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2014 HINO TRUCK COE 155 155H 195 195H J05E WORKSHOP MANUAL – PDF DOWNLOAD
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2014 HINO TRUCK COE 155 155H 195 195H J05E WORKSHOP MANUAL
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2014 HINO TRUCK COE 155 155H 195 195H J05E WORKSHOP MANUAL
Language : English
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2014 HINO TRUCK COE 155 155H 195 195H J05E WORKSHOP MANUAL – PDF DOWNLOAD:
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Table Of Contents:
2014 HINO TRUCK COE 155 155H 195 195H J05E WORKSHOP MANUAL
FOREWORD.................................................................................................................................. 2 CHAPTER REFERENCES........................................................................................................................ 3 INDEX..................................................................................................................................... 4 GENERAL INTRODUCTION ..................................................................................................................... 6 HOW TO IDENTIFY VEHICLE TYPE.......................................................................................................... 7 HOW TO IDENTIFY VEHICLE TYPE...................................................................................................... 7 VEHICLE MODEL................................................................................................................. 7 VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE................................................................................. 8 APPEARANCE OF VEHICLE................................................................................................................. 9 APPEARANCE........................................................................................................................ 9 APPEARANCE OF VEHICLE......................................................................................................... 9 SAFETY INSTRUCTIONS AND READINESS TO WORK............................................................................................. 10 WARNING........................................................................................................................... 10 GENERAL PRECAUTIONS........................................................................................................... 10 IDENTIFICATION INFORMATION.................................................................................................... 14 SAFETY INSTRUCTIONS FOR WORK...................................................................................................... 17 PRECAUTIONS................................................................................................................... 17 INTRODUCTION TO WORKSHOP MANUAL................................................................................................... 21 GENERAL....................................................................................................................... 21 INTRODUCTION TO DESCRIPTIONS.................................................................................................. 22 TIGHTENING OF BOLTS AND NUTS...................................................................................................... 25 BOLTS AND NUTS................................................................................................................ 25 PURPOSES OF TIGHTENING TORQUE................................................................................................. 25 CAUTIONS TO PREVENT LOOSENESS................................................................................................. 25 TYPES AND IDENTIFICATION...................................................................................................... 26 COMPATIBILITY (NO COMPATIBILITY IN BOLTS AND NUTS)............................................................................ 27 STRENGTH CLASSES AND SYMBOLS.................................................................................................. 28 PART No....................................................................................................................... 29 LIST OF TIGHTENING TORQUE..................................................................................................... 30 TIGHTENING OF FLARE NUTS AND HOSES............................................................................................ 32 HANDLING OF LIQUID GASKET......................................................................................................... 33 LIQUID GASKET................................................................................................................. 33 GLOSSARY.............................................................................................................................. 34 DEFINITION OF ABBREVIATION IN THIS MANUAL......................................................................................... 34 LIST OF ABBREVIATION.......................................................................................................... 34 GLOSSARY OF SAE AND HINO TERMS................................................................................................ 37 LUBRICANTS............................................................................................................................ 40 LUBRICANTS........................................................................................................................ 40 RECOMMENDED LUBRICANTS........................................................................................................ 40 HYBRID ................................................................................................................................... 41 STANDARD VALUE........................................................................................................................ 42 HYBRID SYSTEM..................................................................................................................... 42 SERVICE PLUG.................................................................................................................. 42 PCU........................................................................................................................... 42 HV BATTERY.................................................................................................................... 43 HV BATTERY COOLING FAN........................................................................................................ 43 HV BATTERY ECU................................................................................................................ 43 SYSTEM MAIN RELAY JUNCTION BLOCK.............................................................................................. 43 INVERTER...................................................................................................................... 44 HV-ECU........................................................................................................................ 44 HYBRID JUNCTION BLOCK......................................................................................................... 44 WATER PUMP.................................................................................................................... 45 INVERTER RADIATOR............................................................................................................. 45 COOLANT....................................................................................................................... 45 MOTOR CABLE................................................................................................................... 45 REQUIRED ITEMS........................................................................................................................ 46 HYBRID SYSTEM..................................................................................................................... 46 HYBRID SYSTEM................................................................................................................. 46 SERVICE PLUG.................................................................................................................. 46 COOLANT....................................................................................................................... 46 HYBRID SYSTEM......................................................................................................................... 47 HYBRID SYSTEM..................................................................................................................... 47 CAUTIONS...................................................................................................................... 47 SERVICE PLUG...................................................................................................................... 50 COMPONENT LOCATOR............................................................................................................. 50 UNIT CHECK.................................................................................................................... 50 REPLACEMENT................................................................................................................... 51 PCU............................................................................................................................... 53 COMPONENT LOCATOR............................................................................................................. 53 REPLACEMENT................................................................................................................... 57 HV BATTERY........................................................................................................................ 62 COMPONENT LOCATOR............................................................................................................. 62 REPLACEMENT................................................................................................................... 64 HV BATTERY COOLING FAN............................................................................................................ 68 COMPONENT LOCATOR............................................................................................................. 68 REPLACEMENT................................................................................................................... 70 HV SYSTEM ECU..................................................................................................................... 73 COMPONENT LOCATOR............................................................................................................. 73 REPLACEMENT................................................................................................................... 74 SYSTEM MAIN RELAY JUNCTION BLOCK.................................................................................................. 77 COMPONENT LOCATOR............................................................................................................. 77 REPLACEMENT................................................................................................................... 78 INVERTER.......................................................................................................................... 80 COMPONENT LOCATOR............................................................................................................. 80 REPLACEMENT................................................................................................................... 81 HV-ECU............................................................................................................................ 85 COMPONENT LOCATOR............................................................................................................. 85 REPLACEMENT................................................................................................................... 86 HYBRID JUNCTION BLOCK............................................................................................................. 88 COMPONENT LOCATOR............................................................................................................. 88 REPLACEMENT................................................................................................................... 89 WATER PUMP........................................................................................................................ 92 COMPONENT LOCATOR............................................................................................................. 92 REPLACEMENT................................................................................................................... 93 INVERTER RADIATOR................................................................................................................. 96 COMPONENT LOCATOR............................................................................................................. 96 REPLACEMENT................................................................................................................... 97 COOLANT........................................................................................................................... 100 REPLACEMENT................................................................................................................... 100 MOTOR CABLE....................................................................................................................... 102 COMPONENT LOCATOR............................................................................................................. 102 REPLACEMENT................................................................................................................... 105 TRANSMISSION (A465) ...................................................................................................................... 111 STANDARD VALUE........................................................................................................................ 0 TRANSMISSION CONTROL.............................................................................................................. 114 SHIFT LEVER ASSEMBLY.......................................................................................................... 114 TRANSMISSION MECHANICAL........................................................................................................... 114 TURBINE SENSOR................................................................................................................ 114 SPEED SENSOR.................................................................................................................. 114 NEUTRAL SWITCH................................................................................................................ 115 REQUIRED ITEMS........................................................................................................................ 116 ATTACHING AND DETACHING THE TRANSMISSION.......................................................................................... 116 AUTOMATIC TRANSMISSION ASSEMBLY............................................................................................... 116 NEUTRAL SWITCH................................................................................................................ 116 ATTACHING AND DETACHING THE TRANSMISSION.............................................................................................. 117 AUTOMATIC TRANSMISSION ASSEMBLY................................................................................................... 117 REPLACEMENT................................................................................................................... 117 TRANSMISSION CONTROL.................................................................................................................. 159 CONTROL COMPUTER ASSEMBLY......................................................................................................... 159 COMPONENT LOCATOR............................................................................................................. 159 OVERHAUL...................................................................................................................... 160 SHIFT LEVER ASSEMBLY.............................................................................................................. 166 COMPONENT LOCATOR............................................................................................................. 166 OVERHAUL...................................................................................................................... 167 TRANSMISSION MECHANICAL............................................................................................................... 171 TURBINE SENSOR.................................................................................................................... 171 COMPONENT LOCATOR............................................................................................................. 171 OVERHAUL...................................................................................................................... 172 SPEED SENSOR...................................................................................................................... 173 COMPONENT LOCATOR............................................................................................................. 173 OVERHAUL...................................................................................................................... 174 NEUTRAL SWITCH.................................................................................................................... 175 COMPONENT LOCATOR............................................................................................................. 175 OVERHAUL...................................................................................................................... 176 PROPELLER SHAFT (LD) ..................................................................................................................... 179 STANDARD VALUE........................................................................................................................ 180 PROPELLER SHAFT MECHANICAL........................................................................................................ 180 PROPELLER SHAFT ASSEMBLY...................................................................................................... 180 REQUIRED ITEMS........................................................................................................................ 181 PROPELLER SHAFT MECHANICAL........................................................................................................ 181 PROPELLER SHAFT ASSEMBLY...................................................................................................... 181 PROPELLER SHAFT MECHANICAL............................................................................................................ 183 PROPELLER SHAFT ASSEMBLY.......................................................................................................... 183 COMPONENT LOCATOR............................................................................................................. 183 OVERHAUL...................................................................................................................... 185 AXLE ..................................................................................................................................... 200 STANDARD VALUE........................................................................................................................ 201 FRONT AXLE........................................................................................................................ 201 STEERING KNUCKLE.............................................................................................................. 201 FRONT AXLE HUB................................................................................................................ 202 REAR AXLE......................................................................................................................... 203 REAR AXLE HUB................................................................................................................. 203 REAR AXLE SHAFT............................................................................................................... 203 REQUIRED ITEMS........................................................................................................................ 204 FRONT AXLE........................................................................................................................ 204 STEERING KNUCKLE.............................................................................................................. 204 FRONT AXLE HUB................................................................................................................ 205 REAR AXLE......................................................................................................................... 208 REAR AXLE HUB................................................................................................................. 208 REAR AXLE SHAFT............................................................................................................... 209 FRONT AXLE............................................................................................................................ 211 STEERING KNUCKLE.................................................................................................................. 211 COMPONENT LOCATOR............................................................................................................. 211 OVERHAUL...................................................................................................................... 215 FRONT AXLE HUB.................................................................................................................... 229 COMPONENT LOCATOR............................................................................................................. 229 OVERHAUL...................................................................................................................... 231 FRONT AXLE HUB BOLT............................................................................................................... 242 COMPONENT LOCATOR............................................................................................................. 242 OVERHAUL...................................................................................................................... 243 REAR AXLE............................................................................................................................. 245 REAR AXLE HUB..................................................................................................................... 245 COMPONENT LOCATOR............................................................................................................. 245 OVERHAUL...................................................................................................................... 247 REAR AXLE SHAFT................................................................................................................... 258 COMPONENT LOCATOR............................................................................................................. 258 OVERHAUL...................................................................................................................... 259 WHEEL AND TIRE........................................................................................................................ 260 WHEEL AND TIRE.................................................................................................................... 260 COMPONENT LOCATOR............................................................................................................. 260 INSPECTION.................................................................................................................... 261 REPLACEMENT................................................................................................................... 263 OVERHAUL (TUBELESS TIRE)...................................................................................................... 267 DIFFERENTIAL (SH13) ...................................................................................................................... 274 STANDARD VALUE........................................................................................................................ 275 DIFFERENTIAL...................................................................................................................... 275 DIFFERENTIAL CARRIER.......................................................................................................... 275 REQUIRED ITEMS........................................................................................................................ 277 DIFFERENTIAL...................................................................................................................... 277 DIFFERENTIAL CARRIER.......................................................................................................... 277 DIFFERENTIAL.......................................................................................................................... 280 DIFFERENTIAL CARRIER.............................................................................................................. 280 COMPONENT LOCATOR............................................................................................................. 280 OVERHAUL...................................................................................................................... 286 BRAKE .................................................................................................................................... 316 STANDARD VALUE........................................................................................................................ 318 BRAKE CONTROL..................................................................................................................... 318 SERVICE BRAKE................................................................................................................. 318 BRAKE FLUID................................................................................................................... 318 BRAKE ACTUATOR................................................................................................................ 319 SPEED SENSOR.................................................................................................................. 319 BRAKE PEDAL................................................................................................................... 320 BRAKE MASTER CYLINDER......................................................................................................... 320 BRAKE BOOSTER................................................................................................................. 320 HYDRO BOOSTER................................................................................................................. 321 ELECTRIC VACUUM PUMP.......................................................................................................... 321 VACUUM PUMP................................................................................................................... 321 HYDRO PUMP.................................................................................................................... 322 VACUUM RESERVOIR.............................................................................................................. 322 FRONT FLEXIBLE HOSE........................................................................................................... 322 REAR FLEXIBLE HOSE............................................................................................................ 322 VACUUM WARNING BUZZER......................................................................................................... 322 VACUUM SENSOR (FOR SKID CONTROL).............................................................................................. 323 DISC BRAKE........................................................................................................................ 323 FRONT DISC CALIPER............................................................................................................ 323 REAR DISC CALIPER............................................................................................................. 324 PARKING BRAKE..................................................................................................................... 325 PARKING BRAKE................................................................................................................. 325 PARKING BRAKE CABLE No.2...................................................................................................... 325 PARKING BRAKE CABLE No.3...................................................................................................... 325 PARKING BRAKE LEVER........................................................................................................... 325 PARKING BRAKE DRUM............................................................................................................ 326 PARKING BRAKE SWITCH.......................................................................................................... 326 REQUIRED ITEMS........................................................................................................................ 327 SERVICE BRAKE..................................................................................................................... 327 SERVICE BRAKE................................................................................................................. 327 BRAKE FLUID................................................................................................................... 327 SPEED SENSOR.................................................................................................................. 327 BRAKE PEDAL................................................................................................................... 327 BRAKE BOOSTER................................................................................................................. 327 HYDRO BOOSTER................................................................................................................. 328 VACUUM RESERVOIR.............................................................................................................. 328 DISC BRAKE........................................................................................................................ 328 FRONT DISC CALIPER............................................................................................................ 328 REAR DISC CALIPER............................................................................................................. 328 PARKING BRAKE..................................................................................................................... 329 PARKING BRAKE DRUM............................................................................................................ 329 BRAKE CONTROL......................................................................................................................... 330 SERVICE BRAKE..................................................................................................................... 330 INSPECTION AND ADJUSTMENT..................................................................................................... 330 BRAKE FLUID....................................................................................................................... 335 REPLACEMENT................................................................................................................... 335 ABS ACTUATOR...................................................................................................................... 338 COMPONENT LOCATOR............................................................................................................. 338 REPLACEMENT................................................................................................................... 339 UNIT CHECK.................................................................................................................... 341 SPEED SENSOR...................................................................................................................... 342 COMPONENT LOCATOR............................................................................................................. 342 UNIT CHECK.................................................................................................................... 344 REPLACEMENT................................................................................................................... 345 BRAKE PEDAL....................................................................................................................... 348 COMPONENT LOCATOR............................................................................................................. 348 REPLACEMENT................................................................................................................... 349 BRAKE MASTER CYLINDER............................................................................................................. 352 COMPONENT LOCATOR............................................................................................................. 352 REPLACEMENT................................................................................................................... 353 BRAKE BOOSTER..................................................................................................................... 357 COMPONENT LOCATOR............................................................................................................. 357 REPLACEMENT................................................................................................................... 358 HYDRO BOOSTER..................................................................................................................... 366 COMPONENT LOCATOR............................................................................................................. 366 REPLACEMENT................................................................................................................... 367 ELECTRIC VACUUM PUMP.............................................................................................................. 372 COMPONENT LOCATOR............................................................................................................. 372 OVERHAUL...................................................................................................................... 373 VACUUM PUMP....................................................................................................................... 377 COMPONENT LOCATOR............................................................................................................. 377 OVERHAUL...................................................................................................................... 378 HYDRO PUMP........................................................................................................................ 380 COMPONENT LOCATOR............................................................................................................. 380 OVERHAUL...................................................................................................................... 381 VACUUM RESERVOIR.................................................................................................................. 382 COMPONENT LOCATOR............................................................................................................. 382 REPLACEMENT................................................................................................................... 383 FRONT FLEXIBLE HOSE............................................................................................................... 385 COMPONENT LOCATOR............................................................................................................. 385 REPLACEMENT................................................................................................................... 386 REAR FLEXIBLE HOSE................................................................................................................ 388 COMPONENT LOCATOR............................................................................................................. 388 REPLACEMENT................................................................................................................... 389 VACUUM WARNING BUZZER............................................................................................................. 391 BEHIND-THE-WHEEL INSPECTION................................................................................................... 391 REPLACEMENT................................................................................................................... 391 VACUUM SENSOR (FOR SKID CONTROL).................................................................................................. 392 COMPONENT LOCATOR............................................................................................................. 392 REPLACEMENT................................................................................................................... 393 DISC BRAKE............................................................................................................................ 396 FRONT BRAKE CALIPER............................................................................................................... 396 COMPONENT LOCATOR............................................................................................................. 396 OVERHAUL...................................................................................................................... 397 REAR BRAKE CALIPER................................................................................................................ 404 COMPONENT LOCATOR............................................................................................................. 404 OVERHAUL...................................................................................................................... 405 PARKING BRAKE......................................................................................................................... 412 PARKING BRAKE..................................................................................................................... 412 INSPECTION AND ADJUSTMENT..................................................................................................... 412 PARKING BRAKE CABLE No.2.......................................................................................................... 414 COMPONENT LOCATOR............................................................................................................. 414 REPLACEMENT................................................................................................................... 415 PARKING BRAKE CABLE No.3.......................................................................................................... 421 COMPONENT LOCATOR............................................................................................................. 421 REPLACEMENT................................................................................................................... 422 PARKING BRAKE LEVER............................................................................................................... 427 COMPONENT LOCATOR............................................................................................................. 427 REPLACEMENT................................................................................................................... 428 PARKING BRAKE DRUM................................................................................................................ 432 COMPONENT LOCATOR............................................................................................................. 432 OVERHAUL...................................................................................................................... 434 PARKING BRAKE SWITCH.............................................................................................................. 444 COMPONENT LOCATOR............................................................................................................. 444 REPLACEMENT................................................................................................................... 445 STEERING ................................................................................................................................. 447 STANDARD VALUE........................................................................................................................ 448 STEERING CONTROL.................................................................................................................. 448 POWER STEERING SYSTEM......................................................................................................... 448 STEERING WHEEL................................................................................................................ 448 STEERING COLUMN............................................................................................................... 448 STEERING LINKAGE.............................................................................................................. 449 POWER STEERING GEAR........................................................................................................... 449 POWER STEERING PUMP........................................................................................................... 449 REQUIRED ITEMS........................................................................................................................ 450 STEERING CONTROL.................................................................................................................. 450 POWER STEERING SYSTEM......................................................................................................... 450 STEERING WHEEL................................................................................................................ 450 STEERING COLUMN............................................................................................................... 451 STEERING LINKAGE.............................................................................................................. 451 POWER STEERING GEAR........................................................................................................... 451 POWER STEERING PUMP........................................................................................................... 452 STEERING CONTROL...................................................................................................................... 453 POWER STEERING SYSTEM............................................................................................................. 453 PERFORMANCE INSPECTION........................................................................................................ 453 STEERING WHEEL.................................................................................................................... 456 COMPONENT LOCATOR............................................................................................................. 456 REPLACEMENT................................................................................................................... 457 STEERING COLUMN................................................................................................................... 460 COMPONENT LOCATOR............................................................................................................. 460 REPLACEMENT................................................................................................................... 461 STEERING LINKAGE.................................................................................................................. 468 COMPONENT LOCATOR............................................................................................................. 468 REPLACEMENT................................................................................................................... 469 POWER STEERING GEAR............................................................................................................... 476 COMPONENT LOCATOR............................................................................................................. 476 REPLACEMENT................................................................................................................... 477 POWER STEERING PUMP............................................................................................................... 481 COMPONENT LOCATOR............................................................................................................. 481 REPLACEMENT................................................................................................................... 482 SUSPENSION ............................................................................................................................... 484 STANDARD VALUE........................................................................................................................ 485 FRONT SUSPENSION.................................................................................................................. 485 SHOCK ABSORBER................................................................................................................ 485 LEAF SPRING................................................................................................................... 485 STABILIZER.................................................................................................................... 486 WHEEL ALIGNMENT............................................................................................................... 486 REAR SUSPENSION....................................................................................................................... 487 SHOCK ABSORBER.................................................................................................................... 487 LEAF SPRING....................................................................................................................... 487 REQUIRED ITEMS........................................................................................................................ 488 FRONT SUSPENSION.................................................................................................................. 488 SHOCK ABSORBER................................................................................................................ 488 LEAF SPRING................................................................................................................... 488 WHEEL ALIGNMENT............................................................................................................... 489 REAR SUSPENSION................................................................................................................... 490 LEAF SPRING................................................................................................................... 490 FRONT SUSPENSION...................................................................................................................... 491 SHOCK ABSORBER.................................................................................................................... 491 COMPONENT LOCATOR............................................................................................................. 491 REPLACEMENT................................................................................................................... 492 LEAF SPRING....................................................................................................................... 495 COMPONENT LOCATOR............................................................................................................. 495 OVERHAUL...................................................................................................................... 496 STABILIZER........................................................................................................................ 504 COMPONENT LOCATOR............................................................................................................. 504 REPLACEMENT................................................................................................................... 505 WHEEL ALIGNMENT................................................................................................................... 507 ADJUSTMENT.................................................................................................................... 507 REAR SUSPENSION....................................................................................................................... 511 SHOCK ABSORBER.................................................................................................................... 511 COMPONENT LOCATOR............................................................................................................. 511 REPLACEMENT................................................................................................................... 512 LEAF SPRING....................................................................................................................... 515 COMPONENT LOCATOR............................................................................................................. 515 OVERHAUL...................................................................................................................... 517 FRAME AND FRAME ACCESSORY ................................................................................................................ 526 STANDARD VALUE........................................................................................................................ 527 FRAME............................................................................................................................. 527 CHASSIS FRAME................................................................................................................. 527 FRONT BUMPER.................................................................................................................. 527 REQUIRED ITEMS........................................................................................................................ 528 FRAME............................................................................................................................. 528 CHASSIS FRAME & CHASSIS FRAME ACCESSORIES..................................................................................... 528 FRAME................................................................................................................................. 529 FRAME AND FRAME ACCESSORIES....................................................................................................... 529 COMPONENT LOCATOR............................................................................................................. 529 FRAME............................................................................................................................. 530 INSPECTION.................................................................................................................... 530 REPAIR........................................................................................................................ 531 FRONT BUMPER...................................................................................................................... 536 COMPONENT LOCATOR............................................................................................................. 536 REPLACEMENT................................................................................................................... 537 CAB MOUNTING AND CAB SUSPENSION .......................................................................................................... 0 STANDARD VALUE........................................................................................................................ 541 CAB MOUNTING AND CAB SUSPENSION................................................................................................... 541 ASSEMBLY...................................................................................................................... 541 CAB MOUNTING.................................................................................................................. 541 TILT CAB STAY & CAB LOCK...................................................................................................... 542 MOUNTING AND DISMOUNTING CAB.......................................................................................................... 543 CAB ASSEMBLY...................................................................................................................... 543 REPLACEMENT................................................................................................................... 543 CAB MOUNTING AND CAB SUSPENSION....................................................................................................... 557 CAB MOUNTING...................................................................................................................... 557 COMPONENT LOCATOR............................................................................................................. 557 PRECAUTIONS IN TILTING AND LOWERING THE CAB................................................................................... 561 REPLACEMENT................................................................................................................... 562 CAB TILT STAY..................................................................................................................... 573 COMPONENT LOCATOR............................................................................................................. 573 PRECAUTIONS IN TILTING AND LOWERING THE CAB................................................................................... 576 REPLACEMENT................................................................................................................... 577 BODY INSIDE ACCESSORY .................................................................................................................... 582 STANDARD VALUE........................................................................................................................ 583 INSTRUMENT PANEL AND DRIVER INFORMATION........................................................................................... 583 INSTRUMENT PANEL.............................................................................................................. 583 INTERIOR ACCESSORY................................................................................................................ 583 ROOF ACCESSORY................................................................................................................ 583 SEAT.............................................................................................................................. 583 DRIVER'S SEAT................................................................................................................. 583 ASSISTANT'S SEAT.............................................................................................................. 584 REAR SEAT..................................................................................................................... 584 INSTRUMENT PANEL AND DRIVER INFORMATION............................................................................................... 585 INSTRUMENT PANEL.................................................................................................................. 585 COMPONENT LOCATOR............................................................................................................. 585 REPLACEMENT................................................................................................................... 587 COMBINATION METER................................................................................................................. 597 REPLACEMENT................................................................................................................... 597 INTERIOR ACCESSORY.................................................................................................................... 598 INTERIOR ACCESSORY................................................................................................................ 598 COMPONENT LOCATOR............................................................................................................. 598 REPLACEMENT................................................................................................................... 600 FLOOR ACCESSORY................................................................................................................... 603 COMPONENT LOCATOR............................................................................................................. 603 REPLACEMENT................................................................................................................... 604 ROOF ACCESSORY.................................................................................................................... 605 COMPONENT LOCATOR............................................................................................................. 605 REPLACEMENT................................................................................................................... 606 SEAT.................................................................................................................................. 613 DRIVER'S SEAT..................................................................................................................... 613 COMPONENT LOCATOR............................................................................................................. 613 OVERHAUL...................................................................................................................... 615 ASSISTANT'S SEAT.................................................................................................................. 627 COMPONENT LOCATOR............................................................................................................. 627 OVERHAUL (THREE-SEATER)....................................................................................................... 630 OVERHAUL (CREW CAB)........................................................................................................... 638 REAR SEAT......................................................................................................................... 644 COMPONENT LOCATOR............................................................................................................. 644 OVERHAUL...................................................................................................................... 646 BODY OUTSIDE ACCESSORY ................................................................................................................... 656 STANDARD VALUE........................................................................................................................ 657 DOOR.............................................................................................................................. 657 DOOR HINGE.................................................................................................................... 657 DOOR ACCESSORIES.............................................................................................................. 657 REQUIRED ITEMS........................................................................................................................ 658 DOOR.............................................................................................................................. 658 DOOR ACCESSORIES.............................................................................................................. 658 POWER WINDOW.................................................................................................................. 658 AUTO DOOR LOCK SYSTEM......................................................................................................... 658 WINDOW GLASS...................................................................................................................... 659 GLASS......................................................................................................................... 659 MIRROR............................................................................................................................ 660 POWER MIRROR.................................................................................................................. 660 DOOR.................................................................................................................................. 661 DOOR HINGE........................................................................................................................ 661 INSPECTION AND ADJUSTMENT..................................................................................................... 661 DOOR ACCESSORY.................................................................................................................... 665 COMPONENT LOCATOR............................................................................................................. 665 OVERHAUL...................................................................................................................... 671 POWER WINDOW...................................................................................................................... 693 SINGLE UNIT INSPECTION........................................................................................................ 693 AUTO DOOR LOCK SYSTEM............................................................................................................. 696 PERFORMANCE INSPECTION........................................................................................................ 696 SINGLE UNIT INSPECTION........................................................................................................ 696 KEYLESS ENTRY..................................................................................................................... 698 PERFORMANCE INSPECTION........................................................................................................ 698 WINDOW GLASS.......................................................................................................................... 699 GLASS............................................................................................................................. 699 COMPONENT LOCATOR............................................................................................................. 699 REPLACEMENT................................................................................................................... 701 MIRROR................................................................................................................................ 711 REAR VIEW MIRROR.................................................................................................................. 711 COMPONENT LOCATOR............................................................................................................. 711 REPLACEMENT................................................................................................................... 712 POWER MIRROR.......................................................................................................................... 713 SINGLE UNIT INSPECTION............................................................................................................ 713 ACCESSORY............................................................................................................................. 714 OUTSIDE ACCESSORY................................................................................................................. 714 COMPONENT LOCATOR............................................................................................................. 714 REPLACEMENT................................................................................................................... 715 AIR BAG AND SEAT BELT .................................................................................................................... 720 STANDARD VALUE........................................................................................................................ 721 SEAT BELT......................................................................................................................... 721 SEAT BELT..................................................................................................................... 721 CENTER SEAT BELT.............................................................................................................. 721 REAR SEAT BELT................................................................................................................ 722 SEAT BELT............................................................................................................................. 723 SEAT BELT......................................................................................................................... 723 COMPONENT LOCATOR............................................................................................................. 723 REPLACEMENT................................................................................................................... 724 CENTER SEAT BELT.................................................................................................................. 726 COMPONENT LOCATOR............................................................................................................. 726 REPLACEMENT................................................................................................................... 727 REAR SEAT BELT.................................................................................................................... 728 COMPONENT LOCATOR............................................................................................................. 728 REPLACEMENT................................................................................................................... 729 HEATER AND AIR CONDITIONER ............................................................................................................... 730 STANDARD VALUE........................................................................................................................ 731 AIR CONDITIONER................................................................................................................... 731 AIR CONDITIONER............................................................................................................... 731 V-BELT........................................................................................................................ 732 COOLER COMPRESSOR............................................................................................................. 732 CONDENSER (WIDE CAB MODEL TYPE WITH FAN)...................................................................................... 733 HVAC (WIDE CAB MODEL)......................................................................................................... 733 HEATER CONTROL................................................................................................................ 733 REAR HEATER (CREW CAB)........................................................................................................ 734 REAR COOLER (CREW CAB)........................................................................................................ 734 REQUIRED ITEMS........................................................................................................................ 735 AIR CONDITIONER................................................................................................................... 735 AIR CONDITIONER............................................................................................................... 735 V-BELT........................................................................................................................ 735 COOLER COMPRESSOR............................................................................................................. 735 CONDENSER (REGULAR CAB MODEL TYPE WITH FAN)................................................................................... 736 CONDENSER (WIDE CAB MODEL TYPE WITH FAN)...................................................................................... 736 AIR CONDITIONER....................................................................................................................... 737 AIR CONDITIONER................................................................................................................... 737 SAFETY INSTRUCTIONS FOR WORK.................................................................................................. 737 COLLECTION/FILLING OF REFRIGERANT............................................................................................. 741 MAINTENANCE................................................................................................................... 749 V-BELT............................................................................................................................ 752 COMPONENT LOCATOR............................................................................................................. 752 REPLACEMENT................................................................................................................... 753 COOLER COMPRESSOR................................................................................................................. 757 COMPONENT LOCATOR............................................................................................................. 757 REPLACEMENT................................................................................................................... 758 CONDENSER (WIDE CAB MODEL TYPE WITH FAN).......................................................................................... 762 COMPONENT LOCATOR............................................................................................................. 762 REPLACEMENT................................................................................................................... 763 HVAC (WIDE CAB MODEL)............................................................................................................. 768 COMPONENT LOCATOR............................................................................................................. 768 REPLACEMENT................................................................................................................... 770 HEATER CONTROL.................................................................................................................... 777 COMPONENT LOCATOR............................................................................................................. 777 REPLACEMENT................................................................................................................... 778 REAR HEATER (CREW CAB)............................................................................................................ 781 COMPONENT LOCATOR............................................................................................................. 781 REPLACEMENT................................................................................................................... 782 REAR HEATER BLOWER SWITCH (CREW CAB).............................................................................................. 788 COMPONENT LOCATOR............................................................................................................. 788 REPLACEMENT................................................................................................................... 789 REAR COOLER (CREW CAB)............................................................................................................ 791 COMPONENT LOCATOR............................................................................................................. 791 REPLACEMENT................................................................................................................... 792 COOLER CONTROL SWITCH (CREW CAB).................................................................................................. 799 COMPONENT LOCATOR............................................................................................................. 799 REPLACEMENT................................................................................................................... 800 ELECTRICAL ............................................................................................................................... 803 STANDARD VALUE........................................................................................................................ 804 LIGHTING.......................................................................................................................... 804 HEADLIGHT..................................................................................................................... 804 WIPER AND WASHER.................................................................................................................. 804 WIPER......................................................................................................................... 804 WASHER........................................................................................................................ 804 REQUIRED ITEMS........................................................................................................................ 805 LIGHTING.......................................................................................................................... 805 COMBINATION SWITCH............................................................................................................ 805 LIGHTING.............................................................................................................................. 806 HEADLIGHT......................................................................................................................... 806 COMPONENT LOCATOR............................................................................................................. 806 OPTICAL AXIS ADJUSTMENT....................................................................................................... 807 REPLACEMENT................................................................................................................... 808 ID LIGHT.......................................................................................................................... 809 COMPONENT LOCATOR............................................................................................................. 809 REPLACEMENT................................................................................................................... 810 ROOM LIGHT........................................................................................................................ 811 COMPONENT LOCATOR............................................................................................................. 811 REPLACEMENT................................................................................................................... 812 COMBINATION SWITCH................................................................................................................ 813 COMPONENT LOCATOR............................................................................................................. 813 REPLACEMENT................................................................................................................... 814 INSPECTION.................................................................................................................... 814 WIPER AND WASHER...................................................................................................................... 817 WIPER............................................................................................................................. 817 COMPONENT LOCATOR............................................................................................................. 817 REPLACEMENT................................................................................................................... 818 WASHER............................................................................................................................ 821 COMPONENT LOCATOR............................................................................................................. 821 REPLACEMENT................................................................................................................... 822 COMPUTER.............................................................................................................................. 824 COMPUTER.......................................................................................................................... 824 MOUNTING POSITION............................................................................................................. 824 SWITCH................................................................................................................................ 826 SWITCH............................................................................................................................ 826 MOUNTING POSITION............................................................................................................. 826 FUSE AND RELAY........................................................................................................................ 827 FUSE BLOCK........................................................................................................................ 827 MOUNTING POSITION............................................................................................................. 827 RELAY............................................................................................................................. 829 MOUNTING POSITION............................................................................................................. 829 CONTROL SYSTEM ........................................................................................................................... 830 REQUIRED ITEMS........................................................................................................................ 831 IDLE STOP......................................................................................................................... 831 SLOPE LEARNING................................................................................................................ 831 IDLE STOP............................................................................................................................. 832 IDLE STOP SYSTEM.................................................................................................................. 832 SLOPE LEARNING................................................................................................................ 832 CRUISE CONTROL........................................................................................................................ 834 CRUISE MAIN SWITCH................................................................................................................ 834 COMPONENT LOCATOR............................................................................................................. 834 REPLACEMENT................................................................................................................... 835 SINGLE UNIT INSPECTION........................................................................................................ 836 FOREWORD.................................................................................................................................. 838 CHAPTER REFERENCES........................................................................................................................ 839 INDEX..................................................................................................................................... 840 GENERAL INTRODUCTION...................................................................................................................... 842 HOW TO IDENTIFY VEHICLE TYPE.......................................................................................................... 843 VEHICLE MODEL..................................................................................................................... 843 VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE..................................................................................... 844 APPEARANCE OF VEHICLE................................................................................................................. 845 APPEARANCE OF VEHICLE............................................................................................................. 845 SAFETY INSTRUCTIONS AND READINESS TO WORK............................................................................................. 846 WARNING........................................................................................................................... 846 IDENTIFICATION INFORMATION........................................................................................................ 850 SAFETY INSTRUCTIONS FOR WORK...................................................................................................... 853 INTRODUCTION TO WORKSHOP MANUAL................................................................................................... 856 TIGHTENING OF BOLTS AND NUTS...................................................................................................... 860 HANDLING OF LIQUID GASKET......................................................................................................... 870 GLOSSARY.............................................................................................................................. 871 DEFINITION OF ABBREVIATION IN THIS MANUAL......................................................................................... 871 LUBRICANTS............................................................................................................................ 877 RECOMMENDED LUBRICANTS............................................................................................................ 877 STANDARD VALUE............................................................................................................................ 878 MOUNTING AND DISMOUNTING THE ENGINE................................................................................................... 880 ENGINE ASSEMBLY................................................................................................................... 880 ENGINE CONTROL........................................................................................................................ 881 ENGINE ECU........................................................................................................................ 881 ENGINE SPEED MAIN SENSOR.......................................................................................................... 881 ENGINE SPEED SUB SENSOR........................................................................................................... 881 IDLE SET VOLUME................................................................................................................... 881 ACCELERATOR PEDAL................................................................................................................. 882 BLOCK HEATER...................................................................................................................... 882 FUEL SYSTEM........................................................................................................................... 883 FUEL TANK......................................................................................................................... 883 FUEL SENDER GAUGE................................................................................................................. 883 ENGINE-SIDE FUEL FILTER & CASE.................................................................................................... 884 WATER LEVEL WARNING SWITCH........................................................................................................ 884 SUPPLY PUMP....................................................................................................................... 885 INJECTOR.......................................................................................................................... 885 COMMON RAIL....................................................................................................................... 886 VEHICLE-SIDE FUEL FILTER.......................................................................................................... 886 FUEL COOLER....................................................................................................................... 886 EMISSION CONTROL...................................................................................................................... 887 EGR VALVE & COOLER................................................................................................................ 887 CLOSED VENTILATOR................................................................................................................. 887 INTAKE................................................................................................................................ 888 INTAKE MANIFOLD................................................................................................................... 888 DIESEL THROTTLE................................................................................................................... 888 INTAKE PIPE (EXHAUST SIDE)........................................................................................................ 888 STACK DUCT........................................................................................................................ 888 AIR CLEANER....................................................................................................................... 889 INTAKE TEMPERATURE SENSOR......................................................................................................... 889 BOOST PRESSURE SENSOR............................................................................................................. 889 AIR FLOW SENSOR................................................................................................................... 889 ENGINE MECHANICAL..................................................................................................................... 890 HEAD COVER........................................................................................................................ 890 ROCKER ARM ASSEMBLY............................................................................................................... 890 CAMSHAFT ASSEMBLY................................................................................................................. 891 CYLINDER HEAD ASSEMBLY............................................................................................................ 892 VALVE SYSTEM...................................................................................................................... 893 CRANKSHAFT PULLEY................................................................................................................. 894 FRONT OIL SEAL RETAINER........................................................................................................... 894 FLYWHEEL ASSEMBLY................................................................................................................. 894 FLYWHEEL HOUSING.................................................................................................................. 894 TIMING GEAR & CAM IDLE GEAR....................................................................................................... 895 PISTON & CONNECTING ROD........................................................................................................... 896 CRANKSHAFT........................................................................................................................ 897 CYLINDER LINER.................................................................................................................... 898 CYLINDER BLOCK.................................................................................................................... 898 ENGINE MOUNTING AND BRACKET....................................................................................................... 898 GLOW PLUG......................................................................................................................... 898 EXHAUST............................................................................................................................... 900 EXHAUST MANIFOLD.................................................................................................................. 900 EXHAUST PIPE...................................................................................................................... 900 EXHAUST PIPE (ATC)................................................................................................................ 900 DEF-SCR........................................................................................................................... 901 DPR CLEANER....................................................................................................................... 901 FUEL ADDITION VALVE............................................................................................................... 902 FUEL CUTOFF VALVE................................................................................................................. 902 DEF PUMP.......................................................................................................................... 902 DEF INJECTOR...................................................................................................................... 903 DEF TANK.......................................................................................................................... 903 COOLANT CUTOFF VALVE.............................................................................................................. 903 DCU............................................................................................................................... 903 DPR DIFFERENTIAL PRESSURE SENSOR.................................................................................................. 904 SCR UPSTREAM NOx SENSOR........................................................................................................... 904 SCR DOWNSTREAM NOx SENSOR......................................................................................................... 904 ATC DOWNSTREAM TEMPERATURE SENSOR................................................................................................. 904 DOC UPSTREAM TEMPERATURE SENSOR................................................................................................... 905 DPR UPSTREAM TEMPERATURE SENSOR................................................................................................... 905 DPR DOWNSTREAM TEMPERATURE SENSOR................................................................................................. 905 SCR UPSTREAM TEMPERATURE SENSOR................................................................................................... 906 EXHAUST BRAKE..................................................................................................................... 906 EXHAUST BRAKE MAGNETIC VALVE...................................................................................................... 906 COOLING............................................................................................................................... 907 RADIATOR.......................................................................................................................... 907 RADIATOR CAP...................................................................................................................... 907 RESERVE TANK...................................................................................................................... 907 INTERCOOLER....................................................................................................................... 908 THERMOSTAT CASE & THERMOSTAT...................................................................................................... 908 COOLANT PUMP...................................................................................................................... 908 COOLING FAN & FAN CLUTCH.......................................................................................................... 909 COOLANT TEMPERATURE SENSOR........................................................................................................ 909 LUBRICATION........................................................................................................................... 910 OIL COOLER........................................................................................................................ 910 OIL PUMP.......................................................................................................................... 910 OIL PAN........................................................................................................................... 911 OIL STRAINER...................................................................................................................... 911 OIL PRESSURE SWITCH............................................................................................................... 911 STARTING/CHARGING..................................................................................................................... 912 STARTER........................................................................................................................... 912 V-BELT............................................................................................................................ 912 ALTERNATOR (130 A)................................................................................................................ 913 TURBOCHARGER.......................................................................................................................... 914 TURBOCHARGER ASSEMBLY............................................................................................................. 914 REQUIRED ITEMS............................................................................................................................ 915 MOUNTING AND DISMOUNTING THE ENGINE................................................................................................... 916 ENGINE ASSEMBLY................................................................................................................... 916 ENGINE CONTROL........................................................................................................................ 917 ENGINE ECU........................................................................................................................ 917 ENGINE MAIN REVOLUTION SENSOR..................................................................................................... 917 ENGINE SUB REVOLUTION SENSOR...................................................................................................... 918 ACCELERATOR PEDAL................................................................................................................. 919 IDLE SET VOLUME................................................................................................................... 919 FUEL SYSTEM........................................................................................................................... 920 FUEL SENDER GAUGE................................................................................................................. 920 WATER LEVEL WARNING SWITCH........................................................................................................ 920 SUPPLY PUMP....................................................................................................................... 921 INJECTOR.......................................................................................................................... 922 COMMON RAIL....................................................................................................................... 923 FUEL FILTER AND CASE (VEHICLE SIDE)............................................................................................... 924 EMISSION CONTROL...................................................................................................................... 925 EGR VALVE AND COOLER.............................................................................................................. 925 CLOSED VENTILATOR................................................................................................................. 926 INTAKE................................................................................................................................ 927 DIESEL THROTTLE................................................................................................................... 927 BOOST PRESSURE SENSOR............................................................................................................. 928 AIR FLOW SENSOR................................................................................................................... 929 ENGINE MECHANICAL..................................................................................................................... 930 HEAD COVER........................................................................................................................ 930 ROCKER ARM ASSEMBLY............................................................................................................... 930 CAMSHAFT ASSEMBLY................................................................................................................. 930 CYLINDER HEAD ASSEMBLY............................................................................................................ 931 VALVE SYSTEM...................................................................................................................... 932 CRANKSHAFT FRONT OIL SEAL......................................................................................................... 933 FRONT OIL SEAL RETAINER........................................................................................................... 933 FLYWHEEL ASSEMBLY................................................................................................................. 933 CRANKSHAFT REAR OIL SEAL.......................................................................................................... 934 FLYWHEEL HOUSING.................................................................................................................. 934 TIMING GEAR AND CAM IDLE GEAR..................................................................................................... 935 PISTON AND CONNECTING ROD......................................................................................................... 936 CRANKSHAFT........................................................................................................................ 938 CYLINDER LINER.................................................................................................................... 939 CYLINDER BLOCK.................................................................................................................... 940 GLOW PLUG......................................................................................................................... 940 EXHAUST............................................................................................................................... 941 EXHAUST MANIFOLD.................................................................................................................. 941 DPR............................................................................................................................... 942 FUEL ADDITION VALVE............................................................................................................... 943 DEF PUMP.......................................................................................................................... 943 DEF INJECTOR...................................................................................................................... 943 DEF TANK.......................................................................................................................... 944 DPR DIFFERENTIAL PRESSURE SENSOR.................................................................................................. 944 SCR UPSTREAM NOx SENSOR........................................................................................................... 944 SCR DOWNSTREAM NOx SENSOR......................................................................................................... 944 ATC DOWNSTREAM TEMPERATURE SENSOR................................................................................................. 945 DOC UPSTREAM TEMPERATURE SENSOR................................................................................................... 945 DPR UPSTREAM TEMPERATURE SENSOR................................................................................................... 945 DPR DOWNSTREAM TEMPERATURE SENSOR................................................................................................. 946 SCR UPSTREAM TEMPERATURE SENSOR................................................................................................... 946 DPR EXHAUST GAS TEMPERATURE SENSOR................................................................................................ 946 EXHAUST BRAKE..................................................................................................................... 947 EXHAUST BRAKE MAGNETIC VALVE...................................................................................................... 947 COOLING............................................................................................................................... 948 RADIATOR CAP...................................................................................................................... 948 THERMOSTAT CASE AND THERMOSTAT.................................................................................................... 948 COOLANT PUMP...................................................................................................................... 949 COOLANT TEMPERATURE SENSOR........................................................................................................ 949 LUBRICATION........................................................................................................................... 950 OIL FILTER........................................................................................................................ 950 OIL COOLER........................................................................................................................ 950 OIL PUMP.......................................................................................................................... 951 OIL PAN........................................................................................................................... 951 OIL PRESSURE SWITCH............................................................................................................... 951 STARTING/CHARGING..................................................................................................................... 952 STARTER........................................................................................................................... 952 V-BELT............................................................................................................................ 952 ALTERNATOR (130A)................................................................................................................. 952 TURBOCHARGER.......................................................................................................................... 953 TURBOCHARGER ASSEMBLY............................................................................................................. 953 MOUNTING AND DISMOUNTING THE ENGINE....................................................................................................... 955 ENGINE ASSEMBLY....................................................................................................................... 956 PRECAUTIONS IN TILTING AND LOWERING THE CAB....................................................................................... 956 MEASUREMENT OF COMPRESSION PRESSURE............................................................................................... 956 ADJUSTING THE VALVE CLEARANCE..................................................................................................... 959 REPLACEMENT....................................................................................................................... 961 ENGINE CONTROL............................................................................................................................ 970 CONTROL PARTS......................................................................................................................... 971 SYSTEM BLOCK DIAGRAM.............................................................................................................. 971 ENGINE ECU............................................................................................................................ 972 COMPONENT LOCATOR................................................................................................................. 972 REPLACEMENT....................................................................................................................... 973 VEHICLE CONTROL ECU................................................................................................................... 979 REPLACEMENT....................................................................................................................... 979 ENGINE SPEED MAIN SENSOR.............................................................................................................. 980 COMPONENT LOCATOR................................................................................................................. 980 INSPECTION........................................................................................................................ 981 REPLACEMENT....................................................................................................................... 981 ENGINE SPEED SUB SENSOR............................................................................................................... 982 COMPONENT LOCATOR................................................................................................................. 982 INSPECTION........................................................................................................................ 983 REPLACEMENT....................................................................................................................... 983 IDLE SET VOLUME....................................................................................................................... 984 COMPONENT LOCATOR................................................................................................................. 984 REPLACEMENT....................................................................................................................... 985 ACCELERATOR PEDAL..................................................................................................................... 987 COMPONENT LOCATOR................................................................................................................. 987 REPLACEMENT....................................................................................................................... 988 BLOCK HEATER.......................................................................................................................... 989 COMPONENT LOCATOR................................................................................................................. 989 REPLACEMENT....................................................................................................................... 990 FUEL SENDER GAUGE..................................................................................................................... 991 REPLACEMENT....................................................................................................................... 991 INTAKE TEMPERATURE SENSOR............................................................................................................. 991 REPLACEMENT....................................................................................................................... 991 DIESEL THROTTLE....................................................................................................................... 991 REPLACEMENT....................................................................................................................... 991 BOOST PRESSURE SENSOR................................................................................................................. 992 REPLACEMENT....................................................................................................................... 992 AIR FLOW SENSOR....................................................................................................................... 992 REPLACEMENT....................................................................................................................... 992 DPR DIFFERENTIAL PRESSURE SENSOR...................................................................................................... 993 REPLACEMENT....................................................................................................................... 993 SCR UPSTREAM NOx SENSOR............................................................................................................... 993 REPLACEMENT....................................................................................................................... 993 SCR DOWNSTREAM NOx SENSOR............................................................................................................. 993 REPLACEMENT....................................................................................................................... 993 ATC DOWNSTREAM TEMPERATURE SENSOR..................................................................................................... 994 REPLACEMENT....................................................................................................................... 994 DOC UPSTREAM TEMPERATURE SENSOR....................................................................................................... 994 REPLACEMENT....................................................................................................................... 994 DPR UPSTREAM TEMPERATURE SENSOR....................................................................................................... 995 REPLACEMENT....................................................................................................................... 995 DPR DOWNSTREAM TEMPERATURE SENSOR..................................................................................................... 995 REPLACEMENT....................................................................................................................... 995 SCR UPSTREAM TEMPERATURE SENSOR....................................................................................................... 996 REPLACEMENT....................................................................................................................... 996 OUTSIDE TEMPERATURE SENSOR............................................................................................................ 996 REPLACEMENT....................................................................................................................... 996 COOLANT TEMPERATURE SENSOR............................................................................................................ 997 REPLACEMENT....................................................................................................................... 997 OIL PRESSURE SWITCH................................................................................................................... 997 REPLACEMENT....................................................................................................................... 997 FUEL SYSTEM............................................................................................................................... 998 FUEL SYSTEM........................................................................................................................... 999 FUEL SYSTEM DIAGRAM............................................................................................................... 999 FUEL TANK.............................................................................................................................1000 COMPONENT LOCATOR.................................................................................................................1000 REPLACEMENT (30 GALLON)...........................................................................................................1001 REPLACEMENT (33 GALLON)...........................................................................................................1004 FUEL SENDER GAUGE.....................................................................................................................1008 COMPONENT LOCATOR.................................................................................................................1008 REPLACEMENT.......................................................................................................................1009 FUEL FILTER AND CASE (ENGINE SIDE)....................................................................................................1011 COMPONENT LOCATOR.................................................................................................................1011 REPLACEMENT.......................................................................................................................1012 WATER LEVEL WARNING SWITCH............................................................................................................1021 COMPONENT LOCATOR.................................................................................................................1021 REPLACEMENT.......................................................................................................................1022 SUPPLY PUMP...........................................................................................................................1024 COMPONENT LOCATOR.................................................................................................................1024 REPLACEMENT.......................................................................................................................1025 INJECTOR..............................................................................................................................1033 COMPONENT LOCATOR.................................................................................................................1033 REPLACEMENT.......................................................................................................................1034 COMMON RAIL...........................................................................................................................1043 COMPONENT LOCATOR.................................................................................................................1043 INSPECTION........................................................................................................................1044 REPLACEMENT.......................................................................................................................1045 FUEL FILTER AND CASE (VEHICLE SIDE)...................................................................................................1050 COMPONENT LOCATOR.................................................................................................................1050 REPLACEMENT.......................................................................................................................1051 FUEL COOLER...........................................................................................................................1059 COMPONENT LOCATOR.................................................................................................................1059 REPLACEMENT.......................................................................................................................1060 EMISSION CONTROL..........................................................................................................................1062 EGR VALVE & COOLER....................................................................................................................1063 COMPONENT LOCATOR.................................................................................................................1063 INSPECTION........................................................................................................................1064 REPLACEMENT.......................................................................................................................1064 CLOSED VENTILATOR.....................................................................................................................1071 COMPONENT LOCATOR.................................................................................................................1071 REPLACEMENT.......................................................................................................................1073 INTAKE....................................................................................................................................1079 INTAKE MANIFOLD.......................................................................................................................1080 COMPONENT LOCATOR.................................................................................................................1080 REPLACEMENT.......................................................................................................................1081 DIESEL THROTTLE.......................................................................................................................1086 COMPONENT LOCATOR.................................................................................................................1086 INSPECTION........................................................................................................................1087 REPLACEMENT.......................................................................................................................1087 INTAKE PIPE (EXHAUST SIDE)............................................................................................................1089 COMPONENT LOCATOR.................................................................................................................1089 REPLACEMENT.......................................................................................................................1090 INTERCOOLER...........................................................................................................................1092 OVERHAUL..........................................................................................................................1092 STACK DUCT............................................................................................................................1093 COMPONENT LOCATOR.................................................................................................................1093 CLEANING THE PRECLEANER HOUSING...................................................................................................1094 REPLACEMENT.......................................................................................................................1095 AIR CLEANER...........................................................................................................................1097 COMPONENT LOCATOR.................................................................................................................1097 REPLACEMENT.......................................................................................................................1099 CLEANING THE AIR CLEANER ELEMENT..................................................................................................1103 INTAKE TEMPERATURE SENSOR.............................................................................................................1104 COMPONENT LOCATOR.................................................................................................................1104 REPLACEMENT.......................................................................................................................1106 BOOST PRESSURE SENSOR.................................................................................................................1107 COMPONENT LOCATOR.................................................................................................................1107 INSPECTION........................................................................................................................1108 REPLACEMENT.......................................................................................................................1108 AIR FLOW SENSOR.......................................................................................................................1110 COMPONENT LOCATOR.................................................................................................................1110 INSPECTION........................................................................................................................1111 REPLACEMENT.......................................................................................................................1113 ENGINE MECHANICAL.........................................................................................................................1114 HEAD COVER............................................................................................................................1115 COMPONENT LOCATOR.................................................................................................................1115 REPLACEMENT.......................................................................................................................1116 ROCKER ARM ASSEMBLY...................................................................................................................1119 COMPONENT LOCATOR.................................................................................................................1119 OVERHAUL..........................................................................................................................1120 CAMSHAFT ASSEMBLY.....................................................................................................................1127 COMPONENT LOCATOR.................................................................................................................1127 OVERHAUL..........................................................................................................................1129 CYLINDER HEAD ASSEMBLY................................................................................................................1134 COMPONENT LOCATOR.................................................................................................................1134 REPLACEMENT.......................................................................................................................1135 OVERHAUL..........................................................................................................................1143 VALVE SYSTEM..........................................................................................................................1149 COMPONENT LOCATOR.................................................................................................................1149 OVERHAUL..........................................................................................................................1150 CRANKSHAFT PULLEY.....................................................................................................................1159 COMPONENT LOCATOR.................................................................................................................1159 REPLACEMENT.......................................................................................................................1160 CRANKSHAFT FRONT OIL SEAL.............................................................................................................1162 COMPONENT LOCATOR.................................................................................................................1162 REPLACEMENT.......................................................................................................................1163 FRONT OIL SEAL RETAINER...............................................................................................................1166 COMPONENT LOCATOR.................................................................................................................1166 REPLACEMENT.......................................................................................................................1167 FLYWHEEL ASSEMBLY.....................................................................................................................1169 COMPONENT LOCATOR.................................................................................................................1169 OVERHAUL..........................................................................................................................1170 CRANKSHAFT REAR OIL SEAL..............................................................................................................1174 COMPONENT LOCATOR.................................................................................................................1174 REPLACEMENT.......................................................................................................................1175 FLYWHEEL HOUSING......................................................................................................................1178 COMPONENT LOCATOR.................................................................................................................1178 REPLACEMENT.......................................................................................................................1179 TIMING GEAR & CAM IDLE GEAR...........................................................................................................1183 COMPONENT LOCATOR.................................................................................................................1183 CONFIGURATION DIAGRAM.............................................................................................................1184 OVERHAUL..........................................................................................................................1184 PISTON AND CONNECTING ROD.............................................................................................................1197 COMPONENT LOCATOR.................................................................................................................1197 OVERHAUL..........................................................................................................................1198 CRANKSHAFT............................................................................................................................1214 COMPONENT LOCATOR.................................................................................................................1214 REPLACEMENT.......................................................................................................................1216 CYLINDER LINER........................................................................................................................1225 COMPONENT LOCATOR.................................................................................................................1225 REPLACEMENT.......................................................................................................................1226 CYLINDER BLOCK........................................................................................................................1229 COMPONENT LOCATOR.................................................................................................................1229 OVERHAUL..........................................................................................................................1230 ENGINE MOUNTING AND BRACKET...........................................................................................................1238 COMPONENT LOCATOR.................................................................................................................1238 REPLACEMENT.......................................................................................................................1239 GLOW PLUG.............................................................................................................................1241 COMPONENT LOCATOR.................................................................................................................1241 REPLACEMENT.......................................................................................................................1242 GCU...................................................................................................................................1245 COMPONENT LOCATOR.................................................................................................................1245 REPLACEMENT.......................................................................................................................1245 EXHAUST...................................................................................................................................1246 EXHAUST MANIFOLD......................................................................................................................1248 COMPONENT LOCATOR.................................................................................................................1248 REPLACEMENT.......................................................................................................................1249 EXHAUST PIPE..........................................................................................................................1253 COMPONENT LOCATOR.................................................................................................................1253 REPLACEMENT.......................................................................................................................1254 EXHAUST PIPE (ATC)....................................................................................................................1261 COMPONENT LOCATOR.................................................................................................................1261 REPLACEMENT.......................................................................................................................1262 DEF-SCR & DPR.........................................................................................................................1264 CONFIGURATION DIAGRAM.............................................................................................................1264 CAUTIONS ON DEF/COOLANT PIPING ATTACHING AND DETACHING ...........................................................................1265 DEF-SCR...............................................................................................................................1266 COMPONENT LOCATOR.................................................................................................................1266 REPLACEMENT.......................................................................................................................1267 DPR CLEANER...........................................................................................................................1271 COMPONENT LOCATOR.................................................................................................................1271 DPR MAINTENANCE...................................................................................................................1272 DPR INSPECTION....................................................................................................................1272 INSPECTION PROCEDURE FOLLOWED WHEN “EXHAUST GAS AFTER TREATMENT SYSTEM MAINTENANCE REQUIREMENT LIGHT” LIGHT UP....................1273 INSPECTION BY WAY OF HINO-DX......................................................................................................1274 INSPECTION PROCEDURE FOLLOWED WHEN MALFUNCTION INDICATOR LIGHT ILLUMINATES (ABNORMAL).............................................1278 DETERMINATION BY WAY OF DPR STATE DETERMINATION MONITOR OF HINO-DX................................................................1281 CHECKING THE DPR STATE............................................................................................................1281 REPLACEMENT.......................................................................................................................1282 OVERALL OPERATION FLOW............................................................................................................1286 AIR CLEANING FLOW.................................................................................................................1293 FUEL ADDITION VALVE...................................................................................................................1294 COMPONENT LOCATOR.................................................................................................................1294 REPLACEMENT.......................................................................................................................1295 FUEL CUTOFF VALVE.....................................................................................................................1303 COMPONENT LOCATOR.................................................................................................................1303 REPLACEMENT.......................................................................................................................1304 DEF PUMP..............................................................................................................................1305 COMPONENT LOCATOR.................................................................................................................1305 REPLACEMENT.......................................................................................................................1306 DEF INJECTOR..........................................................................................................................1311 COMPONENT LOCATOR.................................................................................................................1311 REPLACEMENT.......................................................................................................................1312 DEF TANK..............................................................................................................................1317 COMPONENT LOCATOR.................................................................................................................1317 INSPECTION........................................................................................................................1318 REPLACEMENT.......................................................................................................................1319 DEF SENSOR............................................................................................................................1328 COMPONENT LOCATOR.................................................................................................................1328 REPLACEMENT.......................................................................................................................1329 COOLANT CUTOFF VALVE..................................................................................................................1331 COMPONENT LOCATOR.................................................................................................................1331 REPLACEMENT.......................................................................................................................1332 DCU...................................................................................................................................1334 COMPONENT LOCATOR.................................................................................................................1334 REPLACEMENT.......................................................................................................................1335 DPR DIFFERENTIAL PRESSURE SENSOR......................................................................................................1340 COMPONENT LOCATOR.................................................................................................................1340 REPLACEMENT.......................................................................................................................1341 SCR UPSTREAM NOx SENSOR...............................................................................................................1343 COMPONENT LOCATOR.................................................................................................................1343 REPLACEMENT.......................................................................................................................1344 SCR DOWNSTREAM NOx SENSOR.............................................................................................................1346 COMPONENT LOCATOR.................................................................................................................1346 REPLACEMENT.......................................................................................................................1347 ATC UPSTREAM TEMPERATURE SENSOR.......................................................................................................1349 COMPONENT LOCATOR.................................................................................................................1349 REPLACEMENT.......................................................................................................................1350 DOC UPSTREAM TEMPERATURE SENSOR.......................................................................................................1352 COMPONENT LOCATOR.................................................................................................................1352 REPLACEMENT.......................................................................................................................1353 DPR UPSTREAM TEMPERATURE SENSOR.......................................................................................................1355 COMPONENT LOCATOR.................................................................................................................1355 REPLACEMENT.......................................................................................................................1356 DPR DOWNSTREAM TEMPERATURE SENSOR.....................................................................................................1357 COMPONENT LOCATOR.................................................................................................................1357 REPLACEMENT.......................................................................................................................1358 SCR UPSTREAM TEMPERATURE SENSOR.......................................................................................................1360 COMPONENT LOCATOR.................................................................................................................1360 REPLACEMENT.......................................................................................................................1361 OUTSIDE TEMPERATURE SENSOR............................................................................................................1364 COMPONENT LOCATOR.................................................................................................................1364 REPLACEMENT.......................................................................................................................1365 EXHAUST BRAKE.........................................................................................................................1366 COMPONENT LOCATOR.................................................................................................................1366 REPLACEMENT.......................................................................................................................1367 EXHAUST BRAKE MAGNETIC VALVE..........................................................................................................1370 COMPONENT LOCATOR.................................................................................................................1370 REPLACEMENT.......................................................................................................................1371 COOLING...................................................................................................................................1373 COOLING SYSTEM........................................................................................................................1374 COOLING SYSTEM DIAGRAM............................................................................................................1374 RADIATOR..............................................................................................................................1375 COMPONENT LOCATOR.................................................................................................................1375 INSPECTION........................................................................................................................1376 REPLACEMENT.......................................................................................................................1377 RADIATOR CAP..........................................................................................................................1387 COMPONENT LOCATOR.................................................................................................................1387 REPLACEMENT.......................................................................................................................1388 RESERVE TANK..........................................................................................................................1390 COMPONENT LOCATOR.................................................................................................................1390 REPLACEMENT.......................................................................................................................1391 INTERCOOLER...........................................................................................................................1392 COMPONENT LOCATOR.................................................................................................................1392 OVERHAUL..........................................................................................................................1393 THERMOSTAT CASE AND THERMOSTAT........................................................................................................1395 COMPONENT LOCATOR.................................................................................................................1395 OVERHAUL..........................................................................................................................1396 COOLANT PUMP..........................................................................................................................1402 COMPONENT LOCATOR.................................................................................................................1402 REPLACEMENT.......................................................................................................................1403 COOLING FAN AND FAN CLUTCH............................................................................................................1405 COMPONENT LOCATOR.................................................................................................................1405 OVERHAUL..........................................................................................................................1406 COOLANT TEMPERATURE SENSOR............................................................................................................1409 COMPONENT LOCATOR.................................................................................................................1409 REPLACEMENT.......................................................................................................................1410 LUBRICATION...............................................................................................................................1412 LUBRICATION SYSTEM....................................................................................................................1413 LUBRICATION SYSTEM DIAGRAM........................................................................................................1413 OIL FILTER............................................................................................................................1414 COMPONENT LOCATOR.................................................................................................................1414 REPLACEMENT.......................................................................................................................1415 OIL COOLER............................................................................................................................1417 COMPONENT LOCATOR.................................................................................................................1417 OVERHAUL..........................................................................................................................1418 OIL PUMP..............................................................................................................................1425 COMPONENT LOCATOR.................................................................................................................1425 OVERHAUL..........................................................................................................................1426 OIL PAN...............................................................................................................................1434 COMPONENT LOCATOR.................................................................................................................1434 REPLACEMENT.......................................................................................................................1435 OIL STRAINER..........................................................................................................................1439 COMPONENT LOCATOR.................................................................................................................1439 REPLACEMENT.......................................................................................................................1440 OIL PRESSURE SWITCH...................................................................................................................1441 COMPONENT LOCATOR.................................................................................................................1441 REPLACEMENT.......................................................................................................................1442 OIL LEVEL GAUGE AND GUIDE.............................................................................................................1444 COMPONENT LOCATOR.................................................................................................................1444 REPLACEMENT.......................................................................................................................1445 STARTING/CHARGING.........................................................................................................................1447 STARTER...............................................................................................................................1448 COMPONENT LOCATOR.................................................................................................................1448 REPLACEMENT.......................................................................................................................1449 V-BELT................................................................................................................................1454 COMPONENT LOCATOR.................................................................................................................1454 REPLACEMENT.......................................................................................................................1455 ALTERNATOR (130A).....................................................................................................................1458 COMPONENT LOCATOR.................................................................................................................1458 OVERHAUL..........................................................................................................................1459 TURBOCHARGER..............................................................................................................................1472 TURBOCHARGER ASSEMBLY.................................................................................................................1473 COMPONENT LOCATOR.................................................................................................................1473 INSPECTION........................................................................................................................1474 REPLACEMENT.......................................................................................................................1476 FOREWORD..................................................................................................................................1485 CHAPTER REFERENCES........................................................................................................................1486 INDEX.....................................................................................................................................1487 GENERAL INTRODUCTION......................................................................................................................1488 HOW TO USE THIS MANUAL................................................................................................................1489 GRAPHICAL SYMBOLS FOR WIRING DIAGRAMS, ABBREVIATIONS AND TERMS....................................................................1489 WIRING DIAGRAM....................................................................................................................1494 WIRE TO WIRE CONNECTOR............................................................................................................1495 JUNCTION CONNECTOR................................................................................................................1496 LOCATION..........................................................................................................................1497 RELAY LOCATION / FUSE AND RELAY BLOCK.............................................................................................1498 ABOUT CONNECTOR...................................................................................................................1502 WIRING DIAGRAM ACCORDING TO SYSTEM........................................................................................................1504 WIRING DIAGRAM........................................................................................................................1505 WIRING HARNESS CODE...............................................................................................................1505 AC. POWER SUPPLY CIRCUIT..........................................................................................................1507 AF. GROUND CIRCUIT................................................................................................................1511 AH. CHARGING CIRCUIT..............................................................................................................1513 AK. ENGINE STARTING CIRCUIT.......................................................................................................1515 AN. CAN COMMUNICATION CIRCUIT.....................................................................................................1517 AO. CAN COMMUNICATION CIRCUIT [HV]................................................................................................1519 BG. ENGINE ECU CIRCUIT [J05] 1/2..................................................................................................1523 BH. ENGINE ECU CIRCUIT [J05] 2/2..................................................................................................1527 BI. DEF SCR CIRCUIT...............................................................................................................1535 BJ. HYDRO BOOST SYSTEM CIRCUIT....................................................................................................1537 BN. GLOW PLUG CIRCUIT.............................................................................................................1539 BP. FUEL HEATER CIRCUIT...........................................................................................................1541 CC. AT CIRCUIT [MY600]............................................................................................................1543 CE. CLUTCH ECU CIRCUIT............................................................................................................1549 CF. HV PCU CIRCUIT................................................................................................................1553 DA. ABS/PAB+VSC CIRCUIT...........................................................................................................1555 DD. VEHICLE CONTROL ECU CIRCUIT...................................................................................................1557 EC. POWER DOOR LOCK CIRCUIT.......................................................................................................1559 ED. KEYLESS ENTRY CIRCUIT.........................................................................................................1561 EG. POWER WINDOW CIRCUIT [FRONT]..................................................................................................1563 EH. POWER WINDOW CIRCUIT [REAR]...................................................................................................1565 FA. COMBINATION METER CIRCUIT.....................................................................................................1567 FB. PARKING BRAKE WARNING CIRCUIT.................................................................................................1571 FC. WEAR INDICATOR CIRCUIT........................................................................................................1573 FD. HORN RELAY CIRCUIT............................................................................................................1575 FF. DIAGNOSIS MONITOR CIRCUIT.....................................................................................................1577 FJ. RHEOSTAT CIRCUIT..............................................................................................................1579 FK. TELEMATICS CIRCUIT............................................................................................................1581 GA. HEADLIGHT CIRCUIT.............................................................................................................1583 GD. HEADLIGHT SUB CIRCUIT.........................................................................................................1585 GG. TAIL LIGHT CIRCUIT............................................................................................................1587 GH. STOP LIGHT CIRCUIT............................................................................................................1589 GJ. TURN / HAZARD CIRCUIT.........................................................................................................1591 GL. COMBINATION LIGHT CIRCUIT.....................................................................................................1593 HA. ROOM LIGHT CIRCUIT............................................................................................................1595 JA. WIPER AND WASHER CIRCUIT......................................................................................................1597 JD. MIRROR HEATER CIRCUIT.........................................................................................................1599 JE. REMOTE CONTROL MIRROR CIRCUIT.................................................................................................1601 KA. RADIO CIRCUIT.................................................................................................................1603 KB. CIGAR LIGHTER CIRCUIT.........................................................................................................1605 LB. HEATER AND AIR CONDITIONER CIRCUIT............................................................................................1607 LF. REAR HEATER AND AIR CONDITIONER CIRCUIT.......................................................................................1611 MA. OUTLET POWER SUPPLY CIRCUIT...................................................................................................1613 WIRE TO WIRE CONNECTOR....................................................................................................................1615 WIRE TO WIRE CONNECTOR................................................................................................................1616 WIRE TO WIRE CONNECTOR LIST.......................................................................................................1616 JUNCTION CONNECTOR........................................................................................................................1631 JUNCTION CONNECTOR....................................................................................................................1632 JUNCTION CONNECTOR LIST...........................................................................................................1632 LOCATION..................................................................................................................................1649 CONNECTOR LOCATION....................................................................................................................1650 CONTENTS..........................................................................................................................1650 QUICK REFERENCE...................................................................................................................1651 IP-1 [INSTRUMENT PANEL (1 of 6)]..................................................................................................1652 IP-2 [INSTRUMENT PANEL (2 of 6)]..................................................................................................1654 IP-3 [INSTRUMENT PANEL (3 of 6)]..................................................................................................1656 IP-4 [INSTRUMENT PANEL (4 of 6)]..................................................................................................1658 IP-5 [INSTRUMENT PANEL (5 of 6)]..................................................................................................1662 IP-6 [INSTRUMENT PANEL (6 of 6)]..................................................................................................1664 CA-1 [CAB (1 of 2)] (Models: Single cab (Floor / Cowl))...........................................................................1666 CA-2 [CAB (2 of 2)] (Models: Single cab (Roof / Door))............................................................................1668 CA-3 [CAB (1 of 2)] (Models: Crew cab (Floor))....................................................................................1670 CA-4 [CAB (2 of 2)] (Models: Crew cab (Roof / Door))..............................................................................1672 EG-1 [ENGINE (1 of 4)] (Models: J05E Engine)......................................................................................1674 EG-2 [ENGINE (2 of 4)] (Models: J05E Engine)......................................................................................1676 EG-3 [ENGINE (3 of 4)] (Models: J05E Engine)......................................................................................1678 EG-4 [ENGINE (4 of 4)] (Models: J05E Engine)......................................................................................1680 EG-5 [ENGINE] (Models: J05E Engine (Right rear))..................................................................................1682 EG-6 [ENGINE (1 of 4)] (Models: J05E Engine HV)...................................................................................1684 EG-7 [ENGINE (2 of 4)] (Models: J05E Engine HV)...................................................................................1686 EG-8 [ENGINE (3 of 4)] (Models: J05E Engine HV)...................................................................................1688 EG-9 [ENGINE (4 of 4)] (Models: J05E Engine HV)...................................................................................1690 EG-10 [ENGINE] (Models: J05E Engine HV (Right rear))..............................................................................1692 RR-1 [REAR].......................................................................................................................1694 RR-2 [REAR] (Models: HV)..........................................................................................................1696 RELAY LOCATION/FUSE AND RELAY BLOCK.......................................................................................................1698 RELAY LOCATION........................................................................................................................1699 INSTRUMENT PANEL..................................................................................................................1699 CHASSIS...........................................................................................................................1700 FUSE AND RELAY BLOCK..................................................................................................................1701 CHASSIS RELAY BLOCK...............................................................................................................1701 CAB RELAY.........................................................................................................................1704 RELAY BLOCK No.2..................................................................................................................1705 JUNCTION BLOCK........................................................................................................................1706 JUNCTION BLOCK....................................................................................................................1706 WIRE TO WIRE BOX......................................................................................................................1708 WIRE TO WIRE ALIGNMENT............................................................................................................1708 INDEX.....................................................................................................................................1709 CONNECTOR INDEX.......................................................................................................................1710 ELECTRICAL EQUIPMENT CONNECTOR....................................................................................................1710 WIRE TO WIRE CONNECTOR............................................................................................................1726 JUNCTION CONNECTOR................................................................................................................1729 FOREWORD..................................................................................................................................1733 CHAPTER REFERENCES .......................................................................................................................1734 INDEX.....................................................................................................................................1735 GENERAL INTRODUCTION......................................................................................................................1737 HOW TO IDENTIFY VEHICLE TYPE..........................................................................................................1738 HOW TO IDENTIFY VEHICLE TYPE......................................................................................................1738 VEHICLE TYPE .................................................................................................................1738 VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE.................................................................................1739 APPEARANCE OF VEHICLE.................................................................................................................1740 APPEARANCE........................................................................................................................1740 APPEARANCE OF VEHICLE.........................................................................................................1740 SAFETY INSTRUCTIONS AND READINESS TO WORK.............................................................................................1741 WARNING...........................................................................................................................1741 GENERAL PRECAUTIONS...........................................................................................................1741 IDENTIFICATION INFORMATION....................................................................................................1746 SAFETY INSTRUCTIONS FOR WORK......................................................................................................1748 PRECAUTIONS...................................................................................................................1748 INTRODUCTION TO WORKSHOP MANUAL...................................................................................................1752 GENERAL.......................................................................................................................1752 INTRODUCTION TO DESCRIPTIONS..................................................................................................1753 DEFINITION OF TERM............................................................................................................1756 TROUBLE SHOOTING......................................................................................................................1757 TROUBLESHOOTING WITH DIAGNOSIS MONITOR............................................................................................1757 TROUBLESHOOTING PROCEDURE.....................................................................................................1757 APPARATUS FOR TROUBLE SHOOTING................................................................................................1759 TROUBLESHOOTING WITH COMPUTER (HINO-DX)...........................................................................................1760 STEP OF TROUBLE SHOOTING......................................................................................................1760 APPARATUS FOR TROUBLE SHOOTING................................................................................................1761 GLOSSARY..............................................................................................................................1762 DEFINITION OF ABBREVIATION........................................................................................................1762 LIST OF ABBREVIATION..........................................................................................................1762 GLOSSARY OF SAE AND HINO TERMS................................................................................................1765 ENGINE(J05E)..............................................................................................................................1768 TROUBLESHOOTING.......................................................................................................................1771 ENGINE ECU (J05E).................................................................................................................1771 PRECAUTIONS FOR DIAGNOSIS.....................................................................................................1771 ELECTRICAL....................................................................................................................1773 PRECAUTIONS...................................................................................................................1774 COMPUTER (ECU) PIN ASSIGNMENT.................................................................................................1778 ENGINE ECU CONNECTOR..........................................................................................................1782 INSPECTION....................................................................................................................1786 DIAGNOSIS USING THE PC DIAGNOSIS TOOL.........................................................................................1787 DIAGNOSTIC TROUBLE CODE (DTC) TABLE...........................................................................................1788 GROUP SHARING THE SENSOR SUPPLY TERMINAL......................................................................................1809 GROUP SHARING THE SENSOR GND TERMINAL.........................................................................................1810 MALFUNCTION CODES IN CASE OF DISRUPTION OF CAN COMMUNICATION..................................................................1811 PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (250 k)......................................................................1815 DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (250 k) [DIESEL]...............................................1820 DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (250 k) [HYBRID]...............................................1829 PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (500 k) [DIESEL]............................................................1839 PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (500 k) [HYBRID]............................................................1844 DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (500 k) [DIESEL]...............................................1850 DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (500 k) [HYBRID]...............................................1855 MALFUNCTION CODES FOR FAULTY ACTUATOR POWER RELAY.............................................................................1860 ENG BASIC INSPECTION SHEET (ENGINE INSPECTION CHECK SHEET)....................................................................1861 NO DTC........................................................................................................................1865 DTC: P0005....................................................................................................................1869 DTC: P0006 and P0007..........................................................................................................1875 DTC: P0016....................................................................................................................1882 DTC: P0027....................................................................................................................1886 DTC: P003A....................................................................................................................1893 DTC: P0045....................................................................................................................1900 DTC: P0047....................................................................................................................1905 DTC: P0048....................................................................................................................1910 DTC: P006E....................................................................................................................1915 DTC: P006F....................................................................................................................1920 DTC: P007B....................................................................................................................1925 DTC: P007C and P007D..........................................................................................................1943 DTC: P0088....................................................................................................................1953 DTC: P0096....................................................................................................................1978 DTC: P0097 and P0098 .........................................................................................................1993 DTC: P00AF....................................................................................................................2003 DTC: P0101....................................................................................................................2008 DTC: P0104....................................................................................................................2021 DTC: P0106....................................................................................................................2030 DTC: P0108....................................................................................................................2038 DTC: P0112 and P0113..........................................................................................................2046 DTC: P0115....................................................................................................................2056 DTC: P0117 and P0118..........................................................................................................2069 DTC: P011A....................................................................................................................2079 DTC: P011C....................................................................................................................2091 DTC: P0122 and P0123..........................................................................................................2099 DTC: P0128....................................................................................................................2110 DTC: P0148 ...................................................................................................................2118 DTC: P016E and P016F .........................................................................................................2136 DTC: P0182 and P0183 .........................................................................................................2162 DTC: P0191....................................................................................................................2172 DTC: P0192 and P0193 .........................................................................................................2196 DTC: P01A5....................................................................................................................2208 DTC: P01A6....................................................................................................................2217 DTC: P0200....................................................................................................................2226 DTC: P0201, P0202, P0203 and P0204............................................................................................2229 DTC: P0217....................................................................................................................2236 DTC: P0219....................................................................................................................2243 DTC: P0222 and P0223..........................................................................................................2252 DTC: P0234....................................................................................................................2264 DTC: P0237....................................................................................................................2272 DTC: P0263, P0266, P0269 and P0272............................................................................................2280 DTC: P026C and P026D..........................................................................................................2296 DTC: P0299....................................................................................................................2315 DTC: P0300....................................................................................................................2323 DTC: P0301, P0302, P0303 and P0304............................................................................................2333 DTC: P0335....................................................................................................................2345 DTC: P0336....................................................................................................................2354 DTC: P0340....................................................................................................................2364 DTC: P0341....................................................................................................................2370 DTC: P0381....................................................................................................................2380 DTC: P0401....................................................................................................................2388 DTC: P0402....................................................................................................................2408 DTC: P0404....................................................................................................................2422 DTC: P0405 and P0406..........................................................................................................2429 DTC: P041B....................................................................................................................2436 DTC: P041C and P041D..........................................................................................................2453 DTC: P0420....................................................................................................................2463 DTC: P0421....................................................................................................................2466 DTC: P0422....................................................................................................................2470 DTC: P0489 and P0490..........................................................................................................2474 DTC: P049D....................................................................................................................2481 DTC: P04D5 and P04D6..........................................................................................................2488 DTC: P0500 and P0501..........................................................................................................2498 DTC: P0504....................................................................................................................2507 DTC: P0519....................................................................................................................2514 DTC: P0521....................................................................................................................2519 DTC: P0524....................................................................................................................2525 DTC: P0545 and P0546..........................................................................................................2532 DTC: P0562 and P0563..........................................................................................................2542 DTC: P05F1....................................................................................................................2550 DTC: P0605....................................................................................................................2561 DTC: P0606....................................................................................................................2564 DTC: P0607....................................................................................................................2567 DTC: P0610....................................................................................................................2570 DTC: P0611....................................................................................................................2574 FORWORD...................................................................................................................................2578 CHAPTER REFERENCES........................................................................................................................2579 INDEX.....................................................................................................................................2580 ENGINE (J05E).............................................................................................................................2582 TROUBLESHOOTING....................................................................................................................... 0 ENGINE ECU (J05E)................................................................................................................. 0 DTC: P0617....................................................................................................................2585 DTC: P0628 and P0629..........................................................................................................2590 DTC: P062F....................................................................................................................2600 DTC: P0630....................................................................................................................2605 DTC: P0642....................................................................................................................2610 DTC: P0643....................................................................................................................2618 DTC: P064C....................................................................................................................2628 DTC: P0652....................................................................................................................2635 DTC: P0653....................................................................................................................2643 DTC: P0671 and P0672 .........................................................................................................2652 DTC: P0673 and P0674..........................................................................................................2659 DTC: P0683....................................................................................................................2666 DTC: P0686....................................................................................................................2674 DTC: P06D3 and P06D4..........................................................................................................2680 DTC: P073D....................................................................................................................2692 DTC: P081A....................................................................................................................2697 DTC: P081B....................................................................................................................2705 DTC: P0A7B....................................................................................................................2710 DTC: P0AC4....................................................................................................................2713 DTC: P0CA1....................................................................................................................2716 DTC: P1133....................................................................................................................2719 DTC: P119F....................................................................................................................2727 DTC: P1426....................................................................................................................2735 DTC: P1427....................................................................................................................2744 DTC: P1428....................................................................................................................2753 DTC: P1458....................................................................................................................2763 DTC: P1459....................................................................................................................2770 DTC: P14B0....................................................................................................................2777 DTC: P14B2....................................................................................................................2782 DTC: P14B3 and P14B4..........................................................................................................2787 DTC: P14B7 and P14B8..........................................................................................................2794 DTC: P14BC and P14BD..........................................................................................................2801 DTC: P14BF....................................................................................................................2808 DTC: P1515....................................................................................................................2815 DTC: P1530....................................................................................................................2822 DTC: P1601....................................................................................................................2827 DTC: P200C....................................................................................................................2832 DTC: P2032 and P2033..........................................................................................................2844 DTC: P203F....................................................................................................................2854 DTC: P204F....................................................................................................................2859 DTC: P207F....................................................................................................................2863 DTC: P2080....................................................................................................................2875 DTC: P2084....................................................................................................................2885 DTC: P20CD....................................................................................................................2895 DTC: P20CE....................................................................................................................2901 DTC: P20CF....................................................................................................................2906 DTC: P20D8....................................................................................................................2910 DTC: P20DE....................................................................................................................2916 DTC: P20DF....................................................................................................................2921 DTC: P20E0....................................................................................................................2929 DTC: P20EE....................................................................................................................2938 DTC: P2100....................................................................................................................2950 DTC: P2101....................................................................................................................2958 DTC: P2103....................................................................................................................2967 DTC: P2120....................................................................................................................2975 DTC: P2122 and P2123..........................................................................................................2980 DTC: P2127 and P2128..........................................................................................................2991 DTC: P2135....................................................................................................................3001 DTC: P2138....................................................................................................................3007 DTC: P2146....................................................................................................................3013 DTC: P2147 and P2148..........................................................................................................3022 DTC: P2149....................................................................................................................3032 DTC: P2150 and P2151..........................................................................................................3041 DTC: P2184 and P2185..........................................................................................................3051 DTC: P2214....................................................................................................................3061 DTC: P2227....................................................................................................................3076 DTC: P2228 and P2229..........................................................................................................3081 DTC: P2269....................................................................................................................3087 DTC: P226C....................................................................................................................3094 DTC: P22D3....................................................................................................................3103 DTC: P240F....................................................................................................................3108 DTC: P2428....................................................................................................................3122 DTC: P242B....................................................................................................................3128 DTC: P242C and P242D..........................................................................................................3138 DTC: P244A....................................................................................................................3148 DTC: P244B....................................................................................................................3174 DTC: P2457....................................................................................................................3197 DTC: P2458....................................................................................................................3215 DTC: P2459....................................................................................................................3229 DTC: P2463....................................................................................................................3233 DTC: P246F....................................................................................................................3244 DTC: P2470 and P2471..........................................................................................................3254 DTC: P24A0....................................................................................................................3264 DTC: P24A1....................................................................................................................3268 DTC: P24A2....................................................................................................................3271 DTC: P2562....................................................................................................................3285 DTC: P259E....................................................................................................................3290 DTC: P259F....................................................................................................................3297 DTC: P2635....................................................................................................................3304 DTC: P268A and P2696..........................................................................................................3329 DTC: P26C8....................................................................................................................3336 DTC: P2BA9....................................................................................................................3339 DTC: U0073....................................................................................................................3346 DTC: U010A....................................................................................................................3349 DTC: U010C....................................................................................................................3357 DTC: U010E....................................................................................................................3365 DTC: U0293....................................................................................................................3374 DTC: U029D (DIESEL)...........................................................................................................3381 DTC: U029D (HYBRID)...........................................................................................................3389 DTC: U029E (DIESEL)...........................................................................................................3397 DTC: U029E (HYBRID)...........................................................................................................3405 DTC: U02A2....................................................................................................................3413 DTC: U0301....................................................................................................................3421 DTC: U1001....................................................................................................................3425 DTC: U110A....................................................................................................................3434 FOREWORD..................................................................................................................................3444 CHAPTER REFERENCES .......................................................................................................................3445 INDEX.....................................................................................................................................3446 ENGINE (COMMON ITEMS).....................................................................................................................3448 TROUBLESHOOTING.......................................................................................................................3450 DCU...............................................................................................................................3450 PRECAUTIONS FOR DIAGNOSIS.....................................................................................................3450 DIAGRAM.......................................................................................................................3452 SIGNAL CHECK HARNESS..........................................................................................................3453 INSPECTION....................................................................................................................3453 DIAGNOSIS USING THE PC DIAGNOSIS TOOL.........................................................................................3455 DTC: P0071....................................................................................................................3462 DTC: P0072....................................................................................................................3476 DTC: P0073....................................................................................................................3485 DTC: P0562....................................................................................................................3494 DTC: P0563....................................................................................................................3499 DTC: P060C....................................................................................................................3504 DTC: P062F....................................................................................................................3507 DTC: P0667....................................................................................................................3510 DTC: P0668....................................................................................................................3513 DTC: P0669....................................................................................................................3516 DTC: P068A....................................................................................................................3519 DTC: P142A....................................................................................................................3525 DTC: P142B....................................................................................................................3530 DTC: P202E....................................................................................................................3546 DTC: P203C....................................................................................................................3551 DTC: P203D....................................................................................................................3554 DTC: P2044....................................................................................................................3557 DTC: P2045....................................................................................................................3560 DTC: P2047....................................................................................................................3563 DTC: P2048....................................................................................................................3567 DTC: P2049....................................................................................................................3574 DTC: P204B....................................................................................................................3581 DTC: P204C....................................................................................................................3584 DTC: P204D....................................................................................................................3591 DTC: P205B....................................................................................................................3598 DTC: P205C....................................................................................................................3611 DTC: P205D....................................................................................................................3614 DTC: P206A....................................................................................................................3617 DTC: P208A....................................................................................................................3620 DTC: P208B....................................................................................................................3629 DTC: P208C....................................................................................................................3632 DTC: P208D....................................................................................................................3639 DTC: P20A0....................................................................................................................3646 DTC: P20A1....................................................................................................................3653 DTC: P20A2....................................................................................................................3658 DTC: P20A3....................................................................................................................3665 DTC: P20B1....................................................................................................................3672 DTC: P20B2....................................................................................................................3679 DTC: P20B3....................................................................................................................3692 DTC: P20B4....................................................................................................................3699 DTC: P20E8....................................................................................................................3706 DTC: P20E9....................................................................................................................3718 DTC: P20F4....................................................................................................................3727 DTC: P2201....................................................................................................................3734 DTC: P2202....................................................................................................................3744 DTC: P2203....................................................................................................................3747 DTC: P2204....................................................................................................................3750 DTC: P2209....................................................................................................................3760 DTC: P2212....................................................................................................................3771 DTC: P2215....................................................................................................................3781 DTC: P2216....................................................................................................................3784 DTC: P2222....................................................................................................................3787 DTC: P2481....................................................................................................................3798 DTC: P2482....................................................................................................................3805 DTC: P2483....................................................................................................................3812 DTC: P2510....................................................................................................................3830 DTC: P2BAE....................................................................................................................3836 DTC: U0029....................................................................................................................3847 DTC: U0038....................................................................................................................3856 DTC: U0100....................................................................................................................3864 DTC: U029D (DIESEL)...........................................................................................................3869 DTC: U029D (HYBRID)...........................................................................................................3878 DTC: U029E (DIESEL)...........................................................................................................3887 DTC: U029E (HYBRID)...........................................................................................................3896 DTC: U02A2....................................................................................................................3905 DTC: U0597....................................................................................................................3914 VEHICLE CONTROL ECU...............................................................................................................3918 CAUTIONS ON TROUBLESHOOTING...................................................................................................3918 SYSTEM BLOCK DIAGRAM..........................................................................................................3919 COMPUTER PIN ASSIGNMENT.......................................................................................................3920 TROUBLESHOOTING WITH COMPUTER (HINO-DX).......................................................................................3924 DIAGNOSIS CODE TABLE..........................................................................................................3925 DTC: C1244....................................................................................................................3927 DTC: C1245....................................................................................................................3934 DTC: C1249....................................................................................................................3937 DTC: C1491....................................................................................................................3946 DTC: P0335....................................................................................................................3949 DTC: P0501(DIESEL)............................................................................................................3953 DTC: P0501(HYBRID)............................................................................................................3955 DTC: P0503....................................................................................................................3961 DTC: P0555....................................................................................................................3968 DTC: P0562....................................................................................................................3971 DTC: P0563....................................................................................................................3976 DTC: P0572....................................................................................................................3980 DTC: P0573....................................................................................................................3990 DTC: P0577....................................................................................................................4000 DTC: P05BF....................................................................................................................4006 DTC: P0604....................................................................................................................4011 DTC: P0605(DIESEL)............................................................................................................4014 DTC: P0605(HYBRID) ...........................................................................................................4017 DTC: P0606....................................................................................................................4020 DTC: P0617....................................................................................................................4023 DTC: P062F....................................................................................................................4027 DTC: P0702....................................................................................................................4030 DTC: P081D....................................................................................................................4033 DTC: P1143....................................................................................................................4040 DTC: P161F....................................................................................................................4046 DTC: P1649....................................................................................................................4050 DTC: P165A....................................................................................................................4056 DTC: P165B....................................................................................................................4059 DTC: P2525....................................................................................................................4062 DTC: P2526....................................................................................................................4065 DTC: P258D....................................................................................................................4068 DTC: U0101....................................................................................................................4071 DTC: U0105....................................................................................................................4074 DTC: U0121....................................................................................................................4077 DTC: U0155....................................................................................................................4080 DTC: U0293....................................................................................................................4083 DTC: U0418....................................................................................................................4086 DTC: U1136....................................................................................................................4089 FOREWORD..................................................................................................................................4093 CHAPTER REFERENCES .......................................................................................................................4094 INDEX.....................................................................................................................................4095 HYBRID....................................................................................................................................4097 TROUBLE SHOOTING......................................................................................................................4100 HYBRID CONTROL SYSTEM.............................................................................................................4100 TROUBLE SHOOTING STEPS FOR HYBRID SYSTEM......................................................................................4100 SAFETY MEASURES FOR HIGH-VOLTAGE WORK.........................................................................................4108 LIST OF CONNECTOR SYMBOLS.....................................................................................................4111 HV SYSTEM WIRING DIAGRAM......................................................................................................4115 HEARING SHEET.................................................................................................................4117 HYBRID ECU........................................................................................................................4118 DIAGNOSIS CODE TABLE..........................................................................................................4118 FREEZE FRAME DATA LIST........................................................................................................4126 LIST OF DATA MONITOR ITEMS....................................................................................................4129 COMMON INSPECTION CHART.......................................................................................................4132 DTC: P0500 (TC51).............................................................................................................4137 DTC: P0501 (TC5B).............................................................................................................4147 DTC: P0562 (TC71).............................................................................................................4153 DTC: P060B (TCB2).............................................................................................................4162 DTC: P0617 (TC59).............................................................................................................4165 DTC: P062F (TCB3).............................................................................................................4174 DTC: P0810 (TC9C).............................................................................................................4177 DTC: P0810 (TC9D).............................................................................................................4181 DTC: P0A01 (TC7B).............................................................................................................4185 DTC: P0A02 (TC78).............................................................................................................4194 DTC: P0A03 (TC79).............................................................................................................4202 DTC: P0A06 (TC7F).............................................................................................................4209 DTC: P0A07 (TC7E).............................................................................................................4221 DTC: P0A0F (TC31) ............................................................................................................4225 DTC: P0A1D (TC12).............................................................................................................4229 DTC: P0A1D (TC17).............................................................................................................4232 DTC: P0A78 (TC21).............................................................................................................4235 DTC: P0A78 (TC22).............................................................................................................4238 DTC: P0A7E (TC48).............................................................................................................4241 DTC: P0A82 (TC67).............................................................................................................4247 DTC: P0A84 (TC66).............................................................................................................4260 DTC: P0A85 (TC65).............................................................................................................4273 DTC: P0A90 (TC2A).............................................................................................................4279 DTC: P0A92 (TC29).............................................................................................................4291 DTC: P0A93 (TC7A).............................................................................................................4306 DTC: P0AFD (TC6B).............................................................................................................4313 DTC: P0BCA (TC68).............................................................................................................4317 DTC: P0C73 (TC80).............................................................................................................4323 DTC: P3000 (TC42).............................................................................................................4330 DTC: P3001 (TC41).............................................................................................................4339 DTC: P3001 (TC43).............................................................................................................4342 DTC: P3001 (TC44).............................................................................................................4345 DTC: P3001 (TC45).............................................................................................................4348 DTC: P3001 (TC46).............................................................................................................4351 DTC: P3001 (TC47).............................................................................................................4355 DTC: P3001 (TC4A).............................................................................................................4359 DTC: P3001 (TC4B).............................................................................................................4363 DTC: P3001 (TC4C).............................................................................................................4366 DTC: P3009 (TC49).............................................................................................................4369 DTC: P3128 (TC7D).............................................................................................................4385 DTC: P3129 (TC7C).............................................................................................................4397 DTC: P314C (TC82).............................................................................................................4402 DTC: P314D (TC81).............................................................................................................4407 DTC: P324B (TC62).............................................................................................................4419 DTC: P324C (TC61).............................................................................................................4424 DTC: P33B1 (TC64).............................................................................................................4430 DTC: P33B2 (TC63).............................................................................................................4435 DTC: U0073 (TC11).............................................................................................................4441 DTC: U0074 (TC16).............................................................................................................4446 DTC: U0100 (TC13).............................................................................................................4450 DTC: U0101 (TC18).............................................................................................................4454 DTC: U0110 (TC14).............................................................................................................4461 DTC: U0111 (TC15).............................................................................................................4469 DTC: U0121 (TC24).............................................................................................................4477 DTC: U0155 (TC25).............................................................................................................4484 DTC: U110A (TC26).............................................................................................................4491 DTC: U1136 (TC27).............................................................................................................4498 INVERTER..........................................................................................................................4505 DIAGNOSIS CODE TABLE..........................................................................................................4505 FREEZE FRAME DATA LIST........................................................................................................4511 DATA MONITOR ITEM LIST........................................................................................................4513 CONNECTION DIAGRAM............................................................................................................4516 INSULATION RESISTANCE MEASUREMENT PROCEDURE FOR HYBRID MOTOR [ROTATION MACHINE]...............................................4517 DTC: P0562 (TC96) ............................................................................................................4519 DTC: P0562 (TCA0) ............................................................................................................4529 DTC: P0604 (TC18) ............................................................................................................4539 DTC: P0604 (TCD2).............................................................................................................4541 DTC: P0605 (TC17) ............................................................................................................4543 DTC: P0605 (TCD1) ............................................................................................................4545 DTC: P060B (TC1A).............................................................................................................4547 DTC: P060C (TC1C).............................................................................................................4550 DTC: P062F (TC41).............................................................................................................4552 DTC: P0A0D (TC20).............................................................................................................4554 DTC: P0A1B (TC16).............................................................................................................4561 DTC: P0A1B (TC92).............................................................................................................4568 DTC: P0A1B (TC97).............................................................................................................4570 DTC: P0A1B (TC3F).............................................................................................................4572 DTC: P0A1B (TCA1).............................................................................................................4574 DTC: P0A1B (TCA2).............................................................................................................4576 DTC: P0A1B (TCA3).............................................................................................................4578 DTC: P0A1B (TCA4).............................................................................................................4580 DTC: P0A1B (TCA5).............................................................................................................4582 DTC: P0A1B (TCA6).............................................................................................................4584 DTC: P0A1B (TCA7).............................................................................................................4586 DTC: P0A1B (TCA8) ............................................................................................................4588 DTC: P0A1B (TCA9).............................................................................................................4590 DTC: P0A1B (TCAA).............................................................................................................4592 DTC: P0A1B (TCBB).............................................................................................................4599 DTC: P0A1B (TCBC).............................................................................................................4601 DTC: P0A1B (TCBD).............................................................................................................4603 DTC: P0A1B (TCBE).............................................................................................................4605 DTC: P0A1B (TCBF).............................................................................................................4607 DTC: P0A1B (TCD3).............................................................................................................4609 DTC: P0A1B (TCD4).............................................................................................................4611 DTC: P0A1B (TCD5).............................................................................................................4613 DTC: P0A1D (TC21).............................................................................................................4615 DTC: P0A2B (TCE9).............................................................................................................4619 DTC: P0A2B (TCED).............................................................................................................4630 DTC: P0A2C (TCDA).............................................................................................................4641 DTC: P0A2D (TCDB).............................................................................................................4651 DTC: P0A2F (TC33) ............................................................................................................4662 DTC: P0A3C (TC34).............................................................................................................4669 DTC: P0A3F (TCB7).............................................................................................................4689 DTC: P0A41 (TCC0).............................................................................................................4698 DTC: P0A42 (TCC1).............................................................................................................4710 DTC: P0A51 (TCD6).............................................................................................................4722 DTC: P0A51 (TCD7).............................................................................................................4725 DTC: P0A78 (TC13).............................................................................................................4728 DTC: P0A78 (TC14).............................................................................................................4741 DTC: P0A78 (TC15).............................................................................................................4760 DTC: P0AA1 (TCD8).............................................................................................................4767 DTC: P0AA4 (TCD9).............................................................................................................4774 DTC: P0ADB (TC1F).............................................................................................................4783 DTC: P0ADC (TC93).............................................................................................................4790 DTC: P0ADF (TC1E).............................................................................................................4798 DTC: P0AE0 (TC95).............................................................................................................4805 DTC: P0AE6 (TC1D).............................................................................................................4813 DTC: P0AE7 (TC94).............................................................................................................4820 DTC: P0AEE (TC22).............................................................................................................4828 DTC: P0AEE (TC23).............................................................................................................4831 DTC: P0AEF (TC24).............................................................................................................4834 DTC: P0AF0 (TC25).............................................................................................................4838 DTC: P0BEA (TCB3).............................................................................................................4842 DTC: P0BEA (TCB4).............................................................................................................4845 DTC: P0BEB (TC9A).............................................................................................................4848 DTC: P0BEC (TC9B).............................................................................................................4851 DTC: P0BEE (TCB5).............................................................................................................4854 DTC: P0BEE (TCB6).............................................................................................................4857 DTC: P0BEF (TC9C).............................................................................................................4860 DTC: P0BF0 (TC9D).............................................................................................................4863 DTC: P3126 (TC12).............................................................................................................4866 DTC: U0073 (TC91).............................................................................................................4879 DTC: U0074 (TC3E).............................................................................................................4884 DTC: U0293 (TC31).............................................................................................................4888 FOREWORD..................................................................................................................................4898 CHAPTER REFERENCES........................................................................................................................4899 INDEX.....................................................................................................................................4900 HYBRID....................................................................................................................................4902 TROUBLE SHOOTING...................................................................................................................... 0 BATTERY ECU.......................................................................................................................4905 DIAGNOSIS CODE TABLE..........................................................................................................4905 LIST OF FREEZE FRAME DATA.....................................................................................................4908 LIST OF DATA MONITOR ITEMS....................................................................................................4910 CONNECTION DIAGRAM............................................................................................................4913 DTC: P0562....................................................................................................................4914 DTC: P0604....................................................................................................................4920 DTC: P0605....................................................................................................................4923 DTC: P060B....................................................................................................................4926 DTC: P062F....................................................................................................................4929 DTC: P0A1F....................................................................................................................4932 DTC: P0A7D....................................................................................................................4935 DTC: P0A7F....................................................................................................................4939 DTC: P0A80....................................................................................................................4944 DTC: P0A95....................................................................................................................4949 DTC: P0A9D....................................................................................................................4954 DTC: P0A9E....................................................................................................................4958 DTC: P0AAE....................................................................................................................4962 DTC: P0AAF....................................................................................................................4966 DTC: P0ABF....................................................................................................................4970 DTC: P0AC0....................................................................................................................4977 DTC: P0AC1....................................................................................................................4984 DTC: P0AC2....................................................................................................................4991 DTC: P0AC7....................................................................................................................4998 DTC: P0AC8....................................................................................................................5002 DTC: P0ACC....................................................................................................................5006 DTC: P0ACD....................................................................................................................5010 DTC: P0AEA....................................................................................................................5014 DTC: P0AEB....................................................................................................................5018 DTC: P0AFC....................................................................................................................5022 DTC: P0B25....................................................................................................................5025 DTC: P0B3D....................................................................................................................5029 DTC: P0B42....................................................................................................................5034 DTC: P0B47....................................................................................................................5039 DTC: P0B4C....................................................................................................................5044 DTC: P0B51....................................................................................................................5049 DTC: P0B56....................................................................................................................5054 DTC: P0B5B....................................................................................................................5059 DTC: P0B60....................................................................................................................5064 DTC: P0B65....................................................................................................................5069 DTC: P0B6A....................................................................................................................5074 DTC: P0B6F....................................................................................................................5079 DTC: P0B74....................................................................................................................5084 DTC: P0B79....................................................................................................................5089 DTC: P0B7E....................................................................................................................5094 DTC: P0B83....................................................................................................................5099 DTC: P0B88....................................................................................................................5104 DTC: P0B8D....................................................................................................................5109 DTC: P0B92....................................................................................................................5114 DTC: P0B97....................................................................................................................5119 DTC: P0B9C....................................................................................................................5124 DTC: P0BA1....................................................................................................................5129 DTC: P0C30....................................................................................................................5134 DTC: P3004....................................................................................................................5140 DTC: P3011....................................................................................................................5143 DTC: P3012....................................................................................................................5148 DTC: P3013....................................................................................................................5153 DTC: P3014....................................................................................................................5158 DTC: P3015....................................................................................................................5163 DTC: P3016....................................................................................................................5168 DTC: P3017....................................................................................................................5173 DTC: P3018....................................................................................................................5178 DTC: P3019....................................................................................................................5183 DTC: P301B....................................................................................................................5188 DTC: P3020....................................................................................................................5191 DTC: P3021....................................................................................................................5196 DTC: P3022....................................................................................................................5201 DTC: P3023....................................................................................................................5206 DTC: P3024....................................................................................................................5211 DTC: P3025....................................................................................................................5216 DTC: P3026....................................................................................................................5221 DTC: P3027....................................................................................................................5226 DTC: P3028....................................................................................................................5231 DTC: P3029....................................................................................................................5236 DTC: P302F....................................................................................................................5241 DTC: P3065....................................................................................................................5246 DTC: P308A....................................................................................................................5251 DTC: U0074....................................................................................................................5256 DTC: U0293....................................................................................................................5260 TRANSMISSION..............................................................................................................................5265 TROUBLESHOOTING.......................................................................................................................5267 TROUBLE SHOOTING BY TRANSMISSION SYMPTOM..........................................................................................5267 AUTOMATIC TRANSMISSION........................................................................................................5267 TROUBLESHOOTING.......................................................................................................................5269 AUTOMATIC TRANSMISSION............................................................................................................5269 PRECAUTIONS FOR DIAGNOSIS.....................................................................................................5269 AT LEARNED VALUE INITIALIZATION...............................................................................................5270 INSPECTING/CLEARING DIAGNOSIS CODES...........................................................................................5274 SYSTEM BLOCK DIAGRAM..........................................................................................................5277 COMPUTER PIN ASSIGNMENT.......................................................................................................5278 DIAGNOSIS CODE TABLE..........................................................................................................5281 DTC: P0500/DIAGNOSIS MONITOR CODE: 42.........................................................................................5283 DTC: P0562/DIAGNOSIS MONITOR CODE: 11.........................................................................................5292 DTC: P0705/DIAGNOSIS MONITOR CODE: 43.........................................................................................5296 DTC: P0706/DIAGNOSIS MONITOR CODE: 44.........................................................................................5305 DTC: P0710/DIAGNOSIS MONITOR CODE: 38.........................................................................................5311 DTC: P0715/DIAGNOSIS MONITOR CODE: 12.........................................................................................5319 DTC: P0720/DIAGNOSIS MONITOR CODE: 61.........................................................................................5327 DTC: P0725/DIAGNOSIS MONITOR CODE: 86.........................................................................................5336 DTC: P0730/DIAGNOSIS MONITOR CODE: 37.........................................................................................5343 DTC: P0746/DIAGNOSIS MONITOR CODE: 31.........................................................................................5355 DTC: P0748/DIAGNOSIS MONITOR CODE: 25.........................................................................................5362 DTC: P0751/DIAGNOSIS MONITOR CODE: 45.........................................................................................5368 DTC: P0756/DIAGNOSIS MONITOR CODE: 46.........................................................................................5375 DTC: P0761/DIAGNOSIS MONITOR CODE: 47, 48.....................................................................................5382 DTC: P0776/DIAGNOSIS MONITOR CODE: 32.........................................................................................5389 DTC: P0778/DIAGNOSIS MONITOR CODE: 26.........................................................................................5396 DTC: P0810/DIAGNOSIS MONITOR CODE: 88.........................................................................................5402 DTC: P0973/DIAGNOSIS MONITOR CODE: 62.........................................................................................5407 DTC: P0974/DIAGNOSIS MONITOR CODE: 62.........................................................................................5412 DTC: P0976/DIAGNOSIS MONITOR CODE: 63.........................................................................................5417 DTC: P0977/DIAGNOSIS MONITOR CODE: 63.........................................................................................5422 DTC: P0979/DIAGNOSIS MONITOR CODE: 64.........................................................................................5427 DTC: P0980/DIAGNOSIS MONITOR CODE: 64.........................................................................................5432 DTC: P0985/DIAGNOSIS MONITOR CODE: 65.........................................................................................5437 DTC: P0986/DIAGNOSIS MONITOR CODE: 65.........................................................................................5442 DTC: P0A40/DIAGNOSIS MONITOR CODE: 88.........................................................................................5447 DTC: P1604/DIAGNOSIS MONITOR CODE: 24.........................................................................................5453 DTC: P1604/DIAGNOSIS MONITOR CODE: 54.........................................................................................5458 DTC: P2545/DIAGNOSIS MONITOR CODE: 88.........................................................................................5463 DTC: P2716/DIAGNOSIS MONITOR CODE: 28.........................................................................................5468 DTC: P2740/DIAGNOSIS MONITOR CODE: 17.........................................................................................5474 DTC: P2757/DIAGNOSIS MONITOR CODE: 33.........................................................................................5480 DTC: P2759/DIAGNOSIS MONITOR CODE: 27.........................................................................................5487 DTC: P2764/DIAGNOSIS MONITOR CODE: 36.........................................................................................5493 DTC: U0100/DIAGNOSIS MONITOR CODE: 88.........................................................................................5499 DTC: U110A/DIAGNOSIS MONITOR CODE: 88.........................................................................................5509 TROUBLESHOOTING.......................................................................................................................5519 CLUTCH ECU........................................................................................................................5519 SYSTEM BLOCK DIAGRAM..........................................................................................................5519 COMPUTER PIN ASSIGNMENT.......................................................................................................5520 DIAGNOSIS CODE TABLE..........................................................................................................5522 CAUTIONS ON HV DAMPER REPLACEMENT.............................................................................................5523 DTC: P0560....................................................................................................................5524 DTC: P0563....................................................................................................................5529 DTC: P0710....................................................................................................................5532 DTC: P0775....................................................................................................................5540 DTC: P0811....................................................................................................................5548 DTC: P081E....................................................................................................................5551 DTC: P0883....................................................................................................................5554 DTC: P0942....................................................................................................................5560 DTC: P1538....................................................................................................................5578 DTC: P1539....................................................................................................................5591 DTC: P191A....................................................................................................................5601 DTC: P2859....................................................................................................................5604 DTC: P3156....................................................................................................................5607 DTC: P3157....................................................................................................................5620 DTC: U0101....................................................................................................................5625 DTC: U0293....................................................................................................................5632 FOREWORD..................................................................................................................................5640 CHAPTER REFERENCES........................................................................................................................5641 INDEX.....................................................................................................................................5642 AXLE......................................................................................................................................5644 TROUBLESHOOTING.......................................................................................................................5645 TROUBLE SHOOTING BY AXLE SYMPTOM..................................................................................................5645 FRONT AXLE....................................................................................................................5645 REAR AXLE.....................................................................................................................5646 WHEEL AND TIRE................................................................................................................5646 DIFFERENTIAL..............................................................................................................................5648 TROUBLESHOOTING.......................................................................................................................5649 TROUBLE SHOOTING BY DIFFERENTIAL SYMPTOM..........................................................................................5649 REAR DIFFERENTIAL.............................................................................................................5649 BRAKE.....................................................................................................................................5650 TROUBLESHOOTING.......................................................................................................................5651 TROUBLE SHOOTING BY BRAKE SYMPTOM.................................................................................................5651 BRAKE.........................................................................................................................5651 ABS WITH EBD......................................................................................................................5653 CAUTIONS......................................................................................................................5653 TROUBLESHOOTING PROCEDURE.....................................................................................................5654 ACT PART No. CORRESPONDENCE...................................................................................................5656 HEARING TABLE.................................................................................................................5656 PRIOR CHECK...................................................................................................................5657 LIST OF DIAGNOSIS CODE........................................................................................................5671 PARTS ARRANGEMENT.............................................................................................................5674 ECU TERMINAL ARRANGEMENT......................................................................................................5676 SYMPTOM LIST..................................................................................................................5679 ELECTRIC CIRCUIT DIAGRAM......................................................................................................5680 ABS WARNING LIGHT ALWAYS ON...................................................................................................5681 BRAKE WARNING LIGHT ALWAYS ON.................................................................................................5684 ABS ACTIVATION TOO FAST (ABS OPERATES BEFORE THE WHEEL LOCKS).................................................................5688 THE BRAKE PEDAL GETS STUCK....................................................................................................5689 DTC: C1203 (Diagnosis monitor code 59)........................................................................................5691 DTC: C1225 (Diagnosis monitor code 25)........................................................................................5696 DTC: C1241 (Diagnosis monitor code 41)........................................................................................5702 DTC: C1249 (Diagnosis monitor code 49)........................................................................................5721 DTC: C1265 (Diagnosis monitor code 65)........................................................................................5728 DTC: C1300 (Diagnosis monitor code 62)........................................................................................5743 DTC: C1337 (Diagnosis monitor code 37)........................................................................................5747 DTC: C1361 (Diagnosis monitor code 91)........................................................................................5752 DTC: C1401 (Diagnosis monitor code 31)........................................................................................5763 DTC: C1402 (Diagnosis monitor code 32)........................................................................................5777 DTC: C1403 (Diagnosis monitor code 33)........................................................................................5791 DTC: C1404 (Diagnosis monitor code 34)........................................................................................5805 DTC: C1405 (Diagnosis monitor code 31)........................................................................................5819 DTC: C1406 (Diagnosis monitor code 32)........................................................................................5833 DTC: C1407 (Diagnosis monitor code 33)........................................................................................5847 DTC: C1408 (Diagnosis monitor code 34)........................................................................................5861 DTC: C1413 (Diagnosis monitor code 35)........................................................................................5875 DTC: C1414 (Diagnosis monitor code 36)........................................................................................5886 DTC: C1415 (Diagnosis monitor code 38)........................................................................................5896 DTC: C1416 (Diagnosis monitor code 39)........................................................................................5906 DTC: C1417 (Diagnosis monitor code 41)........................................................................................5916 DTC: C1421 (Diagnosis monitor code 46)........................................................................................5935 DTC: C1422 (Diagnosis monitor code 46)........................................................................................5941 DTC: C1423 (Diagnosis monitor code 46)........................................................................................5947 DTC: C1424 (Diagnosis monitor code 46)........................................................................................5953 DTC: C1425 (Diagnosis monitor code 49)........................................................................................5959 DTC: C1427 (Diagnosis monitor code 51)........................................................................................5966 DTC: C1428 (Diagnosis monitor code 51)........................................................................................5972 DTC: C1468 (Diagnosis monitor code 21)........................................................................................5978 DTC: C1469 (Diagnosis monitor code 22)........................................................................................5984 DTC: C146A (Diagnosis monitor code 23)........................................................................................5990 DTC: C146B (Diagnosis monitor code 24)........................................................................................5996 DTC: C146C (Diagnosis monitor code 13)........................................................................................6002 DTC: C146D (Diagnosis monitor code 14)........................................................................................6013 DTC: C146E (Diagnosis monitor code 11)........................................................................................6024 DTC: C146F (Diagnosis monitor code 12)........................................................................................6034 DTC: U0073 (Diagnosis monitor code 94)........................................................................................6044 ELECTRIC VACUUM PUMP SYSTEM.......................................................................................................6047 CAUTIONS FOR TROUBLESHOOTING..................................................................................................6047 SYSTEM BLOCK DIAGRAM..........................................................................................................6048 ELECTRIC CIRCUIT DIAGRAM......................................................................................................6049 CONNECTOR TERMINAL ARRANGEMENT................................................................................................6050 SYSTEM SELF-DIAGNOSTIC........................................................................................................6051 RESETTING THE ELECTRIC VACUUM PUMP OPERATION COUNT AND OPERATION TIME AND THE ELECTRIC VACUUM PUMP RELAY ACTUATION COUNT......6052 ACTIVE TEST...................................................................................................................6052 DATA MONITOR..................................................................................................................6052 DIAGNOSIS CODE TABLE..........................................................................................................6053 EXCESSIVE OPERATION OF ELECTRIC VACUUM PUMP (DIAGNOSIS CODE P165A)...........................................................6054 EXCESSIVE OPERATION OF ELECTRIC VACUUM PUMP RELAY (DIAGNOSIS CODE P165B).....................................................6056 ABNORMALITY IN VACUUM SENSOR CIRCUIT (DIAGNOSIS CODE P2525)...................................................................6058 FALSE DETECTION OF VACUUM SENSOR PRESSURE (DIAGNOSIS CODE P2526).............................................................6064 ELECTRIC VACUUM PUMP RELAY CONTACT STUCK AT ON (DIAGNOSIS CODE P258D)........................................................6084 HOW TO VERIFY AND CHANGE VEHICLE INFORMATION VALUES...........................................................................6087 STEERING..................................................................................................................................6089 TROUBLESHOOTING.......................................................................................................................6090 TROUBLE SHOOTING BY STEERING SYMPTOM..............................................................................................6090 STEERING......................................................................................................................6090 SUSPENSION................................................................................................................................6092 TROUBLESHOOTING.......................................................................................................................6093 TROUBLE SHOOTING BY SUSPENSION SYMPTOM............................................................................................6093 LEAF SUSPENSION...............................................................................................................6093 ELECTRICAL................................................................................................................................6094 TROUBLESHOOTING.......................................................................................................................6095 INTEGRATED UNIT...................................................................................................................6095 SYSTEM BLOCK DIAGRAM..........................................................................................................6095 COMPUTER PIN ASSIGNMENT.......................................................................................................6098 TROUBLE SHOOTING..............................................................................................................6099 CONTROL SYSTEM............................................................................................................................6106 TROUBLESHOOTING.......................................................................................................................6109 CAN COMMUNICATION.................................................................................................................6109 INSPECTION IN THE EVENT OF ABNORMALITY IN CAN COMMUNICATION LINE..............................................................6109 ECU INDIVIDUAL CODELIST (DIESEL)..............................................................................................6111 ECU INDIVIDUAL CODELIST (HYBRID)..............................................................................................6112 BASIC TROUBLESHOOTING PROCEDURE ON CAN COMMUNICATION..........................................................................6115 ENGINE CAN COMMUNICATION LINE (DIESEL)............................................................................................6117 ENGINE CAN LINE...............................................................................................................6117 PRIOR INSPECTION OF THE CAN COMMUNICATION LINE................................................................................6119 INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION........................................................................6123 INSPECTING THE CAN H LINE FOR SHORT CIRCUIT...................................................................................6128 INSPECTING THE CAN L LINE FOR SHORT CIRCUIT...................................................................................6137 INSPECTING THE EGR CONTROLLER CAN COMMUNICATION LINE..........................................................................6146 INSPECTING THE NOx SENSOR 1 CAN COMMUNICATION LINE............................................................................6149 INSPECTING THE NOx SENSOR 2 CAN COMMUNICATION LINE............................................................................6156 INSPECTING THE VNT CONTROLLER CAN COMMUNICATION LINE..........................................................................6163 INSPECTING THE DEF SENSOR CAN COMMUNICATION LINE..............................................................................6166 ENGINE CAN COMMUNICATION LINE (HYBRID)............................................................................................6171 ENGINE CAN LINE...............................................................................................................6171 PRIOR INSPECTION OF THE CAN COMMUNICATION LINE................................................................................6173 INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION........................................................................6177 INSPECTING THE CAN H LINE FOR SHORT CIRCUIT...................................................................................6182 INSPECTING THE CAN L LINE FOR SHORT CIRCUIT...................................................................................6192 INSPECTING THE EGR CONTROLLER CAN COMMUNICATION LINE..........................................................................6202 INSPECTING THE NOx SENSOR 1 CAN COMMUNICATION LINE............................................................................6205 INSPECTING THE NOx SENSOR 2 CAN COMMUNICATION LINE............................................................................6212 INSPECTING THE VNT CONTROLLER CAN COMMUNICATION LINE..........................................................................6219 INSPECTING THE DEF SENSOR CAN COMMUNICATION LINE..............................................................................6222 DIAGNOSIS CAN COMMUNICATION LINE (DIESEL).........................................................................................6226 DIAGNOSIS CAN LINE............................................................................................................6226 PRIOR INSPECTION OF THE CAN COMMUNICATION LINE................................................................................6228 INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION........................................................................6234 INSPECTING THE CAN H LINE FOR SHORT CIRCUIT...................................................................................6237 INSPECTING THE CAN L LINE FOR SHORT CIRCUIT...................................................................................6245 INSPECTING THE ABS ECU CAN COMMUNICATION LINE.................................................................................6252 INSPECTING THE AT ECU CAN COMMUNICATION LINE..................................................................................6255 INSPECTING THE ENGINE ECU CAN COMMUNICATION LINE..............................................................................6258 INSPECTING THE VEHICLE CONTROL ECU CAN COMMUNICATION LINE.....................................................................6263 DIAGNOSIS CAN COMMUNICATION LINE (HYBRID).........................................................................................6267 DIAGNOSIS CAN LINE............................................................................................................6267 PRIOR INSPECTION OF THE CAN COMMUNICATION LINE................................................................................6270 INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION........................................................................6277 INSPECTING THE CAN H LINE FOR SHORT CIRCUIT...................................................................................6284 INSPECTING THE CAN L LINE FOR SHORT CIRCUIT...................................................................................6295 INSPECTING THE ABS ECU CAN COMMUNICATION LINE.................................................................................6306 INSPECTING THE AT ECU CAN COMMUNICATION LINE..................................................................................6309 INSPECTING THE ENGINE ECU CAN COMMUNICATION LINE..............................................................................6312 INSPECTING THE INVERTER CAN COMMUNICATION LINE................................................................................6315 INSPECTING THE CLUTCH ECU CAN COMMUNICATION LINE..............................................................................6318 INSPECTING THE BATTERY ECU CAN COMMUNICATION LINE.............................................................................6321 INSPECTING THE VEHICLE CONTROL ECU CAN COMMUNICATION LINE.....................................................................6324 CONTROL CAN COMMUNICATION LINE (DIESEL)...........................................................................................6327 CONTROL CAN LINE..............................................................................................................6327 PRIOR INSPECTION OF THE CAN COMMUNICATION LINE................................................................................6329 INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION........................................................................6334 INSPECTING THE CAN H LINE FOR SHORT CIRCUIT...................................................................................6337 INSPECTING THE CAN L LINE FOR SHORT CIRCUIT...................................................................................6343 INSPECTING THE ABS ECU CAN COMMUNICATION LINE.................................................................................6349 INSPECTING THE AT ECU CAN COMMUNICATION LINE..................................................................................6352 INSPECTING THE VEHICLE CONTROL ECU CAN COMMUNICATION LINE.....................................................................6355 CONTROL CAN COMMUNICATION LINE (HYBRID)...........................................................................................6358 CONTROL CAN LINE..............................................................................................................6358 PRIOR INSPECTION OF THE CAN COMMUNICATION LINE................................................................................6362 INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION........................................................................6367 INSPECTING THE CAN H LINE FOR SHORT CIRCUIT...................................................................................6374 INSPECTING THE CAN L LINE FOR SHORT CIRCUIT...................................................................................6385 INSPECTING THE ABS ECU CAN COMMUNICATION LINE.................................................................................6396 INSPECTING THE AT ECU CAN COMMUNICATION LINE..................................................................................6399 INSPECTING THE HV ECU CAN COMMUNICATION LINE..................................................................................6402 INSPECTING THE INVERTER CAN COMMUNICATION LINE................................................................................6405 INSPECTING THE CLUTCH ECU CAN COMMUNICATION LINE..............................................................................6409 INSPECTING THE VEHICLE CONTROL ECU CAN COMMUNICATION LINE.....................................................................6413 CAN COMMUNICATION (HYBRID SYSTEM).................................................................................................6416 SAFETY MEASURES TO BE TAKEN IN HIGH VOLTAGE WORK..............................................................................6416 LIST OF CONNECTOR MARKINGS....................................................................................................6419 CONNECTION DIAGRAM............................................................................................................6420 LIST OF DTC CODES FOR CAN SYSTEM-RELATED ABNORMALITIES........................................................................6421 CAN COMMUNICATION FAILURE.....................................................................................................6423 BASIC INSPECTION ITEMS IN CASE OF ABNORMALITY IN DIAG CAN SYSTEM..............................................................6427 BASIC INSPECTION ITEMS IN CASE OF ABNORMALITY IN CONTROL CAN SYSTEM...........................................................6442 ABNORMALITY IN INVERTER (ECU SYSTEM) / DIAG CAN RESISTER SEIZURE (DTC CODE P0A1B / TC3F)......................................6451 ABNORMALITY IN THE INVERTER (ECU SYSTEM) / CONTROL CAN RESISTER SEIZURE (DTC CODE P0A1B / TC92)...............................6452 ABNORMALITY IN HV ECU FUNCTION / CONTROL CAN REGISTER SEIZURE (DTC CODE P0A1D / TC12).........................................6453 ABNORMALITY IN HV ECU FUNCTION / DIAG CAN REGISTER SEIZURE (DTC CODE P0A1D / TC17)...........................................6454 HV ECU CAN COMMUNICATION FAILURE (CONTROL CAN) / CONTROL CAN COMMUNICATION SHUTDOWN DUE TO BUS OFF (DTC CODE U0073 / TC11)....6455 CAN COMMUNICATION FAILURE (CONTROL CAN) / CONTROL CAN COMMUNICATION SHUTDOWN DUE TO BUS OFF (DTC CODE U0073 / TC91)...........6457 HV ECU CAN COMMUNICATION FAILURE (DIAG CAN) / DIAG CAN COMMUNICATION SHUTDOWN DUE TO BUS OFF (DTC CODE U0074 / TC16)..........6459 CAN COMMUNICATION FAILURE (DIAG CAN) / COMMUNICATION SHUTDOWN DUE TO DIAG CAN BUS OFF (DTC CODE U0074 / TC3E).................6460 ENGINE ECU CAN COMMUNICATION BLACKOUT / ENGINE ECU CAN COMMUNICATION BLACKOUT (DTC CODE U0100 / TC13).........................6461 TCM ECU CAN COMMUNICATION BLACKOUT / AT ECU CAN COMMUNICATION BLACKOUT (DTC CODE U0101 / TC18)................................6462 INVERTER CAN COMMUNICATION BLACKOUT / INVERTER CAN COMMUNICATION BLACKOUT (DTC CODE U0110 / TC14).............................6464 BATTERY ECU CAN COMMUNICATION BLACKOUT / BATTERY ECU CAN COMMUNICATION BLACKOUT (DTC CODE U0111 / TC15).......................6467 ABS ECU CAN COMMUNICATION BLACKOUT / ABS ECU CAN COMMUNICATION BLACKOUT (DTC CODE U0121/TC24).................................6470 METER CAN COMMUNICATION BLACKOUT / METER CAN COMMUNICATION BLACKOUT (DTC CODE U0155 / TC25)...................................6472 HV ECU COMMUNICATION FAILURE (DTC CODE U0293).................................................................................6474 HV ECU CAN COMMUNICATION BLACKOUT / HV ECU CAN COMMUNICATION BLACKOUT (DTC CODE U0293 / TC31).................................6476 VEHICLE CONTROL ECU CAN COMMUNICATION BLACKOUT / VEHICLE CONTROL ECU CAN COMMUNICATION BLACKOUT (DTC CODE U110A / TC26)......6480 CLUTCH ECU CAN COMMUNICATION BLACKOUT / CLUTCH ECU CAN COMMUNICATION BLACKOUT (DTC CODE U1136 / TC27).........................6482 COMMUNICATION DISABLED DUE TO DIAG CAN BUS OFF (DTC CODE U0074)..............................................................6484 FOREWORD..................................................................................................................................6486 CHAPTER REFERENCES........................................................................................................................6487 INDEX.....................................................................................................................................6488 System Configuration, Connection and Setup................................................................................................6489 Special Tool and Outline of Function..................................................................................................6490 Recommended system................................................................................................................6492 Installing Interface Driver...........................................................................................................6496 Installing Interface Driver.......................................................................................................6496 Upgrading Hino-Bowie..................................................................................................................6497 Upgrading Hino-Bowie..............................................................................................................6497 Instruction for Updating the Hino Bowie Interface.................................................................................6497 Object Devices....................................................................................................................6497 Materials Required for Updates....................................................................................................6497 Hino-Bowie Interface Update Instruction...........................................................................................6498 Hino-Bowie Hardware Driver Update Instructions....................................................................................6501 Activation of Software................................................................................................................6504 Activation of Software............................................................................................................6504 Connection to the vehicle.............................................................................................................6505 Connection to the vehicle.........................................................................................................6505 System Design.........................................................................................................................6506 Registration of user (Administrator)..............................................................................................6506 Setting-up Option.................................................................................................................6508 HINO Diagnostic eXplorer..................................................................................................................6526 Outline of HINO-DX Function...........................................................................................................6528 Outline of HINO-DX Function.......................................................................................................6528 Method of Diagnosis...............................................................................................................6529 HINO-DX Name of the Screen............................................................................................................6530 HINO-DX Name of the Screen........................................................................................................6530 Starting up HINO DX...................................................................................................................6532 Starting up HINO DX...............................................................................................................6532 Reading DTC code......................................................................................................................6534 Reading DTC code..................................................................................................................6534 How to read DTC...................................................................................................................6534 After System Fix..................................................................................................................6536 Diagnostic Information................................................................................................................6542 Diagnostic Information............................................................................................................6542 Symptom Based Diagnostic Information..............................................................................................6543 DTC Based Diagnostic Information..................................................................................................6544 System individual function............................................................................................................6545 System individual function........................................................................................................6545 Injector correction...............................................................................................................6546 Accelerator sensor adjust.........................................................................................................6553 Intake air volume check...........................................................................................................6555 Fuel leak check...................................................................................................................6557 VNT check.........................................................................................................................6559 EGR check.........................................................................................................................6561 Turbocharger check................................................................................................................6563 Inspecting common rail pressure...................................................................................................6565 DPR status display................................................................................................................6567 Deviation learning after pump replacement.........................................................................................6572 Intake throttle valve check.......................................................................................................6575 Change setting of upper limit of vehicle speed....................................................................................6577 ES start..........................................................................................................................6579 System Protection Data................................................................................................................6581 System Protection Data............................................................................................................6581 What can be done in System Protection Data........................................................................................6582 Sample of system protection data items (Engine)...................................................................................6583 Sample of system protection data items (Hybrid)...................................................................................6586 Sample of system protection data items (Transmission).............................................................................6587 Sample of system protection data items (Vehicle Control System)...................................................................6588 Learned values........................................................................................................................6589 Learned values....................................................................................................................6589 What can be done in Learned values................................................................................................6589 Sample of learned value items.....................................................................................................6590 Past Work Information.................................................................................................................6591 Past Work Information.............................................................................................................6591 What can be done in Past Work Information.........................................................................................6592 Save/Load ECU Feature.................................................................................................................6596 Save/Load ECU Feature.............................................................................................................6596 What can be done in Save/Load ECU Feature.........................................................................................6596 Save ECU configuration data.......................................................................................................6597 Write ECU configuration data......................................................................................................6598 Delete the ECU configuration data.................................................................................................6599 Procedure - Import / Export ECU configuration data................................................................................6600 Activation Test.......................................................................................................................6603 Activation Test...................................................................................................................6603 What can be done in Activation Test...............................................................................................6603 Procedure - Activation Test.......................................................................................................6604 Diagnostic simulation.................................................................................................................6612 Diagnostic simulation.............................................................................................................6612 Procedure - Simulation............................................................................................................6612 Vehicle Feature Confirmation..........................................................................................................6613 Vehicle Feature Confirmation......................................................................................................6613 HINO DX version information...........................................................................................................6614 HINO DX version information.......................................................................................................6614 Headlight Autoleveling................................................................................................................6616 Headlight Autoleveling............................................................................................................6616 Customization.........................................................................................................................6617 Customization.....................................................................................................................6617 What can be done in Customization.................................................................................................6617 Procedure - Customization.........................................................................................................6618 Detail of customization items (Engine)............................................................................................6620 Detail of customization items (Hybrid)............................................................................................6634 Detail of customization items (Transmission)......................................................................................6634 Detail of customization items (VCS)...............................................................................................6635 Data Monitor..........................................................................................................................6636 Data Monitor......................................................................................................................6636 What can be done in Data Monitor..................................................................................................6636 Procedure - Data Monitor..........................................................................................................6637 Monitor set up....................................................................................................................6637 Data Monitor Setup................................................................................................................6642 Data Monitor Operation............................................................................................................6645 Trigger function..................................................................................................................6649 Graph Line Drawing................................................................................................................6651 Graph Print.......................................................................................................................6651 Reproducing method of data monitor (making a graph of data).......................................................................6652 Data monitor items (ABS)..........................................................................................................6660 Data monitor items (Automatic Transmission).......................................................................................6664 Data monitor items (Engine).......................................................................................................6666 Data monitor items (Headlight Autoleveling).......................................................................................6676 Data monitor items (Hybrid).......................................................................................................6677 Data monitor items (Inverter).....................................................................................................6682 Data monitor items (Battery)......................................................................................................6685 Data monitor items (Transmission).................................................................................................6688 Data monitor items (VCS)..........................................................................................................6692 Data monitor items (Immobilizer)..................................................................................................6696 Manufacturer Parameter................................................................................................................6697 Manufacturer Parameter............................................................................................................6697 What can be done in Manufacturer Parameter........................................................................................6697 Procedure - Manufacturer Parameter................................................................................................6698 Manufacturer parameter items (ABS)................................................................................................6700 Manufacturer parameter items (VCS)................................................................................................6700 Manufacturer parameter items (Engine).............................................................................................6700 HINO Reprog Manager.......................................................................................................................6704 General outline of HINO RM function...................................................................................................6705 General outline of HINO RM function...............................................................................................6705 Screen name of HINO-RM................................................................................................................6706 Screen name of HINO-RM............................................................................................................6706 Reprogramming function................................................................................................................6708 Reprogramming function............................................................................................................6708 ECU Replacement...................................................................................................................6709 ECU program update................................................................................................................6710 Engine exchange...................................................................................................................6711 Startup of HINO-RM....................................................................................................................6712 Startup of HINO-RM................................................................................................................6712 Re-programming work...................................................................................................................6714 Re-programming work...............................................................................................................6714 Reprogramming to the state of vehicle.................................................................................................6724 VCS Reprogramming.................................................................................................................6724 ABS Reprogramming.................................................................................................................6731 SS DATA Creator...........................................................................................................................6737 SS DATA Creator - Outline of function.................................................................................................6738 SS DATA Creator - Outline of function.............................................................................................6738 Procedure - SS DATA Creator...........................................................................................................6739 Procedure - SS DATA Creator.......................................................................................................6739 HINO Re-programming Service Server........................................................................................................6746 Why Repro server is necessary.........................................................................................................6747 Management of production information..............................................................................................6747 Management of updated data........................................................................................................6747 Consolidated management of data...................................................................................................6747 Reduction of Equipment Investment.................................................................................................6747 Connection procedure..................................................................................................................6748 Connection........................................................................................................................6748 Download..........................................................................................................................6750 Upload (Repair report)............................................................................................................6754 Logout............................................................................................................................6759 Management of Production information..................................................................................................6760 Management of Production information..............................................................................................6760 Production information (shown by a list)..........................................................................................6760 Production information (Registration) for production plant only...................................................................6762 Production information (Switch country code)......................................................................................6764 Management of Verified information....................................................................................................6766 Management of Verified information................................................................................................6766 Management of verified information (SearchEdit)..................................................................................6766 Management of Registered verification information (New)...............................................................................6770 Newly purchased DX and PIN is registered..........................................................................................6770 Log information...................................................................................................................6772 Management of Dealer information......................................................................................................6774 Management of Dealer information..................................................................................................6774 Management of dealer information (Edit)...........................................................................................6774 Management of dealer information (New registration)...............................................................................6776 Management of announcement information................................................................................................6778 Management of announcement information............................................................................................6778 Management of announcement information (Edit).....................................................................................6778 Management of announcement information (New registration).........................................................................6780 Management of Bulletin Board to Hino..................................................................................................6782 Management of Bulletin Board to Hino..............................................................................................6782 Management of display language........................................................................................................6784 Management of display language....................................................................................................6784 Management of display language (Edit).............................................................................................6784 Right to access.......................................................................................................................6786 Right to access...................................................................................................................6786 Analysis Example..........................................................................................................................6787 Power RELEVANT ENGINE MODEL N04C: J05E: J08E..........................................................................................6788 Phenomenon: Experience a lack of engine power.....................................................................................6788 Power RELEVANT ENGINE MODEL All engine series.........................................................................................6790 Phenomenon: Experience a lack of engine power.....................................................................................6790 Power RELEVANT ENGINE MODELModels adopting VN Turbo...................................................................................6792 Phenomenon: Lack of engine power (Engine does not blow up whenrunning at high speed)..............................................6792 Power RELEVANT ENGINE MODEL All engine series.........................................................................................6794 Phenomenon: Lack of engine power..................................................................................................6794 Power RELEVANT ENGINE MODEL E13C......................................................................................................6796 Phenomenon: Lack of engine power (Poor response to accelerator)...................................................................6796 Power RELEVANT ENGINE MODEL E13C......................................................................................................6798 Phenomenon: Lack of power (Slow vehicle speed)....................................................................................6798 Overheat RELEVANT ENGINE MODELEngines adopting Cool EGR...............................................................................6800 Phenomenon: Overheat(Large quantity of white smoke after replacing LLC)...........................................................6800 Starting malfunction RELEVANT ENGINE MODEL All engine series..........................................................................6802 Phenomenon: Poor engine start ability.............................................................................................6802 Starting malfunction RELEVANT ENGINE MODEL N04C, J05E, J08E...........................................................................6804 Phenomenon: Hunting...............................................................................................................6804 Reference information.....................................................................................................................6806 Trouble case example..................................................................................................................6807 Trouble case example..............................................................................................................6807 List of DTC (Diagnostic Trouble Code).................................................................................................6810 Related to Common Rail............................................................................................................6810 Pitfalls of Trouble Diagnosis.........................................................................................................6815 Pitfalls of Trouble Diagnosis.....................................................................................................6815
Description:
2014 HINO TRUCK COE 155 155H 195 195H J05E WORKSHOP MANUAL
- This workshop manual has been prepared to provide information regarding repair procedures on Hino Trucks
- . Applicable for HINO 155, 155h, 195, 195h series, equipped with J05E engine When making any repairs on your vehicle, be careful not to be injured through improper procedures.
- As for maintenance items, refer to the Owner’s Manual. All information and specifications in this manual are based upon the latest product information available at the time of printing.
- Hino Motors Sales U.S.A. , Inc. reserves the right to make changes at any time without prior notice.
- Please note that the publications below have also been prepared as relevant workshop manuals for the components and systems in these vehicles.
Please Note:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
