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GROUP INDEX

   

GENERAL

00

   

MAINTENANCE SCHEDULE

01

   

ENGINE

11

   

12

SERVICE MANUAL

LUBRICATION FUEL AND ENGINE CONTROL

13A

2005 Model

ELECTRONICALLY CONTROLLED

13E

 

FOREWORD

FUEL SYSTEM COOLING

14

   

15

This Service Manual contains maintenance and repair

May 2004

INTAKE AND EXHAUST EMISSION CONTROL

17

methods for the Mitsubishi Fuso Truck FE. FG Series.

CLUTCH

21

Read this manual carefully as an aid in providing cor-

MANUAL TRANSMISSION

22

rect, efficient maintenance. Please note that the infor- mation and specifications contained within this manual

AUTOMATIC TRANSMISSION

23

may change without notice. This is due to product

TRANSFER

24

modifications and continued vehicle improvements that are made throughout the model years. Should you

PROPELLER SHAFT

25

encounter any discrepancy in the information provid- ed, please do not hesitate to contact your nearest Mi-

FRONT AXLE <FE>

26A

tsubishi Fuso Dealer or Mitsubishi Fuso Truck of

<FG>

26B

America, Inc.

27

 

REAR AXLE WHEEL AND TIRE

31

 

FRONT SUSPENSION

33

 

REAR SUSPENSION

34

   

BRAKE

35A

   

ANTI-LOCK BRAKE SYSTEM

35E

   

PARKING BRAKE

36

   

STEERING

37

   

FRAME

41

   

CAB

42

   

DOOR

43

   

EXTERIOR

51

   

INTERIOR

52

   

ELECTRICAL

54

   

AIR-CONDITIONER

55A

   

HEATER

55B

 
     
     

INDEX

EQUIPMENT TYPE CODES LIST

00-2

POWER TRAIN LIST

00-3

HOW TO READ THIS MANUAL

00-4

CHASSIS NUMBER, ENGINE NUMBER, POWER TRAIN LABEL

00-10

VEHICLE IDENTIFICATION NUMBER

00-11

PRECAUTIONS FOR MAINTENANCE OPERATION

00-12

JACKING UP THE VEHICLE

00-24

DIAGNOSIS CODES

1. Connecting Multi-Use Tester

00-26

2. Accessing / Erasing Diagnosis Codes <Common Rail, Exhaust Gas Recirculation, Pre-heater>

00-30

3. Accessing / Erasing Diagnosis Codes <Automatic Transmission>

00-32

4. Accessing / Erasing Diagnosis Codes <Anti-lock Brake System>

00-34

TABLE OF STANDARD TIGHTENING TORQUES

00-36

EQUIPMENT TYPE CODES LIST

Component Name plate marking Code description Engine 4M50-T 4 M 5 0 T Turbocharged Order
Component
Name plate marking
Code description
Engine
4M50-T
4
M
5
0
T
Turbocharged
Order of development within same series
Order of development among different series
Diesel engine
No. of cylinders (4)
Clutch
C5W33
C
5
W
33
Disc OD
Facing material (W: Woven)
Load carrying capacity of truck class (tonnage)
on which the clutch is primarily used
Initial letter of the clutch
Transmission
M036S5W
M
036
S
5
W
Variation (W: With directly-mounted transfer)
Forward speeds
Type of mesh (S: Synchromesh)
Load carrying capacity of truck class (tonnage)
on which the clutch is primarily used
Initial letter of the transmission
Propeller shaft
P3
P
3
Load carrying capacity of truck class (tonnage)
on which the clutch is primarily used
Initial letter of the propeller shaft
Front axle
F200T
F
200
T
Vehicle type (T: Truck)
Load carrying capacity of truck class (tonnage)
on which the clutch is primarily used
Initial letter of the front axle
Rear axle
R033T
R
03
3
T
Vehicle type (T: Truck)
Order of development within same series
Load carrying capacity of truck class (tonnage)
on which the clutch is primarily used
Initial letter of the rear axle
Reduction and differential
D033H
D
03
3
H
Tooth profile (H: Hypoid gear)
Order of development within same series
Load carrying capacity of truck class (tonnage)
on which the clutch is primarily used
Initial letter of the reduction & differential

POWER TRAIN TABLE

00

           

Reduction &

Vehicle model

Engine

Clutch

Transmission

Propeller shaft

Rear axle

differential

FE83DDZSLSUA

4M50-T7

C5W33

M036S5

P3

R033T

D033H

FE83DEZSLSUA

4M50-T7

C5W33

M036S5

P3

R033T

D033H

FE83DGZSLSUA

4M50-T7

C5W33

M036S5

P3

R033T

D033H

FE83DDZSLSUB

4M50-T8

Torque

M036A6

P3

R033T

D033H

converter

FE83DEZSLSUB

4M50-T8

Torque

M036A6

P3

R033T

D033H

converter

FE83DGZSLSUB

4M50-T8

Torque

M036A6

P3

R033T

D033H

converter

FE84DDZSLSUA

4M50-T7

C5W33

M036S5

P3

R033T

D033H

FE84DEZSLSUA

4M50-T7

C5W33

M036S5

P3

R033T

D033H

FE84DGZSLSUA

4M50-T7

C5W33

M036S5

P3

R033T

D033H

FE84DHZSLSUA

4M50-T7

C5W33

M036S5

P3

R033T

D033H

FE84DDZSLSUB

4M50-T8

Torque

M036A6

P3

R033T

D033H

converter

FE84DEZSLSUB

4M50-T8

Torque

M036A6

P3

R033T

D033H

converter

FE84DGZSLSUB

4M50-T8

Torque

M036A6

P3

R033T

D033H

converter

FE84DHZSLSUB

4M50-T8

Torque

M036A6

P3

R033T

D033H

converter

FE84DHWSLSUB

4M50-T8

Torque

M036A6

P3

R033T

D033H

converter

FE85DDZSLSUC

4M50-T8

C5W33

M036S6

P3

R035T

D035H

FE85DEZSLSUC

4M50-T8

C5W33

M036S6

P3

R035T

D035H

FE85DGZSLSUC

4M50-T8

C5W33

M036S6

P3

R035T

D035H

FE85DHZSLSUC

4M50-T8

C5W33

M036S6

P3

R035T

D035H

FE85DJZSLSUC

4M50-T8

C5W33

M036S6

P3

R035T

D035H

FE85DDZSLSUB

4M50-T8

Torque

M036A6

P3

R035T

D035H

converter

FE85DEZSLSUB

4M50-T8

Torque

M036A6

P3

R035T

D035H

converter

FE85DGZSLSUB

4M50-T8

Torque

M036A6

P3

R035T

D035H

converter

FE85DHZSLSUB

4M50-T8

Torque

M036A6

P3

R035T

D035H

converter

FE85DJZSLSUB

4M50-T8

Torque

M036A6

P3

R035T

D035H

converter

       

Front: P2

 

Front: D1H

FG84DC6SLSUA

4M50-T7

C5W33

M036S5W

Rear: P3

R033T

Rear: D033H

       

Front: P2

 

Front: D1H

FG84DE6SLSUA

4M50-T7

C5W33

M036S5W

Rear: P3

R033T

Rear: D033H

HOW TO READ THIS MANUAL

This manual consists of the following parts:

Specifications

Structure and Operation

Troubleshooting

On-vehicle Inspection and Adjustment

Service procedures

On-vehicle Inspection and Adjustment

Procedures for inspection and adjustment of individual parts and assemblies as mounted on the vehicle are de- scribed including specific items to check and adjust. Specified or otherwise, inspection should be performed for looseness, play, backlash, crack, damage, etc.

Service procedure

Procedures for servicing components and parts off the vehicle are described centering on key points in their re- moval, installation, disassembly, reassembly, inspection, etc.

Inspection

Check items subject to acceptance or otherwise on the basis of service standards are all given.

Some routine visual checks and cleaning of some reused parts are not described but must be always included in actual service work.

Caution

This service manual contains important cautionary instructions and supplementary information under the following four headings which identify the nature of the instructions and information:

DANGER WARNING CAUTION NOTE
DANGER
WARNING
CAUTION
NOTE

Terms and Units

information: DANGER WARNING CAUTION NOTE Terms and Units Front and rear Precautions that should be taken

Front and rear

Precautions that should be taken in handing potentially dangerous substances such as battery fluid and coolant additives.

Precautionary instructions, which, if not observed, could result in serious injury or death.

Precautionary instructions, which, if not observed, could result in damage to or de- struction of equipment or parts.

Suggestions or supplementary information for more efficient use of equipment or a better understandings.

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

Left and rightis the front and the reversing direction is the rear. Left hand side and right hand

Left hand side and right hand side, when facing the forward running direction of the vehicle, are respectively left and right.

direction of the vehicle, are respectively left and right. Standard value Standard value dimensions in designs

Standard value

Standard value dimensions in designs indicating: the design dimensions of individual parts, the standard clearance between two parts when assembled, and the standard value for an assembly part, as the case may be.

the standard value for an assembly part, as the case may be. Limit When the value

Limit

When the value of a part exceeds this, it is no longer serviceable in respect of performance and strength and must be replaced or repaired.

00

Tightening torque00 • Values are directly specified for out-of-standard tightening torques for bolts and nuts. • Where

Values are directly specified for out-of-standard tightening torques for bolts and nuts.

Where there is no specified figure for tightening torque, follow the table covering standard tightening torques. (Values for standard tightening torques are based on thread size and material.)

When the item is to be tightened in a wet state, “wet” is indicated. Where there is no indication, read it as dry.

Unitsis indicated. Where there is no indication, read it as dry. Tightening torques and other parameters

Tightening torques and other parameters are given in SI* units with imperial unit and metric units added in brackets { }. *SI: Le Système International d’Unités

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

d’Unités Example: 390 N·m {290 ft.lbs, 40 kgf·m} Metric unit Imperial unit SI unit   Unit
d’Unités Example: 390 N·m {290 ft.lbs, 40 kgf·m} Metric unit Imperial unit SI unit   Unit
d’Unités Example: 390 N·m {290 ft.lbs, 40 kgf·m} Metric unit Imperial unit SI unit   Unit

Metric unit

Imperial unit

SI unit

 

Unit

SI unit {imperial unit, metric unit}

Conversion factor

Force

 

N

{lbs, kgf}

9.80665 N {2.2046 lbs, 1 kgf}

Moment of force

N·m {ft.lbs, kgf·m}

9.80665 N·m {7.2329 ft.lbs, 1 kgf·m}

Pressure

Positive pressure

kPa {psi, kgf/cm 2 }

98.0665 kPa {14.22 psi, 1 kgf/cm 2 }

Vacuum pressure

kPa {in.Hg, mmHg}

0.133322 kPa {0.03937 in.Hg, 1 mmHg}

Volume

J

{BTU, kcal}

4186.05 J {3.96825BTU, 1 kcal}

Heat quantity

W {BTU/h, kcal/h}

1.16279W {3.96825BTU/h, 1 kcal/h}

Example: 30 mm {1.18 in.}

1.16279W {3.96825BTU/h, 1 kcal/h} Example: 30 mm {1.18 in.} Imperial unit SI unit Unit SI unit

Imperial unit

SI unit

Unit

SI unit {imperial unit}

 

Conversion factor

   

mm

{in.}

1

mm {0.03937 in.}

Length

 

m

{ft.}

 

1

m {3.2808 ft.}

 

km {mile}

1

km {0.6214 mile}

Mass

 

kg

{lb}

 

1 kg {2.2046 lb}

 

g {oz}

 

1 g {0.035274 oz}

Temperature (in degree Celsius)

 

°C {° F}

1°C {(1°C × 1.8 + 32)° F}

Velocity

 

km/h {mph}

1 km/h {0.6214 mph}

 

m/s

{ft/s}

 

1 m/s {3.281 ft/s}

Volume

L

{qts}, L {gal}

1 L {1.05336 qts}, 1 L {0.2642 gal}

 

cm

3 {cu.in.}

1 cm 3 {0.061023 cu.in.}

Area

m 2 {in 2 }, m 2 {ft 2 }

1 m 2 {1.550 × 10 3 in 2 }, 1 m 2 {1.076 × 10 ft 2 }

HOW TO READ THIS MANUAL

Symbol

Denotation

Application

Remarks

   

Parts not tightened to standard torques

Specified values shown in table See Table of Standard Tightening Torques for parts for which no tightening torques are speci- fied.

Tightening torque (standard torques specified where neces- sary for servicing)

Tightening torque

(standard torques specified where neces- sary for servicing)

 
  Locating pin Parts to be positioned for installation  

Locating pin

Parts to be positioned for installation

 
 
    Non-reusable parts Parts not to be reused  
 

Non-reusable parts

Parts not to be reused

 
 

sealantLubricant and/or

Lubricant and/or

Parts to be coated with lubricant or sealant for assembly or installation

Necessary lubricant and/or sealant, quantity re- quired, etc. are specified in table.

 

Special tool  Parts for which special tools are required for service operation Tool name/shape and part number

Parts for which special tools are required for service operation

Tool name/shape and part number are shown in table.

 

*a

Associated part

Parts associated with those removed/disas- sembled for servicing

 
table.   *a Associated part Parts associated with those removed/disas- sembled for servicing   00-6
table.   *a Associated part Parts associated with those removed/disas- sembled for servicing   00-6
table.   *a Associated part Parts associated with those removed/disas- sembled for servicing   00-6
table.   *a Associated part Parts associated with those removed/disas- sembled for servicing   00-6
table.   *a Associated part Parts associated with those removed/disas- sembled for servicing   00-6
table.   *a Associated part Parts associated with those removed/disas- sembled for servicing   00-6
table.   *a Associated part Parts associated with those removed/disas- sembled for servicing   00-6
table.   *a Associated part Parts associated with those removed/disas- sembled for servicing   00-6
table.   *a Associated part Parts associated with those removed/disas- sembled for servicing   00-6
table.   *a Associated part Parts associated with those removed/disas- sembled for servicing   00-6
table.   *a Associated part Parts associated with those removed/disas- sembled for servicing   00-6
table.   *a Associated part Parts associated with those removed/disas- sembled for servicing   00-6
table.   *a Associated part Parts associated with those removed/disas- sembled for servicing   00-6
table.   *a Associated part Parts associated with those removed/disas- sembled for servicing   00-6

00

00 00-7
00 00-7
00 00-7
00 00-7
00 00-7

HOW TO READ THIS MANUAL

How to Use Diagnosis Codes <Electronic Control System (Gr13E, Gr17, Gr23, Gr35E, Gr54)>

TROUBLESHOOTING 1. INSPECTION PROCEDURE 2. CAUTIONS TO OBSERVE WHEN PERFORMING INSPECTIONS This section suggests areas
TROUBLESHOOTING
1. INSPECTION PROCEDURE
2. CAUTIONS TO OBSERVE WHEN
PERFORMING INSPECTIONS
This section suggests areas to
inspect for each diagnosis code.
3. INSPECTIONS DIAGNOSIS BASED ON
DIAGNOSIS CODES
4. MULTI-USE TESTER SERVICE DATA
5. ACTUATOR TESTS PERFORMED USING
MULTI-USE TESTER
6. INSPECTIONS PERFORMED AT
ELECTRONIC CONTROL UNIT CONNECTORS
7. INSPECTION OF ELECTRICAL EQUIPMENT
8. INSTALLED LOCATIONS OF PARTS
9. ELECTRIC CIRCUIT DIAGRAM
They are the diagnosis code and message displayed on Multi-Use Tester. The figure
in the brackets indicates the number of warning lamp flashes, which is the diagnosis
code (this is only applicable to system compatible with Multi-Use Tester-III ).
P1463: Exhaust Brake M/V1 (Warning lamp flashes: 93)
Code generation criteria
Exhaust Brake 3-Way magnetic valve (output side) power-supply circuit
shorted out
Resettability
Normal signal with starter switch in the ON position
Electronic Control Unit control
Auxiliary brake control disabled
Service data
87: Exhaust Brake M/V1
Actuator test
AC: Auxiliary Brake M/V1
In-
spec-
Electronic control unit
connector
17
: Exhaust Brake 3-Way magnetic valve
tion
item
Electrical part
#565: Exhaust Brake 3-Way magnetic valve
Wiring diagram
Exhaust Brake 3-Way magnetic valve circuit
Refer to “Inspection of Electrical
Components.”
Refer to “Wiring Diagrams.”

00

M

E

M

O

CHASSIS NUMBER, ENGINE NUMBER, POWER TRAIN LABEL

Chassis and engine numbers are allocated to each vehicle and engine respectively in the order of production. These numbers are required at vehicle inspection for registration.

numbers are required at vehicle inspection for registration. • Power train label located in the position
numbers are required at vehicle inspection for registration. • Power train label located in the position
numbers are required at vehicle inspection for registration. • Power train label located in the position

Power train label located in the position illustrated indicates the vehicle model, chassis number and information relevant to the vehicle’s power - train components.

VEHICLE IDENTIFICATION NUMBER

00

VEHICLE IDENTIFICATION NUMBER 00 • The vehicle identification number is punch-marked on the plate, which is

The vehicle identification number is punch-marked on the plate, which is attached in the position as illustrated. The vehicle identification number consists of a 17-digit set of al- phanumeric characters. Each digit represents the following specifications.

J L 6 A A D 1 S 5 K (1) (2) (3) (4) (5)
J
L
6
A
A
D
1
S
5
K
(1) (2) (3)
(4) (5)
(6)
(7)
(8) (9)
(10) (11)
(12)
(1)
Country
J:
(2)
Make
L:
(3)
Type
6:
Japan
Mitsubishi Fuso
Incomplete vehicle

(4)

Gross vehicle weight / Brake system

 

A:

10,001 to 14,000 lbs. / Hydraulic

B:

14,001 to 16,000 lbs. / Hydraulic

C:

16,001 to 19,500 lbs. / Hydraulic

(5)

Line

A:

FE83D

 

B:

FE84D

C:

FE85D

(6)

Series (Wheel base)

D:

2.9 to 3.19 m (9.51 to 10.46 ft.)

 

E:

3.2 to 3.49 m (10.49 to 11.44 ft.)

(7)

Cab chassis type

1:

Chassis cab

(8)

Engine

S:

4.899 L Diesel turbo charged and charge air cooled

(9)

Check digit

(10)

Model year

5:

2005

(11) Plant

K:

Kawasaki

(12) Plant sequential number

PRECAUTIONS FOR MAINTENANCE OPERATION

DANGER

PRECAUTIONS FOR MAINTENANCE OPERATION DANGER This product contains or emits chemicals known to the State of

This product contains or emits chemicals known to the State of California to cause cancer and birth de- fects or other reproductive harm.

Before performing service operations, inquire into the customer’s complaints and ascertain the condition by checking the total distance traveled, the conditions under which the vehicle is operated, and other relevant factors on the vehicle. And note the necessary information. This information will help you to service the vehicle efficiently.

Check the location of the fault, and identify its cause. Based on your findings, determine whether parts must be re- moved or disassembled. Then, follow the service procedure given in this manual.

Then, follow the service procedure given in this manual. • Perform service operations on a level

Perform service operations on a level surface. Before starting, take the following preparatory steps:

To prevent soiling and damage, place covers over the seats, trim and floor in the cab and over the paintwork of the body.

• Prepare all the general and special tools necessary for the job. WARNING • Special
• Prepare all the general and special tools necessary for the job.
WARNING
• Special tools must be used wherever specified in this man-
ual. Do not attempt to use other tools since they could
cause injuries and/or vehicle damage.
since they could cause injuries and/or vehicle damage. • After manually tilting the cab, be sure
since they could cause injuries and/or vehicle damage. • After manually tilting the cab, be sure

After manually tilting the cab, be sure to engage the stopper with the lock lever to secure the cab stay in a rigid state.

Take extreme care when removing/installing heavy items such as engine, transmission and axle. When lifting heavy items using a cable etc., observe the following precautions.

Identify the mass of the item being lifted. Use the cable that is strong enough to support the mass.

00

00 • If lifting eyes are not provided on the item being lifted, tie a ca-
00 • If lifting eyes are not provided on the item being lifted, tie a ca-
00 • If lifting eyes are not provided on the item being lifted, tie a ca-
00 • If lifting eyes are not provided on the item being lifted, tie a ca-

If lifting eyes are not provided on the item being lifted, tie a ca- ble around the item taking into account the item’s center of gravity.

Do not allow anyone to pass or stay under a lifted item which may possibly fall.

Inspect for oil leakage etc. before washing the vehicle. If the or- der is reversed, any oil leakage or fault that may exist could go unnoticed during inspection.

PRECAUTIONS FOR MAINTENANCE OPERATION

PRECAUTIONS FOR MAINTENANCE OPERATION • Prepare replacement parts ready for installation. • Oil seals, packings,

Prepare replacement parts ready for installation.

Oil seals, packings, O-rings and other rubber parts, gaskets, and split pins must be replaced with new ones after removal. Use only genuine MITSUBISHI replacement parts.

When disassembling parts, visually check them for wear, cracks, damage, deformation, deterioration, rust, corrosion, defective ro- tation, fatigue, clogging and any other possible defect.

To facilitate correct reassembly of parts, make alignment marks on them before disassembly and arrange disassembled parts neatly. Make punch marks and other alignment marks where they will not detract from parts’ functionality and appearance.

After removing parts from the vehicle, cover the area to keep it free of dust.

CAUTION

the vehicle, cover the area to keep it free of dust. CAUTION • Be careful not

• Be careful not to mix up identical parts, similar parts and parts that have left/right alignments.

• Keep new replacement parts and original (removed) parts separately.

replacement parts and original (removed) parts separately. • Apply the specified oil or grease to U-seals,

Apply the specified oil or grease to U-seals, oil seals, dust seals and bearings before reassembly.

Always use the specified oils and greases when performing in- spection or replacement. Immediately wipe away any excess oil or grease with a rag.

00

00 • Wear safety goggles when using a grinder or welder. Wear gloves when necessary, and

Wear safety goggles when using a grinder or welder. Wear gloves when necessary, and watch out for sharp edges and oth- er items that might wound your hands.

• Before working on the electrical system, disconnect the battery (–) terminal to prevent short
• Before working on the electrical system, disconnect the battery
(–) terminal to prevent short circuits.
CAUTION
• Make sure the starter switch and lighting switches are OFF
before disconnecting or connecting battery terminals.
Semiconductor components may otherwise be damaged.
Semiconductor components may otherwise be damaged. • Carefully handle sensors relays, and other items that
Semiconductor components may otherwise be damaged. • Carefully handle sensors relays, and other items that
Semiconductor components may otherwise be damaged. • Carefully handle sensors relays, and other items that

Carefully handle sensors relays, and other items that are sensi- tive to shock and heat. Do not remove or paint the cover of any control unit.

When separating connectors, grasp the connectors themselves rather than the harnesses.

To separate locking connectors, first push them in the direction of the arrows. To reconnect locking connectors, push them to- gether until they click.

Before washing the vehicle, cover electrical parts to keep them dry. (Use plastic sheets or the like.) Keep water away from har- ness connectors and sensors and immediately wipe off any wa- ter that gets on them.

PRECAUTIONS FOR MAINTENANCE OPERATION

PRECAUTIONS FOR MAINTENANCE OPERATION • When applying a voltage to a part for inspection purposes, check

When applying a voltage to a part for inspection purposes, check that the (+) and (–) cables are connected properly then gradually increase the voltage from zero. Do not exceed the specified voltage. Remember that control units and sensors do not necessarily op- erate on the battery voltage.

1. Handling Precautions for Electric Circuits CAUTION • Do not pierce wire insulation with test
1. Handling Precautions for Electric Circuits
CAUTION
• Do not pierce wire insulation with test probes or alligator
clips when performing electrical inspections. Doing so can,
particularly with the chassis harness, hasten corrosion.
particularly with the chassis harness, hasten corrosion. 1.1 Inspection of harnesses (1) Inspections with connectors
particularly with the chassis harness, hasten corrosion. 1.1 Inspection of harnesses (1) Inspections with connectors
particularly with the chassis harness, hasten corrosion. 1.1 Inspection of harnesses (1) Inspections with connectors

1.1 Inspection of harnesses

(1) Inspections with connectors fitted together

(1.1) Waterproof connectors

Connect an inspection harness and connector A between the connectors B of the circuit to be inspected. Perform the inspec- tion by applying a test probe C to the connectors of the inspec- tion harness. Do not insert the test probe C into the wire-entry sides of the waterproof connectors since this would damage their waterproof seals and lead to rust.

(1.2) Non-waterproof connectors

Perform the inspection by inserting a test probe C into the wire- entry sides of the connectors. An extra-narrow probe is required for control unit connectors, which are smaller than other types of connector. Do not force a regular-size probe into control unit connectors since this would cause damage.

00

00 (2) Inspections with connectors separated (2.1) Inspections on female terminals • Perform the inspection by

(2) Inspections with connectors separated

(2.1) Inspections on female terminals

Perform the inspection by carefully inserting a test probe into the terminals. Do not force the test probe into the terminals since this could deform them and cause poor connections.

(2.2) Inspections on male terminals • Perform the inspection by applying test probes directly to
(2.2) Inspections on male terminals
Perform the inspection by applying test probes directly to the
pins.
.
CAUTION
• Be careful not to short-circuit pins together with the test
probes. With control unit connectors, short-circuiting of
pins can cause damage to the control unit’s internal circuit-
ry.
cause damage to the control unit’s internal circuit- ry. • When using a multimeter to check
cause damage to the control unit’s internal circuit- ry. • When using a multimeter to check
cause damage to the control unit’s internal circuit- ry. • When using a multimeter to check

When using a multimeter to check continuity, do not allow the test probes to touch the wrong terminals.

1.2 Inspection of connectors

(1) Visual inspection

Check that the connectors are fitted together securely.

Check whether wires have been separated from their terminals due to pulling of the harness.

PRECAUTIONS FOR MAINTENANCE OPERATION

PRECAUTIONS FOR MAINTENANCE OPERATION • Check that male and female te rminals fit together tightly. •
PRECAUTIONS FOR MAINTENANCE OPERATION • Check that male and female te rminals fit together tightly. •
PRECAUTIONS FOR MAINTENANCE OPERATION • Check that male and female te rminals fit together tightly. •

Check that male and female terminals fit together tightly.

Check for defective connections caused by loose terminals, by rust on terminals, or by contamination of terminals by foreign substances.

(2) Checking for loose terminals

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

1.3 Inspections when a fuse blows

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

The main causes of short circuits are as follows:

Harnesses trapped between chassis parts

Harness insulation damage due to friction or heat

Moisture in connectors or circuitry

Human error (accidental short-circuiting of components)

00

00 1.4 Inspection of chassis ground • A special ground bolt is used to tighten a

1.4 Inspection of chassis ground

A special ground bolt is used to tighten a ground terminal. When servicing the ground point, be sure to follow the procedures de- scribed below:

When reinstalling the ground bolt Tighten the ground bolt to the specified torque.

When relocating the ground point A special ground bolt must be used. Spot-weld a nut to a frame and tighten the ground bolt to the specified torque. Be

sure to apply touch-up paint to the welded point.

2. Service Precautions for Alternators

to the welded point. 2. Service Precautions for Alternators • When servicing alternators, observe the following
to the welded point. 2. Service Precautions for Alternators • When servicing alternators, observe the following

When servicing alternators, observe the following precautions:

Never reverse the polarity of battery connections. If the polarity of the battery connections was reversed, a large current would flow from the battery to the alternator, damag- ing the diodes and regulator.

Never disconnect the battery terminals with the engine running. Disconnection of the battery terminals during engine operation would cause a surge voltage, leading to deterioration of the di- odes and regulator.

• Never perform inspections using a high-voltage multimeter. The use of a high-voltage multimeter could
• Never perform inspections using a high-voltage multimeter.
The use of a high-voltage multimeter could damage the diodes
and regulator.
• Keep alternators dry.
Water on alternators can cause internal short circuits and dam-
age.

PRECAUTIONS FOR MAINTENANCE OPERATION

PRECAUTIONS FOR MAINTENANCE OPERATION • Never operate an alternator with the B and L terminals short-cir-
PRECAUTIONS FOR MAINTENANCE OPERATION • Never operate an alternator with the B and L terminals short-cir-
PRECAUTIONS FOR MAINTENANCE OPERATION • Never operate an alternator with the B and L terminals short-cir-

Never operate an alternator with the B and L terminals short-cir- cuited. Operation with the B and L terminals connected together would damage the diode trio.

Disconnect the battery terminals before quick-charging the bat- tery with a quick charger. Unless the battery terminals are disconnected, quick-charging can damage the diodes and regulator.

00

3. Intermittent Faults

  • An intermittent fault typically occurs only under certain operating conditions. Once these condit
 

An intermittent fault typically occurs only under certain operating conditions. Once these conditions have been identified, the cause of the intermittent fault can be ascertained easily. First, ask the customer about the vehicle operating conditions and weather conditions under which the fault occurs. Also ask about the frequency with which the fault occurs and about the fault symptoms. Then, reproduce the fault based on this information. In accordance with the conditions under which the fault occurs, determine whether the fault is caused by vibration, heat or other

factors. if vibration is a possible factor, see if the fault can be re- produced
factors. if vibration is a possible factor, see if the fault can be re- produced
factors. if vibration is a possible factor, see if the fault can be re- produced
factors. if vibration is a possible factor, see if the fault can be re- produced
factors. if vibration is a possible factor, see if the fault can be re- produced
factors. if vibration is a possible factor, see if the fault can be re- produced

factors. if vibration is a possible factor, see if the fault can be re- produced by performing the following checks on individual con- nectors and other parts:

 
  • Gently move connectors up and down and to left and right.
  • Gently move connectors up and down and to left and right.
 

Gently move connectors up and down and to left and right.

Gently move wiring harnesses up and down and to left and right.

Gently wiggle sensors and other devices by hand.

Gently wiggle wiring harnesses on suspension systems and other moving parts.

• Connectors and other parts to be checked are those included or given as likely
• Connectors and other parts to be checked are those included or given as likely
• Connectors and other parts to be checked are those included or given as likely

Connectors and other parts to be checked are those included or given as likely fault locations in inspection procedures corre- sponding to diagnosis codes and/or fault symptoms.

or given as likely fault locations in inspection procedures corre- sponding to diagnosis codes and/or fault
or given as likely fault locations in inspection procedures corre- sponding to diagnosis codes and/or fault
or given as likely fault locations in inspection procedures corre- sponding to diagnosis codes and/or fault
or given as likely fault locations in inspection procedures corre- sponding to diagnosis codes and/or fault
or given as likely fault locations in inspection procedures corre- sponding to diagnosis codes and/or fault
or given as likely fault locations in inspection procedures corre- sponding to diagnosis codes and/or fault

PRECAUTIONS FOR MAINTENANCE OPERATION

4. Precautions for Arc Welding

When arc welding is performed, current from the welder flows to ground via the vehicle’s metal parts. Unless ap- propriate steps are taken, this current can damage control units, other electrical devices and wiring harnesses. And, any electrical device near the point on vehicle, to which the negative cable of the welder is connected might be largely damaged.

cable of the welder is connected might be largely damaged. • Current flows backward as shown

Current flows backward as shown below.

largely damaged. • Current flows backward as shown below. 4.1 From battery (–) terminal To prevent

4.1 From battery (–) terminal

To prevent damage to the battery an d to electrical devices that are connected directly to the battery, it is essential to disconnect the battery’s (–) terminal.

4.2 Procedure

Turn the starter switch to the LOCK position.

Disconnect the battery’s (–) terminal.

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

Connect the welder’s (–) cable to the vehicle as close as possi- ble to the area being welded. Do not connect the welder’s (–) ca- ble to the cab if the frame is being welded, and vice versa.

Set the welding current in accordance with the part being weld-

ed.

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JACKING UP THE VEHICLE

<Front of vehicle>

JACKING UP THE VEHICLE <Front of vehicle> Jacking up procedure 1 Place chocks against the rear
JACKING UP THE VEHICLE <Front of vehicle> Jacking up procedure 1 Place chocks against the rear
JACKING UP THE VEHICLE <Front of vehicle> Jacking up procedure 1 Place chocks against the rear
JACKING UP THE VEHICLE <Front of vehicle> Jacking up procedure 1 Place chocks against the rear
JACKING UP THE VEHICLE <Front of vehicle> Jacking up procedure 1 Place chocks against the rear
JACKING UP THE VEHICLE <Front of vehicle> Jacking up procedure 1 Place chocks against the rear

Jacking up procedure

1 Place chocks against the rear wheels.

2 Set a bottle jack or garage jack and jack up the front of the vehicle.

3 Support the front of the vehicle frame on jack stands.

WARNING

the front of the vehicle frame on jack stands. WARNING • Chock the wheels firmly to

• Chock the wheels firmly to prevent the vehicle from rolling away.

• Do not attempt to remove the chocks until the operation is completed.

• It is extremely dangerous to support the vehicle with only bottle jack or garage jack. Be sure to addition- ally support the front of the vehicle frame on rigid racks.

• Never attempt to remove any of the bottle jack, garage jack, or jack stands until the operation is complet- ed.

00

<Rear of Vehicle>

00 <Rear of Vehicle> Jacking up procedure 1 Place chocks against the rear wheels. 2 Set
00 <Rear of Vehicle> Jacking up procedure 1 Place chocks against the rear wheels. 2 Set
00 <Rear of Vehicle> Jacking up procedure 1 Place chocks against the rear wheels. 2 Set
00 <Rear of Vehicle> Jacking up procedure 1 Place chocks against the rear wheels. 2 Set
00 <Rear of Vehicle> Jacking up procedure 1 Place chocks against the rear wheels. 2 Set

Jacking up procedure

1 Place chocks against the rear wheels.

2 Set a bottle jack or garage jack and jack up the rear of the vehicle.

3 Support the vehicle frame on jack stands on both sides.

WARNING

the vehicle frame on jack stands on both sides. WARNING • Chock the wheels firmly to

• Chock the wheels firmly to prevent the vehicle from rolling away.

• Do not attempt to remove the chocks until the operation is completed.

• It is extremely dangerous to support the vehicle with only bottle jack or garage jack. Be sure to addition- ally support the vehicle frame on jack stands on both sides.

• Never attempt to remove any of the bottle jack, garage jack, or jack stands until the operation is complet- ed.

DIAGNOSIS CODES

1. Connecting Multi-Use Tester

The type of Multi-Use Tester to be used varies depending on which system is being inspected. Select and connect the correct type of Multi-Use Tester to the system being inspected by referring to the following tables.

System compatible with Multi-Use Tester-III

System

Reference

Gr

Multi-Use Tester to be used

Common rail

13E

Multi-Use Tester- III only

Exhaust gas recirculation

17

Automatic transmission

23

Pre-heater

54

System compatible with Multi-Use Tester-II

System

Reference

Gr

Relevant electronic control unit

Anti-lock Brake System

35E

Multi-Use Tester- II or Multi-Use Tester- III

1.1 Connecting Multi-Use Tester- III

Special tools

Mark Tool name and shape Part No. Application FMS-E04-1 (Multi-Use PC Data transmission to/from V.C.I.
Mark
Tool name and shape
Part No.
Application
FMS-E04-1
(Multi-Use
PC
Data transmission to/from V.C.I.
Tester-III ver-
sion)
V.C.I.
MH062927
Data transmission between electronic
control unit and PC
Multi-Use Tester- III
Test Harness B (used
for communication)
MH062929
Power supply to V.C.I. and communi-
cation with electronic control unit
Multi-Use Tester -III
Test Harness D
(used for extension)
MH062951
Multi-Use Tester-III test harness B
extension

00

Mark

Tool name and shape

Part No.

Application

USB cable MB991827 Communication between V.C.I. and PC

USB cable

USB cable

MB991827

Communication between V.C.I. and PC

 
 
 
 
 
 
 
MB991827 Communication between V.C.I. and PC   • Move the starter switch to the LOCK position.
MB991827 Communication between V.C.I. and PC   • Move the starter switch to the LOCK position.
MB991827 Communication between V.C.I. and PC   • Move the starter switch to the LOCK position.

Move the starter switch to the LOCK position.

Connect

Connect the Multi-Use Tester-II/III connector with the connector (16 terminals) on the vehicle.

NOTE

For Multi-Use Tester operations, refer to the Multi-Use Tester instruction book.

, ,
,
,

and

as illustrated.refer to the Multi-Use Tester instruction book. , , and • Use to extend the cable

Use

to extend the cable ifTester instruction book. , , and as illustrated. • Use is not long enough such as

is not long enough such asbook. , , and as illustrated. • Use to extend the cable if when using Multi-Use

when using Multi-Use Tester outside the vehicle.

DIAGNOSIS CODES

1.2 Connecting Multi-Use Tester- II

Special tools

Mark Tool name and shape Part No. Application Multi-Use Tester MB991946 System check Multi-Use Tester
Mark
Tool name and shape
Part No.
Application
Multi-Use Tester
MB991946
System check
Multi-Use Tester Har-
ness
(used for communica-
tion)
MK327601
Power supply to Multi-Use Tester unit
and communication with vehicle elec-
trical equipment
ROM Pack
MH062942
(MRT-E11)
Electronic control unit inspection/con-
trol data
Move the starter switch to the LOCK position.
Connect
with
. Insert
.
Connect the connector (16 terminals) with the Multi-Use Tester
II/ III connector (16 terminals) in the fuse box.
NOTE
For Multi-Use Tester operations, refer to the Multi-Use
Tester instruction book.

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DIAGNOSIS CODES

2. Accessing / Erasing Diagnosis Codes <Common Rail, Exhaust Gas Recircula- tion, Pre-heater>

2.1 Diagnosis codes

There are two types of diagnosis codes: present codes and past codes.

(1) Present diagnosis codes

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

(2) Past diagnosis codes

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

2.2 Accessing and erasing diagnosis codes

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

Removing/installing the dedicated fuses will turn the diagnosis and memory clear switches ON/OFF.

NOTE

• Be sure to restore the fuse to the original location after accessing and/or erasing diagnosis codes.

(1) Accessing/erasing diagnosis codes using Multi-Use Tester

(1.1) Present diagnosis codes

Turn the starter switch ON.

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

(1.2) Past diagnosis codes

Turn the starter switch ON.

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

(1.3) Erasing diagnosis codes

Turn the starter switch ON.

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

(2) Accessing/erasing diagnosis codes without using Multi-Use Tester

diagnosis codes without using Multi-Use Tester • Using the diagnosis and memory clear switches, display
diagnosis codes without using Multi-Use Tester • Using the diagnosis and memory clear switches, display
diagnosis codes without using Multi-Use Tester • Using the diagnosis and memory clear switches, display
diagnosis codes without using Multi-Use Tester • Using the diagnosis and memory clear switches, display

Using the diagnosis and memory clear switches, display diagnosis codes that may have been stored in electronic control unit.

00

00 (2.1) Reading diagnosis codes • To read a diagnosis code, observe how may times the

(2.1) Reading diagnosis codes

To read a diagnosis code, observe how may times the warning lamp flashes and how long each illumination lasts.

The duration of illumination differs between the first and second digits.

Second digit: 1.2 sec.

First digit: 0.4 sec.

A diagnosis code consists of the flashing of second digit and the flashing of first digit in that order. If a diagnosis code has “0” in the second digit, only the first digit will be displayed.

The same diagnosis code will be displayed 3 times in a row be- fore moving to the display of the next code.

After the last diagnosis code is displayed, the first code will be displayed again 3 times in a row and then the subsequent codes. This will be repeated.

When the diagnosis switch is connected, electronic control unit will immediately stop (terminate) displaying diagnosis codes.

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

(2.3) Present and past diagnosis codes

After present diagnosis codes are displayed, (with the diagnosis switch still removed) remove the memory clear switch.

This will cause the warning lamp to start flashing again to indi- cate present and past diagnosis codes. Observe the codes that

will be displayed, and identify the faults.

(2.4) Erasing diagnosis codes

All diagnosis codes stored in electronic control unit can be erased by removing the memory clear switch and then installing it again.

NOTE

• Be careful not to erase diagnosis codes by mistake. They can easily be erased simply by operating the memory clear switch only.

• If you do not wish to erase diagnosis codes after they

have been displayed, turn the starter switch OFF with the memory clear switch still removed, and then connect the memory clear switch.

DIAGNOSIS CODES

3. Accessing / Erasing Diagnosis Codes <Automatic Transmission>

3.1 Diagnosis codes

There are two types of diagnosis codes: present codes and past codes.

(1) Present diagnosis codes

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

(2) Past diagnosis codes

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

3.2 Accessing and erasing diagnosis codes

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

Removing/installing the dedicated fuses will turn the diagnosis and memory clear switches ON/OFF.

NOTE

• Be sure to restore the fuse to the original location after accessing and/or erasing diagnosis codes.

(1) Accessing/erasing diagnosis codes using Multi-Use Tester

(1.1) Present diagnosis codes

Turn the starter switch ON.

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

(1.2) Past diagnosis codes

Turn the starter switch ON.

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

(1.3) Erasing diagnosis codes

Turn the starter switch ON.

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

(2) Accessing/erasing diagnosis codes without using Multi-Use Tester

diagnosis codes without using Multi-Use Tester • Using the diagnosis and memory clear switches, display
diagnosis codes without using Multi-Use Tester • Using the diagnosis and memory clear switches, display
diagnosis codes without using Multi-Use Tester • Using the diagnosis and memory clear switches, display
diagnosis codes without using Multi-Use Tester • Using the diagnosis and memory clear switches, display
diagnosis codes without using Multi-Use Tester • Using the diagnosis and memory clear switches, display

Using the diagnosis and memory clear switches, display diagnosis codes that may have been stored in electronic control unit.

00

00 (2.1) Reading diagnosis codes • To read a diagnosis code, observe how may times the

(2.1) Reading diagnosis codes

To read a diagnosis code, observe how may times the warning lamp flashes and how long each illumination lasts.

The duration of illumination differs between the first and second digits.

Second digit: 1.2 sec.

First digit: 0.4 sec.

A diagnosis code consists of the flashing of second digit and the flashing of first digit in that order. If a diagnosis code has “0” in the second digit, only the first digit will be displayed.

The same diagnosis code will be displayed 3 times in a row be- fore moving to the display of the next code.

After the last diagnosis code is displayed, the first code will be displayed again 3 times in a row and then the subsequent codes. This will be repeated.

When the diagnosis switch is connected, electronic control unit will immediately stop (terminate) displaying diagnosis codes.

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

(2.3) Present and past diagnosis codes

After present diagnosis codes are displayed, (with the diagnosis switch still removed) remove the memory clear switch.

This will cause the warning lamp to start flashing again to indi- cate present and past diagnosis codes. Observe the codes that

will be displayed, and identify the faults.

(2.4) Erasing diagnosis codes

All diagnosis codes stored in electronic control unit can be erased by removing the memory clear switch and then installing it again.

NOTE

• Be careful not to erase diagnosis codes by mistake. They can easily be erased simply by operating the memory clear switch only.

• If you do not wish to erase diagnosis codes after they

have been displayed, turn the starter switch OFF with the memory clear switch still removed, and then connect the memory clear switch.

DIAGNOSIS CODES

4. Accessing / Erasing Diagnosis Codes <Anti-lock Brake System>

4.1 Diagnosis codes

There are two types of diagnosis codes: present codes and past codes.

(1) Present diagnosis codes

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

(2) Past diagnosis codes

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

4.2 Accessing and erasing diagnosis codes

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

Removing/installing the dedicated fuses will turn the diagnosis and memory clear switches ON/OFF.

NOTE

• Be sure to restore the fuse to the original location after accessing and/or erasing diagnosis codes.

(1) Accessing/erasing diagnosis codes using Multi-Use Tester

(1.1) Present diagnosis codes

Turn the starter switch ON.

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

(1.2) Past diagnosis codes

Turn the starter switch ON.

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

(1.3) Erasing diagnosis codes

Turn the starter switch ON.

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

(2) Accessing/erasing diagnosis codes without using Multi-Use Tester

diagnosis codes without using Multi-Use Tester • Using the diagnosis and memory clear switches, display
diagnosis codes without using Multi-Use Tester • Using the diagnosis and memory clear switches, display
diagnosis codes without using Multi-Use Tester • Using the diagnosis and memory clear switches, display
diagnosis codes without using Multi-Use Tester • Using the diagnosis and memory clear switches, display
diagnosis codes without using Multi-Use Tester • Using the diagnosis and memory clear switches, display

Using the diagnosis and memory clear switches, display diagnosis codes that may have been stored in electronic control unit.

00

00 (2.1) Reading diagnosis codes • To read a diagnosis code, observe how may times the

(2.1) Reading diagnosis codes

To read a diagnosis code, observe how may times the warning lamp flashes and how long each illumination lasts.

The duration of illumination differs between the first and second digits.

Second digit: 1.2 sec.

First digit: 0.4 sec.

A diagnosis code consists of the flashing of second digit and the flashing of first digit in that order. If a diagnosis code has “0” in the second digit, only the first digit will be displayed.

The same diagnosis code will be displayed 3 times in a row be- fore moving to the display of the next code.

After the last diagnosis code is displayed, the first code will be displayed again 3 times in a row and then the subsequent codes. This will be repeated.

When the diagnosis switch is connected, electronic control unit will immediately stop (terminate) displaying diagnosis codes.

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

(2.3) Present and past diagnosis codes

After present diagnosis codes are displayed, (with the diagnosis switch still removed) remove the memory clear switch.

This will cause the warning lamp to start flashing again to indi- cate present and past diagnosis codes. Observe the codes that

will be displayed, and identify the faults.

(2.4) Erasing diagnosis codes

All diagnosis codes stored in electronic control unit can be erased by removing the memory clear switch and then installing it again.

NOTE

• Be careful not to erase diagnosis codes by mistake. They can easily be erased simply by operating the memory clear switch only.

• If you do not wish to erase diagnosis codes after they

have been displayed, turn the starter switch OFF with the memory clear switch still removed, and then connect the memory clear switch.

TABLE OF STANDARD TIGHTENING TORQUES

Use specified bolts and nuts, tightening them to the torques specified in this section unless otherwise stated.

Threaded portions and bearing surfaces should be dry.

Where the property class differs between the nut and bolt (or stud bolt), use the tightening torque specified in the table for the bolt.

Hexagon Headed Bolt, Stud Bolt (Unit: N·m {ft.lbs, kgf·m})

Strength

 

4T

   

7T

   

8T

 
Identification symbol Nominal diameter
Identification
symbol
Nominal
diameter
Identification symbol Nominal diameter
Identification symbol Nominal diameter
Identification symbol Nominal diameter
Identification symbol Nominal diameter
Identification symbol Nominal diameter
Identification symbol Nominal diameter
 

(Stud)

 

(Stud)

 

(Stud)

M5

2

to 3

 

4

to 6

 

5

to 7

 

{1.5 to 2.2, 0.2 to 0.3}

 

{3.0 to 4.4, 0.4 to 0.6}

 

{3.7 to 5.2, 0.5 to 0.7}

 

M6

4

to 6

 

7

to 10

 

8

to 12

 

{3.0 to 4.4, 0.4 to 0.6}

 

{5.2 to 7.4, 0.7 to 1.0}

 

{5.9 to 8.9, 0.8 to 1.2}

 

M8

9

to 13

 

16

to 24

 

19

to 28

 

{6.6 to 9.6, 0.9 to 1.3}

 

{12 to 18, 1.7 to 2.5}

 

{14 to 21, 2.0 to 2.9}

 

M10

18

to 27

17

to 25

34

to 50

32

to 48

45

to 60

37

to 55

{13 to 20, 1.8 to 2.7}

{13 to 18, 1.8 to 2.6}

{25 to 37, 3.5 to 5.1}

{24 to 35, 3.3 to 4.9}

{33 to 44, 4.5 to 6.0}

{27 to 41, 3.8 to 5.7}

M12

34

to 50

31

to 45

70

to 90

65

to 85

80

to 105

75

to 95

{25 to 37, 3.4 to 5.1}

{23 to 33, 3.1 to 4.6}

{52 to 66, 7.0 to 9.5}

{48 to 63, 6.5 to 8.5}

{59 to 77, 8.5 to 11}

{55 to 70, 7.5 to 10}

M14

60

to 80

55

to 75

110

to 150

100

to 140

130

to 170

120

to 160

{44 to 59, 6.0 to 8.0}

{41 to 55, 5.5 to 7.5}

{81 to 110, 11 to 15}

{74 to 105, 11 to 14}

{96 to 125, 13 to 17}

{89 to 120, 12 to 16}

M16

90

to 120

90 to 110 {66 to 81, 9 to 11}

170

to 220

160

to 210

200

to 260

190

to 240

{66 to 89, 9 to 12}

{125 to 160, 17 to 23}

{120 to 155, 16 to 21}

{145 to 190, 20 to 27}

{140 to 175, 19 to 25}

M18

130

to 170

120

to 150

250

to 330

220

to 290

290

to 380

250

to 340

{96 to 125, 14 to 18}

{89 to 110, 12 to 16}

{185 to 245, 25 to 33}

{160 to 215, 23 to 30}

{215 to 280, 30 to 39}

{185 to 250, 26 to 35}

M20

180

to 240

170

to 220

340

to 460

310

to 410

400

to 530

360

to 480

{130 to 175, 19 to 25}

{125 to 160, 17 to 22}

{250 to 340, 35 to 47}

{230 to 300, 32 to 42}

{295 to 390, 41 to 55}

{265 to 355, 37 to 49}

M22

250 to 330 {185 to 245, 25 to 33}

230

to 300

460

to 620

420

to 560

540

to 720

490

to 650

{170 to 220, 23 to 30}

{340 to 455, 47 to 63}

{310 to 415, 43 to 57}

{400 to 530, 55 to 73}

{360 to 480, 50 to 67}

M24

320

to 430

290

to 380

600

to 810

540

to 720

700

to 940

620

to 830

{235 to 315, 33 to 44}

{215 to 280, 29 to 39}

{440 to 595, 62 to 83}

{400 to 530, 55 to 73}

{515 to 695, 72 to 96}

{455 to 610, 63 to 85}

Hexagon Headed Flange Bolt (Unit: N·m {ft.lbs, kgf·m})

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

00

Hexagon Nuts (Unit: N·m {ft.lbs, kgf·m})

Strength

 

4T

   

6T

Identification symbol Nominal diameter
Identification
symbol
Nominal
diameter
 
Identification symbol Nominal diameter    
 
Identification symbol Nominal diameter    

Standard screw

Coarse screw

   

thread

thread

Standard screw thread

Coarse screw thread

M5

2

to 3

 

4

to 6

 

{1.5 to 2.2, 0.2 to 0.3}

 

{3.0 to 4.4, 0.4 to 0.6}

 

M6

4

to 6

 

7

to 10

 

{3.0 to 4.4, 0.4 to 0.6}

 

{5.2 to 7.4, 0.7 to 1.0}

 

M8

9

to 13

 

16

to 24

 

{6.6 to 9.6, 0.9 to 1.3}

 

{12 to 18, 1.7 to 2.5}

 

M10

18

to 27

17

to 25

34

to 50

32

to 48

{13 to 20, 1.8 to 2.7}

{13 to 18, 1.8 to 2.6}

{25 to 37, 3.5 to 5.1}

{24 to 35, 3.3 to 4.9}

M12

34

to 50

31

to 45

70

to 90

65

to 85

{25 to 37, 3.4 to 5.1}

{23 to 33, 3.1 to 4.6}

{52 to 66, 7.0 to 9.5}

{48 to 63, 6.5 to 8.5}

M14

60

to 80

55

to 75

110

to 150

100

to 140

{44 to 59, 6.0 to 8.0}

{41 to 55, 5.5 to 7.5}

{81 to 110, 11 to 15}

{74 to 105, 11 to 14}

M16

90

to 120

90 to 110 {66 to 81, 9 to 11}

170

to 220

160

to 210

{66 to 89, 9 to 12}

{125 to 160, 17 to 23}

{120 to 155, 16 to 21}

M18

130

to 170

120

to 150

250

to 330

220

to 290

{96 to 125, 14 to 18}

{89 to 110, 12 to 16}

{185 to 245, 25 to 33}

{160 to 215, 23 to 30}

M20

180

to 240

170

to 220

340

to 460

310

to 410

{130 to 175, 19 to 25}

{125 to 160, 17 to 22}

{250 to 340, 35 to 47}

{230 to 300, 32 to 42}

M22

250 to 330 {185 to 245, 25 to 33}

230

to 300

460

to 620

420

to 560

{170 to 220, 23 to 30}

{340 to 455, 47 to 63}

{310 to 415, 43 to 57}

M24

320

to 430

290

to 380

600

to 810

540

to 720

{235 to 315, 33 to 44}

{215 to 280, 29 to 39}

{440 to 595, 62 to 83}

{400 to 530, 55 to 73}

Hexagon Flange Nuts (Unit: N·m {ft.lbs, kgf·m})

Strength

 

4T

 
Identification symbol Nominal diameter
Identification
symbol
Nominal
diameter
 
Identification symbol Nominal diameter    
 

Standard screw

Coarse screw

thread

thread

M6

4

to 6

 

{3.0 to 4.4, 0.4 to 0.6}

 

M8

10

to 15

 

{7.4 to 11, 1.0 to 1.5}

 

M10

21

to 31

20

to 29

{15 to 23, 2.1 to 3.1}

{15 to 21, 2.0 to 3.0}

M12

38

to 56

35

to 51

{28 to 41, 3.8 to 5.6}

{26 to 38, 3.5 to 5.2}

TABLE OF STANDARD TIGHTENING TORQUES

Tightening Torque for General-Purpose Flare Nut (Unit: N·m {ft.lbs, kgf·m})

Pipe diameter

φ4.76 mm

φ6.35 mm

φ8 mm

φ10 mm

φ12 mm

φ15 mm

{0.19 in.}

{0.25 in.}

{0.31 in.}

{0.39 in.}

{0.47 in.}

{0.59 in.}

Tightening torque

17 {13, 1.7}

25 {18, 2.6}

39 {29, 4.0}

59 {44, 6.0}

88 {65, 9.0}

98 {72, 10}

Tightening Torque for General-Purpose Air Piping Nylon Tube (DIN Type) (Unit: N·m {ft.lbs, kgf·m})

Nominal diameter × wall thickness

6 × 1 mm {0.24 × 0.039 in.}

 

10 × 1.25 mm {0.39 × 0.049 in.}

 

12 × 1.5 mm {0.47 × 0.059 in.}

 

15 × 1.5 mm {0.59 × 0.059 in.}

 

Tightening torque

20

+6

{15

+4.4

2.0

+0.6

}

34

+10

{25

+7.4

3.5

+1.0

}

49

+10

{36

+7.4

5.0

+1.0

}

54

+5

{40

+3.7

5.5

+0.5

}

0

0

0

0

0

0

0

0

0

0

0

0

Tightening Torque for General-Purpose Air Piping Nylon Tube (SAE Type) (Unit: N·m {ft.lbs, kgf·m})

 

Nominal diameter

 

1/4 in.

   

3/8 in.

   

1/2 in.

   

5/8 in.

 

Tightening torque

13

+4

{9.6

+3.0

1.3

+0.4