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GROUP INDEX

GENERAL ........................................

ENGINE ............................................

LUBRICATION .................................

FUEL AND ENGINE CONTROL ......

ENGINE CONTROL SYSTEM .........

COOLING .........................................

INTAKE AND EXHAUST..................
TURBOCHARGER CONTROL

SYSTEM ...........................................

EMISSION CONTROL .....................
EXHAUST GAS RECIRCULATION SYSTEM

AND DIESEL PARTICULATE FILTER ........

FOREWORD

This Shop Manual is published for the information and
guidance of personnel responsible for maintenance of
Mitsubishi Fuso CANTER series truck, and includes 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, please consult your nearest authorized
Mitsubishi Fuso dealer or distributors.
Kindly note that the specifications and maintenance ser-
vice figures are subject to change without prior notice in
line with improvement which will be effected from time to
time in the future.

MARCH 2015

Applicable models (engine)
4M50T5

Shop Manual

4M5 diesel engine

For Colombia

(EURO 4)

©2015 Mitsubishi Fuso Truck & Bus Corporation Printed in Japan

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Содержание Fuso CANTER FE85DE6SLGP

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 8: ...M E M O 00 5 00...

Страница 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...

Страница 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...

Страница 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...

Страница 12: ...00 00 9...

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

Страница 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...

Страница 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...

Страница 16: ...M E M O 00 13 00...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 51: ...M E M O 11 13 11...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 59: ...M E M O 11 21 11...

Страница 60: ...11 22 ROCKER COVER...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 67: ...M E M O 11 29 11...

Страница 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...

Страница 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...

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

Страница 71: ...M E M O 11 33 11...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 79: ...M E M O 11 41 11...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 95: ...M E M O 11 57 11...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 101: ...M E M O 11 63 11...

Страница 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...

Страница 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...

Страница 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...

Страница 105: ...M E M O 11 67 11...

Страница 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...

Страница 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...

Страница 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...

Страница 109: ...M E M O 11 71 11...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 117: ...M E M O 11 79 11...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 140: ...M E M O 12 11 12...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 150: ...M E M O 12 21 12...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 169: ...M E M O 13 15 13...

Страница 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...

Страница 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...

Страница 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...

Страница 173: ...M E M O 13 19 13...

Страница 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...

Страница 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...

Страница 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...

Страница 177: ...M E M O 13 23 13...

Страница 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...

Страница 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...

Страница 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...

Страница 181: ...M E M O 13 27 13...

Страница 182: ...13 28 SUPPLY PUMP...

Страница 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...

Страница 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...

Страница 185: ...M E M O 13 31 13...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 253: ...M E M O 14 3 14...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 267: ...14 14 17...

Страница 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...

Страница 269: ...M E M O 14 19 14...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 277: ...M E M O 14 27 14...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 296: ...M E M O 15 17 15...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 306: ...M E M O 15 27 15...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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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