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2017 HINO TRUCK COE 155 155H 195 195H J05E WORKSHOP MANUAL – PDF DOWNLOAD
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2017 HINO TRUCK COE 155 155H 195 195H J05E WORKSHOP MANUAL
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2017 HINO TRUCK COE 155 155H 195 195H J05E WORKSHOP MANUAL
Language : English
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2017 HINO TRUCK COE 155 155H 195 195H J05E WORKSHOP MANUAL – PDF DOWNLOAD:
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Table of Contents:
2017 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 DEFINITION OF TERM............................................................................................................ 24 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...................................................................................................................... 51 COMPONENT LOCATOR............................................................................................................. 51 UNIT CHECK.................................................................................................................... 51 REPLACEMENT................................................................................................................... 52 PCU............................................................................................................................... 54 COMPONENT LOCATOR............................................................................................................. 54 REPLACEMENT................................................................................................................... 58 HV BATTERY........................................................................................................................ 63 COMPONENT LOCATOR............................................................................................................. 63 REPLACEMENT................................................................................................................... 65 HV BATTERY COOLING FAN............................................................................................................ 69 COMPONENT LOCATOR............................................................................................................. 69 REPLACEMENT................................................................................................................... 71 HV BATTERY ECU.................................................................................................................... 74 COMPONENT LOCATOR............................................................................................................. 74 REPLACEMENT................................................................................................................... 75 SYSTEM MAIN RELAY JUNCTION BLOCK.................................................................................................. 78 COMPONENT LOCATOR............................................................................................................. 78 REPLACEMENT................................................................................................................... 79 INVERTER.......................................................................................................................... 81 COMPONENT LOCATOR............................................................................................................. 81 REPLACEMENT................................................................................................................... 82 HV-ECU............................................................................................................................ 86 COMPONENT LOCATOR............................................................................................................. 86 REPLACEMENT................................................................................................................... 87 HYBRID JUNCTION BLOCK............................................................................................................. 89 COMPONENT LOCATOR............................................................................................................. 89 REPLACEMENT................................................................................................................... 90 WATER PUMP........................................................................................................................ 93 COMPONENT LOCATOR............................................................................................................. 93 REPLACEMENT................................................................................................................... 94 INVERTER RADIATOR................................................................................................................. 97 COMPONENT LOCATOR............................................................................................................. 97 REPLACEMENT................................................................................................................... 98 COOLANT........................................................................................................................... 101 REPLACEMENT................................................................................................................... 101 MOTOR CABLE....................................................................................................................... 103 COMPONENT LOCATOR............................................................................................................. 103 REPLACEMENT................................................................................................................... 106 TRANSMISSION (A465)....................................................................................................................... 112 STANDARD VALUE........................................................................................................................ 113 ATTACHING AND DETACHING THE TRANSMISSION.......................................................................................... 113 AUTOMATIC TRANSMISSION ASSEMBLY............................................................................................... 113 TRANSMISSION CONTROL.............................................................................................................. 115 SHIFT LEVER ASSEMBLY.......................................................................................................... 115 TRANSMISSION MECHANICAL........................................................................................................... 115 TURBINE SENSOR................................................................................................................ 115 SPEED SENSOR.................................................................................................................. 115 NEUTRAL SWITCH................................................................................................................ 116 REQUIRED ITEMS........................................................................................................................ 117 ATTACHING AND DETACHING THE TRANSMISSION.......................................................................................... 117 AUTOMATIC TRANSMISSION ASSEMBLY............................................................................................... 117 NEUTRAL SWITCH................................................................................................................ 117 ATTACHING AND DETACHING THE TRANSMISSION.............................................................................................. 118 AUTOMATIC TRANSMISSION ASSEMBLY................................................................................................... 118 REPLACEMENT................................................................................................................... 118 TRANSMISSION CONTROL.................................................................................................................. 161 CONTROL COMPUTER ASSEMBLY ........................................................................................................ 161 COMPONENT LOCATOR............................................................................................................. 161 OVERHAUL...................................................................................................................... 162 SHIFT LEVER ASSEMBLY.............................................................................................................. 168 COMPONENT LOCATOR............................................................................................................. 168 OVERHAUL...................................................................................................................... 169 TRANSMISSION MECHANICAL............................................................................................................... 173 OIL PAN GASKET.................................................................................................................... 173 COMPONENT LOCATOR............................................................................................................. 173 OVERHAUL...................................................................................................................... 174 REAR CASE GASKET.................................................................................................................. 176 COMPONENT LOCATOR............................................................................................................. 176 OVERHAUL...................................................................................................................... 177 TURBINE SENSOR.................................................................................................................... 180 COMPONENT LOCATOR............................................................................................................. 180 OVERHAUL...................................................................................................................... 181 SPEED SENSOR...................................................................................................................... 182 COMPONENT LOCATOR............................................................................................................. 182 OVERHAUL...................................................................................................................... 183 NEUTRAL SWITCH.................................................................................................................... 184 COMPONENT LOCATOR............................................................................................................. 184 OVERHAUL...................................................................................................................... 185 PROPELLER SHAFT (LD)...................................................................................................................... 188 STANDARD VALUE........................................................................................................................ 189 PROPELLER SHAFT MECHANICAL........................................................................................................ 189 PROPELLER SHAFT ASSEMBLY...................................................................................................... 189 REQUIRED ITEMS........................................................................................................................ 190 PROPELLER SHAFT MECHANICAL........................................................................................................ 190 PROPELLER SHAFT ASSEMBLY...................................................................................................... 190 PROPELLER SHAFT MECHANICAL............................................................................................................ 192 PROPELLER SHAFT ASSEMBLY.......................................................................................................... 192 COMPONENT LOCATOR............................................................................................................. 192 OVERHAUL...................................................................................................................... 194 AXLE...................................................................................................................................... 209 STANDARD VALUE........................................................................................................................ 210 FRONT AXLE........................................................................................................................ 210 STEERING KNUCKLE.............................................................................................................. 210 FRONT AXLE HUB................................................................................................................ 211 REAR AXLE......................................................................................................................... 212 REAR AXLE HUB................................................................................................................. 212 REAR AXLE SHAFT............................................................................................................... 212 REQUIRED ITEMS........................................................................................................................ 213 FRONT AXLE........................................................................................................................ 213 STEERING KNUCKLE.............................................................................................................. 213 FRONT AXLE HUB................................................................................................................ 214 REAR AXLE......................................................................................................................... 217 REAR AXLE HUB................................................................................................................. 217 REAR AXLE SHAFT............................................................................................................... 218 FRONT AXLE............................................................................................................................ 220 STEERING KNUCKLE.................................................................................................................. 220 COMPONENT LOCATOR............................................................................................................. 220 OVERHAUL...................................................................................................................... 224 FRONT AXLE HUB.................................................................................................................... 238 COMPONENT LOCATOR............................................................................................................. 238 OVERHAUL...................................................................................................................... 240 FRONT AXLE HUB BOLT............................................................................................................... 251 COMPONENT LOCATOR............................................................................................................. 251 OVERHAUL...................................................................................................................... 252 REAR AXLE............................................................................................................................. 254 REAR AXLE HUB..................................................................................................................... 254 COMPONENT LOCATOR............................................................................................................. 254 OVERHAUL...................................................................................................................... 256 REAR AXLE SHAFT................................................................................................................... 266 COMPONENT LOCATOR............................................................................................................. 266 OVERHAUL...................................................................................................................... 267 WHEEL AND TIRE........................................................................................................................ 268 WHEEL AND TIRE.................................................................................................................... 268 COMPONENT LOCATOR............................................................................................................. 268 INSPECTION.................................................................................................................... 269 REPLACEMENT................................................................................................................... 271 OVERHAUL (TUBELESS TIRE)...................................................................................................... 274 DIFFERENTIAL (SH13)....................................................................................................................... 281 STANDARD VALUE........................................................................................................................ 282 DIFFERENTIAL...................................................................................................................... 282 DIFFERENTIAL CARRIER.......................................................................................................... 282 REQUIRED ITEMS........................................................................................................................ 284 DIFFERENTIAL...................................................................................................................... 284 DIFFERENTIAL CARRIER.......................................................................................................... 284 DIFFERENTIAL.......................................................................................................................... 287 DIFFERENTIAL CARRIER.............................................................................................................. 287 COMPONENT LOCATOR............................................................................................................. 287 OVERHAUL...................................................................................................................... 293 BRAKE..................................................................................................................................... 323 STANDARD VALUE........................................................................................................................ 325 BRAKE CONTROL..................................................................................................................... 325 SERVICE BRAKE................................................................................................................. 325 BRAKE FLUID................................................................................................................... 325 BRAKE ACTUATOR................................................................................................................ 326 SPEED SENSOR.................................................................................................................. 326 BRAKE PEDAL................................................................................................................... 327 BRAKE MASTER CYLINDER......................................................................................................... 327 BRAKE BOOSTER................................................................................................................. 327 HYDRO BOOSTER................................................................................................................. 328 ELECTRIC VACUUM PUMP.......................................................................................................... 328 VACUUM PUMP................................................................................................................... 328 HYDRO PUMP.................................................................................................................... 329 VACUUM RESERVOIR.............................................................................................................. 329 FRONT FLEXIBLE HOSE........................................................................................................... 329 REAR FLEXIBLE HOSE............................................................................................................ 329 VACUUM WARNING BUZZER......................................................................................................... 329 VACUUM SENSOR (FOR SKID CONTROL).............................................................................................. 330 DISC BRAKE ....................................................................................................................... 330 FRONT DISC CALIPER............................................................................................................ 330 REAR DISC CALIPER............................................................................................................. 331 PARKING BRAKE..................................................................................................................... 332 PARKING BRAKE................................................................................................................. 332 PARKING BRAKE CABLE No.2...................................................................................................... 332 PARKING BRAKE CABLE No.3...................................................................................................... 332 PARKING BRAKE LEVER........................................................................................................... 332 PARKING BRAKE DRUM............................................................................................................ 333 PARKING BRAKE SWITCH.......................................................................................................... 333 REQUIRED ITEMS........................................................................................................................ 334 SERVICE BRAKE..................................................................................................................... 334 SERVICE BRAKE................................................................................................................. 334 BRAKE FLUID................................................................................................................... 334 SPEED SENSOR.................................................................................................................. 334 BRAKE PEDAL................................................................................................................... 334 BRAKE BOOSTER................................................................................................................. 334 HYDRO BOOSTER................................................................................................................. 335 VACUUM RESERVOIR.............................................................................................................. 335 DISC BRAKE........................................................................................................................ 335 FRONT DISC CALIPER............................................................................................................ 335 REAR DISC CALIPER............................................................................................................. 335 PARKING BRAKE..................................................................................................................... 336 PARKING BRAKE DRUM............................................................................................................ 336 BRAKE CONTROL......................................................................................................................... 337 SERVICE BRAKE..................................................................................................................... 337 INSPECTION AND ADJUSTMENT..................................................................................................... 337 BRAKE FLUID....................................................................................................................... 342 REPLACEMENT................................................................................................................... 342 ABS ACTUATOR...................................................................................................................... 345 COMPONENT LOCATOR............................................................................................................. 345 REPLACEMENT................................................................................................................... 346 UNIT CHECK.................................................................................................................... 348 SPEED SENSOR...................................................................................................................... 349 COMPONENT LOCATOR............................................................................................................. 349 UNIT CHECK.................................................................................................................... 351 REPLACEMENT................................................................................................................... 352 BRAKE PEDAL....................................................................................................................... 355 COMPONENT LOCATOR............................................................................................................. 355 REPLACEMENT................................................................................................................... 356 BRAKE MASTER CYLINDER............................................................................................................. 359 COMPONENT LOCATOR............................................................................................................. 359 REPLACEMENT................................................................................................................... 360 BRAKE BOOSTER..................................................................................................................... 364 COMPONENT LOCATOR............................................................................................................. 364 REPLACEMENT................................................................................................................... 365 HYDRO BOOSTER..................................................................................................................... 373 COMPONENT LOCATOR............................................................................................................. 373 REPLACEMENT................................................................................................................... 374 ELECTRIC VACUUM PUMP.............................................................................................................. 379 COMPONENT LOCATOR............................................................................................................. 379 OVERHAUL...................................................................................................................... 380 VACUUM PUMP....................................................................................................................... 384 COMPONENT LOCATOR............................................................................................................. 384 OVERHAUL...................................................................................................................... 385 HYDRO PUMP........................................................................................................................ 387 COMPONENT LOCATOR............................................................................................................. 387 OVERHAUL...................................................................................................................... 388 VACUUM RESERVOIR.................................................................................................................. 389 COMPONENT LOCATOR............................................................................................................. 389 REPLACEMENT................................................................................................................... 390 FRONT FLEXIBLE HOSE............................................................................................................... 392 COMPONENT LOCATOR............................................................................................................. 392 REPLACEMENT................................................................................................................... 393 REAR FLEXIBLE HOSE................................................................................................................ 395 COMPONENT LOCATOR............................................................................................................. 395 REPLACEMENT................................................................................................................... 396 VACUUM WARNING BUZZER............................................................................................................. 398 BEHIND-THE-WHEEL INSPECTION................................................................................................... 398 REPLACEMENT................................................................................................................... 398 VACUUM SENSOR (FOR SKID CONTROL).................................................................................................. 399 COMPONENT LOCATOR............................................................................................................. 399 REPLACEMENT................................................................................................................... 400 DISC BRAKE............................................................................................................................ 403 FRONT BRAKE CALIPER............................................................................................................... 403 COMPONENT LOCATOR............................................................................................................. 403 OVERHAUL...................................................................................................................... 404 REAR BRAKE CALIPER................................................................................................................ 411 COMPONENT LOCATOR............................................................................................................. 411 OVERHAUL...................................................................................................................... 412 PARKING BRAKE......................................................................................................................... 419 PARKING BRAKE..................................................................................................................... 419 INSPECTION AND ADJUSTMENT..................................................................................................... 419 PARKING BRAKE CABLE No.2.......................................................................................................... 421 COMPONENT LOCATOR............................................................................................................. 421 REPLACEMENT................................................................................................................... 422 PARKING BRAKE CABLE No.3.......................................................................................................... 428 COMPONENT LOCATOR............................................................................................................. 428 REPLACEMENT................................................................................................................... 429 PARKING BRAKE LEVER............................................................................................................... 434 COMPONENT LOCATOR............................................................................................................. 434 REPLACEMENT................................................................................................................... 435 PARKING BRAKE DRUM................................................................................................................ 439 COMPONENT LOCATOR............................................................................................................. 439 OVERHAUL...................................................................................................................... 441 PARKING BRAKE SWITCH.............................................................................................................. 451 COMPONENT LOCATOR............................................................................................................. 451 REPLACEMENT................................................................................................................... 452 STEERING.................................................................................................................................. 454 STANDARD VALUE........................................................................................................................ 455 STEERING CONTROL.................................................................................................................. 455 POWER STEERING SYSTEM......................................................................................................... 455 STEERING WHEEL................................................................................................................ 455 STEERING COLUMN............................................................................................................... 455 STEERING LINKAGE.............................................................................................................. 456 POWER STEERING GEAR........................................................................................................... 456 POWER STEERING PUMP........................................................................................................... 456 REQUIRED ITEMS........................................................................................................................ 457 STEERING CONTROL.................................................................................................................. 457 POWER STEERING SYSTEM......................................................................................................... 457 STEERING WHEEL................................................................................................................ 457 STEERING COLUMN............................................................................................................... 458 STEERING LINKAGE.............................................................................................................. 458 POWER STEERING GEAR........................................................................................................... 458 POWER STEERING PUMP........................................................................................................... 459 STEERING CONTROL...................................................................................................................... 460 POWER STEERING SYSTEM............................................................................................................. 460 PERFORMANCE INSPECTION........................................................................................................ 460 STEERING WHEEL.................................................................................................................... 463 COMPONENT LOCATOR............................................................................................................. 463 REPLACEMENT................................................................................................................... 464 STEERING COLUMN................................................................................................................... 467 COMPONENT LOCATOR............................................................................................................. 467 REPLACEMENT................................................................................................................... 468 STEERING LINKAGE.................................................................................................................. 475 COMPONENT LOCATOR............................................................................................................. 475 REPLACEMENT................................................................................................................... 476 POWER STEERING GEAR............................................................................................................... 483 COMPONENT LOCATOR............................................................................................................. 483 REPLACEMENT................................................................................................................... 484 POWER STEERING PUMP............................................................................................................... 488 COMPONENT LOCATOR............................................................................................................. 488 REPLACEMENT .................................................................................................................. 489 SUSPENSION................................................................................................................................ 491 STANDARD VALUE........................................................................................................................ 492 FRONT SUSPENSION.................................................................................................................. 492 SHOCK ABSORBER................................................................................................................ 492 LEAF SPRING................................................................................................................... 492 STABILIZER.................................................................................................................... 493 WHEEL ALIGNMENT............................................................................................................... 493 REAR SUSPENSION................................................................................................................... 494 SHOCK ABSORBER................................................................................................................ 494 LEAF SPRING................................................................................................................... 494 REQUIRED ITEMS........................................................................................................................ 495 FRONT SUSPENSION.................................................................................................................. 495 SHOCK ABSORBER................................................................................................................ 495 LEAF SPRING................................................................................................................... 495 WHEEL ALIGNMENT............................................................................................................... 496 REAR SUSPENSION................................................................................................................... 497 SHOCK ABSORBER................................................................................................................ 497 LEAF SPRING................................................................................................................... 497 FRONT SUSPENSION...................................................................................................................... 498 SHOCK ABSORBER.................................................................................................................... 498 COMPONENT LOCATOR............................................................................................................. 498 REPLACEMENT................................................................................................................... 499 LEAF SPRING....................................................................................................................... 502 COMPONENT LOCATOR............................................................................................................. 502 OVERHAUL...................................................................................................................... 503 STABILIZER........................................................................................................................ 511 COMPONENT LOCATOR............................................................................................................. 511 REPLACEMENT................................................................................................................... 512 WHEEL ALIGNMENT................................................................................................................... 514 ADJUSTMENT.................................................................................................................... 514 REAR SUSPENSION....................................................................................................................... 518 SHOCK ABSORBER.................................................................................................................... 518 COMPONENT LOCATOR............................................................................................................. 518 REPLACEMENT................................................................................................................... 519 LEAF SPRING....................................................................................................................... 522 COMPONENT LOCATOR............................................................................................................. 522 OVERHAUL...................................................................................................................... 524 FRAME AND FRAME ACCESSORY................................................................................................................. 533 STANDARD VALUE........................................................................................................................ 534 FRAME............................................................................................................................. 534 CHASSIS FRAME................................................................................................................. 534 FRONT BUMPER.................................................................................................................. 534 REQUIRED ITEMS........................................................................................................................ 535 FRAME............................................................................................................................. 535 CHASSIS FRAME & CHASSIS FRAME ACCESSORIES..................................................................................... 535 FRAME................................................................................................................................. 536 FRAME AND FRAME ACCESSORIES....................................................................................................... 536 COMPONENT LOCATOR............................................................................................................. 536 FRAME............................................................................................................................. 537 INSPECTION.................................................................................................................... 537 REPAIR........................................................................................................................ 538 FRONT BUMPER...................................................................................................................... 543 COMPONENT LOCATOR............................................................................................................. 543 REPLACEMENT................................................................................................................... 544 CAB MOUNTING AND CAB SUSPENSION........................................................................................................... 547 STANDARD VALUE........................................................................................................................ 548 CAB MOUNTING AND CAB SUSPENSION................................................................................................... 548 ASSEMBLY...................................................................................................................... 548 CAB MOUNTING.................................................................................................................. 548 TILT CAB STAY................................................................................................................. 549 MOUNTING AND DISMOUNTING CAB.......................................................................................................... 550 CAB ASSEMBLY...................................................................................................................... 550 REPLACEMENT................................................................................................................... 550 CAB MOUNTING AND CAB SUSPENSION....................................................................................................... 564 CAB MOUNTING...................................................................................................................... 564 COMPONENT LOCATOR............................................................................................................. 564 PRECAUTIONS IN TILTING AND LOWERING THE CAB................................................................................... 568 REPLACEMENT................................................................................................................... 569 CAB TILT STAY..................................................................................................................... 580 COMPONENT LOCATOR............................................................................................................. 580 PRECAUTIONS IN TILTING AND LOWERING THE CAB................................................................................... 583 REPLACEMENT................................................................................................................... 584 BODY INSIDE ACCESSORY..................................................................................................................... 589 STANDARD VALUE........................................................................................................................ 590 INSTRUMENT PANEL AND DRIVER INFORMATION........................................................................................... 590 INSTRUMENT PANEL.............................................................................................................. 590 INTERIOR ACCESSORY................................................................................................................ 590 ROOF ACCESSORY................................................................................................................ 590 SEAT.............................................................................................................................. 590 DRIVER'S SEAT................................................................................................................. 590 ASSISTANT'S SEAT.............................................................................................................. 591 REAR SEAT..................................................................................................................... 591 INSTRUMENT PANEL AND DRIVER INFORMATION............................................................................................... 592 INSTRUMENT PANEL.................................................................................................................. 592 COMPONENT LOCATOR............................................................................................................. 592 REPLACEMENT................................................................................................................... 594 COMBINATION METER................................................................................................................. 604 REPLACEMENT................................................................................................................... 604 INTERIOR ACCESSORY.................................................................................................................... 605 INTERIOR ACCESSORY................................................................................................................ 605 COMPONENT LOCATOR............................................................................................................. 605 REPLACEMENT................................................................................................................... 607 FLOOR ACCESSORY................................................................................................................... 610 COMPONENT LOCATOR............................................................................................................. 610 REPLACEMENT................................................................................................................... 611 ROOF ACCESSORY.................................................................................................................... 612 COMPONENT LOCATOR............................................................................................................. 612 REPLACEMENT................................................................................................................... 613 SEAT.................................................................................................................................. 620 DRIVER'S SEAT..................................................................................................................... 620 COMPONENT LOCATOR............................................................................................................. 620 OVERHAUL...................................................................................................................... 622 ASSISTANT'S SEAT.................................................................................................................. 634 COMPONENT LOCATOR............................................................................................................. 634 OVERHAUL (THREE-SEATER)....................................................................................................... 637 OVERHAUL (CREW CAB)........................................................................................................... 645 REAR SEAT......................................................................................................................... 651 COMPONENT LOCATOR............................................................................................................. 651 OVERHAUL...................................................................................................................... 653 BODY OUTSIDE ACCESSORY.................................................................................................................... 663 STANDARD VALUE........................................................................................................................ 664 DOOR.............................................................................................................................. 664 DOOR HINGE.................................................................................................................... 664 DOOR ACCESSORIES.............................................................................................................. 664 REQUIRED ITEMS........................................................................................................................ 665 DOOR.............................................................................................................................. 665 DOOR ACCESSORIES.............................................................................................................. 665 POWER WINDOW.................................................................................................................. 665 AUTO DOOR LOCK SYSTEM......................................................................................................... 665 WINDOW GLASS...................................................................................................................... 666 GLASS......................................................................................................................... 666 MIRROR............................................................................................................................ 667 POWER MIRROR.................................................................................................................. 667 DOOR.................................................................................................................................. 668 DOOR HINGE........................................................................................................................ 668 INSPECTION AND ADJUSTMENT..................................................................................................... 668 DOOR ACCESSORY.................................................................................................................... 672 COMPONENT LOCATOR............................................................................................................. 672 OVERHAUL...................................................................................................................... 678 POWER WINDOW...................................................................................................................... 700 SINGLE UNIT INSPECTION........................................................................................................ 700 AUTO DOOR LOCK SYSTEM............................................................................................................. 703 PERFORMANCE INSPECTION........................................................................................................ 703 SINGLE UNIT INSPECTION........................................................................................................ 703 KEYLESS ENTRY..................................................................................................................... 705 PERFORMANCE INSPECTION........................................................................................................ 705 WINDOW GLASS.......................................................................................................................... 706 GLASS............................................................................................................................. 706 COMPONENT LOCATOR............................................................................................................. 706 REPLACEMENT................................................................................................................... 708 MIRROR................................................................................................................................ 718 REAR VIEW MIRROR.................................................................................................................. 718 COMPONENT LOCATOR............................................................................................................. 718 REPLACEMENT................................................................................................................... 719 POWER MIRROR...................................................................................................................... 720 SINGLE UNIT INSPECTION........................................................................................................ 720 ACCESSORY............................................................................................................................. 721 OUTSIDE ACCESSORY................................................................................................................. 721 COMPONENT LOCATOR............................................................................................................. 721 REPLACEMENT................................................................................................................... 722 AIR BAG AND SEAT BELT..................................................................................................................... 727 STANDARD VALUE........................................................................................................................ 728 SEAT BELT......................................................................................................................... 728 SEAT BELT..................................................................................................................... 728 CENTER SEAT BELT.............................................................................................................. 728 REAR SEAT BELT................................................................................................................ 729 SEAT BELT............................................................................................................................. 730 SEAT BELT......................................................................................................................... 730 COMPONENT LOCATOR............................................................................................................. 730 REPLACEMENT................................................................................................................... 731 CENTER SEAT BELT.................................................................................................................. 733 COMPONENT LOCATOR............................................................................................................. 733 REPLACEMENT................................................................................................................... 734 REAR SEAT BELT.................................................................................................................... 735 COMPONENT LOCATOR............................................................................................................. 735 REPLACEMENT................................................................................................................... 736 HEATER AND AIR CONDITIONER................................................................................................................ 737 STANDARD VALUE........................................................................................................................ 738 AIR CONDITIONER................................................................................................................... 738 AIR CONDITIONER............................................................................................................... 738 V-BELT........................................................................................................................ 739 COOLER COMPRESSOR............................................................................................................. 739 CONDENSER (WIDE CAB MODEL TYPE WITH FAN)...................................................................................... 740 HVAC (WIDE CAB MODEL)......................................................................................................... 740 HEATER CONTROL................................................................................................................ 740 REAR HEATER (CREW CAB)........................................................................................................ 741 REAR COOLER (CREW CAB)........................................................................................................ 741 REQUIRED ITEMS........................................................................................................................ 742 AIR CONDITIONER................................................................................................................... 742 AIR CONDITIONER............................................................................................................... 742 V-BELT........................................................................................................................ 742 COOLER COMPRESSOR............................................................................................................. 742 CONDENSER (REGULAR CAB MODEL TYPE WITH FAN)................................................................................... 743 CONDENSER (WIDE CAB MODEL TYPE WITH FAN)...................................................................................... 743 AIR CONDITIONER....................................................................................................................... 744 AIR CONDITIONER................................................................................................................... 744 SAFETY INSTRUCTIONS FOR WORK.................................................................................................. 744 COLLECTION/FILLING OF REFRIGERANT............................................................................................. 748 MAINTENANCE................................................................................................................... 756 V-BELT............................................................................................................................ 759 COMPONENT LOCATOR............................................................................................................. 759 REPLACEMENT................................................................................................................... 760 COOLER COMPRESSOR................................................................................................................. 764 COMPONENT LOCATOR............................................................................................................. 764 REPLACEMENT................................................................................................................... 765 CONDENSER (WIDE CAB MODEL TYPE WITH FAN).......................................................................................... 769 COMPONENT LOCATOR............................................................................................................. 769 REPLACEMENT................................................................................................................... 770 HVAC (WIDE CAB MODEL)............................................................................................................. 774 COMPONENT LOCATOR............................................................................................................. 774 REPLACEMENT................................................................................................................... 776 HEATER CONTROL.................................................................................................................... 783 COMPONENT LOCATOR............................................................................................................. 783 REPLACEMENT................................................................................................................... 784 REAR HEATER (CREW CAB)............................................................................................................ 787 COMPONENT LOCATOR............................................................................................................. 787 REPLACEMENT................................................................................................................... 788 REAR HEATER BLOWER SWITCH (CREW CAB).............................................................................................. 794 COMPONENT LOCATOR............................................................................................................. 794 REPLACEMENT................................................................................................................... 795 REAR COOLER (CREW CAB)............................................................................................................ 797 COMPONENT LOCATOR............................................................................................................. 797 REPLACEMENT................................................................................................................... 798 COOLER CONTROL SWITCH (CREW CAB).................................................................................................. 805 COMPONENT LOCATOR............................................................................................................. 805 REPLACEMENT................................................................................................................... 806 ELECTRICAL................................................................................................................................ 809 STANDARD VALUE........................................................................................................................ 810 LIGHTING.......................................................................................................................... 810 HEADLIGHT..................................................................................................................... 810 WIPER AND WASHER.................................................................................................................. 810 WIPER......................................................................................................................... 810 WASHER........................................................................................................................ 810 REQUIRED ITEMS........................................................................................................................ 811 LIGHTING.......................................................................................................................... 811 COMBINATION SWITCH............................................................................................................ 811 LIGHTING.............................................................................................................................. 812 HEADLIGHT......................................................................................................................... 812 COMPONENT LOCATOR............................................................................................................. 812 OPTICAL AXIS ADJUSTMENT....................................................................................................... 813 REPLACEMENT................................................................................................................... 814 ID LIGHT.......................................................................................................................... 815 COMPONENT LOCATOR............................................................................................................. 815 REPLACEMENT................................................................................................................... 816 ROOM LIGHT........................................................................................................................ 817 COMPONENT LOCATOR............................................................................................................. 817 REPLACEMENT................................................................................................................... 818 COMBINATION SWITCH................................................................................................................ 819 COMPONENT LOCATOR............................................................................................................. 819 REPLACEMENT................................................................................................................... 820 INSPECTION.................................................................................................................... 820 WIPER AND WASHER...................................................................................................................... 823 WIPER............................................................................................................................. 823 COMPONENT LOCATOR............................................................................................................. 823 REPLACEMENT................................................................................................................... 824 WASHER............................................................................................................................ 827 COMPONENT LOCATOR............................................................................................................. 827 REPLACEMENT .................................................................................................................. 828 COMPUTER.............................................................................................................................. 830 COMPUTER.......................................................................................................................... 830 MOUNTING POSITION............................................................................................................. 830 SWITCH................................................................................................................................ 832 SWITCH............................................................................................................................ 832 MOUNTING POSITION............................................................................................................. 832 FUSE AND RELAY........................................................................................................................ 833 FUSE BLOCK........................................................................................................................ 833 MOUNTING POSITION............................................................................................................. 833 RELAY............................................................................................................................. 835 MOUNTING POSITION............................................................................................................. 835 CONTROL SYSTEM............................................................................................................................ 836 REQUIRED ITEMS........................................................................................................................ 837 IDLING STOP....................................................................................................................... 837 SLOPE LEARNING................................................................................................................ 837 IDLING STOP........................................................................................................................... 838 IDLING STOP SYSTEM................................................................................................................ 838 SLOPE LEARNING................................................................................................................ 838 CRUISE CONTROL........................................................................................................................ 840 CRUISE MAIN SWITCH................................................................................................................ 840 COMPONENT LOCATOR............................................................................................................. 840 REPLACEMENT................................................................................................................... 841 SINGLE UNIT INSPECTION........................................................................................................ 842 FOREWORD.................................................................................................................................. 844 CHAPTER REFERENCES........................................................................................................................ 845 INDEX..................................................................................................................................... 846 GENERAL INTRODUCTION...................................................................................................................... 848 HOW TO IDENTIFY VEHICLE TYPE.......................................................................................................... 849 VEHICLE MODEL..................................................................................................................... 849 VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE..................................................................................... 850 APPEARANCE OF VEHICLE................................................................................................................. 851 APPEARANCE OF VEHICLE............................................................................................................. 851 SAFETY INSTRUCTIONS AND READINESS TO WORK............................................................................................. 852 WARNING........................................................................................................................... 852 IDENTIFICATION INFORMATION........................................................................................................ 856 SAFETY INSTRUCTIONS FOR WORK...................................................................................................... 859 INTRODUCTION TO WORKSHOP MANUAL................................................................................................... 862 TIGHTENING OF BOLTS AND NUTS...................................................................................................... 866 HANDLING OF LIQUID GASKET......................................................................................................... 876 GLOSSARY.............................................................................................................................. 877 DEFINITION OF ABBREVIATION IN THIS MANUAL......................................................................................... 877 LUBRICANTS............................................................................................................................ 883 RECOMMENDED LUBRICANTS............................................................................................................ 883 STANDARD VALUE............................................................................................................................ 884 MOUNTING AND DISMOUNTING THE ENGINE................................................................................................... 886 ENGINE ASSEMBLY................................................................................................................... 886 ENGINE CONTROL........................................................................................................................ 887 ENGINE ECU........................................................................................................................ 887 ENGINE SPEED MAIN SENSOR.......................................................................................................... 887 ENGINE SPEED SUB SENSOR........................................................................................................... 887 ACCELERATOR PEDAL................................................................................................................. 888 BLOCK HEATER...................................................................................................................... 888 FUEL SYSTEM........................................................................................................................... 889 FUEL TANK......................................................................................................................... 889 FUEL SENDER GAUGE................................................................................................................. 889 ENGINE-SIDE FUEL FILTER & CASE.................................................................................................... 890 WATER LEVEL WARNING SWITCH........................................................................................................ 890 SUPPLY PUMP....................................................................................................................... 891 INJECTOR.......................................................................................................................... 891 COMMON RAIL....................................................................................................................... 892 VEHICLE-SIDE FUEL FILTER.......................................................................................................... 892 FUEL COOLER....................................................................................................................... 892 EMISSION CONTROL...................................................................................................................... 893 EGR VALVE & COOLER................................................................................................................ 893 CLOSED VENTILATOR................................................................................................................. 893 INTAKE................................................................................................................................ 894 INTAKE MANIFOLD................................................................................................................... 894 DIESEL THROTTLE................................................................................................................... 894 INTAKE PIPE (EXHAUST SIDE)........................................................................................................ 894 STACK DUCT........................................................................................................................ 894 AIR CLEANER....................................................................................................................... 895 INTAKE TEMPERATURE SENSOR......................................................................................................... 895 BOOST PRESSURE SENSOR............................................................................................................. 895 AIR FLOW SENSOR................................................................................................................... 895 ENGINE MECHANICAL..................................................................................................................... 896 HEAD COVER........................................................................................................................ 896 ROCKER ARM ASSEMBLY............................................................................................................... 896 CAMSHAFT ASSEMBLY................................................................................................................. 897 CYLINDER HEAD ASSEMBLY............................................................................................................ 898 VALVE SYSTEM...................................................................................................................... 899 CRANKSHAFT PULLEY................................................................................................................. 900 FRONT OIL SEAL RETAINER........................................................................................................... 900 FLYWHEEL ASSEMBLY................................................................................................................. 900 FLYWHEEL HOUSING.................................................................................................................. 900 TIMING GEAR & CAM IDLE GEAR....................................................................................................... 901 PISTON & CONNECTING ROD........................................................................................................... 902 CRANKSHAFT........................................................................................................................ 903 CYLINDER LINER.................................................................................................................... 904 CYLINDER BLOCK.................................................................................................................... 904 ENGINE MOUNTING AND BRACKET....................................................................................................... 905 GLOW PLUG......................................................................................................................... 905 EXHAUST............................................................................................................................... 906 EXHAUST MANIFOLD.................................................................................................................. 906 EXHAUST PIPE...................................................................................................................... 906 EXHAUST PIPE (ATC)................................................................................................................ 906 DEF-SCR........................................................................................................................... 907 DPR CLEANER....................................................................................................................... 907 FUEL ADDITION VALVE............................................................................................................... 908 FUEL CUTOFF VALVE................................................................................................................. 908 DEF PUMP.......................................................................................................................... 908 DEF INJECTOR...................................................................................................................... 909 DEF TANK.......................................................................................................................... 909 COOLANT CUTOFF VALVE.............................................................................................................. 909 DCU............................................................................................................................... 910 DPR DIFFERENTIAL PRESSURE SENSOR.................................................................................................. 910 SCR UPSTREAM NOx SENSOR........................................................................................................... 910 SCR DOWNSTREAM NOx SENSOR......................................................................................................... 910 ATC UPSTREAM TEMPERATURE SENSOR................................................................................................... 911 DOC UPSTREAM TEMPERATURE SENSOR................................................................................................... 911 DPR UPSTREAM TEMPERATURE SENSOR................................................................................................... 911 DPR DOWNSTREAM TEMPERATURE SENSOR................................................................................................. 912 SCR UPSTREAM TEMPERATURE SENSOR................................................................................................... 912 EXHAUST BRAKE..................................................................................................................... 913 EXHAUST BRAKE MAGNETIC VALVE...................................................................................................... 913 COOLING............................................................................................................................... 914 RADIATOR.......................................................................................................................... 914 RADIATOR CAP...................................................................................................................... 914 RESERVE TANK...................................................................................................................... 914 INTERCOOLER....................................................................................................................... 915 THERMOSTAT CASE & THERMOSTAT...................................................................................................... 915 COOLANT PUMP...................................................................................................................... 915 COOLING FAN & FAN CLUTCH.......................................................................................................... 916 COOLANT TEMPERATURE SENSOR........................................................................................................ 916 LUBRICATION........................................................................................................................... 917 OIL COOLER........................................................................................................................ 917 OIL PUMP.......................................................................................................................... 917 OIL PAN........................................................................................................................... 918 OIL STRAINER...................................................................................................................... 918 OIL PRESSURE SWITCH............................................................................................................... 918 STARTING/CHARGING..................................................................................................................... 919 STARTER........................................................................................................................... 919 V-BELT............................................................................................................................ 919 ALTERNATOR (130 A)................................................................................................................ 920 TURBOCHARGER.......................................................................................................................... 921 TURBOCHARGER ASSEMBLY............................................................................................................. 921 REQUIRED ITEMS............................................................................................................................ 922 MOUNTING AND DISMOUNTING THE ENGINE................................................................................................... 923 ENGINE ASSEMBLY................................................................................................................... 923 ENGINE CONTROL........................................................................................................................ 924 ENGINE ECU........................................................................................................................ 924 ENGINE MAIN REVOLUTION SENSOR..................................................................................................... 924 ENGINE SUB REVOLUTION SENSOR...................................................................................................... 925 ACCELERATOR PEDAL................................................................................................................. 926 IDLE SET VOLUME................................................................................................................... 926 FUEL SYSTEM........................................................................................................................... 927 FUEL SENDER GAUGE................................................................................................................. 927 WATER LEVEL WARNING SWITCH........................................................................................................ 927 SUPPLY PUMP....................................................................................................................... 928 INJECTOR.......................................................................................................................... 929 COMMON RAIL....................................................................................................................... 930 FUEL FILTER AND CASE (VEHICLE SIDE)............................................................................................... 930 EMISSION CONTROL...................................................................................................................... 931 EGR VALVE AND COOLER.............................................................................................................. 931 INTAKE................................................................................................................................ 932 DIESEL THROTTLE................................................................................................................... 932 BOOST PRESSURE SENSOR............................................................................................................. 933 AIR FLOW SENSOR................................................................................................................... 934 ENGINE MECHANICAL..................................................................................................................... 935 HEAD COVER........................................................................................................................ 935 ROCKER ARM ASSEMBLY............................................................................................................... 935 CAMSHAFT ASSEMBLY................................................................................................................. 935 CYLINDER HEAD ASSEMBLY............................................................................................................ 936 VALVE SYSTEM...................................................................................................................... 937 CRANKSHAFT FRONT OIL SEAL......................................................................................................... 938 FRONT OIL SEAL RETAINER........................................................................................................... 938 FLYWHEEL ASSEMBLY................................................................................................................. 938 CRANKSHAFT REAR OIL SEAL.......................................................................................................... 939 FLYWHEEL HOUSING.................................................................................................................. 939 TIMING GEAR AND CAM IDLE GEAR..................................................................................................... 940 PISTON AND CONNECTING ROD......................................................................................................... 941 CRANKSHAFT........................................................................................................................ 943 CYLINDER LINER.................................................................................................................... 944 CYLINDER BLOCK.................................................................................................................... 945 GLOW PLUG......................................................................................................................... 945 EXHAUST............................................................................................................................... 946 EXHAUST MANIFOLD.................................................................................................................. 946 DPR............................................................................................................................... 946 FUEL ADDITION VALVE............................................................................................................... 947 DEF PUMP.......................................................................................................................... 947 DEF INJECTOR...................................................................................................................... 947 DEF TANK.......................................................................................................................... 948 DPR DIFFERENTIAL PRESSURE SENSOR.................................................................................................. 948 SCR UPSTREAM NOx SENSOR........................................................................................................... 948 SCR DOWNSTREAM NOx SENSOR......................................................................................................... 948 ATC UPSTREAM TEMPERATURE SENSOR................................................................................................... 949 DOC UPSTREAM TEMPERATURE SENSOR................................................................................................... 949 DPR UPSTREAM TEMPERATURE SENSOR................................................................................................... 949 DPR DOWNSTREAM TEMPERATURE SENSOR................................................................................................. 950 SCR UPSTREAM TEMPERATURE SENSOR................................................................................................... 950 DPR EXHAUST GAS TEMPERATURE SENSOR................................................................................................ 950 EXHAUST BRAKE..................................................................................................................... 951 EXHAUST BRAKE MAGNETIC VALVE...................................................................................................... 951 COOLING............................................................................................................................... 952 RADIATOR CAP...................................................................................................................... 952 THERMOSTAT CASE AND THERMOSTAT.................................................................................................... 952 COOLANT PUMP...................................................................................................................... 953 COOLANT TEMPERATURE SENSOR........................................................................................................ 953 LUBRICATION........................................................................................................................... 954 OIL FILTER........................................................................................................................ 954 OIL COOLER........................................................................................................................ 954 OIL PUMP.......................................................................................................................... 955 OIL PAN........................................................................................................................... 955 OIL PRESSURE SWITCH............................................................................................................... 955 STARTING/CHARGING..................................................................................................................... 956 STARTER........................................................................................................................... 956 V-BELT............................................................................................................................ 956 ALTERNATOR (130A)................................................................................................................. 956 TURBOCHARGER.......................................................................................................................... 957 TURBOCHARGER ASSEMBLY............................................................................................................. 957 MOUNTING AND DISMOUNTING THE ENGINE....................................................................................................... 959 ENGINE ASSEMBLY....................................................................................................................... 960 PRECAUTIONS IN TILTING AND LOWERING THE CAB....................................................................................... 960 MEASUREMENT OF COMPRESSION PRESSURE............................................................................................... 960 ADJUSTING THE VALVE CLEARANCE..................................................................................................... 963 REPLACEMENT....................................................................................................................... 965 ENGINE CONTROL............................................................................................................................ 974 CONTROL PARTS......................................................................................................................... 975 SYSTEM BLOCK DIAGRAM.............................................................................................................. 975 ENGINE ECU............................................................................................................................ 976 COMPONENT LOCATOR................................................................................................................. 976 REPLACEMENT....................................................................................................................... 977 VEHICLE CONTROL ECU................................................................................................................... 983 REPLACEMENT....................................................................................................................... 983 ENGINE SPEED MAIN SENSOR.............................................................................................................. 984 COMPONENT LOCATOR................................................................................................................. 984 INSPECTION........................................................................................................................ 985 REPLACEMENT....................................................................................................................... 985 ENGINE SPEED SUB SENSOR............................................................................................................... 986 COMPONENT LOCATOR................................................................................................................. 986 INSPECTION........................................................................................................................ 987 REPLACEMENT....................................................................................................................... 987 ACCELERATOR PEDAL..................................................................................................................... 988 COMPONENT LOCATOR................................................................................................................. 988 REPLACEMENT....................................................................................................................... 989 BLOCK HEATER.......................................................................................................................... 990 COMPONENT LOCATOR................................................................................................................. 990 REPLACEMENT....................................................................................................................... 991 FUEL SENDER GAUGE..................................................................................................................... 992 REPLACEMENT....................................................................................................................... 992 INTAKE TEMPERATURE SENSOR............................................................................................................. 992 REPLACEMENT....................................................................................................................... 992 DIESEL THROTTLE....................................................................................................................... 992 REPLACEMENT....................................................................................................................... 992 BOOST PRESSURE SENSOR................................................................................................................. 993 REPLACEMENT....................................................................................................................... 993 AIR FLOW SENSOR....................................................................................................................... 993 REPLACEMENT....................................................................................................................... 993 DPR DIFFERENTIAL PRESSURE SENSOR...................................................................................................... 994 REPLACEMENT....................................................................................................................... 994 SCR UPSTREAM NOx SENSOR............................................................................................................... 994 REPLACEMENT....................................................................................................................... 994 SCR DOWNSTREAM NOx SENSOR............................................................................................................. 994 REPLACEMENT....................................................................................................................... 994 ATC UPSTREAM TEMPERATURE SENSOR....................................................................................................... 995 REPLACEMENT....................................................................................................................... 995 DOC UPSTREAM TEMPERATURE SENSOR....................................................................................................... 995 REPLACEMENT....................................................................................................................... 995 DPR UPSTREAM TEMPERATURE SENSOR....................................................................................................... 996 REPLACEMENT....................................................................................................................... 996 DPR DOWNSTREAM TEMPERATURE SENSOR..................................................................................................... 996 REPLACEMENT....................................................................................................................... 996 SCR UPSTREAM TEMPERATURE SENSOR....................................................................................................... 997 REPLACEMENT....................................................................................................................... 997 OUTSIDE TEMPERATURE SENSOR............................................................................................................ 997 REPLACEMENT....................................................................................................................... 997 COOLANT TEMPERATURE SENSOR............................................................................................................ 998 REPLACEMENT....................................................................................................................... 998 OIL PRESSURE SWITCH................................................................................................................... 998 REPLACEMENT....................................................................................................................... 998 FUEL SYSTEM............................................................................................................................... 999 FUEL SYSTEM...........................................................................................................................1000 FUEL SYSTEM DIAGRAM...............................................................................................................1000 FUEL TANK.............................................................................................................................1001 COMPONENT LOCATOR.................................................................................................................1001 REPLACEMENT (30 GALLON)...........................................................................................................1002 REPLACEMENT (33 GALLON)...........................................................................................................1005 FUEL SENDER GAUGE.....................................................................................................................1009 COMPONENT LOCATOR.................................................................................................................1009 REPLACEMENT.......................................................................................................................1010 FUEL FILTER AND CASE (ENGINE SIDE)....................................................................................................1012 COMPONENT LOCATOR.................................................................................................................1012 REPLACEMENT.......................................................................................................................1013 WATER LEVEL WARNING SWITCH............................................................................................................1022 COMPONENT LOCATOR.................................................................................................................1022 REPLACEMENT.......................................................................................................................1023 SUPPLY PUMP...........................................................................................................................1025 COMPONENT LOCATOR.................................................................................................................1025 REPLACEMENT.......................................................................................................................1026 INJECTOR..............................................................................................................................1034 COMPONENT LOCATOR.................................................................................................................1034 REPLACEMENT.......................................................................................................................1035 COMMON RAIL...........................................................................................................................1044 COMPONENT LOCATOR.................................................................................................................1044 INSPECTION........................................................................................................................1045 REPLACEMENT.......................................................................................................................1046 FUEL FILTER AND CASE (VEHICLE SIDE)...................................................................................................1051 COMPONENT LOCATOR.................................................................................................................1051 REPLACEMENT.......................................................................................................................1052 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....................................................................................................................................1077 INTAKE MANIFOLD.......................................................................................................................1078 COMPONENT LOCATOR.................................................................................................................1078 REPLACEMENT.......................................................................................................................1079 DIESEL THROTTLE.......................................................................................................................1084 COMPONENT LOCATOR.................................................................................................................1084 INSPECTION........................................................................................................................1085 REPLACEMENT.......................................................................................................................1085 INTAKE PIPE (EXHAUST SIDE)............................................................................................................1087 COMPONENT LOCATOR.................................................................................................................1087 REPLACEMENT.......................................................................................................................1088 INTERCOOLER...........................................................................................................................1094 OVERHAUL..........................................................................................................................1094 STACK DUCT............................................................................................................................1095 COMPONENT LOCATOR.................................................................................................................1095 CLEANING THE PRECLEANER HOUSING...................................................................................................1096 REPLACEMENT.......................................................................................................................1097 AIR CLEANER...........................................................................................................................1099 COMPONENT LOCATOR.................................................................................................................1099 REPLACEMENT.......................................................................................................................1101 CLEANING THE AIR CLEANER ELEMENT..................................................................................................1105 INTAKE TEMPERATURE SENSOR.............................................................................................................1106 COMPONENT LOCATOR.................................................................................................................1106 REPLACEMENT.......................................................................................................................1108 BOOST PRESSURE SENSOR.................................................................................................................1109 COMPONENT LOCATOR.................................................................................................................1109 INSPECTION........................................................................................................................1110 REPLACEMENT.......................................................................................................................1110 AIR FLOW SENSOR.......................................................................................................................1112 COMPONENT LOCATOR.................................................................................................................1112 INSPECTION........................................................................................................................1113 REPLACEMENT.......................................................................................................................1115 ENGINE MECHANICAL.........................................................................................................................1116 HEAD COVER............................................................................................................................1117 COMPONENT LOCATOR.................................................................................................................1117 REPLACEMENT.......................................................................................................................1118 ROCKER ARM ASSEMBLY...................................................................................................................1121 COMPONENT LOCATOR.................................................................................................................1121 OVERHAUL..........................................................................................................................1122 CAMSHAFT ASSEMBLY.....................................................................................................................1129 COMPONENT LOCATOR.................................................................................................................1129 OVERHAUL..........................................................................................................................1131 CYLINDER HEAD ASSEMBLY................................................................................................................1136 COMPONENT LOCATOR.................................................................................................................1136 REPLACEMENT.......................................................................................................................1137 OVERHAUL..........................................................................................................................1145 VALVE SYSTEM..........................................................................................................................1151 COMPONENT LOCATOR.................................................................................................................1151 OVERHAUL..........................................................................................................................1152 CRANKSHAFT PULLEY.....................................................................................................................1161 COMPONENT LOCATOR.................................................................................................................1161 REPLACEMENT.......................................................................................................................1162 CRANKSHAFT FRONT OIL SEAL.............................................................................................................1164 COMPONENT LOCATOR.................................................................................................................1164 REPLACEMENT.......................................................................................................................1165 FRONT OIL SEAL RETAINER...............................................................................................................1168 COMPONENT LOCATOR.................................................................................................................1168 REPLACEMENT.......................................................................................................................1169 FLYWHEEL ASSEMBLY.....................................................................................................................1171 COMPONENT LOCATOR.................................................................................................................1171 OVERHAUL..........................................................................................................................1172 CRANKSHAFT REAR OIL SEAL..............................................................................................................1176 COMPONENT LOCATOR.................................................................................................................1176 REPLACEMENT.......................................................................................................................1177 FLYWHEEL HOUSING......................................................................................................................1180 COMPONENT LOCATOR.................................................................................................................1180 REPLACEMENT.......................................................................................................................1181 TIMING GEAR & CAM IDLE GEAR...........................................................................................................1185 COMPONENT LOCATOR.................................................................................................................1185 CONFIGURATION DIAGRAM.............................................................................................................1186 OVERHAUL..........................................................................................................................1186 PISTON AND CONNECTING ROD.............................................................................................................1199 COMPONENT LOCATOR.................................................................................................................1199 OVERHAUL..........................................................................................................................1200 CRANKSHAFT............................................................................................................................1216 COMPONENT LOCATOR.................................................................................................................1216 REPLACEMENT.......................................................................................................................1218 CYLINDER LINER........................................................................................................................1227 COMPONENT LOCATOR.................................................................................................................1227 REPLACEMENT.......................................................................................................................1228 CYLINDER BLOCK........................................................................................................................1231 COMPONENT LOCATOR.................................................................................................................1231 OVERHAUL..........................................................................................................................1232 ENGINE MOUNTING AND BRACKET...........................................................................................................1240 COMPONENT LOCATOR.................................................................................................................1240 REPLACEMENT.......................................................................................................................1241 GLOW PLUG.............................................................................................................................1243 COMPONENT LOCATOR.................................................................................................................1243 REPLACEMENT.......................................................................................................................1244 GCU...................................................................................................................................1247 COMPONENT LOCATOR.................................................................................................................1247 REPLACEMENT.......................................................................................................................1247 EXHAUST...................................................................................................................................1248 EXHAUST MANIFOLD......................................................................................................................1250 COMPONENT LOCATOR.................................................................................................................1250 REPLACEMENT.......................................................................................................................1251 EXHAUST PIPE..........................................................................................................................1255 COMPONENT LOCATOR.................................................................................................................1255 REPLACEMENT.......................................................................................................................1256 EXHAUST PIPE (ATC)....................................................................................................................1263 COMPONENT LOCATOR.................................................................................................................1263 REPLACEMENT.......................................................................................................................1264 DEF-SCR & DPR.........................................................................................................................1266 CONFIGURATION DIAGRAM.............................................................................................................1266 CAUTIONS ON DEF/COOLANT PIPING ATTACHING AND DETACHING ...........................................................................1267 DEF-SCR...............................................................................................................................1268 COMPONENT LOCATOR.................................................................................................................1268 REPLACEMENT.......................................................................................................................1269 DPR CLEANER...........................................................................................................................1273 COMPONENT LOCATOR.................................................................................................................1273 DPR MAINTENANCE...................................................................................................................1274 DPR INSPECTION....................................................................................................................1274 INSPECTION PROCEDURE FOLLOWED WHEN “EXHAUST GAS AFTER TREATMENT SYSTEM MAINTENANCE REQUIREMENT LIGHT” LIGHT UP....................1275 INSPECTION BY WAY OF HINO DXⅡ.....................................................................................................1276 INSPECTION PROCEDURE FOLLOWED WHEN MALFUNCTION INDICATOR LIGHT ILLUMINATES (ABNORMAL).............................................1280 DETERMINATION BY WAY OF DPR STATE DETERMINATION MONITOR OF HINO DXⅡ...............................................................1283 CHECKING THE DPR STATE............................................................................................................1283 REPLACEMENT.......................................................................................................................1284 OVERALL OPERATION FLOW............................................................................................................1288 AIR CLEANING FLOW.................................................................................................................1295 FUEL ADDITION VALVE...................................................................................................................1296 COMPONENT LOCATOR.................................................................................................................1296 REPLACEMENT.......................................................................................................................1297 FUEL CUTOFF VALVE.....................................................................................................................1305 COMPONENT LOCATOR.................................................................................................................1305 REPLACEMENT.......................................................................................................................1306 DEF PUMP..............................................................................................................................1307 COMPONENT LOCATOR.................................................................................................................1307 REPLACEMENT.......................................................................................................................1308 DEF INJECTOR..........................................................................................................................1316 COMPONENT LOCATOR.................................................................................................................1316 REPLACEMENT.......................................................................................................................1317 DEF TANK..............................................................................................................................1322 COMPONENT LOCATOR.................................................................................................................1322 INSPECTION........................................................................................................................1323 REPLACEMENT.......................................................................................................................1324 DEF SENSOR............................................................................................................................1333 COMPONENT LOCATOR.................................................................................................................1333 REPLACEMENT.......................................................................................................................1334 COOLANT CUTOFF VALVE..................................................................................................................1336 COMPONENT LOCATOR.................................................................................................................1336 REPLACEMENT.......................................................................................................................1337 DCU...................................................................................................................................1339 COMPONENT LOCATOR.................................................................................................................1339 REPLACEMENT.......................................................................................................................1340 DPR DIFFERENTIAL PRESSURE SENSOR......................................................................................................1346 COMPONENT LOCATOR.................................................................................................................1346 REPLACEMENT.......................................................................................................................1347 SCR UPSTREAM NOx SENSOR...............................................................................................................1349 COMPONENT LOCATOR.................................................................................................................1349 REPLACEMENT.......................................................................................................................1350 SCR DOWNSTREAM NOx SENSOR.............................................................................................................1352 COMPONENT LOCATOR.................................................................................................................1352 REPLACEMENT.......................................................................................................................1353 ATC UPSTREAM TEMPERATURE SENSOR.......................................................................................................1355 COMPONENT LOCATOR.................................................................................................................1355 REPLACEMENT.......................................................................................................................1356 DOC UPSTREAM TEMPERATURE SENSOR.......................................................................................................1358 COMPONENT LOCATOR.................................................................................................................1358 REPLACEMENT.......................................................................................................................1359 DPR UPSTREAM TEMPERATURE SENSOR.......................................................................................................1361 COMPONENT LOCATOR.................................................................................................................1361 REPLACEMENT.......................................................................................................................1362 DPR DOWNSTREAM TEMPERATURE SENSOR.....................................................................................................1364 COMPONENT LOCATOR.................................................................................................................1364 REPLACEMENT.......................................................................................................................1365 SCR UPSTREAM TEMPERATURE SENSOR.......................................................................................................1367 COMPONENT LOCATOR.................................................................................................................1367 REPLACEMENT.......................................................................................................................1368 OUTSIDE TEMPERATURE SENSOR............................................................................................................1371 COMPONENT LOCATOR.................................................................................................................1371 REPLACEMENT.......................................................................................................................1372 EXHAUST BRAKE.........................................................................................................................1373 COMPONENT LOCATOR.................................................................................................................1373 REPLACEMENT.......................................................................................................................1374 EXHAUST BRAKE MAGNETIC VALVE..........................................................................................................1377 COMPONENT LOCATOR.................................................................................................................1377 REPLACEMENT.......................................................................................................................1378 COOLING...................................................................................................................................1380 COOLING SYSTEM........................................................................................................................1381 COOLING SYSTEM DIAGRAM............................................................................................................1381 RADIATOR..............................................................................................................................1382 COMPONENT LOCATOR.................................................................................................................1382 INSPECTION........................................................................................................................1383 REPLACEMENT.......................................................................................................................1384 RADIATOR CAP..........................................................................................................................1394 COMPONENT LOCATOR.................................................................................................................1394 REPLACEMENT.......................................................................................................................1395 RESERVE TANK..........................................................................................................................1397 COMPONENT LOCATOR.................................................................................................................1397 REPLACEMENT.......................................................................................................................1398 INTERCOOLER...........................................................................................................................1399 COMPONENT LOCATOR.................................................................................................................1399 OVERHAUL..........................................................................................................................1400 THERMOSTAT CASE AND THERMOSTAT........................................................................................................1402 COMPONENT LOCATOR.................................................................................................................1402 OVERHAUL..........................................................................................................................1403 COOLANT PUMP..........................................................................................................................1409 COMPONENT LOCATOR.................................................................................................................1409 REPLACEMENT.......................................................................................................................1410 COOLING FAN AND FAN CLUTCH............................................................................................................1412 COMPONENT LOCATOR.................................................................................................................1412 OVERHAUL..........................................................................................................................1413 COOLANT TEMPERATURE SENSOR............................................................................................................1416 COMPONENT LOCATOR.................................................................................................................1416 REPLACEMENT.......................................................................................................................1417 LUBRICATION...............................................................................................................................1419 LUBRICATION SYSTEM....................................................................................................................1420 LUBRICATION SYSTEM DIAGRAM........................................................................................................1420 OIL FILTER............................................................................................................................1421 COMPONENT LOCATOR.................................................................................................................1421 REPLACEMENT.......................................................................................................................1422 OIL COOLER............................................................................................................................1424 COMPONENT LOCATOR.................................................................................................................1424 OVERHAUL..........................................................................................................................1425 OIL PUMP..............................................................................................................................1432 COMPONENT LOCATOR.................................................................................................................1432 OVERHAUL..........................................................................................................................1433 OIL PAN...............................................................................................................................1441 COMPONENT LOCATOR.................................................................................................................1441 REPLACEMENT.......................................................................................................................1442 OIL STRAINER..........................................................................................................................1446 COMPONENT LOCATOR.................................................................................................................1446 REPLACEMENT.......................................................................................................................1447 OIL PRESSURE SWITCH...................................................................................................................1448 COMPONENT LOCATOR.................................................................................................................1448 REPLACEMENT.......................................................................................................................1449 OIL LEVEL GAUGE AND GUIDE.............................................................................................................1451 COMPONENT LOCATOR.................................................................................................................1451 REPLACEMENT.......................................................................................................................1452 STARTING/CHARGING.........................................................................................................................1454 STARTER...............................................................................................................................1455 COMPONENT LOCATOR.................................................................................................................1455 REPLACEMENT.......................................................................................................................1456 V-BELT................................................................................................................................1461 COMPONENT LOCATOR.................................................................................................................1461 REPLACEMENT.......................................................................................................................1462 ALTERNATOR (130A).....................................................................................................................1465 COMPONENT LOCATOR.................................................................................................................1465 OVERHAUL..........................................................................................................................1466 TURBOCHARGER..............................................................................................................................1479 TURBOCHARGER ASSEMBLY.................................................................................................................1480 COMPONENT LOCATOR.................................................................................................................1480 INSPECTION........................................................................................................................1481 REPLACEMENT.......................................................................................................................1483 FOREWORD..................................................................................................................................1492 CHAPTER REFERENCES........................................................................................................................1493 INDEX.....................................................................................................................................1494 GENERAL INTRODUCTION......................................................................................................................1495 HOW TO USE THIS MANUAL................................................................................................................1496 GRAPHICAL SYMBOLS FOR WIRING DIAGRAMS, ABBREVIATIONS AND TERMS....................................................................1496 WIRING DIAGRAM....................................................................................................................1501 WIRE TO WIRE CONNECTOR............................................................................................................1502 JUNCTION CONNECTOR................................................................................................................1503 LOCATION..........................................................................................................................1504 RELAY LOCATION / FUSE AND RELAY BLOCK.............................................................................................1505 ABOUT CONNECTOR...................................................................................................................1509 WIRING DIAGRAM ACCORDING TO SYSTEM........................................................................................................1511 WIRING DIAGRAM........................................................................................................................1512 WIRING HARNESS CODE...............................................................................................................1512 AC. POWER SUPPLY CIRCUIT..........................................................................................................1513 AF. GROUND CIRCUIT................................................................................................................1517 AH. CHARGING CIRCUIT..............................................................................................................1519 AK. ENGINE STARTING CIRCUIT.......................................................................................................1521 AN. CAN COMMUNICATION CIRCUIT.....................................................................................................1523 AO. CAN COMMUNICATION CIRCUIT [HV]................................................................................................1525 BG. ENGINE ECU CIRCUIT [J05] 1/2..................................................................................................1529 BH. ENGINE ECU CIRCUIT [J05] 2/2..................................................................................................1533 BI. DEF SCR CIRCUIT...............................................................................................................1541 BJ. HYDRO BOOST SYSTEM CIRCUIT....................................................................................................1543 BN. GLOW PLUG CIRCUIT.............................................................................................................1545 BP. FUEL HEATER CIRCUIT...........................................................................................................1547 CC. AT CIRCUIT [A465].............................................................................................................1549 CE. CLUTCH ECU CIRCUIT............................................................................................................1555 CF. HV PCU CIRCUIT................................................................................................................1559 DA. ABS/PAB+VSC CIRCUIT...........................................................................................................1561 DD. VEHICLE CONTROL ECU CIRCUIT...................................................................................................1563 EC. POWER DOOR LOCK CIRCUIT.......................................................................................................1565 ED. KEYLESS ENTRY CIRCUIT.........................................................................................................1567 EG. POWER WINDOW CIRCUIT [FRONT]..................................................................................................1569 EH. POWER WINDOW CIRCUIT [REAR]...................................................................................................1571 FA. COMBINATION METER CIRCUIT.....................................................................................................1573 FB. PARKING BRAKE WARNING CIRCUIT.................................................................................................1577 FC. WEAR INDICATOR CIRCUIT........................................................................................................1579 FD. HORN RELAY CIRCUIT............................................................................................................1581 FF. DIAGNOSIS MONITOR CIRCUIT.....................................................................................................1583 FJ. RHEOSTAT CIRCUIT..............................................................................................................1585 FK. TELEMATICS CIRCUIT............................................................................................................1587 GA. HEADLIGHT CIRCUIT.............................................................................................................1589 GD. HEADLIGHT SUB CIRCUIT ........................................................................................................1591 GG. TAIL LIGHT CIRCUIT............................................................................................................1593 GH. STOP LIGHT CIRCUIT............................................................................................................1595 GJ. TURN / HAZARD CIRCUIT.........................................................................................................1597 GL. COMBINATION LIGHT CIRCUIT.....................................................................................................1599 HA. ROOM LIGHT CIRCUIT............................................................................................................1601 JA. WIPER AND WASHER CIRCUIT......................................................................................................1603 JD. MIRROR HEATER CIRCUIT.........................................................................................................1605 JE. REMOTE CONTROL MIRROR CIRCUIT.................................................................................................1607 KA. RADIO CIRCUIT.................................................................................................................1609 KB. CIGAR LIGHTER CIRCUIT.........................................................................................................1611 LB. HEATER AND AIR CONDITIONER CIRCUIT............................................................................................1613 LF. REAR HEATER AND AIR CONDITIONER CIRCUIT.......................................................................................1617 MA. OUTLET POWER SUPPLY CIRCUIT...................................................................................................1619 WIRE TO WIRE CONNECTOR....................................................................................................................1621 WIRE TO WIRE CONNECTOR................................................................................................................1622 WIRE TO WIRE CONNECTOR LIST.......................................................................................................1622 JUNCTION CONNECTOR........................................................................................................................1638 JUNCTION CONNECTOR....................................................................................................................1639 JUNCTION CONNECTOR LIST...........................................................................................................1639 LOCATION..................................................................................................................................1655 CONNECTOR LOCATION....................................................................................................................1656 CONTENTS..........................................................................................................................1656 QUICK REFERENCE...................................................................................................................1657 IP-1 [INSTRUMENT PANEL (1 of 6)]..................................................................................................1658 IP-2 [INSTRUMENT PANEL (2 of 6)]..................................................................................................1660 IP-3 [INSTRUMENT PANEL (3 of 6)]..................................................................................................1662 IP-4 [INSTRUMENT PANEL (4 of 6)]..................................................................................................1664 IP-5 [INSTRUMENT PANEL (5 of 6)]..................................................................................................1667 IP-6 [INSTRUMENT PANEL (6 of 6)]..................................................................................................1669 CA-1 [CAB (1 of 2)] (Models: Single cab (Floor / Cowl))...........................................................................1671 CA-2 [CAB (2 of 2)] (Models: Single cab (Roof / Door))............................................................................1673 CA-3 [CAB (1 of 2)] (Models: Crew cab (Floor))....................................................................................1675 CA-4 [CAB (2 of 2)] (Models: Crew cab (Roof / Door))..............................................................................1677 EG-1 [ENGINE (1 of 4)] (Models: J05E Engine)......................................................................................1679 EG-2 [ENGINE (2 of 4)] (Models: J05E Engine)......................................................................................1681 EG-3 [ENGINE (3 of 4)] (Models: J05E Engine)......................................................................................1683 EG-4 [ENGINE (4 of 4)] (Models: J05E Engine)......................................................................................1685 EG-5 [ENGINE] (Models: J05E Engine (Right rear))..................................................................................1687 EG-6 [ENGINE (1 of 4)] (Models: J05E Engine HV)...................................................................................1689 EG-7 [ENGINE (2 of 4)] (Models: J05E Engine HV)...................................................................................1691 EG-8 [ENGINE (3 of 4)] (Models: J05E Engine HV)...................................................................................1693 EG-9 [ENGINE (4 of 4)] (Models: J05E Engine HV)...................................................................................1695 EG-10 [ENGINE] (Models: J05E Engine HV (Right rear))..............................................................................1697 RR-1 [REAR] (Models: Except HV)...................................................................................................1699 RR-2 [REAR] (Models: HV)..........................................................................................................1701 RELAY LOCATION/FUSE AND RELAY BLOCK.......................................................................................................1703 RELAY LOCATION........................................................................................................................1704 INSTRUMENT PANEL..................................................................................................................1704 CHASSIS...........................................................................................................................1705 FUSE AND RELAY BLOCK..................................................................................................................1706 CHASSIS RELAY BLOCK...............................................................................................................1706 CAB RELAY.........................................................................................................................1709 RELAY BLOCK No.2..................................................................................................................1710 JUNCTION BLOCK........................................................................................................................1711 JUNCTION BLOCK....................................................................................................................1711 WIRE TO WIRE BOX......................................................................................................................1713 WIRE TO WIRE ALIGNMENT............................................................................................................1713 INDEX.....................................................................................................................................1714 CONNECTOR INDEX.......................................................................................................................1715 ELECTRICAL EQUIPMENT CONNECTOR....................................................................................................1715 WIRE TO WIRE CONNECTOR............................................................................................................1731 JUNCTION CONNECTOR................................................................................................................1734 FOREWORD..................................................................................................................................1738 CHAPTER REFERENCES........................................................................................................................1739 INDEX.....................................................................................................................................1740 GENERAL INTRODUCTION......................................................................................................................1742 HOW TO IDENTIFY VEHICLE TYPE..........................................................................................................1743 HOW TO IDENTIFY VEHICLE TYPE......................................................................................................1743 VEHICLE TYPE .................................................................................................................1743 VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE.................................................................................1744 APPEARANCE OF VEHICLE.................................................................................................................1745 APPEARANCE........................................................................................................................1745 APPEARANCE OF VEHICLE.........................................................................................................1745 SAFETY INSTRUCTIONS AND READINESS TO WORK.............................................................................................1746 WARNING...........................................................................................................................1746 GENERAL PRECAUTIONS...........................................................................................................1746 IDENTIFICATION INFORMATION....................................................................................................1751 SAFETY INSTRUCTIONS FOR WORK......................................................................................................1754 PRECAUTIONS...................................................................................................................1754 INTRODUCTION TO WORKSHOP MANUAL...................................................................................................1758 GENERAL.......................................................................................................................1758 INTRODUCTION TO DESCRIPTIONS..................................................................................................1759 DEFINITION OF TERM............................................................................................................1762 TROUBLE SHOOTING......................................................................................................................1763 TROUBLESHOOTING WITH DIAGNOSIS MONITOR............................................................................................1763 TROUBLESHOOTING PROCEDURE.....................................................................................................1763 APPARATUS FOR TROUBLE SHOOTING................................................................................................1765 TROUBLE DIAGNOSIS USING THE COMPUTER (HINO DXⅡ)...................................................................................1766 STEP OF TROUBLE DIAGNOSIS.....................................................................................................1766 APPARATUS FOR TROUBLE DIAGNOSIS...............................................................................................1767 GLOSSARY..............................................................................................................................1768 DEFINITION OF ABBREVIATION........................................................................................................1768 LIST OF ABBREVIATION..........................................................................................................1768 GLOSSARY OF SAE AND HINO TERMS................................................................................................1771 ENGINE (J05E).............................................................................................................................1774 TROUBLESHOOTING.......................................................................................................................1777 ENGINE ECU (J05E).................................................................................................................1777 PRECAUTIONS FOR DIAGNOSIS.....................................................................................................1777 ELECTRICAL....................................................................................................................1779 PRECAUTIONS...................................................................................................................1780 COMPUTER (ECU) PIN ASSIGNMENT.................................................................................................1784 ENGINE ECU CONNECTOR..........................................................................................................1788 INSPECTION....................................................................................................................1792 TROUBLE DIAGNOSIS USING THE COMPUTER (HINO DXⅡ)...............................................................................1793 DIAGNOSTIC TROUBLE CODE (DTC) TABLE...........................................................................................1794 GROUP SHARING THE SENSOR SUPPLY TERMINAL......................................................................................1816 GROUP SHARING THE SENSOR GND TERMINAL.........................................................................................1817 MALFUNCTION CODES IN CASE OF DISRUPTION OF CAN COMMUNICATION..................................................................1818 PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (250 k)......................................................................1821 DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (250 k) [DIESEL]...............................................1826 DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (250 k) [HYBRID]...............................................1835 PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (500 k) [DIESEL]............................................................1845 PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (500 k) [HYBRID]............................................................1850 DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (500 k) [DIESEL]...............................................1856 DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (500 k) [HYBRID]...............................................1861 MALFUNCTION CODES FOR FAULTY ACTUATOR POWER RELAY.............................................................................1866 ENG BASIC INSPECTION SHEET (ENGINE INSPECTION CHECK SHEET)....................................................................1867 NO DTC........................................................................................................................1871 INSPECTION PROCEDURE FOR WHEN THE DEF MIXED INTO THE ENGINE COOLANT...........................................................1875 DTC: P0005....................................................................................................................1877 DTC: P0006 and P0007..........................................................................................................1881 DTC: P0016....................................................................................................................1886 DTC: P0027....................................................................................................................1889 DTC: P003A....................................................................................................................1894 DTC: P0045....................................................................................................................1899 DTC: P0047....................................................................................................................1903 DTC: P0048....................................................................................................................1907 DTC: P006E....................................................................................................................1911 DTC: P006F....................................................................................................................1915 DTC: P007B....................................................................................................................1919 DTC: P007C and P007D..........................................................................................................1933 DTC: P0088....................................................................................................................1941 DTC: P0096....................................................................................................................1949 DTC: P0097 and P0098 .........................................................................................................1960 DTC: P00AF....................................................................................................................1968 DTC: P0101....................................................................................................................1972 DTC: P0104....................................................................................................................1981 DTC: P0106....................................................................................................................1988 DTC: P0108....................................................................................................................1994 DTC: P0112 and P0113..........................................................................................................2000 DTC: P0115....................................................................................................................2008 DTC: P0117 and P0118..........................................................................................................2017 DTC: P011A....................................................................................................................2025 DTC: P011C....................................................................................................................2034 DTC: P0122 and P0123..........................................................................................................2040 DTC: P0128....................................................................................................................2049 DTC: P0148 ...................................................................................................................2055 DTC: P016E and P016F .........................................................................................................2067 DTC: P0182 and P0183 .........................................................................................................2077 DTC: P0191....................................................................................................................2085 DTC: P0192 and P0193 .........................................................................................................2094 DTC: P01A5....................................................................................................................2104 DTC: P01A6....................................................................................................................2111 DTC: P0200....................................................................................................................2118 DTC: P0201, P0202, P0203 and P0204............................................................................................2121 DTC: P0217....................................................................................................................2126 DTC: P0219....................................................................................................................2131 DTC: P0222 and P0223..........................................................................................................2139 DTC: P0234....................................................................................................................2149 DTC: P0237....................................................................................................................2155 DTC: P0263, P0266, P0269 and P0272............................................................................................2161 DTC: P026C and P026D..........................................................................................................2172 DTC: P0299....................................................................................................................2185 DTC: P0300....................................................................................................................2191 DTC: P0301, P0302, P0303 and P0304............................................................................................2199 DTC: P0335....................................................................................................................2208 DTC: P0336....................................................................................................................2215 DTC: P0340....................................................................................................................2222 DTC: P0341....................................................................................................................2226 DTC: P0381....................................................................................................................2234 DTC: P0401....................................................................................................................2240 DTC: P0402....................................................................................................................2256 DTC: P0404....................................................................................................................2267 DTC: P0405 and P0406..........................................................................................................2272 DTC: P041B....................................................................................................................2278 DTC: P041C and P041D..........................................................................................................2291 DTC: P0420....................................................................................................................2299 DTC: P0421....................................................................................................................2301 DTC: P0422....................................................................................................................2304 DTC: P0489 and P0490..........................................................................................................2307 DTC: P049D....................................................................................................................2313 DTC: P04D5 and P04D6..........................................................................................................2318 DTC: P04DA....................................................................................................................2326 DTC: P0500 and P0501..........................................................................................................2336 DTC: P0504....................................................................................................................2343 DTC: P0506....................................................................................................................2348 DTC: P0507....................................................................................................................2352 DTC: P0521....................................................................................................................2356 DTC: P0524....................................................................................................................2360 DTC: P0545 and P0546..........................................................................................................2365 DTC: P054E....................................................................................................................2373 DTC: P054F....................................................................................................................2377 DTC: P0562 and P0563..........................................................................................................2381 DTC: P05F1....................................................................................................................2386 DTC: P0605....................................................................................................................2394 DTC: P0606....................................................................................................................2396 DTC: P0607....................................................................................................................2398 DTC: P0610....................................................................................................................2400 DTC: P0611....................................................................................................................2403 DTC: P0617....................................................................................................................2405 DTC: P0628 and P0629..........................................................................................................2409 DTC: P062F....................................................................................................................2417 DTC: P0630....................................................................................................................2421 DTC: P0642....................................................................................................................2425 DTC: P0643....................................................................................................................2431 DTC: P064C....................................................................................................................2439 DTC: P0652....................................................................................................................2444 DTC: P0653....................................................................................................................2450 DTC: P0671 and P0672 .........................................................................................................2457 DTC: P0673 and P0674..........................................................................................................2463 DTC: P0683....................................................................................................................2469 DTC: P0686....................................................................................................................2475 DTC: P06D3 and P06D4..........................................................................................................2480 DTC: P073D....................................................................................................................2489 DTC: P081A....................................................................................................................2493 DTC: P081B....................................................................................................................2499 DTC: P0A7B....................................................................................................................2503 DTC: P0AC4....................................................................................................................2505 DTC: P0CA1....................................................................................................................2507 DTC: P1133....................................................................................................................2509 DTC: P119F....................................................................................................................2515 DTC: P1426....................................................................................................................2521 DTC: P1427....................................................................................................................2528 DTC: P1428....................................................................................................................2535 DTC: P1458....................................................................................................................2543 DTC: P1459....................................................................................................................2548 DTC: P14B0....................................................................................................................2553 DTC: P14B2....................................................................................................................2557 DTC: P14B3 and P14B4..........................................................................................................2561 DTC: P14B7 and P14B8..........................................................................................................2567 DTC: P14BC and P14BD..........................................................................................................2573 DTC: P14BF....................................................................................................................2579 DTC: P1515....................................................................................................................2584 DTC: P1530....................................................................................................................2589 DTC: P1601....................................................................................................................2593 FOREWORD..................................................................................................................................2598 CHAPTER REFERENCES........................................................................................................................2599 INDEX.....................................................................................................................................2600 ENGINE (J05E).............................................................................................................................2602 TROUBLESHOOTING.......................................................................................................................2605 ENGINE ECU (J05E).................................................................................................................2605 DTC: P200C....................................................................................................................2605 DTC: P2032 and P2033..........................................................................................................2614 DTC: P203F....................................................................................................................2622 DTC: P204F....................................................................................................................2626 DTC: P207F....................................................................................................................2629 DTC: P2080....................................................................................................................2637 DTC: P2084....................................................................................................................2645 DTC: P20CD....................................................................................................................2653 DTC: P20CE....................................................................................................................2657 DTC: P20CF....................................................................................................................2660 DTC: P20D8....................................................................................................................2663 DTC: P20DE....................................................................................................................2669 DTC: P20DF....................................................................................................................2673 DTC: P20E0....................................................................................................................2679 DTC: P20EE....................................................................................................................2685 DTC: P2100....................................................................................................................2693 DTC: P2101....................................................................................................................2698 DTC: P2103....................................................................................................................2705 DTC: P2120....................................................................................................................2710 DTC: P2122 and P2123..........................................................................................................2714 DTC: P2127 and P2128..........................................................................................................2723 DTC: P2135....................................................................................................................2731 DTC: P2138....................................................................................................................2736 DTC: P2146....................................................................................................................2741 DTC: P2147 and P2148..........................................................................................................2748 DTC: P2149....................................................................................................................2756 DTC: P2150 and P2151..........................................................................................................2763 DTC: P2184 and P2185..........................................................................................................2771 DTC: P2214....................................................................................................................2779 DTC: P2227....................................................................................................................2790 DTC: P2228 and P2229..........................................................................................................2794 DTC: P2269....................................................................................................................2799 DTC: P226C....................................................................................................................2804 DTC: P22D3....................................................................................................................2810 DTC: P240F....................................................................................................................2814 DTC: P2428....................................................................................................................2824 DTC: P242B....................................................................................................................2828 DTC: P242C and P242D..........................................................................................................2836 DTC: P244A....................................................................................................................2844 DTC: P244B....................................................................................................................2864 DTC: P2457....................................................................................................................2881 DTC: P2458....................................................................................................................2896 DTC: P2459....................................................................................................................2906 DTC: P2463....................................................................................................................2909 DTC: P246F....................................................................................................................2917 DTC: P2470 and P2471..........................................................................................................2925 DTC: P24A0....................................................................................................................2933 DTC: P24A1....................................................................................................................2936 DTC: P24A2....................................................................................................................2938 DTC: P2562....................................................................................................................2947 DTC: P259E....................................................................................................................2951 DTC: P259F....................................................................................................................2957 DTC: P2635....................................................................................................................2962 DTC: P268A and P2696..........................................................................................................2971 DTC: P26C8....................................................................................................................2977 DTC: P2BA9....................................................................................................................2979 DTC: U0073....................................................................................................................2984 DTC: U010A....................................................................................................................2987 DTC: U010C....................................................................................................................2993 DTC: U010E....................................................................................................................2999 DTC: U0293....................................................................................................................3005 DTC: U029D (DIESEL)...........................................................................................................3010 DTC: U029D (HYBRID)...........................................................................................................3016 DTC: U029E (DIESEL)...........................................................................................................3022 DTC: U029E (HYBRID)...........................................................................................................3028 DTC: U02A2....................................................................................................................3034 DTC: U0301....................................................................................................................3040 DTC: U1001....................................................................................................................3043 DTC: U110A....................................................................................................................3050 ENGINE (COMMON ITEMS).....................................................................................................................3057 TROUBLESHOOTING.......................................................................................................................3059 DCU...............................................................................................................................3059 PRECAUTIONS FOR DIAGNOSIS.....................................................................................................3059 DIAGRAM.......................................................................................................................3061 SIGNAL CHECK HARNESS..........................................................................................................3062 INSPECTION....................................................................................................................3062 TROUBLE DIAGNOSIS USING THE COMPUTER (HINO DXⅡ)...............................................................................3064 DTC: P0071....................................................................................................................3072 DTC: P0072....................................................................................................................3082 DTC: P0073....................................................................................................................3088 DTC: P0562....................................................................................................................3094 DTC: P0563....................................................................................................................3098 DTC: P060C....................................................................................................................3102 DTC: P062F....................................................................................................................3104 DTC: P0667....................................................................................................................3106 DTC: P0668....................................................................................................................3108 DTC: P0669....................................................................................................................3110 DTC: P068A....................................................................................................................3112 DTC: P142A....................................................................................................................3117 DTC: P142B....................................................................................................................3128 DTC: P202E....................................................................................................................3139 DTC: P203C....................................................................................................................3143 DTC: P203D....................................................................................................................3146 DTC: P2044....................................................................................................................3149 DTC: P2045....................................................................................................................3152 DTC: P2047....................................................................................................................3155 DTC: P2048....................................................................................................................3158 DTC: P2049....................................................................................................................3163 DTC: P204B....................................................................................................................3168 DTC: P204C....................................................................................................................3171 DTC: P204D....................................................................................................................3176 DTC: P205B....................................................................................................................3181 DTC: P205C....................................................................................................................3190 DTC: P205D....................................................................................................................3193 DTC: P206A....................................................................................................................3196 DTC: P208A....................................................................................................................3199 DTC: P208B....................................................................................................................3205 DTC: P208C....................................................................................................................3208 DTC: P208D....................................................................................................................3213 DTC: P20A0....................................................................................................................3218 DTC: P20A1....................................................................................................................3223 DTC: P20A2....................................................................................................................3227 DTC: P20A3....................................................................................................................3232 DTC: P20B1....................................................................................................................3237 DTC: P20B2....................................................................................................................3242 DTC: P20B3....................................................................................................................3252 DTC: P20B4....................................................................................................................3257 DTC: P20BD, P20B9 and P20C1...................................................................................................3262 DTC: P20C0, P20BC and P20C4...................................................................................................3269 DTC: P20FC....................................................................................................................3275 DTC: P20FD....................................................................................................................3279 DTC: P20FE....................................................................................................................3284 DTC: P20E8....................................................................................................................3289 DTC: P20E9....................................................................................................................3300 DTC: P20F4....................................................................................................................3306 DTC: P2201....................................................................................................................3310 DTC: P2202....................................................................................................................3317 DTC: P2203....................................................................................................................3320 DTC: P2204....................................................................................................................3323 DTC: P2209....................................................................................................................3330 DTC: P2212....................................................................................................................3338 DTC: P2215....................................................................................................................3345 DTC: P2216....................................................................................................................3348 DTC: P2222....................................................................................................................3351 DTC: P2481....................................................................................................................3359 DTC: P2482....................................................................................................................3364 DTC: P2483....................................................................................................................3369 DTC: P2510....................................................................................................................3382 DTC: P2BAE....................................................................................................................3387 DTC: U0029....................................................................................................................3394 DTC: U0038....................................................................................................................3400 DTC: U0100....................................................................................................................3406 DTC: U029D (DIESEL)...........................................................................................................3410 DTC: U029D (HYBRID)...........................................................................................................3416 DTC: U029E (DIESEL)...........................................................................................................3422 DTC: U029E (HYBRID)...........................................................................................................3428 DTC: U02A2....................................................................................................................3434 DTC: U0597....................................................................................................................3441 FOREWORD..................................................................................................................................3445 CHAPTER REFERENCES........................................................................................................................3446 INDEX.....................................................................................................................................3447 ENGINE (COMMON ITEMS).....................................................................................................................3449 TROUBLESHOOTING.......................................................................................................................3451 VEHICLE CONTROL ECU...............................................................................................................3451 CAUTIONS ON TROUBLESHOOTING...................................................................................................3451 SYSTEM BLOCK DIAGRAM..........................................................................................................3452 COMPUTER PIN ASSIGNMENT.......................................................................................................3453 TROUBLESHOOTING WITH COMPUTER (HINO DXⅡ)......................................................................................3457 DIAGNOSIS CODE TABLE..........................................................................................................3458 DTC: C1244....................................................................................................................3460 DTC: C1245....................................................................................................................3465 DTC: C1249....................................................................................................................3467 DTC: C1418....................................................................................................................3473 DTC: C1491....................................................................................................................3477 DTC: P0335....................................................................................................................3479 DTC: P0501....................................................................................................................3482 DTC: P0503....................................................................................................................3488 DTC: P0555....................................................................................................................3493 DTC: P0562....................................................................................................................3495 DTC: P0563....................................................................................................................3499 DTC: P0572....................................................................................................................3502 DTC: P0573....................................................................................................................3509 DTC: P0577....................................................................................................................3515 DTC: P05BF....................................................................................................................3519 DTC: P0604....................................................................................................................3522 DTC: P0605 ...................................................................................................................3524 DTC: P0605 ...................................................................................................................3526 DTC: P0606....................................................................................................................3528 DTC: P0617....................................................................................................................3530 DTC: P062F....................................................................................................................3533 DTC: P0702....................................................................................................................3535 DTC: P081D....................................................................................................................3537 DTC: P1143....................................................................................................................3542 DTC: P161F....................................................................................................................3546 DTC: P1649....................................................................................................................3549 DTC: P165A....................................................................................................................3553 DTC: P165B....................................................................................................................3556 DTC: P2525....................................................................................................................3559 DTC: P2526....................................................................................................................3562 DTC: P258D....................................................................................................................3565 DTC: U0101....................................................................................................................3568 DTC: U0105....................................................................................................................3571 DTC: U0121....................................................................................................................3574 DTC: U0155....................................................................................................................3577 DTC: U0293....................................................................................................................3580 DTC: U0418....................................................................................................................3583 DTC: U1136....................................................................................................................3586 HYBRID....................................................................................................................................3589 TROUBLE SHOOTING......................................................................................................................3592 HYBRID CONTROL SYSTEM.............................................................................................................3592 TROUBLE SHOOTING STEPS FOR HYBRID SYSTEM......................................................................................3592 SAFETY MEASURES FOR HIGH-VOLTAGE WORK.........................................................................................3600 LIST OF CONNECTOR SYMBOLS.....................................................................................................3603 HV SYSTEM WIRING DIAGRAM......................................................................................................3607 HEARING SHEET.................................................................................................................3609 HYBRID ECU........................................................................................................................3610 DIAGNOSIS CODE TABLE..........................................................................................................3610 FREEZE FRAME DATA LIST........................................................................................................3618 LIST OF DATA MONITOR ITEMS....................................................................................................3621 COMMON INSPECTION CHART.......................................................................................................3624 DTC: C0081 (TCA0).............................................................................................................3629 DTC: P0500 (TC51).............................................................................................................3631 DTC: P0501 (TC5B).............................................................................................................3638 DTC: P0562 (TC71).............................................................................................................3642 DTC: P060B (TCB2).............................................................................................................3648 DTC: P0617 (TC59).............................................................................................................3650 DTC: P062F (TCB3).............................................................................................................3656 DTC: P0810 (TC9C).............................................................................................................3658 DTC: P0810 (TC9D).............................................................................................................3661 DTC: P0A01 (TC7B).............................................................................................................3664 DTC: P0A02 (TC78).............................................................................................................3670 DTC: P0A03 (TC79).............................................................................................................3676 DTC: P0A06 (TC7F).............................................................................................................3681 DTC: P0A07 (TC7E).............................................................................................................3689 DTC: P0A0F (TC31) ............................................................................................................3692 DTC: P0A1D (TC12).............................................................................................................3695 DTC: P0A1D (TC17).............................................................................................................3697 DTC: P0A78 (TC21).............................................................................................................3699 DTC: P0A78 (TC22).............................................................................................................3701 DTC: P0A7E (TC48).............................................................................................................3703 DTC: P0A82 (TC67).............................................................................................................3707 DTC: P0A84 (TC66).............................................................................................................3716 DTC: P0A85 (TC65).............................................................................................................3724 DTC: P0A90 (TC2A).............................................................................................................3728 DTC: P0A92 (TC29).............................................................................................................3736 DTC: P0A93 (TC7A).............................................................................................................3745 DTC: P0AFD (TC6B).............................................................................................................3750 DTC: P0BCA (TC68).............................................................................................................3753 DTC: P0C73 (TC80).............................................................................................................3757 DTC: P3000 (TC42).............................................................................................................3762 DTC: P3001 (TC41).............................................................................................................3768 DTC: P3001 (TC43).............................................................................................................3770 DTC: P3001 (TC44).............................................................................................................3772 DTC: P3001 (TC45).............................................................................................................3774 DTC: P3001 (TC46).............................................................................................................3776 DTC: P3001 (TC47).............................................................................................................3779 DTC: P3001 (TC4A).............................................................................................................3782 DTC: P3001 (TC4B).............................................................................................................3785 DTC: P3001 (TC4C).............................................................................................................3787 DTC: P3009 (TC49).............................................................................................................3789 DTC: P3128 (TC7D).............................................................................................................3799 DTC: P3129 (TC7C).............................................................................................................3807 DTC: P314C (TC82).............................................................................................................3811 DTC: P314D (TC81).............................................................................................................3815 DTC: P324B (TC62).............................................................................................................3823 DTC: P324C (TC61).............................................................................................................3827 DTC: P33B1 (TC64).............................................................................................................3832 DTC: P33B2 (TC63).............................................................................................................3836 DTC: U0073 (TC11).............................................................................................................3840 DTC: U0074 (TC16).............................................................................................................3844 DTC: U0100 (TC13).............................................................................................................3847 DTC: U0101 (TC18).............................................................................................................3850 DTC: U0110 (TC14).............................................................................................................3855 DTC: U0111 (TC15).............................................................................................................3861 DTC: U0121 (TC24).............................................................................................................3867 DTC: U0155 (TC25).............................................................................................................3872 DTC: U110A (TC26).............................................................................................................3877 DTC: U1136 (TC27).............................................................................................................3882 INVERTER..........................................................................................................................3887 DIAGNOSIS CODE TABLE..........................................................................................................3887 FREEZE FRAME DATA LIST........................................................................................................3893 DATA MONITOR ITEM LIST........................................................................................................3895 CONNECTION DIAGRAM............................................................................................................3898 INSULATION RESISTANCE MEASUREMENT PROCEDURE FOR HYBRID MOTOR [ROTATION MACHINE]...............................................3899 DTC: P0562 (TC96) ............................................................................................................3901 DTC: P0562 (TCA0) ............................................................................................................3908 DTC: P0604 (TC18) ............................................................................................................3915 DTC: P0604 (TCD2).............................................................................................................3917 DTC: P0605 (TC17) ............................................................................................................3919 DTC: P0605 (TCD1) ............................................................................................................3921 DTC: P060B (TC1A).............................................................................................................3923 DTC: P060C (TC1C).............................................................................................................3926 DTC: P062F (TC41).............................................................................................................3928 DTC: P0A0D (TC20).............................................................................................................3930 DTC: P0A1B (TC16).............................................................................................................3935 DTC: P0A1B (TC92).............................................................................................................3940 DTC: P0A1B (TC97).............................................................................................................3942 DTC: P0A1B (TC3F).............................................................................................................3944 DTC: P0A1B (TCA1).............................................................................................................3946 DTC: P0A1B (TCA2).............................................................................................................3948 DTC: P0A1B (TCA3).............................................................................................................3950 DTC: P0A1B (TCA4).............................................................................................................3952 DTC: P0A1B (TCA5).............................................................................................................3954 DTC: P0A1B (TCA6).............................................................................................................3956 DTC: P0A1B (TCA7).............................................................................................................3958 DTC: P0A1B (TCA8) ............................................................................................................3960 DTC: P0A1B (TCA9).............................................................................................................3962 DTC: P0A1B (TCAA).............................................................................................................3964 DTC: P0A1B (TCBB).............................................................................................................3968 DTC: P0A1B (TCBC).............................................................................................................3970 DTC: P0A1B (TCBD).............................................................................................................3972 DTC: P0A1B (TCBE).............................................................................................................3974 DTC: P0A1B (TCBF).............................................................................................................3976 DTC: P0A1B (TCD3).............................................................................................................3978 DTC: P0A1B (TCD4).............................................................................................................3980 DTC: P0A1B (TCD5).............................................................................................................3982 DTC: P0A1D (TC21).............................................................................................................3984 DTC: P0A2B (TCE9).............................................................................................................3987 DTC: P0A2B (TCED).............................................................................................................3994 DTC: P0A2C (TCDA).............................................................................................................4001 DTC: P0A2D (TCDB).............................................................................................................4007 DTC: P0A2F (TC33) ............................................................................................................4014 DTC: P0A3C (TC34).............................................................................................................4017 DTC: P0A3F (TCB7).............................................................................................................4030 DTC: P0A41 (TCC0).............................................................................................................4036 DTC: P0A42 (TCC1).............................................................................................................4044 DTC: P0A51 (TCD6).............................................................................................................4052 DTC: P0A51 (TCD7).............................................................................................................4054 DTC: P0A78 (TC13).............................................................................................................4056 DTC: P0A78 (TC14).............................................................................................................4064 DTC: P0A78 (TC15).............................................................................................................4076 DTC: P0AA1 (TCD8).............................................................................................................4081 DTC: P0AA4 (TCD9).............................................................................................................4086 DTC: P0ADB (TC1F).............................................................................................................4092 DTC: P0ADC (TC93).............................................................................................................4097 DTC: P0ADF (TC1E).............................................................................................................4103 DTC: P0AE0 (TC95).............................................................................................................4108 DTC: P0AE6 (TC1D).............................................................................................................4114 DTC: P0AE7 (TC94).............................................................................................................4119 DTC: P0AEE (TC22).............................................................................................................4125 DTC: P0AEE (TC23).............................................................................................................4127 DTC: P0AEF (TC24).............................................................................................................4129 DTC: P0AF0 (TC25).............................................................................................................4132 DTC: P0BEA (TCB3).............................................................................................................4135 DTC: P0BEA (TCB4).............................................................................................................4137 DTC: P0BEB (TC9A).............................................................................................................4139 DTC: P0BEC (TC9B).............................................................................................................4141 DTC: P0BEE (TCB5).............................................................................................................4143 DTC: P0BEE (TCB6).............................................................................................................4145 DTC: P0BEF (TC9C).............................................................................................................4147 DTC: P0BF0 (TC9D).............................................................................................................4149 DTC: P3126 (TC12).............................................................................................................4151 DTC: U0073 (TC91).............................................................................................................4159 DTC: U0074 (TC3E).............................................................................................................4163 DTC: U0293 (TC31).............................................................................................................4166 FOREWORD..................................................................................................................................4174 CHAPTER REFERENCES........................................................................................................................4175 INDEX.....................................................................................................................................4176 HYBRID....................................................................................................................................4178 TROUBLE SHOOTING......................................................................................................................4181 BATTERY ECU.......................................................................................................................4181 DIAGNOSIS CODE TABLE..........................................................................................................4181 LIST OF FREEZE FRAME DATA.....................................................................................................4184 LIST OF DATA MONITOR ITEMS....................................................................................................4186 CONNECTION DIAGRAM............................................................................................................4189 DTC: P0562....................................................................................................................4190 DTC: P0604....................................................................................................................4194 DTC: P0605....................................................................................................................4196 DTC: P060B....................................................................................................................4198 DTC: P062F....................................................................................................................4200 DTC: P0A1F....................................................................................................................4202 DTC: P0A7D....................................................................................................................4204 DTC: P0A7F....................................................................................................................4207 DTC: P0A80....................................................................................................................4211 DTC: P0A95....................................................................................................................4215 DTC: P0A9D....................................................................................................................4219 DTC: P0A9E....................................................................................................................4222 DTC: P0AAE....................................................................................................................4225 DTC: P0AAF....................................................................................................................4228 DTC: P0ABF....................................................................................................................4231 DTC: P0AC0....................................................................................................................4236 DTC: P0AC1....................................................................................................................4241 DTC: P0AC2....................................................................................................................4246 DTC: P0AC7....................................................................................................................4251 DTC: P0AC8....................................................................................................................4254 DTC: P0ACC....................................................................................................................4257 DTC: P0ACD....................................................................................................................4260 DTC: P0AEA....................................................................................................................4263 DTC: P0AEB....................................................................................................................4266 DTC: P0AFC....................................................................................................................4269 DTC: P0B25....................................................................................................................4271 DTC: P0B3D....................................................................................................................4274 DTC: P0B42....................................................................................................................4278 DTC: P0B47....................................................................................................................4282 DTC: P0B4C....................................................................................................................4286 DTC: P0B51....................................................................................................................4290 DTC: P0B56....................................................................................................................4294 DTC: P0B5B....................................................................................................................4298 DTC: P0B60....................................................................................................................4302 DTC: P0B65....................................................................................................................4306 DTC: P0B6A....................................................................................................................4310 DTC: P0B6F....................................................................................................................4314 DTC: P0B74....................................................................................................................4318 DTC: P0B79....................................................................................................................4322 DTC: P0B7E....................................................................................................................4326 DTC: P0B83....................................................................................................................4330 DTC: P0B88....................................................................................................................4334 DTC: P0B8D....................................................................................................................4338 DTC: P0B92....................................................................................................................4342 DTC: P0B97....................................................................................................................4346 DTC: P0B9C....................................................................................................................4350 DTC: P0BA1....................................................................................................................4354 DTC: P0C30....................................................................................................................4358 DTC: P3004....................................................................................................................4362 DTC: P3011....................................................................................................................4364 DTC: P3012....................................................................................................................4368 DTC: P3013....................................................................................................................4372 DTC: P3014....................................................................................................................4376 DTC: P3015....................................................................................................................4380 DTC: P3016....................................................................................................................4384 DTC: P3017....................................................................................................................4388 DTC: P3018....................................................................................................................4392 DTC: P3019....................................................................................................................4396 DTC: P301B....................................................................................................................4400 DTC: P3020....................................................................................................................4402 DTC: P3021....................................................................................................................4406 DTC: P3022....................................................................................................................4410 DTC: P3023....................................................................................................................4414 DTC: P3024....................................................................................................................4418 DTC: P3025....................................................................................................................4422 DTC: P3026....................................................................................................................4426 DTC: P3027....................................................................................................................4430 DTC: P3028....................................................................................................................4434 DTC: P3029....................................................................................................................4438 DTC: P302F....................................................................................................................4442 DTC: P3065....................................................................................................................4446 DTC: P308A....................................................................................................................4450 DTC: U0074....................................................................................................................4454 DTC: U0293....................................................................................................................4457 TRANSMISSION..............................................................................................................................4461 TROUBLESHOOTING.......................................................................................................................4463 TROUBLE SHOOTING BY TRANSMISSION SYMPTOM..........................................................................................4463 AUTOMATIC TRANSMISSION........................................................................................................4463 TROUBLESHOOTING.......................................................................................................................4465 AUTOMATIC TRANSMISSION............................................................................................................4465 PRECAUTIONS FOR DIAGNOSIS.....................................................................................................4465 AT LEARNED VALUE INITIALIZATION...............................................................................................4466 INSPECTING/CLEARING DIAGNOSIS CODES...........................................................................................4470 SYSTEM BLOCK DIAGRAM..........................................................................................................4473 COMPUTER PIN ASSIGNMENT.......................................................................................................4474 DIAGNOSIS CODE TABLE..........................................................................................................4477 DTC: P0500/DIAGNOSIS MONITOR CODE: 42.........................................................................................4479 DTC: P0562/DIAGNOSIS MONITOR CODE: 11.........................................................................................4485 DTC: P0705/DIAGNOSIS MONITOR CODE: 43.........................................................................................4488 DTC: P0706/DIAGNOSIS MONITOR CODE: 44.........................................................................................4494 DTC: P0710/DIAGNOSIS MONITOR CODE: 38.........................................................................................4498 DTC: P0715/DIAGNOSIS MONITOR CODE: 12.........................................................................................4502 DTC: P0720/DIAGNOSIS MONITOR CODE: 61.........................................................................................4507 DTC: P0725/DIAGNOSIS MONITOR CODE: 86.........................................................................................4513 DTC: P0730/DIAGNOSIS MONITOR CODE: 37.........................................................................................4518 DTC: P0746/DIAGNOSIS MONITOR CODE: 31.........................................................................................4526 DTC: P0748/DIAGNOSIS MONITOR CODE: 25.........................................................................................4531 DTC: P0751/DIAGNOSIS MONITOR CODE: 45.........................................................................................4535 DTC: P0756/DIAGNOSIS MONITOR CODE: 46.........................................................................................4540 DTC: P0761/DIAGNOSIS MONITOR CODE: 47, 48.....................................................................................4545 DTC: P0776/DIAGNOSIS MONITOR CODE: 32.........................................................................................4550 DTC: P0778/DIAGNOSIS MONITOR CODE: 26.........................................................................................4555 DTC: P0810/DIAGNOSIS MONITOR CODE: 88.........................................................................................4559 DTC: P0973/DIAGNOSIS MONITOR CODE: 62.........................................................................................4563 DTC: P0974/DIAGNOSIS MONITOR CODE: 62.........................................................................................4567 DTC: P0976/DIAGNOSIS MONITOR CODE: 63.........................................................................................4571 DTC: P0977/DIAGNOSIS MONITOR CODE: 63.........................................................................................4575 DTC: P0979/DIAGNOSIS MONITOR CODE: 64.........................................................................................4579 DTC: P0980/DIAGNOSIS MONITOR CODE: 64.........................................................................................4583 DTC: P0985/DIAGNOSIS MONITOR CODE: 65.........................................................................................4587 DTC: P0986/DIAGNOSIS MONITOR CODE: 65.........................................................................................4591 DTC: P0A40/DIAGNOSIS MONITOR CODE: 88.........................................................................................4595 DTC: P1604/DIAGNOSIS MONITOR CODE: 24.........................................................................................4599 DTC: P1604/DIAGNOSIS MONITOR CODE: 54.........................................................................................4603 DTC: P2545/DIAGNOSIS MONITOR CODE: 88.........................................................................................4607 DTC: P2716/DIAGNOSIS MONITOR CODE: 28.........................................................................................4611 DTC: P2740/DIAGNOSIS MONITOR CODE: 17.........................................................................................4615 DTC: P2757/DIAGNOSIS MONITOR CODE: 33.........................................................................................4619 DTC: P2759/DIAGNOSIS MONITOR CODE: 27.........................................................................................4624 DTC: P2764/DIAGNOSIS MONITOR CODE: 36.........................................................................................4628 DTC: U0100/DIAGNOSIS MONITOR CODE: 88.........................................................................................4632 DTC: U110A/DIAGNOSIS MONITOR CODE: 88.........................................................................................4638 TROUBLESHOOTING.......................................................................................................................4644 CLUTCH ECU........................................................................................................................4644 SYSTEM BLOCK DIAGRAM..........................................................................................................4644 COMPUTER PIN ASSIGNMENT.......................................................................................................4645 DIAGNOSIS CODE TABLE..........................................................................................................4647 CAUTIONS ON HV DAMPER REPLACEMENT.............................................................................................4648 DTC: P0560....................................................................................................................4649 DTC: P0563....................................................................................................................4653 DTC: P0710....................................................................................................................4655 DTC: P0775....................................................................................................................4660 DTC: P0811....................................................................................................................4665 DTC: P081E....................................................................................................................4667 DTC: P0883....................................................................................................................4669 DTC: P0942....................................................................................................................4673 DTC: P1538....................................................................................................................4685 DTC: P1539....................................................................................................................4695 DTC: P191A....................................................................................................................4702 DTC: P2859....................................................................................................................4704 DTC: P3156....................................................................................................................4706 DTC: P3157....................................................................................................................4716 DTC: U0101....................................................................................................................4720 DTC: U0293....................................................................................................................4725 AXLE......................................................................................................................................4730 TROUBLESHOOTING.......................................................................................................................4731 TROUBLE SHOOTING BY AXLE SYMPTOM..................................................................................................4731 FRONT AXLE....................................................................................................................4731 REAR AXLE.....................................................................................................................4732 WHEEL AND TIRE................................................................................................................4732 DIFFERENTIAL..............................................................................................................................4734 TROUBLESHOOTING.......................................................................................................................4735 TROUBLE SHOOTING BY DIFFERENTIAL SYMPTOM..........................................................................................4735 REAR DIFFERENTIAL.............................................................................................................4735 FOREWORD..................................................................................................................................4737 CHAPTER REFERENCES........................................................................................................................4738 INDEX.....................................................................................................................................4739 BRAKE.....................................................................................................................................4741 TROUBLESHOOTING.......................................................................................................................4742 TROUBLE SHOOTING BY BRAKE SYMPTOM.................................................................................................4742 BRAKE.........................................................................................................................4742 ABS WITH EBD......................................................................................................................4744 CAUTIONS......................................................................................................................4744 TROUBLESHOOTING PROCEDURE.....................................................................................................4745 ACT PART No. CORRESPONDENCE...................................................................................................4747 HEARING TABLE.................................................................................................................4747 PRIOR CHECK...................................................................................................................4748 LIST OF DIAGNOSIS CODE........................................................................................................4762 PARTS ARRANGEMENT.............................................................................................................4765 ECU TERMINAL ARRANGEMENT......................................................................................................4767 SYMPTOM LIST..................................................................................................................4770 ELECTRIC CIRCUIT DIAGRAM......................................................................................................4771 ABS WARNING LIGHT ALWAYS ON...................................................................................................4772 BRAKE WARNING LIGHT ALWAYS ON.................................................................................................4775 ABS ACTIVATION TOO FAST (ABS OPERATES BEFORE THE WHEEL LOCKS).................................................................4779 THE BRAKE PEDAL GETS STUCK....................................................................................................4780 DTC: C1203 (Diagnosis monitor code 59)........................................................................................4782 DTC: C1225 (Diagnosis monitor code 25)........................................................................................4786 DTC: C1241 (Diagnosis monitor code 41)........................................................................................4790 DTC: C1249 (Diagnosis monitor code 49)........................................................................................4803 DTC: C1265 (Diagnosis monitor code 65)........................................................................................4808 DTC: C1300 (Diagnosis monitor code 62)........................................................................................4818 DTC: C1337 (Diagnosis monitor code 37)........................................................................................4821 DTC: C1361 (Diagnosis monitor code 91)........................................................................................4825 DTC: C1401 (Diagnosis monitor code 31)........................................................................................4833 DTC: C1402 (Diagnosis monitor code 32)........................................................................................4842 DTC: C1403 (Diagnosis monitor code 33)........................................................................................4851 DTC: C1404 (Diagnosis monitor code 34)........................................................................................4860 DTC: C1405 (Diagnosis monitor code 31)........................................................................................4869 DTC: C1406 (Diagnosis monitor code 32)........................................................................................4878 DTC: C1407 (Diagnosis monitor code 33)........................................................................................4887 DTC: C1408 (Diagnosis monitor code 34)........................................................................................4896 DTC: C1413 (Diagnosis monitor code 35)........................................................................................4905 DTC: C1414 (Diagnosis monitor code 36)........................................................................................4912 DTC: C1415 (Diagnosis monitor code 38)........................................................................................4918 DTC: C1416 (Diagnosis monitor code 39)........................................................................................4924 DTC: C1417 (Diagnosis monitor code 41)........................................................................................4930 DTC: C1421 (Diagnosis monitor code 46)........................................................................................4943 DTC: C1422 (Diagnosis monitor code 46)........................................................................................4947 DTC: C1423 (Diagnosis monitor code 46)........................................................................................4951 DTC: C1424 (Diagnosis monitor code 46)........................................................................................4955 DTC: C1425 (Diagnosis monitor code 49)........................................................................................4959 DTC: C1427 (Diagnosis monitor code 51)........................................................................................4964 DTC: C1428 (Diagnosis monitor code 51)........................................................................................4968 DTC: C1468 (Diagnosis monitor code 21)........................................................................................4972 DTC: C1469 (Diagnosis monitor code 22)........................................................................................4976 DTC: C146A (Diagnosis monitor code 23)........................................................................................4980 DTC: C146B (Diagnosis monitor code 24)........................................................................................4984 DTC: C146C (Diagnosis monitor code 13)........................................................................................4988 DTC: C146D (Diagnosis monitor code 14)........................................................................................4996 DTC: C146E (Diagnosis monitor code 11)........................................................................................5004 DTC: C146F (Diagnosis monitor code 12)........................................................................................5011 DTC: U0073 (Diagnosis monitor code 94)........................................................................................5018 ELECTRIC VACUUM PUMP SYSTEM.......................................................................................................5021 CAUTIONS FOR TROUBLESHOOTING..................................................................................................5021 SYSTEM BLOCK DIAGRAM..........................................................................................................5022 ELECTRIC CIRCUIT DIAGRAM......................................................................................................5023 CONNECTOR TERMINAL ARRANGEMENT................................................................................................5024 SYSTEM SELF-DIAGNOSTIC........................................................................................................5025 RESETTING THE ELECTRIC VACUUM PUMP OPERATION COUNT AND OPERATION TIME AND THE ELECTRIC VACUUM PUMP RELAY ACTUATION COUNT......5026 ACTIVE TEST...................................................................................................................5026 DATA MONITOR..................................................................................................................5026 DIAGNOSIS CODE TABLE..........................................................................................................5027 EXCESSIVE OPERATION OF ELECTRIC VACUUM PUMP (DIAGNOSIS CODE P165A)...........................................................5028 EXCESSIVE OPERATION OF ELECTRIC VACUUM PUMP RELAY (DIAGNOSIS CODE P165B).....................................................5029 ABNORMALITY IN VACUUM SENSOR CIRCUIT (DIAGNOSIS CODE P2525)...................................................................5030 FALSE DETECTION OF VACUUM SENSOR PRESSURE (DIAGNOSIS CODE P2526).............................................................5034 ELECTRIC VACUUM PUMP RELAY CONTACT STUCK AT ON (DIAGNOSIS CODE P258D)........................................................5046 HOW TO VERIFY AND CHANGE VEHICLE INFORMATION VALUES...........................................................................5048 STEERING..................................................................................................................................5050 TROUBLESHOOTING.......................................................................................................................5051 TROUBLE SHOOTING BY STEERING SYMPTOM..............................................................................................5051 STEERING......................................................................................................................5051 SUSPENSION................................................................................................................................5057 TROUBLESHOOTING.......................................................................................................................5058 TROUBLE SHOOTING BY SUSPENSION SYMPTOM............................................................................................5058 LEAF SUSPENSION...............................................................................................................5058 ELECTRICAL................................................................................................................................5059 TROUBLESHOOTING.......................................................................................................................5060 INTEGRATED UNIT...................................................................................................................5060 SYSTEM BLOCK DIAGRAM..........................................................................................................5060 COMPUTER PIN ASSIGNMENT.......................................................................................................5063 TROUBLE SHOOTING..............................................................................................................5064 CONTROL SYSTEM............................................................................................................................5071 TROUBLESHOOTING.......................................................................................................................5074 CAN COMMUNICATION.................................................................................................................5074 INSPECTION IN THE EVENT OF ABNORMALITY IN CAN COMMUNICATION LINE..............................................................5074 ECU INDIVIDUAL CODELIST (DIESEL)..............................................................................................5076 ECU INDIVIDUAL CODELIST (HYBRID)..............................................................................................5077 BASIC TROUBLESHOOTING PROCEDURE ON CAN COMMUNICATION..........................................................................5080 ENGINE CAN COMMUNICATION LINE (DIESEL)............................................................................................5082 ENGINE CAN LINE...............................................................................................................5082 PRIOR INSPECTION OF THE CAN COMMUNICATION LINE................................................................................5084 INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION........................................................................5088 INSPECTING THE CAN H LINE FOR SHORT CIRCUIT...................................................................................5093 INSPECTING THE CAN L LINE FOR SHORT CIRCUIT...................................................................................5102 INSPECTING THE EGR CONTROLLER CAN COMMUNICATION LINE..........................................................................5111 INSPECTING THE NOx SENSOR 1 CAN COMMUNICATION LINE............................................................................5114 INSPECTING THE NOx SENSOR 2 CAN COMMUNICATION LINE............................................................................5121 INSPECTING THE VNT CONTROLLER CAN COMMUNICATION LINE..........................................................................5128 INSPECTING THE DEF SENSOR CAN COMMUNICATION LINE..............................................................................5131 ENGINE CAN COMMUNICATION LINE (HYBRID)............................................................................................5135 ENGINE CAN LINE...............................................................................................................5135 PRIOR INSPECTION OF THE CAN COMMUNICATION LINE................................................................................5137 INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION........................................................................5141 INSPECTING THE CAN H LINE FOR SHORT CIRCUIT...................................................................................5146 INSPECTING THE CAN L LINE FOR SHORT CIRCUIT...................................................................................5156 INSPECTING THE EGR CONTROLLER CAN COMMUNICATION LINE..........................................................................5166 INSPECTING THE NOx SENSOR 1 CAN COMMUNICATION LINE............................................................................5169 INSPECTING THE NOx SENSOR 2 CAN COMMUNICATION LINE............................................................................5176 INSPECTING THE VNT CONTROLLER CAN COMMUNICATION LINE..........................................................................5183 INSPECTING THE DEF SENSOR CAN COMMUNICATION LINE..............................................................................5186 DIAGNOSIS CAN COMMUNICATION LINE (DIESEL).........................................................................................5190 DIAGNOSIS CAN LINE............................................................................................................5190 PRIOR INSPECTION OF THE CAN COMMUNICATION LINE................................................................................5192 INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION........................................................................5198 INSPECTING THE CAN H LINE FOR SHORT CIRCUIT...................................................................................5201 INSPECTING THE CAN L LINE FOR SHORT CIRCUIT...................................................................................5209 INSPECTING THE ABS ECU CAN COMMUNICATION LINE.................................................................................5216 INSPECTING THE AT ECU CAN COMMUNICATION LINE..................................................................................5219 INSPECTING THE ENGINE ECU CAN COMMUNICATION LINE..............................................................................5222 INSPECTING THE VEHICLE CONTROL ECU CAN COMMUNICATION LINE.....................................................................5227 DIAGNOSIS CAN COMMUNICATION LINE (HYBRID).........................................................................................5231 DIAGNOSIS CAN LINE............................................................................................................5231 PRIOR INSPECTION OF THE CAN COMMUNICATION LINE................................................................................5234 INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION........................................................................5241 INSPECTING THE CAN H LINE FOR SHORT CIRCUIT...................................................................................5247 INSPECTING THE CAN L LINE FOR SHORT CIRCUIT...................................................................................5258 INSPECTING THE ABS ECU CAN COMMUNICATION LINE.................................................................................5269 INSPECTING THE AT ECU CAN COMMUNICATION LINE..................................................................................5272 INSPECTING THE ENGINE ECU CAN COMMUNICATION LINE..............................................................................5275 INSPECTING THE INVERTER CAN COMMUNICATION LINE................................................................................5278 INSPECTING THE CLUTCH ECU CAN COMMUNICATION LINE..............................................................................5281 INSPECTING THE BATTERY ECU CAN COMMUNICATION LINE.............................................................................5284 INSPECTING THE VEHICLE CONTROL ECU CAN COMMUNICATION LINE.....................................................................5287 CONTROL CAN COMMUNICATION LINE (DIESEL)...........................................................................................5290 CONTROL CAN LINE..............................................................................................................5290 PRIOR INSPECTION OF THE CAN COMMUNICATION LINE................................................................................5292 INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION........................................................................5297 INSPECTING THE CAN H LINE FOR SHORT CIRCUIT...................................................................................5300 INSPECTING THE CAN L LINE FOR SHORT CIRCUIT...................................................................................5306 INSPECTING THE ABS ECU CAN COMMUNICATION LINE.................................................................................5312 INSPECTING THE AT ECU CAN COMMUNICATION LINE..................................................................................5315 INSPECTING THE VEHICLE CONTROL ECU CAN COMMUNICATION LINE.....................................................................5318 CONTROL CAN COMMUNICATION LINE (HYBRID)...........................................................................................5321 CONTROL CAN LINE..............................................................................................................5321 PRIOR INSPECTION OF THE CAN COMMUNICATION LINE................................................................................5325 INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION........................................................................5330 INSPECTING THE CAN H LINE FOR SHORT CIRCUIT...................................................................................5337 INSPECTING THE CAN L LINE FOR SHORT CIRCUIT...................................................................................5348 INSPECTING THE ABS ECU CAN COMMUNICATION LINE.................................................................................5359 INSPECTING THE AT ECU CAN COMMUNICATION LINE..................................................................................5362 INSPECTING THE HV ECU CAN COMMUNICATION LINE..................................................................................5365 INSPECTING THE INVERTER CAN COMMUNICATION LINE................................................................................5368 INSPECTING THE CLUTCH ECU CAN COMMUNICATION LINE..............................................................................5372 INSPECTING THE VEHICLE CONTROL ECU CAN COMMUNICATION LINE.....................................................................5375 CAN COMMUNICATION (HYBRID SYSTEM).................................................................................................5378 SAFETY MEASURES TO BE TAKEN IN HIGH VOLTAGE WORK..............................................................................5378 LIST OF CONNECTOR MARKINGS....................................................................................................5381 CONNECTION DIAGRAM............................................................................................................5382 LIST OF DTC CODES FOR CAN SYSTEM-RELATED ABNORMALITIES........................................................................5383 CAN COMMUNICATION FAILURE.....................................................................................................5385 BASIC INSPECTION ITEMS IN CASE OF ABNORMALITY IN DIAG CAN SYSTEM..............................................................5389 BASIC INSPECTION ITEMS IN CASE OF ABNORMALITY IN CONTROL CAN SYSTEM...........................................................5404 ABNORMALITY IN INVERTER (ECU SYSTEM) / DIAG CAN RESISTER SEIZURE (DTC CODE P0A1B / TC3F)......................................5413 ABNORMALITY IN THE INVERTER (ECU SYSTEM) / CONTROL CAN RESISTER SEIZURE (DTC CODE P0A1B / TC92)...............................5414 ABNORMALITY IN HV ECU FUNCTION / CONTROL CAN REGISTER SEIZURE (DTC CODE P0A1D / TC12).........................................5415 ABNORMALITY IN HV ECU FUNCTION / DIAG CAN REGISTER SEIZURE (DTC CODE P0A1D / TC17)...........................................5416 HV ECU CAN COMMUNICATION FAILURE (CONTROL CAN) / CONTROL CAN COMMUNICATION SHUTDOWN DUE TO BUS OFF (DTC CODE U0073 / TC11)....5417 CAN COMMUNICATION FAILURE (CONTROL CAN) / CONTROL CAN COMMUNICATION SHUTDOWN DUE TO BUS OFF (DTC CODE U0073 / TC91)...........5419 HV ECU CAN COMMUNICATION FAILURE (DIAG CAN) / DIAG CAN COMMUNICATION SHUTDOWN DUE TO BUS OFF (DTC CODE U0074 / TC16)..........5421 CAN COMMUNICATION FAILURE (DIAG CAN) / COMMUNICATION SHUTDOWN DUE TO DIAG CAN BUS OFF (DTC CODE U0074 / TC3E).................5422 ENGINE ECU CAN COMMUNICATION BLACKOUT / ENGINE ECU CAN COMMUNICATION BLACKOUT (DTC CODE U0100 / TC13).........................5423 TCM ECU CAN COMMUNICATION BLACKOUT / AT ECU CAN COMMUNICATION BLACKOUT (DTC CODE U0101 / TC18)................................5424 INVERTER CAN COMMUNICATION BLACKOUT / INVERTER CAN COMMUNICATION BLACKOUT (DTC CODE U0110 / TC14).............................5426 BATTERY ECU CAN COMMUNICATION BLACKOUT / BATTERY ECU CAN COMMUNICATION BLACKOUT (DTC CODE U0111 / TC15).......................5429 ABS ECU CAN COMMUNICATION BLACKOUT / ABS ECU CAN COMMUNICATION BLACKOUT (DTC CODE U0121/TC24).................................5432 METER CAN COMMUNICATION BLACKOUT / METER CAN COMMUNICATION BLACKOUT (DTC CODE U0155 / TC25)...................................5434 HV ECU COMMUNICATION FAILURE (DTC CODE U0293).................................................................................5436 HV ECU CAN COMMUNICATION BLACKOUT / HV ECU CAN COMMUNICATION BLACKOUT (DTC CODE U0293 / TC31).................................5438 VEHICLE CONTROL ECU CAN COMMUNICATION BLACKOUT / VEHICLE CONTROL ECU CAN COMMUNICATION BLACKOUT (DTC CODE U110A / TC26)......5442 CLUTCH ECU CAN COMMUNICATION BLACKOUT / CLUTCH ECU CAN COMMUNICATION BLACKOUT (DTC CODE U1136 / TC27).........................5444 COMMUNICATION DISABLED DUE TO DIAG CAN BUS OFF (DTC CODE U0074)..............................................................5446
Description:
2017 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]
