Mitsubishi Fuso CANTER FE85DE6SLGP Shop Manual Download | Manualshive

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11

11-23

Disassembly sequence

WARNING

• Fuel is highly combustible. Keep fire and heat away.
• Wipe off the leaked fuel. It may cause a fire.

CAUTION

• Be careful not to hit the injectors with a tool or any other hard object during removal.
• Do not allow dust to enter the injectors or injection pipes. Otherwise, faulty injection may result.

•

After confirming that no water, oil or any other substance is accumulated in the injector mounting hole, remove the
injector.

Assembly sequence

Follow the disassembly sequence in reverse.

CAUTION

• Be sure to tighten the injector mounting bolts to the specified torque. If they are over-tightened, the injec-

tors may be deformed, resulting in faulty injection.

Tightening torque (Unit: N·m {kgf·m})

Lubricant and/or sealant

Mark

Parts to be tightened

Tightening torque

Remarks

Bolt (cover installation)

23.2 {2.4}

–

Bolt (rocker cover installation)
Bolt (PCV pipe installation)
Injection pipe (union nut installation)

30.4 to 35 {3.1 to 3.6}

–

Bolt (injector installation)

5.2 to 7.2 {0.53 to 0.73}

–

Bolt (cylinder sensor installation)

8 {0.82}

–

Mark

Points of application

Specified lubricant and/or sealant

Quantity

O-ring

Engine oil

As required

1

Oil filler cap

2

Grommet

3

Spacer

4

Insulator

5

Cover

6

–

7

Snap ring

8

Fuel return hose

9

Injection pipe

10

Bolt (with hexagonal hole)

11

Injector

12

O-ring

13

Tip gasket

14

PCV pipe

15

–

16

Cylinder sensor

17

Rocker cover

18

Rocker cover gasket A

19

Rocker cover gasket B

: Non-reusable parts

PCV: Positive Crankcase Ventilation

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Summary of Contents for Fuso CANTER FE85DE6SLGP

Page 1: ...15 Shop Manual Shop Manual Pub No 00ELT0085 MARCH 2015 4M5 diesel engine 4M5 diesel engine For For Colombia Colombia EURO 4 Shop Manual Shop Manual 4M5 diesel engine 4M5 diesel engine Pub No 00ELT0085...

Page 2: ...pro cedures for adjustment and maintenance services We earnestly look forward to seeing that this manual is made full use of in order to perform correct services with no wastage For more details pleas...

Page 3: ...87 Group No Group subject 00 GENERAL 11 ENGINE 12 LUBRICATION 13 FUEL AND ENGINE CONTROL 13E ENGINE CONTROL SYSTEM 14 COOLING 15 INTAKE AND EXHAUST 15E TURBOCHARGER CONTROL SYSTEM 17 EMISSION CONTROL...

Page 4: ...ery 00 19 3 Handling of Sensors Relays and Electronic Control Units 00 19 4 Handling Precautions for Electric Circuits 00 20 5 Service Precautions for Alternators 00 23 6 Intermittent Faults 00 24 7 P...

Page 5: ...duty vehicle G V M 7000 kg or more 5 Engine D 4M50T 6 Wheelbase E 3350 mm G 3850 mm H 4710 mm 7 Chassis arrangement for use None Standard use Z Wide frame Rear tire arrangement Payload 6 Rear double P...

Page 6: ...n tonnes of main model Initial letter of the transmission Propeller shaft P3 P 3 Load capacity in tonnes of main model Initial letter of the propeller shaft Front axle F350T F 350 T Vehicle type T Tru...

Page 7: ...lutch Transmission Propeller shaft Rear axle Reduction Differential FE85DE6SLGP 4M50T5 C5W33 M036S6 P3 R035T D035H FE85DG6SLGP 4M50T5 C5W33 M036S6 P3 R035T D035H FE85DHZSLGP 4M50T5 C5W33 M036S6 P3 R03...

Page 8: ...M E M O 00 5 00...

Page 9: ...ns and supplementary information under the following four headings which identify the nature of the instructions and information Terms and Units Front and rear The forward running direction of the veh...

Page 10: ...dication read it as dry Units Tightening torques and other parameters are given in SI units with metric units added in brackets SI Le Syst me International d Unit s Unit SI unit metric unit Conversion...

Page 11: ...are speci fied Locating pin Parts to be positioned for installation Non reusable parts Parts not to be reused Lubricant and or sealant Parts to be coated with lubricant or sealant for assembly or inst...

Page 12: ...00 00 9...

Page 13: ...00 10 How to Read Circuits Electrical HOW TO READ THIS MANUAL...

Page 14: ...nal number 1 6 Major harness division Major harness divisions are shown 1 7 Wiring variations between different specifications Variations in wiring circuit between different vehicle specifications are...

Page 15: ...e black LO Blue orange LG Blue green LGr Blue gray LBr Blue brown Lg Light green LgR Light green red LgY Light green yellow LgB Light green black LgW Light green white O Orange OL Orange blue OB Orang...

Page 16: ...M E M O 00 13 00...

Page 17: ...ing sequence Every vehicle and engine has its own number These numbers are required for registration and related inspection of the vehicle Chassis number Engine number An engine name plate indicates t...

Page 18: ...meanings of VIN are listed below Example 1 Geographic area J Asia Japan 2 Country L Japan 3 Manufacture C Mitsubishi Fuso Truck Bus 4 GVW Brake type B 3 5 t GVW 12 t Hydraulic 5 Model C FE84P D FE85P...

Page 19: ...ting take the following preparatory steps To prevent soiling and damage place covers over the seats trim and floor in the cab and over the paintwork of the body Prepare all the general and special too...

Page 20: ...fall Never work in shoes that have oily soles When working with a partner or in a group use pre arranged sig nals and pay constant attention to safety Be careful not to touch switches and levers unin...

Page 21: ...l not detract from parts functionality and appearance After removing parts from the vehicle cover the area to keep it free of dust CAUTION Be careful not to mix up identical parts similar parts and pa...

Page 22: ...remain constantly applied to the B terminal inviting danger of electric shock 3 Handling of Sensors Relays and Electronic Control Units Carefully handle sensors relays and other items that are sensi...

Page 23: ...ircuit to be inspected Perform the inspec tion by applying a test probe C to the connectors of the inspec tion harness Do not insert the test probe C into the wire entry sides of the waterproof connec...

Page 24: ...ting of pins can cause damage to the control unit s internal circuit ry When using a multimeter to check continuity do not allow the test probes to touch the wrong terminals 4 2 Inspection of connecto...

Page 25: ...cuit between the switch and the load If the resistance measurement is not zero the circuit is not cur rently short circuited the fuse probably blew due to a momen tary short circuit The main causes of...

Page 26: ...bles with the engine running Disconnection of the battery cables during engine operation would cause a surge voltage leading to deterioration of the di odes and regulator Never perform inspections usi...

Page 27: ...Then reproduce the fault based on this information In accordance with the conditions under which the fault occurs determine whether the fault is caused by vibration heat or other factors if vibration...

Page 28: ...switch to the LOCK position Disconnect the battery s cable Cover all parts of the vehicle that may be damaged by welding sparks Connect the welder s cable to the vehicle as close as possi ble to the a...

Page 29: ...ck the wheels firmly to prevent the vehicle from rolling away Do not attempt to remove the chocks until the operation is completed It is extremely dangerous to support the vehicle with only bottle jac...

Page 30: ...both sides WARNING Chock the wheels firmly to prevent the vehicle from rolling away Do not attempt to remove the chocks until the operation is completed It is extremely dangerous to support the vehic...

Page 31: ...iagnosis code stored in the memory of the elec tronic control unit With the vehicle restored to its normal condition or the starter switch turned from OFF to ON after inspection or re pair against pre...

Page 32: ...ss E A For inspection and drive recorder B For drive recorder C Drive recorder har ness D Cigar plug harness MH063659 A MH063661 B MH063663 C MH063665 D MH063666 Power supply to V C I and communi cati...

Page 33: ...stored in the memory of the electronic control unit and identify the location of the fault 3 Clearing of diagnosis code Set the starter switch to ON the engine not to be started Operate the Multi Use...

Page 34: ...move the diagnosis switch Present diagnosis codes will be displayed by flashing of the warning lamp When the diagnosis switch is connected electronic control unit will stop terminate displaying diagno...

Page 35: ...g tables Provided Tightening torque is shown in the text Strength 4T 7T 8T stud stud stud Automotive screw thread Coarse screw thread Automotive screw thread Coarse screw thread Automotive screw threa...

Page 36: ...w thread Coarse screw thread Nominal diameter mm M6 4 to 6 0 4 to 0 6 8 to 12 0 8 to 1 2 10 to 14 1 0 to 1 4 M8 10 to 15 1 0 to 1 5 19 to 28 1 9 to 2 9 22 to 33 2 2 to 3 4 M10 21 to 31 2 1 to 3 2 20 t...

Page 37: ...140 10 to 14 130 to 170 13 to 17 120 to 160 12 to 16 M16 90 to 120 9 2 to 12 90 to 110 9 to 11 170 to 220 17 to 22 160 to 210 16 to 21 200 to 260 20 to 27 190 to 240 19 to 24 M18 130 to 170 13 to 17...

Page 38: ...ubes for general air piping SAE Unit N m kgf m Nominal diameter wall thickness mm 6 1 10 1 25 12 1 5 15 1 5 Tightening torque 20 2 0 34 3 5 49 5 0 54 5 5 Nominal diameter in 1 4 3 8 1 2 5 8 Tightening...

Page 39: ...in Bearings 11 9 10 Oil Seals 11 11 TROUBLESHOOTING 11 12 ON VEHICLE INSPECTION AND ADJUSTMENT 1 Measuring Compression Pressure 11 14 2 Inspection and Adjustment of Valve Clearances 11 16 ENGINE REMOV...

Page 40: ...cycle diesel engine Combustion chamber Direct injection type Valve mechanism Double overhead camshaft DOHC Maximum output kW PS rpm 132 180 2700 Maximum torque N m kgf m rpm 530 54 1600 Bore stroke m...

Page 41: ...11 11 3 1 Exploded View STRUCTURE AND OPERATION...

Page 42: ...amshaft and the intake camshaft have identical gears but dif ferent cams The thirteen shortest bolts and four shorter bolts fasten the camshaft frame onto the cylinder head The two long bolts fasten t...

Page 43: ...11 11 5 3 Valve Mechanism The short rockers and the long rockers are installed differently as shown in the illustration Each valve has an inner valve spring and an outer valve spring...

Page 44: ...per crankcase that has the same size mark as the piston The pistons are marked with either A or B where B stands for the larger and A for the smaller of the two avail able diameters The pistons have b...

Page 45: ...All gears except the vacuum pump gear each has timing mark s to ensure correct engagement during assem bly 7 Flywheel One side of each flywheel ring gear tooth is chamfered to facilitate the engagemen...

Page 46: ...m dead center BDC due to inertia The balance shaft LH and the balance shaft RH rotate so that their weight portions are at the bottom positions when a piston is at TDC and at the top positions when th...

Page 47: ...wer crankcase which hold the crankshaft in between Cylinder liners are inserted into the cylinder bores in the upper crankcase An water jacket is formed in the walls of these cylinders to cool them do...

Page 48: ...gine oil is sup plied to the crankshaft journals An oil groove is provided in the No 1 lower bearing 9 3 Thrust plates Two upper and lower thrust plate pairs are installed on both sides of the up per...

Page 49: ...s lip with the front oil seal slinger The front oil seal slinger is press fitted onto the fan shaft 10 2Rear oil seal The rear oil seal is fitted in the crank case assembly and prevents oil from leaki...

Page 50: ...maged piston ring s O O Worn piston pin and connecting rod small end O Crankshaft Excessive end play in crankshaft O Incorrectly fitted crankshaft O Worn damaged crankshaft pins and connecting rod bea...

Page 51: ...M E M O 11 13 11...

Page 52: ...Turn off the lights and auxiliaries Place the transmission in neutral Place the steering wheel in the straight ahead position Remove the fuse M9 to prevent fuel from being injected when the engine is...

Page 53: ...g holes Make sure to stay away from the injector mounting holes when the engine is being cranked Attach the gasket and to one of the injector mounting holes Then connect a compression gauge to Crank t...

Page 54: ...rms for both the intake and exhaust valves can be pushed down by hand by the valve clearance amounts has its piston at TDC Rotate the engine by one full turn to switch the TDCs of the No 1 and No 4 cy...

Page 55: ...t have a slight drag when taking measure ments If the feeler gauge can be moved without any resistance the measurement will be incorrect If the measurements are not within the standard value range adj...

Page 56: ...ne and transmission weight approximately 600 kg Tightening torque Unit N m kgf m Mark Parts to be tightened Tightening torque Remarks Bolt front mounting installation 69 to 88 7 to 9 Nut rear mounting...

Page 57: ...nt hanger and flange bolt Install and on the engine Mark Tool name and shape Part No Application Engine front hanger MH063636 Removal and installation of engine Flange bolt MF140429 MF140433 MF140421...

Page 58: ...and transmission assembly weighing approximately 600 kg Be sure to keep the slings away from the exhaust gas recir culation pipes Make sure that all harnesses and pipes are disconnected Lift the engin...

Page 59: ...M E M O 11 21 11...

Page 60: ...11 22 ROCKER COVER...

Page 61: ...ors may be deformed resulting in faulty injection Tightening torque Unit N m kgf m Lubricant and or sealant Mark Parts to be tightened Tightening torque Remarks Bolt cover installation 23 2 2 4 Bolt r...

Page 62: ...ad individually Do not change the upper and lower camshaft bearing combinations Do not interchange the position of an upper and lower camshaft bearing set with that of another Assembly sequence Follow...

Page 63: ...ts to be tightened Tightening torque Remarks Bolt rocker shaft installation 10 places 27 2 8 Wet Bolt camshaft frame installation 13 places Bolt camshaft installation 2 places 23 5 2 4 Bolt camshaft f...

Page 64: ...nd camshaft frame Loosen the rocker shaft installation bolts 10 places and the camshaft frame installation bolts 13 places in several passes in the order indicated in the illustration 1 to 23 Then rem...

Page 65: ...t be exactly aligned with that on the head idler gear as the posi tion that the head idler gear takes when it is installed may make it impossible to align them Such a misalignment does not lead to any...

Page 66: ...afts to the camshaft frame and then remove Tighten the bolts 1 to 23 to the specified torque in the order in dicated in the illustration CAUTION Reapply sealant to the areas specified above if any of...

Page 67: ...M E M O 11 29 11...

Page 68: ...Unit mm Tightening torque Unit N m kgf m Lubricant and or sealant Location Maintenance item Standard value Limit Remedy 2 6 8 9 Rocker bushing to rocker shaft clearance 0 01 to 0 08 0 12 Replace 3 7...

Page 69: ...surement is not within the standard value range Inspection Rocker bushing to rocker shaft clearance Replace the bushing if the measurement exceeds the specified limit Replacement of rocker bushing Rem...

Page 70: ...11 32 Installation Press fit each rocker bushing in the rocker with its ends facing in the illustrated directions ROCKERS AND CAMSHAFTS...

Page 71: ...M E M O 11 33 11...

Page 72: ...he camshaft using a press CAUTION Do not use a hammer to remove the camshaft gear Be sure to use a press for this purpose Location Maintenance item Standard value Limit Remedy 1 3 4 6 Camshaft gear to...

Page 73: ...the journals at the ends of the camshaft and measure the bend of the camshaft at the central journal The amount of camshaft bend is obtained by giving the camshaft one turn and dividing the dial gaug...

Page 74: ...11 36 CYLINDER HEAD AND VALVE MECHANISM...

Page 75: ...ushing clearance 0 01 to 0 05 0 1 Replace 5 a Head idler gear to idler gear backlash 0 103 to 0 158 0 3 Replace Mark Parts to be tightened Tightening torque Remarks Cylinder head bolt 147 15 90 Wet Re...

Page 76: ...al procedure Removal Cylinder head Loosen the cylinder head bolts 1 to 18 in several passes in the order indicated in the illustration and remove the cylinder head Removal Cylinder head gasket CAUTION...

Page 77: ...ad idler gear until it is flush with the lower edge of the chamfer on the head idler gear Remeasure the clearance between the bushing and head idler shaft Ream the bushing if the measurement is less t...

Page 78: ...the upper crankcase and front case at two places Install the cylinder head and its gasket on the upper crankcase within three minutes of applying the sealant being careful not to dislodge the sealant...

Page 79: ...M E M O 11 41 11...

Page 80: ...Valve cotter 2 Upper retainer 3 Outer valve spring 4 Inner valve spring 5 Valve stem seal 6 Exhaust valve 7 Intake valve 8 Exhaust valve guide 9 Intake valve guide 10 Exhaust valve seat 11 Intake valv...

Page 81: ...ve guide clearance 0 07 to 0 10 0 2 Replace 7 Intake valve Stem outside diameter 8 7 85 Replace Sinkage from cylinder head bottom surface 1 5 0 25 2 0 Replace Valve margin 1 5 1 2 Replace Seat angle 4...

Page 82: ...seal installer MH063607 Installation of valve stem seals Valve lapper 30091 07500 Lapping valves and valve seats Valve guide remover 31391 10500 Removal of valve guides Valve guide installer MH063604...

Page 83: ...em s outside diameter is below the lim it or is severely worn 2 Valve seat angle Reface the valve if the measured value is not within the standard value range 3 Valve margin Replace the valve if the m...

Page 84: ...eat Strike the valve once against the valve seat Do not rotate the valve during this operation If the red lead deposited on the valve indicates a poor contact pattern take either of the following corr...

Page 85: ...urement exceeds the limit reface or replace the valve seat 2 Valve sinkage from cylinder head bottom surface Measure the sinkage with the valve seat in intimate contact If the measurement exceeds the...

Page 86: ...he valve seat thoroughly by immersing in it in liquid nitro gen Install the valve seat in the cylinder head using and with the chamfered edge of toward the valve seat Turn over so that its chamfered e...

Page 87: ...n Valve stem seal Apply engine oil to the lip of the valve stem seal Install the valve stem seal until sits snugly on the cylinder head CAUTION After installing the valve stem seal check that its spri...

Page 88: ...rod bearing span when free 69 5 Replace 1 3 b Connecting rod bearing to crankshaft oil clearance 0 034 to 0 093 0 2 4 5 Piston to cylinder liner clearance 0 181 to 0 201 Replace 5 Cylinder liner Flan...

Page 89: ...h a bolt and wash er Mark Tool name and shape Part No Application Piston guide clamp MH063432 Installation of piston and connecting rod assembly Piston guide lever MH061658 Cylinder liner extractor MH...

Page 90: ...between all relevant parts Select and use a cylinder head gasket that can accommodate the average piston projection average value of the eight mea surements See the CYLINDER HEAD section Inspection Co...

Page 91: ...sure the inside diameter of the bearing and the diameter of the crankshaft pin If the clearance exceeds the limit replace the defective part s If a bearing has to be replaced with an undersized one ma...

Page 92: ...in the engine Apply a thin coat of engine oil to the surfaces surrounding the cylinder liner of the upper crankcase the shaded areas in the il lustration Insert the cylinder liner into the upper crank...

Page 93: ...ring gap Front mark on piston Check that the pistons and the cylinder liners have identical size marks A or B Install the pistons in the cylinder liners Be careful not to scratch the inner surface of...

Page 94: ...e mating marks on the connecting rod and connecting rod cap and tighten the bolts alternately in the following manner First tighten the bolt to a torque of 29 N m 3 0 kgf m Tighten the bolt further by...

Page 95: ...M E M O 11 57 11...

Page 96: ...ession ring 0 4 to 0 55 Oil ring 0 3 to 0 5 1 to 3 8 Piston ring side clearance in piston groove 1st compression ring 0 02 to 0 10 0 2 Replace 2nd compression ring 0 065 to 0 105 0 15 Oil ring 0 025 t...

Page 97: ...the piston ring horizontally into a cylinder in the cylinder liner until it reaches the lower part of the cylinder liner where there is relatively small wear Taking care not to move the piston ring me...

Page 98: ...limit replace the de fective part s Inspection Piston pin to connecting rod bushing clearance If any of the measurements exceeds the specified limit replace the bushing Replacement of connecting rod...

Page 99: ...place After press fitting the connecting rod bushing measure the clearance between the piston pin and connecting rod bushing If the measurement is less than the standard clearance range ream the bushi...

Page 100: ...piston F Front mark on connecting rod If the piston pin is difficult to insert heat the piston in hot water or with a piston heater Installation Piston rings With the manufacturer s marks found near t...

Page 101: ...M E M O 11 63 11...

Page 102: ...item Standard value Limit Remedy 4 Flywheel Friction surface runout when fitted 0 2 Rectify or replace Friction surface height 19 5 18 5 Replace Friction surface distortion 0 05 0 2 Rectify or replace...

Page 103: ...e ring gear following the procedure below Removal Heat the ring gear evenly with a gas burner or the like until it reaches approximately 200 C then remove it from the flywheel assembly WARNING Never t...

Page 104: ...rror not exceeding 0 1 mm Installation procedure Installation Flywheel Tighten all the bolts to 58 N m 5 9 kgf m and then additionally tighten them by the following procedure Rotate the holder of coun...

Page 105: ...M E M O 11 67 11...

Page 106: ...stallation 29 4 to 39 2 3 to 4 Vacuum pipe 29 4 3 0 Nut fan pulley installation 373 38 Eyebolt oil jet installation 10 1 0 Bolt vacuum pump installation 24 2 4 1 Power steering oil pipe 2 Power steeri...

Page 107: ...LH CAUTION Do not press the screwdriver hard against the balance shaft LH as this may damage No 1 journal of the balance shaft Put the tip of the screwdriver or the like into the shaft supporting hole...

Page 108: ...ool by using nuts Tighten the fan pulley mounting nut to the specified torque while holding Installation Vacuum pump The vacuum pump also serves as an element holding the bal ance shaft LH in place Th...

Page 109: ...M E M O 11 71 11...

Page 110: ...11 72 TIMING GEARS AND BALANCE SHAFTS...

Page 111: ...t to fan gear shaft clearance 0 01 to 0 05 0 1 Replace 11 13 No 1 idler gear bushing to No 1 idler shaft clearance 0 03 to 0 07 0 1 Replace 20 Balance shaft RH bend 0 025 0 05 Replace 25 Balance shaft...

Page 112: ...ective part s Removal procedure Removal Balance shaft Remove the balance shaft RH by turning its nut counterclock wise and the balance shaft LH by turning its nut clockwise Mark Tool name and shape Pa...

Page 113: ...he idler gear bushing until sits snugly on the chamfered end of the idler gear After press fitting the bushing measure the clearance If the measurement is less than the minimum of the standard value r...

Page 114: ...ft if the measurement exceeds the specified limit Inspection No 1 idler gear bushing to No 1 idler shaft clearance Replace the bushing if the measurement exceeds the specified limit Replacement of No...

Page 115: ...RH and LH shafts are different Balancer shaft RH No special positioning or the like is re quired Just install the shaft to the crankcase Adjustment of balancer shaft timing will be performed when ins...

Page 116: ...ntil the vacuum pump is installed Installation Timing gears Install the oil pump gear by aligning mating mark 6 with that on the crankshaft gear and mating mark 7 with that on the bal ance shaft gear...

Page 117: ...M E M O 11 79 11...

Page 118: ...disassembly sequence in reverse 1 Rear plate 2 Rear oil seal 3 Main bearing cap bolt 4 No 1 Lower main bearing 5 Lower main bearing 6 Lower crankcase 7 Lower thrust plate 8 Upper thrust plate 9 Crank...

Page 119: ...s 0 05 Replace Pins and journals Out of round ness 0 01 or less 0 03 Rectify or replace Taper 0 006 or less Center to center distance between the journal and pin 60 0 05 Replace Journal width No 1 33...

Page 120: ...illustration 1 to 16 After loosening the bolts loosen the main cap bolts in several passes in the order indicated in the illustration 17 to 26 then remove the main cap bolts Removal Crankshaft gear CA...

Page 121: ...e difference between the measurements exceeds the speci fied limit machine the crankshaft journal to one of the specified undersize dimensions indicated on the next page Inspection Crankshaft 1 Bend S...

Page 122: ...nt Crankshaft undersize dimensions Unit mm When grinding turn both the crankshaft and the grinder counter clockwise as viewed from the crankshaft front end When finishing the crankshaft with whetstone...

Page 123: ...se on the outer plates outward as shown in the illustration CAUTION Be sure to orient the oil grooves as indicated above other wise seizures may occur in the engine Use oversize thrust plates when adj...

Page 124: ...the bolt heads then tighten them to a torque of 49 N m 5 0 kgf m in the order indicated in the illustration 1 to 10 Tighten each main cap bolt further by 90 in the same order Finally tighten each bolt...

Page 125: ...r oil seal evenly without any breaks Install the rear oil seal within three minutes after applying the sealant Be careful not to let the applied sealant slip out of place during installation CAUTION A...

Page 126: ...Replace the bushing if the measurement exceeds the specified limit Location Maintenance item Standard value Limit Remedy 1 to 3 a Balance shaft to balance shaft bushing clearance No 1 0 055 to 0 099...

Page 127: ...e of each bushing Unit mm Remove the No 1 bushing by tapping on the rod from the front of the engine Remove the No 2 bushing by tapping on the rod from the front of the engine Remove the No 3 bushing...

Page 128: ...the measurement as a means of identifica tion Unit mm Align the oil hole in the No 3 bushing with the oil hole in the up per crankcase Force the No 3 bushing into the upper crankcase as deep as the m...

Page 129: ...oil hole s in the No 1 bushing with the oil hole s in the upper crankcase Force the No 1 bushing into the upper crankcase as deep as the mark in the illustration by tapping on the rod from the front...

Page 130: ...il Cooler 12 5 4 Oil Filter 12 6 5 Lubrication of Engine Components 12 7 TROUBLESHOOTING 12 10 ON VEHICLE INSPECTION AND ADJUSTMENT 1 Oil Filter Replacement 12 12 2 Engine Oil Replacement 12 14 3 Oil...

Page 131: ...ion CD CE CF 4 CH 4 Quantity dm3 L Oil pan Approx 8 8 Oil filter Approx 1 1 Oil cooler Model Shell and plate type multiple plate type Bypass valve opening pressure kPa kgf cm2 390 29 4 0 0 3 Oil filte...

Page 132: ...jet for gear 12 Vacuum pump 13 Idler bushing 14 Timing gear 15 Balance shaft bushing LH 16 Crankshaft main bearing 17 Connecting rod bearing 18 Connecting rod bushing 19 Piston 20 Balance shaft bushin...

Page 133: ...12 4 2 Oil Pump This engine uses a gear type oil pump driven by the rotation of the crankshaft transmitted through the engage ment of the crankshaft gear and the oil pump gear STRUCTURE AND OPERATION...

Page 134: ...pens to let the engine oil by pass the oil cooler and flow directly to the main oil gallery 3 2 Engine oil pressure switch When the pressure of the engine oil to the main oil gallery drops below the s...

Page 135: ...ve opens to let the engine oil bypass the filter elements and flow directly to the oil cooler thereby preventing seizures in the engine A regulator valve is installed on the oil filter head When the o...

Page 136: ...lowing ways 5 1 Main bearing and connecting rod bearing Engine oil supplied through an oil passage in the crankshaft lubricates the big end connecting rod bearing of each connecting rod Simultaneously...

Page 137: ...il pan 5 4 Check valves and oil jets An oil jet is fitted in the lower part of the main oil gallery for each cylinder Engine oil is sprayed out of the oil jet into the piston to cool the piston Each o...

Page 138: ...arged into the front case from the air discharge port of the vacuum pump along with air and returns to the oil pan 5 6 Turbocharger Engine oil is fed to the bearing hous ing from the main oil gallery...

Page 139: ...filter Incorrect installation O Clogged element O O Defective gasket O Weakened regulator valve spring O Incorrectly mounted and or clogged oil strainer O O Defective fan shaft front oil seal O Gr11 D...

Page 140: ...M E M O 12 11 12...

Page 141: ...or grease may easily slip resulting in deteriorated performance of the cooling system Removal Remove the drain plug and drain the oil out of the oil filter Mark Parts to be tightened Tightening torque...

Page 142: ...ter head Then tighten the filter by turning it further by three quar ters 3 4 of a turn After installing the oil filter start the engine and check that there are no oil leaks Remove and reinstall the...

Page 143: ...il pan to drain out the engine oil for 5 minutes or longer Refilling Tighten the drain plug to the specified torque then pour a speci fied amount of new engine oil into the engine Run the engine for 1...

Page 144: ...tch using the following procedure Cool the engine adequately so that the engine oil pressure switch can be tightened with an accurate tightening torque Apply sealant to the threaded portion of the eng...

Page 145: ...e defec tive operation resulting in engine seizure Tightening torque Unit N m kgf m Lubricant and or sealant Mark Parts to be tightened Tightening torque Remarks Drain plug 34 3 to 43 1 3 5 to 4 4 Che...

Page 146: ...ace of the oil pan evenly and without any breaks as shown in the illustration Mount the oil pan within three minutes of applying the sealant Make sure that the sealant stays in place CAUTION Do not st...

Page 147: ...learance 0 04 to 0 075 0 15 Replace 2 3 Gear and case to driven gear shaft clearance 0 04 to 0 075 0 15 Replace 2 3 a Sinkage of each gear from gear and case end surface 0 05 to 0 11 0 15 Replace Gear...

Page 148: ...ase If the measurements are not within the standard value range re place the oil pump Installation procedure Installation Oil pump cover and gear and case Apply engine oil to each component Hold the o...

Page 149: ...e crankshaft gear to an appropriate position Inject approximately 5 cm3 5 mL of engine oil Align the mating mark 6 on the crankshaft gear and the mating mark 7 on the balance shaft gear RH with the co...

Page 150: ...M E M O 12 21 12...

Page 151: ...l or grease may easily slip resulting in deteriorated perfor mance of the cooling system Make sure to install the gasket in the correct position so that it does not cover up the oil hole Service stand...

Page 152: ...the filter by turning it further by three quar ters 3 4 of a turn After installing the oil filter start the engine and check that there are no oil leaks from the gasket Remove and reinstall the oil fi...

Page 153: ...pipe 3 Plug 4 O ring 5 Bypass valve spring 6 Bypass valve 7 Oil cooler element 8 Gasket 9 Water drain plug 10 Engine oil pressure switch 11 Coolant temperature sensor for water temperature gage 12 Co...

Page 154: ...f bypass valve spring installed length 48 95 3 4 9 N 9 7 0 5 kgf Replace 8 Air leakage from oil cooler element air pressure 980 kPa 10 kgf cm2 for 15 seconds 0 cm3 0 mL Replace Mark Parts to be tighte...

Page 155: ...Fuel Filter 13 5 TROUBLESHOOTING 13 6 ON VEHICLE INSPECTION AND ADJUSTMENT 1 Inspecting and Adjusting No load Minimum and Maximum Speeds 13 8 2 Air bleeding of Fuel System 13 9 3 Fuel Filter Replacem...

Page 156: ...mmon rail pressure MPa kgf cm2 180 1840 Common rail Manufacturer Bosch Common rail capacity cm3 ml 18 7 18 7 Pressure limiting valve opening pressure MPa kgf cm2 210 to 220 2141 to 2243 Common rail pr...

Page 157: ...l is accumulated in the common rail for a time then sprayed out through the injection nozzles into the combustion chamber The excess fuel from the injectors returns to the fuel tank through the fuel r...

Page 158: ...ally controlled by the engine electronic control unit By processing accelerator pedal posi tion data from the accelerator position sensor the engine electronic control unit controls the injectors for...

Page 159: ...A priming pump is provided at the fuel filter head The priming pump is used for air bleeding the fuel system When the fuel temperature rises the thermostat swells and the valve of the fuel filter hea...

Page 160: ...ircuit failure poor contact of supply pump magnetic valve O O O O O Defective supply pump magnetic valve defec tive base supply pump O O O O Incorrect injector fuel injection Open or short circuit fai...

Page 161: ...valve and valve seat O O Distorted valve springs O O Worn or damaged piston rings O O Worn or damaged piston ring groove O Worn piston and or cylinder liner O O Poorly functioning cooling system O O G...

Page 162: ...in the standard value range in spect the accelerator position sensor and accelerator switch See Gr13E If no defects are evident during the above inspection check the diagnosis code in the engine elect...

Page 163: ...lug to the specified torque Feed the fuel some more by operating the priming pump further until a strong resistance is felt When the fuel temperature is low you may not feel the resis tance Be sure to...

Page 164: ...y spilled fuel CAUTION Be careful not to damage the case Installation Clean the O ring mounting surface of the fuel filter head and the O ring groove of the case Mark Parts to be tightened Tightening...

Page 165: ...nts The use of non genuine fuel filters can cause engine failure Prevent fine dust particles from entering the fuel filter and fuel hose as they can cause problems such as faulty fuel injection Use to...

Page 166: ...tube into fuel tank bracket while taking care not to pinch or crush with the fuel tank band Tightening torque Unit N m kgf m Mark Parts to be tightened Tightening torque Remarks Drain plug 19 6 4 9 2...

Page 167: ...le Keep it away from flames and sources of heat To avoid risk of fire wipe up any spilled fuel Insert the air vent tube into fuel tank bracket while taking care not to pinch or crush with the fuel tan...

Page 168: ...of heat To avoid risk of fire wipe up any spilled fuel Tightening torque Unit N m kgf m Mark Parts to be tightened Tightening torque Remarks Bolt fuel tank bracket mounting 70 to 90 7 1 to 9 1 Nut fu...

Page 169: ...M E M O 13 15 13...

Page 170: ...avoid risk of fire wipe up any spilled fuel CAUTION Be careful not to damage the case Tightening torque Unit N m kgf m Lubricant and or sealant Special tools Mark Parts to be tightened Tightening torq...

Page 171: ...O ring groove of the case Replace the filter element and O ring with new one Apply a thin coat of engine oil to the O ring and install it on the case and water separator sensor CAUTION Be sure to use...

Page 172: ...the case to the specified torque Install the water separator sensor and then air bleed the fuel system Start the engine and check that there is no fuel leakage Reinstall the fuel filter if there is an...

Page 173: ...M E M O 13 19 13...

Page 174: ...al while turning the hook by about 15 degrees CAUTION Do not yank on the stopper as this may damage it Installation procedure Installation Accelerator pedal Depress the accelerator pedal until the acc...

Page 175: ...Stopper bolt 5 Accelerator pedal bracket Assembly sequence Follow the disassembly sequence in re verse Lubricant and or sealant Mark Points of application Specified lubricant and or sealant Quantity...

Page 176: ...ubber stopper 10 Accelerator link bracket Assembly sequence Follow the disassembly sequence in re verse NOTE Perform the inspection and adjust ment of the accelerator position sensor See Gr13E Lubrica...

Page 177: ...M E M O 13 23 13...

Page 178: ...arts are removed Also wash eyebolts gaskets etc in light oil to clear of dirt Contact Bosch service station for any service needs of the common rail Assembly sequence Follow the disassembly sequence i...

Page 179: ...ptor mounting 44 5 4 5 Bolt common rail mounting 23 2 2 4 Fuel temperature sensor 17 6 to 21 5 1 8 to 2 2 Eyebolt fuel suction pipe mounting 39 2 4 0 Eyebolt fuel return pipe mounting Eyebolt fuel ret...

Page 180: ...lying an excessive force After temporary tightening position the torque wrench on and then tighten them to the specified torque Inspection after installation Fuel pressure sensor Start the engine and...

Page 181: ...M E M O 13 27 13...

Page 182: ...13 28 SUPPLY PUMP...

Page 183: ...control unit cannot control the supply pump and the fault of the engine may result Tightening torque Unit N m kgf m Lubricant and or sealant Special tools Mark Parts to be tightened Tightening torque...

Page 184: ...he valve clearance amounts has its piston at TDC Ro tate the engine by one full turn to switch the TDCs of the No 1 and No 4 cylinder pistons Align the match mark P on the supply pump idler gear with...

Page 185: ...M E M O 13 31 13...

Page 186: ...collected around the injection mounting position and then remove the injector Contact Bosch service station for any service needs of the injector Assembly sequence Follow the disassembly sequence in...

Page 187: ...th mounting surfaces of the connector evenly and temporarily tighten it without applying an excessive force After temporary tightening position the torque wrench on and then tighten them to the specif...

Page 188: ...13E 16 TROUBLESHOOTING 1 Inspections Based on Diagnosis Codes 13E 18 2 Multi Use Tester Service Data 13E 52 3 Actuator Test Using Multi Use Tester 13E 55 4 Work When Replacing the Engine Electronic C...

Page 189: ...quantity fuel injection timing and fuel injection pressure in order to optimize the engine s operation The electronic control unit has a diagnosis function that enables it to recognize abnormalities i...

Page 190: ...d via the inlet valves to the plunger chambers The fuel in the plunger chambers is pressurized The outlet valves are then opened and the fuel is fed under pressure to the common rail The pressurized f...

Page 191: ...13E 4 1 1 Supply pump STRUCTURE AND OPERATION...

Page 192: ...a highly pressurized state Fuel drawn from the fuel tank by the feed pump is not supplied directly to the plungers It is supplied first to the MPROP rail pressure control valve which controls the amo...

Page 193: ...uel can flow through the MPROP rail pres sure control valve to the plunger even when the MPROP reduc es fuel flow to the fullest extent To stop the fuel feed to the plunger the zero delivery throttle...

Page 194: ...ection of fuel from the injector The common rail pressure sensor is used in feedback control It senses the fuel pressure inside the common rail and feeds a corresponding signal to the electronic contr...

Page 195: ...e opti mal quantity The injector is divided into the control section and the injector section The control section consists of the control chamber magnet valve spring armature plate valve ball valve bo...

Page 196: ...needle stays in its downward pushed position and injection does not take place 5 2 Start of injection When the magnet is energized the re sulting electromagnetic force draws the armature plate upward...

Page 197: ...stopped the armature plate is pushed downward by the valve spring such that the ball seat closes At this time fuel flows into the control chamber via orifice Z pushing down the valve pis ton and nozzl...

Page 198: ...13E 13E 11 2 Electronic Control System 2 1 System block diagram...

Page 199: ...sed Transmission neutral switch Detection of transmission neutral condition OFF with transmission in neutral Exhaust brake switch Exhaust brake ON OFF control Air flow sensor Sensing of intake air flo...

Page 200: ...o or more times ahead of the main injection Split injection increases the fuel s combustibility and thus en hances the engine s cold startability 2 3 Fuel injection quantity control 1 Fuel injection q...

Page 201: ...2 5 Fuel injection pressure control The fuel injection pressure is calculated from the fuel injection quantity and engine speed 2 6 Warm up acceleration function The warm up acceleration function acc...

Page 202: ...osis code and the control during fault is initiated While the control during fault is taking place the system s functionality is limited to ensure vehicle and driver safe ty It is possible to read the...

Page 203: ...WER VB 3 GND POWER GND GND ANALOG GND GND POWER GND Engine electronic control unit MPROP rail pressure control valve B33 B45 Common rail pressure sensor Boost pressure sensor Idling speed adjustment p...

Page 204: ...st pair SIG CAN H CAN L Clutch switch To Starter relay Engine electronic control unit Safety relay Transmission neutral switch Exhaust brake switch Diagnosis code display Auxiliary Brake SW 1 Exhaust...

Page 205: ...1 MPROP Low 63 O P0092 MPROP High 63 O P0093 CRS Fuel Leak 22 O O P0101 Airflow Sensor Plausibility 17 O P0102 Airflow Sensor Low 17 O P0103 Airflow Sensor High 17 O P0112 INT Air Temp SNSR Low 44 O P...

Page 206: ...0 Vehicle Speed Sensor 25 O P0508 Idle Volume Idle Acc Low 31 P0509 Idle Volume Idle Acc High 31 P0562 Power Supply Voltage Low 33 O P0563 Power Supply Voltage High 33 O P0600 CAN Communication 64 O 7...

Page 207: ...High 16 O P2135 TVA SNSR Voltage 28 O P2138 Acc Sensor Correlation 24 58 O P2147 Injector Bank 1 Low 82 O P2148 Injector Bank 1 High 82 O P2150 Injector Bank 2 Low 82 O P2151 Injector Bank 2 High 82 O...

Page 208: ...warning lamp does not go out unless 3 consecutive valid signals are input Control effected by electronic control unit Injection quantity is limited Exhaust gas recirculation control is stopped Thrott...

Page 209: ...d from OFF to ON the warning lamp does not go out unless 3 consecutive valid signals are input Control effected by electronic control unit Injection quantity is limited Exhaust gas recirculation contr...

Page 210: ...electronic control unit and MPROP rail pressure control valve Malfunction of each connector Malfunction of MPROP rail pressure control valve Malfunction of engine electronic control unit Generation co...

Page 211: ...onnector Malfunction of air flow sensor Malfunction of engine electronic control unit Generation condition Airflow sensor voltage is lower than specified value Recoverability System recovers if any va...

Page 212: ...rness between engine electronic control unit and intake air temperature sensor 1 Malfunction of each connector Malfunction of intake air temperature sensor 1 Malfunction of engine electronic control u...

Page 213: ...each connector Malfunction of motor built in intake throttle Malfunction of throttle position sensor built in intake throttle Malfunction of electronic drive unit Malfunction of electronic drive unit...

Page 214: ...short circuit of harness between engine electronic control unit and common rail pressure sensor Malfunction of each connector Malfunction of common rail pressure sensor Malfunction of engine electroni...

Page 215: ...stopped Throttle control is stopped Possible causes Open circuited or short circuited harness between engine electronic control unit and injector magnetic valve No 3 cylinder Malfunction of each conn...

Page 216: ...t pressure sensor Malfunction of each connector Malfunction of Boost pressure sensor Malfunction of engine electronic control unit Generation condition Boost pressure sensor voltage is at or below the...

Page 217: ...tronic control unit and injector magnetic valve No 1 cylinder Malfunction of each connector Malfunction of injector magnetic valve No 1 cylinder Malfunction of engine electronic control unit Generatio...

Page 218: ...gine electronic control unit and injector magnetic valve No 3 cylinder Malfunction of each connector Malfunction of injector magnetic valve No 3 cylinder Malfunction of engine electronic control unit...

Page 219: ...engine electronic control unit and engine speed sensor Malfunction of each connector Malfunction of engine speed sensor Malfunction of engine electronic control unit Generation condition No cylinder r...

Page 220: ...eneration conditions Exhaust gas recirculation flow rate is excessively low Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON the warning lamp do...

Page 221: ...lation system Generation condition Exhaust gas recirculation electronic drive unit judges exhaust gas recirculation position sensor faulty Recoverability System recovers if any valid signal is input w...

Page 222: ...electronic control unit and exhaust shutter 3 way magnetic valve Malfunction of each connector Malfunction of exhaust shutter 3 way magnetic valve Malfunction of engine electronic control unit Genera...

Page 223: ...e electronic control unit Generation condition Idling speed adjustment potentiometer voltage is at or below the specified value 0 7 V Recoverability System recovers if any valid signal is input when s...

Page 224: ...Open circuit or short circuit of harness between engine electronic control unit and each of electronic drive units exhaust gas recirculation throttle and tur bocharger Malfunction of each connector Ma...

Page 225: ...electronic control unit Generation conditions Safety relay Battery short or open circuit Recoverability System recovers if signal becomes with starter switch ON position Control effected by electronic...

Page 226: ...ers is deactivated Exhaust gas recirculation control is deactivated Throttle control is deactivated Possible causes Open circuited or short circuited harness between engine electronic control unit and...

Page 227: ...loaded Recoverability System recovers if signal becomes normal with starter switch in ON position Control effected by electronic control unit Effects no special control Possible causes Open circuited...

Page 228: ...ontrol of auxiliary braking function is stopped Possible causes Open circuited or short circuited harness between engine electronic control unit and exhaust shutter 3 way magnetic valve Malfunction of...

Page 229: ...sensor 2 Malfunction of each connector Malfunction of common rail pressure sensor Malfunction of diesel particulate filter differential pressure sensor Malfunction of intake air temperature sensor 2 M...

Page 230: ...linder was faulty in comparison with the condition of other injector magnetic valves Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON the warnin...

Page 231: ...by electronic control unit Fuel injection amount is limited to a default value Occurrence of abnormal injection control is communicated through CAN Injector magnetic valve for No 1 and No 4 cylinders...

Page 232: ...on control is stopped Throttle control is stopped Possible causes Open circuited or short circuited harness between electronic drive unit and in take throttle Malfunction of motor built in intake thro...

Page 233: ...al position sensor 2 Malfunction of each connector Malfunction of accelerator pedal position sensor 2 Malfunction of engine electronic control unit Generation condition Accelerator pedal position sens...

Page 234: ...netic valve cylinder 1 4 Malfunction of each connector Malfunction of injector magnetic valve cylinder 1 4 Malfunction of engine electronic control unit Generation condition Injector magnetic valve No...

Page 235: ...is limited Exhaust gas recirculation control is stopped Throttle control is stopped Possible causes Open circuit or short circuit of harness between engine electronic control unit and Intake air tempe...

Page 236: ...ector Malfunction of motor built in turbocharger actuator Malfunction of position sensor built in turbocharger actuator Malfunction of electronic drive unit Malfunction of electronic drive unit relay...

Page 237: ...nput when starter switch is turned from OFF to ON the warning lamp does not go out unless 3 consecutive valid signals are input Control effected by electronic control unit Injection quantity is limite...

Page 238: ...lt in turbocharger actuator Malfunction of position sensor built in turbocharger actuator Malfunction of electronic drive unit Malfunction of engine electronic drive unit relay Generation condition Di...

Page 239: ...e 1 Accelerator pedal gradually pressed from released position 0 85 to 4 15 V 41 Accel Pedal Sensor Voltage 2 Accelerator pedal gradually pressed from released position 0 85 to 4 15 V 42 Accel Pedal P...

Page 240: ...FF Exhaust brake operating ON Exhaust brake not operating OFF Actuator test AB Auxiliary Brake Indicator Lamp D1 Glow Relay ON OFF With engine coolant temperature at 60 C or less turn starter switch O...

Page 241: ...ted ON No error after engine startup OFF Actuator test B0 MIL E1 Diagnosis Lamp ON OFF Starter switch ON engine not started ON No error after engine startup OFF Actuator test B1 Diagnosis Lamp No Item...

Page 242: ...on 55 Actual VGT Position A5 EGR ETV VGT Maintain exhaust gas recirculation intake throttle and turbo charger throttle opening indicated by Multi Use Tester during engine operation or stop Can be exec...

Page 243: ...topped ON OFF condition of warn ing lamp red Service data E1 Diagnosis Lamp B2 Fuel Leak Check Rail pressure increased on a constant slope for 6 seconds Can be executed when the following conditions a...

Page 244: ...heck menu After a while a menu related to POWERTRAIN ENGINE appears Select ENGINE OBD requirements are automatically detected Confirm that TYPE EOBD is detected Click the OK button Connect the Multi U...

Page 245: ...dow Select Coding Coding window Select VIN Writing VIN Writing window Enter the VIN 17 digits which has been confirmed from the ve hicle nameplate If a VIN was entered previously the VIN entered curre...

Page 246: ...the OK button Result of VIN writing window The VIN that was written to the engine electronic control unit is displayed Confirm that the VIN is the right one If the right VIN is displayed click the Ba...

Page 247: ...the Confirmed Stored DTCs button Check the Confirmed Stored DTCs field for generation of a di agnosis code If a diagnosis code is generated in either Pending DTC or Confirmed Stored DTCs click the Del...

Page 248: ...magnetic valve No 1 cylinder A72 A23 Output Conditions Starter switch OFF Disconnect connector Perform inspection on vehicle side con nector Requirements 0 255 0 04 Injector magnetic valve No 2 cylin...

Page 249: ...5 Exhaust shutter 3 way magnetic valve A76 A6 Output Conditions Starter switch ON Vehicle side harness connected Perform inspection on back of connector Requirements With exhaust brake operating Corre...

Page 250: ...V Glow drive relay A73 A7 Output Conditions Keep the vehicle harnesses connected to the electronic control unit connector halves Inspection is made at the back of the vehicle connectors Carry out the...

Page 251: ...ction and Adjustment of Belt Tension 14 8 2 Inspection of Cracks or Damage of the Belt 14 12 3 Coolant Replacement and Cleaning of Cooling System 14 13 4 Air Bleeding of Cooling System 14 15 5 Air Gas...

Page 252: ...circulation system Water pump Belt driven involute type Thermostat Wax pellet bottom bypass type with jiggle valve Automatic cooling fan coupling Continuous control type Radiator Tube and corrugated...

Page 253: ...M E M O 14 3 14...

Page 254: ...14 4 1 Cooling System Flow of Coolant STRUCTURE AND OPERATION...

Page 255: ...quid changing its total volume This allows the valve to open or close in accordance with the coolant temperature regulating and adjusting the flow of coolant to the ra diator and to the cylinder head...

Page 256: ...and or separation in welds O O Cracks in upper tank and or lower tank O O Poor clinching of upper tank and or lower tank O O Defective packing of upper tank and or lower tank O O Automatic cooling fa...

Page 257: ...installation of breather cover O O Gr17 Poor installation of gaskets O O Damaged O rings O O Tension pulley Poor installation of bearing O O Poorly airtight pressure cap O Insufficient coolant amount...

Page 258: ...ulley D Water pump pulley Place the small O ring on at the scale mark corresponding to 98 N 10 kgf press force Place the large O ring on at the scale mark corresponding to the maximum permissible defl...

Page 259: ...ic belt tension gauge refer to the in struction manual of the sonic belt tension gauge A Alternator pulley B Tension pulley without air conditioner C Fan pulley D Water pump pulley P1 Measuring point...

Page 260: ...bed belt Enter the number of ribs and push means execute Enter the length of span and push means execute Measuring point on the belt Unit mass of the belt P1 0 016 kg m Measuring point on the belt Num...

Page 261: ...late the average val ue If the average value is out of the standard value adjust the belt tension Adjustment Loosen the tension pulley mounting sleeve and turn in or out the adjustment bolt to adjust...

Page 262: ...belt was replaced whichever is more recent The driving distance over the which the belt can still be used is about half of that over which the belt has been used since the vehi cle was new or since t...

Page 263: ...t the thermostat valve remains open and the coolant continues to circulate in the radiator For the sake of convenience you can raise the coolant temperature quickly by covering the front of the radiat...

Page 264: ...the solution at approximately 90 C CAUTION Limit the engine idling period to one hour Operating an engine containing the cleaning solution for long er time may lead to damage of the cooling system Dr...

Page 265: ...e pressure cap WARNING If the engine is hot boiling coolant may spurt out from the filler port when the pressure cap is loosened To avoid a scold make sure to remove the pressure cap only when the coo...

Page 266: ...14 16 DISCONNECTION AND CONNECTION OF HOSES AND PIPES...

Page 267: ...14 14 17...

Page 268: ...unting 26 2 7 Bolt adapter mounting 23 2 2 4 Eyebolt water pipe mounting 25 5 2 6 Mark Points of application Specified lubricant and or sealant Quantity Clamp screw threads Engine oil As required O ri...

Page 269: ...M E M O 14 19 14...

Page 270: ...adiator hoses into the radiator as well as the correct tightening torque of clamps 1 Upper shroud 2 Lower shroud 3 Baffle plate RH 4 Baffle plate RH 5 Baffle plate LH 6 Baffle plate LH 7 Baffle plate...

Page 271: ...cm2 and check for air leakage If air leakage is found repair or replace the radiator Location Maintenance item Standard value Limit Remedy Air leakage from radiator air pressure 177 kPa 1 77 kgf cm2...

Page 272: ...oil or grease may easily slip result ing in deteriorated performance of the cooling system After installation check and adjust the belt tension See ON VEHICLE INSPECTION AND ADJUSTMENT Tightening tor...

Page 273: ...d man ually and the automatic cooling fan coupling does not move too much when pushed and pulled in the axial directions when the en gine is cold Cleaning Automatic cooling fan coupling When removing...

Page 274: ...procedure Installation Fan pulley Put in position on the studs of the fan pulley and fix the tool by using nuts Tighten the fan pulley mounting nut to the specified torque while holding COOLING FAN B...

Page 275: ...g 4 Tension pulley 5 Spacer 6 Shaft 7 Tension pulley bracket Assembly sequence Follow the disassembly sequence in re verse Tightening torque Unit N m kgf m Mark Parts to be tightened Tightening torque...

Page 276: ...keep it away from the heat source Heat the water gradually to the valve opening temperature Maintain this temperature for five minutes and make sure that the valve is completely open Make sure that th...

Page 277: ...M E M O 14 27 14...

Page 278: ...valve opening pressure 110 15 kPa 1 1 0 15 kgf cm3 Replace Mark Parts to be tightened Tightening torque Remarks Bolt water pipe mounting 23 2 2 4 Bolt water outlet pipe mounting Eyebolt water pipe mo...

Page 279: ...ir tank noticeably rises Wait until the coolant temperature drops to the ambient tempera ture Then check if the coolant in the reservoir tank has returned to the same level as that confirmed before th...

Page 280: ...Turbocharger Boost Pressure 15 6 2 Cleaning and Inspection of Air Cleaner Element 15 12 3 Check for Looseness in Intake Manifold Mounting Bolts and Nuts 15 12 4 Check for Cracks and Gas Leakage in Exh...

Page 281: ...unloader valve allows the air cleaner to automatically discharge any water and dust that has accumulated in its inside Item Specifications Air cleaner element type Filter paper type Turbocharger Mode...

Page 282: ...3 2 Turbocharger TD04 model is equipped with turbocharger which is a variable nozzle vane type turbocharger with adjustable heat resistive alloy turbine vanes provided at the turbine exhaust gas inlet...

Page 283: ...ter valve 4 Diesel Particulate Filter The diesel particulate filter consists of the following 2 sections an oxidation catalyst and a metal filter The oxidation catalyst oxidizes PM particulate matter...

Page 284: ...terfly valve malfunction O O O Front pipe diesel particulate filter tail pipe deformed O Front pipe diesel particulate filter tail pipe fitted poorly O Incorrect valve clearances O Gr11 Head gasket de...

Page 285: ...strated range of Mode 1 Select A4 VGT1 in Actuator Test of the Multi Use Tester Set Target Value to 80 and execute When A4 VGT1 is executed the engine speed should be auto matically increased to 2500...

Page 286: ...correction value Measured boost pressure intake air temperature correction value atmospheric tempera ture correction value If boost pressure correction value deviates from the standard value adjust t...

Page 287: ...2 given later If control crank contacts position bolt see 3 given later Adjust actuator shaft length Measure boost pressure Check for contact between control crank and position bolt Adjust position bo...

Page 288: ...ing guide Shaft length changes by 1 mm with one turn of the joint After the adjustment reinstall the snap rings and pins and tight en the lock nut NOTE If proper control crank to position bolt contact...

Page 289: ...turn of the joint After the adjustment reinstall the snap rings and pins and tight en the lock nut NOTE If proper control crank to position bolt contact cannot be achieved despite full shaft extension...

Page 290: ...illustrated di rections to bring it into a position clear of the control crank Turn the starter switch ON If the engine warning lamp stays off for more than 30 seconds it is in normal condition Adjust...

Page 291: ...the element is damp with oily smoke or soot regardless of the replacement schedule Installation Alignment mark 3 Check for Looseness in Intake Manifold Mounting Bolts and Nuts Check for looseness in t...

Page 292: ...r hose and turbocharger and remove the air hose Turn the compressor wheel by turning the shaft tip with fingers Check that the compressor wheel rotate smoothly without touch ing the compressor If any...

Page 293: ...r flow sensor mounting 1 2 to 1 8 0 12 to 0 18 Intake air temperature sensor 10 1 0 1 Air inlet duct 2 Connector 3 Air hose 4 Insulator 5 Air duct 6 Air flow sensor 7 Connector 8 Mesh filter 9 Intake...

Page 294: ...the engine Do not strike the element or hit it against another object to remove dust Do not blow compressed air against outside surfaces of the element Inspection procedure Inspection Element Shine s...

Page 295: ...the connector and the air cleaner case measures the amount shown in the figure Installation Air duct Align the mark on air duct with the connector s and push the air duct in until it hits stopper Ins...

Page 296: ...M E M O 15 17 15...

Page 297: ...5 Insulator 6 Eyebolt 7 Oil pipe 8 Eyebolt 9 Water pipe 10 Eyebolt 11 Eyebolt 12 Water pipe 13 Eyebolt 14 Water pipe 15 Oil return pipe 16 Gasket 17 Front pipe 18 Gasket 19 Exhaust coupler 20 Gasket...

Page 298: ...4 0 3 to 0 35 Clamp 3 9 to 4 9 0 4 to 0 5 Bolt turbocharger coupler mounting 23 8 2 4 Bolt insulator mounting Bolt exhaust coupler stay mounting Nut front pipe mounting 45 to 60 4 6 to 6 1 Nut turboch...

Page 299: ...hat they do not strike the compressor cover The turbine assembly is a non disassemble component When it becomes unsmooth in rotation or has a damaged compressor wheel replace the turbocharger Installa...

Page 300: ...t the parts and blow them dry with compressed air Re move any hard deposits with a stiff brush or plastic scraper CAUTION Do not immerse the cartridge assembly in the solvent Do ing so will cause the...

Page 301: ...with a dial gauge If the measurement exceeds the specified limit replace the tur bine assembly Inspection Pin outer diameter If the measurement is less than the limit replace the pin Inspection Lever...

Page 302: ...on and install the position bolt to the turbine assembly Make sure that the position bolt is in contact with the control crank In this state give the position bolt two and half turns then tight en the...

Page 303: ...rque Unit N m kgf m Location Maintenance item Standard value Limit Remedy 8 Intercooler air leakage air pressure 200 kPa 2 0 kgf cm2 maintained for 30 seconds 0 cm3 0 mL Replace Mark Parts to be tight...

Page 304: ...ce the intercooler if any air leakage is evident Installation procedure Installation Air inlet hose Install the air inlet hose in the intercooler to the dimension shown in the illustration Install the...

Page 305: ...oses to the intercooler LH air inlet pipe and air inlet duct to the dimensions indicated in the illustrations Connect the air inlet hose to the LH air inlet pipe with the blue paint on the hose aligne...

Page 306: ...M E M O 15 27 15...

Page 307: ...boost pressure sensor bracket mounting 23 2 2 4 Bolt intake manifold mounting Bolt boost pressure sensor mounting 12 7 1 3 Boost air temperature sensor 25 5 2 5 0 5 1 Intake throttle 2 Gasket 3 Vacuum...

Page 308: ...aying wipe the sensor portion clear of the sprayed cleaner using a soft waste cloth the like CAUTION Be sure to wait for 20 to 30 seconds before wiping It takes the cleaner that long to dissolve forei...

Page 309: ...ssembly sequence in re verse Tightening torque Unit N m kgf m Installation procedure Installation Gasket Install the gasket on the cylinder head with their surfaces facing in the illustrated direction...

Page 310: ...ont of and be hind the bellows are smaller than the dimension indicated in the illustration CAUTION The bellows on the front pipe have the purpose of reducing the level of noise from the vehicle It is...

Page 311: ...mit Remedy Average of top and bottom clearances between butter fly valve and body with valve fully closed with power chamber vacuum of 87 to 93 kPa 650 to 700 mmHg or above 0 80 to 0 95 Adjust 4 Air t...

Page 312: ...s such that the hole in the clevis is aligned by half with the hole in the lever Adjustment Butterfly valve 1 Average of top and bottom clearance between butterfly valve and body with valve fully clos...

Page 313: ...15 34 FE85DE FE85DG DIESEL PARTICULATE FILTER...

Page 314: ...ality Installation sequence Follow the removal sequence in reverse 1 Pressure hose 2 Pressure pipe 3 Tail pipe 4 Pressure hose 5 DPF differential pressure sensor 6 Diesel particulate filter band 7 Die...

Page 315: ...particulate filter Check the inner exhaust channel of diesel particulate filter for clogging with foreign material If clogged the inner exhaust channel must be cleaned with com pressed air or diesel p...

Page 316: ...Control Unit Wiring Diagram 15E 5 TROUBLESHOOTING 1 Inspection Based on Diagnosis Codes See Gr13E 2 Multi Use Tester Service Data See Gr13E 3 Actuator Test Using Multi Use Tester See Gr13E 4 Electroni...

Page 317: ...the relevant sensors and are sent to the engine electronic con trol unit and turbocharger electronic drive unit which then control the engine based on the information received The turbocharger actuato...

Page 318: ...gine warning lamp Indication of system abnormalities EDU relay Switching ON OFF supply of power to exhaust gas recirculation elec tronic drive unit throttle and turbocharger electronic drive unit CAN...

Page 319: ...faults In the event that the engine electronic control unit finds a component faulty it causes an indication to be made in the meter cluster to alert the driver At the same time it memorizes the faul...

Page 320: ...SENSOR 2 B33 B45 GND GND Accelerator pedal switch SENSOR 1 SENSOR 2 5V GND Water temperature sensor Red Amber Engine warning lamp 1 8 12 4 11 10 4 7 3 6 2 5 14 13 5 2 3 4 1 6 7 8 15 16 8 12 16 3 7 11...

Page 321: ...EMISSION CONTROL STRUCTURE AND OPERATION 1 Exhaust Gas Recirculation System 17 2 2 Crankcase Emission Control System 17 3 EXHAUST GAS RECIRCULATION VALVE PIPE AND COOLER 17 4 CRANKCASE EMISSION CONTRO...

Page 322: ...etc Exhaust gas recirculation involves the introduction of inert gases in the post combustion exhaust emissions into the intake manifold By reducing the combustion temperature it reduces the amount of...

Page 323: ...ntrol System The crankcase emission control system returns blowby gases to an air duct to prevent them from being released to the outside air The positive crankcase ventilation valve keeps constant th...

Page 324: ...nt air pressure 196 kPa 2 0 kgf cm2 0 cm3 0 mL Repair Leakage into exhaust gas air pressure 294 kPa 3 0 kgf cm2 0 cm3 0 mL Mark Parts to be tightened Tightening torque Remarks Connector 59 6 0 Nut mou...

Page 325: ...ner of water Make sure the coolant passage is full of water Apply air pressure of 294 kPa 3 kgf cm2 through the hose Check that air does not leak from any part of the exhaust gas re circulation cooler...

Page 326: ...ver 23 2 2 4 Bolt mounting of PCV valve Bolt mounting of breather cover 9 8 1 0 Screw mounting of breather cover A 2 to 3 0 2 to 0 3 Clamp 4 0 4 1 Washer 2 Rubber bushing 3 Spacer 4 Breather cover A 5...

Page 327: ...e pipe aligned as shown in the illustration Installation Breather cover A Clean the sealant application surfaces of each part Apply a bead of sealant to the breather cover A evenly and with out any br...

Page 328: ...4 3 Electronic Control Unit Connection Diagram 17E 7 TROUBLESHOOTING 1 Inspection Based on Diagnosis Codes See Gr13E 2 Multi Use Tester Service Data See Gr13E 3 Actuator Test Using Multi Use Tester S...

Page 329: ...pening etc Exhaust gas recirculation involves the introduction of inert gases in the post combustion exhaust emissions into the intake manifold By reducing the combustion temperature it reduces the am...

Page 330: ...m the en gine minimizing PM loading deposit onto the subsequent filter As a result the filter is unlikely to clog up even un der the driving conditions that require long hours of drive with relatively...

Page 331: ...etween DPF inlet pressure and at mospheric pressure Engine warning lamp Indication of system abnormalities Exhaust shutter 3 way magnetic valve ON OFF control of exhaust shutter valve EDU relay Switch...

Page 332: ...it possible for the target exhaust gas recirculation valve opening indicated by the engine electronic control unit to be precisely maintained 1 1 Exhaust gas recirculation valve DC motor in the exhau...

Page 333: ...ral times Diagnosis codes shown by the Multi Use Tester and those indicated by flashing of the warning lamp are different The Multi Use Tester is capable of showing more detailed diagnosis codes 2 3 D...

Page 334: ...de display EGR Gas Temp Sensor Water temperature sensor Intake air temperature sensor 1 Red Amber Engine warning lamp Position sensor Position sensor Opened when pressed closed when released Accelerat...

Page 335: ...MARCH 2015 Shop Manual 4M5 diesel engine For Colombia EURO 4...

Page 336: ...15 Shop Manual Shop Manual Pub No 00ELT0085 MARCH 2015 4M5 diesel engine 4M5 diesel engine For For Colombia Colombia EURO 4 Shop Manual Shop Manual 4M5 diesel engine 4M5 diesel engine Pub No 00ELT0085...

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