00-1
GROUP 00
GENERAL
CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 GENERAL<ELECTRICAL> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00E
NOTES
00-1
GROUP 00
GENERAL
CONTENTS
HOW TO USE THIS MANUAL. . . . . . |
00-2 |
HOW TO USE |
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TROUBLESHOOTING/INSPECTION |
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SERVICE POINTS . . . . . . . . . . . . . . . |
00-5 |
CONTENTS OF TROUBLESHOOTING . . . |
00-5 |
DIAGNOSIS FUNCTION. . . . . . . . . . . . . . . |
00-7 |
HOW TO USE THE INSPECTION |
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PROCEDURES. . . . . . . . . . . . . . . . . . . . . . |
00-8 |
CONNECTOR MEASUREMENT SERVICE |
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POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . |
00-10 |
CONNECTOR INSPECTION SERVICE |
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POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . |
00-11 |
INSPECTION SERVICE POINTS FOR A |
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BLOWN FUSE . . . . . . . . . . . . . . . . . . . . . . |
00-12 |
HOW TO COPE WITH INTERMITTENT |
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MALFUNCTIONS . . . . . . . . . . . . . . . . . . . . |
00-12 |
HOW TO TREAT PAST TROUBLE . . . . . . |
00-13 |
VEHICLE IDENTIFICATION . . . . . . . |
00-13 |
GENERAL DATA AND SPECIFICATIONS |
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00-17 |
PRECAUTIONS BEFORE SERVICE. |
00-23 |
SUPPLEMENTAL RESTRAINT SYSTEM |
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(SRS) AND SEAT BELT WITH PRE- |
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TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . |
00-23 |
WHAT THE COMMON RAIL ENGINE LEARNS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-24
INJECTOR IDENTIFICATION CODE |
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REGISTRATION PROCEDURE . . . . . . . . . |
00-24 |
SMALL INJECTION QUANTITY LEARNING |
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PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . |
00-25 |
SUPPLY PUMP CORRECTION LEARNING |
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PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . |
00-26 |
LEARNING PROCEDURE FOR IDLING. . . |
00-27 |
SERVICING ELECTRICAL SYSTEM . . . . . |
00-27 |
VEHICLES WITH SEMI AUTOMATIC AIR |
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CONDITIONER . . . . . . . . . . . . . . . . . . . . . . |
00-27 |
APPLICATION OF ANTI-CORROSION |
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AGENTS AND UNDERCOATS . . . . . . . . . . |
00-27 |
VEHICLE WASHING . . . . . . . . . . . . . . . . . . |
00-27 |
PRE-INSPECTION CONDITION. . . . . . . . . |
00-27 |
MULTI USE TESTER (M.U.T.-III) SUB |
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ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . |
00-28 |
HOW TO USE THE THROTTLE CONTROLLER |
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
00-28 |
IN ORDER TO PREVENT VEHICLES FROM |
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FIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
00-29 |
ENGINE OILS . . . . . . . . . . . . . . . . . . . . . . . |
00-29 |
SUPPLEMENTAL RESTRAINT SYSTEM (SRS). . . . . . . . . . . . . . . . . . . . . . . . . . 00-30
SRS SERVICE PRECAUTIONS . . . . . 00-31
SUPPORT LOCATIONS FOR LIFTING
AND JACKING . . . . . . . . . . . . . . . . . . 00-33
STANDARD PART/TIGHTENING-
TORQUE TABLE . . . . . . . . . . . . . . . . 00-37
00-2 GENERAL
HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL
SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS
This manual provides explanations, etc. concerning procedures for the inspection, maintenance, repair and servicing of the subject model. Note, however, that for engine and transmission-related component parts, this manual covers only on-vehicle inspections, adjustments, and the removal and installation procedures for major components. For detailed information concerning the inspection, checking, adjustment, disassembly and reassembly of the engine, transmission and major components after they have been removed from the vehicle, please refer to separate manuals covering the engine and the transmission.
ON-VEHICLE SERVICE
"On-vehicle Service" is procedures for performing inspections and adjustments of particularly important locations with regard to the construction and for maintenance and servicing, but other inspection (for looseness, play, cracking, damage, etc.) must also be performed.
INSPECTION
Under this title are presented inspection and checking procedures to be performed by using special tools and measuring instruments and by feeling, but, for actual maintenance and servicing procedures, visual inspections should always be performed as well.
DEFINITION OF TERMS STANDARD VALUE
Indicates the value used as the standard for judging the quality of a part or assembly on inspection or the value to which the part or assembly is corrected and adjusted. It is given by tolerance.
LIMIT
Shows the standard for judging the quality of a part or assembly on inspection and means the maximum or minimum value within which the part or assembly must be kept functionally or in strength. It is a value established outside the range of standard value.
M1001000101016
REFERENCE VALUE
Indicates the adjustment value prior to starting the work (presented in order to facilitate assembly and adjustment procedures, and so they can be completed in a shorter time).
DANGER, WARNING, AND CAUTION
DANGER, WARNING, and CAUTION call special attention to a necessary action or to an action that must be avoided. The differences among DANGER, WARNING, and CAUTION are as follows:
•If a DANGER is not followed, the result is severe bodily harm or even death.
•If a WARNING is not followed, the result could be bodily injury.
•If a CAUTION is not followed, the result could be damage to the vehicle, vehicle components or service equipment.
INDICATION OF TIGHTENING TORQUE
Tightening torques (units: N m) are set to take into account the central value and the allowable tolerance. The central value is the target value, and the allowable tolerance provides the checking range for tightening torques. If bolts and nuts are not provided with tightening torques, refer to P.00-37.
MODEL INDICATIONS
The following abbreviations are used in this manual for identification of model types.
2500:Indicates an engine with the 2,477mL <4D56> diesel engine.
3200:Indicates an engine with the 3,200mL <4M41> diesel engine.
DOHC: Indicates an engine with the double overhead camshaft.
M/T:Indicates the manual transmission. A/T:Indicates the automatic transmission. A/C:Indicates the air conditioner.
GENERAL |
00-3 |
HOW TO USE THIS MANUAL |
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EXPLANATION OF MANUAL CONTENTS
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Indicates the |
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section title. |
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Denotes tightening torque. |
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For bolts and nuts which do |
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not have a tightening torque |
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listed, refer to the "Standard |
Indicates the |
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Indicates the |
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Parts tightening-torque Table" |
group title. |
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group number. |
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Maintenance and servicing procedures
Indicates the page number.
Indicates procedures to be performed before the work in that section is started, and procedures to be performed after the work in that section is finished.
Component diagram
A diagram of the component parts is provided near the front of each section in order to give the reader a better understanding of the installed condition of component parts.
Mark N denotes nonreusable part.
Repair kit or parts sets are shown.
(Only very frequently used parts are shown.)
The numbers provided within the diagram indicate the sequence for maintenance and servicing procedures.
Removal steps :
The part designation number corresponds to the number in the illustration to indicate removal steps.
Disassembly steps :
The part designation number corresponds to the number in the illustration to indicate disassembly steps.
Installation steps :
Specified in case installation is impossible in reverse order of removal steps. Omitted if installation is possible in reverse order of removal steps.
Reassembly steps :
Specified in case installation is impossible in reverse order of removal steps. Omitted if reassembly is possible in reverse order of disassembly steps.
AC311238AB
00-4 |
GENERAL |
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HOW TO USE THIS MANUAL |
Classifications of major maintenance / service points
When there are major points relative to maintenance and servicing procedures (such as essential maintenance and service points, maintenance and service standard values, information regarding the use of special tools, etc.). These are arranged together as major maintenance and service points and explained in detail.
<<A>> : Indicates that there are essential points for removal or disassembly. >>A<< : Indicates that there are essential points for installation or reassembly.
35A-21 |
Operating procedures, |
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cautions, etc. on removal, |
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installation, disassembly and |
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reassembly are described |
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The title of the page |
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(following the page on which |
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the diagram of component |
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parts is presented) indicating |
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the locations of lubrication and |
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sealing procedures. |
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Indicates (by symbols) where |
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lubrication is necessary. |
Symbols for lubrication, sealants and adhesives
Symbols are used to show the locations for lubrication and for application of sealants and adhesives.
These symbols are included in the diagram of component parts or on the page following the component parts page. The symbols do not always have accompanying text to support that symbol.
Grease
(Multi-purpose grease unless there is a brand or type specified)
Sealant or adhesive
Brake fluid or automatic transmission fluid
Engine oil, gear oil or air conditioning compressor oil
Adhesive tape or butyl rubber tape
AC311239AB
GENERAL |
00-5 |
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS |
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HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE
POINTS
CONTENTS OF TROUBLESHOOTING
M1001013300211
CAUTION
During diagnosis, a diagnosis code associated with other system may be set when the ignition switch is turned on with connector(s) disconnected. On completion, confirm all systems for diagnosis code(s). If diagnosis code(s) are set, erase them all.
WARNING
Since the radiator fan rotates during CAN bus line diagnostics, make sure that no one is servicing the engine compartment before diagnosing the CAN bus line. Since the CAN communication stops when diagnosing the CAN bus line, the ETACS-ECU detects the time-out of the engine-ECU, and activates the radiator fan to prevent overheating as fail-safe.
Troubleshooting of electronic control systems for which the M.U.T.-III can be used follows the basic outline described below. Even in systems for which the M.U.T.-III cannot be used, some of these systems still follow this outline.
1. STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING
Troubleshooting sections are based on the diagnostic flow as below. If the diagnostic flow is different from that given below, or if additional explanation is required, the details of such differences or additions will also be listed.
00-6 |
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GENERAL |
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HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS |
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Diagnosis method |
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Gathering information |
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from the customer. |
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Reoccurs |
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Does not reoccur |
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Check trouble symptom. |
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NG |
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CAN bus diagnosis*1 |
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CAN bus diagnosis chart*2 |
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OK |
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Diagnosis code |
Diagnosis code |
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Read the diagnosis code. |
displayed. |
displayed. |
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Read the diagnosis code. |
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(Current trouble)*3 |
(Current trouble)*3 |
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No diagnosis code |
Diagnosis code |
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Diagnosis code |
No diagnosis |
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or communication |
displayed. |
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malfunction code, erase the |
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displayed. |
code. |
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with M.U.T.-III not |
(Past trouble)*3 |
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diagnosis code memory. |
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(Past trouble)*3 |
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How to treat past |
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Recheck trouble symptom. |
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trouble*4 |
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trouble*4 |
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Read the diagnosis codes. |
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No diagnosis |
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Diagnosis code |
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code. |
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displayed. |
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Refer to the INSPECTION CHART FOR TROUBLE SYMPTOMS (Refer to applicable group).
Refer to the INSPECTION CHART FOR DIAGNOSIS CODES
(Refer to applicable group).
INTERMITTENT MALFUNCTIONS*5
AC501888
•*1: For how to diagnose CAN bus lines, refer to GROUP 54C .
•*2: For the CAN bus diagnosis chart, refer to GROUP 54C .
•*3: When the M.U.T.-III detects a diagnosis code, its display informs users whether a mechanical problem currently exists or whether it existed before. The message for the former state identifies it as a "Active" and the message for the latter identifies it as a "Stored".
•*4: For how to treat past trouble, refer to P.00-13.
•*5: For how to cope with intermittent malfunctions, refer to P.00-12.
2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS
If verification of the symptom(s) is difficult, procedures for checking operation and verifying symptoms are shown.
3. DIAGNOSIS FUNCTION
Details which are different from those in the "Diagnosis Function P.00-7" section are described.
5. DIAGNOSIS CODE PROCEDURES
Indicates the inspection procedures corresponding to each diagnosis code (Refer to How to Use Inspection Procedures P.00-8).
6. TROUBLE SYMPTOM CHART
If there are trouble symptoms even though the M.U.T.-III does not find any diagnosis codes, Inspection procedures for each trouble symptom will be found by means of this chart.
4. DIAGNOSIS CODE CHART
Diagnostic trouble codes and diagnostic items are shown.
GENERAL |
00-7 |
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS |
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7. SYMPTOM PROCEDURES
Indicates the inspection procedures corresponding to each symptoms classified in the Symptom Chart (Refer to How to Use Inspection Procedures P.00-8).
8. SERVICE DATA REFERENCE TABLE
Inspection items and normal judgment values have been provided in this chart as reference information.
9. ACTUATOR TEST TABLE
The Actuator Test item numbers, inspection items, and judgment values have been provided in this chart as reference information.
10. CHECK AT ECU TERMINALS
Terminal numbers for the ECU connectors, inspection items, and judgment values have been provided in this chart as reference information.
11. INSPECTION PROCEDURE BY USING AN OSCILLOSCOPE
When there are inspection procedures using an oscilloscope, these are described here.
DIAGNOSIS FUNCTION
M1001013400100
HOW TO READ DIAGNOSIS CODE
CAUTION
Before connecting or disconnecting the M.U.T.-III, turn the ignition switch to the "LOCK" (OFF) position.
Diagnosis
connector
MB991910
MB991824
MB991827 |
AC501413AB |
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Connect the M.U.T.-III to the 16-pin diagnosis connector, and read the diagnosis code.
NOTE: For details on how to use the M.U.T.-III, refer to the "M.U.T.-III operation manual."
1.Ensure that the ignition switch is at the "LOCK" (OFF).
2.Start up the personal computer.
3.Connect M.U.T.-III USB cable MB991827 to special tool Vehicle Communication Interface (V.C.I.) MB991824 and the personal computer.
4.Connect M.U.T.-III main harness A MB991910 to the V.C.I.
5.Connect the M.U.T.-III main harness A to the diagnosis connector.
6.Turn the V.C.I. power switch to the "ON" position.
NOTE: When the V.C.I. is energized, the V.C.I. indicator lamp will be illuminated in a green colour.
7.Start the M.U.T.-III system on the personal computer and turn the ignition switch to the "ON" position.
8.Read the diagnosis code.
9.Disconnecting the M.U.T.-III is the reverse of the connecting sequence, making sure that the ignition switch is at the "LOCK" (OFF).
ERASING DIAGNOSIS CODE
CAUTION
Before connecting or disconnecting the M.U.T.-III, turn the ignition switch to the "LOCK" (OFF) position.
Diagnosis
connector
MB991910
MB991824
MB991827 |
AC501413AB |
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00-8 |
GENERAL |
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HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS |
Connect the M.U.T.-III to the diagnosis connector, and erase the diagnosis code. The procedure is the same as "How to Read Diagnosis Code ."
HOW TO USE THE INSPECTION PROCEDURES
M1001013500237
The causes of many of the problems occurring in electric circuitry are generally the connectors, components, the ECU, the wiring harnesses between connectors, in that order. These inspection procedures follow this order. They first try to discover a problem with a connector or a defective component.
Relevant circuit(s) of the component which the Code No. indicates are described.
AC301964AB
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GENERAL |
00-9 |
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HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS |
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Explains about the basic |
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Start of diagnosis |
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Describes |
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procedure |
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operation of the components. |
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inspection |
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procedure. |
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M.U.T.-III datalist
Explains about technical details.
Describes the conditions for that diagnosis code being set.
Describes possible causes(s) for that diagnosis code.
AC313955AC
CURRENT TROUBLE
Indicates that the status is "Active" and the trouble is currently present. Carry out troubleshooting as described in the applicable inspection procedure.
PAST TROUBLE
Indicates that the status is "Stored" and the trouble is historic. Since the trouble may still be present, set the vehicle to the diagnosis code detection condition and check that the status changes to "Active". If the status does not change from "Stored", observe the applicable inspection procedure with particular emphasis on connector(s) and wiring harness.
HARNESS CHECK
Check for an open or short circuit in the harness between the terminals which are faulty according to the connector measurements. Carry out this inspection while referring to the Electrical Wiring Manual. Here, "Check the wiring harness between the power supply and terminal xx" also includes checking for blown fuse. For inspection service points when there is a blown fuse, refer to "Inspection Service Points for a Blown Fuse P.00-12."
MEASURES TO TAKE AFTER REPLACING THE ECU
If the trouble symptoms have not disappeared even after replacing the ECU, repeat the inspection procedure from the beginning.
00-10 |
GENERAL |
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HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS |
CONNECTOR MEASUREMENT SERVICE POINTS
M1001013600223
CAUTION
During diagnosis, a diagnosis code associated with other system may be set when the ignition switch is turned on with connector(s) disconnected. On completion, confirm all systems for diagnosis code(s). If diagnosis code(s) are set, erase them all.
Turn the ignition switch to the "LOCK" (OFF) position when connecting and disconnecting the connectors. Turn the ignition switch to "ON" when measuring, unless there are instructions to the contrary.
IF INSPECTING WITH THE CONNECTOR CONNECTED <WATERPROOF CONNECTORS>
CAUTION
Never insert a test probe from the harness side, as this will reduce the waterproof performance and result in corrosion.
Special tool |
AC105597AB |
Use the special tools such as test harness, harness connector or check harness.
IF INSPECTING WITH THE CONNECTOR CONNECTED <ORDINARY (NON-WATERPROOF) CONNECTORS>
MB992006 |
AC105598AH |
Inspect by inserting a test probe from the harness side. If the connector is too small to insert a test probe (e.g. control unit connector), do not insert it forcibly. Use special tool extra fine probe (MB992006).
IF INSPECTING WITH THE CONNECTOR DISCONNECTED <WHEN INSPECTING A FEMALE PIN>
CAUTION
•Use special tool check harness (MB991219). If the test bar is inserted forcibly, it will cause a poor contact.
•If the connector is disconnected, a diagnosis code may be stored for the system to be checked or other systems.
MB991219 |
AC105599AB |
Use check harness (MB991219) of special tool harness set (MB991223).
IF INSPECTING WITH THE CONNECTOR DISCONNECTED <WHEN INSPECTING A MALE PIN>
CAUTION
•Be careful not to short the connector pins with the test bars. To do so may damage the circuits inside the ECU.
•If the connector is disconnected, a diagnosis code may be stored for the system to be checked or other systems.
AC105600 |
Touch the pin directly with the test bar.
GENERAL |
00-11 |
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS |
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CONNECTOR INSPECTION SERVICE POINTS
M1001013700189
VISUAL INSPECTION
• |
Connector disconnected or |
improperly connected |
Stretched or broken wires |
Harness wire breakage |
at terminal section |
Low contact |
pressure |
Good |
Bad |
AC300896AB |
Connector is disconnected or improperly connected
•Connector pins are pulled out
•Due to harness tension at terminal section
•Low contact pressure between male and female terminals
•Low connection pressure due to rusted terminals or foreign matter lodged in terminals
CONNECTOR PIN INSPECTION
AC300898
If the connector pin stopper is damaged, the terminal connections (male and female pins) will not be perfect even if the connector body is connected, and the pins may pull out of the reverse side of the connector. Therefore, gently pull the harnesses one by one to make sure that no pins pull out of the connector.
CONNECTOR ENGAGEMENT
INSPECTION
MB991219
AC300899AB
Use special tool inspection harness (MB991219) (connector pin connection pressure inspection harness of the inspection harness set) to inspect the engagement of the male pins and female pins. (Pin drawing force: 1 N or more)
00-12 |
GENERAL |
|
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS |
INSPECTION SERVICE POINTS FOR A BLOWN FUSE
M1001013800186
CAUTION
A diagnosis code may be stored due to a blown fuse.
Battery
Fuse
Short-circuit Load occurrence switch section
Load
AC300900AB
Remove the blown fuse and measure the resistance between the load side of the blown fuse and the earth. Close the switches of all circuits which are connected to this fuse. If the resistance is almost 0 Ω at this time, there is a short somewhere between these switches and the load. If the resistance is not 0 Ω, there is no short at the present time, but a momentary short has probably caused the fuse to blow. The main causes of a short circuit are the following.
•Harness being clamped by the vehicle body
•Damage to the outer casing of the harness due to wear or heat
•Water getting into the connector or circuitry
•Human error (mistakenly shorting a circuit, etc.)
HOW TO COPE WITH INTERMITTENT MALFUNCTIONS
M1001013900183
AC300901
Intermittent malfunctions often occur under certain conditions, and if these conditions can be ascertained, determining the cause becomes simple. In order to ascertain the conditions under which an intermittent malfunction occurs, first ask the customer for details about the driving conditions, weather conditions, frequency of occurrence and trouble symptoms, and then try to recreate the trouble symptoms. Next, ascertain whether the reason why the trouble symptom occurred under these conditions is due to vibration, temperature or some other factor. If vibration is thought to be the cause, carry out the following checks with the connectors and components to confirm whether the trouble symptom occurs. The objects to be checked are connectors and components which are indicated by inspection procedures or given as probable causes (which generates diagnosis codes or trouble symptoms).
GENERAL |
00-13 |
VEHICLE IDENTIFICATION |
|
•Gently shake the connector up, down and to the left and right.
•Gently shake the wiring harness up, down and to the left and right.
•Gently rock each sensor and relay, etc. by hand.
•Gently shake the wiring harness at suspensions and other moving parts.
NOTE: If determining the cause is difficult, the drive recorder function of the M.U.T.-III can also be used. (For details on how to use the M.U.T.-III, refer to the "M.U.T.-III operation manual).
HOW TO TREAT PAST TROUBLE
M1001014100157
Since the trouble may still be present even the status is "Stored", set the vehicle to the diagnosis code detection condition and check that the status changes to "Active". If the status does not change from "Stored", carry out the following procedure.
1.Establish from the customer whether a fuse or connector has been replaced or disconnected.
2.If yes, erase the diagnosis code, and then check that no diagnostic code is reset. If no diagnosis code is reset, the diagnosis is complete.
3.If no, follow the applicable Diagnostic Trouble Code Chart. Then check the wiring harness and connector, and refer to "How to Cope with Intermittent Malfunction P.00-12 ."
VEHICLE IDENTIFICATION
VEHICLE NAME PLATE
AC501406AB |
The name plate is riveted to the cowl top outer panel in the engine compartment.
|
M1001000401255 |
1 |
2 |
|
AC501266AB |
No. |
Item |
Content |
|
1 |
MODEL |
KA4 |
Vehicle model |
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KB4 |
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KB8 |
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2 |
ENGINE |
4D56 |
Engine model |
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|
4M41 |
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|
00-14 |
|
|
GENERAL |
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VEHICLE IDENTIFICATION |
|
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||
MODELS |
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<CLUB CAB> |
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Model code |
Engine model |
Transmission model |
Fuel supply system |
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||
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|
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KA4T |
NCNMFRU |
4D56 IDI (Indirect |
2WD |
R5M21 |
Electrical fuel injection |
|
|
|
Diesel Injection) SOHC |
(rear axle |
(5-speed manual |
(distribution type |
|
|
|
engine with Turbo |
drive) |
transmission) |
injection pump system) |
|
|
|
charger (2,477 mL) |
|
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NCNUZRU |
4D56 DI-D (Direct |
|
R5MB1 |
Electrical fuel injection |
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|
|
Injection-Diesel) DOHC |
|
(5-speed manual |
(common rail engine |
|
|
|
engine with Turbo |
|
transmission) |
control system) |
|
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|
charger (2,477 mL) |
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NCRUZRU |
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R4AW4 |
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(4-speed automatic |
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transmission) |
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KB4T |
GCNHZRU |
4D56 DI-D (Direct |
4WD |
V5MB1 |
|
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|
|
Injection-Diesel) DOHC |
(easy select |
(5-speed manual |
|
|
|
|
engine with Inter cooler, |
4WD) |
transmission) |
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|
|
Turbo charger (2,477 |
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mL) |
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KB8T |
GCNHZRU |
4M41 DI-D (Direct |
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Injection-Diesel) engine |
|
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with Inter cooler, Turbo |
|
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charger (3,200 mL) |
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<DOUBLE CAB> |
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Model code |
Engine model |
Transmission model |
Fuel supply system |
|
||
KA4T |
NJNMZRU |
4D56 DI-D (Direct |
2WD |
R5MB1 |
Electrical fuel injection |
|
|
|
Injection-Diesel) DOHC |
(rear axle |
(5-speed manual |
(common rail engine |
|
|
|
engine with Turbo |
drive) |
transmission) |
control system) |
|
|
|
charger (2,477 mL) |
|
|
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NJNUZRU |
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NJRUZRU |
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R4AW4 |
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(4-speed automatic |
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transmission) |
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KB4T |
GJNHZRU |
4D56 DI-D (Direct |
4WD |
V5MB1 |
|
|
|
|
Injection-Diesel) DOHC |
(easy select |
(5-speed manual |
|
|
|
|
engine with Inter cooler, |
4WD) |
transmission) |
|
|
|
|
Turbo charger (2,477 |
|
|
|
|
|
|
mL) |
|
|
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|
|
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KB8T |
GJNHZRU |
4M41 DI-D (Direct |
|
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|
|
Injection-Diesel) engine |
|
|
|
|
|
|
with Inter cooler, Turbo |
|
|
|
|
|
|
charger (3,200 mL) |
|
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GJNXZRU |
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GJRXZRU |
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V4A5A |
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(4-speed automatic |
|
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transmission) |
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GENERAL |
00-15 |
VEHICLE IDENTIFICATION |
|
MODEL CODE
|
1 |
2 |
3 |
4 |
5 |
6 |
7 |
8 |
9 |
10 |
11 |
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AC407365AB |
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No. |
Item |
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Content |
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1 |
Development |
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K |
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TRITON |
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2 |
Drive system |
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A |
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2WD |
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B |
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4WD |
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||
3 |
Engine type |
|
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4 |
|
2,477 mL |
|
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||
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||
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|
8 |
|
3,200 mL |
|
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||
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4 |
Sort |
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T |
|
Truck |
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5 |
Vehicle width |
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N |
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Standard |
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||
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|||
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G |
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Wide fender |
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|||
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||
6 |
Body style |
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C |
|
Club cab |
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||
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J |
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Double cab |
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||
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||||
7 |
Transmission type |
|
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N |
|
5-speed manual transmission |
||||
|
|
|
|
|
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|
||||
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R |
|
4-speed automatic transmission |
||||
|
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8 |
Vehicle grade |
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M |
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GL |
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U |
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GLX |
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H |
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GLS |
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X |
|
GLS-S |
|
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|||
9 |
Specification engine feature |
|
|
|
F |
|
Turbo charger |
|
|||
|
|
|
|
|
|
|
|
||||
9 |
Specification engine feature |
|
|
|
Z |
|
Inter cooler, turbo charger |
||||
|
|
|
|
|
|
|
|
|
|
||
10 |
Steering wheel location |
|
|
|
R |
|
Right hand |
|
|
||
|
|
|
|
|
|
|
|
|
|||
11 |
Destination |
|
|
|
U |
|
For Thailand |
|
|||
|
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|
|
|
|
|
|
00-16 |
GENERAL |
|
VEHICLE IDENTIFICATION |
CHASSIS NUMBER |
The chassis number is stamped on the side wall of |
|
the frame near the rear wheel (RH). |
Frame
AC501503AB
|
1 |
2 |
3 |
4 |
5 |
6 |
7 |
8 |
9 |
10 |
11 |
12 |
|
|
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|
AC501425AB |
|
|
|
|
|
|
|
|
|
|
|
|
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No. |
Item |
|
|
|
|
|
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Content |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
||
1 |
Country of manufacture |
|
|
M |
|
Asia |
|
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||
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|
|
|
|
|
|
|||
2 |
Maker |
|
|
|
|
M |
|
MMC Sittipol Co., Ltd. |
|
|||
|
(distribution channel) |
|
|
|
|
|
(Thailand) |
|
|
|
||
|
|
|
|
|
|
|
||||||
3 |
Destination and steering wheel |
|
T |
|
For Thailand, right hand |
|
||||||
|
location |
|
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4 |
Body style |
|
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C |
|
Club cab |
|
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|
|
|
|
|
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|
|
|
|
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||
|
|
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|
J |
|
Double cab |
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||
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|
|||||
5 |
Transmission type |
|
|
|
N |
|
5-speed manual transmission |
|||||
|
|
|
|
|
|
|
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|
||||
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R |
|
4-speed automatic transmission |
||||
|
|
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|
|
|
|
|
|
|
|||
6 |
Vehicle line |
|
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|
K |
|
MITSUBISHI TRITON |
|
|||
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|
|
|
|
|
|
|
|||
7 |
Development order |
|
|
|
A |
|
2-wheel drive |
|
|
|||
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|
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|
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|
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|
||
|
|
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B |
|
4-wheel drive |
|
|
||
|
|
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|
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|
|
|
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|
|||
8 |
Engine type |
|
|
|
|
4 |
|
2,477mL diesel engine |
|
|||
|
|
|
|
|
|
|
|
|
|
|||
|
|
|
|
|
|
8 |
|
3,200mL diesel engine |
|
|||
|
|
|
|
|
|
|
|
|
|
|||
9 |
MSC internal purpose |
|
|
|
0 |
|
No meaning |
|
|
|||
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10 |
Model year |
|
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|
7 |
|
2006 |
|
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|||
11 |
Plant |
|
|
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|
D |
|
MMC Sittipol Co., Ltd. |
|
|||
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12 |
Serial number |
|
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− |
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− |
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|
GENERAL |
00-17 |
GENERAL DATA AND SPECIFICATIONS |
|
ENGINE MODEL STAMPING
<4D5-SOHC>
AC502319AB
<4D5-DOHC, 4M4> |
AC502538AB |
The engine model is stamped on the cylinder block. This engine model numbers is as shown as follow.
Engine model |
Engine displacement |
4D56 |
2,477 mL |
|
|
4M41 |
3,200 mL |
|
|
The engine serial number is stamped near the |
|
engine model number. |
|
|
|
Engine serial number |
AA0201 to YY9999 |
|
|
GENERAL DATA AND SPECIFICATIONS
M1001000900945
CLUB CAB
<2WD> |
|
|
|
|
|
|
|
|
11 |
|
|
|
10 |
12 |
|
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8 |
|
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|
|
13 |
1 |
3 |
4 |
5 |
7 |
2 |
|
6 |
|
9 |
|
|
|
|
AC502183AB |
00-18 |
|
|
|
GENERAL |
|
|
|
|
GENERAL DATA AND SPECIFICATIONS |
|
|||
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|
Items |
|
|
KA4T |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
NCNMFRU |
NCNUZRU |
NCRUZRU |
Vehicle |
|
Front track |
1 |
1,505 |
1,505 |
1,505 |
dimensions |
|
|
|
|
|
|
|
Overall width |
2 |
1,750 |
1,750 |
1,750 |
|
mm |
|
|||||
|
|
|
|
|
|
|
|
Front overhang |
3 |
785 |
785 |
785 |
|
|
|
|||||
|
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|
|
|
|
Wheel base |
4 |
3,000 |
3,000 |
3,000 |
|
|
|
|
|
|
|
|
|
Rear overhang |
5 |
1,325 |
1,325 |
1,325 |
|
|
|
|
|
|
|
|
|
Overall length |
6 |
5,110 |
5,110 |
5,110 |
|
|
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|
|
|
|
|
|
Ground clearance (unladen) |
7 |
200 |
195 |
195 |
|
|
|
|
|
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|
|
Overall height (unladen) |
8 |
1,660 |
1,655 |
1,655 |
|
|
|
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|
|
|
|
Rear track |
9 |
1,500 |
1,500 |
1,500 |
|
|
|
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|
|
|
|
|
BED interior length |
10 |
1,805 |
1,805 |
1,805 |
|
|
|
|
|
|
|
|
|
BED interior width |
11 |
1,470 |
1,470 |
1,470 |
|
|
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|
|
|
|
|
BED interior height |
12 |
405 |
405 |
405 |
|
|
|
|
|
|
|
|
|
Cargo floor height (unladen) |
13 |
725 |
720 |
720 |
|
|
|
|
|
|
|
Vehicle weight |
|
Kerb weight |
|
1,565 |
1,600 |
1,600 |
kg |
|
|
|
|
|
|
|
Max. gross vehicle weight |
|
2,285 |
2,330 |
2,330 |
|
|
|
|
||||
|
|
|
|
|
|
|
|
|
Max. axle weight rating-front |
|
1,030 |
1,030 |
1,030 |
|
|
|
|
|
|
|
|
|
Max. axle weight rating-rear |
|
1,500 |
1,500 |
1,500 |
|
|
|
|
|
|
|
Seating capacity |
|
|
|
2 |
2 |
2 |
|
|
|
|
|
|
|
Engine |
|
Model No. |
|
4D56 IDI (Indirect |
4D56 DI-D |
4D56 DI-D (Direct |
|
|
|
|
Diesel Injection) |
(Direct |
Injection-Diesel) |
|
|
|
|
engine with |
Injection-Diesel) |
engine with Turbo |
|
|
|
|
Turbo charger |
engine with |
charger |
|
|
|
|
|
Turbo charger |
|
|
|
|
|
|
|
|
|
|
Total displacement mL |
|
2,477 |
2,477 |
2,477 |
|
|
|
|
|
|
|
|
|
Max. output kW (SP)/rpm |
|
66 (90)/4,000 |
81 (110)/4,000 |
81 (110)/4,000 |
|
|
|
|
|
|
|
|
|
Max. torque N m/rpm |
|
196 (20)/2,000 |
240 (24.5)/2,000 |
240 (24.5)/2,000 |
|
|
|
|
|
|
|
Transmission |
|
Model No. |
|
R5M21 |
R5MB1 |
R4AW4 |
|
|
|
|
|
|
|
|
|
Type |
|
5-speed manual |
5-speed manual |
4-speed |
|
|
|
|
|
|
automatic |
|
|
|
|
|
|
|
Fuel system |
|
Fuel supply system |
|
Electrical fuel |
Electrical fuel |
Electrical fuel |
|
|
|
|
injection |
injection |
injection |
|
|
|
|
(distribution type |
(common rail |
(common rail |
|
|
|
|
injection pump |
engine control |
engine control |
|
|
|
|
system) |
system) |
system) |
|
|
|
|
|
|
|
Max speed km/h |
|
|
|
150 |
160 |
158 |
|
|
|
|
|
||
Turning radius m |
|
5.7 |
5.7 |
5.7 |
||
|
|
|
|
|
|
|
GENERAL |
00-19 |
GENERAL DATA AND SPECIFICATIONS |
|
<4WD> |
|
|
|
|
|
|
|
|
11 |
|
|
|
10 |
12 |
|
|
|
|
|
|
|
|
|
8 |
|
|
|
|
13 |
1 |
3 |
4 |
5 |
7 |
2 |
|
6 |
|
9 |
|
|
|
|
AC502184 AB |
Items |
|
|
KB4T |
KB8T |
|
|
|
|
|
GCNHZRU |
GCNHZRU |
|
|
|
|
|
|
Vehicle |
|
Front track |
1 |
1,520 |
1,520 |
dimensions |
|
|
|
|
|
|
Overall width |
2 |
1,800 |
1,800 |
|
mm |
|
||||
|
|
|
|
|
|
|
Front overhang |
3 |
785 |
785 |
|
|
|
||||
|
|
|
|
|
|
|
|
Wheel base |
4 |
3,000 |
3,000 |
|
|
|
|
|
|
|
|
Rear overhang |
5 |
1,325 |
1,325 |
|
|
|
|
|
|
|
|
Overall length |
6 |
5,110 |
5,110 |
|
|
|
|
|
|
|
|
Ground clearance (unladen) |
7 |
205 |
205 |
|
|
|
|
|
|
|
|
Overall height (unladen) |
8 |
1,780 |
1,780 |
|
|
|
|
|
|
|
|
Rear track |
9 |
1,515 |
1,515 |
|
|
|
|
|
|
|
|
BED interior length |
10 |
1,805 |
1,805 |
|
|
|
|
|
|
|
|
BED interior width |
11 |
1,470 |
1,470 |
|
|
|
|
|
|
|
|
BED interior height |
12 |
405 |
405 |
|
|
|
|
|
|
|
|
Cargo floor height (unladen) |
13 |
860 |
860 |
|
|
|
|
|
|
Vehicle weight |
|
Kerb weight |
|
1,795 |
1,840 |
kg |
|
|
|
|
|
|
Max. gross vehicle weight |
|
2,535 |
2,605 |
|
|
|
|
|||
|
|
|
|
|
|
|
|
Max. axle weight rating-front |
|
1,250 |
1,250 |
|
|
|
|
|
|
|
|
Max. axle weight rating-rear |
|
1,600 |
1,600 |
|
|
|
|
|
|
Seating capacity |
|
|
|
2 |
2 |
|
|
|
|
|
|
Engine |
|
Model No. |
|
4D56 DI-D (Direct |
4M41 DI-D (Direct |
|
|
|
|
Injection-Diesel) engine |
Injection-Diesel) engine |
|
|
|
|
with Inter cooler, Turbo |
with Inter cooler, Turbo |
|
|
|
|
charger |
charger |
|
|
|
|
|
|
|
|
Total displacement mL |
|
2,477 |
3,200 |
|
|
|
|
|
|
|
|
Max. output kW (PS)/rpm |
|
100 (136)/4,000 |
118 (136)/3,800 |
|
|
|
|
|
|
|
|
Max. torque N m/rpm |
|
314 (32)/2,000 |
343 (35)/2,000 |
|
|
|
|
|
|
Transmission |
|
Model No. |
|
V5MB1 |
|
|
|
|
|
|
|
|
|
Type |
|
5-speed manual |
|
|
|
|
|
|
|
00-20 |
|
GENERAL |
|
|
|
|
GENERAL DATA AND SPECIFICATIONS |
|
|
|
|
|
|
|
Items |
|
KB4T |
KB8T |
|
|
|
|
|
|
|
|
|
GCNHZRU |
GCNHZRU |
Fuel system |
Fuel supply system |
|
Electrical fuel injection |
Electrical fuel injection |
|
|
|
(common rail engine |
(common rail engine |
|
|
|
control system) |
control system) |
|
|
|
|
|
Max speed km/h |
|
|
175 |
175 |
|
|
|
|
|
Turning radius m |
|
5.9 |
5.9 |
|
|
|
|
|
|
DOUBLE CAB
<2WD> |
|
|
|
|
|
|
|
|
11 |
|
|
|
10 |
12 |
|
|
|
|
|
|
|
|
|
8 |
|
|
|
|
13 |
1 |
3 |
4 |
5 |
7 |
2 |
|
6 |
|
9 |
|
|
|
|
AC502185AB |
Items |
|
|
KA4T |
|
|
|
|
|
|
NJNMZRU |
NJNUZRU |
NJRUZRU |
|
|
|
|
|
|
|
|
Vehicle |
Front track |
1 |
1,505 |
1,505 |
1,505 |
|
dimensions |
|
|
|
|
|
|
Overall width |
2 |
1,750 |
1,750 |
1,750 |
||
mm |
||||||
|
|
|
|
|
||
Front overhang |
3 |
785 |
785 |
785 |
||
|
||||||
|
|
|
|
|
|
|
|
Wheel base |
4 |
3,000 |
3,000 |
3,000 |
|
|
|
|
|
|
|
|
|
Rear overhang |
5 |
1,210 |
1,210 |
1,210 |
|
|
|
|
|
|
|
|
|
Overall length |
6 |
4,995 |
4,995 |
4,995 |
|
|
|
|
|
|
|
|
|
Ground clearance (unladen) |
7 |
200 |
195 |
195 |
|
|
|
|
|
|
|
|
|
Overall height (unladen) |
8 |
1,655 |
1,650 |
1,650 |
|
|
|
|
|
|
|
|
|
Rear track |
9 |
1,500 |
1,500 |
1,500 |
|
|
|
|
|
|
|
|
|
BED interior length |
10 |
1,325 |
1,325 |
1,325 |
|
|
|
|
|
|
|
|
|
BED interior width |
11 |
1,470 |
1,470 |
1,470 |
|
|
|
|
|
|
|
|
|
BED interior height |
12 |
405 |
405 |
405 |
|
|
|
|
|
|
|
|
|
Cargo floor height (unladen) |
13 |
715 |
710 |
710 |
|
|
|
|
|
|
|
|
Vehicle |
Kerb weight |
|
1,640 |
1,640 |
1,640 |
|
weight kg |
|
|
|
|
|
|
Max. gross vehicle weight |
|
2,330 |
2,330 |
2,330 |
||
|
|
|||||
|
|
|
|
|
|
|
|
Max. axle weight rating-front |
|
1,030 |
1,030 |
1,030 |
|
|
|
|
|
|
|
|
|
Max. axle weight rating-rear |
|
1,500 |
1,500 |
1,500 |
|
|
|
|
|
|
|
|
Seating capacity |
|
|
5 |
5 |
5 |
|
|
|
|
|
|
|
|
|
GENERAL |
|
00-21 |
|
|
GENERAL DATA AND SPECIFICATIONS |
|
|||
|
|
|
|
|
|
Items |
|
|
KA4T |
|
|
|
|
|
|
|
|
|
|
|
NJNMZRU |
NJNUZRU |
NJRUZRU |
Engine |
Model No. |
|
4D56 DI-D |
4D56 DI-D |
4D56 DI-D (Direct |
|
|
|
(Direct |
(Direct |
Injection-Diesel) |
|
|
|
Injection-Diesel) |
Injection-Diesel) |
engine with Turbo |
|
|
|
engine with |
engine with |
charger |
|
|
|
Turbo charger |
Turbo charger |
|
|
|
|
|
|
|
|
Total displacement mL |
|
2,477 |
2,477 |
2,477 |
|
|
|
|
|
|
|
Max. output kW (PS)/rpm |
|
81 (110)/4,000 |
81 (110)/4,000 |
81 (110)/4,000 |
|
|
|
|
|
|
|
Max. torque N m/rpm |
|
240 (24.5)/2,000 |
240 (24.5)/2,000 |
240 (24.5)/2,000 |
|
|
|
|
|
|
Transmission |
Model No. |
|
R5MB1 |
R5MB1 |
R4AW4 |
|
|
|
|
|
|
|
Type |
|
5-speed manual |
5-speed manual |
4-speed |
|
|
|
|
|
automatic |
|
|
|
|
|
|
Fuel system |
Fuel supply system |
|
Electrical fuel |
Electrical fuel |
Electrical fuel |
|
|
|
injection |
injection |
injection |
|
|
|
(common rail |
(common rail |
(common rail |
|
|
|
engine control |
engine control |
engine control |
|
|
|
system) |
system) |
system) |
|
|
|
|
|
|
Max speed km/h |
|
160 |
160 |
158 |
|
|
|
|
|
|
|
Turning radius m |
|
5.7 |
5.7 |
5.7 |
|
|
|
|
|
|
|
00-22 |
GENERAL |
|
GENERAL DATA AND SPECIFICATIONS |
<4WD> |
|
|
|
|
|
|
|
|
11 |
|
|
|
10 |
12 |
|
|
|
|
|
|
|
|
|
8 |
|
|
|
|
13 |
1 |
3 |
4 |
5 |
7 |
2 |
|
6 |
|
9 |
|
|
|
|
AC502186AB |
Items |
|
|
KB4T |
KB8T |
|
|
|
|
|
|
GJNHZRU |
GJNHZRU |
GJNXZRU |
GJRXZRU |
|
|
|
|
|
|
|
|
|
Vehicle |
Front track |
1 |
1,520 |
1,520 |
1,520 |
1,520 |
|
dimensions |
|
|
|
|
|
|
|
Overall width |
2 |
1,800 |
1,800 |
1,800 |
1,800 |
||
mm |
|||||||
|
|
|
|
|
|
||
Front overhang |
3 |
785 |
785 |
785 |
785 |
||
|
|||||||
|
|
|
|
|
|
|
|
|
Wheel base |
4 |
3,000 |
3,000 |
3,000 |
3,000 |
|
|
|
|
|
|
|
|
|
|
Rear overhang |
5 |
1,210 |
1,210 |
1,210 |
1,210 |
|
|
|
|
|
|
|
|
|
|
Overall length |
6 |
4,995 |
4,995 |
4,995 |
4,995 |
|
|
|
|
|
|
|
|
|
|
Ground clearance (unladen) |
7 |
205 |
205 |
205 |
205 |
|
|
|
|
|
|
|
|
|
|
Overall height (unladen) |
8 |
1,780 |
1,780 |
1,780 |
1,780 |
|
|
|
|
|
|
|
|
|
|
Rear track |
9 |
1,515 |
1,515 |
1,515 |
1,515 |
|
|
|
|
|
|
|
|
|
|
BED interior length |
10 |
1,325 |
1,325 |
1,325 |
1,325 |
|
|
|
|
|
|
|
|
|
|
BED interior width |
11 |
1,470 |
1,470 |
1,470 |
1,470 |
|
|
|
|
|
|
|
|
|
|
BED interior height |
12 |
405 |
405 |
405 |
405 |
|
|
|
|
|
|
|
|
|
|
Cargo floor height (unladen) |
13 |
850 |
850 |
850 |
850 |
|
|
|
|
|
|
|
|
|
Vehicle |
Kerb weight |
|
1,860 |
1,920 |
1,930 |
1,940 |
|
weight kg |
|
|
|
|
|
|
|
Max. gross vehicle weight |
|
2,535 |
2,605 |
2,605 |
2,605 |
||
|
|
||||||
|
|
|
|
|
|
|
|
|
Max. axle weight rating-front |
|
1,250 |
1,250 |
1,250 |
1,250 |
|
|
|
|
|
|
|
|
|
|
Max. axle weight rating-rear |
|
1,600 |
1,600 |
1,600 |
1,600 |
|
|
|
|
|
|
|
|
|
Seating capacity |
|
|
5 |
5 |
5 |
5 |
|
|
|
|
|
|
|
|
|
Engine |
Model No. |
|
4D56 DI-D |
4M41 DI-D |
4M41 DI-D |
4M41 DI-D |
|
|
|
|
(Direct |
(Direct |
(Direct |
(Direct |
|
|
|
|
Injection-Dies |
Injection-Die |
Injection-Die |
Injection-Die |
|
|
|
|
el) engine |
sel) engine |
sel) engine |
sel) engine |
|
|
|
|
with Inter |
with Inter |
with Inter |
with Inter |
|
|
|
|
cooler, Turbo |
cooler, Turbo |
cooler, Turbo |
cooler, Turbo |
|
|
|
|
charger |
charger |
charger |
charger |
|
|
|
|
|
|
|
|
|
|
Total displacement mL |
|
2,477 |
3,200 |
3,200 |
3,200 |
|
|
|
|
|
|
|
|
|
|
Max. output kW (PS)/rpm |
|
100 |
118 |
118 |
118 |
|
|
|
|
(136)/4,000 |
(160)/3,800 |
(160)/3,800 |
(160)/3,800 |
|
|
|
|
|
|
|
|
|
|
Max. torque N m/rpm |
|
314 |
343 |
343 |
343 |
|
|
|
|
(32)/2,000 |
(35)/2,000 |
(35)/2,000 |
(35)/2,000 |
|
|
|
|
|
|
|
|
|
|
GENERAL |
|
|
00-23 |
|
|
|
PRECAUTIONS BEFORE SERVICE |
|
|
||
|
|
|
|
|
|
|
Items |
|
|
KB4T |
KB8T |
|
|
|
|
|
|
|
|
|
|
|
|
GJNHZRU |
GJNHZRU |
GJNXZRU |
GJRXZRU |
Transmission |
Model No. |
|
V5MB1 |
V5MB1 |
V5MB1 |
V4A5A |
|
|
|
|
|
|
|
|
Type |
|
5-speed |
5-speed |
5-speed |
4-speed |
|
|
|
manual |
manual |
manual |
automatic |
|
|
|
|
|
|
|
Fuel system |
Fuel supply system |
|
Electrical fuel |
Electrical fuel |
Electrical |
Electrical |
|
|
|
injection |
injection |
fuel injection |
fuel injection |
|
|
|
(common rail |
(common rail |
(common rail |
(common rail |
|
|
|
engine |
engine |
engine |
engine |
|
|
|
control |
control |
control |
control |
|
|
|
system) |
system) |
system) |
system) |
|
|
|
|
|
|
|
Max speed km/h |
|
175 |
175 |
175 |
175 |
|
|
|
|
|
|
|
|
Turning radius m |
|
5.9 |
5.9 |
5.9 |
5.9 |
|
|
|
|
|
|
|
|
PRECAUTIONS BEFORE SERVICE
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT WITH PRE-TENSIONER
M1001011600238
CAUTION
Items to review when servicing SRS:
1.Be sure to read GROUP 52B −Supplemental
Restraint System (SRS). For safe operation, please follow the directions and heed all warnings.
2.Wait at least 60 seconds after disconnecting the battery cable before doing any further work. The SRS system is designed to retain enough voltage to deploy the air bag even after the battery has been disconnected. Serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cable is disconnected.
3.Warning labels must be heeded when servicing or handling SRS components. Warning labels can be found in the following locations.
•SRS air bag control unit (SRS-ECU)
•Front impact sensor
•Clock spring
•Driver's and front passenger's air bag modules
•Seat belt with pre-tensioner
4.Always use the designated special tools and test equipment.
5.Store components removed from the SRS in a clean and dry place. The air bag module should be stored on a flat surface and placed
so that the pad surface is facing upward. Do not place anything on top of it.
6.Never attempt to disassemble or repair the SRS components (SRS-ECU, air bag module and clock spring).
7.Whenever you finish servicing the SRS, check the SRS warning lamp operation to make sure that the system functions properly.
8.Be sure to deploy the air bag before disposing of the air bag module or disposing of a
vehicle equipped with an air bag (Refer to GROUP 52B −Air Bag Module Disposal Procedures).
Observe the following when carrying out operations on places where SRS components are installed, including operations not directly related to the SRS air bag.
1.When removing or installing parts, do not allow any impact or shock to the SRS components.
2.If heat damage may occur during paint work, remove the SRS-ECU, the air bag module, clock spring, the front impact sensor, and the seat belt pre-tensioner.
•SRS-ECU, air bag module, clock spring, front impact sensor: 93 ° C or more
•Seat belt pre-tensioner: 90 ° C or more
00-24 |
GENERAL |
|
PRECAUTIONS BEFORE SERVICE |
WHAT THE COMMON RAIL ENGINE LEARNS
M1001012500018
After fuel-related parts are replaced, the common rail engine must register their identification codes with the engine-ECU and execute learning.
The table below shows what should be registered and learned after each type of operation.
Correspondence table
NOTE: When the engine-ECU is replaced, collect in advance the injector identification code from the current engine-ECU. Doing it makes registration easy.
Registration and |
Operation type |
|
|
learning item |
|
|
|
Injector replacement |
Supply pump |
Engine-ECU |
|
|
|
replacement |
replacement |
|
|
|
|
Injector identification |
appricable |
− |
appricable |
code registration |
|
|
|
|
|
|
|
Small injection quantity |
appricable |
− |
appricable |
learning |
|
|
|
|
|
|
|
Supply pump correction |
− |
appricable |
− |
learning |
|
|
|
|
|
|
|
REGISTRATION AND LEARNING PROCE- |
Small injection quantity learning |
DURE |
Refer to P.00-25, SMALL INJECTION QUANTITY |
Injector identification code registration |
LEARNING PROCEDURE. |
|
|
Refer to P.00-24, INJECTOR IDENTIFICATION |
Supply pump correction learning |
CODE REGISTRATION PROCEDURE. |
Refer to P.00-26, SUPPLY PUMP CORRECTION |
|
|
|
LEARNING PROCEDURE. |
INJECTOR IDENTIFICATION CODE REGISTRATION PROCEDURE
CAUTION
1.If the injector identification code is not registered, the engine warning lamp goes on and diagnosis code No. P1626 is logged.
2.Failure to register the injector identification code correctly will cause rough idling, abnormal noise, and emission deterioration.
M1001012600015 |
PURPOSE |
Identification code |
AK501491 AB |
Because individual injectors have different injection characteristics, the engine-ECU corrects injection time for each cylinder to improve injection accuracy. For this reason, when the injector or engine-ECU is replaced, injector correction data must be registered afterwards in the engine-ECU using the Multi Use Tester III (M.U.T.-III).
Correction data is converted into an identification code consisting of 30 alphanumeric characters and printed on the injector connector.
GENERAL |
00-25 |
PRECAUTIONS BEFORE SERVICE |
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REGISTRATION PROCEDURE
1.When replacing the engine-ECU, connect the current engine-ECU to the body harness.
NOTE: This operation is purposed to read the injector identification code stored in the engine-ECU. Reading the identification code in this way before replacement can eliminate manual input of the identification code after replacement.
2.After the ignition switch is in "LOCK" (OFF) position, connect the M.U.T.-III to the diagnosis connector.
3.Turn the ignition switch to "ON" position.
4.Select SPECIAL FUNCTION from the function menu.
5.When the current engine-ECU is still mounted, read and register the injector identification code as follows:
(1)Select Read Injector ID Code (for engine-ECU replacement) from the SPECIAL FUNCTION menu.
(2)Select Write and Save Injector ID Code from the menu to read data from the current engine-ECU and save the data if it could be read normally.
(3)Mount the new engine-ECU on the vehicle.
(4)Select SPECIAL FUNCTION from the function menu.
(5)Select Write Injector ID Code (for engine-ECU replacement) from the SPECIAL FUNCTION menu.
(6)Select SAVED INJECTOR ID WRITING from the Write Injector ID Code menu to write the data, which was saved previously, to the engine-ECU.
6.If the injector has been replaced or data has not been read from the current engine-ECU, register the injector identification code as follows:
(1)Select Write Injector ID Code from the SPECIAL FUNCTION menu.
(2)If the injector was replaced, specify whether to write to every cylinder or a specific cylinder.
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Frame 1 |
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Frame 2 |
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(4 digits) |
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(4 digits) |
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Frame 3 |
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Frame 4 |
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(4 digits) |
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(4 digits) |
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Frame 6 |
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Frame 5 |
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(4 digits) |
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(4 digits) |
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Frame 7 |
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Frame 8 |
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(4 digits) |
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(2 digits) |
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AK501492 AB |
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(3)Select the write mode from the menu, enter the identification code printed on the injector, and execute writing.
CAUTION
Even if the number of the cylinder to be registered does not match the actual injector mounting location, registration ends normally. Specify the cylinder number correctly.
NOTE: The identification code is displayed in order of the frame numbers when it is read.
7.Makes sure that the engine warning lamp that is on changes to blinking, indicating the registration is complete.
NOTE: When the injector is replaced, executing the write operation also clears the values of small injection quantity learning.
8.Execute small injection quantity learning.
Refer to P.00-25, the SMALL INJECTION QUANTITY LEARNING PROCEDURE for the learning procedure.
9.Confirm that the engine warning lamp is off. Confirm also that the diagnosis code is not stored.
SMALL INJECTION QUANTITY LEARNING PROCEDURE
M1001014300010
CAUTION
1.If small injection quantity learning has not been executed, the engine warning lamp blinks.
2.When the requirements for learning are satisfied by operation after replacement of the engine-ECU, learning is automatically executed even if no instruction is given from the M.U.T.-III. Accordingly, the malfunction indicator lamp goes off. However, the learning thus executed is tentative and limited. Be sure to complete leaning using the M.U.T.-III.
PURPOSE
To keep emission and noise level at adequate levels, the engine-ECU must learn injector fuel injection in idle mode.
During learning, the engine-ECU calculates actual injection from each cylinder based on changes in engine speeds and corrects pilot injection control. It then keeps records of this amount of correction as a learned value.
For this reason, after the engine-ECU or injector is replaced, learning must be executed using the M.U.T.-III.
00-26 |
GENERAL |
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PRECAUTIONS BEFORE SERVICE |
NOTE: Engine friction changes or injector deterioration over time may cause fluctuation in pilot injection. After use over time, it may prevent injection of an accurate amount of fuel according to the indication by the engine-ECU. This is why learning must be executed again periodically.
For this reason, the engine-ECU periodically leans injection according to the cumulative mileage.
Note that making the M.U.T.-III learn again resets the cumulative mileage.
NOTE: The engine sound may change or idling engine speeds may increase during injection learning. These are not abnormalities.
LEARNING PROCEDURE
1.After the ignition switch is in "LOCK" (OFF) position, connect the M.U.T.-III to the diagnosis connector.
2.Put the vehicle in the following idling stable conditions:
•Engine coolant temperature: 80 −90° C
•Automatic transmission fluid temperature: 60° C or higher
•Lamps, A/C condenser fan and all accessories: OFF
•Transmission: Neutral <M/T>, "P" range <A/T>
•Power steering: Static state
3.Select SPECIAL FUNCTION from the function menu.
4.Select SMALL INJECTION QUANTITY LEARNING from the SPECIAL FUNCTION menu to execute learning.
CAUTION
If the vehicle conditions go out of the learning conditions during idling, learning is interrupted.
To reexecute learning, the ignition switch must once be turned off.
5.Continue idling for about 3 minutes before learning is completed.
6.Confirm that the engine warning lamp is off. If it still blinks, reexecute learning.
SUPPLY PUMP CORRECTION LEARNING PROCEDURE
M1001014400017
PURPOSE
The engine-ECU learns the relation between the suction control valve (linear solenoid valve) of the supply pump drive current and the fuel injection volume.
The learning value is calculated from the suction control valve drive current and the rail pressure sensor output voltage.
When the supply pump is replaced, therefore, this learning must be executed.
Re-learning is executed when the engine is idling after the learning value in the engine-ECU has been reset by the M.U.T.-III.
GENERAL |
00-27 |
PRECAUTIONS BEFORE SERVICE |
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LEARNING PROCEDURE FOR IDLING
After the ignition switch is in "LOCK" (OFF) position, connect the M.U.T.-III to the diagnosis connector.
1.Turn the ignition switch to "ON" position. (Do not start the engine.)
2.Select SPECIAL FUNCTION from the function menu.
3.Select SUPPLY PUMP CORRECTION LEARNING from the SPECIAL FUNCTION menu and execute the initializing of the learning value.
4.After initializing, run the engine at idle in the following conditions.
•Accelerator pedal: OFF
•Engine coolant temperature: 60° C or higher
•Fuel temperature: 30° C or higher
5.Confirm that the item No. 65 High pressure pump learned status on M.U.T.-III Service Data is "2".
NOTE: "2" indicates that the learning has completed.
SERVICING ELECTRICAL SYSTEM
M1001011900217
CAUTION
Before connecting or disconnecting the negative (−) cable, be sure to turn off the ignition switch and the lighting switch (If this is not done, there is the possibility of semiconductor parts being damaged).
AC300693
Before replacing a component related to the electrical system and before undertaking any repair procedures involving the electrical system, be sure to first disconnect the negative (−) cable from the battery in order to avoid damage caused by short-circuiting.
VEHICLES WITH SEMI AUTOMATIC AIR CONDITIONER
M1001011300055
CAUTION
Never start the engine with the refrigerant system empty as it will damage the A/C compressor.
M1001014500014
APPLICATION OF ANTI-CORROSION AGENTS AND UNDERCOATS
M1001011000173
If oil or grease gets onto the oxygen sensor, it will cause a drop in the performance of the sensor. Cover the oxygen sensor with a protective cover when applying anti-corrosion agents and undercoats.
VEHICLE WASHING
M1001012000206
Approximately 40 cm
AC300832AB
If high-pressure car-washing equipment or steam car-washing equipment is used to wash the vehicle, be sure to note the following information in order to avoid damage to plastic components, etc.
•Spray nozzle distance: Approximately 40 cm or more
•Spray pressure: 3,900 kPa or less
•Spray temperature: 82° C or less
•Time of concentrated spray to one point: within 30 sec.
PRE-INSPECTION CONDITION
M1001012100117
"Pre-inspection condition" refers to the condition that the vehicle must be in before proper engine inspection can be carried out. If you see the words "Set the vehicle to the pre-inspection condition" in this manual. It means to set the vehicle to the following condition.
•Engine coolant temperature 80 to 90° C
•Lamps, electric cooling fan and all accessories: OFF
•M/T: Neutral
•A/T: N range
00-28 |
GENERAL |
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PRECAUTIONS BEFORE SERVICE |
MULTI USE TESTER (M.U.T.-III) SUB ASSEMBLY
M1001012400011
MULTI USE TESTER (M.U.T.-III) sub assembly
Vehicle communication interface (V.C.I.)
MB991824
M.U.T.-III USB cable
MB991827
M.U.T.-III main harness A
MB991910
M.U.T.-III main harness B
Do not use
MB991911
M.U.T.-III measurement adapter |
MB991825 |
M.U.T.-III trigger harness
MB991826
AC305090AI
Refer to the "M.U.T.-III OPERATION MANUAL" for instructions on handling the M.U.T.-III.
CAUTION
Diagnosis
connector
MB991910
MB991824
MB991827 |
AC501413AB |
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Turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting the M.U.T.-III.
Connect the M.U.T.-III to the diagnosis connector as shown in the illustration.
HOW TO USE THE THROTTLE CONTROLLER
M1001009300014
As for a vehicle with the electronic control throttle
valve*, engine operations such as racing can not be performed from outside the vehicle. Thus, the throttle valve controller (MB991791) is provided as a special tool to enable the engine operation from outside the vehicle.
NOTE: *: A vehicle with the accelerator pedal position sensor (APS) installed to the accelerator pedal
THE THROTTLE CONTROLLER CONNECTION
APS harness |
side connector |
MB991894 |
MB991791 |
AC103781AC |