Daewoo KORANDO Service Manual Download Page 1108 | Manualshive

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5B-10 MANUAL TRANSMISSION

1 Filler/Drain Plug
2 Shift Mechanism Cover
3 Shift Shaft Lever
4 Outer Select Lever
5 Inner Select Lever
6 Offset Control Lever
7 Bias Spring
8 Bolt
9 Pin

10 Washer

11 Bolt

12 Bolt
13 Extension and Plate Assembly
14 Oil Seal
15 Oiling Funnel
16 Bolt
17 Alignment Bolt
18 Selector Arm Pin
19 Shift Shaft
20 3/4 Shift Fork
21 1/2 Shift Fork
22 Insert
23 Selector Arm Assembly
24 Interlock Plate Assembly
25 Selector Plate
26 O-ring
27 Plug
28 Case Cover
29 Retaining Ring
30 Pivot Pin
31 Back-up Switch
32 5/Reverse Shift Lever
33 Snap Ring
34 5th Synchronizer Retainer
35 5th Synchronizer Assembly
36 Synchronizer Spring
37 Synchronizer Assembly

38 Insert
39 Synchronizer Hub
40 Roll Pin
41 5th Shift Fork
42 Insert
43 Shift Rail Assembly
44 Blocking Ring
45 5th Speed Drive Gear
46 Snap Ring
47 Speed Gear
48 Speed Gear Clip
49 Bolt
50 Input Bearing Retainer
51 Oil Seal
52 Shim
53 Bearing Cup
54 Bearing Cone
55 Input Shaft
56 A. Roller Bearing
56 B. Bearing Assembly
57 Spacer
58 Thrust Bearing
59 Thrust Bearing Race
60 5th Speed Driven Gear
61 Bearing Cup
62 Bearing Cone
63 1st Speed Gear
64 Bearing Sleeve Assembly
65 A. Bearing
65 B. Bearing
65 C. Spacer
66 Sleeve
67 Blocking Ring Assembly
68 3/4 synchronizer Assembly
69 Synchronizer Spring
70 Synchronizer Sleeve
71 Insert

72 Synchronizer Sleeve
73 3rd Speed Gear
74 Needle Bearing
75 Spacer
76 Snap Ring
77 Thrust Washer
78 2nd Speed Gear
79 2nd Speed Gear Bearing
80 Spacer
81 Output Shaft Assembly
82 Retaining Ring
83 Thrust Washer
84 Inner Cone
85 Outer Cone Race
86 1/2 Blocking Ring
87 Spring
88 Reverse Sliding Gear
89 Insert
90 Pin
91 Shaft and Hub Assembly
92 Spring
93 Pin Fork and Reverse Roller

Assembly

94 Bolt
95 Rear Retainer
96 Shim
97 Roll Pin
98 Reverse Idler Shaft
99 Reverse Idler Gear Assembly

100 O-ring
101 Bearing Cup
102 Bearing Cup Assembly
103 O-ring
104 Bearing Cup
105 Bearing Cone
106 Counter Shaft Gear
107 Transmission Case Assembly

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Summary of Contents for KORANDO

Page 1: ...s manual are based on the latest product information available at the time of manual approval The right is reserved to make changes at any time without notice SECTION INDEX DRIVE LINE AXLE BRAKES TRANSMISSION STEERING HVAC HEATING VENTILATION AND AIR CONDITIONING RESTRAINTS BODY AND ACCESSORIES 3 4 5 6 7 8 9 ENGINE SUSPENSION 1 2 FRONT MATTER GENERAL INFORMATION 0A 0B INCHON KOREA DAEWOO MOTOR CO ...

Page 2: ...es from the instructions provided in this manual must ensure their own safety and preserve the safety and integrity of the vehicle The following list contains general precautions that should always be followed while working on a vehicle Safety stands are required whenever a procedure calls for underbody work Do not smoke when you work on a vehicle To prevent serious burns do not touch any hot meta...

Page 3: ... available at the time of publication approval The right is reserved to make changes at any time without notice Daewoo Motor Company Limited Overseas Technical Service Department 391 9 Chong Chon 2 Dong Pu Pyung Gu Inchon Korea Tel 82 32 509 4161 4164 Fax 82 32 509 4160 E mail m8610452 dwmc co kr m9610883 dwmc co kr Daewoo Motor Company Limited All rights Reserved No part of this publication may b...

Page 4: ...Section 4B Master Cylinder Section 4C Power Booster Section 4D Front Disc Brakes Section 4E Rear Disc Brakes Section 4F Antilock Brake System Section 4G Parking Brakes Section 5 Transmission Section 5A Automatic Transmission Section 5B Manual Transmission Section 5C Clutch Section 5D1 Transfer Case Part Time 4480 Section 5D2 Transfer Case TOD Section 6 Steering Section 6A Power Steering System Sec...

Page 5: ...ISSUED BY OVERSEAS TECH SERVICE DAEWOO MOTOR CO LTD 391 9 CHONG CHON 2DONG PU PYUNG GU INCHON KOREA TELEPHONE 82 32 509 4161 4164 FACSIMILE 82 32 509 4160 KORANDO SERVICE MANUAL ...

Page 6: ...NERAL ENGINE INFORMATION SECTION 1B2 M161 ENGINE MECHANICAL SECTION 1D2 M161 ENGINE COOLING SECTION 1E2 M161 ENGINE ELECTRICAL SECTION 1F2 M161 ENGINE CONTROLS SECTION 1G2 M161 ENGINE INTAKE EXHAUST SECTION 1A3 OM600 GENERAL ENGINE INFORMATION SECTION 1B3 OM600 ENGINE MECHANICAL SECTION 1D3 OM600 ENGINE COOLING SECTION 1E3 OM600 ENGINE ELECTRICAL SECTION 1F3 OM600 ENGINE CONTROLS SECTION 1G3 OM600...

Page 7: ...SUSPENSION CONTENTS SECTION 2A SUSPENSION DIAGNOSIS SECTION 2B WHEEL ALIGNMENT SECTION 2C FRONT SUSPENSION SECTION 2D REAR SUSPENSION SECTION 2E TIRES AND WHEELS ...

Page 8: ...DRIVE LINE AXLE CONTENTS SECTION 3A FRONT DRIVE AXLE SECTION 3C PROPELLER SHAFT SECTION 3D REAR DRIVE AXLE ...

Page 9: ...E CONTENTS SECTION 4A HYDRAULIC BRAKES SECTION 4B MASTER CYLINDER SECTION 4C POWER BOOSTER SECTION 4D FRONT DISC BRAKES SECTION 4E REAR DISC BRAKES SECTION 4F ANTILOCK BRAKE SYSTEM SECTION 4G PARKING BRAKE ...

Page 10: ...TRANSMISSION CONTENTS SECTION 5A AUTOMATIC TRANSMISSION SECTION 5B MANUAL TRANSMISSION SECTION 5C CLUTCH SECTION 5D1 TRANSFER CASE PART TIME 4408 SECTION 5D2 TRANSFER CASE TOD ...

Page 11: ...STEERING CONTENTS SECTION 6A POWER STEERING SYSTEM SECTION 6E STEERING WHEEL AND COLUMN ...

Page 12: ... AIR CONDITIONING CONTENTS SECTION 7B C MANUAL CONTROL SEMIAUTO TEMPERATURE CONTROL HEATING VENTILATION AND AIR CONDITIONING SYSTEM SECTION 7D FULL AUTOMATIC TEMPERATURE CONTROL HEATING VENTILATION AND AIR CONDITIONING SYSTEM ...

Page 13: ...RESTRAINTS CONTENTS SECTION 8A SEAT BELTS SECTION 8B SUPPLEMENTAL RESTRAINT SYSTEM SRS ...

Page 14: ...N SECTION 9F AUDIO SYSTEM SECTION 9G INTERIOR TRIM SECTION 9H SEATS SECTION 9L GLASS AND MIRRORS SECTION 9M EXTERIOR TRIM SECTION 9N FRAME AND UNDERBODY SECTION 9O BUMPERS AND FASCIAS SECTION 9P DOORS SECTION 9Q ROOF SECTION 9R BODY FRONT END SECTION 9T REMOTE KEYLESS ENTRY AND ANTI THEFT SYSTEM SECTION 9U CONTROL UNITS AND SYSTEM SECTION 9V SWITCHES SECTION 9W IMMOBILIZER SYSTEM ...

Page 15: ...Twice A Month 0B 12 At Least Monthly 0B 12 At Least Twice a Year 0B 12 Each Time The Oil is Changed 0B 13 At Least Annually 0B 13 Recommended Fluids and Lubricants 0B 14 General Description and System Operation 0B 15 General Repair Instructions 0B 15 Vehicle Identification Number System 0B 16 Vehicle Lifting Procedures 0B 19 SPECIFICATIONS TECHNICAL DATA Performance ManualTransaxle Application Max...

Page 16: ...d 4th 5th Reverse Final Drive Ratio Oil Capacity L ManualTransmission 662NA TREMEC T5 3 969 2 341 1 457 1 000 0 851 3 705 4 55 3 4 662LA TREMEC T5 3 969 2 341 1 457 1 000 0 851 3 705 4 27 3 4 2 0L DOHC TREMEC T5 3 969 2 341 1 457 1 000 0 851 3 705 4 89 3 4 2 3L DOHC TREMEC T5 3 969 2 341 1 457 1 000 0 851 3 705 4 55 3 4 3 2L DOHC TREMEC T5 3 969 2 341 1 457 1 000 0 851 3 705 3 73 3 4 Engine 661LA ...

Page 17: ...fications RACK PINION 0 4 mm 2 30 30 0 30 1L Tire and Wheel Specifications P235 75 R15 255 70 R15 7JJ 15 30 Psi 30 Psi 30 Psi 30 Psi Application Standard Tire Size Standard Wheel Size Inflation Pressure At Full Lode P235 75 Front Rear P255 75 Front Rear Application Booster Size Master Cylinder Diameter mm Booster Ratio Front Brake Disc Type Rear Brake Disc Type Specifications 8inch 9inch 7inch 8in...

Page 18: ...System 661LA 8 0 662NA 9 0 662LA 9 5 2 0L DOHC 7 2 2 3L DOHC 7 5 3 2L DOHC 8 2 External Gear pump Combination Full Part Full Flow Cooling Type Coolant Capacity L Radiator Type Water Pump Type CoolingSystem 661LA 9 5 10 662NA 10 5 662LA 10 5 11 2 0L DOHC 10 5 2 3L DOHC 10 5 3 2L DOHC 11 3 Forced Circulation Centrifugal Application Battery MF Generator Starter Electric System 661LA 75A 2 2kw 662NA 7...

Page 19: ...eDimensions Application Manual Curb Weight kg Gross Vehicle Weight kg Automatic Curb Weight kg Gross Vehicle Weight kg Passenger Capacity Vehicle Weights Application 4330 1841 1840 2840 1510 1520 661LA 1790 2515 1810 2515 5 662NA 1810 2515 1815 2515 5 662LA 1830 2515 1850 2515 5 2 0L DOHC 1790 2515 5 2 3L DOHC 1790 2515 1810 2515 5 3 2L DOHC 1840 2515 1860 2515 5 ...

Page 20: ...b in 44 1 N m 33 lb in 82 3 N m 61 lb in 77 4 N m 57 lb in 127 4 N m 94 lb in 196 0 N m 145 lb in 284 2 N m 210 lb in 392 0 N m 290 lb in 529 2 N m 392 lb in 686 0 N m 508 lb in 666 4 N m 493 lb in 0 7 N m 6 3 lb in 1 6 N m 14 lb in 3 1 N m 28 lb in 5 4 N m 49 lb in 12 7 N m 9 lb in 25 5 N m 19 lb in 24 5 N m 18 lb in 45 0 N m 33 lb in 43 1 N m 32 lb in 71 6 N m 53 lb in 107 8 N m 80 lb in 156 8 N...

Page 21: ... and Wheel in section 2E l To be driven on reasonable road surfaces and within legal operating limits EXPLANATION OF SCHEDULED MAINTENANCE SERVICES The services listed in the maintenance schedule are further explained below When the following maintenance services are performed make sure all the parts are replaced and all the necessary repairs are done before driving the vehicle Always use the prop...

Page 22: ...ndition short distance driving extensive idling or driving in dusty condition Change engine oil and the filter every 7 500 km or 6 months whichever comes first 2 More frequent maintenance is required if under dusty driving condition 3 Refer to Recommended fluids and lubricants Drive belt Engine oil filter 1 3 Cooling system hose connections Engine coolant 3 Fuel filter 2 Fuel line connections Air ...

Page 23: ...I I I I I I I I I I I I I I I I I I I I I R R I I I I I I I I I I I I I I I I I Transfer case fluid R I I I Inspect ADJUST when abnormal condition is noted I I I I I I I I I Chart Symbols I Inspect these items and their related parts If necessary correct clean replenish adjust or replace R Replace or change 3 Refer to Recommended fluids and lubricants 4 Change the brake clutch fluid every 15 000 k...

Page 24: ... vehicle is operated under severe condition short distance driving extensive idling or driving in dusty condition change engine oil every 5 000km or 3 months whichever comes first 2 More frequent maintenance is required if under dusty driving conditing 3 Refer to Recommended fluids and lubricants Drive belt Engine oil fillter 1 3 Cooling system hose connections Engine coolant 3 Fuel filter 2 Fuel ...

Page 25: ...I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I Transfer case fluid 3 R I R I I I I I I I I I I I I I I I I I Inspect ADJUST when abnormal condition is noted I I I Chart Symbols I Inspect these items and their related parts If necessary correct clean replenish adjust or replace R Replace or change 3 Refer to Recommended fluids and lubricants 4 Change the brake clutch fluid mo...

Page 26: ...he oil level on it 5 Add oil if needed to keep the oil level above the lower mark Avoid overfilling the engine since this may cause engine damage 6 Push the indicator all the way back down into the engine after taking the reading If you check the oil level when the oil is cold do not run the engine first The cold oil will not drain back to the pan fast enough to give a true oil level reading Engin...

Page 27: ... for cracks fraying wear and proper tension Adjust or replace the belts as needed Hood Latch Operation When opening the hood note the operation of the secondary latch It should keep the hood from opening all the way when the primary latch is released The hood must close firmly AT LEAST ANNUALLY Lap and Shoulder Belts Condition and Operation Inspect the belt system including the webbing the buckles...

Page 28: ... 10 5 L 10 5 11 0 L 9 5 10 0 L Approx 0 5L level must be maintained between MAX MIN level 1 0 L As required As required As required As required Fluid Lubricant Quality class API SH grade or above ACEA A2 or A3 MB sheet 229 1 Viscosity MB sheet 224 1 Quality class API CG grade or above ACEA B2 or B3 MB sheet 228 1 228 3 228 5 229 1 Viscosity MB sheet 224 1 ALUTEC P 78 DOT 3 SAE J 1703 ATFDEXRON II ...

Page 29: ...re important for efficient and reliable performance of the service repairs l Use genuine DAEWOO parts l Discard used cotter pins gaskets O rings oil seals lock washers and self locking nuts Prepare new ones for installation Normal function of these parts cannot be maintained if these parts are reused l Keep the disassembled parts neatly in groups to facilitate proper and smooth reassembly l Keep a...

Page 30: ... In line 4Cylinder Gasoline E23 8 1998cc In line 4Cylinder Gasoline E20 9 3199cc In line 6Cylinder Gasoline E32 A 2299cc In line 4Cylinder Diesel OM661 B 2874cc In line 5Cylinder Diesel OM662 7 Restraint System 1 3 Point Safety Belt 2 2 Point Safety Belt 6 TrimLevel A Standard B Deluxe C Super Deluxe 5 Body Type 2 3 Door 4 3 Door Soft Top 4 Line Models L Korando LHD R Korando RHD 3 Vehicle Type T ...

Page 31: ...GENERAL INFORMATION 0B 17 Manufacturer s Plate Manufacturer s Plate Location 1 Type Approval No 2 Vehicle Identification No Diesel Engine Gasoline Engine ...

Page 32: ...rive ENGINE TYPE 3 KORANDO 2300 DOHC The engine number is stamped on the upper rear left hand side of the cylinder block IL6 3200 The engine number is stamped on the lower rear side of the alternator Diesel Engine Number 662 920 1 0 012345 Serial Number 0 Manual T M 1 Hydr Auto Coupling 2 Automatic T M 910 Non Intercooler Engine 920 Intercooler Engine 0 Common 1 Left Hand Drive 2 Right Hand Drive ...

Page 33: ...lities and service stations are equipped with automative hoists that bear upon some parts of the frame in order to lift the vehicle If any other hoist method is used use special care to avoid damaging the fuel tank the filter neck the exhaust system or the underbody DieselEngine The engine number is stamped on the cylinder block in front of injection pump Vehicle Lifting Points Using Jack Rearward...

Page 34: ...al Information 1A1 13 Cleanliness and Care 1A1 13 On Engine Service 1A1 13 Application Engine Model Displacement CC Cylinder Bore x Stroke mm Fuel Injection Ignition System Compression Ratio Number of Cylinders Camshaft Valve Arrangement Camshaft Drive Type Max Output ps rpm Max Torque kg m rpm Firing Order Ignition Type Ignition Timing Valve Timing Intake Open Close Exhaust Open Close Valve Clear...

Page 35: ...pacity liter Lubrication Type Oil Filter Type Fuel ENGINE SPECIFICATIONS Cont d E32 Engine 700 50 3 4 8 2 Forced by Gear Pump Full Flow with Paper Filter Unleaded Gasoline MSE 3 62S 3 53S Motorsteuer Elektronik German MSE Engine Control Electronic 3 62S 6 Cylinder Version 3 53S 4 Cylinder Version ...

Page 36: ...der Head Cover 5 Exhaust Camshaft 6 Intake Camshaft 7 Cylinder Head 8 Spark Plug Connector 9 Valve Tappet 10 Injector 11 Exhaust Valve 12 Intake Manifold 13 Connecting Rod 14 Exhaust Manifold 15 Crankshaft 16 Engine Mounting Bracket 17 Starter 18 Crankcase 19 Oil Pump Sprocket 20 Oil Strainer 21 Oil Pan 22 Drain Plug ...

Page 37: ...1 4 GENERAL ENGINE INFORMATION 23 Camshaft Adjuster 24 Cooling Fan and Viscous Clutch 25 Piston 26 Flywheel of Drive Plate 27 Oil Pump Drive Chain 28 Oil Return Pipe 29 Timing Chain 30 Oil Pump SIDE VIEW ...

Page 38: ...GENERAL ENGINE INFORMATION 1A1 5 PERFORMANCE CURVE E32 ENGINE ...

Page 39: ...1A1 6 GENERAL ENGINE INFORMATION SPECIAL TOOLS SPECIAL TOOLS TABLE 000 589 10 99 01 Torque Wrench 001 589 76 21 00 Compression Pressure Tester 119 589 01 09 00 Spark Plug Wrench 001 589 65 09 00 Socket ...

Page 40: ... the suspected component You should be able to trace the leak path over the white powder surface to the source Black Light and Dye Method A dye and light kit is available for finding leaks Refer to the manufacturer s directions when using the kit 1 Pour the specified amount of dye into the engine oil fill tube 2 Operate the vehicle normal operating conditions as directed in the kit 3 Direct the li...

Page 41: ...moval of cooling fan 1 Vibration Damper Assembly 2 Crankshaft Pulley Notice l Remove the negative ground cable before proceeding the work l Rotate the pulley in normal engine rotating direction when cranking 3 Bolt 8 6 0 9 Nm Tools Required 000 589 10 99 01 Torque wrench 001 589 65 09 00 Socket ...

Page 42: ...s Required 001 589 76 21 00 Compression Pressure Tester 119 589 01 09 00 Spark Plug Wrench Standard Service Data Compression Ratio Normal Engine Temperature Normal Compression Pressure Permissible Pressure Difference Between Individual Cylinders 10 1 80 C Min 10 bar Max 14 bar Min 6 bar Max 10 bar Max 1 5 bar General Fuel Optimization ...

Page 43: ...hole 5 Crank the engine approx eight revolutions by using the start motor 6 Compare the measurements of compression pressure tester with the specifications 7 Measure the compression pressure of the other cylinders in the same way 8 If measured value is not within the specifications perform the cylinder pressure leakage test Notice l Discharge the combustion residues in the cylinders before testing...

Page 44: ...e 6 Cylinder Pressure Leakage Tester with Connecting Hose UniversalTool At Whole Engine At Valve and Cylinder Head Gasket At Piston and Piston Ring Max 25 Max 10 Max 20 Cylinder Number By Mark On Vibration Damper At TDC TDC Mark Cylinder Number b 240 3 4 a 120 2 5 OT TDC 1 6 Cylinder Pressure Leakage Tester Bosch EFAW 210A Sun CLT 228 ...

Page 45: ...e and adjust the scale of tester 7 Install the connecting hose to spark plug hole 9 Connect the connecting hose to tester and measure the leakage volume after blowing up 5bar of compressed air Notice Measure the leakage volume in the completely opening condition of throttle valve by pulling the acceleration cable 10 Perform the pressure test according to the firing order Notice Firing Order 1 5 3 ...

Page 46: ... kept in order They should be installed in the same locations and with the same mating surfaces as when they were removed Battery cables should be disconnected before any major work is performed on the engine Failure to disconnect cables may result in damage to wire harness or other electrical parts ON ENGINE SERVICE Caution Disconnect the negative battery cable before removing or installing any e...

Page 47: ...19 3 4000 ATDC 13 15 ABDC 13 57 BBDC 16 58 BTDC 17 05 Application Engine Model Displacement CC Cylinder Bore x Stroke mm Fuel Injection Ignition System Compression Ratio Number of Cylinders Camshaft Valve Arrangement Camshaft Drive Type Max Output ps rpm Max Torque kg m rpm Firing Order Ignition Type Ignition Timing Valve Timing Intake Open Close Exhaust Open Close Valve Clearance Adjustment SPECI...

Page 48: ...l Capacity liter Lubrication Type Oil Filter Type Fuel ENGINE SPECIFICATIONS Cont d E23 Engine 750 50 3 2 4 2 7 5 Forced by Gear Pump Full Flow with Paper Filter Unleaded Gasoline MSE 3 62S 3 53S Motorsteuer Elektronik German MSE Engine Control Electronic 3 62S 6 cylinder version 3 53S 4 cylinder version ...

Page 49: ...oil 5 Spark Plug Connector 6 Fuel Distributor 7 Injector 8 Exhaust Camshaft 9 Intake Camshaft 10 Valve Tappet 11 Intake Valve 12 Intake Manifold 13 Cylinder Head 14 Exhaust Manifold 15 Dipstick Guide Tube and Gauge 16 Connecting Rod 17 Crankshaft 18 Engine Mounting Bracket 19 Starter 20 Crankcase 21 Oil Pump Sprocket 22 Oil Pan ...

Page 50: ...Camshaft Adjuster 24 Oil Filler Cap 25 Engine Hanger Bracket 26 Cooling Fan and Viscous Clutch 27 Oil Filter 28 Timing Chain 29 Oil Pump Drive Chain 30 Oil Strainer 31 Oil Pump 32 Ring Gear and Flywheel of Drive Plate 33 Piston SIDE VIEW ...

Page 51: ...GENERAL ENGINE INFORMATION 1A2 5 PERFORMANCE CURVE E23 ENGINE ...

Page 52: ...1A2 6 GENERAL ENGINE INFORMATION E20 ENGINE ...

Page 53: ...GENERAL ENGINE INFORMATION 1A2 7 SPECIAL TOOLS SPECIAL TOOLS TABLE 000 589 10 99 01 Torque Wrench 001 589 76 21 00 CompressionPressure Tester 119 589 01 09 00 Spark Plug Wrench 001 589 65 09 00 Socket ...

Page 54: ... the suspected component You should be able to trace the leak path over the white powder surface to the source Black Light and Dye Method A dye and light kit is available for finding leaks Refer to the manufacturer s directions when using the kit 1 Pour the specified amount of dye into the engine oil fill tube 2 Operate the vehicle normal operating conditions as directed in the kit 3 Direct the li...

Page 55: ...moval of cooling fan 1 Vibration Damper Assembly 2 Crankshaft Pulley Notice l Remove the negative ground cable before proceeding the work l Rotate the pulley in normal engine rotating direction when cranking 3 Bolt 8 6 0 9 Nm Tools Required 000 589 10 99 01 Torque wrench 001 589 65 09 00 Socket ...

Page 56: ...ed 001 589 76 21 00 Compression Pressure Tester 119 589 01 09 00 Spark Plug Wrench Standard Service Data Compression Ratio Normal Engine Temperature Normal Compression Pressure Permissible Pressure Difference Between Individual Cylinders 10 4 9 6 80 C Min 11 bar Max 15 bar Min 10 5 bar Max 14 bar Max 1 5 bar E23 Engine e 10 4 E20 Engine e 9 6 ...

Page 57: ...hole 5 Crank the engine approx eight revolutions by using the start motor 6 Compare the measurements of compression pressure tester with the specifications 7 Measure the compression pressure of the other cylinders in the same way 8 If measured value is not within the specifications perform the cylinder pressure leakage test Notice l Discharge the combustion residues in the cylinders before testing...

Page 58: ...age 6 Cylinder Pressure Leakage Tester with Connecting Hose UniversalTool At Whole Engine At Valve and Cylinder Head Gasket At Piston and Piston Ring Max 25 Max 10 Max 20 Cylinder Number By Mark On Vibration Damper At TDC TDC Mark Cylinder Number UT BDC 180 2 3 OT TDC 1 4 Cylinder Pressure Leakage Tester Bosch EF AW 210A Sun CLT 228 ...

Page 59: ...ine and adjust the scale of tester 7 Install the connecting hose to spark plug hole 9 Connect the connecting hose to tester and measure the leakage volume after blowing up 5bar of compressed air Notice Measure the leakage volume in the completely opening condition of throttle valve by pulling the acceleration cable 10 Perform the pressure test according to the firing order Notice Firing Order 1 3 ...

Page 60: ...ept in order They should be installed in the same locations and with the same mating surfaces as when they were removed Battery cables should be disconnected before any major work is performed on the engine Failure to disconnect cables may result in damage to wire harness or other electrical parts ON ENGINE SERVICE Caution Disconnect the negative battery cable be fore removing or installing any el...

Page 61: ...al Tools 1A3 9 SPECIFICATIONS ENGINE SPECIFICATIONS Special Tools Table 1A3 9 Diagnosis 1A3 10 Oil Leak Diagnosis 1A3 10 Compression Pressure Test 1A3 11 Cylinder Pressure Leakage Test 1A3 13 General Information 1A3 15 Cleanliness and Care 1A3 15 On Engine Service 1A3 15 OM662LA Four Stroke Diesel 2874 89 x 92 4 PES 5 M55 C320 RS 168 22 1 5 SOHC Chain Drive 120 4000 25 5 4000 1 2 4 5 3 BTDC 18 10 ...

Page 62: ...bined Full Flow and Partial Flow Filter Diesel Application Idle Speed rpm Fuel Injection Pressure bar Oil Capacity liter Lubrication Type Oil Filter Type Fuel ENGINE SPECIFICATIONS Cont d OM 661 LA 750 850 135 143 6 5 8 0 Forced by Gear Pump Combined Full Flow and Partial Flow Filter Diesel ...

Page 63: ...GENERAL ENGINE INFORMATION 1A3 3 SECTIONAL VIEW OM662LA ENGINE Front View ...

Page 64: ...1A3 4 GENERAL ENGINE INFORMATION Side View ...

Page 65: ...GENERAL ENGINE INFORMATION 1A3 5 OM661LA ENGINE Front View ...

Page 66: ...1A3 6 GENERAL ENGINE INFORMATION Side View ...

Page 67: ...GENERAL ENGINE INFORMATION 1A3 7 PERFORMANCE CURVE OM662LA ENGINE rpm ...

Page 68: ...1A3 8 GENERAL ENGINE INFORMATION OM661LA ENGINE rpm ...

Page 69: ...GENERAL ENGINE INFORMATION 1A3 9 SPECIAL TOOLS SPECIAL TOOLS TABLE 000 589 10 99 01 Torque Wrench 001 589 76 21 00 Compression Pressure Tester 001 589 73 21 00 Hand Vacuum Pump 001 589 65 09 00 Socket ...

Page 70: ... the suspected component You should be able to trace the leak path over the white powder surface to the source Black Light and Dye Method A dye and light kit is available for finding leaks Refer to the manufacturer s directions when using the kit 1 Pour the specified amount of dye into the engine oil fill tube 2 Operate the vehicle normal operating conditions as directed in the kit 3 Direct the li...

Page 71: ...2 Flexible Connector 3 Compression Pressure Recorder Tools Required 000 589 65 09 00 Socket 001 589 73 21 00 Hand Vacuum Pump Service Data Normal Compression Pressure Minimum Compression Pressure Permissible Pressure Difference Between Individual Cylinders lEngine at normal operating temperature of 80 C ...

Page 72: ...ression Pressure Recorder 001 589 76 21 00 4 Disconnect the vacuum line from the stop unit and connect the hand vacuum pump to the stop unit 5 Pump the hand vacuum pump and make the fuel injection pump in stop position Operating Pressure Approx 500bar Hand Vacuum Pump 001 589 73 21 00 6 Using a starter motor crank the engine 8 revolutions 7 Measure the remaining cylinder compression pressure in th...

Page 73: ... LEAKAGE TEST 1 Connector 2 Connection Piece 3 Connection Hose Permissible Pressure Leakage Engine at Normal Operating Temperature of 80 C At Whole Engine At Valve and Cylinder Head Gasket At Piston and Piston Ring Max 25 Max 10 Max 20 Commercial Tools BOSCH EFAW210AorSUNCLT228 BOSCHorderno 1687010016 ...

Page 74: ...er and connect the connection hose 3 10 Pressurize with compressed air and compare the pressure changes with permissible pressure leakage 11 If permissible pressure leakage is out of standard check followings Intake and exhaust lines Sounds in oil filler area Air bubbles in radiator coolant 12 Do pressure leakage test for the remaining cylinders according to the firing order l OM 662LA Engine 1 2 ...

Page 75: ... kept in order They should be installed in the same locations and with the same mating surfaces as when they were removed Battery cables should be disconnected before any major work is performed on the engine Failure to disconnect cables may result in damage to wire harness or other electrical parts ON ENGINE SERVICE Caution Disconnect the negative battery cable before removing or installing any e...

Page 76: ... 32 Cylinder Head 1B1 34 Timing Gear Case Cover 1B1 37 Crankshaft Sealing Rear Cover 1B1 39 Belt Pulley and Vibration Damper 1B1 41 Crankshaft Front Radial Seal 1B1 44 Crankshaft Rear Radial Seal 1B1 45 Crankshaft 1B1 46 Flywheel Driven Plate 1B1 52 Camshaft Adjuster 1B1 54 Camshaft Sprocket Bolt 1B1 57 Camshaft 1B1 58 TABLE OF CONTENTS Camshaft Timing Position 1B1 63 Valve Spring 1B1 66 Valve Ste...

Page 77: ...ler Shaft to Transmission Engine Mounting Nut Alternator Carrier Bolt Belt Pulley Bolt Steering Pump Bolt A C Bracket Bolt Intake Air Duct Bolt Ignition Cable Cover Bolt Cylinder Head Cover Bolt Camshaft Adjuster Bolt Cylinder Head Front Cover Bolt Flange Bolt in Exhaust Camshaft Sprocket Cylinder Head Bolt Cooling Fan Bracket Bolt Timing Gear Case Cover Bolt M8 M6 Crankshaft Rear Cover Bolt Vibra...

Page 78: ...ft Oil Pump Sprocket Bolt Tensioning Device Bolt Water Pump Pulley Upper Intake Manifold Bolt Lower Intake Mainfold Bolt Flange Bolt to Exhaust Mainfold Exhaust Mainfold Nut to Stud Bolt Rivet Nut in Exhuast Mainfold Hole Pre silencer Bolt Oil Drain Plug Oil Filter Cover Oil Filter Bolt Oil Pump Drive Sprocket Bolt Oil Pump Mounting Bolt Oil Strainer Bracket Bolt Oil Pressure Relief Valve Screw Pl...

Page 79: ... 001 589 66 21 00 Torque Wrench 000 589 01 10 00 Box Wrench Insert 124 589 15 21 00 Radiator Cap Testing Unit 116 589 02 34 00 Screw Fixed Pin 000 589 10 99 01 Torque Wrench 112 589 00 72 00 Oil Extractor 000 589 72 21 00 Torque Wrench 000 589 40 37 00 Hose Clamp ...

Page 80: ...S TABLE Cont d 104 589 01 01 00 Spanner 111 589 18 61 00 Lever Pusher 111 589 25 63 00 Thrust Piece 111 589 01 59 00 Supporting Bar 116 589 06 63 00 Magnetic Finger 119 589 00 43 00 Drift 000 589 58 43 00 Chain Assembly 104 589 00 37 00 Pliers ...

Page 81: ...ABLE Cont d 116 589 20 33 00 Sliding Hammer 602 589 00 40 00 Engine Lock 103 589 00 33 00 Puller 601 589 03 43 00 Sleeve 001 589 65 09 00 Socket Wrench Insert 001 589 74 21 00 Torque Wrench 000 589 04 14 00 Clamping Strap 000 589 88 33 00 Puller ...

Page 82: ...TABLE Cont d 103 589 01 63 00 Rivet Set 103 589 02 09 00 Oil Filter Socket Wrench 102 589 12 15 00 Drift 615 589 01 33 00 Caulking Bolt 102 589 00 15 00 Drift 000 589 51 37 00 Clamping Strap 001 589 72 21 00 Torque Wrench 601 589 03 14 00 Sleeve ...

Page 83: ...AND REPAIR ON VEHICLE SERVICE ENGINE ASSEMBLY Tools Required 000 589 10 99 01 Torque Wrench 000 589 40 37 00 Hose Clamp 112 589 00 72 00 Oil Extractor 000 589 72 21 00 Torque Wrench 001 589 66 21 00 Torque Wrench 124 589 15 21 00 Radiator Cap Testing Unit Removal Installation Procedure 1 Disconnect the negative terminal of battery 2 Remove the hood 3 Remove the under cover Installation Notice Tigh...

Page 84: ...ce Open the coolant reservoir cap 7 Loosen the cylinder block drain plug and then drain the coolant completely Installation Notice Tightening Torque 30 Nm Notice Replace the seal before installation of the drain plug 8 Remove the cooling fan shroud 9 Disconnect the each hose from radiator ...

Page 85: ...he discharge pipe and suction pipe from the compressor 13 Remove the acceleration control cable and automatic transmission pressure cable 10 Remove the upper mounting bolts of radiator and then remove the radiator 11 Remove the hydraulic pipe of power steering Notice Completely drain the oil ...

Page 86: ...l lines release the pressure in the fuel system Installation Notice Tightening Torque 21 25 Nm 15 Remove the automatic transmission dipstick guide tube 16 Disconnect the wire of alternator 17 Disconnect the wire of starter motor and remove the starter motor 18 Disconnect the engine main harness ground ...

Page 87: ... knock sensors l Camshaft and crankshaft sensors 21 After removing the ignition coil cover disconnect the ignition coil connector 22 Remove the harness cover and disconnect the 6 injection valve connectors Disconnect the main harness 23 Separate the hose toward engine from canister purge solenoid valve 24 Remove the automatic transmission oil cooler line ...

Page 88: ...Notice 25 Separate the vacuum hose for brake booster 26 Separate the other vacuum hoses 27 Remove the propeller shaft from the front axle Installation Notice 28 By rotating the crankshaft from the front of engine remove the 6 torque converter mounting bolts from the engine ring gear plate Tightening Torque 81 89 Nm ...

Page 89: ...on Notice Tightening Torque 65 Nm 31 Remove the bolts for engine mounting bracket Installation Notice Tightening Torque 50 75 Nm 32 Hook the chain to the bracket of engine and by using a hoist or crane carefully separate the engine assembly from the vehicle 33 Installation should follow the removal procedure in the reverse order ...

Page 90: ...ain Pipe 8 Oil Pan 9 Air Admission Line 10 Vent Line 11 Restriction Hole Diameter 2 mm 12 Intake Manifold 13 Intake Air Duct Cross Pipe 14 Cylinder Head Cover 15 Oil Separator 16 Oil Separator 17 Air Admission and Vent Connection 18 Air Admission and Vent Connection 19 Throttle Valve 20 Vent Line A Fresh Air B Blowby Gas in Partial Load C Blowby Gas in Full Load ...

Page 91: ...d at the air conditioner bracket 6 and then returns into the oil pan through the drain pipe 7 The vacuum pressure generated at the crankcase sucks fresh air from intake air line 13 through the air admission and vent connection 17 18 The fresh air prevents engine oil from being contami nated and the air admission and vent connection 17 18 is designed to control the rapid pressure changes in intake ...

Page 92: ... Removal Installation Procedure 1 Remove the drive belt 2 Remove the alternator 3 Unscrew the alternator carrier bolts and remove the carrier Installation Notice 4 Bolt M8 x 70 1 piece 22 5 27 5 Nm 5 Bolt M8 x 75 1 piece 22 5 27 5 Nm Tightening Torque 22 5 27 5 Nm 4 Installation should follow the removal procedure in the reverse order ...

Page 93: ...oud 1 Vent Hose 2 Bolt M8 x 91 2 pieces 22 5 27 5 Nm 3 Power Steering Pump 4 Bolt M8 x 105 4 pieces 22 5 27 5 Nm 5 Washer 6 A C Compressor 7 Bolt M8 x 40 3 pieces M8 x 95 2 pieces 22 5 27 5 Nm 8 A C Bracket 9 Gasket Replace 10 Bracket 11 Bolt M8 x 22 2 pieces 22 5 27 5 Nm 12 Tensioning Pulley 13 Nut 40 5 49 5 Nm ...

Page 94: ...he oil 3 Unscrew the bolts arrows and remove the steering pump Installation Notice Notice Pull the tensioning pulley clockwise as shown in the figure 4 Remove the compressor after disconnecting the wiring connector and refrigerant pipe of A C compressor Notice Discharge all the refrigerant before removing the pipes Tightening Torque 40 5 49 5 Nm Tightening Torque 22 5 27 5 Nm ...

Page 95: ...bolts arrows and remove the A C bracket and the gasket Installation Notice 7 Clean the sealing surface 8 Replace the gasket with new one 9 Installation should follow the removal procedure in the reverse order 10 Check the oil leakage by operating the engine after installation Tightening Torque 22 5 27 5 Nm ...

Page 96: ...M162 ENGINE MECHANICAL 1B1 21 HYDRAULIC ENGINE MOUNTING INSULATOR Service Data ...

Page 97: ...CHANICAL SectionalView 1 Rubber Body 2 Brackek 3 Core 4 Lower Bolt 5 Rubber Plunger 6 Plunger Plate 7 Rubber 8 Plate 9 Lower Orifice 10 Upper Orifice 11 Diaphram 12 Cover Plate 13 Upper Bolt 14 Flange Bolt 15 Rivet 16 Fluid ...

Page 98: ...ine mounting and remove the engine Installation Notice 3 Installation should follow the removal procedure in the reverse order Tightening Torque 62 93 Nm 2 Unscrew the lower nut 3 and remove the hydraulic engine mounting insulator Installation Notice Tightening Torque 28 47 Nm Notice If the insulator is spotted with oil replace the hydraulic insulator assembly ...

Page 99: ... Procedure 1 Release the belt tension by turning the belt tensioning pulley nut clockwise 2 Remove the poly v belt Notice Check the belt for damage and tensioning pulley bearing point for wear and replace them if necessary 3 Install the belt by turning the nut of tensioning pulley clockwise 2 Belt Tensioning Pulley ...

Page 100: ...AL 1B1 25 Poly V Belt Arrangement 1 Belt Tensioning Pulley 2 Crankshaft Belt Pulley 3 A C Compressor Pulley 4 Cooling Fan Pulley 5 Alternator Pulley 6 Idler 7 Power Steering Pump Pulley 8 Cooling Fan and Water Pump Pulley ...

Page 101: ...5 2 Bolt Combi M8 x 14 3 pieces Washer 22 5 27 5Nm Removal Installation Procedure 1 Remove the poly v belt 2 Remove the tensioning pulley by turning its mounting nut counter clockwise as shown in figure Installation Notice 3 Water Pump Pulley 4 Nut 5 Tensioning Pulley Tightening Torque 40 5 49 5 Nm ...

Page 102: ...nsioning device and remove the tensioning device arrow Installation Notice 3 Remove the 3 bolts 2 and remove the water pump pulley arrow Installation Notice 5 Installation should follow the removal procedure in the reverse order Tightening Torque 22 5 27 5 Nm Tightening Torque 26 32 Nm ...

Page 103: ...Y V BELT INSPECTION l Make marks on the belt with chalk l Rotate the engine and check the belt for damage Notice If one of the following types of damages is found replace the belt 1 Rubber lumps in the base of rib 2 Dirt or grit ingrained 5 Cord torn out at the side 6 Outer cords frayed ...

Page 104: ...M162 ENGINE MECHANICAL 1B1 29 7 Rib detached from the base of belt 8 Splits across the rib 9 Sections of rib torn out 10 Splits across several ribs 11 Splits across the back of the belt ...

Page 105: ...x 65 8 pieces 9 11 Nm 3 Bolt M6 x 50 4 pieces 9 11 Nm 4 Spacer Sleeve 5 Thrust Piece Composition of The Cylinder Head Cover Bolts A M6 x 50 4 Pieces Bolts Washers B M6 x 65 8 Pieces Bolts Washers 6 Cylinder Head Cover 7 Gasket Replace 8 Spart Plug Hole Seal Replace 9 Camshaft Seal Replace ...

Page 106: ...Unscrew all the bolts 2 3 and remove the head cover and the gasket Installation Notice Notice Unscrew the seven M6 x 60 bolts and remove the ignition cable cover Notice Replace the gasket with a new one if necessary 5 Installation should follow the removal procedure in the reverse order 6 Check for oil leaks by operating the engine Tightening Torque 8 4 0 65 Nm Tightening Torque 9 10 Nm Tightening...

Page 107: ...ction fitting 1 Camshaft Position Sensor 2 Magnet Assembly 3 Upper Guide Rail 4 Bolt M6 x 60 3 pieces 22 5 27 5 Nm 5 Bolt M8 x 80 3 pieces 22 5 27 5 Nm 6 Front Cover 7 Rubber Gasket Replace 8 Bolt M6 x 16 3 pieces 9 11 Nm Removal Installation Procedure 1 Remove the magnet assembly Installation Notice Tightening Torque 9 11 Nm ...

Page 108: ...e gasket with new one and apply the sealant 5 Installation should follow the removal procedure in the reverse order Apply the sealant at the mating surface of the cylinder head and the front cover 3 Remove the upper guide rail pin and the guide rail 3 Installation Notice Install it while the chain tensioner is loose Tightening Torque 22 5 27 5 Nm ...

Page 109: ...er Removal of cylinder head front cover Removal of upper intake manifold 1 Cylinder Head Bolt 14 pieces 1st step 55 Nm 2nd step 90 3rd step 90 2 Washers 14 pieces 3 Flange Bolts 3 pieces 1st step 20 Nm 2nd step 90 4 Exhaust Camshaft Sprocket 5 Cylinder Head 6 Gasket Replace 7 Dowel Sleeve ...

Page 110: ... bolts Tools Required 000 589 01 10 00 Box Wrench Insert 116 589 02 34 00 Screw fixed Pin 116 589 20 33 00 Sliding Hammer Removal Installation Procedure 1 Rotate the crankshaft so that the piston of number 1 cylinder is at TDC Notice Rotate the crankshaft in the normal engine direction 2 Put the alignment marks arrows on the timing chain and camshaft sprocket 3 Drain the coolant from the crankcase...

Page 111: ... length l Apply the oil to the thread surface of bolt 9 Carefully remove the cylinder head and check the mating surface 10 Installation should follow the removal procedure in the reverse order 6 Remove the guide rail fixing pin from the cylinder head using the sliding hammer 01 and the threaded pin 02 Sliding Hammer 116 589 20 33 00 Threaded Pin 116 589 02 34 00 Tightening Torque 1st step 55 Nm 2n...

Page 112: ...eces 22 5 27 5 Nm 2 A C Bracket 3 Bolt M8 x 65 3 pieces 22 5 27 5 Nm 4 Bolt M8 x 40 1 piece 22 5 27 5 Nm 5 Bolt M8 x 60 1 piece 22 5 27 5 Nm 6 Seal 7 Timing Gear Case Cover 8 Roll Pin 9 Bolt M6 x 22 6 pieces 9 11 Nm Removal Installation Procedure 1 Put the alignment marks arrows on the timing chain and camshaft sprocket 2 Unscrew the A C bracket bolts 1 and remove the bracket Installation Notice T...

Page 113: ...gear case cover and the bolt 9 from the oil pan Notice Be careful not to damage the oil pan gasket Installation Notice l Apply the sealant after cleaning the timing gear case cover surface l Be careful not to stain the oil chamber of chain tensioner with the sealant 5 Installation should follow the removal procedure in the reverse order 6 Warm up the engine and check for oil leaks Tightening Torqu...

Page 114: ...CAL 1B1 39 CRANKSHAFT SEALING REAR COVER Preceding Work Removal of the automatic transmission drive plate 1 Bolt M6 x 20 6 pieces 9 11 Nm 2 Radial Shaft Seal 3 Rear Cover 4 Sleeve 5 Bolt M6 x 85 2 pieces 9 11 Nm 6 Washer ...

Page 115: ...e rear sealing cover 3 Check the radial shaft seal and replace it if necessary 4 Apply the Loctite 573 to the rear cover sealing surface 5 Apply the engine oil to the dust lip of the radial shaft seal Notice Do not use the grease 6 Using the special tool press the radial shaft seal and the rear cover 7 Tighten the rear cover bolt 1 and then tighten the oil pan bolt 5 as specified and remove the sp...

Page 116: ...0 10 2 Vibration Damper Disk 3 Bolt M6 x 20 6 pieces 7 7 9 5 Nm BELT PULLEY AND VIBRATION DAMPER Preceding Work Removal of cooling fan and viscous clutch Removal of fan shroud Removal of drive belt 4 Vibration Damper Assembly 5 Key 6 Bolt M6 x 12 4 pieces 9 11 Nm 7 Cooling Fan Pulley ...

Page 117: ...iven 8 Crankshaft Sprocket Oil pump Driven 9 Crankshaft 10 Oil Pan 11 Oil Pan Gasket 12 Oil Pan Mounting Bolt M6 x 22 Service Data Standard Permissble Deviation of The Vibration Damper Radial Runout Axial Runout 0 6 mm 0 6 mm Tools Required 103 589 00 33 00 Puller 001 589 65 09 00 Socket Wrench Insert 602 589 00 40 00 Engine Lock Removal Installation Procedure 1 Adjust the piston of number 1 cylin...

Page 118: ...he flywheel ring gear 3 Remove the center bolt Installation Notice Tightening Torque 1st step 200 220 Nm 2nd step 90 10 4 Remove the vibration damper assembly using the puller 5 Installation should follow the removal procedure in the reverse order Notice If possible don t separate the vibration damper and the pulley ...

Page 119: ... seal with a screw driver Notice Use a clean cloth not to damage the radial seal mounting hole and the crankshaft 5 Remove the sleeve and install the belt pulley and the vibration damper 6 Check for leaks while operating the engine 2 Coat the radial sealing lip with engine oil 3 Using the sleeve assemble the radial seal 4 Align the sleeve groove and the woodruff key and tighten the center bolt unt...

Page 120: ...dre 1 Remove the radial seal with a screw driver Notice Use a clean cloth not to damage the radial seal mounting hole and the crankshaft 2 Install the special tool 2 to the crankshaft 3 Apply the engine oil on the special tool 2 Notice Do not use the grease 4 Install the radial seal on the inner parts assembler 5 Press in the special tool 1 until the radial seal is stopped 6 Check for leaks while ...

Page 121: ...val of engine assembly Removal of timing gear case cover Removal of cylinder head Removal of oil pump Removal of oil shield 1 12 sided Stretch Bolt 55 Nm x 90 Iubricate 2 Crank Shaft Bearing Cap 3 Crank Shaft Low Main Bearing 4 Lower Thrust Bearing 5 Crank Shaft ...

Page 122: ... 7 l Color Dot Marking The color dot marking are put on the 1 2 4 6 8 10 12 and it indicates the diameter of crankshaft journal by color as below A Crankcase Side B Bearing Cap Side Oil Pan Side C Axial Fit Bearing Number 5 Bearing Point D Radial Bearing 1 Upper Main Bearing 2 Upper Thrust Bearing 3 Crankshaft 4 Lower Main Bearing 5 Lower Thrust Bearing ...

Page 123: ...nkshaft Journal Diameter mm 57 960 57 965 57 955 57 960 57 950 57 955 57 945 57 950 57 940 57 945 Punching Mark Bearing Color Selected Blue Yellow Red Marking Letter B Y R W V Bearing Color Selected Blue Yellow Red White Violet Service Data Unit mm Crankshaft Bearing Jour nal Diameter Crankshaft Bearing Diameter Crankshaft Journal Width at fit bearing Connecting Rod Bearing Journal Diameter Connec...

Page 124: ...r and lower bearing shells do not change each other and coat with engine oil l The oil grooves arrows in the thrust washers must face outward and insert the thrust bearing into the bearing cap l There are five kinds of thrust washers by thickness Select the proper washer when repaired 3 Remove the crankshaft 4 Installation should follow the removal procedure in the reverse order 5 After completion...

Page 125: ...e at 2 points 1 2 l Measure A B and C as shown If average value of B and C is less than value A then the average value of B and C is actual average value If average value of B and C is more than value A is actual average value 4 Measure and record the diameter of the crankshaft bearing journal Notice l Record the mean value when measured at 3 points A B C l Measure the inner diameter of bearing an...

Page 126: ...g Journal NO 3 4 6 Measuring Position Radial Axial Radial Axial Gap mm Static condition 0 015 0 039 Dynamic condition 0 031 0 051 Consider the expansion 0 011 0 016 0 010 0 254 Static condition 0 011 0 039 Dynamic condition 0 031 0 051 Consider the expansion 0 015 0 022 0 010 0 254 Item Connecting Rod Bearing Measuring Position Radial Gap mm 0 030 0 050 ...

Page 127: ...Flywheel Mounting Bolt M10 x 22 8 pieces 1st step 45 5 Nm 2nd step 90 10 2 Plate 3 Driven Plate A T 4 Dowel Pin Service Data Standard Stretch Bolt Nominal Size Stretch Side Diameter Bolt Length Tightening Torque M x 1 5 8 5 0 2 mm 8 0 mm 21 8 22 2 mm When New Min Diameter When New D d L 1st step 50 Nm 2nd step 90 ...

Page 128: ...Rivet 13 Segment 14 Ring Gear l Replace the bolt when the stretch side diameter d of the flywheel mounting bolt is less than 8 0mm l For the stretch bolt tightening keep the socket wrench and Tommy bar to be 90 and tighten as specified 2 Remove the flywheel for manual transmission vehicles or the driven plate 3 and plate 2 for Auto transmission vehicle 3 Installation should follow the removal proc...

Page 129: ...ut M20 x 1 5 60 70 Nm 7 Front Cover 8 Seal 9 Camshaft Position Sensor 10 Bolt M6 x 16 2 pieces 9 11 Nm 11 Seal 12 Seal Cover 13 Camshaft Sprocket and Position Indicator b 14 Adjuster piston 15 Flange bolt M7 x 13 3 pieces 1st step 18 22 Nm 2nd step 90 5 16 Flange Shaft 17 Compression Spring 18 Control Piston 19 Circlip 20 Oil Gallery 21 Pin 22 Intake Camshaft ...

Page 130: ...nscrew the bolt 3 from the armature 4 and remove the armature Installation Notice 3 Bolt 4 Amarture 6 Nut M20 x 1 5 11 Seal Cover 5 Unscrew the nut 6 and remove the ring and seal cover 11 Installation Notice Tightening Torque 35 Nm Tightening Torque 60 70 Nm 12 Camshaft Sprocket 17 Control Piston 21 Intake Camshaft 6 Unscrew the sprocket bolt from the exhaust camshaft and remove the sprocket Insta...

Page 131: ...t 16 from the intake camshaft 22 after removing the bolt 15 Installation Notice The sprocket bolt is designed to be used only once so always replace with new one 8 Installation should follow the removal procedure in the reverse order 9 Adjust the camshaft timing Tightening Torque 1st step 18 22 Nm 2nd step 90 5 ...

Page 132: ...haft Sprocket Bolt Notice The sprocket bolts are designed to be used only once so always replace with new one C M7 x 13 Collar Bolt Torx T30 e 6 8mm 16 Flange Shaft 18 Control Piston 22 Intake Camshaft E M7 x 13 Collar Bolt Torx T30 e 6 8mm 13a Camshaft Sprocket 22a Exhaust Camshaft Tightening Torque 1st step 18 22 Nm 2nd step 90 5 Tightening Torque 1st step 18 22 Nm 2nd step 90 5 ...

Page 133: ...ding Work Removal of cylinder head cover removal of coolant connection fitting 1 Chain Tensioner Assembly 72 88 Nm 2 Exhaust Camshaft Sprocket 3 Upper Guide Rail 4 Cylinder Head Front Cover 5 Intake Camshaft Sprocket 6 Chain 7 Wrench Special Tool ...

Page 134: ... BTDC 30 2 Remove the alternator 3 Remove the chain tensioner 4 Remove the cylinder head front cover and the upper guide rail 6 Unscrew the exhaust camshaft sprocket bolt and remove the sprocket 7 Separate the chain from the intake camshaft sprocket and put the chain not to be dropped into timing case 5 Put the alignment marks arrows on the camshaft sprocket 2 5 and the timing chain 6 ...

Page 135: ...ice Turn the crankshaft in the direction of engine rotation 3 Turn the camshaft using the wrench special tool so that the intake camshaft adjustment hole lines up with the cylinder head upper side 3 o clock direction at the intake 9 o clock direction at the exhaust Notice Turn the crankshaft and adjust it to OT so that no 1 cylinder s piston would be at TDC Install the bearing caps according to th...

Page 136: ... Notice 7 Rotate the crankshaft 2 revolutions and check followings TDC of No 1 cylinder OT Alignment between camshaft adjustment hole and cylinder head surface Alignments between timing chain and sprocket marks Notice l Turn the crankshaft in the direction of engine rotation l Read just if not aligned 6 Install the chain tensioner and tighten it as specified Notice l Make sure that the camshaft sp...

Page 137: ...1B1 62 M162 ENGINE MECHANICAL 8 Install the upper guide rail and cylinder head front cover 9 Install the alternator ...

Page 138: ...ITION Preceding Work Removal of cylinder head cover Removal of cylinder head front cover 1 Chain Tensioner Assembly 2 Exhaust Camshaft Sprocket 3 Upper Guide Rail 4 Cylinder Head Front Cover 5 Wrench Special Tool 6 Adjustment Hole Fitting Pin f4 0 mm ...

Page 139: ...he guide rail in gear case cover Tools Required 104 589 01 01 00 Spanner Inspection 1 Position the No 1 cylinder piston to TDC OT by turning the crankshaft Notice When the OT mark on vibration damper is aligned with timing gear case cover the intake and exhaust cam of cylinder will make the slope to the center and will face up In this way the adjustment hole of the intake and exhaust camshaft will...

Page 140: ...ce so replace with new one 10 Install the chain tensioner Installation Notice Tightening Torque 1st step 18 22 Nm 2nd step 90 5 9 Install the chain to the exhaust camshaft sprocket and install it to the camshaft Installation Notice Sprocket Bolt Tightening Torque Screw Plug 40 Nm Tensioner Assembly 72 88 Nm ...

Page 141: ...moval of camshaft Removal of spark plug 1 Valve Tappet Assembly 2 Valve Cotter 3 Upper Retainer 4 Valve Spring Check Replace if necessary 5 Valve Stem Seal 6 Lower Retainer 7 Connecting Hose 8 Thrust Piece 9 Slide 10 Adjust Bolt 11 Lever Pusher 12 Supporting Bar ...

Page 142: ... to position the each cylinder piston at TDC 5 Install the engine lock to the ring gear to prevent the crankshaft from rotating 6 Blow up with compressed air Notice l Remove the valve spring only at TDC l Always rotate the crankshaft by holding the chain to prevent from timing chain damage and tangling and for smooth rotation 3 Remove the valve tappet 1 using the magnetic finger 4 Install the leak...

Page 143: ...e thrust piece 8 and the slide 9 perpendicular to each other 11 Secure the slide 9 by turning the adjust bolt 10 12 Press the valve spring 4 by using the lever pusher 11 14 Remove the upper retainer 3 and the valve spring 4 15 Remove the valve stem seal and replace if necessary Notice Check the valve stem seal and replace if necessary 16 Remove the lower retainer 6 Notice Check the retainer for da...

Page 144: ... MECHANICAL 1B1 69 Test Upper and Lower Valve Tappet and Valve Cotter l Upper Valve Spring Retainer l Lower Valve Spring Retainer l Valve Cotter 12 3 D d 8 5 Size mm Thickness mm a 0 8 1 0 9 2 9 8 H B 9 0 Size mm ...

Page 145: ...00 Pliers 104 589 00 37 00 Tools Required 104 589 00 37 00 Pliers 119 589 00 43 00 Drift Replacement Procedure 1 Remove the valve stem seal 2 using the pliers Notice Check the valve stem seal for damage and replace if necessary 2 Coat the valve stem seal with oil and assemble it with the protective sleeve 3 Insert the valve stem seal by pressing it with the drift ...

Page 146: ...ion and check whether the intake camshaft cam s lobe arrow stays in the upper side 2 Cover the alternator with a clean cloth 3 Release the tension by unscrewing the screw plug once Notice In case that the tension is reduced by unscrewing the screw plug reinstall after completely removing the chain tensioner If the chain tensioner is tightened again without completely reducing its tension then the ...

Page 147: ... the removal of screw plug be careful that it can be jumped out due to the force of compression spring l Remove the screw plug only when the seal and compression spring are damaged 5 Carefully remove the filler pin 3 compression spring 4 snap ring 5 and the thrust pin 6 6 Remove the chain tensioner housing 7 and the seal 8 3 Insert the compression spring 4 with the filler pin 3 into chain tensione...

Page 148: ...ler Pin 7 Compression Spring 8 Snap Ring 9 Thrust Pin 10 Ball Nonreturn Valve 11 Compression Spring 12 Thrust Piece 13 Chain Tensioner Housing 14 Seal 15 Timing Gear Case Cover 16 Cylinder Head 17 Bolt Washer 18 Tensioning Rail 19 Cylinder Head Gasket 20 Timing Chain 21 Tensioning Rail Base Sliding Surface A Oil Supply Hole B Chain Tensioner Oil Storage Hole 5 Check for leaks by operating the engi...

Page 149: ...1B1 74 M162 ENGINE MECHANICAL TIMING CHAIN Preceding Work Removal of cylinder head cover Removal of spark plug 1 Pin 2 New Timing Chain 3 Timing Chain Used 4 Wedge 5 Link 6 Center Plate 7 Outer Plate ...

Page 150: ...sition the No 1 cylinder to TDC OT 4 Mount the wedges to both sides of the camshaft sprocket as shown in the figure 2 Insert the f4mm pin to the intake and exhaust camshaft flange not to rotate camshaft 3 Remove the chain tensioner 5 Cover the chain housing with a clean cloth and grind off the timing chain pin from the intake camshaft sprocket with the grinder ...

Page 151: ...ng chain against the exhaust camshaft sprocket to prevent it to be tangled Notice Be sure to remove the wedge before cranking the engine 9 Take out the used timing chain out from the chain housing 10 Connect both separators of the new timing chain with the link 5 and the center plate 6 6 Remove the outer plate 7 with the screw driver and remove the link 5 11 Install the jaw a and the thrust piece ...

Page 152: ... 13 Install the assembly tool above the link and tighten the spindle c until a block is felt 14 Place the assembly tool 12 Place the outer plate 7 thickness 1 2mm inside the thrust piece b 16 Install the assembly tool to the link pin and tighten the spindle c Tightening Torque 30 Nm ...

Page 153: ...NICAL 17 Rivet the link pin Check the condition and it again if necessary 18 Install the chain tensioner Installation Notice 19 Check the camshaft timing position Tightening Torque Screw Plug 40 Nm Tensioner Assembly 72 88 Nm ...

Page 154: ...mark at the camshaft sprocket and the timing chain with the paint arrow 2 Remove the exhaust camshaft sprocket 3 Remove the tensioning rail 1 from the tensioning rail pin 3 Notice l Replace the plastic guide 2 if it is damaged l For installation exactly align the plastic guide 2 with the tensioning rail 1 4 Installation should follow the removal procedure in the reverse order 5 Check the camshaft ...

Page 155: ... the guide rail 2 4 Turn the exhaust camshaft to the opposite direction of rotation using the wrench 4 special tool 104 589 01 01 00 5 Check for damages at the upper sliding rail and replace it if necessary Install the upper guide rail pin 6 Install the chain tensioner Installation Notice CYLINDER HEAD GUIDE RAIL Preceding Work Removal of cylinder head cover 1 Chain Tensioner 2 Upper Guide Rail 3 ...

Page 156: ... mark at the camshaft sprocket and the timing chain with the paint arrow 2 Remove the exhaust camshaft sprocket 3 Remove the guide rail 1 from the guide rail pin 3 Notice l Replace the plastic guide 2 if damaged l Connect the plastic guide 2 and the guide rail 1 by aligning them accurately when installing 4 Installation should follow the removal procedure in the reverse order 5 Check the camshaft ...

Page 157: ...l pan Removal of tensioning rail Removal of crank case guide rail 6 Bolt M8 x 20 1 piece Washer 29 35 Nm 7 Oil Pump Sprocket 8 Oil Pump 9 Oil Pump Roller Chain 10 Timing Chain 1 Oil Pump Chain Tensioner 2 Oil Pump Chain Bushing 3 Oil Pump Chain Spring 4 Crankshaft Sprocket 5 Key ...

Page 158: ...stalling 2 Unscrew the bolt 6 and remove the oil pump sprocket 7 from the oil pump Installation Notice Puller 04 615 589 01 33 00 3 Remove the oil pump roller chain 9 4 Remove the oil pump chain tensioner 1 oil pump chain bushing 2 and the oil pump chain spring 3 5 Remove the crankshaft sprocket 4 using the puller 04 special tool Notice l Make sure not to lose the crankshaft pulley key 5 when remo...

Page 159: ...Removal of engine Removal of cylinder head Removal of oil pan Removal of oil pump Removal of baffle plate 1 Connecting Rod Bearing Cap 2 Connecting Rod 3 Connecting Rod Bolt M9 x 52 12 pieces 1st step 40 Nm 2nd step 90 5 4 Piston 5 Snap Ring 6 Piston Pin ...

Page 160: ...nd remove the cap 2 Remove the connecting rod and the piston upward Notice Make sure that the bearing cap and shell are not changed each other 3 Remove the snap ring 5 and pull out the piston pin 6 Notice Remove the snap ring using a clean cloth as shown in the right picture so that the piston piston ring and the snap ring don t get damaged Installation Procedure ...

Page 161: ...earing shell and the piston and coat them with engine oil 4 Install the piston ring using the tensioning strap 000 589 04 14 00 5 Install the piston so that the arrow on the piston head faces to the forward of the vehicle 6 After aligning the connecting rod and the bearing cap mark or a number tighten the bolts Installation Notice Tightening Torque 1st step 35 45 Nm 2nd step 90 5 Apply the engine ...

Page 162: ...The Connecting Rod b at Bushing Bore Basic Bore at The Bearing Shell D1 Basic Bore at The Bushing d1 Bushing Inner Diameter d Clearance Between The Piston Pin and The Bushing Peak to valley Height of Connecting Rod Bushing on Inside Permissible Wwist of Connecting Rod Bearing Bore to Connecting Rod Bushing Bore Permissible Deviation of Axial Paralleism of Connecting Rod Bearing Bore to Connecting ...

Page 163: ...indication or number arrow of the connecting rods and the bearing cap when installing Notice l Make sure it doesn t exceed over 4g with other connecting rods when replacing the connecting rods l Check if the connecting rod and the bearing cap are accurately seated on the groove when replacing the bearing Notice If the length exceeds max length replace it Length When New L Max Length L Tightening T...

Page 164: ... 6 Hook Spring Notice If out of specification replace the piston ring Tools Required 000 589 51 37 00 Clamping Strap Replacement Procedure 1 Measure the piston ring s gap Gap Between The Piston and The Piston Ring Groove 1 0 20 0 40 mm Groove 2 0 20 0 40 mm Groove 3 0 20 0 45 mm Groove 1 0 015 0 050 mm Groove 2 0 020 0 040 mm Groove 3 0 010 0 045 mm End Gap of The Piston Ring ...

Page 165: ...with a pliers 3 For installation position the piston ring to be the TOP mark on the piston ring upward and arrange the piston ring ends to be 120 apart 4 Adjust the hook spring joint in the oil ring 180 away from the ring end Clamping Strap 000 589 51 37 00 ...

Page 166: ...il level switch 3 Unscrew the bolts 10 for oil level switch and check the O ring 11 for wear or damage And replace it if necessary 4 Unscrew the bolts and remove the oil pan and gasket Notice Arrange the bolts according to each size 5 Clean the inside of oil pan and sealing surface then apply the sealant 6 Replace the gasket with new one 7 Install the oil pan with gasket and tighten each bolt in s...

Page 167: ... Head 16 Ball f 15mm 17 Oil Restriction Inner f 4mm 18 Oil Supply To Exhaust Camshaft 19 Oil Supply To Intake Camshaft 20 Oil Supply To Exhaust Camshaft Bearing 21 Oil Supply To Intake Camshaft Bearing 22 Oil Gallery Oil Supply to Exhaust Valve Tappet 23 Oil Gallery Oil Supply to Exhaust Valve Tappet 24 Camshaft Closing Cover 25 Ball f8 mm 26 Screw Plug 27 Camshaft Adjuster 28 Front Closing Cover ...

Page 168: ...h special tool 2 Install the wrench to the upper bolt in the socket wrench and remove the oil cover by turning it 3 Remove the oil filter element Notice Work with a cloth under the vehicle when removing the oil filter element to not drain the oil Replace the seal washer with new one 6 Replace the O ring 5 in the oil filter cover with new one Notice Apply the engine oil to the O ring 7 Insert new o...

Page 169: ...ipstickGauge 9 Fill up engine oil through the engine oil filler opening 3 10 Check for oil leaks at normal engine temperature after starting the engine 11 Stop the engine and wait 5 minutes Check the oil level and fill up as specified if necessary ...

Page 170: ...M162 ENGINE MECHANICAL 1B1 95 OIL FILTER Preceding Work Removal of starter motor Removal of upper intake manifold 1 Coolant Line 2 O ring Replace 3 Clip 4 Hose 5 Bolt 23 Nm 6 Oil Filter 7 Gasket Replace ...

Page 171: ...low the removal procedure in the reverse order 5 Check engine oil level 6 Run the engine at idle and check the engine for leaks 3 Remove the oil filter bolt and then remove the oil filter Installation Notice Removal Installation Procedure 1 Drain the coolant from the crank case 2 Remove the each coolant line and hose ...

Page 172: ...M162 ENGINE MECHANICAL 1B1 97 1 Bolt M8 x 20 1 piece 29 35 Nm 2 Sprocket Oil Pump Drive 3 Bolt M8 x 35 3 pieces 22 5 27 5 Nm OIL PUMP Preceding Work Removal of oil pan 4 Spring Pin 5 Oil Pump ...

Page 173: ...lace the strainer in oil pump if necessary 6 Installation should follow the removal procedure in the reverse order Tighten the baffle plate and the oil pump with the two bolts in right side first and then tighten the other bolt 3 Unscrew the bolt 9 from the oil strainer bracket Installation Notice 2 Unscrew the oil pump mounting bolts 3 Installation Notice Tightening Torque 29 35 Nm Tightening Tor...

Page 174: ...2 Compression Spring Removal Installation Procedure 1 Remove the screw plug 1 Installation Notice 2 Remove the spring 2 guide pin 3 and the piston 4 3 Installation should follow the removal procedure in the reverse order Notice Don t use the seal for the screw plug 3 Guide Pin 4 Piston Tightening Torque 50 Nm ...

Page 175: ...turn valve prevents the oil in the chain tensioner from drying up In other words it stops oil returning in order to prevent the oil in the chain tensioner from getting dry As a result the chain tensioner can be activated with oil in itself Replacement Procedure 1 Remove the non return valve using a pliers 2 Insert new non return valve with hand ...

Page 176: ... dipstick level gauge 1 2 Remove the bolt 4 in the upper intake manifold and remove the oil dipstick guide tube Installation Notice 3 Install new O ring to the dipstick guide tube 4 Installation should follow the removal procedure in the reverse order 5 Check for leaks by starting the engine 3 O ring 4 Bolt M6 x 12 1 piece 9 11 Nm Tightening Torque 9 11 Nm ...

Page 177: ...k Removal of crankshaft removal of oil spray nozzle 1 Plug 2 Steel Ball Cleaning Procedure 1 Remove the plug 1 with a screwdriver 2 Using a round bar 3 and hammer remove the steel ball 2 3 Using the compressed air blow into the oil galleries and clean it off 3 Round Bar f11 x 750 mm ...

Page 178: ...ameter of 16mm depth of 15mm 2 Using an M16 x 1 5 thread tap make the thread at the end of main oil gallery 4 3 Throughly clean the oil gallery with compressed air and tighten the screw plug M16 x 1 5 after applying sealing bond on it 4 Apply Loctite 270 on new plug and tighten to the hole until the drift is stopped after inserting new plug into the drift 3 Screw Plug ...

Page 179: ...l of cylinder head Removal of camshaft Removal of tappet 1 Screw Plug 15 Nm 2 Seal Cleaning Procedure 1 Remove the screw plug 1 and the seal 2 Installation Notice Replace the seal with new one 2 Clean the oil gallery using the compressed air 3 Steel Ball f8mm Tightening Torque 15 Nm ...

Page 180: ...ng the round bar 12 f6 x 700 mm 4 Enlarge the oil gallery at the rear of the cylinder head to be diameter 9mm depth 8mm 5 Tap in the steel ball 3 from the side to the oil gallery using the punch 13 6 Pull out the steel ball 3 using the round bar 12 7 Enlarge the oil gallery to be diameter 9mm depth 8mm Tightening Torque 15 Nm 3 Remove the plug 8 using the screw driver ...

Page 181: ...rrow Screw Plug Part No 000 908 01 00 02 Seal Part No 007 603 01 01 03 8 Make a screw hole at the oil gallery using M10 x 1 thread 9 All the oil gallery should be cleaned with the compressed air 10 Apply the Loctite 270 to new plug and press in using a suitable drift arrow ...

Page 182: ...M162 ENGINE MECHANICAL 1B1 107 CORE PLUGS IN CRANKCASE Preceding Work Draining of the coolant 1 Core Plug Replace ...

Page 183: ... the core plug until the end of one side comes out using the screw driver 3 Pull out the plug carefully using a pliers 5 Press in new plug using a drift Notice Wait for about 45minutes before filling the coolant so that the Loctite 240 hardens 6 Warm up the engine and check the coolant for leaks 4 Clean the sealing surface and apply Loctite 241 ...

Page 184: ...to be Used A or X A X or B X or B X 5 X 10 Cylinder Bore Size mm f 89 900 f 90 906 f 89 906 f 89 912 f 89 912 f 89 918 f 89 950 f 89 968 f 90 000 f 90 018 Type Standard Size f 89 9 1st Repair Size Standard Size 0 25 2nd Repair Size Standard Size 0 5 Group Code Letter1 A X B A X B A X B Cylinder Bore Size mm f 89 900 f 90 906 f 89 906 f 89 912 f 89 912 f 89 918 f 90 150 f 90 156 f 89 156 f 90 162 f...

Page 185: ...ansverse Direction a LocationoftheNo 1PistonRingatTDC b Location of the Piston BDC c Location of the Oil Ring at BDC ChamferAngle Wear Limit in Longitudinal and Transverse Direction Permissible Deviation of Cylinder Out of round Permissible Deviation of Rectangular Cylinder Height Except Chamfered Area Basic Peak to valley Height After Final Honing and Brushing Chamfer Angle Honing Angle When new ...

Page 186: ...g Flatness Permissible Deviation of Parallelism of The Upper to Lower Mating Surface Peak to valley Height Crankcase Upper Mating Surface Crankcase Lower Mating Surface Axial Direction Transverse Direction Crankcase Upper Mating Surface Crankcase Lower Mating Surface 282 25 282 35mm 281 95mm 0 03mm 0 04mm 0 1mm 0 05mm 0 005 0 020mm 0 025mm ...

Page 187: ...1B1 112 M162 ENGINE MECHANICAL Chamfering Procedure 1 Chamfer angle 60 2 Polish the lower chamfered area evenly with a grinder after finishing the chamfering with a suitable tool e g hand milling cutter ...

Page 188: ...he mating surface of crankcase and cylinder head Overall Height of Cylinder Head Minimum Height After Machining Flatness Distance T Between Camshaft Bearing and Valve Stem Axial Direction Transverse Direction Standard Size Repair Size 135 9 136 0 mm 135 5 mm 0 08 mm 0 0 mm 24 21 24 75 mm 22 21 22 75 mm 23 96 24 51 mm 21 96 22 51 mm Intake Exhaust Intake Exhaust ...

Page 189: ...ad 3 Mill the sharp edge of the combustion chamber 4 Re measure the height H of the cylinder head 5 Seal the intake and exhaust valves 6 Measure the dimension T between the camshaft bearing and the valve system refer to Service data standard 7 Mill the cylinder head valve seat refer to Service data standard UniversalTool Surface Grinding Machine Sceledum Type RTY Roaro Schio Italy ...

Page 190: ...1B2 31 Cylinder Head Cover 1B2 34 Cylinder Head Front Cover 1B2 36 Cylinder Head 1B2 38 Timing Gear Case Cover 1B2 43 Crankshaft Sealing Rear Cover 1B2 46 Belt Pulley and Vibration Damper 1B2 48 Crankshaft Front Radial Seal 1B2 51 Crankshaft Rear Radial Seal 1B2 52 Crankshaft 1B2 53 Flywheel Driven Plate 1B2 59 Camshaft Adjuster 1B2 61 TABLE OF CONTENTS Camshaft Sprocket Bolt 1B2 64 Camshaft 1B2 6...

Page 191: ...ler Shaft to Transmission Engine Mounting Nut Alternator Carrier Bolt Belt Pulley Bolt Steering Pump Bolt A C Bracket Bolt Intake Air Duct Bolt Ignition Cable Cover Bolt Cylinder Head Cover Bolt Camshaft Adjuster Bolt Cylinder Head Front Cover Bolt Flange Bolt in Exhaust Camshaft Sprocket Cylinder Head Bolt Cooling Fan Bracket Bolt Timing Gear Case Cover Bolt M8 M6 Crankshaft Rear Cover Bolt Vibra...

Page 192: ...ft Oil Pump Sprocket Bolt Tensioning Device Bolt Water Pump Pulley Upper Intake Manifold Bolt Lower Intake Mainfold Bolt Flange Bolt to Exhaust Mainfold Exhaust Mainfold Nut to Stud Bolt Rivet Nut in Exhuast Mainfold Hole Pre Silencer Bolt Oil Drain Plug Oil Filter Cover Oil Filter Bolt Oil Pump Drive Sprocket Bolt Oil Pump Mounting Bolt Oil Strainer Bracket Bolt Oil Pressure Relief Valve Screw Pl...

Page 193: ... 000 589 10 99 01 Torque Wrench 112 589 00 72 00 Oil Extractor 000 589 72 21 00 Torque Wrench 001 589 66 21 00 Torque Wrench 000 589 01 10 00 Box Wrench Insert 124 589 15 21 00 Radiator Cap Testing Unit 116 589 02 34 00 Screw Fixed Pin 000 589 40 37 00 Hose Clamp ...

Page 194: ...S TABLE Cont d 104 589 01 01 00 Spanner 111 589 18 61 00 Lever Pusher 111 589 25 63 00 Thrust Piece 111 589 01 59 00 Supporting Bar 116 589 06 63 00 Magnetic Finger 119 589 00 43 00 Drift 000 589 58 43 00 Chain Assembly 104 589 00 37 00 Pliers ...

Page 195: ...ABLE Cont d 116 589 20 33 00 Sliding Hammer 602 589 00 40 00 Engine Lock 103 589 00 33 00 Puller 601 589 03 43 00 Sleeve 001 589 65 09 00 Socket Wrench Insert 001 589 74 21 00 Torque Wrench 000 589 04 14 00 Clamping Strap 000 589 88 33 00 Puller ...

Page 196: ...TABLE Cont d 103 589 01 63 00 Rivet Set 103 589 02 09 00 Oil Filter Socket Wrench 102 589 12 15 00 Drift 615 589 01 33 00 Caulking Bolt 102 589 00 15 00 Drift 000 589 51 37 00 Clamping Strap 001 589 72 21 00 Torque Wrench 601 589 03 14 00 Sleeve ...

Page 197: ...1B2 8 M161 ENGINE MECHANICAL SPECIAL TOOLS TABLE Cont d 617 589 00 10 00 Wrench Socket 104 589 00 40 00 Holder 111 589 03 15 00 Insert Pin 116 589 01 34 00 Threaded Bolt ...

Page 198: ...h 001 589 66 21 00 Torque Wrench 124 589 15 21 00 Radiator Cap Testing Unit 4 Disconnect the coupling of HFM sensor and remove the air cleaner cross pipe 5 Remove the air cleaner cover Remove the mounting bolts and air cleaner housing and element assembly Removal Installation Procedure 1 Disconnect the negative terminal of battery 2 Remove the hood 3 Remove the under cover Installation Notice Tigh...

Page 199: ...ice Open the coolant reservoir cap 7 Loosen the cylinder block drain plug and then drain the coolant completely Installation Notice Tightening Torque 30 Nm Notice Replace the seal before installation of the drain plug 8 Remove the cooling fan shroud 9 Disconnect the each hose from radiator ...

Page 200: ...e the radiator 12 Discharge the refrigerant from A C system and disconnect the discharge pipe and suction pipe from the compressor 13 Remove the acceleration control cable and automatic transmission pressure cable 11 Remove the hydraulic pipe of power steering Notice Completely drain the oil ...

Page 201: ...l lines release the pressure in the fuel system Installation Notice Tightening Torque 21 25 Nm 15 Remove the automatic transmission dipstick guide tube 16 Disconnect the wire of alternator 17 Disconnect the wire of starter motor and remove the starter motor 18 Disconnect the engine main harness ground ...

Page 202: ...ant temperature sensor l 2 knock sensors l Camshaft and crankshaft sensors 21 After removing the ignition coil cover disconnect the ignition coil connector 22 Remove the harness cover and disconnect the 6 injection valve connectors Disconnect the main harness 23 Separate the hose toward engine from canister purge solenoid valve ...

Page 203: ...the vacuum hose for brake booster 26 Separate the other vacuum hoses 27 Remove the propeller shaft from the front axle Installation Notice 28 By rotating the crankshaft from the front of engine remove the 6 torque converter mounting bolts from the engine ring gear plate Tightening Torque 81 89 Nm ...

Page 204: ...te the transmission from the engine Installation Notice Tightening Torque 65 Nm 31 Remove the bolts for engine mounting bracket Installation Notice Tightening Torque 50 75 Nm 32 Hook the chain to the bracket of engine and by using a hoist or crane carefully separate the engine assembly from the vehicle 33 Installation should follow the removal procedure in the reverse order ...

Page 205: ...Air Duct Cross Pipe 5 Vent Line Full Load or Over Mid Load 6 Throttle Valve 7 Restrictor Diameter 1 1mm Mid Load at Idling 8 Intake Manifold 9 Vent Line Mid Load at Idling 10 Air Conditioner Bracket 11 Oil Separation Chamber Mid Load at Idling 12 Crank Chamber 13 Oil Return Pipe 14 Oil Pan 15 Timing Gear Case Cover 16 Crankcase 17 Chain Housing A Fresh Air C Blow by Gas D Vent Connection ...

Page 206: ...crank chamber 12 through the oil separation chamber 11 air conditioner bracket 10 vent line 9 and restrictor 7 mounted to the cylinder head The circulated engine oil returns to the oil pan through the oil return pipe 13 at the bottom of oil separation chamber 11 The fresh air gets supplied to the crank chamber 12 through the HFM sensor 1 intake air duct 4 vent line 5 oil separation chamber 3 chain...

Page 207: ...oss Pipe 5 Vent Line Full Load or Over Mid Load 6 Throttle Valve 7 Restrictor Diameter 1 1mm Mid Load at Idling 8 Intake Manifold 9 Vent Line Mid Load at Idling 10 Air Conditioner Bracket 11 Oil Separation Chamber Mid Load at Idling 12 Crank Chamber 13 Oil Return Pipe 14 Oil Pan 15 Timing Gear Case Cover 16 Crankcase 17 Chain Housing A Fresh Air C Blow by Gas D Vent Connection ...

Page 208: ...d The air flows very rapidly through the vent line 5 s connection D and the intake air duct when full load at partial load Consequently most of the low by gases are supplied to the combustion chamber through the timing gear case cover 15 chain housing 17 oil separation chamber 3 vent line 5 throttle valve 6 and intake manifold 8 ...

Page 209: ...n Notice Tightening torque 22 5 27 5 Nm Notice Apply 3Nm of torque when mounting the bolt 1 apply 25 2 5Nm of torque when mounting the bolts 2 and 3 and then tighten the bolt 1 with 25 2 5Nm of torque 4 Installation should follow the removal procedure in the reverse order 1 Bolt M8 X 40 3 pieces 22 5 27 5 Nm 2 Bolt M8 X 70 2 pieces 22 5 27 5 Nm 3 Bolt M8 X 85 1 piece 22 5 27 5 Nm 4 Alternator Brac...

Page 210: ...TEERING PUMP AND A C BRACKET Preceding Work Removal of cooling fan and shroud Removal of drive belt 1 Nut 35 2 28 8 Nm 2 Washer 3 Belt Pulley 4 Bracket 5 A C Bracket 6 A C Compressor 7 Bolt 22 5 27 5 Nm 8 Bolt M8 X 20 2 pieces 22 5 27 5 Nm ...

Page 211: ...and drain the oil 3 Unscrew the bolts arrows and remove the steering pump Installation Notice Notice Pull the tensioning pulley counterclockwise as shown in the figure 4 Remove the compressor after disconnecting the wiring connector and refrigerant pipe of A C compressor Notice Discharge all the refrigerant before removing the pipes Tightening Torque 40 5 49 5 Nm Tightening Torque 22 5 27 5 Nm ...

Page 212: ...bolts arrows and remove the A C bracket and the gasket Installation Notice 7 Clean the sealing surface 8 Replace the gasket with new one 9 Installation should follow the removal procedure in the reverse order 10 Check the oil leakage by operating the engine after installation Tightening Torque 22 5 27 5 Nm ...

Page 213: ...1B2 24 M161 ENGINE MECHANICAL HYDRAULIC ENGINE MOUNTING INSULATOR Service Data ...

Page 214: ...L 1B2 25 SectionalView 1 Rubber Body 2 Brackek 3 Core 4 Lower Bolt 5 Rubber Plunger 6 Plunger Plate 7 Rubber 8 Plate 9 Lower Orifice 10 Upper Orifice 11 Diaphram 12 Cover Plate 13 Upper Bolt 14 Flange Bolt 15 Rivet 16 Fluid ...

Page 215: ...ine mounting and remove the engine Installation Notice 3 Installation should follow the removal procedure in the reverse order Tightening Torque 62 93 Nm 2 Unscrew the lower nut 3 and remove the hydraulic engine mounting insulator Installation Notice Tightening Torque 28 47 Nm Notice If the insulator is spotted with oil replace the hydraulic insulator assembly ...

Page 216: ...l Installation Procedure 1 Release the belt tension by turning the stud on the cap with 12 sided wrench or spanner counterclockwise 2 Remove the poly v belt Notice Check the belt for damage and tensioning pulley bearing point for wear and replace them if necessary 3 Install the belt after prying the tensioning pulley 3 Belt Tensioner ...

Page 217: ...1B2 28 M161 ENGINE MECHANICAL Poly V belt Arrangement 1 Belt Tensioning Pulley 2 Crankshaft Belt Pulley 3 A C Compressor Pulley 5 Alternator Pulley 7 Power Steering Pump Pulley 8 Water Pump Pulley ...

Page 218: ...r 22 5 27 5 Nm Removal Installation Procedure 1 Turn the stud bolt to counterclockwise 2 Insert the pin 111 589 01 15 00 into the hole in tensioning arm 3 Unscrew the bolts 1 2 and remove the tensioning device Installation Notice 4 Installation should follow the removal procedure in the reverse order 3 Tensioning Device 4 Stud bolt 5 Tensioning Arm Tightening Torque 22 5 27 5 Nm ...

Page 219: ... 5 Nm Removal Installation Procedure 1 Remove the end cover 1 2 Remove the nut 2 and remove the tensioning pulley 3 Installation Notice 5 Tensioning Device 6 Bolt M8 X 35 Washer 22 5 27 5 Nm 7 Shock Absorber Tightening Torque 40 5 49 5 Nm 3 Unscrew the bolts 4 6 and remove the shock absorber 7 Installation Notice Tightening Torque 22 5 27 5 Nm ...

Page 220: ...le in the base of rib POLY V BELT INSPECTION l Make marks on the belt with chalk l Rotate the engine and check the belt for damage Notice If one of the following types of damages is found replace the belt 1 Rubber lumps in the base of rib 2 Dirt or grit ingrained ...

Page 221: ...1B2 32 M161 ENGINE MECHANICAL 5 Cord torn out at the side 6 Outer cords frayed 7 Rib detached from the base of belt 8 Splits across the rib 9 Sections of rib torn out 10 Splits across several ribs ...

Page 222: ...M161 ENGINE MECHANICAL 1B2 33 11 Splits across the back of the belt ...

Page 223: ...1B2 34 M161 ENGINE MECHANICAL CYLINDER HEAD COVER 1 Ignition Coil Cover 2 Spark Plug Connector 3 Bolt M6 X 45 4 pieces M6 X 60 6 pieces 10 1 Nm 4 Cylinder Head Cover 5 Gasket Replace ...

Page 224: ...ke air duct Installation Notice 2 Remove the ignition coil cover Installation Notice 3 Remove the spark plug connector and ignition cable Notice Release 3 screws from the ignition cover and remove the cover for M161 Engine coil Tightening Torque 9 11 Nm Tightening Torque 9 10 Nm ...

Page 225: ...Installation Procedure 1 Disconnect the camshaft adjuster connector and remove the camshaft adjuster E23 engine only Installation Notice Tightening Torque 9 11 Nm 1 Bolt M6 X 16 3 pieces 9 11 Nm 2 Camshaft Adjuster 3 Bolt M8 X 35 2 pieces 22 5 27 5 Nm 4 Bolt M6 X 22 6 pieces 9 11 Nm 5 Front Cover E23 M161 970 6 Front Cover E20 M161 940 7 Sleeve 8 O ring Replace 9 Thermostat Housing ...

Page 226: ...ng Torque 3 22 5 27 5 Nm Tightening Torque 4 9 11 Nm Apply the sealant at the mating surface of the cylinder head and the front cover 3 Remove the O ring Installation Notice Replace the O ring with new one and apply the sealant 4 Installation should follow the removal procedure in the reverse order ...

Page 227: ...over Removal of intake manifold Removal of cylinder head lower line intake manifold side 1 Cylinder Head Bolt M12 X 100 10 pieces 1st step 55 Nm 2nd step 90 rotation added 3rd step 90 rotation added 2 Bolt M8 X 35 4 pieces 22 5 27 5 Nm 3 Camshaft Bearing cap 22 5 27 5 Nm 4 Cylinder Head 5 Gasket Replace 6 Dowel Sleeve Note ...

Page 228: ...t the piston of No 1 cylinder is at ATDC 20 2 Put the pin into the camshaft bearing cap Pin 111 589 03 15 00 3 Put the alignment marks arrows on the timing chain and camshaft sprocket 4 Remove the chain tensioner Installation Notice Tightening Torque 72 88 Nm Tightening Torque 1st step 18 22 Nm 2nd step 85 95 5 Remove the exhaust camshaft sprocket Installation Notice Notice The flange bolt is desi...

Page 229: ... Piston 5 Camshaft Sprocket 6 Seal Cover 7 Nut Tightening Torque 1st step 18 22 Nm 2nd step 85 95 Notice The flange bolt is designed to be used only once so always replace with new one 8 Remove the guide rail pin using the sliding hammer 02 and the threaded pin 03 Notice Apply the sealant on guide rail pin when installation 9 Unscrew the bolts A Installation Notice Tightening Torque 22 5 27 5 Nm B...

Page 230: ...Gasket 6 Hanger Bracket Tightening Torque 1st step 55 5 Nm 2nd step 90 3rd step 90 11 Remove the No 1 bearing cap of the exhaust camshaft Installation Notice Tightening Torque 22 5 27 5 Nm 12 Install the special tool 05 on the bearing cap removed place and hook the engine hoist into them and remove the cylinder head carefully 13 Check the cylinder head mating surface and clean the crankcase head b...

Page 231: ...eck the length of the cylinder head bolt Length of the bolt L When New 100 mm Max Length 105 mm Notice Replace the bolt if the measured length exceed the max length 16 Installation should follow the removal procedure in the reverse order ...

Page 232: ...ch Removal of cylinder head front cover Removal of tensioning device Removal of water pump Removal of oil filter element Removal of oil pan Removal of alternator bracker 1 Bolt M8 X 60 3 Pieces 22 5 27 5 Nm 2 Bolt M8 X 75 1 Piece 22 5 27 5 Nm 3 Seal 4 Timing Gear Case Cover 5 O ring 6 Sleeve ...

Page 233: ... 00 Threaded Pin 116 589 02 34 00 4 Put the alignment marks arrows on the timing chain and camshaft sprocket 5 Remove the chain tensioner Installation Notice Tightening Torque 22 5 27 5 Nm 6 Remove the intake and exhaust camshaft sprocket remove the camshaft adjuster assembly in E23 engine Installation Notice Tightening Torque 1st step 18 22 Nm 2nd step 85 95 Notice The flange bolt is designed to ...

Page 234: ...tion Notice Tightening Torque 22 5 27 5 Nm Notice Be careful not to damage the cylinder head gasket 11 Remove the radial shaft seal Notice Installation note replace the seal with new one 12 Clean the timing gear case cover and crankcase sealing surface 13 Replace the O ring with new one and apply the sealant on the sealing surface Notice Be careful not to stain the oil chamber of chain tensioner w...

Page 235: ...ICAL CRANKSHAFT SEALING REAR COVER Preceding Work Removal of the automatic transmission drive plate or flywheel 1 Bolt M6 x 20 6 pieces 9 11 Nm 2 Radial Shaft Seal 3 Rear Cover 4 Sleeve 5 Bolt M6 x 85 2 pieces 9 11 Nm 6 Washer ...

Page 236: ...e rear sealing cover 3 Check the radial shaft seal and replace it if necessary 4 Apply the Loctite 573 to the rear cover sealing surface 5 Apply the engine oil to the dust lip of the radial shaft seal Notice Do not use the grease 6 Using the special tool press the radial shaft seal and the rear cover 7 Tighten the rear cover bolt 1 and then tighten the oil pan bolt 5 as specified and remove the sp...

Page 237: ...VIBRATION DAMPER Preceding Work Removal of cooling fan and viscous clutch Removal of fan shroud Removal of drive belt 1 Center Bolt M18 X 55 1st step 200 220 Nm 2nd step 90 10 rotation added 2 Vibration Damper Disk 5 Vibration Damper Assembly 6 Key ...

Page 238: ...00 Puller 000 589 88 33 00 Torque Wrench 602 589 00 40 00 Engine Lock Removal Installation Procedure 1 Adjust the piston of number 1 cylinder to the TDC 1 Center Bolt M18 x 50 2 Center Bolt Washer 3 Vibration Damper and Pulley Assembly 4 Key 5 Crankshaft Front Seal 6 Timing Gear Case Cover 7 Crankshaft Sprocket Camshaft Driven 8 Crankshaft Sprocket Oil pump Driven 9 Crankshaft 10 Oil Pan 11 Oil Pa...

Page 239: ... the flywheel ring gear 3 Remove the center bolt Installation Notice 4 Remove the vibration damper assembly using the puller 5 Installation should follow the removal procedure in the reverse order Notice If possible don t separate the vibration damper and the pulley Tightening Torque 1st step 180 220 Nm 2nd step 90 ...

Page 240: ... seal with a screw driver Notice Use a clean cloth not to damage the radial seal mounting hole and the crankshaft 5 Remove the sleeve and install the belt pulley and the vibration damper 6 Check for leaks while operating the engine 2 Coat the radial sealing lip with engine oil 3 Using the sleeve assemble the radial seal 4 Align the sleeve groove and the woodruff key and tighten the center bolt unt...

Page 241: ...dre 1 Remove the radial seal with a screw driver Notice Use a clean cloth not to damage the radial seal mounting hole and the crankshaft 2 Install the special tool 2 to the crankshaft 3 Apply the engine oil on the special tool 2 Notice Do not use the grease 4 Install the radial seal on the inner parts assembler 5 Press in the special tool 1 until the radial seal is stopped 6 Check for leaks while ...

Page 242: ...gear case cover Removal of crankcase sealing rear cover Removal of oil pan Removal of baffle plate Removal of oil pump 1 Bearing Cap Bolt M8 X 55 10 pieces 1st step 50 60 Nm 2nd step 90 5 rotation added 2 Bearing Cap 3 Upper Main Bearing 4 Lower Main Bearing 5 Upper Thrust Bearing 6 Lower Thrust Bearing 8 Crank Shaft ...

Page 243: ...int j1 j5 Journal Main Bearing 1 5 l Color Dot Marking The color dot marking are put on the 1 2 4 6 8 and it indicates the diameter of crankshaft journal by color as below A Crankcase Side B Bearing Cap Side Oil Pan Side 1 Upper Main Bearing 2 Upper Thrust Bearing 3 Crankshaft 4 Lower Main Bearing 5 Lower Thrust Bearing ...

Page 244: ...nkshaft Journal Diameter mm 57 960 57 965 57 955 57 960 57 950 57 955 57 945 57 950 57 940 57 945 Punching Mark Bearing Color Selected Blue Yellow Red Marking Letter B Y R W V Bearing Color Selected Blue Yellow Red White Violet Service Data Unit mm Crankshaft Bearing Jour nal Diameter Crankshaft Bearing Diameter Crankshaft Journal Width at fit bearing Connecting Rod Bearing Journal Diameter Connec...

Page 245: ...r and lower bearing shells do not change each other and coat with engine oil l The oil grooves arrows in the thrust washers must face outward and insert the thrust bearing into the bearing cap l There are five kinds of thrust washers by thickness Select the proper washer when repaired 3 Remove the crankshaft 4 Installation should follow the removal procedure in the reverse order 5 After completion...

Page 246: ...e at 2 points 1 2 l Measure A B and C as shown If average value of B and C is less than value A then the average value of B and C is actual average value If average value of B and C is more than value A is actual average value 4 Measure and record the diameter of the crankshaft bearing journal Notice l Record the mean value when measured at 3 points A B C l Measure the inner diameter of bearing an...

Page 247: ... Connecting Rod Bearing Gap Item Main Bearing Journal NO 1 5 7 Measuring Position Radial Axial Gap mm Static condition 0 015 0 039 Dynamic condition 0 031 0 051 Consider the expansion 0 011 0 016 0 010 0 254 Item Connecting Rod Bearing Measuring Position Radial Gap mm 0 020 0 065 ...

Page 248: ...el Mounting Bolt M10 x 22 8 pieces 1st Step 45 Nm 2nd Step 90 10 2 Plate 3 Driven Plate A T 4 Dowel Pin 5 Flywheel M T Service Data Standard Stretch Bolt Nominal Size Stretch Side Diameter Bolt Length Tightening Torque M x 1 5 8 5 0 2 mm 8 0 mm 21 8 22 2 mm When New Min Diameter When New D d L 1st step 50 Nm 2nd step 90 ...

Page 249: ...Rivet 13 Segment 14 Ring Gear l Replace the bolt when the stretch side diameter d of the flywheel mounting bolt is less than 8 0mm l For the stretch bolt tightening keep the socket wrench and Tommy bar to be 90 and tighten as specified 2 Remove the flywheel for manual transmission vehicles or the driven plate 3 and plate 2 for Auto transmission vehicle 3 Installation should follow the removal proc...

Page 250: ... Roll Pin 6 Nut M20 X 1 5 60 70 Nm 7 Seal Cover 8 Camshaft Sprocket 9 Adjust Piston 10 Conical Spring 11 Flange Bolt M7 X 13 3 pieces 1st Step 20 2 Nm 2nd Step 90 5 Rotation Added 12 Flange Shaft 13 Compression Spring 14 Control Piston 15 Circlip 16 Oil Gallery 17 Straight Pin 18 Intake Camshaft Y49 Magnetic Actuator 2 pin connector ...

Page 251: ...he alignment marks arrows on the camshaft sprocket and the timing chain 4 Insert the insert pin into the No 1 and no 6 bearing cap hole on camshaft to secure intake and exhaust camshaft 5 Remove the chain tensioner 6 Unscrew the exhaust sprocket bolt and remove the exhaust camshaft sprocket Installation Notice Tightening Torque 1st step 20 Nm 2nd step 90 Notice The flange bolt is designed to be us...

Page 252: ...f nut toward armarture 9 Take off the timing chain from intake camshaft sprocket 10 Remove the cover 7 adjuster piston 9 and conical spring 10 from intake camshaft sprocket 11 Unscrew the bolt 11 and remove the flange shaft Installation Notice Tightening Torque 1st step 20 Nm 2nd step 95 Notice The flange bolt is designed to be used only once so always replace with new one 12 Installation should f...

Page 253: ... Camshaft Sprocket Bolt Notice The sprocket bolts are designed to be used only once so always replace with new one C M7 x 13 Collar Bolt Torx T30 e 6 8mm 16 Flange Shaft 18 Control Piston 22 Intake Camshaft E M7 x 13 Collar Bolt Torx T30 e 6 8mm 13a Camshaft Sprocket 22a Exhaust Camshaft Tightening Torque 1st step 20 Nm 2nd step 90 Tightening Torque 1st step 20 Nm 2nd step 90 ...

Page 254: ...tuator and cylinder head front cover 1 Bolt M7 X 13 3 pieces 1st Step 18 22 Nm 2nd Step 90 5 Rotation Added 2 Exhaust Camshaft Sprocket 3 Timing Chain 4a Intake Camshaft Spocket E20 4b Camshaft Adjuster and Camshaft Sprocket E23 5 Bearing Cap Bolt 20 pieces 22 5 27 5 Nm 6 Camshaft Bearing Cap 7 Wrench Special Tool ...

Page 255: ...in tensioner Installation Notice Tightening Torque 40 Nm 72 88 Nm Screw Plug Tensioner Assembly 4 Remove the exhoust camshaft sprocket Installation Notice Tightening Torque 1st step 35 45 Nm 2nd step 85 95 Notice The sprocket bolt is designed to be used only once so always replace with new one 5 Take off the timing chain from intake camshaft sprocket and secute it not to fall down into the timing ...

Page 256: ...on the bearing cap not to be miked up 8 Apply the engine oil on the valve tappet and camshaft bearing 9 Installation should follow the removal procedure in the reverse order Notice l Base circle of cam should cantact with the valve tappet l Install the camshaft bearing caps according to the numbers on the cylinder head cast and bearing cap 10 Check the camshaft timing position ...

Page 257: ...oval of cylinder head cover Removal of cylinder head front cover 1 Insert Pin f 6 5mm Special Tool 2 Intake Camshaft Sprocket 3 Camshaft Bearing Cap 4 Timing Chain 5 Exhaust Camshaft Sprocket 6 Bolt M7 X 13 3 pieces 1st step 20 2 Nm 2nd step 90 5 rotation added 7 Strate Pin ...

Page 258: ...se cover the intake and exhaust cam of cylinder will make the slope to the center and will face up In this way the insert hole in No 1 and No 4 camshaft bearing cap will match in line with the flange hole for camshaft sprocket 2 Check the timing as below procedure Check if the insert pin 111 589 03 15 00 can be inserted into the No 1 and No 4 bearing cap hole At this condition check if the ATDC 20...

Page 259: ... hole and flange hole while rotating the camshaft by using wrench 104 589 01 01 00 5 Install the chain to the intake camshaft sprocket 6 Install the chain to the exhaust camshaft sprocket and tighten the bolt Installation Notice Tightening Torque 1st step 20 Nm 2nd step 90 The sprocket bolt is designed to be used only once so replace with new one 7 Install the chain tensioner Installation Notice S...

Page 260: ...moval of camshaft Removal of spark plug 1 Valve Tappet Assembly 2 Valve Cotter 3 Upper Retainer 4 Valve Spring Check Replace if necessary 5 Valve Stem Seal 6 Lower Retainer 7 Connecting Hose 8 Thrust Piece 9 Slide 10 Adjust Bolt 11 Lever Pusher 12 Supporting Bar ...

Page 261: ...shaft to position the each cylinder piston at TDC 5 Install the engine lock to the ring gear to prevent the crankshaft from rotating 6 Blow up with compressed air Notice l Remove the valve spring only at TDC l Always rotate the crankshaft by holding the chain to prevent from timing chain damage and tangling and for smooth rotation 3 Remove the valve tappet 1 using the magnetic finger 4 Install the...

Page 262: ...e thrust piece 8 and the slide 9 perpendicular to each other 11 Secure the slide 9 by turning the adjust bolt 10 12 Press the valve spring 4 by using the lever pusher 11 14 Remove the upper retainer 3 and the valve spring 4 15 Remove the valve stem seal and replace if necessary Notice Check the valve stem seal and replace if necessary 16 Remove the lower retainer 6 Notice Check the retainer for da...

Page 263: ... ENGINE MECHANICAL Test Upper and Lower Valve Tappet and Valve Cotter l Upper Valve Spring Retainer l Lower Valve Spring Retainer l Valve cotter 12 3 D d 8 5 Size mm Thickness mm a 0 8 1 0 9 2 9 8 H B 9 0 Size mm ...

Page 264: ...00 Pliers 104 589 00 37 00 Tools Required 104 589 00 37 00 Pliers 119 589 00 43 00 Drift Replacement Procedure 1 Remove the valve stem seal 2 using the pliers Notice Check the valve stem seal for damage and replace if necessary 2 Coat the valve stem seal with oil and assemble it with the protective sleeve 3 Insert the valve stem seal by pressing it with the drift ...

Page 265: ...position and check whether the intake camshaft cam s lobe arrow stays in the upper side 2 Cover the alternator with a clean cloth 3 Release the tension by unscrewing the screw plug once Notice In case that the tension is reduced by unscrewing the screw plug reinstall after completely removing the chain tensioner If the chain tensioner is tightened again without completely reducing its tension then...

Page 266: ... the removal of screw plug be careful that it can be jumped out due to the force of compression spring l Remove the screw plug only when the seal and compression spring are damaged 5 Carefully remove the filler pin 3 compression spring 4 snap ring 5 and the thrust pin 6 6 Remove the chain tensioner housing 7 and the seal 8 3 Insert the compression spring 4 with the filler pin 3 into chain tensione...

Page 267: ...ler Pin 7 Compression Spring 8 Snap Ring 9 Thrust Pin 10 Ball Nonreturn Valve 11 Compression Spring 12 Thrust Piece 13 Chain Tensioner Housing 14 Seal 15 Timing Gear Case Cover 16 Cylinder Head 17 Bolt Washer 18 Tensioning Rail 19 Cylinder Head Gasket 20 Timing Chain 21 Tensioning Rail Base Sliding Surface A Oil Supply Hole B Chain Tensioner Oil Storage Hole 5 Check for leaks by operating the engi...

Page 268: ...M161 ENGINE MECHANICAL 1B2 79 TIMING CHAIN Preceding Work Removal of cylinder head cover Removal of spark plug 1 Pin 2 New Timing Chain 3 Timing Chain Used 4 Wedge 5 Link 6 Center Plate 7 Outer Plate ...

Page 269: ...Procedure 1 Position the No 1 cylinder to ATDC 20 4 Mount the wedges to both sides of the camshaft sprocket as shown in the figure 2 Insert the pin to the intake and exhaust camshaft flange 3 Remove the chain tensioner 5 Cover the chain housing with a clean cloth and grind off the timing chain pin from the intake camshaft sprocket with the grinder ...

Page 270: ...ng chain against the exhaust camshaft sprocket to prevent it to be tangled Notice Be sure to remove the wedge before cranking the engine 9 Take out the used timing chain out from the chain housing 10 Connect both separators of the new timing chain with the link 5 and the center plate 6 6 Remove the outer plate 7 with the screw driver and remove the link 5 11 Install the jaw a and the thrust piece ...

Page 271: ... 13 Install the assembly tool above the link and tighten the spindle c until a block is felt 14 Place the assembly tool 12 Place the outer plate 7 thickness 1 2mm inside the thrust piece b 16 Install the assembly tool to the link pin and tighten the spindle c Tightening Torque 30 Nm ...

Page 272: ...B2 83 17 Rivet the link pin Check the condition and it again if necessary 18 Install the chain tensioner Installation Notice 19 Check the camshaft timing position Tightening Torque Screw Plug 40 Nm Tensioner Assembly 72 88 Nm ...

Page 273: ...tice Be careful not to damage the gasket 2 Remove the sliding rail 1 from the sliding rail pin 2 Notice l Replace the plastic guide 2 if it is damaged l For installation exactly align the plastic guide 2 with the sliding rail 1 3 Installation should follow the removal procedure in the reverse order 1 Sliding Rail Pin 2 Sliding Rail 3 Timing Gear Case Cover ...

Page 274: ...r 1 cylinder to ATDC20 guide rail 2 Install the pin special tool 111 589 03 15 00 into the no 1 and no 6 bearing cap hole 3 Remove the chain tensioner Installation Notice Tightening Torque Screw Plug 40 Nm Tensioner Assembly 72 88 Nm 4 Unscrew the bolt 1 and remove the guide rail Installation Notice Tightening Torque 9 11 Nm 5 Installation should follow the removal procedure in the reverse order ...

Page 275: ...o damage the gasket when removing installing the timing gear case cover 2 Remove the guide rail 2 from the guide rail pin 1 Notice l Replace the plastic guide 2 if damaged l Connect the plastic guide 2 and the guide rail 1 by aligning them accurately when installing 3 Installation should follow the removal procedure in the reverse order 1 Guide Rail Pin 2 Guide Rail 3 Timing Gear Case Cover ...

Page 276: ...of tensioning rail Removal of crank case guide rail Removal of cylinder head 6 Bolt M8 x 20 1 piece Washer 29 35 Nm 7 Oil Pump Sprocket 8 Oil Pump 9 Oil Pump Roller Chain 10 Timing Chain 1 Oil Pump Chain Tensioner 2 Oil Pump Chain Spring 3 Oil Pump Chain Bushing Pin 4 Crankshaft Sprocket 5 Key ...

Page 277: ...installing 2 Unscrew the bolt 6 and remove the oil pump sprocket 7 from the oil pump Installation Notice Caulking 04 615 589 01 33 00 3 Remove the oil pump roller chain 9 4 Remove the oil pump chain tensioner 1 oil pump chain bushing 3 and the oil pump chain spring 2 5 Remove the crankshaft sprocket 4 using the puller 04 special tool Notice l Make sure not to lose the crankshaft pulley key 5 when ...

Page 278: ...Removal of engine Removal of cylinder head Removal of oil pan Removal of oil pump Removal of baffle plate 1 Connecting Rod Bearing Cap 2 Connecting Rod 3 Connecting Rod Bolt M9 x 52 8 pieces 1st step 40 Nm 2nd step 90 5 4 Piston 5 Snap Ring 6 Piston Pin ...

Page 279: ...nd remove the cap 2 Remove the connecting rod and the piston upward Notice Make sure that the bearing cap and shell are not changed each other 3 Remove the snap ring 5 and pull out the piston pin 6 Notice Remove the snap ring using a clean cloth as shown in the right picture so that the piston piston ring and the snap ring don t get damaged Installation Procedure ...

Page 280: ...earing shell and the piston and coat them with engine oil 4 Install the piston ring using the tensioning strap 000 589 04 14 00 5 Install the piston so that the arrow on the piston head faces to the forward of the vehicle 6 After aligning the connecting rod and the bearing cap mark or a number tighten the bolts Installation Notice Tightening Torque 1st step 35 45 Nm 2nd step 90 5 Apply the engine ...

Page 281: ...re Basic Bore at The Bearing Shell D1 Basic Bore at The Bushing d1 Bushing Inner Diameter d Clearance Between The Piston Pin and The Bushing Peak to valley Height of Connecting Rod Bushing on Inside Permissible Wwist of Connecting Rod Bearing Bore to Connecting Rod Bushing Bore Permissible Deviation of Axial Paralleism of Connecting Rod Bearing Bore to Connecting Rod Bushing Bore Permissible Devia...

Page 282: ...indication or number arrow of the connecting rods and the bearing cap when installing Notice l Make sure it doesn t exceed over 4g with other connecting rods when replacing the connecting rods l Check if the connecting rod and the bearing cap are accurately seated on the groove when replacing the bearing Notice If the length exceeds max length replace it Length When New L Max Length L Tightening T...

Page 283: ...6 Side Rail Notice If out of specification replace the piston ring Tools Required 000 589 51 37 00 Clamping Strap Replacement Procedure 1 Measure the piston ring s gap Gap Between The Piston and The Piston Ring Groove 1 0 20 0 40 mm Groove 2 0 20 0 40 mm Groove 3 0 20 0 45 mm Groove 1 0 028 0 060 mm Groove 2 0 010 0 045 mm Groove 3 0 010 0 045 mm End Gap of The Piston Ring ...

Page 284: ...with a pliers 3 For installation position the piston ring to be the TOP mark on the piston ring upward and arrange the piston ring ends to be 120 apart 4 Adjust the hook spring joint in the oil ring 180 away from the ring end Clamping Strap 000 589 51 37 00 ...

Page 285: ...rrange the bolts according to each size 3 Clean the inside of oil pan and sealing surface then apply the sealant 4 Replace the gasket with new one 5 Install the oil pan with gasket and tighten each bolt in specified torque 6 Check for oil leaks while running the engine M8 X 40 4 pieces M6 X 35 1 pieces M6 X 100 2 piece M6 X 85 3 pieces M6 X 20 20 pieces 5 Bolt 6 Oil Pan 7 Gasket u ...

Page 286: ...kshaft Bearing 12 Connecting Rod 13 Piston 14 Oil Spray Piston Crown Area 15 Non Return Valve Crankcase 16 Oil Supply To Chain Tensioner 17 Camshaft 18 Cam Bearing 19 Valve 20 Oil Gallery Supply Oil to Intake Tappet 21 Oil Gallery Supply Oil to Exhaust Tappet 22 Ball f8mm 23 Camshaft Plug 24 Seal 25 Screw Plug 26 Oil Return Gallery Cylinder Head and Crankcase 27 Oil Return Gallery Crankcase 28 End...

Page 287: ...1B2 98 M161 ENGINE MECHANICAL ENGINE OIL AND OIL FILTER ELEMENT 1 Oil Filter Cover 25 Nm 2 O ring Replace 3 Oil Filter Element 4 Oil Drain Plug 5 Oil Filter Bypass Valve 6 Oil Filter Cap ...

Page 288: ...ver 2 Notice Make the screw cover removable by tightening the bolt at the side of the socket wrench special tool 2 Install the wrench to the upper bolt in the socket wrench and remove the oil cover by turning it 3 Remove the oil filter element Notice Work with a cloth under the vehicle when removing the oil filter element to not drain the oil Replace the seal washer with new one 6 Replace the O ri...

Page 289: ... Nm 2 Oil Pump 3 Oil Strainer Assembly 4 Bolt M6 X 12 2 pieces 9 11 Nm In E23 Engine These Bolts are Combined with Baffle Plate 5 Bolt M8 X 20 1 pieces 29 35 Nm 6 Washer 7 Sprocket Oil Pump Drive 8 Chain Oil Pump Drive 9 Plate Baffle 10 Bolt M6 X 12 6 piece 9 11 Nm E23 Engine Only Baffle Plate Mounting Bolt ...

Page 290: ...11 Nm Bolt 5 9 11 Nm Tightening Torque 29 35 Nm 2 Unscrew the bolts 4 5 and remove the oil strainer assembly 3 Installation Notice Insert the steel gasket into the oil pump and bolt 4 mounting surface 3 Unscrew the six bolts 11 and remove the haffle plate Installation Notice Tightening Torque 9 11 Nm 4 Unscrew the three bolt 1 and remove the oil pump Installation Notice Tightening Torque 22 5 27 5...

Page 291: ... 2 Compression Spring Removal Installation Procedure 1 Remove the screw plug 1 Installation Notice 2 Remove the spring 2 guide pin 3 and the piston 4 3 Installation should follow the removal procedure in the reverse order Notice Don t use the seal for the screw plug 3 Guide Pin 4 Piston Tightening Torque 50 Nm ...

Page 292: ...turn valve prevents the oil in the chain tensioner from drying up In other words it stops oil returning in order to prevent the oil in the chain tensioner from getting dry As a result the chain tensioner can be activated with oil in itself Replacement Procedure 1 Remove the non return valve using a pliers 2 Insert new non return valve with hand ...

Page 293: ... 1 2 Unscrew the bolt 4 and remove the oil dipstick guide tube 2 Installation Notice 4 Bolt M6 X 16 1 piece 9 11 Nm 5 Clamp Tightening Torque 9 11 Nm It is very hard to remove the oil dipstick guide tube without special tool If it is not necessary do not remove the guide tube 3 Installation should follow the removal procedure in the reverse order 4 Check for leaks by starting the engine ...

Page 294: ...M161 ENGINE MECHANICAL 1B2 105 UNIT REPAIR CORE PLUGS IN CRANKCASE Preceding Work Draining of the coolant 1 Core Plug Replace ...

Page 295: ... the core plug until the end of one side comes out using the screw driver 3 Pull out the plug carefully using a pliers 5 Press in new plug using a drift Notice Wait for about 45minutes before filling the coolant so that the Loctite 241 hardens 6 Warm up the engine and check the coolant for leaks 4 Clean the sealing surface and apply Loctite 241 ...

Page 296: ...5 X 10 A X B X 5 X 10 Piston Type to be Used A or X A X or B X or B X 5 X 10 A or X A X or B X or B X 5 X 10 Cylinder Bore Size mm f 90 906 f 90 912 f 90 906 f 90 912 f 90 912 f 90 918 f 90 950 f 90 968 f 91 000 f 91 018 f 89 900 f 90 906 f 89 906 f 89 912 f 89 912 f 89 918 f 89 950 f 89 968 f 90 000 f 90 018 Engine E23 E20 ...

Page 297: ... of round Permissible Deviation of Rectangular Cylinder Height Except Chamfered Area Basic Peak to valley Height After Final Honing and Brushing Chamfer Angle Honing Angle When new Wear limit 0 1 mm 0 007 mm 0 05 mm 0 05 mm 0 003 0 006 mm 75 50 10 1 The group code letters are carved on the surface of the piston crown and in the mating surface of the crankcase Type Standard Size E20 f 89 9 E23 f 90...

Page 298: ...latness Permissible Deviation of Parallelism of the Upper to Lower Mating Surface Peak to valley Height Crankcase Upper Mating Surface Crankcase Lower Mating Surface Axial Direction Transverse Direction Crankcase Upper Mating Surface Crankcase Lower Mating Surface 289 35 289 45mm 289 05mm 0 03mm 0 04mm 0 1mm 0 05mm 0 012 0 009mm 0 025 0 020mm ...

Page 299: ...1B2 110 M161 ENGINE MECHANICAL Chamfering Procedure 1 Chamfer angle 75 2 Polish the lower chamfered area evenly with a grinder after finishing the chamfering with a suitable tool e g hand milling cutter ...

Page 300: ...he mating surface of crankcase and cylinder head Overall Height of Cylinder Head Minimum Height After Machining Flatness Distance T Between Camshaft Bearing and Valve Stem Axial Direction Transverse Direction Standard Size Repair Size 135 9 136 0 mm 135 5 mm 0 08 mm 0 0 mm 24 21 24 75 mm 22 21 22 75 mm 23 96 24 51 mm 21 96 22 51 mm Intake Exhaust Intake Exhaust ...

Page 301: ...ad 3 Mill the sharp edge of the combustion chamber 4 Re measure the height H of the cylinder head 5 Seal the intake and exhaust valves 6 Measure the dimension T between the camshaft bearing and the valve system refer to Service data standard 7 Mill the cylinder head valve seat refer to Service data standard UniversalTool Surface Grinding Machine Sceledum Type RTY Roaro Schio Italy ...

Page 302: ...B3 80 Crankshaft Ball Bearing 1B3 82 Crankshaft 1B3 83 Flywheel 1B3 93 Machining of Flywheel 1B3 97 Flywheel Ring Gear 1B3 98 Hydraulic Valve Clearance Compensation Element Check 1B3 101 Valve Tappets 1B3 103 Valve Springs Check 1B3 105 Valve Springs Cylinder Head Removed 1B3 106 TABLE OF CONTENTS Valve Springs Cylinder Head Installed 1B3 109 Valve Stem Seals 1B3 112 Check and Replacement of Valve...

Page 303: ...t Bolt Nut Axle Propeller Shaft Bolt Nut T C Engine Mounting Nut Application Cooling Fan Belt Pulley Bolt Socket Bolt Tighten The Bolt End Cover Bolt Crankshaft Bearing Cap Bolt Ball Bearing Camshaft Sprocket Bolt Oil Pump Sprocket Bolt Application Connecting Rod Bolt Application 12 Sided Stretch Bolt Engine Assembly Crankshaft Assembly Piston Flywheel Cylinder Head Application Prechamber Threaded...

Page 304: ...n Bolt M6 Oil Pan Bolt M23 Belt Pulley Bolt Guide Pulley Bolt Guide Pulley Bracket Nut Chain Tensioner Tesioning Lever Bolt Cylinder Head Application Camshaft Bearing Cap Bolt Camshaft Sprocket Bolt Exhaust Pipe Bolt Nut Chain Tensioner Injection Nozzle Intake Manifold Not Injection Nozzle Pipe Not Oil Dipstick Tube Bolt Screw Plug M18 x 15 N m 25 25 90 25 80 40 25 18 10 50 Cam Support Shaft Timin...

Page 305: ...TABLE 603 589 00 09 00 Serration Wrench 657 589 03 63 00 Sliding Hammer 000 589 77 03 00 Box Wrench Insert 601 589 00 66 00 Counter Sink 667 589 00 23 00 Height Gauge 602 589 00 40 00 Engine Lock 116 589 20 33 00 Sliding Hammer 603 589 00 40 00 Counter Holder ...

Page 306: ... Type Socket Wrench 601 589 00 25 00 SPECIAL TOOLS TABLE Cont d 115 589 34 63 00 601 589 00 10 00 Cylinder Head Bolt 102 102 589 12 15 00 f f f f f 17 Drift 102 589 00 15 00 f f f f f 34 Drift 617 589 10 21 00 RI Sensor 601 589 05 14 00 Assembly Cage ...

Page 307: ...08 15 00 Drift 001 589 53 21 00 Dial Gauge 601 589 03 14 00 Sleeve SPECIAL TOOLS TABLE Cont d 103 589 00 33 00 Puller 601 589 07 21 00 Depth Gauge 667 589 01 21 00 Fixing Device 366 589 00 21 05 Extension 601 589 03 43 00 Oil Seal Assembler ...

Page 308: ...Gauge Holder 000 589 33 33 00 Counter Support 000 589 04 14 00 Tensioning Strap SPECIAL TOOLS TABLE Cont d 116 589 07 15 00 Drift 000 589 25 33 00 Internal Extractor 102 589 05 33 00 Puller 601 589 01 59 00 Assembling Board 102 589 03 40 00 Magnetic Bar ...

Page 309: ...Supporting Bridge 667 589 00 31 00 Press Lever 104 589 00 37 00 Pliers SPECIAL TOOLS TABLE Cont d 667 584 02 63 00 Supporting Bar 116 589 06 63 00 Magnetic Finger 603 589 01 40 00 Holding Wheel 000 589 10 68 00 Cylinder Brush 601 589 02 43 00 Drift ...

Page 310: ... 589 03 15 00 Drift for Intake 601 589 06 15 00 Drift for Exhaust SPECIAL TOOLS TABLE Cont d 601 589 05 15 00 Drift for Intake 103 589 02 15 00 Drift for Exhaust 346 589 00 63 00 Super Cooling Box 000 589 21 53 00 Reamer for Intake 000 589 10 53 00 Reamer for Exhaust ...

Page 311: ...ial Gauge 001 589 53 21 00 Dial Gauge 667 589 02 21 00 TDC Pulse Generator SPECIAL TOOLS TABLE Cont d 124 589 15 21 00 Tester 000 589 58 43 00 Chain Assembling Device 201 589 13 21 00 Vacuum Tester 617 589 04 21 00 Tester 501 589 73 21 00 Vacuum Pump ...

Page 312: ... Tester 001 589 65 09 00 Serration Wrench 116 589 02 34 00 Thread Bolt SPECIAL TOOLS TABLE Cont d 000 589 00 68 00 Cleaning Set 601 589 05 21 00 Looking Screw 617 589 08 21 00 Position Sensor 667 589 04 63 00 Retaining Plate 601 589 00 08 00 Flange ...

Page 313: ...1B3 12 OM600 ENGINE MECHANICAL Removal Installation Procedure 1 Disconnect the negative terminal of battery 2 Remove the hood MAINTENANCE AND REPAIR ON VEHICLE SERVICE ENGINE ASSEMBLY ...

Page 314: ...ap 3 Remove the skid plate Installation Notice Tightening Torque 28 47 Nm 5 Remove the drain plug 1 and seal 2 from the cylinder block and drain the coolant completely 6 After draining replace the seal and reinstall the drain plug Installation Notice 7 Disconnect the lower coolant hose from the radiator Tightening Torque 30 Nm ...

Page 315: ...t and remove the coolant pipe and cooling fan shroud 10 Remove the hoses air intake to intercooler intercooler to intake duct 8 Disconnect the upper coolant hose from the radiator Tightening Torque 3 7 Nm 11 Remove the pipes connected to intercooler ...

Page 316: ...rom the compressor Notice Evacuate the refrigerant before removal 12 Remove the hose air cleaner to turbocharger with blow by hose 13 Disconnect the air cleaner intake hose and remove the air cleaner cover and element 14 Disconnect the coolant hose from the water inlet ...

Page 317: ...Completely drain the fluid 17 Disconnect the fuel feed line with prefilter from the feed pump on injection pump 18 Vehicle with automatic transmission Remove the hydraulic lines 19 20 from oil cooler 2 19 Disconnect the engine harness 20 Disconnect the preheating time relay cable ...

Page 318: ...res and remove the starter motor 21 Remove the fuel lines from the fuel filter and cover the filter with plug 22 Disconnect the brake booster hose from vacuum pump 23 Disconnect the other vacuum lines 24 Disconnect the ground cable 25 Disconnect the alternator wires ...

Page 319: ...me relay sensor plug 28 Disconnect the coolant temperature sensor plug 29 Disconnect the accelerator cable from the control linkage Installation Notice Tightening Torque 8 18 Nm 30 Loosen the connection of control pressure cable an arrow used in auto transmission ...

Page 320: ...tening Torque Axle 70 80 Nm T C 81 89 Nm Tightening Torque 20 34 Nm 31 Separate the exhaust pipe flange from the turbo charger Installation Notice 32 Loosen the installing bolt of clutch release cylinder and remove the clutch release cylinder Installation Notice Tightening Torque 30 Nm Tightening Torque 30 Nm 34 Remove the propeller shaft from the transmission Installation Notice ...

Page 321: ...7 Loosen the engine mounting bracket nut Installation Notice 38 Remove the engine assembly from the vehicle by using a hoist or crane 39 Installation should follow the removal procedure in the reverse order Tightening Torque 50 75 Nm ...

Page 322: ...OM600 ENGINE MECHANICAL 1B3 21 POLY V BELT 1 Nut 23Nm 2 Tensioning Lever 3 Bolt 4 Spring 5 Tensioning Lever 6 Poly V Belt ...

Page 323: ...ll out the bolt to the rear 3 Push back the tensioning lever arrow direction to release the spring tension and remove the belt 4 Install the poly V belt beginning at the tensioning pulley 7 7 Tensioning Pulley 8 Crankshaft 9 Alternator 10 Coolant Pump 11 Guide Pulley 12 Power Steering Pump 13 Aircon Compressor Lengthe of Belt Length L Without Air Conditioner 2 100 mm 2 040 mm ...

Page 324: ...f cooling fan 1 Bolt 21Nm 2 Damper 3 Nut 21Nm 4 Tensioning Lever 5 Guide Rail Pin 6 Bolt 7 Poly V Belt 8 Belt Pulley 9 Bolt 10Nm 10 Tensioning Pulley 11 Socket Bolt 29Nm 12 Closing Cover 13 Washer 14 Tensioning Lever 15 Fit Bolt 100Nm 16 Closing Cover 17 Spring 18 Bolt 20Nm ...

Page 325: ...nsioning lever in direction of arrow with a rod F12 180mm and push out the bolt to the rear 3 Push back the tensioning lever to release the spring tension and remove the belt 4 Remove the bolt 9 and then remove the belt pulley 8 5 Remove the bolt 1 18 and take off the damper 2 Notice Pay attention to installation position of the damper ...

Page 326: ...emove the socket bolt 11 and then remove the tensioning pulley 10 Installation Notice Tightening Torque 29 Nm 9 Pry off the closing cover 16 and remove the fit bolt 15 10 Remove the tensioning lever 14 and washer 13 11 Clean thread in the timing case cover and fit bolt Installation Notice Apply Loctite on thread of fit bolt Tightening Torque 100 Nm 12 Installation should follow the removal procedu...

Page 327: ...1B3 26 OM600 ENGINE MECHANICAL POLY V BELT ALIGNMENT INSPECTION Without Air Conditioner With Air Conditioner ...

Page 328: ... point with chalk l Rotate the engine and check the belt Notice If one of the following types of damage is found replace the belt 1 Rubber lumps in the base of rips 2 Dirt or grit ingrained 5 Cord torn out at the side 6 Outer cords frayed 3 Pointed rips 4 Belt cord visible in the base of rips ...

Page 329: ...1B3 28 OM600 ENGINE MECHANICAL 7 Belt detached from the base of rip 8 Splits across the rips 9 Sections of rip torn out 10 Splits across several rips 11 Splits across the back ...

Page 330: ...OM600 ENGINE MECHANICAL 1B3 29 1 Threaded Ring 130 Nm 2 Prechamber PRECHAMBER Preceding Work Removal of glow plug Removal of fuel injection nozzle 3 Cylinder Head ...

Page 331: ...readed ring 1 Serration Wrench 603 589 00 09 00 3 Remove the perchamber 2 Notice After removing the prechamber cover over the bores with clean rag 603 589 00 09 00 Serration Wrench 667 589 03 63 00 Sliding Hammer 4 Inspect the prechamber Notice If the prechamber seats in the cylinder head are leaking or if the prechambers are replaced the sealing surfaces in the cylinder head must be remachined ...

Page 332: ...mber 2 Insert the prechamber into the cylinder head at the same time aligning the cam on the collar of the prechambers with the slots in the cylinder head Notice If the spacer rings are fitted to the prechambers the spacer rings should be replaced with rings of the same thickness Thickness of Spacer Ring 0 3 0 6 1 0 mm 3 Coat the threaded ring with oil and assemble the ring by using the serration ...

Page 333: ...essential to adhere to the specified projection C of the prechamber of 7 6 8 1mm This ensures that the required clearance exists between prechamber and piston crown with the piston in TDC For this reason spacer rings should be inserted on remachined sealing surfaces If a spacer ring is already fitted or a marking is made on the cylinder head the cylinder head must be removed and size C measured if...

Page 334: ...njection nozzle 2 Remove the prechamber 3 Cover the prechamber bore to avoid any chips dropping into the combustion chamber 4 Remove the protective sleeve from the countersink and rotate the countersink into the prechamber bore to be machined as far as the stop Counter Sink 601 589 00 66 00 5 Maintain size X from the top edge of mandrel to the top edge of the sleeve with the gauge Height Gauge 667...

Page 335: ...nstalled is 0 3mm 9 Remove the countersink tool and clean the chips Notice If the sealing surface is not completely flat remachine the sealing surface 10 emove rag from the prechamber bore and crank the engine with starter motor to threw out any chips which may have got into the combustion chamber 11 Insert the proper spacer ring into the prechamber sealing surface 12 Punch a mark on the cylinder ...

Page 336: ... 00 Fixing Device Notice l The TDC sensor bracket must be adjusted in case of followings l When replacing the TDC sensor bracket l When replacing the crankshaft the hub or the vibration damper l When replacing or installing the timing case cover l After engine overhauling If the cylinder head is removed the measuring pin of the dial gauge can be positioned on the piston crown This is done by placi...

Page 337: ...f TDC is when the large pointer on the dial gauge is stopped before moving back 5 remove the reinstall the measuring device and position the dial gauge scale at 0 6 Slowly rotate the crankshaft in the direction of engine rotation until the dial gauge has moved back counterclockwise by 3 65mm 7 Insert fixing device into the sensor bracket Notice The pin on the vibration damper must engage into the ...

Page 338: ...Washer 15 Bolt 25 Nm 16 Cylinder Head Bolt See Table 17 Cylinder Head Cover 18 Bolt 10 Nm 19 Gasket 20 Camshaft 21 Camshaft Drive Sprocket Replace 22 Washer 23 Bolt 12 Sided 25Nm 90 24 Sliding Rail 25 Sliding Rail Pin 26 Sliding Rail Pin 27 Chain Tensioner 80 Nm 28 Gasket Replace 29 Cooling Fan Check 30 Hexagon Socket Bolt 45 Nm 31 Tensioning Lever 32 Bolt 25 Nm 33 Bolt 34 Nut 23 Nm 35 Fuel Filter...

Page 339: ...00 Type Socket Wrench 116 589 20 33 00 Sliding Hammer 601 589 00 10 00 Cylinder Head Bolt Wrench 602 589 00 40 00 Engine Lock 603 589 00 40 00 Counter Holder Tools Required Cylinder Bolts 12 sided socket head Engine cold M8 Cylinder Head Bolts Tightening Torque stage1 stage2 stage3 10 Nm 35 Nm 180 25 Nm Tightening Sequence for Cylinder Head Bolts OM 662LA Engine OM 661LA Engine ...

Page 340: ...ngle It is not necessary to retighten the cylinder head bolts at the 1000 1500km inspection or after 1000 1500km of repairs Notice The cylinder head may only be removed when the engine has cooled down The cylinder head is removed together with the exhaust manifold As the cylinder head bolts undergo a permanent tightening They require to be replaced if they exceed the maximum lengthes indicated in ...

Page 341: ...lt and then remove the cooling fan Notice Keep the fan in vertical position Counter Holder 603 589 00 40 00 5 Remove the nut 6 Remove the nut on the tensioning lever and insert the rod F12 180mm By pushing the rod to the arrow direction pull back the bolt 7 Push the tensioning lever to the opposite direction to release the spring tension and remove the poly V belt 4 Remove the bracket oil dipstick...

Page 342: ...ove the oil return hose and plug Notice Cover them to prevent chips from coming into 10 Unscrew the EGR pipe mounting bolts onto the exhaust manifold 11 Remove the duct bracket from the cylinder head 12 Unscrew the intake duct mounting bolts onto the intake manifold 13 Separate the connecting rod from the control lever ...

Page 343: ... Remove the fuel injection line 1 from the fuel injection nozzle 12 Box Wrench Inset 000 589 77 03 00 16 Remove the fuel injection line from the fuel injection pump Box Wrench Insert 000 589 77 03 00 17 Remove the bracket mounting bolts and then remove the fuel injection line 1 ...

Page 344: ...NICAL 1B3 43 18 Disconnect the booster hose connected to intake manifold 19 Remove the intake manifold and gasket 20 Remove the cylinder head cover and gasket with the blow by gas hose 21 Disconnect the glow plug cables ...

Page 345: ...e the cable channel 23 Disconnect the cables from the glow plug sensor and coolant temperature sensor 24 Remove the heater pipe bracket from the oil filter 25 Pry off the clamp and push the heater feed pipe forward and then pull out the pipe ...

Page 346: ...5 26 Disconnect the fuel lines from the fuel filter 27 Disconnect the fuel lines from the injection pump 28 Remove the fuel filter 35 29 Remove the fuel injection nozzle 12 and nozzle washer 11 Socket Wrench Insert 001 589 65 09 00 ...

Page 347: ...te the crankshaft to the opposite direction of engine revolution 31 Place alignment marks on the camshaft gear and timing chain 32 Ensure that the camshaft and the bearing cap marking are aligned 33 Remove the starter motor and install the engine lock onto the flywheel ring gear Engine Lock 602 589 00 40 00 ...

Page 348: ...e exhaust manifold and gasket 36 Remove the chain tensioner and seal 37 Remove the bolt and separate the drive sprocket 21 Notice During removal be careful not to drop the sprocket and chain into the timing case Carefully pull off the chain and then pull out the sprocket ...

Page 349: ...move the No 2 bolts Do not remove the bolts at a time completely but remove them step by step evenly or camshaft can be seriously damaged OM662LA 39 Remove the bearing caps and then pull out the camshaft 20 upward Notice Be careful not to miss the locking washer 40 Remove the locking washer Notice Check the locking washer and replace if necessary OM661LA ...

Page 350: ...l out the tensioning lever 31 43 Pry off the closing cover Remove the bolt and then remove the idle pulley 44 Using the sliding hammer 36 and the threaded pin 37 pull out the sliding rail pins 25 26 and remove the sliding rail 24 SlidingHammer116589203300 Threaded Pin 116 589 02 34 00 ...

Page 351: ... thermo valve 47 Remove the socket bolts 13 of the chain box T Type Socket Wrench 116 589 03 07 00 Magnetic Bar 102 589 03 40 00 48 Remove the cylinder head bolts in numerical se quence Cylinder Head Bolt Wrench 601 589 00 10 00 45 Remove the vacuum line from the vacuum pump ...

Page 352: ...OM600 ENGINE MECHANICAL 1B3 51 49 Remove the cylinder head 2 and gasket 3 OM661LA ...

Page 353: ... with the guide pins 3 Measure the length L of cylinder head bolts Notice If the max length is exceeded replace the bolts Thread Dia Max Limit L M10 M10 M10 80mm 102mm 115mm 82mm 104mm 117mm when new 4 Coat the head contact surface of bolts and thread with oil and insert them as shown Cylinder head bolts arrangement Bore 1 M10 80 2 M10 102 3 M10 115 4 M 8 50 5 M 8 80 OM662LA ...

Page 354: ...ad bolts to specified torque and torque angle OM 662LA OM 661LA 6 Install the socket bolts in the chain box Tightening Torque 25 Nm 7 Connect the vacuum pipe to the thermo valve Stage 1 Stage 2 Torque Angle Wait For Torque Angle 15 Nm 35 Nm 90 10 minutes 90 ...

Page 355: ...tening Torque 25 Nm Notice Be careful not to be confused the connections and hoses 10 Connect the fuel pipe to the injection pump 11 Install the sliding rail 24 and insert the sliding rail pins 25 26 Notice Apply sealing compound on the each collar of the sliding rail pins SlidingHammer116589203300 Threaded Pin 116 589 02 34 00 ...

Page 356: ...ightening Torque 25 Nm 13 Insert the tensioning lever 31 and install the spring 14 Install the damper Tightening Torque 23 Nm Notice Insert the tensioning lever bolts onto the mounting hole 15 Insert the locking washer 16 Inspect the valve tappet and check that the tappet moves smoothly ...

Page 357: ...ay 0 06 0 21mm Notice If out of standard adjust it with the proper thickness of locking washer 19 Install the bearing caps on the camshaft according to the number on the caps 20 Tighten the bearing cap bolts according to the numerical sequence Tightening Torque 25 Nm Notice Tighten the No 1 bolts light arrow first and then tighten the No 2 bolts dark arrow stage by stage OM662LA OM661LA ...

Page 358: ... Position the camshaft on marking and install the camshaft sprocket Notice Align the alignment marks on the chain and sprocket 23 Install the camshaft sprocket bolt 22 Check the TDC position of the crankshaft Tightening Torque 25 Nm 90 ...

Page 359: ...ANICAL 24 Install the exhaust manifold and gasket 25 Install the turbocharger 26 Install the exhaust pipe onto the turbocharger Tightening Torque 25 Nm Notice Measure the max length L and replace the bolt if it exceeds 53 6mm ...

Page 360: ...nsioner 27 Tightening Torque 80 Nm 28 Remove the engine lock 29 Insert the nozzle washer into the hole to face round part downward 30 Install the fuel injection nozzle Tightening Torque 40 Nm 31 Connect the fuel hose 32 Install the cable channel and connect the cables to glow plugs ...

Page 361: ...he coolant temperature sensor and the glow plug sensor 36 Replace the intake manifold gasket 37 Install the intake manifold Tightening Torque 25 Nm 33 Replace the gasket and install the cylinder head cover Tightening Torque 10 Nm 34 Install the blow by hose ...

Page 362: ...r head Notice For installation clean the hole 39 Install the bracket of heater feed pipe to the oil filter 40 Install the fuel pipe and the accelerator control linkage 41 Connect the fuel lines to the injection nozzles and to the injection pump Box Wrench Insert 000 589 77 03 00 Tightening Torque 18 Nm ...

Page 363: ...and pulling the rod install the bolt and then tighten the nut 44 Install the oil dipstick tube bracket Tightening Torque 10 Nm 45 Hold the cooling fan with the counter holder and tighten the bolt 42 Install the poly V belt Notice Be careful not to contaminate the belt Tightening Torque 23 Nm ...

Page 364: ...olt 10Nm 2 Cylinder Head Cover 3 Gasket Replace 4 Socket Bolt 25Nm 5 Fuel Filter 6 Square Nut 7 Oil Pan 8 Socket Bolt 10Nm 9 Bolt M6 10Nm M8 23Nm 10 Power Steering Pump 11 Bolt 12 Belt Pulley 13 Bolt 32Nm 14 Timing Case Cover 15 Bolt 23Nm 16 Alternator Bracket 17 Bolt 45Nm 18 Bolt 25Nm 19 Bolt 10Nm 20 Closing Cover 21 Socket Bolt 23Nm 22 Guide Pulley 23 Bolt 9Nm 24 Guide Pulley Bracket 25 Nut 23Nm...

Page 365: ...ve the fan clutch and cooling fan belt pulley 2 Drain the engine oil completely 3 Remove the oil dipstick tube bracket bolts 4 Remove the crankshaft pulley 5 Loosen the bolt 1 and then remove the cylinder head cover 2 and gasket 6 Remove the vacuum pump 7 Detach the closing cover 20 Remove the bolts 21 and then remove the guide pulley 22 ...

Page 366: ...the alternator bracket 16 9 Disconnect the pipes of power steering pump and remove the belt pulley Notice Be careful not to lose the key 10 Remove the nut and pull out the bolt and then remove the power steering pump 12 Remove the fuel filter ...

Page 367: ...mage the cylinder head gasket or oil pan gasket 13 Remove the camshaft 14 Remove the socket bolts 4 in the chain box Socket Wrench 115 589 03 07 00 15 Remove the injection pump Notice See the Removal of fuel injection pump 16 Remove the oil pan bolts 8 9 in the area of the timing case cover 14 17 Slightly loosen the remaining oil pan bolts ...

Page 368: ...ce and apply sealant 2 Install the timing case cover Notice Bolts arrangement 1 M6 x 60 2 M6 x 70 3 M6 x 40 3 Tighten the socket bolts in the chain box Tightening Torque 10 Nm Tightening Torque 23 Nm Tightening Torque 10 Nm 10 Nm 23 Nm Socket bolt M6 bolt M8 bolt 4 Tighten the oil pan bolts ...

Page 369: ...shaft belt pulley Notice Replace front radial seal if necessary 6 Install the alternator bracket 25 Nm Front Side 7 Install the alternator Tightening Torque 8 Install the cylinder head cover Tightening Torque 10 Nm 9 Tighten the injection pump mounting bolts Tightening Torque 23 Nm 25 Nm 25 Nm Upper Low ...

Page 370: ... 11 Install the vacuum pump 12 Install the power steering pump 13 Install the power steering pump pulley Tightening Torque 25 Nm Tightening Torque 10 Nm Tightening Torque 23 Nm Tightening Torque 32 Nm 14 Install the guide pulley bracket Tightening Torque 9Nm ...

Page 371: ...e gasket 3 and install the cylinder head cover 2 17 Install the cooling fan belt pulley and fan clutch 18 Install the belt tensioning device and then install the belt 19 Install the cooling fan 20 Fill the engine oil and check oil leaks by running the engine Tightening Torque 23 Nm Tightening Torque 10 Nm ...

Page 372: ...NICAL 1B3 71 CRANKSHAFT END COVER Preceding Work Removal of flywheel and driven plate 1 Crankshaft Flange 2 End Cover Clean Loctite 573 3 Bolt 10Nm Loctite 573 4 Radial Seal Replace 5 Dowel Sleeve 6 Bolt 10Nm Loctite 573 ...

Page 373: ... 2 Remove the radial seal 4 with care not to damage the sealing surface Installation Procedure 1 Thoroughly clean the sealing surface of end cover and apply Loctite 573 2 Clean the groove of radial seal 3 Apply Loctite 573 on the bolts and install the end cover Tightening Torque 10 Nm Notice Be careful not to damage the oil pan gasket 4 Install the inner oil seal assembler to the crankshaft flange...

Page 374: ...ler on he seal and by tightening the bolts press the radial seal into the end cover as far as the stop Notice The seal must be positioned exactly at right angles in the end cover to ensure that it provides a proper seal Oil Seal Assembler 601 589 03 43 00 A Standard Radial Seal BRepairRadialSeal 5 Coat a little oil on the sealing lip of new radial seal and contacting surface Notice Don t use greas...

Page 375: ...ON DAMPER AND HUB Preceding Work Removal of the cooling fan Removal of poly V belt 1 Bolt 10Nm 2 Cooling Fan Belt Pulley 3 Socket Bolt 23Nm 4 Crankshaft Belt Pulley 5 Vibration Damper 6 Bolt 200Nm 90 7 Washer 8 Straight Pin 9 Hub 10 Oil Pan ...

Page 376: ... 5 Vibration Damper 6 Bolt 7 Washer 8 Straight Pin Notice The mounting position of vibration damper is fixed by straight pin 8 Tools Required 602 589 00 40 00 Engine Lock 103 589 00 30 00 Puller 9 Hub 11 Radial Seal 12 Timing Gear Case Cover 13 Key 14 Crankshaft Sprocket 16 Crankshaft ...

Page 377: ...el ring gear Engine Lock 602 589 00 40 00 2 Remove the poly V belt 3 Remove the cooling fan Notice Keep the fan in vertical position 4 Remove the cooling fan belt pulley 2 5 Place alignment marks arrow on the vibration damper 5 and crankshaft belt pulley 4 6 Remove the timing sensor bracket Notice Remove if necessary ...

Page 378: ...ECHANICAL 1B3 77 7 Remove the socket bolts 3 and then remove the belt pulley 4 and vibration damper 5 8 Remove the washer and bolt 9 Remove the hub by using a puller Puller 103 589 00 33 00 10 Replace the radial seal ...

Page 379: ...lign the woodruff key and the groove of hub arrow 2 Install the washer 7 and tighten the bolt 6 Washer new 1 EA 200 Nm 90 3 Install the vibration damper Notice Exactly align and insert onto the straight pin 4 Install the belt pulley Tightening Torque 25 Nm Notice Align the alignment marks ...

Page 380: ...E MECHANICAL 1B3 79 5 Install the timing sensor bracket Notice See the TDC setting 6 Install the cooling fan pulley Tightening Torque 10 Nm 7 Install the cooling fan 8 Install the fan belt 9 Remove the engine lock ...

Page 381: ...1B3 80 OM600 ENGINE MECHANICAL CRANKSHAFT FRONT RADIAL SEAL 1 Radial Seal 2 Timing Case Cover Tools Required 601 589 03 14 00 Sleeve 3 Woodruff Key ...

Page 382: ...rd Radial Seal B RepairRadialSeal Replacement Procedure 1 Pull out the radial seal 1 and be careful not to damage the sealing surface of timing case cover 2 Thoroughly clean the mounting bore of the radial seal 3 Coat a little oil on the sealing lip of new radial 1 and contact surface Notice Don t use grease 4 Install the radial seal 1 by using a sleeve 4 Notice Align the groove of sleeve and wood...

Page 383: ...rnal Extractor Removal Installation Procedure 1 Remove the manual transmission 2 Using a puller pull out the locking ring and ball bearing together Counter Support 000 589 33 33 00 Internal Extractor 000 589 25 33 00 3 Apply Loctite 241 on the new ball bearing and then insert the ball bearing to be stopped at the spacer ring by using a proper mandrel 3 Ball Bearing 4 Bolt 45Nm 90 ...

Page 384: ... 3 Crankshaft Main Bearing Shells Upper 4 Trust Bearings Upper 5 Crankshaft 6 Crankshaft Main Bearing Shells Lower 7 Thrust Bearings Lower 8 Crankshaft Bearing Cap 9 Crankshaft Bearing Cap Fit Bearing 10 12 sided Stretch Bolts 55Nm 90 Tools Required 001 589 53 21 00 Dial Gauge 363 589 02 21 00 Dial Gauge Holder 366 589 00 21 05 Extension ...

Page 385: ...ankshaft Main Bearing Shells Lower 7 Thrust Bearings Lower A Radial Bearings B Radial and Axial Bearings Thrust Bearing Notice The gaps between the bearing shell and bore and between the bearing shell and journal are different each other Refer to service data Thrust Washer and Bearing Arrangement OM662LA Engine ...

Page 386: ...r 5 Crankshaft 6 Crankshaft Main Bearing Shells Lower 7 Thrust Bearings Lower A Radial Bearings B Radial and Axial Bearings Thrust Bearing Notice The gaps between the bearing shell and bore and between the bearing shell and journal are different each other Refer to service data OM661LA Engine ...

Page 387: ...earing 47 700 47 715 47 450 47 650 47 200 47 215 46 950 46 965 57 500 57 715 57 450 57 465 57 200 57 215 56 950 56 965 Repair size 1 Repair size 2 Repair size 3 Repair size 4 Bearing Clearances Thrust bearing Crankshaft bearing 0 026 0 068 Max 0 080 0 027 0 051 Max 0 070 0 100 0 254 Max 0 300 Matching Fit Bearing Journal Width to Thrust Bearings Fit bearing journal width Thrust bearings thickness ...

Page 388: ...ic bearing bore in lower Color code of relevant crankshaft parting surface 1 punch mark or blue 2 punch marks or yellow 3 punch marks or red bearing shell Blue or white blue Yellow or white yellow Red or white red Marking of bearing journals on crank webs Color code of relevant crankshaft Blue or white blue Yellow or white blue Red or white blue Blue or white blue Yellow or white yellow Red or whi...

Page 389: ...t bearing caps are marked with stamped numbers Remove the bearing cap from the vibration damper side 3 Remove the crankshaft bearing caps 9 and lower thrust bearings 7 4 Remove the lower thrust bearings 6 from the bearing cap 9 5 Remove the crankshaft 5 6 Remove the upper thrust bearings 4 7 Remove the upper bearing shells 3 from crankcase ...

Page 390: ... and into the crankshaft bearing caps Notice Do not mix up upper and lower crankshaft bearing shells 11 Install the bearing caps according to marking and tighten the 12 sided stretch bolts Tightening Torque 35 40 Nm Notice No 1 is vibration damper side 12 Measure crankshaft bearing diameters E Extension 366 589 00 21 05 13 Measure at 3 points A B and C and if the average value of B and C is less t...

Page 391: ...ap 17 Measure width of thrust bearing journal H and adjust with proper thrust bearings see table Notice The same thickness of thrust washers should be installed on both sides of the thrust bearing 18 Coat the upper thrust bearing 4 with oil and insert into the crankcase so that the oil grooves are facing the crank webs arrow 19 Coat the lower thrust bearing 7 with oil and insert into the crankshaf...

Page 392: ... 55 Nm 90 Notice Install from No 1 cap 22 Rotate the crankshaft with hand and check whether it rotates smoothly 23 Measure crankshaft bearing axial clearance Clearance 0 100 0 245mm Notice If the clearance is out of standard adjust the axial clearance of crankshaft bearing by replacing the thrust washers Dial Gauge 001 589 53 21 00 Dial Gauge Holder 363 589 02 21 00 Notice The same thickness of th...

Page 393: ... oil filter element and then change the engine oil and oil filter element after 1 000 1 500km 27 Measure the radial clearance L of the connecting rod bearing Example Measured value J 47 700mm Measured value K 47 653mm Clearance L 0 047mm Radial clearance L 0 026 0 068mm Notice If the clearance is out of standard adjust the radial clearance of connecting rod bearing by replacing the connecting rod ...

Page 394: ...1B3 93 FLYWHEEL Preceding Work Removal of the transmission Removal of the clutch 1 Oil Pan 2 Straight Pin 3 Flywheel 4 12 Sided Stretch Bolt Check 45Nm 90 5 Drive Plate Automatic Transmission 6 Flywheel Automatic Transmission ...

Page 395: ...1B3 94 OM600 ENGINE MECHANICAL l Manual transmission flywheel l Automatic transmission flywheel OM661LA OM662LA ...

Page 396: ...ctly align the position of dowel pin 2 Tools Required 602 589 00 40 00 Engine Lock Removal Installation Procedure 1 Install the engine lock Engine Lock 602 589 02 40 00 2 Remove the 12 sided stretch bolts 4 Installation Notice Tightening Torque 45 Nm 90 Notice If the length L of bolts exceeds 22 5mm replace the bolts ...

Page 397: ...ANICAL 4 Remove the flywheel 6 and driven plate 5 if equipped with automatic transmission Installation Notice Correctly align the position of dowel pin 2 5 Installation should follow the removal procedure in the reverse order ...

Page 398: ...s are severe than permissible specifications replace the flywheel l When machining the clutch surface A the mounting surface B for the clutch pressure plate should also be machined in accordance with A to keep the distance a l Do not machine under b value l When machining fix the flywheel exactly not to exceed the standard runout OM662LA Max axial runout Distance a New Repair up to 19 3 19 5 mm 16...

Page 399: ... OM600 ENGINE MECHANICAL FLYWHEEL RING GEAR Preceding Work Removal of flywheel 1 Ring Gear 2 Flywheel 3 Centering Collar Diameter Tools Required 001 589 53 21 00 Dial Gauge 363 589 02 21 00 Dial Gauge Holder ...

Page 400: ...p with a chisel 2 Thoroughly clean the collar surfaces of ring gear 3 Measure diameter a of centering collar Notice If out of standard replace the flywheel 4 Heat up the new ring gear up to 220 C by using a heating device Notice Use temperature measuring chalk 5 Install the new ring gear 1 onto the flywheel by using a drift ...

Page 401: ...MECHANICAL 6 Measure axial runout of ring gear 1 on a surface plate Limit Max 0 4mm Notice For correct measurement put the flywheel on the flat measuring board Dial Gauge 001 589 53 21 00 Dial Gauge Holder 363 589 02 21 00 ...

Page 402: ...OM600 ENGINE MECHANICAL 1B3 101 HYDRAULIC VALVE CLEARANCE COMPENSATION ELEMENT CHECK 1 Cylinder Head Cover 2 Bolt 10Nm 3 Gasket Replace 4 Valve Tappet 5 Cylinder Head ...

Page 403: ...ngine After 5minutes check the engine oil level and adjust if necessary 3 Remove the cylinder head cover 4 Check the valve tappets at TDC position of each cylinders 5 Using a drift lightly press the valve tappet and measure clearance between the cam and valve tappet Notice If the clearance exceeds 0 4mm replace the valve tappet 6 If a valve tappet moves down too far in comparison to the others rep...

Page 404: ...OM600 ENGINE MECHANICAL 1B3 103 VALVE TAPPETS Preceding Work Removal of camshaft 1 Valve Tappet 2 Cylinder Head 3 Oil Gallery 4 Seal Replace 5 Screw Plug Tools Required 102 589 03 40 00 Magnetic Bar ...

Page 405: ...ic Bar 102 589 03 40 00 2 Remove the plug 5 and blow compressed air into the oil gallery 3 At this time check that the outlet bores arrow at the seat of the valve tappet are clear 3 Replace the seal 4 and tighten the plug 5 4 Insert the new valve tappet Notice Coat the valve tappet with oil ...

Page 406: ...B3 105 VALVE SPRINGS CHECK Preceding Work Removal of valve spring 1 Valve Spring Service Data Outer diameter 33 1mm Wire diameter 4 20mm Free length 50 0mm At preloaded Length Tension new 680 740N 27mm Limit 612N 2 Spring Scale ...

Page 407: ...INE MECHANICAL VALVE SPRINGS CYLINDERHEADREMOVED 1 Valve Tappet 2 Valve Cotters 3 Spring Retainer 4 Valve Spring Check replace if necessary 5 Cylinder Head 6 Stud Bolt 12Nm 7 Washer 8 Nut Replace 25Nm 9 Exhaust Manifold ...

Page 408: ... 589 06 63 00 Magnetic Finger 601 589 01 59 00 Assembling Board 601 589 02 59 00 Supporting Bridge 667 589 00 31 00 Press Lever Replace the gasket and tighten the nuts 8 2 Install the assembling board 11 to the cylinder head with 4 cylinder head blots 10 Assembling Board 601 589 01 59 00 3 Pull out the valve tappet 1 with magnetic bar 12 Notice Place the valve tappets upside down open end upward M...

Page 409: ...areful not to damage guide bore of the valve tappet 6 Remove the spring retainer 3 and spring 4 Installation Notice Install the valve spring with the color coding arrow facing down 7 Check the valve spring and replace if necessary 8 Installation should follow the removal procedure in the reverse order 667 589 00 31 00 116 589 0663 00 Press Lever MagneticFinger ...

Page 410: ...otters 3 Spring Retainer 4 Valve Spring Check replace if necessary 5 Timing Chain 6 Cylinder Head Notice Remove the valve springs only when the piston is at TDC Tools Required 102 589 03 40 00 Magnetic Bar 116 589 06 63 00 Magnetic Finger 603 589 01 40 00 Holding Wheel 667 589 00 31 00 Press Lever 667 589 02 63 00 Supporting Bar ...

Page 411: ...Procedure 1 Remove the valve tappet 1 with magentic lifter Notice Place the valve tappets upside down open end upward Magentic Liter 102 589 03 40 00 2 Install the holding wheel 7 into the timing chain of camshaft sprocket piston Holding Wheel 603 589 01 40 00 3 Position the piston of relevant cylinder at TDC 4 Install the supporting bar 8 Supporting Bar 667 589 02 63 00 Press Lever 667 589 00 31 ...

Page 412: ...and insert valve spring Retainer 3 9 By press the spring retainer 3 with press lever 90 install the valve cotters with magnetic finger 10 Press Lever 667 589 00 31 00 Magnetic Finger 116 589 06 63 00 10 Remove the supporting bar 11 Remove the holding wheel 7 from the timing chain 5 Holding Wheel 603 589 01 40 00 13 Coat the valve tappet with oil and install it Magnetic Bar 102 589 03 40 00 ...

Page 413: ...VE STEM SEALS Preceding Work Removal of camshaft 1 Valve Tappet 2 Valve Cotters 3 Spring Retainer 4 Valve Spring Check replace if necessary 5 Valve Stem Seal 6 Valve Notice Remove the valve stem seals when the piston is positioned at TDC ...

Page 414: ...etic Lifter 603 589 01 40 00 Holding Wheel 601 589 02 43 00 Drift 116 589 06 63 00 Magnetic Finger 667 589 02 63 00 Supporting Bar A Intake valve stem seal B Exhaust valve stem seal Chamfer Inner diameter d Color Wire ring Intake valve stem seal Offset 7 3mm Brown Black Exhaust valve stem seal All round 8 2mm Green Yellow ...

Page 415: ...89 03 40 00 2 Install the holding wheel 7 into the timing chain 11 Holding Wheel 603 589 01 40 00 3 Position the piston of relevant cylinder at TDC 4 Install the supporting bar 8 Supporting Bar 667 589 02 63 00 5 Using press lever 9 press the spring retainer 3 downward and remove the valve collets with magnetic finger 10 Press Lever 667 589 00 31 00 Magnetic Finger 116 589 06 63 00 ...

Page 416: ...ert the cap 12 onto the valve 6 and install the new valve stem seal 5 and then remover the cap Drift 601 589 02 43 00 9 By pressing the spring seat with press lever 9 install the valve cotters 2 with magnetic finger 10 Notice Be careful not to damage guide bore of the valve tappet Press Lever 667 589 00 31 00 Magnetic Finger 116 589 06 63 00 ...

Page 417: ...size 1 Repair size 2 Outer Diameter D 14 251 14 440 14 451 14 240 14 251 14 440 14 451 Color Code 14 200 14 211 14 400 14 411 14 200 14 211 14 400 14 411 Overlap D a Valve Guide Inner Diameter A 37 7 Length L CHECK AND REPLACEMENT OF VALVE GUIDES Preceding Work Removal of cylinder head Removal of valve spring Removal of valve 1 Cylinder Head 2 Valve Guide 3 Valve Seat Ring a Basic Bore Diameter ...

Page 418: ... 346 589 00 63 00 Super Cooling Box 601 589 02 23 00 GO NO GO Gauge 601 589 05 15 00 Drift for Intake Notice Measure center arrow of the valve guide and if the inner diameter A exceeds standard value replace the guide 601 589 06 15 00 Drift for Exhaust Matching Valve Seat Broaching Tools Guide Sleeves Valve Seat Intake Exhaust Intake Exhaust Broaching Tool No 115 589 00 53 00 14 2mm 115 589 01 53 ...

Page 419: ...to the valve guide bore If the NO GO side is inserted fully replace the valve guide Intake 8mm Exhaust 9mm GO NOGOGauge601589022300 Replacement Procedure 1 Drive out the valve guide 2 by using a drift 5 Notice The valve guide must be driven out upward of the cylinder head Drift for Intake 103 589 03 15 00 Drift for Exhaust 103 589 02 15 00 Checking Procedure 1 Thoroughly clean the valve guide bore...

Page 420: ...aching tool must be cleared of swarf with a stiff plastic brush Lubricate the basic bore guide sleeve and broaching tool with petroleum Push broaching tool 6 in broaching direction arrow into the guide sleeve 7 far enough so that the first cut of the broaching tool is positioned in the basic bore when guide sleeve is fitted onto the valve seat ring 3 6 B ndard tool 7 Guide sleeve See the standard ...

Page 421: ...r Intake 102 589 00 23 00 GO NO GO Gauge for Exhaust 117 589 03 23 00 6 Cool down the new valve guide 2 with liquid nitrogen Notice Do not touch the cooled valve guide by hand Super Cooling box 346 589 00 63 00 7 Drive in new valve guide with drift 8 until the wire ring makes contact Notice The valve guide must be driven in from the cylinder head cover Drift for Intake 601 589 05 15 00 Drift for E...

Page 422: ...ENGINE MECHANICAL 1B3 121 9 If necessary ream the valve guide bore evenly Notice Never turn the reamer against the direction of rotation Reamer for Exhaust 000 589 10 53 00 Reamer for Intake 000 589 21 53 00 ...

Page 423: ...Surface B Height cylinder Head Cover Surface Seat of Valve Seat Ring D Valve Seat Ring Outer Diameter D1 Valve Seat Ring Inner Diameter D2 Basic Bore Diameter H Height of Valve Seat Ring Service Data Item D2 D D1 H Overlap U D D2 B A Intake 40 000 40 016mm 40 084 40 100mm 33 400 33 600mm 6 955 7 045mm 0 068 0 100mm 133 4mm 142 5mm Exhaust 37 000 37 016mm 37 084 37 100mm 30 400 30 600mm 6 955 7 045...

Page 424: ...ectrically Heated Water Tank CommercialTools Hunger D 8000 München 70 Type Ventilknecht K2000 Order No 221 00 100 Hunger D 8000 München 70 Type VDS 1A Order No 236 03 308 Hunger D 8000 München 70 Type RDS 1 Order No 219 00 100 Hunger D 8000 München 70 Type PVM 1 Hunger D 8000 München 70 Order No 250 15 250 Hunger D 8000 München 70 Order No 217 93 601 Hunger D 8000 München 70 Order No 216 69 210 Ma...

Page 425: ...mm and dimension E is approx 6mm 4 Remove the cylinder head from the clamping device and place it onto wooden blocks 5 Remove the valve guide 3 Drift Intake 8mm Drift Exhaust 9mm 6 Insert the tensioning head 4 and extracted wedges arrow by turning the bolt 5 Notice Carefully tighten the bolt 5 otherwise the valve seat ring in the cylinder head will be excessively tensioned 7 Lock the bolt 5 with n...

Page 426: ...value U 0 090mm If overlap value U is out of standard machine the basic bore for the valve seat ring 13 Clamp the cylinder head with clamping device 14 Machining basic bore for valve seat ring repair size Notice Maintain minimum value of B Machine the basic bore Limit Intake Exhaust Max D2 Min B 40 516mm 37 516mm 133 4mm Measure machined basic bore and outer diameter D of valve seat ring repair si...

Page 427: ...ve guide must be driven in from the cylinder head cover Drift Intake 8mm Drift Exhaust 9mm 19 Machine the valve seats 15 Hang the cylinder head 1 to the lifting device and heat in a water tank to approx 80 C 16 Cool down new valve seat ring 2 into the cooling box with liquid nitrogen Notice Do not touch the cooled valve seat rings with hand Super Cooling Box 345 589 00 63 00 ...

Page 428: ...ceding Works Removal of cylinder head Removal of the vale spring Removal of the valve I Valve Length W Camshaft Cam Basic Diameter X Distance Camshaft Basic Bore Valve Stem Y Half Camshaft Basic Bore Diameter Z Distance Cylinder Head Cover Parting Surface Valve Stem ...

Page 429: ...mm Exhaust Valve 34 90 35 10 mm 1 7 mm 45 9 945 8 960 mm 106 20 106 60 mm 105 30 105 70 mm 0 03 mm Standard Repair Max permissible runout at valve stem and valve seat w 38 0 0 2mm MatchingValves Camshaft cam basic dia Size x Size x Size x 19 5 20 3mm 20 4 21 4mm 21 4 21 97mm w 36 6 0 2mm Camshaft cam basic dia 19 5 20 1mm 20 2 21 2mm 21 2 21 97mm Valve to be used Use machined valve if needed new r...

Page 430: ...h wobbled valve disc with worn or scored valve stem should be replaced 2 Measure valve disc height h Service data Intake Exhaust 1 7 0 15 mm 1 7 0 15 mm 3 Machine the valve Notice Pay attention to setting angle a Commercial Tool Valve corn grinding machine 4 Measure radial runout between valve stem and valve seat Limit Max 0 03mm Dial Gauge 001 589 32 21 00 ...

Page 431: ...valve guides 6 Coat the valve stem with oil and insert it into valve guide 7 Insert the valves 1 into the valve guides according to marking 8 Measure amount by which the valve arrears a Arrears a 0 1 0 7 mm Notice If out of standard replace the valve seat ring 9 Measure camshaft cam basic diameter w Diameter w 38 0 2 mm or 37 6 0 2 mm ...

Page 432: ...re valve stem x z y Determine the valve to use according to this measurement See matching valves Example Measured value w 38 2 mm Measured value z 36 5 mm Value y 15 5 mm x 36 5 15 5 21 0mm In this case according to Matching valves table the installed valve may be used ...

Page 433: ...ing Work Removal of prechamber Removal and inspection of valve replace if necessary Inspection of valve guide replace if necessary 1 Valve 2 Valve Seat Ring 3 Cylinder Head 4 Valve Guide a Valve Arreare b Valve Seat Width a Valve Seat Angle b Valve Seat Free Angle ...

Page 434: ... MatchingValves Camshaft cam basic dia Size x Size x Size x 19 5 20 3mm 20 4 21 4mm 21 4 21 97mm w 37 6 0 2 mm Camshaft cam basic dia 19 5 20 1mm 20 2 21 2mm 21 2 21 97mm Valve to be used Use machined valve if needed use pair valve 1 105 5 0 2mm Reuse valve Use standard size valve I 106 4 0 2mm CommercialTools Hunger D 8000 München 70 Type Ventilknecht K2000 Order No 221 00 100 Hunger D 8000 Münch...

Page 435: ...eplacing the valve guide When replacing the valve seat or valve seat ring 1 Machine the valve seat a 45 2 Measure valve seat width b Valve seat width b 1 2 1 7 mm 1 5 2 0 mm Intake Exhaust 3 If the specification is exceeded the valve seat width has to be corrected at the lower free angle of b 65 4 Measure radial runout Runout Max 0 03mm ...

Page 436: ...5 Insert the valve 1 into the valve guide according to marking and measure amount by which the valve arrears a Arrears a 0 1 0 7mm 6 Measure camshaft cam basic circle diameter w Diameter w 7 Measure distance z cylinder head cover parting surface valve stem ...

Page 437: ...z Distance Cylinder head cover parting surface valve stem 8 Measure x Camshaft basic bore valve stem x z y 9 Determine the valve to be used See Matching valves Example Measured value w 38 2 mm Measured value z 36 5 mm Value y 15 5 mm x 36 5 15 5 21 0 mm In the case of a camshaft cam basic circle diameter w 38 2mmandadistance x 21 0mm theinstalled valve may be used ...

Page 438: ...g 1 Cylinder Head Cover 2 Bolt 10Nm 3 Gasket Replace 4 Valve Tappet 5 Cylinder Head Timing Condition of camshaft New After approx 20 000km Intake valve Open ATDC 11 33 ATDC 12 Close ABDC 17 ABDC 18 Exhaust valve Open BBDC 28 BBDC 27 Close BTDC 15 25 BTDC 14 At 2mm of valve lifting stroke ...

Page 439: ...ot rotate the engine at the bolt of the crankshaft sprocket Do not rotate the engine in the opposite direction of engine rotation If do this will cause serious measuring errors 3 Install the dial gauge holder and dial gauge 7 with the extension 8 to the cylinder head and position the tracer pin 9 onto the valve tappet intake valve of cylinder no 1 with a preload of min 3mm Notice The tracer pin sh...

Page 440: ...oval of cylinder head cover 1 Bolt 25Nm 2 Washer 3 Camshaft Bearing Cap 4 Camshaft 5 Dowel Pin 6 Locking Washer 7 Timing Chain 8 Cylinder Head 9 Oil Pan 10 Camshaft Sprocket 11 Washer 12 12 Sided Bolt M11 Check 25Nm 90 13 Gasket Replace 14 Chain Tensioner 80Nm ...

Page 441: ...40 00 Engine Lock Removal Procedure 1 Rotate the crankshaft and position the piston of No 1 cylinder at TDC Notice Do not rotate the crankshaft in the opposite direction of engine rotation In this position the markings of the camshaft camshaft bearing cap arrow must be aligned 2 Place alignment marks on the camshaft sprocket and timing chain ...

Page 442: ...cket 5 Remove the chain tensioner 6 Remove the camshaft bearing cap bolts according to the removal order Notice Remove the camshaft bearing cap bolts of 1 dark arrow first and then remove the bolts of 2 light arrow one revolution in stages until the counter pressure is released In order to avoid damaging the camshaft it is essential to adhere to the removal order for the camshaft bearing caps OM66...

Page 443: ...to miss front locking washer 9 Pull out the locking washer Notice Check the condition of locking washer and replace if necessary Installation Procedure 1 Insert the locking washer 2 Check the valve tappet and ensure that tappet moves smoothly 3 Coat the camshaft with oil and install the camshaft onto the cylinder head so that the TDC marking arrow is positioned upward vertically ...

Page 444: ...gned the markings of the camshaft camshaft bearing cap arrow Notice Align the alignment marks on the timing chain and sprocket Tightening Torque 25 Nm Notice Tighten the No 1 bolts light arrow by one revolution in stages first and then tighten the No 2 bolts dark arrow OM661LA OM662LA 7 Tighten the camshaft sprocket bolt Tightening Torque 25Nm 90 ...

Page 445: ...T on the crankshaft 8 Install the chain tensioner Tightening Torque 80 Nm Notice Replace the seal Before installation by pumping in the oil approx 10 times fill the oil 9 Remove the engine lock Notice If max length L of the 12 sided bolt exceeds 53 6mm replace it ...

Page 446: ...OM600 ENGINE MECHANICAL 1B3 145 CHAIN TENSIONER 1 Chain Tensioner 80Nm 2 Seal Replace ...

Page 447: ... facing up Slowly push down the thrust pin as far as the stop 7 10 times with the aid of a press or a column drill Faulty chain tensioners should be replaced completely 3 Screw Plug 4 Aluminum Gasket 5 Ball 6 Ball Guide 7 Compression Spring 8 Compression Spring 9 Housing 10 Thrust Pin 11 Valve Disc 12 O Ring 13 Snap Ring 14 Compression Spring 15 Filler A Feed Bore from Cylinder Head B To Oil Pan ...

Page 448: ...E MECHANICAL 1B3 147 TIMING CHAIN Preceding Work Removal of glow plug Removal of chain tensioner Removal of cooling fan Removal of cylinder head cover 1 Chain Link 2 Timing Chain 3 Camshaft Sprocket 4 Outer Plate ...

Page 449: ...ire arrow Tools Required 000 589 58 43 00 Chain Assembling Device Replacement Procedure 1 Cover over the chain box with cleaning rag and grind off both chain pins arrow at a chain link 1 of the timing chain 2 Remove the outer plate 4 and chain link 1 Notice Ensure that the ends of the timing chain do not drop into the chain box 3 Loosen the chain tension with approx 4 turns 4 Connect the new timin...

Page 450: ... Insert the new outer plate 4 into the fitting tool 8 and then the outer plate will be held by a magnet Chain Assembling Device 000 589 58 43 00 9 Place the fitting tool 8 onto the chain link and press the outer plate on as far as the stop 10 Switch over the die 9 of the fitting tool 8 ...

Page 451: ...markings are not aligned the timing chain must be re set and the injection pump timing has to be set 14 Position the no 1 cylinder at TDC 11 Place the fitting tool 8 onto the chain link and rivet the chain pins one by one 12 Check the riveting of chain pins and re rivet if necessary 13 Remove the wire Tightening Torque 35 40 Nm ...

Page 452: ...GINE MECHANICAL 1B3 151 TENSIONING RAIL Preceding Work Removal of cylinder head Removal of timing case cover 1 Tensioning Rail 2 Bearing Pin Notice The plastic coating of the tensioning rail can not be replaced ...

Page 453: ... belt Removal of chain tensioner 1 Cylinder Head Cover 2 Bolt 10Nm 3 Gasket Replace 4 Camshaft Sprocket 5 Washer 6 12 Sided Bolt M11 Inspect 25Nm 90 7 Tensioning Lever 8 Bolt 23Nm 9 Bearing Pin Sealing Compound 10 Guide Rail 11 Bearing Pin 12 Guide Pulley 13 Socket Bolt 23Nm 14 Closing Cover 15 Spring 16 Timing Chain ...

Page 454: ...emoval Procedure 1 Removal the cylinder head cover 2 Pull off the tensioning lever 7 and remove from the spring 15 3 Pry off the closing cover 14 and remove the bolt 13 and then remove the guide pulley 12 4 Place alignment marks arrow on the timing chain 16 and camshaft sprocket 4 5 Remove the camshaft sprocket ...

Page 455: ...ve the guide rail 10 SlidingHammer116589203300 Threaded Pin 116 589 02 34 00 Installation Procedure 1 Apply collar of both bearing pins with sealing compound 2 Position the guide rail and insert the bearing pins 3 Install the camshaft sprocket Tightening Torque 10 Nm Notice If the max length L of the 12 sided bolt exceeds 53 6mm replace it ...

Page 456: ...g on the camshaft camshaft bearing cap arrow must also be aligned 5 Install the guide pulley 12 Tightening Torque 23 Nm 6 Attach the tensioning lever 7 to the spring 15 and install 7 Replace the gasket and install the cylinder head cover Tightening Torque 10 Nm ...

Page 457: ... OM600 ENGINE MECHANICAL TIMING CASE COVER GUIDE RAIL Preceding Work Removal of cylinder head cover 1 Bearing Pin 2 Bearing Pin 3 Guide Rail 4 Oil Pump Chain 5 Crankshaft 6 Spring 7 Bushing 8 Tensioning Lever ...

Page 458: ...tensioning lever 8 off the bearing pin 2 and carefully remove the spring 6 Remove the tensioning lever 8 together with the spring 6 and bushing 7 3 Remove the guide rail 3 Installation Procedure 1 Install the guide rail 3 Attach the spring 6 to the guide rail and to the tensioning lever 8 Notice Ensure that the spring is correctly located in the guide rail arrow 2 Push the guide rail spring bushin...

Page 459: ...iming case cover 1 12 Sided Stretch Bolt M11 Check 25Nm 90 2 Washer 3 Camshaft Sprocket 4 Timing Chain 5 Bearing Pin 6 Bearing Pin 7 Oil Pump 8 Oil Pump Sprocket 9 Oil Pump Chain 10 Washer 11 Bolt 25Nm 12 Crankshaft Sprocket 13 Crankshaft 14 Key 15 Guide Rail 16 Spring 17 Bushing 18 Tensioning Lever ...

Page 460: ...ther with the spring 17 and guide rail 16 far enough until the tensioning lever has passed the oil pump chain 9 and is resting against the crankshaft 13 2 Pull out tensioning lever 19 spring 17 and bushing 18 from the bearing pin 6 3 Pull out the guide rail 16 4 Remove the bolt 11 and then remove the washer 10 oil pump chin 9 and sprocket 8 ...

Page 461: ...er 102 589 05 33 00 5 Place alignment marks arrow on the timing chain 4 and crankshaft sprocket 12 6 Remove the key 15 7 Place alignment marks arrow on the timing chain 4 and camshaft sprocket 3 8 Remove the chain tensioner 9 Remove the bolt 1 and then remove the washer 2 and camshaft sprocket 3 ...

Page 462: ...sprocket for wear and replace if necessary 2 Install the new crankshaft sprocket 12 by using a drift 21 Notice Align the groove of sprocket and woodruff key arrow exactly Drift 116 589 07 15 00 3 Fit the timing chain 4 on the crankshaft sprocket 12 Notice Align the alignment marks arrow on the chain and sprocket 4 Install the camshaft sprocket 3 Tightening Torque 25 Nm 90 Notice Pay attention on t...

Page 463: ...oil pump sprocket 8 into the oil pump chain and then install it on the oil pump Notice The curved side of the oil pump sprocket should face the oil pump 6 Insert the woodruff key 15 7 Install the guide rail 16 Attach the spring 17 to guide rail and to tensioning lever together onto the bearing pins 5 6 Notice Ensure that the spring is correctly located in the guide rail arrow ...

Page 464: ...9 Connecting Rod Upper Bearing Shell 10 Connecting Rod Lower Bearing Shell 11 Connecting Rod Bearing Cap 12 Connecting Rod Bolt 35Nm 90 13 Crankcase 14 Cylinder Bore Notice There are two kinds of connecting rods for machining and they are different in weight approx 15g When replacing the connecting rod measure its weight and ensure that a engine has the same weight of connecting rods If not there ...

Page 465: ...ushing diameter Max 0 12 mm 0 735 0 965 mm 26 012 26 018 mm Connecting Rod Bolt Dimensions Thread Stretch shaft C diameter new Minimum stretch shaft diameter C Length L new Tools Required 000 589 04 14 00 Tensioning Strap 001 589 53 21 00 Dial Gauge 363 589 02 21 00 Dial Gauge Holder M9 x 1 7 4 0 1 mm 7 1 mm 52 0 3 mm ...

Page 466: ...g rod bolts 12 and then remove the connecting rod bearing caps 11 3 Remove the connecting rod bearing shells 9 10 Notice Be careful not mix the bearing caps and shells each other 4 Remove the piston 6 and connecting rod 8 5 Remove the snap ring 4 and pull out the piston pin 5 6 Separate the piston and connecting rod ...

Page 467: ...t 16 are facing in direction of the vehicle 2 Coat the piston pin 15 with engine oil and insert it by hand Notice Do not heat up the piston 3 Install the new snap ring 4 into the grooves arrow 4 Check the piston rings 1 2 3 and replace them if necessary 5 Install and arrange the piston rings to be evenly 120 from each ends gap ...

Page 468: ...inder with a wooden stick 18 Notice The arrow on the piston crown must point toward the front of vehicle 9 Insert the connecting rod bearing shells 9 10 Notice Be careful of the difference in upper and lower bearing shells and not to be changed 10 Position the connecting rod bearings caps Notice Position so that the retaining lugs are on the same side of the connecting rod bearing arrow 11 Measure...

Page 469: ...l clearance between the connecting rod and crankshaft 14 Measure clearance between the piston crown and cylinder Standard Max 0 12mm 15 Position the piston at TDC and measure the distance between the piston crown and the crankcase surface Notice Measure at points marked Dial Gauge 001 589 00 53 21 Dial Gauge Holder 363 589 02 21 00 Standard Max 0 965 mm ...

Page 470: ... ENGINE MECHANICAL 1B3 169 OIL FILTER 1 Nut 25 Nm 2 Oil Filter Cover 3 O Ring Replace 4 Oil Filter Element Replace If necessary 5 Oil Filter Housing 6 Bolt M6 10Nm 7 Oil Pressure Switch 8 Gasket 9 Bolt 25 Nm ...

Page 471: ...stallation Procedure 1 Remove the oil filter cover and then drain the oil 2 Remove the oil pressure switch line 3 Remove the oil filter housing 4 Clean the sealing surface 5 Installation should follow the removal procedure in the reverse order ...

Page 472: ...il Pan 3 Combination Bolt 10 Nm 4 Combination Bolt 10 Nm 5 Gasket Replace 6 Lower Oil Pan 7 Combination Bolt 25 Nm 8 Drain Plug 25 Nm 9 Washer Seal Replace 10 Oil Pan Remove and install as numerical sequence Notice Replace the washer seal with new one OM662LA OM661LA ...

Page 473: ...1B3 172 OM600 ENGINE MECHANICAL Oil Circulation ...

Page 474: ...OM600 ENGINE MECHANICAL 1B3 173 Oil Filter a From Oil Pump b To Main Oil Gallery c To Oil Pan ...

Page 475: ... OM600 ENGINE MECHANICAL OIL SPRAY NOZZLE 1 Fitting Sleeve 2 Oil Spray Nozzle DisassemblyProcedure 1 Remove oil pan or crankshaft 2 Loose the bolt and then remove the nozzle 3 Combination Bolt 10 Nm A Oil Duct ...

Page 476: ...CAL 1B3 175 OIL PUMP 1 Oil Pump 2 Piston 3 Pressure Spring 4 Guide Pin 5 Screw Plug 50 Nm 6 Combination Bolt 25 Nm 7 Oil Strainer 8 Bracket DisassemblyProcedure 1 Remove the oil pan 2 Unscrew the mounting bolt of spracket ...

Page 477: ... MECHANICAL Tightening Torque 10 Nm 3 Unscrew the oil strainer bracket bolt 4 Remove the oil pump 5 Unscrew the screw plug and remove the relief valve 6 Installation should follow the removal procedure in the reverse order ...

Page 478: ...tion 4 Gasket Replace 5 Coolant Gallery Sealing 6 Pressure Measuring Plate Completely tight to the cylinder head 7 Cylinder Head Immerse with pressure measuring plate into warm water of approx 60 C and pressurize with compressed airof 2 bar Notice If air bubbles are seen replace the cylinderhead Tools Required 115 589 34 63 00 Pressure Measuring Plate 601 589 00 25 00 Suspension Device UNIT REPAIR...

Page 479: ...a Prechamber Protrusion Service Data In Longitudinal Direction In Transverse Direction Intake Valve Exhaust Valve 142 9 143 1mm 142 5mm 0 08mm 0 0mm Max 0 1mm 0 0017mm 0 1 0 7mm 0 1 0 7mm 7 6 8 1mm FACING CYLINDER HEAD MATING SURFACE Preceding Work Removal of prechamber Cylinder head pressure leakage test 1 Valve 2 Cylinder Head 3 Prechamber A Height of Cylinder Head B Longitudinal Direction C Tra...

Page 480: ...e height is less than 142 5mm replace the cylinder head 2 Insert the valve 1 and measure valve arrears a Valve arrears a 0 1 0 7 mm Notice If out of standard machine the valve seat 3 Install the prechamber and measure protrusion C Protrusion C 7 6 8 1mm 4 Assemble the engine and check the valve timing ...

Page 481: ...CHANICAL REPLACEMENT OF CRANKCASE CORE PLUG Left Right Core plug f34mm OM661LA 2EA OM662LA 3EA Core plug f34mm OM661LA 2EA OM662LA 3EA Core plug f17mm OM661LA 1EA OM662LA 1EA Core plug f34mm OM661LA 1EA OM662LA 1EA Left Right ...

Page 482: ...pdrawn edge of the core plug and pull forward and then rotate 90 4 Pull out the core plug with pliers 5 Thoroughly clean the sealing surface and apply Loctite 241 6 Install the new core plug by using a drift Drift 102 589 00 15 00 F34 Drift 102 589 12 15 00 F17 7 Install the removed parts and fill the coolant Notice The adhesive must be allowed to harden for about 45 minutes before filling of cool...

Page 483: ...in longitudinal direction Piston protrusion at TDC to crankcase upper surface In longitudinal direction B In transverse direction C Min 299 62 mm 0 06 mm 0 06 mm 0 0006 0 0016 mm 0 05 mm 0 965 mm 0 735 mm Max Min FACING CRANKCASE CONTACTING SURFACE 1 Crankcase 2 Crankcase Contacting Surface Y Height crankcase upper surface crankcase lower surface B Longitudinal Direction C Transverse Direction H C...

Page 484: ...ing Work Removal of cooling fan Removal of the coolant pump housing Removal of the flywheel and driven plate 1 Steel Ball f15mm 2 Screw Plug M16 x 1 5 Loctite 241 50Nm Notice The screw plug 2 has to be installed as a repair solution if the steel ball 1 is leaking ...

Page 485: ...NGINE MECHANICAL 3 Steel Ball f17mm 4 Seal 5 Screw Plug M18 x 1 5 50Nm Notice The seal 4 and screw plug 5 have to be installed as a repair solution if the steel ball 3 is leaking Tools Required 601 589 08 15 00 Drift ...

Page 486: ... not to damage the bores of the steel balls 6Shop madetool 3 Thoroughly clean the bores of steel balls 4 Place the steel ball 3 onto the drift 7 with a little grease and position to the bore and then tap until the drift stops Drift 601 589 08 15 00 5 Place the steel ball 1 onto the drift 7 with a little grease and position to the bore and then tap until the drift stops Drift 601 589 08 15 6 Warm u...

Page 487: ...ug 1 Remove the steel ball 2 Tap thread into the bores of the oil gallery Notice Front bore M18 1 5 depth 10mm Rear bore M16 1 5 depth 14mm 3 Thoroughly clean the oil gallery 4 Tighten the front plug 5 with seal 4 5 Apply Loctite 241 and then tighten the rear plug 2 Tightening Torque 50 Nm Tightening Torque 50 Nm ...

Page 488: ...er shape Honing angle CYLINDER BORE MEASUREMENT a Longitudinal Direction b Transverse Direction c d e Measuring Point 1 Crankcase Contacting Surface 2 TDC of 1st Piston Ring 4 BDC of Ring Service Data Code letter A Code letter X Code letter B When new Wear limit 89 000 89 006mm 89 006 89 012mm 89 012 89 018mm Max 0 20mm 0 01mm 0 05mm 50 10 ...

Page 489: ...ry cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals Disconnecting this cable will help prevent personal injury and damage to the vehicle The ignition must also be in LOCK unless otherwise noted TABLE OF CONTENTS Description Water Cooling Forced Circulation Double Cross Flow 70 000 kcal h 580 x 482 x 4...

Page 490: ...5 9 11 9 11 9 11 40 5 49 5 3 7 3 7 Application Coolant Drain Plug Engine Hanger Bracket and Coolant Outlet Port Bolt Thermostat Cover Bracket Bolt Oil Cooler Pipe Line Bolt Cooling Fan Bolt Viscous Clutch Bolt Automatic Transmission Oil Cooling Hose Bolt Cooling Fan Shroud Bolt ...

Page 491: ...M162 ENGINE COOLING 1D1 3 SPECIAL TOOLS SPECIAL TOOLS TABLE 124 589 15 21 00 Tester 603 589 00 40 Counter Holder ...

Page 492: ...cedure 1 Loosen the cap a little and release pressure and remove the cap Notice For the risk of scalding cap must not be opened unless the coolant temperature is below 90 C 2 Fill coolant up to upper edge arrow of reservoir Tester 124 589 15 21 00 4 If the pressure on the tester drops check leakage at the all coolant hoses and pipes and each connections Replace or retighten if necessary ...

Page 493: ... coolant Notice Collect coolant by using a proper container 3 Drain the coolant from the crankcase by inserting a hose dia 14mm onto the drain bolt on the side of crankcase exhaust manifold and by loosening the plug Notice l Just loosen the drain plug to drain the coolant and do not remove the plug completely l Collect coolant by using proper container 4 After complete draining of the coolant remo...

Page 494: ...atch the anti freeze and the water ratio to 50 50 l Supplement the coolant until the coolant overflows to the deaeration hose 8 Insert the de aeration hose and completely tighten the clamp 9 Check the coolant level in the coolant reservoir tank 10 Warm up until thermostat is opened the engine and recheck the coolant level in the reservoir tank and fill up the coolant if necessary ...

Page 495: ...rom the radiator 2 Remove the hose mounting clamp 5 and disconnect the coolant hose 6 3 Remove the two bolts 1 the engine hanger bracket 2 and coolant outlet port 3 Installation Notice 4 O ring 5 Hose Mounting Clamp 6 Hose Replace the O ring with new one 4 Installation should follow the removal procedure in the reverse order 5 Fill up the coolant as specified 6 Check the leaks in the cooling syste...

Page 496: ... belt Removal of air admission housing 1 Air Admission Housing 2 Oil Cooler Pipe Line 3 Seal Replace 4 Bolt 9 11 Nm 5 Coolant Hose 6 Coolant Hose 7 Outlet Coolant Hose 8 Coolant Hose 9 Inlet Coolant Hose 10 Coolant Pump 11 Bolt 21 Nm 12 Dowel Sleeve 13 Seal Replace ...

Page 497: ...ve the coolant line bolts 4 and then remove the coolant line 2 Installation Notice Notice Replace the seal 3 5 Remove the mounting bolts 11 and carefully pull out coolant pump 10 Installation Notice Tightening Torque 9 11 Nm Notice Replace the seal 13 Tightening Torque 21 Nm 6 Installation should follow the removal procedure in the reverse order 7 Fill up coolant 8 Do coolaing system leakage test ...

Page 498: ... 5 and remove the thermostat cover bracket thermostat cover and the thermostat in order Installation Notice 1 Thermostat Cover 2 Thermostat 3 O ring 4 Thermostat Cover Bracket 5 Bolt M6 X 25 3 pieces 9 11 Nm 6 Hose Mounting Clamp 7 Heater Hose Do not separate the thermostat cover and thermostat 4 Replace the O ring if necessary 5 Check the leakage in the cooling system Tightening T orque 9 11 Nm ...

Page 499: ...Bolt M6 X 16 2 pieces 9 11 Nm 4 Oil Cooler Pipe Line 5 O ring Replace Removal Installation Procedure 1 Drain the coolant 2 Unscrew the bolts 2 3 and remove the oil cooler pipe line 4 Replace the O ring with new one Installation Notice 3 Installation should follow the removal procedure in the reverse order 4 Fill up the coolant as specified 5 Check the leaks in the cooling system ...

Page 500: ... ENGINE COOLING COOLING FAN AND VISCOUS CLUTCH Preceding Work Removal of cooling fan shroud 1 Cooling Fan Pulley 2 Viscous Clutch 3 Cooling Fan 4 Bolt M6 X 12 4 pieces 9 11 Nm 5 Bolt M10 X 45 1 piece 40 5 49 5 Nm ...

Page 501: ...special tool 603 589 00 40 00 and remove the cooling fan after unscrewing the four bolts 4 Installation Notice 2 Remove the bolt 5 from the viscous clutch and remove the viscous clutch from the cooling fan pulley Installation Notice Tightening Torque 9 11 Nm Tightening Torque 40 5 49 5 Nm 3 Installation should follow the removal procedure in the reverse order ...

Page 502: ... For installation exactly align the lower fan shroud pin into the hole of the fan shroud assembly 4 and insert the clips 3 Remove the bolts 3 and then remove the cooling fan shroud assembly 4 Installation Notice 1 Clip 2 Lower Fan Shroud 3 Bolt 4 Installation should follow the removal procedure in the reverse order Tightening Torque 7Nm 4 Fan Shroud Assembly 5 Radiator ...

Page 503: ...k Removal of cooling fan shroud 1 Radiator Inlet Coolant Hose 2 Radiator Outlet Coolant Hose 3 Make Up Coolant Hose 4 Automatic Transmission Oil Cooling Hose 5 Automatic Transmission Oil Cooling Line 6 Bolt 7 Insulator 8 Stopper 9 Bolt 7Nm 10 Radiator ...

Page 504: ...sion oil cooling hose Installation Notice 5 Remove the automatic transmission oil cooling line bolts and then remove the oil cooling line 6 Remove the radiator upper mounting bolts and then remove the bracket and insulator 7 Remove the radiator 8 Check the radiator pin for crack damage leakage and bending and replace if necessary 9 Installation should follow the removal procedure in the reverse or...

Page 505: ...N Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals Disconnecting this cable will help prevent personal injury and damage to the vehicle The ignition must also be in LOCK unless otherwise noted TABLE OF CONTENTS Description Water Cooling Forced Circulation Down Flow 61 5...

Page 506: ...5 9 11 9 11 9 11 40 5 49 5 3 7 3 7 Application Coolant Drain Plug Engine Hanger Bracket and Coolant Outlet Port Bolt Thermostat Cover Bracket Bolt Oil Cooler Pipe Line Bolt Cooling Fan Bolt Viscous Clutch Bolt Automatic Transmission Oil Cooling Hose Bolt Cooling Fan Shroud Bolt ...

Page 507: ...M161 ENGINE COOLING 1D2 3 SPECIAL TOOLS SPECIAL TOOLS TABLE 124 589 15 21 00 Tester 603 589 00 40 Counter Holder 111 589 02 01 00 Open End Wrench 111 589 00 40 00 Open End Wrench ...

Page 508: ...cedure 1 Loosen the cap a little and release pressure and remove the cap Notice For the risk of scalding cap must not be opened unless the coolant temperature is below 90 C 2 Fill coolant up to upper edge arrow of reservoir Tester 124 589 15 21 00 4 If the pressure on the tester drops check leakage at the all coolant hoses and pipes and each connections Replace or retighten if necessary ...

Page 509: ...coolant Notice Collect coolant by using a proper container 3 Drain the coolant from the crankcase by inserting a hose dia 14mm onto the drain bolt on the side of crankcase exhaust manifold and by loosening the plug Notice l Just loosen the drain plug to drain the coolant and do not remove the plug completely l Collect coolant by using proper container 4 After complete draining of the coolant remov...

Page 510: ...atch the anti freeze and the water ratio to 50 50 l Supplement the coolant until the coolant overflows to the deaeration hose 8 Insert the de aeration hose and completely tighten the clamp 9 Check the coolant level in the coolant reservoir tank 10 Warm up until thermostat is opened the engine and recheck the coolant level in the reservoir tank and fill up the coolant if necessary ...

Page 511: ...M161 ENGINE COOLING 1D2 7 COOLING FAN AND VISCOUS CLUTCH 1 Bolt M6 X 14 3 piece 9 11 Nm 2 Cooling Fan 3 Viscous Clutch 4 Union Nut Left Threaded Screw 40 5 49 5 Nm ...

Page 512: ... pulley 2 Remove the viscous clutch using an open end wrench special tool 111 589 02 01 00 Installation Notice Notice The union nut is left threaded screw 3 Remove the 3 bolts 1 from the viscous clutch and remove the cooling fan and the viscous clutch Installation Notice Tightening Torque 40 5 49 5 Nm Tightening Torque 9 11 Nm Notice You may change the procedure 2 and 3 if necessary 4 Installation...

Page 513: ...utch 1 Bolt M6 X 45 1 piece 9 11 Nm 2 Bolt M6 X 95 1 piece 9 11 Nm 3 Bolt M6 X 25 4 piece 9 11 Nm 4 Bolt M8 X 85 2 piece 20 5 20 5 Nm 5 Coolant Pump Housing 6 Bolt M6 X 16 4 piece 9 11 Nm 7 Coolant Pump Pulley 8 Coolant Inlet Hose 9 Heater Hose 10 Coolant Bypass Hose 11 Gasket ...

Page 514: ... 5 Nm 1 2 3 4 Notice Hold the pulley with special tool 603 589 00 40 00 while removing the pulley Tightening Torque 9 11 Nm 5 Unscrew the bolts 1 2 3 4 from coolant pump housing 5 and remove the coolant pump Installation Notice 6 Clean the sealing surface 7 Replace the gasket with new one Notice Apply the sealant when the sealing surface of coolant pump housing and coolant mounting area is clean 8...

Page 515: ...screw the three bolts 1 and remove the thermostat cover assembly from thermostat housing Installation Notice Do not separate the thermostat cover and thermostat 4 Replace the O ring if necessary 5 Check the leakage in the cooling system Tightening Torque 9 11 Nm 1 Bolt M6 X 25 3 pieces 9 11 Nm 2 Thermostat Cover 3 De aeration Hose 4 Coolant Outlet Hose 5 Thermostat 6 O ring ...

Page 516: ...viscous clutch 1a Bolt M6 X 95 2 pieces 9 11 Nm 1b Bolt M8 X 75 2 pieces 22 5 27 5 Nm 1c Bolt M8 X 35 1 piece 22 5 27 5 Nm 2 Thermostat Housing Assembly 3 O ring 4 De aeration Hose 5 Coolant Outlet Hose 6 Coolant Bypass Hose 7 Tensioning Device Shock Absorber 8 Engine Hanger Brocket ...

Page 517: ... Unscrew the bolt 1c and pry off the tensioning device shock absorber 7 Installation Notice 6 Replace the O ring with new one 7 Installation should follow the removal procedure in the reverse order 8 Check for leaks in cooling system 5 Unscrow the bolts 1a 1b and remove the engine hanger bracket and thermostat housing Installation Notice Tightening Torque 22 5 27 5 Nm Tightening Torque 9 11 Nm 22 ...

Page 518: ...ROUD Removal Installation Procedure 1 Unscrew two bolts from cooling fan shroud and remove the shrud Installation notice 1 Fan Suroud Assembly Tightening Torque 3 7 Nm 2 Bolt M6 X 16 2 pieces 3 7 Nm 2 Installation should follow the removal procedure in the reverse order ...

Page 519: ...k Removal of cooling fan shroud 1 Inlet Hose 2 Hose to Engine 3 Hose to 3 way Connector 4 Make up Hose to Coolant Reservoir 5 3 way Connector 6 Automatic Transmission Oil Cooling Hose A T Equippend Vehicle 7 Bolt M6 X 20 4 pieces 3 7 Nm 8 Insulator 9 Radiator Bracket 10 Radiator ...

Page 520: ...se Installation Notice 5 Unscrew the bolts from radiator bracket and remove the bracket and insulator Installation Notice Tightening Torque 3 7 Nm 6 Remove the radiator upper mounting bolts and then remove the bracket and insulator 7 Remove the radiator 8 Check the radiator pin for crack damage leakage and bending and replace if necessary 9 Installation should follow the removal procedure in the r...

Page 521: ...ore removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals Disconnecting this cable will help prevent personal injury and damage to the vehicle The ignition must also be in LOCK unless otherwise noted Application Coolant Mixing Ratio Water anticorrosion Capacity Description ALUTEC P 78 50 50 10 5L 11L 662LA 9 5L 10L 661...

Page 522: ...1D3 2 OM600 ENGINE COOLING COOLING CIRCULATION A Thermostat B Radiator D From Heater E Hose G Deaeration Line H Reservoir DIAGNOSIS ...

Page 523: ...e closes until temperature of coolant reaches to 85 C B FromRadiator C FromCrankcase D To Crankcase 2 At partial opening Valve opens partially as temperature of coolant is maintained between 85 100 C 3 At full opening Valve opens full as temperature of coolant is more then 100 C ...

Page 524: ... remove the cap after Notice Do not remove radiator cap when coolant is above 90 C 2 Add the coolant to the arrow mark of coolant reservoir 3 Connect the special tool to the injector of reservoir and apply 1 4bar pressure Tester 124 589 15 21 00 4 If the pressure on the tester drops check the hose pipe and leakage and replace or retighten ...

Page 525: ...nt by using the proper bottle 3 Remove the drain plug 1 and seal 2 of cylinder block and drain the coolant 4 Replace the seal to new one and tighten the drain plug Installation Notice Tightening Torque 30 Nm 5 Tighten the drain plug of the lower radiator 6 Fill the coolant through coolant reservoir tank Notice l A proportion of 50 by volume of water anticorrosion must be ensured 7 After engine is ...

Page 526: ...1D3 6 OM600 ENGINE COOLING COOLANT PUMP Preceding Work Removal of cooling fan Removal of V belt 1 Tensioning Lever 2 Gasket Replace 3 Bolt 10 Nm 4 Belt Pulley 5 Bolt 10 Nm 6 Coolant Pump ...

Page 527: ...tening Torque 10 Nm 2 Loose the bolts 3 Installation Notice Tightening Torque 10 Nm 3 Pull the tensioning lever 1 to the arrow direction 4 Remove the coolant pump 6 Notice Clean gasket residues on the sealing surface of coolant pump and replace the gasket 5 Installation should follow the removal procedure in the reverse order ...

Page 528: ...ding Work Removal of coolant pump Removal of thermostat Removal of alternator 1 Gasket Replace 2 Coolant Pump Housing 3 Connector 4 Bolt 10 Nm 5 Coolant Hose 6 Return Pipe 7 O Ring 8 Temperature Sensor Notice The bolt on the arrow should be installed last ...

Page 529: ...coolant hose 5 and return pipe 6 3 Remove the bolts 4 evenly Installation Notice Tightening Torque 10 Nm Notice Clean gasket residues on the sealing surface of coolant pump and replace the gasket 4 Remove the coolant pump housing 2 5 Installation should follow the removal procedure in the reverse order ...

Page 530: ...1D3 10 OM600 ENGINE COOLING COOLING FAN CLUTCH 1 Belt Pulley 2 Cooling Fan Clutch 3 Cooling Fan 4 Socket Bolt 45 Nm 5 Socket Bolt 10 Nm Tools Required 603 589 00 40 00 Counter Holder ...

Page 531: ...e bolt 4 Counter Holder 603 589 00 40 00 Installation Notice Tightening Torque 45 Nm 2 Remove the socket bolt 5 and then remove the cooling fan 3 and fan clutch 2 Notice Keep the fan clutch vertically Installation Notice Tightening Torque 10 Nm 3 Installation should follow the removal procedure in the reverse order ...

Page 532: ...RADIATOR Preceding Removal of cooling fan shroud 1 Radiator Inlet Hose OM662LA 220mm OM661LA 321mm 2 Radiator outlet Hose 3 Radiator Deaeration Tube Hose 4 Clamp 5 Spring Clamp 6 Bolt 3 7 Nm 7 Radiator 8 Spring Clamp 9 Bolt 3 7Nm ...

Page 533: ... hose 4 Remove the auto T M oil cooling hose and cooling line Installation Notice 5 Loosen the radiator upper mounting bolt and remove the mounting stopper and insulator 6 Remove the radiator 7 Check the radiator pin for crack leakage and bending and replace it if necessany 8 Installation should follow the removal procedure in the reverse order Tightening Torque Hose 29 40Nm ...

Page 534: ...NG COOLING SUB SYSTEM 1 Radiator 2 Cooling Fan Shroud 3 Bolt 3 7Nm 4 Cooling Fan Shroud 5 Radiator Deaieration Hose 7 Mounting Bracket 8 Make up Cooling Hose 9 Bolt 3 7Nm 10 Cooling Reservoir tank Cap 11 Cooling Reservoir tank ...

Page 535: ...ghtening torque 3 7Nm 2 Check the shroud 3 Installation should follow the removal procedure in the reverse order Coolant Sub Tank 1 Drain the coolant from radiator 2 Remove the each hose 3 Loosen the mounting bolt of sub tank and remove the coolant sub tank Installation Notice 4 Installation should follow the removal procedure in the reverse order Tightening Torque 3 7 Nm ...

Page 536: ...1D3 16 OM600 ENGINE COOLING THERMOSTAT 1 Thermostat 2 Seal Replace 3 Thermostat Housing Cover 4 Coolant Hose 5 Bolt 10Nm ...

Page 537: ...se 4 from the thermostat housing cover 3 3 Remove the bolts 5 and then remove the thermostat 1 and housing cover 3 Installation Notice Align the groove on thermostat and the housing cover rib arrow Tightening Torque 10 Nm Notice Replace the seal 2 4 Installation should follow the removal procedure in the reverse order ...

Page 538: ...g 1E1 7 Ignition Cable 1E1 9 Unit Repair 1E1 12 Battery 1E1 12 SPECIFICATIONS ALTERNATOR SPECIFICATIONS CAUTION Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals Disconnecting this cable will help prevent personal injury and damage to the vehicle The ignition must also b...

Page 539: ...PECIFICATIONS Application Capacity Specific Gravity Max Tolerance Between Cells Description 90 Ah 1 24 0 04 Application Alternator Terminal B Nut Alternator Terminal D Nut Alternator Combinction Bolt Battery Cable Nut on Starting Motor Electric Wire Nut on Starting Motor Starting Motor Mounting Nut Battery Mounting Bracket Nut Battery Negative Cable Battery Positive Cable Ignition Cable Cover Bolt...

Page 540: ...M162 ENGINE ELECTRICAL 1E1 3 SPECIAL TOOLS SPECIAL TOOLS TABLE 120 589 02 09 00 Spark Plug Wrench ...

Page 541: ...he nut and disconnect the terminal 1 Installation Notice 1 Terminal B 2 Terminal D 3 CombinationBolt 4 Alternator 3 Unscrew the nut and disconnect the terminal 2 Installation Notice Tightening Torque 14 18 Nm 4 Unscrew the combination bolt 3 Installation Notice Tightening Torque 4 5 Nm 5 Remove the alternator 6 Installation should follow the removal procedure in the reverse order Tightening Torque...

Page 542: ...he removal procedure in the reverse order Tightening Torque 35 48 Nm STARTING MOTOR Removal Installation Procedure 1 Disconnect the ground cable 2 Unscrew the nut and disconnect the battery cable 1 Installation Notice 1 Battery Cable 2 EngineElectricWire 3 Unscrew the nut and disconnect the engine electric wire 2 Installation Notice Tightening Torque 12 15 Nm Tightening Torque 6 7 Nm ...

Page 543: ...l Cap 4 Nut 5 Fuseblink Box 6 Terminal 7 Battery holddown Bracket 8 Battery Clamp Bolt 9 Battery 10 Sub Tray 11 Battery Tray Removal Installation Procedure Notice l Disconnect the battery negative cable first l Insert the clamp bolt 8 into the battery tray hole 11 from inside when installing ...

Page 544: ...1 Ignition Coil Cable Cover 2 Bolt M6 X 60 7 pieces 9 11 Nm 3 Spark Plug SPARK PLUG Preceding Work Removal of intake air duct T1 1Ignition Coil Cylinder 2 and 5 T1 2Ignition Coil Cylinder 3 and 4 T1 3Ignition Coil Cylinder 1 and 6 ...

Page 545: ...ove the ignition cable cover Installation Notice Tightening Torque 9 11 Nm Tightening Torque 9 11 Nm Tightening Torque 9 11 Nm 2 Remove the two bolts M6 X 25 from each ignition cable and remove the ignition cable Installation Notice 3 Remove the spark plug using the special tool Installation Notice Spark Plug Wrench 120 589 02 09 00 ...

Page 546: ...TION CABLE Preceding Work Removal of intake air duct 1 Control Cable Connection 2 Ignition Cable 3 Spark Plug Connector 4 Coupling Plug 5a 5b Secondary Voltage Connection E Iron Core L2 Primary Ignition Coil L1 Secondary Ignition Coil ...

Page 547: ...econdary spark plug connectors from the each spark plugs and remove the ignition cable Installation Notice 3 The secondary output voltage 5a is supplied to the No 2 cylinder spark plug through the spark plug connector The secondary output voltage 5b is supplied to the No 5 cylinder spark plug through the ignition cable The guide pin W acts as a ground while the ignition cable is operated l Make su...

Page 548: ... and No 15 2 During engine cranking measure primary voltage T1 1 between ECU terminal No 71 and No 69 Notice If out of specified value replace the ignition coil Specified Value 0 9 1 6 W 20 C Specified Value 200 350 V Notice l Measure remaining cables T1 2 No 72 and 69 T1 3 No 70 and 69 l If out of specified value check ignition cable and ECU 3 Using a multi tester measure the secondary coil resis...

Page 549: ... battery and replace if any defects were found on it 2 Check if the specific gravity of the electrolyte is within the specified value Notice l Replace the battery if the maximum tolerance of the electrolyte between cells is out of the specified value l Measure the specific gravity in the approx 20 C of ambient temperature 3 Replenish the electrolyte if necessary Battery capacity Ah Battery specifi...

Page 550: ...g 1E2 7 Ignition Cable 1E2 9 Unit Repair 1E2 12 Battery 1E2 12 CAUTION Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals Disconnecting this cable will help prevent personal injury and damage to the vehicle The ignition must also be in LOCK unless otherwise noted TABLE OF...

Page 551: ...PECIFICATIONS Application Capacity Specific Gravity Max Tolerance Between Cells Description 90 Ah 1 24 0 04 Application Alternator Terminal B Nut Alternator Terminal D Nut Alternator Combinction Bolt Battery Cable Nut on Starting Motor Electric Wire Nut on Starting Motor Starting Motor Mounting Nut Battery Mounting Bracket Nut Battery Negative Cable Battery Positive Cable Ignition Cable Cover Bolt...

Page 552: ...M161 ENGINE ELECTRICAL 1E2 3 SPECIAL TOOLS SPECIAL TOOLS TABLE 120 589 02 09 00 Spark Plug Wrench ...

Page 553: ...e nut and disconnect the terminal 1 Installation Notice 1 Terminal B 2 Terminal D 3 Combination Bolt 4 Alternator 3 Unscrew the nut and disconnect the terminal 2 Installation Notice Tightening Torque 14 18 Nm 4 Unscrew the combination bolt 3 Installation Notice Tightening Torque 4 5 Nm 5 Remove the alternator 6 Installation should follow the removal procedure in the reverse order Tightening Torque...

Page 554: ...he removal procedure in the reverse order Tightening Torque 35 48 Nm STARTING MOTOR Removal Installation Procedure 1 Disconnect the ground cable 2 Unscrew the nut and disconnect the battery cable 1 Installation Notice 1 Battery Cable 2 Engine Electric Wire 3 Unscrew the nut and disconnect the engine electric wire 2 Installation Notice Tightening Torque 12 15 Nm Tightening Torque 6 7 Nm ...

Page 555: ...l Cap 4 Nut 5 Fuseblink Box 6 Terminal 7 Battery holddown Bracket 8 Battery Clamp Bolt 9 Battery 10 Sub Tray 11 Battery Tray Removal Installation Procedure Notice l Disconnect the battery negative cable first l Insert the clamp bolt 8 into the battery tray hole 11 from inside when installing ...

Page 556: ...Tools Required 119 589 01 09 00 Spark Plug Wrence 1 Screw 3 pieces 9 11 Nm 2 Adaptor 3 pieces 3 Ignition Coil Cable Cover 4 Spark Plug Connector 5 Ignition Coil Connector 6 Bolts M6 X 25 4 pieces 9 11 Nm 7 Ignition Coil T1 1 8 Coupling Plug 9 Spark Plug 25 30 Nm 10 Ignition Coil T1 2 ...

Page 557: ... coil and spark plug 4 Using the special tool remove the spark plug Installation Notice Spark Plug Wrench 119 589 01 09 00 Notice l Tighten the spark plug with specified torque l nstall the ignition coil to No 2 and 4 cylinder and connect the cable to No 1 4 and 2 3 cylinder T1 1 cylinder 1 and 4 T1 2 cylinder 2 and 3 3 Unscrew two bolts M6 X 25 from each ignition coil and remove the ignition coil...

Page 558: ...TION CABLE Preceding Work Removal of intake air duct 1 Control Cable Connection 2 Ignition Cable 3 Spark Plug Connector 4 Coupling Plug 5a 5b Secondary Voltage Connection E Iron Core L2 Primary Ignition Coil L1 Secondary Ignition Coil ...

Page 559: ...n cable duct cover Installation Notice 3 Seperate the cable from the ignition cable and the spark plug 4 Remove the 2 bolts from each ignition cable and remove the ignition cables Installation Notice Install the ignition cable to the cylinder 2 and 4 and connect the cable from 1 to 4 and from 2 to 3 T1 1 Cylinder 1 and 4 T1 2 Cylinder 2 and 3 5 Installation should follow the removal procedure in t...

Page 560: ...on coil if out of the specified resistance l T1 2 between No 71 and No 69 Notice Check the ignition cable and the ECU if out of the specified value 3 Measure the secondary cable resistance between the ignition coil 5a and 5b using a multimeter 2 Measure the primary voltage T1 1 between the ECU terminals No 72 and No 69 during the engine cranking starter motor activated Specified Value 6 8 5 KW Spe...

Page 561: ... battery and replace if any defects were found on it 2 Check if the specific gravity of the electrolyte is within the specified value Notice l Replace the battery if the maximum tolerance of the electrolyte between cells is out of the specified value l Measure the specific gravity in the approx 20 C of ambient temperature 3 Replenish the electrolyte if necessary Battery Capacity Ah Battery Specifi...

Page 562: ...talling any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals Disconnecting this cable will help prevent personal injury and damage to the vehicle The ignition must also be in LOCK unless otherwise noted Application Alternator Starter Glow Plug Description 12V 75A 12V 2 2kW 11 5V SPECIFICATIONS GENERAL SPECIFICATIONS Glow Plug 1E3 2 Alternat...

Page 563: ...on The preheating system consists of control coolant temperature sensor and glow plugs l Control relay preheating time l Coolant temperature sensor l Glow plug GLOW PLUG 1 Wiring Harness 2 Nut 4Nm 3 Wire Terminal 4 Glow Plug MAINTENANCE AND REPAIR ON VEHICLE SERVICE ...

Page 564: ...a parallel circuit with the specified voltage of 11 5V The heating element has a heating coil and a control coil and they are connected in series 1ControlCoil 2 HeaterCoil 4 Current and temperature of glow plug l Current of glow plug While the preheating system operates current of about 30A flows in each glow plug and temperature of heating coil rises very fast Due to the rise of temperature the r...

Page 565: ...icator comes on after starting for about one minute it indicates on or several plugs are faulty Possible cause One or several glow are faulty Problem Glow indicator does not come on in preheating time and comes on after starting the engine Glow indicator does not come on while preheating and after starting engine Glow indicator does not come on and engine s starting is difficult or does not start ...

Page 566: ...CAL 1E3 5 Removal Installation Procedure 1 Disconnect the negative terminal of battery 2 Remove the nut 2 3 Remove the glow plug 4 4 Install the glow plug 4 5 Tighten the nut 2 Tightening Torque 20 Nm Tightening Torque 4Nm ...

Page 567: ...1E3 6 OM600 ENGINE ELECTRICAL ALTERNATOR Preceding Work Removal of poly V belt 1 Cooling Fan 2 Bolt 45Nm 3 Bolt 45Nm 4 Alternator 5 Plug Connection ...

Page 568: ...negative terminal of the battery 2 Disconnect the plug connection 5 3 OM 662 Engine Align the groove of cooling fan with bolt 2 arrow 4 Remove the bolts 2 3 and take out the alternator 5 Installation should follow the removal procedure in the reverse order Tightening Torque 45 Nm ...

Page 569: ...sher 3 Nut 15Nm 4 Bolt 48Nm Removal Installation Procedure 1 Disconnect the battery terminals 2 Disconnect the starter motor cable harnesses 3 Remove the bolts and then remove the starter motor 4 Installation should follow the removal procedure in the reverse order ...

Page 570: ...n Numbers and Descriptions 1F1 5 Self Diagnosis Failure Code 1F1 6 Test Box Connection 1F1 9 Fuel Injection System Test MSE 3 62 1F1 10 Ignition System Test 1F1 20 Idling Control and Electronic Pedal System Test 1F1 25 Air Conditioner Control System Test 1F1 27 Fuel Pressure and Internal Leakage Test 1F1 28 Fuel Pump Test 1F1 30 Injector Test 1F1 32 Maintenance and Repair 1F1 34 On Vehicle Service...

Page 571: ...upply Line Fuel Distributor Assembly Bolt Pressure Test Connector Fuel Inlet and Outlet Line Fuel Filter Mounting Bracket Bolt Crankshaft Position Sensor Bolt Camkshaft Position Sensor Bolt Knock Sensor Mounting Bolt Coolant Temperature Bolt N m 25 30 22 5 27 5 21 6 26 4 25 30 4 8 9 11 9 11 22 5 27 5 18 22 ...

Page 572: ...M162 ENGINE CONTROLS 1F1 3 SPECIAL TOOLS SPECIAL TOOLS TABLE 129 589 00 21 00 Test Box 119 589 04 63 00 Pressure Hose 106 589 00 21 00 Pressure Tester 210 589 08 63 00 ECU Test Cable 210201 Adaptor Line ...

Page 573: ...1F1 4 M162 ENGINE CONTROLS SCHEMATIC AND ROUTING DIAGRAMS E32 ECU MSE ...

Page 574: ...ower Supply Fuse NO 17 4 REKES PIN 6 5 Engine Speed Signal MSE PIN 60 6 TCCU Part time 7 STICS PIN 26 8 9 10 Air Bag PIN 20 11 Remote Engine Start Unit PIN 10 12 13 Brake System ABS 5 3 PIN 11 ABS ABD 5 3 PIN 46 14 MSE 3 62S 3 53S ECU Data Output PIN 58 15 TOD PIN 20 16 Immobilizer 17 18 TCU PIN 23 19 20 K LINE ECS PIN 23 ...

Page 575: ...ailure TOD E32 only CAN communication failure communication initialization failure Fuel pump relay short PWR Fuel pump relay open short GND Purge valve short Failure code Description Purge valve open short Condenser fan HI relay short PWR Condenser fan HI relay short GND No 1 knock sensor signal failure No 2 knock sensor signal failure No 1 cylinder synchronization failure Cluster S W defectave No...

Page 576: ...130 131 132 Short learning control failure Lambda control failure rich stop Lambda control failure lean stop Lambda idle adaptation failure above rich threshold Lambda idle adaptation failure below lean threshold learning control failure rich low load learning control failure lean low load learning control failure rich high load learning control failure lean high load Low throttle position sensor ...

Page 577: ...essor relay open short GND Over acceleration limit Over acceleration limit CPU2 193 194 195 198 199 226 227 228 229 232 233 Failure code Description Failure code Description Control lever dual operation CPU2 Control lever safety terminal failure CPU2 Unusual pedal position variation CPU2 Unusal throttle position variation CPU2 Unusal throttle control data CPU2 Unusal pedal position sensor CPU2 Thr...

Page 578: ...NE CONTROLS 1F1 9 TEST BOX CONNECTION 1 ECU 2 Test Coupling No 1 60 3 Test Coupling No 61 120 4 Multi tester 01 Test Box 02 ECU Test Cable Tools Required 129 589 00 21 00 Test Box 210 589 08 63 00 ECU Test Cable ...

Page 579: ...2 11 14V Ground cable Battery ground Ground cable Ground condition Diagnosis socket 69 2 Diagnosis socket Þ 1 2 Ignition ON 1 12 11 14V Power supply terminal 30 TM 30 Power supply cable Diagnosis socket Þ 2 0 Ignition ON 5 11 11 14V ECU power supply terminal 87 TM 87 08 Þ 1 1 Þ 2 1 Þ 2 1 Ignition ON 11 14V Ground cable Electronic ground Ground cable 5 2 Diagnosis socket 1 11 Diagnosis socket Ignit...

Page 580: ...d 4 7 5 2V Cable ECU coupling HFMsensor 5V power supply HFM sensor Þ 4 2 3 108 Ignition ON HFM sensor connectorremoved 4 7 5 2V Þ 4 3 Cable HFMsensor 5V power supply HFM sensor Þ 4 3 104 2 Ignition ON HFM sensor connectorremoved 11 14V Cable OVPR HFMsensor 12V power supply HFM sensor 03 04 05 Þ 5 0 Intake air temperature sensor Voltage 105 80 Ignition ON Þ 5 1 ECU 5 Þ 5 1 Ignition OFF No 2 ECU cou...

Page 581: ...on switch is turned to ON after stopping the engine Engine cranking 33 11 Cable Fuel pump relay Fuel pump relay Operation 34 11 14V approx 1 2sec 11 14V Cranking or driving 5 33 Þ 7 1 Ignition OFF Remove the No 2 coupling from ECU 79 78 Þ 7 2 Cable Coolant temperature sensor Resistance cable C W 20 2500 80 322 100 185 5 Þ 7 2 Coolant temperature sensor Resistance Coolant temperature sensor 1 4 Rem...

Page 582: ...ygen sensor Heating function operated Þ 11 0 No 1 cylinder injector Operating injection time When the coolant temperature is approx 20 C Engine in cranking 8 0 ms Cable ECU No 1 Injector Coolant temperature sensor Oxygen sensor Intake air temperature sensor Voltage Engine in cranking or idle above 5V in idling 16 17 5 9 9 11 Ignition ON 11 14 V ECU Cable Oxygen sensor Current consumption 0 2 2 0 A...

Page 583: ... the coolant temperature is approx 80 C Engine at idling speed Engine at sharp acceleration full throttle refer to figure 3 and 4 approx 2 7 5 0ms approx 14ms Ignition OFF injector temperature is 20 C 14 17 W Internal resistance No 2 injector 61 11 Þ 13 0 No 3 cylinder injector Operating injection time When the coolant temperature is approx 20 C Engine in cranking 8 0 ms Cable ECU No 3 Injector Co...

Page 584: ...the coolant temperature is approx 80 C Engine at idling speed Engine at sharp acceleration full throttle refer to figure 3 and 4 approx 2 7 5 0ms approx 14ms Ignition OFF injector temperature is 20 C 14 17 W Internal resistance No 4 injector 62 11 192 193 Þ 15 0 No 5 cylinder injector Operating injection time When the coolant temperature is approx 20 C Engine in cranking 8 0 ms Cable ECU No 5 Inje...

Page 585: ...n the coolant temperature is approx 20 C Engine in cranking 8 0 ms Cable ECU No 6 Injector Coolant temperature sensor Oxygen sensor Intake air temperature sensor 194 195 64 11 When the coolant temperature is approx 80 C Engine at idling speed Engine at sharp acceleration full throttle refer to figure 3 and 4 approx 2 7 5 0ms approx 14ms Ignition OFF injector temperature is 20 C 14 17 W Internal re...

Page 586: ...chanical Actuation Mechanical failure of camshaft actuator Þ 20 0 Engine in idling 34 11 The purge control valve should be operated after approx 1minute refer to figure 5 Purge control valve Operating 226 227 ECU Cable Purge control valve Ignition ON 0 3 0 5 A Current consumption 10 34 Creating above 50mbar of vacuum after approx 1 minute Þ 22 0 Ignition OFF 38 37 Databus Þ 22 1 Þ 22 2 55 65 W CAN...

Page 587: ...module resistance in ABS ABD ASR control unit Cable ABS ABD ASR control unit Ignition OFF disconnect the coupling No 1 from ECU Þ 22 2 38 37 115 125 W CAN module resistance in ECUcontrol unit ECU Ignition OFF disconnect the coupling No 1 from ECU Þ 23 0 5 58 11 14 V Diagnosis cable operating ECU Cable Ignition ON 22 23 24 26 27 29 30 31 59 60 ...

Page 588: ...ENGINE CONTROLS 1F1 19 Reference Figures Figure2 RPM Sgnal Output Figure 3 Injection Valve Wave at idle speed Figure 4 Injection Valve Wave at sharp acceleration Figure 5 Purge Control Valve Operationg Wave ...

Page 589: ...nd Ground cable Ground condition figure1 Diagnosis socket 69 2 Diagnosis socket Þ 1 2 Ignition ON 1 12 11 14V Power supply terminal 30 TM 30 Power supply cable Fuse No 8 Diagnosis socket Þ 2 0 Ignition ON 5 11 11 14V ECU power supply terminal 87 TM 87 08 Þ 2 1 Þ 2 2 Þ 2 1 Ignition ON 11 14V Ground cable Electronic ground Ground cable 5 2 Diagnosis socket 1 11 Diagnosis socket Ignition OFF 11 14V 1...

Page 590: ...ivenplate 5 V 99 100 99 100 1050 1400W Þ 7 0 Engine in cranking 104 106 Þ 7 1 Cable Camshaft position sensor Measure the signal refer to figure 7 Camshaft position sensor Signal Þ 4 0 Ignition ON 69 72 11 14 V Ignition coil T1 2 No 3 4 Cylinder 65 Cable Ignition coil T1 2 Fuse No 17 Engine in cranking 10 V Engine in idling Voltage alternating Engine in cranking Engine in idling 2 5 V 19 58 Þ 5 0 I...

Page 591: ...starteroperating Measuring range 400 V Timerange 100 usingenginetester Ignition OFF 200 350 V Camshaft position sensor 64 Þ 8 0 Þ 8 1 Þ 8 1 Connecting resistance of ignition coil between T1 1 and T1 2 Cable Ignition coil T1 1 Ignition coil T1 2 72 11 Ignition coil T1 2 primary coil voltage No 3 and 4 cylinder Engine in cranking starteroperating Measuring range 400 V Timerange 100 usingenginetester...

Page 592: ...ion coil T1 1 T1 2 T1 3 Secondary coil resistance Remove the high tension cable of T1 1 T1 2 T1 3 Þ 11 1 Ignition coil T1 1 T1 2 T1 3 Ignition coil T1 1 Ignition coil T1 2 Ignition coil T1 3 TM 4a TM 4b 56 11 Ignition coil T1 3 primary coil voltage No 1 and 6 cylinder Engine in cranking starteroperating Measuring range 400 V Timerange 100 200 350 V 66 Þ 10 0 Þ 10 1 0 9 1 6 W 70 72 Ignition OFF Þ 1...

Page 593: ...Crankshaft Position Sensor Signal a Voltage b Identifying the No 1 2 Missing Teeth Figure 7 Camshaft Position Sensor Signal Figure 8 Signal Function 1 Crank Angle 2 Cylinder 3 Crankshaft Position Sensor Signal 4 Camshaft Position Sensor Signal 5 RPM Signal ...

Page 594: ... 160 161 164 167 4 3 4 8 V Þ 1 1 Cable Pedal valve sensor Þ 1 1 Ignition ON 31 32 4 75 5 25 V Pedal valve sensor Power supply potentiometer 1 Cable ECU Þ 2 0 Ignition ON Position of accelerator pedal Closed throttle position Full throttle with kick down 50 48 0 1 0 4 V Pedal valve sensor Signal potentiometer 2 162 163 164 167 2 1 2 5 V Þ 2 1 Cable Pedal valve sensor Þ 3 0 Engine in idling 84 87 0 ...

Page 595: ...alue will be changed in 1 0 2 5V Throttle valve actuator Signal Throttle valve actuator motor voltage supply 104 105 108 109 116 119 185 ECU Cable E GAS actuator Engine in idling Coolant temperature 70 C 84 85 4 0 4 6 V Throttle valve potentiometer 2 0 3 0 9 V Position of accelerator pedal Closed throttle position Full throttle with kick down Throttle valve potentiometer 1 2 Ignition OFF 10 W Thro...

Page 596: ...conditioner switch ON OFF Air conditioner switch OFF Air conditioner switch ON Test step Requirement Specified value Possible cause 10 44 1 V Air conditioner signal Input signal input signal from thermo amplifier 44 45 11 14 V Þ 5 1 Cable Thermo amp Auto amp Dual pressure switch Air conditioner control panel Þ 1 1 Engine In idling Air conditioner switch ON OFF Air conditioner switch OFF Air condit...

Page 597: ...n Connection of the Equipment 1 Turn the ignition switch to OFF position 2 Remove the air cleaner cross pipe 3 Remove the cap on fuel pressure test plug and connect the pressure hose and pressure tester 4 Prepare the beaker for measuring the amount of fuel Tools Required 103 589 00 21 00 Pressure Tester 119 589 04 63 00 Pressure Hose ...

Page 598: ...ator 3 7 4 2 bar Fuel pressure in idling speed When the vacuum is not applied Engine in idling Close the valve screw on pressure tester Þ 2 0 Connect the fuel pressure test plug to the pressure tester refer to the flgure on previous page Fuel pressure regulator 3 0 bar Fuel system internal leakage Engine stop Þ 3 0 Connect the fuel pressure test plug to the pressure tester refer to the flgure on p...

Page 599: ... 120 4 Stop Watch 5 Measuring Beaker Connection of the Equipment 1 Turn the ignition switch to OFF position 2 Connect the test box to the ECU 03 Test Box 04 ECU Test Cable Tools Required 103 589 00 21 00 Pressure Tester 210 589 00 99 00 Adaptor Line 129 589 00 21 00 Test Box 210 589 08 63 00 Ecu Test Cable ...

Page 600: ...he fuel return pipe and connect the host to beaker to collect the supplied fuel Þ 1 0 Þ 2 0 Check the fuel line 5 9 A Fuel pump Current consumption Ignition ON Remove the fuel relay from the fuse and relay box in luggage compartment and connect the amperemeter between No 1 and No 3 in relay box fuel pump relay removedposition for measuring current consumption Þ 2 0 Fuel pump 5 33 Multi tester DC c...

Page 601: ...jector with a unit At this time do not remove the supply and return line 4 Connect the shop made cable to the injector with a firing order 5 Collect the fuel from injector Tools Required 129 589 00 21 00 Test Box 210 589 08 63 00 Ecu Test Cable INJECTOR TEST 1 ECU 2 Test Coupling No 1 60 3 Test Coupling No 61 120 4 Measuring Beaker 5 Shop Made Cable Preparation 03 Test Box 04 ECU Test Cable ...

Page 602: ...er drops from the injector Injector Leakage test Ignition ON Remove the fuel distributor and fuel injector with a unit Þ 1 0 The spray pattern of the injector most show inthe figure10 Ignition ON Connect the shop made cable to the injector Collect the spraying fuel with a beaker Connect the shop made cable to No 21 and No 3 terminal in test box Þ 2 0 Injector 5 33 Injector Function test and spray ...

Page 603: ...AND REPAIR ON VEHICLE SERVICE ECU Appearance 1 Cover 2 Plate 3 Connector 4 Flat Pin Vehicle Side Number 1 12 Engine Side Number 61 72 5 Pin Vehicle Side Number 13 60 Engine Side Number 73 120 A Vehicle Connector Black B Engine Connector Gray ...

Page 604: ...urn the ignition switch to OFF position 2 Disconnect the battery negative cable 3 Remove the cowl side trim form passenger side 4 Unscrew four securing nuts for ECU from mounting bracket Installation Notice 5 Pulling out the ECU from bracket 6 Disconnect the vehicle side coupling B 7 Installation should follow the removal procedure in the reverse order Tightening Torque 9 11 Nm ...

Page 605: ... TM 50 GND LSH1 TM 31 TM 87 TM 30 WFS I O WFS O GND LS1 Starter motor TM 50 Electronic ground Lambda probe 1 heating Power ground TM 31 V BATTERY TM 87 V BATTERY TM 30 Immobilizer crypto read Immobilizer crypto write Lambda probe 1 ground Lambda probe 1 signal ECU Pin Numbers and Descriptions Vehicle Connector ...

Page 606: ...h Air conditioning clutch relay Starter control 1 Pedal potentiometer 1 ground Pedal potentiometer 1 supply Fuel pump relay Tank purge valve Engine fan CAN Low CAN High Clutch switch Air conditioning Electronic traction signal Pedal potentiometer 1 signal Pedal potentiometer 2 signal Brake light switch Pedal potentiometer 2 ground Pedal potentiometer 2 supply Cruise accelerate Set Cruise resume Cr...

Page 607: ...ZSC16 ZSA25 ZSB34 NWS MT GND LT Injector cylinder 2 Injector cylinder 4 Injector cylinder 1 Injector cylinder 6 Injector cylinder 5 Injector cylinder 3 E GAS motor plus E GAS motor minus Power ground TM 31 Ignition coil cylinder 1 6 Ignition coil cylinder 2 5 Ignition coil cylinder 3 4 Camshaft control Engine coolant temperature Temperature ground Intake air temperature ...

Page 608: ...E V REF HFM V REF DK GND KS2 GND KS1 Hot film air mass signal E GAS potentiometer ground E GAS potentiometer 2 signal E GAS potentiometer 1 signal Intake manifold resonance flap Crankshaft sensor ground Crankshaft sensor signal Camshaft sensor ground Hot film air mass ground Camshaft sensor signal Hot film air mass supply E GAS potentiometer supply Knock sensor 2 ground Knock sensor 2 signal Knock...

Page 609: ...pto read Immobilizer crypto write Lambda probe 1 ground Lambda probe 1 signal Brake switch Air conditioning clutch relay Starter control E32 ENG 5speed M T E32 ENG 4speed A T BTRA 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 TM 50 GND LSH1 TM 31 TM 87 TM 30 WFS I O WFS O GND LS1 BRS KLIKU START l l l l l l l l l l l l l l l l l l l l l l Remarks l Standard Optio...

Page 610: ...d Pedal potentiometer 2 supply Cruise accelerate Set Cruise resume Cruise decelerate Set Cruise safety contact switch Cruise off switch Diagnostics Vehicle speed signal Engine speed signal 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 GND SP1 5V KP TEV ML CAN L CANH KPL KLIMA ETS SP1S SP2S BLS GND SP2 2 5V S B WA S B KSK AUS DIAG V SIG TN SIG l l l l l l...

Page 611: ... 31 Ignition coil cylinder 1 6 Ignition coil cylinder 2 5 Ignition coil cylinder 3 4 Camshaft control Engine coolant temperature Temperature ground Intake air temperature Hot film air mass signal E GAS potentiometer ground E GAS potentiometer 2 signal E GAS potentiometer 1 signal EV5 EV6 EV1 EV4 EV2 EV3 M M TM 31 ZSC16 ZSA25 ZSB34 NWS MT GND LT HFM GND IP2S IP1S l l l l l l l l l l l l l l l l l l...

Page 612: ...ir mass supply E GAS potentiometer supply Knock sensor 2 ground Knock sensor 2 signal Knock sensor 1 ground Knock sensor 1 signal 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 SRV KW KW NOWE GND NOWE V REF HFM V REF DK GND KS2 GND KS1 l l l l l l l l l l l l l l l l l l l l l l l l Remarks Abbreviation E32 ENG 5speed M T E32 ENG 4spe...

Page 613: ...6 8 Nm 5 7 Nm 1 3 Tightening Torque 5 7 Nm 8 Unscrew the bolts 5 and disconnect the ECU 6 from the bracket assenbly Installation Notice l When Removing the ECU with ABS or ABS ASR Unit 1 Turn the ignition switch to OFF position 2 Disconnect the negative battery cable 3 Disconnect the couplings from ECU 4 Disconnect the coupling from ABS or ABS ASR unit 5 Unscrew the bolt 1 and the left and right f...

Page 614: ...M162 ENGINE CONTROLS 1F1 45 1 Vacuum Hose 2 Circlip 3 Fuel Pressure Regulator FUEL PRESSURE REGULATOR 4 O ring replace 5 O ring replace ...

Page 615: ... oil to O ring lightly and then replace it 6 Installation should follow the removal procedure in the reverse order 7 Check for fuel pressure and internal leaks by operating the engine 2 Discharge the pressure in fuel supply system by pressing the service valve Removal Installation Procedure 1 Remove the fuel pressure test connector ...

Page 616: ...phragm 6 CompressionSpring 8 FuelChamber 9 SpringChamber 1 FuelPressureRegulator 2 IntakeManifold 3 Fuel Return to fuel tank 4 Fuel Supply form fuel pump 5 Fuel Pressure approx 3 8 bars 6 Intake Manifold Negative Pressure 0 bar Function of the Fuel Pressure Regulator The fuel pressure regulator maintains the fuel pressure in the fuel line with the pressure of 3 2 bars to 3 8 bars according to the ...

Page 617: ...prox 3 2 bars during idling Fuel Pressure Diagram 1 FuelPressureRegulator 2 IntakeManifold 3 Fuel Return to fuel tank 4 Fuel Supply from fuel pump 7 Fuel Pressure approx 3 2 bars 8 Intake Manifold Negative Pressure 0 6 bars A Fuel pressure B IntakeManifoldNegativePressure LL Idling TL Partialload VL Fullload ...

Page 618: ...Vacuum Hose 2 Fuel Return Line 25 30Nm 3 Fuel Supply Line 25 30Nm 4 Injector Connector FUEL DISTRIBUTOR Preceding Work Removal of intake air duct 5 Bolt M8 X 50 22 5 27 5 Nm 6 Fuel Distributor 7 O ring Replace if damaged 8 Injector ...

Page 619: ...emove the fuel return and supply line Notice l For removal cover around parts with cloths not to be stained by fuel l In case of checking the injector only do not remove the fuel return and supply line Installation Notice 6 Remove the six injector connectors 7 Remove the two left and two right bolts and one center bolt of the fuel distributor assembly from the intake manifold Installation Notice T...

Page 620: ...kage by operating the engine Fuel Pressure Test 1 Turn the ignition switch to OFF position 2 Remove the fuel pressure test connector Vacuum Hose Connected bar 3 2 3 6 Vacuum Hose Disconnected bar 3 7 4 2 5 Replace the pressure regulator diaphragm if out of the specification 3 Connect the fuel pressure gauge to the fuel pressure test connector 4 Test the fuel pressure at idling by operating the eng...

Page 621: ...l pressure drops slowly Fuel leakage at the injector Faulty fuel pressure regulator s diaphragm and O ring Fuel pressure drops rapidly Faulty check valve in the fuel pump Possible Cause Pressure Change Fuel Pressure bar 2 5 Discharging the pressure in fuel system 1 Remove the fuel pressure test connector Installation Notice 2 Remove the fuel pressure in fuel system by pressing the service valve wi...

Page 622: ...M162 ENGINE CONTROLS 1F1 53 INJECTOR Preceding Work Removal of fuel distributor 1 O ring rplace if damaged 2 Injector Bracket 3 Injector 4 O ring replace if damaged 5 Fuel Distributor ...

Page 623: ...e shop made test plug to the injector and place it into the tank 3 Position the ignition switch to ON 4 Connect the pin 63 and 69 of the contact box with a test cable 5 Check the injector spray pattern Notice Replace the injector if the injector spray pattern is abnormal or the fuel doesn t inject Injector Resistance Inspection 1 Remove the injector connector 2 Measure the injector coil resistance...

Page 624: ...y and return line Notice Prepare the beaker for taking the poping fuel 4 Connect either end of shop made cable to the injector 5 Connect the other end of shop made cable to the 63 and 69 terminal of the test box 6 Turn the ignition switch to ON position 7 Check the injector for normal spray pattern as shown in the figure Check injector for leaks or later drops Notice Refer to fuel injector test of...

Page 625: ...lation Notice Notice Place the fuel pump pad There may be a corrosion due to the contact between the fuel filter and the bracket 4 Check for leaks by operating the engine Notice Installation should follow the removal procedure in the reverse order 3 Remove the mounting bracket bolt 4 and remove the fuel filter 1 Installation Notice 3 Inlet Tightening Torque 25 30 Nm Tightening Torque 4 8 Nm ...

Page 626: ...V 3 8 bar 30 70 C Minimum pressure 5 0 bar 12 V Maximum allowable current 7 5 A Nominal voltage 12 V Ambient temperature 30 70 C 1 Reservoir Tank 2 Fuel Sensor float arm 3 Resistance 4 Wiring Connector 5 Fuel Supply Pipe 7 Float 10 Flange and Harness Assembly 11 Fuel Pump 12 Spring 13 Thermister Housing 14 Thermister 15 Resistor Card and Wiper 16 Float Arm Operating voltage 8 V Maximum amount of f...

Page 627: ...l Pump Connector Wiring 2 Fuel Return Pipe 3 Fuel Supply Pipe 4 Bolts 5 Fuel Return Pipe 6 Fuel Supply Pipe 7 Float 8 Ground Stud Sender COLOR Pump Thermister Ground Sender Unit USE Harness Location Connector A B C D 2 0 BR 0 5 W 2 0 B 0 5 RY ...

Page 628: ...t the negative battery cable 2 Disconnect the harness connector 1 3 Disconnect the fuel supply 6 and return 5 pipes 4 Using a special tool Unscrew the eight fuel retaining bolts and remove the pump from fuel tank Notice Check the condition of the seal and replace if necessary Drain the fuel before removing the pump ...

Page 629: ... ON position 2 Using a multi tester measure the current consumption by connecting the terminal No 1 and No 3 of pump Measure the Fuel Delivery From the Fuel Pump 1 Disconnect the return pipe from fuel distributor and insert the appropriate hose into it 2 Place the hose end into the beaker with the minimum capacity of 1Liter 3 Turn the ignition switch to ON position 4 Connect the terminal No 33 and...

Page 630: ...ept the decreasing mode and coolant temperature of over 80 C For this reason the ECU transacts the engine speed air inflow quantity coolant temperature and intake temperature The purge switchover valve is activated by the ECU frequency according with the engine rotating speed to adjust the purification rate The purification rate is determined by the continuous valve opening interval The purge swit...

Page 631: ...utput waves using the scanner Notice Test during purge control switchover valve operation after the minimum of 1 minute after the engine turned on 3 Connect the ECU terminal No 34 and No 10 and check for current consumption during the ignition switch ON Purge switchover valve output wave Specified Value 0 3 0 5 Specified Value 50mbar after approx 1min purge switchover valve operates at this time N...

Page 632: ... 3 Insulator 4 Fuel Tube 5 Molded Hose 6 Idle Regulator 7 Resonance Flap 8 Intake Manifold 9 Fuel Pressure Regulator 10 Vacuum Line Rubber Hose 11 Vacuum Tube Gray 270mm 12 Molded Hose 13 Rubber Cap 18 Rubber Hose 19 Vacuum Tube Brown or Black 770mm 20 Rubber Hose A To Canicter ...

Page 633: ...OR Removal Installation Procedure 1 Disconnect the wiring connector at the crankshaft position sensor 2 Unscrew the bolt and remove the crankshaft position sensor unit Installation Notice 3 Installation should follow the removal procedure in the reverse order 3 Segment 4 Flywheel Tightening Torque 9 11Nm ...

Page 634: ...sure the output wave between the ECU terminals No 99 and No 100 using the scanner or the oscilloscope while engine cranking starter motor activated Notice Check the segment or crankshaft position sensor and air gap if cannot get the output wave as shown in the figure Specified Value 1050 1400 W Specified Value 20kW Crankshaft Position Sensor Insulator Resistance Inspection 1 Disconnect the engine ...

Page 635: ...ng connector from the camshaft position sensor 2 Unscrew the bolt 2 and remove the camshaft position sensor Installation Notice 3 Shim 5 O ring Tightening Torque 9 11 Nm 3 Check the clearance and replace the shim if necessary 4 Check the O ring for damage and replace it if necessary 5 Installation should follow the removal procedure in the reverse order ...

Page 636: ...age will be changed in the range of 1 2 1 7V Camshaft Position Sensor Output Wave Inspection 1 Connect the test box to the ECU 2 Measure the output wave between the ECU terminal No 104 and No 106 using the scanner or the oscilloscope while the engine speed is at idle Notice Replace the camshaft position sensor if cannot get the output wave as shown in the figure Specified Value 11 14 V Specified V...

Page 637: ... in the figure in the right so that it gets separated from the contact surface Notice Make sure the HFM sensor coupling connects completely with the contact surface Installation 2 Remove the clip with a screw driver 3 Pry off two tensioning clamps 4 Remove the HFM sensor 5 Installation should follow the removal procedure in the reverse order 4 Connector 5 Hot film Sensor 6 Measuring Port ...

Page 638: ...M162 ENGINE CONTROLS 1F1 69 Circuit Diagram 1 Housing 2 Electronic Housing 3 Connector RH Heat Resistance RT Temperature Resistance RS Sensor Resistance ...

Page 639: ...FM sensor signal voltage between the ECU terminal No 81 and No 105 Specified Value coolant temperature is over 70 C If the measured value is not within the specified value the possible cause may be in cable or ECU coupling HFM Sensor 12V Power Supply Inspection 1 Measure the voltage between the HFM sensor No 2 pin and No 3 after removing the HFM sensor connector If the measured value is not within...

Page 640: ...il 7 Open Space 8 Protector Tube Functions The oxygen sensor optimizes the combustion Air Fuel Ratio 14 7 1 and resets the Air fuel ratio in the ECU after sensing the amount of oxygen from the exhaust gases to diminish the exhaust gases Rich 1 above approx 450mV Lean 1 below approx 450mV Locatoin of Sensor Oxygen sensor is located on the front exhaust pipe ...

Page 641: ... voltage between the ECU terminal No 11 and No 9 Maintain the engine speed ia at idle while the coolant temperature is over 80 C If the measured value is not within the specified value the possible cause may be in cable oxygen sensor or ECU Oxygen Sensor Heating Current Consumption Inspection 1 Measure the oxygen sensor heating current consumption between the ECU terminal No 9 and No 5 while the i...

Page 642: ...lock to recognize knocking in all cylinders The ECU compares the signal and the retards firing point Removal Installation Procedure 1 Disconnect the knock sensor connector from the intake manifold bracket 2 Unscrew the mounting bolt M8 X 28 from the knock sensor installed on the cylinder block and remove the knocking sensor Installation Notice 3 Installation should follow the removal procedure in ...

Page 643: ...the pressure by opening the pressure cap in the coolant subtank 2 Disconnect the connector and remove the coolant temperature sensor Installation Notice Replace the seals with new one 3 Installation should follow the removal procedure in the reverse order 4 Check for leaks at each connections after starting the engine 4 Connector 5 Coolant Temperature Sensor Tightening Torque 18 22 Nm ...

Page 644: ...onnected Inspection 1 Measure the coolant sensor input voltage between the ECU terminal No 79 and No 78 while the ignition switch in ON position Notice Replace wiring and coolant temperature sensor if out of specified value allowable error 5 allowable error 5 Voltage V 3 57 1 22 0 78 Temperature C 20 30 40 Resistance W 2 500 322 185 Temperature C 20 30 40 ...

Page 645: ...oltage V Temperature C Resistance W Voltage V 40 48 550 4 8991 60 594 1 8632 30 27 000 4 8214 70 434 1 5132 20 15 670 4 7001 80 322 1 2179 10 9 450 4 5215 90 243 0 9775 0 5 890 4 4273 100 185 0 7806 10 3 790 3 9562 110 143 0 6255 20 2 500 3 5714 120 111 6 0 5020 30 1 692 3 1426 130 88 0 0 4044 40 1 170 2 6959 140 71 2 0 3323 50 826 2 2618 ...

Page 646: ...m Removal and Installation Procedure 1 Disconnect the 6 pin connector arrow 2 Unscrew the 2 bolts 3 1 nut 6 and remove the pedal and sensor assembly Installatoin Notice Tightining Torque 4 8 Nm 2 Installation should follow the removal procedure in the reverse order 4 6 Pin Connector 5 Kick Down Switch 6 Nut 1 Piece 4 8 Nm ...

Page 647: ...nector VehicleSide Potentiometer 1 Pin no 3 Red Black Pin no 1 Blue Green Pin no 5 Yellow Green Potentiometer 2 Pin no 6 Green Pin no 4 Blue Red Pin no 2 LightGreen Function Potentiometer 1 Power Supply Potentiometer 1 Signal Potentiometer 2 Ground Potentiometer 2 Power Supply Pin no 3 Pin no 1 Pin no 5 Pin no 6 Pin no 4 Pin no 2 Potentiometer 2 Signal Potentiometer 2 Ground Circuit Diagram Potent...

Page 648: ...cket Pin Numbers and Descriptions 1F2 6 Self Diagnosis Failure Code for E23 ENG 1F2 7 Test Box Connection 1F2 10 Fuel Injection System Test 1F2 11 Ignition System Test 1F2 20 Idling Control and Electronic Pedal System Test 1F2 25 Air Conditioner Control System Test 1F2 27 Fuel Pressure and Internal Leakage Test 1F2 28 Fuel Pump Test 1F2 30 Injector Test 1F2 32 Maintenance and Repair 1F2 34 On Vehi...

Page 649: ...upply Line Fuel Distributor Assembly Bolt Pressure Test Connector Fuel Inlet and Outlet Line Fuel Filter Mounting Bracket Bolt Crankshaft Position Sensor Bolt Camkshaft Position Sensor Bolt Knock Sensor Mounting Bolt Coolant Temperature Bolt N m 25 30 22 5 27 5 21 6 26 4 25 30 4 8 9 11 9 11 22 5 27 5 18 22 ...

Page 650: ...M161 ENGINE CONTROLS 1F2 3 SPECIAL TOOLS SPECIAL TOOLS TABLE 129 589 00 21 00 Test Box 119 589 04 63 00 Pressure Hose 106 589 00 21 00 Pressure Tester 210 589 08 63 00 ECU Test Cable 210201 Adaptor Line ...

Page 651: ...1F2 4 M161 ENGINE CONTROLS SCHEMATIC AND ROUTING DIAGRAMS E23 ECU MSE ...

Page 652: ...M161 ENGINE CONTROLS 1F2 5 E20 ECU MSE ...

Page 653: ...ower Supply Fuse NO 17 4 REKES PIN 6 5 Engine Speed Signal MSE PIN 60 6 TCCU Part time 7 STICS PIN 26 8 9 10 Air Bag PIN 20 11 Remote Engine Start Unit PIN 10 12 13 Brake System ABS 5 3 PIN 11 ABS ABD 5 3 PIN 46 14 MSE 3 62S 3 53S ECU Data Output PIN 58 15 TOD PIN 20 16 Immobilizer 17 18 TCU PIN 23 19 20 K LINE ECS PIN 23 ...

Page 654: ...lant temperature sensor open Coolant temperature sensor short Coolant temperature sensor signal failure Intake temperature sensor open Intake temperature sensor short Intake temperature sensor signal failure Low battery voltage HFM sensor signal failure HFM sensor signal failure Low HFM sensor signal failure High Crankshaft position sensor signal failure no engine revolution signal Crankshaft posi...

Page 655: ...0 151 160 161 162 163 164 167 185 186 187 188 189 190 192 193 194 195 198 199 226 227 228 learning control failure lean high load Low throttle position sensor IP1 voltage High throttle position sensor IP1 voltage Low throttle position sensor IP2 voltage High throttle position sensor IP2 voltage Throttle actuator learning data fault Throttle actuator learning control failure Exceed fuel cut safety ...

Page 656: ...2 Cycle monitor fault degected by CPU2 A C compressor relay open short GND Decel limit defected by CPU2 Accel limit defected by CPU2 Cruise control lever double input CPU2 Cruise control lever safety terminal failure CPU2 Unusual pedal position variation CPU2 Unusual throttle position variation CPU2 Unusual throttle control data CPU2 Unusual pedal position sensor CPU2 Throttle potentiometer fault ...

Page 657: ...1 ENGINE CONTROLS TEST BOX CONNECTION 1 ECU 2 Test Coupling No 1 60 3 Test Coupling No 61 120 4 Multi tester 01 Test Box 02 ECU Test Cable Tools Required 129 589 00 21 00 Test Box 210 589 08 63 00 ECU Test Cable ...

Page 658: ... 14V Ground cable Battery ground Ground cable Ground condition Diagnosis socket 69 2 Diagnosis socket Þ 1 2 Ignition ON 1 12 11 14V Power supply terminal 30 TM 30 Power supply cable Diagnosis socket Þ 2 0 Ignition ON 5 11 11 14V ECU power supply terminal 87 TM 87 08 Þ 1 1 Þ 2 1 Þ 2 1 Ignition ON 11 14V Ground cable Electronic ground Ground cable 5 2 Diagnosis socket 1 11 Diagnosis socket Ignition ...

Page 659: ...FM sensor Þ 4 2 3 108 Ignition ON HFM sensor connector removed 4 7 5 2V Þ 4 3 Cable HFM sensor 5V power supply HFM sensor Þ 4 3 104 2 Ignition ON HFM sensor connector removed 11 14V Cable OVPR HFM sensor 12V power supply HFM sensor 03 04 05 Þ 5 0 Intake air temperature sensor Voltage 105 80 Ignition ON Þ 5 1 ECU Þ 5 1 Ignition OFF No 2 ECU coupling removed 105 80 Cable HFM sensor Intake air temper...

Page 660: ...n switch is turned to ON after stopping the engine Engine cranking 33 11 Cable Fuel pump relay ECU Fuel pump relay Operation 34 35 11 14V approx 1 2sec 11 14V Cranking or driving 5 33 Þ 7 1 Ignition OFF Remove the No 2 coupling from ECU 79 78 Þ 7 2 cable Coolant temperature sensor Resistance cable C W 20 2500 80 322 100 185 5 Þ 7 2 Coolant temperature sensor Resistance Coolant temperature sensor 1...

Page 661: ...ygen sensor Heating function operated Þ 11 0 No 1 cylinder injector Operating injection time When the coolant temperature is approx 20 C Engine in cranking 8 0 ms Cable ECU No 1 Injector Coolant temperature sensor Oxygen sensor Intake air temperature sensor Voltage Engine in cranking or idle above 5V in idling 16 17 5 9 9 11 Ignition ON 11 14 V ECU Cable Oxygen sensor Current consumption 0 2 2 0 A...

Page 662: ... the coolant temperature is approx 80 C Engine at idling speed Engine at sharp acceleration full throttle refer to figure 3 and 4 approx 2 7 5 0ms approx 14ms Ignition OFF injector temperature is 20 C 14 17 W Internal resistance No 2 injector 64 11 Þ 13 0 No 3 cylinder injector Operating injection time When the coolant temperature is approx 20 C Engine in cranking 8 0 ms Cable ECU No 3 Injector Co...

Page 663: ...r Oxygen sensor Intake air temperature sensor 78 79 66 11 When the coolant temperature is approx 80 C Engine at idling speed Engine at sharp acceleration full throttle refer to figure 3 and 4 approx 2 7 5 0ms approx 14ms Ignition OFF injector temperature is 20 C 14 17 W Internal resistance No 4 injector 66 11 226 227 Þ 15 0 Camshaft actuator Current consumption 1 2 Camshaft actuator 1 1 5 A ECU Þ ...

Page 664: ...amshaft actuator Mechanical actuation E23 only Mechanical failure of camshaft actuator Þ 17 0 Engine in idling 34 11 The purge control valve should be operated after approx 1minute refer to figure 5 Purge control valve Operating 226 227 ECU Cable Purge control valve Ignition ON 0 2 0 4 A Current consumption 10 34 Creating above 50mbar of vacuum after approx 1 minute Þ 19 0 Ignition OFF 38 37 Data ...

Page 665: ...115 125 W CAN module resistance in ABS ABD ASR control unit Cable ABS ABD ASR control unit Ignition OFF disconnect the coupling No 1 from ECU Þ 19 2 38 37 115 125 W CAN module resistance in ECU control unit ECU Ignition OFF disconnect the coupling No 1 from ECU Þ 20 0 5 58 11 14 V Diagnosis cable operating ECU Cable Ignition ON ...

Page 666: ...ENGINE CONTROLS 1F2 19 Reference Figures Figure1 RPM Sgnal Output Figure 2 Injection Valve Wave at idle speed Figure 3 Injection Valve Wave at sharp acceleration Figure 4 Purge Control Valve Operationg Wave ...

Page 667: ...Battery ground Ground cable Ground condition figure 1 Diagnosis socket 69 2 Diagnosis socket Þ 1 2 Ignition ON 1 12 11 14V Power supply terminal 30 TM 30 Power supply cable Diagnosis socket Þ 2 0 Ignition ON 5 11 11 14V ECU power supply terminal 87 TM 87 08 Þ 2 1 Þ 2 2 Þ 2 1 Ignition ON 11 14V Ground cable Electronic ground Ground cable 5 2 Diagnosis socket 1 11 Diagnosis socket Ignition OFF 11 14...

Page 668: ...00 99 100 1050 1400W Þ 6 0 Engine in cranking 104 106 Þ 6 1 Cable Camshaft position sensor Measure the signal refer to figure 8 Camshaft position sensor E23 only Signal Þ 4 0 Ignition ON 69 71 11 14 V Ignition coil T1 2 No 2 3 Cylinder 65 Cable Ignition coil T1 2 Fuse No 17 Engine in cranking 10 V Engine idling Voltage alternating Engine in cranking Engine idling 2 5 V 19 58 106 11 The value will ...

Page 669: ...coil T1 2 Primary coil voltage No 2 3 cylinder Engine in cranking starter operating Measuring range 400 V Time range 100 using engine tester 200 350 V 65 Þ 8 0 Þ 8 1 0 9 1 6 W 71 72 Ignition OFF Þ 8 1 Connection ignition coil between T1 1 and T1 2 Cable Ignition coil T1 1 Ignition coil T1 2 The resistance of ignition coil at 20 C is approached 0 6W The resistance of ignition coil at 20 C is approa...

Page 670: ...se 10 MW 117 118 Ignition OFF Disconnect the coupling No 2 from ECU Þ 10 1 Knock sensor Resistance Connecting condition Cable ECU 6 8 5 KW Ignition coil T1 1 T1 2 Secondary coil resistance Remove the high tension cable of T1 1 T1 2 Þ 9 1 Ignition coil T1 1 T1 2 Ignition coil T1 1 Ignition coil T1 2 TM 4a TM 4b 56 ...

Page 671: ...Crankshaft Position Sensor Signal a Voltage b Identifying the No 1 2 Missing Teeth Figure 6 Camshaft Position Sensor Signal Figure 7 Signal Function 1 Crank Angle 2 Cylinder 3 Crankshaft Position Sensor Signal 4 Camshaft Position Sensor Signal 5 RPM Signal ...

Page 672: ... 160 161 164 167 4 3 4 8 V Þ 1 1 Cable Pedal valve sensor Þ 1 1 Ignition ON 31 32 4 75 5 25 V Pedal valve sensor Power supply potentiometer 1 Cable ECU Þ 2 0 Ignition ON Position of accelerator pedal Closed throttle position Full throttle with kick down 50 48 0 1 0 4 V Pedal valve sensor Signal potentiometer 2 162 163 164 167 2 1 2 5 V Þ 2 1 Cable Pedal valve sensor Þ 3 0 Engine in idling 84 87 0 ...

Page 673: ...lue will be changed in 1 0 2 5V Throttle valve actuator Signal Throttle valve actuator motor voltage supply 104 105 108 109 116 119 185 ECU Cable E GAS actuator Engine in idling Coolant temperature 70 C 84 85 4 0 4 6 V Throttle valve potentiometer 2 0 3 0 9 V Position of accelerator pedal Closed throttle position Full throttle with kick down Throttle valve potentiometer 1 2 Ignition OFF 10 W Throt...

Page 674: ...method Engine In idling Air conditioner switch ON OFF Air conditioner switch OFF Air conditioner switch ON Test step Requirement Specified value 10 44 1 V Air conditioner signal Input signal input signal from thermo amplifier 44 45 11 14 V Þ 5 1 Cable Thermo amp Auto amp Dual pressure switch Air conditioner control panel Þ 1 1 Engine In idling Air conditioner switch ON OFF Air conditioner switch O...

Page 675: ...n Connection of the Equipment 1 Turn the ignition switch to OFF position 2 Remove the air cleaner cross pipe 3 Remove the cap on fuel pressure test plug and connect the pressure hose and pressure tester 4 Prepare the beaker for measuring the amount of fuel Tools Required 103 589 00 21 00 Pressure Tester 119 589 04 63 00 Pressure Hose ...

Page 676: ...4 2 bar Fuel pressure in idling speed When the vacuum is not applied Engine in idling Colse the valve screw on pressure tester Þ 2 0 Connect the fuel pressure test plug to the pressure tester refer to the flgure on previous page Þ Fuel pump test Fuel pressure regulator 3 0 bar Fuel system internal leakage Engine stop Þ 3 0 Connect the fuel pressure test plug to the pressure tester refer to the flg...

Page 677: ... 120 4 Stop Watch 5 Measuring Beaker Connection of the Equipment 1 Turn the ignition switch to OFF position 2 Connect the test box to the ECU 03 Test Box 04 ECU Test Cable Tools Required 103 589 00 21 00 Pressure Tester 210 589 00 99 00 Adaptor Line 129 589 00 21 00 Test Box 210 589 08 63 00 Ecu Test Cable ...

Page 678: ...ect the fuel return pipe and connect the host to beaker to collect the supplied fuel Þ 1 0 Þ 2 0 Fuel line 5 9 A Fuel pump Current consumption Ignition ON Remove the fuel relay from the fuse and relay box in luggage compartment and connect the amperemeter between No 1 and No 3 in relay box fuel pump relay removed position for measuring current consumption Þ 2 0 Fuel pump 5 33 Multi tester DC curre...

Page 679: ...jector with a unit At this time do not remove the supply and return line 4 Connect the shop made cable to the injector with a firing order 5 Collect the fuel from injector Tools Required 129 589 00 21 00 Test Box 210 589 08 63 00 ECU Test Cable INJECTOR TEST 1 ECU 2 Test Coupling No 1 60 3 Test Coupling No 61 120 4 Measuring Beaker 5 Shop Made Cable Preparation 03 Test Box 04 ECU Test Cable ...

Page 680: ...from the injector Injector Leakage test Ignition ON Remove the fuel distributor and fuel injector with a unit Þ 1 0 Þ 2 0 Injector The spray pattern of the injector most show in the figure 10 Ignition ON Connect the shop made cable to the injector Collect the spraying fuel with a beaker Connect the shop made cable to No 11 and No 5 terminal in test box Þ 2 0 Injector 5 33 Injector Function test an...

Page 681: ...AND REPAIR ON VEHICLE SERVICE ECU Appearance 1 Cover 2 Plate 3 Connector 4 Flat pin Vehicle side number 1 12 Engine side number 61 72 5 Pin Vehicle side number 13 60 Engine side number 73 120 A Vehicle Connector Black B Engine Connector Gray ...

Page 682: ...urn the ignition switch to OFF position 2 Disconnect the battery negative cable 3 Remove the cowl side trim form passenger side 4 Unscrew four securing nuts for ECU from mounting bracket Installation Notice 5 Pulling out the ECU from bracket 6 Disconnect the vehicle side coupling B 7 Installation should follow the removal procedure in the reverse order Tightening Torque 9 11 Nm ...

Page 683: ...FS I O WFS O GND LS1 GND LS2 Starter motor TM 50 Electronic ground Lambda probe 2 heating Lambda probe 1 heating Power ground TM 31 V BATTERY TM 87 V BATTERY TM 30 Immobilizer crypto read Immobilizer crypto write Lambda probe 1 ground Lambda probe 1 signal Lambda probe 2 ground Lambda probe 2 signal ECU Pin Numbers and Descriptions Vehecle Connector ...

Page 684: ...e switch Air conditioning clutch relay Pedal potentiometer 1 ground Pedal potentiometer 1 supply Fuel pump relay Tank purge valve Engine fan IGH CAN Low CAN High Air conditioning Electronic traction signal Pedal potentiometer 1 signal Pedal potentiometer 2 signal Brake light switch Pedal potentiometer 2 ground Pedal potentiometer 2 supply Cruise accelerate Set Cruise resume Cruise decelerate Set C...

Page 685: ...23 ZSA14 NWS EGR SLP MT GND LT Injector cylinder 1 Injector cylinder 2 Injector cylinder 3 Injector cylinder 4 E GAS motor plus E GAS motor minus Power ground TM 31 Ignition coil cylinder 2 3 Ignition coil cylinder 1 4 Camshaft control EGR Exhaust Gas Recirculation Second air pump relay Engine coolant temperature Intake air temperature ground Intake air temperature ...

Page 686: ...ND NOWE V REF HFM V REF DK GND KS1 Hot film air mass signal Pressure sensor supply E GAS potentiometer ground E GAS potentiometer 2 signal E GAS potentiometer 1 signal Crankshaft sensor ground Crankshaft sensor signal Intake manifold pressure signal Intake manifold pressure ground Camshaft sensor ground Hot film air mass ground Camshaft sensor signal Hot film air mass supply E GAS potentiometer su...

Page 687: ...er crypto read Immobilizer crypto write Lambda probe 1 ground Lambda probe 1 signal Brake switch Air conditioning clutch relay 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 TM 50 GND LSH2 LSH1 TM 31 TM 87 TM 30 WFS I O WFS O GND LS1 BRS KLIKU l l l l l l l l l l l l l l l l l l l l l l l Standard Option l l l l l l l l l l l E23 ENG 4speed A T E23 ENG 5speed A T ...

Page 688: ...ground Pedal potentiometer 2 supply Cruise accelerate Set Cruise resume Cruise decelerate Set Cruise safety contact switch Cruise off switch Diagnostics Vehicle speed signal Engine speed signal 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 GND SP1 5V KP TEV ML CAN L CANH KLIMA ETS SP1S SP2S BLS GND SP2 2 5V S B WA S B KSK AUS DIAG V SIG TN SIG l l l l l ...

Page 689: ... 3 Ignition coil cylinder 1 4 Camshaft control EGR Exhaust Gas Recirculation Second air pump relay Engine coolant temperature Temperature ground Intake air temperature Hot film air mass signal E GAS potentiometer ground E GAS potentiometer 2 signal E GAS potentiometer 1 signal EV1 EV4 EV2 EV3 M M TM 31 ZSB23 ZSA14 NWS EGR SLP MT GND LT HFM IP2S IP1S l l l l l l l l l l l l l l l l l l l l l l l l ...

Page 690: ...r signal Hot film air mass supply E GAS potentiometer supply Knock sensor 1 ground Knock sensor 1 signal 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 KW KW NOWE GND NOWE V REF HFM V REF DK GND KS1 l l l l l l l l l l l l l l l l l l E23 ENG 4speed A T E23 ENG 5speed A T E20 ENG 4speed A T l l l l l l l l l ...

Page 691: ...6 8 Nm 5 7 Nm 1 3 Tightening torque 5 7 Nm 8 Unscrew the bolts 5 and disconnect the ECU 6 from the bracket assenbly Installation Notice When Removing the ECU with ABS or ABS ASR Unit 1 Turn the ignition switch to OFF position 2 Disconnect the negative battery cable 3 Disconnect the couplings from ECU 4 Disconnect the coupling from ABS or ABS ASR unit 5 Unscrew the bolt 1 and the left and right fla...

Page 692: ...M161 ENGINE CONTROLS 1F2 45 1 Vacuum Hose 2 Circlip 3 Fuel Pressure Regulator FUEL PRESSURE REGULATOR 4 O ring replace 5 O ring replace ...

Page 693: ... oil to O ring lightly and then replace it 6 Installation should follow the removal procedure in the reverse order 7 Check for fuel pressure and internal leaks by operating the engine 2 Discharge the pressure in fuel supply system by pressing the service valve Removal Installation Procedure 1 Remove the fuel pressure test connector ...

Page 694: ...hragm 6 CompressionSpring 8 Fuelchamber 9 SpringChamber 1 Fuel pressure Regulator 2 IntakeManifold 3 Fuel return to fuel tank 4 Fuel supply form fuel pump 5 Fuel pressure approx 3 8 bars 6 Intake Manifold Negative Pressure 0 bar Function of the Fuel Pressure Regulator The fuel pressure regulator maintains the fuel pressure in the fuel line with the pressure of 3 2 bars to 3 8 bars according to the...

Page 695: ...rox 3 2 bars during idling Fuel Pressure Diagram 1 Fuel pressure Regulator 2 IntakeManifold 3 Fuel Return to fuel tank 4 Fuel Supply from fuel pump 7 Fuel Pressure approx 3 2 bars 8 Intake Manifold Negative Pressure 0 6 bars A Fuel pressure B IntakeManifoldNegativePressure LL Idling TL Partialload VL Fullload ...

Page 696: ...el Distributor 2 Circlip 3 Fuel Pressure Regulator 4 O ring 5 Fuel Pressure Test Connector 6 Seal Ring 7 Vacuum Hose 8 Combination Bolt M8 X 120 22 5 27 5 Nm 9 Fuel Return Line 10 Seal Ring 11 Hollow Bolt 22 5 27 5 Nm 12 Clamp 13 Bolt M8 X 22 9 11 Nm 14 Injector Bracket 15 Injector 16 O ring ...

Page 697: ...y ground cable 3 Disconnect the vacuum hose from the fuel pressure regulator 4 Disconnect the cable from ignition coil 5 Remove the fuel return and supply line Installation Notice Notice l For removal cover around parts with cloths not to bestained by fuel l In case of checking the injector only do not remove the fuel return and supply line 6 Remove the four injector connectors arrows 7 Unscrew th...

Page 698: ...ck for fuel pressure and internal leakage by operating the engine 8 Pull out the injector from intake manifold and remove the fuel distributor Notice Replace the injector O ring with new one Ignition Coil Cable l Ignition coil T1 1 No 1 cylinder No 4 cylinder l Inition coil T1 2 No 1 cylinder No 4 cylinder ...

Page 699: ...he fuel pressure test connector Vacuum Hose Connected bar 3 2 3 6 Vacuum Hose Disconnected bar 3 7 4 2 5 Replace the pressure regulator diaphragm if out of the specification 3 Connect the fuel pressure gauge to the fuel pressure test connector 4 Test the fuel pressure at idling by operating the engine ...

Page 700: ...l pressure drops slowly Fuel leakage at the injector Faulty fuel pressure regulator s diaphragm and O ring Fuel pressure drops rapidly Faulty check valve in the fuel pump Possible Cause Pressure Change Fuel Pressure bar 2 5 Discharging the pressure in fuel system 1 Remove the fuel pressure test connector Installation Notice 2 Remove the fuel pressure in fuel system by pressing the service valve wi...

Page 701: ...1F2 54 M161 ENGINE CONTROLS INJECTOR Preceding Work Removal of fuel distributor 1 O ring Replace if damaged 2 Injector Bracket 3 Injector 4 O ring Replace if damaged 5 Fuel Distributor ...

Page 702: ...hop made test plug to the injector and place it into the tank 3 Position the ignition switch to ON 4 Connect the pin No 11 and No 5 of the contact box with a test cable 5 Check the injector spray pattern Notice Replace the injector if the injector spray pattern is abnormal or the fuel doesn t inject Injector Resistance Inspection 1 Remove the injector connector 2 Measure the injector coil resistan...

Page 703: ...nd return line Notice Prepare the beaker for taking the poping fuel 4 Connect either end of shop made cable to the injector 5 Connect the other end of shop made cable to the No 11 and No 5 terminal of the test box 6 Turn the ignition switch to ON position 7 Check the injector for normal spray pattern as shown in the figure Check injector for leaks or later drops Notice Refer to fuel injector test ...

Page 704: ...ion Notice Notice Place the fuel pump pad There may be a corrosion due to the contact between the fuel filter and the bracket 4 Check for leaks by operating the engine Notice Installation should follow the removal procedure in the reverse order 3 Remove the mounting bracket bolt 4 and remove the fuel filter 1 Installation Notice 3 Inlet Tightening Torque 25 30 Nm Tightening Torque 4 8 Nm 1 3 2 ...

Page 705: ...V 3 8 bar 30 70 C Minimum pressure 5 0 bar 12 V Maximum allowable current 7 5 A Nominal voltage 12 V Ambient temperature 30 70 C 1 Reservoir Tank 2 Fuel Sensor float arm 3 Resistance 4 Wiring Connector 5 Fuel Supply Pipe 7 Float 10 Flange and Harness Assembly 11 Fuel Pump 12 Spring 13 Thermister Housing 14 Thermister 15 Resistor Card and Wiper 16 Float Arm Operating voltage 8 V Maximum amount of f...

Page 706: ...l Pump Connector Wiring 2 Fuel Return Pipe 3 Fuel Supply Pipe 4 Bolts 5 Fuel Return Pipe 6 Fuel Supply Pipe 7 Float 8 Ground Stud Sender COLOR Pump Thermister Ground Sender Unit USE Harness Location Connector A B C D 2 0 BR 0 5 W 2 0 B 0 5 RY ...

Page 707: ...t the negative battery cable 2 Disconnect the harness connector 1 3 Disconnect the fuel supply 6 and return 5 pipes 4 Using a special tool Unscrew the eight fuel retaining bolts and remove the pump from fuel tank Notice Check the condition of the seal and replace if necessary Drain the fuel before removing the pump ...

Page 708: ...ch to ON position 2 Using a multi tester measure the current consumption by connecting the terminal No 1 and No 3 Measure the Fuel Delivery From the Fuel Pump 1 Disconnect the return pipe from fuel distributor and insert the appropriate hose into it 2 Place the hose end into the beaker with the minimum capacity of 1Liter 3 Turn the ignition switch to ON position 4 Connect the terminal No 33 and No...

Page 709: ...pt the decreasing mode and coolant temperature of over 80 C For this reason the ECU transacts the engine speed air inflow quantity coolant temperature and intake temperature The purge switchover valve is activated by the ECU frequency according with the engine rotating speed to adjust the purification rate The purification rate is determined by the continuous valve opening interval The purge switc...

Page 710: ...utput waves using the scanner Notice Test during purge control switchover valve operation after the minimum of 1 minute after the engine turned on 3 Connect the ECU terminal No 34 and No 10 and check for current consumption during the ignition switch ON Purge switchover valve output wave Specified Value 0 3 0 5 Specified Value 50mbar after approx 1min purge switchover valve operates at this time N...

Page 711: ...d Hose 3 Fuel Tube 270 mm 4 Clamp 5 Molded Hose 6 Intake Manifold 7 Throttle Body VACUUM SYSTEM ManualTransmission 8 Fuel Pressure Regulator 9 Vacuum Line Rubber Hose 40 mm 10 Vacuum Tube Gray 540 mm 11 Rubber Cap 12 Molded Hose 13 Vacuum Tube Brown 14 Connector ...

Page 712: ...M161 ENGINE CONTROLS 1F2 65 15 Manual Transmission 16 Distributor AutomaticTransmission A To Canister B To Auto Locking Hub ...

Page 713: ...N SENSOR Removal Installation Procedure 1 Disconnect the wiring connector at the crankshaft position sensor 2 Unscrew the bolt 2 and remove the crankshaft position sensor unit 3 Installation Notice 3 Installation should follow the removal procedure in the reverse order 3 Sensor Unit Tightening Torque 9 11 Nm ...

Page 714: ...sure the output wave between the ECU terminals No 99 and No 100 using the scanner or the oscilloscope while engine cranking starter motor activated Notice Check the segment or crankshaft position sensor and air gap if cannot get the output wave as shown in the figure Specified Value 1050 1400 W Specified Value 20kW Crankshaft Position Sensor Insulator Resistance Inspection 1 Disconnect the engine ...

Page 715: ...ng connector from the camshaft position sensor 2 Unscrew the bolt 2 and remove the camshaft position sensor Installation Notice 3 Shim 5 O ring Tightening Torque 9 11 Nm 3 Check the clearance and replace the shim if necessary 4 Check the O ring for damage and replace it if necessary 5 Installation should follow the removal procedure in the reverse order ...

Page 716: ...age will be changed in the range of 1 2 1 7V Camshaft Position Sensor Output Wave Inspection 1 Connect the test box to the ECU 2 Measure the output wave between the ECU terminal No 104 and No 106 using the scanner or the oscilloscope while the engine speed is at idle Notice Replace the camshaft position sensor if cannot get the output wave as shown in the figure Specified Value 11 14 V Specified V...

Page 717: ... in the figure in the right so that it gets separated from the contact surface Notice Make sure the HFM sensor coupling connects completely with the contact surface Installation 2 Remove the clip with a screw driver 3 Pry off two tensioning clamps 4 Remove the HFM sensor 5 Installation should follow the removal procedure in the reverse order 4 Connector 5 Hot film Sensor 6 Measuring Port ...

Page 718: ...M161 ENGINE CONTROLS 1F2 71 Circuit Diagram 1 Housing 2 Electronic Housing 3 Connector RH Heat Resistance RT Temperature Resistance RS Sensor Resistance ...

Page 719: ...FM sensor signal voltage between the ECU terminal No 81 and No 105 Specified Value coolant temperature is over 70 C If the measured value is not within the specified value the possible cause may be in cable or ECU coupling HFM Sensor 12V Power Supply Inspection 1 Measure the voltage between the HFM sensor No 2 pin and No 3 after removing the HFM sensor connector If the measured value is not within...

Page 720: ...il 7 Open Space 8 Protector Tube Functions The oxygen sensor optimizes the combustion Air Fuel Ratio 14 7 1 and resets the Air fuel ratio in the ECU after sensing the amount of oxygen from the exhaust gases to diminish the exhaust gases Rich 1 above approx 450mV Lean 1 below approx 450mV Locatoin of Sensor Oxygen sensor is located on the front exhaust pipe ...

Page 721: ...g voltage between the ECU terminal No 11 and No 9 Maintain the engine speed ia at idle while the coolant temperature is over 80 C If the measured value is not within the specified value the possible cause may be in cable oxygen sensor or ECU Oxygen Sensor Heating Current Consumption Inspection 1 Measure the oxygen sensor heating current consumption between the ECU terminal No 9 and No 5 while the ...

Page 722: ...lock to recognize knocking in all cylinders The ECU compares the signal and the retards firing point Removal Installation Procedure 1 Disconnect the knock sensor connector from the intake manifold bracket 2 Unscrew the mounting bolt M8 X 28 from the knock sensor installed on the cylinder block and remove the knocking sensor Installation Notice 3 Installation should follow the removal procedure in ...

Page 723: ...the pressure by opening the pressure cap in the coolant subtank 2 Disconnect the connector and remove the coolant temperature sensor Installation Notice Replace the seals with new one 3 Installation should follow the removal procedure in the reverse order 4 Check for leaks at each connections after starting the engine 4 Connector 5 Coolant Temperature Sensor Tightening Torque 18 22 Nm ...

Page 724: ...onnected Inspection 1 Measure the coolant sensor input voltage between the ECU terminal No 79 and No 78 while the ignition switch in ON position Notice Replace wiring and coolant temperature sensor if out of specified value allowable error 5 allowable error 5 Voltage V 3 57 1 22 0 78 Temperature C 20 30 40 Resistance W 2 500 322 185 Temperature C 20 30 40 ...

Page 725: ...oltage V Temperature C Resistance W Voltage V 40 48 550 4 8991 60 594 1 8632 30 27 000 4 8214 70 434 1 5132 20 15 670 4 7001 80 322 1 2179 10 9 450 4 5215 90 243 0 9775 0 5 890 4 4273 100 185 0 7806 10 3 790 3 9562 110 143 0 6255 20 2 500 3 5714 120 111 6 0 5020 30 1 692 3 1426 130 88 0 0 4044 40 1 170 2 6959 140 71 2 0 3323 50 826 2 2618 ...

Page 726: ...m Removal and Installation Procedure 1 Disconnect the 6 pin connector arrow 2 Unscrew the 2 bolts 3 1 nut 6 and remove the pedal and sensor assembly Installatoin Notice Tightining Torque 4 8 Nm 2 Installation should follow the removal procedure in the reverse order 4 6 Pin Connector 5 Kick down Switch 6 Nut 1 piece 4 8 Nm ...

Page 727: ...entiometer 2 Power Supply Pin no 3 Pin no 1 Pin no 5 Pin no 6 Pin no 4 Pin no 2 Potentiometer 2 Signal Potentiometer 2 Ground Circuit Diagram Potentiometer 1 Potentiometer 2 Pin no 3 Red Black Pin no 1 Blue Green Pin no 5 Yellow Green Potentiometer 2 Pin no 6 Green Pin no 4 Blue Red Pin no 2 LightGreen Potentiometer 1 Pin no 3 Red Pin no 1 Yellow Pin no 5 Brown Potentiometer 2 Pin no 6 Violet Pin ...

Page 728: ...on of Injection Timing Device 1F3 30 Injection Timing Device 1F3 35 Start of Delivery Test Position Sensor RIV Method 1F3 37 Fuel Injection Pump 1F3 46 TABLE OF CONTENTS Caution Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals Disconnecting this cable will help prevent ...

Page 729: ...ROLS FUEL SYSTEM 1 Fuel Injection Pump 2 Fuel Feed Pump 3 Overflow Valve 4 Injection Nozzle 5 Pre filter 6 Fuel Return Hose 7 Injection Line 8 Fuel Tank 9 Fuel Filter 10 Choke Orifice MAINTENANCE AND REPAIR ON VEHICLE SERVICE ...

Page 730: ...ge Mounting 5 Number of Cylinders 5EA M Pump Size 55 Element Diameter C Modification Letter 320 Assembly Number R Direction of Rotation clockwise S188 Special Version RSF Governor R Governor S Coil Spring F Drive Governor Component Location 1 Fuel Injection Pump 2 Vacuum Unit Stop Unit 3 Control Lever 4 PLA Vacuum Unit Idle Speed Adjustment 5 Governor 6 Fuel Pump OM661 LA Engine OM662 LA Engine ...

Page 731: ...EL TANK 1 Fuel Tank 2 The Sender of Fuel Tank 3 2 way Check Valve 4 Pre Filter 5 Front Fuel Filler Neck 6 Rear Fuel Filler Neck 7 Fuel Supply Tube 8 Fuel Return Tube 9 Filter Hose 10 Fuel Tank Hose 11 Fuel Filler Cap 12 Clip 13 Clip ...

Page 732: ... Engine Stop Valve Unit 5 PLA Vacuum Unit Idle Speed Adjustment 6 Engine 7 Vacuum Pump 8 30 Thermovalve 9 Fuel Injection Pump 10 Filter with Restriction 11 Check Valve 12 Modulating Pressure Line Automatic T M Test Data Idle Speed Increase Permissible Pressure Drop of System At least 100 rpm at approx 500mbr 400 500mbar approx 1 min ...

Page 733: ...tester Tools Required 001 589 73 21 00 Vacuum Pump 201 589 13 21 00 Vacuum Tester 667 589 00 21 00 TDC pulse generator Commercial Tools e g Bosch MOT 001 03 Sun DIT 9000 e g Ahlborn Therm 2263 2 Eichenfeldstrabe 1 3 D 8150 Holzkirchen Tester Connection 11 TDCPulseSenderUnit 12 DigitalTester ...

Page 734: ...ose from vacuum pump Connect vacuum pump 14 direct to PLA vacuum unit 5 and pressurize with vacuum Vacuum is built up and idle speed increases approx 150 200 rpm YES NO Faulty PLA vacuum unit CoolantTemperature30 C Stop the engine Seal the air admission line with plug Connect the vacuum pump to line to thermovalve and pressurize the line with vacuum Vacuum is built up YES NO Lines and connectors l...

Page 735: ...am of air admission filter 13 Vacuum drops Faulty thermovalve Fit the line onto air admission filter Built up vacuum with vacuum pump Detach the plug from air admission line Vacuum drops Faulty filter with restriction Go to test step 2 YES NO YES NO ...

Page 736: ...PLA vacuum unit 5 Run the engine at idle speed Vacuum drops to 0 at approx 30 C of the thermovalve Faulty thermovalve Defective filter with restriction Stop the engine Detach the filter with restriction Filter with restriction is clear Defective filter with restriction YES NO YES NO ...

Page 737: ... Valve 6 Safety Valve 7 O Ring 8 Pump Housing 9 Pump Cover 12 Lever 14 Outer Return Spring 15 Inner Spring Retainer 16 Roller Cam 17 Piston Rod 21 Inner Return Spring 23 Upper Spring Retainer 28 Piston Ring 30 Seal Ring 31 Oil Return Valve 32 Restrictor SB To Brake Booster SK To Vacuum Lines ...

Page 738: ...OM600 ENGINE CONTROLS 1F3 11 VACUUM PUMP TEST 1 Fuel Filter 2 Vacuum Line 3 Ancillaries Connection 4 Vacuum Tester Tools Required 201 589 13 21 00 Vacuum Tester ...

Page 739: ...om ancillaries connection 3 3 Connect the vacuum tester 4 to the ancillaries connection 3 Vacuum Tester 201 589 13 21 00 4 Run the engine at idle and check vacuum pressure after 30 sec Notice If out of standard replace the vacuum pump 5 Remove the vacuum tester 6 Connect the vacuum line to the ancillaries connection 7 Install the fuel filter Standard 70 mbar ...

Page 740: ...OM600 ENGINE CONTROLS 1F3 13 VACUUM PUMP Preceding Work Remove the poly V belt 1 Bolt 10Nm 2 Vacuum Pump 3 Vacuum Line Ancillaries 4 Vacuum Line Brake Booster 5 Gasket Replace ...

Page 741: ... evenly Notice If necessary rotate the engine until the pressure on the tappet of the vacuum pump is released 3 Remove the vacuum pump 2 4 Install the vacuum pump 2 Tightening Torque 10 Nm Notice Clean the gasket residues of sealing surface of vacuum pump and replace the gasket 5 5 Connect the vacuum line 3 4 ...

Page 742: ...OM600 ENGINE CONTROLS 1F3 15 VACUUM UNIT REPLACEMENT 1 Bracket 2 Bolt 3 Vacuum Unit 4 Vacuum Line 5 Seal Replace ...

Page 743: ... 03 Sun DIT 9000 Digital tester Adjustment 1 Connect the digital tester 1 and TDC pulse sender unit 11 2 Run the engine and warm up the coolant to 60 80 C TDC pulse generator 667 589 02 21 00 3 Disconnect the vacuum hose 4 from the PLA unit to check idle speed with tester 4 Check idle speed with tester Notice To adjust idle speed loosen the locking nut 6 of PLA unit OM 661LA Engine 750 850rpm OM 6...

Page 744: ...unit and build up vacuum approx 500mbar If engine rpm increases by approx 100rpm It is normal Vacuum Pump 001 589 73 21 00 8 Connect the vacuum line 4 9 Switch on all ancillaries and check the idle speed 5 Ensure not to damage the idle spring in the governor and adjust idle speed by turning the PLA unit 5 slowly Notice Do not rotate the PLA unit over turn from the position marking If do idle sprin...

Page 745: ... fuel return line 1 and seal up it with plug 2 Insert the plastic hose 5 and put the end into the measuring beaker 6 3 Disconnect the vacuum line 4 from vacuum unit engine stop 5 and connect the vacuum pump 7 to the vacuum unit 4 To avoid the engine starting build up vacuum approx 500 mbar 5 Operate the starter motor for exactly 30 seconds and measure fuel volume in the beaker 3 ...

Page 746: ...OM600 ENGINE CONTROLS 1F3 19 Fuel Pressure Test ...

Page 747: ...the fuel injection pump and remove the seals 3 and fuel line 2 3 Connect the tester 5 4 Start the engine and read off the fuel pressure on tester 5 Notice If out of standard replace the fuel feed pump Tester 617 589 04 21 00 5 Stop the engine At idle Speed At full load 0 3bar 0 5bar 6 Remove the tester 7 Replace the seal and connect the fuel line 2 ...

Page 748: ...OM600 ENGINE CONTROLS 1F3 21 FUEL PUMP 1 Fuel Injection Pump 2 Pressure Line 13Nm 3 Suction Line 4 Hose Clip Replace 5 Gasket Replace 6 Spring Lock Washer 7 Hexagon Nuts 8 Fuel Pump ...

Page 749: ...2 OM600 ENGINE CONTROLS INJECTION NOZZLE TEST Preceding Work Removal of fuel injection nozzle 1 Fuel Injection Nozzle New 115 125bar Used min 100bar A Closed Spray good B Stringy Spray poor 2 Tester 3 Valve ...

Page 750: ...zzle to the tester 2 Tester 000 589 14 27 00 2 Close the valve 3 and pump 5 times strongly 3 Chatter test Slowly operate the hand lever at tester approx 1 stroke per second The nozzle must spray with a gentle chattering 4 Spray pattern test Operate the hand lever at tester rapidly approx 2 3 strokes per second l Good The spray pattern shows closed and well atomized l Poor The spray pattern shows s...

Page 751: ...g pressure Notice If out of standard repair the injection nozzle NewNozzle UsedNozzle Difference Between Nozzles 115 125bar Min 100bar Max 5bar 6 Leak test Slowly operate the hand lever at the tester until get a pressure of approx 90bar Maintain this pressure for more than 20 seconds and within this period no drop of fuel should build up at the nozzle tip ...

Page 752: ...OM600 ENGINE CONTROLS 1F3 25 INJECTION NOZZLES 1 Fuel Injection Nozzle 35 40Nm 2 Fuel Return Hose 3 Plug 4 Nozzle Washer Replace 5 Fuel Injection Pipe 18Nm ...

Page 753: ... the fuel return hose 3 Disconnect the injection pipes from the injection nozzles and push them to the side 4 Remove the fuel injection nozzle Serration Wrench 001 589 65 09 00 Notice Replace the washers 5 Installation should follow the removal procedure in the reverse order Notice Pay attention to the installation position of new nozzle washer and tightening torque ...

Page 754: ... 1F3 27 INJECTION NOZZLE REPAIR Preceding Work Removal of fuel injection nozzle 1 Nozzle Holder 2 Steel Washer 3 Compression Spring 4 Thrust Pin 5 Intermediate Disc 6 NozzleNeedle 7 Nozzle Body 8 Nozzle Tensioning Nut 80Nm ...

Page 755: ...n the nozzle needle 6 and nozzle body 7 with an abradant 4 Clean the nozzle seat with cleaning cutter Cleaning Set 000 589 00 68 00 5 Immerse nozzle needle 6 and nozzle body 7 in filtered diesel fuel When the nozzle body is held vertical the weight of the nozzle needle must cause it to slide down toward the nozzle needle seat 6 Assemble the injection nozzle so that the tip of the thrust 4 pin is f...

Page 756: ... injection nozzle and adjust opening pressure if necessary Opening pressure adjustment Disassemble the fuel injection nozzle and replace the steel washer 2 Notice Each 0 05mm thickness of the washer results in a pressure difference of approx 3bar ...

Page 757: ...ump 1 Cylinder Head Cover 2 Bolt 10Nm 3 Gasket Replace 4 Fuel Injection Pump 5 Seal Replace 6 Screw Plug 30Nm 7 Oil Pan 8 Locking Pin 9 Injection Timing Device 10 Washer 11 Bolt Left Hand Thread 46Nm 12 Camshaft Sprocket 13 Washer 14 12 Sided Stretch Bolt Check 25Nm 90 15 Timing Chain 16 Seal 17 Chain Tensioner 80Nm ...

Page 758: ... then remove the cylinder head cover 1 and gasket 3 Installation Notice Tightening Torque 10 Nm Notice Replace the gasket Rotate the engine 1 revolution by hand and check TDC marking of the crankshaft and camshaft 2 Loosen the camshaft sprocket bolt 14 Notice Do not remove the bolt Installation Notice Notice If max length of bolt exceeds 53 6mm replace it Tightening Torque 25Nm 90 3 Loosen the bol...

Page 759: ...jection pump Notice Before tightening the bolts for the injection timing device and the camshaft sprocket always remove the locking screw from the injection pump and reinstall the plug Locking Screw 601 589 05 21 00 7 Place alignment marks arrow on the timing chain 12 and camshaft sprocket 15 4 Position the no 1 cylinder at ATDC 15 Notice Do not rotate the engine with camshaft sprocket bolt or opp...

Page 760: ...e 46 Nm 11 Using special tool 24 25 remove the locking pin 8 SlidingHammer 116 589 203300 Threaded Bolt 116 589 02 34 00 8 Remove the chain tensioner 17 Installation Notice Tightening Torque 80 Nm Notice Replace the seal 16 10 Pull out the bolt 11 and washer 10 Notice Be careful that the bolt is left hand thread Installation Notice ...

Page 761: ...ng chain with retaining plate 26 and remove the injection timing device 9 RetainingPlate667589046300 13 Installation should follow the removal procedure in the reverse order 14 After assembling the engine check start of delivery and adjust if necessary ...

Page 762: ... ENGINE CONTROLS 1F3 35 INJECTION TIMING DEVICE Preceding Work Removal of injection timing device 1 Cam Sprocket Check 2 Bushing Check 3 Governor Weights 4 Segment Flange and Drive Hub 5 Compression Springs ...

Page 763: ...y Assembly 1 Remove the governor weights 3 2 Pull out the compression springs 5 and cam sprocket 1 from the segment flange 4 3 Knock out the bushing with a proper drift 4 Installation should follow the removal procedure in the reverse order ...

Page 764: ...00 ENGINE CONTROLS 1F3 37 START OF DELIVERY TEST POSITION SENSOR RIV METHOD 1 Position Sensor 2 Battery 3 Fuel Injection Pump 4 Seal Replace 5 Screw Plug 30Nm Service Data Start of Delivery RIV ATDC 14 16 ...

Page 765: ...r facing up 3 Connect the battery terminal of position sensor 1 to positive terminal of battery Position Sensor 617 589 08 21 00 4 Rotate the crankshaft by hand in direction of engine rotation until the lamp B lights up Rotate the crankshaft carefully further until both lamps A and B come on In this position check the Rl value on the crankshaft vibration damper Notice If only lamp A lights up repe...

Page 766: ...OM600 ENGINE CONTROLS 1F3 39 Digital Tester RIV Method Connection Diagram for Testers Without Adapter 1 Fuel Injection Pump 2 Rl Sensor 3 Digital Tester 4 TDC Pulse Sender Unit 5 Battery ...

Page 767: ... Delivery RIV Idle Speed Connection Diagram for Testers With Adapter 1 Fuel Injection Pump 2 Rl Sensor 3 Digital Tester 4 TDC Pulse Sender Unit 5 Battery 6 Rl Pulse Generator Service Data ATDC 14 16 OM661LA 720 820 rpm OM662LA 750 850 rpm ...

Page 768: ...l 8 collect oil in a suitable vessel 2 Install the Rl sensor into the governor housing of injection pump 1 Rl Sensor 617 589 10 21 00 3 Connect the digital tester and TDC pulse sender unit according to connection diagram 4 Run the engine at idle speed and check the Rl value on the digital tester Notice If out of standard adjust the start of delivery 5 Stop the engine 6 Remove the Rl sensor digital...

Page 769: ...2 OM600 ENGINE CONTROLS After Testing Preceding Work Start of delivery test Position Sensor RIV method 1 Adjusting Screw 2 Bolt 23Nm 3 Fuel Injection Pump 4 Bolt 23Nm 5 Scale Rl start of delivery 14 16 ATDC ...

Page 770: ... 2 Remove the bolt 2 at the supporting bracket 3 Remove the bolt 4 4 Turn the adjusting screw 1 until both lamps A B on the position sensor light up Notice If the adjustment range is not adequate remove the injection pump and reinstall Position Sensor 617 589 08 21 00 5 After adjusting retighten all the bolt to the specified torque To the right To the left Start of delivery retarded Start of deliv...

Page 771: ... Pulse Generator Without Pulse Generator Tools Bosch MOT 001 03 Hartmann Braun EOMT3 Bosch ETD 019 00 Sun DIT 9000 ALV Diesel Tester 875 Digital tester RIV Method 1 Bolt 23Nm 2 Adjusting Screw To the right start of delivery retarded To the left start of delivery advanced 3 Bolt 23Nm Service Data Start of Delivery RIV Ldling Speed ATDC 14 16 OM661LA 720 820 rpm OM662LA 750 850 rpm ...

Page 772: ...he supporting bracket 2 remove the bolts 1 at the timing case cover 3 Run the engine at idle speed 4 Turn the adjusting screw 2 until the specification 15 1 ATDC is indicated on the digital tester To the Right To the Left Start of Delivery Retarded Start of Delivery Advanced ...

Page 773: ...89 05 14 00 Assembly CageRemoval FUEL INJECTION PUMP Preceding Work Removal of vacuum pump Removal of air cleaner housing Removal of intake manifold 18 Chain Tensioner 80Nm 19 Seal Replace 20 Bolt Left Hand Thread 46Nm 21 Washer 22 Bolt 23Nm 23 Seal Replace 24 Oil Pan 25 Fuel Injection Pump 26 Seal Replace 27 Screw Plug 30Nm 28 Square Nut ...

Page 774: ...ressure line 4 6 Remove the banjo bolt 1 and then remove the seal 2 and fuel line 3 7 Remove the plastic clip 8 on the injection line Removal Procedure 1 Position then no 1 cylinder at 15 ATDC Notice Do not rotate the engine in opposition direction of engine rotation 8 Disconnect the injection lines 15 from the injection pump 25 9 Remove the banjo bolt 1 and then remove the seal 7 and return line ...

Page 775: ... the washer 21 Notice Be careful that the bolt 20 is left hand thread Assembly Cage 601 589 05 14 00 11 Remove the chain tensioner 18 and seal 19 12 Remove the bolt 12 and pull off the washer 11 13 Remove the bolt 22 and pull off the square nut 28 14 Pull out the fuel injection pump 25 and seal 23 ...

Page 776: ...al 26 and collect oil in a vessel 2 Insert flange 31 onto the injection pump camshaft and turn until the cam of the governor is visible in the hole Flange 601 589 00 08 00 3 Tighten the locking screw Locking Screw 601 589 05 21 00 4 Ensure that the no 1 cylinder is positioned at ATDC 15 ...

Page 777: ...on and Pressure Line 46 Nm 18 Nm 13 Nm 13 Nm 5 Coat the new seal 23 with engine oil and install it 6 Insert the fuel injection pump 25 and tighten the bolts 22 7 Remove the locking screw 32 Tightening Torque 23 Nm 8 Tighten the bolt 12 9 Insert the washer 21 and tighten the bolts 20 and then remove the assembly cage 29 Tightening Torque 23 Nm Tightening Torque 46 Nm ...

Page 778: ... 13 14 13 Connect the connecting rod 9 14 connect the accelerator control damper 10 Manual transmission vehicle 15 Install the chain tensioner 16 Install the vacuum pump 17 Check the start of delivery 18 Adjust the idle speed 11 Assemble the plastic clip 8 ...

Page 779: ... 2 TABLE OF CONTENTS Intake Air Duct 1G1 4 Intake Manifold 1G1 5 Resonance Flap 1G1 7 Exhaust Manifold 1G1 9 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Nlm 9 11 22 5 27 5 22 5 27 5 9 5 12 5 15 28 28 47 Application Air Cleaner Housing Cover Nut Intake Manifold Bolt M8 x 20 Intake Manifold Bolt M8 Exhaust Mainfold Stud Bolt Exhaust Pipe Nut Engine Exhaust Pipe Bolt ...

Page 780: ...HAUST MAINTENANCE AND REPAIR ON VEHICLE SERVICE AIR CLEANER 1 Element Assembly 2 Cleaner Assembly Air 3 Shield Cover Air Intake 4 Shield Assembly Air Intake 5 Braket Assembly Air Cleaner Mounting 6 Braket Assembly Shield Surport ...

Page 781: ...amp from air cleaner assembly housing and remove the cover 5 Remove the air cleaner assembly 6 Remove the air cleaner housing from insulator Notice Make sure the air cleaner to be seated in insulator 7 Disengage the air duct hose and air cleaner housing and remove the housing 8 Remove the air duct hose 9 Unscrew the two bolts 7 from air inlet duct Installation Notice 10 Remove the air inlet duct 1...

Page 782: ... Remove the intake air duct 5 carefully Installation Notice Exactly seat the pin of intake air duct onto the crankcase ventilation rubber mount 5 Installation should follow the removal procedure in the reverse order Removal Installation Procedure 1 Remove the clamp 1 and disconnect the HFM sensor 2 Remove the nut 3 arrow ...

Page 783: ...per Intake Manifold 6 Bolt M8 x 50 9 pieces 22 5 27 5 Nm 7 Gasket Replace 8 Blow by Hose 9 Blow by Hose 10 Clamp 11 Blow by Nipple 12 Inlet Air Housing 13 Bolt M6 x 40 4 pieces 9 11 Nm 14 Throttle Body Electric 15 Gasket Replace 16 Lower Intake Manifold 17 Bolt M8 x 40 4 pieces 22 5 27 5 Nm 18 Nipple Replace 19 Seal Ring 20 Connection House 21 Clamp 22 Noise Damper Assembly 23 Tapping Screw ...

Page 784: ...tion should follow the removal procedure in the reverse order l Lower Intake Manifold Preceding work removal of upper intake manifold 1 Remove the hose of brake booster vacuum line and idle speed connector 2 Disconnect the hot water inlet pipe from the bottom of lower intake manifold 3 Unscrew the bolt 17 and remove the lower intake manifold 16 Installation Notice 4 Start the engine and check for ...

Page 785: ... 1 2 Remove the upper resonance flap coupling after removing 4 bolts 2 Notice Connect carefully the vacuum hose 4 for installation 3 Check the O ring 3 and replace it if necessary 4 Remove the lower resonance flap 5 5 Replace the gasket 6 6 Installation should follow the removal procedure in the reverse order 4 Vacuum Hose 5 Resonance Flap 6 Gasket Replace ...

Page 786: ...800 rpm The switch valve 7 will be adjusted by ECU and resonance falp will be colosed By increasing air flow passage through dividing intaking air flow toward both air collection housing 8 This leads to a signficant increase in the torque in the lower speed range 2 Resonance flap open at full load over 3 800 rpm The switch valve 7 will not be adjusted by ECU and resonance falp 5 will be open The c...

Page 787: ...M162 ENGINE INTAKE EXHAUST 1G1 9 EXHAUST MANIFOLD Preceding Work Removal of air cleaner 1 Nut 36 44 Nm 2 Gasket Replace 3 Exhaust Manifold ...

Page 788: ... the stud bolt and remove the exhaust manifold Installation Notice 3 Replace the gasket 2 4 Installation is reverse order of the removal Replacement of Rivet Nut 1 Pull out the rivet nut from the connecting point of the exhaust manifold and the exhaust pipe using a proper bolt arrow 2 Insert a new rivet nut into the exhaust manifold hole and tighten with a special tool Caulking Bolt Installation N...

Page 789: ...1 Exhaust Manifold 2 Rivet Nut 3 Bolt 30 Nm 4 Front Pipe 5 Oxygen Sensor 6 Bolt 28 47 Nm 7 Rubber Pad 8 Catalytic Converter 9 Gasket Replace 10 Nut 11 Gasket Replace 12 Rubber Pad 13 Nut 28 47 Nm 14 Center Muffler 15 Rubber Pad 16 Tail Muffler 17 Gasket Replace 18 Nut 28 47 Nm ...

Page 790: ... Cleaner Housing Cover Nut Intake Manifold Bolt M8 x 20 Intake Manifold Bolt M8 Exhaust Mainfold Stud Bolt Exhaust Pipe Nut Engine Exhaust Pipe Bolt Specifications 1G2 1 Fastener Tightening Specifications 1G2 1 Maintenance and Repair 1G2 2 On Vehicle Service 1G2 2 Air Cleaner 1G2 2 Air Intake Shield 1G2 4 Intake Air Duct 1G2 5 Intake Manifold 1G2 7 Exhaust Manifold 1G2 9 ...

Page 791: ...1G2 2 M161 ENGINE INTAKE EXHAUST MAINTENANCE AND REPAIR ON VEHICLE SERVICE AIR CLEANER 1 Air Cleaner Assembly 2 Element Assembly 3 Insulator 4 Air Duct Hose 6 Bolt M8 30 22 5 27 5 Nm ...

Page 792: ...amp from air cleaner assembly housing and remove the cover 5 Remove the air cleaner assembly 6 Remove the air cleaner housing from insulator Notice Make sure the air cleaner to be seated in insulator 7 Disengage the air duct hose and air cleaner housing and remove the housing 8 Remove the air duct hose 9 Unscrew the two bolts 7 from air inlet duct Installation Notice 10 Remove the air inlet duct 1...

Page 793: ...on Procedure 1 Remove the upper cover 3 from the air intake shield 5 upper mounting pin 2 Remove the bolts 4 and 6 3 Remove the air intake shield 5 4 Installation should follow the removal procedure in the reverse order 1 Air Cleaner Assembly 3 Insulator 4 Air Duct Hose 5 Air Inlet Duct 7 Bolt M6 35 9 11 Nm ...

Page 794: ...NTAKE AIR DUCT 1 Clamp 2 Sleeve 3 HFM Sensor 4 Intake Air Duct 5 Blow by Hose 7 Clamp 2 pieces 8 Intake Air Duct Mounting Bracket Removal Installation Procedure 1 Release the clamp 1 and intake air duct 2 Remove the Blow by hose 5 arrow ...

Page 795: ...1G2 6 M161 ENGINE INTAKE EXHAUST 3 Release the clamp 7 and remove the intake air duct Notice Completely fit the intake air duct with the mounting bracket 8 ...

Page 796: ... air duce Removal of fuel distributor and injector 1 Bolt M6 X 40 6 pieces 22 5 27 5 Nm 2 Intake Manifold 3 Gasket 2 pieces Replace 4 Bolt M8 X 40 3 pieces 22 5 27 5 Nm 5 Idle Regulator 6 Intermediate Flange 7 Bolt M6 X 35 4 pieces 9 11 Nm 8 Connection Piece With Seal Ring 36 44 Nm ...

Page 797: ...the three bolts 4 and remove the idle regulator and intermediate flange 6 Installation Notice Tightening Torque 22 5 27 5 Nm 6 Unscrew the two bolts M8 X 16 and remove the support assembly arrow Installation Notice 7 Unscrew the intake manifold assembly mounting bolts 1 and remove the intake manifold and gasket Installation Notice Notice Replace the gasket with new one 8 Installation should follow...

Page 798: ...asket Replace Removal Installation Procedure 1 Remove the oxygen sensor if necessary Installation Notice Tightening Torque 49 5 60 5 Nm 2 Unscrew the bolt 2 and remove the exhaust manifold upper cover 3 3 Unscrew the flange bolt 6 of front exhaust pipe and separate the front exhaust pipe Installation Notice Tightening Torque 30 Nm Notice Check the exhaust pipe mounting nut and replace it with new ...

Page 799: ... 4 Unscrew the eleven nuts 4 and remove the exhaust manifold 5 and gasket 7 Installation Notice Tightening Torque 31 5 38 5 Nm 5 Replace the gasket 7 with new one 6 Installation should follow the removal procedure in the reverse order ...

Page 800: ...r Assembly Complete 3 Gasket 4 Hanger Converter Mounting 5 Ring 6 Gasket E Pipe to Manifold 7 Ring 8 Ring Exhaust Mounting 9 Muffler Assembly Complete 10 Pipe Assembly Tail Exhaust 11 Nut Hex Flang M8X1 25 12 Bolt Hex M8X1 25X55 13 Bolt Hex M10X1 25X35 14 Nut Hex Flang M10X1 25 15 Heat Protecter L ARM Mounting Bush ...

Page 801: ...th exposed electrical terminals Disconnecting this cable will help prevent personal injury and damage to the vehicle The ignition must also be in LOCK unless otherwise noted SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Air Cleaner Housing Cover Nut Intake Manifold Bolt M8 x 20 Intake Manifold Bolt M8 Exhaust Mainfold Stud Bolt Exhaust Pipe Nut Engine Exhaust Pipe Bolt N m 9 11 22 ...

Page 802: ... DUCT HOSE MAINTENANCE AND REPAIR ON VEHICLE SERVICE 1 Air Intake Shield Assembly 2 Air Cleaner Assembly 3 Mounting Bracket 4 Air Cleaner Element Clean 20 000km Replace 60 000km 5 Bolt 9 11Nm 6 House 7 Clamp 8 Engine Cover Assembly Turbo 9 Mounting Bracket ...

Page 803: ...e cover and element Tightening Torque 9 11 Nm 3 Loosen the nut 4EA and remove the air cleaner housing from the intake manifold Notice Do not fold the rubber Operating Interval Clean Replace every 20 000km every 60 000km 4 Loosen the clamp and remove the air duct hose 5 Loosen the mounting nut and bolt 6 Remove the air inlet duct and hose 7 Installation should follow the removal procedure in the re...

Page 804: ...HAUST MANIFOLD 1 Nut 22 5 27 5 Nm 2 Washer 3 Support Assembly Bar 4 Nut 22 5 27 5 Nm 5 Exhaust Manifold Assembly 6 Exhaust Gasket 7 Stud Bolt 9 9 12 1 Nm 8 Bolt M8 22 5 27 5 Nm 9 Intake Duct 10 Intake Duct Gasket 11 Intake Manifold 12 Intake Gasket ...

Page 805: ... EXHAUST 1G3 5 Exhaust Line 1 Heat Protector Assembly 2 Heat Protector Floor 3 Exhaust Front Pipe Assembly 4 Ring 5 Exhaust Rear Pipe Assembly 6 Muffler 7 Mounting 8 Heat Protector Front Floor 9 Tail Exhaust Pipe Assembly ...

Page 806: ...pe 2 Remove the nut from the front of center muffler and then remove the front exhaust pipe Installation Notice 3 Remove the nut from the rear of center muffler and then remove the tail muffler Installation Notice 4 Remove the muffler mounting hanger from the rubber pad and remove the center muffler and tail muffler Notice Check the gasket if necessary replace the new one 5 Installation should fol...

Page 807: ... EXHAUST 1G3 7 1 Turbocharger Oil Inlet 2 Turbine Wheel 3 Waste Gate 4 Oil Outlet 5 Compressor Wheel 6 Air Inlet 7 Exhaust Gas Outlet 8 Compressed Air Flow 9 Intercooler 10 Cylinder TURBOCHARGER CHARGE AIR SYSTEM DIAGRAM ...

Page 808: ...1G3 8 OM600 ENGINE INTAKE EXHAUST INTERCOOLER 1 Hoses 2 Pipes 3 Hoses 4 Intercooler 5 Cover 6 Bolts 7 Screws 8 Bolts ...

Page 809: ... hose connected to turbocharger and intake duct 2 Remove the protective cover 3 Loosen the clamps and remove the pipe and hose connected to intercooler 4 Unscrew the mounting bolts and remove the intercooler 5 Installation should follow the removal procedure in the reverse order ...

Page 810: ...1G3 10 OM600 ENGINE INTAKE EXHAUST TURBOCHARGER ASSEMBLY 1 Oil Supply Line 2 Oil Return Line 3 Nuts 4 Turbocharger ...

Page 811: ...tallation Procedure 1 Remove the 2 hoses connected to intercooler 2 Remove the hose air cleaner to turbocharger with blow by hose 3 Disconnect the oil supply pipe 4 Remove the oil return pipe 5 Remove the support assembly 6 Remove the 3 nuts arrows ...

Page 812: ...1G3 12 OM600 ENGINE INTAKE EXHAUST 7 Remove the turbocharger disconnecting the exhaust pipe from the turbocharger 8 Installation should follow the removal procedure in the reverse order ...

Page 813: ... Layout 2A 5 Damping Force Control Logic 2A 6 Normal Control 2A 6 Self Diagnosis 2A 7 Actuator Inspection 2A 8 Schematic and Routing Diagrams 2A 9 ECS Circuit 2A 9 Self Diagnosis Test 2A 11 Diagnosis Test 2A 11 SPECIFICATIONS GENERAL SPECIFICATIONS 188 Application Front 3 stage Variable Damping Force Control Type Rear ECS Control Type 344 350 Shock Absorber 517 523 Max Length mm 245 3 Compressed L...

Page 814: ...e Voltage Rating V DC12 Current Rating A Less than 2 5 Current Time mS 95 105 4 75 5 25 Power Voltage V Body Vertical and Lateral Acceleration Sensor Less than 10 Consuming Current mA Less than 2 0 Output Current mA Operating Characteristics Output Voltage 0 75 2 5 4 25 1 5g 1g 3 5g Acceleration Vertical Acceleration Sensor Output Voltage 0 75 2 5 4 25 1g 0g 1g Acceleration Lateral Acceleration Se...

Page 815: ...spension the tires and the wheels involve several systems Consider all systems when you diagnose a complaint Some problems such as abnormal or excessive tire wear and scuffed tires may by the result of hard driving Always road test the vehicle first If possible do this road test with the customer Proceed with the following preliminary checks Correct any substandard conditions Checks Incorrect Whee...

Page 816: ...ENSION DIAGNOSIS Checks Worn or Broken Coil Spring Checks Incorrect Front wheel Alignment Worn or Loosened Lower Arm Bushing Action Replace Repair or Replace Steering Instability Action Replace VehicleBottoming ...

Page 817: ...amping force of shock absorber in SOFT MEDIUM HARD SYSTEM LAYOUT 1 ECS ECU 2 Body Vertical Acceleration Sensor Vertical Sensor 3 Body Lateral Acceleration Sensor Lateral Sensor Speed Sensor Axle Vertical Acceleration Sensor Wheel G Sensor Stop Lamp Switch Body Vertical Acceleration Sensor Vertical Sensor ECS Switch Indicator Lamp Actuator Shock Absorber Self Diagnosis Connector Damping Force Adjus...

Page 818: ...When ignition switch is ON system initialization will be performed for approx 3 seconds During this time warning lamp will stay ON and damping force will be switched to Hard status After 3 seconds warning lamp will turn off and normal control status will be restored Normal Damping Force Control Establishment Damping force will have Soft Medium Hard status in AUTO mode and Medium Hard status in SPO...

Page 819: ...al acceleration sensor wheel G sensor When sensor output voltage is less than 0 5 4 5V more than 4 5V 03 0 9 1 1sec Sensor Voltage 2 0 0 1V 3 0 0 1V 0 9 1 1sec Stop ride control Front actuator Check step motor power supply detecting circuit for open and short check for relative connectors 04 0 4 0 6sec IGN SW OFF ON Stop control after returning to the previ ous mode Rear actuator When defective de...

Page 820: ...hould be changed as below when battery voltage is applied between actuator connector terminals Connector terminal Battery Voltage Position of The Actuator Output Remark 1 White 2 Black OPEN 3 Red 1 White 2 Black 3 Red OPEN 1 White OPEN 2 Black 3 Red SOFT Mode MEDIUMMode HARD Mode ...

Page 821: ...SUSPENSION DIAGNOSIS 2A 9 ECS CIRCUIT SCHEMATIC AND ROUTING DIAGRAMS ...

Page 822: ... Sensor Wheel G Sensor Ground Vertical G Sensor Sensor 5V Chassis Ground Indicator Lamp NO Circuit NO Circuit 1 14 2 15 3 16 4 17 5 18 6 19 7 20 8 21 9 22 10 23 11 24 12 25 13 26 Chassis Ground Actuator R HEAD Actuator F MEDIUM Actuator F SOFT Brake Switch Lateral G Sensor Lateral G Sensor Ground Vertical G Sensor Ground Diagnosis K Line Diagnosis L Line ...

Page 823: ...agnosis from function selection display and press Enter 5 Select Korando 98 model year from vehicle model selection display and press Enter 6 Select Elctronic suspension system ECS from control system selection display and press Enter 7 Select Self diagnosis from diagnosis item selection display Notice Check sensor value output display if necessary 8 Determine the fault code and check defective co...

Page 824: ...ge l Condition IGN ON l Standard value voltage between pin 11 and 8 of ECU 4 5 5 0V 2 Check sensor output voltage l Condition IGN ON l Standard value voltage between pin 10 and 11 of ECU 0 5 4 5V 3 Check the sensor 4 Check circuit for open 5 Check connection of other connectors 1 Check step motor supply voltage 2 Check circuit for open 3 Check connection of other connectors 1 Check step motor supp...

Page 825: ...ption 0 30 2 30 30 0 4 mm 12 30 Specifications 2B 1 Wheel Alignment Specifications 2B 1 Diagnosis 2B 2 Tire Diagnosis 2B 2 Radial Tire Lead Pull 2B 3 Vibration Diagnosis 2B 5 Maintenance and Repair 2B 6 On Vehicle Service 2B 6 Wheel Alignment 2B 6 General Description and System Operation 2B 9 Four Wheel Alignment 2B 9 Toe 2B 9 Caster 2B 9 Camber 2B 9 ...

Page 826: ...oves at six locations Radial Tire Waddle Waddle is side to side movement at the front or rear of the vehicle It is caused by the steel belt not being straight within the tire or by excessive lateral runout of the tire or wheel The vehicle must be road tested to determine which end of the vehicle has the faulty tire The rear end of the vehicle will shake from side to side or waddle if the waddle ti...

Page 827: ... in the vehicle 011 center belts on radial tires can cause the tire to develop a side force while the vehicle rolls straight down the road If one side of the tire has even a little larger diameter than the diameter of the other side the tire will tend to roll to one side Unequal diameters will cause the tire to develop a side force which can produce vehicle lead pull The radial lead pull diagnosis...

Page 828: ...bly 3 Road test the vehicle Does the vehicle still lead pull 1 Switch the left front tire and wheel assembly with the left rear tire and wheel assembly and replace the left front tire Does the repair complete 1 Switch the right front tire and wheel assembly with the right rear tire and wheel assembly 2 Road test the vehicle Does the vehicle still lead pull 1 Switch the right front tire and wheel a...

Page 829: ...us drive axle runout l Improper tire inflation l Incorrect trim height l Bent or damaged wheels l Debris build up on the tire or the wheel l Irregular or excessive tire wear l Improper tire bead seating on the rim l Imperfections in the tires including tread deformations separations or bulges from impact damage Slight sidewall indentations are normal and will not affect ride quality TireBalancing ...

Page 830: ...easure B from the center of the steering knuckle shaft to the ground 4 If the difference between A and B is not within specification adjust vehicle height using torsion bar height control bolt B A Notice Before wheel alignment adjust vehicle height adjustment first 31 36mm Toe in 1 Measure toe in Specification 0 4mm 2 If toe in is not within specification loosen the tie rod nuts and adjust it by t...

Page 831: ... number of adjusting shims 1 inserted between the upper arm shaft and cross bracket Camber Change Specification 0 30 Notice Difference between the left and right should be adjusted within 30 Caster 1 Remove the free wheel hub 2 Measure caster with a wheel alignment equipment and a turning radius gauge Specification 2 30 30 Adjusting Shims 1 6 Iarge 3 2 large Increasing 1ea 19 38 Decreasing 1ea 19 ...

Page 832: ...on adjust it by increasing 1ea rear or decreasing 1ea front Caster Change Notice Difference between the left and right should be adjusted within 30 0 4 small 1 6 small Decreasing 1ea 11 43 FRONT Adjusting Shims Increasing 1 ea 11 43 0 4 small 1 6 small Decreasing 1 ea 11 43 REAR Adjusting Shims ...

Page 833: ...ension systems Each component must be strong enough to withstand and absorb extreme punishment Both the steering system and the front and the rear suspension must function geometrically with thebody mass The steering and the suspension systems require that the front wheels self return and that the tire rolling effort and the road friction be held to a negligible force in order to allow the custome...

Page 834: ...pring Specifications 2C 1 General Specifications 2C 1 Fastener Tightening Specifications 2C 2 Component Locator 2C 3 Front Suspension 2C 3 Maintenance and Repair 2C 4 On Vehicle Service 2C 4 Front Stabilizer Bar 2C 4 Application Description Torsion Bar 2C 6 Front Lower and Upper Arm 2C 8 Front Shock Absorber 2C 10 Axle Vertical Acceleration Sensor Wheel G Sensor 2C 12 Vertical and Lateral Sensor 2...

Page 835: ...ut Nlm 30 45 60 80 16 22 Torsion Bar Lower and Upper Arm Application Upper Arm Nut Upper Arm End Castle Nut Lower Arm Nut Lower Arm End Castle Nut Nlm 120 140 80 150 150 180 120 180 Steering Knuckle and Drive Shaft Application Brake Caliper Hose Bolt Brake Caliper Mounting Bolt Tie Rod Retaining Nut Upper Arm Retaining Nut Lower Arm Retaining Nut Nlm 25 35 85 105 35 45 80 150 120 180 M10 M12 ...

Page 836: ...FRONT SUSPENSION 2C 3 COMPONENT LOCATOR FRONT SUSPENSION 1 Shock Absorber 2 Upper Arm 3 Steering Knuckle 4 Lower Arm 5 Stabilizer Bar Link 6 Stabilizer Bar 7 Suspension Bumper ...

Page 837: ... ON VEHICLE SERVICE FRONT STABILIZER BAR 1 Front Stabilizer Bar 2 Bolt 30 45 Nm 3 Fixing Cap 4 Bushing 5 Nut 60 80 Nm 6 Stabilizer Bar Link Assembly 7 Outer Washer 8 Bushing 9 Center Washer 10 Lower Arm 11 Bushing 12 Outer Washer 13 Nut 16 22 Nm ...

Page 838: ... link Installation Notice 3 Remove the stabilizer bar fixing cap bolts arrow and Tightening Torque 60 80 Nm remove the stabilizer bar 4 Installation should follow the removal precedure in the reverse order Notice The distance between the end of the nut and the end of the link should be in 10 13 mm at the connection of the stabilizer bar link and lower arm Tightening Torque 30 45 Nm Tightening Torq...

Page 839: ...R 1 Nut 2 Torque Arm 3 Washer 4 Bolt M10 40 60 Nm M12 60 80 Nm 5 Torsion Bar End Seat 6 Dust Cover 7 Torsion Bar 8 Dust Cover 9 Height Control Arm Assembly 10 Height Control Bolt End Piece 11 Height Control Bolt 12 Height Control Seat ...

Page 840: ...end piece and the bolt end becomes 0 5 mm Installation Notice Install the torsion bar spring and adjust the distance between the end of the height control bolt and piece end the bolt end to be 50 55 mm Adjust the vehicle height Tightening Torque 60 80 Nm Tightening Torque 16 22 Nm 4 Remove the torque arm fixing nuts and bolts and then withdraw the torsion bar spring Installation Notice M10 M12 Tig...

Page 841: ...Adjusting Shim 4 Bolt 5 Bolt 6 Washer 7 Upper Arm End 8 Nut 16 22 Nm 9 Castle Nut 80 150 Nm 10 Cotter Pin Replace 11 Nut 150 180 Nm 12 Washer 13 Bolt 14 Lower Arm Assembly and Lower Arm End 15 Bolt 16 Washer 17 Nut 60 80 Nm Preceding Work Removal of the torsion bar spring Removal of the steering knuckle and drive shaft ...

Page 842: ... nut end and the screw end Tightening Torque 6 9 mm 60 80 Nm 3 Remove the lower arm mounting bolts 2 Installation Notice Tightening Torque 120 140 Nm 4 Pull out the cotter pin from the lower arm ball end assembly and remove lower arm after loosening the slotted nut Installation Notice Tightening Torque 150 180 Nm Notice Replace the cotter pin with new one 5 Installation should follow the removal p...

Page 843: ...2C 10 FRONT SUSPENSION FRONT SHOCK ABSORBER 1 Front Shock Absorber 2 Washer 3 Bush 4 Center Washer 5 Actuator Mounting Bracket 6 Nut 40 60Nm ...

Page 844: ... the nut actuator contacting surface of the mounting bracket and rod end should be 0 5 1 5mm 3 Remove the mounting bracket 5 Notice When installing the bracket it should be vertical to the frame side member 4 Remove the bush and check for damage and replace if necessary 5 Unscrew shock absorber lower bolt and nut and remove the shock absorber Notice Shock absorber is filled with gas never attempt ...

Page 845: ...own in the right drawing 2 Unscrew bolts 3 and remove the axle vertical acceleration sensor 1 Notice When installing the sensor to the bracket the sensor wiring should be upward 3 Installation should follow the removal procedure in the reverse order 1 Actuator Connector 2 Axle Vertical Acceleration Sensor Connector 3 FrontHoseMountingBracket 4 FrameSideMember AXLE VERTICAL ACCELERATION SENSOR WHEE...

Page 846: ... of the lateral sensor 2 should be in the right and connector connection of the vertical sensor 1 should face downward 2 Unscrew bolts and remove vertical sensor and lateral sensor Installation Notice 1 Body Vertical Acceleration Sensor Vertical Sensor 2 Body Lateral Acceleration Sensor Lateral Sensor 3 Installation should follow the removal procedure in the reverse order Tightening Torque 20 30 N...

Page 847: ...Removal Installation Procedure 1 Disconnect each connectors from the console box and remove the console box 2 Disconnect ECU connector 3 Unscrew 10mm x 2 bolts and remove ECS ECU 4 Installation should follow the removal procedure in the reverse order 4 Parking Brake Lever 5 Over Voltage Protection Relay ...

Page 848: ...ring Constant kg m Application Specifications 2D 1 General Specifications 2D 1 Fastener Tightening Specifications 2D 1 Diagnosis 2D 2 Noise During Straight Driving 2D 2 Oil Leakage 2D 2 Noise During Turning 2D 2 Heating 2D 3 Component Locator 2D 4 Maintenance and Repair 2D 5 On Vehicle Service 2D 5 Rear Suspension 5 Link 2D 5 Rear Shock Absorber 2D 9 FASTENER TIGHTENING SPECIFICATIONS Application ...

Page 849: ... Adjust Retightening NOISE DURING TURNING Check Worn or Damaged Tooth of Pinion or Side Gear Worn Pinion Shaft Excessive Backlash of Pinion Gear and Side Gear Excessive End play of Rear Axle Shaft Incorrect Contact of Side Gear and Differential Case Axle Housing Crack Bent or Poor Installation of Drive Pinion Oil Seal Damaged or Torn Drive Pinion Oil Seal Loosened Bearing Collar Worn or Damaged Un...

Page 850: ...REAR SUSPENSION 2D 3 HEATING Check Lack of Oil Insufficient Backlash of Gears Excessive Preload of Bearing Action Replenish Adjust Adjust ...

Page 851: ...2D 4 REAR SUSPENSION 1 Spring Seat 2 Coil Spring 3 Lateral Rod 4 Shock Absorber 5 Upper Arm 6 Lower Arm 7 Connecting Link 8 Stabilizer Bar COMPONENT LOCATOR ...

Page 852: ...EAR SUSPENSION 2D 5 MAINTENANCE AND REPAIR ON VEHICLE SERIVCE REAR SUSPENSION 5 LINK 1 Spring Seat 2 Coil Spring 3 Lateral Rod 4 Shock Absorber 5 Upper Arm 6 Lower Arm 7 Connecting Link 8 Stabilizer Bar ...

Page 853: ... Installation Notice Tightening Torque 16 22 Nm Distance Between the Nut end and the Screw end 10 13 mm Tightening Torque 30 45 Nm l Lateral Rod 1 Remove the lateral rod fixing nut from the frame Notice Completely press the coil springs Installation Notice 2 Remove the lateral rod fixing nut from the rear axle and remove the lateral rod Installation Notice Tightening Torque 150 180 Nm Tightening T...

Page 854: ...orque 50 65 Nm l Upper Arm 1 Remove the upper arm fixing nut from the frame Installation Notice 2 Remove the upper arm fixing nut from the rear axle and remove the upper arm Installation Notice Tightening Torque 150 180 Nm Tightening Torque 150 180 Nm l Lower arm 1 Remove the parking brake cable bracket Tightening Torque 30 45 Nm Distance between the nut end and the screw end 6 9 mm ...

Page 855: ... Remove the lower arm fixing nut from the frame Installation Notice 3 Remove the lower arm fixing nut from the rear axle and remove the lower arm Installation Notice Tightening Torque 150 180 Nm Tightening Torque 150 180 Nm ...

Page 856: ...REAR SUSPENSION 2D 9 REAR SHOCK ABSORBER 1 Rear Shock Absorber 2 Washer 3 Bush 4 Center Washer 5 Actuator Mounting Bracket 6 Nut M12 x 1 25 40 60Nm ...

Page 857: ...n clip 2 Unscrew the upper nut 6 Notice When screwing the nut actuator contacting surface of the mounting bracket and rod end should be 0 5 1 5mm 3 Remove the mounting bracket 5 Notice When installing the bracket it should be parallel to the frame side member 4 Remove the bush and check for damage and replace if necessary 5 Unscrew shock absorber lower bolt and nut and remove the shock absorber No...

Page 858: ...SPECIFICATIONS Application Wheel Bolt Nlm 80 120 110 130 Specifications 2E 1 General Specifications 2E 1 Fastener Tightening Specifications 2E 1 Diagnosis 2E 2 Wear Pattern Diagnosis 2E 2 Identification 2E 3 Radial Tire 2E 3 Wheel Disc 2E 3 Component Locator 2E 4 Wheel and Tire 2E 4 Maintenance and Repair 2E 5 On Vehicle Service 2E 5 Wheels and Tires 2E 5 Material Size Tire Type Size and Tire Pres...

Page 859: ...n Out Under Inflation One sided Tread Wear Incorrect Camber or Toe in Feather Edging of Tread Incorrect Toe in Spotty Tread Wear Out of Wheel Balance Spotty Wear wear Localized on Shoulder Sections Out of Wheel Balance Play in Hub Bearings Play in Ball Joint Defective Shock Absorber W05 40 003 Adjust Adjust Adjust Adjust Adjust Adjust Adjust Check play Adjust preload Check Check ...

Page 860: ...rom Rim Center to Wheel have Contacting Surface mm a Rim Width Inch d Rim Diameter Inch Section Height Rim Diameter Four Season Mud Snow P 215 75 R 15 94 H M S Speed Rating max 210km h Load Range below 670kg Rim Diameter inch Radial Tire Aspect Ratio Section Height Section Width x 100 Section Width mm Passenger Car 215 65 R 16 93 V Speed Rating max 240km h Load Range below 650kg Rim Diameter inch ...

Page 861: ...2E 4 TIRES AND WHEELS COMPONENT LOCATOR WHEEL AND TIRE 1 Wheel Bolts Steel Wheel 80 120 Nm Aluminium Wheel 110 130 Nm 2 Steel Wheel 3 Aluminium Wheel 4 Tire 5 Steel Wheel Weight Balance 6 Hub Cap ...

Page 862: ...ed D l The wear limit of snow tire is the same as normal tire 1 6mm and indicator location is marked Limit 1 6mm Standard 2 66mm Standard 2 03mm 2 Wear limit 3 Runout measurement l Excessive runout of tires and wheels can cause the abnormal wear of tire Using a dial indicator measure wheel and tire runout l Measure radial runout at the rim flange and center of the tire tread area l Measure lateral...

Page 863: ...ng and uneven wear Front Rear P235 75R15 2 1kg cm 30PSI 2 5 Wheel balance l Balance weights should be on each side When the wheel is out of balance or a tire has been repaired be sure to balance the wheel again l If total weight is over 150g readjust the balance by reinstalling the tire on the wheel l Balance weight should not protrude from the wheel rim over 3mm l For aluminum wheel use aluminum ...

Page 864: ...ions for installation and removal l Clean the mounting surfaces of hub and wheel l Do not apply grease or oil on the nuts and bolts It will cause looseness and poor tightening l Using a jack lift up the tire about 3cm from the ground l Tighten nuts in a criss cross pattern 2 3 times 10g 0 4oz 20g 0 7oz 30g 1 10oz 40g 1 40oz 50g 1 80oz 60g 2 1oz Steel 80 120Nm Aluminium 110 130Nm Tighten Torque ...

Page 865: ...ng Hub 3A 4 Vacuum Circuit 3A 5 Maintenance and Repair 3A 6 On Vehicle Service 3A 6 Vacuum Line 3A 6 Steering Knuckle and Drive Shaft 3A 8 Front Axle 3A 14 Unit Repair 3A 16 Axle Housing 3A 16 Application Drive Shaft Type Axle Housing Type Differential Type Differential Gear CV Joint Build up Conventional Hypoid Gear 4 56 4 56 3 73 4 56 5 38 4 27 4 89 4 89 4 55 4 55 4 55 5 86 3 73 3 73 4 89 1 3 L ...

Page 866: ...IGHTENING SPECIFICATIONS Steering Knuckle and Drive Shaft Application Drive Shaft to Front Axle Inner Shaft Wheel Speed Sensor Drive Shaft Cover Bolt Locking Hub Washer Screw Hub Flange Bolt Hub Nut Nlm 25 35 85 105 50 60 2 4 70 90 15 ...

Page 867: ...FRONT DRIVE AXLE 3A 3 1 Drive Shaft 2 Axle Housing Mounting Bolt 3 Axle Housing 4 Cross Member COMPONENT LOCATOR FRONT AXLE 5 Brake Disc 6 Hub Wheel 7 Locking Hub ...

Page 868: ...er 3 Vacuum Diaphragm 4 Diaphragm Retainer 5 Piston 6 Bolt M10 7 Lock Washer 8 O ring 9 Retaining Ring 10 Clutch Ring 11 Body 12 Return Spring 13 Bearing 14 O ring 15 Retaining Ring 16 Inner Drive Gear 17 Oil Seal 18 Oil Seal Race 19 Axle Retaining Ring ...

Page 869: ...FRONT DRIVE AXLE 3A 5 VACUUM CIRCUIT 1 Engine 2 Vacuum Pump 3 3 way Connector 4 T connector 5 Check Valve 6 Auto locking Hub Solenoid Valve 7 T connector Hose 8 Hub Hose left 9 Hub Hose right ...

Page 870: ...60 Nm 3 Cam Washer 4 Auto locking Hub Cap 5 Retainer Ring 6 Shim 7 Locking Hub 8 Band 9 Hose L 400 10 T connector 11 Hose L 250 white 12 Check Valve 13 Hose L 100 green 14 Auto Locking Hub Solenoid Valve 15 Bolt 16 Hose L 100 green 17 T connector 18 Hose L 720 yellow 19 Hose L 2 360 red 20 Corrugated Tube 21 Clip 22 Clip ...

Page 871: ...en connecting the check valve and each hose 2 Adjust the clearance between the retainer ring 5 and locking hub 7 using the shim 6 Notice Shim thickness 0 1 0 2 0 3 0 5 1 0 mm Normal Max 0 2 mm 3 Tighten the auto locking hub cap bolt to the specified torque and order Tightening Torque 50 60 Nm ...

Page 872: ...3A 8 FRONT DRIVE AXLE STEERING KNUCKLE AND DRIVE SHAFT 1 Front Axle Inner Shaft 2 Front Axle Drive Shaft 3 Spring Washer 4 Bolt 45 60 Nm 5 Steering Knuckle ...

Page 873: ... 130 Nm 2 Remove the autolocking hub vacuum hose 3 With ABS Remove the wheel speed sensor from the steering knuckle Installation Notice 4 Remove the mounting bolts and pull off the caliper assembly Installation Notice Tightening Torque 6 8 Nm Hose Bolt Mounting Bolt Tightening Torque 25 35 Nm 85 105 Nm Notice Be careful not to damage the brake hose ...

Page 874: ... not to exceed 0 2 mm Shim thickness 0 1 0 2 0 3 0 5 1 0 mm Tightening Torque 50 60 Nm 6 With full time transfer case 6 1 Detach the hub cap with screw driver and remove the snap ring on drive shaft Installation Notice Tightening Torque 2 4 Nm 5 3 Remove the screws and pull off the locking hub washer Installation Notice Notice For assembly adjust the clearance between the snap ring and hub not to ...

Page 875: ...sk brake dust shield Installation Notice Tightening Torque 4 6 Nm 6 2 Unscrew the bolts and remove hub flange Installation Notice Tightening Torque 70 90 Nm Before installation apply loctite on the mating surface 7 Remove the hub nut with special tool Tightening Torque 15 Nm ...

Page 876: ...que 35 45 Nm 11 Remove the cotter pin and nut from the steering knuckle arm and upper arm ball joint connection Installation Notice Tightening Torque 80 150 Nm Replace the cotter pin with new one 12 Remove the cotter pin and nut from the steering knuckle arm and lower and lower arm boll joint connection 13 Carefully remove the knuckle arm Installation Notice Tightening Torque 120 180 Nm ...

Page 877: ... Remove the drive shaft mounting bolts and remove the drive shaft Installation Notice Tightening Torque 45 60 Nm 15 Installation should follow the removal precedure in the reverse order Observe the tighening torque and sequence ...

Page 878: ... Nut 95 142 Nm 5 Cross Member 6 Bolt Front 7 Bushing 8 Spacer FRONT AXLE 9 Bushing 10 Nut 95 142 Nm 11 Front Axle Assembly 12 Nut 70 80 Nm 13 Bolt 14 Inner Axle Shaft LH 15 Inner Axle Shaft RH Preceding Work Removal of the front axle drive shaft Removla of the steering gear box ...

Page 879: ...tallation Notice Tightening Torque 70 80 Nm 4 Remove the cross member mounting nuts 2 from the frame and remove the cross member Installation Notice Tightening Torque 95 142 Nm 5 Support the axle housing on a suitable jack Remove the axle housing mounting bracket nuts Installation Notice Tightening Torque 62 93 Nm Tightening Torque 95 142 Nm 6 Lowering the jack carefully remove the axle housing as...

Page 880: ...3A 16 FRONT DRIVE AXLE UNIT REPAIR AXLE HOUSING Preceding Work Removal of the axle housing ...

Page 881: ...13 Washer 14 Companion Flange 15 Oil Seal Replace Apply Grease to the Sealing Rib 16 Bearing 17 Shim 18 Bearing Baffle 19 Shim 20 Bearing 21 Oil Slinger 22 Drive Pinion 23 Oil Filler Plug 28 41 Nm 24 Bolt 39 46 Nm 25 Axle Housing Cover Apply Liquid Gasket to the Contact Surface 26 Ring Gear 27 Bearing 28 Shim 29 Shaft Lock Pin 30 Differential Case 31 Bolt 75 90 Nm 32 Bolt 48 69 Nm 33 Washer 34 Bea...

Page 882: ... Torque 28 41 Nm 2 Unscrew the axle housing and housing mounting bracket bolts and remove the bracket and inner shaft assembly 3 Remove the bearing fixing snap ring of the inner shaft and pull out the bearing Separate the inner shaft and the mounting bracket 4 Remove the axle housing cover Notice Clean the cover and housing contact surfaces ...

Page 883: ...parts of the differential carrier assembly 7 Remove the drive pinion lock nut Disassemble the parts of the drive pinion AssemblyProcedure 1 Clean the all parts and check the followings l Check the ring gear and drive pinion for wear and damage If damaged replace it as a set l Check the bearing for sticks wear noise and turning resistance l Check the side gear pinion pinion shaft and thrust washer ...

Page 884: ...ide gear and pinion 5 Install the differential carrier assembly into the axle housing Notice Be careful not to change the caps Be sure to keep the original position of the caps Tightening Torque of the Lock Nut 240 310 Nm Tightening Torque of the Ring Gear Bolts 75 90 Nm Standard 0 0 05 mm Tightening Torque of the Bearing Cap Bolts 48 69 Nm ...

Page 885: ...parts of the front axle shaft and housing mounting bracket Notice Apply grease to the oil seal rib 9 Align the axle shaft and differential carrier spline and insert the axle shaft Assemble the axle housing mounting bracket to the axle housing Specified Value 0 13 0 20 mm Tightening Torque 39 46 Nm Tightening Torque 55 65 Nm ...

Page 886: ... apart from the ring gear l Noise can be occurred Insufficient backlash much l Gear contacts on the low flank l Gear can be damaged or worn l Noise can be occurred Adjust backlash Decrease backlash l Select proper shim s to move the drive pinion toward the ring gear toward toe Adjust backlash Increase backlash l Select proper shim s to move the drive pinion against the ring gear toward heel Adjust...

Page 887: ...truction Joint Type Number of Spider Tube Run Out after installation Front Shaft Dimension L I D O D Rear Shaft Dimension L I D O D Universal Joint with Yoke and Spider Spider Needle Roller Bearing 3 2 Within 0 3 mm Within 0 4 mm 579 f59 5 f63 5 583 5 f44 7 f50 8 617 6 f44 7 f50 8 595 6 f44 7 f50 8 824 f59 5 f63 5 777 f59 5 f63 5 Front Part Time T C Rear E 32 Engine The Others Diesel M T A T 4408 ...

Page 888: ...5 Grease Nipple 6 Dust Cap 7 Oil Seal 8 Split Washer 9 Slip Tube Shaft 10 Tube 11 Tube Yoke 12 Flange Yoke Notice Only the length of shaft is different and the components of front rear shaft are the same The deadener is inserted to the inside of tube of rear shaft both ends COMPONENT LOCATOR M T A T PART TIME T C ...

Page 889: ... Front Propeller Shaft 661LA 662LA 4 Front Propeller Shaft E32 5 Bolt 81 89 Nm MAINTENANCE AND REPAIR ON VEHICLE SERVICE PROPELLER SHAFT 6 Transfer Case 7 Bolt 81 89 Nm 8 Rear Propeller Shaft 9 Bolt 70 80 Nm 10 Rear Axle 11 Front Propeller Shaft E20 E23 ...

Page 890: ...marks and remove the propeller shaft 2 Place alignment marks before removing the spider 3 Using a snap ring pliers remove the snap ring 4 Slightly tapping the yoke shoulder using a brass hammer remove the bearing Remove the remaining bearings in the same way ...

Page 891: ...andard 16 668 Limit 16 647 5 If difficult to remove clamp the yoke side in a vise and tap off the needle bearing using a proper tool 6 Disassemble the universal joint parts l As axles move up and down universal joints allow drive angles to change without binding propeller shaft 1 Grease Nipple 2 Flange Yoke 3 Spider 4 Seal 5 Needle Roller Bearing 6 Snap Ring ...

Page 892: ...ect it using a press Standard 0 03 0 098 mm Limit 0 25 mm Limit 0 4 mm 5 Universal joint starting torque 6 Possible cause of vibration l Drift away of balance weights l Excessive runout of the propeller shaft l Using normal bolts l Excessive wear of the universal joint l Sticks in sleeve joint l Drive angle changes in universal joints or cross causes vibration and can be detected around 60 100 km ...

Page 893: ...he snap ring 4 Align the alignment marks and install the front and rear propeller shaft Tighten the nuts to the specified torque Installation Procedure Clean the disassembled parts and replace them if damaged 1 Align the alignment marks of the yoke and assemble the spider bearing and snap ring 2 Apply grease to the inner of the bearing cap of the needle roller bearing and assemble the needle rolle...

Page 894: ...omponent Locator 3D 5 Maintenance and Repair 3D 6 On Vehicle Service 3D 6 Axle Shaft 3D 6 Axle 3D 9 Unit Repair 3D 11 Axle Housing 3D 11 LSD Limited Slip Diffrential 3D 16 SPECIFICATIONS GENERAL SPECIFICATIONS Axle Shaft Type Axle Housing Type Differential Reduction Ratio Type Gear M T M T A T MB M T A T BTRA M T A T BTRA Description Semi floating Salibury Build up Conventional Type Hypoid Gear 4 ...

Page 895: ...r Bar Mounting Bolt Lateral Rod Mounting Nut Drive Pinion Lock Nut Oil Drain Plug Ring Gear Mounting Bolt Oil Filler Plug N m 50 65 70 80 150 180 50 65 150 180 30 45 150 180 240 310 28 42 75 90 28 42 4 89 4 55 4 55 4 55 5 86 3 73 3 73 4 89 1 9 L SEA 80W 90 API GL 5 M T A T MB M T A T MB A T BTRA M T A T MB A T BTRA Oil Capacity Oil Specification Application Description GENERAL SPECIFICATIONS Cont ...

Page 896: ...Seal Checks Lack of Oil Low Viscosity of Oil Insufficient Oil Excessive Backlash of Ring Gear Worn or Damaged Tooth of Ring and Pinion Gear Worn or Damaged Drive Pinion Bearing Bent Axle Housing Bent Differential Case Worn Pinion Shaft Incorrect Drive Pinion Preload Incorrect Contact of Ring Gear and Pinion DIAGNOSIS NOISE DURING STRAIGHT DRIVING Action Replenish Replace Replace Adjust Replace Rep...

Page 897: ...iversal Joint Snap Ring Loosened Yoke Bolts Action Adjust Replace Adjust Tighten NOISE Checks Worn or Damaged Universal Joint Bearing Fallen Off Universal Joint Snap Ring Loosened Yoke Connection Worn Sliding Joint Spline Insufficient Grease Action Replace Adjust or Replace Tighten Replace Apply as Necessary ...

Page 898: ...REAR DRIVE AXLE 3D 5 1 Spring Seat 2 Coil Spring 3 Lateral Rod 4 Shock Absorber 5 Upper Arm 6 Lower Arm 7 Connecting Link 8 Stabilizer Bar COMPONENT LOCATOR ...

Page 899: ...REPAIR ON VEHICLE SERVICE AXLE SHAFT 1 Brake Disc 2 Dust Plug 3 Rear Axle Shaft 4 Nut 50 65 Nm 5 Washer 6 Parking Brake Cable 7 Parking Brake Lining and Back Plate Assembly 8 Caliper Assembly 9 Gasket 10 Bolt 85 100 Nm 11 Rear Axle Housing ...

Page 900: ...heel Tightening Torque 3 Remove the bolts and the brake caliper Installation Notice Be careful not to damage the brake hose Tightening Torque 85 100 Nm 4 Remove the brake disc Notice To remove the disc install the bolts M8 x 1 25 into the service hole and uniformly tighten the bolts 5 Disconnect the parking brake cable 80 120 Nm 110 130 Nm ...

Page 901: ...m 6 Remove the plug from the axle shaft flange and remove the inner shaft mounting nuts Installation Notice 7 Remove the axle shaft parking brake lining and back plate assembly 8 Installation should follow the removal precedure in the reverse order ...

Page 902: ...ightening Torque 150 180 Nm 3 Remove the propeller shaft from the rear axle input shaft Installation Notice Notice Place alignment marks before removal Tightening Torque 81 89 Nm 4 Disconnect the parking brake cable and brake hose 5 Remove the lower arm mounting nuts and remove the lower arm from the axle housing Installation Notice ...

Page 903: ...ning Torque 50 65 Nm 8 Remove the stabilizer bar Installation Notice Tightening Torque 150 180 Nm 9 Remove the lateral rod mounting nuts and remove the lateral rod from the axle housing Installation Notice Tightening Torque 30 45 Nm 10 Lowering the axle housing slowly remove the coil springs and spring seats 11 Installation should follow the removal precedure in the reverse order Tightening Torque...

Page 904: ...g 7 Shim 8 Shim 9 Bearing Cup 10 Breather Nipple 11 Rear Axle Housing 12 Oil Drain Plug 28 42 Nm 13 Shim 14 Bearing 15 Drive Pinion 16 Bearing Cap 17 Bolt 87 124 Nm 18 Bearing 19 Shim 20 Ring Gear 21 Shaft Lock Pin 22 Differential Case 23 Ring Gear Mounting Bolt 75 90 Nm 24 Thrust Washer 25 Differential Pinion 26 Thrust Washer 27 Side Gear 28 Differential Shaft 29 Housing Cover 30 Bolt 38 46 Nm 31...

Page 905: ...ntact surface 3 Remove the bearing cap bolts and remove the bearing caps Pull out the differential carrier assembly Notice Place alignment marks on the bearing cap not to change the caps before removal When pulling out the differential carrier assembly be careful not to damage the axle housing 4 Disassemble the parts of the differential carrier assembly Tightening Torque 28 42Nm ...

Page 906: ...as set l Check the bearing for sticks wear noise or turning resistance l Check the side gear pinion pinion shaft and thrust washer for wear or damage l Check the differential carrier for crack or wear bearing contact surface Check the gear case for crack 2 Assemble the parts of the drive pinion 3 Assemble the parts of the differential carrier Tightening Torque of The Pinion Lock Nut 240 310 Nm Tig...

Page 907: ...al carrier assembly into the axle housing Tightening Torque of The Bearing Cap Bolts 48 69 Nm Notice Be careful no to change the caps Be sure to keep the original position of the caps 6 Measure backlash of the drive pinion and ring gear 7 Install the axle housing cover Specified Value 0 13 0 20 mm Tightening Torque 39 46 Nm ...

Page 908: ... apart from the ring gear l Noise can be occurred Insufficient backlash much l Gear contacts on the low flank l Gear can be damaged or worn l Noise can be occurred Adjust backlash Decrease backlash l Select proper shim s to move the drive pinion toward the ring gear toward toe Adjust backlash Increase backlash l Select proper shim s to move the drive pinion against the ring gear toward heel Adjust...

Page 909: ...ed Slip Differential Assembly 2 Shaft Hub Left 3 Shim 4 Thrust Washer 5 Face Cam Left 6 Cam Whillom 7 Thrust Bearing 8 Radial Bearing 9 Shaft Hub Right 10 Thrust Washer 11 Face Cam Right 12 Cage 13 Thrust Bearing 14 Plate Spring 15 Radial Bearing 16 Oil Catcher ...

Page 910: ...load torque l If necessary replace LSD assembly Procedure 1 Fix the right shaft of LSD to the special tool A 2 Install the special tool B to the left shaft and rotate counterclockwise and check the pre load torque Normal Torque 3 6 9 0kgm Notice If necessary replace LSD assembly ...

Page 911: ... exposed electrical terminals Disconnecting this cable will help prevent personal injury and damage to the vehicle The ignition must also be in LOCK unless otherwise noted Type Pedal Ratio Pedal Stroke Pedal Freeplay Type Inner Diameter Type Ratio Type I D of Caliper Cylinder Thickness of Brake Pad Thickness of Disc Plate Type I D of caliper Cylinder Thickness of Brake Pad Thickness of Disc Plate ...

Page 912: ...Adjuster Action Repair Retighten Replace Replace Repair Repair Lubricate Retighten Check Incorrectly Mounted Back Plate or Caliper Loosened Bolt of Back Plate or Caliper Crack or Uneven Wear of Brake Drum or Disc Pad or Lining Sticking to Contact Surface Excessive Clearance Between Caliper and Pad Uneven Contact of Pad Lack of Lubrication Loosened Suspension DIAGNOSIS NOISE OR VEHICLE VIBRATION WH...

Page 913: ... Lubrication Damaged Master Cylinder Check Valve or Piston Return Spring Action Bleeding Repair Adjust Repair Adjust Replace Repair Replace lubricate Replace INCREASING PEDAL STROKE PEDAL GOES TO FLOOR OR BRAKE DRAGGING Check Insufficient Clearance Between Push Rod and Master Cylinder Worn Brake Lining Oil or Grease on Lining Binding Parking Brake Cable Faulty Auto Adjuster Excessive Lever Stroke ...

Page 914: ...R ABS 1 Actuation Assembly Booster TMC 2 ABS Control Unit 3 Master Cylinder 2nd Tube Secondary 4 Master Cylinder 1st Tube Primary 5 Front Tube LH 6 Front Tube RH 7 Brake Hose 8 Rear Tube 9 Bolt 25 35 Nm 10 2 way Connector 11 3 way Connector ...

Page 915: ...4A 5 ABS ABD 1 Actuation Assembly Booster TMC 2 Master Cylinder 1st Tube Primary 3 Master Cylinder 2nd Tube Secondary 4 Hydraulic Modulator 5 Front Tube LH 6 Front Tube RH 7 Rear Tube RH 8 Rear Tube LH 9 2 way Connector ...

Page 916: ...4A 6 HYDRAULIC BRAKES NON ABS ABD 1 Actuation Assembly Booster TMC 2 3 way Connector 3 Front Tube LH 4 Front Tube RH 5 2 way Connector 6 Rear Tube 7 3 way Connector 8 LCRV ...

Page 917: ...tem at the hydraulic unit outlet pipe and wheel if pressure building is not enough by depressing the pedal only after above air bleeding For Caliper and Brake Hose Replacement 1 Check the oil level from the oil reservoir and refill if necessary 2 Run the engine and depress the pedal several times to build pressure and then keep the pedal fully depressed 3 Connect a vinyl tube to the caliper breath...

Page 918: ...l times to build pressure and then keep the pedal fully depressed 3 Loosen hydraulic pipe screws at the hydraulic unit outlets to bleed air 4 Repeat above step No 3 several times until there are no more air bubbles 5 Bleed air in the system from the wheels if pressure building is not enough by pressing the pedal only after above air bleeding ...

Page 919: ...E PEDAL 1 Clevis Pin 2 Brake Pedal 3 Stop Lamp Switch 4 Pad 5 Nut 21 35 Nm 6 Yoke Pin 7 Fulcrum Pin 8 Return Spring 9 Pedal Mounting Bracket 10 Washer 11 Nut 16 32 Nm 12 Bolt 8 18 Nm 13 Stopper Bolt Adjust 14 Rubber Pad Replace ...

Page 920: ...tice l Install in the upper hole 1 in case of Mando brake and in the below hole 2 incase of PBR brake l Install the snap pin fully in the hole of clevis pin l Apply the grease around the hole of clevis pin 3 Loosen the nut 4EA and bolt 2EA and remove the brake pedal 4 Installation should follow the removal procedure in the reverse order Tightening Torque 8 18 Nm ...

Page 921: ... F and adjust the pedal stroke 3 Free Play Stroke C Mando 138 mm PBR 132 mm Notice To adjust depress the brake pedal several times until there is no more vacuum left in the vacuum line To adjust loosen the lock nut D of the push rod and turn the rod Free Play E 1 4 mm Inspection Procedure 1 Inspect the wear of bushing 2 Inspect the warp and bend of brake pedal 3 Inspect the return spring of brake ...

Page 922: ...AULIC BRAKES LCRV LOAD CONSCIOUS REDUCING VALVE 1 Brake Tube from the master cylinder 2 Brake Tube from the rear brake 3 LCRV Bracket 4 Bolt 12 Nm 5 LCRV Assembly 6 Connecting Link 7 Spring Washer 8 Nut 14 18 Nm ...

Page 923: ...o vehicle load 2 Hydraulic Control Part It consists of valve stem devices which controls hydraulic pressure according to load detected by sensing part Trouble Shooting Poor Braking Possible Cause Air in Brake System Poor Adjustment of Sensor Spring Damaged Sensor Spring Fluid Leaking from LCRV Remedy Bleeding Adjust Replace Replace Possible Cause Poor Adjustment of Sensor Spring Internal Fluid Lea...

Page 924: ...g rod a to the No 1 hole 3 Adjust the clearance X to be 0 mm and tighten the bolt c using the lock nut b Tightening Torque 14 18 Nm 4 Remove the connecting rod a from the No 1 hole and reinstall it to the No 2 hole Tightening Torque 14 18 Nm 5 Place alignment marks between the lock nut b and adjusting screw c after the valve setting ...

Page 925: ...stener Tightening Specifications 4B 1 Maintenance and Repair 4B 2 TABLE OF CONTENTS SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Master Cylinder Nut Booster Nut N m 14 22 8 18 On Vehicle Service 4B 2 Booster Brake Master Cylinder 4B 2 ...

Page 926: ...4 Oil Level Sensor 5 Check Valve 6 Booster 7 Clevis Pin 8 Snap Pin 9 Seal 10 Spacer 11 Nut 8 18 Nm 12 Front Tube LH 13 Front Tube RH 14 Rear Tube 15 1st Tube Primary 16 2nd Tube Secondary MANDO PBR MAINTENANCE AND REPAIR ON VEHICLE SERVICE BOOSTER AND BRAKE MASTER CYLINDER ...

Page 927: ...ly sweep up 3 Remove the booster vacuum hose Notice l Connect fully to the end of vacuum hose when installing 4 Loosen the nut of master cylinder Installatione Notice 5 Remove the clevis pin and disconnect the pedal and brake booster push rod Notice l Install in the upper hole when PBR brake l Connect the snap pin in the hole of clevis pin fully l Apply the grease around the hole of clevis pin Tig...

Page 928: ...nd remove the booster from the dash panel Installation Notice Tightening Torque 8 18 Nm 7 Installation should follow the removal procedure in the reverse order 8 Add the fluid and bleed 9 If necessary adjust the pedal height pedal stroke and free play ...

Page 929: ...ecifications 4C 1 General Specifications 4C 1 Maintenance and Repair 4C 2 TABLE OF CONTENTS SPECIFICATIONS GENERAL SPECIFICATIONS Description Vacuum Assisted 5 6 1 On Vehicle Service 4C 2 Booster Brake Master Cylinder 4C 2 Pedal Stroke Inspection 4C 5 ...

Page 930: ... Oil Level Sensor 5 Check Valve 6 Booster 7 Clevis Pin 8 Snap Pin MAINTENANCE AND REPAIR ON VEHICLE SERVICE BOOSTER AND BRAKE MASTER CYLINDER 9 Seal 10 Spacer 11 Nut 8 18 Nm 12 Front Tube LH 13 Front Tube RH 14 Rear Tube 15 1st Tube Primary 16 2nd Tube Secondary MANDO PBR ...

Page 931: ...y sweep up 3 Remove the booster vacuum hose Notice l Connect fully to the end of vacuum hose when installing 4 Loosen the nut of master cylinder Installation Notice 5 Remove the clevis pin and disconnect the pedal and brake booster push rod Notice l Install in the upper hole when PBR brake l Connect the snap pin in the hole of clevis pin fully l Apply the grease around the hole of clevis pin Tight...

Page 932: ...d remove the booster from the dash panel Installation Notice Tightening Torque 8 18 Nm 7 Installation should follow the removal procedure in the reverse order 8 Add the fluid and bleed 9 If necessary adjust the pedal height pedal stroke and free play ...

Page 933: ...r third time brake booster is normal If there is no change in pedal stroke the brake booster is abnormal 2 Depress the brake pedal several times with engine stopped and depress the brake pedal and start the engine If the pedal goes down slightly the booster is normal 3 Depress the brake pedal with engine running and stop it with the pedal depressed If there is no change in pedal height during 30 s...

Page 934: ...htening Specifications 4D 1 Maintenance and Repair 4D 2 On Vehicle Service 4D 2 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Caliper Mounting Bolt Brake Hose Bolt Nut Caliper Bolt N m 85 105 25 35 22 34 Front Disc Brake 4D 2 Unit Repair 4D 5 Front Disc Brake 4D 5 ...

Page 935: ...e 3 Brake Hose 4 Brake Caliper 5 Bolt 20 Nm 6 Washer MAINTENANCE AND REPAIR ON VEHICLE SERVICE FRONT DISC BRAKE Preceding Work Removal of wheels and tires 7 Front Disc Assembly 8 Brake Pad 9 Brake Hose and Nut 25 35 Nm 10 Gasket Replace 11 Washer 12 Bolt 85 105 Nm ...

Page 936: ... disconnect the hose Installation Notice Tightening Torque 15 18 Nm 3 Remove the wheel speed sensor for ABS vehicles Installation Notice Tightening Torque 6 8 Nm 4 Remove the mounting bolts and then caliper assembly Installation Notice Tightening Torque 85 105 Nm Remove the hose mounting nut and disconnect the hose Installation Notice ...

Page 937: ...RAKES 5 Pull out the brake pads Replace pads if necessary Notice Always change the all pads on one wheel at a time 6 Installation should follow the removal procedure in the reverse order 7 Bleed the air from the system ...

Page 938: ... body and guide pin for wear damage or crank l Check the pads for uneven wear or oiliness l Check the boots for damage or tear Item With PBR With MANDO Wear Limit f 61 4mm f 61 0mm Standard 10 mm Wear Limit 2 0 mm Standard f 60 4mm f 60 0mm 3 Measure pad thickness Notice Always change the all pads on one wheel at a time 5 Check the rotor disc for score or runout Standard 24 mm Wear Limit 22 mm 2 M...

Page 939: ...ner Tightening Specifications 4E 1 Maintenance and Repair 4E 2 On Vehicle Service 4E 2 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Caliper Mounting Bolt Brake Hose Caliper Bolt N m 85 105 15 18 20 Rear Disc Brake 4E 2 Unit Repair 4E 4 Rear Disc Brake 4E 4 ...

Page 940: ...ake Pad 3 Brake Caliper 4 Gasket Replace 5 Bolt 20 Nm 6 Gasket Replace MAINTENANCE AND REPAIR ON VEHICLE SERVICE REAR DISC BRAKE Preceding Work Removal of wheels and tires 7 Brake Hose 8 Gasket Replace 9 Eye Hose Bolt 15 18 Nm 10 Washer 11 Bolt 85 105 Nm ...

Page 941: ... disconnect the hose Installation Notice 2 Unscrew the mounting bolts and remove the brake caliper assembly Installation Notice 3 Pull out the brake pads Replace pads if necessary Notice Always change the all pads on one wheel at a time 4 Installation should follow the removal procedure in the reverse order 5 Bleed the air from the system ...

Page 942: ...r body and guide pin for wear damage or crank l Check the pads for uneven wear or oiliness l Check the boots for damage or tear Standard f40 5 mm f38 2 mm Wear Limit f41 5 mm f39 2 mm 2 Measure caliper housing inner diameter 3 Measure pad thickness Standard 9 5 mm Wear Limit 2 0 mm Notice Always change the all pads on one wheel at a time 4 Measure rotor disc thickness 5 Check the rotor disc for sc...

Page 943: ... Component Locator 4F 4 ABS ABS ABD 5 3 4F 4 ABD System Description 4F 5 Self Diagnosis 4F 7 ABS ABS ABD 5 3 4F 7 Defect Codes 4F 9 Maintenance and Repair 4F 15 On Vehicle Service 4F 15 Wheel Speed Sensor 4F 15 Hydraulic Circuit 4F 17 ABS 5 3 4F 17 ABS ABD 5 3 4F 20 SPECIFICATIONS GENERAL SPECIFICATIONS Application Model ECU Number of Pins Operating Temperature Motor Operating Current Solenoid Coi...

Page 944: ...4F 2 ANTILOCK BRAKE SYSTEM ABS 5 3 SCHEMATIC AND ROUTING DIAGRAMS ...

Page 945: ...ANTILOCK BRAKE SYSTEM 4F 3 ABS ABD 5 3 ...

Page 946: ... ABS ABS ABD 5 3 1 ABS ABD Hydraulic Unit with ECU in cose of ABS only 2 ABS ABD ECU Unit in case of ABD 3 Rear Wheel Speed Sensor 4 ABS Warning Indicator Light 5 Diagnosis Connector 6 Front Wheel Speed Sensor COMPONENT LOCATOR ...

Page 947: ...m the ABS speed processing With the speed difference of the driven wheels the control deviation is calculated If the control deviation exceeds a certain threshold value the wheel with the greater slip is braked actively The threshold value depends on the vehicle speed It is reduced with increasing vehicle speed down to a constant value Pressure Modulation Depending on the control deviation and the...

Page 948: ...0 C ABD is disabled for this wheel It is permitted again if the model has calculated down the 350 C Lamp Concepts The system is equipped with an ABD information lamp which is blinking during ABD operation The activation of the EBD ABS warning lamp and the ABD info lampo is summarized in the following table Ignition ON ABS Operation ABD Operation System failure EBD ABS or ABD are not distinguished ...

Page 949: ... 2 Abnormal 1 pulse fault code Notice l If appeared initial fault code and above 2 differnt fault code perform again initialization l Fault code will be output the numbers of fault code with a interval of 1 second turn on 0 75 sec turn off 0 25 sec Fault Code Elimination After repairing the defect parts eliminate the fault from ECU 1 Ground the diagnosis No 13 terminal to No 1 ground terminal for ...

Page 950: ...ences of Normal Code 01 TW1 T Te TW2 l Time Differences of Fault Code 15 TW1 T Te TW2 Time Characteristics 1 Initialization Tba 5 0 sec Tba 1 8 2 2 sec 2 Output of Fault Code TW1 1 8 2 2 sec TW2 1 8 2 2 sec T 0 75 sec Te 0 25 sec 3 Elimination of Fault Code Tb1 5 0 sec ...

Page 951: ...andard air gap 0 35 1 60 mm l Check output voltage of the sensor by rotating the wheel 1 2 1 revolution per second and shaking sen sor wire When measured by multi meter AC output voltage 70 mV When measured in oscilloscope output voltage 120 mV P P l Replace the sensor l Check wire for ground and open l Check connection of the wheel speed sensor con nector and ECU side connector l Measure the air ...

Page 952: ... side connector l Measure air gap between wheel teeth and wheel speed sensor and check installation of wheel tooth Standard air gap 0 15 1 20 mm l Check output voltage of the sensor by rotating the wheel 1 2 1 revolution per second and shaking sen sor wire When measured by multi meter AC output voltage 70 mV When measured in oscilloscope output voltage 120 mV P P l Replace the sensor l Check numbe...

Page 953: ...CU hydraulic modulator l Check terminals for open or short When connector is removed l Replace the hydraulic modulator l Check each valve by using SCANER s solenoid valve overriding function l Check connection of connector and terminals in the ECU hydraulic modulator l Check terminals for open or short When connector is removed l Replace the hydraulic modulator l Check each valve by using SCANER s...

Page 954: ...y using SCANER s solenoid valve overriding function l Check connection of connector and terminals in the ECU and hydraulic modulator l Check terminals for open or short When connector is removed l Replace the hydraulic modulator l Check each valve by using SCANER s pump motor overriding function l Check resistance between pump motor ground ter minal and battery negative terminal total resistance s...

Page 955: ...age is applied to ECU ABD No 1 ABS No 15 pin when ignition switch is turned to ON or OFF l Check ABS fuses of 15A and 80A l Replace the ECU l Check wire ECU No 50 for open or loose contact l Check connection between connectors l Check relevant wires for open or short When connector is removed l Check voltage between ECU side ground ABD No 1 ABS No 15 pin and acceleration sensor side ground ABD No ...

Page 956: ...de ground ABD No 1 ABS No 15 pin ECU side ABD No 39 ABS No 30 pin When connector is installed and power is applied Voltage less than 0 25 V l Check voltage among related terminals When connector is installed and power is applied Voltage between ECU ABD No 51 ABS No 10 pin and ABD No39 ABS No 30 pin 4 75 5 25 V Signal voltage between ECU ABD No 51 ABS No 10 pin and ABD No39 ABS No 30 pin 1 95 V 3 4...

Page 957: ...ANTILOCK BRAKE SYSTEM 4F 15 MAINTENANCE AND REPAIR ON VEHICLE SERVICE WHEEL SPEED SENSOR 1 Bolt 2 Front Wheel Speed Sensor 3 Knuckle 4 Bolt 5 Rear Wheel Speed Sensor 6 Rear Axle ...

Page 958: ...move the hydraulic lines of the hydraulic unit During removal be careful not to drip brake fuid on the body Installation Notice 3 Unscrew hydraulic unit mounting nuts 2EA and remove the unit from the bracket Installation Notice Tightening Torque 9 12 Nm Removal of the ABS ABD Unit Location Under the front passenger s seat 1 Remove the wiring connector of the ABS ABD or ABS Attached type ECU 2 Remo...

Page 959: ...ULIC CIRCUIT ABS 5 3 Pressure Increased 1 Master Cylinder 2 Hydraulic Unit 3 Damping Chamber 4 Return Pump 5 Return Pump Motor 6 Accumulator Chamber 7 Inlet Valve for Each Wheel 8 Outlet Valve for Each Wheel 9 Front Wheel 10 Rear Wheel ...

Page 960: ... SYSTEM Pressure Decreased 1 Master Cylinder 2 Hydraulic Unit 3 Damping Chamber 4 Return Pump 5 Return Pump Motor 6 Accumulator Chamber 7 Inlet Valve for Each Wheel 8 Outlet Valve for Each Wheel 9 Front Wheel 10 Rear Wheel ...

Page 961: ... 4F 19 Pressure Maintained 1 Master Cylinder 2 Hydraulic Unit 3 Damping Chamber 4 Return Pump 5 Return Pump Motor 6 Accumulator Chamber 7 Inlet Valve for Each Wheel 8 Outlet Valve for Each Wheel 9 Front Wheel 10 Rear Wheel ...

Page 962: ...1 Master Cylinder 2 Hydraulic Unit 3 Damping Chamber 4 Return Pump 5 Return Pump Motor 6 Accumulator Chamber 7 Inlet Valve for Each Wheel 8 Outlet Valve for Each Wheel 9 Wheel 10 Prime Valve ASV 11 Pilot Valve USV 12 Check Valve 13 ISD Integrated Suction Damper ...

Page 963: ...er Cylinder 2 Hydraulic Unit 3 Damping Chamber 4 Return Pump 5 Return Pump Motor 6 Accumulator Chamber 7 Inlet Valve for Each Wheel 8 Outlet Valve for Each Wheel 9 Wheel 10 Prime Valve ASV 11 Pilot Valve USV 12 Check Valve 13 ISD Integrated Suction Damper ...

Page 964: ...aster Cylinder 2 Hydraulic Unit 3 Damping Chamber 4 Return Pump 5 Return Pump Motor 6 Accumulator Chamber 7 Inlet Valve for Each Wheel 8 Outlet Valve for Each Wheel 9 Wheel 10 Prime Valve ASV 11 Pilot Valve USV 12 Check Valve 13 ISD Integrated Suction Damper ...

Page 965: ... installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals Disconnecting this cable will help prevent personal injury and damage to the vehicle The ignition must also be in LOCK unless otherwise noted SPECIFICATIONS GENERAL SPECIFICATIONS Application Parking Brake Lever Bolt Cable Mounting Bracket Bolt N m 8 18 8 18 FASTENER TIGHTENIN...

Page 966: ...4G 2 PARKING BRAKE COMPONENT LOCATOR PARKING BRAKE 1 Parking Brake Lever 2 Bolt 8 18 Nm 3 Front Parking Brake Cable 4 Equalizer 5 Nut 6 Bolt 8 18 Nm 7 Rear Parking Brake Cable 8 Brake Disc ...

Page 967: ...ight and left cable from equalizer while parking brake lever is released 3 Unscrew 8 bolts and remove the parking brake lever assembly Installation Notice Notice Tighten the bolts with sequence number while the lever is pulled up 4 to 6 notches Tightening Torque 8 18 Nm 4 Unscrew the frame and lower arm side cable mounting bracket bolts Installation Notice Tightening Torque 8 18 Nm ...

Page 968: ...4G 4 PARKING BRAKE 5 Remove the retainer with a screwdriver and disconnect the brake cable 6 Installation should follow the removal procedure in the reverse order ...

Page 969: ...c Control System 5A 31 Power Train System 5A 42 Torque Converter 5A 43 Clutch Packs 5A 44 Bands 5A 45 One Way Clutches 5A 45 Planetary Gear Set 5A 45 Parking Mechanism 5A 46 Power Flows 5A 47 Introduction 5A 47 Power Flow Park and Neutral 5A 48 Power Flow Reverse 5A 49 Power Flow Manual 1 5A 50 Power Flow Drive 1 5A 51 Power Flow Drive 2 and Manual 2 5A 52 Power Flow Drive 3 and Manual 3 5A 54 Pow...

Page 970: ...iplication Stall speed rpm 0574 000001 D23LA 0574 000002 E32 0574 000004 D29LA 0574 000005 E23 0574 000020 0574 000021 Gear Ratios First Second Third Fourth Reverse Lubricant Type Capacity Dry System Service Refill Gear Train End Float Gear Set Pinion End Float Descriprtion 260 2 0 1 2100 2250 2050 2250 2100 2200 1800 2100 2 741 1 1 508 1 1 000 1 0 708 1 2 429 1 Castrol TQ95 or other approved flui...

Page 971: ...sition Steel C3 Composition Steel C4 Composition Steel 0574 000002 5 5 2 5 4 2 4 4 2 3 4 1 0574 000001 0574 000004 0574 000005 4 6 2 4 5 2 3 5 2 3 4 1 Note Numbers in brackets indicate number of selective thickness steel plates required to achieve specifed clutch pack clearance ...

Page 972: ...0555 336269 0555 336270 0555 332895 Description Solenoid Thermistor Electronic Tester Solenoid Bench Tester Transmission Bench Cradle Pump Puller Pin Remover Installer Tool Cross Shaft Detent Lever Clutch Spring Compressor Clutch Pack Clearance Kit Seal Removal Tool Cross Shaft Oil Seal Dolly Cross Shaft Assembly Bullet Seal Compressor Pin Press Seal Dolly Alignment Tool Pump Seal Dolly End Float ...

Page 973: ...AUTOMATIC TRANSMISSION 5A 5 SCHEMATIC AND ROUTING DIAGRAMS TCU CIRCUIT 4WD DIESEL ...

Page 974: ...5A 6 AUTOMATIC TRANSMISSION TCU CIRCUIT 4WD GASOLINE ...

Page 975: ...AUTOMATIC TRANSMISSION 5A 7 SHIFT PATTERN DIAGRAM 661LA NORMAL MODE ...

Page 976: ...5A 8 AUTOMATIC TRANSMISSION 661LA POWER MODE ...

Page 977: ...AUTOMATIC TRANSMISSION 5A 9 662LA NORMAL MODE ...

Page 978: ...5A 10 AUTOMATIC TRANSMISSION 662LA POWER MODE ...

Page 979: ...AUTOMATIC TRANSMISSION 5A 11 662LA LOW MODE ...

Page 980: ...5A 12 AUTOMATIC TRANSMISSION E32 POWER MODE ...

Page 981: ...AUTOMATIC TRANSMISSION 5A 13 E32 NORMAL MODE ...

Page 982: ...5A 14 AUTOMATIC TRANSMISSION E32 LOW MODE ...

Page 983: ...AUTOMATIC TRANSMISSION 5A 15 E23 POWER MODE ...

Page 984: ...5A 16 AUTOMATIC TRANSMISSION E23 NORMAL MODE ...

Page 985: ...AUTOMATIC TRANSMISSION 5A 17 E23 LOW MODE ...

Page 986: ...ons a kickdown switch to control all shift feel and shift schedule aspects The TCU drives a single proportional solenoid multiplexed to three regulator valves to control all shift feel aspects The output pressure of this solenoid is controlled as a function of transmission sump temperature to maintain consistent shift feel throughout the operating range Shift scheduling is highly flexible and seve...

Page 987: ...AUTOMATIC TRANSMISSION 5A 19 Figure 1 1 Conventional VS Electronic Transmission Control System ...

Page 988: ...ator interfaces are described below GEAR SELECT LEVER OPERATION The transmission uses a conventional selector lever The selector lever can be moved from one position to another within the staggered configuration of the selector lever gate to positively indicate the gear selection as shown on figure 2 1 For information about the gear selections available refer to table 2 1 Figure 2 1 Typical Gear S...

Page 989: ... with inhibited engagement as a function of vehicle speed engine speed and throttle position The inhibitor switch allows the en gine to start Reverse gear operation with inhibitor engagement as a function of vehicle speed engine speed and throttle position The inhibitor switch enables reverse lamp operation Rear band applied only with inhibited engagement as a function of vehicle speed engine spee...

Page 990: ...trols the hydraulic control system This control is via the hydraulic valve body which contains seven electro magnetic solenoids Six of the seven solenoids are used to control the line pressure operate the shift valves and the torque converter lock up clutch and to turn on and off the two regulator valves The two regulator valves control the shift feel The seventh solenoid is the proportional or va...

Page 991: ...perature C 20 0 20 100 135 Overheat Mode Threshold Maximum 17 287 6 616 2 723 196 85 Minimum 13 638 5 177 2 278 177 75 Resistance Ohms Table 3 1 Temperature Resistance Characteristics Figure 3 2 Temperature Resistance Characteristics ...

Page 992: ... with the object to maintain maximum driveability without damaging the transmission In general input failures are handled by providing a default value Output failures which are capable of damaging the transmission result in full limp mode giving only third or fourth gear and reverse For further details of limp modes and memory retention refer to the Diagnostic Section The TCU is designed to operat...

Page 993: ...minates slippage in the torque converter Both these actions combine to reduce the oil temperature in the transmission Connects To Solenoid 1 Solenoid 2 Solenoid 3 Solenoid 4 Solenoid 5 Solenoid 6 Solenoid 7 Solenoid 5 Temp Sensor Temp Sensor Wire Color Red Blue Yellow Orange Green Violet Brown Green White White Pin No 1 2 3 4 5 6 7 8 9 10 Table 3 2 Pin No Codes for Temperature Sensor Location In S...

Page 994: ...nd if a change occurs stores the new voltage values However these limits will be lost and will require relearning should a new TCU be installed or the throttle calibration data is cleared by the execution of a particular sequence This last instance depends on the installation and reference should be made to the Diagnostics Section of this manual The relearning will happen automatically Notice Abov...

Page 995: ...to the positive side of the battery The signal is taken from the main supply to the TCU If operating conditions are such that the battery voltage at the TCU falls below 11 3V the transmission will adopt a low voltage mode of operating in which shifts into first gear are inhibited All other shifts are allowed but may not occur because of the reduced voltage This condition normally occurs only when ...

Page 996: ...noids that combine to control shift quality and sequencing S3 switches the clutch regulator valve off or on S4 switches the front band regulator valve off or on S5 is a variable force solenoid that ramps the pressure during gear changes This solenoid provides the signal pressure to the clutch and band regulator thereby controlling the shift pressures S6 is a normally open On off solenoid that sets...

Page 997: ... S3 OFF S4 OFF S3 OFF S4 OFF S4 OFF S1 OFF S4 OFF S1 OFF S2 ON S3 OFF S2 ON S3 OFF S4 OFF S4 OFF S1 ON S2 ON S3 OFF S4 OFF S1 ON S4 OFF S7 OFF Typical S5 Current Ramp 750mA to 600mA 850mA to 750mA 850mA to 750mA 700mA to 500mA 750mA to 600mA 750mA to 900mA 750mA to 950mA 600mA to 1000mA 600mA to 450mA 20 kph 550mA to 400mA 60 kph 800mA to 650mA 100 kph 700mA to 950mA 800mA to 950mA 700mA to 400mA ...

Page 998: ... is always below line 500 pressure When the VPS is at standby that is no gearshift is taking place the VPS current is set to 200 mA giving maximum output pressure Under steady state conditions the band and clutch regulator valve solenoids are switched off This applies full Line 500 pressure to the plunger and because Line 500 pressure is always greater than S5 pressure it squeezes the S5 oil out b...

Page 999: ... on a shift valve s switching VPS pressure to the band and or clutch regulator valve and then sending the VPS a ramped current The shift is completed by switching the regulators off and at the same time causing the VPS to reach maximum pressure All downshifts are accomplished by switching VPS pressure to the band and or clutch regulator valve and sending a ramped current to the VPS The shift is co...

Page 1000: ...5A 32 AUTOMATIC TRANSMISSION Figure 3 7 Hydraulic Control Circuit ...

Page 1001: ...AUTOMATIC TRANSMISSION 5A 33 Figure 3 8 Valve Body Figure 3 9 Pump Cover Valve Body Figure 3 8 depicts the valve body as a unit as viewed from the transmission sump Figure 3 9 depicts the pump cover ...

Page 1002: ...is allowed to exhaust via the 1 2 shift valve The 1 2 shift valve works in conjunction with the 3 4 shift valve described below to disengage the C4 clutch in first gear and engage C4 in second gear When Manual 1 is selected the C4 clutch and rear band B2 are engaged Figure 3 11 1 2 Shift Valve ManualValve The manual valve refer to figure 3 10 is connected to the vehicle selector mechanism and cont...

Page 1003: ... located at the end of the valve spool During a 3 4 gearshift the 3 4 shift valve l Exhausts the front band release circuit B 1R thereby allowing the application of the front band B1 l Connects the inner apply area of the front servo B 1AI to the band apply feed circuit BAF thus allowing greater apply forces to the front band l Exhausts the overrun clutch circuit OC which allows the C4 clutch to d...

Page 1004: ...Supply Pressure Regulator Valve and Line Pressure Control Valve Solenoid Supply Pressure Regulator Valve The solenoid supply valve refer figure 3 15 supplies a constant pressure to all solenoids 51 to 57 Line pressure is used as the feed oil to this regulator and the output is termed line 500 Line Pressure Boost Valve Line pressure is controlled by 56 which acts as the line pressure boost valve re...

Page 1005: ...2 25 times the S5 signal pressure when S3 is On When S3 is Off the output pressure is 2 25 times the line 500 pressure Band Apply regulator Valve The band apply regulator valve refer figure 3 17 is a fixed ratio valve It provides a regulated pressure to the front servo and controls the rate of change of state of the front band B1 to give the desired shift quality This ratio is 1 4 1 Second gear oi...

Page 1006: ...oadspeed 3 km h 2 In R road speed 10 km h 3 Engine speed 1400 rpm 4 For diesel vehicles throttle 25 5 For gasoline vehicles throttle 12 Under these conditions the TCU switches solenoids S1 and S2 to Off The reverse lockout valve toggles under the influence of the S1 S2 pressure to connect the line pressure to the B2 feed Oil is fed to both the inner and outer apply areas of the rear servo piston a...

Page 1007: ...pressures are controlled by separate band and clutch regulator valves and the output of S5 When reverse gear is selected both the low and high line pressure values are boosted to guard against slippage This is achieved by applying reverse oil line pressure to the PRV to assist the spring load The other end of the valve contains ports for line pressure feedback and 56 pressure The PRV also regulate...

Page 1008: ...ve is governed by the signal pressure from S7 When the valve is in the off or released position converter feed oil from the PRV is directed to the release side of the converter clutch After flowing through the converter oil returns to the converter clutch control valve and is then directed to the oil cooler When the valve is in the on or applied position regulated oil from the converter clutch reg...

Page 1009: ...ailure Figure 3 22 C1 Bias Valve B1R Exhaust Valve The B1R exhaust valve refer figure 3 23 is a two position spring loaded valve located in the transmission case directly adjacent to the front servo It permits the servo release oil to be rapidly exhausted into the transmission case during application of the front band B1 This prevents the need to force the oil back from the front servo through the...

Page 1010: ... Clutch 1 2 OWC The 1 2 shift is accomplished by applying the B1 band and overrunning the 1 2 OWC The 2 3 shift is accomplished by applying the C1 clutch and releasing the B1 band The 3 4 shift is accomplished by re applying the B1 band and overrunning the 3 4 OWC Reverse gear is engaged by applying the C3 clutch and the B2 band The C4 clutch is applied in the Manual 1 2 and 3 ranges to provide en...

Page 1011: ... and piston assembly enables the torque converter to lock up under favourable conditions Lock up is only permitted to occur in third and fourth gears under specified throttle and road speed conditions Lock up is achieved by applying hydraulic pressure to the damper and piston assembly which couples the turbine to the converter cover locking up the converter and eliminating unwanted slippage Whenev...

Page 1012: ...urth gears C2 CLUTCH When applied this clutch pack allows the input shaft to drive the forward sun gear via the 3 4 OWC This occurs in all forward gears C3 CLUTCH When applied this clutch pack allows the input shaft to drive the reverse sun gear This only occurs in reverse gear C4 CLUTCH When applied this clutch provides engine braking on overrun This occurs in Manual 1 2 and 3 and also Drive 2 an...

Page 1013: ...s the planet carrier assembly from rotating In Manual 1 only the inner area of the apply piston is utilised In Park Reverse and Neutral both areas are utilised for greater clamping force Figure 4 4 Bands ONE WAY CLUTCHES The transmission uses two OWCs the 1 2 OWC and the 34 OWC Note that a third OWC is located in the torque converter also known as a sprag The 1 2 OWC is located between the planeta...

Page 1014: ...ngage the parking pawl refer to figure 4 5 The pawl will engage the external teeth on the ring gear thus locking the output shaft to the transmission case When Park is not selected a return spring holds the parking pawl clear of the output shaft preventing accidental engagement of Park Figure 4 5 Park Rod and Cross Shaft ...

Page 1015: ...l Power Flow Drive4 Lock Up Each power flow is described in the following sections Table 5 1 details the engaged elements versus the gear selected for all transmission selections Gear State Park and Neutral Reverse Manual 1 Drive 1 Drive 2 and Manual 2 Drive 3 and Manual 3 Drive 3 Lock Up and Manual 3 Lock Up Drive 4 Overdrive Drive 4 Lock Up C1 X X X X C2 X X X X X X X C3 X C4 X X X X B1 X B2 X X...

Page 1016: ...are activated as follows l Solenoids S1 and S2 are switched off l Line pump pressure is applied to the primary regulator valve PRV and to the solenoid supply valve l The converter oil cooler and lubrication circuits are charged from the primary regulator valve l The line 500 circuit is charged by the solenoid supply valve l The S5 circuit is charged by the variable pressure solenoid S5 l Line pres...

Page 1017: ...ockwise or reverse direction Control To maintain this arrangement in the steady state solenoids and valves are activated as follows l Solenoids S1 and S2 are switched off l Line pressure is directed through the reverse lockout valve to both the inner and outer apply areas of the rear servo piston for B2 band application l Line pressure feeds the reverse oil circuit via the manual valve l Reverse o...

Page 1018: ...haft in a clockwise or forward direction l The C4 clutch provides engine braking through the 3 4 OWC on overrun Control To maintain this arrangement in the steady state solenoids and valves are activated as follows l Solenoids S1 and S2 are switched ON l The 1 2 2 3 and 34 shift valves are held in their first gear positions by line 500 pressure l Drive line pressure oil from the manual valve engag...

Page 1019: ...on force and the long pinion rotates on its axis driving the internal ring gear and output shaft in a clockwise or forward direction l There is no engine braking on overrun Control To maintain this arrangement in the steady state solenoids and valves are activated as follows l Solenoids S1 and S2 are switched On l The 1 2 2 3 and 3 4 shift valves are held in their first gear positions by line 500 ...

Page 1020: ...On l Drive line pressure oil from the manual valve engages the C2 clutch l When S1 switches off S1 oil pressure which is derived from line 500 pressure moves the 3 4 shift valve to the left At the same time S1 oil is directed to the 1 2 shift valve which moves the valve to the second gear position l 2nd oil line pressure from the 1 2 shift valve is directed to the band apply regulator valve and to...

Page 1021: ...AUTOMATIC TRANSMISSION 5A 53 ...

Page 1022: ...the 2 3 shift valve l The band apply regulator valve supplies 2nd oil regulated to line pressure multiplied by the valve ratio to the band apply feed BAF circuit l Band apply feed oil is directed to The outer apply area of the front servo The 1 2 shift valve to provide an exhaust port when the transmission is shifted to first gear The 3 4 shift valve for use when the transmission is shifted into f...

Page 1023: ...AUTOMATIC TRANSMISSION 5A 55 ...

Page 1024: ... and allowed to exhaust through the S7 solenoid This allows the valve to move to the clutch engage position l Regulated apply feed oil derived from line 500 oil at the converter clutch regulator valve is directed by the converter clutch control valve to the engage side of the converter clutch l Converter clutch release oil is exhausted at the converter clutch control valve l Converter feed oil is ...

Page 1025: ...urth gear position by line 500 pressure on the large end of the valve l The 1 2 shift valve is held in the fourth gear position by S2 oil pressure l 2nd oil line pressure from the 1 2 shift valve is directed to the band apply regulator valve and to the 2 3 shift valve l The band apply regulator valve supplies 2nd oil regulated to line pressure multiplied by the valve ratio to the band apply feed B...

Page 1026: ...5A 58 AUTOMATIC TRANSMISSION ...

Page 1027: ...d to exhaust through the S7 solenoid This allows the valve to move to the clutch engage position l Regulated apply feed oil delved from Line 500 oil at the converter clutch regulator valve is directed by the converter clutch control valve to the engage side of the converter clutch l Converter clutch release oil is exhausted at the converter clutch control valve l Converter feed oil is re routed by...

Page 1028: ... Information that is available includes engine and road shaft speed transmission oil temperature throttle position solenoid gear status and gear lever position Current and stored faults detected by the electronics are also available TCU Pin Description The TCU pin descriptions are listed in table 6 1 1 The wiring loom pins are shown in figure 6 1 1 Pin No 1 2 3 4 5 6 7 8 Identification Common Grou...

Page 1029: ... when a kickdown is required at high throttle position Switch to select NORMAL POWER or WIN TER shift schedule Voltage varies from OV to 12V Switch to indicate 4WD HIGH RANGE is se lected Ignition power is used as the main power source to drive the unit and the solenoids Drives jewel in the instrument cluster to indi cate gear leverposition 1 Drives jewel in the instru ment cluster to indicate gea...

Page 1030: ...to set the selected gear This ensures the earth path for the VPS and the current in this line is monitored to give feed back control of the VPS PRNDL switch ground Ground reference for temperature sensor in put On Off solenoid normally open sets low high line pressure On off solenoid normally open combines with other On off solenoid to set the selected gear On off solenoid normally open combines w...

Page 1031: ...AUTOMATIC TRANSMISSION 5A 63 Figure 6 1 1 Wiring Loom Pins ...

Page 1032: ...he throttle being higher more open than it is There ore at zero throttle settings the transmission may calculate that sufficient throttle opening is present to justify high line pressure and switch solenoid 6 to OFF Other symptoms are a late upshifts and b lock up maintained at zero throttle when the vehicle speed is sufficiently high 3 Engine Speed Fault l All shifts will be firm because an engin...

Page 1033: ...lt conditions are listed in table 6 1 2 10 ON OFF Solenoid Fault Solenoids 6 7 If solenoid 6 is found faulty it is always disabled resulting in high line pressure being applied continuously If solenoid 7 is found faulty it is disabled resulting in the transmission being locked always The transmission does not go into LHM 11 Variable Pressure Solenoid Fault The transmission adopts its LHM operation...

Page 1034: ...esults in a 1 2 then 2 1 overrun downshift as the vehicle accelerates from rest The following shifts become poor 1 3 1 4 2 1 2 3 2 4 4 2 4 1 The following shifts become poor 3 4 4 3 3 2 There may be slippage in the gears during torque converter locking The following shifts become poor 1 2 1 3 1 4 2 3 2 4 3 1 3 2 All Including Manual 3 4 4 1 4 3 The following shifts become poor 2 4 3 2 There may be...

Page 1035: ...pically be caused by a loose connection or short to ground in the wiring to or within the inhibitor switch which has caused the signal at the TCU to read 0V or 5V The signal from the ignition of ignition pulses has either been non existent or has been unreliable There are two reasons this fault could occur The first is due to a lack of ignition pulses when other TCU inputs would indicate that the ...

Page 1036: ...veral of these fault codes are presents check the wiring or connectors that are common to the selected solenoids especially the earth connections The state of the solenoid feedback voltage is outside acceptable limits but the faulty solenoid could not be isolated The current to solenoid 5 was outside acceptable limits This fault results from a mismatch between the current set point for solenoid 5 ...

Page 1037: ...run the vehicle in second gear Troubleshooting Charts The troubleshooting charts are set out as follows l Table 6 2 1 Drive Faults l Table 6 2 2 Faulty Shift Patterns l Table 6 2 3 Shift Quality Faults l Table 6 2 4 After Teardown Faults Table 6 2 1 Drive Faults Action Check the fluid level Top up as necessary Inspect and clean C1 C2 feed Reinstall renew the z link Remove clean and re install the ...

Page 1038: ...e Repair or re place as necessary Inspect inhibitor switch Repair or replace as necessary Inspect the 1 2 shift valve Repair or replace as necessary Inspect inhibitor switch Repair or replace as necessary Inspect the 2 3 shift valve Repair or replace as necessary Possible Cause S1 always OFF S1 always ON S2 always OFF S2 always ON B1 failed Loose band adjustment Front servo piston or seal failed S...

Page 1039: ... valve Repair or replace as necessary Inspect the band Adjust as necessary Inspect the O rings Refit or replace as neces sary Inspect S5 Repair or replace as necessary Inspect the regulator valve Repair or replace as necessary Possible Cause Inhibitor switch fault 1 2 3 only 3 4 shift valve jammed Jammed band 1 release valve Faulty S3 or S2 solenoid Faulty clutch apply regulator valve Missing or d...

Page 1040: ...ce the sealing rings and or shaft as necessary Inspect and repair the C1 clutch as necessary Refit the valve Replace the ball Possible Cause Incorrect auto transmission fluid ATF S5 faulty won or incorrectly fitted Band apply and clutch apply regulator springs misplaced Over run clutch OC Low 1st ball misplaced C4 clutch worn or burnt C4 wave plate not lined up with the holes in the piston C4 wave...

Page 1041: ...epair or replace the BAR as neces sary Inspect and repair as necessary Inspect and clean CCCV Inspect repair or replace as necessary Possible Cause Faulty inhibitor switch Faulty throttle position sensor Incorrect front band adjustment Damaged front servo piston 0 rings Faulty or damaged variable pressure so lenoid S5 Faulty S1 or S4 solenoid Faulty band apply regulator valve BAR Misassembled fron...

Page 1042: ...s sary Repair C1 Inspect and replace the ball as neces sary Inspect and adjust the band as necessary Inspect and refit the ball as necessary Inspect and replace the O ring as necessary Inspect and refit the valve as necessary Inspect and replace the O ring as necessary Inspect and refit the valve as necessary Possible Cause T bar linkage out of adjustment 56 foiled stuck low Overdrive output shaft...

Page 1043: ...icle diagnosis from the function selection display and press Enter 5 Select Korando 98 face lift from the vehicle model selection model selection display and press Enter 6 Select Transmission control unit TCU from the control system selection and press Enter 7 Select Self diagnosis from diagnosis items Notice Check sensor output value displays if necessary 8 Determine the fault code and check the ...

Page 1044: ...Standard value 1st gear 4 4 4 kW 2nd gear 4 8 2 2 kW 3rd gear 3 3 4 kW D gear 4 5 4 g kW N gear 6 8 7 2 kW R gear 10 8 11 2 kW P gear 18 6 19 kW l Check voltage between terminal 31 and 37 of TCU Standard value 0 5V P R N D L l Check cable for open short l Check connection of other connectors l Check mode switch l Check condition between terminal 1 and 13 of TCU Winter mode 12V Normal mode Open sta...

Page 1045: ...le for open short l Check connection of other connectors l Check resistance between terminal 1 and 34 of TCU when the connector is disconnected Standard value 26 30W l Check solenoid l Check cable for open short l Check connection of other connectors l Check resistance between terminal 1 and 40 of TCU when the connector is disconnected Standard value 26 30W l Check solenoid l Check cable for open ...

Page 1046: ...ck solenoid l Check cable for short l Check connection of other connectors l Check solenoid l Check cable for short l Check connection of other connectors l Check solenoid l Check cable for short l Check connection of other connectors l Check solenoid l Check cable for short l Check connection of other connectors l Check solenoid l Check cable for short l Check connection of other connectors l Che...

Page 1047: ...warm and a speedo fault is registered then fluid should be added to the transmission Checking Adding Fluid and Filling When adding or changing transmission oil use only Castrol TQ 95 automatic transmission fluid ATF or other approved fluids The use of incorrect oil will cause the performance and durability of the transmission to be severely degraded Do not underfill the transmission Incorrect till...

Page 1048: ... litres of ATF 7 Switch off the engine and raise the vehicle on the hoist Remove the filler pump and replace the filler plug The plug shall be tightened to specification 8 The vehicle is then to be driven between 3 5 and 4 5 kilometers at light throttle so that the engine does not exceed 2500 rpm This should result in the transmission temperature being in the range 50 to 60 C 9 With the engine idl...

Page 1049: ...brake applied and engine OFF 2 Select M1 and WINTER mode 3 Move the T bar to M2 and then select NORMAL or POWER mode 4 Move the T bar to M3 and then select WINTER mode VehicleCoding The vehicle coding is integrated as part of the diagnostic software The coding applies to the following vehicle models 1 4WD Gasoline E32 2 4WD Gasoline 523 3 4WD Gasoline 520 4 4WD Diesel D29NA 5 4WD Diesel D29LA 6 4W...

Page 1050: ...Installation Notice REMOVAL AND INSTALLATION OF TRANSMISSION 1 Disconnect the negative battery cable 2 Disconnect the connectors from transfer case 3 Disconnect the speedometer connector from transfer case 4 Disconnect the inhibitor and Sear position sensor connector 6 Unscrew the eight bolts and two nuts and remove the cross member ...

Page 1051: ...by rotating the engine and remove the torque converter Installation Notice Tightening Torque 42 Nm 7 Remove the rear propeller shaft Installation Notice 8 Unscrew the five bolts and remove the transfer case 9 Disconnect the 10 Pins Plug connector from transmission 10 Separate the locking clip on shift lever and remove the shift rod Notice Removal and installation performed when the shift procedure...

Page 1052: ...r the starter 15 Unscrew the eight transmission housing bolts and remove the transmission assembly Installation Notice Be careful not to drop the torque converter while removing the transmission 16 Installation should follow the removal procedure in the reverse order ...

Page 1053: ...he positive side of the battery l Follow the throttle position calibration procedure in section 7 of this manual if the powertrain control module transmission control unit PCM TCU is swapped DISASSEMBLY PROCEDURE Transmission Notice Remove the inhibitor switch before washing the transmission in solvent or hot wash It is assumed that the transmission fluid has been drained when the transmission was...

Page 1054: ... as this will cause permanent damage to the thrust bearing surfaces 16 Remove the centre support 1 2 one way clutch planetary gear set and output shaft as an assembly 17 Remove the parking rod cam plate T40 Torx bit 18 Remove the rear band struts and remove the band 4 Detach each end of the filter retaining clip from the valve body and remove the filter 5 Detach the wires from each solenoid and la...

Page 1055: ...o 0555 331893 3 Remove the circlip from the cross shaft Pull the shaft to release the drive pin from the selector quadrant 4 Using tool No 0555 331897 press the pin from the cross shaft and withdraw the shaft from the case Retrieve the spring and pin 5 Remove the manual valve lever and the park rod 6 Remove the 10 pin plug from the wiring loom bracket adjacent to the inhibitor switch RWD models 7 ...

Page 1056: ...tment shims 14 Inspect the output shaft bushing in the case and replace if necessary 15 Inspect cooler line fittings and replace as necessary 16 Inspect the case for damage 17 To remove the park rod lever Remove the circlip from the inner end of the pivot shaft and tap the outer end of the shaft until it moves free from the case then using a wide shallow tapered drift as a wedge drive the pin out ...

Page 1057: ...rom the clutch cylinder 5 Remove the C1 clutch plates from the cylinder 6 Remove the circlip retaining the C3 clutch hub in the rear of the clutch cylinder and remove the hub 7 Remove the C2 C4 clutch hub assembly and remove the thrust bearing from the C4 hub 8 Remove the C2 clutch plates 9 Invert the clutch cylinder and remove the C4 clutch sleeve clutch plates and the two wave washers The 3 4 on...

Page 1058: ...the clutch cylinder on tool No 0555 331899 with the C2 C4 end uppermost and compress the piston return spring Remove the spring retaining circlip Release the tool and remove the circlip keeper and spring 12 Invert the clutch cylinder on the compressor tool and remove the C1 clutch piston return spring in a similar manner 13 To remove the clutch pistons from the clutch cylinder apply air pressure t...

Page 1059: ...spring Remove the circlip and release the spring Notice Make sure that the spring keeper has not been caught in the circlip groove and that all spring pressure has been released before removing the tool 4 Remove the tool circlip keeper and spring 5 Remove the sealing rings from the C3 clutch cylinder 6 Remove the clutch plate retaining circlip and remove the clutch plates 7 To remove the clutch pi...

Page 1060: ...y regulator valve To remove the pump proceed as follows 1 Remove the wiring loom retainer plate and remove solenoid 7 with a T30 Torx bit 2 Remove the five washer head bolts from the cover plate using a multi point 8 mm socket 3 Remove the five Torx head screws from the cover plate Torx bit No 30 Note that the odd screw holds the pump body to the pump body cover Notice Do not strike the converter ...

Page 1061: ...e body 8 Remove the five nylon check balls exposed in the valve body 9 Remove the retainer plate plug spring and reverse lockout valve 10 Remove the two filters and the large nylon check ball from the lower valve body Notice Once the pins are removed the plates are loose in the valve body and will drop out when the valve body is turned over 11 Remove the keeper plates and pins from the 1 2 2 3 3 4...

Page 1062: ...case If this is not fitted the valve will peen its way into and through the separator plate 2 Ensure that the E clip is fitted to the cross shaft 3 Ensure that all aspects of the parking mechanism are working To assemble the transmission proceed as follows 1 Turn the transmission case upside down on the bench and mount it to the transmission cradle No 0555 331895 2 Install all fittings plugs and t...

Page 1063: ...mall amount of sealant to the outer end of the pivot pin Notice That the lever must pivot freely on its pin and the spring must return the park rod lever to its correct location 6 Secure the pivot pin with the circlip Notice The pawl must pivot freely on its pin 7 Install the parking pawl pivot pin and spring 8 Connect the park rod to the manual valve detent lever Ensure the spring and cam collar ...

Page 1064: ...0555 331897 with the adaptor over the pin 14 Press the pin into the shaft until the tool bottoms 15 Remove the tool and fit the spring retaining circlip to the shaft 16 Install the new cross shaft seals using tool No 0555 331894 17 Install the inhibitor switch on the case Torque the screws as per specifications Press the pin into the shaft until the tool bottoms 4WD models using tool No 0555 33294...

Page 1065: ...nector in the case engaging the tangs on the connector in the notches in case 4WD MODELS ONLY 21 Route the portion of the wiring loom coming out of the case down between the inhibitor switch and the case Position the ten pin plug on the wiring loom bracket ...

Page 1066: ...ce If fitting a new band soak the new band in automatic transmission fluid or a minimum of five minutes prior to assembly 3 Carefully install the rear band into the transmission case and ensure that it is properly fitted in the case 4 Position the apply strut on the rear band then engage the apply strut in the servo lever 5 Install the cam plate and tighten the screws to specification Figure8 19 T...

Page 1067: ... groove 7 Fit the thrust bearing assembly No 10 onto the output shaft using petroleum jelly 8 Carefully install the output shaft assembly in the case to prevent damage to the sealing rings Rear Servo Assembly To assemble the rear servo assembly refer to figure 8 18 proceed as follows 1 Check the servo piston O rings and gasket for any damage 2 Lubricate the servo piston O rings with automatic tran...

Page 1068: ...o the outer race with the lip edge uppermost Lubricate the sprags with automatic transmission fluid Refer to figure 8 20 5 Check that the plugs are fitted to the centre support then assemble the centre support into the OWC ensuring that the support will rotate in an anti clockwise direction only Refer to figure 8 21 Figure 8 20 Planet Carrier Assembly and Centre Support 6 Lubricate the No 9 needle...

Page 1069: ...o specification Front Servo Assembly NOTICE Ensure that the front servo snap ring is installed correctly Orient the circlip with the gap at the bottom near the pan rail Refer to figure 8 22 To assemble the front servo assembly refer to figure 8 22 proceed as follows 1 Lubricate the cover O ring with automatic transmission fluid and fit to the cover 2 Lubricate the piston O rings with automatic tra...

Page 1070: ...C4 clutch assembly refer to figure 8 24 proceed as follows 1 Check the feed orifices in the cylinder bore are clear of obstructions 2 Check the C2 piston bleed orifices are clear of obstructions 3 Lubricate the O rings with automatic transmission fluid Notice O rings must not be twisted in the grooves 4 Fit the small O ring onto the inner groove and the large O ring onto the outer groove of the pi...

Page 1071: ...tall the piston into the cylinder until the outer diameter of the piston enters the inner diameter of the cylinder 16 Install the spring and spring retainer onto the piston Notice The wire diameter of this spring is 5 26 mm 17 Using special tool No 0555 331899 compress the spring sufficiently to enable the installation of the retaining circlip ensuring that the circlip is firmly seated in its groo...

Page 1072: ...5A 104 AUTOMATIC TRANSMISSION Figure 8 25 C4 Clutch Pack Clearance ...

Page 1073: ...n is to be the actual thickness of the pressure plate plus 1 4 1 8 mm 23 Use selective plates to achieve the correct specification If new friction plates are being fitted remove the clutch pack and soak the friction plates in ATF for a minimum of 5 minutes prior to reassembly Notice The clutch pack clearance must be taken before the elements are soaked in Automatic Transmission Fluid ATF 24 Reasse...

Page 1074: ... C2 C4 clutch hub assembly in the C4 clutch plates 36 Install the C2 clutch plates 37 Install the C3 hub and secure it with the circlip ensuring that the circlip is firmly seated in its groove Refer to figure 8 32 Figure 8 26 Typical C2 Clutch Pack Clearance 26 Check the clutch pack clearance using only the weight from tool No 0555 331900 Refer to figure 8 26 Notice With the clutch pack supporting...

Page 1075: ...outer ring of the C3 piston 6 Check that the bleed orifices of the piston are clean and clear of obstructions 7 Install the C3 piston in the cylinder until the outside diameter of the piston enters the inside diameter of the cylinder Notice Take care not to cut the O ring 8 Assemble the spring and spring retainer on the piston Using tool No 0555 331899 compress the spring sufficiently to enable th...

Page 1076: ...linder to the top of the pressure plate e Record this figure f Subtract the second reading from the first reading to obtain the clutch pack clearance Notice With the clutch pack supporting a weight of 2 kg the clearance between the snap ring and the top of the pressure plate is to be between 1 20 1 45 mm 14 If new friction plates are being fitted remove the clutch pack and soak the friction elemen...

Page 1077: ...e sun gear Refer to figure 8 33 3 Align and fit the C3 clutch assembly over the forward sun gear 4 Lubricate the No 6 needle thrust bearing with petroleum jelly and fit it to the thrust plate Ensure the lugs on the outside diameter of the bearing fit in the thrust plate counterbore Refer to figure 8 19 5 Align and fit the plastic thrust washer to the thrust plate with petroleum jelly Refer to to f...

Page 1078: ... disc l steel plate l friction disc l steel plate l steel plate 0574 GOOGOl 0574 000003 0574 000004 0574 000005 0574 000020 0574 000021 or friction disc 0574 000002 l steel plate selective l friction disc l steel plate selective l friction disc 4 Check the clutch pack clearance using special tool No 0555 331900 Refer to figure 8 31 Use selective plates to achieve the correct specification Notice T...

Page 1079: ...b thrust washer in place with petroleum jelly Refer to figure 8 19 10 Check the input shaft for any defect Fit the input shaft into the cylinder and secure it with the circlip ensuring that the circlip is completely seated in the groove 11 Coat the sealing rings with petroleum jelly and fit onto the input shaft 12 Assemble the C1 C2 C4 clutch assembly to the C3 clutch and sun gear assembly Refer t...

Page 1080: ...oceed as follows 1 Check the pump body for any damage chips or irregularity Check that the bush is firmly staked in the drive gear 2 Install the seal flush with the front face of the pump body 3 Lubricate the pump bush and the drive and driven gears with automatic transmission fluid 4 Install the pump driven gear and the pump drive gear into the pump body 5 Using a straight edge and thickness gaug...

Page 1081: ...o the pump cover ensuring that the regulator valve slides freely then fit the regulator valve plug and O ring 10 Install the retaining pin 11 Install the converter clutch regulator valve refer to figure 8 37 plug and O ring Figure 8 36 Primary Regulator Valve Figure 8 37 Converter Clutch Regulator Valve ...

Page 1082: ...er clutch control valve refer to figure 8 38 spring plug and O ring 14 Install the retaining pin Refer to figure 8 39 Figure 8 39 Valve Retaining Plugs and Pins Figure 8 38 Converter Clutch Control Valve 12 Install the retaining pin Refer to figure 8 39 ...

Page 1083: ...efer to figure 8 40 16 Install the retaining pin Refer to figure 8 39 17 Install the converter release check ball and spring and the feed ball Refer to figures 8 41 8 42 and 8 43 Figure 8 40 C1 Bias Valve Figure 8 41 Converter Relief Ball and Spring Figure8 42 PeedBall Figure 8 42 Feed Ball ...

Page 1084: ...cation Refer to figure 8 45 20 Tighten the solenoid 7 screw Refer to figure 8 39 Notice Check that neither the wiring nor the connector protrudes excessively in order that at assembly neither the wiring and the connector contacts or rubs on the input shaft or the C1 C2 clutch cylinder 21 Assemble the pump to the pump cover Tighten all bolts and the crescent screw finger tight ensuring that the pum...

Page 1085: ... Perform the following steps to check the end float a Attach a dial indicator to the front of the transmission case with the stylus resting on the end of the input shaft b Apply a force of approximately 250 newtons or 25 kg to the input shaft c Zero the dial indicator d Place a small lever behind the forward clutch cylinder and lever the cylinder forward e The measurement recorded on the dial indi...

Page 1086: ...he orifices in the valve body are for stability and safeguard do not drill them any larger 9 When servicing the transmission ensure that the solenoid 5 damper spring is not broken 10 Locate the detent spring central to the detent lever To assemble the valve bodies proceed as follows 1 Wash the upper and lower valve bodies refer to figures 8 47 and 8 48 thoroughly with cleansing solvent and blow dr...

Page 1087: ...l pin Refer to figure 8 49 7 Install the solenoid 5 damper guide spring piston and retaining pin Refer to figure 8 49 Figure 8 49 Solenoid 5 and Damper Lo 1st Check Valve Assemblies Figure 8 50 1 2 Shift Valve 8 Install the 1 2 shift valve plug and retaining pin Refer to figure 8 50 ...

Page 1088: ...Refer to figure 8 51 Figure 8 51 3 4 Shift Valve 10 Install the 2 3 shift valve and retaining pin Refer to figure 8 52 Figure 8 52 Solenoid 2 and 2 3 Shift Valve 11 Install the 4 3 sequence valve spring plug and retaining plate Refer to figure 8 53 Figure 8 53 4 3 Sequence Valve ...

Page 1089: ...tor Valve and Solenoid 4 13 Install the clutch apply regulator CAR valve refer to figure 8 55 springs plunger and retainer pin Figure 8 55 Clutch Apply Regulator Valve and solenoid 3 14 Install the solenoid supply valve spring and retainer plate Refer to figure 8 56 Notice This aluminum valve is easily damaged Figure 8 56 Solenoid Supply Valve and Solenoid 6 ...

Page 1090: ...tor plate as necessary 18 Check the upper and lower valve body gaskets for damage Replace the gaskets as necessary 19 Install the lower valve body gasket on the lower valve body 20 Install the reverse lockout valve spring plug and retainer plate Ensure that the valve is correctly oriented Refer to figure 8 57 Figure 8 57 Reverse Lockout Valve 21 Position the five nylon ball checks in the upper val...

Page 1091: ... and 6 Ensure the solenoid is firmly secured by the retainer and that the screw is tightened to specification 25 Install solenoid 5 Ensure that the solenoid is pushed firmly into the valve body by the retainer Notice The wiring loom ground wire eyelet terminal is secured beneath the solenoid retainer 26 Install the line pressure relief valve tapered end first refer to figure 8 59 and the spring an...

Page 1092: ...detent spring assembly spring support plate and screw ensuring that the screw is tightened to specification Check the spring for wear or damage 29 Install the manual shift valve Refer to figure 8 60 Notice Be aware that the manual valve will fall out of the valve body Figure 8 62 Wiring Installation Figure 8 60 Manual Shift Valve ...

Page 1093: ...ecification in the specified sequence Refer to figure 8 61 31 Check the alignment of the detent roller and the manual lever quadrant 32 Connect the solenoid wiring as detailed below l Solenoid 1 red l Solenoid 2 bIue l Solenoid 3 yellow l Solenoid 4 orange l Solenoid 5 green l Solenoid 6 violet Refer to figure 8 62 Notice All hardware must be correctly installed and torqued to specification Figure...

Page 1094: ...he oil filter and pan assembly refer to figures 8 63 and 8 64 proceed as follows 1 Lubricate the oil filter sealing ring with automatic transmission fluid 2 Carefully assemble the oil filter to the valve body The spigot must not lean on one side while being fitted Refer to figure 8 63 3 Secure the oil falter assembly with the retainer 4 Check that the magnet is located in the dimple in the comer o...

Page 1095: ...1 Torque Specifications Torque Specifications Torque converter housing to case Extension housing to case Rear servo cover Pan to case Inhibitor switch to case Cooler connectors Transmission filler plug Output flange lock nut RWD models Centre support to case Cam plate to case parking pawl Valve body to case Upper valve body to lower valve body ON OFF solenoid retainers Variable pressure solenoid r...

Page 1096: ...s required at all times minimum shim size is 1 mm The thicknesses of available shims are listed in table 8 2 2 Fit the selected shim s to the shank of the anchor strut as follows a Inspect the shim s for damage wear or corrosion Replace as necessary b The shim s are to be installed between the case abutment face and the anchor strut flange Refer to figure 8 66 c The shim s are to be fitted by hand...

Page 1097: ... Notice A minimum of one shim is required at all times minimum shim size is 1 mm The thickness of available shims are listed in table 8 2 2 Fit the selected shim s to the shank of the anchor strut as follows a Inspect the shim s for damage wear or corrosion and replace as necessary The shim s are to be installed between the case abutment face and the anchor strut flange Refer to figure 8 68 c The ...

Page 1098: ...hims Thickness 0 95 1 05 1 15 1 25 1 44 1 56 1 73 1 87 Part Number 0574 037017 0574 037018 0574 037019 0574 037020 Thickness 1 93 2 07 2 12 2 28 2 42 2 58 2 61 2 79 Part Number 0574 037021 0574 037022 0574 037023 0574 037024 Figure 8 68 Thickness of Available Shims ...

Page 1099: ...n Leakage 5B 7 Diagnosis Table 5B 8 Component Locator 5B 9 Maintenance and Repair 5B 11 On Vehicle Service 5B 11 Shift Control Cable 5B 11 Transmission 5B 14 Unit Repair 5B 17 Major Unit 5B 17 Main Shaft 5B 27 Input Shaft 5B 32 Counter Shaft 5B 34 Extension Housing 5B 35 Shift Cover 5B 36 Inspection of Components 5B 40 Pre Installation Checks 5B 45 SPECIFICATIONS GENERAL SPECIFICATIONS Application...

Page 1100: ...plication Transmission Oil Filler Plug Transmission Mounting Bolt Housing Oil Drain Plug Front Propeller Shaft T C Rear Propeller Shaft T C Cross Member Bolt Center Cross Member Bolt Side Control Cable Shift Lever Bolt Nlm 25 77 87 25 81 89 70 90 21 35 62 93 20 30 ...

Page 1101: ...MANUAL TRANSMISSION 5B 3 EXTERNAL VIEW GEAR TRAIN ...

Page 1102: ...5B 4 MANUAL TRANSMISSION POWER FLOW ...

Page 1103: ... INTO GEAR Action Adjust or replace clutch Add or replace with specified oil Remove extension adapter or case cover Check or replace damaged parts Remove extension adapter or case cover Check synchronizers and gears and replace damaged parts Check or replace backup switch Replace pilot bushing GEARS CRASH WHEN SHIFTING Check Engine idle speed too high Damaged or faulty clutch Pilot bearing between...

Page 1104: ...orks offset lever shaft or rail Worn or damaged synchronizer Worn or damaged gears TRANSMISSION LOCKED IN ONE GEAR Action Replace extension adapter or case cover Check or replace loose parts on shaft or rail Replace roll pin s Remove extension adapter or case cover Check for wear or damaged Replace damaged parts Check worn or damaged synchronizer parts and replace if necessary Check worn or damage...

Page 1105: ...eather clogged Too much oil Loose bolts at sealing faces Improperly applied sealant Worn or damaged oil seal Action Clean all exposed surfaces then check for leaks Clean or replace vent or breather Check oil level Tighten as specified Clean leaking surfaces Reapply sealant Replace oil seal ...

Page 1106: ... Set Reverse Speed Gear Set 1st Speed Gear Set 5th Speed Gear Set Clutch Housing and Release Derive Crankshaft Pilot Bushing and Release Bearing Input Bearing Main Shaft Input Bearing Main Shaft Thrust Bearing 3rd Speed Gear Bearing 2nd Speed Gear Bearing 1st Speed Gear Bearing Reverse Idler Gear Bushing Counter Shaft Front Bearing Counter Shaft Rear Bearing Counter Shaft Thrust Bearing 5th Speed ...

Page 1107: ...MANUAL TRANSMISSION 5B 9 COMPONENT LOCATOR ...

Page 1108: ...ing Retainer 51 Oil Seal 52 Shim 53 Bearing Cup 54 Bearing Cone 55 Input Shaft 56 A Roller Bearing 56 B Bearing Assembly 57 Spacer 58 Thrust Bearing 59 Thrust Bearing Race 60 5th Speed Driven Gear 61 Bearing Cup 62 Bearing Cone 63 1st Speed Gear 64 Bearing Sleeve Assembly 65 A Bearing 65 B Bearing 65 C Spacer 66 Sleeve 67 Blocking Ring Assembly 68 3 4 synchronizer Assembly 69 Synchronizer Spring 7...

Page 1109: ... REPAIR ON VEHICLE SERVICE SHIFT CONTROL CABLE 1 Shift Lever Assembly 2 Bolt 20 30 Nm 3 Select Cable 4 Shift Cable 5 Snap Pin 6 Snap Pin 7 Transmission 8 Shift Cable 9 Select Cable 10 Clip 11 Clip 12 Snap Pin 13 Snap Pin 14 Protector 15 Washer ...

Page 1110: ...d remove the knob 2 Remove the screw from the console box side and remove the shift lever cover 3 Disconnect the cables by removing the snap pins from the control cable connections to the select lever and shift lever 4 Remove the shift lever an cable mounting snap pin and washer of the select lever ...

Page 1111: ...ct cable 6 Installation is reverse order of the removal Inspection Procedure 1 The shift lever should be positioned in neutral 2 Apply liquid gasket on the cable contact surface 3 Keep 130 mm between the center of the cable end eye and floor Notice If necessary adjust the adjust nut Standard 130 mm ...

Page 1112: ... Nm 3 Transmission Assembly 4 Back up Switch 5 Washer 6 Bolt 77 87 Nm 7 Oil Drain Plug 25 Nm 8 Bolt 81 89 Nm 9 Washer 10 Front Propeller Shaft 11 Transfer Case Assembly 12 Speedometer Cable 13 Rear Propeller Shaft 14 Washer 15 Bolt 70 80 Nm 16 Cross Member 17 Washer 18 Bolt 21 35 Nm 19 Washer 20 Bolt 62 93 Nm 21 Breather Hose ...

Page 1113: ...p the vehicle and fix it safely 3 Remove the drain plug from the transmission housing and drain the oil Reinstall the drain plug Installation Notice Tightening Torque 25 Nm 4 Disconnect the back up switch connector 5 Remove the breather hose 6 Remove the speedometer connector and other wiring harnesses and connectors ...

Page 1114: ...g nuts and each sides mounting bolts and remove the cross member Installation Notice 9 Unscrew the transmission mounting bolts Installation Notice Tightening Torque 1 Tightening Torque 2 21 35 Nm 62 93 Nm 10 Move the transmission jack backward careful and disengage the transmission input shaft from the engine Remove the transmission 11 Installation should follow the removal procedure in the revers...

Page 1115: ...position other than 3 4 of neutral will be difficult 3 Using a pin punch and a hammer remove the roll pin to remove the shift lever from the offset lever 4 Using a 15 mm wrench remove the 8 bolts from the extension housing 5 Separate the extension housing from the case and shift cover Separate the offset lever from the shift Notice Do not remove the offset lever while the extension housing is stil...

Page 1116: ...rom the end of the counter shaft 10 Using a 10 mm wrench remove the 10 bolts from the shift cover Notice For assembly note the location of the two bolts 11 Lift up the shift cover after sliding it toward the drain plug about 3 cm At this time remove sealer bond 12 Using a needle nose pliers remove the 5 R lever clip ...

Page 1117: ...Using a 22 mm wrench remove the back up lamp switch from the 5 R lever side Notice Apply sealer to the threads 15 Pull out the 5 R lever out of the transmission 16 Using a snap ring pliers remove the 5th synchronizer snap ring from the end of the counter shaft 17 Remove the 5th synchronizer assembly with its fork and rail assembly from the counter shaft ...

Page 1118: ...lts using a 13 mm wrench Notice Apply sealer on these bolts during assembly Remove the input bearing retainer with the bearing outer race and shim 21 Remove the input shaft from the case by rotating it until the flat surface appears 22 Remove the following parts from the input shaft l 4th speed gear blocking ring l Main shaft thrust race and bearing l Main shaft pilot bearing rollers 15 rollers No...

Page 1119: ...lift the main shaft from the case 24 Remove the reverse fork and spring from the case 25 Remove the counter shaft as follows l Using a punch and hammer pry up the lock tabs l Using a 13 mm wrench or T 40 bit remove the 4 bolts l Remove the retainer and shim from the case l Push the counter shaft rearward to remove the rear bearing outer race ...

Page 1120: ... and a hammer remove the roll pin fixed on the reverse idler shaft 27 By pushing the reverse idler shaft rearward and out of the case remove the reverse idler gear and O ring 28 Using a puller remove the rear bearing assembly from the counter shaft ...

Page 1121: ...ounter shaft rear bearing outer race Tighten the 4 retainer bolts 3 Place a dial indicator on the case and measure counter shaft end play by moving up and down 4 Select a shim which is the same thickness as the indicator rearing up to 0 004 inch and assemble it 5 When the end play is correctly adjusted remove the counter shaft rear bearing retainer and outer race 6 Using a pin punch and rubber ham...

Page 1122: ...l Install the input shaft onto the front of the main shaft l Install the input bearing retainer without shim onto the front of the case l Using a torque wrench tighten the 4 bolts 9 Install the 5th speed drive gear and blocking ring on the counter shaft 10 Install the 5th synchronizer and rail fork 11 Install the 5th synchronizer snap ring and oiling funnel 12 Align the slots of the lever with the...

Page 1123: ...e that the 1 2 and 3 4 synchronizer sleeves and 5 R shift lever are in neutral position 17 Align the holes the case and cover with alignment type bolts Tighten the 10 bolts 18 Apply RTV sealant on the sealing surface of the extension housing 19 Apply grease on the detent guide plate in the extension housing Install the detent ball in the 3 4 position 20 Place the detent spring and offset lever in ...

Page 1124: ... thickness as the measurement 0 001 inch After shim installation the end play should be 0 26 Remove the input bearing retainer and do the following l Install the adjusting shim behind the input bearing outer race in the retainer and if 2 shims are used install the thinner one in first l Install the retainer to the case and tighten the bolts l If end play is not 0 change the shim again l Apply RTV ...

Page 1125: ...ronizer hub and sleeve 2 Using a hydraulic press and puller plate remove the 3 4 Synchronizer assembly and the 3rd speed gear 3 Remove the 3rd speed gear bearing and spacer 4 Using a snap ring pliers remove the 2nd speed gear snap ring 5 Remove the 2nd speed gear thrust washer 6 Remove the 2nd speed gear bearing and spacer ...

Page 1126: ...ring assembly 9 For correct reassembly place an alignment mark on the 1 2 synchronizer hub and sleeve 10 Remove the 1 2 synchronizer sleeve from the hub with following parts l The anti rattle ball and spring l The three keys l One of the 3 springs 11 Using a hydraulic press and puller plate remove the 5th speed driven gear from the main shaft ...

Page 1127: ...ar bearing assembly from the shaft 13 Remove the 1st speed gear and bearing 14 Remove the inner race 15 Remove the tree piece 1st speed blocking ring assembly and remaining synchronizer spring 16 Check and clean all removed parts and replace if necessary ...

Page 1128: ...earing race l 1st speed gear and its bearing 3 Install the rear bearing assembly to the main shaft 4 Using a hydraulic press and installer press the 5th driven gear onto the main shaft While the main shaft is still on the press bed install the 5th driven gear snap ring If the snap ring does not fit completely continue pressing the 5th driven gear 5 Install the following parts l 2nd speed blocking ...

Page 1129: ...MANUAL TRANSMISSION 5B 31 6 Using a hydraulic press and installer install the 3 4 synchronizer hub onto the main shaft Notice Align the blocking ring with the synchronizer keys while installing the hub ...

Page 1130: ...shaft l Main shaft thrust race and bearing l Main shaft pilot bearing rollers 15 rollers 2 Using a hydraulic press and puller plate remove the input shaft bearing assembly from the shaft 3 Remove the input bearing 4 Remove the input shaft seal 5 Check and clean all removed parts and replace if necessary ...

Page 1131: ...pply grease to the thrust bearing inner roller 15 rollers and install the main shaft thrust bearing and its race in the rear of the input shaft 3 Using a rubber hammer and installer install the input bearing retainer and input shaft seal after applying grease 4 Install the bearing outer race to the retainer without end play adjusting shim ...

Page 1132: ... parts and replace if necessary AssemblyProcedure 1 Using a hydraulic press and installer press the front bearing assembly onto the counter shaft 2 Install is as follows l Install a new O ring on the counter shaft outer race and lubricate it l Using a installer lightly tap the race into its bore until the O ring is compressed l Install the race to be fully seated on the inside of the case ...

Page 1133: ...he extension housing 2 Remove the O ring and steel ring from the rear of the extension housing 3 Check and clean all removed parts and replace if necessary AssemblyProcedure 1 Install the O ring and steel ring to the rear of the extension housing 2 Install the vent to the extension housing ...

Page 1134: ...remove the shift shaft 3 Check and clean all removed parts and replace if necessary AssemblyProcedure 1 If the shaft cup plug was removed apply plug outer surface with sealer and install it into the cover 2 Install the fork pads and selector plates onto the 1 2 and 3 4 shift forks 3 Assemble the sift cover parts as follows Push the shift shaft into the cover until the front of the shaft is at the ...

Page 1135: ...ift fork and its selector plate l Push the shift shaft through the 1 2 shift fork l Place the selector arm and interlock plate in the cover Note the position of the interlock plate and selector arm l Push the shift shaft through the 3 4 shift fork ...

Page 1136: ... 4 shift fork l Install the roll pin that fixes the selector arm to the shift shaft 4 Check the shift cover parts for proper assembly as follows l Insert a pin punch 3 16 into the offset lever hole of the shift shaft l Place the shift cover to the flat ground and rotate the shift shaft so that the punch is vertical ...

Page 1137: ...MANUAL TRANSMISSION 5B 39 l Selector arm should be aligned with the 3 4 shift fork selector plate 5 Lubricate and install the O ring on the rear of the shift cover ...

Page 1138: ...over l Input bearing retainer l Counter shaft rear bearing retainer 2 Check the parts which support bearings and shafts for excessive wear and replace them if necessary 3 Check the bearing surfaces of the following parts l Input shaft l Main shaft and its gears l Counter shaft and 5th drive gear 4 Check the reverse idler shaft and its gears Notice Replace excessive wear parts and do not file on th...

Page 1139: ... Selector arm Interlock plate Selector plates for the 1 2 and 3 4 shift forks 5 R shift lever and the rollers on the reverse fork and the 5th shift rail fork l Check worn mating surfaces on the following parts 1 2 shift fork pads and synchronizer sleeve 3 4 shift fork pads and synchronizer sleeve 5th shift rail fork pads and synchronizer sleeve Reverse fork and reverse idler gear sleeve ...

Page 1140: ... Main shaft pilot bearing rollers l Main shaft thrust Bearing and its surfaces l Speed gear roller bearing on the main shaft l Main shaft rear bearing l Counter shaft front and rear bearings 7 Check the gear tooth surfaces of all gear sets 8 Check the reverse gear set surfaces Check the surfaces of gear teeth for excessive wear pitting scoring and spalling and replace if necessary ...

Page 1141: ...h synchronizer l Excessively tight or loose hub to sleeve fit l Wear of the cone clutch surfaces of brass blocking rings and gears 11 Measure the clearance between the blocking ring and the speed gear l New 1 2 blocking ring 0 87 1 4mm l New 3 4 blocking ring 0 88 1 5mm Notice Excessive wear of the blocking ring or the speed gear cone surface will cause shift block out gear clash ...

Page 1142: ...5B 44 MANUAL TRANSMISSION 12 Check for gear clash on the synchronizer sleeve teeth or the clutch teeth on the speed gear 13 Check the synchronizer sleeve and gear clutch tooth for hop out ...

Page 1143: ...ivot Fork and release bearing 3 Check the pressure plate spring Notice Inspect each parts and replace the excessively worn parts 4 Check the clutch housing alignment as follows l Place the magnetic base on the pressure plate spring l Check the housing bore alignment Place the dial indicator on the bore By rotating the crankshaft one revolution record the dial indicator reading ...

Page 1144: ...dicator reading Notice If the reading is greater than 0 010 inch insert the shim between the engine and clutch housing and adjust the alignment 5 Check the following parts l Pressure plate spring assembly l Disc l Flywheel l Input shaft pilot bearing Notice Replace the excessively worn parts 6 Lubricate the clutch release bearing bore fork pivot head during assembly ...

Page 1145: ... SPECIFICATIONS GENERAL SPECIFICATIONS Caution Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals Disconnecting this cable will help prevent personal injury and damage to the vehicle The ignition must also be in LOCK unless otherwise noted Application Type Max Pedal Strok...

Page 1146: ...NG SPECIFICATIONS Application Clutch Cover Bolt Clutch Housing Bolt Clutch Release Cylinder Master Cylinder Nut Clutch Tube Nut Pedal Push Rod Nut Pedal Mounting Bracket Bolt Stopper Bolt N m 37 47 30 40 8 18 15 18 16 22 8 18 21 25 ...

Page 1147: ...CLUTCH 5C 3 SPECIAL TOOLS SPECIAL TOOLS TABLE 602 589 00 40 00 Engine Lock 661 589 00 15 00 Centering Pin ...

Page 1148: ...ion or Excessive Run out of Disc Rust or Wear of Disc Spline Oily Facing Damaged Diaphragm Spring Excessive Clutch Pedal Freeplay DIAGNOSIS CLUTCH SLIPS Checks Excessive Wear of Facing Hard or Oily Facing Damaged Pressure Plate or Flywheel Damaged or Burnt Diaphragm Spring Clutch Pedal Freeplay Insufficient Faulty Operation of Clutch Pedal Worn or Damaged Clutch Disc Action Replace Repair or Repla...

Page 1149: ...Action Lubricate or Replace Lubricate or Replace Repair CLUTCH NOISY Checks Action Adjust Replace Replace Replace Repair Replace Insufficient Clutch Pedal Freeplay Excessive Wear of Facing Worn or Damaged Release Bearing Poor Lubricationon Contact Surface of Bearing Faulty Installation of Clutch Assembly or Bearing Damaged Pilot Bushing Clutch pedal is partially depressed and vehicle speed is redu...

Page 1150: ...se Bearing 5 Release Fork Pivot 6 Release Cylinder 7 Release Fork Boot 8 Bolt 9 Release Fork 10 Bolt 11 Spring Lock Washer 12 Transmission Input Spline 13 Release Bearing Contacting Surface 14 Contacting Point of Release Fork and Pivot Notice Apply the long term grease DBL 6811 00 to No 12 13 and 14 ...

Page 1151: ...CLUTCH 5C 7 PEDAL AND MASTER CYLINDER 1 Clutch Pedal 2 Clutch Master Cylinder 3 Clutch Tube 4 Clutch Damper Cylinder 5 Clutch Tube 6 Clutch Hose 7 Clutch Release Cylinder ...

Page 1152: ... contact a painted surface 1 Remove the air bolt cap of the release cylinder Connect a vinyl tube to the bolt 2 Insert the other end of the tube in a vacant container 3 Slowly depress the clutch pedal sever81 times 4 With clutch pedal fully depressed open the air bolt and release air rind fluid in the fluid line 5 Repeat this procedure until there are no more air bubbles in the fluid flows ...

Page 1153: ...Preceding Work Removal of the transmission 1 Clutch Disc 2 Clutch Cover Assembly 3 Release Bearing 4 Clutch Housing Tools 602 589 00 40 00 Engine Lock 661 589 00 15 00 Centering Pin 5 Washer 6 Bolt 23 Nm 7 Washer 8 Bolt 44 Nm ...

Page 1154: ...inder mounting bolts and remove the release cylinder 3 Unscrew the clutch housing bolts and remove the clutch housing release fork and release bearing Installation Notice 4 Insert the centering pin into the clutch spline Loosen the clutch cover bolts 1 2 turn in crisscross sequence until the spring tension is released Notice Do not remove the bolts at a time or clutchcover can be damaged or deform...

Page 1155: ...areful not to drop the pressure plate and clutch disc Installation Notice Tightening Torque 23 Nm 6 Installation should follow the removal procedure in the reverse order Notice l Before installation clean oil and grease on the flywheel surface l Do not clean the clutch disc and release bearing in solvent ...

Page 1156: ... Unevenness Limit 0 8 mm 2 Clutch Disc l Check the facing for rivet looseness excessive runout sticks oil and grease l Measure the rivet head depth If out limit replace the disc 3 Clutch Release Bearing l The release bearing is permanently lubricated and requires no cleaning l Check the bearing for sticks damage abnormal noise turning drag and wear 4 Release Fork l If there is abnormal wear in con...

Page 1157: ... 1 Snap Pin 2 Clevis Pin 3 Clevis 4 Lock Nut 5 Flange Nut 30 40 Nm 6 Push Rod 7 Cylinder Body 8 Oil Pipe 15 18 Nm 9 Clamp 10 Reservoir 11 Spring 12 Piston Assembly 13 Boot 14 Plate 15 Snap Ring Notice Do not disassemble the No 12 ...

Page 1158: ... Installation Notice Tightening Torque 15 18 Nm Notice Be careful not the fluid contact a painted surface 4 Remove the master cylinder mounting nuts and pull off the master cylinder Installation Notice Tightening Torque 8 18 Nm 5 Installation should follow the removal procedure in the reverse order 6 Check the clutch pedal operation 7 Bleed the clutch system ...

Page 1159: ...Nm 8 Fulcrum Pin 9 Turn Over Spring Apply Grease 10 Bushing Replace Apply Grease 11 Full Stroke Stopper Contact Pad 12 Clutch Pedal 13 Pedal Pad 14 Pedal Mounting Bracket 15 Stopper Bolt 21 25Nm 16 Clutch Interlock Switch Notice Assembly should follow the disassembly procedure in the reverse order Grease specification Long term grease T Mn DBL6611 00 ...

Page 1160: ...adjust the pedal height loosen the lock nut C of the stopper bolt D and turn the stopper bolt until the height is correct Height From the Floor Carpet 169 5 172 5 mm 3 Pedal free play E Notice To adjust the pedal free play loosen the lock nut F of the master cylinder and turn the push rod until the free play is correct 4 Check the fulcrum pin and the bushing for wear the pedal for bending and the ...

Page 1161: ...2 Hydraulic Tube 3 Bolt 4 Clutch Oil Chamber 5 Hydraulic Tube 6 Clutch Release Cylinder Notice l Installation should follow the removal procedure in the reverse order l When installing perform the bleeding procedures from chamber cylinder and release cylinder ...

Page 1162: ...al terminals Disconnecting this cable will help prevent personal injury and damage to the vehicle The ignition must also be in LOCK unless otherwise noted Specifications 5D1 1 General Specifications 5D1 1 Schematic and Routing Diagram 5D1 2 Part Time Transfer Case 4408 5D1 2 Diagnosis 5D1 3 Self Diagnosis 5D1 4 System Description 5D1 4 Self Diagnosis Test 5D1 8 Diagnostic Diagram 5D1 9 Maintenance...

Page 1163: ...5D1 2 TRANSFER CASE PART TIME 4408 SCHEMATIC AND ROUTING DIAGRAM PART TIME TRANSFER CASE 4408 ...

Page 1164: ...Action Drain and replace with specified oil Retighten as specified Disassemble bearings and parts and check for wear or damage Replace if necessary Check for wear and damage including speedometer gear replace if necessary Noise in 4H or 4L Checks Worn or Damaged Sprockets or Drive Chain Incorrect Tire Pressure Action Disassemble and check for wear and damage replace if necessary Adjust tire pressu...

Page 1165: ...h l Motor position sensor 3 Transfer case system is malfunctioning when l 4H 4L indicator lights are remain on after 0 6 second when turning the ignition switch ON l 4H 4L indicator lights are continuously come on during driving 4 If only 1 part is malfunctioning 4WD CHECK indicator light will display defective code 3 times continuously 5 If more then 2 part is malfunctioning the first malfunction...

Page 1166: ...ignition switch to ON 4 Read the flashing 4WD CHECK indicator light and identify the malfunctioning part How to Eliminate the Falut Code 1 Position the ignition switch to OFF 2 Using a service connector connect the No 2 pin GND and No 6 pin TCCU of the diagnosis socket in the engine room 3 Position the ignition switch to ON over 5 seconds 4 Do defective code reading and make sure that all defectiv...

Page 1167: ...n off for 3 seconds and then display a defective code 3times continuously No Defective Code Malfunctioning Part 1 2 3 4 5 TCCU Shift Motor Synchronizer Clutch Speed Sensor Hub Solenoid 4WD CHECK Light ON OFF Defective Code 4WD CHECK Light ON OFF Defective Code 4WD CHECK Light ON OFF Defective Code 4WD CHECK Light ON OFF Defective Code 4WD CHECK Light ON OFF Defective Code ...

Page 1168: ...TRANSFER CASE PART TIME 4408 5D1 7 No Defective Code Malfunctioning Part 6 7 Selector Switch Motor Positon Sensor 4WD CHECK Light ON OFF Defective Code 4WD CHECK Light ON OFF Defective Code ...

Page 1169: ...rom vehicle model selection display and press Enter 5 Select TCCU from control system selection display and press Enter 6 Select TCCU Part Time from TCCU diagnosis selection display Notice Check sensor valve output display if necessary 7 Select Self diagnosis from diagnosis items selection display 8 Turn the ignition switch to OFF position and press ENTER Turn the ignition swtich to ON position ag...

Page 1170: ...TRANSFER CASE PART TIME 4408 5D1 9 DIAGNOSTIC DIAGRAM ...

Page 1171: ...lug Oil Change l Clean the oil level plug and surrounding area l Place a suitable container under the transfer case l Remove the oil and tighten the drain plug l Fill the oil through the oil level plug until oil begins to drip out l Tighten the oil level plug Cautions for oil level check and plugs tightening l Do not use an impact wrench to remove or tighten the oil level plug or drain plug since ...

Page 1172: ...E 1 Rear Companion Flange 2 Case Cover 3 Front Companion Flange 4 Breather Plug 5 Case 6 Input Shaft 7 Mounting Bolt 38 52 Nm 8 Transmission Adapter 9 Bolt 81 59 Nm 10 Washer 11 Front Propeller Shaft 12 Bolt 81 89 Nm 13 Washer 14 Rear Propeller Shaft ...

Page 1173: ... plug If planal damper is installed unscrew 4bolts and remove the planar damper Installation Notice Tightening Torque 19 30 Nm 4 Remove the breather hose 5 Disconnect the speedometer cable connector and other cable connectors and wiring harnesses 6 Support the transfer case with jack and remove the front and rear propeller shafts from the transfer case Installation Notice Front Rear 81 89 Nm 70 80...

Page 1174: ...n Notice Tightening Torque 1 Tightening Torque 2 21 35 Nm 62 93 Nm 8 Remove the transfer case by removing the bolts attaching the transfer case to the transmission Installation Notice Notice Apply long term grease to the inner spline of the transfer case input shaft 9 Installation should follow the removal procedure in the reverse order Tightening Torque 38 51 Nm ...

Page 1175: ...5D1 14 TRANSFER CASE PART TIME 4408 UNIT REPAIR TRANSFER CASE Preceding Work Removal of the transfer case ...

Page 1176: ...mbly 49 Screw 50 Pump Housing 51 Pump Gear Set 52 Pump Cover 53 Spring Pin 54 Hose Clamp 55 Hose Coupling 56 Oil Strainer 57 Output Shaft 58 Reduction Hub 59 Shift Fork Assembly 60 Shift Fork Facing 61 Pin Roller and Retainer 62 Pin 63 Cam Roller 64 Retainer 65 Reduction Shift Fork 66 Nut 67 Plane Washer 68 Oil Seal 70 Companion Flange 71 Spacer 72 Front Output Assembly 73 Breather Hose 74 Bolt 75...

Page 1177: ... the 2 plugs from the cover 1 Nut 2 Washer 3 Oil Seal 4 Companion Flange 5 Plug 25 Cover 6 Bolt 7 Washer 8 Bolt 9 Sensor and Harness Bracket 10 Sensor Assembly 11 Speed Sensor 12 O ring 13 Motor Assembly 25 Cover Extension Electric Shift 1 Remove the bolt washer 3 bolts and harness bracket 2 Remove the sensor assembly and remove the O ring from the speed sensor 3 Remove the motor assembly ...

Page 1178: ...p 16 Identification Tag 17 Cover Assembly 18 Oil Seal 19 Bearing 20 Nut 21 Clutch Coil Assembly 22 Snap Ring 23 Ball Bearing 4 Remove the snap ring and pull out the ball bearing from the cover to remove the speed gear 5 Pull out the needle bearing from the cover 6 Pull out the oil seal from the slot in cover 7 Remove the magnet form the slot in case 8 Remove the return spring from the rail shaft 9...

Page 1179: ... 42 Drive Sprocket 43 Driven Sprocket 44 Drive Chain 55 Output Shaft Rear 71 Output Shaft Front Drive Chains 1 Remove the snap ring and spacer from the output shaft 2 Remove the drive chain driven sprocket and drive sprocket from the output shaft 3 Separate the chain and sprocket when removing the assembly Pump Parts 1 Remove the 4 bolts and retainer and separate the output shaft and rear pump cov...

Page 1180: ...ut Shaft front 111 Case 57 Reduction Hub 58 Shift Fork Facing 59 Reduction Shift Fork Assembly 60 Roller Pin and Retainer Assembly 61 Retainer 62 Pin 63 Roller Cam 64 Reduction Shift Fork Reduction Shift Parts 1 Remove the reduction hub and reduction shift fork assembly from the case 2 Remove the 2 shill fork facings from the shift fork assembly 3 To remove the roller cam and pin cut elf the plast...

Page 1181: ...embly input shaft assembly and carrier gear assembly 4 Remove the snap ring and oil seal from the front adapter 5 After removing snap ring pull out the bearing and thrust washer from the input shaft assembly and separate the input shaft assembly from the carrier gear assembly 6 Remove the needle bearing and sleeve bearing from the input shaft assembly 7 Remove the retaining ring thrust plate rind ...

Page 1182: ...nd spacer from the shift shaft using a screw driver 100 Electric Shift Cam 101 Torsion Spring 102 Spacer 103 Shift Shaft 111 Case 105 Transfer Case Assembly 106 Oil Seal 107 Retaining Ring 108 Ball Bearing 119 Pin 110 Ring Gear 111 Case CaseAssembly 1 Remove the oil seal 2 Remove the retaining ring and bearing 3 Remove the pin from the transfer case Notice Be careful not to damage the pin 4 Using ...

Page 1183: ...ng protruding sharp edge l Chip An area from which a small fragment has been broken off or cut l Crack Surface break of line nature indicating partial or complete separation of material l Excessive wear Heavy or obvious wear beyond expectations considering conditions of operation l Indentation Displacement of material caused by localized heavy contact l Galling Breakdown of metal surface due to ex...

Page 1184: ...ferring to normal gear tooth face specifically inspect the uneven wear and chips of gear tooth Replace or repair if necessary 4 Inspection of Contact Patterns Description Normal Abnormal Normal Wear End Face Wear Traveling Face Wear Upper Face Wear Lower Face Wear ...

Page 1185: ...ASE PART TIME 4408 Description Repair Description Repair Corner chip at drive face Edge chip at drive face Corner chip at coast face Side edge chip at drive face Chip within contact pattern Chip completely through tooth ...

Page 1186: ...te bearings oil seals and bushings before assembly 105 Case Assembly 106 Oil Seal 107 Retaining Ring 108 Ball Bearing 109 Pin 110 Ring Gear 111 Case 106 Oil Seal 109 Pin 110 Ring Gear 111 Case Transfer Case 1 If the ring gear was removed align the outer diameter of the new replaced ring gear with transfer case and assemble it 2 Insert the pin 3 Insert the ball bearing to the case and install the r...

Page 1187: ...rive tang 4 Push the end of the second spring to right and fix it on the drive tang 101 Torsion Spring 102 Spacer 103 Shift Shaft 5 Push the torsion spring and spacer together back them completely 6 Slide the electric the electric shift cam onto the shift shaft 7 Install the electric shift cam assembly into the transfer case after installation of the shift fork 101 Torsion spring 102 Spacer 103 Sh...

Page 1188: ...th the hub end up into the planet carrier assembly and rotate the sun gear to make sure that gears are fully engaged 3 Align the tabs and install the thrust plate into the planet carrier assembly 4 Install the retaining ring to the planet carrier assembly 5 Press the needle bearing into the input shaft and press the new sleeve bearing into the input shaft assembly 82 Sleeve Bearing 83 Needle Beari...

Page 1189: ...front adapter assembly Notice After installation make sure that snap ring is correctly installed into the groove 11 Position the input shaft assembly over front cover and engage into the bearing groove by expanding the ends of snap ring 12 Apply 1 6mm bead of sealant on the mounting face for the transfer case and tighten the 6 bolts 13 Install the breather 75 Snap Ring 76 Oil Seal 77 Spiral Pin 78...

Page 1190: ... Assembly 61 Retainer 62 Pin 63 Roller Cam 64 Reduction Shift Fork Reduction Shift Parts 1 Install the new pin roller and retainer into the reduction shift fork 2 Press the pin roller and retainer into the reduction spilt fork bore completely Notice Make sure that the cam roller turns freely 3 Install the 2 fork facing on the reduction shift fork assembly 4 Install the reduction shift fork onto th...

Page 1191: ... retainer on the cover so that tab on the retainer is in notch in the transfer case Apply Loctite to the bolts and tighten the bolts with turning the output shaft by hand to make the pump pins move freely 45 Shaft and Pump Assembly 46 Bolt 47 Pump Retainer 48 Rear Pump Cover 49 Hose Clamp 50 Hose Coupling 54 Pump Housing 52 Pump Pin 53 Spring 54 Front Pump Cover 55 Output Shaft 56 Strainer 40 Snap...

Page 1192: ...to right so that the end of the torsion spring contacts with reduction shift fork side l Holding the rail shaft lift up the fork assembly slightly Adjust electric shift cam assembly so that the roller on reduction shift fork assembly is in groove in shift cam and button on lockup fork is on cam end l Install the clutch housing over shift collar hub and insert the retaining ring into the clutch col...

Page 1193: ...contacts with transfer case 3 Press the ball bearing into the cover and install the snap ring 4 Install remaining parts as follows l Install the 4 O rings on the stud bolts of the clutch coil assembly l Install the clutch coil assembly inside the cover and tighten 3 nuts 18 Oil Seal 19 Bushing 20 Nut 21 Clutch Coil Assembly 22 Snap Ring 23 Ball Bearing 24 Needle Bearing 25 Cover Tightening Torque ...

Page 1194: ... Assembly 26 Magnet 27 Speed Gear 28 Oil Seal 29 Return Spring 38 Rail Shaft 111 Case 1 Install the return spring over rail shaft in the transfer case 2 Insert the magnet into the transfer case slot 3 Apply 1 6mm bead of Loctite RTV 598 to the transfer case mounting surface Notice For installation of cover align the transfer case with cover not to use excessive force 13 Motor Assembly 14 Bolt 15 W...

Page 1195: ...cover androtate the motor clockwise direction to check correctengagement 6 Bolt 7 Washer 8 Bolt 9 Sensor and Harness Bracket 10 Sensor Assembly 14 Speed Sensor 12 O ring 13 Motor Assembly 25 Cover 13 Motor Assembly 103 Shift Shaft 3 Insert the 0 ring on the speed sensor speed sensor assembly to the cover 4 Install the bracket to the motor assembly and tighten 3bolts Tightening Torque 8 11 Nm ...

Page 1196: ...the 2 plugs to the cover 2 Install the companion flange oil seal and washer 3 Holding the companion flange tighten the nut 1 Nut 2 Washer 3 Oil Seal 4 Companion Flange 5 Plug 25 Cover Notice Apply loctite 262 to nut before installation Tightening Torque 346 380 Nm ...

Page 1197: ...or light will turn on 2 Shifting from 4H to 2H l Position the transfer case switch from 4H to 2H l Shifting is possible during driving l 4WD Hl indicator light will turn off 3 Shifting between 4H and 4L l Shifting is possible when the vehicle is almost stopped approx 2 km h so it would be better stop the vehicle l In case of manual transmission equipped vehicle apply clutch pedal l In case of outo...

Page 1198: ... 4L Clutch pedal applied Clutch pedal released 4L indicator light ON 4L indicator light OFF Motor OFF Motor ON Motor OFF Motor ON Auto locking hub ON Auto locking hub OFF Voltage V 4 75 5 35 0 0 50 1 00 11 00 4 75 5 35 0 0 50 0 50 11 00 1 00 11 00 1 00 11 00 1 00 11 00 11 00 1 00 J1 7 J1 8 J1 13 J1 14 J1 15 J1 16 J1 17 J1 23 Notice l DC 12V for the TCCU operation should be maintained l In case of ...

Page 1199: ...GENERAL SPECIFICATIONS Model Length mm Weight kg Shift Mode Gear Ratio Oil Max Torque High Low Specification Capacity Interval TOD Torque On Demand Transfer Case 4423E 343 0 36 6 4H and 4L 1 1 2 48 1 ATF S 3 S 4 or Dexron II III 1 4 L Inspect Every 15 000km Replace Every 50 000km 550 lb ft 76kg m Application Description Diagnosis 5D2 19 Maintenance and Repair 5D2 31 On Vehicle Service 5D2 31 TOD C...

Page 1200: ...f speed in front and rear propeller shafts l Function of 4L Mode When select 4L mode EMC is locked to apply maximum torque into front and rear propeller shafts Shift motor rotates also 4L position by rotation of cam thus propeller shaft torque changes from 1 1 to 2 48 1 by planetary gear set l Shift Motor It locates backside transfer case which drives rotary helical cam When mode select switch cha...

Page 1201: ...the front propshaft is turning at a rate which is faster than the rear propshaft Rear Overrun A condition where the rear propshaft is turning at a rate which is faster than the front propshaft High Range The highest numerically lowest 1 1 gear ratio between the input and outputs of the Transfer Case Low Range The lowest numerically highest 2 48 1 gear ratio between the input and outputs of the Tra...

Page 1202: ... Position Encoder 2 Position Encoder 3 Position Encoder 4 4H 4L Switch Signal A T N Position Signal Speed TPS Supply Front Speed Sensor Input Rear Speed Sensor Input ABS Operation Signal Brake Switch Signal 4 5 27 10 28 30 9 24 16 11 29 25 26 19 CANH CAN L Shift Motor output port LO HI Shift Motor output port HI LO EMC 4L Indicator Position Return 4WD CHECK IND TPS speed Sensor Ground Speed TPS Re...

Page 1203: ...er case mode input 24 Auto T M Neutral Check of neutral gear position in Auto T M 16 Speed 5V supply TPS speed sensor 11 Front Speed Front speed sensor signal input Signal Input 29 Rear Speed Rear speed sensor signal input 25 ABS Operation ABS ON OFF 6 Position Return Position encoder ground 13 Speed TPS Return Ground for speed sensor TPS 22 CAN L CAN bus low line 23 CAN H CAN bus high line 2 15 M...

Page 1204: ...on Encoder The Position Encoder is used by the TCCU to determine the position of the Shift Motor Each motor position is identified by a position code as shown Notice 1 All other position codes are invalid 2 Position Input Open Circuit 4 5V 1 3 Position Input shorted to Speed Position Return 0 5V 0 Motor Position Left Stop Left of High High Right of High Zone 1 Position Code 1 2 3 4 1001 0001 0101 ...

Page 1205: ...f 5 seconds Motor Position Left Stop Left of High High Right of High Zone 1 Neutral Zone 2 Low Right Stop Left Stop Left of High High Right of High Zone 1 Neutral Zone 2 Low Right Stop Action No action required 4L bulb off No action required 4L bulb off No action required 4L bulb off Blink 4L bulb After the shift conditions are met attempt a shift to 4H under conditions of below 87 rpm in front an...

Page 1206: ...efore 2 seconds has elapsed or either propshaft speed increases above the limit the shift will be suspended and the 4L Indicator will continue to blink until the criteria are met again or the 4H 4L Switch is returned to the original position 2 Range Change When the shift criteria are met the motor is rotated in the appropriate direction as determined by the selector switch until one of the followi...

Page 1207: ... front and rear axles The TCCU monitors the propshaft speeds operating range High Low and ABS activity and then applies a calculated amount of torque to the front axle by Pulse Width Modulating the current applied to the EMC 1 Touch off Torque The minimum EMC Duty Cycle is based on the vehicle speed and throttle position The TCCU receives the TPS signal from the following sources On vehicles equip...

Page 1208: ... TRANSFER CASE TOD TOD CONTROL UNIT Location of TOD Control Unit It locates below front left handed seat towards door side which is beside rear heating duct on the floor Shape and function of TOD Control Unit ...

Page 1209: ...el Speed TPS Return Motor HI LO Motor LO HI Speed Reference Pin 17 18 19 20 21 22 23 24 Function Ground Ground Battery K LINE 4L Illumination CAN H CAN L Auto T M Neutral Pin 25 26 27 28 29 30 Function ABS Input Brake Switch Position 1 Position 3 Rear Speed Position 4 Shift Mtor Connector Speed Sensor Clutch Coil Connector Rear View for Connector Pin A B C D E F G Function Position 4 Motor Counter...

Page 1210: ...5D2 12 TRANSFER CASE TOD Motor HI LO clockwise Motor LO HI counterclockwise PIN13 SCHEMATIC AND ROUTING DIAGRAMS TOD CONTROL UNIT 14 ...

Page 1211: ...EPROM fault can only be cleared by cycling ignition off on 2 Shift Motor Assembly Test If the TCCU detects a shift motor or position encoder fault continuously for one second the 4WD CHECK lamp is turned on and the appropriate fault code is stored in memory a A shift motor fault when the motor is off is defined as follows Motor H L shorted to Ground Motor L H shorted to Ground Motor open circuit b...

Page 1212: ...es the Front Speed Sensor to determine the EMC Touch Off level and wheel slip control is suspended b If the system is in Low Range the EMC Duty Cycle is set to maximum independent of vehicle speed until the system is shifted out of 4L c All Electric Shift activity is halted until the Ignition is cycled If a shift is in progress it will be completed If the Rear Speed Sensor recovers continuously fo...

Page 1213: ...715 1716 1721 1722 1731 1732 1733 1734 1735 1736 1741 1742 1743 1750 1751 1752 1753 1754 Description EEPROM Checksum Fault TPS Loss of Signal TPS Out of Range EMC Open Short to Battery EMC Short to ground Front Speed Sensor Voltage Low Front Speed Sensor Voltage High Rear Speed Sensor Voltage Low Rear Speed Sensor Voltage High Speed Sensor Reference Voltage Low Speed Sensor Reference Voltage High ...

Page 1214: ...oding Tool Construct SCANNER into diagnosis connector 20 pins near fuse box in engine room as below figure 1 Diagnosis Connector 2 SCANNER Notice Coding An input activity of data for the proper performance by matching specification devices and system with control unit ...

Page 1215: ...SSO KORANDO 3 73 4 55 4 89 5 38 5 86 P215 P235 P255 P275 Coding Method 1 Check and record engine type axle ratio and tire size 2 Ignition OFF 3 Connect SCANNER with diagnosis connector in engine room 4 Ignition ON 5 Read the current memorized specification in TOD control unit 6 Compare memorized specification with the checked record If not matched perform a coding 7 Read again memorized coding spe...

Page 1216: ...ts against all fault codes And then you should delete the memorized fault codes in TOD control unit using SCANNER as follows 1 Connect SCANNER with diagnosis connector 2 Select trouble code clear in SCANNER 3 In trouble code clear screen press enter key to erase the fault code 4 Confirm deletion of fault code and if not repeat 2 3 process ...

Page 1217: ...connection status Is it connected exactly 2 In case of mal connection connect tightly then perform the follows a Delete fault code using Scan 100 b Ignition OFF c Ignition ON d Diagnose by Scan 100 Does it display fault code 1714 Yes No Yes No Check short of 10A fuse fuse No 20 1 Detach No 20 fuse from engine room fuse box 2 Check the existence of short Is fuse normal Yes No Check ground of TOD co...

Page 1218: ...ECK lamp illuminates continuously when ignition ON b Shift is not possible even 4H 4L switch operation c Upon diagnosis by Scan 100 it displays on impossible communication with TOD control unit or fault code 1714 1715 1716 Do occur the above defects Yes No Replace TOD control unit Normal system A5 Test Stage Contents Result Stage Test Contents and Procedure Specified Value Yes No Countermeasure ...

Page 1219: ...Yes No Check connection status of CAN communication line towards E G ECU 1 Ignition OFF 2 Disconnect 30 pin connector towards TOD control unit 3 Measure resistance between pin No 22 and 23 in wiring connector using multi tester Specified value Measured value is within specified range B2 115 125W Yes No Check connection status of CAN communication line towards TOD control unit 1 Ignition OFF 2 Disc...

Page 1220: ...multi tester Specified value Measured value is within specified range Check output signal from throttle position sensor 1 and 2 1 Keep E G idle status 2 Measure output voltage between pin 87 and 84 keeping E G ECU coupling connection status using multi tester potentiometer 1 Specified value min acc Pedal max acc Pedal Measured value is within specified range 3 Measure output voltage between pin 85...

Page 1221: ...case Does it connect correctly 3 In case of bad connection connect it correctly then perform the follows a Delete the memorized fault code in control unit with Scan 100 b Ignition OFF c Ignition ON d Diagnose by SCAN 100 Does it display on fault codes 1721 1722 Check supply voltage into electro magnetic clutch 1 Ignition ON 2 Measure voltage between pin 4 19 and 17 18 in TOD control unit connector...

Page 1222: ...ecified Value Yes No Countermeasure Check resistance of electro magnetic clutch 1 Disconnect 30 pin connector from TOD control unit 2 Measure resistance between pin 3 and 7 in wiring connector using multi tester Specified value Measured value is within specified range Perform C4 stage l 0W short l W open ...

Page 1223: ...igital multi tester Specified value Measured value is within specified range Check connection status of connector 1 Check connection status of speed sensor clutch coil connector and TOD control unit connector Does it connect correctly 2 In case of bad connection connect it correctly then perform the follows a Delete the memorized fault code in control unit by SCANNER b Ignition OFF c Ignition ON d...

Page 1224: ...2 Measure output voltage of front and rear speed sensor by multi tester Check voltage whether it varies within specified range Specified value Front speed sensor Pin 11 13 in TOD control unit connector Rear speed sensor Pin 29 13 in TOD control unit connector Measure value is within specified range Check function of control unit It necessary replace then delete fault codes and re diagnose Perform ...

Page 1225: ...igital Multi tester or which is located between No G connector and body after detaching T C motor connector The specified value When operates 4H 4L switch Measured value is within specified range 3 Measure the Hi Low voltage of motor which is located between No 2 No 5 and No 1 No 14 connector or which is located No B connector and body after detaching T C motor connector The specified value When o...

Page 1226: ... 2 Measure the resistance between No 1 No 14 and No 2 No 15 connector after detaching 30pin connector of TOD control unit Or check the resistance between No G and No B after detaching motor connector of T C side Specified value Measured value is within specified range Execute the test after detaching shift motor when the fault is not solved after executing E1 E4 stage 1 Detach the motor connector ...

Page 1227: ...otor connector of T C portion Is it installed properly 2 If the connector installation is improper install properly and then execute follow procedure a Delete the all fault code from memory by scan scope b Turn off ignition switch c Turn on ignition switch d Rediagnosis the system Does the fault codes display one or more among 1750 1754 Check the each wiring whether it is shorted or not 1 Turn off...

Page 1228: ...Positioned Auto T M to neutral At this time keep the neutral position for 2 second Stop the vehicle The R P M of front Rear propeller shaft is below 80 4 4L lamp blinks based on 0 3 second 5 When the shifting is engaged the blinking of 4L lamp is stopped 4H 4L goes on 4L lamp 4L 4H goes on 4L lamp 6 When the 4L indicator lamp continuous blinking repositioned to first position and diagnose the syst...

Page 1229: ...ND REPAIR ON VEHICLE SERVICE TOD CONTROL UNIT TOD Electric Characteristics Voltage Parasitic Current Under max operation Voltage Max Operation Current Under max operation Voltage Normal Operation Range CAN communication Operation Range Ignition OFF Ignition ON Motor OFF Motor ON 4 Installation should follow the removal procedure in the reverse order Notice When replace TOD control unit it is requi...

Page 1230: ...5D2 32 TRANSFER CASE TOD TRANSFER CASE TOD 1 Transmission 2 TOD Transfer Case 3 Extension Housing 4 Bolt 35 60Nm 5 Front Propeller Shaft 6 Bolt 81 89Nm 7 Rear Propeller Shaft 8 Bolt 81 89Nm ...

Page 1231: ...ar damper Notice Oil drain should be along with whole transfer case disassembly and assembly 5 Disconnect transmission extension wiring connector back side transfer case Notice When disconnect connector make sure on direction of locking tab towards inside 6 Disconnect shift motor clutch coil connect Black 7 pin connector upper backside 7 Disconnect front and rear speed sensor connector white 7 pin...

Page 1232: ...lange then disconnect rear propeller shaft from transfer case Installation Notice 13 Unscrew 5 units of mounting bolt M12 from extension housing in transmission Installation Notice Tightening Torque 81 89 Nm Tightening Torque 35 60 Nm Notice Make sure the connecting surface is clean Applying long life grease spline inside transfer case input shaft 14 Installation should follow the removal procedur...

Page 1233: ...m motor and bracket 5 Keep shift motor even then pull rearward 6 Clean connection surface of transfer case and shift motor 7 If necessary make a test by SCAN 100 with shift motor assembly Notice Do not disassemble shift motor If necessary replace by shift motor assembly unit 8 Applying sealant into connecting surface for new shift motor 9 Installation should follow the removal procedure in the rev...

Page 1234: ...d sensor connect from locking sleeve by pushing 5 Disconnect wire stick cap from the detached connector 6 Unscrew rear speed sensor mounting bolt M10 from upper side of rear case flange 7 Detach sensor from transfer case by lifting up using tool Notice When disconnect sensor make sure on adequate pressure due to sensitiveness with shock 8 Disconnect taping from both protection tube ends that wrap ...

Page 1235: ... long nose plier connect tightly by pulling pins 15 Apply rubber cap into connector using long nose plier not to detach 16 Connect protection tube with wire 17 Tape both ends of tube 18 Putting rear speed sensor into hole connect exactly pushing both ends 19 Screw 1 unit of bolt M10 Installation Notice Tightening Torque 9 11 Nm 20 Connect speed sensor connector then locking sleeve Reference Front ...

Page 1236: ...0km OilReplacement 1 Lift on vehicle then make sure on safety 2 Prepare a vessel to drain transfer case oil 3 Release filler plug 4 Drain oil completely 5 Wash drain plug and than tighten Installation Notice Tightening Torque 19 30 Nm 6 Replenish standardized oil by specified level through filler plug hole 7 Tighten filler plug after washing Installation Notice 8 Check oil leakage Tightening Torqu...

Page 1237: ...TRANSFER CASE TOD 5D2 39 UNIT REPAIR TRANSFER CASE ...

Page 1238: ... 32 Upper Speed Sensor Rear 33 Nut 34 Washer 37 Bolt 38 Tag Identification 39 Thrust Bearing 40 Clutch Coil Assembly 41 Fork Reduction Shift 42 Shift Rail 43 Shaft Shift 44 Spacer 45 Torsion Spring 46 Shift Cam 47 Transfer Case Shift Motor 48 Bolt 49 J clip 50 Connector Retainer 51 Bolt 52 Support Stud 53 Lower Speed Sensor Front 54 Plug 55 Identification Decal 56 Cover 57 Tone Wheel Lower 58 Chai...

Page 1239: ...e 27 Nut 28 Washer 30 Case Flange Tightening Torque 137 196 Nm Notice When disconnect connector pull forwards grasping connector housing 4 Remove outer tube on speed sensor connector 5 Remove wire supporting cape back side of speed sensor connector 6 Disconnect pin of clutch coil wire yellow from speed sensor connector white 7 pin using long nose plier 7 Remove shift motor Notice When remove shift...

Page 1240: ...drive gear and upper tone wheel 69 Yoke to Flange Seal 75 Snap Ring 76 Bearing 77 Speedometer Drive Gear 79 Upper Tone Wheel 40 Clutch Coil 40a Clutch Coil Retaining Bolts 40b Wire 11 If the rear output shaft bearing requires replacing remove the internal snap ring that retains the bearing in the bore From the outside of the case drive out the bearing 12 Remove the three nuts and washers retaining...

Page 1241: ... 18 Pull out the shift rail 18 Drive Sprocket 58 Drive Chain 59 Driven Sprocket 12 Rear Output Shaft 16 Oil Pump 61 Magnet 19 Remove the helical cam from the front case If required remove the helical cam torsion spring and sleeve from the shaft 20 Remove the high low range shift fork and collar as an assembly 21 Expand the tangs of the large snap ring in the case With the input shaft against a ben...

Page 1242: ...ement of the needle bearing and bushing is required press the bearing and bushing is required press the bearing and bushing out as follows a Position the input shaft on Axle Bearing Seal plate and using Pinion Bearing Cone Replacer as a spacer b Insert Input Shaft Bearing Remover into the input shaft so it is resting on top of the bearing cage c Tighten the actuator pin until it stops then press t...

Page 1243: ...the input shaft needle bearing and bushing were removed install a new bearing and bushing as detailed in the following steps Press a new needle bearing then a new bushing in the input shaft as follows a Position the input shaft on Axle Bearing Seal Plate or equivalent and Pinion Bearing Cone Replacer as a spacer b Press a new needle bearing into the end of the input shaft until it seats in the inp...

Page 1244: ...stalled on the shift fork and snapped securely into place 12 Rear Output Shaft 13 Oil Strainer 14 Coupling Hose 15 Hose Clamp 16 Pump Body 10 If new pump is used align the flat of the output shaft and the flat of the pump Slide the pump onto the output shaft Notice Do not disassemble oil pump It is serviced only as an assembly Check the pump to make sure the pump rotates freely Notice Do not remov...

Page 1245: ...rocket on the front output shaft must be installed with the marking REAR facing toward the rear case if so marked Notice Drive sprocket has a bushing pressed into it 16 Install tone wheel onto the front output shaft Make sure the spline on the tone wheel engages the spline on the front output shaft 17 Install clutch pack assembly onto the rear output shaft Make sure the spline of the clutch pack e...

Page 1246: ...t Shaft Bearing Replacer and Driver Handle Make sure that the bearing is not cocked in the bore Install the internal snap ring that retains the bearing to the rear case 23 Install the clutch coil from inside the rear case until the wire and studs extend through the cover Install the washers and nuts and tighten CAUTION Do not kink or trap the wire while seating the clutch coil to the case 24 Slide...

Page 1247: ...il wire through the upper speed sensor wire shield 28 Install upper tone wheel speedometer gear and rear output seal Use Output Shaft Seal Replacer and Driver or equivalent to install seal 29 Coat the mating surface of the front case with a bead of Black Non Acid Cure Silicone Rubber or equivalent 30 The following procedure must be followed prior to installing the rear case onto the front case hal...

Page 1248: ...bber or equivalent to motor housing base and install on transfer case 36 Install the transfer case shift motor and three bolts along with speed sensor wire harness bracket and tighten Notice The wire harness must be routed as shown to provide clearance and to prevent the wire harness from grounding the damper 37 Holding the slotted support bracket tight against the motor housing end secure the bra...

Page 1249: ... 42 Fill the transfer case with 1 4 liters of Automatic Transmission Fluid or equivalent Notice Fluid level should be just below the filler plug hole Tightening Torque 19 30 Nm Tightening Torque 19 30 Nm 43 Install the fill pulg and tighten 44 Install the transfer case as outlined in removal and Installation transfer case in the section Notice Make sure proper drain and fill plugs are installed if...

Page 1250: ...Component Locator 6A 4 Steering System 6A 4 Maintenance and Repair 6A 5 On Vehicle Service 6A 5 Inspection 6A 5 Oil Pump Pressure Check 6A 6 Bleeding of Power Steering System 6A 6 Steering Gear Box 6A 7 Number of Spoke Outer Diameter Type Gear Ratio Inner Steering Angle Outer Steering Angle Type Maximum Pressure Upper Tilting Angle Lower Tilting Angle Type Capacity Change Interval Description 4 39...

Page 1251: ...ng Pinion Faulty Steering Shaft Joint Steering Fluid Leaks Lack of Fluid or Air in System Faulty Steering Oil Pump Damaged or Loosened Pump Drive Belt Clogging Oil Line Damaged Wheel or Tire Faulty Suspension System DIAGNOSIS HARD STEERING Action Lubricate Replace Replace gear assembly Adjust Replace Repair or replace Replenish or bleed Replace Adjust or replace Repair or replace Repair or replace...

Page 1252: ...ystem Faulty Oil Pump Checks Damaged Steering Linkage Loosened Steering Gearbox Mounting Bolt Damaged or Binding Steering Ball Joint Worn or Damaged Front Wheel Bearing Damaged Wheel or Tire Faulty Suspension System STEERING WHEEL SHIMMY Action Replace Retighten Replace Replace Repair or replace Repair or replace ABNORMAL NOISE FROM STEERING SYSTEM Action Retighten Replace gear assembly Replace Re...

Page 1253: ...6A 4 POWER STEERING SYSTEM 1 Steering Wheel 2 Steering Column Shaft 3 Steering Gear Box 4 End Ass y Tie Rod COMPONENT LOCATOR STEERING SYSTEM 5 Lower Shaft 6 Oil Reservoir 7 Oil Pump 8 Steering Knuckle ...

Page 1254: ... Replace or repair if necessary Steering Angle Inspection Procedure 1 Place the front wheel on a measuring tool 2 Rotate steering wheel all the way right and left and measure steering angle Notice If out of standard check or adjust toe in Standard 33 37 31 50 Inner Outer Steering Effort Inspection Procedure 1 Place a vehicle on the paved flat ground with front wheels in a straight ahead position 2...

Page 1255: ...eeding procedure BLEEDING OF POWER STEERING SYSTEM Bleeding of Power Steering System 1 Disconnect the fuel line Using a starter motor crank the engine and turn the steering wheel from lock to lock 5 or 6times Notice Do bleeding with engine cranking If bleed with idling there can be a air contact with oil 2 Connect the fuel feed line and start the engine at idle speed 3 Turn the steering wheel from...

Page 1256: ...A 7 STEERING GEAR BOX 1 Bolt 30 40Nm 2 Spring Washer 3 Lower Shaft 4 Pressure Hose 12 18Nm 5 Return Pipe 12 18Nm 6 Cotter Pin 7 Slotted Nut 35 45Nm 8 Nut 9 Spring Washer 10 Bolt 35 45Nm 11 Washer 12 Steering Gearbox Assembly ...

Page 1257: ...40 Nm 3 Remove the oil pipe from the steering gear box and drain the oil Installation Notice 4 Remove the clamp bolts and remove the steering gear box assembly Installation Notice Tightening Torque 12 18 Nm Notice l Be careful not to damage the rubber 1 l When installing tighten the bolt 3 with the rubber 2 being inserted to the hole of clamp 5 Bleed the air from system 6 Check the toe in Tighteni...

Page 1258: ...djust as below 2 Adjustment l Unscrew the adjuster nut 1 and adjust the distance by turning the rod 2 counterclockwise Distance of Tie Rod 152mm Toe in 0 4 mm Torque 65 80Nm l Check the toe in date A B l If the ton in is normal tighten the adjuster nut 1 to the specified toque with tie rod 2 being fixed Tightening ...

Page 1259: ...ightening Specifications 6E 1 Maintenance and Repair 6E 2 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Steering Wheel Mounting Nut Shaft Bolt Steering Column Shaft Bolt Steering Column Mounting Bolt Nlm 50 80 30 40 9 14 15 20 On Vehicle Service 6E 2 Steering Column 6E 2 ...

Page 1260: ...Horn Pad 2 Nut 50 80 Nm 3 Washer 4 Steering Wheel 5 Combination Switch Assembly 6 Combination Switch Lower Cover 7 Combination Switch Upper Cover 8 Bolt 9 Bolt 10 Bolt 11 Crash Pad Panel 12 Bolt 30 40 Nm 13 Spring Washer 14 Lower Shaft 15 Bolt 9 14 Nm 16 Bolt 13 40 Nm 17 Steering Column Shaft ...

Page 1261: ...nnect the connectors 2 Place an alignment marks on the column shaft end and fixing nut and then remove the fixing nut Installation Notice 3 Remove the steering wheel and combination switch covers Tightening Torque 50 80 Nm 4 Remove the crash pad panel Notice Remove the hood release wire and the other switch connectors ...

Page 1262: ...from ignition switch Diesel only 8 Disconnect the steering column shaft from lower shaft by unscrewing the bolt Installation Notice 9 Unscrew the steering column housing fixing bolts to fixing bolts to floor Installation Notice Tightening Torque 30 40 Nm 7 Remove the combination switch assembly Tightening Torque 9 14 Nm ...

Page 1263: ...EEL AND COLUMN 6E 5 Tightening Torque 15 20 Nm 11 Installation should follow the removal procedure in the reverse order 10 Unscrew the steering column upper bolt and remove the column assembly Installation Notice ...

Page 1264: ...fications 7B C 2 Cooling Capacity 7B C 2 Compressor 7B C 2 Condenser 7B C 2 Receiver Drier 7B C 2 Dual Pressure Switch 7B C 2 Evaporator 7B C 3 Heater Unit 7B C 3 Fastener Tightening Specifications 7B C 3 Diagnosis 7B C 4 Defectives in Fan Motor Circuit 7B C 5 Defectives in Compressor Circuit 7B C 5 TABLE OF CONTENTS Component Locator 7B C 6 Ventilation 7B C 6 Air Conditioner System 7B C 8 Diesel ...

Page 1265: ...DRIER Application High Low Description OFF 27 2kgf cm2 DIFF 6 2kgf cm2 G OFF 1 8 0 2kgf cm2 ON 1 9 0 3kgf cm2 G DUAL PRESSURE SWITCH SPECIFICATIONS COOLING CAPACITY Application Type Max Capacity Max Blowing Capacity Refrigerant Refrigerant Amount Description Air mix type 4 500kcal h 7 Om3 mim R134a 650 75Og Application Model Type Output Oil Magnetic Clutch Output Description FK ll Vane rotary type...

Page 1266: ... DIFF 2 0 5 C EVAPORATOR Application Heater Core Type Heating Capacity Heater Core Size LxWxT Description 2 ROW 4 600 kcal h AT 300 CMH 219 5x151 8x52 0 HEATER UNIT Application Condenser Bolt Condenser Fan Nut Condenser Bolt Receiver Drier Pipe Bolt Receiver Drier Pipe Bolt Condenser Pressure Pipe Bolt Pressure Mounting Bolt Nlm 4 6 4 6 4 6 5 8 4 6 20 30 20 26 FASTENER TIGHTENING SPECIFICATIONS ...

Page 1267: ...7B C 4 MANUAL SEMIAUTO HVAC DIAGNOSIS m ...

Page 1268: ...on Action Replace resistor Check heater cooling unit and blower for proper connection Fan Motor Runs in 4 position Only 3 2 1 Does Not Run Frosted Evaporator DEFECTIVES IN COMPRESSOR CIRCUIT Compressor Does Not Run Checks Faulty thermo amp Action Frosted evaporator reduces cooling capacity Off compressor and maximize blowing capacity Checks Faulty high low pressure Faulty A C relay Action Check co...

Page 1269: ...7B C 6 MANUAL SEMIAUTO HVAC COMPONENT LOCATOR VENTILATION 1 Foot Face 2 Foot Defroster 3 Foot 4 Defroster 5 Face ...

Page 1270: ...ch Door VENT Door FOOT Door DEF Door INTAKE Door AIR MIX Door Air Flow Mode Switch VENT A C D Recirculation Switch Temperature Control Lever MANUAL SEMI AUTO B L B B D FOOT C A D D F C B B DEF C C A REC FRE A B C INDI On A INDI Off B ...

Page 1271: ...TO HVAC AIR CONDITIONER SYSTEM DIESEL ENGINE 1 Compressor 2 High Pressure Hose 3 Condenser 4 Condenser Fan 5 Liquid Pipe A 6 Receiver Drier 7 Liquid B 8 Evaporator Assembly 9 Blower Unit 10 Heater Unit 11 Low Pressure Hose ...

Page 1272: ... Assembly Add 6 Supplement Assembly c fan Mounting 7 Receiver Bracket Assembly 8 Hose Discharge 9 Bolt Hex Sems M8x1 25x30 10 Hose Assembly Suction 11 Pipe Assembly Suction 12 Pipe Liquid A 13 Pipe Liquid B 14 Resister Condenser Fan 15 Clip Closed CT M8 16 Bolt Hex FLG M8x1 25x25 17 Nut Hex M6x1 0 18 Screw Hex SEMS M6x1 0x25 19 Screw Hex SEMS M6x1 0x16 ...

Page 1273: ... 2 Heater Unit 3 Heater Control Box Assembly 4 Heater Unit Amp 5 Mix Actuator Assembly 6 Mode Actuator Assembly 7 Blower Unit 8 Duct Assembly HTR to Blower 9 Duct Assy Side A VENT No 1 LH 10 Water Inlet Hose 11 Water Outlet Hose 12 Heater Pipe Gromet 13 Duct Assy HTR Connector ...

Page 1274: ...ssure charging valve and the high pressure hose of the gauge to high pressure charging valve Tighten the hose nuts by hand Discharging of Refrigerant 1 Connect the manifold gauge to the charging valve 2 Place the free end of center hose in a shop towel 3 Slowly open the high pressure hand valve and discharge refrigerant Notice If refrigerant is allowed to escape too fast compressor oil will be dra...

Page 1275: ...h refrigerant gas 3 Charge until the low pressure gauge reads 1 0kg cm and close the valve 4 Using a gas leak detector check the system for leaks 5 If a leak is found replace a O ring or repair the faulty connection 2 6 Stop the vacuum pump and wait about 5 minutes 7 After 5 minutes check that low pressure gauge reading is changed or not 8 If low pressure gauge reading is changed check the system ...

Page 1276: ...e and charge the system with refrigerant Standard 650 750 g 6 Close the low pressure valve after charging Notice Checking the pressure through the sight glass is impossible by applying R 134a 7 Stop the engine and disconnect the manifold gauge from the system Operation Check 1 Place a dry bulb thermometer to the front duct 2 Place a psychrometer close to the inlet of the cooling unit under the glo...

Page 1277: ...hed to inflated portion of pipe and always replace used O rings 3 After inserting the pipe to the union tighten the nut by hand as much as possible and tighten the nut to specified torque 4 When connecting liquid pipe B and low pressure hose A to evaporate pipe apply compressor oil to the O ring 5 When tightening set the center of pipe and tighten fully 6 Tighten the nut by specified wrench Instal...

Page 1278: ...MANUAL SEMIAUTO HVAC 7B C 15 CONDENSER Preceding Work Removal of the radiator 1 Condenser 2 Bolt 4 6 Nm 3 Condenser Fan 4 Sub Fan Gasoline Engine 5 Resister Gasoline Engine ...

Page 1279: ...nt from the system Tightening Torque Inlet Side to 10 15 Nm Outlet Side to 4 6 Nm Notice When installing check the O ring and apply compressor oil 2 Remove the mounting bolts 2EA and condenser assembly Installation Notice Tightening Torque 4 6 Nm 4 Installation should follow the removal procedure in the reverse order 3 Remove the main condenser fan from condenser ...

Page 1280: ...MANUAL SEMIAUTO HVAC 7B C 17 RECEIVER DRIER 1 Condenser 2 Receiver Drier 3 Bolt 4 6 Nm 4 Bolt 5 8 Nm 5 Bracket ...

Page 1281: ...se to High Low pressure line discharge the refrigerant 3 Disconnect the inlet and outlet pipes of receiver drier Notice When installing check the O ring and apply the compressor oil Installation Notice 4 Remove the bracket bolt and then remove the receiver drier Installation Notice Tightening Torque 4 6 Nm 5 Installation should follow the removal procedure in the reverse order Tightening Torque 5 ...

Page 1282: ...cedure in the reverse order AIR CONDITIONER COMPRESSOR 1 Compressor Bracket 2 High Pressure Hose 3 Low Pressure Hose 4 Compressor Removal Installation Procedure 1 Disconnect the negative terminal from the battery 2 Discharge refrigerant from the system Notice By connecting a manifold gauge connection hose to High Low pressure line discharge the refrigerant 3 Disconnect the high low pressure pipe a...

Page 1283: ...7B C 20 MANUAL SEMIAUTO HVAC HEATER AND AIR CONDITIONER CONTROL BOX 1 Blower Switch 2 Recirculation Switch 3 Mode Switch 4 A C Switch 5 Temperature Control Lever 6 In vehicle Sensor MANUAL SATC ...

Page 1284: ...on Procedure 1 Remove the switch panel Notice Be careful not to damage the switch panel 2 Remove the fixing screws 4 screws of the control box 3 Disconnect the wire connectors and remove the control box 4 Installation is reverse order of the removal ...

Page 1285: ...ng 7D 15 FATC Full Automatic Temperature Control is full automatic heater and airconditioning system that detects incar temperature ambient temperature sun load and coolant temperature and controls airconditioner system blowing capacity outlet temperature and intaking outlet mode to maintain interior comfort SPECIFICATIONS SPECIFICATIONS Application Core Size LxWxT Core Type Expansion Valve Type T...

Page 1286: ...ion Replacement Description Every 10 000 km replace earlier if air pollution is heavy Air Filter Application Model Type Displacement cc rev Pulley Oil Description FK II DKV 14C Vane rotary 140 5 f143 0 ZXL 200 PG PAG Oil Compressor Application Heater Core Type Heating Capacity Heater Core Size LxWxT Description 2 ROW 4 600 Kcal h AT 300 CMH 219 5 x 151 8 x 52 Heater Unit Application Type High OFF ...

Page 1287: ...emperature Sensor Description Input Section 2 186kW 0 07kW 5V 3mA 1 0kW 0 03kW 5V 3mA 0 55kW 0 02kW 5V 3mA Current Rating at 12V LOCK Current Current Rating at 12V LOCK Current Current Rating at 12V LOCK Current Ic Pc Application Intake Actuator Mode Actuator Mix Actuator Power TR Blower Motor Power Consumption Description Output Section 70 30mA Less than 500mA 100 40mA Less than 500mA 100 40mA Le...

Page 1288: ...7D 4 FATC HAVC CIRCUIT DIAGRAM SCHEMATIC AND ROUTING DIAGRAMS ...

Page 1289: ...R SWITCH MODE SWITCH DEFROSTER SWITCH INTAKE SWITCH AUTO SWITCH A CON SWITCH OFF SWITCH TEMP DOOR POSITION FEEDBACK VOLTAGE POWER TRANSISTOR COLLECTOR VOLTAGE VFD MAX HI RELAY POWER T R BLOWER MOTOR ECU COMPRESSOR MIXACTUATOR MIXDOOR INTAKE ACTUATOR INTAKE DOOR MODE ACTUATOR MODE DOOR Airconditioner output C O N T R O L U N I T ...

Page 1290: ...7D 6 FATC HAVC VENTILATION SYSTEM COMPONENT LOCATOR ...

Page 1291: ...2 C l When pressed more than 1 second it will be automatically UP DOWN by interval of 0 28 sec after 1 second l When it changed 17 5 C 17 C 31 5 C 32 C and DOWN switch is pressed after 17 C or UP switch is pressed after 32 C there will be operating sounds 3 times during 0 1 sec 5 DEFROST switch l By pressing this switch DEF will turn on and mode door will be fixed at DEF l Recirculation fresh air ...

Page 1292: ...ion Press AUTO Press AUTO Press OFF Press OFF DIAGNOSIS TEST FATC airconditioner system has self diagnosis function Turn the ignition switch ON and press intake switch more than 4 times within 2 seconds while the AUTO switch is 1 AUTO Switch 2 Intake Switch 3 OFF Switch 4 Airconditioner Switch 5 Set temperature Display pressed then it will diagnose incar sensor ambient sensor water temperature sen...

Page 1293: ...er 00 will blink Display during continuous action A Normal or 1 fault 00 or 11 15 coolant Sensor Open 16 coolant Sensor Short 17 temperature Actuator Open Short 18 temperature Actuator Drive Fault 00 normal 11 incar Sensor Open 12 incar Sensor Short 13 ambient Sensor Open 14 ambient Sensor Short B Multiple faults 11 13 15 Display during step action A Normal or 1 fault the same as continuous action...

Page 1294: ...er NO Item Defects Fault safety function 1 Incar sensor Open or short Control When substituted 25 C 2 Ambient sensor Control When substituted 20 C 3 Water temperature sensor Perform heating maneuver control function under refrigeration maneuver control entering conditions and release after 10 minutes 4 Temperature door potentiometer Set temperature 17 24 5 C max COLD position Set temperature 25 32...

Page 1295: ...h 2 MODE Switch 3 OFF Switch 4 Temperature UP DOWN Switch 5 Defrost Switch 6 Airconditioner Switch 7 Recirculation fresh Air Switch 8 Blower Switch UP DOWN 9 VFD Vacuum Fluorescent Display MAINTENANCE AND REPAIR FATC CONTROL PANEL ...

Page 1296: ...I speed relay Photo sensor Photo sensor Temperature actuator F B Temperature actuator CW IG2 Ground Connector A Pin No 1 Connection circuit 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Incar sensor Ambient sensor Coolant sensor Sensor voltage 5V Sensor ground Intake ambient Intake incar VENT B L FLR MIX DEF Connector B 17 18 19 20 16 20 pin B 16 pin A 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 1 9 2 ...

Page 1297: ...clock 3 Unscrew the screw from the center panel pull out each switches and remove the center panel 4 Unscrew the 6 screws and remove the audio control panel assembly 5 Unscrew the 4 screws and remove the airconditioner control panel assembly 6 Installation should follow the removal procedure in the reverse order ...

Page 1298: ...to release the upper left and right locking portion Notice Remove the glove box by unscrewing lower 2 screws if necessary 2 Press the 2 filter cover holds and remove the air filter cover 3 Remove the 2 air filters Notice For installation remember the installed direction of the air filter before removal Replacement Interval Every 10 000km ...

Page 1299: ...nsor terminals is as shown in the right side graph Notice Measure resistance value by soaking the sensor in the ice water and check changes in resistance values after soaking it in the very hot water 4 If resistance value is out of specification replace the incar sensor 5 Install the sensor and turn the ignition switch to ON position and check that voltage between No 12A terminal of incar sensor a...

Page 1300: ...e sensor 3 Check that measured resistance value among ambient sensor terminals is as shown in the right side graph Notice Measure resistance value by soaking the sensor in the ice water and check changes in resistance values after soaking it in the very hot water 4 If resistance value is out of specification replace the ambient sensor 5 Install the sensor and turn the ignition switch to ON positio...

Page 1301: ...istance value by soaking the sensor in the ice water and check changes in resistance values after soaking it in the very hot water 4 If resistance value is out of specification replace the water sensor 5 Install the sensor and turn the ignition switch to ON position and check that voltage between No 7a terminal of the water sensor and body is 5V 6 Check current between the No 7a and 7b connector t...

Page 1302: ... can be measured as current by using multimeter according to increasing sun loads 1 Check current on the circuits between the sun load sensor and the airconditioner control unit 2 Turn the ignition switch to ON position and check that voltage between No 13a terminal of the sun load sensor and vehicle ground is 5V 3 Measure current between No 13a terminal of the sun load sensor and No 11 terminal o...

Page 1303: ...after connecting the battery to the 6C terminal of intake actuator and ground 6A 6B to the body 6C 6B 6A Wiring side connector Actuator connector Intake actuator is normal Yes Repair and replace the intake actuator No Check intake actuator linkage and door for proper operation and repair if necessary Disconnect 20 pin connector from the airconditioner control unit Check current between the intake ...

Page 1304: ...l 8J 8H 8F 8D 8B of the mode actuator alternatively Mode actuator connector Mode actuator is normal Yes Repair and replace the mode actuator No Check the intake actuator linkage and door for proper operation and repair if necessary Disconnect 20 pin connector from the airconditioner control unit Check current between the mode actuator 8J 8H 8F 8D 8B and the airconditioner control unit 11 12 13 14 ...

Page 1305: ...electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals Disconnecting this cable will help prevent personal injury and damage to the vehicle The ignition must also be in LOCK unless otherwise noted General Description and System Operation 8A 4 Driver Seat Belt Warning 8A 4 Operation and Functional Checks 8A 4 SPECIFICATIONS FASTENER TIGHTENING SPE...

Page 1306: ...ONENT LOCATOR FRONT SEAT BELT 1 Seat Belt Assembly 3 Point 2 Buckle Assembly 3 Seat Belt Dust Cover 4 Seat Belt Webbing Guide 5 Seat Belt Reel Assembly 6 Anchor Bolt 35 55 Nm 7 Anchor Bolt 35 55 Nm 8 Anchor Bolt 35 55 Nm ...

Page 1307: ... SEAT BELT 1 Seat Belt Assembly 3 point 2 Seat Belt Stalk Plate Assembly 3 Seat Belt Assembly 2 Point 4 Webbing Buckle Assembly Center 5 Webbing Buckle Assembly Rear 6 Webbing Hanger 7 Seat Belt Dust Cover 8 Webbing Guide ...

Page 1308: ...n order to clean the belts l When installing the seat belt anchor bolts and the screws start the bolts and screws by hand in order to prevent crossthreading l Do not attempt any repairs on the retractor mechsemblies with new assemblies l Replace any belts that are cut r damaged in any way 1 Inspect all saet belt anchor bolts and the screw in order to verify that they are secure 2 Inspect the seat ...

Page 1309: ...ICATIONS GENERAL SPECIFICATIONS Application Air bag System Deployment Time Detection Time Operating Temperature Storage Temperature Air Bag Replacement Interval Voltage Range Current Consumption Acceleration Range Max Acceleration Voltage Ramp Energy Reservation Inflator Ignition Energy Squib Resistance Air Bag Warning Lamp ON Time When Ignition ON Description 20ms 5ms 40 C 85 C 40 C 90 C Every 10...

Page 1310: ...wn the sun visor and see SRS air bag warning lamp on the head lining B Head Lining Warning 1 This vehicle is equipped with air bag Air bag is supplemental device for the seatbelt Fasten your seatbelt 2 This air bag should be replaced by authorized supplier within replacement intervals 3 When the ignition key is turned to ON position SRS warning lamp will turn on for 6 sec and go off In this case t...

Page 1311: ...that control all functions and determines whether deploy the air bag or not with the collision signal from the built in accelerometer sensor and has function of diagnosing system defects Internal air bag control unit is consisted as follows l Microprocessor l ASICs Upper side ASIC lower side ASIC l Accelerometer sensor l Arming sensor l System energy backup condenser l Squib energy backup condense...

Page 1312: ...ing Bar 19 Shorting Bar 20 Diagnosis 21 Shorting Bar 22 Shorting Bar 23 No Pin 24 No Pin 25 Shorting Bar 26 Shorting Bar 27 N A 28 Shorting Bar 29 Shorting Bar 30 N A 1 Lamp 2 Ground 3 N A 4 N A 5 Ignition 6 N A 7 N A 8 CONF 9 N A 10 N A 11 N A 12 N A 13 Squib Line 1 upper 14 Squib Line 1 lower 15 N A IGN GND Warning lamp RxD TxD Inflator line 1 5 2 1 20 13 14 Air bag lamp Communication diagnosis ...

Page 1313: ...ial and bag When crashed the air bag control unit sends current to the air bag module through squib line and this current ignites as ignition energy 6mJ momentarily igniting explosives and bag will be inflated by nitrogen gas protecting driver at the same and then deflates 1 Air bag Module 2 Module Housing 3 Bag 4 Module Bracket 5 Retainer Ring 6 Inflator 7 Horn Switch 8 Backing Plate ...

Page 1314: ... 40 5 resistance but also short resistance 1 10k status between the battery and ground to indicate defects in squib line by blinking warning lamp Air bag control unit AC4 can measure squib resistance Warning Lamp Turning On Air bag control unit detects system defects during ignition ON or driving and displays following 2 warning lamps Warning lamp ON internal defects of the air bag control unit Wa...

Page 1315: ...hutdown status Accelerometer Check Accelerometer function will be checked during start up During operation accelerometer off set signal will be checked If there is fault module will enter overall shutdown status ASIC Overheat Module monitors upper side ASIC overheats continuously If overheated the module will enter overall shutdown status Microprocessor Fault Module checks EEPROM ROM checksum and ...

Page 1316: ... Start up ignition ON During Driving Lamp Blinking Mode There are 2 kinds of blinking mode 1 When system internal fault is found the lamp will stay on 2 The lamp will blink according to external fault and there are 2 blinking codes Blinking code 1 Squib resistance fault in the driver s air bag squib line Blinking code 2 Squib short on plus and minus in the air bag squib line Lamp blinking code is ...

Page 1317: ...ection display and press Enter 5 Select Korando 98 model year from vehicle model selection display and press Enter 6 Select Electronic air bag from control system selection display and press Enter 7 Select Self diagnosis from diagnosis item selection display Notice Check sensor value of output display if necessary 8 Determine the fault code and trace defective component Notice Refer to self diagno...

Page 1318: ...hort of ground side No 3 in the driver s squib circuit l Check and replace the ECU X 08 Driver s squib ground side No 4 l Short of ground side No 4 in the driver s squib circuit l Check and replace the ECU X 09 Energy shutdown switch No 1 l Air bag control unit internal defects l Check and replace the ECU 10 Energy shutdown switch No 2 l Air bag control unit internal defects l Check and replace th...

Page 1319: ...tion of connector l Check the ECU l Replace the squib wire l Plus side short 7k ground side short 6kW l Driver s squib resistance is higher than standard 4 5 0 5W l Check related circuits for open short l Check connection of connector l Check the ECU l Replace the squib wire l Plus side short 7k ground side short 6kW l Driver s squib resistance is lower than standard 1 4 0 3W l Check related circu...

Page 1320: ...e ECU l Air bag control unit internal defects l Check and replace the ECU l Air bag control unit internal defects l Check and replace the ECU l Air bag control unit internal defects l Check and replace the ECU l Air bag control unit internal defects l Check and replace the ECU l Air bag control unit internal defects l Check and replace the ECU l Air bag control unit internal defects l Check and re...

Page 1321: ... for voltage and charging l Check related circuits for open short l Check connection of connector l Check the ECU l Air bag control unit internal defects l Check the ECU l Air bag control unit internal defects l Check and replace the ECU l Air bag control unit internal defects l Check and replace the ECU l Air bag control unit internal defects l Check and replace the ECU l Air bag control unit int...

Page 1322: ...YSTEM SRS Fault Code Defects Service Hint Appli cation 127 Collision signal 128 Collision number l Air bag control unit internal defects l Check and replace the ECU l Air bag control unit internal defects l Check and replace the ECU ...

Page 1323: ...SUPPLEMENTAL RESTRAINT SYSTEM SRS 8B 15 CIRCUIT DIAGRAM ...

Page 1324: ...8B 16 SUPPLEMENTAL RESTRAINT SYSTEM SRS AIR BAG DIAGRAM ...

Page 1325: ...teering wheel rid LH RH with a screwdriver Installation Notice Each position mark LH RH is stamped on the inner surface of the rids Tightening Torque 7 11 Nm 3 Disconnect the connectors and remove the air bag module 4 Installation should follow the removal procedure in the reverse order 2 Unscrew the bolts from both sides Installation Notice ...

Page 1326: ...ing Range DC 12V DC 6 18V 10 30mA 6A 0 1second 200 220mA 15mA 0 16 0 38W 40 C 85 C 5MW 2 7 3 1 Rotation from neutral Position to Both Sides Notice l Clock spring can not be repaired l Do not disassemble or modify l To adjust to the center position rotate clockwise until it stops and then rotate it counterclockwise 2 3 0 2 revolutions and align marks If not airbag system can not work normally and d...

Page 1327: ...Start the procedure after waiting over 3oseconds 2 Unscrew 3 screws from lower cover on steering column shaft and remove the lower cover 3 Unscrew 4 screws from clock spring and remove the clock spring Installation Notice l Don t try to repair and modify the clock spring l When aligning the neutral position turn to clockwise until it stops and turn to counter clockwise until the marks are aligned ...

Page 1328: ...up power for 150ms and air bag can be inflated so wait for min 30 seconds 2 Remove the console box and center fascia panel assembly 3 Remove the heater control switch and audio assembly 4 Remove the lower side panel of the driver s portion and glove box 5 Remove the lower main panel 6 Release the lock lever of the AC4 connector and disconnect the connector 7 Unscrew 3 nuts and remove the AC4 Notic...

Page 1329: ...or the air bag system as ordered if not the air bag can be operated suddenly and it could result in damage of air bag or injury Before service removal installation checking and replacement of parts observe the following instructions and service correctly 1 To service turn the ignition switch to LOCK position and disconnect the negative battery cable and continue the procedures after approx 30 seco...

Page 1330: ...TENTS Caution Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals Disconnecting this cable will help prevent personal injury and damage to the vehicle The ignition must also be in LOCK unless otherwise noted Engine Room 9A 10 Main 9A 11 Floor and Rear 9A 13 Air Conditioner...

Page 1331: ...9A 2 BODY WIRING SYSTEM SCHEMATIC AND ROUTING DIAGRAMS POWER DISTRIBUTION ...

Page 1332: ...BODY WIRING SYSTEM 9A 3 STARTING AND CHARGING GASOLINE ...

Page 1333: ...9A 4 BODY WIRING SYSTEM STARTING AND CHARGING DIESEL ...

Page 1334: ...NG SYSTEM 9A 5 FUSE BOX AND RELAY 1 Automatic Door Lock Relay 2 Engine Room Fuse Box 3 ABD Motor and Valve Relay 4 Interior Fuse Box 5 Interior Relay 6 Window Auto Down Relay 7 Over Voltage Protection Relay OVPR ...

Page 1335: ...A 18 Engine 30A 19 Ignition Switch 30A 20 Battery 50A Relay 1 Tail Lamp 2 Horn 3 Register Gasoline 4 Front Fog Lamp 5 Condenser Fan 6 Compressor Diesel Condenser Fan Gasoline 7 Condenser Fan 8 Head Lamp HI 9 Head Lamp LOW Fuse 10 Horn 10A 11 Tail Rear Fog Lamp 15A 12 Head Lamp HI 15A 13 Head Lamp LO 15A 14 Front Fog Lamp 15A ...

Page 1336: ...r Relay F15 F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 Stop Lamp Switch Air Conditioner Door Lock Seat Warmer Unit Power Window Relay Diagnosis Connector Engine Room Relay Hazard Switch Back up Lamp T O D T C C U Sun Roof Auto Dimming Room Mirror Speed Sensor Diagnosis Connector Joint Conn 5 Diode OVPR Preheat Control Unit Shift Lock Relay Air Bag Unit ECS Relay Antenna Motor FRT Wiper Re...

Page 1337: ...ssion Neutral Relay 4P Automatic Transmission Checking The Fuses It is possible to check the condition of blade type fuses without pulling out them from fuse block Lighting on the test lamp is normal when the one lead wire of test lamp is contacted with fuse end and the other one is grounded 1 In case of melting out the fuse owing to the over voltage replace the damaged fuse to the rated one after...

Page 1338: ...BODY WIRING SYSTEM 9A 9 Relay ...

Page 1339: ...ondenser Fan Motor 19 Resistor 22 Ambient Sensor 23 LH Horn 24 Cooling Fan Motor Relay 25 RH Horn 26 Thermos Switch 2 E20 Only 27 RH Condenser Fan Motor 28 RH Front Fog Lamp 29 RH Head Lamp 30 RH Head Lamp Leveling Deivce 31 Hood Switch 32 Turn Signal Lamp RH Tail Lamp 33 Ground 2 34 Alternator 35 Alternator Extension Wiring Connector 36 Receiver Drier 37 Washer Motor 39 Front Wheel Speed Sensor 4...

Page 1340: ...Wiring connector 19 T C C U 20 Ground 22 Floor Wiring Connector 23 Floor Wiring Connector 24 Clutch Switch1 M T 25 Clutch Switch2 M T 26 Stop Lamp Switch 27 Multifunction Switch1 28 Multifunction Switch2 29 Ignition Switch 30 Auto Cruise Switch 31 Multifunction Switch3 32 Immobilizer Antenna Connector 4pin 33 Diagnosis Connector 37 Transmission Wiring Connector 38 Transmission Wiring Connector A T...

Page 1341: ...e Lighter 77 Audio 78 Buzzer 79 Chime 80 Accelerator Sensor ABD 5 3 only 82 ECS Unit Connector 83 T C U A T BTRA Only 85 STICS 86 STICS 87 STICS 88 Ground 92 ABD 5 ECU 93 ABD 5 ECU Ground 95 Parking Brake Switch 96 O2 Sensor 97 Shift Lock Solenoid 98 P W Mode Switch 100 P Position Switch 102 RH Engine Wiring Connector 103 Combination Connector 104 O2 Sensor E20 E23 105 Engine Wiring Connector ABD ...

Page 1342: ...r 7 Main Wiring Connector 8 RH Rear Speaker 9 Tail Gate Switch 10 RH Rear Combination Lamp 11 LH Rear Speaker FLOOR AND REAR 12 Ground 13 Luggage Room Lamp 14 LH Rear Combination Lamp 15 Rear Bumper Wiring Connector 16 Tail Gate Wiring Connector 17 Tail Gate Wiring Connector 20 RH Rear Damper 21 LH Rear Damper 22 Door Switch ...

Page 1343: ...NDITIONER Semi A C 1 Main Wiring Connector 2 Floor Fan Switch 3 A C Diode 4 HI Relay 5 MH Relay 6 ML Relay 7 LO Relay 8 A C Relay 9 Mix Actuator 10 Auto Amp 11 Auto Amp 12 Floor Switch 13 Mode Switch 14 PTC 15 In Car Sensor Connector ...

Page 1344: ...BODY WIRING SYSTEM 9A 15 1 Mode Actuator 2 In Car Sensor 3 Blower Relay 4 High Speed Relay 5 Intake Actuator 6 Temperature Actuator Full A C ...

Page 1345: ...9A 16 BODY WIRING SYSTEM 1 Main Wiring Connector 2 Sun Roof Wiring Connector 3 Front Room Lamp 4 Sun Roof 5 Center Room Lamp ROOF ...

Page 1346: ...SYSTEM 9A 17 1 Main Wiring 2 Tweeter Speaker 3 Outside Mirror Motor 4 Power Window Motor Main 5 LH Front Speaker 6 Power Window Switch Main 7 Door Cylinder Switch 8 Door Lamp 9 Door Lock Actuator DOOR Dirver s Door ...

Page 1347: ...NG SYSTEM 1 Main Wiring Connector 2 Tweeter Speaker 3 Outside Mirror Motor 4 Power Window Motor Sub 5 RH Front Speaker 6 Power Window Switch Sub 7 Door Cylinder Switch 8 Door Lamp 9 Door Lock Actuator Passenger s Door ...

Page 1348: ...TEM 9A 19 TAIL GATE 1 Floor Wiring Connector 2 Floor Wiring Connector 3 Rear Heated Glass 4 Rear Wiper Motor 5 Rear Washer Motor 6 Linkage Lamp 7 Tail Gate Lock Actuator 8 Rear Heated Glass 9 Tail Gate Cylinder Switch ...

Page 1349: ...HART Specifications 9B 1 Bulb Usage Chart 9B 1 Schematic and Routing Diagrams 9B 2 Tail Lamp 9B 2 Head Lamp 9B 3 Turn Signal Lamp and Hazard Lamp 9B 4 Back Up Lamp and Stop Lamp 9B 5 Front and Rear Fog Lamp 9B 6 Room Lamp 9B 7 Maintenance and Repair 9B 8 On Vehicle Service 9B 8 Lamps 9B 8 Position Lamp Head Lamp Turn Signal Lamp Room Lamp Door Courtesy Lamp Front Fog Lamp Stop Lamp Back up Lamp Ap...

Page 1350: ...9B 2 LIGHTING SYSTEM TAIL LAMP SCHEMATIC AND ROUTING DIAGRAMS ...

Page 1351: ...LIGHTING SYSTEM 9B 3 HEAD LAMP ...

Page 1352: ...9B 4 LIGHTING SYSTEM TURN SIGNAL LAMP AND HAZARD LAMP ...

Page 1353: ...LIGHTING SYSTEM 9B 5 BACK UP LAMP AND STOP LAMP ...

Page 1354: ...9B 6 LIGHTING SYSTEM FRONT AND REAR FOG LAMP ...

Page 1355: ...LIGHTING SYSTEM 9B 7 ROOM LAMP ...

Page 1356: ...ND REPAIR ON VEHICLE SERVICE LAMPS Front and Room Lamps 1 Head Lamp 2 Bulb 3 Front Fog Lamp 4 Bulb 5 Front Turn Signal Position Lamp 6 Bulb 7 Bulb 8 Screw 9 Side Repeater Lamp 13 Front Room Lamp 14 Center Room Lamp 15 Luggage Room Lamp ...

Page 1357: ...LIGHTING SYSTEM 9B 9 Rear Lamps 16 License Plate Lamp 17 Door Courtesy Lamp 18 Rear Combination Lamp 19 Screw 20 Screw Notice Removing and installing order is followed by the nos on the above picture ...

Page 1358: ... during engine is idling 4 Align the head light angle by turning the adjusting screw l Horizontal adjustment screw 1 l Vertical adjustment screw 2 5 Adjust the head light angle to 150mm 25mm at the tester by turning the adjusting screw Alignment for Fog Lamp 1 Set the vehicle onto the flat ground and adjust the distance 25m from fog lamp tester to vehicle 2 Adjust the vertical angle of fog lamp to...

Page 1359: ...cal unit or when a tool or equipment could easily come in contact with exposed electrical terminals Disconnecting this cable will help prevent personal injury and damage to the vehicle The ignition must also be in LOCK unless otherwise noted TABLE OF CONTENTS Schematic and Routing Diagrams 9C 2 Horn 9C 2 ...

Page 1360: ...9C 2 HORN HORN SCHEMATIC AND ROUTING DIAGRAMS ...

Page 1361: ... in contact with exposed electrical terminals Disconnecting this cable will help prevent personal injury and damage to the vehicle The ignition must also be in LOCK unless otherwise noted TABLE OF CONTENTS Schematic and Routing Diagrams 9D 2 Rear Wiper and Washer 9D 2 Maintenance and Repair 9D 3 On Vehicle Service 9D 3 Front Wiper and Washer 9D 3 Rear Wiper and Washer 9D 6 ...

Page 1362: ...9D 2 WIPERS WASHER SYSTEM SCHEMATIC AND ROUTING DIAGRAMS REAR WIPER AND WASHER ...

Page 1363: ...SYSTEM 9D 3 MAINTENANCE AND REPAIR ON VEHICLE SERVICE FRONT WIPER AND WASHER 1 Windshield Wiper Linkage 2 Nut 3 Wiper Arm 4 Blade 5 Windshield Washer Reservir Assembly 6 Washer Nozzle 7 Washer Hose 8 Mounting Holder ...

Page 1364: ...edure 1 Remove the wiper arm and blade 2 Remove the linkage connected to the wiper motor 3 Disconnect the connector from the wiper motor 4 Unscrew the locking bolts from wiper motor 5 Installation should follow the removal procedure in the reverse order ...

Page 1365: ...WIPERS WASHER SYSTEM 9D 5 Connector Appearance and Connecting Circuit Connector Terminal H P B L HI high speed Intermittent Ground Low low speed Diagram for Connecting Circuit ...

Page 1366: ...9D 6 WIPERS WASHER SYSTEM REAR WIPER AND WASHER 1 Blade 2 Clip 3 Wiper Arm Assembly 4 Wiper Cap 5 Wiper Cap Mounting Nut 6 Wiper Cap 7 Washer Reservoir Assembly 8 Washer Nozzle 9 Wiper Motor ...

Page 1367: ...ew the locking nut and remove the wiper 3 Unscrew the locking nut of wiper motor 4 Remove the tailgate trim panel 5 Disconnect the connector from the wiper motor 6 Unscrew four screws arrows and remove the wiper motor 7 Installation should follow the removal procedure in the reverse order ...

Page 1368: ...9D 8 WIPERS WASHER SYSTEM Connector Appearance and Connecting Circuit Connector Terminal B E WP Battery Power Source Ground From Switch Diagram for Connecting Circuit OFF ON WS E WP E WS ...

Page 1369: ... easily come in contact with exposed electrical terminals Disconnecting this cable will help prevent personal injury and damage to the vehicle The ignition must also be in LOCK unless otherwise noted TABLE OF CONTENTS Schematic and Routing Diagrams 9E 2 Cluster 9E 2 Component Locator 9E 3 Combination Meter 9E 3 Maintenance and Repair 9E 4 On Vehicle Service 9E 4 Cluster 9E 4 ...

Page 1370: ...9E 2 INSTRUMENTATION DRIVER INFORMATION CLUSTER SCHEMATIC AND ROUTING DIAGRAMS ...

Page 1371: ...ndicator 12 EBD Indicator 13 ECS SPORT Mode Indicator 14 ABS Warning Lamp 15 Alternator Warning Lamp 16 Oil Pressure Warning Lamp 17 Brake Parking Brake Warning Lamp 18 Seat Belt Warning Lamp 19 Fuel Level Warning Lamp 20 Air Bag Warning Lamp 21 Pre Glow 22 WINTER Mode Indicator 23 Rear Heated Glass Indicator 24 Front Fog Lamp Indicator 25 4WD Multfunction Indicator 26 Hazard Warning Lamp 27 TCS I...

Page 1372: ...e should be no clerance between crash pad assembly 4 and cluster fascia assembly and the clearance between combination meter 3 and cluster fascia have to be maintained 2mm 2 Remove 4 screws 3 Disconnect connectors and remove the combination meter 4 Installation should follow the removal procedure in the leverse order MAINTENANCE AND REPAIR ON VEHICLE SERVICE ...

Page 1373: ...lerance 20 3 0 40 60 5 0 80 5 0 120 5 5 0 5 140 5 5 0 5 160 4 0 100 5 5 0 4 0 6 1 6 1 20 4 0 Revolution Tolerance 1000 137 63 2000 3000 261 39 4000 298 2 5000 199 51 DIESEL Revolution Tolerance 1000 150 2000 3000 150 4000 180 5000 150 GASOLINE 6000 100 125 4 Temperature Gauge Temperature Sensor Resistance W Tolerance E 1 2 F 97 32 5 6 2 5 5 2 5 Temperature Resistance W 50 156 9 86 44 5 105 5 27 3 ...

Page 1374: ... a tool or equipment could easily come in contact with exposed electrical terminals Disconnecting this cable will help prevent personal injury and damage to the vehicle The ignition must also be in LOCK unless otherwise noted TABLE OF CONTENTS Schematic and Routing Diagrams 9F 2 Audio 9F 2 Diagnosis 9F 3 General Diagnosis 9F 3 ...

Page 1375: ...9F 2 AUDIO SYSTEM AUDIO SCHEMATIC AND ROUTING DIAGRAMS ...

Page 1376: ...AUDIO SYSTEM 9F 3 DIAGNOSIS GENERAL DIAGNOSIS No sounds ...

Page 1377: ...electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals Disconnecting this cable will help prevent personal injury and damage to the vehicle The ignition must also be in LOCK unless otherwise noted TABLE OF CONTENTS Component Locator 9G 2 Console Box 9G 2 ...

Page 1378: ...IOR TRIM COMPONENT LOCATOR CONSOLE BOX 1 Console Box 2 Tray 3 Arm Rest 4 Parking Lever Strip 5 Facia BTRE A T 6 Indicator Cover 7 Facia M T 8 Boot Assembly M T 9 Facia MB A T 10 Rear Facia Strip 11 Rear Facia Cap ...

Page 1379: ...al unit or when a tool or equipment could easily come in contact with exposed electrical terminals Disconnecting this cable will help prevent personal injury and damage to the vehicle The ignition must also be in LOCK unless otherwise noted TABLE OF CONTENTS Component Locator 9H 2 Front Seat Rear Seat 9H 2 ...

Page 1380: ... COMPONENT LOCATOR FRONT SEAT REAR SEAT 1 Front Seat Assembly Driver s 2 Front Seat Assembly Passenger s 3 Head Restraint 4 Rear Seat Assembly 5 Rear Seat Head Restraint 6 Arm Rest 7 Bolt 17 27 Nm 8 Bolt 35 55 Nm ...

Page 1381: ...xposed electrical terminals Disconnecting this cable will help prevent personal injury and damage to the vehicle The ignition must also be in LOCK unless otherwise noted TABLE OF CONTENTS Schematic and Routing Diagrams 9L 2 Outside Mirror 9L 2 Component Locator 9L 3 Glass 9L 3 Auto Dimming Room Mirror 9L 4 Maintenance and Repair 9L 5 On Vehicle Service 9L 5 Auto Dimming Room Mirror 9L 5 ...

Page 1382: ...9L 2 GLASS AND MIRRORS OUTSIDE MIRROR SCHEMATIC AND ROUTING DIAGRAMS ...

Page 1383: ...ORS 9L 3 COMPONENT LOCATOR GLASS 1 Wind Shield Tinted Glass 2 Wind Shield Dam 3 Spacer Pad 4 Wind Shield Upper Mounlding 5 Side Fixed Glass 6 Side Glass Nut 7 Tailgate Tinted Glass Assembly 8 Tailgate Glass Moulding ...

Page 1384: ...9L 4 GLASS AND MIRRORS 1 Auto Dimming Room Mirror Assembly 2 Sensor Front 3 Sensor Rear AUTO DIMMING ROOM MIRROR 4 Switch 5 Cover 6 Lamp ...

Page 1385: ...t DV 12V 1 A 3 A AUTO DIMMING ROOM MIRROR Function When ignition switch is turned ON green lamp on auto dimming mirror will turn in and glare reflection ratio will be automatically adjusted By positioning AUTO switch to ON 2Sensors will automatically adjust refection ratio after sensing rear and surrounding brightness to reduce driver s eye fatigue during driving though tunnel or in night When OFF...

Page 1386: ... AND MIRRORS Removal Installation Procedure 1 Removal the room mirror cover arrow 2 Disconnect 3 pin connector 3 Removal the mirror assembly 4 Installation should follow the removal procedure in the reverse order ...

Page 1387: ...SECTION 9M EXTERIOR TRIM TABLE OF CONTENTS Component Locator 9M 2 Side Trim 9M 2 Rear End Trim 9M 3 Under Trim 9M 4 ...

Page 1388: ... Cover 3 Air Extractor Grill 4 Air Extractor Grill Tape 5 Door Moulding 6 Front Wheel Arch Moulding 7 Rear Eheel Arch Moulding 8 Side Step 9 Side Step Upper Cover 10 Bolt 11 Wheel Arch Clip 12 Garnish Clip 13 Garnish Clip 14 Door Moulding Clip 15 Door Moulding Strip ...

Page 1389: ...EXTERIOR TRIM 9M 3 REAR END TRIM 1 Clip 2 C Piller Cover 3 Clip 4 Tailgate Garnish 5 Roof Moulding 6 Roof Moulding Endcap 7 Clip ...

Page 1390: ...IOR TRIM UNDER TRIM 1 Wheel House Cover A 2 Wheel House Cover B 3 Rivet 4 Front Mud Guard 5 Rear Mud Guard 6 Spring Nut 7 Splash Guide 8 Flange Cap Nut 9 Rivet 10 Rear Wheel House Cover 11 Rear Wheel House Geaner ...

Page 1391: ...N FRAME AND UNDERBODY TABLE OF CONTENTS Dimension 9N 2 Frame 9N 2 Component Locator 9N 4 Body Mountings 9N 4 Body Mounting Sectional View 9N 5 Maintenance and Repair 9N 6 On Vehicle Service 9N 6 Skid Plate 9N 6 ...

Page 1392: ...9N 2 FRAME AND UNDERBODY DIMENSION FRAME Length Length Length 910 420 5 47 232 166 722 8 681 485 1035 50 99 S51 178 5 ...

Page 1393: ...FRAME AND UNDERBODY 9N 3 Point Length Point A Transmission Mounting Point ...

Page 1394: ... Assembly 4 No 3 Insulator Assembly 5 No 4 Insulator Assembly 6 No 5 Insulator Assembly 7 Blind Plug 8 Bolt M10 1 25 9 Washer M14 10 Washer and Tube 11 Upper Insulator 12 Upper Insulator 13 Upper Plate 14 Lower Insulator 15 Upper Insulator 16 Bolt 17 Plain Washer 18 Lower Insulator 19 Nut 20 Bolt 21 Plain Washer ...

Page 1395: ...pper Insulator 2 Lower Insulator 3 Washer and Tube 4 Washer 5 Bolt 25 30 Nm 6 Nut M10 25 30 Nm 7 Washer M14 8 Nut M10 25 30 Nm 9 Plug M40 10 Washer and Tube 11 Washer and Tube 12 Washer and Tube 13 Plate 14 Bolt 25 30 Nm 15 Upper Insulator 16 Lower Insulator ...

Page 1396: ...PAIR ON VEHICLE SERVICE SKID PLATE 2 Skid Plate Removal Installation Procedure 1 Loosen the mounting bolts 4EA of skid plate and remove the skid plate Installation Notice 2 Installation should follow the removal procedure in the reverse order Tightening Torque 28 47 Nm ...

Page 1397: ...SECTION 9O BUMPERS AND FASCIAS TABLE OF CONTENTS Maintenance and Repair 9O 2 On Vehicle Service 9O 2 Front Bumper 9O 2 Rear Bumper 9O 4 ...

Page 1398: ...PAIR ON VEHICLE SERVICE FRONT BUMPER Notice Removal and installation is as shown in upper drawings 1 Front Bumper Assembly 2 Pad 3 Fog Lamp Mounting Bracket 4 Side Mounting Bracket 5 Rivet 6 Bolt 7 Front Nudge Bar Assembly 8 Side Support Bracket ...

Page 1399: ...BUMPERS AND FASCIAS 9O 3 MountingInspection 1 Clearance between the upper bumper and radiator grille 2 Clearance between the upper bumper and headlamp moding Clearance 10 13 mm Clearance 11 14 mm ...

Page 1400: ...UMPERS AND FASCIAS REAR BUMPER Notice Removal and installation is as shown in upper drawings 1 Front Bumper Assembly 3 Rivet 4 Protection Tape 5 Rear Bumper Spacer 6 Side Bracket 7 Nut 8 License Lamp Assembly ...

Page 1401: ...MPERS AND FASCIAS 9O 5 MountingInspection 1 Clearance between the upper bumper facia and tailgate 2 Clerance between the facia of rear bumper and quarter outer panel Clearance 12 15 mm Clearance 10 13 mm ...

Page 1402: ... contact with exposed electrical terminals Disconnecting this cable will help prevent personal injury and damage to the vehicle The ignition must also be in LOCK unless otherwise noted TABLE OF CONTENTS Schematic and Routing Diagrams 9P 2 Power Window 9P 2 Maintenance and Repair 9P 3 On Vehicle Service 9P 3 Front Door 9P 3 Tail Gate 9P 5 Power Window Motor 9P 7 ...

Page 1403: ...9P 2 DOORS SCHEMATIC AND ROUTING DIAGRAMS POWER WINDOW ...

Page 1404: ...froster Nozzle 6 Door Defroster Duct 7 Door Trim Panel 8 Door Pocket 9 Belt Inside Strap 10 Door Trim Mounting Fastener 11 Door Courtesy Lamp 12 Screw 13 Door Pull Handle Mounting Support Bracket 14 Door Trim Complete Mounting Clip 15 Door Inside handle Mounting Gromet 16 Door Defroster Gromet 17 Door Defroster Gromet Vessel 18 Door Pocket Mounting Screw 19 Door Trim Pad ...

Page 1405: ...outer panel and tighten the screw slightly 2 Unlock the door and check the clearance between door and side outer panel 3 If necessary insert the seam 4 Adjust latch lever to the center of striker and tighten the screw Clearance 3 5 5 5 Nm Tightening Torque 10 19 Nm ...

Page 1406: ...DOORS 9P 5 TAIL GATE 1 Upper Bracket 2 Lower Bracket 3 Bolt 4 Tail Gate 5 Stopper ...

Page 1407: ...er mounting bolt 2 Disconnect the wiring connector 3 Remove the mounting bolt and remove the tail gate Adjustment Door Striker Adjust the striker in horizontal vertical directions and then adjust the height of striker l Clearance between tailgate and quarter outer rear panel Clearance 4 3 6 3 Nm ...

Page 1408: ...9P 7 POWER WINDOW MOTOR 1 Door 2 Door Trim Panel 3 Inside Handle Mounting Plate 4 Door Opening Lamp 5 Door Pulling Handle 6 Door Trim Mounting Bracket 7 Door Defroster Grommet 8 Power Window Motor 9 Regulator ...

Page 1409: ...e the power window switch assembly 3 Remove the inside handle mounting plate 4 Remove the door trim panel assembly 5 Unscrew two screws arrows and remove the door lock opening handle assembly and disconnect opening handle ratch dar 6 Unscrew three screw arrow and remove the door trim mounting bracket 7 Disconnect the opening lamp connector ...

Page 1410: ...DOORS 9P 9 8 Remove the door vinyl 9 Unscrew the upper and lower nuts 4 piecess and remove the door regulator 10 Unscrew three nuts arrow and remove the power window motor ...

Page 1411: ...enger s Door Terminal No 1 2 3 4 5 6 7 8 Connecting Circuit B E ILL D 1 U D 2 U 2 U Size and Color 2 0 YR 2 0 B 1 25 GW 1 25 LW 1 25 BR 1 25 LR 1 25 BW 1 25 BL Terminal No 1 2 3 4 5 6 7 Connecting Circuit D 2 U 2 B MU MD ILL ILL Size and Color 2 0 LR 1 25 BW 1 25 YR 1 25 BR 1 25 L 1 25 GW 1 25 GB Diagram for Connecting Circuit ...

Page 1412: ...SECTION 9Q ROOF TABLE OF CONTENTS Maintenance and Repair 9Q 2 On Vehicle Service 9Q 2 Sun Roof System 9Q 2 ...

Page 1413: ...Inner Sliding Sun Roof Assembly 2 Sun Roof Body Mounting Bracket 3 Drain Hose Rear Grommet 4 Sun Roof Motor Spanner 5 Mounting Clip 6 Mounting Bracket 7 Mounting Bracket Assembly 8 Sun Roof Mounting Bracket 9 Drain Front Hose 10 Drain Rear Hose 11 Sun Roof Module Assembly ...

Page 1414: ...tion Procedure 1 Disconnect the connector and remove the sun roof module assembly 2 Disconnect the front and rear drain hose 3 Unscrew the sun roof mounting bracket bolts arrows and remove the inner sliding and sun roof assembly ...

Page 1415: ...SECTION 9R BODY FRONT END TABLE OF CONTENTS Maintenance and Repair 9R 2 On Vehicle Service 9R 2 HOOD 9R 2 ...

Page 1416: ...9R 2 BODY FRONT END 1 Bolt 2 Hood Striker Safety Assembly 3 Bolt 4 Mounting Ball Stud 5 Hood Lifter Assembly 6 Bolt 7 Hood Hinge Assembly 8 Hood MAINTENANCE AND REPAIR ON VEHICLE SERVICE HOOD ...

Page 1417: ...que 8 11 Nm 2 Remove the hood bolt 2EA of hood lifter assembly Installation Notice 3 Remove the hood lifter assembly from the upper ball stud Notice Insert the hood lifter assembly into ball stud fully until it sounds click Tightening Toque 14 26 Nm 4 Loosen the hood hinge assembly bolt and remove the hood Installation Notice 5 Installation should follow the removal procedure in the reverse order ...

Page 1418: ...rward and left right directions Then align the center between hood striker and latch hole Notice Tighten the bolt fully after alignment Installation Notice Tightening Toque 13 26 Nm 2 Adjusting the height of hood overslam bumper Unlock the hood and check the clearance between hood and fender by adjusting the hood overslam bumper in left right directions Normal 20 22 Nm ...

Page 1419: ...ifications 9T 1 Schematic and Routing Diagrams 9T 2 REKES 9T 2 Diagnosis 9T 3 Diagnosis Test 9T 3 SPECIFICATIONS REKES SPECIFICATIONS Maintenance and Repair 9T 5 On Vehicle Service 9T 5 REKES 9T 5 Function Description 9T 8 Burglar Alarm 9T 8 Transmitter Description DC 3V 10 C 60 C Changeable Coin Type LITHIUM Battery CR2032 Above 2 years 10 times day Application Rated Voltage Rated Range of Operat...

Page 1420: ...9T 2 REMOTE KEYLESS ENTRY AND ANTI THEFT SYSTEM REKES SCHEMATIC AND ROUTING DIAGRAMS ...

Page 1421: ...tion of No 7 and ground No 1 Tail lamp ON warning buzzer output stop door lock unlock output stop Seat belt warning chime bell output stop Key reminder warning chime bell output stop door lock unlock output stop Central door lock door lock unlock output stop 3 Functions in No 2 should be restored when diagnosis switch is OFF 4 Checked output should be made once while the diagnosis switch is ON 5 W...

Page 1422: ...ce check operation Confirm the diagnosis function start Check the battery Tailgate rear door lock switch Driver s door lock switch Passenger s door lock switch Driver s door switch Passenger and rear door switch REKES input Key reminder switch IGN and power window relay Parking brake switch Seat belt switch Washer switch Wiper auto switch ALT L Volume variable switch Defogger switch Speed sensor s...

Page 1423: ...REMOTE KEYLESS ENTRY AND ANTI THEFT SYSTEM 9T 5 MAINTENANCE AND REPAIR ON VEHICLE SERVICE REKES 1 REKES Receiver 2 Antenna 3 Bolt 4 Wiring Connector 6P ...

Page 1424: ...shing the lock or unlock button on the REKES transmitter l When the transmitter is faulty 1 Replace the REKES transmitter with a new one and connect the wiring connector 2 Set the input switch of the REKES receiver onto the No 1 or No 2 position and push the lock or unlock button on the REKES transmitter 3 Set the input switch of the REKES receiver onto the central position and close all doors 4 C...

Page 1425: ...om the key hole 2 Characteristic Signal Right Picture 3 Time Interval T1 0 05 0 02sec lock signal T2 0 1 0 02sec unlock signal T3 within 0 25sec T4 0 5 0 1sec T5 within 0 35sec T6 T7 0 5 0 1sec T8 1 0 25sec Connector Appearance and Connecting Circuit Pin No 1 2 3 4 5 6 Connecting Circuit B Memory Terminal Key Reminder Switch STICS Ground Memory Terminal ...

Page 1426: ...9T 8 REMOTE KEYLESS ENTRY AND ANTI THEFT SYSTEM FUNCTION DESCRIPTION BURGLAR ALARM Diagram for Burglar Alarm ...

Page 1427: ...e for 0 05second and the tail lamp will light up twice for 0 5 second 5 Character Signal Right Picture 6 Time Interval T1 0 05 0 02sec T2 within 0 25sec T3 0 5 0 1sec T4 within 0 5sec T5 within 0 35sec T6 0 05 0 01sec T7 T8 0 5 0 1sec l Operate The Burglar Alarm 1 Burglar alarm must operate immediately when the door tailgate or hood is opened with improper ways after all doors and hood were closed...

Page 1428: ... l Cancellation of The Burglar Alarm 1 It is only possible to release the burglar alarm when unlocking the driver s door key cylinder switch unlocking by REKES transmitter or turning on the IGN 1 2 2 Cancellation by an ignition key 3 Characteristic Signal Right Picture 4 Time Interval T1 1 0 25sec 5 Cancellation by REKES transmitter 6 Characteristic Signal Light Picture 7 Time Interval T1 1 0 2sec...

Page 1429: ... CONTENTS Specifications 9U 1 STICS Specifications 9U 1 Schematic and Routing Diagrams 9U 2 STICS 9U 2 Function Description 9U 3 SPECIFICATIONS STICS SPECIFICATIONS Description DC 12V Dc 9V 16V Less than 1mA key is removed and all doors locked 30 C 80 C Between terminal No 5 and 3 4 8 12 18 25 Between terminal No 5 and 2 6 7 16 17 Between terminal No 5 and 11 27 Application Voltage Rating Voltage ...

Page 1430: ...9U 2 CONTROL UNITS AND SYSTEM STICS SCHEMATIC AND ROUTING DIAGRAMS ...

Page 1431: ...g ON the defogger switch while engine is running l Defogger will be stopped by pushing the switch again l The defogger will be operated 6 min if push ON the switch within 10 min after 12 min of operation 6 Seat belt warning l The warning lamp will be turned on for about 6 sec with an intermittent chime bell when the IGN switch is ON unless fastening the seat belt 7 Parking brake warning l The indi...

Page 1432: ...e locked automatically if the vehicle speed reaches 50km h though the doors are in unlock 15 Auto door unlock l All doors will be automatically unlocked if the vehicle crashes while driving over 15km h 16 Input checking function l Self diagnostic function for each sensor switches and loads for the system 12 Coupled with REKES l Being coupled with REKES remote keyless entry system all doors will be...

Page 1433: ... WIPER ON OUTPUT OFF Operating Characteristics 1 Wiper INT sensing vehicle speed T1 within 0 5 sec T2 Wiper motor 1 revolution time T3 1 5 0 2 sec 20 2 sec 2 Washer relating wiper T1 0 6 1 0 sec T2 motor 3 revolution including motor revolution time 3 Dimming room lamp T1 2 0 3 sec T2 3 0 5 sec 4 Time delayed power window control T 30 2 sec ...

Page 1434: ...ning timer T1 6 1 sec T2 0 3 0 1 sec T3 0 6 0 1 sec 7 Parking brake warning T1 0 3 0 1 sec T2 0 3 0 1 sec V1 3km h 5km h 8 Tail lamp lighting warning l When the driver s door is opened after removing the IGN key while the tail lamp switch is still ON the buzzer should be operated T1 0 3 0 1 sec T2 0 3 0 1 sec ...

Page 1435: ...s or passenger s door should be unlocked when it locked T1 within 0 2 5 sec T2 5 0 5 sec 9 Door ajar warning T1 0 3 0 1 sec T2 0 3 0 1 sec V1 3 5km h 10 IGN key reminder warning T1 within 0 2 sec T2 5 0 5 sec T3 0 3 0 1 sec T4 0 3 0 1 sec T5 0 5 0 1 sec ...

Page 1436: ...door lock T1 within 0 2 sec T2 0 5 0 1 12 Coupled with REKES mode T1 0 05 0 02 sec lock signal T2 0 1 0 02 sec unlock signal T3 within 0 2 5 sec T4 0 5 0 1 sec T5 within 0 3 sec T6 T7 0 5 0 1 sec T8 1 0 25 sec 13 Ignition key hole illumination ...

Page 1437: ...CONTROL UNITS AND SYSTEM 9U 9 14 Auto door lock V1 50 5km h T1 0 5 0 1 sec 15 Auto door unlock T1 0 5 0 1 sec V1 15km h ...

Page 1438: ...in the sensors and load Removal Installation Procedure 1 Disconnector the battery negative cable 2 Unscrew 4screw from center console box 3 Remove the center console box and disconnect 3 STICS connectors 4 Unscrew 3 fastening bolts and remove the STICS unit 5 Installation should follow the removal procedure in the reverse order 1 STICS Unit 2 STICS Connector 3 STICS Unit Fastening Bolt 4 Parking B...

Page 1439: ... 9V 4 Other Switches 9V 8 SPECIFICATIONS GENERAL SPECIFICATIONS Description each 0 2 0 3A 0 8 1 7Kgf Cm Axial less than 1 0mm Radial less than 1 5mm each 6 1 6 7A Less than 2 5mm in width from the lever end HU 15A HL 10A P 20A INT 0 25 0 05A LO 6A HI 8A LOCK max 23A Less than 2 5mm in width from the lever end 4A Max 7A 0 2 0 3A Max 25mA Load Rating relay load Operating Force knob rotation Free Pla...

Page 1440: ...Window Switch 4 Center Fascia Switch Cover 5 6 ECS Switch 7 Glove Box Switch 8 Air Conditioner Panel Assembly 9 Rear Wiper And Washer Switch 10 4WD Switch 11 4WD Switch Cover 12 Kick Down Switch 4P 13 Outside Mirror Switch 14 Head Lamp Leveling Switch Assembly Optional Item ...

Page 1441: ...ch 16 Door Switch 17 Tail Gate Switch 18 Atmospheric Sensor 19 Sun Light Sensor Assembly 20 Speed Sensor Assembly 21 Power Window Main Switch 22 Power Window Sub Switch 23 Band 24 Multi Function Switch Assembly 25 Blanking Cover ...

Page 1442: ... the steering wheel and unscrew 2 bolts 10mm Installation Notice 3 Disconnect steering wheel audio remote control connector horn connector and airbag module connector and remove the airbag module Notice Refer to airbag module removal 4 Mark the alignment marks on the steering nut and upper column shaft and unscrew nut 22mm Installation Notice Tightening Torque 7 11 Nm Tightening Torque 50 80 Nm MA...

Page 1443: ...e both upper and lower covers 6 Unscrew the 4 screws of clock spring and remove the clock spring Notice Refer to clock spring removal for its installation notes 7 Unscrew the 3 screws and remove the multifunction switch 8 Installation should follow the removal procedure in the reverse order ...

Page 1444: ...mp LH 9 TR 0 5Y Turn Signal Lamp RH 10 ES 0 3B Head lamp Switch Ground 11 HO 0 5BW Horn 12 WA 0 5LY Washer 13 P 0 85GB Wiper Parking 14 HI 0 85RB Wiper High Speed 15 INT 0 5G Intermittent Wiper 16 LO 0 85GR Wiper Speed LO 17 ES 0 85B Wiper and Washer Ground 18 19 F 2 0 3Br Front Fog Lamp 20 FR 0 3G Front fog Lamp Ground 21 22 23 24 25 HO 0 5GR Horn 26 ES 0 5BW Remote Control Ground 27 AUD 0 5Y Rem...

Page 1445: ...minals for current flow Light Switch Head Lamp Terminal No 1 2 3 4 5 6 7 8 9 10 19 20 OFF Tail Head OFF LH RH Passing LOWER UPPER OFF ON Turn Signal Dimmer and Passing Front Fog Lamp Front Wiper and Washer Switch Terminal No 12 13 14 15 16 17 21 22 23 24 OFF AUTO LO HI Washer Wiper and Washer Switch Switch Switch 37 38 ...

Page 1446: ...nsidered that there is a short between A and terminal 4 Find out where the voltage abruptly changes to the 0V by moving tester bar to the terminal side slightly 5 If the voltage indicates 0V at point A it is considered that there is a short between A and terminal 6 Find out where the voltage abruptly changes to the 12V by moving tester bar to the terminal side slightly 2 Checking the switch 1 Remo...

Page 1447: ...SWITCHES 9V 9 Circuit Diagram 1 Hazard Switch 2 Rear defogger Door unlock switch 3 ECS switch ...

Page 1448: ...able before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals Disconnecting this cable will help prevent personal injury and damage to the vehicle The ignition must also be in LOCK unless otherwise noted Diesel Engine Immobilizer 9W 12 Gasoline Engine Immobilizer 9W 13 Maintenance and Repair 9W 14 On Vehicle Servic...

Page 1449: ...tem will never be removed from the vehicle So never attempt to remove it to install a remote ignition device or others l If engine does not start during service use every key to start the engine and then check immobilizer system finally FUNCTION DESCRIPTION Immobilizer is a device disabling vehicle ignition unless a speific key is used and designed to help prevent vehicle theft Immobilizer is comp...

Page 1450: ...nt system EMS The Active Antenna is mounted at the ignition lock and handles the following tasks l To supply the transponder with power l To receive the data from the EMS and transmit it to the transponder l To receive and demodulate the data from the transponder and transmit it to the EMS The whole Immobilizer software the authentication and the management of valid keys is completely managed by t...

Page 1451: ...ector 1 2 3 4 1 IGN red 2 Ground brown 3 Data in yellow 4 Data Out green Notice Pin arrangement and spec of connector is same for gasoline and diesel vehicles l Wire circuit diagram 3 4 Ant 14 13 E G ECU IGN Ground 13 Crypto read 14 Crypto write ...

Page 1452: ...mit it to the transponder l to receive and demodulate the data from the transponder and transmit it to the ICU The whole Immobilizer software the authentication and the management of valid keys and controlling the fuel valve is managed completely by the ICU l Connector Immobilizer unit Solenoid valve 16 8 15 7 14 6 13 5 12 4 11 3 10 2 9 1 1 2 3 1 Data out 3 Data in 6 Ground 7 Data line 8 K Line 9 ...

Page 1453: ...9W 6 IMMOBILIZER SYSTEM ...

Page 1454: ...hut off only after the KL 15 has been deactivated The structure allows to obtain the highest degree of safe operation functionality fail start a failure in the microprocessor unit cannot cause the shut off of the valve The main consequence of this type of failure is to prevent the next engine start up As a result of the above considerations the med 98 2 immobilizer can realize its anti theft funct...

Page 1455: ...performed 1 Perform immobilizer programming 2 Replace transponders only new Immobilizer programming is not performed 2 Perform immobilizer programming 3 Replace ECU only new 3 1 Replace the transponders with new 3 2 Perform immobilizer programming 4 Replace the transponder only Programmed for other ECU 4 1 Replace the transponders with new 4 2 Perform immobilizer programming 5 Re programming is no...

Page 1456: ...zer No 4 wire 0 5Y ECU No 13 pin 0 75Y Reading immobilizer cod number l Check starter wires l Check TCU wires only for 5 speed automatic transmission l Check starter and TCU l ECU No 2 pin check normal signal of the starter 1 Engine cranking voltage 8 15V l Check engine speed sensor wires and replace l Replace immobilizer antenna l Replace transponder and ECU Notice1 MSE ECU equipped vehicle is de...

Page 1457: ...programming 2 Replace transponders only new Immobilizer programming is not performed 2 Perform immobilizer programming 3 Replace ICU only new 3 1 Replace the transponders with new 3 2 Perform immobilizer programming 4 Replace the transponder only Programmed for other ICU 4 1 Replace the transponders with new 4 2 Perform immobilizer programming 5 Re programming is not performed after clearing trans...

Page 1458: ...d number l Check starter wires l Check TCU wires only for 5 speed automatic transmission l Check starter and TCU l ECU No 2 pin check normal signal of the starter 1 Engine cranking voltage 8 15V l Check engine speed sensor wires and replace l Replace immobilizer antenna Notice2 New valve is possible coded either with a new ICU or an already used ICU But old coded valve is only possible coded with ...

Page 1459: ...9W 12 IMMOBILIZER SYSTEM SCHEMATIC AND ROUTING DIAGRAMS DIESEL ENGINE IMMOBILIZER NO 3 10A ...

Page 1460: ...IMMOBILIZER SYSTEM 9W 13 GASOLINE ENGINE IMMOBILIZER ...

Page 1461: ...ehicle refer to the ECU diagram IMMOBILIZER ANTENNA Immobilizer antenna is installed in key set outer surface it is installed in the location of key hall illuminat ion see the figure 1 Immobilizer Antenna 2 Key 3 Transponder MAINTENANCE AND REPAIR ON VEHICLE SERVICE ...

Page 1462: ...plied 5 Replace the transponder with new one and apply the small amount of shock absorbing sealant 6 Installation should follow the removal procedure in the reverse order 1 Transponder Replacement Procedure 1 Open the cover on key handle 2 Remove the small screw in symmetrical position of key illumination 3 Remove the cover ...

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