Tf4jk-We-1211th 1st WSMW 120 TF Tis 12tf

2012MY
WORKSHOP MANUAL
ENGINE
(4JK1 model)
No.TF4JK-WE-1211TH
67209_Maegaki 2011.7.22 9:41 AM ページ 1
This Workshop Manual deals only with the screen toned section(s) in the table below.
Section Sub Section
0 GENERAL INFORMATION 0 Introduction
14A Service Information Guide
14B Vehicle Information
1 ENGINE 15B Maintenance Information
15C Functional Inspection
15D Symptom
15E DTC Information
1A Engine Control
1B Mechanical
1C Fuel System
1D Cooling
1E Lubrication
1F Induction
1G Exhaust
1H Aux. Emission Control Devices
1I Speed Control Systems
1J Electrical
2 SUSPENSION 16B Maintenance Information
16D Symptom
2B Front Suspension
2C Rear Suspension
2D Wheel, Tire System
3 DRIVELINE, AXLE 17B Maintenance Information
17D Symptom
17E DTC Information
3A Driveline Control
3B Differentials
3C Drive Shaft System
3D Transfer Case
4 BRAKES 18B Maintenance Information
18D Symptom
18E DTC Information
4A Brake Control
4B Brake System
4C Parking Brake System
4D ABS
5 TRANSMISSION, TRANSAXLE 19B Maintenance Information
19D Symptom
19E DTC Information
5A Transmission Control
5B Automatic
5C Manual
5E Clutch System
6 STEERING 20B Maintenance Information
20D Symptom
6B Power Assisted System
67209_Maegaki 2011.7.22 9:41 AM ページ 2
Section Sub Section

7 HVAC 21B Maintenance Information
21D Symptom
7B Heater, Ventilator, Airconditioner
8 RESTRAINTS 22B Maintenance Information
22D Symptom
22E DTC Information
8A SRS Control
8B Air Bag Systems
8C Seat Belt Systems
9 BODY, CAB, ACCESSORIES 23B Maintenance Information
23D Symptom
9A Lighting Systems
9B Wiper, Washer Systems
9C Electrical Control, Entertainment
9E Instrumentation, Driver Info.
9G Hood, Fenders, Doors
9H Cab Structure
9I Seats
9J Security and Locks
9L Exterior, Interior Trim
9P Unibody Sub-frames
9T Glass, Windows, Mirrors
10 BODY CONTROL 36B Maintenance Information
36D Symptom
36E DTC Information
10I Body Control
10 SECURITY AND LOCKS CONTROL 42B Maintenance Information
42E DTC Information
10S Security and Locks Control
11 FRAME 24B Maintenance Information
- ETM - Using the Wiring Diagram
- Power System
- Engine
- Chassis
- Brake
- Safety
- Driver Assist
- Accessory
- Light
- Data Communications
- Location Diagram
- Connector List
Maintenance Information (4JK1) 15B-1
Description Engine
Maintenance Information
(4JK1)
Table of Contents
Maintenance precautions of engine...............................15B-2
Function, structure, operation of engine........................15B-4
Primary specifications of engine.................................15B-38
Introduction to the trouble diagnosis of engine...........15B-40
15B-2 Maintenance Information (4JK1)
Maintenance precautions of engine

1. Maintenance precautions of engine An example of charging by friction is a person sliding
across a vehicle seat.
ECM maintenance precautions
The exclamation mark warns you of an electric shock Caution：
hazard. To avoid shock and possible serious injury, DO ・ To prevent damage caused by electrostatic
NOT touch the terminals. When disconnecting the discharge, do not touch the ECM connector
harness connectors, always turn OFF the ignition switch pins or solenoid components on the ECM
or disconnect the battery ground cable. circuit board.
・ To prevent damage caused by electrostatic
discharge, do not open the replacement part
package until the part is ready to be installed.
discharge, connect the packaging to a properly
working ground connection of the vehicle
before removing a part from the packaging.
discharge, touch a properly working ground
before attaching a part when handling the part
while sliding across the seat, sitting down from
a standing position, or walking a certain
distance.
・ Take note that charge by electrostatic
induction occurs when a person with well
insulated shoes stands near a highly charged
object and momentarily touches a grounded
Aftermarket electrical and vacuum equipment object. The charge of the same polarity flows
Aftermarket or add-on electrical and vacuum equipment outward, leaving the person highly charged
is defined as any equipment which is connected to the with opposite polarity.
electrical or vacuum systems that is installed on a vehicle Note：
after the vehicle is shipped from the factory. No
・ To prevent damaging the engine and to ensure
allowances have been made in the vehicle design for this
the reliability of engine performance, be careful
type of equipment. No add-on vacuum equipment should
of the following points when performing engine
be added to this vehicle. Add-on electrical equipment
maintenance.
must only be connected to the vehicle's electrical system
at the battery power source and ground. Add-on electrical Do not disconnect the battery cable and the wiring of the
equipment, even when installed based on these charging circuit while the engine is running. Do not also
guidelines, may still cause the powertrain system to open or close the battery relay.
malfunction. This may also include equipment not When lifting or supporting the engine, do not directly
connected to the vehicle electrical system such as attach the jack to the oil pan.
portable telephones and audio systems. Therefore, the When lowering the engine to the ground, do not let the oil
first step in diagnosing any powertrain fault is to pan directly contact the ground.
eliminate all aftermarket electrical equipment from the Use a wooden frame, etc. to support it with the engine
vehicle. After this is completed, if the fault still exists, the foot or flywheel housing.
fault should be diagnosed in the normal manner. There is only a small gap between the oil pan and oil
Electrostatic discharge damage pump strainer, so be careful not to damage the oil pan and
Electronic components used in the ECM are often oil pump strainer.
designed to carry very low voltage. Electronic To perform maintenance operations for the engine body,
components are susceptible to damage caused by confirm that the ignition switch, lighting switch, etc. are
electrostatic discharge. By comparison, as much as 4000 turned off, and disconnect the battery ground cable. If the
volts of voltage may be needed for a person to feel a battery ground cable is not disconnected while
static discharge. There are several ways for a person to performing work, there is the possibility of damaging the
become statically charged. The most common methods of wire harness or electrical components. Take adequate
charging are by friction and induction.
precautions for safety, such as short circuits, when The fuel moisture removal agent causes moisture to be
inspections require an energized state. absorbed into the diesel oil and is the cause of rust.
Therefore, do not use moisture removal agents in the fuel
When connecting the battery ground cable, pay attention
tank.
to the battery poles.
If the battery poles are reversely connected, the generator Leaking fuel may cause fires. Therefore, after completing
diode, etc. may be damaged. the work, wipe away any leaked fuel, and confirm that no
fuel leakage is present after starting the engine.
When disconnecting the harness, inspect the connectors
and clips for damage and replace them as necessary. Do not loosen or remove the radiator cap when the
coolant is hot. Steam and boiling water can burst out
When connecting the harness, be sure to connect it in the
from the radiator possibly causing burns or heat related
same position and with the same routing as before.
injuries. When opening the radiator cap, place a thick
When washing the engine with steam, care should be cloth over the cap when the coolant is cooled, and turn it
taken not to allow steam or fluid to contact directly with gradually to release the pressure before opening it.
the battery or other electrical system parts.
When the air intake system, such as the air duct or air
Whenever removing the gasket, oil seals, O-rings, etc., cleaner, has been removed, cover the air intake to prevent
replace them with new ones. foreign material from entering the cylinder. If the
cylinder is dirty, the cylinder may be severely damaged
When assembling and installing, tighten to the specified
while the engine is running.
torque.
The turbocharger has an extremely precise finish and
When reinstalling them, use the same part and install it in
rotates at high speeds, and therefore, it cannot be
the same position as when it was removed.
disassembled. Replace the turbocharger assembly, if even
To protect and lubricate the sliding surfaces when small abnormalities such as bent fins or bent housing or
running for the first time, apply an adequate amount of scratches are found.
engine oil to the sliding surfaces. Take measures to prevent foreign material from entering
When disassembling, use a scraper to completely scrape the turbine housing, compressor housing, the oil filler and
off old liquid gasket from the locations where it is used. outlet while performing the maintenance work.
After cleaning any oil, moisture and filth using a shop After maintenance of the turbocharger, pour in 0.5 cc
cloth, etc., apply the specified liquid gasket. {0.000011 lmp･gal} of clean engine oil into the fuel filler
Apply the proper amount to avoid an excess or lack in before installing the oil pipe.
application. If an excessive amount is applied, it leads to
If you grip the actuator rod to lift the turbocharger, it will
engine seizures. If an insufficient amount is applied, it
deform, causing improper operation. Always hold the
causes oil and water leaks.
turbocharger main unit without gripping the rod.
Overlap the beginning and ending of the application.
Vibrations and looseness of the exhaust system are
After applying the liquid gasket, install it within the
caused by mispositioning at the time of assembly.
specified amount of time. If the specified amount of time
Temporarily install all bolts and nuts until all components
is exceeded, wipe away the liquid gasket and reapply it.
are positioned. After positioning is completed, tighten
When the valve related parts, injector, pistons, piston them from the engine side to the rear side.
rings, connecting rod, connecting rod bearing, crankshaft
When assembling the EGR system, temporarily tighten
journal bearing, etc. have been removed, organize them in
once, then firmly tighten in order not to apply
order for storage.
unnecessary stress on the components.
Store the eyebolt in a clean parts box with a cover so that
Be careful not to over-tighten the glow plug since as it
foreign material does not attach to them.
can be damaged.
Including the inside of the injector, the holes and gaps
Disconnect the battery ground cable when recharging the
that are the fuel paths for the fuel system have an
battery using an external device.
extremely precise finish. Therefore, because there is the
possibility of damage if foreign material becomes mixed
in, cover the cap after removing parts, etc. to prevent the
entry of foreign material.
The fuel injector QR plate is specific to that fuel injector.
Do not confuse with other injector QR plates. When
replacing a fuel injector, the ECM is needed to learn the
injector ID code.
Function, structure, operation of engine

1. Function, structure, operation of engine
ECM
The ECM is designed to withstand normal current draws
associated with vehicle operations. Avoid overloading
any circuit. When testing for open circuits and short
circuits, do not ground or apply voltage to any of the
ECU circuits unless instructed to do so. In some cases,
these circuits should only be tested using a DMM. The
ECM should remain connected to the ECM harness. The
ECM mainly controls the following items.
Fuel system control
EGR system control
Glow system control
A/C compressor control
Immobilizer system control
On-board diagnosis for engine control
The ECM constantly monitors the information from
various sensors. The ECM controls the systems that
Note：
affect vehicle performance. The ECM performs the
diagnostic function of the system. The ECM can ・ ECM input/output
recognize operational problems, alert the driver through
the MIL, and store DTCs. DTCs identify the system
faults to aid the technician in making repairs.
ECM voltage description The MIL indicates that an engine performance related
The ECM applies the buffer voltage to various switches fault has occurred and vehicle service is required. The
and sensors. The ECM can do this because resistance in following is a list of operation modes for the MIL.
the ECM is so high in value that a test light may not The MIL illuminates when the ignition switch is turned
illuminate when connected to the circuit. An ordinary ON and the engine is turned OFF. This is a light test to
shop voltmeter may not give an accurate reading because confirm that the MIL is able to illuminate.
the voltmeter input impedance is too low. Use a 10- The MIL turns OFF after the engine is started if a
megaohm input impedance DMM to ensure accurate diagnostic fault is not present.
voltage readings. The input and/or output devices in the The MIL remains illuminated after the engine is started if
ECM include analog-to-digital converters, signal buffers, the ECM detects a fault. A DTC is stored any time the
counters, and special drivers. The ECM controls most ECM illuminates the MIL due to an engine performance
components with electronic switches which complete a related fault.
ground circuit when turned ON.
MIL operation
The MIL is located in the instrument panel cluster. The
MIL displays the engine symbol when "ON" is
commanded.
pressure. The barometric pressure sensor provides a
signal to the ECM on the signal circuit, which is relative
to the pressure changes of the barometric pressure. The
ECM should detect a low signal voltage at a low
barometric pressure at places with high altitude, etc. The
ECM should detect high signal voltage at a high
barometric pressure. The ECM uses this voltage signal to
calibrate the fuel injection quantity and injection timing
for altitude compensation.
Accelerator pedal position sensor

The accelerator pedal position sensor is mounted together
with the accelerator pedal. The sensor consists of 2
individual sensors within 1 housing. The ECM uses the
accelerator pedal position sensor to determine the amount
of acceleration or deceleration that is desired. The
accelerator pedal position sensors are hall element type
sensors. Each accelerator pedal position sensor provides a
different signal to the ECM on each signal circuit, which
is relative to the position changes of the accelerator pedal
Boost sensor
angle. The signal voltage of accelerator pedal position
The boost sensor is located in the air induction tubing.
sensor 1 and 2 is low at rest and increases as the pedal is
The boost sensor is a transducer that varies voltage
depressed.
according to changes in the air pressure inside the air
tubing. The boost sensor provides a signal to the ECM on
the signal circuit, which is relative to the pressure
changes in the air tubing. The ECM should detect a low
signal voltage at a low boost pressure, such as when the
engine load is low. The ECM should detect high signal
voltage at a high boost pressure, such as when the engine
load is high.
1. Accelerator pedal position sensor

2. Accelerator pedal
Barometric pressure sensor

The barometric pressure sensor is installed onto the air
cleaner. The barometric pressure sensor is a transducer
that varies voltage according to changes in the barometric
CMP sensor
The CMP sensor is installed on the timing chain sprocket
cover at the front of the camshaft idle gear. The CMP
sensor detects five projections in total per one engine
rotation. Four projections arranged equally every 90° and
one reference projection on the timing chain sprocket
surface. The CMP sensor is a magnetic resistance element
type sensor, which generates a square wave signal pulse.
1. CKP sensor
2. Sensor rotor
3. Rotational direction
Engine coolant temperature sensor

The engine coolant temperature sensor is installed onto
the thermostat housing. The engine coolant temperature
sensor is a variable resistor and it measures the
temperature of the engine coolant. When the engine
1. Timing chain sprocket coolant temperature sensor is cold, the sensor resistance
2. CMP sensor is high. When the engine coolant temperature increases,
3. Rotational direction the sensor resistance decreases. With high sensor
resistance, the ECM detects a high voltage on the signal
CKP sensor
circuit. With lower sensor resistance, the ECM detects a
The CKP sensor is located on the left-hand of the
lower voltage on the signal circuit.
cylinder block rear section. The sensor rotor is secured to
the crankshaft. There are 56 notches spaced 6° apart and
a 30° opening. This opening allows for detection of top
dead center. The CKP sensor is a magnetic resistance
element type sensor, which generates a square wave
signal pulse. Detecting the opening from the CKP sensor
and one reference projection from the CMP sensor, the
ECM determines cylinder No. 1 compression top dead
center, and confirms that they correlate with each other.
Fuel temperature sensor

The fuel temperature sensor is installed on the fuel supply
pump.
The fuel temperature sensor is a variable resistor and it
measures the temperature of the fuel entering the fuel
supply pump. When the fuel temperature sensor is cold, MAF sensor
the sensor resistance is high. When the fuel temperature The MAF sensor is an air flow meter that measures the
increases, the sensor resistance decreases. With high amount of air that enters the engine. It is attached
sensor resistance, the ECM detects a high voltage on the between the air cleaner and turbocharger. A small
signal circuit. With lower sensor resistance, the ECM quantity of air that enters the engine indicates
detects a lower voltage on the signal circuit. deceleration or idle rotation. A large quantity of air that
enters the engine indicates acceleration or a high load
condition. The MAF sensor assembly consists of an MAF
sensor element and an IAT sensor. Both components are
exposed to the air flow to be measured. The MAF sensor
element measures the inflow air volume through a
measurement duct on the sensor housing.
1. Fuel temperature sensor

2. FRP regulator
IAT sensor
The IAT sensor is attached between the air cleaner and
turbocharger. It is inside the MAF sensor. The IAT
sensor is a variable resistor and it measures the Common rail type electronic control fuel injection system
temperature of the air entering the engine. When the IAT The common rail system uses an accumulator, which is
sensor is cold, the sensor resistance is high. When the air also called a common rail, to store pressurized fuel and
temperature increases, the sensor resistance decreases. also use injectors including the electric control solenoid
With high sensor resistance, the ECM detects a high valve to inject the pressurized fuel into the combustion
voltage on the signal circuit. With lower sensor chamber. Injection pressure, injection rate and injection
resistance, the ECM detects a lower voltage on the signal timing are controlled by the ECM, and therefore the
circuit. common rail system can be controlled independently, free
from the influence of engine speed and load. This ensures
stable injection pressure at all time, particularly in the
low engine speed range, and therefore, black smoke
specific to diesel engines generated during vehicle
starting or acceleration can be significantly reduced. As a
result, the cleanliness and volume of exhaust gas are
improved and higher output can be achieved.
High pressure control Injection rate control

Enables high pressure injection from low engine speed Pre injection control that performs a small amount of
range. injection before main injection.
Optimizes control to minimize particulate matter and
The common rail system consists primarily of a fuel
NOx emissions.
supply pump, fuel rail, injectors, and ECM.
Injection timing control
Note：
Enables finely tuned optimized control in accordance
with running conditions. ・ Fuel system diagram
1. Fuel rail 8. Fuel filler cap

2. Pressure limiter 9. Fuel feed pipe
3. Fuel leak-off pipe 10. Fuel filter with sedimenter
4. Injector 11. Clogging switch
5. Fuel return pipe 12. Fuel supply pump
6. Fuel tank
7. Fuel tank unit
Injector
Electronic control type injectors controlled by the ECM
are used. Compared with conventional injection nozzles,
a command piston, solenoid valve, etc. are added. ID
codes displaying various injector characteristic are laser
marked in the connector housing. This system uses
injector flow rate information indicated by the ID codes
to optimize the injection quantity control. When an
injector is newly installed in a vehicle, it is necessary to
input the ID codes in the ECM. QR codes or injector flow
rate information are used to enhance the injection
quantity precision of the injectors. The use of codes
enables injection quantity dispersion control throughout
all pressure ranges, contributing to improvement in
combustion efficiency and reduction in exhaust gas
emissions.
4. Fuel inlet port
5. O-ring
Non-injection state
The TWV closes the outlet orifice by means of a spring
force, when no current is supplied from the ECM to the
solenoid. At this point, the fuel pressure applied to the
nozzle leading end is equivalent to the fuel pressure
applied through the inlet orifice to the control chamber.
As for the force competition in this state, the sum of
pressure on the command piston upper surface and nozzle
spring force is greater than the pressure applied to the
nozzle leading end, and therefore the nozzle is pressed
down and the injection hole is closed.
Injection start
When current is supplied from the ECM to the solenoid,
the TWV is raised to open the outlet orifice and the fuel
flows into the return port. As a result, the nozzle is
pressed up along with the command piston by the fuel
pressure applied to the nozzle leading end and then the
nozzle injection hole opens to inject the fuel.
Injection end
When the ECM finishes supplying power to the solenoid,
the TWV comes down and the outlet orifice is closed. As
a result, the fuel stops flowing into the return port from
the control chamber and the fuel pressure within the
control chamber sharply rises. Then, the nozzle is pressed
1. Injector ID code
down by the command piston and the nozzle injection
2. Fuel leak-off pipe
hole is closed to stop fuel injection.
3. 2D barcode
Fuel supply pump regulated by the FRP regulator which is solely controlled
The fuel supply pump is the heart of the common rail by current supplied from the ECM. No current to the
type electronic fuel injection system. The fuel supply solenoid results in maximum fuel flow whereas full
pump is installed at the same location as the conventional current to the solenoid produces no fuel flow. As the
injection type pump, which rotates at a 1 to 1 ratio of fuel engine rotates, these two plungers produce high pressure
supply pump to crankshaft speed. The FRP regulator and in the fuel rail. Since the ECM controls the flow of fuel
fuel temperature sensor are part of the fuel supply pump into the 2 plunger chambers, it therefore controls the
assembly. quantity and pressure of the fuel supply to the fuel rail.
Fuel is drawn from the fuel tank via the fuel supply pump This optimizes performance, improves fuel economy and
by the use of a trochoid type internal feed pump. This reduces NOx emissions.
feed pump feeds fuel into 2 plunger chambers within the
fuel supply pump. Fuel into this plunger chamber is
Fuel rail
Along with the employment of a common rail type
electronic control fuel injection system, the fuel rail is
provided to store high pressure fuel between the fuel
supply pump and injectors. The FRP sensor and pressure
limiter are installed on the fuel rail. The FRP sensor
detects the fuel pressure inside the fuel rail and sends
signals to the ECM. Based on these signals, the ECM
controls the fuel pressure inside the fuel rail via the FRP
regulator of the fuel supply pump. The pressure limiter
opens the valve mechanically to relieve the pressure
when the fuel pressure inside the fuel rail is excessive.
1. Pressure limiter valve

2. FRP sensor
FRP sensor
The FRP sensor is installed onto the fuel rail and it
detects the fuel pressure in the fuel rail, converts the
pressure into a voltage signal, and sends the signal to the
ECM. The ECM monitors the FRP sensor signal voltage.
Higher fuel rail pressure provides higher signal voltage
while lower pressure provides lower signal voltage. The
ECM calculates actual fuel pressure from the voltage
signal and uses the result in fuel injection control and
other control tasks.
Pressure limiter valve
The pressure limiter relieves pressure by opening the
valve if abnormally high pressure is generated. The valve
opens when pressure in fuel rail reaches approximately
220 MPa (32000 psi), and closes when pressure falls to
approximately 50 MPa (7250 psi). Fuel relieved from the
pressure limiter returns to the fuel tank.

2. FRP regulator
Fuel injection quantity control

This control determines the fuel injection quantity by
adding coolant temperature, fuel temperature, intake air
temperature, barometric pressure and some switch input
information corrections to the basic injection quantity
calculated by the ECM based on the engine operating
conditions. More fuel rate indicates that the engine load is
1. Valve increased as the accelerator pedal is stepped on at
2. Valve body constant engine speed.
3. Valve guide Combined with high pressure injection of atomized fuel,
4. Spring this control improves exhaust gas and ensures proper fuel
5. Housing consumption. Compared with conventional mechanical
6. Fuel inlet governors, an electronic control system provides higher
7. Fuel outlet degree of freedom of fuel injection quantity control,
thereby presenting high accelerator response.
FRP regulator
Starting injection quantity control
The FRP regulator is installed on the fuel supply pump.
At the engine starting, optimum fuel injection quantity is
The ECM controls the duty ratio of the FRP regulator in
controlled based on the information on the engine speed
order to control the quantity of fuel supplied to the high-
and coolant temperature. At low temperature, the fuel
pressure plungers. Since only the quantity of fuel that is
injection quantity increases. When the engine started
required for achieving the target fuel rail pressure is
completely, this boosted quantity mode at the starting is
drawn in, the drive load of the fuel supply pump is
cancelled and normal running mode is restored.
decreased. When current flows to the FRP regulator,
variable electromotive force is created in accordance with Idle speed control
the duty ratio, moving the solenoid plunger to the right A control is made so as to achieve stable idling speed at
side and changing the opening of the fuel passage and all time regardless of changes to the engine overtime or
thus regulating the fuel quantity. With the FRP regulator engine condition variations. The ECM sets target idling
is off, the return spring stretches, completely opening the speed and controls the fuel injection quantity according to
fuel passage and supplying fuel to the plungers. When the the engine conditions so that the actual engine speed
FRP regulator is on, the fuel path is closed by the return follows the target idling speed ensuring a stable idling
spring force. By turning the FRP regulator on and off, the speed.
fuel is supplied in an amount corresponding to the
Idle vibration control
actuation duty ratio, and the fuel is discharged by the
Controls are performed to reduce the engine vibration
plungers.
caused by torque variations between cylinders due to
variations in fuel injection quantity of each cylinder or
injector performance. The ECM corrects the injection
quantity between cylinders based on the rotation signals ECM operates a motor to control the lift amount of EGR
from the CKP sensor. Normal range of correction valve. Also, the actual valve lift amount is fed back to the
quantity between cylinders is within (-5) - 5 mm 3. ECM for more precise control of the EGR amount.
The EGR control starts when the conditions for engine
EGR system
speed, coolant temperature, intake air temperature and
The EGR system re-circulates a part of the exhaust gas to
barometric pressure are satisfied. Then, the valve opening
the intake manifold, and by mixing in inert gas to the
is calculated according to the engine speed, and the target
intake air, the combustion temperature is lowered and the
fuel injection quantity is determined. Based on this valve
generation of NOx is suppressed. The EGR control
opening, the drive duty of the motor is provided and the
system uses an electronic control system to ensure both
valve is driven accordingly.
drivability and low emission. A control current from the
1. EGR cooler 5. ECM

2. Coolant outlet 6. MAF sensor
3. Coolant inlet 7. Intake throttle valve
4. EGR valve
EGR valve signal voltage at a small lift amount or closed position.

The EGR valve is mounted on the inlet manifold. The The ECM should detect high signal voltage at a large lift
ECM controls the EGR valve opening based on the amount.
engine running condition. The ECM controls the EGR
valve by controlling the motor. The motor is controlled
based on pulse width modulation signal sent from the
ECM via CAN. The EGR valve control is performed by
changing the duty ratio from 0 % to an appropriate
percentage. When the duty ratio increases, the valve
opens. When the duty ratio decreases, the valve closes.
The EGR valve position is detected by the controller
installed inside the EGR valve body, and signals are sent
to the ECM via CAN. The ECM should detect a low
The turbocharger is used to increase the amount of air
that enters the engine cylinders. This allows a
proportional increase of fuel to be injected into the
cylinders, resulting in increased power output, more
complete combustion of fuel, and increased cooling of the
cylinder heads, pistons, valves, and exhaust gas. This
cooling effect helps extend engine life.
Heat energy and pressures in the engine exhaust gas are
utilized to drive the turbine. Exhaust gas is directed to the
turbine housing. The turbine housing acts as a nozzle to
direct the shaft wheel assembly.
Since the compressor wheel is attached directly to the
shaft, the compressor wheel rotates at the same speed as
the turbine wheel. Clean air from the air cleaner is drawn
into the compressor housing and wheel. The air is
compressed and delivered through a crossover pipe to the
engine air intake manifold, then into the cylinders.
Intake throttle valve

The intake throttle valve is located on the inlet manifold.
The ECM controls the intake throttle valve opening based
on the engine running condition. The ECM controls the
intake throttle valve by controlling the motor. The motor
is controlled based on pulse width modulation signal sent
from the ECM. The intake throttle valve opening angle is
controlled by changing the duty ratio from 0 % to the
appropriate percentage. When the duty ratio increases, the
valve closes. When the duty ratio decreases, the valve
opens.
The intake throttle valve position is detected by the
position sensor, and relayed to the ECM. The position
sensor provides a signal to the ECM on the signal circuit,
which is relative to the position changes of the intake
throttle valve. The ECM should detect a low signal
voltage at a small opening amount or closed position. The
ECM should detect high signal voltage at a large opening
amount.
1. Exhaust gas
2. Wastegate valve
3. Turbine wheel
4. Compressor wheel
5. Air cleaner
6. Intercooler
The amount of air pressure rise and air volume delivered

to the engine from the compressor outlet is regulated by
the wastegate in the exhaust housing. The wastegate
valve position is controlled by the pressure amount
Turbocharger accumulated at the intake side of the turbocharger. The
diaphragm inside the wastegate is sensitive to pressure. It
controls the valve position inside the turbocharger. The
valve position increases or decreases boost amount to the
turbocharger. (Standard output engine)
The amount of air pressure rise and air volume delivered
to the engine from compressor outlet is regulated by a
turbocharger nozzle control actuator indirectly. The
position of the turbocharger nozzle is controlled by the
ECM. The ECM utilizes a turbocharger nozzle control
solenoid valve and a boost pressure sensor to control the
turbocharger nozzles. When the engine is not under load,
the turbocharger nozzles are in open position A, or no
boost condition. When the engine is under load, the ECM
commands the control solenoid valve to close the
turbocharger nozzles as B, thus increasing the boost. The
ECM varies the boost dependent upon the load
requirements of the engine. The ECM uses a pulse width
modulation on the control circuit to open and control the
solenoid valve. (High-output engine)
The intercooler also helps the performance of the diesel.
Intake air is drawn through the air cleaner and into the
turbocharger compressor housing. Pressurized air from
the turbocharger then flows forward through the
intercooler located in the front of the radiator. The air
from the intercooler flows back into the intake manifold.
The intercooler is a heat exchanger that uses air flow to
dissipate hear from the intake air. As the turbocharger
increases air pressure, the air temperature increases. 1. Turbocharger nozzle control actuator
Lowering the intake air temperature increases the engine 2. Nozzle
efficiency and power by packing more air molecules into
the same space. Cylinder block
The cylinder block is cast iron, and has a highly rigid
structure with appropriate rib placement.
Piston
The pistons are thermal flow pistons made of an
aluminum alloy and cast struts, and the combustion
chamber is a spherical re-entrant type.
Cylinder heads
The heads are aluminum alloy. They have four valves per
cylinder. Tighten the head bolts using the plastic region
rotational angle tightening method. The plastic region
rotational angle tightening method further improves
reliability and durability.
Connecting rod cap bolt
Tighten the mounting bolt of the connecting rod cap
using the plastic region rotational angle tightening
method.
Fuel filter with sedimenter
This is a fuel filter that has a sedimenter to remove
moisture content by using the difference of the relative
density of light diesel oil and water, and has an indicator
which shows water accumulation.
3. Sedimenter switch
Cooling system
The cooling system is a force-circulation system, and its
main components are a water pump, thermostat, cooling
fan and radiator.
For the engine to run smoothly, the coolant circulates
through the bypass pipe by the water pump and
thermostat to return to the cylinder body, in order to raise
the temperature of the engine coolant quickly. At this
time, the coolant does not circulate through the radiator.
When the coolant temperature reaches the specified
value, the thermostat begins to open to gradually increase
the amount of coolant circulating through the radiator.
When the coolant temperature reaches the specified
value, the thermostat is fully opened. Then all of the
coolant circulates through the radiator to cool the engine
effectively.
1. Clogging switch The diagram shows the high-output specifications.
2. Fuel filter element
1. Thermostat 7. Cylinder block

2. Turbocharger 8. Water pump
3. EGR cooler, with EGR cooler specification only 9. Cooling fan
4. Cylinder head 10. Radiator
5. Oil cooler 11. Reserve tank
6. Heater
Water pump The water pump cannot be disassembled.

The centrifugal water pump performs forced circulation
of the coolant through the cooling system.
Thermostat The thermostat is a wax pellet type.
Radiator
The radiator is a tube type with corrugated fins. To raise
the boiling point of the coolant, a pressurized radiator cap
is attached. The open valve pressure of the radiator cap is
93.3 - 122.7 kPa (0.95 - 1.25 kg/cm2 / 13.5 - 17.8 psi).
Opening/closing mechanism of the radiator cap is double-
action.
Manual transmission vehicles are not equipped with an
oil cooler.
Caution：
・ When removing the radiator cap, do not pull it
by force, but loosen it until it cannot rotate
further.
・ To install the cap, turn the radiator cap until it
does not turn.
Starting system relay, etc. Each of these main components are wired as
The starting system is composed of the batteries, starter, shown in the starter circuit diagram.
ignition switch, inhibitor switch (for A/T only), starter
1. Pinion clutch 7. Inhibitor switch (for A/T vehicles only)

2. Ring gear 8. Starter relay
3. Shift lever 9. Ignition switch
4. Magnetic switch 10. Battery
5. S-terminal 11. Armature
6. B-terminal
Note：
・ Starting circuit diagram
Starter ring gear, and when the ring gear rotates the engine starts.
The starter is a magnetic shift type starter and is an outer After the engine starts, the plunger returns, the pinion
gearing mesh method reduction starter. separates from the ring gear, and the armature stops
The contact point of the magnetic switch closes and the rotating when the ignition switch is turned OFF. When
armature rotates when the ignition switch is turned ON. the engine rotation increases faster than the pinion, the
At the same time, the plunger is drawn in and the pinion pinion will be caused to turn in reverse, but because the
is pushed to the front via the shift lever to mesh with the pinion is idling, it does not drive the armature.
1. Lead wire 13. Yoke

2. Bolt 14. Armature
3. Magnetic switch assembly 15. Bolt
4. Torsion spring 16. Bearing retainer
5. Plunger 17. Pinion assembly
6. Dust cover 18. Pinion stopper clip
7. Magnetic switch 19. Pinion stopper
8. Screw 20. Return spring
9. Through bolt 21. Pinion shaft
10. Rear cover 22. Clutch
11. Motor assembly 23. Dust cover
12. Brush holder 24. Shift lever
25. Gear case
Note：
・ Ignition switch
Charging system There are 8 diodes in the rectifier connected to the stator
The charging system is an IC integral regulator charging coil to convert alternating current voltage into direct
method. The main components are connected as shown in current voltage. The direct current voltage is connected to
the circuit diagram. The regulator is an integrated solid- the generator output terminal.
state type regulator. This is installed onto the rear end The generator used for 4JK1 engine cannot be
cover along with the brush holder assembly and is built- disassembled.
in to the generator.
Note：
Generator maintenance, such as adjusting the voltage is
unnecessary. ・ Generator
Note：
・ Circuit diagram
Exhaust system The main components consist of front exhaust pipe and
exhaust silencer.
1. Front hanger rubber 4. Rear hanger rubber

2. Front exhaust pipe 5. Exhaust silencer
3. Silencer hanger rubber
Lubrication system Oil flows through the water cooling oil cooler and around
A full-flow bypass integrated filter element, water- each sliding section from the oil gallery for lubrication.
cooling oil cooler, and piston coolant oil jet are adopted
for the lubrication system.
Note：
・ Engine control component location diagram
1. Accelerator pedal position sensor

1. Barometric pressure sensor 1. CMP sensor

2. Engine coolant temperature sensor
1. No.1 cylinder injector

2. No.2 cylinder injector 1. CKP sensor
1. Boost sensor 1. Common rail

2. Turbocharger control solenoid valve 2. Pressure limiter valve
3. FRP sensor
1. EGR valve
2. Intake throttle valve 1. FRP regulator
1. Swirl control solenoid valve

2. Swirl control actuator
1. Vehicle speed sensor, MT specification

2. Vehicle speed sensor, AT specification 2WD
1. MAF sensor 3. Vehicle speed sensor, 4WD
1. ECM
Note：
・ Vacuum hose routing diagram
1. Swirl control solenoid valve 7. Actuator control vacuum hose

2. Actuator control vacuum hose 8. Air cleaner
3. Swirl control actuator 9. Turbocharger nozzle control actuator
4. Brake booster 10. Solenoid valve ventilation hose
5. Vacuum pipe 11. Turbocharger nozzle control solenoid valve
6. Vacuum pump
Note：
・ Brief wiring diagram
ECM pin layout (81 pin connector）
PIN No. Pin function

A1 ECM power ground
A2 Battery voltage
A3 ECM power ground
A4 ECM power ground
A5 Battery voltage
A6 MIL control
A7 Not used
A8 Not used
A9 Not used
A10 Glow plug relay control
A11 Not used
A12 A/C compressor relay control
A13 Not used
A14 Starter cut relay control

A15 Not used
A16 Not used
A17 Not used
A18 Not used
A19 VSS signal
A20 APP sensor 1 shield ground
A21 ECM main relay control
A22 MAF sensor low reference
A23 Not used
A24 Ignition voltage
A25 Not used
A26 Clutch pedal switch 1 signal
A27 Brake switch signal
A28 Not used
A29 Ground
A30 Clutch pedal switch 2 signal
A31 Not used
A32 Not used
A33 Not used
A34 Thermo relay signal
A35 Not used
A36 Not used
A37 Not used
A38 Not used
A39 APP sensor 2 shield ground
A40 ECM main relay control
A41 APP sensor 1 low reference
A42 APP sensor 1 5 volts reference
A43 ECM signal ground
A44 Not used
A45 Not used
A46 Ignition switch signal
A47 Not used
A48 Not used
A49 Not used
P or N range switch (A/T)
A50
Neutral switch (M/T)
A51 Not used
A52 Diagnostic request switch
A53 Not used
A54 Not used
A55 Not used
A56 Not used
A57 Not used
A58 CAN high signal
A59 MAF sensor shield ground

A60 APP sensor 2, BARO sensor and IAT sensor low reference
A61 APP sensor 2 and BARO sensor 5 volts reference
A62 ECM signal ground
A63 APP sensor 1 signal
A64 APP sensor 2 signal
A65 Not used
A66 Not used
A67 Not used
A68 Not used
A69 MAF sensor signal
A70 Not used
A71 BARO sensor signal
A72 IAT sensor signal
A73 Not used
A74 Not used
A75 Not used
A76 Not used
A77 Not used
A78 CAN low signal
A79 Not used
A80 Not used
A81 ECM case ground
ECM pin layout (40 pin connector）
PIN No. Pin function

B1 FRP sensor signal
B2 FT sensor signal
B3 ECT sensor signal
B4 Intake throttle position sensor signal
B5 Not used
B6 CMP sensor and FRP sensor 5 volts reference
B7 Swirl control solenoid valve control
B8 FRP regulator low side
B9 FRP sensor signal
B10 Boost pressure sensor signal
B11 Not used
B12 Not used
B13 Not used
B14 CKP sensor, intake throttle position sensor and boost pressure sensor 5 volts reference
B15 Turbocharger nozzle control solenoid valve control
B16 FRP regulator low control
B17 CMP sensor signal
B18 Not used
B19 CMP sensor and FRP sensor shield ground
B20 CMP sensor and FRP sensor low reference

B21 Not used
B22 Not used
B23 Intake throttle control low side
B24 FRP regulator control high side
B25 Fuel filter switch signal
B26 CKP sensor signal
B27 CKP sensor and boost pressure sensor shield ground
B28 CKP sensor, intake throttle position sensor, boost pressure sensor, FT sensor and ECT sensor low reference
B29 Not used
B30 Not used
B31 Intake throttle drive voltage
B32 FRP regulator control high side
B33 Not used
B34 Not used
B35 Common 2 (Cylinder #2 and #3) fuel injector charge voltage
B36 Cylinder #4 fuel injector control
B40 Common 1 (Cylinder #1 and #4) fuel injector charge voltage
2. Engine number Note：
・ Engine number stamping position
1. Engine model 3. Front

2. Engine number
Primary specifications of engine

1. Primary specifications of engine Note：
・ Engine mechanical primary specifications
Item Specifications
Engine model 4JK1
Type Diesel, 4-cycle, water-cooled inline DOHC
Shape of combustion chamber Direct injection
Cylinder liner type No liner
Number of cylinders - inner diameter x stroke 4 - 95.4 x 87.4 mm {3.76 x 3.44 in}
Total piston displacement ： 2.499 L {152 in3}
Compression ratio 18.1
Compression pressure ： 3 MPa { 435 psi } / 200 r/min
Idling speed ： 675 to 725 r/min
Valve Intake ： 0.15 mm { 0.0059 in } , while cool
clearance Exhaust ： 0.15 mm { 0.0059 in } , while cool
Ignition system Compressed ignition
Injection order 1, 3, 4, 2
Lubrication Lubricating method Force feed method
device Type of oil pump Gear type
Lubricant total capacity ： 7.8 L { 1.7 Imp.gal }
Type of oil filter Full-flow filter, cartridge type
Oil cooler type Built-in type, water cooled
Cooling Cooling method Coolant forced-circulation system
device Radiator type Corrugated fin type, force feed type
Water pump type Centrifugal impeller type, belt driven type
Thermostat type Wax type unit
Coolant capacity
： 4.0 L { 0.88 Imp.gal }
engine only
： 10.2 L { 2.24 Imp.gal } MT vehicles, with heater
： 10.1 L { 2.22 Imp.gal } AT vehicles, with heater
Coolant capacity ： 9.4 L { 2.07 Imp.gal } MT vehicles, excluding those with
radiator included heater
： 9.3 L { 2.05 Imp.gal } AT vehicles, excluding those with
heater
Fuel device Injection pump type Fuel supply pump, common rail type
Injection nozzle type Electronically controlled injector, 8 holes
Charging Generator type Alternating current type
device Power output ： 12 V - 90 A
Regulator type IC type
Starter device Starting method Engage magnet type
Starter type Reduction type
Power output ： 12 V - 2.3 kW
Preheat Type Glow plug
device Glow plug standard - current ： 12 V - 3.5 A
Note：
・ Primary specifications of the cooling system
Item Specifications
Radiator Heat dissipation capacity ： 93 kW {80.2 kcal/h}
Heat dissipation surface 11.63 m2 {125.2 ft2}
Front surface area 0.28 m2 {3 ft2}
Dry mass M/T
： 5.2 kg { 11.5 lb }
vehicles
AT
： 5.4 kg { 11.9 lb }
vehicles
Radiator cap ： 93.3 to 122.7 kPa { 0.95 to 1.25 kgf/cm2 / 13.5 to
Open valve pressure
17.8 psi }
Water pump Pulley ratio 1.250
Delivery amount
Pump rotation speed 5600 rpm ： 240 L { 52.8 Imp.gal } /min
At water temperature 30 ℃ {86 °F}
Pump bearing type Double row axle
Thermostat Initial opening temperature ： 85 ℃ { 185 °F }
Full-open temperature ： 100 ℃ { 212 °F }
Valve lift amount when fully
： 10 mm { 0.39 in }
opened
Note：
・ Primary specifications of lubrication system
Item Specifications
Oil pump relief valve operating pressure ： 490 to 686 kPa { 5.0 to 7.0 kgf/cm2 / 71.1 to 99.5 psi }
Oil cooler relief valve operating pressure ： 176 to 216 kPa { 1.8 to 2.2 kgf/cm2 / 25.5 to 31.3 psi }
Oil filter relief valve operating pressure ： 80 to 120 kPa { 0.8 to 1.2 kgf/cm2 / 11.6 to 17.4 psi }
Oil pressure switch operating pressure ： 29.4 to 49.0 kPa { 0.3 to 0.5 kgf/cm2 / 4.3 to 7.1 psi }
Regulating valve ： 176 to 216 kPa { 1.8 to 2.2 kgf/cm2 / 25.5 to 31.3 psi }
Note：
・ Primary specifications of the electrical system
Generator primary specifications

Battery power source ： 12 V
Generator output ： 90 A
Rotational direction , seen from the pulley side Clockwise
Rated speed ： 5000 r/min
Maximum speed ： 18000 r/min
Note：
・ Exhaust system primary specifications
Silencer Round section shell structures of double-skin and end plate, baffle and
Type
and tail pipe perforated tube internal structures
Installation Suspension
4
Number of points
Type Rubber
Introduction to the trouble diagnosis of engine

1. Introduction to the trouble diagnosis of engine The use of the Diagnostic System Check - Engine
Controls will identify the correct procedure for
Begin the system diagnosis with Diagnostic System
diagnosing the system and where the procedure is
Check - Engine Controls. The Diagnostic System Check -
located.
Engine Controls provides the following information.
Identification of the control modules which command the Engine Control System Check Sheet must be used to
system. verify the customer complaint. You need to know the
The functions of the control modules to communicate correct operating behavior of the system and verify that
through the serial data circuit. the customer complaint is a valid failure of the system.
Identification of stored DTCs and their statuses.
Reading blinking DTCs The system for communicating with the ECM is the Data
Link Connector (DLC). The DTC(s) stored in the ECM
memory can be read either by connecting a hand-held indicates that there is a current failure DTC or DTC in the
diagnostic scanner such as a scan tool with the DLC or by failure history. If more than one DTC has been stored in
counting the number of blinking of the MIL when the the ECM's memory, the DTCs will be output numerical
diagnostic test terminal of the DLC is grounded. order with each DTC being displayed three times. The
The DLC terminal 12 is grounded by shorting to the blinking DTC display continues as long as the DLC is
ground line DLC terminal 4. Once terminals 12 and 4 shorted.
have been connected, turn the ignition switch on, without
starting the engine. If the MIL blinks DTC three times, it
DTC type definition The current DTC is cleared when the diagnosis is
The DTC has three types; Type A, B, and D. Among completed successfully after the one driving cycle.
these DTCs, Type A and B DTCs are related to emission After 40 consecutive warm-up cycles with no failure
whereas Type D DTCs are related to items other than detected, the DTC history will be deleted.
emission. Use a scan tool to clear the MIL and the DTC.
Actions taken when a DTC is set, Type A Actions taken when a DTC is set, Type D
When a diagnosis is conducted and an abnormality is The ECM does not illuminate the MIL.
detected, the ECM illuminates the MIL. The ECM records the operating conditions at the time
The ECM records the operating conditions at the time when the abnormality is detected. The ECM stores this
when the abnormality is detected. The ECM stores this information in the Failure records.
information in the Freeze frame/Failure records.
Condition for clearing the DTC, Type D
Actions taken when a DTC is set, Type B The current DTC is cleared when the diagnosis is
When a diagnosis is conducted and an abnormality is successfully completed after one driving cycle.
detected in the consecutive driving cycle, the ECM After 40 consecutive warm-up cycles with no failure
causes the MIL to illuminate during the second detected, the DTC history will be deleted.
consecutive driving cycle. Use a scan tool to clear the DTC.
The ECM records the operating conditions at the time
when an abnormality is detected. The first time the
abnormality is detected, the ECM stores this information
in the Failure records. If a second abnormality is detected
during the next driving cycle, the ECM records the
operating conditions at the time when it is detected and
stores this information in the Freeze frame. At this time,
the Failure records are updated.
Condition for clearing the MIL/DTC
When a diagnosis is formed, and no DTC is detected after
the one driving cycle, the ECM turns MIL OFF.
Functional Inspection (4JK1) 15C-1
Description Engine
Functional Inspection
(4JK1)
Table of Contents
Diagnostic system check-engine controls.....................15C-2
Scan tool does not communicate with CAN device......15C-4
Lost communication with the ECM..............................15C-7
Fuel system check.........................................................15C-9
EGR control system check..........................................15C-12
Glow control system check.........................................15C-13
Engine compression pressure inspection.....................15C-14
Glow system check......................................................15C-15
Lubricating system inspection.....................................15C-16
Turbocharger control system check............................15C-17
Charging system check................................................15C-19
15C-2 Functional Inspection (4JK1)
Diagnostic system check-engine controls

1. Diagnostic system check-engine controls description Note：
of function ・ If it does not start, check for a DTC with a scan
Inspection of the engine control system is a method for tool.
checking problems caused by malfunctions in the engine If the immobilizer system is activated, the ECM
control system. This system check is the starting point of deactivates the fuel injection and performs starter cut to
drivability complaint diagnosis. Move from system check cancel cranking.
to the next logical step to diagnose a problem(s).
Understanding and correctly using the diagnostic table Note：
reduces diagnostic time, and prevents the replacement of ・ If a DTC is detected, inspect the applicable
good parts. DTC.
Note：・ If a DTC is not detected, inspect the starting
system.
・ Important points to remember regarding the
engine control system inspection 3. Use a scan tool to check for a DTC of the ECU that
has communication established.
If there are no complaints on drivability, do not perform
these diagnostic steps unless otherwise instructed to do Loss of communication with a scan tool occurs due to the
so. abnormalities in the communication circuit of each ECU
Confirm the service technical report before starting the and a scan tool.
diagnosis.
Note：
Do not delete the DTCs unless it is instructed in a
diagnostic step. ・ If a DTC related to communication with other
If a malfunction is found in the engine starting system, ECUs or a DTC beginning with U is detected,
inspect the starting system. inspect the applicable DTC.
The battery should be fully charged. Detection of a DTC beginning with U indicates that there
The battery cable should be normal and securely is no communication with other ECUs.
connected.
The ground of the ECM should be securely connected in Note：
the correct position. ・ If DTCs P0601, P0602, P0604, P0606, or
Ensure that the ECM harness connectors are clean and P1621 are detected in the ECM, inspect the
correctly connected. applicable DTC.
Do not attempt to crank the engine with the ECM harness ・ If DTC P0562 or P0563 has been detected in
connectors disconnected. the ECM, inspect the applicable DTC.
Ensure that the ECM terminals are correctly connected. ・ If other DTCs have been detected, inspect the
Ensure that the injector ID code is programmed correctly. applicable DTC.
Ensure that immobilizer information is programmed
correctly. When multiple DTCs are set, start diagnosing from a
If fuel system DTCs (P0087, P0088, P0089, P0093 or DTC with a smaller number unless otherwise instructed
P1093) or other DTCs are detected, diagnose sensor in the diagnostic step.
DTCs, solenoid DTCs, actuator DTCs and relay DTCs Diagnose multiple DTCs in this range in order of DTCs
first. at the component level such as the sensor DTC, actuator
2. Diagnostic system check-engine controls inspection DTC, and relay DTC.
Inspection for determining the failure location in the 4. Check for a failure which makes starting difficult.
engine control system 5. Check for failures such as hunching or rough idle.
1. Check if communication with the ECM is available 6. Check for high idling rotation failure.
using a scan tool.
7. Check for sudden stop failure.
Note：
8. Check for sudden change failure.
・ If communication is not possible, check the
communication circuit of the scan tool. 9. Check for insufficient output or blowup failure.
2. Start the engine. 10. Check for chuffing or acceleration failure.
11. Check for abnormal combustion sound failure.
12. Check for poor fuel economy failure.
13. Check for black smoke failure.
14. Check for white smoke failure.
Scan tool does not communicate with CAN device

1. Scan tool does not communicate with CAN device 12. Turn ON the ignition switch.
description of function
13. Confirm if communication can be made with the
The ECM, EHCU, TCM, TCCM, SRS control unit, ICU, control units other than the TCM using a scan tool.
BCM, and instrument panel cluster communicate with a
14. When communication can be made with all the
scan tool via the CAN communication circuit. The
control units, replace the TCM.
EHCU, ECM, TCM, TCCM, auto A/C control unit, SRS
control unit, immobilizer control unit, BCM, instrument Refer to "5.Transmission, Transaxle
panel cluster, DRM and EGR control unit communicate 5B.Automatic(TB-50LS) TCM removal".
with each other via the same CAN communication
Refer to "5.Transmission, Transaxle
circuit. CAN terminating resistors are installed on the
5B.Automatic(TB-50LS) TCM installation".
ECM and the instrument panel cluster.
15. Set the vehicle information on the TCM.
2. Scan tool does not communicate with CAN device
inspection Refer to "5.Transmission, Transaxle
5B.Automatic(TB-50LS) TCM setting".
1. Check the vehicle specifications and confirm the
status of communication with the following control 16. Turn OFF the ignition switch.
unit using the scan tool. 17. Connect the harness connector to the TCM.
Note： 18. Disconnect the harness connector from the ICU.
・ ECM
19. Turn ON the ignition switch.
・ EHCU (if equipped)
・ TCM (A/T TB-50LS only) 20. Confirm if communication can be made with the
control units other than the ICU using a scan tool.
・ TCCM (4WD)
・ SRS control unit (if equipped) 21. When communication can be made with all the
control units, replace the ICU.
・ ICU (if equipped)
・ BCM (if equipped) Refer to "9.Body, Cab, Accessories 9J.Security and
Locks(All models) ICU removal".
・ Instrument panel cluster
Refer to "9.Body, Cab, Accessories 9J.Security and
2. When communication cannot be made with the Locks(All models) ICU installation".
ECM, inspect a scan tool communication circuit.
22. Set the authentication information on the ICU.
3. When communication cannot be made with any of
the control units other than the ECM, inspect a scan Refer to "9.Body, Cab, Accessories 9J.Security and
tool communication circuit of the relevant system. Locks(All models) ICU setting".
4. If communication cannot be made with all the 23. Turn OFF the ignition switch.
control units, turn the ignition switch OFF. 24. Connect the harness connector to the ICU.
5. Disconnect the harness connector from the DRM. 25. Disconnect the harness connector from the
6. Turn ON the ignition switch. instrument panel cluster.
7. Confirm if communication can be made with the 26. Turn ON the ignition switch.
control units other than the DRM using a scan tool. 27. Confirm if communication can be made with the
8. When communication can be made with all the control units other than the instrument panel cluster
control units, replace the DRM. using a scan tool.
Refer to "9.Body, Cab, Accessories 9E.Instrumentation, 28. When communication can be made with all the
Driver Info.(All models) DRM removal". control units, replace the instrument panel cluster.
Refer to "9.Body, Cab, Accessories 9E.Instrumentation, Refer to "9.Body, Cab, Accessories 9E.Instrumentation,
Driver Info.(All models) DRM installation". Driver Info.(All models) Instrument panel
cluster removal".
9. Turn OFF the ignition switch.
Refer to "9.Body, Cab, Accessories 9E.Instrumentation,
10. Connect the harness connector to the DRM. Driver Info.(All models) Instrument panel
11. Disconnect the harness connector from the TCM. cluster installation".
29. Write the vehicle information into the instrument Refer to "4.Brakes 4D.ABS(All models)
panel cluster. EHCU installation".
Refer to "9.Body, Cab, Accessories 9E.Instrumentation, 48. Write the vehicle information into the EHCU.
Driver Info.(All models) Instrument panel
Refer to "4.Brakes 4D.ABS(All models)
cluster setting".
EHCU setting".
31. Connect the harness connector to the instrument
50. Connect the harness connector to the EHCU.
panel cluster.
51. Disconnect the harness connector from the EGR
32. Disconnect the harness connector from the auto A/C
valve.
control unit.
53. Confirm if communication can be made with the all
34. Confirm if communication can be made with the all
control units using a scan tool.
control units using a scan tool.
control units, replace the EGR valve.
control units, replace the auto A/C control unit.
Refer to "1.Engine 1H.Aux. Emission Control
Refer to "7.HVAC 7B.Heater, Ventilator,
Devices(4JK1) EGR valve removal".
Airconditioner(All models) Control panel
assembly removal". Refer to "1.Engine 1H.Aux. Emission Control
Devices(4JK1) EGR valve installation".
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Control panel 55. Turn OFF the ignition switch.
assembly installation".
56. Connect the harness connector to the EGR valve.
57. Disconnect the harness connector from the SRS
37. Connect the harness connector to the auto A/C control unit.
control unit.
38. Disconnect the harness connector from the TCCM.
39. Turn ON the ignition switch. control units other than the SRS control unit using a
scan tool.
control units other than the TCCM using a scan tool. 60. When communication can be made with all the
control units, replace the SRS control unit.
control units, replace the TCCM. Refer to "8.Restraints 8B.Air Bag Systems(All models)
SRS control unit removal".
Refer to "3.Driveline, Axle 3D.Transfer Case(All
models) TCCM removal". Refer to "8.Restraints 8B.Air Bag Systems(All models)
SRS control unit installation".
Refer to "3.Driveline, Axle 3D.Transfer Case(All
models) TCCM installation". 61. Turn OFF the ignition switch.
42. Turn OFF the ignition switch. 62. Connect the harness connector to the SRS control
unit.
43. Connect the harness connector to the TCCM.
63. Disconnect the harness connector from the BCM.
44. Disconnect the harness connector from the EHCU.
control units other than the BCM using a scan tool.
control units other than the EHCU using a scan tool.
control units, replace the BCM.
control units, replace the EHCU.
Driver Info.(All models) BCM removal".
EHCU removal".
Driver Info.(All models) BCM installation".
67. Write the vehicle information into the BCM.
Driver Info.(All models) BCM setting".
68. If communication cannot be made with all the
control units, inspect CAN low and CAN high
circuits.
Note：
・ There should be no short circuit to the battery
or ignition power supply circuit.
・ There should be no short circuit between CAN
circuits.
・ There should be no short circuit to the low
reference circuit.
・ There should be no short circuit with a metal
component such as the frame.
69. When the circuit is normal, replace the ECM.
Refer to "1.Engine 1J.Electrical(4JK1)
ECM removal".
ECM installation".
70. Set the immobilizer function and injector ID code on
the ECM.
Refer to "1.Engine 1J.Electrical(4JK1) ECM setting".
71. Conduct the unit difference learning of fuel supply
pumps on the ECM.
Refer to "1.Engine 1J.Electrical(4JK1) ECM writing".
72. Restore the vehicle.
74. Confirm that communication can be made with the
all control units using a scan tool.
Lost communication with the ECM

1. Lost communication with the ECM description of 14. When the CAN circuit is normal, replace the ECM.
function
The ECM, EHCU, TCM, TCCM, SRS control unit, ICU, ECM removal".
BCM, and instrument panel cluster communicate with a
scan tool via the CAN communication circuit. The
ECM installation".
EHCU, ECM, TCM, TCCM, auto A/C control unit, SRS
control unit, immobilizer control unit, BCM, instrument 15. Set the immobilizer function and injector ID code on
panel cluster, DRM and EGR control unit communicate the ECM.
with each other via the same CAN communication
circuit. CAN terminating resistors are installed on the
ECM and the instrument panel cluster. 16. Conduct the unit difference learning of fuel supply
pumps on the ECM.
2. Lost communication with the ECM inspection
1. Inspect the ECM harness connector for any improper
connection. 17. Turn OFF the ignition switch.
2. If a problem is found, repair connection with the 18. Disconnect the harness connector from the ECM.
harness connector. 19. Turn ON the ignition switch.
3. Inspect the ECM 40 A slow blow fuse and Engine 10 20. Connect a test light to the ignition power supply
A fuse. circuit of the ECM harness connector.
4. If a problem is found, replace the fuse. 21. When the test light does not turn on, repair any open
Note： circuit in the ignition power supply circuit.
・ When the fuse is wire-melted again, repair the 22. Inspect the ECM ground circuit.
cause of fuse meltdown.
Note：
5. Disconnect a scan tool from the DLC. ・ There should be no open circuit.
6. Measure the resistance value between the CAN high 23. If a problem is found, repair the ground circuit.
and CAN low circuits of the DLC.
24. Connect the harness connector to the ECM.
Standard： 50 to 70 Ω
25. Replace the ECM main relay with a heater relay or a
7. When the resistance value is outside the standard non-defective part.
value range, disconnect the harness connector from
the ECM. 26. Turn ON the ignition switch.
8. Inspect the ECM harness connector for a contact 27. Confirm if communication with the ECM is
failure. available using a scan tool.
9. If a problem is found, repair the harness connector. 28. When communication can be made, replace the ECM
main relay.
10. Inspect the CAN Low circuit between the ECM and
DLC. 29. Turn OFF the ignition switch.
Note： 30. Remove the ECM main relay.
・ There should be no open circuit or high 31. Turn ON the ignition switch.
resistance.
32. Connect a test light between the power supply circuit
11. If a problem is found, repair the CAN low circuit. of the ECM main relay and the frame ground.
12. Inspect the CAN high circuit between the ECM and 33. When the test light does not turn on, repair the power
DLC. supply circuit for the ECM main relay.
Note： 34. Turn OFF the ignition switch.
・ There should be no open circuit or high 35. Install the ECM main relay.
resistance.
36. Turn the ignition switch ON while touching the
13. If a problem is found, repair the CAN high circuit. ECM main relay.
37. Turn the ignition switch OFF after 7 seconds.
38. If the operation sounds of the ECM main relay
cannot be heard, inspect the ECM main relay and the
ground terminal for an improper connection.
39. If the relay connection is normal, repair the ground
circuit of the ECM main relay.
40. Inspect the battery power supply circuit between the
ECM main relay and the ECM.
Note：
・ There should be no open circuit or high
resistance.
41. If a problem is found, repair the battery power
supply circuit.
42. When the battery power supply circuit is normal,
replace the ECM.
ECM removal".
ECM installation".
the ECM.
pumps on the ECM.
Fuel system check

1. Fuel system check description of function Note：
A typical common rail system is comprised of the ・ If an injector does not click (which is a solenoid
following 2 fuel pressure sections. A suction side operating noise) but an interfering noise or
between the fuel tank and the fuel supply pump and a abnormal noise is heard when "ON" is
high-pressure side between the fuel supply pump and the commanded, replace the injector.
injector assembly. Caution：
Fuel is drawn from the fuel tank and then pumped into
・ Be sure to program the replaced injector
the common rail by two plungers in the fuel supply
assembly.
pump.
This high pressure is regulated by the ECM using the 7. Inspect the high pressure side between the fuel
suction control valve depending on values from the FRP supply pump and the injector assembly to confirm
sensor attached to the common rail. that there is no fuel leakage.
If the common rail pressure becomes excessive, the
Note：
pressure limiter valve in the common rail opens to release
excessive pressure and return the fuel into the fuel tank. ・ The following components may leak to the
outside.
A service technician performs an appropriate inspection
・ Fuel supply pump
by inspecting the fuel system.
The inspection of the fuel system assumes the following ・ Common rail
conditions are met. ・ Pressure limiter valve
The battery is fully charged and terminals are cleaned and ・ FRP sensor
tightly connected. ・ Fuel pipe between the fuel supply pump and
The engine cranking speed is normal. the common rail
There is adequate fuel in the fuel tank.
There is no air in the fuel line. ・ Fuel pipe between the common rail and the
Fuse and slow blow fuse are normal. injector assembly
・ Sleeve nut of the fuel pipe
The vacuum state in the fuel system from the fuel tank(s)
to the fuel supply pump comes loose with the engine 8. Inspect the engine oil level.
running. As a result, air can enter the fuel system if these Fuel may leak under the cylinder head cover from the
connections are not tight. Air in the fuel system will fuel high pressure line. In such case, the engine oil level
cause common rail pressure fluctuations especially at will rise.
high engine speed and load.
If the fuel tank is empty or near empty, air might be 9. Inspect the fuel system line between the fuel tank
allowed to go into the fuel system. and the fuel supply pump.
With air in the fuel system, smooth flow of fuel into the Note：
supply pump is interrupted and this DTC may be set.
・ There should be no compression in the fuel
Perform air removal of the fuel system after refilling.
system line.
2. Fuel system check inspection ・ There should be no cuts or cracks in the fuel
1. Install a scan tool. hose.
・ Clamps should be correctly used.
2. Turn the ignition switch OFF for 30 seconds.
The vacuum state in the fuel system from the fuel tank(s)
3. Turn the ignition switch ON with the engine being
to the fuel supply pump comes loose with the engine
OFF.
running. As a result, air can enter the fuel system if these
4. Monitor the DTC information with a scan tool. connections are not tight. Air in the fuel system will
Note： cause common rail pressure fluctuations especially at
high engine speed and load, which may set a DTC.
・ If a DTC has been detected, inspect the
applicable DTC. 10. Pump the priming pump until it becomes stable.
5. Perform the injector forced drive with a scan tool. If there is a leak on the suction side of the fuel system
between the priming pump and the fuel supply pump, the
6. Command "ON" to each injector, and confirm that a priming pump will not be sufficiently stable and fuel
clicking noise from solenoid operation is heard. leakage may occur.
11. Inspect fuel. Caution：
Note：・ Use a pan to collect the fuel from the removed
fuel line.
・ Confirm that the fuel tank has an adequate
amount of fuel and that the fuel quality is good 20. Install the vacuum pump to the fuel feed hose.
by taking a sample.
12. Start the engine and put it into the idling state.
Note：
・ Bleed the air from the fuel system as
necessary.
・ When the engine does not start, continue to
crank.
SST: 5-8840-0279-0 - vacuum pump
13. Observe the actual common rail pressure and the
target common rail pressure parameter on the scan Caution：
tool while cranking the engine or running the engine. ・ The vacuum pump must be cleaned before
connecting to the fuel line.
Note：
・ Confirm that the difference between the actual 21. Confirm that the vacuum pump and the fuel line are
common rail pressure and the targeted securely connected.
common rail pressure is within the standard 22. Crank the engine while monitoring the gauge on the
value range. vacuum pump.
Standard： -5.0 to 5.0 MPa { -50.99 to 50.99 kgf/cm2 / Note：
-725 to 725 psi } ・ Repeat this procedure 3 times.
14. Turn the ignition switch OFF. Caution：
15. Disconnect the fuel feed hose from the fuel supply ・ Cranking should be performed within 5
pump. seconds at a time, and should not exceed 15
16. Install the vacuum pump to the fuel feed hose. seconds in total.
Standard value: -27 kPa {-0.28 kg/cm2 / 8 inHg / -3.98
psi}
Caution：
・ Release the clamp or open the plug when the
gauge of the vacuum pump is likely to be more
than -27 kPa {-0.28 kg/cm2 / 8 inHg / -3.98 psi}
during the test.
SST: 5-8840-0279-0 - vacuum pump 23. Replace the fuel line between the fuel supply pump
17. Operate the vacuum pump to confirm that the fuel and the fuel filter with a clear hose.
flows smoothly. 24. Bleed the air from the fuel system.
Caution： 25. Start the engine, and confirm that air has not mixed
・ The vacuum pump must be cleaned before into the fuel.
26. Inspect the fuel filter and the sensor.
・ Otherwise, foreign material in the tools line
may damage the fuel supply pump. 27. Inspect the fuel line between the fuel supply pump
and the fuel tank for damage, twisting, or looseness.
・ Be careful not to allow the fuel to enter the
vacuum pump. 28. Inspect the breather hose of the fuel tank for a
plugged or kinked condition.
18. Disconnect the fuel injector in-line harness connector
from the fuel injector in order to disable the fuel 29. Inspect the fuel tank cap for a plugged or kinked
injection. condition.
19. Disconnect the fuel feed hose from the fuel tank. 30. Inspect the inside of the fuel tank for any foreign
material that may be getting drawn into the fuel line
pickup, causing clogging.
31. Turn the ignition switch OFF. 43. Inspect for fuel leakage into the combustion
chamber.
32. Confirm that each injector harness connector is
disconnected from all injector assemblies. 44. If there is no fuel leakage into the combustion
chamber, replace the fuel supply pump.
33. Remove the rubber hose from the leak-off pipe.
Caution：
34. Remove the leak-off pipe assembly that is connected
with the fuel feed pipe and the pressure limiter from ・ The fuel supply pump must be timed to the
the engine. engine and adjustment value must be learned
to the ECM.
Caution：
45. If there is fuel leakage from the cylinder head into
・ Use a pan to collect the fuel from the removed
the combustion chamber, replace the injector
fuel line.
assembly.
35. Turn the ignition switch ON.
Caution：
36. Inspect for fuel leakage from the pressure limiter. ・ Be sure to program the replaced injector
Note： assembly.
・ Crank over the engine wile observing the fuel Note：
leak form the pressure limiter. ・ Retest after replacement of the injector
Caution： assembly.
・ Fuel may splash if the pressure limiter is 46. Reconnect all previously disconnected harness
defective, so be sure to wear safety glasses. connector(s) or components.
Note： 47. Turn the ignition switch OFF for 30 seconds.
・ If fuel leaks from the pressure limiter, replace 48. Bleed the air from the fuel system.
the pressure limiter.
49. Start the engine and put it into the idling state.
37. Turn the ignition switch OFF.
50. Observe the actual common rail pressure and the
38. Remove the rubber hoses from the leak-off pipes that target common rail pressure with a scan tool.
are connected to each injector assembly.
Note：
・ Confirm that the difference between the actual
40. Inspect for fuel leakage from each injector common rail pressure and the targeted
assembly's leak-off pipe. common rail pressure is within the standard
value range.
Note：
・ Crank over the engine while observing the fuel Standard： -5.0 to 5.0 MPa { -50.99 to 50.99 kgf/cm2 /
leak from the leak-off pipe of each injector -725 to 725 psi }
assembly.
Caution：
・ Fuel may splash if the injector assembly is
defective, so be sure to wear safety glasses.
41. Replace the injector assembly that returns excessive
fuel.
Note：
・ After replacing the injector assembly, inspect
the engine mechanism for any damage or poor
engine compression.
Caution：
・ Be sure to program the replaced injector
assembly.
42. Remove each glow plug from the cylinder head.
EGR control system check

1. EGR control system check description of function 10. Repeatedly depress the accelerator pedal.
The EGR system re-circulates a part of exhaust gas back 11. Confirm if the difference between the Desired
into the intake manifold, which results in reducing NOx Exhaust Gas Recirculation (EGR) Valve Position
emissions. display and the Exhaust Gas Recirculation (EGR)
Higher operability and emission reduction are realized by Valve Position display is within the standard value
controlling the EGR system. A control current from the range with a scan tool.
ECM operates a motor to control the lift amount of the
Specified value： -5 to 5 %
EGR valve. In addition, the micro processor installed in
the EGR valve is used for detection of actual valve lift 12. Conduct the EGR solenoid control with a scan tool
amount and precision control of EGR amount. and execute increase and decrease commands for the
The EGR is activated when specified conditions of Desired Exhaust Gas Recirculation (EGR) Valve
engine speed, engine water temperature, intake air Position.
temperature and barometric pressure are met. Then, the
Note：
valve opening angle is obtained based on engine speed
and the target fuel injection amount. From this valve ・ Confirm that the difference between the
opening angle, motor drive duty is determined, based on Desired Exhaust Gas Recirculation (EGR)
which the valve is driven. When the EGR is activated, the Valve Position display and the Exhaust Gas
intake throttle valve is closed by adjusting to the Recirculation (EGR) Valve Position display is
appropriate intake manifold negative pressure. within the standard value range.
Note： Specified value： -5 to 5 %

・ Operating conditions for EGR control 13. Disconnect the harness connector from the EGR
valve.
Engine water temperature 5 - 100 ℃ (41 - 212 °F)
Intake air temperature 5 ℃ (41 °F) or above 14. Inspect each of the disconnected terminals.
Barometric pressure 90 kPa (13 psi) or above 15. Disconnect the harness connector from the ECM.
2. EGR control system check inspection 16. Inspect the EGR circuit.
1. Perform the inspection for the engine control system. 17. Remove the EGR valve.
2. Check for a DTC using a scan tool. Refer to "1.Engine 1H.Aux. Emission Control
Note： Devices(4JK1) EGR valve removal".
・ If a DTC has been detected, inspect the 18. Inspect the EGR valve.
applicable DTC.
19. Install the EGR valve.
3. Perform the EGR solenoid control with a scan tool.
Note： Devices(4JK1) EGR valve installation".
・ Confirm if the EGR valve operates in 20. Remove the intake throttle valve.
conformity to increase/decrease of the Desired
Exhaust Gas Recirculation (EGR) Valve Refer to "1.Engine 1B.Mechanical(4JK1) Intake
Position. throttle valve removal".
4. Inspect for EGR gas leakage. 21. Inspect the intake throttle valve.
5. Inspect the EGR piping. 22. Install the intake throttle valve.
6. Inspect the MAF sensor. Refer to "1.Engine 1B.Mechanical(4JK1) Intake
throttle valve installation".
7. Inspect the engine coolant temperature sensor.
8. Inspect the barometric pressure sensor.
9. Start the engine.
Note：
・ Warm up until the water temperature reaches
60 ℃ (140 °F) or higher.
Glow control system check

1. Glow control system check description of function Note：
The glow control system consists of the ECM, glow relay ・ When the value is outside the standard value,
and glow plug. This system is activated to assist engine inspect the applicable glow plug.
starting when the engine water temperature is low. The
ECM turns the glow relay ON for a specified time with
the ignition switch turned ON and the engine turned OFF.
During after glow, the glow plug works for a specified
time even during the engine operation.
2. Glow control system check inspection
Inspection when there may be an abnormality in the
locations related to the glow control
1. Perform the inspection for the engine control system.
2. Check for a DTC using a scan tool.
Note：
・ If DTCs P0117, P0118, or P0380 are detected,
inspect the applicable DTC.
4. Inspect the glow plug terminal.
Note：
・ The power supply terminal for the glow plug
must be firmly secured.
5. Connect the test light between the power supply
terminal and frame ground.
7. Perform the glow relay control with a scan tool.
Executing the glow relay "ON" command illuminates the
test light only when it is turned on.
9. Inspect the glow slow blow fuse.
10. Inspect the glow relay.
11. Inspect the harness between the glow slow blow fuse
and glow relay.
12. Inspect the harness between the glow relay and glow
plug terminal.
13. Remove the metallic busbar from the glow plug.
14. Use the DMM to measure the resistance between the
glow plug terminal and frame ground.
Note：
・ Measurement should be conducted quickly so
that the engine temperature does not change
during measurement.
Standard： 1.00 Ω
Engine compression pressure inspection

1. Engine compression pressure inspection inspection
Note：
・ Warm up the engine.
3. Disconnect the battery ground cable from the battery.
4. Remove the glow plug from the cylinder head
assembly.
Note：
・ Remove all the glow plugs.
5. Remove the harness connector from the injector.
6. Connect the battery ground cable to the battery.
7. Turn the starter.
Note： 9. Measure the compression pressure.
・ Crank the engine to discharge foreign material Note：
from the inside of the cylinders. ・ Rotate the starter, and read the compression
8. Install special tool to the cylinder head. pressure when the compression gauge needle
stabilizes.
Note：
・ Measure the compression pressure of all
・ Insert the compression gauge adapter into the cylinders.
glow plug installation hole and install the
compression gauge. Standard： 2.840 to 3.240 MPa { 29 to 33 kgf/cm2 / 412
to 470 psi } Engine speed 200 r/min
Limit： 1.96 MPa { 20 kgf/cm2 / 284 psi } Engine speed
200 r/min
Difference between each cylinder： 294 kPa { 3.0 kgf/
cm2 / 43 psi } Engine speed 200 r/min
Caution：
・ Use a fully charged battery.
SST: 5-8840-2815-0 - compression gauge adapter
・ Be careful. Air will burst out through the glow
plug hole during rotation.
・ Since DTC is recorded by turning the ignition
switch ON with the injector harness connector
removed, make sure to delete DTC after
completion of inspection.
10. Remove special tool from the cylinder head.
SST: 5-8840-2675-0（5-8531-7002-0） - compression 11. Disconnect the battery ground cable from the battery.
gauge
12. Install the glow plug to the cylinder head assembly.
Note：
・ Install all the glow plugs.
Tightening torque： 18 N・m { 1.8 kgf・m / 13 lb・ft }
13. Connect the harness connector to the injector.
Glow system check

1. Glow system check inspection
Note：
Note：
・ The engine does not start.
5. Disconnect the engine coolant temperature sensor
connector.
6. Connect the voltage meter to the glow plug.
7. Connect the voltage meter to the engine ground
cable.
Note：
・ The engine does not start.
9. Inspect the glow plug.
Note：
・ Confirm that the voltage meter indicates the
power voltage for approximately 18 seconds.
10. If the inspection reveals an abnormality, inspect the
glow relay, engine coolant temperature sensor and
glow plug.
11. If they are normal, inspect the engine control system.
Lubricating system inspection

1. Lubricating system inspection inspection Note：
Note：・ Confirm that there is no oil leakage.
・ Oil pressure inspection ・ Inspection for engine oil leakage
1. Inspect whether the engine oil is dirty, or contains Inspect for oil leakage from the cylinder head cover, oil
water. pan, etc. while the vehicle is lifted up.
Note：
・ If oil is excessively dirty or contains water,
change the oil after investigating the causes
and taking appropriate measures.
2. Inspect the engine oil level.
Note：
・ Confirm that the oil level is between the two
holes of the level gauge.
・ When the oil level is low, replenish it.
3. Remove the oil pressure switch.
4. Install the oil pressure gauge.
1. Oil pressure switch

Note：
6. Measure to see if the oil pressure is 400 kPa (4.1 kg/
cm2 / 58 psi) or higher at 3600 r/min.
8. Remove the oil pressure gauge.
9. Install the oil pressure switch.
Turbocharger control system check

1. Turbocharger control system check description of 12. Put the transmission in the neutral position to apply
function the parking brake.
The position of the turbocharger nozzle is controlled by 13. Start the engine.
the ECM. The ECM utilizes a turbocharger nozzle control
14. Repeatedly depress the accelerator pedal.
solenoid valve and a boost pressure sensor to control the
turbocharger nozzles. When the engine is not under load, 15. Use a scan tool to confirm if the difference between
the turbocharger nozzles are in an open position, or no the Boost Pressure display and the Desired Boost
boost condition. When the engine is under load, the ECM Pressure display is within the standard value range.
commands the control solenoid valve to close the
Standard： -20 to 20 kPa { -3 to 3 psi }
turbocharger nozzles, thus increasing the boost. The ECM
varies the boost dependent upon the load requirements of 16. Drive the vehicle for 10 seconds or longer under the
the engine. The ECM uses a pulse width modulation on following conditions, while checking the Calculated
the control circuit to open and control the solenoid valve. Engine Load display with a scan tool.
2. Turbocharger control system check inspection Engine speed: 2,000 r/min
Calculated Engine Load: 50 % or higher
1. Perform the inspection for the engine control system.
17. Use a scan tool to confirm if the difference between
the Boost Pressure display and the Desired Boost
3. If DTCs P0045, P0112, P0113, P0117, P0118, Pressure display is within the standard value range.
P0234, P0237, P0238, P0299, P0638, P0697, P2227,
Standard： -20 to 20 kPa { -3 to 3 psi }
P2228 or P2229 are detected, inspect the applicable
DTC. 18. If any of the values is outside the standard value
range, turn the ignition switch OFF.
4. Inspect the installation section of the boost pressure
sensor for air leaks. 19. Remove the vacuum hose from the turbocharger
nozzle control actuator diaphragm.
5. Inspect for air leakage around the intake pipe
between the turbocharger the intake manifold. 20. Connect special tool to the vacuum hose.
6. Inspect the vacuum hose piping of the turbocharger Note：
nozzle control actuator for a disconnection or ・ Connect the vacuum pump to the removed
bending. vacuum hose.
7. Inspect the turbine shaft.
Note：
・ There is no cause to interfere with rotation of
the turbine shaft.
・ The turbocharger nozzle control actuator has
no operation failure, and is free from sticking.
Refer to "1.Engine 1F.Induction(4JK1) Turbocharger SST: 5-8840-0279-0 - vacuum pump
assembly inspection".
8. Perform the intake throttle solenoid control with a
scan tool to inspect the intake throttle valve. 22. Conduct the turbocharger solenoid control with a
scan tool and execute increase and decrease
Note： commands for the desired turbocharger position.
・ The intake throttle valve should be free from
Note：
sticking.
・ The standard value of the vacuum pump
9. Inspect the air cleaner element or the intake piping. indicates 50 cmHg (20 inHg) or higher as
10. Inspect that oil is not attached to inside the intake increase to the maximum level, and 0 as
pipe, intercooler or turbocharger. decrease to the minimum level.
11. If a problem is found through the inspections above, 23. If the value is not at the standard value, perform the
repair or replace the applicable parts. following inspections.
24. Inspect the vacuum hose piping of the turbocharger
nozzle control actuator.
25. Inspect the ventilation hose of the solenoid valve.
26. Inspect the vacuum hose or pipe.
27. If a problem is found through the inspections above,
repair or replace the applicable parts.
28. Replace the turbocharger nozzle control solenoid
valve.
Refer to "1.Engine 1F.Induction(4JK1) Turbocharger
control solenoid removal".
control solenoid installation".
Charging system check

1. Charging system check description of function Note：
The charging system warning light notifies a driver of ・ When the warning light still illuminates,
system abnormalities. continue the procedure.
When the ignition switch is turned ON, the charging 12. Repair or replace the generator.
system warning light illuminates. The light turns off
immediately after the engine is started. If the warning
light remains on while the engine is running, there is a
problem in the charging system.
2. Charging system check inspection
1. Inspect the generator drive belt.
Note：
・ Inspect the generator drive belt for damage or
looseness.
2. Inspect the harness connector.
Note：
・ Inspect the harness connector for looseness or
breakage.
Note：
・ Stop the engine.
Note：
・ Do not start the engine.
5. Inspect the charging system warning light.
Note：
・ Confirm that the charging system warning light
illuminates.
・ When the charging system warning light does
not illuminate, continue the procedure.
6. Remove the harness connector from the generator.
7. Ground the IG terminal of the harness connector.
Note：
・ Confirm that the charging system warning light
has illuminated.
・ If the charging system warning light does not
illuminate, the bulb of the warning light is
burned out.
9. Replace the bulb of the charging system warning
light.
Symptom (4JK1) 15D-1
Description Engine
Symptom
(4JK1)
Table of Contents
High idle speed..............................................................15D-2
Engine does not turn over.............................................15D-3
Engine has overcooled..................................................15D-4
Abnormal sound in generator........................................15D-5
Cuts out.........................................................................15D-6
Preheating time is too long............................................15D-7
Engine has overheated...................................................15D-8
Preheating time is too short...........................................15D-9
Preheating does not operate........................................15D-10
Engine does not stop...................................................15D-11
Hard start.....................................................................15D-12
White smoke................................................................15D-13
Rough, unstable...........................................................15D-14
Surges..........................................................................15D-16
Engine slow to warm up..............................................15D-17
Starter overrun.............................................................15D-18
Exhaust gas leak, noise...............................................15D-19
Defect of charging system...........................................15D-20
Clogging of the exhaust system..................................15D-21
Black smoke................................................................15D-22
Abnormal combustion noise.......................................15D-23
Poor fuel economy......................................................15D-24
Hesitation, sag or stumble...........................................15D-25
Intermittent conditions of engine................................15D-27
Maximum engine speed is too low..............................15D-30
Lack of power, sluggishness or sponginess................15D-31
Vibrations and rattling sounds from the exhaust system
.....................................................................................15D-33
Defect of turbocharger................................................15D-34
15D-2 Symptom (4JK1)
High idle speed

1. High idle speed description of symptom
The idling speed is higher than normal regardless of the
engine coolant temperature.
2. High idle speed diagnostics
Note：
・ Preliminary inspection
Perform the inspection for the engine control system.
Inspect whether the harness connector is properly
connected.
Compare the Engine Speed display on a scan tool with
the value of the tachometer in the meter.
Inspect the battery voltage. When the battery voltage is
less than 11 V, the ECM sets the idling speed 50 rpm
higher than normal.
Inspect the operation of the A/C.
Inspect the fuel type and quality.
Inspect the engine oil level.
Check the scan tool data list.
Check the service technical report.
Note：
・ Sensor inspection
Compare each display of the Engine Coolant
Temperature (ECT), Intake Air Temperature (IAT) and
Fuel Temperature to the scan tool data list with the
engine stopped and being cold. When the difference
between the temperature values is 5 ℃ (9 ˚F) or larger,
inspect for high resistance in each circuit and sensor
failure while the engine is cold.
{When the ignition switch is turned on, the MAF sensor
is heated, and as a result, the IAT shows a higher value
than the normal intake air temperature.}
Confirm the Fuel Rail Pressure (FRP) Sensor display on a
scan tool. It is normal if the Fuel Rail Pressure (FRP)
Sensor display shows 0.9 - 1.0 V when the ignition
switch is turned ON without starting the engine after
waiting at least 1 minute after the stop of engine
operation. If not, inspect for high resistance in each
circuit and any sensor failure.
Fully depress the accelerator pedal during idling in
neutral and confirm the Fuel Rail Pressure (FRP) display.
It is normal when the display is always in the range
between 27 - 33 MPa (3,900 - 4,800 psi).
Confirm the accelerator pedal position. Scan tool data
display. It is normal if the accelerator pedal opening
angle changes linearly from 0 to 100 % in conformity to
the accelerator pedal operation.
Note：
・ Fuel system inspection
Remove the injector, and visually inspect it.
{The tip of the injector may be damaged.}
Engine does not turn over

1. Engine does not turn over diagnostics
Note：
・ The starter does not rotate even when the
ignition switch is turned on.
Running out or weakening of the battery.
Charge or replace.
Incomplete circuit.
Repair the wiring or the connector.
Sticking, worn or damage of starter motor brush.
Replace.
Starter motor internal damage.
Replace.
Note：
・ The starter motor does not engage with the
flywheel.
Ring gear worn.
Replace.
Starter motor magnetic switch adjustment failure.
Adjust.
Note：
・ The starter motor pinion meshes with the ring
gear, but it does not rotate.
Running out or weakening of the battery.
Charge or replace.
Insufficient contact tension between the starter motor
brush and the commutator.
Adjust.
Sticking of the armature.
Repair.
Engine internal damage.
Repair.
Engine has overcooled

1. Engine has overcooled diagnostics
Thermostat failure.
Replace.
Abnormal sound in generator

1. Abnormal sound in generator diagnostics
Loosening of the belt tension.
Adjust.
Bearing failure.
Replace.
The rotor core is contacting with the stator core.
Repair.
Diode failure.
Replace.
Near short circuit or open circuit in the stator coil.
Repair.
Cuts out
1. Cuts out description of symptom Inspect for collapsing, twisting, improper tightening,
cracking, and clogging in the fuel system between the
A constant jerking proportional to the engine rpm
fuel tank and fuel supply pump.
{Usually, it is notable when the engine load increases}.
Inspect the vent valve and hose of the fuel tank for
Continuous hissing sounds {boiling sounds} are
clogging.
generated from the exhauster when the engine is idling,
{The piping may be clogged due to foreign matters from
the engine rpm is low or accelerating abruptly, and fuel
the fuel tank mixed into the fuel system.}
deficiency occurs, which results in engine stop.
Perform the cylinder balance test with a scan tool.
2. Cuts out diagnostics Perform the injector forced drive with a scan tool.
Confirm the Fuel Compensation display of each cylinder
Note：
with a scan tool while idling.
Note：
Perform the inspection for the engine control system.
Confirm if the ground of the ECM is free of dirt, and is ・ Air intake system inspection
firmly secured in the correct position. Inspect the air cleaner and air intake duct for clogging,
Inspect whether the harness connector is properly holes and leakage.
connected. Inspect for any condition that restricts the flow within the
Check the scan tool data list. turbocharger inlet duct.
Check the service technical report. Inspect the intake throttle valve to see if it is stuck closed.
Inspect for clogging or air leakage in the intake manifold.
Note：
Inspect the MAF sensor for dirt and damage.
Note：
scan tool. It is normal if the Fuel Rail Pressure (FRP) ・ Exhaust system inspection
Sensor display shows 0.9 - 1.0 V when the ignition Inspect for any condition that restricts the flow of the
switch is turned ON without starting the engine after exhaust system.
Note：
circuit and any sensor failure. ・ Other inspections
Fully depress the accelerator pedal while idling in neutral, EMI may cause an engine failure.
and confirm the Fuel Rail Pressure (FRP) and Desired A scan tool can usually detect EMI by checking the
Fuel Rail Pressure (FRP) displays. It is normal if the Fuel engine rpm. If the value of rotation speed sharply
Rail Pressure (FRP) display follows the Desired Fuel Rail increases even when the actual engine rpm hardly
Pressure (FRP) display with the tolerance of (-5) - 5 MPa changes, EMI occurs. If any problem is found, inspect
{(-725) - 725 psi}. whether any high-voltage component such as wiring of
Confirm the accelerator pedal position. It is normal if the the injector is connected to the area around the sensor
Accelerator Pedal Position (APP) display changes circuit.
linearly from 0 to 100 % in conformity to the accelerator
pedal operation.
The CKP sensor is securely installed, and the sensor rotor
is not damaged.
The CMP sensor is securely installed, and the camshaft
gear is not damaged.
Note：
Inspect for air intrusion in the fuel system.
Inspect for water intrusion in the fuel.
Inspect whether the fuel is becoming waxy or freezing.
Inspect whether the fuel filter indicator light turns ON
continuously or frequently when the engine is driven.
Inspect the fuel filter element for clogging.
Inspect for fuel leakage from the pressure limiter and
injector.
Preheating time is too long

1. Preheating time is too long diagnostics
Thermosensor failure, open circuit or short circuit.
Replace the thermosensor or repair the circuit.
Glow plug failure.
Replace or tighten the glow plug.
Engine control system failure.
Inspect the engine control system.
Engine has overheated

1. Engine has overheated diagnostics
Coolant is insufficient.
Inspection for water leakage and coolant refill.
Thermometer unit failure.
Repair.
Thermostat failure.
Replace.
Engine Coolant Temperature Sensor failure.
Repair or replace.
Water pump failure.
Replace.
Clogging of radiator.
Clean or replace.
Defective radiator cap.
Replace.
Insufficient engine oil.
Refill the engine oil.
Use of inappropriate engine oil.
Replace.
Insufficient coolant or use of improper coolant.
Refill or replace the coolant.
Defective cylinder head gasket.
Replace.
Loosening of the generator drive belt.
Adjust or replace.
Clogging in the exhaust system.
Clean or replace.
Throttle position sensor failure.
Replace the intake throttle valve.
Open circuit or short circuit in the throttle position sensor
circuit.
Repair or replace.
Excessive fuel injection amount.
Diagnose the engine control system.
Improper fuel injection timing.
Low fuel injection starting pressure.
Preheating time is too short

1. Preheating time is too short diagnostics
Thermosensor failure, open circuit or short circuit.
Replace the thermosensor or repair the circuit.
Glow plug failure.
Replace or tighten the glow plug.
Preheating does not operate

1. Preheating does not operate diagnostics
Slow blow fuse meltdown.
Replace the slow blow fuse.
Glow relay connector contact failure or defect.
Reinstall or replace the glow relay.
Engine does not stop

1. Engine does not stop diagnostics
Hard start
1. Hard start description of symptom Inspect for fuel leakage from the pressure limiter and
injector.
The engine cranks but does not start for a long time. The
Inspect the fuel system for collapsing, twisting, improper
engine does eventually run, or may start but immediately
tightening, cracking and clogging.
stops.
2. Hard start diagnostics clogging.
Note：
・ Preliminary inspection Inspect the supply pump operation.
Perform the inspection for the engine control system. {The supply pump must be timed with the engine, and the
Confirm if the driver is using the correct starting adjusted value should be written into the ECM.}
procedure. Conduct the cylinder balance test with a scan tool.
Confirm if the ground of the ECM is free of dirt, and is Perform the injector forced drive with a scan tool.
firmly secured in the correct position. Confirm the Fuel Rail Pressure (FRP) Regulator Valve
Inspect whether the harness connector is properly Feedback Current display on a scan tool.
connected. Note：
Inspect the fuel type, quality and level.
Check the injector ID code of each cylinder. ・ Air intake system inspection
Check the scan tool data list. Inspect the air cleaner and air intake duct for clogging,
Check the service technical report. holes and leakage.
Inspect for any condition that restricts the flow within the
Note：
turbocharger inlet duct.
・ Sensor inspection Inspect the intake throttle valve to see if it is stuck closed.
Compare each display of the Engine Coolant Inspect for clogging and leakage in the intake manifold.
Temperature (ECT), Intake Air Temperature (IAT) and Note：
engine in a cold state. ・ Exhaust system inspection
When the difference between the temperature values is 5 Inspect for any condition that restricts the flow of the
℃ (9 ˚F) or larger, inspect for high resistance in each exhaust system.
circuit and sensor failure while the engine is cold.
Note：
{When the ignition switch is turned ON, the MAF sensor
is heated, and as a result, the IAT shows a higher value ・ Engine mechanical inspection
than the normal intake air temperature.} Inspect the compression pressure of the engine.
Confirm the Fuel Rail Pressure (FRP) Sensor display on a Inspect for improper idle gear timing.
scan tool. It is normal if the Fuel Rail Pressure (FRP) Inspect the valve clearance.
Sensor display shows 0.9 - 1.0 V when the ignition Inspect the valve spring for damage and fatigue.
switch is turned ON without starting the engine after Inspect the camshaft for worn.
waiting at least 1 minute after the stop of engine Inspect the ring gear for worn.
operation. If not, inspect for high resistance in each Inspect the inside of the engine for seizure.
The CKP sensor is securely installed, and the sensor rotor Note：
is not damaged. ・ Electrical system inspection
The CMP sensor is securely installed, and the camshaft
Inspect the glow plug control system operation.
gear is not damaged.
Inspect the cranking speed.
Note： Inspect the battery for deterioration.
Inspect for external fuel leakage, or excessive engine oil.
White smoke
1. White smoke description of symptom Note：
White smoke is generated when the engine is under load, ・ Fuel system inspection
idling or hot, or when starting the engine in a cold state. Inspect for water intrusion in the fuel.
2. White smoke diagnostics Remove the injector, and visually inspect it.
Note： Perform the injector forced drive with a scan tool.
・ Preliminary inspection Confirm the Fuel Compensation display of each cylinder
Confirm if any problem exists in the vehicle.
Confirm if the ground of the ECM is free of dirt, and is Note：
firmly secured in the correct position. ・ Air intake system inspection
Inspect the fuel quality.
Check the injector ID code of each cylinder. Inspect the air cleaner and air intake duct for clogging,
Check the scan tool data list. holes and leakage.
Check the service technical report. Inspect for any condition that restricts the flow within the
turbocharger inlet duct.
Note： Inspect the intake throttle valve to see if it is stuck closed.
・ Sensor inspection Inspect for clogging or air leakage in the intake manifold.
Perform the swirl control solenoid control with a scan
tool. Inspect the diaphragm valve operation when the
"ON/OFF" command is executed on the diaphragm valve.
engine stopped and cold. If the difference between
Inspect the turbocharger turbine wheel, shaft or
temperature values is 5 °C (9 °F) or above, inspect for
compressor wheel for worn and damage.
high resistance in each circuit or sensor failure with the
Inspect the turbocharger oil seal for oil leakage.
engine is cold.
Inspect the turbocharger oil return pipe for clogging.
is heated, and as a result, the IAT shows a higher value Note：
than the normal intake air temperature.} ・ Engine mechanical inspection
Check the Fuel Rail Pressure (FRP) sensor display on the
scan tool. It is normal if the Fuel Rail Pressure (FRP) Inspect the compression pressure of the engine.
Sensor display shows 0.9 - 1.0 V when the ignition Inspect for improper idle gear timing.
switch is turned ON without starting the engine after Inspect the valve clearance.
waiting at least 1 minute after the stop of engine Inspect the valve stem for sticking.
operation. If not, inspect for high resistance in each Inspect for the valve stem oil seal failure.
circuit and any sensor failure. Inspect the valve seat for worn.
Fully depress the accelerator pedal while idling in neutral, Inspect the valve spring for damage and fatigue.
and confirm the Fuel Rail Pressure (FRP) and Desired Inspect the camshaft for worn.
Fuel Rail Pressure (FRP) displays. It is normal if the Fuel Inspect for compression leakage due to piston ring
Rail Pressure (FRP) display follows the Desired Fuel Rail damage.
Pressure (FRP) display with the tolerance of (-5) - 5 MPa Inspect for gasket failure.
{(-725) - 725 psi}. Inspect the piston for seizure.
Confirm the accelerator pedal position. It is normal if the Inspect for oil intrusion into the combustion chamber.
Accelerator Pedal Position (APP) display changes Note：
・ Electrical system inspection
pedal operation.
Confirm the Boost Pressure and Barometric Pressure Inspect the glow plug control system operation.
(BARO) displays with the ignition switch ON and the
engine OFF.
It is normal if the difference between both data displays is
within 7.0 kPa (1.0 psi).
The CKP sensor is securely installed and the sensor rotor
is not damaged.
Rough, unstable
1. Rough, unstable description of symptom Inspect for external fuel leakage or excessive engine oil.
The engine idling speed is not constant. The engine or
vehicle may shake in severe situations. The engine idling
speed may vary. Any of the above conditions is so severe
that engine stalling can occur.
2. Rough, unstable diagnostics injector.
Inspect for collapsing, twisting, improper tightening,
Note：
・ Preliminary inspection fuel tank and fuel supply pump.
Perform the inspection for the engine control system. Inspect the vent valve and hose of the fuel tank for
Remove the air cleaner and inspect for dirt, collapsing of clogging.
the air duct or any condition that restricts the flow. {The piping may be clogged due to foreign matters from
Confirm if the ground of the ECM is free of dirt and is the fuel tank mixed into the fuel system.}
firmly secured in the correct position. Inspect the fuel supply pump operation.
Inspect whether the harness connector is properly {The fuel supply pump must be timed with the engine,
connected. and the adjusted value should be written into the ECM.}
Inspect the fuel type and quality. Conduct the cylinder balance test with a scan tool.
Check the injector ID code of each cylinder. Perform the injector forced drive with a scan tool.
Check the scan tool data list. Confirm the Fuel Rail Pressure (FRP) Regulator Valve
Check the service technical report. Feedback Current display on a scan tool.
Note： Note：
・ Sensor inspection ・ Air intake system inspection
Compare each display of the Engine Coolant Inspect the air cleaner and air intake duct for clogging,
Temperature (ECT), Intake Air Temperature (IAT) and holes and leakage.
Fuel Temperature to the scan tool data list with the Inspect for any condition that restricts the flow within the
engine stopped and being cold. When the difference turbocharger inlet duct.
between the temperature values is 5 ℃ (9 ˚F) or larger, Inspect the intake throttle valve to see if it is stuck closed.
inspect for high resistance in each circuit and sensor Inspect for clogging and air leakage in the intake
failure while the engine is cold. manifold.
{When the ignition switch is turned ON, the MAF sensor Note：
than the normal intake air temperature.} ・ Exhaust system inspection
Confirm the Fuel Rail Pressure (FRP) Sensor display on a Inspect for any condition that restricts the flow of the
scan tool. It is normal if the Fuel Rail Pressure (FRP) exhaust system.
Note：
waiting at least 1 minute after the stop of engine ・ Engine mechanical inspection
operation. If not, inspect for high resistance in each Inspect the compression pressure of the engine.
circuit and any sensor failure. Inspect for improper idle gear timing.
Fully depress the accelerator pedal during idling in Inspect the valve clearance.
neutral and confirm the Fuel Rail Pressure (FRP) display. Inspect the valve spring for damage and fatigue.
It is normal when the display is always in the range Inspect the camshaft for worn.
between 27 - 33 MPa (3,900 - 4,800 psi). Inspect the basic components of the engine including the
The CKP sensor is securely installed, and the sensor rotor camshaft, cylinder head, piston, etc.
is not damaged.
The CMP sensor is securely installed, and the camshaft Note：
gear is not damaged. ・ Other inspections
Note： EMI may cause an engine failure.
・ Fuel system inspection A scan tool can usually detect EMI by checking the
engine rpm. If the value of rotation speed sharply
Inspect for air intrusion in the fuel system. increases even when the actual engine rpm hardly
changes, EMI occurs. If any problem is found, inspect
whether any high-voltage component such as wiring of
the injector is connected to the area around the sensor
circuit.
Inspect the engine mounting for an abnormality.
Inspect the crank pulley for an abnormality.
Inspect the generator or A/C compressor.
Inspect the generator output voltage.
Inspect the EGR system operation.
Surges
1. Surges description of symptom Inspect for collapsing, twisting, improper tightening,
The vehicle speeds up and slows down with no change in
fuel tank and the supply pump.
the accelerator pedal position.
2. Surges diagnostics clogging.
Note：
・ Preliminary inspection Inspect the supply pump operation.
Perform the inspection for the engine control system. {The supply pump must be timed with the engine, and the
The driver must be familiar with the A/C compressor adjusted value should be written into the ECM.}
operation. Conduct the cylinder balance test with a scan tool.
Use a scan tool in order to confirm that the data display Perform the injector forced drive with a scan tool.
value for the vehicle speed matches with the value of the Note：
speedometer on the vehicle.
Confirm if the ground of the ECM is free of dirt, and is ・ Air intake system inspection
firmly secured in the correct position. Inspect the air cleaner and air intake duct for clogging,
Inspect whether the harness connector is properly holes and leakage.
connected. Inspect for any condition that restricts the flow within the
Inspect the fuel type and quality. turbocharger inlet duct.
Check the injector ID code of each cylinder. Inspect the intake throttle valve to see if it is stuck closed.
Check the scan tool data list. Inspect for clogging or air leakage in the intake manifold.
Check the service technical report. Inspect the MAF sensor for dirt and damage.
Note：
・ Sensor inspection "ON/OFF" command is executed on the diaphragm valve.
Confirm the Fuel Rail Pressure (FRP) Sensor display on a Inspect the operation of nozzle control actuator of the
scan tool. It is normal if the Fuel Rail Pressure (FRP) turbocharger.
Sensor display shows 0.9 - 1.0 V when the ignition Note：
switch is turned on without starting the engine after
waiting at least 1 minute after the stop of engine ・ Exhaust system inspection
operation. If not, inspect for high resistance in each Inspect for any condition that restricts the flow of the
circuit and any sensor failure. exhaust system.
Fully depress the accelerator pedal while idling in neutral,
Note：
and confirm the Fuel Rail Pressure (FRP) and Desired
Fuel Rail Pressure (FRP) displays. It is normal if the Fuel ・ Other inspections
Rail Pressure (FRP) display follows the Desired Fuel Rail Inspect the output voltage of the generator.
Pressure (FRP) display with the tolerance of (-5) - 5 MPa Inspect whether the EGR system is operating properly.
{(-725) - 725 psi}. Inspect the operation of the A/C.
Confirm the accelerator pedal position. It is normal if the
Accelerator Pedal Position (APP) display changes Note：
linearly from 0 to 100 % in conformity to the accelerator ・ Other than automatic transmission models
pedal operation.
Inspect the output voltage of the generator.
Note： Inspect whether the EGR system is operating properly.
・ Fuel system inspection Inspect the operation of the A/C.
Inspect the operation of the torque converter clutch.
Inspect for water intrusion in the fuel. Note：
Inspect whether the fuel is becoming waxy or freezing. ・ Automatic transmission models
injector.
Engine slow to warm up

1. Engine slow to warm up diagnostics
Thermostat failure.
Replace.
Thermo unit failure.
Replace.
Starter overrun
1. Starter overrun diagnostics
Improper return of ignition switch contact point.
Replace the ignition switch.
Improper return of starter relay contact point.
Replace the starter relay.
Magnetic switch coil short circuit.
Replace the magnetic switch.
Exhaust gas leak, noise

1. Exhaust gas leak, noise diagnostics
Improper installation or connection.
Retighten after aligning the connections.
Exhaust pipe, silencer damage or burning.
Replace the damaged parts.
Defective exhaust system components such as clamps,
pipes and silencer.
Replace any defective component.
Internal damage of silencer.
Replace the damaged parts.
Defect of charging system

1. Defect of charging system diagnostics Replace.
Note： Note：
・ Not charged at all. ・ Charged current is unstable.
Battery failure. Intermittent contact or near open circuit of wiring.
Replace. Repair.
Open circuit, short circuit, disengaged connection of Loosening of the generator drive belt.
wiring or current meter. Adjust.
Repair.
Near short circuit or open circuit in the stator coil.
Ammeter open circuit or short circuit. Repair.
Repair.
Improper terminal contact.
Open circuit in each coil, ground short circuit or damaged Repair.
diode of the generator.
IC regulator failure.
Replace.
Replace.
IC regulator terminal contact failure.
Replace.
Repair.
Note：
Repair.
・ There is an abnormal operation sound.
Note：
・ Charge is insufficient.
Adjust.
Battery failure.
Bearing failure.
Replace.
Replace.
Open circuit, short circuit, disengaged connection of
Loosening of the rotor core or the stator core
wiring or current meter.
Repair. Diode failure.
Replace.
Adjust. Stator coil open circuit or short circuit.
Replace.
Stator coil layer short.
Replace.
Diode failure.
Replace.
Contact failure of each terminal.
Repair.
Replace.
Repair.
Note：
・ Overcharged.
Replace.
Open circuit, short circuit, disengaged connection of
wiring or current meter.
Repair.
Battery failure.
Clogging of the exhaust system

1. Clogging of the exhaust system diagnostics
Clogging of the exhaust pipe.
Repair or replace.
Black smoke
1. Black smoke description of symptom It is normal if the difference between both data displays is
Black smoke is generated when the engine is under load,
idling or hot, or when starting the engine in a cold state. Note：
2. Black smoke diagnostics ・ Fuel system inspection
Note： Inspect for water intrusion in the fuel.

Confirm if any problem exists in the vehicle. Perform the injector forced drive with a scan tool.
Remove the air cleaner and inspect for dirt, collapsing of Confirm the Fuel Compensation display of each cylinder
the air duct or any condition that restricts the flow. with a scan tool while idling.
Confirm if the ground of the ECM is free of dirt, and is
Note：
firmly secured in the correct position.
Inspect the fuel quality. ・ Air intake system inspection
Inspect the engine oil level and quality. Inspect the air cleaner and air intake duct for clogging,
Check the injector ID code of each cylinder. holes and leakage.
Check the scan tool data list. Inspect for any condition that restricts the flow within the
Check the service technical report. turbocharger inlet duct and air leakage.
Note： Inspect the intake throttle valve to see if it is stuck closed.
Inspect for clogging or air leakage in the intake manifold.
Compare each display of the Engine Coolant Inspect the turbocharger turbine wheel, shaft or
Temperature (ECT), Intake Air Temperature (IAT) and compressor wheel for worn and damage.
Fuel Temperature to the scan tool data list with the Inspect the turbocharger oil seal for oil leakage.
engine stopped and cold. If the difference between Inspect the actuator for damage.
temperature values is 5 °C (9 °F) or above, inspect for
Note：
high resistance in each circuit or sensor failure with the
engine is cold. ・ Exhaust system inspection
{When the ignition switch is turned ON, the MAF sensor Inspect for any condition that restricts the flow of the
is heated, and as a result, the IAT shows a higher value exhaust system.
Check the Mass Air Flow (MAF) sensor display with a Note：
scan tool. ・ Engine mechanical inspection
Check the Fuel Rail Pressure (FRP) sensor display on the
Inspect the compression pressure of the engine.
Inspect for improper idle gear timing.
Inspect the valve clearance.
Inspect the valve stem for sticking.
Inspect the valve seat for worn.
Inspect the valve spring for damage and fatigue.
Inspect the camshaft for worn.
Inspect for compression leakage due to piston ring
damage.
Fuel Rail Pressure (FRP) displays. It is normal if the Fuel
Inspect for gasket failure.
Rail Pressure (FRP) display follows the Desired Fuel Rail
Inspect the piston for seizure.
Pressure (FRP) display with the tolerance of (-5) - 5 MPa
Inspect for oil intrusion into the combustion chamber.
{(-725) - 725 psi}.
Confirm the accelerator pedal position. It is normal if the Note：
Accelerator Pedal Position (APP) display changes ・ Other inspections
pedal operation. Inspect for the appropriate EGR system operation.
Confirm the Boost Pressure and Barometric Pressure Inspect for excessive blow-by gas.
engine OFF.
Abnormal combustion noise

1. Abnormal combustion noise description of symptom Perform the injector forced drive with a scan tool.
Confirm the Fuel Compensation display of each cylinder
Engine knocking occurs many times. Usually, it becomes
particularly notable when accelerating. A sharp metallic
sound is produced when the throttle opening angle is Note：
changed. ・ Air intake system inspection
2. Abnormal combustion noise diagnostics Inspect the air cleaner element for clogging.
Note： Inspect the intake air duct for clogging.
・ Preliminary inspection Note：
Perform the inspection for the engine control system. ・ Engine mechanical inspection
Confirm if any problem exists in the vehicle. Inspect the compression pressure of the engine.
Inspect whether smoke is generated with combustion Inspect the basic components of the engine including the
noise. camshaft, cylinder head, piston, etc.
Inspect the fuel quality. Inspect the combustion chamber for excessive oil
Check the injector ID code of each cylinder. intrusion.
Check the service technical report. Note：
・ Other inspections
Note：
・ Sensor inspection Inspect for any other cause that generates similar sound,
such as loose components, bracket, mount, deteriorated
Compare each display of the Engine Coolant clutch damper spring.
{(-725) - 725 psi}.
The CKP sensor is securely installed, and the sensor rotor
is not damaged.
Note：
If excessive smoke is present, inspect the injector for
stuck open. Inspect the combustion chamber for fuel
intrusion.
Poor fuel economy

1. Poor fuel economy description of symptom Inspect the engine coolant level.
Inspect whether the engine thermostat is always open,
The fuel mileages measured in an actual road test and in
and inspect for an incorrect heat range.
multiple fuel tanks are significantly lower than the
Inspect whether the engine cooling fan is always "ON".
predicted values. Also, they are significantly lower than
the fuel mileage obtained in the previous road test. Note：
2. Poor fuel economy diagnostics ・ Air intake system inspection
Note： Inspect the air cleaner and air intake duct for clogging,
holes and leakage.
Inspect for any condition that restricts the flow within the
Remove the air cleaner and inspect for dirt, collapsing of turbocharger inlet duct.
the air duct or any condition that restricts the flow. Inspect the intake throttle valve to see if it is stuck closed.
Check the driver's driving habits. Inspect for clogging or air leakage in the intake manifold.
Confirm if the A/C is always "ON" and the defroster Inspect the MAF sensor for dirt and damage.
mode is "ON". Perform the swirl control solenoid control with a scan
Confirm if the tire air pressure is appropriate. tool. Inspect the diaphragm valve operation when the
Confirm if the tire size has ever been changed. "ON/OFF" command is executed on the diaphragm valve.
Confirm if excessively heavy loads are being carried. Inspect the turbocharger turbine wheel, shaft or
Confirm if too many or too frequent accelerations have compressor wheel for worn and damage.
been made. Inspect the operation of nozzle control actuator of the
Inspect for clutch slip. turbocharger.
Inspect for brake drag.
Note：
Inspect the drive belt tension.
Inspect whether the transmission shift pattern and down ・ Exhaust system inspection
shift operation are normal. Inspect for any condition that restricts the flow of the
Inspect the fuel quality. exhaust system.
Inspect the engine oil level and quality.
Instruct the owner to recheck the fuel mileage after Note：
refilling the fuel tank. ・ Engine mechanical inspection
Inspect whether the odometer is operating properly.
Check the service technical report.
Note： Inspect the camshaft for worn.
Note：
Inspect the fuel type and quality.
Inspect for fuel leakage.
Note：
・ Cooling system inspection
Hesitation, sag or stumble

1. Hesitation, sag or stumble description of symptom Confirm the accelerator pedal position. It is normal if the
Accelerator Pedal Position (APP) display changes
Response is delayed for a moment when the accelerator
pedal is depressed. This occurs at every vehicle speed.
pedal operation.
Normally, this situation is most notable when starting the
Confirm the Boost Pressure and Barometric Pressure
vehicle from the stopped state.
Engine stalling will occur in severe situations.
engine OFF.
2. Hesitation, sag or stumble diagnostics It is normal if the difference between both data displays is
Note：
The CKP sensor is securely installed and the sensor rotor
・ Preliminary inspection is not damaged.
Perform the inspection for the engine control system. Note：
Compare the vehicle with a similar vehicle. Confirm if
any problem exists in the vehicle. ・ Fuel system inspection
Remove the air cleaner and inspect for dirt, collapsing of Inspect for air intrusion in the fuel system.
the air duct or any condition that restricts the flow. Inspect for water intrusion in the fuel.
Inspect whether the transmission shift pattern and down Inspect for external fuel leakage or excessive engine oil.
shift operation are normal. Inspect whether the fuel is becoming waxy or freezing.
Inspect the fuel quality. Inspect whether the fuel filter indicator light turns ON
Inspect the engine oil level and quality. continuously or frequently when the engine is driven.
Confirm if the ground of the ECM is free of dirt, and is Inspect the fuel filter element for clogging.
firmly secured in the correct position. Inspect for fuel leakage from the pressure limiter and
Check the injector ID code of each cylinder. injector.
Check the scan tool data list. Inspect for collapsing, twisting, improper tightening,
Check the service technical report. cracking, and clogging in the fuel system between the
fuel tank and fuel supply pump.
Note：
・ Sensor inspection clogging.
Compare each display of the Engine Coolant {The piping may be clogged due to foreign matters from
Temperature (ECT), Intake Air Temperature (IAT) and the fuel tank mixed into the fuel system.}
Fuel Temperature to the scan tool data list with the Inspect the fuel supply pump operation.
engine stopped and cold. If the difference between {The fuel supply pump must be timed with the engine,
temperature values is 5 °C (9 °F) or above, inspect for and the adjusted value should be written into the ECM.}
high resistance in each circuit or sensor failure with the Conduct the cylinder balance test with a scan tool.
engine is cold. Perform the injector forced drive with a scan tool.
{When the ignition switch is turned ON, the MAF sensor Confirm the Fuel Compensation display of each cylinder
is heated, and as a result, the IAT shows a higher value with a scan tool while idling.
than the normal intake air temperature.} Note：
Check the Mass Air Flow (MAF) sensor display with a
scan tool. ・ Air intake system inspection
Check the Fuel Rail Pressure (FRP) sensor display on the Inspect the air cleaner and air intake duct for clogging,
scan tool. It is normal if the Fuel Rail Pressure (FRP) holes and leakage.
Sensor display shows 0.9 - 1.0 V when the ignition Inspect for any condition that restricts the flow within the
switch is turned ON without starting the engine after turbocharger inlet duct.
waiting at least 1 minute after the stop of engine Inspect the intake throttle valve to see if it is stuck closed.
operation. If not, inspect for high resistance in each Inspect for clogging or air leakage in the intake manifold.
circuit and any sensor failure. Inspect the MAF sensor for dirt and damage.
Fully depress the accelerator pedal while idling in neutral, Perform the swirl control solenoid control with a scan
and confirm the Fuel Rail Pressure (FRP) and Desired tool. Inspect the diaphragm valve operation when the
Fuel Rail Pressure (FRP) displays. It is normal if the Fuel "ON/OFF" command is executed on the diaphragm valve.
Rail Pressure (FRP) display follows the Desired Fuel Rail Inspect the turbocharger turbine wheel, shaft or
Pressure (FRP) display with the tolerance of (-5) - 5 MPa compressor wheel for worn and damage.
{(-725) - 725 psi}. Inspect the operation of nozzle control actuator of the
turbocharger.
Note：
・ Exhaust system inspection
Inspect for any condition that restricts the flow of the
exhaust system.
Note：
・ Engine mechanical inspection
Note：
Inspect whether the EGR system is operating properly.
Inspect the engine for an overheat condition.
Note：
・ Other than automatic transmission models
Inspect the engine for an overheat condition.
Inspect the operation of the A/C. Inspect the operation of
the torque converter clutch.
Note：
・ Automatic transmission models
Intermittent conditions of engine

1. Intermittent conditions of engine description of Repair or replace the connector terminal of the circuit
symptom with the problem, and make the connection status
appropriate. Remove the terminals from the connector
Note：
body and inspect the wires of the terminals for a contact
・ Important preliminary inspections before failure.
starting Connect a DMM to the suspected circuit, and conduct a
Before using the list of symptoms, perform the inspection road test for the vehicle. If an abnormal value is displayed
for the engine control system and confirm all of the when the malfunction occurs, it can be determined that
following items. The malfunction indicator light is the circuit that has been monitored is actually causing the
functioning properly. problem. A scan tool is useful in detecting intermittent
The scan tool data is within the normal range of operation conditions. A scan tool has the following convenient
values. functions.
Confirm the customer's complaint, and locate the It is possible to review the information and comprehend
appropriate symptom in the table of contents. Inspect the the particular operation condition that resulted in the
items presented for the symptom. malfunction.
Note： By using the plot function of a scan tool, it is possible to
graph the selected data parameters.
・ Visual inspection and actual inspection
This recorded information can be reviewed, and the
A careful visual inspection and actual inspection are location of the intermittent malfunction can be confirmed.
required for some symptom procedures. This procedure is
If an intermittent condition that may cause stalling after
extremely important. By conducting visual and actual
engine start exists, check for a DTC relating to the
inspections, it is possible to save valuable time by fixing
vehicle theft deterrent system. Check for an improper
problems without performing further inspections.
installation of optional accessories such as a light or
Confirm the following items.
mobile phone.
The ground of the ECM should be clean and firmly
Under the following conditions, DTCs are not recorded,
secured in the correct position.
but the MIL may light intermittently.
There is no partitioning or twisting of the air hose. It is
also appropriately connected. Conduct a thorough The ground of the ECM is loose or dirty.
inspection to make sure that there are no leaks or An intermittent short circuit to the ground circuit of the
clogging. MIL
The intake air duct is not crushed or damaged. An interference in the electric system due to a failure in a
The exhaust pipe is not crushed or damaged. relay, a driven solenoid in the ECM or a switch. There
The wiring and terminals for engine harnesses are may be cases where the voltage increases sharply due to
appropriately connected, and they are not pinched or an electric component. Normally, a problem occurs when
disconnected. the component with a failure operates.
The diode has an open circuit.
Note：
・ Intermittent In the following list of symptoms, causes for each
symptom are organized. There is no significance to the
If an intermittent condition exists, inspect whether there order of this procedure. If the value on a scan tool is not
are any installation failures for accessories. Inspect indicating an abnormality, the next procedure to perform
whether there is any accessory, light or mobile phone that should be one that can be most easily inspected or is most
was additionally installed. Confirm that any device that likely to be the cause.
was additionally installed is not connected to the serial Use the following list when diagnosing symptoms of
data circuits such as CAN. complaints.
Depending on the problem, the MIL may light or DTCs
may be recorded. Intermittent malfunctions are often Engine intermittent
caused by electrical connection failures and wiring Difficulty in starting
failures. Conduct a careful visual inspection, or conduct Hunching, rough idle
an actual inspection to see whether the following High idling speed
conditions exist in the suspected connector. Sudden stop of engine
Sudden change in engine rotation
Incomplete connection between connectors. Output shortage, blowup failure
Seating failure of terminal. Chuffing, acceleration failure
Deformation or damage of terminal. Abnormal combustion sound
Deterioration of fuel mileage requires the terminal to be removed from the connector
Black smoke body.
White smoke Corrosion or water intrusion. Moisture can enter the
Overheat wiring when the insulation area is damaged or has holes.
Overcooling The conductor inside the insulation area corrodes, but this
Too low maximum engine rotation usually cannot be confirmed visually.
Engine does not stop. Look for any swollen or stiff section of the wires in the
Starter overrun circuit suspected for an abnormality.
Charging failure Wiring damaged inside the insulation area.
Abnormal noise from the generator Pinched or disconnected wiring, or friction between
Vibrations and rattling sounds from the exhaust system wires.
Clogging in the exhaust system Confirm that the wiring does not come in contact with a
Exhaust leakage, abnormal noise hot exhaust system component.
Turbocharger failure
Note：
Preheating does not operate
Too long preheating time ・ Power source and ground of the control
Too short preheating time module, and power source and ground of the
Engine does not rotate components
Engine slow to warm up Various symptoms can occur due to defective
There is no problem currently occurring, but past DTCs connections with the power source or ground.
exist. Or, there is a complaint from the customer not Test all control module power supply circuits. In many
related to a DTC, and that symptom cannot be vehicles, there are multiple circuits that supply power
reproduced. source to the control module. Other components in the
system have separate power supply circuits that may also
Note： need to be tested. Inspect the connections and fuses of the
・ Preliminary inspection module and component connectors, as well as
intermediate connections between the power source and
the module and between components. A test light or a
Note： DMM may indicate that voltage is present, but neither of
・ Harness and connector them tests the ability of the circuit to carry sufficient
current.
Intermittent open circuits or short circuits are often Confirm if the circuit is carrying the current necessary to
caused by the harness or connector moving due to operate the components.
vibrations, engine torque, or bumps on the road. Test all control module ground circuits and system
Move the related connectors and wiring while checking ground circuits. Some control modules have multiple
the applicable scan tool data. ground circuits. Other components in the system have
Execute an "ON" or "OFF" command to the component separate ground circuits that may also need to be tested.
using a scan tool, and move the related connectors and Inspect whether the ground is clean, and is securely
wiring. Check the component operation. connected to the ground point. Inspect the connections of
With the engine operating, move the related connectors the components and the splice pack. Confirm if the circuit
and wiring while checking the operation of the engine. is carrying the current necessary to operate the
If the harness or connector movement affects the data components.
display, the operation of the component or system, or the
engine operation, inspect the harness or connection and Note：
repair it as necessary. ・ Temperature sensitivity
Note： An intermittent condition may occur when a component
・ Electrical connection of wiring or connection reaches its operating temperature. For an
intermittent condition that may occur only when the
An intermittent condition is often caused by an improper component or connection is cold, or only when it is hot,
electrical connection, terminal installation or wiring. failure records or snapshot data can be helpful, where
Defective connections between connectors or improper possible.
terminal seating to the connector body. If an intermittent condition is related to heat, review the
Terminal deformation or damage Test the terminals for data relating to the following items.
improper installation. High outside air temperature.
Defective connections between the wires and terminals Heat emitted under the cab or by the engine.
including solderless terminals with insulation. This
Heat emitted from a circuit due to a defective connection snapshot function can be set manually to start recording
or high load. when the symptom occurs, or can be configured to start
Load conditions higher than normal, such as when recording when the DTC is set. Abnormal values in the
towing. recorded data may indicate systems or components that
If an intermittent condition is related to low temperature, require further inspection.
review the data relating to the following items.
Note：
Low outside air temperature. In an extremely low
temperature, ice may form in a connection or component. ・ DRM memory
Test for water intrusion. Use the data stored in the DRM, or use the manual trigger
This condition only occurs during a cold start. switch. The DRM has the ability to store the engine log
It does not occur after the vehicle has been warmed up. data at the time of a DTC event. The manual trigger
Based on the information from the customer, determine if switch stores the log data by an arbitrary operation of the
the failure is caused by temperature. driver on the occurrence of a wrong vehicle performance
Note： event instead of a DTC event. If the driver presses and
releases the manual trigger switch once, that time
・ EMI and electrical noise
becomes a trigger, and the log data after the trigger is
Certain electrical parts and circuits may respond stored in the DRM memory. Refer to the DRM users
sensitively to electrical noises such as EMI. guide for more information.
A harness is placed too close to a high voltage or high
current device such as a injection part, motor, or
generator due to incorrect wiring.
These components may induce electrical noises that could
interfere with normal circuit operation on the circuit.
Interference in the electric system due to a failure in a
relay, a driven solenoid of the ECM or a switch. There
may be cases where the voltage increases sharply due to
this condition. Normally, a problem occurs when the
component with a failure operates.
Improper installation of non-genuine or aftermarket add-
on accessories such as lights, 2-way radios, amplifiers,
electric motors, remote starters, alarm systems, mobile
phones, etc. These accessories may possibly lead to an
emission related failure while in use, but do not affect
when the accessories are not in use.
Test the diode for an open circuit. Some of relays include
clamping diodes.
Inspect the rectifier bridge of the generator for a problem
that generates A/C noises in the electrical system.
Note：
・ Reproducing failure conditions
When none of the tests are successful, try reproducing or
recording the failure condition.
An alternative method is to drive the vehicle with the
DMM connected to the suspicious circuit. If an abnormal
value is displayed on the DMM when the problem occurs,
this can be helpful in identifying the defective area.
Note：
・ Scan tool snapshot
By connecting a scan tool, snapshots of the parameters
that can be used via the serial data can be taken. The
snapshot function records the actual data for a certain
period of time. The recorded data can be replayed and
analyzed. Also, a scan tool can display a single parameter
or multiple parameters as a graph for comparison. The
Maximum engine speed is too low

1. Maximum engine speed is too low diagnostics
Inspect the fuel system for collapsing, twisting, improper
tightening, cracking and clogging.
Repair or replace.
Lack of power, sluggishness or sponginess

1. Lack of power, sluggishness or sponginess description Fully depress the accelerator pedal while idling in neutral,
of symptom and confirm the Fuel Rail Pressure (FRP) and Desired
The engine output is less than expected. The engine rpm
hardly increases or does not increase at all even when the
accelerator pedal is depressed.
{(-725) - 725 psi}.
2. Lack of power, sluggishness or sponginess diagnostics Confirm the accelerator pedal position. It is normal if the
Accelerator Pedal Position (APP) display changes
Note：
・ Preliminary inspection pedal operation.
Perform the inspection for the engine control system. Confirm the Boost Pressure and Barometric Pressure
Compare the vehicle with a similar vehicle. Confirm if (BARO) displays with the ignition switch ON and the
any problem exists in the vehicle. engine OFF.
Remove the air cleaner and inspect for dirt, collapsing of It is normal if the difference between both data displays is
the air duct or any condition that restricts the flow. within 7.0 kPa (1.0 psi).
Confirm if the tire size has been changed. Note：
Confirm if excessively heavy loads are being carried.
Inspect for clutch slip. ・ Fuel system inspection
Inspect for brake drag. Inspect for air intrusion in the fuel system.
Inspect whether the transmission shift pattern and down Inspect for water intrusion in the fuel.
shift operation are normal. Inspect for external fuel leakage or excessive engine oil.
Inspect the fuel quality. Inspect whether the fuel is becoming waxy or freezing.
Inspect the engine oil level and quality. Inspect whether the fuel filter indicator light turns ON
Use a scan tool in order to confirm that the Vehicle Speed continuously or frequently when the engine is driven.
display matches with the value of the speedometer on the Inspect the fuel filter element for clogging.
vehicle. Inspect for fuel leakage from the pressure limiter and
Confirm if the ground of the ECM is free of dirt, and is injector.
firmly secured in the correct position. Inspect the injector nozzle for sticking.
Check the injector ID code of each cylinder. Inspect for collapsing, twisting, improper tightening,
Check the scan tool data list. cracking, and clogging in the fuel system between the
Check the service technical report. fuel tank and fuel supply pump.
Note：
clogging.
・ Sensor inspection {The piping may be clogged due to foreign matters from
Compare each display of the Engine Coolant the fuel tank mixed into the fuel system.}
Temperature (ECT), Intake Air Temperature (IAT) and Inspect the fuel supply pump operation.
Fuel Temperature to the scan tool data list with the {The fuel supply pump must be timed with the engine,
engine stopped and cold. If the difference between and the adjusted value should be written into the ECM.}
temperature values is 5 °C (9 °F) or above, inspect for Conduct the cylinder balance test with a scan tool.
high resistance in each circuit or sensor failure with the Perform the injector forced drive with a scan tool.
engine is cold. Confirm the Fuel Compensation display of each cylinder
{When the ignition switch is turned ON, the MAF sensor with a scan tool while idling.
is heated, and as a result, the IAT shows a higher value Note：
Check the Mass Air Flow (MAF) sensor display with a ・ Air intake system inspection
scan tool. Inspect the air cleaner and air intake duct for clogging,
Check the Fuel Rail Pressure (FRP) sensor display on the holes and leakage.
scan tool. It is normal if the Fuel Rail Pressure (FRP) Inspect for any condition that restricts the flow within the
Sensor display shows 0.9 - 1.0 V when the ignition turbocharger inlet duct.
switch is turned ON without starting the engine after Inspect the intake throttle valve to see if it is stuck closed.
waiting at least 1 minute after the stop of engine Inspect for clogging or air leakage in the intake manifold.
operation. If not, inspect for high resistance in each Inspect the MAF sensor for dirt and damage.
"ON/OFF" command is executed on the diaphragm valve.
Inspect the turbocharger turbine wheel, shaft or
compressor wheel for worn and damage.
Inspect the operation of nozzle control actuator of the
turbocharger.
Note：
・ Exhaust system inspection
Inspect for any condition that restricts the flow of the
exhaust system.
Note：
・ Engine mechanical inspection
Note：
Confirm the Neutral switch display on a scan tool.
Inspect the engine for an overheating condition.
Note：
・ Other than automatic transmission models
Confirm the Neutral switch display on a scan tool.
Inspect the engine for an overheating condition.
Inspect the operation of the torque converter clutch.
Note：
・ Automatic transmission models
Vibrations and rattling sounds from the exhaust system

1. Vibrations and rattling sounds from the exhaust
system diagnostics
Loosening or improper installation of components.
Retighten after aligning the connections. Or, inspect the
mounting brackets, clamps, mount rubbers and bushings
for damage.
Defect of turbocharger
1. Defect of turbocharger diagnostics Note：
Note：・ When there are abnormal vibrations in the
turbocharger.
・ When the output has dropped although the
engine appears to be normal. The cause is bearing damage and contact of the rotating
section with the surrounding sections. Degraded oil, entry
Deformed or damaged turbine fins and compressor fins.
of foreign material in the fuel hose, clogging of the oil
Replace.
filter, or repeated sudden starting and stopping can cause
The fins and housing are touching to each other. bearing failure.
Replace. Replace.
There is a large amount of carbon deposits adhering to When there is no problem in the lubricating oil system,
the turbine exhaust outlet and are in contact with the but there are damages from contacts found in the rotating
turbine fins. section and the surrounding sections, it is suspected that
Clean or replace. the rotating section has become unbalanced or the shaft
has been bent. This is caused by bearing worn, or damage
When the turbine shaft is manually turned, it catches on
on the turbine wheel or compressor wheel made by flying
something or the rotation is heavy.
debris.
Replace.
Replace.
The clearance in the axis direction or rotation direction of
the turbine shaft is large. Note：
Measure the clearance and replace it if it exceeds the ・ Oil is leaking into the exhaust or intake pipe,
standard value. and exhaust becomes white.
Note： Oil leakage from the turbocharger oil seal.
Repair or replace.
・ When output has dropped although the
turbocharger appears to be basically normal. Insufficient oil level due to dirty or clogged oil separator.
Clean or replace.
Air leakage from the rubber hose of the intake air pipe.
Repair. Clogging in the oil passage of the center housing.
Replace.
Air leakage from the intake manifold.
Repair. Clogging, collapsing or deformation of the oil return
pipe.
Clogging of the air cleaner element.
Repair or replace.
Clean or replace.
Large turbine shaft clearance.
Sticking of the intake throttle valve.
Measure the clearance and replace it if it exceeds the
Repair or replace.
standard value.
Gas leak from each exhaust section.
Degraded engine oil.
Repair or replace.
Replace.
Excessive exhaust resistance caused by deformed exhaust
muffler or carbon clogging. Note：
Repair or replace. ・ When noise is generated from the
turbocharger.
Air leakage from the compressor outlet side.
Repair. Air leakage from the coupling of the rubber hose on the
compressor outlet side or gas leakage from the exhaust
Clogging in the intercooler cooling section. system.
Clean. Repair.
Defective boost sensor. Contact of the turbine fins with the housing.
Replace. Replace.
Cause due to the vehicle side, such as dragging of the Internal damage due to foreign material catching.
brake. Replace.
Repair.
Worn or seizure of the turbine shaft bearing.
Replace.
Note：
・ When excessive worn exists in the rotating
section.
Degraded engine oil.
Replace.
Clogging in the turbocharger oil feed pipe.
Repair.
Low engine oil pressure.
Repair.
DTC Information (4JK1) 15E-1
Description Engine
DTC Information
(4JK1)
Table of Contents
DTC P0016 (Flash Code 16) Crankshaft Position - Camshaft DTC P0202 (Flash Code 272) Injector Circuit - Cylinder 2
Position Correlation.......................................................15E-3 .....................................................................................15E-24
DTC P0045 (Flash Code 33) Turbocharger Boost Control DTC P0203 (Flash Code 273) Injector Circuit - Cylinder 3
Solenoid Circuit.............................................................15E-4 .....................................................................................15E-25
DTC P0087 (Flash Code 225) Fuel Rail/System Pressure - DTC P0204 (Flash Code 274) Injector Circuit - Cylinder 4
Too Low........................................................................15E-5 .....................................................................................15E-26
DTC P0088 (Flash Code 118) Fuel Rail/System Pressure - DTC P0217 (Flash Code 542) Engine Coolant Over
Too High........................................................................15E-6 Temperature Condition................................................15E-27
DTC P0089 (Flash Code 151) Fuel Pressure Regulator DTC P0219 (Flash Code 543) Engine Overspeed Condition
Performance...................................................................15E-7 .....................................................................................15E-28
DTC P0091 (Flash Code 247) Fuel Pressure Regulator DTC P0234 (Flash Code 42) Turbocharger Overboost
Control Circuit Low.......................................................15E-8 Condition.....................................................................15E-29
DTC P0092 (Flash Code 247) Fuel Pressure Regulator DTC P0237 (Flash Code 32) Turbocharger Boost Sensor
Control Circuit High......................................................15E-9 Circuit Low..................................................................15E-30
DTC P0093 (Flash Code 227) Fuel System Leak Detected DTC P0238 (Flash Code 32) Turbocharger Boost Sensor
.....................................................................................15E-10 Circuit High.................................................................15E-31
DTC P0102 (Flash Code 91) Mass Air Flow Circuit Low DTC P0299 (Flash Code 65) Turbocharger Underboost
Input.............................................................................15E-11 .....................................................................................15E-32
DTC P0103 (Flash Code 91) Mass Air Flow Circuit High DTC P0335 (Flash Code 15) Crankshaft Position Sensor
Input.............................................................................15E-12 Circuit..........................................................................15E-33
DTC P0112 (Flash Code 22) Intake Air Temperature Sensor DTC P0336 (Flash Code 15) Crankshaft Position Sensor
Circuit Low..................................................................15E-13 Circuit Range/Performance.........................................15E-34
DTC P0113 (Flash Code 22) Intake Air Temperature Sensor DTC P0340 (Flash Code 14) Camshaft Position Sensor
Circuit High.................................................................15E-14 Circuit..........................................................................15E-35
DTC P0117 (Flash Code 23) Engine Coolant Temperature DTC P0380 (Flash Code 66) Glow Plug Circuit.........15E-36
Sensor Circuit Low......................................................15E-15 DTC P0403 (Flash Code 347) Exhaust Gas Recirculation
DTC P0118 (Flash Code 23) Engine Coolant Temperature Control Circuit.............................................................15E-37
Sensor Circuit High.....................................................15E-16 DTC P0404 (Flash Code 45) Exhaust Gas Recirculation
DTC P0122 (Flash Code 43) Throttle Position Sensor Control Circuit Range/Performance............................15E-38
Circuit Low..................................................................15E-17 DTC P0500 (Flash Code 25) Vehicle Speed Sensor...15E-39
DTC P0123 (Flash Code 43) Throttle Position Sensor DTC P0501 (Flash Code 25) Vehicle Speed Sensor Range/
Circuit High.................................................................15E-18 Performance.................................................................15E-40
DTC P0182 (Flash Code 211) Fuel Temperature Sensor DTC P0562 (Flash Code 35) System Voltage Low....15E-41
Circuit Low..................................................................15E-19
DTC P0563 (Flash Code 35) System Voltage High....15E-42
DTC P0183 (Flash Code 211) Fuel Temperature Sensor
Circuit High.................................................................15E-20 DTC P0601 (Flash Code 53) Internal Control Module
Memory Check Sum Error..........................................15E-43
DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor
Circuit Low..................................................................15E-21 DTC P0602 (Flash Code 154) Control Module
Programming Error......................................................15E-44
Circuit High.................................................................15E-22 DTC P0604 (Flash Code 153) Internal Control Module
Random Access Memory (RAM) Error......................15E-45
DTC P0201 (Flash Code 271) Injector Circuit - Cylinder 1
.....................................................................................15E-23 DTC P0606 (Flash Code 51) ECM/PCM Processor. . .15E-46
15E-2 DTC Information (4JK1)
DTC P0633 (Flash Code 176) Immobilizer Key Not DTC U0001 (Flash Code 84) High Speed CAN
Programmed - ECM/PCM...........................................15E-47 Communication Bus....................................................15E-72
DTC P0638 (Flash Code 61) Throttle Actuator Control DTC U0101 (Flash Code 85) Lost Communication With
Range/Performance.....................................................15E-48 TCM.............................................................................15E-73
DTC P0641 (Flash Code 55) Sensor Reference Voltage 1 DTC U010A (Flash Code 346) Lost Communication With
Circuit..........................................................................15E-49 Exhaust Gas Recirculation Control Module................15E-74
DTC P0650 (Flash Code 77) Malfunction Indicator Lamp DTC U0167 (Flash Code 177) Lost Communication With
(MIL) Control Circuit..................................................15E-50 Vehicle Immobilizer Control Module.........................15E-75
DTC P0651 (Flash Code 56) Sensor Reference Voltage 2
Circuit..........................................................................15E-51
DTC P0661 (Flash Code 58) Intake Manifold Tuning Valve
Control Circuit Low.....................................................15E-52
Control Circuit High....................................................15E-53
Circuit..........................................................................15E-54
DTC P0700 (Flash Code 185) Transmission Control System
(MIL Request).............................................................15E-55
DTC P1093 (Flash Code 227) Fuel Rail Pressure (FRP) Too
Low..............................................................................15E-56
DTC P1261 (Flash Code 34) Injector Positive Voltage
Control Circuit Group 1...............................................15E-57
Control Circuit Group 2...............................................15E-58
DTC P1404 (Flash Code 45) Exhaust Gas Recirculation
(EGR) Closed Position Performance...........................15E-59
DTC P161B (Flash Code 179) Immobilizer Wrong
Response......................................................................15E-60
DTC P1621 (Flash Code 54, 254) Control Module Long
Term Memory Performance........................................15E-61
DTC P2122 (Flash Code 121) Pedal Position Sensor 1
Circuit Low Input........................................................15E-62
Circuit High Input........................................................15E-63
Circuit Low Input........................................................15E-64
Circuit High Input........................................................15E-65
DTC P2138 (Flash Code 124) Pedal Position Sensor 1 - 2
Voltage Correlation.....................................................15E-66
DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply
Voltage Circuit............................................................15E-67
Voltage Circuit............................................................15E-68
DTC P2227 (Flash Code 71) Barometric Pressure Circuit
Range/Performance.....................................................15E-69
Low..............................................................................15E-70
High.............................................................................15E-71
DTC P0016 (Flash Code 16)

Crankshaft Position - Camshaft Position Correlation
1. DTC P0016 description of DTC
The CKP sensor is installed on the rear of the cylinder
block left side. The sensor rotor is fixed on the
crankshaft. There are 56 notches spaced 6° apart and a
30° opening. The top dead center of the cylinder No. 1
can be detected through this opening.
sensor detects 5 projections in total per 1 engine rotation.
The timing chain sprocket has 4 projections evenly
spaced 90° apart and 1 reference projection. By detecting
the opening with the CKP sensor and 1 reference
projection with the CMP sensor, the ECM determines the
compression top dead center of the cylinder No. 1 to
confirm that they correlate with each other.
If the ECM detects that both signals are out of
synchronization, the DTC is set.
2. DTC P0016 condition for setting the DTC
DTCs P0335, P0336 and P0340 are not set.
The battery voltage is 9 V or higher.
The ignition switch is on.
Pulses of the CKP sensor signal have been detected.
Pulses of the CMP sensor signal have been detected.
The ECM detects that the CKP sensor signal and the
CMP sensor signal are not synchronized while the engine
is rotating.
3. DTC P0016 action taken when the DTC sets
The ECM illuminates the MIL when the diagnostic runs
and fails.
The ECM records the operating conditions at the time the
diagnostic fails. The ECM stores this information in the
Freeze Frame/Failure Records.

Turbocharger Boost Control Solenoid Circuit
The opening angle of the turbocharger variable nozzle is
controlled by the ECM. The ECM activates the
turbocharger control solenoid valve based on the boost
pressure and controls the variable nozzle with negative
pressure. When the engine is free from load, the variable
nozzle is opened or free from boost pressure. When the
engine is under load, the ECM controls the control
solenoid valve to close the variable nozzle. As a result,
the boost pressure increases. The ECM performs the
control that changes the boost pressure in accordance
with the load requirements for the engine.
The ECM controls the solenoid valve open/close
operation by using the pulse width modulation method.
When the ECM detects an open circuit or short circuit in
the solenoid valve circuit, the DTC is set.
Either of the following conditions is met.
The ECM detects a low voltage condition in the
turbocharger control solenoid circuit when the solenoid is
commanded off.
The ECM detects a high voltage condition in the
turbocharger control solenoid circuit when the solenoid is
commanded on.
and fails.

Fuel Rail/System Pressure - Too Low
A typical common rail system is comprised of the
following 2 fuel pressure sections. There is a suction side
between the fuel tank and the fuel supply pump and a
high-pressure side between the fuel supply pump and the
injectors. The fuel is drawn from the fuel tank and then
pumped into the fuel rail by 2 plungers that are located
inside the fuel supply pump. The fuel rail pressure is
regulated through controlling the FRP regulator by the
ECM based on the signals from the FRP sensor. When
the fuel rail pressure becomes excessive, the fuel rail
pressure limiter valve opens to release the excessive
pressure and return the fuel into the fuel tank.
The ECM sets the DTC when the fuel rail pressure
sharply decreases after the pressure goes excessively
high. This DTC detects activation of the pressure limiter
valve.
DTCs P0192 and P0193 are not set.
The engine is running.
The ECM detects that the pressure limiter valve is
activated with the excessive pressure of 190 MPa (27600
psi) or higher in the fuel rail.
The ECM does not light the MIL.
when the abnormality is detected. The ECM stores this
information in the Failure records.

Fuel Rail/System Pressure - Too High
injectors. The fuel is drawn from the fuel tank via the fuel
supply pump and then pumped into the fuel rail by 2
plungers that are located inside the fuel supply pump. The
fuel rail pressure is regulated through controlling the FRP
regulator by the ECM based on the signals from the FRP
sensor.
When the ECM detects the fuel pressure even higher than
the amount to set DTC P0088 for a certain length of time
during the same ignition cycle, the MIL lights. When the
MIL lights, this DTC detects that the fuel pressure
becomes abnormally high due to inactivation or delayed
operation of the pressure limiter valve.
The ECM detects that the fuel rail pressure has been 200
MPa (29000 psi) or higher for 15 seconds or longer.
and fails.
The ECM limits the fuel delivery.
The ECM inhibits the pre-injection.

Fuel Pressure Regulator Performance
ECM based on the signals from the FRP sensor.
When the ECM detects that the fuel pressure is higher
than the desired fuel pressure, this DTC is set.
DTCs P0091, P0092, P0192, P0193, P0201-P0204,
P0651, P2146 and P2149 are not set.
The ECM detects that the common rail pressure has been
40 MPa (5800 psi) higher than the desired pressure for 25
seconds or longer.
The PCM illuminates the MIL on the second consecutive
driving cycle that the diagnostic runs and fails on the
consecutive driving cycle.
when abnormality is detected. The first time the
in the Failure records. If the second abnormality is
detected during the next driving cycle, the ECM records
the operating conditions at the time when it is detected
and stores this information in the Freeze frame. At this
time, the Failure records are updated.

Fuel Pressure Regulator Control Circuit Low
The FRP regulator is installed on the fuel supply pump,
and controls the fuel amount sucked into the fuel rail. The
FRP regulator is fully opened in the normal state, and the
opening of the regulator becomes smaller when the drive
current becomes larger. The ECM calculates the fuel rail
desired pressure and the fuel flow rate, and compares the
calculated fuel rail pressure to the actual pressure value to
determine the opening angle of the FRP regulator. If the
actual fuel rail pressure is higher than the desired
pressure, the FRP regulator closes to decrease the fuel
flow rate.
When the ECM detects an abnormally low feedback
current of the FRP regulator, the DTC is set.
The ECM detects that the feedback current of the FRP
regulator is 100 mA or lower, or 1000 mA or more lower
than the desired current.
and fails.

Fuel Pressure Regulator Control Circuit High
The FRP regulator is installed on the fuel supply pump,
and controls the fuel amount sucked into the fuel rail. The
FRP regulator is fully opened in the normal state, and the
opening of the regulator becomes smaller when the drive
current becomes larger. The ECM calculates the fuel rail
desired pressure and the fuel flow rate, and compares the
calculated fuel rail pressure to the actual pressure value to
determine the opening angle of the FRP regulator. If the
actual fuel rail pressure is higher than the desired
pressure, the FRP regulator closes to decrease the fuel
flow rate. When the ECM detects an abnormally high
feedback current of the FRP regulator, the DTC is set.
The ECM detects that the feedback current of the FRP
regulator is 2450 mA or higher, or 1000 mA or more
higher than the desired current.
and fails.

Fuel System Leak Detected
ECM based on the signals from the FRP sensor. If the
ECM detects that the fuel rail pressure is low as
compared with the engine speed, the DTC is set.
DTCs P0087, P0091, P0092, P0192, P0193, P0201-
P0204, P0651, P2146 and P2149 are not set.
The ECM detects that the actual fuel rail pressure has
been 15 MPa (2180 psi) or lower for 5 seconds or longer.

Mass Air Flow Circuit Low Input
The MAF sensor is an air flow meter that measures the
amount of air that enters into the engine. It is installed
between the air cleaner and the turbocharger. When the
amount of air entering into the engine is small, it
indicates deceleration or idling speed. If the amount of air
entering into the engine is large, it indicates acceleration
or high load state. The sensor has the following circuits.
12 V voltage circuit
Low reference circuit
MAF sensor signal circuit
The ECM monitors the MAF sensor signal voltage. The
scan tool indicates this output voltage in voltage
parameter and grams per cylinder (g/cyl).
If the ECM detects an excessively low signal voltage, the
DTC is set.
The battery voltage is between 10 and 16 V.
The ECM detects that the MAF sensor signal voltage is
0.1 V or lower.
The ECM lights the MIL when a diagnosis is performed
and any failure is detected.
information in the Freeze Frame/Failure Records.
The ECM substitutes a default value of the MAF.
The ECM restricts the fuel injection amount.
The ECM prohibits the EGR control.
The ECM prohibits the pre-injection.

Mass Air Flow Circuit High Input
The MAF sensor is an air flow meter that measures the
amount of air that enters into the engine. It is installed
between the air cleaner and the turbocharger. When the
amount of air entering into the engine is small, it
indicates deceleration or idling speed. If the amount of air
entering into the engine is large, it indicates acceleration
or high load state. The sensor has the following circuits.
12 V voltage circuit
MAF sensor signal circuit
The ECM monitors the MAF sensor signal voltage. The
scan tool indicates this output voltage in voltage
parameter and grams per cylinder (g/cyl).
If the ECM detects an excessively high signal voltage, the
DTC is set.
The ECM detects that the MAF sensor signal voltage is
4.9 V or higher for 3 seconds.
The ECM substitutes a default value of the MAF.

Intake Air Temperature Sensor Circuit Low
The IAT sensor is installed between the air cleaner and
the turbocharger. This is integral with the MAF sensor.
The IAT sensor is a variable resistor, and it measures the
temperature of the air flowing into the engine. This
sensor has a signal circuit and low reference circuit. The
ECM supplies 5 V to the signal circuit, and the low
reference to the low reference circuit. When the IAT
sensor is cold, the resistance of the sensor is high. When
the air temperature increases, the sensor resistance
decreases. The ECM detects a high voltage when the
sensor resistance is high. The ECM detects a low voltage
when the sensor resistance is low.
DTC is set.
The ECM detects that the IAT sensor signal voltage is 0.1
V or lower for 3 seconds.
The ECM substitutes a default value of the IAT.

Intake Air Temperature Sensor Circuit High
The IAT sensor is installed between the air cleaner and
the turbocharger. This is integral with the MAF sensor.
The IAT sensor is a variable resistor, and it measures the
temperature of the air flowing into the engine. This
sensor has a signal circuit and low reference circuit. The
ECM supplies 5 V to the signal circuit, and the low
reference to the low reference circuit. When the IAT
sensor is cold, the resistance of the sensor is high. When
the air temperature increases, the sensor resistance
decreases. The ECM detects a high voltage when the
sensor resistance is high. The ECM detects a low voltage
when the sensor resistance is low.
DTC is set.
The engine running time is 3 minutes or longer.
The ECM detects that the IAT sensor signal voltage is
4.75 V or higher for 3 seconds.
The ECM substitutes a default value of the IAT.

Engine Coolant Temperature Sensor Circuit Low
The engine coolant temperature sensor is installed in the
thermostat housing. The engine coolant temperature
temperature of the engine coolant. This sensor has a
signal circuit and low reference circuit. The ECM
supplies 5 V to the signal circuit, and the low reference
circuit connects to low reference. When the engine
coolant temperature sensor is cold, the resistance of the
sensor is high. When the engine coolant temperature
increases, the sensor resistance decreases. The ECM
detects a high voltage when the sensor resistance is high.
The ECM detects a low voltage when the sensor
resistance is low.
DTC is set.
The ECM detects that the engine coolant temperature
sensor signal voltage is 0.1 V or lower for 3 seconds.
and fails.
The ECM substitutes the default value of the ECT.
The ECM inhibits the EGR control.

Engine Coolant Temperature Sensor Circuit High
temperature of the engine coolant. This sensor has a
signal circuit and low reference circuit. The ECM
supplies 5 V to the signal circuit, and the low reference
circuit connects to the low reference. When the engine
coolant temperature sensor is cold, the resistance of the
sensor is high. When the engine coolant temperature
increases, the sensor resistance decreases. The ECM
detects a high voltage when the sensor resistance is high.
The ECM detects a low voltage when the sensor
resistance is low.
DTC is set.
The engine running time is 3 minutes or longer.
The ECM detects that the engine coolant temperature
sensor signal voltage is 4.75 V or higher for 3 seconds.
and fails.
The ECM substitutes the default value of the ECT.

Throttle Position Sensor Circuit Low
The intake throttle position sensor is installed on the
intake throttle valve body together with the control
solenoid. The intake throttle position sensor changes the
signal voltage in accordance with the intake throttle valve
opening angle. The sensor has the following circuits.
5 V power supply circuit
Intake throttle position sensor signal circuit
The intake throttle position sensor transmits the signal for
opening angle change in the intake throttle valve to the
ECM.
DTC is set.
DTC P0697 is not set.
The ECM detects that the intake throttle position sensor
signal voltage is 0.1 V or lower.

Throttle Position Sensor Circuit High
The intake throttle position sensor is installed on the
intake throttle valve body together with the control
solenoid. The intake throttle position sensor changes the
signal voltage in accordance with the intake throttle valve
opening angle. The sensor has the following circuits.
Intake throttle position sensor signal circuit
The intake throttle position sensor transmits the signal for
opening angle change in the intake throttle valve to the
ECM.
DTC is set.
The ECM detects that the intake throttle position sensor
signal voltage is 4.75 V or higher.

Fuel Temperature Sensor Circuit Low
pump. The fuel temperature sensor is a variable resistor
and it measures the temperature of the fuel entering the
fuel supply pump. This sensor has a signal circuit and
low reference circuit. The ECM supplies 5 V to the signal
circuit, and the low reference circuit connects to the low
reference. When the fuel temperature sensor is cold, the
resistance of the sensor is high. When the fuel
temperature increases, the sensor resistance decreases.
The ECM detects a high voltage when the sensor
resistance is high. The ECM detects a low voltage when
the sensor resistance is low.
DTC is set.
The ECM detects that the fuel temperature sensor signal
voltage is 0.1 V or lower for 3 seconds.
The ECM substitutes a default value of the FT.

Fuel Temperature Sensor Circuit High
pump. The fuel temperature sensor is a variable resistor
and it measures the temperature of the fuel entering the
fuel supply pump. This sensor has a signal circuit and
low reference circuit. The ECM supplies 5 V to the signal
circuit, and the low reference circuit connects to the low
reference. When the fuel temperature sensor is cold, the
resistance of the sensor is high. When the fuel
temperature increases, the sensor resistance decreases.
The ECM detects a high voltage when the sensor
resistance is high. The ECM detects a low voltage when
the sensor resistance is low.
DTC is set.
The engine operation time is 3 minutes or longer.
The ECM detects that the fuel temperature sensor signal
voltage is 4.75 V or higher for 3 seconds.
The ECM substitutes a default value of the FT.

Fuel Rail Pressure Sensor Circuit Low
The FRP sensor is installed to the fuel rail, and it detects
the fuel pressure in the fuel rail and converts the pressure
into a voltage signal. The sensor has the following
circuits.
FRP sensor signal circuit
The ECM monitors the FRP sensor signal voltage. The
signal voltage increases as the fuel rail pressure rises,
while it decreases as the pressure declines. The ECM
calculates the actual fuel rail pressure from the voltage
signal and uses the result in the fuel injection control and
DTC is set.
The ECM detects that the FRP sensor signal voltage is
0.4 V or lower.
The ECM substitutes a default value of the fuel rail
pressure.

Fuel Rail Pressure Sensor Circuit High
The FRP sensor is installed to the fuel rail, and it detects
the fuel pressure in the fuel rail and converts the pressure
into a voltage signal. The sensor has the following
circuits.
FRP sensor signal circuit
The ECM monitors the FRP sensor signal voltage. The
signal voltage increases as the fuel rail pressure rises,
while it decreases as the pressure declines. The ECM
calculates the actual fuel rail pressure from the voltage
signal and uses the result in the fuel injection control and
DTC is set.
The ECM detects that the FRP sensor signal voltage is
4.75 V or higher.
The ECM substitutes a default value of the fuel rail
pressure.

Injector Circuit - Cylinder 1
The ECM calculates the optimum fuel injection "ON"
time based on the data sent from sensors. The injector
charge voltage circuits of the common power supplies 1
and 2 supply high voltage, and the ECM drives the
injector of each cylinder along with grounding the
injector solenoid control circuit.
The ECM sets a DTC when an abnormality is inspected
in the 1st cylinder injector circuit.
The ECM detects an open circuit in the injector solenoid
circuit.

in the 2nd cylinder injector circuit.
circuit.

in the 3rd cylinder injector circuit.
circuit.

in the 4th cylinder injector circuit.
circuit.

Engine Coolant Over Temperature Condition
temperature of the engine coolant.
If the ECM detects an excessively high coolant
temperature, the DTC is set.
The ECM detects that the engine coolant temperature has
been 110°C (230°F) or higher for 5 seconds.

Engine Overspeed Condition
block left side. The ECM calculates the engine speed and
accurate crankshaft position based on the signal pulse
from the CKP sensor.
If the ECM detects that the engine is in overrun state, the
DTC is set.
When the ECM detects that the engine rpm is 4800 r/min
or higher. (high output engine)
When the ECM detects that the engine rpm is 5000 r/min
or higher. (standard output engine)
and fails.
When the vehicle speed is less than 5 km/h (3 mph) for 5
seconds, the ECM stops the engine drive.
The engine is ready to start after the ignition switch is
turned off for 10 seconds or longer.

Turbocharger Overboost Condition
The boost sensor is located within the air intake pipe.
This sensor changes the signal voltage in accordance with
changes of air pressure within the air intake pipe. The
ECM monitors the boost sensor signal.
If the ECM detects an excessively high sensor signal, the
DTC is set. This indicates that the boost pressure is
abnormally high.
The ECM detects that the actual boost pressure has
exceeded the desired boost pressure by 20 kPa (3 psi) or
more for 10 seconds or longer under a particular
condition.
and fails.

Turbocharger Boost Sensor Circuit Low
boost sensor has the following circuits.
Boost sensor signal circuit
The boost sensor transmits the signal of pressure change
within the air intake pipe to the ECM. The ECM detects
high voltage signal when the air pressure is high, i.e. high
load on the engine. When the ECM detects an excessively
low signal voltage, the DTC is set.
DTC P0697 has not been set.
The ignition switch is ON.
The ECM detects that the boost sensor signal voltage is
0.1 V or lower.
The ECM substitutes a default boost value.

Turbocharger Boost Sensor Circuit High
boost sensor has the following circuits.
Boost sensor signal circuit
The boost sensor transmits the signal of pressure change
within the air intake pipe to the ECM. The ECM detects
high voltage signal when the air pressure is high, i.e. high
load on the engine. When the ECM detects an excessively
high signal voltage, the DTC is set.
DTC P0697 has not been set.
The ECM detects that the boost sensor signal voltage is
4.75 V or higher.
The ECM substitutes a default boost value.

Turbocharger Underboost
ECM monitors the boost sensor signal. If the ECM
detects an excessively low sensor signal, the DTC is set.
This indicates that the boost pressure is abnormally low.
DTCs P0045, P0087, P0088, P0089, P0091, P0092,
P0093, P0102, P0103, P0117, P0118, P0122, P0123,
P0192, P0193, P0237, P0238, P0403, P0404, P0638,
P0651, P0697, P1093, P1404, P2227, P2228 and P2229
have not been set.
The fuel injection amount is at or higher than a certain
value.
The ECM detects that the actual boost pressure has been
lower than the desired boost pressure by 40 kPa (6 psi) or
more for 10 seconds or longer under a particular
condition.
and fails.

Crankshaft Position Sensor Circuit
30° opening. The top dead center of the cylinder No. 1
can be detected through this opening. The CKP sensor
generates pulse signals. The sensor has the following
circuits.
CKP sensor signal circuit
The ECM monitors the signal pulses of the CKP sensor
and the CMP sensor to confirm that they correlate with
each other.
When the ECM receives a certain amount of CMP sensor
signal pulses without a CKP sensor signal pulse, the DTC
is set.
Pulses of the CMP sensor signal are detected.
The ECM detects that no CKP sensor signal pulse is
generated while the engine is running.
and fails.

Crankshaft Position Sensor Circuit Range/Performance
30° opening. The top dead center of the cylinder No.1 can
be detected through this opening. The ECM monitors the
signal pulses of the CKP sensor and the CMP sensor to
confirm that they correlate with each other.
When the ECM receives excessive or short CKP sensor
signal pulses, the DTC is set.
Pulses of the CKP sensor signal are detected.
The ECM detects excessive or short CKP sensor signal
pulses while the engine is running.
and fails.

Camshaft Position Sensor Circuit
sensor detects 5 projections in total per 1 engine rotation.
The timing chain sprocket has 4 projections evenly
spaced 90° apart and 1 reference projection. The CMP
sensor generates pulse signals. The sensor has the
following circuits.
CMP sensor signal circuit
The ECM monitors the signal pulses of the CKP sensor
and the CMP sensor to confirm that they correlate with
each other. If the ECM receives a certain amount of CKP
sensor signal pulses without a CMP sensor signal pulse,
the DTC is set.
Pulses of the CKP sensor signal are detected.
The ECM detects that no CMP sensor signal pulse is
generated while the engine is running.

Glow Plug Circuit
The ECM controls the glow relay which supplies power
source to the glow plugs based on the engine coolant
temperature. During the after glow period, the glow plug
operates for a certain period of time. If the ECM detects
an open circuit or short circuit on the relay control circuit,
the DTC is set.
The ECM detects a low voltage state on the glow relay
control circuit for 3 seconds or longer when the off
command is executed on the relay.
The ECM detects a high voltage state on the glow relay
control circuit for 3 seconds or longer when the on
command is executed on the relay.
and fails.

Exhaust Gas Recirculation Control Circuit
The EGR valve has a built-in microprocessor. The
internal microprocessor controls the EGR solenoid in
response to instructions from the ECM. The ECM
calculates the desired EGR position depending on the
engine running condition. The EGR valve
lift amount is detected by the position sensor, and is
relayed to the ECM. The EGR valve has the following
circuits.
Ignition power supply circuit
CAN high circuit
CAN low circuit
Ground circuit
The EGR valve and the ECM communicate the control
information and diagnosis information via CAN
communication. The microprocessor diagnoses problems
inside the EGR valve.
When the ECM receives a failure message from the EGR
valve, the DTC is set.
The ECM receives a failure message from the EGR
valve.
The ECM substitutes a default value of the actual EGR
position.
The ECM substitutes a default value of the desired EGR
position.

Exhaust Gas Recirculation Control Circuit Range/Performance
internal microprocessor controls the EGR solenoid in
engine running condition. The EGR valve lift amount is
detected by the position sensor, and is relayed to the
ECM.
If the ECM detects a variance between the actual EGR
valve position and desired EGR valve position for a
predetermined period of time with the EGR commanded
on, the DTC is set.
DTCs P0112, P0113, P0117, P0118, P0403, P0651,
P2227, P2228, P2229 and U010A have not been set.
The battery voltage is between 10 - 16 V.
The engine coolant temperature is between 20 - 110 ℃
(68 - 230 ℉).
The intake air temperature is 0 - 110 ℃ (32 - 230 ℉).
The barometric pressure is between 60 - 120 kPa (8.7 -
17.4 psi).
The "ON" command has been executed on the EGR
control.
When the ECM detects that the actual EGR valve
positions is 10 % or more below the desired position for
11 seconds or longer.
When a diagnosis is conducted and an abnormality is
detected in the consecutive driving cycles, the ECM
lights the MIL during the second driving cycle.

Vehicle Speed Sensor
The vehicle speed sensor is used by the ECM and the
speedometer, and generates a speed signal from the
transmission output shaft rotational speed. The sensor has
the following circuits.
Vehicle speed signal circuit
The vehicle speed sensor uses hall elements. They
interact with magnetic fields generated by rotating
magnets to output pulse signals. The ECM calculates the
vehicle speed based on the vehicle speed sensor.
If the ECM detects that the vehicle speed sensor signals
are not generated, the DTC is set.
The fuel injection is off with the accelerator pedal not
depressed.
The engine speed is 1000 r/min or higher.
The ECM detects that no vehicle speed signal has been
generated for 5 seconds.

Vehicle Speed Sensor Range/Performance
The vehicle speed sensor is used by the ECM and the
speedometer, and generates a speed signal from the
transmission output shaft rotational speed. The sensor has
the following circuits.
Vehicle speed signal circuit
The vehicle speed sensor uses hall elements. They
interact with magnetic fields generated by rotating
magnets to output pulse signals. The ECM calculates the
vehicle speed based on the vehicle speed sensor.
When the ECM detects that the vehicle speed sensor
signal has changed drastically, the DTC is set.
The ECM detects that the vehicle speed signal has
changed greater than the predetermined speed within a
very short adjustment time.

System Voltage Low
The ECM monitors the voltage of the ignition power
source to confirm that the voltage stays within the proper
range.
When the ECM detects that the voltage of the ignition
power source is abnormally low, the DTC is set.
The ECM detects that the ignition power supply circuit is
8 V or lower for 5 seconds.
and fails.

System Voltage High
The ECM monitors the voltage of the ignition power
source to confirm that the voltage stays within the proper
range.
When the ECM detects that the voltage of the ignition
power source is abnormally high, the DTC is set.
The ECM detects that the ignition power supply circuit is
16 V or higher for 5 seconds.
and fails.

Internal Control Module Memory Check Sum Error
This diagnosis is to confirm the internal microprocessor
integrity of the ECM.
When the ECM detects a calculated checksum does not
agree with the ECM internal registered checksum
and fails.

Control Module Programming Error
The injector ID code information is stored in EEPROM
within the ECM. If no injector ID code is programmed in
the ECM or the ECM detects an error in programmed
injector ID code, the DTC is set.
The ECM detects that no injector ID code is
programmed.
The ECM detects an error in the programmed injector ID
code.
and fails.

Internal Control Module Random Access Memory (RAM) Error
When the ECM detects an abnormality of the internal
RAM
and fails.

ECM/PCM Processor
When the ECM detects an abnormality in the internal
main central processing unit (CPU) or sub integrated
circuit (IC)
and fails.

Immobilizer Key Not Programmed - ECM/PCM
The EEPROM within the ECM stores the immobilizer
security information to enable communication with ICU
and engine starting.
If the ECM detects that the immobilizer security
information is not programmed into the ECM, the DTC is
set.
When the ECM detects that the immobilizer security
information is not programmed

Throttle Actuator Control Range/Performance
The ECM opens/closes the intake throttle valve by
controlling the intake throttle motor depending upon the
engine operating status. The intake throttle valve opening
angle is detected by the position sensor, and relayed to
the ECM.
If the ECM detects that the actual and desired opening
angles of the intake throttle are different while the "ON"
command has been executed on the intake throttle motor,
the DTC is set.
DTCs P0122, P0123 and P0697 have not been set.
The intake throttle motor has executed the "ON"
command.
The desired intake throttle opening angle is constant.
The ECM detects that the difference between the actual
and desired opening angles of the intake throttle is 10 %
or more for 5 seconds.

Sensor Reference Voltage 1 Circuit
The ECM supplies 5 V power to the accelerator pedal
position sensor 1 via the 5 V power supply circuit 1.
The ECM monitors the voltage of the 5 V power supply
circuit 1, and sets the DTC when it detects that the
voltage is abnormally low or high.
DTC P060B is not set.
The ECM detects that the voltage of the 5 V power
supply circuit 1 is 4.7 V or lower or 5.3 V or higher.
and fails.

Malfunction Indicator Lamp (MIL) Control Circuit
The MIL is located within the instrument panel cluster.
The MIL informs the driver that a malfunction has
occurred in the engine control system and it is necessary
to repair the vehicle.
The ECM monitors for any status different from MIL
command status in the MIL control circuit. The circuit is
defective if the ECM detects a low voltage when the MIL
is commanded off, or if the ECM detects a high voltage
when the MIL is commanded on.
If the ECM detects any abnormal value of control circuit
voltage, the DTC is set.
Either of following conditions is met.
When the ECM executes an off command, a low voltage
status is detected in the MIL control circuit.
When the ECM executes an on command, a high voltage
status is detected in the MIL control circuit.
and fails.

The ECM supplies 5 V power to the following sensors
through 5 V power supply circuit 2.
Accelerator pedal position sensor 2
IAT sensor
The ECM also supplies 5 V power to the following
sensors through 5 V power supply circuit 5.
FRP sensor
CMP sensor
5 V power supply circuits 2 and 5 are independent of
each other outside of the ECM, but share the bus inside
the ECM. Therefore, the entire 5 V power supply circuits
2 and 5 may be affected by a short circuit in either of the
sensor 5 V power supply circuits.
circuits 2 and 5, and sets the DTC when it detects that the
The ECM detects that voltage of the 5 V power supply
circuit 2 or 5 is 4.7 V or lower or 5.3 V or higher.
The ECM blinks the exhaust brake indicator light.

Intake Manifold Tuning Valve Control Circuit Low
The ECM controls the flow amount and energizes the
swirl control solenoid valve, based on the engine running
status. The ECM sends instructions to the swirl control
solenoid valve, adds vacuum pressure to the diaphragm
actuator, and operates the swirl control butterfly that is
installed to every intake port. When the ECM detects an
open circuit in the solenoid valve circuit, the DTC is set.
The ECM detects low voltage status on the swirl control
solenoid valve circuit when the solenoid is commanded
off.
and fails.

Intake Manifold Tuning Valve Control Circuit High
The ECM controls the flow amount and energizes the
swirl control solenoid valve, based on the engine running
status. The ECM sends instructions to the swirl control
solenoid valve, adds vacuum pressure to the diaphragm
actuator, and operates the swirl control butterfly that is
installed to every intake port. When the ECM detects a
short circuit in the solenoid valve circuit, the DTC is set.
The ECM detects high voltage status on the swirl control
solenoid valve circuit when the solenoid is commanded
on.
and fails.

The ECM supplies 5 V power to the following sensors
through the power supply circuit 4.
CKP sensor
Boost sensor
Intake throttle position sensor
The 5 V power supply circuits 4 are independent of each
other outside of the ECM, but share the bus inside the
ECM. Therefore, the entire 5 V power supply circuit 4
may be affected by a short circuit in one of the sensor 5 V
power supply circuits.
circuit 4, and sets the DTC when it detects that the
The ECM detects that voltage of the 5 V power supply
circuit 4 is 4.7 V or lower or 5.3 V or higher.

Transmission Control System (MIL Request)
The TCM requests to illuminate the MIL to the ECM via
the CAN when the TCM sets the MIL illumination
request DTC.
If the ECM detects the MIL illumination request signal,
this DTC is set.
DTCs U0001 and U0101 are not set.
The ECM detects the MIL illumination request from the
TCM.

Fuel Rail Pressure (FRP) Too Low
ECM based on the signals from the FRP sensor.
If the ECM detects that actual fuel pressure is lower than
the desired fuel pressure, the DTC is set.
DTCs P0087, P0091, P0092, P0192, P0193, P0201-
P0204, P0651, P2146 and P2149 are not set.
The FRP regulator instructs the fuel flow rate higher than
certain level.
The ECM detects that the fuel rail pressure has been 20
MPa (2900 psi) or more lower than the desired fuel
pressure for 25 seconds or longer.
The PCM illuminates the MIL on the second consecutive
driving cycle that the diagnostic runs and fails on the
consecutive driving cycle.

Injector Positive Voltage Control Circuit Group 1
The charge up circuit within the ECM increases the
voltage applied to the injector. The charge up circuit is
divided into 2 banks: common power supply 1 and
common power supply 2. The common power supply 1
serves for the injectors of No.1 and No.4 cylinders, while
the common power supply 2 serves for the injectors of
No.2 and No.3 cylinders.
The charge up voltage DTC
When the common 1 fuel injector charge up circuit within
the ECM is in an insufficient charge or excessive charge
condition, this DTC is set.
The supply voltage high or low DTC
When the voltage supplied to the common 1 and 2 fuel
injector charge up circuits is abnormally high or low, this
DTC is set.
The charge up voltage DTC
The engine is not running.
The ECM detects that the common 1 fuel injector charge
up circuit is in an insufficient charge condition or in an
excessive charge condition.
The supply voltage high or low DTC
The ECM detects that the voltage supplied to the
common 1 and 2 fuel injector charge up circuits is
abnormally high or low.
and fails.

The charge up circuit within the ECM increases the
voltage applied to the injector. The charge up circuit is
divided into 2 banks: common power supply 1 and
common power supply 2. The common power supply 1
serves for the injectors of No.1 and No.4 cylinders, while
the common power supply 2 serves for the injectors of
No.2 and No.3 cylinders.
When the common 2 fuel injector charge up circuit within
the ECM is in an insufficient charge or excessive charge
condition, the DTC is set.
The engine is not running.
The ECM detects that the common 2 fuel injector charge
up circuit is in an insufficient charge condition or in an
excessive charge condition.
and fails.

Exhaust Gas Recirculation (EGR) Closed Position Performance
internal microprocessor controls the EGR motor in
engine running condition. The EGR valve lift amount is
detected by the position sensor, and is relayed to the
ECM.
For a closed position error DTC, if the ECM detects that
the actual EGR valve opening angle is larger than certain
amount, this DTC is set.
For a learned position error DTC, if the ECM detects a
variance between the learned closed position and actual
closed position, the DTC is set.
Closed position error DTC
DTCs P0112, P0113, P0117, P0118, P0403, P0404,
P0651, P2227, P2228, P2229 and U010A have not been
set.
The engine coolant temperature is between 20 and 110 ℃
(68 and 230 ℉).
The intake air temperature is between 0 and 110 ℃ (32
and 230 ℉).
The barometric pressure is between 60 and 120 kPa (8.7
and 17.4 psi).
The ECM detects that the difference between the actual
and the desired EGR valve opening angle is 20 % or more
for 11 seconds or longer.
Learned position error DTC
DTCs P0404 and U010A have not been set.
The ECM detects that when the ignition switch becomes
off, the EGR learned position is 10 % or higher or -10 %
or lower.
When a diagnosis is conducted and an abnormality is
detected in the consecutive driving cycles, the ECM
lights the MIL during the second driving cycle.
The ECM prohibits the EGR control. (Closed position
error DTC)
DTC P161B (Flash Code 179)

Immobilizer Wrong Response
1. DTC P161B description of DTC
The ECM communicates with the ICU to execute
immobilizer function. The ECM sends a request signal to
the ICU. The ECM receives a response signal from the
ICU. Both communication signals are carried out via
CAN communication.
If the ECM receives a wrong response signal from the
ICU, the DTC is set.
2. DTC P161B condition for setting the DTC
When the ECM receives a wrong immobilizer response
signal from the ICU
3. DTC P161B action taken when the DTC sets
DTC P1621 (Flash Code 54, 254)

Control Module Long Term Memory Performance
The electrically erasable and programmable read only
memory (EEPROM) memorizes learned data, VIN data,
and immobilizer security information. When the ECM
detects an error with one of these data, the DTC is set.
The ECM detects an error with the learned data within
the EEPROM (flash code 54).
The ECM detects an error with the VIN data and the
immobilizer security information within the EEPROM
(flash code 254).
The ECM limits the fuel injection amount. (Flash code
54)

Pedal Position Sensor 1 Circuit Low Input
The accelerator pedal position sensor is installed to the
accelerator pedal control assembly. The sensor consists of
2 sensors within 1 housing. The ECM uses the accelerator
pedal position sensor to calculate target acceleration and
deceleration. Accelerator pedal position sensor 1 has
following circuits.
Accelerator pedal position sensor 1 signal circuit
Accelerator pedal position sensor 1 sends signals
concerning the acceleration pedal angle position change
to the ECM via the signal circuit. If the ECM detects an
excessively low signal voltage, the DTC is set.
The ECM detects that the accelerator pedal position
sensor 1 signal voltage is less than 0.15 V.
and fails.

Pedal Position Sensor 1 Circuit High Input
deceleration. Accelerator pedal position sensor 1 has the
following circuits.
excessively high signal voltage, the DTC is set.
sensor 1 signal voltage is 4.85 V or higher.
and fails.

following circuits.
excessively low signal voltage, the DTC is set.
sensor 2 signal voltage is less than 0.15 V.
and fails.

following circuits.
to the ECM via the signal circuit.
DTC is set.
sensor 2 signal voltage is 4.85 V or higher.
and fails.

Pedal Position Sensor 1 - 2 Voltage Correlation
2 sensors within 1 housing. Accelerator pedal position
sensor 1 and accelerator pedal position sensor 2 are hall
IC type sensors with following circuits.
Signal circuit
The ECM supplies 5 V to the accelerator pedal position
sensors via the 5 V power supply circuit, and the low
reference circuit connects to the low reference. The
accelerator pedal position sensor sends signals related to
acceleration pedal angle position change to the ECM via
the signal circuit. Signal voltage of accelerator pedal
position sensor 1 is kept low first and increases as the
pedal is depressed. Signal voltage of accelerator pedal
position sensor 2 is kept high first and decreases as the
pedal is depressed.
If the ECM detects that voltages of both the accelerator
pedal position sensor 1 signal and accelerator pedal
position sensor 2 signal are not correlated, the DTC is set.
The signal voltage of accelerator pedal position sensor 1
is between 0.15 and 4.85 V.
The signal voltage of accelerator pedal position sensor 2
is between 0.15 and 4.85 V.
sensors 1 and 2 are apart from each other by more than 40
% or larger.
and fails.

Fuel Injector Group 1 Supply Voltage Circuit
and 2 supply high voltage, and the injectors of each
cylinder are driven along with grounding of the injector
solenoid control circuit by the ECM. Common power
supply 1 serves the injectors of cylinders No.1 and No.4,
while common power supply 2 serves the injectors of
cylinders No.2 and No.3. When the injector charge
voltage circuit of common power supply 1 or 2 has an
open circuit or a short circuit to the low reference or
voltage circuit, the DTC is set depending upon the
defective injector common power supply circuit.
In case of a short circuit of the injector solenoid control
circuit with the low reference, the DTC is set.
DTCs P0201 and P0204 have not been set.
The ECM detects that the injector charge voltage circuit
of common power supply 1 has an open circuit or short
circuit to the low reference or voltage circuit, or the
cylinder No. 1 or No. 4 injector solenoid coil control
circuit has a short circuit to the low reference.
and fails.

and 2 supply high voltage, and the injectors of each
cylinder are driven along with grounding of the injector
solenoid control circuit by the ECM. Common power
supply 1 serves the injectors of cylinders No.1 and No.4,
while common power supply 2 serves the injectors of
cylinders No.2 and No.3. When the injector charge
voltage circuit of common power supply 1 or 2 has an
open circuit or a short circuit to the low reference or
voltage circuit, the DTC is set depending upon the
defective injector common power supply circuit.
In case of a short circuit of the injector solenoid control
circuit with the low reference, the DTC is set.
DTCs P0202 and P0203 have not been set.
The ECM detects that the injector charge voltage circuit
of common power supply 2 has an open circuit or short
circuit to the low reference or voltage circuit, or the
cylinder No. 2 or No. 3 injector solenoid coil control
circuit has a short circuit to the low reference.
and fails.

Barometric Pressure Circuit Range/Performance
The barometric pressure sensor is installed to the air
pressure. Within the ECM, the diagnosis compares the
barometric pressure sensor input with the boost sensor
input.
If the ECM detects that the inputs are not within a
specified amount of each other, this DTC is set.
DTCs P0102, P0103, P0117, P0118, P0122, P0123,
P0237, P0238, P0500, P0501, P0638, P0651, P0697,
P2228 and P2229 have not been set.
The engine coolant temperature is 5 ℃ (41 ℉).
The engine rpm is lower than 800 r/min.
The fuel injection amount is at or below the
predetermined value.
The accelerator pedal is not depressed.
The vehicle is not running.
The engine runtime is 5 seconds or longer.
The ECM detects that the barometric pressure is 10 kPa
(1.5 psi) higher than the boost pressure and the condition
continues for 10 seconds or longer.
and fails.

Barometric Pressure Circuit Low
pressure. The sensor has the following circuits.
Barometric pressure sensor signal circuit
The barometric pressure sensor sends signals related to
barometric pressure change to the ECM. The ECM
detects low signal voltage at high altitudes and with low
barometric pressure. The ECM detects high signal
voltage with high barometric pressure. The ECM uses
this voltage signal to adjust fuel injection amount and
injection timing and make altitude correction.
DTC is set.
The ECM detects that the barometric pressure sensor
signal voltage is 0.1 V or lower for 3 seconds.
and fails.
The ECM substitutes a default value of barometric
pressure.

Barometric Pressure Circuit High
pressure. The sensor has the following circuits.
Barometric pressure sensor signal circuit
The barometric pressure sensor sends signals related to
barometric pressure change to the ECM. The ECM
detects low signal voltage at high altitudes and with low
barometric pressure. The ECM detects high signal
voltage with high barometric pressure. The ECM uses
this voltage signal to adjust fuel injection amount and
injection timing and make altitude correction.
DTC is set.
The ECM detects that the barometric pressure sensor
signal voltage is 4.3 V or higher for 3 seconds.
and fails.
The ECM substitutes a default value of barometric
pressure.
DTC U0001 (Flash Code 84)

High Speed CAN Communication Bus
1. DTC U0001 description of DTC
The ECM, TCM, ICU, DRM and instrument panel cluster
communicate the control information and diagnosis
information via CAN communication. The ECM
monitors CAN operational status by predicting a constant
message flow from each module.
If the ECM fails to receive an expected message, the
DTC is set.
2. DTC U0001 condition for setting the DTC
The ECM detects the CAN Bus off status.
3. DTC U0001 action taken when the DTC sets

Lost Communication With TCM
The ECM, TCM, ICU, DRM and instrument panel cluster
communicate the control information and diagnosis
information via CAN communication. The ECM
monitors CAN operational status by predicting a constant
message flow from each module.
If the ECM fails to receive an expected message, the
DTC is set.
The ECM detects that the CAN Bus messages from the
TCM are not being received.
DTC U010A (Flash Code 346)

Lost Communication With Exhaust Gas Recirculation Control Module
1. DTC U010A description of DTC
The ECM communicates with the EGR valve to perform
the EGR control. The ECM sends a request signal to the
EGR valve. The ECM receives a response signal from the
EGR valve. Both communication signals are carried out
via CAN communication.
When the ECM does not detect a response signal from
the EGR valve, the DTC is set.
2. DTC U010A condition for setting the DTC
The ECM detects that the CAN Bus messages from the
EGR valve have not been received.
3. DTC U010A action taken when the DTC sets
The ECM substitutes a default value of the actual EGR
position.
The ECM substitutes a default value of the desired EGR
position.

Lost Communication With Vehicle Immobilizer Control Module
The ECM communicates with the ICU to execute
immobilizer function. The ECM sends a request signal to
the ICU. The ECM receives a response signal from the
ICU. Both communication signals are carried out via
CAN communication.
If the ECM does not detect a response signal from the
ICU, the DTC is set.
The ECM does not receive an immobilizer response
signal from the ICU.
Engine Control (4JK1) 1A-1
Engine Control
Engine Control
(4JK1)
Table of Contents
DTC P0016 (Flash Code 16) Crankshaft Position - Camshaft DTC P0202 (Flash Code 272) Injector Circuit - Cylinder 2
Position Correlation........................................................1A-3 .......................................................................................1A-37
DTC P0045 (Flash Code 33) Turbocharger Boost Control DTC P0203 (Flash Code 273) Injector Circuit - Cylinder 3
Solenoid Circuit..............................................................1A-4 .......................................................................................1A-38
DTC P0087 (Flash Code 225) Fuel Rail/System Pressure - DTC P0204 (Flash Code 274) Injector Circuit - Cylinder 4
Too Low..........................................................................1A-5 .......................................................................................1A-39
DTC P0088 (Flash Code 118) Fuel Rail/System Pressure - DTC P0217 (Flash Code 542) Engine Coolant Over
Too High.........................................................................1A-8 Temperature Condition.................................................1A-40
DTC P0089 (Flash Code 151) Fuel Pressure Regulator DTC P0219 (Flash Code 543) Engine Overspeed Condition
Performance..................................................................1A-11 .......................................................................................1A-41
DTC P0091 (Flash Code 247) Fuel Pressure Regulator DTC P0234 (Flash Code 42) Turbocharger Overboost
Control Circuit Low......................................................1A-13 Condition.......................................................................1A-42
DTC P0092 (Flash Code 247) Fuel Pressure Regulator DTC P0237 (Flash Code 32) Turbocharger Boost Sensor
Control Circuit High.....................................................1A-15 Circuit Low...................................................................1A-44
DTC P0093 (Flash Code 227) Fuel System Leak Detected DTC P0238 (Flash Code 32) Turbocharger Boost Sensor
.......................................................................................1A-17 Circuit High...................................................................1A-45
DTC P0102 (Flash Code 91) Mass Air Flow Circuit Low DTC P0299 (Flash Code 65) Turbocharger Underboost
Input..............................................................................1A-20 .......................................................................................1A-46
DTC P0103 (Flash Code 91) Mass Air Flow Circuit High DTC P0335 (Flash Code 15) Crankshaft Position Sensor
Input..............................................................................1A-21 Circuit............................................................................1A-48
DTC P0112 (Flash Code 22) Intake Air Temperature Sensor DTC P0336 (Flash Code 15) Crankshaft Position Sensor
Circuit Low...................................................................1A-22 Circuit Range/Performance...........................................1A-50
DTC P0113 (Flash Code 22) Intake Air Temperature Sensor DTC P0340 (Flash Code 14) Camshaft Position Sensor
Circuit High...................................................................1A-23 Circuit............................................................................1A-51
DTC P0117 (Flash Code 23) Engine Coolant Temperature DTC P0380 (Flash Code 66) Glow Plug Circuit..........1A-53
Sensor Circuit Low.......................................................1A-25 DTC P0403 (Flash Code 347) Exhaust Gas Recirculation
DTC P0118 (Flash Code 23) Engine Coolant Temperature Control Circuit..............................................................1A-54
Sensor Circuit High.......................................................1A-26 DTC P0404 (Flash Code 45) Exhaust Gas Recirculation
DTC P0122 (Flash Code 43) Throttle Position Sensor Control Circuit Range/Performance..............................1A-56
Circuit Low...................................................................1A-28 DTC P0500 (Flash Code 25) Vehicle Speed Sensor.....1A-57
DTC P0123 (Flash Code 43) Throttle Position Sensor DTC P0501 (Flash Code 25) Vehicle Speed Sensor Range/
Circuit High...................................................................1A-29 Performance..................................................................1A-59
DTC P0182 (Flash Code 211) Fuel Temperature Sensor DTC P0562 (Flash Code 35) System Voltage Low......1A-61
Circuit Low...................................................................1A-30
DTC P0563 (Flash Code 35) System Voltage High.....1A-62
DTC P0183 (Flash Code 211) Fuel Temperature Sensor
Circuit High...................................................................1A-31 DTC P0601 (Flash Code 53) Internal Control Module
Memory Check Sum Error............................................1A-63
Circuit Low...................................................................1A-33 DTC P0602 (Flash Code 154) Control Module
Programming Error.......................................................1A-64
Circuit High...................................................................1A-34 DTC P0604 (Flash Code 153) Internal Control Module
Random Access Memory (RAM) Error........................1A-65
DTC P0201 (Flash Code 271) Injector Circuit - Cylinder 1
.......................................................................................1A-36 DTC P0606 (Flash Code 51) ECM/PCM Processor.....1A-66
1A-2 Engine Control (4JK1)
DTC P0633 (Flash Code 176) Immobilizer Key Not DTC U0001 (Flash Code 84) High Speed CAN
Programmed - ECM/PCM.............................................1A-67 Communication Bus......................................................1A-97
DTC P0638 (Flash Code 61) Throttle Actuator Control DTC U0101 (Flash Code 85) Lost Communication With
Range/Performance.......................................................1A-68 TCM..............................................................................1A-99
DTC P0641 (Flash Code 55) Sensor Reference Voltage 1 DTC U010A (Flash Code 346) Lost Communication With
Circuit............................................................................1A-69 Exhaust Gas Recirculation Control Module...............1A-100
DTC P0650 (Flash Code 77) Malfunction Indicator Lamp DTC U0167 (Flash Code 177) Lost Communication with
(MIL) Control Circuit...................................................1A-70 Vehicle Immobilizer Control Module.........................1A-101
Circuit............................................................................1A-72
Control Circuit Low......................................................1A-74
Control Circuit High.....................................................1A-75
Circuit............................................................................1A-76
DTC P0700 (Flash Code 185) Transmission Control System
(MIL Request)...............................................................1A-78
DTC P1093 (Flash Code 227) Fuel Rail Pressure (FRP) Too
Low...............................................................................1A-79
Control Circuit Group 1................................................1A-82
Control Circuit Group 2................................................1A-83
DTC P1404 (Flash Code 45) Exhaust Gas Recirculation
(EGR) Closed Position Performance............................1A-84
DTC P161B (Flash Code 179) Immobilizer Wrong
Response.......................................................................1A-85
DTC P1621 (Flash Code 54, 254) Control Module Long
Term Memory Performance..........................................1A-86
Circuit Low Input..........................................................1A-87
Circuit High Input.........................................................1A-88
Circuit Low Input..........................................................1A-89
Circuit High Input.........................................................1A-90
DTC P2138 (Flash Code 124) Pedal Position Sensor 1 - 2
Voltage Correlation.......................................................1A-91
Voltage Circuit..............................................................1A-92
Voltage Circuit..............................................................1A-93
Range/Performance.......................................................1A-94
Low...............................................................................1A-95
High...............................................................................1A-96

Crankshaft Position - Camshaft Position Correlation
1. DTC P0016 priority DTC Note：
DTC P0335 ・ When the engine does not start, crank the
engine for 10 seconds.
DTC P0336
4. Perform a test-run.
DTC P0340
5. Use the scan tool to confirm that a DTC has not been
2. DTC P0016 diagnostics detected.
1. Inspect the CKP sensor.
Refer to "1.Engine 1B.Mechanical(4JK1) CKP
sensor inspection".
2. If a problem is found, replace the crankshaft position
sensor.
sensor removal".
sensor installation".
3. Inspect the CMP sensor.
Refer to "1.Engine 1B.Mechanical(4JK1) CMP
sensor inspection".
4. If a problem is found, replace the camshaft position
sensor.
sensor removal".
5. Inspect the timing gear for improper installation.
6. If a problem is found, repair the timing gear.
7. Inspect the timing chain.
Note：
・ The timing chain should be correctly installed.
・ Timing chain tensioner should be free from
defect.
・ There should be no excessive play in the
timing chain.
・ There should be no damage to the teeth of the
timing chain.
8. If a problem is found, repair the timing chain.
3. DTC P0016 confirm resolution
1. Clear the DTCs with the scan tool.
2. Turn OFF the ignition switch for more than 30
seconds.

Turbocharger Boost Control Solenoid Circuit
1. DTC P0045 diagnostics inspect the harness connector of the turbocharger
control solenoid valve for a poor connection.
seconds. 18. If a problem is found, repair the harness connector.
2. Start the engine. 19. When the harness connector is normal, replace the
turbocharger control solenoid valve.
3. Inspect the solenoid control circuit between the ECM
and the turbocharger control solenoid valve. Refer to "1.Engine 1F.Induction(4JK1) Turbocharger
control solenoid removal".
Note：
・ There should be no short to the low reference Refer to "1.Engine 1F.Induction(4JK1) Turbocharger
circuit. control solenoid installation".
・ There should be no short circuit with a metal 20. Inspect the control circuit between the ECM and the
component such as a frame. turbocharger control solenoid valve.
4. If a problem is found, repair the solenoid control Note：
circuit. ・ There should be no open or high resistance.
5. Turn OFF the starter switch. ・ There should not be a short circuit to the
battery or ignition power supply circuit.
6. Disconnect the harness connector from the
turbocharger control solenoid valve. 21. If a problem is found, repair the control circuit.
7. Connect a test light between the ignition power 22. When the circuit is normal, inspect the ECM harness
supply circuit of the turbocharger control solenoid connector for a poor connection.
valve harness connector and the frame ground.
23. If a problem is found, repair the harness connector.
8. Turn ON the starter switch.
24. If the harness connector is normal, replace the ECM.
9. Check if the test lamp illuminate.
10. If the test lamp does not illuminate, inspect the ECM ECM removal".
main 10 A fuse.
11. If a problem is found, replace the fuse. ECM installation".
Note： 25. Set the immobilizer function and injector ID code in
・ When the fuse is wire-melted again, repair the the ECM.
cause of ECM main 10 A fuse meltdown. Refer to "1.Engine 1J.Electrical(4JK1) ECM setting".
12. When the ECM main 10 A fuse is normal, repair any 26. Conduct learning of unit differences in the fuel
open circuit or high resistance in the ignition power supply pumps for the ECM.
supply circuit between the ECM main 10 A fuse and
the turbocharger control solenoid valve. Refer to "1.Engine 1J.Electrical(4JK1) ECM writing".
13. Connect a test lamp between the ignition power 2. DTC P0045 confirm resolution
supply circuit and the control circuit of the 1. Clear the DTCs with the scan tool.
turbocharger control solenoid valve harness
connector. 2. Turn OFF the ignition switch for more than 30
seconds.
14. Start the engine while observing the test lamp.
15. Stop the engine while observing the test lamp.
16. Ensure that the test lamp illuminates when starting
the engine and the test lamp does not illuminate 5. Use the scan tool to confirm that a DTC has not been
when stopping the engine. detected.
17. When the test light turns on when the engine is

started and turns off when the engine is stopped,

Fuel Rail/System Pressure - Too Low
1. DTC P0087 priority DTC 12. If the Fuel Rail Pressure (FRP) Sensor display shows
a value that is within the specified range, start the
DTC P0088
engine.
DTC P0089
13. Conduct a Cylinder Balance Test with the scan tool.
DTC P0091
14. Command each injector OFF, and confirm that the
DTC P0092 engine rpm changes in each injector.
DTC P0192 15. If there is an injector whose engine rpm does not
change when OFF is commanded, replace the
DTC P0193
relevant injector.
DTC P0201
Note：
DTC P0202 ・ When the injector has been replace, set the
DTC P0203 injector ID code on the ECM.
DTC P0204 Refer to "1.Engine 1C.Fuel System(4JK1)
Injector removal".
DTC P2146
Refer to "1.Engine 1C.Fuel System(4JK1)
DTC P2149 Injector installation".
2. DTC P0087 diagnostics 16. Inspect the fuel system between the fuel tank and the
1. Turn OFF the starter switch. fuel supply pump for clogging.
2. Wait for the specified period of time to reduce the 17. If a problem is found, repair the clogging in the fuel
fuel pressure from the common rail. system.
specified time： 1 min 18. Inspect the fuel hose between the fuel tank and the
fuel supply pump for cuts and cracks.
19. If a problem is found, replace the fuel hose.
4. Check the Fuel Rail Pressure (FRP) Sensor display
on the scan tool. Note：
standard： 0.9 to 1.0 V ・ When the fuel hose is not connected securely,
the air can get inside.
5. If the Fuel Rail Pressure (FRP) Sensor display shows
・ When the engine RPM or the engine load
a value that is outside of the specified range, inspect
increases while the air has intruded in the fuel
the fuel pressure sensor harness connector for a poor
system, fluctuation in the common rail
connection.
pressure is caused, and the DTC P0087 may
6. If a problem is found, repair the harness connector. be detected.
7. Inspect the ECM harness connector for a poor 20. Confirm that an appropriate clamp is being used
connection. between the fuel tank and the fuel supply pump.
8. If a problem is found, repair the harness connector. 21. If a problem is found, replace the clamp.
9. Inspect each circuit for high resistance. 22. Operate the priming pump until the pushing weight
gets heavy.
10. If a problem is found, repair the circuit.
Note：
11. When the harness connector and each circuit are
normal, replace the fuel pressure sensor. ・ When a leak exists in the fuel system between
the primping pump and fuel supply pump, the
Refer to "1.Engine 1C.Fuel System(4JK1) Fuel pushing weight of the priming pump does not
pressure sensor removal". get heavy.
Refer to "1.Engine 1C.Fuel System(4JK1) Fuel 23. Start the engine.
pressure sensor installation".
24. Inspect the high pressure side of the fuel system to specified time： 1 min
see whether a fuel leak exists between the fuel
35. While keeping the engine speed higher than the
supply pump and the common rail.
specified speed for the specified time, observe the
Note： clear hose.
・ The fuel may leak under the cylinder head specified time： 1 min
cover from the inlet of the high pressure hose.
rotational speed： 3000 r/min Engine
・ When the fuel leaks out to the bottom the
cylinder head cover, the engine oil level 36. During the inspection, ensure that many air bubbles
increases. is entering in the fuel.
・ Inspect for a fuel leak into the engine oil. 37. If many air bubbles enter the fuel, repair the fuel
25. If a fuel leak is found, repair the appropriate portion. system.
26. Turn OFF the starter switch. Note：

・ If air bubbles enter the fuel, inspect the fuel
27. Disconnect the fuel feed hose from the fuel supply
line connections between the fuel supply pump
pump.
and the fuel tank for tightness and fuel hose
28. Install the vacuum pump to the fuel feed hose. for cuts, cracks and for the use of the proper
clamps.
38. Connect the fuel feed hose to the fuel supply pump.
from the fuel injector in order to disable the fuel
injection.
40. Disconnect the fuel feed hose from the fuel tank.
SST: 5-8840-0279-0 - vacuum pump Caution：
29. Operate the vacuum pump to confirm that the fuel ・ Use a pan to collect the fuel from the removed
flows smoothly. fuel line.
Caution： 41. Install the vacuum pump to the fuel feed hose.
・ The vacuum pump must be cleaned before
・ Otherwise, foreign material internal to the tools
line may damage the fuel supply pump.
vacuum pump.
30. When the fuel does not flow smoothly, repair the
SST: 5-8840-0279-0 - vacuum pump
fuel system.
Caution：
Note：
・ When any leakage or restriction exists on the
suction side, fuel leakage, clogging in the fuel
filter, twisting or collapsing of the fuel hose or 42. Confirm that the vacuum pump and the fuel line are
pipe, etc. are likely to prevent the fuel from securely connected.
flowing smoothly. Also, foreign materials inside 43. Crank the engine while monitoring the gauge on the
the fuel tank may possibly enter the fuel line vacuum pump.
pickup.
Note：
31. Replace the fuel hose between the fuel supply pump
and the fuel filter with a clear hose. ・ Repeat this procedure 3 times.
32. Bleed the air from the fuel system. Caution：

・ Cranking should be performed within 5
seconds at a time, and should not exceed 15
34. Let the engine idle for the specified period of time or seconds in total.
longer.
psi}
Caution：
gauge on the vacuum pump is likely to indicate
a value at or above the standard value during
the test.
44. When the value is at or below the standard value,
replace the fuel supply pump and the fuel filter
element.
Note：
・ If the fuel supply pump is replaced, the fuel
filter element is also required to be replaced at
the same time.
・ If the fuel supply pump is replaced, perform
learning of unit differences in the fuel supply
pump for the ECM.
Refer to "1.Engine 1C.Fuel System(4JK1) Fuel supply
pump removal".
pump installation".
Refer to "1.Engine 1C.Fuel System(4JK1) Fuel filter
element removal".
element installation".
seconds.
detected.

Fuel Rail/System Pressure - Too High
1. DTC P0088 priority DTC 10. If the Fuel Rail Pressure (FRP) Sensor display shows
a value that is outside of the specified range, inspect
DTC P0089
DTC P0091 connection.
DTC P0092 11. If a problem is found, repair the harness connector.
DTC P0192 12. Inspect the ECM harness connector for a poor
connection.
DTC P0193
DTC P0201
14. Inspect each circuit for high resistance.
DTC P0202
DTC P0203
DTC P0204
normal, replace the fuel pressure sensor.
DTC P2146
Refer to "1.Engine 1C.Fuel System(4JK1) Fuel
DTC P2149 pressure sensor removal".
2. DTC P0088 diagnostics Refer to "1.Engine 1C.Fuel System(4JK1) Fuel
1. Place the shift lever in the neutral position, and pull pressure sensor installation".
the parking brake lever all the way up. 17. Start the engine.
2. Start the engine. 18. Conduct a Cylinder Balance Test with the scan tool.
3. Operate the engine from the idle status to the status 19. Command each injector OFF, and confirm that the
where the accelerator pedal is fully depressed for engine rpm changes in each injector.
several times while checking the Fuel Rail Pressure
20. If there is an injector whose engine rpm does not
(FRP) display on a scan tool.
4. Use a scan tool to confirm the Fuel Rail Pressure relevant injector.
(FRP) display.
Note：
standard： 190 MPa { 27550 psi } ・ When the injector has been replace, set the
5. If the reading is less than the specified value, replace injector ID code on the ECM.
the fuel filter element. Refer to "1.Engine 1C.Fuel System(4JK1)
Note： Injector removal".
・ An intermittent problem due to foreign object in Refer to "1.Engine 1C.Fuel System(4JK1)
the fuel can be suspected. Injector installation".
Refer to "1.Engine 1C.Fuel System(4JK1) Fuel filter 21. Inspect the fuel system between the fuel tank and the
element removal". fuel supply pump for clogging.
Refer to "1.Engine 1C.Fuel System(4JK1) Fuel filter 22. If a problem is found, repair the clogging in the fuel
element installation". system.
6. Turn OFF the starter switch. 23. Inspect the fuel hose between the fuel tank and the
7. Wait for the specified period of time to reduce the fuel supply pump for cuts and cracks.
fuel pressure from the common rail. 24. If a problem is found, replace the fuel hose.
specified time： 1 min Note：
8. Turn ON the starter switch. ・ The fuel hose between the fuel tank and the
fuel supply pump is slightly vacuumed when
9. Check the Fuel Rail Pressure (FRP) Sensor display the engine is running.
on the scan tool.
・ When the fuel hose is not connected securely,
standard： 0.9 to 1.0 V the air can get inside.
・ When the engine RPM or the engine load 35. When the fuel does not flow smoothly, repair the
increases while the air has intruded in the fuel fuel system.
system, fluctuation in the common rail Note：
pressure is caused, and the DTC P0088 may
・ If there is a leakage or a restriction in the
be detected.
suction side, fuel leakage, clogged fuel filter,
25. Confirm that an appropriate clamp is being used and twisting or crushing of the fuel hose and
between the fuel tank and the fuel supply pump. the pipes, will cause insufficient flow of
fuel.Foreign matters in the fuel tank may also
26. If a problem is found, replace the clamp.
enter into the fuel line pickup.
27. Operate the priming pump until the pushing weight
36. Replace the fuel hose between the fuel supply pump
gets heavy.
and the fuel filter with a clear hose.
Note：
37. Bleed the air from the fuel system.
・ When a leak exists in the fuel system between
the primping pump and fuel supply pump, the 38. Start the engine.
pushing weight of the priming pump does not 39. Let the engine idle for the specified period of time or
get heavy. longer.
28. Start the engine. specified time： 1 min
29. Inspect the high pressure side of the fuel system to 40. While keeping the engine speed higher than the
see whether a fuel leak exists between the fuel specified speed for the specified time, observe the
supply pump and the common rail. clear hose.
Note： specified time： 1 min
・ The fuel may leak under the cylinder head
Rotational speed： 3000 r/min Engine
・ When the fuel leaks out to the bottom the 41. During the inspection, ensure that many air bubbles
cylinder head cover, the engine oil level is entering in the fuel.
increases. 42. If many air bubbles enter the fuel, repair the fuel
・ Inspect for a fuel leak into the engine oil. system.
30. If a fuel leak is found, repair the appropriate portion. Note：
31. Turn OFF the starter switch. ・ If air bubbles enter the fuel, inspect the fuel
32. Disconnect the fuel feed hose from the fuel supply and the fuel tank for tightness and fuel hose
pump. for cuts, cracks and for the use of the proper
33. Install the vacuum pump to the fuel feed hose. clamps.
injection.
Caution：
SST: 5-8840-0279-0 - vacuum pump ・ Use a pan to collect the fuel from the removed
fuel line.
34. Operate the vacuum pump to confirm that the fuel
flows smoothly. 46. Install the vacuum pump to the fuel feed hose.
Caution：
vacuum pump.
SST: 5-8840-0279-0 - vacuum pump 5. Use the scan tool to confirm that a DTC has not been
detected.
Caution：
47. Confirm that the vacuum pump and the fuel line are
securely connected.
48. Crank the engine while monitoring the gauge on the
vacuum pump.
Note：
・ Repeat this procedure 3 times.
Caution：
seconds in total.
psi}
Caution：
the test.
element.
Note：
the same time.
pump for the ECM.
pump removal".
pump installation".
element removal".
seconds.

Fuel Pressure Regulator Performance
1. DTC P0089 priority DTC 12. Inspect the suction control valve harness connector
for a poor connection.
DTC P0091
DTC P0092
14. Inspect the ECM harness connector for a poor
DTC P0192
connection.
DTC P0193
DTC P0201
DTC P0202
DTC P0203
18. Turn OFF the starter switch.
DTC P0204
19. Place the shift lever in the neutral position, and pull
DTC P0219 the parking brake.
DTC P2146 20. Start the engine.
DTC P2149 21. Operate the engine from the idle status to the status
where the accelerator pedal is fully depressed for
2. DTC P0089 diagnostics
several times while checking the Fuel Fail Pressure
1. Turn OFF the starter switch. (FRP) and desired Fuel Rail Pressure (FRP) displays
2. Wait for the specified period of time to reduce the on a scan tool.
fuel pressure from the common rail. 22. Use a scan tool to confirm if the Fuel Rail Pressure
specified time： 1 min (FRP) display shows a value within the standard
value range quickly enough.
standard： -5 to 5 MPa { -725 to 725 psi }
on the scan tool. Note：
・ If possible, compare with other vehicle
standard： 0.9 to 1.0 V equipped with the same model engine.
5. If the Fuel Rail Pressure (FRP) Sensor display shows 23. If the reading is within the specified range, replace
a value that is outside of the specified range, inspect the fuel filter element.
connection. Refer to "1.Engine 1C.Fuel System(4JK1) Fuel filter
element removal".
7. Inspect the ECM harness connector for a poor element installation".
connection.
24. If the reading is outside the specified range, replace
8. If a problem is found, repair the harness connector. the fuel supply pump and the fuel filter element.
9. Inspect each circuit for high resistance. Note：
10. If a problem is found, repair the circuit. ・ If the fuel supply pump is replaced, the fuel
11. When the harness connector is normal and no high filter element is also required to be replaced at
resistance is found in each circuit, replace the fuel the same time.
pressure sensor. ・ If the fuel supply pump is replaced, perform
pump for the ECM.
pressure sensor removal".
pump removal".
pump installation".
element removal".
seconds.
detected.

Fuel Pressure Regulator Control Circuit Low
1. DTC P0091 diagnostics 14. Connect a test lamp between the suction control
valve Low side circuit and the battery power supply.
1. Use a scan tool to confirm the Fuel Rail Pressure
(FRP) Regulator Valve Feedback Current display. 15. Turn ON the starter switch.
standard： 300 to 1300 mA 16. Check if the test lamp illuminate.
2. When the value is at or above the standard value, 17. When it does not turn on, inspect the Low side
inspect the high side circuit between the ECM and circuit between the ECM and the suction control
the suction control valve. valve.
Note： Note：
・ There should be no short circuit to the battery ・ There should be no open or high resistance.
or ignition power supply circuit. ・ There should be no short circuit to the battery
・ When the suction control valve high side circuit or ignition power supply circuit.
has a short circuit with the power supply
18. If a problem is found, repair the Low side circuit.
circuit, the engine stalls and does not start.
19. Inspect the suction control valve harness connector
3. If a problem is found, repair the High side circuit.
4. When the value is within the standard value range,
inspect the low side circuit between the ECM and the
suction control valve. 21. When the harness connector is normal, replace the
suction control valve.
Note：
・ There should be no short circuit to the ground. Refer to "1.Engine 1C.Fuel System(4JK1) Suction
control valve removal".
・ When the suction control valve low side circuit
has a short circuit with the ground, the DTC Refer to "1.Engine 1C.Fuel System(4JK1) Suction
P0091 may not be detected. control valve installation".
・ When the suction control valve low side circuit 22. Inspect the ECM harness connector for a poor
has a short circuit with the ground, the engine connection.
stalls and does not start.
7. Disconnect the harness connector from the suction ECM removal".
control valve.
8. Connect a test light between the suction control ECM installation".
valve high side circuit and the frame ground.
25. Set the immobilizer function and injector ID code in
9. Turn ON the starter switch. the ECM.
10. Check if the test lamp illuminate. Refer to "1.Engine 1J.Electrical(4JK1) ECM setting".
11. When it does not turn on, inspect the High side 26. Conduct learning of unit differences in the fuel
circuit between the ECM and the suction control supply pumps for the ECM.
valve.
Note：
・ There should be no open or high resistance.
・ There should be no short circuit to the ground. 1. Clear the DTCs with the scan tool.
・ There should not be a short circuit to the Low 2. Turn OFF the ignition switch for more than 30
side circuit. seconds.
12. If a problem is found, repair the High side circuit. 3. Start the engine.
13. Turn OFF the starter switch. 4. Perform a test-run.
detected.

Fuel Pressure Regulator Control Circuit High
1. DTC P0092 diagnostics 14. Connect a test lamp between the suction control
valve Low side circuit and the battery power supply.
1. Use a scan tool to confirm the Fuel Rail Pressure
(FRP) Regulator Valve Feedback Current display. 15. Turn ON the starter switch.
standard： 300 to 1300 mA 16. Check if the test lamp illuminate.
2. When the value is at or above the standard value, 17. When it does not turn on, inspect the Low side
inspect the high side circuit between the ECM and circuit between the ECM and the suction control
the suction control valve. valve.
Note： Note：
・ There should be no short circuit to the battery ・ There should be no open or high resistance.
or ignition power supply circuit. ・ There should be no short circuit to the battery
・ When the suction control valve high side circuit or ignition power supply circuit.
has a short circuit with the power supply
circuit, the engine stalls and does not start.
19. Inspect the suction control valve harness connector
3. If a problem is found, repair the High side circuit.
4. If the reading is within the specified range, inspect
the Low side circuit between the ECM and the
suction control valve. 21. When the harness connector is normal, replace the
suction control valve.
Note：
・ There should be no short circuit to the ground. Refer to "1.Engine 1C.Fuel System(4JK1) Suction
control valve removal".
・ When the suction control valve low side circuit
has a short circuit with the ground, the DTC Refer to "1.Engine 1C.Fuel System(4JK1) Suction
P0092 may not be detected. control valve installation".
・ When the suction control valve low side circuit 22. Inspect the ECM harness connector for a poor
has a short circuit with the ground, the engine connection.
stalls and does not start.
7. Disconnect the harness connector from the suction ECM removal".
control valve.
8. Connect a test light between the suction control ECM installation".
valve high side circuit and the frame ground.
9. Turn ON the starter switch. the ECM.
10. Check if the test lamp illuminate. Refer to "1.Engine 1J.Electrical(4JK1) ECM setting".
11. When it does not turn on, inspect the High side 26. Conduct learning of unit differences in the fuel
circuit between the ECM and the suction control supply pumps for the ECM.
valve.
Note：
・ There should be no short circuit to the ground. 1. Clear the DTCs with the scan tool.
・ There should not be a short circuit to the Low 2. Turn OFF the ignition switch for more than 30
side circuit. seconds.
12. If a problem is found, repair the High side circuit. 3. Start the engine.
detected.

Fuel System Leak Detected
1. DTC P0093 priority DTC ・ When any foreign object is contacting, replace
DTC P0087 the injector and the high pressure pipe.
DTC P0091 3. Remove each glow plug from the cylinder head
assembly.
DTC P0092
Refer to "1.Engine 1J.Electrical(4JK1) Glow
DTC P0192 plug removal".
DTC P0193 4. Inspect for fuel leakage into the combustion
DTC P0201 chamber.
DTC P0202 5. Inspect whether there is any cylinder that has fuel
leakage into the combustion chamber.
DTC P0203
6. If a fuel leak is found, replace the applicable injector.
DTC P0204
Note：
DTC P2146
・ When the injector has been replace, set the
2. DTC P0093 diagnostics Refer to "1.Engine 1C.Fuel System(4JK1)
1. Inspect the high pressure side fuel leakage between Injector removal".
the fuel supply pump and fuel injector. Refer to "1.Engine 1C.Fuel System(4JK1)
Note： Injector installation".
・ There should not be a fuel leak from the fuel 7. Turn OFF the starter switch.
supply pump. 8. Wait for the specified period of time to reduce the
・ There should not be a fuel leak from the fuel pressure from the common rail.
common rail.
specified time： 1 min
・ There should not be a fuel leak from the
pressure limiter valve. 9. Turn ON the starter switch.
・ There should not be a fuel leak from the fuel 10. Check the Fuel Rail Pressure (FRP) Sensor display
pressure sensor. on the scan tool.
・ There should be no fuel leaks from the fuel standard： 0.9 to 1.0 V
pipe between the fuel supply pump and the
common rail. 11. If the Fuel Rail Pressure (FRP) Sensor display shows
a value that is within the specified range, place the
・ There should be no fuel leaks from the fuel
shift lever in the neutral position and pull the parking
pipe between the common rail and the injector.
brake lever.
・ There should not be a fuel leak from the fuel
pipe sleeve nut. 12. If a problem is found, repair the harness connector.
2. If a fuel leak is found, repair the appropriate portion. 13. Inspect the ECM harness connector for a poor
connection.
Note：
cover from the inlet of the high pressure pipe. 15. Inspect each circuit for high resistance.
・ When the fuel leaks out to the bottom the 16. If a problem is found, repair the circuit.
cylinder head cover, the engine oil level
increases. 17. When the harness connector is normal and no high
resistance is found in each circuit, replace the fuel
・ Inspect for a fuel leak into the engine oil.
pressure sensor.
・ Remove and inspect the high pressure pipe
joints connected to the injectors for fuel leaks Refer to "1.Engine 1C.Fuel System(4JK1) Fuel
from the sleeve nut(s). pressure sensor removal".
Refer to "1.Engine 1C.Fuel System(4JK1) Fuel Note：
pressure sensor installation". ・ When a leak exists in the fuel system between
18. When the Fuel rail pressure (FRP) sensor display is the primping pump and fuel supply pump, the
within the standard value range, place the shift lever pushing weight of the priming pump does not
in the neutral position and pull the parking brake get heavy.
lever. 30. Start the engine.
19. Start the engine. 31. Inspect the high pressure side of the fuel system to
20. Conduct a Cylinder Balance Test with the scan tool. see whether a fuel leak exists between the fuel
supply pump and the common rail.
engine rpm changes in each injector. Note：
relevant injector. ・ When the fuel leaks out to the bottom the
cylinder head cover, the engine oil level
Note： increases.
・ When the injector has been replace, set the ・ Inspect for a fuel leak into the engine oil.
injector ID code on the ECM.
32. If a fuel leak is found, repair the appropriate portion.
Injector removal". 33. Turn OFF the starter switch.
Refer to "1.Engine 1C.Fuel System(4JK1) 34. Disconnect the fuel feed hose from the fuel supply
Injector installation". pump.
23. Inspect the fuel system between the fuel tank and the 35. Install the vacuum pump to the fuel feed hose.
fuel supply pump for clogging.
24. If a problem is found, repair the clogging in the fuel
system.
25. Inspect the fuel hose in the fuel system between the
fuel tank and the fuel supply pump for cuts and
cracks.
26. If a problem is found, replace the fuel hose. SST: 5-8840-0279-0 - vacuum pump
Note： 36. Operate the vacuum pump to confirm that the fuel
・ The fuel hose between the fuel tank and the flows smoothly.
supply pump is slightly vacuumed when the
engine is running. Caution：
・ When the fuel hose is not connected securely, ・ The vacuum pump must be cleaned before
the air can get inside. connecting to the fuel line.
・ When the engine RPM or the engine load ・ Otherwise, foreign material internal to the tools
increases while the air has intruded in the fuel line may damage the fuel supply pump.
system, fluctuation in the common rail ・ Be careful not to allow the fuel to enter the
pressure is caused, and the DTC P0093 may vacuum pump.
be detected. 37. When the fuel does not flow smoothly, repair the
27. Confirm that an appropriate clamp is being used fuel system.
between the fuel tank and the fuel supply pump. Note：
28. If a problem is found, replace the clamp with a ・ When any leakage or restriction exists on the
proper one. suction side, fuel leakage, clogging in the fuel
29. Operate the priming pump until the pushing weight filter, twisting or collapsing of the fuel hose or
gets heavy. pipe, etc. are likely to disturb the sufficient fuel
flow from the hose. Also, foreign materials
inside the fuel tank may possibly enter the fuel
line pickup.
38. Replace the fuel hose between the fuel supply pump Note：
and the fuel filter with a clear hose. ・ Repeat this procedure 3 times.
39. Bleed the air from the fuel system. Caution：
40. Start the engine. ・ Cranking should be performed within 5
41. Let the engine idle for the specified period of time or
seconds in total.
longer.
psi}
42. While keeping the engine speed higher than the
Caution：
specified speed for the specified time, observe the
clear hose. ・ Release the clamp or open the plug when the
specified time： 1 min a value at or above the standard value during
Rotational speed： 3000 r/min ENGINE the test.
43. During the inspection, ensure that many air bubbles 51. When the value is at or below the standard value,
is entering in the fuel. replace the fuel supply pump and the fuel filter
element.
44. If many air bubbles enter the fuel, repair the fuel
system. Note：
Note：
・ If air bubbles enter the fuel, inspect the fuel the same time.
and the fuel tank for tightness and fuel hose
for cuts, cracks and for the use of the proper
pump for the ECM.
clamps.
pump removal".
pump installation".
injection.
element removal".
Caution：
・ Use a pan to collect the fuel from the removed element installation".
fuel line.
48. Install the vacuum pump to the fuel feed hose.
seconds.
SST: 5-8840-0279-0 - vacuum pump detected.
Caution：
securely connected.
vacuum pump.

Mass Air Flow Circuit Low Input
1. DTC P0102 diagnostics 14. Inspect the ECM harness connector for a poor
connection.
2. Inspect the ECM 10 A fuse.
3. If a problem is found, replace the ECM 10 A fuse.
Note：
ECM removal".
・ When the fuse is wire-melted again, repair the
cause of ECM 10 A fuse meltdown. Refer to "1.Engine 1J.Electrical(4JK1)
ECM installation".
4. Disconnect the harness connector from the mass air
flow sensor. 17. Set the immobilizer function and injector ID code in
the ECM.
5. Inspect the ignition power supply circuit between the
ECM and the MAF sensor. Refer to "1.Engine 1J.Electrical(4JK1) ECM setting".
Note： 18. Conduct learning of unit differences in the fuel

supply pumps for the ECM.
resistance. Refer to "1.Engine 1J.Electrical(4JK1) ECM writing".
6. If a problem is found, repair the ignition power 2. DTC P0102 confirm resolution
supply circuit.
7. Connect a test cable with fuse between the ignition
power supply circuit and the signal circuit of the
seconds.
MAF sensor harness connector.
8. Check the Mass Air Flow (MAF) Sensor display on
the scan tool. 4. Perform a test-run.
standard： 4.9 V 5. Use the scan tool to confirm that a DTC has not been
detected.
9. If the reading is more than the specified value,
inspect the mass air flow sensor harness connector
11. When the harness connector is normal, replace the
mass air flow sensor.
Refer to "1.Engine 1F.Induction(4JK1) MAF and IAT
sensor removal".
12. Inspect the signal circuit between the ECM and the
Note：
・ There should be no short to the low reference
circuit.
component such as a frame.
13. If a problem is found, repair the signal circuit.

Mass Air Flow Circuit High Input
1. DTC P0103 diagnostics Refer to "1.Engine 1J.Electrical(4JK1) ECM setting".
1. Turn OFF the starter switch. 15. Conduct learning of unit differences in the fuel
2. Disconnect the harness connector from the mass air
flow sensor. Refer to "1.Engine 1J.Electrical(4JK1) ECM writing".
3. Check the Mass Air Flow (MAF) Sensor display on 2. DTC P0103 confirm resolution
the scan tool.
standard： 0.1 V
4. If the reading is more than the specified value, seconds.
inspect the signal circuit between the ECM and the
Note：
・ There should be no short circuit to the battery 5. Use the scan tool to confirm that a DTC has not been
or ignition power supply circuit. detected.
・ There should not be a short circuit to the 5 V
power supply circuit.
6. Inspect the low reference circuit between the ECM
and the MAF sensor.
Note：
resistance.
7. If a problem is found, repair the low reference
circuit.
8. Inspect the mass air flow sensor harness connector
sensor removal".
connection.
ECM removal".
ECM installation".
the ECM.

Intake Air Temperature Sensor Circuit Low
1. DTC P0112 priority DTC 3. Start the engine.
DTC P0651 4. Perform a test-run.
2. DTC P0112 diagnostics 5. Use the scan tool to confirm that a DTC has not been
detected.
2. Disconnect the harness connector from the intake air
temperature sensor.
3. Check the Intake Air Temperature (IAT) Sensor
display on the scan tool.
standard： 4.5 V
replace the intake air temperature sensor.
sensor removal".
IAT sensor.
Note：
circuit.
connection.
ECM removal".
ECM installation".
the ECM.
11. Conduct learning of unit differences in the fuel
seconds.

Intake Air Temperature Sensor Circuit High
1. DTC P0113 priority DTC 15. Check the Intake Air Temperature (IAT) Sensor
DTC P0651
standard： 0.1 V
inspect the low reference circuit between the ECM
2. Disconnect the harness connector from the intake air and the IAT sensor.
temperature sensor.
Note：
3. Turn ON the starter switch. ・ There should be no open circuit or high
4. Measure the voltage value between the IAT sensor resistance.
signal circuit and the frame ground. ・ The IAT sensor shares the low reference
standard： 5.5 V circuit with other sensors.
・ The DTCs of the sensors that share this circuit
5. If the reading is more than the specified value, may be detected.
intake air temperature sensor. 17. If a problem is found, repair the low reference
circuit.
Note：
IAT sensor.
6. If a problem is found, repair the signal circuit. Note：
7. Connect a test cable with fuse between the IAT resistance.
sensor signal circuit and the low reference circuit.
8. Check the Intake Air Temperature (IAT) Sensor
display on the scan tool. 20. Inspect the ECM harness connector for a poor
connection.
standard： 0.1 V
inspect the signal circuit between the ECM and the 22. If the harness connector is normal, replace the ECM.
IAT sensor. Refer to "1.Engine 1J.Electrical(4JK1)
Note： ECM removal".
・ There should not be a short circuit to the 5 V Refer to "1.Engine 1J.Electrical(4JK1)
power supply circuit. ECM installation".
10. If a problem is found, repair the signal circuit. 23. Set the immobilizer function and injector ID code in
the ECM.
11. Inspect the intake air temperature sensor harness
connector for a poor connection. Refer to "1.Engine 1J.Electrical(4JK1) ECM setting".
12. If a problem is found, repair the harness connector. 24. Conduct learning of unit differences in the fuel
intake air temperature sensor. Refer to "1.Engine 1J.Electrical(4JK1) ECM writing".
Refer to "1.Engine 1F.Induction(4JK1) MAF and IAT 3. DTC P0113 confirm resolution
sensor removal".
seconds.
14. Connect a test cable with fuse between the IAT
sensor signal circuit and the frame ground.
detected.

Engine Coolant Temperature Sensor Circuit Low
detected.
2. Disconnect the harness connector from the water
temperature sensor.
3. Check the Engine Coolant Temperature (ECT)
standard： 4.5 V
replace the water temperature sensor.
Refer to "1.Engine 1D.Cooling(4JK1) Engine coolant
temperature sensor removal".
temperature sensor installation".
engine coolant temperature sensor.
Note：
circuit.
connection.
ECM removal".
ECM installation".
the ECM.
seconds.

Engine Coolant Temperature Sensor Circuit High
1. DTC P0118 priority DTC 14. Connect a test cable with fuse between the engine
coolant temperature sensor signal circuit and the
DTC P0697
frame ground.
15. Check the Engine coolant temperature (ECT) sensor
1. Turn OFF the starter switch. display with the scan tool.
2. Disconnect the harness connector from the water standard： 0.1 V
temperature sensor.
3. Turn ON the starter switch. inspect the engine coolant temperature sensor low
reference circuit.
4. Measure the voltage value between the engine
coolant temperature sensor signal circuit and the Note：
frame ground. ・ There should be no open circuit or high
standard： 5.5 V resistance.
5. When the value is at or above the standard value, ・ The engine coolant temperature sensor shares
inspect the signal circuit between the ECM and the the low reference circuit with other sensors.
engine coolant temperature sensor. ・ The DTCs of the sensors that share this circuit
may be detected.
Note：
circuit.
engine coolant temperature sensor.
7. Connect a test cable with fuse between the engine
coolant temperature sensor signal circuit and the low Note：
reference circuit. ・ There should be no open circuit or high
resistance.
8. Check the Engine Coolant Temperature (ECT)
Sensor display on the scan tool. 19. If a problem is found, repair the signal circuit.
standard： 0.1 V 20. Inspect the ECM harness connector for a poor
connection.
inspect the signal circuit between the ECM and the 21. If a problem is found, repair the harness connector.
engine coolant temperature sensor. 22. If the harness connector is normal, replace the ECM.
Note： Refer to "1.Engine 1J.Electrical(4JK1)
・ There should not be a short circuit to the 5 V ECM removal".
10. If a problem is found, repair the signal circuit. ECM installation".
11. Inspect the water temperature sensor harness 23. Set the immobilizer function and injector ID code in
connector for a poor connection. the ECM.
12. If a problem is found, repair the harness connector. Refer to "1.Engine 1J.Electrical(4JK1) ECM setting".
13. When the harness connector is normal, replace the 24. Conduct learning of unit differences in the fuel
water temperature sensor. supply pumps for the ECM.
Refer to "1.Engine 1D.Cooling(4JK1) Engine coolant Refer to "1.Engine 1J.Electrical(4JK1) ECM writing".
seconds.
detected.

Throttle Position Sensor Circuit Low
1. DTC P0122 priority DTC ・ There should be no short to the low reference
DTC P0697 circuit.
2. Disconnect the harness connector from the intake
throttle valve.
connection.
4. Measure the voltage value between the intake
throttle position sensor 5 V power supply circuit and
the frame ground. Refer to "1.Engine 1J.Electrical(4JK1)
ECM removal".
standard： 4.7 V
ECM installation".
inspect the 5 V power supply circuit between the
ECM and the intake throttle position sensor. 17. Set the immobilizer function and injector ID code in
the ECM.
Note：
・ There should be no open circuit or high Refer to "1.Engine 1J.Electrical(4JK1) ECM setting".
resistance. 18. Conduct learning of unit differences in the fuel
・ The intake throttle position sensor shares the 5 supply pumps for the ECM.
V power supply circuit with other sensors.
may be detected. 3. DTC P0122 confirm resolution
6. If a problem is found, repair the 5 V power supply 1. Clear the DTCs with the scan tool.
circuit. 2. Turn OFF the ignition switch for more than 30
7. Connect a fused jumper wire between the 5 V power seconds.
supply circuit and the signal circuit of the intake 3. Start the engine.
throttle position sensor.
8. Check the Intake Throttle Position Sensor display on
the scan tool. 5. Use the scan tool to confirm that a DTC has not been
detected.
standard： 4.7 V
inspect the intake throttle valve harness connector
intake throttle valve.
Refer to "1.Engine 1B.Mechanical(4JK1) Intake
throttle valve removal".
intake throttle position sensor.
Note：

Throttle Position Sensor Circuit High
1. DTC P0123 priority DTC Refer to "1.Engine 1J.Electrical(4JK1)
ECM removal".
DTC P0697
ECM installation".
2. Disconnect the harness connector from the intake the ECM.
throttle valve.
3. Check the Intake Throttle Position Sensor display on
the scan tool.
standard： 0.1 V
intake throttle position sensor. 1. Clear the DTCs with the scan tool.
Note： 2. Turn OFF the ignition switch for more than 30
・ There should be no short circuit to the battery seconds.
or ignition power supply circuit. 3. Start the engine.
detected.
6. Inspect the intake throttle valve harness connector
intake throttle valve.
and the intake throttle position sensor.
Note：
resistance.
・ The intake throttle position sensor shares the
low reference circuit with other sensors.
may be detected.
circuit.
11. Check the ECM harness connector for a poor
connection.

Fuel Temperature Sensor Circuit Low
detected.
2. Disconnect the harness connector from the fuel
temperature sensor.
3. Use a scan tool to confirm the Fuel Temperature
Sensor display.
standard： 4.7 V
replace the fuel temperature sensor.
fuel temperature sensor.
Note：
reference circuit.
connection.
ECM removal".
ECM installation".
the ECM.
seconds.

Fuel Temperature Sensor Circuit High
1. DTC P0183 priority DTC 14. Connect a test cable with fuse between the fuel
temperature sensor signal circuit and the frame
DTC P0697
ground.
1. Turn OFF the starter switch. Sensor display.
2. Disconnect the harness connector from the fuel standard： 0.1 V
temperature sensor.
3. Turn ON the starter switch. inspect the low reference circuit between the ECM
and the fuel temperature sensor.
4. Measure the voltage value between the fuel
temperature sensor signal circuit and the frame Note：
ground. ・ There should be no open circuit or high
standard： 5.3 V resistance.
5. When the value is at or above the standard value, ・ The fuel temperature sensor shares the low
inspect the signal circuit between the ECM and the reference circuit with other sensors.
fuel temperature sensor. ・ The DTCs of the sensors that share this circuit
may be detected.
Note：
circuit.
fuel temperature sensor.
7. Connect a test cable with fuse between the fuel
temperature sensor signal circuit and the low Note：
reference circuit. ・ There should be no open circuit or high
resistance.
Sensor display. 19. If a problem is found, repair the signal circuit.
connection.
inspect the signal circuit between the ECM and the 21. If a problem is found, repair the harness connector.
fuel temperature sensor. 22. If the harness connector is normal, replace the ECM.
・ There should not be a short circuit to the 5 V ECM removal".
10. If a problem is found, repair the signal circuit. ECM installation".
11. Inspect the fuel temperature sensor harness 23. Set the immobilizer function and injector ID code in
connector for a poor connection. the ECM.
12. If a problem is found, repair the harness connector. Refer to "1.Engine 1J.Electrical(4JK1) ECM setting".
13. When the harness connector is normal, replace the 24. Conduct learning of unit differences in the fuel
fuel temperature sensor. supply pumps for the ECM.
Refer to "1.Engine 1C.Fuel System(4JK1) Fuel Refer to "1.Engine 1J.Electrical(4JK1) ECM writing".
seconds.
Note：
・ Run the engine for 3 minute or longer.
detected.

Fuel Rail Pressure Sensor Circuit Low
1. DTC P0192 priority DTC 12. Inspect the ECM harness connector for a poor
connection.
DTC P0651
ECM removal".
pressure sensor.
ECM installation".
on the scan tool.
standard： 4.7 V
the ECM.
fuel pressure sensor. 16. Conduct learning of unit differences in the fuel
Note：
・ There should be no short circuit to the low Refer to "1.Engine 1J.Electrical(4JK1) ECM writing".
reference circuit. 3. DTC P0192 confirm resolution
seconds.
6. Measure the voltage value between the fuel pressure
sensor 5 V power supply circuit and the frame
ground. 4. Perform a test-run.
standard： 4.7 V 5. Use the scan tool to confirm that a DTC has not been
detected.
inspect the fuel pressure sensor harness connector for
a poor connection.
fuel pressure sensor.
10. Inspect the 5 V power supply circuit between the
ECM and the fuel pressure sensor.
Note：
resistance.
・ The fuel pressure sensor shares the 5 V power
supply circuit with other sensors.
may be detected.
11. If a problem is found, repair the 5 V power supply
circuit.

Fuel Rail Pressure Sensor Circuit High
1. DTC P0193 priority DTC Refer to "1.Engine 1C.Fuel System(4JK1) Fuel
DTC P0651
2. Disconnect the harness connector from the fuel and the fuel pressure sensor.
pressure sensor.
Note：
4. Measure the voltage value between the fuel pressure resistance.
sensor signal circuit and the frame ground. ・ The fuel pressure sensor shares the low
standard： 5.5 V reference circuit with other sensors.
5. When the value is at or above the standard value, may be detected.
fuel pressure sensor. 17. If a problem is found, repair the low reference
circuit.
Note：
6. If a problem is found, repair the signal circuit. Note：
7. Connect a test light between the fuel pressure sensor resistance.
harness connector signal circuit and the frame
ground. 19. If a problem is found, repair the signal circuit.
8. Measure the voltage value between the probe of the 20. Inspect the ECM harness connector for a poor
test light and the frame ground. connection.
standard： 4.7 V 21. If a problem is found, repair the harness connector.
9. When the value is at or above the standard value, 22. If the harness connector is normal, replace the ECM.
inspect the signal circuit between the ECM and the Refer to "1.Engine 1J.Electrical(4JK1)
fuel pressure sensor. ECM removal".
・ There should not be a short circuit to the 5 V ECM installation".
10. If a problem is found, repair the signal circuit. the ECM.
11. Connect a test cable with fuse between the fuel Refer to "1.Engine 1J.Electrical(4JK1) ECM setting".
pressure sensor signal circuit and the low reference
circuit.
on the scan tool.
standard： 0.1 V
13. If the reading is less than the specified value, inspect
the fuel pressure sensor harness connector for a poor 2. Turn OFF the ignition switch for more than 30
connection. seconds.
14. If a problem is found, repair the harness connector. 3. Start the engine.
15. When the harness connector is normal, replace the 4. Perform a test-run.
detected.

1. DTC P0201 diagnostics 14. If a problem is found, repair the harness connector.
1. Turn OFF the starter switch. 15. If the harness connector is normal, replace the ECM.
2. Disconnect the harness connector from the cylinder Refer to "1.Engine 1J.Electrical(4JK1)
No. 1 injector. ECM removal".
3. Inspect the cylinder No. 1 injector harness connector Refer to "1.Engine 1J.Electrical(4JK1)
for a poor connection. ECM installation".
4. If a problem is found, repair the harness connector. 16. Set the immobilizer function and injector ID code in
the ECM.
5. Measure the No. 1 cylinder injector solenoid
resistance. Refer to "1.Engine 1J.Electrical(4JK1) ECM setting".
standard： 2.0 Ω 17. Conduct learning of unit differences in the fuel
replace the cylinder No. 1 injector. Refer to "1.Engine 1J.Electrical(4JK1) ECM writing".
Note： 2. DTC P0201 confirm resolution
・ When the injector has been replace, set the 1. Clear the DTCs with the scan tool.
Refer to "1.Engine 1C.Fuel System(4JK1) seconds.
Injector removal".
Injector installation". 4. Perform a test-run.
7. Disconnect the harness connector from the cylinder 5. Use the scan tool to confirm that a DTC has not been
No. 4 injector. detected.
8. Measure the resistance value on the charge voltage

circuit between the cylinders No. 1 and No. 4
injectors.
standard： 1.0 Ω
9. When the value is at or above the standard value,
inspect the charge voltage circuit between the ECM
and the cylinder No. 1 injector.
Note：
resistance.
10. If a problem is found, repair the charge voltage
circuit.
inspect the control circuit between the ECM and the
cylinder No. 1 injector.
Note：
resistance.
12. If a problem is found, repair the control circuit.
13. If each circuit is normal, inspect the ECM harness
connector for a poor connection.

the ECM.
Injector removal".

injectors.
standard： 1.0 Ω
Note：
resistance.
circuit.
Note：
resistance.

the ECM.
Injector removal".

injectors.
standard： 1.0 Ω
Note：
resistance.
circuit.
Note：
resistance.

the ECM.
Injector removal".

injectors.
standard： 1.0 Ω
Note：
resistance.
circuit.
Note：
resistance.

Engine Coolant Over Temperature Condition
1. DTC P0217 priority DTC 4. Use a scan tool to confirm that the Engine Coolant
Temperature (ECT) display does not show a value at
DTC P0117
or above the standard value.
standard： 110 ℃ { 230 °F }
1. Inspect the engine coolant system.
Refer to "1.Engine 1D.Cooling(4JK1) detected.
Coolant inspection".
Refer to "1.Engine 1D.Cooling(4JK1) Cooling fan
belt inspection".
Refer to "1.Engine 1D.Cooling(4JK1)
Thermostat inspection".
Refer to "1.Engine 1D.Cooling(4JK1) Water pump
assembly inspection".
Refer to "1.Engine 1D.Cooling(4JK1)
Radiator inspection".
Refer to "1.Engine 1D.Cooling(4JK1) Cooling fan
clutch inspection".
2. Start the engine and completely warm it up.
3. Use a scan tool to confirm if the Engine Coolant
Temperature (ECT) display shows a value at or
above the standard value.
standard： 110 ℃ { 230 °F }
check with the driver if the overrun occurred due to
low engine coolant level, etc.
5. If an engine overheat has happened in the past, make
sure to inspect the engine.
6. Inspect the engine coolant temperature sensor.
temperature sensor inspection".
7. If any abnormality is found in the inspection results,
replace the water temperature sensor.
seconds.
3. Start the engine and completely warm it up.

Engine Overspeed Condition
1. DTC P0219 priority DTC
DTC P0335
DTC P0336
2. Check the Engine Speed display on the scan tool.
Note：
・ Increase the engine speed as necessary.
Values: 5000 r/min
3. When the standard value has not been exceeded,
check with the driver if the overrun occurred due to
gear slip, wrong shift operation, downhill operation,
etc.
4. If an engine overrun has happened in the past, make
sure to inspect the engine.
sensor inspection".
6. If any abnormality is found in the inspection results,
replace the crankshaft position sensor.
sensor removal".
seconds.
4. While observing the Engine Speed display on the
scan tool, increase the engine rpm by depressing and
releasing the accelerator pedal several times
repeatedly between the idling and full travel
positions.
5. Ensure that the Engine Speed display does not
exceed the specified value.
Values: 5000 r/min
detected.

Turbocharger Overboost Condition
1. DTC P0234 priority DTC 14. Use a scan tool to confirm if the Barometric Pressure
(BARO) display shows a value within the standard
DTC P0045
value range.
DTC P0237
Note：
DTC P0238 ・ The barometric pressure in the scan tool
DTC P0638 normally indicates a value, which is close to
the surrounding barometric pressure.
DTC P2227
Barometric
DTC P2228
Altitude Altitude pressure
DTC P2229 measured in measured in feet measured in
meters (m) (ft) kilopascals
(kPa)
1. Turn ON the starter switch. Determine your altitude by contacting a local weather
2. Use a scan tool to check the difference between the station or by using another reference source.
Boost Pressure display and the Barometric Pressure 4267 14000 56-64
(BARO) display. 3962 13000 58-66
standard： 10 kPa { 1.5 psi } 3658 12000 61-69
Note： 3353 11000 64-72
・ When the boost pressure on the scan tool 3048 10000 66-74
shows a value close to the barometric 2743 9000 69-77
pressure while the starter switch is ON with the 2438 8000 71-79
engine stopped, it is considered as normal.
2134 7000 74-82
3. If the reading is less than the specified value, inspect 1829 6000 77-85
the hose of the turbocharger nozzle actuator for
1524 5000 80-88
improper installation.
1219 4000 83-91
4. If a problem is found, repair the improper installation
914 3000 87-95
of the hose.
610 2000 90-98
5. Inspect the actuator controlling the nozzle of the
305 1000 94-102
turbocharger for a failure.
0 0 sea level 96-104
6. If a problem is found, repair the actuator.
-305 -1000 101-105
7. Perform the Intake Throttle Solenoid Control with
the scan tool to check the intake throttle valve for 15. When the Barometric Pressure (BARO) display
sticking. shows a value within the standard value range,
inspect the boost sensor system.
8. If a problem is found, repair the intake throttle valve.
Refer to "1.Engine 1F.Induction(4JK1) Boost
9. Inspect inside the air intake piping for oil intrusion. sensor inspection".
10. If the oil is attached to inside the piping, intercooler 16. If any abnormality is found in the boost sensor
or turbocharger, wipe it off. inspection results, replace the boost sensor.
11. Use a scan tool to confirm that the boost sensor Refer to "1.Engine 1F.Induction(4JK1) Boost
signal is normal. sensor removal".
12. Compare the sensor values under all load conditions Refer to "1.Engine 1F.Induction(4JK1) Boost
for an excessively high value. sensor installation".
13. If the reading is more than the specified value, 17. When the Barometric Pressure (BARO) display
compare the value of the barometric pressure with shows a value outside the standard value range,
the surrounding barometric pressure. inspect the Barometric Pressure sensor system.
18. If any abnormality is found in the inspection results
of the barometric pressure sensor, replace the
barometric pressure sensor.
Refer to "1.Engine 1J.Electrical(4JK1) Barometric
connection.
seconds.
4. While observing the Calculated Engine Load display
on a scan tool, accelerate the vehicle until engine
load is greater than the specified value.
Specified value： 50 %
5. While monitoring the Boost Pressure display and the
Desired Boost Pressure display with a scan tool,
keep the speed for 10 seconds.
6. Ensure that the Boost Pressure display is within the
specified value and it follows the Desired Boost
Pressure display.
standard： -20 to 20 kPa { -3 to 3 psi }
detected.

Turbocharger Boost Sensor Circuit Low
1. DTC P0237 priority DTC ・ There should be no short circuit with a metal
DTC P0697 component such as the frame.
2. DTC P0237 diagnostics 12. If a problem is found, repair the signal circuit.
1. Turn OFF the ignition switch. 13. Inspect the ECM harness connector for a contact
failure.
2. Disconnect the harness connector from the boost
sensor. 14. If a problem is found, repair the harness connector.
3. Turn ON the ignition switch. 15. When the harness connector is normal, replace the
ECM.
4. Measure the voltage value between the boost sensor
harness connector 5 V power supply circuit and the Refer to "1.Engine 1J.Electrical(4JK1)
frame ground. ECM removal".
Standard： 4.7 V Refer to "1.Engine 1J.Electrical(4JK1)

ECM installation".
inspect the 5 V power supply circuit between the 16. Set the immobilizer function and injector ID code on
ECM and the boost sensor. the ECM.
Note： Refer to "1.Engine 1J.Electrical(4JK1) ECM setting".

・ There should be no open circuit or high 17. Conduct the unit difference learning of fuel supply
resistance. pumps on the ECM.
・ The DTCs of the sensors that share this circuit Refer to "1.Engine 1J.Electrical(4JK1) ECM writing".
may be detected.
circuit. 1. Clear the DTC with a scan tool.
7. Connect a test cable with fuse between the 5 V 2. Turn the ignition switch OFF for 30 seconds or
power supply circuit and the signal circuit of the longer.
boost sensor harness connector. 3. Start the engine.
8. Use a scan tool to confirm the Boost Pressure Sensor 4. Perform a test-run.
display.
5. Use a scan tool to confirm that a DTC has not been
Standard： 4.7 V detected.
inspect the boost sensor harness connector for a
contact failure.
sensor removal".
boost sensor.
Note：
resistance.
circuit.

Turbocharger Boost Sensor Circuit High
1. DTC P0238 priority DTC 13. When the harness connector is normal, replace the
ECM.
DTC P0697
ECM removal".
2. Disconnect the harness connector from the boost ECM installation".
sensor.
3. Use a scan tool to confirm the Boost Pressure Sensor the ECM.
display.
Standard： 0.1 V
4. When the value is at or above the standard value, pumps on the ECM.
boost sensor.
Note：
・ There should be no short circuit to the battery 1. Clear the DTC with a scan tool.
or ignition power supply circuit. 2. Turn the ignition switch OFF for 30 seconds or
・ There should not be a short circuit to the 5 V longer.
and the boost sensor.
detected.
Note：
resistance.
・ The boost sensor shares the low reference
circuit with other sensors.
may be detected.
circuit.
8. Inspect the boost sensor harness connector for a
contact failure.
boost sensor.
sensor removal".
11. Inspect the ECM harness connector for a contact
failure.

Turbocharger Underboost
1. DTC P0299 priority DTC 10. Perform the Intake Throttle Solenoid Control with
the scan tool to check the intake throttle valve for
DTC P0045
sticking.
DTC P0237
11. If a problem is found, replace the intake throttle
DTC P0238 valve.
DTC P2227 Refer to "1.Engine 1B.Mechanical(4JK1) Intake
DTC P2228
DTC P2229
12. Inspect the air cleaner element.
1. Inspect the installation condition of the boost sensor.
Refer to "1.Engine 1F.Induction(4JK1) Air cleaner
Note： element inspection".
・ There should no be an air leak from 13. If a problem is found, replace the air cleaner
surroundings of the boost sensor. element.
・ There should not be any foreign object
blocking the hole of the boost sensor.
element removal".
2. If a problem is found, repair the installation
condition of the boost sensor.
3. Inspect the surroundings of the air intake piping
14. Check the duct between the air cleaner and the boost
between the turbocharger and intake manifold.
sensor for collapsing and conditions restricting the
Note： flow.
・ The air intake piping should be free from 15. If a problem is found, repair the appropriate portion.
damage.
16. Inspect inside the air intake piping for oil intrusion.
・ There should be no such cracks that open up
only while the engine is in a specific operating 17. When oil intrusion is found, repair it.
condition.
18. If the oil is attached to inside the piping, intercooler
・ There should be no loosening in the clamps. or turbocharger, wipe it off.
4. If a problem is found, repair the appropriate portion. 19. Compare the Barometric Pressure (BARO) display
5. Inspect the turbocharger assembly. on the scan tool with the surrounding barometric
pressure.
assembly inspection". 20. Ensure that the value shown for the Barometric
Pressure (BARO) display is within the specified
6. Inspect the hose of the turbocharger nozzle actuator range.
for improper installation and twisting.
Note：
7. If a problem is found, repair the hose.
・ The barometric pressure in the scan tool
8. Perform the Turbocharger Solenoid Control with the normally indicates a value, which is close to
scan tool to inspect the turbocharger control actuator the surrounding barometric pressure.
and the turbocharger control solenoid valve for
sticking. Barometric
9. If a problem is found, replace the turbocharger measured in measured in feet measured in
control solenoid valve. meters (m) (ft) kilopascals
Refer to "1.Engine 1F.Induction(4JK1) Turbocharger (kPa)
control solenoid removal". Determine your altitude by contacting a local weather
station or by using another reference source.
control solenoid installation". 4267 14000 56-64
3962 13000 58-66 5. Use the scan tool to confirm that a DTC has not been
3658 12000 61-69 detected.
3353 11000 64-72
3048 10000 66-74
2743 9000 69-77
2438 8000 71-79
2134 7000 74-82
1829 6000 77-85
1524 5000 80-88
1219 4000 83-91
914 3000 87-95
610 2000 90-98
305 1000 94-102
-305 -1000 101-105
21. If the value shown for the Barometric Pressure
(BARO) display is close to the barometric pressure,
turn OFF the ignition switch.
boost sensor.
sensor removal".
24. If the Barometric Pressure (BARO) display is
outside the standard value range, inspect the
atmospheric pressure sensor harness connector for a
poor connection.
failure.
seconds.

Crankshaft Position Sensor Circuit
DTC P0340 ・ There should be no open or high resistance.
DTC P0697
circuit.
2. DTC P0335 diagnostics ・ There should be no short circuit with a metal
1. Turn OFF the starter switch. component such as a frame.
2. Disconnect the harness connector from the 12. If a problem is found, repair the signal circuit.
crankshaft position sensor. 13. Connect a test light between the CKP sensor harness
3. Turn ON the starter switch. connector signal circuit and the frame ground.
4. Measure the voltage value between the CKP sensor 14. Measure the voltage value between the probe of the
harness connector 5 V power supply circuit and the test light and the frame ground.
frame ground. standard： 4.7 V
standard： 4.7 V 15. When the value is at or above the standard value,
5. When the value is at or below the standard value, inspect the signal circuit between the ECM and the
inspect the 5 V power supply circuit between the CKP sensor.
ECM and the CKP sensor. Note：
Note：・ There should not be a short circuit to the 5 V
・ There should be no open circuit or high power supply circuit.
resistance. 16. If a problem is found, repair the signal circuit.
・ The crankshaft position sensor shares the 5 V
17. Measure the voltage value between the 5 V power
power supply circuit with other sensors.
supply circuit and the low reference circuit of the
・ The DTCs of the sensors that share this circuit CKP sensor harness connector.
may be detected.
standard： 4.7 V
circuit. 18. If the reading is more than the specified value,
inspect the crankshaft position sensor harness
7. Measure the voltage value between the CKP sensor connector for a poor connection.
harness connector signal circuit and the frame
ground. 19. If a problem is found, repair the harness connector.
standard： 5.5 V 20. When the harness connector is normal, inspect the
crankshaft position sensor.
inspect the signal circuit between the ECM and the Refer to "1.Engine 1B.Mechanical(4JK1) CKP
CKP sensor. sensor inspection".
Note： 21. If a problem is found, replace the crankshaft position

sensor.
or ignition power supply circuit. Refer to "1.Engine 1B.Mechanical(4JK1) CKP
sensor removal".
10. Again, measure the voltage value between the CKP
sensor harness connector signal circuit and the frame
ground. 22. Inspect the low reference circuit between the ECM
and the CKP sensor.
standard： 4.7 V
Note：
the signal circuit between the ECM and the ・ There should be no open circuit or high
crankshaft position sensor. resistance.
・ The CKP sensor shares the low reference

may be detected.
circuit.
connection.
ECM removal".
ECM installation".
the ECM.
seconds.
detected.

Crankshaft Position Sensor Circuit Range/Performance
1. DTC P0336 priority DTC 5. Use the scan tool to confirm that a DTC has not been
detected.
DTC P0335
DTC P0340
DTC P0697
1. Inspect the crankshaft position sensor circuit.
Note：
・ It should not be too close to the wiring or parts
of the fuel injection system.
・ It should not be too close to any electronic
device that was additionally installed.
・ It should not be too close to the solenoid and
the relay.
2. If a problem is found, repair the crankshaft position
sensor circuit.
4. Disconnect the harness connector from the ECM.
connection.
crankshaft position sensor.
8. Inspect the crankshaft position sensor harness
sensor inspection".
11. If a problem is found, replace the crankshaft position
sensor.
sensor removal".
seconds.

Camshaft Position Sensor Circuit
1. DTC P0340 priority DTC ・ There should be no short to the low reference
DTC P0651 circuit.
2. Disconnect the harness connector from the camshaft
13. Connect a test light between the CMP sensor harness
position sensor.
connector signal circuit and the frame ground.
14. Measure the voltage value between the probe of the
4. Measure the voltage value between the CMP sensor test light and the frame ground.
harness connector 5 V power supply circuit and the
standard： 4.7 V
frame ground.
standard： 4.7 V
5. When the value is at or below the standard value, CMP sensor.
inspect the 5 V power supply circuit between the
Note：
ECM and the CMP sensor.
Note： power supply circuit.
resistance.
・ The camshaft position sensor shares the 5 V 17. Measure the voltage value between the 5 V power
power supply circuit with other sensors. supply circuit and the low reference circuit of the
CMP sensor harness connector.
may be detected. standard： 4.7 V
6. If a problem is found, repair the 5 V power supply 18. If the reading is more than the specified value,
circuit. inspect the camshaft position sensor harness
7. Measure the voltage value between the CMP sensor
harness connector signal circuit and the frame 19. If a problem is found, repair the harness connector.
ground.
20. When the harness connector is normal, inspect the
standard： 5.5 V camshaft position sensor.
8. When the value is at or above the standard value, Refer to "1.Engine 1B.Mechanical(4JK1) CMP
inspect the signal circuit between the ECM and the sensor inspection".
CMP sensor.
21. If a problem is found, replace the camshaft position
Note： sensor.
・ There should be no short circuit to the battery Refer to "1.Engine 1B.Mechanical(4JK1) CMP
or ignition power supply circuit. sensor removal".
9. If a problem is found, repair the signal circuit. Refer to "1.Engine 1B.Mechanical(4JK1) CMP
10. Again, measure the voltage value between the CMP sensor installation".
sensor harness connector signal circuit and the frame 22. Inspect the timing chain.
ground.
Note：
standard： 4.7 V
・ The timing chain should be free from damage.
11. If the reading is less than the specified value, inspect ・ The timing chain should be correctly installed.
the signal circuit between the ECM and the camshaft
position sensor. 23. If a problem is found, repair the chain sprocket.
Note： 24. Inspect the low reference circuit between the ECM
and the CMP sensor.
Note：
resistance.
・ The CMP sensor shares the low reference
may be detected.
circuit.
connection.
ECM removal".
ECM installation".
the ECM.
seconds.
detected.

Glow Plug Circuit
1. DTC P0380 diagnostics Refer to "1.Engine 1J.Electrical(4JK1)
ECM installation".
2. Replace the glow relay with a starter relay or non-
the ECM.
defective relay.
3. Perform the Glow Relay Control with a scan tool.
4. Execute ON and OFF commands to the glow relay.
5. Check whether an operation sound of the glow relay
is heard upon execution of each command.
6. When the operation sounds of the glow relay are
heard, remove the glow relay. 1. Clear the DTCs with the scan tool.
7. Inspect the glow relay terminal for a poor 2. Turn OFF the ignition switch for more than 30
connection. seconds.
8. If a problem is found, repair the glow relay terminal. 3. Perform the Glow Relay Control to execute ON and
OFF commands with the scan tool.
9. When the glow relay terminal is normal, replace the
glow relay. 4. Check whether an operation sound of the glow relay
is heard upon execution of each command.
11. Inspect the ECM 10 A fuse.
detected.
12. If a problem is found, replace the fuse.
13. Inspect the ignition power supply circuit between the
ECM 10 A fuse and the glow relay coil side.
Note：
resistance.
14. If a problem is found, repair the ignition power
supply circuit.
15. Inspect the glow relay control circuit between the
ECM and the glow relay.
Note：
16. If a problem is found, repair the glow relay control
circuit.
connection.
ECM removal".

Exhaust Gas Recirculation Control Circuit
1. DTC P0403 diagnostics ・ There should be no short circuit with a metal
1. Turn the ignition switch OFF. component such as a frame.
2. Disconnect the harness connector from the EGR 13. If a problem is found, repair the CAN low circuit.
valve. 14. Inspect the CAN high circuit between the EGR valve
3. Turn the ignition switch ON. and the ECM.
4. Measure the voltage value between the EGR valve Note：

harness connector ignition power supply circuit and ・ There should be no short circuit to the battery
the frame ground. or ignition power supply circuit.
Standard： 9.0 V ・ There should be no open circuit or high
resistance.
inspect the engine 10 A fuse.
circuit.
6. If a problem is found, replace the engine 10 A fuse. ・ There should be no short circuit with a metal
Note： component such as a frame.
・ When the fuse is wire-melted again, repair the 15. If a problem is found, repair the CAN high circuit.
cause of engine 10 A fuse meltdown.
16. When the CAN circuit is normal, inspect the ECM
7. When the engine 10 A fuse is normal, repair any harness connector for a contact failure.
open circuit or high resistance in the ignition power
supply circuit between the engine 10 A fuse and the
EGR valve. 18. When the harness connector is normal, replace the
ECM.
8. Measure the voltage value between the ignition
power supply circuit and the low reference circuit of Refer to "1.Engine 1J.Electrical(4JK1)
the EGR valve harness connector. ECM removal".
Standard： 9.0 V Refer to "1.Engine 1J.Electrical(4JK1)
ECM installation".
repair any open circuit or high resistance in the low 19. Set the immobilizer function and injector ID code on
reference circuit between the EGR valve and the the ECM.
ground terminal.
10. Measure the voltage value between the EGR valve
harness connector CAN low circuit and the frame
pumps on the ECM.
ground.
harness connector CAN high circuit and the frame 21. When the voltage value in the CAN circuit is within
ground. the standard value range, inspect the EGR valve
harness connector for a contact failure.
Standard： 1.5 to 3.5 V
inspect the CAN low circuit between the EGR valve 23. When the harness connector is normal, replace the
and the ECM. EGR valve.
Note： Refer to "1.Engine 1H.Aux. Emission Control
・ There should be no short circuit to the battery Devices(4JK1) EGR valve removal".
or ignition power supply circuit. Refer to "1.Engine 1H.Aux. Emission Control
・ There should be no open circuit or high Devices(4JK1) EGR valve installation".
resistance. 2. DTC P0403 confirm resolution
circuit. 1. Clear the DTC with a scan tool.
2. Turn the ignition switch OFF for 30 seconds or
longer.
detected.

Exhaust Gas Recirculation Control Circuit Range/Performance
ECM removal".
1. Remove the EGR valve from the engine.
ECM installation".
2. Inspect the EGR valve.
the ECM.
Note：
・ There should be no obstacle restricting the
flow in the EGR valve. 20. Conduct the unit difference learning of fuel supply
pumps on the ECM.
・ The EGR valve should be free from excessive
deposits. Refer to "1.Engine 1J.Electrical(4JK1) ECM writing".
・ There should be no bending in the valve shaft 2. DTC P0404 confirm resolution
of the EGR valve or the valve itself.
1. Clear the DTC with a scan tool.
Note：
・ Past DTCs cannot be cleared.
valve.
5. Inspect the EGR valve harness connector for a
longer.
contact failure.
detected.
failure.
EGR valve.
Note：
・ Past DTCs cannot be cleared.
14. Turn the ignition switch OFF for 30 seconds.
18. When the DTC P0404 has been detected, replace the
ECM.

Vehicle Speed Sensor
1. DTC P0500 priority DTC 11. If the scan tool does not display the vehicle speed,
DTC P0219
vehicle speed sensor
Note：
Note：
・ With ABS
ABS DTC C0221 or ignition power supply circuit.
ABS DTC C0222 ・ There should be no open or high resistance.
ABS DTC C0225 ・ There should be no short circuit to the ground
circuit.
ABS DTC C0226 ・ There should be no short circuit with a metal
ABS DTC C0231 component such as a frame.
ABS DTC C0232 12. If a problem is found, repair the signal circuit.
ABS DTC C0235 13. When the circuit is normal, inspect the ECM harness
ABS DTC C0236
ABS DTC C0238
Note： ECM removal".
・ Without ABS
1. Turn OFF the starter switch. ECM installation".
2. Disconnect the harness connector from the speed 16. Set the immobilizer function and injector ID code in
sensor. the ECM.
3. Turn ON the starter switch. Refer to "1.Engine 1J.Electrical(4JK1) ECM setting".
4. Connect a test light between the vehicle speed sensor 17. Conduct learning of unit differences in the fuel
harness connector ignition power supply circuit and supply pumps for the ECM.
the frame ground.
5. Check if the test lamp illuminate.
18. Connect a test light between the ignition power
6. If the test lamp does not illuminate, inspect the supply circuit and the ground circuit of the vehicle
Meter10 A fuse. speed sensor harness connector.
7. If a problem is found, replace the Meter 10 A fuse. 19. Check if the test lamp illuminate.
Note： 20. When the test light does not turn on, repair any open
・ If the blowout of the fuse is repeated, repair circuit or high resistance in the vehicle speed sensor
the cause of Meter10 A fuse blowout. ground circuit.
8. If the Meter 10 A fuse is normal, repair the open or 21. Inspect the installation condition of the speed sensor.
high resistance in the ignition power supply circuit Note：
between the Meter 10 A fuse and the vehicle speed
sensor. ・ There should be no damage.
・ Installation should be performed properly.
9. Intermittently jump the vehicle speed sensor signal
circuit using a test light connected to the frame 22. If a problem is found, repair the installation
ground while checking the Vehicle Speed display on condition of the speed sensor.
a scan tool. 23. Inspect the speedometer driven gear.
10. Ensure that the scan tool display any vehicle speed. Note：
・ There should be no damage.
・ Installation should be performed properly. 38. If a problem is found, repair the signal circuit.
24. If a problem is found, replace the speedometer 39. When the circuit is normal, inspect the ECM harness
driven gear. connector for a poor connection.
25. Inspect the speedometer drive gear. 40. If a problem is found, repair the harness connector.
Note： 41. If the harness connector is normal, replace the ECM.

・ There should be no damage. Refer to "1.Engine 1J.Electrical(4JK1)
・ Installation should be performed properly. ECM removal".
26. If a problem is found, replace the speedometer drive Refer to "1.Engine 1J.Electrical(4JK1)
gear. ECM installation".
27. Inspect the transmission output shaft. 42. Set the immobilizer function and injector ID code in
the ECM.
Note：
・ The teeth should be free from damage.
・ There should be no excessive play. 43. Conduct learning of unit differences in the fuel
28. If a problem is found, replace the transmission
output shaft. Refer to "1.Engine 1J.Electrical(4JK1) ECM writing".
29. Inspect the speed sensor harness connector for a poor 44. Inspect the EHCU harness connector for a poor
connection. connection.
30. If a problem is found, repair the harness connector. 45. If a problem is found, repair the harness connector.
31. If the harness connector is normal, replace the speed 46. When the harness connector is normal, replace the
sensor. EHCU.
Refer to "9.Body, Cab, Accessories 9E.Instrumentation, Refer to "4.Brakes 4D.ABS(All models)

Driver Info.(All models) Vehicle speed EHCU removal".
sensor removal". Refer to "4.Brakes 4D.ABS(All models)
Refer to "9.Body, Cab, Accessories 9E.Instrumentation, EHCU installation".
Driver Info.(All models) Vehicle speed 47. Set the vehicle information on the EHCU.
Note： EHCU setting".
・ With ABS
34. Turn ON the starter switch. seconds.
35. Intermittently jump the EHCU vehicle speed signal 3. Start the engine.
output circuit using a test light connected to the
frame ground while checking the Vehicle Speed
display on a scan tool. 5. Use the scan tool to confirm that a DTC has not been
detected.
36. Ensure that the scan tool display any vehicle speed.
37. If the scan tool does not display the vehicle speed,
inspect the vehicle speed signal circuit between the
ECM and the EHCU.
Note：

Vehicle Speed Sensor Range/Performance
1. DTC P0501 diagnostics ・ Installation should be performed properly.
Note： 16. If a problem is found, replace the speedometer drive
・ Without ABS gear.
1. Turn OFF the starter switch. 17. Inspect the transmission output shaft.
2. Inspect all the wheel speed sensor circuit. Note：
Note：・ The teeth should be free from damage.
・ No wiring harness has placed too close to the ・ There should be no excessive play.
fuel injection circuit or components. 18. If a problem is found, replace the transmission
・ No wiring harness is placed too close to the output shaft.
commercial electrical accessories.
19. Disconnect the harness connector from the speed
・ Ensure that the harness is not routed too sensor.
closely to the solenoid, the relay and the
motor. 20. Inspect the speed sensor harness connector for a poor
connection.
3. If a problem is found, repair the harness.
4. Inspect the Meter 10 A fuse.
22. If the harness connector is normal, replace the speed
5. If a problem is found, replace the Meter 10 A fuse. sensor.
Note： Refer to "9.Body, Cab, Accessories 9E.Instrumentation,
・ When the fuse is wire-melted again, repair the Driver Info.(All models) Vehicle speed
cause of Meter 10 A fuse meltdown. sensor removal".
6. Inspect the ground terminal of the vehicle speed Refer to "9.Body, Cab, Accessories 9E.Instrumentation,
sensor ground circuit for a contact failure. Driver Info.(All models) Vehicle speed
7. If a problem is found, repair the ground terminal.
Note：
・ With ABS
connection. 23. Turn OFF the starter switch.
10. If a problem is found, repair the harness connector. 24. Inspect the vehicle speed signal circuit between the
ECM and EHCU.
11. Inspect the installation condition of the speed sensor.
Note：
Note：
・ No wiring harness has placed too close to the
・ There should be no damage. fuel injection circuit or components.
・ Installation should be performed properly. ・ No wiring harness is placed too close to the
12. If a problem is found, repair the installation commercial electrical accessories.
condition of the speed sensor. ・ Ensure that the harness is not routed too
13. Inspect the speedometer driven gear. closely to the solenoid, the relay and the
motor.
Note：
25. If a problem is found, repair the harness.
・ Installation should be performed properly.
14. If a problem is found, replace the speedometer
connection.
driven gear.
15. Inspect the speedometer drive gear.
29. Inspect all the wheel speed sensor harness
Note：
connectors for a poor connection.
32. Inspect the EHCU harness connector for a poor
connection.
EHCU.
EHCU removal".
EHCU installation".
35. Set the vehicle information on the EHCU.
EHCU setting".
seconds.
detected.

System Voltage Low
1. Turn OFF the ignition switch for 30 seconds.
connection.
5. If the harness connector is normal, check the
charging system.
6. If a problem is found, repair the charging system.
seconds.
4. Turn ON the headlights and air conditioning to apply
the electrical load.
5. With a scan tool, observe the Ignition Voltage
display and check if it is greater than the specified
value.
standard： 10.0 V
detected.

System Voltage High
1. Check if the battery charger has been connected to
the battery recently.
2. Start the engine and idle it.
3. Check the Ignition Voltage display on the scan tool.
standard： 16.0 V
inspect the charging system.
5. If a problem is found, repair the charging system.
seconds.
3. Start the engine and idle it.
4. Check the Ignition Voltage display on the scan tool
to confirm that the value does not exceed the
standard value.
standard： 16.0 V
detected.

Internal Control Module Memory Check Sum Error
1. Replace the ECM.
ECM removal".
ECM installation".
the ECM.
seconds.
detected.

Control Module Programming Error
1. Confirm that all connecting sections are securely
connected.
2. Ensure that programming equipment is operating
correctly.
3. Confirm that the correct injector ID code is input
into the ECM with the scan tool.
Note：
・ When the injector ID code has been correctly
input, clear the DTC with the scan tool.
4. Turn OFF the starter switch for 30 seconds.
6. Check whether a DTC has been detected with the
scan tool.
7. If a DTC is detected, replace the ECM.
ECM removal".
ECM installation".
the ECM.
seconds.
detected.

Internal Control Module Random Access Memory (RAM) Error
1. Replace the ECM.
ECM removal".
ECM installation".
the ECM.
seconds.
detected.

ECM/PCM Processor
1. Replace the ECM.
ECM removal".
ECM installation".
the ECM.
seconds.
detected.

Immobilizer Key Not Programmed - ECM/PCM
1. Set the immobilizer security information on the
ECM.
seconds.
detected.

Throttle Actuator Control Range/Performance
1. DTC P0638 priority DTC ・ There should be no short circuit to the battery
DTC P0122 or ignition power supply circuit.
・ There should be no short circuit between
DTC P0123
circuits.
2. DTC P0638 diagnostics ・ There should not be a short circuit to the
1. Remove the air intake hose from the intake throttle intake throttle position sensor circuit.
valve. 14. If a problem is found, repair the motor circuit.
Refer to "1.Engine 1B.Mechanical(4JK1) Intake 15. When the motor circuit between the ECM and the
throttle valve removal". intake throttle valve is normal, replace the intake
2. Inspect the intake throttle valve. throttle valve.
Note： Refer to "1.Engine 1B.Mechanical(4JK1) Intake
・ The flow of the intake throttle valve should not
be restricted. Refer to "1.Engine 1B.Mechanical(4JK1) Intake
・ The throttle bore of the intake throttle valve throttle valve installation".
should be free from excessive deposits. 16. Restore the vehicle.
・ There should be no bending in the butterfly
valve of the intake throttle valve.
・ The intake throttle valve should be free from 18. Turn OFF the starter switch for 30 seconds.
sticking. 19. Start the engine.
3. If a problem is found, replace the intake throttle 20. Check whether a DTC has been detected with the
valve. scan tool.
Refer to "1.Engine 1B.Mechanical(4JK1) Intake 21. If a DTC is detected, replace the ECM.
Refer to "1.Engine 1B.Mechanical(4JK1) Intake ECM removal".
4. Turn OFF the starter switch. ECM installation".
5. Disconnect the harness connector from the intake 22. Set the immobilizer function and injector ID code in
throttle valve. the ECM.
6. Inspect the intake throttle valve harness connector Refer to "1.Engine 1J.Electrical(4JK1) ECM setting".
7. If a problem is found, repair the harness connector. supply pumps for the ECM.
8. Disconnect the harness connector from the ECM. Refer to "1.Engine 1J.Electrical(4JK1) ECM writing".
9. Inspect the ECM harness connector for a poor 3. DTC P0638 confirm resolution
connection.
11. Inspect each circuit for high resistance. seconds.
12. If a problem is found, repair the intake throttle valve 3. Start the engine.
circuit.
13. Inspect the motor circuit between the ECM and the
intake throttle valve. 5. Use the scan tool to confirm that a DTC has not been
detected.
Note：

2. Disconnect the harness connector from the Refer to "1.Engine 1J.Electrical(4JK1)
accelerator pedal position sensor. ECM removal".
3. Turn ON the starter switch. Refer to "1.Engine 1J.Electrical(4JK1)
ECM installation".
supply circuit for accelerator pedal position sensor 1 14. Set the immobilizer function and injector ID code in
of the accelerator pedal position sensor harness the ECM.
connector and the frame ground.
standard： 5.3 V
5. When the value is at or above the standard value, supply pumps for the ECM.
inspect the 5 V power supply circuit of the
accelerator pedal position sensor 1 between the ECM
and the accelerator pedal position sensor. 2. DTC P0641 confirm resolution
Note： 1. Clear the DTCs with the scan tool.
・ There should be no short circuit to the battery 2. Turn OFF the ignition switch for more than 30
or ignition power supply circuit. seconds.
6. If a problem is found, repair the 5 V power supply 3. Start the engine.
circuit of the accelerator pedal position sensor 1.
supply circuit for accelerator pedal position sensor 1 5. Use the scan tool to confirm that a DTC has not been
of the accelerator pedal position sensor harness detected.
standard： 4.7 V
8. If the reading is more than or equal to the specified
value, replace the accelerator pedal assembly.
Refer to "1.Engine 1I.Speed Control Systems(4JK1)
Accelerator pedal assembly removal".
Accelerator pedal assembly installation".
and the accelerator pedal position sensor.
Note：
reference circuit.
11. When the circuit is normal, inspect the ECM harness

Malfunction Indicator Lamp (MIL) Control Circuit
ECM installation".
1. Ensure that the instrument panel cluster is operating
correctly. 21. Set the immobilizer function and injector ID code in
the ECM.
3. Inspect the Meter 10 A fuse.
4. If a problem is found, replace the Meter 10 A fuse.
Note：
・ When the fuse is wire-melted again, repair the
cause of Meter 10 A fuse meltdown. 23. When the check engine warning light does not turn
on, inspect the ignition power supply circuit between
5. Disconnect the harness connector from the ECM. the Meter 10 A fuse and the instrument panel cluster.
6. Turn ON the starter switch. Note：
7. Check whether the check engine warning light is ・ There should be no open circuit or high
turned off. resistance.
8. When the check engine warning light is not turned 24. If a problem is found, repair the ignition power
off, repair any short circuit to the ground between the supply circuit.
ECM and the instrument panel cluster.
25. Inspect the check engine warning light control circuit
9. Turn OFF the starter switch. between the ECM and the instrument panel cluster.
10. Remove the Meter 10 A fuse. Note：
resistance.
12. Measure the voltage value between the check engine
warning light control circuit of the ECM harness 26. If a problem is found, repair the check engine
connector and the frame ground. warning light control circuit.
standard： 1 V 27. Inspect the instrument panel cluster harness
repair any short circuit to the battery power supply or 28. If a problem is found, repair the harness connector.
ignition power supply circuit between the ECM and 29. When the harness connector is normal, replace the
the instrument panel cluster. instrument panel cluster.
14. Turn OFF the starter switch. Refer to "9.Body, Cab, Accessories 9E.Instrumentation,
15. Install the Meter 10 A fuse. Driver Info.(All models) Instrument panel
cluster removal".
16. Connect a test cable with fuse between the ECM
harness connector check engine warning light control Refer to "9.Body, Cab, Accessories 9E.Instrumentation,
circuit and the frame ground. Driver Info.(All models) Instrument panel
cluster installation".
30. Write the vehicle information into the instrument
18. When the check engine warning light turns on, panel cluster.
inspect the ECM harness connector for a poor
connection. Refer to "9.Body, Cab, Accessories 9E.Instrumentation,
Driver Info.(All models) Instrument panel
19. If a problem is found, repair the harness connector. cluster setting".
20. If the harness connector is normal, replace the ECM. 2. DTC P0650 confirm resolution
Refer to "1.Engine 1J.Electrical(4JK1) 1. Clear the DTCs with the scan tool.
ECM removal".
seconds.
3. Turn the starter switch on and wait for 10 seconds.
detected.

1. DTC P0651 diagnostics 13. When the value is at or below the standard value,
measure the voltage value between the 5 V power
supply circuit for the accelerator pedal position
2. Disconnect the harness connector from the sensor 2 of the accelerator pedal position sensor
accelerator pedal position sensor. harness connector and the frame ground.
3. Turn ON the starter switch. standard： 4.7 V
4. Measure the voltage value between the 5 V power 14. If the reading is more than or equal to the specified
supply circuit for accelerator pedal position sensor 2 value, replace the accelerator pedal assembly.
of the accelerator pedal position sensor harness
standard： 5.3 V
5. When the value is at or above the standard value, Accelerator pedal assembly installation".
15. If the reading is less than the specified value, turn
OFF the starter switch.
Note：
pressure sensor.
or ignition power supply circuit. 17. Turn ON the starter switch.
6. If a problem is found, repair the 5 V power supply 18. Measure the voltage value between the 5 V power
circuit of the accelerator pedal position sensor 2. supply circuit for accelerator pedal position sensor 2
7. Inspect the fuel pressure sensor 5 V power supply connector and the frame ground.
circuit between the ECM and the fuel pressure
sensor. standard： 4.7 V
Note： 19. If the reading is more than the specified value,

replace the fuel pressure sensor.
or ignition power supply circuit. Refer to "1.Engine 1C.Fuel System(4JK1) Fuel
8. If a problem is found, repair the fuel pressure sensor
5 V power supply circuit. Refer to "1.Engine 1C.Fuel System(4JK1) Fuel
9. Inspect the CMP sensor 5 V power supply circuit
between the ECM and the CMP sensor. 20. If the reading is less than the specified value, turn
Note：
・ There should be no short circuit to the battery 21. Disconnect the harness connector from the camshaft
or ignition power supply circuit. position sensor.
10. If a problem is found, repair the camshaft position 22. Turn ON the starter switch.
sensor 5 V power supply circuit. 23. Measure the voltage value between the 5 V power
11. Inspect the barometric pressure sensor 5 V power supply circuit for accelerator pedal position sensor 2
supply circuit between the ECM and the barometric of the accelerator pedal position sensor harness
pressure sensor. connector and the frame ground.
Note： standard： 4.7 V

・ There should be no short circuit to the battery 24. If the reading is more than the specified value,
or ignition power supply circuit. replace the camshaft position sensor.
12. If a problem is found, repair the barometric pressure Refer to "1.Engine 1B.Mechanical(4JK1) CMP
sensor 5 V power supply circuit. sensor removal".
Refer to "1.Engine 1B.Mechanical(4JK1) CMP 35. If a problem is found, repair the camshaft position
sensor installation". sensor 5 V power supply circuit.
25. If the reading is less than the specified value, turn 36. Inspect the barometric pressure sensor 5 V power
OFF the starter switch. supply circuit between the ECM and the barometric
pressure sensor.
barometric pressure sensor. Note：
27. Turn ON the starter switch. ・ There should be no short to the low reference
circuit.
supply circuit for accelerator pedal position sensor 2
connector and the frame ground. 37. If a problem is found, repair the barometric pressure
sensor 5 V power supply circuit.
standard： 4.7 V
38. When the circuit is normal, replace the ECM.
replace the barometric pressure sensor. Refer to "1.Engine 1J.Electrical(4JK1)
ECM removal".
pressure sensor removal". Refer to "1.Engine 1J.Electrical(4JK1)
ECM installation".
pressure sensor installation". 39. Set the immobilizer function and injector ID code in
the ECM.
inspect the 5 V power supply circuit of the Refer to "1.Engine 1J.Electrical(4JK1) ECM setting".
Note：
circuit. 2. DTC P0651 confirm resolution
・ There should be no short circuit with a metal 1. Clear the DTCs with the scan tool.
component such as a frame. 2. Turn OFF the ignition switch for more than 30
31. If a problem is found, repair the 5 V power supply seconds.
32. Inspect the fuel pressure sensor 5 V power supply
circuit between the ECM and the fuel pressure
sensor. 5. Use the scan tool to confirm that a DTC has not been
detected.
Note：
circuit.
33. If a problem is found, repair the fuel pressure sensor
5 V power supply circuit.
34. Inspect the CMP sensor 5 V power supply circuit
between the ECM and the CMP sensor.
Note：
circuit.

Intake Manifold Tuning Valve Control Circuit Low
1. DTC P0661 diagnostics 15. If a problem is found, repair the control circuit.
1. Turn OFF the starter switch. 16. When the test light remains off, inspect the control
circuit between the ECM and the swirl control
2. Disconnect the harness connector from the swirl
solenoid valve.
control solenoid valve.
Note：
3. Connect a test light between the swirl control
solenoid valve harness connector battery power ・ There should be no open circuit or high
supply circuit and the frame ground. resistance.
4. Turn ON the starter switch. 17. If a problem is found, repair the control circuit.
5. If the test lamp does not illuminate, inspect the 18. Turn OFF the starter switch.
Engine10 A fuse. 19. Disconnect the harness connector from the ECM.
6. If a problem is found, replace the Engine 10 A fuse. 20. Inspect the ECM harness connector for a poor
Note： connection.
・ If the blowout of the fuse is repeated, repair 21. If a problem is found, repair the harness connector.
the cause of Engine 10A fuse blowout.
7. Repair the open or the high resistance in the battery
power supply circuit between the Engine 10 A fuse
ECM removal".
and the swirl control solenoid valve.
8. If the test lamp illuminates, connect the test lamp
ECM installation".
between the control circuit of the swirl control valve
harness connector and the battery power supply. 23. Set the immobilizer function and injector ID code in
the ECM.
9. Perform the Swirl Control Solenoid Control with a
scan tool. Refer to "1.Engine 1J.Electrical(4JK1) ECM setting".
10. Command the swirl control solenoid valve ON and 24. Conduct learning of unit differences in the fuel
OFF. supply pumps for the ECM.
Note： Refer to "1.Engine 1J.Electrical(4JK1) ECM writing".
・ When commanded ON, the test lamp 2. DTC P0661 confirm resolution
illuminates and when commanded OFF, the
test lamp does not illuminate. 1. Clear the DTCs with the scan tool.
11. If a test lamp operates properly, inspect the swirl 2. Turn OFF the ignition switch for more than 30
control solenoid valve harness connector for a poor seconds.
connection. 3. Start the engine.
12. If a problem is found, repair the harness connector. 4. Perform a test-run.
13. If the harness connector is normal, replace the swirl 5. Use the scan tool to confirm that a DTC has not been
control solenoid valve. detected.
Refer to "1.Engine 1B.Mechanical(4JK1) Swirl control
solenoid valve removal".
solenoid valve installation".
14. When the test light remains on, inspect the control
solenoid valve.
Note：
・ There should be no short circuit to the ground.

Intake Manifold Tuning Valve Control Circuit High
2. Disconnect the harness connector from the swirl
control solenoid valve.
3. Check the DTC using the scan tool.
4. When the DTC P0661 has been detected without the
DTC P0662 being detected on the scan tool, replace
the swirl control solenoid valve.
solenoid valve removal".
solenoid valve installation".
5. When the DTC P0662 has been detected without the
DTC P0661 being detected, inspect the control
solenoid valve.
Note：
7. If the circuit is normal, replace the ECM.
ECM removal".
ECM installation".
the ECM.
seconds.
detected.

1. DTC P0697 diagnostics 13. If the reading is less than the specified value, turn
14. Disconnect the harness connector from the intake
2. Disconnect the harness connector from the boost
throttle valve.
sensor.
5 V power supply circuit of the boost sensor harness
5 V power supply circuit of the boost sensor harness
standard： 4.7 V
standard： 5.3 V
replace the intake throttle valve.
inspect the boost sensor 5 V power supply circuit
between the ECM and the boost sensor. Refer to "1.Engine 1B.Mechanical(4JK1) Intake
Note：
・ There should be no short circuit to the battery Refer to "1.Engine 1B.Mechanical(4JK1) Intake
or ignition power supply circuit. throttle valve installation".
6. If a problem is found, repair the boost sensor 5 V 18. If the reading is less than the specified value, turn
power supply circuit. OFF the starter switch.
7. Inspect the intake throttle position sensor 5 V power 19. Disconnect the harness connector from the
supply circuit between the ECM and the intake crankshaft position sensor.
throttle valve. 20. Turn ON the starter switch.
Note： 21. Measure the voltage value between the boost sensor
・ There should be no short circuit to the battery 5 V power supply circuit of the boost sensor harness
or ignition power supply circuit. connector and the frame ground.
8. If a problem is found, repair the intake throttle standard： 4.7 V
position sensor 5 V power supply circuit.
9. Inspect the CKP sensor 5 V power supply circuit replace the crankshaft position sensor.
between the ECM and the CKP sensor.
Note： sensor removal".
・ There should be no short circuit to the battery Refer to "1.Engine 1B.Mechanical(4JK1) CKP
or ignition power supply circuit. sensor installation".
10. If a problem is found, repair the crankshaft position 23. If the reading is less than the specified value, turn
sensor 5 V power supply circuit. OFF the starter switch.
11. When the value is at or below the standard value, 24. When the value is at or below the standard value,
measure the voltage value between the boost sensor inspect the boost sensor 5 V power supply circuit
5 V power supply circuit of the boost sensor harness between the ECM and the boost sensor.
Note：
standard： 4.7 V
12. If the reading is more than the specified value, reference circuit.
replace the boost sensor. ・ There should be no short circuit with a metal
Refer to "1.Engine 1F.Induction(4JK1) Boost component such as a frame.
sensor removal". 25. If a problem is found, repair the boost sensor 5 V
Refer to "1.Engine 1F.Induction(4JK1) Boost power supply circuit.
26. Inspect the intake throttle position sensor 5 V power
supply circuit between the ECM and the intake
throttle valve.
Note：
reference circuit.
27. If a problem is found, repair the intake throttle
position sensor 5 V power supply circuit.
28. Inspect the CKP sensor 5 V power supply circuit
between the ECM and the CKP sensor.
Note：
reference circuit.
29. If a problem is found, repair the crankshaft position
sensor 5 V power supply circuit.
30. Replace the ECM.
ECM removal".
ECM installation".
the ECM.
seconds.
detected.

Transmission Control System (MIL Request)
1. Use the scan tool to check whether a DTC of the
transmission control system is detected.
2. If a DTC is detected, repair the applicable DTC.
3. If a DTC is not detected, replace the ECM.
ECM removal".
ECM installation".
the ECM.
seconds.
detected.

Fuel Rail Pressure (FRP) Too Low
1. DTC P1093 priority DTC shift lever in the neutral position and pull the parking
brake lever.
DTC P0087
DTC P0091
14. Conduct a Cylinder Balance Test with the scan tool.
DTC P0092
DTC P0192
engine rpm changes in each injector.
DTC P0193
DTC P0201 change when OFF is commanded, replace the
relevant injector.
DTC P0202
DTC P0203 Note：
・ When the injector has been replace, set the
DTC P2146 Refer to "1.Engine 1C.Fuel System(4JK1)
DTC P2149 Injector removal".
2. DTC P1093 diagnostics Refer to "1.Engine 1C.Fuel System(4JK1)
Injector installation".
17. If the engine rpm changes in all injectors when OFF
2. Wait for the specified period of time to reduce the is commanded to them, replace the pressure limiter
fuel pressure from the common rail. valve.
specified time： 1 min Refer to "1.Engine 1C.Fuel System(4JK1) Pressure
3. Turn ON the starter switch. limiter removal".
4. Check the Fuel Rail Pressure (FRP) Sensor display Refer to "1.Engine 1C.Fuel System(4JK1) Pressure
on the scan tool. limiter installation".
standard： 0.9 to 1.0 V Note：
5. If the Fuel Rail Pressure (FRP) Sensor display shows ・ There is a possibility that the pressure limiter
a value that is outside of the specified range, inspect valve may be stuck open or the operating
the fuel pressure sensor harness connector for a poor pressure may fall down.
connection. 18. Inspect the fuel system between the fuel tank and the
6. If a problem is found, repair the harness connector. fuel supply pump for clogging.
7. Inspect the ECM harness connector for a poor 19. If a problem is found, repair the clogging in the fuel
connection. system.
8. If a problem is found, repair the harness connector. 20. Inspect the fuel hose between the fuel tank and the
fuel supply pump for cuts and cracks.
21. If a problem is found, replace the fuel hose.
Note：
・ The fuel hose between the fuel tank and the
normal, replace the fuel pressure sensor.
fuel supply pump is slightly vacuumed when
Refer to "1.Engine 1C.Fuel System(4JK1) Fuel the engine is running.
pressure sensor removal". ・ When the fuel hose is not connected securely,
Refer to "1.Engine 1C.Fuel System(4JK1) Fuel the air can get inside.
pressure sensor installation". ・ When the engine RPM or the engine load
increases while the air has intruded in the fuel
12. If the Fuel Rail Pressure (FRP) Sensor display shows
system, fluctuation in the common rail
a value that is within the specified range, place the
pressure occurs, and the DTC P1093 may be Note：

detected. ・ If there is a leakage or a restriction in the
suction side, fuel leakage, clogged fuel filter,
22. Confirm that an appropriate clamp is being used
and twisting or crushing of the fuel hose and
between the fuel tank and the fuel supply pump.
the pipes, will cause insufficient flow of
23. If a problem is found, replace the clamp. fuel.Foreign matters in the fuel tank may also
24. Operate the priming pump until the pushing weight enter into the fuel line pickup.
gets heavy. 33. Replace the fuel hose between the fuel supply pump
and the fuel filter with a clear hose.
Note：
・ When a leak exists in the fuel system between 34. Bleed the air from the fuel system.
the primping pump and fuel supply pump, the 35. Start the engine.
pushing weight of the priming pump does not
get heavy. 36. Let the engine idle for the specified period of time or
longer.
26. Inspect the high pressure side of the fuel system to
see whether a fuel leak exists between the fuel 37. While keeping the engine speed higher than the
supply pump and the common rail. specified speed for the specified time, observe the
clear hose.
Note：
cover from the inlet of the high pressure hose. Rotational speed： 3000 r/min Engine
・ When the fuel leaks out to the bottom the 38. During the inspection, ensure that many air bubbles
cylinder head cover, the engine oil level is entering in the fuel.
increases.
39. If many air bubbles enter the fuel, repair the fuel
・ Inspect for a fuel leak into the engine oil.
system.
27. If a fuel leak is found, repair the appropriate portion.
Note：
28. Turn OFF the starter switch. ・ If air bubbles enter the fuel, inspect the fuel
29. Disconnect the fuel feed hose from the fuel supply line connections between the fuel supply pump
pump. and the fuel tank for tightness and fuel hose
for cuts, cracks and for the use of the proper
30. Install the vacuum pump to the fuel feed hose. clamps.
injection.
Caution：
SST: 5-8840-0279-0 - vacuum pump ・ Use a pan to collect the fuel from the removed
31. Operate the vacuum pump to confirm that the fuel fuel line.
flows smoothly. 43. Install the vacuum pump to the fuel feed hose.
Caution：
vacuum pump.
32. When the fuel does not flow smoothly, repair the SST: 5-8840-0279-0 - vacuum pump
fuel system.
Caution：
securely connected.
vacuum pump.
Note：
・ Repeat this procedure 3 times.
Caution：
seconds in total.
psi}
Caution：
the test.
element.
Note：
the same time.
pump for the ECM.
pump removal".
pump installation".
element removal".
seconds.
detected.

1. Inspect the engine ground terminal of the ECM
ground circuit for a contact failure.
2. If a problem is found, repair the engine ground
terminal.
3. Inspect the ECM ground circuit between the ECM
and the engine ground terminal.
Note：
・ There should be no intermittent open circuit or
high resistance.
4. If a problem is found, repair the ECM ground circuit.
ECM and the ECM main relay.
Note：
high resistance.
supply circuit.
connection.
ECM removal".
ECM installation".
the ECM.
seconds.
detected.

1. Inspect the engine ground terminal of the ECM
ground circuit for a contact failure.
2. If a problem is found, repair the engine ground
terminal.
3. Inspect the ECM ground circuit between the ECM
and the engine ground terminal.
Note：
high resistance.
4. If a problem is found, repair the ECM ground circuit.
ECM and the ECM main relay.
Note：
high resistance.
supply circuit.
connection.
ECM removal".
ECM installation".
the ECM.
seconds.
detected.

Exhaust Gas Recirculation (EGR) Closed Position Performance
1. DTC P1404 priority DTC 4. Perform a test-run.
DTC P0404 5. Use a scan tool to confirm that a DTC has not been
detected.
1. Remove the EGR valve from the engine.
Note：
・ There should be no obstacle restricting the
flow in the EGR valve.
・ The EGR valve should be free from excessive
deposits.
・ There should be no bending in the valve shaft
of the EGR valve or the valve itself.
3. If a problem is found, repair or replace the EGR
valve.
valve.
contact failure.
failure.
EGR valve.
longer.
DTC P161B (Flash Code 179)

Immobilizer Wrong Response
1. DTC P161B priority DTC
DTC P0633
DTC U0001
DTC U0167
2. DTC P161B diagnostics
1. Check for an immobilizer DTC using the scan tool.
2. Check whether a DTC of the immobilizer is
detected.
3. If a DTC of the immobilizer has been detected,
perform diagnosis for the immobilizer DTC.
4. Set or reset the immobilizer functions on the ECM.
5. If the problem has not been resolved after
performing setting or resetting, replace the ECM.
ECM removal".
ECM installation".
the ECM.
3. DTC P161B confirm resolution
seconds.
detected.
DTC P1621 (Flash Code 54, 254)

Control Module Long Term Memory Performance
1. Confirm that all connecting sections are securely
connected.
2. Ensure that programming equipment is operating
correctly.
3. Turn OFF the starter switch for more than 30
seconds.
scan tool.
6. If the DTC is detected, check if correct VIN and
immobilizer code are properly written in the ECM
with a scan tool.
8. Turn OFF the starter switch for more than 30
seconds.
scan tool.
ECM removal".
ECM installation".
the ECM.
seconds.
detected.

circuit.
1. Turn OFF the starter switch. ・ There should be no short circuit with a metal
2. Disconnect the harness connector from the component such as a frame.
accelerator pedal position sensor. 13. If a problem is found, repair the signal circuit.
3. Turn ON the starter switch. 14. Inspect the ECM harness connector for a poor
4. Measure the voltage value between the 5 V power connection.
supply circuit of the accelerator pedal position sensor 15. If a problem is found, repair the harness connector.
1 and the frame ground.
standard： 4.7 V ECM.
5. When the value is at or below the standard value, Refer to "1.Engine 1J.Electrical(4JK1)
inspect the 5 V power supply circuit between the ECM removal".
ECM and the accelerator pedal position sensor 1.
Note： ECM installation".
resistance.
the ECM.
・ The accelerator pedal position sensor 1 shares
the 5 V power supply circuit with other Refer to "1.Engine 1J.Electrical(4JK1) ECM setting".
sensors. 18. Conduct learning of unit differences in the fuel
・ The DTCs of the sensors that share this circuit supply pumps for the ECM.
may be detected.
circuit.
7. Connect a fused jumper wire between the 5 V power
supply circuit and the signal circuit of the accelerator 2. Turn OFF the ignition switch for more than 30
pedal position sensor 1. seconds.
8. Use a scan tool to confirm the Accelerator Pedal 3. Start the engine.
Position (APP) Sensor 1 display.
4. Fully depress the accelerator pedal and then release it
standard： 4.7 V while checking the Accelerator Pedal Position (APP)
Sensor 1 display on a scan tool.
inspect the accelerator pedal position sensor harness 5. In the operation of depressing and then releasing the
connector for a poor connection. pedal, confirm that the scan tool does not show a
value at or below the standard value.
standard： 0.2 V
11. If the harness connector is normal, replace the
accelerator pedal assembly. 6. Use the scan tool to confirm that a DTC has not been
detected.
the signal circuit between the ECM and the
accelerator pedal position sensor 1.

connection.
DTC P0641
ECM.
accelerator pedal position sensor.
ECM removal".
3. Use a scan tool to confirm the Accelerator Pedal
ECM installation".
standard： 0.1 V
4. If the reading is more than the specified value, the ECM.
Note：
or ignition power supply circuit. Refer to "1.Engine 1J.Electrical(4JK1) ECM writing".
・ There should be no short circuit to the 5 V 3. DTC P2123 confirm resolution
power source.
6. Connect a test light between the accelerator pedal seconds.
position sensor 1 low reference circuit and battery
power source.
7. If the test light illuminates, inspect the accelerator
while checking the Accelerator Pedal Position (APP)
pedal position sensor harness connector for a poor
connection.
5. In the operation of depressing and then releasing the
pedal, confirm that the scan tool does not show a
9. If the harness connector is normal, replace the value at or above the standard value.
accelerator pedal assembly.
standard： 4.8 V
detected.
10. When the test light does not turn on, inspect the low
reference circuit between the ECM and the
Note：
resistance.
the low reference circuit with other sensors.
may be detected.
circuit.

circuit.
accelerator pedal position sensor. 13. If a problem is found, repair the signal circuit.
4. Measure the voltage value between the 5 V power connection.
supply circuit of the accelerator pedal position sensor 15. If a problem is found, repair the harness connector.
2 and the frame ground.
ECM and the accelerator pedal position sensor 2.
resistance.
the ECM.
the 5 V power supply circuit with other Refer to "1.Engine 1J.Electrical(4JK1) ECM setting".
sensors. 18. Conduct learning of unit differences in the fuel
・ The DTCs of the sensors that share this circuit supply pumps for the ECM.
may be detected.
circuit.
supply circuit and the signal circuit of the accelerator 2. Turn OFF the ignition switch for more than 30
pedal position sensor 2. seconds.
8. Use a scan tool to confirm the Accelerator Pedal 3. Start the engine.
standard： 4.7 V while checking the Accelerator Pedal Position (APP)
inspect the accelerator pedal position sensor harness 5. In the operation of depressing and then releasing the
connector for a poor connection. pedal, confirm that the scan tool does not show a
value at or below the standard value.
standard： 0.2 V
11. If the harness connector is normal, replace the
accelerator pedal assembly. 6. Use the scan tool to confirm that a DTC has not been
detected.

connection.
DTC P0651
ECM.
ECM removal".
3. Use a scan tool to confirm the Accelerator Pedal
ECM installation".
standard： 0.1 V
Note：
power source.
6. Connect a test light between the accelerator pedal seconds.
position sensor 2 low reference circuit and battery
power source.
7. If the test light illuminates, inspect the accelerator
while checking the Accelerator Pedal Position (APP)
pedal position sensor harness connector for a poor
connection.
5. In the operation of depressing and then releasing the
pedal, confirm that the scan tool does not show a
9. If the harness connector is normal, replace the value at or above the standard value.
accelerator pedal assembly.
standard： 4.8 V
detected.
Note：
resistance.
the low reference circuit with other sensors.
may be detected.
circuit.

Pedal Position Sensor 1 - 2 Voltage Correlation
1. DTC P2138 priority DTC 17. Fully depress the accelerator pedal and then release it
while checking for a DTC with the scan tool.
DTC P0641
DTC P0651
DTC P2122
ECM removal".
DTC P2123
DTC P2127 ECM installation".
DTC P2128 19. Set the immobilizer function and injector ID code in
the ECM.
3. Inspect the accelerator pedal position sensor harness
connector for a poor connection. 3. DTC P2138 confirm resolution
4. If a problem is found, repair the harness connector. 1. Clear the DTCs with the scan tool.
5. Disconnect the harness connector from the ECM. 2. Turn OFF the ignition switch for more than 30
seconds.
connection. 3. Start the engine.
7. If a problem is found, repair the harness connector. 4. Fully depress the accelerator pedal and then release it
while checking the DTC information with the scan
8. Inspect the circuit between the ECM and the
tool.
Note：
detected.
・ There should not be a high resistance.
Note：
・ There should be no short circuit between
circuits.
12. If the signal circuit is normal, replace the accelerator
pedal assembly.
15. Turn OFF the starter switch for 30 seconds.

1. DTC P2146 diagnostics Standard： 1 MΩ
1. Turn OFF the starter switch. 13. If the reading is less than the specified value, replace
the appropriate injector.
2. Disconnect the harness connectors from the cylinders
No. 1 and No. 4 injectors. Note：
3. Turn ON the starter switch. ・ When the injector has been replace, set the
4. Measure the voltage value between the solenoid
control circuit and the frame ground. Refer to "1.Engine 1C.Fuel System(4JK1)
Injector removal".
Note：
・ Cylinder No. 1 injector solenoid control circuit
and frame ground
・ Cylinder No. 4 injector solenoid control circuit 14. If the reading is more than the specified value,
and frame ground disconnect the harness connector from the ECM.
connection.
inspect the control circuit between the ECM and the 16. If a problem is found, repair the harness connector.
injector. 17. Inspect the charge voltage circuit between the ECM
Note： and the cylinder No. 1 injector.
・ There should be no short circuit to the ground. Note：
6. If a problem is found, repair the control circuit. ・ There should be no open circuit or high
resistance.
7. Inspect the charge voltage circuit between the ECM
and the injector. 18. Inspect the charge voltage circuit between the ECM
Note：
Note：
or ignition power supply circuit. ・ There should be no open circuit or high
resistance.
circuit.
circuit.
9. If the charge voltage circuit between the ECM and
the injector is normal, replace the ECM. 1. Clear the DTCs with the scan tool.
Refer to "1.Engine 1J.Electrical(4JK1) 2. Turn OFF the ignition switch for more than 30
ECM removal". seconds.
Refer to "1.Engine 1J.Electrical(4JK1) 3. Start the engine.
ECM installation".
the ECM.
detected.
12. Check whether the insulation resistance between the
injectors of the cylinders No. 1 and No. 4 is at or

1. DTC P2149 diagnostics Standard： 1 MΩ
1. Turn OFF the starter switch. 13. If the reading is less than the specified value, replace
the appropriate injector.
2. Disconnect the harness connectors from the cylinders
No. 2 and No. 3 injectors. Note：
3. Turn ON the starter switch. ・ When the injector has been replace, set the
4. Measure the voltage value between the solenoid
control circuit and the frame ground. Refer to "1.Engine 1C.Fuel System(4JK1)
Injector removal".
Note：
・ Cylinder No. 2 injector solenoid control circuit
and frame ground
・ Cylinder No. 3 injector solenoid control circuit 14. If the reading is more than the specified value,
and frame ground disconnect the harness connector from the ECM.
connection.
inspect the control circuit between the ECM and the 16. If a problem is found, repair the harness connector.
injector. 17. Inspect the charge voltage circuit between the ECM
Note： and the cylinder No. 2 injector.
・ There should be no short circuit to the ground. Note：
6. If a problem is found, repair the control circuit. ・ There should be no open circuit or high
resistance.
7. Inspect the charge voltage circuit between the ECM
and the injector. 18. Inspect the charge voltage circuit between the ECM
Note：
Note：
or ignition power supply circuit. ・ There should be no open circuit or high
resistance.
circuit.
circuit.
9. If the charge voltage circuit between the ECM and
the injector is normal, replace the ECM. 1. Clear the DTCs with the scan tool.
Refer to "1.Engine 1J.Electrical(4JK1) 2. Turn OFF the ignition switch for more than 30
ECM removal". seconds.
Refer to "1.Engine 1J.Electrical(4JK1) 3. Start the engine.
ECM installation".
the ECM.
detected.
12. Check whether the insulation resistance between the
injectors of the cylinders No. 2 and No. 3 is at or

Barometric Pressure Circuit Range/Performance
1. DTC P2227 priority DTC 5. If a problem is found, repair the harness connector.
DTC P0237 6. Inspect the circuit between the ECM and the
DTC P0238
Note：
DTC P2228
DTC P2229
8. Replace the barometric pressure sensor.
1. Use a scan tool to confirm the Barometric Pressure
(BARO) display. Refer to "1.Engine 1J.Electrical(4JK1) Barometric
Note：
・ The barometric pressure in the scan tool
normally indicates a value, which is close to
the surrounding barometric pressure. 9. When the Barometric Pressure (BARO) display is
close to the surrounding Barometric Pressure, turn
Barometric the ignition switch OFF.
measured in measured in feet measured in 10. Disconnect the harness connector from the boost
meters (m) (ft) kilopascals sensor.
(kPa) 11. Inspect the boost sensor harness connector for a poor
Determine your altitude by contacting a local weather connection.
station or by using another reference source.
4267 14000 56-64
13. Inspect the circuit between the ECM and the boost
3962 13000 58-66
sensor.
3658 12000 61-69
Note：
3353 11000 64-72
3048 10000 66-74
2743 9000 69-77 14. If a problem is found, repair the circuit.
2438 8000 71-79 15. Replace the boost sensor.
2134 7000 74-82 Refer to "1.Engine 1F.Induction(4JK1) Boost
1829 6000 77-85 sensor removal".
1524 5000 80-88 Refer to "1.Engine 1F.Induction(4JK1) Boost
1219 4000 83-91 sensor installation".
914 3000 87-95 3. DTC P2227 confirm resolution
610 2000 90-98
305 1000 94-102
seconds.
-305 -1000 101-105
2. When the difference between the Barometric
Pressure (BARO) display and the surrounding 4. Use the scan tool to confirm that a DTC has not been
Barometric Pressure is large, turn the ignition switch detected.
OFF.
4. Inspect the barometric pressure sensor harness

Barometric Pressure Circuit Low
circuit.
barometric pressure sensor. 13. If a problem is found, repair the signal circuit.
4. Measure the voltage value between the barometric connection.
pressure sensor 5 V power supply circuit and the 15. If a problem is found, repair the harness connector.
frame ground.
ECM and the barometric pressure sensor.
resistance.
the ECM.
・ The barometric pressure sensor shares the 5
V power supply circuit with other sensors. Refer to "1.Engine 1J.Electrical(4JK1) ECM setting".
・ The DTCs of the sensors that share this circuit 18. Conduct learning of unit differences in the fuel
may be detected. supply pumps for the ECM.
6. If a problem is found, repair the 5 V power supply Refer to "1.Engine 1J.Electrical(4JK1) ECM writing".
circuit.
supply circuit and the signal circuit of the barometric
pressure sensor. 2. Turn OFF the ignition switch for more than 30
seconds.
(BARO) Sensor display. 3. Start the engine.
standard： 4.7 V 4. Perform a test-run.
9. If the reading is more than the specified value, 5. Use the scan tool to confirm that a DTC has not been
inspect the barometric pressure sensor harness detected.

Barometric Pressure Circuit High
connection.
DTC P0651
ECM.
ECM removal".
(BARO) Sensor display.
ECM installation".
standard： 0.1 V
Note：
power source.
6. Connect a test light between the barometric pressure seconds.
sensor low reference circuit and the battery power
source.
7. If the test light illuminates, inspect the barometric
pressure sensor harness connector for a poor 5. Use the scan tool to confirm that a DTC has not been
connection. detected.
Note：
resistance.
・ The barometric pressure sensor shares the
low reference circuit with other sensors.
may be detected.
circuit.

High Speed CAN Communication Bus
1. DTC U0001 diagnostics 22. Disconnect the harness connector from the
instrument panel cluster.
2. Disconnect the harness connector from the DRM.
25. If a DTC is not detected, replace the instrument
panel cluster.
5. If a DTC is not detected, replace the DRM.
Refer to "9.Body, Cab, Accessories 9E.Instrumentation, Driver Info.(All models) Instrument panel
Driver Info.(All models) DRM removal". cluster removal".
Refer to "9.Body, Cab, Accessories 9E.Instrumentation, Refer to "9.Body, Cab, Accessories 9E.Instrumentation,
Driver Info.(All models) DRM installation". Driver Info.(All models) Instrument panel
cluster installation".
26. Write the vehicle information into the instrument
7. Connect the harness connector to the DRM.
panel cluster.
8. Disconnect the harness connector from the TCM.
9. Turn ON the starter switch. Driver Info.(All models) Instrument panel
10. Check the DTC using the scan tool. cluster setting".
11. If a DTC is not detected, replace the TCM. 27. Turn OFF the starter switch.
Refer to "5.Transmission, Transaxle 28. Connect the harness connector to the instrument
5B.Automatic(TB-50LS) TCM removal". panel cluster.
Refer to "5.Transmission, Transaxle 29. Disconnect the harness connector from the auto air
5B.Automatic(TB-50LS) TCM installation". conditioner control unit.
12. Set the vehicle information on the TCM. 30. Turn ON the starter switch.
Refer to "5.Transmission, Transaxle 31. Check the DTC using the scan tool.
5B.Automatic(TB-50LS) TCM setting". 32. If a DTC is not detected, replace the auto air
13. Turn OFF the starter switch. conditioner control unit.
14. Connect the harness connector to the TCM. Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Control panel
15. Disconnect the ICU harness connector from the ICU. assembly removal".
16. Turn ON the starter switch. Refer to "7.HVAC 7B.Heater, Ventilator,
17. Check the DTC using the scan tool. Airconditioner(All models) Control panel
18. If a DTC is not detected, replace the ICU.
Locks(All models) ICU removal". 34. Connect the harness connector to the auto air
conditioner control unit.
Locks(All models) ICU installation". 35. Disconnect the harness connector from the TCCM.
19. Set authentication information on the ICU. 36. Turn ON the starter switch.
Refer to "9.Body, Cab, Accessories 9J.Security and 37. Check the DTC using the scan tool.
Locks(All models) ICU setting". 38. When a DTC is not detected, replace the TCCM.
20. Turn OFF the starter switch. Refer to "3.Driveline, Axle 3D.Transfer Case(All
21. Connect the harness connector to the ICU. models) TCCM removal".
Refer to "3.Driveline, Axle 3D.Transfer Case(All 61. Turn ON the starter switch.
models) TCCM installation".
63. If a DTC is not detected, replace the BCM.
40. Connect the harness connector to the TCCM.
41. Disconnect the harness connector from the EHCU. Driver Info.(All models) BCM removal".
42. Turn ON the starter switch. Refer to "9.Body, Cab, Accessories 9E.Instrumentation,
Driver Info.(All models) BCM installation".
64. Set the vehicle information on the BCM.
44. If a DTC is not detected, replace the EHCU.
Driver Info.(All models) BCM setting".
EHCU removal".
65. When a DTC is detected, inspect the CAN low and
CAN high circuits.
EHCU installation".
Note：
45. Set the vehicle information on the EHCU.
Refer to "4.Brakes 4D.ABS(All models) or ignition power supply circuit.
EHCU setting".
46. Turn OFF the starter switch. resistance.
47. Connect the harness connector to the EHCU. ・ There should be no short circuit between CAN
circuits.
valve. ・ There should be no short to the low reference
circuit.
49. Turn ON the ignition switch. ・ There should be no short circuit with a metal
50. Check for a DTC using a scan tool. component such as a frame.
51. When a DTC is not detected, replace the EGR valve. 66. If a problem is found, repair the CAN circuit.
Refer to "1.Engine 1H.Aux. Emission Control 67. When the CAN circuit is normal, replace the ECM.
Devices(4JK1) EGR valve removal". Refer to "1.Engine 1J.Electrical(4JK1)
Refer to "1.Engine 1H.Aux. Emission Control ECM removal".
Devices(4JK1) EGR valve installation". Refer to "1.Engine 1J.Electrical(4JK1)
52. Turn OFF the ignition switch. ECM installation".
53. Connect the harness connector to the EGR valve. 68. Set the immobilizer function and injector ID code on
the ECM.
54. Disconnect the harness connector from the SRS
control unit. Refer to "1.Engine 1J.Electrical(4JK1) ECM setting".
55. Turn ON the starter switch. 69. Conduct the unit difference learning of fuel supply
pumps on the ECM.
57. If a DTC is not detected, replace the SRS control
unit. 2. DTC U0001 confirm resolution
Refer to "8.Restraints 8B.Air Bag Systems(All models) 1. Clear the DTCs with the scan tool.
SRS control unit removal". 2. Turn OFF the ignition switch for more than 30
Refer to "8.Restraints 8B.Air Bag Systems(All models) seconds.
SRS control unit installation". 3. Start the engine.
59. Connect the harness connector to the SRS control 5. Use the scan tool to confirm that a DTC has not been
unit. detected.
60. Disconnect the harness connector from the BCM.

Lost Communication With TCM
1. DTC U0101 priority DTC 1. Clear the DTCs with the scan tool.
DTC U0001 2. Turn OFF the ignition switch for more than 30
seconds.
2. DTC U0101 diagnostics
1. Check if communication with the TCM is available
using the scan tool. 4. Perform a test-run.
2. If communication with the TCM is not available, 5. Use the scan tool to confirm that a DTC has not been
check the automatic transmission control system. detected.
4. Disconnect the harness connector from the TCM.
6. Measure the voltage value between the TCM harness
connector CAN low circuit and the frame ground.
7. Measure the voltage value between the TCM harness
connector CAN high circuit and the frame ground.
standard： 1.5 to 3.5 V
8. When the value is outside the standard value range,
inspect the CAN high circuit between the TCM and
the ECM.
Note：
resistance.
9. If a problem is found, repair the CAN High circuit.
10. Inspect the CAN low circuit between the TCM and
the ECM.
Note：
resistance.
11. If a problem is found, repair the CAN Low circuit.
12. If the reading is within the specified value, inspect
the TCM harness connector for a poor connection.
14. If the harness connector is normal, replace the TCM.
5B.Automatic(TB-50LS) TCM removal".
5B.Automatic(TB-50LS) TCM installation".
15. Set the vehicle information on the TCM.
5B.Automatic(TB-50LS) TCM setting".
3. DTC U0101 confirm resolution
DTC U010A (Flash Code 346)

Lost Communication With Exhaust Gas Recirculation Control Module
1. DTC U010A priority DTC 4. Use a scan tool to confirm that a DTC has not been
detected.
DTC U0001
2. DTC U010A diagnostics
valve.
harness connector CAN low circuit and the frame
ground.
harness connector CAN high circuit and the frame
ground.
Standard： 1.5 to 3.5 V
inspect the CAN low circuit between the EGR valve
and the ECM.
Note：
resistance.
7. If a problem is found, repair the CAN low circuit.
8. Inspect the CAN high circuit between the EGR valve
and the ECM.
Note：
resistance.
9. If a problem is found, repair the CAN high circuit.
contact failure.
EGR valve.
3. DTC U010A confirm resolution
longer.

Lost Communication with Vehicle Immobilizer Control Module
1. DTC U0167 priority DTC
DTC U0101
2. DTC U0167 diagnostics
1. Check if communication with the ICU is available
using the scan tool.
2. If communication with the ICU is not available,
inspect the immobilizer control system.
3. Check whether a DTC of the immobilizer is
detected.
4. When a DTC of the immobilizer is detected,
diagnose the immobilizer DTC.
5. When a DTC of the immobilizer is not detected,
replace the ECM.
ECM removal".
ECM installation".
the ECM.
3. DTC U0167 confirm resolution
seconds.
detected.
Mechanical (4JK1) 1B-1
Engine
Mechanical
(4JK1)
Table of Contents
Engine assembly..............................................................1B-3 inspection................................................................1B-272
removal.......................................................................1B-3 installation...............................................................1B-274
installation.................................................................1B-10 Crankshaft...................................................................1B-320
Cylinder head cover.......................................................1B-20 removal...................................................................1B-320
removal.....................................................................1B-20 disassembly.............................................................1B-350
installation.................................................................1B-25 inspection................................................................1B-351
Intake throttle valve.......................................................1B-30 reassembly..............................................................1B-354
removal.....................................................................1B-30 installation...............................................................1B-355
installation.................................................................1B-31 CKP sensor..................................................................1B-398
Exhaust manifold...........................................................1B-33 removal...................................................................1B-398
removal.....................................................................1B-33 inspection................................................................1B-399
inspection..................................................................1B-41 installation...............................................................1B-400
installation.................................................................1B-42 Inlet manifold..............................................................1B-401
Timing chain..................................................................1B-51 removal...................................................................1B-401
installation.................................................................1B-59 Rocker arm shaft assembly..........................................1B-412
Camshaft........................................................................1B-69 removal...................................................................1B-412
inspection..................................................................1B-75 Timing gear train.........................................................1B-428
installation.................................................................1B-79 removal...................................................................1B-428
Cylinder head assembly.................................................1B-86 inspection................................................................1B-434
disassembly.............................................................1B-108 Valve stem oil seal and valve spring...........................1B-445
inspection................................................................1B-112 removal...................................................................1B-445
reassembly..............................................................1B-118 inspection................................................................1B-468
installation...............................................................1B-124 installation...............................................................1B-469
Flywheel......................................................................1B-153 Piston and connecting rod...........................................1B-499
removal...................................................................1B-153 removal...................................................................1B-499
inspection................................................................1B-155 disassembly.............................................................1B-529
installation...............................................................1B-156 inspection................................................................1B-530
Crankshaft front oil seal..............................................1B-158 reassembly..............................................................1B-535
removal...................................................................1B-158 installation...............................................................1B-536
installation...............................................................1B-163 Crankcase....................................................................1B-575
Crankshaft rear oil seal................................................1B-170 removal...................................................................1B-575
removal...................................................................1B-170 disassembly.............................................................1B-604
installation...............................................................1B-172 reassembly..............................................................1B-605
Timing gear case.........................................................1B-175 installation...............................................................1B-606
removal...................................................................1B-175 CMP sensor.................................................................1B-644
installation...............................................................1B-203 removal...................................................................1B-644
Cylinder block.............................................................1B-239 inspection................................................................1B-645
removal...................................................................1B-239 installation...............................................................1B-646
1B-2 Mechanical (4JK1)
Swirl control solenoid valve........................................1B-647

removal...................................................................1B-647
installation...............................................................1B-648
Engine mounting (2WD).............................................1B-649
removal...................................................................1B-649
installation...............................................................1B-654
Engine mounting (4WD).............................................1B-660
removal...................................................................1B-660
installation...............................................................1B-666
Supplementary Information.........................................1B-673
Engine assembly
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
3. Raise vehicle using the jack.
2. Front under guard removal
Note：
・ The following applies to 2WD.
1. Remove the front under guard from the frame.
Note：
・ Remove the 5 bolts and the clip.
3. Coolant drain
1. Drain coolant from the radiator.
Note：
・ Open the drain plug at the bottom of the
radiator.
1. Bolt
2. Clip
Note：
Note：
・ Remove the 5 bolts. 2. Remove the radiator cap from the radiator.
3. Remove the rear under guard from the frame. Warning：
Note：・ In order to prevent burns, do not open the cap
・ Remove the 4 bolts. while the engine and radiator are hot.
・ Heat liquid and steam may gush out by
pressure.
4. Intake air duct removal
1. Remove the intake air duct from the turbocharger
and the intercooler.
Note：
・ Remove the part together with the intake hose.
1. Air cleaner assembly

2. MAF sensor
3. Blow-by hose
5. Blow-by hose disconnect 4. Intake pipe
1. Disconnect the blow-by hose from the cylinder head 5. Barometric pressure sensor
cover.
7. Boost sensor disconnect
6. Air cleaner assembly removal
1. Disconnect the connector from the boost sensor.
1. Disconnect the harness connector from the MAF
sensor.
Note：
・ The following applies to the high-output
specifications.
3. Disconnect the vacuum hose from the air cleaner
assembly.
4. Disconnect the intake pipe from the turbocharger
assembly.
5. Remove the air cleaner assembly from vehicle.

1. Remove the intake air duct from the intake throttle
valve and the intercooler.
Note：
9. Battery removal 1. Radiator upper hose

1. Disconnect the battery ground cable from the frame. 12. Radiator reserve tank removal
2. Disconnect the battery cable from the battery. 1. Disconnect the radiator reserve tank hose from the
3. Remove the battery bracket from the frame. radiator.
4. Remove the battery from vehicle. 2. Remove the radiator reserve tank from the upper fan
guide.
1. Battery cable
2. Battery bracket 13. A/C compressor drive belt removal
3. Earth 1. Remove the A/C compressor drive belt from the
pulley.
10. Fuse box disconnect
1. Remove the fuse box cover from the fuse box.
2. Disconnect the engine harness from the fuse box.
3. Disconnect the battery harness from the fuse box.
11. Radiator upper hose removal
1. Remove the radiator upper hose from the water
outlet pipe and the radiator.
1. A/C compressor drive belt 1. Upper fan guide

2. Clip
14. A/C compressor assembly disconnect 3. Lower fan guide
1. Remove the A/C compressor assembly from the A/C 4. Fan shroud
compressor bracket.
16. Generator cover removal
1. Remove the generator cover from the bracket and the
adjust plate.
1. A/C compressor bracket

2. A/C compressor
15. Fan guide removal 17. Cooling fan belt removal

1. Remove the fan guide from the radiator. 1. Loosen the adjust bolt using a wrench.
Note： Note：
・ Remove the clips and bottom locks on both ・ Loosen the tension adjust bolt of the
sides and remove the upper fan guide. generator.
2. Remove the cooling fan belt from the pulley.
18. Cooling fan removal
1. Remove the cooling fan from the fan clutch
assembly.
Note：
・ Remove the 4 screws.
1. Fan clutch assembly

2. Cooling fan
19. Fan shroud removal 1. Glove box

2. Instrument panel assist side lower cover
1. Remove the fan guide from the radiator.
Note： 22. ECM disconnect
・ Remove the lower fan guide together with the 1. Disconnect the harness connector from the ECM.
fan shroud.
Note：
20. Glove box removal ・ Pull out the harness to the engine room side.
1. Remove the glove box from the instrument panel. 2. Disconnect the harness from the frame.
23. Vacuum hose disconnect
1. Disconnect the vacuum hose from the vacuum pipe.
1. Glove box
21. Instrument panel assist-side lower cover removal

24. Fuel hose disconnect
1. Remove the instrument panel assist-side lower cover
1. Disconnect the fuel hose from the fuel supply pump.
from the instrument panel.
2. Disconnect the fuel hose from the fuel leak-off pipe.
Caution：・ Remove the engine side from the crankcase.
・ Cover the exposed portion to prevent foreign
material from getting into the fuel system.
27. Power steering oil pump assembly removal

1. Remove the power steering oil pump from the timing
1. Fuel hose
gear case.
25. Catalyst converter disconnect Note：
1. Disconnect the catalyst converter from the front ・ Remove the power steering pump together
exhaust pipe. with the hose.
26. Catalyst converter removal
1. Disconnect the catalyst converter from the catalyst
converter bracket.
2. Remove the catalyst converter from the turbocharger
assembly.
1. Power steering oil pump

2. Nut
2. Remove the power steering oil hose from the

bracket.
3. Remove the catalyst converter bracket from the rear

cover.
Note：
・ Remove the exhaust side from the engine.
Note：
・ Suspend slightly.
2. Disconnect the engine mounting from the engine.
Note：
・ Remove the tightening bolts on the engine
mounting at the engine side.
31. Engine assembly removal
1. Remove the engine assembly from vehicle.
1. Bracket
28. Radiator lower hose disconnect

1. Disconnect the radiator lower hose from the engine.
1. Radiator lower hose
29. Transmission removal

5B.Automatic(TB-50LS) Transmission
assembly removal".
Refer to "5.Transmission, Transaxle 5C.Manual(MUA)
Transmission removal".
Refer to "5.Transmission, Transaxle 5C.Manual(MUX)
Transmission removal".
30. Engine mounting disconnect
1. Raise the engine.
installation 5. Power steering oil pump assembly installation

1. Install the power steering oil pump to the timing gear
1. Engine assembly installation
case.
1. Operate the hoist.
Note：
・ Slowly operate to move the engine to the
installation position.
・ Slowly operate the hoist so that the
transmission side is low, while pulling to the
rear of the engine.
2. Install the engine to the frame.
2. Engine mounting connect
1. Connect the engine mounting to the engine.
Note：
・ Keep holding up the engine as high as not to
be lifted up, and connect the engine mounting.
3. Transmission installation
1. Power steering pump
2. Nut
Refer to "5.Transmission, Transaxle 5C.Manual(MUA) 2. Install the power steering oil hose to the bracket.
Transmission installation".
Refer to "5.Transmission, Transaxle 5C.Manual(MUX)
Transmission installation".
4. Radiator lower hose connect
1. Connect the radiator lower hose to the engine.
Tightening torque： 5 N・m { 0.5 kgf・m / 44 lb・in }
Hose clip
1. Bracket
6. Catalyst converter installation

1. Install the catalyst converter to the turbocharger
assembly.

2. Connect the catalyst converter to the catalyst Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
converter bracket. Bolt 1, 3
Note： Tightening torque： 51 N・m { 5.2 kgf・m / 38 lb・ft }
・ Temporarily tighten the bolts in the order Bolt 2
shown in the diagram. 7. Catalyst converter connect
1. Connect the catalyst converter to the front exhaust
pipe.
Note：
・ Firmly tighten the bolts in the order shown in
the diagram.
8. Fuel hose connect

1. Connect the fuel hose to the fuel supply pump.
1. Fuel hose 1. Glove box

2. Connect the fuel hose to the leak-off pipe.
12. Glove box installation
9. Vacuum hose connect
1. Install the glove box to the instrument panel.
1. Glove box
10. ECM connect
1. Connect the harness to the frame.
13. Fan shroud installation
Note：
1. Install the fan guide to the radiator.
・ Pull in the harness toward inside the room.
Note：
・ Install the lower fan guide together with the fan
11. Instrument panel assist-side lower cover installation shroud.
1. Install the instrument panel assist-side lower cover to 14. Cooling fan installation
the instrument panel.
1. Install the cooling fan to the fan clutch assembly.
Note：
・ Install the 4 screws.
1. Fan clutch assembly 1. Upper fan guide

2. Cooling fan 2. Clip
3. Lower fan guide
15. Cooling fan belt installation 4. Fan shroud
1. Install the cooling fan belt to the pulley.
18. A/C compressor assembly connect
16. Generator cover installation
1. Install the A/C compressor assembly to the A/C
1. Install the generator cover to the bracket and the compressor bracket.
adjust plate.

17. Fan guide installation 2. A/C compressor
1. Install the fan guide to the radiator. 19. A/C compressor drive belt installation
Note： 1. Install the A/C compressor drive belt to the pulley.
・ Install the upper fan guide.
1. Install the radiator upper hose to the water outlet
pipe and the radiator.
Hose clip
1. A/C compressor drive belt
20. Radiator reserve tank installation

1. Install the radiator reserve tank to the upper fan
guide.
1. Radiator upper hose
22. Fuse box connect
1. Connect the battery harness to the fuse box.
2. Connect the engine harness to the fuse box.
3. Install the fuse box cover to the fuse box.
23. Battery installation
1. Install the battery to vehicle.
2. Connect the radiator reserve tank hose to the

radiator.
Note：
・ When the radiator reserve tank is dirty, clean it
before installation.
・ Clean the radiator reserve tank using
detergent.
・ Scrub the inside with a detergent and water. 1. Battery cable
・ Wash it thoroughly with clean water, and drain 2. Battery bracket
the water. 3. Earth
21. Radiator upper hose installation 2. Install the battery bracket to the frame.
Tightening torque： 4 N・m { 0.4 kgf・m / 35 lb・in } 1. Install the air cleaner assembly to vehicle.
Battery side
Frame side
3. Connect the battery cable to the battery.
4. Connect the battery ground cable to the frame.
24. Intake air duct installation
1. Install the intake air duct to the intake throttle valve
and the intake hose.
Bolt
Clip

2. MAF sensor
3. Blow-by hose
4. Intake pipe
5. Barometric pressure sensor
2. Connect the intake pipe to the turbocharger

assembly.
Note：
specifications.
3. Connect the vacuum hose to the air cleaner
25. Boost sensor connect
assembly.
1. Connect the connector to the boost sensor.
4. Connect the harness connector to the barometric
pressure sensor.
5. Connect the harness connector to the MAF sensor.
27. Blow-by hose connect
1. Connect the blow-by hose to the cylinder head cover.
1. Install the intake air duct to the turbocharger and the
intake hose.
Bolt
Clip
26. Air cleaner assembly installation

Note：
・ Tighten the 5 bolts.
29. Front under guard installation

Note：
・ The following applies to 2WD. 30. A/C compressor drive belt adjustment
1. Install the front under guard to the frame. 1. Adjust tension to a standard value using a tension
meter.
Note：
・ Tighten the clip and the 5 bolts. Note：
・ The following is the belt tension adjusting
method based on belt deflection.
・ Apply a load to measurement points 2, 3, and
4 of the A/C compressor drive belt and adjust
the amount of flex.
Load： 98 N { 10 kg / 22 lb }
Measurement point 2
Amount of belt
Frequency
deflection
： 12.5 to 16.5 mm
New ： 92 to 112 Hz
{ 0.492 to 0.650 in }
： 16.5 to 19.1 mm
Reuse ： 79 to 91 Hz
{ 0.650 to 0.752 in }
Measurement point 3
Amount of belt
Frequency
deflection
1. Bolt
2. Clip ： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
Note：： 16.5 to 19.1 mm
・ The following applies to 4WD. { 0.650 to 0.752 in }
2. Install the front under guard to the frame. Measurement point 4
Note： Amount of belt
Frequency
・ Tighten the 4 bolts. deflection
： 15.9 to 20.7 mm
3. Install the rear under guard to the frame. New ： 70 to 86 Hz
{ 0.626 to 0.815 in }
： 20.7 to 23.7 mm Note：

{ 0.815 to 0.933 in } ・ After adjusting the tension, tighten the
tensioner fixing nut.
Note：
・ The following is the belt tension adjusting Tightening torque： 41 N・m { 4.2 kgf・m / 30 lb・ft }
method with a sonic tension meter. 31. Cooling fan belt adjustment
・ Measure the frequency at measurement point
1. Adjust tension to a standard value using a tension
2, 3, and 4 with a sonic tension meter.
meter.
Measurement point 2 Note：
Amount of belt ・ Move the generator to adjust the tension.
Frequency
deflection
2. Check tension of the cooling fan belt.
： 12.5 to 16.5 mm
New ： 92 to 112 Hz
{ 0.492 to 0.650 in } Note：
： 16.5 to 19.1 mm ・ The following is the belt tension adjusting
{ 0.650 to 0.752 in } method based on belt deflection.
・ Apply a load to measurement point 1 of the
Measurement point 3
cooling fan belt and adjust the amount of flex.
Amount of belt
Frequency Load： 98 N { 10 kg / 22 lb }
deflection
： 12.4 to 16.4 mm Note：
New ： 92 to 112 Hz
{ 0.488 to 0.646 in } ・ The following is the belt tension adjusting
： 16.5 to 19.1 mm method with a sonic tension meter.
{ 0.650 to 0.752 in } ・ Measure the frequency at measurement point
1 with a sonic tension meter.
Measurement point 4
Amount of belt Position of the belt tension
Frequency
deflection Deflection Frequency
： 15.9 to 20.7 mm ： 5.4 to 6.6 mm
New ： 70 to 86 Hz New ： 188 to 210 Hz
{ 0.626 to 0.815 in } { 0.213 to 0.260 in }
： 20.7 to 23.7 mm ： 7.7 to 8.5 mm
Reuse ： 62 to 70 Hz Reuse ： 160 to 174 Hz
{ 0.815 to 0.933 in } { 0.303 to 0.335 in }
1. Measurement point 1 1. Measurement point 1

Note：
Caution：
・ After adjusting the tension, tighten the adjust
・ Insufficient air removal work may lead to
plate lock bolt and the mounting bolt under the
malfunction of the engine.
generator.
34. Battery ground cable connect
Generator tightening torque
： 40 N・m { 4.1 kgf・m /
Mounting bolt
30 lb・ft } 2. Close the engine hood assembly.
： 25 N・m { 2.5 kgf・m / 3. Lower vehicle.
Adjust plate lock bolt
18 lb・ft }
35. ECM setting
Note：
Note：
・ If the cooling fan belt is replaced with a new
one, make the new cooling fan belt fit in to ・ When replacing the engine assembly, writing
cope with initial elongation. the injector ID codes into the ECM is required.
・ After making the cooling fan belt fit in, adjust 1. Check the Injector ID Code of the cylinder head
its tension once again. cover.
32. Coolant filling Note：
1. Replenish the radiator with coolant. ・ Record the injector ID codes from the cylinder
head cover labels.
Note：
・ Use the coolant contains 50 % anti-freeze
solution.
・ Pour the coolant up to the filler neck.
2. Replenish the radiator reserve tank with coolant.
Note：
・ Pour the coolant up to the MAX line.
3. Install the radiator cap to the radiator.
33. Fuel air bleed
1. Press the priming pump.
Note：
・ Press the priming pump until it gets stiff.
1. Cylinder No. 1 injector ID code

5. Injector ID code label
2. Connect a scan tool to the DLC.

4. Select the Diagnostics.
5. Select the Engine.
6. Select the engine model.
7. Select Programming.
8. Select the Injector ID Code.
1. Priming pump
9. Select the Injector Flow.
2. Fuel filter with sedimenter
Note：
・ Follow the directions on the screen and write
the injector ID codes into the ECM.
Note：
・ After the programming is complete, turn the
ignition switch to OFF for 30 seconds.
36. ECM writing
Note：
・ When replacing the engine assembly, unit
difference learning for the supply pump is
required.
Note：
・ Start the engine and warm it up.
3. Check the Data List of a scan tool.
Note：
・ Confirm that the coolant temperature display is
at the standard value or higher.
Standard： 65 ℃ { 149 °F }
Note：
・ Confirm that the Fuel Supply Pump Learning
Status display changes from Not Learned to
Learned.
5. Check the DTC of a scan tool.
Note：
・ Confirm that the scan tool does not detect a
DTC.
Cylinder head cover
removal
2. Engine cover removal
1. Remove the engine cover from the engine.

1. Engine cover

Note：

Note：
6. Bracket removal 7. Vacuum pipe removal

Note： Note：
・ The following applies to high-output ・ The following applies to high-output
specifications. specifications.
1. Disconnect the vacuum hose from the turbocharger 1. Remove the vacuum pipe from the cylinder head
control solenoid. cover.
2. Disconnect the connector from the turbocharger
control solenoid.
3. Remove the bracket from the cylinder head cover.
Note：
・ Remove it together with the turbocharger
control solenoid.
8. Injector disconnect
1. Disconnect the connector from the injector.
9. Fuel leak-off hose removal
1. Remove the fuel leak-off hose from the leak-off
pipe.
Note：
・ The following applies to standard-output
specifications
sensor.
assembly.
1. Fuel leak-off hose

2. Injector connector
Caution：
・ Do not reuse the clip of the fuel leak-off hose.
2. Remove the leak-off pipe from the injector.

2. MAF sensor
3. Blow-by hose
4. Intake pipe
5. Disconnect the turbocharger water feed hose from

the water feed and return pipes.
1. Injector leak-off pipe

2. Clip
Caution：
・ Do not reuse the leak-off pipe and the clip.
10. Blow-by hose disconnect
1. Disconnect the blow-by hose from the cylinder head
cover.
11. EGR pipe removal
1. Turbocharger water feed hose
Note： 2. Turbocharger water return hose
・ The following applies to the EGR pipe
specifications.
the outlet pipe.
7. Remove the water pipe from the cylinder head
assembly.
12. Cylinder head cover removal

1. Remove the cylinder head cover from the cylinder
head.
8. Remove the exhaust manifold heat protector from

the exhaust manifold.
13. Cam end gasket removal

1. Remove the cam end gasket from the cylinder head.
Note：
9. Remove the EGR pipe from the inlet manifold and
the exhaust manifold. ・ Remove the liquid gasket sticking to the
cylinder head.
1. Cam end gasket
14. Oil seal removal

1. Remove the oil seal from the cylinder head cover.
Note：
・ Remove from the bottom of the cylinder head
cover.
installation
1. Oil seal installation
1. Apply the engine oil to the oil seal.
2. Install the oil seal to the cylinder head cover.
Note：
・ Install from the bottom of the cylinder head
cover and insert all the way in.
2. Cam end gasket installation
1. Apply liquid gasket to the cam end gasket.
Note：
・ Apply ThreeBond 1207B to the area indicated
in the diagram.
Bead width： 2.0 to 3.0 mm { 0.079 to 0.118 in }
1. 3.0 - 5.0 mm {0.118 - 0.197 in}
2. 3.0 - 5.0 mm {0.118 - 0.197 in}
2. Install the cylinder head cover to the cylinder head.

Note：
・ Tighten the nuts in the order shown in the
diagram.
1. Cam end gasket

2. Application area
3. Bead width
2. Install the cam end gasket to the cylinder head.

3. Cylinder head cover installation
1. Apply liquid gasket to the cylinder head.
Note：
・ Apply ThreeBond 1207B to the area indicated 4. EGR pipe installation
in the diagram. Note：
specifications.
1. Install the EGR pipe to the inlet manifold and the
exhaust manifold.
Bolt, nut
2. Install the exhaust manifold heat protector to the 4. Connect the turbocharger water feed hose to the
exhaust manifold. outlet pipe.
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } 5. Connect the turbocharger water feed hose to the
water feed and return pipes.
3. Install the turbocharger water feed hose to the

cylinder head assembly. 1. Turbocharger water feed hose
2. Turbocharger water return hose
Bolt, nut 6. Install the air cleaner assembly to vehicle.
2. Install the fuel leak-off hose to the leak-off pipe.

2. MAF sensor
1. Leak-off pipe
3. Blow-by hose
2. Clip
4. Intake pipe
5. Barometric pressure sensor Caution：
7. Connect the intake pipe to the turbocharger ・ Do not reuse the leak-off pipe and the clip.
assembly. 7. Injector connect
8. Connect the harness connector to the barometric 1. Connect the harness connector to the injector.
pressure sensor.
8. Vacuum pipe installation
Note：
・ The following applies to high-output
1. Connect the blow-by hose to the cylinder head cover. specifications.
6. Fuel leak-off hose installation 1. Install the vacuum pipe to the cylinder head cover.
1. Install the leak-off pipe to the injector. Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
9. Bracket installation
Note：
specifications.
1. Install the bracket to the cylinder head cover.
Note：
・ Install the part together with the turbocharger
control solenoid.
1. Leak-off pipe
2. Clip
2. Connect the connector to the turbocharger control 11. Boost sensor connect
solenoid.
3. Connect the vacuum hose to the turbocharger control
solenoid.
Note：
specifications

intake hose.
Bolt
10. Intake air duct installation Clip
Bolt
Clip
13. Engine cover installation

1. Install the engine cover to the engine.
1. Engine cover

2. Close the engine hood assembly.
Intake throttle valve
removal Note：
5. Intake throttle valve disconnect

1. Disconnect the connector from the intake throttle
valve.
6. Intake throttle valve removal
1. Remove the intake throttle valve from the inlet
1. Engine cover manifold.
2. Remove the gasket from the intake throttle valve.
1. Intake throttle valve

2. Gasket
installation
1. Intake throttle valve installation
1. Install the gasket to the intake throttle valve.
2. Install the intake throttle valve to the inlet manifold.


2. Gasket
2. Intake throttle valve connect

1. Connect the connector to the intake throttle valve.
Bolt
Clip 5. Engine cover installation
1. Engine cover

Exhaust manifold
removal
Note：
Note：
3. Coolant drain
Note：
radiator.
1. Bolt
2. Clip
Note：
Note：
pressure.
Note：
specifications.
assembly.
assembly.
1. Engine cover

Note：

2. MAF sensor
3. Blow-by hose
4. Intake pipe
8. Vacuum hose removal

Note：
specifications.
1. Remove the vacuum hose from the turbocharger and
the vacuum pipe.

cover.
sensor.
9. Turbocharger water feed pipe disconnect 1. Turbocharger water feed hose

the water feed and return pipe. 10. Water pipe removal
Note： 1. Disconnect the turbocharger water feed hose from
・ The following applies to the high-output the outlet pipe.
specifications.
assembly.
1. Water feed and return pipes

11. Water hose disconnect
3. Water pipe
4. Turbocharger water feed hose Note：
5. Turbocharger water return hose ・ The following applies to the EGR cooler
specifications.
Note：
・ The following applies to the standard output 1. Disconnect the water hose from the EGR cooler.
specifications. Note：
・ Disconnect both the feed hose and return hose
from the EGR cooler.
1. Feed hose 13. EGR cooler removal

2. Return hose
Note：
Note：・ The following applies to the high-output
・ The following applies to the EGR pipe specifications.
specifications. 1. Remove the EGR cooler from the cylinder head and
2. Disconnect the water hose from the oil cooler the exhaust manifold.
assembly.

1. Water hose Note：
12. Exhaust manifold heat protector removal ・ The following applies to the EGR pipe
specifications.
the exhaust manifold. 1. Remove the EGR pipe from the inlet manifold and
15. Turbocharger control solenoid disconnect 1. Turbocharger water feed hose

1. Disconnect the vacuum hose from the turbocharger
control solenoid. 17. Turbocharger feed oil pipe removal
16. Turbocharger water return hose disconnect 1. Remove the turbocharger feed oil pipe from the
1. Disconnect the turbocharger water return hose from turbocharger and the oil cooler.
the water feed and return pipe. Note：
・ The following applies to the high-output specifications.
specifications.
1. Turbocharger feed oil pipe

Note：
3. Water pipe ・ The following applies to the standard output
4. Turbocharger water feed hose specifications.
Note：
・ The following applies to the standard output
specifications.
1. Turbocharger feed oil pipe 19. Water feed and return pipe removal
18. Oil return pipe removal Note：

1. Remove the oil return pipe from the turbocharger
specifications.
and the crankcase.
1. Remove the water feed and return pipe from the
Note：
turbocharger.
specifications.
20. Catalyst converter disconnect
Note： 1. Disconnect the catalyst converter from the front

exhaust pipe.
specifications. 21. Catalyst converter removal
converter bracket.
assembly.
3. Remove the catalyst converter bracket from the rear 23. Turbocharger assembly removal
cover.
1. Remove the turbocharger from the exhaust manifold.
Note：
Note：
・ Remove the engine side from the crankcase. specifications.
22. Turbocharger bracket removal Note：

Note：・ The following applies to the standard output
specifications.
1. Remove the turbocharger bracket from the
turbocharger and the cylinder block.

adjust plate.
25. Generator disconnect

1. Disconnect the harness from the generator.
26. Exhaust manifold removal
1. Remove the exhaust manifold from the cylinder
head.
Note：
・ Remove the 8 nuts from the exhaust manifold.
inspection
1. Exhaust manifold measurement
1. Align a simple straight ruler to the exhaust manifold.
Note：
・ Align the simple straight ruler as shown in the
diagram below.
2. Measure deformation using a feeler gauge.
Note：
・ Use the feeler gauge to measure deformation
of the exhaust manifold.
Standard： 0.3 mm or less { 0.01 in or less }
Limit： 0.5 mm { 0.02 in }
Note：
・ Replace the exhaust manifold if it exceeds the
limit.
2. Exhaust manifold inspection

1. Inspect the exhaust manifold.
Note：
・ Visually inspect the damage of the exhaust
manifold.
installation 3. Securely tighten the exhaust manifold to the cylinder

head.
1. Exhaust manifold installation
Note：
1. Install the gasket to the engine. ・ Tighten the 8 nuts according to the order given
Note： in the diagram.
・ Assemble the projection section to the rear Tightening torque： 52 N・m { 5.3 kgf・m / 38 lb・ft }
side of the cylinder head.
Caution：
・ Avoid tightening them too much because doing
so may hamper expansion and contraction of
the manifold due to heat.
1. Projection
2. Temporarily tighten the exhaust manifold to the

cylinder head.
2. Generator connect
Note：
・ Install the washer and nut, and tighten them 1. Connect the harness to the generator.
temporarily as shown in the diagram. Tightening torque： 12 N・m { 1.2 kgf・m / 106 lb・
in } Terminal nut
1. Install the generator cover to the bracket and the
adjust plate.
1. Stub bolt
2. Washer
3. Nut
4. Turbocharger assembly installation Note：

1. Install the gasket to the turbocharger. ・ Feed 0.5 cc engine oil from the oil filler.
2. Install the turbocharger to the exhaust manifold. 5. Turbocharger bracket installation
Tightening torque： 27 N・m { 2.8 kgf・m / 20 lb・ft } Note：

Note：
specifications.
specifications. 1. Install the turbocharger bracket to the turbocharger
and the cylinder block.
Note：
specifications. 6. Catalyst converter installation
assembly.
2. Connect the catalyst converter to the catalyst Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
converter bracket. Bolt 1, 3
・ Temporarily tighten the bolts in the order Bolt 2
shown in the diagram. 7. Catalyst converter connect
pipe.
Note：
the diagram.
8. Water feed and return pipe installation

Note：
specifications.
1. Install the water feed and return pipe to the
turbocharger.
9. Oil return pipe installation 10. Turbocharger feed oil pipe installation
1. Install the oil return pipe to the turbocharger and the 1. Install the turbocharger feed oil pipe to the
crankcase. turbocharger and the oil cooler.
Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in } Tightening torque： 23 N・m { 2.3 kgf・m / 17 lb・ft }
Turbocharger side
Note：
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } ・ The following applies to the high-output
Crankcase side specifications.
Note：
specifications.
Note：
Note：
specifications.
specifications.
1. Turbocharger feed oil pipe 1. Turbocharger water feed hose

11. Turbocharger water return hose connect
12. Turbocharger control solenoid connect
1. Connect the turbocharger water return hose to the
water feed and return pipe. 1. Connect the vacuum hose to the turbocharger control
solenoid.
Note：
・ The following applies to the high-output 13. EGR cooler installation
specifications.
1. Install the gasket to the EGR cooler.
2. Temporarily tighten the EGR cooler to the cylinder
head and the exhaust manifold.
Note：
・ Temporarily tighten the nuts and bolts in the
order of 2, 1, 4, 5, and 3 as shown in the
diagram.
3. Securely tighten the EGR cooler to the cylinder head
and the exhaust manifold.
Note：
・ Completely tighten the nuts and bolts in the
diagram.
Tightening torque of the EGR valve
3. Water pipe Nut ： 27 N・m { 2.8 kgf・m / 20 lb・ft }
4. Turbocharger water feed hose Bolt ： 24 N・m { 2.4 kgf・m / 18 lb・ft }
Note：
specifications.
14. EGR pipe installation 16. Water hose connect

Note： Note：
・ The following applies to the EGR pipe ・ The following applies to the EGR cooler
1. Install the EGR pipe to the inlet manifold and the 1. Connect the water hose to the EGR cooler.
exhaust manifold.
Note：
Tightening torque： 27 N・m { 2.8 kgf・m / 20 lb・ft } ・ Connect both the feed hose and return hose to
Bolt, nut the EGR cooler.
15. Exhaust manifold heat protector installation 1. Feed hose

1. Install the exhaust manifold heat protector to the 2. Return hose
exhaust manifold.
Note：
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } ・ The following applies to the EGR pipe
specifications.
2. Install the water hose to the oil cooler assembly.
1. Water hose 1. Water feed and return pipes

17. Water pipe installation 3. Water pipe
1. Install the turbocharger water feed hose to the 4. Turbocharger water feed hose
cylinder head assembly. 5. Turbocharger water return hose
Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in } Note：

Bolt, nut ・ The following applies to the standard output
specifications.
2. Connect the turbocharger water feed hose to the

outlet pipe. 1. Turbocharger water feed hose
18. Turbocharger water feed pipe connect 2. Turbocharger water return hose
1. Connect the turbocharger water feed hose to the 19. Vacuum hose installation
water feed and return pipe.
Note：
specifications.
1. Install the vacuum hose to the turbocharger and the
vacuum pipe.
pressure sensor.
intake hose.
Bolt
Clip

1. Install the air cleaner assembly to vehicle.


2. MAF sensor
3. Blow-by hose
4. Intake pipe

assembly.
Note：
specifications.
assembly. 1. Engine cover
Note：
1. Install the front under guard to the frame.
Note：
・ Tighten the clip and the 5 bolts.
25. Coolant filling

1. Replenish the radiator with coolant.
Note：
solution.
1. Bolt
2. Clip Note：
Note：
・ The following applies to 4WD. 3. Install the radiator cap to the radiator.
2. Install the front under guard to the frame. 26. Battery ground cable connect
Note： 1. Connect the battery ground cable to the battery.

・ Tighten the 4 bolts. 2. Close the engine hood assembly.
3. Install the rear under guard to the frame. 3. Lower vehicle.
Note：
Timing chain
removal
2. Crankshaft adjustment
1. Align the No.1 cylinder to compression top dead
center.
Note：
・ Rotate the crankshaft and align to the
compression top dead center (TDC).
1. Engine cover

Note：
1. Top dead center alignment mark on the gear case

cover
2. Top dead center alignment mark on the crank
pulley


Note：
control solenoid.

Note： Note：
・ Remove the part together with the intake hose. ・ The following applies to standard-output
specifications
7. Bracket removal
Note：
8. Vacuum pipe removal
1. Disconnect the vacuum hose from the turbocharger ・ The following applies to high-output
control solenoid. specifications.
2. Disconnect the connector from the turbocharger 1. Remove the vacuum pipe from the cylinder head

9. Injector disconnect 1. Injector leak-off pipe

2. Clip
10. Fuel leak-off hose removal Caution：
pipe. 11. Blow-by hose disconnect
cover.
Note：
specifications.
sensor.
assembly.

Caution：
1. Air cleaner assembly 8. Remove the exhaust manifold heat protector from
2. MAF sensor the exhaust manifold.
3. Blow-by hose
4. Intake pipe




the outlet pipe.
assembly.
13. Cylinder head cover removal 1. Cam end gasket

1. Remove the cylinder head cover from the cylinder 15. Noise cover removal
head.
1. Remove the noise cover from the timing chain lower
cover.

1. Remove the cam end gasket from the cylinder head. 1. Noise cover
Note：
16. Timing chain lower cover removal
・ Remove the liquid gasket sticking to the
cylinder head. 1. Remove the timing chain lower cover from the gear
case cover.
17. CMP sensor disconnect 19. Baffle plate removal

1. Disconnect the connector from the CMP sensor. 1. Install the lock bolt to the sub gear.
Note：
・ Use an M5 lock bolt to fix the sub gear.
1. CMP sensor
18. Timing chain upper cover removal

2. Remove the baffle plate from the cylinder head.
1. Remove the timing chain upper cover from the
cylinder head.
20. Camshaft bearing cap removal 21. Inlet camshaft removal

1. Install the bolt to the camshaft gear. 1. Remove the inlet camshaft from the cylinder head.
Note：
・ Install the M5 bolt.
22. Exhaust camshaft removal

1. Remove the exhaust camshaft from the cylinder
2. Remove the camshaft bearing cap from the cylinder head.
head.
Note：
・ Confirm that it is marked.
23. Timing chain tensioner removal 25. Idle gear D removal

1. Remove the timing chain tensioner from the cylinder 1. Remove the idle gear D from the cylinder head.
head.
Note：
・ Drop the timing chain backward.
1. Timing chain tensioner

2. Gasket
3. Nut 26. Timing chain removal
1. Remove the timing chain from the supply pump
24. Timing chain lever pivot removal
sprocket.
1. Remove the timing chain lever pivot from the timing
chain tension lever.
installation
center.
Note：
1. Surface and inside of the idle gear shaft

2. Threaded portion and seat surface of the bolt
Note：
・ Align the two timing marks as indicated in the
diagram.

cover
pulley
2. Timing chain installation

1. Install the timing chain to the idle gear D.
3. Idle gear D installation
1. Apply the engine oil to the idle gear shaft.
Note：
・ Apply it to the surface and inside.
2. Apply the engine oil to the bolt.
Note： 1. Timing chain
・ Apply it to the threaded portion and the seat 2. Timing mark
surface. 3. Blue link
4. Yellow link
3. Install the idle gear D to the cylinder head.
Note： 4. Timing chain lever pivot installation
・ Install the timing chain onto the sprocket of idle 1. Install the timing chain lever pivot to the timing
gear D, and then install idle gear D. chain tension lever.
Tightening torque： 59 N・m { 6.0 kgf・m / 44 lb・ft } Tightening torque： 27 N・m { 2.8 kgf・m / 20 lb・ft }
5. Timing chain tensioner installation 1. Timing chain tensioner

2. Gasket
1. Connect the hook to the pin.
3. Nut
Note：
3. Disconnect the hook from the pin.
・ Keep the state where the latch is being
pushed. Note：
・ Insert the plunger. ・ Lightly push the area indicated by an arrow in
・ Install the hook to the pin, and fasten the the diagram.
plunger. ・ The hook of the tensioner opens and the
plunger pushes the tension lever to pull the
chain.
1. Pin
2. Plunger
3. Latch 6. Exhaust camshaft installation
1. Install the exhaust camshaft to the cylinder head.
5. Hook
Note：
2. Install the timing chain tensioner to the cylinder
・ Align the timing mark to the idle gear D to
head.
install it.
3. Install the camshaft bearing cap to the cylinder head.
4. Install the bolt to the camshaft bearing cap.
5. Align the camshaft to the alignment mark.
Note：
・ Align the marks of inlet camshaft and the
exhaust camshaft to the mark of the bearing
cap.
1. Exhaust camshaft gear

2. Inlet camshaft gear
3. Idle gear D
7. Inlet camshaft installation

1. Install the inlet camshaft to the cylinder head.
Note：
install it. 1. Alignment mark

Note：
・ Apply it to the threaded portion.
Note：
・ Tighten it to the prescribed torque according to
the order given in the diagram.

3. Idle gear D
8. Camshaft bearing cap installation

1. Apply the engine oil to the camshaft bearing cap.
Note：
・ Apply it to the surface of the bearing.
2. Apply the engine oil to the camshaft journal.
1. Loosen the adjust screw using special tool.
8. Remove the lock bolt from the camshaft gear.

Note： 1. Driver
・ Remove the bolts from the inlet camshaft gear 2. Ring spanner
and exhaust camshaft gear. 3. Adjust nut wrench
9. Turn the crankshaft pulley.

Note：
・ Turn 2 rotations {720°}.
10. Align the alignment mark to the camshaft bearing
cap.
Note：
・ Align the alignment mark of the camshaft to SST: 5-8840-2822-0 - valve clearance adjust nut wrench
the mark of the camshaft bearing cap. 2. Adjust the valve clearance to a standard value using
a feeler gauge.
Note：
・ Insert a 0.15 mm {0.0059 in} feeler gauge
between the rocker arm roller and the cam,
and tighten the rocker arm adjust screw.
・ When the movement of the feeler gauge
becomes stiff, fasten the adjust screw nut of
the rocker arm.

3. Idle gear D
9. Rocker arm adjustment

Caution：
・ Within 5 minutes of applying the liquid gasket,
install the cover.
1. Cam: Exhaust side

2. Cam: Intake side
3. Roller: Intake side
4. Roller: Exhaust side
1. Liquid gasket
Note： 2. Bead height
・ When the No. 1 cylinder is at the compression 3. Bead width
top dead center, a circle is marked in the table;
Note：
when the No. 4 cylinder is at the compression
top dead center, an X is marked in the table for ・ Apply Loctite 262 or equivalent to the threaded
adjustment of valve clearance. portion on the cylinder head side.
2. Install the timing chain upper cover to the cylinder
Cylinder No. 1 2 3 4
head.
E E E E
Valve arrangement IN IN IN IN Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
X X X X
When the No. 1
cylinder is at
O O O O
compression top
dead center
When the No. 4
cylinder is at
X X X X
compression top
dead center
10. Baffle plate installation
1. Install the baffle plate to the cylinder head.
11. Timing chain upper cover installation
1. Apply liquid gasket to the timing chain upper cover.
Note：
・ Apply ThreeBond 1207C or equivalent.
12. CMP sensor connect
Bead height： 2.0 to 2.5 mm { 0.079 to 0.098 in }
1. Connect the connector to the CMP sensor.
14. Noise cover installation
1. Install the noise cover to the timing chain lower
cover.
1. CMP sensor
13. Timing chain lower cover installation

1. Apply liquid gasket to the timing chain lower cover.
Note：
1. Noise cover
Bead width： 2.0 to 2.5 mm { 0.079 to 0.098 in } 15. Cam end gasket installation
Caution： 1. Apply liquid gasket to the cam end gasket.

・ Within 5 minutes of applying the liquid gasket, Note：
install the cover. ・ Apply ThreeBond 1207B to the area indicated
in the diagram.
1. Liquid gasket
2. Bead height
3. Bead width
1. Cam end gasket
2. Install the timing chain lower cover to the gear case 2. Application area
cover. 3. Bead width
2. Install the cam end gasket to the cylinder head. Note：
16. Cylinder head cover installation ・ The following applies to the EGR pipe
specifications.
Note： exhaust manifold.
in the diagram.
Bolt, nut
1. 3.0 - 5.0 mm {0.118 - 0.197 in}

2. Install the exhaust manifold heat protector to the
2. 3.0 - 5.0 mm {0.118 - 0.197 in}
exhaust manifold.
2. Install the cylinder head cover to the cylinder head. Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
Note：
diagram.

cylinder head assembly.
Bolt, nut
17. EGR pipe installation
4. Connect the turbocharger water feed hose to the 1. Air cleaner assembly
outlet pipe. 2. MAF sensor
3. Blow-by hose
4. Intake pipe

assembly.
pressure sensor.
19. Fuel leak-off hose installation
1. Install the leak-off pipe to the injector.

1. Leak-off pipe
2. Clip
2. Connect the connector to the turbocharger control

solenoid.
1. Leak-off pipe
2. Clip 3. Connect the vacuum hose to the turbocharger control
solenoid.
Caution：
Note：
20. Injector connect specifications
1. Connect the harness connector to the injector. 4. Install the bracket to the cylinder head cover.
Note：
specifications.
1. Install the vacuum pipe to the cylinder head cover.
Note：
specifications.
Note：
control solenoid.
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } 23. Intake air duct installation
Bolt
Clip
24. Boost sensor connect 26. Engine cover installation

1. Connect the connector to the boost sensor. 1. Install the engine cover to the engine.
25. Intake air duct installation 1. Engine cover

1. Install the intake air duct to the turbocharger and the 27. Battery ground cable connect
intake hose.
Bolt 2. Close the engine hood assembly.

Clip
Camshaft
removal
center.
Note：
1. Engine cover

Note：

cover
pulley


Note：
control solenoid.

Note： Note：
specifications
7. Bracket removal
Note：


2. Clip
cover.
Note：
specifications.
sensor.
assembly.

Caution：
1. Air cleaner assembly 13. Cylinder head cover removal

2. MAF sensor
3. Blow-by hose
head.
4. Intake pipe


Note：
1. Turbocharger water feed hose ・ Remove the liquid gasket sticking to the
2. Turbocharger water return hose cylinder head.

the outlet pipe.
assembly.
1. Cam end gasket 16. Camshaft bearing cap removal
15. Baffle plate removal 1. Install the bolt to the camshaft gear.
1. Install the lock bolt to the sub gear. Note：

Note：
2. Remove the camshaft bearing cap from the cylinder

head.
Note：
17. Inlet camshaft removal

1. Remove the inlet camshaft from the cylinder head.

head.
inspection
1. Inlet camshaft inspection
1. Inspect the inlet camshaft.
Note：
・ Inspect the camshaft journal and the cam for
worn and damage.
・ Replace if there are abnormalities.
2. Inlet camshaft measurement
1. Measure the clearance using a feeler gauge.
Note：
・ Measure the clearance of the camshaft gear
and camshaft bracket in the axis direction.
・ Replace the camshaft gear or camshaft if the
measured value exceeds the limit.
3. Measure the camshaft journal using the micrometer.
Standard： 0.050 to 0.170 mm { 0.002 to 0.007 in }
Note：
Limit： 0.25 mm { 0.010 in }
・ Measure the diameter of the camshaft journal.
Note：
・ Measure the clearance of the camshaft in the
axis direction prior to disassembly. Limit： 29.809 mm { 1.1736 in }
Note：
・ Measure uneven worn with the camshaft
journal.
Limit： 0.05 mm { 0.002 in }
Note：
・ Replace the camshaft if the worn exceeds the
limit.
2. Measure worn using the micrometer.

Note：
・ Measure the cam lobe height.
・ Replace the camshaft if the cam lobe height is
under the limit.
Standard： 40.6 mm { 1.60 in }
Limit： 39.6 mm { 1.56 in }
4. Put the camshaft on the V-block.
5. Measure fluctuation using a dial gauge.
Note：
・ Slowly rotate the camshaft to measure
fluctuation of the dial gauge.
・ Replace the camshaft if the deflection exceeds
the limit.
Limit： 0.05 mm { 0.002 in }
3. Exhaust camshaft inspection

1. Inspect the exhaust camshaft.
Note：
・ Inspect the camshaft journal and the cam for
worn and damage.
・ Replace if there are abnormalities.
6. Measure the camshaft bearing using a cylinder
4. Exhaust camshaft measurement
gauge.
Note：
・ Measure the inner diameter of the camshaft Note：
bearing. ・ Measure the clearance of the camshaft gear
and camshaft bracket in the axis direction.
7. Calculate the clearance from measured value.
・ Replace the camshaft gear or camshaft if the
Note： measured value exceeds the limit.
・ Read the difference of the inner diameter of
the camshaft bearing and diameter of the
camshaft journal and calculate the camshaft Limit： 0.25 mm { 0.010 in }
journal oil clearance.
Note：
Standard： 0.070 to 0.112 mm { 0.00276 to 0.00441 in } ・ Measure the clearance of the camshaft in the
Limit： 0.15 mm { 0.0059 in } axis direction prior to disassembly.
Note：
・ Replace the camshaft bearing if the measured
oil clearance exceeds the limit.
Limit： 0.05 mm { 0.0020 in }
Note：
・ Replace the camshaft if the worn exceeds the
limit.
2. Measure worn using the micrometer.

Note：
・ Measure the cam lobe height.
・ Replace the camshaft if the cam lobe height is
under the limit. 4. Put the camshaft on the V-block.
Standard： 40.6 mm { 1.60 in } 5. Measure fluctuation using a dial gauge.
Limit： 39.6 mm { 1.56 in } Note：
・ Slowly rotate the camshaft to measure
fluctuation of the dial gauge.
・ Replace the camshaft if the deflection exceeds
the limit.
Limit： 0.05 mm { 0.0020 in }
3. Measure the camshaft journal using the micrometer.

Note：
・ Measure the diameter of the camshaft journal.
Limit： 29.809 mm { 1.1736 in }
6. Measure the camshaft bearing using a cylinder
Note： gauge.
・ Measure uneven worn with the camshaft
journal.
Note：
・ Measure the inner diameter of the camshaft
bearing.
Note：
・ Read the difference of the inner diameter of
the camshaft bearing and diameter of the
camshaft journal and calculate the camshaft
journal oil clearance.
Limit： 0.15 mm { 0.0059 in }
Note：
・ Replace the camshaft bearing if the measured
oil clearance exceeds the limit.
installation 1. Exhaust camshaft gear

1. Crankshaft adjustment 3. Idle gear D
1. Align the No.1 cylinder to compression top dead 3. Inlet camshaft installation
center.
Note：
・ Rotate the crankshaft and align to the Note：
compression top dead center (TDC). ・ Align the timing mark to the idle gear D to
install it.

cover 1. Exhaust camshaft gear
2. Top dead center alignment mark on the crank 2. Inlet camshaft gear
pulley 3. Idle gear D
2. Exhaust camshaft installation 4. Camshaft bearing cap installation

1. Install the exhaust camshaft to the cylinder head. 1. Apply the engine oil to the camshaft bearing cap.
Note： Note：
・ Align the timing mark to the idle gear D to ・ Apply it to the surface of the bearing.
install it. 2. Apply the engine oil to the camshaft journal.
Note：
cap.
1. Alignment mark 1. Driver

2. Ring spanner
6. Apply the engine oil to the bolt. 3. Adjust nut wrench
Note：
Note：
Tightening torque： 18 N・m { 1.8 kgf・m / 13 lb・ft } SST: 5-8840-2822-0 - valve clearance adjust nut wrench
2. Adjust the valve clearance to a standard value using
a feeler gauge.
Note：
・ Insert a 0.15 mm {0.0059 in} feeler gauge
between the rocker arm roller and the cam,
and tighten the rocker arm adjust screw.
・ When the movement of the feeler gauge
becomes stiff, fasten the adjust screw nut of
the rocker arm.

Note：
・ Remove the bolts from the inlet camshaft gear
and exhaust camshaft gear.
5. Rocker arm adjustment
1. Loosen the adjust screw using special tool.
1. Cam: Exhaust side 1. Cam end gasket

2. Cam: Intake side 2. Application area
3. Roller: Intake side 3. Bead width
4. Roller: Exhaust side
Note：
・ When the No. 1 cylinder is at the compression
top dead center, a circle is marked in the table; 1. Apply liquid gasket to the cylinder head.
when the No. 4 cylinder is at the compression Note：
top dead center, an X is marked in the table for
adjustment of valve clearance.
in the diagram.
Cylinder No. 1 2 3 4
E E E E
Valve arrangement IN IN IN IN
X X X X
When the No. 1
cylinder is at
O O O O
compression top
dead center
When the No. 4
cylinder is at
X X X X
compression top
dead center
1. Apply liquid gasket to the cam end gasket. 1. 3.0 - 5.0 mm {0.118 - 0.197 in}
Note： 2. 3.0 - 5.0 mm {0.118 - 0.197 in}
・ Apply ThreeBond 1207B to the area indicated 2. Install the cylinder head cover to the cylinder head.
in the diagram.
Note：
Bead width： 2.0 to 3.0 mm { 0.079 to 0.118 in } ・ Tighten the nuts in the order shown in the
diagram.
9. EGR pipe installation 3. Install the turbocharger water feed hose to the
Note：
・ The following applies to the EGR pipe Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in }
specifications. Bolt, nut

exhaust manifold.
Bolt, nut

outlet pipe.

exhaust manifold.

1. Leak-off pipe
6. Install the air cleaner assembly to vehicle. 2. Clip

2. MAF sensor
1. Leak-off pipe
3. Blow-by hose
2. Clip
4. Intake pipe
pressure sensor.
Note：
Note：
specifications.
Note：
control solenoid.

Bolt
Clip

solenoid.
solenoid.
Note：
specifications


intake hose.

Clip

Cylinder head assembly
removal
2. Engine hood assembly removal
1. Open the engine hood.
Note：
・ Support the engine hood.
2. Remove the hinge bolt from the engine hood.
Note：
・ Before removing the hinge from the engine
hood, put a marking of the hinge location for
putting the hinge back in place. 1. Bolt
2. Clip
Note：
Note：
・ Remove the 5 bolts.
3. Remove the rear under guard from the frame.
Note：

Note：
Note：

Note：
・ After draining oil, tighten the drain plug to the
specified torque.
Caution：
・ Do not forget to tighten the drain plug.
7. Washer hose disconnect
1. Disconnect the washer hose from the joint.
8. Wiper arm cover removal
1. Remove the wiper arm cover from the wiper arm.
9. Wiper arm removal
1. Remove the wiper arm from vehicle.
Note：
1. Engine cover ・ Remove the nut to remove the wiper arm and
the blade.
5. Coolant drain
Note：
radiator.
1. Wiper arm cover

2. Nut
3. Wiper arm, blade
10. Side cowl cover removal

1. Remove the side cowl cover from the body.
2. Remove the radiator cap from the radiator.
11. Cowl cover removal
Warning：
1. Remove the cowl cover from the body.
・ In order to prevent burns, do not open the cap
while the engine and radiator are hot. 12. Wiper linkage removal
・ Heat liquid and steam may gush out by 1. Remove the wiper linkage from vehicle.
pressure.
Note：
6. Engine oil drain
・ Remove the bolt and nut from the wiper
1. Drain the engine oil from the oil pan. linkage.
・ Remove the connector from the wiper motor.
1. Nut 15. Blow-by hose disconnect

2. Bolt
Note： cover.
・ Remove together with the wiper motor. 16. Air cleaner assembly removal
13. Cowl panel removal 1. Disconnect the harness connector from the MAF
sensor.
2. Remove the cowl panel from vehicle.
Note：
specifications.
assembly.
assembly.

Note：
1. Air cleaner assembly 4. Remove the battery from vehicle.
2. MAF sensor
3. Blow-by hose
4. Intake pipe

1. Battery cable
2. Battery bracket
3. Earth

Note：
21. Radiator reserve tank removal

1. Disconnect the radiator reserve tank hose from the
radiator.
19. Battery removal 2. Remove the radiator reserve tank from the upper fan
guide.
1. Disconnect the battery ground cable from the frame.
2. Disconnect the battery cable from the battery.
3. Remove the battery bracket from the frame.
22. Generator cover removal 1. A/C compressor drive belt

1. Remove the generator cover from the bracket and the 25. Cooling fan belt removal
adjust plate.
1. Loosen the adjust bolt using a wrench.
Note：
・ Loosen the tension adjust bolt of the
generator.
26. Adjust plate removal
1. Remove the adjust plate from the timing gear case.

24. A/C compressor drive belt removal
1. Remove the A/C compressor drive belt from the
pulley.
27. Generator removal

1. Remove the generator from the bracket.
28. A/C compressor assembly disconnect 30. Tension pulley removal

1. Remove the A/C compressor assembly from the A/C 1. Remove the tension pulley from the cylinder head.
compressor bracket.
31. Fan guide removal

2. A/C compressor
Note：
29. A/C compressor bracket removal
・ Remove the clips and bottom locks on both
1. Remove the A/C compressor bracket from the sides and remove the upper fan guide.
cylinder head.
valve.
manifold.
1. Upper fan guide

2. Clip
3. Lower fan guide
4. Fan shroud

assembly.
2. Gasket
36. EGR valve disconnect

1. Disconnect the connector from the EGR valve.
1. Disconnect the vacuum hose from the inlet manifold.
Caution：

2. Cooling fan
33. Oil level gauge guide tube removal

1. Remove the oil level gauge from the oil level gauge
guide tube.
2. Remove the oil level gauge guide tube from the
crankcase.
1. Fuel hose 1. Leak-off pipe
39. Vacuum hose disconnect 41. Bracket removal

1. Disconnect the vacuum hose from the vacuum pipe. Note：
specifications.
control solenoid.
control solenoid.
Note：
control solenoid.
40. Leak-off pipe removal

1. Remove the leak-off pipe from the fuel supply pump
and the common rail assembly.
Caution：
Note：
specifications
1. Glow plug terminal

2. Glow plug connector
42. Injection pipe removal
1. Remove the clip from the injection pipe. 44. Glow plug removal
2. Remove the injection pipe from the injector and the 1. Remove the glow plug from the cylinder head.
common rail assembly.
1. Glow plug
43. Glow plug connector removal
45. Water pipe removal
1. Remove the glow plug connector from the glow
plug.
the outlet pipe.
Note：
・ Remove it together with the glow plug terminal. assembly.
46. Water outlet pipe removal 1. Front

2. Thermostat
3. Jiggle valve
the water outlet pipe.
2. Remove the water outlet pipe from the cylinder head. 48. Vacuum hose removal
Note：
specifications.
the vacuum pipe.
47. Thermostat removal

1. Remove the thermostat from the thermostat housing.
Caution：
・ Take care not to damage the thermostat.
49. Turbocharger water feed pipe disconnect

the water feed and return pipe.
Note：
specifications.
Note：

3. Water pipe
5. Turbocharger water return hose 1. Feed hose
2. Return hose
Note：
Note：
specifications. ・ The following applies to the EGR pipe
specifications.
2. Disconnect the water hose from the oil cooler
assembly.


1. Water hose
Note：
51. Exhaust manifold heat protector removal
・ The following applies to the EGR cooler
specifications. 1. Remove the exhaust manifold heat protector from
1. Disconnect the water hose from the EGR cooler.
52. Air duct bracket removal 1. Water feed and return pipes
1. Remove the air duct bracket from the cylinder head.
3. Water pipe
Note：
specifications.
53. Turbocharger water return hose disconnect

1. Disconnect the turbocharger water return hose from
Note：
specifications. 1. Turbocharger water feed hose
54. Turbocharger feed oil pipe removal

1. Remove the turbocharger feed oil pipe from the
turbocharger and the oil cooler.
Note：
specifications.
1. Turbocharger feed oil pipe Note：

Note：
specifications.
specifications.
1. Turbocharger feed oil pipe 1. Disconnect the catalyst converter from the front
exhaust pipe.
55. Oil return pipe removal
and the crankcase.
converter bracket.
Note：
・ The following applies to the high-output assembly.
specifications.
3. Remove the catalyst converter bracket from the rear 59. Water intake pipe removal
cover.
1. Remove the water intake pipe from the oil filter and
Note： the oil cooler assembly.
・ Remove the exhaust side from the engine. Note：
・ Remove the engine side from the crankcase. ・ Remove it with the hose attached.
58. Heater bypass pipe removal 2. Remove the pipe bracket from the generator bracket
1. Disconnect the heater bypass pipe from the water and the water intake pipe.
intake pipe. 60. Water bypass pipe removal
2. Remove the heater bypass pipe from the oil cooler 1. Remove the water bypass pipe from the oil filter.
assembly and the water bypass hose.
Note：
・ Remove the water bypass pipe on the oil filter
side.
2. Remove the water bypass pipe from the cylinder 62. Injector disconnect
head assembly.
Note：
・ Remove the water bypass pipe on the cylinder
head side. 1. Remove the fuel leak-off hose from the leak-off
pipe.
61. Oil filter bracket removal

1. Remove the oil filter bracket from the oil filter and 2. Injector connector
the engine hanger.
Caution：
1. Injector leak-off pipe 66. Cylinder head cover removal

2. Clip
Caution： head.
Note：
specifications.
1. Remove the vacuum pipe from the cylinder head
cover.

Note：
cylinder head.

Note：
specifications.
1. Cam end gasket 3. Remove the gasket from the injector.
68. Injector removal 4. Remove the O-ring from the injector.
1. Remove the injector from the cylinder head. 69. Crankshaft adjustment
Note： 1. Align the No.1 cylinder to compression top dead

center.
・ Loosen the injector clamp fixing bolt to remove
the injector clamp. Note：
・ If it is difficult to remove the injector, use a ・ Rotate the crankshaft and align to the
remover. compression top dead center (TDC).
2. Remove the injector clamp from the injector.
Caution：
・ With the cylinder number on it, store the
removed injector.
・ Take sufficient care not to hit the injector hole.
・ Absolutely never touch the injector solenoids
because that can hinder their performance or
cause damage.
Note：
・ When replacing all injectors, remove the
injector ID code label on the cylinder head
cover.
・ When replacing some of the injectors, erase
the injector ID code label on the cylinder head
cover by using a pen, etc.
cover
pulley
70. Baffle plate removal

1. Install the lock bolt to the sub gear.
Note：
2. Remove the baffle plate from the cylinder head. 2. Remove the camshaft bearing cap from the cylinder
head.
Note：
71. Camshaft bearing cap removal

1. Install the bolt to the camshaft gear.
Note：
72. Inlet camshaft removal
1. Remove the inlet camshaft from the cylinder head.
73. Exhaust camshaft removal 1. Noise cover

1. Remove the exhaust camshaft from the cylinder 75. Timing chain lower cover removal
head.
1. Remove the timing chain lower cover from the gear
case cover.
74. Noise cover removal

1. Remove the noise cover from the timing chain lower 76. CMP sensor disconnect
cover.
1. Disconnect the connector from the CMP sensor.
1. CMP sensor 1. Timing chain tensioner

2. Gasket
77. Timing chain upper cover removal 3. Nut
cylinder head.
78. Timing chain tensioner removal

1. Remove the timing chain tensioner from the cylinder
80. Idle gear D removal
head.
1. Remove the idle gear D from the cylinder head.
Note：
Note：
・ Store the removed rocker arm shaft assembly
so that it can be returned to their original
positions.
81. Timing chain removal

sprocket.
82. Timing chain tension lever removal
1. Exhaust rocker arm shaft assembly
1. Remove the timing chain tension lever from the 2. Bolt, long
cylinder head assembly. 3. Bolt, short
Note： 4. Intake rocker arm shaft assembly
5. Front
・ Pull out the timing chain tension lever.
83. Timing chain guide removal Note：
1. Install the timing chain guide to the cylinder head ・ Be very careful not to drop the parts into the
assembly and the cylinder block. cylinder head front-side gear case or the front
side oil return hole.
・ Make sure to remember the original position.
85. Cylinder head assembly removal
1. Install the rear engine hanger to the cylinder head.
Note：
specifications.
SST: 5-8840-2861-0 - engine hanger
84. Rocker arm shaft assembly removal

1. Remove the rocker arm shaft assembly from the
cylinder head.
4. Remove the head bolt from the cylinder head.
Note：
・ Loosen it in the order shown in the diagram.
1. Rear engine hanger
Note：
specifications. Caution：
・ Do not reuse the head bolt.
5. Remove the cylinder head assembly from the
cylinder block.
Note：
・ Install the wire to the engine hanger and the
hoist to lift the cylinder head assembly.
SST: 5-8840-2886-0 - rear engine hanger 86. Cylinder head gasket removal
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } 1. Remove the cylinder head gasket from the cylinder
2. Remove the nut from the timing gear case. head.
3. Remove the bolt from the timing gear case. Caution：

・ Replace the removed cylinder head gasket
with a new one.
1. Nut
2. Bolt
disassembly 1. Remove the rear engine hanger bracket from the

1. Sprocket removal
1. Remove the sprocket from the idle gear D.
4. EGR valve removal

1. Remove the EGR valve from the inlet manifold.
2. Front engine hanger removal
1. Remove the engine hanger from the cylinder head
assembly.
5. Inlet manifold removal

1. Remove the inlet manifold from the cylinder head.
Note：
・ Remove the wire from the engine hanger and
hoist, and remove the engine hanger.
・ Remove both the front engine hanger and rear
engine hanger together.
3. Rear engine hanger bracket removal
Note：
specifications.
2. Remove the gasket from the inlet manifold. Note：

6. EGR cooler removal ・ The following applies to the standard output
specifications.
Note：
specifications.
1. Remove the EGR cooler from the cylinder head and
8. Exhaust manifold removal

head.
Note：
7. Turbocharger assembly removal ・ Remove the 8 nuts from the exhaust manifold.

Note：
specifications.
9. Valve stem end cap removal 1. Valve spring compressor lever

2. Valve spring compressor pivot
1. Remove the valve stem end cap from the split collar.
10. Split collar removal 11. Spring upper seat removal
1. Remove the split collar from the using special tool. 1. Remove the spring upper seat from the valve spring.
Note： 12. Valve spring removal
・ Compress the valve springs using a valve 1. Remove the valve spring from the cylinder head.
spring compressor lever and valve spring
Note：
compressor pivot, and then remove the split
collars. ・ Organize the removed valve springs in the
order of the cylinder number.
13. Inlet valve removal
1. Remove the inlet valve from the cylinder head.
Note：
・ Organize the removed inlet valves according
to the cylinders using tags, etc.
SST: 5-8840-2818-0 - valve spring compressor lever 14. Exhaust valve removal
1. Remove the exhaust valve from the cylinder head.
Note：
・ Organize the removed exhaust valves
according to the cylinders using tags, etc.
SST: 5-8840-2819-0 - valve spring compressor pivot

SST: 5-8840-2816-0 - valve guide remover and installer
15. Valve stem oil seal removal

1. Remove the valve stem oil seal from the cylinder
head using a pliers.
18. Oil seal removal

1. Remove the oil seal from the cylinder head.
Caution：
・ Do not reuse the removed oil seal.
16. Spring lower seat removal
1. Remove the spring lower seat from the cylinder
head.
17. Valve guide removal
1. Remove the valve guide from the cylinder head
using special tool.
Note：
・ Use the valve guide remover and installer to
push out the valve guide out from the lower
inspection Caution：
・ Do not allow to regrind the bottom surface of
1. Cylinder head assembly measurement the cylinder head.
1. Align a simple straight ruler to the cylinder head. Note：
Note：・ Measure the height of the cylinder head.
・ Align the simple straight ruler as shown in the Standard： 143.4 mm { 5.646 in } Reference
diagram below.
Note：
・ As shown in the diagram, measure the four
sides and two diagonal lines with a feeler
gauge.
・ Replace the cylinder head if the deformation of
the bottom surface of the cylinder head
exceeds the limit.
3. Align a simple straight ruler to the cylinder head.

Note：
・ Align the simple straight ruler as shown in the
diagram below.
Note：
・ Measure the four sides and diagonal line of the
exhaust manifold installation surface with a
feeler gauge.

Limit： 0.20 mm { 0.008 in } Standard： 0.05 mm or less { 0.002 in or less }
Limit： 0.2 mm { 0.008 in } Note：
Note：・ Calculate the clearance between the outer
diameter of the inlet valve and the inner
・ If the measured value exceeds the specified
diameter of the valve guide.
limit and is less the maximum polish
allowance, regrind the installation surface of Standard： 0.030 to 0.060 mm { 0.0012 to 0.0024 in }
the manifold.
Limit： 0.200 mm { 0.008 in }
： 0.4 mm { 0.016 in } Maximum polish allowance
Note：
Note：・ If the measured value exceeds the specified
・ If the measured value exceeds the maximum limit, replace the valve and valve guide
polish allowance, the cylinder head must be together.
replaced.
2. Valve stem end cap inspection
1. Inspect the valve stem end cap.
Note：
・ Replace if the worn or damage is excessive.
3. Inlet valve measurement
1. Measure outer diameter using the micrometer.
Note：
・ Measure the outer diameters at three points.
Limit： 6.935 mm { 0.2730 in }
Note：
・ If the measured value is smaller than the
specified limit, replace the valve and valve
4. Measure thickness using the micrometer.
guide together.
Limit： 1.1 mm { 0.043 in }
Note：
guide together.
2. Measure the valve guide using the gauge.

Note：
・ Measure the inner diameter of the valve guide
using a caliper calibrator or telescoping gauge.
4. Exhaust valve measurement
Note：
・ Measure the outer diameters at three points.
Limit： 6.920 mm { 0.2724 in }
Note：
guide together.
4. Measure thickness using the micrometer.

Limit： 1.1 mm { 0.043 in }
Note：
guide together.
2. Measure the valve guide using the gauge.

Note：
・ Measure the inner diameter of the valve guide
using a caliper calibrator or telescoping gauge.
Note：
・ Calculate the clearance between the outer
diameter of the exhaust valve and the inner
diameter of the valve guide.
Limit： 0.250 mm { 0.0098 in }
5. Valve seat insert measurement
Note：
・ If the measured value exceeds the specified 1. Install the to the cylinder head.
limit, replace the valve and valve guide 2. Measure the inlet valve using a depth gauge.
together.
Note：
・ Use a depth gauge or simple steel straight
ruler to measure the sinking amount of the
valve from the bottom surface of the cylinder
head.
Limit： 2.5 mm { 0.098 in } 6. Valve seat insert adjustment
Note： Note：
・ If the measured value exceeds the limit, the ・ Remove the carbon from the valve seat insert
valve seat insert must be replaced. top surface.
1. Adjust the valve seat to a standard value using the
seat cutter.
Note：
・ Minimize the scratches and other uneven
parts, and return the touching width to the
standard value.
3. Check the contact surface of the valve seat.

Note：
・ Check for chaps and unevenness.
・ Smooth the contact surface of the valve.
・ Measure the contact surface of the valve seat.
Standard： 1.4 mm { 0.055 in } Inlet side
1. 90°
Limit： 2.2 mm { 0.087 in } Inlet side 2. 50°
Standard： 1.4 mm { 0.055 in } Exhaust side Caution：
Limit： 2.5 mm { 0.098 in } Exhaust side ・ Remove scratches and uneven parts only, and
Note： do not cut the surface too much.
・ If the measured value exceeds the limit, the ・ Use an adjustable valve cutter pilot.
valve seat insert must be replaced. ・ The valve cutter pilot should not be allowed to
scrape inside the valve guide.
Note：
・ Arc-weld the entire inner circumference of the
valve seat insert.
・ Cool the valve seat insert for 2 to 3 minutes.
・ Cooling makes it easier to remove the valve
seat insert due to the contraction.
1. Remove the valve seat insert from the cylinder head
using the driver.
Note：
・ Remove it using a screwdriver.
Caution：
・ Be careful not to damage the cylinder head.
2. Apply the compound to the valve seat insert.

Note：
・ Apply the compound to the valve seat surface.
3. Install the to the valve guide.
4. Adjust the contact surface to a standard value using
the valve lapper.
Note：
・ Gently tap the valve while turning it.
5. Check the contact surface of the valve seat insert.
Note：
・ Confirm that it is touching evenly around the
entire circumference.
1. Arc welding
2. Valve seat insert
3. Screwdriver
8. Valve seat insert installation

1. Put the washer on the valve seat insert.
Note：
・ Place the washer which is smaller outer
diameter than the valve seat insert with care
over the valve seat insert.
2. Install the valve seat insert to the cylinder head using
the press.
Note：
・ Gradually apply pressure to the washer and
push in the valve seat insert.
Caution：
Caution：・ Do not apply excessive pressure with the
press.
・ After fitting, remove all applied compound.
7. Valve seat insert removal
1. Washer
2. Valve seat insert
3. Press
3. Apply the compound to the valve seat insert.

Note：
・ Add compound to the valve seat surface and
gently tap the valve while turning it.
Caution：
・ Confirm that it is touching evenly around the
entire circumference.
reassembly
1. Oil seal installation
1. Install the oil seal to the cylinder head using special
tool.
Note：
・ Install it to the injection pipe insertion surface
using the oil seal installer.
・ Tap the seal so that it is not slanted.
Caution：
・ Be careful not to damage the lip section.
1. Cylinder head
2. Oil seal installer
SST: 5-8840-2820-0 - oil seal installer 2. Valve guide installation

1. Install the valve guide to the cylinder head using
special tool.
Note：
・ Use the valve guide remover and installer to
tap the valve guide from the upper surface
SST: 5-8840-2816-0 - valve guide remover and installer

Caution：
・ When replacing the valve guide, replace as a
set with the valve.
SST: 5-8840-2882-0 - valve stem seal installer
5. Exhaust valve installation

1. Apply the engine oil to the exhaust valve.
Note：
・ Apply it to the valve stem portion.
2. Install the exhaust valve to the cylinder head.
6. Inlet valve installation
1. Apply the engine oil to the inlet valve.
1. The height from the upper surface of the cylinder
head to the end surface of the valve guide Note：
2. Cylinder head ・ Apply it to the valve stem portion.
Valve stem height： 12.5 to 12.7 mm { 0.4921 to 0.5000 2. Install the inlet valve to the cylinder head.
in }
7. Valve spring installation
3. Spring lower seat installation
1. Install the valve spring to the cylinder head.
1. Install the spring lower seat to the cylinder head.
8. Spring upper seat installation
4. Valve stem oil seal installation
1. Install the spring upper seat to the valve spring.
1. Apply the engine oil to the valve stem oil seal.
9. Split collar installation
Note：
1. Install the split collar to the using special tool.
・ Apply it to the outer circumference of the valve
guide. Note：
・ Using a valve spring compressor lever and
2. Install the valve stem oil seal to the cylinder head
valve spring compressor pivot, compress the
using special tool.
valve springs and install the split collars.
Note：
・ Install it using a valve stem seal installer.
SST: 5-8840-2818-0 - valve spring compressor lever

1. Projection

cylinder head.
Note：
・ Install the washer and nut, and tighten them
temporarily as shown in the diagram.
1. Valve spring compressor lever

2. Valve spring compressor pivot
Caution：
・ Move it up and down to confirm that it moves
smoothly.
10. Valve stem end cap installation
1. Install the valve stem end cap to the split collar. 1. Stub bolt
11. Exhaust manifold installation 2. Washer
3. Nut
1. Install the gasket to the engine.
3. Securely tighten the exhaust manifold to the cylinder
Note：
head.
・ Assemble the projection section to the rear
side of the cylinder head. Note：
・ Tighten the 8 nuts according to the order given
in the diagram.
Caution：
Note：
・ Feed 0.5 cc engine oil from the oil filler.
13. EGR cooler installation
Note：
12. Turbocharger assembly installation
1. Install the gasket to the turbocharger. specifications.
2. Install the turbocharger to the exhaust manifold. 1. Install the gasket to the EGR cooler.
Tightening torque： 27 N・m { 2.8 kgf・m / 20 lb・ft } 2. Temporarily tighten the EGR cooler to the cylinder
Note： head and the exhaust manifold.
・ The following applies to the high-output Note：
specifications. ・ Temporarily tighten the nuts and bolts in the
diagram.
Note：
diagram.
Nut ： 27 N・m { 2.8 kgf・m / 20 lb・ft }
Bolt ： 24 N・m { 2.4 kgf・m / 18 lb・ft }
Note：
specifications.
Note：
specifications.
1. Install the rear engine hanger bracket to the cylinder
head assembly.
14. Inlet manifold installation

1. Install the gasket to the inlet manifold.
2. Install the inlet manifold to the cylinder head.
Note：
・ Tighten the nuts and bolts in the order in the
diagram.
17. Front engine hanger installation
1. Install the front engine hanger to the cylinder head
assembly.
15. EGR valve installation

1. Install the EGR valve to the inlet manifold.
Tightening torque of the EGR valve 2. Install the rear engine hanger to the cylinder head.
Nut ： 27 N・m { 2.8 kgf・m / 20 lb・ft }
Note：
Bolt ： 24 N・m { 2.4 kgf・m / 18 lb・ft }
16. Rear engine hanger bracket installation specifications.
Note：
specifications.
SST: 5-8840-2886-0 - rear engine hanger

18. Sprocket installation
1. Install the sprocket to the idle gear D.
installation
1. Cylinder head gasket preparation
1. Select the cylinder head gasket.
Note：
・ Select the grade for the cylinder head gasket
by measuring the protrusion amount of the
piston head.
・ Three types of gaskets with different thickness
are provided.
・ Select the appropriate grade from three types
of gaskets following the following steps.
・ Before measurement, remove carbon from the
piston head and the cylinder block surface,
and clean the gasket installation portion.
2. Measure the piston using a dial gauge.
Note：
Note：
・ Measure the point 1, 2, 3, and 4 to calculate
・ Measure the protrusion amount of the piston the difference between 1 and, 2, and between
head. 3 and 4 of each cylinder.
3. Calculate average value from measured value.
Note：
・ Calculate the average value for the protrusion
amount of the piston head for each cylinder.
・ Determine the grade of the gasket required for
the maximum value mentioned above
according to the following table.
Note：
・ Refer to the diagram for the measurement
position of the protrusion amount.
・ Make sure that all measuring points are
located as close to the cylinder block as
possible.
1. Measurement point
Note：
・ Cylinder head gasket combination
1. Bead height
2. Bead width
Caution：
・ After applying the liquid gasket, install the
cylinder head within 5 minutes.
3. Cylinder head assembly installation
1. Install the cylinder head assembly to the cylinder
block.
Note：
・ Wipe off the bottom surface of the cylinder
head.
・ Adjust the cylinder block dowel to install the
cylinder head.
2. Install the head bolt to the cylinder head.
Note： Caution：
・ The difference in the protrusion amount of ・ Use new head bolts.
each piston should not exceed 0.05 mm {0.002
in}.
2. Cylinder head gasket installation
1. Apply liquid gasket to the cylinder block.
Note：
・ Apply ThreeBond-1207B or equivalent to the
cylinder block as shown in the diagram.
Bead height： 2 to 3 mm { 0.079 to 0.118 in }
Bead width： 3 to 4 mm { 0.118 to 0.157 in }
3. Tighten the head bolt using a torque wrench.
Note：
・ Tighten the head bolts in the order shown in
the diagram.
Note：
the diagram.
5. Tighten the head bolt using special tool.
Note：
the diagram using a angle gauge.
9. Remove the wire from the engine hanger and the
hoist.
10. Remove the rear engine hanger from the cylinder
head.
SST: 5-8840-0266-0 - angle gauge

Specified angle： 60 to 75 °
Note：
7. Install the bolt to the timing gear case.
8. Install the nut to the timing gear case.
Note：
the order given in the diagram. 1. Rear engine hanger
center.
Note：
6. Timing chain guide installation

1. Install the timing chain guide to the cylinder head.

cover
pulley
5. Rocker arm shaft assembly installation 7. Timing chain tension lever installation
1. Apply the engine oil to the rocker arm shaft 1. Install the timing chain tension lever to the cylinder
assembly. head.
2. Install the rocker arm shaft assembly to the cylinder Note：
head.
・ Place the timing chain tension lever in
Note： between the timing gear case and the cylinder
・ Install the rocker arm shaft assemblies from block.
No. 1 to No. 4 in the numbering order. 8. Timing chain installation
Tightening torque： 21 N・m { 2.1 kgf・m / 15 lb・ft } 1. Install the timing chain to the idle gear D.
Note：
Note：
・ Apply it to the threaded portion and the seat
surface.
Note：
・ Install the timing chain onto the sprocket of idle
gear D, and then install idle gear D.

2. Bolt, long
3. Bolt, short
4. Intake rocker arm shaft assembly
5. Front
1. Surface and inside of the idle gear shaft 11. Timing chain tensioner installation
Note： Note：
・ Align the two timing marks as indicated in the ・ Keep the state where the latch is being
diagram. pushed.
・ Insert the plunger.
・ Install the hook to the pin, and fasten the
plunger.
1. Timing chain
2. Timing mark
3. Blue link
4. Yellow link
1. Pin
10. Timing chain lever pivot installation 2. Plunger
3. Latch
1. Install the timing chain lever pivot to the timing
5. Hook
head.
1. Timing chain tensioner 1. Exhaust camshaft gear

2. Gasket 2. Inlet camshaft gear
3. Nut 3. Idle gear D
3. Disconnect the hook from the pin. 13. Inlet camshaft installation
Note： 1. Install the inlet camshaft to the cylinder head.
・ Lightly push the area indicated by an arrow in Note：
the diagram.
・ The hook of the tensioner opens and the install it.
chain.

12. Exhaust camshaft installation 3. Idle gear D
Note：
install it. Note：
Note：
cap.

Note：
Note：
1. Alignment mark 10. Align the alignment mark to the camshaft bearing
cap.
Note：
Note：
・ Align the alignment mark of the camshaft to
the mark of the camshaft bearing cap.
Note：

3. Idle gear D

Note：
Caution：
install the cover.

1. Liquid gasket
2. Bead height
3. Bead width
Note：
・ Apply Loctite 262 or equivalent to the threaded
portion on the cylinder head side.
head.
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } 1. CMP sensor

Note：
Caution：
install the cover.
1. Install the O-ring to the injector.
2. Install the gasket to the injector.
Note：
・ Push the part in by hand until it stops.
・ When the clamp is tightened, the gasket is
pushed in until it hits the end. Therefore, do
not push in the gasket by force.
Caution：
1. Liquid gasket
2. Bead height
3. Bead width
2. Install the timing chain lower cover to the gear case

cover.
cover.
Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in } 1. Injector
2. Leak-off pipe
3. Clip
4. O-ring
5. Gasket
3. Install the injector clamp to the injector.
1. Noise cover

1. Injector
20. Injector installation
2. Bolt
3. Injector clamp Tightening torque： 7.8 N・m { 0.8 kgf・m / 69 lb・in }
4. Apply the engine oil to the bolt. 22. Cam end gasket installation
Note： 1. Apply liquid gasket to the cam end gasket.

・ Apply it to the threaded portion and the seat Note：
surface. ・ Apply ThreeBond 1207B to the area indicated
5. Install the injector to the cylinder head. in the diagram.
Note： Bead width： 2.0 to 3.0 mm { 0.079 to 0.118 in }

・ Confirm that the gasket has been attached to
the injector.
6. Temporarily tighten the injector clamp to the
cylinder head.
21. Injection pipe installation
1. Apply the engine oil to the injection pipe.
Note：
・ Apply engine oil to the injector-side sleeve nut
threaded portion and the O-ring of the injector.
2. Temporarily tighten the injection pipe to the injector
Note：
・ Temporarily tighten the sleeve nut by hand
until the nut does not turn further.
1. Cam end gasket
2. Application area
3. Bead width

Note：
in the diagram.
3. Temporarily tighten the clip to the injection pipe.

4. Securely tighten the injector clamp to the cylinder
head.
5. Securely tighten the injection pipe to the injector and
the common rail assembly.
Tightening torque： 29.5 N・m { 3.0 kgf・m / 22 lb・
ft }
6. Securely tighten the clip to the injection pipe.
1. 3.0 - 5.0 mm {0.118 - 0.197 in} Note：
2. 3.0 - 5.0 mm {0.118 - 0.197 in} ・ The following applies to high-output
specifications.
Note：
・ Tighten the nuts in the order shown in the Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
diagram. 26. Fuel leak-off hose installation
Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in } 1. Install the leak-off pipe to the injector.
24. EGR pipe installation 1. Leak-off pipe

Note： 2. Clip
・ The following applies to the EGR pipe 2. Install the fuel leak-off hose to the leak-off pipe.
specifications.
exhaust manifold.
Bolt, nut
1. Leak-off pipe
2. Clip
Caution：
25. Vacuum pipe installation 27. Injector connect

1. Connect the harness connector to the injector. ・ Temporarily tighten each bolt until it gets
28. Oil filter bracket installation seated, and then, firmly tighten it.
1. Install the oil filter bracket to the oil filter and the Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
engine hanger.
30. Water intake pipe installation

Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } 1. Temporarily tighten the pipe bracket to the water
29. Water bypass pipe installation intake pipe.
1. Install the water bypass pipe to the cylinder head 2. Install the water intake pipe to the oil filter.
assembly. Note：
Note：・ Insert the water intake pipe into the oil filter.
・ Install the water bypass pipe on the cylinder ・ Apply soapy water on the O-ring when
head side. inserting the pipe.
・ Apply soapy water on the O-ring when 3. Temporarily tighten the water intake pipe to the oil
inserting the pipe. cooler and the generator bracket.
Note：
order shown in the diagram.
2. Install the water bypass pipe to the oil filter.

Note：
・ Install the water bypass pipe on the oil filter
side.
4. Securely tighten the water intake pipe to the oil 32. Catalyst converter installation
cooler and the generator bracket.
Note： assembly.
・ Firmly tighten the nuts and bolts in the order Tightening torque： 27 N・m { 2.8 kgf・m / 20 lb・ft }
shown in the diagram.
2. Connect the catalyst converter to the catalyst

Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } converter bracket.
31. Heater bypass pipe installation Note：
1. Install the heater bypass pipe to the oil cooler and the ・ Temporarily tighten the bolts in the order
water bypass hose. shown in the diagram.
Note：
・ Temporarily tighten nuts starting from the rear
side, and then firmly tighten them in the same
order.
Note：
the diagram.
2. Connect the heater bypass pipe to the water inlet

pipe.
Note：
specifications.

Bolt 1, 3
Bolt 2 Note：
33. Catalyst converter connect ・ The following applies to the standard output
specifications.
pipe.
35. Turbocharger feed oil pipe installation

1. Install the turbocharger feed oil pipe to the
34. Oil return pipe installation
1. Install the oil return pipe to the turbocharger and the
crankcase. Note：
Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in } ・ The following applies to the high-output
Turbocharger side specifications.

Crankcase side
1. Turbocharger feed oil pipe 1. Water feed and return pipes

Note： 3. Water pipe
・ The following applies to the standard output 4. Turbocharger water feed hose
specifications. 5. Turbocharger water return hose
Note：
specifications.

water feed and return pipe. 1. Turbocharger water feed hose
Note：
・ The following applies to the high-output 37. Air duct bracket installation
specifications. 1. Temporarily tighten the air duct bracket to the
Note：
・ Temporarily tighten in the order shown in the
diagram.
2. Securely tighten the air duct bracket to the cylinder 39. Water hose connect
head assembly.
Note：
Note：・ The following applies to the EGR cooler
・ Firmly tighten in the order shown in the specifications.
diagram.
1. Connect the water hose to the EGR cooler.
Note：
・ Connect both the feed hose and return hose to
the EGR cooler.

Bolt 1
Bolt 2
1. Feed hose
38. Exhaust manifold heat protector installation 2. Return hose
Note：
exhaust manifold.
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } specifications.
1. Water hose 1. Turbocharger water feed hose

40. Turbocharger water feed pipe connect
41. Vacuum hose installation
water feed and return pipe. Note：
specifications.
specifications. 1. Install the vacuum hose to the turbocharger and the
vacuum pipe.

2. Turbocharger water feed hose 42. Thermostat installation
3. Water pipe
1. Install the thermostat to the thermostat housing.
5. Turbocharger water return hose Note：
・ Install the jiggle valve in such a way that the
Note：
valve faces the engine.
specifications.
1. Front 2. Connect the turbocharger water feed hose to the

2. Thermostat outlet pipe.
3. Jiggle valve
45. Glow plug installation
43. Water outlet pipe installation 1. Install the glow plug to the cylinder head.
1. Install the water outlet pipe to the cylinder head Tightening torque： 18 N・m { 1.8 kgf・m / 13 lb・ft }
assembly.
1. Glow plug
46. Glow plug connector installation

water outlet pipe. 1. Install the glow plug connector to the glow plug.
44. Water pipe installation Note：
1. Install the turbocharger water feed hose to the ・ Install it together with the glow plug terminal.
cylinder head assembly. Tightening torque： 1 N・m { 0.1 kgf・m / 9 lb・in }
Bolt, nut
Note：
specifications


Note：
・ The following applies to high-output 48. Leak-off pipe installation
specifications. 1. Install the leak-off pipe to the fuel supply pump and
1. Install the bracket to the cylinder head cover. the common rail assembly.
Note： Tightening torque： 10.3 N・m { 1.1 kgf・m / 91 lb・

in }
control solenoid.
1. Leak-off pipe

2. Connect the connector to the turbocharger control 1. Disconnect the vacuum hose from the vacuum pipe.
solenoid.
solenoid.
50. Fuel hose connect 1. Intake throttle valve

2. Gasket
55. Oil level gauge guide tube installation
1. Apply the engine oil to the O-ring.
2. Install the oil level gauge guide tube to the
crankcase.
1. Fuel hose

1. Connect the vacuum hose to the inlet manifold.
52. EGR valve connect
1. Connect the connector to the EGR valve.
56. Cooling fan installation
1. Fan clutch assembly 59. A/C compressor bracket installation

2. Cooling fan
1. Install the A/C compressor bracket to the cylinder
57. Fan guide installation head.
1. Install the fan guide to the radiator. Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
Note：

compressor bracket.
1. Upper fan guide
2. Clip Tightening torque： 51 N・m { 5.2 kgf・m / 38 lb・ft }
3. Lower fan guide
4. Fan shroud
58. Tension pulley installation

1. Install the tension pulley to the cylinder head.
1. A/C compressor bracket 63. Cooling fan belt installation

2. A/C compressor
61. Generator installation 64. Cooling fan belt adjustment
1. Install the generator to the bracket. 1. Adjust tension to a standard value using a tension
meter.
Note：
・ Move the generator to adjust the tension.
Note：
Load： 98 N { 10 kg / 22 lb }
Note：
method with a sonic tension meter.
62. Adjust plate installation
Position of the belt tension
1. Install the adjust plate to the timing gear case.
Deflection Frequency
： 5.4 to 6.6 mm
New ： 188 to 210 Hz
{ 0.213 to 0.260 in }
： 7.7 to 8.5 mm
{ 0.303 to 0.335 in }
1. Measurement point 1 1. A/C compressor drive belt

2. Measurement point 2
3. Measurement point 3 66. A/C compressor drive belt adjustment
4. Measurement point 4 1. Adjust tension to a standard value using a tension
meter.
Note：
・ After adjusting the tension, tighten the adjust Note：
plate lock bolt and the mounting bolt under the ・ The following is the belt tension adjusting
generator. method based on belt deflection.
： 40 N・m { 4.1 kgf・m / the amount of flex.
Mounting bolt
30 lb・ft }
Load： 98 N { 10 kg / 22 lb }
： 25 N・m { 2.5 kgf・m /
18 lb・ft } Measurement point 2
Frequency
・ If the cooling fan belt is replaced with a new deflection
one, make the new cooling fan belt fit in to ： 12.5 to 16.5 mm
New ： 92 to 112 Hz
cope with initial elongation. { 0.492 to 0.650 in }
・ After making the cooling fan belt fit in, adjust ： 16.5 to 19.1 mm
its tension once again. { 0.650 to 0.752 in }
65. A/C compressor drive belt installation Measurement point 3
1. Install the A/C compressor drive belt to the pulley. Amount of belt
Frequency
deflection
： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 4
Amount of belt
Frequency
deflection
： 15.9 to 20.7 mm
New ： 70 to 86 Hz
{ 0.626 to 0.815 in }
： 20.7 to 23.7 mm
{ 0.815 to 0.933 in }
Note： Note：
・ The following is the belt tension adjusting ・ After adjusting the tension, tighten the
method with a sonic tension meter. tensioner fixing nut.
・ Measure the frequency at measurement point Tightening torque： 41 N・m { 4.2 kgf・m / 30 lb・ft }
Measurement point 2
1. Connect the harness to the generator.
Amount of belt
Frequency Tightening torque： 12 N・m { 1.2 kgf・m / 106 lb・
deflection
in } Terminal nut
： 12.5 to 16.5 mm
New ： 92 to 112 Hz
{ 0.492 to 0.650 in } 68. Generator cover installation
： 16.5 to 19.1 mm 1. Install the generator cover to the bracket and the
{ 0.650 to 0.752 in } adjust plate.
Measurement point 3 Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in }
Amount of belt
Frequency
deflection
： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 4
Amount of belt
Frequency
deflection
： 15.9 to 20.7 mm
New ： 70 to 86 Hz
{ 0.626 to 0.815 in }
： 20.7 to 23.7 mm
{ 0.815 to 0.933 in }

guide.
radiator.
Note：
detergent.
・ Scrub the inside with a detergent and water.
・ Wash it thoroughly with clean water, and drain
the water.
70. Radiator upper hose installation
Hose clip
1. Battery cable
2. Battery bracket
3. Earth
2. Install the battery bracket to the frame.

Battery side
Frame side
1. Radiator upper hose Bolt
Clip
73. Boost sensor connect 1. Air cleaner assembly

2. MAF sensor
3. Blow-by hose
4. Intake pipe

assembly.
Note：
specifications.
assembly.
pressure sensor.
74. Air cleaner assembly installation 1. Connect the blow-by hose to the cylinder head cover.
1. Install the air cleaner assembly to vehicle. 76. Intake air duct installation
Tightening torque： 20 N・m { 2.0 kgf・m / 15 lb・ft } 1. Install the intake air duct to the turbocharger and the
intake hose.
Bolt
Clip
77. Cowl panel installation 1. Nut

2. Bolt
1. Install the cowl panel to vehicle.
Tightening torque： 5.3 N・m { 0.5 kgf・m / 47 lb・in }
Note：
・ Connect the connector to the wiper motor.
79. Cowl cover installation
1. Install the cowl cover to the body.
80. Side cowl cover installation
1. Install the side cowl cover to the body.
81. Wiper arm installation
1. Install the wiper arm to vehicle.
Caution：
・ Confirm that the wiper motor is stopped
at the auto stop position.
2. Connect the washer hose to the joint.

78. Wiper linkage installation
1. Install the wiper linkage to vehicle.
Note：
・ Install it together with the wiper motor.
1. 29 mm (1.14 in)
2. 36.5 - 51.5 mm (1.44 - 2.03 in)
3. 18 mm (0.71 in)
Tightening torque： 31.0 N・m { 3.2 kgf・m / 22.9 lb・

ft }
82. Wiper arm cover installation
1. Install the wiper arm cover to the wiper arm.
83. Engine hood assembly installation
1. Temporarily tighten the hinge bolt to the engine
hood assembly.
Note：
・ Align the hinge with the marking made during
removal.
2. Inspect the clearance.
Note：
1. Hood rest
・ Check the engine hood assembly and the
fender. 4. Apply the grease to the striker.
3. Adjust the clearance to a standard value. Note：
Note：・ Apply a thin layer of grease to the striker.
・ Adjust the installation of the engine hood hinge 5. Install the engine hood garnish to the engine hood.
to adjust the clearance.
Note：
・ Tighten the 6 nuts to the specified torque.
6. Securely tighten the hinge bolt to the engine hood
assembly.
84. Washer hose connect
1. Clearance: 4.0 mm {0.16 in}

2. Height, level difference: -1.5 mm {-0.06 in}
Note：
・ Turn the hood rest to adjust its height, and
adjust the level difference against the engine
hood.
1. Engine cover

Note：
Note：
87. Engine oil filling

1. Replenish the engine with the engine oil.
Note：
・ Check the tightening of the oil pan drain plug.
88. Coolant filling
1. Bolt Note：
2. Clip ・ Use the coolant contains 50 % anti-freeze
solution.
Note：
Note：
Note：
3. Install the rear under guard to the frame.
Note：
・ Tighten the 5 bolts. 1. Connect the battery ground cable to the battery.
3. Lower vehicle.
Flywheel
removal
2. Transmission assembly removal SST: 5-8840-0214-0 - crankshaft stopper
Refer to "5.Transmission, Transaxle Note：

5B.Automatic(TB-50LS) Transmission ・ For automatic transmission vehicles, after
assembly removal". loosening the flywheel mounting bolts, remove
the washers, flexible plate, flywheel and sleeve
3. Clutch assembly removal
in that order.
Refer to "5.Transmission, Transaxle 5E.Clutch
5. Pilot bearing removal
System(MUA) Clutch assembly removal".
1. Remove the pilot bearing from the flywheel using
special tool.
System(MUX) Clutch assembly removal".
Note：
4. Flywheel removal
・ Pull out it using a pilot bearing remover and
1. Remove the flywheel from the crankshaft. sliding hammer.
Note：
・ Gradually loosen the flywheel mounting bolts
in the order shown in the diagram while
confirming that the flywheel does not rotate.
SST: 5-8840-2000-0 - pilot bearing remover
SST: 5-8840-0019-0 - sliding hammer
2. Remove special tool from the rear plate.

Note：
・ Remove the crankshaft stopper from the
starter installation section of the rear plate.
6. Ring gear removal

1. Remove the ring gear from the flywheel using a
hammer.
Note：
・ Drive the ring gear, using a drift and hammer.
inspection Note：
・ Inspect the flywheel installation bolts.
1. Flywheel inspection
・ Replace with a new one if it is significantly
1. Inspect the flywheel. damaged.
Note：
・ Inspect the friction surface for cracks and
damage. Replace if there are abnormalities.
2. Ring gear inspection
1. Inspect the ring gear.
Note：
・ Inspect the tooth surfaces. Replace the ring
gear if it is damaged or significantly worn.
3. Flywheel measurement
1. Measure the flywheel using a vernier caliper.
Note：
・ Measure the depth of the flywheel friction
surface.
・ Adjust it if the measured value is within the
standard value or does not exceed the limit.
・ If the measured value exceeds the limit, the
flywheel must be replaced.
Standard： 18 mm { 0.7087 in } Standard output
Limit： 19 mm { 0.7480 in } Standard output
Standard： 12 mm { 0.4724 in } High-output
Limit： 13 mm { 0.5118 in } High-output
Note：
・ The depth from the pressure plate installation
surface to the friction surface is indicated.
1. Flywheel friction surface depth

installation
1. Ring gear installation
1. Heat the ring gear with the gas burner.
Note：
・ Uniformly heat the ring gear using the gas
burner. SST: 5-8522-0024-0 - pilot bearing installer
Heating temperature： 200 ℃ or less { 392 °F or less }
3. Flywheel installation
2. Install the ring gear to the flywheel. 1. Apply the engine oil to the bolt.
Note： Note：
・ Install it with the chamfered side of the ring ・ Apply it to the threaded portion of the bolt.
gear facing the front.
・ Install the ring gear so that the pattern side 2. Temporarily tighten the flywheel to the crankshaft.
faces toward front. Note：
・ After shrink-fitting, confirm that the ring gear is ・ Temporarily tighten in the order shown in the
airtight against the flywheel. diagram.
2. Pilot bearing installation
1. Put the pilot bearing on the flywheel.
Note：
・ Place the pilot bearing so that it crosses
perpendicular to the crankshaft bearing
installation hole.
2. Install the pilot bearing to the flywheel using special
tool.
Note：
・ Hit the pilot bearing outer race with a brass
hammer using a pilot bearing installer, and
then hit the bearing in the crankshaft bearing
installation hole.
Note：
・ For automatic transmission vehicles, install the
sleeve, flywheel, flexible plate, washer in that
order, and temporarily tighten in the order in
the diagram.
3. Install special tool to the rear plate.
Note：
・ Install the crankshaft stopper to the starter
installation section of the rear plate.
SST: 5-8840-0214-0 - crankshaft stopper 4. Clutch assembly installation
4. Securely tighten the flywheel to the crankshaft. Refer to "5.Transmission, Transaxle 5E.Clutch
System(MUA) Clutch assembly installation".
Note：
・ Tighten in the order in the diagram. System(MUX) Clutch assembly installation".
Tightening torque： 59 N・m { 6.0 kgf・m / 44 lb・ft } 5. Transmission assembly installation
3. Lower vehicle.
5. Securely tighten the flywheel to the crankshaft.

Note：
・ Tighten in the order in the diagram.
Crankshaft front oil seal
removal
Note：
Note：
3. Coolant drain
Note：
radiator.
1. Bolt
2. Clip
Note：
Note：
pressure.
4. Intake pipe

Note：
1. Engine cover

sensor.
Note：
・ The following applies to the high-output 7. Boost sensor disconnect
specifications.
assembly.
assembly.

Note：
2. MAF sensor
3. Blow-by hose
9. Generator cover removal 11. Radiator upper hose removal

1. Remove the generator cover from the bracket and the 1. Remove the radiator upper hose from the water
adjust plate. outlet pipe and the radiator.
10. Radiator reserve tank removal 1. Radiator upper hose

1. Disconnect the radiator reserve tank hose from the 12. Fan guide removal
radiator.
2. Remove the radiator reserve tank from the upper fan
guide. Note：
sides and remove the upper fan guide.
1. Remove the cooling fan clutch from the water pump
assembly.
Note：
・ Remove the part together with the cooling fan.
1. Upper fan guide

2. Clip
3. Lower fan guide
4. Fan shroud

16. Fan pulley removal
1. Remove the fan pulley from the water pump
pulley.
assembly.
17. Fan shroud removal
Note：
・ Remove the lower fan guide together with the
fan shroud.
18. Crankshaft pulley removal
1. Remove the crankshaft pulley from the crankshaft.
Caution：
・ Do not reuse the crank pulley bolt.
14. Cooling fan belt removal

Note：
generator.
15. Cooling fan clutch removal
19. Crankshaft front oil seal removal
1. Remove the crankshaft front oil seal from the gear
case cover.
Note：
・ To avoid damages on the oil seal contact
surface of the gear case cover and the shaft,
remove the oil seal using a driver or
equivalents.
installation 1. Install the crankshaft pulley to the crankshaft.

Note：
1. Crankshaft front oil seal installation
・ Align the crankshaft pulley to the key of the
1. Install the crankshaft front oil seal to the gear case crankshaft and install it.
cover using special tool.
・ Hold the fly wheel ring gear in a stopped state,
Note： and lock the crankshaft when tightening the
・ Install it using the oil seal installer. crankshaft pulley bolt.
Tightening torque： 294 N・m { 30.0 kgf・m / 217 lb・
ft }
Caution：
・ Take care not to damage the crankshaft
damper pulley boss portion.
・ Use new crank pulley bolts.
1. Oil seal installer
2. Apply the engine oil to the crankshaft front oil seal.

Note：
・ Apply it to the lip section.
・ Check the dimension of the oil seal section,
while pushing the seal in.
Note：
shroud.
4. Fan pulley installation
1. Install the fan pulley to the water pump assembly.
5. Cooling fan clutch installation
1. Install the cooling fan clutch to the water pump
assembly.
Note：
・ Install the part together with the cooling fan.
1. Standard value
2. Crankshaft pulley installation

Tightening torque： 8 N・m { 0.8 kgf・m / 71 lb・in } 1. Measurement point 1

6. Cooling fan belt installation
1. Install the cooling fan belt to the pulley. 4. Measurement point 4
7. Cooling fan belt adjustment Note：
1. Adjust tension to a standard value using a tension ・ After adjusting the tension, tighten the adjust
meter. plate lock bolt and the mounting bolt under the
Note： generator.
・ Move the generator to adjust the tension. Generator tightening torque
2. Check tension of the cooling fan belt. ： 40 N・m { 4.1 kgf・m /
Mounting bolt
30 lb・ft }
Note：
： 25 N・m { 2.5 kgf・m /
・ The following is the belt tension adjusting Adjust plate lock bolt
18 lb・ft }
・ Apply a load to measurement point 1 of the Note：
cooling fan belt and adjust the amount of flex. ・ If the cooling fan belt is replaced with a new
one, make the new cooling fan belt fit in to
Load： 98 N { 10 kg / 22 lb } cope with initial elongation.
Note：・ After making the cooling fan belt fit in, adjust
・ The following is the belt tension adjusting its tension once again.
method with a sonic tension meter. 8. A/C compressor drive belt installation
1 with a sonic tension meter. 1. Install the A/C compressor drive belt to the pulley.

： 5.4 to 6.6 mm
New ： 188 to 210 Hz
{ 0.213 to 0.260 in }
： 7.7 to 8.5 mm
{ 0.303 to 0.335 in }
Note：
Measurement point 2
Amount of belt
Frequency
deflection
： 12.5 to 16.5 mm
New ： 92 to 112 Hz
{ 0.492 to 0.650 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 3
Amount of belt
Frequency
deflection
1. A/C compressor drive belt ： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
9. A/C compressor drive belt adjustment
： 16.5 to 19.1 mm
1. Adjust tension to a standard value using a tension { 0.650 to 0.752 in }
meter.
Measurement point 4
Note：
Amount of belt
・ The following is the belt tension adjusting Frequency
deflection
： 15.9 to 20.7 mm
・ Apply a load to measurement points 2, 3, and New ： 70 to 86 Hz
{ 0.626 to 0.815 in }
： 20.7 to 23.7 mm
the amount of flex. Reuse ： 62 to 70 Hz
{ 0.815 to 0.933 in }
Load： 98 N { 10 kg / 22 lb }
Measurement point 2
Amount of belt
Frequency
deflection
： 12.5 to 16.5 mm
New ： 92 to 112 Hz
{ 0.492 to 0.650 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 3
Amount of belt
Frequency
deflection
： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 4 1. Measurement point 1

Amount of belt 2. Measurement point 2
Frequency 3. Measurement point 3
deflection
： 15.9 to 20.7 mm 4. Measurement point 4
New ： 70 to 86 Hz
{ 0.626 to 0.815 in }
： 20.7 to 23.7 mm
{ 0.815 to 0.933 in }
Note：
・ After adjusting the tension, tighten the
10. Fan guide installation
Note：

guide.
1. Upper fan guide

2. Clip
3. Lower fan guide
4. Fan shroud

Hose clip

radiator.
Note：
detergent.
the water.
adjust plate.

intake hose.
14. Intake air duct installation Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
Bolt
and the intake hose. Tightening torque： 4 N・m { 0.4 kgf・m / 35 lb・in }
Clip
Bolt
Clip

1. Air cleaner assembly 1. Engine cover

2. MAF sensor
3. Blow-by hose 19. Front under guard installation
4. Intake pipe Note：
2. Connect the intake pipe to the turbocharger 1. Install the front under guard to the frame.
assembly.
Note：
Note：
specifications.
assembly.
pressure sensor.
1. Bolt
2. Clip
Note：
Note：
Note：
20. Coolant filling

Note：
solution.
Note：
3. Lower vehicle.
Crankshaft rear oil seal
removal
2. Transmission assembly removal SST: 5-8840-0214-0 - crankshaft stopper
Refer to "5.Transmission, Transaxle Note：

5B.Automatic(TB-50LS) Transmission ・ For automatic transmission vehicles, after
assembly removal". loosening the flywheel mounting bolts, remove
in that order.
5. Rear plate removal
1. Remove the rear plate from the cylinder block and
the crankcase.
4. Flywheel removal
1. Remove the flywheel from the crankshaft.
Note：
6. Oil seal retainer removal

1. Remove the oil seal retainer from the cylinder block
and the crankcase.
Note：
・ Remove it together with the oil seal.

Note：
7. Crankshaft rear oil seal removal

1. Remove the crankshaft rear oil seal from the retainer.
2. Remove the slinger from the oil seal retainer using
special tool.
Note：
・ Install the slinger puller, and remove the oil
seal as shown in the diagram.
SST: 5-8840-2360-0 - rear oil seal remover

installation 1. Install the rear plate to the cylinder block and the
crankcase.
1. Oil seal retainer installation
1. Apply liquid gasket to the oil seal retainer.
Note：
3. Crankshaft rear oil seal installation

1. Install the crankshaft rear oil seal to the crankshaft
using special tool.
1. 1 - 1.5 mm {0.039 - 0.059 in} Note：
2. 1 - 1.5 mm {0.039 - 0.059 in}
・ Use a rear oil seal installer for installation.
2. Install the oil seal retainer to the cylinder block and
the crankcase.
SST: 5-8840-2359-0 - oil seal installer kit
Caution：
・ After applying the liquid gasket, install it within
5 minutes.
2. Rear plate installation
1. 12.2 – 12.8 mm {0.48 – 0.50 in}
Note：
・ Apply it to the threaded portion of the bolt.
2. Temporarily tighten the flywheel to the crankshaft.
Note：
diagram.

Note：
Note：
the diagram.
Note：
5. Transmission assembly installation

6. Clutch assembly installation
SST: 5-8840-0214-0 - crankshaft stopper
4. Securely tighten the flywheel to the crankshaft. System(MUA) Clutch assembly installation".
Note： Refer to "5.Transmission, Transaxle 5E.Clutch
・ Tighten in the order in the diagram. System(MUX) Clutch assembly installation".
Tightening torque： 59 N・m { 6.0 kgf・m / 44 lb・ft } 7. Battery ground cable connect
3. Lower vehicle.
Timing gear case
removal
Note：
Note：
2. Clip
Note：
Note：
Note：

Note：
Note：

Note：
specified torque.
Caution：
Note：
the blade.
5. Coolant drain
Note：
radiator.
1. Wiper arm cover

2. Nut
3. Wiper arm, blade

Warning：
pressure.
Note：
6. Engine oil drain

2. Bolt
Note： cover.
sensor.
Note：
specifications.
assembly.
assembly.

Note：
2. MAF sensor
3. Blow-by hose
4. Intake pipe

1. Battery cable
2. Battery bracket
3. Earth

Note：

radiator.
guide.

adjust plate.
Note：
generator.

pulley.


compressor bracket.

2. A/C compressor
Note：
cylinder head.
1. Upper fan guide 34. Fan pulley removal

2. Clip
3. Lower fan guide
assembly.
4. Fan shroud
assembly. Note：
fan shroud.
guide tube.
crankcase.
valve.
manifold.

2. Cooling fan

assembly.
Note：
1. Intake throttle valve 43. Leak-off pipe removal

2. Gasket
39. EGR valve disconnect and the common rail assembly.
1. Disconnect the connector from the EGR valve. Caution：

Caution：
1. Leak-off pipe
44. Bracket removal

Note：
specifications.
control solenoid.
1. Fuel hose 2. Disconnect the connector from the turbocharger
control solenoid.
Note：
control solenoid.

plug.
Note： Note：
・ The following applies to standard-output ・ Remove it together with the glow plug terminal.
specifications

47. Glow plug removal
1. Remove the clip from the injection pipe.
1. Remove the glow plug from the cylinder head.
2. Remove the injection pipe from the injector and the
1. Glow plug 50. Turbocharger water feed pipe disconnect
48. Water pipe removal 1. Disconnect the turbocharger water feed hose from
the outlet pipe. Note：
specifications.
assembly.

・ The following applies to the high-output 4. Turbocharger water feed hose
1. Remove the vacuum hose from the turbocharger and Note：

the vacuum pipe. ・ The following applies to the standard output
specifications.
assembly.

51. Water hose disconnect 1. Water hose
Note： 52. Exhaust manifold heat protector removal

・ The following applies to the EGR cooler 1. Remove the exhaust manifold heat protector from
specifications. the exhaust manifold.
Note：
53. Air duct bracket removal

1. Feed hose
2. Return hose
Note：
specifications.
54. Turbocharger water return hose disconnect 1. Turbocharger water feed hose
the water feed and return pipe. 55. Turbocharger feed oil pipe removal
Note： 1. Remove the turbocharger feed oil pipe from the
・ The following applies to the high-output turbocharger and the oil cooler.
specifications.
Note：
specifications.

3. Water pipe
4. Turbocharger water feed hose 1. Turbocharger feed oil pipe
Note：
・ The following applies to the standard output specifications.
specifications.
1. Turbocharger feed oil pipe 57. Catalyst converter disconnect
56. Oil return pipe removal 1. Disconnect the catalyst converter from the front
exhaust pipe.
and the crankcase. 58. Catalyst converter removal
Note： 1. Disconnect the catalyst converter from the catalyst

converter bracket.
specifications. 2. Remove the catalyst converter from the turbocharger
assembly.
Note：
・ The following applies to the standard output 3. Remove the catalyst converter bracket from the rear
specifications. cover.
Note：
・ Remove the engine side from the crankcase.
and the water intake pipe.
1. Disconnect the heater bypass pipe from the water
Note：
side.
60. Water intake pipe removal

the oil cooler assembly. 2. Remove the water bypass pipe from the cylinder
Note： head assembly.
・ Remove it with the hose attached. Note：
head side.
62. Oil filter bracket removal 1. Fuel leak-off hose

1. Remove the oil filter bracket from the oil filter and
the engine hanger. Caution：

64. Fuel leak-off hose removal 1. Injector leak-off pipe
2. Clip
pipe. Caution：
Note：
specifications.
cover.
66. EGR pipe removal 68. Cam end gasket removal

Note： 1. Remove the cam end gasket from the cylinder head.
・ The following applies to the EGR pipe Note：
specifications.
1. Remove the EGR pipe from the inlet manifold and cylinder head.
1. Cam end gasket

69. Injector removal
head. 1. Remove the injector from the cylinder head.
Note：
the injector clamp.
・ If it is difficult to remove the injector, use a
remover.
Caution：
removed injector.
cause damage.
Note：
cover.
cover
pulley

Note：
3. Remove the gasket from the injector.

4. Remove the O-ring from the injector.
center.
Note：

Note：

head.
Note：
75. Noise cover removal 77. CMP sensor disconnect

1. Remove the noise cover from the timing chain lower 1. Disconnect the connector from the CMP sensor.
cover.
1. CMP sensor
1. Noise cover
1. Remove the timing chain lower cover from the gear cylinder head.
case cover.
79. Fuel supply pump preparation 1. Alignment mark

1. Turn the crankshaft. 80. Supply pump gear nut removal
Note： 1. Turn the nut.
・ Rotate the crankshaft in the forward direction
Note：
to align the 1st cylinder to the compression top
dead center. ・ Loosen the nut of the supply pump gear.
・ Check the TDC alignment position by using a
mirror, etc.
1. Supply pump gear nut
81. Timing chain tensioner removal

cover 1. Remove the timing chain tensioner from the cylinder
2. Top dead center alignment mark on the crank head.
pulley
Note：
・ Confirm that the alignment marks of the
camshaft bearing cap and the camshaft are
aligned.
1. Timing chain tensioner 1. Timing chain lever pivot

2. Gasket 2. Sprocket
3. Nut 3. Nut
82. Timing chain lever pivot removal Note：

1. Remove the timing chain lever pivot from the timing ・ Lift up the timing chain.
84. Supply pump gear removal

83. Sprocket removal Note：
1. Remove the nut from the sprocket. ・ Mark the alignment positions on idle gear A
and the supply pump gear.
2. Remove the sprocket from the supply pump gear.

2. Suction control valve
3. Remove the fuel supply pump from the timing gear

case.
1. Remove the supply pump gear from the fuel supply

pump using the gear puller.
1. Fuel supply pump
Caution：
・ Do not hold the high-pressure pipe when
removing the supply pump.
4. Remove the O-ring from the fuel supply pump.
85. Fuel supply pump removal
temperature sensor.
2. Disconnect the harness connector from the suction
control valve.
Note：
89. Timing chain guide removal
1. Install the timing chain guide to the cylinder head
assembly and the cylinder block.
1. Supply pump
2. O-ring
Caution：
carrying the supply pump.
86. Idle gear D removal 90. Rocker arm shaft assembly removal
1. Remove the idle gear D from the cylinder head. 1. Remove the rocker arm shaft assembly from the
Note： cylinder head.
・ Drop the timing chain backward. Note：
positions.

sprocket.
88. Timing chain tension lever removal 2. Bolt, long
1. Remove the timing chain tension lever from the 3. Bolt, short
cylinder head assembly. 4. Intake rocker arm shaft assembly
5. Front
Note： 3. Remove the bolt from the timing gear case.
・ Be very careful not to drop the parts into the
cylinder head front-side gear case or the front
Note：
specifications.
1. Nut
SST: 5-8840-2861-0 - engine hanger 2. Bolt

Note：
Note：
specifications.
Caution：
cylinder block.
Note：
92. Cylinder head gasket removal
1. Remove the cylinder head gasket from the cylinder
Caution：
with a new one.
Caution：

2. Nut

bracket.
94. Water pump assembly removal

1. Remove the water pump assembly from the timing
gear case.
1. Bracket
96. Vacuum pump assembly removal

1. Remove the vacuum hose from the vacuum pipe and
the vacuum pump assembly.

gear case.
Note：
・ Remove the power steering pump together
with the hose.
2. Remove the vacuum pump oil pipe from the vacuum 98. Gear case cover removal
pump assembly and the cylinder block.
1. Remove the gear case cover from the timing gear
3. Remove the vacuum pump assembly from the gear case.
case cover.
99. Idle gear A removal

97. Cover removal
1. Install the bolt to the idle gear A.
1. Remove the cover from the gear case cover.
Note：
2. Remove the idle gear A flange from the idle gear A.
3. Remove the idle gear A from the idle gear A shaft.
4. Remove the idle gear A shaft from the timing gear
case.
100.Idle gear C removal 102.Oil pump assembly removal

1. Remove the idle gear C from the idle gear C shaft. 1. Remove the oil pump from the timing gear case.
2. Remove the idle gear C shaft from the timing gear
case.
1. Oil pump
103.Timing gear case bracket removal

101.Crank gear removal
1. Remove the timing gear case bracket from the timing
1. Remove the crank gear from the crankshaft. gear case and the cylinder block.
1. Timing gear case bracket 1. Timing gear case

2. Bolt L = 25 mm {0.98 in}
104.Timing gear case removal 3. Bolt L = 60 mm {2.36 in}
1. Remove the timing gear case from the cylinder 4. Bolt L = 45 mm {1.77 in}
block. 5. Bolt L = 35 mm {1.38 in}
6. Bolt L = 16 mm {0.63 in}
2. Remove the gasket from the cylinder block. 7. Bolt L = 20 mm {0.79 in}
8. Bolt
1. Timing gear case

2. Gasket
Caution：
・ Do not remove the bolt in the diagram 8 during
maintenance.
installation
1. Timing gear case installation
1. Apply liquid gasket to the gasket.
Note：
・ Apply ThreeBond 1207B or equivalent to the
area indicated in the diagram.
Note：
1. Timing gear case

2. Bolt L = 25 mm {0.98 in}
3. Bolt L = 60 mm {2.36 in}
4. Bolt L = 45 mm {1.77 in}
5. Bolt L = 35 mm {1.38 in}
6. Bolt L = 16 mm {0.63 in}
7. Bolt L = 20 mm {0.79 in}
8. Bolt
2. Timing gear case bracket installation

1. Temporarily tighten the timing gear case bracket to
the timing gear case and the cylinder block.
Note：
1. Liquid gasket application area ・ Temporarily tighten the nut and bolt on the
gear case side.
3. Install the gasket to the cylinder block.
・ Temporarily tighten the bolt on the cylinder
4. Install the timing gear case to the cylinder block. block side.
Note： 2. Securely tighten the timing gear case bracket to the
・ Align to the dowel pin, install the timing gear timing gear case and the cylinder block.
case, and then install the bolt in the order
Note：
・ Temporarily tighten the nut and bolt on the
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } gear case side.
Caution：・ Temporarily tighten the bolt on the cylinder
・ Do not remove the bolt in the diagram 8 during block side.
maintenance. Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
1. Timing gear case bracket 1. Top dead center alignment mark on the gear case
cover
3. Oil pump assembly installation 2. Top dead center alignment mark on the crank
1. Apply the engine oil to the oil pump gear. pulley
2. Install the oil pump to the timing gear case. 6. Idle gear C installation
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } 1. Apply the engine oil to the idle gear C shaft.
Note：
・ Apply it to the gear assembly sections.
2. Install the idle gear C shaft to the timing gear case.
3. Install the idle gear C to the idle gear C shaft.
Note：
・ Apply it to the thread and the seat.
5. Temporarily tighten the bolt to the timing gear case.
1. Oil pump
4. Crank gear installation

1. Install the crank gear to the crankshaft.
center.
Note：
7. Idle gear A installation
1. Fasten the sub gear to the idle gear A.
Note：
・ When fixing of the sub gear is released.
・ Tighten the sub gear mounting bolt.
・ Turn the sub gear to the right until the M6 bolt
holes between the idle gear A and sub gear
are aligned, by using a sub gear and a lever.
・ Install the M6 bolt with the appropriate torque
so that the sub gear does not move.
Note：
・ Align the oil holes of the cylinder block and the
idle gear A shaft.
2. Apply the engine oil to the idle gear A shaft.
3. Install the idle gear A shaft to the timing gear case.
4. Install the idle gear A to the idle gear A shaft.
5. Install the idle gear A flange to the idle gear A.
Note：
・ Install the idle gear A with the alignment mark
aligned. Note：
8. Securely tighten the bolt to the timing gear case. 1. M6 bolt

Tightening torque： 32 N・m { 3.3 kgf・m / 24 lb・ft } 8. Gear case cover installation
Idle gear A
1. Apply liquid gasket to the timing gear case.
Idle gear C Note：
in the diagram.
1. Idle gear A bolt

2. Idle gear C bolt
1. Liquid gasket application area
9. Remove the bolt from the idle gear A.
Note： Caution：
・ Remove the M6 bolt. ・ Within 5 minutes after applying the liquid
gasket, install the cover.
2. Install the gasket to the gear case cover.
3. Install the gear case cover to the timing gear case.
9. Cover installation Tightening torque： 12 N・m { 1.2 kgf・m / 106 lb・

in }
1. Install the cover to the gear case cover.
3. Install the vacuum hose to the vacuum pipe and the
vacuum pump assembly.
Tightening torque： 25 N・m { 3 kgf・m } Hose clip
10. Vacuum pump assembly installation

1. Install the vacuum pump assembly to the gear case
11. Power steering oil pump assembly installation
cover.
case.
2. Install the vacuum pump oil pipe to the vacuum
1. Power steering pump 13. Crankshaft pulley installation

2. Nut
1. Install the crankshaft pulley to the crankshaft.
2. Install the power steering oil hose to the bracket. Note：
crankshaft and install it.
and lock the crankshaft when tightening the
crankshaft pulley bolt.
ft }
Caution：
1. Bracket
12. Water pump assembly installation

1. Install the water pump assembly to the timing gear
case.
Note：
・ Attach a new gasket and install the water
pump assembly.

Note：
piston head.
are provided.
Note：
・ Measure the protrusion amount of the piston
head.
Note：
the difference between 1 and, 2, and between
3 and 4 of each cylinder.
Note：
Note：
possible.
Note：
1. Bead height
2. Bead width
Caution：
block.
Note：
head.
cylinder head.
Note： Caution：
in}.
Note：
Note：
the diagram.
Note：
the diagram.
Note：
hoist.
head.

Note：
Note：
17. Rocker arm shaft assembly installation
1. Apply the engine oil to the rocker arm shaft
assembly.
2. Install the rocker arm shaft assembly to the cylinder
head.
Note：
・ Install the rocker arm shaft assemblies from
No. 1 to No. 4 in the numbering order.
Note：
Note：
surface.
Note：
2. Bolt, long
3. Bolt, short
5. Front


Note：
diagram.
19. Timing chain tension lever installation

1. Install the timing chain tension lever to the cylinder
head.
Note：
between the timing gear case and the cylinder
block.
1. Timing chain 23. Supply pump gear installation

2. Timing mark
1. Install the supply pump gear to the fuel supply pump.
3. Blue link
4. Yellow link Note：
・ Align the alignment mark of the supply pump
22. Fuel supply pump installation
gear and the mark on idle gear A.
1. Apply soapy water to the O-ring. ・ Confirm that the supply pump gear and the
2. Install the O-ring to the fuel supply pump. main gear of idle gear A are engaged.
・ Push in the supply pump gear while the supply
Caution：
pump gear is engaged with the sub gear of idle
・ Be careful not to twist it. gear A.
3. Install the fuel supply pump to the timing gear case.
1. Alignment mark of the supply pump gear

2. Idle gear marking
3. Main gear
1. Fuel supply pump 4. Sub gear
Note： 24. Sprocket installation
・ Confirm that the supply pump camshaft key is
1. Install the timing chain to the sprocket.
in a horizontal position on the right side.
Note：
・ Install it to each sprocket.
2. Align the timing chain to the alignment mark.
Note：
・ Align the timing mark of the crankshaft
sprocket and the timing chain link of the dark
plate.
・ Align the timing mark of the fuel supply
sprocket and the timing chain link of the yellow
plate.
3. Temporarily tighten the sprocket to the supply pump
gear.
Note：
・ Align the dowel pin attached to the gear, and
install the fuel supply pump sprocket to the fuel
pump shaft. 26. Timing chain tensioner installation
・ Tighten the fuel supply pump shaft nut by 1. Connect the hook to the pin.
hand.
Note：
pushed.
plunger.
1. Timing mark
2. Dark plate
3. Timing mark
4. Yellow plate
25. Timing chain lever pivot installation

1. Temporarily tighten the timing chain lever pivot to 1. Pin
the timing chain tension lever. 2. Plunger
Note： 3. Latch
・ Tighten the pivot bolt by hand. 4. Timing chain tensioner
5. Hook
・ Confirm that the tension lever moves
smoothly. 2. Install the timing chain tensioner to the cylinder
head.
1. Timing chain tensioner 1. Nut

2. Gasket
3. Nut 2. Securely tighten the timing chain lever pivot to the
timing chain tension lever.
Note：
28. Exhaust camshaft installation
・ Lightly push the area indicated by an arrow in
the diagram. 1. Install the exhaust camshaft to the cylinder head.
・ The hook of the tensioner opens and the Note：
plunger pushes the tension lever to pull the ・ Align the timing mark to the idle gear D to
chain. install it.
27. Supply pump gear nut installation 1. Exhaust camshaft gear

1. Securely tighten the sprocket to the supply pump 2. Inlet camshaft gear
gear. 3. Idle gear D
Tightening torque： 130 N・m { 13.3 kgf・m / 96 lb・ 29. Inlet camshaft installation
ft }
Note：
install it.
1. Alignment mark

Note：
2. Inlet camshaft gear ・ Apply it to the threaded portion.
3. Idle gear D 7. Install the bolt to the camshaft bearing cap.
30. Camshaft bearing cap installation Note：
1. Apply the engine oil to the camshaft bearing cap. ・ Tighten it to the prescribed torque according to
Note：
Note：
cap.

Note：
Note：
cap.
Note：
1. Liquid gasket
2. Bead height
3. Bead width
Note：
head.
2. Inlet camshaft gear Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
3. Idle gear D

Note：
Caution：
install the cover.

cover.
1. CMP sensor

Note：
1. Noise cover
Bead width： 2.0 to 2.5 mm { 0.079 to 0.098 in } 35. Baffle plate installation
Caution： 1. Install the baffle plate to the cylinder head.

・ Within 5 minutes of applying the liquid gasket, Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in }
install the cover.
Note：
Caution：
1. Liquid gasket
2. Bead height
3. Bead width

cover.
cylinder head.
Note：
Note：
1. Injector
2. Leak-off pipe
3. Clip
4. O-ring
5. Gasket

head.
ft }
1. Injector
2. Bolt


the injector.
1. Cam end gasket 40. EGR pipe installation

2. Application area
Note：
3. Bead width
2. Install the cam end gasket to the cylinder head. specifications.
39. Cylinder head cover installation 1. Install the EGR pipe to the inlet manifold and the
exhaust manifold.
Note：
Bolt, nut
in the diagram.
1. 3.0 - 5.0 mm {0.118 - 0.197 in} Note：

specifications.
Note：
1. Leak-off pipe Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }

2. Clip
45. Water bypass pipe installation
2. Install the fuel leak-off hose to the leak-off pipe. 1. Install the water bypass pipe to the cylinder head
assembly.
Note：
・ Install the water bypass pipe on the cylinder
head side.
・ Apply soapy water on the O-ring when
inserting the pipe.
1. Leak-off pipe
2. Clip
Caution：
43. Injector connect
1. Connect the harness connector to the injector. 2. Install the water bypass pipe to the oil filter.
44. Oil filter bracket installation Note：
1. Install the oil filter bracket to the oil filter and the ・ Install the water bypass pipe on the oil filter
engine hanger. side.
・ Temporarily tighten each bolt until it gets
seated, and then, firmly tighten it.
Note：
・ Firmly tighten the nuts and bolts in the order

1. Temporarily tighten the pipe bracket to the water
intake pipe.
2. Install the water intake pipe to the oil filter. Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
Note： 47. Heater bypass pipe installation

・ Insert the water intake pipe into the oil filter. 1. Install the heater bypass pipe to the oil cooler and the
・ Apply soapy water on the O-ring when water bypass hose.
inserting the pipe. Note：
3. Temporarily tighten the water intake pipe to the oil ・ Temporarily tighten nuts starting from the rear
cooler and the generator bracket. side, and then firmly tighten them in the same
order.
Note：
・ Temporarily tighten the nuts and bolts in the Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }

4. Securely tighten the water intake pipe to the oil pipe.
cooler and the generator bracket. 48. Catalyst converter installation
assembly.

Bolt 1, 3
Bolt 2
converter bracket. 49. Catalyst converter connect
Note： 1. Connect the catalyst converter to the front exhaust
・ Temporarily tighten the bolts in the order pipe.
shown in the diagram. Tightening torque： 67 N・m { 6.8 kgf・m / 49 lb・ft }
Note： 50. Oil return pipe installation

the diagram.
crankcase.
Turbocharger side
Crankcase side
Note：
specifications.
Note：
Note： specifications.
specifications.
51. Turbocharger feed oil pipe installation 52. Turbocharger water return hose connect
1. Install the turbocharger feed oil pipe to the 1. Connect the turbocharger water return hose to the
turbocharger and the oil cooler. water feed and return pipe.

Note：
specifications.
specifications.
1. Water feed and return pipes 2. Securely tighten the air duct bracket to the cylinder
2. Turbocharger water feed hose head assembly.
3. Water pipe
Note：
5. Turbocharger water return hose ・ Firmly tighten in the order shown in the
diagram.
Note：
specifications.

Bolt 1
1. Turbocharger water feed hose Bolt 2
54. Exhaust manifold heat protector installation
53. Air duct bracket installation 1. Install the exhaust manifold heat protector to the
1. Temporarily tighten the air duct bracket to the exhaust manifold.
cylinder head assembly. Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
Note：
diagram.
55. Water hose connect 1. Water hose

Note： 56. Vacuum hose installation
Note：
specifications.
1. Connect the water hose to the EGR cooler. specifications.
Note： 1. Install the vacuum hose to the turbocharger and the
・ Connect both the feed hose and return hose to vacuum pipe.
the EGR cooler.

1. Feed hose
2. Return hose
Note： Note：
・ The following applies to the EGR pipe ・ The following applies to the high-output
1. Water feed and return pipes 2. Connect the turbocharger water feed hose to the
2. Turbocharger water feed hose outlet pipe.
3. Water pipe
5. Turbocharger water return hose 1. Install the glow plug to the cylinder head.

specifications.
1. Glow plug

2. Turbocharger water return hose 1. Install the glow plug connector to the glow plug.
Note：
58. Water pipe installation
・ Install it together with the glow plug terminal.

Bolt, nut
Note：
specifications


Note：

in }
control solenoid.
1. Leak-off pipe

solenoid.
solenoid.

2. Gasket
crankcase.
1. Fuel hose

Note：
Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in } ・ Install the lower fan guide together with the fan
shroud.
1. Install the fan pulley to the water pump assembly. Note：
72. Cooling fan clutch installation ・ Install the upper fan guide.

assembly.
Note：
1. Upper fan guide

2. Clip
3. Lower fan guide
4. Fan shroud

76. A/C compressor bracket installation

1. Fan clutch assembly head.
2. Cooling fan
77. A/C compressor assembly connect 79. Adjust plate installation

1. Install the A/C compressor assembly to the A/C 1. Install the adjust plate to the timing gear case.
compressor bracket.

2. A/C compressor
81. Cooling fan belt adjustment
78. Generator installation
1. Install the generator to the bracket. meter.
Note：
Note：
Load： 98 N { 10 kg / 22 lb } 1. Install the A/C compressor drive belt to the pulley.
Note：
： 5.4 to 6.6 mm
New ： 188 to 210 Hz
{ 0.213 to 0.260 in }
： 7.7 to 8.5 mm
{ 0.303 to 0.335 in }

meter.
Note：
the amount of flex.
Load： 98 N { 10 kg / 22 lb }
2. Measurement point 2 Measurement point 2
3. Measurement point 3 Amount of belt
4. Measurement point 4 Frequency
deflection
Note：： 12.5 to 16.5 mm
New ： 92 to 112 Hz
{ 0.492 to 0.650 in }
plate lock bolt and the mounting bolt under the ： 16.5 to 19.1 mm
generator. { 0.650 to 0.752 in }
Generator tightening torque Measurement point 3

： 40 N・m { 4.1 kgf・m / Amount of belt
Mounting bolt Frequency
30 lb・ft } deflection
： 25 N・m { 2.5 kgf・m / ： 12.4 to 16.4 mm
Adjust plate lock bolt New ： 92 to 112 Hz
18 lb・ft } { 0.488 to 0.646 in }
： 16.5 to 19.1 mm
Note： Reuse ： 80 to 92 Hz
{ 0.650 to 0.752 in }
one, make the new cooling fan belt fit in to Measurement point 4
cope with initial elongation. Amount of belt
Frequency
・ After making the cooling fan belt fit in, adjust deflection
its tension once again. ： 15.9 to 20.7 mm
New ： 70 to 86 Hz
82. A/C compressor drive belt installation { 0.626 to 0.815 in }
： 20.7 to 23.7 mm Note：

Note：
method with a sonic tension meter. 84. Generator connect
Measurement point 2 in } Terminal nut
Amount of belt
Frequency 85. Generator cover installation
deflection
New ： 92 to 112 Hz adjust plate.
{ 0.492 to 0.650 in }
： 16.5 to 19.1 mm Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in }
{ 0.650 to 0.752 in }
Measurement point 3
Amount of belt
Frequency
deflection
： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 4
Amount of belt
Frequency
deflection
： 15.9 to 20.7 mm
New ： 70 to 86 Hz
{ 0.626 to 0.815 in }
： 20.7 to 23.7 mm
{ 0.815 to 0.933 in }
guide.
radiator.
Note：
detergent.
the water.
Hose clip
1. Battery cable
2. Battery bracket
3. Earth

Battery side
Frame side
Clip

2. MAF sensor
3. Blow-by hose
4. Intake pipe

assembly.
Note：
specifications.
assembly.
pressure sensor.
intake hose.
Bolt
Clip

2. Bolt
Note：
Caution：

Note：
1. 29 mm (1.14 in)
2. 36.5 - 51.5 mm (1.44 - 2.03 in)
3. 18 mm (0.71 in)

ft }
100.Engine hood assembly installation
hood assembly.
Note：
removal.
Note：
1. Hood rest
Note：
assembly.
101.Washer hose connect
102.Engine cover installation

Note：
hood.
1. Engine cover
103.Front under guard installation

Note：
Note：
104.Engine oil filling

Note：
105.Coolant filling
1. Bolt Note：
2. Clip ・ Use the coolant contains 50 % anti-freeze
solution.
Note：
Note：
Note：
106.Battery ground cable connect
Note：
・ Tighten the 5 bolts. 1. Connect the battery ground cable to the battery.
3. Lower vehicle.
Cylinder block
removal
Note：
Note：

1. Bolt
2. Clip
Note：
1. Engine cover
Note： 4. Coolant drain
・ Remove the 5 bolts. 1. Drain coolant from the radiator.
3. Remove the rear under guard from the frame. Note：
Note：・ Open the drain plug at the bottom of the
radiator.
2. Remove the radiator cap from the radiator. 7. Blow-by hose disconnect
Warning： 1. Disconnect the blow-by hose from the cylinder head
・ In order to prevent burns, do not open the cap cover.
while the engine and radiator are hot. 8. Air cleaner assembly removal
pressure.
sensor.
5. Engine oil drain
1. Drain the engine oil from the oil pan. barometric pressure sensor.
Note： Note：
・ After draining oil, tighten the drain plug to the ・ The following applies to the high-output
specified torque. specifications.
Tightening torque： 44 N・m { 4.5 kgf・m / 32 lb・ft } 3. Disconnect the vacuum hose from the air cleaner
assembly.
Caution：
・ Do not forget to tighten the drain plug. 4. Disconnect the intake pipe from the turbocharger
assembly.
Note：
2. MAF sensor
3. Blow-by hose
4. Intake pipe

1. Battery cable
2. Battery bracket
3. Earth

valve and the intercooler. 13. Radiator upper hose removal
Note： 1. Remove the radiator upper hose from the water
・ Remove the part together with the intake hose. outlet pipe and the radiator.
guide.

adjust plate. Note：
generator.

pulley.

compressor bracket.

2. A/C compressor
Note：
cylinder head.
1. Upper fan guide 27. Fan pulley removal

2. Clip
3. Lower fan guide
assembly.
4. Fan shroud
assembly. Note：
fan shroud.
29. Glove box removal
1. Remove the glove box from the instrument panel.

2. Cooling fan

assembly. 1. Glove box
Note：
・ Remove the part together with the cooling fan. 30. Instrument panel assist-side lower cover removal
Note： 1. Fuel hose
1. Disconnect the catalyst converter from the front
exhaust pipe.
converter bracket.
assembly.
1. Glove box
31. ECM disconnect

Note：
・ Pull out the harness to the engine room side.
2. Disconnect the harness from the frame.
cover.
Note：
2. Disconnect the fuel hose from the fuel leak-off pipe. ・ Remove the exhaust side from the engine.

gear case.
Note：
with the hose.
37. Transmission assembly removal

assembly removal".
2. Nut
2. Remove the power steering oil hose from the System(MUA) Clutch assembly removal".
bracket.
Note：
Note：
41. Oil pan removal
1. Remove the oil pan from the crankcase.
1. Bracket

2. Disconnect the earth cable from the crankcase. 1. Intake throttle valve
2. Gasket

Caution：
1. Earth cable

guide tube.
crankcase.
valve.
manifold. 1. Leak-off pipe
48. Bracket removal
Note： 1. Remove the clip from the injection pipe.
・ The following applies to high-output 2. Remove the injection pipe from the injector and the
specifications. common rail assembly.
control solenoid.
control solenoid.
Note：
control solenoid.
50. Leak off pipe removal

2. Disconnect the fuel leak-off hose from the leak-off
pipe.
3. Remove the leak-off pipe from the inlet manifold.
Note：
specifications
51. Fuel feed pipe removal

1. Remove the fuel feed pipe from the fuel supply
pump and the common rail assembly.
Caution：

1. Remove the common rail assembly from the
common rail bracket.
2. Remove the bracket from the cylinder block.
Caution：
・ Do not grasp the pressure sensor during work.
・ Be careful not to damage the connector unit of
the pressure sensor.
3. Remove the swirl control solenoid valve bracket
from the common rail bracket.
1. Fuel feed pipe
52. Fuel pressure sensor disconnect

1. Disconnect the connector from the fuel pressure
sensor.
1. Common rail assembly

2. Vacuum pipe
3. Common rail bracket
4. Swirl control solenoid valve bracket

plug.
Note：
・ Remove it together with the glow plug terminal.
1. Connector
53. Swirl control solenoid valve removal

1. Disconnect the harness connector from swirl control
solenoid valve.
2. Remove swirl control solenoid valve from the
bracket.
3. Disconnect the vacuum hose from swirl control
solenoid valve.
1. Remove the vacuum pipe from the bracket.
55. Common rail assembly removal
1. Glow plug terminal 59. Vacuum hose removal

Note：
57. Glow plug removal ・ The following applies to the high-output
specifications.
the vacuum pipe.
1. Glow plug
58. Water pipe removal 60. Turbocharger water feed pipe disconnect
1. Disconnect the turbocharger water feed hose from 1. Disconnect the turbocharger water feed hose from
the outlet pipe. the water feed and return pipe.
2. Remove the water pipe from the cylinder head Note：
assembly.
specifications.
1. Water feed and return pipes Note：

2. Turbocharger water feed hose ・ The following applies to the standard output
3. Water pipe specifications.
Note：
specifications.


61. Water hose removal

1. Remove the water hose from the oil cooler assembly.
Note：
specifications.
3. Water pipe
Note：
specifications.

Note：

Note：
specifications.

Note：
specifications.
specifications.
67. Heater bypass pipe removal
1. Turbocharger feed oil pipe 1. Disconnect the heater bypass pipe from the water
intake pipe.
2. Remove the heater bypass pipe from the oil cooler
1. Remove the oil return pipe from the turbocharger assembly and the water bypass hose.
and the crankcase.
Note：
specifications.
68. Water intake pipe removal 2. Remove the water bypass pipe from the cylinder
head assembly.
the oil cooler assembly. Note：
Note：・ Remove the water bypass pipe on the cylinder
head side.
・ Remove it with the hose attached.

2. Remove the pipe bracket from the generator bracket
and the water intake pipe. 1. Remove the oil filter bracket from the oil filter and
the engine hanger.
69. Water bypass pipe removal
1. Remove the water bypass pipe from the oil filter.
Note：
side.

2. Clip
pipe. 73. Vacuum pipe removal
Note：
specifications.
cover.

Caution：
Note：
specifications.

1. Remove the cylinder head cover from the cylinder 77. Injector removal
head.
1. Remove the injector from the cylinder head.
Note：
the injector clamp.
remover.
Caution：
removed injector.
cause damage.
Note：
1. Remove the cam end gasket from the cylinder head. ・ When replacing all injectors, remove the
Note： injector ID code label on the cylinder head
・ Remove the liquid gasket sticking to the cover.
cylinder head. ・ When replacing some of the injectors, erase
3. Remove the gasket from the injector. 2. Remove the baffle plate from the cylinder head.
center.
Note：
80. Camshaft bearing cap removal

Note：

cover
pulley

Note：
2. Remove the camshaft bearing cap from the cylinder 82. Exhaust camshaft removal
head.
Note： head.

81. Inlet camshaft removal 1. Remove the noise cover from the timing chain lower
1. Remove the inlet camshaft from the cylinder head. cover.
1. Noise cover 1. CMP sensor
84. Timing chain lower cover removal 86. Timing chain upper cover removal
1. Remove the timing chain lower cover from the gear 1. Remove the timing chain upper cover from the
case cover. cylinder head.
85. CMP sensor disconnect 87. Fuel supply pump preparation

1. Disconnect the connector from the CMP sensor. 1. Turn the crankshaft.
Note：
dead center.
mirror, etc.
1. Top dead center alignment mark on the gear case 1. Supply pump gear nut
cover
2. Top dead center alignment mark on the crank 89. Timing chain tensioner removal
pulley 1. Remove the timing chain tensioner from the cylinder
head.
Note：
aligned.

2. Gasket
3. Nut
1. Alignment mark 90. Timing chain lever pivot removal
88. Supply pump gear nut removal 1. Remove the timing chain lever pivot from the timing
1. Turn the nut.
Note：
・ Loosen the nut of the supply pump gear.
91. Sprocket removal 92. Supply pump gear removal

1. Remove the nut from the sprocket. Note：
2. Remove the sprocket from the supply pump gear. ・ Mark the alignment positions on idle gear A
1. Timing chain lever pivot

2. Sprocket
3. Nut
Note：
・ Lift up the timing chain.

93. Fuel supply pump removal 1. Fuel supply pump

1. Disconnect the harness connector from the fuel Caution：
temperature sensor.
2. Disconnect the harness connector from the suction removing the supply pump.
control valve.

1. Supply pump
2. O-ring
Caution：
case.
Note：
Note：
positions.

sprocket.
1. Remove the timing chain tension lever from the 2. Bolt, long
cylinder head assembly. 3. Bolt, short
Note： 4. Intake rocker arm shaft assembly
5. Front
97. Timing chain guide removal Note：
1. Install the timing chain guide to the cylinder head ・ Be very careful not to drop the parts into the
assembly and the cylinder block. cylinder head front-side gear case or the front
Note：
specifications.

cylinder head.
Note：
Note：
specifications. Caution：
cylinder block.
Note：
SST: 5-8840-2886-0 - rear engine hanger 100.Cylinder head gasket removal
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } 1. Remove the cylinder head gasket from the cylinder

with a new one.
101.Crankshaft pulley removal
Caution：
1. Nut
2. Bolt
102.Water pump assembly removal 2. Remove the vacuum pump oil pipe from the vacuum
gear case. 3. Remove the vacuum pump assembly from the gear
case cover.
103.Vacuum pump assembly removal

104.Cover removal
the vacuum pump assembly. 1. Remove the cover from the gear case cover.
105.Gear case cover removal 107.Idle gear C removal

1. Remove the gear case cover from the timing gear 1. Remove the idle gear C from the idle gear C shaft.
case.
case.
106.Idle gear A removal

1. Install the bolt to the idle gear A. 108.Crank gear removal
Note： 1. Remove the crank gear from the crankshaft.
case.
109.Oil pump assembly removal 1. Timing gear case bracket

1. Remove the oil pump from the timing gear case. 111.Timing gear case removal
1. Remove the timing gear case from the cylinder
block.
2. Remove the gasket from the cylinder block.
1. Oil pump

gear case and the cylinder block. 1. Timing gear case
2. Gasket
Caution：
maintenance.

Note：
・ For automatic transmission vehicles, after
loosening the flywheel mounting bolts, remove
in that order.
113.Rear plate removal
the crankcase.
1. Timing gear case
2. Bolt L = 25 mm {0.98 in}
3. Bolt L = 60 mm {2.36 in}
4. Bolt L = 45 mm {1.77 in}
5. Bolt L = 35 mm {1.38 in}
6. Bolt L = 16 mm {0.63 in}
7. Bolt L = 20 mm {0.79 in}
8. Bolt
112.Flywheel removal
Note：
114.Oil seal retainer removal

and the crankcase.
Note：
・ Remove it together with the oil seal.

Note：
115.Crankcase removal 3. Clean the cylinder liner using a scraper.

1. Remove the crankcase from the cylinder block. Note：
・ Remove carbon from the top of the cylinder
block using a scraper.
4. Remove the piston from the cylinder block.
Note：
・ Pull out the piston and the connecting rod out
to the cylinder head side.
Caution：
・ When pushing out the connecting rod, be
careful not to damage the oil jet and cylinder
block.
5. Remove the connecting rod bearing from the
connecting rod.
Note：
・ When reusing the bearing, organize them
according to the order of the cylinders so that
1. O-ring other cylinder bearings do not get mistaken.
2. Crankcase 117.Crankshaft removal
Caution： 1. Remove the bearing cap bolt from the cylinder
・ Take care not to damage the O-ring. block.
116.Piston removal Note：

・ Gradually loosen the bolts in the order of the
1. Remove the connecting rod bearing cap from the
numbers indicated in the diagram.
connecting rod.
connecting rod bearing cap.
Note：
・ Organize the removed bearings according to
the cylinders using tags, etc.
Note：
・ Remove both of the left side and right side.
2. Remove the bearing cap from the cylinder block.

3. Remove the lower crankshaft bearing from the
bearing cap. 1. Left side engine foot
4. Remove the crankshaft from the cylinder block. 2. Right side engine foot
5. Remove the thrust bearing from the cylinder block. 120.Oil cooler assembly removal
6. Remove the upper crankshaft bearing from the 1. Remove the oil cooler assembly from the cylinder
cylinder block. block.
118.Generator bracket removal
1. Remove the generator bracket from the cylinder
block.
121.Oil jet pipe removal

1. Remove the oil jet pipe from the cylinder block.
119.Engine foot removal

1. Remove the battery cable bracket from the engine
foot.
Note：
・ Remove the engine foot on the left side first.
2. Remove the engine foot from the cylinder block.
inspection Note：
・ Measure the cylinder block inner diameter
1. Cylinder block cleaning according to the average value of the two
Note： locations actually measured.
・ Gently remove foreign materials such as water ・ Replace the cylinder block or widen the
deposit adhering to the top surface of the diameter if it exceeds the limit.
cylinder block.
Caution：
・ Be careful not to damage the cylinder block.
Note：
・ Gently remove the liquid gasket on the
crankcase installation surface.
・ Clean the cylinder block.
2. Cylinder block inspection
1. Inspect the cylinder block.
Note：
・ Visually inspect the cylinder block.
2. Inspect the cylinder block using the dye penetrant
check.
Note：
・ Perform the dye penetrant check and the 1. Measurement position
water pressure or the air pressure test. 2. Thrust
・ If cracks or other damage is found, replace the 3. Radial
cylinder block. Standard： 95.421 to 95.450 mm { 3.7567 to 3.7579 in }
Limit： 95.48 mm { 3.7590 in }
2. Measure deformation using a simple straight ruler.
Note：
・ Use a simple straight ruler and feeler gauge to
measure the 4 sides of the cylinder block top
surface and 2 locations in a diagonal line.
・ Repair the cylinder block if the measured value
exceeds the limit.
Limit： 0.20 mm { 0.008 in }
3. Cylinder block measurement

1. Measure inner diameter using a cylinder gauge.
Note：
・ Take measurements in the thrust direction and
the radial direction at the specified position.
Measurement position： 20 mm { 0.79 in } From the top
surface of the cylinder block
1. Simple straight ruler

2. Feeler gauge
Note：
・ Measure the height of the cylinder block.
Standard：259.945 to 260.055 mm { 10.2340 to 10.2384
in }
installation
1. Oil jet pipe installation
1. Install the oil jet pipe to the cylinder block.
Note：
・ Align the oil jet pipe dowel pin with the cylinder
block pin hole and tighten with a relief valve.
Relief valve
M8 bolt
M6 bolt
Caution：
・ Be careful not to deform or damage the nozzle
of the oil jet pipe. Note：
・ Within 5 minutes after application, install the oil
cooler assembly.
2. Install the O-ring to the oil cooler assembly.
Note：
・ Grease may be applied to the O-ring.
3. Install the oil cooler assembly to the cylinder block.
Note：
diagram.
2. Oil cooler assembly installation

1. Apply liquid gasket to the oil cooler assembly.
Note：
・ Apply liquid gasket, ThreeBond 1207C, to the
portion indicated in the diagram.

3. Engine foot installation
1. Install the engine foot to the cylinder block.
Note：
・ Install it on both the intake and exhaust sides.
Tightening torque： 157 N・m { 16.0 kgf・m / 116 lb・ 1. Install the upper crankshaft bearing to the cylinder
ft } M14 bolt block.
M10 bolt ・ The upper crankshaft bearing have both an oil
hole and an oil groove. The lower crankshaft
bearing do not have oil holes or grooves.
・ It does not exist on the lower crankshaft
bearing.
・ Carefully wipe out foreign materials from the
upper crankshaft bearing.
・ When reusing the removed upper crankshaft
bearing, find the position mark that was
marked at the time of disassembly.
2. Apply the engine oil to the upper crankshaft bearing.
Note：
・ Apply enough engine oil before installing the
crankshaft.
Caution：
・ Do not apply engine oil to the back surface of
the bearing and the bearing installation surface
1. Left side engine foot of the cylinder block.
2. Right side engine foot
2. Install the battery cable bracket to the engine foot.

Note：
・ Install to the intake side engine foot.
4. Generator bracket installation
1. Install the generator bracket to the cylinder block.
3. Apply the engine oil to the crankshaft.

Note：
・ Apply enough engine oil to the journal section.
4. Install the crankshaft to the cylinder block.
5. Crankshaft installation
according to the following table to determine

the appropriate size of the crankshaft bearing.
・ The grade of the crankshaft bearing housing
(1, 2, or 3) is marked on the rear right of the
cylinder block.
5. Apply the engine oil to the thrust bearing.

Note：
・ Apply enough engine oil to it.
6. Install the thrust bearing to the cylinder block.
Note： 1. No. 1
・ Install the thrust bearing onto the cylinder 2. No. 2
block No. 3 journal section front side and rear 3. No. 3
side. 4. No. 4
・ The thrust bearing oil groove must always face 5. No. 5
the sliding surface.
Note：
・ The crank journal grade mark is marked on the
each crankshaft journal web section.
・ After installing the crankshaft and crankshaft
bearing, each clearance of the crankshaft
journal and bearing must be the same.
7. Select the crankshaft bearing.

Note：
・ Select the crankshaft bearing according to the
measured diameter of the crankshaft journal
and the bearing insertion section.
・ Align the crankshaft bearing housing grade 1. No. 1
mark with the crankshaft journal grade mark 2. No. 2
3. No. 3 1. Lot No.
4. No. 4 2. Size code
5. No. 5
Caution：
・ Be careful not to mistake the bearing shape
when installing.
Crankshaft bearing housing Crankshaft journal Crankshaft bearing

Grade mark Diameter Grade mark Diameter bearing size code, color
： 69.927 to 69.932 mm
1 or -
{ 2.7530 to 2.7532 in }
： 73.992 to 74.000 mm ： 69.922 to 69.927 mm
1 2 or -- 4, yellow
{ 2.9131 to 2.9134 in } { 2.7528 to 2.7530 in }
： 69.917 to 69.922 mm
3 or ---
{ 2.7526 to 2.7528 in }
： 69.927 to 69.932 mm
1 or - 2, black
{ 2.7530 to 2.7532 in }
： 73.983 to 73.991 mm ： 69.922 to 69.927 mm
2 2 or -- 3, blue
{ 2.9127 to 2.9130 in } { 2.7528 to 2.7530 in }
： 69.917 to 69.922 mm
3 or --- 4, yellow
{ 2.7526 to 2.7528 in }
： 69.927 to 69.932 mm
1 or - 1, green
{ 2.7530 to 2.7532 in }
： 73.975 to 73.982 mm ： 69.922 to 69.927 mm
3 2 or --
{ 2.9124 to 2.9127 in } { 2.7528 to 2.7530 in }
2, black
： 69.917 to 69.922 mm
3 or ---
{ 2.7526 to 2.7528 in }
8. Install the lower crankshaft bearing to the bearing
cap.
9. Install the bearing cap to the cylinder block.
Note： 6. Piston installation

・ Install in numerical order, so that the bearing 1. Install the connecting rod bearing to the connecting
cap arrows point toward the front of the rod.
engine.
2. Apply the engine oil to the connecting rod bearing.
・ Always face the number of the bearing cap
upward. 3. Apply the engine oil to the piston ring.
Note：
・ Thoroughly apply it to the piston ring and the
ring groove.
4. Apply the engine oil to the piston.
Note：
・ Thoroughly apply it to the piston side surface.
5. Install the piston to the cylinder block using special
tool.
Note：
・ Face the notch of the piston front mark
towards the front.
・ Use the piston ring compressor to insert it into
the cylinder block.
Note：
・ Gradually tighten the crankshaft bearing cap
bolts to the specified torque in the order
indicated in the diagram.
ft } SST: 5-8840-9018-0 - piston setting tool
Caution： Caution：
・ Manually rotate the crankshaft to confirm that ・ When pushing the piston, be careful not to
the crankshaft works smoothly. touch the oil jet against the connecting rod.
・ When pushing the piston, be careful not to
damage the inside of the cylinder block.
6. Install the connecting rod bearing to the connecting Tightening torque： 29.4 N・m { 3.0 kgf・m / 22 lb・
rod bearing cap. ft }
7. Apply the engine oil to the connecting rod bearing. 11. Securely tighten the connecting rod bearing cap to
8. Apply the engine oil to the bolt. the connecting rod.
Note：
surface of the tightening bolts.
9. Temporarily tighten the connecting rod bearing cap
to the connecting rod.
Note：
・ Align the cap and the connecting rod number
markings and install the cap. Note：
・ Tighten the bolts to the specified angle in the
Note：
・ Confirm that the crankshaft turns smoothly.
10. Securely tighten the connecting rod bearing cap to

the connecting rod.
Note：
・ Tighten the bolts to the specified torque in the
Note：
7. Crankcase installation
1. Apply liquid gasket to the crankcase.
Note： 1. 1 - 1.5 mm {0.039 - 0.059 in}
2. 1 - 1.5 mm {0.039 - 0.059 in}
・ When applying it around the O-ring, adjust the 2. Install the oil seal retainer to the cylinder block and
amount so that a liquid gasket does not the crankcase.
protrude.
1. 2.0 - 3.0 mm {0.079 - 0.118 in}

Caution：
2. 4.0 - 5.0 mm {0.157 - 0.197 in}
2. Install the crankcase to the cylinder block. 5 minutes.
Caution： 9. Rear plate installation
・ After applying the liquid gasket, install it within 1. Install the rear plate to the cylinder block and the
5 minutes. crankcase.
Note：

Note：
Note：
Note：
diagram.

Note：
Note：
the diagram.
Caution：
maintenance.

Note：
area indicated in the diagram. 1. Timing gear case
2. Bolt L = 25 mm {0.98 in}
3. Bolt L = 60 mm {2.36 in}
Note： 4. Bolt L = 45 mm {1.77 in}
・ Apply ThreeBond 1207B or equivalent to the 5. Bolt L = 35 mm {1.38 in}
area indicated in the diagram. 6. Bolt L = 16 mm {0.63 in}
7. Bolt L = 20 mm {0.79 in}
8. Bolt

Note：
gear case side.
block side.
2. Securely tighten the timing gear case bracket to the
timing gear case and the cylinder block.
Note：
gear case side.
1. Liquid gasket application area ・ Temporarily tighten the bolt on the cylinder
block side.
4. Install the timing gear case to the cylinder block.
Note：
・ Align to the dowel pin, install the timing gear
cover
Note：
Note：
1. Oil pump

center.
Note：
Note：
Note：
idle gear A shaft.
Note：
aligned. Note：

Idle gear A
Idle gear C Note：
in the diagram.
1. Idle gear A bolt

2. Idle gear C bolt
Note： Caution：
in }

cover.
case.
Note：
pump assembly.
Note：
piston head.
are provided.
Note：
head.

Note：
ft }
Caution：
Note：
possible.

Note：
Note：
Note：
・ The difference in the protrusion amount of
in}.
Note：
1. Measurement point Bead width： 3 to 4 mm { 0.118 to 0.157 in }

Note：
Note：
the diagram.
Note：
the diagram.
Note：
1. Bead height
2. Bead width
Caution：
1. Install the cylinder head assembly to the cylinder SST: 5-8840-0266-0 - angle gauge
block.
Note：
head. Note：
・ Adjust the cylinder block dowel to install the ・ Tighten the head bolts in the order shown in
cylinder head. the diagram using a angle gauge.
2. Install the head bolt to the cylinder head. Specified angle： 60 to 75 °
Caution： 7. Install the bolt to the timing gear case.

・ Use new head bolts. 8. Install the nut to the timing gear case.
Note：
9. Remove the wire from the engine hanger and the 1. Exhaust rocker arm shaft assembly
hoist. 2. Bolt, long
3. Bolt, short
head.
5. Front


assembly.
head. 1. Install the timing chain tension lever to the cylinder
head.
Note：
・ Install the rocker arm shaft assemblies from Note：
No. 1 to No. 4 in the numbering order. ・ Place the timing chain tension lever in
block.
Note：
Note：
surface.
Note：
1. Timing chain
2. Timing mark
3. Blue link
4. Yellow link

1. Apply soapy water to the O-ring.
2. Install the O-ring to the fuel supply pump.
Caution：
・ Be careful not to twist it.

Note：
diagram.
1. Fuel supply pump
Note：
Note：
Note：
plate.
plate.
gear.
Note：
32. Supply pump gear installation pump shaft.
1. Install the supply pump gear to the fuel supply pump. ・ Tighten the fuel supply pump shaft nut by
hand.
Note：
・ Confirm that the supply pump gear and the
main gear of idle gear A are engaged.
gear A.
1. Timing mark
2. Dark plate
3. Timing mark
4. Yellow plate

1. Temporarily tighten the timing chain lever pivot to
the timing chain tension lever.
1. Alignment mark of the supply pump gear Note：
2. Idle gear marking ・ Tighten the pivot bolt by hand.
3. Main gear
4. Sub gear ・ Confirm that the tension lever moves
smoothly.

2. Gasket
3. Nut
Note：
pushed. Note：
chain.
1. Pin
2. Plunger
3. Latch 36. Supply pump gear nut installation
1. Securely tighten the sprocket to the supply pump
5. Hook
gear.
2. Install the timing chain tensioner to the cylinder Tightening torque： 130 N・m { 13.3 kgf・m / 96 lb・
head. ft }
Note：
install it.
1. Nut
2. Securely tighten the timing chain lever pivot to the

1. Install the exhaust camshaft to the cylinder head. 39. Camshaft bearing cap installation
Note： 1. Apply the engine oil to the camshaft bearing cap.
Note：
install it.
Note：
cap.

3. Idle gear D

Note：
cap.
Note：
1. Alignment mark

Note：
Note：
・ Tighten it to the prescribed torque according to 1. Exhaust camshaft gear
the order given in the diagram. 2. Inlet camshaft gear
Tightening torque： 18 N・m { 1.8 kgf・m / 13 lb・ft } 3. Idle gear D

Note：
Caution：
install the cover.

Note：
1. Liquid gasket 1. CMP sensor

2. Bead height
3. Bead width 42. Timing chain lower cover installation
Note：
・ Apply Loctite 262 or equivalent to the threaded Note：
portion on the cylinder head side. ・ Apply ThreeBond 1207C or equivalent.
2. Install the timing chain upper cover to the cylinder Bead height： 2.0 to 2.5 mm { 0.079 to 0.098 in }
head.
Caution：
install the cover.

1. Liquid gasket
2. Bead height
3. Bead width

cover.
cover.
1. Injector
2. Leak-off pipe
3. Clip
4. O-ring
5. Gasket

1. Noise cover

Note：
Caution：
1. Injector
2. Bolt
3. Injector clamp

Note：
surface.
5. Install the injector to the cylinder head.
Note：
the injector.
cylinder head.
Note：
Note：
1. Cam end gasket

2. Application area
3. Bead width

Note：
in the diagram.

head.
ft }
2. 3.0 - 5.0 mm {0.118 - 0.197 in}
Note：
diagram.

2. Clip
Note：
specifications.
exhaust manifold.
Bolt, nut
1. Leak-off pipe
2. Clip
Caution：
Note：
・ The following applies to high-output 53. Oil filter bracket installation
specifications. 1. Install the oil filter bracket to the oil filter and the
1. Install the vacuum pipe to the cylinder head cover. engine hanger.

Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } 55. Water intake pipe installation
54. Water bypass pipe installation 1. Temporarily tighten the pipe bracket to the water
intake pipe.
1. Install the water bypass pipe to the cylinder head
assembly. 2. Install the water intake pipe to the oil filter.
Note： Note：
・ Install the water bypass pipe on the cylinder ・ Insert the water intake pipe into the oil filter.
head side. ・ Apply soapy water on the O-ring when
・ Apply soapy water on the O-ring when inserting the pipe.
inserting the pipe.
3. Temporarily tighten the water intake pipe to the oil
Note：

Note：
side.
・ Temporarily tighten each bolt until it gets 4. Securely tighten the water intake pipe to the oil
seated, and then, firmly tighten it. cooler and the generator bracket.
Note： 1. Install the oil return pipe to the turbocharger and the
・ Firmly tighten the nuts and bolts in the order crankcase.
shown in the diagram. Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in }
Turbocharger side
Crankcase side
Note：
specifications.

56. Heater bypass pipe installation
1. Install the heater bypass pipe to the oil cooler and the
water bypass hose.
Note：
side, and then firmly tighten them in the same Note：
order. ・ The following applies to the standard output
specifications.

pipe. 1. Install the turbocharger feed oil pipe to the
Note：
specifications.

3. Water pipe
1. Turbocharger feed oil pipe 5. Turbocharger water return hose
Note： Note：
・ The following applies to the standard output ・ The following applies to the standard output

1. Connect the turbocharger water return hose to the 60. Air duct bracket installation
water feed and return pipe. 1. Temporarily tighten the air duct bracket to the
Note： cylinder head assembly.
specifications. ・ Temporarily tighten in the order shown in the
diagram.
2. Securely tighten the air duct bracket to the cylinder 62. Water hose installation
head assembly.
Note：
Note：
・ Firmly tighten in the order shown in the
diagram.
specifications.

Note：
Bolt 1
Tightening torque： 51 N・m { 5.2 kgf・m / 38 lb・ft } specifications
Bolt 2
exhaust manifold.
63. Turbocharger water feed pipe connect 1. Turbocharger water feed hose
water feed and return pipe. 64. Vacuum hose installation
Note： Note：
・ The following applies to the high-output ・ The following applies to the high-output
vacuum pipe.

3. Water pipe
4. Turbocharger water feed hose 65. Water pipe installation
5. Turbocharger water return hose 1. Install the turbocharger water feed hose to the
Note：
・ The following applies to the standard output Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in }
2. Connect the turbocharger water feed hose to the 1. Glow plug terminal
outlet pipe. 2. Glow plug connector
66. Glow plug installation 68. Common rail assembly installation
1. Install the glow plug to the cylinder head. 1. Install the swirl control solenoid valve bracket to the
Tightening torque： 18 N・m { 1.8 kgf・m / 13 lb・ft } common rail bracket.
1. Glow plug
2. Vacuum pipe
1. Install the glow plug connector to the glow plug. 3. Common rail bracket
Note：
・ Install it together with the glow plug terminal. 2. Install the common rail assembly to the cylinder
Tightening torque： 1 N・m { 0.1 kgf・m / 9 lb・in } block.
Note：
・ Install the part together with the common rail
bracket.
diagram.
Caution：
1. Injection pipe sleeve nut
72. Fuel pressure sensor connect

1. Connect the connector to the fuel pressure sensor.

1. Install the vacuum pipe to the bracket.
70. Swirl control solenoid valve installation
1. Connect the vacuum hose to swirl control solenoid
valve.
2. Install swirl control solenoid valve to the bracket.
3. Connect the connector to swirl control solenoid
valve.
71. Injection pipe connect
1. Connect the injection pipe to the common rail
assembly. 1. Connector
Note： 73. Leak off pipe installation
・ Tighten the injection pipe sleeve nut.
1. Install the leak-off pipe to the inlet manifold.
2. Connect the fuel leak-off hose to the leak-off pipe.

3. Connect the vacuum hose to the vacuum pipe. 2. Connect the connector to the turbocharger control
solenoid.
74. Fuel feed pipe installation
1. Install the fuel feed pipe to the fuel supply pump and
solenoid.
Note：
ft } ・ The following applies to standard-output
specifications
1. Fuel feed pipe

76. Leak-off pipe installation
Note：
1. Install the leak-off pipe to the fuel supply pump and
・ The following applies to high-output the common rail assembly.
specifications.
1. Install the bracket to the cylinder head cover. in }
Note：
control solenoid.
crankcase.
1. Leak-off pipe

82. Oil pan installation
1. Apply liquid gasket to the oil pan.
Note：
・ Apply ThreeBond 1207B or equivalent.
1. 2.0 mm {0.079 in}

2. 3.0 mm {0.118 in}
1. Intake throttle valve 2. Install the oil pan to the crankcase.
2. Gasket
Caution：
80. Intake throttle valve connect ・ After applying the liquid gasket, install it within
1. Connect the connector to the intake throttle valve. 5 minutes.
81. Oil level gauge guide tube installation Tightening torque： 22 N・m { 2.2 kgf・m / 16 lb・ft }
83. Engine assembly installation 1. Radiator lower hose

1. Operate the hoist. 88. Power steering oil pump assembly installation
Note： 1. Install the power steering oil pump to the timing gear
・ Slowly operate to move the engine to the case.
rear of the engine.
Note：
1. Power steering pump
86. Transmission assembly installation 2. Nut
2. Install the power steering oil hose to the bracket.
Hose clip
1. Bracket Note：
the diagram.
assembly.

Bolt 1, 3
2. Connect the catalyst converter to the catalyst Bolt 2
converter bracket.
90. Catalyst converter connect
Note：
91. Fuel hose connect 1. Glove box

1. Fuel hose

1. Glove box
92. ECM connect
Note：
Note：
93. Instrument panel assist-side lower cover installation shroud.
1. Install the instrument panel assist-side lower cover to 96. Fan pulley installation
Note：
assembly.
Note：
1. Upper fan guide

2. Clip
3. Lower fan guide
4. Fan shroud
100.Tension pulley installation

101.A/C compressor bracket installation

head.
2. Cooling fan
Note：
102.A/C compressor assembly connect 104.Adjust plate installation

compressor bracket.
105.Cooling fan belt installation

2. A/C compressor
106.A/C compressor drive belt installation
103.Generator installation
1. Install the A/C compressor drive belt to the pulley.
1. Install the generator to the bracket.
1. A/C compressor drive belt 2. Connect the radiator reserve tank hose to the
radiator.
107.Generator connect
Note：
Tightening torque： 12 N・m { 1.2 kgf・m / 106 lb・ before installation.
in } Terminal nut ・ Clean the radiator reserve tank using
108.Generator cover installation detergent.
adjust plate. ・ Wash it thoroughly with clean water, and drain
the water.
110.Radiator upper hose installation
Hose clip
109.Radiator reserve tank installation

guide.
111.Fuse box connect

112.Battery installation
114.Boost sensor connect

1. Battery cable
2. Battery bracket
3. Earth

Battery side
Frame side
113.Intake air duct installation 115.Air cleaner assembly installation
1. Install the intake air duct to the intake throttle valve 1. Install the air cleaner assembly to vehicle.
Bolt
Clip
1. Air cleaner assembly 118.Front under guard installation

2. MAF sensor
Note：
3. Blow-by hose
4. Intake pipe ・ The following applies to 2WD.
5. Barometric pressure sensor 1. Install the front under guard to the frame.
2. Connect the intake pipe to the turbocharger Note：
assembly. ・ Tighten the clip and the 5 bolts.
Note：
specifications.
assembly.
pressure sensor.
116.Blow-by hose connect
117.Intake air duct installation
intake hose.
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } 1. Bolt
Bolt 2. Clip

Clip ・ The following applies to 4WD.
Note：
Note：： 20.7 to 23.7 mm
・ Tighten the 5 bolts. { 0.815 to 0.933 in }
Note：
Measurement point 2
Amount of belt
Frequency
deflection
： 12.5 to 16.5 mm
New ： 92 to 112 Hz
{ 0.492 to 0.650 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 3
Amount of belt
Frequency
deflection
119.A/C compressor drive belt adjustment ： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
meter. ： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Note：
・ The following is the belt tension adjusting Measurement point 4
method based on belt deflection. Amount of belt
Frequency
・ Apply a load to measurement points 2, 3, and deflection
4 of the A/C compressor drive belt and adjust ： 15.9 to 20.7 mm
New ： 70 to 86 Hz
the amount of flex. { 0.626 to 0.815 in }
Load： 98 N { 10 kg / 22 lb } ： 20.7 to 23.7 mm
{ 0.815 to 0.933 in }
Measurement point 2
Amount of belt
Frequency
deflection
： 12.5 to 16.5 mm
New ： 92 to 112 Hz
{ 0.492 to 0.650 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 3
Amount of belt
Frequency
deflection
： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 4
Amount of belt
deflection
New ： 70 to 86 Hz
{ 0.626 to 0.815 in } 4. Measurement point 4
Note： Note：
・ After adjusting the tension, tighten the ・ After adjusting the tension, tighten the adjust
tensioner fixing nut. plate lock bolt and the mounting bolt under the
generator.
120.Cooling fan belt adjustment Generator tightening torque
： 40 N・m { 4.1 kgf・m /
1. Adjust tension to a standard value using a tension Mounting bolt
30 lb・ft }
meter.
： 25 N・m { 2.5 kgf・m /
Note： Adjust plate lock bolt
18 lb・ft }
Note：
2. Check tension of the cooling fan belt. ・ If the cooling fan belt is replaced with a new
Note： one, make the new cooling fan belt fit in to
cope with initial elongation.
method based on belt deflection. ・ After making the cooling fan belt fit in, adjust
its tension once again.
cooling fan belt and adjust the amount of flex. 121.Engine oil filling
Load： 98 N { 10 kg / 22 lb } 1. Replenish the engine with the engine oil.
Note： Note：
・ The following is the belt tension adjusting ・ Check the tightening of the oil pan drain plug.
1 with a sonic tension meter. 122.Coolant filling
Position of the belt tension 1. Replenish the radiator with coolant.

Deflection Frequency Note：
： 5.4 to 6.6 mm ・ Use the coolant contains 50 % anti-freeze
New ： 188 to 210 Hz solution.
{ 0.213 to 0.260 in }
： 7.7 to 8.5 mm ・ Pour the coolant up to the filler neck.
{ 0.303 to 0.335 in } 2. Replenish the radiator reserve tank with coolant.
Note：
123.Fuel air bleed
Note：
1. Priming pump
Caution：
3. Lower vehicle.
Crankshaft
removal
Note：
Note：
3. Coolant drain
Note：
radiator.
1. Bolt
2. Clip
Note：
Note：
pressure.
4. Engine oil drain
1. Drain the engine oil from the oil pan.
Note：
specified torque.
Caution：
Note：

2. MAF sensor
3. Blow-by hose
4. Intake pipe


cover.
sensor.
Note：
specifications.
assembly.
Note：
assembly. ・ Remove the part together with the intake hose.


guide.
1. Battery cable
2. Battery bracket 14. Generator cover removal
3. Earth 1. Remove the generator cover from the bracket and the
adjust plate.
15. Generator disconnect 19. Generator removal

1. Disconnect the harness from the generator. 1. Remove the generator from the bracket.
pulley.
20. A/C compressor assembly disconnect

1. Remove the A/C compressor assembly from the A/C
compressor bracket.

Note：
generator.
1. A/C compressor bracket 23. Fan guide removal

2. A/C compressor
21. A/C compressor bracket removal Note：
1. Remove the A/C compressor bracket from the ・ Remove the clips and bottom locks on both
cylinder head. sides and remove the upper fan guide.
22. Tension pulley removal 1. Upper fan guide

2. Clip
1. Remove the tension pulley from the cylinder head.
3. Lower fan guide
4. Fan shroud

assembly.

2. Cooling fan
1. Glove box
25. Cooling fan clutch removal 2. Instrument panel assist side lower cover
1. Remove the cooling fan clutch from the water pump 29. Instrument panel assist-side lower cover removal
assembly.
Note： from the instrument panel.
・ Remove the part together with the cooling fan. Note：

1. Remove the fan pulley from the water pump 1. Glove box
assembly. 2. Instrument panel assist side lower cover
27. Fan shroud removal 30. ECM disconnect
1. Remove the fan guide from the radiator. 1. Disconnect the harness connector from the ECM.
Note： Note：
・ Remove the lower fan guide together with the ・ Pull out the harness to the engine room side.
fan shroud.
31. Vacuum hose disconnect 2. Remove the catalyst converter from the turbocharger
assembly.

cover.
Note：

1. Fuel hose gear case.

converter bracket.
1. Power steering oil pump 1. Radiator lower hose

2. Nut
bracket.
assembly removal".
Note：
Note：
1. Bracket
41. Oil pan removal
2. Gasket

Caution：
1. Earth cable

guide tube.
crankcase.
valve.
48. Bracket removal
control solenoid.
control solenoid.
Note：
control solenoid.

plug.
Note：
Note：
specifications



specifications.
assembly.


specifications.
assembly.


Note：

1. Feed hose
2. Return hose
Note：
specifications.
specifications.
Note：
specifications.

3. Water pipe
Note：
specifications.
1. Turbocharger feed oil pipe 61. Heater bypass pipe removal
60. Oil return pipe removal 1. Disconnect the heater bypass pipe from the water
intake pipe.
and the crankcase. 2. Remove the heater bypass pipe from the oil cooler
Note：
specifications.

the oil cooler assembly.
Note：
・ The following applies to the standard output Note：
specifications. ・ Remove it with the hose attached.
2. Remove the pipe bracket from the generator bracket 64. Oil filter bracket removal
63. Water bypass pipe removal the engine hanger.
Note：
side.

2. Remove the water bypass pipe from the cylinder pipe.
head assembly.
Note：
head side.
1. Fuel leak-off hose 68. EGR pipe removal

Note：
Caution：・ The following applies to the EGR pipe
・ Do not reuse the clip of the fuel leak-off hose. specifications.
2. Remove the leak-off pipe from the injector. 1. Remove the EGR pipe from the inlet manifold and

2. Clip 69. Cylinder head cover removal
Caution：
head.
Note：
specifications.
cover.
Caution：
removed injector.
cause damage.
Note：
cover.
Note：
cylinder head.

center.
1. Cam end gasket
Note：
71. Injector removal ・ Rotate the crankshaft and align to the
1. Remove the injector from the cylinder head. compression top dead center (TDC).
Note：
the injector clamp.
remover.
1. Top dead center alignment mark on the gear case 74. Camshaft bearing cap removal
cover
pulley Note：
Note：

head.
Note：
75. Inlet camshaft removal 77. Noise cover removal

1. Remove the inlet camshaft from the cylinder head. 1. Remove the noise cover from the timing chain lower
cover.

1. Noise cover
head. 78. Timing chain lower cover removal
case cover.

Note：
dead center.
mirror, etc.
1. CMP sensor

cylinder head.

cover
pulley
Note：
aligned.
1. Alignment mark 1. Timing chain tensioner

2. Gasket
82. Supply pump gear nut removal 3. Nut
1. Turn the nut.
Note：
・ Loosen the nut of the supply pump gear. chain tension lever.
1. Supply pump gear nut 85. Sprocket removal

83. Timing chain tensioner removal 1. Remove the nut from the sprocket.
1. Remove the timing chain tensioner from the cylinder 2. Remove the sprocket from the supply pump gear.
head.

2. Sprocket
3. Nut
Note：


Note：
・ Mark the alignment positions on idle gear A
temperature sensor.
control valve.
1. Fuel temperature sensor 1. Supply pump

2. Suction control valve 2. O-ring
3. Remove the fuel supply pump from the timing gear Caution：
case. ・ Do not hold the high-pressure pipe when
Note：
1. Fuel supply pump
Caution：
sprocket.
1. Remove the timing chain tension lever from the
Note： Note：
・ Pull out the timing chain tension lever. ・ Be very careful not to drop the parts into the
1. Install the timing chain guide to the cylinder head ・ Make sure to remember the original position.
Note：
specifications.

cylinder head.
Note：
positions.
Note：
specifications.

2. Bolt, long SST: 5-8840-2886-0 - rear engine hanger
3. Bolt, short
4. Intake rocker arm shaft assembly Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
5. Front 2. Remove the nut from the timing gear case.
with a new one.
Caution：
1. Nut
2. Bolt

Note：

gear case.
Caution：
cylinder block.
Note： 97. Vacuum pump assembly removal
・ Install the wire to the engine hanger and the 1. Remove the vacuum hose from the vacuum pipe and
hoist to lift the cylinder head assembly. the vacuum pump assembly.
head.
case cover.

98. Cover removal
Note：
case.

case.
1. Oil pump


2. Bolt L = 25 mm {0.98 in}
6. Bolt L = 16 mm {0.63 in}
8. Bolt
Note：
1. Timing gear case

2. Gasket
Caution：
maintenance.

Note：

Note：
in that order.
the crankcase.
109.Crankcase removal
1. Remove the crankcase from the cylinder block.

and the crankcase. 1. O-ring
2. Crankcase
Note：
・ Remove it together with the oil seal. Caution：
・ Take care not to damage the O-ring.
110.Piston removal
connecting rod.
Note：
3. Clean the cylinder liner using a scraper. 2. Remove the bearing cap from the cylinder block.
Note： 3. Remove the lower crankshaft bearing from the
・ Remove carbon from the top of the cylinder bearing cap.
block using a scraper. 4. Remove the crankshaft from the cylinder block.
4. Remove the piston from the cylinder block. 5. Remove the thrust bearing from the cylinder block.
Note： 6. Remove the upper crankshaft bearing from the
・ Pull out the piston and the connecting rod out cylinder block.
Caution：
block.
connecting rod.
Note：
other cylinder bearings do not get mistaken.
111.Crankshaft removal
1. Remove the bearing cap bolt from the cylinder
block.
Note：
・ Gradually loosen the bolts in the order of the
numbers indicated in the diagram.
disassembly
1. Crank angle sensor rotor removal
1. Remove the crank angle sensor rotor from the
crankshaft.
Note：
・ Confirm that the pin is not removed.
1. Crank angle sensor rotor

2. Pin
inspection ・ Inspect the bearings for damage and excess

worn.
1. Thrust bearing setting
・ If damage and excess worn is found, replace
1. Measure the clearance using a feeler gauge. the bearings in sets.
Note： 6. Install the upper crankshaft bearing to the cylinder
・ Measure the play of the crankshaft end at the block.
center of the crankshaft journal. 7. Install the crankshaft to the cylinder block.
・ Replace the thrust bearing if the measured
Note：
value exceeds the limit.
・ Install the crankshaft to be level.
8. Turn the crankshaft.
Note：
・ Rotate the crankshaft approximately 30
degrees to stabilize the bearing.
9. Put the plasti-gauge on the crankshaft.
Note：
・ As shown in the diagram, place the plastigage
on the crankshaft journal.
Caution：
・ Measure the thrust clearance prior to
disassembly.
2. Crankshaft bearing measurement
1. Remove the bearing cap from the cylinder block.
2. Remove the lower crankshaft bearing from the
bearing cap.
Note：
・ The removed crankshaft bearing should be cap.
lined in the order of the number.
3. Remove the crankshaft from the cylinder block.
Note：
4. Remove the upper crankshaft bearing from the
cylinder block.
Note：
Tightening torque： 166 N・m { 16.9 kgf・m / 122.4
・ The removed crankshaft bearing should be lb・ft }
lined in the order of the number.
5. Inspect the crankshaft bearing.
Note：
・ Clean the crankshaft journal and top/bottom
bearings.
Note：
・ Replace all of the crankshaft bearings or the
crankshaft if the oil clearance of the journal
exceeds the limit.
・ Remove the plastigage from the bearing and
the crankshaft.
3. Crankshaft inspection
1. Inspect the crankshaft.
Note：
・ Check the crankshaft journal and crank pin
surface for worn and damage.
・ Check the oil seal contact surface for
excessive worn and damage.
・ Check the oil port for clogging.
4. Crankshaft measurement
Caution：
1. Put the crankshaft on the V-block.
・ After tightening the bolts, do not turn the
crankshaft. Note：
・ Carefully set the crankshaft.
12. Remove the bearing cap bolt from the cylinder
block. 2. Measure fluctuation using a dial gauge.
Note： Note：
・ Remove it gently. ・ Slowly rotate the crankshaft to measure the
runout.
13. Measure the oil clearance using the plasti-gauge.
・ Replace the crankshaft if the crankshaft
Note： fluctuation exceeds the limit.
・ Measure the maximum width portion of the
plastigage crushed by tightening the
crankcase.
・ Determine the oil clearance of the journal.

Note：
・ Measure the journal and the pin outer
diameters to calculate the difference of the
maximum and minimum.
・ Measure in 4 sections on the journal and on

the pin.
Journal section
Pin
1. Drip prohibited area

2. Test liquid drop section
3. Pin or journal sliding surface
Caution：
・ Do not allow the solution to come into contact
with the oil port.
Note： Note：
・ Inspection of the TUFFTRIDE layer of the ・ Wait 30 to 40 seconds.
crankshaft ・ If the color does not change after 30 or 40
seconds, it indicates a residual layer of
Caution：
TUFFTRIDE and the crankshaft can be used.
・ TUFFTRIDE (soft nitriding treatment) is
・ If the test surface turns copper-colored,
implemented to increase the strength of the
replace the crankshaft.
crankshaft.
・ Therefore, the crankshaft surface cannot be Caution：
polished. ・ Copper chloride ammonium solution is highly
corrosive.
4. Clean the crankshaft using organic solvent.
・ Therefore, it is important to immediately clean
Note： the test surface when the test is completed.
・ Thoroughly clean the crankshaft to completely
remove the oil from the test locations.
5. Prepare inspection solution.
Note：
・ Prepare a solution of copper chloride
ammonium of 5 to 10 %.
6. Apply inspection solution to the crankshaft.
Note：
・ Use an oil drop to apply the solution to the test
locations.
・ Maintain the inspection surface at a complete
level so that the solution does not flow.
reassembly
1. Crank angle sensor rotor installation
1. Apply thread locking adhesive to the bolt.
Note：
・ Apply LOCTITE 262 or equivalent to the
threaded portion.
・ LOCTITE is not necessary to be applied for
new bolts.
2. Install the crank angle sensor rotor to the crankshaft.
Note：
・ Install it so that the side without rotor gear
toward front.
・ Align the pin to the hole to install.
in }
1. Crank angle sensor rotor

2. Hole
3. Pin
installation
1. Crankshaft installation
1. Install the upper crankshaft bearing to the cylinder
block.
Note：
・ The upper crankshaft bearing have both an oil
hole and an oil groove. The lower crankshaft
bearing do not have oil holes or grooves.
・ It does not exist on the lower crankshaft
bearing.
・ Carefully wipe out foreign materials from the
upper crankshaft bearing.
・ When reusing the removed upper crankshaft
bearing, find the position mark that was
marked at the time of disassembly.
2. Apply the engine oil to the upper crankshaft bearing. 5. Apply the engine oil to the thrust bearing.
Note： Note：
・ Apply enough engine oil before installing the ・ Apply enough engine oil to it.
crankshaft. 6. Install the thrust bearing to the cylinder block.
Caution： Note：
・ Do not apply engine oil to the back surface of ・ Install the thrust bearing onto the cylinder
the bearing and the bearing installation surface block No. 3 journal section front side and rear
of the cylinder block. side.
・ The thrust bearing oil groove must always face
the sliding surface.
3. Apply the engine oil to the crankshaft.

Note：
・ Apply enough engine oil to the journal section. 7. Select the crankshaft bearing.
4. Install the crankshaft to the cylinder block. Note：

・ Select the crankshaft bearing according to the
measured diameter of the crankshaft journal
and the bearing insertion section.
・ Align the crankshaft bearing housing grade
mark with the crankshaft journal grade mark
according to the following table to determine 1. No. 1

the appropriate size of the crankshaft bearing. 2. No. 2
3. No. 3
・ The grade of the crankshaft bearing housing
4. No. 4
(1, 2, or 3) is marked on the rear right of the
5. No. 5
cylinder block.
Caution：
・ Be careful not to mistake the bearing shape
when installing.
1. No. 1
2. No. 2
3. No. 3
4. No. 4
1. Lot No.
5. No. 5
2. Size code
Note：
・ The crank journal grade mark is marked on the
each crankshaft journal web section.
・ After installing the crankshaft and crankshaft
bearing, each clearance of the crankshaft
journal and bearing must be the same.
Crankshaft bearing housing Crankshaft journal Crankshaft bearing

Grade mark Diameter Grade mark Diameter bearing size code, color
： 69.927 to 69.932 mm
1 or -
{ 2.7530 to 2.7532 in }
： 73.992 to 74.000 mm ： 69.922 to 69.927 mm
1 2 or -- 4, yellow
{ 2.9131 to 2.9134 in } { 2.7528 to 2.7530 in }
： 69.917 to 69.922 mm
3 or ---
{ 2.7526 to 2.7528 in }
： 69.927 to 69.932 mm
1 or - 2, black
{ 2.7530 to 2.7532 in }
： 73.983 to 73.991 mm ： 69.922 to 69.927 mm
2 2 or -- 3, blue
{ 2.9127 to 2.9130 in } { 2.7528 to 2.7530 in }
： 69.917 to 69.922 mm
3 or --- 4, yellow
{ 2.7526 to 2.7528 in }
： 69.927 to 69.932 mm
1 or - 1, green
{ 2.7530 to 2.7532 in }
： 73.975 to 73.982 mm ： 69.922 to 69.927 mm
3 2 or --
{ 2.9124 to 2.9127 in } { 2.7528 to 2.7530 in }
2, black
： 69.917 to 69.922 mm
3 or ---
{ 2.7526 to 2.7528 in }
cap.
Note：
・ Gradually tighten the crankshaft bearing cap
bolts to the specified torque in the order
indicated in the diagram.
Note：
・ Install in numerical order, so that the bearing
ft }
cap arrows point toward the front of the
engine. Caution：
・ Always face the number of the bearing cap ・ Manually rotate the crankshaft to confirm that
upward. the crankshaft works smoothly.
2. Piston installation 6. Install the connecting rod bearing to the connecting

rod bearing cap.
1. Install the connecting rod bearing to the connecting
rod. 7. Apply the engine oil to the connecting rod bearing.
2. Apply the engine oil to the connecting rod bearing. 8. Apply the engine oil to the bolt.
3. Apply the engine oil to the piston ring. Note：
Note：・ Apply it to the threaded portion and the seat
ring groove. 9. Temporarily tighten the connecting rod bearing cap
Note：
Note：
markings and install the cap.
tool.
Note：
・ Face the notch of the piston front mark
towards the front.
the cylinder block.
SST: 5-8840-9018-0 - piston setting tool

Caution：
・ When pushing the piston, be careful not to 10. Securely tighten the connecting rod bearing cap to
touch the oil jet against the connecting rod. the connecting rod.
・ When pushing the piston, be careful not to Note：
damage the inside of the cylinder block. ・ Tighten the bolts to the specified torque in the
Tightening torque： 29.4 N・m { 3.0 kgf・m / 22 lb・ 3. Crankcase installation

ft }
Note：
the connecting rod.
・ When applying it around the O-ring, adjust the
amount so that a liquid gasket does not
protrude.

Note：
Note：
1. 2.0 - 3.0 mm {0.079 - 0.118 in}

2. 4.0 - 5.0 mm {0.157 - 0.197 in}
2. Install the crankcase to the cylinder block.

Caution：
5 minutes.
Note：
1. 1 - 1.5 mm {0.039 - 0.059 in} Note：
2. 1 - 1.5 mm {0.039 - 0.059 in}
2. Install the oil seal retainer to the cylinder block and 2. Temporarily tighten the flywheel to the crankshaft.
the crankcase.
Note：
diagram.
Caution：
・ After applying the liquid gasket, install it within Note：
5 minutes.
5. Rear plate installation sleeve, flywheel, flexible plate, washer in that
1. Install the rear plate to the cylinder block and the
the diagram.
crankcase.
Note：

Note：
Note：
Note：

Note：

Note：
Caution：
maintenance.
1. Timing gear case bracket
9. Oil pump assembly installation

1. Apply the engine oil to the oil pump gear.
2. Install the oil pump to the timing gear case.
1. Timing gear case
2. Bolt L = 25 mm {0.98 in} Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
3. Bolt L = 60 mm {2.36 in}
4. Bolt L = 45 mm {1.77 in}
5. Bolt L = 35 mm {1.38 in}
6. Bolt L = 16 mm {0.63 in}
7. Bolt L = 20 mm {0.79 in}
8. Bolt

Note：
gear case side.
block side.
1. Oil pump
Note：
・ Temporarily tighten the nut and bolt on the 10. Crank gear installation
gear case side. 1. Install the crank gear to the crankshaft.
block side.
center.
Note：
Note：

cover
pulley
12. Idle gear C installation

1. Apply the engine oil to the idle gear C shaft.
Note：
Note：
3. Install the idle gear C to the idle gear C shaft. ・ Align the oil holes of the cylinder block and the
4. Apply the engine oil to the bolt. idle gear A shaft.
Note： 2. Apply the engine oil to the idle gear A shaft.

・ Apply it to the thread and the seat. 3. Install the idle gear A shaft to the timing gear case.
5. Temporarily tighten the bolt to the timing gear case. 4. Install the idle gear A to the idle gear A shaft.
Note：
aligned.

8. Securely tighten the bolt to the timing gear case.

Idle gear A
Idle gear C

Note：
7. Temporarily tighten the bolt to the timing gear case. 1. Idle gear A bolt
2. Idle gear C bolt

Note：
・ Remove the M6 bolt.
1. M6 bolt 15. Cover installation
14. Gear case cover installation 1. Install the cover to the gear case cover.
1. Apply liquid gasket to the timing gear case. Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in }
Note：
in the diagram.

cover.
1. Liquid gasket application area Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
Caution：
・ Within 5 minutes after applying the liquid
Tightening torque： 12 N・m { 1.2 kgf・m / 106 lb・ 18. Crankshaft pulley installation
in }
Note：
Tightening torque： 25 N・m { 3 kgf・m } Hose clip crankshaft and install it.
ft }
Caution：

case.
Note：
pump assembly.

Note：
piston head.
are provided.
Note：
head.
Note：
Note：
Note：
possible.
Note：
1. Bead height
2. Bead width
Caution：
block.
Note：
head.
cylinder head.
Note： Caution：
in}.
Note：
Note：
the diagram.
Note：
the diagram.
Note：
hoist.
head.

Note：
Note：
assembly.
head.
Note：
Note：
Note：
surface.
Note：
2. Bolt, long
3. Bolt, short
5. Front


Note：
diagram.

head.
Note：
block.
1. Timing chain 28. Supply pump gear installation

2. Timing mark
3. Blue link
4. Yellow link Note：
Caution：

3. Main gear
Note：
Note：
plate.
plate.
gear.
Note：
pump shaft. 31. Timing chain tensioner installation
・ Tighten the fuel supply pump shaft nut by 1. Connect the hook to the pin.
hand.
Note：
pushed.
plunger.
1. Timing mark
2. Dark plate
3. Timing mark
4. Yellow plate

1. Temporarily tighten the timing chain lever pivot to 1. Pin
the timing chain tension lever. 2. Plunger
Note： 3. Latch
・ Tighten the pivot bolt by hand. 4. Timing chain tensioner
5. Hook
・ Confirm that the tension lever moves
smoothly. 2. Install the timing chain tensioner to the cylinder
head.

2. Gasket
Note：
the diagram. 1. Install the exhaust camshaft to the cylinder head.
chain. install it.

1. Securely tighten the sprocket to the supply pump 2. Inlet camshaft gear
gear. 3. Idle gear D
ft }
Note：
install it.
1. Alignment mark

Note：
2. Inlet camshaft gear ・ Apply it to the threaded portion.
3. Idle gear D 7. Install the bolt to the camshaft bearing cap.
35. Camshaft bearing cap installation Note：
1. Apply the engine oil to the camshaft bearing cap. ・ Tighten it to the prescribed torque according to
Note：
Note：
cap.

Note：
Note：
cap.
Note：
1. Liquid gasket
2. Bead height
3. Bead width
Note：
head.
2. Inlet camshaft gear Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
3. Idle gear D

Note：
Caution：
install the cover.

cover.
1. CMP sensor

Note：
1. Noise cover
Bead width： 2.0 to 2.5 mm { 0.079 to 0.098 in } 40. Baffle plate installation
Caution： 1. Install the baffle plate to the cylinder head.

・ Within 5 minutes of applying the liquid gasket, Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in }
install the cover.
Note：
Caution：
1. Liquid gasket
2. Bead height
3. Bead width

cover.
cylinder head.
Note：
Note：
1. Injector
2. Leak-off pipe
3. Clip
4. O-ring
5. Gasket

head.
ft }
1. Injector
2. Bolt


the injector.
1. Cam end gasket 45. EGR pipe installation

2. Application area
Note：
3. Bead width
2. Install the cam end gasket to the cylinder head. specifications.
44. Cylinder head cover installation 1. Install the EGR pipe to the inlet manifold and the
exhaust manifold.
Note：
Bolt, nut
in the diagram.
1. 3.0 - 5.0 mm {0.118 - 0.197 in} Note：

specifications.
Note：
1. Leak-off pipe Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }

2. Clip
2. Install the fuel leak-off hose to the leak-off pipe. 1. Install the water bypass pipe to the cylinder head
assembly.
Note：
・ Install the water bypass pipe on the cylinder
head side.
inserting the pipe.
1. Leak-off pipe
2. Clip
Caution：
1. Connect the harness connector to the injector. 2. Install the water bypass pipe to the oil filter.
49. Oil filter bracket installation Note：
1. Install the oil filter bracket to the oil filter and the ・ Install the water bypass pipe on the oil filter
engine hanger. side.
seated, and then, firmly tighten it.
Note：

intake pipe.
2. Install the water intake pipe to the oil filter. Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
Note： 52. Heater bypass pipe installation

・ Apply soapy water on the O-ring when water bypass hose.
inserting the pipe. Note：
3. Temporarily tighten the water intake pipe to the oil ・ Temporarily tighten nuts starting from the rear
cooler and the generator bracket. side, and then firmly tighten them in the same
order.
Note：
・ Temporarily tighten the nuts and bolts in the Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }

4. Securely tighten the water intake pipe to the oil pipe.
cooler and the generator bracket. 53. Oil return pipe installation
1. Install the oil return pipe to the turbocharger and the Note：
crankcase. ・ The following applies to the high-output
Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in } specifications.
Turbocharger side
Crankcase side
Note：
specifications.
Note：
specifications.
Note：
specifications.

54. Turbocharger feed oil pipe installation Note：
1. Install the turbocharger feed oil pipe to the ・ The following applies to the high-output
turbocharger and the oil cooler. specifications.
1. Water feed and return pipes 2. Securely tighten the air duct bracket to the cylinder
2. Turbocharger water feed hose head assembly.
3. Water pipe
Note：
5. Turbocharger water return hose ・ Firmly tighten in the order shown in the
diagram.
Note：
specifications.

Bolt 1
1. Turbocharger water feed hose Bolt 2
56. Air duct bracket installation 1. Install the exhaust manifold heat protector to the
1. Temporarily tighten the air duct bracket to the exhaust manifold.
cylinder head assembly. Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
Note：
diagram.

Note： 59. Turbocharger water feed pipe connect
specifications.
Note：
・ Connect both the feed hose and return hose to specifications.
the EGR cooler.

1. Feed hose 2. Turbocharger water feed hose
2. Return hose 3. Water pipe
specifications.
1. Turbocharger water feed hose 2. Connect the turbocharger water feed hose to the
2. Turbocharger water return hose outlet pipe.
60. Vacuum hose installation 62. Glow plug installation
Note： 1. Install the glow plug to the cylinder head.

・ The following applies to the high-output Tightening torque： 18 N・m { 1.8 kgf・m / 13 lb・ft }
specifications.
vacuum pipe.
1. Glow plug
61. Water pipe installation 1. Install the glow plug connector to the glow plug.
1. Install the turbocharger water feed hose to the Note：

cylinder head assembly. ・ Install it together with the glow plug terminal.
Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in } Tightening torque： 1 N・m { 0.1 kgf・m / 9 lb・in }
Bolt, nut
Note：
specifications


Note：

in }
control solenoid.
1. Leak-off pipe

2. Connect the connector to the turbocharger control 1. Connect the fuel hose to the fuel supply pump.
solenoid.
solenoid.
crankcase.
1. Fuel hose

Note：
1. 2.0 mm {0.079 in}

2. 3.0 mm {0.118 in}
1. Intake throttle valve 2. Install the oil pan to the crankcase.
2. Gasket
Caution：
70. Intake throttle valve connect ・ After applying the liquid gasket, install it within
1. Connect the connector to the intake throttle valve. 5 minutes.

73. Engine assembly installation 78. Power steering oil pump assembly installation
1. Operate the hoist. 1. Install the power steering oil pump to the timing gear
Note： case.
・ Slowly operate to move the engine to the Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
rear of the engine.
Note：
Refer to "5.Transmission, Transaxle 5E.Clutch 1. Power steering pump
System(MUX) Clutch assembly installation". 2. Nut
2. Install the power steering oil hose to the bracket.
Hose clip
1. Bracket Note：
the diagram.
assembly.

Bolt 1, 3
2. Connect the catalyst converter to the catalyst Bolt 2
converter bracket.
Note：
81. Vacuum hose connect 1. Glove box

82. ECM connect

Note： 1. Glove box
2. Connect the harness connector to the ECM. 85. Fan shroud installation
83. Instrument panel assist-side lower cover installation 1. Install the fan guide to the radiator.
1. Install the instrument panel assist-side lower cover to Note：
the instrument panel. ・ Install the lower fan guide together with the fan
Note： shroud.
・ Install the 4 screws. 86. Fan pulley installation
assembly.
Note：
1. Upper fan guide

2. Clip
3. Lower fan guide
4. Fan shroud


head.
2. Cooling fan
Note：
92. A/C compressor assembly connect 94. Adjust plate installation

compressor bracket.

2. A/C compressor
96. A/C compressor drive belt installation
1. A/C compressor drive belt 2. Connect the radiator reserve tank hose to the
radiator.
Note：
Tightening torque： 12 N・m { 1.2 kgf・m / 106 lb・ before installation.
in } Terminal nut ・ Clean the radiator reserve tank using
98. Generator cover installation detergent.
adjust plate. ・ Wash it thoroughly with clean water, and drain
the water.
100.Radiator upper hose installation
Hose clip

guide.

104.Boost sensor connect

1. Battery cable
2. Battery bracket
3. Earth

Battery side
Frame side
103.Intake air duct installation 105.Air cleaner assembly installation
1. Install the intake air duct to the intake throttle valve 1. Install the air cleaner assembly to vehicle.
Bolt
Clip
1. Air cleaner assembly 108.Front under guard installation

2. MAF sensor
Note：
3. Blow-by hose
4. Intake pipe ・ The following applies to 2WD.
5. Barometric pressure sensor 1. Install the front under guard to the frame.
2. Connect the intake pipe to the turbocharger Note：
assembly. ・ Tighten the clip and the 5 bolts.
Note：
specifications.
assembly.
pressure sensor.
intake hose.
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } 1. Bolt
Bolt 2. Clip

Clip ・ The following applies to 4WD.
Note：
Note：： 20.7 to 23.7 mm
・ Tighten the 5 bolts. { 0.815 to 0.933 in }
Note：
Measurement point 2
Amount of belt
Frequency
deflection
： 12.5 to 16.5 mm
New ： 92 to 112 Hz
{ 0.492 to 0.650 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 3
Amount of belt
Frequency
deflection
109.A/C compressor drive belt adjustment ： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
meter. ： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Note：
Frequency
New ： 70 to 86 Hz
Load： 98 N { 10 kg / 22 lb } ： 20.7 to 23.7 mm
{ 0.815 to 0.933 in }
Measurement point 2
Amount of belt
Frequency
deflection
： 12.5 to 16.5 mm
New ： 92 to 112 Hz
{ 0.492 to 0.650 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 3
Amount of belt
Frequency
deflection
： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 4
Amount of belt
deflection
New ： 70 to 86 Hz
Note： Note：
generator.
110.Cooling fan belt adjustment Generator tightening torque
： 40 N・m { 4.1 kgf・m /
30 lb・ft }
meter.
： 25 N・m { 2.5 kgf・m /
18 lb・ft }
Note：
2. Check tension of the cooling fan belt. ・ If the cooling fan belt is replaced with a new
cooling fan belt and adjust the amount of flex. 111.Engine oil filling
Load： 98 N { 10 kg / 22 lb } 1. Replenish the engine with the engine oil.
Note： Note：
・ The following is the belt tension adjusting ・ Check the tightening of the oil pan drain plug.
1 with a sonic tension meter. 112.Coolant filling
Position of the belt tension 1. Replenish the radiator with coolant.

Deflection Frequency Note：
： 5.4 to 6.6 mm ・ Use the coolant contains 50 % anti-freeze
New ： 188 to 210 Hz solution.
{ 0.213 to 0.260 in }
： 7.7 to 8.5 mm ・ Pour the coolant up to the filler neck.
{ 0.303 to 0.335 in } 2. Replenish the radiator reserve tank with coolant.
Note：
113.Fuel air bleed
Note：
1. Priming pump
Caution：
3. Lower vehicle.
CKP sensor
removal
2. CKP sensor removal
1. Disconnect the connector from the CKP sensor.
2. Remove the CKP sensor from the cylinder block.
1. CKP sensor
2. O-ring
inspection
1. CKP sensor inspection
Note：
・ Inspect whether the CKP sensor is securely
installed.
・ Inspect the sensor and connector sections for
damage and dirt.
installation
1. CKP sensor installation
1. Install the CKP sensor to the cylinder block.
1. CKP sensor
2. O-ring
2. Connect the connector to the CKP sensor.

3. Lower vehicle.
Inlet manifold
removal Note：

guide tube.
crankcase.
1. Engine cover 6. A/C compressor drive belt removal
pulley.

valve and the intercooler. 1. Remove the A/C compressor assembly from the A/C
compressor bracket.
1. A/C compressor bracket 1. Intake throttle valve

2. A/C compressor 2. Gasket
8. A/C compressor bracket removal 11. Fuel leak-off hose removal

1. Remove the A/C compressor bracket from the 1. Remove the fuel leak-off hose from the leak-off
cylinder head. pipe.
pipe.
3. Remove the leak-off pipe from the inlet manifold.

valve.
manifold.

Note：
15. EGR valve disconnect ・ The following applies to the EGR pipe
1. Disconnect the connector from the EGR valve. specifications.
16. EGR valve removal 1. Disconnect the harness connector from the MAF
sensor.
assembly.

Note：
specifications.
the vacuum pipe.
2. MAF sensor
3. Blow-by hose
4. Intake pipe


the outlet pipe.
assembly.
19. Inlet manifold removal

1. Remove the inlet manifold from the cylinder head.

2. Remove the gasket from the inlet manifold.

Note：
specifications.
3. Remove the EGR pipe adapter from the inlet
manifold.
installation Note：
1. Inlet manifold installation specifications.
Note： 1. Install the EGR pipe to the inlet manifold and the
・ The following applies to the EGR pipe exhaust manifold.
specifications.
1. Install the EGR pipe adapter to the inlet manifold. Bolt, nut

2. Install the gasket to the inlet manifold. exhaust manifold.
3. Install the inlet manifold to the cylinder head. Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
Note：
・ Tighten the nuts and bolts in the order in the
diagram.

Bolt, nut

4. Connect the turbocharger water feed hose to the 1. Air cleaner assembly
outlet pipe. 2. MAF sensor
3. Blow-by hose
4. Intake pipe

assembly.
pressure sensor.
Note：
specifications.
vacuum pipe.


1. Install the EGR valve to the inlet manifold. 3. Connect the vacuum hose to the vacuum pipe.
Tightening torque of the EGR valve 9. Fuel leak-off hose installation
Nut ： 27 N・m { 2.8 kgf・m / 20 lb・ft } 1. Install the fuel leak-off hose to the leak-off pipe.
Bolt ： 24 N・m { 2.4 kgf・m / 18 lb・ft } 10. Intake throttle valve installation
5. EGR valve connect 1. Install the gasket to the intake throttle valve.
1. Connect the connector to the EGR valve. 2. Install the intake throttle valve to the inlet manifold.
6. Injection pipe installation Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in }
Note：
Note：
ft }
Tightening torque： 7.8 N・m { 0.8 kgf・m / 69 lb・in } 2. Gasket
7. Vacuum hose connect 11. Intake throttle valve connect
1. Connect the vacuum hose to the inlet manifold. 1. Connect the connector to the intake throttle valve.
8. Leak off pipe installation 12. A/C compressor bracket installation
1. Install the leak-off pipe to the inlet manifold. 1. Install the A/C compressor bracket to the cylinder
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } head.

compressor bracket.

Bolt
2. A/C compressor Tightening torque： 4 N・m { 0.4 kgf・m / 35 lb・in }
Clip


crankcase.
Note：
Measurement point 2
Amount of belt
Frequency
deflection
： 12.5 to 16.5 mm
New ： 92 to 112 Hz
{ 0.492 to 0.650 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 3
Amount of belt
Frequency
deflection
18. A/C compressor drive belt adjustment ： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
meter. ： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Note：
Frequency
New ： 70 to 86 Hz
Load： 98 N { 10 kg / 22 lb } ： 20.7 to 23.7 mm
{ 0.815 to 0.933 in }
Measurement point 2
Amount of belt
Frequency
deflection
： 12.5 to 16.5 mm
New ： 92 to 112 Hz
{ 0.492 to 0.650 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 3
Amount of belt
Frequency
deflection
： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 4
Amount of belt
deflection
New ： 70 to 86 Hz
： 20.7 to 23.7 mm
{ 0.815 to 0.933 in }
Note：
1. Engine cover

Rocker arm shaft assembly
removal
center.
Note：
1. Engine cover

Note：

cover
pulley


Note：
control solenoid.

Note： Note：
specifications
7. Bracket removal
Note：


2. Clip
cover.
Note：
specifications.
sensor.
assembly.

Caution：
3. Blow-by hose
4. Intake pipe




the outlet pipe.
assembly.

1. Remove the cylinder head cover from the cylinder 15. Baffle plate removal
head.
Note：

Note：
cylinder head.

Note：

head.
Note：

cause damage.
Note：
cover.


cylinder head.
Note：
20. Injector removal positions.

Note：
the injector clamp.
remover.
Caution：
removed injector.

2. Bolt, long
3. Bolt, short
5. Front
Note：
installation
center.
Note：

2. Bolt, long
3. Bolt, short
5. Front
cover Note：
2. Top dead center alignment mark on the crank ・ Push the part in by hand until it stops.
pulley ・ When the clamp is tightened, the gasket is
2. Rocker arm shaft assembly installation not push in the gasket by force.
1. Apply the engine oil to the rocker arm shaft Caution：
assembly.
head.
Note：
1. Injector
2. Leak-off pipe
3. Clip
4. O-ring
5. Gasket

head.
1. Injector 5. Securely tighten the injection pipe to the injector and
2. Bolt the common rail assembly.
3. Injector clamp
4. Apply the engine oil to the bolt. ft }
Note： 6. Securely tighten the clip to the injection pipe.
・ Apply it to the threaded portion and the seat Tightening torque： 7.8 N・m { 0.8 kgf・m / 69 lb・in }
surface.
Note：
Note：
the injector. ・ Align the timing mark to the idle gear D to
install it.
cylinder head.
Note：
Note：

3. Idle gear D

Note：
install it.
1. Alignment mark

Note：
Note：
1. Exhaust camshaft gear the order given in the diagram.
3. Idle gear D Tightening torque： 18 N・m { 1.8 kgf・m / 13 lb・ft }

Note：
Note：
cap.

Note：
Note：
cap.
Note：
1. Cam end gasket

2. Application area
3. Bead width

Note：
in the diagram.
3. Idle gear D

Note：
in the diagram.
1. 3.0 - 5.0 mm {0.118 - 0.197 in}

2. 3.0 - 5.0 mm {0.118 - 0.197 in}

Note：
diagram.
Note：

exhaust manifold.
Bolt, nut

outlet pipe.

exhaust manifold.

1. Leak-off pipe

2. MAF sensor
1. Leak-off pipe
3. Blow-by hose
2. Clip
4. Intake pipe
pressure sensor.
Note：
Note：
specifications.
Note：
control solenoid.

Bolt
Clip

solenoid.
solenoid.
Note：
specifications


intake hose.

Clip

Timing gear train
removal
Note：
Note：
3. Coolant drain
Note：
radiator.
1. Bolt
2. Clip
Note：
Note：
pressure.
1. Engine cover 7. Intake air duct removal
5. Intake air duct removal 1. Remove the intake air duct from the intake throttle
and the intercooler. Note：
Note：
6. Boost sensor disconnect 1. Remove the radiator upper hose from the water
Note：

1. Upper fan guide
pulley.
2. Clip
3. Lower fan guide
4. Fan shroud

assembly.
Note：

Note：
generator.
assembly.
1. Remove the fan guide from the radiator. Note：
Note：・ Remove the power steering pump together
with the hose.
fan shroud.
cover.

2. Nut

bracket.
1. Noise cover

Caution：
1. Bracket


gear case.
case cover.
21. Idle gear A removal

19. Cover removal
Note：
case.
22. Idle gear C removal

1. Remove the idle gear C from the idle gear C shaft.
case.
23. Crank gear removal

1. Remove the crank gear from the crankshaft.
inspection
1. Idle gear measurement
1. Measure the backlash using a dial gauge.
Note：
・ Touch the dial gauge to the idle gear tooth to
be measured, and gently move the gear left
and right to read the fluctuation on the dial
gauge.
・ Always fasten the gear.
・ Replace the idle gear if the measured value
exceeds the limit.
・ Measure the idle gear backlash before
removing the idle gear A.
Limit： 0.30 mm { 0.01 in } 2. Measure the idle gear using a cylinder gauge.
2. Measure the clearance using a feeler gauge. Note：
Note：・ Measure the inner diameter of the idle gear
・ Insert a feeler gauge into the gap between the bushing.
idle gear and thrust collar to measure the
clearance.
・ Replace either the idle gear or the thrust collar
if the measured value exceeds the limit.
・ Measure the idle gear clearance before
removing the idle gear B.
Limit： 0.20 mm { 0.008 in }
2. Idle gear shaft measurement
Idle gear A shaft
Limit： 44.80 mm { 1.764 in } Idle gear A shaft
Idle gear C shaft 3. Calculate the clearance from measured value.
Limit： 24.80 mm { 0.976 in } Idle gear C shaft Note：
・ Calculate the clearance between the inner
diameter of the idle gear bushing and the outer
diameter of the idle gear shaft.
・ Replace either the idle gear or the shaft if the
measured value exceeds the limit.
Clearance between the idle gear A and shaft
Limit： 0.200 mm { 0.0079 in } Clearance between the
idle gear A and shaft
Clearance between the idle gear C and shaft
Limit： 0.200 mm { 0.0079 in } Clearance between the
idle gear C and shaft
installation
Note：
Note：
5. Temporarily tighten the bolt to the timing gear case. Note：
idle gear A shaft.
Note：
aligned.

Note：
8. Securely tighten the bolt to the timing gear case.

Idle gear A
Idle gear C

Note：
7. Temporarily tighten the bolt to the timing gear case. 1. Idle gear A bolt
2. Idle gear C bolt

Note：
・ Remove the M6 bolt.
1. M6 bolt 5. Cover installation
Note：
in the diagram.

cover.
Caution：
Tightening torque： 12 N・m { 1.2 kgf・m / 106 lb・ 1. Power steering pump
in } 2. Nut
3. Install the vacuum hose to the vacuum pipe and the 2. Install the power steering oil hose to the bracket.
1. Bracket

case. Note：
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } ・ Align the crankshaft pulley to the key of the
ft }
Caution：
・ Use new crank pulley bolts. 1. Install the cooling fan clutch to the water pump
assembly.
Note：

cover.
Note：
1. Noise cover

Note：
1. Upper fan guide
・ Install the lower fan guide together with the fan 2. Clip
shroud. 3. Lower fan guide
11. Fan pulley installation 4. Fan shroud
1. Install the fan pulley to the water pump assembly. 14. Cooling fan belt installation
12. Cooling fan clutch installation 1. Install the cooling fan belt to the pulley.
1. Adjust tension to a standard value using a tension ： 40 N・m { 4.1 kgf・m /
meter. Mounting bolt
30 lb・ft }
Note：： 25 N・m { 2.5 kgf・m /
・ Move the generator to adjust the tension. 18 lb・ft }
2. Check tension of the cooling fan belt. Note：

Note：
・ The following is the belt tension adjusting cope with initial elongation.
・ After making the cooling fan belt fit in, adjust
・ Apply a load to measurement point 1 of the its tension once again.
Load： 98 N { 10 kg / 22 lb }
Note：
： 5.4 to 6.6 mm
New ： 188 to 210 Hz
{ 0.213 to 0.260 in }
： 7.7 to 8.5 mm
{ 0.303 to 0.335 in }

meter.
Note：
the amount of flex.
1. Measurement point 1 Load： 98 N { 10 kg / 22 lb }
Frequency
deflection
Note：： 12.5 to 16.5 mm
・ After adjusting the tension, tighten the adjust New ： 92 to 112 Hz
{ 0.492 to 0.650 in }
generator. Reuse ： 79 to 91 Hz
{ 0.650 to 0.752 in }
Measurement point 3
Amount of belt
Frequency
deflection
： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 4
Amount of belt
Frequency
deflection
： 15.9 to 20.7 mm
New ： 70 to 86 Hz
{ 0.626 to 0.815 in }
： 20.7 to 23.7 mm
{ 0.815 to 0.933 in }
Note：
method with a sonic tension meter. 1. Measurement point 1
・ Measure the frequency at measurement point 2. Measurement point 2
2, 3, and 4 with a sonic tension meter. 3. Measurement point 3
Measurement point 2
Amount of belt Note：
Frequency
deflection ・ After adjusting the tension, tighten the
： 12.5 to 16.5 mm tensioner fixing nut.
New ： 92 to 112 Hz
{ 0.492 to 0.650 in } Tightening torque： 41 N・m { 4.2 kgf・m / 30 lb・ft }
： 16.5 to 19.1 mm
Reuse ： 79 to 91 Hz 18. Radiator upper hose installation
{ 0.650 to 0.752 in }
Measurement point 3 pipe and the radiator.
Amount of belt
Frequency Tightening torque： 5 N・m { 0.5 kgf・m / 44 lb・in }
deflection
Hose clip
： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 4
Amount of belt
Frequency
deflection
： 15.9 to 20.7 mm
New ： 70 to 86 Hz
{ 0.626 to 0.815 in }
： 20.7 to 23.7 mm
{ 0.815 to 0.933 in }

Bolt
Clip


1. Engine cover

Note：
21. Intake air duct installation Note：
1. Install the intake air duct to the turbocharger and the ・ Tighten the clip and the 5 bolts.
intake hose.
Bolt
Clip

Note：
3. Lower vehicle.
1. Bolt
2. Clip
Note：
Note：
Note：
24. Coolant filling

Note：
solution.
Valve stem oil seal and valve spring
removal
Note：
Note：
2. Clip
Note：
Note：
Note：

Note：
Note：

Note：
specified torque.
Caution：
Note：
the blade.
5. Coolant drain
Note：
radiator.
1. Wiper arm cover

2. Nut
3. Wiper arm, blade

Warning：
pressure.
Note：
6. Engine oil drain

2. Bolt
Note： cover.
sensor.
Note：
specifications.
assembly.
assembly.

Note：
2. MAF sensor
3. Blow-by hose
4. Intake pipe

1. Battery cable
2. Battery bracket
3. Earth

Note：

radiator.
guide.

adjust plate.
Note：
generator.

pulley.


compressor bracket.

2. A/C compressor
Note：
cylinder head.
valve.
manifold.
1. Upper fan guide

2. Clip
3. Lower fan guide
4. Fan shroud

assembly.
2. Gasket

Caution：

2. Cooling fan

guide tube.
crankcase.
1. Fuel hose 1. Leak-off pipe
39. Vacuum hose disconnect 41. Bracket removal

1. Disconnect the vacuum hose from the vacuum pipe. Note：
specifications.
control solenoid.
control solenoid.
Note：
control solenoid.

Caution：
Note：
specifications

1. Remove the clip from the injection pipe. 44. Glow plug removal
2. Remove the injection pipe from the injector and the 1. Remove the glow plug from the cylinder head.
1. Glow plug
plug.
the outlet pipe.
Note：
・ Remove it together with the glow plug terminal. assembly.
46. Water outlet pipe removal 1. Front

2. Thermostat
3. Jiggle valve
2. Remove the water outlet pipe from the cylinder head. 48. Vacuum hose removal
Note：
specifications.
the vacuum pipe.

Caution：
・ Take care not to damage the thermostat.

Note：
specifications.
Note：

3. Water pipe
5. Turbocharger water return hose 1. Feed hose
2. Return hose
Note：
Note：
specifications. ・ The following applies to the EGR pipe
specifications.
assembly.


1. Water hose
Note：
specifications. 1. Remove the exhaust manifold heat protector from
3. Water pipe
Note：
specifications.

Note：

Note：
specifications.

Note：
specifications.
specifications.
1. Turbocharger feed oil pipe 1. Disconnect the catalyst converter from the front
exhaust pipe.
and the crankcase.
converter bracket.
Note：
・ The following applies to the high-output assembly.
specifications.
3. Remove the catalyst converter bracket from the rear 59. Water intake pipe removal
cover.
Note： the oil cooler assembly.
・ Remove the exhaust side from the engine. Note：
・ Remove the engine side from the crankcase. ・ Remove it with the hose attached.
1. Disconnect the heater bypass pipe from the water and the water intake pipe.
Note：
side.
2. Remove the water bypass pipe from the cylinder 62. Injector disconnect
head assembly.
Note：
head side. 1. Remove the fuel leak-off hose from the leak-off
pipe.

1. Remove the oil filter bracket from the oil filter and 2. Injector connector
the engine hanger.
Caution：
head.

2. Clip
Caution：
・ Do not reuse the leak-off pipe and the clip. 67. Cam end gasket removal
64. Vacuum pipe removal 1. Remove the cam end gasket from the cylinder head.
Note： Note：
・ The following applies to high-output ・ Remove the liquid gasket sticking to the
specifications. cylinder head.
cover.
1. Cam end gasket

Note：
Note：
specifications. ・ Loosen the injector clamp fixing bolt to remove
the injector clamp.
remover.
Caution：
removed injector.
cause damage.
Note：
cover.
cover by using a pen, etc. 1. Top dead center alignment mark on the gear case
cover
pulley

Note：

center.
Note：

Note：

head.
Note：
74. Noise cover removal 76. CMP sensor disconnect

1. Remove the noise cover from the timing chain lower 1. Disconnect the connector from the CMP sensor.
cover.
1. CMP sensor
1. Noise cover
1. Remove the timing chain lower cover from the gear cylinder head.
case cover.
78. Timing chain tensioner removal 80. Idle gear D removal

1. Remove the timing chain tensioner from the cylinder 1. Remove the idle gear D from the cylinder head.
head.
Note：

2. Gasket
3. Nut 81. Timing chain removal
sprocket.
Note：
1. Install the timing chain guide to the cylinder head
Note：
specifications.

cylinder head.
Note：
positions.
Note：
specifications.

2. Bolt, long
3. Bolt, short SST: 5-8840-2886-0 - rear engine hanger
5. Front
2. Remove the nut from the timing gear case.
Note：
3. Remove the bolt from the timing gear case.
Caution：
with a new one.
87. Valve stem end cap removal
1. Remove the valve stem end cap from the split collar.
88. Split collar removal
1. Remove the split collar from the using special tool.
Note：
・ Compress the valve springs using a valve
spring compressor lever and valve spring
compressor pivot, and then remove the split
collars.
1. Nut
2. Bolt

Note：
Caution：
cylinder block.
Note：
1. Valve spring compressor lever
86. Cylinder head gasket removal 2. Valve spring compressor pivot
head. 89. Spring upper seat removal
1. Remove the spring upper seat from the valve spring.
90. Valve spring removal
1. Remove the valve spring from the cylinder head.
Note：
・ Organize the removed valve springs in the
order of the cylinder number.
91. Inlet valve removal
1. Remove the inlet valve from the cylinder head.
Note：
・ Organize the removed inlet valves according
to the cylinders using tags, etc.
92. Exhaust valve removal
1. Remove the exhaust valve from the cylinder head.
Note：
・ Organize the removed exhaust valves
Caution：
according to the cylinders using tags, etc.
・ Do not reuse the removed oil seal.
94. Spring lower seat removal
1. Remove the spring lower seat from the cylinder
head.
93. Valve stem oil seal removal

1. Remove the valve stem oil seal from the cylinder
head using a pliers.
inspection
1. Valve spring inspection
1. Inspect the valve spring.
Note：
・ Visually inspect the valve springs and replace
them when damage or abnormal worn is
found.
2. Valve spring measurement
1. Measure free length using a vernier caliper.
Note：
・ If the measured value is lower than the
specified limit, replace the valve spring.
Limit： 48.15 mm { 1.90 in } 3. Measure tension using the spring tester.
Note：
・ Compress the spring to the installation height.
： 37.8 mm { 1.488 in } Installation length
Note：
・ Measure the compressed spring tension.
Standard： 213 N { 21.7 kg / 47.9 lb }
Limit： 188 N { 19.2 kg / 42.3 lb }
2. Measure perpendicularity using a right-angle gauge.

Note：
・ Replace the valve spring if the measured value
exceeds the limit.
Limit： 2.1 mm { 0.083 in }
Note：
・ If the measured value is lower than the limit,
replace the spring.
installation 2. Install the inlet valve to the cylinder head.

5. Valve spring installation
1. Spring lower seat installation
1. Install the valve spring to the cylinder head.
1. Install the spring lower seat to the cylinder head.
6. Spring upper seat installation
2. Valve stem oil seal installation
1. Install the spring upper seat to the valve spring.
1. Apply the engine oil to the valve stem oil seal.
7. Split collar installation
Note：
・ Apply it to the outer circumference of the valve 1. Install the split collar to the using special tool.
guide. Note：
2. Install the valve stem oil seal to the cylinder head ・ Using a valve spring compressor lever and
using special tool. valve spring compressor pivot, compress the
valve springs and install the split collars.
Note：
・ Install it using a valve stem seal installer.
SST: 5-8840-2882-0 - valve stem seal installer
3. Exhaust valve installation

1. Apply the engine oil to the exhaust valve.
Note：
・ Apply it to the valve stem portion.
2. Install the exhaust valve to the cylinder head.
4. Inlet valve installation 1. Valve spring compressor lever
1. Apply the engine oil to the inlet valve. 2. Valve spring compressor pivot
Note： Caution：
・ Apply it to the valve stem portion. ・ Move it up and down to confirm that it moves
smoothly.
8. Valve stem end cap installation
1. Install the valve stem end cap to the split collar.
Note：
piston head.
are provided.
2. Measure the piston using a dial gauge. Note：
Note：
・ Measure the protrusion amount of the piston 3 and 4 of each cylinder.
head.
Note：
Note：
possible.
Note：
1. Bead height
2. Bead width
Caution：
block.
Note：
head.
cylinder head.
Note： Caution：
in}.
Note：
Note：
the diagram.
Note：
the diagram.
Note：
hoist.
head.

Note：
Note：
center.
Note：


cover
pulley
13. Rocker arm shaft assembly installation 15. Timing chain tension lever installation
1. Apply the engine oil to the rocker arm shaft 1. Install the timing chain tension lever to the cylinder
assembly. head.
2. Install the rocker arm shaft assembly to the cylinder Note：
head.
Note： between the timing gear case and the cylinder
・ Install the rocker arm shaft assemblies from block.
No. 1 to No. 4 in the numbering order. 16. Timing chain installation
Tightening torque： 21 N・m { 2.1 kgf・m / 15 lb・ft } 1. Install the timing chain to the idle gear D.
Note：
Note：
surface.
Note：

2. Bolt, long
3. Bolt, short
5. Front
1. Surface and inside of the idle gear shaft 19. Timing chain tensioner installation
Note： Note：
・ Align the two timing marks as indicated in the ・ Keep the state where the latch is being
diagram. pushed.
plunger.
1. Timing chain
2. Timing mark
3. Blue link
4. Yellow link
1. Pin
3. Latch
5. Hook
head.
1. Timing chain tensioner 1. Exhaust camshaft gear

2. Gasket 2. Inlet camshaft gear
3. Nut 3. Idle gear D
3. Disconnect the hook from the pin. 21. Inlet camshaft installation
Note： 1. Install the inlet camshaft to the cylinder head.
・ Lightly push the area indicated by an arrow in Note：
the diagram.
・ The hook of the tensioner opens and the install it.
chain.

Note：
install it. Note：
Note：
cap.

Note：
Note：
1. Alignment mark 10. Align the alignment mark to the camshaft bearing
cap.
Note：
Note：
Note：

3. Idle gear D

Note：
Caution：
install the cover.

1. Liquid gasket
2. Bead height
3. Bead width
Note：
head.

Note：
Caution：
install the cover.
Note：
Caution：
1. Liquid gasket
2. Bead height
3. Bead width

cover.
cover.
2. Leak-off pipe
3. Clip
4. O-ring
5. Gasket
1. Noise cover

1. Injector
2. Bolt


the injector.
cylinder head.
Note：
Note：
1. Cam end gasket
2. Application area
3. Bead width

Note：
in the diagram.

head.
ft }
1. 3.0 - 5.0 mm {0.118 - 0.197 in} Note：
specifications.
Note：

Note： 2. Clip
specifications.
exhaust manifold.
Bolt, nut
1. Leak-off pipe
2. Clip
Caution：

engine hanger.

assembly. Note：
Note：

Note：
side.
4. Securely tighten the water intake pipe to the oil 40. Catalyst converter installation
Note： assembly.
・ Firmly tighten the nuts and bolts in the order Tightening torque： 27 N・m { 2.8 kgf・m / 20 lb・ft }

Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } converter bracket.
39. Heater bypass pipe installation Note：
1. Install the heater bypass pipe to the oil cooler and the ・ Temporarily tighten the bolts in the order
water bypass hose. shown in the diagram.
Note：
order.
Note：
the diagram.

pipe.
Note：
specifications.

Bolt 1, 3
Bolt 2 Note：
41. Catalyst converter connect ・ The following applies to the standard output
specifications.
pipe.

1. Install the turbocharger feed oil pipe to the
crankcase. Note：
Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in } ・ The following applies to the high-output
Turbocharger side specifications.

Crankcase side

Note：
specifications.

water feed and return pipe. 1. Turbocharger water feed hose
Note：
・ The following applies to the high-output 45. Air duct bracket installation
specifications. 1. Temporarily tighten the air duct bracket to the
Note：
diagram.
head assembly.
Note：
diagram.
Note：
the EGR cooler.

Bolt 1
Bolt 2
1. Feed hose
Note：
exhaust manifold.

specifications.
vacuum pipe.

2. Turbocharger water feed hose 50. Thermostat installation
3. Water pipe
5. Turbocharger water return hose Note：
Note：
specifications.
1. Front 2. Connect the turbocharger water feed hose to the

2. Thermostat outlet pipe.
3. Jiggle valve
51. Water outlet pipe installation 1. Install the glow plug to the cylinder head.
1. Install the water outlet pipe to the cylinder head Tightening torque： 18 N・m { 1.8 kgf・m / 13 lb・ft }
assembly.
1. Glow plug

water outlet pipe. 1. Install the glow plug connector to the glow plug.
52. Water pipe installation Note：
1. Install the turbocharger water feed hose to the ・ Install it together with the glow plug terminal.
Bolt, nut
Note：
specifications


Note：

in }
control solenoid.
1. Leak-off pipe

solenoid.
solenoid.

2. Gasket
crankcase.
1. Fuel hose

1. Fan clutch assembly 67. A/C compressor bracket installation

2. Cooling fan
65. Fan guide installation head.
1. Install the fan guide to the radiator. Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
Note：

compressor bracket.
1. Upper fan guide
2. Clip Tightening torque： 51 N・m { 5.2 kgf・m / 38 lb・ft }
3. Lower fan guide
4. Fan shroud

1. A/C compressor bracket 71. Cooling fan belt installation

2. A/C compressor
69. Generator installation 72. Cooling fan belt adjustment
1. Install the generator to the bracket. 1. Adjust tension to a standard value using a tension
meter.
Note：
Note：
Load： 98 N { 10 kg / 22 lb }
Note：
： 5.4 to 6.6 mm
New ： 188 to 210 Hz
{ 0.213 to 0.260 in }
： 7.7 to 8.5 mm
{ 0.303 to 0.335 in }
1. Measurement point 1 1. A/C compressor drive belt

3. Measurement point 3 74. A/C compressor drive belt adjustment
4. Measurement point 4 1. Adjust tension to a standard value using a tension
meter.
Note：
・ After adjusting the tension, tighten the adjust Note：
plate lock bolt and the mounting bolt under the ・ The following is the belt tension adjusting
generator. method based on belt deflection.
： 40 N・m { 4.1 kgf・m / the amount of flex.
Mounting bolt
30 lb・ft }
Load： 98 N { 10 kg / 22 lb }
： 25 N・m { 2.5 kgf・m /
18 lb・ft } Measurement point 2
Frequency
・ If the cooling fan belt is replaced with a new deflection
one, make the new cooling fan belt fit in to ： 12.5 to 16.5 mm
New ： 92 to 112 Hz
cope with initial elongation. { 0.492 to 0.650 in }
・ After making the cooling fan belt fit in, adjust ： 16.5 to 19.1 mm
its tension once again. { 0.650 to 0.752 in }
73. A/C compressor drive belt installation Measurement point 3
1. Install the A/C compressor drive belt to the pulley. Amount of belt
Frequency
deflection
： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 4
Amount of belt
Frequency
deflection
： 15.9 to 20.7 mm
New ： 70 to 86 Hz
{ 0.626 to 0.815 in }
： 20.7 to 23.7 mm
{ 0.815 to 0.933 in }
Note： Note：
・ The following is the belt tension adjusting ・ After adjusting the tension, tighten the
method with a sonic tension meter. tensioner fixing nut.
・ Measure the frequency at measurement point Tightening torque： 41 N・m { 4.2 kgf・m / 30 lb・ft }
Measurement point 2
Amount of belt
Frequency Tightening torque： 12 N・m { 1.2 kgf・m / 106 lb・
deflection
in } Terminal nut
： 12.5 to 16.5 mm
New ： 92 to 112 Hz
{ 0.492 to 0.650 in } 76. Generator cover installation
{ 0.650 to 0.752 in } adjust plate.
Measurement point 3 Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in }
Amount of belt
Frequency
deflection
： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 4
Amount of belt
Frequency
deflection
： 15.9 to 20.7 mm
New ： 70 to 86 Hz
{ 0.626 to 0.815 in }
： 20.7 to 23.7 mm
{ 0.815 to 0.933 in }

guide.
radiator.
Note：
detergent.
the water.
Hose clip
1. Battery cable
2. Battery bracket
3. Earth

Battery side
Frame side
Clip

2. MAF sensor
3. Blow-by hose
4. Intake pipe

assembly.
Note：
specifications.
assembly.
pressure sensor.
intake hose.
Bolt
Clip

2. Bolt
Note：
Caution：

Note：
1. 29 mm (1.14 in)
2. 36.5 - 51.5 mm (1.44 - 2.03 in)
3. 18 mm (0.71 in)

ft }
hood assembly.
Note：
removal.
Note：
1. Hood rest
Note：
assembly.
Note：
Note：
Note：
hood.
1. Bolt 1. Engine cover

2. Clip
Note：
Note：
Note：
96. Coolant filling
Note：
Note：
solution.
Note：
3. Lower vehicle.

Piston and connecting rod
removal
Note：
Note：
3. Coolant drain
Note：
radiator.
1. Bolt
2. Clip
Note：
Note：
pressure.
4. Engine oil drain
Note：
specified torque.
Caution：
Note：

2. MAF sensor
3. Blow-by hose
4. Intake pipe


cover.
sensor.
Note：
specifications.
assembly.
Note：


guide.
1. Battery cable
adjust plate.

pulley.

compressor bracket.

Note：
generator.

2. A/C compressor

2. Clip
3. Lower fan guide
4. Fan shroud

assembly.

2. Cooling fan
1. Glove box
assembly.

Note： Note：
fan shroud.
31. Vacuum hose disconnect 2. Remove the catalyst converter from the turbocharger
assembly.

cover.
Note：

1. Fuel hose gear case.

converter bracket.

2. Nut
bracket.
assembly removal".
Note：
Note：
1. Bracket
41. Oil pan removal
2. Gasket

Caution：
1. Earth cable

guide tube.
crankcase.
valve.
48. Bracket removal
control solenoid.
control solenoid.
Note：
control solenoid.

plug.
Note：
Note：
specifications



specifications.
assembly.


specifications.
assembly.


Note：

1. Feed hose
2. Return hose
Note：
specifications.
specifications.
Note：
specifications.

3. Water pipe
Note：
specifications.
intake pipe.
Note：
specifications.

Note：
Note：
side.

head assembly.
Note：
head side.

Note：

Caution：
head.
Note：
specifications.
cover.
Caution：
removed injector.
cause damage.
Note：
cover.
Note：
cylinder head.

center.
1. Cam end gasket
Note：
Note：
the injector clamp.
remover.
cover
pulley Note：
Note：

head.
Note：

cover.

1. Noise cover
case cover.

Note：
dead center.
mirror, etc.
1. CMP sensor

cylinder head.

cover
pulley
Note：
aligned.

2. Gasket
1. Turn the nut.
Note：

head.

2. Sprocket
3. Nut
Note：


Note：
temperature sensor.
control valve.

Note：
1. Fuel supply pump
Caution：
sprocket.
Note： Note：
Note：
specifications.

cylinder head.
Note：
positions.
Note：
specifications.

3. Bolt, short
with a new one.
Caution：
1. Nut
2. Bolt

Note：

gear case.
Caution：
cylinder block.
head.
case cover.

98. Cover removal
Note：
case.

case.
1. Oil pump


2. Bolt L = 25 mm {0.98 in}
6. Bolt L = 16 mm {0.63 in}
8. Bolt
Note：
1. Timing gear case

2. Gasket
Caution：
maintenance.

Note：

Note：
in that order.
the crankcase.

2. Crankcase
Note：
110.Piston removal
connecting rod.
Note：
3. Clean the cylinder liner using a scraper.

Note：
・ Remove carbon from the top of the cylinder
block using a scraper.
4. Remove the piston from the cylinder block.
Note：
・ Pull out the piston and the connecting rod out
Caution：
block.
connecting rod.
Note：
other cylinder bearings do not get mistaken.
disassembly
1. Piston disassembly
1. Remove the piston ring from the piston using a ring
pliers.
Note：
・ When reusing the piston rings, organize them
other cylinder pistons and piston rings do not
get mistaken.
4. Remove the snap ring from the piston.
2. Connecting rod assembly disassembly

1. Remove the snap ring from the piston.
2. Remove the piston pin from the connecting rod.
3. Remove the connecting rod from the piston.
Caution：
・ Classify the disassembled piston pin, piston
and connecting rods according to the order of
the cylinders.
inspection 2. Measure the piston using the micrometer.

Note：
1. Piston inspection
・ Measure the piston pin at the specified
Note： position and the outer diameter of the piston at
・ Clean the piston. the perpendicular direction.
・ Carefully clean the carbon from the piston Measurement position： 11.00 mm { 0.43 in } From the
heads and the piston ring grooves. bottom surface of the piston
Caution：
・ Do not use a wire brush to clean the pistons,
because it causes flaws on the pistons.
1. Inspect the piston.
Note：
・ Visually inspect the piston pin for cracks,
burning or other excessive worn. If there is an
abnormality, replace the piston pin.
2. Piston measurement
1. Measure the cylinder block using a cylinder gauge.
Note：
・ Measure the inner diameter in the thrust
direction and the radial direction at the
specified position.
Measurement position： 20 mm { 0.79 in } From the top
surface of the cylinder block 1. Measurement position
Note： 3. Calculate the clearance from measured value.

・ Measure the cylinder block inner diameter Note：
according to the average value of the two
・ Calculate the clearance according to the inner
locations actually measured.
diameter of the cylinder block and the outer
Standard： 95.421 to 95.450 mm { 3.7567 to 3.7579 in } diameter of the piston.
Caution：
・ If the clearance exceeds the standard value,
replace the piston or widen the diameter of the
cylinder block.
4. Select the piston.
Note：
・ Grades A, B, and C are marked on the top of
the piston.
Grade Outer diameter
： 95.350 to 95.379 mm { 3.7539 to
A
3.7551 in }
： 95.360 to 95.389 mm { 3.7543 to
B
3.7555 in }
： 95.370 to 95.399 mm { 3.7547 to
1. Measurement position C
3.7559 in }
2. Radial
3. Thrust
1. Grade
2. Front mark notch
3. Piston ring measurement

1. Install the piston ring to the cylinder block.
Note：
・ Install it horizontally at the position supposed
to be installed to the piston.
1. Measurement position 1
2. Measurement position 2

Note：
・ Measure the clearance of the piston ring.
・ If the measured value exceeds the limit, the
piston ring must be replaced.
Note： Standard： 0.27 to 0.51 mm { 0.0106 to 0.0201 in } 1st

piston ring
・ Push the piston ring into the cylinder until the
cylinder block bore reaches the measurement Standard： 0.42 to 0.66 mm { 0.0165 to 0.0260 in } 2nd
position 1 or 2 in which the cylinder block bore piston ring
is minimum.
Standard： 0.27 to 0.56 mm { 0.0106 to 0.0220 in } Oil
・ Do not decline the piston ring in either ring
direction.
・ It must be completely level.
Note：
Measurement position： 10 mm { 0.4 in } 1
・ Measure the clearance between the piston ring
Measurement position： 120 mm { 4.7 in } 2 grooves and the piston.
・ Remove all carbon in the piston ring grooves.

・ Insert the piston ring into the piston ring
groove, and measure the clearance.
・ If the clearance between the piston ring groove
and the piston exceeds the limit, replace the
piston and piston ring.
Standard： 0.05 to 0.09 mm { 0.0020 to 0.0035 in } 2nd
piston ring
Limit： 1.50 mm { 0.059 in } 2nd piston ring
Standard： 0.03 to 0.07 mm { 0.0012 to 0.0028 in } Oil
ring
Limit： 1.50 mm { 0.059 in } Oil ring
Note：
・ The 1st piston ring cannot be measured.
5. Piston pin measurement

Note：
・ Replace the piston pin if the measured value
exceeds the limit.
4. Piston pin inspection

1. Inspect the piston pin.
Note：
・ Visually inspect for cracks, scratches or other
damages, and replace it as necessary.
・ Inspect for a certain degree of resistance when
the piston pin is lightly pushed, when the
piston is at room temperature. 6. Connecting rod assembly measurement
・ Replace the piston or the piston pin if there is 1. Measure inner diameter using a dial gauge.
significant looseness or slackening at normal
Note：
temperature.
・ Measure the inner diameter of the connecting
rod small end bushing.
Note：
・ Calculate the clearance of the connecting rod
small end and the piston pin outer diameter.
・ If the clearance between the bushing inner

diameter and pin outer diameter exceeds the
limit, replace the bushing or the connecting rod
assembly and pin.
Limit： 0.05 mm { 0.0020 in }
7. Connecting rod bearing measurement

rod.
Note：
・ Install it to the large end.
3. Apply the engine oil to the piston pin. to the connecting rod.
4. Install the piston pin to the piston. 3. Securely tighten the connecting rod bearing cap to
the connecting rod.
5. Turn the piston pin.
Note：
Note：
・ Tighten the bolts to the specified torque.
・ If the pin rotates stably and smoothly, the
clearance is normal. Tightening torque： 29.4 N・m { 3.0 kgf・m / 22 lb・
・ If there is unstable, measure the clearance. ft }
・ Replace the piston and piston pin if the 4. Securely tighten the connecting rod bearing cap to
clearance exceeds the limit. the connecting rod.
Standard： 0.006 to 0.019 mm { 0.0002 to 0.0007 in } Note：
6. Measure the connecting rod assembly using the ・ Tighten the bolts to the specified angle.
connecting rod aligner. Specified angle： 45 °
Note： 5. Measure inner diameter using a cylinder gauge.
・ For connecting rod alignment 100 mm {3.94
in}, measure the twisting and degree of
parallelization of the large end hole and small Note：
end hole. ・ Apply engine oil to the aligning surface and
・ If the measured value exceeds the limit, it threaded portion of the connecting rod bearing
must be replaced. cap bolt.
Standard： 0.08 mm { 0.003 in } Twisting 7. Calculate the clearance from measured value.
Limit： 0.20 mm { 0.008 in } Twisting Note：
Standard： 0.05 mm { 0.002 in } Degree of ・ Calculate the clearance according to the outer
parallelization diameter of the piston pin and the inner
diameter of the connecting rod bearing.
Limit： 1.50 mm { 0.059 in } Degree of parallelization
・ Replace the connecting rod bearing or the
crankshaft if the clearance exceeds the limit.
reassembly
1. Connecting rod assembly reassembly
1. Install the connecting rod to the piston.
Note：
・ Install so that the piston head front mark and
the connecting rod cast mark face the same
direction.
2. Install the snap ring to the piston.
2. Piston reassembly
1. Install the piston ring to the piston using a ring
pliers.
Note：
・ Install the piston ring in the order shown in the
diagram.
・ Install the second and first compression rings
so that the laser markings face upward.
・ Before installing the oil ring, do not create a
1. Front mark gap on the both sides of the expander coil, and
2. Cast mark then install the expander coil in the oil ring
groove.
3. Apply the engine oil to the piston pin.
Note：
・ Apply it enough.
4. Install the piston pin to the connecting rod.
Note：
・ Push it into the piston and the connecting rod
small end portion.
5. Install the snap ring to the piston using a snap ring
pliers.
Caution：
・ Confirm that the snap ring is installed in the
ring groove.
・ Confirm that the connecting rod slides
smoothly.
1. First compression ring

2. Second compression ring
3. Oil ring
4. Expander
installation
1. Piston installation
rod.
2. Apply the engine oil to the connecting rod bearing.
3. Apply the engine oil to the piston ring.
Note：
ring groove.
Note：
tool. 6. Install the connecting rod bearing to the connecting
Note： rod bearing cap.
・ Face the notch of the piston front mark 7. Apply the engine oil to the connecting rod bearing.
towards the front.
the cylinder block. Note：
Note：
markings and install the cap.
SST: 5-8840-9018-0 - piston setting tool
Caution：
touch the oil jet against the connecting rod.
damage the inside of the cylinder block.

the connecting rod.
Note：
Tightening torque： 29.4 N・m { 3.0 kgf・m / 22 lb・ 2. Crankcase installation

ft }
Note：
the connecting rod.
protrude.

Note：
Note：
1. 2.0 - 3.0 mm {0.079 - 0.118 in}

2. 4.0 - 5.0 mm {0.157 - 0.197 in}

Caution：
5 minutes.
Note：
1. 1 - 1.5 mm {0.039 - 0.059 in} Note：
2. 1 - 1.5 mm {0.039 - 0.059 in}
2. Install the oil seal retainer to the cylinder block and 2. Temporarily tighten the flywheel to the crankshaft.
the crankcase.
Note：
diagram.
Caution：
・ After applying the liquid gasket, install it within Note：
5 minutes.
4. Rear plate installation sleeve, flywheel, flexible plate, washer in that
the diagram.
crankcase.
Note：

Note：
Note：
Note：

Note：

Note：
Caution：
maintenance.
1. Timing gear case bracket
8. Oil pump assembly installation

1. Apply the engine oil to the oil pump gear.
2. Install the oil pump to the timing gear case.
1. Timing gear case
2. Bolt L = 25 mm {0.98 in} Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
3. Bolt L = 60 mm {2.36 in}
4. Bolt L = 45 mm {1.77 in}
5. Bolt L = 35 mm {1.38 in}
6. Bolt L = 16 mm {0.63 in}
7. Bolt L = 20 mm {0.79 in}
8. Bolt

Note：
gear case side.
block side.
1. Oil pump
Note：
・ Temporarily tighten the nut and bolt on the 9. Crank gear installation
gear case side. 1. Install the crank gear to the crankshaft.
block side.
Note：
4. Apply the engine oil to the bolt. Note：
Note：・ Align the oil holes of the cylinder block and the
idle gear A shaft.
Note：
aligned.

Note：

Note：

Idle gear A
Idle gear C Note：
in the diagram.
1. Idle gear A bolt

2. Idle gear C bolt
Note： Caution：
in }

cover.
case.
Note：
pump assembly.
Note：
piston head.
are provided.
Note：
head.

Note：
ft }
Caution：
Note：
possible.

Note：
Note：
Note：
in}.
Note：

Note：
Note：
the diagram.
Note：
the diagram.
Note：
1. Bead height
2. Bead width
Caution：
block.
Note：
head. Note：

Note：
9. Remove the wire from the engine hanger and the 1. Top dead center alignment mark on the gear case
hoist. cover
pulley
head.
assembly.
head.
Note：

center.
Note：

2. Bolt, long
3. Bolt, short
5. Front


Note：
23. Timing chain tension lever installation diagram.
head.
Note：
block.
Note：
Note：
1. Timing chain
2. Timing mark
surface.
3. Blue link
3. Install the idle gear D to the cylinder head. 4. Yellow link
Note： 26. Fuel supply pump installation
gear D, and then install idle gear D. 1. Apply soapy water to the O-ring.
Tightening torque： 59 N・m { 6.0 kgf・m / 44 lb・ft } 2. Install the O-ring to the fuel supply pump.
Caution：
1. Fuel supply pump 1. Alignment mark of the supply pump gear

Note： 3. Main gear
・ Confirm that the supply pump camshaft key is 4. Sub gear
Note：
Note：
plate.
plate.
gear.
Note：
27. Supply pump gear installation ・ Align the dowel pin attached to the gear, and
1. Install the supply pump gear to the fuel supply pump. install the fuel supply pump sprocket to the fuel
pump shaft.
Note：・ Tighten the fuel supply pump shaft nut by
・ Align the alignment mark of the supply pump hand.
gear A.
1. Timing mark 1. Pin

2. Dark plate 2. Plunger
3. Timing mark 3. Latch
4. Yellow plate 4. Timing chain tensioner
5. Hook
head.

30. Timing chain tensioner installation
2. Gasket
1. Connect the hook to the pin. 3. Nut
Note： 3. Disconnect the hook from the pin.
Note：
pushed.
the diagram.
plunger.

chain. install it.

3. Idle gear D
gear.
ft } 1. Install the inlet camshaft to the cylinder head.
Note：
install it.
1. Nut

Tightening torque： 27 N・m { 2.8 kgf・m / 20 lb・ft } 1. Exhaust camshaft gear
Note：
Note：
cap.

Note：
Note：
cap.
Note：
1. Alignment mark ・ Align the alignment mark of the camshaft to
Note：
Note：

3. Idle gear D

Note：
Caution：
install the cover.

1. Liquid gasket
2. Bead height
3. Bead width
Note：
head.

Note：
Caution：
install the cover.
Note：
Caution：
1. Liquid gasket
2. Bead height
3. Bead width

cover.
cover.
2. Leak-off pipe
3. Clip
4. O-ring
5. Gasket
1. Noise cover

1. Injector
2. Bolt


the injector.
cylinder head.
Note：
Note：
1. Cam end gasket
2. Application area
3. Bead width

Note：
in the diagram.

head.
ft }
1. 3.0 - 5.0 mm {0.118 - 0.197 in} Note：
specifications.
Note：

Note： 2. Clip
specifications.
exhaust manifold.
Bolt, nut
1. Leak-off pipe
2. Clip
Caution：

engine hanger.

assembly. Note：
Note：

Note：
side.
4. Securely tighten the water intake pipe to the oil 52. Oil return pipe installation
Note： crankcase.
・ Firmly tighten the nuts and bolts in the order Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in }
shown in the diagram. Turbocharger side
Crankcase side
Note：
specifications.

water bypass hose.
Note：
・ Temporarily tighten nuts starting from the rear Note：
side, and then firmly tighten them in the same ・ The following applies to the standard output
order. specifications.

2. Connect the heater bypass pipe to the water inlet 1. Install the turbocharger feed oil pipe to the
pipe. turbocharger and the oil cooler.
Note：
specifications.

3. Water pipe
Note：
specifications.

54. Turbocharger water return hose connect 55. Air duct bracket installation
1. Connect the turbocharger water return hose to the 1. Temporarily tighten the air duct bracket to the
water feed and return pipe. cylinder head assembly.
Note： Note：
・ The following applies to the high-output ・ Temporarily tighten in the order shown in the
specifications. diagram.
head assembly.
Note：
diagram.
Note：
the EGR cooler.

Bolt 1
Bolt 2
1. Feed hose
Note：
exhaust manifold.

specifications.
vacuum pipe.

3. Water pipe
Note： Bolt, nut
specifications.
61. Glow plug installation 63. Bracket installation
1. Install the glow plug to the cylinder head. Note：
Tightening torque： 18 N・m { 1.8 kgf・m / 13 lb・ft } ・ The following applies to high-output
specifications.
Note：
control solenoid.
1. Glow plug

1. Install the glow plug connector to the glow plug.
Note：
Tightening torque： 1 N・m { 0.1 kgf・m / 9 lb・in } 2. Connect the connector to the turbocharger control
solenoid.
solenoid.
Note： 1. Install the gasket to the intake throttle valve.
・ The following applies to standard-output 2. Install the intake throttle valve to the inlet manifold.
specifications

64. Leak-off pipe installation 2. Gasket
in } 69. Oil level gauge guide tube installation
crankcase.
1. Leak-off pipe

Note：・ Slowly operate the hoist so that the
・ Apply ThreeBond 1207B or equivalent. transmission side is low, while pulling to the
rear of the engine.
Note：
System(MUX) Clutch assembly installation".
1. 2.0 mm {0.079 in}
2. 3.0 mm {0.118 in}
2. Install the oil pan to the crankcase. assembly installation".
Caution： 75. Radiator lower hose connect

・ After applying the liquid gasket, install it within 1. Connect the radiator lower hose to the engine.
5 minutes.
Tightening torque： 22 N・m { 2.2 kgf・m / 16 lb・ft } Hose clip

1. Power steering pump 2. Connect the catalyst converter to the catalyst

2. Nut converter bracket.

・ Temporarily tighten the bolts in the order
1. Bracket
77. Catalyst converter installation Note：

1. Install the catalyst converter to the turbocharger ・ Firmly tighten the bolts in the order shown in
assembly. the diagram.
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } 1. Fuel hose

Bolt 1, 3
Bolt 2 80. Vacuum hose connect
78. Catalyst converter connect 1. Disconnect the vacuum hose from the vacuum pipe.

pipe.
81. ECM connect

Note：
79. Fuel hose connect ・ Pull in the harness toward inside the room.
1. Connect the fuel hose to the fuel supply pump. 2. Connect the harness connector to the ECM.
82. Instrument panel assist-side lower cover installation
1. Install the instrument panel assist-side lower cover to
Note：
assembly.
Note：
1. Glove box

1. Glove box

Note： 1. Fan clutch assembly
2. Cooling fan
shroud. 88. Fan guide installation
85. Fan pulley installation 1. Install the fan guide to the radiator.
1. Upper fan guide 91. A/C compressor assembly connect

2. Clip
3. Lower fan guide
compressor bracket.
4. Fan shroud

2. A/C compressor

head.
93. Adjust plate installation 1. A/C compressor drive belt

1. Install the adjust plate to the timing gear case. 96. Generator connect
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } 1. Connect the harness to the generator.
in } Terminal nut
adjust plate.


guide.

radiator.
Note：
detergent.
1. Battery cable
・ Scrub the inside with a detergent and water. 2. Battery bracket
・ Wash it thoroughly with clean water, and drain 3. Earth
the water.
1. Install the radiator upper hose to the water outlet Battery side
Tightening torque： 5 N・m { 0.5 kgf・m / 44 lb・in } Frame side
Hose clip
Bolt
Clip

103.Boost sensor connect 1. Air cleaner assembly

2. MAF sensor
3. Blow-by hose
4. Intake pipe

assembly.
Note：
specifications.
assembly.
pressure sensor.
104.Air cleaner assembly installation 1. Connect the blow-by hose to the cylinder head cover.
1. Install the air cleaner assembly to vehicle. 106.Intake air duct installation
intake hose.
Bolt
Clip
Note：

Note：
・ The following applies to 2WD. 108.A/C compressor drive belt adjustment
meter.
Note：
the amount of flex.
Load： 98 N { 10 kg / 22 lb }
Measurement point 2
Amount of belt
Frequency
deflection
： 12.5 to 16.5 mm
New ： 92 to 112 Hz
{ 0.492 to 0.650 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 3
Amount of belt
Frequency
deflection
1. Bolt
2. Clip ： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
Note：： 16.5 to 19.1 mm
Frequency
： 15.9 to 20.7 mm
{ 0.626 to 0.815 in }
： 20.7 to 23.7 mm Note：

Note：
method with a sonic tension meter. 109.Cooling fan belt adjustment
meter.
Frequency
deflection
： 12.5 to 16.5 mm
New ： 92 to 112 Hz
{ 0.492 to 0.650 in } Note：
Measurement point 3
Amount of belt
deflection
： 12.4 to 16.4 mm Note：
New ： 92 to 112 Hz
Measurement point 4
Frequency
： 15.9 to 20.7 mm ： 5.4 to 6.6 mm
New ： 70 to 86 Hz New ： 188 to 210 Hz
{ 0.626 to 0.815 in } { 0.213 to 0.260 in }
： 20.7 to 23.7 mm ： 7.7 to 8.5 mm
{ 0.815 to 0.933 in } { 0.303 to 0.335 in }

Note：
generator.
： 40 N・m { 4.1 kgf・m /
Mounting bolt
30 lb・ft }
： 25 N・m { 2.5 kgf・m /
18 lb・ft }
Note：
110.Engine oil filling 1. Priming pump
1. Replenish the engine with the engine oil. 2. Fuel filter with sedimenter
Note： Caution：
・ Check the tightening of the oil pan drain plug. ・ Insufficient air removal work may lead to
111.Coolant filling
Note：
・ Use the coolant contains 50 % anti-freeze 3. Lower vehicle.
solution.
Note：
112.Fuel air bleed
Note：
Crankcase
removal
Note：
Note：
3. Coolant drain
Note：
radiator.
1. Bolt
2. Clip
Note：
Note：
pressure.
4. Engine oil drain
Note：
specified torque.
Caution：
Note：

2. MAF sensor
3. Blow-by hose
4. Intake pipe


cover.
sensor.
Note：
specifications.
assembly.
Note：


guide.
1. Battery cable
adjust plate.

pulley.

compressor bracket.

Note：
generator.

2. A/C compressor

2. Clip
3. Lower fan guide
4. Fan shroud

assembly.

2. Cooling fan
1. Glove box
assembly.

Note： Note：
fan shroud.

cover.
Note：
Caution：

gear case.
Note：
1. Disconnect the catalyst converter from the front with the hose.
exhaust pipe.
converter bracket.
assembly.

2. Nut
bracket.
assembly removal".
Note：
Note：
1. Bracket
41. Oil pan removal
2. Gasket

Caution：
1. Earth cable

guide tube.
crankcase.
valve.
48. Bracket removal
control solenoid.
control solenoid.
Note：
control solenoid.

plug.
Note：
Note：
specifications



specifications.
assembly.


specifications.
assembly.


Note：

1. Feed hose
2. Return hose
Note：
specifications.
specifications.
Note：
specifications.

3. Water pipe
Note：
specifications.
intake pipe.
Note：
specifications.

Note：
Note：
side.

head assembly.
Note：
head side.

Note：

Caution：
head.
Note：
specifications.
cover.
Caution：
removed injector.
cause damage.
Note：
cover.
Note：
cylinder head.

center.
1. Cam end gasket
Note：
Note：
the injector clamp.
remover.
cover
pulley Note：
Note：

head.
Note：

cover.

1. Noise cover
case cover.

Note：
dead center.
mirror, etc.
1. CMP sensor

cylinder head.

cover
pulley
Note：
aligned.

2. Gasket
1. Turn the nut.
Note：

head.

2. Sprocket
3. Nut
Note：


Note：
temperature sensor.
control valve.

Note：
1. Fuel supply pump
Caution：
sprocket.
Note： Note：
Note：
specifications.

cylinder head.
Note：
positions.
Note：
specifications.

3. Bolt, short
with a new one.
Caution：
1. Nut
2. Bolt

Note：

gear case.
Caution：
cylinder block.
head.
case cover.

98. Cover removal
Note：
case.

case.
1. Oil pump


2. Bolt L = 25 mm {0.98 in}
6. Bolt L = 16 mm {0.63 in}
8. Bolt
Note：
1. Timing gear case

2. Gasket
Caution：
maintenance.

Note：

Note：
in that order.
the crankcase.

2. Crankcase
Note：
disassembly
1. Oil strainer removal
1. Remove the oil strainer from the crankcase.
1. Gasket
2. Oil strainer
3. Bolt
4. Crankcase
reassembly
1. Oil strainer installation
1. Install the gasket to the oil strainer.
2. Install the oil strainer to the crankcase.
1. Gasket
2. Oil strainer
3. Bolt
4. Crankcase
installation
1. Crankcase installation
Note：
protrude.
1. 1 - 1.5 mm {0.039 - 0.059 in}

2. 1 - 1.5 mm {0.039 - 0.059 in}
2. Install the oil seal retainer to the cylinder block and

the crankcase.
1. 2.0 - 3.0 mm {0.079 - 0.118 in}

2. 4.0 - 5.0 mm {0.157 - 0.197 in}

Caution：
5 minutes.
Note：
・ Apply ThreeBond 1207C or equivalent. Caution：
5 minutes.
3. Rear plate installation
crankcase.
Note：

Note：
Note：
Note：
diagram.

Note：
Note：
the diagram.
Caution：
maintenance.

Note：
area indicated in the diagram. 1. Timing gear case
2. Bolt L = 25 mm {0.98 in}
3. Bolt L = 60 mm {2.36 in}
Note： 4. Bolt L = 45 mm {1.77 in}
・ Apply ThreeBond 1207B or equivalent to the 5. Bolt L = 35 mm {1.38 in}
area indicated in the diagram. 6. Bolt L = 16 mm {0.63 in}
7. Bolt L = 20 mm {0.79 in}
8. Bolt

Note：
gear case side.
block side.
Note：
gear case side.
1. Liquid gasket application area ・ Temporarily tighten the bolt on the cylinder
block side.
Note：
cover
Note：
Note：
1. Oil pump

center.
Note：
Note：
Note：
idle gear A shaft.
Note：
aligned. Note：

Idle gear A
Idle gear C Note：
in the diagram.
1. Idle gear A bolt

2. Idle gear C bolt
Note： Caution：
in }

cover.
case.
Note：
pump assembly.
Note：
piston head.
are provided.
Note：
head.

Note：
ft }
Caution：
Note：
possible.

Note：
Note：
Note：
in}.
Note：

Note：
Note：
the diagram.
Note：
the diagram.
Note：
1. Bead height
2. Bead width
Caution：
block.
Note：
head. Note：

Note：
9. Remove the wire from the engine hanger and the 1. Exhaust rocker arm shaft assembly
hoist. 2. Bolt, long
3. Bolt, short
head.
5. Front


assembly.
head. 1. Install the timing chain tension lever to the cylinder
head.
Note：
・ Install the rocker arm shaft assemblies from Note：
No. 1 to No. 4 in the numbering order. ・ Place the timing chain tension lever in
block.
Note：
Note：
surface.
Note：
1. Timing chain
2. Timing mark
3. Blue link
4. Yellow link

1. Apply soapy water to the O-ring.
Caution：

Note：
diagram.
1. Fuel supply pump
Note：
Note：
Note：
plate.
plate.
gear.
Note：
26. Supply pump gear installation pump shaft.
1. Install the supply pump gear to the fuel supply pump. ・ Tighten the fuel supply pump shaft nut by
hand.
Note：
gear A.
1. Timing mark
2. Dark plate
3. Timing mark
4. Yellow plate

1. Alignment mark of the supply pump gear Note：
2. Idle gear marking ・ Tighten the pivot bolt by hand.
3. Main gear
4. Sub gear ・ Confirm that the tension lever moves
smoothly.

2. Gasket
3. Nut
Note：
pushed. Note：
chain.
1. Pin
2. Plunger
3. Latch 30. Supply pump gear nut installation
5. Hook
gear.
2. Install the timing chain tensioner to the cylinder Tightening torque： 130 N・m { 13.3 kgf・m / 96 lb・
head. ft }
Note：
install it.
1. Nut

1. Install the exhaust camshaft to the cylinder head. 33. Camshaft bearing cap installation
Note： 1. Apply the engine oil to the camshaft bearing cap.
Note：
install it.
Note：
cap.

3. Idle gear D

Note：
cap.
Note：
1. Alignment mark

Note：
Note：
・ Tighten it to the prescribed torque according to 1. Exhaust camshaft gear
the order given in the diagram. 2. Inlet camshaft gear
Tightening torque： 18 N・m { 1.8 kgf・m / 13 lb・ft } 3. Idle gear D

Note：
Caution：
install the cover.

Note：
1. Liquid gasket 1. CMP sensor

2. Bead height
3. Bead width 36. Timing chain lower cover installation
Note：
・ Apply Loctite 262 or equivalent to the threaded Note：
portion on the cylinder head side. ・ Apply ThreeBond 1207C or equivalent.
2. Install the timing chain upper cover to the cylinder Bead height： 2.0 to 2.5 mm { 0.079 to 0.098 in }
head.
Caution：
install the cover.

1. Liquid gasket
2. Bead height
3. Bead width

cover.
cover.
1. Injector
2. Leak-off pipe
3. Clip
4. O-ring
5. Gasket

1. Noise cover

Note：
Caution：
1. Injector
2. Bolt
3. Injector clamp

Note：
surface.
Note：
the injector.
cylinder head.
Note：
Note：
1. Cam end gasket

2. Application area
3. Bead width

Note：
in the diagram.

head.
ft }
2. 3.0 - 5.0 mm {0.118 - 0.197 in}
Note：
diagram.

2. Clip
Note：
specifications.
exhaust manifold.
Bolt, nut
1. Leak-off pipe
2. Clip
Caution：
Note：
・ The following applies to high-output 47. Oil filter bracket installation
specifications. 1. Install the oil filter bracket to the oil filter and the
1. Install the vacuum pipe to the cylinder head cover. engine hanger.

Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } 49. Water intake pipe installation
48. Water bypass pipe installation 1. Temporarily tighten the pipe bracket to the water
intake pipe.
assembly. 2. Install the water intake pipe to the oil filter.
Note： Note：
・ Install the water bypass pipe on the cylinder ・ Insert the water intake pipe into the oil filter.
head side. ・ Apply soapy water on the O-ring when
・ Apply soapy water on the O-ring when inserting the pipe.
inserting the pipe.
Note：

Note：
side.
・ Temporarily tighten each bolt until it gets 4. Securely tighten the water intake pipe to the oil
seated, and then, firmly tighten it. cooler and the generator bracket.
Note： 1. Install the oil return pipe to the turbocharger and the
・ Firmly tighten the nuts and bolts in the order crankcase.
shown in the diagram. Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in }
Turbocharger side
Crankcase side
Note：
specifications.

water bypass hose.
Note：
side, and then firmly tighten them in the same Note：
order. ・ The following applies to the standard output
specifications.

pipe. 1. Install the turbocharger feed oil pipe to the
Note：
specifications.

3. Water pipe
Note： Note：
・ The following applies to the standard output ・ The following applies to the standard output

1. Connect the turbocharger water return hose to the 54. Air duct bracket installation
water feed and return pipe. 1. Temporarily tighten the air duct bracket to the
specifications. ・ Temporarily tighten in the order shown in the
diagram.
head assembly.
Note：
diagram.
Note：
the EGR cooler.

Bolt 1
Bolt 2
1. Feed hose
Note：
exhaust manifold.

specifications.
vacuum pipe.

3. Water pipe
Note： Bolt, nut
specifications.
60. Glow plug installation 62. Bracket installation
1. Install the glow plug to the cylinder head. Note：
Tightening torque： 18 N・m { 1.8 kgf・m / 13 lb・ft } ・ The following applies to high-output
specifications.
Note：
control solenoid.
1. Glow plug

Note：
Tightening torque： 1 N・m { 0.1 kgf・m / 9 lb・in } 2. Connect the connector to the turbocharger control
solenoid.
solenoid.
Note： 1. Install the gasket to the intake throttle valve.
・ The following applies to standard-output 2. Install the intake throttle valve to the inlet manifold.
specifications

63. Leak-off pipe installation 2. Gasket
in } 68. Oil level gauge guide tube installation
crankcase.
1. Leak-off pipe

Note：・ Slowly operate the hoist so that the
・ Apply ThreeBond 1207B or equivalent. transmission side is low, while pulling to the
rear of the engine.
Note：
System(MUX) Clutch assembly installation".
1. 2.0 mm {0.079 in}
2. 3.0 mm {0.118 in}
2. Install the oil pan to the crankcase. assembly installation".
Caution： 74. Radiator lower hose connect

・ After applying the liquid gasket, install it within 1. Connect the radiator lower hose to the engine.
5 minutes.
Tightening torque： 22 N・m { 2.2 kgf・m / 16 lb・ft } Hose clip

1. Power steering pump 2. Connect the catalyst converter to the catalyst

2. Nut converter bracket.

1. Bracket
76. Catalyst converter installation Note：

1. Install the catalyst converter to the turbocharger ・ Firmly tighten the bolts in the order shown in
assembly. the diagram.
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } 1. Fuel hose

Bolt 1, 3
Bolt 2 79. Vacuum hose connect
77. Catalyst converter connect 1. Disconnect the vacuum hose from the vacuum pipe.

pipe.
80. ECM connect

Note：
78. Fuel hose connect ・ Pull in the harness toward inside the room.
1. Connect the fuel hose to the fuel supply pump. 2. Connect the harness connector to the ECM.
Note：
assembly.
Note：
1. Glove box

1. Glove box

Note： 1. Fan clutch assembly
2. Cooling fan
shroud. 87. Fan guide installation
84. Fan pulley installation 1. Install the fan guide to the radiator.
1. Upper fan guide 90. A/C compressor assembly connect

2. Clip
3. Lower fan guide
compressor bracket.
4. Fan shroud


2. A/C compressor

head.
92. Adjust plate installation 1. A/C compressor drive belt

1. Install the adjust plate to the timing gear case. 95. Generator connect
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } 1. Connect the harness to the generator.
in } Terminal nut
adjust plate.


guide.

radiator.
Note：
detergent.
1. Battery cable
・ Scrub the inside with a detergent and water. 2. Battery bracket
・ Wash it thoroughly with clean water, and drain 3. Earth
the water.
1. Install the radiator upper hose to the water outlet Battery side
Tightening torque： 5 N・m { 0.5 kgf・m / 44 lb・in } Frame side
Hose clip
Bolt
Clip
99. Fuse box connect

102.Boost sensor connect 1. Air cleaner assembly

2. MAF sensor
3. Blow-by hose
4. Intake pipe

assembly.
Note：
specifications.
assembly.
pressure sensor.
103.Air cleaner assembly installation 1. Connect the blow-by hose to the cylinder head cover.
1. Install the air cleaner assembly to vehicle. 105.Intake air duct installation
intake hose.
Bolt
Clip
Note：

Note：
・ The following applies to 2WD. 107.A/C compressor drive belt adjustment
meter.
Note：
the amount of flex.
Load： 98 N { 10 kg / 22 lb }
Measurement point 2
Amount of belt
Frequency
deflection
： 12.5 to 16.5 mm
New ： 92 to 112 Hz
{ 0.492 to 0.650 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 3
Amount of belt
Frequency
deflection
1. Bolt
2. Clip ： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
Note：： 16.5 to 19.1 mm
Frequency
： 15.9 to 20.7 mm
{ 0.626 to 0.815 in }
： 20.7 to 23.7 mm Note：

Note：
method with a sonic tension meter. 108.Cooling fan belt adjustment
meter.
Frequency
deflection
： 12.5 to 16.5 mm
New ： 92 to 112 Hz
{ 0.492 to 0.650 in } Note：
Measurement point 3
Amount of belt
deflection
： 12.4 to 16.4 mm Note：
New ： 92 to 112 Hz
Measurement point 4
Frequency
： 15.9 to 20.7 mm ： 5.4 to 6.6 mm
New ： 70 to 86 Hz New ： 188 to 210 Hz
{ 0.626 to 0.815 in } { 0.213 to 0.260 in }
： 20.7 to 23.7 mm ： 7.7 to 8.5 mm
{ 0.815 to 0.933 in } { 0.303 to 0.335 in }

Note：
generator.
： 40 N・m { 4.1 kgf・m /
Mounting bolt
30 lb・ft }
： 25 N・m { 2.5 kgf・m /
18 lb・ft }
Note：
109.Engine oil filling 1. Priming pump
1. Replenish the engine with the engine oil. 2. Fuel filter with sedimenter
Note： Caution：
・ Check the tightening of the oil pan drain plug. ・ Insufficient air removal work may lead to
110.Coolant filling
Note：
・ Use the coolant contains 50 % anti-freeze 3. Lower vehicle.
solution.
Note：
111.Fuel air bleed
Note：
CMP sensor
removal 1. Remove the CMP sensor from the timing chain

upper cover.
1. O-ring
2. CMP sensor
1. Engine cover
3. CMP sensor disconnect

1. CMP sensor
4. CMP sensor removal

inspection
1. CMP sensor inspection
1. Inspect the CMP sensor.
Note：
・ Inspect whether the CMP sensor is securely
installed.
damage and dirt.
installation
1. CMP sensor installation
1. Install the CMP sensor to the timing chain upper
cover.
1. Engine cover

1. O-ring
2. CMP sensor

1. CMP sensor

Swirl control solenoid valve
removal
solenoid valve.
bracket.
solenoid valve.
installation
valve.
valve.
Engine mounting (2WD)
removal
Note：
Note：

Note：
Note：
putting the hinge back in place.
1. Bolt
2. Clip
Note：
Note：
Note：
10. Wiper linkage removal
1. Remove the wiper linkage from vehicle.
Note：
linkage.
1. Engine cover

Note： 1. Nut
・ Remove the nut to remove the wiper arm and 2. Bolt
the blade.
Note：
・ Remove together with the wiper motor.
11. Cowl panel removal
1. Wiper arm cover

2. Nut
3. Wiper arm, blade

Note：

2. MAF sensor
3. Blow-by hose
4. Intake pipe

1. Disconnect the blow-by hose from the cylinder head adjust plate.
cover.
sensor.
Note：
specifications.
assembly.
assembly.

exhaust pipe.
converter bracket.
assembly.
3. Remove the catalyst converter bracket from the rear 19. Oil level gauge guide tube removal
cover.
Note： guide tube.
・ Remove the exhaust side from the engine. 2. Remove the oil level gauge guide tube from the
・ Remove the engine side from the crankcase. crankcase.
20. Transmission oil level gauge tube removal
1. Remove transmission oil level gauge tube from the
oil pan.
21. Starter motor removal
1. Disconnect the earth cable from the starter motor.
2. Remove the starter motor from the rear plate.
22. Oil pressure switch disconnect
1. Disconnect the connector from the oil pressure
switch.
Note：
specifications.
18. Turbocharger bracket removal
Note：
specifications.

Note：
・ Remove from the right side engine mounting.
Note：
specifications.

2. Install the wire to the engine hanger and the hoist.
Note：
・ Hold up the engine as high as not to be lifted
up.
Note：
Note：
24. Engine mounting removal
1. Remove the engine mounting from the frame.
Note：
・ Remove both of the left and right engine
mountings.
2. Remove the heat protector from the engine
mounting.
installation
1. Engine mounting installation
1. Install the heat protector to the engine mounting.
Note：
・ Install to the right side engine mounting.
2. Install the engine mounting to the frame.
Note：
・ Install both of the left and right engine
mountings.
3. Oil pressure switch connect

1. Connect the connector to the oil pressure switch.
4. Starter motor installation
1. Install the starter motor to the rear plate.
2. Connect the earth cable to the starter motor.
5. Transmission oil level gauge tube installation
1. Install transmission oil level gauge tube to the oil
pan.
2. Engine mounting connect 1. Apply the engine oil to the O-ring.
1. Connect the engine mounting to the engine. 2. Install the oil level gauge guide tube to the
Note： crankcase.
・ Keep holding up the engine as high as not to Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
hoist.
head.
Note：
specifications.
7. Turbocharger bracket installation
Note：
specifications.
1. Install the turbocharger bracket to the turbocharger
Note：
the diagram.

assembly.

Bolt 1, 3
Bolt 2
pipe.

converter bracket.
Note：
10. Generator cover installation 1. Air cleaner assembly

2. MAF sensor
3. Blow-by hose
adjust plate.
4. Intake pipe
Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in } 5. Barometric pressure sensor

assembly.
Note：
specifications.
assembly.
pressure sensor.
13. Cowl panel installation
Caution：

Note：
1. 29 mm (1.14 in)
2. 36.5 - 51.5 mm (1.44 - 2.03 in)
3. 18 mm (0.71 in)

ft }
1. Nut
2. Bolt

Note：
17. Wiper arm installation 1. Engine cover

Note：
Note：

hood assembly.
Note：
removal.
1. Bolt Note：
2. Clip
Note： fender.
・ The following applies to 4WD. 3. Adjust the clearance to a standard value.
2. Install the front under guard to the frame. Note：
Note：・ Adjust the installation of the engine hood hinge
Note：

Note：
hood.
1. Hood rest
4. Apply the grease to the striker.

Note：
・ Apply a thin layer of grease to the striker.
5. Install the engine hood garnish to the engine hood.
Note：
assembly.
3. Lower vehicle.
24. Engine mounting inspection
2. Inspect the engine mounting.
Note：
・ Confirm that there are no abnormalities in the
engine mounting.
Engine mounting (4WD)
removal
2. Disc wheel removal
1. Remove the disc wheel from vehicle.
Note：
Note： 1. Bolt
・ Before removing the hinge from the engine 2. Clip
putting the hinge back in place. Note：
Note：
Note：

Note：
Note：
5. Power steering unit removal

Refer to "6.Steering 6B.Power Assisted System(All
models) Power steering unit removal".
6. Front propeller shaft assembly removal 1. Engine cover
1. Remove the front propeller shaft assembly from 8. Washer hose disconnect
vehicle.
Note：
・ Remove the exhaust and the transfer
protector. 1. Remove the wiper arm cover from the wiper arm.
・ Put the alignment marks on the flanges on 10. Wiper arm removal
both the front and rear sides of the front
propeller shaft. 1. Remove the wiper arm from vehicle.
Note：
・ Remove the nut to remove the wiper arm and
the blade.
Note：
・ Remove the bolt, nut and washer on the front
axle.
・ Remove the bolt, nut and washer on the 1. Wiper arm cover
transfer. 2. Nut
・ Remove the front propeller shaft assembly. 3. Wiper arm, blade
7. Engine cover removal 11. Side cowl cover removal

1. Remove the engine cover from the engine. 1. Remove the side cowl cover from the body.
13. Wiper linkage removal
1. Remove the wiper linkage from vehicle.
Note：
linkage.

2. Bolt
Note： cover.
sensor.
Note：
specifications.
assembly.
assembly.

Note：
2. MAF sensor
3. Blow-by hose
4. Intake pipe


exhaust pipe.
converter bracket.
19. Intake air duct removal assembly.
Note：

cover.
Note：
20. Generator cover removal ・ Remove the engine side from the crankcase.
adjust plate.
switch.
Note：
specifications.

Note： SST: 5-8840-2861-0 - engine hanger
specifications.
Note：
specifications.
guide tube.
crankcase.
1. Remove transmission oil level gauge tube from the SST: 5-8840-2886-0 - rear engine hanger
oil pan.
2. Install the wire to the engine hanger and the hoist.
Note：
・ Hold up the engine as high as not to be lifted
up.
Note：
Note：
29. Engine mounting removal
1. Remove the engine mounting from the frame.
Note：
・ Remove both of the left and right engine
mountings.
2. Remove the heat protector from the engine
mounting.
Note：
・ Remove from the right side engine mounting.
installation
1. Engine mounting installation
1. Install the heat protector to the engine mounting.
Note：
・ Install to the right side engine mounting.
2. Install the engine mounting to the frame.
Note：
・ Install both of the left and right engine
mountings.

pan.
2. Engine mounting connect 1. Apply the engine oil to the O-ring.
1. Connect the engine mounting to the engine. 2. Install the oil level gauge guide tube to the
Note： crankcase.
・ Keep holding up the engine as high as not to Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
hoist.
head.
7. Turbocharger bracket installation
Note：
specifications.
Note：
the diagram.

assembly.

Bolt 1, 3
Bolt 2
pipe.

converter bracket.
Note：
10. Generator cover installation 12. Boost sensor connect

1. Install the generator cover to the bracket and the 1. Connect the connector to the boost sensor.
adjust plate.

Bolt
Clip
1. Air cleaner assembly 16. Cowl panel installation

2. MAF sensor
3. Blow-by hose
4. Intake pipe

assembly.
Note：
specifications.
assembly.
pressure sensor.
1. Connect the blow-by hose to the cylinder head cover. 2. Connect the washer hose to the joint.
15. Intake air duct installation 17. Wiper linkage installation
1. Install the intake air duct to the turbocharger and the 1. Install the wiper linkage to vehicle.
intake hose. Note：
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } ・ Install it together with the wiper motor.
Bolt
Clip
2. 36.5 - 51.5 mm (1.44 - 2.03 in)
3. 18 mm (0.71 in)

ft }
1. Nut
2. Bolt

Note：
1. Install the wiper arm to vehicle. 1. Engine cover
Caution： 24. Front propeller shaft assembly installation

・ Confirm that the wiper motor is stopped 1. Install the front propeller shaft assembly to the
at the auto stop position. flange.
Note：
・ Install the front propeller shaft assembly with
the bolt, nut and washer on the transfer side.
Note：
・ Install the front propeller shaft assembly with
the bolt, nut and washer on the front axle side.
Note：
・ Install the exhaust and the transfer protector.
・ After installing the propeller shaft, be sure to
apply black paint to the whole exposed area
except for the flange coupling mating surface.
1. 29 mm (1.14 in)
Note：
Note：
1. Flange coupling exposed area
25. Power steering unit installation

Refer to "6.Steering 6B.Power Assisted System(All
models) Power steering unit installation".
Note： 27. Engine hood assembly installation
・ The following applies to 2WD. 1. Temporarily tighten the hinge bolt to the engine
hood assembly.
Note：
Note：
removal.
Note：
fender.
3. Adjust the clearance to a standard value.
Note：
・ Adjust the installation of the engine hood hinge
1. Bolt
2. Clip
Note：
28. Disc wheel installation
1. Install the disc wheel to vehicle.
Note：
・ Install the wheel nuts in the numbered order.
Tightening torque： 118 N・m { 12.0 kgf・m / 87.0 lb・
ft }

Note：
hood.

3. Lower vehicle.
1. Hood rest
4. Apply the grease to the striker.

Note：
・ Apply a thin layer of grease to the striker.
5. Install the engine hood garnish to the engine hood.
Note：
assembly.
Supplementary Information
1. Component Views Note：
・ Engine mounting (2WD)
1. Left side engine foot 5. Right side engine foot

2. Left side mounting cover 6. Right side mounting cover
3. Left side engine mounting 7. Right side engine mounting
4. Heat protector
Note：
1. Left side engine foot 5. Right side engine foot

2. Left side mounting cover 6. Right side mounting cover
3. Left side engine mounting 7. Right side engine mounting
4. Heat protector
Note：
・ Cylinder head cover
1. Oil filler cap 4. Oil seal

2. Oil filler cap gasket 5. Cylinder head gasket
3. Cylinder head cover
Note：
・ Inlet manifold (The specifications with EGR
cooler)
1. Intake air duct 6. EGR valve

2. Bracket 7. EGR valve gasket
3. Intake throttle valve 8. Inlet manifold gasket
4. Intake throttle gasket
5. Inlet manifold
Note：
・ Inlet manifold (with EGR pipe specification)
1. Intake air duct 7. EGR valve

2. Bracket 8. EGR valve gasket
3. EGR pipe adapter 9. Inlet manifold
4. Intake throttle valve 10. Inlet manifold gasket
5. Intake throttle valve gasket
6. EGR pipe adapter gasket
Note：
・ Exhaust manifold (with EGR cooler
specification)
1. Exhaust manifold 3. Exhaust manifold heat protector

2. Exhaust manifold gasket
Note：
・ Exhaust manifold (with EGR pipe specification)
1. Exhaust manifold 3. Exhaust manifold heat protector

2. Exhaust manifold gasket
Note：
・ Timing gear train
1. Oil pump gear 8. Injection pump sprocket

2. Crankshaft gear 9. Injection pump gear
3. Idle gear D 10. Idle gear A
4. Exhaust camshaft gear 11. Vacuum pump gear
5. Intake camshaft gear 12. Power steering oil pump gear
6. Idle gear D sprocket 13. Idle gear C
7. Timing chain
Note：
・ Camshaft assembly
1. Exhaust camshaft 4. Inlet camshaft

2. Camshaft bearing cap
3. Bolt
Note：
・ Valve stem oil seal and valve spring
1. Exhaust rocker arm shaft assembly 9. Spring lower seat

2. Bolt, long 10. Valve stem oil seal
3. Bolt, short 11. Valve spring
4. Intake rocker arm shaft assembly 12. Spring upper seat
5. Fuel injector 13. Split collar
6. Bolt 14. Valve stem end cap
7. Injector clamp
8. Pin
Note：
・ Rocker arm shaft assembly
1. Exhaust rocker arm shaft assembly 9. Spring lower seat

2. Bolt, long 10. Valve stem oil seal
3. Bolt, short 11. Valve spring
4. Intake rocker arm shaft assembly 12. Spring upper seat
5. Fuel injector 13. Split collar
6. Bolt 14. Valve stem end cap
7. Injector clamp
8. Pin
Note：
・ Cylinder head
1. Timing chain tensioner 6. Cylinder head

2. Glow plug 7. Timing chain guide
3. Intake and exhaust valves 8. Timing chain tension lever
4. Fuel injector
5. Injector clamp
Note：
・ Piston and connecting rod
1. Snap ring 5. Connecting rod

2. Piston pin 6. Connecting rod bearing
3. Piston ring
4. Piston
Note：
・ Flywheel
1. Flywheel, MUA transmission vehicle 5. Flexible plate

2. Flywheel, automatic transmission vehicle 6. Washer
3. Clutch disc
4. Clutch pressure plate
Note：
・ Gear case assembly
1. Adjust plate 4. Gasket

2. Generator 5. Timing gear case
3. Gear case bracket
Note：
・ Crankshaft front oil seal
1. Washer 3. Crankshaft front oil seal

2. Crankshaft pulley
Note：
・ Crankshaft rear oil seal
1. Oil seal retainer 3. Slinger

2. Crankshaft rear oil seal
Note：
・ Crankshaft
1. Upper crankshaft bearing 5. Lower crankshaft bearing

2. Thrust bearing 6. Bearing cap
3. Crank gear
4. Crankshaft
Note：
・ Cylinder block
1. Cylinder block
2. Tightening Torque Views Note：

1： 52 N・m { 5.3 kgf・m / 38 lb・ft } 5： 51 N・m { 5.2 kgf・m / 38 lb・ft }

3： 157 N・m { 16.0 kgf・m / 116 lb・ft } 7： 8.2 N・m { 0.8 kgf・m / 73 lb・in }
9： 51 N・m { 5.2 kgf・m / 38 lb・ft } Note：
10： 51 N・m { 5.2 kgf・m / 38 lb・ft } ・ Engine mounting (4WD)
11： 51 N・m { 5.2 kgf・m / 38 lb・ft }

5： 51 N・m { 5.2 kgf・m / 38 lb・ft } Note：
6： 52 N・m { 5.3 kgf・m / 38 lb・ft } ・ Inlet manifold (with EGR cooler specification)
7： 8.2 N・m { 0.8 kgf・m / 73 lb・in }


3： 5 N・m { 0.5 kgf・m / 44 lb・in } 9： 25 N・m { 2.5 kgf・m / 18 lb・ft }
4： 10 N・m { 1.0 kgf・m / 89 lb・in } Note：
5： 27 N・m { 2.8 kgf・m / 20 lb・ft } ・ Inlet manifold (with EGR pipe specification)
6： 24 N・m { 2.4 kgf・m / 18 lb・ft }


4： 10 N・m { 1.0 kgf・m / 89 lb・in } Note：
5： 25 N・m { 2.5 kgf・m / 18 lb・ft } ・ Exhaust manifold (with EGR cooler
specification)
6： 25 N・m { 2.5 kgf・m / 18 lb・ft }
7： 27 N・m { 2.8 kgf・m / 20 lb・ft }

3： 25 N・m { 2.5 kgf・m / 18 lb・ft } Note：
4： 25 N・m { 2.5 kgf・m / 18 lb・ft } ・ Exhaust manifold (with EGR pipe specification)

3： 25 N・m { 2.5 kgf・m / 18 lb・ft } Note：
4： 25 N・m { 2.5 kgf・m / 18 lb・ft } ・ Timing gear train
1： 8 N・m { 0.8 kgf・m / 71 lb・in } 5： 10 N・m { 1.0 kgf・m / 89 lb・in }

3： 32 N・m { 3.3 kgf・m / 24 lb・ft } Note：
4： 59 N・m { 6.0 kgf・m / 44 lb・ft } ・ Camshaft assembly
1： 18 N・m { 1.8 kgf・m / 13 lb・ft } Note：

2： 10 N・m { 1.0 kgf・m / 89 lb・in } ・ Cylinder head

2： 25 N・m { 2.5 kgf・m / 18 lb・ft } 6： 2 N・m { 0.2 kgf・m / 18 lb・in }
4-1： 70 N・m { 7.1 kgf・m / 52 lb・ft } 8： 25 N・m { 2.5 kgf・m / 18 lb・ft }
4-2： 70 N・m { 7.1 kgf・m / 52 lb・ft } 9： 27 N・m { 2.8 kgf・m / 20 lb・ft }
4-3： 60 to 75 ° Angle method Note：
4-4： 60 to 75 ° Angle method ・ Piston and connecting rod
1-1： 29.4 N・m { 3.0 kgf・m / 22 lb・ft } Note：

1-2： 45 to 60 ° Angle method ・ Flywheel
1-1： 59 N・m { 6.0 kgf・m / 44 lb・ft } Note：

1-2： 60 to 90 ° Angle method ・ Gear case assembly
2： 15 to 21 N・m { 1.5 to 2.1 kgf・m / 11 to 15 lb・ft }


4： 40 N・m { 4.1 kgf・m / 30 lb・ft } Note：
5： 25 N・m { 2.5 kgf・m / 18 lb・ft } ・ Crankshaft front oil seal
1： 294 N・m { 30.0 kgf・m / 217 lb・ft } Note：

・ Crankshaft rear oil seal
1： 82 N・m { 8.4 kgf・m / 60 lb・ft } Note：

2： 25 N・m { 2.5 kgf・m / 18 lb・ft } ・ Crankshaft
1： 166 N・m { 16.9 kgf・m / 122 lb・ft }

2： 12 N・m { 1.2 kgf・m / 106 lb・in }
Fuel System (4JK1) 1C-1
Engine
Fuel System
(4JK1)
Table of Contents
Fuel..................................................................................1C-2 installation...............................................................1C-113
inspection....................................................................1C-2 Fuel sedimenter switch................................................1C-116
Injector.............................................................................1C-3 removal...................................................................1C-116
removal.......................................................................1C-3 inspection................................................................1C-117
installation...................................................................1C-8 installation...............................................................1C-118
Common rail assembly..................................................1C-15 Fuel filter switch..........................................................1C-119
removal.....................................................................1C-15 inspection................................................................1C-119
installation.................................................................1C-18 Fuel filter.....................................................................1C-120
Fuel temperature sensor.................................................1C-21 removal...................................................................1C-120
removal.....................................................................1C-21 installation...............................................................1C-121
inspection..................................................................1C-36 Supplementary Information.........................................1C-122
installation.................................................................1C-37
Pressure limiter..............................................................1C-53
removal.....................................................................1C-53
installation.................................................................1C-54
Fuel pressure sensor......................................................1C-55
removal.....................................................................1C-55
installation.................................................................1C-56
Suction control valve.....................................................1C-57
removal.....................................................................1C-57
installation.................................................................1C-59
Fuel tank........................................................................1C-61
removal.....................................................................1C-61
installation.................................................................1C-63
Fuel tank unit.................................................................1C-66
removal.....................................................................1C-66
inspection..................................................................1C-68
installation.................................................................1C-70
Fuel filter element.........................................................1C-73
removal.....................................................................1C-73
installation.................................................................1C-74
Fuel supply pump..........................................................1C-75
removal.....................................................................1C-75
installation.................................................................1C-89
Fuel filler cap...............................................................1C-105
inspection................................................................1C-105
Filler neck....................................................................1C-106
removal...................................................................1C-106
installation...............................................................1C-108
Fuel tube......................................................................1C-110
removal...................................................................1C-110
1C-2 Fuel System (4JK1)
Fuel
inspection Caution：
・ Confirm that no flammable substances exist
1. Fuel air bleed under the drain hose.
1. Press the priming pump. Note：
Note：・ Press the priming pump several times to
・ Press the priming pump until it gets stiff. completely drain water.
4. Tighten the drain plug using a wrench.
Note：
・ Turn ON the ignition switch for 15 seconds and
check for fuel leakage.
・ Confirm that the fuel filter drain warning light is
turned off.
Caution：
・ If the fuel filter drain warning light frequently
turns on, have the fuel in the fuel tank drained
at the nearest ISUZU dealer.
・ When draining fuel from the fuel tank, make
sure to stop the engine.
・ When draining fuel from the fuel tank, confirm
1. Priming pump that no flammable substance exists under the
2. Fuel filter with sedimenter drain hose.
Caution：
2. Fuel drain water
Note：
・ If the fuel filter drain warning light turns on,
follow the procedure described below in order
to drain.
1. Install the hose to the drain plug.
Note：
・ Install it on the tip of the drain plug.
2. Prepare a container.
Note：
・ Place the container at the end of the hose
attached to the drain plug.
3. Drain water from the sedimenter.
Note：
・ Loosen the drain plug, and drain the water.
Injector
removal
1. Injector safety information
Caution：
・ The holes and gaps constituting the fuel paths
for the fuel system, including the inside of the
injector, have an extremely precise finish.
Therefore, entry of any foreign material may
cause trouble.
・ Be very careful to prevent entry of foreign
material after removing parts, etc.
1. Remove the engine cover from the engine. 5. Boost sensor disconnect
1. Engine cover
Note：
Note：

Note： Note：
control solenoid.
Note：
control solenoid.
pipe.
Note：
specifications
sensor.
assembly.

Caution：

2. MAF sensor
3. Blow-by hose
4. Intake pipe


2. Clip
Caution：
cover.
specifications.
the outlet pipe.
assembly.

head.


Note：
the exhaust manifold. ・ Remove the liquid gasket sticking to the
cylinder head.

removed injector.
cause damage.
Note：
cover.
1. Cam end gasket

1. Cylinder #1 injector ID code

5. Injector ID code label


Note：
the injector clamp.
remover.
Caution：
installation
Note：
Caution：
1. Injector
2. Bolt
3. Injector clamp

Note：
surface.
Note：
the injector.
1. Injector cylinder head.
2. Leak-off pipe
3. Clip 2. Injection pipe installation
4. O-ring 1. Apply the engine oil to the injection pipe.
5. Gasket
Note：
3. Install the injector clamp to the injector. ・ Apply engine oil to the injector-side sleeve nut
Note：
1. Cam end gasket
2. Application area
3. Bead width

Note：
in the diagram.

head.
ft }
Tightening torque： 7.8 N・m { 0.8 kgf・m / 69 lb・in } 1. 3.0 - 5.0 mm {0.118 - 0.197 in}
2. 3.0 - 5.0 mm {0.118 - 0.197 in}
1. Apply liquid gasket to the cam end gasket. 2. Install the cylinder head cover to the cylinder head.
Note： Note：
・ Apply ThreeBond 1207B to the area indicated ・ Tighten the nuts in the order shown in the
in the diagram. diagram.
Bead width： 2.0 to 3.0 mm { 0.079 to 0.118 in } Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in }
Note：
specifications.
exhaust manifold.
Bolt, nut

outlet pipe.

exhaust manifold.


Bolt, nut

2. MAF sensor
1. Leak-off pipe
3. Blow-by hose
2. Clip
4. Intake pipe
8. Connect the harness connector to the barometric Note：
pressure sensor.
・ When replacing the injectors, record the
9. Connect the harness connector to the MAF sensor. injector ID code data from each of the injector
harness connector housings.
1. Disconnect the harness connector from the injector.
Note：
・ Record all of the harness connector housing
1. Install the leak-off pipe to the injector. numbers.
・ The diagram below shows the correct order for
the injector ID codes.
・ 72 04 F9 F8 F0 00 F0 E7 09 F6 F9 96
1. Leak-off pipe
2. Clip
1. Injector ID code 2. Connect the connector to the turbocharger control

2. Injector solenoid.
2. Connect the harness connector to the injector. 3. Connect the vacuum hose to the turbocharger control
solenoid.
Note：
Note：
・ The following applies to high-output specifications
specifications.
Note：
specifications.
Note：
control solenoid.

Bolt
Clip
12. Boost sensor connect 14. Engine cover installation

1. Connect the connector to the boost sensor. 1. Install the engine cover to the engine.

intake hose.
Tightening torque： 4 N・m { 0.4 kgf・m / 35 lb・in } 16. ECM setting

Clip Note：
・ When the injectors have been replaced, this
procedure is required.
Note：
the injector ID codes into the ECM.
Note：
Note：
・ Confirm that a scan tool does not detect a
DTC.
Common rail assembly
removal Caution：
1. Battery ground cable disconnect material from getting into the fuel system.
Caution：
cause trouble.
1. Fuel hose
pump and the common rail assembly. 6. Vacuum hose disconnect
Caution： 1. Disconnect the vacuum hose from the vacuum pipe.

1. Fuel feed pipe
5. Fuel hose disconnect pipe.
1. Disconnect the fuel hose from the fuel supply pump. 3. Remove the leak-off pipe from the inlet manifold.

8. Leak-off pipe removal 1. Connector

1. Remove the leak-off pipe from the fuel supply pump 10. Injection pipe disconnect
1. Disconnect the injection pipe from the common rail
Note：
・ Remove the injection pipe sleeve nut.
Caution：
1. Leak-off pipe

sensor. 1. Injection pipe sleeve nut

solenoid valve.
bracket.
solenoid valve.
Caution：

2. Vacuum pipe
installation
1. Common rail assembly installation
1. Install the swirl control solenoid valve bracket to the

valve.
2. Vacuum pipe 2. Install swirl control solenoid valve to the bracket.
2. Install the common rail assembly to the cylinder valve.
block.
Note：
・ Install the part together with the common rail
assembly.
bracket.
・ Tighten the nuts in the order shown in the Note：
diagram. ・ Tighten the injection pipe sleeve nut.
Caution： Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
1. Injection pipe sleeve nut 1. Leak-off pipe
5. Fuel pressure sensor connect 7. Leak off pipe installation

1. Connect the connector to the fuel pressure sensor. 1. Install the leak-off pipe to the inlet manifold.
1. Connector
6. Leak-off pipe installation 2. Connect the fuel leak-off hose to the leak-off pipe.
1. Install the leak-off pipe to the fuel supply pump and 3. Connect the vacuum hose to the vacuum pipe.
the common rail assembly. 8. Vacuum hose connect
Tightening torque： 10.3 N・m { 1.1 kgf・m / 91 lb・ 1. Disconnect the vacuum hose from the vacuum pipe.
in }
9. Fuel hose connect 1. Fuel feed pipe

1. Connect the fuel hose to the fuel supply pump. 11. Starter motor installation
1. Fuel hose

ft }
removal Note：
Caution：
cause trouble.
Note：
1. Remove the front under guard from the frame. 4. Coolant drain
Note： 1. Drain coolant from the radiator.

・ Remove the 5 bolts and the clip. Note：
radiator.
1. Bolt
2. Clip
Note：
・ The following applies to 4WD. Warning：
while the engine and radiator are hot.
Note：・ Heat liquid and steam may gush out by
・ Remove the 5 bolts. pressure.
3. Remove the rear under guard from the frame. 5. Engine cover removal

1. Engine cover 1. Remove the intake air duct from the intake throttle
Note：
Note：

1. Radiator upper hose 12. Fan guide removal
10. Battery removal 1. Remove the fan guide from the radiator.
1. Disconnect the battery ground cable from the frame. Note：

4. Remove the battery from vehicle.
1. Upper fan guide

2. Clip
3. Lower fan guide
1. Battery cable
4. Fan shroud
2. Battery bracket
3. Earth 13. Cooling fan removal
11. Radiator reserve tank removal 1. Remove the cooling fan from the fan clutch
assembly.
radiator.
guide.
1. Fan clutch assembly 17. Oil level gauge guide tube removal
2. Cooling fan
14. Fan shroud removal guide tube.
1. Remove the fan guide from the radiator. 2. Remove the oil level gauge guide tube from the
crankcase.
Note：
fan shroud. 1. Remove the A/C compressor assembly from the A/C
compressor bracket.
pulley.

2. A/C compressor
1. A/C compressor drive belt 19. A/C compressor bracket removal

1. Remove the A/C compressor bracket from the
16. Tension pulley removal
cylinder head.
Caution：

1. Fuel hose
pump and the common rail assembly. 1. Disconnect the vacuum hose from the vacuum pipe.
Caution：

1. Fuel feed pipe pipe.
22. Fuel hose disconnect 3. Remove the leak-off pipe from the inlet manifold.

Note：
Caution：
1. Leak-off pipe


solenoid valve.
bracket.
solenoid valve.
Caution：
Note：
specifications

2. Vacuum pipe

Note： Note：
control solenoid.
Note：
control solenoid.

2. Clip
pipe. Caution：
cover.
Note：
specifications.
sensor.
assembly.
1. Fuel leak-off hose 4. Remove the air cleaner assembly from vehicle.
Caution：
3. Blow-by hose
4. Intake pipe




the outlet pipe.
assembly.

1. Remove the cylinder head cover from the cylinder 38. CMP sensor disconnect
head.

1. CMP sensor
Note：
・ Remove the liquid gasket sticking to the 1. Remove the noise cover from the timing chain lower
cylinder head. cover.
1. Noise cover 42. Timing chain lower cover removal
40. Water pipe removal 1. Remove the timing chain lower cover from the gear
case cover.
the outlet pipe.
assembly.
43. Fuel supply pump preparation

Note：
41. Timing chain upper cover removal ・ Rotate the crankshaft in the forward direction
dead center.
cylinder head.
mirror, etc.
cover
head.
Note：
aligned.

2. Gasket
3. Nut
1. Turn the nut.
Note：


2. Sprocket
3. Nut
Note：


temperature sensor.
control valve.

1. Supply pump
2. O-ring
Caution：
case.
50. Fuel temperature sensor removal
1. Remove the fuel temperature sensor from the fuel
supply pump.
2. Remove the O-ring from the fuel temperature sensor.

inspection
1. Fuel temperature sensor inspection
1. Measure a resistance using tester.
Note：
・ The fuel temperature sensor is a thermistor
type with electrical resistance reducing
properties in accordance with rises in
temperature.
Temperature Resistance
： 110 ℃ { 230 °F } ： 140 Ω
： 100 ℃ { 212 °F } ： 180 Ω
： 90 ℃ { 194 °F } ： 240 Ω
： 80 ℃ { 176 °F } ： 310 Ω
： 70 ℃ { 158 °F } ： 420 Ω
： 60 ℃ { 140 °F } ： 580 Ω
： 50 ℃ { 122 °F } ： 810 Ω
： 40 ℃ { 104 °F } ： 1150 Ω
： 30 ℃ { 86 °F } ： 1660 Ω
： 20 ℃ { 68 °F } ： 2450 Ω
： 10 ℃ { 50 °F } ： 3700 Ω
： 0 ℃ { 32 °F } ： 5740 Ω
： -10 ℃ { 14 °F } ： 9160 Ω
： -20 ℃ { -4 °F } ： 15000 Ω
： -30 ℃ { -22 °F } ： 25400 Ω
Note：
・ Replace if there are any abnormalities in the
inspection results.
1. Fuel temperature sensor installation in a horizontal position on the right side.
1. Install the O-ring to the fuel temperature sensor.
2. Install the fuel temperature sensor to the fuel supply
pump.
3. Supply pump gear installation

Note：
2. Fuel supply pump installation gear and the mark on idle gear A.
Caution： pump gear is engaged with the sub gear of idle

3. Main gear
Note：
Note：
plate.
plate.
gear.
Note：
6. Timing chain tensioner installation
install the fuel supply pump sprocket to the fuel 1. Connect the hook to the pin.
pump shaft. Note：
・ Tighten the fuel supply pump shaft nut by ・ Keep the state where the latch is being
hand. pushed.
plunger.
1. Timing mark
2. Dark plate
3. Timing mark
4. Yellow plate
1. Pin
3. Latch
1. Install the timing chain lever pivot to the timing 4. Timing chain tensioner
chain tension lever. 5. Hook
head.

2. Gasket
Note：
the diagram. 1. Apply liquid gasket to the timing chain lower cover.
plunger pushes the tension lever to pull the ・ Apply ThreeBond 1207C or equivalent.
chain.
Caution：
install the cover.
7. Supply pump gear nut installation

gear.
ft }
1. Liquid gasket
2. Bead height
3. Bead width

cover.
Note：
Caution：
install the cover.

Bolt, nut
1. Liquid gasket
2. Bead height
3. Bead width
Note：
2. Install the timing chain upper cover to the cylinder 2. Connect the turbocharger water feed hose to the
head. outlet pipe.
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } 11. Noise cover installation
cover.
1. Noise cover 1. Cam end gasket

2. Application area
12. CMP sensor connect 3. Bead width
Note：
in the diagram.
1. CMP sensor

Note：
in the diagram. 1. 3.0 - 5.0 mm {0.118 - 0.197 in}
Bead width： 2.0 to 3.0 mm { 0.079 to 0.118 in } 2. 3.0 - 5.0 mm {0.118 - 0.197 in}

Note：
diagram.
Note：

exhaust manifold.
Bolt, nut

outlet pipe.

exhaust manifold.

1. Leak-off pipe

2. MAF sensor
1. Leak-off pipe
3. Blow-by hose
2. Clip
4. Intake pipe
assembly. 18. Vacuum pipe installation
pressure sensor.
9. Connect the harness connector to the MAF sensor. specifications.
16. Blow-by hose connect 1. Install the vacuum pipe to the cylinder head cover.
1. Connect the blow-by hose to the cylinder head cover. Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
17. Fuel leak-off hose installation 19. Bracket installation
Note： 20. Common rail assembly installation
・ The following applies to high-output 1. Install the swirl control solenoid valve bracket to the
specifications. common rail bracket.
1. Install the bracket to the cylinder head cover. Tightening torque： 15 N・m { 1.5 kgf・m / 11 lb・ft }
Note：
control solenoid.

2. Vacuum pipe
2. Connect the connector to the turbocharger control 2. Install the common rail assembly to the cylinder
solenoid. block.
3. Connect the vacuum hose to the turbocharger control Note：
solenoid. ・ Install the part together with the common rail
bracket.
Note：
diagram.
specifications
Caution：
21. Vacuum pipe installation 1. Injection pipe sleeve nut

1. Install the vacuum pipe to the bracket. 24. Fuel pressure sensor connect
Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in } 1. Connect the connector to the fuel pressure sensor.
valve.
valve.
assembly.
Note：
1. Connector

in }
1. Leak-off pipe 1. Fuel hose
26. Leak off pipe installation 2. Connect the fuel hose to the leak-off pipe.
1. Install the leak-off pipe to the inlet manifold. 28. Fuel feed pipe installation
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } 1. Install the fuel feed pipe to the fuel supply pump and
ft }

3. Connect the vacuum hose to the vacuum pipe.
1. Fuel feed pipe
head.

31. A/C compressor assembly connect 1. Install the tension pulley to the cylinder head.
1. Install the A/C compressor assembly to the A/C Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
compressor bracket.

2. A/C compressor

crankcase.
Note：
Measurement point 2
Amount of belt
Frequency
deflection
： 12.5 to 16.5 mm
New ： 92 to 112 Hz
{ 0.492 to 0.650 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 3
Amount of belt
Frequency
deflection
1. A/C compressor drive belt ： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
： 16.5 to 19.1 mm
1. Adjust tension to a standard value using a tension { 0.650 to 0.752 in }
meter.
Measurement point 4
Note：
Amount of belt
・ The following is the belt tension adjusting Frequency
deflection
： 15.9 to 20.7 mm
・ Apply a load to measurement points 2, 3, and New ： 70 to 86 Hz
{ 0.626 to 0.815 in }
： 20.7 to 23.7 mm
the amount of flex. Reuse ： 62 to 70 Hz
{ 0.815 to 0.933 in }
Load： 98 N { 10 kg / 22 lb }
Measurement point 2
Amount of belt
Frequency
deflection
： 12.5 to 16.5 mm
New ： 92 to 112 Hz
{ 0.492 to 0.650 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 3
Amount of belt
Frequency
deflection
： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 4 1. Measurement point 1

Amount of belt 2. Measurement point 2
deflection
New ： 70 to 86 Hz
{ 0.626 to 0.815 in }
： 20.7 to 23.7 mm
{ 0.815 to 0.933 in }
Note：
Note：
shroud.
1. Upper fan guide

2. Clip
3. Lower fan guide
4. Fan shroud

guide.

2. Cooling fan

Note：

radiator.
Note：
detergent.

the water.

1. Battery cable Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in }
2. Battery bracket Bolt
3. Earth
2. Install the battery bracket to the frame. Clip

Battery side
Frame side
Hose clip


1. Install the intake air duct to the turbocharger and the 46. Fuel air bleed
intake hose.
Bolt Note：
Clip
1. Priming pump
1. Install the engine cover to the engine. Caution：
47. Coolant filling
Note：
solution.

Note：
Note：
Note：

1. Bolt
2. Clip
Note：
Note：
Note：
Pressure limiter
removal
Caution：

2. Fuel pressure sensor
3. Pressure limiter
1. Leak-off pipe
3. Pressure limiter removal

1. Remove the pressure limiter from the common rail
assembly.
installation 3. Battery ground cable connect

1. Pressure limiter installation
1. Install the pressure limiter to the common rail
assembly.
ft }

3. Pressure limiter

in }
1. Leak-off pipe
Fuel pressure sensor
removal
sensor.

3. Pressure limiter
1. Connector
3. Fuel pressure sensor removal

1. Remove the fuel pressure sensor from the common
rail assembly.
Caution：
installation
1. Fuel pressure sensor installation
1. Install the fuel pressure sensor to the common rail
assembly.

3. Pressure limiter

1. Connector

Suction control valve
removal Caution：
・ Be careful not to damage the connector by
1. Injector safety information applying excessive force.
Caution：
cause trouble.
3. Battery removal
4. Remove the battery from vehicle. 2. Disconnect the connector from the suction control
valve.

Caution：
1. Battery cable
2. Battery bracket
3. Earth
4. Suction control valve disconnect

1. Disconnect the connector from the suction control
valve.
Note：
・ Disconnect the engine harness that fastens
1. Fuel hose
the area around the fuel supply pump.
6. Suction control valve removal
1. Remove the suction control valve from the fuel
supply pump.
1. O-ring
installation
1. Suction control valve installation
1. Fuel hose

3. Suction control valve connect
1. O-ring 1. Connect the connector to the suction control valve.
2. Temporarily tighten the suction control valve to the

fuel supply pump.
Caution：
・ Be careful not to have the O-ring pinched in.
Note：
・ Temporarily tighten it by hand until it adheres
to the supply pump.
3. Securely tighten the suction control valve to the fuel
supply pump.

Note：
・ Connect the engine harness that fastens the
area around the fuel supply pump.
Note：
Learned.
Note：
・ Start the engine and warm the engine up.
10. Check the data display of a scan tool.
Note：
Standard： 65 ℃ { 149 °F }
Note：
1. Battery cable ・ Confirm that the pump unit difference learning
2. Battery bracket complete status display changes from Not
3. Earth Learned to Learned.
2. Install the battery bracket to the frame. 12. Check the DTC of a scan tool.
Battery side ・ Confirm that a scan tool does not detect a
Tightening torque： 20 N・m { 2.0 kgf・m / 15 lb・ft } DTC.
Frame side
6. ECM writing
Note：
・ When replacing the fuel supply pump or
suction control valve, this procedure is
required.
6. Select the Actuator Test.
7. Select the Fuel Supply Pump Learn Resetting.
Note：
・ Follow the directions on the screen and reset
the ECM Fuel Pump Learning Status.
Fuel tank
removal
2. Fuel filler cap removal
1. Remove the fuel filler cap from the filler neck.
Note：
・ Gradually loosen the fuel filler cap.
Caution：
・ Be careful with fuel spouts due to a pressure
change in the fuel tank.
・ Cover the opening of the filler neck to prevent
foreign material from getting inside. 1. J-type nut
3. Fuel tube disconnect 2. Inner liner
3. Spats
1. Disconnect the fuel tube from the fuel hose. 4. Screw
2. Disconnect the fuel return tube from the fuel hose. 5. Rear mud guard removal
Note：
・ The following applies to vehicles equipped with
rear mud guards.
1. Remove the rear mud guard from the rear body.
Note：
1. Fuel tube
2. Fuel return tube
4. Front flap removal

Note：
・ The following applies to standard cabs.
1. Remove the front flap from the rear body.
Note： 1. Screw
・ Remove the 3 screws. 2. J-type nut
3. Inner liner
4. Rear mud guard
6. Inner liner removal
1. Remove the inner liner from the rear body.
Note：
・ The following applies to standard cabs with
front flaps.
・ Left side: Remove the 7 clips.
・ Right side: Remove the 6 clips.
・ The following applies to standard cabs without
front flaps.
・ The following applies to wide cabs.
・ Left side: Remove the 9 clips and the screw.
・ Right side: Remove the 8 clips and the screw.
7. Filler neck removal
3. Disconnect the connector from the fuel gauge unit.
Note：
4. Remove the fuel tank from vehicle.
・ Put a mark on each fixing section and band
clip of the clamp so that the filler neck Note：
assembly can be installed to the original ・ Lower the lifter and remove the fuel tank from
positions. the vehicle.
1. Remove the filler neck from the rear body and the Caution：
fuel filler hose. ・ Do not damage the hose or the tube by
Note： contacting with other parts.
・ Cover the ends of each hose and pipe to
prevent foreign material from getting inside.
2. Disconnect the evaporator hose from the filler neck.
Note：
8. Fuel tank removal
1. Hold the fuel tank using the lifter.
Note：
・ Support the bottom of the fuel tank by using
the lifter.
2. Remove the fuel tank band from the frame.
installation Tightening torque： 6 N・m { 0.6 kgf・m / 53 lb・in }

Filler neck
1. Fuel tank installation
1. Install the fuel tank to vehicle. in } Fuel tank side clamp
Caution： Tightening torque： 3 N・m { 0.31 kgf・m / 26.6 lb・
・ Do not damage the hose or the tube by in } Filler pipe side clamp
contacting with other parts. 3. Inner liner installation
Note： 1. Install the inner liner to the rear body.
・ Put the fuel tank on the lifter and install the fuel
Note：
tank by elevating the lifter.
2. Connect the connector to the fuel gauge unit. front flaps.
Caution：・ Left side: Install the 7 clips.
・ Securely connect the connector to the stopper. ・ Right side: Install the 6 clips.
3. Install the fuel tank band to the frame. ・ The following applies to standard cabs without
front flaps.
・ Left side: Install the 10 clips.
Caution：・ Right side: Install the 9 clips.
・ Securely install the anchor of the tank band to ・ The following applies to wide cabs.
the guide hole of the frame.
・ Left side: Install the 9 clips and the screw.
・ Right side: Install the 8 clips and the screw.
4. Rear mud guard installation
Note：
rear mud guards.
1. Install the rear mud guard to the rear body.
Note：
・ Tighten the 3 screws to the specified torque.
Note：
・ Securely insert the J-type nut until it hits the
inner end of the panel.
4. Remove the lifter from the fuel tank.

2. Filler neck installation
1. Connect the evaporator hose to the filler neck.
Note：
・ Install it to the original position by aligning
each mark.
2. Install the filler neck to the rear body and the fuel
filler hose.
Note：
each mark.
1. Screw
2. J-type nut
3. Inner liner
4. Rear mud guard
5. Front flap installation

Note：
1. Install the front flap to the rear body.
Note：
1. Fuel tube
2. Fuel return tube
7. Fuel filler cap installation

1. Install the fuel filler cap to the filler neck.
Note：
・ Tighten the filler cap until it clicks at least 3
times.
8. Fuel air bleed
Note：
1. J-type nut
2. Inner liner
3. Spats
4. Screw
6. Fuel tube connect

1. Connect the fuel return tube to the fuel hose.
2. Connect the fuel tube to the fuel hose.
1. Priming pump
Caution：
3. Lower vehicle.
10. Fuel inspection
Note：
・ Check for loosening or fuel leakage at the
connections of the fuel system.
Fuel tank unit
removal
Note：
Caution：
foreign material from getting inside. 1. J-type nut
3. Fuel tube disconnect 2. Inner liner
3. Spats
1. Disconnect the fuel tube from the fuel hose. 4. Screw
2. Disconnect the fuel return tube from the fuel hose. 5. Rear mud guard removal
Note：
rear mud guards.
1. Remove the rear mud guard from the rear body.
Note：
1. Fuel tube
2. Fuel return tube

Note：
Note： 1. Screw
・ Remove the 3 screws. 2. J-type nut
3. Inner liner
4. Rear mud guard
Note：
front flaps.
front flaps.
・ Left side: Remove the 9 clips and the screw.
・ Right side: Remove the 8 clips and the screw.
Note：
・ Put a mark on each fixing section and band
clip of the clamp so that the filler neck Note：
assembly can be installed to the original ・ Lower the lifter and remove the fuel tank from
positions. the vehicle.
1. Remove the filler neck from the rear body and the Caution：
fuel filler hose. ・ Do not damage the hose or the tube by
Note： contacting with other parts.
・ Cover the ends of each hose and pipe to 9. Fuel tank unit removal
prevent foreign material from getting inside. 1. Remove the fuel tube from the fuel gauge unit.
2. Disconnect the evaporator hose from the filler neck. 2. Remove the fuel return tube from the fuel gauge unit.
Note： 3. Remove the fuel gauge unit from the fuel tank.
prevent foreign material from getting inside. Note：
・ Remove it gradually paying attention not to
8. Fuel tank removal distort the float arm.
1. Hold the fuel tank using the lifter. Caution：
Note：・ Cover the opening of the fuel gauge unit to
・ Support the bottom of the fuel tank by using prevent foreign material from getting inside.
the lifter. ・ Dispose of the fuel gauge unit seal because it
2. Remove the fuel tank band from the frame. cannot be reused.
inspection
1. Fuel tank unit seal inspection
1. Connect the filler neck to the fuel tank.
Note：
・ Connect both the filler hose and the
evaporator hose.
2. Remove the cap from the breather.
3. Install the hose to the fuel tank unit.
Note：
・ Connect the breather to the return-side pipe.
Note：
・ Tighten it until it clicks at least once.
5. Apply soapy water to the seal. 1. Positive side power supply terminal
2. Ground terminal
Note：
・ Apply soapy water to the area around the fuel
gauge unit seal.
・ Inject air from the feed-side pipe of the fuel
tank unit to the fuel tank for at least 15
seconds at the specified pressure.
Standard： 34.3 kPa { 0.35 kgf/cm2 / 5 psi }
Note：
・ Confirm that bubbles are not coming out
around the fuel gauge unit seal.
2. Fuel tank unit inspection
1. Inspect the fuel tank unit.
Note：
・ The fuel tank unit changes the internal
resistance in accordance with the float
position, which varies depending on the fluid
1. Distance from point E to the 1/4 point
surface height, and operates the fuel meter
indicator.
・ While moving the float from E to F, measure 4. Distance from point E to point F
the resistance value between the positive 5. Point F
power supply terminal and the ground terminal 6. 3/4 point
of the connector. 7. 1/2 point
8. 1/4 point
9. Point E
Float
Actual Resistance
posit Distance
capacity value
ion
： 73.5 L
Poin ： 171.6 mm
{ 16.17 ： 14 to 20 Ω
tF { 6.756 in }
Imp.gal }
： 55.2 L
： 116.2 mm ： 31.25 to
3/4 { 12.14
{ 4.575 in } 37.25 Ω
Imp.gal }
： 39.9 L
： 76.8 mm
1/2 { 8.78 ： 42 to 48 Ω
{ 3.024 in }
Imp.gal }
： 24.7 L
： 43.1 mm ： 67.75 to
1/4 { 5.43
{ 1.697 in } 77.75 Ω
Imp.gal }
Poin ： 0 mm { 0 ： 9.5 L { 2.09 ： 100.5 to
tE in } Imp.gal } 104.5 Ω
Note：
・ Connect the fuel tank unit to the connector on
the vehicle and move the float.
・ Confirm that the low fuel warning light turns on
when the float is in the E position.
・ If any abnormality is found in the inspection
results, replace the relevant part with a normal
one.
installation Caution：
・ Do not damage the hose or the tube by
1. Fuel tank unit installation contacting with other parts.
Note： Note：
・ Clean the seal surfaces of the fuel tank and ・ Put the fuel tank on the lifter and install the fuel
the fuel gauge unit. tank by elevating the lifter.
Caution： 2. Connect the connector to the fuel gauge unit.
・ Foreign material on the seal surface causes
Caution：
fuel leakage.
・ Securely connect the connector to the stopper.
1. Install the seal to the fuel tank.
3. Install the fuel tank band to the frame.
Note：
・ Install a new fuel gauge unit seal along the
groove of the fuel tank opening. Caution：
2. Install the fuel gauge unit to the fuel tank. ・ Securely install the anchor of the tank band to
Note：
・ Install it gradually not to distort the float arm.
・ Install the flange of the fuel gauge unit on the
fuel gauge unit seal so that the convex portion
of the fuel gauge unit fits with the concave
portion of the fuel tank.
3. Install the retainer ring to the fuel tank.
Note：
・ Align the positions of the alignment mark on
the retainer side and the alignment mark on
the fuel tank side, as shown in the diagram.

Note：
each mark.
filler hose.
Note：
1. Alignment mark on the retainer side
each mark.
2. Alignment mark on the fuel tank side
2. Fuel tank installation Filler neck
1. Install the fuel tank to vehicle. Tightening torque： 2 N・m { 0.20 kgf・m / 17.7 lb・
in } Fuel tank side clamp
Tightening torque： 3 N・m { 0.31 kgf・m / 26.6 lb・ 6. Front flap installation
in } Filler pipe side clamp
Note：
4. Inner liner installation ・ The following applies to standard cabs.
1. Install the inner liner to the rear body. 1. Install the front flap to the rear body.
Note： Note：
・ The following applies to standard cabs with ・ Install the 3 screws.
front flaps.
・ Left side: Install the 7 clips. inner end of the panel.
・ Right side: Install the 6 clips.
front flaps.
Note：
rear mud guards.
Note：
1. J-type nut
Tightening torque： 3 N・m { 0.3 kgf・m / 27 lb・in } 2. Inner liner
Note： 3. Spats
4. Screw
inner end of the panel. 7. Fuel tube connect
1. Screw
2. J-type nut
3. Inner liner
4. Rear mud guard 1. Fuel tube
2. Fuel return tube

Note：
times.
9. Fuel air bleed
Note：
1. Priming pump
Caution：
3. Lower vehicle.
11. Fuel inspection
Note：
Fuel filter element
removal
2. Fuel filter removal
1. Disconnect the connector from the fuel sedimenter
switch.
2. Disconnect the connector from the pressure switch.
3. Disconnect the fuel hose from the fuel filter
assembly.
Note：
・ Disconnect the feed hose and the return hose,
and plug the hoses to prevent the fuel from
spilling.
1. Fuel filter body
4. Remove the fuel filter from the fuel filter bracket. 2. Fuel filter element
3. O-ring
4. Element case
Caution：
・ Use the ISUZU genuine fuel filters for
replacement.
3. Fuel filter element removal

1. Remove the element case from the fuel filter body.
2. Remove the fuel filter element from the fuel filter
body.
Note：
・ Do not reuse the O-ring and gasket.
installation
1. Fuel filter element installation
1. Install the fuel filter element to the fuel filter body.
2. Install the element case to the fuel filter body.
3. Fuel air bleed

Note：
1. Fuel filter body

2. Fuel filter element
3. O-ring
4. Element case
2. Fuel filter installation

1. Install the fuel filter to the fuel filter bracket.
2. Connect the fuel hose to the fuel filter assembly.
Note：
・ Connect the feed hose and the return hose.
3. Connect the harness connector to the pressure
switch.
4. Connect the connector to the fuel sedimenter switch.
5. Connect the water drain hose to the element case.
1. Priming pump
Caution：
Fuel supply pump
removal Note：
Caution：
cause trouble.
Note：

・ Remove the 5 bolts and the clip. Note：
radiator.
1. Bolt
2. Clip
Note：
・ The following applies to 4WD. Warning：
Note：・ Heat liquid and steam may gush out by
・ Remove the 5 bolts. pressure.
3. Remove the rear under guard from the frame. 5. Engine cover removal

1. Engine cover 1. Remove the intake air duct from the intake throttle
Note：
Note：

1. Radiator upper hose 12. Fan guide removal
10. Battery removal 1. Remove the fan guide from the radiator.
1. Disconnect the battery ground cable from the frame. Note：

4. Remove the battery from vehicle.
1. Upper fan guide

2. Clip
3. Lower fan guide
1. Battery cable
4. Fan shroud
2. Battery bracket
3. Earth 13. Cooling fan removal
11. Radiator reserve tank removal 1. Remove the cooling fan from the fan clutch
assembly.
radiator.
guide.
1. Fan clutch assembly 17. Oil level gauge guide tube removal
2. Cooling fan
14. Fan shroud removal guide tube.
1. Remove the fan guide from the radiator. 2. Remove the oil level gauge guide tube from the
crankcase.
Note：
fan shroud. 1. Remove the A/C compressor assembly from the A/C
compressor bracket.
pulley.

2. A/C compressor
1. A/C compressor drive belt 19. A/C compressor bracket removal

1. Remove the A/C compressor bracket from the
16. Tension pulley removal
cylinder head.
Caution：

1. Fuel hose
pump and the common rail assembly. 1. Disconnect the vacuum hose from the vacuum pipe.
Caution：

1. Fuel feed pipe pipe.
22. Fuel hose disconnect 3. Remove the leak-off pipe from the inlet manifold.

Note：
Caution：
1. Leak-off pipe


solenoid valve.
bracket.
solenoid valve.
Caution：
Note：
specifications

2. Vacuum pipe

Note： Note：
control solenoid.
Note：
control solenoid.

2. Clip
pipe. Caution：
cover.
Note：
specifications.
sensor.
assembly.
1. Fuel leak-off hose 4. Remove the air cleaner assembly from vehicle.
Caution：
3. Blow-by hose
4. Intake pipe




the outlet pipe.
assembly.

1. Remove the cylinder head cover from the cylinder 38. CMP sensor disconnect
head.

1. CMP sensor
Note：
・ Remove the liquid gasket sticking to the 1. Remove the noise cover from the timing chain lower
cylinder head. cover.
1. Noise cover 42. Timing chain lower cover removal
40. Water pipe removal 1. Remove the timing chain lower cover from the gear
case cover.
the outlet pipe.
assembly.
43. Fuel supply pump preparation

Note：
41. Timing chain upper cover removal ・ Rotate the crankshaft in the forward direction
dead center.
cylinder head.
mirror, etc.
cover
head.
Note：
aligned.

2. Gasket
3. Nut
1. Turn the nut.
Note：


2. Sprocket
3. Nut
Note：


temperature sensor.
control valve.

1. Supply pump
2. O-ring
Caution：
case.
1. Fuel supply pump installation gear and the mark on idle gear A.
Caution： pump gear is engaged with the sub gear of idle

3. Main gear
Note：
Note：
plate.
plate.
gear.
Note：
pump shaft.
2. Supply pump gear installation
・ Tighten the fuel supply pump shaft nut by
1. Install the supply pump gear to the fuel supply pump. hand.

plunger.
1. Timing mark
2. Dark plate
3. Timing mark
4. Yellow plate 1. Pin
2. Plunger
4. Timing chain lever pivot installation 3. Latch
5. Hook
Note： 2. Install the timing chain tensioner to the cylinder
head.
・ Tighten the pivot bolt by hand.
・ Confirm that the tension lever moves Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in }
smoothly.

5. Timing chain tensioner installation 2. Gasket
3. Nut
Note：
・ Keep the state where the latch is being Note：
pushed. ・ Lightly push the area indicated by an arrow in
・ Insert the plunger. the diagram.
・ The hook of the tensioner opens and the Bead height： 2.0 to 2.5 mm { 0.079 to 0.098 in }
plunger pushes the tension lever to pull the Bead width： 2.0 to 2.5 mm { 0.079 to 0.098 in }
chain.
Caution：
install the cover.
6. Supply pump gear nut installation

gear.
1. Liquid gasket
Tightening torque： 130 N・m { 13.3 kgf・m / 96 lb・ 2. Bead height
ft } 3. Bead width

cover.
Note：
Caution：
install the cover.
1. Nut

Note：
1. Liquid gasket 2. Connect the turbocharger water feed hose to the

2. Bead height outlet pipe.
3. Bead width
Note： 1. Install the noise cover to the timing chain lower
・ Apply Loctite 262 or equivalent to the threaded cover.
head.
1. Noise cover
9. Water pipe installation 1. Connect the connector to the CMP sensor.

Bolt, nut
Note：
in the diagram.
1. CMP sensor

1. 3.0 - 5.0 mm {0.118 - 0.197 in}
Note： 2. 3.0 - 5.0 mm {0.118 - 0.197 in}
in the diagram.
Note：
diagram.
1. Cam end gasket

2. Application area
3. Bead width
Note：
1. Apply liquid gasket to the cylinder head. specifications.
exhaust manifold.
Bolt, nut

outlet pipe.
2. Install the exhaust manifold heat protector to the 5. Connect the turbocharger water feed hose to the
exhaust manifold. water feed and return pipes.

cylinder head assembly. 6. Install the air cleaner assembly to vehicle.
Bolt, nut

2. MAF sensor
1. Leak-off pipe
3. Blow-by hose
2. Clip
4. Intake pipe
assembly. 17. Vacuum pipe installation
pressure sensor.
9. Connect the harness connector to the MAF sensor. specifications.
15. Blow-by hose connect 1. Install the vacuum pipe to the cylinder head cover.
1. Connect the blow-by hose to the cylinder head cover. Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
16. Fuel leak-off hose installation 18. Bracket installation
1. Install the leak-off pipe to the injector. Note：
specifications.
Note：
control solenoid.
1. Leak-off pipe
2. Clip
2. Connect the connector to the turbocharger control 1. Common rail assembly

solenoid. 2. Vacuum pipe
solenoid.
Note： 2. Install the common rail assembly to the cylinder
block.
specifications Note：
4. Install the bracket to the cylinder head cover. ・ Install the part together with the common rail
bracket.
diagram.
Caution：
19. Common rail assembly installation

1. Install the swirl control solenoid valve bracket to the

valve.
valve.
assembly.
Note：
1. Connector
in }
1. Injection pipe sleeve nut

1. Leak-off pipe
25. Leak off pipe installation

1. Install the leak-off pipe to the inlet manifold.
2. Connect the fuel leak-off hose to the leak-off pipe. 1. Fuel feed pipe
3. Connect the vacuum hose to the vacuum pipe. 28. Starter motor installation
26. Fuel hose connect 1. Install the starter motor to the rear plate.
1. Connect the fuel hose to the fuel supply pump. Tightening torque： 94 N・m { 9.6 kgf・m / 69 lb・ft }
head.
1. Fuel hose

Tightening torque： 44.1 N・m { 4.5 kgf・m / 33 lb・ 30. A/C compressor assembly connect
ft }
compressor bracket.
1. A/C compressor bracket 33. A/C compressor drive belt installation

2. A/C compressor
crankcase.

meter.
Note：
32. Tension pulley installation ・ The following is the belt tension adjusting
1. Install the tension pulley to the cylinder head. method based on belt deflection.
the amount of flex.
Load： 98 N { 10 kg / 22 lb }
Measurement point 2
Amount of belt
Frequency
deflection
： 12.5 to 16.5 mm
New ： 92 to 112 Hz
{ 0.492 to 0.650 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 3
Amount of belt
Frequency
deflection
： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 4
Amount of belt
Frequency
deflection
： 15.9 to 20.7 mm
New ： 70 to 86 Hz
Reuse ： 62 to 70 Hz 3. Measurement point 3
{ 0.815 to 0.933 in }
Note：
・ The following is the belt tension adjusting Note：
method with a sonic tension meter. ・ After adjusting the tension, tighten the
・ Measure the frequency at measurement point tensioner fixing nut.
2, 3, and 4 with a sonic tension meter. Tightening torque： 41 N・m { 4.2 kgf・m / 30 lb・ft }
Measurement point 2 35. Fan shroud installation
Amount of belt 1. Install the fan guide to the radiator.
Frequency
deflection
Note：
： 12.5 to 16.5 mm
New ： 92 to 112 Hz ・ Install the lower fan guide together with the fan
{ 0.492 to 0.650 in }
shroud.
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in } 36. Cooling fan installation
Measurement point 3 1. Install the cooling fan to the fan clutch assembly.
Amount of belt Tightening torque： 8 N・m { 0.8 kgf・m / 71 lb・in }
Frequency
deflection
： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 4
Amount of belt
Frequency
deflection
： 15.9 to 20.7 mm
New ： 70 to 86 Hz
{ 0.626 to 0.815 in }
： 20.7 to 23.7 mm
{ 0.815 to 0.933 in }
1. Fan clutch assembly Note：
2. Cooling fan ・ When the radiator reserve tank is dirty, clean it
1. Install the fan guide to the radiator. detergent.
Note：・ Scrub the inside with a detergent and water.
・ Install the upper fan guide. ・ Wash it thoroughly with clean water, and drain
the water.
1. Upper fan guide

2. Clip
3. Lower fan guide
4. Fan shroud
1. Battery cable
38. Radiator reserve tank installation 2. Battery bracket
1. Install the radiator reserve tank to the upper fan 3. Earth
guide.
Battery side
Frame side
Hose clip

radiator.
1. Radiator upper hose 43. Intake air duct installation
41. Intake air duct installation 1. Install the intake air duct to the turbocharger and the
intake hose.
and the intake hose. Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
Bolt
Bolt Tightening torque： 4 N・m { 0.4 kgf・m / 35 lb・in }
Clip
Clip
42. Boost sensor connect 1. Install the engine cover to the engine.


Note：
Note：
Note：
1. Engine cover
45. Fuel air bleed

Note：
1. Bolt
2. Clip
Note：
Note：
1. Priming pump 3. Install the rear under guard to the frame.
Note：
Caution：・ Tighten the 5 bolts.
46. Coolant filling
Note：
solution.
Note：
Standard： 65 ℃ { 149 °F }
Note：
・ Confirm that the pump unit difference learning
complete status display changes from Not
Learned to Learned.
Note：
・ Confirm that a scan tool does not detect a
DTC.

49. ECM writing
Note：
・ When replacing the fuel supply pump or
suction control valve, this procedure is
required.
6. Select the Actuator Test.
7. Select the Fuel Supply Pump Learn Resetting.
Note：
the ECM Fuel Pump Learning Status.
Note：
Learned.
Note：
Fuel filler cap
inspection
1. Fuel filler cap inspection
1. Inspect the fuel filler cap.
Note：
・ Inspect the seal state of the fuel cap.
1. Seal ring
Caution：
・ The same fuel cap must be used for
replacement.
・ It must be replaced with the same type
because the fuel filler cap is designed mainly
for this application.
・ Otherwise, it may cause the fall of the engine
performance.
Filler neck
removal Note：
1. Battery ground cable disconnect rear mud guards.
1. Open the engine hood assembly. 1. Remove the rear mud guard from the rear body.
2. Disconnect the battery ground cable from the battery. Note：
3. Raise vehicle using the jack. ・ Remove the 3 screws.
Note：
Caution：
foreign material from getting inside.
Note：
Note：
・ Remove the 3 screws. 1. Screw
2. J-type nut
3. Inner liner
4. Rear mud guard

Note：
front flaps.
front flaps.
1. J-type nut ・ Left side: Remove the 9 clips and the screw.
2. Inner liner ・ Right side: Remove the 8 clips and the screw.
3. Spats
4. Screw
Note：
4. Rear mud guard removal ・ Put a mark on each fixing section and band
clip of the clamp so that the filler neck
assembly can be installed to the original

positions.
1. Remove the filler neck from the rear body and the
fuel filler hose.
Note：
2. Disconnect the evaporator hose from the filler neck.
Note：
installation
Note：
each mark.
filler hose.
Note：
each mark.
Filler neck
in } Fuel tank side clamp 1. Screw
2. J-type nut
Tightening torque： 3 N・m { 0.31 kgf・m / 26.6 lb・ 3. Inner liner
in } Filler pipe side clamp 4. Rear mud guard
2. Inner liner installation
1. Install the inner liner to the rear body.
Note：
Note：・ The following applies to standard cabs.
front flaps.
・ Left side: Install the 7 clips. Note：
・ Right side: Install the 6 clips. ・ Install the 3 screws.
・ The following applies to standard cabs without ・ Securely insert the J-type nut until it hits the
front flaps. inner end of the panel.
Note：
rear mud guards.
Note：
Note：
1. J-type nut
2. Inner liner
3. Spats
4. Screw

Note：
times.
3. Lower vehicle.
Fuel tube
removal
1. Fuel tube safety information
Caution：
・ Do not light a match, or do not generate a
flame.
・ Avoid fire at the workshop, and prevent
inflammables from catching fire.
・ Disconnect the battery ground cable and
prevent electric short circuit.
・ When performing welding or similar heat-
generating work, preprocess the pipelines or
associated parts in order to protect them from
thermal damage or spattering.
・ Do not contact the assembly with the
electrolyte of the battery.
・ Do not wipe the assembly with the cloth that 1. Fuel tube
has been used to wipe the spilled electrolyte. 2. Fuel return tube
・ Do not use the piping to which the electrolyte
of the battery was scattered or the cloth that 5. Front flap removal
was soaked with the electrolyte of the battery Note：
after wiping the piping. ・ The following applies to standard cabs.
2. Battery ground cable disconnect 1. Remove the front flap from the rear body.
Note：
2. Disconnect the battery ground cable from the battery. ・ Remove the 3 screws.
Note：
Caution：
foreign material from getting inside.
4. Fuel tube disconnect
1. Disconnect the fuel tube from the fuel hose.
2. Disconnect the fuel return tube from the fuel hose.
1. J-type nut
2. Inner liner
3. Spats
4. Screw
6. Rear mud guard removal

Note： 1. Remove the filler neck from the rear body and the
・ The following applies to vehicles equipped with fuel filler hose.
rear mud guards. Note：
1. Remove the rear mud guard from the rear body. ・ Cover the ends of each hose and pipe to
Note：
・ Remove the 3 screws. 2. Disconnect the evaporator hose from the filler neck.
Note：
9. Fuel tank removal
1. Hold the fuel tank using the lifter.
Note：
・ Support the bottom of the fuel tank by using
the lifter.
2. Remove the fuel tank band from the frame.
1. Screw
2. J-type nut
3. Inner liner
4. Rear mud guard

Note：
front flaps.
front flaps. Note：
・ Left side: Remove the 10 clips. ・ Lower the lifter and remove the fuel tank from
・ Right side: Remove the 9 clips. the vehicle.
・ The following applies to wide cabs. Caution：
・ Left side: Remove the 9 clips and the screw. ・ Do not damage the hose or the tube by
・ Right side: Remove the 8 clips and the screw. contacting with other parts.
8. Filler neck removal 10. Fuel tube removal
Note： 1. Clean the fuel tube using air.

・ Put a mark on each fixing section and band Note：
clip of the clamp so that the filler neck ・ Remove the dirt on the quick connector fitting
assembly can be installed to the original by using compressed air.
positions.
2. Remove the fuel tube from the fuel gauge unit. Caution：
Note：・ Cover the removed connector with a plastic
bag to prevent dust or rain water from
・ To remove the quick connector, hold the quick
entering.
connector with one hand while pushing the
square release button of the connector as
shown in the diagram, and pull out the
connector with the other hand.
1. O-ring
2. Port
3. Connector
4. Plastic tube
Caution：
・ Do not use any tool.
・ When disconnecting the connector, remove it
with bare hands.
・ Use lubricating oil, or push and pull the
connector until the pipe is disconnected.
・ Securely connect the connector to the stopper.
1. Fuel tube installation
3. Install the fuel tank band to the frame.
1. Inspect the fuel tube.
Note：
Caution：
・ If there are flaws, dents, or cracks, replace the
port and connector. ・ Securely install the anchor of the tank band to
・ When installing a connector, remove dust
collected on the port.
・ If there is rust, dents, or damage, replace the
connector.
2. Install the fuel tube to the fuel gauge unit.
Note：
・ Insert the connector straight until it clicks.
・ After the connector clicks, pull it out with the
force of 49 N {5 kg /11 lb}, and securely lock it
so as not to be drawn in.

Note：
each mark.
filler hose.
Note：
Note：
・ Advice on assembly
each mark.
・ Applying engine oil or diesel oil to the pipe
makes port installation easy. Tightening torque： 6 N・m { 0.6 kgf・m / 53 lb・in }
Filler neck
・ Install immediately after applying oil.
2. Fuel tank installation
in } Fuel tank side clamp
1. Install the fuel tank to vehicle.
Caution： in } Filler pipe side clamp
・ Do not damage the hose or the tube by 4. Inner liner installation
contacting with other parts.
1. Install the inner liner to the rear body.
Note：
Note：
・ Put the fuel tank on the lifter and install the fuel
tank by elevating the lifter. ・ The following applies to standard cabs with
front flaps.
2. Connect the connector to the fuel gauge unit.
・ Right side: Install the 6 clips. ・ Securely insert the J-type nut until it hits the
・ The following applies to standard cabs without inner end of the panel.
front flaps.
Note：
rear mud guards.
Note：
Note： 1. J-type nut
2. Inner liner
3. Spats
4. Screw
7. Fuel tube connect

1. Screw
2. J-type nut
3. Inner liner
4. Rear mud guard

1. Fuel tube
Note： 2. Fuel return tube
Note：
Note：
times.
9. Fuel air bleed
Note：
1. Priming pump
Caution：
3. Lower vehicle.
11. Fuel inspection
Note：
12. Fuel tube inspection
Note：
・ Start the engine and observe the engine idle
speed.
・ Dust in the fuel system may affect the fuel
injection system.
2. Inspect the fuel tube.
Note：
・ Check for fuel leakage.
Fuel sedimenter switch
removal
switch.
assembly.
Note：
spilling.
1. Element case
4. Remove the fuel filter from the fuel filter bracket.
3. Fuel sedimenter switch removal

1. Remove the element case from the fuel filter body.
Note：
・ Do not reuse the O-ring and gasket.
inspection
1. Fuel sedimenter switch inspection
1. Check continuity of the fuel sedimenter switch.
Note：
・ Confirm that there is continuity between the
switch connector terminals when the float of
the fuel sedimenter is above the drain line.
switch.
4. Check lighting of the warning light.
Note：
・ Connect the connector terminal to the harness
side, and confirm that the sedimenter warning
light turns on.
・ If any abnormality is found in the inspection,
replace the switch section and repair any
connection failure or open circuit between the
circuits.
1. Sensor
2. Vehicle-side connector
3. Harness
4. Drain valve
installation 1. Press the priming pump.

Note：
1. Fuel sedimenter switch installation
1. Install the element case to the fuel filter body.
1. Priming pump
1. Element case 2. Fuel filter with sedimenter
2. Fuel filter installation Caution：
1. Install the fuel filter to the fuel filter bracket. ・ Insufficient air removal work may lead to
2. Connect the fuel hose to the fuel filter assembly. malfunction of the engine.
Note： 4. Battery ground cable connect

・ Connect the feed hose and the return hose. 1. Connect the battery ground cable to the battery.
3. Connect the harness connector to the pressure 2. Close the engine hood assembly.
switch.
3. Fuel air bleed

Fuel filter switch
inspection
1. Fuel filter switch inspection
1. Inspect the fuel filter switch using the circuit tester.
Note：
・ Attach the circuit tester on the terminals of the
fuel filter switch and confirm that no continuity
exists.
・ If there is continuity, replace the part.
2. Install the vacuum pump to the fuel filter.
Note：
・ Install a vacuum pump to the engine-side pipe
of the fuel filter.
・ Seal the pipe on the fuel tank side.
Caution：
・ Be careful to prevent fuel from entering the
vacuum pump.
3. Inspect the fuel filter switch using the circuit tester.
Note：
・ Generate a negative pressure with the vacuum
pump and inspect that continuity exists at the
specified pressure value.
Specified pressure： -38 to -42 kPa { -0.39 to -0.43 kgf/
cm2 / 285 to 315 mmHg }
Note：
・ If there is no continuity, replace the part.
Fuel filter
removal
switch.
assembly.
Note：
spilling.
4. Remove the fuel filter from the fuel filter bracket.
installation 2. Fuel filter with sedimenter
1. Fuel filter installation Caution：

1. Install the fuel filter to the fuel filter bracket. ・ Insufficient air removal work may lead to
2. Connect the fuel hose to the fuel filter assembly.
Note：
・ Connect the feed hose and the return hose.
3. Connect the harness connector to the pressure
switch.
2. Fuel air bleed

Note：
1. Priming pump
・ Fuel filter assembly
1. Fuel filter sensor 5. Fuel return hose

2. Priming pump 6. Fuel feed hose, supply pump side
3. Fuel feed hose, fuel tank side
4. Fuel filter assembly
Note：
・ Fuel injector
1. Injector 5. Injection pipe

2. Injector clamp 6. Common rail assembly
3. Injector clamp bolt 7. Fuel supply pump
4. Injector leak-off hose
Note：
・ Common rail assembly
1. Common rail assembly 2. Common rail bracket
Note：
・ Fuel supply pump
1. Supply pump gear nut 4. Fuel supply pump

2. Sprocket
3. Supply pump gear
Note：
・ Suction control valve
1. Fuel supply pump 3. Suction control valve

2. O-ring
Note：
・ Fuel tank
1. Fuel tube 5. Fuel tank band

2. Fuel tank 6. Fuel return tube
3. Fuel filler hose
4. Breather hose
Note：
・ Fuel gauge unit
1. Retainer ring 4. Fuel tank

2. Fuel tank unit
3. O-ring

・ Fuel injector
1： 25 N・m { 2.5 kgf・m / 18 lb・ft } Note：

2： 29.5 N・m { 3.0 kgf・m / 22 lb・ft } ・ Common rail assembly
3： 7.8 N・m { 0.8 kgf・m / 69 lb・in }


2： 10 N・m { 1.0 kgf・m / 89 lb・in } Note：
3： 15 N・m { 1.5 kgf・m / 11 lb・ft } ・ Fuel supply pump
1： 25 N・m { 2.5 kgf・m / 18 lb・ft }

2： 130 N・m { 13.3 kgf・m / 96 lb・ft }
Cooling (4JK1) 1D-1
Engine
Cooling
(4JK1)
Table of Contents
Coolant............................................................................1D-2
inspection....................................................................1D-2
Cooling fan belt...............................................................1D-4
removal.......................................................................1D-4
inspection....................................................................1D-6
installation..................................................................1D-7
Water pump assembly...................................................1D-10
removal.....................................................................1D-10
inspection..................................................................1D-14
installation................................................................1D-15
Thermostat.....................................................................1D-20
removal.....................................................................1D-20
inspection..................................................................1D-22
installation................................................................1D-23
Engine coolant temperature sensor...............................1D-25
removal.....................................................................1D-25
inspection..................................................................1D-27
installation................................................................1D-28
Cooling fan clutch.........................................................1D-29
removal.....................................................................1D-29
inspection..................................................................1D-33
installation................................................................1D-34
Radiator.........................................................................1D-39
removal.....................................................................1D-39
inspection..................................................................1D-42
installation................................................................1D-44
Radiator cap..................................................................1D-48
removal.....................................................................1D-48
inspection..................................................................1D-49
installation................................................................1D-50
A/C compressor drive belt............................................1D-51
removal.....................................................................1D-51
inspection..................................................................1D-52
installation................................................................1D-53
Supplementary Information..........................................1D-55
1D-2 Cooling (4JK1)
Coolant
inspection Note：
・ Inspection of coolant leaks
1. Coolant inspection
2. Inspect water leak using the radiator cap tester.
Note：
Note：
・ Inspection of the coolant level
・ Apply the pressure specified below, and
1. Inspect coolant. inspect the locations described below for a
Note： leak.
・ Inspect the coolant level in the reserve tank, Pressure： 196 kPa { 2.0 kgf/cm2 }
and when the level is between MAX and MIN,
then the level is appropriate. Inspection points for coolant leakage
・ Open the radiator cap and confirm that the Radiator
radiator is filled with the coolant up to the filler Water pump
portion inside the radiator. Parts
Radiator hose
Caution： Heater hose
・ Make sure to inspect the coolant level only
when the engine is cool.
Note：
・ If the coolant is insufficient, remove the cap of
the reserve tank and refill the coolant to the
level around the MAX line.
Reference amount of coolant
Manual transmission ： 8.7 L { 1.91 Imp.gal }
Automatic transmission ： 8.6 L { 1.89 Imp.gal }
Note：
・ Reference replacement period: Every 2 years
Note：
・ Engine coolant concentration
3. Set concentration to a standard value.
Note：
・ The concentration of the engine coolant affects
its freezing temperature. Therefore, the
concentration should be adjusted to the lowest
atmospheric temperature.
・ Use the genuine Isuzu engine coolant.
・ When the mixing ratio of the engine coolant is
60 % or higher, it overheats easily, and when it
is 30 % or lower, it cannot sufficiently prevent
1. Radiator reserve tank corrosion. Therefore, make sure to use the
2. MAX engine coolant with a specified concentration.
3. MIN ・ If the engine coolant with concentrations other
than a specified one is used, the anti-freezing
Cooling (4JK1) 1D-3
performance may decrease, causing freezing

to occur.
Long life coolant concentration

Warm region, up to -12 Cold region, up to -30
℃ {10 °F} ℃ {- 22 °F}
Isuzu genuine coolant ： 30 % ： 50 %
Other than Isuzu genuine
： 50 % ： 50 %
coolant
Note： Note：
・ However, if the engine or vehicle is used at -30 ・ After measuring the temperature and specific
℃ {- 22 °F} or below, the coolant concentration gravity, find the concentration from the table
of 55% is recommended. below.
・ Measurements of engine coolant concentration
・ Hydrometry
4. Measure coolant using hydrometer.
Note：
・ Use an antifreeze hydrometer and
thermometer to measure the specific gravity
and coolant temperature.
Caution：
・ Be aware that the coolant bursts out when the
cap is removed while the engine is still hot.
Note：
・ Use a container that has a depth larger than
the length of the hydrometer.
Note：
・ Coolant scope method
・ Measure the concentration using a coolant
scope.
1. Radiator
2. Hydrometer
Note：
・ The temperature of the coolant should be
within the specified range.
Specified temperature： 0 to 50 ℃ { 32 to 122 °F }
1D-4 Cooling (4JK1)
Cooling fan belt
removal
Note：

2. MAF sensor
3. Blow-by hose
4. Intake pipe

pulley.

cover.
sensor.
Note：
specifications.
assembly. 1. A/C compressor drive belt
4. Disconnect the intake pipe from the turbocharger 6. Cooling fan belt removal
assembly. 1. Loosen the adjust bolt using a wrench.
5. Remove the air cleaner assembly from vehicle. Note：
generator.
Cooling (4JK1) 1D-5
1D-6 Cooling (4JK1)
inspection Note：
1. Cooling fan belt inspection plate lock bolt and the mounting bolt under the
1. Inspect the cooling fan belt. generator.
Note： Generator tightening torque
・ Inspect the belt for worn and damage, and ： 40 N・m { 4.1 kgf・m /
Mounting bolt
replace it with a new one as necessary. 30 lb・ft }
・ Adjust the tension of the cooling fan belt as ： 25 N・m { 2.5 kgf・m /
necessary. 18 lb・ft }
2. Inspect tension. Note：
Note：・ If the cooling fan belt is replaced with a new
・ The following is the belt tension adjusting one, make the new cooling fan belt fit in to
method based on belt deflection. cope with initial elongation.
・ Apply a load to measurement point 1 of the ・ After making the cooling fan belt fit in, adjust
cooling fan belt and adjust the amount of flex. its tension once again.
Load： 98 N { 10 kg / 22 lb }
Note：
： 5.4 to 6.6 mm
New ： 188 to 210 Hz
{ 0.213 to 0.260 in }
： 7.7 to 8.5 mm
{ 0.303 to 0.335 in }
Cooling (4JK1) 1D-7
1. Cooling fan belt installation plate lock bolt and the mounting bolt under the
1. Install the cooling fan belt to the pulley. generator.
2. Cooling fan belt adjustment Generator tightening torque
Mounting bolt
meter. 30 lb・ft }
： 25 N・m { 2.5 kgf・m /
18 lb・ft }
Note：
cooling fan belt and adjust the amount of flex. 3. A/C compressor drive belt installation
Load： 98 N { 10 kg / 22 lb } 1. Install the A/C compressor drive belt to the pulley.
Note：
： 5.4 to 6.6 mm
New ： 188 to 210 Hz
{ 0.213 to 0.260 in }
： 7.7 to 8.5 mm
{ 0.303 to 0.335 in }

meter.
Note：
the amount of flex.

Amount of belt
4. Measurement point 4 Frequency
deflection
1D-8 Cooling (4JK1)
： 12.5 to 16.5 mm
New ： 92 to 112 Hz
{ 0.492 to 0.650 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 3
Amount of belt
Frequency
deflection
： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 4
Amount of belt
Frequency
deflection
： 15.9 to 20.7 mm
New ： 70 to 86 Hz
Reuse ： 62 to 70 Hz 3. Measurement point 3
{ 0.815 to 0.933 in }
Note：
・ The following is the belt tension adjusting Note：
method with a sonic tension meter. ・ After adjusting the tension, tighten the
・ Measure the frequency at measurement point tensioner fixing nut.
2, 3, and 4 with a sonic tension meter. Tightening torque： 41 N・m { 4.2 kgf・m / 30 lb・ft }
Measurement point 2 5. Air cleaner assembly installation
Amount of belt 1. Install the air cleaner assembly to vehicle.
Frequency
deflection
： 12.5 to 16.5 mm
New ： 92 to 112 Hz
{ 0.492 to 0.650 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 3
Amount of belt
Frequency
deflection
： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 4
Amount of belt
Frequency
deflection
： 15.9 to 20.7 mm
New ： 70 to 86 Hz
{ 0.626 to 0.815 in }
： 20.7 to 23.7 mm 1. Air cleaner assembly
Reuse ： 62 to 70 Hz 2. MAF sensor
{ 0.815 to 0.933 in }
3. Blow-by hose
4. Intake pipe
Cooling (4JK1) 1D-9
assembly.
Note：
specifications.
assembly.
pressure sensor.
intake hose.
Bolt
Clip

1D-10 Cooling (4JK1)
Water pump assembly
removal
Note：
Note：
3. Coolant drain
Note：
radiator.
1. Bolt
2. Clip
Note：
Note：
pressure.
Cooling (4JK1) 1D-11
1. Engine cover 7. Radiator upper hose removal
5. Intake air duct removal 1. Remove the radiator upper hose from the water
Note：

6. Radiator reserve tank removal sensor.
1. Disconnect the radiator reserve tank hose from the 2. Disconnect the harness connector from the
radiator. barometric pressure sensor.
2. Remove the radiator reserve tank from the upper fan Note：
guide. ・ The following applies to the high-output
specifications.
assembly.
assembly.
1. Upper fan guide

2. Clip
3. Lower fan guide
2. MAF sensor
4. Fan shroud
3. Blow-by hose
4. Intake pipe 11. A/C compressor drive belt removal
9. Generator cover removal pulley.
adjust plate.

Note：
Note：
・ Remove the clips and bottom locks on both generator.
assembly.
Note：

assembly.
gear case.
inspection
1. Water pump assembly inspection
1. Inspect the water pump assembly.
Note：
・ The water pump assembly cannot be
disassembled.
・ If excessive wear or damage is found, replace
the water pump assembly.
・ If cracks are found on the water pump body,
replace the water pump assembly.
・ If coolant leakage from the seal unit is found,
・ If excessive radial play during manual rotation
of the fan center or abnormal sounds are
found, replace the water pump assembly.
・ If cracks or corrosion is found on the impeller,
・ If excessive thrust play of the fan center is
found, replace the water pump assembly.
Standard： 0.2 mm { 0.0079 in } or less
installation Tightening torque： 8 N・m { 0.8 kgf・m / 71 lb・in }

case. 5. A/C compressor drive belt installation
Note： 1. Install the A/C compressor drive belt to the pulley.
pump assembly.

meter.
Note：
3. Cooling fan clutch installation ・ Move the generator to adjust the tension.
1. Install the cooling fan clutch to the water pump 2. Check tension of the cooling fan belt.
assembly.
Note：
Note：
・ Install the part together with the cooling fan. method based on belt deflection.
Load： 98 N { 10 kg / 22 lb }
Note：
： 5.4 to 6.6 mm
New ： 188 to 210 Hz
{ 0.213 to 0.260 in }
： 7.7 to 8.5 mm
{ 0.303 to 0.335 in }
： 12.5 to 16.5 mm
New ： 92 to 112 Hz
{ 0.492 to 0.650 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 3
Amount of belt
Frequency
deflection
： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 4
Amount of belt
Frequency
deflection
： 15.9 to 20.7 mm
New ： 70 to 86 Hz
1. Measurement point 1 { 0.626 to 0.815 in }
2. Measurement point 2 ： 20.7 to 23.7 mm
3. Measurement point 3 Reuse ： 62 to 70 Hz
{ 0.815 to 0.933 in }
Note：
Note：・ The following is the belt tension adjusting
・ After adjusting the tension, tighten the adjust method with a sonic tension meter.
plate lock bolt and the mounting bolt under the ・ Measure the frequency at measurement point
generator. 2, 3, and 4 with a sonic tension meter.
： 25 N・m { 2.5 kgf・m / ： 12.5 to 16.5 mm
18 lb・ft } { 0.492 to 0.650 in }
Note：： 16.5 to 19.1 mm
・ If the cooling fan belt is replaced with a new { 0.650 to 0.752 in }
Measurement point 3
Amount of belt
・ After making the cooling fan belt fit in, adjust Frequency
deflection
： 12.4 to 16.4 mm
7. A/C compressor drive belt adjustment New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
1. Adjust tension to a standard value using a tension ： 16.5 to 19.1 mm
meter. { 0.650 to 0.752 in }
Note： Measurement point 4
・ The following is the belt tension adjusting Amount of belt
method based on belt deflection. Frequency
deflection
・ Apply a load to measurement points 2, 3, and ： 15.9 to 20.7 mm
4 of the A/C compressor drive belt and adjust New ： 70 to 86 Hz
{ 0.626 to 0.815 in }
the amount of flex.
： 20.7 to 23.7 mm
Load： 98 N { 10 kg / 22 lb } { 0.815 to 0.933 in }
Measurement point 2
Amount of belt
Frequency
deflection
adjust plate.
Note：
tensioner fixing nut. 1. Install the air cleaner assembly to vehicle.
Note：

2. MAF sensor
3. Blow-by hose
4. Intake pipe

assembly.
1. Upper fan guide
2. Clip Tightening torque： 4 N・m { 0.4 kgf・m / 35 lb・in }
3. Lower fan guide
4. Fan shroud
Note：
specifications.
assembly.
pressure sensor.
Hose clip

radiator.
Note：
detergent.
the water.
intake hose.
12. Radiator reserve tank installation Tightening torque： 4 N・m { 0.4 kgf・m / 35 lb・in }
Clip
guide.
14. Engine cover installation Note：
1. Install the engine cover to the engine. ・ Tighten the 4 bolts.
Note：
1. Engine cover

Note：
16. Coolant filling
Note：
Note：
solution.
Note：
3. Lower vehicle.
1. Bolt
2. Clip
Note：
Thermostat
removal Note：
Note：
Note：
1. Engine cover

Note：
Note：
radiator.
1. Bolt
2. Clip
2. Remove the radiator cap from the radiator. Caution：
Warning：・ Take care not to damage the thermostat.
pressure.
1. Front
2. Thermostat
3. Jiggle valve
5. Water outlet pipe removal

2. Remove the water outlet pipe from the cylinder head.
inspection
1. Thermostat inspection
1. Inspect the thermostat.
Note：
・ Make the necessary adjustments, repairs, and
part replacements if excessive worn or
damage is found.
2. Measure the thermostat using the engine coolant
temperature gauge.
Note：
・ Place the thermostat in water completely.
・ Heat the water.
・ Stir water continually to avoid directly heating
the thermostat.
・ Check the valve temperature of the
thermostat.
Initial valve-opening
： 85 ℃ { 185 °F }
temperature
Full-open temperature ： 100 ℃ { 212 °F }
Valve lift amount at full-
： 10 mm { 0.39 in }
open
1. Piece of wood
2. Stirring stick
installation 3. Radiator upper hose installation

1. Thermostat installation
Note： Hose clip
1. Front 4. Coolant filling

2. Thermostat 1. Replenish the radiator with coolant.
3. Jiggle valve
Note：
2. Water outlet pipe installation ・ Use the coolant contains 50 % anti-freeze
solution.
1. Install the water outlet pipe to the cylinder head
assembly. ・ Pour the coolant up to the filler neck.
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } 2. Replenish the radiator reserve tank with coolant.
Note：
Note：
Note：

water outlet pipe.
1. Bolt 1. Engine cover

2. Clip
Note：
Note：
Note：

removal
Note：
Note：
3. Coolant drain
Note：
radiator.
1. Bolt
2. Clip
Note：
Note：
3. Remove the rear under guard from the frame. 2. Remove the radiator cap from the radiator.
Note： Warning：
・ Remove the 4 bolts. ・ In order to prevent burns, do not open the cap
pressure.
4. Engine coolant temperature sensor removal
1. Disconnect the connector from the engine coolant
temperature sensor.
1. Water outlet pipe

2. Engine coolant temperature sensor
2. Remove the engine coolant temperature sensor from

the cylinder head assembly.
inspection ： 50 ℃ { 122 °F } ： 840 Ω

： 40 ℃ { 104 °F } ： 1200 Ω
1. Engine coolant temperature sensor inspection
： 30 ℃ { 86 °F } ： 1730 Ω
Note：
： 20 ℃ { 68 °F } ： 2560 Ω
・ The ECM engine coolant temperature sensor
： 10 ℃ { 50 °F } ： 3870 Ω
is a thermistor type sensor which has a
characteristic of decreasing electrical ： 0 ℃ { 32 °F } ： 6000 Ω
resistance as the temperature rises. ： -10 ℃ { 14 °F } ： 9200 Ω
1. Measure a resistance using the circuit tester. ： -20 ℃ { -4 °F } ： 15700 Ω
： -30 ℃ { -22 °F } ： 26500 Ω
Note：
・ Put the temperature sensing section of the
engine coolant temperature sensor into water,
and confirm if the resistance value correspond
to the values in the thermistor characteristic
graph while changing the water temperature.
・ Measure the resistance between the terminals.
Note：
・ If any abnormality is found in the resistance
value, replace the engine coolant temperature
sensor.
Caution：
・ Be careful not to allow water to get into the
terminal section.
・ Wipe off the water droplets on the sensor after
the inspection.
Note：
・ Temperature vs resistance value, approximate
value
Temperature Resistance value
： 120 ℃ { 248 °F } ： 115 Ω
： 110 ℃ { 230 °F } ： 150 Ω
： 100 ℃ { 212 °F } ： 190 Ω
： 90 ℃ { 194 °F } ： 250 Ω
： 80 ℃ { 176 °F } ： 330 Ω
： 70 ℃ { 158 °F } ： 450 Ω
： 60 ℃ { 140 °F } ： 610 Ω
1. Engine coolant temperature sensor installation
1. Apply thread locking adhesive to the engine coolant
temperature sensor.
Note：
portion.
2. Install the engine coolant temperature sensor to the
Tightening torque： 20 N・m { 2.0 kgf・m }
1. Bolt
2. Clip
Note：
Note：
1. Water outlet pipe Note：
2. Engine coolant temperature sensor ・ Tighten the 5 bolts.
3. Connect the connector to the engine coolant
temperature sensor.
2. Coolant filling
Note：
solution.
Note：
Note：
Cooling fan clutch
removal
Note：
Note：
3. Coolant drain
Note：
radiator.
1. Bolt
2. Clip
Note：
Note：
pressure.
Note：

6. Radiator reserve tank removal sensor.
1. Disconnect the radiator reserve tank hose from the 2. Disconnect the harness connector from the
radiator. barometric pressure sensor.
2. Remove the radiator reserve tank from the upper fan Note：
guide. ・ The following applies to the high-output
specifications.
assembly.
assembly.
1. Upper fan guide

2. Clip
3. Lower fan guide
2. MAF sensor
4. Fan shroud
3. Blow-by hose
4. Intake pipe 11. A/C compressor drive belt removal
9. Generator cover removal pulley.
adjust plate.

Note：
Note：
・ Remove the clips and bottom locks on both generator.
assembly.
Note：

assembly.
assembly.

2. Cooling fan
inspection
1. Cooling fan clutch inspection
1. Inspect the cooling fan clutch.
Note：
・ If any worn, damage, or other abnormalities
are found, repair or replace the defective parts.
・ Visually inspect for abnormalities such as
silicone grease leak.
・ Vehicle inspection
・ Rotate the fan clutch by hand while the engine
is still cool before starting, and confirm that it
rotates easily.
・ Start the engine and warm it up until the
temperature of the fan clutch section reaches
about 85 ℃ {185 ℉}.
・ Then, stop the engine, and confirm that 1. Hot air gun
considerable labor and clutch torque are 2. Thermistor
necessary to rotate the fan clutch by hand.
・ If the fan clutch is easier to rotate, that
indicates that silicone grease leaks inside.
Replace it with a new one.
Note：
・ Unit inspection
・ When measuring with a thermistor, warm the
bimetal of the fan clutch with a hot air gun until
the temperature reaches about 85 ˚C {185 ˚F}.
・ Then, confirm that considerable labor and
clutch torque are necessary to rotate the fan
clutch.
・ If the fan clutch is easy to rotate, that indicates
that silicone grease leaks inside. Replace it
with a new one.
installation 1. Install the cooling fan belt to the pulley.

1. Fan clutch assembly 6. Cooling fan belt adjustment

2. Cooling fan 1. Adjust tension to a standard value using a tension
meter.
Note：
assembly. Note：
Note：
Load： 98 N { 10 kg / 22 lb }
Note：
： 5.4 to 6.6 mm
New ： 188 to 210 Hz
{ 0.213 to 0.260 in }
： 7.7 to 8.5 mm
{ 0.303 to 0.335 in }

： 12.5 to 16.5 mm
New ： 92 to 112 Hz
{ 0.492 to 0.650 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 3
Amount of belt
Frequency
deflection
： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 4
Amount of belt
Frequency
deflection
： 15.9 to 20.7 mm
New ： 70 to 86 Hz
1. Measurement point 1 { 0.626 to 0.815 in }
2. Measurement point 2 ： 20.7 to 23.7 mm
3. Measurement point 3 Reuse ： 62 to 70 Hz
{ 0.815 to 0.933 in }
Note：
・ After adjusting the tension, tighten the adjust method with a sonic tension meter.
plate lock bolt and the mounting bolt under the ・ Measure the frequency at measurement point
generator. 2, 3, and 4 with a sonic tension meter.
： 25 N・m { 2.5 kgf・m / ： 12.5 to 16.5 mm
18 lb・ft } { 0.492 to 0.650 in }
Note：： 16.5 to 19.1 mm
Measurement point 3
Amount of belt
・ After making the cooling fan belt fit in, adjust Frequency
deflection
： 12.4 to 16.4 mm
{ 0.488 to 0.646 in }
meter. { 0.650 to 0.752 in }
・ The following is the belt tension adjusting Amount of belt
deflection
・ Apply a load to measurement points 2, 3, and ： 15.9 to 20.7 mm
{ 0.626 to 0.815 in }
the amount of flex.
： 20.7 to 23.7 mm
Load： 98 N { 10 kg / 22 lb } { 0.815 to 0.933 in }
Measurement point 2
Amount of belt
Frequency
deflection
adjust plate.
Note：
tensioner fixing nut. 1. Install the air cleaner assembly to vehicle.
Note：

2. MAF sensor
3. Blow-by hose
4. Intake pipe
1. Upper fan guide 2. Connect the intake pipe to the turbocharger

2. Clip assembly.
3. Lower fan guide
4. Fan shroud
Note：
specifications.
assembly.
pressure sensor.
Hose clip

radiator.
Note：
detergent.
the water.
intake hose.
12. Radiator reserve tank installation Tightening torque： 4 N・m { 0.4 kgf・m / 35 lb・in }
Clip
guide.
Note：
1. Engine cover

Note：
16. Coolant filling
Note：
Note：
solution.
Note：
3. Lower vehicle.
1. Bolt
2. Clip
Note：
Radiator
removal
Note：
Note：
3. Coolant drain
Note：
radiator.
1. Bolt
2. Clip
Note：
Note：
pressure.
Note：

6. Radiator reserve tank removal Note：
1. Disconnect the radiator reserve tank hose from the ・ Remove the clips and bottom locks on both
radiator. sides and remove the upper fan guide.
guide.
1. Upper fan guide 1. Radiator lower hose

2. Clip
3. Lower fan guide 12. ATF hose disconnect
4. Fan shroud 1. Disconnect the ATF hose from the radiator.
9. Cooling fan removal 13. Radiator removal
1. Remove the cooling fan from the fan clutch 1. Remove the bracket from the radiator.
assembly.
2. Remove the radiator from vehicle.
Note：
・ Be careful not to damage the radiator core with
the fan blades. Suspend the radiator together
with the hose and remove them.

2. Cooling fan

Note：
fan shroud.
inspection Note：
・ Cleaning the inside of the radiator and the
1. Radiator inspection water path.
1. Inspect the radiator. ・ Wash the inside of the radiator and coolant
Note： path with water.
・ A bent fin causes ventilation to fall, and may ・ Remove all scales and rust.
cause overheat. ・ Washing the radiator core
・ Any bent fin must be straightened. Caution：
・ When straightening, pay attention especially to ・ Do not apply high-pressure washing to the
the bottom of the fin. radiator, intercooler, and peripheral parts while
・ Remove filth, insects, or any other foreign they are installed in the vehicle.
matter. Note：
2. Clean the radiator using detergent. ・ Seal the hose connection with a cap or fabric
Note： tape.
・ Wash the inside of the radiator and the engine ・ Wet the front and rear surfaces of the radiator
coolant path with water and a mild detergent. sufficiently.
・ Remove every sign of scales and rust. ・ For fouling that can be removed by splashing
tap water, thoroughly wash them off.
3. Inspect the radiator using the radiator cap tester. ・ Do not use a high-pressure washing machine
Note： or brush.
・ Send the air of the specified pressure from the 2. Apply detergent to the radiator.
filler neck to the radiator using a radiator cap
tester. Note：
・ Leakage from the radiator ・ Apply a type of mild detergent which contains
approximately 8 % of surface acting agent,
・ Leakage from the coolant pump and leave it for 10 minutes.
・ Leakage from the water hose ・ Use of material other than mild detergent may
・ Confirm the bulge of the rubber hose. cause corrosion.
・ Spray mild detergent on the front and rear
surfaces of the fin, and leave it for 10 minutes.
3. Clean the radiator using the high-pressure washing
machine.
Note：
・ Wash off mild detergent with a high-pressure
washing machine.
・ Wash the radiator from the engine side.
・ Apply high-pressure water perpendicular to the
fins.
・ Do not bring the high-pressure water too close
to the fins.
Caution：
・ Watch for deformation of the fins.
Note：
・ Clean the radiator core if it is found dirty.
2. Radiator cleaning
1. Clean the radiator using tap water.
1. Radiator
Note：
・ After washing, inspect the fins to confirm that
dirt has been completely washed off.
・ If washing is insufficient, wash them again.
・ If dirt remains, fine black particles are seen
attached on the fins.
4. Clean the radiator using tap water.
Note：
・ Wash off detergent ingredients on the fins and
resin parts thoroughly with the tap water.
・ Remove the seal on the hose connection.
・ Thoroughly clean and dry the hose connection.
installation
1. Radiator installation
1. Install the radiator to vehicle.
Note：
・ Be careful not to damage the radiator core with
the fan blades. Install the radiator together with
the hose as a unit.
2. Install the bracket to the radiator.
Note：
・ Support the radiator upper tank with the
bracket to fix the radiator.

Note：
shroud.
2. ATF hose connect

1. Connect the ATF hose to the radiator.
Hose clip

2. Cooling fan

Note：
1. Upper fan guide 2. Connect the radiator reserve tank hose to the
2. Clip radiator.
3. Lower fan guide
Note：
4. Fan shroud
7. Radiator upper hose installation before installation.
1. Install the radiator upper hose to the water outlet ・ Clean the radiator reserve tank using
pipe and the radiator. detergent.
Hose clip ・ Wash it thoroughly with clean water, and drain
the water.
intake hose.
Bolt
Clip

guide.
Note：
1. Engine cover

Note：
12. Coolant filling
Note：
Note：
solution.
Note：
13. Coolant air bleed
Note：
・ Idle the engine for 2 to 3 minutes.
2. Stop the engine.
4. Inspect water level.
Note：
1. Bolt
2. Clip ・ If the water level is low, refill the water.
Warning：
Note：
・ Do not loosen or remove the radiator cap
・ The following applies to 4WD. when the coolant is heated to a high
2. Install the front under guard to the frame. temperature.
・ Otherwise, you might be burnt with hot vapor

or boiling water.
・ To opening the radiator cap, place a folded
thick cloth over the cap when the coolant is
cooled, and turn it gradually to release the
pressure before opening it.
Note：
・ Warm up the engine at approximately 2000 r/
min.
・ Set the temperature adjustment of the heater
to the maximum temperature and circulate the
coolant in the heater water system.
・ Confirm that the thermostat has opened
according to the position of the engine coolant
temperature gauge indicator, and then idle the
engine for about 5 minutes.
7. Stop the engine.
Caution：
・ Remove the engine after it gets cold.
9. Inspect water level.
Note：
・ Check the water level at the filler neck and add
more if necessary.
・ If the coolant is excessively low, inspect the
coolant path and reserve tank hose for leaks.
Note：
3. Lower vehicle.
Radiator cap
removal
1. Radiator cap removal
Caution：
・ Do not loosen or remove the radiator cap
when the coolant is hot.
・ Steam and boiling water may burst out causing
burns or heat related injuries.
・ When opening the radiator cap, place a thick
cloth over the cap when the coolant is cooled,
and turn it gradually to release the pressure
before opening it.
inspection
1. Radiator cap inspection
1. Inspect the radiator cap.
Note：
damage is found.
2. Measure the radiator cap using the radiator cap
tester.
Note：
・ Measure the open valve pressure of the
pressure valve.
・ Replace the cap if the open valve pressure is
not at the standard value.
Standard： 93.3 to 122.7 kPa { 0.95 to 1.25 kgf/cm2 /
13.5 to 17.8 psi }
SST: 5-8840-0277-0 - radiator cap tester
SST: 5-8840-2603-0 - adapter

3. Inspect the radiator cap.
Note：
・ Check the condition of the negative pressure
valve in the center of the valve seat side.
・ If there are remarkable rust and dirt or the
valve seat cannot be operated smoothly by
hand, clean or replace the cap.
4. Measure the radiator cap using the radiator cap
tester.
Note：
・ Measure the open valve negative pressure.
Standard： 1.96 to 4.91 kPa { 0.02 to 0.05 kgf/cm2 /
0.28 to 0.71 psi }
installation
1. Radiator cap installation
A/C compressor drive belt
removal
1. Engine cover

pulley.

inspection ： 12.5 to 16.5 mm

New ： 92 to 112 Hz
{ 0.492 to 0.650 in }
1. A/C compressor drive belt inspection
： 16.5 to 19.1 mm
1. Inspect the A/C compressor drive belt. { 0.650 to 0.752 in }
・ Inspect the belt for worn and damage, and Amount of belt
replace it with a new one as necessary. Frequency
deflection
・ Adjust the tension of the A/C compressor drive ： 12.4 to 16.4 mm
belt as necessary. New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
2. Inspect tension. ： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Note：
Frequency
the amount of flex. New ： 70 to 86 Hz
{ 0.626 to 0.815 in }
Load： 98 N { 10 kg / 22 lb } ： 20.7 to 23.7 mm
{ 0.815 to 0.933 in }
Measurement point 2
Amount of belt
Frequency
deflection
： 12.5 to 16.5 mm
New ： 92 to 112 Hz
{ 0.492 to 0.650 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 3
Amount of belt
Frequency
deflection
： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 4
Amount of belt
deflection
New ： 70 to 86 Hz 3. Measurement point 3
{ 0.626 to 0.815 in }
： 20.7 to 23.7 mm
{ 0.815 to 0.933 in } Note：
Note：・ After adjusting the tension, tighten the
method with a sonic tension meter. Tightening torque： 41 N・m { 4.2 kgf・m / 30 lb・ft }
Measurement point 2
Amount of belt
Frequency
deflection
installation Amount of belt

Frequency
deflection
： 15.9 to 20.7 mm
New ： 70 to 86 Hz
1. Install the A/C compressor drive belt to the pulley. { 0.626 to 0.815 in }
： 20.7 to 23.7 mm
{ 0.815 to 0.933 in }
Note：
Measurement point 2
Amount of belt
Frequency
deflection
： 12.5 to 16.5 mm
New ： 92 to 112 Hz
{ 0.492 to 0.650 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 3
1. A/C compressor drive belt Amount of belt
Frequency
deflection
： 12.4 to 16.4 mm
1. Adjust tension to a standard value using a tension New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
meter. ： 16.5 to 19.1 mm
Note： { 0.650 to 0.752 in }
Amount of belt
・ Apply a load to measurement points 2, 3, and Frequency
deflection
the amount of flex. ： 15.9 to 20.7 mm
New ： 70 to 86 Hz
{ 0.626 to 0.815 in }
Load： 98 N { 10 kg / 22 lb } ： 20.7 to 23.7 mm
Measurement point 2 { 0.815 to 0.933 in }
Amount of belt
Frequency
deflection
： 12.5 to 16.5 mm
New ： 92 to 112 Hz
{ 0.492 to 0.650 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 3
Amount of belt
Frequency
deflection
： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 4
Note：
1. Engine cover

・ Radiator
1. Radiator upper hose 6. Lower fan guide

2. Upper fan guide 7. Lower hose
3. Radiator 8. Drain plug
4. Radiator reserve tank hose
5. Radiator reserve tank
Lubrication (4JK1) 1E-1
Engine
Lubrication
(4JK1)
Table of Contents
Engine oil.........................................................................1E-2
inspection....................................................................1E-2
Oil filter element..............................................................1E-4
removal........................................................................1E-4
installation...................................................................1E-5
Oil filter...........................................................................1E-6
removal........................................................................1E-6
installation.................................................................1E-13
Oil cooler assembly.......................................................1E-22
removal......................................................................1E-22
installation.................................................................1E-34
Oil pressure switch........................................................1E-49
removal......................................................................1E-49
inspection..................................................................1E-50
installation.................................................................1E-51
Oil pan...........................................................................1E-52
removal......................................................................1E-52
installation.................................................................1E-54
Oil pump assembly........................................................1E-56
removal......................................................................1E-56
disassembly...............................................................1E-61
inspection..................................................................1E-62
reassembly.................................................................1E-64
installation.................................................................1E-65
Supplementary Information...........................................1E-72
1E-2 Lubrication (4JK1)
Engine oil
inspection
1. Engine oil inspection
Caution：
・ Park the vehicle on a level area. Conduct
inspection about 30 minutes after stopping the
engine.
guide tube.
2. Clean the oil level gauge using the shop cloth.
Note：
・ Wipe off the engine oil attached on the tip of
the oil level gauge.
3. Install the oil level gauge to the oil level gauge guide
tube.
4. Remove the oil level gauge from the oil level gauge 1. Lower limit
guide tube. 2. Upper limit
5. Inspect the engine oil. Oil amount Processing Supplement

Note： Between the lower
- Good
・ Check the engine oil attached on the oil level and upper limits
gauge to inspect the engine oil amount. At or above the Replace the
-
upper limit engine oil.
Refill the
engine oil up to
At or below the Refill the
a level between
lower limit engine oil.
the lower and
upper limits.
Note：
・ Replace or refill the engine oil as necessary.
Engine oil refill amount
Condition 4×2 4×4 Notice
Drain the oil
from the drain
With the ：7L ： 7.5 L
bolt, and then,
oil filter { 1.54 { 1.65
refill the oil up
replaced Imp.gal } Imp.gal }
to the upper
level.
Drain the oil
from the drain
With no oil ： 6.4 L ： 6.9 L
bolt, and then,
filter { 1.41 { 1.52
refill the oil up
replaced Imp.gal } Imp.gal }
to the upper
level.
：8L ：8L Refill the oil up
The engine
{ 1.76 { 1.76 to the upper
is dry.
Imp.gal } Imp.gal } level.
Caution：
・ The value is a target value. It is assumed that
a check will be made with a level gauge.
Oil filter element
removal
2. Oil filter element removal
1. Install the hose to the oil drain pipe.
1. Oil filter wrench
1. Oil filter element

2. Oil pan section of the oil filter bracket
3. Hose
4. Oil pan tray
Note：
・ Prepare the oil pan tray to catch the drain oil.
2. Remove the oil filter element from the oil filter
bracket using special tool.
Note：
・ Use the oil filter wrench to remove the oil filter
element.
SST: 5-8840-0203-0 - oil filter wrench

1. Oil filter element installation
Note：
・ Remove oil, foreign materials, and dust on the
pan of the oil filter bracket. 1. Connect the battery ground cable to the battery.
・ Clean the oil filter installation surface. 2. Close the engine hood assembly.
1. Apply the engine oil to the oil filter element.
Note：
・ Apply grease or engine oil to the seal section.
2. Install the oil filter element to the oil filter bracket
using special tool.
Note：
・ Use the oil filter wrench to install it.

ft }
Note：
・ Or, after contacting the oil seal, further tighten
it by rotating it 1 and a quarter round.
3. Remove the hose from the oil drain pipe.

Oil filter
removal
Note：
Note：

1. Bolt
2. Clip
Note：
2. Remove the front under guard from the frame. 2. Oil pan section of the oil filter bracket
Note： 3. Hose
・ Remove the 5 bolts. 4. Oil pan tray
3. Remove the rear under guard from the frame. Note：

Note：・ Prepare the oil pan tray to catch the drain oil.
・ Remove the 4 bolts. 2. Remove the oil filter element from the oil filter
Note：
element.
Note：

cover.
1. Oil filter wrench sensor.
4. Engine cover removal 2. Disconnect the harness connector from the
Note：
specifications.
assembly.
assembly.
1. Engine cover

1. Air cleaner assembly 1. Water feed and return pipes

2. MAF sensor 2. Turbocharger water feed hose
3. Blow-by hose 3. Water pipe
4. Intake pipe 4. Turbocharger water feed hose
5. Barometric pressure sensor 5. Turbocharger water return hose
8. Vacuum hose removal Note：

specifications.
specifications.
the vacuum pipe.


9. Turbocharger water feed pipe disconnect 1. Disconnect the turbocharger water feed hose from
1. Disconnect the turbocharger water feed hose from the outlet pipe.
the water feed and return pipe. 2. Remove the water pipe from the cylinder head
Note： assembly.
specifications.

specifications.
Note：

adjust plate.
1. Feed hose
2. Return hose
Note：
specifications.
assembly.

pulley.

intake pipe.
1. A/C compressor drive belt 2. Remove the heater bypass pipe from the oil cooler
Note：
generator.
head assembly.
head side.

the engine hanger.
Note：
side.
23. Oil filter removal

1. Remove the oil filter from the oil cooler assembly.
installation ・ Clean the oil filter installation surface.
1. Oil filter installation 1. Apply the engine oil to the oil filter element.
1. Install the gasket to the oil cooler assembly. Note：

2. Install the oil filter to the oil cooler.
Note：
using special tool.
・ Take sufficient care to prevent dust and
foreign materials from getting inside. Note：

ft }
Note：
2. Oil filter bracket installation

1. Install the oil filter bracket to the oil filter and the
engine hanger.

assembly.
3. Oil filter element installation ・ Install the water bypass pipe on the cylinder
head side.
Note：・ Apply soapy water on the O-ring when
・ Remove oil, foreign materials, and dust on the inserting the pipe.
pan of the oil filter bracket.
Note：

Note：
side.
seated, and then, firmly tighten it. 4. Securely tighten the water intake pipe to the oil
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } cooler and the generator bracket.
Note：

intake pipe.
2. Install the water intake pipe to the oil filter.
Note：
water bypass hose.
inserting the pipe.
Note：
order.


pipe.

8. Adjust plate installation in } Terminal nut
1. Install the adjust plate to the timing gear case. 12. Generator cover installation
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } 1. Install the generator cover to the bracket and the
adjust plate.

2. Return hose
exhaust manifold. Note：
specifications.
14. Water hose connect

Note：
・ The following applies to the EGR cooler 1. Water hose
specifications.
・ Connect both the feed hose and return hose to Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in }
the EGR cooler. Bolt, nut
2. Connect the turbocharger water feed hose to the 1. Turbocharger water feed hose
outlet pipe. 2. Turbocharger water return hose
16. Turbocharger water feed pipe connect 17. Vacuum hose installation
1. Connect the turbocharger water feed hose to the Note：
・ The following applies to the high-output 1. Install the vacuum hose to the turbocharger and the
specifications. vacuum pipe.
1. Water feed and return pipes 18. Air cleaner assembly installation
3. Water pipe 1. Install the air cleaner assembly to vehicle.
4. Turbocharger water feed hose Tightening torque： 20 N・m { 2.0 kgf・m / 15 lb・ft }
Note：
specifications.
1. Air cleaner assembly 21. Engine cover installation

2. MAF sensor
3. Blow-by hose
4. Intake pipe

assembly.
Note：
specifications.
assembly.
pressure sensor.
1. Connect the blow-by hose to the cylinder head cover. 1. Engine cover
20. Intake air duct installation 22. Front under guard installation
1. Install the intake air duct to the turbocharger and the Note：
intake hose. ・ The following applies to 2WD.
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } 1. Install the front under guard to the frame.
Bolt
Note：
Tightening torque： 4 N・m { 0.4 kgf・m / 35 lb・in } ・ Tighten the clip and the 5 bolts.
Clip
24. Coolant filling
Note：
solution.
Note：
meter.
Note：
1. Bolt
2. Clip ・ The following is the belt tension adjusting
Note：・ Apply a load to measurement points 2, 3, and
・ The following applies to 4WD. 4 of the A/C compressor drive belt and adjust
the amount of flex.
Load： 98 N { 10 kg / 22 lb }
Note：
・ Tighten the 4 bolts. Measurement point 2
3. Install the rear under guard to the frame. Amount of belt
Frequency
deflection
Note：
： 12.5 to 16.5 mm
・ Tighten the 5 bolts. New ： 92 to 112 Hz
{ 0.492 to 0.650 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 3
Amount of belt
Frequency
deflection
： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 4
Amount of belt
Frequency
deflection
： 15.9 to 20.7 mm
New ： 70 to 86 Hz
{ 0.626 to 0.815 in }
： 20.7 to 23.7 mm
23. Engine oil filling { 0.815 to 0.933 in }
1. Replenish the engine with the engine oil. Note：
Tightening torque： 44 N・m { 4.5 kgf・m / 32 lb・ft } 2, 3, and 4 with a sonic tension meter.

Frequency
deflection 2. Check tension of the cooling fan belt.
： 12.5 to 16.5 mm
New ： 92 to 112 Hz Note：
{ 0.492 to 0.650 in }
： 16.5 to 19.1 mm
Reuse ： 79 to 91 Hz method based on belt deflection.
{ 0.650 to 0.752 in }
Measurement point 3 cooling fan belt and adjust the amount of flex.
Amount of belt Load： 98 N { 10 kg / 22 lb }
Frequency
deflection
Note：
： 12.4 to 16.4 mm
New ： 92 to 112 Hz ・ The following is the belt tension adjusting
{ 0.488 to 0.646 in }
： 16.5 to 19.1 mm
Reuse ： 80 to 92 Hz ・ Measure the frequency at measurement point
{ 0.650 to 0.752 in }
Measurement point 4
Amount of belt
Frequency Deflection Frequency
deflection
： 15.9 to 20.7 mm ： 5.4 to 6.6 mm
New ： 70 to 86 Hz New ： 188 to 210 Hz
{ 0.626 to 0.815 in } { 0.213 to 0.260 in }
： 20.7 to 23.7 mm ： 7.7 to 8.5 mm
{ 0.815 to 0.933 in } { 0.303 to 0.335 in }

Note： Note：
generator.
： 40 N・m { 4.1 kgf・m /
30 lb・ft }
meter.
： 25 N・m { 2.5 kgf・m /

18 lb・ft }
Note：
3. Lower vehicle.
Oil cooler assembly
removal
Note：
Note：
3. Coolant drain
Note：
radiator.
1. Bolt
2. Clip
Note：
Note：
pressure.
1. Engine cover


Note：

2. Oil pan section of the oil filter bracket
3. Hose
4. Oil pan tray
Note：
・ Prepare the oil pan tray to catch the drain oil.
2. Remove the oil filter element from the oil filter
Note：
element. 7. Blow-by hose disconnect
cover.
sensor.
Note：
specifications.
assembly.
assembly.

Note：
specifications.

2. MAF sensor
3. Blow-by hose
4. Intake pipe

Note：
specifications. 1. Water feed and return pipes
1. Remove the vacuum hose from the turbocharger and 3. Water pipe
the vacuum pipe. 4. Turbocharger water feed hose
Note：
specifications.
1. Turbocharger water feed hose 1. Feed hose

2. Turbocharger water return hose 2. Return hose
11. Water pipe removal Note：

1. Disconnect the turbocharger water feed hose from ・ The following applies to the EGR pipe
the outlet pipe. specifications.
2. Remove the water pipe from the cylinder head 2. Disconnect the water hose from the oil cooler
assembly. assembly.

Note：
14. EGR pipe removal 16. Turbocharger control solenoid disconnect

Note： 1. Disconnect the vacuum hose from the turbocharger
・ The following applies to the EGR pipe control solenoid.
specifications. 17. Turbocharger water return hose disconnect
1. Remove the EGR pipe from the inlet manifold and 1. Disconnect the turbocharger water return hose from
the exhaust manifold. the water feed and return pipe.
Note：
specifications.
15. EGR cooler removal

Note：
specifications. 1. Water feed and return pipes
1. Remove the EGR cooler from the cylinder head and 2. Turbocharger water feed hose
the exhaust manifold. 3. Water pipe
Note：
specifications.

1. Remove the turbocharger feed oil pipe from the and the crankcase.
Note：
specifications.
Note：
1. Turbocharger feed oil pipe ・ The following applies to the standard output
specifications.
Note：
specifications.
20. Water feed and return pipe removal 3. Remove the catalyst converter bracket from the rear
cover.
Note：
specifications. ・ Remove the exhaust side from the engine.
1. Remove the water feed and return pipe from the ・ Remove the engine side from the crankcase.
turbocharger.

1. Disconnect the catalyst converter from the front ・ The following applies to the high-output
exhaust pipe. specifications.
22. Catalyst converter removal 1. Remove the turbocharger bracket from the
converter bracket.
assembly.
24. Turbocharger assembly removal 25. Generator cover removal

1. Remove the turbocharger from the exhaust manifold. 1. Remove the generator cover from the bracket and the
adjust plate.
Note：
specifications.

Note： 27. Exhaust manifold removal
specifications.
head.
Note：
・ Remove the 8 nuts from the exhaust manifold.
28. A/C compressor drive belt removal 31. Generator removal

1. Remove the A/C compressor drive belt from the 1. Remove the generator from the bracket.
pulley.

29. Cooling fan belt removal intake pipe.
1. Loosen the adjust bolt using a wrench. 2. Remove the heater bypass pipe from the oil cooler
Note：
generator.
head assembly.
head side.

the engine hanger.
Note：
side.
36. Oil filter removal Note：

1. Remove the oil filter from the oil cooler assembly. ・ The following applies to the standard output
specifications.
37. Water hose removal

38. Oil cooler assembly removal
1. Remove the water hose from the oil cooler assembly.
1. Remove the oil cooler assembly from the cylinder
Note： block.
specifications.
installation Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }

2. Water hose installation
1. Oil cooler assembly installation
1. Apply liquid gasket to the oil cooler assembly.
Note：
Note：
・ Apply liquid gasket, ThreeBond 1207C, to the
specifications.
portion indicated in the diagram.
Note：
Note：
・ Within 5 minutes after application, install the oil
specifications
cooler assembly.
2. Install the O-ring to the oil cooler assembly.
Note：
・ Grease may be applied to the O-ring.
3. Install the oil cooler assembly to the cylinder block.
Note：
diagram.
3. Oil filter installation

1. Install the gasket to the oil cooler assembly.
2. Install the oil filter to the oil cooler.
Note：
・ Take sufficient care to prevent dust and
foreign materials from getting inside.

ft }
Note：
4. Oil filter bracket installation

1. Install the oil filter bracket to the oil filter and the
engine hanger.

assembly.
5. Oil filter element installation ・ Install the water bypass pipe on the cylinder
Note： head side.
・ Remove oil, foreign materials, and dust on the ・ Apply soapy water on the O-ring when
pan of the oil filter bracket. inserting the pipe.
・ Clean the oil filter installation surface.
1. Apply the engine oil to the oil filter element.
Note：
using special tool.
Note：
Note：

Note：
side.
seated, and then, firmly tighten it. 4. Securely tighten the water intake pipe to the oil
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } cooler and the generator bracket.
Note：

intake pipe.
2. Install the water intake pipe to the oil filter.
Note：
water bypass hose.
inserting the pipe.
Note：
order.


pipe.
13. Exhaust manifold installation

1. Install the gasket to the engine.
Note：
10. Adjust plate installation ・ Assemble the projection section to the rear
1. Install the adjust plate to the timing gear case. side of the cylinder head.

Caution：
1. Projection

cylinder head.
Note：
・ Install the washer and nut, and tighten them
temporarily as shown in the diagram. 1. Connect the harness to the generator.
in } Terminal nut
adjust plate.
1. Stub bolt
2. Washer
3. Nut
3. Securely tighten the exhaust manifold to the cylinder

head.
Note：
・ Tighten the 8 nuts according to the order given 16. Turbocharger assembly installation
in the diagram.
1. Install the gasket to the turbocharger.
2. Install the turbocharger to the exhaust manifold.
Note：
specifications.

assembly.
specifications.

converter bracket.
Note：
Note：
・ Feed 0.5 cc engine oil from the oil filler.
17. Turbocharger bracket installation shown in the diagram.
Note：
specifications.
Note： 20. Water feed and return pipe installation

・ Firmly tighten the bolts in the order shown in Note：
the diagram.
specifications.
turbocharger.

Bolt 1, 3
Bolt 2
pipe.
crankcase.
Turbocharger side
Crankcase side
Note：
specifications.
Note：
specifications.
22. Turbocharger feed oil pipe installation 23. Turbocharger water return hose connect
1. Install the turbocharger feed oil pipe to the 1. Connect the turbocharger water return hose to the
turbocharger and the oil cooler. water feed and return pipe.

Note：
specifications.
specifications.
Note：
diagram.
Note：
diagram.
Nut ： 27 N・m { 2.8 kgf・m / 20 lb・ft }
Bolt ： 24 N・m { 2.4 kgf・m / 18 lb・ft }
3. Water pipe
Note：
specifications.

Note：
specifications.
exhaust manifold.
2. Turbocharger water return hose Bolt, nut
solenoid.
Note：
specifications.

2. Return hose
exhaust manifold. Note：
specifications.
28. Water hose connect

Note：
・ The following applies to the EGR cooler 1. Water hose
specifications.
・ Connect both the feed hose and return hose to Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in }
the EGR cooler. Bolt, nut
2. Connect the turbocharger water feed hose to the 1. Turbocharger water feed hose
outlet pipe. 2. Turbocharger water return hose
30. Turbocharger water feed pipe connect 31. Vacuum hose installation
1. Connect the turbocharger water feed hose to the Note：
・ The following applies to the high-output 1. Install the vacuum hose to the turbocharger and the
specifications. vacuum pipe.
3. Water pipe 1. Install the air cleaner assembly to vehicle.
Note：
specifications.

2. MAF sensor
3. Blow-by hose
4. Intake pipe

assembly.
Note：
specifications.
assembly.
pressure sensor.
1. Connect the blow-by hose to the cylinder head cover. 1. Engine cover
34. Intake air duct installation 36. Front under guard installation
1. Install the intake air duct to the turbocharger and the Note：
intake hose. ・ The following applies to 2WD.
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } 1. Install the front under guard to the frame.
Bolt
Note：
Tightening torque： 4 N・m { 0.4 kgf・m / 35 lb・in } ・ Tighten the clip and the 5 bolts.
Clip
38. Coolant filling
Note：
solution.
Note：
meter.
Note：
1. Bolt
2. Clip ・ The following is the belt tension adjusting
Note：・ Apply a load to measurement points 2, 3, and
・ The following applies to 4WD. 4 of the A/C compressor drive belt and adjust
the amount of flex.
Load： 98 N { 10 kg / 22 lb }
Note：
・ Tighten the 4 bolts. Measurement point 2
3. Install the rear under guard to the frame. Amount of belt
Frequency
deflection
Note：
： 12.5 to 16.5 mm
・ Tighten the 5 bolts. New ： 92 to 112 Hz
{ 0.492 to 0.650 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 3
Amount of belt
Frequency
deflection
： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 4
Amount of belt
Frequency
deflection
： 15.9 to 20.7 mm
New ： 70 to 86 Hz
{ 0.626 to 0.815 in }
： 20.7 to 23.7 mm
37. Engine oil filling { 0.815 to 0.933 in }
1. Replenish the engine with the engine oil. Note：
Tightening torque： 44 N・m { 4.5 kgf・m / 32 lb・ft } 2, 3, and 4 with a sonic tension meter.

Frequency
deflection 2. Check tension of the cooling fan belt.
： 12.5 to 16.5 mm
New ： 92 to 112 Hz Note：
{ 0.492 to 0.650 in }
： 16.5 to 19.1 mm
Reuse ： 79 to 91 Hz method based on belt deflection.
{ 0.650 to 0.752 in }
Measurement point 3 cooling fan belt and adjust the amount of flex.
Amount of belt Load： 98 N { 10 kg / 22 lb }
Frequency
deflection
Note：
： 12.4 to 16.4 mm
New ： 92 to 112 Hz ・ The following is the belt tension adjusting
{ 0.488 to 0.646 in }
： 16.5 to 19.1 mm
Reuse ： 80 to 92 Hz ・ Measure the frequency at measurement point
{ 0.650 to 0.752 in }
Measurement point 4
Amount of belt
Frequency Deflection Frequency
deflection
： 15.9 to 20.7 mm ： 5.4 to 6.6 mm
New ： 70 to 86 Hz New ： 188 to 210 Hz
{ 0.626 to 0.815 in } { 0.213 to 0.260 in }
： 20.7 to 23.7 mm ： 7.7 to 8.5 mm
{ 0.815 to 0.933 in } { 0.303 to 0.335 in }

Note： Note：
generator.
： 40 N・m { 4.1 kgf・m /
30 lb・ft }
meter.
： 25 N・m { 2.5 kgf・m /

18 lb・ft }
Note：
3. Lower vehicle.
Oil pressure switch
removal
switch.
3. Oil pressure switch removal
1. Remove the oil pressure switch from the cylinder
block.
inspection
1. Oil pressure switch inspection
1. Inspect continuity using tester.
Note：
・ Confirm the continuity between the switch
terminal and body ground without a load
applied.
・ If there is no continuity, replace it with a
normal one.
3. Check a circuit of the oil pressure switch.

Note：
・ Disconnect the oil pressure switch connector.
・ Inspect that the oil pressure warning light turns
on when the harness side connector is
connected to the ground.
・ When it does not turn on, inspect the circuit
between the meter and the oil pressure switch.
・ Repair any open circuit.
2. Check a circuit of the oil pressure switch.

Note：
・ Turn the ignition switch ON.
・ Disconnect the oil pressure switch connector.
・ Inspect that the oil pressure warning light turns
off at the time of the disconnection.
・ When it does not turn off, inspect the circuit
between the meter and the oil pressure switch.
・ Repair any open circuit.
installation
1. Oil pressure switch installation
1. Install the oil pressure switch to the cylinder block.

3. Lower vehicle.
Oil pan
removal
Note：
Note：
3. Engine oil drain

Note：
specified torque.
Caution：
4. Oil pan removal
1. Bolt
2. Clip
Note：
Note：
Note：
2. Disconnect the earth cable from the crankcase.

1. Earth cable
Note：
Note：
Note：
1. 2.0 mm {0.079 in}

2. 3.0 mm {0.118 in}
2. Install the oil pan to the crankcase.

Caution：
1. Bolt
2. Clip
5 minutes.
Note：
Note：


3. Lower vehicle.
Oil pump assembly
removal
Note：
Note：
3. Coolant drain
Note：
radiator.
1. Bolt
2. Clip
Note：
Note：
pressure.
Note：

6. Intake air duct removal pulley.

Note：
assembly.
Note：

Note：
generator. 12. Fan pulley removal
2. Remove the cooling fan belt from the pulley. 1. Remove the fan pulley from the water pump
assembly.
Note：
Note：
sides and remove the upper fan guide. ・ Remove the lower fan guide together with the
fan shroud.
cover.
1. Upper fan guide

2. Clip
3. Lower fan guide
4. Fan shroud
1. Noise cover

Caution：
1. Bracket


gear case.
Note：
with the hose.
2. Remove the vacuum pump oil pipe from the vacuum

3. Remove the vacuum pump assembly from the gear
case cover.

2. Nut

bracket.
18. Cover removal 20. Oil pump assembly removal

1. Remove the cover from the gear case cover. 1. Remove the oil pump from the timing gear case.
19. Gear case cover removal 1. Oil pump

case.
disassembly
1. Oil pump assembly disassembly
1. Remove the spring pin from the oil pump.
2. Remove the spring seat from the oil pump.
3. Remove the spring from the oil pump.
4. Remove the from the oil pump.
1. Spring pin
2. Spring seat
3. Spring
4. Valve
inspection
1. Oil pump assembly inspection
Note：
・ Measure the outer diameter of the driven gear
shaft and the drive gear shaft.
Standard： 15.989 to 16.000 mm { 0.62949 to 0.62992
in }
Limit： 15.900 mm { 0.62598 in }
4. Measure the oil pump gear using the micrometer.

Note：
・ Measure the width of the driven gear and the
drive gear.
2. Measure inner diameter using a dial gauge.

Note：
・ Measure the bushing inner diameter of the
cylinder block.
Note：
・ Calculate the clearance by deducting the outer
diameters of the driven gear shaft and the
drive gear shaft, and the inner diameter of the
cylinder block bushing.
Standard： 0.04 to 0.07 mm { 0.0016 to 0.0028 in } 5. Measure depth using the micrometer.
Limit： 0.20 mm { 0.0079 in } Note：

・ Measure the depth of the gear case housing
Note：
surface and the oil pump housing gear case
・ When the gap between the gear shaft and the side.
bushing exceeds the limit, replace the oil pump
assembly. Standard： 14.500 to 14.527 mm { 0.57087 to 0.57193
in }

Note：
・ Calculate the clearance between the gear side
surface and the gear side surface of the oil
pump housing.
Limit： 0.20 mm { 0.0079 in }
reassembly
1. Oil pump assembly reassembly
1. Install the to the oil pump.
2. Install the spring to the oil pump.
3. Install the spring seat to the oil pump.
4. Install the spring pin to the oil pump.
1. Spring pin
2. Spring seat
3. Spring
4. Valve
1. Oil pump assembly installation gasket, install the cover.
1. Apply the engine oil to the oil pump gear. 2. Install the gasket to the gear case cover.
2. Install the oil pump to the timing gear case. 3. Install the gear case cover to the timing gear case.
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } Tightening torque： 8 N・m { 0.8 kgf・m / 71 lb・in }
1. Oil pump 3. Cover installation

Note：
in the diagram.

cover.
Tightening torque： 12 N・m { 1.2 kgf・m / 106 lb・ 1. Power steering pump
in } 2. Nut
3. Install the vacuum hose to the vacuum pipe and the 2. Install the power steering oil hose to the bracket.
1. Bracket

case. Note：
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } ・ Align the crankshaft pulley to the key of the
ft }
Caution：
・ Use new crank pulley bolts. 1. Install the cooling fan clutch to the water pump
assembly.
Note：

cover.
Note：
1. Noise cover

Note：
1. Upper fan guide
・ Install the lower fan guide together with the fan 2. Clip
shroud. 3. Lower fan guide
9. Fan pulley installation 4. Fan shroud
1. Install the fan pulley to the water pump assembly. 12. Cooling fan belt installation
10. Cooling fan clutch installation 1. Install the cooling fan belt to the pulley.
meter. Mounting bolt
30 lb・ft }
Note：： 25 N・m { 2.5 kgf・m /
・ Move the generator to adjust the tension. 18 lb・ft }
2. Check tension of the cooling fan belt. Note：

Note：
Load： 98 N { 10 kg / 22 lb }
Note：
： 5.4 to 6.6 mm
New ： 188 to 210 Hz
{ 0.213 to 0.260 in }
： 7.7 to 8.5 mm
{ 0.303 to 0.335 in }

meter.
Note：
the amount of flex.
Frequency
deflection
Note：： 12.5 to 16.5 mm
・ After adjusting the tension, tighten the adjust New ： 92 to 112 Hz
{ 0.492 to 0.650 in }
generator. Reuse ： 79 to 91 Hz
{ 0.650 to 0.752 in }
Measurement point 3
Amount of belt
Frequency
deflection
： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 4
Amount of belt
Frequency
deflection
： 15.9 to 20.7 mm
New ： 70 to 86 Hz
{ 0.626 to 0.815 in }
： 20.7 to 23.7 mm
{ 0.815 to 0.933 in }
Note：
method with a sonic tension meter. 1. Measurement point 1
・ Measure the frequency at measurement point 2. Measurement point 2
2, 3, and 4 with a sonic tension meter. 3. Measurement point 3
Measurement point 2
Amount of belt Note：
Frequency
deflection ・ After adjusting the tension, tighten the
： 12.5 to 16.5 mm tensioner fixing nut.
New ： 92 to 112 Hz
{ 0.492 to 0.650 in } Tightening torque： 41 N・m { 4.2 kgf・m / 30 lb・ft }
： 16.5 to 19.1 mm
Reuse ： 79 to 91 Hz 16. Radiator upper hose installation
{ 0.650 to 0.752 in }
Measurement point 3 pipe and the radiator.
Amount of belt
Frequency Tightening torque： 5 N・m { 0.5 kgf・m / 44 lb・in }
deflection
Hose clip
： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 4
Amount of belt
Frequency
deflection
： 15.9 to 20.7 mm
New ： 70 to 86 Hz
{ 0.626 to 0.815 in }
： 20.7 to 23.7 mm
{ 0.815 to 0.933 in }

Bolt
Clip
1. Engine cover

Note：
18. Intake air duct installation Note：
1. Install the intake air duct to the turbocharger and the ・ Tighten the clip and the 5 bolts.
intake hose.
Bolt
Clip
1. Bolt
2. Clip
Note：
Note：
Note：
21. Coolant filling

Note：
solution.
Note：
3. Lower vehicle.
・ Oil filter cartridge
1. Oil filter cartridge
Note：
・ Oil cooler
1. Oil cooler
Note：
・ Oil pan
1. Oil pan
Note：
・ Oil pump
1. Bolt 2. Oil pump assembly
Note：
・ Oil pressure switch
1. Oil pressure switch

・ Oil pan
1： 22 N・m { 2.2 kgf・m / 16 lb・ft }

2： 44 N・m { 4.5 kgf・m / 32 lb・ft }
Induction (4JK1) 1F-1
Engine
Induction
(4JK1)
Table of Contents
Air cleaner element..........................................................1F-2
removal........................................................................1F-2
inspection....................................................................1F-3
installation...................................................................1F-4
Turbocharger assembly....................................................1F-5
removal........................................................................1F-5
inspection..................................................................1F-13
installation.................................................................1F-15
Turbocharger control solenoid.......................................1F-24
removal......................................................................1F-24
inspection..................................................................1F-25
installation.................................................................1F-26
Boost sensor...................................................................1F-27
removal......................................................................1F-27
inspection..................................................................1F-28
installation.................................................................1F-29
Intercooler......................................................................1F-30
removal......................................................................1F-30
inspection..................................................................1F-33
installation.................................................................1F-34
MAF and IAT sensor.....................................................1F-37
removal......................................................................1F-37
inspection..................................................................1F-38
installation.................................................................1F-39
Supplementary Information...........................................1F-40
1F-2 Induction (4JK1)
Air cleaner element
removal
1. Air cleaner element removal
2. Remove the air cleaner cover from the air cleaner
box.
3. Remove the air cleaner element from the air cleaner
box.
inspection
1. Air cleaner element inspection
1. Inspect the air cleaner element.
Note：
・ Inspect for excessive dirt or damage.
2. Air cleaner element cleaning
Note：
・ Dry element
1. Clean the air cleaner element using air.
Note：
・ Clean the element by applying the
compressed air from the element clean side.
Air pressure： 392 to 490 kPa { 4 to 5 kgf/cm2 / 57 to 71
psi }
installation
1. Air cleaner element installation
1. Install the air cleaner element to the air cleaner box.
2. Install the air cleaner cover to the air cleaner box.
Turbocharger assembly
removal
Note：
Note：
3. Coolant drain
Note：
radiator.
1. Bolt
2. Clip
Note：
Note：
pressure.
Note：
specifications.
assembly.
assembly.
1. Engine cover

Note：

2. MAF sensor
3. Blow-by hose
4. Intake pipe

Note：
specifications.
the vacuum pipe.

cover.
sensor.

specifications.
assembly.

3. Water pipe
specifications.
Note：
1. Feed hose 13. EGR pipe removal

2. Return hose
Note：
Note：・ The following applies to the EGR pipe
・ The following applies to the EGR pipe specifications.
specifications. 1. Remove the EGR pipe from the inlet manifold and
2. Disconnect the water hose from the oil cooler the exhaust manifold.
assembly.
14. EGR cooler removal

1. Water hose Note：
12. Exhaust manifold heat protector removal ・ The following applies to the high-output
specifications.
the exhaust manifold. 1. Remove the EGR cooler from the cylinder head and
15. Turbocharger control solenoid disconnect 1. Turbocharger water feed hose

control solenoid. 17. Turbocharger feed oil pipe removal
16. Turbocharger water return hose disconnect 1. Remove the turbocharger feed oil pipe from the
1. Disconnect the turbocharger water return hose from turbocharger and the oil cooler.
the water feed and return pipe. Note：
specifications.

Note：
3. Water pipe ・ The following applies to the standard output
4. Turbocharger water feed hose specifications.
Note：
specifications.
1. Turbocharger feed oil pipe 19. Water feed and return pipe removal
18. Oil return pipe removal Note：

specifications.
and the crankcase.
1. Remove the water feed and return pipe from the
Note：
turbocharger.
specifications.
Note： 1. Disconnect the catalyst converter from the front

exhaust pipe.
specifications. 21. Catalyst converter removal
converter bracket.
assembly.
3. Remove the catalyst converter bracket from the rear 23. Turbocharger assembly removal
cover.
Note：
Note：
・ Remove the engine side from the crankcase. specifications.
22. Turbocharger bracket removal Note：

specifications.
24. Turbocharger heat protector removal 26. Water return pipe removal
Note： Note：
・ The following applies to the high-output ・ The following applies to the standard output
1. Remove the turbocharger heat protector from the 1. Remove the water return pipe from the turbocharger.
turbocharger.
25. Water feed pipe removal

Note：
specifications.
1. Remove the water feed pipe from the turbocharger.
inspection
1. Turbocharger assembly inspection
1. Measure play using a dial gauge.
Note：
・ Measure the play of the wheel in the direction
of the wheel axis when a load is applied on the
both sides of the compressor wheel.
Load： 12 N { 1.2 kg / 2.7 lb }
Limit： 0.09 mm { 0.0035 in }
1. Oil outlet
2. Oil inlet
Note：
・ Operation inspection on the actuator of the
high-output turbocharger
3. Install the vacuum pump to the actuator.
2. Measure the clearance using a dial gauge.

Note：
・ Measure the clearance between the wheel
shaft and the bearing.
Limit： 0.14 mm { 0.0055 in }
1. Actuator
2. Vacuum pump
4. Operate the vacuum pump.

5. Add negative pressure to the actuator.
Note：
・ Confirm that the lever hits the stopper when a
negative pressure is applied.
・ Place the vernier caliper at the control rod end
of the actuator.
6. Release negative pressure. Moving amount of
Pressure
Note： the control rod
・ Gradually release the negative pressure and ： 2 mm { 0.08 ： 113.6 kPa { 1.16 kgf/cm2 / 16
confirm if the control rod moves. in } psi }
・ Confirm that the lever hits the stopper when ： 4 mm { 0.16 ： 132.6 kPa { 1.35 kgf/cm2 / 19
the negative pressure is reduced below the in } psi }
specified value.
7. Measure length using a vernier caliper.
Note：
・ Confirm that the control rod has moved only
for the standard value when the lever hits the
stopper by releasing the negative pressure.
Note：
・ Operation inspection on the actuator of the
standard-output turbocharger
8. Install the air pump to the actuator.
1. Air pump
2. Actuator
9. Operate the air pump.

10. Add the pressure to the actuator.
Note：
・ Put a vernier caliper against the end surface of
the control rod, and operate the air pump.
11. Measure length using a vernier caliper.
Note：
・ Inspect that the relationship between the
moving amount of the control rod and the
pressure follows the behavior shown in the
table.
1. Water return pipe installation specifications.
Note： 1. Install the turbocharger heat protector to the
・ The following applies to the standard output turbocharger.
specifications.
1. Install the water return pipe to the turbocharger.
4. Turbocharger assembly installation

1. Install the gasket to the turbocharger.
2. Water feed pipe installation
2. Install the turbocharger to the exhaust manifold.
Note：
1. Install the water feed pipe to the turbocharger.
specifications.
Note：
3. Turbocharger heat protector installation ・ The following applies to the standard output
specifications.
Note： 2. Connect the catalyst converter to the catalyst

・ Feed 0.5 cc engine oil from the oil filler. converter bracket.
5. Turbocharger bracket installation Note：

Note：
specifications.
Note：
the diagram.

assembly.
Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft } 9. Oil return pipe installation
Bolt 1, 3
Tightening torque： 51 N・m { 5.2 kgf・m / 38 lb・ft } crankcase.
Bolt 2
7. Catalyst converter connect Turbocharger side
1. Connect the catalyst converter to the front exhaust Tightening torque： 25 N・m { 2.5 kgf・m / 18 lb・ft }
pipe. Crankcase side
specifications.
8. Water feed and return pipe installation

Note：
Note：
specifications. ・ The following applies to the standard output
specifications.
turbocharger.
10. Turbocharger feed oil pipe installation 1. Turbocharger feed oil pipe
1. Install the turbocharger feed oil pipe to the 11. Turbocharger water return hose connect
Tightening torque： 23 N・m { 2.3 kgf・m / 17 lb・ft } water feed and return pipe.
Note： Note：
・ The following applies to the high-output ・ The following applies to the high-output

Note：
3. Water pipe
Note：
specifications.
1. Turbocharger water feed hose 14. EGR pipe installation

Note：
12. Turbocharger control solenoid connect ・ The following applies to the EGR pipe
specifications.
solenoid. 1. Install the EGR pipe to the inlet manifold and the
exhaust manifold.
Note：
Bolt, nut
specifications.
Note：
diagram.
Note：
diagram.
Tightening torque of the EGR valve 15. Exhaust manifold heat protector installation
Nut ： 27 N・m { 2.8 kgf・m / 20 lb・ft }
Bolt ： 24 N・m { 2.4 kgf・m / 18 lb・ft } exhaust manifold.

Note： 17. Water pipe installation
specifications.
Note： Bolt, nut
the EGR cooler.

outlet pipe.
1. Feed hose 18. Turbocharger water feed pipe connect
2. Return hose
Note： water feed and return pipe.
・ The following applies to the EGR pipe Note：
specifications.
2. Install the water hose to the oil cooler assembly. specifications.
3. Water pipe
Note：
specifications.

2. MAF sensor
3. Blow-by hose
4. Intake pipe
2. Turbocharger water return hose 2. Connect the intake pipe to the turbocharger
assembly.
Note：
Note：
specifications.
specifications.
vacuum pipe.
assembly.
4. Connect the harness connector to the barometric 24. Front under guard installation
pressure sensor.
Note：
5. Connect the harness connector to the MAF sensor. ・ The following applies to 2WD.
21. Blow-by hose connect 1. Install the front under guard to the frame.
1. Connect the blow-by hose to the cylinder head cover. Note：
22. Intake air duct installation ・ Tighten the clip and the 5 bolts.
intake hose.
Bolt
Clip
1. Bolt
2. Clip
Note：
Note：
Note：
1. Engine cover
25. Coolant filling

Note：
solution.
Note：
3. Lower vehicle.
Turbocharger control solenoid
removal
1. Engine cover
3. Turbocharger control solenoid disconnect

control solenoid.
4. Turbocharger control solenoid removal
1. Remove the harness connector from the turbocharger
control solenoid.
2. Remove the turbocharger control solenoid from the
bracket.
inspection
1. Turbocharger control solenoid inspection
1. Inspect the turbocharger control solenoid using the
circuit tester.
Note：
・ Measure the resistance value between
terminals 1 and 2.
Temperature of the condition： 20 ℃ { 68 °F }
resistance characteristics
Resistance： 11 to 13 Ω
installation 4. Battery ground cable connect

1. Turbocharger control solenoid installation
Note：
・ For the high-output specifications only
1. Install the turbocharger control solenoid to the
bracket.
2. Install the harness connector to the turbocharger

control solenoid.
solenoid.
1. Engine cover
Boost sensor
removal
1. Engine cover

4. Boost sensor removal

1. Remove the boost sensor from the air duct.
inspection
1. Boost sensor inspection
1. Inspect the boost sensor.
Note：
・ Inspect the boost sensor for filth or damage.
・ Inspect the connector terminal section for
abnormality.
installation
1. Boost sensor installation
1. Install the boost sensor to the air duct.
Tightening torque： 2 N・m { 0.2 kgf・m }
1. Engine cover


Intercooler
removal 1. Screw
2. Clip
1. Intercooler safety information
4. Front bumper assembly removal
Caution：
・ If oil builds up inside the intercooler, remove 1. Remove the front bumper assembly from vehicle.
the drain plug to drain the oil. Note：
1. Remove the drain plug from the intercooler. ・ Remove the 10 clips.
Note：
・ Put the hand into the bumper opening and
remove the drain plug with a tool.
2. Drain the engine oil from the intercooler.
Note：
・ Prepare a shop cloth under the drain plug to
catch the drained oil with it.
3. Install the drain plug to the intercooler.
Note：
・ Confirm that the engine oil has been drained
before installing the drain plug.
in }
1. Open the engine hood assembly. 5. Front bumper impact bar assembly removal
2. Disconnect the battery ground cable from the battery. 1. Remove the bumper seal from vehicle.
3. Radiator grille removal Note：
1. Remove the radiator grille from vehicle. ・ Remove the 6 clips on one side.
Note：
・ Remove the screws.
・ Remove the 4 clips.
1. Upper bumper seal

2. Lower bumper seal
2. Remove the front bumper support from vehicle.

3. Remove the front bumper impact bar assembly from 7. Intercooler removal
vehicle.
1. Disconnect the intake air hose from the intercooler.
Note：
・ Disconnect it at both the turbocharger and
intake throttle sides.
6. Front end engine hood stay removal

1. Remove the front end engine hood stay from the
frame.
1. Intake hose, turbocharger side

2. Intake hose, intake throttle side
2. Remove the intercooler from the frame.

inspection Note：
・ If dirt is not thoroughly washed off, repeat the
1. Intercooler inspection cleaning work.
1. Inspect the intercooler. ・ If dirt remains, fine black particles are seen
Note： attached on the fins.
・ Repair the intercooler fins if they are deformed 4. Clean the intercooler using tap water.
as it can lead to a drop in heat dissipation and Caution：
reduce engine performance.
・ Thoroughly rinse off the detergent ingredients
・ When repairing, take sufficient care not to to prevent it from remaining on the fins and the
damage the base of the fins. resin portions.
2. Intercooler cleaning 5. Clean the connection using tap water.
Caution： Note：
・ Do not apply high-pressure washing to the ・ Remove the seal, and clean the hose
radiator, intercooler, and peripheral parts while connection.
they are installed in the vehicle.
・ Thoroughly clean and dry the hose connection.
Note：
・ Before cleaning, seal the hose connections
with caps, fabric tape, etc.
1. Clean the intercooler using tap water.
Note：
・ Wet the front and rear surfaces of the
intercooler sufficiently.
・ For fouling that can be removed by splashing
tap water, thoroughly wash them off.
Caution：
・ Do not use a high-pressure washing machine
or brush.
2. Apply detergent to the intercooler.
Note：
・ Apply a type of mild detergent which contains
approximately 8 % of surface acting agent,
and leave it for 10 minutes.
Caution：
・ Do not use materials other than mild detergent
because doing so may cause corrosion.
3. Clean the intercooler using the high-pressure
washing machine.
Note：
・ Wash off mild detergent with a high-pressure
washing machine.
Caution：
・ Apply the high pressure water perpendicular to
the fins from the engine side of the intercooler.
・ Do not bring the high-pressure water too close
to the fins.
・ Watch for deformation of the fins.
installation 1. Install the front end engine hood stay to the frame.
1. Intercooler installation
1. Install the intercooler to the frame.
3. Front bumper impact bar assembly installation

1. Install the front bumper impact bar assembly to
vehicle.
Note：
2. Connect the intake air hose to the intercooler. ・ Tighten the fixing bolt to the specified torque.
・ Connect it at both the turbocharger and intake
throttle sides.
Clamp
Duct
2. Install the front bumper support to vehicle.
1. Intake hose, turbocharger side

2. Intake hose, intake throttle side
2. Front end engine hood stay installation

3. Install the bumper seal to vehicle. 5. Radiator grille installation

Note： 1. Install the radiator grille to vehicle.
・ Install the 6 clips on one side. Note：
・ Put the claw of the radiator grille in the
installation hole of the front bumper shown in
the diagram.
1. Upper bumper seal

2. Lower bumper seal
4. Front bumper assembly installation

1. Radiator grille
1. Install the front bumper assembly to vehicle.
Note：
Note：
・ Install the 4 clips.
・ Install the 10 clips.
・ Install the screws.
1. Screw
2. Clip

MAF and IAT sensor
removal
2. MAF and IAT sensor disconnect
1. Remove the harness connector from the MAF sensor.
3. MAF and IAT sensor removal
1. Remove the MAF sensor from the air cleaner
assembly.
Note：
・ Remove the MAF sensor and the IAT sensor
from the air cleaner assembly.
inspection
1. MAF sensor inspection
1. Inspect the MAF sensor.
Note：
・ Inspect the MAF sensor for filth and damage.
Caution：
・ There should be no solvents or lubricants
adhering to the detecting section of the sensor.
2. IAT sensor inspection
1. Inspect the IAT sensor using the circuit tester.
1. Gasket
2. MAF sensor power source
3. MAF sensor GND
4. MAF sensor signal
5. IAT sensor signal
6. IAT sensor GND
Note：
・ Measure the resistance value between the
signal terminal and the GND terminal of the
IAT sensor in the temperature of the condition
with a circuit tester.
Temperature of the condition： 25 ℃ { 77 °F }
Resistance： 1.8 to 2.2 kΩ
Caution：
・ There should be no solvents or lubricants
adhering to the detecting section of the sensor.
installation
1. MAF and IAT sensor installation
1. Install the MAF sensor to the air cleaner assembly.
Note：
・ Install the MAF sensor and the IAT sensor to
the air cleaner assembly.
in }
2. MAF and IAT sensor connect
1. Install the harness connector to the MAF sensor and
the IAT sensor.
・ Turbocharger (standard output)
1. Intake air duct 5. Water return pipe

2. Water feed pipe 6. Oil return pipe
3. Oil feed pipe 7. Catalyst converter
4. Turbocharger
Note：
・ Turbocharger (high-output)
1. Intake air duct 6. Oil return pipe

2. Oil feed pipe 7. Turbocharger bracket
3. Turbocharger assembly 8. Catalyst converter
5. Turbocharger heat protector

・ Turbocharger (standard output)

7： 54 N・m { 5.5 kgf・m / 40 lb・ft } Note：
8： 10 N・m { 1.0 kgf・m / 89 lb・in } ・ Turbocharger (high-output)

2： 5 N・m { 0.5 kgf・m / 44 lb・in }
3： 27 N・m { 2.8 kgf・m / 20 lb・ft }
4： 23 N・m { 2.3 kgf・m / 17 lb・ft }
5： 4 N・m { 0.4 kgf・m / 35 lb・in }
6： 10 N・m { 1.0 kgf・m / 89 lb・in }
7： 25 N・m { 2.5 kgf・m / 18 lb・ft }
8： 25 N・m { 2.5 kgf・m / 18 lb・ft }
9： 10 N・m { 1.0 kgf・m / 89 lb・in }
10： 25 N・m { 2.5 kgf・m / 18 lb・ft }
11： 51 N・m { 5.2 kgf・m / 38 lb・ft }
12： 25 N・m { 2.5 kgf・m / 18 lb・ft }
13： 25 N・m { 2.5 kgf・m / 18 lb・ft }
Exhaust (4JK1) 1G-1
Engine
Exhaust
(4JK1)
Table of Contents
Exhaust pipe....................................................................1G-2
removal.......................................................................1G-2
inspection....................................................................1G-3
installation..................................................................1G-4
Catalyst converter............................................................1G-5
removal.......................................................................1G-5
installation..................................................................1G-6
Supplementary Information............................................1G-7
1G-2 Exhaust (4JK1)
Exhaust pipe
removal
1. Exhaust silencer assembly removal
1. Remove the rear hanger rubber from the exhaust
silencer.
2. Remove the exhaust silencer from the front exhaust
pipe.
3. Remove the silencer hanger rubber from the exhaust

silencer.
2. Front exhaust pipe removal
1. Remove the front hanger rubber from the front
exhaust pipe.
2. Remove the front exhaust pipe from the catalyst
converter.
Exhaust (4JK1) 1G-3
inspection
1. Exhaust pipe inspection
1. Inspect the exhaust pipe.
Note：
damage is found.
・ Check the pipe for corrosion, cracks, damage,
or improper installation, and make repairs if
necessary.
・ Check the rubber ring for degradation or
damage, and make repairs if necessary.
2. Exhaust silencer assembly inspection
1. Inspect the exhaust silencer.
Note：
damage is found.
・ Check the pipe for corrosion, cracks, damage,
or improper installation, and make repairs if
necessary.
・ Check the rubber ring for degradation or
damage, and make repairs if necessary.
1G-4 Exhaust (4JK1)
installation
1. Front exhaust pipe installation
1. Install the front exhaust pipe to the catalyst
converter.
2. Install the front hanger rubber to the front exhaust

pipe.
2. Exhaust silencer assembly installation
1. Install the silencer hanger rubber to the exhaust
silencer.
2. Install the exhaust silencer to the front exhaust pipe.
3. Install the rear hanger rubber to the exhaust silencer.

Exhaust (4JK1) 1G-5
Catalyst converter
removal
exhaust pipe.
converter bracket.
assembly.

cover.
Note：
1G-6 Exhaust (4JK1)
installation
assembly.

Bolt 1, 3
Bolt 2
2. Connect the catalyst converter to the catalyst pipe.
converter bracket.
Note：

Note： 2. Close the engine hood assembly.

・ Firmly tighten the bolts in the order shown in 3. Lower vehicle.
the diagram.
Exhaust (4JK1) 1G-7
・ Exhaust pipe
1. Front hanger rubber 4. Rear hanger rubber

2. Front exhaust pipe 5. Silencer assembly
3. Silencer hanger rubber

・ Exhaust pipe
1G-8 Exhaust (4JK1)
1： 67 N・m { 6.8 kgf・m / 49 lb・ft }

2： 43 N・m { 4.4 kgf・m / 32 lb・ft }
Aux. Emission Control Devices (4JK1) 1H-1
Engine
Aux. Emission Control Devices
(4JK1)
Table of Contents
EGR cooler......................................................................1H-2
removal.......................................................................1H-2
installation..................................................................1H-6
EGR valve.....................................................................1H-10
removal.....................................................................1H-10
inspection..................................................................1H-11
installation................................................................1H-12
EGR pipe.......................................................................1H-13
removal.....................................................................1H-13
installation................................................................1H-16
Supplementary Information..........................................1H-19
1H-2 Aux. Emission Control Devices (4JK1)
EGR cooler
removal
Note：
Note：
3. Coolant drain
Note：
radiator.
1. Bolt
2. Clip
Note：
Note：
pressure.
Note：
specifications.
assembly.
assembly.
1. Engine cover

Note：

2. MAF sensor
3. Blow-by hose
4. Intake pipe

Note：
specifications.
the vacuum pipe.

cover.
sensor.

specifications.
assembly.

3. Water pipe
specifications.
Note：
1. Feed hose 13. EGR cooler removal

2. Return hose
1. Remove the EGR cooler from the cylinder head and
Note： the exhaust manifold.
specifications.
assembly.
1. Water hose

installation
Note：
diagram.
Note：
diagram. 3. Water hose connect
Tightening torque of the EGR valve Note：
Nut ： 27 N・m { 2.8 kgf・m / 20 lb・ft } ・ The following applies to the EGR cooler
Bolt ： 24 N・m { 2.4 kgf・m / 18 lb・ft } specifications.
Note：
the EGR cooler.

exhaust manifold.
1. Feed hose
2. Return hose
Note：
specifications.
1. Water hose 1. Water feed and return pipes

4. Water pipe installation 3. Water pipe
1. Install the turbocharger water feed hose to the 4. Turbocharger water feed hose
cylinder head assembly. 5. Turbocharger water return hose

Bolt, nut ・ The following applies to the standard output
specifications.

outlet pipe. 1. Turbocharger water feed hose
5. Turbocharger water feed pipe connect 2. Turbocharger water return hose
1. Connect the turbocharger water feed hose to the 6. Vacuum hose installation
Note：
specifications.
vacuum pipe.
pressure sensor.
intake hose.
Bolt
Clip



2. MAF sensor
3. Blow-by hose
4. Intake pipe

assembly.
Note：
specifications.
assembly. 1. Engine cover
11. Coolant filling
Note：
solution.
Note：
Note：
1. Install the front under guard to the frame. 13. Battery ground cable connect
Note： 1. Connect the battery ground cable to the battery.
3. Lower vehicle.
1. Bolt
2. Clip
Note：
Note：
Note：
EGR valve
removal
3. EGR valve removal
inspection
1. EGR valve inspection
Note：
・ Clean the EGR valve if carbon is piled up.
installation
1. Install the EGR valve to the inlet manifold.
Nut ： 27 N・m { 2.8 kgf・m / 20 lb・ft }
Bolt ： 24 N・m { 2.4 kgf・m / 18 lb・ft }
EGR pipe
removal
Note：
Note：
3. Coolant drain
Note：
radiator.
1. Bolt
2. Clip
Note：
Note：
pressure.
assembly.
1. Engine cover

Note：
2. MAF sensor
3. Blow-by hose
4. Intake pipe


cover.
7. EGR pipe removal
Note：
specifications.
1. Disconnect the harness connector from the MAF 6. Disconnect the turbocharger water feed hose from
sensor. the outlet pipe.
assembly.


installation
Note：
specifications.
exhaust manifold.
Bolt, nut

outlet pipe.

exhaust manifold.


Bolt, nut

2. MAF sensor
3. Blow-by hose
4. Intake pipe

assembly.
pressure sensor.
intake hose.
Bolt
1. Engine cover
Clip 5. Coolant filling
Note：
solution.
Note：
Note： 7. Battery ground cable connect
・ The following applies to 2WD. 1. Connect the battery ground cable to the battery.
1. Install the front under guard to the frame. 2. Close the engine hood assembly.
Note： 3. Lower vehicle.
1. Bolt
2. Clip
Note：
Note：
Note：
・ EGR pipe, EGR pipe specifications
1. EGR pipe
Note：
・ EGR cooler, EGR cooler specifications
1. EGR cooler

・ EGR pipe, EGR pipe specifications
1： 27 N・m { 2.8 kgf・m / 20 lb・ft } Note：

2： 27 N・m { 2.8 kgf・m / 20 lb・ft } ・ EGR cooler, EGR cooler specifications
1： 27 N・m { 2.8 kgf・m / 20 lb・ft }

2： 24 N・m { 2.4 kgf・m / 18 lb・ft }
3： 27 N・m { 2.8 kgf・m / 20 lb・ft }
Speed Control Systems (4JK1) 1I-1
Engine
Speed Control Systems
(4JK1)
Table of Contents
Accelerator pedal assembly..............................................1I-2
removal.........................................................................1I-2
inspection.....................................................................1I-3
installation....................................................................1I-4
1I-2 Speed Control Systems (4JK1)
Accelerator pedal assembly
removal
2. Accelerator pedal assembly removal
2. Remove the accelerator pedal assembly from the
dash panel.
Speed Control Systems (4JK1) 1I-3
inspection
1. Accelerator pedal assembly inspection
1. Connect a scan tool to vehicle.
3. Adjust the accelerator pedal position sensor.
Note：
・ Check the voltage of the accelerator pedal
position sensor as shown in the table below.
Pedal
Position
Voltage as
Pedal as
APP Sensor observed on
Position observe
the Tech2
d on the
Tech2
： 0.75 to
1 Pedal at reset 0
0.85 V
Pedal at full ： 3.12 to
1 1
travel 3.22 V
： 1.55 to
2 Pedal at reset 0
1.65 V
Pedal at full ： 3.95 to
2 1
travel 4.05 V
1I-4 Speed Control Systems (4JK1)
installation
1. Accelerator pedal assembly installation
1. Install the accelerator pedal assembly to the dash
panel.
2. Connect the harness connector to the accelerator

pedal position sensor.
3. Lower vehicle.
Electrical (4JK1) 1J-1
Engine
Electrical
(4JK1)
Table of Contents
Generator..........................................................................1J-2
removal........................................................................1J-2
installation....................................................................1J-4
Glow plug.........................................................................1J-8
removal........................................................................1J-8
inspection...................................................................1J-10
installation..................................................................1J-11
Glow relay......................................................................1J-13
inspection...................................................................1J-13
ECM...............................................................................1J-14
removal......................................................................1J-14
installation..................................................................1J-17
writing........................................................................1J-18
setting.........................................................................1J-19
Barometric pressure sensor.............................................1J-21
removal......................................................................1J-21
inspection...................................................................1J-22
installation..................................................................1J-23
Starter motor...................................................................1J-24
removal......................................................................1J-24
disassembly................................................................1J-25
inspection...................................................................1J-28
reassembly..................................................................1J-31
installation..................................................................1J-34
Ignition switch................................................................1J-35
inspection...................................................................1J-35
Supplementary Information............................................1J-36
1J-2 Electrical (4JK1)
Generator
removal 4. Blow-by hose disconnect

cover.
2. Engine cover removal sensor.
1. Remove the engine cover from the engine. 2. Disconnect the harness connector from the
Note：
specifications.
assembly.
assembly.
1. Engine cover

Note：

2. MAF sensor
3. Blow-by hose
4. Intake pipe

adjust plate.

pulley.

Note：
generator.
1. Generator installation method based on belt deflection.
1. Install the generator to the bracket. ・ Apply a load to measurement point 1 of the
Load： 98 N { 10 kg / 22 lb }
Note：
： 5.4 to 6.6 mm
New ： 188 to 210 Hz
{ 0.213 to 0.260 in }
： 7.7 to 8.5 mm
{ 0.303 to 0.335 in }

Note：
1. Install the cooling fan belt to the pulley. generator.
4. Cooling fan belt adjustment Generator tightening torque
Mounting bolt
meter. 30 lb・ft }
Note：： 25 N・m { 2.5 kgf・m /
18 lb・ft }
Note：： 16.5 to 19.1 mm
cope with initial elongation. Measurement point 4
・ After making the cooling fan belt fit in, adjust Amount of belt
Frequency
its tension once again. deflection
： 15.9 to 20.7 mm
5. A/C compressor drive belt installation New ： 70 to 86 Hz
{ 0.626 to 0.815 in }
1. Install the A/C compressor drive belt to the pulley. ： 20.7 to 23.7 mm
{ 0.815 to 0.933 in }
Note：
Measurement point 2
Amount of belt
Frequency
deflection
： 12.5 to 16.5 mm
New ： 92 to 112 Hz
{ 0.492 to 0.650 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 3
Amount of belt
Frequency
1. A/C compressor drive belt deflection
： 12.4 to 16.4 mm
{ 0.488 to 0.646 in }
meter. Reuse ： 80 to 92 Hz
{ 0.650 to 0.752 in }
Note：
Measurement point 4
Amount of belt
deflection
： 15.9 to 20.7 mm
{ 0.626 to 0.815 in }
the amount of flex.
： 20.7 to 23.7 mm
Load： 98 N { 10 kg / 22 lb } Reuse ： 62 to 70 Hz
{ 0.815 to 0.933 in }
Measurement point 2
Amount of belt
Frequency
deflection
： 12.5 to 16.5 mm
New ： 92 to 112 Hz
{ 0.492 to 0.650 in }
： 16.5 to 19.1 mm
{ 0.650 to 0.752 in }
Measurement point 3
Amount of belt
Frequency
deflection
： 12.4 to 16.4 mm
New ： 92 to 112 Hz
{ 0.488 to 0.646 in }
Note： 1. Air cleaner assembly

2. MAF sensor
3. Blow-by hose
4. Intake pipe
Tightening torque： 41 N・m { 4.2 kgf・m / 30 lb・ft } 5. Barometric pressure sensor
7. Generator connect 2. Connect the intake pipe to the turbocharger
1. Connect the harness to the generator. assembly.
Tightening torque： 12 N・m { 1.2 kgf・m / 106 lb・ Tightening torque： 4 N・m { 0.4 kgf・m / 35 lb・in }
in } Terminal nut Note：
8. Generator cover installation ・ The following applies to the high-output
specifications.
adjust plate. 3. Connect the vacuum hose to the air cleaner
assembly.
pressure sensor.
intake hose.
Bolt
Clip

1. Engine cover

Glow plug
removal Note：

valve.
1. Engine cover manifold.

2. Gasket
valve and the intercooler. 1. Remove the glow plug connector from the glow
plug.
Note：


1. Glow plug
inspection
1. Glow plug inspection
1. Inspect the glow plug.
Note：
damage is found.
・ Check the main fuse for damage.
・ Replace the parts if necessary.
2. Glow plug measurement
1. Measure a resistance using the circuit tester.
Standard： 0.9 Ω Reference
installation 2. Install the intake throttle valve to the inlet manifold.

1. Install the glow plug to the cylinder head.

2. Gasket

1. Glow plug
Note： and the intake hose.
・ Install it together with the glow plug terminal. Tightening torque： 10 N・m { 1.0 kgf・m / 89 lb・in }
Tightening torque： 1 N・m { 0.1 kgf・m / 9 lb・in } Bolt
Clip


1. Engine cover

Glow relay
inspection
1. Glow relay inspection
1. Inspect the glow relay.
Note：
damage is found.
・ Check the main fuse for damage.
・ Replace the parts if necessary.
2. Glow relay measurement
Note：
・ The glow relay is installed in the relay box in
the engine compartment.
1. Measure a resistance using the circuit tester.
Note：
・ Measure the resistance value between the
measurement terminals No. 1 and No. 2, and
replace the glow relay if the measured value is
not within the specified range.
Standard： 94 to 114 Ω
1. Measurement terminal No. 1

2. Measurement terminal No. 2
ECM
removal Note：
・ If the injector ID codes have been recorded
1. ECM safety information from the cylinder head cover labels, do not
Caution： perform the following procedure.
・ When replacing the ECM, the vehicle data 2. Disconnect the harness connector from the injector.
must be written into the new ECM.
Note：
・ When replacing the ECM, before removal
・ Disconnect all of the harness connectors from
upload the old ECM data to a scan tool.
the injectors.
・ When communication with a scan tool is not
possible, remove as-is. 3. Check the Injector ID Code of the injector.
・ Use the same scan tool for the replacement Note：
procedure from beginning until end. ・ Record all of the harness connector housing
・ If the scan tool is changed during the numbers.
procedure, the correct information cannot be ・ The following diagram shows the proper order
written. of the injector ID codes.
Note：・ 72 04 F9 F8 F0 00 F0 E7 09 F6 F9 96
・ When replacing the ECM, this procedure is
required.
1. Check the Injector ID Code of the cylinder head
cover.
Note：
・ Record the injector ID codes from the cylinder
head cover labels.
Caution：
・ Only perform this procedure when the injectors
have not been replaced in the past.
1. Injector ID code
2. Injector

Note：
・ Connect the harness connectors to all of the
injectors.
2. ECM upload
Note：
required.
2. Cylinder No. 2 injector ID code ・ When the ECM to be replaced cannot
3. Cylinder No. 3 injector ID code communicate with a scan tool, do not perform
4. Cylinder No. 4 injector ID code this procedure.
5. Injector ID code label 1. Connect a scan tool to the DLC.
2. Turn ON the ignition switch. Note：
3. Select the Diagnostics. ・ Confirm that the engine does not start for all
transponder keys.
8. Select the Injector ID Upload.
Note：
・ Follow the directions on the screen and upload
the injector ID codes to a scan tool.
3. ECM reset
Note：
・ If an immobilizer is equipped, this procedure is
required.
required.
・ When the ECM to be replaced cannot
communicate with a scan tool, do not perform
this procedure.
Caution：
・ When resetting the ICU and ECM at the same
time, replacement of the transponder key is
required.
1. Connect a scan tool to the DLC. 1. Glove box
6. Instrument panel assist-side lower cover removal
4. Select the Body.
5. Select Immobilizer.
Note：
6. Select the Additional Function. ・ Remove the 4 screws.
7. Select Reset Engine Control Module.
Note：
the ECM immobilizer security information.
Caution：
・ When an incorrect security code is input, the
security wait time begins.
・ When turning the ignition switch to ON or OFF,
wait at least 5 seconds.
Note：
・ After the resetting of the ECM is complete, turn
the ignition switch to OFF for 30 seconds.
1. Glove box
7. ECM removal
1. Remove the ECM from the reinforcement.
Note：
・ Remove it together with the ECM bracket.
2. Remove the ECM from the ECM bracket.
1. Bolt
2. Nut
3. Bolt
4. ECM bracket
5. ECM
installation 1. Glove box

1. ECM installation
1. Install the ECM to the bracket.
2. Install the ECM to the reinforcement.
Note：
・ Install it together with the ECM bracket.
1. Glove box

1. Bolt
2. Nut 1. Connect the battery ground cable to the battery.
3. Bolt 2. Close the engine hood assembly.
4. ECM bracket
5. ECM

Note：
writing
1. ECM writing
Note：
・ Re-learning of the supply pump
Note：
Note：
・ Confirm that the Engine Coolant Temperature
(ECT) display is at the standard value or
higher.
Standard： 65 ℃ { 149 °F }
Note：
Learned.
Note：
・ Confirm that the scan tool does not detect a
DTC.
・ If required, perform an engine control system
inspection.
setting 1. Connect a scan tool to the DLC.

1. ECM safety information
Caution：
・ When replacing the ECM, the vehicle data 4. Select the engine model.
must be written into the new ECM. 5. Select Programming.
・ When replacing the ECM, after removal
6. Select the VIN (Vehicle Identification Number).
download the old ECM data to the new ECM,
referring to the following. 7. Select the VIN (Vehicle Identification Number).
・ Use the same scan tool for the replacement Note：
procedure from beginning until end.
・ If the VIN does not display or is not correct,
・ If the scan tool is changed during the input the correct VIN.
procedure, the correct information cannot be
written. 8. Select the Program VIN (Vehicle Identification
Number).
2. ECM writing
Note：
Note：
・ If an immobilizer is equipped, this procedure is the VIN into the ECM.
required.
・ When the ECM to be replaced can
1. Connect a scan tool to the DLC. communicate with a scan tool, do not perform
the following procedure.
4. Select the Body.
Note：
5. Select Immobilizer.
6. Select Programming. the injector ID codes into the ECM.
7. Select Program Immobilizer Function. 11. Turn OFF the ignition switch.
Note： Note：
・ Follow the directions on the screen and write ・ After the programming is complete, turn the
the immobilizer security information into the ignition switch to OFF for 30 seconds.
ECM.
4. ECM download
Caution：
Note：
・ If an incorrect security code is input, the
security wait time begins. ・ When the ECM to be replaced can
communicate with a scan tool, download the
・ When turning the ignition switch to ON or OFF,
injector ID codes.
wait at least 5 seconds.
・ Keep transponder keys to be programmed Caution：
away from other keys, other transponder keys, ・ Confirm the vehicle specifications before
key number plates, and other metal parts. downloading.
8. Turn OFF the ignition switch. ・ Perform the download after installing the new
ECM in the vehicle.
Note：
ignition switch to OFF for 30 seconds. 2. Turn ON the ignition switch.
9. Turn ON the ignition switch. 3. Select the Diagnostics.
Note： 4. Select the Engine.
・ Confirm that the engine starts for all 5. Select the engine model.
transponder keys.
3. ECM setting
8. Select the Injector ID Download.
Note：
・ Follow the directions on the screen and
download the injector ID codes to the ECM.
Caution：
・ Confirm that the injector ID codes displayed on
the screen match the injector ID codes
recorded before removing the ECM.
Note：
・ If the injector ID codes do not display or are
not correct, input the correct injector ID codes.
Note：
・ After the downloading is complete, turn the
removal
2. Barometric pressure sensor removal
1. Disconnect the connector from the barometric
pressure sensor.
2. Remove the barometric pressure sensor from the air
cleaner assembly.
inspection
1. Barometric pressure sensor inspection
1. Inspect the barometric pressure sensor.
Note：
・ Confirm that the barometric pressure sensor is
securely installed.
damage and dirt.
installation
1. Barometric pressure sensor installation
1. Install the barometric pressure sensor to the air
cleaner assembly.
2. Install the connector to the barometric pressure

sensor.
Starter motor
removal
1. Remove transmission oil level gauge tube from the
oil pan.
guide tube.
crankcase.
disassembly
1. Magnetic switch removal
1. Disconnect the lead wire from the magnetic switch.
3. Rear cover removal

1. Remove the rear cover from the motor assembly.
2. Remove the magnetic switch from the shift lever.
4. Yoke removal
1. Remove the brush from the brush holder.
Note：
2. Magnetic switch disassembly
・ Remove the 4 brushes.
1. Remove the torsion spring from the magnetic switch.
2. Remove the plunger from the magnetic switch.
3. Remove the dust cover from the magnetic switch.
2. Remove the yoke from the gear case. 5. Pinion assembly removal
Note： 1. Remove the bearing retainer from the gear case.
・ Remove it together with the armature and the 2. Remove the pinion assembly from the gear case.
brush holder.
3. Remove the dust cover from the gear case.
4. Remove the shift lever from the gear case.
3. Remove the brush holder from the yoke.

Note：
5. Remove the stopper ring from the pinion assembly.
・ Avoid the yoke, and pull out the armature
assembly to remove it. 6. Disassemble the pinion assembly.
inspection
1. Armature measurement
1. Measure the commutator using a dial gauge.
Note：
・ Measure the fluctuation, and replace the
commutator if the measured value exceeds the
limit.
Standard： 0.05 mm { 0.0020 in }
Limit： 0.25 mm { 0.0098 in }
1. Insulator
3. Commutator segment
4. Normal
5. Defect
4. Measure the commutator using a vernier caliper.

Note：
・ Measure the outer diameter.
・ If the measured outer diameter is less than the
specified limit, the commutator must be
replaced.
2. Inspect the commutator.
Note：
Limit： 35.5 mm { 1.398 in }
・ Check the mica segments for excessive worn.
3. Measure the commutator using a vernier caliper.
Note：
・ Measure the mica segment depth.
Limit： 0.2 mm { 0.008 in }
Note：
・ If the mica segment depth is at or below the
standard value but larger than the limit, the
commutator can be reground.
・ If the mica segment depth is less than the limit,
the commutator must be replaced.
5. Measure the armature using the circuit tester.

Note：
・ Check whether the armature is grounded.
・ Hold one probe against the commutator Note：

segment. ・ Check the field winding ground.
・ Hold the other probe against the armature ・ Hold one probe against the field winding end
core. or brush.
・ If there is continuity, the armature is grounded, ・ Hold the other probe against the bare surface
so replace the armature. of the yoke body.
・ If there is continuity, replace the yoke.
6. Measure the armature using the circuit tester.

Note： Note：
・ Check the armature for continuity. ・ Confirm the continuity of the field winding.
・ Hold the probes against 2 locations of the ・ Hold one probe against the M-terminal lead
commutator segment. wire.
・ Hold the probes also against other areas. ・ Hold the other probe against the field winding
brush.
・ There should be continuity between all
segments of the commutator. ・ If there is no continuity, replace the yoke.
・ Otherwise, the armature must be replaced.
3. Brush holder measurement

2. Yoke measurement 1. Measure the brush using a vernier caliper.
1. Measure the yoke using the circuit tester.
Note：・ When the negative brushes have excessive
・ Replace the brushes as a set if the measured worn, the brush holder assembly must be
brush length is less than the specified limit. replaced.
Standard： 15 mm { 0.59 in } ・ When the positive brushes have excessive
worn, the yoke must be replaced.
Limit： 12 mm { 0.47 in }
4. Pinion assembly inspection
1. Inspect the overrunning clutch.
Note：
・ Inspect the gear teeth for excessive worn and
damage.
・ Replace the overrunning clutch if necessary.
2. Turn the pinion.
Note：
・ Rotate it clockwise.
・ It should turn smoothly.
・ Rotate the pinion in the opposite direction.
・ The pinion should lock.
2. Measure the brush holder using the circuit tester.

Note：
・ Check the insulation.
・ Hold one probe against the holder plate.
・ Hold the other probe against the plus brush
holder.
・ There should be no continuity.
3. Inspect the brush.

Note：
・ Inspect for excessive worn.
reassembly 3. Pinion assembly installation

1. Assemble the pinion assembly.
1. Magnetic switch reassembly
2. Install the stopper ring to the pinion assembly.
1. Install the dust cover to the magnetic switch.
3. Apply the grease to the gear.
2. Install the plunger to the magnetic switch.
3. Install the torsion spring to the magnetic switch.
Note：
・ Install it to the magnetic switch hole.
4. Install the pinion assembly to the armature.

5. Install the bearing retainer to the gear case.
4. Yoke installation
4. Install the shift lever to the magnetic switch. 1. Install the armature to the yoke.
Note： 2. Install the brush to the brush holder.

・ Install it to the plunger hole. Note：
2. Magnetic switch installation ・ Install it by raising the spring end of the brush
spring.
1. Install the magnetic switch to the gear case.
Caution：
2. Install the dust cover to the gear case.
・ Take care not to damage the commutator
Tightening torque： 8 N・m { 0.8 kgf・m / 71 lb・in } surface.
3. Install the brush holder to the yoke.
Note：
・ Install it while aligning the peripheries of the
yoke and the brush holder.
4. Install the yoke to the gear case. 6. Pinion assembly measurement

Note： 1. Measure play using a vernier caliper.
・ Install it together with the armature and the Note：
brush holder.
・ Measure the play of the pinion shaft thrust.
5. Rear cover installation ・ The play in the pinion shaft thrust is equal to
1. Install the rear cover to the motor assembly. the clearance between the pinion shaft end
and the pinion stopper.
2. Connect the lead wire to the magnetic switch.

1. Clearance
7. Magnetic switch inspection
Caution：
・ The following tests must be performed with the
starter motor fully assembled.
・ Do not connect the lead wire of the yoke to the
M-terminal.
・ To prevent coil burning, complete each test

within 3 to 5 seconds as far as possible.
Note：
・ Temporarily connect the solenoid switch
between the clutch and the housing and
perform the following test.
1. Inspect the magnetic switch.
Note：
・ Pull-in test
・ Connect the battery negative terminal with the
solenoid switch body and the M-terminal.
・ When the current flows to the S-terminal from
the battery positive terminal, the pinion should
flutter.
Note：
・ Hold-in maintenance test
・ Disconnect the lead at the M-terminal.
・ The pinion should continue to flutter.

Note：
・ Return test
・ Disconnect the battery positive lead at the S-
terminal.
・ The pinion should return to its home position.
installation
crankcase.

pan.
3. Lower vehicle.
Ignition switch
inspection 1. Inspect the ignition switch using the circuit tester.

Note：
1. Ignition switch removal
・ Inspect the continuity between the ignition
Refer to "9.Body, Cab, Accessories 9C.Electrical switch terminals.
Control, Entertainment(All models) Ignition
・ If any abnormality is found in the inspection
switch removal".
results, repair or replace it.
2. Ignition switch inspection
3. Ignition switch installation

Refer to "9.Body, Cab, Accessories 9C.Electrical
Control, Entertainment(All models) Ignition
switch installation".
・ Starter motor
1. Plunger 3. Dust cover

2. Magnetic switch assembly 4. Magnetic switch
5. Dust cover 16. Pinion
6. Torsion spring 17. Bolt
7. Shift lever 18. Bolt
8. Gear case 19. Penetration bolt
9. Bolt 20. Rear cover
10. Pinion assembly 21. Brush holder
11. Bearing retainer 22. Lead wire
12. Pinion stopper clip 23. Yoke
13. Pinion stopper 24. Motor assembly
14. Return spring 25. Armature
15. Clutch

・ Starter motor
1： 8.6 N・m { 0.88 kgf・m / 76 lb・in } 2： 8.1 N・m { 0.83 kgf・m / 72 lb・in }
TF4JK-WE-1211TH_67209_奥付 2011.7.22 9:41 AM ページ 1
Published: Jul., 2011 All rights reserved.

First Edition
WORKSHOP MANUAL
ENGINE
(4JK1 model)
Issued by ISUZU MOTORS LIMITED
E-Solutions & Service Marketing Dept.
Shinagawa-ku, Tokyo, 140-8722 Japan
0-XXXKI
TF4JK-WE-1211TH_67209_奥付 2011.7.22 9:41 AM ページ 2
2012MY
WORKSHOP MANUAL
ENGINE
(4JK1 model)
No.TF4JK-WE-1211TH

Tf4jk-We-1211th 1st WSMW 120 TF Tis 12tf

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Section Sub Section

Maintenance precautions of engine

Function, structure, operation of engine

Accelerator pedal position sensor

1. Accelerator pedal position sensor

Barometric pressure sensor

Engine coolant temperature sensor

Fuel temperature sensor

1. Fuel temperature sensor

High pressure control Injection rate control

1. Fuel rail 8. Fuel filler cap

1. Pressure limiter valve

1. Fuel temperature sensor

Fuel injection quantity control

1. EGR cooler 5. ECM

EGR valve signal voltage at a small lift amount or closed position.

Intake throttle valve

The amount of air pressure rise and air volume delivered

1. Thermostat 7. Cylinder block

Water pump The water pump cannot be disassembled.

Thermostat The thermostat is a wax pellet type.

1. Pinion clutch 7. Inhibitor switch (for A/T vehicles only)

1. Lead wire 13. Yoke

1. Front hanger rubber 4. Rear hanger rubber

1. Accelerator pedal position sensor

1. Barometric pressure sensor 1. CMP sensor

1. No.1 cylinder injector

1. Boost sensor 1. Common rail

1. Swirl control solenoid valve

1. Vehicle speed sensor, MT specification

1. Swirl control solenoid valve 7. Actuator control vacuum hose

ECM pin layout (81 pin connector）

PIN No. Pin function

A14 Starter cut relay control

A59 MAF sensor shield ground

PIN No. Pin function

B20 CMP sensor and FRP sensor low reference

1. Engine model 3. Front

Primary specifications of engine

Generator primary specifications

Introduction to the trouble diagnosis of engine

Diagnostic system check-engine controls

Scan tool does not communicate with CAN device

Lost communication with the ECM

Fuel system check

EGR control system check

Note： Specified value： -5 to 5 %

Glow control system check

Engine compression pressure inspection

Glow system check

Lubricating system inspection

1. Oil pressure switch

5. Start the engine.

Turbocharger control system check

Charging system check

High idle speed