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2020 HINO TRUCK COE 155 155H 195 195H WORKSHOP MANUAL – PDF DOWNLOAD
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2020 HINO TRUCK COE 155 155H 195 195H WORKSHOP MANUAL
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2020 HINO TRUCK COE 155 155H 195 195H WORKSHOP MANUAL
Language : English
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2020 HINO TRUCK COE 155 155H 195 195H WORKSHOP MANUAL – PDF DOWNLOAD:
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2020 HINO TRUCK COE 155 155H 195 195H WORKSHOP MANUAL
How to use ............................................................................................................................... 2 1 .................................................................................................................................... 2 2 .................................................................................................................................... 3 3 .................................................................................................................................... 4 4 .................................................................................................................................... 5 5 .................................................................................................................................... 6 FOREWORD.................................................................................................................................. 8 CHAPTER REFERENCES........................................................................................................................ 9 INDEX..................................................................................................................................... 10 GENERAL INTRODUCTION...................................................................................................................... 12 HOW TO IDENTIFY VEHICLE TYPE.......................................................................................................... 13 HOW TO IDENTIFY VEHICLE TYPE...................................................................................................... 13 VEHICLE MODEL................................................................................................................. 13 VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE................................................................................. 14 APPEARANCE OF VEHICLE................................................................................................................. 15 APPEARANCE........................................................................................................................ 15 APPEARANCE OF VEHICLE......................................................................................................... 15 SAFETY INSTRUCTIONS AND READINESS TO WORK............................................................................................. 16 WARNING........................................................................................................................... 16 GENERAL PRECAUTIONS........................................................................................................... 16 IDENTIFICATION INFORMATION.................................................................................................... 20 SAFETY INSTRUCTIONS FOR WORK...................................................................................................... 23 PRECAUTIONS................................................................................................................... 23 INTRODUCTION TO WORKSHOP MANUAL................................................................................................... 27 GENERAL....................................................................................................................... 27 INTRODUCTION TO DESCRIPTIONS.................................................................................................. 28 DEFINITION OF TERM............................................................................................................ 30 TIGHTENING OF BOLTS AND NUTS...................................................................................................... 31 BOLTS AND NUTS................................................................................................................ 31 PURPOSES OF TIGHTENING TORQUE................................................................................................. 31 CAUTIONS TO PREVENT LOOSENESS................................................................................................. 31 TYPES AND IDENTIFICATION...................................................................................................... 32 COMPATIBILITY (NO COMPATIBILITY IN BOLTS AND NUTS)............................................................................ 33 STRENGTH CLASSES AND SYMBOLS.................................................................................................. 34 PART No....................................................................................................................... 35 LIST OF TIGHTENING TORQUE..................................................................................................... 36 TIGHTENING OF FLARE NUTS AND HOSES............................................................................................ 38 HANDLING OF LIQUID GASKET......................................................................................................... 39 LIQUID GASKET................................................................................................................. 39 GLOSSARY.............................................................................................................................. 40 DEFINITION OF ABBREVIATION IN THIS MANUAL......................................................................................... 40 LIST OF ABBREVIATION.......................................................................................................... 40 GLOSSARY OF SAE AND HINO TERMS................................................................................................ 43 LUBRICANTS............................................................................................................................ 46 LUBRICANTS........................................................................................................................ 46 RECOMMENDED LUBRICANTS........................................................................................................ 46 HYBRID.................................................................................................................................... 48 STANDARD VALUE........................................................................................................................ 49 HYBRID SYSTEM..................................................................................................................... 49 SERVICE PLUG.................................................................................................................. 49 PCU........................................................................................................................... 49 HV BATTERY.................................................................................................................... 50 HV BATTERY COOLING FAN........................................................................................................ 50 HV BATTERY ECU................................................................................................................ 50 SYSTEM MAIN RELAY JUNCTION BLOCK.............................................................................................. 50 INVERTER...................................................................................................................... 51 HV-ECU........................................................................................................................ 51 HYBRID JUNCTION BLOCK......................................................................................................... 51 WATER PUMP.................................................................................................................... 52 INVERTER RADIATOR............................................................................................................. 52 COOLANT....................................................................................................................... 52 MOTOR CABLE................................................................................................................... 52 REQUIRED ITEMS........................................................................................................................ 53 HYBRID SYSTEM..................................................................................................................... 53 HYBRID SYSTEM................................................................................................................. 53 SERVICE PLUG.................................................................................................................. 53 COOLANT....................................................................................................................... 53 HYBRID SYSTEM......................................................................................................................... 54 HYBRID SYSTEM..................................................................................................................... 54 CAUTIONS...................................................................................................................... 54 SERVICE PLUG...................................................................................................................... 58 COMPONENT LOCATOR............................................................................................................. 58 UNIT CHECK.................................................................................................................... 58 REPLACEMENT................................................................................................................... 59 PCU............................................................................................................................... 61 COMPONENT LOCATOR............................................................................................................. 61 REPLACEMENT................................................................................................................... 65 HV BATTERY........................................................................................................................ 70 COMPONENT LOCATOR............................................................................................................. 70 REPLACEMENT................................................................................................................... 72 HV BATTERY COOLING FAN............................................................................................................ 77 COMPONENT LOCATOR............................................................................................................. 77 REPLACEMENT................................................................................................................... 79 HV BATTERY ECU.................................................................................................................... 82 COMPONENT LOCATOR............................................................................................................. 82 REPLACEMENT................................................................................................................... 83 SYSTEM MAIN RELAY JUNCTION BLOCK.................................................................................................. 87 COMPONENT LOCATOR............................................................................................................. 87 REPLACEMENT................................................................................................................... 88 INVERTER.......................................................................................................................... 90 COMPONENT LOCATOR............................................................................................................. 90 REPLACEMENT................................................................................................................... 91 HV-ECU............................................................................................................................ 95 COMPONENT LOCATOR............................................................................................................. 95 REPLACEMENT................................................................................................................... 96 HYBRID JUNCTION BLOCK............................................................................................................. 98 COMPONENT LOCATOR............................................................................................................. 98 REPLACEMENT................................................................................................................... 99 WATER PUMP........................................................................................................................ 103 COMPONENT LOCATOR............................................................................................................. 103 REPLACEMENT................................................................................................................... 104 INVERTER RADIATOR................................................................................................................. 108 COMPONENT LOCATOR............................................................................................................. 108 REPLACEMENT................................................................................................................... 109 COOLANT........................................................................................................................... 111 REPLACEMENT................................................................................................................... 111 MOTOR CABLE....................................................................................................................... 113 COMPONENT LOCATOR............................................................................................................. 113 REPLACEMENT................................................................................................................... 116 TRANSMISSION (A465)....................................................................................................................... 122 STANDARD VALUE........................................................................................................................ 123 MOUNTING AND DISMOUNTING THE TRANSMISSION......................................................................................... 123 AUTOMATIC TRANSMISSION ASSEMBLY............................................................................................... 123 TRANSMISSION CONTROL.............................................................................................................. 125 SHIFT LEVER ASSEMBLY.......................................................................................................... 125 TRANSMISSION MECHANICAL........................................................................................................... 125 TURBINE SENSOR................................................................................................................ 125 SPEED SENSOR.................................................................................................................. 125 NEUTRAL SWITCH................................................................................................................ 126 EOP........................................................................................................................... 126 VALVE BODY ASSEMBLY........................................................................................................... 126 REQUIRED ITEMS........................................................................................................................ 127 MOUNTING AND DISMOUNTING THE TRANSMISSION......................................................................................... 127 AUTOMATIC TRANSMISSION ASSEMBLY............................................................................................... 127 NEUTRAL SWITCH................................................................................................................ 127 FRONT OIL SEAL................................................................................................................ 127 MOUNTING AND DISMOUNTING THE TRANSMISSION............................................................................................. 128 AUTOMATIC TRANSMISSION ASSEMBLY................................................................................................... 128 REPLACEMENT................................................................................................................... 128 TRANSMISSION CONTROL.................................................................................................................. 170 CONTROL COMPUTER ASSEMBLY ........................................................................................................ 170 COMPONENT LOCATOR............................................................................................................. 170 OVERHAUL...................................................................................................................... 171 SHIFT LEVER ASSEMBLY.............................................................................................................. 178 COMPONENT LOCATOR............................................................................................................. 178 OVERHAUL...................................................................................................................... 179 TRANSMISSION MECHANICAL............................................................................................................... 183 OIL PAN GASKET.................................................................................................................... 183 COMPONENT LOCATOR............................................................................................................. 183 OVERHAUL...................................................................................................................... 184 REAR CASE GASKET.................................................................................................................. 186 COMPONENT LOCATOR............................................................................................................. 186 OVERHAUL...................................................................................................................... 187 TURBINE SENSOR.................................................................................................................... 191 COMPONENT LOCATOR............................................................................................................. 191 OVERHAUL...................................................................................................................... 192 SPEED SENSOR...................................................................................................................... 193 COMPONENT LOCATOR............................................................................................................. 193 OVERHAUL...................................................................................................................... 194 NEUTRAL SWITCH.................................................................................................................... 195 COMPONENT LOCATOR............................................................................................................. 195 OVERHAUL...................................................................................................................... 196 EOP............................................................................................................................... 198 OVERHAUL...................................................................................................................... 198 VALVE BODY ASSEMBLY............................................................................................................... 206 OVERHAUL...................................................................................................................... 206 FRONT OIL SEAL.................................................................................................................... 216 OVERHAUL...................................................................................................................... 216 PROPELLER SHAFT (LD)...................................................................................................................... 218 STANDARD VALUE........................................................................................................................ 219 PROPELLER SHAFT MECHANICAL........................................................................................................ 219 PROPELLER SHAFT ASSEMBLY...................................................................................................... 219 REQUIRED ITEMS........................................................................................................................ 220 PROPELLER SHAFT MECHANICAL........................................................................................................ 220 PROPELLER SHAFT ASSEMBLY...................................................................................................... 220 PROPELLER SHAFT MECHANICAL............................................................................................................ 222 PROPELLER SHAFT ASSEMBLY.......................................................................................................... 222 COMPONENT LOCATOR............................................................................................................. 222 OVERHAUL...................................................................................................................... 224 AXLE...................................................................................................................................... 242 STANDARD VALUE........................................................................................................................ 243 FRONT AXLE........................................................................................................................ 243 STEERING KNUCKLE.............................................................................................................. 243 FRONT AXLE HUB................................................................................................................ 244 REAR AXLE......................................................................................................................... 245 REAR AXLE HUB................................................................................................................. 245 REAR AXLE SHAFT............................................................................................................... 246 REQUIRED ITEMS........................................................................................................................ 247 FRONT AXLE........................................................................................................................ 247 STEERING KNUCKLE.............................................................................................................. 247 FRONT AXLE HUB................................................................................................................ 248 REAR AXLE......................................................................................................................... 251 REAR AXLE HUB................................................................................................................. 251 REAR AXLE SHAFT............................................................................................................... 252 WHEEL AND TIRE................................................................................................................ 253 FRONT AXLE............................................................................................................................ 254 STEERING KNUCKLE.................................................................................................................. 254 COMPONENT LOCATOR............................................................................................................. 254 OVERHAUL...................................................................................................................... 258 FRONT AXLE HUB.................................................................................................................... 272 COMPONENT LOCATOR............................................................................................................. 272 OVERHAUL...................................................................................................................... 274 FRONT AXLE HUB BOLT............................................................................................................... 286 COMPONENT LOCATOR............................................................................................................. 286 OVERHAUL...................................................................................................................... 287 REAR AXLE............................................................................................................................. 289 REAR AXLE HUB..................................................................................................................... 289 COMPONENT LOCATOR............................................................................................................. 289 OVERHAUL...................................................................................................................... 291 REAR AXLE SHAFT................................................................................................................... 301 COMPONENT LOCATOR............................................................................................................. 301 OVERHAUL...................................................................................................................... 302 WHEEL AND TIRE........................................................................................................................ 304 WHEEL AND TIRE.................................................................................................................... 304 COMPONENT LOCATOR............................................................................................................. 304 INSPECTION.................................................................................................................... 305 REPLACEMENT................................................................................................................... 307 OVERHAUL (TUBELESS TIRE)...................................................................................................... 312 DIFFERENTIAL (SH13)....................................................................................................................... 319 STANDARD VALUE........................................................................................................................ 320 DIFFERENTIAL...................................................................................................................... 320 DIFFERENTIAL CARRIER.......................................................................................................... 320 REQUIRED ITEMS........................................................................................................................ 322 DIFFERENTIAL...................................................................................................................... 322 DIFFERENTIAL CARRIER.......................................................................................................... 322 DIFFERENTIAL.......................................................................................................................... 325 DIFFERENTIAL CARRIER.............................................................................................................. 325 COMPONENT LOCATOR............................................................................................................. 325 OVERHAUL...................................................................................................................... 333 BRAKE..................................................................................................................................... 371 STANDARD VALUE........................................................................................................................ 373 BRAKE CONTROL..................................................................................................................... 373 SERVICE BRAKE................................................................................................................. 373 BRAKE FLUID................................................................................................................... 373 BRAKE ACTUATOR................................................................................................................ 374 SPEED SENSOR.................................................................................................................. 374 BRAKE PEDAL................................................................................................................... 375 BRAKE MASTER CYLINDER......................................................................................................... 375 BRAKE BOOSTER................................................................................................................. 375 HYDRO BOOSTER................................................................................................................. 376 ELECTRIC VACUUM PUMP.......................................................................................................... 376 VACUUM PUMP................................................................................................................... 376 HYDRO PUMP.................................................................................................................... 376 VACUUM RESERVOIR.............................................................................................................. 377 FRONT FLEXIBLE HOSE........................................................................................................... 377 REAR FLEXIBLE HOSE............................................................................................................ 377 VACUUM WARNING BUZZER......................................................................................................... 377 VACUUM SENSOR (FOR SKID CONTROL).............................................................................................. 377 DISC BRAKE ....................................................................................................................... 378 FRONT DISC CALIPER............................................................................................................ 378 REAR DISC CALIPER............................................................................................................. 379 PARKING BRAKE..................................................................................................................... 380 PARKING BRAKE................................................................................................................. 380 PARKING BRAKE CABLE No.2...................................................................................................... 380 PARKING BRAKE CABLE No.3...................................................................................................... 380 PARKING BRAKE LEVER........................................................................................................... 380 PARKING BRAKE DRUM............................................................................................................ 381 PARKING BRAKE SWITCH.......................................................................................................... 381 REQUIRED ITEMS........................................................................................................................ 382 SERVICE BRAKE..................................................................................................................... 382 SERVICE BRAKE................................................................................................................. 382 BRAKE FLUID................................................................................................................... 382 SPEED SENSOR.................................................................................................................. 382 BRAKE PEDAL................................................................................................................... 382 BRAKE BOOSTER................................................................................................................. 382 HYDRO BOOSTER................................................................................................................. 383 VACUUM RESERVOIR.............................................................................................................. 383 DISC BRAKE........................................................................................................................ 384 FRONT DISC CALIPER............................................................................................................ 384 REAR DISC CALIPER............................................................................................................. 384 PARKING BRAKE..................................................................................................................... 385 PARKING BRAKE DRUM............................................................................................................ 385 BRAKE CONTROL......................................................................................................................... 386 SERVICE BRAKE..................................................................................................................... 386 INSPECTION AND ADJUSTMENT..................................................................................................... 386 BRAKE FLUID....................................................................................................................... 391 REPLACEMENT................................................................................................................... 391 ABS ACTUATOR...................................................................................................................... 394 COMPONENT LOCATOR............................................................................................................. 394 REPLACEMENT................................................................................................................... 395 UNIT CHECK.................................................................................................................... 397 SPEED SENSOR...................................................................................................................... 398 COMPONENT LOCATOR............................................................................................................. 398 UNIT CHECK.................................................................................................................... 400 REPLACEMENT................................................................................................................... 401 BRAKE PEDAL....................................................................................................................... 405 COMPONENT LOCATOR............................................................................................................. 405 REPLACEMENT................................................................................................................... 406 BRAKE MASTER CYLINDER............................................................................................................. 409 COMPONENT LOCATOR............................................................................................................. 409 REPLACEMENT................................................................................................................... 410 BRAKE BOOSTER..................................................................................................................... 414 COMPONENT LOCATOR............................................................................................................. 414 REPLACEMENT................................................................................................................... 415 HYDRO BOOSTER..................................................................................................................... 423 COMPONENT LOCATOR............................................................................................................. 423 REPLACEMENT................................................................................................................... 424 ELECTRIC VACUUM PUMP.............................................................................................................. 430 COMPONENT LOCATOR............................................................................................................. 430 OVERHAUL...................................................................................................................... 431 VACUUM PUMP....................................................................................................................... 435 COMPONENT LOCATOR............................................................................................................. 435 OVERHAUL...................................................................................................................... 436 HYDRO PUMP........................................................................................................................ 438 COMPONENT LOCATOR............................................................................................................. 438 OVERHAUL...................................................................................................................... 439 VACUUM RESERVOIR.................................................................................................................. 440 COMPONENT LOCATOR............................................................................................................. 440 REPLACEMENT................................................................................................................... 441 FRONT FLEXIBLE HOSE............................................................................................................... 443 COMPONENT LOCATOR............................................................................................................. 443 REPLACEMENT................................................................................................................... 444 REAR FLEXIBLE HOSE................................................................................................................ 446 COMPONENT LOCATOR............................................................................................................. 446 REPLACEMENT................................................................................................................... 447 VACUUM WARNING BUZZER............................................................................................................. 449 BEHIND-THE-WHEEL INSPECTION................................................................................................... 449 REPLACEMENT................................................................................................................... 449 VACUUM SENSOR (FOR SKID CONTROL).................................................................................................. 450 COMPONENT LOCATOR............................................................................................................. 450 REPLACEMENT................................................................................................................... 451 DISC BRAKE............................................................................................................................ 455 FRONT BRAKE CALIPER............................................................................................................... 455 COMPONENT LOCATOR............................................................................................................. 455 OVERHAUL...................................................................................................................... 456 REAR BRAKE CALIPER................................................................................................................ 463 COMPONENT LOCATOR............................................................................................................. 463 OVERHAUL...................................................................................................................... 464 PARKING BRAKE......................................................................................................................... 471 PARKING BRAKE..................................................................................................................... 471 INSPECTION AND ADJUSTMENT..................................................................................................... 471 PARKING BRAKE CABLE No.2.......................................................................................................... 473 COMPONENT LOCATOR............................................................................................................. 473 REPLACEMENT................................................................................................................... 474 PARKING BRAKE CABLE No.3.......................................................................................................... 480 COMPONENT LOCATOR............................................................................................................. 480 REPLACEMENT................................................................................................................... 481 PARKING BRAKE LEVER............................................................................................................... 487 COMPONENT LOCATOR............................................................................................................. 487 REPLACEMENT................................................................................................................... 488 PARKING BRAKE DRUM................................................................................................................ 492 COMPONENT LOCATOR............................................................................................................. 492 OVERHAUL...................................................................................................................... 494 PARKING BRAKE SWITCH.............................................................................................................. 506 COMPONENT LOCATOR............................................................................................................. 506 REPLACEMENT................................................................................................................... 507 STEERING.................................................................................................................................. 510 STANDARD VALUE........................................................................................................................ 511 STEERING CONTROL.................................................................................................................. 511 POWER STEERING SYSTEM......................................................................................................... 511 STEERING WHEEL................................................................................................................ 511 STEERING COLUMN............................................................................................................... 511 STEERING LINKAGE.............................................................................................................. 512 POWER STEERING GEAR........................................................................................................... 512 POWER STEERING PUMP........................................................................................................... 512 REQUIRED ITEMS........................................................................................................................ 513 STEERING CONTROL.................................................................................................................. 513 POWER STEERING SYSTEM......................................................................................................... 513 STEERING WHEEL................................................................................................................ 513 STEERING COLUMN............................................................................................................... 514 STEERING LINKAGE.............................................................................................................. 514 POWER STEERING GEAR........................................................................................................... 515 POWER STEERING PUMP........................................................................................................... 515 STEERING CONTROL...................................................................................................................... 516 POWER STEERING SYSTEM............................................................................................................. 516 PERFORMANCE INSPECTION........................................................................................................ 516 STEERING WHEEL.................................................................................................................... 519 COMPONENT LOCATOR............................................................................................................. 519 REPLACEMENT................................................................................................................... 520 STEERING COLUMN................................................................................................................... 523 COMPONENT LOCATOR............................................................................................................. 523 REPLACEMENT................................................................................................................... 524 STEERING LINKAGE.................................................................................................................. 532 COMPONENT LOCATOR............................................................................................................. 532 REPLACEMENT................................................................................................................... 533 POWER STEERING GEAR............................................................................................................... 541 COMPONENT LOCATOR............................................................................................................. 541 REPLACEMENT................................................................................................................... 542 POWER STEERING PUMP............................................................................................................... 553 COMPONENT LOCATOR............................................................................................................. 553 REPLACEMENT .................................................................................................................. 554 SUSPENSION................................................................................................................................ 556 STANDARD VALUE........................................................................................................................ 557 FRONT SUSPENSION.................................................................................................................. 557 SHOCK ABSORBER................................................................................................................ 557 LEAF SPRING................................................................................................................... 557 STABILIZER.................................................................................................................... 558 WHEEL ALIGNMENT............................................................................................................... 558 REAR SUSPENSION................................................................................................................... 559 SHOCK ABSORBER................................................................................................................ 559 LEAF SPRING................................................................................................................... 559 REQUIRED ITEMS........................................................................................................................ 560 FRONT SUSPENSION.................................................................................................................. 560 SHOCK ABSORBER................................................................................................................ 560 LEAF SPRING................................................................................................................... 560 WHEEL ALIGNMENT............................................................................................................... 561 REAR SUSPENSION................................................................................................................... 562 SHOCK ABSORBER................................................................................................................ 562 LEAF SPRING................................................................................................................... 562 FRONT SUSPENSION...................................................................................................................... 563 SHOCK ABSORBER.................................................................................................................... 563 COMPONENT LOCATOR............................................................................................................. 563 REPLACEMENT................................................................................................................... 564 LEAF SPRING....................................................................................................................... 567 COMPONENT LOCATOR............................................................................................................. 567 OVERHAUL...................................................................................................................... 568 STABILIZER........................................................................................................................ 577 COMPONENT LOCATOR............................................................................................................. 577 REPLACEMENT................................................................................................................... 578 WHEEL ALIGNMENT................................................................................................................... 580 ADJUSTMENT.................................................................................................................... 580 REAR SUSPENSION....................................................................................................................... 583 SHOCK ABSORBER.................................................................................................................... 583 COMPONENT LOCATOR............................................................................................................. 583 REPLACEMENT................................................................................................................... 584 LEAF SPRING....................................................................................................................... 587 COMPONENT LOCATOR............................................................................................................. 587 OVERHAUL...................................................................................................................... 589 FRAME AND FRAME ACCESSORY................................................................................................................. 598 STANDARD VALUE........................................................................................................................ 599 FRAME............................................................................................................................. 599 CHASSIS FRAME................................................................................................................. 599 FRONT BUMPER.................................................................................................................. 600 REQUIRED ITEMS........................................................................................................................ 601 FRAME............................................................................................................................. 601 CHASSIS FRAME & CHASSIS FRAME ACCESSORIES..................................................................................... 601 FRAME................................................................................................................................. 602 FRAME AND FRAME ACCESSORIES....................................................................................................... 602 COMPONENT LOCATOR............................................................................................................. 602 FRAME............................................................................................................................. 603 INSPECTION.................................................................................................................... 603 REPAIR........................................................................................................................ 604 FRONT BUMPER...................................................................................................................... 609 COMPONENT LOCATOR............................................................................................................. 609 REPLACEMENT................................................................................................................... 611 CAB MOUNTING AND CAB SUSPENSION........................................................................................................... 616 STANDARD VALUE........................................................................................................................ 617 CAB MOUNTING AND CAB SUSPENSION................................................................................................... 617 ASSEMBLY...................................................................................................................... 617 CAB MOUNTING.................................................................................................................. 617 TILT CAB STAY................................................................................................................. 618 MOUNTING AND DISMOUNTING CAB.......................................................................................................... 619 CAB ASSEMBLY...................................................................................................................... 619 REPLACEMENT................................................................................................................... 619 CAB MOUNTING AND CAB SUSPENSION....................................................................................................... 633 CAB MOUNTING...................................................................................................................... 633 COMPONENT LOCATOR............................................................................................................. 633 PRECAUTIONS IN TILTING AND LOWERING THE CAB................................................................................... 637 REPLACEMENT................................................................................................................... 638 CAB TILT STAY..................................................................................................................... 651 COMPONENT LOCATOR............................................................................................................. 651 PRECAUTIONS IN TILTING AND LOWERING THE CAB................................................................................... 654 REPLACEMENT................................................................................................................... 655 CAB DIMENSIONAL DRAWING............................................................................................................... 661 CAB ASSEMBLY...................................................................................................................... 661 SINGLE CAB.................................................................................................................... 661 CREW CAB...................................................................................................................... 663 BODY INSIDE ACCESSORY..................................................................................................................... 665 STANDARD VALUE........................................................................................................................ 666 INSTRUMENT PANEL AND DRIVER INFORMATION........................................................................................... 666 INSTRUMENT PANEL.............................................................................................................. 666 INTERIOR ACCESSORY................................................................................................................ 666 ROOF ACCESSORY................................................................................................................ 666 SEAT.............................................................................................................................. 667 DRIVER'S SEAT................................................................................................................. 667 ASSISTANT'S SEAT.............................................................................................................. 667 REAR SEAT..................................................................................................................... 667 INSTRUMENT PANEL AND DRIVER INFORMATION............................................................................................... 669 INSTRUMENT PANEL.................................................................................................................. 669 COMPONENT LOCATOR............................................................................................................. 669 REPLACEMENT................................................................................................................... 671 COMBINATION METER................................................................................................................. 681 REPLACEMENT................................................................................................................... 681 INTERIOR ACCESSORY.................................................................................................................... 682 INTERIOR ACCESSORY................................................................................................................ 682 COMPONENT LOCATOR............................................................................................................. 682 REPLACEMENT................................................................................................................... 684 FLOOR ACCESSORY................................................................................................................... 687 COMPONENT LOCATOR............................................................................................................. 687 REPLACEMENT................................................................................................................... 688 ROOF ACCESSORY.................................................................................................................... 689 COMPONENT LOCATOR............................................................................................................. 689 REPLACEMENT................................................................................................................... 690 SEAT.................................................................................................................................. 697 DRIVER'S SEAT..................................................................................................................... 697 COMPONENT LOCATOR............................................................................................................. 697 OVERHAUL...................................................................................................................... 699 ASSISTANT'S SEAT.................................................................................................................. 711 COMPONENT LOCATOR............................................................................................................. 711 OVERHAUL (THREE-SEATER)....................................................................................................... 714 OVERHAUL (CREW CAB)........................................................................................................... 722 REAR SEAT......................................................................................................................... 728 COMPONENT LOCATOR............................................................................................................. 728 OVERHAUL...................................................................................................................... 730 BODY OUTSIDE ACCESSORY.................................................................................................................... 739 STANDARD VALUE........................................................................................................................ 740 DOOR.............................................................................................................................. 740 DOOR HINGE.................................................................................................................... 740 DOOR ACCESSORIES.............................................................................................................. 740 REQUIRED ITEMS........................................................................................................................ 741 DOOR.............................................................................................................................. 741 DOOR ACCESSORIES.............................................................................................................. 741 POWER WINDOW.................................................................................................................. 741 AUTO DOOR LOCK SYSTEM......................................................................................................... 741 WINDOW GLASS...................................................................................................................... 742 GLASS......................................................................................................................... 742 MIRROR............................................................................................................................ 743 POWER MIRROR.................................................................................................................. 743 DOOR.................................................................................................................................. 744 DOOR HINGE........................................................................................................................ 744 INSPECTION AND ADJUSTMENT..................................................................................................... 744 DOOR ACCESSORY.................................................................................................................... 748 COMPONENT LOCATOR............................................................................................................. 748 OVERHAUL...................................................................................................................... 754 POWER WINDOW...................................................................................................................... 777 SINGLE UNIT INSPECTION........................................................................................................ 777 AUTO DOOR LOCK SYSTEM............................................................................................................. 779 PERFORMANCE INSPECTION........................................................................................................ 779 SINGLE UNIT INSPECTION........................................................................................................ 780 KEYLESS ENTRY..................................................................................................................... 782 PERFORMANCE INSPECTION........................................................................................................ 782 WINDOW GLASS.......................................................................................................................... 783 GLASS............................................................................................................................. 783 COMPONENT LOCATOR............................................................................................................. 783 REPLACEMENT................................................................................................................... 785 MIRROR................................................................................................................................ 797 REAR VIEW MIRROR.................................................................................................................. 797 COMPONENT LOCATOR............................................................................................................. 797 REPLACEMENT................................................................................................................... 798 POWER MIRROR...................................................................................................................... 799 SINGLE UNIT INSPECTION........................................................................................................ 799 ACCESSORY............................................................................................................................. 800 OUTSIDE ACCESSORY................................................................................................................. 800 COMPONENT LOCATOR............................................................................................................. 800 REPLACEMENT................................................................................................................... 801 AIR BAG AND SEAT BELT..................................................................................................................... 806 STANDARD VALUE........................................................................................................................ 807 SEAT BELT......................................................................................................................... 807 SEAT BELT..................................................................................................................... 807 CENTER SEAT BELT.............................................................................................................. 807 REAR SEAT BELT................................................................................................................ 808 SEAT BELT............................................................................................................................. 809 SEAT BELT......................................................................................................................... 809 COMPONENT LOCATOR............................................................................................................. 809 REPLACEMENT................................................................................................................... 810 CENTER SEAT BELT.................................................................................................................. 812 COMPONENT LOCATOR............................................................................................................. 812 REPLACEMENT................................................................................................................... 813 REAR SEAT BELT.................................................................................................................... 814 COMPONENT LOCATOR............................................................................................................. 814 REPLACEMENT................................................................................................................... 815 HEATER AND AIR CONDITIONER................................................................................................................ 819 STANDARD VALUE........................................................................................................................ 820 AIR CONDITIONER................................................................................................................... 820 AIR CONDITIONER............................................................................................................... 820 V-BELT........................................................................................................................ 821 COOLER COMPRESSOR............................................................................................................. 821 CONDENSER..................................................................................................................... 821 HVAC (HEATING, VENTILATING AND AIR CONDITIONING UNIT)......................................................................... 822 HEATER CONTROL................................................................................................................ 822 REAR HEATER (CREW CAB)........................................................................................................ 822 REAR COOLER (CREW CAB)........................................................................................................ 823 REQUIRED ITEMS........................................................................................................................ 824 AIR CONDITIONER................................................................................................................... 824 AIR CONDITIONER............................................................................................................... 824 V-BELT........................................................................................................................ 824 COOLER COMPRESSOR............................................................................................................. 825 CONDENSER..................................................................................................................... 825 AIR CONDITIONER....................................................................................................................... 826 AIR CONDITIONER................................................................................................................... 826 SAFETY INSTRUCTIONS FOR WORK.................................................................................................. 826 COLLECTION/FILLING OF REFRIGERANT............................................................................................. 830 MAINTENANCE................................................................................................................... 838 V-BELT............................................................................................................................ 841 COMPONENT LOCATOR............................................................................................................. 841 REPLACEMENT................................................................................................................... 842 COOLER COMPRESSOR................................................................................................................. 847 COMPONENT LOCATOR............................................................................................................. 847 REPLACEMENT................................................................................................................... 848 CONDENSER......................................................................................................................... 853 COMPONENT LOCATOR............................................................................................................. 853 REPLACEMENT................................................................................................................... 854 HVAC (HEATING, VENTILATING AND AIR CONDITIONING UNIT)............................................................................. 858 COMPONENT LOCATOR............................................................................................................. 858 REPLACEMENT................................................................................................................... 860 HEATER CONTROL.................................................................................................................... 867 COMPONENT LOCATOR............................................................................................................. 867 REPLACEMENT................................................................................................................... 868 REAR HEATER (CREW CAB)............................................................................................................ 872 COMPONENT LOCATOR............................................................................................................. 872 REPLACEMENT................................................................................................................... 873 REAR HEATER BLOWER SWITCH (CREW CAB).............................................................................................. 879 COMPONENT LOCATOR............................................................................................................. 879 REPLACEMENT................................................................................................................... 880 REAR COOLER (CREW CAB)............................................................................................................ 882 COMPONENT LOCATOR............................................................................................................. 882 REPLACEMENT................................................................................................................... 883 COOLER CONTROL SWITCH (CREW CAB).................................................................................................. 891 COMPONENT LOCATOR............................................................................................................. 891 REPLACEMENT................................................................................................................... 892 ELECTRICAL................................................................................................................................ 896 STANDARD VALUE........................................................................................................................ 897 LIGHTING.......................................................................................................................... 897 HEADLIGHT..................................................................................................................... 897 WIPER AND WASHER.................................................................................................................. 897 WIPER......................................................................................................................... 897 WASHER........................................................................................................................ 897 REQUIRED ITEMS........................................................................................................................ 898 LIGHTING.......................................................................................................................... 898 COMBINATION SWITCH............................................................................................................ 898 LIGHTING.............................................................................................................................. 899 HEADLIGHT......................................................................................................................... 899 COMPONENT LOCATOR............................................................................................................. 899 OPTICAL AXIS ADJUSTMENT....................................................................................................... 900 REPLACEMENT................................................................................................................... 901 FOG LIGHT......................................................................................................................... 902 REPLACEMENT................................................................................................................... 902 ID LIGHT.......................................................................................................................... 903 COMPONENT LOCATOR............................................................................................................. 903 REPLACEMENT................................................................................................................... 904 ROOM LIGHT........................................................................................................................ 905 COMPONENT LOCATOR............................................................................................................. 905 REPLACEMENT................................................................................................................... 906 COMBINATION SWITCH................................................................................................................ 907 COMPONENT LOCATOR............................................................................................................. 907 REPLACEMENT................................................................................................................... 908 INSPECTION.................................................................................................................... 908 WIPER AND WASHER...................................................................................................................... 911 WIPER............................................................................................................................. 911 COMPONENT LOCATOR............................................................................................................. 911 REPLACEMENT................................................................................................................... 912 WASHER............................................................................................................................ 916 COMPONENT LOCATOR............................................................................................................. 916 REPLACEMENT .................................................................................................................. 917 COMPUTER.............................................................................................................................. 919 COMPUTER.......................................................................................................................... 919 MOUNTING POSITION............................................................................................................. 919 SWITCH................................................................................................................................ 921 SWITCH............................................................................................................................ 921 MOUNTING POSITION............................................................................................................. 921 FUSE AND RELAY........................................................................................................................ 922 FUSE BLOCK........................................................................................................................ 922 MOUNTING POSITION............................................................................................................. 922 RELAY............................................................................................................................. 924 MOUNTING POSITION............................................................................................................. 924 CONTROL SYSTEM............................................................................................................................ 925 REQUIRED ITEMS........................................................................................................................ 926 HINO STOP&START SYSTEM............................................................................................................ 926 SLOPE LEARNING................................................................................................................ 926 HINO STOP&START SYSTEM................................................................................................................ 927 HINO STOP&START SYSTEM............................................................................................................ 927 SLOPE LEARNING................................................................................................................ 927 CRUISE CONTROL........................................................................................................................ 929 CRUISE MAIN SWITCH................................................................................................................ 929 COMPONENT LOCATOR............................................................................................................. 929 REPLACEMENT................................................................................................................... 930 SINGLE UNIT INSPECTION........................................................................................................ 931 FOREWORD.................................................................................................................................. 933 CHAPTER REFERENCES........................................................................................................................ 934 INDEX..................................................................................................................................... 935 GENERAL INTRODUCTION...................................................................................................................... 936 HOW TO USE THIS MANUAL................................................................................................................ 937 GRAPHICAL SYMBOLS FOR WIRING DIAGRAMS, ABBREVIATIONS AND TERMS.................................................................... 937 WIRING DIAGRAM.................................................................................................................... 942 WIRE TO WIRE CONNECTOR............................................................................................................ 943 JUNCTION CONNECTOR................................................................................................................ 944 LOCATION.......................................................................................................................... 945 RELAY LOCATION / FUSE AND RELAY BLOCK............................................................................................. 946 ABOUT CONNECTOR................................................................................................................... 950 WIRING DIAGRAM ACCORDING TO SYSTEM........................................................................................................ 952 WIRING DIAGRAM........................................................................................................................ 953 WIRING HARNESS CODE............................................................................................................... 953 AC. POWER SUPPLY CIRCUIT.......................................................................................................... 955 AF. GROUND CIRCUIT................................................................................................................ 959 AH. CHARGING CIRCUIT.............................................................................................................. 961 AK. ENGINE STARTING CIRCUIT....................................................................................................... 963 AN. CAN COMMUNICATION CIRCUIT..................................................................................................... 965 AO. CAN COMMUNICATION CIRCUIT [HV]................................................................................................ 967 BG. ENGINE ECU CIRCUIT [J05] 1/2.................................................................................................. 971 BH. ENGINE ECU CIRCUIT [J05] 2/2.................................................................................................. 975 BI. DEF SCR CIRCUIT............................................................................................................... 983 BJ. HYDRO BOOST SYSTEM CIRCUIT.................................................................................................... 985 BN. GLOW PLUG CIRCUIT............................................................................................................. 987 BP. FUEL HEATER CIRCUIT........................................................................................................... 989 CC. AT CIRCUIT [A465]............................................................................................................. 991 CE. CLUTCH ECU CIRCUIT............................................................................................................ 997 CF. HV PCU CIRCUIT................................................................................................................1001 DA. ABS/PAB+VSC CIRCUIT...........................................................................................................1003 DD. VEHICLE CONTROL ECU CIRCUIT...................................................................................................1005 EC. POWER DOOR LOCK CIRCUIT.......................................................................................................1007 ED. KEYLESS ENTRY CIRCUIT.........................................................................................................1009 EG. POWER WINDOW CIRCUIT [FRONT]..................................................................................................1011 EH. POWER WINDOW CIRCUIT [REAR]...................................................................................................1013 FA. COMBINATION METER CIRCUIT.....................................................................................................1015 FB. PARKING BRAKE WARNING CIRCUIT.................................................................................................1019 FC. WEAR INDICATOR CIRCUIT........................................................................................................1021 FD. HORN RELAY CIRCUIT............................................................................................................1023 FE. COOLANT LEVEL WARNING CIRCUIT.................................................................................................1025 FF. DIAGNOSIS MONITOR CIRCUIT.....................................................................................................1027 FJ. RHEOSTAT CIRCUIT..............................................................................................................1029 FK. TELEMATICS CIRCUIT............................................................................................................1031 GA. HEADLIGHT CIRCUIT.............................................................................................................1033 GD. HEADLIGHT SUB CIRCUIT ........................................................................................................1035 GG. TAIL LIGHT CIRCUIT............................................................................................................1037 GH. STOP LIGHT CIRCUIT............................................................................................................1039 GJ. TURN / HAZARD CIRCUIT.........................................................................................................1041 GL. COMBINATION LIGHT CIRCUIT.....................................................................................................1043 GM. FOG LIGHT CIRCUIT [FRONT].....................................................................................................1045 HA. ROOM LIGHT CIRCUIT............................................................................................................1047 JA. WIPER AND WASHER CIRCUIT......................................................................................................1049 JD. MIRROR HEATER CIRCUIT.........................................................................................................1051 JE. REMOTE CONTROL MIRROR CIRCUIT.................................................................................................1053 KA. RADIO CIRCUIT.................................................................................................................1055 KB. CIGAR LIGHTER CIRCUIT.........................................................................................................1057 LB. HEATER AND AIR CONDITIONER CIRCUIT............................................................................................1059 LF. REAR HEATER AND AIR CONDITIONER CIRCUIT.......................................................................................1063 MA. OUTLET POWER SUPPLY CIRCUIT...................................................................................................1065 MB. PASS THROUGH CIRCUIT..........................................................................................................1067 MC. VAN LIGHT CIRCUIT.............................................................................................................1069 MD. TRAILER BRAKE CIRCUIT.........................................................................................................1071 WIRE TO WIRE CONNECTOR....................................................................................................................1073 WIRE TO WIRE CONNECTOR................................................................................................................1074 WIRE TO WIRE CONNECTOR LIST.......................................................................................................1074 JUNCTION CONNECTOR........................................................................................................................1091 JUNCTION CONNECTOR....................................................................................................................1092 JUNCTION CONNECTOR LIST...........................................................................................................1092 LOCATION..................................................................................................................................1109 CONNECTOR LOCATION....................................................................................................................1110 CONTENTS..........................................................................................................................1110 QUICK REFERENCE...................................................................................................................1111 IP-1 [INSTRUMENT PANEL (1 of 6)]..................................................................................................1112 IP-2 [INSTRUMENT PANEL (2 of 6)]..................................................................................................1114 IP-3 [INSTRUMENT PANEL (3 of 6)]..................................................................................................1116 IP-4 [INSTRUMENT PANEL (4 of 6)]..................................................................................................1118 IP-5 [INSTRUMENT PANEL (5 of 6)]..................................................................................................1122 IP-6 [INSTRUMENT PANEL (6 of 6)]..................................................................................................1124 CA-1 [CAB (1 of 2)] (Models: Single cab (Floor / Cowl))...........................................................................1126 CA-2 [CAB (2 of 2)] (Models: Single cab (Roof / Door))............................................................................1128 CA-3 [CAB (1 of 2)] (Models: Crew cab (Floor))....................................................................................1130 CA-4 [CAB (2 of 2)] (Models: Crew cab (Roof / Door))..............................................................................1132 EG-1 [ENGINE (1 of 4)] (Models: J05E Engine)......................................................................................1134 EG-2 [ENGINE (2 of 4)] (Models: J05E Engine)......................................................................................1136 EG-3 [ENGINE (3 of 4)] (Models: J05E Engine)......................................................................................1138 EG-4 [ENGINE (4 of 4)] (Models: J05E Engine)......................................................................................1140 EG-5 [ENGINE] (Models: J05E Engine (Right rear))..................................................................................1142 EG-6 [ENGINE (1 of 4)] (Models: J05E Engine HV)...................................................................................1144 EG-7 [ENGINE (2 of 4)] (Models: J05E Engine HV)...................................................................................1146 EG-8 [ENGINE (3 of 4)] (Models: J05E Engine HV)...................................................................................1148 EG-9 [ENGINE (4 of 4)] (Models: J05E Engine HV)...................................................................................1150 EG-10 [ENGINE] (Models: J05E Engine HV (Right rear))..............................................................................1152 RR-1 [REAR] (Models: Except HV)...................................................................................................1154 RR-2 [REAR] (Models: HV)..........................................................................................................1156 RELAY LOCATION/FUSE AND RELAY BLOCK.......................................................................................................1158 RELAY LOCATION........................................................................................................................1159 INSTRUMENT PANEL..................................................................................................................1159 CHASSIS...........................................................................................................................1160 FUSE AND RELAY BLOCK..................................................................................................................1161 CHASSIS RELAY BLOCK...............................................................................................................1161 CAB RELAY.........................................................................................................................1164 RELAY BLOCK No.2..................................................................................................................1165 RELAY BLOCK No.3..................................................................................................................1166 JUNCTION BLOCK........................................................................................................................1167 JUNCTION BLOCK....................................................................................................................1167 WIRE TO WIRE BOX......................................................................................................................1169 WIRE TO WIRE ALIGNMENT............................................................................................................1169 INDEX.....................................................................................................................................1170 CONNECTOR INDEX.......................................................................................................................1171 ELECTRICAL EQUIPMENT CONNECTOR....................................................................................................1171 WIRE TO WIRE CONNECTOR............................................................................................................1188 JUNCTION CONNECTOR................................................................................................................1192 FOREWORD..................................................................................................................................1196 CHAPTER REFERENCES........................................................................................................................1197 INDEX.....................................................................................................................................1198 GENERAL INTRODUCTION......................................................................................................................1200 HOW TO IDENTIFY VEHICLE TYPE..........................................................................................................1201 VEHICLE MODEL.....................................................................................................................1201 VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE.....................................................................................1202 APPEARANCE OF VEHICLE.................................................................................................................1203 APPEARANCE OF VEHICLE.............................................................................................................1203 SAFETY INSTRUCTIONS AND READINESS TO WORK.............................................................................................1204 WARNING...........................................................................................................................1204 IDENTIFICATION INFORMATION........................................................................................................1208 SAFETY INSTRUCTIONS FOR WORK......................................................................................................1211 INTRODUCTION TO WORKSHOP MANUAL...................................................................................................1214 TIGHTENING OF BOLTS AND NUTS......................................................................................................1218 HANDLING OF LIQUID GASKET.........................................................................................................1228 GLOSSARY..............................................................................................................................1229 DEFINITION OF ABBREVIATION IN THIS MANUAL.........................................................................................1229 LUBRICANTS............................................................................................................................1235 RECOMMENDED LUBRICANTS............................................................................................................1235 STANDARD VALUE (J05E).....................................................................................................................1236 MOUNTING AND DISMOUNTING THE ENGINE...................................................................................................1238 ENGINE ASSEMBLY...................................................................................................................1238 ENGINE CONTROL........................................................................................................................1239 ENGINE ECU........................................................................................................................1239 ENGINE SPEED MAIN SENSOR..........................................................................................................1239 ENGINE SPEED SUB SENSOR...........................................................................................................1239 ACCELERATOR PEDAL.................................................................................................................1240 BLOCK HEATER......................................................................................................................1240 FUEL SYSTEM...........................................................................................................................1241 FUEL TANK.........................................................................................................................1241 FUEL SENDER GAUGE.................................................................................................................1241 FUEL FILTER AND CASE (ENGINE SIDE)................................................................................................1242 SUPPLY PUMP.......................................................................................................................1243 INJECTOR..........................................................................................................................1243 COMMON RAIL.......................................................................................................................1244 FUEL FILTER AND CASE (VEHICLE SIDE)...............................................................................................1244 FUEL COOLER.......................................................................................................................1244 EMISSION CONTROL......................................................................................................................1245 EGR VALVE & COOLER................................................................................................................1245 CLOSED VENTILATOR.................................................................................................................1245 INTAKE................................................................................................................................1246 INTAKE MANIFOLD...................................................................................................................1246 DIESEL THROTTLE...................................................................................................................1246 INTAKE PIPE (EXHAUST SIDE)........................................................................................................1246 STACK DUCT........................................................................................................................1246 AIR CLEANER.......................................................................................................................1247 INTAKE TEMPERATURE SENSOR.........................................................................................................1247 BOOST PRESSURE SENSOR.............................................................................................................1247 AIR FLOW SENSOR...................................................................................................................1247 ENGINE MECHANICAL.....................................................................................................................1248 HEAD COVER........................................................................................................................1248 ROCKER ARM ASSEMBLY...............................................................................................................1248 CAMSHAFT ASSEMBLY.................................................................................................................1249 CYLINDER HEAD ASSEMBLY............................................................................................................1250 VALVE SYSTEM......................................................................................................................1251 CRANKSHAFT PULLEY.................................................................................................................1252 FRONT OIL SEAL RETAINER...........................................................................................................1252 FLYWHEEL ASSEMBLY.................................................................................................................1252 FLYWHEEL HOUSING..................................................................................................................1252 TIMING GEAR AND CAM IDLE GEAR.....................................................................................................1253 PISTON AND CONNECTING ROD.........................................................................................................1255 CRANKSHAFT........................................................................................................................1256 CYLINDER LINER....................................................................................................................1257 CYLINDER BLOCK....................................................................................................................1257 ENGINE MOUNTING AND BRACKET.......................................................................................................1258 GLOW PLUG.........................................................................................................................1258 EXHAUST...............................................................................................................................1259 EXHAUST MANIFOLD..................................................................................................................1259 EXHAUST PIPE......................................................................................................................1259 EXHAUST PIPE (ATC)................................................................................................................1259 DEF-SCR...........................................................................................................................1260 DPR CLEANER.......................................................................................................................1260 AFTERTREATMENT FUEL INJECTOR......................................................................................................1261 AFTERTREATMENT FUEL CUTOFF VALVE..................................................................................................1261 DEF PUMP..........................................................................................................................1261 DEF INJECTOR......................................................................................................................1262 DEF TANK..........................................................................................................................1262 COOLANT CUTOFF VALVE..............................................................................................................1262 DCU...............................................................................................................................1263 DPR DIFFERENTIAL PRESSURE SENSOR..................................................................................................1263 SCR UPSTREAM NOx SENSOR...........................................................................................................1263 SCR DOWNSTREAM NOx SENSOR.........................................................................................................1263 PM SENSOR.........................................................................................................................1264 EXHAUST TEMPERATURE SENSOR 1 (ATC INLET)..........................................................................................1264 EXHAUST TEMPERATURE SENSOR 2 (ATC OUTLET).........................................................................................1264 EXHAUST TEMPERATURE SENSOR 3 (DOC INLET)..........................................................................................1265 EXHAUST TEMPERATURE SENSOR 4 (DPR INLET)..........................................................................................1265 EXHAUST TEMPERATURE SENSOR 5 (DPR OUTLET).........................................................................................1265 DEF SCR TEMPERATURE SENSOR (SCR INLET)............................................................................................1266 EXHAUST BRAKE.....................................................................................................................1267 EXHAUST BRAKE MAGNETIC VALVE......................................................................................................1267 COOLING...............................................................................................................................1268 RADIATOR..........................................................................................................................1268 RADIATOR CAP......................................................................................................................1268 RESERVE TANK......................................................................................................................1268 INTERCOOLER.......................................................................................................................1269 THERMOSTAT CASE AND THERMOSTAT....................................................................................................1269 COOLANT PUMP......................................................................................................................1270 COOLING FAN AND FAN CLUTCH........................................................................................................1270 COOLANT TEMPERATURE SENSOR........................................................................................................1270 LUBRICATION...........................................................................................................................1271 OIL FILTER........................................................................................................................1271 OIL COOLER........................................................................................................................1271 OIL PUMP..........................................................................................................................1272 OIL PAN...........................................................................................................................1273 OIL STRAINER......................................................................................................................1273 OIL PRESSURE SWITCH...............................................................................................................1273 OIL LEVEL GAUGE AND GUIDE.........................................................................................................1273 STARTING/CHARGING.....................................................................................................................1274 STARTER...........................................................................................................................1274 V-BELT............................................................................................................................1274 ALTERNATOR (130 A)................................................................................................................1275 TURBOCHARGER..........................................................................................................................1276 TURBOCHARGER ASSEMBLY.............................................................................................................1276 REQUIRED ITEMS (J05E).....................................................................................................................1277 MOUNTING AND DISMOUNTING THE ENGINE...................................................................................................1278 ENGINE ASSEMBLY...................................................................................................................1278 ENGINE CONTROL........................................................................................................................1279 ENGINE ECU........................................................................................................................1279 ENGINE MAIN REVOLUTION SENSOR.....................................................................................................1279 ENGINE SUB REVOLUTION SENSOR......................................................................................................1280 ACCELERATOR PEDAL.................................................................................................................1281 IDLE SET VOLUME...................................................................................................................1281 FUEL SYSTEM...........................................................................................................................1282 FUEL SENDER GAUGE.................................................................................................................1282 WATER LEVEL WARNING SWITCH........................................................................................................1282 SUPPLY PUMP.......................................................................................................................1283 INJECTOR..........................................................................................................................1284 COMMON RAIL.......................................................................................................................1285 FUEL FILTER AND CASE (VEHICLE SIDE)...............................................................................................1285 EMISSION CONTROL......................................................................................................................1286 EGR VALVE AND COOLER..............................................................................................................1286 INTAKE................................................................................................................................1287 DIESEL THROTTLE...................................................................................................................1287 BOOST PRESSURE SENSOR.............................................................................................................1288 AIR FLOW SENSOR...................................................................................................................1289 ENGINE MECHANICAL.....................................................................................................................1290 HEAD COVER........................................................................................................................1290 ROCKER ARM ASSEMBLY...............................................................................................................1290 CAMSHAFT ASSEMBLY.................................................................................................................1290 CYLINDER HEAD ASSEMBLY............................................................................................................1291 VALVE SYSTEM......................................................................................................................1292 CRANKSHAFT FRONT OIL SEAL.........................................................................................................1293 FRONT OIL SEAL RETAINER...........................................................................................................1293 FLYWHEEL ASSEMBLY.................................................................................................................1293 CRANKSHAFT REAR OIL SEAL..........................................................................................................1294 FLYWHEEL HOUSING..................................................................................................................1294 TIMING GEAR AND CAM IDLE GEAR.....................................................................................................1295 PISTON AND CONNECTING ROD.........................................................................................................1297 CRANKSHAFT........................................................................................................................1299 CYLINDER LINER....................................................................................................................1300 CYLINDER BLOCK....................................................................................................................1301 GLOW PLUG.........................................................................................................................1301 EXHAUST...............................................................................................................................1302 EXHAUST MANIFOLD..................................................................................................................1302 DPR CLEANER.......................................................................................................................1302 AFTERTREATMENT FUEL INJECTOR......................................................................................................1303 DEF PUMP..........................................................................................................................1303 DEF INJECTOR......................................................................................................................1303 DEF TANK..........................................................................................................................1304 DEF SENSOR........................................................................................................................1304 DPR DIFFERENTIAL PRESSURE SENSOR..................................................................................................1304 SCR UPSTREAM NOx SENSOR...........................................................................................................1304 SCR DOWNSTREAM NOx SENSOR.........................................................................................................1305 EXHAUST GAS TEMPERATURE SENSOR 1 (ATC INLET)......................................................................................1305 EXHAUST GAS TEMPERATURE SENSOR 2 (ATC OUTLET).....................................................................................1305 EXHAUST GAS TEMPERATURE SENSOR 3 (DOC INLET)......................................................................................1306 EXHAUST GAS TEMPERATURE SENSOR 4 (DPR INLET)......................................................................................1306 EXHAUST GAS TEMPERATURE SENSOR 5 (DPR OUTLET).....................................................................................1306 DEF SCR TEMPERATURE SENSOR (SCR INLET)............................................................................................1307 EXHAUST BRAKE.....................................................................................................................1307 EXHAUST BRAKE MAGNETIC VALVE......................................................................................................1307 COOLING...............................................................................................................................1308 RADIATOR CAP......................................................................................................................1308 THERMOSTAT CASE AND THERMOSTAT....................................................................................................1308 COOLANT PUMP......................................................................................................................1309 COOLANT TEMPERATURE SENSOR........................................................................................................1309 LUBRICATION...........................................................................................................................1310 OIL FILTER........................................................................................................................1310 OIL COOLER........................................................................................................................1310 OIL PUMP..........................................................................................................................1311 OIL PAN...........................................................................................................................1311 OIL PRESSURE SWITCH...............................................................................................................1311 STARTING/CHARGING.....................................................................................................................1312 STARTER...........................................................................................................................1312 V-BELT............................................................................................................................1312 ALTERNATOR (130A).................................................................................................................1312 TURBOCHARGER..........................................................................................................................1313 TURBOCHARGER ASSEMBLY.............................................................................................................1313 MOUNTING AND DISMOUNTING THE ENGINE (J05E)................................................................................................1315 ENGINE ASSEMBLY.......................................................................................................................1316 PRECAUTIONS IN TILTING AND LOWERING THE CAB.......................................................................................1316 MEASUREMENT OF COMPRESSION PRESSURE...............................................................................................1316 ADJUSTING THE VALVE CLEARANCE.....................................................................................................1319 REPLACEMENT.......................................................................................................................1321 ENGINE CONTROL (J05E).....................................................................................................................1330 CONTROL PARTS.........................................................................................................................1331 SYSTEM BLOCK DIAGRAM..............................................................................................................1331 ENGINE ECU............................................................................................................................1332 COMPONENT LOCATOR.................................................................................................................1332 REPLACEMENT.......................................................................................................................1333 VEHICLE CONTROL ECU...................................................................................................................1339 REPLACEMENT.......................................................................................................................1339 ENGINE SPEED MAIN SENSOR..............................................................................................................1340 COMPONENT LOCATOR.................................................................................................................1340 INSPECTION........................................................................................................................1341 REPLACEMENT.......................................................................................................................1341 ENGINE SPEED SUB SENSOR...............................................................................................................1342 COMPONENT LOCATOR.................................................................................................................1342 INSPECTION........................................................................................................................1343 REPLACEMENT.......................................................................................................................1343 ACCELERATOR PEDAL.....................................................................................................................1344 COMPONENT LOCATOR.................................................................................................................1344 REPLACEMENT.......................................................................................................................1345 BLOCK HEATER..........................................................................................................................1346 COMPONENT LOCATOR.................................................................................................................1346 REPLACEMENT.......................................................................................................................1347 FUEL SENDER GAUGE.....................................................................................................................1348 REPLACEMENT.......................................................................................................................1348 INTAKE TEMPERATURE SENSOR.............................................................................................................1348 REPLACEMENT.......................................................................................................................1348 DIESEL THROTTLE.......................................................................................................................1348 REPLACEMENT.......................................................................................................................1348 BOOST PRESSURE SENSOR.................................................................................................................1349 REPLACEMENT.......................................................................................................................1349 AIR FLOW SENSOR.......................................................................................................................1349 REPLACEMENT.......................................................................................................................1349 DPR DIFFERENTIAL PRESSURE SENSOR......................................................................................................1350 REPLACEMENT.......................................................................................................................1350 SCR UPSTREAM NOx SENSOR...............................................................................................................1350 REPLACEMENT.......................................................................................................................1350 SCR DOWNSTREAM NOx SENSOR.............................................................................................................1350 REPLACEMENT.......................................................................................................................1350 PM SENSOR.............................................................................................................................1351 REPLACEMENT.......................................................................................................................1351 EXHAUST GAS TEMPERATURE SENSOR 1 (ATC INLET)..........................................................................................1351 REPLACEMENT.......................................................................................................................1351 EXHAUST GAS TEMPERATURE SENSOR 2 (ATC OUTLET).........................................................................................1352 REPLACEMENT.......................................................................................................................1352 EXHAUST GAS TEMPERATURE SENSOR 3 (DOC INLET)..........................................................................................1352 REPLACEMENT.......................................................................................................................1352 EXHAUST GAS TEMPERATURE SENSOR 4 (DPR INLET)..........................................................................................1353 REPLACEMENT.......................................................................................................................1353 EXHAUST GAS TEMPERATURE SENSOR 5 (DPR OUTLET).........................................................................................1353 REPLACEMENT.......................................................................................................................1353 DEF SCR TEMPERATURE SENSOR (SCR INLET)................................................................................................1354 REPLACEMENT.......................................................................................................................1354 AMBIENT AIR TEMPERATURE SENSOR........................................................................................................1354 REPLACEMENT.......................................................................................................................1354 COOLANT TEMPERATURE SENSOR............................................................................................................1355 REPLACEMENT.......................................................................................................................1355 OIL PRESSURE SWITCH...................................................................................................................1355 REPLACEMENT.......................................................................................................................1355 FUEL SYSTEM (J05E)........................................................................................................................1356 FUEL SYSTEM...........................................................................................................................1357 FUEL SYSTEM DIAGRAM...............................................................................................................1357 FUEL TANK.............................................................................................................................1358 COMPONENT LOCATOR.................................................................................................................1358 REPLACEMENT (30 GALLON)...........................................................................................................1359 REPLACEMENT (33 GALLON)...........................................................................................................1362 FUEL SENDER GAUGE.....................................................................................................................1366 COMPONENT LOCATOR.................................................................................................................1366 REPLACEMENT.......................................................................................................................1367 FUEL FILTER AND CASE (ENGINE SIDE)....................................................................................................1369 COMPONENT LOCATOR.................................................................................................................1369 REPLACEMENT.......................................................................................................................1371 SUPPLY PUMP...........................................................................................................................1380 COMPONENT LOCATOR.................................................................................................................1380 REPLACEMENT.......................................................................................................................1381 INJECTOR..............................................................................................................................1391 COMPONENT LOCATOR.................................................................................................................1391 REPLACEMENT.......................................................................................................................1392 COMMON RAIL...........................................................................................................................1401 COMPONENT LOCATOR.................................................................................................................1401 INSPECTION........................................................................................................................1402 REPLACEMENT.......................................................................................................................1403 FUEL FILTER AND CASE (VEHICLE SIDE)...................................................................................................1408 COMPONENT LOCATOR.................................................................................................................1408 REPLACEMENT.......................................................................................................................1409 FUEL COOLER...........................................................................................................................1416 COMPONENT LOCATOR.................................................................................................................1416 REPLACEMENT.......................................................................................................................1417 EMISSION CONTROL (J05E)...................................................................................................................1419 EGR VALVE & COOLER....................................................................................................................1420 COMPONENT LOCATOR.................................................................................................................1420 INSPECTION........................................................................................................................1421 REPLACEMENT.......................................................................................................................1421 CLOSED VENTILATOR.....................................................................................................................1428 COMPONENT LOCATOR.................................................................................................................1428 REPLACEMENT.......................................................................................................................1430 INTAKE (J05E).............................................................................................................................1434 INTAKE MANIFOLD.......................................................................................................................1435 COMPONENT LOCATOR.................................................................................................................1435 REPLACEMENT.......................................................................................................................1436 DIESEL THROTTLE.......................................................................................................................1441 COMPONENT LOCATOR.................................................................................................................1441 INSPECTION........................................................................................................................1442 REPLACEMENT.......................................................................................................................1442 INTAKE PIPE (EXHAUST SIDE)............................................................................................................1444 COMPONENT LOCATOR.................................................................................................................1444 REPLACEMENT.......................................................................................................................1445 INTERCOOLER...........................................................................................................................1451 OVERHAUL..........................................................................................................................1451 STACK DUCT............................................................................................................................1452 COMPONENT LOCATOR.................................................................................................................1452 CLEANING THE PRECLEANER HOUSING...................................................................................................1453 REPLACEMENT.......................................................................................................................1454 AIR CLEANER...........................................................................................................................1456 COMPONENT LOCATOR.................................................................................................................1456 REPLACEMENT.......................................................................................................................1458 CLEANING THE AIR CLEANER ELEMENT..................................................................................................1462 INTAKE TEMPERATURE SENSOR.............................................................................................................1463 COMPONENT LOCATOR.................................................................................................................1463 REPLACEMENT.......................................................................................................................1465 BOOST PRESSURE SENSOR.................................................................................................................1466 COMPONENT LOCATOR.................................................................................................................1466 INSPECTION........................................................................................................................1467 REPLACEMENT.......................................................................................................................1467 AIR FLOW SENSOR.......................................................................................................................1469 COMPONENT LOCATOR.................................................................................................................1469 INSPECTION........................................................................................................................1470 REPLACEMENT.......................................................................................................................1472 ENGINE MECHANICAL (J05E)..................................................................................................................1473 HEAD COVER............................................................................................................................1474 COMPONENT LOCATOR.................................................................................................................1474 REPLACEMENT.......................................................................................................................1475 ROCKER ARM ASSEMBLY...................................................................................................................1478 COMPONENT LOCATOR.................................................................................................................1478 OVERHAUL..........................................................................................................................1479 CAMSHAFT ASSEMBLY.....................................................................................................................1486 COMPONENT LOCATOR.................................................................................................................1486 OVERHAUL..........................................................................................................................1488 CYLINDER HEAD ASSEMBLY................................................................................................................1493 COMPONENT LOCATOR.................................................................................................................1493 REPLACEMENT.......................................................................................................................1494 OVERHAUL..........................................................................................................................1502 VALVE SYSTEM..........................................................................................................................1508 COMPONENT LOCATOR.................................................................................................................1508 OVERHAUL..........................................................................................................................1509 CRANKSHAFT PULLEY.....................................................................................................................1518 COMPONENT LOCATOR.................................................................................................................1518 REPLACEMENT.......................................................................................................................1519 CRANKSHAFT FRONT OIL SEAL.............................................................................................................1521 COMPONENT LOCATOR.................................................................................................................1521 REPLACEMENT.......................................................................................................................1522 FRONT OIL SEAL RETAINER...............................................................................................................1525 COMPONENT LOCATOR.................................................................................................................1525 REPLACEMENT.......................................................................................................................1526 FLYWHEEL ASSEMBLY.....................................................................................................................1528 COMPONENT LOCATOR.................................................................................................................1528 OVERHAUL..........................................................................................................................1529 CRANKSHAFT REAR OIL SEAL..............................................................................................................1533 COMPONENT LOCATOR.................................................................................................................1533 REPLACEMENT.......................................................................................................................1534 FLYWHEEL HOUSING......................................................................................................................1537 COMPONENT LOCATOR.................................................................................................................1537 REPLACEMENT.......................................................................................................................1538 TIMING GEAR & CAM IDLE GEAR...........................................................................................................1542 COMPONENT LOCATOR.................................................................................................................1542 CONFIGURATION DIAGRAM.............................................................................................................1543 OVERHAUL..........................................................................................................................1544 PISTON AND CONNECTING ROD.............................................................................................................1561 COMPONENT LOCATOR.................................................................................................................1561 OVERHAUL..........................................................................................................................1562 CRANKSHAFT............................................................................................................................1578 COMPONENT LOCATOR.................................................................................................................1578 REPLACEMENT.......................................................................................................................1580 CYLINDER LINER........................................................................................................................1589 COMPONENT LOCATOR.................................................................................................................1589 REPLACEMENT.......................................................................................................................1590 CYLINDER BLOCK........................................................................................................................1594 COMPONENT LOCATOR.................................................................................................................1594 OVERHAUL..........................................................................................................................1595 ENGINE MOUNTING AND BRACKET...........................................................................................................1603 COMPONENT LOCATOR.................................................................................................................1603 REPLACEMENT.......................................................................................................................1604 GLOW PLUG.............................................................................................................................1606 COMPONENT LOCATOR.................................................................................................................1606 REPLACEMENT.......................................................................................................................1607 GCU...................................................................................................................................1609 COMPONENT LOCATOR.................................................................................................................1609 REPLACEMENT.......................................................................................................................1609 EXHAUST (J05E)............................................................................................................................1610 EXHAUST MANIFOLD......................................................................................................................1612 COMPONENT LOCATOR.................................................................................................................1612 REPLACEMENT.......................................................................................................................1613 EXHAUST PIPE..........................................................................................................................1616 COMPONENT LOCATOR.................................................................................................................1616 REPLACEMENT.......................................................................................................................1617 EXHAUST PIPE (ATC)....................................................................................................................1625 COMPONENT LOCATOR.................................................................................................................1625 REPLACEMENT.......................................................................................................................1626 DEF-SCR & DPR.........................................................................................................................1628 CONFIGURATION DIAGRAM.............................................................................................................1628 HANDLING OF DEF...................................................................................................................1629 CAUTIONS ON DEF/COOLANT PIPING ATTACHING AND DETACHING ...........................................................................1630 DEF-SCR...............................................................................................................................1632 COMPONENT LOCATOR.................................................................................................................1632 REPLACEMENT.......................................................................................................................1633 DPR CLEANER...........................................................................................................................1637 COMPONENT LOCATOR.................................................................................................................1637 DPR INSPECTION....................................................................................................................1638 INSPECTION PROCEDURE FOLLOWED WHEN “EXHAUST GAS AFTER TREATMENT SYSTEM MAINTENANCE REQUIREMENT LIGHT” LIGHT UP....................1639 INSPECTION BY WAY OF HINO DXⅡ.....................................................................................................1640 INSPECTION PROCEDURE FOLLOWED WHEN MALFUNCTION INDICATOR LIGHT ILLUMINATES (ABNORMAL).............................................1644 DETERMINATION BY WAY OF DPR STATE DETERMINATION MONITOR OF HINO DX Ⅱ..............................................................1647 CHECKING THE DPR STATE............................................................................................................1647 REPLACEMENT.......................................................................................................................1648 OVERALL OPERATION FLOW............................................................................................................1653 AIR CLEANING FLOW.................................................................................................................1660 AFTERTREATMENT FUEL INJECTOR..........................................................................................................1661 COMPONENT LOCATOR.................................................................................................................1661 REPLACEMENT.......................................................................................................................1662 AFTERTREATMENT FUEL CUTOFF VALVE......................................................................................................1671 COMPONENT LOCATOR.................................................................................................................1671 REPLACEMENT.......................................................................................................................1672 DEF PUMP..............................................................................................................................1674 COMPONENT LOCATOR.................................................................................................................1674 REPLACEMENT.......................................................................................................................1675 DEF INJECTOR..........................................................................................................................1685 COMPONENT LOCATOR.................................................................................................................1685 REPLACEMENT.......................................................................................................................1686 DEF TANK..............................................................................................................................1691 COMPONENT LOCATOR.................................................................................................................1691 INSPECTION........................................................................................................................1692 REPLACEMENT.......................................................................................................................1693 DEF SENSOR............................................................................................................................1701 COMPONENT LOCATOR.................................................................................................................1701 REPLACEMENT.......................................................................................................................1702 COOLANT CUTOFF VALVE..................................................................................................................1704 COMPONENT LOCATOR.................................................................................................................1704 REPLACEMENT.......................................................................................................................1705 DCU...................................................................................................................................1707 COMPONENT LOCATOR.................................................................................................................1707 REPLACEMENT.......................................................................................................................1708 DPR DIFFERENTIAL PRESSURE SENSOR......................................................................................................1714 COMPONENT LOCATOR.................................................................................................................1714 REPLACEMENT.......................................................................................................................1715 SCR UPSTREAM NOx SENSOR...............................................................................................................1717 COMPONENT LOCATOR.................................................................................................................1717 REPLACEMENT.......................................................................................................................1718 SCR DOWNSTREAM NOx SENSOR.............................................................................................................1720 COMPONENT LOCATOR.................................................................................................................1720 REPLACEMENT.......................................................................................................................1721 PM SENSOR.............................................................................................................................1723 COMPONENT LOCATOR.................................................................................................................1723 REPLACEMENT.......................................................................................................................1724 EXHAUST GAS TEMPERATURE SENSOR 1 (ATC INLET)..........................................................................................1726 COMPONENT LOCATOR.................................................................................................................1726 REPLACEMENT.......................................................................................................................1727 EXHAUST GAS TEMPERATURE SENSOR 2 (ATC OUTLET).........................................................................................1729 COMPONENT LOCATOR.................................................................................................................1729 REPLACEMENT.......................................................................................................................1730 EXHAUST GAS TEMPERATURE SENSOR 3 (DOC INLET)..........................................................................................1732 COMPONENT LOCATOR.................................................................................................................1732 REPLACEMENT.......................................................................................................................1733 EXHAUST GAS TEMPERATURE SENSOR 4 (DPR INLET)..........................................................................................1735 COMPONENT LOCATOR.................................................................................................................1735 REPLACEMENT.......................................................................................................................1736 EXHAUST GAS TEMPERATURE SENSOR 5 (DPR OUTLET).........................................................................................1738 COMPONENT LOCATOR.................................................................................................................1738 REPLACEMENT.......................................................................................................................1739 DEF SCR TEMPERATURE SENSOR (SCR INLET)................................................................................................1741 COMPONENT LOCATOR.................................................................................................................1741 REPLACEMENT.......................................................................................................................1742 AMBIENT AIR TEMPERATURE SENSOR........................................................................................................1745 COMPONENT LOCATOR.................................................................................................................1745 REPLACEMENT.......................................................................................................................1746 EXHAUST BRAKE.........................................................................................................................1747 COMPONENT LOCATOR.................................................................................................................1747 REPLACEMENT.......................................................................................................................1748 EXHAUST BRAKE MAGNETIC VALVE..........................................................................................................1751 COMPONENT LOCATOR.................................................................................................................1751 REPLACEMENT.......................................................................................................................1752 COOLING (J05E)............................................................................................................................1754 COOLING SYSTEM........................................................................................................................1755 COOLING SYSTEM DIAGRAM............................................................................................................1755 RADIATOR..............................................................................................................................1756 COMPONENT LOCATOR.................................................................................................................1756 INSPECTION........................................................................................................................1757 REPLACEMENT.......................................................................................................................1758 RADIATOR CAP..........................................................................................................................1768 COMPONENT LOCATOR.................................................................................................................1768 REPLACEMENT.......................................................................................................................1769 RESERVE TANK..........................................................................................................................1771 COMPONENT LOCATOR.................................................................................................................1771 REPLACEMENT.......................................................................................................................1772 INTERCOOLER...........................................................................................................................1773 COMPONENT LOCATOR.................................................................................................................1773 OVERHAUL..........................................................................................................................1774 THERMOSTAT CASE AND THERMOSTAT........................................................................................................1776 COMPONENT LOCATOR.................................................................................................................1776 OVERHAUL..........................................................................................................................1777 COOLANT PUMP..........................................................................................................................1783 COMPONENT LOCATOR.................................................................................................................1783 REPLACEMENT.......................................................................................................................1784 COOLING FAN AND FAN CLUTCH............................................................................................................1786 COMPONENT LOCATOR.................................................................................................................1786 OVERHAUL..........................................................................................................................1787 COOLANT TEMPERATURE SENSOR............................................................................................................1790 COMPONENT LOCATOR.................................................................................................................1790 REPLACEMENT.......................................................................................................................1791 LUBRICATION (J05E)........................................................................................................................1793 LUBRICATION SYSTEM....................................................................................................................1794 LUBRICATION SYSTEM DIAGRAM........................................................................................................1794 OIL FILTER............................................................................................................................1795 COMPONENT LOCATOR.................................................................................................................1795 REPLACEMENT.......................................................................................................................1796 OIL COOLER............................................................................................................................1799 COMPONENT LOCATOR.................................................................................................................1799 OVERHAUL..........................................................................................................................1800 OIL PUMP..............................................................................................................................1807 COMPONENT LOCATOR.................................................................................................................1807 OVERHAUL..........................................................................................................................1808 OIL PAN...............................................................................................................................1814 COMPONENT LOCATOR.................................................................................................................1814 REPLACEMENT.......................................................................................................................1815 OIL STRAINER..........................................................................................................................1819 COMPONENT LOCATOR.................................................................................................................1819 REPLACEMENT.......................................................................................................................1820 OIL PRESSURE SWITCH...................................................................................................................1821 COMPONENT LOCATOR.................................................................................................................1821 REPLACEMENT.......................................................................................................................1822 OIL LEVEL GAUGE AND GUIDE.............................................................................................................1824 COMPONENT LOCATOR.................................................................................................................1824 REPLACEMENT.......................................................................................................................1825 STARTING/CHARGING (J05E)..................................................................................................................1827 STARTER...............................................................................................................................1828 COMPONENT LOCATOR.................................................................................................................1828 REPLACEMENT.......................................................................................................................1829 V-BELT................................................................................................................................1834 COMPONENT LOCATOR.................................................................................................................1834 REPLACEMENT.......................................................................................................................1835 ALTERNATOR (130A).....................................................................................................................1838 COMPONENT LOCATOR.................................................................................................................1838 OVERHAUL..........................................................................................................................1839 TURBOCHARGER (J05E).......................................................................................................................1853 TURBOCHARGER ASSEMBLY.................................................................................................................1854 COMPONENT LOCATOR.................................................................................................................1854 INSPECTION........................................................................................................................1855 REPLACEMENT.......................................................................................................................1857 FOREWORD..................................................................................................................................1866 CHAPTER REFERENCES........................................................................................................................1867 INDEX.....................................................................................................................................1868 GENERAL INTRODUCTION......................................................................................................................1870 HOW TO IDENTIFY VEHICLE TYPE..........................................................................................................1871 HOW TO IDENTIFY VEHICLE TYPE......................................................................................................1871 VEHICLE TYPE .................................................................................................................1871 VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE.................................................................................1872 APPEARANCE OF VEHICLE.................................................................................................................1873 APPEARANCE........................................................................................................................1873 APPEARANCE OF VEHICLE.........................................................................................................1873 SAFETY INSTRUCTIONS AND READINESS TO WORK.............................................................................................1874 WARNING...........................................................................................................................1874 GENERAL PRECAUTIONS...........................................................................................................1874 IDENTIFICATION INFORMATION....................................................................................................1879 SAFETY INSTRUCTIONS FOR WORK......................................................................................................1882 PRECAUTIONS...................................................................................................................1882 INTRODUCTION TO WORKSHOP MANUAL...................................................................................................1886 GENERAL.......................................................................................................................1886 INTRODUCTION TO DESCRIPTIONS..................................................................................................1887 DEFINITION OF TERM............................................................................................................1890 TROUBLE SHOOTING......................................................................................................................1891 TROUBLESHOOTING WITH DIAGNOSIS MONITOR............................................................................................1891 TROUBLESHOOTING PROCEDURE.....................................................................................................1891 APPARATUS FOR TROUBLE SHOOTING................................................................................................1893 TROUBLE DIAGNOSIS USING THE COMPUTER (HINO DXII) .................................................................................1894 STEP OF TROUBLE DIAGNOSIS.....................................................................................................1894 APPARATUS FOR TROUBLE DIAGNOSIS...............................................................................................1895 GLOSSARY..............................................................................................................................1896 DEFINITION OF ABBREVIATION........................................................................................................1896 LIST OF ABBREVIATION..........................................................................................................1896 GLOSSARY OF SAE AND HINO TERMS................................................................................................1899 ENGINE (J05E).............................................................................................................................1902 TROUBLESHOOTING.......................................................................................................................1905 ENGINE ECU (J05E).................................................................................................................1905 PRECAUTIONS FOR DIAGNOSIS.....................................................................................................1905 ELECTRICAL....................................................................................................................1907 PRECAUTIONS...................................................................................................................1908 COMPUTER (ECU) PIN ASSIGNMENT.................................................................................................1912 ENGINE ECU CONNECTOR..........................................................................................................1918 INSPECTION....................................................................................................................1922 TROUBLE DIAGNOSIS USING THE COMPUTER (HINO DXⅡ)...............................................................................1923 DIAGNOSTIC TROUBLE CODE (DTC) TABLE...........................................................................................1924 GROUP SHARING THE SENSOR SUPPLY TERMINAL......................................................................................1952 GROUP SHARING THE SENSOR GND TERMINAL.........................................................................................1953 MALFUNCTION CODES IN CASE OF DISRUPTION OF CAN COMMUNICATION..................................................................1954 PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (250 k)......................................................................1957 DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (250 k) [DIESEL]...............................................1962 DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (250 k) [HYBRID]...............................................1972 PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (500 k) [DIESEL]............................................................1983 PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (500 k) [HYBRID]............................................................1988 DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (500 k) [DIESEL]...............................................1994 DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (500 k) [HYBRID]...............................................1999 MALFUNCTION OF STARTER........................................................................................................2004 MALFUNCTION OF ALTERNATOR.....................................................................................................2011 MALFUNCTION CODES FOR FAULTY ACTUATOR POWER RELAY.............................................................................2015 ENG BASIC INSPECTION SHEET (ENGINE INSPECTION CHECK SHEET)....................................................................2016 NO DTC........................................................................................................................2020 DTC: P0005....................................................................................................................2024 DTC: P0006 and P0007..........................................................................................................2028 DTC: P0016....................................................................................................................2034 DTC: P0027....................................................................................................................2037 DTC: P003A....................................................................................................................2042 DTC: P0045....................................................................................................................2047 DTC: P0047....................................................................................................................2051 DTC: P0048....................................................................................................................2055 DTC: P006E....................................................................................................................2059 DTC: P006F....................................................................................................................2063 DTC: P007B....................................................................................................................2067 DTC: P007C and P007D..........................................................................................................2081 DTC: P0088....................................................................................................................2089 DTC: P0096....................................................................................................................2097 DTC: P0097 and P0098 .........................................................................................................2108 DTC: P0101....................................................................................................................2117 DTC: P0104....................................................................................................................2126 DTC: P0106....................................................................................................................2133 DTC: P0107....................................................................................................................2139 DTC: P0108....................................................................................................................2145 DTC: P0111....................................................................................................................2151 DTC: P0112 and P0113..........................................................................................................2157 DTC: P0115....................................................................................................................2165 DTC: P0117 and P0118..........................................................................................................2174 DTC: P011A....................................................................................................................2182 DTC: P0122 and P0123..........................................................................................................2191 DTC: P0126....................................................................................................................2201 DTC: P0128....................................................................................................................2205 DTC: P0148 ...................................................................................................................2210 DTC: P016E and P016F .........................................................................................................2221 DTC: P0182 and P0183 .........................................................................................................2231 DTC: P0191....................................................................................................................2239 DTC: P0192 and P0193 .........................................................................................................2247 DTC: P01A5....................................................................................................................2257 DTC: P01A6....................................................................................................................2264 DTC: P0200....................................................................................................................2271 DTC: P0201, P0202, P0203 and P0204............................................................................................2274 DTC: P0217....................................................................................................................2279 DTC: P0219....................................................................................................................2284 DTC: P0222 and P0223..........................................................................................................2292 DTC: P0234....................................................................................................................2302 DTC: P0263, P0266, P0269 and P0272............................................................................................2308 DTC: P026C and P026D..........................................................................................................2319 DTC: P0299....................................................................................................................2332 DTC: P0300....................................................................................................................2338 DTC: P0301, P0302, P0303 and P0304............................................................................................2346 DTC: P0335....................................................................................................................2355 DTC: P0336....................................................................................................................2362 DTC: P0340....................................................................................................................2370 DTC: P0341....................................................................................................................2374 DTC: P0381....................................................................................................................2382 DTC: P0401....................................................................................................................2388 DTC: P0402....................................................................................................................2404 DTC: P0404....................................................................................................................2414 DTC: P0405 and P0406..........................................................................................................2419 DTC: P041B....................................................................................................................2425 DTC: P041C and P041D..........................................................................................................2438 DTC: P0420....................................................................................................................2446 DTC: P0421....................................................................................................................2448 DTC: P0422....................................................................................................................2462 DTC: P0489 and P0490..........................................................................................................2465 DTC: P049D....................................................................................................................2471 DTC: P04D5 and P04D6..........................................................................................................2476 DTC: P04DA....................................................................................................................2484 DTC: P04DB....................................................................................................................2493 DTC: P0500 and P0501..........................................................................................................2501 DTC: P0504....................................................................................................................2508 DTC: P0506....................................................................................................................2513 DTC: P0507....................................................................................................................2517 DTC: P0521....................................................................................................................2521 DTC: P0524....................................................................................................................2525 DTC: P0545 and P0546..........................................................................................................2530 DTC: P054E....................................................................................................................2538 DTC: P054F....................................................................................................................2542 DTC: P0562 and P0563..........................................................................................................2546 DTC: P0605....................................................................................................................2551 DTC: P0606....................................................................................................................2553 DTC: P0607....................................................................................................................2555 DTC: P0610....................................................................................................................2557 DTC: P0611....................................................................................................................2560 DTC: P0617....................................................................................................................2562 DTC: P0628 and P0629..........................................................................................................2566 DTC: P062F....................................................................................................................2574 DTC: P0630....................................................................................................................2578 DTC: P0642....................................................................................................................2582 DTC: P0643....................................................................................................................2587 DTC: P064C....................................................................................................................2593 DTC: P0652....................................................................................................................2598 DTC: P0653....................................................................................................................2604 DTC: P0671 and P0672 .........................................................................................................2611 DTC: P0673 and P0674..........................................................................................................2617 DTC: P0683....................................................................................................................2623 DTC: P0686....................................................................................................................2629 DTC: P0698....................................................................................................................2634 DTC: P0699....................................................................................................................2637 DTC: P06A4....................................................................................................................2640 DTC: P06A5....................................................................................................................2643 DTC: P06D3 and P06D4..........................................................................................................2646 DTC: P0700....................................................................................................................2654 DTC: P073D....................................................................................................................2656 DTC: P081A....................................................................................................................2660 DTC: P081B....................................................................................................................2666 DTC: P0A7B....................................................................................................................2670 DTC: P0AC4....................................................................................................................2672 DTC: P0CA1....................................................................................................................2674 DTC: P104E....................................................................................................................2676 DTC: P104F....................................................................................................................2680 DTC: P1133....................................................................................................................2684 DTC: P119F....................................................................................................................2691 DTC: P1426....................................................................................................................2697 DTC: P1427....................................................................................................................2704 DTC: P1428....................................................................................................................2711 DTC: P1458....................................................................................................................2719 DTC: P1459....................................................................................................................2724 DTC: P146F (2 digit diagnosis code: 01).......................................................................................2729 FOREWORD..................................................................................................................................2734 CHAPTER REFERENCES........................................................................................................................2735 INDEX.....................................................................................................................................2736 ENGINE (J05E).............................................................................................................................2738 TROUBLESHOOTING.......................................................................................................................2741 ENGINE ECU (J05E).................................................................................................................2741 DTC: P14B0....................................................................................................................2741 DTC: P14B2....................................................................................................................2745 DTC: P14B3 and P14B4..........................................................................................................2749 DTC: P14B7 and P14B8..........................................................................................................2755 DTC: P14BC and P14BD..........................................................................................................2761 DTC: P14BF....................................................................................................................2767 DTC: P1515....................................................................................................................2772 DTC: P1530....................................................................................................................2777 DTC: P2002....................................................................................................................2781 DTC: P200C....................................................................................................................2803 DTC: P2032 and P2033..........................................................................................................2812 DTC: P203F....................................................................................................................2820 DTC: P204F....................................................................................................................2824 DTC: P206B....................................................................................................................2827 DTC: P207F....................................................................................................................2852 DTC: P2080....................................................................................................................2860 DTC: P2084....................................................................................................................2868 DTC: P20CD....................................................................................................................2876 DTC: P20CE....................................................................................................................2881 DTC: P20D8....................................................................................................................2885 DTC: P20DE....................................................................................................................2891 DTC: P20DF....................................................................................................................2895 DTC: P20E0....................................................................................................................2901 DTC: P20EE....................................................................................................................2907 DTC: P20EF....................................................................................................................2915 DTC: P2100....................................................................................................................2917 DTC: P2101....................................................................................................................2923 DTC: P2103....................................................................................................................2930 DTC: P2120....................................................................................................................2935 DTC: P2122 and P2123..........................................................................................................2939 DTC: P2127 and P2128..........................................................................................................2949 DTC: P2135....................................................................................................................2958 DTC: P2138....................................................................................................................2963 DTC: P2146....................................................................................................................2968 DTC: P2147 and P2148..........................................................................................................2975 DTC: P2149....................................................................................................................2983 DTC: P2150 and P2151..........................................................................................................2990 DTC: P2184 and P2185..........................................................................................................2998 DTC: P2201....................................................................................................................3006 DTC: P2227....................................................................................................................3051 DTC: P2228 and P2229..........................................................................................................3055 DTC: P2269....................................................................................................................3060 DTC: P226C....................................................................................................................3064 DTC: P229F....................................................................................................................3070 DTC: P22D3....................................................................................................................3118 DTC: P240F....................................................................................................................3122 DTC: P2428....................................................................................................................3132 DTC: P242B....................................................................................................................3136 DTC: P242C and P242D..........................................................................................................3144 DTC: P244A....................................................................................................................3152 DTC: P244B....................................................................................................................3173 DTC: P2457....................................................................................................................3183 DTC: P2458....................................................................................................................3198 DTC: P2459....................................................................................................................3211 DTC: P2463....................................................................................................................3214 DTC: P246F....................................................................................................................3221 DTC: P2470 and P2471..........................................................................................................3229 DTC: P2481 and P2482..........................................................................................................3237 DTC: P2483....................................................................................................................3245 DTC: P24A0....................................................................................................................3253 DTC: P24A1....................................................................................................................3256 DTC: P24A2....................................................................................................................3264 DTC: P24AE (2 digit diagnosis code: 04, 05, 06, 14, 25, 26, 27, 28)...........................................................3274 DTC: P24AF (2 digit diagnosis code: 23).......................................................................................3276 DTC: P24B0 (2 digit diagnosis code: 19, 20, 21)...............................................................................3279 DTC: P24B1 (2 digit diagnosis code: 18).......................................................................................3281 DTC: P24B4 (2 digit diagnosis code: 10, 11, 15, 17)...........................................................................3283 DTC: P24B7 (2 digit diagnosis code: 08).......................................................................................3285 DTC: P24C7 (2 digit diagnosis code: 09).......................................................................................3288 DTC: P24D0 (2 digit diagnosis code: 02).......................................................................................3292 DTC: P24D1 (2 digit diagnosis code: 12).......................................................................................3296 DTC: P24DA (2 digit diagnosis code: 07).......................................................................................3298 DTC: P24FE....................................................................................................................3302 DTC: P2562....................................................................................................................3321 DTC: P259E....................................................................................................................3325 DTC: P259F....................................................................................................................3331 DTC: P2635....................................................................................................................3336 DTC: P268A and P2696..........................................................................................................3345 DTC: P26C8....................................................................................................................3351 DTC: P2A00....................................................................................................................3353 DTC: P2A01....................................................................................................................3357 DTC: P2BA9....................................................................................................................3361 DTC: U0073....................................................................................................................3366 DTC: U010A....................................................................................................................3369 DTC: U010C....................................................................................................................3374 DTC: U010E....................................................................................................................3379 DTC: U0293....................................................................................................................3385 DTC: U029D (DIESEL)...........................................................................................................3390 DTC: U029D (HYBRID)...........................................................................................................3396 DTC: U029E (DIESEL)...........................................................................................................3402 DTC: U029E (HYBRID)...........................................................................................................3408 DTC: U02A2....................................................................................................................3414 DTC: U02A3....................................................................................................................3420 DTC: U0301....................................................................................................................3423 DTC: U1001....................................................................................................................3426 DTC: U110A....................................................................................................................3433 ENGINE (COMMON ITEMS).....................................................................................................................3440 TROUBLESHOOTING.......................................................................................................................3442 DCU...............................................................................................................................3442 PRECAUTIONS FOR DIAGNOSIS.....................................................................................................3442 DIAGRAM.......................................................................................................................3444 SIGNAL CHECK HARNESS..........................................................................................................3445 INSPECTION....................................................................................................................3445 TROUBLE DIAGNOSIS USING THE COMPUTER (HINO DXⅡ)...............................................................................3447 DTC: P0071....................................................................................................................3454 DTC: P0072....................................................................................................................3464 DTC: P0073....................................................................................................................3470 DTC: P0562....................................................................................................................3476 DTC: P0563....................................................................................................................3480 DTC: P060B....................................................................................................................3484 DTC: P060C....................................................................................................................3487 DTC: P062F....................................................................................................................3489 DTC: P0667....................................................................................................................3491 DTC: P068A....................................................................................................................3493 DTC: P06AD....................................................................................................................3498 DTC: P06AE....................................................................................................................3500 DTC: P142A....................................................................................................................3502 DTC: P142B....................................................................................................................3513 DTC: P14C1....................................................................................................................3524 DTC: P14C2....................................................................................................................3538 DTC: P14C3....................................................................................................................3543 DTC: P202E....................................................................................................................3548 DTC: P203C....................................................................................................................3553 DTC: P203D....................................................................................................................3556 DTC: P2044....................................................................................................................3559 DTC: P2045....................................................................................................................3562 DTC: P2047....................................................................................................................3565 DTC: P2048....................................................................................................................3569 DTC: P2049....................................................................................................................3574 DTC: P204B....................................................................................................................3579 DTC: P204C....................................................................................................................3582 DTC: P204D....................................................................................................................3587 FOREWORD..................................................................................................................................3593 CHAPTER REFERENCES........................................................................................................................3594 INDEX.....................................................................................................................................3595 ENGINE (COMMON ITEMS).....................................................................................................................3597 TROUBLESHOOTING.......................................................................................................................3597 DCU...............................................................................................................................3597 DTC: P205B....................................................................................................................3599 DTC: P205C....................................................................................................................3608 DTC: P205D....................................................................................................................3611 DTC: P206A....................................................................................................................3614 DTC: P206C....................................................................................................................3617 DTC: P206D....................................................................................................................3620 DTC: P208A....................................................................................................................3623 DTC: P208B....................................................................................................................3629 DTC: P208C....................................................................................................................3632 DTC: P208D....................................................................................................................3637 DTC: P20A0....................................................................................................................3642 DTC: P20A1....................................................................................................................3647 DTC: P20A2....................................................................................................................3651 DTC: P20A3....................................................................................................................3656 DTC: P20B1....................................................................................................................3661 DTC: P20B2....................................................................................................................3666 DTC: P20B3....................................................................................................................3675 DTC: P20B4....................................................................................................................3680 DTC: P20BD, P20B9 and P20C1...................................................................................................3685 DTC: P20C0, P20BC and P20C4...................................................................................................3693 DTC: P20E8....................................................................................................................3699 DTC: P20E9....................................................................................................................3710 DTC: P20F4....................................................................................................................3716 DTC: P21C2....................................................................................................................3721 DTC: P21C3....................................................................................................................3725 DTC: P21C4....................................................................................................................3730 DTC: P2202....................................................................................................................3735 DTC: P2203....................................................................................................................3738 DTC: P2204....................................................................................................................3741 DTC: P2209....................................................................................................................3748 DTC: P22A0....................................................................................................................3756 DTC: P22A1....................................................................................................................3759 DTC: P22A2....................................................................................................................3762 DTC: P22A7....................................................................................................................3769 DTC: P2510....................................................................................................................3777 DTC: P2BAE....................................................................................................................3782 DTC: U0029....................................................................................................................3790 DTC: U0038....................................................................................................................3796 DTC: U0100....................................................................................................................3802 DTC: U029D (DIESEL)...........................................................................................................3806 DTC: U029D (HYBRID)...........................................................................................................3812 DTC: U029E (DIESEL)...........................................................................................................3818 DTC: U029E (HYBRID)...........................................................................................................3824 DTC: U02A2....................................................................................................................3830 VEHICLE CONTROL ECU...............................................................................................................3836 CAUTIONS ON TROUBLESHOOTING...................................................................................................3836 SYSTEM BLOCK DIAGRAM..........................................................................................................3837 COMPUTER PIN ASSIGNMENT.......................................................................................................3838 TROUBLESHOOTING WITH COMPUTER (HINO DXII) ....................................................................................3842 DIAGNOSIS CODE TABLE..........................................................................................................3843 DTC: C1244....................................................................................................................3845 DTC: C1245....................................................................................................................3850 DTC: C1249....................................................................................................................3852 DTC: C1418....................................................................................................................3858 DTC: C1491....................................................................................................................3862 DTC: P0335....................................................................................................................3864 DTC: P0501....................................................................................................................3867 DTC: P0503....................................................................................................................3873 DTC: P0555....................................................................................................................3878 DTC: P0562....................................................................................................................3880 DTC: P0563....................................................................................................................3884 DTC: P0572....................................................................................................................3887 DTC: P0573....................................................................................................................3893 DTC: P0577....................................................................................................................3899 DTC: P05BF....................................................................................................................3903 DTC: P0604....................................................................................................................3906 DTC: P0605 ...................................................................................................................3908 DTC: P0605 ...................................................................................................................3910 DTC: P0606....................................................................................................................3912 DTC: P0617....................................................................................................................3914 DTC: P062F....................................................................................................................3917 DTC: P0702....................................................................................................................3919 DTC: P081D....................................................................................................................3921 DTC: P161F....................................................................................................................3926 DTC: P1649....................................................................................................................3931 DTC: P165A....................................................................................................................3935 DTC: P165B....................................................................................................................3938 DTC: P2525....................................................................................................................3941 DTC: P2526....................................................................................................................3944 DTC: P258D....................................................................................................................3947 DTC: U0101....................................................................................................................3950 DTC: U0105....................................................................................................................3953 DTC: U0121....................................................................................................................3956 DTC: U0155....................................................................................................................3959 DTC: U0293....................................................................................................................3962 DTC: U0418....................................................................................................................3965 DTC: U1136....................................................................................................................3968 HYBRID....................................................................................................................................3971 TROUBLE SHOOTING......................................................................................................................3974 HYBRID CONTROL SYSTEM.............................................................................................................3974 TROUBLE SHOOTING STEPS FOR HYBRID SYSTEM......................................................................................3974 SAFETY MEASURES FOR HIGH-VOLTAGE WORK.........................................................................................3983 LIST OF CONNECTOR SYMBOLS.....................................................................................................3986 HV SYSTEM WIRING DIAGRAM......................................................................................................3990 HEARING SHEET.................................................................................................................3992 HYBRID ECU........................................................................................................................3993 DIAGNOSIS CODE TABLE..........................................................................................................3993 FREEZE FRAME DATA LIST........................................................................................................4003 LIST OF DATA MONITOR ITEMS....................................................................................................4006 ACTIVE TEST...................................................................................................................4009 COMMON INSPECTION CHART.......................................................................................................4010 DTC: C0081 (TCA0).............................................................................................................4015 DTC: P0500 (TC51).............................................................................................................4017 DTC: P0501 (TC5B).............................................................................................................4024 DTC: P0562 (TC71).............................................................................................................4028 DTC: P060B (TCB2).............................................................................................................4034 DTC: P0617 (TC59).............................................................................................................4036 DTC: P062F (TCB3).............................................................................................................4042 DTC: P0810 (TC9C).............................................................................................................4044 DTC: P0810 (TC9D).............................................................................................................4047 DTC: P0A01 (TC7B).............................................................................................................4050 DTC: P0A02 (TC78).............................................................................................................4056 DTC: P0A03 (TC79).............................................................................................................4062 DTC: P0A06 (TC7F).............................................................................................................4067 DTC: P0A07 (TC7E).............................................................................................................4075 DTC: P0A0F (TC31) ............................................................................................................4078 DTC: P0A1D (TC12).............................................................................................................4081 DTC: P0A1D (TC17).............................................................................................................4083 DTC: P0A78 (TC21).............................................................................................................4085 DTC: P0A78 (TC22).............................................................................................................4087 DTC: P0A7E (TC48).............................................................................................................4089 DTC: P0A82 (TC67).............................................................................................................4093 DTC: P0A84 (TC66).............................................................................................................4103 DTC: P0A85 (TC65).............................................................................................................4114 DTC: P0A90 (TC2A).............................................................................................................4119 DTC: P0A92 (TC29).............................................................................................................4128 DTC: P0A93 (TC7A).............................................................................................................4137 DTC: P0AFD (TC6B).............................................................................................................4142 DTC: P0BC9 (TC69).............................................................................................................4145 DTC: P0BCA (TC68).............................................................................................................4157 DTC: P0C73 (TC80).............................................................................................................4163 DTC: P3000 (TC42).............................................................................................................4168 DTC: P3001 (TC41).............................................................................................................4174 DTC: P3001 (TC43).............................................................................................................4176 DTC: P3001 (TC45).............................................................................................................4178 DTC: P3001 (TC46).............................................................................................................4180 DTC: P3001 (TC47).............................................................................................................4183 DTC: P3001 (TC4A).............................................................................................................4186 DTC: P3001 (TC4B).............................................................................................................4189 DTC: P3001 (TC4C).............................................................................................................4191 DTC: P3001 (TC4D).............................................................................................................4193 DTC: P3009 (TC49).............................................................................................................4196 DTC: P3010 (TC4E).............................................................................................................4206 DTC: P3010 (TC4F).............................................................................................................4208 DTC: P3128 (TC7D).............................................................................................................4211 DTC: P3129 (TC7C).............................................................................................................4219 DTC: P314C (TC82).............................................................................................................4223 DTC: P314D (TC81).............................................................................................................4227 DTC: P324B (TC62).............................................................................................................4235 DTC: P324C (TC61).............................................................................................................4239 DTC: P33B1 (TC64).............................................................................................................4244 DTC: P33B2 (TC63).............................................................................................................4248 DTC: U0073 (TC11).............................................................................................................4252 DTC: U0074 (TC16).............................................................................................................4256 DTC: U0100 (TC13).............................................................................................................4259 DTC: U0101 (TC18).............................................................................................................4262 DTC: U0110 (TC14).............................................................................................................4267 DTC: U0111 (TC15).............................................................................................................4273 DTC: U0121 (TC24).............................................................................................................4279 DTC: U0155 (TC25).............................................................................................................4284 DTC: U110A (TC26).............................................................................................................4289 DTC: U1136 (TC27).............................................................................................................4294 INVERTER..........................................................................................................................4299 DIAGNOSIS CODE TABLE..........................................................................................................4299 FREEZE FRAME DATA LIST........................................................................................................4305 DATA MONITOR ITEM LIST........................................................................................................4307 CONNECTION DIAGRAM............................................................................................................4310 INSULATION RESISTANCE MEASUREMENT PROCEDURE FOR HYBRID MOTOR..................................................................4311 DTC: P0562 (TC96) ............................................................................................................4313 DTC: P0562 (TCA0) ............................................................................................................4320 DTC: P0604 (TC18) ............................................................................................................4327 DTC: P0604 (TCD2).............................................................................................................4329 DTC: P0605 (TC17) ............................................................................................................4331 DTC: P0605 (TCD1) ............................................................................................................4333 DTC: P060B (TC1A).............................................................................................................4335 DTC: P060C (TC1C).............................................................................................................4338 DTC: P062F (TC41).............................................................................................................4340 DTC: P0A0D (TC20).............................................................................................................4342 DTC: P0A1B (TC16).............................................................................................................4347 DTC: P0A1B (TC92).............................................................................................................4352 DTC: P0A1B (TC97).............................................................................................................4354 DTC: P0A1B (TC3F).............................................................................................................4356 DTC: P0A1B (TCA1).............................................................................................................4358 DTC: P0A1B (TCA2).............................................................................................................4360 DTC: P0A1B (TCA3).............................................................................................................4362 DTC: P0A1B (TCA4).............................................................................................................4364 DTC: P0A1B (TCA5).............................................................................................................4366 DTC: P0A1B (TCA6).............................................................................................................4368 DTC: P0A1B (TCA7).............................................................................................................4370 DTC: P0A1B (TCA8) ............................................................................................................4372 DTC: P0A1B (TCA9).............................................................................................................4374 DTC: P0A1B (TCAA).............................................................................................................4376 DTC: P0A1B (TCBB).............................................................................................................4380 DTC: P0A1B (TCBC).............................................................................................................4382 DTC: P0A1B (TCBD).............................................................................................................4384 DTC: P0A1B (TCBE).............................................................................................................4386 DTC: P0A1B (TCBF).............................................................................................................4388 DTC: P0A1B (TCD3).............................................................................................................4390 DTC: P0A1B (TCD4).............................................................................................................4392 DTC: P0A1B (TCD5).............................................................................................................4394 DTC: P0A1D (TC21).............................................................................................................4396 DTC: P0A2B (TCE9).............................................................................................................4399 DTC: P0A2B (TCED).............................................................................................................4406 DTC: P0A2C (TCDA).............................................................................................................4413 DTC: P0A2D (TCDB).............................................................................................................4419 FOREWORD..................................................................................................................................4427 CHAPTER REFERENCES........................................................................................................................4428 INDEX.....................................................................................................................................4429 HYBRID....................................................................................................................................4431 TROUBLE SHOOTING......................................................................................................................4434 INVERTER..........................................................................................................................4434 DTC: P0A2F (TC33) ............................................................................................................4434 DTC: P0A3C (TC34).............................................................................................................4440 DTC: P0A3F (TCB7).............................................................................................................4453 DTC: P0A41 (TCC0).............................................................................................................4459 DTC: P0A42 (TCC1).............................................................................................................4467 DTC: P0A51 (TCD6).............................................................................................................4475 DTC: P0A51 (TCD7).............................................................................................................4477 DTC: P0A78 (TC13).............................................................................................................4479 DTC: P0A78 (TC14).............................................................................................................4486 DTC: P0A78 (TC15).............................................................................................................4497 DTC: P0AA1 (TCD8).............................................................................................................4502 DTC: P0AA4 (TCD9).............................................................................................................4506 DTC: P0ADB (TC1F).............................................................................................................4510 DTC: P0ADC (TC93).............................................................................................................4515 DTC: P0ADF (TC1E).............................................................................................................4521 DTC: P0AE0 (TC95).............................................................................................................4526 DTC: P0AE6 (TC1D).............................................................................................................4532 DTC: P0AE7 (TC94).............................................................................................................4537 DTC: P0AEE (TC22).............................................................................................................4543 DTC: P0AEE (TC23).............................................................................................................4545 DTC: P0AEF (TC24).............................................................................................................4547 DTC: P0AF0 (TC25).............................................................................................................4550 DTC: P0BEA (TCB3).............................................................................................................4553 DTC: P0BEA (TCB4).............................................................................................................4555 DTC: P0BEB (TC9A).............................................................................................................4557 DTC: P0BEC (TC9B).............................................................................................................4559 DTC: P0BEE (TCB5).............................................................................................................4561 DTC: P0BEE (TCB6).............................................................................................................4563 DTC: P0BEF (TC9C).............................................................................................................4565 DTC: P0BF0 (TC9D).............................................................................................................4567 DTC: P3126 (TC12).............................................................................................................4569 DTC: U0073 (TC91).............................................................................................................4576 DTC: U0074 (TC3E).............................................................................................................4580 DTC: U0293 (TC31).............................................................................................................4583 BATTERY ECU.......................................................................................................................4590 DIAGNOSIS CODE TABLE..........................................................................................................4590 LIST OF FREEZE FRAME DATA.....................................................................................................4594 LIST OF DATA MONITOR ITEMS....................................................................................................4596 CONNECTION DIAGRAM............................................................................................................4599 DTC: P0562....................................................................................................................4600 DTC: P0604....................................................................................................................4604 DTC: P0605....................................................................................................................4606 DTC: P060B....................................................................................................................4608 DTC: P062F....................................................................................................................4610 DTC: P0A1F....................................................................................................................4612 DTC: P0A7D....................................................................................................................4614 DTC: P0A7F....................................................................................................................4617 DTC: P0A80....................................................................................................................4622 DTC: P0A95....................................................................................................................4627 DTC: P0A9C....................................................................................................................4631 DTC: P0A9D....................................................................................................................4636 DTC: P0A9E....................................................................................................................4640 DTC: P0ABF....................................................................................................................4644 DTC: P0AC0....................................................................................................................4649 DTC: P0AC1....................................................................................................................4654 DTC: P0AC2....................................................................................................................4659 DTC: P0AC6....................................................................................................................4664 DTC: P0AC7....................................................................................................................4669 DTC: P0AC8....................................................................................................................4673 DTC: P0ACB....................................................................................................................4677 DTC: P0ACC....................................................................................................................4682 DTC: P0ACD....................................................................................................................4686 DTC: P0AE9....................................................................................................................4690 DTC: P0AEA....................................................................................................................4695 DTC: P0AEB....................................................................................................................4699 DTC: P0AFC....................................................................................................................4703 DTC: P0B25....................................................................................................................4705 DTC: P0B3D....................................................................................................................4708 DTC: P0B42....................................................................................................................4712 DTC: P0B47....................................................................................................................4716 DTC: P0B4C....................................................................................................................4720 DTC: P0B51....................................................................................................................4724 DTC: P0B56....................................................................................................................4728 DTC: P0B5B....................................................................................................................4732 DTC: P0B60....................................................................................................................4736 DTC: P0B65....................................................................................................................4740 DTC: P0B6A....................................................................................................................4744 DTC: P0B6F....................................................................................................................4748 DTC: P0B74....................................................................................................................4752 DTC: P0B79....................................................................................................................4756 DTC: P0B7E....................................................................................................................4760 DTC: P0B83....................................................................................................................4764 DTC: P0B88....................................................................................................................4768 DTC: P0B8D....................................................................................................................4772 DTC: P0B92....................................................................................................................4776 DTC: P0B97....................................................................................................................4780 DTC: P0B9C....................................................................................................................4784 DTC: P0BA1....................................................................................................................4788 DTC: P0C30....................................................................................................................4792 DTC: P3004....................................................................................................................4799 DTC: P3011....................................................................................................................4801 DTC: P3012....................................................................................................................4806 DTC: P3013....................................................................................................................4811 DTC: P3014....................................................................................................................4816 DTC: P3015....................................................................................................................4821 DTC: P3016....................................................................................................................4826 DTC: P3017....................................................................................................................4831 DTC: P3018....................................................................................................................4836 DTC: P3019....................................................................................................................4841 DTC: P301B....................................................................................................................4846 DTC: P3020....................................................................................................................4848 DTC: P3021....................................................................................................................4853 DTC: P3022....................................................................................................................4858 DTC: P3023....................................................................................................................4863 DTC: P3024....................................................................................................................4868 DTC: P3025....................................................................................................................4873 DTC: P3026....................................................................................................................4878 DTC: P3027....................................................................................................................4883 DTC: P3028....................................................................................................................4888 DTC: P3029....................................................................................................................4893 DTC: P302F....................................................................................................................4898 DTC: P3065....................................................................................................................4903 DTC: P308A....................................................................................................................4908 DTC: U0074....................................................................................................................4912 DTC: U0293....................................................................................................................4915 TRANSMISSION..............................................................................................................................4919 TROUBLESHOOTING.......................................................................................................................4921 TROUBLE SHOOTING BY TRANSMISSION SYMPTOM..........................................................................................4921 AUTOMATIC TRANSMISSION........................................................................................................4921 TROUBLESHOOTING.......................................................................................................................4923 AUTOMATIC TRANSMISSION............................................................................................................4923 PRECAUTIONS FOR DIAGNOSIS.....................................................................................................4923 AT LEARNED VALUE INITIALIZATION...............................................................................................4924 INSPECTING/CLEARING DIAGNOSIS CODES...........................................................................................4928 SYSTEM BLOCK DIAGRAM..........................................................................................................4931 COMPUTER PIN ASSIGNMENT.......................................................................................................4932 DIAGNOSIS CODE TABLE..........................................................................................................4935 DTC: P0500/DIAGNOSIS MONITOR CODE: 42.........................................................................................4937 DTC: P0562/DIAGNOSIS MONITOR CODE: 11.........................................................................................4943 DTC: P0705/DIAGNOSIS MONITOR CODE: 43.........................................................................................4946 DTC: P0706/DIAGNOSIS MONITOR CODE: 44.........................................................................................4954 DTC: P0710/DIAGNOSIS MONITOR CODE: 38.........................................................................................4959 DTC: P0715/DIAGNOSIS MONITOR CODE: 12.........................................................................................4966 DTC: P0720/DIAGNOSIS MONITOR CODE: 61.........................................................................................4972 DTC: P0725/DIAGNOSIS MONITOR CODE: 86.........................................................................................4978 DTC: P0730/DIAGNOSIS MONITOR CODE: 37.........................................................................................4984 DTC: P0746/DIAGNOSIS MONITOR CODE: 31.........................................................................................4992 DTC: P0748/DIAGNOSIS MONITOR CODE: 25.........................................................................................4998 DTC: P0751/DIAGNOSIS MONITOR CODE: 45.........................................................................................5003 DTC: P0756/DIAGNOSIS MONITOR CODE: 46.........................................................................................5009 DTC: P0761/DIAGNOSIS MONITOR CODE: 47.48......................................................................................5015 DTC: P0776/DIAGNOSIS MONITOR CODE: 32.........................................................................................5025 DTC: P0778/DIAGNOSIS MONITOR CODE: 26.........................................................................................5031 DTC: P0810/DIAGNOSIS MONITOR CODE: 88.........................................................................................5036 DTC: P0973/DIAGNOSIS MONITOR CODE: 62.........................................................................................5040 DTC: P0974/DIAGNOSIS MONITOR CODE: 62.........................................................................................5045 DTC: P0976/DIAGNOSIS MONITOR CODE: 63.........................................................................................5050 DTC: P0977/DIAGNOSIS MONITOR CODE: 63.........................................................................................5055 DTC: P0979/DIAGNOSIS MONITOR CODE: 64.........................................................................................5060 DTC: P0980/DIAGNOSIS MONITOR CODE: 64.........................................................................................5065 DTC: P0985/DIAGNOSIS MONITOR CODE: 65.........................................................................................5070 DTC: P0986/DIAGNOSIS MONITOR CODE: 65.........................................................................................5075 DTC: P0A40/DIAGNOSIS MONITOR CODE: 88.........................................................................................5080 DTC: P1604/DIAGNOSIS MONITOR CODE: 24.........................................................................................5084 DTC: P1604/DIAGNOSIS MONITOR CODE: 54.........................................................................................5088 DTC: P2545/DIAGNOSIS MONITOR CODE: 88.........................................................................................5092 DTC: P2716/DIAGNOSIS MONITOR CODE: 28.........................................................................................5096 DTC: P2740/DIAGNOSIS MONITOR CODE: 17.........................................................................................5102 DTC: P2757/DIAGNOSIS MONITOR CODE: 33.........................................................................................5107 DTC: P2759/DIAGNOSIS MONITOR CODE: 27.........................................................................................5113 DTC: P2764/DIAGNOSIS MONITOR CODE: 36.........................................................................................5119 DTC: U0100/DIAGNOSIS MONITOR CODE: 88.........................................................................................5123 DTC: U110A/DIAGNOSIS MONITOR CODE: 88.........................................................................................5132 TROUBLESHOOTING.......................................................................................................................5141 CLUTCH ECU........................................................................................................................5141 SYSTEM BLOCK DIAGRAM..........................................................................................................5141 COMPUTER PIN ASSIGNMENT.......................................................................................................5142 DIAGNOSIS CODE TABLE..........................................................................................................5144 CAUTIONS ON HV DAMPER REPLACEMENT.............................................................................................5146 DTC: P0560....................................................................................................................5147 DTC: P0563....................................................................................................................5151 DTC: P0604....................................................................................................................5153 DTC: P0605....................................................................................................................5155 DTC: P062F....................................................................................................................5157 DTC: P0775....................................................................................................................5159 DTC: P0778....................................................................................................................5164 DTC: P0811....................................................................................................................5169 DTC: P081E....................................................................................................................5171 DTC: P0883....................................................................................................................5173 DTC: P0948....................................................................................................................5177 DTC: P1538....................................................................................................................5182 DTC: P1539....................................................................................................................5192 DTC: P18F2....................................................................................................................5199 DTC: P18F3....................................................................................................................5209 DTC: P18F5....................................................................................................................5219 DTC: P18F7....................................................................................................................5229 DTC: P18F8....................................................................................................................5239 DTC: P18F9....................................................................................................................5249 DTC: P18FB....................................................................................................................5259 DTC: P18FC....................................................................................................................5264 DTC: P18FD....................................................................................................................5269 DTC: P191A....................................................................................................................5274 DTC: P2859....................................................................................................................5276 DTC: P3156....................................................................................................................5278 DTC: P3157....................................................................................................................5288 DTC: U0073....................................................................................................................5292 DTC: U0101....................................................................................................................5295 DTC: U0110....................................................................................................................5298 DTC: U0293....................................................................................................................5301 DTC: U110A....................................................................................................................5304 AXLE......................................................................................................................................5307 TROUBLESHOOTING.......................................................................................................................5308 TROUBLE SHOOTING BY AXLE SYMPTOM..................................................................................................5308 FRONT AXLE....................................................................................................................5308 REAR AXLE.....................................................................................................................5309 WHEEL AND TIRE................................................................................................................5309 DIFFERENTIAL..............................................................................................................................5311 TROUBLESHOOTING.......................................................................................................................5312 TROUBLE SHOOTING BY DIFFERENTIAL SYMPTOM..........................................................................................5312 REAR DIFFERENTIAL.............................................................................................................5312 FOREWORD..................................................................................................................................5314 CHAPTER REFERENCES........................................................................................................................5315 INDEX.....................................................................................................................................5316 BRAKE.....................................................................................................................................5318 TROUBLESHOOTING.......................................................................................................................5319 TROUBLE SHOOTING BY BRAKE SYMPTOM.................................................................................................5319 BRAKE.........................................................................................................................5319 ABS WITH EBD......................................................................................................................5321 CAUTIONS......................................................................................................................5321 TROUBLESHOOTING PROCEDURE.....................................................................................................5322 ACT PART No. CORRESPONDENCE...................................................................................................5324 HEARING TABLE.................................................................................................................5324 PRIOR CHECK...................................................................................................................5325 LIST OF DIAGNOSIS CODE........................................................................................................5337 PARTS ARRANGEMENT.............................................................................................................5340 ECU TERMINAL ARRANGEMENT......................................................................................................5342 SYMPTOM LIST..................................................................................................................5345 ELECTRIC CIRCUIT DIAGRAM......................................................................................................5346 ABS WARNING LIGHT ALWAYS ON...................................................................................................5347 BRAKE WARNING LIGHT ALWAYS ON.................................................................................................5351 ABS ACTIVATION TOO FAST (ABS OPERATES BEFORE THE WHEEL LOCKS).................................................................5355 THE BRAKE PEDAL GETS STUCK....................................................................................................5356 DTC: C1203 (Diagnosis monitor code 59)........................................................................................5358 DTC: C1225 (Diagnosis monitor code 25)........................................................................................5362 DTC: C1241 (Diagnosis monitor code 41)........................................................................................5366 DTC: C1249 (Diagnosis monitor code 49)........................................................................................5378 DTC: C1265 (Diagnosis monitor code 65)........................................................................................5382 DTC: C1300 (Diagnosis monitor code 62)........................................................................................5392 DTC: C1337 (Diagnosis monitor code 37)........................................................................................5395 DTC: C1361 (Diagnosis monitor code 91)........................................................................................5399 DTC: C1401 (Diagnosis monitor code 31)........................................................................................5407 DTC: C1402 (Diagnosis monitor code 32)........................................................................................5416 DTC: C1403 (Diagnosis monitor code 33)........................................................................................5425 DTC: C1404 (Diagnosis monitor code 34)........................................................................................5434 DTC: C1405 (Diagnosis monitor code 31)........................................................................................5443 DTC: C1406 (Diagnosis monitor code 32)........................................................................................5452 DTC: C1407 (Diagnosis monitor code 33)........................................................................................5461 DTC: C1408 (Diagnosis monitor code 34)........................................................................................5470 DTC: C1413 (Diagnosis monitor code 35)........................................................................................5479 DTC: C1414 (Diagnosis monitor code 36)........................................................................................5486 DTC: C1415 (Diagnosis monitor code 38)........................................................................................5492 DTC: C1416 (Diagnosis monitor code 39)........................................................................................5501 DTC: C1417 (Diagnosis monitor code 41)........................................................................................5510 DTC: C1421 (Diagnosis monitor code 46)........................................................................................5522 DTC: C1422 (Diagnosis monitor code 46)........................................................................................5526 DTC: C1423 (Diagnosis monitor code 46)........................................................................................5530 DTC: C1424 (Diagnosis monitor code 46)........................................................................................5534 DTC: C1425 (Diagnosis monitor code 49)........................................................................................5538 DTC: C1427 (Diagnosis monitor code 51)........................................................................................5542 DTC: C1428 (Diagnosis monitor code 51)........................................................................................5546 DTC: C1468 (Diagnosis monitor code 21)........................................................................................5550 DTC: C1469 (Diagnosis monitor code 22)........................................................................................5554 DTC: C146A (Diagnosis monitor code 23)........................................................................................5558 DTC: C146B (Diagnosis monitor code 24)........................................................................................5562 DTC: C146C (Diagnosis monitor code 13)........................................................................................5566 DTC: C146D (Diagnosis monitor code 14)........................................................................................5573 DTC: C146E (Diagnosis monitor code 11)........................................................................................5580 DTC: C146F (Diagnosis monitor code 12)........................................................................................5586 DTC: U0073 (Diagnosis monitor code 94)........................................................................................5592 ELECTRIC VACUUM PUMP SYSTEM.......................................................................................................5595 CAUTIONS FOR TROUBLESHOOTING..................................................................................................5595 SYSTEM BLOCK DIAGRAM..........................................................................................................5596 ELECTRIC CIRCUIT DIAGRAM......................................................................................................5597 CONNECTOR TERMINAL ARRANGEMENT................................................................................................5598 SYSTEM SELF-DIAGNOSTIC........................................................................................................5599 RESETTING THE ELECTRIC VACUUM PUMP OPERATION COUNT AND OPERATION TIME AND THE ELECTRIC VACUUM PUMP RELAY ACTUATION COUNT......5600 ACTIVE TEST...................................................................................................................5600 DATA MONITOR..................................................................................................................5600 DIAGNOSIS CODE TABLE..........................................................................................................5601 EXCESSIVE OPERATION OF ELECTRIC VACUUM PUMP (DIAGNOSIS CODE P165A)...........................................................5602 EXCESSIVE OPERATION OF ELECTRIC VACUUM PUMP RELAY (DIAGNOSIS CODE P165B).....................................................5603 ABNORMALITY IN VACUUM SENSOR CIRCUIT (DIAGNOSIS CODE P2525)...................................................................5604 FALSE DETECTION OF VACUUM SENSOR PRESSURE (DIAGNOSIS CODE P2526).............................................................5608 ELECTRIC VACUUM PUMP RELAY CONTACT STUCK AT ON (DIAGNOSIS CODE P258D)........................................................5620 HOW TO VERIFY AND CHANGE VEHICLE INFORMATION VALUES...........................................................................5622 STEERING..................................................................................................................................5624 TROUBLESHOOTING.......................................................................................................................5625 TROUBLE SHOOTING BY STEERING SYMPTOM..............................................................................................5625 STEERING......................................................................................................................5625 SUSPENSION................................................................................................................................5631 TROUBLESHOOTING.......................................................................................................................5632 TROUBLE SHOOTING BY SUSPENSION SYMPTOM............................................................................................5632 LEAF SUSPENSION...............................................................................................................5632 ELECTRICAL................................................................................................................................5633 TROUBLESHOOTING.......................................................................................................................5634 TROUBLE SHOOTING BY ELECTRICAL SYMPTOM............................................................................................5634 SIMULTANEOUS MALFUNCTION OF MULTIPLE ELECTRIC SYSTEMS.........................................................................5634 INTEGRATED UNIT...................................................................................................................5639 SYSTEM BLOCK DIAGRAM..........................................................................................................5639 COMPUTER PIN ASSIGNMENT.......................................................................................................5642 TROUBLE SHOOTING..............................................................................................................5643 CONTROL SYSTEM............................................................................................................................5650 TROUBLESHOOTING.......................................................................................................................5653 CAN COMMUNICATION.................................................................................................................5653 INSPECTION IN THE EVENT OF ABNORMALITY IN CAN COMMUNICATION LINE..............................................................5653 ECU INDIVIDUAL CODELIST (DIESEL)..............................................................................................5655 ECU INDIVIDUAL CODELIST (HYBRID)..............................................................................................5656 BASIC TROUBLESHOOTING PROCEDURE ON CAN COMMUNICATION..........................................................................5659 ENGINE CAN COMMUNICATION LINE (DIESEL)............................................................................................5661 ENGINE CAN LINE...............................................................................................................5661 PRIOR INSPECTION OF THE CAN COMMUNICATION LINE................................................................................5663 INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION........................................................................5667 INSPECTING THE CAN H LINE FOR SHORT CIRCUIT...................................................................................5672 INSPECTING THE CAN L LINE FOR SHORT CIRCUIT...................................................................................5682 INSPECTING THE ENGINE ECU CAN COMMUNICATION LINE..............................................................................5692 INSPECTING THE EGR CONTROLLER CAN COMMUNICATION LINE..........................................................................5697 INSPECTING THE NOx SENSOR 1 CAN COMMUNICATION LINE............................................................................5700 INSPECTING THE NOx SENSOR 2 CAN COMMUNICATION LINE............................................................................5707 INSPECTING THE VNT CONTROLLER CAN COMMUNICATION LINE..........................................................................5714 INSPECTING THE DEF SENSOR CAN COMMUNICATION LINE..............................................................................5717 INSPECTING THE PM SENSOR CAN COMMUNICATION LINE...............................................................................5721 ENGINE CAN COMMUNICATION LINE (HYBRID)............................................................................................5727 ENGINE CAN LINE...............................................................................................................5727 PRIOR INSPECTION OF THE CAN COMMUNICATION LINE................................................................................5729 INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION........................................................................5733 INSPECTING THE CAN H LINE FOR SHORT CIRCUIT...................................................................................5738 INSPECTING THE CAN L LINE FOR SHORT CIRCUIT...................................................................................5749 INSPECTING THE ENGINE ECU CAN COMMUNICATION LINE..............................................................................5760 INSPECTING THE EGR CONTROLLER CAN COMMUNICATION LINE..........................................................................5765 INSPECTING THE NOx SENSOR 1 CAN COMMUNICATION LINE............................................................................5768 INSPECTING THE NOx SENSOR 2 CAN COMMUNICATION LINE............................................................................5775 INSPECTING THE VNT CONTROLLER CAN COMMUNICATION LINE..........................................................................5782 INSPECTING THE DEF SENSOR CAN COMMUNICATION LINE..............................................................................5785 INSPECTING THE PM SENSOR CAN COMMUNICATION LINE...............................................................................5789 DIAGNOSIS CAN COMMUNICATION LINE (DIESEL).........................................................................................5796 DIAGNOSIS CAN LINE............................................................................................................5796 PRIOR INSPECTION OF THE CAN COMMUNICATION LINE................................................................................5798 INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION........................................................................5804 INSPECTING THE CAN H LINE FOR SHORT CIRCUIT...................................................................................5807 INSPECTING THE CAN L LINE FOR SHORT CIRCUIT...................................................................................5815 INSPECTING THE ABS ECU CAN COMMUNICATION LINE.................................................................................5822 INSPECTING THE AT ECU CAN COMMUNICATION LINE..................................................................................5825 INSPECTING THE ENGINE ECU CAN COMMUNICATION LINE..............................................................................5828 INSPECTING THE VEHICLE CONTROL ECU CAN COMMUNICATION LINE.....................................................................5833 DIAGNOSIS CAN COMMUNICATION LINE (HYBRID).........................................................................................5837 DIAGNOSIS CAN LINE............................................................................................................5837 PRIOR INSPECTION OF THE CAN COMMUNICATION LINE................................................................................5840 INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION........................................................................5847 INSPECTING THE CAN H LINE FOR SHORT CIRCUIT...................................................................................5853 INSPECTING THE CAN L LINE FOR SHORT CIRCUIT...................................................................................5864 INSPECTING THE ABS ECU CAN COMMUNICATION LINE.................................................................................5875 INSPECTING THE AT ECU CAN COMMUNICATION LINE..................................................................................5878 INSPECTING THE ENGINE ECU CAN COMMUNICATION LINE..............................................................................5881 INSPECTING THE INVERTER CAN COMMUNICATION LINE................................................................................5884 INSPECTING THE CLUTCH ECU CAN COMMUNICATION LINE..............................................................................5887 INSPECTING THE BATTERY ECU CAN COMMUNICATION LINE.............................................................................5890 INSPECTING THE VEHICLE CONTROL ECU CAN COMMUNICATION LINE.....................................................................5893 CONTROL CAN COMMUNICATION LINE (DIESEL)...........................................................................................5896 CONTROL CAN LINE..............................................................................................................5896 PRIOR INSPECTION OF THE CAN COMMUNICATION LINE................................................................................5898 INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION........................................................................5903 INSPECTING THE CAN H LINE FOR SHORT CIRCUIT...................................................................................5907 INSPECTING THE CAN L LINE FOR SHORT CIRCUIT...................................................................................5913 INSPECTING THE ABS ECU CAN COMMUNICATION LINE.................................................................................5919 INSPECTING THE AT ECU CAN COMMUNICATION LINE..................................................................................5922 INSPECTING THE VEHICLE CONTROL ECU CAN COMMUNICATION LINE.....................................................................5925 CONTROL CAN COMMUNICATION LINE (HYBRID)...........................................................................................5928 CONTROL CAN LINE..............................................................................................................5928 PRIOR INSPECTION OF THE CAN COMMUNICATION LINE................................................................................5932 INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION........................................................................5937 INSPECTING THE CAN H LINE FOR SHORT CIRCUIT...................................................................................5944 INSPECTING THE CAN L LINE FOR SHORT CIRCUIT...................................................................................5955 INSPECTING THE ABS ECU CAN COMMUNICATION LINE.................................................................................5966 INSPECTING THE AT ECU CAN COMMUNICATION LINE..................................................................................5969 INSPECTING THE HV ECU CAN COMMUNICATION LINE..................................................................................5972 INSPECTING THE INVERTER CAN COMMUNICATION LINE................................................................................5975 INSPECTING THE CLUTCH ECU CAN COMMUNICATION LINE..............................................................................5979 INSPECTING THE VEHICLE CONTROL ECU CAN COMMUNICATION LINE.....................................................................5982 CAN COMMUNICATION (HYBRID SYSTEM).................................................................................................5985 SAFETY MEASURES TO BE TAKEN IN HIGH VOLTAGE WORK..............................................................................5985 LIST OF CONNECTOR MARKINGS....................................................................................................5988 CONNECTION DIAGRAM............................................................................................................5989 LIST OF DTC CODES FOR CAN SYSTEM-RELATED ABNORMALITIES........................................................................5990 CAN COMMUNICATION FAILURE.....................................................................................................5992 BASIC INSPECTION ITEMS IN CASE OF ABNORMALITY IN DIAG CAN SYSTEM..............................................................5996 BASIC INSPECTION ITEMS IN CASE OF ABNORMALITY IN CONTROL CAN SYSTEM...........................................................6011 ABNORMALITY IN INVERTER (ECU SYSTEM) / DIAG CAN RESISTER SEIZURE (DTC CODE P0A1B / TC3F)......................................6020 ABNORMALITY IN THE INVERTER (ECU SYSTEM) / CONTROL CAN RESISTER SEIZURE (DTC CODE P0A1B / TC92)...............................6021 ABNORMALITY IN HV ECU FUNCTION / CONTROL CAN REGISTER SEIZURE (DTC CODE P0A1D / TC12).........................................6022 ABNORMALITY IN HV ECU FUNCTION / DIAG CAN REGISTER SEIZURE (DTC CODE P0A1D / TC17)...........................................6023 HV ECU CAN COMMUNICATION FAILURE (CONTROL CAN) / CONTROL CAN COMMUNICATION SHUTDOWN DUE TO BUS OFF (DTC CODE U0073 / TC11)....6024 CAN COMMUNICATION FAILURE (CONTROL CAN) / CONTROL CAN COMMUNICATION SHUTDOWN DUE TO BUS OFF (DTC CODE U0073 / TC91)...........6026 HV ECU CAN COMMUNICATION FAILURE (DIAG CAN) / DIAG CAN COMMUNICATION SHUTDOWN DUE TO BUS OFF (DTC CODE U0074 / TC16)..........6028 CAN COMMUNICATION FAILURE (DIAG CAN) / COMMUNICATION SHUTDOWN DUE TO DIAG CAN BUS OFF (DTC CODE U0074 / TC3E).................6029 ENGINE ECU CAN COMMUNICATION BLACKOUT / ENGINE ECU CAN COMMUNICATION BLACKOUT (DTC CODE U0100 / TC13).........................6030 TCM ECU CAN COMMUNICATION BLACKOUT / AT ECU CAN COMMUNICATION BLACKOUT (DTC CODE U0101 / TC18)................................6031 INVERTER CAN COMMUNICATION BLACKOUT / INVERTER CAN COMMUNICATION BLACKOUT (DTC CODE U0110 / TC14).............................6033 BATTERY ECU CAN COMMUNICATION BLACKOUT / BATTERY ECU CAN COMMUNICATION BLACKOUT (DTC CODE U0111 / TC15).......................6036 ABS ECU CAN COMMUNICATION BLACKOUT / ABS ECU CAN COMMUNICATION BLACKOUT (DTC CODE U0121/TC24).................................6039 METER CAN COMMUNICATION BLACKOUT / METER CAN COMMUNICATION BLACKOUT (DTC CODE U0155 / TC25)...................................6041 HV ECU COMMUNICATION FAILURE (DTC CODE U0293).................................................................................6043 HV ECU CAN COMMUNICATION BLACKOUT / HV ECU CAN COMMUNICATION BLACKOUT (DTC CODE U0293 / TC31).................................6045 VEHICLE CONTROL ECU CAN COMMUNICATION BLACKOUT / VEHICLE CONTROL ECU CAN COMMUNICATION BLACKOUT (DTC CODE U110A / TC26)......6049 CLUTCH ECU CAN COMMUNICATION BLACKOUT / CLUTCH ECU CAN COMMUNICATION BLACKOUT (DTC CODE U1136 / TC27).........................6051 COMMUNICATION DISABLED DUE TO DIAG CAN BUS OFF (DTC CODE U0074)..............................................................6053
Description:
2020 HINO TRUCK COE 155 155H 195 195H WORKSHOP MANUAL
- This workshop manual has been prepared to provide information on electrical circuits for the following Hino Vehicles
- Applicable for HINO 155, 155h, 195, 195h series, equipped with J05E engine 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]
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Phoenix Ben –
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