated
320 Accelerator Ignition switch: ON Release the 0% Code No. P.13A-333,
pedal accelerator pedal P2122, P.13A-341,
(main) (After gradually the pedal
compensati depression
on) stroke
accelerator pedal
fully
13A-554 DIESEL FUEL
TROUBLESHOOTING

procedure
No.
326 4L mode • Ignition switch: Transfer position: OFF − −
<M/T-high ON except 4LLc
power • Transmission: Transfer position: ON
engine Neutral 4LLc
vehicle>
401 Alternator G • Engine: Idling after warming up the Increased − −
duty engine
<Euro5> • Head lamp switch: OFF → ON
402 Battery Ignition switch: ON When the battery −20°C Code No. P.13A-255
temperature or engine running temperature sensor P0515
sensor ambient air
<Euro5> temperature is −
20°C
When the battery 0°C
temperature sensor
ambient air
temperature is 0°C
temperature sensor
ambient air
temperature sensor
ambient air
temperature sensor
ambient air
NOTE: *1: Except Euro5 and vehicles for Morocco
NOTE: *2: Euro5, vehicles for Morocco
NOTE: *3: Euro5-A/T, vehicles for Morocco
NOTE: *4: Euro5-A/T, Except Euro5-2WD-Except high rider
NOTE: *5: Except Euro5-high rider and 4WD
NOTE: *6: At an outside temperature of approximately 20°C. When the EGR valve position sensor is checked
at the outside temperature of 20°C or more, the value would be possibly below the opening degree (normal
value). Also, the value would be possibly below the opening degree (normal value) under the following condi-
tions:
• When the volumetric efficiency of the intake air is reduced due to the higher intake air temperature
Engine-ECU Monitor Item
• Items useful for grasping the engine control condition by the engine-ECU are provided in this monitor item
section.
DIESEL FUEL
TROUBLESHOOTING
13A-555
• Values of these monitor items vary greatly depending on marginal difference of measurement conditions,
difference of the environment, aged deterioration of vehicles and so on, and it is difficult to show the pre-
cise specification values. Therefore, check conditions, display range and movement of values are
described.
Ite Inspectio Explanation of M.U.T. display Guideline for inspection Display range,
m n item numerical
No. value
13 Accelerato Learning value of not depressed Ignition switch: ON 700 − 1,300mV
r pedal accelerator pedal state is shown
position
sensor
(main)
learned
closed
position
46 Throttle Learning value of fully closed Ignition switch: ON 9 deg or less
position throttle valve state is shown
sensor
learned
closed
position
57 Fuel Indicates the final injection • Engine: After warm-up, idle 3 − 10 mm3/st
quantity quantity operation
final • Lights and all accessories:
OFF
• Transmission: Neutral <M/T>
or P range <A/T>
58 Fuel Indicates the pre injection quantity • Engine: After warm-up, idle 0.5 − 3 mm3/st
quantity operation
pre • Lights and all accessories:
OFF
or P range <A/T>
59 Fuel Indicates the limit of injection Engine: After warm-up, 2,000r/ 35 mm3/st or
quantity quantity determined by the min more
smoke charging pressure
limit
60 Fuel Indicates the pilot injection Ignition switch: When engine 40 − 50 mm3/st
quantity quantity determined by water ON coolant
start temperature temperature
is 0°C
When engine 30 − 40 mm3/st
coolant
temperature
is 70°C
61 Fuel Interval between end of pilot Engine: After warm-up 200 − 2,000 us
injection injection and start of main injection
interval
pilot
13A-556 DIESEL FUEL
TROUBLESHOOTING
m n item numerical
No. value
62 Fuel Main injection timing Engine: After warm-up, idle −3 to 4°CA
injection operation
timing
main
65 Supply Although the fuel discharge Ignition switch: ON 2*
pump quantity is decided depending on
learned the drive current of the suction
status control valve of the supply pump,
learning is executed in idle state
because there is a machine
difference. The learned status is
indicated.
78 Small Indicates the final learned value of Ignition switch: ON −0.41 to 0.36
injection the small injection quantity of No. ms
quantity at 1 cylinder at 25 MPa
pressure 1
− No. 1
cylinder
pressure 1
− No. 2
cylinder
pressure 1
− No. 3
cylinder
pressure 1
− No. 4
cylinder
pressure 2
− No. 1
cylinder
pressure 2
− No. 2
cylinder
DIESEL FUEL
TROUBLESHOOTING
13A-557
m n item numerical
No. value
pressure 2
− No. 3
cylinder
pressure 2
− No. 4
cylinder
pressure 3
− No. 1
cylinder
pressure 3
− No. 2
cylinder
pressure 3
− No. 3
cylinder
pressure 3
− No. 4
cylinder
pressure 4
− No. 1
cylinder
13A-558 DIESEL FUEL
TROUBLESHOOTING
m n item numerical
No. value
pressure 4
− No. 2
cylinder
pressure 4
− No. 3
cylinder
pressure 4
− No. 4
cylinder
pressure 5
− No. 1
cylinder
pressure 5
− No. 2
cylinder
pressure 5
− No. 3
cylinder
pressure 5
− No. 4
cylinder
DIESEL FUEL
TROUBLESHOOTING
13A-559
m n item numerical
No. value
106 Idle speed Target torque for idle speed control • Engine: After warm-up, idle 50 − 120 Nm
control (ISC) operation
torque • Lights and all accessories:
OFF
or P range <A/T>
116 Request • Indicates the DPF regeneration Ignition switch: ON Changes
of mode request mode. depending on
DPF Not request: Not reached to the the vehicle
regenerati load amount which requires the status.
on regeneration
<Euro5> Distance1: State in which the
regeneration is required by the
actual driving distance
Distance2: State in which the
distance calculated by subtracting
the distance on the natural
regeneration during driving from
the actual driving distance
Summ: State in which the
load amount calculated by the
quantity survey
Pressure difference: State in which
the regeneration is required by the
difference pressure
Manual: State in which the
regeneration is forcibly performed
by the M.U.T.-III.
126 No. 2 Indicates the highest temperature Ignition switch: ON −200 to
exhaust of the temperatures, saved in the 1,075°C
gas engine-ECU, that are detected by
temperatu the No.2 exhaust gas temperature
re sensor sensor (catalyst temperature).
(catalyst
temperatu
re) max
value
<Euro5>
13A-560 DIESEL FUEL
TROUBLESHOOTING
m n item numerical
No. value
127 No. 3 Indicates the highest temperature Ignition switch: ON −200 to
exhaust of the temperatures, saved in the 1,075°C
gas engine-ECU, that are detected by
temperatu the No.3 exhaust gas temperature
re sensor sensor (DPF temperature).
(DPF
temperatu
re) max
value
<Euro5>
128 Odometer Indicates the driving distance at Ignition switch: ON 0 − 1,999,999
at No. 3 the time of the highest km
exhaust temperature of the temperatures,
gas saved in the engine-ECU, that are
temperatu detected by the No.3 exhaust gas
re sensor temperature sensor (DPF
(DPF temperature).
temperatu
re) max
value
<Euro5>
145 Odometer Indicates the total driving distance Ignition switch: ON 0 − 1,999,999
calculated saved to the odometer. km
by engine-
ECU
148 Count of Indicates the DPF regeneration Ignition switch: ON 0 − 65,535
DPF times saved to the engine-ECU.
regenerati
on
<Euro5>
151 Status of Indicates the calibrated value to Ignition switch: ON 0−3
soot load calculate the soot load amount by
by the difference pressure.
differential
pressure
<Euro5>
153 Soot Indicates the driving distance after Ignition switch: ON 0 − 2,550 km
loading by the last DPF regeneration.
distance 1
<Euro5>
154 Soot Indicates the driving distance Ignition switch: ON 0 − 2,550 km
loading by calculated by subtracting the
distance 2 driving distance on natural
<Euro5> regeneration from the distance
after the last DPF regeneration.
DIESEL FUEL
TROUBLESHOOTING
13A-561
m n item numerical
No. value
155 Soot Indicates the soot load amount Ignition switch: ON 0 − 12.75 g/L
loading by calculated by the quantity survey.
accumulat
ion
<Euro5>
156 Soot Indicates the soot load amount Ignition switch: ON 0 − 12.75 g/L
loading by calculated by the difference
differential pressure.
pressure
<Euro5>
160 Last DPF • Last DPF regeneration request Ignition switch: ON Displays the
regenerati mode last DPF
on mode Not request: Not reached to the regeneration
<Euro5> load amount which requires the request mode.
regeneration
quantity survey
difference pressure
by the M.U.T.-III.
190 Odometer Indicates the driving distance for Ignition switch: ON 0 − 1,999,999
for DPF by the mounted DPF. km
engine-
ECU
<Euro5>
191 Nonunifor Indicates the non-uniform soot Ignition switch: ON 0 − 100 g
m soot load amount.
accumulat
ion
<Euro5>
13A-562 DIESEL FUEL
TROUBLESHOOTING
m n item numerical
No. value
192 Max value Indicates the maximum Ignition switch: ON or DPF −400 to 2,150
of DPF temperature of last DPF regeneration °C
temperatu regeneration saved to the engine
re (last ECU.
DPF
regenerati
on)
<Euro5>
193 DPF Indicates the distance where the Ignition switch: ON 0 − 2,550 km
regenerati DPF regeneration request mode of
on start "Distance1" launches.
distance 1
<Euro5>
194 DPF Indicates the soot load amount Ignition switch: ON 0 − 12.75 g/L
regenerati where the DPF regeneration
on start request mode of "Summ"
accumulat launches.
ion
<Euro5>
195 DPF Indicates the soot load amount Ignition switch: ON 0 − 12.75 g/L
regenerati where the DPF regeneration
on start request mode of "Pressure
differential difference" launches.
pressure
<Euro5>
196 DPF Indicates the distance where the Ignition switch: ON 0 − 2,550 km
regenerati DPF regeneration request mode of
on start "Distance2" launches.
distance 2
<Euro5>
197 DPF Indicates the present estimated Ignition switch: ON or DPF −400 to 2,150
temperatu DPF centre temperature. regeneration °C
re
<Euro5>
198 Engine oil Indicates the estimated engine oil Engine: Idle operation −1,000 to 1,500
level level difference. cc
calculated
<Euro5>
199 Engine oil Indicates the estimated descend Engine: Idle operation −1,000 to 1,500
consumpti of the engine oil level. cc
on
calculate
<Euro5>
DIESEL FUEL
TROUBLESHOOTING
13A-563
m n item numerical
No. value
200 Fuel Indicates the estimated ascend of Engine: Idle operation −1,000 to 1,500
dilution engine oil level. cc
calculated
by engine-
ECU
<Euro5>
201 Pre- Indicates the target amount of Ignition switch: ON 0 − 12.75 g
regenerati burned soot in the DPF
on remain regeneration step 1.
soot value
<Euro5>
202 Pre- Indicates the current amount of Ignition switch: ON 0 − 12.75 g
regenerati burned soot in the DPF
on soot regeneration step 1.
value
<Euro5>
204 DPF • DPF regeneration request Ignition switch: ON Displays the
regenerati mode of 2 times before DPF
on mode 2 Not request: Not reached to the regeneration
times load amount which requires the request mode
before regeneration of 2 times
<Euro5> Distance1: State in which the before
quantity survey
difference pressure
by the M.U.T.-III.
13A-564 DIESEL FUEL
TROUBLESHOOTING
m n item numerical
No. value
<Euro5> Distance1: State in which the before.
quantity survey
difference pressure
by the M.U.T.-III.
quantity survey
difference pressure
by the M.U.T.-III.
DIESEL FUEL
TROUBLESHOOTING
13A-565
m n item numerical
No. value
quantity survey
Pressure diff.: State in which the
difference pressure
by the M.U.T.-III.
208 Short Indicates the times of DPF Ignition switch: ON Displays the
interval regeneration performed under the regeneration
DPF distance of 10 km or less after the times.
regenerati last DPF regeneration.
on count
<Euro5>
217 Variable Indicates the target boost Engine: Excessive acceleration 0 − 340 kPa
geometry pressure. after warm-up
turbochar
ger
feedback
target
boost
pressure
<Euro5>
219 Fuel Indicates the main injection Engine: Idle operation 0 − 90 mm3/st
injection quantity of the injector.
quantity
main
220 Fuel Indicates the after injection Engine: Idle operation or DPF 0 − 25.5 mm3/
injection quantity. regeneration st
quantity
after
13A-566 DIESEL FUEL
TROUBLESHOOTING
m n item numerical
No. value
221 Fuel Indicates the 1st post injection On DPF regeneration 0 − 25.5 mm3/
injection quantity on the DPF regeneration. st
quantity
post 1
222 Fuel Indicates the 2nd post injection On DPF regeneration 0 − 25.5 mm3/
quantity
post 2
223 Fuel Indicates the 3rd post injection On DPF regeneration 0 − 25.5 mm3/
quantity
post 3
224 Differentia Indicates the temperature when Ignition switch: ON −35 to −26°C
l pressure the compensation amount (M0) of
learning exhaust differential pressure
temperatu sensor was saved.
re (M0)
<Euro5>
225 Differentia Indicates the compensation Ignition switch: ON −5.12 to 5.08
l pressure amount (M0) of exhaust differential kPa
learning pressure sensor when the exhaust
zero (M0) differential pressure sensor
<Euro5> ambient air temperature is
between −35 and −26°C.
226 Differentia Indicates the temperature when Ignition switch: ON −25 to −16 °C
re (M1)
<Euro5>
229 Differentia Indicates the temperature when Ignition switch: ON −15 to −6°C
re (M2)
<Euro5>
learning pressure sensor when exhaust
DIESEL FUEL
TROUBLESHOOTING
13A-567
m n item numerical
No. value
231 Differentia Indicates the temperature when Ignition switch: ON −5 to 4 °C
re (M3)
<Euro5>
between −5 and 4°C.
234 Differentia Indicates the temperature when Ignition switch: ON 5 to 14°C
re (M4)
<Euro5>
between 5 and 14°C.
re (M5)
<Euro5>
re (M6)
<Euro5>
between 25 to 34°C.
13A-568 DIESEL FUEL
TROUBLESHOOTING
m n item numerical
No. value
241 Differentia Indicates the temperature when Ignition switch: ON 35 to 44 °C
re (M7)
<Euro5>
re (M8)
<Euro5>
re (M9)
<Euro5>
l pressure the compensation amount (M10)
learning of exhaust differential pressure
re (M10)
<Euro5>
l pressure amount (M10) of exhaust kPa
learning differential pressure sensor when
zero the exhaust differential pressure
(M10) sensor ambient air temperature is
<Euro5> between 65 to 74°C.
DIESEL FUEL
TROUBLESHOOTING
13A-569
m n item numerical
No. value
251 Differentia Indicates the temperature when Ignition switch: ON 75 to 84 °C
re (M11)
<Euro5>
zero (M11) the exhaust differential pressure
<Euro5> sensor ambient air temperature is
between 75 to 84°C.
re (M12)
<Euro5>
<Euro5> between 85 and 94°C.
re (M13)
<Euro5>
re (M14)
<Euro5>
13A-570 DIESEL FUEL
TROUBLESHOOTING
m n item numerical
No. value
re (M15)
<Euro5>
318 DPF Indicating DPF regeneration On DPF regeneration Indicating DPF
regenerati remaining time. If DPF regeneration
on temperature is low, numerical remaining time
remaining value is not reduced.
time
<Euro5>
321 DPF Showing whether DPF Ignition switch: ON ON (during
regenerati regeneration is being performed or DPF
on not. regeneration),
<Euro5> OFF (during
not DPF
regeneration)
328 DPF Showing whether engine-ECU Ignition switch: ON ON (during
regenerati requires DPF regeneration or not. DPF
on request regeneration
<Euro5> request), OFF
(during not
DPF
regeneration
request)
377 Max value Indicating maximum temperature Ignition switch: ON −400 to 2,150
of DPF of DPF regeneration stored in °C
temperatu engine-ECU
re
<Euro5>
384 Odometer Indicates the driving distance at Ignition switch: ON 0 − 1,999,999
at DPF the maximum DPF temperature km
temperatu saved to the engine-ECU.
re max
value
<Euro5>
391 Count of Indicates the DPF regeneration Ignition switch: ON 0 − 65,535
Regenerat request times saved to the engine-
ion ECU.
Request
<Euro5>
DIESEL FUEL
TROUBLESHOOTING
13A-571
m n item numerical
No. value
404 Battery Indicates the learning value of Ignition switch: ON −6 to 6 A
current battery current sensor calibration.
sensor
(learning
value)
<Euro5>
435 Last Indicates the travel distance when Ignition switch: ON 0 − 262,140 km
battery the battery is judged to be low at
deteriorat the last time.
ed
odometer
<Euro5>
436 2nd last Indicates the travel distance when Ignition switch: ON 0 − 262,140 km
battery the battery was judged to be low
deteriorat two times before.
ed
odometer
<Euro5>
437 3rd last Indicates the travel distance when Ignition switch: ON 0 − 262,140 km
battery the battery was judged to be low
deteriorat three times before.
ed
odometer
<Euro5>
452 Battery • Indicates learning conditions of Ignition switch: ON Varies
current battery current sensor depending on
sensor calibration. the learning
(learning • Message "Completed" means conditions
value of learning has been completed.
neutral Message "Not completed"
point) means learning has been not
<Euro5> completed.
454 Battery Indicates the battery deterioration. Ignition switch: ON ON
degrade (deteriorated)*2
judgement , OFF (not
flag deteriorated)
<Euro5>
455 Battery Indicates the battery full charge Ignition switch: ON ON (the battery
full-charge control is being taken. full charge
mode flag control is being
<Euro5> taken.),
OFF (the
battery full
charge control
is not taken.)
13A-572 DIESEL FUEL
TROUBLESHOOTING
m n item numerical
No. value
488 Brake Shows the driving distance when Ignition switch: ON 0 − 1,999,999
override the engine-ECU activates the km
operated previous brake override control.
odometer
<Euro5>
489 Fuel Indicates the final target torque • Engine: After warm-up, idle 0 − 60 Nm
torque operation
target • Lights and all accessories:
OFF
or P range <A/T>
490 Fuel Indicates the pilot injection • Engine: After warm-up, idle 0 − 3 mm3/st
injection quantity operation
quantity • Lights and all accessories:
pilot 1 OFF
or P range <A/T>
pilot 2 OFF
or P range <A/T>
pilot 3 OFF
or P range <A/T>
NOTE: *1: This item is indicated as follows. FF: Initial condition, 0: Non-learning state, 1: Temporary learning
completed status, 2: Learning completed status, 3: Non-learning state.
NOTE: *2: The deterioration level does not request that the battery must be replaced soon.
DIESEL FUEL
TROUBLESHOOTING
13A-573
Actuator Test Reference Table
M1133004400711
Item Check item Drive Inspection Value to be determined Code No. or Reference
No. contents conditions as normal inspection page
procedure
No.
1 Engine Turn the Ignition switch: The warning lamp turns Procedure P.13A-
check lamp warning ON on. No. 2, 3 438,
lamp on or P.13A-441
off
2 Glow lamp Turn the Ignition switch: The glow lamp turns on. − −
glow lamp ON
on or off
3 Glow plug Turning the Ignition switch: Battery charge is − −
relay relay from ON energized to the glow plug
OFF to ON when the glow plug relay
is ON.
4 A/C relay Turning the Ignition switch: The A/C compressor Procedure P.13A-512
relay from ON clutch makes an audible No. 23
OFF to ON sound.
5 Condenser Turning the Ignition switch: The condenser fan rotates Procedure P.13A-507
fan relay relay from ON No. 21
<Vehicles OFF to ON
with A/C
condenser
fan>
15 Injector No. 1 Cut off No. 1 • Ignition ON → Engine is Code No. P.13A-158
injector switch: ON OFF changed P0201
• Engine: Idling (becomes
• Vehicle unstable)
speed: 0 km/
h
• Ignition OFF → The solenoid
switch: ON ON of Injector is
• Engine: not driven.
running
injector switch: ON OFF changed P0202 <Euro5>,
• Engine: Idling (becomes P.13A-164
• Vehicle unstable) <Except
speed: 0 km/ Euro5>
h
running
13A-574 DIESEL FUEL
TROUBLESHOOTING
procedure
No.
speed: 0 km/ Euro5>
h
running
speed: 0 km/ Euro5>
h
running
19 Suction Turn the • Ignition The suction control valve Code No. P.13A-26,
control valve suction switch: ON of supply pump is driven. P0003, P.13A-29,
control valve • Engine: not P0004, P.13A-63
from OFF to running P0089 <Euro5>
ON <Euro5>
P.13A-63,
P0089,
P.13A-
P0628,
276,
P0629
<Except P.13A-279
Euro5> <Except
Euro5>
25 EGR valve 0 Lift position • Ignition EGR valve lift driven into − −
% reaches 0 % switch: ON 0% position
• Engine: Idling
• Vehicle
speed: 0 km/
h
26 EGR valve Lift position • Ignition EGR valve lift driven into − −
50 % reaches 50 switch: ON 50% position
% • Engine: Idling
• Vehicle
speed: 0 km/
h
DIESEL FUEL
TROUBLESHOOTING
13A-575
procedure
No.
27 EGR valve Lift position • Ignition EGR valve lift driven into − −
100 % reaches 100 switch: ON 100% position
% • Engine: Idling
• Vehicle
speed: 0 km/
h
28 Throttle Throttle • Ignition Throttle valve is driven − −
valve 0 deg valve is 0 switch: ON into 0 deg position
deg open • Engine: not
running
running
running
36 Variable Turn the Engine: Idling Variable geometry Code No. P.13A-34,
geometry variable actuator is operated. P0047, P.13A-40
control geometry P0048
solenoid control
valve solenoid
<Euro5> valve from
OFF to ON
44 DPF lamp Turn the Ignition switch: Turn the DPF lamp on. Procedure P.13A-537
<Euro5> DPF lamp ON No. 29
on
CHECK AT THE ECU TERMINALS NOTE: .

M1133004500901 1. Make the voltage measurement with the
TERMINAL VOLTAGE CHECK CHART engine-ECU connector connected.
WARNING 2. You may find it convenient to pull out the
A high-tension voltage is flowing between engine-ECU to make it easier to reach the
the engine-ECU and the injectors while the connector terminals.
engine is running. Handle them carefully to 3. The chart procedures do not have the particu-
avoid receiving electric shocks from the volt- lar order.
age. CAUTION
1. Connect a needle-nosed wire probe to a voltmeter Short-circuiting the positive (+) probe between a
probe. connector terminal and earth could damage the
2. Insert the needle-nosed wire probe into each of vehicle wiring, the sensor, engine-ECU or all of
the engine-ECU connector terminals from the wire them. Be careful to prevent this!
side, and measure the voltage while referring to 3. If voltmeter shows any division from standard
the check chart. value, check the corresponding sensor, actuator
and related electrical wiring, then repair or
replace.
13A-576 DIESEL FUEL
TROUBLESHOOTING
4. After repair or replacement, recheck with the

voltmeter to confirm that the repair has corrected
the problem.
Engine-ECU Connector Terminal Arrangement

Engine-ECU connector
D-213 D-215
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24 92103104105106107108109110
93 94 95 96 97 98111112113100 114115
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
10191
102 99 129130101
118119120121122123124125126127128
102 103 104 105 106 107 108 109
116 117 110 111
112 113 114 115 116 117 118 119
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 131132133134135136137138139140 141142143
128 129 130
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 144120
145121146147148149150151152153154155156
122 123 124 125 126 127 157158
AK800887AB
Terminal Check item Inspection condition (engine status) Normal condition:

No.
6 PTC heater control • Heater temperature setting: Maximum System voltage
signal <Vehicles • Blower fan: ON
with PTC heater> Other than the above 1 V or less
8 A/C switch Engine: Idle speed A/C switch: OFF 1 V or less
(after warning up) A/C switch: ON (A/C System voltage
compressor in
operation)
9 Back-up lamp shift Ignition switch: ON Shift position: Reverse System voltage
switch Shift position: Except 1 V or less
<M/T> reverse
10 Rear window Engine: Idling after Rear window defogger: 1 V or less
defogger relay warning up the OFF
<Euro5> engine Rear window defogger: System voltage
ON
11 1st and 2nd shift Ignition switch: ON Shift position: 1st System voltage
switch Shift position: Except 1 V or less
<M/T> 1st
12 A/C load signal • Engine: Idling A/C compressor clutch 1 V or less
<Vehicles with after warning up not in operation
automatic A/C> the engine A/C compressor clutch 1 V or less ⇔ System
• A/C switch: ON in operation voltage (Changes
repeatedly)
13 4LLC switch <M/T- Ignition switch: ON Shift position: Except 1 V or lower
high power engine 4LLC
vehicle> Shift position: 4LLC System voltage
17 Variable geometry Ignition switch: ON System voltage
solenoid control Engine: Acceleration Changed in accordance
valve <Euro5> with amount of depression
of accelerator pedal
DIESEL FUEL
TROUBLESHOOTING
13A-577
No.
19 A/C compressor Engine: Idle speed A/C switch: OFF System voltage
relay (after warning up) A/C switch: ON (A/C 1 V or less
compressor in
operation)
20 Glow plug relay Ignition switch: OFF Engine coolant 1 V or less → System
<Except Euro5> → ON temperature: lower than voltage (after several
60 °C seconds have elapsed)
Engine coolant System voltage
temperature: higher
than 60 °C
21 Condenser fan relay Engine: Idling after A/C switch: OFF System voltage
<Vehicles with A/C warming up the A/C switch: ON 1 V or less ⇔ System
condenser fan> engine voltage (Changes
repeatedly)
22 Glow lamp • Ignition switch: OFF → ON 1 V or lower → System
• Engine coolant temperature: lower than voltage (after several
60°C seconds have elapsed)
36 EGR gas Engine: Idling after Intake air temperature: 4.2 − 4.6 V
temperature sensor warming up the 20 °C
<Euro5> engine Intake air temperature: 3.7 − 4.1 V
50 °C
Intake air temperature: 2.7 − 3.1 V
100 °C
200 °C
400 °C
37 Manifold absolute Ignition switch: ON 0.7 − 1.2 V
pressure sensor Engine: Acceleration Increases
38 No. 2 intake air Ignition switch: ON Intake air temperature: 4.0 − 4.6 V
temperature sensor −20 °C
<Except Euro5> Intake air temperature: 3.1 − 3.7 V
0 °C
20 °C
40 °C
60 °C
80 °C
13A-578 DIESEL FUEL
TROUBLESHOOTING

No.
39 Battery temperature Ignition switch: ON Battery temperature 3.9 − 4.5 V
sensor <Euro5> ambient air
temperature: −20 °C
Battery temperature 3.2 − 3.8 V
ambient air
temperature: 0 °C
ambient air
temperature: 20 °C
ambient air
temperature: 40 °C
ambient air
temperature: 60 °C
ambient air
temperature: 80 °C
40 Throttle position • Remove the Fully close the throttle 0.3 − 0.7 V
sensor intake air hose at valve with your finger
the throttle body Fully open the throttle 4.0 V or more
• Disconnect the valve with your finger
connector of the
electronic-
controlled throttle
valve
tool test harness
(MB991658)
bridge only the
mating terminals
of No. 1, No. 2,
and No. 4 of the
disconnected
connectors
ON (engine
stopped)
43 PTC heater relay 1 • Engine coolant temperature: lower than 1 V or less
<Vehicles with PTC 75°C
heater> • Heater temperature setting: Maximum
• Blower fan: ON
• 2 seconds later after the engine has start
up
Other than the above System voltage
DIESEL FUEL
TROUBLESHOOTING
13A-579
No.
44 PTC heater relay 2 • Engine coolant temperature: lower than 1 V or lower
<Vehicles with PTC 75°C
heater> • Heater switch (warm up switch) is ON or
vehicle speed is 20 km/h or more
• Blower fan: ON
• Heater temperature setting: Maximum
• 2 seconds later after the engine has start
up
• The PTC heater 1 has been ON
Other than the above System voltage
46 Engine check lamp Ignition switch: LOCK (OFF) → ON 1 V or lower → System
voltage (after 5 seconds
have elapsed)
47 DPF lamp Ignition switch: LOCK (OFF) → ON 1 V or lower → System
voltage (after 5 seconds
have elapsed)
55 Fuel temperature Ignition switch: ON Fuel temperature: −20 3.9 − 4.5 V
sensor °C
Fuel temperature: 0 °C 3.1 − 3.7 V
56 Exhaust differential • Remove the Leave each end open. 0.5 − 1.5 V
pressure sensor pressure hoses, Connect a manual Changes depending on
<Euro5> which are pump (pressure- the pressure
connected to application type) to the
each end of the nipple on one side, and
exhaust apply pressure.
differential
pressure sensor.
ON
57 Exhaust gas Engine: Idling (after warning up) 2.0 V or more
recirculation Engine: 3,500 r/min (after warning up) 1.5 V or less
position sensor
58 No. 1 exhaust gas Engine: Idling after Exhaust gas 4.0 − 4.6 V
temperature sensor warming up the temperature: 200 °C
<Euro5> engine Exhaust gas 2.4 − 3.0 V
temperature: 400 °C
Exhaust gas 1.2 − 1.8 V
Exhaust gas 0.5 − 1.1 V
13A-580 DIESEL FUEL
TROUBLESHOOTING

No.
59 No. 2 exhaust gas Engine: Idling after Catalyst temperature: 4.0 − 4.6 V
temperature sensor warming up the 200 °C
(catalyst engine Catalyst temperature: 2.4 − 3.0 V
temperature) 400 °C
<Euro5>
Catalyst temperature: 1.2 − 1.8 V
600 °C
Catalyst temperature: 0.5 − 1.1 V
800 °C
60 No. 3 exhaust gas Engine: Idling after DPF temperature: 200 4.0 − 4.6 V
temperature sensor warming up the °C
(DPF temperature) engine DPF temperature: 400 2.4 − 3.0 V
<Euro5>
°C
DPF temperature: 600 1.2 − 1.8 V
°C
DPF temperature: 800 0.5 − 1.1 V
°C
62 No. 1 intake air Ignition switch: ON Intake air temperature: 4.0 − 4.6 V
temperature sensor −20 °C
0 °C
20 °C
40 °C
60 °C
80 °C
63 Engine coolant Ignition switch: ON Engine coolant 4.4 − 4.9 V
temperature sensor temperature: −20 °C
Engine coolant 4.4 − 4.6 V
temperature: 0 °C
temperature: 20 °C
temperature: 40 °C
temperature: 60 °C
temperature: 80 °C
64 Rail pressure Engine: Idling (after warning up) 1.15 − 1.75 V
sensor
66 Camshaft position Engine: Cranking 0.1 − 3.0 V*
sensor Engine: Idling 0.5 − 1.5 V*
DIESEL FUEL
TROUBLESHOOTING
13A-581
No.
67 Crank angle sensor Engine: Cranking 1.5 − 4.5 V*
Engine: Idling 2.5 − 3.5 V*
68 Crank angle sensor Ignition switch: ON 4.9 − 5.1 V
power supply
69 Camshaft position Ignition switch: ON 4.9 − 5.1 V
sensor power
supply
70 Rail pressure Ignition switch: ON 4.9 − 5.1 V
sensor power
supply
71 Exhaust gas Ignition switch: ON 4.9 − 5.1 V
recirculation
position sensor
power supply
72 Manifold absolute Ignition switch: ON 4.9 − 5.1 V
pressure sensor
power supply
93 Throttle position Ignition switch: ON 4.9 − 5.1 V
sensor power
supply
94 Exhaust differential Ignition switch: ON 4.9 − 5.1 V
pressure sensor
power supply
<Euro5>
101 Battery Ignition switch: ON System voltage
102
103 Backup power Ignition switch: "LOCK" (OFF) System voltage
supply
104 Ignition switch-IG Ignition switch: ON System voltage
110 Fuel filter pressure Engine: Idling (after warning up) System voltage
switch <Vehicles for • Engine: Acceleration 1 V or less
Russia and • Squeeze the fuel hose with one's fingers at
Morocco> the inlet side of the fuel filter.
111 Ignition switch-ST Engine: Cranking System voltage
114 Throttle valve Engine: Stopped from idling speed Voltage changed for few
control servo seconds
(positive)
115 Exhaust gas Engine: Idling (after warning up) 1 − 3 V*
recirculation motor Engine: 3,500 r/min (after warning up) 1.0 V or less
(positive)
118 Engine control relay Ignition switch: "LOCK" (OFF) System voltage
Ignition switch: ON 1 V or less
13A-582 DIESEL FUEL
TROUBLESHOOTING

No.
120 Glow control unit Engine: Idling Engine coolant System voltage
<Euro5> temperature: lower than
40°C
Engine coolant 1 V or less
temperature: lower than
80°C
121 Alternator G • Engine: Idle operation after warm-up Voltage increase
terminal <Euro5> • Head lamp switch: OFF → ON
• Rear window defogger switch: OFF → ON
125 Blower switch Engine Idle speed Blower fan: OFF 1 V or less
<Euro5> (after warning up) Blower fan: ON System voltage
126 Glow diagnostic Engine: Idling Engine coolant System voltage
signal <Euro5> temperature: lower than
40°C
Engine coolant 1 V or less
temperature: lower than
80°C
127 Power steering fluid Engine: Idling When steering wheel is System voltage
pressure switch stationary
When steering wheel is 1.0 V or less
turned
129 Throttle valve Engine: Stopped from idling speed Voltage changed for few
control servo seconds
(negative)
131 Suction control Engine: Idling 5 − 6 V*
valve (positive) Engine: Acceleration Decreases
134 Accelerator pedal Ignition switch: ON 4.9 − 5.1 V
position sensor
(sub) power supply
135 Accelerator pedal Ignition switch: ON Release the accelerator 0.2 − 0.8 V
position sensor pedal
(sub) Depress the accelerator 2.0 V or more
pedal fully
138 Battery current The battery is being discharged. The value changes by the
sensor <Euro5> • Engine: Cranking value less than 3.5 V.
The battery is being charged. The value changes by the
• Leave the ignition switch being in the ON value more than 3.5 V*2
position for several minutes, and then after
the engine start.
140 Air flow sensor Engine: Gradually increase the speed Voltage increase
141 Vehicle speed • Ignition switch: ON 0 ⇔ 5 V (Changes
sensor • Move the vehicle forward slowly repeatedly)
148 Battery current Ignition switch: ON 4.9 − 5.1 V
sensor power
supply <Euro5>
DIESEL FUEL
TROUBLESHOOTING
13A-583
No.
149 Accelerator pedal Ignition switch: ON 4.9 − 5.1 V
position sensor
(main) power supply
150 Accelerator pedal Ignition switch: ON Release the accelerator 0.7 − 1.3 V
position sensor pedal
(main) Depress the accelerator 4.0 V or more
pedal fully
NOTE: *:The average voltage is shown when an NOTE: .
analog voltmeter is used (because the average volt- 1. When measuring resistance and checking
age might not be shown stably when digital voltmeter continuity, a harness for checking contact pin
is used). pressure should be used instead of inserting a
test probe.
CHECK CHART FOR RESISTANCE AND 2. The chart procedures do not have the particu-
CONTINUITY BETWEEN TERMINALS lar order.
1. Turn the ignition switch to "LOCK" (OFF) position. CAUTION
2. Disconnect the engine-ECU connector. If the terminals that should be checked are mis-
3. Measure the resistance and check for continuity taken, or if connector terminals are not correctly
between the terminals of the engine-ECU shorted to earth, damage may be caused to the
harness-side connector while referring to the vehicle wiring, sensors, engine-ECU and/or ohm-
check chart. meter. Be careful to prevent this!
4. If the ohmmeter shows any deviation from the
standard value, check the corresponding sensor,
actuator and related electrical wiring, and the
repair or replace.
5. After repair or replacement, recheck with the
ohmmeter to confirm that the repair or
replacement has corrected the problem.
13A-584 DIESEL FUEL
TROUBLESHOOTING
Engine-ECU Harness Side Connector Terminal Arrangement

Engine-ECU harness side connector
D-215 D-213
115 114 113 112 111 110 109 108 107 106 105 104 103 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
117 116
143 142 141 140 139138 137 136 135 134 133 132 131 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
AK800888 AB
Terminal No. Inspection item Normal condition (Check condition)

1−2 No. 1 injector Approximately 0.45 Ω (at 20°C)
73 − 75 No. 2 injector
<Euro5>
25 − 75 <Except
Euro5>
<Euro5>
25 − 50 <Except
Euro5>
<Euro5>
1 − 27 <Except
Euro5>
17 − 101 Variable geometry control solenoid 10 − 14 Ω (at 20°C)
valve <Euro5>
30 − 36 EGR gas temperature sensor 55 − 78 kΩ (at −20°C)
<Euro5> 29 − 41 kΩ (at 0°C)
17 − 23 kΩ (at 20°C)
10 − 14 kΩ (at 40°C)
7.1 − 8.8 kΩ (at 60°C)
4.8 − 5.9 kΩ (at 80°C)
32 − 38 No. 2 intake air temperature sensor 13 − 18 kΩ (at −20°C)
<Except Euro5> 5.1 − 6.9 kΩ (at 0°C)
2.0 − 3.0 kΩ (at 20°C)
0.9 − 1.5 kΩ (at 40°C)
0.40 − 0.78 kΩ (at 60°C)
0.23 − 0.42 kΩ (at 80°C)
39 − 155 Battery temperature sensor <Euro5> 4.9 − 5.3 kΩ (at 0°C)
2.2 − 2.6 kΩ (at 20°C)
1.0 − 1.4 kΩ (at 40°C)
55 − 79 Fuel temperature sensor 2.0 − 3.0 kΩ (at 20 °C)
58 − 82 No. 1 exhaust gas temperature 120 − 560 kΩ (at 20°C)
sensor
<Euro5>
DIESEL FUEL
TROUBLESHOOTING
13A-585
Terminal No. Inspection item Normal condition (Check condition)
sensor (catalyst temperature)
<Euro5>
sensor (DPF temperature)
<Euro5>
62 − 86 No. 1 intake air temperature sensor 13 − 18 kΩ (at −20°C)
4.8 − 7.0 kΩ (at 0°C)
2.1 − 2.8 kΩ (at 20°C)
0.9 − 1.5 kΩ (at 40°C)
0.47 − 0.69 kΩ (at 60°C)
0.27 − 0.39 kΩ (at 80°C)
63 − 87 Engine coolant temperature sensor 14 − 17 kΩ (at −20°C)
5.1 − 6.5 kΩ (at 0°C)
2.1 − 2.7 kΩ (at 20°C)
0.9 − 1.3 kΩ (at 40°C)
0.48 − 0.68 kΩ (at 60°C)
0.26 − 0.36 kΩ (at 80°C)
116 − Body Engine-ECU earth Continuity (2 Ω or less)
earth
117 − Body
earth
145 − Body
earth
114 − 129 Throttle valve control servo 0.3 − 100 Ω (at 20 °C)
131 − 146 Suction control valve Approximately 2.1 Ω (at 20°C)
INSPECTION PROCEDURE USING CAMSHAFT POSITION SENSOR AND

OSCILLOSCOPE CRANK ANGLE SENSOR
M1133004600588
The output signals of the sensors and the conditions Measurement Method
of the actuation signals of the actuators can be Crank angle sensor
inspected visually by observing the waveforms on connector
the oscilloscope. Special patterns
1 2 3 pick-up Oscilloscope
1 2 3
Camshaft position
sensor connector
AK501436 AB
1. Disconnect the camshaft position sensor harness (MB991709) in between (All terminals
connector and connect the special tool test should be connected).
13A-586 DIESEL FUEL
TROUBLESHOOTING
2. Connect the oscilloscope special pattern pickup to 2. Connect the oscilloscope special pattern pickup to
camshaft position sensor terminal No. 2. engine-ECU terminal No. 67 (When checking the
3. Disconnect the crank angle sensor intermediate crank angle sensor signal wave pattern.)
connector and connect the special tool test
harness (MB991709) in between. Standard Wave Pattern
4. Connect the oscilloscope special pattern pickup to Observation conditions
crank angle sensor terminal No. 2. Function Special patterns
Alternate Method (Test harness not available) Pattern height Low
1. Connect the oscilloscope special pattern pickup to Pattern selector Display
engine-ECU terminal No. 66 (When checking the Engine speed Idle
camshaft position sensor signal wave pattern.)
Standard Wave Pattern
(V) 2 engine revolutions

(1 camshaft revolution)
Crank angle
sensor output
wave pattern 5
Camshaft
position 5
sensor output
wave pattern
0
Time
AK501437AB
Wave Pattern Observation Points Wave pattern characteristics

• Check that cycle time T becomes shorter when Rectangular wave pattern is output even when
the engine speed increases. the engine is not started.
•
Examples of Abnormal Wave Patterns

•
AK501439
AK501438
Example 2
Cause of problem
Example 1
Loose timing belt
Cause of problem Abnormality in sensor disk
Sensor interface malfunction
Wave pattern characteristics
DIESEL FUEL
TROUBLESHOOTING
13A-587
Wave pattern is displaced to the left or right. 1. Disconnect the suction control valve connector,
and then connect the special tool test harness
SUCTION CONTROL VALVE (MB991658) in between (All terminals should be
Measurement Method connected).
2. Connect the oscilloscope special pattern pickup to
Oscilloscope terminal No. 1, of the suction control valve
connector.
Alternate Method (Test harness not available)

1 2
1. Connect the oscilloscope special pattern pickup to
Special engine-ECU terminal No. 131.
patterns
pickup
AK900016 AB

(V)
Time
0
AK501441 AB
Observation conditions
Function Special patterns
Pattern height Variable
Variable knob Adjust while viewing
the wave pattern
Pattern selector Display
Engine Idle
Engine load is high
AK501442 AB
Wave Pattern Observation Points

When fuel pressure rises while the engine load is
high, the driving time of the suction control valve
becomes short.
13A-588 DIESEL FUEL
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
EVACUATION OF WATER FROM FUEL
Hand pump
FILTER
M1133001200406
Air plug
<Vehicles with steel fuel filter case>
Water is in the fuel filter when fuel filter indicator
lamp illuminates. Evacuate water by the following
procedures.
Hand pump AC503662AB
1. Remove the fuel filter air plug and O-ring

<Vehicles with air plug>.
2. Cover the circumference of the air plug hole with
cloth and use a hand pump repeatedly until no
bubbles come out of the air plug hole <Vehicles
Drain plug with air plug>.
AC506328AB
3. Replace the air plug and O-ring with a new one.
1. Loosen the drain plug. Tighten the air plug to the specified torque
2. After water is evacuated by using an hand pump, <Vehicles with air plug>.
tighten the drain plug. Tightening torque: 5.0 ± 1.0 N⋅m
4. Repeat until the hand pump operation becomes
<Vehicles with plastic fuel filter case> stiff.
Water is in the fuel filter when fuel filter indicator
lamp illuminates. Evacuate water by the following <Vehicles with plastic fuel filter case>
procedures.
When the following service work(s) is done, refill the
fuel tank and then evacuate air from the fuel line.
• Fuel hose or pipe is removed
Hand pump • Fuel filter is replaced
• Fuel injector is removed
• If necessary for access, fuel is drained from the
fuel tank.
Drain plug
Hand pump
ACB01923AB
1. Loosen the drain plug.

2. After water is evacuated by using an hand pump,
tighten the drain plug.
EVACUATION OF AIR FROM FUEL LINE

M1133001300362 ACB01924AB

1. Repeat until the hand pump operation becomes
When the following service work(s) is done, refill the stiff.
fuel tank and then evacuate air from the fuel line.
• Fuel hose or pipe is removed FUEL FILTER REPLACEMENT
• Fuel filter is replaced M1133010800387
• Fuel injector is removed <Vehicles with steel fuel filter case>
• If necessary for access, fuel is drained from the Refer to GROUP 13B − Fuel Filter .
fuel tank.
DIESEL FUEL
ON-VEHICLE SERVICE
13A-589
<Vehicles with plastic fuel filter case> CAUTION
Refer to GROUP 13B − Fuel Filter . Before connecting or disconnecting the M.U.T.-
III, turn the ignition switch to the "LOCK" (OFF)
FUEL LINE LEAK CHECK position.
M1133011700189
NOTE: Since the fuel injection pipe connection on <LH drive vehicles>
the fuel injector assembly side is located inside the
engine (rocker cover), visual check for fuel leak can-
not be performed. Due to this, use the oil leak detec-
tion agent to check for fuel leak. As for other fuel
injection pipe and the fuel supply pump pipe connec-
Diagnosis
tion, visually check for fuel leak. connector
NOTE: The oil leak detection agent detects oil leak
by colour change when it is applied to the area to be MB991910
checked. For details on how to use the product, refer
to the instruction manual.
MB991824
1. Remove the engine cover assembly upper (Refer
to GROUP 11A − Engine Assembly ).
CAUTION
Degrease the area between the flare nut and the
pipe of the fuel injection pipe by fully spraying
the parts cleaner.
Rocker cover
MB991827 AC509179AB
Fuel <RH drive vehicles>

injection Diagnosis
pipe connector
Flare nut ACA00283 AC

MB991910
2. Carefully degrease the flare nut at the fuel injector
assembly side of the fuel injection pipe with parts
cleaner (MZ100387) or equivalent. MB991824
3. If the parts cleaner remains in the area between
the flare nut for connection and the fuel injection
pipe, the oil leak detection agent detects that
there is a fuel leak. Therefore, use an air gun to
blow off the remaining parts cleaner and fully dry
the degreased area.
4. Apply the oil leak detection agent to the flare nut
and the pipe of the fuel injection pipe. MB991827 AC501413AC
NOTE: It is easy to detect the oil leak when the oil
leak detection agent is dry enough because the 5. Ensure that the ignition switch is at the "LOCK"
colour changes clearly. Use a dryer to dry the oil (OFF) position.
leak detection agent when it is hard to dry. 6. Start up the personal computer.
7. Connect special tool M.U.T.-III USB cable
(MB991827) to V.C.I. (MB991824) and the
personal computer.
8. Connect special tool M.U.T.-III main harness A
(MB991910) to the V.C.I.
13A-590 DIESEL FUEL
ON-VEHICLE SERVICE
9. Connect the M.U.T.-III main harness A to the 16.Turn the ignition switch to the "LOCK" (OFF)
diagnosis connector of the vehicle. position, and stop the engine.
10.Turn the V.C.I. power switch to the "ON" position. 17.Disconnecting the M.U.T.-III is the reverse of the
NOTE: When the V.C.I. is energized, the V.C.I. connecting sequence.
indicator lamp will be illuminated in a green col- 18.Check the colour change of the oil leak detection
our. agent at the flare nut and pipe of the fuel injection
11.Start the M.U.T.-III system on the personal pipe to check if the fuel is leaking from the fuel
computer and turn the ignition switch to the "ON" injection pipe connection at the fuel injector
position. assembly side.
12.Start the engine, and let it run at idle. 19.Visually check other fuel line connections for fuel
13.Select "MPI/GDI/DIESEL" from System select leak.
Screen of the M.U.T.-III. 20.If the fuel is leaking, replace the fuel injection pipe
and the fuel supply pump pipe. (Refer to P.13A-
14.Select "SPECIAL FUNCTION" from MPI/GDI/
DIESEL Screen. 604.)
15.Select "FUEL LEAKAGE CHECK" from Test 21.If the fuel is not leaking, wipe off the oil leak
Screen. Carry out the fuel leakage check (during detection agent using parts cleaner (MZ100387)
the test, the engine speed and the fuel pressure is or equivalent completely.
2,000 r/min and 180 MPa for 20 seconds 22.Install the engine cover assembly upper (Refer to
respectively) five times in a row (20 seconds × 5 GROUP 11A − Engine Assembly ).
times = 100 seconds).
COMPONENT LOCATION
M1133004700660
Name Symbol Name Symbol

Accelerator pedal position sensor V 1st and 2nd rail switch <M/T> R
A/C compressor relay Q Fuel filter pressure switch <Vehicle for I
Russia and Morocco>
A/C switch Y Fuel temperature sensor N
Air flow sensor (incorporating intake air J Glow control unit <Euro5> I
temperature sensor No. 1)
Back-up lamp switch <M/T> S Glow plug relay <Except Euro5> I
Battery current sensor (incorporating P Injector C
battery temperature sensor) <Euro5>
Camshaft position sensor E Intake air temperature sensor No. 2 G
<Except Euro5>
Crank angle sensor M Manifold absolute pressure sensor G
Diagnosis connector X No. 1 exhaust gas temperature sensor B
<Euro5>
DPF lamp <Euro5> W No. 2 exhaust gas temperature sensor a
(catalyst temperature) <Euro5>
EGR gas temperature sensor <Euro5> D No. 3 exhaust gas temperature sensor b
(DPF temperature) <Euro5>
EGR valve (DC motor) (incorporating F Power steering fluid pressure switch K
EGR valve position sensor)
Electronic-controlled throttle valve G PTC heater relay 1,2 <Vehicles with PTC H
(incorporating throttle position sensor) heater>
Engine-ECU Z Rail pressure sensor E
Engine control relay Q Starter relay Q
DIESEL FUEL
ON-VEHICLE SERVICE
13A-591
Name Symbol Name Symbol
Engine coolant temperature sensor O Suction control valve L
Engine warning lamp (check engine U Variable geometry control solenoid valve L
lamp) <Euro5>
Exhaust differential pressure sensor A Vehicle speed sensor <2WD-M/T, 4WD> T
<Euro5>
A B C D E F G H I
J K L M N O P Q
AKB00282AB
13A-592 DIESEL FUEL
ON-VEHICLE SERVICE
<2WD-M/T> <4WD-M/T> <4WD-A/T>
R S T R S T T
<L. H. drive vehicles> <R. H. drive vehicles>
U V W X Y Z Z Y X U W V
a b
AKB00329 AB
DIESEL FUEL
ON-VEHICLE SERVICE
13A-593
ENGINE CONTROL RELAY CONTINUITY 1. Remove the engine coolant temperature sensor
CHECK using the special tool engine coolant temperature
M1133008300459 sensor wrench (MB992042).
Engine control
relay
1 2
3
4
Equipment side
connector AK501444 AB AKX01622
Tester Battery Voltage Normal State 2. With temperature sensing portion of engine
Connection coolant temperature sensor immersed in hot
Terminal water, check resistance.
1−2 No voltage Continuity Standard value:
3−4 No voltage No continuity 14 − 17 kΩ (at −20°C)
5.1 − 6.5 kΩ (at 0°C)
Voltage (Connect Continuity (2 Ω
2.1 − 2.7 kΩ (at 20°C)
positive (+) terminal of or less)
0.9 − 1.3 kΩ (at 40°C)
battery to terminal No.
0.48 − 0.68 kΩ (at 60°C)
1 and negative (−)
0.26 − 0.36 kΩ (at 80°C)
terminal of battery to
terminal No. 2.) 3. If the resistance deviates from the standard value
greatly, replace the sensor.
ENGINE COOLANT TEMPERATURE
SENSOR CHECK
M1133005000404
Engine coolant
temperature sensor
AKX01623AD
1 2
4. Apply sealant to threaded portion.
Equipment side
connector AK501445AB Specified sealant:
3M NUT Locking Part No. 4171 or equivalent
5. Tighten the engine coolant temperature sensor to
MB992042 the specified torque, using engine coolant
temperature sensor wrench, special tool
(MB992042).
AK503116 AC
13A-594 DIESEL FUEL
ON-VEHICLE SERVICE
INJECTOR CHECK
M1133008100314
Injector
No. 1 intake
1 2 air temperature
sensor AK603026AB
Equipment side
connector AKA00359AB 4. Measure resistance while heating the sensor
using a hair drier.
1. Disconnect the injector connector.
Normal condition:
2. Measure the resistance between terminals No. 1
and No. 2. Temperature (°C) Resistance (kΩ)
Standard value: Approximately 0.45 Ω (at Higher Smaller
20°C)
5. If the value deviates from the standard value or
3. If not within the standard value, replace the the resistance remains unchanged, replace the air
injector. After replacing the injector, register the flow sensor assembly.
injector identification code and learn fuel injection.
6. Install the air flow sensor and tighten it to the
specified torque.
Service − What The common Rail Engine Learns
). Tightening torque: 0.7 ± 0.1 N⋅m
INTAKE AIR TEMPERATURE SENSOR No. INTAKE AIR TEMPERATURE SENSOR No.
1 CHECK 2 CHECK <Except Euro5>
M1133010400301
M1133010300296
1 2 3 4 5 sensor No.2
Equipment side
connector
Air flow sensor

(incorporating intake
air temperature sensor
No.1)
1 2
Equipment side
AKA00360 AB
1. Disconnect the air flow sensor connector. 1. Disconnect the intake air temperature sensor No.
2 connector.
2. Measure resistance between terminals No. 1 and
No. 2. 2. Measure resistance between terminals No. 1 and
No. 2.
Standard value:
13 − 17 kΩ (at −20°C) Standard value:
5.4 − 6.6 kΩ (at 0°C) 13 − 18 kΩ (at −20°C)
2.3 − 3.0 kΩ (at 20°C) 5.1 − 6.9 kΩ (at 0°C)
1.0 − 1.5 kΩ (at 40°C) 2.0 − 3.0 kΩ (at 20°C)
0.56 − 0.76 kΩ (at 60°C) 0.9 − 1.5 kΩ (at 40°C)
0.31 − 0.43 kΩ (at 80°C) 0.40 − 0.78 kΩ (at 60°C)
0.23 − 0.42 kΩ (at 80°C)
3. Remove the air flow sensor
3. Remove the intake air temperature sensor No. 2
DIESEL FUEL
ON-VEHICLE SERVICE
13A-595
FUEL TEMPERATURE SENSOR CHECK
Intake air temperature M1133006800317
sensor No.2
1 2
Equipment side
connector
AK501451AB
4. Measure resistance while heating the sensor AK501453 AB

using a hair drier.
1. Disconnect the fuel temperature sensor
Normal condition:
connector.
Temperature (°C) Resistance (kΩ) 2. Measure resistance between terminal No. 1 and
Higher Smaller No. 2
Standard value: Approximately 2.0 − 3.0 kΩ
(at 20 °C)
the resistance remains unchanged, replace the
intake air temperature sensor No. 2 sensor 3. If not within the standard value, replace the supply
assembly. pump assembly. After replacing the supply pump,
6. Install the air flow sensor and tighten it to the learn the supply pump. (Refer to GROUP 00 −
specified torque. Precautions Before Service − What The common
Rail Engine Learns ).
COMMON RAIL CHECK
SUCTION CONTROL VALVE CHECK M1133010600253
M1133010500290
CAUTION
High pressure fuel is supplied to the common
1 2 rail. It is dangerous to remove the rail pressure
Equipment side sensor and rail pressure limiter from the com-
connector mon rail because it may cause fuel leaks. Do not
Suction control
valve remove the rail pressure sensor and rail pressure
limiter from the common rail.
AK501452 AB
1. Disconnect the suction control valve connector.

2. Measure resistance between terminal No. 1 and Common rail
No. 2
Standard value: Approximately 2.1 Ω (at 20
°C)
AK501454AB
3. If not within the standard value, replace the
suction control valve. After replacing the suction 1. Visually check the common rail for cracks,
control valve, learn the supply pump. (Refer to damage, and corrosion.
GROUP 00 − Precautions Before Service − What 2. If an abnormality is found, replace the common
The common Rail Engine Learns ). rail.
13A-596 DIESEL FUEL
ON-VEHICLE SERVICE
THROTTLE VALVE CONTROL SERVO CHECK THE COIL RESISTANCE

CHECK
M1133010700283 1 2 3 4 5 6
OPERATION CHECK Equipment side
1. Remove the air intake hose from the throttle body. connector
2. Turn the ignition switch to "ON" position.

3. Make sure that the throttle valve is open.
4. Turn the ignition switch to "OFF" position. Electronic-controlled
throttle valve
(incorporating throttle
position sensor) AK501458 AB
1. Disconnect the electronic - controlled throttle

valve connector.
2. Measure resistance between terminal No. 5 and
No. 6 at the throttle valve control servo connector.
Standard value: 0.3 − 100 Ω (at 20 °C)
3. If resistance is outside the standard value, replace
the throttle body assembly.
DIESEL FUEL
FUEL INJECTOR
13A-597
FUEL INJECTOR
M1133009400299

• Inlet Manifold Removal (Refer to GROUP 15 − Inlet Mani- • Fuel Injection Pipe Installation (Refer to P.13A-604).
fold ). • Inlet Manifold Installation (Refer to GROUP 15 − Inlet
• Fuel Injection Pipe Removal (Refer to P.13A-604). Manifold ).
<Except Euro5>
N 4 3.0 ± 1.0 N·m to 10 ± 2 N·m

1
5N
10
6
7N
10 9N
8N
15 ± 2 N·m 11 14
15 ± 2 N·m 10 ± 1 N·m to +120˚ – +125˚
N 13
(Engine oil)
15
11 16
12
17
N 13
18 N
10 ± 2 N·m
10 ± 2 N·m
2 AC502869AE
13A-598 DIESEL FUEL
FUEL INJECTOR

• When the fuel injector is replaced, 8. Rocker cover gasket B
register the injector identification 9. Rocker cover gasket C
code and perform the fuel injection >>B<< 10. Semi-circular packing
learning (Refer to GROUP 00 − >>A<< 11. Eye bolt
Precautions before Service, What >>A<< 12. Fuel leakage pipe
the Common Rail Engine Learns ) >>A<< 13. Fuel leak-off gasket
<Installation only>. >>A<< 14. Injector holder bolt
1. Breather hose connection >>A<< 15. Injector supporter
2. Harness bracket >>A<< 16. Pivot boss
3. Timing belt front upper cover >>A<< 17. Fuel injector
>>D<< 4. Oil seal >>A<< 18. Nozzle gasket
>>D<< 5. Oil seal
<<A>> >>C<< 6. Rocker cover assembly
7. Rocker cover gasket A
DIESEL FUEL
FUEL INJECTOR
13A-599
<Euro5>
N 5 3.0 ± 1.0 N·m to 10 ± 2 N·m
8
1
6N
23 ± 6 N·m 12
12
9N
11 N
7 10 N
13 16
15 ± 2 N·m
15 ± 2 N·m 10 ± 1 N·m to +120˚ – +125˚
N 15
(Engine oil)
17
13 18
14
19
N 15
20 N
10 ± 2 N·m
10 ± 2 N·m
3 AC805674 AD

• When the fuel injector is replaced, >>D<< 6. Oil seal
register the injector identification 7. Vacuum pipe and hose assembly
code and perform the fuel injection connection
learning (Refer to GROUP 00 − <<A>> >>C<< 8. Rocker cover assembly
Precautions before Service, What 9. Rocker cover gasket A
the Common Rail Engine Learns ) 10. Rocker cover gasket B
<Installation only>. 11. Rocker cover gasket C
1. Breather hose connection >>B<< 12. Semi-circular packing
2. Harness bracket >>A<< 13. Eye bolt
3. Solenoid valve and harness >>A<< 14. Fuel leakage pipe
bracket assembly >>A<< 15. Fuel leak-off gasket
4. Timing belt front upper cover >>A<< 16. Injector holder bolt
>>D<< 5. Oil seal >>A<< 17. Injector supporter
13A-600 DIESEL FUEL
FUEL INJECTOR
Removal steps (Continued) CAUTION

>>A<< 18. Pivot boss Do not clean the injection part of the nozzle with
>>A<< 19. Fuel injector
a resin spatula.
>>A<< 20. Nozzle gasket
REMOVAL SERVICE POINT

<<A>> ROCKER COVER ASSEMBLY REMOVAL Fuel injector
Timing belt rear cover

Camshaft sprocket mounting bolt
A: Nozzle side face
Injection part of the nozzle AC900270 AB
(1) Using a resin spatula, scrape off the carbon

deposit on the fuel injector nozzle side face
AC502870AB ("A" shown in the figure).
1. Turn the crankshaft clockwise, and remove the

Fuel injector
timing belt rear cover mounting bolts shown in the
figure from the gap of the camshaft sprocket.
9
5 2 8
4
3 AC900203 AB
(2) Spray the carburetor cleaner (MZ100139) or

equivalent to the nozzle side face ("A" shown
7 1 10 6 in the figure).
AC502871AB
CAUTION
2. In the order shown in the figure, loosen the rocker Do not touch the injection part of the nozzle with
cover assembly mounting bolts, and then remove hand or wipe it with a rag.
the rocker cover assembly. (3) Leave the injection part for a while until the
carbon deposit melts down, and then blow air
INSTALLATION SERVICE POINTS to the injection part.
>>A<< NOZZLE GASKET/FUEL INJECTOR/PIVOT
BOSS/INJECTOR SUPPORTER/INJECTOR
HOLDER BOLT/FUEL LEAK-OFF GASKET/FUEL
Cylinder head
LEAKAGE PIPE/EYE BOLT INSTALLATION
1. Clean the fuel injector assembly (nozzle) and the
cylinder head (fuel injector insertion hole) by
following the procedure below.
MB990784
AC900204AB
(4) Insert special tool ornament remover

(MB990784) to the cylinder head (fuel injector
insertion hole) with turning the special tool as
shown, and scrape off the carbon deposit.
DIESEL FUEL
FUEL INJECTOR
13A-601
CAUTION Tightening torque: 10 ± 1 N⋅m
In order to prevent carbon from adhering to the CAUTION
inner surface of the cylinder, blow air with the • If the bolt is tightened less than the specified
piston in the TDC position. lower limit of 120°, the bolt may become
(5) Remove the special tool, and blow off the loose. Be sure to tighten correctly.
carbon deposit on the cylinder head (fuel • If the bolt is tightened in excess of the speci-
injector insertion hole) by air. fied upper limit of 125°, loosen the nut com-
(6) Check that there is no carbon deposit pletely and repeat the entire procedures.
remaining on the contact surface of the fuel
injector nozzle gasket.
NOTE: Repeat step 4 to step 6 several times
until the carbon deposit is completely removed.
MB991614
Injector holder bolt
Fuel injector
Injector supporter
AC502873AB
Pivot boss
8. Using special tool angle gauge (MB991614),
Nozzle tighten the injector holder bolt in the illustrated
gasket sequence by a further 120° to 125°.
AC502872 AB
2. Install the nozzle gasket, fuel injector, pivot boss, >>B<< SEMI-CIRCULAR PACKING
and injector supporter to the cylinder head as INSTALLATION
3. Apply a small amount of engine oil to the seat
surface and thread of injector holder bolt, and Semi-circular packing
then temporarily tighten the bolt to the cylinder
head.
4. Set the fuel leak-off gasket to the fuel leakage
pipe, and temporarily tighten to the fuel injector
and to the cylinder head using the eye bolt.
5. Tighten the eye bolt of the fuel injector side to the
specified torque. AC502874AB
Tightening torque: 15 ± 2 N⋅m Apply specified sealant to portions indicated in illus-

tration.
6. Tighten the eye bolt of the cylinder head side to
the specified torque. Specified sealant: Three bond 1217G or
equivalent
NOTE: Install the semi-circular packing immediately
7. Tighten the injector holder bolt to the specified after applying sealant.
torque.
13A-602 DIESEL FUEL
FUEL INJECTOR
>>C<< ROCKER COVER ASSEMBLY CAUTION

INSTALLATION After the installation, until a sufficient period of
10mm oil or water to the sealant application area or
start the engine.
4. Tighten the rocker cover assembly mounting bolts
to the specified torque in the order shown in the
Semi-
circular
figure again.
10mm
packing Tightening torque: 10 ± 2 N⋅m
Cylinder head
AC502875AB >>D<< OIL SEAL INSTALLATION
1. Apply specified sealant to portions indicated in Socket wrench

illustration. Rocker cover
Specified sealant: Three bond 1217G or

equivalent
NOTE: Install the rocker cover assembly immedi-
ately after applying sealant.
2. Install the rocker cover assembly to the cylinder Oil seal
head. (Engine oil)
AC502876AB
2
6 9 3
Socket wrench
7
8
Oil seal Rocker cover
4 10 1 5
AC502871AC
(Engine oil)
3. Tighten the rocker cover assembly mounting bolts AC502877AB
to the specified torque in the order shown in the Apply engine oil to the oil seal outer surface and
figure. drive in with a socket wrench.
DIESEL FUEL
13A-603
M1133009600389
CAUTION
• The reinstallation histories of the removed fuel injection pipe and fuel supply pump pipe are up to
five times. To count how many times the fuel injection pipe and fuel supply pump pipe are rein-
stalled, record the number of the reinstallation histories on the service booklet by adding this lat-
est number of the histories, which is usually "1", to the previous one. Use a new fuel injection pipe
or fuel supply pump pipe when the total reinstallation history numbers reach five times, or when
the fuel injector assembly, common rail assembly or supply pump assembly is replaced. In this
case, record " a new fuel injection pipe or fuel supply pump pipe, the number of the reinstallation
histories is zero" on the service booklet.
• If a fuel leak is present in the fuel injection pipe and fuel supply pump pipe once, do not reuse it
and replace with a new one.
• If the fuel injector assembly, common rail assembly or supply pump assembly is replaced, the
contact surface (seal surface) between the fuel injection pipe and fuel supply pump pipe, and the
other side component is changed, do not reuse the fuel injection pipe and fuel supply pump pipe
and replace with a new one.
• When the injection pipe is reinstalled, confirm there is no foreign material on the seal surface or in
the pipe and then install it not to deviate from the axis, fitting the seal surface.
• Inlet Manifold Removal (Refer to GROUP 15 − Inlet Mani- • Inlet Manifold Installation (Refer to GROUP 15 − Inlet
fold ). Manifold ).
• Fuel Line Leak Check (Refer to P.13A-590).
<Except Euro5>
20 ± 2 N·m
11 N
17 ± 2 N·m 6
35 ± 5 N·m
8 N
12 10
10 ± 2 N·m 35 ± 5 10 ± 2 N·m
N·m
10 ± 2 N·m
7 35 ± 5 N·m
2 6 35 ± 5 N·m
10 ± 2 N·m 10 ± 2 N·m
4N
1
3 35 ± 5 N·m
9
64 ± 5 N·m
24 ± 4 N·m
24 ± 4 N·m
5
AC502865 AG
13A-604 DIESEL FUEL
Supply pump assembly removal Fuel injection pipe removal

• When the supply pump assembly <> >>B<< 4. Fuel supply pump pipe
is replaced, perform the supply <<C>> >>B<< 6. Fuel injection pipe
pump learning.(Refer to GROUP Common rail assembly removal
00 − Precautions before Service, steps
What the Common Rail Engine 2. Fuel return hose
Learns ) <Installation only>. 3. Fuel inline hose
• Timing belt (Refer to GROUP 11A <> >>C<< 4. Fuel supply pump pipe
− Timing belt ). <<C>> >>A<< 6. Fuel injection pipe
<<A>> >>D<< 1. Injection pump sprocket >>A<< 7. Eye bolt
2. Fuel return hose >>A<< 8. Fuel return gasket
3. Fuel inline hose >>A<< 9. Common rail assembly
<> >>C<< 4. Fuel supply pump pipe >>A<< 10. Eye bolt
>>C<< 5. Supply pump assembly >>A<< 11. Fuel return gasket
Fuel injection pipe removal >>A<< 12. Fuel return pipe
steps
2. Fuel return hose <Euro5>
3. Fuel inline hose
20 ± 2 N·m
12 N
20 ± 2 N·m 6
35 ± 5 N·m
9N
13 11
35 ± 5
10 ± 2 N·m N·m 10 ± 2 N·m
10 ± 2 N·m
35 ± 5
8 N·m 6 35 ± 5 N·m
10 ± 2 N·m
2 7 35 ± 5 N·m
10 ± 2 N·m 10 ± 2 N·m
4N
1
3 35 ± 5 N·m
10
64 ± 5 N·m 24 ± 4 N·m
24 ± 4 N·m
5
AC805678 AB
DIESEL FUEL
13A-605
Supply pump assembly removal 1. Using special tool sprocket holder (MB992048),
steps lock the injection pump sprocket, and then loosen
• When the supply pump assembly the injection pump sprocket mounting nut.
is replaced, perform the supply
pump learning.(Refer to GROUP Injection pump
00 − Precautions before Service, sprocket MB992098
What the Common Rail Engine
Learns ) <Installation only>.
• Timing belt (Refer to GROUP 11A
− Timing belt ).
<<A>> >>D<< 1. Injection pump sprocket
MB992099
2. Fuel return hose
3. Fuel inline hose
<> >>C<< 4. Fuel supply pump pipe AC502178 AB
>>C<< 5. Supply pump assembly
Fuel injection pipe removal 2. Using the special tools below, remove the
steps injection pump sprocket.
2. Fuel return hose • Injection pump sprocket puller (MB992098)
3. Fuel inline hose • Crank pulley puller (MB992099)
<> >>B<< 4. Fuel supply pump pipe
<<C>> >>B<< 6. Fuel injection pipe
Common rail assembly removal <> FUEL SUPPLY PUMP PIPE REMOVAL
steps CAUTION
2. Fuel return hose When removing the fuel supply pump pipe, the
3. Fuel inline hose fuel pressure in the fuel line is high. Thus, wait
<> >>C<< 4. Fuel supply pump pipe for 3 minutes or longer after the engine stops,
<<C>> >>A<< 6. Fuel injection pipe
and cover the fuel supply pump pipe with a rag or
7. Fuel injection pipe bracket
>>A<<
similar materials to prevent the fuel splash, and
8. Eye bolt
>>A<< 9. Fuel return gasket then disconnect the fuel supply pump pipe.
>>A<< 10. Common rail assembly
>>A<<
<<C>> FUEL INJECTION PIPE REMOVAL
11. Eye bolt
>>A<< 12. Fuel return gasket
>>A<< 13. Fuel return pipe

<<A>> INJECTION PUMP SPROCKET REMOVAL
Injection pump
MB992048 sprocket MB992188
AC901507AB
Using special tool fuel injection pipe wrench

(MB992188), remove the fuel injection pipe assem-
bly No.1 to No.4.
AC503013 AB
13A-606 DIESEL FUEL

>>A<< FUEL RETURN PIPE/FUEL RETURN GAS-
KET/EYE BOLT/COMMON RAIL ASSEMBLY/FUEL
INJECTION PIPE INSTALLATION
MB992188
AK600656 AB
Common rail
Fuel return pipe assembly
AC502866AB
1. Temporarily tighten the fuel return pipe with bolts.

2. Tighten the eye bolt and the fuel return gasket
located at the cylinder head side to the specified
torque.
MB992188
Tightening torque:
AK600668 AB
17 ± 2 N⋅m <Except Euro5>
20 ± 2 N⋅m <Euro5> 5. Using special tool fuel injection pipe wrench
CAUTION (MB992188), start tightening the fuel injector
• When operating, do not support the common assembly side flare nut in the fuel injection pipe,
rail assembly by holding the rail pressure lim- and then tighten the fuel injector assembly side
iter and the pressure sensor at both ends. flare nut and common rail assembly side flare nut
alternately in several steps to the specified torque.
• Before the installation, make sure that there is
no foreign object or rust to the thread and to Tightening torque: 35 ± 5 N⋅m
the high-pressure pipe sheet surface. 6. Tighten the common rail assembly to the specified
torque.
Pressure Tightening torque: 24 ± 4 N⋅m
sensor
Pressure limiter 7. Tighten the eye bolt and the fuel return gasket
located at the common rail assembly side to the
specified torque.
Common rail
8. Tighten the fuel return pipe to the specified
torque.
AC502867AB Tightening torque: 10 ± 2 N⋅m
9. Tighten the bolts of the fuel injection pipe to the
3. Temporarily tighten the common rail assembly
specified torque.
with bolts, holding the common rail assembly.
4. Align the fuel injection pipe centre axis with the
other side components (fuel injector assembly 10.Tighten the common rail assembly side flare nut
and common rail assembly) centre axis to install in the fuel supply pump pipe and the supply pump
the fuel injection pipe. Then, tighten the flare nut assembly side flare nut alternately in several
temporarily until the tip of pipe (seal surface) steps to the specified torque.
contacts with the other side components. Tightening torque: 35 ± 5 N⋅m
NOTE: When the fuel injection pipe is installed,
tighten the flare nut while shaking the pipe lightly
to align the centre axis of both components.
DIESEL FUEL
13A-607
>>B<< FUEL INJECTION PIPE/FUEL SUPPLY
PUMP PIPE INSTALLATION
CAUTION
MB992188
Pressure
sensor
Pressure limiter
AK600656 AB
Common rail
AC502867AB
• When operating, do not support the common

rail assembly by holding the rail pressure lim-
iter and the pressure sensor at both ends.
• Before the installation, make sure that there is
no foreign object or rust to the thread and to
the high-pressure pipe sheet surface. MB992188
1. Loosen the common rail assembly mounting bolts AK600668 AB
so that the common rail assembly will be in the

3. Using special tool fuel injection pipe wrench
temporarily installed state.
(MB992188), start tightening the fuel injector
2. Align the fuel injection pipe centre axis with the assembly side flare nut in the fuel injection pipe,
other side components (fuel injector assembly and then tighten the fuel injector assembly side
and common rail assembly) centre axis to install flare nut and common rail assembly side flare nut
the fuel injection pipe. Then, tighten the flare nut alternately in several steps to the specified torque.
temporarily until the tip of pipe (seal surface)
contacts with the other side components.
NOTE: When the fuel injection pipe is installed, 4. Tighten the common rail assembly to the specified
tighten the flare nut while shaking the pipe lightly torque.
to align the centre axis of both components. Tightening torque: 24 ± 4 N⋅m
5. Tighten the common rail assembly side flare nut in
the fuel supply pump pipe and the supply pump
assembly side flare nut alternately in several
steps to the specified torque.
>>C<< SUPPLY PUMP ASSEMBLY/FUEL SUPPLY

PUMP PIPE INSTALLATION
1. Temporarily tighten the supply pump assembly
with bolts.
2. Align the fuel supply pump pipe centre axis with
the other side components (common rail
assembly and supply pump assembly) centre axis
to install the fuel supply pump pipe. Then, tighten
the flare nut temporarily until the tip of pipe (seal
surface) contacts with the other side components.
NOTE: When the fuel supply pump pipe is
installed, tighten the flare nut while shaking the
pipe lightly to align the centre axis of both compo-
nents.
13A-608 DIESEL FUEL
3. Tighten the common rail assembly side flare nut in >>D<< INJECTION PUMP SPROCKET
the fuel supply pump pipe and the supply pump INSTALLATION
assembly side flare nut alternately in several
Injection pump
steps to the specified torque. MB992048 sprocket
4. Tighten the supply pump assembly bolts to the
specified torque.
5. Tighten the fuel supply pump pipe bolt.
AC503013 AB
In the same manner as for removal, using special

tool sprocket holder (MB992048), lock the injection
pump sprocket, and then tighten the injection pump
sprocket mounting nut to the specified torque.
DIESEL FUEL
SUCTION CONTROL VALVE
13A-609
M1133011900213

• Battery and Battery Tray Stay Removal and Installation
(Refer to GROUP 54A − Battery ).
48 ± 6 N·m
(Engine oil)
N7
2 N 6
5
1
8.9 ± 1.9 N·m
4
N3
(Engine oil)
AC704545 AC

• Supply pump assembly correction <<A>> SUCTION CONTROL VALVE/GASKET/O-
learning (Refer to GROUP 00 − RING REMOVAL.
Precautions Refer Service, Supply
Pump Correction Learning 1. Clean the area around the suction control valve
procedure ) <only at installation>. with a cleaner, etc.
1. Battery wiring cable connection CAUTION
2. Engine oil level gauge and guide Pay attention not to let foreign materials get into
assembly the supply pump assembly during and after the
3. O-ring
suction control valve removal.
4. Suction control valve connector
connection 2. Loosen the suction control valve mounting bolts,
<<A>> >>A<< 5. Suction control valve and remove the suction control valve from the
<<A>> >>A<< 6. Gasket supply pump assembly.
<<A>> >>A<< 7. O-ring 3. Remove the gasket
4. Remove the o-ring from the supply pump
assembly.
13A-610 DIESEL FUEL

>>A<< O-RING/GASKET/SUCTION CONTROL
VALVE INSTALLATION Suction control
CAUTION valve connector
• Pay attention not to let the suction control
valve be contaminated with foreign material
when installing it.
• Pay attention not to let foreign materials get
into the supply pump assembly during the Supply pump AC704546AB
suction control valve installation.
1. Fit the O-ring to the O-ring groove on the supply 3. Apply a drop of new engine oil to the O-ring in the
pump assembly. supply pump assembly groove, and insert the
2. Install the gasket to the suction control valve. suction control valve by hands until it contacts
with the supply pump assembly. When inserting
the suction control valve, make sure that the
suction control valve connector is in the direction
CAUTION
Tighten the two suction control valve mounting
bolts evenly.
4. Tighten the suction control valve mounting bolts to
DIESEL FUEL
THROTTLE BODY ASSEMBLY
13A-611
THROTTLE BODY ASSEMBLY
M1133007600435
3.0 ± 0.5 N·m
13 ± 2 N·m
5N
3
6.0 ± 1.0 N·m
AC502843AD

1. Engine cover >>A<< THROTTLE BODY GASKET INSTALLA-
2. Inter cooler outlet air hose TION
connection
3. Throttle body connector
4. Throttle body
>>A<< 5. Throttle body gasket Projection
Throttle body
gasket
Throttle body AC502844AB
Install the throttle body gasket as shown in the illus-

tration.
13A-612 DIESEL FUEL
CAMSHAFT POSITION SENSOR
CAMSHAFT POSITION SENSOR

M1133010000091
(Engine oil)
3N
2
11 ± 1 N·m
AC502938 AC

1. Camshaft position sensor 2. Camshaft position sensor
connector 3. O-ring
CRANK ANGLE SENSOR

M1133010200147

• A/C Compressor Drive Belt Removal and Installation
(Refer to GROUP 11A − Crankshaft Pulley ).
44 ± 8 N·m
N 5
(Engine oil)
4
11 ± 1 N·m
3 2
1
22 ± 4 N·m AC805916 AC
DIESEL FUEL
ENGINE-ECU
13A-613
<<A>> 1. A/C compressor assembly <<A>> A/C COMPRESSOR ASSEMBLY
2. A/C compressor bracket assembly REMOVAL
3. Crankshaft position sensor
connector 1. With the hose installed, remove the A/C
4. Crankshaft position sensor compressor assembly from the bracket.
5. O-ring 2. After removing the A/C compressor assembly,
secure it with a cord in the location where the
removal and installation of the crankshaft position
sensor cannot be hindered.
ENGINE-ECU
M1133009200767
CAUTION
• After having replaced the engine-ECU, use the M.U.T.-III to register the chassis number. [Refer to
GROUP 00 − Precautions before Service, How to perform chassis number (Chassis No.) writing ].
• When the engine-ECU is replaced, register the injector identification code and perform the small
injection quantity learning. (Refer to GROUP 00 − Precautions before Service, What the Common
Rail Engine Learns ).
• When the engine-ECU is replaced, make the battery current sensor learn the neutral point by
using M.U.T.-III (Refer to GROUP 00 − Precautions before Service, Battery Current Sensor Calibra-
tion ) <Euro5>.
<LH drive vehicles>
5.0 ± 2.0 N·m

5.0 ± 2.0 N·m
6
4 5
5.0 ± 2.0 N·m

3
2
AC508203 AD

1. Scuff plate 4. Engine-ECU
2. Cowl side trim 5. ECU lower bracket
3. Engine-ECU connectors 6. ECU upper bracket
13A-614 DIESEL FUEL
ENGINE-ECU
<RH drive vehicles>
8
5.0 ± 2.0 N·m
6 5.0 ± 2.0 N·m

7
5 3
5.0 ± 2.0 N·m
7.5 ± 1.5 N·m
2
1
AC805918 AB
Removal steps 1. Drill in the break off bolt a hole deep enough for
1. Scuff plate the tap to stand.
2. Cowl side trim 2. Use the recommended tool screw extractor set
<<A>> >>A<< 3. Brake off bolt (MB992678) or equivalent to remove the break off
4. ECU cover
bolt.
5. Engine-ECU connectors
6. Engine-ECU
7. ECU lower bracket INSTALLATION SERVICE POINT
8. ECU upper bracket >>A<< BREAK OFF BOLT INSTALLATION <RH
DRIVE VEHICLES>
REMOVAL SERVICE POINT Tighten the break off bolt until its head is broken off.
<<A>> BREAK OFF BOLT REMOVAL <RH DRIVE
VEHICLES>
Break off bolt

ECU bracket
MB992678 or equivalent AC609908AG

13B-1
GROUP 13B
FUEL SUPPLY
CONTENTS
GENERAL INFORMATION . . . . . . . . 13B-2 FUEL GAUGE UNIT DISASSEMBLY AND

REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 13B-5
SPECIAL TOOL(S) . . . . . . . . . . . . . . 13B-2 FUEL GAUGE UNIT CHECK . . . . . . . . . . . 13B-5
ON-VEHICLE SERVICE. . . . . . . . . . . 13B-2 FUEL FILTER . . . . . . . . . . . . . . . . . . . 13B-6

FUEL LEAK CHECK OF FUEL TANK . . . . 13B-2 FUEL FILTER REMOVAL AND INSTALLATION
<Vehicles with steel fuel filter case> . . . . . . 13B-6
FUEL DRAINING . . . . . . . . . . . . . . . . . . . . 13B-3
FUEL FILTER REMOVAL AND INSTALLATION
<Vehicles with plastic fuel filter case> . . . . . 13B-8
FUEL TANK . . . . . . . . . . . . . . . . . . . . 13B-4
FUEL FILTER INSPECTION . . . . . . . . . . . . 13B-9
FUEL TANK REMOVAL AND INSTALLATION
...................................... 13B-4
13B-2 FUEL SUPPLY
GENERAL INFORMATION
GENERAL INFORMATION
M1135000100725
Fuel tank is mounted on the front of the rear axle to
reduce the shock at impact. A fuel cut valve, which
prevents fuel leakage when the vehicle banks or rolls
over, has been located inside the fuel tank for fewer
openings and hose bonding points on the fuel tank
top surface.
SPECIAL TOOLS
M1135000601143

MB992145 Fuel leak check cap Fuel leak check
B992145
MB992264 Fuel hand pump Fuel draining
B992264
MB992265 Fuel hose adaptor A
B992265
MB992266 Fuel hose adaptor B
B992266
ON-VEHICLE SERVICE
FUEL LEAK CHECK OF FUEL TANK
M1135005900566 MB992145
CAUTION
Always check the fuel leak of fuel tank with the
vehicle loaded. If it is checked with the fuel tank
removed, the fuel tank may be damaged.
AC600149 AC
FUEL SUPPLY
ON-VEHICLE SERVICE
13B-3
1. Remove the fuel tank cap, install special tool fuel 5. Leave it for approximately 3 minutes and check
leak check cap (MB992145). that the pressure is not weakened.
6. If the pressure is weakened, apply soapy water to
each part with pressurized state and check the
leak while confirming if air bubbles are seen.
MB992145 Pressure
gauge
FUEL DRAINING
M1135006900321
CAUTION
• Working area should be airy and kept from
flame.
• Prepare a fire extinguisher before working.
• Install the earth lines to the vehicle and fuel
Trigonal joint tank to prevent static electricity, and water the
work place to keep the footing from slipping.
• Touch the vehicle with hands to release the
Air gun charged static.
• Keep the drained fuel in the safety place.
Hose blocking plier
Fuel hose
AC600150AB
2. Install the hose and pressure gauge to the special

tool (MB992145) as shown.
Fuel tank hose

Fuel pipe AC711661 AB
Fuel filler
neck 1. Disconnect the fuel pipe on the side of fuel tank
from the fuel hose on the front side of fuel tank.
Hose
blocking
plier MB992265
Rear tire (LH) MB992264
AC711418 AC
Fuel hose
3. Remove the splash shield rear (LH) (Refer to
GROUP 42 − Splash Shield ), and block the fuel
tank hose. Fuel hose
(bore: 7.6 mm)
CAUTION AC711667AB
• Do not pressurize suddenly.
• Do not pressurize 11.76 kPa or more to pre- 2. Connect the special tools fuel hand pump
vent the damage of components. (MB992264), fuel hose adaptor A (MB992265)
4. Pressurize while checking the pressure gauge and two fuel hoses (Inner diameter 7.6 ± 0.4 mm)
and hold if it reaches from 9.80 to 11.76 kPa. to the disconnected fuel hose.
3. Operate the special tool (MB992264) to drain fuel
from the fuel tank.
13B-4 FUEL SUPPLY
FUEL TANK
FUEL TANK
M1135001902913

• Rear Splash Shield (LH) Removal and Installation (Refer
to GROUP 42 − Splash Shield ).
18
2.5 ± 0.4 N·m

7
20
17
11
9
12 N 19
4 16
3
2 15
10
5
14
1
13
6N
55 ± 3 N·m
N 6
55 ± 3 N·m
AC805923 AB
Fuel tank removal steps Fuel tank removal steps

1. Fuel filler hose connection 11. Fuel gauge unit
2. Vapour hose connection 12. Packing
3. Levelling hose connection 13. Front lower protector
4. Fuel return pipe connection 14. Fuel tank
5. Fuel main pipe connection Fuel filler neck removal steps
<<A>> >>A<< 6. Self-locking nut 15. Fuel filler hose
<<A>> 7. Fuel gauge unit connector and 16. Vapour hose
harness clamp 17. Levelling hose
<<A>> 8. Fuel tank assembly 18. Fuel filler cap
9. Fuel return hose 19. Fuel filler neck
10. Fuel main hose 20. Packing
FUEL SUPPLY
FUEL TANK
13B-5
REMOVAL SERVICE POINT 3. Disconnect fuel gauge unit connector, and
<<A>> SELF-LOCKING NUT/FUEL GAUGE UNIT harness clamp. Then, remove the fuel tank
CONNECTOR AND HARNESS CLAMP/FUEL assembly.
TANK ASSEMBLY REMOVAL
CAUTION
Be careful not to open circuit in the harness >>A<< SELF-LOCKING NUT INSTALLATION
when removing the fuel tank assembly. CAUTION
Front lower protector Fuel tank

Fuel tank assembly
or reinforcement part
Self-locking nut
Transmission jack
AC504246AB AC505408 AC
1. Support the fuel tank assembly using the When tightening the self-locking nut, be careful
transmission jack, and remove self-locking nuts. not to let the nut touch the bent part of the rein-
forcement of the fuel lower protector and the fuel
2. Using the transmission jack while taking care of
tank.
the fuel harness, lower the fuel tank assembly
until the fuel harness installation position over the DISASSEMBLY AND REASSEMBLY
fuel tank assembly can be checked. M1135051100251
FUEL GAUGE UNIT
AC611598AB
Disassembly steps FUEL GAUGE UNIT CHECK

1. Fuel in-tank filter M1135003100586
2. Fuel tank gauge Refer to GROUP 54A − On-vehicle Service, Fuel

Gauge Unit Check .
13B-6 FUEL SUPPLY
FUEL FILTER
FUEL FILTER
REMOVAL AND INSTALLATION <Vehicles with steel fuel filter case>
M1135002800559
Post-installation Operation
• Evacuation of Air from Fuel Line (Refer to GROUP 13A −
On-vehicle Service, Evacuation of Air from Fuel Line ).
1 1
7N
5.0 ± 1.0 N·m
6
N5
12 ± 2 N·m
2
4
6.0 ± 1.0 N·m
N 3 0.6 ± 0.2 N·m
AC807196 AB

>>B<< 1. Fuel line hose connection <<A>> FUEL FILTER REMOVAL
2. Fuel filter assembly
3. Fuel line plug (drain plug)
4. Water level switch
<<A>> >>A<< 5. Fuel filter
6. Fuel filter pump
7. Fuel line plug (air plug) and O-
ring
AC502833AB
Fix the fuel filter body to a vice, and then remove the
fuel filter using an oil filter wrench.

>>A<< FUEL FILTER INSTALLATION
1. Clean the mounting surface on the fuel filter body
side.
FUEL SUPPLY
FUEL FILTER
13B-7
2. Tighten the fuel filter to the specified torque from >>B<< FUEL LINE HOSE INSTALLATION
the point where the gasket contacts the mounting
surface.
Tightening torque: Approximately 3/4 − 1
turn (12 ± 2 N⋅m)
20 – 25 mm
AC503372AB
If the pipe has a stepped part, connect securely up to

the stepped part. If the pipe has no stepped part,
insert so that the inserted portion 20 − 25 mm long.
13B-8 FUEL SUPPLY
FUEL FILTER
REMOVAL AND INSTALLATION <Vehicles with plastic fuel filter case>

M1135002800560
• Evacuation of Air from Fuel Line (Refer to GROUP 13A −
On-vehicle Service, Evacuation of Air from Fuel Line ).
2 11 ± 2 N·m
N 6
1
N 7
11 ± 2 N·m
N 4
8 11 ± 2 N·m
ACB01919AB
Fuel filter removal steps Removal steps (Continued)

1. Fuel filter protector B 7. O-ring
<<A>> >>A<< 5. Fuel filter cap 8. Fuel filter case
6. Fuel filter and O-ring • Glow plug control relay and
7. O-ring bracket (Refer to GROUP 16 −
Removal steps Glow System, Glow Plug Relay )
1. Fuel filter protector B 9. Fuel filter protector A
>>B<< 2. Fuel line hose C connection
>>B<< 3. Fuel line hose B connection REMOVAL SERVICE POINTS
4. Fuel line plug (drain plug) and O- <<A>> FUEL FILTER CAP REMOVAL
ring
1. Loosen the drain plug to drain the fuel. Then,
<> >>A<< 5. Fuel filter cap
6. Fuel filter and O-ring tighten the drain plug.
FUEL SUPPLY
FUEL FILTER
13B-9
Mark
OPEN
Fastener
nut
ACB01912 AB ACB01914AB
2. Insert a flat-tipped screwdriver into the groove of 2. Securely tighten the fastener nut until the mark is
the fastener nut. in the position shown in the figure (until it clicks in
3. Loosen the fastener nut using the flat-tipped place).
screwdriver until it can be loosened by hand.
>>B<< FUEL LINE HOSE CONNECTION
<> FUEL FILTER CAP REMOVAL
Under 2 mm
Fastener
nut ACB02187AB
ACB01912 AB Securely insert the fuel line hose to the fuel filter and
install the hose clip in the position shown in the fig-
1. Insert a flat-tipped screwdriver into the groove of ure.
the fastener nut.
2. Loosen the fastener nut using the flat-tipped INSPECTION
screwdriver until it can be loosened by hand. M1135002900233

INSTALLATION SERVICE POINTS WATER LEVEL SWITCH CHECK
>>A<< FUEL FILTER CAP INSTALLATION 1. Connect the circuit tester to the water level switch.
1 2
Float
ACB01913 AC502835 AC
1. Install the fuel filter cap by aligning the marks on 2. There should be continuity when the float is
the fuel filter cap and the fuel filter case. raised, while there is no continuity when it is
lowered.
3. Replace the fuel filter assembly if it is faulty.
13B-10 FUEL SUPPLY
FUEL FILTER
<Vehicles with plastic fuel filter case> 3. Replace the fuel filter assembly if it is faulty.
WATER LEVEL SWITCH CHECK
1. Connect the circuit tester to the water level switch. FUEL FILTER VACUUM SWITCH CHECK
Float
ACB01916AB
ACB01915AB
1. Connect the circuit tester to the fuel filter vacuum

2. There should be continuity when the float is
switch and check to see that there is continuity
raised, while there is no continuity when it is
between the terminals.
lowered.
2. Replace the fuel filter assembly if it is faulty.
14-1
GROUP 14
ENGINE COOLING
CONTENTS
GENERAL INFORMATION . . . . . . . . 14-2 RADIATOR FAN REMOVAL AND INSTALLATION

...................................... 14-6
SERVICE SPECIFICATION(S) . . . . . 14-2
THERMOSTAT . . . . . . . . . . . . . . . . . . 14-7
LUBRICANT(S) . . . . . . . . . . . . . . . . . 14-2 THERMOSTAT REMOVAL AND INSTALLATION
...................................... 14-7
THERMOSTAT INSPECTION . . . . . . . . . . . 14-8
SEALANT(S) OR ADHESIVE(S) . . . . 14-2
WATER PUMP . . . . . . . . . . . . . . . . . . 14-9
SPECIAL TOOL(S) . . . . . . . . . . . . . . 14-3
WATER PUMP REMOVAL AND INSTALLATION
...................................... 14-9
ON-VEHICLE SERVICE. . . . . . . . . . . 14-3
ENGINE COOLANT LEAK CHECK . . . . . . 14-3
WATER HOSE AND WATER PIPE . . 14-10
RADIATOR CAP OPENING PRESSURE CHECK
WATER HOSE AND WATER PIPE REMOVAL AND
...................................... 14-3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 14-10
ENGINE COOLANT CHANGE . . . . . . . . . . 14-4
WATER HOSE AND WATER PIPE INSPECTION
ENGINE COOLANT CONCENTRATION TEST ...................................... 14-15
...................................... 14-4
WATER PUMP COOLANT LEAK CHECK . 14-4 RADIATOR . . . . . . . . . . . . . . . . . . . . . 14-16
RADIATOR REMOVAL AND INSTALLATION
RADIATOR FAN . . . . . . . . . . . . . . . . 14-6 ...................................... 14-16
14-2 ENGINE COOLING
GENERAL INFORMATION
GENERAL INFORMATION
M1141000101824
The cooling system is designed to keep every part of ature, the thermostat opens to circulate the coolant
the engine at appropriate temperature in whatever through the radiator as well so that the heat
condition the engine may be operated. The cooling absorbed by the coolant may be radiated into the air.
method is of the water-cooled, pressure forced circu- The water pump is of the centrifugal type and is
lation type in which the water pump pressurizes cool- driven by the drive belt from the crankshaft. The radi-
ant and circulates it throughout the engine. If the ator is the corrugated fin, cross-flow type.
coolant temperature exceeds the prescribed temper-
Item Specification
Radiator Performance kJ/h 244,300
Built-in A/T oil cooler Performance kJ/h 6,800
M1141000300739

High-pressure valve opening pressure of radiator cap kPa 93 − 123 Minimum 83
Range of coolant antifreeze concentration of radiator % 30 − 60 -
Thermostat Valve opening temperature of thermostat °C 82 ± 2 -
Full-opening temperature of thermostat °C 95 -
Valve lift mm 10 or more -
LUBRICANT
M1141000400662
Item Specified coolant Quantity L

Engine coolant (including DIA QUEEN SUPER LONG LIFE COOLANT or 8.2
radiator condense tank) equivalent
SEALANTS
M1141000501576

Engine coolant temperature gauge unit 3M ATD Part No.8660 or exact equivalent
Engine coolant temperature sensor ThreeBond 1324N, LOCTITE 262 or equivalent
ENGINE COOLING
SPECIAL TOOLS
14-3
SPECIAL TOOLS
M1141000601432

MB991871 LLC changer Coolant refilling
MB991871
MB992042 Engine coolant Removal and installation of

temperature sensor the engine coolant
wrench temperature sensor
MB992042
ON-VEHICLE SERVICE
ENGINE COOLANT LEAK CHECK 2. If there is leakage, repair or replace the
M1141001000515 appropriate part.
WARNING
When pressure testing the cooling system, RADIATOR CAP VALVE OPENING
slowly release cooling system pressure to PRESSURE CHECK
avoid getting burned by hot coolant. M1141001300646
NOTE: Be sure that the cap is clean before test-
CAUTION
ing. Rust or other foreign material on the cap seal
• Be sure to completely clean away any mois-
will cause an improper reading.
ture from the places checked.
• When the tester is taken out, be careful not to
spill any coolant.
• Be careful when installing and removing the Cap adapter
tester and when testing not to deform the
filler neck of the radiator.
Cap adapter
Adapter AC211643 AB
1. Use a cap adapter to attach the cap to the tester.

2. Increase the pressure until the indicator of the
gauge stops moving.
Minimum limit: 83 kPa
ACX01844 AC Standard value: 93 − 123 kPa
1. Check that the coolant level is up to the filler neck. 3. Replace the radiator cap if the reading does not
Install a radiator tester and apply 160 kPa remain at or above the limit.
pressure, and then check for leakage from the
radiator hose or connections.
14-4 ENGINE COOLING
ON-VEHICLE SERVICE
ENGINE COOLANT REPLACEMENT 8. By referring to the section on coolant, select an

M1141001201921 appropriate concentration for safe operating
WARNING temperature within the range of 30 to 60%. Use
When removing the radiator cap, use care to special tool LLC changer (MB991871) to refill the
avoid contact with hot coolant or steam. coolant. A convenient mixture is a 50% water and
Place a shop towel over the cap and turn the 50% antifreeze solution (freezing point: −31°C).
cap anti-clockwise a little to let the pressure Recommended antifreeze: DIA QUEEN SUPER
escape through the vinyl tube. After relieving LONG LIFE COOLANT or equivalent
the steam pressure, remove the cap by Quantity: 8.2 L
slowly turning it anti-clockwise. NOTE: For how to use special tool MB991871,
1. Drain the water from the radiator, heater core and refer to its manufacturer’s instructions.
engine after unplugging the radiator drain plug 9. Reinstall the radiator cap.
and removing the radiator cap. 10.Start the engine and let it warm up until the
thermostat opens.
11.After repeatedly revving the engine up to 3,000 r/
Engine oil cooler min several times, then stop the engine.
12.Remove the radiator cap after the engine has
become cold, and pour in coolant up to the brim.
Reinstall the cap.
Water hose
CAUTION
Alternator Do not overfill the radiator condenser tank.
AC503674AC 13.Add coolant to the radiator condenser tank
between the "F" and "L" mark if necessary.
2. Drain the water in the water jacket by disconnect
the engine oil cooler water hose. CONCENTRATION MEASUREMENT
M1141001100631
3. Remove the radiator condenser tank and drain
Measure the temperature and specific gravity of the
the coolant.
engine coolant to check the antifreeze concentration.
4. Drain the coolant then clean the path of the
Standard value: 30 − 60% (allowable concen-
coolant by injecting water into the radiator from
tration range)
the radiator cap area.
Recommended antifreeze: DIAQUEEN SUPER
5. Connect the engine oil cooler water hose. LONG LIFE COOLANT or equivalent
6. Securely tighten the drain plug of the radiator.
CAUTION
7. Reinstall the radiator condenser tank.
If the concentration of the anti-freeze is below
CAUTION 30%, the anti-corrosion property will be
Do not use alcohol or methanol anti-freeze or any adversely affected. In addition, if the concentra-
engine coolants mixed with alcohol or methanol tion is above 60%, both the anti-freezing and
anti-freeze. The use of an improper anti-freeze engine cooling properties will decrease, affecting
can cause corrosion of the aluminium compo- the engine adversely. For these reasons, be sure
nents. to maintain the concentration level within the
specified range.
MB991871
WATER PUMP COOLANT LEAK CHECK
M1141008600392
If a residue of the coolant draining is found on the
drain hole, the vapour hole and the installation sur-
face of the water pump, check the water pump leak-
age by following method.
1. Wipe off the residue of the coolant draining on the
water pump.
AC503144AB
ENGINE COOLING
ON-VEHICLE SERVICE
14-5
WARNING 3. Install the radiator tester and pressures at 100
Make sure that the coolant is cold when kPa.
removing the radiator cap. 4. Hold the pressurized state for 20 minutes, and
check that the water leakage from the drain hole,
2. Remove the radiator cap.
the vapour hole or the installation surface of the
CAUTION water pump.
Do not pressures 100 kPa or more. 5. Remove the radiator tester, and install the radiator
cap.
6. Warm up the engine, let it idle for 20 minutes and
Cap adapter
stop it.
Adapter 7. Stop the engine.
8. Check that the water leakage from the drain hole,
the vapour hole or the installation surface of the
water pump.
9. If the water leakage is found in step 4 or 8,
replace the water pump (Refer to P.14-9).
ACX01844 AC
14-6 ENGINE COOLING
RADIATOR FAN
RADIATOR FAN
M1141002100872

• A/C Compressor Drive Belt, Alternator and Power Steer-
ing Oil Pump Drive Belt Removal and Installation (Refer to
GROUP 11A − Crankshaft Pulley ).
• Air Duct Removal and Installation (Refer to GROUP 15 −
Air Cleaner ).
2
4 5 3
11 ± 1 N·m
11 ± 1 N·m
1
AC805946 AB

1. Cooling fan shroud cover 3. Water pump pulley
2. Cooling fan and cooling fan clutch 4. Cooling fan
assembly 5. Cooling fan clutch
ENGINE COOLING
THERMOSTAT
14-7
THERMOSTAT
M1141002402631

• Engine Coolant Draining and Refilling (Refer to P.14-4).
• Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 − Air Cleaner ).
11 ± 1 N·m 2 3 AC502980
24 ± 3 N·m
4 5
AC507713 AB
Removal steps Make mating marks on the radiator lower hose and
<<A>> >>A<< 1. Radiator lower hose connection the hose clip as shown to install them in the original
2. Battery wiring harness connection position. Disconnect the radiator lower hose.
3. Harness bracket
4. Water pump inlet hose fitting INSTALLATION SERVICE POINT
5. Thermostat
>>A<< RADIATOR LOWER HOSE CONNECTION
REMOVAL SERVICE POINT Protrusion
<<A>> RADIATOR LOWER HOSE DISCONNEC-
TION
Water pump inlet Mating marks

hose fitting
AC606082 BB
Mating marks
1. Insert each hose as far as the projection of the
water pump inlet hose fitting.
AC606081AE
2. Align the mating marks on the radiator lower hose
and hose clamp, and then connect the radiator
lower hose.
14-8 ENGINE COOLING
THERMOSTAT
INSPECTION
M1141002500676
THERMOSTAT CHECK
Valve lift
ACX00401AC
2. Check that the amount of valve lift is at the

ACX00400AB
standard value when the water is at the full-
opening temperature.
1. Immerse the thermostat in water, and heat the NOTE: Measure the valve height when the ther-
water while stirring. Check the thermostat valve mostat is fully closed, and use this measurement
opening temperature. to compare the valve height when the thermostat
Standard value: 82 ± 2°C is fully open.
Standard value:
Full-opening temperature: 95°C
Amount of valve lift: 10 mm or more
ENGINE COOLING
WATER PUMP
14-9
WATER PUMP
M1141002702342

• Engine Coolant Draining (Refer to P.14-4). • Thermostat Installation (Refer to P.14-7).
• Timing Belt and Timing Belt B Removal (Refer to GROUP • Timing Belt and Timing Belt B Installation (Refer to
11A − Timing Belt ). GROUP 11A − Timing Belt ).
• Thermostat Removal (Refer to P.14-7). • Engine Coolant Refilling (Refer to P.14-4).
N 5
2N
1
10 ± 2 N·m
4N
3
24 ± 3 N·m
AC502983AB

1. Water pump inlet fitting plate >>A<< O-RING INSTALLATION
2. Water pump inlet fitting gasket
• Oil hose and oil pipe (Refer to Water pump
GROUP 11A − Vacuum Pump ).
3. Water pump
4. Water pump gasket
O-ring
>>A<< 5. O-ring
Water pipe
AC103005AG
Fit the O-ring to the groove in the water pipe. Then

lubricate the O-ring and the inside of the water pump
with water, and then insert the water pipe to the
water pump.
14-10 ENGINE COOLING
WATER HOSE AND WATER PIPE

M1141003304138

• Engine Coolant Draining and Refilling (Refer to P.14-4).
<Except Euro5>
3.0 ± 0.5 N·m
1
11 ± 1 N·m
53 ± 7 N·m
5 13 11 ± 1 N·m
N 6 7
24 ± 3 N·m
12
4
N 14 39 ± 5 N·m 2
11 53 ± 7 N·m
N3
10
8
24 ± 3 N·m
9 54 ± 4 N·m
AC502984 AB

• Under skid plate and engine room 5. Water pipe C
under cover (Refer to GROUP 51 6. Gasket
− Under Cover ). 7. Water hose
• Air cleaner assembly (Refer to 8. Water hose
GROUP 15 − Air Cleaner ). 9. Water hose
1. Engine cover 10. Water pipe D
2. Water pipe B 11. Joint
3. Gasket 12. Heater piping hose connection
4. Water hose >>E<< 13. Water pipe
>>E<< 14. O-ring
ENGINE COOLING
14-11
24 ± 3 N·m
15 24 ± 3 N·m
24 ± 3 N·m
17
50 ± 5 N·m
22 N 21
16
11 ± 1 N·m
18
19
20 24 ± 3 N·m 30 ± 9 N·m
AC502985AD

• Inlet manifold (Refer to GROUP <<A>> >>B<< 19. Engine coolant temperature
15 − Inlet Manifold ). sensor
15. Water pipe A <> >>A<< 20. Radiator upper hose connection
16. Water hose 21. Cooling water outlet hose fitting
>>D<< 17. Front upper case stiffener 22. Cooling water outlet hose fitting
>>C<< 18. Engine coolant temperature gauge gasket
unit
<Euro5>
3.0 ± 0.5 N·m
24 ± 3 N·m 5 4
2
1
N 6
39 ± 5 N·m 11 ± 1 N·m
3 9
8
24 ± 3 N·m
54 ± 4 N·m
7
AC805754 AB

• Under skid plate and engine room 3. Water hose
under cover (Refer to GROUP 51 4. Heater piping hose connection
− Under Cover ). >>E<< 5. Water pipe
• Air cleaner assembly (Refer to >>E<< 6. O-ring
GROUP 15 − Air Cleaner ). 7. Water hose
1. Engine cover 8. Water pipe D
2. Water hose connection 9. Joint
ENGINE COOLING
14-13
23 ± 6 N·m
18
19
19
20
17 N
16
11 ± 1 N·m
11
10
15
13
14 24 ± 3 N·m 12
30 ± 9 N·m
AC805755 AC

10. Engine coolant temperature gauge <<A>> ENGINE COOLANT TEMPERATURE SEN-
unit connector SOR REMOVAL
>>C<< 11. Engine coolant temperature gauge
unit
12. Engine coolant temperature
sensor connector MB992042
<<A>> >>B<< 13. Engine coolant temperature
sensor
<> >>A<< 14. Radiator upper hose connection
15. Water hose
16. Cooling water outlet hose fitting
17. Cooling water outlet hose fitting
gasket
AC701469 AB
18. Water hose
19. Vacuum hose connection Use special tool water temperature sensor wrench
20. Vacuum pipe assembly (MB992042) to remove the engine coolant tempera-
ture sensor.
<> RADIATOR UPPER HOSE Specified sealant: ThreeBond 1324N or

DISCONNECTION equivalent
NOTE: Install the engine coolant temperature
sensor immediately after applying sealant.
CAUTION
Mating marks start the engine.
AC606081AE
MB992042
Make mating marks on the radiator upper hose and
the hose clip as shown to install them in the original
position. Disconnect the radiator upper hose.

>>A<< RADIATOR UPPER HOSE CONNECTION
AC701469 AB
Protrusion
2. In the same manner as for removal, using special
tool water temperature sensor wrench
(MB992042), tighten to the specified torque.
Cooling water outlet Mating marks >>C<< ENGINE COOLANT TEMPERATURE

hose fitting GAUGE UNIT INSTALLATION
AC606082 BC CAUTION
1. Insert radiator upper hose as far as the protrusion
of the cooling water outlet hose fitting.
2. Align the mating marks on the radiator upper hose start the engine.
and hose clamp, and then connect the radiator
upper hose.
>>B<< ENGINE COOLANT TEMPERATURE

SENSOR INSTALLATION
AC502986AB
Apply the specified sealant to the thread of the

engine coolant temperature gauge unit, and then
tighten it to the specified torque.
AC103399AB Specified Sealant: 3M ATD Part No. 8660
1. Apply the sealant to the thread of engine coolant NOTE: Install the engine coolant temperature gauge
temperature sensor. unit immediately after applying sealant.
ENGINE COOLING
14-15
>>D<< FRONT UPPER CASE STIFFENER >>E<< O-RING/WATER PIPE INSTALLATION
INSTALLATION CAUTION
Front upper case Do not allow engine oil or other grease to adhere
Bolt A
stiffener to the cooling water line O-ring
Bolt B Water pump
O-ring
Bolt A Bolt B AC502987AB

Water pipe
1. Temporarily tighten the front upper case stiffener AC103005AG
with bolts.
2. Tighten the bolt A located at the front upper case Fit the O-ring to the groove in the water pipe. Then
side to the specified torque. lubricate the rim of O-ring or the inside of water pipe
fixing position with water, and then insert the water
Tightening torque: 50 ± 5 N⋅m pipe to the water pump.
3. Next, tighten the bolt B located at the cylinder
block side to the specified torque. INSPECTION
M1141003400467
WATER PIPE AND HOSE CHECK
Check the water pipe and hose for cracks, damage
and clogs. Replace them if necessary.
RADIATOR
RADIATOR
M1141001503393

• Engine Coolant Draining (Refer to P.14-4). • Air Cleaner Intake Duct Installation (Refer to GROUP 15 −
• Air Cleaner Intake Duct Removal (Refer to GROUP 15 − Air Cleaner ).
Air Cleaner ). • Engine Coolant Refilling (Refer to P.14-4).
• A/T Fluid Supplying and Checking (Refer to GROUP 23A
− On-vehicle Service, A/T Fluid Check ).
11 11 ± 2 N·m
3 16
11 ± 2 N·m
4 6
10 11 ± 2 N·m
11 ± 2 N·m 5.0 ± 1.0 N·m 5.0 ± 1.0 N·m
14
15 13
15 5
2N 5.0 ± 1.0 N·m
1
7
5.0 ± 1.0 N·m 9 42 ± 8 N·m

5.0 ± 1.0 N·m
18
8 12
5.0 ± 1.0 N·m
5.0 ± 1.0 N·m
17
42 ± 8 N·m
AC903736 AB

1. Drain plug 11. Radiator condenser tank hose
2. O-ring 12. Cooling fan shroud cover
3. Radiator cap 13. Cooling fan shroud
<<A>> >>A<< 4. Radiator upper hose 14. Radiator
<<A>> >>A<< 5. Radiator lower hose 15. Radiator support lower insulator
6. Cooler hose connection <A/T> 16. Radiator condenser tank
7. Hose <A/T> 17. Radiator guard <2WD (Except
8. Return hose connection <A/T> High rider)>
9. Return pipe <A/T> 18. Air guide panel <2WD (High
10. Feed hose clamp <A/T> rider), 4WD>
ENGINE COOLING
RADIATOR
14-17
REMOVAL SERVICE POINT INSTALLATION SERVICE POINT
<<A>> RADIATOR UPPER HOSE/RADIATOR >>A<< RADIATOR LOWER HOSE/RADIATOR
LOWER HOSE DISCONNECTION UPPER HOSE CONNECTION
Protrusion
Mating marks
Pipe, fitting, or etc. Mating marks
AC606081AE AC606082 AU
Make mating marks on the radiator hose and the

1. Insert radiator hose as far as the projection of the
hose clamp. Disconnect the radiator hose.
water pump inlet hose fitting, cooling water outlet
hose fitting, cooling water outlet pipe or radiator.
2. Align the mating marks on the radiator hose and
hose clamp, and then connect the radiator hose.
15-1
GROUP 15
INTAKE AND
EXHAUST
CONTENTS
GENERAL INFORMATION . . . . . . . . 15-2 <Except Euro5> . . . . . . . . . . . . . . . . . . . . . . 15-8

INTERCOOLER REMOVAL AND INSTALLATION
SERVICE SPECIFICATION(S) . . . . . 15-2 <Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-12
SPECIAL TOOL(S) . . . . . . . . . . . . . . 15-3 INLET MANIFOLD . . . . . . . . . . . . . . . 15-15

INLET MANIFOLD REMOVAL AND INSTALLATION
...................................... 15-15
INLET MANIFOLD INSPECTION . . . . . . . . 15-18
TURBOCHARGER BOOST PRESSURE CHECK
...................................... 15-3
TURBOCHARGER WASTE GATE ACTUATOR EXHAUST MANIFOLD AND
CHECK <Except Euro5>. . . . . . . . . . . . . . . 15-4 TURBOCHARGER . . . . . . . . . . . . . . . 15-19
VARIABLE GEOMETRY ACTUATOR CHECK EXHAUST MANIFOLD AND TURBOCHARGER
<Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5 REMOVAL AND INSTALLATION <Except Euro5>
...................................... 15-19
VARIABLE GEOMETRY SOLENOID VALVE CHECK
<Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5 EXHAUST MANIFOLD AND TURBOCHARGER
REMOVAL AND INSTALLATION <Euro5> . 15-21
AIR CLEANER . . . . . . . . . . . . . . . . . . 15-6 EXHAUST MANIFOLD AND TURBOCHARGER
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-23
AIR CLEANER REMOVAL AND INSTALLATION
...................................... 15-6
EXHAUST PIPE AND MAIN MUFFLER
INTERCOOLER . . . . . . . . . . . . . . . . . 15-8 ................................. 15-24
INTERCOOLER REMOVAL AND INSTALLATION EXHAUST PIPE AND MAIN MUFFLER . . . 15-24
15-2 INTAKE AND EXHAUST
GENERAL INFORMATION
GENERAL INFORMATION
M1151000101568
The exhaust pipe is divided into three parts.
M1151000302189

Turbocharger supercharging pressure kPa Except Euro 5 178.9 − 188.2 −
Euro 5-low power 194.9 − 233.5 −
engine
Euro 5-normal 199.4 − 237.6 −
power engine
Euro 5-high 203.1 − 238.6 −
power engine
Initial activation pressure of waste gate actuator (at the stroke of 132.6 − 143.6 −
approximately 1 mm) <Except Euro 5> kPa
Initial activation vacuum of variable geometry actuator (at the stroke 45.4 − 49.2 −
approximately 1.5 mm from full close) <Euro 5> kPa
Variable geometry solenoid valve coil resistance (at 20 °C) <Euro 10 − 14 −
5> Ω
Manifold distortion of the installation surface mm 0.15 or less 0.20
INTAKE AND EXHAUST
SPECIAL TOOLS
15-3
SPECIAL TOOLS
M1151000601842

A A: MB991824 A: Vehicle For vehicles with CAN
B: MB991827 communication communication, use M.U.T.-III
C: MB991910 interface (V.C.I.) main harness A to send
D: MB991911 B: M.U.T.-III USB cable simulated vehicle speed. If you
MB991824 E: MB991825 C: M.U.T.-III main connect M.U.T.-III main harness
B F: MB991826 harness A (Vehicles B instead, the CAN
with CAN communication does not
communication function correctly.
system) Measurement of turbocharger
MB991827 D: M.U.T.-III main supercharging pressure
harness B (Vehicles
C
without CAN
communication
system)
E: M.U.T.-III adapter
MB991910
harness
D F: M.U.T.-III trigger
harness
DO NOT USE
MB991911
MB991825
MB991826
MB991955
ON-VEHICLE SERVICE
TURBOCHARGER SUPERCHARGING 1. Set the vehicle to the pre-inspection condition.
PRESSURE CHECK
M1151001001069
CAUTION
Conduct the driving test in a location where driv-
ing at full acceleration can be done with safety.
Two person should be in the vehicle when the
test is conducted; the person in the passenger
seat should read the indications shown by the
M.U.T.-III.
ON-VEHICLE SERVICE
<LH drive vehicles>

203.1 − 238.6 kPa <Euro 5-high power engine>
4. If the supercharging pressure deviates from the
standard value, check the following items for
possible cause.
• Malfunction of the waste gate actuator <Except
Euro 5>
Diagnosis
connector
• Malfunction of the variable geometry actuator
<Euro 5>
• Malfunction of the variable geometry solenoid
MB991910 valve <Euro 5>
• Malfunction of the variable nozzle <Euro 5>
MB991824 • Malfunction of the boost pressure sensor
• Leakage of supercharging pressure
• Malfunction of the turbocharger
5. When the indicated supercharging is more than
standard value, supercharging control may be
faulty, therefore check the followings.
• Disconnection or cracks of the waste gate actua-
tor rubber hose <Except Euro 5>
MB991827 • Malfunction of the waste gate actuator <Except
<RH drive vehicles> Diagnosis Euro 5>
connector • Malfunction of the waste gate valve <Except Euro
5>
• Malfunction of the variable geometry actuator
<Euro 5>
• Malfunction of the variable geometry solenoid
valve <Euro 5>
MB991910
• Malfunction of the variable nozzle <Euro 5>
• Malfunction of the manifold absolute pressure
sensor
MB991824 WASTE GATE ACTUATOR CHECK
<Except Euro5>
M1151001200673
MB991827 AK600277AB
2. Turn the ignition switch to "LOOK" (OFF) position,

and connect the diagnosis connector to the
M.U.T.-III.
AK403495
3. Use the data list function named "Item No. 6"
boost pressure sensor of the M.U.T.-III to check 1. Connect a manual pump (pressure-application
the supercharging pressure when the engine type) to nipple.
speed increases to approximately 3,000 r/min or
CAUTION
more by driving at full acceleration in 2nd.
In order to avoid damage to the diaphragm, do
Standard value: not apply a pressure of 159 kPa or higher.
178.9 − 188.2 kPa <Except Euro 5> 2. While gradually applying pressure, check the
194.9 − 233.5 kPa <Euro 5-low power engine> pressure that begins to activate (approximately 1
199.4 − 237.6 kPa <Euro 5-normal power mm stroke) the waste gate actuator rod.
engine>
INTAKE AND EXHAUST
ON-VEHICLE SERVICE
15-5
Standard value: 4. If the vacuum pressure significantly deviates from
132.6 − 143.6 kPa the standard value, check the actuator or the
3. If there is a significant deviation from the standard variable nozzle. Replace the turbocharger
value, check the actuator or the waste gate valve: assembly if necessary.
replace actuator or turbocharger assembly if
necessary. VARIABLE GEOMETRY SOLENOID
VALVE CHECK <EURO5>
VARIABLE GEOMETRY ACTUATOR M1151011100202
CHECK <EURO5>
M1151011000249 Variable geometry
control solenoid valve
Variable geometry actuator
AK801719 AB
1. Disconnect the vacuum hoses from the variable

AK801720 AB
geometry solenoid valve.
1. Remove the vacuum hose from the variable NOTE: When disconnecting the vacuum hose,
geometry (VG) actuator. Connect the hand always make sure that it can be reconnected at its
vacuum pump to the nipple. original position.
2. Disconnect the harness connector.
A
Stopper bolt
B
Variable geometry
actuator
1 2
AK802451AB
6V
CAUTION AK603599AB
In order to avoid damage to the diaphragm, do
not apply a vacuum of 60 kPa or higher. 3. Connect a hand vacuum pump to nipple (A) of the
2. By applying the vacuum pressure until the VG variable geometry solenoid valve.
actuator link touches the stopper bolt, fully shrink 4. As described in the chart below, check
the actuator rod. The vacuum pressure is airtightness by applying a vacuum with voltage
approximately 55 kPa at that time. applied directly from the battery to the variable
3. Leak the vacuum pressure gradually as much as geometry solenoid valve, and without applying
possible to check the vacuum pressure when the voltage.
VG actuator rod moves approximately 1.5 mm in Battery positive Nipple (B) Normal
the extension direction. voltage condition condition
Standard value: Approximately 45.4 − 49.2 Applied Open Vacuum leaks
kPa
Closed Vacuum
maintained
Not applied Open Vacuum
maintained
AIR CLEANER
Standard value: 10 − 14 Ω (at 20°C)

6. Replace the solenoid if airtightness or resistance
is out of specification.
1 2
AK603600AB
5. Measure the resistance between the terminals of

the variable geometry solenoid valve.
AIR CLEANER
M1151002103485
0.7 ± 0.1 N·m
2 3
5 4N
6
4.0 ± 1.0 N·m 7

8
4.0 ± 1.0 N·m

1
9.0 ± 1.0 N·m 10

9
9.0 ± 1.0 N·m
11
13
9.0 ± 1.0 N·m
12
AC903806AB
INTAKE AND EXHAUST
AIR CLEANER
15-7
Removal steps INSTALLATION SERVICE POINTS
1. Air cleaner element >>A<< VACUUM HOSE CONNECTION
2. Air flow sensor connector
connection Air intake hose
3. Air flow sensor Vacuum hose
4. Air flow sensor O-ring
5. Harness clamp
6. Air cleaner cover
7. Breather hose connection
8. Blow-by hose heater connector
<Vehicles for cold zone>
>>A<< 9. Vacuum hose connection <Euro5> White marking
10. Air intake hose
ACB00064AB
11. Radiator condenser tank hose
connection Clamp vacuum hose with clip of air intake hose
12. Air cleaner intake duct beside white marking as shown.
13. Air cleaner body
INTERCOOLER
INTERCOOLER
M1151002401208
CAUTION
• Degrease the air hose and air pipe by isopropyl alcohol, parts cleaner (MZ100387) or equivalent.
• As for the parts cleaner, use the petroleum cleaner whose major component is aliphatic hydrocar-
bon.
• Working area should be airy and kept from flame.
• Air Cleaner Intake Duct Removal (Refer to P.15-6). • Air Cleaner Intake Duct Installation (Refer to P.15-6).
6.0 ± 1.0 N·m

1
6.0 ± 1.0 N·m

18 ± 2 N·m
7.0 ± 1.0 N·m

2
5N
4
3
6 6.0 ± 1.0 N·m
6.0 ± 1.0 N·m
6.0 ± 1.0 N·m
12 ± 2 N·m
8
7
9.0 ± 1.0 N·m
AC804002AB

>>A<< 1. Intercooler inlet air hose >>A<< INTERCOOLER OUTLET AIR PIPE/INTER-
>>A<< 2. Intercooler outlet air hose COOLER OUTLET AIR HOSE/INTERCOOLER
• Front bumper reinforcement
INLET AIR PIPE/INTERCOOLER OUTLET AIR
(Refer to GROUP 51 − Front
Bumper Assembly ).
HOSE/INTERCOOLER INLET AIR HOSE INSTAL-
3. Intercooler inlet air pipe and LATION
intercooler assembly 1. If the oil adheres to the insertion area of the
>>A<< 4. Intercooler inlet air pipe intercooler air hose or the intercooler air pipe,
>>B<< 5. Intercooler inlet air pipe gasket degrease it.
6. Intercooler assembly
>>A<< 7. Intercooler outlet air hose
>>A<< 8. Intercooler outlet air pipe
INTAKE AND EXHAUST
INTERCOOLER
15-9
Throttle body
A/C compressor assembly
suction pipe
Matching
mark
Turbocharger
assembly
Matching
mark
View A Intercooler
outlet air hose
View B
Intercooler
Power steering Intercooler
inlet air hose
suction hose outlet air pipe
Radiator
upper hose
Matching
marks
Matching
marks
Intercooler Intercooler
inlet air pipe outlet air hose
AC804003AB
Intercooler
outlet air hose
Intercooler
outlet air pipe
Matching
marks Matching
marks
Intercooler
outlet air hose
Intercooler
assembly
AC804005AB
INTERCOOLER
Intercooler
inlet air hose
15 mm or more
Radiator
upper hose
A/C compressor
suction pipe
Power steering
suction hose
Intercooler
outlet air hose
20 mm or more 20 mm or more
View B View A
AC804004AB
2. Install the intercooler air hose to the intercooler air 5. After installing the intercooler inlet air hose, check
pipe with the matching marks aligned as shown in that the clearance between the intercooler inlet air
the figure. hose and the A/C compressor suction pipe is 20
3. When installing the intercooler air hose to the mm or more (View B).
throttle body assembly or the turbocharger 6. After installing the intercooler inlet air hose, check
assembly, install the intercooler air hose with its that the clearance between the intercooler inlet air
matching mark located as shown in the figure. hose and the power steering suction hose is 20
4. After installing the intercooler outlet air hose, mm or more (View B).
check that the clearance between the intercooler
outlet air hose and the radiator upper hose is 15
mm or more (View A).
INTAKE AND EXHAUST
INTERCOOLER
15-11
7. Insert intercooler air hose to stopper end and not
Bulge 5 ± 1 mm Stopper end overlap with stopper.
Stopper 8. Place the hose clamp as shown in the figure so
that it does not overlap with the bulge and the
stopper end. When installing the hose clamp to
the intercooler air pipe or intercooler assembly,
Intercooler Intercooler set the hose clamp 5 ± 1 mm away from the
air hose air pipe stopper end. When installing the hose clamp to
the throttle body assembly or turbocharger
Hose clamp
AC712053 AB assembly, set the hose clamp 4 ± 1 mm away
from the stopper end.
Stopper end Bulge
5 ± 1 mm
>>B<< INTERCOOLER INLET AIR PIPE GASKET
Intercooler INSTALLATION
Intercooler outlet
assembly air hose
Protrusion
Hose clamp
Stopper AC712054 AB
4 ± 1 mm Bulge
Stopper end
AC504286AC
Stopper Install the intercooler inlet air pipe gasket as its pro-
trusion is in the direction shown.
Intercooler
outlet
air hose
Throttle body
Hose clamp
assembly AC804006 AB
Intercooler Turbocharger
inlet air assembly
hose
Stopper
Stopper end
Bulge 4 ± 1 mm
Hose clamp
AC804007AB
INTERCOOLER

M1151002401219
CAUTION
• Degrease the air hose and air pipe by isopropyl alcohol, parts cleaner (MZ100387) or equivalent.
• As for the parts cleaner, use the petroleum cleaner whose major component is aliphatic hydrocar-
bon.
• Working area should be airy and kept from flame.
• Air Cleaner Intake Duct Removal (Refer to P.15-6). • Air Cleaner Intake Duct Installation (Refer to P.15-6).
6.0 ± 1.0 N·m

1
6.0 ± 1.0 N·m

18 ± 2 N·m
7.0 ± 1.0 N·m

2
5N
4
3
6 6.0 ± 1.0 N·m
6.0 ± 1.0 N·m
6.0 ± 1.0 N·m
12 ± 2 N·m
8
7
9.0 ± 1.0 N·m
AC804002AB

>>A<< 1. Intercooler inlet air hose >>A<< INTERCOOLER OUTLET AIR PIPE/INTER-
>>A<< 2. Intercooler outlet air hose COOLER OUTLET AIR HOSE/INTERCOOLER
• Front bumper reinforcement
INLET AIR PIPE/INTERCOOLER OUTLET AIR
(Refer to GROUP 51 − Front
Bumper Assembly ).
HOSE/INTERCOOLER INLET AIR HOSE INSTAL-
3. Intercooler inlet air pipe and LATION
intercooler assembly 1. If the oil adheres to the insertion area of the
>>A<< 4. Intercooler inlet air pipe intercooler air hose or the intercooler air pipe,
>>B<< 5. Intercooler inlet air pipe gasket degrease it.
6. Intercooler assembly
>>A<< 7. Intercooler outlet air hose
>>A<< 8. Intercooler outlet air pipe
INTAKE AND EXHAUST
INTERCOOLER
15-13
Throttle body
assembly
Matching
Turbocharger mark
assembly
Matching
mark Intercooler
outlet air hose
Intercooler
inlet air hose Intercooler
outlet air pipe
Matching
marks
Matching
marks
inlet air pipe outlet air hose
ACB00692AB
Intercooler
outlet air hose
Intercooler
outlet air pipe
Matching
marks Matching
marks
Intercooler
outlet air hose
Intercooler
assembly
ACB00693AB
INTERCOOLER
2. Install the intercooler air hose to the intercooler air 4. Insert intercooler air hose to stopper end and not
pipe with the matching marks aligned as shown in overlap with stopper.
the figure. 5. Place the hose clamp as shown in the figure so
3. When installing the intercooler air hose to the that it does not overlap with the bulge and the
throttle body assembly or the turbocharger stopper end. When installing the hose clamp to
assembly, install the intercooler air hose with its the intercooler air pipe or intercooler assembly,
matching mark located as shown in the figure. set the hose clamp 5 ± 1 mm away from the
stopper end. When installing the hose clamp to
Bulge 5 ± 1 mm Stopper end the throttle body assembly or turbocharger
assembly, set the hose clamp 4 ± 1 mm away
Stopper
from the stopper end.
>>B<< INTERCOOLER INLET AIR PIPE GASKET

INSTALLATION
air hose air pipe
Hose clamp Protrusion

AC712053 AB
Stopper end Bulge

5 ± 1 mm
Intercooler
Intercooler outlet
assembly air hose
AC504286AC
Install the intercooler inlet air pipe gasket as its pro-

trusion is in the direction shown.
Hose clamp
Stopper AC712054 AB
4 ± 1 mm Bulge
Stopper end
Stopper
Intercooler
outlet
air hose
Throttle body
Hose clamp
assembly AC804006 AB
Turbocharger assembly
Stopper end
Bulge Stopper
Intercooler
inlet air
hose
4 ± 1 mm
Hose clamp
ACB00694AB
INTAKE AND EXHAUST
INLET MANIFOLD
15-15
INLET MANIFOLD
M1151003004655

• Throttle Body Removal (Refer to GROUP 13A − Throttle • Cowl Top Panel Front Installation
Body ). • Windshield Wiper Installation (Refer to GROUP 51 −
• EGR Valve and EGR Pipe Removal (Refer to GROUP 17 Windshield Wiper ).
− EGR Valve and EGR Cooler ). • EGR Valve and EGR Pipe Installation (Refer to GROUP
• Windshield Wiper Removal (Refer to GROUP 51 − Wind- 17 − EGR Valve and EGR Cooler ).
shield Wiper ). • Throttle Body Installation (Refer to GROUP 13A − Throttle
• Cowl Top Panel Front Removal Body ).
• Air Bleeding from Fuel Line (Refer to GROUP 13A − On-
vehicle Service, Evacuation of Air from Fuel Line ).
<Except Euro5>
INLET MANIFOLD
1 3
5.0 ± 1.0 N·m
5.0 ± 1.0 N·m
2
24 ± 3 N·m
20 ± 2 N·m
24 ± 3 N·m
4
N 5
24 ± 3 N·m 7
24 ± 3 N·m 14 ± 1 N·m
24 ± 3 N·m
24 ± 3 N·m 6
24 ± 3 N·m
10
24 ± 3 N·m
9
N 11
N 12 8
24 ± 4 N·m
ACB00688 AB

1. Control wiring harness connection 9. Inlet manifold stay
2. Earth cable connection • Fuel injection pipe No.3, 4 clamp
3. Emission control hose mounting bolt (Refer to GROUP
4. Intake air temperature sensor 13A − Common Rail and Supply
5. Intake air temperature sensor Pump )
gasket >>B<< 10. Inlet manifold
6. Vacuum pump pipe 11. Inlet manifold gasket
7. Engine cover stay 12. Inlet manifold gasket
8. Fuel inlet pipe mounting bolt
INTAKE AND EXHAUST
INLET MANIFOLD
15-17
<Euro5>
1
3
5.0 ± 1.0 N·m
20 ± 4 N·m 2
24 ± 3 N·m
4
20 ± 2 N·m
24 ± 3 N·m
24 ± 3 N·m 6
24 ± 3 N·m
24 ± 3 N·m
24 ± 3 N·m 5
24 ± 3 N·m
24 ± 3 N·m
8
N 10
N 11 7
24 ± 4 N·m
ACB00689 AB

1. Control wiring harness connection • Fuel injection pipe No.3, 4 clamp
2. Earth cable connection mounting bolt (Refer to GROUP
3. Emission control hose 13A − Common Rail and Supply
<<A>> 4. EGR gas temperature sensor Pump )
5. Vacuum pump pipe >>B<< 9. Inlet manifold
6. Engine cover stay 10. Inlet manifold gasket
7. Fuel inlet pipe mounting bolt >>A<< 11. Inlet manifold gasket
8. Inlet manifold stay
INLET MANIFOLD
REMOVAL SERVICE POINT >>B<< INLET MANIFOLD ASSEMBLY

<<A>> EGR GAS TEMPERATURE SENSOR INSTALLATION
REMOVAL
CAUTION
Side B
Do not use the EGR gas temperature sensor
which dropped.
NOTE:
Flare nut (14) socket (MB992692)
Side A
Inlet
manifold AC502862AB
1. As shown in the illustration, temporarily tighten to

6.5 ± 1.5 N⋅m the bolts located at side A.
2. As shown in the illustration, tighten the bolts and
nuts located at side B to the specified torque.
ACA01741AB
Tightening torque:
Use the recommended tool flare nut (14) socket 24 ± 3 N⋅m <Bolts>
(MB992692) to remove the EGR gas temperature 20 ± 2 N⋅m <Nuts>
sensor.
3. As shown in the illustration, tighten the bolts
INSTALLATION SERVICE POINTS located at side A to the specified torque.
>>A<< INLET MANIFOLD GASKET INSTALLA- Tightening torque: 24 ± 3 N⋅m
TION
INSPECTION
M1151003100843
Check the following points; replace the part if a prob-
lem is found.
INLET MANIFOLD CHECK
1. Check for damage or cracking of any part.
2. Clogging of the negative pressure (vacuum) outlet
port.
3. Using a straight edge and feeler gauge, check for
distortion of the cylinder head installation surface.
ACB00690AB
Standard value: 0.15 mm or less
Position the projection as shown in the illustration. Limit: 0.20 mm
INTAKE AND EXHAUST
EXHAUST MANIFOLD AND TURBOCHARGER
15-19
M1151008901353

• Under Skid Plate and Engine Room Under Cover • Catalytic Converter Installation (Refer to GROUP 17 −
Removal (Refer to GROUP 51 − Under Cover ). Catalytic Converter ).
• Engine Coolant Draining (Refer to GROUP 14 − On-vehi- • Intercooler Inlet Air Hose Installation (Refer to P.15-8).
cle Service, Engine Coolant Replacement ). • Battery and Battery Box Installation (Refer to GROUP
• Air Cleaner Assembly Removal (Refer to P.15-6). 54A − Battery ).
• Battery and Battery Box Removal (Refer to GROUP 54A • Air Cleaner Assembly Installation (Refer to P.15-6).
− Battery ). • Under Skid Plate and Engine Room Under Cover Installa-
• Intercooler Inlet Air Hose Removal (Refer to P.15-8). tion (Refer to GROUP 51 − Under Cover ).
• Catalytic Converter Removal (Refer to GROUP 17 − Cat- • Engine Coolant Refilling (Refer to GROUP 14 − On-vehi-
alytic Converter ). cle Service, Engine Coolant Replacement ).
17 ± 2 N·m
17 ± 2 N·m 14 ± 1 N·m
11 ± 1 N·m
53 ± 7 N·m 2N
9.0 ± 1.0 N·m
N 2 15
59 ± 10 N·m
1
11 ± 1 N·m
12 N
3
N 8 4
53 ± 7 N·m
7 18 ± 2 N·m
6 18 N 30 ± 2 N·m
18 N
13 17 5N
N 10 19 20 N
N 16
9 14 N
18 ± 2 N·m
9.0 ± 1.0 N·m
30 ± 2 N·m 18 N
9.0 ± 1.0 N·m
N 11
AC804075 AC

1. Turbocharger oil feed pipe 6. Turbocharger water feed hose
2. Turbocharger oil feed pipe gasket connection
3. Turbocharger water return hose 7. Turbocharger water return pipe
connection 8. Turbocharger water return pipe
4. Turbocharger water feed pipe gasket
5. Turbocharger water feed pipe 9. Turbocharger oil return pipe
gasket 10. Turbocharger oil return pipe
gasket
Removal steps (Continued) Position the projection as shown in the illustration.

>>C<< 11. Turbocharger oil return pipe
gasket >>B<< TURBOCHARGER ASSEMBLY
12. Nut and washer INSTALLATION
>>B<< 13. Turbocharger assembly
>>A<< 14. Turbocharger gasket 1. Check the internal surface, the eye bolt and the
15. Exhaust manifold cover mating surface of the oil pipe and water pipe for
16. Flange nut clogging, and clean if necessary.
17. Engine hanger CAUTION
18. Nut and washer Be careful not to allow foreign material to enter
19. Exhaust manifold
the turbocharger.
20. Exhaust manifold gasket
2. If deposits of carbon are accumulated on the
REMOVAL SERVICE POINT turbocharger oil passage, remove them and clean
<<A>> OIL PIPE REMOVAL using the compressed air.
3. Add clean engine oil through the oil feed pipe port
CAUTION
on the turbocharger.
Take care not to allow foreign objects to get into
the oil passage hole of the turbocharger assem-
bly after the oil pipe is removed. >>C<< OIL RETURN PIPE GASKET
INSTALLATION
>>A<< TURBOCHARGER GASKET INSTALLA-
TION
Section A-A
Oil return
pipe
A
Projection
AC502996AB
Projection
A
AC502995AB
INTAKE AND EXHAUST
15-21
M1151008901364

• Under Skid Plate and Engine Room Under Cover • Catalytic Converter Installation (Refer to GROUP 17 −
Removal (Refer to GROUP 51 − Under Cover ). Catalytic Converter ).
• Engine Coolant Draining (Refer to GROUP 14 − On-vehi- • Intercooler Inlet Air Hose Installation (Refer to P.15-12).
cle Service, Engine Coolant Replacement ). • Battery and Battery Box Installation (Refer to GROUP
• Air Cleaner Assembly Removal (Refer to P.15-6). 54A − Battery ).
• Battery and Battery Box Removal (Refer to GROUP 54A • Air Cleaner Assembly Installation (Refer to P.15-6).
− Battery ). • Under Skid Plate and Engine Room Under Cover Installa-
• Intercooler Inlet Air Hose Removal (Refer to P.15-12). tion (Refer to GROUP 51 − Under Cover ).
• Catalytic Converter Removal (Refer to GROUP 17 − Cat- • Engine Coolant Refilling (Refer to GROUP 14 − On-vehi-
alytic Converter ). cle Service, Engine Coolant Replacement ).
14 ± 1 N·m
2 3.0 ± 0.5 N·m
24 ± 3 N·m
17 ± 2 N·m
17 ± 2 N·m
3 4N
N4 9.0 ± 1.0 N·m
59 ± 10 N·m 5
N 11 9.0 ± 1.0 N·m
13 24 ± 3 N·m 1
14 N 6
7
34 ± 3 N·m 14 ± 1 N·m
N 18 59 ± 10 N·m
N 12
10 62 ± 5 N·m
18 N 15
9
14 ± 1 N·m
16 8
17
N 18 19
34 ± 3 N·m
62 ± 5 N·m
N 20
AC900935AC

1. Engine cover 8. Water hose connection
2. Turbocharger heat protector 9. Oil return hose
<<A>> 3. Oil pipe 10. Vacuum hose connection
4. Gasket 11. Nut and washer
5. Heat protector 12. Bolt and washer
6. Heat protector bracket 13. Turbocharger, turbocharger water
7. Water hose connection pipe and oil return pipe assembly

>>D<< 14. Turbocharger gasket
15. Exhaust manifold heat protector A
16. Exhaust manifold heat protector B
17. Engine hanger
18. Nut and washer
19. Exhaust manifold
20. Exhaust manifold gasket
26
25 N
11 ± 1 N·m
24
N 22
9.0 ± 1.0 N·m 24 ± 3 N·m

23
21
AC805771 AC
Removal steps CAUTION

21. Oil return pipe Be careful not to allow foreign material to enter
>>C<< 22. Oil return pipe gasket the turbocharger.
23. Water hose
24. Turbocharger water pipe 2. If deposits of carbon are accumulated on the
>>B<< 25. Turbocharger water pipe gasket turbocharger oil passage, remove them and clean
>>A<< 26. Turbocharger assembly using the compressed air.
3. Add clean engine oil through the oil pipe port on
REMOVAL SERVICE POINT the turbocharger.
<<A>> OIL PIPE REMOVAL
>>B<< TURBOCHARGER WATER PIPE GASKET
CAUTION
INSTALLATION
Take care not to allow foreign objects to get into
the oil passage hole of the turbocharger assem- Turbocharger Projection
bly after the oil pipe is removed. assembly
Turbocharger
INSTALLATION SERVICE POINTS water pipe
>>A<< TURBOCHARGER ASSEMBLY INSTALLA-

TION
1. Check the internal surface, the eye bolt and the
mating surface of the oil pipe and water pipe for Turbocharger
clogging, and clean if necessary. water pipe
gasket AC805773 AB
INTAKE AND EXHAUST
15-23
Position the projection as shown in the illustration. Position the projection as shown in the illustration.
>>C<< OIL RETURN PIPE GASKET INSPECTION

M1151009400057
INSTALLATION
Check the following points; replace the part if a prob-
lem is found.
EXHAUST MANIFOLD CHECK
1. Check for damage or cracking of any part.
Oil return 2. Using a straight edge and a feeler gauge, check
pipe gasket
for distortion of the cylinder head installation
Turbocharger surface.
assembly Standard value: 0.15 mm or less
Projection Oil return pipe Limit: 0.20 mm
AC805772 AB
TURBOCHARGER ASSEMBLY CHECK
Position the projection as shown in the illustration. 1. Visually check the turbine wheel and the
compressor wheel for cracking or other damage.
>>D<< TURBOCHARGER GASKET 2. Check whether the turbine wheel and the
INSTALLATION compressor wheel can be easily turned by hand.
Turbocharger 3. Check for oil leakage from the turbocharger
assembly assembly.
4. Check whether or not the turbocharger waste gate
regulating valve remains open. If any problem is
found, replace the part after disassembly.
OIL PIPE AND OIL RETURN PIPE CHECK

Check the oil pipe and oil return pipe for clogging,
Projection Projection bending or other damage. If there is clogging, clean
AC805775AB it.

M1151008600586
<Except Euro5>
• Under Skid Plate and Engine Room Under Cover • Under Skid Plate and Engine Room Under Cover Installa-
Removal (Refer to GROUP 51 − Under Cover ). tion (Refer to GROUP 51 − Under Cover ).
N 5
N 2
57 ± 7 N·m
6
25 ± 4 N·m
4
25 ± 4 N·m 1 3N
49 ± 5 N·m
ACB00721 AB

1. Front exhaust pipe 5. Exhaust pipe gasket
2. Exhaust pipe gasket 6. Exhaust main muffler
3. Seal ring 7. Dash heat protector panel
4. Centre exhaust pipe
INTAKE AND EXHAUST
15-25
<Euro5>
CAUTION
When the DPF is replaced, use the M.U.T.-III to initialise the learning value (Refer to GROUP 00 − Pre-
cautions before Service, Initialisation Procedure for Learning Value in DPF System ).
10
8.0 ± 2.0 N·m
8.0 ± 2.0 N·m 4 6 36 ± 4 N·m
5 N 8
N 2 4 6
57 ± 7 N·m 7
36 ± 4 N·m
9
25 ± 4 N·m
25 ± 4 N·m 1 3N
49 ± 5 N·m
ACB00722 AB

• No.2 exhaust gas temperature • No.3 exhaust gas temperature
sensor (Refer to GROUP 17 − sensor (Refer to GROUP 17 −
Emission Control, DPF System Emission Control, DPF System
Sensors ) Sensors )
1. Front exhaust pipe 4. Exhaust pressure hose connection
2. Exhaust pipe gasket 5. Exhaust pressure pipe and DPF
3. Seal ring assembly
• No.2 crossmember (Refer to 6. Exhaust pressure pipe
GROUP 32 − Rear Engine 7. DPF
Mounting ) <2WD> 8. Exhaust pipe gasket
9. Exhaust main muffler
10. Front floor heat protector panel
16-1
GROUP 16
ENGINE
ELECTRICAL
CONTENTS
CHARGING SYSTEM . . . . . . . . . . . . 16-2 GLOW SYSTEM . . . . . . . . . . . . . . . . . 16-18

GENERAL INFORMATION. . . . . . . . . . . . . 16-2 GENERAL INFORMATION . . . . . . . . . . . . . 16-18
SERVICE SPECIFICATION(S) . . . . . . . . . . 16-4 SERVICE SPECIFICATION(S) . . . . . . . . . . 16-21
SPECIAL TOOL(S) . . . . . . . . . . . . . . . . . . . 16-5 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . 16-22
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . 16-6 GLOW PLUG CHECK <Euro5> . . . . . . . . . 16-22
ALTERNATOR OUTPUT LINE VOLTAGE DROP SELF-REGULATING GLOW SYSTEM CHECK
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-6 <Except Euro5> . . . . . . . . . . . . . . . . . . . . . . 16-22
OUTPUT CURRENT TEST. . . . . . . . . . . . . 16-7 CHECK THE ENGINE ECU TERMINALS <Euro5>
REGULATED VOLTAGE TEST . . . . . . . . . 16-9 ...................................... 16-23
WAVE PATTERN CHECK USING AN CHECK THE ENGINE ECU TERMINALS <Except
OSCILLOSCOPE . . . . . . . . . . . . . . . . . . . . 16-10 Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-23
ALTERNATOR ASSEMBLY . . . . . . . . . . . . 16-13 GLOW PLUG RELAY CHECK <Except Euro5>
...................................... 16-23
ALTERNATOR ASSEMBLY REMOVAL AND
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 16-13 GLOW PLUG CHECK <Except Euro5> . . . 16-24
ENGINE COOLANT TEMPERATURE SENSOR
STARTING SYSTEM . . . . . . . . . . . . . 16-14 CHECK <Except Euro5> . . . . . . . . . . . . . . . 16-24
GLOW PLUG . . . . . . . . . . . . . . . . . . . . . . . . 16-25
GENERAL INFORMATION. . . . . . . . . . . . . 16-14
SERVICE SPECIFICATION(S) . . . . . . . . . . 16-15 GLOW PLUG REMOVAL AND INSTALLATION
...................................... 16-25
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . 16-16
GLOW PLUG RELAY <Except Euro5> . . . . 16-25
STARTER RELAY CONTINUITY CHECK . 16-16
GLOW PLUG RELAY REMOVAL AND INSTALLATION
STARTER MOTOR ASSEMBLY. . . . . . . . . 16-16 ...................................... 16-25
STARTER MOTOR ASSEMBLY REMOVAL AND GLOW CONTROL UNIT <Euro5> . . . . . . . . 16-26
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 16-16
GLOW CONTROL UNIT REMOVAL AND
STARTER MOTOR ASSEMBLY INSPECTION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 16-26
...................................... 16-17
16-2 ENGINE ELECTRICAL
CHARGING SYSTEM
CHARGING SYSTEM
GENERAL INFORMATION
M1161000102045
The charging system uses the alternator output to When the ignition switch is turned on, current flows in
keep the battery charged at a constant level under the field coil and initial excitation of the field coil
various electrical loads. occurs.
OPERATION When the stator coil begins to generate power after
the engine is started, the field coil is excited by the
Voltage output current of the stator coil.
The alternator output voltage rises as the field cur-
rent increases and it falls as the field current
decreases. When the battery voltage (alternator "S"
Approximately terminal voltage) reaches a regulated voltage of
14.4 V
approximately 14.4 V, the field current is cut off.
When the battery voltage drops below the regulated
Time
voltage, the voltage regulator regulates the output
voltage to a constant level by controlling the field cur-
AK400075AB
rent.
Rotation of the excited field coil generates AC volt- In addition, when the field current is constant, the
age in the stator. alternator output voltage rises as the engine speed
This alternating current is rectified through diodes to increases.
DC voltage having a waveform shown in the illustra- CAUTION
tion.
When the specified alternator is not used, each
The average output voltage fluctuates slightly with
ECU would probably fail.
the alternator load condition.
ENGINE ELECTRICAL
CHARGING SYSTEM
16-3
<Except Euro 5>
Alternator
B
Stator
coil
Field coil S
+
L
Voltage
regulator Charging
warning lamp Ignition
switch Battery
Combination
meter
–
AK403859 AB
<Euro 5>
Alternator
Engine-ECU
Stator coil Stator coil
G
Field coil S
L Ignition
Voltage Charging
regulator FR switch-IG
warning lamp
Combination
meter Battery
AK802592AE
ALTERNATOR SPECIFICATIONS
CHARGING SYSTEM
Item Except Euro 5 Euro 5

Type Battery voltage sensing Battery voltage sensing
Rated output V/A 12/90 <Standard> 12/95 <Standard>
12/120 <Cold climate zone> 12/130 <Cold climate zone>
Voltage regulator Electronic built-in type Electronic built-in type
M1161000301370

Alternator output line voltage drop (at 30 A) V − Maximum 0.3
Regulated voltage ambient −20°C 14.2 − 15.4 −
temperature at voltage regulator 20°C 13.9 − 14.9 −
(vehicle stationary) V
60°C 13.4 − 14.6 −
80°C 13.1 − 14.5 −
Output current − 70 % of normal output current
ENGINE ELECTRICAL
CHARGING SYSTEM
16-5
SPECIAL TOOL
M1161000600646

MB991955 M.U.T.-III sub assembly • Checking the engine speed
A A: • A: Vehicle CAUTION
MB991824 communication For vehicles with CAN
B: interface (V.C.I.) communication, use M.U.T.-III main
MB991827 • B: M.U.T.-III USB harness A to send simulated
MB991824 C: cable vehicle speed. If you connect
B MB991910 • C: M.U.T.-III main M.U.T.-III main harness B instead,
D: harness A (Vehicles the CAN communication does not
MB991911 with CAN function correctly.
E: communication
MB991827 MB991825 system)
F: • D: M.U.T.-III main
C
MB991826 harness B (Vehicles
without CAN
communication
system)
MB991910
• E: M.U.T.-III
D measurement adapter
• F: M.U.T.-III trigger
DO NOT USE
harness
MB991911
MB991825
MB991826
MB991955
MB991519 Alternator test harness Checking the alternator

("S" terminal voltage)
CHARGING SYSTEM
ON-VEHICLE SERVICE
ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST

M1161000900926
Ammeter (clamp-type)
Alternator
Voltmeter (digital-type)
Battery
"B" terminal
AK203361AD
This test determines whether the wiring from the 5. Connect a digital-type voltmeter between the
alternator "B" terminal to the battery (+) terminal alternator "B" terminal and the battery (+)
(including the fusible line) is in a good condition or terminal. [Connect the (+) lead of the voltmeter to
not. the "B" terminal and connect the (−) lead of the
1. Always be sure to check the following before the voltmeter to the battery (+) cable].
test. 6. Reconnect the negative battery cable.
• Alternator installation 7. Connect the M.U.T.-III or tachometer
• Drive belt tension
8. Leave the hood open.
(Refer to GROUP 11A − On-Vehicle Service − Alter-
nator and Power Steering Oil Pump Drive Belt 9. Start the engine.
Tension Check and Adjustment ). 10.With the engine running at 2,500 r/min, turn the
• Fusible link headlamps and other lamps on and off to adjust
• Abnormal noise from the alternator while the the alternator load so that the value displayed on
engine is running the ammeter is slightly above 30 A.
2. Turn the ignition switch to the "LOCK" (OFF) Adjust the engine speed by gradually decreasing
position. it until the value displayed on the ammeter is 30
3. Disconnect the negative battery cable. A. Take a reading of the value displayed on the
4. Connect a clamp-type DC test ammeter with a voltmeter at this time.
range of 0 − 100 A to the alternator "B" terminal Limit: Maximum 0.3 V
output wire. NOTE: When the alternator output is high and the
NOTE: The way of disconnecting the alternator value displayed on the ammeter does not
output wire and of connecting the ammeter is pos- decrease until 30 A, set the value to 40 A. Read
sibly not found the problem that the output current the value displayed on the voltmeter at this time.
is dropping due to the insufficient connection When the value range is 40 A, the limit is maxi-
between terminal "B" and the output wire. mum 0.4 V.
ENGINE ELECTRICAL
CHARGING SYSTEM
16-7
11.If the value displayed on the voltmeter is above 12.After the test, run the engine at idle.
the limit value, there is probably a malfunction in 13.Turn off all lamps.
the alternator output wire, so check the wiring 14.Turn the ignition switch to the "LOCK" (OFF)
between the alternator "B" terminal and the position.
battery (+) terminal (including fusible link).
15.Remove the M.U.T.-III or tachometer.
If a terminal is not sufficiently tight or if the 16.Disconnect the negative battery cable.
harness has become discoloured due to
overheating, repair and then test again. 17.Disconnect the ammeter and voltmeter.
18.Connect the negative battery cable.
OUTPUT CURRENT TEST

M1161001002427
Load
Ammeter
Voltmeter (clamp-type)
– +
Combination meter
Ignition Charging
switch-IG warning lamp B
L
S
G
Alternator
+
Engine-ECU
Battery <Euro 5>
AKB00234 AB
This test determines whether the alternator output • Drive belt tension
current is normal. (Refer to GROUP 11A − On-Vehicle Service − Alter-
1. Before the test, always be sure to check the nator and Power Steering Oil Pump Drive Belt
following. Tension Check and Adjustment .)
• Alternator installation • Fusible link
• Battery (Refer to GROUP 54A − Battery − On- • Abnormal noise from the alternator while the
Vehicle Service − Battery Test .) engine is running.
NOTE: The battery should be slightly discharged. 2. Turn the ignition switch to the "LOCK" (OFF)
The load needed by a fully-charged battery is position.
insufficient for an accurate test. 3. Disconnect the negative battery cable.
CHARGING SYSTEM
CAUTION Limit: 70% of normal current output

Never use clips but tighten bolts and nuts to con- NOTE: .
nect the line. Otherwise loose connections (e.g. • For the nominal current output, refer to the
using clips) will lead to a serious accident Alternator Specifications.
because of high current. • Because the current from the battery will soon
4. Connect a clamp-type DC test ammeter with a drop after the engine is started, the above step
range of 0 − 100 A to the alternator "B" terminal should be carried out as quickly as possible in
output wire. order to obtain the maximum current output
value.
NOTE: The way of disconnecting the alternator
• The current output value will depend on the
output wire and of connecting the ammeter is pos-
electrical load and the temperature of the
sibly not found the problem that the output current
alternator body.
is dropping due to the insufficient connection
• If the electrical load is small while testing, the
between terminal "B" and the output wire.
specified level of current may not be output
5. Connect a voltmeter with a range of 0 − 20 V even though the alternator is normal. In such
between the alternator "B" terminal and the earth cases, increase the electrical load by leaving
[Connect the (+) lead of the voltmeter to the "B" the headlamps turned on for some time to dis-
terminal, and then connect the (−) lead of the charge the battery or by using the lighting sys-
voltmeter to the earth]. tem in another vehicle, and then test again.
6. Connect the negative battery cable. • The specified level of current also may not be
7. Connect the M.U.T.-III or tachometer. output if the temperature of the alternator body
8. Leave the hood open. or the ambient temperature is too high. In such
cases, cool the alternator and then test again.
9. Check that the reading on the voltmeter is equal
to the battery voltage. 12.The reading on the ammeter should be above the
limit value. If the reading is below the limit value
NOTE: If the voltage is 0 V, the cause is probably
and the alternator output wire is normal, remove
an open circuit in the wire or fusible link between
the alternator from the engine and check the
the alternator "B" terminal and the battery (+) ter-
alternator.
minal.
13.Run the engine at idle after the test.
10.Turn the light switch on to turn on headlamps and
then start the engine. 14.Turn the ignition switch to the "LOCK" (OFF)
position.
11.Immediately after setting the headlamps to high
beam and turning the heater blower switch to the 15.Remove the M.U.T.-III or tachometer.
high revolution position, increase the engine 16.Disconnect the negative battery cable.
speed to 2,500 r/min and read the maximum 17.Disconnect the ammeter and voltmeter.
current output value displayed on the ammeter. 18.Connect the negative battery cable.
ENGINE ELECTRICAL
CHARGING SYSTEM
16-9
REGULATED VOLTAGE TEST
M1161001102457
Load
Ammeter (clamp-type)
Combination meter
Ignition Charging MB991519

switch-IG warning lamp
Blue
L Alternator
S
G
+ Black
Engine-ECU Yellow Red

Battery
<Euro 5>
–
Voltmeter (digital-type)
+ –
AKB00235 AB
This test determines whether the voltage regulator 4. Use the special tool Alternator test harness
correctly controlling the alternator output voltage. (MB991519) to connect a digital voltmeter
1. Always be sure to check the following before the between the alternator "S" terminal and earth
test. [Connect the (+) lead of the voltmeter to the "S"
• Alternator installation terminal, and then connect the (−) lead of the
• Check that the battery installed in the vehicle is voltmeter to a secure earth or to the battery (−)
fully charged. terminal].
(Refer to GROUP 54A − Battery − On-Vehicle Serv- 5. Connect a clamp-type DC test ammeter to the
ice − Battery Test .) alternator "B" terminal output wire.
• Drive belt tension 6. Reconnect the negative battery cable.
(Refer to GROUP 11A − On-Vehicle Service − Alter-
7. Connect the M.U.T.-III or tachometer.
nator and Power Steering Oil Pump Drive Belt
Tension Check and Adjustment .) 8. Turn the ignition switch to the "ON" position and
• Fusible link check that the reading on the voltmeter is equal to
• Abnormal noise from the alternator while the the battery voltage.
engine is running NOTE: If the voltage is 0 V, the cause is probably
2. Turn the ignition switch to the "LOCK" (OFF) an open circuit in the wire or fusible link between
position. the alternator "S" terminal and the battery (+) ter-
3. Disconnect the negative battery cable. minal.
9. Turn all lamps and accessories off.
10.Start the engine.
NOTE: Do not drive the vehicle after the engine
starts.
11.Increase the engine speed to 2,500 r/min.
CHARGING SYSTEM
12.Read the value displayed on the voltmeter when 14.After the test, lower the engine speed to the idle
the alternator output current alternator becomes speed.
10 A or less. 15.Turn the ignition switch to the "LOCK" (OFF)
13.If the voltage reading conforms to the value in the position.
voltage regulation, then the voltage regulator is 16.Remove the M.U.T.-III or tachometer.
operating normally. 17.Disconnect the negative battery cable.
If the voltage is not within the standard value, 18.Disconnect the ammeter and voltmeter.
there is a malfunction of the voltage regulator or of 19.Remove the special tool, and return the connector
the alternator. to the original condition.
20.Connect the negative battery cable.
Voltage Regulation Table
STANDARD VALUE:
Inspection terminal Voltage regulator ambient Voltage V
temperature °C
Terminal "S" −20 14.2 − 15.4
20 13.9 − 14.9
60 13.4 − 14.6
80 13.1 − 14.5
WAVEFORM CHECK USING AN OSCILLOSCOPE

M1161001201428
MEASUREMENT METHOD Connect the oscilloscope special patterns pick-up to

the alternator "B" terminal.
Alternator
CH1
"B" terminal AK701885AC
STANDARD WAVEFORM
Observation Conditions
Function Special pattern
Pattern height Variable
Variable knob Adjust while viewing the waveform.
Pattern selector Raster
Engine speed Curb idle speed
ENGINE ELECTRICAL
CHARGING SYSTEM
16-11
0.4
0.2
Voltage
at alternator 0
"B" terminal
-0.2
-0.4
Time
AK701886AB
NOTE: when the voltage waveform reaches an excessively

high value (approximately 2 V or higher at idle), it
often indicates an open circuit due to a brown fuse
between alternator "B" terminal and battery, but not a
defective alternator.
AK701862
The voltage waveform of the alternator "B" terminal

can undulate as shown in the illustration. This wave-
form is produced when the regulator operates
according to fluctuations in the alternator load (cur-
rent), and is normal for the alternator. In addition,
EXAMPLE OF ABNORMAL WAVEFORMS
NOTE: .
1. The size of the waveform patterns differs largely, depending on the adjustment of the variable knob on the
oscilloscope.
2. Identification of abnormal waveforms is easier when there is a large output current (regulator is not oper-
ating). (Waveforms can be observed when the headlamps are illuminated.)
3. Check the conditions of the charging warning lamp (illuminated/not illuminated). Also, check the charging
system totally.
CHARGING SYSTEM
Abnormal waveform Problem cause

Except Euro 5 Euro 5
Example 1 Example 1 Open diode
AK703778
AK502669
Example 2 Example 2 Short in diode
AK703780
AK502670
Example 3 Example 3 Broken wire in

stator coil
AK703781
AK502671
Example 4 Example 4 Short in stator

coil
AK703782
AK502672
ENGINE ELECTRICAL
CHARGING SYSTEM
16-13
ALTERNATOR ASSEMBLY

M1161001403804
CAUTION
When the specified alternator is not used, each ECU would probably fail.
• Air Cleaner Assembly Removal (Refer to GROUP 15 − Air • A/C Compressor Drive Belt, Alternator and Power Steer-
Cleaner ). ing Oil Pump Drive Belt Installation (Refer to GROUP 11A
• Intercooler Inlet Air Hose Removal (Refer to GROUP 15 − − Crankshaft Pulley ).
Intercooler ) <Except Euro5>. • Intercooler Inlet Air Hose Installation (Refer to GROUP 15
• Intercooler Inlet Air Hose Removal (Refer to GROUP 15 − − Intercooler ) <Except Euro5>.
Intercooler ) <Euro5>. • Intercooler Inlet Air Hose Installation (Refer to GROUP 15
• A/C Compressor Drive Belt, Alternator and Power Steer- − Intercooler ) <Euro5>.
ing Oil Pump Drive Belt Removal (Refer to GROUP 11A − • Air Cleaner Assembly Installation (Refer to GROUP 15 −
Crankshaft Pulley ). Air Cleaner ).
• Alternator and Power Steering Oil Pump Drive Belt Ten-
sion Check (Refer to GROUP 11A − On-vehicle Service,
Alternator and Power Steering Oil Pump Drive Belt Ten-
sion Check ).
• A/C Compressor Drive Belt Tension Check and Adjust-
ment (Refer to GROUP 11A − On-vehicle Service, A/C
Compressor Drive Belt Tension Check and Adjustment ).
14 ± 4 N·m
3 2
1
44 ± 10 N·m
23 ± 2 N·m
AC503001AC

1. Alternator connector connection 2. Alternator terminal connection
<<A>> 3. Alternator assembly
STARTING SYSTEM
REMOVAL SERVICE POINT 1. Remove the rubber shield from the wheelhouse
<<A>> ALTERNATOR ASSEMBLY REMOVAL (RH), and put the pipe, hose, etc. to side so that
they will not be a hindrance when removing and
installing the alternator assembly.
2. Remove the alternator assembly from the
wheelhouse (RH).
ACB00699AB
STARTING SYSTEM
GENERAL INFORMATION
M1161000100845
If the ignition switch is turned to the "START" posi- When the ignition switch is returned to the "ON" posi-
tion, current flows in the pull-in and holding coils pro- tion after starting the engine, the starter clutch is dis-
vided inside magnetic switch, attracting the plunger, engaged from the ring gear.
When the plunger is attracted, the lever connected to An overrunning clutch is provided between the pinion
the plunger is actuated to engage the starter clutch. and the armature shaft, to prevent damage to the
On the other hand, attracting the plunger will turn on starter.
the magnetic switch, allowing the "B" terminal and
"M" terminal to conduct. Thus, current flows to
engage the starter motor.
ENGINE ELECTRICAL
STARTING SYSTEM
16-15
SYSTEM DIAGRAM
Holding coil Plunger
Pull-in coil
Lever
B Overrunning clutch
Ignition switch - ST M
Pinion gear
S
+ Armature
Battery
Brush Field coil

Yoke
AK500030 AB
STARTER MOTOR SPECIFICATIONS

Item Specification
Type Reduction drive with planetary gear
Rated output kW/V 2.2/12
Number of pinion teeth 10
M1161000300689

Pinion gap mm 0.5 − 2.0 −
STARTING SYSTEM
ON-VEHICLE SERVICE Battery voltage Terminal No. to Continuity test

be connected results
STARTER RELAY CHECK to tester
M1162001401113
Not applied 3−4 Open circuit
Connect 3−4 Continuity (Less
Starter relay
terminal No.2 than 2 Ω)
and battery (+)
terminal.
Connect
terminal No.1
and battery (−)
terminal.
Engine compartment relay box STARTER MOTOR ASSEMBLY

AC501631

M1162001003296
AC503883 AB

2
11 ± 1 N·m 3
30 ± 3 N·m
AC601313AD

1. Starter connector connection <<A>> STARTER ASSEMBLY REMOVAL
2. Starter terminal connection <2WD>
<<A>> 3. Starter assembly
Remove the starter assembly from below the vehicle.
ENGINE ELECTRICAL
STARTING SYSTEM
16-17
<4WD>
Remove the rubber shield from the wheelhouse (LH),
and remove the starter assembly.
ACB00700AB
STARTER MOTOR ASSEMBLY INSPECTION

M1162001101112
PINION GAP ADJUSTMENT
Switch
B
battery S
M
Starter Wire
motor
AKX00199
AK403864 AB
5. If the pinion gap is out of specification, adjust by
1. Disconnect the field coil wire from the M-terminal adding or removing gasket(s) between the
of the magnetic switch. magnetic switch and front bracket.
2. Connect a 12-volt battery between the S-terminal
and M-terminal.
MAGNETIC SWITCH PULL-IN TEST
CAUTION
This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.
3. Set the switch to "ON", and the pinion will move B
out.
Battery M S
Stopper
Starter Wire
motor
AK403868 AB
1. Disconnect the field coil wire from the M-terminal

of the magnetic switch.
Pinion
CAUTION
Pinion gap
AKX00198 AC This test must be performed quickly (in less than
4. Check the pinion-to-stopper clearance (pinion
gap) with a feeler gauge. 2. Connect a 12-volt battery between the S-terminal
and M-terminal.
3. If the pinion moves out, the pull-in coil is good. If it
doesn't, replace the magnetic switch.
GLOW SYSTEM
MAGNETIC SWITCH HOLD-IN TEST 2. Connect a voltmeter (15-volt scale) across the
starter motor.
3. Rotate the rheostat to full-resistance position.
B
4. Connect the battery cable from the negative
battery terminal to the starter motor body.
Battery S 5. Adjust the rheostat until the battery positive
M voltage shown on the voltmeter is 11 V.
Starter
6. Confirm that the maximum amperage is within the
Wire
motor specifications and that the starter motor turns
smoothly and freely.
AK403869 AB
Current: Maximum 130 A
of the magnetic switch. MAGNETIC SWITCH RETURN TEST
CAUTION
This test must be performed quickly (in less than
B
2. Connect a 12-volt battery between the S-terminal
and body. S
Battery
3. Manually pull out the pinion as far as the pinion M
stopper position.
Starter Wire
4. If the pinion remains out, everything is in order. If motor
the pinion moves in, the hold-in circuit is open.
Replace the magnetic switch. AK403871 AB

FREE RUNNING TEST of the magnetic switch.
Ammeter CAUTION
A This test must be performed quickly (in less than
B 10 seconds) to prevent the coil from burning.
Carbon-pile
rheostat
S 2. Connect a 12-volt battery between the M-terminal
M
and body.
Battery
Starter V WARNING
motor Voltmeter Be careful not to get your fingers caught
when pulling out the pinion.
AK403870 AB 3. Pull the pinion out and release. If the pinion
quickly returns to its original position, everything is
1. Connect a test ammeter (150-ampere scale or
operating properly. If it doesn't, replace the
more) and carbon pile rheostat in series between
magnetic switch.
the positive battery terminal and starter motor
terminal.
GLOW SYSTEM
GENERAL INFORMATION The glow control unit carries out the duty control to
M1164000100178 the energization of the glow plug, in accordance with
GLOW SYSTEM <EURO5> the signal from the engine-ECU.This achieves the
GLOW CONTROL optimum voltage of the glow plug in accordance with
The glow control unit of the glow system employs the the engine conditions at the after glow to stabilize the
method of energizing the glow plug of each cylinder combustion. Also the combustion noise or hydrocar-
respectively. bon (HC) emissions are reduced.
ENGINE ELECTRICAL
GLOW SYSTEM
16-19
System Configuration Diagram
Combination
Glow indicator meter
Engine control relay lamp
Battery
Engine coolant
temperature sensor
Control Ignition switch-IG

signal
Engine-ECU Ignition switch-ST
Glow plug Diagnosis
control circuit signal
Crank angle sensor

sensor
Manifold absolute
Power pressure sensor
MOSFET
Glow control unit Glow plug
AKB00122 AB
The engine-ECU determines the glow start, the glow Glow Indicator Lamp Control
time and the energization duty cycle of the glow plug. When the engine coolant temperature is below a pre-
The engine-ECU outputs the PWM signal of the glow determined level, engine-ECU illuminates the glow
operation request to the glow control unit when the indicator lamp. This causes the glow indicator lamp
following conditions are satisfied. to illuminate, in order to inform the driver of the timing
for starting the engine.
Before starting (Pre-glow control)
• Ignition switch: ON GLOW CONTROL UNIT
• Engine coolant temperature is 60°C or less.
Under the conditions of the engine not starting, the
maximum energization time of the glow plug (duty of
100%) is 20 seconds.
While running a cold engine (After-glow control)
• Engine coolant temperature is 70°C or less.
• Engine speed is 350 r/min or more.
NOTE: The glow duty is determined in accordance
with the engine coolant temperature and the intake AKB00123
air temperature (at the air flow sensor). The glow control unit is installed to the fuel filter pro-
The maximum energization time of the glow plug is tector. The engine-ECU supplies the power to the
300 seconds. control part of the glow control unit when the ignition
switch is turned ON. The energization to the glow
plug from the battery is controlled by installing the
power-MOSFET (Metal Oxide Semiconductor Field
GLOW SYSTEM
Effect Transistor) to the glow control unit for each cyl-

Heated portion temperature (˚C)
inder. When receiving the signal from the engine-
ECU through the control signal wire, the glow control
unit controls the Power-MOSFET, based on the sig- 1000
nal duty, to control the voltage for each glow plug. If
When 11 V is applied
detecting the open or short circuit of the glow plug, or
communication failures to the engine-ECU, the glow
control unit sends the malfunction signal to the 500
engine-ECU through the diagnosis signal wire.
GLOW PLUG
Driving current (A)
5
When 11 V is applied
Ceramic heating element
AK802950 AB 0
30
Energization time (s)
The glow plug is installed to each cylinder of the cyl- AK802953AB
inder head. The glow plug performs preheating of the
combustion chamber with the ceramic heating ele- The self control resistance is built in the ceramic
ment on the acral part. The heating temperature of heating element of the glow plug. When the current
the glow plug is changed by adjusting the voltage is going through the glow plug, the heating element
applied to the glow plug through the duty control of heats up and the self control resistance increases,
the glow control unit. too.This gradually decreases the current going
through the heating element to restrict the amount of
heating the glow plug.
SELF-REGULATING GLOW SYSTEM

<EXCEPT EURO 5>
The self-regulating glow system enables the vehicle
to start ideally at low temperature by preheating the
glow plug at super speed. When the ignition switch is
turned to the ON position, the engine-ECU supplies
electric currents and controls the glow lamp illumina-
tion in accordance with the engine coolant tempera-
ture. The control resistance wire built in the glow plug
has a higher resistance as the glow plug temperature
becomes higher. Because of this, the currents in the
heater wire gradually decrease. The glow plug is sta-
bilized at the specified temperature. After the engine
start at low temperature, the current going to the
glow plug is controlled to perform the stable combus-
tion.
ENGINE ELECTRICAL
GLOW SYSTEM
16-21
Battery
Engine
control
relay
Ignition
switch
Engine-ECU
Glow plug
OFF relay
ON
Engine coolant
temperature sensor
Glow lamp
Ignition switch-IG
Ignition switch-ST
Glow plugs
Crank angle sensor
AK403873AB
SERVICE SPECIFICATION
M1164000300194
<EURO5>
Item Standard value
Glow plug resistance (at 20°C) Ω 0.6 − 1.4
<EXCEPT EURO5>
Item Standard value
Resistance between glow plug plate and glow plug body (parallel 0.15 − 0.25
resistance for 4 glow plugs) (at 20°C) Ω
Voltage between glow plug plate and Immediately after ignition 9 − 11 (Drops to 0 V after 4 − 8
glow plug body V switch is turned to ON seconds have passed)
(without starting the engine)
While engine is cranking 6 or more
While engine is warning up 12 − 15 (Drops to 0 V when the
engine coolant temperature
increases to 60°C or more or if
180 seconds have passed since
the engine was started)
Glow plug relay resistance (at 20°C) Ω 18 − 22
Glow plug resistance (at 20°C) Ω 0.6 − 1.0
GLOW SYSTEM
ON-VEHICLE SERVICE
GLOW PLUG CHECK <EURO5>

M1164003400305
1. Disconnect the glow plug connector.
2. Measure the resistance between the glow plug
terminal and the body, or the glow plug terminal
and the cylinder head.
(-) Standard value: 0.6 − 1.4 Ω (at 20°C)
(+)
AK403892AC
SELF-REGULATING GLOW SYSTEM CHECK <EXCEPT EURO5>

M1164001000260
SELF-REGULATING GLOW SYSTEM CHECK 4. Connect a voltmeter between the glow plug plate
1. Check that the battery voltage is 11 − 13 V. and the glow plug body (earth).
2. Check that the engine coolant temperature is 5. Measure the voltage immediately after the ignition
40°C or less. switch is turned to ON (without starting the
NOTE: If the engine coolant temperature is too engine).
high, disconnect the engine coolant temperature Standard value: 9 − 11 V (Drops to 0 V after 4
sensor connector. − 8 seconds have passed)
In addition, check to be sure that the glow indicator
lamp (red) illuminates immediately after the ignition
switch is turned to ON.
NOTE: The time during which the voltage appears
(-) (energizing time) will depend on the engine cool-
ant temperature.
6. Measure the voltage while the engine is cranking.
Standard value: 6 V or more
(+)
AK403875AC 7. Start the engine and measure the voltage while
the engine is warming up.
However, if the engine coolant temperature rises
plate and the glow plug body (earth).
above 60°C or when 180 seconds have passed
Standard value: 0.15 − 0.25 Ω (at 20°C) since the engine was started, the voltage will
NOTE: The resistance value is the parallel resist- always return to 0 V (Refer to the Glow Plug
ance value for the four glow plugs. Energization Timing Chart).
Standard value: 12 − 15 V
ENGINE ELECTRICAL
GLOW SYSTEM
16-23
Glow Plug Energization Timing Chart <Reference>
Ignition START
switch
ON
OFF
T1
Glow ON
lamp
OFF
T2 T3
Glow plug ON
relay
OFF
Crank angle Idle

sensor
0 r/min
T1: Glow lamp

T2: Glow plug relay drive time after ignition switch is turned ON
T3: Glow plug relay drive time after engine starts (after glow)
NOTE
After glow time T3 becomes longer as the engine coolant temperature drops
AK403877 AG
CHECK AT THE ECU TERMINALS <EURO5>

M1164003600246
Refer to GROUP 13A − Troubleshooting − Check at
the engine-ECU terminals .
CHECK AT THE ECU TERMINALS <EXCEPT EURO5>

M1164003600257
Refer to GROUP 13A − Troubleshooting − Check at
the engine-ECU terminals.
GLOW PLUG RELAY CHECK <EXCEPT EURO5>

M1164003300160
1. Disconnect the glow plug relay connector.
2. Measure resistance between terminal C and
Glow plug relay
terminal E.
Standard value: 18 − 22 Ω (at 20°C)
3. Use jumper cables to connect terminal C of the
glow plug relay to the battery (+) terminal and
terminal E to the battery (−) terminal.
AK403878AB
GLOW SYSTEM
CAUTION 4. Check the continuity between glow plug relay

1. Always be sure to disconnect the harnesses terminals B and G while disconnecting and
connected to glow plug relay terminals B and connecting the jumper cable at the battery (+)
G before using the jumper cable. terminal.
2. The terminals of the disconnected harnesses
must not be shorted to earth.
3. When connecting the jumper cable, be very
careful not to make a mistake in connecting
the terminal, as this will cause damage to the
relay.
B G C E
B terminal
G terminal
C E
AK403881AB
Jumper cable at battery (+) Continuity between

terminal terminals B − G
Connected Continuity (0.01 Ω or less)
Disconnected No continuity (infinite
resistance)
GLOW PLUG CHECK <EXCEPT EURO5> 1. Remove the glow plug plate.
M1164003400316
terminals and the body.
Standard value: 0.6 − 1.0 Ω (at 20°C)
ENGINE COOLANT TEMPERATURE

(-)
SENSOR CHECK <EXCEPT EURO5>
M1164003500067
Refer to GROUP 13A − On-vehicle service − Engine
coolant temperature sensor check.
(+)
AK403892AC
ENGINE ELECTRICAL
GLOW SYSTEM
16-25
GLOW PLUG

M1164001800512

• Throttle Body Assembly Removal (Refer to GROUP 13A • EGR Valve and EGR Valve Pipe Installation (Refer to
− Throttle Body ). GROUP 17 − EGR Valve and EGR Cooler ).
• EGR Valve and EGR Valve Pipe Removal (Refer to • Throttle Body Assembly Installation (Refer to GROUP
GROUP 17 − EGR Valve and EGR Cooler ). 13A − Throttle Body ).
5.0 ± 1.0 N·m
1.8 ± 0.2 N·m
1
17 ± 2 N·m
AC503049AE
Removal steps GLOW PLUG RELAY <Except Euro5>

1. Glow plug connecting plate
<Except Euro5> REMOVAL AND INSTALLATION
2. Glow plug M1164002400023
5.0 ± 1.0 N·m

1
9.0 ± 1.0 N·m
9.0 ± 1.0 N·m
2
3
AC807146 AB
GLOW SYSTEM
Removal steps GLOW CONTROL UNIT <Euro5>

1. Glow plug control relay terminal
connection REMOVAL AND INSTALLATION
2. Glow plug control relay M1164002100077
3. Glow plug relay bracket
9.0 ± 1.0 N·m
ACB00697AB
Removal Set the connector of the glow control unit to the area
>>A<< 1. Glow control unit shown in the figure, and tighten the mounting nut to
INSTALLATION SERVICE POINT Tightening torque: 9.0 ± 1.0 N⋅m
>>A<< GLOW CONTROL UNIT INSTALLATION
4˚
30˚ ACB00698 AB
17-1
GROUP 17
ENGINE AND
EMISSION
CONTROL
CONTENTS
ENGINE CONTROL . . . . . . . . . . . . . . 17-3 SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-26

GENERAL INFORMATION. . . . . . . . . . . . . 17-3 CRUISE CONTROL INDICATOR LIGHT INSIDE
COMBINATION METER DOES NOT ILLUMINATE
ACCELERATOR PEDAL . . . . . . . . . . . . . . 17-4
(HOWEVER, CRUISE CONTROL IS NORMAL).
ACCELERATOR PEDAL REMOVAL AND ...................................... 17-27
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 17-4
DATA LIST REFERENCE TABLE . . . . . . . . 17-29
CHECK AT ECU TERMINAL. . . . . . . . . . . . 17-30
CRUISE CONTROL . . . . . . . . . . . . . . 17-5
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . 17-30
GENERAL INFORMATION. . . . . . . . . . . . . 17-5
CRUISE CONTROL SWITCH CHECK . . . . 17-30
SPECIAL TOOL(S) . . . . . . . . . . . . . . . . . . . 17-7
CRUISE CONTROL SYSTEM COMPONENT CHECK
TROUBLESHOOTING . . . . . . . . . . . . . . . . 17-9
...................................... 17-32
DIAGNOSIS TROUBLESHOOTING FLOW 17-9
CRUISE CONTROL SWITCH . . . . . . . . . . . 17-33
DIAGNOSIS FUNCTION. . . . . . . . . . . . . . . 17-9
CRUISE CONTROL SWITCH REMOVAL AND
DIAGNOSIS CODE CHART . . . . . . . . . . . . 17-9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 17-33
DIAGNOSIS CODE PROCEDURES . . . . . 17-10
CODE NO. P1564: Cruise Control Switch System EMISSION CONTROL . . . . . . . . . . . . 17-33
...................................... 17-10 GENERAL INFORMATION . . . . . . . . . . . . . 17-33
CODE NO. P1571: Stop Lamp Switch system SERVICE SPECIFICATION(S) . . . . . . . . . . 17-34
...................................... 17-15
VACUUM HOSE . . . . . . . . . . . . . . . . . . . . . 17-35
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 17-20
VACUUM HOSE PIPING DIAGRAM . . . . . . 17-35
SYMPTOM PROCEDURES . . . . . . . . . . . . 17-20
VACUUM CIRCUIT DIAGRAM . . . . . . . . . . 17-37
WHEN BRAKE PEDAL IS DEPRESSED, CRUISE
VACUUM HOSE CHECK . . . . . . . . . . . . . . 17-37
CONTROL IS NOT CANCELLED . . . . . . . . 17-20
VACUUM HOSE INSTALLATION . . . . . . . . 17-37
WHEN CLUTCH PEDAL IS DEPRESSED, CRUISE
CONTROL IS NOT CANCELLED <M/T> . . 17-21 EXHAUST GAS RECIRCULATION (EGR) SYSTEM
...................................... 17-37
WHEN SELECTOR LEVER IS MOVED TO "N"
POSITION, CRUISE CONTROL IS NOT CANCELLED GENERAL INFORMATION (EGR SYSTEM)
<A/T> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-23 ...................................... 17-37
WHEN "CANCEL" SWITCH IS TURNED ON, CRUISE COMPONENT LOCATION (EGR SYSTEM)
CONTROL IS NOT CANCELLED . . . . . . . . 17-24 ...................................... 17-38
CRUISE CONTROL CANNOT BE SET. . . . 17-24 EGR VALVE CHECK. . . . . . . . . . . . . . . . . . 17-38
HUNTING (REPEATED ACCELERATION AND EGR GAS TEMPERATURE SENSOR CHECK
DECELERATION) OCCURS AT THE SET VEHICLE <Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-40
17-2
AIR FLOW SENSOR CHECK . . . . . . . . . . . 17-40 NO. 2 EXHAUST GAS TEMPERATURE SENSOR
CRANK ANGLE SENSOR CHECK. . . . . . . 17-40 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-47
ENGINE COOLANT TEMPERATURE SENSOR NO. 3 EXHAUST GAS TEMPERATURE SENSOR
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-40 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-48
AIR TEMPERATURE SENSOR CHECK . . 17-40 CHECK AT THE ENGINE ECU TERMINALS
...................................... 17-48
CHECK AT THE ENGINE ECU TERMINALS
...................................... 17-40 DIESEL PARTICULATE FILTER (DPF) <Euro5>
...................................... 17-49
EGR VALVE AND EGR COOLER . . . . . . . 17-41
DIESEL PARTICULATE FILTER (DPF) REMOVAL
EGR VALVE AND EGR COOLER REMOVAL AND
AND INSTALLATION . . . . . . . . . . . . . . . . . 17-49
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 17-41
DIESEL PARTICULATE FILTER (DPF) SYSTEM
SENSORS <Euro5> . . . . . . . . . . . . . . . . . . 17-49
<Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-43
GENERAL INFORMATION (DPF SYSTEM)
SENSORS REMOVAL AND INSTALLATION
...................................... 17-43
...................................... 17-49
COMPONENT LOCATION (DPF SYSTEM) 17-45
CATALYTIC CONVERTER . . . . . . . . . . . . . 17-50
FORCIBLE DPF REGENERATION . . . . . . 17-46
CATALYTIC CONVERTER REMOVAL AND
NO. 1 EXHAUST GAS TEMPERATURE SENSOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 17-50
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-47
ENGINE AND EMISSION CONTROL
ENGINE CONTROL
17-3
ENGINE CONTROL
GENERAL INFORMATION This system detects the amount of the accelerator
M1171000101162 pedal movement by using an accelerator pedal posi-
For the accelerator system, a common rail fuel con- tion sensor in the accelerator pedal assembly for
trol system has been adopted, eliminating of an electronic control of the fuel injection.
accelerator cable.
CONSTRUCTION DIAGRAM
Accelerator pedal assembly

(Built-in accelerator pedal
position sensor)
Accelerator pedal
arm stopper
AC501713 AB
17-4 ENGINE AND EMISSION CONTROL
ENGINE CONTROL
ACCELERATOR PEDAL

M1171003001238
CAUTION
• Never loosen the screw fixing the accelerator pedal assembly resin cover. If the screw is loos-
ened, the sensor position which exists inside the resin cover is off and the accelerator pedal posi-
tion sensor does not work normally.
• Do not remove the accelerator pedal pad. If the pad is removed and installed, excessive force may
damage accelerator pedal position sensor.
Instrument Panel Driver’s Side Under Cover Removal and
Installation (Refer to GROUP 52A − Instrument Panel ).
13 ± 2 N·m
13 ± 2 N·m
N 3
AC501727 AD

1. Accelerator pedal position sensor >>A<< ACCELERATOR PEDAL ARM STOPPER
connector INSTALLATION
2. Accelerator pedal assembly
<<A>> >>A<< 3. Accelerator pedal arm stopper
Accelerator
REMOVAL SERVICE POINT pedal arm
stopper
<<A>> ACCELERATOR PEDAL ARM STOPPER
REMOVAL
Remove turning the accelerator pedal arm stopper. Stud bolt
Body
AC600545 AD
1. Insert the accelerator pedal arm stopper straight

into the stud bolt of the floor.
2. Install the accelerator pedal arm stopper securely
by turning it clockwise until its underside contacts
with the body as shown in the figure.
CRUISE CONTROL
17-5
3. After the installation, slightly pull the accelerator
pedal arm stopper by hand to check that it cannot
be removed easily (appropriate holding power:
100 N or more).
CRUISE CONTROL
GENERAL INFORMATION For this cruise control system, in conjunction with the
M1172000101228 common rail fuel control system, the engine-ECU
By using the cruise control system, the driver can electronically controls the fuel injection system.
drive at preferred speeds in a range of approximately
40 to 200 km/h without depressing the accelerator CONSTRUCTION DIAGRAM
pedal.
Accelerator pedal Stop lamp switch

(Built-in accelerator
pedal position sensor) Clutch switch <M/T>
Hydraulic unit
assembly
(integrated with
ASTC-ECU)
Fuel injection system Vehicle

speed sensor
Inhibitor switch
<A/T> AC711389 AC
<R H drive vehicles>

<L H drive vehicles>
Engine-ECU
Engine-ECU
AC500966AJ
AC509982AG
CRUISE CONTROL
<L H drive vehicles> Cruise control

indicator lamp
A/T-ECU
AC509994AC AC900932 AB

<L H drive vehicles>
A/T-ECU
AC500965AJ Diagnosis connector

AC711565AB

Cruise control
switch
Diagnosis connector
AC801078AB AC501596AC
CRUISE CONTROL
17-7
SPECIAL TOOLS
M1172000601740
CRUISE CONTROL

MB991955 M.U.T.-III sub-assembly CAUTION
a
a: MB991824 a: Vehicle Communication M.U.T.-III main harness A
b: MB991827 Interface (V.C.I.) should be used. M.U.T.-III
c: MB991910 b: M.U.T.-III USB cable main harness B should not be
d: MB991911 c: M.U.T.-III main harness A used for this vehicle. If you
MB991824
e: MB991825 (Vehicles with CAN connect M.U.T.-III main
d: M.U.T.-III main harness B communication does not
(Vehicles without CAN function correctly.
communication system) • Checking diagnosis trouble
MB991827 e: M.U.T.-III measurement codes
c adapter • Checking data list
f: M.U.T.-III trigger harness
MB991910
DO NOT USE
MB991911
MB991825
MB991826
MB991955
CRUISE CONTROL
17-9
MB991223 Harness set Making voltage and resistance
a
a: MB991219 a: Check harness measurement during
b: MB991220 b: LED harness troubleshooting
c: MB991221 c: LED harness adapter a: Connector pin contact
d: MB991222 d: Probe pressure inspection
b b: Power circuit inspection
c: Power circuit inspection
d: Commercial tester
connection
c
d
DO NOT USE
MB991223BF
MB992006 Extra fine probe Making voltage and resistance

measurement during
troubleshooting
MB992006
MB992291 Power plant ECU check • Measurement of voltage

harness during troubleshooting
• Measure engine-ECU
terminal voltage.
MB992044
TROUBLESHOOTING NOTE: When reading the diagnosis code, do not

select the item under "CRUISE CONTROL," but
DIAGNOSIS TROUBLESHOOTING FLOW select the item under "DIESEL ENGINE."
M1172002001045
Refer to GROUP 00 − How to Use Troubleshooting/ METHOD OF ERASING THE DIAGNOSIS
Inspection Service Points, Contents of Troubleshoot-
CODE
ing .
Use the M.U.T.-III to erase the diagnosis code (Refer
DIAGNOSIS FUNCTION to GROUP 00 − How to Use Troubleshooting/Inspec-
M1172002100964 tion Service Points, Diagnosis Function ).
METHOD OF READING THE DIAGNOSIS NOTE: When erasing the diagnosis code, do not
CODE select the item under "CRUISE CONTROL," but
Use the M.U.T.-III to read the diagnosis code (Refer select the item under "DIESEL ENGINE."
to GROUP 00 − How to Use Troubleshooting/Inspec-
tion Service Points, Diagnosis Function ). CHECK CHART FOR DIAGNOSIS CODES
M1172002201180
Code No. Diagnosis item Reference page

P1564 Abnormal voltage at cruise control switch P.17-10
P1571 Malfunction of the stop lamp switch P.17-15
CRUISE CONTROL
Code No.P1564: Abnormal voltage at cruise control switch
Cruise Control Switch System Circuit
CRUISE
CONTROL
SWITCH
CLOCK
SPRING
ENGINE-ECU
NOTE
: LH drive vehicles
: RH drive vehicles
Wire colour code

B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet PU : Purple Sl : Silver ACA01400 AB
Connector: C-103 <LH drive vehicles> Connector: C-103 <RH drive vehicles>
C-103 (B)
C-103 (B)
ACA01401 AB ACA01402 AB
CRUISE CONTROL
17-11
Connectors: C-306, C-309, C-310 DIAGNOSIS PROCEDURE
<LH drive vehicles>
Clock spring STEP 1. Check the data list.

Using M.U.T.-III, check the data list (Refer to P.17-29
C-309 (L) − data list reference table).
• Item 136: "ON/OFF" switch
• Item 137: "CANCEL" switch
C-310 • Item 138: "COAST/SET" switch
C-306 (B) • Item 139: "ACC/RES" switch
AC903921 AB
Connectors: C-306, C-309, C-310 YES : Go to Step 25.
<RH drive vehicles> NO : Go to Step 2.
Clock spring
STEP 2. Measure the terminal voltage at cruise
C-309 (L)
control switch connector C-309.
(1) Remove the cruise control switch from the
C-306 (B)
steering wheel with the cruise control switch
C-310
connector connected (Refer to P.17-33).
(2) Connect the negative battery terminal that was
AC903919 AB
disconnected when the driver's air bag module
was removed.
OPERATION (3) Turn the ignition switch to the "ON" position.
This circuit judges the signals of each switch ("ON/ (4) Do not operate the cruise control switch.
OFF", "CANCEL", "COAST/SET" and "ACC/RES") of (5) Measure the terminal voltage between cruise
the cruise control switch. The engine-ECU detects control switch connector C-309 terminal No.3 and
the state of the cruise control switch by sensing the earth with cruise control switch connector C-309
voltages shown below. connected.
• When all switches are released: 4.7 − 5.0 volts OK: 4.7 − 5.0 V
• When the "ON/OFF" switch is pressed: 0 − 0.5
volt YES : Go to Step 14.
• When the "CANCEL" switch is pressed: 1.0 − 1.8 NO : Go to Step 3.
volts
• When the "COAST/SET" switch is pressed: 2.3 −
3.0 volts STEP 3. Measure the terminal voltage at engine-
• When the "ACC/RES" switch is pressed: 3.5 − ECU connector C-103.
4.2 volts (1) Remove the engine-ECU (Refer to GROUP 13A
− Engine-ECU ).
DIAGNOSIS CODE SET CONDITIONS (2) Connect special tool power plant ECU check
• If the cruise control switch is operated, this diag- harness (MB992291) between the engine-ECU
nosis code will be set when the engine-ECU ter- and the body-side harness connector.
minal voltage is different from the standard value. (3) Turn the ignition switch to the "ON" position.
• Or, this code is set when the "COAST/SET" (4) Do not operate the cruise control switch.
switch or "ACC/RES" switch is stuck to ON. (5) Measure the terminal voltage between special
tool 58-pin connector terminal No.139 (engine-
PROBABLE CAUSES ECU connector C-103 terminal No.139) and
• Damaged harness or connector. earth.
• Malfunction of the cruise control switch.
OK: 4.7 − 5.0 V
• Malfunction of the clock spring.
• Malfunction of the engine-ECU. Q: Is the check result normal?
NO : Go to Step 4.
CRUISE CONTROL
STEP 4. Connector check: C-103 engine-ECU STEP 8. Check the clock spring.
connector. Refer to GROUP 52B − Driver’s, Front Passenger’s
Air Bag Module(s) and Clock Spring Inspection .
NO : Repair or replace the damaged connector. YES : Go to Step 9.
Then go to Step 26. NO : Replace the clock spring [Refer to GROUP
52B − Driver’s, Front Passenger’s Air Bag
STEP 5. Check the harness wire for short circuit Module(s) and Clock Spring ]. Then go to
to earth between engine-ECU connector C-103 Step 26.
terminal No.139 and cruise control switch
connector C-309 terminal No.3. STEP 9. Check the cruise control switch.
(1) Disconnect engine-ECU connector C-103 and Refer to P.17-32.
measure at the harness connector side (Refer to Q: Is the check result normal?
GROUP 13A − Engine-ECU ). YES : Go to Step 13.
(2) Turn the ignition switch to the "LOCK" (OFF) NO : Replace the cruise control switch (Refer to
position. P.17-33). Then go to Step 26.
(3) Measure the continuity between engine-ECU
connector C-103 terminal No.139 and earth.
STEP 10. Connectors check: C-103 engine-ECU
OK: open circuit
connector, C-309 cruise control switch
Q: Is the check result normal? connector, C-306 and C-310 clock spring
YES : Go to Step 24 . connectors and C-53 <LHD> or C-35 <RHD>
NO : Go to Step 6. intermediate connector.
STEP 6. Connectors check: C-309 cruise control YES : Go to Step 11.
switch connector, C-306 and C-310 clock spring NO : Repair or replace the damaged connector.
connectors and C-53 <LHD> or C-35 <RHD> Then go to Step 26.
intermediate connector.
Q: Is the check result normal? STEP 11. Check the harness wire between
YES : Go to Step 7. engine-ECU connector C-103 terminal No.139
NO : Repair or replace the damaged connector. and clock spring connector C-306 terminal No.5,
Then go to Step 26. and between clock spring connector C-310
terminal No.2 and cruise control switch
STEP 7. Check the harness wire between engine- connector C-309 terminal No.3.
ECU connector C-103 terminal No.139 and clock • Check harness wire for open circuit and damage.
spring connector C-306 terminal No.5, and Q: Is the check result normal?
between clock spring connector C-310 terminal YES : Go to Step 12.
No.2 and cruise control switch connector C-309 NO : Repair or replace the damaged harness
terminal No.3. wire. Then go to Step 26.
• Check harness wire for short circuit and damage.
Q: Is the check result normal? STEP 12. Check the clock spring.
YES : Go to Step 8. Refer to GROUP 52B − Driver’s, Front Passenger’s
NO : Repair or replace the damaged harness Air Bag Module(s) and Clock Spring Inspection .
wire. Then go to Step 26.
NO : Replace the clock spring [Refer to GROUP
52B − Driver’s, Front Passenger’s Air Bag
Module(s) and Clock Spring ]. Then go to
Step 26.
CRUISE CONTROL
17-13
STEP 13. Check the data list. STEP 16. Connector check: C-103 engine-ECU
Using M.U.T.-III, check the data list (Refer to P.17-29 connector.
− data list reference table). Q: Is the check result normal?
• Item 136: "ON/OFF" switch YES : Go to Step 24.
• Item 137: "CANCEL" switch NO : Repair or replace the damaged connector.
• Item 138: "COAST/SET" switch Then go to Step 26.
• Item 139: "ACC/RES" switch
Q: Is the check result normal? STEP 17. Connectors check: C-309 cruise control
YES : Go to Step 25. switch connector, C-306 and C-310 clock spring
NO : Go to Step 14. connectors and C-53 <LHD> or C-35 <RHD>
STEP 14. Measure the terminal voltage at cruise Q: Is the check result normal?
control switch connector C-309. YES : Go to Step 18.
(1) Remove the cruise control switch from the NO : Repair or replace the damaged connector.
steering wheel with the cruise control switch Then go to Step 26.
connector connected (Refer to P.17-33).
(2) Connect the negative battery terminal that was
disconnected when the driver's air bag module STEP 18. Check the harness wire between
was removed. engine-ECU connector C-103 terminal No.154
(3) Turn the ignition switch to the "ON" position. and clock spring connector C-306 terminal No.4,
(4) Push the "ON/OFF" switch with cruise control and between clock spring connector C-310
switch connector C-309 connected, and measure terminal No.3 and cruise control switch
the terminal voltage between cruise control connector C-309 terminal No.2.
switch connector C-309 terminal No.2 and earth. • Check harness wire for open circuit and damage.
OK: 0 − 0.5 V Q: Is the check result normal?
Q: Is the check result normal? NO : Repair or replace the damaged harness
YES : Go to Step 20. wire. Then go to Step 26.
NO : Go to Step 15.
STEP 19. Check the clock spring.

STEP 15. Measure the terminal voltage at engine- Refer to GROUP 52B − Driver’s, Front Passenger’s
ECU connector C-103. Air Bag Module(s) and Clock Spring Inspection .
(1) Remove the engine-ECU (Refer to GROUP 13A
− Engine-ECU ). Q: Is the check result normal?
(2) Connect special tool power plant ECU check YES : Go to Step 20.
harness (MB992291) between the engine-ECU NO : Replace the clock spring and install the
and the body-side harness connector. driver’s air bag module [Refer to GROUP
(3) Turn the ignition switch to the "ON" position. 52B − Driver’s, Front Passenger’s Air Bag
(4) Push the "ON/OFF" switch, and measure the Module(s) and Clock Spring ]. Then go to
terminal voltage between special tool 58-pin Step 26.
connector terminal No.154 (engine-ECU
connector C-103 terminal No.154) and earth. STEP 20. Connectors check: C-103 engine-ECU
OK: 0 − 0.5 V connector, C-309 cruise control switch
connector, C-306 and C-310 clock spring
connectors and C-53 <LHD> or C-35 <RHD>
NO : Go to Step 16.
NO : Repair or replace the damaged connector.
Then go to Step 26.
CRUISE CONTROL
STEP 21. Check the harness wire between (2) Turn the ignition switch to the "ON" position, and
engine-ECU connector C-103 terminal No.154 push the "ON/OFF" switch to turn the cruise
and clock spring connector C-306 terminal No.4, control system to ON (turn ON the cruise control
and between clock spring connector C-310 indicator lamp).
terminal No.3 and cruise control switch (3) After turning the cruise control system to ON,
connector C-309 terminal No.2. when 2 minutes or more has elapsed without
• Check harness wire for short circuit and damage. operating the cruise control switches, use the
M.U.T.-III to read the diagnosis code of the cruise
Q: Is the check result normal? control system (Refer to P.17-9).
NO : Repair or replace the damaged harness Q: Is diagnosis code No.P1564 set?
wire. Then go to Step 26. YES : Replace the engine-ECU (Refer to GROUP
13A − Engine-ECU ). Then go to Step 26.
NO : It can be assumed that this malfunction is
STEP 22. Check the clock spring. intermittent (Refer to GROUP 00 − How to
Refer to GROUP 52B − Driver’s, Front Passenger’s Use Troubleshooting/Inspection Service
Air Bag Module(s) and Clock Spring Inspection . Points, How to Cope with Intermittent
Q: Is the check result normal? Malfunction ).
NO : Replace the clock spring [Refer to GROUP STEP 26. Check the data list.
52B − Driver’s, Front Passenger’s Air Bag Using M.U.T.-III, check the data list (Refer to P.17-29
Module(s) and Clock Spring ]. Then go to − data list reference table).
Step 26. • Item 136: "ON/OFF" switch
• Item 137: "CANCEL" switch
STEP 23. Check the cruise control switch. • Item 138: "COAST/SET" switch
Refer to P.17-32. • Item 139: "ACC/RES" switch
NO : Replace the cruise control switch (Refer to NO : Return to Step 2.
P.17-33). Then go to Step 26.
STEP 27. Read the diagnosis code.
STEP 24. Check the data list. (1) Use the M.U.T.-III, erase the diagnosis code of
Using M.U.T.-III, check the data list (Refer to P.17-29 the cruise control system (Refer to P.17-9).
− data list reference table). (2) Turn the ignition switch to the "ON" position, and
• Item 136: "ON/OFF" switch push the "ON/OFF" switch to turn the cruise
• Item 137: "CANCEL" switch control system to ON (turn ON the cruise control
• Item 138: "COAST/SET" switch indicator lamp).
• Item 139: "ACC/RES" switch (3) After turning the cruise control system to ON,
when 2 minutes or more has elapsed without
Q: Is the check result normal? operating the cruise control switches, use the
M.U.T.-III to read the diagnosis code of the cruise
NO : Replace the engine-ECU (Refer to GROUP
control system (Refer to P.17-9).
Q: Is diagnosis code No.P1564 set?
YES : Return to Step 1.
STEP 25. Read the diagnosis code. NO : The procedure is complete.
(1) Use the M.U.T.-III, erase the diagnosis code of
the cruise control system (Refer to P.17-9).
CRUISE CONTROL
17-15
Code No.P1571: Malfunction of the stop lamp switch
Stop Lamp Switch System Circuit (EURO 5)

FUSIBLE LINK 23
RELAY
BOX
STOP LAMP
SWITCH
STOP LAMP
NOTE
: LH drive vehicles
ENGINE-ECU : RH drive vehicles
Wire colour code

BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet PU : Purple SI : Silver
ACB01743
CRUISE CONTROL
Stop Lamp Switch System Circuit (Except EURO 5)

FUSIBLE LINK 23
RELAY
BOX
STOP LAMP
SWITCH
STOP LAMP
ENGINE-ECU
Wire colour code
ACB01742
Connectors: C-10, C-114 <LH drive vehicles> Connectors: C-10, C-114, C-120
<RH drive vehicles>
C-10 (GR)
C-114 C-114
C-10 (GR)
C-120 (L)
ACA01405 AB ACA01406 AB
CRUISE CONTROL
17-17
Connector: C-103, C-105 <LH drive vehicles>

DIAGNOSIS PROCEDURE
STEP 1. Check the data list.

− data list reference table).
• Item 135: Stop lamp switch
C-103 (B)
C-105 (B)
ACA01401 AD
NO : Go to Step 2.
Connector: C-105 <RH drive vehicles> STEP 2. Check the stop lamp operation.
Check the stop lamp operation.
OK:
Brake pedal depressed: Stop lamp will illumi-
nate.
Brake pedal not depressed: Stop lamp does
not illuminate.
ACA01402 AC YES : Go to Step 3.
NO : Go to Step 6.
OPERATION
• For the stop lamp switch, two switches, a stop STEP 3. Connectors check: C-103 engine-ECU
lamp switch for the stop lamp illumination and a connector, C-10 J/C (9) and C-53 <LHD> or C-35
brake switch exclusively for the cruise control <RHD> intermediate connector.
system, are incorporated to improve the reliabil- Q: Is the check result normal?
ity. YES : Go to Step 4.
• The engine-ECU connector C-103 terminal NO : Repair or replace the damaged connector.
No.125 and terminal No.126 monitor the state of Then go to Step 22.
the stop lamp switch and brake switch.
• The stop lamp switch and brake switch turn ON/
STEP 4. Check the harness wire between engine-
OFF when the brake pedal is depressed/
ECU connector C-103 terminal No.125 and C-10
released, and the input signal to the engine-ECU
J/C (9) terminal No.6 <LHD>, or between engine-
changes. According to this change, the engine-
ECU connector C-103 terminal No.125 and C-10
ECU judges the state of the stop lamp switch and
J/C (9) terminal No.2 <RHD>.
the brake switch.
• Check harness wire for open/short circuit and
DIAGNOSIS CODE SET CONDITIONS damage.
Check Condition Q: Is the check result normal?

YES : Go to Step 5.
• The cruise control indicator lamp illuminates.
NO : Repair or replace the damaged harness
Judgement Criteria wire. Then go to Step 22.
• Open/short in stop lamp switch circuit.
• Open circuit in the brake switch circuit (between
engine-ECU connector C-103 terminal No.126
and earth).
PROBABLE CAUSES • Item 135: Stop lamp switch
• Damaged harness or connector. Q: Is the check result normal?
• Malfunction of the stop lamp switch. YES : Go to Step 14.
• Malfunction of the engine-ECU. NO : Replace the engine-ECU (Refer to GROUP
CRUISE CONTROL

STEP 6. Measure the terminal voltage at stop
lamp switch connector C-114.
(1) Disconnect stop lamp switch connector C-114
and measure at the harness side connector.
(2) Measure the terminal voltage between stop lamp STEP 12. Check the stop lamp switch.
switch harness C-114 terminal No.2 and earth. Refer to GROUP 35A − Brake Pedal, Inspection,
OK: System voltage Stop Lamp Switch Check .

NO : Go to Step 7. NO : Replace the stop lamp switch (Refer to
GROUP 35A − Brake Pedal ). Then go to
Step 22.
STEP 7. Connectors check: C-114 stop lamp
switch connector and C-54 <LHD> or C-14
<RHD> intermediate connector. STEP 13. Check the data list.
Q: Is the check result normal? − data list reference table).
YES : Go to Step 8.
• Item 135: Stop lamp switch
Then go to Step 22. Q: Is the check result normal?
STEP 8. Check the harness wire between fuse 13A − Engine-ECU ). Then go to Step 22.
No.12 at the relay box in engine compartment
and stop lamp switch connector C-114 terminal
No.2. STEP 14. Check the data list.
• Check harness wire for open/short circuit and Using M.U.T.-III, check the data list (Refer to P.17-29
damage. − data list reference table).
• Item 134: Brake switch
NO : Repair or replace the damaged harness YES : Go to Step 21.
wire. Then go to Step 22. NO : Go to Step 15.
STEP 9. Check the fuse No.12 at the relay box in STEP 15. Connectors check: C-103 engine-ECU
engine compartment. connector <EURO 5>, C-105 engine-ECU
connector <Except EURO 5>, C-53 <LHD> or C-35
<RHD> intermediate connector and C-114 stop
NO : Check the stop lamp system harness and
lamp switch connector.
replace the fuse. Then go to Step 22. Q: Is the check result normal?
STEP 10. Connectors check: C-114 stop lamp
Then go to Step 22.
switch connector and C-10 J/C (9).
STEP 16. Check the harness wire between
engine-ECU connector C-103 terminal No.126
Then go to Step 22. <EURO 5>, engine-ECU connector C-105 terminal
No.7 <Except EURO 5> and stop lamp switch
connector C-114 terminal No.3.
STEP 11. Check the harness wire between stop • Check harness wire for open/short circuit and
lamp switch connector C-114 terminal No.1 and damage.
C-10 J/C (9) terminal No.7.
damage.
Q: Is the check result normal? wire. Then go to Step 22.
CRUISE CONTROL
17-19
STEP 17. Connectors check: C-114 stop lamp push the "ON/OFF" switch to turn the cruise
switch connector and C-120 J/C (1) <RHD>. control system to ON (turn ON the cruise control
indicator lamp).
Q: Is the check result normal? (3) With the cruise control switches not operated,
YES : Go to Step 18. depress the brake pedal for several seconds, and
NO : Repair or replace the damaged connector. then use the M.U.T.-III to read the diagnosis code
Then go to Step 22. of the cruise control system (Refer to P.17-9).
STEP 18. Check the harness wire between stop YES : Replace the engine-ECU (Refer to GROUP
lamp switch connector C-114 terminal No.4 and 13A − Engine-ECU ). Then go to Step 22.
earth. NO : It can be assumed that this malfunction is
• Check harness wire for open/short circuit and intermittent (Refer to GROUP 00 − How to
damage. Use Troubleshooting/Inspection Service
Q: Is the check result normal? Points, How to Cope with Intermittent
YES : Go to Step 19. Malfunction ).
wire. Then go to Step 22. STEP 22. Check the data list.
STEP 19. Check the stop lamp switch. − data list reference table).
Refer to GROUP 35A − Brake Pedal, Inspection, • Item 134: Brake switch
Stop Lamp Switch Check . • Item 135: Stop lamp switch
NO : Replace the stop lamp switch (Refer to NO : Return to Step 1.
GROUP 35A − Brake Pedal ). Then go to
Step 22. STEP 23. Read the diagnosis code.
STEP 20. Check the data list. the cruise control system (Refer to P.17-9).
Using M.U.T.-III, check the data list (Refer to P.17-29 (2) Turn the ignition switch to the "ON" position, and
− data list reference table). push the "ON/OFF" switch to turn the cruise
• Item 134: Brake switch control system to ON (turn ON the cruise control
indicator lamp).
(3) With the cruise control switches not operated,
NO : Replace the engine-ECU (Refer to GROUP depress the brake pedal for several seconds, and
13A − Engine-ECU ). Then go to Step 22. then use the M.U.T.-III to read the diagnosis code
of the cruise control system (Refer to P.17-9).
the cruise control system (Refer to P.17-9).
(2) Turn the ignition switch to the "ON" position, and
CRUISE CONTROL
CHECK CHART FOR TROUBLE

SYMPTOMS
M1172002301938
Trouble symptom Inspection Reference page

procedure No.
Communication Communication with the engine-ECU only − GROUP 13A −
with M.U.T.-III is is impossible. Troubleshooting,
not possible. Symptom Procedures,
Inspection Procedure 1
When the brake pedal is depressed, cruise control is not 1 P.17-20
cancelled.
When the clutch pedal is depressed, cruise control is not 2 P.17-21
cancelled <M/T>.
When the select lever is set to "N" position, cruise control is 3 P.17-23
not cancelled <A/T>.
When the "CANCEL" switch is pushed, cruise control is not 4 P.17-24
cancelled.
Cruise control cannot be set (No response when the 5 P.17-24
"COAST/SET" switch and the "ACC/RES" switch is pushed).
Hunting (repeated acceleration and deceleration) occurs at 6 P.17-26
the set vehicle speed.
When the "ON/OFF" switch is turned ON, the cruise control 7 P.17-27
indicator lamp does not illuminate (However, the cruise
control system is normal).
SYMPTOM PROCEDURES
Inspection Procedure 1: When the Brake Pedal is Depressed, Cruise Control is not Cancelled.
COMMENT ON TROUBLE SYMPTOM YES : Go to Step 2.

The stop lamp switch circuit is suspected. NO : Check the stop lamp switch system (Refer
to P.17-15 − Diagnosis Code Procedures,
PROBABLE CAUSE Code No.P1571: Malfunction of the stop
• Damaged harness or connector. lamp switch system). Then go to Step 3 .
• Malfunction of the stop lamp switch.
• Malfunction of the engine-ECU.
STEP 2. Check the symptom.
DIAGNOSIS PROCEDURE Q: When the brake pedal is depressed, is the cruise
control cancelled?
YES : It can be assumed that this malfunction is
STEP 1. Check the data list. intermittent (Refer to GROUP 00 − How to
Using M.U.T.-III, check the data list (Refer to P.17-29 Use Troubleshooting/Inspection Service
− data list reference table). Points, How to Cope with Intermittent
• Item 134: Brake switch Malfunction ).
• Item 135: Stop lamp switch NO : Replace the engine-ECU (Refer to GROUP
Q: Is the check result normal? 13A − Engine-ECU ). Then go to Step 3.
CRUISE CONTROL
17-21
YES : The procedure is complete.
NO : Return to Step 1.
Q: When the brake pedal is depressed, is the cruise
control cancelled?
Inspection Procedure 2: When the Clutch Pedal is Depressed, Cruise Control is not Cancelled <M/T>.
Clutch Switch System Circuit

ENGINE-ECU
CLUTCH
SWITCH
Wire colour code

ACA01419 AB
Connector: C-103 <LH drive vehicles>

C-152
C-103 (B)
ACA01401 AB
ACA01405 AC
Connector: C-103 <RH drive vehicles>
C-103 (B)
ACA01402 AB
CRUISE CONTROL
Connector: C-152 <RH drive vehicles> STEP 3. Check the harness wire between engine-
ECU connector C-103 terminal No.112 and clutch
switch connector C-152 terminal No.1, and
between clutch switch connector C-152 terminal
C-152 No.2 and earth.
damage.
YES : Go to Step 4.
ACA01406 AC NO : Repair or replace the damaged harness
OPERATION
• The engine-ECU connector C-103 terminal STEP 4. Check the clutch switch.
No.112 monitor the clutch switch state. Refer to GROUP 21A − Clutch Pedal, Inspection,
• The clutch switch turn ON/OFF when the clutch Clutch Switch Continuity Check .
pedal is depressed/released, and the input signal
to the engine-ECU change. According to this Q: Is the check result normal?
YES : Go to Step 5.
change, the engine-ECU judges the clutch switch
NO : Replace the clutch switch (Refer to GROUP
status.
21A − Clutch Pedal ). Then go to Step 7.
The cause is probably a malfunction of the clutch STEP 5. Check the data list
switch circuit. Using M.U.T.-III, check the data list (Refer to P.17-29
POSSIBLE CAUSES
• Item 131: Clutch switch
• Damaged harness or connector.
• Malfunction of the clutch switch. Q: Is the check result normal?
• Malfunction of the engine-ECU. YES : Go to Step 6.
DIAGNOSIS PROCEDURE 13A − Engine-ECU ). Then go to Step 7.
STEP 1. Check the data list. STEP 6. Check the symptom.

Using M.U.T.-III, check the data list (Refer to P.17-29 Q: When the clutch pedal is depressed, is the cruise
− data list reference table). control cancelled?
• Item 131: Clutch switch YES : It can be assumed that this malfunction is
intermittent (Refer to GROUP 00 − How to
Q: Is the check result normal? Use Troubleshooting/Inspection Service
YES : Go to Step 6.
Points, How to Cope with Intermittent
NO : Go to Step 2.
Malfunction ).
STEP 2. Connectors check: C-103 engine-ECU 13A − Engine-ECU ). Then go to Step 7.
connector and C-152 clutch switch connector.
Q: Is the check result normal? STEP 7. Check the symptom.
YES : Go to Step 3.
Q: When the clutch pedal is depressed, is the cruise
control cancelled?
Then go to Step 7. YES : The procedure is complete.
CRUISE CONTROL
17-23
Inspection Procedure 3: When the Selector Lever is Set to "N" Position, Cruise Control is not
Cancelled <A/T>.
OPERATION YES : Go to Step 3.

When the selector lever is operated, the selector NO : Check the inhibitor switch system [Refer to
lever position signal from the inhibitor switch is sent GROUP 23A − Troubleshooting, Diagnosis
to the A/T-ECU. Engine-ECU receives the selector Code Procedures Code No.P1770: Inhibitor
lever position signal from the A/T-ECU via the CAN switch system (Open Circuit) or , Code
bus line. No.P1771: Inhibitor switch system (Short
Circuit) ] <4A/T> or [Refer to GROUP 23A −
COMMENTS ON TROUBLE SYMPTOM Troubleshooting, Diagnosis Code
• The inhibitor switch circuit is suspected. Procedures Code No.P1770: Inhibitor
• The CAN bus line between the engine-ECU and switch system (Open Circuit) or , Code
the A/T-ECU, the A/T-ECU, the engine-ECU may No.P1771: Inhibitor switch system (Short
be defective. Circuit) ] <5A/T>. Then go to Step 5.
PROBABLE CAUSES
• Malfunction of CAN bus system. STEP 3. Check the A/T system diagnosis code.
• Damaged harness or connector. Using M.U.T.-III, perform A/T system diagnosis code
• Malfunction of the inhibitor switch. (Refer to GROUP 23A − Troubleshooting, Diagnosis
• Malfunction of the A/T-ECU. Function ).
• Malfunction of the engine-ECU. Q: Is any diagnosis code set?
YES : Repair the A/T system (Refer to GROUP
DIAGNOSIS PROCEDURE 23A − Troubleshooting, Diagnosis Code
CAUTION Chart ). Then go to Step 5.
NO : Go to Step 4.
• If there is any problem in the CAN bus lines,
an incorrect diagnosis code may be set. Prior
to this diagnosis, diagnose the CAN bus STEP 4. Check the symptom.
lines. Q: When the selector lever is set to "N" position, is
• Before replacing the ECU, ensure that the the cruise control cancelled?
CAN bus lines is normal. YES : It can be assumed that this malfunction is
STEP 1. Check the CAN bus system diagnosis. Use Troubleshooting/Inspection Service
Using M.U.T.-III, perform CAN bus diagnosis (Refer Points, How to Cope with Intermittent
to GROUP 54C − Explanation About The M.U.T-III Malfunction ).
Can Bus Diagnostics ). NO : Replace the engine-ECU (Refer to GROUP
Q: Is the check result satisfactory?
YES : Go to Step 2.
NO : Repair the CAN bus lines (Refer to GROUP STEP 5. Check the symptom.
54C − Troubleshooting, Can Bus Diagnostic Q: When the selector lever is set to "N" position, is
Table ). Then go to Step 5. the cruise control cancelled?
• Item 42: Inhibitor switch
CRUISE CONTROL
Inspection Procedure 4: When the "CANCEL" Switch is Pushed, Cruise Control is not Cancelled.
COMMENT ON TROUBLE SYMPTOM STEP 2. Check the symptom.

The cause is probably an open-circuit in the circuit
inside the "CANCEL" switch. Q: When the "CANCEL" switch is pushed, is the
cruise control cancelled?
PROBABLE CAUSE YES : It can be assumed that this malfunction is
• Malfunction of the cruise control switch. intermittent (Refer to GROUP 00 − How to
• Malfunction of the engine-ECU. Use Troubleshooting/Inspection Service
DIAGNOSIS PROCEDURE Malfunctions ).
− data list reference table). STEP 3. Check the symptom.
• Item 137: "CANCEL" switch Q: When the "CANCEL" switch is pushed, is the
cruise control cancelled?
YES : Go to Step 2.
NO : Check the cruise control switch system
(Refer to P.17-10 − Diagnosis Code
Procedures, Code No.P1564: Abnormal
voltage at cruise control switch. Then go to
Step 3 .
Inspection Procedure 5: Cruise Control cannot be Set (No Response when the "COAST/SET" Switch
and the "ACC/RES" Switch is Pushed).
COMMENTS ON TROUBLE SYMPTOM DIAGNOSIS PROCEDURE

The fail-safe function is probably cancelling cruise
CAUTION
control system. In this case, checking the cruise con-
• If there is any problem in the CAN bus lines,
trol system, diesel fuel system, CAN bus system, A/T
an incorrect diagnosis code may be set. Prior
system <A/T> and ASTC system diagnosis codes.
to this diagnosis, diagnose the CAN bus
The M.U.T.-III can also be used to check if the cir-
lines.
cuits of each input switches are normal or not by
checking the data list. • Before replacing the ECU, ensure that the
CAN bus lines is normal.
NOTE: Push the cruise control switches one by one
securely. Otherwise, the cruise control system may
not be started. STEP 1. Check the CAN bus system diagnosis.
Using M.U.T.-III, perform CAN bus diagnosis (Refer
PROBABLE CAUSE to GROUP 54C − Explanation About The M.U.T-III
• Malfunction of CAN bus system. Can Bus Diagnostics ).
• Malfunction of the diesel fuel system.
Q: Is the check result satisfactory?
• Malfunction of the A/T system <A/T>. YES : Go to Step 2.
• Malfunction of the ASTC system. NO : Repair the CAN bus lines (Refer to GROUP
• Malfunction of the cruise control switch. 54C − Troubleshooting, Can Bus Diagnostic
• Malfunction of the stop lamp switch. Table ). Then go to Step 11.
• Malfunction of the clutch switch <M/T>.
• Malfunction of the inhibitor switch <A/T>.
CRUISE CONTROL
17-25
YES : Repair the cruise control system (Refer to
STEP 2. Check the diesel fuel system diagnosis
code. P.17-9 − Diagnosis Code Chart). Then go to
Using M.U.T.-III, perform diesel fuel system diagno- Step 11.
NO : Go to Step 6.
sis code (Refer to GROUP 13A − Troubleshooting,
Diagnosis Function ).
Q: Is any diagnosis code set?
YES : Repair the diesel fuel system (Refer to Using M.U.T.-III, check the data list (Refer to P.17-29
GROUP 13A − Troubleshooting, Inspection − data list reference table).
Chart for Diagnosis Code ). Then go to Step • Item 136: "ON/OFF" switch
11. • Item 137: "CANCEL" switch
NO : Go to Step 4 <M/T>. • Item 138: "COAST/SET" switch
NO : Go to Step 3 <A/T>. • Item 139: "ACC/RES" switch
STEP 3. Check the A/T system diagnosis code YES : Go to Step 7.
<A/T>. NO : Check the cruise control switch system
Using M.U.T.-III, perform A/T system diagnosis code (Refer to P.17-10 − Diagnosis Code
(Refer to GROUP 23A − Troubleshooting, Diagnosis Procedures, Code No.P1564: Abnormal
Function ). voltage at cruise control switch). Then go to
Step 11 .
YES : Repair the A/T system (Refer to GROUP
23A − Troubleshooting, Diagnosis Code STEP 7. Check the data list.
Chart ). Then go to Step 11. Using M.U.T.-III, check the data list (Refer to P.17-29
NO : Go to Step 4. − data list reference table).
• Item 134: Brake switch
STEP 4. Check the ASTC system diagnosis code. • Item 135: Stop lamp switch
Using M.U.T.-III, perform ASTC system diagnosis Q: Is the check result normal?
code (Refer to GROUP 35C − Troubleshooting, YES : Go to Step 8 <M/T>.
Diagnosis Function ). YES : Go to Step 9 <A/T>.
NO : Check the stop lamp switch system (Refer
to P.17-15 − Diagnosis Code Procedures,
YES : Repair the ASTC system (Refer to GROUP
Code No.P1571: Malfunction of the stop
35C − Troubleshooting, Diagnosis Code
lamp switch system). Then go to Step 11 .
Chart ). Then go to Step 11.
NO : Go to Step 5.
STEP 8. Check the data list <M/T>.
(1) Use the M.U.T.-III, erase the diagnosis code of − data list reference table).
the cruise control system (Refer to P.17-9). • Item 131: Clutch switch
(2) Turn the ignition switch to the "ON" position, and Q: Is the check result normal?
push the "ON/OFF" switch to turn the cruise YES : Go to Step 10.
control system to ON (turn on the cruise control NO : Check the clutch switch system (Refer to
indicator lamp). P.17-21 − Symptom Procedures, Inspection
(3) After turning the cruise control system to ON, Procedure 2). Then go to Step 11.
when 2 minutes or more has elapsed without
operating the cruise control switches.
STEP 9. Check the data list <A/T>.
(4) With the cruise control switches not operated,
depress the brake pedal for several seconds, and
then use the M.U.T.-III to read the diagnosis code
• Item 42: Inhibitor switch
of the cruise control system (Refer to P.17-9).
CRUISE CONTROL

NO : Check the inhibitor switch system [Refer to
GROUP 23A − Troubleshooting, Diagnosis Q: Can cruise control be set?
Code Procedures Code No.P1770: Inhibitor YES : It can be assumed that this malfunction is
switch system (Open Circuit) , Code intermittent (Refer to GROUP 00 − How to
No.P1771: Inhibitor switch system (Short Use Troubleshooting/Inspection Service
Circuit) ] <4A/T> or [Refer to GROUP 23A − Points, How to Cope with Intermittent
Troubleshooting, Diagnosis Code Malfunctions ).
Procedures Code No.P1770: Inhibitor NO : Replace the engine-ECU (Refer to GROUP
switch system (Open Circuit) , Code 13A − Engine-ECU ). Then go to Step 11.
No.P1771: Inhibitor switch system (Short
Circuit) ] <5A/T>. Then go to Step 11. STEP 11. Check the symptom.
Q: Can cruise control be set?
Inspection Procedure 6: Hunting (Repeated Acceleration and Deceleration) Occurs at the Set Vehicle
Speed.
COMMENTS ON TROUBLE SYMPTOM STEP 2. Check the A/T system diagnosis code
The vehicle speed sensor or the diesel fuel system is <A/T>.
suspected. Using M.U.T.-III, perform A/T system diagnosis code
NOTE: When the vehicle is driven with the low- (Refer to GROUP 23A − Troubleshooting, Diagnosis
speed gear in the sport mode, hunting occurs easily, Function ).
however, this is not a failure <A/T>.
PROBABLE CAUSE YES : Repair the A/T system (Refer to GROUP
• Malfunction of the vehicle speed sensor. 23A − Troubleshooting, Diagnosis Code
• Malfunction of the diesel fuel system. Chart ). Then go to Step 5.
• Malfunction of the A/T system <A/T>. NO : Go to Step 3.
DIAGNOSIS PROCEDURE Using M.U.T.-III, check the data list (Refer to P.17-29
STEP 1. Check the diesel fuel system diagnosis • Item 04: Vehicle speed signal
code. Q: Is the check result normal?
Using M.U.T.-III, perform diesel fuel system diagno- YES : Go to Step 4.
sis code (Refer to GROUP 13A − Diagnosis Function NO : Replace the engine-ECU (Refer to GROUP
). 13A − Engine-ECU ). Then go to Step 5.
YES : Repair the diesel fuel system (Refer to STEP 4. Check the symptom.
GROUP 13A − Troubleshooting, Inspection Q: Does a hunting occur?
Chart for Diagnosis Code ). Then go to Step YES : Replace the engine-ECU (Refer to GROUP
5. 13A − Engine-ECU ). Then go to Step 5.
NO : Go to Step 3 <M/T>. NO : It can be assumed that this malfunction is
NO : Go to Step 2 <A/T>.
Use Troubleshooting/Inspection Service
Malfunctions ).
CRUISE CONTROL
17-27
Q: Does a hunting occur?
Inspection Procedure 7: When the "ON/OFF" Switch is Turned ON, the Cruise Control Indicator Lamp
does not Illuminate (However, the Cruise Control System is Normal).
Cruise Control Indicator Lamp System Circuit

CRUISE CONTROL IGNITION
SWITCH SWITCH (IG1)
COMBINATION
CLOCK METER
SPRING
NOTE
: LH drive vehicles
: RH drive vehicles
ENGINE-ECU
Wire colour code

ACA01422 AB
CRUISE CONTROL
PROBABLE CAUSE
• Damaged harness or connector.
• Malfunction of the combination meter.
C-105 (B) DIAGNOSIS PROCEDURE
STEP 1. Check the cruise control indicator lamp.

(1) Disconnect engine-ECU connector C-105 and
ACA01401 AC check at the harness side connector.
(2) Turn the ignition switch to the "ON" position.
(3) Check the illumination condition of the cruise
control indicator lamp when engine-ECU
connector C-105 terminal No.45 is earthed.
OK: The cruise control indicator lamp
illuminates.
YES : Go to Step 5.
C-105 (B) NO : Go to Step 2.
ACA01402 AC
STEP 2. Connectors check: C-111 combination

meter connector, C-105 engine-ECU connector
and C-53 <LHD> or C-35 <RHD> intermediate
connector.
YES : Go to Step 3.
Then go to Step 6.
STEP 3. Check the harness wire between

ACA01405 AD
combination meter connector C-111 terminal
No.53 and engine-ECU connector C-105 terminal
No.45.
damage.
YES : Go to Step 4.
ACA01406 AD STEP 4. Check the combination meter.

Refer to GROUP 54A − Combination Meter, Trouble-
OPERATION shooting, Check at ECU Terminals .
The engine-ECU detects "ON/OFF" switch ON signal Q: Is the check result normal?
to illuminate the cruise control indicator lamp on the YES : Go to Step 5.
combination meter. NO : Replace the combination meter (Refer to
GROUP 54A − Combination Meter ). Then
COMMENT go to Step 6.
The combination meter or engine-ECU may also be
defective.
CRUISE CONTROL
17-29
STEP 5. Check the symptom. STEP 6. Check the symptom.
Q: When the "ON/OFF" switch is turned ON, is the Q: When the "ON/OFF" switch is turned ON, is the
cruise control indicator lamp illuminated? cruise control indicator lamp illuminated?
YES : It can be assumed that this malfunction is YES : The procedure is complete.
intermittent (Refer to GROUP 00 − How to NO : Return to Step 1.
Use Troubleshooting/Inspection Service
Points, How to Cope with Intermittent DATA LIST REFERENCE TABLE
M1172002401980
Malfunctions ).
CAUTION
• Road test always need two people: one driver and one observer.
• When shifting the selector lever to "D" position the brakes should be applied so that the vehicle
does not move forward.
NOTE: When reading the data list, do not select the
item under "CRUISE CONTROL," but select the item
under "DIESEL ENGINE."
Item No. Check item Check condition Normal condition
04 Vehicle speed sensor Road test the vehicle. The speedometer and
M.U.T.-III display the
same value.
42 Inhibitor switch <A/T> Ignition switch: Selector lever: "N" or "P" position ON
"ON" Selector lever: Other than "N" or OFF
"P" position
130 Cancel code Ignition switch: "ON" The cancel code,
which set when the
cruise control system
was cancelled at the
last time, is set again.
131 Clutch switch <M/T> Ignition switch: Clutch pedal: Depressed ON
"ON" Clutch pedal: Released OFF
134 Brake switch (for Ignition switch: Brake pedal: Depressed ON
cruise control circuit) "ON" Brake pedal: Released OFF
135 Stop lamp switch (for Ignition switch: Brake pedal: Depressed ON
stop lamp circuit) "ON" Brake pedal: Released OFF
136 Cruise control switch Ignition switch: "ON/OFF" switch: Pushed ON
("ON/OFF" switch) "ON" "ON/OFF" switch: Pushed again OFF
137 Cruise control switch Ignition switch: "CANCEL" switch: Pushed ON
("CANCEL" switch) "ON" "CANCEL" switch: Released OFF
138 Cruise control switch Ignition switch: "COAST/SET" switch: Pushed ON
("COAST/SET" "ON" "COAST/SET" switch: Released OFF
switch)
139 Cruise control switch Ignition switch: "ACC/RES" switch: Pushed ON
("ACC/RES" switch) "ON" "ACC/RES" switch: Released OFF
140 Cruise control Cruise control system: active ON
operation Cruise control system: Inactive OFF
CRUISE CONTROL
CHECK AT ENGINE-ECU TERMINAL 2. Connect special tool MB992291 between the

M1172002701936 engine-ECU and the body-side harness
Use special tool power plant ECU check harness connector.
(MB992291), check the engine-ECU terminal volt-
age. 3. Measure the voltages between the check
connector terminals of special tool MB992291 and
1. Remove the engine-ECU (Refer to GROUP 13A −
earth terminals No.116, 117 or 145.
Engine-ECU ).
Special tool - Power plant ECU check harness (MB992291) connector
58-Pin connector 96-Pin connector

(Engine-ECU connector C-103) (Engine-ECU connector C-105)
115114113112111110109108107106105104103 24 23 22 2120 19 1817 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

130129128127126125124123122121120119118
102 101
48 47 46 4544 43 42 41 40 39 38 3736 35 3433 32 31 30 29 28 27 26 25
117 116
143142141140139138137136135134133132131 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
145 144
158157156155154153152151150149148147146 96 95 94 93 92 91 90 89 8887 86 8584 83 8281 80 79 78 77 76 75 74 73
AC809546 AE
Terminal No. Check item Check condition Normal condition

7 <Except Stop lamp switch Ignition switch: Depress the brake pedal. System voltage
EURO 5> (brake switch) "ON" Release the brake pedal. 1V or less
112 Clutch switch Ignition switch: Release the clutch pedal. 10 V or more
<M/T> "ON" Depress the clutch pedal. 1 V or less
125 Stop lamp switch Ignition switch: Depress the brake pedal. System voltage
"ON" Release the brake pedal. 1V or less
126 <EURO Stop lamp switch Ignition switch: Depress the brake pedal. System voltage
5> (brake switch) "ON" Release the brake pedal. 1V or less
139 Cruise control Ignition switch: All switches: Released 4.7 − 5.0 V
switch power "ON" "ON/OFF" switch: Pushed. 0 − 0.5 V
supply
"CANCEL" switch: Pushed. 1.0 − 1.8 V
"COAST/SET" switch: Pushed. 2.3 − 3.0 V
"ACC/RES" switch: Pushed. 3.5 − 4.2 V
ON-VEHICLE SERVICE
CRUISE CONTROL SWITCH CHECK
M1172001201295
CRUISE CONTROL "ON/OFF" SWITCH

CHECK
CRUISE CONTROL
17-31
NOTE: If the vehicle speed decreases to approxi-
Cruise control switch
mately 15 km/h below the set speed because of
climbing a hill for example, it is normal for the
cruise control to be cancelled. When the vehicle
speed is decelerated to the low speed limit
(approximately 40 km/h) or less, the constant
speed driving will be cancelled even if the vehicle
speed is not decelerated 15 km/h or more from
"ON/OFF"
the set speed.
switch
AC807212 AC
SPEED-INCREASE SETTING
Cruise control 1. Turn the ignition switch to "ON" position.
indicator lamp 2. Push the "ON/OFF" switch (cruise control system:
ON, cruise control indicator lamp: illuminated).
3. Set to the desired speed within the range of
approximately 40 − 200 km/h.
"ACC/RES"
AC900932 AB switch
2. Push the "ON/OFF" switch of the cruise control

switch, and check that the cruise control indicator
lamp within the combination meter illuminates.
3. Push the "ON/OFF" switch again, and check that
the cruise control indicator lamp within the Cruise control switch AC807212 AE
combination meter goes out.
4. Push the "ACC/RES" switch.
CRUISE CONTROL SETTING 5. Check to be sure that acceleration continues
1. Turn the ignition switch to "ON" position. while the "ACC/RES" switch is pushed, and that
the speed at the time it was released becomes the
2. Push the "ON/OFF" switch (cruise control system:
constant driving speed.
3. Drive at the desired speed within the range of NOTE: When the vehicle speed reaches the high
approximately 40 − 200 km/h. speed limit (approximately 200 km/h) during
acceleration, the vehicle is driven at a constant
Cruise control switch speed of the high speed limit (approximately 200
km/h).
SPEED-REDUCTION SETTING
"COAST/SET" ON, cruise control indicator lamp: illuminated).
switch
AC807212 AD approximately 40 − 200 km/h.
4. Press the "COAST/SET" switch.
4. Push the "COAST/SET" switch.
5. Check to be sure that deceleration continues
5. Check to be sure that when the "COAST/SET" while the "COAST/SET" switch is pushed, and
switch is released the speed is the desired that the speed at the time it was released
constant speed. becomes the constant driving speed.
CRUISE CONTROL
NOTE: When the vehicle speed reaches the low

speed limit (approximately 40 km/h) during decel- Cruise control
eration, the vehicle is driven at a constant speed switch
of the low speed limit (approximately 40 km/h).
1 2 3 4
RETURN TO THE SET SPEED BEFORE
CANCELLATION AND CRUISE CONTROL
CANCELLATION
approximately 40 − 200 km/h.
4. When any of the following operations are
performed while at constant speed during cruise
control system, check if normal driving is resumed
and deceleration occurs.
4 1 3 2
AC800937 AF
"CANCEL" 2. Measure the resistance between terminal No.2

switch
and terminal No.3 when each of the "ON/OFF",
"CANCEL", "COAST/SET" and "ACC/RES"
switches is pushed. If the values measured at the
time each switch is pushed correspond to those in
the table below, the resistance values are correct.
Cruise control switch AC807212 AF
Terminal Switch Specified
(1) The "CANCEL" switch is pushed. connector position condition
(2) The brake pedal is depressed. of tester
5. At a vehicle speed of the low speed limit 2−3 All switches are Open circuit
(approximately 40 km/h) or higher, check if when released.
the "ACC/RES" switch is pushed, the vehicle
"ON/OFF" Continuity (less
speed returns to the speed before cruise control
switch is than 2 ohms)
driving was cancelled, and constant speed driving
pushed
occurs.
6. When the "ON/OFF" switch is pushed again "CANCEL" 202.5 - 208 Ω
(cruise control system: OFF) while driving at switch is
constant speed, check if normal driving is pushed
resumed and deceleration occurs. "COAST/SET" 610.5 - 624.5 Ω
switch is
CRUISE CONTROL SYSTEM pushed
COMPONENT CHECK "ACC/RES" 1838 - 1877 Ω
M1172001701687
switch is
CRUISE CONTROL SWITCH CHECK pushed
1. Remove the cruise control switch (Refer to P.17- 3. Check that illumination of the cruise control switch
33). illumination lamp turns on when the battery
positive terminal is connected to cruise control
switch connector terminal No.4, and the battery
negative terminal is connected to cruise control
switch connector terminal No.1.
EMISSION CONTROL
17-33
STOP LAMP SWITCH CHECK INHIBITOR SWITCH (N POSITION)
Refer to GROUP 35A − Brake Pedal, Inspection, CHECK <A/T>
Stop Lamp Switch Check . Refer to GROUP 23A − On-vehicle Service, Essen-
tial Service, Inhibitor Switch Continuity Check .
CLUTCH SWITCH CHECK <M/T>
Refer to GROUP 21A − Clutch Pedal, Inspection, CRUISE CONTROL SWITCH
Clutch Switch Continuity Check .
M1172007600845
WARNING
For vehicles with SRS, before removing the air bag module assembly, refer to GROUP 52B −
Service Precautions , and Driver’s and Front Passenger’s Air Bag Module(s) and Clock
Spring .
1 2
9.0 ± 2.0 N·m
AC801079 AB
Removal steps
1. Driver’s air bag module [Refer to
GROUP 52B − Driver’s, Front
Passenger’s Air Bag Module(s) and
Clock Spring ]
2. Cruise control switch
EMISSION CONTROL
GENERAL INFORMATION • Exhaust gas recirculation system
M1175000100484 • Diesel particulate filter (DPF) system <Euro5>
The emission control system consists of the following • Emission reduction system
subsystems:
EMISSION CONTROL
Item Name Specification

Exhaust gas recirculation system EGR valve DC motor type
(Purpose: NOx reduction) EGR valve position sensor Hall element type
EGR cooler Water cooled type
Air flow sensor Thermo-sensing type
EGR gas temperature sensor Thermistor type
<Euro5>
Diesel particulate filter (DPF) Diesel particulate filter (DPF) Closed type
system <Euro5> (Purpose: PM No. 1 exhaust gas temperature Thermistor type
removal) sensor
No. 2 exhaust gas temperature Thermistor type
sensor (catalyst temperature)
No. 3 exhaust gas temperature Thermistor type
sensor (DPF temperature)
Exhaust differential pressure Piezo resistive semiconductor
sensor type
Emission reduction system Fuel injection control (Purpose: Common rail type
PM reduction)
Catalytic converter (Purpose: CO, Monolith type
HC reduction)
SERVICE SPECIFICATION(S)
M1175000300295
Items Standard value

No. 1 exhaust gas temperature sensor (at 20°C) Ω <Euro5> 120 − 560
No. 2 exhaust gas temperature sensor (catalyst converter) (at 20°C) kΩ 120 − 560
<Euro5>
No. 3 exhaust gas temperature sensor (DPF temperature) (at 20°C) kΩ 120 − 560
<Euro5>
EGR gas temperature sensor kΩ <Euro5> At −20°C 55 − 78
At 0°C 29 − 41
At 20°C 17 − 23
At 40°C 10 − 14
At 60°C 7.1 − 8.8
At 80°C 4.8 − 5.9
EMISSION CONTROL
17-35
VACUUM HOSE
VACUUM HOSE PIPING DIAGRAM
M1175004200524
<Euro5>
EGR valve position sensor

EGR valve (DC motor)
Air
EGR gas temperature

sensor
To brake system
To fuel tank
Variable geometry
Injector
Variable geometry
actuator
Engine coolant
temperature sensor
Catalytic
converter
No. 1 exhaust
gas temperature Catalytic From fuel
sensor converter DPF tank
Exhaust differential pressure sensor
No. 2 exhaust gas

temperature sensor No. 3 exhaust gas temperature sensor
(catalyst temperature) (DPF temperature) AKB00295 AB
EMISSION CONTROL
<Except Euro5>
Intake air temperature sensor No. 2

EGR valve (DC motor)
Air
To brake system
To fuel tank
Injector
Engine coolant
temperature sensor
Catalytic
Waste gate converter
actuator
From fuel
tank
AK500419 AB
EMISSION CONTROL
17-37
VACUUM CIRCUIT DIAGRAM
M1175004400380
<Euro5>
R R
Variable
geometry
control
Variable geometry solenoid valve
turbocharger
Vacuum
pump
White paint
B
Vacuum hose colour
B : Black
R : Red
AKB00241 AB
VACUUM HOSE CHECK EXHAUST GAS RECIRCULATION

M1175004900307
1. Using the vacuum circuit diagram as a guide, (EGR) SYSTEM
check to be sure that the vacuum hoses are
correctly connected. GENERAL INFORMATION (EGR SYSTEM)
M1175002600399
2. Check the connection condition of the vacuum The electronically controlled EGR system consists of
hoses, (removed, loose, etc.) and check to be an EGR valve, engine-ECU and sensors.
sure that there are no bends or damage. The EGR valve aims at reducing the amount of NOx
(nitric oxide) discharge that increases with the rise in
VACUUM HOSE INSTALLATION the exhaust gas temperature. Thus, the engine-ECU
M1175005000288
1. When connecting the vacuum hoses, they should optimally controls the exhaust gas temperature in
be securely inserted onto the nipples. accordance with the operating conditions of the
engine.
2. Connect the hoses correctly, using the vacuum
circuit diagram as a guide.
EMISSION CONTROL
To further improve the exhaust gas reduction per-

formance, the system provides the engine-ECU SYSTEM DIAGRAM
feedback on the EGR valve opening. Thus, it effects
EGR control to optimize the operating conditions of
the engine.

EGR valve
(DC motor) Air flow sensor
Crank angle sensor
Engine coolant temperature sensor
Intake air temperature sensor
No. 1
EGR gas temperature sensor
<Euro5>
Engine-ECU Intake air temperature sensor
No. 2 <Except Euro5>
Manifold absolute pressure sensor
Barometric pressure sensor
A/C switch
EGR cooler
A/C load signal
AKB00296 AB
COMPONENT LOCATION <Euro5>

M1175003900304
EGR gas
temperature
sensor
EGR valve AKB00297AB

(in which
EGR valve position sensor built) AK500430 AE
EGR VALVE (DC MOTOR) CHECK

M1175004600179
System check
EMISSION CONTROL
17-39
3. A tester is to be connected between the terminal
No.1 and No. 2.
4. Connect the terminal (+) of the power supply with
the terminal No. 6 of the EGR valve connector,
and connect the terminal (−) of the power supply
with the terminal No. 4. Confirm the EGR valve is
opened.
EGR valve
NOTE: At this time, the power supply voltage is to
(in which be 5V. When the valve is not opened, increase the
EGR valve position sensor built) AK500430 AE voltage 1V by 1V. For each voltage, current is to
be applied within 5 seconds. Once the valve is
1. Connect the M.U.T.-III to the diagnosis connector
opened, the voltage is not to be increased any
to check for date list item No.16.
more.
2. Start the engine, and warm up the engine.
3. Raise the engine speed gradually, and make sure
that the valve open degree changes from 0% to
100%.
Operation check
Valve open
AK500442AB
1 2 3 5. Confirm the voltage is changed between the

EGR valve
4 5 6
terminal No. 1 and No. 2 together with the EGR
valve opening movement.
6. By the voltage changed, the DC is recognized as
AK500440AB being normal
7. Use a new gasket and tighten the installation bolt
1. Remove the EGR valve. to the tightening torque.
5V
Cleaning the EGR valve
1 2 3 CAUTION
4 5 6 Do not use a solvent or detergent, which could
enter the motor and cause it to malfunction.
5V 1. Remove the EGR valve and check that the EGR
valve is not stuck or clogged with carbon deposits.
AK500441AB Use a wire brush to clean the valve if necessary.
2. Using a new gasket, install the EGR valve by
2. Connect the terminal (+) of the sensor power
tightening its mounting bolts to the specified
supply (5V) with the terminal No.3 of the EGR
torque.
valve connector, and connect the terminal (−) of
the sensor power supply (5V) with the terminal Tightening torque: 48 ± 6 N⋅m
No. 2.
EMISSION CONTROL
EGR GAS TEMPERATURE SENSOR 3. Remove the EGR gas temperature sensor
CHECK <Euro5>
M1175011500022 EGR gas
temperature sensor
1 2
Equipment side
connector
EGR gas
temperature
sensor
AKA00756 AB
AKB00298AB 4. Measure resistance while heating the sensor

using a hair drier.
1. Disconnect the EGR gas temperature sensor
Normal condition:
connector.
2. Measure resistance between terminals No. 1 and Temperature (°C) Resistance (kΩ)
No. 2. Higher Smaller
Standard value:
55 − 78 kΩ (at −20°C)
29 − 41 kΩ (at 0°C)
EGR gas temperature sensor.
17 − 23 kΩ (at 20°C)
10 − 14 kΩ (at 40°C) 6. Install the EGR gas temperature sensor and
7.1 − 8.8 kΩ (at 60°C) tighten it to the specified torque.
4.8 − 5.9 kΩ (at 80°C) Tightening torque: 20 ± 4 N⋅m
AIR FLOW SENSOR CHECK

M1175005700027
Refer to GROUP 13A − Troubleshooting − Inspec-
tion Chart for Diagnosis Code.
CRANK ANGLE SENSOR CHECK

M1175005200044
Refer to GROUP 13A −Troubleshooting − Inspection
Chart for Diagnosis Code.
ENGINE COOLANT TEMPERATURE SENSOR CHECK

M1175001500054
Refer to GROUP 13A − On-vehicle service − Engine
coolant temperature sensor check.
INTAKE AIR TEMPERATURE SENSOR CHECK

M1175005800035
<Intake air temperature sensor No. 1>

Refer to GROUP 13A − On-vehicle service − Air
temperature sensor No. 1 check.
<Intake air temperature sensor No. 2>

Refer to GROUP 13A − On-vehicle service − Air
temperature sensor No. 2 check.
CHECK AT THE ECU TERMINALS

M1175003000055
Refer to GROUP 13A − Troubleshooting − Check at the ECU terminals.
EMISSION CONTROL
17-41
EGR VALVE AND EGR COOLER

M1175007200493
<Except Euro5>
• Under Skid Plate and Engine Room Under Cover • Battery and Battery Box Installation (Refer to 54A − Bat-
Removal (Refer to GROUP 51 − Under Cover ). tery ).
• Engine Coolant Draining (Refer to GROUP 14 − On-vehi- • Engine Coolant Refilling (Refer to GROUP 14 − On-vehi-
cle Service, Engine Coolant Replacement ). cle Service, Engine Coolant Replacement ).
• Battery and Battery Box Removal (Refer to 54A − Battery • Under Skid Plate and Engine Room Under Cover Installa-
). tion (Refer to GROUP 51 − Under Cover ).
3.0 ± 0.5 N·m
48 ± 6 N·m
2 (ATF)
3
22 ± 4 N·m 6N
1 (Engine oil)
5
N 4
N 8 7
13
N 14 12 50 ± 7 N·m
11 ± 1 N·m 48 ± 6 N·m
N 15 17 ± 2 N·m
18 9N
17
10
19
17 ± 2 N·m
24 ± 3 N·m 24 ± 3 N·m
11 N 17 ± 2 N·m
49 ± 6 N·m
24 ± 3 N·m 16
AC509026AC

1. Engine cover 10. EGR pipe B
2. Wiring harness connection >>A<< 11. EGR pipe gasket
3. Engine oil level gauge and guide 12. EGR pipe heat protector
assembly 13. EGR pipe A
4. O-ring >>A<< 14. EGR pipe gasket
5. Transmission fluid level gauge and >>A<< 15. EGR pipe gasket
guide assembly <A/T> 16. Water hose
6. O-ring <A/T> 17. Heater piping hose connection
7. EGR valve 18. EGR cooler
>>B<< 8. EGR valve gasket 19. EGR cooler bracket
>>A<< 9. EGR pipe gasket
EMISSION CONTROL
<Euro5>
• Engine Cover Removal (Refer to GROUP 11A − Engine • Battery and Battery Box Installation (Refer to 54A − Bat-
Assembly ). tery ).
• Under Skid Plate and Engine Room Under Cover • Engine Coolant Refilling (Refer to GROUP 14 − On-vehi-
Removal (Refer to GROUP 51 − Under Cover ). cle Service, Engine Coolant Replacement ).
• Engine Coolant Draining (Refer to GROUP 14 − On-vehi- • Under Skid Plate and Engine Room Under Cover Installa-
cle Service, Engine Coolant Replacement ). tion (Refer to GROUP 51 − Under Cover ).
• Battery and Battery Box Removal (Refer to 54A − Battery • Engine Cover Installation (Refer to GROUP 11A − Engine
). Assembly ).
2
4
48 ± 6 N·m
1 (ATF)
5N
(Engine oil) 22 ± 4 N·m

N 3 50 ± 7 N·m
17 ± 2 N·m
N 7 9 48 ± 6 N·m
12
N 13 17 ± 2 N·m
10 N
15 11 6
N 14 49 ± 6 N·m
17 ± 2 N·m
17 ± 2 N·m
18 8 N
22 19 N
24 ± 3 N·m
20
21
28 ± 4 N·m
16
24 ± 3 N·m
17 ACB00714AB

1. Wiring harness connection 3. O-ring
2. Engine oil level gauge and guide 4. Transmission fluid level gauge and
assembly guide assembly <A/T>
EMISSION CONTROL
17-43
Removal steps (Continued) INSTALLATION SERVICE POINTS
5. O-ring <A/T>
>>A<< EGR PIPE GASKET INSTALLATION
6. EGR valve and EGR pipe B fitting
>>B<< 7. EGR valve gasket <Except Euro5>
9. EGR valve
11. EGR pipe B fitting
12. EGR pipe A
15. Heater piping hose connection
• Starter assembly (Refer to GROUP
16 − Starting System, Starter ACB00713AB
Assembly )
16. Water hose <Euro5>
<<A>> 17. EGR pipe B, EGR cooler and
bracket assembly
18. EGR pipe B
20. EGR cooler bracket A
21. EGR cooler bracket B
22. EGR cooler
REMOVAL SERVICE POINT ACB00715AB

<<A>> EGR PIPE B, EGR COOLER AND The projection on the EGR pipe gasket should be
BRACKET ASSEMBLY REMOVAL position as shown.
1. Remove the EGR bracket mounting bolts from the
wheelhouse (LH). >>B<< EGR VALVE GASKET INSTALLATION
2. Remove the EGR pipe B, EGR cooler and bracket
assembly from above the vehicle.
AC502840AC
The projection on the EGR valve gasket should be

position as shown.
DIESEL PARTICULATE FILTER (DPF)

SYSTEM <Euro5>
GENERAL INFORMATION (DIESEL
PARTICULATE FILTER SYSTEM)
M1175006600261
The Diesel Particulate Filter (DPF) system is used to
adsorb and remove the Particulate Matter (PM) con-
tained in the exhaust gas. The engine-ECU antici-
pates the amount of PM accumulated in the DPF
through the input signal from each sensor.
EMISSION CONTROL
If the PM accumulates more than the standard, the SYSTEM DIAGRAM

engine-ECU carries out the control that automatically
regenerates the DPF under certain conditions to
remove the PM. At the DPF regeneration, the DPF
temperature gets high and high temperature exhaust
gases are given off.
Variable geometry
Throttle valve control

servo (DC motor)
Injector
Air flow sensor
No. 1 intake air temperature

sensor
EGR gas temperature sensor

Catalytic
converter
Manifold absolute pressure
sensor
pressure sensor Engine-ECU
Crank angle sensor
Engine coolant temperature

sensor
Catalytic No. 3 exhaust gas temperature
converter DPF sensor (DPF temperature)
Rail pressure sensor
No. 2 exhaust gas temperature sensor Accelerator pedal position

(catalyst temperature) sensor
No. 1 exhaust gas temperature sensor

AKB00299 AB
EMISSION CONTROL
17-45
DPF LAMP
No. 2 exhaust gas
temperature sensor
connector
DPF lamp
AKB00242 AB
When the engine oil level or the amount of accumu-

lated PM within the DPF exceeds the specified value,
the DPF lamp is lit or blinked. When the vehicle is No. 2 exhaust gas
brought into the shop with the DPF lamp blinked, temperature sensor
service the vehicle in accordance with the following
procedures.
DPF Engine State and service
lamp warning AKB00301 AB
lamp
Being Being lit Carry out the forcible DPF No. 3 exhaust gas
temperature sensor
blinked regeneration using M.U.T.-III (DPF temperature)
because PM being connector
excessively accumulated
within DPF is assumed.
(Refer to P.17-46)
Being Not Replace engine oil because
blinked being lit engine oil level excessively
increasing is assumed. (Refer
to GROUP 12 − On-vehicle
service − Engine Oil
Replacement )
After turning the ignition switch to "ON" position, the
DPF lamp is lit for the purpose of the operational No. 3 exhaust gas
temperature sensor
check for about 5 seconds. (DPF temperature)
COMPONENT LOCATION (DPF SYSTEM)

M1175006700138
AKB00302 AB
No. 1 exhaust gas
temperature sensor
pressure sensor
AKB00300 AB
AKB00303AB
EMISSION CONTROL
FORCIBLE DPF REGENERATION CAUTION

M1175006800221
Connection and disconnection of M.U.T.-III
WARNING should be always performed with the ignition
When the forcible DPF regeneration is car- switch turned to the "LOCK" (OFF) position.
ried out, confirm that no people or no com-
<LH drive vehicles>
bustible material is within its vicinity. If
people or combustible material is around the
muffler, serious injury or damage such as
heat injury or fires may occur because high
temperature exhaust gases are put out.
Diagnosis
WARNING connector
Perform the forcible DPF regeneration in a
well-ventilated and flat place when the vehi-
MB991910
cle is stopped (If perform the forcible DPF
regeneration indoors, surely carry out
MB991824
enforced ventilation).
WARNING
If the engine warning lamp is lit, the DPF sys-
tem might be abnormal. Carry out the inspec-
tion chart for diagnosis code, and then
perform the forcible DPF regeneration (Refer
to , GROUP 13A − Troubleshooting − Inspec-
tion Chart For Diagnosis codes). MB991827 AC509179AB
Set the vehicle to the pre-inspection condition.

connector
MB991910
MB991824
MB991827 AC501413AC
1. Connect the M.U.T.-III to the diagnosis connector.

2. Start the engine and let it run at idle.
3. From "FUNCTION MENU" on M.U.T.-III, select
"SPECIAL FUNCTION".
4. From "SPECIAL FUNCTION", select "DPF
REGENERATION".
EMISSION CONTROL
17-47
CAUTION
Exhaust gas
If the forcible regeneration of the DPF is carried temperature sensor
out while the accumulated amount of the PM in
the DPF exceeds the limit, the forcible regenera-
tion might not be correctly completed. This could
be caused by the detection in the DPF system
malfunction. Carry out the check procedure for
the diagnosis code and solve the malfunction.
(Refer to , GROUP 13A − Troubleshooting −
Inspection Chart For Diagnosis Codes) AKB00243 AB
5. Perform Item No. 33, DPF Regeneration.
4. Measure resistance while heating the sensor
NOTE: Carrying out the forcible DPF regeneration using a hair drier.
increases the engine speed 1,500 − 2,000 r/min
Normal condition:
(the temperature increases within the DPF and is
maintained at approximately 600°C). Temperature (°C) Resistance (kΩ)
NOTE: When performed for about 25 minutes, the Higher Smaller
forcible DPF regeneration automatically stops.
Depressing the accelerator pedal during the 5. If the value deviates from the standard value or
regeneration, however, can cancel the forcible the resistance remains unchanged, replace the
DPF regeneration. No. 1 exhaust gas temperature sensor assembly.
NOTE: If the DPF regeneration is carried out 6. Install the No. 1 exhaust gas temperature sensor
while the DPF lamp is illuminated or blinked due and tighten it to the specified torque.
to the accumulated PM, the DPF lamp is turned Tightening torque: 30 ± 5 N⋅m
off as soon as the forcible regeneration is cor-
rectly completed. No. 2 EXHAUST GAS TEMPERATURE
6. Turn the ignition switch to the "LOCK" (OFF) SENSOR (CATALYST TEMPERATURE)
position and then remove the M.U.T.-III. CHECK
M1175007000198
No. 1 EXHAUST GAS TEMPERATURE
No. 2 exhaust gas
SENSOR CHECK temperature sensor
M1175006900206 (catalyst temperature)
connector
No. 1 exhaust gas
temperature sensor
1 2
Equipment side
connector
1 2
Equipment side
1. Disconnect the No. 1 exhaust gas temperature No. 2 exhaust gas

sensor connector. temperature sensor
No. 2.
Standard value: 120 − 560 kΩ (at 20°C)
AKB00305 AB
3. Remove the No. 1 exhaust gas temperature
sensor. 1. Disconnect the No. 2 exhaust gas temperature
sensor (catalyst temperature) connector.
No. 2.
EMISSION CONTROL
Standard value: 120 − 560 kΩ (at 20°C) 1. Disconnect the No. 3 exhaust gas temperature
3. Remove the No. 2 exhaust gas temperature sensor (DPF temperature) connector.
sensor (catalyst temperature). 2. Measure resistance between terminals No. 1 and
No. 2.
Exhaust gas Standard value: 120 − 560 kΩ (at 20°C)
temperature sensor
3. Remove the No. 3 exhaust gas temperature
sensor (DPF temperature).
Exhaust gas
temperature sensor
AKB00243 AB

using a hair drier.
Normal condition:
AKB00243 AB
Temperature (°C) Resistance (kΩ)
Higher Smaller using a hair drier.
5. If the value deviates from the standard value or Normal condition:
No. 2 exhaust gas temperature sensor (catalyst Temperature (°C) Resistance (kΩ)
temperature) assembly. Higher Smaller
6. Install the No. 2 exhaust gas temperature sensor 5. If the value deviates from the standard value or
(catalyst temperature) and tighten it to the the resistance remains unchanged, replace the
specified torque. No. 3 exhaust gas temperature sensor (DPF
Tightening torque: 30 ± 5 N⋅m temperature) assembly.
6. Install the No. 3 exhaust gas temperature sensor
No. 3 EXHAUST GAS TEMPERATURE (DPF temperature) and tighten it to the specified
SENSOR (DPF TEMPERATURE) CHECK torque.
M1175007300177
No. 3 exhaust gas
temperature sensor CHECK AT THE ECU TERMINALS
(DPF temperature) M1175003000390
connector
Refer GROUP 13A − Troubleshooting − Check at
the ECU terminals.
1 2
Equipment side
connector
No. 3 exhaust gas

temperature sensor
(DPF temperature)
AKB00306 AB
EMISSION CONTROL
17-49
<Euro5>
M1175007700238
Refer to GROUP 15 − Exhaust Pipe and Main Muffler .

SYSTEM SENSORS <Euro5>

M1175008000180
CAUTION
• When the exhaust differential pressure sensor is replaced, use the M.U.T.-III to initialise the learn-
ing value (Refer to GROUP 00 − Precautions before Service, Initialisation Procedure for Learning
Value in DPF System ).
• When the exhaust differential pressure sensor is replaced, perform the forcible DPF regeneration
after learning value in DPF system (Refer to P.17-46).
• When the No.1, No.2 or No.3 exhaust gas temperature sensor is replaced, perform the forcible DPF
regeneration (Refer to P.17-46).
11 ± 1 N·m
2
3 30 ± 5 N·m
4.5 ± 1.5 N·m
1 ACB00708 ACB00705
Hydraulic unit Turbocharger
4 30 ± 5 N·m 5 30 ± 5 N·m
Front exhaust pipe DPF
ACB00706 ACB00707
ACB02032 AB
EMISSION CONTROL

1. Exhaust pressure hose connection <<A>> EXHAUST GAS TEMPERATURE SENSOR
2. Exhaust differential pressure REMOVAL
sensor
• Engine cover (Refer to GROUP CAUTION
11A − Engine Assembly ). Do not use the exhaust gas temperature sensor
<<A>> 3. No.1 exhaust gas temperature which dropped.
sensor
• Under skid plate and engine room CATALYTIC CONVERTER
under cover (Refer to GROUP 51 −
Under Cover ).
<<A>> 4. No.2 exhaust gas temperature
sensor
<<A>> 5. No.3 exhaust gas temperature
sensor

M1175002100673
<Except Euro5>
• Under Skid Plate and Engine Room Under Cover • Battery and Battery Box Installation (Refer to 54A − Bat-
Removal (Refer to GROUP 51 − Under Cover ). tery ) <Vehicles with Sub Battery>.
• Battery and Battery Box Removal (Refer to 54A − Battery • Under Skid Plate and Engine Room Under Cover Installa-
) <Vehicles with Sub Battery>. tion (Refer to GROUP 51 − Under Cover ).
9.0 ± 1.0 N·m

59 ± 5 N·m
59 ± 5 N·m
5N
59 ± 5 N·m
2N
57 ± 7 N·m
AC502841 AD

1. Front exhaust pipe connection 4. Catalytic converter
2. Exhaust pipe gasket 5. Catalytic converter gasket
3. Catalytic converter protector
EMISSION CONTROL
17-51
<Euro5>
CAUTION
• When the catalytic converter is replaced, use the M.U.T.-III to initialise the learning value (Refer to
GROUP 00 − Precautions before Service, Initialisation Procedure for Learning Value in DPF Sys-
tem ).
• When the catalytic converter is replaced, perform the forcible DPF regeneration after learning
value in DPF system (Refer to P.17-46).
• Under Skid Plate and Engine Room Under Cover • No.1 Exhaust Gas Temperature Sensor Installation (Refer
Removal (Refer to GROUP 51 − Under Cover ). to GROUP 17 − Emission Control, DPF System Sensors
• Battery and Battery Box Removal (Refer to 54A − Battery P.17-49).
) <Vehicles with Sub Battery>. • Battery and Battery Box Installation (Refer to 54A − Bat-
• No.1 Exhaust Gas Temperature Sensor Removal (Refer tery ) <Vehicles with Sub Battery>.
to GROUP 17 − Emission Control, DPF System Sensors • Under Skid Plate and Engine Room Under Cover Installa-
P.17-49). tion (Refer to GROUP 51 − Under Cover ).
9.0 ± 1.0 N·m
59 ± 5 N·m 5N
3
59 ± 5 N·m
4
2N
57 ± 7 N·m
AC805698 AB

1. Front exhaust pipe connection 4. Catalytic converter
2. Exhaust pipe gasket 5. Catalytic converter gasket
3. Catalytic converter protector
21-1
GROUP 21
CLUTCH
CONTENTS
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A
CLUTCH OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21B

21A-1
GROUP 21A
CLUTCH
CONTENTS
GENERAL INFORMATION . . . . . . . . 21A-2 CLUTCH PEDAL SWITCH OPERATING CHECK

...................................... 21A-5
SERVICE SPECIFICATION(S) . . . . . 21A-2
CLUTCH MASTER CYLINDER . . . . . 21A-5
LUBRICANT(S) . . . . . . . . . . . . . . . . . 21A-2 CLUTCH MASTER CYLINDER ASSEMBLY
REMOVAL AND INSTALLATION . . . . . . . . 21A-5
CLUTCH MASTER CYLINDER ASSEMBLY
ON-VEHICLE SERVICE. . . . . . . . . . . 21A-2
DISASSEMBLY AND REASSEMBLY . . . . . 21A-6
CLUTCH PEDAL CHECK AND ADJUSTMENT
CLUTCH MASTER CYLINDER ASSEMBLY
...................................... 21A-2
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 21A-6
CLUTCH BLEEDING . . . . . . . . . . . . . . . . . 21A-3
CLUTCH RELEASE CYLINDER . . . . 21A-7
CLUTCH PEDAL . . . . . . . . . . . . . . . . 21A-4
CLUTCH RELEASE CYLINDER ASSEMBLY
CLUTCH PEDAL REMOVAL AND INSTALLATION REMOVAL AND INSTALLATION . . . . . . . . 21A-7
...................................... 21A-4
CLUTCH CONTROL INSPECTION. . . . . . . 21A-7
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 21A-5
21A-2 CLUTCH
GENERAL INFORMATION
GENERAL INFORMATION
M1211000100308
The clutch is a dry single-disc, diaphragm type;
hydraulic pressure is used for the clutch control.
M1211000300421
Item Standard value

Clutch pedal height mm 183.5 − 186.5 <LHD>
178.5 − 181.5 <RHD>
Clutch pedal clevis pin play mm 1−3
Clutch pedal free play mm 4 − 13
Distance between the clutch pedal and the floorboard when 91 or more <LHD>
the clutch is released mm 86 or more <RHD>
LUBRICANTS
M1211000400257
Item Specified lubricant Quantity

Clutch fluid Brake Fluid DOT 3 or DOT 4 As required
Pushrod assembly Rubber grease As required
Release cylinder pushrod MITSUBISHI genuine grease Part As required
No.0101011 or equivalent
ON-VEHICLE SERVICE
CLUTCH PEDAL CHECK AND 2. Measure the clutch pedal height. If the height is
ADJUSTMENT outside the standard value, go to step 4.
M1211000900940 Standard value (A):
1. Turn back the carpet etc. under the clutch pedal. 183.5 − 186.5 mm <LHD>
Clutch pedal height Clutch pedal clevis pin play 178.5 − 181.5 mm <RHD>
3. Measure the clutch pedal clevis pin play. If the
play is outside the standard value, go to Step 5.
Standard value (B): 1 − 3 mm
4. Remove the clutch switch. (Refer to P.21A-4.)
<Vehicles with cruise control>
A B
AC001133 AD
CLUTCH
ON-VEHICLE SERVICE
21A-3
CAUTION 8. After the adjustments, confirm that the clutch
Do not push in the master cylinder pushrod at pedal free play (measured at the face of the pedal
this time, otherwise the clutch will not operate pad) and the distance between the clutch pedal
properly. (the face of the pedal pad) and the floorboard
when the clutch is disengaged are within the
standard value ranges.
Adjusting bolt
Standard value (C): 4 − 13 mm
Standard value (D):
Pushrod 91 mm or more <LHD>
86 mm or more <RHD>
Locking nut
9. If the measured free play and distance do not
Clutch pedal agree with the standard value ranges, it is
Setting nut
probably the result of either air in the hydraulic
13 ± 2 N·m
AC502646AC system or a faulty master cylinder or clutch. Bleed
the air, or disassemble and inspect the master
5. If the clutch pedal height is not within the standard cylinder or clutch.
value, loosen the setting nut and the locking nut
10.Reinstall the carpet, etc.
<Vehicles without cruise control> to adjust the
clutch pedal height to the standard value and CLUTCH BLEEDING
move the pushrod and the adjusting bolt M1211001400733
<Vehicles without cruise control>. CAUTION
6. Install the clutch switch. (Refer to P.21A-4.) Use the specified brake fluid. Do not mix brake
<Vehicles with cruise control> fluids.
7. If the clutch pedal clevis pin play is not within the Specified fluid: Brake fluid DOT 3 or DOT 4
standard value, loosen the setting nut and move
the pushrod to adjust.
Clutch damper
assembly
Clutch pedal free play
Clutch release
C
cylinder assembly AC609129 AC
1. Connect a hose with a bottle to the bleeder screw.

2. Open the bleed nipple.
Distance between the clutch pedal 3. Depress the clutch pedal slowly. Open the bleeder
and the floorboard when the clutch screw to let air and brake fluid out. Close the
is disengaged
bleeder screw. Release the clutch pedal. Repeat
until only brake fluid and no air comes out.
4. After air bleeding, tighten the bleeder screw to the
specified torque.
D
5. Check that the brake fluid reservoir level stays
AC001135AB between "MAX" and "MIN" marks throughout the
clutch bleeding process.
21A-4 CLUTCH
CLUTCH PEDAL
CLUTCH PEDAL
M1211001601008

• Lower Panel Assembly Removal (Refer to GROUP 52A − • ETACS-ECU Installation. <LHD>
Instrument Panel Assembly ). • Drivers side under cover <Except vehicles Single cab>
• Drivers side under cover <Except vehicles Single cab> Installation (Refer to GROUP 52A − Instrument Panel
Removal (Refer to GROUP 52A − Instrument Panel Assembly ).
Assembly ). • Lower Panel Assembly Installation (Refer to GROUP 52A
• ETACS-ECU Removal. <LHD> − Instrument Panel Assembly ).
• Clutch Pedal Adjustment (Refer to P.21A-2).
6
7 7
12 ± 2 N·m
13 ± 2 N·m
1 5 <Vehicles with
cruise control>
3
4 <Vehicles without
cruise control>
13 ± 2 N·m 9
13 ± 2 N·m
12 ± 2 N·m
10 N
2 8
AC900934AB

1. Snap pin >>A<< CLUTCH SWITCH <VEHICLES WITH
2. Clevis pin CRUISE CONTROL> INSTALLATION
3. Clutch pedal assembly
4. Adjusting bolt <Vehicles without Clutch switch
cruise control>
>>A<< 5. Clutch switch <Vehicles with cruise
control>
6. Return spring
7. Bushing
8. Stopper
9. Pedal stopper
Clutch pedal
10. Pedal pad 0.5 – 1.0 mm
AC309757AC
Install the clutch switch at the specified dimension

when the clutch pedal is released.
CLUTCH
CLUTCH MASTER CYLINDER
21A-5
INSPECTION 1. Check for continuity between the terminals of the
switch.
CLUTCH SWITCH CONTINUITY CHECK Tester Plunger Specified
M1211001000263
connection condition condition
CAUTION
Do not apply grease or lubricant to the switch 1-2 Released Continuity (less
and the switch installation section to avoid mal- than 2 Ω)
function of the switch. In addition, do not use Pushed Open circuit
gloves which have grease on them. 2. If the continuity is incorrect, replace the clutch
switch.
Open circuit Continuity
Plunger
Clutch switch 4.0 ± 1.0 mm

AC807040AB

M1211050100068

Clutch Fluid Draining • Clutch Fluid Supplying
• Clutch Bleeding (Refer to P.21A-3).
1
3 4
15 ± 2 N·m (Except High rider 4WD) 13 ± 2 N·m

18 ± 2 N·m (High rider 4WD)
AC809413AD
Clutch master cylinder removal Clutch master cylinder removal

• Lower panel assembly (Refer to 2. Clevis pin
GROUP 52A − Instrument Panel 3. Clutch master cylinder assembly
Assembly ). 4. Sealer
1. Snap pin
21A-6 CLUTCH
DISASSEMBLY AND REASSEMBLY

M1211002100542
CAUTION
Do not disassemble the piston assembly.
13 ± 2 N·m
6 7
2
1N
3N
5
1 3
3
3
Clutch fluid:
Piston repair kit Brake fluid DOT3 or DOT4 Grease: Rubber grease
AC712190 AB
Disassembly steps REASSEMBLY SERVICE POINT

1. Piston stopper ring
>>A<< 2. Pushrod assembly
3. Piston assembly
4. Reservoir cap
5. Spring pin
6. Reservoir tank
7. Seal
8. Master cylinder body
120.4 122.4 mm
AC800214AB
>>A<< PUSHROD ASSEMBLY INSTALLATION

Set the length of the pushrod assembly to the dimen-
sion shown to make the adjustment of the clutch
pedal easier.
INSPECTION
M1211002200196
• Check inside the cylinder body for rust and scars.
• Check the piston for rust and scars.
• Check the pipe connection for clogging.
CLUTCH
CLUTCH RELEASE CYLINDER
21A-7
M1211005500129

Clutch Fluid Draining • Clutch Fluid Supplying
• Clutch Bleeding (Refer to P.21A-3).
<Except High rider, 4WD)> <High rider, 4WD>
9 30 ± 3 N·m 23 ± 2 N·m
15 ± 2 N·m 8 10 6N
8 5
9 10 4 15 ± 2 N·m
7
15 ± 2 N·m
4
48 ± 6 N·m
30 ± 3 N·m 11 ± 2 N·m 3 11 ± 2 N·m 18 ± 2 N·m
1
23 ± 2 N·m
48 ± 6 N·m
6N 7 2N
5 35 ± 6 N·m
3 23 ± 2 N·m
1 Release fork
35 ± 6 N·m N 2 23 ± 2 N·m
Release cylinder
3 pushrod
Specified grease:
MITSUBISHI genuine grease
PART No. 0101011 or equivalent
AC903922AB
Clutch release cylinder assembly Clutch release cylinder assembly

and clutch damper assembly and clutch damper assembly
removal steps removal steps (Continued)
• Side rubber cover rear (front 8. Clutch damper assembly
wheelhouse left side). 9. Clutch damper bracket
1. Eye bolt 10. Clutch damper
2. Gasket
3. Clutch release cylinder assembly INSPECTION
M1211002000200
4. Clutch pipe
• Check the clutch fluid line for fluid leakage.
5. Eye bolt
6. Gasket
• Check the clutch hose and pipe for cracks or
7. Clutch hose clogging.
21B-1
GROUP 21B
CLUTCH
OVERHAUL
CONTENTS
GENERAL SPECIFICATIONS . . . . . . 21B-2 CLUTCH . . . . . . . . . . . . . . . . . . . . . . . 21B-3

CLUTCH REMOVAL AND INSTALLATION 21B-3
SERVICE SPECIFICATIONS. . . . . . . 21B-2 CLUTCH INSPECTION . . . . . . . . . . . . . . . . 21B-5
TORQUE SPECIFICATIONS . . . . . . . 21B-2 CLUTCH RELEASE CYLINDER . . . . 21B-6

CLUTCH RELEASE CYLINDER DISASSEMBLY AND
LUBRICANTS . . . . . . . . . . . . . . . . . . 21B-2 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 21B-6
CLUTCH RELEASE CYLINDER INSPECTION
...................................... 21B-7
21B-2 CLUTCH OVERHAUL
M1212000201356
Item R5MB1-J-ND1 R5MB1-J-NC,V5MB1

Clutch operating method Hydraulic type
Clutch disc type Single dry disc type
Clutch disc size O.D. × I.D. mm 225 × 150 250 × 160
Clutch cover type Diaphragm spring type
Clutch cover setting load N 5,394 ± 441 5,850 ± 470
M1212000300286
Item Limit
Diaphragm spring end height difference mm 0.5
Facing rivet sink mm 0.3
Release cylinder I.D. to piston O.D. clearance mm 0.15
M1212001800347
Item N⋅m
Fulcrum 35 ± 6
Clutch release cylinder mounting bolt 35 ± 6
Clutch cover mounting bolt 19 ± 3
Air bleeder 8.0 ± 1.0
LUBRICANTS
M1212000400681
Items Specified lubricants Quantity

Clutch release bearing to release fork Mitsubishi Part No. 0101011 or equivalent As required
contact surface
Fulcrum to release fork contact surface
Clutch release cylinder push rod to release
fork contact surface
Clutch release bearing inside
Clutch disc spline
Clutch release cylinder inner surface Brake Fluid DOT 3 or DOT 4
Piston and piston cups outer surface Rubber grease
CLUTCH OVERHAUL
CLUTCH
21B-3
CLUTCH
M1212001001065
3
1
2 4 7
8
35 ± 6 N·m
19 ± 3 N·m
35 ± 6 N·m 6
AK403591AB
Removal steps DISASSEMBLY SERVICE POINT

>>C<< 1. Clutch cover <<A>> RELEASE FORK REMOVAL
>>C<< 2. Clutch disc
3. Return clip
>>B<< 4. Clutch release bearing
5. Clutch release cylinder Fulcrum
6. Boot
<<A>> >>A<< 7. Release fork Clip
8. Fulcrum
Release fork
AK403602 AB
Slide the release fork in direction of the arrow and

disengage the fulcrum from the clip to remove the
release fork. Be careful not to damage the clip by
pushing the release fork in the wrong direction or
removing it with force.
CLUTCH
REASSEMBLY SERVICE POINTS 3. Install the return clip to engage the clutch release
>>A<< RELEASE FORK INSTALLATION bearing with the fork.
>>C<< CLUTCH DISC / CLUTCH COVER

INSTALLATION
Flywheel
Clutch disc
Fulcrum
Release fork
Clutch disc guide
Clutch release cylinder

AK403592AB Clutch cover
1. Apply the specified grease to the release fork.
Specified grease: Mitsubishi Part No. AK403594AB
0101011 or equivalent
1. Apply the specified grease to the clutch disc
2. Install the release fork onto the fulcrum. splines and rub it in splines with a brush.
Specified grease: Mitsubishi Part No.
>>B<< CLUTCH RELEASE BEARING 0101011 or equivalent
INSTALLATION
2. Using the clutch disc guide to position the clutch
disc on the flywheel.
8 1
5 3
4 6
AK503501AB :
Dowel pin
1. Apply the specified grease to the clutch release position 2 7 AK500601AE
bearing inside, and fill grease in the groove.
3. Install the clutch cover, aligning its installation
Specified grease: Mitsubishi Part No.
position with the dowel pins, and then tighten the
bolts to the specified torque of 19 ± 3 N⋅m in the
2. Install the clutch release bearing on the bearing order shown in the illustration.
retainer of the transmission.
CLUTCH OVERHAUL
CLUTCH
21B-5
INSPECTION 1. Check the facing for loose rivets, uneven contact,
M1212001100252 deterioration due to seizure, adhesion of oil or
CLUTCH COVER grease. Replace the clutch disc if defective.
2. Measure the rivet sink and replace the clutch disc
Diaphragm spring if it is out of specification.
Limit: 0.3 mm
3. Check for the torsion spring play and damage. If
defective, replace the clutch disc.
4. Combine the clutch disc with the input shaft and
check sliding condition and play in the rotating
direction. If it does not slide smoothly or the play
AK403603AB
is excessive, check after cleaning and
reassembling. If the play is excessive, replace the
1. Check the diaphragm spring end for wear and clutch disc and/or the input shaft.
uneven height. Replace if wear is evident or
height difference exceeds the limit. CLUTCH RELEASE BEARING
Limit: 0.5 mm CAUTION
2. Check the pressure plate surface for wear, cracks The clutch release bearing is packed with grease.
and seizure. Do not wash it in cleaning solvent.
3. Check the strap plate rivets for looseness and 1. Check the bearing for seizure, damage, noise, or
replace the clutch cover assembly if loose. improper rotation. If defective, replace the
bearing.
CLUTCH DISC 2. Check for wear on the surface which contacts with
the diaphragm spring. If abnormally worn, replace
CAUTION
the bearing.
Don't clean the clutch disc in a cleaning solvent.
3. Check for wear on the surface which contacts with
the release fork. If abnormally worn, replace the
bearing.
Rivet sink
RELEASE FORK
Check for wear on the surface which contacts with
the bearing. If abnormally worn, replace the release
fork.
AK400613 AC

M1212001500573
4
7 1
8.0 ± 1.0 N·m
8 2
9 3
5
6
AK503444 AE
Disassembly steps DISASSEMBLY SERVICE POINT

1. Push rod <<A>> PISTON CUP A / PISTON CUP B / PISTON
2 Boot REMOVAL
<<A>> >>A<< 3. Piston cup B
<<A>> >>A<< 4. Piston WARNING
<<A>> >>A<< 5. Piston cup A • Cover with a shop towel to prevent the
6. Conical spring piston from popping out.
7. Cap • Apply compressed air slowly to prevent
8 Bleeder plug
brake fluid from splashing.
>>A<< 9. Release cylinder
AK102083
Remove the piston and piston cup from the release

cylinder using compressed air.
CLUTCH OVERHAUL
21B-7
REASSEMBLY SERVICE POINT 2. Apply grease to the piston and piston cups and
>>A<< RELEASE CYLINDER / PISTON CUP A / insert the piston assembly into the release
PISTON CUP B / PISTON INSTALLATION cylinder.
Specified grease: Rubber grease
INSPECTION
M1212001600246
PISTON CUP
Check the lip of piston cup for scratch. If there are
any scratches, check if there are any scores inside
the release cylinder.
RELEASE CYLINDER
AK704100AB
1. Check the inner surface of the release cylinder for
1. Apply brake fluid to the entire inner surface of the rust or scratches.
release cylinder. 2. Use a cylinder gauge to measure the inside
Specified brake fluid: Brake fluid DOT 3 or diameter of the release cylinder at three different
DOT 4 points (innermost, middle, and outermost points).
Replace the release cylinder assembly if the
clearance between the piston and cylinder
exceeds the limit at any of the measurement
points.
Limit: 0.15 mm
Piston Piston cup

AK203875 AH
22-1
GROUP 22
MANUAL
TRANSMISSION
(FR)
CONTENTS
MANUAL TRANSMISSION (FR). . . . . . . . . . . . . . . . . . . . . . . . . 22A
MANUAL TRANSMISSION OVERHAUL <R5MB1> . . . . . . . . . 22B
MANUAL TRANSMISSION OVERHAUL <V5MB1> . . . . . . . . . 22C

22A-1
GROUP 22A
MANUAL
TRANSMISSION
(FR)
CONTENTS
GENERAL INFORMATION . . . . . . . . 22A-2 4WD OPERATION DETECTION SWITCH

CONTINUITY CHECK <SUPER SELECT 4WD>
...................................... 22A-6
LUBRICANT(S) . . . . . . . . . . . . . . . . . 22A-2
HIGH/LOW DETECTION SWITCH CONTINUITY
CHECK <SUPER SELECT 4WD> . . . . . . . 22A-6
SEALANT AND ADHESIVE. . . . . . . . 22A-2
4LLc DETECTION SWITCH CONTINUITY CHECK
<HIGH POWER ENGINE> . . . . . . . . . . . . . 22A-6
ON-VEHICLE SERVICE. . . . . . . . . . . 22A-3
TRANSMISSION OIL LEVEL CHECK . . . . 22A-3 TRANSMISSION CONTROL . . . . . . . 22A-7
TRANSMISSION OIL CHANGE . . . . . . . . . 22A-3 TRANSMISSION CONTROL REMOVAL AND
TRANSFER OIL LEVEL CHECK . . . . . . . . 22A-4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 22A-7
TRANSFER OIL CHANGE . . . . . . . . . . . . . 22A-4
4WD DETECTION SWITCH CONTINUITY CHECK TRANSMISSION ASSEMBLY . . . . . . 22A-9
<EASY SELECT 4WD> . . . . . . . . . . . . . . . 22A-4 TRANSMISSION ASSEMBLY REMOVAL AND
HIGH/LOW DETECTION SWITCH CONTINUITY INSTALLATION <2WD> . . . . . . . . . . . . . . . 22A-9
CHECK <EASY SELECT 4WD>. . . . . . . . . 22A-5 TRANSMISSION ASSEMBLY REMOVAL AND
CENTRE DIFFERENTIAL LOCK DETECTION INSTALLATION <4WD> . . . . . . . . . . . . . . . 22A-10
SWITCH CONTINUITY CHECK <SUPER SELECT
4WD> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22A-5 4WD INDICATOR-ECU. . . . . . . . . . . . 22A-11
2WD/4WD DETECTION SWITCH CONTINUITY 4WD INDICATOR-ECU REMOVAL AND
CHECK <SUPER SELECT 4WD> . . . . . . . 22A-5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 22A-11
CENTRE DIFFERENTIAL LOCK OPERATION INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 22A-11
DETECTION SWITCH CONTINUITY CHECK <SUPER
SELECT 4WD> . . . . . . . . . . . . . . . . . . . . . . 22A-5
22A-2 MANUAL TRANSMISSION (FR)
GENERAL INFORMATION
GENERAL INFORMATION
M1221100100403
The R5MB1 and V5MB1 type manual transmission
has been adopted.
SPECIFICATIONS
Item Specification
Transmission mode R5MB1 V5MB1-J- V5MB1-J- V5MB1-J- V5MB1-J- V5MB1-J-
NEG PCG NE PD2 NEZ
Engine model 4D56
Transmission type 5 forward speed, one reverse, constant mesh
Gear ratio 1st 4.313
2nd 2.330
3rd 1.436
4th 1.000
5th 0.788
Reverse 4.220
Drive system 2WD Easy select 4WD Super select 4WD
Centre differential - Not provided Provided
Transfer type - 2speeds, constant mesh
Transfer gear ratio High - 1.000
Low - 1.900
LUBRICANT
M1221100200154
Item Specified lubricant Quantity L

Transmission oil 2WD Gear oil API classification GL-3 SAE 75W-85 2.3
4WD 3.4
Transfer oil <4WD> Gear oil API classification GL-3 SAE 75W-85 or API 2.5
classification GL-4 SAE 75W-85
SEALANTS
M1221102000060

Transmission control lever assembly and 3M ATD Part No.8660 or equivalent
transfer control lever assembly
MANUAL TRANSMISSION (FR)
ON-VEHICLE SERVICE
22A-3
ON-VEHICLE SERVICE
TRANSMISSION OIL LEVEL CHECK TRANSMISSION OIL REPLACEMENT
M1221100600259 M1221100700342
Filler plug hole Filler plug

Gasket
Drain plug
Filler plug
Transmission oil
AC700330AL AC502641AD
Filler plug Filler plug hole
Gasket
Drain plug
Filler plug
Transmission oil
AC502641AD AC700330AL
1. Remove the filler plug and gasket. 1. Remove the filler plug and gasket.
2. Check that the oil level is up to the lower edge of 2. Remove the drain plug and drain the oil.
the filler plug hole. 3. Tighten the drain plug to the specified torque.
3. Check that the oil is not noticeably dirty. Tightening torque: 37 ± 11 N⋅m
4. Install the filler plug and new gasket, then tighten 4. Fill with gear oil API classification GL-3 SAE 75W-
them to the specified torque. 85 until the level comes to the lower portion of
Tightening torque: 37 ± 11 N⋅m filler plug hole.
Quantity:
2.3 L <2WD>
3.4 L <4WD>
5. Install the filler plug and new gasket, then tighten
them to the specified torque.
ON-VEHICLE SERVICE
TRANSFER OIL LEVEL CHECK TRANSFER OIL REPLACEMENT

M1221102500117 M1221102600147
Filler plug Filler plug
Drain plug Drain plug
AC502640AB AC502640AB
Filler plug hole Filler plug hole
Gasket Gasket
Filler plug Filler plug
Transfer oil Transfer oil

AC700330AM AC700330AM
1. Remove the filler plug and gasket. 1. Remove the filler plug and gasket.
2. Check that the oil level is up to the lower edge of 2. Remove the drain plug and gasket, and then drain
the filler plug hole. the oil.
3. Check that the oil is not noticeably dirty. 3. Install the drain plug and new gasket, then tighten
4. Install the filler plug and new gasket, then tighten them to the specified torque.
them to the specified torque. Tightening torque: 32 ± 2 N⋅m
Tightening torque: 32 ± 2 N⋅m 4. Fill with gear oil API classification GL-3 SAE 75W-
85 or API classification GL-4 SAE 75W-85 until
the level comes to the lower portion of filler plug
hole.
Quantity: 2.5 L
5. Install the filler plug and new gasket, then tighten
4WD DETECTION SWITCH CONTINUITY

CHECK <EASY SELECT 4WD>
M1221102700122
AC503108AB
ON-VEHICLE SERVICE
22A-5
Check the continuity between terminals of the black Transfer lever position Specified condition
connector and earth indicated in the illustration.
4HLc and 4LLc Continuity (Less than 2
Transfer lever position Specified condition Ω)
2H Open circuit 2H and 4H Open circuit
4H, 4L Continuity (Less than 2
Ω) 2WD/4WD DETECTION SWITCH
CONTINUITY CHECK <SUPER SELECT
HIGH/LOW DETECTION SWITCH 4WD>
CONTINUITY CHECK <EASY SELECT M1221103200119
4WD>
M1221102800141
AC509434AB
Check the continuity between terminals of the black

AC503107AB
Check the continuity between terminals of the grey Transfer lever position Specified condition
2H Open circuit
Transfer lever position Specified condition
4H, 4HLc and 4LLc Continuity (Less than 2
While switching between Open circuit Ω)
4H and 4L
2H, 4H, 4L Continuity (Less than 2 CENTRE DIFFERENTIAL LOCK
Ω) OPERATION DETECTION SWITCH
CENTRE DIFFERENTIAL LOCK
4WD>
DETECTION SWITCH CONTINUITY M1221103300075
CHECK <SUPER SELECT 4WD>
M1221103100112
AC509434AD
Check the continuity between terminals of the black

AC509434AC
Check the continuity between terminals of the brown
connector and earth indicated in the illustration. Transfer lever position Specified condition
2H and 4H Open circuit
4HLc and 4LLc Continuity (Less than 2
Ω)
ON-VEHICLE SERVICE
4WD OPERATION DETECTION SWITCH Check the continuity between terminals of the white
CONTINUITY CHECK <SUPER SELECT connector and earth indicated in the illustration.
4WD> Transfer lever position Specified condition
M1221103400038
While switching between Open circuit
4HLc and 4LLc
2H, 4H, 4HLc and 4LLc Continuity (Less than 2
Ω)
4LLc SWITCH CONTINUITY CHECK

<HIGH POWER ENGINE>
M1221144400024
AC509434AF
Check the continuity between terminals of the brown

2H Open circuit
4H, 4HLc and 4LLc Continuity (Less than 2
Ω) AC509434AE
HIGH/LOW DETECTION SWITCH Check the continuity between terminals of the white
M1221102800152 2H, 4H, and 4HLc Continuity (Less than 2
Ω)
4LLc Open circuit
AC509434AG
TRANSMISSION CONTROL
22A-7
M1221102200116
<2WD>
Move the transmission control lever to the Neutral position. Check that the transmission control lever is moved to each
position smoothly and correctly.
1
4
4
3.2 ± 0.2 N·m
2 19 ± 3 N·m
3 N 5
Semi-drying sealant:
3M ATD Part No.8660 or
equivalent
AC609267AB

1. Shift knob 4. Transmission control lever assembly
• Front floor console assembly (Refer 5. Gasket
to GROUP 52A, Floor Consol
Assembly .)
2. Dust cover retaining plate
3. Dust cover
<4WD>
Move the transmission control lever and transfer control Check that the transmission control lever and the transfer
lever to the following positions. control lever are moved to each position smoothly and
• Transmission control lever: Neutral correctly.
• Transfer control lever: 4H
3.2 ± 0.2 N·m

4
7
5
1
2
3
3M ATD Part No.8660 or equivalent
19 ± 3 N·m
19 ± 3 N·m
AC509473AB

1. Shift knob >>A<< SLEEVE INSTALLATION
>>A<< 2. Sleeve
3. Transfer shift lever knob
• Front floor console assembly
<Vehicles with front floor consol
assembly> (Refer to GROUP 52A,
Floor Consol Assembly .) Sleeve
4. Dust cover retaining plate
5. Control lever cover <Vehicles without
front floor consol assembly>
6. Dust cover Shift knob
7. Transmission control lever assembly
AC503137AB
and transfer control lever assembly
Install the sleeve with its groove facing to the direc-
tion shown in the figure, and then install the shift
knob.
TRANSMISSION ASSEMBLY
22A-9
REMOVAL AND INSTALLATION <2WD>
M1221102400488
Pre-removal and Post-installation Operations

• Transmission Control Lever Assembly Removal and
Installation (Refer to P.22A-7).
• Transmission Oil Draining and Refilling (Refer to P.22A-
3).
• Under Skid Plate and Engine Room Under Cover
Removal and Installation.
• Propeller Shaft Assembly Removal and Installation (Refer
to GROUP 25 − Propeller Shaft ).
• Clutch Release Cylinder Assembly and Clutch Damper
Assembly Removal and Installation (Disconnect the con-
nection with transmission only and do not disconnect the
clutch line.).
• Starter Assembly Removal and Installation (Refer to
GROUP 16 − Starter Motor Assembly ).
• No.2 Crossmember Assembly and Transmission Mount
Insulator Assembly Removal and Installation (Refer to
GROUP 32 − Rear Engine Mounting ).
4 6
25 ± 4 N·m 48 ± 6 N·m
5
3
48 ± 6 N·m 1
11 ± 1 N·m
9.0 ± 1.0 N·m AC807940 AC

1. Transmission harness connector 3. Transmission assembly lower part
connection coupling bolts
• Support the transmission with a 4. Front exhaust pipe bracket
transmission jack 5. Transmission assembly upper part
2. Bell housing cover coupling bolts
6. Transmission assembly
REMOVAL AND INSTALLATION <4WD>

M1221102400499
Pre-removal and Post-installation Operations

• Transmission Control Lever Assembly and Transfer Con-
trol Lever Assembly Removal and Installation (Refer to
P.22A-7).
• Transmission Oil Draining and Refilling (Refer to P.22A-
3).
• Transfer Oil Draining and Refilling (Refer to P.22A-4).
Removal and Installation (Refer to GROUP 51 − Under
Cover ).
• Front and Rear Propeller Shaft Removal and Installation
(Refer to GROUP 25 ).
• Front Exhaust Pipe Removal and Installation (Refer to
GROUP 15 − Front Exhaust Pipe and Main Muffler .)
• Clutch Release Cylinder Assembly and Clutch Damper
Assembly Removal and Installation (Disconnect the con-
nection with transmission only and do not disconnect the
clutch line.) (Refer to GROUP 21A − Clutch Release Cyl-
inder Assembly ).
• Starter Assembly Removal and Installation (Refer to
GROUP 16 − Starter Motor Assembly ).
• Transfer Mount Bracket Assembly Removal and Installa-
tion (Refer to GROUP 32 − Transfer Mounting ).
• No.2 Crossmember Assembly and Transmission Mount
Insulator Assembly Removal and Installation (Refer to
GROUP 32 − Rear Engine Mounting ).
6
4
1
25 ± 4 N·m
48 ± 6 N·m
5
3
48 ± 6 N·m
11 ± 1 N·m 9.0 ± 1.0 N·m

AC809607AB

1. Transmission harness connector 3. Transmission assembly lower part
connection coupling bolts
• Support the transmission with a 4. Front exhaust pipe bracket
transmission jack 5. Transmission assembly upper part
6. Transmission assembly
4WD INDICATOR-ECU
22A-11
4WD INDICATOR-ECU
M1221102900029
<Vehicles with LHD>
<Vehicles with RHD>
AC509527AB
Removal steps 1. Measure the voltage with the control unit and
• Glove Box Cover (Refer to GROUP harness still connected.
52A, Instrument Panel Assembly ). 2. Earth terminal (8) and then measure the terminal
1. 4WD indicator-ECU voltage.
INSPECTION
M1221101200157 EASY SELECT 4WD
4WD INDICATOR-ECU
VIEW A
A
AC504329AB
Terminal Inspection item Ignition switch Transfer shift position Terminal voltage
No.
1 Free wheel engage switch ON 2H System voltage
4H*1 1 V or less
2 4WD detection switch ON 2H System voltage
4H, 4L 1 V or less
3 Ignition switch ON − System voltage
OFF − 1 V or less
6 High/low detection switch ON While switching between System voltage
4H and 4L
2H, 4H, 4L 1 V or less
4WD INDICATOR-ECU
No.
7 Free wheel clutch changeover ON 4H, 4L 1 V or less
solenoid valve System voltage
2H*2
10 4WD indicator lamp ON 2H 1 V or less
4H, 4L System voltage
NOTE: .
*1
: When vehicle has been moved once.
*2
: Shift the lever from 4H to 2H, and then turn the ignition switch to OFF and then back to ON.
<SUPER SELECT 4WD>
No.
1 Free wheel engage switch ON 2H System voltage
4H*1 1 V or less
2 4WD operation detection ON 2H System voltage
switch 4H, 4HLc, 4LLc 1 V or less
3 Ignition switch ON − System voltage
OFF − 1 V or less
4 Centre differential lock indicator ON 4H 1 V or less
lamp 4HLc System voltage
5 Rear wheel indicator lamp ON While switching between 1 V or less
4HLc and 4LLc
2H, 4H, 4HLc, 4LLc System voltage
6 High/low detection switch ON While switching between System voltage
4HLc and 4LLc
2H, 4H, 4HLc, 4LLc 1 V or less
7 Centre differential lock ON 4HLc 1 V or less
operation detection switch System voltage
4H*2
9 Centre differential lock ON 4HLc 1 V or less
detection switch System voltage
4H*2
10 Front wheel indicator lamp ON While switching between 1 V or less
4HLc and 4LLc
4H, 4HLc, 4LLc System voltage
NOTE: .
*1
: When vehicle has been moved once.
*2: Shift the lever from 4HLc to 4H, and then turn the ignition switch to OFF and then back to ON.
22B-1
GROUP 22B
MANUAL
TRANSMISSION
OVERHAUL
<R5MB1>
CONTENTS
GENERAL INFORMATION . . . . . . . . 22B-2 INPUT SHAFT. . . . . . . . . . . . . . . . . . . 22B-29

INPUT SHAFT DISASSEMBLY AND REASSEMBLY
GENERAL SPECIFICATIONS . . . . . . 22B-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22B-29
INPUT SHAFT INSPECTION . . . . . . . . . . . 22B-30
SERVICE SPECIFICATIONS. . . . . . . 22B-2
OUTPUT SHAFT. . . . . . . . . . . . . . . . . 22B-31
SNAP RING, SPACER AND THRUST PLATE OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . 22B-31
FOR ADJUSTMENT. . . . . . . . . . . . . . 22B-3 OUTPUT SHAFT INSPECTION . . . . . . . . . 22B-35
TORQUE SPECIFICATIONS . . . . . . . 22B-4 COUNTERSHAFT. . . . . . . . . . . . . . . . 22B-37

COUNTERSHAFT DISASSEMBLY AND
SEALANT(S) AND ADHESIVE(S) . . . 22B-5 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 22B-37
COUNTERSHAFT INSPECTION . . . . . . . . 22B-38
LUBRICANTS . . . . . . . . . . . . . . . . . . 22B-6
REVERSE IDLER GEAR . . . . . . . . . . 22B-39
SPECIAL TOOLS. . . . . . . . . . . . . . . . 22B-6 REVERSE IDLER GEAR DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 22B-39
TRANSMISSION . . . . . . . . . . . . . . . . 22B-8 REVERSE IDLER GEAR INSPECTION . . . 22B-39
TRANSMISSION DISASSEMBLY AND REASSEMBLY
...................................... 22B-8 EXTENSION HOUSING . . . . . . . . . . . 22B-40
TRANSMISSION INSPECTION . . . . . . . . . 22B-27 EXTENSION HOUSING DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 22B-40
22B-2 MANUAL TRANSMISSION OVERHAUL <R5MB1>
GENERAL INFORMATION
GENERAL INFORMATION
M1222000101275
MANUAL TRANSMISSION MODELS

Transmission model Engine model Vehicle model
R5MB1-J-NC 4D56 DI-D DOHC KA4T
R5MB1-J-ND1
M1222000200785
Item Specifications
Transmission model R5MB1
Transmission type 5-speed transmission, floor shift
Transmission gear ratio 1st 4.313
2nd 2.330
3rd 1.436
4th 1.000
5th 0.789
Reverse 4.220
M1222000300492

Transmission
Gear spline piece No.5 end play mm 0 − 0.1 −
Clearance between the synchronizer ring and the gear mm 0.52 - 1.88 0.52
Counter shaft gear No.5 thrust 0.10 - 0.35 0.35
clearance mm
radial 0.015 − 0.068 0.068
clearance mm
inside diameter 38.015 − 38.040 38.040
mm
Input shaft
Input shaft radial ball bearing end play mm 0 − 0.1 −
clearance between the synchronizer ring and the 4th gear mm 0.70 − 1.70 0.70
Output shaft
Thrust clearance mm 1st gear 0.20 − 0.45 0.45
2nd gear 0.10 − 0.25 0.25
3rd gear 0.10 − 0.25 0.25
MANUAL TRANSMISSION OVERHAUL <R5MB1>
SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENT
22B-3
Radial clearance mm 1st gear 0.020 − 0.073 0.073
2nd gear 0.015 − 0.068 0.068
3rd gear 0.015 − 0.068 0.068
Transmission clutch hub No.1 end play mm 0 − 0.1 −
5th gear end play mm 0 − 0.1 −
Clearance between the synchronizer ring and the 1st gear 0.65 − 1.75 0.65
each gear mm 2nd gear 0.65 − 1.75 0.65
3rd gear 0.65 − 1.75 0.65
Clearance between the each sleeve and the shift sleeve No.1 0.15 − 0.41 0.41
fork mm sleeve No.2 0.15 − 0.35 0.35
sleeve No.3 0.26 − 0.84 0.84
Output shaft outer shape of the needle roller A 37.984 − 38.000 37.984
bearing race mm B 46.984 − 47.000 46.984
C 38.979 − 38.995 38.979
Output shaft flange thickness mm − 4.800
Output shaft runout mm − 0.015
Each gear inside diameter mm 1st gear 46.015 − 46.040 46.040
2nd gear 53.015 − 53.040 53.040
3rd gear 44.015 − 44.040 44.040
Counter shaft
Counter gear shaft cylindrical roller bearing end play mm 0 − 0.1 −
Counter shaft outer shape of the needle roller D 34.000 − 34.105 34.000
bearing race mm E 29.984 − 30.000 29.984
Reverse idler gear
Reverse idler gear radial clearance mm 0.040 − 0.082 0.082
SNAP RING, SPACER AND THRUST PLATE FOR

ADJUSTMENT
M1222012000595
Shaft snap ring (For adjustment of gear spline piece No.5 end play)
Thickness mm Identification symbol Thickness mm Identification symbol
2.80 − 2.85 A 3.00 − 3.05 E
2.85 − 2.90 B 3.05 − 3.10 F
2.90 − 2.95 C 3.10 − 3.15 G
2.95 − 3.00 D
Shaft snap ring (For adjustment of input shaft radial ball bearing end play)
2.10 − 2.15 A 2.30 − 2.35 E
2.15 − 2.20 B 2.35 − 2.40 F
2.20 − 2.25 C 2.40 − 2.45 G
2.25 − 2.30 D
Shaft snap ring (For adjustment of transmission clutch hub No.2 end play)
1.80 − 1.85 A 2.00 − 2.05 E
1.85 − 1.90 B 2.05 − 2.10 F
1.90 − 1.95 C 2.10 − 2.15 G
1.95 − 2.00 D
2.30 − 2.35 A 2.50 − 2.55 E
2.35 − 2.40 B 2.55 − 2.60 F
2.40 − 2.45 C 2.60 − 2.65 G
2.45 − 2.50 D
Shaft snap ring (For adjustment of 5th gear end play)
2.75 − 2.80 C 3.05 − 3.10 J
2.80 − 2.85 D 3.10 − 3.15 K
2.85 − 2.90 E 3.15 − 3.20 L
2.90 − 2.95 F 3.20 − 3.25 M
2.95 − 3.00 G 3.25 − 3.30 N
3.00 − 3.05 H 3.30 − 3.35 P
Shaft snap ring (For adjustment of counter gear shaft cylindrical roller bearing end play)
2.05 − 2.10 A 2.20 − 2.25 D
2.10 − 2.15 B 2.25 − 2.30 E
2.15 − 2.20 C 2.30 − 2.35 F
M1222013900494
Item N⋅m
Intermediate plate − reverse shift arm bracket mounting bolt 18 ± 5
Transmission case − clutch housing mounting bolt 36 ± 7
Transmission case − clutch housing mounting bolt (with seal) 34 ± 6
Transmission case − front bearing retainer sub-assembly mounting bolt 16.5 ± 5.0
SEALANTS
22B-5
Item N⋅m
Transmission case − back-up lamp switch assembly 44 ± 9
Transmission case − shift position switch assembly <R5MB1-J-NC> 34 ± 5
Transmission case − vehicle speed sensor mounting bolt 11 ± 1
Extension housing − straight screw plug with head 18.5 ± 5.5
Transmission case − extension housing sub-assembly, and intermediate plate 37 ± 11
mounting bolt
Intermediate plate − straight screw plug with head 18.5 ± 5.5
Gear shift fork No.1 mounting bolt 19.5 ± 3.9
Gear shift fork No.2 mounting bolt 19.5 ± 3.9
Intermediate plate − rear bearing output retainer mounting bolt 18 ± 5
Oil receiver pipe mounting bolt 11 ± 4
Shift lever housing mounting bolt 33 ± 3
SEALANTS
M1222000501132
Item Specified sealant and adhesive

Between transmission case sub-assembly and Mitsubishi Part No.MD974421 or equivalent
intermediate plate
Between front bearing retainer and transmission
case
Between intermediate plate and extension housing
sub-assembly
Straight screw plug with head
Front bearing retainer mounting bolt
Clutch housing mounting bolt
FORM-IN-PLACE GASKET (FIPG) CAUTION
This transmission has several areas where the form- When re-applying liquid gasket (FIPG), be sure
in-place gasket (FIPG) is used for sealing. To ensure that:
that the FIPG fully serves its purpose, it is necessary
1. Residues of FIPG are cleared from all the ins
to observe some precautions when applying it. Bead and outs of parts;
size, continuity and location are of paramount impor-
2. Use Mitsubishi genuine parts cleaner
tance.
(MZ100387) or equivalent to well degrease the
Too thin a bead could cause leaks. Too thick a bead,
FIPG-applied surface.
on the other hand, could be squeezed out of location,
causing blocking or narrowing of fluid passages. To 3. FIPG is correctly applied in accordance with
prevent leaks or blocking of passages, therefore, it is FIPG Application.
absolutely necessary to apply the FIPG evenly with- Disassembly
out a break, while observing the correct bead size. Parts sealed with a FIPG can be easily removed
FIPG hardens as it reacts with the moisture in the without need for the use of a special method. In
atmospheric air, and it is usually used for sealing some cases, however, the FIPG in joints may have to
metallic flange areas. be broken by tapping parts with a mallet or similar
tool.
LUBRICANTS
Surface Preparation FIPG Application

Thoroughly remove all substances deposited on the Applied FIPG bead should be of the specified size
FIPG application surface, using a gasket scraper. and free of any break. FIPG can be wiped away
Make sure that the FIPG application surfaces is flat unless it has completely hardened. Install the mating
and smooth. Also make sure that the surface is free parts in position while the FIPG is still wet. Do not
from oils, greases and foreign substances. Do not fail allow FIPG to spread beyond the sealing areas dur-
to remove old FIPG that may remain in the fastener ing installation. Avoid operating the transmission or
fitting holes. letting oils or water come in contact with the sealed
area before a time sufficient for FIPG to harden
(approximately one hour) has passed.
FIPG application method may vary from location to
location. Follow the instruction for each particular
case described later in this manual.
LUBRICANTS
M1222000400994
Item Specified lubricant

Transmission oil Gear oil API classification GL-3 SAE 75W-85
SPECIAL TOOLS
M1222000600534
Tool Tool number Name Use

MB990803 Steering wheel puller Removal of gear spline
piece No.5
MB990803
MB990811 Side bearing puller cup Use with Steering wheel

puller
MB990811
MD998812 Installer cap Use with installer and

adapter
MD998813 Installer-100 Use with installer cap and

adapter
SPECIAL TOOLS
22B-7
MD998827 Installer adapter (56) Use with installer cap and
adapter
MD998801 Remover Removal of roller bearing

and ball bearing, input gear
corn ring, transmission
clutch hub No.1 and
transmission clutch hub
No.2
adapter
MD998823 Installer adapter (48) Installation of ball bearing,

5th gear, transmission
clutch hub No.1 and
transmission hub No.2

adapter
MB990699 Differential oil seal Installation of oil seal

installer
MB990929 Installer adapter Installation of oil seal
MB990938 Installer bar Use with installer adaoter

TRANSMISSION
TRANSMISSION
M1222001001765
34 ± 5 N·m 44 ± 9 N·m
2 1 18
<R5MB1-J-NC>
3
15
14
19
16 17 8
7
13
16.5 ± 5.0 N·m 7
36 ± 7 N·m
5
12
34 ± 6 N·m 4
6 11 ± 1 N·m
11
10
18.5 ± 5.5 N·m
9 37 ± 11 N·m
AK701068AD
Disassembly steps Disassembly steps (Continued)

1. Back-up lamp switch assembly 12. Reverse restrict pin assembly
2. Shift position switch assembly 13. Front bearing retainer
<R5MB1-J-NC> 14. Oil seal
3. Clutch housing 15. Shaft snap ring
4. Vehicle speed sensor 16. Shaft snap ring
5. O-ring 17. Transmission case sub-assembly
6. Wiring harness clamp bracket 18. Intermediate plate with shaft sub-
7. Wiring harness clamp bracket assembly
8. Extension housing sub-assembly 19. Transmission magnet
9. Oil receiver pipe
10. Straight screw plug with head
11. Slotted spring pin
TRANSMISSION
22B-9
18.5 ± 5.5 N·m

18.5 ± 5.5 N·m
20 23
20 21
24
22 21
22
26 29
19.5 ± 3.9 N·m
27
25
30
28
19.5 ± 3.9 N·m
33
32
31
40
38 37 41 35
34 36
39 44
42 43
AK602734 AC

20. Straight screw plug with head 34. Gear shift fork shaft No.3
21. Compression spring 35. Gear shift fork No.3
22. Ball 36. Roller A
23. Shaft snap ring 37. Ball
24. Gear shift fork shaft No.2 38. Shaft snap ring
25. Gear shift fork No.2 39. Gear shift fork shaft No.4
26. Roller A 40. Ball
27. Shaft snap ring 41. Compression spring
28. Gear shift fork shaft No.1 42. E-ring
29. Straight pin 43. Reverse shift arm
30. Roller A 44. Reverse shift fork
31. Gear shift fork No.1
32. Shaft snap ring
TRANSMISSION
47
65
18 ± 5 N·m 46
45
45
68
61 60
59
66
63
58 57
67
64
62
18 ± 5 N·m
48
Apply gear oil to
all moving parts
50
before installation. 51
53 49
56 54 55
52 AK701069AB

45. Shaft snap ring 57. Needle roller bearing
46. Rotor 58. 5th gear thrust washer
47. Ball 59. Straight pin
48. Shaft snap ring 60. Rear bearing output shaft retainer
49. Transmission hub sleeve No.3 61. Shaft snap ring
50. Gear spline piece No.5 62. Reverse idler gear
51. Synchronizer outer race No.3 63. Cylindrical roller bearing
52. Counter shaft gear No.5 64. Counter shaft sub-assembly
53. Shaft snap ring 65. Input shaft sub-assembly
54. Synchromesh shifting key spring 66. Output shaft sub-assembly
No.3 67. Reverse shift arm bracket
55. Synchromesh shifting key spring 68. Intermediate plate
No.3
56. Synchromesh shifting key No.3
TRANSMISSION
22B-11
DISASSEMBLY SERVICE POINTS Wiring Wiring harness
harness clamp bracket
<R5MB1-J-NC> clamp
bracket
Shift position switch

Back-up lamp switch assembly AK604895AB
assembly
AK704967AC
4. Remove the extension housing sub-assembly and
<R5MB1-J-ND1> wiring harness clamp bracket.
Back-up lamp switch

assembly
AK704968AD
1. Remove the back-up lamp switch assembly and AK403777
shift position switch assembly <R5MB1-J-NC>. 5. Remove the oil receiver pipe.
AK403768
AK604896AB
2. Remove the clutch housing.
6. Remove the straight screw plug with head.
AK500816
AK604897AB
3. Remove the vehicle speed sensor.
7. Remove the slotted spring pin.
TRANSMISSION
AK403781 AK403783
8. Remove the reverse restrict pin assembly. 12.Remove the shaft snap ring.
AK403774 AK403784
9. Remove the front bearing retainer. 13.Remove the transmission case sub-assembly.
AK403775AC AK500257
10.Remove the oil seal. 14.Remove the transmission magnet.
AK403782 AK403786AB
11.Remove the shaft snap ring. 15.Remove the straight screw plug with head (3
places).
TRANSMISSION
22B-13
AK403788AB AK500260
16.Remove the compression spring (3 places). 20.Remove the gear shift fork No.2.
AK403789AB AK500261
17.Remove the ball (3 places). 21.Remove the roller A.
AK403792 AB AK500262AB
18.Remove the shaft snap ring of the gear shift fork 22.Remove the shaft snap ring of the gear shift fork
shaft No.2 and the washer based hexagon bolt of shaft No.1 and the washer based hexagon bolt of
the gearshift fork No.2. the gear shift fork No.1.
AK500259 AK500263
19.Remove the gear shift fork shaft No.2. 23.Remove the gear shift fork shaft No.1.
TRANSMISSION
AK500270 AK403790AB
24.Remove the straight pin of the gear shift fork shaft 28.Remove the slotted spring pin of the gear shift
No.1. fork No.3 assembly.
Gear shift fork shaft No.3
Gear shift fork No.3
AK500264 AK500461AB
25.Remove the roller A. 29.Remove the gear shift fork No.3 and the gear shift
fork shaft No.3.
AK500265
AK403800
26.Remove the gear shift fork No.1.
30.Remove the roller A.
AK500266AB
AK403801
27.Remove the shaft snap ring of the gear shift fork
shaft No.3. 31.Remove the ball.
TRANSMISSION
22B-15
AK500453AB AK403805
32.Remove the shaft snap ring of the gear shift fork 35.Remove the compression spring.
shaft No.4.
AK403806
AK403802
36.Remove the reverse shift fork and the reverse
shift arm.
AK403803
33.Remove the gear shift fork shaft No.4. AK500455
37.Remove the E-ring.

Reverse shift arm
Reverse shift fork
AK403804
34.Remove the ball. AK500454AB
38.Remove the reverse shift arm and reverse shift

fork.
TRANSMISSION
• Steering wheel puller (MB990803)

Rotor • Side bearing puller cup (MB990811)
Ball
Shaft snap ring

AK500818AB
39.Remove the shaft snap ring (2 places). AK403983

40.Remove the rotor.
45.Remove the synchronizer outer race No.3.
41.Remove the ball.
AK403984
AK403807
46.Remove the counter shaft gear No.5.

42.Remove the shaft snap ring.
Transmission
hub sleeve No.3
AK500526
AK500269AB
47.Remove the shaft snap ring.

43.Remove the transmission hub sleeve No.3.
MB990811 MB990803
AK500456
AK403982 AC
48.Remove the synchromesh shifting key spring

44.Use special tools to remove the gear spline piece
No.3.
No.5.
TRANSMISSION
22B-17
AK500457 AK403785AB
49.Remove the synchromesh shifting key spring 53.Remove the straight pin.
No.3.
AK403986
AK500458
54.Remove the rear bearing output shaft retainer.
50.Remove the synchromesh shifting key No.3.
AK403987
AK500459
55.Remove the snap ring.
51.Remove the needle roller bearing.
Reverse idler
gear
AK403989 AC
AK403985
56.Remove the reverse idler gear.
52.Remove the 5th gear thrust washer.
TRANSMISSION
REASSEMBLY SERVICE POINTS

Cylindrical roller
bearing
Counter gear
sub-assembly
AK403990AB
AK403993
57.Remove the counter gear sub-assembly and
cylindrical roller bearing. 1. Set the reverse shift arm bracket to the
intermediate plate and tighten the bolts to the
AK403991
58.Remove the input shaft sub-assembly.

AK403992
2. Install the output shaft sub-assembly to the

intermediate plate.
AK403992
59.Remove the output shaft sub-assembly.

AK403991
3. Install the input shaft sub-assembly to the output

shaft sub-assembly.
Cylindrical roller
bearing
Counter gear
sub-assembly
AK403993
60.Remove the reverse shift arm bracket.
AK403990AB
TRANSMISSION
22B-19
4. Insert the counter gear sub-assembly into the
intermediate plate and hold it. Insert the cylindrical
roller bearing into the intermediate plate and the
counter gear sub-assembly.
Reverse idler
gear
AK403785AB
8. Install the straight pin.
Installtion 5th gear

AK403989 AC direction thrust
washer
5. Install the reverse idler gear shaft and reverse
idler gear sub-assembly to the intermediate plate.
Penetration
groove
Straight pin
AK501229AB
AK403987
6. Install the shaft snap ring to the radial ball bearing

of the input shaft sub-assembly.
AK403985
9. Check the installation direction of 5th gear thrust

washer, and install it.
AK403986AB
7. Set the rear bearing output shaft retainer and

tighten the bolts to the specified torque of 18 ± 5
N⋅m.
NOTE: Fit the rear bearing output shaft retainer
into the reverse idler gear shaft slot. AK500459
10.Install the needle roller bearing.

TRANSMISSION
14.Install the shaft snap ring to the counter shaft gear

No.5.
AK500458
11.Install the synchromesh shifting key No.3 to the

AK403984
counter shaft gear No.5.
15.Install the counter shaft gear No.5.
Protrusion
Key
AK500457
AK403983AB
12.Install the synchromesh shifting key spring No.3
to the counter shaft gear No.5. CAUTION
Fit the protrusions of synchronizer ring between
keys.
16.Install the synchronizer outer race No.3.
AK500456

MD998827
to the counter shaft gear No.5. MD998813
MD998812
AK404049AB
17.Use special tools to install the gear spline piece

No.5.
• Installer cap (MD998812)
• Installer-100 (MD998813)
• Installer adapter (56) (MD998827)
AK500526
TRANSMISSION
22B-21
20.Install the ball to the rotor.
21.Install the rotor to the output shaft.
Installation 22.Remove the shaft snap ring to the output shaft (2
direction places).
Reverse shift arm
Reverse shift fork
AK500610 AB
Transmission
hub sleeve No.3
AK500454AB
23.Install the reverse shift arm to the reverse shift

fork.
AK500269AB
18.Check the installation direction of the

transmission hub sleeve No.3 and install it on the
counter shaft.
NOTE: After installation, check the sleeve operate
smoothly.
AK500455
24.Install the E-ring.
AK403807
19.Select a snap ring which will make the gear spline

pice No.5 end play equal the standard value. AK403806
Standard value: 0 − 0.1 mm 25.Install the reverse shift fork and the reverse shift
arm to the intermediate plate.
Rotor
Ball
Shaft snap ring

AK500818AB
AK403805
TRANSMISSION
26.Install the compression spring into the reverse

shift fork.
AK500453AB
29.Install the shaft snap ring into the gear shift fork
AK403804
shaft No.4.
27.Install the ball into the reverse shift fork.
AK403801
AK403803
AK403802 AK403800
CAUTION 31.Install the roller A to the intermediate plate.

Install the gear shift fork shaft No.4 carefully in
the specified direction. If the installation direc- Gear shift fork shaft No.3
tion is wrong, the roller would be in the shaft
concave and the gearshift fork shaft No.4 would
not be installed.
28.Install the gear shift fork shaft No.4 into the
intermediate plate and the reverse shift fork.
AK500461AB
32.Install the gear shift fork No.3 assembly on the

transmission hub sleeve No.3 and hold it. Insert
the gear shift fork shaft No.3 into the gear shift
fork No.3 assembly, the intermediate plate and
the reverse shift fork.
TRANSMISSION
22B-23
AK500267 AK500270
33.Install the slotted spring pin to the gear shift fork 37.Install the straight pin to the gear shift fork shaft
No.3 assembly. No.1.
AK500266AB AK500263
34.Install the snap ring to the gear shift fork shaft 38.Install the gear shift fork shaft No.1 to the
No.3. intermediate plate and the gear shift fork No.1.
AK500265 AK500262AB
35.Install the gear shift fork No.1 on the reverse gear. 39.Install the shaft snap ring to the gear shift fork
shaft No.1. Tighten the washer based hexagon
bolt to the specified torque of 19.5 ± 3.9 N⋅m.
AK500264
36.Install the roller A to the intermediate plate. AK500261
40.Install the roller A to the intermediate plate.

TRANSMISSION
44.Install the ball to the intermediate plate (3 places).
AK500260
AK403788AB
41.Install the gear shift fork No.2 on the transmission
hub sleeve No.2. 45.Install the compression spring to the intermediate
plate (3 places).
AK500259
AK403786AB
42.Install the gear shift fork shaft No.2 to the
intermediate plate, the gear shift fork No.1 and the 46.Apply sealant to the threads. Tighten the straight
gear shift fork No.2. screw plug with head to the specified torque of
18.5 ± 5.5 N⋅m (3 places).
Special sealant: Mitsubishi genuine sealant
Part No. MD974421 or equivalent
NOTE: The new bolt does not require sealant
application as it is precoated with sealant.
AK403792 AB
43.Install the shaft snap ring to the gear shift fork

shaft No.2. Tighten the washer based hexagon
bolt to the specified torque of 19.5 ± 3.9 N⋅m.
AK500257
47.Install the transmission magnet to the

intermediate plate.
AK403789AB
TRANSMISSION
22B-25
AK500527AB AK403782
48.Completely degrease the FIPG-applied surface 52.Install the snap ring to the radial ball bearing.
so that water and oil including the old sealant
cannot adhere to the surface coated with the
MB990938
sealant.
Never touch the degreased surface by hand.
49.Apply a 1.2 mm diameter bead of liquid gasket to
the intermediate plate mounting surface of the
transmission case sub-assembly.
Special sealant: Mitsubishi genuine sealant MB990929
AK600320 AB
53.Using special tool, install the oil seal to the front

bearing retainer.
• Installer adapter (MB990929)
• Installer bar (MB990938)
AK701366
50.Install the transmission case sub-assembly to the

intermediate plate.
AK403775AB
54.Completely degrease the FIPG-applied surface

sealant.
AK403783
the transmission case sub-assembly mounting
51.Install the snap ring to the cylindrical roller surface of the front bearing retainer sub-assembly
bearing. with seal.
TRANSMISSION
AK403774
AK604896AB
CAUTION 59.Apply sealant to the threads. Tighten the straight

Do not damage to the oil seal lip during the screw plug with head to the specified torque of
installation. 18.5 ± 5.5 N⋅m.
56.Apply sealant to the threads. Install the front Special sealant: Mitsubishi genuine sealant
bearing retainer to the transmission case sub- Part No. MD974421 or equivalent
assembly and tighten the bolts to the specified NOTE: The new bolt does not require sealant
torque of 16.5 ± 5.0 N⋅m. application as it is precoated with sealant.
AK403777
60.Install the oil receiver pipe into the extension

housing sub-assembly.
AK403781
57.Install the reverse restrict pin assembly to the

extension housing sub-assembly.
AK500527AB

AK604897AB sealant.
58.Install the slotted spring pin to the reverse restrict Never touch the degreased surface by hand.
pin assembly. 62.Apply a 1.2 mm diameter bead of liquid gasket to
extension housing sub-assembly.
TRANSMISSION
22B-27
Wiring Wiring harness <R5MB1-J-NC>
harness clamp bracket
clamp
bracket

Back-up lamp switch assembly
assembly
AK604895AB AK704967AC
63.Install the extension housing sub-assembly. <R5MB1-J-ND1>

Install the wiring harness clamp bracket (3 places)
and tighten the bolts to the specified torque of 37
± 11 N⋅m.
Back-up lamp switch
assembly
AK704968AD
66.Tighten the shift position switch assembly of 34 ±

5 N⋅m. <R5MB1-J-NC>
67.Tighten the back-up lamp switch assembly and of
AK500816 44 ± 9 N⋅m.
64.Install the vehicle speed sensor and tighten the INSPECTION
bolts to the specified torque of 11 ± 1 N⋅m. M1222001100491
BACK-UP LAMP SWITCH
AK500460AB
AK500505
CAUTION
Install the bolt and washer (with sealant) to the Check for the continuity between the connector ter-
position having the arrow as shown in the illus- minals.
tration. Switch Connector Continuity
65.Install the clutch housing into the transmission condition terminals
case sub-assembly. Tighten the bolt with washer Switch end 1−2 Conductive
to the specified torque of 36 ± 7 N⋅m (7 places). pressed
Tighten the bolt with washer (with sealant) to the
Switch end 1−2 Open
specified torque of 34 ± 6 N⋅m (2 places).
released
TRANSMISSION
SHIFT POSITION SWITCH 2. Check the needle roller bearing cage for
deformation.
COUNTER SHAFT GEAR No.5

THRUST CLEARANCE
Inspect the thrust clearance of counter shaft gear
No.5.
Limit: 0.35 mm
AK501632
RADIAL CLEARANCE
Check for the continuity between the connector ter- 1. Fix the output shaft in a vice.
minals. 2. Inspect the radial clearance of counter shaft gear
Switch Connector Continuity No.5.
condition terminals Standard value: 0.015 − 0.068 mm
Switch end 1−2 Open Limit: 0.068 mm
pressed
Switch end 1−2 Conductive INSIDE DIAMETER
released
SYNCHRONIZER SLEEVE AND HUB

1. Combine the synchronizer sleeve and hub, and
check that they slide smoothly.
2. Check that the sleeve is free from damage at its
inside splines ends.
3. Using the thickness gauge, check the clearance
between the synchronizer ring and the gear.
AK404027
Limit: 0.52 mm Using the cylinder gauge, check the inside diameter
of the counter shaft gear No.5.
NEEDLE ROLLER BEARING Standard value: 38.015 − 38.040 mm
1. Combine the needle roller bearing with the shaft Limit: 38.040 mm
and gear, and check that it rotates smoothly
without noise or play.
INPUT SHAFT
22B-29
INPUT SHAFT
M1222001600526
Apply gear oil to

all moving parts
5
2
4
3
AK500516 AB
Disassembly steps REASSEMBLY SERVICE POINTS

>>B<< 1. Shaft snap ring >>A<< RADIAL BALL BEARING INSTALLATION
<<A>> >>A<< 2. Radial ball bearing
3. Synchronizer ring No.2
4. Needle roller bearing
5. Input shaft sub-assembly
Installation
direction
DISASSEMBLY SERVICE POINT
<<A>> RADIAL BALL BEARING REMOVAL
AK500606AB
MD998801
1. Check the installation direction of the radial ball
bearing, and put it on the input shaft.
CAUTION
AK403995AC Never push on the sealing area when installing.
Using special tool Bearing remover (MD998801),
MD998812
support the radial ball bearing and remove it.
MD998814
MD998823
AK403996 AB
INPUT SHAFT
2. Using special tools to install the radial ball SYNCHRONIZER RING No.2
bearing.
>>B<< SNAP RING INSTALLATION
AK500676AB
1. Check the clutch gear on the synchronizer ring for

damaged and missing teeth.
2. Check the synchronizer ring inner cone surface
for damage or wear. Also check that the inside
AK403997 ridges are intact.
1. Select a snap ring to secure the standard

clearance between the radial ball bearing and the
input shaft sub-assembly.
Standard value: 0 − 0.1 mm
2. Install the selected snap ring.
INSPECTION
M1222001700222
INPUT SHAFT SUB-ASSEMBLY AK403998
3. After applying oil to the taper portion on gear,

press and fit the synchronizer ring by hand.
Confirm the synchronizer ring cannot be rotated.
AK500677AB
1. Check the helical gear teeth and clutch gear teeth

of each input shaft sub-assembly for damage and
excessive wear.
AK403999
2. Check the synchronizer cone surface of each
input shaft sub-assembly for roughness, damage, 4. Using the thickness gauge, check the clearance
and excessive wear. between the synchronizer ring and the 4th gear.
3. Check the inside surface and front and back sides Standard value: 0.70 − 1.70 mm
of each input shaft sub-assembly for damage and Minimum limit: 0.70 mm
excessive wear.
NEEDLE ROLLER BEARING
1. Combine the needle roller bearing with the input
shaft, and check that it rotates smoothly without
noise or play.
OUTPUT SHAFT
22B-31
2. Check the needle roller bearing cage for
deformation.
OUTPUT SHAFT
M1222002100160
Apply gear oil to

23
all moving parts
22
19
21
20
18
15
17 16
26
25 6
24
12 1
2
13 5 3
7
8
4
10 9
14 11
AK500517AB

>>G<< 1. Shaft snap ring <<C>> >>C<< 13. Compression spring
<<A>> >>F<< 2. 5th gear <<C>> >>C<< 14. Transmission clutch No.1 hub
<> >>E<< 3. Radial ball bearing <<C>> >>C<< 15. Synchronizer ring set No.1
<> >>E<< 4. 1st gear sub-assembly <<C>> >>C<< 16. 2nd gear sub-assembly
5. 1st gear thrust washer 17. Needle roller bearing
6. Straight pin >>B<< 18. Shaft snap ring
7. Needle roller bearing <<D>> >>A<< 19. Transmission hub sleeve No.2
8. D spacer <<D>> >>A<< 20. Synchronizer shifting key No.2
9. Synchronizer ring set No.1 <<D>> >>A<< 21. Compression spring
>>D<< 10. Shaft snap ring <<D>> >>A<< 22. Transmission clutch No.2 hub
<<C>> >>C<< 11. Reverse gear <<D>> >>A<< 23. Synchronizer ring set No.2
<<C>> >>C<< 12. Synchronizer shifting key No.1 <<D>> >>A<< 24. 3rd gear sub-assembly
OUTPUT SHAFT
Disassembly steps (Continued) DISASSEMBLY SERVICE POINTS

<<A>> 5TH GEAR REMOVAL
26. Output shaft
INSPECTION BEFORE DISASSEMBLY

THRUST CLEARANCE FOR EACH GEAR
2nd 1st MD998801
AK404004AB

support the 5th gear and remove it.
3rd
AK404000AB
<> RADIAL BALL BEARING / 1ST GEAR SUB-
Inspect the thrust clearance of each gear.
ASSEMBLY REMOVAL
Gear Standard value mm Limit mm
1st 0.20 − 0.45 0.45
2nd 0.10 − 0.25 0.25
3rd 0.10 − 0.25 0.25 MD998801
RADIAL CLEARANCE FOR EACH GEAR
AK404006AB

support the 1st gear sub-assembly and remove the
radial ball bearing and the 1st gear sub-assembly.
<<C>> REVERSE GEAR / SYNCHRONIZER

AK404001AB SHIFTING KEY No.1 / COMPRESSION SPRING /
TRANSMISSION CLUTCH No.1 HUB /
1. Fix the output shaft by a vice. SYNCHRONIZER RING SET No.1 / 2ND GEAR
2. Inspect the radial clearance of each gear. SUB-ASSEMBLY REMOVAL
1st 0.020 − 0.073 0.073
2nd 0.015 − 0.068 0.068
3rd 0.015 − 0.068 0.068 MD998801
AK404014 AB
Using special tool Bearing remover (MD998801), assembly.

support the 2nd gear sub-assembly and remove the
reverse gear, synchronizer shifting key No.1, com-
pression spring, the transmission clutch No.1 hub,
synchronizer ring set No.1 and the 2nd gear sub-
OUTPUT SHAFT
22B-33
<<D>> TRANSMISSION CLUTCH HUB No.2 / 2. Using special tools to install the transmission
SYNCHRONIZER SHIFTING KEY No.2 / clutch hub No. 2, synchronizer shifting key No. 2,
COMPRESSION SPRING / TRANSMISSION HUB compression spring, the transmission hub sleeve
SLEEVE No.2 / SYNCHRONIZER RING SET No.2 / No. 2, synchronizer ring set No. 2 and the 3rd
3RD GEAR SUB-ASSEMBLY REMOVAL gear sub-assembly.
MD998801
AK404020AB

support the 3rd gear sub-assembly and remove the
transmission clutch hub No.2, synchronizer shifting AK500508
key No.2, compression spring, the transmission hub

3. Confirm the thrust clearance of the 3rd gear sub-
sleeve No.2, synchronizer ring set and the 3rd gear
assembly is within the standard value.
sub-assembly.
REASSEMBLY SERVICE POINTS Limit: 0.25 mm
>>A<< TRANSMISSION CLUTCH HUB No. 2 /
SYNCHRONIZER SHIFTING KEY No. 2 / COM- >>B<< SHAFT SNAP RING INSTALLATION
PRESSION SPRING / TRANSMISSION HUB
SLEEVE No. 2 / SYNCHRONIZER RING SET No. 2
/ 3RD GEAR SUB-ASSEMBLY INSTALLATION
Installation
direction
AK404019
1. Select a shaft snap ring to secure the standard

clearance between the transmission clutch hub
AK500607AB No.2 and the output shaft.
1. Check the installation direction of the transmission Standard value: 0 − 0.1 mm
clutch hub No. 2, and put it on the output shaft. 2. Install the selected snap ring.
MD998812
MD998813
MD998823
AK404029AC
OUTPUT SHAFT
>>C<< REVERSE GEAR / SYNCHRONIZER

SHIFTING KEY No. 1 / COMPRESSION SPRING / >>D<< SHAFT SNAP RING INSTALLATION
TRANSMISSION CLUTCH No. 1 HUB /
SYNCHRONIZER RING SET No. 1 / 2ND GEAR
SUB-ASSEMBLY INSTALLATION
Installation
direction
AK404031

clearance between the transmission clutch No. 1
AK500608 AB
hub and the output shaft.
1. Check the installation direction of the reverse Standard value: 0 − 0.1 mm
gear, and put it on the output shaft. 2. Install the selected snap ring.
MD998812
>>E<< RADIAL BALL BEARING / 1ST GEAR SUB-
MD998813
MD998814
MD998823 Installation
direction
AK404030AC
2. Using special tools to install the reverse gear,

synchronizer shifting key No. 1, compression
spring, the transmission clutch No. 1 hub, AK500606AB
synchronizer ring set No. 1 and the 2nd gear sub-

assembly.
bearing, and put it on the output shaft.
• Installer-200 (MD998814) CAUTION
• Installer adapter (48) (MD998823) Never push on the sealing area when installing.
MD998812
MD998814
MD998823
AK404032 AK404038AB
3. Confirm the thrust clearance of the 2nd gear sub- 2. Using special tools to install the radial ball bearing
assembly is within the standard value. and the 1st gear sub-assembly.
Limit: 0.25 mm • Installer-200 (MD998814)
OUTPUT SHAFT
22B-35
>>G<< SHAFT SNAP RING INSTALLATION
AK500513
AK404040
3. Confirm the thrust clearance of the 1st gear sub-
assembly is within the standard value. 1. Select a shaft snap ring to secure the standard
Standard value: 0.20 − 0.45 mm clearance between the 5th gear and the output
Limit: 0.45 mm shaft
>>F<< 5TH GEAR INSTALLATION 2. Install the selected snap ring.
INSPECTION
M1222002300261
Installation SYNCHRONIZER RING
direction
CAUTION
When any of the outer ring, inner ring or cone
has to be replaced, replace them as a set.
AK500609AB
1. Check the installation direction of the 5th gear,

and put it on the output shaft.
MD998812
MD998814 AK500672AB
MD998823 1. Check to ensure that the clutch gear tooth surface

and cone surface are not damaged and broken.
AK404039AB
2. Using special tools to install the 5th gear.

AK500603
2. After applying oil to the taper portion on each

gear, press and fit the synchronizer ring by hand.
OUTPUT SHAFT

1. Combine the needle roller bearing with the output
shaft and gear, and check that it rotates smoothly
deformation.
SYNCHRONIZER KEYS
AK404022

1st 0.65 − 1.75 0.65
2nd 0.65 − 1.75 0.65
3rd 0.65 − 1.75 0.65
AK500680AB
HUB SLEEVE AND SHIFT FORK
Check the synchronizer hub contact surfaces of each
CAUTION
synchronizer key for damage and excessive wear.
When any of the hub sleeve or shift fork has to be
replaced, replace them as a set.
COMPRESSION SPRINGS
Check the compression springs for loss of tension,
deformation, and breakage.
OUTPUT SHAFT
AK404023
Using the thickness gauge, check the clearance

between the sleeve and the shift fork.
A B C
sleeve Standard Limit mm
value mm AK404024AB
No.1 0.15 − 0.41 0.41 1. Using the micrometer, check the outer shape of
No.2 0.15 − 0.35 0.35 the needle roller bearing race.
No.3 0.26 − 0.84 0.84 Measurement Standard value mm Limit mm
part
SYNCHRONIZER SLEEVE AND HUB A 37.984 − 38.000 37.984

1. Combine the synchronizer sleeve and hub, and B 46.984 − 47.000 46.984
check that they slide smoothly. C 38.979 − 38.995 38.979
COUNTERSHAFT
22B-37
3. Using the dial gauge and V-block, check the
output shaft runout.
Limit: 0.015 mm
AK404025
2. Using the slide gauge, check the flange thickness.

Minimum limit: 4.800 mm
AK404027
4. Using the cylinder gauge, check the inside

diameter of each gear.
1st 46.015 − 46.040 46.040
2nd 53.015 − 53.040 53.040
3rd 44.015 − 44.040 44.040
AK404026
COUNTERSHAFT
M1222007300158
Apply gear oil to

all moving parts
AK500518AB
COUNTERSHAFT
Disassembly steps 2. Using special tools to install the cylindrical roller

>>B<< 1. Shaft snap ring bearing.
<<A>> >>A<< 2. Cylindrical roller bearing • Installer cap (MD998812)
3. Counter gear • Installer-100 (MD998813)
<<A>> CYLINDRICAL ROLLER BEARING >>B<< SHAFT SNAP RING INSTALLATION
REMOVAL
MD998801
AK404042
AK404043 AB
Using special tool Bearing remover (MD998801), 1. Select a snap ring to secure clearance of standard
support the cylindrical roller bearing and remove it. value between the cylinder roller bearing and
counter shaft.
REASSEMBLY SERVICE POINTS Standard value: 0 − 0.1 mm
>>A<< CYLINDRICAL ROLLER BEARING 2. Install the selected snap ring.
INSTALLATION
INSPECTION
M1222007400025
COUNTER GEAR
Installation
direction
D E
AK500644 AB
1. Check the installation direction of the cylindrical

AK404041AB
roller bearing, and put it on the counter shaft.
Using the micrometer, check the outer shape of the
CAUTION needle roller bearing race.
Never push the sealing area at the press fit.
Measurement Standard value Limit mm
MD998812
part mm
D 34.000 − 34.105 34.000
MD998813 E 29.984 − 30.000 29.984
MD998817
AK404046AB
REVERSE IDLER GEAR
22B-39
REVERSE IDLER GEAR
M1222012500233
Apply gear oil to

all moving parts
1
AK500519AB
Disassembly steps INSPECTION

1. Reverse idler gear sub-assembly M1222012400076
2. Reverse idler gear shaft REVERSE IDLER GEAR SUB-ASSEMBLY
AK500525AB
Check the radial clearance of the reverse idler gear.

Limit: 0.082 mm
EXTENSION HOUSING
EXTENSION HOUSING
M1222004300074
33 ± 3 N·m
5 2
4 3
11 ± 4 N·m
AK500815AB

1. Oil receiver pipe >>A<< OIL SEAL INSTALLATION
2. Extension housing oil deflector
>>A<< 3. Oil seal
4. Shift & select lever
5. Shift lever housing MB990699
6. Extension housing
Oil seal AK500819AB
Using the special tool Differential oil seal installer

(MB990699), install the oil seal.
22C-1
GROUP 22C
MANUAL
TRANSMISSION
OVERHAUL
<V5MB1>
CONTENTS
GENERAL INFORMATION . . . . . . . . 22C-3 OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . 22C-39

OUTPUT SHAFT INSPECTION . . . . . . . . . 22C-43
GENERAL SPECIFICATIONS . . . . . . 22C-3
COUNTERSHAFT. . . . . . . . . . . . . . . . 22C-45
SERVICE SPECIFICATIONS. . . . . . . 22C-3 COUNTERSHAFT DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 22C-45
SNAP RING, SPACER AND THRUST PLATE COUNTERSHAFT INSPECTION . . . . . . . . 22C-46
FOR ADJUSTMENT. . . . . . . . . . . . . . 22C-5
REVERSE IDLER GEAR . . . . . . . . . . 22C-47
TORQUE SPECIFICATIONS . . . . . . . 22C-8 REVERSE IDLER GEAR DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 22C-47
SEALANT(S) AND ADHESIVE(S) . . . 22C-9 REVERSE IDLER GEAR INSPECTION . . . 22C-47
LUBRICANTS . . . . . . . . . . . . . . . . . . 22C-10 TRANSFER . . . . . . . . . . . . . . . . . . . . . 22C-48

TRANSFER DISASSEMBLY AND REASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22C-48
SPECIAL TOOLS. . . . . . . . . . . . . . . . 22C-10
ADJUSTMENT OF TRANSFER . . . . . . . . . 22C-59
TRANSMISSION . . . . . . . . . . . . . . . . 22C-14 TRANSFER INSPECTION . . . . . . . . . . . . . 22C-60

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22C-14 TRANSFER CASE PLATE . . . . . . . . . 22C-61
TRANSMISSION INSPECTION . . . . . . . . . 22C-36 TRANSFER CASE PLATE DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 22C-61
INPUT SHAFT . . . . . . . . . . . . . . . . . . 22C-37
TRANSFER INPUT GEAR . . . . . . . . . 22C-62
INPUT SHAFT DISASSEMBLY AND REASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22C-37 TRANSFER INPUT GEAR DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 22C-62
INPUT SHAFT INSPECTION . . . . . . . . . . . 22C-38
COUNTERSHAFT. . . . . . . . . . . . . . . . 22C-63
OUTPUT SHAFT . . . . . . . . . . . . . . . . 22C-39
COUNTERSHAFT DISASSEMBLY AND
22C-2
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 22C-63 REASSEMBLY <V5MB1-J-NEG, JER> . . . 22C-69

REAR OUTPUT SHAFT INSPECTION <V5MB1-J-
2-4WD SYNCHRONIZER <V5MB1-J-ND2, NEG, JER> . . . . . . . . . . . . . . . . . . . . . . . . . 22C-71
NEZ, PD2> . . . . . . . . . . . . . . . . . . . . . 22C-65
2-4WD SYNCHRONIZER DISASSEMBLY AND REAR OUTPUT SHAFT <V5MB1-J-ND2, NEZ,
REASSEMBLY <V5MB1-J-ND2, NEZ, PD2> PD2> . . . . . . . . . . . . . . . . . . . . . . . . . . 22C-72
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22C-65 REAR OUTPUT SHAFT DISASSEMBLY AND
2-4WD SYNCHRONIZER INSPECTION <V5MB1-J- REASSEMBLY <V5MB1-J-ND2, NEZ, PD2>
ND2, NEZ, PD2>. . . . . . . . . . . . . . . . . . . . . 22C-66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22C-72
CENTRE DIFFERENTIAL CASE <V5MB1-J- TRANSFER DRIVE SHAFT <V5MB1-J-ND2,

ND2, NEZ, PD2> . . . . . . . . . . . . . . . . 22C-67 NEZ, PD2> . . . . . . . . . . . . . . . . . . . . . 22C-74
CENTRE DIFFERENTIAL CASE DISASSEMBLY AND TRANSFER DRIVE SHAFT DISASSEMBLY AND
REASSEMBLY <V5MB1-J-ND2, NEZ, PD2> REASSEMBLY <V5MB1-J-ND2, NEZ, PD2>
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22C-67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22C-74
H-L SHIFT FORK . . . . . . . . . . . . . . . . 22C-68 FRONT OUTPUT SHAFT . . . . . . . . . . 22C-75

H-L SHIFT FORK DISASSEMBLY AND FRONT OUTPUT SHAFT DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 22C-68 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 22C-75
REAR OUTPUT SHAFT <V5MB1-J-NEG, JER> SPEEDOMETER GEAR . . . . . . . . . . . 22C-76

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22C-69 SPEEDOMETER GEAR DISASSEMBLY AND
REAR OUTPUT SHAFT DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 22C-76
MANUAL TRANSMISSION OVERHAUL <V5MB1>
GENERAL INFORMATION
22C-3
GENERAL INFORMATION
M1222000101606
MANUAL TRANSMISSION MODELS

Transmission model Speedometer gear ratio Combined engine Vehicle model
V5MB1-J-NEZ 25/9 4D56 DI-D DOHC KB4T
V5MB1-J-ND2 24/9 4D56 DI-D DOHC KB4T
V5MB1-J-PD2 24/9 4D56 DI-D DOHC KB4T
V5MB1-J-NEG 25/9 4D56 DI-D DOHC KB4T
V5MB1-J-JER 25/9 4D56 DI-D DOHC KB4T
M1222000201261
Item Specifications
Transmission model V5MB1
Applicable engine 4D56
Transmission type 5-speed transmission, floor shift
2nd 2.330
3rd 1.436
4th 1.000
5th 0.788
Reverse 4.220
Transfer type Constant mesh
Transfer gear ratio High 1.000
Low 1.900
M1222000300975

Transmission
Gear spline piece No.5 end play mm 0 − 0.1 −
Clearance between the synchronizer ring and the gear mm 0.52 - 1.88 0.52
Counter shaft gear No.5 thrust clearance 0.10 - 0.35 0.35
mm
radial clearance 0.015 − 0.068 0.068
mm
inside diameter 38.015 − 38.040 38.040
mm
Input shaft
22C-4 MANUAL TRANSMISSION OVERHAUL <V5MB1>

Input shaft radial ball bearing end play mm 0 − 0.1 −
clearance between the synchronizer ring and the 4th gear mm 0.70 − 1.70 0.70
Output shaft
Thrust clearance mm 1st gear 0.20 − 0.45 0.45
2nd gear 0.10 − 0.25 0.25
3rd gear 0.10 − 0.25 0.25
Radial clearance mm 1st gear 0.020 − 0.073 0.073
2nd gear 0.015 − 0.068 0.068
3rd gear 0.015 − 0.068 0.068
5th gear end play mm 0 − 0.1 −
Clearance between the synchronizer ring and 1st gear 0.65 − 1.75 0.65
the each gear mm 2nd gear 0.65 − 1.75 0.65
3rd gear 0.65 − 1.75 0.65
Clearance between the each sleeve and the sleeve No.1 0.15 − 0.41 0.41
shift fork mm sleeve No.2 0.15 − 0.35 0.35
sleeve No.3 0.26 − 0.84 0.84
Output shaft outer shape of the needle roller A 37.984 − 38.000 37.984
bearing race mm B 46.984 − 47.000 46.984
C 38.979 − 38.995 38.979
Output shaft flange thickness mm − 4.800
Output shaft runout mm − 0.015
Each gear inside diameter mm 1st gear 46.015 − 46.040 46.040
2nd gear 53.015 − 53.040 53.040
3rd gear 44.015 − 44.040 44.040
Counter shaft
Counter gear shaft cylindrical roller bearing end play mm 0 − 0.1 −
Counter shaft outer shape of the needle roller D 34.000 − 34.105 34.000
bearing race mm E 29.984 − 30.000 29.984
Reverse idler gear
Reverse idler gear radial clearance mm 0.040 − 0.082 0.082
Transfer
Countershaft gear end play mm 0 − 0.15 −
H-L clutch hub end play mm 0 − 0.08 −
Differential lock hub end play mm <V5MB1-J-ND2, NEZ, PD2> 0 − 0.08 −
22C-5
Rear output shaft bearing to rear cover <V5MB1-J-NEG, JER> 0 − 0.1 −
clearance mm <V5MB1-J-ND2, NEZ, 0.025 − 0.150 −
PD2>
Input gear bearing end play mm 0 − 0.06 −
Counter shaft gear bearing end play mm 0 − 0.08 −
2-4WD synchronizer hub end play mm <V5MB1-J-ND2, NEZ, 0 − 0.08 −
PD2>
2-4WD synchronizer ring and gear mm <V5MB1-J-ND2, NEZ, − 0.3
PD2>
Rear output shaft bearing end play mm <V5MB1-J-ND2, NEZ, 0 − 0.08 −
PD2>
Drive sprocket and synchronizer ring mm <V5MB1-J-NEG> − 0.3
SNAP RING, SPACER AND THRUST PLATE FOR

ADJUSTMENT
M1222012001059
Transmission
Shaft snap ring (For adjustment of gear spline piece No.5 end play)
2.80 − 2.85 A 3.00 − 3.05 E
2.85 − 2.90 B 3.05 − 3.10 F
2.90 − 2.95 C 3.10 − 3.15 G
2.95 − 3.00 D
Shaft snap ring (For adjustment of input shaft radial ball bearing end play)
2.10 − 2.15 A 2.30 − 2.35 E
2.15 − 2.20 B 2.35 − 2.40 F
2.20 − 2.25 C 2.40 − 2.45 G
2.25 − 2.30 D
1.80 − 1.85 A 2.00 − 2.05 E
1.85 − 1.90 B 2.05 − 2.10 F
1.90 − 1.95 C 2.10 − 2.15 G
1.95 − 2.00 D
2.30 − 2.35 A 2.50 − 2.55 E
2.35 − 2.40 B 2.55 − 2.60 F
2.40 − 2.45 C 2.60 − 2.65 G
2.45 − 2.50 D
Shaft snap ring (For adjustment of 5th gear end play)
2.75 − 2.80 C 3.05 − 3.10 J
2.80 − 2.85 D 3.10 − 3.15 K
2.85 − 2.90 E 3.15 − 3.20 L
2.90 − 2.95 F 3.20 − 3.25 M
2.95 − 3.00 G 3.25 − 3.30 N
3.00 − 3.05 H 3.30 − 3.35 P
Shaft snap ring (For adjustment of counter gear shaft cylindrical roller bearing end play)
2.05 − 2.10 A 2.20 − 2.25 D
2.10 − 2.15 B 2.25 − 2.30 E
2.15 − 2.20 C 2.30 − 2.35 F
Transfer
Snap ring (For adjustment input gear bearing end play)
Thickness mm Identification color Thickness mm Identification color
2.30 None 2.45 Blue
2.35 Red 2.50 Green
2.40 White
Spacer (For adjustment of countershaft gear end play)
1.77 None 2.19 White
1.91 Blue 2.33 Red
2.05 Brown
Snap ring (For adjustment of countershaft gear bearing end play)
1.48 Blue 1.62 None
Spacer (For adjustment of rear output shaft to rear cover clearance)
<V5MB1-J-NEG, JER>
2.75 B75 2.95 B95
2.79 B79 2.99 B99
22C-7
2.83 B83 3.03 C03
2.87 B87 3.07 C07
2.91 B91 3.11 C11
<V5MB1-J-ND2, NEZ, PD2>
0.84 84 1.47 47
0.93 93 1.56 56
1.02 02 1.65 65
1.11 11 1.74 74
1.20 20 1.83 83
1.29 29 1.92 92
1.38 38 2.01 01
Snap ring (For adjustment of H-L clutch hub end play)
2.18 − 2.32 −
2.25 − 2.39 −
Snap ring (For adjustment of differential lock hub end play) <V5MB1-J-ND2, NEZ, PD2>
Thickness mm IdentificatioN color Thickness mm IdentificatioN color
2.56 None 2.84 Yellow
2.63 Red 2.91 Green
2.70 White 2.98 Purple
2.77 Blue
Snap ring (For adjustment of 2-4WD synchronizer hub end play) <V5MB1-J-ND2, NEZ, PD2>
2.56 None 2.77 Blue
2.63 Red 2.84 Yellow
2.70 White
Snap ring (For adjustment of rear output shaft bearing end play) <V5MB1-J-ND2, NEZ, PD2>
2.33 Red 2.47 Blue
M1222013900632
Transmission
Item N⋅m
Reverse shift arm bracket mounting bolt 18 ± 5
Rear bearing output retainer mounting bolt 18 ± 5
Gear shift fork shaft mounting bolt 19.5 ± 3.9
Straight screw plug with head 18.5 ± 5.5
Front bearing retainer sub-assembly mounting bolt 16.5 ± 5.0
Wiring harness clamp bracket mounting bolt 18 ± 3
Transfer adaptor sub-assembly mounting bolt 37 ± 11
Shift lever housing mounting bolt 33 ± 3
Cover mounting bolt 18 ± 5
Reverse restrict pin assembly mounting bolt 37 ± 11
Clutch housing mounting bolt 36 ± 7
Clutch housing mounting bolt (with seal) 34 ± 6
Shift position switch assembly 34 ± 5
Back-up lamp switch assembly 44 ± 9
Transfer mounting bolt and nut 35 ± 6
Transfer
Item N⋅m
Side cover tightening bolt 9.0 ± 1.0
Chain cover tightening bolt 35 ± 6
Rear cover tightening bolt 35 ± 6
Plug <V5MB1-J-NEG, JER> 35 ± 6
Transfer case tightening bolt and nut 35 ± 6
Speedometer sleeve clamp mounting bolt 19 ± 3
Vehicle speed sensor 25 ± 4
4WD operation detection switch 34 ± 5
Center differential lock detection switch <V5MB1-J-ND2, NEZ, PD2> 35 ± 6
2WD/4WD detection switch <V5MB1-J-ND2, NEZ, PD2> 35 ± 6
Center differential lock operation detection switch <V5MB1-J-ND2, NEZ, PD2> 34 ± 5
High range/Low range detection switch 34 ± 5
4LLc operation detection switch <V5MB1-J-PD2> 34 ± 5
Bearing retainer mounting bolt 19 ± 3
H-L shift fork mounting bolt 9.0 ± 2.0
Rear output shaft lock nut <V5MB1-J-NEG, JER> 255 ± 10
Rear bearing retainer <V5MB1-J-ND2, NEZ, PD2> 20 ± 2
Oil pool cover <V5MB1-J-ND2, NEZ, PD2> 9.0 ± 1.0
SEALANTS
22C-9
Item N⋅m
Plug <V5MB1-J-ND2, NEZ, PD2> 34 ± 5
Plug 32 ± 2
Center differential case mounting bolt <V5MB1-J-ND2, NEZ, PD2> 69 ± 10
SEALANTS
M1222000501251
Transmission
Between transmission case sub-assembly and Mitsubishi genuine sealant Part No.MD974421 or
intermediate plate equivalent
Between front bearing retainer and transmission
case sub-assembly
Between intermediate plate and extension housing
sub-assembly
Between intermediate plate and transfer adaptor
sub-assembly
Between transfer adaptor sub-assembly and cover
Straight screw plug
Front bearing retainer mounting bolt
Clutch housing mounting bolt
Transfer
Chain cover Mitsubishi genuine sealant Part No.MD997740 or
Rear cover equivalent
Control housing
Transfer case plate
Plug 3M AAD part No.8672 or equivalent
Return spring plug 3M STUD Looking No.4170 or equivalent
Bearing retainer mounting bolt
FORM-IN-PLACE GASKET (FIPG) FIPG hardens as it reacts with the moisture in the
This transmission has several areas where the form- atmospheric air, and it is usually used for sealing
in-place gasket (FIPG) is used for sealing. To ensure metallic flange areas.
that the FIPG fully serves its purpose, it is necessary CAUTION
to observe some precautions when applying it. Bead When re-applying liquid gasket (FIPG), be sure
size, continuity and location are of paramount impor- that:
tance.
1. Residues of FIPG are cleared from all the ins
Too thin a bead could cause leaks. Too thick a bead,
and outs of parts;
on the other hand, could be squeezed out of location,
2. Use Mitsubishi genuine parts cleaner
causing blocking or narrowing of fluid passages. To
(MZ100387) or equivalent to well degrease the
prevent leaks or blocking of passages, therefore, it is
FIPG-applied surface.
absolutely necessary to apply the FIPG evenly with-
out a break, while observing the correct bead size. 3. FIPG is correctly applied in accordance with
FIPG Application.
LUBRICANTS
Disassembly FIPG Application

Parts sealed with a FIPG can be easily removed Applied FIPG bead should be of the specified size
without need for the use of a special method. In and free of any break. FIPG can be wiped away
some cases, however, the FIPG in joints may have to unless it has completely hardened. Install the mating
be broken by tapping parts with a mallet or similar parts in position while the FIPG is still wet. Do not
tool. allow FIPG to spread beyond the sealing areas dur-
ing installation. Avoid operating the transmission or
Surface Preparation letting oils or water come in contact with the sealed
Thoroughly remove all substances deposited on the area before a time sufficient for FIPG to harden
FIPG application surface, using a gasket scraper. (approximately one hour) has passed.
Make sure that the FIPG application surfaces is flat FIPG application method may vary from location to
and smooth. Also make sure that the surface is free location. Follow the instruction for each particular
from oils, greases and foreign substances. Do not fail case described later in this manual.
to remove old FIPG that may remain in the fastener
fitting holes.
LUBRICANTS
M1222000400381

Transmission oil Gear oil API classification GL-3 SAE 75W-85W As required
Transfer oil
Oil seal Mitsubishi Part No. 0101011 or equivalent
SPECIAL TOOLS
M1222000601139
Transmission
MB990803 Steering wheel puller Removal of gear spline
piece No.5
MB990803
MB990811 Side bearing puller cup Use with Steering wheel

puller
MB990811

adapter
SPECIAL TOOLS
22C-11
adapter

adapter
MB990938 Installer bar Installation of oil seal
MB990929 Installer adapter
MD998801 Remover Removal of roller bearing

and ball bearing, input gear
corn ring, transmission
clutch hub No.1 and
transmission clutch hub
No.2
adapter
MD998823 Installer adapter (48) Installation of ball bearing,

5th gear, transmission
clutch hub No.1 and
transmission hub No.2

adapter
SPECIAL TOOLS
Transfer
MB990938 Installer bar Installation of oil seal
MD998801 Remover Removal and installation

of bearing

installer adapter

installer-200
SPECIAL TOOLS
22C-13
MD998824 Installer adapter (50) Installation of transfer
input gear bearing
MD998368 Bearing Installer Installation of

countershaft gear bearing
MD998818 Installer adapter (38) Installation of

countershaft gear
bearing, front output shaft
bearing
MB991013 power steering lock nut Removal and installation

special spanner of output shaft locking nut

installer adapter
MD998829 Installer adapter (60) Installation of rear output

shaft ball bearing and
stopper plate
MD998821 Installer adapter (44) Installation of clutch hub

and rear output shaft ball
bearing
MD998917 Bearing remover Removal of rear output

shaft bearing <V5MB1-J-
ND2, NEZ, PD2>
TRANSMISSION

shaft ball bearing
<V5MB1-J-ND2, NEZ,
PD2>

drive bearing <V5MB1-J-
ND2, NEZ, PD2>
MD998192 Counter shaft bearing Installation of transfer

puller drive bearing <V5MB1-J-
ND2, NEZ, PD2>
TRANSMISSION
M1222001001925
1 3
35 ± 6 N·m
35 ± 6 N·m
AK500694AB
1. Spring pin 2. Transfer

3. Change shifter
TRANSMISSION
22C-15
44 ± 9 N·m 18 ± 3 N·m 22
34 ± 5 N·m 16
6 4
5
19
23
20 21
8 18 ± 5 N·m
18
17
16.5 ± 5.0 N·m
36 ± 7 N·m 37 ± 11 N·m
34 ± 6 N·m 7 37 ± 11 N·m
12 10
7
15
10
14 9
13 11 37 ± 11 N·m
18.5 ± 5.5 N·m
AK603025AH
4. Back-up lamp switch assembly 16. Wiring harness clamp bracket

5. Shift position switch assembly 17. Front bearing retainer
6. Clutch housing 18. Oil seal
7. Reverse restrict pin assembly 19. Shaft snap ring
8. Cover 20. Shaft snap ring
9. Wiring harness clamp bracket 21. Transmission case sub-assembly
10. Wiring harness clamp bracket 22. Intermediate plate with shaft sub-
11. Transfer adaptor sub-assembly assembly
12. Oil receiver pipe 23. Transmission magnet
13. Straight screw plug with head
15. Reverse restrict pin assembly
TRANSMISSION
18.5 ± 5.5 N·m 33 ± 3 N·m

18.5 ± 5.5 N·m 24
26 25
29
26 27
30
28 27
28
32 35
19.5 ± 3.9 N·m
33
31
36
34
19.5 ± 3.9 N·m
39
38
37
46
44 43 47 41
40 42
50
45 48 49 AK603100AB
24. Control shaft assembly 39. Slotted spring pin

25. Shift lever housing 40. Gear shift fork shaft No.3
26. Straight screw plug with head 41. Gear shift fork No.3
27. Compression spring 42. Roller A
28. Ball 43. Ball
29. Shaft snap ring 44. Shaft snap ring
30. Gear shift fork shaft No.2 45. Gear shift fork shaft No.4
31. Gear shift fork No.2 46. Ball
32. Roller A 47. Compression spring
33. Shaft snap ring 48. E ring
34. Gear shift fork shaft No.1 49. Reverse shift arm
35. Straight pin 50. Reverse shift fork
36. Roller A
37. Gear shift fork No.1
38. Shaft snap ring
TRANSMISSION
22C-17
68
18 ± 5 N·m
71
64 63
62
69
66
61 60
70
67
65
18 ± 5 N·m
51
Apply gear oil to
all moving parts
53
56 52
59 57 58
55 AK603036AB
51. Shaft snap ring 64. Shaft snap ring

52. Transmission hub sleeve No.3 65. Reverse idler gear
53. Gear spline piece No.5 66. Cylindrical roller bearing
54. Synchronizer outer race No.3 67. Counter shaft sub-assembly
55. Counter shaft gear No.5 68. Input shaft sub-assembly
56. Shaft snap ring 69. Output shaft sub-assembly
57. Synchromesh shifting key spring 70. Reverse shift arm bracket
No.3 71. Intermediate plate
58. Synchromesh shifting key spring
No.3 DISASSEMBLY
59. Synchromesh shifting key No.3 1. Remove the spring pin.
61. 5th gear thrust washer
2. Remove the transfer and the gear change shifter.
62. Straight pin
63. Rear bearing output shaft retainer
TRANSMISSION
6. Remove the cover.

Back-up lamp switch assembly
assembly AK403771AB
AK403767AC
3. Remove the shift position switch assembly and 7. Remove the flange bolt.
the back-up lamp switch assembly.
AK403772
AK403768
8. Remove the control shaft assembly.
4. Remove the clutch housing.
AK501350AB
AK403769
9. Remove the shift lever housing.
5. Remove the reverse restrict pin assembly (2
places).
AK403776
10.Remove the transfer adaptor sub-assembly and

AK403770
the wiring harness clamp bracket (3 places).
TRANSMISSION
22C-19
AK403777 AK403773
11.Remove the oil receiver pipe. 15.Remove the wiring harness clamp bracket.
AK403779 AK403774
12.Remove the straight screw plug with head. 16.Remove the front bearing retainer.
AK403780AB AK403775AC
13.Remove the slotted spring pin. 17.Remove the oil seal.
AK403781 AK403782
14.Remove the reverse restrict pin assembly. 18.Remove the shaft snap ring.
TRANSMISSION
AK403783 AK403788AB
19.Remove the shaft snap ring. 23.Remove the compression spring (3 places).
AK403784 AK403789AB
20.Remove the transmission case sub-assembly. 24.Remove the ball (3 places).
AK500257 AK403792 AB
21.Remove the transmission magnet. 25.Remove the shaft snap ring of the gear shift fork
shaft No.2 and the washer based hexagon bolt of
the gearshift fork No.2.
AK403786AB
22.Remove the straight screw plug with head (3 AK500259

places).
26.Remove the gear shift fork shaft No.2.
TRANSMISSION
22C-21
AK500260 AK500270
27.Remove the gear shift fork No.2. 31.Remove the straight pin of the gear shift fork shaft
No.1.
AK500261
AK500264
AK500262AB
AK500265
shaft No.1 and the washer based hexagon bolt of 33.Remove the gear shift fork No.1.
the gear shift fork No.1.
AK500266AB
AK500263
30.Remove the gear shift fork shaft No.1. shaft No.3.
TRANSMISSION
38.Remove the ball.
AK403790AB
AK500453AB
35.Remove the slotted spring pin of the gear shift
fork No.3 assembly. 39.Remove the shaft snap ring of the gear shift fork
shaft No.4.
AK500461AB
AK403802
36.Remove the gear shift fork No.3 assembly and
the gear shift fork shaft No.3.
AK403803
AK403800
40.Remove the gear shift fork shaft No.4.
AK403804
AK403801
41.Remove the ball.
TRANSMISSION
22C-23
AK403805 AK403807
42.Remove the compression spring. 46.Remove the shaft snap ring.
Transmission
hub sleeve No.3
AK403806 AK500269AB
43.Remove the reverse shift fork and the reverse 47.Remove the transmission hub sleeve No.3.
shift arm.
MB990811 MB990803
AK403982 AC
AK500455
48.Use special tools to remove the gear spline piece
44.Remove the E ring. No.5.
• Steering wheel puller (MB990803)
Reverse shift arm • Side bearing puller cup (MB990811)
Reverse shift fork
AK500454AB
45.Remove the reverse shift arm. AK403983
49.Remove the synchronizer outer race No.3.

TRANSMISSION
AK403984 AK500458
50.Remove the counter shaft gear No.5. 54.Remove the synchromesh shifting key No.3.
AK500526 AK500459
51.Remove the shaft snap ring. 55.Remove the needle roller bearing.
AK500456 AK403985
52.Remove the synchromesh shifting key spring 56.Remove the 5th gear thrust washer.
No.3.
AK403785AB
AK500457
57.Remove the straight pin.
53.Remove the synchromesh shifting key spring
No.3.
TRANSMISSION
22C-25
AK403986 AK403991
58.Remove the rear bearing output shaft retainer. 62.Remove the input shaft sub-assembly.
AK403987 AK403992
59.Remove the snap ring. 63.Remove the output shaft sub-assembly.

Reverse idler gear Reverse idler
sub-assembly gear shaft
AK403989 AB AK403993
60.Remove the reverse idler gear shaft and reverse 64.Remove the reverse shift arm bracket.
idler gear sub-assembly.
REASSEMBLY
AK403990
AK403993
61.Remove the counter gear sub-assembly and
cylindrical roller bearing. 1. Set the reverse shift arm bracket to the
intermediate plate and tighten the bolts to the
TRANSMISSION
5. Install the reverse idler gear shaft and reverse

idler gear sub-assembly to the intermediate plate.
AK403992
2. Install the output shaft sub-assembly to the

AK403987
intermediate plate.
6. Install the shaft snap ring to the radial ball bearing
of the input shaft sub-assembly.
AK403991
3. Install the input shaft sub-assembly to the output

AK403986AB
shaft sub-assembly.
7. Set the rear bearing output shaft retainer and
Cylindrical roller
bearing tighten the bolts to the specified torque of 18 ± 5
N⋅m.
NOTE: Fit the rear bearing output shaft retainer
Counter gear
sub-assembly into the reverse idler gear shaft slot.
AK403990AB
4. Insert the counter gear sub-assembly into the

intermediate plate and hold it. Insert the cylindrical
roller bearing into the intermediate plate and the
counter gear sub-assembly.
AK403785AB
Reverse idler gear Reverse idler
sub-assembly gear shaft 8. Install the straight pin.
AK403989 AB
TRANSMISSION
22C-27
Installtion 5th gear

direction thrust
washer
Penetration
groove
Straight pin
AK501229AB AK500457

to the counter shaft gear No.5.
AK403985
9. Check the installation direction of 5th gear thrust

AK500456
washer, and install it.
to the counter shaft gear No.5.
AK500459
10.Install the needle roller bearing.

AK500526
14.Install the shaft snap ring to the counter shaft gear

No.5.
AK500458
11.Install the synchromesh shifting key No.3 to the

counter shaft gear No.5.
AK403984
15.Install the counter shaft gear No.5.

TRANSMISSION
CAUTION 18.Check the installation direction of the

Fit the protrusions of synchronizer ring between transmission hub sleeve No.3 and install it on the
keys. counter shaft.
NOTE: After installation, check the sleeve operate
smoothly.
Protrusion
Key
AK403983AB
16.Install the synchronizer outer race No.3.

AK403807
19.Select a snap ring to secure the thrust clearance.

Install it into the counter gear sub-assembly.
Reverse shift arm

Reverse shift fork
MD998827 MD998812
MD998813
AK404049AB
17.Using special tools to install the gear spline piece

No.5.
• Installer-100 (MD998813) AK500454AB

20.Install the reverse shift arm to the reverse shift
fork.
Installation
direction
AK500610 AB
AK500455
Transmission 21.Install the E ring.

hub sleeve No.3
AK500269AB
TRANSMISSION
22C-29
CAUTION
Install the gear shift fork shaft No.4 carefully in
the specified direction. If the installation direc-
tion is wrong, the roller would be in the shaft
concave and the gearshift fork shaft No.4 would
not be installed.
AK403806
22.Install the reverse shift fork and the reverse shift

arm to the intermediate plate.
AK403803
AK403805
23.Install the compression spring into the reverse

shift fork.
AK403802
25.Install the gear shift fork shaft No.4 into the

intermediate plate and the reverse shift fork.
AK403804
AK500453AB
26.Install the shaft snap ring into the gear shift fork
shaft No.4.
AK403801
TRANSMISSION
27.Install the ball into the reverse shift fork. 31.Install the snap ring to the gear shift fork shaft
No.3.
AK403800
AK500265
28.Install the roller A to the intermediate plate.
32.Install the gear shift fork No.1 on the reverse gear.
AK500461AB
AK500264
29.Install the gear shift fork No.3 assembly on the
transmission hub sleeve No.3 and hold it. Insert 33.Install the roller A to the intermediate plate.
the gear shift fork shaft No.3 into the gear shift
fork No.3 assembly, the intermediate plate and
the reverse shift fork.
AK500270
34.Install the straight pin to the gear shift fork shaft

AK500267
No.1.
30.Install the slotted spring pin to the gear shift fork

No.3 assembly.
AK500263
35.Install the gear shift fork shaft No.1 to the

AK500266AB
intermediate plate and the gear shift fork No.1.
TRANSMISSION
22C-31
AK500262AB AK403792 AB
36.Install the shaft snap ring to the gear shift fork 40.Install the shaft snap ring to the gear shift fork
shaft No.1. Tighten the washer based hexagon shaft No.2. Tighten the washer based hexagon
bolt to the specified torque of 19.5 ± 3.9 N⋅m. bolt to the specified torque of 19.5 ± 3.9 N⋅m.
AK500261 AK403789AB
37.Install the roller A to the intermediate plate. 41.Install the ball to the intermediate plate (3 places).
AK500260 AK403788AB
38.Install the gear shift fork No.2 on the transmission 42.Install the compression spring to the intermediate
hub sleeve No.2. plate (3 places).
AK500259 AK403786AB
39.Install the gear shift fork shaft No.2 to the 43.Apply sealant to the threads. Tighten the straight
intermediate plate, the gear shift fork No.1 and the screw plug with head to the specified torque of
gear shift fork No.2. 18.5 ± 5.5 N⋅m (3 places).
TRANSMISSION

AK403783
48.Install the snap ring to the cylindrical roller

bearing.
AK500257
44.Install the transmission magnet to the

intermediate plate.
AK403782
49.Install the snap ring to the radial ball bearing.
AK500527AB MB990938

sealant.
Never touch the degreased surface by hand. MB990929
the intermediate plate mounting surface of the AK600320 AB
transmission case sub-assembly.

50.Using special tool install the oil seal to the front
Special sealant: Mitsubishi genuine sealant bearing retainer.
Part No. MD974421 or equivalent • Installer adapter (MB990929)
AK500560
AK403775AB
47.Install the transmission case sub-assembly to the
intermediate plate.
TRANSMISSION
22C-33
51.Completely degrease the FIPG-applied surface 54.Install the wiring harness clamp bracket to the
so that water and oil including the old sealant transmission case sub-assembly and tighten the
cannot adhere to the surface coated with the bolt to the specified torque of 18 ± 3 N⋅m.
sealant.
the transmission case sub-assembly mounting
surface of the front bearing retainer sub-assembly
with seal.
AK403781
CAUTION
Do not damage to the oil seal lip during the 55.Install the reverse restrict pin assembly to the
installation. transfer adaptor sub-assembly.
AK403774 AK403780AB
53.Apply sealant to the threads. Install the front 56.Install the slotted spring pin to the reverse restrict
bearing retainer to the transmission case sub- pin assembly.
assembly and tighten the bolts to the specified
torque of 16.5 ± 5.0 N⋅m.
AK403779
57.Apply sealant to the threads. Tighten the straight

screw plug with head to the specified torque of
18.5 ± 5.5 N⋅m.
AK403773
TRANSMISSION
CAUTION
When installing the shift lever housing, securely
fit the shift lever housing into the head of the fork
shaft.
Transfer
adaptor
AK403777
58.Install the oil receiver pipe into the transfer

adaptor sub-assembly.
AK500256AB
AK500527AB
59.Completely degrease the FIPG-applied surface AK501350AB

cannot adhere to the surface coated with the 62. Install the shift lever housing to the transfer
sealant. adaptor sub-assembly.
transfer adaptor sub-assembly.
AK403772
63.Install the control shaft assembly to the transfer

adaptor sub-assembly and the shift lever housing.
AK403776
61.Install the transfer adaptor sub-assembly. Install

the wiring harness clamp bracket (3 places) and
tighten the bolts to the specified torque of 37 ± 11
N⋅m.
AK403771AB
64.Tighten the flange bolt to the specified torque of

33 ± 3 N⋅m.
TRANSMISSION
22C-35
68.Tighten the reverse restrict pin assembly to the
CAUTION
Install the bolt and washer (with sealant) to the
position having the arrow as shown in the illus-
tration.
AK500528AB

sealant.
66.Apply a 1.2 mm diameter bead of liquid gasket to AK500460AB
the case mounting surface of the transfer adaptor
sub-assembly. 69.Install the clutch housing into the transmission
Special sealant: Mitsubishi genuine sealant case sub-assembly. Tighten the bolt with washer
Part No. MD974421 or equivalent to the specified torque of 36 ± 7 N⋅m (7 places).
Tighten the bolt with washer (with sealant) to the
AK403770
67.Install the cover to the transfer adaptor sub-

assembly and tighten the bolt with washer to the
specified torque of 18 ± 5 N⋅m. Back-up lamp switch assembly
assembly
AK403767AC
CAUTION
Install the reverse restrict pin assembly carefully 70.Tighten the shift position switch assembly to the
in the accordance with the identification color as specified torque of 34 ± 5 N⋅m.
shown in the illustration. 71.Tighten the back-up lamp switch assembly to the
Identification Identification 72.Install the transfer and the gear change shifter.
color: black color: white Tighten the bolts to the specified torque of 35 ± 6
N⋅m.
73.Install the spring pin.
AK403769 AB
TRANSMISSION
INSPECTION 2. Check that the sleeve is free from damage at its

M1222001100899 inside splines ends.
BACK-UP LAMP SWITCH
Limit: 0.52 mm

1. Combine the needle roller bearing with the shaft
and gear, and check that it rotates smoothly
AK500505 2. Check the needle roller bearing cage for
Check for the continuity between the connector ter- deformation.
minals.
COUNTER SHAFT GEAR No.5
Switch Connector Continuity
THRUST CLEARANCE
condition terminals
Inspect the thrust clearance of counter shaft gear
Switch end 1−2 Conductive No.5.
pressed
Switch end 1−2 Open Limit: 0.35 mm
released
RADIAL CLEARANCE
SHIFT POSITION SWITCH
1. Fix the output shaft in a vice.
2. Inspect the radial clearance of counter shaft gear
No.5.
Limit: 0.068 mm
INSIDE DIAMETER
AK501632
Check for the continuity between the connector ter-

minals.
condition terminals
pressed AK404027
Switch end 1−2 Conductive
Using the cylinder gauge, check the inside diameter
released
of the counter shaft gear No.5.
SYNCHRONIZER SLEEVE AND HUB Standard value: 38.015 − 38.040 mm
1. Combine the synchronizer sleeve and hub, and Limit: 38.040 mm
check that they slide smoothly.
INPUT SHAFT
22C-37
INPUT SHAFT
M1222001600526
Apply gear oil to

all moving parts
5
2
4
3
AK500516 AB

>>B<< 1. Shaft snap ring >>A<< RADIAL BALL BEARING INSTALLATION
<<A>> >>A<< 2. Radial ball bearing
3. Synchronizer ring No. 2
5. Input shaft sub-assembly
Installation
direction
<<A>> RADIAL BALL BEARING REMOVAL
AK500606AB
MD998801
bearing, and put it on the input shaft.
CAUTION
AK403995AC Never push on the sealing area when installing.
MD998812
support the radial ball bearing and remove it.
MD998814
MD998823
AK403996 AB
INPUT SHAFT
2. Using special tools to install the radial ball SYNCHRONIZER RING No.2
bearing.
>>B<<SNAP RING INSTALLATION
AK500676AB
1. Check the clutch gear on the synchronizer ring for

damaged and missing teeth.
2. Check the synchronizer ring inner cone surface
for damage or wear. Also check that the inside
AK403997 ridges are intact.

clearance between the radial ball bearing and the
input shaft sub-assembly.
INSPECTION
M1222001700222
INPUT SHAFT SUB-ASSEMBLY AK403998
3. After applying oil to the taper portion on gear,

press and fit the synchronizer ring by hand.
AK500677AB
1. Check the helical gear teeth and clutch gear teeth

of each input shaft sub-assembly for damage and
excessive wear.
AK403999
2. Check the synchronizer cone surface of each
input shaft sub-assembly for roughness, damage, 4. Using the thickness gauge, check the clearance
and excessive wear. between the synchronizer ring and the 4th gear.
3. Check the inside surface and front and back sides Standard value: 0.70 − 1.70 mm
of each input shaft sub-assembly for damage and Minimum limit: 0.70 mm
excessive wear.
1. Combine the needle roller bearing with the input
shaft, and check that it rotates smoothly without
noise or play.
OUTPUT SHAFT
22C-39
deformation.
OUTPUT SHAFT
M1222002100160
Apply gear oil to

23
all moving parts
22
19
21
20
18
15
17 16
26
25 6
24
12 1
2
13 5 3
7
8
4
10 9
14 11
AK500517AB

>>G<< 1. Shaft snap ring <<C>> >>C<< 13. Compression spring
<<A>> >>F<< 2. 5th gear <<C>> >>C<< 14. Transmission clutch No. 1 hub
<> >>E<< 3. Radial ball bearing <<C>> >>C<< 15. Synchronizer ring set No. 1
<> >>E<< 4. 1st gear sub-assembly <<C>> >>C<< 16. 2nd gear sub-assembly
5. 1st gear thrust washer 17. Needle roller bearing
6. Straight pin >>B<< 18. Shaft snap ring
7. Needle roller bearing <<D>> >>A<< 19. Transmission hub sleeve No. 2
8. D spacer <<D>> >>A<< 20. Synchronizer shifting key No. 2
9. Synchronizer ring set No. 1 <<D>> >>A<< 21. Compression spring
>>D<< 10. Shaft snap ring <<D>> >>A<< 22. Transmission clutch No. 2 hub
<<C>> >>C<< 11. Reverse gear <<D>> >>A<< 23. Synchronizer ring set No. 2
<<C>> >>C<< 12. Synchronizer shifting key No. 1 <<D>> >>A<< 24. 3rd gear sub-assembly
OUTPUT SHAFT
Disassembly steps (Continued) DISASSEMBLY SERVICE POINTS

<<A>> 5TH GEAR REMOVAL
26. Output shaft
INSPECTION BEFORE DISASSEMBLY

THRUST CLEARANCE FOR EACH GEAR
2nd 1st MD998801
AK404004AB

support the 5th gear and remove it.
3rd
AK404000AB
<> RADIAL BALL BEARING / 1ST GEAR SUB-
Inspect the thrust clearance of each gear.
ASSEMBLY REMOVAL
1st 0.20 − 0.45 0.45
2nd 0.10 − 0.25 0.25
3rd 0.10 − 0.25 0.25 MD998801
RADIAL CLEARANCE FOR EACH GEAR
AK404006AB

support the 1st gear sub-assembly and remove the
radial ball bearing and the 1st gear sub-assembly.
<<C>> REVERSE GEAR / SYNCHRONIZER

AK404001AB SHIFTING KEY No. 1 / COMPRESSION SPRING /
1. Fix the output shaft by a vice. SYNCHRONIZER RING SET No. 1 / 2ND GEAR
2. Inspect the radial clearance of each gear. SUB-ASSEMBLY REMOVAL
1st 0.020 − 0.073 0.073
2nd 0.015 − 0.068 0.068
3rd 0.015 − 0.068 0.068 MD998801
AK404014 AB
OUTPUT SHAFT
22C-41
support the 2nd gear sub-assembly and remove the
reverse gear, synchronizer shifting key No. 1, com- MD998812
pression spring, the transmission clutch No. 1 hub,
synchronizer ring set No. 1 and the 2nd gear sub- MD998813
assembly.
MD998823
<<D>> TRANSMISSION CLUTCH HUB No. 2 /
SYNCHRONIZER SHIFTING KEY No. 2 /
COMPRESSION SPRING / TRANSMISSION HUB AK404029AC
/ 3RD GEAR SUB-ASSEMBLY REMOVAL 2. Using special tools to install the transmission
clutch hub No. 2, synchronizer shifting key No. 2,
compression spring, the transmission hub sleeve
No. 2, synchronizer ring set No. 2 and the 3rd
MD998801 gear sub-assembly.
AK404020AB

support the 3rd gear sub-assembly and remove the
transmission clutch hub No. 2, synchronizer shifting
key No. 2, compression spring, the transmission hub
sleeve No. 2, synchronizer ring set and the 3rd gear
sub-assembly.
AK500508
REASSEMBLY SERVICE POINTS 3. Confirm the thrust clearance of the 3rd gear sub-
>>A<< TRANSMISSION CLUTCH HUB No. 2 / assembly is within the standard value.
SYNCHRONIZER SHIFTING KEY No. 2 / COM- Standard value: 0.10 − 0.25 mm
PRESSION SPRING / TRANSMISSION HUB Limit: 0.25 mm
/ 3RD GEAR SUB-ASSEMBLY INSTALLATION
>>B<< SHAFT SNAP RING INSTALLATION
Installation
direction
AK500607AB
AK404019
1. Check the installation direction of the transmission 1. Select a shaft snap ring to secure the standard
clutch hub No. 2, and put it on the output shaft. clearance between the transmission clutch hub
No.2 and the output shaft.
OUTPUT SHAFT
>>C<< REVERSE GEAR / SYNCHRONIZER

SHIFTING KEY No. 1 / COMPRESSION SPRING / >>D<< SHAFT SNAP RING INSTALLATION
SYNCHRONIZER RING SET No. 1 / 2ND GEAR
SUB-ASSEMBLY INSTALLATION
Installation
direction
AK404031

clearance between the transmission clutch No. 1
AK500608 AB
hub and the output shaft.
1. Check the installation direction of the reverse Standard value: 0 − 0.1 mm
gear, and put it on the output shaft. 2. Install the selected snap ring.
MD998812
>>E<< RADIAL BALL BEARING / 1ST GEAR SUB-
MD998813
MD998814
MD998823 Installation
direction
AK404030AC
2. Using special tools to install the reverse gear,

synchronizer shifting key No. 1, compression
spring, the transmission clutch No. 1 hub, AK500606AB
synchronizer ring set No. 1 and the 2nd gear sub-

assembly.
bearing, and put it on the output shaft.
• Installer-200 (MD998814) CAUTION
• Installer adapter (48) (MD998823) Never push on the sealing area when installing.
MD998812
MD998814
MD998823
AK404032 AK404038AB
3. Confirm the thrust clearance of the 2nd gear sub- 2. Using special tools to install the radial ball bearing
assembly is within the standard value. and the 1st gear sub-assembly.
Limit: 0.25 mm • Installer-200 (MD998814)
OUTPUT SHAFT
22C-43
>>G<< SHAFT SNAP RING INSTALLATION
AK500513
AK404040
3. Confirm the thrust clearance of the 1st gear sub-
assembly is within the standard value. 1. Select a shaft snap ring to secure the standard
Standard value: 0.20 − 0.45 mm clearance between the 5th gear and the output
Limit: 0.45 mm shaft
>>F<< 5TH GEAR INSTALLATION 2. Install the selected snap ring.
INSPECTION
M1222002300261
Installation SYNCHRONIZER RING
direction
AK500609AB
1. Check the installation direction of the 5th gear,

and put it on the output shaft.
AK500672AB
MD998812
CAUTION
MD998814
When any of the outer ring, inner ring or cone
MD998823 1. Check to ensure that the clutch gear tooth surface
AK404039AB
2. Using special tools to install the 5th gear.

AK500603

OUTPUT SHAFT

1. Combine the needle roller bearing with the output
shaft and gear, and check that it rotates smoothly
deformation.
SYNCHRONIZER KEYS
AK404022

1st 0.65 − 1.75 0.65
2nd 0.65 − 1.75 0.65
3rd 0.65 − 1.75 0.65
AK500680AB
HUB SLEEVE AND SHIFTFORK
Check the synchronizer hub contact surfaces of each
synchronizer key for damage and excessive wear.
COMPRESSION SPRINGS
Check the compression springs for loss of tension,
deformation, and breakage.
OUTPUT SHAFT
AK404023
CAUTION
When any of the hub sleeve or shift fork has to be
replaced, replace them as a set.
Using the thickness gauge, check the clearance
between the sleeve and the shift fork.
A B C
sleeve Standard Limit mm
value mm AK404024AB
No.1 0.15 − 0.41 0.41 1. Using the micrometer, check the outer shape of
No.2 0.15 − 0.35 0.35 the needle roller bearing race.
No.3 0.26 − 0.84 0.84 Measurement Standard value mm Limit mm
part
SYNCHRONIZER SLEEVE AND HUB A 37.984 − 38.000 37.984

1. Combine the synchronizer sleeve and hub, and B 46.984 − 47.000 46.984
check that they slide smoothly. C 38.979 − 38.995 38.979
COUNTERSHAFT
22C-45
3. Using the dial gauge and V-block, check the
output shaft runout.
Limit: 0.015 mm Max
AK404025
2. Using the slide gauge, check the flange thickness.

AK404027
4. Using the cylinder gauge, check the inside

diameter of each gear.
1st 46.015 − 46.040 46.040
2nd 53.015 − 53.040 53.040
3rd 44.015 − 44.040 44.040
AK404026
COUNTERSHAFT
M1222007300158
Apply gear oil to

all moving parts
AK500518AB
COUNTERSHAFT
Disassembly steps 2. Using special tools to install the cylindrical roller

>>B<< 1. Shaft snap ring bearing.
<<A>> >>A<< 2. Cylindrical roller bearing • Installer cap (MD998812)
3. Counter gear • Installer-100 (MD998813)
<<A>> CYLINDRICAL ROLLER BEARING >>B<< SHAFT SNAP RING INSTALLATION
REMOVAL
MD998801
AK404042
AK404043 AB
Using special tool Bearing remover (MD998801), 1. Select a snap ring to secure clearance of standard
support the cylindrical roller bearing and remove it. value between the cylinder roller bearing and
counter shaft.
REASSEMBLY SERVICE POINTS Standard value: 0 − 0.1 mm
>>A<< CYLINDRICAL ROLLER BEARING 2. Install the selected snap ring.
INSTALLATION
INSPECTION
M1222007400025
COUNTER GEAR
Installation
direction
D E
AK500644 AB
1. Check the installation direction of the cylindrical

AK404041AB
roller bearing, and put it on the counter shaft.
Using the micrometer, check the outer shape of the
CAUTION needle roller bearing race.
Never push the sealing area at the press fit.
Measurement Standard value Limit mm
MD998812
part mm
D 34.000 − 34.105 34.000
MD998813 E 29.984 − 30.000 29.984
MD998817
AK404046AB
REVERSE IDLER GEAR
22C-47
REVERSE IDLER GEAR
M1222012500233
Apply gear oil to

all moving parts
1
AK500519AB
Disassembly steps INSPECTION

1. Reverse idler gear sub-assembly M1222012400076
2. Reverse idler gear shaft REVERSE IDLER GEAR SUB-ASSEMBLY
AK500525AB
Check the radial clearance of the reverse idler gear.

Limit: 0.082 mm
TRANSFER
TRANSFER
M1222008800327
<V5MB1-J-NEG, JER>
35 ± 6 N·m 34 ± 5 N·m
3
6
35 ± 6 N·m 8
7 4
9
5
32 ± 2 N·m
12
34 ± 5 N·m
13
1
16
19 ± 3 N·m
15
14
22 ± 2 N·m
Apply gear oil to

all moving parts
AKA00412 AB

1. 4WD operation detection switch >>T<< 8. Spring
2. Gasket 9. Steel ball
3. High range/Low range detection >>U<< 10. Plug
switch 11. Gasket
4. Gasket 12. Vehicle speed sensor
5. Steel ball 13. Speedometer sleeve clamp
>>U<< 6. Plug >>S<< 14. Speedometer driven gear sleeve
>>U<< 7. Plug assembly
TRANSFER
22C-49
Apply gear oil to 35 ± 6 N·m

all moving parts
23
28
29
30 24
25
26
27
22
16
19 20 21
35 ± 6 N·m 15 32 ± 2 N·m
35 ± 6 N·m
18
17
35 ± 6 N·m
AK900792AB

15. Bracket 23. Connector bracket
>>R<< 16. Transfer case plate 24. Harness bracket
>>Q<< 17. Countershaft gear >>O<< 25. Rear cover
>>P<< 18. Spacer >>N<< 26. Oil cover
19. Sealing cap >>M<< 27. Spacer
20. Needle bearing 28. Dust seal cover
>>U<< 21. Plug >>L<< 29. Oil seal
>>U<< 22. Plug >>K<< 30. Spring pin
TRANSFER
50
49
47
Apply gear oil to
48 all moving parts
55 49
52
35 ± 6 N·m
38
34 35
54
53 45
31 36
42 44
51
43
41
40
39
46 37
32
33 58
56 57
AK503417AF

<<A>> >>J<< 31. H-L shift rail <> >>B<< 46. Front output shaft
32. H-L shift fork 47. 2-4WD shift fork
>>I<< 33. H-L clutch sleeve 48. Snap ring
34. Harness bracket 49. Spring retainer
35. Harness bracket 50. Return spring
36. Harness bracket 51. 2-4WD shift lug and shift rail
>>H<< 37. Chain cover assembly
38. Interlock plunger >>F<< 52. Spring pin
39. Wave spring 53. 2-4WD shift lug
>>D<< 40. Snap ring 54. Distance piece
>>C<< 41. H-L clutch hub 55. 2-4WD shift rail
42. Low speed gear 56. Dust seal guard
43. Needle bearing >>A<< 57. Oil seal
<> >>B<< 44. Rear output shaft 58. Transfer case
<> >>B<< 45. Chain
TRANSFER
22C-51
<V5MB1-J-ND2, NEZ,PD2>
5 34 ± 5 N·m 26
34 ± 5 N·m
4 6
35 ± 6 N·m
34 ± 5 N·m
35 ± 6 N·m
12
2 34 ± 5 N·m
34 ± 5 N·m
7 31
9
35 ± 6 N·m
<V5MB1-J-PD2>
10
1 8 13 27
11 14
<V5MB1-J-
ND2,NEZ>
32
19 ± 3 N·m
3
28
29
30 19 18
33
25 17 25 ± 4 N·m
20 24 15
16 32 ± 2 N·m
23 Apply gear oil to

22 all moving parts
21
35 ± 6 N·m AK900860AC

>>V<< 1. Center differential lock detection 17. Vehicle speed sensor
switch 18. Speedometer clamp
>>V<< 2. 2WD/4WD detection switch >>S<< 19. Speedometer driven gear sleeve
3. Gasket assembly
>>V<< 4. Center differential lock operation 20. Bracket
detection switch >>R<< 21. Transfer case plate
>>V<< 5. 4WD operation detection switch >>Q<< 22. Countershaft gear
>>V<< 6. High range/Low range detection >>P<< 23. Spacer
switch 24. Sealing cap
7. Gasket 25. Needle bearing
8. Steel ball 26. Connector bracket
>>U<< 9. Plug 27. Harness bracket
>>T<< 10. Spring >>O<< 28. Rear cover
11. Steel ball 29. Oil cover
12. 4LLc operation detection switch >>M<< 30. Spacer
13. Plug 31. Dust seal cover
14. Gasket >>L<< 32. Oil seal
15. Plug >>K<< 33. Spring pin
16. Gasket
TRANSFER
52
Apply gear oil to
all moving parts
51
53
43
57 60
55 45 39
59 41 35 ± 6 N·m
47 44
58
38
56 34
46 37
61
54 63
50
62
64
40
65
48
35
42
49
36
AK801157AE

<<A>> >>J<< 34. H-L shift rail 51. E-ring
35. H-L shift fork 52. Spring seat
>>I<< 36. H-L clutch sleeve 53. Spring
37. Harness bracket 54. 2-4WD shift lug and shift rail
38. Harness bracket assembly
39. Harness bracket >>F<< 55. Spring pin
>>H<< 40. Chain cover 56. 2-4WD shift lug
41. Interlock plunger 57. Spring seat
42. Wave spring 58. Spring
43. Rear output shaft 59. 2-4WD shift rail
44. Needle bearing 60. 2-4WD shift fork
45. Needle bearing 61. 2-4WD synchronizer sleeve
46. Center differential case 62. Spacer
<<C>> >>G<< 47. 2-4WD synchronizer 63. Steel ball
<<C>> >>G<< 48. Chain >>E<< 64. Snap ring
<<C>> >>G<< 49. Front output shaft 65. Differential lock hub
50. Needle bearing
TRANSFER
22C-53
70
Apply gear oil to
all moving parts
71
20 ± 2 N·m
9.0 ± 1.0 N·m
72
69
68 75
67 74
66
73 AK503403AJ
Disassembly steps 1. Fix the H-L shift rail at the high position.
>>D<< 66. Snap ring 2. Shift the 2-4WD shift rail at the 4WD position.
>>C<< 67. H-L clutch hub
68. Low speed gear
NOTE: If the 2-4WD shift rail is at the 2WD posi-
69. Needle bearing tion, the chain cover cannot be removed because
70. Rear bearing retainer interlock is actuated.
71. Transfer drive shaft
72. Oil pool cover <> REAR OUTPUT SHAFT / CHAIN/FRONT
73. Dust seal guard OUTPUT SHAFT REMOVAL
>>A<< 74. Oil seal
75. Transfer case
DISASSEMBLY SERVICE POINTS

<<A>> H-L SHIFT RAIL REMOVAL
AK500492
Remove the rear output shaft, chain and front output

shaft as a set.
2-4WD shift rail
AK503405 AB
TRANSFER
<<C>> 2-4WD SYNCHRONIZER / CHAIN/FRONT >>B<< FRONT OUTPUT SHAFT / CHAIN / REAR
OUTPUT SHAFT REMOVAL OUTPUT SHAFT INSTALLATION
AK101119 AK500492
Remove the 2-4WD synchronizer, chain and front 1. Engage the chain precisely with the sprocket of
output shaft as a set. the rear output shaft and the front output shaft.
2. Install the 2-4WD shift fork on the 2-4WD clutch
ADJUSTMENT BEFORE REASSEMBLY sleeve. While passing them beside the 2-4WD
Spacer selection for adjustment of counter shaft end shift rail, install the front output shaft, and chain
play. (Refer to ADJUSTMENT OF TRANSFER - and rear output shaft.
SPACER SELECTION FOR ADJUSTMENT OF
COUNTER SHAFT END PLAY P.22C-59 >>C<< H-L CLUTCH HUB INSTALLATION

>>A<< OIL SEAL INSTALLATION
Transfer front side Installation

direction
MB990931 MB990938
AK503408 AB
Check that the H-L clutch hub is in the correct direc-

Transfer case
tion for installation.
AK403501 AC
>>D<< SNAP RING INSTALLATION

1. Use special tools to install the oil seal.
2. Apply the specified grease to the lip of oil seal.
Specified lubricant: Mitsubishi Part No.
AK500493
1. Install the thickest snap ring that can be fitted in

the snap ring groove of the rear output shaft.
2. Make sure that the H-L clutch hub end play meets
the standard value.
TRANSFER
22C-55
>>E<< SNAP RING INSTALLATION
AK101124
AK503398
3. Place the chain in tight mesh with the 2-4WD
1. Install the thickest snap ring that can be fitted in synchronizer and front output shaft sprockets.
the snap ring groove of the transfer drive shaft. 4. With both sprockets spaced the farthest apart,
2. Make sure that the differential lock hub end play install them on the transfer case simultaneously.
meets the standard value.
Standard value: 0 − 0.08 mm >>H<< CHAIN COVER INSTALLATION
CAUTION
>>F<< SPRING PIN INSTALLATION Squeeze the sealant out evenly to apply it in
an unbroken, non-excessive quantity.
2 mm Diameter
AK503410
AK403508AB
1. Align the e2-4WD shift lug with the 2-4WD shift
rail spring pin hole. 1. Completely degrease the FIPG-applied surface so
2. Hammer in the spring valve so that the spring pin that water and oil including the old sealant cannot
slit matches the center of the shift rail shaft. adhere to the surface coated with the sealant.
>>G<< 2-4WD SYNCHRONIZER/CHAIN/FRONT 2. Apply sealant to the chain cover, and then install
OUTPUT SHAFT INSTALLATION the chain cover.
Specified sealant: Mitsubishi genuine seal-
ant Part No. MD997740 or equivalent
>>I<< H-L CLUTCH SLEEVE INSTALLATION
Identification groove
AK101123
1. Make a white paint mark on the deep groove Installation

direction
portions (three places) of the 2-4WD
synchronizer.
2. Make a white paint mark on the portions (three AK500678AB
places) of the 2-4WD synchronizer sleeve splines.

TRANSFER
Check that the H-L clutch sleeve is in the correct 1. Align the spring pin holes on the shift rail with the
direction for installation. shift fork. Then tap in the spring pin so that the slit
of the spring pin is facing the shaft center of the
>>J<< H-L SHIFT RAIL INSTALLATION shift rail.
>>L<< OIL SEAL INSTALLATION

<V5MB1-J-NEG, JER>
MB990938
MB990932
H-L shift rail
2-4WD shift rail
Interlock plunger
H-L shift rail
AK403510AQ
MB990938
MB990929
2-4WD shift rail

AK503411AB
1. Tilt the transfer case with the 2-4WD shift rail AK403510AR
downward as shown in the illustration.

2. Move the 2-4WD shift rail in the direction of the
• Installer adapter (MB990932) <V5MB1-J-NEG,
arrow fully.
JER>
3. After making sure that the plunger is not exposed • Installer adapter (MB990929) <V5MB1-J-ND2,
out of the H-L shift rail hole in the transfer case, NEZ, PD2>
install the H-L shift rail. • Installer bar (MB990938)
>>K<< SPRING PIN INSTALLATION
AK503412
TRANSFER
22C-57
>>M<< SPACER INSTALLATION 2. Subtract A from B and let the answer be C. Select
a spacer so that the subtracted value will be the
<V5MB1-J-NEG, JER>
A
Rear cover standard value shown below.
Standard value:
0 − 0.1 mm <V5MB1-J-NEG, JER>
0.025 − 0.150 mm <V5MB1-J-ND2, NEZ, PD2>
B
>>N<< OIL COVER INSTALLATION
Oil hole
Spacer
Oil cover
AK403729 AC
In case of <V5MB1-J-NEG, JER> type, install the oil

cover so that the oil hole shown in the illustration.
AK403504AJ
>>O<< REAR COVER INSTALLATION
Rear cover CAUTION
A Squeeze the sealant out evenly to apply it in
2 mm
Diameter
AKX00172 AC
Spacer 1. Completely degrease the FIPG-applied surface so

that water and oil including the old sealant cannot
adhere to the surface coated with the sealant.
2. Apply the sealant to the chain cover.
AK503414AJ Specified sealant: Mitsubishi genuine seal-
1. Measure projection A of the rear output shaft
bearing and depth B of the second stage of the
rear cover. >>P<< SPACER INSTALLATION
Install the previously selected spacer (Refer to
ADJUSTMENT BEFORE ASSEMBLY).
TRANSFER
>>Q<< COUNTER SHAFT GEAR INSTALLATION >>S<< SPEEDOMETER DRIVEN GEAR SLEEVE
Notched selection
Mating marks
Counter shaft
Input gear AK503394AB

AK503942AB
1. Turn the input gear’s notched selection surface
toward the counter shaft mounting surface. then Match the mating marks to the number of teeth.
install the counter shaft.
>>T<< SPRING INSTALLATION
>>R<< TRANSFER CASE PLATE INSTALLATION
CAUTION
Squeeze the sealant out evenly to apply it in
2 mm Diameter
AK403513
Install the spring with its tapered end toward the ball.
>>U<< PLUG INSTALLATION

AK403617AC
1. Completely degrease the FIPG-applied surface so

that water and oil including the old sealant cannot
adhere to the surface coated with the sealant.
2. Apply the sealant to the transfer case plate.
Specified sealant: Mitsubishi genuine seal-
AK403514AB
CAUTION
The transfer case plate must be installed Apply the sealant to the threads.
smooth and straight to get a good seal. Specified sealant: 3M AAD Part No. 8672 or
3. Install the transfer case plate together with the equivalent
input gear and countershaft. NOTE: .
The new plug is precoated with sealant, so seal-
ant does not need to be applied.
TRANSFER
22C-59
>>V<< DETECTION SWITCH INSTALLATION 1. Put solders (1.0 mm diameter, about 10 mm long)
V V V V
in the illustrated positions of the transfer case
A housing.
B 2. Install the counter shaft into the transfer case.
C 3. Install the transfer case plate and tighten the bolts
E to the specified torque of 35 ± 6 N⋅m.
D 4. Remove the transfer case plate and the counter
1
2 shaft, and then take out crushed solders.
4 6 5 3 5. If the solders have not crushed, use thicker
F
solders (1.6 mm diameter, about 10 mm long) and
AK801184AB repeat steps 2 to 4.
Install with care. Do not make mistake when locating
each switch.
Detection switch name Connector
No./Color
A Center differential lock 1/Brown
detection switch
B 2WD/4WD detection switch 2/Black
C Center differential lock 4/Blown
operation detection switch AK305233
D 4WD operation detection switch 5/Black

6. Measure the thickness of the crushed solder with
E High range/Low range detection 3/white a micrometer and select a spacer that will provide
switch the standard value.
F 4LLc operation detection switch 6/white Spacer thickness: (T − 0) to (T − 0.15)
<V5MB1-J-PD2> T: The crushed solder thickness
ADJUSTMENT OF TRANSFER
M1222016700013
<Measurement using Plastigage>
SPACER SELECTION FOR ADJUST-
MENT OF COUNTER SHAFT END PLAY
<Measurement using a solder>
CAUTION
• f soft solder is not available, select the spacer
in accordance with Plastigage method.
• If the spacer appropriate for the standard
value cannot be selected using soft solder,
select the spacer in accordance with Plasti-
Plastigage
gage method. AK403499AC
1. Put plastigage (about 10 mm long) in the

illustrated positions of the transfer case housing.
2. Install the adjusting spacer having the minimum
thickness.
3. Install the counter shaft into the transfer case.
4. Install the transfer case plate and tighten the bolts
to the specified torque of 35 ± 6 N⋅m.
Solder 5. Remove the transfer case plate and the counter
AK403499AB shaft, and then take out crushed solders.
6. If the Plastigages have not crushed, replace the
spacer with a thicker one and repeat steps 3 to 5.
TRANSFER

minals.
condition terminals
pressed
Plastigage released
Spacer AK402081 AB
4LLc OPERATION DETECTION SWITCH
7. Measure the width of the crushed Plastigage at its
widest part using a scale printed on the Plastigage
package.
INSPECTION
M1222008900153
4WD DETECTION SWITCH
4WD operation detection switch
AK503422

minals.
condition terminals
Switch end 1 − Body earth Open
pressed
AK500505AB
Switch end 1 − Body earth Conductive
Check for the continuity between the connector ter- released
minals.
Switch Connector Continuity DETECTION SWITCH
condition terminals
pressed
released
HIGH RANGE/LOW RANGE DETECTION SWITCH

High range/low range detection
switch
AK503422

minals.
condition terminals
pressed
AK500510AB
released
TRANSFER CASE PLATE
22C-61
TRANSFER CASE PLATE
M1222009100086
Apply gear oil to 19 ± 3 N·m

all moving parts
1
5
4
AK500691AD
Disassembly steps Specified lubricant: Mitsubishi Part No.

>>C<< 1. Seal bolt 0101011 or equivalent
2. Bearing retainer 2. Use socket wrench to install the oil seal.
3. Transfer input gear
>>B<< 4. Oil seal
5. Baffle plate >>B<< OIL SEAL INSTALLATION
>>A<< 6. Oil seal
7. Transfer case plate MB990938
MB990933
socket wrench
AKX00216 AD
1. Apply specified grease to the lip of the oil seal.

AK500692 AB 2. Use special tools to install the oil seal.
1. Apply specified grease to the lip of the oil seal. • Installer adapter (MB990933)
TRANSFER INPUT GEAR
>>C<< SEAL BOLT INSTALLATION 1. Apply the specified sealant to the threads.
Specified sealant: 3M STUD Locking No.
4170 or equivalent
AK403506 AB
TRANSFER INPUT GEAR

M1222009400139
Apply gear oil to

all moving parts
AK800993AB
Disassembly steps DISASSEMBLY SERVICE POINT

>>B<< 1. Snap ring <<A>> BALL BEARING REMOVAL
<<A>> >>A<< 2. Ball bearing
MD998801
AK601073 AC
COUNTERSHAFT
22C-63
Use special tool, Bearing remover (MD998801),
remove the ball bearing. >>B<< SNAP RING INSTALLATION
Ball bearing
Standard value
>>A<< BALL BEARING INSTALLATION
Snap ring
MD998812
MD998826
AK500699AB

the snap ring groove of the transfer input gear.
AK703391 AB
2. Make sure that the transfer input gear bearing end
Use special tools to install the ball bearing. play meets the standard value.
• Installer cap (MD998812) Standard value: 0 − 0.06 mm
COUNTERSHAFT
M1222007300062
Apply gear oil to

all moving parts
AK500663 AB

<<A>> >>C<< 1. Ball bearing <> >>A<< 3. Roller bearing
>>B<< 2. Snap ring 4. Counter shaft gear
COUNTERSHAFT
DISASSEMBLY SERVICE POINTS 1. Use special tools to install the roller bearing.
<<A>> BALL BEARING REMOVAL • Installer cap (MD998812)
2. Install the spacer.
MD998801
AKX00257 AC
Use special tool Remover (MD998801) to remove

the ball bearing.
<> ROLLER BEARING REMOVAL AKX00260
1. Install the thickest snap ring that can be fitted into

MD998801
MD998368 the snap ring groove of the counter shaft gear.
2. Make sure that the counter shaft gear roller
bearing end play meets the standard value.
>>C<< BALL BEARING INSTALLATION
AKX00258 AC
Use special tools to remove the roller bearing. MD998812

• Remover (MD998801)
• Bearing installer (MD998368) MD998818

>>A<< ROLLER BEARING INSTALLATION
AKX00261AC
Use special tools to install the ball bearing.

MD998812 • Installer cap (MD998812)
MD998818 • Installer adapter (38) (MD998818)
AKX00259 AC
2-4WD SYNCHRONIZER <V5MB1-J-ND2, NEZ, PD2>
22C-65
M1222010900020
7
Apply gear oil to
all moving parts
9
8
6 10
5
4
3
9
2
AK503423AB

>>C<< 1. Snap ring >>A<< INNER SYNCHRONIZER RING INSTALLA-
2. 2-4WD Synchronizer hub TION
3. 2-4WD Synchronizer spring
>>B<< 4. Outer synchronizer ring
5. Synchronizer cone
>>A<< 6. Inner synchronizer ring
7. Drive sprocket
8. Bearing spacer
9. Needle bearing
10. Front side gear
AK503426AB
Apply oil the synchronizer ring cone surface before

installation.
>>B<<OUTER SYNCHRONIZER RING CAUTION

INSTALLATION When any of the outer ring, inner ring or cone
1. Check to ensure that the clutch gear tooth surface
AK503427AB

installation.
>>C<<SNAP RING INSTALLATION AK503424

Snap ring
AK101272AD
Select and install the snap ring which adjusts the 2-

4WD synchronizer hub end play to standard value.
AK503425
INSPECTION 3. Using the thickness gauge, check the clearance

M1222011000020
SYNCHRONIZER RING
Limit: 0.3 mm
AK500672AB
CENTRE DIFFERENTIAL CASE <V5MB1-J-ND2, NEZ, PD2>
22C-67
CENTRE DIFFERENTIAL CASE <V5MB1-J-ND2, NEZ, PD2>
M1222010600041
Apply gear oil to

all moving parts
4
6
4
3 3
2
3
69 ± 10 N·m 4
4
1
AK503428 AB

>>A<< 1. Center differential case A >>A<<CENTER DIFFERENTIAL CASE B INSTAL-
2. Dowel pin LATION
3. Differential pinion
4. Thrust washer
5. Pinion shaft
6. Center differential case B Dowel pin
Dowel pin
AK101274AD
Pay attention to the position of the dowel pins when

reassembling, and make sure that the match marks
on the outside circumference are in alignment.
H-L SHIFT FORK
H-L SHIFT FORK

M1222009700022
2
3
4
5
1
6
9.0 ± 2.0 N·m
AK500689AB

>>A<< 1. Return spring plug >>A<< RETURN SPRING PLUG INSTALLATION
2. Return spring
3. Return spring Plunger boss
4. Select plunger
5. Plunger boss
6. High & low shift fork
Return spring plug
AK500693 AC
Apply the sealant to the thread and screw the return

spring plug to be an even surface between the
plunger boss end face and the return spring plug.
Specified sealant: 3M STUD Locking No.
4170 or equivalent
REAR OUTPUT SHAFT <V5MB1-J-NEG, JER>
22C-69
M1222010300181
14
15
16
17
18
255 ± 10 N·m
12 9
11 3
13 4
6
8 7 Apply gear oil to
all moving parts
10 before installation.
AK500645AB

<<A>> >>E<< 1. Lock nut 11. Synchronizer cone <V5MB1-J-
<> >>D<< 2. Ball bearing NEG>
3. Oil guide 12. Synchronizer outer ring <V5MB1-
4. Sprocket spacer J-NEG>
5. Steel ball 13. Synchronizer spring <V5MB1-J-
6. Drive sprocket NEG>
7. Needle bearing >>C<< 14. Clutch sleeve
8. Sprocket sleeve <<C>> >>B<< 15. Clutch hub
9. Steel ball <<C>> >>A<< 16. Stopper plate
10. Synchronizer inner ring <V5MB1- <<C>> >>A<< 17. Ball bearing
J-NEG> 18. Rear output shaft
DISASSEMBLY SERVICE POINTS NOTE: .

<<A>> LOCK NUT REMOVAL The bearing may fit loosely on the shaft, so that
removal is possible without using a press.
<<C>> CLUTCH HUB / STOPPER PLATE / BALL

BEARING REMOVAL
2-4WD clutch hub

MD998801
AK403516
Ball bearing
1. Remove the lock nut from the shaft.
AK403520 AB
MB991013
1. Place special tool Remover (MD998801) so that
the load is applied at the bearing.
2. Use a press to push at the rear end of the rear
output shaft, and then remove the clutch hub and
ball bearing.
NOTE: .
AK500495AB
The clutch hub may fit loosely on the shaft, so
that removal is possible without using a press.
2. Hold the drive sprocket in a soft-jaw vice.
3. Shift the clutch sleeve to the drive sprocket side. REASSEMBLY SERVICE POINTS
4. Use special tool Power steering lock nut special >>A<< BALL BEARING / STOPPER PLATE
spanner (MB991013) to remove the lock nut. INSTALLATION
<> BALL BEARING REMOVAL MD998812

MD998813
MD998814
MD998801
MD998829
Ball bearing
MD998801
AK403521AB
1. Fit the ball bearing and stopper plate onto the rear
AK403518AB
output shaft.
1. Use special tool Remover (MD998801) to support 2. Use special tools to press in the ball bearing.
the ball bearing. • Remover (MD998801)
2. Use a press to push at a rear end of the rear • Installer cap (MD998812)
output shaft, and then remove the radial ball • Installer-100 (MD998813)
bearing. • Installer-200 (MD998814)
22C-71
>>B<< CLUTCH HUB INSTALLATION • Installer cap (MD998812)
MD998812
MD998813
MD998814
NOTE: .
The ball bearing may be fitted loosely on the
MD998821
shaft, so that installation is possible without using a
Installation
direction 2-4WD clutch hub press
MD998801 >>E<< LOCK NUT INSTALLTION
AK500686 AB
MB991013
1. Confirm the clutch hub installation direction, and
fit onto the rear output shaft.
2. Use special tools press in the clutch hub.
• Installer-200 (MD998814) AK500495AB
NOTE: . 1. Hold the drive sprocket in a soft-jaws vice.
The clutch hub may fit loosely on the shaft, so that 2. Shift the clutch sleeve to the drive sprocket side.
installation is possible without using a press. 3. Using special tool Power steering lock nut special
spanner (MB991013) tighten the lock nut to the
>>C<< CLUTCH SLEEVE INSTALLTION specified torque of 255 ± 10 N⋅m.
Installation
direction
AK500685AB AK403516
Check that the clutch sleeve is in the correct direc- 4. Stake the two places of the lock nut as shown in
tion for installation. illustration.
>>D<< BALL BEARING INSTALLATION

INSPECTION
MD998812 M1222010400036
MD998814
Ball bearing
MD998821
MD998801
AK403526AD
Use special tools to install the radial ball bearing. AK403556

REAR OUTPUT SHAFT <V5MB1-J-ND2, NEZ, PD2>
1. Push the synchronizer outer ring, synchronizer Limit: 0.3 mm

cone and the synchronizer inner ring to the drive 2. In case that value is out of limit, exchange as the
sprocket in combined state, and then measure the synchronizer ring set.
indicated dimension of the drive sprocket and
synchronizer outer ring.

M1222010300114
Apply gear oil to

all moving parts
1
4
AK101106 AC
Disassembly steps
>>B<< 1. Snap ring
3. Viscous coupling
4. Rear output shaft
22C-73
DISASSEMBLY SERVICE POINT Use special tools to install the ball bearing.

MD998917
AK101110 AF
Use special tool Bearing remover (MD998917) to

remove the ball bearing.
AK101112

>>A<< BALL BEARING INSTALLATION the snap ring groove of the rear output shaft.
2. Make sure that the rear output shaft bearing end
MD998812 play meets the standard value.
MD998814 Standard value: 0 − 0.08 mm
MD998823
AK101111 AC
TRANSFER DRIVE SHAFT <V5MB1-J-ND2, NEZ, PD2>
TRANSFER DRIVE SHAFT <V5MB1-J-ND2, NEZ, PD2>

M1222011200057
Apply gear oil to

all moving parts
AK503431AB
DIsassembly steps
<<A>> >>A<< 1. Ball bearing REASSEMBLY SERVICE POINT
DISASSEMBLY SERVICE POINT MD998812
<<A>> BALL BEARING REMOVAL MD998814
MD998830
MD998192
MD998801
AK503430 AB
Use special tools to install the inner race.

AK503429 AB
Use special tool Remover (MD998801) to remove • Counter shaft bearing puller (MD998192)
the ball bearing.
FRONT OUTPUT SHAFT
22C-75
FRONT OUTPUT SHAFT
M1222011500025
Apply gear oil to

all moving parts
1
2
AKX00425 AC

<<A>> >>B<< 1. Ball bearing >>A<< BALL BEARING INSTALLATION
3. Front output shaft
MD998812
MD998818
<<A>> BALL BEARING REMOVAL
MD998801
MD998801
MD998801
AK403462 AB
1. Use special tool Remover (MD998801) to support

the front output shaft.
2. Use special tools to install the ball bearing.
AK403522AB • Installer cap (MD998812)
the ball bearing.
2. Press the front output shaft with a press and
remove the ball bearings.
>>B<< BALL BEARING INSTALLATION

SPEEDOMETER GEAR

MD998812
MD998813
MD998818
MD998801
AK403523 AB

the front output shaft.
SPEEDOMETER GEAR
M1222003400175
Apply gear oil to

all moving parts
3
2
AKX00429 AC

1. O-ring 4. O-ring
>>A<< 2. Spring pin 5. Sleeve
3. Driven gear
SPEEDOMETER GEAR
22C-77
REASSEMBLY SERVICE POINT Drive the spring pin in, while making sure that slit
>>A<< SPRING PIN INSTALLATION does not face gear shaft.
Slit
Spring pin
AK403524 AB
23-1
GROUP 23
AUTOMATIC
TRANSMISSION
CONTENTS
AUTOMATIC TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . 23A
AUTOMATIC TRANSMISSION OVERHAUL <R4A5> . . . . . . . . 23B
AUTOMATIC TRANSMISSION OVERHAUL <V4A5> . . . . . . . . 23C
AUTOMATIC TRANSMISSION OVERHAUL <V5A5> . . . . . . . . 23D

23A-1
GROUP 23A
AUTOMATIC
TRANSMISSION
CONTENTS
GENERAL INFORMATION . . . . . . . . 23A-4 VALVE SYSTEM . . . . . . . . . . . . . . . . . . . . . 23A-53

CODE NO. P1774 UNDERDRIVE SOLENOID VALVE
SERVICE SPECIFICATION(S) . . . . . 23A-12 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-57
CODE NO. P1775 SECOND SOLENOID VALVE
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-58
LUBRICANT(S) . . . . . . . . . . . . . . . . . 23A-13
CODE NO. P1776 OVERDRIVE SOLENOID VALVE
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-60
SEALANT(S) AND ADHESIVE(S) . . . 23A-13
CODE NO. P1777 REDUCTION SOLENOID VALVE
SYSTEM <5A/T> . . . . . . . . . . . . . . . . . . . . . 23A-61
SPECIAL TOOL(S) . . . . . . . . . . . . . . 23A-14 CODE NO. P1778 TORQUE CONVERTER CLUTCH
SOLENOID VALVE SYSTEM . . . . . . . . . . . 23A-62
TROUBLESHOOTING . . . . . . . . . . . . 23A-16 CODE NO. P1779, 1780, 1781, 1782, 1783, 1784:
DIAGNOSIS TROUBLESHOOTING FLOW 23A-16 GEAR INCORRECT RATIO <4A/T> . . . . . . 23A-64
DIAGNOSIS FUNCTION. . . . . . . . . . . . . . . 23A-16 CODE NO. P1779, 1780, 1781, 1782, 1783, 1784:
ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . . 23A-17 GEAR INCORRECT RATIO <5A/T> . . . . . . 23A-65
SHIFT PATTERN . . . . . . . . . . . . . . . . . . . . 23A-26 CODE NO. P1786 TORQUE CONVERTER CLUTCH
SYSTEM (STUCK OFF) . . . . . . . . . . . . . . . 23A-67
DAMPER CLUTCH CONTROL. . . . . . . . . . 23A-28
CODE NO. P1787 DAMPER CLUTCH SYSTEM
DIAGNOSIS CODE CHART . . . . . . . . . . . . 23A-30
(STUCK ON) . . . . . . . . . . . . . . . . . . . . . . . . 23A-68
DIAGNOSIS CODE PROCEDURES . . . . . 23A-32
CODE NO. P1788 A/T CONTROL RELAY SYSTEM
CODE NO. P1763 A/T FLUID TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-69
SENSOR SYSTEM . . . . . . . . . . . . . . . . . . . 23A-32
CODE NO. P1790 BACK-UP LINE SYSTEM
CODE NO. P1764 A/T FLUID TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-73
SENSOR SYSTEM . . . . . . . . . . . . . . . . . . . 23A-34
CODE NO. P1901 CAN SIGNAL TIME-OUT (ENGINE-
CODE NO. P1766 INPUT SHAFT SPEED SENSOR ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-74
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-36
CODE NO. U1073 BUS OFF. . . . . . . . . . . . 23A-75
CODE NO. P1767 OUTPUT SHAFT SPEED SENSOR
CODE NO. U1100 ENGINE-ECU TIME-OUT
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-41
(RELATED TO ENGINE) . . . . . . . . . . . . . . . 23A-76
CODE NO. P1770 INHIBITOR SWITCH SYSTEM <4A/
CODE NO. U1102 ASC-ECU TIME-OUT . . 23A-77
T> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-46
CODE NO. U1109 ETACS-ECU TIME-OUT
...................................... 23A-78
T> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-49
CODE NO. U1120 FAILURE INFORMATION OF
ENGINE-ECU . . . . . . . . . . . . . . . . . . . . . . . 23A-79
T> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-51
CODE NO. U1190 THE NETWORK SYSTEM
DIAGNOSIS CODE OUTPUT PERMITTED SIGNAL
T> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-52
CAN NOT BE RECEIVED . . . . . . . . . . . . . . 23A-80
CODE NO. P1773 LOW-REVERSE SOLENOID
CHECK CHART FOR TROUBLE SYMPTOMS
23A-2
...................................... 23A-80 HIGH/LOW DETECTION SWITCH CONTINUITY

SYMPTOM PROCEDURES . . . . . . . . . . . . 23A-81 CHECK <EASY SELECT 4WD> . . . . . . . . . 23A-115
COMMUNICATION WITH THE M.U.T. IS NOT CENTRE DIFFERENTIAL LOCK DETECTION
POSSIBLE . . . . . . . . . . . . . . . . . . . . . . . . . 23A-81 SWITCH CHECK <SUPER SELECT 4WD> 23A-116
ENGINE DOES NOT CRANK . . . . . . . . . . . 23A-83 2WD/4WD DETECTION SWITCH CHECK <SUPER
SELECT 4WD> . . . . . . . . . . . . . . . . . . . . . . 23A-116
DOES NOT MOVE FORWARD . . . . . . . . . 23A-84
CENTRE DIFFERENTIAL LOCK OPERATION
DOES NOT MOVE BACKWARD . . . . . . . . 23A-85
DETECTION SWITCH CHECK <SUPER SELECT
DOES NOT MOVE (FORWARD OR BACKWARD) 4WD>. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-116
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-85
4WD OPERATION DETECTION SWITCH
ENGINE STALLS WHEN MOVING SELECTOR CONTINUITY CHECK <SUPER SELECT 4WD>
LEVER FROM "N" TO "D" OR "N" TO "R" . 23A-86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-116
SHIFT SHOCK WHEN SHIFTING FROM "N" TO "D" HIGH/LOW DETECTION SWITCH CONTINUITY
AND LONG DELAY. . . . . . . . . . . . . . . . . . . 23A-87 CHECK <SUPER SELECT 4WD> . . . . . . . 23A-117
SHIFT SHOCK WHEN SHIFTING FROM "N" TO "R" A/T CONTROL COMPONENT LAYOUT. . . 23A-117
AND LONG DELAY. . . . . . . . . . . . . . . . . . . 23A-88
A/T CONTROL COMPONENT CHECK. . . . 23A-117
SHIFT SHOCK WHEN SHIFTING FROM "N" TO "D,"
OVERDRIVE SWITCH CHECK. . . . . . . . . . 23A-117
"N" TO "R" AND LONG DELAY . . . . . . . . . 23A-89
INHIBITOR SWITCH CHECK . . . . . . . . . . . 23A-118
SHIFT SHOCK AND SLIPPING . . . . . . . . . 23A-90
A/T CONTROL RELAY CHECK . . . . . . . . . 23A-118
EARLY OR LATE SHIFTING IN ALL GEARS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-90 SOLENOID VALVE CHECK . . . . . . . . . . . . 23A-118
EARLY OR LATE SHIFTING IN SOME GEARS A/T FLUID TEMPERATURE SENSOR CHECK
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-119
NO DIAGNOSTIC TROUBLE CODES (DOES NOT 4LLc DETECTION SWITCH CONTINUITY CHECK
SHIFT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-91 <4WD> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-119
POOR ACCELERATION. . . . . . . . . . . . . . . 23A-92 TORQUE CONVERTER STALL CHECK . . 23A-120
VIBRATION. . . . . . . . . . . . . . . . . . . . . . . . . 23A-92 HYDRAULIC PRESSURE TESTS . . . . . . . 23A-120
OVERDRIVE SWITCH SYSTEM <4A/T> . . 23A-93 HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . 23A-128
4L OR 4LLC DETECTION SWITCH SYSTEM <4WD> LINE PRESSURE ADJUSTMENT. . . . . . . . 23A-129
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-96 SELECTOR LEVER OPERATION CHECK. 23A-130
SHIFT SWITCH ASSEMBLY SYSTEM <5A/T>
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-99 TRANSMISSION CONTROL <4A/T> . 23A-131
DATA LIST REFERENCE TABLE . . . . . . . 23A-103 TRANSMISSION CONTROL REMOVAL AND
ACTUATOR TEST REFERENCE TABLE. . 23A-106 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 23A-131
A/T-ECU TERMINAL VOLTAGE REFERENCE CHART INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 23A-132
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-106 SELECTOR LEVER ASSEMBLY DISASSEMBLY AND
OSCILLOSCOPE CHECK PROCEDURE . 23A-110 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 23A-132
ON-VEHICLE SERVICE. . . . . . . . . . . 23A-111 TRANSMISSION CONTROL <5A/T> . 23A-133

ESSENTIAL SERVICE . . . . . . . . . . . . . . . . 23A-111 TRANSMISSION CONTROL REMOVAL AND
A/T FLUID CHECK . . . . . . . . . . . . . . . . . . . 23A-111 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 23A-133
A/T FLUID CHANGE. . . . . . . . . . . . . . . . . . 23A-112 TRANSMISSION CONTROL INSPECTION 23A-134
FLUSHING COOLERS AND TUBES . . . . . 23A-113
INHIBITOR SWITCH CONTINUITY CHECK
TRANSMISSION ASSEMBLY . . . . . . 23A-135
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-113 TRANSMISSION ASSEMBLY REMOVAL AND
INSTALLATION <4A/T> . . . . . . . . . . . . . . . 23A-135
INHIBITOR SWITCH AND CONTROL CABLE
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 23A-114 TRANSMISSION ASSEMBLY REMOVAL AND
INSTALLATION <5A/T> . . . . . . . . . . . . . . . 23A-139
TRANSFER OIL CHECK <4WD> . . . . . . . . 23A-114
TRANSFER OIL REPLACEMENT <4WD>. 23A-115
A/T FLUID COOLER. . . . . . . . . . . . . . 23A-141
4WD DETECTION SWITCH CONTINUITY CHECK
<EASY SELECT 4WD> . . . . . . . . . . . . . . . 23A-115 A/T FLUID COOLER REMOVAL AND INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A-141
23A-3
A/T-ECU . . . . . . . . . . . . . . . . . . . . . . . 23A-143 4WD INDICATOR-ECU. . . . . . . . . . . . 23A-143

A/T-ECU REMOVAL AND INSTALLATION 23A-143 4WD INDICATOR ECU REMOVAL AND
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 23A-143
23A-4 AUTOMATIC TRANSMISSION
GENERAL
GENERAL
M1231100100675
OUTLINE OF CHANGE
V5A5A type automatic transmission (5A/T) has been
newly adopted as well as the R4A5A/V4A5A type
automatic transmission (4A/T). The items for 5A/T
vehicles that differ from 4A/T vehicles are as follows:
SPECIFICATIONS
Item Specification
Transmission model R4A5A V4A5A-J-LEEP V4A5A-J-LEEL V5A5A
V4A5A-J-LEEY
Engine model 4D5 (Except high power) 4D5 (High
power)
Torque Type 3-element, 1-stage, 2-phase type
converter Lock-up Provided
Stall torque 1.62
ratio
Transmission type 4 forward speeds, 1 reverse speed, fully automatic 5 forward
speeds, 1
reverse speed,
fully automatic
Transmission 1st 2.842 3.789
gear ratio 2nd 1.495 2.057
3rd 1.000 1.421
4th 0.731 1.000
5th − 0.731
Reverse 2.720 3.865
Drive system 2WD Easy select 4WD Super select 4WD
Transfer type - 2-speed, constant mesh
Transfer gear High - 1.000
ratio Low - 1.900
Clutch Multi-disk type × 3 sets Multi-disc type 4
sets
Brake Multi-disk type × 2 sets Multi-disc type 2
sets, band type 1
set
Manual control system P-R-N-D-2-L + Overdrive (6 positions) P-R-N-D (4
positions) +
Sport mode (up,
down)
Shift pattern control Electronic control
Hydraulic control during shifting Electronic control (Each clutch hydraulically independently controlled)
Lock-up clutch control Electronic control
AUTOMATIC TRANSMISSION
GENERAL
23A-5
SECTIONAL VIEW
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
34 33 32 31 30 29
AC608404 AB
1. Damper clutch 30. Front output shaft

2. Torque converter 31. Transfer counter gear
3. Oil pump 32. Output shaft
4. Overdrive clutch 33. Valve body
5. Reverse clutch 34. Input shaft
6. Overdrive planetary carrier
7. Second brake CONSTRUCTION AND OPERATON
8. Output planetary carrier
9. Low-reverse brake OD REV UD DIR RED
10. One-way clutch
11. Centre support
12. Underdrive clutch
13. Direct planetary carrier
14. Direct clutch
15. Reduction brake band
16. One-way clutch
17. Output shaft support
18. Parking gear
19. Transfer input gear 2ND LR OWC-L OWC-D
20. High/low clutch AC603484AB
21. Low speed gear
The gear train consists of four multi-disc clutches,
22. Differential lock hub
23. 2WD/4WD synchronizer
two multi-disc brakes, one band type brake, two one-
24. Drive sprocket way clutch, and three planetary gear sets. Each plan-
25. Chain etary gear set consists of a sun gear, carrier, pinion
26. Viscous coupling unit gears, and annulus gear.
27. Centre differential
GENERAL
OPERATING ELEMENTS AND THEIR FUNCTIONS

Operating element Code Function
Underdrive clutch UD Connects input shaft and underdrive sun gear
Reverse clutch REV Connects input shaft and reverse sun gear
Overdrive clutch OD Connects input shaft and overdrive planetary carrier
Direct clutch DIR Connects direct sun gear and direct planetary carrier
Low-reverse brake LR Locks low-reverse annulus gear and the overdrive planetary carrier
Second brake 2ND Locks reverse sun gear
Reduction brake RED Locks direct sun gear
One-way clutch (Direct OWC-D Restricts rotation direction of direct sun gear
clutch position)
One-way clutch (Low OWC-L Restricts rotation direction of low-reverse annulus gear
reverse brake position)
SELECTOR LEVER POSITIONS AND OPERATING ELEMENTS

Selector lever Operating element
position Under Reverse Over Direct Low- Second Reducti One- One-
drive clutch drive clutch reverse brake on way way
clutch (REV) clutch (DIR) brake (2ND) brake clutch clutch
(UD) (OD) (LR) (RED) (OWC- (OWC-
D) L)
P Parking × ×
R Reverse × × ×
N Neutral × ×
D or 1st × ×* × × ×
sport 2nd × × × ×
mode
3rd × × × ×
4th × × ×
5th × × ×
NOTE: .
• ×: Function element.
• *: Operates only when the vehicle is stationary (at approximately 10 km/h or less) and in the sport mode.
GENERAL
23A-7
POWER FLOW
1ST GEAR
Output planetary carrier
Low-reverse brake Underdrive Direct annulus gear
One-way
clutch clutch Reduction brake
One-way clutch
Input shaft Direct planetary

carrier
Direct sun gear

Reverse sun Overdrive Output Underdrive Direct pinion
gear pinion pinion sun gear
AC603606AB
When the 1st gear is selected, the underdrive clutch, locked by the one-way clutch, the direct planetary
the one-way clutch (OWC-L), the low-reverse brake*, carrier rotates anti-clockwise with the fashion that the
the reduction brake and the one-way clutch (OWC- direct pinion revolves around the direct sun gear to
D) are participating. The driving force from the input obtain reduction ratio of the first gear. Since the out-
shaft is transmitted to the underdrive sun gear via the put planetary carrier is connected to the output annu-
underdrive clutch. The driving force transmitted to lus gear, the overdrive pinion gear is driven at the
the underdrive sun gear via the output pinion turns same time. However, since the overdrive planetary
the low reverse annulus gear clockwise and at the carrier is locked by the one-way clutch (OWC-L) and
same time turns the output planetary carrier anti- the reverse sun gear is free to rotate, it runs idle and
clockwise with the fashion that the output pinion has no effect on the rotation of the output planetary
revolves around the underdrive sun gear. However, carrier.
since the one-way clutch (OWC-L) and the low- NOTE: *: The low-reverse brake is activated only
reverse brake* are engaged at this time, the low- when the vehicle is stationary (10 km/h or less) and
reverse annulus gear is locked and the output plane- in the sport mode.
tary carrier only rotates anti-clockwise. This driving
force turns the direct pinion anti-clockwise via the
direct annulus gear. Since the direct sun gear is
2ND GEAR
Output planetary Direct annulus gear
Low-reverse carrier
Second brake annulus gear Underdrive Reduction brake
clutch
One-way clutch
Direct planetary
Input shaft
carrier
Direct sun gear

Reverse sun gear Overdrive Output Underdrive Direct
pinion pinion sun gear pinion
Overdrive planetary Output annulus gear

carrier
AC603607AB
GENERAL
When the 2nd gear is selected, the underdrive reverse annulus gear also rotates anti-clockwise.
clutch, the second brake, the reduction brake and the This rotation of the low-reverse annulus gear is
one-way clutch (OWC-D) are participating. The sec- transmitted to the direct annulus gear via the output
ond brake is operated under the first gear condition, pinion, however, since the elements of the direct
the reverse sun gear is locked and the driving force planetary gear are the same as that of the first gear,
from the output annulus gear turns the overdrive rotation amount of the low-reverse annulus gear is
planetary carrier anti-clockwise with the fashion that added to the rotation of the output planetary carrier to
the overdrive pinion revolves around the reverse sun obtain the reduction ratio of the second gear.
gear. Since the overdrive planetary carrier is con-
nected with the low-reverse annulus gear, the low-
3RD GEAR
Direct planetary Direct annulus gear
Low-reverse carrier
annulus gear Underdrive Reduction brake
Overdrive clutch
clutch
One-way clutch
Direct planetary
Input shaft carrier
Direct sun gear

Overdrive planetary carrier Underdrive Direct pinion
sun gear
AC603608AB
When the 3rd gear is selected, the underdrive clutch, dition, the planetary gear set is locked and rotates as
the overdrive clutch, the reduction brake and the one body to transmit the driving force to the direct
one-way clutch (OWC-D) are participating. Since the annulus gear. The operation of the direct planetary
overdrive clutch connects the input shaft with the carrier elements is the same as the first gear, there-
overdrive planetary carrier and the low reverse annu- fore, the reduction ratio of the third gear is obtained
lus gear, the rotation speed of the underdrive sun by the configuration that the planetary gear set
gear that is connected with the input shaft by the rotates as one body under locked condition.
underdrive clutch and the rotation speed of the low-
reverse annulus gear become equal. Under this con-
4TH GEAR
Output planetary
Second brake carrier Underdrive clutch
Overdrive clutch
Direct annulus gear
Direct planetary
Input shaft carrier
Direct sun gear
Reverse sun gear Direct clutch

Underdrive sun gear Direct
pinion
AC603609AB
GENERAL
23A-9
When the 4th gear is selected, the underdrive clutch, nected with the output planetary carrier, via the direct
the overdrive clutch and the direct clutch are partici- pinion, to the direct sun gear and turns it clockwise.
pating. The operating condition of input shaft ele- On the other hand, since the direct sun gear is con-
ments is the same as that of the third gear, where the nected with the direct planetary carrier by the direct
planetary gear set is locked to rotate as one body. clutch, they rotate anti-clockwise as one body to
The driving force input to the output planetary carrier obtain the reduction ratio of the fourth gear.
is transmitted from the direct annulus gear con-
5TH GEAR
Reverse clutch Direct planetary
Second
carrier
brake
Overdrive clutch
Direct annulus gear
Direct planetary
Input shaft carrier
Reverse sun gear
Direct clutch
Overdrive planetary Overdrive
Output annulus gear
carrier pinion
AC603610AB
When the 5th gear is selected, the overdrive clutch, mitted to the output annulus gear. This driving force
the direct clutch and the second brake are participat- is then transmitted to the output planetary carrier that
ing. The driving force of the input shaft is transmitted is connected to the overdrive planetary carrier and
to the overdrive planetary carrier via the reverse the direct annulus gear. Since the operating ele-
clutch. On the other hand, since the reverse sun gear ments of the direct planetary carrier are the same as
is locked by the second brake, rotation amount of the that of the fourth gear, the reduction ratio of the fifth
overdrive pinion that revolves around the reverse gear is obtained by the revolution of the overdrive
sun gear is added to the rotation of the overdrive pinion.
planetary carrier and the resultant rotation is trans-
REVERSE
Direct annulus gear
Overdrive planetary carrier
Reverse clutch Low-reverse brake Reduction brake
Direct planetary
Input shaft
carrier
Direct sun gear

Reverse sun gear Output pinion Underdrive sun gear
Overdrive
pinion
Output annulus gear
AC603611AB
GENERAL
When the reverse gear is selected, the reverse sun gear is locked by the reduction brake, rotation
clutch, the low-reverse brake and the reduction amount of the direct pinion that revolves around the
brake are participation. The driving force of the input direct sun gear is added to rotate the direct planetary
shaft is transmitted to the reverse sun gear via the carrier clockwise. Thus the reduction ratio of reverse
reverse clutch. On the other hand, since the over- gear is obtained. At this time, the output pinion is
drive planetary carrier is locked by the low-reverse driven by the output planetary carrier, however, since
brake, the driving force of the reverse sun gear is the underdrive sun gear is free to rotate, it runs idle
transmitted to the output annulus gear via the over- and has no effect on the rotation of the output plane-
drive pinion as the clockwise rotating force. This driv- tary carrier.
ing force is then transmitted to the direct annulus
gear via the output planetary carrier. Since the direct
PARKING and NEUTRAL
Overdrive clutch
Low-reverse brake
Reduction brake
Second brake
Underdrive clutch
Input shaft
Direct clutch
AC603612AB
In parking and neutral, all of the clutches are disen-

gaged and driving force from the input shaft is not
transmitted to the planetary carrier. To enable a quick
shift to 1st gear or reverse, the low-reverse brake
and reduction brake is operational.
GENERAL
23A-11
Electronic control system
SYSTEM CONFIGURATION DIAGRAM
Input signals Output signals
Ignition switch A/T control relay

A/T-ECU
Input shaft speed sensor Damper clutch control (DCC)

solenoid valve
Output shaft speed sensor

Low-reverse (LR) / Direct (DIR)
solenoid valve
A/T fluid temperature sensor
Second (2ND) solenoid valve
Inhibitor switch
Underdrive (UD) solenoid valve
4LLc detection switch

Overdrive (OD) solenoid valve
Select switch
Reduction (RED) solenoid valve
Up shift switch
A/T fluid temperature warning lamp
Down shift switch Shift indicator lamp
Fail-safe condition indicator

(flashing N range lamp)
CAN communication
M.U.T.-III
AC903575 AD
SENSORS AND ACTUATORS

Item Function
Sensor Input shaft speed sensor Detects when input shaft speed
Output shaft speed sensor Detects when output shaft speed
A/T fluid temperature sensor Detects A/T fluid temperature
Inhibitor switch Detects selector lever position
4LLc detection switch Detects that 4LLc is selected
Select switch Detects that sport mode is selected
Up shift switch Detects up-shift request of sport mode
Down shift switch Detects down-shift request of sport mode
Item Function
Actuator A/T control relay Turns solenoid valve power supply circuit ON/OFF
DCC solenoid valve Regulates hydraulic pressure to damper clutch control
valve
LR/DIR solenoid valve Regulates hydraulic pressure to pressure control valve
2ND solenoid valve (for gear shift control)
UD solenoid valve
OD solenoid valve
RED solenoid valve
N range lamp Indicates that fail-safe is active and shows a diagnosis
code
Shift indicator lamp Indicates present shift stage by lamp in combination
meter
A/T fluid temperature warning lamp Gives a warning about A/T fluid temperature
SOLENOID VALVE OPERATION

In each gear, the solenoid valves are controlled as
appropriate by instructions from the A/T-ECU.
Gear LR/DIR 2ND UD OD RED
1st OFF*/ON <LR> ON OFF ON OFF
2nd ON <LR> OFF OFF ON OFF
3rd ON <DIR> ON OFF OFF OFF
4th OFF <DIR> ON OFF OFF ON
5th OFF <DIR> OFF ON OFF ON
Reverse OFF <LR> ON ON ON OFF
Neutral/Parking OFF <LR> ON ON ON OFF
NOTE: *Only when in the sport mode and the vehicle
is stationary (approx. 10 km/h or less).
M1231100300259
Item Standard value

A/T fluid temperature sensor resistance kΩ At 0°C 16.7 − 20.5
At 20°C 7.3 − 8.9
At 40°C 3.4 − 4.2
At 60°C 1.9 − 2.2
At 80°C 1.0 − 1.2
At 100°C 0.57 − 0.69
Damper clutch control (DCC) solenoid valve coil resistance (at 20°C) Ω 2.7 − 3.4
Low & reverse (LR) solenoid valve coil resistance (at 20°C) Ω 2.7 − 3.4
Second (2ND) solenoid valve coil resistance (at 20°C) Ω 2.7 − 3.4
Underdrive (UD) solenoid valve coil resistance (at 20°C) Ω 2.7 − 3.4
LUBRICANTS
23A-13
Item Standard value
Overdrive (OD) solenoid valve coil resistance (at 20°C) Ω 2.7 − 3.4
Reduction (RED) solenoid valve coil resistance (at 20°C) Ω <5A/T> 2.7 − 3.4
Stall speed r/min 2,200 − 2,700
Line pressure MPa 1.01 − 1.05
LUBRICANTS
M1231100400171
Item Specified lubricants Capacity L

A/T fluid DIA QUEEN ATF SP III 9.7
Transfer oil Gear oil API classification GL-3 SAE 75W-85 or API 2.5
classification GL-4 SAE 75W-85
SEALANTS
M1231100500145

Transfer control lever assembly 3M ATD Part No.8660 or equivalent
SPECIAL TOOLS
SPECIAL TOOLS
M1231100600368

MB991955 M.U.T.-III sub-assembly CAUTION
a
a. MB991824 a. Vehicle For vehicles with CAN
b. MB991827 Communication communication, use M.U.T.-III
c. MB991910 Interface (V. C. I.) main harness A to send
MB991824 d. MB991911 b. M.U.T.-III USB cable simulated vehicle speed. If you
e. MB991825 c. M.U.T.-III main connect M.U.T.-III main harness B
b
f. MB991826 harness A (Vehicles instead, the CAN communication
with CAN does not function correctly.
communication Checking A/T diagnosis trouble
MB991827 system) codes
c d. M.U.T.-III main
harness B (Vehicles
without CAN
communication
MB991910
system)
d e. M.U.T.-III measure
adapter
DO NOT USE
f. M.U.T.-III trigger
harness
MB991911
MB991825
MB991826
MB991955
MB992006 Extra fine probe Continuity check and voltage

measurement at harness wire or
connector
MB992006
SPECIAL TOOLS
23A-15
MD998330 Oil pressure gauge (3.0 Hydraulic pressure measurement
(including MPa)
MD998331)
AC103525
MD998332 Adapter Oil pressure gauge connection
MD998900 Joint
TROUBLESHOOTING
TROUBLESHOOTING
DIAGNOSIS TROUBLESHOOTING FLOW
M1231104000153
Ask about trouble symptoms
NG
Check the A/T fluid Replace the A/T fluid
OK
Check the trouble symptoms

Communicationwith
Communication withthe
the
M.U.T.-III
MUT-II not not possible
possible
Reading of a diagnosis code To INSPECTION CHART FOR
TROUBLE SYMPTOMS
Diagnosis code output No diagnosis code output
exists
Erase of a diagnosis code Check the trouble symptoms
Perform switch,
Inhibitor the repair
TPS check
Abnormality exists (no diagnosis code output)

Road test
Abnormality exists No abnormality
(diagnostic trouble
code output) Recheck diagnosis codes
Diagnosis code output No diagnosis code output
exists
To INSPECTION CHART FOR To INSPECTION CHART FOR

DIAGNOSIS CODES TROUBLE SYMPTOMS
Check for the cause

Found Not found
Repair INTERMITTENT MALFUNCTIONS

(Refer to GROUP 00 - Points to NG
Note for Intermittent Malfunction)
OK
NG OK
Confirmation test (road test) Completed
AC212495AD
DIAGNOSTIC FUNCTION If there is a problem with any of the A/T system, the
M1231103300151 selector lever position indicator lamp will flash at a
SELECTOR LEVER POSITION INDICATOR rate of approximately once per second.
LAMP SYSTEM If the selector lever position indicator lamp is flashing
at a rate of approximately once per second, check
the diagnosis output.
Selector lever position indicator lamp flashing
item
• Input shaft speed sensor system
• Output shaft speed sensor system
• Solenoid valves system
• Non-synchronization at various shift ranges
• A/T control relay system
AC504108AB
TROUBLESHOOTING
23A-17
NOTE: If the A/T fluid temperature warning lamp is METHOD OF ERASING THE DIAGNOSIS
illuminating, the A/T fluid temperature is high. (It illu- CODE
minates when the fluid is approximately 135°C or
Use the M.U.T.-III to erase the diagnosis code.
more and goes off when the fluid is approximately
(Refer to GROUP 00 − How to Use Troubleshooting/
115°C or less.)
Inspection Service Points .)
METHOD OF READING THE DIAGNOSIS ROAD TEST
CODE M1231100800500
Use the M.U.T.-III to read the diagnosis code. (Refer

to GROUP 00 − How to Use Troubleshooting/Inspec-
tion Service Points .)
Proced Pre-test/ Test/operation Judgment value Check Diagnosi Inspection
ure operation item s code procedure if
conditions No. there is an
abnormality
1 Ignition switch: Ignition switch Data List No.8 A/T P1788 A/T control
LOCK (OFF) (1) ON (1) System voltage control relay system
position [V] relay
TROUBLESHOOTING

abnormality
2 Ignition switch: Selector lever Data List No.34 Inhibitor P1770, Inhibitor switch
ON position <4A/T> (1) P switch P1771 system
Engine: (1) P (2) R
Stopped (2) R (3) N
Selector lever (3) N (4) D
position: P (4) D (5) 2
(5) 2 (6) L
(6) L
Selector lever Data List No.34
position <5A/T> (1) P
(1) P (2) R
(2) R (3) N
(3) N (4) D
(4) D
Selector lever Data List No.27 Select − Sport mode
position <5A/T> (1) OFF switch switch system
(1) D (2) ON
(2) Select the sport (3) ON
mode (4) ON
(3) Upshift and hold Data List No.28 Upshift
the selector lever (1) OFF switch
in that position (2) OFF
(2nd gear) (3) ON
(4) Downshift and (4) OFF
hold the selector
lever in that Data List No.29 Downshift
position (1st (1) OFF switch
gear) (2) OFF
(3) OFF
(4) ON
Shift indicator lamp Shift
(1) Only D indicator
illuminates lamp
(2) Only 1
illuminates
(3) Only 2
illuminates
(4) Only 1
illuminates
Overdrive switch Data List No.26 Overdrive − Overdrive
<4A/T> (1) ON switch switch system
(1) ON (2) OFF
(2) OFF
Accelerator pedal Data List No.35 APS − Refer to
(1) Fully closed (1) 0% GROUP 13A −
(2) Depressed (2) Gradually Troubleshootin
(3) Fully opened increases from (1) g.
(3) 100%
Transfer shift lever Data List No.31 4LLc − 4LLc switch
position (1) OFF switch system
TROUBLESHOOTING
23A-19
abnormality
3 Ignition switch: Starting test at P or Starting should be Starting − Starting not
START N position possible possible/ possible
not
possible
4 Driving after Drive for 15 minutes Data List No.7 A/T fluid P1763, A/T fluid
engine has or more until the A/ Gradually rises to 70 temperatu P1764 temperature
warmed up T fluid temperature − 80°C re sensor sensor system
rises to 70 − 80°C.
5 Engine: idle A/C switch Data List No.21 A/C − A/C
Selector lever (1) ON (1) ON compress compressor
position: N (2) OFF (2) OFF or relay relay system
Accelerator pedal Data List No.1 Crank − Refer to
(1) Fully closed (1) The engine angle GROUP 13A −
(2) Depressed speed displayed sensor Troubleshootin
on the tachometer g.
is identical to the
engine speed
displayed on
M.U.T.-III.
(2) Gradually
increases from (1)
Selector lever No abnormal shock Malfunctio − Engine stalls
position during shifting n when during shifting
(1) N to D Within 2 seconds of starting − N to D shocks,
(2) N to R time lag off large time lag
− N to R shocks,
large time lag
− N to D, N to R
shocks, large
time lag
Driving − Does not move
not forward
possible − Does not
reverse
− Does not move
(forward or
reverse)
TROUBLESHOOTING

abnormality
6 Selector lever Selector lever Data List No.11 Shift − −
<4A/T> position: D position and vehicle (2) 1st position
(Must be done speed (Each (3) 2nd
on a level and condition should be (4) 3rd
straight road.) maintained for 10 (5) 4th
seconds or more.) Data List No.12 LR P1773 LR solenoid
(1) Engine idling in (2) 0% solenoid valve system
1st gear (vehicle (3) 100% valve duty
stopped) (4) 100% %
(2) Driving at (5) 100%
constant speed
of 10 km/h in 1st Data List No.13 UD P1774 UD solenoid
gear (2) 0% solenoid valve system
(3) Driving at (3) 0% valve duty
constant speed (4) 0% %
of 20 km/h in 2nd (5) 100%
gear Data List No.14 2NDsolen P1775 2ND solenoid
(4) Driving at (2) 100% oid valve valve system
constant speed (3) 0% duty %
of 30 km/h in 3rd (4) 100%
gear (5) 0%
(5) Driving at Data List No.15 OD P1776 OD solenoid
constant speed (2) 100% solenoid valve system
of 40 km/h in 4th (3) 100% valve duty
gear (4) 0% %
(5) 0%
Data List No.5 Input P1766 Input shaft
(4) 1,100 − 1,400 r/ shaft speed sensor
min speed system
sensor
Data List No.6 Output P1767 Output shaft
min speed system
sensor
TROUBLESHOOTING
23A-21
abnormality
6 Selector lever Selector lever Data List No.11 Shift − −
<5A/T> position: Sport position and vehicle (2) 1st position
mode (Must speed (Each (3) 2nd
be done on a condition should be (4) 3rd
level and maintained for 10 (5) 4th
straight road.) seconds or more.) (6) 5th
(1) Engine idling in Data List No.12 LR P1773 LR solenoid
1st gear (vehicle (2) 0% solenoid valve system
stopped) (3) 100% valve duty
(2) Driving at (4) 100% %
constant speed (5) 0%
of 10 km/h in 1st (6) 0%
gear
(3) Driving at Data List No.13 UD P1774 UD solenoid
of 20 km/h in 2nd (3) 0% valve duty
gear (4) 0% %
(4) Driving at (5) 0%
of 40 km/h in 3rd Data List No.14 2NDsolen P1775 2ND solenoid
gear (2) 100% oid valve valve system
(5) Driving at (3) 0% duty %
of 60 km/h in 4th (5) 100%
gear (6) 0%
(6) Driving at Data List No.15 OD P1776 OD solenoid
of 70 km/h in 5th (3) 100% valve duty
gear (4) 0% %
(5) 0%
(6) 0%
Data List No.16 RED P1777 Reduction
(2) 0% solenoid solenoid valve
(3) 0% valve duty system
(4) 0% %
(5) 100%
(6) 100%
Data List No.5 Input P1766 Input shaft
min speed system
sensor
Data List No.6 Output P1767 Output shaft
min speed system
sensor
TROUBLESHOOTING

abnormality
7 Selector lever Selector lever Data List No.17 DCC P1778, DCC solenoid
position: D position and vehicle (1) 70 − 99.6% solenoid P1786, valve system
(Must be done speed (2) 70 − 99.6% to valve duty P1787
on a level and (1) Driving at 0% %
straight road.) constant speed Data List No.10 DCC
90 km/h in 3rd (1) −10 to 10 r/min amount of
gear <4A/T> or (2) The value slippage
100 km/h in 4th changes from (1)
gear <5A/T>
(2) Driving at 90
km/h in 3rd gear
<4A/T> or 100
km/h in 4th gear
<5A/T>, then
fully close the
accelerator pedal
TROUBLESHOOTING
23A-23
abnormality
8 Selector lever (1) Accelerate to Data List No.35, 6 Problem − Shocks, engine
<4A/T> position: D 4th range at an The shifting points during racing
(Must be done APS output of correspond with the shifting
on a level and 1.5 V (opening M.U.T.-III display and Incorrect − All points
straight road) angle 20%). the APS voltage shift
(2) Slowly (opening angle) and − Some points
points
decelerate and output shaft speed,
stop. which are described No − No diagnosis
(3) Accelerate to in the shift pattern. shifting codes
4th range at an P1766 Input shaft
APS output of speed sensor
2.5 V (opening system
angle 50%). P1767 Output shaft
speed sensor
system
(1) Accelerate from Data List No.11 No P1773 LR solenoid
1st gear to 4th (1) 1st → 2nd → 3rd shifting valve system
gear. → 4th from 1st P1775 2ND solenoid
(2) Downshift to 3rd (2) 4th → 3rd to 2nd, or valve system
gear at speed of (3) 3rd → 2nd no shifting
50 km/h in 4th (4) 2nd → 1st from 2nd P1779 1ST without
gear. to 1st completion of
(3) Downshift to shifting
2nd gear at P1780 2ND without
speed of 30 km/h completion of
in 3rd gear. shifting
(4) Downshift to 1st No P1775 2ND solenoid
gear at speed of shifting valve system
20 km/h in 2nd from 2nd P1776 OD solenoid
gear. to 3rd, or valve system
no shifting
from 3rd P1780 2ND without
to 2nd completion of
shifting
P1781 3RD without
completion of
shifting
No P1774 UD solenoid
shifting valve system
from 3rd P1775 2ND solenoid
to 4th, or valve system
no shifting
from 4th P1781 3RD without
to 3rd completion of
shifting
P1782 4TH without
completion of
shifting
TROUBLESHOOTING

abnormality
8 Suspends the (1) Accelerate to Data List No.2, 6 Problem − Shocks, engine
<5A/T> INVECS-II 5th range at an The shifting points during racing
function using APS output of correspond with the shifting
M.U.T.-III 1.5 V (opening M.U.T.-III display and Incorrect − All points
Selector lever angle 20%). the APS voltage shift
position: D (2) Slowly (opening angle) and − Some points
points
(Must be done decelerate and output shaft speed,
on a level and stop. which are described No − No diagnosis
straight road) (3) Accelerate to in the shift pattern. shifting codes
5th range at an P1766 Input shaft
APS output of speed sensor
2.5 V (opening system
angle 50%). P1767 Output shaft
speed sensor
system
TROUBLESHOOTING
23A-25
abnormality
8 Suspends the (1) Accelerate from Data List No.11 No P1773 LR solenoid
<5A/T> INVECS-II 1st gear to 5th (1) 1st → 2nd → 3rd shifting valve system
function using gear. → 4th → 5th from 1st P1775 2ND solenoid
M.U.T.-III (2) Downshift to 4th (2) 5th → 4th to 2nd, or valve system
Selector lever gear at speed of (3) 4th → 3rd no shifting
position: D 60 km/h in 5th (4) 3rd → 2nd from 2nd P1779 1ST without
(Must be done gear. to 1st completion of
(5) 2nd → 1st
on a level and (3) Downshift to 3rd shifting
straight road) gear at speed of P1780 2ND without
50 km/h in 4th completion of
gear. shifting
(4) Downshift to No P1775 2ND solenoid
2nd gear at shifting valve system
speed of 30 km/h from 2nd P1776 OD solenoid
in 3rd gear. to 3rd, or valve system
(5) Downshift to 1st no shifting
gear at speed of from 3rd P1780 2ND without
20 km/h in 2nd to 2nd completion of
gear. shifting
P1781 3RD without
completion of
shifting
No P1773 LR solenoid
from 3rd P1777 RED solenoid
no shifting
from 4th P1781 3RD without
to 3rd completion of
shifting
P1782 4TH without
completion of
shifting
No P1774 UD solenoid
from 4th P1775 2ND solenoid
no shifting
from 5th P1782 4TH without
to 4th completion of
shifting
P1783 5TH without
completion of
shifting
TROUBLESHOOTING

abnormality
9 Selector lever Selector lever The ration of data list No P1766 Input shaft
position: N position and vehicle No.5 and No.6 shifting speed sensor
(Must be done speed should be the same system
on a level and (1) Select R and as the transmission P1767 Output shaft
straight road) drive at 10 km/h ratio when reversing speed sensor
system
P1784 Reverse
without
completion of
shifting
SHIFT PATTERN
M1231126500714
UPSHIFT PATTERN <4A/T>
Throttle
opening (%)
100
1 2 2 3 3 4
80
60
40
20
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000

Output shaft speed (r/min)
0 50 100 150 200

Vehicle speed (km/h)
ACB01830AB
TROUBLESHOOTING
23A-27
UPSHIFT PATTERN <5A/T>
Throttle
opening (%)
100
1 2 2 3 3 4 4 5
80
60
40
20
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000

0 50 100 150 200

AC902176 AB
DOWNSHIFT PATTERN <4A/T>
Throttle
opening (%)
100
1 2 2 3 3 4
80
60
40
2 3 (L, 2) 3 4 (L, 2, D (OD-OFF))
1 2 (L)
20
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000

0 50 100 150 200

ACB01831AB
TROUBLESHOOTING
DOWNSHIFT PATTERN <5A/T>
Throttle
opening (%)
100
1 2 2 3 3 4 4 5
80
1 2 4 5
60 3 4
(Sport mode)
(Sport mode) (Sport mode)
40 2 3
(Sport mode)
20
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000

0 50 100 150 200

AC902177AB
DAMPER CLUTCH CONTROL

M1231126600603
In 4th range <4A/T>
Throttle
opening (%)
100
80 Damper clutch Damper clutch engaged

disengaged
60
Partial lock-up
40 zone Deceleration
lock-up zone
20
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000

0 50 100 150 200

ACB01832AC
TROUBLESHOOTING
23A-29
In 3rd range <4A/T>
Throttle
opening (%)
100
80 Damper clutch Damper clutch engaged

disengaged
60
40 Deceleration
lock-up zone
20
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000

0 50 100 150 200

ACB01833AB
In 5th range <5A/T>
Throttle
opening (%)
100
Damper clutch Damper clutch engaged
80 disengaged
60
Partial lock-up
zone Deceleration
40
lock-up zone
20
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000

0 50 100 150 200

ACB01834AB
TROUBLESHOOTING
In 4th range <5A/T>
Throttle
opening (%)
100
Damper clutch Damper clutch engaged

80
disengaged
60
40 Deceleration
lock-up zone
20
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000

0 50 100 150 200

ACB01835AB
DIAGNOSIS CODE CHART

M1231126700257
Diagnosis code No. Diagnosis item Reference

M.U.T.-III General page
scan tool
P1606 − EEPROM malfunction (A/T-ECU) Replace the
A/T-ECU
P1763 P0710 A/T fluid temperature sensor system P.23A-32
P1764 P.23A-34
P1766 P0715 Input shaft speed sensor system P.23A-36
P1767 P0720 Output shaft speed sensor system P.23A-41
P1770 P0705 Inhibitor switch system P.23A-46
<4A/T>
P.23A-49
<5A/T>
P1771 P.23A-51
<4A/T>
P.23A-52
<5A/T>
P1773 P0750 LR solenoid valve system P.23A-53
P1774 P0755 UD solenoid valve system P.23A-57
P1775 P0760 2ND solenoid valve system P.23A-58
P1776 P0765 OD solenoid valve system P.23A-60
P1777 P0770 RED solenoid valve system <5A/T> P.23A-61
P1778 P0740 DCC solenoid valve system P.23A-62
TROUBLESHOOTING
23A-31
Diagnosis code No. Diagnosis item Reference
M.U.T.-III General page
scan tool
P1779 − 1st gear ratio does not meet the specification P.23A-64
P1780 − 2nd gear ratio does not meet the specification <4A/T>
P.23A-65
P1781 − 3rd gear ratio does not meet the specification <5A/T>
P1782 − 4th gear ratio does not meet the specification
P1783 − 5th gear incorrect ratio <5A/T>
P1784 − Reverse gear ratio does not meet the specification
P1786 − DCC solenoid valve system P.23A-67
P1787 − P.23A-68
P1788 P1751 A/T control relay system P.23A-69
P1790 − Back up line system P.23A-73
P1901 − Can signal time-out (Engine-ECU) P.23A-74
U1073 − Bus Off P.23A-75
U1100* − Engine-ECU time-out (related to engine) P.23A-76
U1102* − ASTC-ECU time-out P.23A-77
U1109* − ETACS-ECU time-out P.23A-78
U1120* − Failure information of Engine-ECU P.23A-79
U1190* − Can’t receive fault detection control signal P.23A-80
NOTE: *: When the diagnosis code related to the
CAN communication error is set, check the vehicle
equipment. If this system is not equipped, the diag-
nosis code is always set, but it is not abnormal.
TROUBLESHOOTING
Code No.P1763 (P0710) A/T fluid temperature sensor system
A/T Fluid Temperature Sensor System Circuit
A/T CONTROL
A/T SOLENOID
FLUID VALVE ASSEMBLY
TEMPERATURE
SENSOR
A/T-ECU
Wire colour code

BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet PU : Purple
AC903903
Connector: B-10
Connector: B-15
B-15 (B)
B-10 (B)
AC510056AD
AC510056AB
Connector: B-11
Harness side
B-11 (B)
AC510056AC
TROUBLESHOOTING
23A-33
Connector: C-12 <LHD> STEP 2. Measure the resistance at A/T control

solenoid valve assembly connector B-15.
Disconnect the connector, and measure the resist-
A/T-ECU
<RHD>
ance between terminal 1 and 2 at the sensor side.
OK:
• 16.7 − 20.5 kΩ (at 0°C)
• 7.3 − 8.9 kΩ (at 20°C)
• 3.4 − 4.2 kΩ (at 40°C)
• 1.9 − 2.2 kΩ (at 60°C)
• 1.0 − 1.2 kΩ (at 80°C)
A/T-ECU
• 0.57 − 0.69 kΩ (at 100°C)
YES : Go to Step 3.
C-12 NO : Replace the A/T fluid temperature sensor.
Harness side
STEP 3. Connector check: B-15 A/T control
solenoid valve assembly
Check for the contact with terminals.
AC510057AB
YES : Go to Step 4.
OPERATION NO : Repair the defective connector.
• The A/T fluid temperature sensor converts the A/
T fluid temperature to voltage, and send the infor- STEP 4. Measure the resistance at A/T control
mation to the A/T-ECU. solenoid valve assembly connector B-15.
• The A/T fluid temperature rises, the resistance Disconnect the connector, and measure the resist-
decreases. Thus, the sensor output voltage ance between terminal 2 and earth at the wiring har-
depends on the A/T fluid temperature. As the A/T ness side.
fluid temperature rises, the output voltage will
OK: Continuity (Less than 2 Ω)
decrease.
DIAGNOSIS CODE SET CONDITIONS YES : Go to Step 9.
If the A/T fluid temperature sensor output voltage is NO : Go to Step 5.
4.5 volts or more after driving for 10 minutes or more,
there is an open circuit in the A/T fluid temperature
STEP 5. Measure the voltage at A/T-ECU
sensor and diagnosis code No.P1763 (P0710) is set.
connector C-12.
PROBABLE CAUSES (1) Connect A/T control solenoid valve assembly
• Malfunction of the A/T fluid temperature sensor connector B-15.
• Damaged harness wires and connectors (2) Turn the ignition switch to the ON position.
• Malfunction of the A/T-ECU (3) Measure the voltage between A/T-ECU
DIAGNOSIS PROCEDURE OK: 0.5 V or less
STEP 1. M.U.T.-III data list YES : Go to Step 8.
Item 07: A/T fluid temperature sensor (Refer to Data NO : Go to Step 6.
List Table P.23A-103).
Q: Is the check result normal? STEP 6. Connector check: C-12 A/T-ECU
YES : Intermittent malfunction (Refer to GROUP connector
00 − How to Cope with Intermittent Check for the contact with terminals.
Malfunction ). Q: Is the check result normal?
NO : Go to Step 2. YES : Go to Step 7.
NO : Repair the defective connector.
TROUBLESHOOTING
STEP 7. M.U.T.-III data list connector C-12 terminal No.44 and earth.
Item 07: A/T fluid temperature sensor (Refer to Data OK:
List Table P.23A-103.) • 3.8 − 4.0 V (at 20°C)
• 3.2 − 3.4 V (at 40°C)
• 1.7 − 1.9 V (at 80°C)
00 − How to Cope with Intermittent Q: Is the check result normal?
Malfunction ). YES : Go to Step 12.
NO : Replace the A/T-ECU. NO : Go to Step 11.
STEP 8. Connector check: B-11 intermediate STEP 11. Connector check: C-12 A/T-ECU
connector, C-12 A/T-ECU connector connector
Check for the contact with terminals. Check for the contact with terminals.
NO : Repair the defective connector. NO : Repair the defective connector.
STEP 9. Measure the voltage at A/T control STEP 12. Connector check: B-10 intermediate
solenoid valve assembly connector B-15. connector, C-12 A/T-ECU connector
(1) Disconnect the connector, and measure the Check for the contact with terminals.
voltage between terminal 1 and earth at the Q: Is the check result normal?
wiring harness side. YES : Go to Step 13.
(2) Turn the ignition switch to the ON position. NO : Repair the defective connector.
OK: 4.5 − 4.9 V
Q: Is the check result normal? STEP 13. Check the harness between A/T control
YES : Go to Step 7. solenoid valve assembly connector B-15 terminal
NO : Go to Step 10. No.1 and A/T-ECU connector C-12 terminal No.44.
Check the output line for short-circuited or open cir-
STEP 10. Measure the voltage at A/T-ECU cuit.
connector C-12. Q: Is the check result normal?
(1) Connect A/T control solenoid valve assembly YES : Go to Step 7.
connector B-15. NO : Repair the wiring harness.
(2) Turn the ignition switch to the ON position.
(3) Measure the voltage between A/T-ECU STEP 14. Check the harness between A/T control
solenoid valve assembly connector B-15 terminal
No.2 and A/T-ECU connector C-12 terminal No.43.
Check the earth line for open circuit.
YES : Go to Step 7.
NO : Repair the wiring harness.
Code No.P1764 (P0710) A/T fluid temperature sensor system
A/T FLUID TEMPERATURE SENSOR SYSTEM DIAGNOSIS CODE SET CONDITION

CIRCUIT If the A/T fluid temperature sensor output voltage has
Refer to P.23A-32. been approximately 0 V for at least one second (indi-
cating abnormally high oil temperature), it indicates
OPERATION that the A/T fluid temperature sensor circuit is
Refer to P.23A-32. shorted and diagnosis code No.1764 (P0710) is set.
TROUBLESHOOTING
23A-35
PROBABLE CAUSES YES : Go to Step 5.
• Malfunction of the A/T fluid temperature sensor NO : Replace the A/T fluid temperature sensor.
• Damaged harness wires and connectors
• Malfunction of the A/T-ECU STEP 5. M.U.T.-III data list
Item 07: A/T fluid temperature sensor (Refer to Data
DIAGNOSIS List Table P.23A-103).
STEP 1. M.U.T.-III data list YES : Intermittent malfunction (Refer to GROUP
Item 07: A/T fluid temperature sensor (Refer to Data 00 − How to Cope with Intermittent
List Table P.23A-103). Malfunction ).
NO : Replace the A/T-ECU.
00 − How to Cope with Intermittent STEP 6. Measure the voltage at A/T-ECU
Malfunction ). connector C-12.
NO : Go to Step 2. (1) Connect A/T control solenoid valve assembly
connector B-15.
STEP 2. Connector check: B-15 A/T control (2) Turn the ignition switch to the ON position.
solenoid valve assembly (3) Measure the voltage between A/T-ECU
Check for the contact with terminals. connector C-12 terminal No.44 and earth.
OK:
YES : Go to Step 3. • 3.8 − 4.0 V (at 20°C)
NO : Repair the defective connector. • 3.2 − 3.4 V (at 40°C)
• 1.7 − 1.9 V (at 80°C)
STEP 3. Measure the voltage at A/T control Q: Is the check result normal?
YES : Go to Step 5.
NO : Go to Step 7.
(1) Disconnect the connector, and measure the
voltage between terminal 1 and earth at the
wiring harness side. STEP 7. Connector check: B-10 intermediate
(2) Turn the ignition switch to the ON position. connector, C-12 A/T-ECU connector
OK: 4.5 − 4.9 V Check for the contact with terminals.
NO : Go to Step 6. NO : Repair the defective connector.
STEP 4. Measure the resistance at A/T control STEP 8. Check the harness between A/T control
solenoid valve assembly connector B-15. solenoid valve assembly connector B-15 terminal
Disconnect the connector, and measure the resist- No.1 and A/T-ECU connector C-12 terminal No.44.
ance between terminal 1 and 2 at the sensor side. Check the output line for short-circuited or open cir-
cuit.
OK:
• 16.7 − 20.5 kΩ (at 0°C) Q: Is the check result normal?
• 7.3 − 8.9 kΩ (at 20°C) YES : Go to Step 5.
• 3.4 − 4.2 kΩ (at 40°C) NO : Repair the wiring harness.
• 1.9 − 2.2 kΩ (at 60°C)
• 1.0 − 1.2 kΩ (at 80°C)
• 0.57 − 0.69 kΩ (at 100°C)
TROUBLESHOOTING
Code No.P1766 (P0715) Input shaft speed sensor system
Input Shaft Speed Sensor System Circuit
IGNITION
SWITCH (IG1)
<4A/T, 5A/T-LHD>
<5A/T-RHD>
INPUT SHAFT
SPEED SENSOR
A/T-ECU
Wire colour code

AC903904
TROUBLESHOOTING
23A-37
Connector: B-10
Connector: C-34 <RHD>
Harness side
Harness side
C-34
B-10 (B)
AC510056AD
AC509930AG
Connector: B-11
Connector: C-52 <LHD>
Harness side
C-52
Harness side
B-11 (B)
AC510056AC
AC509613AG
Connector: B-17
Harness side Connectors: C-207, C-208 <LHD>
Junction block (Front view) Harness side
C-208
B-17 (B) C-207
AC510056AE
AC509934 CX
Connectors: C-207, C-208 <RHD>
Junction block
A/T-ECU Harness side (Front view)
<RHD>
C-207
C-208
A/T-ECU AC509936 BZ
OPERATION
C-12 The input shaft speed sensor detects the speed of
Harness side the underdrive clutch retainer, and sends the infor-
mation to the A/T-ECU as a pulse signal.
AC510057AB
TROUBLESHOOTING
DIAGNOSIS CODE SET CONDITIONS (3) Measure the voltage between A/T-ECU
The diagnosis code No.P1766 (P0715) is set if the connector C-12 terminal No.43 and earth.
input shaft speed sensor does not send a pulse sig- OK: 0.5 V or less
nal for one second or more while the 3rd gears are
engaged and the vehicle speed is 40 km/h or more Q: Is the check result normal?
YES : Go to Step 7.
(the output shaft speed sensor speed is 1,000 r/min
NO : Go to Step 5.
or more).
If the code No.P1766 (P0715) is set four times, the
transmission will be fixed in 3rd gear as a fail-safe STEP 5. Connector check: C-12 A/T-ECU
measure. However, the transmission can be down- connector
shifted to 2nd gear by operating the selector lever. Check for the contact with terminals.
PROBABLE CAUSES
YES : Go to Step 6.
• Malfunction of input shaft speed sensor
• Malfunction of underdrive clutch retainer
Item 05: Input shaft speed sensor (Refer to data list
DIAGNOSIS PROCEDURE reference table P.23A-103).
Item 05: Input shaft speed sensor (Refer to data list 00 − How to Cope with Intermittent
reference table P.23A-103). Malfunction ).
00 − How to Cope with Intermittent STEP 7. Connector check: B-11 intermediate
Malfunction ). connector, C-12 A/T-ECU connector
NO : Go to Step 2. Check for the contact with terminals.
YES : Go to Step 8.
STEP 2. Connector check: B-17 input shaft speed
sensor connector
STEP 8. Check the harness between input shaft
YES : Go to Step 3. speed sensor connector B-17 terminal No.1 and
NO : Repair the defective connector. A/T-ECU connector C-12 terminal No.43.
STEP 3. Measure the resistance at input shaft Q: Is the check result normal?
speed sensor connector B-17. YES : Go to Step 6.
ance between terminal 1 and earth at the wiring har-
ness side. STEP 9. Measure the voltage at input shaft speed
OK: Continuity (Less than 2 Ω) sensor connector B-17.
Q: Is the check result normal? voltage between terminal 3 and earth at the
YES : Go to Step 9.
wiring harness side.
NO : Go to Step 4.
OK: System voltage
(1) Connect input shaft speed sensor connector B-
NO : Go to Step 10.
17.
TROUBLESHOOTING
23A-39
STEP 10. Connectors check: C-208 J/B STEP 15. Check the harness between input shaft
connector, B-10 and C-52 <4A/T, 5A/T-LHD>or C- speed sensor connector B-17 terminal No.2 and
34 <5A/T-RHD> intermediate connector A/T-ECU connector C-12 terminal No.31.
Check for the contact with terminals. Check the output line for short circuit.
NO : Repair the defective connector. NO : Repair the wiring harness.
STEP 11. Check the harness between input shaft STEP 16. Connector check: B-11 intermediate
speed sensor connector B-17 terminal No.3 and connector, C-12 A/T-ECU connector
junction block connector C-208 terminal No.2. Check for the contact with terminals.
Check the power supply line for short or open circuit. Q: Is the check result normal?
YES : Go to Step 6. NO : Repair the defective connector.
STEP 17. Check the harness between input shaft
STEP 12. Measure the voltage at input shaft speed sensor connector B-17 terminal No.2 and
speed sensor connector B-17. A/T-ECU connector C-12 terminal No.31.
(1) Disconnect the connector, and measure the Check the output line for open circuit.
voltage between terminal 2 and earth at the Q: Is the check result normal?
wiring harness side. YES : Go to Step 6.
(2) Turn the ignition switch to the ON position. NO : Repair the wiring harness.
OK: 4.5 − 4.9 V
Q: Is the check result normal? STEP 18. Measure the output wave pattern of the
YES : Go to Step 18. input shaft speed sensor at A/T-ECU connector
NO : Go to Step 13. C-12 (using an oscilloscope).
(1) Shift the selector lever to the D range.
STEP 13. Measure the voltage at A/T-ECU (2) Accelerate the vehicle to approximately 50 km/h
connector C-12. (shift range; 3rd).
(1) Disconnect input shaft speed sensor connector (3) Connect an oscilloscope, and measure the
B-17. voltage between A/T-ECU connector C-12
(2) Turn the ignition switch to the ON position. terminal No.31 and earth.
(3) Measure the voltage between A/T-ECU OK: A wave pattern such as the one
connector C-12 terminal No.31 and earth. shown on P.23A-110 (Check Procedure
OK: 4.5 − 4.9 V Using an Oscilloscope) should be output,
and the maximum value should be 4.8 V
Q: Is the check result normal? or more and the minimum value should
be 0.8 V or less. There should be no noise
NO : Go to Step 14.
in the output wave pattern.
STEP 14. Connector check: B-11 intermediate YES : Go to Step 6.
connector, C-12 A/T-ECU connector NO : Go to Step 19.
Q: Is the check result normal? STEP 19. Connector check: C-12 A/T-ECU
connector
TROUBLESHOOTING
STEP 20. Replace the input shaft speed sensor STEP 21. Underdrive clutch retainer inspection
and then recheck the diagnosis code. Visually check the underdrive clutch retainer for dam-
(1) Replace the input shaft speed sensor. age.
(2) Test drive the vehicle. Q: Is the check result normal?
(3) Check if the diagnosis code is set. YES : Eliminate the cause of the noise.
Q: Is diagnosis code P1766 set? NO : Replace the underdrive clutch retainer.
NO : The inspection is complete.
TROUBLESHOOTING
23A-41
Code No.P1767 (P0720) Output shaft speed sensor system
Output Shaft Speed Sensor System Circuit

IGNITION
SWITCH (IG1)
<4A/T, 5A/T-LHD>
<5A/T-RHD>
OUTPUT SHAFT
SPEED SENSOR
A/T-ECU
Wire colour code

AC903905
TROUBLESHOOTING
Connector: B-10
Harness side
Harness side
C-34
B-10 (B)
AC503225AE
AC509930AG
Connector: B-11
Harness side
C-52
Harness side
B-11 (B)
AC503225AD
AC509613AG
Connector: B-16
Connectors: C-207, C-208 <LHD>
B-16 (GR) Junction block (Front view)
C-208
C-207
AC510056AF
AC509934 CX
Junction block
<RHD>
C-207
C-208
A/T-ECU AC509936 BZ
OPERATION
C-12 The output shaft speed sensor detects the speed of
Harness side the transfer drive gear, and sends the information to
the A/T-ECU as a pulse signal.
AC510057AB
TROUBLESHOOTING
23A-43
DIAGNOSIS CODE SET CONDITIONS (2) Turn the ignition switch to the "ON" position.
If the output pulse from the output shaft speed sen- (3) Measure the voltage between A/T-ECU
sor has been lost for one second or more while the connector C-12 terminal No.43 and earth.
vehicle is being driven, it is judged that there is an OK: 0.5 V or less
open circuit or short circuit in the output shaft speed
sensor, and diagnosis code No.P1767 (P0720) is Q: Is the check result normal?
YES : Go to Step 7.
set.
NO : Go to Step 5.
If the code No.P1767 (P0720) is set four times, the
transmission will be fixed in 3rd gear as a fail-safe
measure. However, the transmission can be down- STEP 5. Connector check: C-12 A/T-ECU
shifted to 2nd gear by operating the selector lever. connector
PROBABLE CAUSES
• Malfunction of output shaft speed sensor
YES : Go to Step 6.
• Malfunction of output shaft <4A/T>
• Malfunction of direct planetary carrier <5A/T>
Item 06: Output shaft speed sensor (Refer to data list
DIAGNOSIS PROCEDURE reference table P.23A-103).
Item 06: Output shaft speed sensor (Refer to data list 00 − How to Cope with Intermittent
reference table P.23A-103). Malfunction ).
00 − How to Cope with Intermittent STEP 7. Connector check: B-11 intermediate
Malfunction ). connector, C-12 A/T-ECU connector
NO : Go to Step 2. Check for the contact with terminals.
YES : Go to Step 8.
STEP 2. Connector check: B-16 output shaft
speed sensor connector
STEP 8. Check the harness between output shaft
YES : Go to Step 3. speed sensor connector B-16 terminal No.1 and
NO : Repair the defective connector. A/T-ECU connector C-12 terminal No.43.
STEP 3. Measure the resistance at output shaft Q: Is the check result normal?
YES : Go to Step 6.
speed sensor connector B-16.
ance between terminal 1 and earth at the wiring har-
ness side. STEP 9. Measure the voltage at output shaft
OK: Continuity (Less than 2 Ω) speed sensor connector B-16.
Q: Is the check result normal? voltage between terminal 3 and earth at the
YES : Go to Step 9.
NO : Go to Step 4.
OK: System voltage
(1) Connect output shaft speed sensor connector B-
NO : Go to Step 10.
16.
TROUBLESHOOTING
STEP 10. Connectors check: C-208 J/B STEP 15. Check the harness between output
connector, B-10 and C-52 <LHD>or C-34 <RHD> shaft speed sensor connector B-16 terminal No.2
intermediate connector and A/T-ECU connector C-12 terminal No.32.
Check for the contact with terminals. Check the output line for short circuit.
STEP 11. Check the harness between output STEP 16. Connector check: B-11 intermediate
shaft speed sensor connector B-16 terminal No.3 connector, C-12 A/T-ECU connector
and junction block connector C-208 terminal Check for the contact with terminals.
No.2. Q: Is the check result normal?
Check the power supply line for short or open circuit. YES : Go to Step 17.
Q: Is the check result normal? NO : Repair the defective connector.
YES : Go to Step 6.
STEP 17. Check the harness between output
shaft speed sensor connector B-16 terminal No.2
STEP 12. Measure the voltage at output shaft and A/T-ECU connector C-12 terminal No.32.
speed sensor connector B-16. Check the output line for open circuit.
(1) Disconnect the connector, and measure the Q: Is the check result normal?
voltage between terminal 2 and earth at the YES : Go to Step 6.
wiring harness side. NO : Repair the wiring harness.
OK: 4.5 − 4.9 V
STEP 18. Measure the output wave pattern of the
Q: Is the check result normal? output shaft speed sensor at A/T-ECU connector
YES : Go to Step 18. C-12 (using an oscilloscope).
NO : Go to Step 13. (1) Shift the selector lever to the D range.
(2) Accelerate the vehicle to approximately 50 km/h
STEP 13. Measure the voltage at A/T-ECU (shift range; 3rd.)
connector C-12. (3) Connect an oscilloscope, and measure the
(1) Disconnect output shaft speed sensor connector voltage between A/T-ECU connector C-12
B-16. terminal No.32 and earth.
(2) Turn the ignition switch to the "ON" position. OK: A wave pattern such as the one
(3) Measure the voltage between A/T-ECU shown on P.23A-110 (Check Procedure
connector C-12 terminal No.32 and earth. Using an Oscilloscope) should be output,
OK: 4.5 − 4.9 V and the maximum value should be 4.8 V
or more and the minimum value should
Q: Is the check result normal? be 0.8 V or less. There should be no noise
in the output wave pattern.
NO : Go to Step 14.
YES : Go to Step 6.
STEP 14. Connector check: B-11 intermediate NO : Go to Step 19.
connector, C-12 A/T-ECU connector
STEP 19. Connector check: C-12 A/T-ECU
Q: Is the check result normal? connector
TROUBLESHOOTING
23A-45
STEP 20. Replace the output shaft speed sensor STEP 21. Check the output shaft <4A/T> or direct
and then recheck the diagnosis code. planetary carrier <5A/T>.
(1) Replace the output shaft speed sensor. Visually check the output shaft <4A/T> or direct plan-
(2) Test drive the vehicle. etary carrier <5A/T> for damage.
(3) Check if the diagnosis code is set. Q: Is the check result normal?
Q: Is diagnosis code P1767 set? YES : Eliminate the cause of the noise.
YES : Go to Step 21. NO : Replace the output shaft <4A/T> or direct
NO : The inspection is complete. planetary carrier <5A/T>.
TROUBLESHOOTING
Code No.P1770 (P0705) Inhibitor switch system <4A/T>
Inhibitor Switch System Circuit

IGNITION
SWITCH (IG1)
INHIBITOR
SWITCH
A/T-ECU
Wire colour code

AC903906
TROUBLESHOOTING
23A-47
Connector: B-10
Harness side Junction block (Front view) Harness side
C-208
C-207
B-10 (B)
AC510056AD
AC509934 CX
Connector: B-14
Harness side Connectors: C-207, C-208 <RHD>
Junction block
Harness side (Front view)
C-207
B-14 (B)
C-208
AC510056AG
AC509936 BZ

OPERATION
The inhibitor switch detects the selector lever posi-
A/T-ECU tion (P, R, N,D, 2 or L) which the driver has selected,
<RHD>
and sends the information to the A/T-ECU.
DIAGNOSIS CODE SET CONDITIONS

If the inhibitor switch has not been sending any sig-
nal for at least 30 seconds, an open circuit may be
present and diagnosis code No.P1770 (P0705) is
A/T-ECU
set.
PROBABLE CAUSES
• Malfunction of the inhibitor switch
C-20 • Damaged harness wires and connectors
• Malfunction of the A/T-ECU
Harness side
DIAGNOSIS PROCEDURE
AC510057AC STEP 1. M.U.T.-III data list

Item 34: Inhibitor switch P.23A-103 (Refer to data list
Connector: C-52 <LHD> reference table).
00 − How to Cope with Intermittent
C-52
Malfunction ).
Harness side NO <none of the selector lever positions are
displayed on M.U.T.-III> : Go to Step 2.
NO <only one of the selector lever positions is not
displayed on M.U.T.-III> : Go to Step 6.
AC509613AG
TROUBLESHOOTING

STEP 2. Check the inhibitor switch.
Refer to P.23A-113.
Malfunction ).
Q: Is the check result normal? NO : Replace the A/T-ECU.
YES : Go to Step 3.
NO : Replace the inhibitor switch.
Refer to P.23A-118.
STEP 3. Connector check: B-14 Inhibitor switch
connector, C-208 J/B connector, B-10 and C-52
YES : Go to Step 7.
intermediate connector
NO : Replace the inhibitor switch.
STEP 7. Connector check: B-14 inhibitor switch
YES : Go to Step 4.
NO : Repair the defective connector. connector, C-20 A/T-ECU connector, B-10
STEP 4. Check the harness between inhibitor
switch connector B-14 terminal No.7 and J/B Q: Is the check result normal?
YES : Go to Step 8.
connector C-208 terminal No.2.
Check the power supply line for open circuit.
YES : Go to Step 5.
switch connector B-14 terminal No.1, 8, 2, 3, 4, 5
and A/T-ECU connector C-20 terminal No.55, 66,
56, 67, 68, 58.
STEP 5. M.U.T.-III data list Check the output line for open circuit.
reference table).
YES : Go to Step 5.
Q: Is the check result normal? NO : Repair the wiring harness.
TROUBLESHOOTING
23A-49
Code No.P1770 (P0705): Inhibitor switch system <5A/T>
Inhibitor switch system circuit
IGNITION
SWITCH (IG1)
<LHD>
<RHD>
INHIBITOR
SWITCH
A/T-ECU
Wire colour code

BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet PU : Purple AC903907
Connector: B-10 Connector: B-14

Harness side
Harness side
B-14 (B)
B-10 (B)
AC510056AD AC510056AG
TROUBLESHOOTING

Junction block
<RHD>
C-207
C-208
A/T-ECU AC509936 BZ
OPERATION
C-20
The inhibitor switch detects the selector lever posi-
Harness side tion (P, R, N, D) which the driver has selected, and
sends the information to the ECU.

If the inhibitor switch has not been sending any sig-
AC510057AC
nal for at least 30 seconds, an open circuit may be
Connector: C-34 <RHD> present and diagnosis code No.P1770 (P0705) is
set.
Harness side
PROBABLE CAUSES
C-34
DIAGNOSIS PROCEDURE
AC509930AG

Item 34: Inhibitor switch (Refer to Data List Refer-
Connector: C-52 <LHD> ence Table P.23A-103).
C-52
Malfunction ).
Harness side NO none of the selector lever positions are
displayed on M.U.T.-III : Go to Step 2.
NO only one of the selector lever positions is not
displayed on M.U.T.-III : Go to Step 6.
AC509613AG
Connectors: C-207, C-208 <LHD> STEP 2. Check the inhibitor switch.

Refer to P.23A-118.
C-208
YES : Go to Step 3.
C-207 NO : Replace the inhibitor switch.
AC509934 CX
TROUBLESHOOTING
23A-51
STEP 3. Connector check: B-14 Inhibitor switch STEP 6. Check the inhibitor switch.
connector, C-208 J/B connector, C-52 <LHD> or Refer to P.23A-118.
C-34 <RHD> and B-10 intermediate connector Q: Is the check result normal?
Check for the contact with terminals. YES : Go to Step 7.
Q: Is the check result normal? NO : Replace the inhibitor switch.
YES : Go to Step 4.
STEP 7. Connector check: B-14 inhibitor switch
connector, C-20 A/T-ECU connector, B-10
STEP 4. Check the harness between inhibitor intermediate connector.
switch connector B-14 terminal No.7 and J/B Check for the contact with terminals.
connector C-208 terminal No 2. Q: Is the check result normal?
Check the power supply line for open circuit. YES : Go to Step 8.
YES : Go to Step 5.
switch connector B-14 terminal No.3, 2, 8, 1 A/T-
STEP 5. M.U.T.-III data list ECU connector C-20 terminal No.67, 56, 66, 55.
Item 34: Inhibitor switch (Refer to Data List Refer- Check the output line for open circuit.
ence Table P.23A-103). Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP NO : Repair the wiring harness.
Malfunction ).
Code No.P1771 (P0705) Inhibitor switch system <4A/T>
INHIBITOR SWITCH SYSTEM CIRCUIT STEP 2. Connector check: B-14 Inhibitor switch
Refer to P.23A-46. connector, B-10 intermediate connector, C-20 A/
OPERATION T-ECU connector
Refer to P.23A-46. Check for the contact with terminals.
If the inhibitor switch has been sending multiple sig- NO : Repair the defective connector.
nals for at least 30 seconds, the circuit may be open
and diagnosis code No.P1771 (P0705) is set.
PROBABLE CAUSES switch connector B-14 terminal No.1, 8, 2, 3, 4, 5
• Malfunction of the inhibitor switch and A/T-ECU connector C-20 terminal No.55, 66,
• Damaged harness wires and connectors 56, 67, 68, 58.
• Malfunction of the A/T-ECU Check the output line for open circuit or short circuit.
Refer to P.23A-113. STEP 4. M.U.T.-III data list
YES : Go to Step 2.
reference table).
NO : Replace the inhibitor switch. Q: Is the check result normal?
TROUBLESHOOTING

Malfunction ).
Code No.P1771 (P0705): Inhibitor switch system <5A/T>
INHIBITOR SWITCH SYSTEM CIRCUIT STEP 2. Connector check: B-14 Inhibitor switch
Refer to P.23A-49. connector, B-10 intermediate connector C-20 A/T-
OPERATION ECU connector
Refer to P.23A-49. Check for the contact with terminals.
If the inhibitor switch has been sending multiple sig- NO : Repair the defective connector.
nals for at least 30 seconds, the circuit may be open
and diagnosis code No.P1771 (P0705) is set.
PROBABLE CAUSES switch connector B-14 terminal No.3, 2, 8, 1 and
• Malfunction of the inhibitor switch A/T-ECU connector C-20 terminal No.67, 56, 66,
• Damaged harness wires and connectors 55.
• Malfunction of the A/T-ECU Check the output line for open circuit or short circuit.
Refer to P.23A-118. STEP 4. M.U.T.-III data list
YES : Go to Step 2.
ence Table P.23A-103).
NO : Replace the inhibitor switch. Q: Is the check result normal?
Malfunction ).
TROUBLESHOOTING
23A-53
Code No.P1773 (P0750) Low-reverse solenoid valve system
Solenoid Valve System Circuit <4A/T>
FUSIBLE
LINK 23
NOTE
RELAY : UNDERDRIVE
SOLENOID VALVE
BOX : SECOND
SOLENOID VALVE
: OVERDRIVE
SOLENOID VALVE
: DAMPER CLUTCH
CONTROL SOLENOID
VALVE
: LOW AND REVERSE
SOLENOID VALVE
A/T
CONTROL
RELAY
A/T CONTROL
SOLENOID
VALVE ASSEMBLY
A/T-ECU
Wire colour code

AC903908
TROUBLESHOOTING
Solenoid Valve System Circuit <5A/T>
FUSIBLE
LINK 23
NOTE
RELAY : UNDERDRIVE
SOLENOID VALVE
BOX : SECOND
SOLENOID VALVE
: OVERDRIVE
SOLENOID VALVE
: DAMPER CLUTCH
CONTROL SOLENOID
VALVE
: LOW AND REVERSE
SOLENOID VALVE
: REDUCTION
SOLENOID VALVE
A/T
CONTROL
RELAY
A/T CONTROL
SOLENOID
VALVE ASSEMBLY
A/T-ECU
Wire colour code
AC903909
TROUBLESHOOTING
23A-55
Connector: A-115 Connector: B-15

Harness side
B-15 (B)
Harness side
A-115
AC509975AO AC510056AB
Connector: A-19X Connector: C-19 <LHD>
A-19X
A/T-ECU
<RHD>
Relay box side
AC510163AG
A/T-ECU
Connector: B-10
Harness side C-19
Harness side
AC510057AD
B-10 (B)
AC510056AD
Connector: B-11
Harness side A/T-ECU

<RHD>
B-11 (B)
AC510056AC A/T-ECU
C-20
Harness side
AC510057AC
TROUBLESHOOTING
OPERATION STEP 4. Measure the resistance at A/T control

• Solenoid valve closes or opens according to the solenoid valve assembly connector B-15.
signals from the A/T-ECU. Disconnect the connector, and measure the resist-
• The A/T-ECU energizes or deenergizes solenoid ance between terminal No.6 and No.10 at the sole-
valve, based on input signals such as accelerator noid valve side.
pedal position sensor opening angle, inhibitor
switch, etc. OK: 2.7 − 3.4 Ω (A/T fluid temperature 20°C)
If the drive terminal voltage of the low-reverse sole- NO : Check the low-reverse solenoid valve and
noid valve is 3.0 V or less, it is judged that there is a solenoid valve harness.
short circuit or open circuit in the low-reverse sole-
noid valve, and diagnosis code No.P1773 (P0750) is
set.
connector C-20.
If diagnosis code No.P1773 (P0750) is output 4
(1) Connect A/T control solenoid valve assembly
times, the transmission is fixed in 3rd as a fail-safe
connector B-15.
measure.
PROBABLE CAUSES (3) Measure the voltage between A/T-ECU
• Malfunction of low-reverse solenoid valve connector C-20 terminal No.62 and earth.
• Damaged harness wires and connectors OK: System voltage
YES : Go to Step 8.
DIAGNOSIS PROCEDURE NO : Go to Step 6.
STEP 1. M.U.T.-III diagnosis code STEP 6. Connector check: B-11 intermediate

Q: Is diagnosis code P1778 (P0740), P1777 (P0770) connector, C-20 A/T-ECU connector
<5A/T> set? Check for the contact with terminals.
Item 01: Low-reverse solenoid valve STEP 7. Check the harness between A/T control
OK: Operating sound can be heard. solenoid valve assembly connector B-15 terminal
No.6 and A/T-ECU connector C-20 terminal No.62.
YES : Intermittent malfunction (Refer to GROUP Check the output line for short or open circuit.
Malfunction .) YES : Go to Step 8.
NO : Go to Step 3. NO : Repair the wiring harness.
STEP 3. Connector check: B-15 A/T control STEP 8. M.U.T.-III actuator test
solenoid valve assembly connector Item 01: Low-reverse solenoid valve
Check for the contact with terminals. OK: Operating sound can be heard.
YES : Go to Step 4. YES : Intermittent malfunction (Refer to GROUP
NO : Repair the defective connector. 00 − How to Cope with Intermittent
Malfunction .)
TROUBLESHOOTING
23A-57
STEP 9. Connector check: B-15 A/T control STEP 11. Connector check: A-19X A/T control
solenoid valve assembly connector relay connector, B-10 intermediate connector
Disconnect the connector, and measure the resist- No.10 and A/T control relay connector A-19X
ance between terminal No.6 and No.10 at the sole- terminal No.3.
noid valve side. Check the power supply line for short or open circuit.
OK: 2.7 − 3.4 Ω (A/T fluid temperature 20°C) Q: Is the check result normal?
YES : Go to Step 11. NO : Repair the wiring harness.
NO : Check the solenoid valve harness.
Code No.P1774 (P0755) Underdrive solenoid valve system
SOLENOID VALVE SYSTEM CIRCUIT STEP 2. M.U.T.-III actuator test

Refer to P.23A-53. Item 02: Underdrive solenoid valve
OPERATION OK: Operating sound can be heard.
Refer to P.23A-53. Q: Is the check result normal?
If the drive terminal voltage of the underdrive sole-
Malfunction .)
noid valve is 3.0 V or less, it is judged that there is a NO : Go to Step 3.
short-circuit or open circuit in the solenoid valve, and
diagnosis code No.P1774 (P0755) is output.
If diagnosis code No.P1774 (P0755) is output 4 STEP 3. Connector check: B-15 A/T control
times, the transmission is fixed in 3rd as a fail-safe solenoid valve assembly connector
measure. Check for the contact with terminals.
• Malfunction of underdrive solenoid valve NO : Repair the defective connector.
STEP 4. Measure the resistance at A/T control
DIAGNOSIS PROCEDURE solenoid valve assembly connector B-15.
ance between terminal No.3 and No.9 at the solenoid
STEP 1. M.U.T.-III diagnosis code valve side.
Q: Are diagnosis codes P1775 (P0760) and P1776 OK: 2.7 − 3.4 Ω (A/T fluid temperature 20°C)
(P0765) set?
YES : Go to Step 9.
YES : Go to Step 5.
NO : Go to Step 2.
NO : Check the underdrive solenoid valve.

connector C-19.
TROUBLESHOOTING
connector B-15. STEP 9. Connector check: B-15 A/T control

(2) Turn the ignition switch to the ON position. solenoid valve assembly connector
(3) Measure the voltage between A/T-ECU Check for the contact with terminals.
OK: 6 − 9 V
YES : Go to Step 8.
NO : Go to Step 6.
STEP 6. Connector check: B-11 intermediate Disconnect the connector, and measure the resist-
connector, C-19 A/T-ECU connector ance between terminal No.3 and No.9 at the solenoid
Check for the contact with terminals. valve side.
Q: Is the check result normal? OK: 2.7 − 3.4 Ω (A/T fluid temperature 20°C)
YES : Go to Step 7.
STEP 7. Check the harness between A/T control
solenoid valve assembly connector B-15 terminal STEP 11. Connector check: A-19X A/T control
No.3 and A/T-ECU connector C-19 terminal No.1. relay connector, B-10 intermediate connector
Check the output line for short or open circuit. Check for the contact with terminals.
YES : Go to Step 8.
STEP 8. M.U.T.-III actuator test STEP 12. Check the harness between A/T control
Item 02: Underdrive solenoid valve solenoid valve assembly connector B-15 terminal
OK: Operating sound can be heard. No.9 and A/T control relay connector A-19X
Q: Is the check result normal? terminal No.3.
YES : Intermittent malfunction (Refer to GROUP Check the power supply line for short or open circuit.
Malfunction .) YES : Go to Step 8.
NO : Replace the A/T-ECU. NO : Repair the wiring harness.
Code No.P1775 (P0760) Second solenoid valve system
SOLENOID VALVE SYSTEM CIRCUIT PROBABLE CAUSES

Refer to P.23A-53. • Malfunction of second solenoid valve
OPERATION • Malfunction of the A/T-ECU
Refer to P.23A-53.
DIAGNOSIS PROCEDURE
If the drive terminal voltage of the second solenoid
valve is 3.0 V or less, it is judged that there is a short STEP 1. M.U.T.-III diagnosis code.
circuit or open circuit in the second solenoid valve,
Q: Are diagnosis code P1774 (P0755) and P1776
and diagnosis code No.P1775 (P0760) is output. (P0765) set?
If diagnosis code No.P1775 (P0760) is output 4 YES : Go to Step 9.
times, the transmission is fixed in 3rd as a fail-safe NO : Go to Step 2.
measure.
TROUBLESHOOTING
23A-59
Item 03: Second solenoid valve solenoid valve assembly connector B-15 terminal
OK: Operating sound can be heard. No.4 and A/T-ECU connector C-19 terminal No.16.
Check the output line for short or open circuit.
00 − How to Cope with Intermittent YES : Go to Step 8.
Malfunction .) NO : Repair the wiring harness.
NO : Go to Step 3.
STEP 3. Connector check: B-15 A/T control Item 03: Second solenoid valve
solenoid valve assembly connector OK: Operating sound can be heard.
Check for the contact with terminals. Q: Is the check result normal?
Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP
YES : Go to Step 4. 00 − How to Cope with Intermittent
NO : Repair the defective connector. Malfunction .)
solenoid valve assembly connector B-15. STEP 9. Connector check: B-15 A/T control
Disconnect the connector, and measure the resist- solenoid valve assembly connector
ance between terminal No.4 and No.9 at the solenoid Check for the contact with terminals.
valve side. Q: Is the check result normal?
OK: 2.7 − 3.4 Ω (A/T fluid temperature 20°C) YES : Go to Step 10.
YES : Go to Step 5.
NO : Check the second solenoid valve and STEP 10. Measure the resistance at A/T control
solenoid valve harness. solenoid valve assembly connector B-15.
STEP 5. Measure the voltage at A/T-ECU ance between terminal No.4 and No.9 at the solenoid
connector C-19. valve side.
(1) Connect A/T control solenoid valve assembly OK: 2.7 − 3.4 Ω (A/T fluid temperature 20°C)
connector B-15. Q: Is the check result normal?
(2) Turn the ignition switch to the ON position. YES : Go to Step 11.
(3) Measure the voltage between A/T-ECU NO : Check the solenoid valve harness.
OK: 6 − 9 V
STEP 11. Connector check: A-19X A/T control
Q: Is the check result normal? relay connector, B-10 intermediate connector
YES : Go to Step 8. Check for the contact with terminals.
NO : Go to Step 6.
STEP 6. Connector check: B-11 intermediate NO : Repair the defective connector.
Q: Is the check result normal? solenoid valve assembly connector B-15 terminal
YES : Go to Step 7. No.9 and A/T control relay connector A-19X
NO : Repair the defective connector. terminal No.3.
Check the power supply line for short or open circuit.
YES : Go to Step 8.
TROUBLESHOOTING
Code No.P1776 (P0765) Overdrive solenoid valve system
SOLENOID VALVE SYSTEM CIRCUIT STEP 4. Measure the resistance at A/T control
Refer to P.23A-53. solenoid valve assembly connector B-15.
OPERATION Disconnect the connector, and measure the resist-
Refer to P.23A-53. ance between terminal No.5 and No.9 at the solenoid
valve side.
DIAGNOSIS CODE SET CONDITIONS OK: 2.7 − 3.4 Ω (A/T fluid temperature 20°C)
If the drive terminal voltage of the overdrive solenoid
valve is 3.0 V or less, it is judged that there is a short
YES : Go to Step 5.
circuit or open circuit in the overdrive solenoid valve, NO : Check the overdrive solenoid valve and
and diagnosis code No.P1776 (P0765) is output. solenoid valve harness.
If diagnosis code No.P1776 (P0765) is output 4
measure. STEP 5. Measure the voltage at A/T-ECU
connector C-19.
PROBABLE CAUSES (1) Connect A/T control solenoid valve assembly
• Malfunction of overdrive solenoid valve connector B-15.
• Damaged harness wires and connectors (2) Turn the ignition switch to the ON position.
• Malfunction of the A/T-ECU (3) Measure the voltage between A/T-ECU
DIAGNOSIS PROCEDURE OK: 6 − 9 V
STEP 1. M.U.T.-III diagnosis code YES : Go to Step 8.
NO : Go to Step 6.
Q: Are diagnosis codes P1774 (P0755) and P1775
(P0760) set?
YES : Go to Step 9. STEP 6. Connector check: B-11 intermediate
NO : Go to Step 2. connector, C-19 A/T-ECU connector
STEP 2. M.U.T.-III actuator test Q: Is the check result normal?
Item 04: Overdrive solenoid valve YES : Go to Step 7.
OK: Operating sound can be heard. NO : Repair the defective connector.

YES : Intermittent malfunction (Refer to GROUP STEP 7. Check the harness between A/T control
00 − How to Cope with Intermittent solenoid valve assembly connector B-15 terminal
Malfunction .) No.5 and A/T-ECU connector C-19 terminal No.14.
NO : Go to Step 3. Check the output line for short or open circuit.
STEP 3. Connector check: B-15 A/T control YES : Go to Step 8.
solenoid valve assembly connector NO : Repair the wiring harness.
Q: Is the check result normal? STEP 8. M.U.T.-III actuator test
YES : Go to Step 4. Item 04: Overdrive solenoid valve
NO : Repair the defective connector. OK: Operating sound can be heard.
Malfunction .)
TROUBLESHOOTING
23A-61
STEP 9. Connector check: B-15 A/T control STEP 11. Connector check: A-19X A/T control
solenoid valve assembly connector relay connector, B-10 intermediate connector
Disconnect the connector, and measure the resist- No.9 and A/T control relay connector A-19X
ance between terminal No.5 and No.9 at the solenoid terminal No.3.
valve side. Check the power supply line for short or open circuit.
OK: 2.7 − 3.4 Ω (A/T fluid temperature 20°C) Q: Is the check result normal?
Code No.P1777 (P0770) Reduction solenoid valve system <5A/T>
SOLENOID VALVE SYSTEM CIRCUIT YES : Intermittent malfunction (Refer to GROUP

Refer to P.23A-53. 00 − How to Cope with Intermittent
Malfunction ).
OPERATION NO : Go to Step 3.
Refer to P.23A-53.
DIAGNOSIS CODE SET CONDITIONS STEP 3. Connector check: B-15 A/T control
If the drive terminal voltage of the reduction solenoid solenoid valve assembly connector
valve is 3.0 V or less, it is judged that there is a short Check for the contact with terminals.
circuit or open circuit in the reduction solenoid valve, Q: Is the check result normal?
and diagnosis code No.P1777 (P0770) is set. YES : Go to Step 4.
If diagnosis code No.P1777 (P0770) is set, the trans- NO : Repair the defective connector.
mission is fixed in 3rd as a fail-safe measure.
PROBABLE CAUSES STEP 4. Measure the resistance at A/T control

• Malfunction of reduction solenoid valve solenoid valve assembly connector B-15.
• Damaged harness wires and connectors Disconnect the connector, and measure the resist-
• Malfunction of the A/T-ECU ance between terminal No.8 and No.10 at the sole-
noid valve side.
DIAGNOSIS PROCEDURE OK: 2.7 − 3.4 Ω (A/T fluid temperature 20°C)
STEP 1. M.U.T.-III diagnosis code YES : Go to Step 5.
NO : Check the reduction solenoid valve and
Q: Are diagnosis codes P1773 (P0750) and P1778 solenoid valve harness.
(P0740) set?
YES : Go to Step 9.
NO : Go to Step 2. STEP 5. Measure the voltage at A/T-ECU
connector C-20.
connector B-15.
Item 5: Reduction solenoid valve
OK: Operating sound can be heard. (3) Measure the voltage between A/T-ECU
TROUBLESHOOTING
connector C-20 terminal No.51 and earth. STEP 9. Connector check: B-15 A/T control
OK: 6 − 9 V solenoid valve assembly connector
Q: Is the check result normal? Check for the contact with terminals.
STEP 6. Connector check: B-11 intermediate
connector, C-20 A/T-ECU connector STEP 10. Measure the resistance at A/T control
Check for the contact with terminals. solenoid valve assembly connector B-15.
Q: Is the check result normal? Disconnect the connector, and measure the resist-
YES : Go to Step 7. ance between terminal No.8 and No.10 at the sole-
NO : Repair the defective connector. noid valve side.
OK: 2.7 − 3.4 Ω (A/T fluid temperature 20°C)
STEP 7. Check the harness between A/T control Q: Is the check result normal?
solenoid valve assembly connector B-15 terminal YES : Go to Step 11.
No.8 and A/T-ECU connector C-20 terminal No.51. NO : Check the solenoid valve harness.
Q: Is the check result normal? STEP 11. Connector check: A-19X A/T control
YES : Go to Step 8. relay connector, B-10 intermediate connector
NO : Repair the wiring harness. Check for the contact with terminals.
STEP 8. M.U.T.-III actuator test YES : Go to Step 12.
Item 5: Reduction solenoid valve NO : Repair the defective connector.
OK: Operating sound can be heard.
Q: Is the check result normal? STEP 12. Check the harness between A/T control
YES : Intermittent malfunction (Refer to GROUP solenoid valve assembly connector B-15 terminal
00 − How to Cope with Intermittent No.10 and A/T control relay connector A-19X
Malfunction ). terminal No.3.
NO : Replace the A/T-ECU. Check the power supply line for short or open circuit.
YES : Go to Step 8.
Code No.P1778 (P0740) Damper clutch control solenoid valve system
SOLENOID VALVE SYSTEM CIRCUIT PROBABLE CAUSES

Refer to P.23A-53. • Malfunction of damper clutch solenoid valve
OPERATION • Malfunction of the A/T-ECU
Refer to P.23A-53.
DIAGNOSIS PROCEDURE
If the drive terminal voltage of the torque converter
control clutch solenoid valve is 3.0 V or less, it is STEP 1. M.U.T.-III diagnosis code
judged that there is a short circuit or open circuit in
Q: Is diagnosis code P1773 (P0750), P1777 (P0770)
the torque converter control clutch solenoid valve, <5A/T> set?
and diagnosis code No.P1778 (P0740) is output. YES : Go to Step 9.
If diagnosis code No.P1778 (P0740) is output 4 NO : Go to Step 2.
measure.
TROUBLESHOOTING
23A-63
Item 06: Damper clutch solenoid valve solenoid valve assembly connector B-15 terminal
OK: Operating sound can be heard. No.7 and A/T-ECU connector C-19 terminal No.15.
00 − How to Cope with Intermittent YES : Go to Step 8.
Malfunction .) NO : Repair the wiring harness.
NO : Go to Step 3.
STEP 3. Connector check: B-15 A/T control Item 06: Damper clutch solenoid valve
solenoid valve assembly connector OK: Operating sound can be heard.
Q: Is the check result normal? YES : Intermittent malfunction (Refer to GROUP
YES : Go to Step 4. 00 − How to Cope with Intermittent
NO : Repair the defective connector. Malfunction .)
solenoid valve assembly connector B-15. STEP 9. Connector check: B-15 A/T control
Disconnect the connector, and measure the resist- solenoid valve assembly connector
ance between terminal No.7 and No.10 at the sole- Check for the contact with terminals.
noid valve side. Q: Is the check result normal?
OK: 2.7 − 3.4 Ω (A/T fluid temperature 20°C) YES : Go to Step 10.
YES : Go to Step 5.
NO : Check the damper clutch solenoid valve and STEP 10. Measure the resistance at A/T control
solenoid valve harness. solenoid valve assembly connector B-15.
STEP 5. Measure the voltage at A/T-ECU ance between terminal No.7 and No.10 at the sole-
connector C-19. noid valve side.
(1) Connect A/T control solenoid valve assembly OK: 2.7 − 3.4 Ω (A/T fluid temperature 20°C)
connector B-15. Q: Is the check result normal?
(3) Measure the voltage between A/T-ECU NO : Check the solenoid valve harness.
OK: 6 − 9 V
Q: Is the check result normal? relay connector, B-10 intermediate connector
YES : Go to Step 8. Check for the contact with terminals.
NO : Go to Step 6.
STEP 6. Connector check: B-10 intermediate NO : Repair the defective connector.
Q: Is the check result normal? solenoid valve assembly connector B-15 terminal
YES : Go to Step 7. No.10 and A/T control relay connector A-19X
NO : Repair the defective connector. terminal No.3.
Check the power supply line for short or open circuit.
YES : Go to Step 8.
TROUBLESHOOTING
Code No.P1779 (1st), P1780 (2nd), P1781 (3rd), P1782 (4th), P1784 (reverse): Gear incorrect ratio <4A/
T>
OPERATION YES <diagnosis code P1766 (P0715) is output> :

The A/T-ECU detects the current gear/speed accord- Refer to diagnosis code P1766 (P0715)
ing to the output signals from the input and output input shaft speed sensor system P.23A-36.
shaft speed sensor. YES <diagnosis code P1767 (P0720) is output> :
Refer to diagnosis code P1767 (P0720)
DIAGNOSIS CODE SET CONDITIONS output shaft speed sensor system P.23A-
If the output from the output shaft speed sensor mul- 41.
tiplied by the gear ratio is not the same as the output NO : Go to Step 2.
from the input shaft speed sensor after completing of
shifting, the corresponding diagnosis code is output.
If each diagnosis code is output 4 times, the trans-
Either of diagnosis codes P1779, P1780, P1781,
mission is fixed in 3rd as a fail-safe measure.
P1782 or P1784 is output, the corresponding sole-
PROBABLE CAUSES noid valve is defective.
• Malfunction of input shaft speed sensor Q: Is either of diagnosis code P1773 (P0750), P1774
• Malfunction of output shaft speed sensor (P0755), P1775 (P0760), P1776 (P0765) output?
• Damaged harness wires and connectors YES <diagnosis code P1773 (P0750) is output> :
• Malfunction of the A/T-ECU Refer to diagnosis code P1773 (P0750):
• Malfunction of solenoid valve Low-reverse solenoid valve system P.23A-
• Malfunction of underdrive clutch retainer 53.
• Malfunction of valve body YES <diagnosis code P1774 (P0755) is output> :
• Malfunction of transfer drive gear or driven gear Refer to diagnosis code P1774 (P0755):
• Malfunction of low-reverse brake system (for Underdrive solenoid valve system P.23A-
diagnosis codes P1779, P1784) 57.
• Malfunction of underdrive clutch system (for diag- YES <diagnosis code P1775 (P0760) is output> :
nosis codes P1779, P1780, P1781) Refer to diagnosis code P1775 (P0760):
• Malfunction of second brake system (for diagno- Second solenoid valve system P.23A-58.
sis codes P1780, P1782) YES <diagnosis code P1776 (P0765) is output> :
• Malfunction of overdrive clutch system (for diag- Refer to diagnosis code P1776 (P0765):
nosis codes P1781, P1782) Overdrive solenoid valve system P.23A-60.
NO : Go to Step 3.
• Malfunction of reverse clutch system (for diagno-
sis code P1784)
• Malfunction of one-way clutch system (for diag- STEP 3. Hydraulic pressure test
nosis code P1779) Each hydraulic pressure of the elements below,
which diagnosis codes indicate, should be within the
DIAGNOSIS PROCEDURE standard value.
• diagnosis code P1779: Underdrive clutch, low-
reverse brake
• diagnosis code P1780: Underdrive clutch, sec-
Either of diagnosis codes P1779, P1780, P1781,
ond brake
P1782 or P1784 is output, the input shaft speed sen-
• diagnosis code P1781: Underdrive clutch, over-
sor or output shaft speed sensor is defective.
drive clutch
Q: Are diagnosis codes P1766 (P0715) or P1767 • diagnosis code P1782: Overdrive clutch, second
(P0720) output? brake
• diagnosis code P1784: Reverse clutch, low-
reverse brake
OK: Refer to Hydraulic Pressure Test P.23A-
120.
TROUBLESHOOTING
23A-65
YES : Go to Step 6. (3) Check the diagnosis code.
NO <some hydraulic pressures are abnormal> :
Go to Step 5.
YES : Go to Step 7.
NO <all hydraulic pressure are abnormal> : Go to
Step 4.
STEP 7. Check the A/T internal clutch and brake,

STEP 4. Adjust the line pressure and recheck the
and then recheck the diagnosis code.
diagnosis code.
(1) Check the following clutches or brakes according
(1) Adjust the line pressure (Refer to P.23A-129).
to the output diagnosis codes, replace if
(2) Test drive the vehicle.
necessary.
(3) Check the diagnosis code.
• If diagnosis code P1779, P1780, P1781 are
Q: Is the diagnosis code set? output individually or in a group, replace the
YES : Go to Step 5. underdrive clutch.
NO : The inspection is complete. • If diagnosis code P1781, P1782 are output
individually or in a group, replace the over-
STEP 5. Disassemble, clean and assemble the drive clutch.
valve body and recheck the diagnosis code. • If diagnosis code P1784 is output, replace the
(1) Check the mounting bolts for looseness, and the reverse clutch.
O-ring, solenoid valve and valve body for • If diagnosis code P1779, P1784 are output
damage. individually or in a group, replace the low-
Replace the valve body assembly if the damages reverse brake.
are thought to be irreparable. • If diagnosis code P1780, P1782 are output
(2) Test drive the vehicle. individually or in a group, replace the second
(3) Check the diagnosis code. brake.
• If diagnosis code P1779 is output, replace the
Q: Is the diagnosis code set? one-way clutch.
YES : Go to Step 7.
STEP 6. Replace the A/T-ECU and then recheck YES : Eliminate the cause of the noise.
the diagnosis code. NO : The inspection is complete.
(1) Replace the A/T-ECU.
Code No.P1779 (1st), P1780 (2nd), P1781 (3rd), P1782 (4th), P1783 (5th), P1784 (reverse): Gear
incorrect ratio <5A/T>
OPERATION • Malfunction of output shaft speed sensor

The ECU detects the current gear/speed according • Damaged harness wires and connectors
to the output signals from the input and output shaft • Malfunction of the A/T-ECU
speed sensor. • Malfunction of solenoid valve
• Malfunction of reverse clutch retainer
DIAGNOSIS CODE SET CONDITIONS • Malfunction of valve body
If the output from the output shaft speed sensor mul- • Malfunction of direct planetary carrier
tiplied by the gear ratio is not the same as the output • Malfunction of low-reverse brake system (for
from the input shaft speed sensor after completing of diagnosis codes P1779, P1784)
shifting, the corresponding diagnosis code is set. • Malfunction of underdrive clutch system (for diag-
If each diagnosis code is set 4 times, the transmis- nosis codes P1779, P1780, P1781, P1782)
sion is fixed in 3rd as a fail-safe measure. • Malfunction of second brake system (for diagno-
sis codes P1780, P1783)
PROBABLE CAUSES
• Malfunction of overdrive clutch system (for diag-
nosis codes P1781, P1782, P1783)
TROUBLESHOOTING
• Malfunction of reverse clutch system (for diagno- STEP 3. Hydraulic pressure test
sis code P1784) Each hydraulic pressure of the elements below,
• Malfunction of direct clutch system (for diagnosis which diagnosis codes indicate, should be within the
codes P1782, P1783) standard value.
• Malfunction of reduction brake system (for diag- • diagnosis code P1779: Underdrive clutch, low-
nosis codes P1779, P1780, P1781, P1784) reverse brake, reduction brake
• Malfunction of one-way clutch (OWC-L) system • diagnosis code P1780: Underdrive clutch, sec-
(for diagnosis code P1779) ond brake, reduction brake
• Malfunction of one-way clutch (OWC-D) system • diagnosis code P1781: Underdrive clutch, over-
(for diagnosis code P1779, P1780, P1781) drive clutch, reduction brake
• diagnosis code P1782: Underdrive clutch, over-
DIAGNOSIS PROCEDURE drive clutch, direct clutch
• diagnosis code P1783: Overdrive clutch, direct
STEP 1. M.U.T.-III diagnosis code clutch, second brake
Either of diagnosis codes P1779, P1780, P1781, • diagnosis code P1784: Reverse clutch, low-
P1782, P1783 or P1784 is set, the input shaft speed reverse brake, reduction brake
sensor or output shaft speed sensor is defective. OK: Refer to Hydraulic Pressure Test P.23A-
Q: Are diagnosis codes P1766 (P0715) or P1767 120.
(P0720) output? Q: Is the check result normal?
YES diagnosis code P1766 (P0715) is set : Refer to YES : Go to Step 6.
diagnosis code P1766 (P0715) input shaft NO some hydraulic pressures are abnormal : Go
speed sensor system P.23A-36. to Step 5.
YES diagnosis code P1767 (P0720) is set : Refer to NO all hydraulic pressure are abnormal : Go to
diagnosis code P1767 (P0720) output shaft Step 4.
speed sensor system P.23A-41.
NO : Go to Step 2.
STEP 4. Adjust the line pressure and recheck the
diagnosis code.
STEP 2. M.U.T.-III diagnosis code (1) Adjust the line pressure (Refer to P.23A-129).
Either of diagnosis codes P1779, P1780, P1781, (2) Test drive the vehicle.
P1782, P1783 or P1784 is set, the corresponding (3) Check the diagnosis code.
solenoid valve is defective.
Q: Is either of diagnosis code P1773 (P0750), P1774 YES : Go to Step 5.
(P0755), P1775 (P0760), P1776 (P0765), P1777 NO : The inspection is complete.
(P0770) output?
YES diagnosis code P1773 (P0750) is set : Refer to
diagnosis code P1773 (P0750): Low- STEP 5. Disassemble, clean and assemble the
reverse solenoid valve system P.23A-53. valve body and recheck the diagnosis code.
YES diagnosis code P1774 (P0755) is set : Refer to (1) Check the mounting bolts for looseness, and the
diagnosis code P1774 (P0755): Underdrive O-ring, solenoid valve and valve body for
solenoid valve system P.23A-57. damage.
YES diagnosis code P1775 (P0760) is set : Refer to Replace the valve body assembly if the damages
diagnosis code P1775 (P0760): Second are thought to be irreparable.
solenoid valve system P.23A-58. (2) Test drive the vehicle.
YES diagnosis code P1776 (P0765) is set : Refer to (3) Check the diagnosis code.
diagnosis code P1776 (P0765): Overdrive Q: Is the diagnosis code set?
solenoid valve system P.23A-60. YES : Go to Step 7.
YES diagnosis code P1777 (P0770) is set : Refer to NO : The inspection is complete.
diagnosis code P1777 (P0770): Reduction
solenoid valve system P.23A-61 .
NO : Go to Step 3. STEP 6. Replace the A/T-ECU and then recheck
the diagnosis code.
TROUBLESHOOTING
23A-67
(3) Check the diagnosis code. necessary.
• If diagnosis code P1779, P1780, P1781,
YES : Go to Step 7. P1782 are set individually or in a group,
NO : The inspection is complete. replace the underdrive clutch.
set individually or in a group, replace the over-
STEP 7. Check the A/T internal clutch and brake, drive clutch.
and then recheck the diagnosis code. • If diagnosis code P1784 is set, replace the
(1) Check the following clutches or brakes according reverse clutch.
to the output diagnosis codes, replace if • If diagnosis code P1779, P1784 are set indi-
vidually or in a group, replace the low-reverse
brake.
• If diagnosis code P1780, P1783 are set indi-
vidually or in a group, replace the second
brake.
• If diagnosis code P1782, P1783 are set indi-
vidually or in a group, replace the direct
clutch.
• If diagnosis code P1779, P1780, P1781,
P1784 are set individually or in a group,
replace the reduction brake.
• If diagnosis code P1779 is set, replace the
one-way clutch (OWC-L).
set individually or in a group, replace the one-
way clutch (OWC-D).
YES : Eliminate the cause of the noise.
Code No.P1786 Damper clutch system (stuck off)
OPERATION • Malfunction of torque converter

The A/T-ECU engages and disengages the damper
clutch (incorporated in the torque converter) by oper- DIAGNOSIS PROCEDURE
ating the DCC solenoid valve in response to driving
conditions.
DIAGNOSIS CODE SET CONDITIONS If diagnosis code P1786 is output, the input shaft
If the damper clutch solenoid valve drive duty ratio is speed sensor may be defective.
100% for a continuous period of 4 seconds or more Q: Is diagnosis code P1766 (P0715) set?
when the damper clutch starts operating, diagnosis YES : Refer to diagnosis code P1766 (P0715):
code No.P1786 is output. Input shaft speed sensor system P.23A-36.
NO : Go to Step 2.
PROBABLE CAUSES
• Damaged harness wires and connectors STEP 2. M.U.T.-III diagnosis code
• Malfunction of the A/T-ECU If diagnosis code P1786 is output, the damper clutch
• Malfunction of damper clutch solenoid valve solenoid valve may be defective.
• Malfunction of valve body assembly Q: Is diagnosis code P1778 (P0740) set?
TROUBLESHOOTING
YES : Refer to diagnosis code P1778 (P0740): (3) Check the diagnosis code.
Damper clutch solenoid valve system
P.23A-62. YES : Go to Step 7.
NO : Go to Step 3. NO : The inspection is complete.
STEP 3. M.U.T.-III data list STEP 6. Replace the A/T-ECU and then recheck
• Item 17: Damper clutch solenoid valve duty ratio the diagnosis code.
(Refer to data list reference table P.23A-103). (1) Replace the A/T-ECU.
• Item 10: Damper clutch slip amount (Refer to (2) Test drive the vehicle.
data list reference table P.23A-103). (3) Check the diagnosis code.
Q: Is the check result normal? Q: Is the diagnosis code set?
NO : Go to Step 4. NO : The inspection is complete.
STEP 4. Hydraulic pressure test STEP 7. Disassemble, clean and assemble the
Measure the torque converter hydraulic pressure. valve body and recheck the diagnosis code.
(Refer to P.23A-120.) (1) Check the mounting bolts for looseness, and the
OK: Refer to Hydraulic Pressure Test P.23A- O-ring, solenoid valve and valve body for
120. damage.
Q: Is the check result normal? Replace the valve body assembly if the damages
YES : Go to Step 6. are thought to be irreparable.
NO : Go to Step 5. (2) Test drive the vehicle.
STEP 5. Adjust the line pressure and recheck the Q: Is the diagnosis code set?
diagnosis code. YES : Check the torque converter and replace it if
(1) Adjust the line pressure (Refer to P.23A-129). necessary.
(2) Test drive the vehicle. NO : The inspection is complete.
Code No.P1787 Damper clutch system (stuck on)

Refer to P.23A-67.
DIAGNOSIS CODE SET CONDITIONS STEP 1. M.U.T.-III diagnosis code

If the damper clutch control remains engaged for a If diagnosis code P1787 is output, the damper clutch
continuous period of ten seconds or more when the solenoid valve may be defective.
A/T-ECU is attempting to disengage the damper Q: Is diagnosis code P1778 (P0740) set?
clutch control, diagnosis code No.P1787 is output. YES : Refer to diagnosis code P1778 (P0740):
Damper clutch solenoid valve system
PROBABLE CAUSES
P.23A-62.
NO : Go to Step 2.
• Malfunction of damper clutch solenoid valve
• Malfunction of valve body assembly STEP 2. M.U.T.-III data list
Item 10: Damper clutch slip amount (Refer to data
list reference table P.23A-103).
Malfunction .)
NO : Go to Step 3.
TROUBLESHOOTING
23A-69
STEP 3. Replace the A/T-ECU and then recheck O-ring, solenoid valve and valve body for
the diagnosis code. damage.
(1) Replace the A/T-ECU. Replace the valve body assembly if the damages
(2) Test drive the vehicle. are thought to be irreparable.
(3) Check the diagnosis code. (2) Test drive the vehicle.
YES : Go to Step 4. Q: Is the diagnosis code set?
NO : The inspection is complete. YES : Check the torque converter and replace it if
necessary.
STEP 4. Disassemble, clean and assemble the
valve body and recheck the diagnosis code.
(1) Check the mounting bolts for looseness, and the
Code No.P1788 (P1751) A/T control relay system
A/T Control Relay System Circuit
IGNITION FUSIBLE
SWITCH (IG1) LINK 23
RELAY
BOX
<4A/T, 5A/T-LHD>
<5A/T-RHD>
A/T
CONTROL
RELAY
A/T-ECU
SOLENOID
VALVE
POWER SOURCE
Wire colour code

AC903910
TROUBLESHOOTING
Connector: A-19X Connector: C-20 <LHD>
A-19X
A/T-ECU
<RHD>
Relay box side
AC510163AG
A/T-ECU
Connector: A-115
C-20
Harness side
A-115 Harness side
AC510057AC
AC509975AO

Connector: C-19 <LHD> Harness side
A/T-ECU
<RHD>
C-34
AC509930AG
A/T-ECU Connector: C-52 <LHD>
C-19 C-52
Harness side
Harness side
AC510057AD AC509613AG
TROUBLESHOOTING
23A-71
Connectors: C-207, C-208 <LHD> STEP 2. Check the A/T control relay connector
Refer to P.23A-118.
C-208
YES : Go to Step 3.
C-207 NO : Replace the A/T control relay.

relay connector
AC509934 CX
Connectors: C-207, C-208 <RHD> YES : Go to Step 4.
Junction block NO : Repair the defective connector.
C-207 STEP 4. Measure the voltage at A/T control relay

connector A-19X.
Disconnect the A/T control relay, and measure the
C-208 voltage between terminal No.4 and earth at the relay
box side.
AC509936 BZ OK: System voltage
OPERATION YES : Go to Step 8.
If a fail-safe operation is activated, the A/T control NO : Go to Step 5.
relay shuts off the power supply to the solenoid valve
in accordance with the signal from the A/T-ECU. STEP 5. Connector check: A-115 intermediate
connector
DIAGNOSIS CODE SET CONDITION Check for the contact with terminals.
Code No.P1788 (P1751) will be set if the A/T control
voltage is less than 7 V after the ignition switch is Q: Is the check result normal?
turned on. YES : Go to Step 6.
If code No.P1788 (P1751) is set, the transmission NO : Repair the defective connector.
will be held in 3rd gear.
PROBABLE CAUSES relay connector A-19X terminal No.4 and fusible
• Malfunction of A/T control relay link (23).
• Damaged harness wires and connectors Check the power supply line for short or open circuit.
YES : Go to Step 7.
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-III data list STEP 7. M.U.T.-III data list

Item 08: Relay voltage (Refer to data list reference Item 08: Relay voltage (Refer to data list reference
table P.23A-103.) table P.23A-103.)
YES : The trouble can be an intermittent
00 − How to Cope with Intermittent malfunction (Refer to GROUP 00 − How to
Malfunction .) Cope with Intermittent Malfunction ).
NO : Go to Step 2.
TROUBLESHOOTING

STEP 8. Measure the voltage at the A/T control
NO : Go to Step 12.
relay connector A-19X.
(2) Disconnect the A/T control relay, and measure STEP 12. Connector check: C-19 A/T-ECU
the voltage between terminal No.1 and earth at connector
the relay box side. Check for the contact with terminals.
OK: System voltage Q: Is the check result normal?
NO : Go to Step 9.
STEP 9. Connectors check: C-52 <4A/T, 5A/T- relay connector A-19X terminal No.3 and A/T-ECU
LHD>or C-34 <5A/T-RHD> intermediate connector C-19 terminal No.2, 3.
connector, C-208 J/B connector Check the power supply line for short or open circuit.
YES : Go to Step 7.
STEP 14. Connector check: C-20 A/T-ECU
STEP 10. Check the wiring harness between A/T connector
control relay connector A-19X terminal No.1 and Check for the contact with terminals.
J/B connector C-208 terminal No.2. Q: Is the check result normal?
Check the power supply line for short or open circuit. YES : Go to Step 15.
YES : Go to Step 7.
NO : Repair the wiring harness. STEP 15. Check the harness between A/T control
relay connector A-19X terminal No.2 and A/T-ECU
STEP 11. Measure the voltage at A/T-ECU connector C-20 terminal No.71.
connector C-19. Check the output line for short or open circuit.
(1) Install the A/T control relay. Q: Is the check result normal?
(3) Measure the voltage between A/T-ECU NO : Repair the wiring harness.
connector C-19 terminal No.2, No.3 and earth.
OK: System voltage
TROUBLESHOOTING
23A-73
Code No.P1790 Back up line system
Back Up Line System Circuit

FUSIBLE
LINK 23
RELAY
BOX
Wire colour code

AC510282 AB
Connector: A-115 Connector: C-12 <LHD>
A/T-ECU
Harness side
<RHD>
A-115
AC509975AO
A/T-ECU
C-12
Harness side
AC510057AB
TROUBLESHOOTING
STEP 2. Connectors check: A-115 intermediate

OPERATION connector, C-12 A/T-ECU connector.
Always power is supplied to the ECU to prevent the Check for the contact with terminals.
reset of A/T-ECU memory when the ignition switch is
turned to the LOCK (OFF) position. Q: Is the check result normal?
YES : Go to Step 3.
DIAGNOSIS CODE SET CONDITION NO : Repair the defective connector.
If the battery voltage is 10 V or more and back-up
voltage is less than 6 V while the ignition switch is STEP 3. Check the harness between A/T-ECU
ON position for 2 seconds or more, it is judged that connector C-12 terminal No.38 and fusible link
there is a open circuit in the back-up line and diagno- (23).
sis code No. P1790 is set. Check the power supply line for short or open circuit.
• Damaged harness wires and connectors YES : Go to Step 5.
• Malfunction of the A/T-ECU NO : Repair the wiring harness.
DIAGNOSIS PROCEDURE STEP 4. Connector check: C-12 A/T-ECU

connector.
(1) Measure the voltage between A/T-ECU YES : Go to Step 5.
connector C-12 terminal No.38 and earth. NO : Repair the defective connector.
OK: System voltage
STEP 5. Replace the A/T-ECU and then recheck
YES : Go to Step 4. the diagnosis code.
NO : Go to Step 2. (1) Replace the A/T-ECU.
YES : Go to Step 1.
Code No.P1901: CAN signal time-out (Engine-ECU)
CAUTION Past trouble

• If diagnosis code P1901 is set in the A/T-ECU, • Carry out diagnosis with particular emphasis on
always diagnose the CAN main bus line. If connector(s) or wiring harness in the CAN bus
there is any fault in the CAN bus lines, an lines between the engine-ECU and the A/T-ECU,
incorrect diagnosis code may be set. and the power supply system to the engine-ECU.
For diagnosis procedures, refer to "How to cope
• Whenever the ECU is replaced, ensure that
with past trouble" (Refer to GROUP 00, How to
the communication circuit is normal.
Use Troubleshooting/Inspection Service Points ).
DIAGNOSIS CODE SET CONDITIONS NOTE: For a past trouble, you may not find it by the
M.U.T.-III CAN bus diagnostics even if there is
Current trouble
any failure in CAN bus lines. In this case, refer to
• Connector(s) or wiring harness in the CAN bus
GROUP 00, How to Use Troubleshooting/Inspec-
lines between the engine-ECU and the A/T-ECU,
tion Service Points − How to Cope with Intermit-
the power supply system to the engine-ECU, the
tent Malfunctions ). and check the CAN bus lines.
engine-ECU itself, or the A/T-ECU may be defec-
tive.
TROUBLESHOOTING
23A-75
You can narrow down the possible cause of the YES : Diagnose the diesel fuel system (Refer to
trouble by referring to the diagnosis code, which GROUP 13A, Troubleshooting ).
is set regarding the CAN communication-linked NO : Go to Step 3.
ECUs (Refer to GROUP 54C, Explanation about
the M.U.T.-III CAN Bus Diagnostics ). STEP 3. M.U.T.-III diagnosis code
Reconfirm whether the diagnosis codes are output
PROBABLE CAUSES
from A/T-ECU.
• Damaged wiring harness or connector
(1) Erase the diagnosis code.
• Malfunction of the engine-ECU
(2) Turn the ignition switch to ON position.
(3) Check if the diagnosis code is set.
DIAGNOSIS PROCEDURE Q: Is the diagnosis code output?
YES : Go to Step 4.
STEP 1. M.U.T.-III CAN bus diagnostics between engine-ECU and A/T-ECU (Refer
Using M.U.T.-III, perform CAN busline diagnosis. to GROUP 00 − How to Use
Q: Is the check result normal? Troubleshooting/Inspection Service Points −
YES : Go to Step 2. How to Cope with Intermittent Malfunction ).
NO : Repair the CAN busline (Refer to
GROUP54C, Diagnosis − Can Bus STEP 4. Replace the engine-ECU
Diagnostic Chart ), and then go to Step 4. After replacing the engine-ECU, re-check the A/T
diagnosis code output.
STEP 2. M.U.T.-III other system diagnosis codes Q: Is the diagnosis code output?
Check whether the diesel fuel system diagnosis YES : Replace the A/T-ECU.
codes are set or not. NO : The check is end.
Code No.U1073: Bus off
CAUTION YES : Go to Step 2.

NO : Repair the CAN bus line (Refer to GROUP
• If diagnosis code U1073 is set in the A/T-ECU,
always diagnose the CAN main bus line. If 54C, CAN bus line Diagnostic flow .) Then
there is any fault in the CAN bus lines, an go to Step 3.
incorrect diagnosis code may be set.
• Whenever the ECU is replaced, ensure that STEP 2. M.U.T.-III diagnosis code
the communication circuit is normal. Check again if the diagnosis code is set.
DIAGNOSIS CODE SET CONDITIONS (2) Erase the diagnosis code.
The failure is possibly caused by malfunction of the (3) Turn the ignition switch to the LOCK (OFF)
harness and connector in CAN busline or by mal- position.
function in A/T-ECU. (4) Turn the ignition switch to the ON position.
(5) Check if the diagnosis code is set.
PROBABLE CAUSES (6) Turn the ignition switch to the LOCK (OFF)
• Damaged wiring harness or connector position.
Q: Is code No.U1073 set?
DIAGNOSIS PROCEDURE YES : Replace the A/T-ECU. Then go to Step 3.
STEP 1. M.U.T.-III CAN bus diagnostics Inspection Service Points ).
Using M.U.T.-III, perform CAN busline diagnosis.
TROUBLESHOOTING
STEP 3. Check whether the diagnosis code is (4) Turn the ignition switch to the ON position.
reset. (5) Check if the diagnosis code is set.
Check again if the diagnosis code is set. (6) Turn the ignition switch to the LOCK (OFF)
(1) Turn the ignition switch to the ON position. position.
(2) Erase the diagnosis code. Q: Is code No.U1073 set?
(3) Turn the ignition switch to the LOCK (OFF) YES : Go to Step 1.
position. NO : The procedure is complete.
Code No.U1100: Engine-ECU time-out (related to engine)
CAUTION DIAGNOSIS PROCEDURE

always diagnose the CAN main bus line. If STEP 1. M.U.T.-III CAN bus diagnostics
there is any fault in the CAN bus lines, an Using M.U.T.-III, perform CAN busline diagnosis.
• Whenever the ECU is replaced, ensure that Q: Is the check result normal?
DIAGNOSIS CODE SET CONDITIONS GROUP54C, Diagnosis − Can Bus
Diagnostic Chart ), and then go to Step 6.
Current trouble
lines between the engine-ECU and the A/T-ECU, STEP 2. M.U.T.-III other system diagnosis codes
the power supply system to the engine-ECU, the Check whether the diesel fuel system diagnosis
engine-ECU itself, or the A/T-ECU may be defec- codes are set or not.
tive. Q: Is the diagnosis code set?
YES : Diagnose the diesel fuel system (Refer to
Past trouble
GROUP 13A, Troubleshooting ).
• Carry out diagnosis with particular emphasis on
NO : Go to Step 3.
connector(s) or wiring harness in the CAN bus
lines between the engine-ECU and the A/T-ECU,
and the power supply system to the engine-ECU. STEP 3. M.U.T.-III other system diagnosis codes
For diagnosis procedures, refer to "How to cope Check if a diagnosis code, which relates to CAN
with past trouble" (Refer to GROUP 00, How to communication-linked systems below, is set.
Use Troubleshooting/Inspection Service Points ). • ETACS-ECU: Code No.U1100
NOTE: For a past trouble, you may not find it by the Q: Is the diagnosis code set?
M.U.T.-III CAN bus diagnostics even if there is YES : Go to Step 4.
any failure in CAN bus lines. In this case, refer to NO : Go to Step 5.
tion Service Points − How to Cope with Intermit- STEP 4. M.U.T.-III diagnosis code
tent Malfunctions ). and check the CAN bus lines. Reconfirm whether the diagnosis codes are output
You can narrow down the possible cause of the from A/T-ECU.
trouble by referring to the diagnosis code, which (1) Erase the diagnosis code.
is set regarding the CAN communication-linked (2) Turn the ignition switch to ON position.
ECUs (Refer to GROUP 54C, Explanation about (3) Check if the diagnosis code is set.
the M.U.T.-III CAN Bus Diagnostics ).
PROBABLE CAUSES YES : Replace engine-ECU. Then go to Step 6.
• Damaged wiring harness or connector NO : Intermittent malfunction in CAN busline
• Malfunction of the engine-ECU between engine-ECU and A/T-ECU (Refer
• Malfunction of the A/T-ECU to GROUP 00 − How to Use
Troubleshooting/Inspection Service Points ).
TROUBLESHOOTING
23A-77
STEP 5. M.U.T.-III diagnosis code STEP 6. M.U.T.-III diagnosis code
Reconfirm whether the diagnosis codes are output Reconfirm whether the diagnosis codes are output
from A/T-ECU. from A/T-ECU.
(1) Erase the diagnosis codes being output. (1) Erase the diagnosis codes being output.
(2) Ignition switch: LOCK (OFF) to ON (2) Ignition switch: LOCK (OFF) to ON
(3) Confirm whether the diagnosis codes are output. (3) Confirm whether the diagnosis codes are output.
YES : Replace A/T-ECU. Then go to Step 6. YES : Go to step 1.
NO : Intermittent malfunction in CAN busline NO : The procedure is complete.
between engine-ECU and A/T-ECU (Refer
Code No. U1102 ASTC-ECU time-out
CAUTION PROBABLE CAUSES

• If diagnosis code U1102 is set in the A/T-ECU, • Damaged wiring harness or connector
always diagnose the CAN main bus line. If • Malfunction of the ASTC-ECU
there is any fault in the CAN bus lines, an • Malfunction of the A/T-ECU
• Whenever the ECU is replaced, ensure that DIAGNOSIS PROCEDURE
DIAGNOSIS CODE SET CONDITIONS Using M.U.T.-III, perform CAN busline diagnosis.
Current trouble Q: Is the check result normal?
• Connector(s) or wiring harness in the CAN bus YES : Go to Step 2.
lines between the ASTC-ECU and the A/T-ECU, NO : Repair the CAN busline (Refer to
the power supply system to the ASTC-ECU, the GROUP54C, Diagnosis − Can Bus
ASTC-ECU itself, or the A/T-ECU may be defec- Diagnostic Chart ), and then go to Step 4.
tive.
Past trouble STEP 2. M.U.T.-III other system diagnosis codes
• Carry out diagnosis with particular emphasis on Check whether the ASTC system diagnosis codes
connector(s) or wiring harness in the CAN bus are set or not.
lines between the ASTC-ECU and the A/T-ECU,
and the power supply system to the ASTC-ECU.
YES : Diagnose the ASTC system (Refer to
For diagnosis procedures, refer to "How to cope
GROUP 35C, Troubleshooting ).
with past trouble" (Refer to GROUP 00, How to
NO : Go to Step 3.
Use Troubleshooting/Inspection Service Points ).
NOTE: For a past trouble, you may not find it by the
M.U.T.-III CAN bus diagnostics even if there is STEP 3. M.U.T.-III diagnosis code
any failure in CAN bus lines. In this case, refer to Reconfirm whether the diagnosis codes are output
GROUP 00, How to Use Troubleshooting/Inspec- from A/T-ECU.
tion Service Points − How to Cope with Intermit- (1) Erase the diagnosis code.
tent Malfunctions ). and check the CAN bus lines. (2) Turn the ignition switch to ON position.
You can narrow down the possible cause of the (3) Check if the diagnosis code is set.
trouble by referring to the diagnosis code, which Q: Is the diagnosis code output?
is set regarding the CAN communication-linked
ECUs (Refer to GROUP 54C, Explanation about
TROUBLESHOOTING
YES : Go to Step 4.
STEP 4. Replace the ASTC-ECU
After replacing the ASTC-ECU, re-check the A/T
between ASTC-ECU and A/T-ECU (Refer to
diagnosis code output.
GROUP 00 − How to Use Troubleshooting/
Inspection Service Points − How to Cope Q: Is the diagnosis code output?
with Intermittent Malfunction ). YES : Replace the A/T-ECU.
Code No.U1109: ETACS-ECU time-out
CAUTION DIAGNOSIS PROCEDURE

always diagnose the CAN main bus line. If STEP 1. M.U.T.-III CAN bus diagnostics
there is any fault in the CAN bus lines, an Using M.U.T.-III, perform CAN busline diagnosis.
• Whenever the ECU is replaced, ensure that Q: Is the check result normal?
DIAGNOSIS CODE SET CONDITIONS GROUP54C, Diagnosis − Can Bus
Current trouble
lines between the ETACS-ECU and the A/T-ECU, STEP 2. M.U.T.-III other system diagnosis codes
the power supply system to the ETACS-ECU, the Check whether the local interconnect network sys-
ETACS-ECU itself, or the A/T-ECU may be defec- tem diagnosis codes are set or not.
tive. Q: Is the diagnosis code set?
YES : Diagnose the ETACS system (Refer to
Past trouble
• Carry out diagnosis with particular emphasis on
NO : Go to Step 3.
connector(s) or wiring harness in the CAN bus
lines between the ETACS-ECU and the A/T-ECU,
and the power supply system to the ETACS-ECU. STEP 3. M.U.T.-III other system diagnosis codes
For diagnosis procedures, refer to "How to cope Check if a diagnosis code, which relates to CAN
with past trouble" (Refer to GROUP 00, How to communication-linked systems below, is set.
Use Troubleshooting/Inspection Service Points ). • Engine-ECU: Code No.U1109
NOTE: For a past trouble, you may not find it by the Q: Is the diagnosis code set?
M.U.T.-III CAN bus diagnostics even if there is YES : Go to Step 4.
any failure in CAN bus lines. In this case, refer to NO : Go to Step 5.
tion Service Points − How to Cope with Intermit- STEP 4. M.U.T.-III diagnosis code
tent Malfunctions ). and check the CAN bus lines. Reconfirm whether the diagnosis codes are output
You can narrow down the possible cause of the from A/T-ECU.
trouble by referring to the diagnosis code, which (1) Erase the diagnosis code.
is set regarding the CAN communication-linked (2) Turn the ignition switch to ON position.
ECUs (Refer to GROUP 54C, Explanation about (3) Check if the diagnosis code is set.
PROBABLE CAUSES YES : Replace ETACS-ECU. Then go to Step 6.
• Damaged wiring harness or connector NO : Intermittent malfunction in CAN busline
• Malfunction of the ETACS-ECU between ETACS-ECU and A/T-ECU (Refer
• Malfunction of the A/T-ECU to GROUP 00 − How to Use
TROUBLESHOOTING
23A-79
STEP 5. M.U.T.-III diagnosis code STEP 6. M.U.T.-III diagnosis code
Reconfirm whether the diagnosis codes are output Reconfirm whether the diagnosis codes are output
from A/T-ECU. from A/T-ECU.
(1) Erase the diagnosis codes being output. (1) Erase the diagnosis codes being output.
(2) Ignition switch: LOCK (OFF) to ON (2) Ignition switch: LOCK (OFF) to ON
(3) Confirm whether the diagnosis codes are output. (3) Confirm whether the diagnosis codes are output.
YES : Replace A/T-ECU. Then go to Step 6. YES : Go to step 1.
NO : Intermittent malfunction in CAN busline NO : The procedure is complete.
between ETACS-ECU and A/T-ECU (Refer
Code No.U1120: Failure information of engine-ECU

A/T-ECU receives the signal from the engine-ECU Reconfirm whether the diagnosis codes are output
via the CAN bus line. When the received signal con- from A/T-ECU.
tains failure information, the diagnosis code No. (1) Erase the diagnosis codes being output.
U1120 is stored. (2) Ignition switch: LOCK (OFF) to ON
PROBABLE CAUSES (3) Confirm whether the diagnosis codes are output.
• Damaged wiring harness or connector Q: Is the diagnosis code output?
• Malfunction of the engine-ECU YES : Replace engine-ECU. Then go to Step 4.
• Malfunction of the A/T-ECU NO : Intermittent malfunction in CAN busline
between engine-ECU and A/T-ECU (Refer
DIAGNOSIS PROCEDURE to GROUP 00 − How to Use
Using M.U.T.-III, perform CAN busline diagnosis. STEP 4. M.U.T.-III diagnosis code
Q: Is the check result normal? from A/T-ECU.
YES : Go to Step 2.
(1) Erase the diagnosis codes being output.
(2) Ignition switch: LOCK (OFF) to ON
GROUP54C, Diagnosis − Can Bus
(3) Confirm whether the diagnosis codes are output.
YES : Replace A/T-ECU. Then go to Step 5.
STEP 2. M.U.T.-III other system diagnosis codes NO : The procedure is complete.
Check whether the diesel fuel system diagnosis
codes are set or not.
Q: Is the diagnosis code set? Reconfirm whether the diagnosis codes are output
YES : Diagnose the diesel fuel system (Refer to
from A/T-ECU.
• Erase the diagnosis codes being output.
NO : Go to Step 3.
• Ignition switch: LOCK (OFF) to ON
• Confirm whether the diagnosis codes are output.
YES : Go to Step 1.
TROUBLESHOOTING
Code No.U1190: Can’t receive fault detection control signal

To each ECU connected to the CAN bus line, Reconfirm whether the diagnosis codes are output
ETACS-ECU sends the diagnosis code (U code) from A/T-ECU.
detection permission or prohibition signal. When A/T- (1) Erase the diagnosis codes being output.
ECU cannot receive the diagnosis code (U code) (2) Ignition switch: LOCK (OFF) to ON
detection permission or prohibition signal for 5 sec- (3) Confirm whether the diagnosis codes are output.
onds, diagnosis code No. U1190 is stored.
PROBABLE CAUSES YES : Replace the ETACS-ECU, and then go to
• Malfunction of the ETACS-ECU Step 3.
• Malfunction of the CAN bus NO : The procedure is complete.
DIAGNOSIS PROCEDURE STEP 3. M.U.T.-III diagnosis code

STEP 1. M.U.T.-III CAN bus diagnostics from A/T-ECU.
Using M.U.T.-III, perform CAN busline diagnosis. (1) Erase the diagnosis codes being output.
(2) Ignition switch: LOCK (OFF) to ON
Q: Is the check result normal? (3) Confirm whether the diagnosis codes are output.
YES : Go to Step 2.
NO : Repair the CAN busline (Refer to Q: Is the diagnosis code output?
GROUP54C, Diagnosis − Can Bus YES : Return to Step 1.
Diagnostic Chart ), and then go to Step 3. NO : The procedure is complete.
TROUBLE SYMPTOMS CHART

M1231128400177

procedure No.
Communication with the M.U.T.-III is not possible 1 P.23A-81
Driving not possible Engine does not start 2 P.23A-83
Does not move forward 3 P.23A-84
Does not move backward 4 P.23A-85
Does not move (forward or backward) 5 P.23A-85
Malfunction when Engine stalls during shifting 6 P.23A-86
starting off Shift shock when shifting from N to D and 7 P.23A-87
long delay
Shift shock when shifting from N to R and 8 P.23A-88
long delay
Shift shock when shifting from N to D, N to 9 P.23A-89
R and long delay
Problem during Shift shock and slipping 10 P.23A-90
shifting
Incorrect shift points Does not shift properly (all point) 11 P.23A-90
Does not shift properly (some point) 12 P.23A-91
No shifting Does not shift (no diagnosis code) 13 P.23A-91
Problem during Poor acceleration 14 P.23A-92
driving Vibration 15 P.23A-92
TROUBLESHOOTING
23A-81
procedure No.
Overdrive switch system <4A/T> 16 P.23A-93
4LLc switch system <4WD> 17 P.23A-96
Shift switch assembly system<5A/T> 18 P.23A-99
SYMPTOM PROCEDURES
Inspection Procedure 1: Communication with the M.U.T.-III is not Possible.
Diagnosis Connector Circuit
A/T-ECU
Wire colour code

B : Black LG : Light green G : Green L : Blue
W : White Y : Yellow SB : Sky blue BR : Brown
O : Orange GR : Grey R : Red P : Pink
V : Violet PU : Purple
DIAGNOSIS
CONNECTOR
AC509577AD
TROUBLESHOOTING

Harness side
(Front side)
AC509613AK C-22 (B)

AC509932AJ
C-119 (GR)
AC509930AM
AC509613AN

A/T-ECU
<RHD>
C-119 (GR)
A/T-ECU AC509932AU
C-20
CAUTION
Harness side If there is any problem in the CAN bus lines, an
incorrect diagnosis code may be set. Diagnose
the CAN bus lines before the diagnosis codes
(Refer to GROUP 54C, CAN bus-line diagnostic
AC510057AC
flow ).
TECHNICAL DESCRIPTION (COMMENT)
Connector: C-22 <LHD> If the M.U.T.-III can not communicate with the A/T
system, the CAN bus lines may be defective. If the A/
T system does not work, the A/T-ECU or its power
supply circuit may be defective.
PROBABLE CAUSES
Harness side
(Front side)
• Damaged wiring harness or connector
C-22 (B)
AC509611AJ
TROUBLESHOOTING
23A-83
DIAGNOSIS PROCEDURE (2) Turn the ignition switch to the ON position.
(3) Diagnose the CAN bus line.
STEP 1. M.U.T.-III CAN bus diagnostics Q: Is the check result normal?
Use M.U.T.-III to diagnose the CAN bus lines. YES : Check and repair the A/T system.
(1) Connect M.U.T.-III to the 16-pin diagnosis NO : Repair the CAN bus lines (Refer to GROUP
connector. 54C, CAN bus line Diagnostic flow ).
Inspection Procedure 2: Engine Does not Start
COMMENTS ON TROUBLE SYMPTOM YES : Go to Step 3.

If the engine does not start when the selector lever is NO : Adjust the positions of the transmission
in P or N position, the cause is probably a malfunc- control cable and inhibitor switch (Refer to
tion of inhibitor switch system, transmission control P.23A-114).
cable, engine system, torque converter or oil pump.
PROBABLE CAUSES STEP 3. Engine system check

• Malfunction of inhibitor switch Q: Is the check result normal?
• Malfunction of transmission control cable YES : Go to Step 4.
• Malfunction of engine system NO : Repair the engine system.
• Malfunction of torque converter
• Malfunction of oil pump STEP 4. A/T-ECU replacement
• Malfunction of the A/T-ECU (1) Replace the A/T-ECU.
DIAGNOSIS PROCEDURE (3) Verify that the condition described by the
customer exists.
STEP 1. M.U.T.-III diagnosis code Q: Does a malfunction take place again?
Either of diagnosis codes P1770 (P0705) or P1771 YES : Go to Step 5.
(P0705) is set, inhibitor switch is defective. NO : The inspection is complete.
Q: Are diagnosis codes P1770 (P0705) or P1771
(P0705) output? STEP 5. Torque converter check
YES <diagnosis code P1770 (P0705) is set> : Refer Check for damaged drive plate, incorrect installation
to diagnosis code P1770 (P0705): Inhibitor in the input shaft (inserted at an angle) or damaged
switch system P.23A-46 <4A/T>, P.23A-49 splines.
<5A/T>.
YES <diagnosis code P1771 (P0705) is set> : Refer Q: Is the check result normal?
YES : Check the oil pump for incorrect installation,
to diagnosis code P1771 (P0705): Inhibitor
switch system P.23A-51 <4A/T>, P.23A-52 damage and etc., and replace the oil pump
<5A/T>. assembly if necessary (The oil pump cannot
NO : Go to Step 2. be disassembled).
NO : If repair is possible, repair the damaged
part. If repair is not possible because the
STEP 2. Transmission control cable check splines on the drive plate or torque
Check the transmission control cable and inhibitor converter are damaged, replace it.
switch for installation condition.
TROUBLESHOOTING
Inspection Procedure 3: Does not Move Forward
COMMENTS ON TROUBLE SYMPTOM STEP 4. Hydraulic pressure test

If the vehicle does not move forward when the selec- Measure the hydraulic pressure of the underdrive
tor lever is shifted N to D, 2, L range or sport mode clutch when the selector lever is at the L range or
(1st, 2nd gear) while the engine is idling, the cause is sport mode (1st gear).
probably abnormal line pressure or a malfunction of
the underdrive clutch or valve body. OK: Refer to P.23A-120.
• Malfunction of underdrive solenoid valve NO : Go to Step 5.
• Malfunction of inhibitor switch
• Abnormal line pressure
STEP 5. A/T-ECU replacement
• Malfunction of the underdrive clutch
• Malfunction of valve body
• Malfunction of the oil pump
(3) Verify that the condition described by the
customer exists.
DIAGNOSIS PROCEDURE Q: Does a malfunction take place again?
YES : Go to Step 6.
Item 02: Underdrive solenoid valve
STEP 6. Valve body disassembly clean and
assembly
Q: Is the check result normal? (1) Check the bolts for looseness and the O-ring,
YES : Go to Step 2. solenoid valve and valve body for damage.
NO : Replace the underdrive solenoid valve. Replace the valve body assembly if the damages
are thought to be irreparable.
STEP 2. M.U.T.-III diagnosis code (2) Test drive the vehicle.
Either of diagnosis codes P1770 (P0705) or P1771 (3) Verify that the condition described by the
(P0705) is set, inhibitor switch is defective. customer exists.
Q: Are diagnosis codes P1770 (P0705) or P1771 Q: Does a malfunction take place again?
(P0705) output? YES : Go to Step 7.
YES <diagnosis code P1770 (P0705) is set> : Refer NO : The inspection is complete.
to diagnosis code P1770 (P0705): Inhibitor
switch system P.23A-46 <4A/T>, P.23A-49 STEP 7. Oil pump check
<5A/T>. (1) If the damage is in the oil pump assembly,
YES <diagnosis code P1771 (P0705) is set> : Refer replace the oil pump assembly.
to diagnosis code P1771 (P0705): Inhibitor (2) Test drive the vehicle.
switch system P.23A-51 <4A/T>, P.23A-52 (3) Verify that the condition described by the
<5A/T>. customer exists.
NO : Go to Step 3.
YES : Go to Step 8.
STEP 3. Underdrive solenoid valve check NO : The inspection is complete.
(2) Shift the selector lever from N to D range.
(3) Confirm the operating sound of the underdrive STEP 8. Underdrive clutch check
solenoid valve. (1) Check the facing for seizure and the piston seal
ring for damage and interference with the
OK: Operating sound can be heard. retainer.
Q: Is the check result normal? (2) Test drive the vehicle.
YES : Go to Step 4. (3) Verify that the condition described by the
NO : Replace the A/T-ECU. customer exists.
TROUBLESHOOTING
23A-85
Q: Is the check result normal? YES : The inspection is complete.
NO : Repair or replace the underdrive clutch.
Inspection Procedure 4: Does not Move Backward

If the vehicle does not move backward when the NO : Go to Step 3.
selector lever is shifted to R range while the engine is
idling, the cause is probably abnormal pressure of STEP 3. A/T-ECU replacement
the reverse clutch and low-reverse brake or a mal- (1) Replace the A/T-ECU.
function of the reverse clutch, low-reverse brake, or (2) Test drive the vehicle.
valve body. (3) Verify that the condition described by the
customer exists.
PROBABLE CAUSES
• Abnormal reverse clutch pressure Q: Does a malfunction take place again?
• Abnormal low-reverse brake pressure YES : Go to Step 4.
• Malfunction of low-reverse solenoid valve NO : The inspection is complete.
• Malfunction of the reverse clutch
• Malfunction of low-reverse brake STEP 4. Valve body disassembly clean and
• Malfunction of valve body assembly
• Malfunction of the A/T-ECU (1) Check the bolts for looseness and the O-ring,
solenoid valve and valve body for damage.
DIAGNOSIS PROCEDURE Replace the valve body assembly if the damages
STEP 1. M.U.T.-III actuator test (2) Test drive the vehicle.
Item 01: Low-reverse solenoid valve (3) Verify that the condition described by the
customer exists.
Q: Does a malfunction take place again?
YES : Go to Step 2.
NO : Replace the low-reverse solenoid valve.
STEP 5. Reverse clutch and low-reverse brake

STEP 2. Hydraulic pressure test
check
Measure the hydraulic pressure for reverse clutch
Check the facing for seizure and the piston seal ring
and low-reverse brake when the selector lever is at
for damage and interference with the retainer.
the R range.
OK: Refer to P.23A-120.
YES : The inspection is complete.
Q: Is the check result normal? NO : Repair or replace the reverse clutch and
low-reverse brake.
Inspection Procedure 5: Does not Move (Forward or Backward)
COMMENTS ON TROUBLE SYMPTOM PROBABLE CAUSES

If the vehicle does not move forward or backward • Abnormal line pressure
when the selector lever is shifted to any position • Malfunction of valve body
while the engine is idling, the cause is probably an • Malfunction of torque converter
abnormal line pressure, a malfunction of the power • Malfunction of oil pump
train components, oil pump or valve body. • Malfunction of each element
• Malfunction of power train components
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 3. Torque converter check

Check for damaged drive plate, incorrect installation
STEP 1. Hydraulic pressure test in the input shaft (inserted at an angle) or damaged
Measure the hydraulic pressure of each element splines.
when the selector lever is 2, L range, sport mode Q: Is the check result normal?
(1st, 2nd gear) or reverse. YES : Check the oil pump for incorrect installation,
OK: Refer to P.23A-120. damage and etc., and replace the oil pump
assembly if necessary (The oil pump cannot
be disassembled.)
YES : Go to Step 4.
NO : Go to Step 2.
splines on the drive plate or torque
STEP 2. Valve body disassembly clean and converter are damaged, replace it.
assembly
(1) Check the bolts for looseness and the O-ring,
STEP 4. Power train components check
solenoid valve and valve body for damage.
Disassemble the transmission and check the input
Replace the valve body assembly if the damages
shaft, planetary carrier, output shaft differential and
each element, etc.
(3) Verify that the condition described by the Q: Is the check result normal?
customer exists. YES : The inspection is complete.
NO : Repair or replace each power train
components.
YES : Go to Step 3.
Inspection Procedure 6: Engine Stalls During Shifting
COMMENTS ON TROUBLE SYMPTOM STEP 2. Valve body disassembly clean and

If the engine stalls when the selector lever is shifted assembly
from N to D or R range while the engine is idling, the (1) Check the bolts for looseness and the O-ring,
cause is probably a malfunction of the engine sys- solenoid valve and valve body for damage.
tem, damper clutch solenoid valve, valve body or Replace the valve body assembly if the damages
torque converter (damper clutch). are thought to be irreparable.
PROBABLE CAUSES (2) Test drive the vehicle.
• Malfunction of engine system (3) Verify that the condition described by the
• Malfunction of damper clutch solenoid valve customer exists.
• Malfunction of valve body Q: Does a malfunction take place again?
• Malfunction of torque converter (damper clutch) YES : Go to Step 3.
• Malfunction of the A/T-ECU NO : The inspection is complete.
DIAGNOSIS PROCEDURE STEP 3. Torque converter check

Check for damaged drive plate, incorrect installation
STEP 1. M.U.T.-III actuator test in the input shaft (inserted at an angle), damaged
Item 06: Damper clutch solenoid valve splines or damper clutch sealing.
OK: Operating sound can be heard. Q: Is the check result normal?
YES : Go to Step 4.
YES : Go to Step 2.
NO : Replace the damper clutch solenoid valve.
splines on the drive plate or torque
converter are damaged, replace it.
TROUBLESHOOTING
23A-87
YES : Replace the A/T-ECU.
STEP 4. Engine system check
NO : Repair the engine system.
Inspection Procedure 7: Shift Shock when Shifting from N to D and Long Delay

If abnormal shock or delay of two seconds or more NO : Go to Step 5.
occurs when the selector lever is shifted from N to D
range while the engine is idling, the cause is proba- STEP 5. Hydraulic pressure test
bly abnormal underdrive clutch pressure or a mal- Measure the hydraulic pressure for underdrive clutch
function of the underdrive clutch, valve body or when the selector lever is shifted from N to D range.
throttle position sensor.
OK: Refer to P.23A-120.
• Malfunction of underdrive solenoid valve YES : Go to Step 9.
• Malfunction of input shaft speed sensor NO : Go to Step 8.
• Abnormal underdrive clutch pressure
• Malfunction of throttle position sensor
STEP 6. Check when shift shock occurs.
• Malfunction of the underdrive clutch
• Malfunction of valve body Q: Does the shift shock always occur?
• Malfunction of the A/T-ECU YES : Go to Step 8.
NO : Go to Step 7.
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-III actuator test Item 35: Accelerator pedal position sensor (Refer to
Item 02: Underdrive solenoid valve data list reference table P.23A-103).
OK: Operating sound can be heard. Q: Is the check result normal?
YES : Go to Step 8.
Q: Is the check result normal? NO : Check the throttle position sensor system
YES : Go to Step 2. (Refer to GROUP 13A, Troubleshooting ).
NO : Replace the underdrive solenoid valve.

STEP 2. M.U.T.-III data list assembly
Item 05: Input shaft speed sensor (Refer to data list (1) Check the bolts for looseness and the O-ring,
reference table P.23A-103). solenoid valve and valve body for damage.
Q: Is the check result normal? Replace the valve body assembly if the damages
YES : Go to Step 3. are thought to be irreparable.
NO : Refer to diagnosis code P1766: Input shaft (2) Test drive the vehicle.
speed sensor system P.23A-36. (3) Verify that the condition described by the
customer exists.
STEP 3. M.U.T.-III data list Q: Does a malfunction take place again?
Item 13: Underdrive solenoid valve duty ratio (Refer YES : Go to Step 9.
to data list reference table P.23A-103). NO : The inspection is complete.
YES : Go to Step 4. STEP 9. Underdrive clutch check
NO : Replace the A/T-ECU. Check the facing for seizure and the piston seal ring
for damage and interference with the retainer.
STEP 4. Check when shift shock occurs. Q: Is the check result normal?
Q: Does the shift shock occur when the vehicle starts
NO : Repair or replace the underdrive clutch.
moving?
TROUBLESHOOTING
Inspection Procedure 8: Shift Shock when Shifting from N to R and Long Delay
COMMENTS ON TROUBLE SYMPTOM YES <diagnosis code P1770 (P0705) is set> : Refer
If abnormal shock or delay of two seconds or more to diagnosis code P1770 (P0705): Inhibitor
occurs when the selector lever is shifted from N to R switch system P.23A-46 <4A/T>, P.23A-49
range while the engine is idling, the cause is proba- <5A/T>.
bly abnormal pressure in reverse clutch and low- YES <diagnosis code P1771 (P0705) is set> : Refer
reverse clutch or a malfunction of the reverse clutch, to diagnosis code P1771 (P0705): Inhibitor
low-reverse brake, valve body or throttle position switch system P.23A-51 <4A/T>, P.23A-52
sensor. <5A/T>.
NO : Go to Step 4.
PROBABLE CAUSES
• Malfunction of low-reverse solenoid valve
Item 12: Low-reverse solenoid valve duty ratio (Refer
to data list reference table P.23A-103).
• Abnormal reverse clutch pressure
• Abnormal low-reverse brake pressure Q: Is the check result normal?
• Malfunction of accelerator pedal position sensor YES : Go to Step 5.
• Malfunction of the reverse clutch NO : Replace the A/T-ECU.
• Malfunction of low-reverse brake
• Malfunction of valve body STEP 5. Check when shift shock occurs.
Q: Does the shift shock occur when the vehicle starts
moving?
NO : Go to Step 6.
Item 01: Low-reverse solenoid valve STEP 6. Hydraulic pressure test
OK: Operating sound can be heard. Measure the hydraulic pressure for reverse clutch
and low-reverse clutch when the selector lever is
YES : Go to Step 2. shifted from N to R range.
NO : Replace the low-reverse solenoid valve. OK: Refer to P.23A-120.
Item 05: Input shaft speed sensor (Refer to data list NO : Go to Step 9.
reference table P.23A-103).
Q: Is the check result normal? STEP 7. Check when shift shock occurs.
YES : Go to Step 3. Q: Does the shift shock always occur?
NO : Refer to diagnosis code P1766: Input shaft YES : Go to Step 9.
speed sensor system P.23A-36. NO : Go to Step 8.
STEP 3. M.U.T.-III diagnosis code STEP 8. M.U.T.-III data list

Either of diagnosis codes P1770 (P0705) or P1771 Item 35: Accelerator pedal position sensor (Refer to
(P0705) is set, inhibitor switch is defective. data list reference table P.23A-103).
Q: Are diagnosis codes P1770 (P0705) or P1771 Q: Is the check result normal?
(P0705) output? YES : Go to Step 9.
NO : Check the throttle position sensor system
(Refer to GROUP 13A, Troubleshooting ).

assembly
(1) Check the bolts for looseness and the O-ring,
TROUBLESHOOTING
23A-89
solenoid valve and valve body for damage. STEP 10. Reverse clutch and low-reverse brake
Replace the valve body assembly if the damages check
are thought to be irreparable. Check the facing for seizure and the piston seal ring
(2) Test drive the vehicle. for damage and interference with the retainer.
customer exists. Q: Is the check result normal?
Q: Does a malfunction take place again? NO : Repair or replace the reverse clutch and
YES : Go to Step 10. low-reverse brake.
Inspection Procedure 9: Shift Shock when Shifting from N to D, N to R and Long Delay

If abnormal shock or delay of two seconds or more NO : Check the oil pump for incorrect installation,
occurs when the selector lever is shifted from N to D damage and etc., and replace the oil pump
range and from N to R range while the engine is assembly if necessary (The oil pump cannot
idling, the cause is probably abnormal line pressure be disassembled.)
or a malfunction of the oil pump, valve body.
STEP 4. Check when shift shock occurs.
PROBABLE CAUSES
• Abnormal line pressure Q: Does the shift shock always occur?
• Malfunction of throttle position sensor YES : Go to Step 7.
• Malfunction of oil pump NO : Go to Step 5.
Item 35: Accelerator pedal position sensor (Refer to
DIAGNOSIS PROCEDURE data list reference table P.23A-103).
STEP 1. Hydraulic pressure test YES : Go to Step 6.
Measure the hydraulic pressure of each element NO : Check the throttle position sensor system
when the selector lever is 2, L range, sport mode (Refer to GROUP 13A, Troubleshooting ).
(1st, 2nd gear) or reverse.
OK: Refer to P.23A-120. STEP 6. A/T-ECU replacement
Q: Is the check result normal? (1) Replace the A/T-ECU.
YES : Go to Step 3. (2) Test drive the vehicle.
NO : Go to Step 2. (3) Verify that the condition described by the
customer exists.
STEP 2. Line pressure adjustment Q: Does a malfunction take place again?
(1) Adjust the line pressure (Refer to P.23A-129). YES : Go to Step 7.
(2) Test drive the vehicle. NO : The inspection is complete.
customer exists. STEP 7. Valve body disassembly clean and
Q: Does a malfunction take place again? assembly
YES : Go to Step 3. Check the bolts for looseness and the O-ring, sole-
NO : The inspection is complete. noid valve and valve body for damage.
STEP 3. Check when shift shock occurs. YES : The inspection is complete.
NO : Replace the valve body assembly if the
Q: Does the shift shock occur when the vehicle starts damages are thought to be irreparable.
moving?
TROUBLESHOOTING
Inspection Procedure 10: Shift Shock and Slipping
COMMENTS ON TROUBLE SYMPTOM STEP 3. Hydraulic pressure test

If shift shock when driving are due to upshifting or Check all hydraulic pressures within the standard
downshifting and the transmission speed become value.
higher than the engine speed, the cause is probably
abnormal line pressure or a malfunction of a solenoid OK: Refer to P.23A-120.
valve, oil pump, valve body or of a brake or clutch. Q: Is the check result normal?
YES : Go to Step 6.
PROBABLE CAUSES NO : Go to Step 4.
• Malfunction of each solenoid valve
• Abnormal line pressure
STEP 4. Line pressure adjustment
(1) Adjust the line pressure (Refer to P.23A-129).
• Malfunction of oil pump
• Malfunction of each brake or each clutch
customer exists.
YES : Go to Step 5.
• Item 01: Low-reverse solenoid valve
• Item 02: Underdrive solenoid valve STEP 5. Valve body disassembly clean and
• Item 03: Second solenoid valve assembly
• Item 04: Overdrive solenoid valve (1) Check the bolts for looseness and the O-ring,
• Item 05: Reduction solenoid valve <5A/T> solenoid valve and valve body for damage.
Replace the valve body assembly if the damages
Q: Is the check result normal? (2) Test drive the vehicle.
YES : Go to Step 2. (3) Verify that the condition described by the
NO : Replace the defective solenoid valve. customer exists.
STEP 2. M.U.T.-III data list YES : Check the oil pump for incorrect installation,
• Item 11: Shift position (Refer to data list reference damage and etc., and replace the oil pump
table P.23A-103). assembly if necessary (The oil pump cannot
• Item 12, 13, 14, 15, 16 <5A/T>: Each solenoid be disassembled).
valve duty ratio (Refer to data list reference table NO : The inspection is complete.
P.23A-103).
Q: Is the check result normal? STEP 6. Each clutch and brake check
YES : Go to Step 3. Check the facing for seizure and the piston seal ring
NO : Replace the A/T-ECU. for damage and interference with the retainer.
NO : Repair or replace each clutch and brake.
Inspection Procedure 11: Does not Shift Properly (all Points)
COMMENTS ON TROUBLE SYMPTOM PROBABLE CAUSES

If all shift points are early or late while driving, the • Malfunction of output shaft speed sensor
cause is probably a malfunction of the output shaft • Malfunction of throttle position sensor
speed sensor, throttle position sensor, or A/T-ECU. • Malfunction of the A/T-ECU
TROUBLESHOOTING
23A-91
NO : Check the throttle position sensor system
(Refer to GROUP 13A, Troubleshooting ).
Item 06: Output shaft speed sensor (Refer to data list
reference table P.23A-103). STEP 3. M.U.T.-III actuator test
(1) Test drive the vehicle (Refer to Road Test,
Q: Is the check result normal? Inspection procedure 8 P.23A-17).
YES : Go to Step 2. (2) Check that the gear shifting corresponds to the
NO : Refer to diagnosis code P1767: Output
standard shift line of the shift pattern diagram.
shaft speed sensor system P.23A-41.
STEP 2. M.U.T.-III data list NO : Replace the A/T-ECU.
Item 35: Accelerator pedal position sensor (Refer to
data list reference table P.23A-103).
Inspection Procedure 12: Does not Shift Properly (some Point)
COMMENTS ON TROUBLE SYMPTOM YES : Is not abnormal.

If some of the shift points are early or late when driv- NO : Go to Step 2.
ing, the cause is probably a malfunction of valve
body. STEP 2. M.U.T.-III actuator test
(1) Test drive the vehicle (Refer to Road Test,
PROBABLE CAUSES
Inspection procedure 8 P.23A-17).
(2) Check that the gear shifting corresponds to the
standard shift line of the shift pattern diagram.
DIAGNOSIS PROCEDURE
STEP 1. Check when the shift points early or late. NO : Replace the A/T-ECU.
Q: Are the shift points early or late only when A/T fluid
is −20°C or less, or 125°C or more?
Inspection Procedure 13: Does not Shift (no Diagnosis Code)

The gear shifting does not occur while driving. If no NO : Replace the A/T-ECU.
diagnosis codes are set, the cause is probably a mal-
function of the shift switch assembly or A/T-ECU . STEP 2. M.U.T.-III data list
PROBABLE CAUSES
ence Table P.23A-103).
• Malfunction of Shift switch assembly
• Malfunction of the A/T-ECU Q: Is the check result normal?
YES : Replace the A/T-ECU.
DIAGNOSIS PROCEDURE NO : Refer to diagnosis code P1770 (P0705):
Inhibitor switch system P.23A-46 <4A/T>,
P.23A-49 <5A/T> and Refer to diagnosis
STEP 1. M.U.T.-III data list code P1771 (P0705): Inhibitor switch
Item 08: A/T control relay (Refer to Data List Refer- system P.23A-51 <4A/T>, P.23A-52 <5A/
ence Table P.23A-103). T>.
TROUBLESHOOTING
Inspection Procedure 14: Poor Acceleration

If acceleration is poor when downshifting occurs NO : Repair the engine system.
while driving, the cause is probably a malfunction of
the engine system. STEP 2. A/T-ECU replacement
PROBABLE CAUSES
• Malfunction of engine system
customer exists.
YES : Go to Step 1.
STEP 1. Engine system check
Inspection Procedure 15: Vibration
COMMENTS ON TROUBLE SYMPTOM STEP 3. A/T-ECU replacement

If vibration occurs when driving at constant speed or (1) Replace the A/T-ECU.
when acceleration in high range, the cause is proba- (2) Test drive the vehicle.
bly an abnormal torque converter pressure, or a mal- (3) Verify that the condition described by the
function of the engine system, damper clutch customer exists.
solenoid valve, valve body or torque converter.
• Malfunction of damper clutch solenoid valve NO : The inspection is complete.
• Malfunction of engine system
• Abnormal torque converter pressure STEP 4. Torque converter check
• Malfunction of valve body Check for damaged drive plate, incorrect installation
• Malfunction of torque converter in the input shaft (inserted at an angle), damaged
• Malfunction of the A/T-ECU splines or damper clutch sealing.
DIAGNOSIS PROCEDURE Q: Is the check result normal?

YES : Go to Step 5.
STEP 1. Check when the vibration occurs. part. If repair is not possible because the
Q: Does the vibration occur when the damper clutch splines on the drive plate or torque
is operating? converter are damaged, replace it.
YES : Go to Step 3.
NO : Go to Step 2. STEP 5. Valve body disassembly clean and
assembly
STEP 2. Engine system check Check the bolts for looseness and the O-ring, sole-
noid valve and valve body for damage.
YES : The inspection is complete. Q: Is the check result normal?
NO : Repair the engine system. YES : The inspection is complete.
NO : Replace the valve body assembly if the
damages are thought to be irreparable.
TROUBLESHOOTING
23A-93
Inspection Procedure 16: Overdrive switch system <4A/T>
Overdrive Switch System Circuit
IGNITION
SWITCH (IG1)
OVERDRIVE
SWITCH Wire colour code
B : Black
LG : Light green
G : Green
L: Blue
W : White
Y: Yellow
SB : Sky blue
BR : Brown
O : Orange
GR : Grey
R : Red
P : Pink
V : Violet
PU: Purple
A/T-ECU
AC903911
TROUBLESHOOTING
Connector: C-20 <LHD> Connector: C-129 <RHD>
A/T-ECU
<RHD> Harness side
C-129
AC509932DE
A/T-ECU
C-20 Junction block (Front view) Harness side

C-208
Harness side
C-207
AC510057AC
Connector: C-34 <RHD> AC509934 CX
Harness side Connectors: C-207, C-208 <RHD>

Junction block
C-34
C-207
AC509930AG C-208
AC509936 BZ
OPERATION
During driving with 4th gear, when the overdrive
switch is turned ON, A/T-ECU performs a downshift
C-52
control to 3rd gear.
Harness side
COMMENTS ON TROUBLE SYMPTOM
If downshifting does not occur when overdrive switch
is turned on while driving in 4th gear, or upshifting
AC509613AG
does not occur when overdrive switch is turned off
while driving in 3rd gear, the cause is probably a
problem in the overdrive switch system.
PROBABLE CAUSES
Harness side • Malfunction of the overdrive switch
C-129
AC509611CX
TROUBLESHOOTING
23A-95

Item 26: Overdrive switch (Refer to data list refer- STEP 6. Measure the voltage at A/T-ECU
ence table P.23A-103). connector C-20.
(1) Disconnect high/low detection switch connector
Q: Is the check result normal? C-129.
YES : Intermittent malfunction (Refer to GROUP (2) Turn the ignition switch to the ON position.
00 − How to Cope with Intermittent (3) Overdrive switch: ON.
Malfunction ). (4) Measure the voltage between A/T-ECU
NO : Go to Step 2. connector C-20 terminal No.57 and earth.
OK: System voltage
STEP 2. Check the overdrive switch.
Refer to P.23A-132.
YES : Go to Step 7.
Q: Is the check result normal? NO : Go to Step 8.
YES : Go to Step 3.
NO : Replace the high/low detection switch.
Item 26: Overdrive switch (Refer to data list refer-
STEP 3. Measure the voltage at overdrive switch ence table P.23A-103).
connector C-129.
Malfunction ).
OK: System voltage
Q: Is the check result normal? STEP 8. Connector check: C-129 overdrive
YES : Go to Step 6. switch connector, C-52 <LHD>or C-34 <RHD>
NO : Go to Step 4. intermediate connector, C-20 A/T-ECU connector
STEP 4. Connector check: C-129 overdrive Q: Is the check result normal?
switch connector, C-208 J/B connector YES : Go to Step 9.
Check for the contact with terminals. NO : Repair the defective connector.
YES : Go to Step 5. STEP 9. Check the harness between overdrive
NO : Repair the defective connector. switch connector C-129 terminal No.4 and A/T-
ECU connector C-20 terminal No.57.
STEP 5. Check the harness between overdrive Check the power supply line for short or open circuit.
switch connector C-129 terminal No.3 and J/B Q: Is the check result normal?
connector C-208 terminal No.2. YES : Go to Step 7.
Check the power supply line for short or open circuit. NO : Repair the wiring harness.
TROUBLESHOOTING
Inspection Procedure 17: 4LLc operation detection switch system <4WD>
4LLc Operation Detection Switch System Circuit
A/T-ECU
4LLc
OPERATION
DETECTION
SWITCH
Wire colour code

AC903912
Connector: A-115
Harness side
A-115 A/T-ECU
<RHD>
AC509975AO
Connector: B-05 A/T-ECU
Harness side
C-19
Harness side
B-05
AC510056AH AC510057AD
TROUBLESHOOTING
23A-97
Connector: C-29 <LHD> STEP 2. Check the 4LLc operation detection
switch.
Refer to P.23A-119.
YES : Go to Step 3.
NO : Replace the 4LLc operation detection
switch.
C-29
AC509611CW
STEP 3. Measure the voltage at 4LLc operation
detection switch connector B-05.
Connector: C-29 <RHD> resistance between terminal 1 and earth at the
OK: System voltage
YES : Go to Step 4.
NO : Go to Step 5.
C-29
AC509930BI STEP 4. M.U.T.-III data list
Item 31: 4LLc operation detection switch (Refer to
data list reference table P.23A-103).
OPERATION
• A battery voltage is applied to the 4LLc operation Q: Is the check result normal?
detection switch output terminal (terminal 1) from YES : Intermittent malfunction (Refer to GROUP
the A/T-ECU (terminal 9) via the resistance in the 00 − How to Cope with Intermittent
unit. Malfunction ).
• The 4LLc operation detection switch is grounded NO : Replace the A/T-ECU.
through the transfer case to the vehicle body.
COMMENTS ON TROUBLE SYMPTOM connector C-19.
If the transmission shifts to 4th gear when the trans- (1) Disconnect 4LLc operation detection switch
fer lever is in the 4L position, the cause is probably a connector B-05.
malfunction of the 4LLc operation detection switch. (2) Turn the ignition switch to the ON position.
(3) Measure the voltage between A/T-ECU
PROBABLE CAUSES
• Malfunction of the 4LLc operation detection
switch OK: System voltage
• Damaged harness wires and connectors Q: Is the check result normal?
• Malfunction of the A/T-ECU YES : Go to Step 6.
NO : Go to Step 8.
DIAGNOSIS PROCEDURE
STEP 6. Connector check: B-05 4LLc operation
STEP 1. M.U.T.-III data list detection switch connector, A-115 and C-29
Item 31: 4LLc operation detection switch (Refer to intermediate connector, C-19 A/T-ECU connector
data list reference table P.23A-103). Check for the contact with terminals.
YES : Intermittent malfunction (Refer to GROUP YES : Go to Step 7.
00 − How to Cope with Intermittent NO : Repair the defective connector.
Malfunction ).
NO : Go to Step 2.
TROUBLESHOOTING
YES : Go to Step 9.
STEP 7. Check the harness between 4LLc
operation detection switch connector B-05
terminal No.1 and A/T-ECU connector C-19
terminal No.9. STEP 9. Check the harness between 4LLc
Check the power supply line for open circuit. operation detection switch connector B-05
terminal No.1 and A/T-ECU connector C-19
terminal No.9.
YES : Go to Step 4.
Check the power supply line for short circuit.
YES : Go to Step 4.
STEP 8. Connector check: B-05 4LLc operation
detection switch connector, A-115 and C-29
intermediate connector, C-19 A/T-ECU connector
TROUBLESHOOTING
23A-99
Inspection Procedure 18: Shift Switch Assembly System <5A/T>
Shift Switch System Circuit
IGNITION
SWITCH (IG1)
<LHD>
<RHD>
INHIBITOR
SWITCH
<LHD>
<RHD>
SHIFT
SWITCH
SELECT SHIFT ASSEMBLY
SWITCH SWITCH
<LHD> <LHD>
<RHD> <RHD>
A/T-ECU
Wire colour code

AC903920
TROUBLESHOOTING
Connector: B-10
Harness side
C-52
Harness side
B-10 (B)
AC510056AD
AC509613AG
Connector: B-14
Harness side Connector: C-172 <RHD>
B-14 (B)
AC510056AG C-172
AC903865AM

A/T-ECU
<RHD>
C-172
A/T-ECU AC903853BF
Connectors: C-208 <LHD>
C-20 Junction block (Front view) Harness side

C-208
Harness side
AC510057AC
Connector: C-34 <RHD> AC509934 AH
Harness side
OPERATION
The shift switch assembly detects the shift range
C-34 (sport mode) which the driver has selected, and
sends the information to the A/T-ECU.
COMMENTS ON TROUBLE SYMPTOM

The cause is probably a malfunction of the shift
AC509930AG
switch and A/T-ECU.
TROUBLESHOOTING
23A-101
PROBABLE CAUSES YES : Intermittent malfunction (Refer to GROUP
• Malfunction of shift switch assembly 00 − How to Cope with Intermittent
• Damaged harness wires and connectors Malfunction ).
• Malfunction of the A/T-ECU NO : Replace the A/T-ECU.
DIAGNOSIS PROCEDURE STEP 5. Check the shift switch assembly.

Refer to P.23A-134.
STEP 1. M.U.T.-III diagnosis code Q: Is the check result normal?
Either of diagnosis codes P1770 or P1771 is set, YES : Go to Step 6.
inhibitor switch is defective. NO : Replace the shift lever assembly.
Q: Are diagnosis codes P1770 or P1771 output?
YES <diagnosis code P1770 is set> : Refer to STEP 6. Connector check: C-172 shift switch
diagnosis code P1770: Inhibitor switch assembly connector
system P.23A-49. Check for the contact with terminals.
YES <diagnosis code P1771 is set> : Refer to
diagnosis code P1771: Inhibitor switch
YES : Go to Step 7.
system P.23A-52.
NO : Go to Step 2.
STEP 7. Measure the voltage at shift switch

assembly connector C-172.
• Item 27: Select switch
• Item 28: Shift switch (Up)
• Item 29: Shift switch (Down)
(Refer to data list reference table P.23A-103).
(2) Ignition switch: ON
Q: Is the check result normal? OK: System voltage
Malfunction ). YES : Go to Step 4.
NO <"NG" for all items> : Go to Step 3. NO : Go to Step 8.
NO <"NG" for items 28 and 29> : Go to Step 5.
NO <"NG" for item 27> : Go to Step 10. STEP 8. Connectors check: C-208 J/B connector
NO <"NG" for item 28> : Go to Step 17. Check for the contact with terminals.
NO <"NG" for item 29> : Go to Step 20.
YES : Go to Step 9.
STEP 3. Connectors check: C-172 shift switch NO : Repair the defective connector.
assembly connector, C-20 A/T-ECU connector.
STEP 9. Check the harness between shift switch
Q: Is the check result normal? assembly connector C-172 terminal No.3 and J/B
YES : Go to Step 4. connector C-208 terminal No.2.
NO : Repair the defective connector. Check the power supply line for short or open circuit.
• Item 27: Select switch NO : Repair the wiring harness.
• Item 28: Shift switch (Up)
• Item 29: Shift switch (Down)
Check the above data list (Refer to data list reference STEP 10. Check the shift switch assembly.
table P.23A-103). Refer to P.23A-134.
NO : Replace the shift lever assembly.
TROUBLESHOOTING
YES : Go to Step 4.
STEP 11. Connector check: C-172 shift switch
assembly connector
STEP 17. Check the shift switch assembly.
Refer to P.23A-134.
NO : Repair the defective connector. Q: Is the check result normal?
NO : Replace the shift switch assembly.
STEP 12. Measure the voltage at shift switch
assembly connector C-172
(1) Disconnect the connector, and measure the STEP 18. Connectors check: C-172 shift switch
voltage between terminal 1 and earth at the assembly connector, C-20 A/T-ECU connector
wiring harness side. and C-34 <RHD> or C-52 <LHD> intermediate
(2) Selector lever position: D connector
(3) Ignition switch: ON Check for the contact with terminals.
OK: System voltage Q: Is the check result normal?
YES : Go to Step 13. NO : Repair the defective connector.
NO : Go to Step 15.
STEP 13. Connectors check: C-20 A/T-ECU assembly connector C-172 terminal No.6 and A/T-
connector, C-34 <RHD> or C-52 <LHD> ECU connector C-20 terminal No.58.
intermediate connector Check the output line for short-circuited or open cir-
Check for the contact with terminals. cuit.

STEP 14. Check the harness between shift switch STEP 20. Check the shift switch assembly.
assembly connector C-172 terminal No.4 and A/T- Refer to P.23A-134.
ECU connector C-20 terminal No.57. Q: Is the check result normal?
Check the output line for short-circuited or open cir- YES : Go to Step 21.
cuit. NO : Replace the shift switch assembly.
YES : Go to Step 15. STEP 21. Connectors check: C-172 shift switch
NO : Repair the wiring harness. assembly connector, C-20 A/T-ECU connector
and C-34 <RHD> or C-52 <LHD> intermediate
STEP 15. Connector check: B-10, C-34 <RHD> or connector
C-52 <LHD> intermediate connector Check for the contact with terminals.
STEP 16. Check the harness between shift switch assembly connector C-172 terminal No.5 and A/T-
assembly connector C-172 terminal No.1 and ECU connector C-20 terminal No.68.
inhibitor switch connector B-14 terminal No.3. Check the output line for short-circuited or open cir-
Check the power supply line for short or open circuit. cuit.

YES : Go to Step 4.
TROUBLESHOOTING
23A-103
DATA LIST REFERENCE TABLE
M1231111300208
Data list Check item Inspection conditions Normal condition

No.
1 Engine speed • Engine: Idling Compare the engine Identical
• Selector lever speeds displayed on the
position: P tachometer and the
M.U.T.-III.
5 Input shaft speed Driving at a constant speed of 40 km/h in 3rd 1,100 − 1,400 r/min
sensor gear <4A/T> or 60 km/h in 4th gear <5A/T> <4A/T>
1,600 − 1,900 r/min
<5A/T>
6 Output shaft speed Driving at a constant speed of 40 km/h in 3rd 1,100 − 1,400 r/min
sensor gear <4A/T> or 60 km/h in 4th gear <5A/T> <4A/T>
1,600 − 1,900 r/min
<5A/T>
7 A/T fluid temperature Driving after engine has warmed up Gradually increases.
sensor
8 A/T control relay Ignition switch: ON System voltage
output voltage
10 Damper clutch Driving at a constant speed 60 km/h in 3rd gear −10 to 10 r/min
amount of slippage Driving at 60 km/h in 3rd gear, then fully close The value changes
the accelerator pedal from the above value.
11 Shift position Selector lever Driving at a constant 1st
position: D, 2, L <4A/ speed of 10 km/h in 1st
T> or Sport mode Driving at a constant 2nd
<5A/T> speed of 20 km/h in 2nd
Driving at a constant 3rd
speed of 40 km/h in 3th
Driving at a constant 4th
Driving at a constant 5th
<5A/T>
Selector lever position: P P, N
Selector lever Driving at a constant REV
position: R speed of 5 km/h in reverse
Selector lever position: N P, N
12 Low-reverse Driving at a constant speed of 10 km/h in 1st 0%
solenoid valve duty Driving at a constant speed of 20 km/h in 2nd 100%
ratio
Driving at a constant speed of 40 km/h in 3rd 100%
Driving at a constant speed of 60 km/h in 4th 100% <4A/T>
0% <5A/T>
Driving at a constant speed of 70 km/h in 5th 0%
<5A/T>
TROUBLESHOOTING

No.
13 Underdrive solenoid Driving at a constant speed of 10 km/h in 1st 0%
valve duty ratio Driving at a constant speed of 20 km/h in 2nd 0%
0% <5A/T>
<5A/T>
14 Second solenoid Driving at a constant speed of 10 km/h in 1st 100%
100% <5A/T>
<5A/T>
15 Overdrive solenoid Driving at a constant speed of 10 km/h in 1st 100%
<5A/T>
16 Reduction solenoid Driving at a constant speed of 10 km/h in 1st 0%
valve duty ratio <5A/ Driving at a constant speed of 20 km/h in 2nd 0%
T>
17 Damper clutch Driving at a constant speed 90 km/h in 3rd gear 70 − 99.6%
control solenoid <4A/T> or 100 km/h in 4th gear <5A/T>
valve duty ratio Driving at 90 km/h in 3rd gear <4A/T> or 100 km/ 70 − 99.6% to 0%
h in 4th gear <5A/T>, then fully close the
accelerator pedal
21 A/C compressor Engine: Idling A/C switch: ON ON
relay A/C switch: OFF OFF
26 Overdrive switch Ignition switch: ON Overdrive switch: ON ON
<4A/T> Overdrive switch: OFF OFF
TROUBLESHOOTING
23A-105
No.
27 Select switch <5A/ Ignition switch: ON Transmission range: D OFF
T> Selector lever operation: ON
Select sport mode
Selector lever operation: ON
Upshift and hold the
selector lever
Downshift and hold the
selector lever
28 Shift lever switch Ignition switch: ON Transmission range: D OFF
(Up) <5A/T> Selector lever operation: OFF
Select sport mode
selector lever
Selector lever operation: OFF
selector lever
29 Shift lever switch Ignition switch: ON Transmission range: D OFF
(Down) <5A/T> Selector lever operation: OFF
Select sport mode
Selector lever operation: OFF
selector lever
selector lever
31 4LLc switch <4WD> Ignition switch: ON Transfer lever position: 4L ON
<Vehicles with easy select
4WD> or 4LLc <Vehicles
with super select 4WD>
Transfer lever position: OFF
Other than the above
34 Inhibitor switch Ignition switch: ON Selector lever position: P P
Selector lever position: R R
Selector lever position: N N
Selector lever position: D D
Selector lever position: 2 2
<4A/T>
Selector lever position: L L
<4A/T>
TROUBLESHOOTING

No.
35 APS Ignition switch: ON Accelerator pedal: Fully 15 − 35%
closed
Accelerator pedal: Gradually increases
Depressed from the above value.
36 Engine torque • Engine: Idling Accelerator pedal: fully Data changes
• Selector lever closed to depressed
position: N, P
ACTUATOR TEST REFERENCE TABLE

M1231111400153
Item No. Inspection item Test description Inspection condition Normal status
1 Low-reverse solenoid • Actuate solenoid • Ignition switch: ON When solenoid valve
valve valve indicated by • Selector lever is actuated, operating
2 Underdrive solenoid M.U.T.-III for 5 position: P sound is audible.
valve seconds at duty • Engine: Stopped
ratio of 50%. • Accelerator pedal:
3 Second solenoid valve • Other remaining Released
4 Overdrive solenoid valve solenoid valve are
5 Reduction solenoid not ON.
valve <5A/T>
6 Damper clutch control
solenoid valve
7 1st indicator lamp <5A/ Illuminate each Shift indicator lamp
T> indicator lamp for 3 illuminates.
8 2nd indicator lamp <5A/ seconds to the signal
T> from the M.U.T.-III.
9 3rd indicator lamp <5A/
T>
10 4th indicator lamp <5A/
T>
11 5th indicator lamp <5A/
T> <5A/T>
12 A/T control relay A/T control relay is • Data list No.8
OFF for three • During test: 0 V
seconds. • Normal: System
voltage (V)
A/T-ECU TERMINAL VOLTAGE

REGERENCE CHART
M1231124500365
C-19 C-12 C-20
AC501291AB
TROUBLESHOOTING
23A-107
Terminal Check item Inspection condition Standard value

No.
1 Underdrive solenoid valve • Engine: Idling System voltage
• Gear range: 1st gear
• Engine: Idling 6−9V
• Selector lever position: P
2 Solenoid valve power Ignition switch: LOCK (OFF) 1 V or less
supply Ignition switch: ON System voltage
3 Solenoid valve power Ignition switch: LOCK (OFF) 1 V or less
supply Ignition switch: ON System voltage
4 Shift indicator C <5A/T> Refer to the notes in the margin.* −
5 Shift indicator A <5A/T> Refer to the notes in the margin.* −
7 A/T fluid temperature Ignition switch: ON 1 V or less to system voltage
warning lamp (after several seconds have
elapsed)
9 4LLc switch Ignition switch: ON 1 V or less
Transfer lever: 4L <Vehicles with
easy select 4WD> or 4LLc
<Vehicles with super select
4WD>
Ignition switch: ON System voltage
Transfer lever: Other than the
above
11 Power supply voltage Always System voltage
12 Earth Always 1 V or less
14 Overdrive solenoid valve • Engine: Idling System voltage
• Gear range: 3rd gear
15 Damper clutch control • Engine: Idling System voltage
solenoid valve • Selector lever position: P
16 Second solenoid valve • Engine: Idling System voltage
• Gear range: 2nd gear
17 Shift indicator B <5A/T> Refer to the notes in the margin.* −
20 Ignition switch Ignition switch: LOCK (OFF) 1 V or less
Ignition switch: LOCK (OFF) to System voltage to 1 V or less
ON (after several seconds have
elapsed)
24 Power supply Always System voltage
TROUBLESHOOTING

No.
31 Input shaft speed sensor • Measure between terminals 31 Refer to P.23A-110, Inspection
and 43 with an oscilloscope. Procedure Using an
• Engine: 2,000 r/min Oscilloscope.
• Gear range: 3rd gear <4A/T>,
4th gear <5A/T>
32 Output shaft speed sensor • Measure between terminals 32 Refer to P.23A-110, Inspection
and 43 with an oscilloscope. Procedure Using an
• Engine: 2,000 r/min Oscilloscope.
• Selector lever position: 3rd
gear <4A/T>, 4th gear <5A/T>
38 Backup power supply Always System voltage
43 Sensor earth Always 1 V or less
44 A/T fluid temperature A/T fluid temperature: 20°C 3.8 − 4.0 V
sensor A/T fluid temperature: 40°C 3.2 − 3.4 V
A/T fluid temperature: 80°C 1.7 − 1.9 V
51 Reduction solenoid valve • Engine: Idling System voltage
<5A/T> • Gear range: 5th gear
55 Inhibitor switch: P • Ignition switch: ON System voltage
• Ignition switch: ON 1 V or less
• Selector lever position: Other
than above
56 Inhibitor switch: N • Ignition switch: ON System voltage
• Selector lever position: N
than above
57 Overdrive switch <4A/T> • Ignition switch: ON 1 V or less
• Overdrive switch: OFF
• Ignition switch: ON System voltage
• Overdrive switch: ON
Select switch <5A/T> • Ignition switch: ON System voltage
• Selector lever position: Sport
mode
than above
TROUBLESHOOTING
23A-109
No.
58 Inhibitor switch: L <4A/T> • Ignition switch: ON System voltage
• Selector lever position: L
than above
Shift switch (Down) <5A/ • Ignition switch: ON System voltage
T> • Selector lever operation:
selector lever
• Selector lever operation: Other
than above
62 Low-reverse solenoid • Engine: Idling System voltage
valve • Selector lever position: P
• Gear range: 2nd gear
66 Inhibitor switch: R • Ignition switch: ON System voltage
• Selector lever position: R
than above
67 Inhibitor switch: D • Ignition switch: ON System voltage
• Selector lever position: D
than above
68 Inhibitor switch: 2 <4A/T> • Ignition switch: ON System voltage
• Selector lever position: 2
than above
Shift switch (Up) <5A/T> • Ignition switch: ON System voltage
• Selector lever operation:
Upshift and hold the selector
lever
• Selector lever operation: Other
than above
69 Vehicle speed sensor • Measure between terminals 69 Refer to P.23A-110, Inspection
<2WD> and body earth with an Procedure Using an
oscilloscope. Oscilloscope.
• Engine: 2,000 r/min
• Gear range: 3rd gear
TROUBLESHOOTING

No.
71 A/T control relay Ignition switch: OFF 1 V or less
Ignition switch: ON System voltage to 1 V or less
(after several seconds have
elapsed)
NOTE: *: Using M.U.T.-III actuator function, check that the terminal voltage when the shift indicator is illumi-
nated is as follows.
Terminal No. 5 17 4
Check item Shift indicator A Shift indicator B Shift indicator C
Shift 1 9V 0V 0V
indicator 2 0V 9V 0V
3 9V 9V 0V
4 0V 0V 9V
5 9V 0V 9V
OSCILLOSCOPE CHECK PROCEDURE

M1231128500271
Terminal Check item Inspection conditions Normal condition

No. (Waveform sample)
31 Input shaft speed Selector lever position: Driving at constant Waveform A
sensor D speed of 50 km/h in 3rd
32 Output shaft speed <4A/T> or 4th <5A/T>
sensor gear (1,400 − 1,700 r/
min)
69 Vehicle speed signal
<2WD>
62 Low-reverse solenoid • Ignition switch: ON Force drive each Waveform B
valve • Selector lever solenoid valve (Actuator
1 Underdrive solenoid position: P test)
valve • Engine: Stopped
• Throttle
16 Second solenoid valve (Accelerator)
14 Overdrive solenoid opening voltage: 1
valve V or less
15 Damper clutch control
solenoid valve
51 Reduction solenoid
valve <5A/T>
ON-VEHICLE SERVICE
23A-111
WAVEFORM SAMPLE
Waveform B
Waveform A
(V) (V)
5 60
40
20
0 0
(ms) (ms)
AC001874AH AC001875AJ
ON-VEHICLE SERVICE
ESSENTIAL SERVICE NOTE: If the A/T fluid has a burnt smell, or if it has
become very contaminated or dirty, it means that
A/T FLUID CHECK the A/T fluid has become contaminated by minute
M1231103700212 particles form bushings (metal) or worn parts. In
CAUTION such a case, the transmission needs to be over-
When replacing the transmission with a new one, hauled and the A/T fluid cooler line needs to be
overhauling the existing transmission, or driving flushed out.
in a harsh condition, the A/T fluid cooler line
should always be flushed out and A/T fluid
should be replaced with a new one.
1. Drive the vehicle until the A/T fluid temperature
reaches the normal temperature (70 − 80°C)
NOTE: Measure A/T fluid temperature using
M.U.T.III.
NOTE:
Fluid level
[mm] 10 AC000846AB
0
HOT
-10
5. Check that the A/T fluid level is between the HOT
-20
marks on the oil level gauge. If the A/T fluid level
is too low, add more A/T fluid until the level
-30 Gauge reaches between the HOT marks.
-40
40 60 80 Automatic transmission fluid: DIA QUEEN
A/T fluid temperature [ ] ATF SP III
AC503813AB NOTE: If the A/T fluid level is too low, the oil pump
Check the fluid level referring to the characteris- draws air into the system along with the A/T fluid,
tics chart shown at left if it takes some time to and air bubbles will thus from in the fluid circuit.
reach the normal operation temperature of A/T This will cause a drop in fluid pressure and cause
fluid (70 − 80°C). the shift points to change and the clutches and
brakes to slip.
2. Park the vehicle on a level surface.
If the A/T fluid level is too high, the gear will churn
3. Move the selector lever to all positions to fully the A/T fluid and cause bubbles to develop, which
charge the torque converter and the fluid lines can then cause the same problems as when the
with A/T fluid, and then move the selector lever to A/T fluid is too low.
the P position. In either case, the air bubbles can cause over-
4. After wiping away any dirt from around the oil heating and oxidation of the A/T fluid, and also
level gauge, pull out the oil level gauge and check
the level of A/T fluid.
ON-VEHICLE SERVICE
prevent the valves, clutches and brakes from Discharge amount: Approx. 2.0 L
operating normally. In addition, if bubbles develop 4. Install the drain plug with a gasket in between,
in the A/T fluid, the A/T fluid can overflow from the and tighten it to the specified torque.
transmission vent holes and be mistaken for
leaks.
6. Securely re-insert the oil level gauge. CAUTION
Stop pouring in the A/T fluid once 5.5 L has been
A/T FLUID CHANGE poured in.
M1231104100279
5. Pour the new A/T fluid in through the oil filler tube.
CAUTION
Before replacing the transmission with a new Amount to add: Approx. 5.5 L
one, overhauling the existing transmission, or 6. Repeat the operation in step 2.
connecting the cooler pipe to the transmission, 7. Pour in new A/T fluid through the oil filler tube.
the A/T fluid cooler line should always be flushed
Amount to add: Approx. 3.5 L
out.
In you have an A/T fluid changer, use the A/T fluid NOTE: Carry out steps 2 and 7 so that at least 8.0
changer to flush the A/T fluid. If you do not have an L has been discharged from the cooler hose. After
A/T fluid changer, follow the procedure given below. this, discharge a small quantity of A/T fluid and
check for contamination. If the A/T fluid is contam-
inated, repeat steps 6 and 7.
AC503850AB
1. Remove the hose shown in the illustration which AC503850AB

allows the A/T fluid to flow from the A/T fluid
cooler to the transmission. 8. Connect the hose which was disconnected in step
1, and then securely re-insert the oil level gauge.
CAUTION
The engine should be stopped within one minute 9. Start the engine, and let it run at idle for 1 − 2
of it being started. If the A/T fluid has all been dis- minutes.
charged before this, stop the engine at that point. 10.Move the selector lever to all positions once, and
then return it to the N position.
2. Start the engine and discharge the A/T fluid.
Driving conditions: N range, idling
Discharge amount: Approx. 3.5 L
AC000846AB
Drain plug 11.Check that the A/T fluid level on the oil level
gauge is at the COLD mark. if it is not up to this
AC503264AB
mark, add more A/T fluid.
3. Remove the drain plug at the bottom of the 12.Drive the vehicle until the A/T fluid temperature
transmission case to drain out the remaining A/T reaches the normal temperature (70 − 80°C), and
fluid. then re check the A/T fluid level.
ON-VEHICLE SERVICE
23A-113
NOTE: The COLD mark is for reference only; the Driving conditions: N range, idling
HOT marks should be used as the standard for Discharge amount: Approx. 3.5 L
judgment.
NOTE: A/T fluid temperature using M.U.T.-III. CAUTION
Stop pouring in the A/T fluid once 3.5 L has been
NOTE: poured in.
Fluid level
[mm] 10 3. Pour in new A/T fluid through the oil filler tube.
0 Amount to add: Approx. 3.5 L
HOT
-10
4. Repeat the operation in step 2 and 3.
-20
-30
NOTE: Carry out steps 2 and 3 so that at least 8.0
Gauge
L has been discharged from the cooler hose. After
-40
40 60 80 this, discharge a small quantity of A/T fluid and
A/T fluid temperature [ ] check for contamination. If the A/T fluid is contam-
AC503813AB
inated, repeat steps 2 and 3.
5. Carry out the procedure in "A/T Fluid Change"
Check the fluid level referring to the characteris-
from step 2 onwards.
tics chart shown at left if it takes some time until
reaching the normal operation temperature of A/T
INHIBITOR SWITCH CONTINUITY CHECK
fluid (70 − 80°C.) M1231101900328
13.When A/T fluid is under the specified level, top up
A/T fluid. When A/T fluid is over the specified
level, drain the excessive A/T fluid from the drain
plug to adjust A/T fluid level to the specified level.
14.Securely insert the oil level gauge into the oil filler
tube.
FLUSHING COOLERS AND TUBES

M1231104800193
Inhibitor switch
CAUTION AC503900AB
If replacing the transmission with a new one, if
overhauling the existing transmission, or if the A/ <5A/T>
T fluid has deteriorated or is contaminated, the A/
T fluid cooler line must always be flushed out.
D N R P
AC503910AE
<4A/T>
AC503850AB
1. Remove the hose shown in the illustration which D N R P

L 2
allows the A/T fluid to flow from the A/T fluid
cooler to the transmission.
CAUTION
The engine should be stopped within one minute
of it being started. If the A/T fluid has all been dis- AC503910AD
charged before this, stop the engine at that point.
2. Start the engine and discharge the A/T fluid.
ON-VEHICLE SERVICE
Item Terminal No. Resistance CAUTION

P 1 − 7, 9 − 10 Continuity (Less Be careful not let the inhibitor switch slip out of
than 2Ω) place.
R 7−8
5. Tighten the inhibitor switch mounting bolt to the
N 2 − 7, 9 − 10 specified torque.
D 3−7 Tightening torque: 11 ± 1 N⋅m
2 <4A/T> 4−7
L <4A/T> 5−7
INHIBITOR SWITCH AND CONTROL

CABLE ADJUSTMENT
M1231109700168 Transmission
1. Move the selector lever to the N position. control cable
2. Loosen the adjusting nut, and set the manual

control lever upper and lower to the free condition. Adjusting nut
3. Move the manual control lever lower to the neutral AC503971AB
position.
6. Gently push the transmission control cable in the
direction as shown in the illustration at left, and
tighten the adjusting nut the specified torque.
Manual control Transmission Tightening torque: 23 ± 4 N⋅m
lever upper control cable
7. Check that the selector lever is at the N position.
8. Check that the transmission shifts to the correct
A range corresponding to the position of the selector
Adjusting nut
lever, and that it functions correctly in that range.
A
Manual 23 ± 4 N·m
TRANSFER OIL CHECK <4WD>
M1231112400305
control
lever lower
Mounting bolts 11 ± 1 N·m
Section A-A Manual control

Hole in End hole lever lower Filler plug
flange
Drain plug
Inhibitor
switch
AC502640AB
AC503967AB
4. Loosen the inhibitor switch mounting bolt, and

Filler plug hole
then turn the inhibitor switch to adjust so that the
hole at the end of the manual control lever lower Gasket
and the hole in the inhibitor switch flange (section
A − A in the illustration at left) are aligned.
NOTE: The inhibitor switch can be aligned by
hand, because the manual control lever lower end Filler plug
is as wide as the switch flange. Alternatively, the
inhibitor switch can also be aligned by inserting a Transfer oil
AC700330AM
5-mm bar in the holes of the manual control lever
end and the inhibitor switch flange. 1. Remove the filler plug and gasket.
2. Check that the oil level is up to the lower edge of
the filler plug hole.
ON-VEHICLE SERVICE
23A-115
3. Check that the oil is not noticeably dirty. 4WD DETECTION SWITCH CONTINUITY
4. Install the filler plug and new gasket, and tighten CHECK <EASY SELECT 4WD>
them to the specified torque. M1231146000023
TRANSFER OIL REPLACEMENT <4WD>

M1231112500357
Filler plug
Drain plug AC503108AB
Check the continuity between terminal of the black

connector indicated in the illustration.
AC502640AB
2H Open circuit
4H, 4L Continuity (Less than 2
Filler plug hole
Ω)
Gasket
HIGH/LOW DETECTION SWITCH
CONTINUITY CHECK <EASY SELECT
4WD>
Filler plug M1231145600022
Transfer oil
AC700330AM
1. Remove the filler plug and gasket.

2. Remove the drain plug and gasket, and then drain
the oil.
3. Install the drain plug and new gasket, then tighten
AC503107AB
4. Fill with gear oil API classification GL-3 SAE 75W-
85 or API classification GL-4 SAE 75W-85 until Check the continuity between terminal of the grey
the level comes to the lower portion of filler plug connector indicated in the illustration.
hole. Transfer lever position Specified condition
Quantity: 2.5 L While switching between Open circuit
5. Install the filler plug and new gasket, then tighten 4H and 4L
them to the specified torque. 2H, 4H, 4L Continuity (Less than 2
Tightening torque: 32 ± 2 N⋅m Ω)
ON-VEHICLE SERVICE
CENTRE DIFFERENTIAL LOCK CENTRE DIFFERENTIAL LOCK

DETECTION SWITCH CHECK <SUPER OPERATION DETECTION SWITCH
SELECT 4WD> CHECK <SUPER SELECT 4WD>
M1231121300191 M1231121400121
AC509434AC AC509434AD
Check the continuity between terminal of the brown Check the continuity between terminal of the black
connector and earth indicated in the illustration. connector and earth indicated in the illustration.
Transfer lever position Specified condition Transfer lever position Specified condition
4HLc and 4LLc Continuity (Less than 2 2H and 4H Open circuit
Ω) 4HLc and 4LLc Continuity (Less than 2
2H and 4H Open circuit Ω)
2WD/4WD DETECTION SWITCH CHECK 4WD OPERATION DETECTION SWITCH

<SUPER SELECT 4WD> CONTINUITY CHECK <SUPER SELECT
M1231111900095
4WD>
M1231131900086
AC509434AB
Check the continuity between terminal of the black AC509434AF

connector and earth indicated in the illustration. Check the continuity between terminal of the brown
Transfer lever position Specified condition connector and earth indicated in the illustration.
4H, 4HLc and 4LLc Open circuit Transfer lever position Specified condition
2H Continuity (Less than 2 2H Open circuit
Ω) 4H, 4HLc and 4LLc Continuity (Less than 2
Ω)
ON-VEHICLE SERVICE
23A-117
HIGH/LOW DETECTION SWITCH Check the continuity between terminal of the white
CONTINUITY CHECK <SUPER SELECT connector and earth indicated in the illustration.
M1231132100083
While switching between Open circuit
4HLc and 4LLc
2H, 4H, 4HLc and 4LLc Continuity (Less than 2
Ω)
A/T CONTROL COMPONENT LAYOUT

M1231102000511
AC509434AG
Name Symbol Name symbol

4WD indicator-ECU H Engine-ECU G
A/T control relay A 4LLc operation detection switch <4WD> B
A/T control solenoid valve assembly E Inhibitor switch D
A/T fluid temperature sensor E Input shaft speed sensor C
A/T-ECU I Output shaft speed sensor F
Diagnosis connector K Overdrive switch <4A/T> J
A B
C D E F
<LHD> <RHD>
I H G G H I
K J J K
AC509780 AB
A/T CONTROL COMPONENT CHECK Refer to P.23A-132.
OVERDRIVE SWITCH CHECK

M1231121800022
ON-VEHICLE SERVICE
INHIBITOR SWITCH CHECK A/T control solenoid

M1231112600150
valve assembly
Refer to P.23A-113. connector
A/T CONTROL RELAY CHECK

M1231110300302
A/T control relay
1 2 3 4 5 6
7 8 9 10
AC501840 AC
2. Disconnect the A/T control solenoid valve

assembly connector.
3. Measure the resistance between the solenoid
AC503999AB
valve terminals.
4. Check that the measured values are within the
1. Removal the A/T control relay. standard values at items 1 and 3.
STANDARD VALUE:
Name Terminal Resistance
No. value
Damper clutch control 7 − 10 2.7 − 3.4 Ω
solenoid valve (A/T fluid
Low-reverse solenoid valve 6 − 10 temperatur
e 20°C)
Second solenoid valve 4−9
Underdrive solenoid valve 3−9
AC504000
Overdrive solenoid valve 5−9
2. Use the jumper leads to connect A/T control relay Reduction solenoid valve 8 − 10
terminal 2 to the negative battery terminal and <5A/T>
terminal 1 to the positive battery terminal.
5. If within the standard value, check the power
3. Check the continuity between A/T control relay
supply and the earth circuits.
connector terminals 3 and 4 while alternately
connecting and disconnecting the jumper leads 6. If not within the standard value, drain the A/T fluid
from the battery terminals. and remove the valve body cover.
Jumper leads Continuity between
terminals 3 and 4
Second solenoid valve
Connected Continuity (Less than 2 Ω)
Disconnected Open circuit Overdrive solenoid valve Reduction solenoid
valve <5A/T>
4. If there is a malfunction, replace the A/T control
relay.
SOLENOID VALVE CHECK Damper clutch control

solenoid valve
Low-reverse solenoid valve
M1231110400291 Underdrive solenoid valve AC606199AC
1. Use the M.U.T.-III to measure the A/T fluid
temperature and check that the A/T fluid 7. Disconnect the solenoid valve connectors.
temperature is 20°C.
ON-VEHICLE SERVICE
23A-119
3. Measure the resistance between A/T control
solenoid valve assembly connector terminals 1
and 2.
Standard value:
Fluid temperature Resistance value (kΩ)
(°C)
0 16.7 − 20.5
20 7.3 − 8.9
AC002289
40 3.4 − 4.2
8. Measure the resistance between terminals 1 and 60 1.9 − 2.2
2 at each solenoid valve side.
80 1.0 − 1.2
Standard value: 2.7 − 3.4 Ω (A/T fluid temper-
100 0.57 − 0.69
ature 20°C)
NOTE: The A/T fluid temperature warning lamp
9. If not within the standard value, replace the
on the combination meter flashes when the tem-
solenoid valve.
perature reaches approximately 135 °C or higher
10.If within the standard value, check the harness and then stops flashing when the temperature
wire between A/T control solenoid valve assembly drops below approximately 115°C.
connector and each solenoid valve connector. If a
4. If the A/T fluid temperature sensor resistance and
problem is not found at the steps above, check
the temperature when the A/T fluid temperature
the solenoid valve O-rings and replace if
warning lamp is illuminating or switched off are
necessary.
outside the standard value ranges, replace the A/
A/T FLUID TEMPERATURE SENSOR T fluid temperature sensor.
CHECK 4LLc SWITCH CONTINUITY CHECK
M1231104200072
M1231131800294
1. Drain the A/T fluid and remove the valve body
cover.
A/T fluid temperature sensor
AC509434AE
Check the continuity between terminal of the white

ACX01206AG
connector indicated in the illustration.
2. Remove the A/T fluid temperature sensor. Transfer lever position Specified condition
4L <Vehicles with easy Continuity (Less than 2
select 4WD> or 4LLc Ω)
<Vehicles with super
select 4WD>
Other than the above Open circuit
A/T
ATFfluid
AC103441AD
ON-VEHICLE SERVICE
TORQUE CONVERTER STALL CHECK Standard stalling engine speed: 2, 200 − 2,

M1231103500177 700 r/min
The purpose of this test is to measure the maximum
6. Move the selector lever to the R position and
engine speed when the torque converter stalls in D
repeat the test described above.
or R ranges in order to check the torque converter
(Stator and one-way clutch operation) and the hold- Standard stalling engine speed: 2, 200 − 2,
ing performance of the clutches and brakes which 700 r/min
are built into the transmission.
TORQUE CONVERTER STALL TEST
WARNING
For safety, the front and rear of the vehicle JUDGMENT RESULTS
should be kept clear of other people while 1. Stall speed is too high in both D and R ranges
this test is being carried out. • Malfunction of the torque converter (Slippage
on the splines of the torque converter and the
1. Check the A/T fluid level, the A/T fluid input shaft)
temperature and the engine coolant temperature. • Low line pressure
• A/T fluid level: HOT position on oil level gauge • Low-reverse brake slippage and malfunction
• A/T fluid temperature: 70 − 80°C of the one-way clutch
• Engine coolant temperature: 80 − 100°C
2. Stall speed is too high in D range only
NOTE: The A/T fluid temperature is measured • Underdrive clutch slippage
with M.U.T.-III. 3. Stall speed is too high in R range only
2. Place wheel locks on both the left and right front • Reverse clutch slippage
wheels. 4. Stall speed is too low in both D and R ranges
3. Pull the parking brake lever to apply the parking • Malfunction of the torque converter (Slippage
brake and depress the brake pedal fully. of the one-way clutch)
4. Start the engine. • Low line pressure
• Poor engine output
CAUTION
• Do not keep the throttle fully open for any HYDRAULIC PRESSURE TESTS
longer than 5 seconds. M1231103800305
• If you repeat the stall test when the A/T fluid CAUTION
temperature is greater than 80°C, move the The A/T fluid temperature should be between 70
selector lever to the "N" position and let the − 80°C during the test.
engine run at approximately 1,000 r/min for at
least one minute. Wait until the A/T fluid tem- 1. Check the A/T fluid level, temperature and engine
perature returns to 80°C or less. coolant temperature.
• A/T fluid level: HOT mark on the level gauge
5. Move the selector lever to the D position, fully • A/T fluid temperature: 70 − 80°C
depress the accelerator pedal and quickly take a • Engine coolant temperature: 80 − 100°C
reading of the maximum engine speed at this
2. Raise the vehicle so that the wheels are free to
time.
turn.
ON-VEHICLE SERVICE
23A-121
NOTE: .
MD998330 • 2B: Second brake pressure port
• UC: Underdrive clutch pressure port
• LB: Low-reverse brake pressure port
MD998900 • TR: Torque converter release pressure port
• TA: Torque converter apply pressure port
• RC: Reverse clutch pressure port
Oil pan • OC: Overdrive clutch pressure port
• DC: Direct clutch pressure port <5A/T>
AC101188AC
• RB: Reduction brake pressure port <5A/T>
4. Restart the engine.
Transmission control 5. Check that there are no leaks around the special
cable
tool port adapters.
MD998330 6. Measure the hydraulic pressure at each port
under the conditions given in the standard
hydraulic pressure table, and check that the
measured values are within the standard value
ranges.
MD998900 7. If the pressure is not within the standard value,
AC101189AC
stop the engine and refer to the hydraulic
pressure test diagnosis table.
<5A/T> 8. Remove the O-ring from the port plug and replace
MD998900 it.
MD998332
9. Remove the special tool, and install the plugs to
the hydraulic pressure ports.
10.Start the engine and check that there are no leaks
around the plugs.
A/T fluid cooler pipe

AC101190AE
3. Connect the special tools (oil pressure gauge (3.0

MPa) [MD998330] and adapters [MD998332,
MD998900]) to each pressure discharge port.
STANDARD HYDRAULIC PRESSURE TABLE

<4A/T>
Measurement condition Standard hydraulic pressure MPa
Selecto Shift Engine Underdriv Reverse Overdrive Low- Second Torque
r lever position speed e clutch clutch clutch reverse brake converter
positio (r/min) pressure pressure pressure brake pressure pressure
n [UC] [RC] [OC] pressure [2B] [TR]
[LB]
P − 2,500 − − − 0.26 − 0.36 − 0.22 − 0.36
R Reverse 2,500 − 1.27 − 1.77 − 1.27 − 1.77 − 0.50 − 0.73
N − 2,500 − − − 0.26 − 0.36 − 0.22 − 0.36
ON-VEHICLE SERVICE

Selecto Shift Engine Underdriv Reverse Overdrive Low- Second Torque
r lever position speed e clutch clutch clutch reverse brake converter
positio (r/min) pressure pressure pressure brake pressure pressure
n [UC] [RC] [OC] pressure [2B] [TR]
[LB]
D 1st gear 2,500 0.98 − 1.05 − − 0.98 − 1.05 − 0.50 − 0.73
(Overdri 2nd gear 2,500 0.98 − 1.05 − 0.98 − 1.05 0.50 − 0.73
− −
ve
switch: 3rd gear 2,500 0.78 − 0.90 − 0.78 − 0.90 − − 0.45 − 0.72
OFF) 4th gear 2,500 − − 0.78 − 0.90 − 0.78 − 0.88 0.45 − 0.72
<5A/T>
Selector Shift Engine Underd Revers Overdri Direct Low- Second Reducti Torque
lever position speed rive e ve clutch reverse brake on convert
position (r/min) clutch clutch clutch pressur brake pressu brake er
pressur pressur pressur e [DC] pressur re [2B] pressur pressur
e [UC] e [RC] e [OC] e [LB] e [RB] e [TR]
P − 2,500 − − − − 0.26 − − 0.26 − 0.22 −
0.36 0.36 0.36
R Reverse 2,500 − 1.27 − − − 1.27 − − 1.27 − 0.50 −
1.77 1.77 1.77 0.73
N − 2,500 − − − − 0.26 − − 0.26 − 0.22 −
0.36 0.36 0.36
Sport 1st gear 2,500 0.98 − − − − 0.98 − − 0.98 − 0.50 −
mode 1.05 1.05 1.05 0.73
2nd gear 2,500 0.98 − − − − − 0.98 − 0.98 − 0.50 −
1.05 1.05 1.05 0.73
3rd gear 2,500 0.78 − − 0.78 − − − − 0.78 − 0.45 −
0.90 0.90 0.88 0.72
4th gear 2,500 0.78 − − 0.78 − 0.78 − − − − 0.45 −
0.90 0.90 0.88 0.72
5th gear 2,500 − − 0.78 − 0.78 − − 0.78 − − 0.45 −
0.90 0.88 0.88 0.72
NOTE: When the torque converter pressure is measured, the engine speed should be 1,500 r/min or less.
HYDRAULIC PRESSURE TEST DIAGNOSIS TABLE

Trouble symptom Probable cause
All hydraulic pressures are high. Malfunction of the regulator valve
ON-VEHICLE SERVICE
23A-123
All hydraulic pressures are low. Malfunction of the oil pump
Clogged internal oil filter
Clogged oil cooler
Malfunction of the regulator valve
Malfunction of the relief valve
Incorrect valve body installation
Improperly installed solenoid valves
Damaged solenoid valve O-rings
Hydraulic pressure is abnormal in reverse Malfunction of the regulator valve
gear only. Clogged orifice
Hydraulic pressure is abnormal in 3rd or 4th Malfunction of the overdrive solenoid valve
gear only. Malfunction of the overdrive pressure control valve
Malfunction of the regulator valve
Malfunction of the switch valve
Clogged orifice
Only underdrive clutch hydraulic pressure is Malfunction of the oil seal K
abnormal. Malfunction of the oil seal L
Malfunction of the oil seal M
Malfunction of the oil seal Q
Malfunction of the underdrive solenoid valve
Malfunction of the underdrive pressure control valve
Malfunction of the check ball
Clogged orifice
Only reverse clutch hydraulic pressure is Malfunction of the oil seal A
abnormal. Malfunction of the oil seal B
Malfunction of the oil seal C
Clogged orifice
Only overdrive clutch hydraulic pressure is Malfunction of the oil seal D
abnormal. Malfunction of the oil seal E
Malfunction of the oil seal F
Malfunction of the overdrive solenoid valve
Malfunction of the overdrive pressure control valve
Clogged orifice
ON-VEHICLE SERVICE

Only direct clutch hydraulic pressure is Malfunction of the oil seal R
abnormal. <5A/T> Malfunction of the oil seal S
Malfunction of the oil seal T
Malfunction of the low-reverse solenoid valve (Shared with
direct clutch)
Malfunction of the low-reverse pressure control valve
Malfunction of the fail safe valve C
Clogged orifice
Only low-reverse brake hydraulic pressure is Malfunction of the oil seal I
abnormal. Malfunction of the oil seal J
Malfunction of the oil seal P
Malfunction of the low-reverse solenoid valve
Malfunction of the low-reverse pressure control valve
Malfunction of the fail safe valve A
Malfunction of all the check ball
Clogged orifice
Only second brake hydraulic pressure is Malfunction of the oil seal G
abnormal. Malfunction of the oil seal H
Malfunction of the oil seal O
Malfunction of the second solenoid valve
Malfunction of the second pressure control valve
Malfunction of the fail safe valve B
Clogged orifice
Only reduction brake hydraulic pressure is Malfunction of the oil seal U
abnormal. <5A/T> Malfunction of the oil seal V
Malfunction of the reduction solenoid valve
Malfunction of the reduction pressure control valve
Clogged orifice
Only torque converter pressure is abnormal. Clogged oil cooler
Malfunction of the oil seal N
Malfunction of the damper clutch control solenoid valve
Malfunction of the damper clutch pressure control valve
Clogged orifice
ON-VEHICLE SERVICE
23A-125
Pressure applied to element which should not Incorrect transmission control cable adjustment
receive pressure. Malfunction of the manual valve
ON-VEHICLE SERVICE
OIL SEAL LAYOUT

<4A/T>
NA BCD EF G H I J K L M Q
O P
AC904046AB
ON-VEHICLE SERVICE
23A-127
<5A/T>
NA BCD EF G H I J K L M T S R Q
O P
Section a - a
U
AC904047 AB
ON-VEHICLE SERVICE
HYDRAULIC CIRCUIT
M1231103900250
<4A/T> (Neutral)
1 2 3 4 5
7
6 6 6 6
8
9 10
11
12
13
14 15 16 17 18
19 20 21 22 23
24
25 26
R ND
P2
L
29
28
27 30
31 ACX01967AE
1. Reverse clutch 17. Underdrive pressure control valve

2. Low-reverse brake 18. Overdrive pressure control valve
3. Second brake 19. Damper clutch control solenoid valve
4. Underdrive clutch 20. Low-reverse solenoid valve
5. Overdrive clutch 21. Second solenoid valve
6. Accumulator 22. Underdrive solenoid valve
7. Check ball 23. Overdrive solenoid valve
8. Damper clutch control 24. Damper clutch pressure control valve
9. Fail-safe valve A 25. Regulator valve
10. Fail-safe valve B 26. Manual valve
11. Damper clutch control valve 27. Oil filter
12. Switch valve 28. Oil pump
13. A/T fluid cooler 29. Oil strainer
14. Lubrication 30. Relief valve
15. Low-reverse pressure control valve 31. Oil pan
16. Second pressure control valve
ON-VEHICLE SERVICE
23A-129
<5A/T> (Neutral)
1 2 3 4 5 6 7
8 8 8 8 8 8
9
12
10 11
13
14
15
16 17 18 19 20
21 22 23 24 25 26
28
27
29
RP D
N
33
31
30 32
34
AC603759AB
1. Reverse clutch 31. Oil pump

2. Low-reverse brake 32. Relief valve
3. Second brake 33. Oil strainer
4. Underdrive clutch 34. Oil pan
5. Overdrive clutch
6. Reduction brake LINE PRESSURE ADJUSTMENT
M1231108700121
7. Direct clutch
8. Accumulator 1. Drain the A/T fluid.
9. Damper clutch NOTE: The hydraulic pressure test must be per-
10. Failsafe valve A formed before attempting any adjustments.
11. Failsafe valve B 2. Remove the valve body cover.
12. Failsafe valve C
13. Damper clutch control valve
14. Switch valve Adjusting screw
15. A/T fluid cooler
16. Low-reverse pressure control valve
17. Second pressure control valve
18. Underdrive pressure control valve
19. Overdrive pressure control valve
20. Reduction pressure control valve
21. Damper clutch solenoid valve
22. Low-reverse solenoid valve
23. Second solenoid valve AC100548AB
24. Underdrive solenoid valve

3. Turn the adjusting screw shown in the illustration
25. Overdrive solenoid valve
26. Reduction solenoid valve
to adjust the line pressure to the standard value.
27. Damper clutch pressure control valve The pressure increases when the screw is turned
28. Regulator valve anti-clockwise.
29. Manual valve NOTE: When adjusting the line pressure, adjust
30. Oil filter to the middle of the standard value range.
ON-VEHICLE SERVICE
Standard value: 1.01 − 1.05 MPa (Change in 1. Apply the parking brake, and check that the
pressure for a single full of the adjusting selector lever moves smoothly and accurately to
screw: 0.035 MPa) each position.
4. Install the valve body cover, and then pour in the 2. Check that the engine starts when the selector
specified amount of A/T fluid. lever is in the N or P position, and that it does not
5. Repeat the hydraulic pressure test (Refer to start when the selector lever is in any other
P.23A-120.) Readjust the line pressure if position.
necessary. 3. Start the engine, release the parking brake, and
check that the vehicle moves forward when the
SELECTOR LEVER OPERATION CHECK selector lever is moved from N position to the D,
M1231101300274 2, L position or sport mode, and that the vehicle
<5A/T> reverses when the selector lever is moved to the
P R position.
R
4. Stop the engine.
N 5. Turn the ignition switch to ON position. Check that
D the backup lamp illuminates and the buzzer
sounds when the selector lever is moved from P
position to R position.
: Operation when the pushbutton is kept pressed.
: Operation when the pushbutton is not pressed.
AC801688 AD
<4A/T>
P
R
N
D
2
L
: Operation when the pushbutton is kept pressed.

: Operation when the pushbutton is not pressed.
AC504093AC
TRANSMISSION CONTROL <4A/T>
23A-131
M1231117900554

• Move the selector lever to the N range position. • Front Floor Console Assembly Installation (Refer to
• Front Floor Console Assembly Removal (Refer to GROUP 52A, Floor Consol Assembly .)
GROUP 52A, Floor Consol Assembly .) • Transmission Control Cable Adjustment (Refer to P.23A-
114).
• Check that the selector lever is moved to each position
smoothly and correctly.
3.2 ± 0.2 N·m
2 4
11 ± 2 N·m 19 ± 3 N·m
19 ± 3 N·m
1 5
6 5
23 ± 4 N·m
equivalent
11 ± 2 N·m
11 ± 2 N·m
8
11 ± 2 N·m
AC509716AB
Selector lever assembly removal Transmission control cable

steps assembly removal steps
1. Transmission control cable 1. Transmission control cable
connection connection
2. Selector lever assembly 6. Adjust lever connection
Transfer control lever removal 7. Cable bracket
steps <4WD> 8. Transmission control cable
3. Dust cover retaining plate assembly
4. Dust cover
5. Transfer control lever assembly
INSPECTION OVERDRIVE SWITCH CHECK

M1231130000132 Terminal Operation Resistance
connection of
ON OFF
tester
3−4 Overdrive switch: Continuity
ON (Less than 2
Overdrive
Ω)
switch
Overdrive switch: Open circuit
OFF
AC509719AB DISASSEMBLY AND ASSEMBLY

M1231118100119
2
1
2.2 ± 0.4 N·m
4
3
AC900376AB

1. Shift knob and Indicator panel 5. Selector lever assembly
assembly
2. Shift knob
3. Shift indicator lamp
4. Indicator panel
23A-133
M1231117900532

• Move the transmission control lever and transfer control • Front Floor Console Assembly Installation (Refer to
lever to the following positions. GROUP 52A − Floor Consol Assembly .)
• Transmission control lever : Neutral • Transmission Control Cable Adjustment (Refer to P.23A-
• Transfer control lever : 4H 114).
• Front Floor Console Assembly Removal (Refer to • Check that the selector lever is moved to each position
GROUP 52A − Floor Consol Assembly .) smoothly and correctly.
3.2 ± 0.2 N·m
1 6
2.2 ± 0.4 N·m
2
11 ± 2 N·m
3 7 19 ± 3 N·m
5
19 ± 3 N·m
8
4
9 8
10
23 ± 4 N·m Semi-drying sealant:

equivalent
11 ± 2 N·m
11 ± 2 N·m
11
11 ± 2 N·m
AC800082 AB

1. Shift knob 4. Transmission control cable
2. Knob cover connection
3. Sleeve 9. Adjust lever connection
4. Transmission control cable 10. Cable bracket
connection • No.2 crossmember (Refer to
5. Selector lever assembly GROUP 32 − Rear Engine
6. Dust cover retaining plate <4WD> Mounting .)
7. Dust cover <4WD> 11. Transmission control cable
8. Transfer control lever assembly assembly
<4WD>
INSPECTION Selector lever Terminal Resistance

M1231118000286
position No.
SHIFT SWITCH ASSEMBLY CONTINUITY CHECK
Sport mode Select 1−2 Open circuit
Auto mode switch Continuity (Less
than 2Ω)
Up Shift 3−5 Continuity (Less
switch (up than 2Ω)
Other than shift) Open circuit
above
Down Shift 3−6 Continuity (Less
switch than 2Ω)
AC807491
Other than (down Open circuit
Selector lever Terminal Resistance above shift)
position No.
Sport mode Select 1−4 Continuity (Less SHIFT LEVER POSITION ILLUMINATION
switch than 2Ω) CONTINUITY CHECK
Auto mode Open circuit Terminal No. Resistance
7−8 Continuity
23A-135
REMOVAL AND INSTALLATION <4A/T>
M1231117000562
<2WD>
• Under Skid Plate and Engine Room Under Cover • No.2 Crossmember Assembly Installation (Refer to
Removal (Refer to GROUP 51 − Under Cover .) GROUP 32 − Rear Engine Mounting .)
• A/T Fluid Draining (Refer to P.23A-112.) • Starter Assembly Installation (Refer to GROUP 16 −
• Propeller Shaft Removal (Refer to GROUP 25 − Propeller Starter Motor Assembly ).
Shaft .) • Pipe Assembly Installation (Refer to P.23A-141.)
• Front Exhaust Pipe Removal (Refer to GROUP 15 − Front • Transmission Control Cable Connection Installation
Exhaust Pipe Main Muffler .) (Refer to P.23A-131.)
• Transmission Control Cable Connection Removal (Refer • Front Exhaust Pipe Installation (Refer to GROUP 15 −
to P.23A-131.) Front Exhaust Pipe Main Muffler .)
• Pipe Assembly Removal (Refer to P.23A-141.) • Propeller Shaft Installation (Refer to GROUP 25 − Propel-
• Starter Assembly Removal (Refer to GROUP 16 − Starter ler Shaft .)
Motor Assembly ). • A/T Fluid Supplying (Refer to P.23A-112.)
• No.2 Crossmember Assembly Removal (Refer to GROUP • Under Skid Plate and Engine Room Under Cover Installa-
32 − Rear Engine Mounting .) tion (Refer to GROUP 51 − Under Cover .)
3
48 ± 6 N·m
9
7
6 6 8
25 ± 4 N·m
24 ± 3 N·m
49 ± 3 N·m
8
4 48 ± 6 N·m
22 ± 4 N·m
11 ± 1 N·m
2N
8.9 ± 0.9 N·m
50 ± 7 N·m
AC904029 AB
Removal steps (Cont.) Removal steps (Cont.)

1. Oil level gauge assembly 3. Harness connector connection
2. O-ring 4. Bell housing cover
Removal steps (Cont.)

5. Drive plate connecting bolts
• Support the transmission with a
transmission jack
6. Transmission assembly lower part
coupling bolts
7. Front exhaust pipe bracket
8. Transmission assembly upper part
coupling bolts
>>A<< 9. Transmission assembly
23A-137
<4WD>
• A/T Fluid Draining (Refer to P.23A-112.) • Transfer Control Lever Assembly Installation (Refer to
• Transfer Oil Draining (Refer to P.23A-115). P.23A-131.)
• Front and Rear Propeller Shaft Removal (Refer to • Starter Assembly Installation (Refer to GROUP 16 −
GROUP 25 − Propeller Shaft .) Starter Motor Assembly ).
• Front Exhaust Pipe Removal (Refer to GROUP 15 − Front • Pipe Assembly Installation (Refer to P.23A-141.)
Exhaust Pipe Main Muffler .) • Transmission Control Cable Connection Installation
• Transmission Control Cable Connection Removal (Refer (Refer to P.23A-131.)
to P.23A-131.) • Front Exhaust Pipe Installation (Refer to GROUP 15 −
• Pipe Assembly Removal (Refer to P.23A-141.) Front Exhaust Pipe Main Muffler .)
• Starter Assembly Removal (Refer to GROUP 16 − Starter • Front and Rear Propeller Shaft Installation (Refer to
Motor Assembly ). GROUP 25 − Propeller Shaft .)
• Transfer Control Lever Assembly Removal (Refer to • Transfer Oil Supplying (Refer to P.23A-115).
P.23A-131.) • A/T Fluid Supplying (Refer to P.23A-112.)
11 6
48 ± 6 N·m
9 3
8 8 10
25 ± 4 N·m
24 ± 3 N·m
49 ± 3 N·m
4
7
8
5 48 ± 6 N·m
22 ± 4 N·m
11 ± 1 N·m
2N
8.9 ± 0.9 N·m
50 ± 7 N·m
AC904030 AB
Removal steps (Cont.) Removal steps (Cont.)

1. Oil level gauge assembly 4. A/T control harness connector
2. O-ring connection
3. Harness connector connection 5. Bell housing cover
Removal steps (Cont.) INSTALLATION SERVICE POINT

6. Dust seal guard
>>A<< TRANSMISSION ASSEMBLY INSTALLA-
Support the transmission with a
TION
•
transmission jack
8. Transmission assembly lower part
coupling bolts
9. Front exhaust pipe bracket
10. Transmission assembly upper part 20.9 mm
coupling bolts
>>A<< 11. Transmission assembly
AC004836AG
Press the torque converter into the transmission

properly, and then assembly into the engine.
23A-139
REMOVAL AND INSTALLATION <5A/T>
M1231117000551

• A/T Fluid Draining (Refer to P.23A-112.) • Transfer Control Lever Assembly Installation (Refer to
• Transfer Oil Draining (Refer to P.23A-115). P.23A-133.)
• Front and Rear Propeller Shaft Removal (Refer to • Starter Assembly Installation (Refer to GROUP 16 −
GROUP 25 − Propeller Shaft .) Starter Motor Assembly .)
• Front Exhaust Pipe and Front Exhaust Pipe Bracket • Pipe Assembly Installation (Refer to P.23A-141.)
Removal (Refer to GROUP 15 − Exhaust Pipe and Main • Transmission Control Cable Connection Installation
Muffler .) (Refer to P.23A-133.)
• Transmission Control Cable Connection Removal (Refer • Front Exhaust Pipe and Front Exhaust Pipe Bracket
to P.23A-133.) Installation (Refer to GROUP 15 −Exhaust Pipe and Main
• Pipe Assembly Removal (Refer to P.23A-141.) Muffler .)
• Starter Assembly Removal (Refer to GROUP 16 − Starter • Front and Rear Propeller Shaft Installation (Refer to
Motor Assembly .) GROUP 25 − Propeller Shaft .)
• Transfer Control Lever Assembly Removal (Refer to • Transfer Oil Supplying (Refer to P.23A-115).
P.23A-133 .) • A/T Fluid Supplying (Refer to P.23A-112.)
10
6
48 ± 6 N·m
8 9 3
8
48 ± 6 N·m
49 ± 3 N·m
7
4
7
48 ± 6 N·m
5
1
11 ± 1 N·m 22 ± 4 N·m
2N
9.0 ± 1.0 N·m
50 ± 7 N·m AC903384 AD
REMOVAL STEPS REMOVAL STEPS (Continued)

1. Oil level gauge assembly 8. Transmission assembly lower part
2. O-ring coupling bolts
3. Harness connector connection • Support the transmission with a
4. A/T control harness connector transmission jack
connection 9. Transmission assembly upper part
6. Dust seal guard >>A<< 10. Transmission assembly
INSTALLATION SERVICE POINT Press the torque converter into the transmission
>>A<< TRANSMISSION ASSEMBLY INSTALLA- properly, and then assembly into the engine.
TION
Approx. 21.0 mm
AC004836AI
A/T FLUID COOLER
23A-141
A/T FLUID COOLER
M1231128700372

Removal and Installation.
• A/T Fluid Draining and Refilling (Refer to P.23A-112).
<Vehicles with air cooled A/T fluid

cooler>
10
11
1
5 48 ± 7 N·m
2N
7
6
2 N
3
12 ± 2 N·m 4 9
AC509593 AE

1. Cooler hose 7. Return pipe
2. Gasket 8. Hose
3. Hose 9. Feed hose
4. A/T fluid cooler assembly 10. Cooler hose
5. Pipe assembly 11. Cooler pipe assembly
6. Return hose
A/T FLUID COOLER
<Vehicles without air cooled A/T fluid

cooler>
11 ± 2 N·m
5 11 ± 2 N·m 48 ± 7 N·m
5.0 ± 1.0 N·m
4 2N
5.0 ± 1.0 N·m
N2
5.0 ± 1.0 N·m 1
3
6
AC807090 AC

1. Pipe assembly 5. Hose
2. Gasket 6. Feed hose
3. Return hose 7. Cooler hose
4. Return pipe 8. Cooler pipe assembly
A/T-ECU
23A-143
A/T-ECU
M1231130200222
<LHD>
<RHD> 5.0 ± 1.0 N·m

3
12 ± 2 N·m
4
5
2
1
AC509596AB

• Driver’s side under cover (Refer to 2. A/T-ECU and A/T-ECU bracket
GROUP 52A, Instrument Panel assembly
Assembly ). 3. Harness connection
1. A/T-ECU connector connection 4. A/T-ECU bracket
5. A/T-ECU
4WD INDICATOR-ECU
M1231119100015
Refer to GROUP 22A .
23B-1
GROUP 23B
AUTOMATIC
TRANSMISSION
OVERHAUL <R4A5>
CONTENTS
GENERAL INFORMATION . . . . . . . . 23B-2 TRANSMISSION . . . . . . . . . . . . . . . . . 23B-14

GENERAL SPECIFICATIONS . . . . . . 23B-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23B-14
SERVICE SPECIFICATIONS. . . . . . . 23B-4 REVERSE AND OVERDRIVE CLUTCH

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23B-41
TORQUE SPECIFICATIONS . . . . . . . 23B-4 REVERSE AND OVERDRIVE CLUTCH
DISASSEMBLY AND REASSEMBLY . . . . . 23B-41
VALVE BODY SPRING IDENTIFICATION
................................. 23B-5 SECOND BRAKE . . . . . . . . . . . . . . . . 23B-44
SECOND BRAKE DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23B-44
SNAP RING, SPACER, THRUST WASHER,
THRUST RACE AND PRESSURE PLATE FOR
ADJUSTMENT . . . . . . . . . . . . . . . . . . 23B-5 LOW REVERSE ANNULUS GEAR . . 23B-45
LOW REVERSE ANNULUS GEAR DISASSEMBLY
AND REASSEMBLY . . . . . . . . . . . . . . . . . . 23B-45
SEALANTS . . . . . . . . . . . . . . . . . . . . 23B-7
CENTRE SUPPORT . . . . . . . . . . . . . . 23B-46
LUBRICANT(S) . . . . . . . . . . . . . . . . . 23B-8
CENTRE SUPPORT DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23B-46
SPECIAL TOOLS. . . . . . . . . . . . . . . . 23B-8
UNDERDRIVE CLUTCH . . . . . . . . . . . 23B-48
TRANSMISSION AND EXTENSION HOUSING
UNDERDRIVE CLUTCH DISASSEMBLY AND
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23B-10 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23B-48
DISASSEMBLY AND REASSEMBLY. . . . . 23B-10 VALVE BODY . . . . . . . . . . . . . . . . . . . 23B-51
VALVE BODY DISASSEMBLY AND REASSEMBLY
EXTENSION HOUSING . . . . . . . . . . . 23B-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23B-51
EXTENSION HOUSING DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23B-12
23B-2 AUTOMATIC TRANSMISSION OVERHAUL <R4A5>
GENERAL INFORMATION
GENERAL INFORMATION
M1233000101848
TRANSMISSION MODEL
R4A5A-J-LH 4D56 DI-D DOHC KA4T
SECTIONAL VIEW
70NT
68NT 17NT
21NT
38NT
25NT
AK801605
AUTOMATIC TRANSMISSION OVERHAUL <R4A5>
GENERAL INFORMATION
23B-3
HYDRAULIC CIRCUIT
1 2 3 4 5
7 8
9 10
11
12 13 14 15
16 17 18 19 20
21
22 23
R ND
P
26
24 27
25
AK600223AB
1. Reverse clutch 15. Overdrive clutch pressure control valve

2. Low/reverse brake 16. Damper clutch control solenoid valve
3. Second brake 17. Low-reverse brake solenoid valve
4. Underdrive clutch 18. Second brake solenoid valve
5. Overdrive clutch 19. Underdrive clutch solenoid valve
6. Damper clutch 20. Overdrive clutch solenoid valve
7. Fail-safe valve A 21. Torque converter pressure control valve
8. Fail-safe valve B 22. Regulator valve
9. Damper clutch control valve 23. Manual valve
10. Switching valve 24. Oil filter
11. Cooler 25. Oil pan
12. Low-reverse brake pressure control valve 26. Oil pump
13. Second brake pressure control valve 27. Oil strainer
14. Underdrive clutch pressure control valve
M1233000201191
Item Specifications
Transmission model R4A5A
Torque converter Type 3-element, 1-stage, 2-phase type
Stall torque ratio 1.62
Lock-up Present
Transmission type Electronically controlled 4-speed full-automatic
2nd 1.495
3rd 1.000
4th 0.731
Reverse 2.720
M1233000300979
Item Standard value

Output shaft end play mm 0.25 − 0.71
Center support end play mm 0 − 0.16
Brake reaction plate end play mm 0 − 0.16
Second brake end play mm 1.49 − 1.95
Low/reverse brake end play mm 1.65 − 2.11
Input shaft end play mm 0.25 − 0.81
Overdrive clutch return spring retainer end play mm 0 − 0.09
Overdrive clutch end play mm 2.0 − 2.2
Reverse clutch end play mm 1.5 − 1.7
Underdrive clutch end play mm 1.6 − 1.8
M1233023101623
Item N⋅m
Transmission case to extension housing mounting bolt 48 ± 6
Cable end bracket mounting bolt 48 ± 6
Clip mounting bolt 11 ± 1
Air breather hose bracket mounting bolt 11 ± 1
Harness clamp bracket mounting bolt 26 ± 5
Oil filler tube mounting bolt 44 ± 8
Output shaft support mounting bolt 23 ± 3
Oil pump mounting bolt 23 ± 3
23B-5
Item N⋅m
Converter housing to transmission case mounting bolt 48 ± 6
Valve body mounting bolt 11 ± 1
Oil temperature sensor mounting bolt 11 ± 1
Detent spring mounting bolt 6.0 ± 1.0
Oil filter mounting bolt 6.0 ± 1.0
Oil pan mounting bolt 11 ± 1
Manual control lever mounting nut 21.5 ± 3.5
Output shaft speed sensor mounting bolt 11 ± 1
Input shaft speed sensor mounting bolt 11 ± 1
Inhibitor switch mounting bolt 11 ± 1
Cover mounting bolt 11 ± 1
Solenoid support mounting bolt 6.0 ± 1.0
Separating plate mounting bolt 6.0 ± 1.0
Lower valve body mounting bolt 11 ± 1
Upper valve body mounting bolt 11 ± 1

M1233022900269
Item Wire Outside Free Number of

diameter diameter height loops
mm mm mm
Orifice check ball spring 0.5 4.5 15.4 15
Damper clutch control valve spring 0.7 5.9 28.1 19
Damping valve A spring 1.0 7.7 35.8 17
Torque converter pressure control valve 1.6 11.2 29.4 9.5
spring
Fail-safe valve a spring 0.7 8.9 21.9 9.5
Pressure control valve spring 0.7 7.6 37.7 25
Line relief valve spring 1.0 7.0 17.3 10
Regulator valve spring 1.8 13.3 44.6 12.5
SNAP RING, SPACER, THRUST WASHER, THRUST RACE

AND PRESSURE PLATE FOR ADJUSTMENT
M1233100500022
Thrust race (For adjustment of output shaft end play)
1.6 None 2.0 None
1.8 None 2.2 None
SNAP RING, SPACER, THRUST WASHER, THRUST RACE AND PRESSURE PLATE FOR
Snap ring (For adjustment of underdrive clutch and overdrive clutch end play)
1.6 Brown 2.4 Blue
1.7 None 2.5 Brown
1.8 Blue 2.6 None
1.9 Brown 2.7 Blue
2.0 None 2.8 Brown
2.1 Blue 2.9 None
2.2 Brown 3.0 Blue
2.3 None
Thrust race (For adjustment of input shaft end play)
1.4 None 2.2 None
1.6 None 2.4 None
1.8 None 2.6 None
2.0 None
Snap ring (For adjustment of overdrive clutch return spring retainer end play)
1.48 Brown 1.58 None
1.53 Black 1.63 Brown
Pressure plate (For adjustment of second brake end play)
1.6 F 2.4 B
1.8 E 2.6 A
2.0 D 2.8 0
2.2 C 3.0 1
Snap ring (For adjustment of center support and brake reaction plate end play)
2.2 None 2.4 Brown
2.3 Blue 2.5 None
Snap ring (For adjustment of reverse clutch end play)
1.6 None 2.3 Blue
1.7 Blue 2.4 Brown
1.8 Brown 2.5 None
1.9 None 2.6 Blue
2.0 Blue 2.7 Brown
2.1 Brown 2.8 None
2.2 None
SEALANTS
23B-7
Pressure plate (For adjustment low/reverse brake end play)
1.6 F 2.4 B
1.8 E 2.6 A
2.0 D 2.8 0
2.2 C 3.0 1
SEALANTS
M1233000501114

Extension housing Mitsubishi Part No.MZ100389 or equivalent
Converter housing
Oil pan
Sealing cap 3M™ ATD Part No.8672 or equivalent
FORM-IN-PLACE GASKET (FIPG) Disassembly
This transaxle has several areas where the form-in- Parts sealed with a FIPG can be easily removed
place gasket (FIPG) is used for sealing. To ensure without need for the use of a special method. In
that the FIPG fully serves its purpose, it is necessary some cases, however, the FIPG in joints may have to
to observe some precautions when applying it. Bead be broken by tapping parts with a mallet or similar
size, continuity and location are of paramount impor- tool.
tance.
Too thin a bead could cause leaks. Too thick a bead, Surface Preparation
on the other hand, could be squeezed out of location, Thoroughly remove all substances deposited on the
causing blocking or narrowing of fluid passages. To FIPG application surface, using a gasket scraper.
prevent leaks or blocking of passages, therefore, it is Make sure that the FIPG application surfaces is flat
absolutely necessary to apply the FIPG evenly with- and smooth. Also make sure that the surface is free
out a break, while observing the correct bead size. from oils, greases and foreign substances. Do not fail
FIPG hardens as it reacts with the moisture in the to remove old FIPG that may remain in the fastener
atmospheric air, and it is usually used for sealing fitting holes.
metallic flange areas.
FIPG Application
CAUTION Applied FIPG bead should be of the specified size
When re-applying liquid gasket (FIPG), be sure and free of any break. FIPG can be wiped away
that: unless it has completely hardened. Install the mating
1. Residues of FIPG are cleared from all the ins parts in position while the FIPG is still wet. Do not
and outs of parts; allow FIPG to spread beyond the sealing areas dur-
2. Use Mitsubishi genuine parts cleaner ing installation. Avoid operating the transaxle or let-
(MZ100387) or equivalent to well degrease the ting oils or water come in contact with the sealed
FIPG-applied surface. area before a time sufficient for FIPG to harden
3. FIPG is correctly applied in accordance with (approximately one hour) has passed.
FIPG Application. FIPG application method may vary from location to
LUBRICANT(S)
LUBRICANT(S)
M1233000400415

Transmission oil DiaQueen ATF SP III As required
Oil seal Mitsubishi Part No.0101011 or equivalent As required
SPECIAL TOOLS
M1233000600743

MB990938 Handle Use with installer adapter
MD998727 Oil pan FIPG cutter Removal of oil pan
D998727
MD998333 Oil pump remover Removal of oil pump
MB991603 Bearing installer stopper Measurement of output

shaft and center support
end plays
MD998029 Oil seal installer Measurement of output

shaft end play
SPECIAL TOOLS
23B-9
MB991632 Clearance dummy plate Measurement of brake
reaction plate, second
brake and low/reverse
brake end plays
MD998913 Dial gauge extension Measurement of brake

brake end plays
MD998412 Guide Installation of oil pump
MD998316 Dial gauge support Measurement of input

shaft end play
MD998924 Spring compressor Use with spring

retainer compressor
MD999590 Spring compressor Removal and installation

of reverse and overdrive
clutch spring retainer
snap ring
MB991629 Spring compressor Measurement of

overdrive clutch and
underdrive clutch end
plays

MB991789 Spring compressor Adjustment reverse clutch
end plays
MB991630 Spring compressor Removal and installation

of center support snap
ring

of underdrive clutch
spring retainer snap ring

DISASSEMBLY AND ASSEMBLY
M1233126900019
8
48 ± 6 N·m
7
10
48 ± 6 N·m
1 6
2
5
4
3
44 ± 8 N·m 11 ± 1 N·m
26 ± 5 N·m
AK800428 AB
23B-11
Disassembly steps CAUTION
1. Oil level gauge • Completely degrease the FIPG-applied sur-
2. Oil filler tube face so that water and oil including the old
3. Harness clamp bracket sealant cannot adhere to the surface coated
4. Air breather hose bracket
with the sealant. Never touch the degreased
5. Clip
6. Cable end bracket
surface by hand.
7. Harness bracket • Make sure the starting point and the ending
8. Harness bracket point are about the middle between the bolts.
>>A<< 9. Extension housing
10. Transmission
REASSEMBLY SERVICE POINTS Ø1.6 mm

diameter
>>A<< EXTENSION HOUSING INSTALLATION
1. Apply vaseline or blue petrolatum jelly on the
bushing inside the extension housing.
AKX00006 AD
2. After squeezing out and applying the sealant on

the extension housing at the section indicated in
the illustration, install onto the transmission case.
Specified sealant:
Mitsubishi Part No.MZ100389 or equivalent
EXTENSION HOUSING
EXTENSION HOUSING
M1233007600120
2 8
1
5
4
AK602526AB
Disassembly steps • Installer adapter (MB990929)

1. Parking sprag shaft • Handle (MB990938)
>>C<< 2. Parking sprag spring
3. Parking sprag >>B<< SEALING CAP INSTALLATION
>>B<< 4. Sealing cap
5. Parking roller support shaft CAUTION
6. Parking roller support • Completely degrease the FIPG-applied sur-
7. Dust seal guard face so that water and oil including the old
>>A<< 8. Oil seal sealant cannot adhere to the surface coated
9. Extension housing with the sealant. Never touch the degreased
surface by hand.
REASSEMBLY SERVICE POINTS • Make sure the starting point and the ending
>>A<< OIL SEAL INSTALLATION point are about the middle between the bolts.
MB990938
Sealing cap
MB990929
1.5 mm 1.5 mm
A K 6 0 2 5 3 1AB A K 6 0 2 5 3 2AB
1. Set special tools as shown in the illustration.

EXTENSION HOUSING
23B-13
1. Press into the dimensions shown in the illustration >>C<< PARKING SPRAG SPRING INSTALLATION
so that it is not slanted.
2. Apply the sealant as shown in the illustration.
Specified sealant:
3M™ ATD Part No.8672 or equivalent
A K 6 0 2 5 3 3A B
Attach the end of the spring to the position shown in

the illustration.
TRANSMISSION
TRANSMISSION
M1233101200013
6
11 ± 1 N·m
3 7
1 5
11 ± 1 N·m
4
2 21.5 ± 3.5 N·m
16
11 ± 1 N·m
14 15
11 ± 1 N·m 13
11 ± 1 N·m
11 ± 1 N·m
11 12
6.0 ± 1.0 N·m
6.0 ± 1.0 N·m 10
8
11 ± 1 N·m
9 AK800429AB
1. Torque converter 8. Oil pan

2. Input shaft speed sensor 9. Magnet
3. Output shaft speed sensor 10. Oil filter
4. Manual control lever 11. O-ring
5. Inhibitor switch 12. Detent spring
6. Snap ring 13. Valve body
7. Parking gear 14. O-ring
TRANSMISSION
23B-15
15. Snap ring
16. Solenoid valve harness
Apply automatic
transmission fluid
to all moving parts
38
37
28 32 34
35
31
25 27 33
30
22 24 26
29 36
21 23 20 20
20 20
18
17
19
AK503511AD
17. Oil seal 28. Outer spring

18. Oil seal 29. Accumulator piston (for underdrive clutch)
19. Oil strainer 30. Inner spring
20. Seal ring 31. Outer spring
21. Accumulator piston (for overdrive clutch) 32. Spring pin
22. Accumulator spring 33. Pin
23. Accumulator piston (for second brake) 34. Manual control shaft
24. Inner spring 35. O-ring
25. Outer spring 36. O-ring
26. Accumulator piston (for low/reverse brake) 37. Detent lever
27. Inner spring 38. Parking roller rod
TRANSMISSION
41
40
23 ± 3 N·m
39
48 ± 6 N·m
46 51
50
44 49
47 48
Apply automatic
transmission fluid
45 to all moving parts
43 AK503512 AE
39. Converter housing 46. Overdrive clutch hub

40. Oil pump 47. Thrust bearing No.4
41. Oil pump gasket 48. Reverse sun gear
42. Thrust race No.1 49. Snap ring
43. Thrust bearing No.2 50. Second brake
44. Reverse and overdrive clutch 51. Return spring
45. Thrust bearing No.3
TRANSMISSION
23B-17
54 58
56 57
52
55
53 62
60
63
59
Apply automatic
transmission fluid
to all moving parts
61
AKX00019 AG
52. Pressure plate 58. Reaction plate

53. Brake plate 59. Snap ring
54. Brake disc 60. Brake plate
55. Low/reverse annulus gear 61. Brake disc
56. Thrust bearing No.7 62. Pressure plate
57. Snap ring 63. Wave spring
TRANSMISSION
70
68
66 80
23 ± 3 N·m
65
64
71
69
67
79
77
74
81
76
73
78
Apply automatic
transmission fluid
to all moving parts
75
72 AK800433 AB
64. Snap ring 73. Thrust bearing No.12

65. Center support 74. Output shaft
66. Thrust race No.8 75. Seal ring
67. Thrust bearing No.9 76. Seal ring
68. Output flange 77. Thrust bearing No.13
69. Thrust bearing No.10 78. Bearing retainer
70. Underdrive clutch hub 79. Output shaft support
71. Thrust bearing No.11 80. Output shaft support gasket
72. Underdrive clutch 81. Transmission case
TRANSMISSION
23B-19
DISASSEMBLY
CAUTION
• The automatic transmission includes many
high-precision parts. Handle these parts
extremely carefully not to scratch or damage
them during disassembly and reassembly.
• Work bench should be covered with a rubber
mat and keep it clean at all times.
• Do not wear any cloth gloves and do not use
AK403342
any rags during disassembly. Use only nylon
cloth or paper towels if necessary. 3. Remove the output shaft speed sensor.
• All removed parts must be washed clean.
Metal parts may be washed in an ordinary sol- Manual control lever
vent, but they should be dried completely
using compressed air.
• Clutch discs, plastic thrust plates and rubber
parts should be washed in automatic trans-
mission fluid (ATF) and keep them free of dirt
after washing.
• If the transmission has been found damaged
and repaired, also disassemble and clean the Inhibitor switch AK403343AB
ATF cooler system.
4. Remove the manual control lever, and then
remove the inhibitor switch.
Snap ring
AK603561
1. Remove the torque converter. Parking gear AK800430AB
5. Remove the snap ring, and remove the parking

gear using a puller (corresponding load
approximately 9,800 N).
AK403341
2. Remove the input shaft speed sensor.

CAUTION
Carefully hammer the special tool so that the oil
pan mounting surface is not damaged.
TRANSMISSION
9. Disconnect the valve body harness connectors.
Oil temperature sensor

MD998727
AK403345AB
AK701362AB
6. Remove the twenty oil pan mounting bolts and
then use the special tool Oil pan FIPG cutter
O-ring
(MD998727) to remove the oil pan.
Oil filter O-ring
AK403349AB
10.Remove the twenty valve body mounting bolts

AK403346AB
and then remove the valve body, O-ring and oil
7. Remove the oil filter and O-ring. temperature sensor.
NOTE: .
• The twenty valve body mounting bolts are
plated bolts.
• The O-ring is mounted on the transmission
case side as shown in the illustration. How-
ever there may be cases when it will come off
with the valve body.
Snap ring
AK403347
8. Remove the detent spring.
AK403350AB
11.Remove the snap ring and disconnect the

solenoid valve harness.
AK700990AB
TRANSMISSION
23B-21
Oil seals
Detent lever
Pin
Manual control
shaft
Parking roller
Oil strainer
AK403351AB rod AK403353AB
12.Remove the oil strainer and two oil seals. 15.Remove the pin, and then remove the manual
control shaft, two O-rings, detent lever and
parking roller rod.
4 3 2 1
AK403352AB
13.Remover each accumulator piston, seal ring and AK503505AB

spring.
No. Name 16.Remove the eight converter housing mounting
bolts, and then the converter housing.
1 For overdrive clutch
2 For second brake
3 For low/reverse brake
4 For underdrive clutch
NOTE: To make assembly easier, attach an iden-
tification tag on the removed accumulator piston.
AK403355AB
Spring pin
17.Remove the ten oil pump mounting bolts.
18.Install special tool Oil pump remover (MD998333)
into the bolt hole shown in the illustration.
AK403378AB
14.Remove the detent lever spring pin.
MD998333
AK403356AB
TRANSMISSION
19.While screwing in special tools Oil pump remover

(MD998333) evenly, remove the oil pump.
20.Remove the oil pump gasket.
Trust race No.1
Trust bearing No.2
Thrust bearing No.4

AK403360AD
24.Remove the thrust bearing No.4.

NOTE: The thrust bearing No.4 may be attached
AK403357AD
to the overdrive clutch hub.
21.Remove the thrust race No.1 and thrust bearing
No.2.
NOTE: The thrust race No.1 may be attached to
the oil pump.
AK403361
25.Remove the reverse sun gear.
AK403358
22.Remove the reverse overdrive clutch.

Thrust bearing No.3
AK403362
Overdrive
clutch hub
Second brake
AK403359AD
23.Remove the overdrive clutch hub and thrust Return spring

bearing No.3.
AK403363AB
27.Remove the second brake and return spring.

TRANSMISSION
23B-23
Reaction plate
AK403364 Brake disc

AK403368AB
28.Remove the low/reverse annulus gear.
32.Remove the reaction plate and one brake disc.
AK403365
AK403369
29.Remove the pressure plate, brake plates and
brake discs. 33.Remove the snap ring.
Thrust bearing No.7
AK403366AD AK403370
30.Remove the thrust bearing No.7. 34.Remove the brake plates, brake discs, and
NOTE: The thrust bearing No.7 may be attached pressure plate.
to the low/reverse annulus gear.
AK403371
AK403367
35.Remove the wave spring.
TRANSMISSION
Snap ring
to the underdrive clutch hub.
Center support AK403372AB
Thrust bearing No.12

36.Remove the snap ring and center support. AK403376AC
Thrust bearing No.9 Output flange

to the underdrive clutch.
Thrust race No.8 AK403373AD
37.Remove the thrust race No.8, thrust bearing No.9

and output flange.
NOTE: The thrust race No.8 may be attached to AK403377
the center support.
41.Remove the output shaft.
Underdrive
clutch hub
Seal ring (small)
Thrust bearing No.10 AK403374AD

Seal ring (large) AK403425AB
38.Remove the thrust bearing No.10 and underdrive
clutch hub. 42.Remove the two large and two small seal rings
from the output shaft.
Thrust bearing
No.13
Thrust
Bearing
bearing
retainer
No.11
Underdrive clutch AK403375AD
AK403380AD
clutch.
TRANSMISSION
23B-25
43.Remove the thrust bearing No.13 and bearing 1. Install a new gasket and output shaft support.
retainer. 2. Tighten the eight output shaft support mounting
NOTE: The thrust bearing No.13 may be attached bolts to the specified torque of 23 ± 3 N⋅m.
to the output shaft support.
CAUTION
Bearing retainer
Output shaft
support AK403379AB
AKX00062 AG
44.Remove the eight output shaft support mounting
bolts, and then remove the output shaft support Make sure the thrust bearing is mounted in the
and gasket. correct direction.
Thrust bearing
REASSEMBLY No.13
CAUTION
• Never reuse any gasket, O-ring, and oil seal. Bearing
retainer
Always replace them with new ones.
• Never use any product other than blue petro-
latum jelly or white vaseline to lubricate or
hold parts during assembly.
• Apply ATF to friction elements, rotating parts,
AK403380AD
and sliding parts before installation.Soak new
clutch discs or brake discs in ATF for at least 3. Install the bearing retainer and thrust bearing
two hours before installing them. No.13 onto the output shaft.
• Never apply sealant or adhesive to gaskets.
• When a bushing requires replacement,
replace the assembly of which the bushing
forms a part.
• Never use any cloth gloves or any rags during
reassembly. Use only nylon cloth or paper
towels if necessary.
• Change also the ATF in the cooler circuit.
CAUTION
Never reuse a gasket.
Output shaft
support AK403379AB
TRANSMISSION
Identification of thrust bearing and thrust race
No.1 No.2 No.3 No.4 No.5 No.6 No.7 No.8 No.9 No.10 No.11 No.12 No.13
AKX00061AE
Symbol O.D. mm I.D. mm Thickness Symbol O.D. mm I.D. mm Thickness

mm mm
No.1 48.9 37 1.4 No.6 57 38.5 4.12
1.6 No.7 70 48.8 4.0
1.8 No.8 73 60 1.6
2.0 1.8
2.2 2.0
2.4 2.2
2.6 No.9 71.45 57 2.81
No.2 59 37 2.8 No.10 72 48.25 4.6
No.3 57 38.5 4.12 No.11 53 34.7 4.01
No.4 57 38.5 4.12 No.12 57 38.5 4.12
No.5 55.4 38.5 3.31 No.13 58 37.5 4.8
Seal ring (small)

TRANSMISSION
23B-27
4. Install new seal rings (two large pieces and two
small pieces) onto the output shaft.
AK403443
7. Install the underdrive clutch.

AK403377
5. Install the output shaft into the output shaft CAUTION

support.
CAUTION Thrust bearing No.11

Underdrive clutch
retainer
AKX00066AE
Output shaft Make sure thrust bearing No.11 is mounted in the

correct direction.
AKX00063AG
Make sure thrust bearing No.12 is mounted in the

correct direction.

AK403444AC
8. Apply vaseline or petroleum jelly on the thrust

bearing No.11, and then install on the front end of
AK403376AC
the underdrive clutch retainer.
the output shaft.
AK403445
9. Install the underdrive clutch hub.

TRANSMISSION
CAUTION CAUTION
Thrust beaing No.10 Thrust bearing No.9
Output flange
Underdrive clutch
hub
AKX00069AE AKX00072 AG
Make sure thrust bearing No.10 is mounted in the Make sure thrust bearing No.9 is mounted in the
correct direction. correct direction.
Thrust bearing No.10 AK403446AC Thrust bearing No.9 AK403448AC
10.Apply vaseline or petroleum jelly on the thrust 12.Apply vaseline or petroleum jelly on the thrust
bearing No.10, and then install it on the bearing No.9, and then install on the output
underdrive clutch hub. flange.
CAUTION
Measure and record the thickness of the thrust
race No.8 to be assembled.
Thrust race No.8
AK403447
11.Install the output flange.
AK403449AD
13.Apply vaseline or blue petroleum jelly on the

thrust race No.8 being used, and then install it on
the rear side of the center support.
TRANSMISSION
23B-29
CAUTION (1) Fix a dial gauge to special tool Bearing
• Install the center support so that the oil holes installer stopper (MB991603).
shown in the illustration face the lower side of
the transmission case.
• Make sure that the thrust race No.8 attached
to the rear side of the center support does not MD998029
fall off.
Output shaft flange
AK403451 AB
(2) Push the output shaft, and the output flange in

alternately, and then measure the end play of
output shaft.
NOTE: .
AK403426 AB
• When pushing the output shaft in, take care
14.Install the center support. that the center support does not move.
• When pushing the output flange in, use the
special tool Oil seal installer (MD998029).
MB991603
Thrust beaing No.9
AK800431AB
Thrust race No.8 End play
15.Remove the two output shaft support mounting AKX00078AD
bolts. (3) Reinstall by selecting the thrust race No.8

16.Using the two removed bolts, install special tool installed by the procedure (13) so that the end
Bearing installer stopper (MB991603) to the play of output shaft becomes the standard
specified torque of 23 ± 3 N⋅m. value.
17.Select the thrust race No.8 with the following NOTE: Refer to the thickness recorded in step
procedure: 13.
MB991603 (For output shaft end play)
(4) Measure the end play again, and confirm that
it is within the standard value.
NOTE: Carry this step out with special tool
Bearing installer stopper (MB991603) and dial
gauge installed.
18.Using the following steps, select the snap ring for
Output shaft fixing the center support.
AK800432AB
TRANSMISSION
(3) Select the snap ring for fixing the center

support installed in step 18 (1) so that the end
play of the center support is at the standard
value. Then, reassemble.
(For center support end play)
AK403369
(1) Install the snap ring used for fixing the center
support used.
MB991603
AK403371

adjusting the brake reaction plate end play and
Output shaft second brake end play, and the pressure plate for
AK800432AB
adjusting the low/reverse brake end play.
(1) Install the wave spring onto the low/reverse
Center support brake piston.
MB991632 Snap ring
AK403453AB
(2) After pushing the output shaft, and the center

support in alternately, and then measure the AKX00082 AC
end play of center support. (2) Install special tool Clearance dummy plate
NOTE: When pushing the output shaft in, be (MB991632) onto the position shown in the
sure to push them in to the point where the illustration instead of the pressure plate for the
center support touches the snap ring. low/reverse brake. Install the six brake disc,
five brake plate and snap ring.
Standard value
Center support
Snap ring
Low/Reverse
brake piston AKX00081AC
TRANSMISSION
23B-31
CAUTION CAUTION
Pay close attention to the assembly direction of Pay close attention to the shape and assembly
the reaction plate. direction of the brake plate A installation.
Second brake Snap ring

MD998913 Snap ring
Return
spring
A
End play MB991632
MB991632
AKX00083 AC AKX00084 AD
(3) Install the reaction plate and snap ring that (7) Next, install special tool Clearance dummy
was used. plate (MB991632) instead of the pressure
(4) Install a dial gauge onto special tool Dial plate for the second brake. Install the four
gauge extension (MD998913) so that the end brake discs and three brake plates.
contacts the brake reaction plate. Measure the (8) Install the return spring, second brake and
end play by moving special tool Clearance snap ring.
dummy plate (MB991632).
(5) Select the snap ring installed in step 19 (3) so
MD998913
that the end play is within the standard value.
Then, reassemble. Moving
amount
(For brake reaction plate end play) MB991632

AKX00085 AC
(9) Install a dial gauge onto special tool Dial

gauge extension (MD998913) so the end
contacts the special tool. Move special tool
Clearance dummy plate (MB991632) and
measure the moving amount. Select a
pressure plate with a thickness that
corresponds to the measured moving amount
from the following table.
Standard value (reference): 1.49 − 1.95 mm
(For second brake end play)
Moving amount mm Pressure plate Moving amount mm Pressure plate

Thickness identifica Thickness identifica
mm tion mm tion
symbol symbol
1.2 or more − less than 1.4 1.6 F 2.2 or more − less than 2.4 2.6 A
1.4 or more − less than 1.6 1.8 E 2.4 or more − less than 2.6 2.8 0
1.6 or more − less than 1.8 2.0 D 2.6 or more − less than 2.8 3.0 1
1.8 or more − less than 2.0 2.2 C (10)Remove the snap ring, second brake, return
spring and special tool Clearance dummy
2.0 or more − less than 2.2 2.4 B plate (MB991632) installed in step (8).
TRANSMISSION
(11)Install the pressure plate selected in step (9), (12)Install a dial gauge onto special tool Dial
and install the return spring, second brake and gauge extension (MD998913) so the end
snap ring again. contacts the special tool. Move special tool
MD998913 measure the moving amount. Select a
(For low/reverse brake end play)
A
MB991632
AKX00086AC
PRESSURE PLATE FOR LOW/REVERSE BRAKE

MOVING Pressure plate CAUTION
AMOUNT mm Thickness mm Identification
symbol
Thrust bearing No.7
1.3 or more − 1.6 F
less than 1.5
1.5 or more − 1.8 E
less than 1.7
1.7 or more − 2.0 D
less than 1.9
1.9 or more − 2.2 C AKX00087AD
less than 2.1 Make sure thrust bearing No.7 is mounted in the
2.1 or more − 2.4 B correct direction.
less than 2.3
2.3 or more − 2.6 A
less than 2.5
2.5 or more − 2.8 0
less than 2.7
2.7 or more − 3.0 1
less than 2.9
Thrust bearing No.7
(13)Remove the parts installed in steps 19 (1) to
(12). AK403366AD
20.Apply vaseline or petroleum jelly on the thrust

bearing No.7, and then install on the rear side of
the low/reverse annulus gear.
TRANSMISSION
23B-33
CAUTION 24.Install the pressure plate, six brake disc and five
Make sure that thrust bearing No.7 attached to brake plate selected in step 19 (12).
the rear side of the low/reverse annulus gear
does not fall off.
AK403396
25.Install the snap ring.

AK403364
21.Install the low/reverse annulus gear. CAUTION

Make sure the reaction plate in the proper direc-
tion.
AK403361
22.Install the reverse sun gear.

AK403397
26.Install the reaction plate.
AK403394
23.Install the wave spring to the low/reverse brake

AK403398
piston.
27.Install the snap ring selected in step 19 (5).
AK403395
TRANSMISSION
CAUTION 29.Install the return spring and second brake.

Make sure the brake plate (reaction plate side) is
installed in the proper direction.
Pressure plate
Brake plate
Reaction
plate
AK403362

AK403399AB
28.Install the brake disc, brake plate and pressure CAUTION

plate selected in step 19 (9).
CAUTION
Thrust
bearing No.4
AKX00099 AD
End coil Make sure thrust bearing No.4 is installed in the

proper direction.
AKX00096 AC
Install the return spring end coil side so that it

faces the back of the transmission. (Only for one
side end coil type)
Second brake
Return spring
Thrust bearing No.4
AK403360AD

bearing No.4, and then install on the reverse sun
AK403400AB
gear.
TRANSMISSION
23B-35
CAUTION CAUTION
Thrust
bearing No.3
Thrust bearing No.2

AKX00101AE AKX00103AD
Thrust bearing No.3
Overdrive
clutch hub
AK403359AD AK403404
32.Apply vaseline or petroleum jelly on the thrust 34.Install the reverse and overdrive clutch.
bearing No.3, and then install on the overdrive Thrust bearing No.2
clutch hub.
33.Install the overdrive clutch hub.
AK403405AD

bearing No.2, and then install on the reverse and
overdrive clutch.
Thrust race No.1
AK403566AD

race No.1 being used, and then install on the oil
pump.
TRANSMISSION
CAUTION
CAUTION • Completely degrease the FIPG-applied sur-
Never reuse a gasket. face so that water and oil including the old
sealant cannot adhere to the surface coated
MD998412
surface by hand.
• Evenly squeeze out the sealant so that it is
not insufficient or excessive.
L1
AK403406AB
37.Install special tools Guide (MD998412) at the

position shown in the illustration, and using this as L2
a guide, install the oil pump and gasket.
38.Tighten the ten oil pump mounting bolts to the AK900786AB
41.Apply the sealant on the converter housing
mounting surface of the transmission case in the
MD998316 following way.
Specified sealant:
L1 φ1.6 mm
L2 φ2.6 mm
AK403407AB
39.Use the special tool Dial gauge support

(MD998316), set a dial gauge as shown in the
illustration. Measure the end play of the input
shaft, and select the thrust race installed in step
36 so that the end play is at the standard value.
Then, reassemble.
Standard value: 0.25 − 0.81 mm AK503505AB
(For input shaft end play)
42.Install the converter housing.
40.Measure the end play again, and confirm that it is
within the standard value. 43.Tighten the eight converter housing mounting
bolts to the specified torque of 48 ± 6 N⋅m.
Parking
roller rod
Detent
lever
AK403455AB
44.Install the parking roller rod to the detent lever.

TRANSMISSION
23B-37
Outer spring
4 3 2 1
Inner spring
O-ring
AK403408AB AKA00051AB
45.Install two new O-rings to the manual control

shaft, and assemble onto the transmission case
together with the detent lever and parking roller
rod.
Pin
4 3 2 1
AK403352AB
48.Install a new seal ring onto each accumulator

piston.
49.Install each accumulator piston and spring.
AK403409AB
NOTE: .
46.Install the pin. • Identification colors are applied on the spring
as shown below. Assemble following this
table.
• Install the accumulator pistons to the original
Spring pin positions following the identification tags
Manual control
shaft attached when removed.
N Name Identification paint
o. application position
1 For overdrive None
clutch
AK403410AB
2 For second Inner Applied on all surfaces
47.Hammer in so that the slit section of the spring brake including both ends
valve is perpendicular to the axial direction of the Outer Applied on half of
manual control shaft. surface including both
ends
TRANSMISSION

O-ring
3 For low/ Inner Applied on half of
reverse brake surface including both
ends
Outer Applied on entire
surface of one side
4 For Inner Applied on half of
underdrive surface including both AK403349AB
clutch ends
Outer Applied on half of 52.Install the new O-ring into the transmission case
surface including both at the position shown in the illustration.
ends
CAUTION
Pay close attention to the installation direction of
the oil seal.
Detent lever
Oil seals
Control shaft
AK503726AD
53.Install the valve body while inserting the manual

valve pin into the detent lever groove.
Oil strainer
AK403351AB
50.Install the oil strainer and two new oil seals. Install
the oil seals so that the notched section is
oriented as shown in the illustration.
Snap ring
AK602028AC
54.Install the oil temperature sensor.
AK403350AB
51.Install the solenoid valve harness, and then

secure the snap ring into connector groove.
NOTE: Install the harness so that it is oriented as
AK701362AB
55.Tighten the twenty valve body mounting bolts to

the specified torque of 11 ± 1 N⋅m.
TRANSMISSION
23B-39
Bolt Length mm 59.Install the oil filter and a new O-ring.
A 25 60.Tighten the oil filter mounting bolts to the specified
torque of 6.0 ± 1.0 N⋅m.
B 30
2.5 mm diameter
C 40
D 45
E 55
Magnet
AK403416AE
61.Install the magnet.

CAUTION
• Completely degrease the FIPG-applied sur-
AK700990AB face so that water and oil including the old
56.Connect the connector to the valve body. sealant cannot adhere to the surface coated
surface by hand.
• Make sure the starting point and the ending
point are about the middle between the bolts.
62.Apply the sealant or equivalent on the oil pan.
Specified sealant:
AK403347
57.Install the detent spring.

58.Tighten the detent spring mounting bolt to the
specified torque of 6.0 ± 1.0 N⋅m.
Oil filter O-ring
AK403456
63.Install the oil pan.

64.Tighten the oil pan mounting bolts to the specified
torque of 11 ± 1 N⋅m.
AK403346AB
TRANSMISSION
CAUTION 67.Install the manual control lever.

68.Tighten the manual control lever mounting bolts to
the specified torque 21.5 ± 3.5 N⋅m.
Identification
symbol A
Transmission
side
AK403457AB
• Install the parking gear so that the side with-

out the spline cut faces the transmission side. AK403342
• Heat the parking gear to 160 − 180 °C and 69.Install the output shaft speed sensor.
shrink fit up to the stepped section of the out-
70.Tighten the output shaft speed sensor mounting
put shaft. Do not heat for longer than neces-
bolt to the specified torque 11 ± 1 N⋅m.
sary at this time.
Snap ring
AK403341
Parking gear AK800430AB
71.Install the input shaft speed sensor.
65.Install the parking gear and snap ring.
72.Tighten the input shaft speed sensor mounting
bolt to the specified torque 11 ± 1 N⋅m.
CAUTION
Apply ATF to the oil pump drive hub before
installing the torque converter. Be careful not to
damage the oil seal lip when installing the torque
converter.
Inhibitor switch
AK601368AC
66.Install the inhibitor switch, and fix the fastening

bolts temporarily. A
Manual control lever
AK503859AB
73.Install the torque converter, and secure it so that

the dimension (A) indicated in the illustration
meets the reference value.
Inhibitor switch AK403343AB
Reference value: 20.9 mm
REVERSE AND OVERDRIVE CLUTCH
23B-41
M1233021200483
Apply automatic 14
transmission fluid
to all moving parts
19
21 12
22 13
2
15
1 16 6
18
20 8
3 9
4
10 5
7
17 14 10 8
22
21
20 15 6
2
1 12
18
16 13 3
11
19 11 9 7 5 4
AK700992 AB

1. Seal ring <<A>> >>D<< 12. Snap ring
2. Snap ring 13. Spring retainer
3. Input shaft >>A<< 14. D-ring
>>H<< 4. Snap ring >>C<< 15. Return spring
>>G<< 5. Reaction plate 16. Overdrive clutch piston
>>G<< 6. Clutch disc >>A<< 17. D-ring
>>G<< 7. Clutch plate >>B<< 18. Reverse clutch piston
>>F<< 8. Snap ring >>A<< 19. D-ring
>>E<< 9. Reaction plate >>A<< 20. D-ring
>>E<< 10. Clutch disc >>A<< 21. D-ring
>>E<< 11. Clutch plate 22. Reverse clutch retainer
DISASSEMBLY SERVICE POINT >>C<< RETURN SPRING INSTALLATION

<<A>> SNAP RING REMOVAL
MD998924
MD999590
AK700994AB
Snap ring
AK403382AB Align the two return spring holes with the two projec-
tions on the overdrive clutch piston, and then assem-
1. Set special tools as shown in the illustration. ble.
• Spring compressor (MD999590)
• Spring compressor retainer (MD998924)
2. Compress the return spring, and remove the snap
ring. MD999590
MD998924

>>A<< D-RING INSTALLATION
1. Apply ATF to the D-ring.
2. Install the D-ring in the reverse clutch retainer,
piston, overdrive clutch piston and spring retainer
grooves. Make sure that the D-ring is not twisted Snap ring
or damaged when installing. AK403382AB
>>B<< REVERSE CLUTCH PISTON 1. Set special tools as shown in the illustration.
INSTALLATION • Spring compressor (MD999590)
2. Tighten the special tool nut, and press the spring
retainer against the reverse clutch retainer.
A 3. Install the thickest snap ring that can be fitted in
the snap ring groove of reverse clutch retainer.
AK705065AB
Align the reverse clutch piston and reverse clutch

retainer holes (A and B), and then assemble.
AK403386
4. Check the clearance between the snap ring and

spring retainer. If the clearance is not within the
standard value range, make adjustment by
selecting a snap ring of an appropriate thickness.
(For overdrive clutch return spring retainer
end play)
23B-43
>>E<< CLUTCH PLATE / CLUTCH DISC / (For overdrive clutch end play)
REACTION PLATE INSTALLATION
Clutch plates Rounded edge >>G<< CLUTCH PLATE / CLUTCH DISC /
Reaction REACTION PLATE INSTALLATION
plate CAUTION
R1
Soak the clutch discs in ATF before installing
stamp them.
B
A
Clutch discs
AKX00126 AE
1. Alternately assemble the clutch disc and clutch

plate in the reverse clutch piston.
2. Install the reaction plate so that it is oriented as
AKX00130 AC
>>F<< SNAP RING INSTALLATION 1. Alternately assemble the clutch plate and clutch
1. Install the snap ring in the reverse clutch piston disc in the reverse clutch retainer. Align and
groove. assemble both clutch plates (where there are no
MD998924 teeth) (A in the illustration) with the reverse clutch
retainer hole (B in the illustration).
Clutch plates Rounded edge Reaction plate
MB991629 R stamp
AK403634AB
2. Set special tools as shown in the illustration, and Clutch discs AKX00131 AC
compress the clutch element
• Spring compressor (MB991629) 2. Install the reaction plate so that it is oriented as
• Spring compressor retainer (MD998924) shown in the illustration. Assemble in the same
manner as the clutch plate so the section with no
teeth (A in the illustration) matches the retainer
hole (B in the illustration).
Snap ring >>H<< SNAP RING INSTALLATION

Standard value MD998924
Standard
value MB991789
Reaction plate
AKX00129 AC
3. Check the clearance (overdrive clutch end play) of

the snap ring and reaction plate is the standard
value. If the clearance is not at the standard
value, select the snap ring and adjust so that the
clearance is within the standard value. AKX00384AD

SECOND BRAKE
1. Install the snap ring in the reverse clutch retainer 3. Check that the clearance between the snap ring
groove. and the clutch reaction plate is within the standard
2. Set special tools as shown in the illustration, and valus.if not within the standard value, select a
compress the clutch element. snap ring to adjust.
• Spring compressor (MB991789) Standard value: 1.5 − 1.7 mm
• Spring compressor retainer (MD998924) (For reverse clutch end play)
SECOND BRAKE
M1233021800258
4
1
2
3
AKX00134 AB

1. Second brake retainer >>A<< D-RING INSTALLATION
2. Second brake piston
>>A<< 3. D-ring
>>A<< 4. D-ring 2. Install the D-ring in the grooves on the outer and
inner periphery of the piston. Make sure that the
D-ring is not twisted or damaged when installing.
LOW REVERSE ANNULUS GEAR
23B-45
M1233027100257
Apply automatic
transmission fluid
to all moving parts
7
8
4
9
2 3
1
10
5 6
AKX00135 AC
Disassembly steps Install the one-way clutch so that the arrow stamp is
1. Snap ring oriented as shown in the illustration.
>>D<< 3. Thrust bearing No.5 >>B<< STOPPER PLATE INSTALLATION
4. Underdrive sun gear
>>C<< 5. Thrust bearing No.6 Claw
>>B<< 7. Stopper plate
>>A<< 8. One-way clutch
9. Snap ring
10. Low/reverse annulus gear

>>A<< ONE-WAY CLUTCH INSTALLATION Groove
Stopper plate AK403388AB
Install the stopper plate onto the low/reverse annulus

gear. Make sure that the stopper plate claw is
securely engaged in the annulus gear groove.
Arrow
AK403387AB
CENTRE SUPPORT
>>C<< THRUST BEARING No.6 INSTALLATION >>D<< THRUST BEARING No.5 INSTALLATION
CAUTION CAUTION
Output planetary
Overdrive planetary
carrier side
carrier side
AKX00138 AC AKX00139 AC
Apply vaseline or petroleum jelly on the thrust bear- Apply vaseline or petroleum jelly on the thrust bear-
ing No.6, and then install onto the output planetary ing No.5, and then install on the overdrive planetary
carrier. carrier.
CENTRE SUPPORT
M1233010000184
Apply automatic
transmission fluid
to all moving parts
5
10
9
4
3 8
2
7
1
6
AKX00140 AC

<<A>> >>C<< 1. Snap ring 3. One-way clutch inner race
2. Plate >>B<< 4. O-ring
CENTRE SUPPORT
23B-47
Disassembly steps (Continued) >>B<< O-RING INSTALLATION
5. Spring retainer
6. Return spring
7. Low/reverse brake piston
>>A<< 8. D-ring
>>A<< 9. D-ring
10. Center support

O-ring
MD998924 MB991630 AK403390AB
Install the O-ring onto the center support at the posi-

tion shown in the illustration.
>>C<< SNAP RING INSTALLATION

MD998924 MB991630
Snap ring
AK403389AB
1. Set special tools as shown in the illustration so

that they are pressed against the inner race of the
one-way clutch.
• Spring compressor (MB991630)
Snap ring
AK403389AB
2. Screw in the special tool nut, and lightly press
against the inner race of the one-way clutch. 1. Set special tools as shown in the illustration.
3. Remove the snap ring. • Spring compressor (MB991630)
REASSEMBLY SERVICE POINTS 2. Screw in the special tool nut, and lightly press
against the inner race of the one-way clutch.
3. Install the snap ring.
2. Install the D-ring in the grooves on the outer and
UNDERDRIVE CLUTCH
UNDERDRIVE CLUTCH
M1233027300273
4
Apply automatic
transmission fluid
to all moving parts
2
1
11
12 13
10
9
8
5 7 1 3
6 7
10
11
12
9
6 13
2 4 AK700896AB
UNDERDRIVE CLUTCH
23B-49
Disassembly steps
>>E<< 1. Snap ring >>C<< SNAP RING INSTALLATION
>>D<< 2. Reaction plate
>>D<< 3. Clutch disc MD998924
MD998907
>>D<< 4. Clutch plate
<<A>> >>C<< 5. Snap ring
6. Spring retainer
>>A<< 7. D-ring
>>B<< 8. Return spring
9. Underdrive clutch piston
>>A<< 10. D-ring
>>A<< 11. D-ring
>>A<< 12. D-ring Snap ring
AK403391AB
13. Underdrive clutch retainer
Use the special tools to install the snap ring.
DISASSEMBLY SERVICE POINT • Spring compressor (MD998924)
<<A>> SNAP RING REMOVAL • Spring compressor retainer (MD998907)
MD998924 >>D<< CLUTCH PLATE / CLUTCH DISC /

MD998907
CAUTION
them.
B
A
Snap ring
AK403391AB
Use the special tools to remove the snap ring.


AKX00146AC
1. Apply ATF to the D-ring. 1. Alternately assemble the clutch plate and clutch
disc in the underdrive clutch retainer. Align and
2. Install the D-ring in the grooves of the underdrive assemble the four clutch plates (where there are
clutch retainer and spring retainer. Make sure that no teeth) (A in the illustration) with the underdrive
the D-ring is not twisted or damaged when clutch retainer hole (B in the illustration).
installing.
Rounded edge Clutch plates
>>B<< RETURN SPRING INSTALLATION
W
stamp
Reaction plate
Clutch discs AKX00147AC

AK602059
shown in the illustration. Assemble in the same
Align the two return spring holes with the two projec- manner as the clutch plate so that the section with
tions on the underdrive clutch piston, and then no teeth (A in the illustration) matches the retainer
assemble. hole (B in the illustration).
UNDERDRIVE CLUTCH

1. Install the snap ring in the groove of the Snap ring
underdrive clutch retainer.
Standard value
MD998924
Reaction plate
AKX00149 AC
3. Check the clearance (underdrive clutch end play)

between the snap ring and reaction plate is the
MB991629 standard value. If the clearance is not at the
AK403459AB
standard value, select the snap ring and adjust so
2. Set special tools as shown in the illustration, and that the clearance is within the standard value.
compress the clutch element. Standard value: 1.6 − 1.8 mm
• Spring compressor retainer (MD998924) (For underdrive clutch end play)
VALVE BODY
23B-51
VALVE BODY
M1233005500666
2 1
11 ± 1 N·m
2
11 ± 1 N·m
6
Apply automatic
transmission fluid 8
to all moving parts 7
5
3
9 4
6.0 ± 1.0 N·m
10
11
15
14
12
13 14
11 ± 1 N·m
2
16
15
AKX00150AC

>>G<< 1. Control shaft 9. Upper valve body gasket
2. Valve body attaching bolt 10. Separating plate
>>F<< 3. Damping valve 11. Lower valve body gasket
>>F<< 4. Seal ring >>E<< 12. Steel ball (line relief)
>>F<< 5. Damping valve spring >>E<< 13. Spring
>>F<< 6. Ball (orifice check ball) >>D<< 14. Knock bushing
>>F<< 7. Steel ball (orifice check ball) >>C<< 15. Knock bushing
>>F<< 8. Spring >>B<< 16. Dowel pin
VALVE BODY
19 17
20
21 18
38
6.0 ± 1.0 N·m
22 24
25
23
Apply automatic 30 27
transmission fluid 32 29
to all moving parts
33
35
37 26
36 31
34
AKX00151AC

17. Solenoid support 29. Fail-safe valve A spring
<<A>> >>A<< 18. Low reverse brake solenoid valve 30. Fail-safe valve A1
<<A>> >>A<< 19. Second brake solenoid valve 31. Stopper plate
<<A>> >>A<< 20. Underdrive clutch solenoid valve 32. Fail-safe valve B sleeve
<<A>> >>A<< 21. Overdrive clutch solenoid valve 33. Fail-safe valve B
<<A>> >>A<< 22. Damper clutch control solenoid 34. Stopper plate
valve 35. Stopper plug
23. Stopper plate 36. Torque converter pressure control
24. Stopper plug valve
25. Switching valve 37. Torque converter pressure control
26. Stopper plate valve spring
27. Fail-safe valve A sleeve 38. Upper valve body
28. Fail-safe valve A2
VALVE BODY
23B-53
40 42
45 43
44 46 41 39
48 47
52 51
49
53 50
54
55 60
67
59
63
to all moving parts
62
61
57
66
11 ± 1 N·m
65
11 ± 1 N·m
AKX00152AC

39. Manual valve 55. Overdrive clutch pressure control
40. Roller valve spring
41. Low/reverse brake pressure control 56. Stopper plate
valve sleeve 57. Regulator valve adjusting screw
42. Low/reverse brake pressure control 58. Regulator valve sleeve
valve 59. Regulator valve spring
43. Low/reverse brake pressure control 60. Regulator valve
valve spring 61. Roller
44. Roller 62. Damper clutch control valve sleeve
45. Second brake pressure control 63. Damper clutch control valve
valve sleeve 64. Damper clutch control valve spring
46. Second brake pressure control 65. Cover
valve 66. Cover gasket
47. Second brake pressure control 67. Lower valve body
valve spring
48. Roller DISASSEMBLY SERVICE POINT
49. Underdrive clutch pressure control <<A>> SOLENOID VALVE REMOVAL
valve sleeve Before removing the solenoid valves, make marks
50. Underdrive clutch pressure control
with white paint, etc., so that the these valves can be
valve
reinstalled in the original positions.
valve spring
52. Roller REASSEMBLY SERVICE POINTS
53. Overdrive clutch pressure control >>A<< SOLENOID VALVE INSTALLATION
valve sleeve 1. Apply ATF, vaseline or petroleum jelly to O-ring,
54. Overdrive clutch pressure control
and install it to solenoid valves.
valve
VALVE BODY
2. Following the marks made when removing, install Install the knock bushing onto the lower valve body
each solenoid valve in its proper position. position shown in the illustration.
>>B<< DOWEL PIN INSTALLATION >>D<< KNOCK BUSHING INSTALLATION
Dowel pin
6 mm
4.5 mm
AK403430AB AK403428AB
Install the dowel pin at the specified position on the Install the knock bushing onto the lower valve body
lower valve body. position shown in the illustration.
>>C<< KNOCK BUSHING INSTALLATION >>E<< SPRING / STEEL BALL (LINE RELIEF)
INSTALLATION
Steel ball
Spring
AK403429AB
Install the spring (7.0 mm diameter, 17.3 mm length)

and the steel ball (6.4 mm diameter) onto the lower
9 mm
valve body position shown in the illustration.
AK403427AB
VALVE BODY
23B-55
>>F<< SPRING / STEEL BALL (ORIFICE CHECK 1. Install the spring (4.5 mm diameter, 15.4 mm
BALL) / BALL (ORIFICE CHECK BALL) / length) and the steel ball (6.4 mm diameter) onto
DAMPING VALVE SPRING / SEAL RING / the upper valve body position shown in the
DAMPING VALVE INSTALLATION illustration.
Steel ball Seal ring 2. Install the ball (rubber) (6.4 mm diameter) onto the
upper valve body position shown in the
illustration.
3. After installing the seal ring onto the damping
valve, install together with the damping valve
Damping Damping spring (7.7 mm diameter, 35.8 mm length) onto
Spring valve spring the upper valve body position shown in the
illustration.
>>G<< CONTROL SHAFT INSTALLATION
Manual valve
Pin
Control shaft
Ball (Rubber) AK403393AB
AK403431AB
Insert the control shaft into the valve body, putting
the pin of the control shaft into the groove of the
manual valve.
23C-1
GROUP 23C
AUTOMATIC
TRANSMISSION
OVERHAUL <V4A5>
CONTENTS
GENERAL INFORMATION . . . . . . . . 23C-3 REVERSE AND OVERDRIVE CLUTCH

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23C-50
GENERAL SPECIFICATIONS . . . . . . 23C-7 REVERSE AND OVERDRIVE CLUTCH
DISASSEMBLY AND REASSEMBLY . . . . . 23C-50
SERVICE SPECIFICATIONS. . . . . . . 23C-7
SECOND BRAKE . . . . . . . . . . . . . . . . 23C-53
TORQUE SPECIFICATIONS . . . . . . . 23C-8 SECOND BRAKE DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23C-53
................................. 23C-9 LOW REVERSE ANNULUS GEAR . . 23C-54
AND REASSEMBLY . . . . . . . . . . . . . . . . . . 23C-54
ADJUSTMENT . . . . . . . . . . . . . . . . . . 23C-10 CENTRE SUPPORT . . . . . . . . . . . . . . 23C-55
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23C-55
SEALANTS . . . . . . . . . . . . . . . . . . . . 23C-12
UNDERDRIVE CLUTCH . . . . . . . . . . . 23C-57
LUBRICANT(S) . . . . . . . . . . . . . . . . . 23C-13
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23C-57
SPECIAL TOOLS. . . . . . . . . . . . . . . . 23C-14
VALVE BODY . . . . . . . . . . . . . . . . . . . 23C-60
TRANSMISSION AND TRANSFER. . 23C-19
TRANSMISSION AND TRANSFER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23C-60
AND REASSEMBLY . . . . . . . . . . . . . . . . . . 23C-19
TRANSFER . . . . . . . . . . . . . . . . . . . . . 23C-65
TRANSFER CASE ADAPTER. . . . . . 23C-21
TRANSFER CASE ADAPTER DISASSEMBLY AND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23C-65
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23C-21
ADJUSTMENT OF TRANSFER . . . . . . . . . 23C-77
TRANSFER INSPECTION . . . . . . . . . . . . . 23C-78
TRANSMISSION . . . . . . . . . . . . . . . . 23C-23
TRANSFER CASE PLATE . . . . . . . . . 23C-80
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23C-23
23C-2
TRANSFER CASE PLATE DISASSEMBLY AND CENTRE DIFFERENTIAL CASE . . . . 23C-87

REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23C-80 CENTRE DIFFERENTIAL CASE DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23C-87
INPUT GEAR . . . . . . . . . . . . . . . . . . . 23C-81
INPUT GEAR DISASSEMBLY AND REASSEMBLY REAR OUTPUT SHAFT . . . . . . . . . . . 23C-88
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23C-81
REAR OUTPUT SHAFT DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23C-88
COUNTERSHAFT GEAR. . . . . . . . . . 23C-83 REAR OUTPUT SHAFT INSPECTION . . . . 23C-92
COUNTERSHAFT GEAR DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23C-83 FRONT OUTPUT SHAFT . . . . . . . . . . 23C-92
FRONT OUTPUT SHAFT DISASSEMBLY AND
2-4WD SYNCHRONIZER. . . . . . . . . . 23C-85 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23C-92
2-4WD SYNCHRONIZER DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23C-85 SPEEDOMETER GEAR . . . . . . . . . . . 23C-94
2-4WD SYNCHRONIZER INSPECTION . . 23C-86
SPEEDOMETER GEAR DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23C-94
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
GENERAL INFORMATION
23C-3
GENERAL INFORMATION
M1233000101859
TRANSMISSION MODELS
V4A5A-J-LE 4D56 DI-D DOHC KB4T
V4A5A-J-LH 4D56 DI-D DOHC KB4T
SECTIONAL VIEW <TRANSMISSION>
70NT
68NT 17NT
21NT
38NT
25NT
AK605052
23C-4 AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
GENERAL INFORMATION
SECTIONAL VIEW <TRANSFER>

<Easy select 4WD>
AK603727
GENERAL INFORMATION
23C-5
<Super select 4WD>
AK403433
GENERAL INFORMATION
HYDRAULIC CIRCUIT
1 2 3 4 5
7 8
9 10
11
12 13 14 15
16 17 18 19 20
21
22 23
R ND
P
26
24 27
25
AK600223AB
1. Reverse clutch 15. Overdrive clutch pressure control valve

2. Low/reverse brake 16. Damper clutch control solenoid valve
3. Second brake 17. Low-reverse brake solenoid valve
4. Underdrive clutch 18. Second brake solenoid valve
5. Overdrive clutch 19. Underdrive clutch solenoid valve
6. Damper clutch 20. Overdrive clutch solenoid valve
7. Fail-safe valve A 21. Torque converter pressure control valve
8. Fail-safe valve B 22. Regulator valve
9. Damper clutch control valve 23. Manual valve
10. Switching valve 24. Oil filter
11. Cooler 25. Oil pan
12. Low-reverse brake pressure control valve 26. Oil pump
13. Second brake pressure control valve 27. Oil strainer
14. Underdrive clutch pressure control valve
23C-7
M1233000201373
Item Specifications
Transmission model V4A5A-J-LEEL V4A5A-J-LEEP
Lock-up Present
Transmission type Electronically controlled 4-speed full-automatic
2nd 1.495
3rd 1.000
4th 0.731
Reverse 2.720
Transfer type Easy select 4WD Super select 4WD
Transfer gear ratio High 1.000
Low 1.900
Speedometer gear ratio (driven/drive) 25/9
SERVICE SPECIFICATION(S)
M1233000301013
Transmission
Item Standard value
Output shaft end play mm 0.25 − 0.71
Transfer
Standard Limit
Item
value
Differential lock hub end play mm <Super select 4WD> 0 − 0.08 −
Rear output shaft bearing to rear cover clearance mm Easy select 4WD 0 − 0.1 −
Super select 4WD 0.025 − 0.150 −
Standard Limit
Item
value
Countershaft gear bearing end play mm 0 − 0.08 −
2-4WD synchronizer hub end play mm 0 − 0.08
Synchronizer ring clearance mm − 0.3
Rear output shaft bearing end play mm 0 − 0.08 −
M1233023101689
Transmission
Item N⋅m
Harness bracket mounting bolt 26 ± 5
Air breather hose bracket mounting bolt 11 ± 1
Transfer to transfer case adapter mounting bolt 35 ± 6
Transmission case to transfer case adapter mounting bolt 48 ± 6
Converter housing to transmission case mounting bolt 48 ± 6
Lower valve body cover mounting bolt 11 ± 1
Transfer
Item N⋅m
Rear bearing retainer mounting bolt <Super select 4WD> 20 ± 2
Oil pool cover mounting bolt <Super select 4WD> 9.0 ± 1.0
Transfer case − chain cover mounting bolt 35 ± 6
Rear cover − chain cover mounting bolt 35 ± 6
Drain plug 32 ± 2
23C-9
Item N⋅m
Filler plug 32 ± 2
Control housing to transfer case mounting bolt 19 ± 3
Transfer case plate − transfer case mounting bolt and nut 35 ± 6
Speedometer sleeve clamp mounting bolt 19 ± 3
Plug 34 ± 5
Vehicle speed sensor 25 ± 4
4LLc detection switch <Super select 4WD> 35 ± 6
Low detection switch <Easy select 4WD> 35 ± 6
High/low detection switch 34 ± 5
4WD operation detection switch 34 ± 5
Center differential lock detection switch <Super select 4WD> 35 ± 6
2WD/4WD detection switch <Super select 4WD> 35 ± 6
Center differential lock operation detection switch <Super select 4WD> 34 ± 5
Bearing retainer mounting bolt 19 ± 3
Center differential case mounting bolt <Super select 4WD> 69 ± 10
Rear output shaft lock nut <Easy select 4WD> 255 ± 10

M1233022900203

diameter diameter height loops
mm mm mm
Damping valve spring 1.0 7.7 35.8 17
Torque converter pressure control valve 1.6 11.2 29.4 9.5
spring
Fail-safe valve A spring 0.7 8.9 21.9 9.5
SNAP RING, SPACER, THRUST RACE AND PRESSURE PLATE FOR ADJUSTMENT
SNAP RING, SPACER, THRUST RACE AND PRESSURE

PLATE FOR ADJUSTMENT
M1233100500044
Transmission
Thrust race (For adjustment of output shaft end play)
1.6 None 2.0 None
1.8 None 2.2 None
1.6 Brown 2.4 Blue
1.7 None 2.5 Brown
1.8 Blue 2.6 None
1.9 Brown 2.7 Blue
2.0 None 2.8 Brown
2.1 Blue 2.9 None
2.2 Brown 3.0 Blue
2.3 None
1.4 None 2.2 None
1.6 None 2.4 None
1.8 None 2.6 None
2.0 None
1.48 Brown 1.58 None
1.53 Black 1.63 Brown
1.6 F 2.4 B
1.8 E 2.6 A
2.0 D 2.8 0
2.2 C 3.0 1
2.2 None 2.4 Brown
2.3 Blue 2.5 None
SNAP RING, SPACER, THRUST RACE AND PRESSURE PLATE FOR ADJUSTMENT
23C-11
1.6 None 2.3 Blue
1.7 Blue 2.4 Brown
1.8 Brown 2.5 None
1.9 None 2.6 Blue
2.0 Blue 2.7 Brown
2.1 Brown 2.8 None
2.2 None
Pressure plate (For adjustment low/reverse brake end play)
1.6 F 2.4 B
1.8 E 2.6 A
2.0 D 2.8 0
2.2 C 3.0 1
Transfer
Snap ring (For adjustment input gear bearing end play)
2.30 None 2.45 Blue
2.35 Red 2.50 Green
2.40 White
Spacer (For adjustment of counter shaft gear end play)
1.91 Blue 2.33 Red
2.05 Brown
Snap ring (For adjustment of counter shaft gear bearing end play)
1.48 Blue 1.62 None
Spacer (For adjustment of rear output shaft to rear cover clearance) <Easy select 4WD>
2.75 B75 2.95 B95
2.79 B79 2.99 B99
2.83 B83 3.03 C03
2.87 B87 3.07 C07
2.91 B91 3.11 C11
SEALANTS AND ADHESIVES

2.18 − 2.32 −
2.25 − 2.39 −
Snap ring (For adjustment of differential lock hub end play) <Super select 4WD>
2.56 None 2.84 Yellow
2.63 Red 2.91 Green
2.70 White 2.98 Purple
2.77 Blue
Snap ring (For adjustment of 2-4WD synchronizer hub end play) <Super select 4WD>
2.56 None 2.77 Blue
2.63 Red 2.84 Yellow
2.70 White
Snap ring (For adjustment of rear output shaft bearing end play) <Super select 4WD>
2.33 Red 2.47 Blue
SEALANTS AND ADHESIVES

M1233000501103
Transmission
Transfer case adapter Mitsubishi Part No. MD997740 or equivalent
Sealing cap 3M™ ATD Part No. 8672 or equivalent
Converter housing Mitsubishi Part No. MD997740 or equivalent
Oil pan
Transfer
Chain cover Mitsubishi Part No. MD997740 or equivalent
Rear cover
Control housing
Transfer case plate
Bearing retainer mounting bolt
Plug 3M™ ATD Part No. 8672 or equivalent
Support pin Sealant 3M™ ATD Part No. 8672 or equivalent
Adhesive Mitsubishi Part No. MB160450 or equivalent
LUBRICANTS
23C-13
This transaxle has several areas where the form-in- Parts sealed with a FIPG can be easily removed
place gasket (FIPG) is used for sealing. To ensure without need for the use of a special method. In
tance.
FIPG Application
2. Use Mitsubishi genuine parts cleaner ing installation. Avoid operating the transaxle or let-
(MZ100387) or equivalent to well degrease the ting oils or water come in contact with the sealed
LUBRICANTS
M1233000400448

A/T fluid DiaQueen ATF SP III As required
Transfer oil Gear oil API classification GL-3 SAE 75W-85W As required
Oil seal Mitsubishi Part No.0101011 or equivalent As required
SPECIAL TOOL(S)
SPECIAL TOOL(S)
M1233000601092
TRANSMISSION
MD998727 Oil pan remover Removal of oil pan
D998727
MB991603 Bearing installer stopper Measurement of output

shaft and center support
end plays
MD998029 Oil seal installer Measurement of output

shaft end play
MB991632 Clearance dummy plate Measurement of brake

brake end plays
MD998913 Dial gauge extension Measurement of brake

brake end plays
SPECIAL TOOL(S)
23C-15
MD998316 Dial gauge support Measurement of input

shaft end play
MD998924 Spring compressor Use with spring

retainer compressor

of reverse and overdrive
clutch spring retainer
snap ring
MB991629 Spring compressor Measurement of

overdrive clutch and
underdrive clutch end
plays
MB991789 Spring compressor Adjustment reverse clutch

end plays
MB991630 Spring compressor Removal and installation

of center support snap
ring

of underdrive clutch
spring retainer snap ring
SPECIAL TOOL(S)
TRANSFER

<Super select 4WD>
MD998801 Bearing remover Removal and installation

of bearing

installer adapter

installer-200
SPECIAL TOOL(S)
23C-17
input gear bearing
MD998368 Bearing Installer Installation of

countershaft gear bearing
MD998818 Installer adapter (38) Installation of counter

shaft gear bearing, front
output shaft bearing
<Easy select 4WD>
MB991013 power steering lock nut Removal and installation

special spanner of output shaft locking nut
MD998917 Bearing remover Removal and installation

of bearing

shaft ball bearing and
stopper plate <Easy
select 4WD>
SPECIAL TOOL(S)

installer adapter
MD998823 Installer adapter Installation of clutch hub

bearing <Super select
4WD>
MD998821 Installer adapter (44) Installation of clutch hub

bearing <Easy select
4WD>
TRANSMISSION AND TRANSFER
23C-19
M1233023300389
35 ± 6 N·m
4
5 3
7 48 ± 6 N·m
9 1
2 48 ± 6 N·m
35 ± 6 N·m
8
6 11 ± 1 N·m
26 ± 5 N·m
AK801717AB

1. Transfer 6. Harness bracket
2. Cable end bracket 7. Air breather hose
3. Harness bracket 8. Air breather hose bracket
4. Harness bracket 9. Transmission
>>A<< 5. Transfer case adapter
REASSEMBLY SERVICE POINT After squeezing out and applying the sealant on the
>>A<< TRANSFER CASE ADAPTER INSTALLA- transfer case adapter at the section indicated in the
TION illustration, install onto the transmission case.
Specified sealant:
CAUTION
Mitsubishi Part No.MD997740 or equivalent
face so that water and oil including the old
surface by hand.
1.6 mm
diameter
AK403460AD
TRANSFER CASE ADAPTER
23C-21
M1233007000292
2
8
3
5
4
1 6
AK602202 AC
Disassembly steps 1. Use special tools to install the oil seal.

1. Parking sprag shaft • Installer adapter (MB990936)
>>C<< 2. Parking sprag spring • Handle (MB990938)
3. Parking sprag 2. Apply specified grease to the lip of the oil seal.
5. Parking roller support shaft Specified lubricants:
6. Parking roller support Mitsubishi Part No. 0101011 or equivalent
>>A<< 7. Oil seal
8. Transfer case adapter >>B<< SEALING CAP INSTALLATION
>>A<< OIL SEAL INSTALLATION Sealing cap
MB990938
MB990936
1.5 mm
1.5 mm
AK403557 AB
1. Press into the dimensions shown in the illustration

AK403339AB so that it is not slanted.
CAUTION >>C<< PARKING SPRAG SPRING INSTALLATION

surface by hand.
Specified sealant: AK403340 AB
3M™ ATD Part No. 8672 or equivalent
the illustration.
TRANSMISSION
23C-23
TRANSMISSION
M1233101200046
3
6
11 ± 1 N·m
7
1
5
2
11 ± 1 N·m
4
21.5 ± 3.5 N·m
14 11 ± 1 N·m
16
11 ± 1 N·m 15
13
11 ± 1 N·m
11 ± 1 N·m
11 ± 1 N·m
11 12
10 Apply automatic
6.0 ± 1.0 N·m transmission fluid
6.0 ± 1.0 N·m to all moving parts
11 ± 1 N·m
9 8 AK801718 AB
1. Torque converter 9. Magnet

2. Input shaft speed sensor 10. Oil filter
3. Output shaft speed sensor 11. O-ring
4. Manual control lever 12. Detent spring
5. Inhibitor switch 13. Valve body
6. Snap ring 14. O-ring
7. Parking gear 15. Snap ring
8. Oil pan 16. Solenoid valve harness
TRANSMISSION
Apply automatic
transmission fluid
to all moving parts
38
37
28 32 34
35
31
25 27 33
30
22 24 26
29 36
21 23 20 20
20 20
18
17
19
AK503511AD
17. Oil seal 28. Outer spring

18. Oil seal 29. Accumulator piston (for underdrive clutch)
19. Oil strainer 30. Inner spring
20. Seal ring 31. Outer spring
21. Accumulator piston (for overdrive clutch) 32. Spring pin
22. Accumulator spring 33. Pin
23. Accumulator piston (for second brake) 34. Manual control shaft
26. Accumulator piston (for low/reverse brake) 37. Detent lever
TRANSMISSION
23C-25
41
40
23 ± 3 N·m
39
48 ± 6 N·m
46 51
50
44 49
47 48
Apply automatic
transmission fluid
43 AK503512 AE

TRANSMISSION
54
58
56 57
52
55
53 62
60
63
59
Apply automatic
transmission fluid
to all moving parts
61
AKX00019 AK

TRANSMISSION
23C-27
71
69
80 23 ± 3 N·m
65
66
64
70
67 68 79
77
81
76
73 78
Apply automatic
transmission fluid
to all moving parts
74
75
72
AKX00020AH
64. Snap ring 73. Thrust bearing No.12

65. Center support 74. Output shaft
67. Thrust bearing No.9 76. Seal ring
68. Output flange 77. Thrust bearing No.13
69. Thrust bearing No.10 78. Bearing retainer
70. Underdrive clutch hub 79. Output shaft support
71. Thrust bearing No.11 80. Output shaft support gasket
72. Underdrive clutch 81. Transmission case
TRANSMISSION
DISASSEMBLY 2. Remove the input shaft speed sensor.

CAUTION
any rags during disassembly. Use only nylon
cloth or paper towels if necessary. AK403342
• All removed parts must be washed clean. 3. Remove the output shaft speed sensor.
Metal parts may be washed in an ordinary sol-
• Clutch discs, plastic thrust plates and rubber
after washing.
and repaired, also disassemble and clean the
ATF cooler system. Inhibitor switch AK403343AB
4. Remove the manual control lever, and then

remove the inhibitor switch.
Snap ring
AK603561
1. Remove the torque converter.


AK403341
TRANSMISSION
23C-29
CAUTION 9. Disconnect the valve body harness connectors.
MD998727
AK701362AB
AK403345AB O-ring

then use the special tool Oil pan remover
(MD998727) to remove the oil pan.
Oil filter O-ring
AK403349AB

and then remove the valve body, O-ring and oil
temperature sensor.
NOTE: .
AK403346AB
• The twenty valve body mounting bolts are
7. Remove the oil filter and O-ring. plated bolts.
• The O-ring is mounted on the transmission
case side as shown in the illustration. How-
ever there may be cases when it will come off
Snap ring
AK403347
8. Remove the detent spring.
AK403350AB

AK700990AB
TRANSMISSION
Oil seals
Detent lever
Pin
Manual control
shaft
Parking roller
Oil strainer
AK403351AB rod AK403353AB
12.Remove the oil strainer and two oil seals. 15.Remove the pin, and then remove the manual
control shaft, two O-rings, detent lever and
parking roller rod.
4 3 2 1
AK403352AB
13.Remover each accumulator piston, seal ring and AK503505AB

spring.
No. Name 16.Remove the eight converter housing mounting
bolts, and then the converter housing.
2 For second brake
AK403355AB
Spring pin
17.Remove the ten oil pump mounting bolts.
18.Install special tool Oil pump remover (MD998333)
into the bolt hole shown in the illustration.
AK403378AB
MD998333
AK403356AB
TRANSMISSION
23C-31
Trust race No.1
Trust bearing No.2
Thrust bearing No.4

AK403360AD

AK403357AD
No.2.
the oil pump.
AK403361
25.Remove the reverse sun gear.
AK403358
22.Remove the reverse overdrive clutch.

Thrust bearing No.3
AK403362
Overdrive
clutch hub
Second brake
AK403359AD
23.Remove the overdrive clutch hub and thrust Return spring

bearing No.3.
AK403363AB
27.Remove the second brake and return spring.

TRANSMISSION

Reaction plate
AK403364 Brake disc

AK403368AB
32.Remove the reaction plate and one brake disc.
AK403365
AK403369
29.Remove the pressure plate, brake plates and
brake discs. 33.Remove the snap ring.
Thrust bearing No.7
AK403366AD AK403370
30.Remove the thrust bearing No.7. 34.Remove the brake plates, brake discs, and
NOTE: The thrust bearing No.7 may be attached pressure plate.
AK403371
AK403367
TRANSMISSION
23C-33
Snap ring
to the underdrive clutch hub.
Center support AK403372AB

36.Remove the snap ring and center support. AK403376AC
Thrust bearing No.9 Output flange

to the underdrive clutch.
Thrust race No.8 AK403373AD
37.Remove the thrust race No.8, thrust bearing No.9

and output flange.
NOTE: The thrust race No.8 may be attached to AK403377
the center support.
41.Remove the output shaft.
Underdrive
clutch hub
Seal ring (small)

clutch hub. 42.Remove the two large and two small seal rings
from the output shaft.
Thrust bearing
No.13
Thrust
Bearing
bearing
retainer
No.11
Underdrive clutch AK403375AD
AK403380AD
clutch.
TRANSMISSION
43.Remove the thrust bearing No.13 and bearing 1. Install a new gasket and output shaft support.
retainer. 2. Tighten the eight output shaft support mounting
NOTE: The thrust bearing No.13 may be attached bolts to the specified torque 23 ± 3 N⋅m.
to the output shaft support.
CAUTION
Bearing retainer
Output shaft
support AK403379AB
AKX00062 AG
44.Remove the eight output shaft support mounting
bolts, and then remove the output shaft support Make sure the thrust bearing is mounted in the
and gasket. correct direction.
Thrust bearing
REASSEMBLY No.13
CAUTION
• Never reuse any gasket, O-ring, and oil seal. Bearing
retainer
Always replace them with new ones.
• Never use any product other than blue petro-
latum jelly or white vaseline to lubricate or
hold parts during assembly.
• Apply ATF to friction elements, rotating parts,
AK403380AD
and sliding parts before installation.Soak new
clutch discs or brake discs in ATF for at least 3. Install the bearing retainer and thrust bearing
two hours before installing them. No.13 onto the output shaft.
• When a bushing requires replacement,
replace the assembly of which the bushing
forms a part.
• Never use any cloth gloves or any rags during
reassembly. Use only nylon cloth or paper
towels if necessary.
• Change also the ATF in the cooler circuit.
CAUTION
Never reuse a gasket.
Output shaft
support AK403379AB
TRANSMISSION
23C-35
Identification of thrust bearing and thrust race
AKX00061AE
Symbol O.D. mm I.D. mm Thickness Symbol O.D. mm I.D. mm Thickness

mm mm
No.1 48.9 37 1.4 No.7 70 48.8 4.0
1.6 No.8 73 60 1.6
1.8 1.8
2.0 2.0
2.2 2.2
2.4 2.4
2.6 No.9 71.45 57 2.81
No.2 59 37 2.8 No.10 72 48.25 4.6
No.3 57 38.5 4.12 No.11 53 34.7 4.01
No.4 57 38.5 4.12 No.12 57 38.5 4.12
No.5 55.4 38.5 3.31 No.13 58 37.5 4.8
No.6 57 38.5 4.12
TRANSMISSION

Seal ring (small) the output shaft.
4. Install new seal rings (two large pieces and two

small pieces) onto the output shaft.
AK403443
7. Install the underdrive clutch.
CAUTION
AK403377
Underdrive clutch
retainer
5. Install the output shaft into the output shaft
support.
AKX00066AE
CAUTION
correct direction.
Output shaft
AKX00063AG
Make sure thrust bearing No.12 is mounted in the Thrust bearing No.11
AK403444AC
correct direction.
the underdrive clutch retainer.

AK403376AC
TRANSMISSION
23C-37
11.Install the output flange.
CAUTION
Thrust bearing No.9
Output flange
AK403445
9. Install the underdrive clutch hub.
AKX00072 AG
CAUTION
correct direction.
Underdrive clutch
hub
AKX00069AE
Make sure thrust bearing No.10 is mounted in the Thrust bearing No.9 AK403448AC
correct direction.
bearing No.9, and then install on the output
flange.
CAUTION
Measure and record the thickness of the thrust
race No.8 to be assembled.
Thrust race No.8

Thrust bearing No.10 AK403446AC

bearing No.10, and then install it on the
underdrive clutch hub.
AK403449AD
13.Apply vaseline or blue petroleum jelly on the

thrust race No.8 being used, and then install it on
AK403447
TRANSMISSION
CAUTION (1) Fix a dial gauge to special tool Bearing

• Install the center support so that the oil holes installer stopper (MB991603).
shown in the illustration face the lower side of
the transmission case.
• Make sure that the thrust race No.8 attached
to the rear side of the center support does not MD998029
fall off.
Output shaft flange
AK403451 AB
(2) Push the output shaft, and the output flange in

alternately, and then measure the end play of
output shaft.
NOTE: .
AK403426 AB
• When pushing the output shaft in, take care
14.Install the center support. that the center support does not move.
• When pushing the output flange in, use the
special tool Oil seal installer (MD998029).
MB991603
Thrust bearing No.9
AK403424AB
Thrust race No.8 End play
15.Remove the two output shaft support mounting AKX00078AD
bolts. (3) Reinstall by selecting the thrust race No.8
16.Using the two removed bolts, install special tool installed by the procedure (13) so that the end
Bearing installer stopper (MB991603) to the play of output shaft becomes the standard
specified torque 23 ± 3 N⋅m. value.
17.Select the thrust race No.8 with the following NOTE: Refer to the thickness recorded in step
procedure. 13.
MB991603
(For output shaft end play)
NOTE: Carry this step out with special tool
Bearing installer stopper (MB991603) and dial
gauge installed.
Output shaft
AK403450AB
TRANSMISSION
23C-39
Standard value
Center support
Snap ring
Low/Reverse
AK403369 brake piston AKX00081AC
18.Using the following steps, select the snap ring for (3) Select the snap ring for fixing the center
fixing the center support. support installed in step 18 (1) so that the end
(1) Install the snap ring used for fixing the center play of the center support is at the standard
support used. value. Then, reassemble.
MB991603 (For center support end play)
Output shaft
AK403450AB
Center support
AK403371

adjusting the brake reaction plate end play and
second brake end play, and the pressure plate for
adjusting the low/reverse brake end play.
AK403453AB
brake piston.
(2) After pushing the output shaft, and the center
MB991632 Snap ring
support in alternately, and then measure the
end play of center support.
NOTE: When pushing the output shaft in, be
sure to push them in to the point where the
center support touches the snap ring.
AKX00082 AC
(2) Install special tool Clearance dummy plate

(MB991632) onto the position shown in the
illustration instead of the pressure plate for the
low/reverse brake. Install the six brake disc,
five brake plate and snap ring.
TRANSMISSION
CAUTION CAUTION
Pay close attention to the assembly direction of Pay close attention to the shape and assembly
the reaction plate. direction of the brake plate A installation.
Second brake Snap ring

MD998913 Snap ring
Return
spring
A
End play MB991632
MB991632
AKX00083 AC AKX00084 AD
(3) Install the reaction plate and snap ring that (7) Next, install special tool Clearance dummy
was used. plate (MB991632) instead of the pressure
(4) Install a dial gauge onto special tool Dial plate for the second brake. Install the four
gauge extension (MD998913) so that the end brake discs and three brake plates.
contacts the brake reaction plate. Measure the (8) Install the return spring, second brake and
end play by moving special tool Clearance snap ring.
dummy plate (MB991632).
(5) Select the snap ring installed in step 19 (3) so
MD998913
that the end play is within the standard value.
Then, reassemble. Moving
amount
(For brake reaction plate end play) MB991632

AKX00085 AC
(9) Install a dial gauge onto special tool Dial

gauge extension (MD998913) so the end
contacts the special tool. Move special tool
measure the moving amount. Select a
(For second brake end play)
PRESSURE PLATE FOR SECOND BRAKE
Moving amount mm Pressure plate Moving amount mm Pressure plate
Thickness Identifica Thickness Identifica
mm tion mm tion
symbol symbol
1.2 or more − less than 1.4 1.6 F 2.2 or more − less than 2.4 2.6 A
1.4 or more − less than 1.6 1.8 E 2.4 or more − less than 2.6 2.8 0
1.6 or more − less than 1.8 2.0 D 2.6 or more − less than 2.8 3.0 1
1.8 or more − less than 2.0 2.2 C (10)Remove the snap ring, second brake, return
spring and special tool Clearance dummy
2.0 or more − less than 2.2 2.4 B plate (MB991632) installed in step (8).
TRANSMISSION
23C-41
(11)Install the pressure plate selected in step (9), (12)Install a dial gauge onto special tool Dial
and install the return spring, second brake and gauge extension (MD998913) so the end
snap ring again. contacts the special tool. Move special tool
MD998913 measure the moving amount. Select a
(For low/reverse brake end play)
A
MB991632
AKX00086AC
PRESSURE PLATE FOR LOW/REVERSE BRAKE

MOVING Pressure plate CAUTION
AMOUNT mm Thickness mm Identification
symbol
Thrust bearing No.7
1.3 or more − 1.6 F
less than 1.5
1.5 or more − 1.8 E
less than 1.7
1.7 or more − 2.0 D
less than 1.9
1.9 or more − 2.2 C AKX00087AD
less than 2.1 Make sure thrust bearing No.7 is mounted in the
2.1 or more − 2.4 B correct direction.
less than 2.3
2.3 or more − 2.6 A
less than 2.5
2.5 or more − 2.8 0
less than 2.7
2.7 or more − 3.0 1
less than 2.9
Thrust bearing No.7
(13)Remove the parts installed in steps 19 (1) to
(12). AK403366AD

bearing No.7, and then install on the rear side of
the low/reverse annulus gear.
TRANSMISSION
CAUTION 24.Install the pressure plate, six brake disc and five
Make sure that thrust bearing No.7 attached to brake plate selected in step 19 (12).
the rear side of the low/reverse annulus gear
does not fall off.
AK403396

AK403364

Make sure the reaction plate in the proper direc-
tion.
AK403361

AK403397
AK403394
23.Install the wave spring to the low/reverse brake

AK403398
piston.
AK403395
TRANSMISSION
23C-43
Make sure the brake plate (reaction plate side) is
installed in the proper direction.
Pressure plate
Brake plate
Reaction
plate
AK403362

AK403399AB
28.Install the brake disc, brake plate and pressure CAUTION

CAUTION
Thrust
bearing No.4
AKX00099 AD
End coil Make sure thrust bearing No.4 is installed in the

proper direction.
AKX00096 AC
Install the return spring end coil side so that it

faces the back of the transmission. (Only for one
side end coil type)
Second brake
Return spring
Thrust bearing No.4
AK403360AD

AK403400AB
gear.
TRANSMISSION
CAUTION CAUTION
Thrust
bearing No.3
Thrust bearing No.2

AKX00101AE AKX00103AD
Thrust bearing No.3
Overdrive
clutch hub
AK403359AD AK403404
32.Apply vaseline or petroleum jelly on the thrust 34.Install the reverse and overdrive clutch.
bearing No.3, and then install on the overdrive Thrust bearing No.2
clutch hub.
AK403405AD

bearing No.2, and then install on the reverse and
overdrive clutch.
Thrust race No.1
AK403566AD

race No.1 being used, and then install on the oil
pump.
TRANSMISSION
23C-45
CAUTION
CAUTION • Completely degrease the FIPG-applied sur-
Never reuse a gasket. face so that water and oil including the old
MD998412
surface by hand.
• Evenly squeeze out the sealant so that it is
not insufficient or excessive.
L1
AK403406AB
37.Install special tools Guide (MD998412) at the

position shown in the illustration, and using this as L2
a guide, install the oil pump and gasket.
38.Tighten the ten oil pump mounting bolts to the AK900786AB
specified torque 23 ± 3 N⋅m.
41.Apply the sealant on the converter housing
mounting surface of the transmission case in the
MD998316 following way.
L1 φ1.6 mm
L2 φ2.6 mm
Specified sealant:
AK403407AB
39.Use the special tool Dial gauge support

shaft, and select the thrust race installed in step
36 so that the end play is at the standard value.
Then, reassemble.
AK503505AB
40.Measure the end play again, and confirm that it is 42.Install the converter housing.
within the standard value. 43.Tighten the eight converter housing mounting
bolts to the specified torque 48 ± 6 N⋅m.
Parking
roller rod
Detent
lever
AK403455AB

TRANSMISSION
Outer spring
4 3 2 1
Inner spring
O-ring
AK403408AB AKX00112 AD

shaft, and assemble onto the transmission case
together with the detent lever and parking roller
rod.
Pin
4 3 2 1
AK403352AB

piston.
49.Install each accumulator piston and spring.
AK403409AB
NOTE: .
46.Install the pin. • Identification colors are applied on the spring
as shown below. Assemble following this
table.
• Install the accumulator pistons to the original
Spring pin positions following the identification tags
Manual control
shaft attached when removed.
1 For overdrive None
clutch
AK403410AB
2 For second Inner Applied on all surfaces
47.Hammer in so that the slit section of the spring brake including both ends
valve is perpendicular to the axial direction of the Outer Applied on half of
manual control shaft. surface including both
ends
TRANSMISSION
23C-47
O-ring
reverse brake surface including both
ends
surface of one side
4 For Inner Applied on half of
underdrive surface including both AK403349AB
clutch ends
Outer Applied on half of 52.Install the new O-ring into the transmission case
surface including both at the position shown in the illustration.
ends
CAUTION
Pay close attention to the installation direction of
the oil seal.
Detent lever
Oil seals
Control shaft
AK503726AD

valve pin into the detent lever groove.
Oil strainer
AK403351AB
oriented as shown in the illustration.
Snap ring
AK602028AC

E B
D
AK403350AB
C
51.Install the solenoid valve harness, and then
secure the snap ring into connector groove.
NOTE: Install the harness so that it is oriented as
shown in the illustration. D A D C
D
AK701362AE
55.Tighten the twenty valve body mounting bolts to

the specified torque 11 ± 1 N⋅m.
TRANSMISSION
Bolt Length mm 59.Install the oil filter and a new O-ring.

A 25 60.Tighten the oil filter mounting bolts to the specified
torque 6.0 ± 1.0 N⋅m.
B 30
2.5 mm diameter
C 40
D 45
E 55
Magnet
AK403416AE
61.Install the magnet.

CAUTION
AK700990AB face so that water and oil including the old
56.Connect the connector to the valve body. sealant cannot adhere to the surface coated
surface by hand.
62.Apply the sealant or equivalent on the oil pan.
Specified sealant:
AK403347
57.Install the detent spring.

58.Tighten the detent spring mounting bolt to the
specified torque 6.0 ± 1.0 N⋅m.
Oil filter O-ring
AK403456
63.Install the oil pan.

64.Tighten the oil pan mounting bolts to the specified
torque 11 ± 1 N⋅m.
AK403346AB
TRANSMISSION
23C-49
CAUTION 67.Install the manual control lever.
68.Tighten the manual control lever mounting bolts to
Identification
symbol A
Transmission
side
AK403457AB

out the spline cut faces the transmission side. AK403342
• Heat the parking gear to 160 − 180 °C and 69.Install the output shaft speed sensor.
70.Tighten the output shaft speed sensor mounting
put shaft. Do not heat for longer than neces-
sary at this time.
Snap ring
AK403341
71.Install the input shaft speed sensor.

72.Tighten the input shaft speed sensor mounting
CAUTION
converter.
Inhibitor switch
AK601368AC
66.Install the inhibitor switch, and fix the fastening

bolts temporarily.
A
AK403458AB

meets the reference value.
Inhibitor switch AK403343AB Reference value: 20.9 mm

M1233021200494
Apply automatic 14
transmission fluid
to all moving parts
19
21 12
22 13
2
15
1 16 6
18
20 8
3 9
4
10 5
7
17 14 10 8
22
21
20 15 6
2
1 12
18
16 13 3
11
19 11 9 7 5 4
AK700992 AB

23C-51
MD998924
MD999590
AK700994AB
Snap ring
AK403382AB Align the two return spring holes with the two projec-
tions on the override clutch piston, and then assem-
1. Set special tools as shown in the illustration. ble.
ring. MD999590
MD998924

2. Install the D-ring in the reverse clutch retainer,
grooves. Make sure that the D-ring is not twisted Snap ring
or damaged when installing. AK403382AB
>>B<< REVERSE CLUTCH PISTON 1. Set special tools as shown in the illustration.
INSTALLATION • Spring compressor (MD999590)
A 3. Install the thickest snap ring that can be fitted in
the snap ring groove of reverse clutch retainer.
AK705065AB
Align the reverse clutch piston and reverse clutch

retainer holes (A and B), and then assemble.
AK403386
4. Check the clearance between the snap ring and

spring retainer. If the clearance is not within the
standard value range, make adjustment by
selecting a snap ring of an appropriate thickness.
end play)

>>E<< CLUTCH PLATE / CLUTCH DISC / (For overdrive clutch end play)
Clutch plates Rounded edge
>>G<< CLUTCH PLATE / CLUTCH DISC /
Reaction
plate CAUTION
R1
stamp
them.
B
A
Clutch discs
AKX00126 AE
1. Alternately assemble the clutch disc and clutch

plate in the reverse clutch piston.
AKX00130 AC
>>F<< SNAP RING INSTALLATION 1. Alternately assemble the clutch plate and clutch
1. Install the snap ring in the reverse clutch piston disc in the reverse clutch retainer. Align and
groove. assemble both clutch plates (where there are no
teeth) (A in the illustration) with the reverse clutch
MD998924
retainer hole (B in the illustration).
Clutch plates Rounded edge Reaction plate
R stamp
MB991629
AK403634AB
2. Set special tools as shown in the illustration, and Clutch discs AKX00131 AC
compress the clutch element
• Spring compressor (MB991629) 2. Install the reaction plate so that it is oriented as
• Spring compressor retainer (MD998924) shown in the illustration. Assemble in the same
manner as the clutch plate so the section with no
teeth (A in the illustration) matches the retainer
Snap ring >>H<< SNAP RING INSTALLATION

Standard value MD998924
Standard
value MB991789
Reaction plate
AKX00129 AC
3. Check the clearance (overdrive clutch end play) of

the snap ring and reaction plate is the standard
value. If the clearance is not at the standard
value, select the snap ring and adjust so that the
AKX00384AD
clearance is within the standard value.
SECOND BRAKE
23C-53
1. Install the snap ring in the reverse clutch retainer 3. Check that the clearance between the snap ring
groove. and the clutch reaction plate is within the standard
2. Set special tools as shown in the illustration, and valus.If not within the standard value, select a
compress the clutch element. snap ring to adjust.
• Spring compressor (MB991789) Standard value: 1.5 − 1.7 mm
• Spring compressor retainer (MD998924) (For reverse clutch end play)
SECOND BRAKE
M1233021800269
4
1
2
3
AKX00134 AB

>>A<< 3. D-ring
>>A<< 4. D-ring 2. Install the D-ring in the grooves on the outer and

M1233027100268
Apply automatic
transmission fluid
to all moving parts
7
8
4
9
2 3
1
10
5 6
AKX00135 AC
>>C<< 5. Thrust bearing No.6 Claw
>>B<< 7. Stopper plate
9. Snap ring

>>A<< ONE-WAY CLUTCH INSTALLATION Groove
Stopper plate AK403388AB

gear. Make sure that the stopper plate claw is
Arrow
AK403387AB
CENTRE SUPPORT
23C-55
CAUTION CAUTION
Output planetary
Overdrive planetary
carrier side
carrier side
AKX00138 AC AKX00139 AC
Apply vaseline or petroleum jelly on the thrust bear- Apply vaseline or petroleum jelly on the thrust bear-
ing No.6, and then install onto the output planetary ing No.5, and then install on the overdrive planetary
carrier. carrier.
CENTRE SUPPORT
M1233010000195
Apply automatic
transmission fluid
to all moving parts
5
10
9
4
3 8
2
7
1
6
AKX00140 AC

CENTRE SUPPORT
Disassembly steps (Continued) >>B<< O-RING INSTALLATION

5. Spring retainer
6. Return spring
7. Low/reverse brake piston
>>A<< 8. D-ring
>>A<< 9. D-ring
10. Center support

O-ring
MD998924 MB991630 AK403390AB


MD998924 MB991630
Snap ring
AK403389AB
1. Set special tools as shown in the illustration so

one-way clutch.
Snap ring
AK403389AB
2. Screw in the special tool nut, and lightly press
against the inner race of the one-way clutch. 1. Set special tools as shown in the illustration.
3. Remove the snap ring. • Spring compressor (MB991630)
REASSEMBLY SERVICE POINTS 2. Screw in the special tool nut, and lightly press
3. Install the snap ring.
2. Install the D-ring in the grooves on the outer and
UNDERDRIVE CLUTCH
23C-57
UNDERDRIVE CLUTCH
M1233027300284
4
Apply automatic
transmission fluid
to all moving parts
2
1
11
12 13
10
9
8
5 7 1 3
6 7
10
11
12
9
6 13
2 4 AK700896AB
UNDERDRIVE CLUTCH
Disassembly steps
>>E<< 1. Snap ring >>C<< SNAP RING INSTALLATION
>>D<< 2. Reaction plate
>>D<< 3. Clutch disc MD998924
MD998907
>>D<< 4. Clutch plate
6. Spring retainer
>>A<< 7. D-ring
>>A<< 10. D-ring
>>A<< 11. D-ring
>>A<< 12. D-ring Snap ring
AK403391AB
Use the special tools to install the snap ring.
DISASSEMBLY SERVICE POINT • Spring compressor (MD998924)
<<A>> SNAP RING REMOVAL • Spring compressor retainer (MD998907)
MD998924 >>D<< CLUTCH PLATE / CLUTCH DISC /

MD998907
CAUTION
them.
B
A
Snap ring
AK403391AB
Use the special tools to remove the snap ring.


AKX00146AC
1. Apply ATF to the D-ring. 1. Alternately assemble the clutch plate and clutch
disc in the underdrive clutch retainer. Align and
2. Install the D-ring in the grooves of the underdrive assemble the four clutch plates (where there are
clutch retainer and spring retainer. Make sure that no teeth) (A in the illustration) with the underdrive
the D-ring is not twisted or damaged when clutch retainer hole (B in the illustration).
installing.
Rounded edge Clutch plates
W
stamp
Reaction plate
Clutch discs AKX00147AC

AK602059
shown in the illustration. Assemble in the same
Align the two return spring holes with the two projec- manner as the clutch plate so that the section with
tions on the underdrive clutch piston, and then no teeth (A in the illustration) matches the retainer
assemble. hole (B in the illustration).
UNDERDRIVE CLUTCH
23C-59

1. Install the snap ring in the groove of the Snap ring
Standard value
MD998924
Reaction plate
AKX00149 AC
3. Check the clearance (underdrive clutch end play)

between the snap ring and reaction plate is the
MB991629 standard value. If the clearance is not at the
AK403459AB
standard value, select the snap ring and adjust so
2. Set special tools as shown in the illustration, and that the clearance is within the standard value.
compress the clutch element. Standard value: 1.6 − 1.8 mm
• Spring compressor retainer (MD998924) (For underdrive clutch end play)
VALVE BODY
VALVE BODY
M1233012100206
2 1
11 ± 1 N·m
2
11 ± 1 N·m
6
Apply automatic
5
3
9 4
6.0 ± 1.0 N·m
10
11
15
14
12
13 14
11 ± 1 N·m
2
16
15
AKX00150AC

2. Valve body attaching bolt 10. Separating plate
>>F<< 3. Damping valve 11. Lower valve body gasket
>>F<< 4. Seal ring >>E<< 12. Steel ball (line relief)
>>F<< 5. Damping valve spring >>E<< 13. Spring
>>F<< 6. Ball (orifice check ball) >>D<< 14. Knock bushing
>>F<< 7. Steel ball (orifice check ball) >>C<< 15. Knock bushing
>>F<< 8. Spring >>B<< 16. Dowel pin
VALVE BODY
23C-61
19 17
20
21 18
38
6.0 ± 1.0 N·m
22 24
25
23
transmission fluid 32 29
to all moving parts
33
35
37 26
36 31
34
AKX00151AC

17. Solenoid support 29. Fail-safe valve A spring
<<A>> >>A<< 18. Low reverse brake solenoid valve 30. Fail-safe valve A1
<<A>> >>A<< 22. Torque converter clutch control 34. Stopper plate
solenoid valve 35. Stopper plug
27. Fail-safe valve a sleeve 38. Upper valve body
28. Fail-safe valve A2
VALVE BODY
40 42
45 43
44 46 41 39
48 47
52 51
49
53 50
54
55 60
67
59
63
to all moving parts
62
61
57
66
11 ± 1 N·m
65
11 ± 1 N·m
AKX00152AC

39. Manual valve 55. Overdrive clutch pressure control
40. Roller valve spring
41. Low/reverse brake pressure control 56. Stopper plate
valve sleeve 57. Regulator valve adjusting screw
42. Low/reverse brake pressure control 58. Regulator valve sleeve
valve 59. Regulator valve spring
43. Low/reverse brake pressure control 60. Regulator valve
valve spring 61. Roller
44. Roller 62. Damper clutch control valve sleeve
45. Second brake pressure control 63. Damper clutch control valve
valve sleeve 64. Damper clutch control valve spring
46. Second brake pressure control 65. Cover
valve 66. Cover gasket
47. Second brake pressure control 67. Lower valve body
valve spring
48. Roller DISASSEMBLY SERVICE POINT
49. Underdrive clutch pressure control <<A>> SOLENOID VALVE REMOVAL
valve sleeve Before removing the solenoid valves, make marks
with white paint, etc., so that the these valves can be
valve
valve spring
52. Roller REASSEMBLY SERVICE POINTS
53. Overdrive clutch pressure control >>A<< SOLENOID VALVE INSTALLATION
valve sleeve 1. Apply ATF, vaseline or petroleum jelly to O-ring,
54. Overdrive clutch pressure control
and install it to solenoid valves.
valve
VALVE BODY
23C-63
2. Following the marks made when removing, install Install the knock bushing onto the lower valve body
each solenoid valve in its proper position. position shown in the illustration.
>>B<< DOWEL PIN INSTALLATION >>D<< KNOCK BUSHING INSTALLATION
Dowel pin
6 mm
4.5 mm
AK403430AB AK403428AB
Install the dowel pin at the specified position on the Install the knock bushing onto the lower valve body
lower valve body. position shown in the illustration.
>>C<< KNOCK BUSHING INSTALLATION >>E<< SPRING / STEEL BALL (LINE RELIEF)
INSTALLATION
Steel ball
Spring
AK403429AB
Install the spring 7.0 mm diameter, 17.3 mm length

and the steel ball 6.4 mm diameter onto the lower
9 mm
valve body position shown in the illustration.
AK403427AB
VALVE BODY
>>F<< SPRING / STEEL BALL (ORIFICE CHECK 1. Install the spring (4.5 mm diameter, 15.4 mm
BALL) / BALL (ORIFICE CHECK BALL) / length) and the steel ball (6.4 mm diameter) onto
DAMPING VALVE SPRING / SEAL RING / the upper valve body position shown in the
DAMPING VALVE INSTALLATION illustration.
Steel ball Seal ring 2. Install the ball (rubber) (6.4 mm diameter) onto the
upper valve body position shown in the
illustration.
Damping Damping spring (7.7 mm diameter, 35.8 mm length) onto
Spring valve spring the upper valve body position shown in the
illustration.
>>G<< CONTROL SHAFT INSTALLATION
Manual valve
Pin
Control shaft
Ball (Rubber) AK403393AB
AK403431AB
manual valve.
TRANSFER
23C-65
TRANSFER
M1233013300333
<Easy select 4WD>
34 ± 5 N·m
3
35 ± 6 N·m
9 35 ± 6 N·m
10 35 ± 6 N·m 4
11
6 5
34 ± 5 N·m
14
34 ± 5 N·m 15
1 7
8 12
13
18
19 ± 3 N·m
17
16
Apply gear oil to
all moving parts 25 ± 4 N·m
AK700638AC

1. 4WD operation detection switch 11. Steel ball
2. Gasket 12. Low detection switch
3. High/low detection switch 13. Gasket
4. Gasket >>X<< 14. Plug
5. Steel ball >>X<< 15. Plug
>>X<< 6. Plug 16. Vehicle speed sensor
>>W<< 7. Spring 17. Speedometer sleeve clamp
8. Steel ball >>V<< 18. Speedometer driven gear sleeve
>>X<< 9. Plug assembly
>>W<< 10. Spring
TRANSFER
19 ± 3 N·m 36
19 ± 3 N·m
25
35 ± 6 N·m 37
Apply gear oil to
all moving parts
26 31
33
28 34
35
35 ± 6 N·m
27
32 ± 2 N·m 32
29
35 ± 6 N·m 24
23
22 30
32 ± 2 N·m
21
19 20
35 ± 6 N·m AK900188AB

19. Bracket 29. Filler plug
>>U<< 20. Transfer case plate 30. Drain plug
>>T<< 21. Countershaft gear 31. Connector bracket
>>O<< 22. Spacer 32. Harness bracket
23. Sealing cap >>P<< 33. Rear cover
24. Needle bearing >>O<< 34. Oil cover
25. Harness bracket >>N<< 35. Spacer
>>R<< 26. Control housing >>J<< 36. Dust seal cover
>>Q<< 27. Support pin >>M<< 37. Oil seal
>>Q<< 28. Return spring
TRANSFER
23C-67
56
57
58
57
63 59
60 62
61 39 35 ± 6 N·m
47 53 46
38 42
40 51
52 43
50 44
41
49
54
45
48
55
Apply gear oil to
all moving parts
66
65
64 AK705024 AD

>>L<< 38. Spring pin <> >>C<< 53. Rear output shaft
<<A>> >>K<< 39. H-L shift rail <> >>C<< 54. Chain
40. H-L shift fork <> >>C<< 55. Front output shaft
>>J<< 41. H-L clutch sleeve 56. Snap ring
43. Harness bracket 58. Return spring
44. Harness bracket 59. 2-4WD shift fork
45. Harness bracket >>B<< 60. Spring pin
<<A>> >>J<< 46. Chain cover 61. 2-4WD shift lug
47. Interlock plunger 62. Spacer
48. Wave spring 63. 2-4WD shift rail
>>E<< 49. Snap ring 64. Dust seal guard
>>D<< 50. H-L clutch hub >>A<< 65. Oil seal
51. Low speed gear 66. Transfer case
52. Needle bearing
TRANSFER
<Super select 4WD>
34 ± 5 N·m
35 ± 6 N·m
34 ± 5 N·m
21 34 ± 5 N·m 8 39
22 9 11
34 ± 5 N·m 23 12 34 ± 5 N·m 34
5 10
6 13 36
14
35 ± 6 N·m
7 15
3 16
1
35 ± 6 N·m
2 19 40
17
4 18 35
19 ± 3 N·m
37 25
41 38
20 27 26
32 ± 2 N·m
33
28 32 24
25 ± 4 N·m
Apply gear oil to

all moving parts
30
29
35 ± 6 N·m AK900189 AB

>>Y<< 1. Center differential lock detection >>X<< 21. Plug
switch >>W<< 22. Spring
2. Gasket 23. Steel ball
>>Y<< 3. 2WD/4WD detection switch 24. Vehicle speed sensor
4. Gasket 25. Gear box
>>Y<< 5. Center differential lock operation 26. Speedometer clamp
detection switch >>V<< 27. Speedometer driven gear sleeve
6. Gasket assembly
7. Steel ball 28. Bracket
>>Y<< 8. 4WD operation detection switch >>U<< 29. Transfer case plate
9. Gasket >>T<< 30. Countershaft gear
10. Steel ball >>N<< 31. Spacer
>>X<< 11. Plug 32. Sealing cap
>>W<< 12. Spring 33. Needle bearing
13. Steel ball 34. Connector bracket
>>Y<< 14. High/low detection switch 35. Harness bracket
15. Gasket >>P<< 36. Rear cover
16. Steel ball 37. Oil cover
>>Y<< 17. 4LLc detection switch >>N<< 38. Spacer
18. Gasket 39. Dust seal cover
19. Harness bracket >>M<< 40. Oil seal
>>X<< 20. Plug >>J<< 41. Spring pin
TRANSFER
23C-69
Apply gear oil to 64

all moving parts
63 55
65
69
67
71 72 35 ± 6 N·m
51
53
70 56
46
68 66 57 50
19 ± 3 N·m 19 ± 3 N·m
58
59
75
62
42 49
73
74
43 45 76
77
52
44
60
47 54
61
48
AK800442 AC

42. Harness bracket <<C>> >>H<< 61. Front output shaft
>>R<< 43. Control housing 62. Needle bearing
>>Q<< 44. Support pin 63. E-ring
>>Q<< 45. Return spring 64. Spring seat
<<A>> >>K<< 46. H-L shift rail 65. Spring
47. H-L shift fork 66. 2-4WD shift lug and shift rail
>>J<< 48. H-L clutch sleeve assembly
49. Harness bracket >>G<< 67. Spring pin
50. Harness bracket 68. 2-4WD shift lug
<<A>> >>I<< 52. Chain cover 70. Spring
53. Interlock plunger 71. 2-4WD shift rail
54. Wave spring 72. 2-4WD shift fork
55. Rear output shaft 73. 2-4WD synchronizer sleeve
56. Needle bearing 74. Spacer
57. Needle bearing 75. Steel ball
58. Center differential case >>F<< 76. Snap ring
<<C>> >>H<< 59. 2-4WD synchronizer 77. Differential lock hub
<<C>> >>H<< 60. Chain
TRANSFER
82
Apply gear oil to
all moving parts
83
20 ± 2 N·m
9.0 ± 1.0 N·m
84
81
80 87
79 86
78
85 AK503403AG
Disassembly steps 1. Fix the H-L shift rail at the high position.
>>E<< 78. Snap ring 2. Shift the 2-4WD shift rail at the 4WD position.
>>D<< 79. H-L clutch hub
80. Low speed gear
NOTE: If the 2-4WD shift rail is at the 2WD posi-
81. Needle bearing tion, the chain cover cannot be removed because
82. Rear bearing retainer interlock is actuated.
84. Oil pool cover <> REAR OUTPUT SHAFT / CHAIN / FRONT
85. Dust seal guard OUTPUT SHAFT REMOVAL
>>A<< 86. Oil seal
87. Transfer case

<<A>> H-L SHIFT RAIL REMOVAL
AK500492
Remove the rear output shaft, chain and front output

shaft as a set.
2-4WD shift rail
AK503405 AB
TRANSFER
23C-71
<<C>> 2-4WD SYNCHRONIZER / CHAIN / FRONT >>B<< SPRING PIN INSTALLATION
OUTPUT SHAFT REMOVEAL
Spring pin
AK403503AB
AK101119
1. Align the 2-4WD shift lug with the 2-4WD shift rail
Remove the 2-4WD synchronizer, chain and front spring pin hole.
output shaft as a set.
2. Hammer in the spring valve so that the spring pin
slit matches the center of the shift rail shaft.
ADJUSTMENT BEFORE REASSEMBLY
>>C<< FRONT OUTPUT SHAFT / CHAIN / REAR
Spacer selection for adjustment of countershaft gear
OUTPUT SHAFT INSTALLATION
end play. (Refer to adjustment of transfer - spacer
selection for adjustment of countershaft gear end
play P.23C-77)

AK500492
MB990931 MB990938 1. Engage the chain precisely with the sprocket of

the rear output shaft and the front output shaft.
2. Install the 2-4WD shift fork on the 2-4WD clutch
Transfer case sleeve. While passing them beside the 2-4WD
AK403501 AC shift rail, install the front output shaft, and chain
and rear output shaft.
• Installer adapter (MB990931) >>D<< H-L CLUTCH HUB INSTALLATION
Specified lubricant:
Mitsubishi Part No. 0101011 or equivalent
Transfer front side Installation
direction
AK503408 AB
Check that the H-L clutch hub is in the correct direc-

TRANSFER
>>E<< SNAP RING INSTALLATION 1. Align the 2-4WD shift lug with the 2-4WD shift rail
spring pin hole.
2. Hammer in the spring valve so that the spring pin
slit matches the center of the shift rail shaft.
>>H<< 2-4WD SYNCHRONIZER / CHAIN / FRONT

OUTPUT SHAFT INSTALLATION
AK500493

2. Make sure that the H-L clutch hub end play meets
the standard value.
(For H-L clutch hub end play) AK101123
1. Make a white paint mark on the deep groove

>>F<< SNAP RING INSTALLATION portions (three places) of the 2-4WD
synchronizer.
2. Make a white paint mark on the portions (three
places) of the 2-4WD synchronizer sleeve splines.
AK503398

the snap ring groove of the transfer drive shaft.
AK101124
2. Make sure that the differential lock hub end play
meets the standard value. 3. Place the chain in tight mesh with the 2-4WD
Standard value: 0 − 0.08 mm synchronizer and front output shaft sprockets.
(For differential lock hub end play) 4. With both sprockets spaced the farthest apart,
install them on the transfer case simultaneously.
>>G<< SPRING PIN INSTALLATION
AK503410
TRANSFER
23C-73
>>I<< CHAIN COVER INSTALLATION >>K<< H-L SHIFT RAIL INSTALLATION
CAUTION
surface by hand.
H-L shift rail
2 mm Diameter 2-4WD shift rail
Interlock plunger
H-L shift rail
AK403508AB
1. Apply sealant to the chain cover, and then install

the chain cover. 2-4WD shift rail
AK503411AB
Specified sealant:
1. Tilt the transfer case with the 2-4WD shift rail
Mitsubishi Part No. MD997740 or equivalent
downward as shown in the illustration.
2. Move the 2-4WD shift rail in the direction of the
>>J<< H-L CLUTCH SLEEVE INSTALLATION arrow fully.
3. After making sure that the plunger is not exposed
Identification groove out of the H-L shift rail hole in the transfer case,
install the H-L shift rail.
>>L<< SPRING PIN INSTALLATION

Installation
direction
AK500678AB
Check that the H-L clutch sleeve is in the correct

direction for installation.
AK503412
1. Align the spring pin holes on the shift rail with the
shift fork. Then tap in the spring pin so that the slit
of the spring pin is facing the shaft center of the
shift rail.
TRANSFER
>>M<< OIL SEAL INSTALLATION >>N<< SPACER INSTALLATION

<Easy select 4WD> <Easy select 4WD>
Rear cover
A
MB990938
MB990932 B
AK403510 AC
<Super select 4WD>
Spacer
MB990938
MB990929
AK403510AH
AK403504AE

<Super select 4WD>
• Installer adapter (MB990932) <Easy select Rear cover
4WD> A
• Installer adapter (MB990929) <Super select
4WD>
B
Spacer
AK503414AE
1. Measure projection A of the rear output shaft

bearing and depth B of the second stage of the
rear cover.
2. Subtract A from B and let the answer be C. Select
a spacer so that the subtracted value will be the
standard value shown below.
Standard value:
• 0 − 0.1 mm <Easy select 4WD>
• 0.025 − 0.150 mm <Super select 4WD>
TRANSFER
23C-75
(For rear output shaft bearing to rear cover >>Q<< RETURN SPRING / SUPPORT PIN
clearance) INSTALLATION
>>O<< OIL COVER INSTALLATION Return spring
Oil hole
AK403511AB
Oil cover 1. Insert the bent section of the return spring into the
AK403729 AC
control housing as shown.
Install the oil cover so that the oil hole shown in the
illustration. CAUTION
>>P<< REAR COVER INSTALLATION face so that water and oil including the old
CAUTION sealant cannot adhere to the surface coated
• Completely degrease the FIPG-applied sur- with the sealant. Never touch the degreased
face so that water and oil including the old surface by hand.
sealant cannot adhere to the surface coated • Make sure the starting point and the ending
with the sealant. Never touch the degreased point are about the middle between the bolts.
surface by hand.
AK403517 AB
2. Apply the sealant to the support pin section and

2 mm
Diameter apply the adhesive to the threads.
AKX00172 AC
Specified sealant:
Apply the sealant to the chain cover.
Specified sealant: Specified adhesive:
Mitsubishi Part No. MD997740 or equivalent Mitsubishi Part No. MB160450 or equivalent
3. Insert the support pin and install the nut.
TRANSFER
>>R<< CONTROL HOUSING INSTALLATION >>U<< TRANSFER CASE PLATE INSTALLATION

CAUTION CAUTION
• Completely degrease the FIPG-applied sur- • Completely degrease the FIPG-applied sur-
face so that water and oil including the old face so that water and oil including the old
sealant cannot adhere to the surface coated sealant cannot adhere to the surface coated
with the sealant. Never touch the degreased with the sealant. Never touch the degreased
surface by hand. surface by hand.
• Make sure the starting point and the ending • Make sure the starting point and the ending
point are about the middle between the bolts. point are about the middle between the bolts.
2 mm 2 mm Diameter
Diameter
AK000033AD AK403617AC
Apply the sealant to the control housing. 1. Apply the sealant to the transfer case plate.
Specified sealant: Specified sealant:
Mitsubishi Part No. 997740 or equivalent Mitsubishi Part No. MD997740 or equivalent
>>S<< SPACER INSTALLATION

CAUTION
Install the previously selected spacer (Refer to
The transfer case plate must be installed smooth
ADJUSTMENT BEFORE ASSEMBLY).
and straight to get a good seal.
>>T<< COUNTER SHAFT GEAR INSTALLATION 2. Install the transfer case plate together with the
input gear and countershaft.
Notched selection
>>V<< SPEEDOMETER DRIVEN GEAR SLEEVE
Mating marks
Counter shaft
Input gear AK503394AB
1. Turn the input gear’s notched selection surface

toward the counter shaft mounting surface. then
install the counter shaft. AK201067AD
Match the mating marks to the number of teeth.

TRANSFER
23C-77
>>W<< SPRING INSTALLATION Install with care. Do not make mistake when locating
each switch.
Detection switch name Connector
No. / Color
A Center differential lock 1 / Brown
detection switch
B 2WD/4WD detection switch 2 / Black
C Center differential lock 4 / Blown
operation detection switch
AK403513 D 4WD operation detection switch 6 / Black
Install the spring with its tapered end toward the ball. E High/low detection switch 3 / white
F 4LLc detection switch 5 / White
>>X<< PLUG INSTALLATION
CAUTION ADJUSTMENT OF TRANSFER
• Completely degrease the FIPG-applied sur- M1233030900060
face so that water and oil including the old SPACER SELECTION FOR ADJUST-
sealant cannot adhere to the surface coated MENT OF COUNTERSHAFT GEAR END
with the sealant. Never touch the degreased PLAY
surface by hand.
<Measurement using a solder>
point are about the middle between the bolts. CAUTION
• If soft solder is not available, select the
spacer in accordance with Plastigage method.
• If the spacer appropriate for the standard
select the spacer in accordance with Plasti-
gage method.
AK403514AB
Apply the sealant to the threads.

Specified sealant:
NOTE: The new plug is percolated with sealant, so Solder
sealant does not need to be applied. AK403499AB
1. Put solders (1.0 mm diameter, about 10 mm long)

>>Y<< DETECTION SWITCH INSTALLATION
in the illustrated positions of the transfer case
housing.
A
2. Install the countershaft gear into the transfer case.
B
C
4. Remove the transfer case plate and the
D countershaft gear, and then take out crushed
1 E solders.
4 5 6
2
F
5. If the solders have not crushed, use thicker
3 AK503496 AB solders (1.6 mm diameter, about 10 mm long) and
repeat steps 2 to 4.
TRANSFER
Plastigage
AK305233 Spacer AK402081 AB
6. Measure the thickness of the crushed solder with 7. Measure the width of the crushed Plastigage at its
a micrometer and select a spacer that will provide widest part using a scale printed on the Plastigage
the standard value. package.
Spacer thickness: (T − 0) to (T − 0.15) Standard value: 0 − 0.15 mm
T: The crushed solder thickness (For countershaft gear end play)
(For countershaft gear end play) INSPECTION
M1233013400114
<Easy select 4WD>

<Measurement using Plastigage>
4WD OPERATION DETECTION SWITCH
Plastigage
AK403499AC
AK500505
minals.
thickness. Switch Connector Continuity
condition terminals
3. Install the countershaft gear into the transfer case.
pressed
5. Remove the transfer case plate and the Switch end 1−2 Open
countershaft gear, and then take out crushed released
solders.
6. If the Plastigages have not crushed, replace the HIGH/LOW DETECTION SWITCH
spacer with a thicker one and repeat steps 3 to 5.
AK500510
TRANSFER
23C-79
Check for the continuity between the connector ter- <Super select 4WD>
minals. CENTER DIFFERENTIAL LOCK DETECTION
Switch Connector Continuity SWITCH, 2WD/4WD DETECTION SWITCH,
condition terminals CENTER DIFFERENTIAL LOCK OPERATION
Switch end 1−2 Open DETECTION SWITCH, 4WD OPERATION DETEC-
pressed TION SWITCH, HIGH/LOW DETECTION SWITCH
released
LOW DETECTION SWITCH
AK503422

minals.
AK500511 condition terminals
Check for the continuity between the connector ter- Switch end 1 − Body earth Open
minals. pressed
Switch Connector Continuity Switch end 1 − Body earth Conductive
condition terminals released
pressed 4LLc DETECTION SWITCH
released
AK503422

minals.
condition terminals
pressed
released
TRANSFER CASE PLATE
TRANSFER CASE PLATE

M1233024200222
19 ± 3 N·m
Apply automatic 1
transmission fluid
to all moving parts
AK700641AB
Disassembly steps
>>B<< 1. Bolt MB990938
2. Bearing retainer
MB990933
>>A<< 4. Oil seal
5. Baffle plate
6. Transfer case plate
REASSEMBLY SERVICE POINT

AKX00216 AD
1. Use socket wrench to install the oil seal.
Specified lubricant: 2. Use special tools to install the oil seal.
Mitsubishi Part No. 0101011 or equivalent • Installer bar (MB990938)
>>B<< BOLT INSTALLATION

INPUT GEAR
23C-81
Specified sealant:
NOTE: The new bolt is percolate with sealant, so
sealant does not need to be applied.
AK403506 AB
Apply the sealant to the threads.
INPUT GEAR
M1233015100249
Apply gear oil to

all moving parts
3
AK700643 AB

>>B<< 1. Snap ring <<A>> >>A<< 2. Ball bearing
3. Input gear
INPUT GEAR
DISASSEMBLY SERVICE POINT Use special tools to install the ball bearing.
• Installer adapter (MD998824)
MD998801 >>B<< SNAP RING INSTALLATION

Ball bearing
Standard value
Snap ring
AKX00253AC

AK500699AB
>>A<< BALL BEARING INSTALLATION the snap ring groove of the transfer input gear.
MD998812
play meets the standard value.
MD998813 (For input gear bearing end play)
MD998824
AK500669AB
COUNTERSHAFT GEAR
23C-83
COUNTERSHAFT GEAR
M1233024000273
Apply gear oil to

all moving parts
AK700644AB
Disassembly steps Use special tool Bearing remover (MD998801) to

<<A>> >>C<< 1. Ball bearing remove the ball bearing.
>>B<< 2. Snap ring
<> >>A<< 3. Roller bearing <> ROLLER BEARING REMOVAL
4. Counter shaft gear
MD998801
DISASSEMBLY SERVICE POINTS MD998368
MD998801
AKX00258 AC
Use special tools to remove the roller bearing.

• Bearing remover (MD998801)
• Bearing installer (MD998368)
AKX00257 AC
COUNTERSHAFT GEAR
REASSEMBLY SERVICE POINTS 1. Install the thickest snap ring that can be fitted into
>>A<< ROLLER BEARING INSTALLATION the snap ring groove of the counter shaft gear.
2. Make sure that the countershaft gear roller
MD998812
(For countershaft gear bearing end play)
MD998818
AKX00259 AC MD998812
1. Use special tools to install the roller bearing. MD998818

2. Install the spacer.
AKX00261AC
AKX00260
2-4WD SYNCHRONIZER
23C-85
2-4WD SYNCHRONIZER
M1233014200072
7
Apply gear oil to
all moving parts
9
8
6 10
5
4
3
9
2
AK503423AB

>>C<< 1. Snap ring >>A<< INNER SYNCHRONIZER RING INSTALLA-
2. 2-4WD Synchronizer hub TION
3. 2-4WD Synchronizer spring
>>B<< 4. Outer synchronizer ring
5. Synchronizer cone
>>A<< 6. Inner synchronizer ring
7. Drive sprocket
8. Bearing spacer
9. Needle bearing
10. Front side gear
AK503426AB

installation.
2-4WD SYNCHRONIZER
>>B<< OUTER SYNCHRONIZER RING CAUTION

INSTALLATION When any of the outer ring, inner ring or cone
1. Check to ensure that the clutch gear tooth surface
AK503427AB

installation.
>>C<< SNAP RING INSTALLATION AK503424

Snap ring
AK101272AD
Select and install the snap ring which adjusts the 2-

4WD synchronizer hub end play to standard value.
(For 2-4WD synchronizer hub end play)
AK503425

INSPECTION between the synchronizer ring and the gear.
M1233014300057
SYNCHRONIZER RING Limit: 0.3 mm
(For synchronizer ring clearance)
AK500672AB
CENTRE DIFFERENTIAL CASE
23C-87
CENTRE DIFFERENTIAL CASE
M1233013900056
Apply gear oil to

all moving parts
4
6
4
3 3
2
3
69 ± 10 N·m 4
4
1
AK503428 AB

>>A<< 1. Center differential case B >>A<< CENTER DIFFERENTIAL CASE B INSTAL-
2. Dowel pin LATION
3. Differential pinion
4. Thrust washer
5. Pinion shaft
6. Center differential case B Dowel pin
Dowel pin
AK101274AD
Pay attention to the position of the dowel pins when

reassembling, and make sure that the match marks
on the outside circumference are in alignment.
REAR OUTPUT SHAFT
REAR OUTPUT SHAFT

M1233013600141
<Easy select 4WD>
14
15
16
17
18
255 ± 10 N·m
12 9
11 3
13 4
6
8 7 Apply gear oil to
all moving parts
AK500645AB

<<A>> >>F<< 1. Lock nut 10. Synchronizer inner ring
<> >>E<< 2. Ball bearing 11. Synchronizer cone
3. Oil guide 12. Synchronizer outer ring
4. Sprocket spacer 13. Synchronizer spring
5. Steel ball >>D<< 14. Clutch sleeve
6. Drive sprocket <<C>> >>C<< 15. Clutch hub
7. Needle bearing <<C>> >>A<< 16. Stopper plate
8. Sprocket sleeve <<C>> >>A<< 17. Ball bearing
9. Steel ball 18. Rear output shaft
REAR OUTPUT SHAFT
23C-89
<Super select 4WD>
Apply gear oil to

all moving parts
1
4
AK101106 AC
Disassembly steps 1. Remove the lock nut from the shaft.

>>B<< 1. Snap ring
<> >>A<< 2. Ball bearing
3. Viscous coupling
MB991013

<<A>> LOCK NUT REMOVAL
AK500495AB
2. Hold the drive sprocket in a soft-jaw vise.

3. Shift the clutch sleeve to the drive sprocket side.
4. Use special tool Power steering lock nut special
spanner (MB991013) to remove the lock nut.
AK403516
REAR OUTPUT SHAFT
<> BALL BEARING REMOVAL NOTE: The clutch hub may fit loosely on the
<Easy select 4WD>
shaft, so that removal is possible without using a
press.
MD998801 REASSEMBLY SERVICE POINTS

>>A<< BALL BEARING / STOPPER PLATE
INSTALLATION
<Easy select 4WD>
MD998812
MD998813
AK403518AC
MD998814
<Super select 4WD>
MD998829
Ball bearing
MD998917
MD998801
AK403521AD
<Super select 4WD>

MD998812
AK101110AG
MD998814
1. Use special tool to support the ball bearing.

• Bearing remover (MD998801) <Easy select
4WD> MD998823
• Bearing remover (MD998817) <Super select
4WD>
AK101111 AD
2. Use a press to push at a rear end of the rear
output shaft, and then remove the radial ball 1. Fit the ball bearing and stopper plate onto the rear
bearing. output shaft.
NOTE: The bearing may fit loosely on the shaft, 2. Use special tools to press in the ball bearing.
so that removal is possible without using a press. • Bearing remover (MD998801) <Easy select
4WD>
<<C>> CLUTCH HUB / STOPPER PLATE / BALL • Installer cap (MD998812)
BEARING REMOVAL • Installer-100 (MD998813) <Easy select 4WD>
• Installer adapter (MD998823) <Super select
4WD>
• Installer adapter (MD998829) <Easy select
2-4WD clutch hub
MD998801 4WD>
Ball bearing >>B<< SNAP RING INSTALLATION
AK403520 AB
1. Place special tool Bearing remover (MD998801)

so that the load is applied at the bearing.
2. Use a press to push at the rear end of the rear
output shaft, and then remove the clutch hub and
ball bearing.
AK101112
REAR OUTPUT SHAFT
23C-91
1. Install the thickest snap ring that can be fitted in >>E<< BALL BEARING INSTALLATION
MD998812
2. Make sure that the rear output shaft bearing end
MD998814
(For rear output shaft end play) Ball bearing
MD998821
>>C<< CLUTCH HUB INSTALLATION MD998801
MD998812
MD998813 AK403526AD
MD998814 1. Use special tools to install the radial ball bearing.

MD998821 • Bearing remover (MD998801)
Installation • Installer cap (MD998812)
direction 2-4WD clutch hub
MD998801 • Installer adapter (MD998821)
NOTE: The ball bearing may be fitted loosely on
AK500686 AB the shaft, so that installation is possible without
using a press
1. Confirm the clutch hub installation direction, and
fit onto the rear output shaft.
>>F<< LOCK NUT INSTALLTION
2. Use special tools press in the clutch hub.
• Bearing remover (MD998801)
MB991013
NOTE: The clutch hub may fit loosely on the shaft,
so that installation is possible without using a
press.
AK500495AB
>>D<< CLUTCH SLEEVE INSTALLTION
1. Hold the drive sprocket in a soft-jaws vise.
2. Shift the clutch sleeve to the drive sprocket side.
3. Using special tool Power steering lock nut special
spanner (MB991013) tighten the lock nut to the
Installation specified torque 255 ± 10 N⋅m.
direction
AK500685AB
Check that the clutch sleeve is in the correct direc-

AK403516
4. Stake the two places of the lock nut as shown in

illustration.
FRONT OUTPUT SHAFT
INSPECTION 1. Push the synchronizer outer ring, synchronizer

M1233013700052 cone and the synchronizer inner ring to the drive
SYNCHRONIZER OUTER RING/SYN- sprocket in combined state, and then measure the
CHRONIZER CONE/SYNCHRONIZER indicated dimension of the drive sprocket and
INNER RING INSTALLATION synchronizer outer ring.
Limit: 0.3mm
(For synchronizer ring clearance)
2. In case that value is out of limit, exchange as the
synchronizer ring set.
AK403556
FRONT OUTPUT SHAFT

M1233006100081
Apply gear oil to

all moving parts
1
AK700646AB

<<A>> >>B<< 1. Ball bearing <<A>> >>A<< 2. Ball bearing
FRONT OUTPUT SHAFT
23C-93
DISASSEMBLY SERVICE POINT 1. Use special tool Bearing remover (MD998801) to
<<A>> BALL BEARING REMOVAL support the front output shaft.
MD998801
MD998801 >>B<< BALL BEARING INSTALLATION
MD998812
MD998813
AK403522AB
MD998818
MD998801
1. Use special tool Bearing remover (MD998801) to
support the ball bearing.
2. Press the front output shaft with a press and
remove the ball bearings. AK403523 AB
REASSEMBLY SERVICE POINTS 1. Use special tool Bearing remover (MD998801) to

support the front output shaft.
MD998812 • Installer-100 (MD998813)
MD998818
MD998801
AK403462 AB
SPEEDOMETER GEAR
SPEEDOMETER GEAR
M1233015700092
4
Apply gear oil to
all moving parts 1
5
AK700647AB

1. O-ring >>A<< SPRING PIN INSTALLATION
>>A<< 2. Spring pin
3. Driven gear Slit
4. O-ring
5. Sleeve
Spring pin
AK403524 AB
Drive the spring pin in, while making sure that slit
does not face gear shaft.
23D-1
GROUP 23D
AUTOMATIC
TRANSMISSION
OVERHAUL <V5A5>
CONTENTS
GENERAL INFORMATION . . . . . . . . 23D-3 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . 23D-54

OIL PUMP DISASSEMBLY AND REASSEMBLY
GENERAL SPECIFICATIONS . . . . . . 23D-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23D-54
SERVICE SPECIFICATIONS. . . . . . . 23D-6 REVERSE AND OVERDRIVE CLUTCH

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23D-55
TORQUE SPECIFICATIONS . . . . . . . 23D-7 REVERSE AND OVERDRIVE CLUTCH
DISASSEMBLY AND REASSEMBLY . . . . . 23D-55
................................. 23D-8 SECOND BRAKE . . . . . . . . . . . . . . . . 23D-58
SECOND BRAKE DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23D-58
ADJUSTMENT . . . . . . . . . . . . . . . . . . 23D-8 LOW REVERSE ANNULUS GEAR . . 23D-59
AND REASSEMBLY . . . . . . . . . . . . . . . . . . 23D-59
SEALANTS . . . . . . . . . . . . . . . . . . . . 23D-14
CENTRE SUPPORT . . . . . . . . . . . . . . 23D-60
LUBRICANT(S) . . . . . . . . . . . . . . . . . 23D-15
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23D-60
SPECIAL TOOLS. . . . . . . . . . . . . . . . 23D-15
UNDERDRIVE CLUTCH . . . . . . . . . . . 23D-62
TRANSMISSION AND TRANSFER. . 23D-20
TRANSMISSION AND TRANSFER DISASSEMBLY REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23D-62
AND REASSEMBLY . . . . . . . . . . . . . . . . . . 23D-20
DIRECT ANNULUS GEAR . . . . . . . . . 23D-64
TRANSFER CASE ADAPTER. . . . . . 23D-22
DIRECT ANNULUS GEAR DISASSEMBLY AND
TRANSFER CASE ADAPTER DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23D-64
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23D-22
DIRECT CLUTCH . . . . . . . . . . . . . . . . 23D-66
TRANSMISSION . . . . . . . . . . . . . . . . 23D-24
DIRECT CLUTCH DISASSEMBLY AND
TRANSMISSION DISASSEMBLY AND REASSEMBLY REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23D-66
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23D-24
23D-2
OUTPUTSHAFT SUPPORT. . . . . . . . 23D-68 2-4 SHIFT RAIL/H-L SHIFT RAIL DISASSEMBLY AND
OUTPUTSHAFT SUPPORT DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23D-88
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23D-68
TRANSFER DRIVE SHAFT . . . . . . . . 23D-89
VALVE BODY . . . . . . . . . . . . . . . . . . 23D-70 TRANSFER DRIVE SHAFT DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23D-89
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23D-70
FRONT OUTPUT SHAFT . . . . . . . . . . 23D-90
TRANSFER . . . . . . . . . . . . . . . . . . . . 23D-75 FRONT OUTPUT SHAFT DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23D-90
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23D-75
ADJUSTMENT OF TRANSFER . . . . . . . . . 23D-84 REAR OUTPUT SHAFT . . . . . . . . . . . 23D-91
REAR OUTPUT SHAFT DISASSEMBLY AND
TRANSFER CASE PLATE . . . . . . . . 23D-85 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23D-91
TRANSFER CASE PLATE DISASSEMBLY AND

REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23D-85 INPUT GEAR . . . . . . . . . . . . . . . . . . . 23D-93
INPUT GEAR DISASSEMBLY AND REASSEMBLY
COUNTERSHAFT GEAR. . . . . . . . . . 23D-86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23D-93
COUNTERSHAFT GEAR DISASSEMBLY AND

REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23D-86 SHIFTRAIL DRIVE GEAR . . . . . . . . . 23D-94
SHIFTRAIL DRIVE GEAR DISASSEMBLY AND
2-4 SHIFT RAIL/H-L SHIFT RAIL . . . 23D-88 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23D-94
GENERAL INFORMATION
23D-3
GENERAL INFORMATION
M1233000101860
TRANSMISSION MODEL
V5A5A-J-LH 4D56 DI-DC I/T KB4T
SECTIONAL VIEW <TRANSMISSION>
AK900017
23D-4 AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
GENERAL INFORMATION
SECTIONAL VIEW <TRANSFER>
AK602539
GENERAL INFORMATION
23D-5
HYDRAULIC CIRCUIT
1 2 3 4 5 28 29
6
7 8 30
9 10
11
13 14 15
16 12 17 18 19 20 31 32
21
22 23
24 26
27
25
AK603794AB
1. Reverse clutch 17. Low-reverse brake solenoid valve

2. Low/reverse brake 18. Second brake solenoid valve
3. Second brake 19. Underdrive clutch solenoid valve
4. Underdrive clutch 20. Overdrive clutch solenoid valve
5. Overdrive clutch 21. Torque converter pressure control valve
6. Damper clutch 22. Regulator valve
7. Fail-safe valve A 23. Manual valve
8. Fail-safe valve B 24. Oil filter
9. Damper clutch control valve 25. Oil pan
10. Switching valve 26. Oil pump
11. Cooler 27. Oil strainer
12. Low-reverse brake pressure control valve 28. Reduction brake
13. Second brake pressure control valve 29. Direct clutch
14. Underdrive clutch pressure control valve 30. Fail-safe valve C
15. Overdrive clutch pressure control valve 31. Reduction brake pressure control valve
16. Torque converter damper clutch control solenoid 32. Reduction brake solenoid valve
valve
M1233000201287
Item Specifications
Transmission model V5A5A
Lock-up Present
Transmission type 5 forward speeds, 1 reverse speed, fully automatic
2nd 2.057
3rd 1.421
4th 1.000
5th 0.731
Reverse 3.865
Transfer type 2-speed, constant mesh
Gear ratio High 1.000
Low 1.900
M1233000301035
Transmission
Item Standard value
Direct planetary carrier end play mm 0.25 − 0.71
Direct clutch end play mm 1.0 − 1.2
Transfer
Differential lock hub end play mm 0 − 0.08 −
2-4WD clutch hub end play mm 0 − 0.08 −
Clearance between outer synchronizer ring and drive sprocket mm − 0.3
Rear output shaft preload mm 0.12 − 0.24 −
23D-7
Rear output shaft end play mm 0 − 0.12 −
Countershaft gear bearing end play mm 0 − 0.08 −
Rear output shaft bearing end play mm 0 − 0.08 −
Rear output shaft annulus gear end play mm 0 − 0.08 −
M1233023101407
Transmission
Item N⋅m
Transfer to transfer case adapter tightening bolt 35 ± 6
Transmission case to transfer case adapter tightening bolt 48 ± 6
Anchor plug 98 ± 15
Reduction brake piston nut 18.5 ± 3.5
Converter housing to transmission case tightening bolt 48 ± 6
Clamp 11 ± 1
Harness bracket 11 ± 1
Lower valve body cover mounting bolt 11 ± 1
Transfer
Item N⋅m
Rear bearing retainer mounting bolt 19 ± 2
Transfer case plate to transfer case tightening bolt and nut 35 ± 6
Transfer case to chain cover tightening bolt 35 ± 6
Item N⋅m
Connector bracket 21 ± 4
Transmission wiring harness protector 5.0 ± 1.0
Rear cover to chain cover tightening bolt 35 ± 6
Shift actuator mounting bolt 11 ± 1
Front output sensor mounting bolt 11 ± 1
Rear output sensor mounting bolt 11 ± 1
Vehicle speed sensor mounting bolt 11 ± 1
Transfer case cover tightening bolt 19 ± 3
2WD-4WD switch 35 ± 6
4H switch 35 ± 6
Center differential lock switch 35 ± 6
2WD switch 35 ± 6
4LLC switch 35 ± 6

M1233030300091

diameter diameter height mm loops
mm mm
Damping valve spring 1.0 7.7 35.8 17
Torque converter pressure control valve spring 1.6 11.2 29.4 9.5
Fail-safe valve A spring 0.7 8.9 21.9 9.5
SNAP RING, SPACER, THRUST WASHER, THRUST RACE

AND PRESSURE PLATE FOR ADJUSTMENT
M1233023000980
Transmission
Thrust race (For adjustment of direct planetary carrier end play)

Thickness mm Identification symbol
1.6 None
1.8 None
2.0 None
2.2 None
AUTOMATIC TRANSMISSION OVERHAUL <V5A5> 23D-9
SNAP RING, SPACER, THRUST WASHER, THRUST RACE AND PRESSURE PLATE FOR ADJUSTMENT
1.6 Brown
1.7 None
1.8 Blue
1.9 Brown
2.0 None
2.1 Blue
2.2 Brown
2.3 None
2.4 Blue
2.5 Brown
2.6 None
2.7 Blue
2.8 Brown
2.9 None
3.0 Blue

1.4 None
1.6 None
1.8 None
2.0 None
2.2 None
2.4 None
2.6 None
1.48 Brown
1.53 Black
1.58 None
1.63 Brown

1.6 F
1.8 E
2.0 D
2.2 C
2.4 B

2.6 A
2.8 0
3.0 1
2.2 None
2.3 Blue
2.4 Brown
2.5 None

1.6 None
1.7 Blue
1.8 Brown
1.9 None
2.0 Blue
2.1 Brown
2.2 None
2.3 Blue
2.4 Brown
2.5 None
2.6 Blue
2.7 Brown
2.8 None
Snap ring (For adjustment of direct clutch end play)

1.9 Brown
2.0 None
2.1 Blue
2.2 Brown
2.3 None
2.4 Blue
2.5 Brown
2.6 None
2.7 Blue
2.8 Brown
2.9 None
3.0 Blue
Pressure plat (For adjustment of low/reverse brake end play)

1.8 E
2.0 D
2.2 C
2.4 B
2.6 A
2.8 0
3.0 1
Transfer
Spacer (For adjustment of input gear bearing end play)

2.30 None
2.35 Red
2.40 White
2.45 Blue
2.50 Green
Spacer (For adjustment of countershaft gear end play)

1.77 None
1.91 Blue
2.05 Brown
2.19 White
2.33 Red
Snap ring (For adjustment of countershaft gear bearing end play)

1.48 Blue
1.62 None

2.18 None
2.25 None
2.32 None
2.39 None
Snap ring (For adjustment of differential lock hub end play)

2.56 None
2.63 Red
2.70 White
2.77 Blue
2.84 Yellow
2.91 Green
2.98 Brown
Snap ring (For adjustment of 2-4WD clutch hub end play)

2.56 None
2.63 Red
2.70 White
2.77 Blue
2.84 Yellow
Snap ring (For adjustment of rear output shaft bearing end play)
2.26 None
2.33 Red
2.40 White
2.47 Blue
Snap ring (For adjustment of rear output shaft annulus gear end play)
1.90 None
1.94 None
1.98 None
2.02 None
2.06 None
2.10 None
Snap ring (For adjustment of rear output shaft preload)

1.57 None
1.63 None
1.69 None
1.75 None
1.81 None
1.87 None
1.93 None

1.99 None
2.05 None
2.11 None
2.17 None
2.23 None
2.29 None
2.35 None
2.41 None
2.47 None
2.53 None
2.59 None
2.65 None
2.71 None
Spacer (For adjustment of rear output shaft end play)

2.57 None
2.63 None
2.69 None
2.75 None
2.81 None
2.87 None
2.93 None
2.99 None
3.05 None
3.11 None
3.17 None
3.23 None
3.29 None
3.35 None
3.41 None
3.47 None
3.53 None
3.59 None
3.65 None
3.71 None
3.77 None
3.83 None
3.89 None
3.95 None
SEALANTS
SEALANTS
M1233000501170
Transmission
Transfer case adapter (transmission side) Mitsubishi Part No. MR166584 or equivalent
Sealing cap 3M™ AAD part No. 8672 or equivalent
Converter housing Mitsubishi Part No. MR166584 or equivalent
Oil pan
Transfer
Bearing retainer mounting bolt 3M™ STUD locking No. 4170 or equivalent
Transfer case Mitsubishi Part No. MD997740 or equivalent
Chain cover
Rear cover
Transfer case cover
This transmission has several areas where the form- Parts sealed with a FIPG can be easily removed
in-place gasket (FIPG) is used for sealing. To ensure without need for the use of a special method. In
tance.
FIPG Application
2. Use Mitsubishi genuine parts cleaner ing installation. Avoid operating the transmission or
(MZ100387) or equivalent to well degrease the letting oils or water come in contact with the sealed
LUBRICANTS
23D-15
LUBRICANTS
M1233000400374
Transmission
Transmission oil DiaQueen ATF SP III
Vaseline application parts White vaseline or Blue petrolatum
Transfer
Transfer oil Gear oil API classification GL-4 SAE 75W-85W
O-ring
Shift fork and shift rail
SPECIAL TOOLS
M1233000601122
Transmission
MB990929 Installer adapter Installation of transfer case adapter oil seal
MB990938 Installer bar Use with installer adapter
MD998727 Oil pan FIPG Removal of oil pan

cutter
D998727

SPECIAL TOOLS

MB991693 Reduction brake Adjustment reduction brake piston
stopper
MB991635 Socket Adjustment reduction brake piston
MB991634 Wrench Adjustment reduction brake piston
MB991603 Bearing installer Measurement of direct planetary carrier and

stopper center support end plays
MD998304 Oil seal installer Measurement of direct planetary carrier end

play
MB991632 Clearance dummy Measurement of brake reaction plate,

plate second brake and low/reverse brake end
plays
MD998913 Dial gauge Measurement of brake reaction plate,

extension second brake and low/reverse brake end
plays

SPECIAL TOOLS
23D-17
MD998316 Dial gauge Measurement of input shaft end play
support
MD998334 Oil pump oil seal Installation of oil pump oil seal
installer
MD999590 Spring Removal and installation of reverse and

compressor overdrive clutch spring retainer snap ring
MD998924 Spring Use with spring compressor

compressor
retainer
MB991629 Spring Measurement of overdrive clutch and

compressor underdrive clutch end plays
MB991789 Spring Adjustment reverse clutch end play

compressor
MB991630 Spring Removal and installation of center support

compressor snap ring and direct clutch snap ring
MD998337 Spring Removal and installation of underdrive

compressor clutch spring retainer snap ring
SPECIAL TOOLS
Transfer
MB990938 Installer bar Use with installer adapter
MD998801 Bearing remover Removal and installation of bearing
MD998368 Bearing installer Installation of bearing
MD998812 Installer cap Use with installer and installer adapter
MD998818 Installer adapter Installation of countershaft gear bearing,

(38) front output shaft bearing
MD998917 Bearing remover Removal and installation of bearing

SPECIAL TOOLS
23D-19
MD998814 Installer-200 Use with installer cap and installer adapter
MD998830 Installer adapter Installation of transfer drive shaft bearing

(66)
MD998198 Puller Installation of transfer drive shaft bearing
MD998821 Installer adapter Installation of front output shaft bearing

(44)
MD998813 Installer-100 Use with installer cap and installer adapter
MD998824 Installer adapter Installation of rear output shaft bearing

(50)
MD998826 Installer adapter Installation of transfer input gear bearing

(54)

M1233123300018
35 ± 6 N·m
4
5 3
7
9 48 ± 6 N·m
2 48 ± 6 N·m
35 ± 6 N·m
8
6 11 ± 1 N·m
26 ± 5 N·m
AK900862 AB

1. Transfer 6. Harness bracket
2. Cable end bracket 7. Air breather hose
3. Harness bracket 8. Air breather hose bracket
4. Harness bracket 9. Transmission
>>A<< 5. Transfer case adapter
23D-21
REASSEMBLY SERVICE POINT After squeezing out and applying the sealant on the
>>A<< TRANSFER CASE ADAPTER INSTALLA- transfer case adapter at the section indicated in the
TION illustration, install onto the transmission case.
Specified sealant:
CAUTION
surface by hand.
• Evenly squeeze out and apply the sealant so
that it is not excessive and dose not ooze out.
1.6 mm
diameter
AK403460AD

M1233007000258
7
2
1
5
6 4
A K X 0 0 0 1 4AC

1. Parking sprag shaft >>A<< OIL SEAL INSTALLATION
>>C<< 2. Parking sprag spring
3. Parking sprag MB990938
MB990936
5. Parking roller support shaft
6. Parking roller support
>>A<< 7. Oil seal
8. Transfer case adapter
AK403339AB

• Handle (MB990938)
23D-23
Specified lubricant: Specified sealant:
Mitsubishi Part No.0101011 or equivalent Mitsubishi 3M™ ATD Part No.8672 or equiva-
lent
>>B<< SEALING CAP INSTALLATION
>>C<< PARKING SPRAG SPRING INSTALLATION
Sealing cap
1.5 mm
1.5 mm
AK403557 AB
AK403340 AB
1. Press into the dimensions shown in the illustration
so that it is not slanted.
the illustration.
TRANSMISSION
TRANSMISSION
M1233101200024
11 ± 1 N·m 6
9
Apply automatic
5
to all moving parts
2
1
11 ± 1 N·m
8
17
7
19
11 ± 1 N·m
11 ± 1 N·m
4 20
3 18 21.5 ± 3.5 N·m
21 16
11 ± 1 N·m
11 ± 1 N·m
14 15
6.0 ± 1.0 N·m
6.0 ± 1.0 N·m 13
12
11
11 ± 1 N·m
AK900863AB
1. Torque converter 12. Magnet

2. Clamp 13. Oil filter
3. Input shaft speed sensor 14. O-ring
4. O-ring 15. Detent spring
5. Output shaft speed sensor 16. Valve body
6. O-ring 17. O-ring
7. Manual control lever 18. Snap ring
8. Inhibitor switch 19. Solenoid valve harness
10. Parking gear 21. O-ring
11. Oil pan
TRANSMISSION
23D-25
37
39
43
38 41 Apply automatic
40 transmission fluid
to all moving parts
42 38 before installation.
40
37
39
43
50
49
44 46
33 47
36 45
30 32
35
27 29 31
34 48
26 28 25
25 25
25
24
23
22
AK900864AB
22. Oil seal 37. Snap ring

23. Oil seal 38. Accumulator cover
24. Oil strainer 39. O-ring
25. Seal ring 40. Accumulator spring
26. Accumulator piston (for overdrive clutch) 41. Accumulator piston (for reduction brake)
27. Accumulator spring 42. Accumulator piston (for direct clutch)
28. Accumulator piston (for second brake) 43. Seal ring
29. Inner spring 44. Spring pin
30. Outer spring 45. Pin
31. Accumulator piston (for Low/reverse brake) 46. Manual control shaft
34. Accumulator piston (for underdrive clutch) 49. Detent lever
36. Outer spring
TRANSMISSION
53
52
23 ± 3 N·m
51
62
60
48 ± 6 N·m 58
63
56 61
Apply automatic
transmission fluid
57
55 AK900865AB

TRANSMISSION
23D-27
Apply automatic 70
transmission fluid
66
64
69
67 74
65 72
71
75
73
AK900817AB

TRANSMISSION
98 ± 15 N·m
80
78 99
97 98
76
101
81
23 ± 3 N·m
79 96
77 100
94
93
82
92
91
95 90
18.5 ± 3.5 N·m 89 87
84 88
86
Apply automatic
AK900818 AB
76. Snap ring 89. Reduction brake piston nut

77. Center support 90. Reduction brake piston
79. Thrust bearing No.9 92. Reduction brake piston adjusting rod
80. Direct annulus gear 93. Reduction brake spring
81. Thrust bearing No.12 94. Direct clutch
82. Direct planetary carrier 95. Thrust bearing No.13
83. Seal ring 96. Reduction brake band
84. Seal ring 97. Anchor plug
86. Reduction brake cover 99. Output shaft support
87. O-ring 100. Output shaft support gasket
88. Snap ring 101. Transmission case
TRANSMISSION
23D-29
DISASSEMBLY
CAUTION
any rags during disassembly. Use only nylon AK601366
cloth or paper towels if necessary. 4. Remove the output shaft speed sensor, and
• All removed parts must be washed clean. detach the O-ring from the output shaft speed
Metal parts may be washed in an ordinary sol- sensor.
• Clutch discs, plastic thrust plates and rubber Manual control lever
after washing.
and repaired, also disassemble and clean the
ATF cooler system.
AK900829AB
5. Remove the manual control lever.
AK603561
Inhibitor switch
1. Remove the torque converter.
2. Remove the clamp. AK601368AC
6. Remove the inhibitor switch.
Snap ring
AK900819
3. Remove the input shaft speed sensor, and detach Parking gear AK601369AC
the O-ring from the input shaft speed sensor.
TRANSMISSION
NOTE: The parking gear may be removed without

using a puller.
CAUTION
AK601373AC
11.Disconnect the harness connectors of the valve

body.
MD998727
AK601370AC

then remove the oil pan using the special tool Oil
pan FIPG cutter (MD998727) to remove the oil
pan.
O-ring AK601374
Oil filter
Oil temperature
sensor
AK601371AC
9. Remove the oil filter and O-ring.

AK601375AC

and then remove the valve body, three O-rings
and oil temperature sensor.
NOTE: The twenty valve body mounting bolts are
plated bolts.
AK601372
10.Remove the detent spring.
O-ring
AK601376 AC
TRANSMISSION
23D-31
NOTE: The O-rings are mounted on the transmis- Remove the snap ring, then remove the
sion case side as shown in the illustration. How- accumulator cover, O-ring and spring.
ever there may be cases where they will come off
No. Name
2 For second brake
Snap ring
5 For reduction brake
6 For direct clutch
AK601377AC

Oil strainer
Spring pin
AK601923AC

Oil seal
AK601378AC
Pin
14.Remove the oil strainer and two oil seals. Parking roller
rod
Manual control
shaft
Detent lever AK601924AC
17.Remove the pin, and then remove the manual

4 3 2 1 control shaft, two O-rings, detent lever and
AK601921AC parking roller rod.
6 5
AK601922 AC AK503505AB
15.Remove each accumulator piston, seal ring and 18.Remove the eight converter housing mounting
spring. bolts, and then converter housing.
TRANSMISSION
AK601926AC AK601929
19.Remove the ten oil pump mounting bolts. 24.Remove the reverse and overdrive clutch.
20.Install the special tool into the bolt hole shown in Thrust bearing No.3
the illustration.
MD998333
AK601930AD

AK601927AC

Thrust race No.1

Thrust bearing No.2
AK601931
26.Remove the overdrive clutch hub.
Thrust bearing No.4

AK601928AD

No.2.
the oil pump.
AK601932AD

TRANSMISSION
23D-33
AB601933 AK601937
28.Remove the reverse sun gear. 32.Remove the pressure plate, brake plates and
brake discs.
AK601934
AK601938
AK601935
30.Remove the second brake.
AK601936
31.Remove the return spring.

AK601940

TRANSMISSION
AK601941 AK601945
36.Remove the reaction plate and one brake disc. 40.Remove the snap ring.
AK601942 AK601946
37.Remove the snap ring. 41.Remove the center support.
Thrust bearing No.9
Thrust race No.8

AK601943 AK601947AD
38.Remove the brake plates, brake discs, and 42.Remove the thrust race No.8 and thrust bearing
pressure plate. No.9.
the center support.
AK601944

AK601948
43.Remove the direct annulus gear.

TRANSMISSION
23D-35
Reduction brake
piston cover
Thrust bearing No.12 Snap ring
AK601949 AD AK601953AC
44.Remove the thrust bearing No.12. 47.Remove the snap ring and then the reduction
NOTE: The thrust bearing No.12 may be attached brake piston cover and O-ring.
to the direct annulus gear.
Reduction brake piston
Snap ring
AK601954 AC
AK601950
48.Remove the snap ring and then the nut, reduction
45.Remove the direct planetary carrier. brake piston, seal ring, adjusting rod and spring.
Seal ring
AK601951AC AK601955
49.Remove the direct clutch.
Seal ring
AK601952AC
AK601956AD
46.Remove the two large and two small seal rings
from the direct planetary carrier. 50.Remove the thrust bearing No.13.
to the direct clutch.
TRANSMISSION
RESASSEMBLY
CAUTION
• Never reuse the gasket, O-ring, oil seal, etc.
Always replace with a new one when reas-
sembling.
• Never use grease other than blue petrolatum
jelly and white vaseline.
• Apply ATF to friction components, rotating
parts, and sliding parts before installation.
AK601957
Immerse a new clutch disc or brake disc in
51.Remove the reduction brake band. ATF for at least two hours before assembling
them.
• When replacing a bushing, replace the reas-
sembly which it belongs to.
• During the work, always use bare hands or
vinyl gloves. Do not use cotton gloves. Use
nylon cloth or paper towels when necessary.
Do not use shop towel.
• Change the oil in the cooler system.
AK601958
CAUTION
52.Remove the anchor plug and the O-ring. Never reuse a gasket.
Output shaft support Output shaft support
AK601959AC AK601959AC
53.Remove the eight output shaft support mounting 1. Install a new gasket and output shaft support.
bolts, and then remove the output shaft support 2. Tighten the eight output shaft support mounting
and gasket. bolts to the specified torque 23 ± 3 N⋅m.
TRANSMISSION
23D-37
Identification of thrust bearings and thrust races
AK900857 AC
Symbol OD mm ID mm Thickness mm
No.1 48.9 37 1.4
1.6
1.8
2.0
2.2
2.4
2.6
No.2 59 37 2.8
No.3 57 38.5 4.12
No.4 57 38.5 4.12
No.5 54.4 38.5 3.31
No.6 57 38.5 4.12
No.7 70 48.8 4.0
No.8 73 60 1.6
1.8
2.0
2.2
No.9 71.45 57 2.81
No.10 72 48.25 4.6
TRANSMISSION
Symbol OD mm ID mm Thickness mm
No.11 53 34.7 4.01
No.12 57 38.5 4.12
No.13 58 37.5 4.8
CAUTION
AK601958 AK601963AD
3. Install a new O-ring on the anchor plug and Take care not to mistake the thrust bearing No.13
tighten the anchor plug to the specified torque 98 mounting direction.
± 15 N⋅m.
AK601962AD
AK601957
5. Install the thrust bearing No.13 onto the direct
4. Install the reduction brake band. clutch retainer.
Anchor plug Reduction brake piston

CAUTION
adjusting rod Take care that the reduction brake band does not
come off the anchor plug and the hole for the
reduction brake piston adjusting rod.
AK601961AC
Fit the anchor bracket hole of the brake band onto

the anchor plug tip, and then insert the apply
bracket part into the hole for reduction brake
piston adjusting rod.
AK601955
6. Install the direct clutch.

TRANSMISSION
23D-39
11.Tighten the reduction brake piston adjusting rod
manually to the full.
MB991693
AK601964
7. Install the reduction brake spring.

AK601968 AC
12.Adjust the reduction brake piston by the following

procedure.
(1) Mount the special tool Reduction brake
stopper (MB991693) so that the reduction
brake piston does not rotate.
MB991635
AK601965
8. Screw the reduction brake piston adjusting rod

into the reduction brake piston manually to the
full.
9. Install new seal ring on the piston.
AK601969 AD
Snap ring
(2) Mount the torque wrench to the special tool
Socket (MB991635), and after repeating
tightening and turning back with a torque of 10
N⋅m twice, tighten the reduction brake piston
adjusting rod to the specified torque of 5 N⋅m.
Then turn the reduction brake piston adjusting
Reduction brake piston rod 5 1/2 to 5 3/4 turns back.
AK601966 AC
10.Press the reduction brake piston into the

transmission case, and then install the snap ring.
NOTE: Set the open of the snap ring at indicated
location.
AK601970
(3) Remove the special tool and tighten the

reduction brake piston nut manually.
AK601967
TRANSMISSION
14.Install new seal rings (two large pieces) onto the

MB991635 front end of the direct planetary carrier, and new
seal rings (two small pieces) onto the shaft of the
direct planetary carrier.
MB991634
AK601971 AD
(4) Using the special tool Wrench (MB991634),

tighten the reduction brake piston nut to the
specified torque 18.5 ± 3.5 N⋅m while fixing the
special tool Socket (MB991635) so as not to AK601973
rotate. 15.Insert the direct planetary carrier into the output

shaft support.
Snap ring
CAUTION
Reduction brake
piston cover
AK601972AC
13.Install a new O-ring on the reduction brake piston

cover, and then install the cover and the snap ring Direct planetary carrie
on the transmission case. AK601975AD
Take care not to mistake the thrust bearing No.12

Seal ring mounting direction.
AK601951AC
AK601974AD
Seal ring
16.Apply vaseline or petrolatum jelly on the thrust
the direct planetary carrier.
AK601952AC
TRANSMISSION
23D-41
CAUTION CAUTION
Confirm that the thrust bearing No.10 in the Measure and record the thickness of the thrust
direct annulus gear is still at the specified loca- race No.8 before assembling.
tion.
Thrust race No.8
AK601979 AD
AK601976
19.Apply vaseline or blue petrolatum jelly on the
17.Install the direct annulus gear. thrust race No.8 removed, and then install it on
CAUTION
CAUTION
• Install the center support so that the oil hole
Thrust bearing No.9 shown in the illustration faces the lower side
of the transmission case.
• Use care that the thrust race No.8 attached to
Direct annulus the rear side of the center support does not
gear
fall off.
AK601978 AD

mounting direction.
Thrust bearing No.9
AK601980
20.Install the center support.

MB991603
AK601977AD
18.Apply vaseline or petrolatum jelly to the thrust

bearing No.9, and then install on the direct
annulus gear.
AK601981AC
21.Using the transfer case adapter bolt, install

special tool Bearing installer stopper (MB991603).
TRANSMISSION
MD998304
MB991603
AK601982AC AK601984
22.Select the thrust race No.8 with the following 23.Using the following steps, select a suitable snap
procedure. ring for fixing the center support.
(1) Fix a dial gauge to the special tool Bearing (1) Install the snap ring which has been used for
installer stopper (MB991603). fixing the center support.
(2) Push the direct planetary carrier and direct
annulus gear in alternately, and measure the
end play of the direct planetary carrier. MB991603
NOTE: .
• When pushing in the direct planetary car-
rier, make sure that the center support does
not move.
• When pushing in the direct annulus gear,
use the special tool Oil seal installer
(MD998304). AK601985AC
(2) Alternately push in the direct planetary carrier

Thrust bearing No. 9 and center support, and measure the end play
of the center support.
NOTE: Be sure to push the direct planetary
carrier in fully until the center support contacts
the snap ring.
Standard value
Thrust race No.8
End play Center support
AK601983AD
(3) Replace the thrust race No.8 installed in step

19 with a suitable one which can bring the end
play of the direct planetary carrier to the
standard value. Then, reassemble. Snap ring
NOTE: Refer to the thickness recorded in step

19. Low/reverse brake piston AK601986AC
Standard value: 0.25 − 0.71 mm (3) Replace the snap ring for fixing the center
(For direct planetary carrier end play) support installed in step 23 (1) with a suitable
(4) Measure the end play again, and confirm that one so that the end play of the center support
it is within the standard value. is at the standard value. Then, reassemble.
NOTE: Carry this step out with the special tool Standard value: 0 − 0.16 mm
and dial gauge installed. (For center support end play)
TRANSMISSION
23D-43
(5) Replace the snap ring installed in step 24 (3)
with a suitable one so that the end play may
fall within the standard value. Then,
reassemble.
(For brake reaction plate end play)
CAUTION
AK601987
Take care to the shape and assembly direction of
24.Using the following steps, select a snap ring for the brake plates installed at section "A" shown in
adjusting the brake reaction plate end play and the illustration.
second brake end play, and a pressure plate for
adjusting the low/reverse brake end play. Second brake
Snap ring
brake piston.
MB991632 Snap ring A Return spring
MB991632
AK601990 AC
(7) Next, install the special tool instead of the

pressure plate for the second brake. Install the
four brake discs and three brake plates.
AK601988 AC
(8) Install the return spring, second brake and
(2) Install the special tool (MB991632) in the snap ring.
position shown in the illustration instead of the
pressure plate for the low/reverse brake. MD998913
Install the brake discs, brake plates and snap
ring. Moving
(3) Install the reaction plate and snap ring that amount
was used. MB991632
CAUTION
Take care to the assembly direction of the reac-
tion plate.
AK601991AC
(9) Install a dial gauge onto special tool

MD998913 Snap ring (MD998913) so that the end contacts the
special tool (MB991632). Move special tool
(MB991632) and measure the moving
amount.
End play Select a pressure plate with a thickness that
MB991632 corresponds to the measured moving amount
AK601989 AC
(4) Install a dial gauge onto special tool (For second brake end play)
(MD998913) so that the tool end contacts the
brake reaction plate. Measure the end play by
moving special tool (MB991632).
TRANSMISSION
Moving amount mm Pressure Moving amount mm Pressure

plate plate
Thickness ID Thickness ID
mm Symbol mm Symbol
1.2 or more − less than 1.4 1.6 F 1.5 or more − less than 1.7 1.8 E
1.4 or more − less than 1.6 1.8 E 1.7 or more − less than 1.9 2.0 D
1.6 or more − less than 1.8 2.0 D 1.9 or more − less than 2.1 2.2 C
1.8 or more − less than 2.0 2.2 C 2.1 or more − less than 2.3 2.4 B
2.0 or more − less than 2.2 2.4 B 2.3 or more − less than 2.5 2.6 A
2.2 or more − less than 2.4 2.6 A 2.5 or more − less than 2.7 2.8 0
2.4 or more − less than 2.6 2.8 0 2.7 or more − less than 2.9 3.0 1
2.6 or more − less than 2.8 3.0 1 (13)Remove the parts installed in steps 24 (1) to
(10)Remove the snap ring, second brake, return (12).
spring and special tool installed in step (8).
(11)Install the pressure plate selected in step (9), CAUTION
and install the return spring, second brake and
snap ring again.
Thrust bearing No.7
MD998913
A AK601993AD
MB991632
AK601992AC mounting direction.
(12)Install a dial gauge onto special tool
Thrust bearing No.7
(MD998913) so that the end contacts the
special tool (MB991632). Move special tool
(MB991632) and measure the moving
amount.
Select a pressure plate with a thickness that
(For low/reverse brake end play) AK601994AD

bearing No.7, and then install the bearing on the
rear side of the low/reverse annulus gear.
TRANSMISSION
23D-45
CAUTION 29.Install the pressure plate selected in step 24 (12),
Make sure that the thrust bearing No.7 attached brake discs and brake plates.
to the rear side of the low/reverse annulus gear
does not fall off.
AK601999

AK601995

Take care not to mistake the reaction plate instal-
lation direction.
AK601996

AK602000
AB601997
28.Install the wave spring onto the low/reverse brake

AK602001
piston.
AK601998
TRANSMISSION

Take care not to mistake the brake plate (reaction
plate side) installation direction.
Pressure plate
Brake plate
Reaction
plate
AK602005

AK602002AC
33.Install the brake discs, brake plates and pressure CAUTION

CAUTION Thrust bearing No.4
AK602007AD
End coil Take care not to mistake the thrust bearing No.4
installation direction.
AK602004AC
Thrust bearing No.4
Install the return spring so that the flat side faces
the back of the transmission.
Second brake
AK602006AD
Return spring
AK602003AC
gear.
TRANSMISSION
23D-47
CAUTION CAUTION
Thrust bearing No.3
Thrust bearing No.2

AK602009 AD AK602012 AD
Take care not to mistake the thrust bearing No.3 Take care not to mistake the thrust bearing No.2
mounting direction. mounting direction.
Thrust bearing No.3

Thrust bearing No.2
Overdrive clutch
hub AK602008AD AK602011AD
37.Apply vaseline or petrolatum jelly on the thrust 40.Apply vaseline or petrolatum jelly on the thrust
bearing No.3, and then install on the overdrive bearing No.2, and then install on the reverse and
clutch hub. overdrive clutch.
Thrust race No.1
AK602013AD
AK602010
39.Install the reverse and overdrive clutch. race No.1, and then install on the oil pump.
TRANSMISSION
CAUTION CAUTION
Never reuse the gasket. Evenly squeeze out the sealant so that it is not
insufficient or excessive.
MD998412
1.6 mm Diameter
AK602014AC
AK503506 AE
42.Install the special tool Guide (MD998412) at the
position shown in the illustration, and using this as 46.Apply sealant on the converter housing.
a guide, install the oil pump and gasket. Specified sealant:
43.Tighten the ten oil pump mounting bolts to the Mitsubishi Part No. MR166584 or equivalent
specified torque 23 ± 3 N⋅m.
MD998316
AK503505AB
AK602015AC
47.Install the converter housing.
44.Using the special tool Dial gauge support
48.Tighten the eight converter housing mounting
shaft, and replace the thrust race installed in step
41 with a suitable one so that the end play may Parking roller rod
meet the standard value. Then, reassemble.
45.Measure the end play again, and confirm that it is
within the standard value. Detent lever
AK602017AC

TRANSMISSION
23D-49
53.Hammer in the spring pin so that its slit is
perpendicular to the axial direction of the manual
O-ring
control shaft.
piston.
Outer spring
AK602018 AC
4 3 2 1
shaft.
Detent lever and Inner spring
parking roller rod
AKX00112 AD
Manual control shaft

AK602019AC
51.Install the assemble into the transmission case

4 3 2 1
together with the detent lever and parking roller AK601921AC
rod.
Accumulator piston
spring
AK602023AC
AK602020
52.Install the pin.
6 5
AK601922 AC
AK602021 55.Install each accumulator piston and spring, then

install accumulator cover with O-ring and snap
ring.
TRANSMISSION
NOTE: .
• Install the accumulator pistons to the original Snap ring
positions following the identification tags
attached when they were removed.
• The springs are identified by paint application
position as shown below. Assemble following
this table.
No. Name Identification paint
application position
1 For overdrive None AK602025AC
clutch 57.Install the solenoid valve harness, and then

2 For second Inner Applied on all surface secure the snap ring to connector groove.
brake including both ends NOTE: Install the harness so that it is oriented as
Outer Applied on half of shown in the illustration.
surface including both
ends
reverse surface including both
brake ends
surface of one side
4 For Inner Applied on half of O-ring
underdrive surface including both
AK602026AC
clutch ends
Outer Applied on half of 58.Install new three O-rings onto the transmission
surface including both case at the positions shown in the illustration.
ends
5 For reduction None Detent lever
brake
Manual valve pin
6 For direct None
clutch
CAUTION
Take care to the installation direction of the oil
seal. AK602027AC

Oil strainer valve pin into the detent lever groove.
Oil seal AK602024AC
oriented as shown in the illustration. AK602028AC

TRANSMISSION
23D-51
D
E B
O-ring
C
D
A D C D
AK602029AC AK602032 AC
61.Tighten the twenty valve body mounting bolts to 65.Install the new O-ring to the oil filter.
the specified torque 11 ± 1 N⋅m.
Bolt Length mm
A 25
B 30
C 40
D 45
E 55
AK602033
66.Install the oil filter.

67.Tighten the oil filter mounting bolt to the specified
torque 6.0 ± 1.0 N⋅m.
Ø2.5 mm
AK602030 AC
Magnet
62.Connect the connector to the valve body.
AK602034AC
68.Install three magnets.
CAUTION
Evenly squeeze out the sealant so that it is not
insufficient or excessive.
AK602031
69.Apply sealant on the oil pan.
63.Install the detent spring. Specified sealant:
64.Tighten the detent spring mounting bolt to the Mitsubishi Part No. MR166584 or equivalent
specified torque 6.0 ± 1.0 N⋅m.
TRANSMISSION
Inhibitor switch
AK602205AC AK601368AC
70.Install the oil pan. 73.Install the inhibitor switch.

71.Tighten the twenty oil pan mounting bolts to the 74.Tighten the two inhibitor switch mounting bolts to
specified torque 11 ± 1 N⋅m. the specified torque 11 ± 1 N⋅m.
CAUTION
Transmission side
AK900829AB
AK602036 AC
75.Install the manual control lever.
76.Tighten the manual control lever mounting nut to
out the spline cut faces the transmission side.
• Heat the parking gear to 160 − 180°C, and
put shaft.
Snap ring
AK700820AB
77.Install the O-ring to the output shaft.

Parking gear AK601369AC
AK601366
78.Install the output shaft speed sensor.

TRANSMISSION
23D-53
79.Tighten the output shaft speed sensor mounting 81.Install the input shaft speed sensor.
bolts to the specified torque 11 ± 1 N⋅m. 82.Tighten the input shaft speed sensor mounting
83.Install the Clamp.
CAUTION
converter.
AK700821AB
80.Install the O-ring to the input shaft.

A
AK900867AB

AK900819 meets the reference value.
Reference value: 20.9 mm
OIL PUMP
OIL PUMP
M1233001300358
1
Apply automatic
transmission fluid
AK602037AC
Disassembly steps 1. Use the special tool Oil seal installer (MD998334)
>>B<< 1. Seal ring to install the oil seal.
>>B<< 2. Seal ring 2. Apply ATF to the lip of the oil seal.
>>A<< 3. Oil seal
4. Oil pump
>>B<< SEAL RING INSTALLATION
REASSEMBLY SERVICE POINTS Install four new seal rings to the outer groove of the
oil pump, and apply ATF to the seal ring.
MD998334
AK602038AC
23D-55
M1233021200513
Apply automatic 14
transmission fluid
to all moving parts
19
21 12
22 13
2
15
1 16 6
18
20 8
3 9
4
10 5
7
17 14 10 8
22
21
20 15 6
2
1 12
18
16 13 3
11
19 11 9 7 5 4
AK700992 AB


MD999590 MD998924
AK602042
Snap ring
AK602040AC Align the two return spring holes with the two projec-
tions on the overdrive clutch piston, and then assem-
1. Set the special tools as shown in the illustration. ble the return springs.
ring. MD999590 MD998924

2. Install the D-rings in the reverse clutch retainer,
grooves. Make sure that they are not twisted or Snap ring
damaged when installing. AK602040AC
1. Set the special tools as shown in the illustration.

>>B<< REVERSE CLUTCH PISTON
INSTALLATION
A
the snap ring groove of the reverse clutch retainer.
4. Confirm that clearance between the snap ring and
spring retainer is the standard value.
B
AK705065AB end play)
Align the holes ("A" and "B") in the reverse clutch pis-
ton and reverse clutch retainer and then assemble. >>E<< CLUTCH PLATE / CLUTCH DISC /
1. Alternately assemble the clutch discs and clutch
plates in the reverse clutch piston.
23D-57
>>G<< CLUTCH PLATE / CLUTCH DISC /
Reaction
plate B
R1 A
Stamp
Clutch discs
AK602043AC
2. Install the reaction plate so that it is oriented as AK602046 AC

Rounded edge Reaction

>>F<< SNAP RING INSTALLATION Clutch plates plate
1. Install the snap ring in the reverse clutch piston
groove.
R Stamp
MD998924
MB991629
Clutch discs AK602047AC
1. Alternately assemble the clutch plates and clutch

discs in the reverse clutch retainer.
When assembling the clutch plates, align the
AK602044AC
section having no teeth (A in the illustration) with
the reverse clutch retainer hole (B in the
illustration).
Snap ring
Assemble in the same manner as the clutch plate
Standard value so that the section with no teeth ("A" in the
illustration) matches the retainer hole ("B" in the
illustration).
Reaction plate
AK602045AC
>>H<< SNAP RING INSTALLATION
2. Set the special tools as shown in the illustration, 1. Install the snap ring in the reverse clutch retainer
and compress the clutch element. groove.
• Spring compressor (MB991629) Standard value MD998924
• Spring compressor retainer (MD998924) MB991789
3. Confirm that the clearance between the snap ring
and reaction plate (overdrive clutch end play) is
the standard value. If the clearance is not at the
standard value, select a suitable snap ring and
adjust so that the clearance is within the standard
value.
(For overdrive clutch end play) AK602048 AC
2. Set the special tools as shown in the illustration,

and compress the clutch element.
SECOND BRAKE
• Spring compressor (MB991789) If the clearance is not at the standard value, select
• Spring compressor retainer (MD998924) a suitable snap ring and adjust so that the
3. Check that the clearance between the snap ring clearance is within the standard value.
and reaction plate (reverse clutch end play) is the Standard value: 1.5 − 1.7 mm
standard value. (For reverse clutch end play)
SECOND BRAKE
M1233021800236
4
1
2
3
AK602178 AC

>>A<< 3. D-ring
>>A<< 4. D-ring 2. Install the D-ring in the groove on the outer and
23D-59
M1233027100202
Apply automatic
transmission fluid
to all moving parts
7
8
4
9
2 3
1
10
5 6
AK602049 AC
>>C<< 5. Thrust bearing No.6
6. Output planetary carrier Stopper
>>B<< 7. Stopper plate plate
>>A<< 8. One-way clutch Claw
9. Snap ring

Groove
>>A<< ONE-WAY CLUTCH INSTALLATION
AK602051AC

gear. Make sure that the stopper plate claws are
AK602050 AC
CENTRE SUPPORT
CAUTION CAUTION
Take care not to mistake the thrust bearing No.6 Take care not to mistake the thrust bearing No.5
mounting direction. mounting direction.
Output planetary Overdrive planetary

carrier side carrier side
AK602052AC AK602053AC
Apply vaseline or petrolatum jelly on the thrust bear- Apply vaseline or petrolatum jelly on the thrust bear-
ing No.6, and then install on the output planetary car- ing No.5, and then install on the overdrive planetary
rier. carrier.
CENTRE SUPPORT
M1233010000162
Apply automatic
transmission fluid
to all moving parts
5
10
4 9
3 8
2
7
1
6
AK602054 AC

CENTRE SUPPORT
23D-61
Disassembly steps (Continued)
5. Spring retainer >>B<< O-RING INSTALLATION
6. Return spring
7. Low/reverse brake piston O-ring
>>A<< 8. D-ring
>>A<< 9. D-ring
10. Center support

MB991630
MD998924
AK602056 AC


Snap ring
MB991630
MD998924
AK602055AC
1. Set the special tools as shown in the illustration so

one-way clutch.
• Spring compressor retainer (MD998924) Snap ring
2. Screw in the special tool nut, and lightly press AK602055AC

3. Remove the snap ring. 1. Set the special tools as shown in the illustration.
REASSEMBLY SERVICE POINTS • Spring compressor retainer (MD998924)
>>A<< D-RING INSTALLATION 2. Screw in the special tool nut, and lightly press
1. Apply ATF to the D-ring. against the inner race of the one-way clutch.
2. Install the D-ring in the groove on the outer and 3. Install the snap ring.
UNDERDRIVE CLUTCH
UNDERDRIVE CLUTCH
M1233027300314
4
Apply automatic
transmission fluid
to all moving parts
2
1
11
12 13
10
9
8
5 7 1 3
6 7
10
11
12
9
6 13
2 4 AK700896AB
UNDERDRIVE CLUTCH
23D-63
Disassembly steps Align the two return spring holes with the two projec-
>>E<< 1. Snap ring tions on the underdrive clutch piston, and then
>>D<< 2. Reaction plate assemble the return springs.
>>D<< 3. Clutch disc
>>D<< 4. Clutch plate >>C<< SNAP RING INSTALLATION
6. Spring retainer
>>A<< 7. D-ring MD998337
>>A<< 10. D-ring
>>A<< 11. D-ring
>>A<< 12. D-ring

Snap ring AK602058AC
1. Set the special tool Spring compressor
MD998337 (MD998337) as shown in the illustration.
2. Compress the return spring, and install the snap
ring.
>>D<< CLUTCH PLATE / CLUTCH DISC /

B
A
Snap ring AK602058AC
1. Set the special tool Spring compressor

(MD998337) as shown in the illustration.
ring.
REASSEMBLY SERVICE POINTS AK602060 AC

1. Apply ATF to the D-ring. Rounded edge Clutch plates
2. Install the D-ring in the groove of the underdrive
clutch retainer and spring retainer. Make sure that
the D-ring is not twisted or damaged when
installing. W Stamp

Reaction plate
Clutch discs AK602061 AC
1. Alternately assemble the clutch plates and clutch

discs in the underdrive clutch retainer.
When assembling the four clutch plates, align the
section having no teeth (A in the illustration) with
the underdrive clutch retainer hole (B in the
illustration).
AK602059 2. Install the reaction plate so that it is oriented as
DIRECT ANNULUS GEAR
Assemble in the same manner as the clutch plate • Spring compressor retainer (MD998924)
so that the section with no teeth ("A" in the • Spring compressor (MB991629)
illustration) matches the retainer hole ("B" in the
illustration).
>>E<< SNAP RING INSTALLATION Snap ring

1. Install the snap ring in the groove of the Standard value
MD998924
Reaction plate
AK602063AC
3. Confirm that the clearance between the snap ring

and reaction plate (underdrive clutch end play) is
the standard value. If the clearance is not at the
standard value, select a suitable snap ring and
MB991629 adjust so that the clearance is within the standard
AK602062AC
value.
2. Set the special tools as shown in the illustration, Standard value: 1.6 − 1.8 mm
and compress the clutch element. (For underdrive clutch end play)
DIRECT ANNULUS GEAR

M1233028000048
Apply automatic
transmission fluid
to all moving parts
2 3 7
1
5 6
AK602064 AC
DIRECT ANNULUS GEAR
23D-65
Disassembly steps Apply vaseline or petrolatum jelly on the thrust bear-
1. Snap ring ing No.11, and then install on the underdrive clutch.
2. Output flange
>>B<< 3. Thrust bearing No.10 >>B<< THRUST BEARING No.10 INSTALLATION
4. Underdrive clutch hub
>>A<< 5. Thrust bearing No.11 CAUTION
6. Underdrive clutch Take care not to mistake the thrust bearing No.10
7. Direct annulus gear mounting direction.

>>A<< THRUST BEARING No.11 INSTALLATION
CAUTION
mounting direction.

AK602066AC
Apply vaseline or petrolatum jelly on the thrust bear-

ing No.10, and then install on the underdrive clutch
hub.
AK602065AC
DIRECT CLUTCH
DIRECT CLUTCH
M1233019400167
4
Apply automatic
transmission fluid
to all moving parts
2
1
3 7 10 11
12
11
10
9
8
5
5 7
6
12
1 2 4 6 8 9
AK602067AC
DIRECT CLUTCH
23D-67
Disassembly steps 1. Set the special tools as shown in the illustration.
>>D<< 1. Snap ring • Spring compressor (MB991630)
>>C<< 2. Reaction plate • Spring compressor retainer (MD998924)
>>C<< 3. Clutch disc 2. Compress the return spring, and install the snap
>>C<< 4. Clutch plate
ring.
<<A>> >>B<< 5. Snap ring
6. Spring retainer
>>A<< 7. D-ring >>C<< CLUTCH PLATE / CLUTCH DISC /
8. Return spring REACTION PLATE INSTALLATION
9. Direct clutch piston B
>>A<< 10. D-ring A
>>A<< 11. D-ring
12. Direct clutch retainer

MD998924
MB991630
AK602069 AC

Reaction plate
Sanp ring
R Stamp
AK602068AC
1. Set the special tools as shown in the illustration.

• Spring compressor retainer (MD998924) Clutch discs
AK602070 AC
ring. 1. Alternately assemble the clutch plates and clutch
discs in the reverse clutch retainer. Align the
REASSEMBLY SERVICE POINTS section having no teeth of the clutch plates (A in
the illustration) with the reverse clutch retainer
>>A<< D-RING INSTALLATION hole (B in the illustration).
2. Install the D-ring in the direct clutch piston and shown in the illustration. Assemble in the same
spring retainer groove. Make sure that the D-ring manner as the clutch plate so that the section with
is not twisted or damaged when installing. no teeth (A in the illustration) matches the retainer
MD998924
MB991630 1. Install the snap ring in the direct clutch retainer
groove.
Sanp ring
AK602068AC
OUTPUTSHAFT SUPPORT
Snap ring 2. Press the entire periphery of the reaction plate

with a force of 49 N, and confirm that the
clearance between the snap ring and reaction
plate (direct clutch end play) is the standard value.
If the clearance is not at the standard value, select
a suitable snap ring and adjust so that the
clearance is within the standard value.
(For direct clutch end play)
AK602071AC
Snap ring
Standard value
Reaction plate
AK602072AC
OUTPUTSHAFT SUPPORT
M1233029000052
Apply automatic
transmission fluid
to all moving parts
4
3
AK602073 AC
OUTPUTSHAFT SUPPORT
23D-69
1. Snap ring >>A<< ONE-WAY CLUTCH INSTALLATION
3. Seal ring
4. Output shaft support Output shaft
supoort
Identification
groove
One-way clutch
AK602074 AC
Install the one-way clutch in such a way that it will be

oriented in the direction shown.
VALVE BODY
VALVE BODY
M1233005500600
1
Apply automatic 11 ± 1 N·m
11 ± 1 N·m
transmission fluid
to all moving parts
5
7
6
4
2
8 3
6.0 ± 1.0 N·m
10
14
13
11
12 13
11 ± 1 N·m
15
14
AK602075 AC

>>F<< 2. Damping valve 9. Separating plate
>>F<< 3. Seal ring 10. Lower valve body gasket
>>F<< 4. Damping valve spring >>E<< 11. Steel ball (line relief)
>>F<< 5. Ball (orifice check ball) >>E<< 12. Spring
>>F<< 6. Steel ball (orifice check ball) >>D<< 13. Knock bushing
>>F<< 7. Spring
VALVE BODY
23D-71
Disassembly steps (Continued)
>>C<< 14. Knock bushing
>>B<< 15. Dowel pin
18
19
20 17
21
38
6.0 ± 1.0 N·m
16
22 24
25
23
32 30 27
29
28
35 33 26
transmission fluid
AK602076 AC

16. Solenoid support 28. Fail-safe valve A2
<<A>> >>A<< 17. Low/reverse brake solenoid valve 29. Fail-safe valve A spring
<<A>> >>A<< 18. Reduction brake solenoid valve 30. Fail-safe valve A1
<<A>> >>A<< 22. Damper clutch control solenoid 34. Stopper plate
valve 35. Stopper plug
27. Fail-safe valve A sleeve 38. Upper valve body
VALVE BODY
41
40 42
48 45 43
52 47 49 44 46
51 53 50
54 39
55
59 56
57
60 58 74
61
62 67
66
71 65
63
70
69
73 68
64
72
11 ± 1 N·m
Apply automatic
transmission fluid
to all moving parts
11 ± 1 N·m
AK602077 AC

39. Manual valve 53. Second brake pressure control
40. Roller valve
41. Low/reverse brake pressure 54. Second brake pressure control
control valve sleeve valve spring
42. Low/reverse brake pressure 55. Roller
control valve 56. Underdrive clutch pressure
43. Low/reverse brake pressure control valve sleeve
control valve spring 57. Underdrive clutch pressure
44. Stopper plate control valve
45. Fail-safe valve C sleeve 58. Underdrive clutch pressure
46. Fail-safe valve C control valve spring
47. Roller 59. Roller
48. Reduction brake pressure control 60. Overdrive clutch pressure control
valve sleeve valve sleeve
valve valve
valve spring valve spring
51. Roller 63. Stopper plate
52. Second brake pressure control 64. Regulator valve adjusting screw
valve sleeve 65. Regulator valve sleeve
66. Regulator valve spring
VALVE BODY
23D-73
Disassembly steps (Continued) >>C<< KNOCK BUSHING INSTALLATION
67. Regulator valve
68. Roller
sleeve
spring
72. Cover
73. Cover gasket
74. Lower valve body
<<A>> SOLENOID VALVE REMOVAL
Before removing the solenoid valves, make marks
with white paint, etc., so that these valves can be
9 mm
>>A<< SOLENOID VALVE INSTALLATION
1. Apply ATF, petrolatum jelly or vaseline to O-rings,
and install them to solenoid valves.
2. Following the marks made during removal, install AK602079 AC
each solenoid valve.
Install the knock bushing onto the lower valve body
position shown in the illustration.
>>B<< DOWEL PIN INSTALLATION
Dowel pin >>D<< KNOCK BUSHING INSTALLATION

6 mm
AK602078 AC
Install the dowel pin at the specified position on the

lower valve body.
4.5 mm
AK602080 AC
Install the knock bushing onto the lower valve body

position shown in the illustration.
VALVE BODY
>>E<< SPRING / STEEL BALL (LINE RELIEF) 1. Install the spring (4.5 mm in diameter, 15.4 mm in
INSTALLATION length) and the steel ball (6.4 mm in diameter)
onto the upper valve body position shown in the
illustration.
Steel ball 2. Install the ball (rubber) (6.4 mm in diameter) onto
the upper valve body position shown in the
illustration.
spring (7.7 mm in diameter, 35.8 mm in length)
Spring
onto the upper valve body position shown in the
AK602081AC illustration.
Install the spring (7 mm in diameter, 17.3 mm in
length) and the steel ball (6.4 mm in diameter) onto >>G<< CONTROL SHAFT INSTALLATION
the lower valve body position shown in the illustra-
tion. Manual valve
>>F<< SPRING / STEEL BALL (ORIFICE CHECK

BALL) / BALL (ORIFICE CHECK BALL) /
DAMPING VALVE SPRING / SEAL RING /
Control
DAMPING VALVE INSTALLATION shaft
AK602083AC

manual valve.
Ball (Rubber)
Seal ring Steel ball
Damping Spring
valve
Damping spring AK602082AC
TRANSFER
23D-75
TRANSFER
M1233006700674
35 ± 6 N·m 35 ± 6 N·m
8
35 ± 6 N·m 5 9 Apply gear oil to
all moving parts
2 6 10 before installation.
3 19 ± 3 N·m
7 35 ± 6 N·m
4 11 11 ± 1 N·m
18
17
12
13 35 ± 6 N·m
14
1
30
15
19 11 ± 1 N·m
32 31
16
27 26 11 ± 1 N·m 22
21 24
25
20 11 ± 1 N·m
28
29
23
35 ± 6 N·m
AK602084AC

1. Vacuum hose 17. Clip
>>X<< 2. 4LLC switch 18. Harness bracket
3. Gasket >>W<< 19. Transfer case cover
4. Steel ball >>V<< 20. Shift rail drive gear
>>X<< 5. 2WD switch >>V<< 21. Shift rail drive gear
6. Gasket 22. Dust seal guard
7. Steel ball 23. Dynamic damper
>>X<< 8. Center differential lock switch 24. Vehicle speed sensor
9. Gasket 25. O-ring
10. Steel ball 26. Rear output sensor
>>X<< 11. 4H switch 27. O-ring
12. Gasket 28. Front output sensor
13. Steel ball 29. O-ring
>>X<< 14. 2WD/4WD switch >>U<< 30. Shift actuator
15. Gasket 31. O-ring
16. Steel ball >>U<< 32. Main shaft rail
TRANSFER
33 34
Apply gear oil to 35 ± 6 N·m 37
all moving parts 36
47
41 39
35 ± 6 N·m
35
49 38
50 40 21 ± 4 N·m
52 45
54
44
57
5.0 ± 1.0 N·m
51 48 42
58 53 43
60
62
55 69
56
59
68 61
71 65
73
66
64
63
72 70
67
AK602085AC

>>T<< 33. Rear cover 53. Center differential planetary
>>S<< 34. Oil seal carrier
35. Snap ring 54. Viscous coupling
36. Sensor rotor <<A>> >>M<< 55. Chain
37. Steel ball <<A>> >>M<< 56. Front output shaft
>>R<< 38. Oil guide >>M<< 57. Drive sprocket
>>Q<< 39. Spacer 58. Needle bearing
40. Snap ring >>L<< 59. Synchronizer inner ring
>>P<< 41. Snap ring >>L<< 60. Synchronizer inner cone
42. Transmission wiring harness >>L<< 61. Synchronizer outer ring
protector 62. Synchronizer inner spring
43. Connector bracket >>K<< 63. Snap ring
44. Connector bracket >>K<< 64. 2-4WD clutch
45. Connector bracket <<A>> >>K<< 65. Sun gear
46. Clip 66. Needle bearing
47. Connector bracket 67. Wave spring
>>O<< 48. Chain cover >>J<< 68. 2-4WD clutch sleeve
>>N<< 49. Rear output shaft >>J<< 69. 2-4WD shift fork
50. O-ring >>I<< 70. Spacer
51. Needle bearing >>I<< 71. Steel ball
52. Snap ring >>H<< 72. Snap ring
73. Differential lock hub
TRANSFER
23D-77
85
Apply gear oil to
all moving parts
91 86
79
19 ± 2 N·m
83
84 90
35 ± 6 N·m
82
81
80
74 89
78 88
76 87
77
75
35 ± 6 N·m
AK602086 AC

74. Harness bracket 83. Low speed gear
>>G<< 75. Transfer case plate 84. Needle bearing
76. Needle bearing >>C<< 85. Rear bearing retainer
77. Countershaft gear 86. Transfer drive shaft
>>F<< 78. Spacer 87. Dust seal guard
>>E<< 79. H-L shift fork >>B<< 88. Oil seal
>>E<< 80. H-L clutch sleeve <> >>A<< 89. Oil pool cover
>>D<< 81. Snap ring 90. Oil guide
82. H-L clutch hub 91. Transfer case
TRANSFER

<<A>> CHAIN / FORNT OUTPUT SHAFT / SUN GEAR REMOVAL
RESASSEMBLY SERVICE POINTS
>>A<< OIL POOL COVER INSTALLATION
5 mm
1.9 mm
AK602087
Remove the chain, front output shaft and sun gear as

a set from the transfer case. AK602089AC
Install the oil pool cover on a new transfer case.

<> OIL POOL COVER REMOVAL Stake the projecting portions of the transfer so that
CAUTION the dimensions will be as illustrated.
The oil pool cover normally does not require dis-
assembly. Once it is removed, the transfer case >>B<< OIL SEAL INSTALLATION
cannot be reused.
MB990938
MB990932
AK602090AC
AK602088AC
Unstake the positions shown in the illustration to • Handle (MB990938)
remove the oil pool cover. • Installer adapter (MB990932)
ADJUSTMENT BEFORE REASSEMBLY
Spacer selection for adjustment of countershaft gear
end play. (Refer to adjustment of transfer - spacer Mitsubishi Part No. 0101011 or equivalent
selection for adjustment of countershaft gear end
play P.23D-84) >>C<< SEAL BOLT INSTALLATION
AK602091AC
1. Apply the specified sealant to the threads.

Specified sealant:
3M STUD locking No. 4170 or equivalent
TRANSFER
23D-79
NOTE: The new bolt does not require sealant appli- >>G<< TRANSFER CASE PLATE INSTALLATION
cation as it is precoated with sealant.
AK602095AC
1. Apply the specified grease to the illustrated

AK602092
position of the H-L shift rail inserting portion of the
transfer case plate.
1. Select a proper snap ring so that the end play of Specified lubricant:
the H-L clutch hub will have the standard value, Mitsubishi Part No. 0101011 or equivalent
and install the snap ring on the transfer drive
shaft.
(For H-L clutch hub end play)
>>E<< H-L SHIFT FORK AND H-L CLUTCH

SLEEVE INSTALLATION
AK602096AC
2. Face the notched portion of the input gear in the

illustrated direction (in the direction of the
countershaft gear bearing hole).
H-L shift fork
AK602093AC
1. Apply the specified grease to the H-L shift fork

shaft inserting portion, and install the H-L shift fork
and H-L clutch sleeve in combined state in the
transfer case.
Mitsubishi Part No. 0101011 or equivalent AK602097AC
3. Apply the specified sealant to the transfer case.

>>F<< SPACER INSTALLATION
Install the previously selected spacer (Refer to Specified sealant:
ADJUSTMENT BEFORE REASSEMBLY.) Mitsubishi Part No. MD997740 or equivalent
TRANSFER
CAUTION
If the sub gear does not readily come in mesh >>J<< 2-4WD SHIFT FORK AND 2-4WD CLUTCH
with the countershaft gear, rote the transfer drive SLEEVE INSTALLATION
shaft, etc. to securely engage it.
4. While making sure that the notched portion of the
input gear positioned in Step 2 is in alignment with
the gear portion of the countershaft, install the
transfer case palate.
>>H<< SNAP RING INSTALLATION
AK602100AC
Apply the specified grease to the 2-4WD shift fork

shaft inserting position and install the 2-4WD shift
fork and 2-4WD clutch sleeve in combined state in
the transfer case.
AK602098
Select a proper snap ring so that the end play of the >>K<< SUN GEAR / 2-4WD CLUTCH HUB / SNAP
differential lock hub will have standard value, and RING INSTALLATION
install it on the transfer drive shaft.
(For differential lock hub end play)
>>I<< STEEL BALL AND SPACER INSTALLATION
Steel ball
AK602101
1. Install the 2-4WD clutch hub on the sun gear.

2. Select the proper snap ring so that the end of play
of the 2-4WD clutch hub will have the standard
value, and install it on the sun gear.
AK602099AC
Install the steel ball in the illustrated position of the (For 2-4WD clutch hub end play)
transfer drive shaft and install the spacer with its oil
groove toward the chain cover.
TRANSFER
23D-81
>>L<< SYNCHRONIZER OUTER RING / 1. Set the chain in mesh with the drive sprocket and
SYNCHRONIZER CONE / SYNCHRONIZER INNER front output shaft sprocket and install them in the
RING INSTALLATION transfer case.
AK602102 AK602104AC
1. Combine the synchronizer outer ring, 2. Install the drive sprocket so that its illustrated
synchronizer cone and synchronizer inner ring, holes will mach the projecting portions of the
press then against the drive sprocket, and synchronizer cone.
measure the dimension shown in the illustration.
Limit: 0.3 mm >>N<< REAR OUTPUT SHAFT INSTALLATION
(For clearance between synchronizer outer
ring and drive sprocket)
2. If the dimension is out of the limit value, replace
them with a synchronizer ring set.
3. Apply gear oil to the synchronizer outer ring and
synchronizer inner ring.
AK602105 AC
>>O<< CHAIN COVER INSTALLATION

AK602103AC
4. Line up the notched portion of the 2-4WD clutch

hub with the projecting portion of the synchronizer
ring and install the ring on the 2-4WD clutch hub.
>>M<< DRIVE SPROCKET / FRONT OUTPUT

SHAFT / CHAIN INSTALLATION
AK602106 AC
1. Apply the specified grease to the indicated 2-4WD

shift rail inserting portion.
2. Apply the specified sealant to the illustration of the
chain cover.
AK602087 Specified sealant:
TRANSFER
>>P<< SNAP RING INSTALLATION

Concave
pprtion
AK602109AC
2. Measure the dimension of the rear cover concave

AK602107
portion at the illustrated position.
1. Install the snap ring in the bearing groove of the Standard value: 0 − 0.12 mm
rear output shaft. (For rear output shaft end play)
2. With the rear output shaft pressed against the
chain cover, measure the clearance between the
>>R<< OIL GUIDE INSTALLATION
chain cover and snap ring.
3. Select a snap ring whose thickness is the
Oil guide
dimension of the measured clearance plus the
standard value.
(For rear output shaft preload)
4. Remove the snap ring from the bearing groove of
the rear output shaft, install the selected snap
ring, and reinstall the removed snap ring in the
bearing groove of the rear output shaft. AK602694AB
Apply specified grease to the lip of the oil seal.

>>Q<< SAPCER INSTALLTION
CAUTION Mitsubishi Part No. 0101011 or equivalent
Measure the projection with the snap ring
installed.
>>S<< OIL SEAL INSTALLATION
Projection
MB990938
MB990932
AK602108 AC
AK602110AC
1. With the output shaft pressed toward the chain
Use special tools to install the oil seal in the rear
cover, measure the projection of the bearing from
cover.
the chain cover.
TRANSFER
23D-83
>>T<< REAR COVER INSTALLTION 2. Apply the specified grease to the O-ring.
3. Combine the main shift rail key with actuator key
and insert them in the transfer case.
>>V<< SHIFT RAIL DRIVE GEAR INSTALLATION
AK602111AC
Apply the specified sealant to the illustration of the

chain cover.
Specified sealant: Mark
Tird gear groove
>>U<< MAIN SHIFT RAIL AND SHIFT ACTUATOR AK602113AC
INSTALLATION Install the shift rail drive gear with its marked tooth in
mesh with the third gear groove of the each shift rail.
50.5mm
>>W<< TRANSFER CASE COVER INSTALLATION

B A
Vew A
Rod A
extends
AK602695AB
1. Contact a 12 voltage power supply across the

terminals of the actuator connector in a polarity
appropriate for causing the actuator motor to AK602114AC
move in the rod extending direction or retracting Apply specified sealant to the illustrated position of
direction until the amount of extension of the rod the transfer case cover.
is as indicated in the drawing. Specified sealant:
Terminal A Terminal B Rod Mitsubishi Part No. MD997740 or equivalent
movement
Power supply (+) Power supply (-) Extension >>X<< SWITCH INSTALLATION
Power supply (-) Power supply (+) Retraction C
E
A D
AK602115 AB
AK602112AC Install the switches as illustrated.

TRANSFER
Mounting Switch name Tube Connecto 5. If the solders have not crushed, use thicker
position color r color solders (1.6 mm diameter, about 10 mm long) and
repeat steps 2 to 4.
A 2WD/4WD Blue Black
switch
B 4LLC switch Black Brown
C 2WD switch Black Black
D 4H switch Green White
E Center Blue Brown
differential lock
switch
ADJUSTMENT OF TRANSFER AK602691
M1233030900071
6. Measure the thickness of the crushed solder with
SPACER SELECTION FOR ADJUST- a micrometer and select a spacer that will provide
MENT OF COUNTERSHAFT GEAR END the standard value.
PLAY Spacer thickness: (T − 0) to (T − 0.15)
<Measurement using a solder> T: The crushed solder thickness
CAUTION Standard value: 0 − 0.15 mm
• If soft solder is not available, select the (For counter shaft gear end play)
spacer in accordance with Plastigage method.
• If the spacer appropriate for the standard <Measurement using plastigage>
select the spacer in accordance with Plasti- Plastigage
gage method.
Solder
AK602692 AB

AK602094AC
1. Put solders (1.0 mm diameter, about 10 mm long) thickness.
in the illustrated positions of the transfer case 3. Install the countershaft gear into the transfer case.
housing.
2. Install the countershaft gear into the transfer case. to the specified torque of 35 ± 6 N⋅m.
3. Install the transfer case plate and tighten the bolts 5. Remove the transfer case plate and the
to the specified torque of 35 ± 6 N⋅m. countershaft gear, and then take out crushed
4. Remove the transfer case plate and the solders.
countershaft gear, and then take out crushed 6. If the plastigages have not crushed, replace the
solders. spacer with a thicker one and repeat steps 3 to 5.
TRANSFER CASE PLATE
23D-85
Spacer thickness: (T − 0) to (T − 0.15)
T: The crushed solder thickness
(For counter shaft gear end play)
Plastigage
Spacer AK602693AB
7. Measure the width of the crushed plastigage at its

widest part using a scale printed on the plastigage
package.
TRANSFER CASE PLATE

M1233024200244
19 ± 2 N·m
Apply gear oil to
all moving parts
6 1
4 AK602116 AC

>>B<< 1. Seal bolt >>A<< 4. Oil seal
2. Bearing retainer 5. Baffle plate
3. Transfer input gear 6. Transfer case plate
COUNTERSHAFT GEAR

>>A<< OIL SEAL INSTALLATION >>B<< SEAL BOLT INSTALLATION
MB990938
MB990933
AK602117 AC AK602091AC
Apply the specified sealant to the threads.

1. Apply specified grease to the lip of the oil seal.
Specified sealant:
3M STUD Locking No. 4170 or equivalent
NOTE: The new bolt does not require sealant appli-
2. Use special tools to install the oil seal. cation as it is precoated with sealant.
COUNTERSHAFT GEAR
M1233024000284
Apply gear oil to

all moving parts
5
2
1 3
AK602118 AC

<<A>> >>C<< 1. Ball bearing <> >>A<< 4. Roller bearing
>>B<< 2. Snap ring <> >>A<< 5. Inner race
>>A<< 3. Spacer 6. Counter shaft gear
COUNTERSHAFT GEAR
23D-87
DISASSEMBLY SERVICE POINTS 1. Use special tools to install the inner race.
MD998801 2. Install the roller bearing and spacer.
AK602119 AC

AK602122
<> SPACER / ROLLER BEARING / INNER
RACE REMOVAL 1. Install the thickest snap ring that can be fitted into
1. Remove the spacer and bearing. the snap ring groove of the counter shaft gear.
2. Make sure that the counter shaft gear roller
MD998801 Standard value: 0 − 0.08 mm
MD998368
(For counter shaft gear bearing end play)
MD998812
AK602120 AC MD998818
2. Using special tool, remove the inner race.

• Bearing installer (MD998368)
NOTE: The removal sequence of roller bearing
parts vary depending on the direction that the
roller bearing was installed, In come cases, the AK602123 AC
inner race, roller bearing and spacer may have to
be simultaneously removed. 1. Use special tools to install the ball bearing.
REASSEMBLY SERVICE POINTS • Installer adapter (38) (MD998818)
>>A<< INNER RACE / ROLLER BEARING /
SPACER INSTALLATION
MD998812
MD998818
AK602121AC
2-4 SHIFT RAIL/H-L SHIFT RAIL
2-4 SHIFT RAIL/H-L SHIFT RAIL

M1233031500054
1
Apply gear oil to
all moving parts 7
6
4
3
5
AK602124AC
Disassembly steps Apply the specified grease to the outer periphery of

>>B<< 1. Spring pin the shift fork mounting portion of the shift rail and
>>A<< 2. 2-4WD shift fork then assemble the shift fork and shift rail.
3. Spring Specified lubricant:
>>A<< 4. 2-4WD shift rail Mitsubishi Part No. 0101011 or equivalent
>>B<< 5. Spring pin
>>A<< 6. H-L shift fork
>>A<< 7. H-L shift rail >>B<< SPRING PIN INSTALLATION
REASSEMBLY SERVICE POINTS H-L shift rail 2-4WD shift rail
>>A<< SHIFT RAIL AND SHIT FORK INSTALLA-

TION
AK603210AC
Install the spring pin with its split toward the forward
end of the transfer.
AK602125AC
TRANSFER DRIVE SHAFT
23D-89
TRANSFER DRIVE SHAFT
M1233014500095
Apply gear oil to

all moving parts
AK602127AC
Disassembly steps 2. Press the transfer drive shaft with a press and
<<A>> >>A<< 1. Ball bearing remove the ball bearing.
MD998812
MD998814
MD998830
MD998917
MD998198
AK602129AC
AK602128AC
Use the special tools to install the ball bearing.
1. Use special tool Bearing remover (MD998917) to • Installer cap (MD998812)
support the ball bearing. • Installer-200 (MD998814)
• Puller (MD998198)
FRONT OUTPUT SHAFT
FRONT OUTPUT SHAFT

M1233006100070
Apply gear oil to

all moving parts
2
1
AK602130 AC
Disassembly steps 2. Press the front output shaft with a press and
<<A>> >>B<< 1. Ball bearing remove the ball bearing with sensor rotor.
2. Sensor rotor
<> >>A<< 3. Ball bearing <> BALL BEARING REMOVAL
DISASSEMBLY SERVICE POINTS MD998801

MD998801
AK602132 AC

AK602131AC 2. Press the front output shaft with a press and
REAR OUTPUT SHAFT
23D-91
REASSEMBLY SERVICE POINTS >>B<< BALL BEARING INSTALLATION
>>A<< BALL BEARING INSTALLATION MD998812
MD998813
MD998812
MD998821 MD998821
AK602134 AC
AK602133AC Use special tool to install the ball bearing with sensor
Use special tool to install the ball bearing. rotor.
• Installer cap (MD998812) • Installer cap (MD998812)
• Installer adapter (44) (MD998821) • Installer-100 (MD998813)
REAR OUTPUT SHAFT

M1233006400220
Apply gear oil to

all moving parts
2
AK602135 AC

>>C<< 1. Snap ring <<A>> >>A<< 4. Ball bearing
2. Annulus gear 5. Rear output shaft
>>B<< 3. Snap ring
REAR OUTPUT SHAFT
DISASSEMBLY SERVICE POINT >>B<< SNAP RING INSTALLATION

MD998801
AK602138
AK602136AC Select and install a proper snap ring so that the end
Use special tool Bearing remover (MD998801), play of the rear output shaft bearing will have the
remove the ball bearing. standard value.
REASSEMBLY SERVICE POINTS (For rear output shaft bearing end play)
MD998812
MD998814
MD998824
AK602137AC
AK602139
• Installer cap (MD998812) Select and install a proper snap ring so that the
• Installer-200 (MD998814) clearance between the annulus gear and rear output
• Installer adapter (50) (MD998824) shaft will have the standard value.
(For rear output shaft annulus gear end play)
INPUT GEAR
23D-93
INPUT GEAR
M1233015100272
Apply gear oil to

all moving parts
AK800993AB

>>B<< 1. Snap ring >>A<< BALL BEARING INSTALLATION
MD998812
DISASSEMBLY SERVICE POINT MD998826
MD998801
AK602142AC

AK602141AC

SHIFTRAIL DRIVE GEAR
>>B<< SNAP RING INSTALLATION 1. Install the thickest snap ring that can be fitted in
the snap ring groove of the transfer input gear.
(For input gear bearing end play)
AK602143
SHIFTRAIL DRIVE GEAR

M1233030500051
1
Apply gear oil to
all moving parts
5
6
AK602144AC

1. Spring pin >>A<< SIFT RAIL DRIVE GEAR INSTALLATION
>>A<< 2. Shift rail drive gear
3. Bearing
4. Shift rail drive gear shaft
5. Washer
6. Spring pin
Washer
Paint mark (blue)

AK602145AC
Install the shift rail drive gear such that its mark does
not face the washer.
25-1
GROUP 25
PROPELLER SHAFT
CONTENTS
GENERAL INFORMATION . . . . . . . . 25-2 PROPELLER SHAFT UNIVERSAL JOINT CHECK

...................................... 25-4
SERVICE SPECIFICATION(S) . . . . . 25-3
PROPELLER SHAFT . . . . . . . . . . . . . 25-6
LUBRICANT(S) . . . . . . . . . . . . . . . . . 25-3 PROPELLER SHAFT REMOVAL AND INSTALLATION
...................................... 25-6
PROPELLER SHAFT INSPECTION . . . . . . 25-8
SPECIAL TOOL(S) . . . . . . . . . . . . . . 25-4
PROPELLER SHAFT DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 25-10
25-2 PROPELLER SHAFT
GENERAL INFORMATION
GENERAL INFORMATION
M1251000100562
<2WD> • A 2-joint type propeller shaft for front propeller
• A 2 way split 3-joint type propeller shaft with cen- shaft, a 2-joint type propeller shaft for rear propel-
tre bearing is adopted. ler shaft are adopted. <Vehicles with Easy select
• A snap ring method of securing the journal bear- 4WD-A/T, Vehicles with Super select 4WD>
ing for the universal joint is adopted. • A snap ring method of securing the journal bear-
ing for the universal joint is adopted.
<4WD> • BJ is adopted for front propeller shaft. <Vehicles
• A 2-joint type propeller shaft for front propeller with Super select 4WD>
shaft, a 2 way split 3-joint type propeller shaft with
NOTE: BJ: Birfield Joint
centre bearing for rear propeller shaft are
adopted. <Vehicles with Easy select 4WD-M/T>
<2WD (except High rider)>
Rear propeller shaft
Front propeller shaft assembly
assembly
Centre bearing assembly
AC407335AC
<2WD (High rider)>
Front propeller shaft Rear propeller shaft
Centre bearing assembly

AC607601AE
<Vehicles with Centre bearing assembly

Easy select 4WD-M/T>
Rear propeller shaft Rear propeller shaft

(Front) (Rear)
Front propeller shaft

assembly AC407336 AC
PROPELLER SHAFT
25-3
<Vehicles with
Rear propeller shaft assembly
Easy select 4WD-A/T>
Front propeller shaft assembly

AC407337AE
<Vehicles with Rear propeller shaft assembly

Super select 4WD>
BJ
Front propeller
shaft assembly
AC510097AB
M1251000300265

Propeller shaft run-out mm − 0.6
Clearance between snap ring and snap ring groove mm 0.06 or less −
LUBRICANT
M1251000400347

Sleeve yoke Gear oil API classification GL-3 SAE 75W-85 As required
SPECIAL TOOLS
SPECIAL TOOLS
M1251000600266

MB990810 Side bearing puller Centre bearing removal
MB990810
MB990840 Universal joint remover Disassembly and

and installer reassembly of universal
joint
MB990840
MB991410 Collar
MB991410
ON-VEHICLE SERVICE
PROPELLER SHAFT UNIVERSAL JOINT <Correct state>
CHECK
M1251002400086
PROPELLER SHAFT VISUAL CHECK
1. Place the gearshift lever to the "N" (neutral Oil seal
position) <M/T> or the selector lever to the "N"
position <A/T>.
2. Then place the transfer shift lever to the "2WD"
position. <4WD>
3. Check the propeller shaft for dent, damage or AC808283AB
crack.
<Incorrect
state>
Oil seal lip

protruded
AC510591AB
4. Check the propeller shaft universal joint, oil seal

for crack or damage. If abnormality is recognized,
replace the universal joint with a new one.
PROPELLER SHAFT
ON-VEHICLE SERVICE
25-5
PROPELLER SHAFT UNIVERSAL JOINT PLAY
CHECK
1. Place the gearshift lever to the "N" (neutral
position) <M/T> or the selector lever to the "N"
position <A/T>.
2. Then place the transfer shift lever to the "2WD"
position. <4WD>
AC501206AC
3. Hold the tube of propeller shaft by one hand, and

apply force by the other hand to the flange yoke or
sleeve yoke in rotating direction, axial direction,
and perpendicular direction for checking
looseness. If looseness is recognized, replace the
universal joint with a new one.
PROPELLER SHAFT
PROPELLER SHAFT
M1251001001118

• Transmission Oil Draining (Refer to GROUP 22A, On- • Transfer Gear Oil Supplying (Refer to GROUP 22A, On-
vehicle service , GROUP 23A,On-vehicle service.) vehicle service , GROUP 23A,On-vehicle service .)
• Set the Transfer Shift Lever to "2H." <4WD> <4WD>
• Transfer Gear Oil Draining (Refer to GROUP 22A, On- • Transmission Oil Supplying (Refer to GROUP 22A, On-
vehicle service , GROUP 23A,On-vehicle service .) vehicle service , GROUP 23A,On-vehicle service.)
<4WD>
2, 3, 4
Gear Oil:
Gear oil API classification GL-3 54 ± 5 N·m<Except High rider>
SAE 75W-85 34 ± 5 N·m
103 ± 5 N·m<High rider>
2 1N
<2WD>
103 ± 5 N·m
4
<4WD>
34 ± 5 N·m
103 ± 5 N·m
1N
54 ± 5 N·m
3
N
32 ± 2 N·m
N
7
6
5
9.0 ± 2.0 N·m 8 AC804490AD

1. Self-locking nut <<A>> >>A<< 4. Rear propeller shaft assembly
<<A>> >>A<< 2. Propeller shaft assembly <Vehicles with Easy select 4WD-
<<A>> >>A<< 3. Rear propeller shaft assembly A/T, Vehicles with Super select
<Vehicles with Easy select 4WD- 4WD>
M/T> <<A>> >>A<< 5. Front propeller shaft assembly
<Vehicles with Easy select 4WD>
6. Spacer <Vehicles with Easy select
4WD>
PROPELLER SHAFT
PROPELLER SHAFT
25-7
Removal steps (Continued) REMOVAL SERVICE POINT
7. Front propeller shaft <Vehicles
<<A>> PROPELLER SHAFT ASSEMBLY/REAR
with Easy select 4WD>
<<A>> >>A<< 8. Front propeller shaft assembly
PROPELLER SHAFT ASSEMBLY/FRONT PRO-
<Vehicles with Super select 4WD> PELLER SHAFT ASSEMBLY REMOVAL
<2WD,
4WD-rear> Mating marks
AC003833 AG
<Vehicles with Mating marks

Easy select
4WD-front>
AC505406AG
<Vehicles with
Super select Mating marks
4WD-font>
AC804574AB
Make mating marks on the differential companion

flange and flange yoke and remove the propeller
shaft.
PROPELLER SHAFT
INSTALLATION SERVICE POINT <Vehicles with

Mating marks
>>A<< FRONT PROPELLER SHAFT ASSEMBLY/ Super select
REAR PROPELLER SHAFT ASSEMBLY/PROPEL- 4WD-font>
LER SHAFT ASSEMBLY INSTALLATION
CAUTION
• Tighten the installation bolts after removing
oil and grease from threads to prevent them
from loosening due to lubrication.
•
AC804574AB

Easy select
4WD-front>
Oil seal
ACX00642 AC
Be careful not to damage the lip section of the

transmission case or transfer case oil seal AC505406AG
when installing the propeller shaft.

<2WD,
4WD-rear> Mating marks
AC003833 AG
1. To reuse the propeller shaft, align the mating

marks that were made during removal, and then
install the propeller shaft assembly to the
companion flange.
2. When installing a new rear propeller shaft
assembly, if there is no phase alignment mark on
the companion flange at the differential side,
assemble while adjusting the hole phases of
propeller shaft flange and differential companion
flange.
INSPECTION
M1251001100394
• Check the sleeve yoke, centre yoke and flange
yoke for wear, damage or cracks.
• Check the propeller shaft for bends, twisting or
damage.
• Check the universal joint for smooth operation in
all directions.
• Check the centre bearing for smooth movement.
PROPELLER SHAFT
PROPELLER SHAFT
25-9
PROPELLER SHAFT RUN-OUT 2. If looseness is recognized, perform service work
or replace the propeller shaft with a new one.
PROPELLER SHAFT UNIVERSAL

GREASE CHECK
Perform grease-up with a grease gun, and check the
grease ejected from the oil seal when grease-up is
completed.
Judgement standard
•
ACX00643AB
Limit: 0.6 mm
Journal
PROPELLER SHAFT UNIVERSAL JOINT
PLAY CHECK
Grease nipple
Journal bearing AC501207AB
If blackish grease is evenly ejected from the oil seal

periphery, it is normal.
• If non-discoloured grease is ejected from the spe-
cific area (partially), the grease amount is insuffi-
cient and the oil seal is worn. Perform service
work or replace the propeller shaft with a new
AC501206
one.
1. Hold the tube of propeller shaft by one hand, and • If the white cloudy grease is ejected, water has
apply force by the other hand to the flange yoke or been mixed in grease. Replace the propeller
sleeve yoke in rotative direction, axial direction, shaft with a new one.
and perpendicular direction for checking
looseness.
PROPELLER SHAFT

M1251001200625
<2WD>
<Except High rider>
4
3
7
9 4
AC407357
187 ± 29 N·m
4 1
2 3
8
10
2 3 1
5 4
4 3
9 1
2
Universal joint kit
2 3 1
AC611838 AB
PROPELLER SHAFT
PROPELLER SHAFT
25-11
<High rider>
4
3
7
9 2
AC407357
4
187 ± 29 N·m 4 3
1
8
2
10 3
1
4 2 4 2
5 3
9
1
3 Universal joint kit
1
AC807773AB

<<A>> >>C<< 1. Snap ring 6. Rear propeller shaft
2. Grease nipple 7. Flange yoke
<> >>B<< 3. Journal bearing <<C>> >>A<< 8. Centre yoke
>>B<< 4. Journal <<D>> >>A<< 9. Centre bearing assembly
5. Sleeve yoke 10. Front propeller shaft
PROPELLER SHAFT
<4WD>
<Front propeller shaft: Vehicles with Easy select 4WD>
4
3
4 6
7
5 4
3 2 1
4
3 3 1
1 2
Universal joint kit

AC611900 AC
<Front propeller shaft: Vehicles with Super select 4WD>
4
3
6
4
5 54 ± 5 N·m
4 3 1
2 3 1
Universal joint kit

AC800360 AC
PROPELLER SHAFT
PROPELLER SHAFT
25-13
<Rear propeller shaft>
4 3
12 AC407357
<Vehicles with Easy select 4WD-A/T,

Vehicles with Super select 4WD> 4
9 5
8 2
4 2
1 3 1 3
<Vehicles with Easy select 4WD-M/T>

11 2
187 ± 29 N·m 3
2 4
8 12 4 10 2 5
4 13 1 3 1
1 3
4 2
3
1
Universal joint kit
AC800582 AB

<<A>> >>C<< 1. Snap ring 8. Sleeve yoke
2. Grease nipple 9. Rear propeller shaft
<> >>B<< 3. Journal bearing 10. Rear propeller shaft (rear)
>>B<< 4. Journal <<C>> >>A<< 11. Centre yoke
5. Flange yoke <<D>> >>A<< 12. Centre bearing assembly
6. Sleeve yoke 13. Rear propeller shaft (front)
7. Front propeller shaft
PROPELLER SHAFT
DISASSEMBLY SERVICE POINTS <<C>> CENTRE YOKE REMOVAL

External Internal Mating Mating marks
type type marks
Mating
marks
AC003847AD
AC003846 AC Make mating marks on the centre yoke and propeller

Make mating marks on the flange yoke and propeller shaft, and then remove the centre yoke.
shaft. Then, remove the snap rings.
<<D>>CENTRE BEARING ASSEMBLY REMOVAL
<> JOURNAL BEARING REMOVAL
CAUTION
Do not tap the journal bearings to remove them, MB990810
as this will upset the balance of the propeller
shaft.
MB990840
AC003863 AD
After removing the rubber mount, use special tool

side bearing puller (MB990810) to remove the centre
bearing assembly.
External type:
MB990840
Internal type: REASSEMBLY SERVICE POINTS
MB991410
MB990840 >>A<<CENTRE BEARING ASSEMBLY/CENTRE
YOKE INSTALLATION
Centre bearing Centre yoke
assembly
MB990840
External type:
MB990840
Internal type:
MB991410
AC611946 AB Lock nut
Propeller shaft
AC407357AB
1. Use the following special tools to press in the
journal bearing on one side, and take out the 1. Set the centre bearing assembly in the direction
journal bearing on the opposite side. shown in the figure and install it to the propeller
• Universal joint remover and installer (MB990840) shaft.
• Collar (MB991410) 2. Install, lining up the mating marks on the centre
2. Insert the special tools into the other side and yoke and the propeller shaft.
press the journal to remove the first journal 3. While tightening the nut, install the centre bearing
bearing that was pushed. assembly with the centre yoke.
PROPELLER SHAFT
PROPELLER SHAFT
25-15
>>B<< JOURNAL/JOURNAL BEARING • Collar (MB991410)
INSTALLATION
CAUTION
Be careful when pressing the journal bearings. If
they are pressed at an angle, the inside of the
journal bearings will be damaged.
MB990840
Mating marks AC003887 AC
3. Align the mating marks on the yoke and propeller

shaft, and install the propeller shaft journal
bearings.
External type Internal type
External type Internal type
Snap ring groove
Snap ring groove
AC003879 AC AC003888 AC
1. Use special tool universal joint remover and 1. Install a snap ring to one side of the journal.
installer (MB990840) to press the journal bearing External Internal
into the centre yoke, sleeve yoke or flange yoke type MB990840 type MB990840
until the snap ring groove is fully visible.
External Internal
type MB990840 type MB990840
Snap ring
Snap ring
MB991410
AC003889 AC
2. Use the following special tools at the opposite

MB990840 MB991410 side of the installed snap ring to press in the
AC003880 AC
journal bearing toward the snap ring.
2. Use the following special tools to press the • Universal joint remover and installer (MB990840)
opposite side journal bearing into the yoke. • Collar (MB991410)
• Universal joint remover and installer (MB990840)
PROPELLER SHAFT
CAUTION 4. If the clearance exceeds the standard value,

Always use snap rings of equal thickness on adjust by changing the thickness of the snap ring.
both sides. Thickness Thickness Identification
External type Internal type type 1 (mm) type 2 (mm) colour
1.28 1.50 −
Snap ring
A 1.31 1.55 Yellow
A 1.34 1.60 Blue
1.37 1.65 Purple
1.40 − Brown
Snap ring − 1.70 Black
AC003890 AC
− 1.75 Grey
3. Install the snap ring on the opposite side, and − 1.80 Brown
measure the clearance of the snap ring groove 1.85 Blue
−
with a thickness gauge.
Standard value (A): 0.06 mm or less − 1.90 −
26-1
GROUP 26
FRONT AXLE
CONTENTS
GENERAL INFORMATION . . . . . . . . 26-2 DRIVESHAFT ASSEMBLY REMOVAL AND

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 26-23
SERVICE SPECIFICATION(S) . . . . . 26-5 DRIVESHAFT ASSEMBLY DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 26-25
DRIVESHAFT ASSEMBLY INSPECTION
LUBRICANT(S) <4WD>. . . . . . . . . . . 26-5
(DISASSEMBLY AND REASSEMBLY) . . . . 26-27
BJ BOOT REPLACEMENT . . . . . . . . . . . . . 26-28
SEALANT(S) OR ADHESIVE(S) <4WD>
................................. 26-6 INNER SHAFT ASSEMBLY <4WD> . 26-30
INNER SHAFT ASSEMBLY REMOVAL AND
SPECIAL TOOL(S) . . . . . . . . . . . . . . 26-6 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 26-30
INNER SHAFT ASSEMBLY DISASSEMBLY AND
ON-VEHICLE SERVICE. . . . . . . . . . . 26-11 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 26-31
FRONT AXLE TOTAL BACKLASH CHECK <4WD>
...................................... 26-11 DIFFERENTIAL CARRIER AND FREE
FRONT AXLE GEAR OIL LEVEL CHECK <4WD> WHEELING CLUTCH <4WD> . . . . . . 26-33
...................................... 26-11
DIFFERENTIAL CARRIER AND FREE WHEELING
GEAR OIL CHANGE <4WD> . . . . . . . . . . . 26-11 CLUTCH REMOVAL AND INSTALLATION 26-33
WHEEL BEARING AXIAL PLAY CHECK . . 26-11 DIFFERENTIAL CARRIER AND FREE WHEELING
HUB BOLT REPLACEMENT . . . . . . . . . . . 26-12 CLUTCH INSPECTION . . . . . . . . . . . . . . . . 26-35
FREE WHEEL SOLENOID VALVE OPERATION FREE WHEELING CLUTCH ASSEMBLY
CHECK <4WD> . . . . . . . . . . . . . . . . . . . . . 26-12 DISASSEMBLY AND REASSEMBLY . . . . . 26-35
DIFFERENTIAL CARRIER ASSEMBLY
FRONT AXLE HUB ASSEMBLY . . . . 26-14 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 26-38
FRONT AXLE HUB ASSEMBLY REMOVAL AND DIFFERENTIAL CARRIER ASSEMBLY
INSTALLATION <2WD: except High Rider> 26-14 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 26-43
FRONT AXLE HUB ASSEMBLY REMOVAL AND
INSTALLATION <2WD: High Rider, 4WD> 26-16 SOLENOID VALVE AND VACUUM HOSE
KNUCKLE DISASSEMBLY AND REASSEMBLY <4WD except for RUSSIA> . . . . . . . . 26-51
<Vehicles for Russia (Option)> . . . . . . . . . . 26-19 SOLENOID VALVE AND VACUUM HOSE REMOVAL
FRONT AXLE HUB ASSEMBLY INSPECTION AND INSTALLATION . . . . . . . . . . . . . . . . . 26-51
...................................... 26-19
FRONT AXLE HUB ASSEMBLY DISASSEMBLY AND FRONT DIFFERENTIAL MOUNT <4WD>
REASSEMBLY <2WD except High rider> . 26-20 ................................. 26-53
FRONT AXLE HUB ASSEMBLY INSPECTION FRONT DIFFERENTIAL MOUNT REMOVAL AND
(DISASSEMBLY AND REASSEMBLY) . . . 26-22 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 26-53
DIFFERENTIAL MOUNTING INSULATOR
DRIVESHAFT ASSEMBLY <4WD>. . 26-23 REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 26-53
26-2 FRONT AXLE
GENERAL INFORMATION
GENERAL INFORMATION
M1261000101555
<2WD> • The wheel bearing uses a unit bearing (double
• The front hub assembly which uses a unit bearing tapered roller bearing) with strong transverse
(double tapered roller bearing) is mounted on the load bearing ability.
knuckle. • The driveshaft incorporates BJ-DOJ type con-
• ABS rotor for detecting the wheel speed is press- stant velocity joints with high transmission effi-
fitted into the front hub. <Vehicles with ABS> ciency for low vibration and noise.
• Due to the use of the inner shaft, the right and left
<4WD> driveshafts are approximately the same in length.
The front axle consists of the front hub assembly, This reduces noise, vibration and torque steer.
driveshaft, inner shaft, front differential, and it has the • ABS rotor for detecting the wheel speed is press-
following features: fitted to the BJ outer wheel. <Vehicles with ABS>
• A free-wheel mechanism that allows changeover BJ: Birfield Joint
between 2WD and 4WD while the vehicle is trav- DOJ:Double Offset Joint
elling.
SPECIFICATIONS
<2WD>
Item Specification
Wheel bearing Type Unit bearing (double taper roller bearing)
Bearing (OD × ID) mm Except High rider 75 × 40
High rider 88 × 50
<4WD>
Item Specification
Vehicles with Easy Vehicles with Super
select 4WD select 4WD
Wheel bearing Type Unit bearing (double Unit bearing (double
tapered roller bearing) tapered roller bearing)
Bearing (OD × ID) mm 88 × 50 88 × 50
Driveshaft Joint type Outer BJ BJ
Inner DOJ DOJ
Length (joint to joint) × LH 323 × 24 323 × 24
diameter mm RH 327.6 × 24 327.6 × 24
Inner shaft Length × diameter mm 342.7 × 31.5 342.7 × 31.5
Bearing (OD × ID) mm 62 × 35 62 × 35
FRONT AXLE
GENERAL INFORMATION
26-3
Item Specification
Vehicles with Easy Vehicles with Super
select 4WD select 4WD
Differential Reduction gear type Hypoid gear Hypoid gear
Reduction ratio 3.917 4.100*1, 3.917*2
Differential gear type Side gear Straight bevel gear × 2 Straight bevel gear × 2
(Type × number of Pinion gear Straight bevel gear × 2 Straight bevel gear × 2
gears)
Number of teeth Drive gear 47 41*1, 47*2
Drive pinion 12 10*1, 12*2
Side gear 14 14
Pinion gear 10 10
Bearing (OD × ID) mm Side 80.0 × 45.2 80.0 × 45.2
Front 68.3 × 30.2 68.3 × 30.2
Rear 76.2 × 36.5 76.2 × 36.5
NOTE: . CONSTRUCTION DIAGRAM
• *1: Vehicles for Europe (4AT) and Russia
<Except High rider>
• *2: Vehicles for Europe (Except 4AT)
Knuckle
Knuckle
ABS rotor Front hub

Front hub
ABS rotor
Wheel bearing
Wheel bearing
AC407388
AC407387AC
26-4 FRONT AXLE
GENERAL INFORMATION
<High rider>
Knuckle Knuckle
Front hub
Front axle shaft
ABS rotor
Front hub
ABS rotor Wheel bearing
Wheel bearing AC605518
Front axle shaft
AC605517 AB
<4WD>
Driveshaft (RH)
Freewheel
clutch assembly
Inner shaft
Driveshaft (LH)
Knuckle
Actuator
Front hub
Differential
Knuckle
ABS rotor DOJ
Driveshaft BJ
Wheel bearing
Front hub
Wheel bearing
AC407394 AB
AC805155AB
FRONT AXLE
26-5
M1261000301258

Front axle total backlash <4WD> mm − 11
Solenoid valve resistance <4WD> Ω 36 − 46 −
Wheel bearing axial play mm − 0
Hub rotary sliding resistance <2WD (except High rider)> N (N⋅m) − 77 (4.4)
Hub starting torque <2WD (High rider), 4WD> N⋅m − 2.5
Setting of DOJ boot length <4WD> mm 85 ± 3 −
Opening dimension of the When the BJ boot band (small) is 2.9 −
special tool (MB991561) crimped
<4WD> mm When the BJ boot band (large) is 3.2 −
crimped
Crimped width of the BJ boot band <4WD> mm 2.4 − 2.8 −
Clearance between the BJ boot (larger diameter side) and the 0.05 − 1.55 −
stepped phase of the BJ housing <4WD> mm
Clearance between the main shaft assembly and the clutch gear 0.05 − 0.3 −
<4WD> mm
Drive gear backlash <4WD> mm 0.11 − 0.16 −
Drive gear runout <4WD> mm − 0.05
Differential gear backlash <4WD> mm 0.01 − 0.250 −
Drive pinion turning torque Without oil seal 0.83 − 1.19 −
<4WD> N⋅m With oil Companion flange (oil 0.89 − 1.78 −
seal seal contacting area) with
anti-rust agent
Companion flange (oil 0.97 − 1.32 −
seal contacting area) with
gear oil applied
LUBRICANTS
M1261000401697

Dust seal Multipurpose grease SAE J310, NLGI No.2 or Inside of dust seal:
equivalent approx. 0.7g
Lip: approx. 0.5g
Differential gear oil Gear oil API classification GL-5 or higher SAE 1.2 L
80W
DOJ boot grease Repair kit grease 125 ± 10 g
BJ boot grease Repair kit grease 120 ± 10 g
26-6 FRONT AXLE
SEALANT AND ADHESIVE <4WD>
SEALANT AND ADHESIVE <4WD>

M1261000500204
Item Specified sealant and adhesive Remark

Differential cover and differential ThreeBond 1217 or equivalent Semi-drying sealant
carrier
Housing tube and differential carrier
Vent plug
Drive gear threaded hole LOCKTITE No.271 or No.270 or Anaerobic adhesive
equivalent
SPECIAL TOOLS
M1261000601691

MB990767 Front hub and Fixing of the hub
flange yoke holder
B990767
MB991618 Hub bolt remover Removal of the hub bolt
MB991618
MB990925 Bearing and oil • Wheel bearing inner race (outside)

seal installer set removal
• Press-fitting of wheel bearing
• Press-fitting of oil seal (differential
carrier)
MB990925
• Press-fitting of drive pinion rear
bearing outer race
• Press-fitting of drive pinion front
bearing outer race
MB991897 or Ball joint remover Ball joint removal
MB992011 NOTE: Use MB992011 to remove lower
arm upper arm ball joint.
NOTE: Steering linkage puller
AC106827
(MB990635 or MB991113) is also used
to disconnect knuckle and tie rod end
ball joint.
MB991033 Mount bushing Press-fitting of the dust seal <Vehicles
remover and for Russia (Option)>
installer base
B991033
FRONT AXLE
SPECIAL TOOLS
26-7
MB991561 Boot band Resin boot band installation <4WD>
crimping tool
MB991561
MB990906 Driveshaft Removal and installation of inner shaft

attachment <4WD> (Used together with MB990211)
MB990906
B MB990590 Rear axle shaft oil • Removal of differential carrier oil seal
A: MB990212 seal remover <4WD>
B: MB990211 A: Adapter • Removal and installation of inner
B: Slide hammer shaft <4WD> (Used together with
MB990906)
A MB990590
MB990560 Bearing remover • Removal of ABS rotor <2WD (except

High rider)>
• Removal and press-fitting of inner
shaft bearing <4WD>
MB990560
MB990955 Oil seal installer Dust seal installation <4WD>
MB990955
MD998917 Bearing remover Removal of front hub <2WD (except

High rider)>
MB991576 Base Wheel bearing installation <2WD

(except High rider)>
MB991576
A A: MB991017 A, B: Front hub • Measurement of hub starting torque

B: MB990998 remover and <2WD (High rider), 4WD>
C: MB991000 installer • Measurement of wheel bearing axial
B C: Spacer play <2WD (High rider), 4WD>
C NOTE: MB991000, which belongs to
AC100320AB
MB990998, should be used as a
spacer.
26-8 FRONT AXLE
SPECIAL TOOLS

MB991318 Lower arm bush Removal of clutch gear and bearing
arbour <4WD>
MB991318
MB990909 Working base Supporting of front differential carrier

assembly <4WD>
MB990909
MB991116 Adapter
MB990810 Side bearing Differential side bearing inner race

puller removal <4WD>
MB990810
MB990811 Differential side

bearing cap
MB990811
MB990339 Bearing puller Removal of drive pinion rear bearing

inner race <4WD>
MB990339
MB990648 Bearing remover
MB990648
MB991171 Pinion height Measurement of drive pinion height

A: MB990819 gauge set <4WD>
B: MB991170 A: Drive pinion
gauge
assembly
B: Cylinder gauge
FRONT AXLE
SPECIAL TOOLS
26-9
MB990326 Preload socket Measurement of wheel bearing turning
torque <2WD (High rider), 4WD>
MB990326
MB990685 Torque wrench • Measurement of wheel bearing

turning torque <2WD (High rider),
4WD>
• Measurement of drive pinion turning
torque <4WD>
MB990031 or Drive pinion oil Press-fitting of drive pinion oil seal

MB990699 seal installer <4WD>
MB990031
MB990799 Ball joint remover • Installation of freewheel clutch

and installer bearing <4WD>
• Installation of freewheel clutch oil
seal <4WD>
MB990799
MB990890 or Rear suspension Installation of freewheel clutch bearing

MB990891 bushing base <4WD>
MB990890
MD999547 Transmission rear Removal of front differential mount

oil seal installer insulator <4WD>
26-10 FRONT AXLE
SPECIAL TOOLS

MB990947 Lower arm Installation of front differential mount
bushing arbour insulator <4WD>
MB990947
MB990847 Rear suspension

bushing remover
and installer base
MB990847
MB990981 Mount bushing

remover and
installer
MB990981
MB990802 Bearing installer Press-fitting of the drive pinion rear

bearing inner race, and the side bearing
inner race <4WD>
MB990802
MB990925 Bearing and oil seal installer set

Tool Type Number O D mm
MB990925 A MB990926 39.0
MB990927 45.0
MB990928 49.5
MB990929 51.0
MB990930 54.0
A MB990931 57.0
Installer adapter
MB990932 61.0
C MB990933 63.5
Remover bar
MB990934 67.5
B MB990935 71.5
Installer bar MB990936 75.5
(Snap-in type)
MB990937 79.0
B MB990938 -
C MB990939 -
Toolbox
ACX02372AE
FRONT AXLE
ON-VEHICLE SERVICE
26-11
ON-VEHICLE SERVICE
FRONT AXLE TOTAL BACKLASH CHECK FRONT AXLE GEAR OIL LEVEL CHECK
<4WD> <4WD>
M1261001300151 M1262000900238
1. If the vehicle vibrates and produces a booming 1. Remove the under cover and filler plug.
sound due to an imbalance in the drive system,
measure the front axle total backlash by the
following procedure to see if the differential carrier
Gear oil
assembly requires removal.
(1) Park the vehicle on a flat, level surface.
(2) Move the transmission control lever to the Upper
neutral position or the selector lever to the "N" limit
position. Then place the transfer shift lever to Lower
limit 8 mm
the "2H" position. Apply the parking brake.
Raise the vehicle on a jack. AC505405 AB
Mating marks 2. Check that gear oil level is not 8 mm below the
bottom of filler plug hole.
3. If the gear oil level is lower than the lower limit,
add the specified gear oil until the level comes to
the lower portion of the filler plug hole.
Specified gear oil:
Gear oil API classification GL-5 or higher
SAE 80W
ACX00962 AC
4. Tighten the filler plug to the specified torque
(3) Turn the companion flange clockwise as far as (Refer to P.26-43).
it will go. Make the mating mark on the dust
cover of the companion flange and on the GEAR OIL REPLACEMENT <4WD>
M1262005100196
differential carrier. 1. Remove the under cover and filler plug.
2. Remove the drain plug and drain oil.
3. Tighten the drain plug to the specified torque
(Refer to P.26-43).
4. Add the oil until the level comes to the lower
portion of the filler plug hole.
Specified gear oil:
Gear oil API classification GL-5 or higher SAE
80W
ACX00964 AB Amount to use: 1.2L
(4) Turn the companion flange anti-clockwise as 5. Tighten the filler plug to the specified torque
far as it will go, and measure the amount of (Refer to P.26-43).
distance the mating marks moved.
WHEEL BEARING AXIAL PLAY CHECK
Limit: 11 mm M1261001100544
2. If the backlash exceeds the limit, remove the 1. Remove the caliper assembly and brake disc, and
differential carrier assembly and final drive gear. retain the caliper assembly with a wire and the like
Then check the differential gear meshing to prevent from falling (Refer to P.26-14, P.26-16).
condition and the looseness of the driveshaft or
inner shaft splines.
26-12 FRONT AXLE
ON-VEHICLE SERVICE
Plain washer
MB990767
AC711178 AB
3. Install the plain washer to the new hub bolt, and

AC602402AB
install the bolt with a nut.
2. Attach a dial gauge as shown in the illustration, 4. Install the brake disc and the caliper assembly
and then measure the axial play while moving the (Refer to P.26-14, P.26-16).
hub in the axial direction.
Limit: 0 mm FREE WHEEL SOLENOID VALVE
OPERATION CHECK <4WD: VEHICLES
3. If axial play exceeds the limit, disassemble the
front hub assembly and check the parts. FOR EUROPE (EXCEPT FOR RUSSIA)>
M1261001500155
4. After checking, install the brake disc and the 1. Remove the vacuum hoses (blue stripe, yellow
caliper assembly (Refer to P.26-14, P.26-16). stripe) from the solenoid valves.
2. Disconnect the harness connectors.
HUB BOLT REPLACEMENT
M1261001000718
1. Remove the caliper assembly and brake disc, and
Intake manifold
retain the caliper assembly with a wire and the like
to prevent from falling (Refer to P.26-14, P.26-16). Vacuum tank
MB991618
Solenoid valve A
MB990767
Solenoid valve B
AC711177AB
AC500363 AB
2. Use the following special tools to remove the hub
bolts. 3. Connect a hand vacuum pump to solenoid valve
• Front hub and flange yoke holder (MB990767) A and carry out the following inspections.
• Hub bolt remover (MB991618) (1) Even if the hand pump is operated with no
other operation, no negative pressure
develops.
(2) Negative pressure does not develop when
battery voltage is applied to solenoid valve A.
Meanwhile, negative pressure is maintained
when the vacuum hose of solenoid valve B is
blocked by bending.
(3) When battery voltage is applied to solenoid
valves A and B, negative pressure is
maintained.
FRONT AXLE
ON-VEHICLE SERVICE
26-13
Intake manifold
Vacuum tank valve B, negative pressure disappears.
valve A, negative pressure disappears.
5. Measure the resistance of the solenoid valves.
Standard value: 36 −46 Ω
Solenoid valve A
Solenoid valve B
AC500364 AB
4. Connect the hand vacuum pump to solenoid valve

B. Apply negative pressure and carry out the
following inspections.
(1) With no other operation, negative pressure is
maintained.
26-14 FRONT AXLE
FRONT AXLE HUB ASSEMBLY

M1261001701215
CAUTION
• For vehicles with ABS, do not strike the ABS rotors installed to the front hub assembly against
other parts when removing or installing the front hub assembly. Otherwise the ABS rotors will be
damaged.
• For vehicles with ABS, be careful not to strike the pole piece at the tip of the front wheel speed
sensor with tools during servicing work.
• Check the dust cover for cracks or damage by pushing it
with your finger.
113 ± 9 N·m
74 ± 14 N·m
2
N 9
10 3
1
N 5
40 ± 4 N·m
11
8
4 6 N 7 147 ± 29 N·m
19 ± 3 N·m
AC500366 AB
Removal steps 2. Secure the removed caliper assembly with a wire

1. Front wheel speed sensor <Vehicles or other similar material at a position where it will
with ABS> not interfere with the removal and installation of
<<A>> 2. Caliper assembly the hub and knuckle assembly.
<> 3. Brake disc
4. Shock absorber lower mounting bolt
<> BRAKE DISC REMOVAL
5. Split pin
<<C>> 6. Tie rod end connection
7. Split pin
<<C>> 8. Lower arm ball joint connection
9. Split pin
<<C>> 10. Upper arm ball joint connection
11. Hub and knuckle assembly

Bolts
<<A>> CALIPER ASSEMBLY REMOVAL (M8×1.25)
1. Remove the caliper assembly with brake hose. AC505409 AB
FRONT AXLE
26-15
If the brake disc is seized, install a M8 × 1.25-mm 1. Install special tool ball joint remover (MB991897
bolts as shown, and remove the disc by tightening or MB992011) as shown in the figure.
the bolts evenly and gradually. NOTE: Use MB992011 to remove lower and
upper arm ball joint.
<<C>>TIE ROD END/LOWER ARM BALL JOINT/
UPPER ARM BALL JOINT DISCONNECTION
Bolt
CAUTION
• Do not remove the nut from ball joint. Loosen
Parallel
it and use the special tool to avoid possible
damage to ball joint threads.
• Hang the special tool with cord to prevent it Knob Correct
from falling.
Cord Wrong AC106821AD
2. Turn the bolt and knob as necessary to make the

jaws of special tool parallel, tighten the bolt by
Nut MB991897 hand and confirm that the jaws are still parallel.
or NOTE: When adjusting the jaws in parallel, make
MB992011
sure the knob is in the position shown in the fig-
Bolt ure.
Ball joint AC208247AJ 3. Tighten the bolt with a wrench to disconnect the
tie rod end.
26-16 FRONT AXLE

(HIGH RIDER), 4WD>
M1261001701226
CAUTION
• For vehicles with ABS, do not strike the ABS rotors installed to the BJ outer race of driveshaft
against other parts when removing or installing the driveshaft. Otherwise the ABS rotors will be
damaged.
• *:Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle
on the earth in the unladen condition.
• Check the dust cover for cracks or damage by pushing it
with your finger.
<2WD (HIGH RIDER)>
113 ± 9 N·m
16
88 ± 10 N·m 19 2
74 ± 14 N·m
8
15 N
105 ± 10 N·m* 10
3
N 11
190 - 210 N·m
40 ± 4 N·m
6
12
14 1 9 ± 2 N·m
9 108 ± 10 N·m 18
147 ± 29 N·m 17
13 N 7 N5 4
AC605728 AD

1. Front wheel speed sensor <Vehicles 10. Shock absorber mounting bolt
with ABS> 11. Split pin
<<A>> 2. Caliper assembly <<C>> 12. Tie rod end connection
3. Brake disc 13. Split pin
4. Hub cap <<C>> 14. Lower arm ball joint connection
5. Split pin 15. Split pin
<> >>A<< 6. Front hub nut <<C>> 16. Upper arm ball joint connection
>>A<< 7. Washer 17. Dust cover
8. Front axle shaft assembly 18. Front hub assembly
9. Stabilizer link assembly to lower arm 19. Knuckle
connection
FRONT AXLE
26-17
<4WD>
AC500386
113 ± 9 N·m
15
88 ± 10 N·m 18 2
74 ± 14 N·m
14 N
105 ± 10 N·m* 9
3
N 10
190 - 210 N·m
40 ± 4 N·m
11 6
8 13 1 9 ± 2 N·m
108 ± 10 N·m 17
147 ± 29 N·m 16
12 N 7 N5 4
AC500367AE
Removal steps 2. Secure the removed caliper assembly with a wire

1. Front wheel speed sensor <Vehicles or other similar material at a position where it will
with ABS> not interfere with the removal and installation of
<<A>> 2. Caliper assembly the hub assembly and knuckle.
3. Brake disc
4. Hub cap
<> FRONT HUB NUT/DRIVESHAFT NUT
5. Split pin
<> >>A<< 6. Driveshaft nut REMOVAL
>>A<< 7. Washer CAUTION
8. Stabilizer link assembly to lower arm Do not apply pressure to wheel bearing by the
connection vehicle weight to avoid possible damage when
9. Shock absorber mounting bolt driveshaft nut is loosened.
10. Split pin
<<C>> 11. Tie rod end connection
12. Split pin
<<C>> 13. Lower arm ball joint connection
14. Split pin
16. Dust cover
17. Front hub assembly
<<D>> 18. Knuckle
MB990767
REMOVAL SERVICE POINTS AC102462 AC
<<A>> CALIPER ASSEMBLY REMOVAL
Use special tool front hub and flange yoke holder
1. Remove the caliper assembly with brake hose.
(MB990767) to fix the hub and remove the front hub
nut or driveshaft nut.
26-18 FRONT AXLE
<<C>> TIE ROD END/LOWER ARM BALL JOINT/ <<D>> KNUCKLE REMOVAL
UPPER ARM BALL JOINT DISCONNECTION When removing the knuckle, retain the driveshaft
CAUTION with a wire and the like to prevent from falling.
• Do not remove the nut from ball joint. Loosen
it and use the special tool to avoid possible INSTALLATION SERVICE POINT
damage to ball joint threads. >>A<< WASHER/ FRONT HUB NUT/DRIVESHAFT
• Hang the special tool with cord to prevent it NUT INSTALLATION
from falling. CAUTION
Before securely tightening the front hub nut or
Cord
driveshaft nuts, make sure there is no load on the
wheel bearings. Otherwise the wheel bearings
will be damaged.
<2WD (High Rider)>
Nut MB991897
or Washer
MB992011
Bolt
Ball joint AC208247AJ
1. Install special tool ball joint remover (MB991897

or MB992011) as shown in the figure.
NOTE: Use MB992011 to remove lower and MB990767
AC606055AC
upper arm ball joint.
<4WD>
Bolt Washer
Parallel
Knob Correct
MB990767 AC607861AC
Wrong AC106821AD
1. Be sure to install the washer in the specified

direction.
hand and confirm that the jaws are still parallel. 2. Using special tool front hub and flange yoke
holder (MB990767), tighten the front hub nut or
NOTE: When adjusting the jaws in parallel, make
driveshaft nut to the specified torque. At this time,
tighten the front hub nut or driveshaft nut to the
ure.
specified torque in expectation of final tightening.
3. Tighten the bolt with a wrench to disconnect the
Tightening torque: 190 − 210 N⋅m
tie rod end.
3. If the pin hole do not align with the pins, tighten
the driveshaft nut (less than 210 N⋅m) and find the
nearest hole then bend the split pin to fit it.
FRONT AXLE
26-19
KNUCKLE DISASSEMBLY AND
REASSEMBLY <VEHICLES FOR RUSSIA
(OPTION)>
M1261003200105
1
2
AC809410AB
Disassembly steps Specified grease: Multipurpose grease SAE

1. Knuckle J310, NLGI No.2 or equivalent
>>A<< 2. Dust seal Amount to use: Inside of dust seal: Approx.
0.7 g, Lip: Approx. 0.5g
>>A<< DUST SEAL INSTALLATION INSPECTION
M1261001800338
• Check the hub for cracks and spline for wear.
• Check the knuckle for cracks.
MB991033
• Check for defective bearing.
NOTE: If the meshing of the wheel bearing outer
race and the knuckle, or of the wheel bearing
inner race and the hub, is loose, replace the
bearing or damaged parts.
HUB STARTING TORQUE CHECK <2WD (HIGH
RIDER), 4WD>
AC809411AB
1. Press-fit the new dust seal into the knuckle by

using special tool mount bushing remover and MB991000
installer base (MB991033). MB991017
190 - 210 N·m

Tighten the nut
Knuckle with the bolt secured
AC500594 AC
Inside of 1. Tighten the following special tools to the specified

dust seal Dust seal torque, and then press-in the hub into the knuckle.
lip • Front hub remover and installer (MB991017)
AC809412AB
• Spacer (MB991000)
2. Apply the multi-purpose grease around the inside 2. Rotate the hub in order to seat the bearing.
and lip of the dust seal.
26-20 FRONT AXLE
WHEEL BEARING AXIAL PLAY CHECK <2WD

(HIGH RIDER), 4WD>
MB990685
MB991000
190 - 210 N·m
Tighten the nut
with the bolt
MB990326 secured
MB991017
AC711871AB
3. Measure the hub starting torque by using the

AC500596 AB
following special tools.
• Torque wrench (MB990685) 1. Measure to determine whether the wheel bearing
• Preload socket (MB990326) axial play is within the limit or not by using the
Limit: 2.5 N⋅m following special tools.
• Front hub remover and installer (MB991017)
4. The starting torque must be within the limit and
• Spacer (MB991000)
the hub rotation must be smooth.
Limit: 0 mm
2. If the play is not within the limit range while the nut
is tightened to 190 − 210 N⋅m, the bearing, hub
and/or knuckle have probably not been installed
correctly. Replace the bearing and re-install.
DISASSEMBLY AND REASSEMBLY <2WD

M1261001900540
1
2
3
4
226 ± 29 N·m 5
N 7
6
9.0 ± 2.0 N·m
AC602034AB

1. Dust cover <<C>> 7. Wheel bearing
<<A>> 2. ABS rotor 8. Knuckle
3. Nut Reassembly steps
4. Washer assembly 8. Knuckle
5. Snap ring >>A<< 7. Wheel bearing
<> 6. Hub 6. Hub
FRONT AXLE
26-21
Reassembly steps (Continued) <<C>> WHEEL BEARING REMOVAL
5. Snap ring
4. Washer assembly
3. Nut
2. ABS rotor
1. Dust cover Bearing cage,
>>B<< • Hub rotary sliding torque check roller
>>C<< • Wheel bearing axial play check bearings

Oil seal
<<A>> ABS ROTOR REMOVAL
AC500585AB
ABS rotor
1. Crush the bearing cage by using chisel etc., and
MB990560
remove roller bearings from the wheel bearing
inner race (outside).
2. Remove the oil seal.
CAUTION
When removing the inner race (outside) from the
hub, be careful not to damage the hub.
AC500581AB
Grinder
Use special tool bearing remover (MB990560) to pull
out the ABS rotor from the hub.
<> HUB REMOVAL

Inner race
CAUTION (outside)
When the hub has been removed, always replace
the wheel bearing with a new part because wheel
bearing frictional surface will be damaged when
removing the hub. AC502019AB
Knuckle 3. Fix the hub and shave off the wheel bearing inner
MD998917
race (outside).
Chisel
Hub
Inner race
Iron piece (outside)
AC500583AB
Use special tool bearing remover (MD998917) and

iron piece to press out the hub as shown in the illus- AC502020AB
tration.
4. Cut in with a chisel the place where the wheel
bearing inner race (outside) has been shaven and
remove the wheel bearing inner race (outside)
26-22 FRONT AXLE
>>B<< HUB ROTARY SLIDING RESISTANCE

MB990938 CHECK
MB990931
AC500582AB
5. Install the inner race (outside) that was removed AC502047

from the hub to the wheel bearing, and then use
the following special tools to remove the wheel 1. Use a spring balance to measure the hub rotary
bearing. sliding resistance (hub rotation starting torque) as
• Installer bar (MB990938) shown in the illustration.
• Installer adapter (MB990931) Limit: 77 N (4.4 N⋅m)
2. If the rotary sliding resistance is not within the
REASSEMBLY SERVICE POINTS standard value, replace the bearing.
>>A<< WHEEL BEARING INSTALLATION
1. Fill the wheel bearing with multipurpose grease. >>C<< WHEEL BEARING AXIAL PLAY CHECK
2. Apply a thin coating of multipurpose grease to the
knuckle and bearing contact surfaces.
CAUTION
Press the outer race when pressing-in the wheel
bearing. Otherwise the wheel bearing will be
damaged.
MB990938
MB991576 AC511153AB
1. Measure to determine whether the wheel bearing

axial play is within the limit or not.
Limit: 0 mm
2. If the play is not within the limit range, replace the
AC500584AB bearing and re-install.
3. Press-in the bearing by using the following special INSPECTION

tools. M1261002000120
• Installer bar (MB990938) • Check the front hub and brake disc mounting sur-
• Base (MB991576) faces for galling and contamination.
• Check the knuckle inner surface for galling and
cracks.
FRONT AXLE
DRIVESHAFT ASSEMBLY <4WD>
26-23
M1261003501723
CAUTION
• *: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle
on the earth in an unladen condition.
• Under Cover Removal (Refer to GROUP 51, Under Cover • Press the dust cover with a finger to check whether the
). dust cover is cracked or damaged.
• Gear Oil Draining (Refer to P.26-11). • Gear Oil Supplying (Refer to P.26-11).
• Under Cover Installation (Refer to GROUP 51, Under
Cover ).
• Wheel Alignment Check and Adjustment (Refer to
GROUP 33, On-vehicle Service ).
20 113 ± 9 N·m
19 15
N 21 2
88 ± 10 N·m 18 74 ± 14 N·m
14 N
105 ± 10 N·m* 9
3
N 10
190 - 210 N·m
40 ± 4 N·m
11 6
8 13 1 9.0 ± 2.0 N·m

108 ± 10 N·m 17
22
147 ± 29 N·m 16
12 N 7 N5 4
60 ± 10 N·m
AC500629
AC500411AE

1. Front wheel speed sensor <Vehicles 8. Stabilizer link assembly to lower arm
with ABS> connection
<<A>> 2. Caliper assembly 9. Shock absorber mounting bolt
3. Brake disc 10. Split pin
4. Hub cap <<C>> 11. Tie rod end connection
5. Split pin 12. Split pin
<> >>A<< 6. Driveshaft nut <<C>> 13. Lower arm ball joint connection
>>A<< 7. Washer 14. Split pin
26-24 FRONT AXLE
Removal steps (Continued) <<C>> TIE ROD END /LOWER ARM BALL JOINT /
16. Dust cover UPPER ARM BALL JOINT DISCONNECTION
17. Front hub assembly
CAUTION
18. Knuckle
19. LH driveshaft assembly
• Do not remove the nut from the ball joint.
20. LH driveshaft Loosen it and use the special tool to avoid
21. Circlip possible damage to ball joint threads.
22. RH driveshaft assembly • Hang the special tool with a cord to prevent
from falling.
<<A>> CALIPER ASSEMBLY REMOVAL Cord
1. Remove the caliper assembly with brake hose.
2. Secure the removed caliper assembly with a wire Ball joint
or other similar material at a position where it will Bolt
not interfere with the removal and installation of
the hub assembly and knuckle. MB991897
or
MB992011
<> DRIVESHAFT NUT REMOVAL Nut
AC106820 AE
CAUTION
Do not apply pressure to wheel bearing by the 1. Install special tool ball joint remover (MB991897
vehicle weight to avoid possible damage when or MB992011) as shown in the figure.
driveshaft nut is loosened.
Bolt
Parallel
Knob Correct
MB990767
Wrong AC106821AC
AC102462 AC
Use special tool front hub and flange yoke holder
(MB990767) to fix the hub and remove the driveshaft
hand and confirm that the jaws are still parallel.
nut.
NOTE: When adjusting the jaws in parallel, make
ure.
3. Tighten the bolt with a wrench to disconnect the
tie rod end.

>>A<<WASHER/ DRIVESHAFT NUT INSTALLA-
Washer
TION
CAUTION
Before securely tightening the driveshaft nuts,
make sure there is no load on the wheel bear-
ings. Otherwise the wheel bearings will be dam-
aged.
MB990767 AC607861 AB
FRONT AXLE
26-25
1. Be sure to install the driveshaft washer in the Tightening torque: 190 − 210 N⋅m
specified direction. 3. If the pin hole do not align with the pins, tighten
2. Using special tool front hub and flange yoke the driveshaft nut (less than 210 N⋅m) and find the
holder (MB990767), tighten the driveshaft nut. At nearest hole then bend the split pin to fit it.
this time, tighten the driveshaft nut to the specified
torque in expectation of final tightening. DISASSEMBLY AND REASSEMBLY
M1261003701147
CAUTION
Never disassemble the BJ assembly except when replacing the BJ boot.
13
11 N
9
N 12
N 2
8 (LH)
N1 5N
7 10 N
N 6
13 N3
12 4
11
2 1
6
10
4
(RH)
3
BJ boot repair kit AC500631
9 8
6 4 1
2 5 3
(LH)
8 2
1
7
2 3 6
1 6
3 10 4 (RH) 10 10
BJ repair kit DOJ repair kit DOJ boot repair kit
AC501569AC

1. DOJ boot band (large) 11. BJ boot band (small)
2. DOJ boot band (small) 12. BJ boot band (large)
3. Circlip 13. BJ boot
4. DOJ outer race Reassembly steps
5. Dust cover 10. Circlip
6. Snap ring 9. BJ assembly
<<A>> 7. DOJ assembly >>A<< 7. DOJ assembly
<> 8. DOJ boot >>A<< 6. Snap ring
9. BJ assembly >>B<< 4. DOJ outer race
10. Circlip 5. Dust cover
3. Circlip
26-26 FRONT AXLE
Reassembly steps (Continued) NOTE: .

>>C<< 8. DOJ boot • DOJ: Double Offset Joint
>>C<< 2. DOJ boot band (small) • BJ: Birfield Joint
>>C<< 1. DOJ boot band (large)
LUBRICATION POINTS
Grease:
Repair kit grease: 120 ± 10 g
Note
The grease in the repair kit should be
divided in half for use, respectively, at
AC500631 the joint and inside the boot.
AC501588 AB
Grease: Repair kit grease Grease:

Repair kit grease: 125 ± 10 g (joint: 80 g, boot: 45 g)
Note
The grease in the repair kit should be divided in half
for use, respectively, at the joint and inside the boot.
CAUTION
Do not mix old and new or different types of grease, as a special grease is used in the joint.
DISASSEMBLY SERVICE POINTS 1. Remove the balls from the DOJ cage.
<<A>> DOJ ASSEMBLY REMOVAL
ACX01095 AB
ACX01094 AB
FRONT AXLE
26-27
2. Remove the DOJ cage from the DOJ inner race in Specified grease: Repair kit grease 125 ± 10
the direction shown in the illustration. g
CAUTION
<> DOJ BOOT REMOVAL Do not secure the boot band (large).
2. Install the circlip onto the DOJ outer race. Place
the DOJ boot over the DOJ outer race, and then
Plastic tape use a boot band (small) to secure the boot.
>>C<< DOJ BOOT/DOJ BOOT BAND

INSTALLATION
A
AC000437AB
Wrap plastic tape around the spline part on the DOJ

side of the driveshaft so that DOJ boot is not dam-
aged when removed.
Boot band (small)
REASSEMBLY SERVICE POINTS Boot band (large)
>>A<< DOJ ASSEMBLY/SNAP RING INSTALLA- ACX02370 AB
TION 1. Position the DOJ outer race so that the distance

Ball
between the boot bands is at the standard value.
Snap ring
Standard value (A): 85 ± 3 mm
Driveshaft
2. Remove part of the DOJ boot from the DOJ outer
race to release the air pressure inside the boot.
CAUTION
Inner race
Direction of driveshaft
Cage rotation when vehicle
is moving forward.
AC004718 AB
Install each part of the DOJ assembly (ball, cage and

inner race) to the driveshaft, and fit the snap ring
securely to the groove in the driveshaft.
Boot band
>>B<< DOJ OUTER RACE INSTALLATION
AC004719 AB
CAUTION
The driveshaft joint use special grease. Do not Be sure that the installation direction of the boot
mix old and new or different types of grease. bands is correct.
3. Secure the boot band (large) on DOJ boot.
INSPECTION
M1261003800271
• Check the driveshaft for damage, bending or cor-
rosion.
• Check the driveshaft spline part for wear or dam-
age.
• Check the boots for deterioration, damage or
cracking.
ACX02369 • Check the dust cover for damage or deteriora-
tion.
1. Fill the inside of the DOJ outer race and DOJ boot
with the specified grease.
26-28 FRONT AXLE
BJ BOOT (RESIN BOOT) REPLACEMENT 4. Place the BJ boot band (small) against the
M1261005200662 projection at the edge of the boot, and then
secure it so that there is a clearance left as shown
by (A) in the illustration.
CAUTION
• Secure the drive shaft in an upright position
and clamp the part of the BJ boot band to be
crimped securely in the jaws of the special
tool MB991561.
• Crimp the BJ boot band until the special tool
touches the stopper.
ACX00982 AB
1. Remove the boot bands (large and small).

NOTE: The BJ boot bands cannot be re-used.
2. Remove the BJ boot.
MB991561
Stopper
MB991561 AC606919AC
(W)
5. Use the special tool to crimp the BJ boot band
(small).
Adjusting bolt
ACX00993AB
3. Turn the adjusting bolt on special tool boot band B

clipping tool (MB991561) so that the size of the
opening (W) is at the standard value.
Standard value (W): 2.9 mm
<If it is larger than 2.9 mm> Tighten the adjust-
ing bolt.
<If it is smaller than 2.9 mm> Loosen the
AC606920AE
adjusting bolt.
NOTE: The value of W will change by approxi- MB991561
mately 0.7 mm for each turn of the adjusting bolt.
Stopper
NOTE: The adjusting bolt should not be turned
more than once.
BJ boot (W)
A
Adjusting bolt
ACX00993AB
BJ boot band
(small)
6. Check that crimping amount (B) of the BJ boot
Projection band is at the standard value.
Standard value (B): 2.4 − 2.8 mm
AC001175 AB
<If the crimping amount is larger than 2.8 mm>
Readjust the value of (W) in step 3 according to
the following formula, and then repeat the
operation in step 5.
FRONT AXLE
26-29
W = 5.5 mm − B
Example: If B = 2.9 mm, then W = 2.6 mm.
<If the crimping amount is smaller than 2.4
mm> BJ boot Projection
Remove the BJ boot band, readjust the value of BJ boot band
(W) in step 3 according to the following for-
mula, and then repeat the operations in D
steps 4 and 5 using a new BJ boot band.
W = 5.5 mm − B
Example: If B = 2.3 mm then W = 3.2 mm. AC001177AB
7. Check that the BJ boot band is not protruding past

the place where it has been installed. If so, 11.Place the BJ boot band (large) against the
remove it and then repeat the operations in steps projection at the edge of the boot, and then
4 to 6 using a new BJ boot band. secure it so that there is a clearance left as shown
by (D) in the illustration.
CAUTION
12.Use special tool MB991561 to crimp the BJ boot
The driveshaft joint uses special grease. Do not
band (large) in the same way as in step 5.
mix old and new grease or different types of
grease.
8. Fill the inside of the BJ boot with the specified
amount of the specified grease.
Specified grease: Repair kit grease 120 ± 10
g
C
E AC004720 AB
MB991561
Stopper
AC001176 AB
(W)
9. Install the BJ boot band (large) so that there is the
clearance (C) between it and the BJ housing is at
the standard value. Adjusting bolt
Standard value (C): 0.05 − 1.55 mm
ACX00993AB
10.Follow the same procedure as in step 3 to adjust 13.Check that the crimping amount (E) of the BJ boot
the size of the opening (W) shown on special tool band is at the standard value.
MB991561 so that it is at the standard value. Standard value (E): 2.4 − 2.8 mm
Standard value (W): 3.2 mm <If the crimping amount is larger than 2.8 mm>
Readjust the value of (W) in step 10 according
to the following formula, and then repeat the
operation in step 12.
W = 5.8 mm − E
Example: If E = 2.9 mm, then W = 2.9 mm.
<If the crimping amount is smaller than 2.4
mm>
Remove the BJ boot band, readjust the value of
(W) in step 10 according to the following for-
mula, and then repeat the operating in steps
11 and 12 using a new BJ boot band.
26-30 FRONT AXLE
INNER SHAFT ASSEMBLY <4WD>
W = 5.8 mm − E 14.Check that the BJ boot band is not protruding

Example: If E = 2.3 mm, then W = 3.5mm. past the place where it has been installed. If so,
remove it and repeat the operations in steps 11 to
13 using a new BJ boot band.

M1261004000201
CAUTION
*:Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on
the earth in the unladen condition.
• Under Cover Removal and Installation (Refer to GROUP
51, Under Cover .)
• Gear Oil Draining and Supplying (Refer to P.26-11.)
• Driveshaft <RH> Removal and Installation (Refer to P.26-
23).
• Shock absorber assembly <RH> Removal and Installation
(Refer to GROUP 33, Shock Absorber Assembly .)
12 ± 2 N·m
3N 10 12 AC500641
11
90 ± 10 N·m
90 ± 10 N·m* N4
1
8
105 ± 15 N·m 7
25 ± 5 N·m
6
N 9
17 ± 3 N·m 5 AC804444AB

1. Bolt >>A<< 4. Dust seal
<<A>> >>B<< 2. Inner shaft assembly 5. Pin <Except for Russia>
3. Circlip 6. Collar <Except for Russia>
FRONT AXLE
26-31
Removal steps (Continued) • driveshaft attachment (MB990906)
7. Actuator assembly <Except for • Sliding hammer (MB990211)
Russia>
8. Free wheel engage switch INSTALLATION SERVICE POINTS
assembly <Except for Russia>
Support the differential with a >>A<< DUST SEAL INSTALLATION
•
transmission jack
9. Gasket <Except for Russia>
10. Differential mounting bracket <RH>
MB990938
11. Breather hose
12. Breather pipe
REMOVAL SERVICE POINT MB990955
<<A>> INNER SHAFT ASSEMBLY REMOVAL

CAUTION
When pulling the inner shaft out from the front ACX01014 AB
differential carrier, be careful that the spline part Press-fit the new dust seal into the housing tube by
of the inner shaft does not damage the oil seal. using the following special tools, until it is flush with
the housing tube end face.
MB990906 • Installer bar (MB990938)
• Oil seal installer (MB990955)
>>B<< INNER SHAFT ASSEMBLY INSTALLATION

CAUTION
Be careful not to damage the lip of the dust seal
and oil seal.
MB990211
ACX00999 AC DISASSEMBLY AND REASSEMBLY
M1261004200131
Pull the inner shaft from the differential carrier by
using the following special tools.
N 2
1
AC804403AB

<<A>> >>B<< 1. Bearing >>A<< 2. Dust cover
3. Inner shaft
26-32 FRONT AXLE
DISASSEMBLY SERVICE POINT 3. Press out the inner shaft from the bearing.
<<A>> BEARING REMOVAL
>>A<< DUST COVER INSTALLATION
Steel pipe
ACX01002AB
1. Bend the outside periphery of dust cover inward ACX01015 AB

with a wooden hammer.
Using a steel pipe, install a new dust cover onto the
A inner shaft.
Steel pipe mm
Overall length 50
Outside diameter 75
Wall thickness 4
MB990560
>>B<< BEARING INSTALLATION
ACX01003 AB
2. After special tool bearing remover (MB990560)

has been installed as shown, tighten the nut of the MB990560
special tool until the portion of the special tool
touches the bearing outer race.
ACX01016AB
Use special tool bearing remover (MB990560) to

MB990560
press-fit the bearing onto the inner shaft.
ACX01013 AB
FRONT AXLE
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>
26-33
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH
<4WD>
M1262001800201
CAUTION
51, Under Cover .)
• Front Axle Gear Oil Level Check (Refer to P.26-11.)
• Driveshaft Removal and Installation (Refer to P.26-23.)
• Inner Shaft Removal and Installation (Refer to P.26-30.)
12 ± 2 N·m
7
8 18
16 54 ± 5 N·m
2N
59 ± 9 N·m 1
90 ± 10 N·m
15 19
13 9
105 ± 15 N·m
90 ± 10 N·m * 5 14 N 17
6
25 ± 5 N·m
6
105 ± 15 N·m
5
17 ± 3 N·m 12 11 10
90 ± 10 N·m * 108 ± 10 N·m
3
Housing
tube end
(Differential 3 108 ± 10 N·m
side)
AC501624
Sealant: 4
ThreeBond 1217 or equivalent
AC804263 AC

<<A>> >>B<< 1. Front propeller shaft connection 4. Front suspension rear
• Support the differential by a crossmember assembly
transmission jack >>A<< 5. Vacuum hose connection
2. Self-locking nut 6. Differential mounting bracket bolt
3. Front suspension rear 7. Housing tube, front differential
crossmember assembly mounting carrier and differential mounting
bolt bracket
26-34 FRONT AXLE
Removal steps (Continued) INSTALLATION SERVICE POINTS

8. Differential mounting bracket <RH>
>>A<< VACUUM HOSE INSTALLATION
9. Differential mounting bracket <LH>
10. Pin <Except for Russia>
11. Collar <Except for Russia>
Actuator
12. Actuator assembly <Except for
Russia>
13. Free wheel engage switch Identification
colour (blue)
assembly <Except for Russia>
14. Gasket <Except for Russia>
15. Breather hose <Vehicles with Easy
select 4WD> Identification
16. Breather hose <Vehicles with colour (yellow)
Super select 4WD> AC500427AB
17. Housing tube assembly Install the vacuum hoses so that they match the
18. Breather pipe identification colours of the actuator assembly nipple.
19. Front differential carrier assembly
REMOVAL SERVICE POINT >>B<< FRONT PROPELLER SHAFT

INSTALLATION
<<A>> FRONT PROPELLER SHAFT REMOVAL
<Vehicles with Mating marks Easy select
Easy select 4WD>
4WD>
AC505406 AD
AC505406 AD
<Vehicles with
<Vehicles with Super select Mating marks
Super select Mating marks
4WD>
4WD>
AC804574AC
AC804574AC
Install the front propeller shaft so that the mating
Make mating marks on the flange yoke and the dif- marks of the flange yoke and the differential carrier
ferential carrier companion flange. Remove the front companion flange are aligned.
propeller shaft.
FRONT AXLE
26-35
INSPECTION Shaft (Switch) Tester Specified
M1262001900123
position connection condition
FREEWHEEL ENGAGE SWITCH CHECK
Pressed (ON) 1-2 Continuity (Less
<Except for Russia>
than 2 Ω)
Released (OFF) - Open circuit
1 2
Ball
FREE WHEEL CLUTCH DISASSEMBLY
AND REASSEMBLY <Except for Russia>
M1262002900159
OFF ON
ACX01021AB
14
13
12
11 AC500711
7 1
3
9 2
10
5
8 4
6
AC804392 AB

1. Main shaft assembly 8. Shift rod
<<A>> >>F<< 2. Main shaft 9. Bushing
<<A>> >>F<< 3. Bearing >>C<< 10. Oil seal
4. Clutch sleeve <> >>B<< 11. Clutch gear
>>E<< 5. Spacer <> >>B<< 12. Bearing
>>D<< 6. Spring pin >>A<< 13. Oil seal
7. Shift fork 14. Housing tube
26-36 FRONT AXLE

<<A>> MAIN SHAFT/BEARING REMOVAL
Iron piece
A
MB990560
AC500716 AB
MB990560
2. Using a press and special tool bearing remover
ACX01023 AB
(MB990560), hold the supports against the
1. After special tool bearing remover (MB990560) bearing inner race, and separate the clutch gear
has been installed as shown, tighten the nut of and bearing.
special tool until portion "A" of special tool touches
the bearing outer race. REASSEMBLY SERVICE POINTS
CAUTION
Do not allow the mainshaft to drop.
2. Press out the mainshaft from the bearing. MB990799
<> CLUTCH GEAR/BEARING REMOVAL
MB991318
Oil seal
Clutch gear Rag Housing tube
AC500717 AB
Use special tool ball joint remover and installer A

(MB990799) to tap the oil seal until it is flush with the
clutch housing.
AC505087AB
>>B<< BEARING/CLUTCH GEAR INSTALLATION
1. Use special tool lower arm bush arbour
(MB991318) to remove the clutch gear and MB990799
bearing together.
NOTE: Apply rag inside of the clutch gear so as
not to damage spline part.
Bearing
Clutch gear
ACX01027AB
1. Use special tool ball joint remover and installer A

(MB990799) to press-fit the bearing to the
shoulder of the clutch gear.
FRONT AXLE
26-37
CAUTION Tap the spring pin from the chamfered side of the
shaft rod until the projection length becomes the
MB990890 length shown in the illustration.
or
Housing MB990891
tube >>E<< SPACER INSTALLATION
Clutch gear Main shaft
assembly
Spacer
AC500718 AB
Place the special tool against the outer race of

the bearing.
2. Use special tool rear suspension housing base A
AC101906AB
(MB990890 or MB990891) to press-fit the bearing
to the side of the clutch housing. 1. Place the current spacer in the area shown in the
illustration to check that the dimensions shown in
>>C<<OIL SEAL INSTALLATION the illustration are within the standard values.
Standard Value (A): 0.05 − 0.3 mm
MB990938 2. If the dimensions are outside of the standard
values, select the correct spacer type to fit in the
Oil seal
MB990926 standard values.
Spacer type
Part Thickness Part Thickness
Housing tube Number mm Number mm
MR111526 1.1 MR111530 2.1
ACX01029AC MR111527 1.35 MR111531 2.35
Use the following special tools to press-fit the oil seal MR111528 1.6 MR111532 2.6
to the clutch housing.
MR111529 1.85 MR111533 2.85
• Bar (MB990938)
>>F<< BEARING/MAIN SHAFT INSTALLATION
>>D<< SPRING PIN INSTALLATION
Main shaft
Spring pin Shift rod
ACX01031AB
0 – 1 mm
AC500719AB
Press-fit the bearing to the shoulder of the mainshaft.
26-38 FRONT AXLE
DISASSEMBLY
M1262002300146
28 21 20 N
N 29
7 34 31
22
32 24 23
26 25
6 27 30
17
N 2 16 33 N
1 4N
3
19
12 18
14 13 16 15
5 17
1811
8 10 9
AC500723AC

<<A>> • Inspection before disassembly 28. Companion flange
1. Filler plug 29. Oil seal
2. Gasket 30. Drive pinion front bearing inner race
3. Drain plug <> 31. Drive pinion front bearing outer race
4. Packing <<J>> 32. Drive pinion rear bearing outer race
5. Differential cover <<K>> 33. Oil seal
6. Vent plug <Vehicles with Easy select 34. Differential carrier
4WD>
7. Bearing cap DISASSEMBLY SERVICE POINTS
<> 8. Differential case assembly <<A>> INSPECTION BEFORE DISASSEMBLY
<> 9. Differential side bearing adjusting spacer 1. Remove the cover.
<> 10. Differential side bearing outer race
<<C>> 11. Differential side bearing inner race
<<D>> 12. Drive gear MB990909
<<E>> 13. Lock pin and
14. Pinion shaft MB991116
15. Pinion gear
16. Pinion washer
17. Side gear
18. Side gear spacer
19. Differential case
<<F>> 20. Self-locking nut
21. Washer AC102883 AC
<<G>> 22. Drive pinion assembly

2. Hold the following special tools in a vise, and
23. Drive pinion front shim (for turning torque
adjustment) install the differential carrier assembly to the
24. Drive pinion spacer special tool.
<<H>> 25. Drive pinion rear bearing inner race • Working base (MB990909)
26. Drive pinion rear shim (For pinion height • Working base adapter (MB991116)
adjustment)
27. Drive pinion
FRONT AXLE
26-39
DRIVE GEAR BACKLASH 4. If adjustment is impossible, replace differential
case, or replace drive gear and pinion as a set.
DIFFERENTIAL GEAR BACKLASH
Wedge
ACX01034AB Side gear

Side gear spacer
1. With the drive pinion locked in place, use a dial spacer
gauge to measure the drive gear backlash in four
AC102885 AC
or more places on the drive gear.
Standard value: 0.11 − 0.16 mm 1. Insert a wedge between the side gear and the
pinion shaft to lock the side gear.
2. If the backlash is not within the standard value,
adjust the final drive gear backlash (Refer to ). 2. While locking the side gear with the wedge,
measure the differential gear backlash with a dial
3. After the adjustment, inspect the final drive gear
indicator on the pinion gear.
tooth contact.
Use the measurement procedure for the other
DRIVE GEAR RUNOUT pinion gear.
3. If the backlash exceeds the standard value, adjust
it by replacing the side gear spacers.
4. If adjustment is not possible, replace the side
gears and pinion gears as a set.
DRIVE GEAR TOOTH CONTACT

Check the tooth contact of drive gear by following the
steps below.
ACX01036 AB
1. Measure the drive gear runout at the shoulder on

the reverse side of the drive gear.
Limit: 0.05 mm
2. When the runout exceeds the limit value, check
for foreign material between drive gear rear side
and differential case, and for loose drive gear
installation bolts.
3. When check (2) gives normal results, reposition ACX01037AB
drive gear and differential case and remeasure.
1. Apply a thin, uniform coat of machine blue to both
surfaces of the drive gear teeth.
26-40 FRONT AXLE
CAUTION 2. Insert special tool remover bar (MB990939)

If the drive gear is rotated too much, the tooth between the differential carrier and the differential
contact pattern will become unclear and difficult case, and then rotate the companion flange by
to check. hand (once in the normal direction, and then once
in the reverse direction) while applying a load to
the drive gear so that the revolution torque
MB990939 (approximately 2.5 − 3.0 N⋅m) is applied to the
drive pinion.
3. Check the tooth contact condition of the drive gear
and drive pinion.
AC102888 AC
Standard tooth contact pattern Problem Solution

1. Narrow tooth side Tooth contact pattern resulting
4
2. Drive-side tooth surface from excessive pinion 2 1
(the side applying power during forward height

movement) 3
3. Wide tooth side 2 1 4 AC107261AB
4. Coast-side tooth surface
Increase the thickness of
(the side applying power during reverse
the drive pinion rear shim,
movement) 3 and position the drive pinion
AC107260 AB
closer to the centre of the
The drive pinion is positioned too drive gear. Also, for
1
far from the centre of the drive backlash adjustment,
2 4 gear. position the drive gear
farther from the drive
pinion.
Tooth contact pattern resulting
3 from insufficient pinion 2 1 4
height.
ACX01039 AF 3
2 1 AC107263 AB
4
Decrease the thickness of
the drive pinion rear shim,
3
AC107262 AB
and position the drive pinion
farther from the centre of
The drive pinion is positioned too the drive gear. Also, for
close to the centre of the drive backlash adjustment,
gear. position the drive gear
closer to the drive pinion.
NOTE: Check the tooth contact pattern to confirm tern. If, even after adjustments have been made,
that the adjustments of the pinion height and the correct tooth contact pattern cannot be
backlash have been done properly. Continue to obtained, it means that the drive gear and the
adjust the pinion height and backlash until the drive pinion have become worn beyond the allow-
tooth contact pattern resembles the standard pat- able limit. Replace the gear set.
FRONT AXLE
26-41
<> DIFFERENTIAL CASE ASSEMBLY/ <<D>> DRIVE GEAR REMOVAL
DIFFERENTIAL SIDE BEARING SPACER/
DIFFERENTIAL SIDE BEARING OUTER RACE
REMOVAL
CAUTION
When taking out the differential case assembly,
be careful not to drop and damage the differential Mating
side bearing spacers and differential side bear- marks
ing outer races.
AC102891 AC
1. Make the mating marks to the differential case

and the drive gear.
2. Loosen the drive gear attaching bolts in diagonal
sequence to remove the drive gear.
<<E>> LOCK PIN REMOVAL

ACX01040AB
Use the wooden handle of a hammer to remove the

differential case assembly, differential side bearing
spacers and differential side bearing outer races.
NOTE: Keep the right and left side bearings and side Punch
bearing adjusting spacers separate, so that they do
not become mixed during assembly.
<<C>> DIFFERENTIAL SIDE BEARING INNER

ACX01048AB
RACE REMOVAL
Drive out the lock pin with a punch.
MB990810
<<F>> SELF-LOCKING NUT REMOVAL
MB990811 MB990767
ACX01041AC
Use the following special tools to pull out the side

bearing inner races.
• Side bearing puller (MB990810)
AC004732 AB
• Differential side bearing cap (MB990811) Use special tool front hub and flange yoke holder
NOTE: There are two notches provided (at the differ- (MB990767) to hold the companion flange, and then
ential case side) for the claw part of the special tools; remove the companion flange self-locking nut.
use special tools at that position.
26-42 FRONT AXLE
<<G>> DRIVE PINION ASSEMBLY REMOVAL <> DRIVE PINION FRONT BEARING OUTER
CAUTION RACE REMOVAL
The mating mark made on the companion flange
MB990939
must not be on the coupling surface of the flange
yoke and the front propeller shaft.
ACX01046AB
Use special tool remover bar (MB990939) to remove

Mating marks the drive pinion front bearing outer race.
AC004790 AB
<<J>> DRIVE PINION REAR BEARING OUTER

1. Make mating marks on the drive pinion and
RACE REMOVAL
companion flange.
2. Drive out the drive pinion together with the drive
pinion spacer and drive pinion shims. MB990939
<<H>> DRIVE PINION REAR BEARING INNER

RACE REMOVAL
MB990339
ACX01047 AB
Use special tool remover bar (MB990939) to remove

the drive pinion rear bearing outer race.
<<K>> OIL SEAL REMOVAL

MB990648
ACX01045 AB
Use the following special tools to pull out the front MB990590
bearing inner race.
• Bearing puller (MB990339)
• Bearing remover (MB990648)
AC004791 AB
Use special tool rear axle shaft oil seal remover

(MB990590) to remove the oil seal.
FRONT AXLE
26-43
REASSEMBLY
M1262002500258
13 14 15 N
28 N 12
1 4
10
9
3 8 216 ± 29 N·m
84 ± 4 N·m 6 7
29 5 11
18 2N
N 33 19
59 ± 4 N·m
34 31 N
16 32 65 ± 5 N·m
23 17
21 22 20
19 18
30 1724
50 ± 10 N·m
27 25 26
18 ± 3 N·m
AC501704AB
23
21 22 20
18
17
17 18 5 15
20
Pinion shaft kit Differential gear set Final drive gear set
Reassembly steps Reassembly steps (Continued)

1. Differential carrier 18. Side gear
>>A<< 2. Oil seal 19. Pinion washer
>>B<< 3. Drive pinion rear bearing outer race 20. Pinion gear
>>C<< 4. Drive pinion front bearing outer race >>F<< • Differential gear backlash adjustment
>>D<< • Drive pinion height adjustment 21. Pinion shaft
5. Drive pinion >>G<< 22. Lock pin
6. Drive pinion rear shim (for pinion height >>H<< 23. Drive gear
adjustment) >>I<< 24. Differential side bearing inner race
7. Drive pinion rear bearing inner race 25. Differential side bearing outer race
>>E<< • Drive pinion turning torque adjustment 26. Differential side bearing adjusting spacer
8. Drive pinion spacer >>J<< • Drive gear backlash adjustment
9. Drive pinion front shim (for turning torque 27. Differential case assembly
adjustment) 28. Bearing cap
10. Drive pinion assembly 29. Vent plug <Vehicles with Easy select
11. Drive pinion front bearing inner race 4WD>
12. Oil seal 30. Differential cover
13. Companion flange 31. Packing
14. Washer 32. Drain plug
15. Self-locking nut 33. Gasket
16. Differential case 34. Filler plug
17. Side gear spacer
26-44 FRONT AXLE
LUBRICATION, SEALING AND ADHE-

SIVE POINTS
Adhesive:
LOCTITE No.271 or No.270 or equivalent
<Vehicles with
A A Easy select 4WD>
Section A-A
2 - 3 mm
AC501724 AC501723
AC502341 AF
FRONT AXLE
26-45
>>A<< OIL SEAL INSTALLATION >>D<< DRIVE PINION HEIGHT ADJUSTMENT
Adjust the drive pinion height as follows:
MB990938
MB990934
Oil seal
MB990819 Washer
ACX01051AB
ACX01054 AB
Use the following special tools to insert the oil seal,
and then apply a thin coat of multipurpose grease to 1. Apply multipurpose grease to the washer of
the lip of the oil seal. special tool drive pinion gauge assembly
• Installer bar (MB990938) (MB990819).
• Installer adapter (MB990934) 2. Install special tool, drive pinion front and rear
bearing inner races to the gear carrier.
>>B<< DRIVE PINION REAR BEARING OUTER
CAUTION
RACE INSTALLATION
There should be no gear oil adhered to the bear-
ing.
MB990819
MB990938
MB990936
AC004801 AB
Use the following special tools to press-fit the drive ACX01055 AB

pinion rear bearing outer races into the gear carrier.
• Installer bar (MB990938) MB990685 MB990326
>>C<< DRIVE PINION FRONT BEARING OUTER MB990819

RACE INSTALLATION
MB990938
MB990934
ACX01056AB
3. Tighten the nut of special tool while measuring the

turning torque of the drive pinion by using the
following special tools. Gradually keep tightening
the nut of special tool until the turning torque of
AC004802 AB
the drive pinion (without oil seal) is at the standard
Use the following special tools to press-fit the drive value.
pinion rear bearing outer races into the gear carrier. • Preload socket (MB990326)
• Installer bar (MB990938) • Torque wrench (MB990685)
• Installer adapter (MB990934) • Drive pinion gauge assembly (MB990819)
26-46 FRONT AXLE
Standard value:
Bearing Bearing Turning torque
division lubrication
New None (with anti- 0.83 − 1.19 N⋅m D
rust agent) Cylinder gauge
NOTE: Because special tool preload socket
(MB990326) cannot be turned one turn, turn it
several times within the range that it can be
turned; then, after fitting to the bearing, measure AC102914 AC
the turning torque.
9. Install the bearing cap, and then use a cylinder
4. Clean the side bearing seat of the differential
gauge and micrometer to measure the inside
carrier and bearing caps.
diameter (D) of the bearing cap as shown in the
Notch MB991170 illustration.
10.Calculate the thickness (E) of the required drive
pinion rear shim by the following formula, and
A then select a shim which most closely matches
this thickness.
E = A + B + C - 1/2D - 100.0 mm
Drive
pinion
Thickness gauge MB990819 ACX01057AC rear MB990802
shim
5. Place the following special tools in the side
bearing seat of the differential carrier, and position
the notch as shown in the illustration. Then install
the bearing caps. MB990802
• Cylinder gauge (MB991170)
• Drive pinion gauge assembly (MB990819) ACX01060 AC
6. Use a thickness gauge to measure the clearance
(A) between special tools. 11.Fit the selected drive pinion rear shim(s) to the
7. Remove the bearing caps and special tools. drive pinion, and press-fit the drive pinion front
bearing inner race by using special tool bearing
MB990819 installer (MB990802).
MB991170 C
>>E<< DRIVE PINION TURNING TORQUE
ADJUSTMENT
Adjust the drive pinion turning torque by using the
following procedure:
1. Insert the drive pinion into the gear carrier, and
B then install the drive pinion spacer, the drive
pinion front shim, the drive pinion front bearing
ACX01058 AE
inner race, and the companion flange in that
8. Use a micrometer to measure the shown order.
dimensions (B, C) of special tools. NOTE: Do not install the oil seal.
FRONT AXLE
26-47
NOTE:
MB990767
Identification
colour
AC004803 AB
ACX01063 AB
2. Tighten the companion flange self-locking nut to When selecting the drive pinion front shims, if the
the specified torque while holding the companion number of shims is large, reduce the number of
flange with special tool front hub and flange yoke shims to a minimum by selecting the drive pinion
holder (MB990767). spacers.
Tightening torque: 216 ± 29 N⋅m Select the drive pinion spacer from the following
two types.
CAUTION
There should be no gear oil adhered to the Height of drive pinion Identification colour
bearing. spacer mm
56.67 White
MB990326
MB990685 57.01 −
MB990031
or
MB990699
ACX01062AB
3. Use the following special tools to measure the

drive pinion turning torque (without the oil seal). ACX01064 AB
• Preload socket (MB990326)
• Torque wrench (MB990685) 5. Remove the companion flange and drive pinion
Standard value: again. Then, after inserting the drive pinion front
bearing inner race into the gear carrier, use
Bearing Bearing Turning torque special tool oil seal installer (MB990031 or
division lubrication MB990699) to press-fit the oil seal.
New None (with anti- 0.83 − 1.19 N⋅m
rust agent) MB990767
4. If the drive pinion turning torque is not within the
range of the standard value, adjust the preload by
replacing the drive pinion front shim(s) or the drive
pinion spacer.
AC004803 AB
26-48 FRONT AXLE
6. Install the drive pinion assembly and companion 2. Temporarily install the pinion shaft.
flange with the mating marks properly aligned. NOTE: Do not drive in the lock pin yet.
Tighten the companion flange self-locking nut to
the specified torque while holding the companion Wedge
flange with special tool.
MB990326
MB990685
Side gear
thrust
Side gear spacer
thrust spacer ACX01035 AB
3. Insert a wedge between the side gear and the

pinion shaft to lock the side gear.
ACX01062AB
4. While locking the side gear with the wedge,
7. Use special tools to measure the drive pinion indicator on the pinion gear.
turning torque (with drive pinion oil seal) to verify Measure by the same procedure for the other
that the drive pinion turning torque complies with pinion gear.
the standard value.
Standard value:
5. If the backlash exceeds the standard value, adjust
Bearing Bearing Turning torque it by replacing the side gear spacers.
division lubrication 6. If adjustment is not possible, replace the side
New None (with anti- 0.89 − 1.78 N⋅m gears and pinion gears as a set.
rust agent) 7. Measure the differential gear backlash once
Gear oil applied 0.97 − 1.32 N⋅m again, and confirm that it is within the standard.
8. If the turning torque is not within the standard
>>G<< LOCK PIN INSTALLATION
value, check the tightening torque of the
companion flange self-locking nut, and the
installation of the oil seal.
>>F<< DIFFERENTIAL GEAR BACKLASH

ADJUSTMENT
Adjust the differential gear backlash by the following
procedure:
ACX01067AB
1. Align the pinion shaft lock pin hole with the

differential case lock pin hole, and drive in the lock
pin.
2. Stake the lock pin with a punch at two points.
>>H<< DRIVE GEAR INSTALLATION

ACX01066AB
1. Clean the drive gear attaching bolts.
1. Assemble the side gears, side gear spacers,
pinion gears and pinion washers into the
differential case.
FRONT AXLE
26-49
>>J<< DRIVE GEAR BACKLASH ADJUSTMENT
Adjust the drive gear backlash by the following pro-
cedures:
Tap ACX01068AB
2. Remove the adhesive adhered to the threaded

holes of the drive gear by turning the tap (M10 x ACX01070AB
1.25), and then clean the threaded holes by
applying compressed air. 1. Install the side bearing spacers, which are thinner
than those removed, to the side bearing outer
races, and then mount the differential case
assembly into the gear carrier.
NOTE: Select side bearing spacers with the same
thickness for both the drive pinion side and the
drive gear side.
AC000438 AB
3. Apply the specified adhesive to the threaded

holes of the drive gear.
Specified adhesive:: LOCKTITE No.271 or
4. Install the drive gear onto the differential case with ACX01071AB
the mating marks properly aligned. Tighten the
bolts to the specified torque in a diagonal 2. Push the differential case assembly to one side,
sequence. and measure the clearance between the gear
carrier and the side bearing adjusting spacer with
a feeler gauge.
>>I<< DIFFERENTIAL SIDE BEARING INNER

RACE INSTALLATION
Piece of
metal
Piece of
metal
MB990802 MB990802 Clearance/2 + 0.05 mm =

Thickness of the spacer on
one side ACX01072 AC
3. Measure the thickness of the side bearing

ACX01069AC adjusting spacers on one side, select two pairs of
spacers which correspond to that thickness plus
Use special tool bearing installer (MB990802) to
one half of the clearance plus 0.05 mm, and then
press-fit the differential side bearing inner races into
install one pair each to the drive pinion side and
the differential case.
the drive gear side.
26-50 FRONT AXLE
7. With the drive pinion locked in place, measure the

drive gear backlash with a dial indicator on the
drive gear.
NOTE: Measure at four points or more on the cir-
cumference of the drive gear.
If backlash is too small

Thinner Thicker
spacer spacer
ACX01070AB
4. Install the side bearing adjusting spacers and

differential case assembly, as shown in the
illustration, to the gear carrier.
Thicker Thinner
spacer spacer
If backlash is too large ACX01075 AB
8. Change the side bearing adjusting spacers as

illustrated, and then adjust the drive gear
MB990939 backlash between the drive gear and the drive
pinion.
NOTE: When increasing the number of side bear-
ing adjusting spacers, use the same number for
ACX01073 AB
each, and as few as possible.
5. Tap the side bearing adjusting spacers with 9. Check the drive gear and drive pinion for tooth
special tool remover bar (MB990939) to fit them to contact. If poor contact is evident, make
the side bearing outer race. adjustment. (Refer to P.26-38.)
ACX01074AB ACX01036 AB
6. Align the mating marks on the gear carrier and the 10.Measure the drive gear runout at the shoulder on
bearing cap, and then tighten the bearing cap. the reverse side of the drive gear.
Tightening torque: 59 ± 4 N⋅m Limit: 0.05 mm
11.If the drive gear runout exceeds the limit, reinstall
by changing the phase of the drive gear and
differential case, and remeasure.
12.If adjustment is not possible, replace the
differential case or replace the drive gear and
drive pinion as a set.
ACX01034AB
FRONT AXLE
SOLENOID VALVE AND VACUUM HOSE <4WD except for RUSSIA>
26-51
SOLENOID VALVE AND VACUUM HOSE <4WD except for
RUSSIA>
M1262004500083
8
7
10
9
11
12
12 ± 2 N·m
13
4
14
2
12
15 6 5
3
12
1
16 5.0 ± 1.0 N·m
12 ± 2 N·m 12 ± 2 N·m
AC903982 AB
Solenoid valve assembly removal Vacuum tank and vacuum hose

steps assembly and vacuum pipe assembly
1. Solenoid valve connector removal steps (Continued)
2. Solenoid valve assembly 8. Vacuum valve cap
Vacuum tank and vacuum hose 9. Vacuum hose
assembly and vacuum pipe assembly 10. Breather cap
removal steps 11. Vacuum pipe
3. Vacuum hose 12. Vacuum hose
4. Vacuum tank >>B<< 13. Check valve
5. Vacuum pipe assembly >>A<< 14. Vacuum hose
6. Vacuum hose >>A<< 15. Vacuum pipe assembly
7. Vacuum hose >>A<< 16. Vacuum hose assembly
26-52 FRONT AXLE
SOLENOID VALVE AND VACUUM HOSE <4WD except for RUSSIA>
INSTALLATION SERVICE POINTS 2. Install the vacuum hose assembly and the
>>A<< VACUUM HOSE ASSEMBLY/VACUUM vacuum hoses to the vacuum pipe assembly, so
PIPE ASSEMBLY/VACUUM HOSE INSTALLATION that colour mark (yellow or blue) of the vacuum
pipe assembly will match colour stripe (yellow or
blue) at the vacuum hose assembly and vacuum
Actuator hoses.
Identification >>B<< CHECK VALVE INSTALLATION

colour (blue)
Vacuum side Solenoid

valve side
Identification
colour (yellow)
AC500427AB
1. Install the vacuum hoses so that they match the

identification colours of the actuator assembly
nipple. Air direction arrow
ACX01077AB
Yellow mark
and stripe Install so that the air direction arrow points to the
vacuum side.
Blue mark
and stripe
Vacuum pipe
assembly
Blue mark Yellow mark
and stripe and stripe
AC500725AB
FRONT AXLE
FRONT DIFFERENTIAL MOUNT <4WD>
26-53
M1262001500095
CAUTION
51, Under Cover .)
• Gear Oil Draining and Refill (Refer to P.26-11.)
• Driveshaft Removal and Installation (Refer to P.26-23.)
• Inner Shaft Removal and Installation (Refer to P.26-30.)
59 ± 9 N·m
90 ± 10 N·m* 4N
108 ± 10 N·m 5
6
44 ± 10 N·m
1
108 ± 10 N·m
105 ± 15 N·m
90 ± 10 N·m*
105 ± 15 N·m
2
90 ± 10 N·m *
AC804264 AB
Differential mount bracket DIFFERENTIAL MOUNTING INSULATOR

assembly (LH/RH) removal REPLACEMENT
steps M1262004900069
1. Differential mount bracket DIFFERENTIAL MOUNT BRACKET <FRONT-LH,
assembly (RH) FRONT- RH, REAR>
2. Differential mount bracket
assembly (LH) MD999547
Differential mount bracket
assembly (rear) removal steps
3. Front suspension rear
crossmember
4. Self-locking nut
5. Differential support bracket
• Differential carrier and housing
assembly
6. Differential mount bracket
ACX01079AB
assembly (rear)
26-54 FRONT AXLE
1. Remove insulator with special tool transmission 2. Using the following special tools with a hydraulic
rear oil seal installer (MD999547). press, press fit each insulator to adjust until the
<Front-LH, RH>
hollow part faces as shown and the difference
MB990947
MB990847 between A and B is 0.7 mm.
• Lower Arm Bushing Arbour (MB990947)
• Rear Suspension Bushing Remover and Installer
MB990981
Base (MB990847)
A <Rear> • Mount Bushing Remover and Installer
Front
(MB990981)
3. Install the differential mount bracket (rear) as
B shown, so that the marking is located forward.
AC500727 AB
27-1
GROUP 27
REAR AXLE
CONTENTS
GENERAL INFORMATION . . . . . . . . 27-2 AXLE SHAFT ASSEMBLY REMOVAL AND

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 27-15
SERVICE SPECIFICATION(S) . . . . . 27-4 AXLE SHAFT ASSEMBLY DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 27-17
AXLE SHAFT INSPECTION (DISASSEMBLY AND
LUBRICANT(S) . . . . . . . . . . . . . . . . . 27-5
REASSEMBLY) . . . . . . . . . . . . . . . . . . . . . . 27-20
SEALANT(S) OR ADHESIVE(S) . . . . 27-5 REAR DIFFERENTIAL LOCK <4WD> 27-21

REAR DIFFERENTIAL LOCK REMOVAL AND
SPECIAL TOOL(S) . . . . . . . . . . . . . . 27-5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 27-21
REAR DIFFERENTIAL LOCK SWITCH CHECK
ON-VEHICLE SERVICE. . . . . . . . . . . 27-8 ...................................... 27-22
REAR AXLE TOTAL BACKLASH CHECK . 27-8 REAR DIFFERENTIAL LOCK CONTROL UNIT
GEAR OIL LEVEL CHECK . . . . . . . . . . . . . 27-9 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-22
GEAR OIL CHANGE. . . . . . . . . . . . . . . . . . 27-9 REAR DIFFERENTIAL LOCK AIR PUMP CHECK
AXLE SHAFT AXIAL PLAY CHECK . . . . . . 27-10 ...................................... 27-23
AXLE SHAFT AXIAL PLAY ADJUSTMENT 27-10 REAR DIFFERENTIAL LOCK DETECTION SWITCH
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-23
HUB BOLT REPLACEMENT . . . . . . . . . . . 27-10
REAR DIFFERENTIAL LOCK DETECTION SWITCH
CHECK <4WD> . . . . . . . . . . . . . . . . . . . . . 27-10
REAR DIFFERENTIAL LOCK SYSTEM AIR LEAKAGE
................................. 27-24
CHECK <4WD> . . . . . . . . . . . . . . . . . . . . . 27-11 DIFFERENTIAL CARRIER ASSEMBLY REMOVAL
AND INSTALLATION . . . . . . . . . . . . . . . . . 27-24
AXLE ASSEMBLY . . . . . . . . . . . . . . . 27-12 DIFFERENTIAL CARRIER ASSEMBLY
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 27-27
AXLE ASSEMBLY REMOVAL AND INSTALLATION
...................................... 27-12 DIFFERENTIAL CARRIER ASSEMBLY
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 27-31
AXLE SHAFT ASSEMBLY . . . . . . . . 27-15 REAR DIFFERENTIAL LOCK DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 27-40
27-2 REAR AXLE
GENERAL INFORMATION
GENERAL INFORMATION
M1271000101426
The rear axle has the following features: • Helical limited slip differential has been adopted
• A banjo type semi-flowing type axle has been as optional. <2WD except High rider>
incorporated. • Hybrid limited slip differential has been adopted
• The wheel bearing is a double taper roller bearing as optional.
and is highly resistant to a thrust load. • Rear differential lock system has been adopted
• ABS rotor for detecting the wheel speed is press- as optional.<4WD>
fitted to the retainer. <Vehicles with ABS>
REAR AXLE
Item Specification
Axle housing Type Banjo
Axle shaft Type Semi-floating
Shaft outer diameter (bearing part × Vehicles without rear 40.0 × 34.5 × 736
centre part) × length mm differential lock
Vehicles with rear 40.0 × 34.5 × 715*2
differential lock − LH
40.0 × 34.5 × 718.5*3
Vehicles with rear 40.0 × 34.5 × 752.25*2
differential lock − RH
40.0 × 34.5 × 749.5*3
Bearing type Double taper roller
Bearing (Outside diameter × inside diameter) mm 80 × 40
DIFFERENTIAL
<2WD>
Item Except High rider High rider
Reduction gear type Hypoid gear Hypoid gear
Reduction ratio 3.909 3.917
Differential type Standard Normal differential Normal differential
equipment
Optional Helical limited slip Hybrid (Helical gear +
equipment differential Viscous coupling unit)
limited slip differential
Differential gear type (Type × Side gear Straight bevel gear × 2 Straight bevel gear × 2
number of gears) Pinion gear Straight bevel gear × 2 Straight bevel gear × 2
Number of teeth Drive gear 43 47
Drive pinion 11 12
Side gear*1 14 19
Pinion gear*1 10 10
Bearing (Outside diameter × Side 80.0 × 45.2 80.0 × 45.2
inside diameter) mm Front 68.3 × 30.2 68.3 × 30.2
Rear 76.2 × 36.5 79.4 × 36.5
REAR AXLE
GENERAL INFORMATION
27-3
<Easy select 4WD>
Item Specification
Reduction gear type Hypoid gear
Reduction ratio 3.917
Differential type Standard Normal differential
equipment
Optional Hybrid (Helical gear + Viscous coupling unit) limited slip
equipment differential or Differential lock system
Number of teeth Drive gear 47
Drive pinion 12
Side gear*1 19
Pinion gear*1 10
Bearing (Outside diameter × Side 80.0 × 45.2
inside diameter) mm Front 68.3 × 30.2
Rear 79.4 × 36.5
<Super select 4WD>
Item Except 5A/T 5A/T
Reduction gear type Hypoid gear Hypoid gear
Reduction ratio 4.100*4, 3.917*5 3.917
Differential type Standard Normal differential Normal differential
equipment
Optional Hybrid (Helical gear + Hybrid (Helical gear +
equipment Viscous coupling unit) Viscous coupling unit)
limited slip differential or limited slip differential or
Differential lock system Differential lock system
Number of teeth Drive gear 41*4, 47*5 47
Drive pinion 10*4, 12*5 12
Side gear*1 19*4,18*5 19
Pinion gear*1 10 10
Bearing (Outside diameter × Side 80.0 × 45.2*4, 90.0 × 55.0*5 80.0 × 45.2
inside diameter) mm
Front 68.3 × 30.2 68.3 × 30.2
Rear 79.4 × 36.5*4, 90.0 × 36.5*5 79.4 × 36.5
NOTE: .
• *1: This indicates vehicles with normal differential,
but there was no reference made to vehicles with
Helical LSD, Hybrid LSD or Rear differential lock
system.
*2
• :5A/T or except vehicles with High power
engine
• *3:Vehicles with High power engine except 5A/T
• *4:Vehicles for Europe (4AT) and Russia
• *5:Vehicles for Europe (Except 4AT)
27-4 REAR AXLE
M1271000301204

Rear axle total backlash mm − 5
Axle shaft axial play mm 0 − 0.25 −
Axle shaft retainer press-fitting force N Initial press-fitting −
force 29,400 or
more
Final press-fitting −
force 98,000 −
107,800
Clearance between axial shaft retainer and snap ring mm 0 − 0.166 −
Rear differential lock air pump pressure kPa 24.5 − 39 (-30 − −
0°C), 24.5 − 34 (0 −
100°C)
Drive gear 2WD except High rider 0.07 − 0.13 −
backlash mm High rider 0.08 − 0.18
4WD 0.08 − 0.18
Drive gear run-out mm − 0.05
Differential gear backlash mm 0.01 − 0.25 −
Drive pinion Without Bearing (oil seal contacting area) with 0.59 − 0.88 −
turning torque oil seal anti-rust agent
N⋅m Bearing (oil seal contacting area) with 0.39 − 0.49 −
gear oil applied
With oil Companion flange (oil seal contacting 0.84 − 1.12 −
seal area) with anti-rust agent
Companion flange (oil seal contacting 0.64 − 0.73 −
area) with gear oil applied
Clearance between differential case and side gear <rear differential 0.05 − 0.20 −
lock (5A/T or except vehicles with High power engine)> mm
REAR AXLE
LUBRICANT
27-5
LUBRICANT
M1271000400907

Rear differential gear oil Gear oil API classification GL- 2WD except High rider 1.5 L
5 or higher SAE 80W High rider 2.6 L <Up to
September>
2.1 L <From
October>
4WD 5A/T or except 2.6 L <Up to
vehicles with High September>
power engine 2.1 L <From
October>
Vehicles with High 3.2 L <Up to
power engine September>
except 5A/T 2.1 L <From
October>
SEALANT AND ADHESIVE

M1271000500506
Item Specified sealant and adhesive Remark

Axle shaft bearing case ThreeBond 1217 or equivalent Semi-drying sealant
Axle housing (differential carrier
mounting part)
Drive gear and differential case LOCTITE No.271 or No.270 or equivalent Anaerobic adhesive
mounting part
SPECIAL TOOLS
M1271000601186

MB990767 Front hub and Fixing of the axle shaft
flange yoke holder assembly
B990767
MB991618 Hub bolt remover Removal of the hub bolt
MB991618
B MB990590 Rear axle shaft oil • Removal of axle shaft (use

A: MB990212 seal remover together with MB990241,
B: MB990211 A: Adapter MB990211)
B: Slide hammer • Removal of axle housing oil
A MB990590 seal
27-6 REAR AXLE
SPECIAL TOOLS

MB991354 Puller body Removal of axle shaft (use
together with MB990211)
MB991354
MB990241 Rear axle shaft Removal of axle shaft (use

puller together with MB990211)
MB990241
MB990925 Bearing and oil • Installation of axle housing oil

A: MB990926 − MB990937 seal installer set seal
C B: MB990938 A:Installer adapter • Press-fitting of bearing outer
C: MB990939 B: Installer bar race
B A MB990925 C: Remover bar • Press fitting of oil seal
• Press-fitting of drive pinion
front bearing outer race
For details of each installer,
refer to GROUP 26 − Special
Tools .
MB991552 Axle shaft bearing Removal of the axle shaft
and case remover bearing and bearing case
MB991522
MB990560 Rear axle shaft Removal of bearing inner race

bearing remover
MB990560
MB990799 Ball joint remover Removal of bearing case,

and installer A bearing outer race
Press-fitting of bearing inner
race
MB990799 Press-fitting of retainer
MB990890 or MB990891 Rear suspension Press-fitting of bearing outer

bushing base race
MB990890
REAR AXLE
SPECIAL TOOLS
27-7
MB991367 Special spanner Removal and adjustment of the
side bearing nut
B991367
MB991385 Pin
B991385
MB990810 Side bearing puller Removal of the side bearing

inner race
MB990810
MB991407 Differential rear Removal of the side bearing

support arbour inner race
MB991407
MB990850 End yoke holder Removal of the companion

flange
MB990850
MD998801 Bearing remover Removal of the drive pinion rear

bearing inner race
MB991445 Bushing remover Press-fitting of the drive pinion

and installer base rear bearing outer race (Use
together with MB990938)
<Vehicles with High power
engine except 5A/T>
A
C MB991171 Pinion height Measurement of the pinion
A: MB990819 gauge set height
B: MB991170 A: Pinion gauge
B
C: MB991169 B: Cylinder gauge
A
C
MB991171 C: Drive pinion
gauge
attachment
MB991534 Cylinder gauge
MB991534
27-8 REAR AXLE
ON-VEHICLE SERVICE

MB990326 Preload socket Measurement of drive pinion
turning torque
MB990326
MB990685 Torque wrench
MB991168 Differential oil seal Press-fitting of the drive pinion

installer oil seal
MB991168
MB990802 Bearing installer Press-fitting of the drive pinion

rear bearing inner race
MB990802
MB990728 Side and rear Installation of side bearing inner

bearing inner race race
installer
MB990728
ON-VEHICLE SERVICE
REAR AXLE TOTAL BACKLASH CHECK 3. Turn the companion flange clockwise as far as it
M1271001200393 will go. Make the mating mark on the dust cover of
1. Park the vehicle on a flat, level surface. the companion flange and on the differential
2. Move the transmission control lever to the neutral carrier.
position or the selector lever to the "N" position.
Then place the transfer sift lever to the "2H"
position <4WD>. Apply the parking brake. Raise
the vehicle on a jack.
Mating marks
ACX00964
4. Turn the companion flange anti-clockwise as far

as it will go, and measure the amount of distance
ACX00962 AB
the mating marks moved.
Limit: 5 mm
REAR AXLE
ON-VEHICLE SERVICE
27-9
5. If the backlash exceeds the limit value, remove Specified gear oil:
the differential carrier assembly and check the Gear oil API classification GL-5 or higher
following. SAE 80W
• Drive gear backlash (Refer to P.27-27) 3. Tighten the filler plug to the specified torque
• Differential gear backlash (Refer to P.27-27) (Refer to P.27-24).
GEAR OIL LEVEL CHECK GEAR OIL REPLACEMENT
M1272001200556 M1272004600683
<Up to September> <Up to September>
1. Remove the filler plug.
2. Remove the drain plug and drain oil.
Gear oil 3. Tighten the drain plug to the specified torque
(Refer to P.27-24).
Upper 4. Add the oil until the level comes to the lower
limit portion of the filler plug hole.
Lower Specified gear oil:
limit 8 mm Gear oil API classification GL-5 or higher SAE
AC505405 AB
80W
Amount to use:
1. Check that gear oil level is not 8 mm below the 1.5 L <2WD (except High rider)>
bottom of filler plug hole. 2.6 L <2WD (High rider), 4WD (5A/T or
2. If the gear oil level is lower than the lower limit, except vehicles with High power
add the specified gear oil until the level comes to engine)>
the lower portion of the filler plug hole. 3.2 L <Vehicles with High power engine
Specified gear oil: except 5A/T>
Gear oil API classification GL-5 or higher 5. Tighten the filler plug to the specified torque
SAE 80W (Refer to P.27-24).
(Refer to P.27-24). <From October>
1. Remove the filler plug.
<From October> 2. Remove the drain plug and drain oil.
CAUTION 3. Tighten the drain plug to the specified torque
Be careful not to drop the inspection tool into the (Refer to P.27-24).
differential.
Inspection tool
24 mm
Bottom edge
A of the filler
Bottom edge
Gear oil plug hole
of the filler
level
Gear oil plug hole ACB00140AC
level ACB00137AH
4. Refill the gear oil until the level satisfies the
1. Insert an inspection tool as shown so that it specification.
touches the bottom of the filler plug. The Specified gear oil:
inspection tool: 6 mm-diameter L shaped bar (e.g. Gear oil API classification GL-5 or higher SAE
6 mm-diameter angled hexagon wrench). 80W
2. Pull out the wrench, and then check that the Amount to use:
dimension to the gear oil level is within 24 mm. 1.5 L <2WD (except High rider)>
27-10 REAR AXLE
ON-VEHICLE SERVICE
2.1 L <2WD (High rider), 4WD (5A/T or

except vehicles with High power
engine)>
2.1 L <Vehicles with High power engine
except 5A/T>
Plain washer
(Refer to P.27-24).
AXLE SHAFT AXIAL PLAY CHECK

M1271001300107 MB990767
AC711178 AC
3. Install the plain washer to the new hub bolt, and

install the bolt with a nut.
4. Install the brake drum.
REAR DIFFERENTIAL LOCK DETECTION

SWITCH CHECK <4WD>
M1272001000091
1. Jack up the vehicle.
AC004839 AB
2. Remove the air pipe and air hose connection.
1. Measure the axle shaft axial play by using a dial
indicator.
2. If not within specifications, replace the axle shaft 1 2
assembly.
AXLE SHAFT AXIAL PLAY ADJUSTMENT

M1271001400104
The axle shaft axial play is preset at factory. It can
not be adjusted.
HUB BOLT REPLACEMENT

M1271001000623
1. Remove the brake drum.
Pressure
Air
gauge
pressure
MB991618
Air valve Air regulator
AC508806AB
3. Connect a pressure gauge and air regulator to the

air pipe.
MB990767 CAUTION
Do not apply a higher pressure so as not to dam-
AC711177AC
age the air regulator.
2. Use the following special tools to remove the hub 4. Adjust the outside air pressure with the air
bolts. regulator until the pressure gauge shows approx.
• Front hub and flange yoke holder (MB990767) 24.5 kPa.
• Hub bolt remover (MB991618)
5. Lock the wheel on one side of the vehicle, and
slowly turn the wheel on the other side.
6. Check for continuity in the rear differential lock
detection switch.
REAR AXLE
ON-VEHICLE SERVICE
27-11
Measurement Specified condition 2. Connect a pressure gauge and air regulator to the
conditions air hose.
When air is applied Continuity (less than 2 CAUTION
Ω) Do not apply a higher pressure so as not to dam-
age the air regulator.
When air is released Open circuit
3. Adjust the outside air pressure with the air
REAR DIFFERENTIAL LOCK SYSTEM AIR regulator until the pressure gauge shows approx.
34 kPa.
LEAKAGE CHECK <4WD>
M1272001100065 4. Shut off the air valve.
1. Remove the rear differential lock air pump and 5. If the pressure has not dropped more than 10 kPa
remove the air hose from the air pump. after 10 minutes have passed, there can be no air
leakage from the air hose etc.
Pressure
Air
gauge
pressure
Air valve Air regulator

AC508807AB
27-12 REAR AXLE
AXLE ASSEMBLY
AXLE ASSEMBLY
M1271001700569
CAUTION
• *: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle
on the ground in an unladen condition.
• Brake Fluid Draining • Brake Fluid Filling and Air Bleeding (Refer to GROUP
35A, On-vehicle Service .)
• Parking Brake Lever Stroke Adjustment (Refer to GROUP
36, On-vehicle Service .)
<2WD (Except High rider)> 15 ± 2 N·m

10
15
17 14
7
2
1
54 ± 5 N·m 7
11
5 6N
52 ± 7 N·m *
4
16
22 ± 3 N·m *
3 12 108 ± 10 N·m
13
AC500808AG
REAR AXLE
AXLE ASSEMBLY
27-13
<2WD (High rider), 4WD>

15
14
<Vehicles with rear differential lock>
4 9
3 8
17 7 10 9.8 ± 2.0 N·m
2
1
103 ± 5 N·m
11
7 5
15 ± 2 N·m 6N
22 ± 3 N·m *
12 108 ± 10 N·m
7 13
AC808344 AD

1. Brake drum <<A>> PROPELLER SHAFT REMOVAL
2. Shoe and lining assembly (Refer to
GROUP 35A, Rear Drum Brake , .) CAUTION
3. Parking brake cable attaching bolt Suspend the propeller shaft from the body with
4. Parking brake cable connection wire, etc. to prevent it from falling.
5. Rear wheel speed sensor <Vehicles
with ABS> Mating marks
6. O-ring <Vehicles with ABS>
7. Brake hose and brake tube
connection
8. Bolt <Vehicles with rear differential
lock>
9. Breather hose <Vehicles with rear
differential lock>
10. Bracket
<<A>> >>B<< 11. Propeller shaft connection AC003833 AC
<> >>A<< 12. Shock absorber connection
Make the mating marks on the flange yoke of the
13. U bolt seat
14. U bolt propeller shaft and the companion flange of the dif-
15. Bump stopper ferential carrier.
16. Shackle assembly
<<C>> 17. Axle assembly
27-14 REAR AXLE
AXLE ASSEMBLY
<> SHOCK ABSORBER DISCONNECTION INSTALLATION SERVICE POINTS

>>A<< SHOCK ABSORBER CONNECTION
Inner Outer
washer washer
AA500013
Support the axle housing with a jack before removing AC805318AB

the shock absorber lower mounting nut.
Be sure to install the shock absorber washers (outer
and inner) in the specified direction.
<<C>> AXLE ASSEMBLY REMOVAL
WARNING >>B<< PROPELLER SHAFT INSTALLATION
Secure the axle assembly to the jack or
equivalent. The axle assembly is heavy and Mating marks
unstable and may fall causing damage to the
assembly, surrounding equipment, or injur-
ing the installer.
Take out the axle assembly from the rear of the vehi-
cle.
AC003833 AC
Align the mating marks on the flange yoke and the

companion flange to install the propeller shaft.
REAR AXLE
AXLE SHAFT ASSEMBLY
27-15
AXLE SHAFT ASSEMBLY
M1271002500267
CAUTION
For vehicles with ABS, be careful not to strike the pole piece at the tip of the front wheel speed sensor
with tools during servicing work.
• Brake Fluid Draining • Brake Fluid Filling and Bleeding (Refer to GROUP 35A,
On-vehicle Service .)
• Parking Brake Lever Stroke Adjustment (Refer to GROUP
36, On-vehicle Service .)
AC501171 AC501171
Apply to entire inside diameter of Sealant: Three Bond 1217 or

oil seal lip equivalent
15 ± 2 N·m 7
9 N
54 ± 5 N·m 1
5
<2WD (High rider),
4WD>
3
6 N
2
<2WD (Except High
rider)> 4
5 6 N
3 4
AC805319 AB

1. Brake drum 5. Rear wheel speed sensor <Vehicles
2. Shoe and lining assembly (Refer to with ABS>
GROUP 35A, Rear Drum Brake , .) 6. O-ring <Vehicles with ABS>
3. Parking brake cable attaching bolt 7. Brake tube connection
4. Parking brake cable connection <<A>> 8. Axle shaft assembly
<> >>A<< 9. Oil seal
27-16 REAR AXLE
AXLE SHAFT ASSEMBLY
REMOVAL SERVICE POINTS <> OIL SEAL REMOVAL

<<A>> AXLE SHAFT ASSEMBLY REMOVAL
<2WD (except MB990211
High rider)> MB991354
MB990211
MB990212
AC500819AB
AC702338AC Use the following special tools with hook attached to

remove the oil seal.
<2WD (High rider), 4WD> • Slide hammer (MB990211)
MB990241
• Adapter (MB990212)
MB990211 INSTALLATION SERVICE POINT

MB990930
AC500818AD
Pull the rear axle shaft from axle housing. If the rear
axle shaft is hard to remove, use the following spe-
cial tools.
• Slide hammer (MB990211) MB990938
• Puller body (MB991354) <2WD (except High
rider)> AC500820AB
• Rear axle shaft puller (MB990241) <2WD (High Drive the new oil seal into the rear axle housing end
rider), 4WD> by using the following special tools.
• Installation adapter (MB990930)
REAR AXLE
AXLE SHAFT ASSEMBLY
27-17
M1271002700186
AC501172
Apply to entire inside diameter of oil
seal lip and bearing inner race.
N1
N 2
8
10 6
4
N 9
3
5
7
AC801655AB
Disassembly steps DISASSEMBLY SERVICE POINTS

1. Snap ring <<A>> RETAINER REMOVAL
<<A>> 2. Retainer
<> 3. Axle shaft
4. Bearing case
5. Backing plate
<<C>> 6. Outer bearing inner race
7. Hub bolt Backing
8. Inner bearing inner race plate
9. Oil seal
<<D>> 10. Bearing outer race Retainer
Reassembly steps bolt
>>A<< 10. Bearing outer race
AC004855AB
>>B<< 9. Oil seal
>>C<< 6. Outer bearing inner race 1. Remove one retainer bolt from the backing plate.
>>C<< 8. Inner bearing inner race
7. Hub bolt Grinder
5. Backing plate
4. Bearing case
3. Axle shaft
>>D<< 2. Retainer
>>E<< 1. Snap ring
Gummed
cloth tape
AC004867 AB
2. Apply gummed cloth tape around the edge of the

bearing case for protection.
27-18 REAR AXLE
AXLE SHAFT ASSEMBLY
CAUTION 1. Secure special tool axle shaft bearing and case

Be careful not to damage the bearing case and remover (MB991552) to the bearing case bolts
the axle shaft. with the nuts and adjust the height of the hanger.
3. As shown in the figure, hold the axle shaft. Using Then install the washers, plate and nuts in that
a grinder, shave off a point of its circumference order.
locally until the wall thickness become as follows: NOTE: The washers are used to eliminate the dif-
• 1.0 − 1.5 mm for axle shaft side ference in height of the bearing case so that the
• 2.0 mm for bearing side plate and the bearing case are parallel.
CAUTION CAUTION
Be careful not to damage the bearing case and The hanger and plate should be placed so that
the axle shaft. they are parallel.
2. Place the end of the bolt against the centre of the
Grinder
axle shaft, and then tighten the bolt to remove the
axle shaft from the bearing case assembly.
<<C>> OUTER BEARING INNER RACE REMOVAL

Bearing
case
Bearing inner
race
MB990560
Retainer
AC004868AB
4. Fix the axle shaft and shave off the remaining 2.0
mm on the side of the retainer bearing.
CAUTION
Be careful not to damage the axle shaft. AC500968 AB
Install special tool rear axle shaft bearing remover

(MB990560) as shown in the illustration, and then
use a press to remove the outer bearing inner race
from the axle shaft.
<<D>> BEARING OUTER RACE REMOVAL
MB990799
AC004869AB
5. Cut in with a chisel the place where the retainer

ring has been shaven and remove the retainer
Bearing outer
ring. race
<> AXLE SHAFT REMOVAL

AC004873 AB
MB991552 Reinstall the outer bearing inner race that was
Plate Washer
removed previously. Use special tool ball joint
remover and installer A (MB990799) and a press to
Hanger Nut
remove the bearing outer race.
Nut
Bearing
Bolt Washer
case
AC103785 AB
REAR AXLE
AXLE SHAFT ASSEMBLY
27-19
REASSEMBLY SERVICE POINTS 1. Apply multipurpose grease to the roller surface
>>A<< BEARING OUTER RACE INSTALLATION and ends of the bearing.
2. Pass the axle shaft through the bearing case and
the inner bearing inner race and outer bearing
inner race.
MB990890 or CAUTION
MB990891
Both the inner bearing inner race and outer bear-
ing inner race should be press-fitted together.
(MB990799) to press-fit the inner bearing inner
race and outer bearing inner race to the axle
AC004875AB shaft.
Use special tool rear suspension bushing base
(MB990890 or MB990891) to press-fit the bearing >>D<< RETAINER/ABS ROTOR INSTALLATION
outer race to the bearing case.
>>B<< OIL SEAL INSTALLATION

1. Set the outer bearing inner race.
MB990938
Retainer
MB990799
MB990936
AC501192AB
Outer bearing
inner race
(MB990799) to press-fit the retainer with ABS
rotor to the axle shaft. Check that the press-fitting
AC004896 AB force is at the standard value.
2. Apply multipurpose grease to the outside of the oil 2. If the initial press-fitting force is less that the
seal. standard value, replace the axle shaft.
3. Use the following special tools, press-fit the oil Standard value:
seal into the bearing case until it is flush with the Initial press-fitting force 29,400 or more
face of the bearing case. N
• Installer bar (MB990938) Final press-fitting force N 98,000 − 107,800
4. Apply multipurpose grease to the lips of the oil
seal. >>E<< SNAP RING INSTALLATION
A
>>C<< INNER BEARING INNER RACE/OUTER
Snap ring
BEARING INNER RACE INSTALLATION
Axle shaft
Outer bearing
inner race Retainer ring
Inner bearing
AC501193 AB
inner race
Bearing case
MB990799
AC501191AB
27-20 REAR AXLE
AXLE SHAFT ASSEMBLY
1. After installing the snap ring, measure clearance Example:

(A) between the snap ring and the retainer with a Clearance 2.0 mm
feeler gauge. Check that it is within the standard Standard value 0 − 0.166 mm
value.
Thickness of snap ring 1.85 mm
Standard value (A): 0 − 0.166 mm
2. If the clearance exceeds the standard value, INSPECTION
M1271002800150
change the snap ring so that the clearance is at
• Check the dust cover for deformation and dam-
the standard value.
age.
Thickness of snap ring Identification colour • Check the inner and outer bearings for seizure,
mm discolouration and rough raceway surface.
2.17 − • Check the axle shaft for cracks, wear and dam-
age.
2.01 Yellow
1.85 Blue
1.69 Purple
1.53 Red
REAR AXLE
REAR DIFFERENTIAL LOCK <4WD>
27-21
M1272002700190
4WD indicator
ECU
AC508535 AC508815
10
5 37 ± 6 N·m 11 N
7
12 ± 2 N·m
5.0 ± 1.0 N·m
12 ± 2 N·m
8
AC510986
3
9 5.0 ± 1.0 N·m
AC511009 AC608183 AB

1. Rear differential lock switch >>A<< VACUUM HOSE CONNECTION
• Glove box cover (Refer to GROUP
52A, Instrument Panel .)
2. Rear differential lock-ECU
>>A<< 3. Vacuum hose
4. Rear differential lock harness
5. Vapour hose
Vacuum
6. Hose
hose
7. Bracket
8. Rear differential lock air pump
9. Bracket
10. Rear differential lock detection switch
(Refer to P.27-24.) AC508703 AB
11. Gasket Connect the vacuum hose so that the white mark is
located upward.
27-22 REAR AXLE
INSPECTION Switch Tester Specified

M1272003300032
position connection condition
REAR DIFFERENTIAL LOCK SWITCH CHECK
ON switch 3-6 Continuity (less
operation (push than 2 Ω)
the upper part
of switch)
N (released 3 - 6 and 2 - 3 Open circuit
switch position)
OFF switch 2-3 Continuity (less
1 2
operation (push than 2 Ω)
3 4 5 6
the lower part of
AC508810 switch)
Check for continuity between the terminals of the
switch. REAR DIFFERENTIAL LOCK-ECU CHECK
M1272003200079
1 2 3 4
5 6 7 8 9 10
AC608602
Terminal Item Condition Terminal voltage

No.
2 Vehicle speed reed Select "D" <A/T>, or "1st"<M/T> and drive 5V
switch forward slowly.
3 Ignition switch (IG1) Ignition switch: OFF 1 V or less
Ignition switch: ON System voltage
4 Rear differential lock air Ignition switch: When filling or holding System voltage
pump ON When releasing 1 V or less
5 Free wheel engage Ignition switch: 4WD 1 V or less
switch ON 2WD System voltage
6 Earth − − −
8 Rear differential lock Ignition switch: Rear differential lock is 1 V or less
detection switch ON locked
Rear differential is free System voltage
9 Rear differential lock Ignition switch: Rear differential lock switch 1 V or less
switch (On position) ON is pushed.
Rear differential lock switch System voltage
is not pushed.
REAR AXLE
27-23
Terminal Item Condition Terminal voltage
No.
1 Rear differential lock Ignition switch: Rear differential lock switch 1 V or less
switch (OFF position) ON is pushed.
Rear differential lock switch System voltage
is not pushed.
10 Rear differential lock Ignition switch: Rear differential is locked 1 V or less
indicator lamp ON Rear differential is free System voltage
REAR DIFFERENTIAL LOCK AIR PUMP 5. Measure the pressure 10 − 20 seconds after the
CHECK pump has stopped.
M1272003100038 Standard value: 24.5 − 39 kPa (-30 − 0°C),
1. Install the air hose to the differential. 24.5 − 34 kPa (0 − 100°C)
Air hose T-joint 6. If the pressure is within the standard value, the
release valve inside the pump is normal.
Differential
7. Check the pump does not begin operating for 5
minutes after it has stopped.
8. If the inspection for steps 4-7 is normal, the pump
Pressure is fully operational.
gauge
REAR DIFFERENTIAL LOCK DETECTION
SWITCH CHECK
M1272001000057
Battery (-)
OFF ON
1
2
Battery (+)
AC508812AB Rod
1 2
2. Connect a pressure gauge to the air pump
discharge outlet nozzle, via the air hose and T-
joint.
3. Apply battery voltage to the air pump connector. AC711365AB
Check for continuity between the terminals of the

Release
switch.
valve
Atmosphere Measurement Terminal Specified
condition connector of condition
tester
Motor When the rod is 1-2 Continuity
pulled (less than 2
Pressure
Differential Ω)
switch
AC508813AB When the rod is Open circuit
returned to its
4. Measure the time when the pump starts and stops
normal position
operating, and if it stops within 5 seconds, the
pressure switch inside the pump is normal.
27-24 REAR AXLE

M1272002000867

• Differential Gear Oil Draining • Axle Shaft Assembly Installation (Refer to P.27-15.)
• Axle Shaft Assembly Removal (Refer to P.27-15.) • Differential Gear Oil Filling (Refer to P.27-9.)
<2WD>
Section A-A <Except High <High rider>
rider>
2.0 - 2.5 mm * 1
2.5 - 3.0 mm * 2 7 9
A A
8
AC808355
Sealant:
Sealant:
7 9
6 8
4
54 ± 5 N·m * 1
50 ± 10 N·m
103 ± 5 N·m* 2
1 5N
27 ± 2 N·m* 1
3N
47 ± 7 N·m* 2
NOTE: 60 ± 10 N·m
* 1 : Except High rider 2
* 2 : High rider
AC808347AD

<<A>> >>C<< 1. Propeller shaft <> 6. Differential carrier assembly
2. Drain plug 7. Vent plug <Except High rider>
3. Packing >>A<< 8. Vent plug <High rider>
4. Filler plug >>A<< 9. Plug cover <High rider>
5. Gasket
REAR AXLE
27-25
<4WD>
<5A/T or 11 ± 2 N·m
Section A-A 9
except vehicles with 12
High power engine>
2.5 - 3.0 mm 11
A A
8 50 ± 10 N·m
2
3 6
Sealant: 7N
<Vehicles with rear differential lock>

1
Breather 5N
103 ± 5 N·m
hose
<Vehicles with 47 ± 7 N·m 60 ± 10 N·m
4
High power engine
11 ± 2 N·m 12
except 5A/T>
11
10
8 50 ± 10 N·m
2
3
12 9 6
11
7N
1
AC808355
103 ± 5 N·m 5N
Sealant: 22 ± 4 N·m
4 60 ± 10 N·m
ThreeBond 1217 or equivalent 47 ± 7 N·m
AC900084AD

<<A>> >>C<< 1. Propeller shaft <<A>> PROPELLER SHAFT REMOVAL
connector connection <Vehicles with CAUTION
rear differential lock> Suspend the propeller shaft from the body with
>>B<< 3. Vacuum hose connection <Vehicles wire, etc. to avoid spilling transmission fluid and
with rear differential lock> to avoid injury from falling propeller shaft when
4. Drain plug not secured.
5. Packing
6. Filler plug Mating marks
7. Gasket
<> 8. Differential carrier assembly
9. Protector <Vehicles with rear
differential lock>
10. Protector <Vehicles with rear
differential lock>
>>A<< 11. Vent plug <Vehicles without rear
differential lock>
>>A<< 12. Plug cover <Vehicles without rear AC003833 AC
differential lock>
Make the mating marks on the flange yoke of the
propeller shaft and the companion flange of the dif-
ferential carrier.
27-26 REAR AXLE
<> DIFFERENTIAL CARRIER REMOVAL >>B<< VACUUM HOSE CONNECTION

CAUTION <5A/T or except vehicles with
Use care not to strike the companion flange. High power engine>
Vacuum
hose
AC508832AE
<Vehicles with
AC502392 High power
Remove the attaching nuts. Strike the lower part of engine
except 5A/T>
differential carrier assembly with a piece of wood
Vacuum
several times to loosen the assembly. Remove the hose
assembly.

>>A<< PLUG COVER/VENT PLUG INSTALLATION
AC600925AE
Plug cover
Vent plug
Connect the vacuum hose so that the red mark is
located upward.
Drain
Slit groove
>>C<< PROPELLER SHAFT INSTALLATION
Mating marks
AC808356AB
1. Place the drain groove of vent plug towards

vehicle wheel side and install it on the axle
housing.
2. Place the plug cover slit towards the vehicle rear AC003833 AC
side and install it.
Align the mating marks on the flange yoke and the
companion flange to install the propeller shaft.
REAR AXLE
27-27
DISASSEMBLY
M1272002200560
CAUTION
Do not disassemble the limited slip differential case assembly.
<Vehicles without rear differential lock> <Conventional differential>
5
2 1 6 4
1312
9
10 11
8 7
14
6 5
29 3 11
12 13 2
10
N 25 27
17
1
28 22 23 24
20 21 <Limited slip differential>
3
N 16 26 19
18 1 5 6 4
7
2
6 5
2
15 1
AC611940AC

<<A>> • Inspection before disassembly <<G>> 16. Self-locking nut
1. Lock plate 17. Washer
<> 2. Side bearing nut <<H>> 18. Companion flange
3. Bearing cap <<H>> 19. Drive pinion assembly
<<C>> 4. Differential case assembly 20. Drive pinion front shim (For adjusting
5. Differential side bearing outer race preload of drive pinion)
<<D>> 6. Differential side bearing inner race 21. Drive pinion spacer
<<E>> 7. Drive gear <> 22. Drive pinion rear bearing inner race
<<F>> 8. Lock pin 23. Drive pinion rear shim (for adjusting
9. Pinion shaft drive pinion height)
10. Pinion gear 24. Drive pinion
11. Pinion washer <<J>> 25. Oil seal
12. Side gear <<J>> 26. Drive pinion front bearing inner race
13. Side gear spacer <<J>> 27. Drive pinion front bearing outer race
14. Differential case <<K>> 28. Drive pinion rear bearing outer race
15. Limited slip differential case assembly 29. Differential carrier
27-28 REAR AXLE
<Vehicles with rear differential lock> 14 4 1
2
3 8 7
9
5
12
15 N 17 33 13
9 8
10 11
16
18
21 N 19
26 27 28
24 25 32 3 2
6
30 31 23
20 N 29 N
22
AC804640AB

<<A>> • Inspection before disassembly <<K>> 32. Drive pinion rear bearing outer race
1. Hose 33. Differential carrier
2. Lock plate
<> 3. Side bearing nut DISASSEMBLY SERVICE POINTS
4. Bolt <<A>> INSPECTION BEFORE DISASSEMBLY
5. Bolt Except for the following standard values, inspection
6. Bearing cap procedure is the same as GROUP 26, inspection
<<C>> 7. Differential case assembly
before disassembly .
8. Differential side bearing outer race
<<D>> 9. Differential side bearing inner race Drive gear backlash
10. Actuator assembly Standard value:
11. Pressure plate 0.07 − 0.13 mm <2WD (except High rider)>
<<E>> 12. Drive gear 0.08 − 0.18 mm <2WD High rider, 4WD>
13. Differential case
14. Air pipe assembly (A) <> SIDE BEARING NUT REMOVAL
15. Eye bolt
MB991367
16. Air pipe assembly (B)
17. Gasket MB991385
19. Gasket
<<G>> 20. Self-locking nut
21. Washer
<<H>> 22. Companion flange
<<H>> 23. Drive pinion assembly
24. Drive pinion front shim (for adjusting
preload of drive pinion) AC004921AB
25. Drive pinion spacer
<> 26. Drive pinion rear bearing inner race Use the following special tools, remove the side
27. Drive pinion rear shim (for adjusting bearing nut.
drive pinion height) • Special spanner (MB991367)
28. Drive pinion • Pin (MB991385)
<<J>> 29. Oil seal NOTE: Keep the right and left side bearings and side
<<J>> 30. Drive pinion front bearing inner race bearing nuts separate, so that they do not become
<<J>> 31. Drive pinion front bearing outer race mixed at the time of assembly.
REAR AXLE
27-29
<<C>> DIFFERENTIAL CASE ASSEMBLY <<E>> DRIVE GEAR REMOVAL
REMOVAL
CAUTION
When taking out the differential case assembly,
be careful not to drop and damage the differential
side shims or the side bearing outer races.
Mating
marks
ACX01042AB
1. Make mating marks to the differential case and

the drive gear.
2. Loosen the drive gear attaching bolts in diagonal
ACX02422
sequence to remove the drive gear.
Use the wooden handle of a hammer to remove the

<<F>> LOCK PIN REMOVAL
differential case assembly, differential side shims and
side bearings.
NOTE: Keep the right and left side bearings and side
bearing outer race separated, so that they do not
become mixed at the time of assembly.
Punch
<<D>> SIDE BEARING INNER RACE REMOVAL
MB990810
ACX01048AB
MB991407 Drive out the lock pin with a punch.
<<G>> SELF-LOCKING NUT REMOVAL
AC203814 AC
Use the following special tools to pull out the side MB990850
bearing inner race.
• Side bearing puller (MB990810)
• Differential support bush arbour (MB991407)
NOTE: Attach the prongs of special tools to the inner
race of the side bearing through the openings in the
ACX01043AB
differential case.
Use special tool end yoke holder (MB990850) to hold
the companion flange, and then remove the compan-
ion flange self-locking nut.
27-30 REAR AXLE
<<H>> DRIVE PINION ASSEMBLY/COMPANION Use special tool remover (MD998801) to pull out the
FLANGE REMOVAL front bearing inner race.
CAUTION
Do not make mating marks on the contact sur- <<J>> OIL SEAL/DRIVE PINION FRONT BEARING
faces of the companion flange and propeller INNER RACE/DRIVE PINION FRONT BEARING
shaft. OUTER RACE REMOVAL
1. Make mating marks to the drive pinion and MB990939
companion flange.
MB990810
Drive pinion rear
bearing outer
Drive pinion front race
bearing outer race
Drive pinion front
bearing inner
race
Oil seal
Companion ACX01101AB
flange
Use special tool brass bar (MB990939) to remove
AC102894 AD
the drive pinion front bearing outer race.
2. Use special tool side bearing puller (MB990810) <<K>> DRIVE PINION REAR BEARING OUTER
to pull out the companion flange. RACE REMOVAL
<> DRIVE PINION REAR BEARING INNER

RACE REMOVAL MB990939
MD998801
ACX01102 AB
Use special tool brass bar (MB990939) to remove

the drive pinion rear bearing outer race.
AC104970AC
REAR AXLE
27-31
REASSEMBLY
M1272002300664
<Vehicles without rear differential lock>

19 ± 3 N·m
25 <Conventional
28 29 24
1718
26 differential>
21
2019
74 ± 4 N·m 22 23
15
24 25
1 27
19 28
20 18 17
N8 3 19 ± 3 N·m
13 29
216 ± 29 N·m 84 ± 5 N·m
4
9 2 6 5 <5A/T or except vehicles with
10 High power engine>
27 152 ± 15 N·m
N 14 7 11 <Vehicles with High power engine
12 except 5A/T>
19 ± 3 N·m
26 <Limited
25 24
29 differential>
23
28 16
24 25
23 28
4 21 19 ± 3 N·m
22
14
29
84 ± 5 N·m
AC502387 AC502388
Final drive gear kit Pinion shaft kit
17 18 20
20 16
17
18 AC502389 AC502391
Differential gear kit Limited slip differential kit

AC508818 AD

1. Differential carrier 10. Drive pinion front shim (for adjusting
>>A<< 2. Drive pinion rear bearing outer race drive pinion preload)
>>B<< 3. Drive pinion front bearing outer race 11. Drive pinion assembly
>>C<< • Drive pinion height adjustment 12. Companion flange
4. Drive pinion 13. Washer
5. Drive pinion rear shim (for adjusting 14. Self-locking nut
drive pinion height) 15. Differential case
6. Drive pinion rear bearing inner race 16. Limited slip differential case assembly
>>D<< • Drive pinion preload adjustment 17. Side gear spacer
7. Drive pinion front bearing inner race 18. Side gear
>>D<< 8. Oil seal 19. Pinion washer
9. Drive pinion spacer 20. Pinion gear
>>E<< • Differential gear backlash adjustment
21. Pinion shaft
27-32 REAR AXLE
Reassembly steps (Continued)

>>F<< 22. Lock pin
>>G<< 23. Drive gear
>>H<< 24. Differential side bearing inner race
25. Differential side bearing outer race
26. Differential case assembly
>>I<< 27. Bearing cap
>>J<< • Drive gear backlash adjustment
28. Side bearing nut
29. Lock plate
<Vehicles with rear differential lock> 8.9 ± 1.9 N·m 30 20
15 ± 2 N·m
33
19 ± 3 N·m
32 26 27
31
25 18 ± 3 N·m
29
6.9 ± 1.0 N·m
74 ± 5 N·m 22
15 ± 2 N·m N 17 21
37 ± 6 N·m
19 24 25 26
16 23
32
18
8.9 ± 1.9 N·m
N 15
5 4
2 6 19 ± 3 N·m
10 9 152 ± 15 N·m 31
28
7 3 11
N 14 13
12 8 N 1
216 ± 29 N·m
22
4
14
21
AC502387 AC511010
Final drive gear kit Differential kit
AC804648 AB

1. Differential carrier 11. Drive pinion assembly
>>A<< 2. Drive pinion rear bearing outer race 12. Companion flange
>>B<< 3. Drive pinion front bearing outer race 13. Washer
>>C<< • Drive pinion height adjustment 14. Self-locking nut
4. Drive pinion 15. Gasket
5. Drive pinion rear shim (for adjusting 16. Rear differential lock detection switch
drive pinion height) 17. Gasket
6. Drive pinion rear bearing inner race 18. Air pipe assembly (B)
>>D<< • Drive pinion preload adjustment 19. Eye bolt
7. Drive pinion front bearing inner race 20. Air pipe assembly (A)
>>D<< 8. Oil seal 21. Differential case
>>G<< 22. Drive gear
9. Drive pinion spacer
10. Drive pinion front shim (for adjusting 23. Pressure plate
drive pinion preload) 24. Actuator assembly
REAR AXLE
27-33
Reassembly steps (Continued) Reassembly steps (Continued)
>>H<< 25. Differential side bearing inner race 30. Bolt
26. Differential side bearing outer race 31. Side bearing nut
27. Differential case assembly 32. Lock plate
>>I<< 28. Bearing cap 33. Hose
>>J<< • Drive gear backlash adjustment
29. Bolt LUBRICATION AND ADHESIVE POINTS
<Conventional differential>
<Limited slip differential>
Adhesive:
LOCTITE No.271 or No.270 or equivalent
AC508830AC

>>A<< DRIVE PINION REAR BEARING OUTER
RACE PRESS-FITTING
27-34 REAR AXLE
MB990938
Drive pinion
MB990936 or
attachment MB990820
MB990937
(MB990819)
or
MB991169
MB990819
Washer ( )
AC102907AI AC004937AG
1. Apply multipurpose grease to the washer of

MB990938 special tool pinion gauge (MB990819).
2. Install the following special tools and drive pinion
MB991445
front and rear bearing inner races to the gear
carrier as shown in the illustration.
• Pinion [MB990820 (MB990819)] <2WD (except
High rider)>
• Drive pinion gauge attachment (MB991169)
<2WD High rider, 4WD>
AC602915AB • Pinion gauge (MB990819)
Use the following special tools to press-fit the drive
MB990819
pinion rear bearing outer races into the gear carrier.
• Installer adapter (MB990936) <2WD (except High
rider)>
• Installer adapter (MB990937) <2WD High rider,
5A/T or except vehicles with High power engine>
• Bushing remover and installer base (MB991445)
<Vehicles with High power engine except 5A/T>
ACX01055 AB
>>B<< DRIVE PINION FRONT BEARING OUTER
RACE PRESS-FITTING MB990685 MB990326
MB990938
MB990819
MB990934
ACX01056AB
ACX01107AB
3. Tighten the nut of special tool a little at a time
Use the following special tools to press-fit the drive while measuring the turning torque of the drive
pinion front bearing outer race. pinion by using the following special tools. Then
• Installer bar (MB990938) confirm that the turning torque (without oil seal) is
• Installer adapter (MB990934) at the standard value.
• Preload socket (MB990326)
>>C<< DRIVE PINION HEIGHT ADJUSTMENT • Torque wrench (MB990685)
Adjust the drive pinion height by the following proce- Standard value:
dures:
REAR AXLE
27-35
8. Use a micrometer to measure the shown
Bearing type Bearing Turning torque
dimensions (B, C) of special tools.
lubrication
rust agent)
New or reuse Gear oil applied 0.39 − 0.49 N⋅m
NOTE: Because special tool preload socket D
Cylinder gauge
(MB990326) cannot be turned one turn, turn it
several times within the range that it can be
turned; then, after fitting to the bearing, measure
the turning torque.
AC102914 AC
4. Clean the side bearing hub.

9. Install the bearing cap, and then use a cylinder
MB991170, Notch gauge to measure the inside diameter (D) of the
MB991534 bearing cap.
10.Calculate thickness (F) of the required drive
pinion rear shim twice by the following formula.
Select a shim which most closely matches this
thickness.
A
F = A + B + C − 1/2D − 100.00 mm <2WD
Thickness (except High rider)>
gauge
MB990820 F = A + B + C − 1/2D − 115.00 mm <2WD High
(MB990819) or MB991169 ACX01109 AL
rider, 5A/T or except vehicles with High
5. Place the following special tools between the side power engine>
bearing hub of the gear carrier, and position the F = A + B + C − 1/2D − 120.00 mm <Vehicles
notch as shown in the illustration. Then tighten with High power engine except 5A/T>
side bearing mounting bolt.
• Cylinder gauge (MB991170) <5A/T or except
vehicles with High power engine>
• Cylinder gauge (MB991534) <Vehicles with High
Drive pinion
power engine except 5A/T>
rear shim MB990802
• Pinion [MB990820 (MB990819)] <2WD (except
High rider)>
• Drive pinion gauge attachment (MB991169)
<2WD High rider, 4WD>
6. Use a thickness gauge to measure the clearance ACX02428 AE
(A) between the special tools.
7. Remove the special tools. 11.Fit the selected drive pinion rear shim(s) to the
drive pinion, and press-fit the drive pinion rear
bearing inner race by using special tool bearing
C installer (MB990802).
>>D<< DRIVE PINION PRELOAD ADJUSTMENT

1. Insert the drive pinion into the gear carrier, and
then install the following parts in sequence from
the carrier rear side. Drive pinion spacer, drive
B pinion front shim and drive pinion front bearing
inner race, companion flange.
AC102913 AC
NOTE: Do not install the oil seal.
27-36 REAR AXLE
NOTE: When selecting the drive pinion front

shims, if the number of shims is large, reduce the
MB990850 number of shims to a minimum by selecting the
drive pinion spacers.
Also, select the drive pinion spacer from the fol-
lowing two types.
Height of drive Identification Applicable
pinion spacer colour model
(A) mm
AC201179 AB 56.67 − 5A/T or except
2. Tighten the companion flange to the specified 57.01 White vehicles with
torque by using special tool end yoke holder High power
(MB990850). engine
Tightening torque: 216 ± 29 N⋅m 52.50 Yellow Vehicles with
52.84 Red High power
engine except
MB990326
MB990685 5A/T
MB991168
ACX01062AB
3. Use the following special tools to measure the

drive pinion turning torque (without oil seal).
• Preload socket (MB990326) ACX01064 AD
• Torque wrench (MB990685)
5. Remove the companion flange and drive pinion
Standard value:
again. Then insert the drive pinion front bearing
Bearing type Bearing Turning torque inner race into the gear carrier. Use special tool
lubrication differential oil seal installer (MB991168) to press-
fit the oil seal.
rust agent)
New or reuse Gear oil applied 0.39 − 0.49 N⋅m MB990850
A AC201179 AB
Identifi-
cation 6. Install the drive pinion assembly and companion
colour flange with mating marks properly aligned.
ACX01063 AE
Tighten the companion flange self-locking nut to
the specified torque using special tool end yoke
4. If the drive pinion turning torque is not within the holder (MB990850).
standard value, adjust the turning torque by Tightening torque: 216 ± 29 N⋅m
replacing the drive pinion front shim(s) or the drive
pinion spacer.
REAR AXLE
27-37
NOTE: Do not assemble the thrust block and lock
MB990326 pin yet.
MB990685
Wedge
Side gear
ACX01062AB
thrust
Side gear spacer
7. Use special tools to measure the drive pinion thrust spacer ACX01035 AB
turning torque (with oil seal) to verify that the drive
pinion turning torque complies with the standard 3. Insert a wedge between the side gear and the
value. pinion shaft to lock the side gear.
Standard value: 4. While locking the side gear with the wedge,
Bearing Companion Turning torque indicator on the pinion gear.
division flange
lubrication Standard value: 0.01 − 0.25 mm
New None (with anti- 0.84 − 1.12 N⋅m 5. Measure by the same procedure for the other
rust agent) pinion gear.
6. If the backlash exceeds the limit value, replace
Gear oil applied 0.64 − 0.73 N⋅m
side bearing adjustment spacers.
8. If the turning torque is not within the standard 7. If adjustment is not possible, replace the side
value, check the tightening torque of the gears and pinion gears as a set.
companion flange self-locking nut, and the
8. Check that the backlash is within the limit value
installation of the oil seal.
and that the differential gear turns smoothly.
>>E<< DIFFERENTIAL GEAR BACKLASH
>>F<< LOCK PIN INSTALLATION
ADJUSTMENT
1. Align the pinion shaft lock pin hole with the
Adjust the differential gear backlash by the following
differential case lock pin hole, and drive in the lock
procedure:
pin.
ACX01066
ACX02429
1. Assemble the side gears, side gear thrust

spacers, pinion gears, and pinion washers into the 2. Stake the lock pin with a punch on both sides.
differential case.
2. Temporarily install the pinion shaft. >>G<< DRIVE GEAR INSTALLATION
1. Clean the drive gear attaching bolts.
27-38 REAR AXLE
Use special tool side and rear bearing inner race

installer (MB990728) to press-fit the side bearing
inner races into the differential case.
>>I<< BEARING CAP INSTALLATION
Tap ACX01068AB
2. Remove the adhesive adhered to the threaded

holes of the drive gear by turning the tap (M10 x
1.25). Clean the threaded holes by applying 74 ± 4 N·m
compressed air. AC004945 AB
Align the mating marks on the gear carrier and the

bearing cap, and then tighten the bearing cap.
>>J<< DRIVE GEAR BACKLASH ADJUSTMENT

Adjust drive gear backlash as follows:
MB991367
MB991385
ACX02430
3. Apply specified adhesive to the threaded holes of

the drive gear.
Specified adhesive: LOCTITE No.271 or
AC004921AB
4. Install the drive gear onto the differential case with
the mating marks properly aligned. Tighten the 1. Using the following special tools, temporarily
bolts to the specified torque in a diagonal tighten the side bearing nut to just before
sequence. preloading of the side bearing.
Tightening torque: • Special spanner (MB991367)
84 ± 5 N⋅m <5A/T or except vehicles with High • Pin (MB991385)
power engine>
152 ± 15 N⋅m <Vehicles with High power
engine except 5A/T>
>>H<< SIDE BEARING INNER RACE

INSTALLATION
Piece of
Piece of metal
metal
AC004946 AB
2. Measure the drive gear backlash.

MB990728 Standard value:
0.07 − 0.13 mm <2WD (except High rider)>
0.08 − 0.18 mm <2WD High rider, 4WD>
AC102942 AC
REAR AXLE
27-39
When backlash is
insufficient MB092153 MB092154
Loosen Tighten
Tighten Loosen
When backlash is
excessive AC004947AB AC004949 AB
3. Using special tools, adjust the backlash to 5. Choose and install the lock plate (two kinds).
standard value by moving the side bearing nut as 6. Check the final drive gear tooth contact. If poor
shown. contact is evident, make adjustment. (Refer to
NOTE: First loosen the side bearing nut then GROUP 26, Inspection Before Disassembly .)
tighten the side bearing nut the same amount as
when it was loosened.
MB991367
MB991385 AC004950 AB
AC004948 AB
7. Measure the drive gear run-out.
Limit: 0.05 mm
4. Using special tools, apply the preload, turn down
both right and left side bearing nuts on half the 8. When drive gear run-out exceeds the limit,
distance between centres of two neighboring remove the differential case and then the drive
holes. gears, moving them to different positions and
reinstall them.
9. If adjustment is not possible, replace the
differential case or drive gear and drive pinion as
a set.
27-40 REAR AXLE
DIFFERENTIAL CASE DISASSEMBLY

AND REASSEMBLY <5A/T or EXCEPT
4WD WITH HIGH POWER ENGINE>
M1274200100051
5
7
1 8 15 14
21 20 6
19
18 4
17 3
16 2
15
14 13 10
12
11
9 AC511011
5 16 7
17 8
14 3, 17
6
13
15 15
10 14
12 3
9 4
AC511013 11 AC511012 AC511014
Pinion shaft kit Differential gear kit Differential spacer set

AC511057AB

<<A>> >>B<< 1. Screw 21. Differential case (B)
2. Differential case (A) >>A<< • Differential case and side gear
3. Differential spacer clearance adjustment
4. Side gear LH
5. Differential pin DISASSEMBLY SERVICE POINT
6. Differential pinion shaft <<A>> SCREW REMOVAL
7. Differential washer
8. Differential pinion gear
9. Differential pin
10. Differential pinion shaft
13. Differential pinion shaft
16. Side gear RH
17. Differential spacer Mating marks
18. Spring washer AC511032AB
19. Spring 1. Make the mating marks.

20. Drive cam
REAR AXLE
27-41
2. Loosen the mounting screws for differential case Standard value: 0.05 − 0.20 mm
(A) and (B) evenly step by step. Spacer thickness mm
3. Separate differential case (B) and differential case 1.1
(A), and take out the parts inside. Do not confuse 1.2
the side gear LH/RH for further reassembly.
1.3
REASSEMBLY SERVICE POINTS 1.4
>>A<< DIFFERENTIAL CASE AND SIDE GEAR 1.5
CLEARANCE ADJUSTMENT
>>B<< SCREW INSTALLATION
Thickness
gauge
Differential
case A
Side
gear LH
AC511076 AB
Mating marks
AC511032AB
1. Insert a thickness gauge from the hole of
differential case (A) between the differential case 1. Align the mating marks (the same numeral on
(A) and side gear LH and measure the clearance. each case) of differential case (A) and differential
2. Select the spacer so that the clearance will meet case (B).
the standard value. 2. Tighten the screw so that the cases are in close
contact.
31-1
GROUP 31
WHEEL AND TYRE

CONTENTS
SERVICE SPECIFICATION(S) . . . . . 31-2 WHEEL RUNOUT CHECK . . . . . . . . . . . . . 31-6
TROUBLESHOOTING . . . . . . . . . . . . 31-2 WHEEL AND TYRE . . . . . . . . . . . . . . 31-6

TROUBLESHOOTING . . . . . . . . . . . . . . . . 31-2 WHEEL AND TYRE REMOVAL AND INSTALLATION
...................................... 31-6
WHEEL BALANCE ACCURACY . . . . . . . . 31-3
ON-VEHICLE SERVICE. . . . . . . . . . . 31-6 SPARE TYRE CARRIER . . . . . . . . . . 31-7

SPARE TYRE CARRIER REMOVAL AND
TYRE INFLATION PRESSURE CHECK . . 31-6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 31-7
TYRE WEAR CHECK . . . . . . . . . . . . . . . . . 31-6
31-2 WHEEL AND TYRE
M1311000300644
Item Limit
Tread depth of tyre mm Minimum 1.6
Wheel runout Radial runout mm 1.2 or less
<Steel wheel> Lateral runout mm 1.2 or less
Wheel runout Radial runout mm 1.0 or less
<Aluminium wheel> Lateral runout mm 1.0 or less
TROUBLESHOOTING
DIAGNOSIS
M1311000700835
Symptom Probable cause Remedy Reference page

Rapid wear Under-inflation Adjust the tyre For tyre inflation
at shoulders or lack of pressure. pressure, refer to
rotation the label on the
driver's side centre
pillar.
ACX00923AB
ACX00924 AB
Rapid wear Over-inflation

at centre or lack of
rotation
ACX00925AB
ACX00926AB
Cracked Under-inflation
treads
ACX00927AB
WHEEL AND TYRE
TROUBLESHOOTING
31-3
Symptom Probable cause Remedy Reference page
Wear on one Excessive Check the camber. Refer to GROUP
side camber 33, On-vehicle
service − Front
wheel alignment
check and
ACX00928 AB
adjustment <2WD
ACX00929 AB (Except HIGH
RIDER) > , <2WD
Feathered Incorrect toe-in Adjust the toe-in.
(HIGH RIDER) and
edge
4WD> .
ACX00930AB
ACX00931AB
Bald spots Unbalanced Balance the wheel. Refer to P.31-3.

wheel
ACX00932AB
ACX00933 AB
Scalloped Lack of rotation of tyre or worn Rotate the tyre, and Refer to GROUP
wear or out-of-alignment suspension check the front 33, On-vehicle
suspension service − Front
alignment. wheel alignment
check and
ACX00934
adjustment <2WD
(Except HIGH
RIDER) > , <2WD
(HIGH RIDER) and
4WD> .
WHEEL BALANCE ACCURACY Check your balancer's calibration approximately

M1311001700537 every 100 balances. Your wheel balancer's instruc-
PURPOSE tion manual should include calibration procedures. If
This section contains tips and procedures for achiev- the calibration procedures specifically for your bal-
ing accurate wheel balance. Steering wheel vibration ancer are missing, use the generic steps in this sec-
and/or body shake can result if any of these proce- tion for zero calibration, static balance, and dynamic
dures are not carefully observed. balance checks. The wheel balancer calibration
1. Wheels and tyres must be properly mounted on a checks are also described in the flowchart (Refer to
balancer in order to achieve correct balance. ).
Centring the wheel on the shaft of the balancer is
essential for proper mounting. PROCEDURE <BALANCING TIPS>
2. Off-the-car wheel balancers must be calibrated 1. Confirm that the balancer's cone and the wheel
periodically to ensure good balancing results. An mounting cone are undamaged and free of dirt
inaccurately calibrated balancer could cause and rust.
unnecessary replacement of tyres, shocks, 2. On this vehicle, the wheel's centre hole on the
suspension components, or steering components. hub side has a chamfered edge. Use a back-
mounting cone on your wheel balancer to centre
the wheel on the balancer shaft.
31-4 WHEEL AND TYRE
TROUBLESHOOTING
3. Install a wheel mounting cone. The appropriate 5. When installing wheel weights, hammer them at a
size cone for this vehicle is 56.0 mm. straight (not diagonal) angle.
4. Before balancing the wheel, remove any wheel
weights from both sides. Also check both sides for
any damage.
Clamping cup
Hub/shaft assembly
Wing nut
Spring plate
Wheel mounting cone AC000041AB
Standard passenger car wheel
<CONFIRMING PROPER BALANCE> • If the imbalance is 5 g or less, the wheel may not
1. After balancing the wheel, loosen the wing nut be centred on the balancer, or the balancing
and turn the wheel 180° against the balancer's cones, the cup, and/or wing nut are damaged,
hub. Then re-tighten the wing nut and check the dirty, or inappropriate for the wheel. You may
balance again. Repeat wheel balance if need to refer to the balancer manufacturer's
necessary. instructions to verify the correct attachments.
After making the necessary corrections, recheck
2. Turn the wheel again 180° against the balancer's
the wheel balance. If OK, then go to Step 4.
hub. If the wheel becomes out-of-balance each
• If the imbalance is more than 5 g, the balancer
time it is turned against the balancer's hub, the
requires calibration. Contact the balancer manu-
wheel balancer may require calibration.
facturer for calibration by their repair representa-
tive.
<WHEEL BALANCER CALIBRATION
4. <<Static Balance Check>>
CHECKS>
Attach a 5 g weight to the outer rim. Recheck the
1. Mount an undamaged original-equipment alloy
balancer. The balancer should detect 5 ± 2 g of
rim and tyre assembly (wheel) onto your off-the-
imbalance 170 to 190° away from the 5 g weight.
car wheel balancer. Balance the wheel.
• If the imbalance is within specification, the static
2. <<Zero Calibration Check>> balance calibration is correct. Go to Step 5 to
Loosen the balancer wing nut, rotate the wheel a check the dynamic balance.
half-turn (180°), and retighten the nut. Recheck • If the imbalance is out of specification, the bal-
the balance. ancer requires calibration. Contact the balancer
• If the imbalance is 5 g or less, the zero calibration manufacturer for calibration by their repair repre-
is OK. Rebalance the wheel, then go to Step 4 to sentative.
check static balance. 5. <<Dynamic Balance Check>>
• If the imbalance is more than 5 g, go to Step 3.
Attach a 5 g weight to the inner rim at 180°
3. Loosen the balancer wing nut, rotate the wheel 1/ opposite the 5 g weight that was added in Step 4.
4 turn (90°), and retighten the nut. Recheck the Recheck the balance. The balancer should detect
wheel balance. 5 ± 2 g of imbalance 170 to 190° away from both
the inner and outer 5 g weights.
• If the imbalance is within specification, the
dynamic balance calibration is correct. The bal-
ancer calibration checks are complete.
WHEEL AND TYRE
TROUBLESHOOTING
31-5
• If the imbalance is out of specification, the bal- WHEEL BALANCER CALIBRATION
ancer requires calibration. Contact the balancer CHECKING FLOW CHART
manufacturer for calibration by their repair repre-
sentative.
Balance wheel.
ZERO CALIBRATION
Rotate wheel 1/2 turn. CHECK
Imbalance = 5 g or less Imbalance = more than 5 g
Rebalance wheel.
Rotate wheel 1/4 turn.
Imbalance = 5 g or less Imbalance = more than 5 g
Verify wheel is properly centred.

Verify cones, cup, and wing nut are clean,
undamaged, and appropriate for wheel.
Make necessary corrections, then recheck
wheel balance.
STATIC BALANCE
Attach a 5 g weight to the outer rim.
CHECK
Is the imbalance 5 ± 2 g at 170 – 190˚ away from the
5 g weight?
YES NO
DYNAMIC BALANCE
Attach a 5 g weight to the inner rim at 180˚ opposite CHECK
the weight on the outer rim.
Is the imbalance 5 ± 2 g at 170 – 190˚ away from
both 5 g weights?
YES NO
Balancer does not require Balancer requires calibration.

calibration. Contact balancer manufacturer.
AC502720AB
31-6 WHEEL AND TYRE
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
TYRE INFLATION PRESSURE CHECK WHEEL RUNOUT CHECK
M1311000900516 M1311001100609
NOTE: For information on tyre inflation pressure,
refer to the label attached to the centre pillar on the
driver's side.
Radial
TYRE WEAR CHECK
M1311001000594
Measure the tread depth of the tyres.
If the remaining tread depth is less than the minimum
limit, replace the tyre. Lateral
ACX00651AB
NOTE: When the tread depth of the tyres is reduced Jack up the vehicle so that the wheels are clear of
to 1.6 mm or less, wear indicators will appear. the floor. While slowly turning the wheel, measure
wheel runout with a dial indicator.
Limit:
Item Steel wheel Aluminium
wheel
Radial runout 1.2 or less 1.0 or less
mm
Lateral runout 1.2 or less 1.0 or less
mm
If wheel runout exceeds the limit, replace the wheel.
WHEEL AND TYRE

INSTALLATION SERVICE POINT Tightening torque:
M1311001300476 147 ± 10 N⋅m <Steel wheel>
Tighten the wheel nuts to the specified torque. 128 ± 9 N⋅m <Aluminium wheel>
WHEEL AND TYRE
SPARE TYRE CARRIER
31-7
SPARE TYRE CARRIER
M1311006700071
13 ± 2 N·m
Spare tyre carrier assembly
AC501849AB
32-1
GROUP 32
POWER PLANT
MOUNT
CONTENTS
GENERAL INFORMATION . . . . . . . . 32-2 REAR ENGINE MOUNTING REMOVAL AND

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 32-5
FRONT ENGINE MOUNTING . . . . . . 32-3 REAR ENGINE MOUNTING INSPECTION 32-6
FRONT ENGINE MOUNTING REMOVAL AND
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 32-3 TRANSFER MOUNTING <4WD-M/T> 32-6
FRONT ENGINE MOUNTING INSPECTION TRANSFER MOUNTING REMOVAL AND
...................................... 32-4 INSTALLATION <M/T> . . . . . . . . . . . . . . . . 32-6
TRANSFER MOUNTING INSPECTION . . . 32-7
REAR ENGINE MOUNTING . . . . . . . 32-5
32-2 POWER PLANT MOUNT
GENERAL INFORMATION
GENERAL INFORMATION
M1321000101699
For engine and transmission mounts, gravity-centre • Cup-type stopper cover made of heat-resistant
support engine type has been adopted as follows: 3- material has been adopted to abolish the heat
point support type (two places at the engine and one protector for light weighting.
place at the transmission) for A/T vehicles, and 4- • Low-speed action spring material has been
point support type (two places at the engine, one adopted for front engine support insulator and
place at the transmission and one place at the trans- rear engine support insulator to reduce vibration
fer) for 4WD-M/T vehicles. transmission ratio of the power plant.
• The clearance of the stopper for front engine sup-
port insulator has been enlarged to improve
vibration at the vehicle start-up.
POWER PLANT MOUNT
FRONT ENGINE MOUNTING
32-3
Front engine support insulator
Stopper cover
Front engine support insulator
Stopper
Transfer roll
stopper <4WD-M/T>
<4WD-M/T>
No.2 crossmember
Rear engine
support insulator
<2WD-High rider> <2WD-Except high rider> <4WD-A/T>

Rear engine
support insulator
Rear engine Rear engine

support insulator support insulator
AC903785 AB

M1321006600020
CAUTION
Do not distort rubber portions, and never stain rubber portions with fuel oil.
• Engine Assembly Removal and Installation (Refer to
GROUP 11A − Engine Assembly ).
1
26 ± 5 N·m
3
1
26 ± 5 N·m
2
48 ± 7 N·m
2
48 ± 7 N·m
3
AC505370AC

1. Engine mounting nut >>A<< FRONT ENGINE SUPPORT INSULATOR
2. Engine mounting bolt INSTALLATION
>>A<< 3. Front engine support insulator
CAUTION
Do not distort rubber portions, and never stain
rubber portions with fuel or oil.
INSPECTION
M1321006700016
Check the front engine support insulator for cracks,
separation or deformation.
POWER PLANT MOUNT
REAR ENGINE MOUNTING
32-5
REAR ENGINE MOUNTING
M1321005600232
<2WD-High rider> <2WD-Except high rider> 42 ± 3 N·m

42 ± 3 N·m
2
2
1
1
83 ± 12 N·m
23 ± 2 N·m
83 ± 12 N·m
23 ± 2 N·m
83 ± 12 N·m 83 ± 12 N·m
<4WD-A/T> <4WD-M/T>
46 ± 8 N·m 3
2
46 ± 8 N·m
44 ± 10 N·m
44 ± 10 N·m 44 ± 10 N·m
44 ± 10 N·m
2
83 ± 12 N·m
46 ± 8 N·m
83 ± 12 N·m
46 ± 8 N·m
83 ± 12 N·m
83 ± 12 N·m
AC903789 AB

<<A>> • Support the manual transmission 2. Rear engine support insulator
assembly or automatic 3. Transmission bracket <4WD-M/
transmission assembly. T>
1. No.2 crossmember
TRANSFER MOUNTING <4WD-M/T>
REMOVAL SERVICE POINT Use a transmission jack to support the manual trans-
<<A>> SUPPORT THE MANUAL TRANSMISSION mission assembly or automatic transmission assem-
ASSEMBLY OR AUTOMATIC TRANSMISSION bly.
ASSEMBLY
INSPECTION
M1321005700079
Check the rear engine support insulator for cracks,
M/T assembly or separation or deformation.
A/T assembly
Transmission jack
AC503630 AB

M1321005300208
25 ± 5 N·m
45 ± 9 N·m
1
25 ± 5 N·m
3
25 ± 5 N·m
25 ± 5 N·m
AC806115AB
Removal steps
>>A<< 1. Transfer roll stopper
(B) Approx. 6 mm
2. Transfer mount bracket
3. Transfer mount bracket assembly Approx.
10 mm
INSTALLATION SERVICE POINT (A)
>>A<< TRANSFER ROLL STOPPER INSTALLA-
TION (B)
1. Tighten the transfer roll stopper provisionally. Approx. 6 mm
Approx. 6 mm (B)
AC503956AB
2. Tighten the transfer roll stopper inner and outer so

that the clearance (A) between them is as shown
POWER PLANT MOUNT
32-7
3. Check that the clearance (B) between the INSPECTION
stoppers are the same. M1321005400078
• Check the transfer roll stopper for cracks, separa-
NOTE: When new, a transfer roll stopper consists of tion or deformation.
one part, but will separate into outer and inner part • Check the transfer mount bracket for deformation
during use.This is normal. or corrosion.
• Check the transfer mount bracket assembly for
deformation or corrosion.
33-1
GROUP 33
FRONT
SUSPENSION
CONTENTS
GENERAL INFORMATION . . . . . . . . 33-2 rider), 4WD> . . . . . . . . . . . . . . . . . . . . 33-15

SHOCK ABSORBER ASSEMBLY REMOVAL AND
SERVICE SPECIFICATIONS. . . . . . . 33-3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 33-15
SHOCK ABSORBER ASSEMBLY INSPECTION
SPECIAL TOOL(S) . . . . . . . . . . . . . . 33-4 ...................................... 33-15
SHOCK ABSORBER ASSEMBLY DISASSEMBLY
AND REASSEMBLY . . . . . . . . . . . . . . . . . . 33-16
SHOCK ABSORBER ASSEMBLY INSPECTION
FRONT WHEEL ALIGNMENT CHECK AND
(DISASSEMBLY AND REASSEMBLY) . . . . 33-18
ADJUSTMENT <2WD (except High rider)> 33-5
FRONT WHEEL ALIGNMENT CHECK AND
ADJUSTMENT <2WD (High rider), 4WD> . 33-6 LOWER ARM . . . . . . . . . . . . . . . . . . . 33-19
LOWER ARM BALL JOINT AXIAL PLAY CHECK LOWER ARM REMOVAL AND INSTALLATION <2WD
...................................... 33-8 (except High rider)> . . . . . . . . . . . . . . . . . . . 33-19
LOWER ARM BALL JOINT DUST COVER CHECK LOWER ARM REMOVAL AND INSTALLATION <2WD
...................................... 33-8 (High rider), 4WD>. . . . . . . . . . . . . . . . . . . . 33-20
LOWER ARM INSPECTION . . . . . . . . . . . . 33-21
UPPER ARM ASSEMBLY . . . . . . . . . 33-9 LOWER ARM BUSHING REPLACEMENT <2WD
(except High rider)> . . . . . . . . . . . . . . . . . . . 33-22
UPPER ARM ASSEMBLY REMOVAL AND
INSTALLATION <2WD (except High rider)> 33-9 LOWER ARM BUSHING REPLACEMENT <2WD (High
rider), 4WD> . . . . . . . . . . . . . . . . . . . . . . . . 33-22
UPPER ARM ASSEMBLY REMOVAL AND
INSTALLATION <2WD (High rider), 4WD> 33-11
UPPER ARM ASSEMBLY INSPECTION . . 33-12 STRUT BAR <2WD (except High rider)>
................................. 33-24
SHOCK ABSORBER AND COIL SPRING STRUT BAR REMOVAL AND INSTALLATION
<2WD (except High rider)>. . . . . . . . 33-13 ...................................... 33-24
SHOCK ABSORBER AND COIL SPRING REMOVAL
AND INSTALLATION . . . . . . . . . . . . . . . . . 33-13 STABILIZER BAR <2WD (High rider), 4WD>
SHOCK ABSORBER AND COIL SPRING ................................. 33-25
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 33-14 STABILIZER BAR REMOVAL AND INSTALLATION
...................................... 33-25
SHOCK ABSORBER ASSEMBLY <2WD (High STABILIZER BAR INSPECTION. . . . . . . . . 33-26
33-2 FRONT SUSPENSION
GENERAL INFORMATION
GENERAL INFORMATION
M1332000102168
The Independent-wishbone, coil springs has been
adopted.
<2WD (except High rider)>
Upper arm
Shock absorber
Strut bar
Coil spring
Lower arm
AC501759 AB
<2WD (High rider)>
Coil spring
Shock absorber Upper arm
Stabilizer bar
Lower arm
AC608652 AC
FRONT SUSPENSION
33-3
<4WD>
Coil spring
Shock absorber Upper arm

12MY L200 (EU) Workshop Manual

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12MY L200 (EU) Workshop Manual

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00-1

GENERAL <ELECTRICAL> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00E

HOW TO USE THIS MANUAL. . . . . . 00-3 PRECAUTIONS BEFORE SERVICE . 00-36

SRS SERVICE PRECAUTIONS . . . . 00-50 SUPPORT LOCATIONS FOR LIFTING AND

SCOPE OF MAINTENANCE, REPAIR AND REFERENCE VALUE

EXPLANATION OF MANUAL CONTENTS

35A-19 Indicates the page number.

Indicates procedures to be performed be-

Mark N denotes nonreusable part.

Repair kit or parts sets are shown.

Maintenance and servicing procedures

Classifications of major maintenance / service points

BRAKE CALIPER ASSEMBLY

The title of the page

Indicates (by symbols) where

Symbols for lubrication, sealants and adhesives

Symbols are used to show the locations for lubrication : Grease

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE

1. STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING

Reoccurs Does not reoccur

How to treat past Recheck trouble symptom. How to treat past

Read the diagnosis codes. No diagnosis

2. SYSTEM OPERATION AND SYMPTOM 5. DIAGNOSIS CODE PROCEDURES

7. SYMPTOM PROCEDURES HOW TO READ DIAGNOSIS CODE

9. ACTUATOR TEST TABLE

10. CHECK AT ECU TERMINALS MB991910

11. INSPECTION PROCEDURE BY USING

DIAGNOSIS FUNCTION MB991827 AC509179AB

Connect the M.U.T.-III to the 16-pin diagnosis con-

HOW TO USE THE INSPECTION

Relevant circuit(s) of the component which

Start of diagnosis Describes

M.U.T.-III data list

CURRENT TROUBLE HARNESS CHECK

Use inspection harness (MB991219) of special tool

IF INSPECTING WITH THE CONNECTOR

Touch the pin directly with the test bar.

Connector disconnected or CONNECTOR PIN INSPECTION

Stretched or broken wires AC300898

If the connector pin stopper is damaged, the terminal

CONNECTOR ENGAGEMENT INSPECTION

Harness wire breakage MB991219

Use special tool inspection harness (MB991219)

INSPECTION SERVICE POINTS FOR A HOW TO COPE WITH INTERMITTENT

Remove the blown fuse and measure the resistance

No. Item Content

No. Item Content

VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the

No. Item Content

The information code plate is riveted to the cowl top 1 2 3 4 5 6 7 8 9 10 11 12 13

No. Item Content

MANUFACTURER PLATE No. Content

ENGINE MODEL STAMPING

The manufacturer plate is riveted to the cowl top

6 Front suspension upper arm <left side>

Item KA4T KB4T

Item KA4T KB4T

GENERAL DATA AND SPECIFICATIONS

GENERAL DATA AND SPECIFICATIONS

PRECAUTIONS BEFORE SERVICE

LABELS .) Before replacing a component related to the electri-

MULTI USE TESTER (M.U.T.-III) SUB CAUTION

M.U.T.-III main harness A