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Daewoo MUSSO Service Manual

Other manuals for MUSSO: Service Manual

Summary of MUSSO

  • Page 1

    Service manual foreword this manual includes procedure for mainte- nance, adjustment, service operation and re- moval and installation of components. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of manual...

  • Page 2: Personal Injury Caution

    Personal injury caution appropriate service methods and proper repair procedure are essential for the safe, reliable operation of all motor vehicles, as well as for the personal safety of the person doing the repair. There are many variations in procedures, techniques, tools and parts for servicing ...

  • Page 3: Musso

    Musso service manual foreword this manual includes procedures for maintenance, adjustment, service operations, and re- moval and installation of components for the musso vehicle. When reference is made in this manual to a brand name, number, or specific tool, an equiva- lent product may be used in p...

  • Page 4: Table of Contents

    Table of contents section 0a front matter section 0b general information section 1 engine section 1a1 m162 general engine information section 1b1 m162 engine mechanical section 1d1 m162 engine cooling section 1e1 m162 engine electrical section 1f1 m162 engine controls section 1g1 m162 engine intake ...

  • Page 5

    Issued by overseas tech. Service daewoo motor co., ltd. 391-9 chong chon-2dong, pu pyung-gu, inchon, korea telephone : 82-32-509-4161~4164 facsimile : 82-32-509-4160 musso service manual.

  • Page 6: Section 1B1

    Section 1a1 m162 general engine information section 1b1 m162 engine mechanical section 1d1 m162 engine cooling section 1e1 m162 engine electrical section 1f1 m162 engine controls section 1g1 m162 engine intake & exhaust section 1a2 m161 general engine information section 1b2 m161 engine mechanical s...

  • Page 7: Suspension

    Suspension contents section 2a suspension diagnosis section 2b wheel alignment section 2c front suspension section 2d rear suspension section 2e tires and wheels.

  • Page 8: Drive Line / Axle

    Drive line / axle contents section 3a front drive axle section 3c propeller shaft section 3d rear drive axle.

  • Page 9: Brake

    Brake contents section 4a hydraulic brakes section 4b master cylinder section 4c power booster section 4d front disc brakes section 4e rear disc brakes section 4f antilock brake system section 4g parking brake.

  • Page 10: Transmission

    Transmission contents section 5a automatic transmission section 5b manual transmission section 5c clutch section 5d1 transfer case (part time 4408) section 5d2 transfer case (tod).

  • Page 11: Steering

    Steering contents section 6a power steering system section 6e steering wheel and column.

  • Page 12: Hvac (Heating, Ventilation &

    Hvac (heating, ventilation & air conditioning) contents section 7b/c manual control/semiauto temperature control heating, ventilation, and air conditioning system section 7d full automatic temperature control heating, ventilation, and air conditioning system.

  • Page 13: Restraints

    Restraints contents section 8a seat belts section 8b supplemental restraint system (srs).

  • Page 14: Body and Accessories

    Body and accessories contents section 9a body wiring system section 9b lighting system section 9c horns section 9d wipers/washer system section 9e instrumentation/driver information section 9f audio system section 9h seats section 9l glass and mirrors section 9n frame and underbody section 9o bumper...

  • Page 15: Section 0B

    Section 0b general information specifications . . . . . . . . . . . . . . . . . . . . . . . . 0b-1 technical data . . . . . . . . . . . . . . . . . . . . . . . . 0b-1 vehicle dimensions and weights . . . . . . . . . . 0b-5 standard bolt specifications . . . . . . . . . . . . . . 0b-6 maintenance and...

  • Page 16

    0b-2 general information 661la 4cylinder diesel 89 92.4 2299 22:1 101/4000 21.5/2400 application engine type bore (mm) stroke (mm) total displacement (cc) compression ratio maximum power (ps/rpm) maximum torque (kg.M/rpm) engine 662na 5cylinder diesel 89 92.4 2874 22:1 95/4000 19.6/2400 662la 5cylin...

  • Page 17

    General information 0b-3 662la mb w4a040 3.871 2.247 1.436 1.000 5.586 5.38 9 - 9.5 auto transmission (mb) application maker type or model gear ratio : 1st 2nd 3rd 4th reverse final drive ratio oil capacity (l) 2.3l dohc mb w4a040 3.871 2.247 1.436 1.000 5.586 4.27 9 - 9.5 3.2l dohc mb w4a040 3.871 ...

  • Page 18

    0b-4 general information specifications rack & pinion 0 - 4 mm 2° 30’ ± 30’ 0° ± 30’ 1l application gear type wheel alignment: front toe-in front caster front camber oil capacity steering system application front type rear type suspension specifications double wishbone 5 - link application fuel pump...

  • Page 19

    General information 0b-5 application overall length (mm) overall width (mm) overall height (mm) wheel base (mm) tread : front (mm) rear (mm) vehicle dimensions and weights vehicle dimensions application manual : curb weight (kg) gross vehicle weight (kg) automatic : curb weight (kg) gross vehicle we...

  • Page 20

    0b-6 general information standard bolts specifications bolt* torque (n · m / ib-in) standard limit 4t 7t 9t 4t 7t 9t m3 ´ 0.5 m4 ´ 0.7 m5 ´ 0.8 m6 ´ 1.0 m8 ´ 1.25 m10 ´ 1.25 m10 ´ 1.5 m12 ´ 1.25 m12 ´ 1.75 m14 ´ 1.5 m16 ´ 1.5 m18 ´ 1.5 m20 ´ 1.5 m22 ´ 0.5 m24 ´ 1.5 m24 ´ 2.0 0.5 n · · · · · m (4.5 l...

  • Page 21: Maintenance and Repair

    General information 0b-7 maintenance and repair maintenance and lubrication fuel filter replacement replace the engine fuel filter every. L gasoline engine : 60,000km (36,000 miles) l diesel engine : 45,000km (24,000 miles) spark plug replacement replace spark plugs with same type. L type : bosch : ...

  • Page 22

    0b-8 general information scheduled maintenance charts (gasoline engine) engine months maintenance item maintenance interval kilometers or time in months, whichever comes first 120 105 9 0 7 5 6 0 4 5 3 0 1 5 1 9 6 8 4 7 2 6 0 4 8 3 6 2 4 1 2 - x1,000 km chart symbols: i - inspect these items and the...

  • Page 23

    General information 0b-9 chassis and body months maintenance item maintenance interval kilometers or time in months, whichever comes first 120 105 9 0 7 5 6 0 4 5 3 0 1 5 1 9 6 8 4 7 2 6 0 4 8 3 6 2 4 1 2 - x1,000 km exhaust pipes & mountings brake/clutch fluid (3)(4) parking brake/brake pads f & r ...

  • Page 24

    0b-10 general information scheduled maintenance charts (diesel engine) engine months - maintenance item maintenance interval kilometers or time in months, whichever comes first 100 9 0 8 0 7 0 6 0 5 0 4 0 3 0 20 10 1 6 0 5 4 4 8 4 2 3 6 3 0 2 4 1 8 12 6 x1,000 km note 1 : injection timing : adjust a...

  • Page 25

    General information 0b-11 chassis and body months - maintenance item maintenance interval kilometers or time in months, whichever comes first 100 9 0 8 0 7 0 6 0 5 0 4 0 3 0 20 10 1 6 0 5 4 4 8 4 2 3 6 3 0 2 4 1 8 12 6 x1,000 km exhaust pipes & mountings brake/clutch fluid (3) (4) parking brake/brak...

  • Page 26: Owner Inspections

    0b-12 general information owner inspections and services while operating the vehicle horn operation blow the horn occasionally to make sure it works. Check all the button locations. Brake system operation be alert for abnormal sounds, increased brake pedal travel or repeated puling to one side when ...

  • Page 27: Each Time The Oil Is Changed

    General information 0b-13 weather-strip lubrication apply a thin film silicone grease using a clean cloth. Each time the oil is changed brake system inspection this inspection should be done when the wheels are removed for rotation. Inspect the lines and the hoses for proper hookup, binding, leaks, ...

  • Page 28

    0b-14 general information usage engine oil (change with filter) engine coolant brake / clutch fluid power steering system parking brake cable hood latch assembly hood and door hinges fuel door hinge rear compartment lid hinges weatherstrips recommended fluids and lubricants capacity 8.2 l 7.5 l 9.5 ...

  • Page 29: General Description

    General information 0b-15 general description and system operation general repair instructions l if a floor jack is used, the following precautions are recommended. L park the vehicle on level ground, “block” the front or rear wheels, set the jack against the frame, raise the vehicle and support it ...

  • Page 30

    0b-16 general information vehicle identification number system k p t p 0 a 1 9 s w p 122357 12~17.Production serial number : 000001- 999999 11.Plant code p : pyongtaek plant 10.Model year m : 1991 n : 1992 p : 1993 r : 1994 s : 1995 t : 1996 v : 1997 w : 1998 x : 1999 y : 2000 9. Check digit constan...

  • Page 31

    General information 0b-17 manufacturer’s plate manufacturer’s plate location 1.Type approval no. 2.Vehicle identification number. Diesel engine gasoline engine.

  • Page 32

    0b-18 general information engine number location diesel engine the engine number is stamped on the cylinder block in front of injection pump. Il6 3200 the engine number is stamped on the lower rear side of the alternator. Gasolind engine number 162 990 1 0 012345 serial number 0 : manual t/m 1 : hyd...

  • Page 33: Vehicle Lifting Procedures

    General information 0b-19 vehicle lifting procedures to raise the vehicle, place the lifting equipment only at the points indicated. Failure to use these precise positions may result in permanent vehicle body deformation. Many dealer service facilities and service stations are equipped with automati...

  • Page 34: Section 1

    Section 1 engine section 1a1(m162 engine) general engine information specifications . . . . . . . . . . . . . . . . . . . . . . . 1a1-1 engine specifications . . . . . . . . . . . . . . . . . . 1a1-1 component locator . . . . . . . . . . . . . . . . . . 1a1-3 front view . . . . . . . . . . . . . . ....

  • Page 35

    1a1-2 general engine information application idle speed (rpm) fuel injection pressure (kg/cm²) oil capacity (liter) lubrication type oil filter type fuel engine specifications (cont'd) e32 engine 700 ± 50 3 - 4 8.2 forced by gear pump full flow with paper filter unleaded gasoline mse 3.62s/3.53s (mo...

  • Page 36: Component Locator

    General engine information 1a1-3 component locator front view 1 hfm sensor 2 intake air duct 3 resonance flap 4 cylinder head cover 5 exhaust camshaft 6 intake camshaft 7 cylinder head 8 spark plug connector 9 valve tappet 10 injector 11 exhaust valve 12 intake manifold 13 connecting rod 14 exhaust ...

  • Page 37: Side View

    1a1-4 general engine information 23 camshaft adjuster 24 cooling fan and viscous clutch 25 piston 26 flywheel of drive plate 27 oil pump drive chain 28 oil return pipe 29 timing chain 30 oil pump side view.

  • Page 38: Performance Curve

    General engine information 1a1-5 performance curve e32 engine.

  • Page 39: Special Tools

    1a1-6 general engine information special tools special tools table 000 589 10 99 01 torque wrench 001 589 76 21 00 compression pressure tester 119 589 01 09 00 spark plug wrench 001 589 65 09 00 socket.

  • Page 40: Oil Leak Diagnosis

    General engine information 1a1-7 oil leak diagnosis most fluid oil leaks are easily located and repaired by visually finding the leak and replacing or repairing the necessary parts. On some occasions a fluid leak may be difficult to locate or repair. The following procedures may help you in locating...

  • Page 41

    1a1-8 general engine information engine cranking at the front of crankshaft preceding work : removal of cooling fan 1 vibration damper assembly 2 crankshaft pulley notice l remove the negative ground cable before proceeding the work. L rotate the pulley in normal engine rotating direction when crank...

  • Page 42: Compression Pressure Test

    General engine information 1a1-9 compression pressure test 1 compression pressure tester 2 diagram sheet 3 adaptor 4 sealing cone tools required 001 589 76 21 00 compression pressure tester 119 589 01 09 00 spark plug wrench standard service data compression ratio normal engine temperature normal co...

  • Page 43

    1a1-10 general engine information measuring procedure 1. Warm the engine up to normal operating temperature. 2. Remove the spark plugs. 3. Place the diagram sheet to compression pressure tester. 4. Connect the adaptor to compression pressure tester and install it into the spark plug hole. 5. Crank t...

  • Page 44

    General engine information 1a1-11 cylinder pressure leakage test 3 engine oil filler cap 4 vibration damper permissible pressure leakage 6 cylinder pressure leakage tester with connecting hose universal tool at whole engine at valve and cylinder head gasket at piston and piston ring max. 25 % max. 1...

  • Page 45

    1a1-12 general engine information leakage test 1. Warm the engine up to normal operating temperature. 2. Disconnect the negative battery cable. 3. Remove the spark plugs. 4. Check the coolant level by opening the coolant surge tank cap and replenish if insufficient. 5. Open the engine oil filler cap...

  • Page 46: General Information

    General engine information 1a1-13 general information cleanliness and care an automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten-thousanths of an inch. When any internal engine parts are serviced, care and cleanliness...

  • Page 47: Section 1

    Section 1 engine section 1a2(m161 engine) general engine information table of contents specifications . . . . . . . . . . . . . . . . . . . . . . . 1a2-1 engine specifications . . . . . . . . . . . . . . . . . . 1a2-1 component locator . . . . . . . . . . . . . . . . . . 1a2-3 front view . . . . . ....

  • Page 48

    1a2-2 general engine information e20 engine ¬ ¬ ¬ ¬ ¬ ¬ application idle speed (rpm) fuel injection pressure (kg/cm²) oil capacity (liter) lubrication type oil filter type fuel engine specifications (cont'd) e23 engine 750 ± 50 3.2 - 4.2 7.5 forced by gear pump full flow with paper filter unleaded g...

  • Page 49: Component Locator

    General engine information 1a2-3 component locator front view 1 hfm sensor 2 intake air duct 3 cylinder head cover 4 ignition coil 5 spark plug connector 6 fuel distributor 7 injector 8 exhaust camshaft 9 intake camshaft 10 valve tappet 11 intake valve 12 intake manifold 13 cylinder head 14 exhaust ...

  • Page 50: Side View

    1a2-4 general engine information 23 camshaft adjuster 24 oil filler cap 25 engine hanger bracket 26 cooling fan and viscous clutch 27 oil filter 28 timing chain 29 oil pump drive chain 30 oil strainer 31 oil pump 32 ring gear and flywheel of drive plate 33 piston side view.

  • Page 51: Performance Curve

    General engine information 1a2-5 performance curve e23 engine.

  • Page 52: E20 Engine

    1a2-6 general engine information e20 engine.

  • Page 53: Special Tools

    General engine information 1a2-7 special tools special tools table 000 589 10 99 01 torque wrench 001 589 76 21 00 compression pressure tester 119 589 01 09 00 spark plug wrench 001 589 65 09 00 socket.

  • Page 54: Oil Leak Diagnosis

    1a2-8 general engine information oil leak diagnosis most fluid oil leaks are easily located and repaired by visually finding the leak and replacing or repairing the necessary parts. On some occasions a fluid leak may be difficult to locate or repair. The following procedures may help you in locating...

  • Page 55

    General engine information 1a2-9 engine cranking at the front of crankshaft preceding work : removal of cooling fan 1 torque wrench 2 socket 3 vibration damper ass'y notice l remove the negative ground cable before proceeding the work. L rotate the pulley in normal engine rotating direction when cra...

  • Page 56: Compression Pressure Test

    1a2-10 general engine information compression pressure test 1 compression pressure tester 2 diagram sheet 3 adaptor 4 sealing cone tools required 001 589 76 21 00 compression pressure tester 119 589 01 09 00 spark plug wrench standard service data compression ratio normal engine temperature normal c...

  • Page 57

    General engine information 1a2-11 measuring procedure 1. Warm the engine up to normal operating temperature. 2. Remove the spark plugs. 3. Place the diagram sheet to compression pressure tester. 4. Connect the adaptor to compression pressure tester and install it into the spark plug hole. 5. Crank t...

  • Page 58

    1a2-12 general engine information cylinder pressure leakage test 3 engine oil filler cap 5 vibration damper permissible pressure leakage 6 cylinder pressure leakage tester with connecting hose universal tool at whole engine at valve and cylinder head gasket at piston and piston ring max. 25 % max. 1...

  • Page 59

    General engine information 1a2-13 leakage test 1. Warm the engine up to normal operating temperature. 2. Disconnect the negative battery cable. 3. Remove the spark plugs. 4. Check the coolant level by opening the coolant surge tank cap and replenish if insufficient. 5. Open the engine oil filler cap...

  • Page 60: General Information

    1a2-14 general engine information general information cleanliness and care an automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten-thousanths of an inch. When any internal engine parts are serviced, care and cleanliness...

  • Page 61: Section 1

    Application engine type displacement (cc) cylinder (bore x stroke) (mm) fuel injection / ignition system compression ratio number of cylinders camshaft valve arrangement camshaft drive type max. Output (ps/rpm) max. Torque (kg•m/rpm) firing order injection timing valve timing intake open/close (at 2...

  • Page 62

    1a3-2 general engine information om 662 la 720 - 820 135 - 143 8.0 - 9.5 forced by gear pump combined full-flow and partial flow filter diesel application idle speed (rpm) fuel injection pressure (bar) oil capacity (liter) lubrication type oil filter type fuel engine specifications (cont'd) om661la ...

  • Page 63: Sectional View

    General engine information 1a3-3 sectional view om662la engine front view.

  • Page 64

    1a3-4 general engine information side view.

  • Page 65: Om661La Engine

    General engine information 1a3-5 om661la engine front view.

  • Page 66

    1a3-6 general engine information side view.

  • Page 67: Performance Curve

    General engine information 1a3-7 performance curve om662la engine rpm.

  • Page 68: Om661La Engine

    1a3-8 general engine information om661la engine rpm.

  • Page 69: Special Tools

    General engine information 1a3-9 special tools special tools table 000 589 10 99 01 torque wrench 001 589 76 21 00 compression pressure tester 001 589 73 21 00 hand vacuum pump 001 589 65 09 00 socket.

  • Page 70: Oil Leak Diagnosis

    1a3-10 general engine information oil leak diagnosis most fluid oil leaks are easily located and repaired by visually finding the leak and replacing or repairing the necessary parts. On some occasions a fluid leak may be difficult to locate or repair. The following procedures may help you in locatin...

  • Page 71: Compression Pressure Test

    General engine information 1a3-11 28bar approx.18bar max. 3bar compression pressure test 1 test adapter 2 flexible connector 3 compression pressure recorder tools required 000 589 65 09 00 socket 001 589 73 21 00 hand vacuum pump service data normal compression pressure minimum compression pressure ...

  • Page 72

    1a3-12 general engine information compression pressure measurement notice ensure that no gear is engaged and that the vehicle is protected from rolling. 1. Run the engine to be the coolant temperature 80°c. 2. Remove the fuel injection nozzle. Socket wrench insert 001 589 65 09 00 3. Install the tes...

  • Page 73

    General engine information 1a3-13 cylinder pressure leakage tester connection piece cylinder pressure leakage test 1 connector 2 connection piece 3 connection hose permissible pressure leakage (engine at normal operating temperature of 80°c) at whole engine at valve and cylinder head gasket at pisto...

  • Page 74

    1a3-14 general engine information leakage test 1. Run the engine to be the coolant temperature 80°c. 2. Remove the fuel injection nozzle. 3. Open the coolant subtank cap. 4. Check the coolant level and replenish if necessary. 5. Open the oil filler cap. 6. Remove the air cleaner cover and element. 7...

  • Page 75: General Information

    General engine information 1a3-15 general information cleanliness and care an automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten-thousanths of an inch. When any internal engine parts are serviced, care and cleanliness...

  • Page 76: Section 1B1

    Section 1b1 m162 engine mechanical caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the...

  • Page 77: Specifications

    1b1-2 m162 engine mechanical specifications fastener tightening specifications n · · · · · m 35 - 40 10 - 15 5 - 10 21 - 25 30 56 - 66 50 - 60 10 - 15 41.5 - 49.5 22.5 - 27.5 22.5 - 27.5 9 - 11 9 - 11 22.5 - 27.5 9 - 11 22.5 - 27.5 10 +90° 55 +90° +90° 22.5 - 27.5 22.5 - 27.5 9 - 10 9 - 10 200 +90° ...

  • Page 78

    M162 engine mechanical 1b1-3 n · · · · · m 20 / +90° 40 72 - 88 20 / +90° 25 - 35 22.5 - 27.5 22.5 - 27.5 22.5 - 27.5 22.5 - 27.5 30 26 - 34 30 8 - 10 25 25 22.5 - 27.5 29 - 35 22.5 - 27.5 9 - 11 50 9 - 11 15 application exhaust camshaft sproket bolt chain tensioner screw plug chain tensioner assemb...

  • Page 79: Special Tools

    1b1-4 m162 engine mechanical special tools special tools table 001 589 66 21 00 torque wrench 000 589 01 10 00 box wrench insert 124 589 15 21 00 radiator cap testing unit 116 589 02 34 00 screw-fixed pin 000 589 10 99 01 torque wrench 112 589 00 72 00 oil extractor 000 589 72 21 00 torque wrench 00...

  • Page 80

    M162 engine mechanical 1b1-5 104 589 01 01 00 spanner 111 589 18 61 00 lever pusher 111 589 25 63 00 thrust piece special tools table (cont’d) 111 589 01 59 00 supporting bar 116 589 06 63 00 magnetic finger 119 589 00 43 00 drift 000 589 58 43 00 chain assembly 104 589 00 37 00 pliers.

  • Page 81

    1b1-6 m162 engine mechanical 116 589 20 33 00 sliding hammer 602 589 00 40 00 engine lock 103 589 00 33 00 puller special tools table (cont’d) 601 589 03 43 00 sleeve 001 589 65 09 00 socket wrench insert 001 589 74 21 00 torque wrench 000 589 04 14 00 clamping strap 000 589 88 33 00 puller.

  • Page 82

    M162 engine mechanical 1b1-7 103 589 01 63 00 rivet set 103 589 02 09 00 oil filter socket wrench 102 589 12 15 00 drift special tools table (cont’d) 615 589 01 33 00 caulking bolt 102 589 00 15 00 drift 000 589 51 37 00 clamping strap 001 589 72 21 00 torque wrench 601 589 03 14 00 sleeve.

  • Page 83: Maintenance and Repair

    1b1-8 m162 engine mechanical maintenance and repair on-vehicle service engine assembly tools required 000 589 10 99 01 torque wrench 000 589 40 37 00 hose clamp 112 589 00 72 00 oil extractor.

  • Page 84

    M162 engine mechanical 1b1-9 4. Disconnect the coupling of hfm sensor and remove the air cleaner cross pipe. 6. Loosen the radiator drain cock and drain the coolant. Notice open the coolant reservoir cap. 5. Remove the air cleaner cover. Remove the mounting bolts and air cleaner housing and element ...

  • Page 85

    1b1-10 m162 engine mechanical 10. Remove the upper mounting bolts of radiator and then remove the radiator. 7. Loosen the cylinder block drain plug and then drain the coolant completely. Installation notice tightening torque 30 nm notice replace the seal before installation of the drain plug. 8. Rem...

  • Page 86

    M162 engine mechanical 1b1-11 12. Discharge the refrigerant from a/c system, and disconnect the discharge pipe and suction pipe from the compressor. 14. Remove the fuel feed and return line. Notice before removing the fuel lines, release the pressure in the fuel system. Installation notice 13. Remov...

  • Page 87

    1b1-12 m162 engine mechanical 19. Disconnect the engine ground wire. 15. Remove the automatic transmission dipstick guide tube. 16. Disconnect the wire of alternator. 17. Disconnect the wire of starter motor and remove the starter motor. 18. Disconnect the engine main harness ground..

  • Page 88

    M162 engine mechanical 1b1-13 20. Disconnect following sensors connector. L hfm sensor. L coolant temperature sensor. L 2 knock sensors. L camshaft and crankshaft sensors. 21. After removing the ignition coil cover, disconnect the ignition coil connector. 22. Remove the harness cover and disconnect ...

  • Page 89

    1b1-14 m162 engine mechanical tightening torque 30 nm 29. Remove the exhaust manifold and exhaust pipe. Installation notice 25. Separate the vacuum hose for brake booster. 26. Separate the other vacuum hoses. 27. Remove the propeller shaft from the front axle. Installation notice 28. By rotating the...

  • Page 90

    M162 engine mechanical 1b1-15 30. Remove the transmission mounting bolts and separate the transmission from the engine. Installation notice tightening torque 65 nm 31. Remove the bolts for engine mounting bracket. Installation notice tightening torque 50 - 75 nm 32. Hook the chain to the bracket of ...

  • Page 91: Crankcase Ventilation System

    1b1-16 m162 engine mechanical crankcase ventilation system 1 crankcase 2 air admission port in crankcase 3 oil drain port 4 filter 5 gasket 6 a/c bracket 7 oil drain pipe 8 oil pan 9 air admission line 10 vent line 11 restriction hole (diameter = 2 mm) 12 intake manifold 13 intake air duct (cross pi...

  • Page 92

    M162 engine mechanical 1b1-17 operation at idling and mid-load l it show that the throttle valve (19) is closed or very partially opened and the vacuum pressure in intake manifold is high. The blowby gas in the crankcase in partial load flows into the intake manifold through the vent line (20) after...

  • Page 93: Alternator

    1b1-18 m162 engine mechanical alternator 1 nut (m8) ......................................... 22.5-27.5 nm 2 bolt (m8 x 30, 3 pieces) ................. 22.5-27.5 nm 3 bolt (m8 x 40, 1 piece) ................... 22.5-27.5 nm removal & installation procedure 1. Remove the drive belt. 2. Remove the alt...

  • Page 94

    M162 engine mechanical 1b1-19 power steering pump and a/c bracket preceding work : removal of cooling fan and shroud 1 vent hose 2 bolt (m8 x 91, 2 pieces) ................. 22.5-27.5 nm 3 power steering pump 4 bolt (m8 x 105, 4 pieces) ............... 22.5-27.5 nm 5 washer 6 a/c compressor 7 bolt (...

  • Page 95

    1b1-20 m162 engine mechanical removal & installation procedure 1. Remove the belt pulley. Installation notice 2. Disconnect the hydraulic pipe of the power steering pump and drain the oil. 3. Unscrew the bolts (arrows) and remove the steering pump. Installation notice notice pull the tensioning pull...

  • Page 96

    M162 engine mechanical 1b1-21 5. Disconnect the vent hose from the a/c bracket. 6. Unscrew all the mounting bolts (arrows) and remove the a/c bracket and the gasket. Installation notice 7. Clean the sealing surface. 8. Replace the gasket with new one. 9. Installation should follow the removal proced...

  • Page 97

    1b1-22 m162 engine mechanical hydraulic engine mounting insulator service data.

  • Page 98

    M162 engine mechanical 1b1-23 sectional view 1 rubber body 2 brackek 3 core 4 lower bolt 5 rubber plunger 6 plunger plate 7 rubber 8 plate 9 lower orifice 10 upper orifice 11 diaphram 12 cover plate 13 upper bolt 14 flange bolt 15 rivet 16 fluid.

  • Page 99

    1b1-24 m162 engine mechanical 1 upper nut 2 hydraulic installor ................. 62-93 nm 3 lower nut ............................. 28-47 nm removal and installation procedure 1. Unscrew the upper nut(1) on engine mounting and remove the engine. Installation notice 3. Installation should follow the...

  • Page 100: Poly V - Belt

    M162 engine mechanical 1b1-25 poly v - belt preceding work : removal of cooling fan 1 poly v-belt removal & installation procedure 1. Release the belt tension by turning the belt tensioning pulley nut clockwise. 2. Remove the poly v-belt. Notice check the belt for damage and tensioning pulley bearin...

  • Page 101

    1b1-26 m162 engine mechanical poly v-belt arrangement 1 belt tensioning pulley 2 crankshaft belt pulley 3 a/c compressor pulley 4 cooling fan pulley 5 alternator pulley 6 idler 7 power steering pump pulley 8 cooling fan and water pump pulley.

  • Page 102: Tensioning Device

    M162 engine mechanical 1b1-27 tensioning device preceding work : removal of poly v-belt 1 belt (l = 2245) 2 bolt combi(m8 x 14, 3 pieces) + washer ....................................................... 22.5-27.5nm removal & installation procedure 1. Remove the poly v-belt. 2. Remove the tensioning ...

  • Page 103

    1b1-28 m162 engine mechanical 4. Remove the mounting bolts(m8 x 30, 3 pieces) at the tensioning device, and remove the tensioning device (arrow). Installation notice 3. Remove the 3 bolts (2) and remove the water pump pulley (arrow). Installation notice 5. Installation should follow the removal proc...

  • Page 104: Poly V - Belt Inspection

    M162 engine mechanical 1b1-29 3. Pointed rib. 4. Belt cord visible in the base of rib. Poly v - belt inspection l make marks on the belt with chalk. L rotate the engine and check the belt for damage. Notice if one of the following types of damages is found, replace the belt. 1. Rubber lumps in the b...

  • Page 105

    1b1-30 m162 engine mechanical 7. Rib detached from the base of belt. 8. Splits across the rib. 9. Sections of rib torn out. 10. Splits across several ribs. 11. Splits across the back of the belt..

  • Page 106: Cylinder Head Cover

    M162 engine mechanical 1b1-31 cylinder head cover 1 ignition cable dust cover 2 bolt (m6 x 65, 8 pieces) ......................... 9-11 nm 3 bolt (m6 x 50, 4 pieces) ......................... 9-11 nm 4 spacer sleeve 5 thrust piece composition of the cylinder head cover bolts a. M6 x 50, 4 pieces - b...

  • Page 107

    1b1-32 m162 engine mechanical removal & installation procedure 1. Remove the intake air duct. Installation notice 2. Remove the ignition cable cover. Installation notice 3. Remove the spark plug connector and ignition cable. 4. Unscrew all the bolts (2,3) and remove the head cover and the gasket. In...

  • Page 108: Cylinder Head Front Cover

    M162 engine mechanical 1b1-33 cylinder head front cover preceding work : removal of cylinder head cover removal of coolant connection fitting 1 camshaft position sensor 2 magnet assembly 3 upper guide rail 4 bolt (m6 x 60, 3 pieces) ................. 22.5-27.5 nm 5 bolt (m8 x 80, 3 pieces) ............

  • Page 109

    1b1-34 m162 engine mechanical 2. Remove the cylinder head front cover (6). Installation notice 4. Remove the gasket (arrow). Installation notice replace the gasket with new one and apply the sealant. 5. Installation should follow the removal procedure in the reverse order. Apply the sealant at the m...

  • Page 110: Cylinder Head

    M162 engine mechanical 1b1-35 cylinder head preceding work : removal of cylinder head cover removal of cylinder head front cover removal of upper intake manifold 1 cylinder head bolt (14 pieces) .................................................... 1st step 55 nm 2nd step 90° 3rd step 90° 2 washers (...

  • Page 111

    1b1-36 m162 engine mechanical 4. Remove the three flange bolts in the exhaust camshaft sprocket. Installation notice 5. Separate the chain from the camshaft sprockrt. Notice be careful not to drop the chain into the timing case. Do not reuse the removed bolts. Tools required 000 589 01 10 00 box wre...

  • Page 112

    M162 engine mechanical 1b1-37 7. Remove the cylinder head bolts in numerical order. Installation notice 8. Check the length of the cylinder head bolt. Installation notice box wrench insert 000 589 01 10 00 l replace the bolt if the measured length exceed the max. Length. L apply the oil to the threa...

  • Page 113: Timing Gear Case Cover

    1b1-38 m162 engine mechanical timing gear case cover preceding work : removal of cylinder head front cover removal of alternator bracket removal of tensioning device removal of belt pulley and vibration damper 1 bolt (m8 x 60, 3 pieces) ................. 22.5-27.5 nm 2 a/c bracket 3 bolt (m8 x 65, 3...

  • Page 114

    M162 engine mechanical 1b1-39 3. Remove the cooling fan and the viscous clutch. Unscrew the three bolts from the cooling fan bracket and remove the bracket (arrows). Installation notice 4. Remove the timing gear case cover after unscrewing the bolts (3) and (4) from the timing gear case cover and th...

  • Page 115

    1b1-40 m162 engine mechanical crankshaft sealing rear cover preceding work : removal of the automatic transmission drive plate 1 bolt (m6 x 20, 6 pieces) ......................... 9-11 nm 2 radial shaft seal 3 rear cover 4 sleeve 5 bolt (m6 x 85, 2 pieces) ......................... 9-11 nm 6 washer.

  • Page 116

    M162 engine mechanical 1b1-41 tools required 601 589 03 43 00 sleeve removal & installation procedure 1. Unscrew the bolts (1) and (5) and remove the closing cover by pulling the rear cover lug (arrows). Notice be careful not to damage the oil pan gasket. 2. Clean the sealing surface of the crankcas...

  • Page 117

    1b1-42 m162 engine mechanical 1 center bolt (m18 x 50) ...... 1st step 200- 220 nm 2nd step 90°+10° 2 vibration damper disk 3 bolt (m6 x 20, 6 pieces) ..................... 7.7-9.5 nm belt pulley and vibration damper preceding work : removal of cooling fan and viscous clutch removal of fan shroud re...

  • Page 118

    M162 engine mechanical 1b1-43 components 1 center bolt (m18 x 50) 2 center bolt washer 3 vibration damper and pulley assembly 4 key 5 crankshaft front seal 6 timing gear case cover 7 crankshaft sprocket (camshaft driven) 8 crankshaft sprocket (oil pump driven) 9 crankshaft 10 oil pan 11 oil pan gask...

  • Page 119

    1b1-44 m162 engine mechanical engine lock 602 589 00 40 00 2. Remove the start motor and install the engine lock to the flywheel ring gear. 3. Remove the center bolt. Installation notice tightening torque 1st step 200 - 220 nm 2nd step 90° +10° 4. Remove the vibration damper assembly using the pulle...

  • Page 120: Crankshaft Front Radial Seal

    M162 engine mechanical 1b1-45 crankshaft front radial seal preceding work : removal of belt pulley and vibration damper 1 center bolt (m18 x 50) ................................ 1st step 200-220 nm 2nd step 90° +10° 2 center bolt washer 3 sleeve (special tool) 4 crankshaft front seal 5 key tools req...

  • Page 121: Crankshaft Rear Radial Seal

    1b1-46 m162 engine mechanical crankshaft rear radial seal preceding work : removal of flywheel or drive plate 1 special tool 2 special tool 3 crankshaft rear seal tools required 601 589 03 43 00 sleeve replacement proceudre 1. Remove the radial seal with a screw driver. Notice use a clean cloth not ...

  • Page 122: Crankshaft

    M162 engine mechanical 1b1-47 crankshaft preceding work : removal of engine assembly removal of timing gear case cover removal of cylinder head removal of oil pump removal of oil shield 1 12-sided stretch bolt ........ 55 nm x 90°, iubricate 2 crank shaft bearing cap 3 crank shaft low main bearing 4...

  • Page 123

    1b1-48 m162 engine mechanical arrangement of the thrust bearing and the main bearing 1 - 12 weight balance/color marking point j1 - j7 journal main bearing #1 - #7 l color dot marking the color dot marking are put on the 1 , 2 , 4 , 6 , 8 , 10 ,12 and it indicates the diameter of crankshaft journal ...

  • Page 124

    M162 engine mechanical 1b1-49 selection of crankshaft main bearing 1. Crankcase side there are seven punching marks on the mating surface to oil pan. This mark is correspondent to the bearing distinguished by color. Select the relevant bearing according to the punching mark when repaired. 2. Cranksh...

  • Page 125

    1b1-50 m162 engine mechanical installation notice l make sure the crankshaft bearing cap properly seated in place in the crankcase side. When perfectly installed, the projected part (arrow) locates in the left side (intake manifold side). L assemble so that the projected part of the cap and crankcas...

  • Page 126

    M162 engine mechanical 1b1-51 inspection 1. If the length ‘l’ of the crankshaft bearing cap bolt exceeds 63.8mm, replace it. 2. Make sure the crankshaft bearing cap is properly seated on the cylinder block (arrows). 3. Measure and record the inner diameter of the crankshaft bearing. Notice l measure...

  • Page 127

    1b1-52 m162 engine mechanical service data standard (crankshaft main bearing gap) (connecting rod bearing gap) item main bearing journal ( no. 1, 5, 7) main bearing journal ( no. 3, 4, 6) measuring position radial axial radial axial gap (mm) static condition :0.015 - 0.039 dynamic condition: 0.031 -...

  • Page 128: Flywheel / Driven Plate

    M162 engine mechanical 1b1-53 flywheel / driven plate preceding work : removal of manual or automatic transmission 1 flywheel mounting bolt (m10 x 22, 8 pieces) ............................................... 1st step 45+5 nm 2nd step +90° +10° 2 plate 3 driven plate (a/t) 4 dowel pin service data s...

  • Page 129

    1b1-54 m162 engine mechanical removal & installation procedure 1. Unscrew the stretch bolt. Installation notice sectional view 1 oil pan 2 cover 3 crankshaft front seal 4 flywheel mtg bolt 5 crankshaft 6 dowel pin 7 plate 8 tgcc 9 bolt 10 front drive plate 11 rear drive plate 12 rivet 13 segment 14 ...

  • Page 130: Camshaft Adjuster

    M162 engine mechanical 1b1-55 camshaft adjuster 1 bolt (m6 x 16, 3 pieces) ........................ 9-11 nm 2 electromagnetic actuator (2 pin connector) 3 bolt ........................................................... 35 nm 4 armature 5 roll pin 6 nut (m20 x 1.5) .....................................

  • Page 131

    1b1-56 m162 engine mechanical removal & installation procedure 1. Turn the crankshaft to the direction of engine rotation and position the no.1 cylinder piston at tdc which the camshaft is positioned at ot. 2. Remove the cylinder head front cover. 3. Paint the alignment marks (arrows) on the intake ...

  • Page 132

    M162 engine mechanical 1b1-57 7. Remove the camshaft sprocket (13) and adjust piston (14), and remove the flange shaft (16) from the intake camshaft (22) after removing the bolt (15). Installation notice the sprocket bolt is designed to be used only once, so always replace with new one. 8. Installat...

  • Page 133: Camshaft Sprocket Bolt

    1b1-58 m162 engine mechanical camshaft sprocket bolt intake flange shaft bolt notice the sprocket bolts are designed to be used only once, so always replace with new one. Exhaust camshaft sprocket bolt notice the sprocket bolts are designed to be used only once, so always replace with new one. C. M7...

  • Page 134: Camshaft

    M162 engine mechanical 1b1-59 camshaft preceding work : removal of cylinder head cover, removal of coolant connection fitting 1 chain tensioner assembly .................. 72-88 nm 2 exhaust camshaft sprocket 3 upper guide rail 4 cylinder head front cover 5 intake camshaft sprocket 6 chain 7 wrench ...

  • Page 135

    1b1-60 m162 engine mechanical tools required 000 589 01 10 00 box wrench insert 104 589 01 01 00 spanner removal procedure 1. Turn the crankshaft and position the no. 1 cylinder piston at btdc 30°. 2. Remove the alternator. 3. Remove the chain tensioner. 4. Remove the cylinder head front cover and t...

  • Page 136

    M162 engine mechanical 1b1-61 8. Unscrew the intake side bolts (8, 11, 13, 14) and the exhaust side bolts (1, 4, 6, 7). 9. Loosen the remaining bolts and unscrew the intake and exhaust side camshaft bearing cap bolts. Notice number the camshaft bearing cap bolts when removing them, so that they don’...

  • Page 137

    1b1-62 m162 engine mechanical 4. Turn the intake camshaft adjuster to the direction of camshaft rotation by hard until it stops and then install the chain. Notice l make sure that the camshaft sprocket and timing chain are aligned with marks. L intake camshaft adjuster should be in retarded position...

  • Page 138

    M162 engine mechanical 1b1-63 8. Install the upper guide rail and cylinder head front cover. 9. Install the alternator..

  • Page 139: Camshaft Timing Position

    1b1-64 m162 engine mechanical camshaft timing position preceding work : removal of cylinder head cover removal of cylinder head front cover 1 chain tensioner assembly 2 exhaust camshaft sprocket 3 upper guide rail 4 cylinder head front cover 5 wrench (special tool) 6 adjustment hole fitting pin ( f ...

  • Page 140

    M162 engine mechanical 1b1-65 adjustment procedure 1. Position the no.1 cylinder to btdc 30° . 2. Remove the chain tensioner. 3. Remove the exhaust camshaft sprocket. 4. Align the intake and exhaust camshaft flange hole with the cylinder head upper surface. L intake side : 3 o’clock direction l exha...

  • Page 141

    1b1-66 m162 engine mechanical 11. Check the camshaft timing. The sprocket bolt is designed to be used only once, so replace with new one. 10. Install the chain tensioner. Installation notice tightening torque 1st step 18 - 22 nm 2nd step 90° ± 5° 9. Install the chain to the exhaust camshaft sprocket...

  • Page 142: Valve Spring

    M162 engine mechanical 1b1-67 valve spring preceding work : removal of camshaft removal of spark plug 1 valve tappet assembly 2 valve cotter 3 upper retainer 4 valve spring .......... Check, replace if necessary 5 valve stem seal 6 lower retainer 7 connecting hose 8 thrust piece 9 slide 10 adjust bo...

  • Page 143

    1b1-68 m162 engine mechanical tools required 111 589 01 59 00 supporting bar 111 589 18 61 00 lever pusher 111 589 25 63 00 thrust piece 116 589 06 63 00 magnetic finger removal & installation procedure 1. Place the supporting bar (12) and the slide (9) at the camshaft bearing cap (nos 1 & 7/8&14) a...

  • Page 144

    M162 engine mechanical 1b1-69 8. Install the lever pusher (11) and the thrust piece (8) to the slide (9). 13. Remove the valve cotter (2) using either the pincette (13) or magnetic finger. Lever pusher 111 589 18 61 00 magnetic finger 116 589 06 63 00 9. Mount the thrust piece (8) vertically to the ...

  • Page 145

    1b1-70 m162 engine mechanical test (upper and lower valve tappet and valve cotter) l upper valve spring retainer l lower valve spring retainer l valve cotter 12.3 (d) (d) 8.5 size (mm) thickness (mm) (a) 0.8 - 1.0 9.2 - 9.8 (h) (b) 9.0 size (mm).

  • Page 146: Valve Stem Seal

    M162 engine mechanical 1b1-71 valve stem seal preceding work : removal of valve spring 1 drift (special tool) 2 valve stem seal 3 protective sleeve drift 119 589 00 43 00 pliers 104 589 00 37 00 tools required 104 589 00 37 00 pliers 119 589 00 43 00 drift replacement procedure 1. Remove the valve s...

  • Page 147: Chain Tensioner

    1b1-72 m162 engine mechanical chain tensioner 1 screw plug ................................................ 40 nm 2 seal 3 filler pin 4 compression spring 5 snap ring 6 thrust pin 7 chain tensioner housing ..................... 72-88 nm 8 seal removal procedure 1. Position the no.1 cylinder to tdc (...

  • Page 148

    M162 engine mechanical 1b1-73 installation procedure 1. Connect the thrust pin (6) and the snap ring (5) to the chain tensioner housing (7). Notice when connecting the thrust pin, push in the thrust pin far enough so that it doesn’t protrude at the chain tensioner housing. 4. Carefully unscrew the s...

  • Page 149

    1b1-74 m162 engine mechanical 4. Lightly apply the grease to the seal (2) and install the screw plug (1). Installation notice sectional view 1 screw plug 2 ball (nonreturn valve) 3 compression spring 4 ball guide 5 seal (aluminum) 6 filler pin 7 compression spring 8 snap ring 9 thrust pin 10 ball (n...

  • Page 150: Timing Chain

    M162 engine mechanical 1b1-75 timing chain preceding work : removal of cylinder head cover removal of spark plug 1 pin 2 new timing chain 3 timing chain (used) 4 wedge 5 link 6 center plate 7 outer plate.

  • Page 151

    1b1-76 m162 engine mechanical tools required 000 589 58 43 00 chain assembly 103 589 01 63 00 rivet set 001 589 72 21 00 torque wrench replacement procedure 1. Position the no.1 cylinder to tdc (ot). 4. Mount the wedges to both sides of the camshaft sprocket as shown in the figure. 2. Insert the f 4...

  • Page 152

    M162 engine mechanical 1b1-77 7. Connect the new timing chain (2) to the used timing chain (3) with the link (5), center plate (6, thickness 1.6mm), and the outer plate (7). 8. Rotate the crankshaft in the direction if engine revolution by pressing the new timing chain against the exhaust camshaft s...

  • Page 153

    1b1-78 m162 engine mechanical 15. Replace the thrust piece (b) as shown in the figure. 13. Install the assembly tool above the link and tighten the spindle (c) until a block is felt. 14. Place the assembly tool. 12. Place the outer plate (7, thickness 1.2mm) inside the thrust piece (b). 16. Install ...

  • Page 154

    M162 engine mechanical 1b1-79 17. Rivet the link pin. Check the condition and it again if necessary. 18. Install the chain tensioner. Installation notice 19. Check the camshaft timing position. Tightening torque screw plug 40 nm tensioner assembly 72 - 88 nm.

  • Page 155: Tensioning Rail

    1b1-80 m162 engine mechanical tensioning rail preceding work : removal of timing gear case cover 1 tensioning rail 2 plastic guide 3 tensioning rail pin 4 guide rail removal & installation procedure 1. Put the assembly mark at the camshaft sprocket and the timing chain with the paint (arrow). 2. Rem...

  • Page 156: Cylinder Head Guide Rail

    M162 engine mechanical 1b1-81 tools required 104 589 01 01 00 spanner removal & installation procedure 1. Remove the chain tensioner (1). 2. Turn the exhaust camshaft to the camshaft rotating direction using the wrench (4) and loosen the timing chain at upper guide rail (2). 3. Pull out the upper gu...

  • Page 157: Crankcase Guide Rail

    1b1-82 m162 engine mechanical crankcase guide rail preceding work : removal of timing gear case cover 1 guide rail 2 plastic guide 3 guide rail pin 4 tensioning rail removal & installation procedure 1. Put the assembly mark at the camshaft sprocket and the timing chain with the paint (arrow). 2. Rem...

  • Page 158: Crankshaft Sprocket

    M162 engine mechanical 1b1-83 crankshaft sprocket preceding work : removal of oil pan removal of tensioning rail removal of crank case guide rail 6 bolt (m8 x 20, 1 piece) / washer .......... 29-35 nm 7 oil pump sprocket 8 oil pump 9 oil pump roller chain 10 timing chain 1 oil pump chain tensioner 2...

  • Page 159

    1b1-84 m162 engine mechanical tools required 615 589 01 33 00 puller removal & installation procedure 1. Put the assembly mark at the crankshaft sprocket (4) and the timing chain (10) with the paint (arrow). Installation notice align the assembly marks on cranshaft sprocket and timing chain. Also, a...

  • Page 160: Piston

    M162 engine mechanical 1b1-85 piston preceding work : removal of engine removal of cylinder head removal of oil pan removal of oil pump removal of baffle plate 1 connecting rod bearing cap 2 connecting rod 3 connecting rod bolt (m9 x 52, 12 pieces) ......................................................

  • Page 161

    1b1-86 m162 engine mechanical tools required 001 589 72 21 00 torqued wrench 000 589 04 14 00 clamping strap removal procedure 1. Unscrew the connecting rod bolt (3) and remove the cap. 2. Remove the connecting rod and the piston upward. Notice make sure that the bearing cap and shell are not change...

  • Page 162

    M162 engine mechanical 1b1-87 1. Check the piston ring gap and apply the engine oil to the piston pin and the connecting rod bushing. 2. Connect the piston and the connecting rod by pressing in the piston pin (6) and install the snap ring to the groove. 3. Clean the cylinder bore, connecting rod bea...

  • Page 163: Connecting Rod

    1b1-88 m162 engine mechanical connecting rod preceding work : removal of piston 1 connecting rod bushing 2 oil gallery 3 balance weight 4 connecting rod bolt (m9 x 52, 12 m pieces) .. 1st step 40+5 nm 2nd step 90°+10° 5 fit sleeve 6 upper connecting rod bearing 7 lower connecting rod bearing 8 beari...

  • Page 164

    M162 engine mechanical 1b1-89 inspection 1. Measure the basic bore of the connecting rod bearing. Notice if the basic bore exceeds the value of 51.614mm, replace the bearing or check the connecting rod. 2. Check connecting rod bolts. 3. Check the assembly mark(indication//or number:arrow) of the con...

  • Page 165: Piston Ring

    1b1-90 m162 engine mechanical piston ring preceding work : removal of piston 1 piston compression ring 2 piston compression ring 3 piston oil ring 4 - 5 coil spring and control ring 6 hook spring notice if out of specification, replace the piston ring. Tools required 000 589 51 37 00 clamping strap ...

  • Page 166

    M162 engine mechanical 1b1-91 2. Remove the piston ring with a pliers. 3. For installation, position the piston ring to be the ‘top’ mark on the piston ring upward and arrange the piston ring ends to be 120° apart. 4. Adjust the hook spring joint in the oil ring 180° away from the ring end. Clamping...

  • Page 167: Engine Oil Specification

    1b1-92 m162 engine mechanical engine oil specification 1 drain plug ................................................. 25 nm 2 oil filter 3 engine oil filler cap 4 dipstick gauge specifications application capacity descrition min : 6.7l, max : 8.2l l api sh or above grade l acea : a2 or a3 l approved...

  • Page 168: Oil Pan

    M162 engine mechanical 1b1-93 oil pan 1 gasket ................................................... Replace 2 bolt (m6 x 22, 6 pieces) ............................ 10 nm 3 drain plug (m6 x 20) ................................. 25 nm 4 bolt (m6 x 20, 22 pieces) .......................... 10 nm 5 bolt ...

  • Page 169

    1b1-94 m162 engine mechanical oil circulation 1 oil pump 2 oil gallery (to oil filter) 3 oil filter 4 oil pressure switch 5 main oil gallery 6 cylinder head closing cover 7 oil gallery (at chain tensioner) 8 oil non-return valve 9 chain tensioner 10 vent (chain tensioner) 11 front closing cover ( f ...

  • Page 170

    M162 engine mechanical 1b1-95 engine oil and oil filter element 4. Remove the drain plug (arrow) and drain the engine oil. Notice leave the oil filler cap open to ease the engine oil discharge. 5. Tighten the engine oil drain plug after cleaning it. Installation notice tools required 103 589 02 09 0...

  • Page 171

    1b1-96 m162 engine mechanical 3 oil filler cap 4 dipstick gauge 9. Fill up engine oil through the engine oil filler opening (3). 10. Check for oil leaks at normal engine temperature after starting the engine. 11. Stop the engine and wait 5 minutes. Check the oil level and fill up as specified if nec...

  • Page 172: Oil Filter

    M162 engine mechanical 1b1-97 oil filter preceding work : removal of starter motor removal of upper intake manifold 1 coolant line 2 o-ring .................................................... Replace 3 clip 4 hose 5 bolt ........................................................... 23 nm 6 oil filter...

  • Page 173

    1b1-98 m162 engine mechanical tightening torque 23 nm notice replace the oil filter gasket. 4. Installation should follow the removal procedure in the reverse order. 5. Check engine oil level. 6. Run the engine at idle and check the engine for leaks. 3. Remove the oil filter bolt and then remove the...

  • Page 174: Oil Pump

    M162 engine mechanical 1b1-99 1 bolt (m8 x 20, 1 piece) ......................... 29-35 nm 2 sprocket (oil pump drive) 3 bolt (m8 x 35, 3 pieces) ................. 22.5-27.5 nm oil pump preceding work : removal of oil pan 4 spring pin 5 oil pump.

  • Page 175

    1b1-100 m162 engine mechanical removal & installation procedure 1. Remove the bolt (1) from the oil pump drive sprocket (2) and separate the gear and the oil pump drive chain. Installation notice 4. Remove the oil pump and oil strainer assembly. 5. Replace the strainer in oil pump if necessary. 6. I...

  • Page 176: Oil Pressure Relief Valve

    M162 engine mechanical 1b1-101 oil pressure relief valve preceding work : removal of oil pan 1 screw plug ................................................ 50 nm 2 compression spring removal & installation procedure 1. Remove the screw plug (1). Installation notice 2. Remove the spring (2), guide pin...

  • Page 177: Oil Non-Return Valve

    1b1-102 m162 engine mechanical oil non-return valve preceding work : removal of timing gear case cover 1 oil non-return valve functions the non-return valve prevents the oil in the chain tensioner from drying up. In other words, it stops oil-returning in order to prevent the oil in the chain tension...

  • Page 178: Oil Dipstick Guide Tube

    M162 engine mechanical 1b1-103 oil dipstick guide tube 1 oil dipstick level gauge 2 oil dipstick guide tube removal & installation procedure 1. Pull out the oil dipstick level gauge (1). 2. Remove the bolt (4) in the upper intake manifold and remove the oil dipstick guide tube. Installation notice 3...

  • Page 179: Unit Repair

    1b1-104 m162 engine mechanical unit repair oil gallery in crankcase preceding work : removal of crankshaft, removal of oil spray nozzle 1 plug 2 steel ball cleaning procedure 1. Remove the plug (1) with a screwdriver. 2. Using a round bar (3) and hammer, remove the steel ball (2). 3. Using the compr...

  • Page 180

    M162 engine mechanical 1b1-105 1 plug ....................................................... Replace 2 main oil gallery tools required 102 589 12 15 00 drift sealing procedure 1. Enlarge the end of main oil gallery (4) to be diameter of 16mm, depth of 15mm. 2. Using an m16 x 1.5 thread (tap), make ...

  • Page 181: Oil Gallery In Cylinder Head

    1b1-106 m162 engine mechanical oil gallery in cylinder head preceding work : removal of cylinder head removal of camshaft removal of tappet 1 screw plug ................................................ 15 nm 2 seal cleaning procedure 1. Remove the screw plug (1) and the seal (2). Installation notice...

  • Page 182

    M162 engine mechanical 1b1-107 sealing procedure 1. Remove the screw plug (1) and the seal. Installation notice 2. Remove the steel ball from the oil gallery (4), (5), (6) and (7) using the round bar (12, f 6 x 700 mm). 4. Enlarge the oil gallery at the rear of the cylinder head to be diameter 9mm, ...

  • Page 183

    1b1-108 m162 engine mechanical 11. Tighten the screw plug with the seal (arrow). Screw plug (part no. 000 908 01 00 02) seal (part no. 007 603 01 01 03) 8. Make a screw hole at the oil gallery using m10 x 1 thread. 9. All the oil gallery should be cleaned with the compressed air. 10. Apply the locti...

  • Page 184: Core Plugs In Crankcase

    M162 engine mechanical 1b1-109 core plugs in crankcase preceding work : draining of the coolant 1 core plug ............................................... Replace.

  • Page 185

    1b1-110 m162 engine mechanical tools required 102 589 00 15 00 drift replacement procedure 1. Remove the intake and exhaust manifolds. 2. Pull back the core plug until the end of one side comes out using the screw driver. 3. Pull out the plug carefully using a pliers. 5. Press in new plug using a dr...

  • Page 186: Cylinder Bore

    M162 engine mechanical 1b1-111 group code letter and cylinder bore size repair size 1) the group code letters are carved on the surface of the piston crown and in the mating surface of the crankcase. Cylinder bore group code letter of cylinder a x b x + 5 x + 10 piston type to be used a or x a, x or...

  • Page 187

    1b1-112 m162 engine mechanical service data standard measurement of cylinder bore 1. Clean the cylinder wall. 2. Using a internal diameter gauge, measure the bore size in axial and transverse direction at three points (1,2,3). 1,2,3. Measuring points a. Axial direction b. Transverse direction a. Loc...

  • Page 188: Crankcase Mating Surface

    M162 engine mechanical 1b1-113 crankcase mating surface service data standard height of the crankcase “h” (when new) minimum height after milling flatness permissible deviation of parallelism of the upper to lower mating surface peak-to-valley height crankcase upper mating surface crankcase lower ma...

  • Page 189

    1b1-114 m162 engine mechanical chamfering procedure 1. Chamfer angle : 60° 2. Polish the lower chamfered area evenly with a grinder after finishing the chamfering with a suitable tool (e.G., hand milling cutter)..

  • Page 190: Cylinder Head Mating Surface

    M162 engine mechanical 1b1-115 cylinder head mating surface preceding work : removal of valves service data standard notice do not exceed 0.4mm for the milling of the mating surface of crankcase and cylinder head. Overall height of cylinder head minimum height after machining flatness distance ‘t’ (...

  • Page 191

    1b1-116 m162 engine mechanical measurement of mating surface 1. Measure the height (h) of the cylinder head (refer to service data standard). 2. Check the mating surface of the cylinder head. 3. Mill the sharp edge of the combustion chamber. 4. Re-measure the height (h) of the cylinder head. 5. Seal...

  • Page 192: Section 1B2

    Section 1b2 m161 engine mechanical caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the...

  • Page 193: Specifications

    1b2-2 m161 engine mechanical specifications fastener tightening specifications n · · · · · m 35 - 40 10 - 15 5 - 10 21 - 25 30 56 - 66 50 - 60 22.5 - 27.5 41.5 - 49.5 22.5 - 27.5 22.5 - 27.5 9 - 11 9 - 11 9 - 11 9 - 11 22.5 - 27.5 10 +90° 55 +90° +90° 22.5 - 27.5 22.5 - 27.5 9 - 10 9 - 10 200 +90° 4...

  • Page 194

    M161 engine mechanical 1b2-3 n · · · · · m 20 / + 90° 40 72 - 88 20 / + 90° 25 - 35 22.5 - 27.5 22.5 - 27.5 22.5 - 27.5 22.5 - 27.5 30 26 - 34 30 8 - 10 25 25 22.5 - 27.5 29 - 35 22.5 - 27.5 9 - 11 50 9 - 11 15 application exhaust camshaft sproket bolt chain tensioner screw plug chain tensioner asse...

  • Page 195: Special Tools

    1b2-4 m161 engine mechanical special tools special tools table 000 589 10 99 01 torque wrench 112 589 00 72 00 oil extractor 000 589 72 21 00 torque wrench 001 589 66 21 00 torque wrench 000 589 01 10 00 box wrench insert 124 589 15 21 00 radiator cap testing unit 116 589 02 34 00 screw-fixed pin 00...

  • Page 196

    M161 engine mechanical 1b2-5 special tools table (cont’d) 104 589 01 01 00 spanner 111 589 18 61 00 lever pusher 111 589 25 63 00 thrust piece 111 589 01 59 00 supporting bar 116 589 06 63 00 magnetic finger 119 589 00 43 00 drift 000 589 58 43 00 chain assembly 104 589 00 37 00 pliers.

  • Page 197

    1b2-6 m161 engine mechanical special tools table (cont’d) 116 589 20 33 00 sliding hammer 602 589 00 40 00 engine lock 103 589 00 33 00 puller 601 589 03 43 00 sleeve 001 589 65 09 00 socket wrench insert 001 589 74 21 00 torque wrench 000 589 04 14 00 clamping strap 000 589 88 33 00 puller.

  • Page 198

    M161 engine mechanical 1b2-7 special tools table (cont’d) 103 589 01 63 00 rivet set 103 589 02 09 00 oil filter socket wrench 102 589 12 15 00 drift 615 589 01 33 00 caulking bolt 102 589 00 15 00 drift 000 589 51 37 00 clamping strap 001 589 72 21 00 torque wrench 601 589 03 14 00 sleeve.

  • Page 199

    1b2-8 m161 engine mechanical special tools table (cont’d) 617 589 00 10 00 wrench socket 104 589 00 40 00 holder 111 589 03 15 00 insert pin 116 589 01 34 00 threaded bolt.

  • Page 200: Maintenance and Repair

    M161 engine mechanical 1b2-9 maintenance and repair on-vehicle service engine assembly tools required 000 589 10 99 01 torque wrench 000 589 40 37 00 hose clamp 112 589 00 72 00 oil extractor.

  • Page 201

    1b2-10 m161 engine mechanical 4. Disconnect the coupling of hfm sensor and remove the air cleaner cross pipe. 6. Loosen the radiator drain cock and drain the coolant. Notice open the coolant reservoir cap. 5. Remove the air cleaner cover. Remove the mounting bolts and air cleaner housing and element...

  • Page 202

    M161 engine mechanical 1b2-11 10. Remove the upper mounting bolts of radiator and then remove the radiator. 7. Loosen the cylinder block drain plug and then drain the coolant completely. Installation notice tightening torque 30 nm notice replace the seal before installation of the drain plug. 8. Rem...

  • Page 203

    1b2-12 m161 engine mechanical 12. Discharge the refrigerant from a/c system, and disconnect the discharge pipe and suction pipe from the compressor. 14. Remove the fuel feed and return line. Notice before removing the fuel lines, release the pressure in the fuel system. Installation notice 13. Remov...

  • Page 204

    M161 engine mechanical 1b2-13 19. Disconnect the engine ground wire. 15. Remove the automatic transmission dipstick guide tube. 16. Disconnect the wire of alternator. 17. Disconnect the wire of starter motor and remove the starter motor. 18. Disconnect the engine main harness ground..

  • Page 205

    1b2-14 m161 engine mechanical 20. Disconnect following sensors connector. L hfm sensor. L coolant temperature sensor. L 2 knock sensors. L camshaft and crankshaft sensors. 21. After removing the ignition coil cover, disconnect the ignition coil connector. 22. Remove the harness cover and disconnect ...

  • Page 206

    M161 engine mechanical 1b2-15 tightening torque 30 nm 29. Remove the exhaust manifold and exhaust pipe. Installation notice 25. Separate the vacuum hose for brake booster. 26. Separate the other vacuum hoses. 27. Remove the propeller shaft from the front axle. Installation notice 28. By rotating the...

  • Page 207

    1b2-16 m161 engine mechanical 30. Remove the transmission mounting bolts and separate the transmission from the engine. Installation notice tightening torque 65 nm 31. Remove the bolts for engine mounting bracket. Installation notice tightening torque 50 - 75 nm 32. Hook the chain to the bracket of ...

  • Page 208: Crankcase Ventilation System

    M161 engine mechanical 1b2-17 crankcase ventilation system operation at idling and mid-load 1 hfm sensor 2 cylinder head cover 3 oil spearation chamber (full-load or over mid-load) 4 intake air duct (cross pipe) 5 vent line (full-load or over mid-load) 6 throttle valve 7 restrictor, diameter 1.1mm (...

  • Page 209

    1b2-18 m161 engine mechanical operation at idling and mid-load l the throttle valve(6) is closed or very partially opened, and the vacuum pressure in intake manifold is high. The blow-by gas and the fresh air that is additionally supplied through the vent connection(d) in the crankcase in partial lo...

  • Page 210

    M161 engine mechanical 1b2-19 operation when full-load at partial load 1 hfm sensor 2 cylinder head cover 3 oil spearation chamber (full-load or over mid-load) 4 intake air duct (cross pipe) 5 vent line (full-load or over mid-load) 6 throttle valve 7 restrictor, diameter 1.1mm (mid-load at idling) 8...

  • Page 211

    1b2-20 m161 engine mechanical operation when full-load at partial load l the throttle valve (6) is partially opened or fully opened. The air flows very rapidly through the vent line(5)s connection(d) and the intake air duct when full-load at partial load. Consequently, most of the low-by gases are s...

  • Page 212: Alternator

    M161 engine mechanical 1b2-21 alternator removal & installation procedure 1. Remove the drive belt. 2. Remove the alternator. 3. Unscrew the alternator carrier bolts (1,2,3) and remove the carrier (4). Installation notice tightening torque 22.5 - 27.5 nm notice apply 3nm of torque when mounting the ...

  • Page 213

    1b2-22 m161 engine mechanical power steering pump and a/c bracket preceding work : removal of cooling fan and shroud removal of drive belt 1 nut ................................................. 35.2-28.8 nm 2 washer 3 belt pulley 4 bolt (m8 x 91, 2 pieces) ................. 22.5-27.5 nm 5 power ste...

  • Page 214

    M161 engine mechanical 1b2-23 removal & installation procedure 1. Remove the belt pulley after removal of poly v-belt. Installation notice 2. Disconnect the hydraulic pipe of the power steering pump and drain the oil. 3. Unscrew the bolts (arrows) and remove the steering pump. Installation notice no...

  • Page 215

    1b2-24 m161 engine mechanical 5. Disconnect the vent hose from the a/c bracket. 6. Unscrew all the mounting bolts (arrows) and remove the a/c bracket and the gasket. Installation notice 7. Clean the sealing surface. 8. Replace the gasket with new one. 9. Installation should follow the removal proced...

  • Page 216

    M161 engine mechanical 1b2-25 hydraulic engine mounting insulator service data.

  • Page 217

    1b2-26 m161 engine mechanical sectional view 1 rubber body 2 brackek 3 core 4 lower bolt 5 rubber plunger 6 plunger plate 7 rubber 8 plate 9 lower orifice 10 upper orifice 11 diaphram 12 cover plate 13 upper bolt 14 flange bolt 15 rivet 16 fluid.

  • Page 218

    M161 engine mechanical 1b2-27 1 upper nut 2 hydraulic installer ................. 62~93 nm 3 lower nut ............................. 28~47 nm removal and installation procedure 1. Unscrew the upper nut(1) on engine mounting and remove the engine. Installation notice 3. Installation should follow the...

  • Page 219: Poly V-Belt

    1b2-28 m161 engine mechanical poly v-belt preceding work : removal of cooling fan 1 poly v-belt (2,155 mm) 2 belt tensioning pulley removal & installation procedure 1. Release the belt tension by turning the stud on the cap with 12 sided wrench or spanner counterclockwise. 2. Remove the poly v-belt....

  • Page 220

    M161 engine mechanical 1b2-29 poly v-belt arrangement 1 belt tensioning pulley 2 crankshaft belt pulley 3 a/c compressor pulley 5 alternator pulley 7 power steering pump pulley 8 water pump pulley.

  • Page 221: Tensioning Device

    1b2-30 m161 engine mechanical tensioning device preceding work : removal of tensioning device shock absorber 1 bolt (m8 x 75, 2 pieces) + washer .......................................... 22.5-27.5 nm 2 bolt (m8 x 25, 1 pieces) + washer .......................................... 22.5-27.5 nm removal...

  • Page 222

    M161 engine mechanical 1b2-31 tensioning device shock absorber 1 end cover 2 nut ................................................. 40.5-49.5 nm 3 tensioning pulley 4 bolt (m8 x 25) + washer ................ 22.5-27.5 nm removal & installation procedure 1. Remove the end cover (1). 2. Remove the nut ...

  • Page 223: Poly V-Belt Inspection

    1b2-32 m161 engine mechanical 3. Pointed rib. 4. Belt cord visible in the base of rib. Poly v-belt inspection l make marks on the belt with chalk. L rotate the engine and check the belt for damage. Notice if one of the following types of damages is found, replace the belt. 1. Rubber lumps in the bas...

  • Page 224

    M161 engine mechanical 1b2-33 5. Cord torn out at the side. 6. Outer cords frayed. 7. Rib detached from the base of belt. 8. Splits across the rib. 9. Sections of rib torn out. 10. Splits across several ribs..

  • Page 225

    1b2-34 m161 engine mechanical 11. Splits across the back of the belt..

  • Page 226: Cylinder Head Cover

    M161 engine mechanical 1b2-35 cylinder head cover 1 ignition coil cover 2 spark plug connector 3 bolt (m6 x 45 : 4 pieces, m6 x 60 : 6 pieces) ............................................. 10 ± 1 nm 4 cylinder head cover 5 gasket ................................................... Replace.

  • Page 227

    1b2-36 m161 engine mechanical removal & installation procedure 1. Remove the intake air duct. Installation notice 2. Remove the ignition coil cover. Installation notice 3. Remove the spark plug connector and ignition cable. Notice release 3 screws from the ignition cover and remove the cover for m16...

  • Page 228: Cylinder Head Front Cover

    M161 engine mechanical 1b2-37 cylinder head front cover preceding work : removal of cylinder head cover removal of thermostat housing assembly removal of engine hanger bracket removal & installation procedure 1. Disconnect the camshaft adjuster connector and remove the camshaft adjuster (e23 engine ...

  • Page 229

    1b2-38 m161 engine mechanical 2. Remove the cylinder head front cover. Installation notice tightening torque (3) 22.5 - 27.5 nm tightening torque (4) 9 - 11 nm apply the sealant at the mating surface of the cylinder head and the front cover. 3. Remove the o-ring. Installation notice replace the o-ri...

  • Page 230: Cylinder Head

    M161 engine mechanical 1b2-39 cylinder head preceding work : removal of cylinder head cover removal of cylinder head front cover removal of intake manifold removal of cylinder head lower line (intake manifold side) 1 cylinder head bolt (m12 x 100, 10 pieces) ............................................

  • Page 231

    1b2-40 m161 engine mechanical tools required 617 589 00 10 00 wrench socket 116 589 20 33 00 sliding hammer 116 589 01 34 00 threaded bolt 001 589 66 21 00 torque wrence 104 589 00 40 00 holder removal & installation procedure 1. Rotate the crankshaft so that the piston of number 1 cylinder is at at...

  • Page 232

    M161 engine mechanical 1b2-41 6. Remove the in take camshaft sprocket (e20 engine). 7. Remove the camshaft adjuster (e23, m161.970 engine). Installation notice (flange bolt) 1 flange shaft 2 flange bolt 3 campression spring 4 adjust piston 5 camshaft sprocket 6 seal cover 7 nut tightening torque 1st...

  • Page 233

    1b2-42 m161 engine mechanical 10. Remove the cylinder head bolts in the reverse order of the numerics (no.10 ® no.1). Installation notice tighten the bolts as numerical order with specified torque (no.1 ® no.10). Holder 104 589 00 40 00 1 cylinder head bolt 2 m8 x 35 bolt & washer 3 bearing cap 4 en...

  • Page 234

    M161 engine mechanical 1b2-43 15. Check the length of the cylinder head bolt. Tightening torque when new 100 mm max. Length 105 mm notice replace the bolt if the measured length exceed the max. Length. 16. Installation should follow the removal procedure in the reverse order..

  • Page 235: Timing Gear Case Cover

    1b2-44 m161 engine mechanical timing gear case cover preceding work : removal of viscous clutch removal of cylinder head front cover removal of tensioning device removal of water pump removal of oil filter element removal of oil pan removal of alternator bracker 1 bolt (m8 x 60, 3 pieces) .............

  • Page 236

    M161 engine mechanical 1b2-45 tools required 001 589 72 21 00 torque wrench 116 589 20 33 00 sliding hammer 116 589 01 34 00 threaded bolt removal & installation procedure 1. Remove the power steering belt pulley and a/c compressor bracket. 2. Remove the oil line from power steering pump. 3. Rotate ...

  • Page 237

    1b2-46 m161 engine mechanical 8. Unscrew the bolts (a). Installation notice tightening torque 22.5 - 27.5 nm 9. Remove the belt pulley and vibration damper. Installation notice (center bolt) tightening torque 1st step 180 - 220 nm 2nd step 80° - 100° 10. Unscrew the bolts (1, 2) on timing gear case ...

  • Page 238

    M161 engine mechanical 1b2-47 crankshaft sealing rear cover preceding work : removal of the automatic transmission drive plate or flywheel 1 bolt (m6 x 20, 6 pieces) ......................... 9-11 nm 2 radial shaft seal 3 rear cover 4 sleeve 5 bolt (m6 x 85, 2 pieces) ......................... 9-11 ...

  • Page 239

    1b2-48 m161 engine mechanical tools required 601 589 03 43 00 sleeve removal & installation procedure 1. Unscrew the bolts (1) and (5) and remove the closing cover by pulling the rear cover lug (arrows). Notice be careful not to damage the oil pan gasket. 2. Clean the sealing surface of the crankcas...

  • Page 240

    M161 engine mechanical 1b2-49 belt pulley and vibration damper preceding work : removal of cooling fan and viscous clutch removal of fan shroud removal of drive belt 1 center bolt (m18 x 55) ....................... 1st step 200-220 nm 2nd step 90° + 10° rotation added 2 vibration damper disk 5 vibra...

  • Page 241

    1b2-50 m161 engine mechanical components service data standard permissble deviation of the vibration damper radial runout axial runout 0.6 mm 0.6 mm tools required 103 589 00 33 00 puller 001 589 65 09 00 socket wrench insert 001 589 74 21 00 puller 000 589 88 33 00 torque wrench 602 589 00 40 00 en...

  • Page 242

    M161 engine mechanical 1b2-51 engine lock 602 589 00 40 00 2. Remove the start motor and install the engine lock to the flywheel ring gear. 3. Remove the center bolt. Installation notice 4. Remove the vibration damper assembly using the puller. 5. Installation should follow the removal procedure in ...

  • Page 243: Crankshaft Front Radial Seal

    1b2-52 m161 engine mechanical crankshaft front radial seal preceding work : removal of belt pulley and vibration damper 1 center bolt (m18 x 50) ............................... 1st step 200-220 nm 2nd step 90° +10° 2 center bolt washer 3 sleeve (special tool) 4 crankshaft front seal 5 key tools requ...

  • Page 244: Crankshaft Rear Radial Seal

    M161 engine mechanical 1b2-53 crankshaft rear radial seal preceding work : removal of flywheel or drive plate 1 special tool 2 special tool 3 crankshaft rear seal tools required 601 589 03 43 00 sleeve replacement proceudre 1. Remove the radial seal with a screw driver. Notice use a clean cloth not ...

  • Page 245: Crankshaft

    1b2-54 m161 engine mechanical crankshaft preceding work : removal of engine removal of cylinder head removal of timing gear case cover removal of crankcase sealing rear cover removal of oil pan removal of baffle plate removal of oil pump 1 bearing cap bolt (m8 x 55-10 pieces) ............ 1st step 5...

  • Page 246

    M161 engine mechanical 1b2-55 arrangement of the thrust bearing and the main bearing 1 - 8 weight balance/color marking point j1 - j5 journal main bearing #1 - #5 l color dot marking the color dot marking are put on the 1 , 2 , 4 , 6 , 8 , and it indicates the diameter of crankshaft journal by color...

  • Page 247

    1b2-56 m161 engine mechanical selection of crankshaft main bearing 1. Crankcase side there are seven punching marks on the mating surface to oil pan. This mark is correspondent to the bearing distinguished by color. Select the relevant bearing according to the punching mark when repaired. 2. Cranksh...

  • Page 248

    M161 engine mechanical 1b2-57 installation notice l make sure the crankshaft bearing cap properly seated in place in the crankcase side. When perfectly installed, the projected part (arrow) locates in the left side (intake manifold side). L assemble so that the projected part of the cap and crankcas...

  • Page 249

    1b2-58 m161 engine mechanical inspection 1. If the length ‘l’ of the crankshaft bearing cap bolt exceeds 63.8mm, replace it. 2. Make sure the crankshaft bearing cap is properly seated on the cylinder block (arrows). 3. Measure and record the inner diameter of the crankshaft bearing. Notice l measure...

  • Page 250

    M161 engine mechanical 1b2-59 service data standard (crankshaft main bearing gap) (connecting rod bearing gap) item main bearing journal ( no. 1, 5, 7) measuring position radial axial gap (mm) static condition :0.015-0.039 dynamic condition: 0.031-0.051 (consider the expansion 0.011-0.016) 0.010 - 0...

  • Page 251: Flywheel/driven Plate

    1b2-60 m161 engine mechanical flywheel/driven plate preceding work : removal of manual or automatic transmission 1 flywheel mounting bolt (m10 x 22, 8 pieces) ................ 1st step 45 nm 2nd step 90°+10° 2 plate 3 driven plate (a/t) 4 dowel pin 5 flywheel (m/t) service data standard (stretch bol...

  • Page 252

    M161 engine mechanical 1b2-61 removal & installation procedure 1. Unscrew the stretch bolt. Installation notice sectional view 1 oil pan 2 cover 3 radial seal 4 bolt 5 crankshaft 6 dowel pin 7 washer (thickness : 3.5 mm) 8 washer 9 bolt 10 front drive plate 11 rear drive plate 12 rivet 13 segment 14...

  • Page 253: Camshaft Adjuster

    1b2-62 m161 engine mechanical camshaft adjuster 1 bolt (m6 x 16, 3 pieces) ......................... 9-11 nm 2 cylinder head front cover 3 bolt ........................................................... 35 nm 4 armature 5 roll pin 6 nut (m20 x 1.5) .................................... 60-70 nm 7 se...

  • Page 254

    M161 engine mechanical 1b2-63 removal & installation procedure 1. Turn the crankshaft and position the n0.1 cylinder piston at atdc 20°. Notice turn the crankshaft in the direction of engine rotation. 2. Remove the cylinder head front cover. 3. Put the alignment marks (arrows) on the camshaft sprock...

  • Page 255

    1b2-64 m161 engine mechanical 7. Unscrew the bolt (3) from the armature (4) and remove the roll pin, and remove the armature. Installation notice tightening torque 35 nm 8. Unscrew the nut (6) and remove the seal cover (7). Installation notice tightening torque 60 - 70 nm notice put the locking slot...

  • Page 256: Camshaft Sprocket Bolt

    M161 engine mechanical 1b2-65 camshaft sprocket bolt intake flange shaft bolt notice the sprocket bolts are designed to be used only once, so always replace with new one. Exhaust camshaft sprocket bolt notice the sprocket bolts are designed to be used only once, so always replace with new one. C. M7...

  • Page 257: Camshaft

    1b2-66 m161 engine mechanical camshaft preceding work : removal of cylinder head cover removal of camshaft adjust actuator and cylinder head front cover 1 bolt (m7 x 13, 3 pieces) ......... 1st step 18-22 nm 2nd step 90°+ 5° rotation added 2 exhaust camshaft sprocket 3 timing chain 4a intake camshaf...

  • Page 258

    M161 engine mechanical 1b2-67 tools required 000 589 01 10 00 box wrench insert 104 589 01 01 00 spanner removal & installation procedure 1. Turn the crankshaft and position the no.1 cylinder piston at atdc20°. 2. Put the alignment marks (arrows) on the camshaft sprocket and the timing chain. 3. Rem...

  • Page 259

    1b2-68 m161 engine mechanical 7. Remove the bearing cap, and remove the intake and the exhaust camshaft. Installation notice tightening torque 22.5 - 27.5 nm notice check the numbers on the bearing cap not to be miked up. 8. Apply the engine oil on the valve tappet and camshaft bearing. 9. Installat...

  • Page 260: Camshaft Timing Position

    M161 engine mechanical 1-1b-69 camshaft timing position preceding work : removal of cylinder head cover removal of cylinder head front cover 1 insert pin ( f 6.5mm, special tool) 2 intake camshaft sprocket 3 camshaft bearing cap 4 timing chain 5 exhaust camshaft sprocket 6 bolt (m7 x 13, 3 pieces) ....

  • Page 261

    1b2-70 m161 engine mechanical tools required 104 589 01 01 00 spanner 111 589 03 15 00 insert pin inspection procedure 1. Position the no.1 cylinder piston to atdc 20° by turning the crankshaft notice when the atdc 20° mark on vibration damper is aligned with timing gear case cover, the intake and e...

  • Page 262

    M161 engine mechanical 1b2-71 adjustment procedure 1. Position the no.1 cylinder to atdc 20° . 2. Remove the chain tensioner. 3. Remove the exhaust camshaft sprocket. 4. Adjust the timing position with inserting the insert pin ( f6.5mm, 111 589 03 15 00) into the no.1 and no.4 camshaft bearing cap h...

  • Page 263: Valve Spring

    1b2-72 m161 engine mechanical valve spring preceding work : removal of camshaft removal of spark plug 1 valve tappet assembly 2 valve cotter 3 upper retainer 4 valve spring .......... Check, replace if necessary 5 valve stem seal 6 lower retainer 7 connecting hose 8 thrust piece 9 slide 10 adjust bo...

  • Page 264

    M161 engine mechanical 1b2-73 tools required 111 589 01 59 00 supporting bar 111 589 18 61 00 lever pusher 111 589 25 63 00 thrust piece 116 589 06 63 00 magnetic finger removal & installation procedure 1. Place the supporting bar (12) and the slide (9) at the camshaft bearing cap (nos 1 & 7/8&14) a...

  • Page 265

    1b2-74 m161 engine mechanical 8. Install the lever pusher (11) and the thrust piece (8) to the slide (9). 13. Remove the valve cotter (2) using either the pincette (13) or magnetic finger. Lever pusher 111 589 18 61 00 magnetic finger 116 589 06 63 00 9. Mount the thrust piece (8) vertically to the ...

  • Page 266

    M161 engine mechanical 1b2-75 test (upper and lower valve tappet and valve cotter) l upper valve spring retainer l lower valve spring retainer l valve cotter 12.3 (d) (d) 8.5 size (mm) thickness (mm) (a) 0.8 - 1.0 9.2 - 9.8 (h) (b) 9.0 size (mm).

  • Page 267: Valve Stem Seal

    1b2-76 m161 engine mechanical valve stem seal preceding work : removal of valve spring 1 drift (special tool) 2 valve stem seal 3 protective sleeve drift 119 589 00 43 00 pliers 104 589 00 37 00 tools required 104 589 00 37 00 pliers 119 589 00 43 00 drift replacement procedure 1. Remove the valve s...

  • Page 268: Chain Tensioner

    M161 engine mechanical 1b2-77 chain tensioner 1 screw plug ................................................ 40 nm 2 seal 3 filler pin 4 compression spring 5 snap ring 6 thrust pin 7 chain tensioner housing ..................... 72-88 nm 8 seal removal procedure 1. Position the number 1 cylinder to a...

  • Page 269

    1b2-78 m161 engine mechanical installation procedure 1. Connect the thrust pin (6) and the snap ring (5) to the chain tensioner housing (7). Notice when connecting the thrust pin, push in the thrust pin far enough so that it doesn’t protrude at the chain tensioner housing. 4. Carefully unscrew the s...

  • Page 270

    M161 engine mechanical 1b2-79 4. Lightly apply the grease to the seal (2) and install the screw plug (1). Installation notice sectional view 1 screw plug 2 ball (nonreturn valve) 3 compression spring 4 ball guide 5 seal (aluminum) 6 filler pin 7 compression spring 8 snap ring 9 thrust pin 10 ball (n...

  • Page 271: Timing Chain

    1b2-80 m161 engine mechanical timing chain preceding work : removal of cylinder head cover removal of spark plug 1 pin 2 new timing chain 3 timing chain (used) 4 wedge 5 link 6 center plate 7 outer plate.

  • Page 272

    M161 engine mechanical 1b2-81 tools required 000 589 58 43 00 chain assembly 103 589 01 63 00 rivet set 001 589 72 21 00 torque wrench replacement procedure 1. Position the no.1 cylinder to atdc 20°. 4. Mount the wedges to both sides of the camshaft sprocket as shown in the figure. 2. Insert the pin...

  • Page 273

    1b2-82 m161 engine mechanical 7. Connect the new timing chain (2) to the used timing chain (3) with the link (5), center plate (6, thickness 1.6mm), and the outer plate (7). 8. Rotate the crankshaft in the direction if engine revolution by pressing the new timing chain against the exhaust camshaft s...

  • Page 274

    M161 engine mechanical 1b2-83 15. Replace the thrust piece (b) as shown in the figure. 13. Install the assembly tool above the link and tighten the spindle (c) until a block is felt. 14. Place the assembly tool. 12. Place the outer plate (7, thickness 1.2mm) inside the thrust piece (b). 16. Install ...

  • Page 275

    1b2-84 m161 engine mechanical 17. Rivet the link pin. Check the condition and it again if necessary. 18. Install the chain tensioner. Installation notice 19. Check the camshaft timing position. Tightening torque screw plug 40 nm tensioner assembly 72 - 88 nm.

  • Page 276: Tensioning Rail

    M161 engine mechanical 1b2-85 tensioning rail preceding work : removal of cylinder head removal & installation procedure 1. Remove the timing gear case cover (3). Notice be careful not to damage the gasket. 2. Remove the sliding rail (1) from the sliding rail pin (2). Notice l replace the plastic gu...

  • Page 277: Cylinder Head Guide Rail

    1b2-86 m161 engine mechanical cylinder head guide rail preceding work : removal of cylinder head cover 1 bolt (m6 x 45, 2 pieces) .................. 9-11 nm 2 guide rail removal & installation procedure 1. Position the number 1 cylinder to atdc20° guide rail. 2. Install the pin (special tool : 111 5...

  • Page 278: Crankcase Guide Rail

    M161 engine mechanical 1b2-87 crankcase guide rail preceding work : removal of timing gear case cover removal & installation procedure 1. Remove the timing gear case cover (3). Notice be careful not to damage the gasket when removing/ installing the timing gear case cover. 2. Remove the guide rail (...

  • Page 279: Crankshaft Sprocket

    1b2-88 m161 engine mechanical crankshaft sprocket preceding work : removal of oil pan removal of tensioning rail removal of crank case guide rail removal of cylinder head 6 bolt (m8 x 20, 1 piece) / washer .......... 29-35 nm 7 oil pump sprocket 8 oil pump 9 oil pump roller chain 10 timing chain 1 o...

  • Page 280

    M161 engine mechanical 1b2-89 tools required 615 589 01 33 00 caulking bolt removal & installation procedure 1. Put the assembly mark at the crankshaft sprocket (4) and the timing chain (10) with the paint (arrow). Installation notice align the assembly marks on cranshaft sprocket and timing chain. ...

  • Page 281: Piston

    1b2-90 m161 engine mechanical piston preceding work : removal of engine removal of cylinder head removal of oil pan removal of oil pump removal of baffle plate 1 connecting rod bearing cap 2 connecting rod 3 connecting rod bolt (m9 x 52, 8 pieces) ...................... 1st step 40 nm 2nd step 90° +...

  • Page 282

    M161 engine mechanical 1b2-91 tools required 001 589 72 21 00 torqued wrench 000 589 04 14 00 clamping strap removal procedure 1. Unscrew the connecting rod bolt (3) and remove the cap. 2. Remove the connecting rod and the piston upward. Notice make sure that the bearing cap and shell are not change...

  • Page 283

    1b2-92 m161 engine mechanical 1. Check the piston ring gap and apply the engine oil to the piston pin and the connecting rod bushing. 2. Connect the piston and the connecting rod by pressing in the piston pin (6) and install the snap ring to the groove. 3. Clean the cylinder bore, connecting rod bea...

  • Page 284: Connecting Rod

    M161 engine mechanical 1b2-93 connecting rod preceding work : removal of piston 1 connecting rod bushing 2 oil gallery 3 balance weight 4 connecting rod bolt (m9 x 52, 8 pieces) ............1st step 40 nm 2nd step 90° 5 fit sleeve 6 upper connecting rod bearing 7 lower connecting rod bearing 8 beari...

  • Page 285

    1b2-94 m161 engine mechanical inspection 1. Measure the basic bore of the connecting rod bearing. Notice if the basic bore exceeds the value of 51.614mm, replace the bearing or check the connecting rod. 2. Check connecting rod bolts. 3. Check the assembly mark(indication//or number:arrow) of the con...

  • Page 286: Piston Ring

    M161 engine mechanical 1b2-95 piston ring preceding work : removal of piston 1 piston compression ring (top ring) 2 piston compression ring (2nd ring) 3 piston oil ring 4 - 5 spacer 6 side rail notice if out of specification, replace the piston ring. Tools required 000 589 51 37 00 clamping strap re...

  • Page 287

    1b2-96 m161 engine mechanical 2. Remove the piston ring with a pliers. 3. For installation, position the piston ring to be the ‘top’ mark on the piston ring upward and arrange the piston ring ends to be 120° apart. 4. Adjust the hook spring joint in the oil ring 180° away from the ring end. Clamping...

  • Page 288: Oil Pan

    M161 engine mechanical 1b2-97 oil pan 1 bolt 2 bolt 3 bolt 4 bolt 1. Remove the drain plug and drain the oil completely. 2. Unscrew the bolts and remove the oil pan and gasket. Notice arrange the bolts according to each size. 3. Clean the inside of oil pan and sealing surface, then apply the sealant...

  • Page 289

    1b2-98 m161 engine mechanical oil circulation 1 oil strainer 2 oil pump 3 oil pan 4 oil non-return valve 5 oil filter 6 oil filter bypass valve 7 main oil gallery 8 closing ball ( f 15mm) 9 crankshaft 10 connecting rod bearing 11 crankshaft bearing 12 connecting rod 13 piston 14 oil spray (piston cr...

  • Page 290

    M161 engine mechanical 1b2-99 engine oil and oil filter element 1 oil filter cover .......................................... 25 nm 2 o-ring .................................................... Replace 3 oil filter element 4 oil drain plug 5 oil filter bypass valve 6 oil filter cap.

  • Page 291

    1b2-100 m161 engine mechanical 9. Fill up engine oil through the engine oil filler opening. 10. Check for oil leaks at normal engine temperature after starting the engine. 11. Stop the engine and wait 5 minutes. Check the oil level and fill up as specified if necessary. 4. Remove the drain plug (1) ...

  • Page 292: Oil Pump

    M161 engine mechanical 1b2-101 oil pump preceding work : removal of oil pan 1 bolt (m8 x 35, 3 piece) ................... 22.5-27.5 nm 2 oil pump 3 oil strainer assembly 4 bolt (m6 x 12, 2 pieces) ......................... 9-11 nm (in e23 engine, these bolts are combined with baffle plate) 5 bolt (m...

  • Page 293

    1b2-102 m161 engine mechanical removal & installation procedure 1. Unscrew the bolt (6) from the oil pump drive sprocket and separate the oil pump drive chain. Installation notice tightening torque bolt (4) 9 - 11 nm bolt (5) 9 - 11 nm tightening torque 29 - 35 nm 2. Unscrew the bolts (4,5) and remo...

  • Page 294: Oil Pressure Relief Valve

    M161 engine mechanical 1b2-103 oil pressure relief valve preceding work : removal of oil pan 1 screw plug ................................................ 50 nm 2 compression spring removal & installation procedure 1. Remove the screw plug (1). Installation notice 2. Remove the spring (2), guide pin...

  • Page 295: Oil Non-Return Valve

    1b2-104 m161 engine mechanical oil non-return valve preceding work : removal of timing gear case cover 1 oil non-return valve functions the non-return valve prevents the oil in the chain tensioner from drying up. In other words, it stops oil-returning in order to prevent the oil in the chain tension...

  • Page 296: Oil Dipstick Guide Tube

    M161 engine mechanical 1b2-105 oil dipstick guide tube 1 oil dipstick level gauge 2 oil dipstick guide tube 3 o-ring removal & installation procedure 1. Pull out the oil dipstick level gauge (1). 2. Unscrew the bolt (4) and remove the oil dipstick guide tube (2). Installation notice 4 bolt (m6 x 16,...

  • Page 297: Unit Repair

    1b2-106 m161 engine mechanical unit repair core plugs in crankcase preceding work : draining of the coolant 1 core plug ............................................... Replace.

  • Page 298

    M161 engine mechanical 1b2-107 tools required 102 589 00 15 00 drift replacement procedure 1. Remove the intake and exhaust manifolds. 2. Pull back the core plug until the end of one side comes out using the screw driver. 3. Pull out the plug carefully using a pliers. 5. Press in new plug using a dr...

  • Page 299: Cylinder Bore

    1b2-108 m161 engine mechanical group code letter and cylinder bore size cylinder bore group code letter of cylinder a x b x + 5 x + 10 a x b x + 5 x + 10 piston type to be used a or x a, x or b x or b x + 5 x + 10 a or x a, x or b x or b x + 5 x + 10 cylinder bore size (mm) f 90.906 - f 90.912 f 90....

  • Page 300

    M161 engine mechanical 1b2-109 service data standard measurement of cylinder bore 1. Clean the cylinder wall. 2. Using a internal diameter gauge, measure the bore size in axial and transverse direction at three points (1,2,3). 1,2,3 measuring points a. Axial direction b. Transverse direction a. Loca...

  • Page 301: Crankcase Mating Surface

    1b2-110 m161 engine mechanical crankcase mating surface service data standard height of the crankcase “h” (when new) minimum height after milling flatness permissible deviation of parallelism of the upper to lower mating surface peak-to-valley height crankcase upper mating surface crankcase lower ma...

  • Page 302

    M161 engine mechanical 1b2-111 chamfering procedure 1. Chamfer angle : 75° 2. Polish the lower chamfered area evenly with a grinder after finishing the chamfering with a suitable tool (e.G., hand milling cutter)..

  • Page 303: Cylinder Head Mating Surface

    1b2-112 m161 engine mechanical cylinder head mating surface preceding work : removal of valves service data standard notice do not exceed 0.4mm for the milling of the mating surface of crankcase and cylinder head. Overall height of cylinder head minimum height after machining flatness distance ‘t’ (...

  • Page 304

    M161 engine mechanical 1b2-113 measurement of mating surface 1. Measure the height (h) of the cylinder head (refer to service data standard). 2. Check the mating surface of the cylinder head. 3. Mill the sharp edge of the combustion chamber. 4. Re-measure the height (h) of the cylinder head. 5. Seal...

  • Page 305: Section 1B3

    Section 1b3 om600 engine mechanical caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to th...

  • Page 306: Specifications

    1b3-2 om600 engine mechanical specifications fastener tightening specifications n · · · · · m 28 - 47 30 3 - 7 8 - 18 20 - 34 30 70 - 80 81 - 84 50 - 75 n · · · · · m 10 23 200 / 90° 10 55 / 90° 45 / 90° 25 / 90° 25 n · · · · · m 35 / 90° n · · · · · m 45 / 90° application skid plate bolt drain plug...

  • Page 307

    Om600 engine mechanical 1b3-3 n · · · · · m 12 25 25 25 / 90° n · · · · · m 10 10 23 32 4 23 80 23 application stud bolt exhaust manifold not camshaft bearing cap bolt 12-sided bolt (m11) application oil pan bolt-socket bolt oil pan bolt- m6 oil pan bolt- m23 belt pulley bolt guide pulley bolt guide...

  • Page 308: Special Tools

    1b3-4 om600 engine mechanical special tools special tools table 603 589 00 09 00 serration wrench 657 589 03 63 00 sliding hammer 000 589 77 03 00 box wrench insert 601 589 00 66 00 counter sink 667 589 00 23 00 height gauge 602 589 00 40 00 engine lock 116 589 20 33 00 sliding hammer 603 589 00 40 ...

  • Page 309

    Om600 engine mechanical 1b3-5 116 589 03 07 00 t type socket wrench 601 589 00 25 00 special tools table (cont’d) 115 589 34 63 00 601 589 00 10 00 cylinder head bolt 102 102 589 12 15 00 ( f f f f f 17) drift 102 589 00 15 00 ( f f f f f 34) drift 617 589 10 21 00 ri sensor 601 589 05 14 00 assembl...

  • Page 310

    1b3-6 om600 engine mechanical 601 589 08 15 00 drift 001 589 53 21 00 dial gauge 601 589 03 14 00 sleeve special tools table (cont’d) 103 589 00 33 00 puller 601 589 07 21 00 depth gauge 667 589 01 21 00 fixing device 366 589 00 21 05 extension 601 589 03 43 00 oil seal assembler.

  • Page 311

    Om600 engine mechanical 1b3-7 363 589 02 21 00 dial gauge holder 000 589 33 33 00 counter support 000 589 04 14 00 tensioning strap special tools table (cont’d) 116 589 07 15 00 drift 000 589 25 33 00 internal extractor 102 589 05 33 00 puller 601 589 01 59 00 assembling board 102 589 03 40 00 magne...

  • Page 312

    1b3-8 om600 engine mechanical 601 589 02 59 00 supporting bridge 667 589 00 31 00 press lever 104 589 00 37 00 pliers special tools table (cont’d) 667 584 02 63 00 supporting bar 116 589 06 63 00 magnetic finger 603 589 01 40 00 holding wheel 000 589 10 68 00 cylinder brush 601 589 02 43 00 drift.

  • Page 313

    Om600 engine mechanical 1b3-9 601 589 02 23 00 go/no go gauge 105 589 03 15 00 drift (for intake) 601 589 06 15 00 drift (for exhaust) special tools table (cont’d) 601 589 05 15 00 drift (for intake) 103 589 02 15 00 drift (for exhaust) 346 589 00 63 00 super cooling box 000 589 21 53 00 reamer (for...

  • Page 314

    1b3-10 om600 engine mechanical 001 589 32 21 00 dial gauge 001 589 53 21 00 dial gauge 667 589 02 21 00 tdc pulse generator special tools table (cont’d) 124 589 15 21 00 tester 000 589 58 43 00 chain assembling device 201 589 13 21 00 vacuum tester 617 589 04 21 00 tester 501 589 73 21 00 vacuum pum...

  • Page 315

    Om600 engine mechanical 1b3-11 000 589 14 21 00 tester 001 589 65 09 00 serration wrench 116 589 02 34 00 thread bolt special tools table (cont’d) 000 589 00 68 00 cleaning set 601 589 05 21 00 looking screw 617 589 08 21 00 position sensor 667 589 04 63 00 retaining plate 601 589 00 08 00 flange.

  • Page 316: Maintenance and Repair

    1b3-12 om600 engine mechanical maintenance and repair on-vehicle service engine assembly.

  • Page 317

    Om600 engine mechanical 1b3-13 4. Remove the radiator drain cock and drain the coolant. Notice open the coolant reservoir tank cap. 3. Remove the skid plate. Installation notice tightening torque 28 - 47 nm 5. Remove the drain plug (1) and seal (2) from the cylinder block and drain the coolant compl...

  • Page 318

    1b3-14 om600 engine mechanical 9. Loosen the bolt and remove the coolant pipe and cooling fan shroud. 10. Remove the hoses (air intake to intercooler, intercooler to intake duct). 8. Disconnect the upper coolant hose from the radiator. Tightening torque 3 -7 nm 11. Remove the pipes connected to inte...

  • Page 319

    Om600 engine mechanical 1b3-15 15. Remove the air-conditioner lines from the compressor. Notice evacuate the refrigerant before removal. 12. Remove the hose(air cleaner to turbocharger) with blow by hose. 13. Disconnect the air cleaner intake hose and remove the air cleaner cover and element. 14. Di...

  • Page 320

    1b3-16 om600 engine mechanical 16. Remove the power steering pump lines. Notice completely drain the fluid. 17. Disconnect the fuel feed line with prefilter from the feed pump on injection pump. 18. Vehicle with automatic transmission. Remove the hydraulic lines (19, 20) from oil cooler (2). 19. Dis...

  • Page 321

    Om600 engine mechanical 1b3-17 26. Disconnect the starter motor wires and remove the starter motor. 21. Remove the fuel lines from the fuel filter and cover the filter with plug. 22. Disconnect the brake booster hose from vacuum pump. 23. Disconnect the other vacuum lines. 24. Disconnect the ground ...

  • Page 322

    1b3-18 om600 engine mechanical 27. Disconnect the preheating time relay sensor plug. 28. Disconnect the coolant temperature sensor plug. 29. Disconnect the accelerator cable from the control linkage. Installation notice tightening torque 8 - 18 nm 30. Loosen the connection of control pressure cable ...

  • Page 323

    Om600 engine mechanical 1b3-19 33. Disconnect the exhaust pipe flange from the exhaust manifold. Installation notice 35. Remove the shift control cable. 36. Remove the transmission. Tightening torque axle 70 ~ 80 nm t/c 81 ~ 89 nm tightening torque 20 - 34 nm 31. Separate the exhaust pipe flange fro...

  • Page 324

    1b3-20 om600 engine mechanical 37. Loosen the engine mounting bracket nut. Installation notice 38. Remove the engine assembly from the vehicle by using a hoist or crane. 39. Installation should follow the removal procedure in the reverse order. Tightening torque 50 - 75 nm.

  • Page 325: Poly V-Belt

    Om600 engine mechanical 1b3-21 poly v-belt 1 nut ............................................................. 23nm 2 tensioning lever 3 bolt 4 spring 5 tensioning lever 6 poly v-belt.

  • Page 326

    1b3-22 om600 engine mechanical with air conditioner removal & installation procedure 1. Remove the nut. 2. Push the tensioning lever in direction of arrow with a rod (f12 ´ 180mm) and pull out the bolt to the rear. 3. Push back the tensioning lever (arrow direction) to release the spring tension and...

  • Page 327: Tensioning Device

    Om600 engine mechanical 1b3-23 tensioning device preceding work : removal of cooling fan 1 bolt ............................................................ 21nm 2 damper 3 nut ............................................................. 21nm 4 tensioning lever 5 guide rail pin 6 bolt 7 poly v-belt...

  • Page 328

    1b3-24 om600 engine mechanical removal & installation procedure 1. Remove the nut. Installation notice tightening torque 10 nm 2. Push the tensioning lever in direction of arrow with a rod ( f12 ´ 180mm ) and push out the bolt to the rear. 3. Push back the tensioning lever to release the spring tens...

  • Page 329

    Om600 engine mechanical 1b3-25 6. Pull off the tensioning lever (4) from guide rail pin. 7. Remove the spring (17). Installation notice insert spring (17) with color coding (blue/violet) facing up. 8. Pry off the closing cover (12) and remove the socket bolt (11) and then remove the tensioning pulle...

  • Page 330

    1b3-26 om600 engine mechanical poly v-belt alignment & inspection without air conditioner with air conditioner.

  • Page 331

    Om600 engine mechanical 1b3-27 inspection procedure l mark poly v-belt at a clearly visible point with chalk. L rotate the engine and check the belt. Notice if one of the following types of damage is found, replace the belt. 1. Rubber lumps in the base of rips. 2. Dirt or grit ingrained. 5. Cord tor...

  • Page 332

    1b3-28 om600 engine mechanical 7. Belt detached from the base of rip. 8. Splits across the rips. 9. Sections of rip torn out. 10. Splits across several rips. 11. Splits across the back..

  • Page 333: Prechamber

    Om600 engine mechanical 1b3-29 1 threaded ring ........................................ 130 nm 2 prechamber prechamber preceding work : removal of glow plug removal of fuel injection nozzle 3 cylinder head.

  • Page 334

    1b3-30 om600 engine mechanical tools required 2. Install the sliding hammer into the prechamber. Sliding hammer 667 589 03 63 00 removal & installation procedure 1. Using the serration wrench (4), remove the threaded ring (1). Serration wrench 603 589 00 09 00 3. Remove the perchamber (2). Notice af...

  • Page 335

    Om600 engine mechanical 1b3-31 assembly procedure notice in case the prechambers are reused, inspect the prechambers thoroughly, if the ball pin by heat and fire is broken, it can not be used. 1. Clean the sealing surface of the prechamber. 2. Insert the prechamber into the cylinder head at the same...

  • Page 336

    1b3-32 om600 engine mechanical milling of prechamber sealing surface 1 drift 2 sleeve 3 milling cutter 4 counter sink (special tool - 601 589 00 66) 5 cylinder head tightening torque 0.3, 0.6, 1.0 mm milling of the prechamber sealing surface notice the prechamber sealing surface may only be remachin...

  • Page 337

    Om600 engine mechanical 1b3-33 6. Measure the ‘x’ by using a vernier caliper. 7. Mount the turning tool onto the countersink tool and rotate to the right approx. 5 revolutions by applying slight pressure. 1. Remove the injection nozzle. 2. Remove the prechamber. 3. Cover the prechamber bore to avoid...

  • Page 338

    1b3-34 om600 engine mechanical 8. Remeasure size ‘x’ and compare it with the first measurement and determine the thickness of spacer ring. Size before machining 25.7 mm size after machining 25.5 mm ex the spacer ring should be selected so that it is at least 0.1mm and not more than 0.3mm thicker tha...

  • Page 339

    Om600 engine mechanical 1b3-35 tdc (tdc sensor bracket) setting preceding work : removal of no.1 cylinder prechamber 1 measuring device 2 dial gauge 3 cylinder head 4 piston ................................................ Set at tdc tools service 001 589 32 21 00 dial gauge 601 589 07 21 00 deqth g...

  • Page 340

    1b3-36 om600 engine mechanical setting (with cylinder head installed) 1. Remove the prechamber of no. 1 cylinder. 2. Position the piston of no.1 cylinder at btdc 10. 3. Install the measuring device into the prechamber bore and position the dial gauge with a preload of 5mm. Dial gauge 001 589 53 21 0...

  • Page 341: Cylinder Head

    Om600 engine mechanical 1b3-37 cylinder head 1 fuel injection pipe ..................................... 18nm 2 cylinder head 3 gasket ................................................... Replace 4 bolt ............................................................ 25nm 5 washer 6 clamp 7 heater feed p...

  • Page 342

    1b3-38 om600 engine mechanical 000 589 77 03 00 box wrench insert 001 589 65 09 00 socket wrench insert 102 589 03 40 00 magnetic bar 116 589 02 34 00 threaded pin 116 589 03 07 00 t type socket wrench 116 589 20 33 00 sliding hammer 601 589 00 10 00 cylinder head bolt wrench 602 589 00 40 00 engine...

  • Page 343

    Om600 engine mechanical 1b3-39 length(l) when new 80mm 102mm 115mm thread dia. M10 m10 m10 max. Length(l) 82mm 104mm 117mm the twelve-sided socket head bolts are tightened with each stages of torque and torque angle. It is not necessary to retighten the cylinder head bolts at the 1000~1500km inspect...

  • Page 344

    1b3-40 om600 engine mechanical disassembly procedure 1. Completely drain the coolant from the radiator and cylinder block. 2. Remove the cooling fan shroud. 3. Hold the fan with counter holder and remove the bolt and then remove the cooling fan. Notice keep the fan in vertical position. Counter hold...

  • Page 345

    Om600 engine mechanical 1b3-41 8. Remove the air cleaner cover and element and then remove the air cleaner housing. 9. Remove the oil return hose and plug. Notice cover them to prevent chips from coming into. 10. Unscrew the egr pipe mounting bolts onto the exhaust manifold. 11. Remove the duct brac...

  • Page 346

    1b3-42 om600 engine mechanical 14. Pull out the accelerator control linkage. 15. Remove the fuel injection line(1) from the fuel injection nozzle(12). Box wrench inset 000 589 77 03 00 16. Remove the fuel injection line from the fuel injection pump. Box wrench insert 000 589 77 03 00 17. Remove the ...

  • Page 347

    Om600 engine mechanical 1b3-43 18. Disconnect the booster hose connected to intake manifold. 19. Remove the intake manifold and gasket. 20. Remove the cylinder head cover and gasket with the blow- by gas hose. 21. Disconnect the glow plug cables..

  • Page 348

    1b3-44 om600 engine mechanical 22. Remove the cable channel. 23. Disconnect the cables from the glow plug sensor and coolant temperature sensor. 24. Remove the heater pipe bracket from the oil filter. 25. Pry off the clamp and push the heater feed pipe forward and then pull out the pipe..

  • Page 349

    Om600 engine mechanical 1b3-45 26. Disconnect the fuel lines from the fuel filter. 27. Disconnect the fuel lines from the injection pump. 28. Remove the fuel filter(35). 29. Remove the fuel injection nozzle(12) and nozzle washer(11). Socket wrench insert 001 589 65 09 00

  • Page 350

    1b3-46 om600 engine mechanical 30. Rotate the crankshaft and set the no.1 cylinder at tdc. Notice do not rotate the crankshaft to the opposite direction of engine revolution. 31. Place alignment marks on the camshaft gear and timing chain. 32. Ensure that the camshaft and the bearing cap marking are...

  • Page 351

    Om600 engine mechanical 1b3-47 34. Remove the turbocharger. 35. Remove the exhaust manifold and gasket. 36. Remove the chain tensioner and seal. 37. Remove the bolt and separate the drive sprocket(21). Notice during removal, be careful not to drop the sprocket and chain into the timing case. Careful...

  • Page 352

    1b3-48 om600 engine mechanical 38. Remove the camshaft bearing cap bolts according to the numerical sequence. Notice remove the no.1 bolts first and then remove the no. 2 bolts. Do not remove the bolts at a time completely but remove them step by step evenly or camshaft can be seriously damaged. Om6...

  • Page 353

    Om600 engine mechanical 1b3-49 41. Remove the bolt(32). 42. Separate the spring and pull out the tensioning lever(31). 43. Pry off the closing cover. Remove the bolt and then remove the idle pulley. 44. Using the sliding hammer(36) and the threaded pin(37), pull out the sliding rail pins(25, 26) and...

  • Page 354

    1b3-50 om600 engine mechanical om 662la 46. Disconnect the vacuum pipe from thermo valve. 47. Remove the socket bolts(13) of the chain box. T type socket wrench 116 589 03 07 00 magnetic bar 102 589 03 40 00 48. Remove the cylinder head bolts in numerical se-quence. Cylinder head bolt wrench 601 589...

  • Page 355

    Om600 engine mechanical 1b3-51 49. Remove the cylinder head(2) and gasket(3). Om 661la.

  • Page 356

    1b3-52 om600 engine mechanical length(l) assembly procedure 1. Replace the cylinder head gasket. 2. Install the cylinder head onto the crankcase. Notice align the cylinder head holes with the guide pins. 3. Measure the length(l) of cylinder head bolts. Notice if the max. Length is exceeded, replace ...

  • Page 357

    Om600 engine mechanical 1b3-53 5. Tighten the cylinder head bolts to specified torque and torque angle. Om 662la om 661la 6. Install the socket bolts in the chain box. Tightening torque 25 nm stage 1 stage 2 torque angle wait for torque angle 15 nm 35 nm 90° 10 minutes 90° 7. Connect the vacuum pipe...

  • Page 358

    1b3-54 om600 engine mechanical 8. Connect the vacuum lines to the vacuum pump. 9. Install the fuel filter and connect the pipe. Tightening torque 25 nm notice be careful not to be confused the connections and hoses. 10. Connect the fuel pipe to the injection pump. 11. Install the sliding rail(24) an...

  • Page 359

    Om600 engine mechanical 1b3-55 12. Install the idle pulley and fit the closing cover. Tightening torque 25 nm 13. Insert the tensioning lever(31) and install the spring. 14. Install the damper. Tightening torque 23 nm notice insert the tensioning lever bolts onto the mounting hole. 15. Insert the lo...

  • Page 360

    1b3-56 om600 engine mechanical 17. Coat the camshaft with oil and install the camshaft on the cylinder head to be tdc mark(arrow) upward. 18. Measure the axial end play of the camshaft. End play 0.06 - 0.21mm notice if out of standard, adjust it with the proper thickness of locking washer. 19. Insta...

  • Page 361

    Om600 engine mechanical 1b3-57 21. Position the camshaft on marking and install the camshaft sprocket. Notice align the alignment marks on the chain and sprocket. 23. Install the camshaft sprocket bolt. 22. Check the tdc position of the crankshaft. Tightening torque 25 nm + 90°.

  • Page 362

    1b3-58 om600 engine mechanical 24. Install the exhaust manifold and gasket. 25. Install the turbocharger. 26. Install the exhaust pipe onto the turbocharger. Tightening torque 25 nm notice measure the max. Length ‘l’ and replace the bolt if it exceeds 53.6mm..

  • Page 363

    Om600 engine mechanical 1b3-59 27. Replace the seal and then install the chain tensioner. Tightening torque 80 nm 28. Remove the engine lock. 29. Insert the nozzle washer into the hole to face round part downward. 30. Install the fuel injection nozzle. Tightening torque 40 nm 31. Connect the fuel ho...

  • Page 364

    1b3-60 om600 engine mechanical 35. Connect the wires to the coolant temperature sensor and the glow plug sensor. 36. Replace the intake manifold gasket. 37. Install the intake manifold. Tightening torque 25 nm 33. Replace the gasket and install the cylinder head cover. Tightening torque 10 nm 34. In...

  • Page 365

    Om600 engine mechanical 1b3-61 38. Replace the o-ring of heater feed pipe and install it to the cylinder head. Notice for installation, clean the hole. 39. Install the bracket of heater feed pipe to the oil filter. 40. Install the fuel pipe and the accelerator control linkage. 41. Connect the fuel l...

  • Page 366

    1b3-62 om600 engine mechanical 43. By inserting a rod into the tensioning lever upper hole and pulling the rod, install the bolt and then tighten the nut. 44. Install the oil dipstick tube bracket. Tightening torque 10 nm 45. Hold the cooling fan with the counter holder and tighten the bolt. 42. Ins...

  • Page 367: Timing Case Cover

    Om600 engine mechanical 1b3-63 timing case cover preceding work : removal of the cooling fan rmoval of the v-belt tensioning device removal of the vibration damper and hub removal of the alternator 1 bolt ............................................................ 10nm 2 cylinder head cover 3 gaske...

  • Page 368

    1b3-64 om600 engine mechanical 8. Remove the guide pulley bracket (24). Tools required 116 589 03 07 00 socket wrench removal procedure 1. Remove the fan clutch and cooling fan belt pulley. 2. Drain the engine oil completely. 3. Remove the oil dipstick tube bracket bolts. 4. Remove the crankshaft pu...

  • Page 369

    Om600 engine mechanical 1b3-65 11. Remove the alternator bracket (16). 9. Disconnect the pipes of power steering pump and remove the belt pulley. Notice be careful not to lose the key. 10. Remove the nut and pull out the bolt and then remove the power steering pump. 12. Remove the fuel filter..

  • Page 370

    1b3-66 om600 engine mechanical 18. Remove the timing case cover (19) bolts and then remove the timing case cover (14). Notice be careful not to damage the cylinder head gasket or oil pan gasket. 13. Remove the camshaft. 14. Remove the socket bolts(4) in the chain box. Socket wrench 115 589 03 07 00 ...

  • Page 371

    Om600 engine mechanical 1b3-67 installation procedure 1. Thoroughly clean the sealing surface and apply sealant. 2. Install the timing case cover. Notice bolts arrangement 1.M6 x 60 2.M6 x 70 3.M6 x 40 3. Tighten the socket bolts in the chain box. Tightening torque 10 nm tightening torque 23 nm 4. T...

  • Page 372

    1b3-68 om600 engine mechanical tightening torque 25 nm 5. Install the flange, vibration damper and crankshaft belt pulley. Notice replace front radial seal if necessary. 6. Install the alternator bracket. 25 nm front side 7. Install the alternator tightening torque upper - 25 nm low - 25 nm 8. Insta...

  • Page 373

    Om600 engine mechanical 1b3-69 10. Install the fuel filter. 11. Install the vacuum pump. 12. Install the power steering pump. 13. Install the power steering pump pulley. Tightening torque 25 nm tightening torque 10 nm tightening torque 23 nm tightening torque 32 nm 14. Install the guide pulley brack...

  • Page 374

    1b3-70 om600 engine mechanical 15. Install the guide pulley (22) and fit the closing cover (20). 16. Replace the gasket (3) and install the cylinder head cover (2). 17. Install the cooling fan belt pulley and fan clutch. 18. Install the belt tensioning device and then install the belt. 19. Install t...

  • Page 375: Crankshaft End Cover

    Om600 engine mechanical 1b3-71 crankshaft end cover preceding work : removal of flywheel and driven plate. 1 crankshaft flange 2 end cover .............................. Clean, loctite 573 3 bolt ......................................... 10nm, loctite 573 4 radial seal .................................

  • Page 376

    1b3-72 om600 engine mechanical tools required 601 589 03 43 00 oil seal assmbler removal procedure 1. Remove the bolts (3, 6) from end cover, by pulling out the lugs (arrow), remove the cover. Notice be careful not to damage the oil pan gasket. 2. Remove the radial seal (4) with care not to damage t...

  • Page 377

    Om600 engine mechanical 1b3-73 notice the sealing lip of the repair radial seal is offset to the inside by 3mm to ensure that it does not run in any groove which the standard radial seal may have left on the crankshaft flange. 7. Install the outer oil seal assembler on he seal and by tightening the ...

  • Page 378: Vibration Damper And Hub

    1b3-74 om600 engine mechanical vibration damper and hub preceding work : removal of the cooling fan removal of poly v-belt 1 bolt ............................................................ 10nm 2 cooling fan belt pulley 3 socket bolt ................................................ 23nm 4 cranksha...

  • Page 379

    Om600 engine mechanical 1b3-75 sectional view 3 socket bolt 4 crankshaft belt pulley 5 vibration damper 6 bolt 7 washer 8 straight pin notice the mounting position of vibration damper is fixed by straight pin (8). Tools required 602 589 00 40 00 engine lock 103 589 00 30 00 puller 9 hub 11 radial se...

  • Page 380

    1b3-76 om600 engine mechanical removal procedure 1. Remove the starter motor and install the engine lock into the wheel ring gear. Engine lock 602 589 00 40 00 2. Remove the poly v-belt. 3. Remove the cooling fan. Notice keep the fan in vertical position. 4. Remove the cooling fan belt pulley (2). 5...

  • Page 381

    Om600 engine mechanical 1b3-77 7. Remove the socket bolts (3) and then remove the belt pulley (4) and vibration damper (5). 8. Remove the washer and bolt. 9. Remove the hub by using a puller. Puller 103 589 00 33 00 10. Replace the radial seal..

  • Page 382

    1b3-78 om600 engine mechanical installation procedure 1. Install the hub. Notice exactly align the woodruff key and the groove of hub (arrow). 2. Install the washer (7) and tighten the bolt (6). Washer (new) : 1 ea 200 nm + 90° 3. Install the vibration damper. Notice exactly align and insert onto th...

  • Page 383

    Om600 engine mechanical 1b3-79 5. Install the timing sensor bracket. Notice see the ‘tdc setting’. 6. Install the cooling fan pulley. Tightening torque 10 nm 7. Install the cooling fan. 8. Install the fan belt. 9. Remove the engine lock..

  • Page 384: Crankshaft Front Radial Seal

    1b3-80 om600 engine mechanical crankshaft front radial seal 1 radial seal 2 timing case cover tools required 601 589 03 14 00 sleeve 3 woodruff key.

  • Page 385

    Om600 engine mechanical 1b3-81 notice the sealing lip of the repair radial seal is offset to the inside by 2mm to ensure that is does not run in any groove which the standard radial seal may have left on the crankshaft flange. A standard radial seal b repair radial seal replacement procedure 1. Pull...

  • Page 386: Crankshaft Ball Bearing

    1b3-82 om600 engine mechanical crankshaft ball bearing 1 spacer 2 cover ......................................... Replace notice manual transmission only. Tools required 000 589 33 33 00 counter support 000 589 25 33 00 internal extractor removal & installation procedure 1. Remove the manual transmi...

  • Page 387: Crankshaft

    Om600 engine mechanical 1b3-83 crankshaft preceding work : removal of the end cover removal of the piston removal of the crankshaft sprocket 3 crankshaft main bearing shells (upper) 4 trust bearings (upper) 5 crankshaft 6 crankshaft main bearing shells (lower) 7 thrust bearings (lower) 8 crankshaft ...

  • Page 388

    1b3-84 om600 engine mechanical 3 crankshaft main bearing shells (upper) 4 thrust bearings (upper) 5 crankshaft 6 crankshaft main bearing shells (lower) 7 thrust bearings (lower) a radial bearings b radial and axial bearings (thrust bearing) notice the gaps between the bearing shell and bore and betw...

  • Page 389

    Om600 engine mechanical 1b3-85 3 crankshaft main bearing shells (upper) 4 thrust bearings (upper) 5 crankshaft 6 crankshaft main bearing shells (lower) 7 thrust bearings (lower) a radial bearings b radial and axial bearings (thrust bearing) notice the gaps between the bearing shell and bore and betw...

  • Page 390

    1b3-86 om600 engine mechanical 24.500 - 24.533 24.600 - 24.633 24.700 - 24.733 24.900 - 24.933 25.000 - 25.033 new limit new limit radial clearances axial clearances crankshaft bearing journal diameter crankshaft standard and repair sizes standard size 50.950 - 57.965 journal width 24.500 - 24.533 2...

  • Page 391

    Om600 engine mechanical 1b3-87 bearing shell matching crankshaft bearing shells to basic bearing bore in crankshaft matching crankshaft bearing shells to basic bearing journal of crankshaft marking of basic bearing bore in lower color code of relevant crankshaft parting surface 1 punch mark or blue ...

  • Page 392

    1b3-88 om600 engine mechanical removal & installation procedure 1. Remove the bearing cab bolt. 2. Remove the bearing caps (8). Notice the crankshaft bearing caps are marked with stamped numbers. Remove the bearing cap from the vibration damper side. 3. Remove the crankshaft bearing caps (9) and low...

  • Page 393

    Om600 engine mechanical 1b3-89 14. Measure crankshaft bearing journal diameter (f). Notice when measured in a and b, the runout should not exceed 0.010mm. 8. Thoroughly clean the oil gallery. 9. Select a proper new bearing shells with reference to table. 10. Coat the new bearing shells with oil and ...

  • Page 394

    1b3-90 om600 engine mechanical 15. Measure radial clearance of crankshaft bearing (g). Clearance ‘g’ 0.027 - 0.051mm notice if ‘g’ is out of standard, replace the bearing shells and adjust the radial clearance of crankshaft bearing. Example) measured value ‘e’ = 57.700mm measured value ‘f’ = 57.659m...

  • Page 395

    Om600 engine mechanical 1b3-91 notice if the max. Length of bolts(l) exceed 63.8mm, replace them. 19. Coat the new crankshaft with engine oil and place it on the crankcase. 20. Install the crankshaft bearing caps according to marking and tighten the bolts. Tightening torque 55 nm + 90° notice instal...

  • Page 396

    1b3-92 om600 engine mechanical 28. Remove the connecting rod bearing cap. 29. Install the piston. 30. Rotate the crankshaft by hand and check whether it rotates smoothly. 31. If the bearings are damaged, - replace the oil presser relief valve. - clean the oil pump and oil filter housing carefully an...

  • Page 397: Flywheel

    Om600 engine mechanical 1b3-93 flywheel preceding work : removal of the transmission removal of the clutch 1 oil pan 2 straight pin 3 flywheel 4 12-sided stretch bolt ............ Check, 45nm + 90° 5 drive plate (automatic transmission) 6 flywheel (automatic transmission).

  • Page 398

    1b3-94 om600 engine mechanical l manual transmission flywheel l automatic transmission flywheel om661la om662la.

  • Page 399

    Om600 engine mechanical 1b3-95 3. Remove the flywheel (3), if equipped with manual transmission. Installation notice correctly align the position of dowel pin (2). Tools required 602 589 00 40 00 engine lock removal & installation procedure 1. Install the engine lock. Engine lock 602 589 02 40 00 2....

  • Page 400

    1b3-96 om600 engine mechanical 4. Remove the flywheel (6) and driven plate (5), if equipped with automatic transmission. Installation notice correctly align the position of dowel pin (2). 5. Installation should follow the removal procedure in the reverse order..

  • Page 401: Machining Of Flywheel

    Om600 engine mechanical 1b3-97 machining of flywheel 1 flywheel machining of flywheel notice flywheels which have scorch marks, scoring or cracks in the clutch surface should be machined by grinding or precision-turning. If the scores or cracks are severe than permissible specifications, replace the...

  • Page 402: Flywheel Ring Gear

    1b3-98 om600 engine mechanical flywheel ring gear preceding work : removal of flywheel 1 ring gear 2 flywheel 3 centering collar diameter tools required 001 589 53 21 00 dial gauge 363 589 02 21 00 dial gauge holder.

  • Page 403

    Om600 engine mechanical 1b3-99 diameter ‘a’ 275 + 0.5mm replacement procedure 1. Drill a hole into the ring gear (1) (arrow) and snap with a chisel. 2. Thoroughly clean the collar surfaces of ring gear. 3. Measure diameter (a) of centering collar. Notice if out of standard, replace the flywheel. 4. ...

  • Page 404

    1b3-100 om600 engine mechanical 6. Measure axial runout of ring gear (1) on a surface plate. Limit max. 0.4mm notice for correct measurement, put the flywheel on the flat measuring board. Dial gauge 001 589 53 21 00 dial gauge holder 363 589 02 21 00

  • Page 405

    Om600 engine mechanical 1b3-101 hydraulic valve clearance compensation element check 1 cylinder head cover 2 bolt ............................................................ 10nm 3 gasket ................................................... Replace 4 valve tappet 5 cylinder head.

  • Page 406

    1b3-102 om600 engine mechanical checking notice the noise which continues short time during short travel (frequent starting of the engine) or engine starting after a long time storage is normal operating conditions. So, it does not need to be repaired. Determine the malfunctions in valve clearance c...

  • Page 407: Valve Tappets

    Om600 engine mechanical 1b3-103 valve tappets preceding work : removal of camshaft 1 valve tappet 2 cylinder head 3 oil gallery 4 seal ....................................................... Replace 5 screw plug tools required 102 589 03 40 00 magnetic bar.

  • Page 408

    1b3-104 om600 engine mechanical replacement procedure 1. Pull out the valve tappet (1). Magnetic bar 102 589 03 40 00 2. Remove the plug (5) and blow compressed air into the oil gallery (3). At this time, check that the outlet bores(arrow) at the seat of the valve tappet are clear. 3. Replace the se...

  • Page 409: Valve Springs Check

    Om600 engine mechanical 1b3-105 valve springs check preceding work : removal of valve spring 1 valve spring service data outer diameter 33.1mm wire diameter 4.20mm free length 50.0mm at preloaded length tension (new) 680 - 740n 27mm limit 612n 2 spring scale.

  • Page 410

    1b3-106 om600 engine mechanical valve springs (cylinder head removed) cylinder head removed 1 valve tappet 2 valve cotters 3 spring retainer 4 valve spring ........... Check, replace if necessary 5 cylinder head 6 stud bolt .................................................... 12nm 7 washer 8 nut ......

  • Page 411

    Om600 engine mechanical 1b3-107 removal & installation procedure 1. Remove the nuts (8) uniformly and then remove the washer (7), exhaust manifold (9) and gasket. Installation notice check the stud bolt (6) for damage and replace if necessary. Tighten torque 12 nm tighten torque 25 nm tools required...

  • Page 412

    1b3-108 om600 engine mechanical 5. Using the press lever (14), press the spring retainer downward and remove the valve cotters (2) with magnetic finger (15). Notice be careful not to damage guide bore of the valve tappet. Press lever 667 589 00 31 00 magnetic finger 116 589 06 63 00 6. Remove the sp...

  • Page 413

    Om600 engine mechanical 1b3-109 valve springs (cylinder head installed) preceding work : removal of camshaft 1 valve tappet 2 valve cotters 3 spring retainer 4 valve spring .......... Check, replace if necessary 5 timing chain 6 cylinder head notice remove the valve springs only when the piston is a...

  • Page 414

    1b3-110 om600 engine mechanical 5. Using the press lever (9), press the spring retainer(3) downward and remove the valve cotters (2) with magnetic finger (10). Notice be careful not to damage guide bore of the valve tappet. Press lever 667 589 00 31 00 magnetic finger 116 589 06 63 00 removal & inst...

  • Page 415

    Om600 engine mechanical 1b3-111 6. Remove the spring retainer(3) and spring (4). 7. Check the valve spring and replace if necessary. 8. Insert valve spring (4) with the color coding (arrow) facing down and insert valve spring retainer(3). 9. By press the spring retainer(3) with press lever (90), ins...

  • Page 416: Valve Stem Seals

    1b3-112 om600 engine mechanical valve stem seals preceding work : removal of camshaft. 1 valve tappet 2 valve cotters 3 spring retainer 4 valve spring ........... Check, replace if necessary 5 valve stem seal 6 valve notice remove the valve stem seals when the piston is positioned at tdc..

  • Page 417

    Om600 engine mechanical 1b3-113 tools required 667 589 00 31 00 press lever 104 589 00 37 00 pliers 102 589 03 40 00 magnetic lifter 603 589 01 40 00 holding wheel 601 589 02 43 00 drift 116 589 06 63 00 magnetic finger 667 589 02 63 00 supporting bar a : intake valve stem seal b : exhaust valve ste...

  • Page 418

    1b3-114 om600 engine mechanical replacement procedure 1. Remove the valve tappet (1) with magnetic lifter. Notice place the valve tappets upside down (open end upward). Magnetic lifter 102 589 03 40 00 2. Install the holding wheel (7) into the timing chain (11). Holding wheel 603 589 01 40 00 3. Pos...

  • Page 419

    Om600 engine mechanical 1b3-115 6. Remove the spring retainer(3) and valve spring (4). 7. Remove the valve stem seal (5). Pliers 104 589 00 37 00 8. Insert the cap (12) onto the valve (6) and install the new valve stem seal (5) and then remover the cap. Drift 601 589 02 43 00 9. By pressing the spri...

  • Page 420

    1b3-116 om600 engine mechanical 8.000 - 8.030 9.000 - 9.050 39.5 intake exhaust 0.029 - 0.051 0.029 - 0.051 red white red white diameter ‘a’ service data item basic bore repair size 1 repair size 2 repair size 1 repair size 2 outer diameter ‘d’ 14.251 14.440 - 14.451 14.240 - 14.251 14.440 - 14.451 ...

  • Page 421

    Om600 engine mechanical 1b3-117 tools required 000 589 10 53 00 reamer (for exhaust) 000 589 10 68 00 cylinder brush 000 589 21 53 00 reamer (for intake) 102 589 00 23 00 go / no go gauge (for intake) 103 589 02 15 00 drift (for exhaust) 103 589 03 15 00 drift (for intake) 117 589 03 25 00 go / no g...

  • Page 422

    1b3-118 om600 engine mechanical 2. Thoroughly clean the basic bore by using a cylinder brush. Cylinder brush 000 589 10 68 00 3. Check the basic bore in cylinder head for scoring marks and ream to next repair size if necessary. 2. Insert the go/no go gauge into the valve guide bore. If the no go sid...

  • Page 423

    Om600 engine mechanical 1b3-119 4. Reaming basic bore in cylinder head (repair size). - thoroughly remove carbon deposits in cylinder head. Notice particularly remove the insides of the valve seat rings. - remove the elevation (arrow) of intake valve seat rings. - select correct broaching tool and g...

  • Page 424

    1b3-120 om600 engine mechanical 8. Check the valve guide bore with go / no go gauge (9). The go side (marked ‘0’) should just still drop. If the go side cannot be inserted, the bore of valve guide should be reamed. Notice perform the check only on cooled down cylinder head. Go / no go gauge (for int...

  • Page 425

    Om600 engine mechanical 1b3-121 9. If necessary, ream the valve guide bore evenly. Notice never turn the reamer against the direction of rotation. Reamer (for exhaust) 000 589 10 53 00 reamer (for intake) 000 589 21 53 00

  • Page 426: Valve Seat Rings

    1b3-122 om600 engine mechanical valve seat rings preceding work : removal of valve checking of valve guide, replace if necessary removal of prechamber 1 cylinder head 2 valve seat ring 3 valve guide a height (cylinder head upper / lower surface) b height (cylinder head cover surface - seat of valve ...

  • Page 427

    Om600 engine mechanical 1b3-123 cylinder head clamping device valve seat turning tool ring seat turning tool pneumatic removal / installation device (drift : 8mm, 9mm, 14mm) tensioning head cutting tool for recessing grooves test set for valves internal dial gauge (range : 25 - 60mm) external microm...

  • Page 428

    1b3-124 om600 engine mechanical 1. Measure dimension ‘a’. Removal procedure limit 142.5mm 2. Clamp the cylinder head with clamping device. 3. Cut groove into the valve seat ring so that dimension ‘c’ is approx. 2mm and dimension ‘e’ is approx. 6mm. 4. Remove the cylinder head from the clamping devic...

  • Page 429

    Om600 engine mechanical 1b3-125 8. Turn over the cylinder head. 9. Remove the tensioning head (4) and valve seat ring (2) with drift (14mm) and removal tool. 10. Clean the basic bore of valve seat ring. 11. Measure the basic bore diameter (d2) and outer diameter (d) of the new valve seat ring (stand...

  • Page 430

    1b3-126 om600 engine mechanical 17. Drive in new valve seat ring (2) with a proper wooden drift. 18. Install the valve guide (3) with a proper drift and assembling tool. Notice the valve guide must be driven in from the cylinder head cover. Drift (intake) 8mm drift (exhaust) 9mm 19. Machine the valv...

  • Page 431

    Om600 engine mechanical 1b3-127 check and machining of valves preceding works : removal of cylinder head removal of the vale spring removal of the valve i valve length w camshaft cam basic diameter x distance (camshaft basic bore - valve stem) y half camshaft basic bore diameter z distance (cylinder...

  • Page 432

    1b3-128 om600 engine mechanical intake valve exhaust valve item valve disc diameter ‘d’ valve disc height ‘h’ setting angle “ a ” or machining the valve valve stem diameter ‘d1’ valve length ‘i’ intake valve 37.90 - 38.10 mm 1.7 mm 45° 7.955 - 7.970 mm 106.20 - 106.60 mm 105.30 - 105.70 0.03 mm exha...

  • Page 433

    Om600 engine mechanical 1b3-129 tools required 001 589 32 21 00 dial gauge checking and machining 1. Clean the valves and do visual check. Valves with wobbled valve disc, with worn or scored valve stem should be replaced. 2. Measure valve disc height ‘h’. Service data intake exhaust 1.7 ± 0.15 mm 1....

  • Page 434

    1b3-130 om600 engine mechanical 10. Measure distance ‘z’ (cylinder head cover parting surface - valve stem). 5. Clean the vales, valve seats and valve guides. 6. Coat the valve stem with oil and insert it into valve guide. 7. Insert the valves (1) into the valve guides according to marking. 8. Measu...

  • Page 435

    Om600 engine mechanical 1b3-131 11. The distance ‘x’ (camshaft basic bore - valve stem). ‘x’ = ‘z’ - ‘y’. Determine the valve to use according to this measurement (see ‘matching valves’) example) measured value ‘w’ = 38.2 mm measured value ‘z’ = 36.5 mm value ‘y’ = 15.5 mm ‘x’ = 36.5 - 15.5 = 21.0mm...

  • Page 436: Machining Of Valve Seat

    1b3-132 om600 engine mechanical machining of valve seat preceding work : removal of prechamber removal and inspection of valve, replace if necessary inspection of valve guide, replace if necessary 1 valve 2 valve seat ring 3 cylinder head 4 valve guide a valve seat angle b valve seat free angle.

  • Page 437

    Om600 engine mechanical 1b3-133 service data item valve arrears ‘a’ valve seat width ‘b’ valve seat angle ‘ a ’ valve seat free angle ‘ b ’ permissible radial runout valve length ‘i’ intake 0.1 - 0.7 mm 1.2 - 1.7 mm 45° 65° 0.03 mm 106.20 - 106.60 mm 105.30 - 105.70 mm exhaust 0.1 - 0.7 mm 1.5 - 2.0...

  • Page 438

    1b3-134 om600 engine mechanical machining procedure valve machining is required : - when the valve is leaking. - when replacing the valve. - when replacing the valve guide. - when replacing the valve seat or valve seat ring. 1. Machine the valve seat (a=45°). 2. Measure valve seat width ‘b’. Valve s...

  • Page 439

    Om600 engine mechanical 1b3-135 38 ± 0.2mm or 37.6 ± 0.2mm 5. Insert the valve (1) into the valve guide according to marking and measure amount by which the valve arrears ‘a’. Arrears ‘a’ 0.1 - 0.7mm 6. Measure camshaft cam basic circle diameter (w). Diameter ‘w’ 7. Measure distance ‘z’ (cylinder he...

  • Page 440

    1b3-136 om600 engine mechanical i length of valve w camshaft cam basic circle diameter x distance (camshaft basic bore - valve stem) y half camshaft basic bore diameter z distance (cylinder head cover parting surface - . Valve stem) 8. Measure ‘x’ (camshaft basic bore - valve stem). ‘x’ = ‘z’ - ‘y’ ...

  • Page 441: Camshaft Timing Test

    Om600 engine mechanical 1b3-137 camshaft timing test preceding work : removal of glow plug 1 cylinder head cover 2 bolt ............................................................ 10nm 3 gasket ................................................... Replace 4 valve tappet 5 cylinder head timing conditi...

  • Page 442

    1b3-138 om600 engine mechanical 6. Check the timing. New after approx. 20,000km atdc 11.33° atdc 12° notice if timing is out standard, the camshaft should be checked for wear and the timing chain for stretch. If a difference of more than 4° exists, the timing chain should be replaced. 7. Replace the...

  • Page 443: Camshaft

    Om600 engine mechanical 1b3-139 camshaft preceding work : removal of cylinder head cover 1 bolt ............................................................ 25nm 2 washer 3 camshaft bearing cap 4 camshaft 5 dowel pin 6 locking washer 7 timing chain 8 cylinder head 9 oil pan 10 camshaft sprocket 11 w...

  • Page 444

    1b3-140 om600 engine mechanical 3. Remove the starter motor and install the engine lock. Engine lock 602 589 00 40 00 tools required 602 589 00 40 00 engine lock removal procedure 1. Rotate the crankshaft and position the piston of no.1 cylinder at tdc. Notice do not rotate the crankshaft in the opp...

  • Page 445

    Om600 engine mechanical 1b3-141 4. Remove the bolt and then remove the camshaft sprocket. Notice during removal, be careful not to drop the sprocket with chain. Remove the chain carefully and then pull out the sprocket. 5. Remove the chain tensioner. 6. Remove the camshaft bearing cap bolts accordin...

  • Page 446

    1b3-142 om600 engine mechanical 4. Install the camshaft bearing caps according to markings(1, 2, 3 etc.). 7. Remove the camshaft bearing cap. 8. Pull off the camshaft. Notice be careful not to miss front locking washer. 9. Pull out the locking washer. Notice check the condition of locking washer and...

  • Page 447

    Om600 engine mechanical 1b3-143 5. Tighten the camshaft bearing cap bolts acccording to installation order. 6. Install the camshaft sprocket to be aligned the markings of the camshaft / camshaft bearing cap (arrow). Notice align the alignment marks on the timing chain and sprocket. Tightening torque...

  • Page 448

    1b3-144 om600 engine mechanical 10. Check the tdc marking of ot on the crankshaft. 8. Install the chain tensioner. Tightening torque 80 nm notice replace the seal. Before installation, by pumping in the oil approx. 10 times, fill the oil. 9. Remove the engine lock. Notice if max. Length ‘l’ of the 1...

  • Page 449: Chain Tensioner

    Om600 engine mechanical 1b3-145 chain tensioner 1 chain tensioner ........................................ 80nm 2 seal ....................................................... Replace.

  • Page 450

    1b3-146 om600 engine mechanical notice always install the chain tensioner to be filled with oil. Place the chain tensioner in engine oil up to over the collar on the hexagon head with the thrust pin facing up. Slowly push down the thrust pin as far as the stop 7~10 times with the aid of a press or a...

  • Page 451: Timing Chain

    Om600 engine mechanical 1b3-147 timing chain preceding work : removal of glow plug removal of chain tensioner removal of cooling fan removal of cylinder head cover 1 chain link 2 timing chain 3 camshaft sprocket 4 outer plate.

  • Page 452

    1b3-148 om600 engine mechanical 5. By rotating the crankshaft in the of engine rotation, pull out the old timing chain with installing the new timing chain. 6. Remove the old timing chain and hold the ends of the new timing chain to camshaft sprocket (3) with wire (arrow). Tools required 000 589 58 ...

  • Page 453

    Om600 engine mechanical 1b3-149 7. Insert the new chain link (1) to connect the chain. 8. Insert the new outer plate (4) into the fitting tool (8) and then the outer plate will be held by a magnet. Chain assembling device 000 589 58 43 00 9. Place the fitting tool (8) onto the chain link and press t...

  • Page 454

    1b3-150 om600 engine mechanical in this position, the marking on camshaft / camshaft bearing cap (arrow) must also be aligned. If the markings are not aligned, the timing chain must be re-set and the injection pump timing has to be set. 14. Position the no.1 cylinder at tdc. 11. Place the fitting to...

  • Page 455: Tensioning Rail

    Om600 engine mechanical 1b3-151 tensioning rail preceding work : removal of cylinder head removal of timing case cover 1 tensioning rail 2 bearing pin notice the plastic coating of the tensioning rail can not be replaced..

  • Page 456: Cylinder Head Guide Rail

    1b3-152 om600 engine mechanical cylinder head guide rail preceding work : removal of the cooling fan removal of poly v-belt removal of chain tensioner 1 cylinder head cover 2 bolt ............................................................ 10nm 3 gasket ................................................

  • Page 457

    Om600 engine mechanical 1b3-153 tools required 115 589 02 34 00 sliding hammer 116 589 20 33 00 threaded pin removal procedure 1. Removal the cylinder head cover. 2. Pull off the tensioning lever (7) and remove from the spring (15). 3. Pry off the closing cover (14) and remove the bolt (13) and then...

  • Page 458

    1b3-154 om600 engine mechanical 4. Position the no. 1 cylinder at the tdc of ot. 6. Pull out the bearing pins (9, 11) with sliding hammer and remove the guide rail 10. Sliding hammer 116 589 20 33 00 threaded pin 116 589 02 34 00 installation procedure 1. Apply collar of both bearing pins with seali...

  • Page 459

    Om600 engine mechanical 1b3-155 in this position, the marking on the camshaft / camshaft bearing cap (arrow) must also be aligned. 5. Install the guide pulley (12). Tightening torque 23 nm 6. Attach the tensioning lever (7) to the spring (15) and install. 7. Replace the gasket and install the cylind...

  • Page 460

    1b3-156 om600 engine mechanical timing case cover guide rail preceding work : removal of cylinder head cover 1 bearing pin 2 bearing pin 3 guide rail 4 oil pump chain 5 crankshaft 6 spring 7 bushing 8 tensioning lever.

  • Page 461

    Om600 engine mechanical 1b3-157 removal procedure 1. Pull out the tensioning lever (8) together with the spring (6) and guide rail (3) far enough until the tensioning lever has moved passed the oil pump chain (4) and is resting against the crankshaft (5) 2. Pull the tensioning lever (8) off the bear...

  • Page 462: Crankshaft Sprocket

    1b3-158 om600 engine mechanical crankshaft sprocket preceding work : removal of oil pan removal of timing case cover 1 12-sided stretch bolt (m11) .. Check, 25nm + 90° 2 washer 3 camshaft sprocket 4 timing chain 5 bearing pin 6 bearing pin 7 oil pump 8 oil pump sprocket 9 oil pump chain 10 washer 11...

  • Page 463

    Om600 engine mechanical 1b3-159 special tools 116 589 07 15 00 drift 102 589 05 33 00 puller removal procedure 1. Pull out the tensioning lever (19) together with the spring (17) and guide rail (16) far enough until the tensioning lever has passed the oil pump chain (9) and is resting against the cr...

  • Page 464

    1b3-160 om600 engine mechanical 10. Remove the crankshaft sprocket (12) by using a puller (20). Puller 102 589 05 33 00 5. Place alignment marks (arrow) on the timing chain (4) and crankshaft sprocket (12). 6. Remove the woodruff key(15). 7. Place alignment marks (arrow) on the timing chain (4) and ...

  • Page 465

    Om600 engine mechanical 1b3-161 installation procedure 1. Put the same alignment mark on the new crankshaft sprocket as in the old sprocket. Notice check the timing chain, camshaft sprocket, injection pump timing sprocket, oil pump chain and oil pump sprocket for wear and replace if necessary. 2. In...

  • Page 466

    1b3-162 om600 engine mechanical notice if the max. Length ‘l’ of the stretch bolt exceeds 53.6mm, replace it. 5. Fit the oil pump chain (9) on the crankshaft sprocket (12) and insert the oil pump sprocket (8) into the oil pump chain and then install it on the oil pump. Notice the curved side of the ...

  • Page 467: Piston

    Om600 engine mechanical 1b3-163 piston preceding work : removal of the cylinder head removal of the oil pump 1 oil ring 2 2nd ring 3 top ring 4 snap ring .............................................. Replace 5 piston pin 6 piston 7 connecting rod bushing .......................... Check 8 connectin...

  • Page 468

    1b3-164 om600 engine mechanical service data piston clearance piston crown protrusion in tdc position connecting rod bushing diameter max. 0.12 mm 0.735 - 0.965 mm 26.012 - 26.018 mm connecting rod bolt dimensions thread stretch shaft(c) diameter (new) minimum stretch shaft diameter (c) length(l)(ne...

  • Page 469

    Om600 engine mechanical 1b3-165 removal procedure 1. Remove combustion residues from the cylinder bores. 2. Remove the connecting rod bolts (12) and then remove the connecting rod bearing caps(11). 3. Remove the connecting rod bearing shells (9, 10). Notice be careful not mix the bearing caps and sh...

  • Page 470

    1b3-166 om600 engine mechanical installation procedure 1. Fit the piston onto the connecting rod so that the arrow (15) and the locking slot (16) are facing in direction of the vehicle. 2. Coat the piston pin (15) with engine oil and insert it by hand. Notice do not heat up the piston. 3. Install th...

  • Page 471

    Om600 engine mechanical 1b3-167 6. Coat the cylinder bore, connecting rod bearing journal, connecting rod bearing shell and piston with oil. 7. Compress the piston rings with a tensioning strap (7). Tensioning strap 000 589 04 14 00 8. Insert the piston assembly into the cylinder with a wooden stick...

  • Page 472

    1b3-168 om600 engine mechanical 12. Coat the bolts (12) with oil and then tighten the bolts. Tightening torque 40nm + 90° 13. Rotate the crankshaft and check axial clearance between the connecting rod and crankshaft. 14. Measure clearance between the piston crown and cylinder standard max. 0.12mm 15...

  • Page 473: Oil Filter

    Om600 engine mechanical 1b3-169 oil filter 1 nut ............................................................ 25 nm 2 oil filter ..................................................... Cover 3 o-ring ................................................... Replace 4 oil filter ............... Element repla...

  • Page 474

    1b3-170 om600 engine mechanical removal & installation procedure 1. Remove the oil filter cover and then drain the oil. 2. Remove the oil pressure switch line. 3. Remove the oil filter housing. 4. Clean the sealing surface. 5. Installation should follow the removal procedure in the reverse order..

  • Page 475: Oil Pan

    Om600 engine mechanical 1b3-171 oil pan 1 gasket ................................................... Replace 2 upper oil pan 3 combination bolt ...................................... 10 nm 4 combination bolt ...................................... 10 nm 5 gasket .........................................

  • Page 476

    1b3-172 om600 engine mechanical oil circulation.

  • Page 477

    Om600 engine mechanical 1b3-173 oil filter a from oil pump b to main oil gallery c to oil pan.

  • Page 478: Oil Spray Nozzle

    1b3-174 om600 engine mechanical oil spray nozzle 1 fitting sleeve 2 oil spray nozzle disassembly procedure 1. Remove oil pan or crankshaft. 2. Loose the bolt and then remove the nozzle. 3 combination bolt ..................................... 10 nm a oil duct.

  • Page 479: Oil Pump

    Om600 engine mechanical 1b3-175 oil pump 1 oil pump 2 piston 3 pressure spring 4 guide pin 5 screw plug ................................................ 50 nm 6 combination bolt ...................................... 25 nm 7 oil strainer 8 bracket disassembly procedure 1. Remove the oil pan. 2. Unsc...

  • Page 480

    1b3-176 om600 engine mechanical tightening torque 10 nm 3. Unscrew the oil strainer bracket bolt. 4. Remove the oil pump. 5. Unscrew the screw plug and remove the relief valve. 6. Installation should follow the removal procedure in the reverse order..

  • Page 481: Unit Repair

    Om600 engine mechanical 1b3-177 cylinder head pressure leakage test preceding work : removal of the cylinder head removal of the exhaust manifold removal of the valve 1 feed pipe 2 bolt 3 return connection 4 gasket ................................................................ Replace 5 coolant ga...

  • Page 482

    1b3-178 om600 engine mechanical height ‘a’ (cylinder head surface - cylinder head cover surface) minimum height after machining permissible unevenness of parting surface permissible variation of parallelism (longitud. Direction) peak-to-valley height valve arrears ‘a’ prechamber protrusion service d...

  • Page 483

    Om600 engine mechanical 1b3-179 measurement procedure 1. Measure height ‘a’. Limit 142.5 mm notice if the height is less than 142.5mm, replace the cylinder head. 2. Insert the valve (1) and measure valve arrears ‘a’. Valve arrears ‘a’ 0.1 - 0.7 mm notice if out of standard, machine the valve seat. 3...

  • Page 484

    1b3-180 om600 engine mechanical replacement of crankcase core plug left right core plug ....................................................... F 34mm om661la - 2ea om662la - 3ea core plug ....................................................... F 34mm om661la - 2ea om662la - 3ea core plug .............

  • Page 485

    Om600 engine mechanical 1b3-181 tools required 102 589 00 15 00 drift 102 589 12 15 00 drift replacement procedure 1. Completely drain the coolant. 2. Remove any parts which impede access. (example : transmission, injection pump) 3. Place the screwdriver to the deepdrawn edge of the core plug and pu...

  • Page 486

    1b3-182 om600 engine mechanical service data height ‘y’ permissible unevenness of contacting surface permissible roughness upper contacting surface permissible variation of parallelism of crankcase upper surface to lower surface in longitudinal direction piston protrusion at tdc to crankcase upper s...

  • Page 487: Oil Gallery Steel Ball

    Om600 engine mechanical 1b3-183 oil gallery steel ball preceding work : removal of cooling fan removal of the coolant pump housing removal of the flywheel and driven plate 1 steel ball ................................................. F 15mm 2 screw plug ............................... Loctite 241,5...

  • Page 488

    1b3-184 om600 engine mechanical 3 steel ball ................................................. F 17mm 4 seal 5 screw plug ................................................. 50nm notice the seal (4) and screw plug (5) have to be installed as a repair solution if the steel ball (3) is leaking. Tools re...

  • Page 489

    Om600 engine mechanical 1b3-185 removal & installation procedure 1. Remove the timing case cover. 2. By inserting a round bar (6) approx. 0.7m from the back to the front side through the oil gallery, knock out the steel balls (1,3). Notice be careful not to damage the bores of the steel balls. 6 sho...

  • Page 490

    1b3-186 om600 engine mechanical installation of screw plug notice if steel ball leaks again, install the screw plug. 1. Remove the steel ball. 2. Tap thread into the bores of the oil gallery. Notice front bore : m18 ´ 1.5, depth 10mm rear bore : m16 ´ 1.5, depth 14mm 3. Thoroughly clean the oil gall...

  • Page 491: Cylinder Bore Measurement

    Om600 engine mechanical 1b3-187 standard size wear limit in direction of travel and in transverse direction permissible deviation of cylinder shape honing angle cylinder bore measurement a longitudinal direction b transverse direction c, d, e. Measuring point 1 crankcase contacting surface 2 tdc of ...

  • Page 492: Section 1D1

    Section 1d1 m162 engine cooling specifications . . . . . . . . . . . . . . . . . . . . . . . 1d1-1 general specifications . . . . . . . . . . . . . . . . . 1d1-1 fastener tightening specifications . . . . . . . . 1d1-2 special tools . . . . . . . . . . . . . . . . . . . . . . . 1d1-3 special tools t...

  • Page 493

    1d1-2 m162 engine cooling fastener tightening specifications n · · · · · m 30 22.5 - 27.5 9 - 11 9 - 11 9 - 11 40.5 - 49.5 3 - 7 3 - 7 application coolant drain plug engine hanger bracket and coolant outlet port bolt thermostat cover bracket bolt oil cooler pipe line bolt cooling fan bolt viscous cl...

  • Page 494: Special Tools

    M162 engine cooling 1d1-3 special tools special tools table 124 589 15 21 00 tester 603 589 00 40 counter holder.

  • Page 495: Diagnosis

    1d1-4 m162 engine cooling diagnosis 3. Connect the special tool to the reservoir filler cap and apply 1.4 bar of pressure. System leakage test tools required 124 589 15 21 00 tester test procedure 1. Loosen the cap a little and release pressure and remove the cap. Notice for the risk of scalding, ca...

  • Page 496: Maintenance and Repair

    M162 engine cooling 1d1-5 maintenance and repair on-vehicle service coolant drain and fill up draning & filling up procedure 1. Loosen the cap a little and release pressure and remove the cap. Notice for the risk of scalding, the cap must not be opened unless the coolant temperature is below 90 o c....

  • Page 497

    1d1-6 m162 engine cooling 6. Remove the de-aeration hose clamp in the coolant pump and remove the de-aeration hose. 7. Fill up the coolant through the coolant reservoir tank. Notice l match the anti-freeze and the water ratio to 50 : 50. L supplement the coolant until the coolant overflows to the de...

  • Page 498: Coolant Connection Fitting

    M162 engine cooling 1d1-7 coolant connection fitting preceding work : removal of cooling fan shroud 1 bolt (m8 x 100, 2 pieces) ............... 22.5-27.5 nm 2 engine hanger bracket 3 coolant outlet port removal & installation procedure 1. Drain coolant from the radiator. 2. Remove the hose mounting ...

  • Page 499: Water Pump

    1d1-8 m162 engine cooling water pump preceding work : removal of v-belt removal of air admission housing 1 air admission housing 2 oil cooler pipe line 3 seal ....................................................... Replace 4 bolt ........................................................ 9-11 nm 5 coo...

  • Page 500

    M162 engine cooling 1d1-9 removal & installation procedure 1. Drain the coolant. 2. Disconnect the coolant pump wire connector. 3. Loosen the hose clip and dsconnect all hoses from the coolant pump 4. Remove the coolant line bolts (4) and then remove the coolant line (2). Installation notice notice ...

  • Page 501: Thermostat

    1d1-10 m162 engine cooling thermostat removal & installation procedure 1. Drain the coolant from the radiator. 2. Loosen the hose mounting clamp (6) and remove the heater hose (7). 3. Unscrew the three bolts (5) and remove the thermostat cover bracket, thermostat cover and the thermostat in order. I...

  • Page 502: Oil Cooler Pipe Line

    M162 engine cooling 1d1-11 oil cooler pipe line preceding work : removal of upper intake manifold tightening torque 9 - 11 nm 1 upper intake manifold 2 bolt (m6 x 35, 1 piece) ........................... 9-11 nm 3 bolt (m6 x 16, 2 pieces) ......................... 9-11 nm 4 oil cooler pipe line 5 o-...

  • Page 503

    1d1-12 m162 engine cooling cooling fan and viscous clutch preceding work : removal of cooling fan shroud 1 cooling fan pulley 2 viscous clutch 3 cooling fan 4 bolt (m6 x 12, 4 pieces) ......................... 9-11 nm 5 bolt (m10 x 45, 1 piece) ................. 40.5-49.5 nm.

  • Page 504

    M162 engine cooling 1d1-13 tools required 603 589 00 40 00 counter holder removal & installation procedure 1. Hold the cooling fan pulley using the counter holder (special tool : 603 589 00 40 00) and remove the cooling fan after unscrewing the four bolts (4). Installation notice 2. Remove the bolt ...

  • Page 505: Cooling Fan Shroud

    1d1-14 m162 engine cooling cooling fan shroud removal & installation procedure 1. Pull out the 2 clips (1) from the fan shroud assembly. 2. Remove the lower fan shroud (2). Notice for installation, exactly align the lower fan shroud pin into the hole of the fan shroud assembly (4) and insert the cli...

  • Page 506: Radiator

    M162 engine cooling 1d1-15 radiator preceding work : removal of cooling fan shroud 1 radiator inlet coolant hose 2 radiator outlet coolant hose 3 make up coolant hose 4 automatic transmission oil cooling hose 5 automatic transmission oil cooling line 6 bolt 7 insulator 8 stopper 9 bolt ................

  • Page 507

    1d1-16 m162 engine cooling removal & installation procedure 1. Drain coolant from the radiator. 2. Remove the coolant thermo connector from the radiator. 3. Remove the each coolant hoses. Tightening torque 14 nm 4. Remove the automatic transmission oil cooling hose. Installation notice 5. Remove the...

  • Page 508: Section 1D2

    Circulation type radiation capability section 1d2 m161 engine cooling specifications . . . . . . . . . . . . . . . . . . . . . . . 1d2-1 general specifications . . . . . . . . . . . . . . . . . 1d2-1 fastener tightening specifications . . . . . . . . 1d2-2 special tools . . . . . . . . . . . . . . ....

  • Page 509

    1d2-2 m161 engine cooling fastener tightening specifications n · · · · · m 30 22.5 - 27.5 9 - 11 9 - 11 9 - 11 40.5 - 49.5 3 - 7 3 - 7 application coolant drain plug engine hanger bracket and coolant outlet port bolt thermostat cover bracket bolt oil cooler pipe line bolt cooling fan bolt viscous cl...

  • Page 510: Special Tools

    M161 engine cooling 1d2-3 special tools special tools table 124 589 15 21 00 tester 603 589 00 40 counter holder 111 589 02 01 00 open end wrench 111 589 00 40 00 open end wrench.

  • Page 511: Diagnosis

    1d2-4 m161 engine cooling diagnosis 3. Connect the special tool to the reservoir filler cap and apply 1.4 bar of pressure. System leakage test tools required 124 589 15 21 00 tester test procedure 1. Loosen the cap a little and release pressure and remove the cap. Notice for the risk of scalding, ca...

  • Page 512: Maintenance and Repair

    M161 engine cooling 1d2-5 maintenance and repair on-vehicle service coolant drain and fill up draning & filling up procedure 1. Loosen the cap a little and release pressure and remove the cap. Notice for the risk of scalding, the cap must not be opened unless the coolant temperature is below 90oc. 2...

  • Page 513

    1d2-6 m161 engine cooling 4. After complete draining of the coolant, remove the hose connector to drain plug and reinstall the drain plug. Installation notice 5. Tighten the radiator lower drain cock. 6. Remove the de-aeration hose clamp in the coolant pump and remove the de-aeration hose. 7. Fill u...

  • Page 514

    M161 engine cooling 1d2-7 cooling fan and viscous clutch 1 bolt (m6 x 14, 3 piece) ........................... 9-11 nm 2 cooling fan 3 viscous clutch 4 union nut (left threaded screw) ... 40.5-49.5 nm.

  • Page 515

    1d2-8 m161 engine cooling tools required 111 589 02 01 00 open end wrench 111 589 00 40 00 open end wrench removal & installation procedure 1. Install the holder (special tool : 111 589 00 40 00) to the bolt at the pulley as shown in the right figure to hold the pulley. 2. Remove the viscous clutch ...

  • Page 516: Coolant Pump

    M161 engine cooling 1d2-9 coolant pump preceding work : removal of viscous clutch 1 bolt (m6 x 45, 1 piece) ........................... 9-11 nm 2 bolt (m6 x 95, 1 piece) ........................... 9-11 nm 3 bolt (m6 x 25, 4 piece) ........................... 9-11 nm 4 bolt (m8 x 85, 2 piece) .........

  • Page 517

    1d2-10 m161 engine cooling tools required 124 589 15 21 00 tester removal & installation procedure 1. Drain the coolant. 2. Disconnect the coolant hoses (8, 9, 10). 3. Tak off the drive belt. 4. Unscrew the four bolts (6) from coolant pump pulley and remove the pulley (7). Installation notice tighte...

  • Page 518: Thermostat

    M161 engine cooling 1d2-11 thermostat removal & installation procedure 1. Drain the coolant from the radiator. 2. Loosen the hose mounting clip and remove the coolant hose (3, 4). 3. Unscrew the three bolts (1) and remove the thermostat cover assembly from thermostat housing. Installation notice do ...

  • Page 519: Thermostat Housing Assembly

    1d2-12 m161 engine cooling thermostat housing assembly preceding work : removal of viscous clutch 1a bolt (m6 x 95, 2 pieces) ......................... 9-11 nm 1b bolt (m8 x 75, 2 pieces) ................. 22.5-27.5 nm 1c bolt (m8 x 35, 1 piece) ................... 22.5-27.5 nm 2 thermostat housing ...

  • Page 520

    M161 engine cooling 1d2-13 removal & installation procedure 1. Drain the coolant. 2. Remove the de-aeration hose (4), coolant outlet hose (5) and coolant bypass hose (6). 3. Disconnect the coolant temperature sensor connector. 4. Unscrew the bolt (1c) and pry off the tensioning device shock absorber...

  • Page 521

    1d2-14 m161 engine cooling removal and installation of cooling fan shroud removal & installation procedure 1. Unscrew two bolts from cooling fan shroud and remove the shrud. Installation notice 1 fan suroud assembly tightening torque 3 - 7 nm 2 bolt (m6 x 16, 2 pieces) ........................... 3-...

  • Page 522

    M161 engine cooling 1d2-15 removal and installation of radiator preceding work : removal of cooling fan shroud 1 inlet hose 2 hose (to engine) 3 hose (to 3-way connector) 4 make-up hose (to coolant reservoir) 5 3-way connector 6 automatic transmission oil cooling hose (a/t equippend vehicle) 7 bolt ...

  • Page 523

    1d2-16 m161 engine cooling removal & installation procedure 1. Drain coolant from the radiator. 2. Remove the coolant thermo connector from the radiator. 3. Remove the each coolant hoses. Tightening torque 14 nm 4. Remove the automatic transmission oil cooling hose. Installation notice 5. Unscrew th...

  • Page 524: Section 1D3

    Section 1d3 om600 engine cooling specifications . . . . . . . . . . . . . . . . . . . . . . . 1d3-1 general specifications . . . . . . . . . . . . . . . . . 1d3-1 fastener tightening specifications . . . . . . . . 1d3-1 diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1d3-2 cooling circ...

  • Page 525: Cooling Circulation

    1d3-2 om600 engine cooling cooling circulation a thermostat b radiator d from heater e hose g deaeration line h reservoir diagnosis.

  • Page 526: Thermostat Operation

    Om600 engine cooling 1d3-3 thermostat operation operation 1. At warming up valve closes until temperature of coolant reaches to 85°c. B. From radiator c. From crankcase d. To crankcase 2. At partial opening. Valve opens partially as temperature of coolant is maintained between 85-100°c. 3. At full o...

  • Page 527: Cooling System Leakage Test

    1d3-4 om600 engine cooling cooling system leakage test tools required 124 589 15 21 00 tester test 1. Loosen the pressure cap by 1 notch and remove the cap after. Notice do not remove radiator cap when coolant is above 90°c. 2. Add the coolant to the arrow mark of coolant reservoir. 3. Connect the s...

  • Page 528: Drain and Filling of Coolant

    Om600 engine cooling 1d3-5 drain and filling of coolant preceding work : removal of skid plate drain / filling 1. Loosen the pressure cap of reservoir by 1 notch and remove pressure and then loosen the cap. Notice do not remove radiator cap when coolant is above 90°c. 2. Open the drain plug and drai...

  • Page 529: Coolant Pump

    1d3-6 om600 engine cooling coolant pump preceding work : removal of cooling fan removal of v-belt 1 tensioning lever 2 gasket ................................................... Replace 3 bolt ........................................................... 10 nm 4 belt pulley 5 bolt .......................

  • Page 530

    Om600 engine cooling 1d3-7 removal & installation procedure 1. Loose the bolts(5) and remove the pulley (4). Installation notice tightening torque 10 nm 2. Loose the bolts (3). Installation notice tightening torque 10 nm 3. Pull the tensioning lever(1) to the arrow direction. 4. Remove the coolant p...

  • Page 531: Coolant Pump Housing

    1d3-8 om600 engine cooling coolant pump housing preceding work : removal of coolant pump removal of thermostat removal of alternator 1 gasket ................................................... Replace 2 coolant pump housing 3 connector 4 bolt ...........................................................

  • Page 532

    Om600 engine cooling 1d3-9 removal & installation procedure 1. Disconnect the connector(3). 2. Separate the coolant hose (5) and return pipe(6). 3. Remove the bolts(4) evenly. Installation notice tightening torque 10 nm notice clean gasket residues on the sealing surface of coolant pump and replace ...

  • Page 533: Cooling Fan Clutch

    1d3-10 om600 engine cooling cooling fan clutch 1 belt pulley 2 cooling fan clutch 3 cooling fan 4 socket bolt ................................................ 45 nm 5 socket bolt ................................................ 10 nm tools required 603 589 00 40 00 counter holder.

  • Page 534

    Om600 engine cooling 1d3-11 removal & installation procedure 1. Hold the bolt pulley with counter holder and remove the bolt(4). Counter holder 603 589 00 40 00 installation notice tightening torque 45 nm 2. Remove the socket bolt(5) and then remove the cooling fan(3) and fan clutch(2). Notice keep ...

  • Page 535: Radiator

    1d3-12 om600 engine cooling radiator preceding : removal of cooling fan shroud 1 radiator inlet hose ............... Om662la : 220mm ............................................. Om661la : 321mm 2 radiator outlet hose 3 radiator deaeration tube & hose 4 clamp 5 spring clamp 6 bolt .....................

  • Page 536

    Om600 engine cooling 1d3-13 removal & installation procedure 1. Drain coolant from the radiator. 2. Remove the coolant thermoswich connector from radiator. 3. Remove the each coolant hose. 4. Remove the auto t/m oil cooling hose and cooling line. Installation notice 5. Loosen the radiator upper moun...

  • Page 537: Cooling Sub-System

    1d3-14 om600 engine cooling cooling sub-system 1 radiator 2 cooling fan shroud 3 bolt .......................................................... 3-7nm 4 cooling fan shroud 5 radiator deaieration hose 7 mounting bracket 8 make-up cooling hose 9 bolt ......................................................

  • Page 538

    Om600 engine cooling 1d3-15 removal & installation procedure cooling fan shroud 1. Remove the radiator deaeration hose and tube. Installation notice tightening torque 3 - 7 nm tightening torque 3-7nm 2. Check the shroud. 3. Installation should follow the removal procedure in the reverse order. Coola...

  • Page 539: Thermostat

    1d3-16 om600 engine cooling thermostat 1 thermostat 2 seal ....................................................... Replace 3 thermostat housing cover 4 coolant hose 5 bolt ............................................................ 10nm.

  • Page 540

    Om600 engine cooling 1d3-17 removal & installation procedure 1. Drain the coolant completely. 2. Disconnect the coolant hose(4) from the thermostat housing cover(3). 3. Remove the bolts(5) and then remove the thermostat(1) and housing cover(3) installation notice align the groove on thermostat and t...

  • Page 541: Section 1E1

    Section 1e1 m162 engine electrical specifications . . . . . . . . . . . . . . . . . . . . . . . 1e1-1 alternator specifications . . . . . . . . . . . . . . . . 1e1-1 starting motor specifications . . . . . . . . . . . . 1e1-2 battery specifications . . . . . . . . . . . . . . . . . . 1e1-2 fastener ...

  • Page 542: Battery Specifications

    1e1-2 m162 engine electrical n · m 14 - 18 4 - 5 45 - 50 12 - 15 6 - 7 35 - 48 12 - 18 12 - 18 12 - 18 9 - 11 9 - 11 25 - 30 starting motor specifications application voltage output power description 12 v 1.7 kw battery specifications fastener tightening specifications application capacity specific ...

  • Page 543: Special Tools

    M162 engine electrical 1e1-3 special tools special tools table 120 589 02 09 00 spark plug wrench.

  • Page 544: Maintenance and Repair

    1e1-4 m162 engine electrical maintenance and repair on-vehicle service alternator preceding work : removal of the drivebelt removal & installation procedure 1. Disconnect the negative battery terminal. 2. Unscrew the nut and disconnect the terminal (1). Installation notice 1 terminal (b+) 2 terminal...

  • Page 545: Starting Motor

    M162 engine electrical 1e1-5 3 fixing bolt 4 starting motor 4. Unscrew the mounting bolts (3) of starting motor. Installation notice 5. Remove the starting motor. 6. Installation should follow the removal procedure in the reverse order. Tightening torque 35 - 48 nm starting motor removal & installat...

  • Page 546: Battery

    1e1-6 m162 engine electrical battery 1 cable terminal (-) 2 cable terminal cap (-) 3 cable terminal cap (+) 4 nut 5 fuseblink box 6 terminal (+) 7 battery holddown bracket 8 battery clamp bolt 9 battery 10 sub tray 11 battery tray removal & installation procedure notice l disconnect the battery nega...

  • Page 547: Spark Plug

    M162 engine electrical 1e1-7 1 ignition coil cable cover 2 bolt (m6 x 60, 7 pieces) ......................... 9-11 nm 3 spark plug spark plug preceding work : removal of intake air duct t1/1 ignition coil : cylinder 2 and 5 t1/2 ignition coil : cylinder 3 and 4 t1/3 ignition coil : cylinder 1 and 6.

  • Page 548

    1e1-8 m162 engine electrical tools required 120 589 09 00 spark plug wrench replacement procedure 1. Remove the seven bolts (2) and remove the ignition cable cover. Installation notice tightening torque 9 - 11 nm tightening torque 9 - 11 nm tightening torque 9 - 11 nm 2. Remove the two bolts (m6 x 2...

  • Page 549: Ignition Cable

    M162 engine electrical 1e1-9 ignition cable preceding work : removal of intake air duct 1 control cable connection 2 ignition cable 3 spark plug connector 4 coupling plug 5a, 5b secondary voltage connection e iron core l1 secondary ignition coil l2 primary ignition coil.

  • Page 550

    1e1-10 m162 engine electrical functions 1. Firing order : 1-5-3-6-2-4 2. The ignition cables are located on the cylinder head cover. Each ignition coil provides the high voltage to two spark plugs simultaneously. - t1/1 : cylinder 2 and 5 - t1/2 : cylinder 3 and 4 - t1/3 : cylinder 1 and 6 removal &...

  • Page 551

    M162 engine electrical 1e1-11 circuit diagram inspection & maintenance procedure (for mse) 1. While the ignition switch is in 'off' position, remove the wiring connectors (1 and 15) from ignition coil and measure the primary resistance between terminal no.1 and no.15. 2. During engine cranking, meas...

  • Page 552: Unit Repair

    1e1-12 m162 engine electrical unit repair battery inspection notice l when charging the battery, do not leave the inflammable objects around it. L when checking the electrolyte of battery, put on an eye protector and gloves. 1. Inspect the surface of the battery and replace if any defects were found...

  • Page 553: Section 1E2

    Section 1e2 m161 engine electrical specifications . . . . . . . . . . . . . . . . . . . . . . . 1e2-1 alternator specifications . . . . . . . . . . . . . . . . 1e2-1 starting motor specifications . . . . . . . . . . . . 1e2-2 battery specifications . . . . . . . . . . . . . . . . . . 1e2-2 fastener ...

  • Page 554: Battery Specifications

    1e2-2 m161 engine electrical n · m 14 - 18 4 - 5 45 - 50 12 - 15 6 - 7 35 - 48 12 - 18 12 - 18 12 - 18 9 - 11 9 - 11 25 - 30 starting motor specifications application voltage output power description 12 v 1.2 kw battery specifications fastener tightening specifications application capacity specific ...

  • Page 555: Special Tools

    M161 engine electrical 1e2-3 special tools special tools table 120 589 02 09 00 spark plug wrench.

  • Page 556: Maintenance and Repair

    1e2-4 m161 engine electrical maintenance and repair on-vehicle service alternator preceding work : removal of the drivebelt removal & installation procedure 1. Disconnect the negative battery terminal. 2. Unscrew the nut and disconnect the terminal (1). Installation notice 1 terminal (b+) 2 terminal...

  • Page 557: Starting Motor

    M161 engine electrical 1e2-5 3 fixing bolt 4 starting motor 4. Unscrew the mounting bolts (3) of starting motor. Installation notice 5. Remove the starting motor. 6. Installation should follow the removal procedure in the reverse order. Tightening torque 35 - 48 nm starting motor removal & installat...

  • Page 558: Battery

    1e2-6 m161 engine electrical battery 1 cable terminal (-) 2 cable terminal cap (-) 3 cable terminal cap (+) 4 nut 5 fuseblink box 6 terminal (+) 7 battery holddown bracket 8 battery clamp bolt 9 battery 10 sub tray 11 battery tray removal & installation procedure notice l disconnect the battery nega...

  • Page 559: Spark Plug

    M161 engine electrical 1e2-7 spark plug preceding work : removal of intake air duct tools required 119 589 01 09 00 spark plug wrence 1 screw (3 pieces) .................................. 9 - 11 nm 2 adaptor (3 pieces) 3 ignition coil cable cover 4 spark plug connector 5 ignition coil connector 6 bo...

  • Page 560

    1e2-8 m161 engine electrical tightening torque 9 - 11nm replacement procedure 1. Unscrew the three screws(1) and remove the ignition coil cable cover installation notice tightening torque clearance 25 - 30 nm 0.8 + 0.1 mm 2. Disconnect the cable from ignition coil and spark plug. 4. Using the specia...

  • Page 561: Ignition Cable

    M161 engine electrical 1e2-9 ignition cable preceding work : removal of intake air duct 1 control cable connection 2 ignition cable 3 spark plug connector 4 coupling plug 5a, 5b secondary voltage connection e iron core l1 secondary ignition coil l2 primary ignition coil.

  • Page 562

    1e2-10 m161 engine electrical ignition cable and cable lay-out 1. Firing order : 1-3-4-2 2. T1/1 : connect the cylinder 1 + 4 3. T1/2 : connect the cylinder 2 + 3 removal & installation procedure 1. Disconnect the battery negative cable. 2. Unscrew the 3 screws and remove the ignition cable duct cov...

  • Page 563

    M161 engine electrical 1e2-11 inspection & maintenance (for e2.3 mse) 1. Measure the primary resistance between the cable terminals 1 and 15 after removing the ignition cable wiring connector (1 and 15) with ignition switch off. Notice replace the ignition coil if out of the specified resistance. L ...

  • Page 564: Unit Repair

    1e2-12 m161 engine electrical unit repair battery inspection notice l when charging the battery, do not leave the inflammable objects around it. L when checking the electrolyte of battery, put on an eye protector and gloves. 1. Inspect the surface of the battery and replace if any defects were found...

  • Page 565: Section 1E3

    Section 1e3 om600 engine electrical specifications . . . . . . . . . . . . . . . . . . . . . . . 1e3-1 general specifications . . . . . . . . . . . . . . . . . 1e3-1 maintenance and repair . . . . . . . . . . . . . . 1e3-2 on-vehicle service . . . . . . . . . . . . . . . . . . . . . 1e3-2 table of c...

  • Page 566: Glow Plug

    1e3-2 om600 engine electrical preheating system general information the preheating system consists of control, coolant temperature sensor and glow plugs. L control relay - preheating time. L coolant temperature sensor. L glow plug. Glow plug 1 wiring harness 2 nut ......................................

  • Page 567

    Om600 engine electrical 1e3-3 1. Preheating time - control relay. Control relay functions as followings : l switching of preheating current. L indication of preheating finish. L control of preheating sequence. L indication of fault. 2. Coolant temperature sensor. Coolant temperature sensor senses co...

  • Page 568

    1e3-4 om600 engine electrical preheating system operation 1. Preheating before start. Preheating time is different by coolant temperature and it is on until the glow indicator light goes off. 2. Preheating after start. Preheating continues for max. 60 seconds to rise in characteristic of warming-up ...

  • Page 569

    Om600 engine electrical 1e3-5 removal & installation procedure 1. Disconnect the negative terminal of battery. 2. Remove the nut (2). 3. Remove the glow plug (4). 4. Install the glow plug (4). 5. Tighten the nut (2). Tightening torque 20 nm tightening torque 4 nm.

  • Page 570: Alternator

    1e3-6 om600 engine electrical alternator preceding work : removal of poly v-belt 1 cooling fan 2 bolt ............................................................ 45nm 3 bolt ............................................................ 45nm 4 alternator 5 plug connection.

  • Page 571

    Om600 engine electrical 1e3-7 removal & installation procedure 1. Disconnect the negative terminal of the battery. 2. Disconnect the plug connection (5). 3. Om 662 engine align the groove of cooling fan with bolt (2) (arrow). 4. Remove the bolts (2, 3) and take out the alternator. 5. Installation sh...

  • Page 572: Starter Motor

    1e3-8 om600 engine electrical starter motor 1 starter motor 2 washer 3 nut ............................................................. 15nm 4 bolt ............................................................ 48nm removal & installation procedure 1. Disconnect the battery terminals. 2. Disconnect t...

  • Page 573: Section 1F1

    Section 1f1 m162 engine controls table of contents caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury a...

  • Page 574: Specifications

    1f1-2 m162 engine controls specifications fastener tightening specifications application fuel return and supply line fuel distributor assembly bolt pressure test connector fuel inlet and outlet line fuel filter mounting bracket bolt crankshaft position sensor bolt camkshaft position sensor bolt knoc...

  • Page 575: Special Tools

    M162 engine controls 1f1-3 special tools special tools table 129 589 00 21 00 test box 119 589 04 63 00 pressure hose 106 589 00 21 00 pressure tester 210 589 08 63 00 ecu test cable 210201adaptor line.

  • Page 576: E32 Ecu (Hfm)

    1f1-4 m162 engine controls e32 ecu (hfm) schematic and routing diagrams.

  • Page 577: E32 Ecu (Mse)

    M162 engine controls 1f1-5 e32 ecu (mse).

  • Page 578: Diagnosis

    1f1-6 m162 engine controls diagnosis self diagnosis socket pin numbers and descriptions 1 ground 2 ignition 1 3 battery power supply (fuse no.17) 4 rekes :pin 6 5 engine speed signal :mse pin 60 6 tccu(part-time) 7 stics(pin 26) 8 - 9 - 10 air bag(pin 20) 11 remote engine start unit(pin 10) 12 - 13 ...

  • Page 579: Self Diagnosis Failure Code

    M162 engine controls 1f1-7 41 44 45 56 57 58 59 60 62 64 65 66 67 71 72 73 74 75 76 77 78 79 80 81 82 83 86 87 89 00 01 02 03 04 05 08 09 10 11 17 18 19 20 21 23 24 25 26 27 29 30 31 34 35 40 failure code description coolant temperature sensor open coolant temperature sensor short coolant temperatur...

  • Page 580

    1f1-8 m162 engine controls cruise control acceleration failure cruise control deceleration failure ecu failure(ram) ecu failure(eprom) servo motor control output inter-ruption memory failure servo motor open/short unprogramed ecu with immobilizer uncoded ecu ecu failure(nvram checksum failure) ecu f...

  • Page 581

    M162 engine controls 1f1-9 234 235 236 237 238 239 240 241 242 243 no.5 injector open/short(gnd) no.6 injector short(pwr) no.6 injector open/short(gnd) variable intake air valve short(pwr) variable intake air valve open/short(gnd) cam actuator short(pwr) cam actuator open/short(gnd) a/c compressor r...

  • Page 582: Test Box Connection

    1f1-10 m162 engine controls test box connection 1 ecu 2 test coupling(no.1 - 60) 3 test coupling(no.61 - 120) 4 multi-tester 01 test box 02 ecu test cable tools required 129 589 00 21 00 test box 210 589 08 63 00 ecu test cable.

  • Page 583

    M162 engine controls 1f1-11 fuel injection system test (mse3.62) failure code item Þ 1.0 checking method · ignition:on test step requirement specified value possible cause 10 12 11 -14v · · · · · ecu:power supply - terminal 30(tm.30) Þ 2.2 · · · · · power supply: - terminal 87(tm.87) · ignition:on ·...

  • Page 584

    1f1-12 m162 engine controls failure code item 09, 10, 11, checking method test step requirement specified value possible cause Þ 4.0 · · · · · hfm sensor signal 105 81 · ignition:on 0.9 - 1.1v · Þ 4.1 - 4.3 · cable · external air inflow · hfm sensor · engine:in idle (coolant temperature : > 70 ° c )...

  • Page 585

    M162 engine controls 1f1-13 failure code item checking method test step requirement specified value possible cause Þ 6.1 · ignition:on 0.1 - 0.3a · cable · fuel pump relay · ecu · · · · · fuel pump relay: - current consumption 00, 01, 02, 06, Þ 7.0 · · · · · coolant temperature sensor: - voltage 79 ...

  • Page 586

    1f1-14 m162 engine controls failure code item checking method test step requirement specified value possible cause Þ 9.0 · keep the engine run above 2 minutes in over 80 ° c of coolant temperature. 6.0 - 7.0 v · ecu · cable · oxygen sensor · · · · · oxygen sensor: - signal 80, 81, 82, 83, 89, 5 60 Þ...

  • Page 587

    M162 engine controls 1f1-15 failure code item checking method test step requirement specified value possible cause · ignition:off(injector temperature is 20 ° c) 14 - 17 w - internal resistance (no.1 injector) 63 11 Þ 12.0 · · · · · no.2 cylinder injector: - operating & injection time · when the coo...

  • Page 588

    1f1-16 m162 engine controls failure code item checking method test step requirement specified value possible cause · ignition:off(injector temperature is 20 ° c) 14 - 17 w - internal resistance (no.3 injector) 66 11 Þ 14.0 · · · · · no.4 cylinder injector: - operating & injection time · when the coo...

  • Page 589

    M162 engine controls 1f1-17 failure code item checking method test step requirement specified value possible cause Þ 17.0 · · · · · variable intake air valve (resonance flap switch valve) - operating · engine:in cranking/ below 3500rpm · ecu · cable · variable intake air valve · ignition:on 0.4 - 0....

  • Page 590

    1f1-18 m162 engine controls failure code item Þ 18.1 checking method test step requirement specified value possible cause 73 2 8 - 12 w · · · · · camshaft actuator: solenoid resistance Þ 21.0 · · · · · purge control valve: - vacuum control · engine:in idling/ normal operating temperature · vacuum li...

  • Page 591

    M162 engine controls 1f1-19 failure code item Þ 22.1 checking method test step requirement specified value possible cause 38 37 115 - 125 w · · · · · can module resistance in abs, abd, asr control unit · cable · abs, abd, asr control unit · ignition:off - disconnect the coupling "no.1" from ecu. Þ 2...

  • Page 592

    1f1-20 m162 engine controls reference figures figure2. Rpm sgnal output figure 3. Injection valve wave(at idle speed) figure 4. Injection valve wave(at sharp acceleration) figure 5. Purge control valve operationg wave.

  • Page 593: Ignition System Test

    M162 engine controls 1f1-21 failure code item checking method test step requirement specified value possible cause 10 12 11 - 14v · · · · · ecu:power supply - terminal 30(tm.30) Þ 2.2 · · · · · power supply: - terminal 87(tm.87) · ignition:on · power supply cable · ovpr ignition system test 08, · Þ ...

  • Page 594

    1f1-22 m162 engine controls failure code item checking method test step requirement specified value possible cause Þ 6.1 · · · · · crankshaft position sensor: - resistance · ignition:off - disconnect the coupling "no.2" from ecu · cable · crankshaft position sensor Þ 6.0 · engine:in cranking 99 100 ...

  • Page 595

    M162 engine controls 1f1-23 failure code item checking method test step requirement specified value possible cause 106 11 the value will be changed in 1.2 - 1.7 v - voltage (alternating) 0.9 - 1.6 w 71 11 71 72 · engine:in cranking Þ 7.1 · ignition:on - remove the connector from the camshaft positio...

  • Page 596

    1f1-24 m162 engine controls failure code item checking method test step requirement specified value possible cause 8 - 20 kv · · · · · ignition coil (t1/1, t1/2, t1/3) - secondary ignition voltage > 10 m w 117 118 · engine:in cranking - select the ignition coil in order of t1/1, t1/2 - measuring ran...

  • Page 597

    M162 engine controls 1f1-25 reference figures figure 6. Crankshaft position sensor signal a voltage b identifying the no.1 - 2 missing teeth figure 7. Camshaft position sensor signal figure 8. Signal function 1 crank angle 2 cylinder 3 crankshaft position sensor signal 4 camshaft position sensor sig...

  • Page 598

    1f1-26 m162 engine controls idling control and electronic pedal system test Þ 2.1 · ignition:on 50 51 2.25 - 2.75 v · · · · · pedal valve sensor: - power supply (potentiometer 2) · cable · ecu failure code item Þ 1.0 checking method · ignition:on · position of accelerator pedal: - closed throttle po...

  • Page 599

    M162 engine controls 1f1-27 failure code item checking method test step requirement specified value possible cause Þ 3.1 · ignition:on 84 112 4.75 - 5.25 v · · · · · throttle valve actuator: - power supply(5v) · cable · ecu Þ 4.0 · ignition:on 68 67 0.8 - 2.3 v the value will be changed in 1.0 - 2.5...

  • Page 600

    1f1-28 m162 engine controls air conditioner control system test Þ 2.0 · engine:in idling · air conditioner switch : on/off air conditioner switch : off air conditioner switch : on coolant temperature: above 105 ° c 10 35 11 - 14 v 11 - 14 v · · · · · condenser fan(hi) control: · condenser fan relay ...

  • Page 601

    M162 engine controls 1f1-29 fuel pressure and internal leakage test 01 pressure tester 02 pressure hose 03 measuring beaker preparation connection of the equipment 1. Turn the ignition switch to "off" position. 2. Remove the air cleaner cross pipe. 3. Remove the cap on fuel pressure test plug and co...

  • Page 602

    1f1-30 m162 engine controls failure code item checking method test step requirement specified value possible cause 3.2 - 3.6 bar · · · · · fuel pressure:in idling speed - when the vacuum is applied · engine:in idling - close the valve screw on pressure tester Þ 1.0 connect the fuel pressure test plu...

  • Page 603: Fuel Pump Test

    M162 engine controls 1f1-31 fuel pump test preparation 1 ecu 2 test coupling(no.1-60) 3 test coupling(no.61-120) 4 stop watch 5 measuring beaker connection of the equipment 1. Turn the ignition switch to "off" position. 2. Connect the test box to the ecu. 03 test box 04 ecu test cable tools required...

  • Page 604

    1f1-32 m162 engine controls failure code item checking method test step requirement specified value possible cause 1 liter of fuel supply for max. 35 seconds · · · · · fuel pump: - fuel supply ratio · ignition:on - disconnect the fuel return pipe and connect the host to beaker to collect the supplie...

  • Page 605: Injector Test

    M162 engine controls 1f1-33 connection of the equipment 1. Connect the test box to the ecu as shown in the figure. 2. Remove the 2-pin coupling from injector. 3. Remove the fuel distributor and injector with a unit. At this time, do not remove the supply and return line. 4. Connect the shop made cab...

  • Page 606

    1f1-34 m162 engine controls figure 9. Shop made cable figure 10. Fuel injector normal spary pattern failure code item checking method test step requirement specified value possible cause there should be no leaks and later drops from the injector · · · · · injector: - leakage test · ignition:on - rem...

  • Page 607: Maintenance and Repair

    M162 engine controls 1f1-35 maintenance and repair on-vehicle service ecu appearance 1 cover 2 plate 3 connector 4 flat pin vehicle side : no. 1 - 12 engine side : no. 61 - 72 5 pin vehicle side : no. 13 - 60 engine side : no. 73 - 120 a vehicle side connector : black b engine side connector : gray.

  • Page 608

    1f1-36 m162 engine controls location engine ecu is located at the inside of cowl side trim in right bottom of instrument panel of passenger side. Removal & installation procedure 1. Turn the ignition switch to "off" position. 2. Disconnect the battery negative cable 3. Remove the cowl side trim form...

  • Page 609

    M162 engine controls 1f1-37 pin no. Abbreciation description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 - tm.50 - - gnd - - - lsh1 tm.31 tm.87 tm.30 wfs i/o wfs o - gnd ls1 - - - - starter motor tm.50 - - electronic ground - - - lambda probe 1 heating power ground tm.31 v-battery tm.87 v-bat...

  • Page 610

    1f1-38 m162 engine controls pin no. Abbreciation decription 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 brs - - - - - kliku - - - gnd sp1+5v kp tev ml - can l can h - - - - kpi klima klima - sp1s sp2s bls gnd sp2+2.5v s+b wa...

  • Page 611

    M162 engine controls 1f1-39 engine connector pin no. Abbreciation decription 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 ev5 ev6 ev1 ev4 ev2 ev3 m+ m- tm.31 zsc16 zsa25 zsb34 nws - - - - mt gnd lt injector-cylinder 2 injector-cylinder 4 injector-cylinder 1 injector-cylinder 6 injecto...

  • Page 612

    1f1-40 m162 engine controls pin no. Abbreciation description 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 hfm - - - ip2s - ip1s - - - - - - - - - srv - kw- kw+ - - - nowe- gnd nowe+ - v-ref.Hfm - - - v-re...

  • Page 613

    M162 engine controls 1f1-41 application pin no. Description - starter motor tm.50 - - electronic ground - - - lambda probe 1 heating power ground tm.31 v-battery tm.87 v-battery tm.30 immobilizer crypto read immobilizer crypto write - lambda probe 1 ground lambda probe 1 signal - - - brake switch - ...

  • Page 614

    1f1-42 m162 engine controls pin no. Description pedal potentiometer 1 ground pedal potentiometer 1 supply fuel pump relay tank purge valve engine fan - can-low can-high - - - - clutch switch air conditioning electronic traction signal(abd) - pedal potentiometer 1 signal pedal potentiometer 2 signal ...

  • Page 615

    M162 engine controls 1f1-43 pin no. 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 description injector-cylinder 2 injector-cylinder 4 injector-cylinder 1 injector-cylinder 6 injector-cylinder 5 injector-cylinder 3 e-gas motor plus e-gas motor minus power g...

  • Page 616

    1f1-44 m162 engine controls pin no. Description - - - - - - intake manifold resonance flap - crankshaft sensor ground crankshaft sensor signal - - - camshaft sensor ground hot film air mass ground camshaft sensor signal - hot film air mass supply - - - e-gas potentiometer supply - knock sensor 2 gro...

  • Page 617

    M162 engine controls 1f1-45 removal & installation procedure l when removing the ecu only 1. Turn the ignition switch to "off" position. 2. Disconnect the negative battery cable. 3. Disconnect the couplings from ecu. 4. Unscrew the left and right bolt (3) on bolt (1) and auxiliarly bracket and remov...

  • Page 618: Fuel Pressure Regulator

    1f1-46 m162 engine controls 1 vacuum hose 2 circlip 3 fuel pressure regulator fuel pressure regulator 4 o-ring ..................................................... Replace 5 o-ring ..................................................... Replace.

  • Page 619

    M162 engine controls 1f1-47 3. Disconnect the vacuum hose. 4. Disconnect the circlip and remove the fuel pressure regulator. 5. Apply the oil to o-ring lightly and then replace it. 6. Installation should follow the removal procedure in the reverse order. 7. Check for fuel pressure and internal leaks...

  • Page 620

    1f1-48 m162 engine controls a. Valves closed b. Valves opened the pressure difference between the fuel pressure and the intake manifold is about 3.8 bars during the full load. The spring chamber(9) is connected to the intake manifold with the vacuum hose at the intake pipe connection(7). The negativ...

  • Page 621

    M162 engine controls 1f1-49 the pressure difference between the fuel pressure and the intake manifold is approx. 3.2 bars during idling. 1. Fuel pressure regulator 2. Intake manifold 3. Fuel return(to fuel tank) 4. Fuel supply(from fuel pump) 7. Fuel pressure(approx. 3.2 bars) 8. Intake manifold neg...

  • Page 622: Fuel Distributor

    1f1-50 m162 engine controls 1 vacuum hose 2 fuel return line ................................... 25-30nm 3 fuel supply line ................................... 25-30nm 4 injector connector fuel distributor preceding work : removal of intake air duct 5 bolt (m8 x 50) ................................ ...

  • Page 623

    M162 engine controls 1f1-51 removal & installation procedure 1. Discharge the fuel pressure from the fuel pressure test connector. 2. Disconnect the battery ground cable. 3. Disconnect the vacuum hose from the fuel pressure regulator. 4. Remove the cable guide. 5. Remove the fuel return and supply l...

  • Page 624

    1f1-52 m162 engine controls 8. Remove the injectors and the fuel distributor carefully. 9. Installation should follow the removal procedure in the reverse order. 10. Check for fuel pressure and internal leakage by operating the engine. Fuel pressure test 1. Turn the ignition switch to "off" position...

  • Page 625

    M162 engine controls 1f1-53 3. If there is no change in fuel pressure and maintain the following pressure over 30 minutes, it is normal. Internal leakage test 1. Connect the fuel pressure gauge to the fuel pressure test connector. 2. Stop the engine for approx. 30 minutes and then check the fuel pre...

  • Page 626: Injector

    1f1-54 m162 engine controls injector preceding work : removal of fuel distributor 1 o-ring .................................... Rplace, if damaged 2 injector bracket 3 injector 4 o-ring .................................. Replace, if damaged 5 fuel distributor.

  • Page 627

    M162 engine controls 1f1-55 removal & installation procedure 1. Remove the o-ring. Check for damage and replace it if necessary. 2. Remove the injector bracket from the injector. Installation notice exactly seat the anti-twist lock into the square groove in injector. 3. Separate the injector from th...

  • Page 628

    1f1-56 m162 engine controls the injector spray pattern check 1. Connect the test box (129 589 00 21 00) to the ecu. 2. Disconnect the connector from connector. 3. Disconnect the fuel distributor and injector with a unit from engine without removing the fuel supply and return line. Notice prepare the...

  • Page 629: Fuel Filter

    M162 engine controls 1f1-57 fuel filter 1 fuel filter 2 outlet removal & installation procedure 1. Open the fuel tank cap and remove the fuel tank pressure. 2. Remove the fuel at (2) and in (3). Installation notice notice place the fuel pump pad. There may be a corrosion due to the contact between t...

  • Page 630: Fuel Pump

    1f1-58 m162 engine controls fuel pump requirements for fuel pump item specified value item specified value system pressure 3.8 bar minimum delivery at 8v 30 litre/hr maximum pressure 8.5 bar (12 v) minimum amount of fuel supply 114 liter/hr (12 v, 3.8 bar, - 30 ~ +70°c) minimum pressure 5.0 bar (12 ...

  • Page 631

    M162 engine controls 1f1-59 1 2 3 4 1 fuel pump connector wiring 2 fuel return pipe 3 fuel supply pipe 4 bolts 5 fuel return pipe 6 fuel supply pipe 7 float 8 ground stud (sender "-") color pump "+" thermister "+" ground sender unit "+" use harness location & connector a b c d 2.0 br 0.5 w 2.0 b 0.5...

  • Page 632

    1f1-60 m162 engine controls tools required 661 589 00 46 00 cap remover removal & installation procedure 1. Disconnect the negative battery cable. 2. Disconnect the harness connector (1). 3. Disconnect the fuel supply (6) and return (5) pipes. 4. Using a special tool, unscrew the eight fuel retainin...

  • Page 633

    M162 engine controls 1f1-61 notice replace the fuel pump relay if the measured value is over 9a. Notice check the fuel filter and fuel line when the fuel delivery is not within specified value. Measure the current consumption of fuel pump 1. Remove the fuel pump relay from fuse and relay box in trun...

  • Page 634: Purge Switchover Valve

    1f1-62 m162 engine controls purge switchover valve 1 purge switchover valve 2 line to engine 3 line to canister 4 canister functions the fuel vaporization control system is installed to inhibit the fuel vaporized gas from discharging into the atmosphere. The fuel vaporized gas that is accumulated in...

  • Page 635

    M162 engine controls 1f1-63 4. Remove the line to canister and measure the pressure with the vacuum pressure gauge. Test 1. Maintain the normal temperature and idling state by operating the engine. 2. Connect the ecu terminal no.11 and no.34 and check for normal operation through the output waves us...

  • Page 636: Vacuum System

    1f1-64 m162 engine controls vacuum system 1 purge control valve 2 molded hose 3 insulator 4 fuel tube 5 molded hose 6 idle regulator 7 resonance flap 8 intake manifold 9 fuel pressure regulator 10 vacuum line rubber hose 11 vacuum tube(gray, 270mm) 12 molded hose 13 rubber cap 18 rubber hose 19 vacu...

  • Page 637: Crankshaft Position Sensor

    M162 engine controls 1f1-65 1 crankshaft position sensor 2 bolt (m6 x 14) ........................................ 9 -11nm crankshaft position sensor removal & installation procedure 1. Disconnect the wiring connector at the crankshaft position sensor. 2. Unscrew the bolt and remove the crankshaft p...

  • Page 638

    1f1-66 m162 engine controls crankshaft position sensor resistance inspection 1. Disconnect the coupling "e" of ecu while the ignition switch is in "off" position. 2. Measure the resistance between the coupling terminal pin no.99 and no.100 using a multimeter. Notice measure the insulator resistance ...

  • Page 639: Camshaft Position Sensor

    M162 engine controls 1f1-67 camshaft position sensor 1 bolt (m6 x 14) ......................................... 9-11nm 2 camshaft position sensor removal & installation procedure 1. Disconnect the wiring connector from the camshaft position sensor. 2. Unscrew the bolt (2) and remove the camshaft pos...

  • Page 640

    1f1-68 m162 engine controls camshaft position sensor power supply inspection 1. Turn the ignition switch to 'on' position. 2. Disconnect the camshaft position sensor connector. 3. Measure the voltage between the no.1 and no.3 pin of camshaft position sensor while the ignition switch is in "on" posit...

  • Page 641

    M162 engine controls 1f1-69 hot film air mass (hfm) sensor 1 housing 2 protector net 3 electronic housing removal & installation procedure 1. Turn the hfm sensor coupling in the direction shown in the figure in the right so that it gets separated from the contact surface. Notice make sure the hfm se...

  • Page 642

    1f1-70 m162 engine controls circuit diagram 1 housing 2 electronic housing 3 connector r h : heat resistance r t : temperature resistance r s : sensor resistance.

  • Page 643

    M162 engine controls 1f1-71 if the measured value is not within the specified value, the possible cause may be in cable or hfm sensor in itself. Perform the 5v power supply inspection procedures. Hfm sensor 5v power supply inspection 1. Measure the voltage between the hfm sensor no.108 (+) and no.10...

  • Page 644: Oxygen Sensor

    1f1-72 m162 engine controls oxygen sensor 1 electricity wire 2 oxygen sensor housing 3 sensor ceramic 4 electrode (internal) 5 electrode (external) 6 heating coil 7 open space 8 protector tube functions the oxygen sensor optimizes the combustion (air-fuel ratio 14.7:1) and resets the air-fuel ratio ...

  • Page 645

    M162 engine controls 1f1-73 oxygen sensor signal voltage inspection 1. Measure the oxygen sensor signal voltage between the ecu terminal no.11 and no.9. Maintain the engine speed ia at idle while the coolant temperature is over 80°c. If the measured value is not within the specified value, the possi...

  • Page 646: Knock Sensor

    1f1-74 m162 engine controls knock sensor functions vibration of the engine block is transmitted to the sensor and transferred to the ecu in the form of an alternating voltage signal via a shielded cable. The knock sensor is fastened to the engine block to recognize knocking in all cylinders. The ecu...

  • Page 647: Coolant Temperature Sensor

    M162 engine controls 1f1-75 coolant temperature sensor 1 artificial resin housing 2 metal housing 3 ntc (negative temperature coefficient) resistor removal & installation procedure 1. Remove the pressure by opening the pressure cap in the coolant subtank. 2. Disconnect the connector and remove the c...

  • Page 648

    1f1-76 m162 engine controls 2. Measure the resistance between the coolant temperature sensor terminal no.1 and no.4 with the coolant temperature sensor disconnected. Inspection 1. Measure the coolant sensor input voltage between the ecu terminal no.79 and no.78 while the ignition switch in "on" posi...

  • Page 649

    M162 engine controls 1f1-77 service data resistance characteristic curve according to the coolant temperature temperature(°c) resistance(w) voltage(v) temperature(°c) resistance(w) voltage(v) -40 48,550 4.8991 60 594 1.8632 -30 27,000 4.8214 70 434 1.5132 -20 15,670 4.7001 80 322 1.2179 -10 9,450 4....

  • Page 650: Accelerator Pedal Module

    1f1-78 m162 engine controls accelerator pedal module 1 accelerator pedal 2 accelerator pedal sensor 3 bolts (2 pieces) ....................................... 4-8 nm removal and installation procedure 1. Disconnect the 6-pin connector(arrow). 2. Unscrew the 2 bolts (3) / 1 nut (6) and remove the ped...

  • Page 651

    M162 engine controls 1f1-79 accelerator pedal sensor connector(sensor side) potentiometer 1. Pin no. 3 :red pin no. 1 :yellow pin no. 5 :brown potentiometer 2. Pin no. 6 :violet pin no. 4 :green pin no. 2 :white accelerator pedal sensor connector(vehicle side) potentiometer 1. Pin no. 3 :red-black p...

  • Page 652: Section 1F2

    Section 1f2 m161 engine controls table of contents caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury a...

  • Page 653: Specifications

    1f2-2 m161 engine controls specifications fastener tightening specifications application fuel return and supply line fuel distributor assembly bolt pressure test connector fuel inlet and outlet line fuel filter mounting bracket bolt crankshaft position sensor bolt camkshaft position sensor bolt knoc...

  • Page 654: Special Tools

    M161 engine controls 1f2-3 special tools special tools table 129 589 00 21 00 test box 119 589 04 63 00 pressure hose 106 589 00 21 00 pressure tester 210 589 08 63 00 ecu test cable 210201 adaptor line.

  • Page 655: E23 Ecu (Mse)

    1f2-4 m161 engine controls schematic and routing diagrams e23 ecu (mse).

  • Page 656: E23 Ecu (Hfm)

    M161 engine controls 1f2-5 e23 ecu (hfm).

  • Page 657: Diagnosis

    1f2-6 m161 engine controls diagnosis self diagnosis socket pin numbers and descriptions 1 ground 2 ignition 1 3 battery power supply (fuse no.17) 4 rekes :pin 6 5 engine speed signal :mse pin 60 6 tccu(part-time) 7 stics(pin 26) 8 - 9 - 10 air bag(pin 20) 11 remote engine start unit(pin 10) 12 - 13 ...

  • Page 658

    M161 engine controls 1f2-7 no ignition voltage output(no.1 ignition coil; 1, 4cylinder) no ignition voltage output(no.2 ignition coil; 2, 3cylinder) cranshaft position sensor adaption failure start signal recognition failure no.1 injector short(pwr) no.1 injector open/short(gnd) no.2 injector short(...

  • Page 659

    1f2-8 m161 engine controls servo motor open/short unprogramed ecu with immobilizer uncoded ecu ecu failure(nvram checksum failure) ecu failure(coding id checksum failure) ecu failure(coding checksum failure) ecu failure(programing checkusm failure) abd input signal short(power) abd input signal shor...

  • Page 660

    M161 engine controls 1f2-9 227 228 229 232 233 234 235 236 237 238 239 240 241 cam actuator open/short(gnd) a/c compressor relay short(pwr) a/c compressor relay open/short(gnd) decel limit defected by cpu2 accel limit defected by cpu2 cruise control lever double input(cpu2) cruise control lever safe...

  • Page 661: Test Box Connection

    1f2-10 m161 engine controls test box connection 1 ecu 2 test coupling(no.1 - 60) 3 test coupling(no.61 - 120) 4 multi-tester 01 test box 02 ecu test cable tools required 129 589 00 21 00 test box 210 589 08 63 00 ecu test cable.

  • Page 662: Fuel Injection System Test

    M161 engine controls 1f2-11 fuel injection system test failure code item Þ 1.0 checking method · ignition:on test step requirement specified value possible cause 10 12 11 -14v · · · · · ecu:power supply - terminal 30 (tm.30) Þ 2.2 · · · · · power supply: - terminal 87 (tm.87) · ignition:on · power s...

  • Page 663

    1f2-12 m161 engine controls failure code item 09, 10, 11, checking method test step requirement specified value possible cause Þ 4.0 · · · · · hfm sensor signal 105 81 · ignition:on 0.9 - 1.1v · Þ 4.1 - 4.3 · cable · external air inflow · hfm sensor · engine:in idle (coolant temperature : > 70 ° c )...

  • Page 664

    M161 engine controls 1f2-13 failure code item checking method test step requirement specified value possible cause Þ 6.1 · ignition:on 0.1 - 0.3a · cable · fuel pump relay · ecu · · · · · fuel pump relay: - current consumption 00, 01, 02, 06, Þ 7.0 · · · · · coolant temperature sensor: - voltage 79 ...

  • Page 665

    1f2-14 m161 engine controls failure code item checking method test step requirement specified value possible cause Þ 9.0 · keep the engine run above 2 minutes in over 80 ° c of coolant temperature 6.0 - 7.0 v · ecu · cable · oxygen sensor · · · · · oxygen sensor: - signal 80, 81, 82, 83, 89, 5 60 Þ ...

  • Page 666

    M161 engine controls 1f2-15 failure code item checking method test step requirement specified value possible cause · ignition:off (injector temperature is 20 ° c) 14 - 17 w - internal resistance (no.1 injector) 63 11 Þ 12.0 · · · · · no.2 cylinder injector: - operating & injection time · when the co...

  • Page 667

    1f2-16 m161 engine controls failure code item checking method test step requirement specified value possible cause · ignition:off (injector temperature is 20 ° c) 14 - 17 w - internal resistance (no.3 injector) 65 11 Þ 14.0 · · · · · no.4 cylinder injector: - operating & injection time · when the co...

  • Page 668

    M161 engine controls 1f2-17 failure code item Þ 15.1 checking method test step requirement specified value possible cause 73 2 8 - 12 w · · · · · camshaft actuator: solenoid resistance (e23 only) Þ 18.0 · · · · · purge control valve: - vacuum control · engine:in idling/ normal operating temperature ...

  • Page 669

    1f2-18 m161 engine controls failure code item Þ 19.1 checking method test step requirement specified value possible cause 38 37 115 - 125 w · · · · · can module resistance in abs, abd, asr control unit · cable · abs, abd, asr control unit · ignition:off - disconnect the coupling"no.1" from ecu Þ 19....

  • Page 670

    M161 engine controls 1f2-19 reference figures figure1. Rpm sgnal output figure 2. Injection valve wave(at idle speed) figure 3. Injection valve wave(at sharp acceleration) figure 4. Purge control valve operationg wave.

  • Page 671: Ignition System Test

    1f2-20 m161 engine controls failure code item Þ 1.0 checking method · ignition:on test step requirement specified value possible cause 10 12 11 - 14v · · · · · ecu:power supply - terminal 30 (tm.30) Þ 2.2 · · · · · power supply: - terminal 87 (tm.87) · ignition:on · power supply cable · ovpr ignitio...

  • Page 672

    M161 engine controls 1f2-21 failure code item checking method test step requirement specified value possible cause Þ 5.1 · · · · · crankshaft position sensor: - resistance · ignition:off - disconnect the coupling “no.2” from ecu (engine side coupling). · cable · crankshaft position sensor Þ 5.0 · en...

  • Page 673

    1f2-22 m161 engine controls failure code item checking method test step requirement specified value possible cause 0.9 - 1.6 w 72 11 72 71 · · · · · ignition coil(t1/1) - primary coil voltage (no.1 , 4 cylinder) · engine:in cranking (starter operating) - measuring range: 400 v - time range: 100 % (u...

  • Page 674

    M161 engine controls 1f2-23 failure code item checking method test step requirement specified value possible cause > 10 m w 117 118 · ignition:off - disconnect the coupling "no.2" from ecu. Þ 10.1 · · · · · knock sensor - resistance · connecting condition · cable · ecu 6 - 8.5 k w · · · · · ignition...

  • Page 675

    1f2-24 m161 engine controls reference figures figure 5. Crankshaft position sensor signal a voltage b identifying the no.1 - 2 missing teeth figure 6. Camshaft position sensor signal figure 7. Signal function 1 crank angle 2 cylinder 3 crankshaft position sensor signal 4 camshaft position sensor sig...

  • Page 676

    M161 engine controls 1f2-25 idling control and electronic pedal system test Þ 2.1 · ignition:on 50 51 2.25 - 2.75 v · · · · · pedal valve sensor: - power supply (potentiometer 2) · cable · ecu failure code item Þ 1.0 checking method · ignition:on · position of accelerator pedal: - closed throttle po...

  • Page 677

    1f2-26 m161 engine controls failure code item checking method test step requirement specified value possible cause Þ 3.1 · ignition:on 84 112 4.75 - 5.25 v · · · · · throttle valve actuator: - power supply · cable · ecu Þ 4.0 · ignition:on 68 67 0.8 - 2.3 v the value will be changed in 1.0 - 2.5v. ·...

  • Page 678

    M161 engine controls 1f2-27 air conditioner control system test Þ 2.0 · engine:in idling · air conditioner switch:on/off air conditioner switch:off air conditioner switch:on coolant temperature: above 150 ° c 10 35 11 - 14 v 11 - 14 v · · · · · condenser fan(hi) control: failure code item Þ 1.0 chec...

  • Page 679

    1f2-28 m161 engine controls fuel pressure and internal leakage test 01 pressure tester 02 pressure hose 03 measuring beaker preparation connection of the equipment 1. Turn the ignition switch to "off" position. 2. Remove the air cleaner cross pipe. 3. Remove the cap on fuel pressure test plug and co...

  • Page 680

    M161 engine controls 1f2-29 failure code item checking method test step requirement specified value possible cause 3.2 - 3.6 bar · · · · · fuel pressure:in idling speed - when the vacuum is applied · engine:in idling - colse the valve screw on pressure tester Þ 1.0 connect the fuel pressure test plu...

  • Page 681: Fuel Pump Test

    1f2-30 m161 engine controls fuel pump test preparation 1 ecu 2 test coupling(no.1-60) 3 test coupling(no.61-120) 4 stop watch 5 measuring beaker connection of the equipment 1. Turn the ignition switch to "off" position. 2. Connect the test box to the ecu. 03 test box 04 ecu test cable tools required...

  • Page 682

    M161 engine controls 1f2-31 failure code item checking method test step requirement specified value possible cause 1 liter of fuel supply for max. 35 seconds · · · · · fuel pump: - fuel supply ratio · ignition:on - disconnect the fuel return pipe and connect the host to beaker to collect the supplie...

  • Page 683: Injector Test

    1f2-32 m161 engine controls injector test 1 ecu 2 test coupling(no.1-60) 3 test coupling(no.61-120) 4 measuring beaker 5 shop made cable preparation 03 test box 04 ecu test cable connection of the equipment 1. Connect the test box to the ecu as shown in the figure. 2. Remove the 2-pin coupling from ...

  • Page 684

    M161 engine controls 1f2-33 figure 8. Shop made cable figure 9. Fuel injector normal spary pattern failure code item checking method test step requirement specified value possible cause there should be no leaks and later drops from the injector · · · · · injector: - leakage test · ignition:on - remo...

  • Page 685: Maintenance and Repair

    1f2-34 m161 engine controls maintenance and repair on-vehicle service ecu appearance 1 cover 2 plate 3 connector 4 flat pin vehicle side : number 1 - 12 engine side : number 61 - 72 5 pin vehicle side : number 13 - 60 engine side : number 73 - 120 a vehicle connector : black b engine connector : gra...

  • Page 686

    M161 engine controls 1f2-35 location engine ecu is located at the inside of cowl side trim in right bottom of instrument panel of passenger side. Removal & installation procedure 1. Turn the ignition switch to "off" position. 2. Disconnect the battery negative cable 3. Remove the cowl side trim form...

  • Page 687

    1f2-36 m161 engine controls pin no. Abbreviation description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 - tm.50 - - gnd - lsh2 - lsh1 tm.31 tm.87 tm.30 wfs i/o wfs o - gnd ls1 - gnd ls2 - starter motor tm.50 - - electronic ground - lambda probe 2 heating - lambda probe 1 heating power ground...

  • Page 688

    M161 engine controls 1f2-37 pin no. Abbreviation description 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 brs - - - - - kliku - - - gnd sp1+5v kp tev ml - can l can h - - - - kpi klima ets - sp1s sp2s bls gnd sp2+2.5v s+b wa ...

  • Page 689

    1f2-38 m161 engine controls engine connector pin no. Abbreviation description 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 - - ev1 ev4 ev2 ev3 m+ m- tm.31 - zsb23 zsa14 nws egr - slp - mt gnd lt - - injector-cylinder 1 injector-cylinder 2 injector-cylinder 3 injector-cylinder 4 e-gas ...

  • Page 690

    M161 engine controls 1f2-39 pin no. Abbreviation description 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 hfm - v-ref.Ps - ip2s - ip1s - - - - - - - - - - - kw- kw+ - psaug gnd nowe- gnd nowe+ - v-ref.Hfm...

  • Page 691

    1f2-40 m161 engine controls application pin no. Abbreviation description - starter motor tm.50 - - electronic ground - lambda probe 2 heating - lambda probe 1 heating power ground tm.31 v-battery tm.87 v-battery tm.30 immobilizer crypto read immobilizer crypto write - lambda probe 1 ground lambda pr...

  • Page 692

    M161 engine controls 1f2-41 pin no. Abbreviation description pedal potentiometer 1 ground pedal potentiometer 1 supply fuel pump relay tank purge valve engine fan - can-low can-high - - - - - air conditioning electronic traction signal(abd option only) - pedal potentiometer 1 signal pedal potentiome...

  • Page 693

    1f2-42 m161 engine controls pin no. 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 abbreviation description - - injector-cylinder 1 injector-cylinder 2 injector-cylinder 3 injector-cylinder 4 e-gas motor plus e-gas motor minus power ground tm.31 - ignition ...

  • Page 694

    M161 engine controls 1f2-43 pin no. Abbreiation description - - - - - - - - crankshaft sensor ground crankshaft sensor signal - - - camshaft sensor ground hot film air mass ground camshaft sensor signal - hot film air mass supply - - - e-gas potentiometer supply - - - - knock sensor 1 ground knock s...

  • Page 695

    1f2-44 m161 engine controls removal & installation procedure · · · · · when removing the ecu only 1. Turn the ignition switch to "off" position. 2. Disconnect the negative battery cable. 3. Disconnect the couplings from ecu. 4. Unscrew the left and right bolt (3) on bolt (1) and auxiliarly bracket a...

  • Page 696: Fuel Pressure Regulator

    M161 engine controls 1f2-45 1 vacuum hose 2 circlip 3 fuel pressure regulator fuel pressure regulator 4 o-ring ..................................................... Replace 5 o-ring ..................................................... Replace.

  • Page 697

    1f2-46 m161 engine controls 3. Disconnect the vacuum hose. 4. Disconnect the circlip and remove the fuel pressure regulator. 5. Apply the oil to o-ring lightly and then replace it. 6. Installation should follow the removal procedure in the reverse order. 7. Check for fuel pressure and internal leaks...

  • Page 698

    M161 engine controls 1f2-47 a. Valves closed b. Valves opened the pressure difference between the fuel pressure and the intake manifold is about 3.8 bars during the full load. The spring chamber(9) is connected to the intake manifold with the vacuum hose at the intake pipe connection(7). The negativ...

  • Page 699

    1f2-48 m161 engine controls the pressure difference between the fuel pressure and the intake manifold is approx. 3.2 bars during idling. 1. Fuel pressure regulator 2. Intake manifold 3. Fuel return(to fuel tank) 4. Fuel supply(from fuel pump) 7. Fuel pressure(approx. 3.2 bars) 8. Intake manifold neg...

  • Page 700: Fuel Distributor

    M161 engine controls 1f2-49 fuel distributor preceding work : removal of intake air duct 1 fuel distributor 2 circlip 3 fuel pressure regulator 4 o-ring 5 fuel pressure test connector 6 seal ring 7 vacuum hose 8 combination bolt (m8 x 120) ......... 22.5-27.5 nm 9 fuel return line 10 seal ring 11 ho...

  • Page 701

    1f2-50 m161 engine controls tightening torque 22.5 - 27.5 nm tightening torque 22.5 - 27.5 nm removal & installation procedure 1. Discharge the fuel pressure from the fuel pressure test connector by pushing service valve (arrow). 2. Disconnect the battery ground cable. 3. Disconnect the vacuum hose ...

  • Page 702

    M161 engine controls 1f2-51 9. Installation should follow the removal procedure in the reverse order. 10. Check for fuel pressure and internal leakage by operating the engine. 8. Pull out the injector from intake manifold and remove the fuel distributor. Notice replace the injector o-ring with new o...

  • Page 703

    1f2-52 m161 engine controls fuel pressure test 1. Turn the ignition switch to "off" position. 2. Remove the fuel pressure test connector. Vacuum hose connected (bar) 3.2-3.6 vacuum hose disconnected (bar) 3.7-4.2 5. Replace the pressure regulator diaphragm if out of the specification. 3. Connect the...

  • Page 704

    M161 engine controls 1f2-53 3. If there is no change in fuel pressure and maintain the following pressure over 30 minutes, it is normal. Internal leakage test 1. Connect the fuel pressure gauge to the fuel pressure test connector. 2. Stop the engine for approx. 30 minutes and then check the fuel pre...

  • Page 705: Injector

    1f2-54 m161 engine controls injector preceding work : removal of fuel distributor 1 o-ring ................................. Replace, if damaged 2 injector bracket 3 injector 4 o-ring ................................. Replace, if damaged 5 fuel distributor.

  • Page 706

    M161 engine controls 1f2-55 removal & installation procedure 1. Remove the o-ring. Check for damage and replace it if necessary. 2. Remove the injector bracket from the injector. Installation notice exactly seat the anti-twist lock into the square groove in injector. 3. Separate the injector from th...

  • Page 707

    1f2-56 m161 engine controls the injector spray pattern check 1. Connect the test box (129 589 00 21 00) to the ecu. 2. Disconnect the connector from connector. 3. Disconnect the fuel distributor and injector with a unit from engine without removing the fuel supply and return line. Notice prepare the...

  • Page 708: Fuel Filter

    M161 engine controls 1f2-57 fuel filter 1 fuel filter 2 outlet removal & installation procedure 1. Open the fuel tank cap and remove the fuel tank pressure. 2. Remove the fuel out (2) and in (3). Installation notice notice place the fuel pump pad. There may be a corrosion due to the contact between ...

  • Page 709: Fuel Pump

    1f2-58 m161 engine controls fuel pump requirements for fuel pump item specified value item specified value system pressure 3.8 bar minimum delivery at 8v 30 litre/hr maximum pressure 8.5 bar (12 v) minimum amount of fuel supply 114 liter/hr (12 v, 3.8 bar, - 30 ~ +70°c) minimum pressure 5.0 bar (12 ...

  • Page 710

    M161 engine controls 1f2-59 1 2 3 4 1 fuel pump connector wiring 2 fuel return pipe 3 fuel supply pipe 4 bolts 5 fuel return pipe 6 fuel supply pipe 7 float 8 ground stud (sender "-") color pump "+" thermister "+" ground sender unit "+" use harness location & connector a b c d 2.0 br 0.5 w 2.0 b 0.5...

  • Page 711

    1f2-60 m161 engine controls tools required 661 589 00 46 00 cap remover removal & installation procedure 1. Disconnect the negative battery cable. 2. Disconnect the harness connector (1). 3. Disconnect the fuel supply (6) and return (5) pipes. 4. Using a special tool, unscrew the eight fuel retainin...

  • Page 712

    M161 engine controls 1f2-61 notice replace the fuel pump relay if the measured value is over 9a. Notice check the fuel filter and fuel line when the fuel delivery is not within specified value. Measure the current consumption of fuel pump 1. Remove the fuel pump relay from fuse and relay box in trun...

  • Page 713: Purge Switchover Valve

    1f2-62 m161 engine controls purge switchover valve 1 purge control valve 2 line to engine 3 line to canister 4 canister functions the fuel vaporization control system is installed to inhibit the fuel vaporized gas from discharging into the atmosphere. The fuel vaporized gas that is accumulated in th...

  • Page 714

    M161 engine controls 1f2-63 4. Remove the line to canister and measure the pressure with the vacuum pressure gauge. Test 1. Maintain the normal temperature and idling state by operating the engine. 2. Connect the ecu terminal no.11 and no.34 and check for normal operation through the output waves us...

  • Page 715: Vacuum System

    1f2-64 m161 engine controls 1 purge switchover valve 2 molded hose 3 fuel tube (270 mm) 4 clamp 5 molded hose 6 intake manifold 7 throttle body vacuum system manual transmission 8 fuel pressure regulator 9 vacuum line rubber hose (40 mm) 10 vacuum tube (gray, 540 mm) 11 rubber cap 12 molded hose 13 ...

  • Page 716

    M161 engine controls 1f2-65 15 manual transmission 16 distributor automatic transmission a. To canister b. To auto locking hub.

  • Page 717: Crankshaft Position Sensor

    1f2-66 m161 engine controls 1 crankshaft position sensor (connector) 2 bolt (m6 x 14) ........................................ 9-11 nm crankshaft position sensor removal & installation procedure 1. Disconnect the wiring connector at the crankshaft position sensor. 2. Unscrew the bolt (2) and remove ...

  • Page 718

    M161 engine controls 1f2-67 crankshaft position sensor resistance inspection 1. Disconnect the coupling "e" of ecu while the ignition switch is in "off" position. 2. Measure the resistance between the coupling terminal pin no.99 and no.100 using a multimeter. Notice measure the insulator resistance ...

  • Page 719: Camshaft Position Sensor

    1f2-68 m161 engine controls camshaft position sensor 1 bolt (m6 x 14) ......................................... 9-11nm 2 camshaft position sensor removal & installation procedure 1. Disconnect the wiring connector from the camshaft position sensor. 2. Unscrew the bolt (2) and remove the camshaft pos...

  • Page 720

    M161 engine controls 1f2-69 camshaft position sensor power supply inspection 1. Turn the ignition switch to 'on' position. 2. Disconnect the camshaft position sensor connector. 3. Measure the voltage between the no.1 and no.3 pin of camshaft position sensor while the ignition switch is in "on" posit...

  • Page 721

    1f2-70 m161 engine controls hot film air mass (hfm) sensor 1 housing 2 protector net 3 electronic housing removal & installation procedure 1. Turn the hfm sensor coupling in the direction shown in the figure in the right so that it gets separated from the contact surface. Notice make sure the hfm se...

  • Page 722

    M161 engine controls 1f2-71 circuit diagram 1 housing 2 electronic housing 3 connector r h : heat resistance r t : temperature resistance r s : sensor resistance.

  • Page 723

    1f2-72 m161 engine controls if the measured value is not within the specified value, the possible cause may be in cable or hfm sensor in itself. Perform the 5v power supply inspection procedures. Hfm sensor 5v power supply inspection 1. Measure the voltage between the hfm sensor no.108(+) and no.105...

  • Page 724: Oxygen Sensor

    M161 engine controls 1f2-73 oxygen sensor 1 electricity wire 2 oxygen sensor housing 3 sensor ceramic 4 electrode (internal) 5 electrode (external) 6 heating coil 7 open space 8 protector tube functions the oxygen sensor optimizes the combustion (air-fuel ratio 14.7:1) and resets the air-fuel ratio ...

  • Page 725

    1f2-74 m161 engine controls oxygen sensor signal voltage inspection 1. Measure the oxygen sensor signal voltage between the ecu terminal no.11 and no.9. Maintain the engine speed ia at idle while the coolant temperature is over 80°c. If the measured value is not within the specified value, the possi...

  • Page 726: Knock Sensor

    M161 engine controls 1f2-75 knock sensor functions vibration of the engine block is transmitted to the sensor and transferred to the ecu in the form of an alternating voltage signal via a shielded cable. The knock sensor is fastened to the engine block to recognize knocking in all cylinders. The ecu...

  • Page 727: Coolant Temperature Sensor

    1f2-76 m161 engine controls coolant temperature sensor 1 artificial resin housing 2 metal housing 3 ntc (negative temperature coefficient) resistor removal & installation procedure 1. Remove the pressure by opening the pressure cap in the coolant subtank. 2. Disconnect the connector and remove the c...

  • Page 728

    M161 engine controls 1f2-77 2. Measure the resistance between the coolant temperature sensor terminal no.1 and no.4 with the coolant temperature sensor disconnected. Inspection 1. Measure the coolant sensor input voltage between the ecu terminal no.79 and no.78 while the ignition switch in "on" posi...

  • Page 729

    1f2-78 m161 engine controls service data resistance characteristic curve according to the coolant temperature temperature( ° c) resistance(w) voltage(v) temperature( ° c) resistance(w) voltage(v) -40 48,550 4.8991 60 594 1.8632 -30 27,000 4.8214 70 434 1.5132 -20 15,670 4.7001 80 322 1.2179 -10 9,45...

  • Page 730: Accelerator Pedal Module

    M161 engine controls 1f2-79 accelerator pedal module 1 accelerator pedal 2 accelerator pedal sensor 3 bolts (2 pieces) ....................................... 4-8 nm removal and installation procedure 1. Disconnect the 6-pin connector(arrow). 2. Unscrew the 2 bolts (3) / 1 nut (6) and remove the ped...

  • Page 731

    1f2-80 m161 engine controls accelerator pedal sensor connector(sensor side) potentiometer 1. Pin no. 3 :red pin no. 1 :yellow pin no. 5 :brown potentiometer 2. Pin no. 6 :violet pin no. 4 :green pin no. 2 :white accelerator pedal sensor connector(vehicle side) potentiometer 1. Pin no. 3 :red-black p...

  • Page 732: Section 1F3

    Section 1f3 om600 engine controls specifications . . . . . . . . . . . . . . . . . . . . . . . 1f3-1 fastener tightening specifications . . . . . . . . 1f3-1 maintenance and repair . . . . . . . . . . . . . . 1f3-2 on-vehicle service . . . . . . . . . . . . . . . . . . . . 1f3-2 fuel system . . . . ...

  • Page 733: Fuel System

    1f3-2 om600 engine controls fuel system 1 fuel injection pump 2 fuel feed pump 3 overflow valve 4 injection nozzle 5 pre-filter 6 fuel return hose 7 injection line 8 fuel tank 9 fuel filter 10 choke orifice maintenance and repair on-vehicle service.

  • Page 734: Fuel Injection Pump Coding

    Om600 engine controls 1f3-3 fuel injection pump coding model code pes 4m 55c 320 rs 167 pes 5m 55c 320 rs 168 fuel injection pump code example) pes 5m 55c 320 rs 168 p pump e self-driven s end flange mounting 5 number of cylinders (5ea) m pump size 55 element diameter c modification letter 320 assem...

  • Page 735: Fuel Tank

    1f3-4 om600 engine controls fuel tank 1 fuel tank 2 the sender of fuel tank 3 2-way check valve 4 pre filter 5 front fuel filler neck 6 rear fuel filler neck 7 fuel supply tube 8 fuel return tube 9 filter hose 10 fuel tank hose 11 fuel filler cap 12 clip 13 clip.

  • Page 736: Vacuum Control System Test

    Om600 engine controls 1f3-5 vacuum control system test 2 engine cut-off valve (ignition key switch) 3 auto-locking hub solenoid valve 4 engine stop valve unit 5 pla vacuum unit (idle speed adjustment) 6 engine 7 vacuum pump 8 30° thermovalve 9 fuel injection pump 10 filter with restriction 11 check ...

  • Page 737

    1f3-6 om600 engine controls temperature measuring instrument with test probe wb24 digital tester tools required 001 589 73 21 00 vacuum pump 201 589 13 21 00 vacuum tester 667 589 00 21 00 tdc pulse generator commercial tools e.G. Bosch mot 001.03 sun dit 9000 e.G. Ahlborn, therm 2263-2 eichenfeldst...

  • Page 738

    Om600 engine controls 1f3-7 vacuum 500 mbar lines and connections leaking. Faulty pla vacuum unit. Test step 1 connect vacuum pump (14) with y adapter to pla vacuum unit (5). Run engine at idle speed. Yes no (remove the connection hose from vacuum pump) connect vacuum pump (14) direct to pla vacuum ...

  • Page 739

    1f3-8 om600 engine controls detach line downstream of air admission filter (13). Vacuum drops. Faulty thermovalve fit the line onto air admission filter. Built up vacuum with vacuum pump. Detach the plug from air admission line. Vacuum drops. Faulty filter with restriction. Go to test step 2. Yes no...

  • Page 740

    Om600 engine controls 1f3-9 test step 2 connect vacuum pump (14) with y adapter to pla vacuum unit (5). Run the engine at idle speed. Vacuum drops to ‘0’ at approx. 30°c of the thermovalve. Faulty thermovalve. Defective filter with restriction. Stop the engine. Detach the filter with restriction. Fi...

  • Page 741: Vacuum Pump (Sectional View)

    1f3-10 om600 engine controls vacuum pump (sectional view) 2 suction valve 4 piston 5 pressure valve 6 safety valve 7 o-ring 8 pump housing 9 pump cover 12 lever 14 outer return spring 15 inner spring retainer 16 roller cam 17 piston rod 21 inner return spring 23 upper spring retainer 28 piston ring ...

  • Page 742: Vacuum Pump Test

    Om600 engine controls 1f3-11 vacuum pump test 1 fuel filter 2 vacuum line 3 ancillaries connection 4 vacuum tester tools required 201 589 13 21 00 vacuum tester.

  • Page 743

    1f3-12 om600 engine controls test procedure 1. Remove the fuel filter (1) and keep the filter not to be damaged from running engine. 2. Remove the vacuum line (2) from ancillaries connection (3). 3. Connect the vacuum tester (4) to the ancillaries connection (3). Vacuum tester 201 589 13 21 00 4 run...

  • Page 744: Vacuum Pump

    Om600 engine controls 1f3-13 vacuum pump preceding work : remove the poly v-belt 1 bolt ............................................................ 10nm 2 vacuum pump 3 vacuum line (ancillaries) 4 vacuum line (brake booster) 5 gasket ................................................... Replace.

  • Page 745

    1f3-14 om600 engine controls removal & installation procedure 1. Remove the vacuum line (3, 4). 2. Remove the bolts (1) evenly. Notice if necessary, rotate the engine until the pressure on the tappet of the vacuum pump is released. 3. Remove the vacuum pump (2). 4. Install the vacuum pump (2). Tight...

  • Page 746: Vacuum Unit Replacement

    Om600 engine controls 1f3-15 vacuum unit replacement 1 bracket 2 bolt 3 vacuum unit 4 vacuum line 5 seal .............................................. Replace.

  • Page 747: Idle Speed Adjustment

    1f3-16 om600 engine controls idle speed 750 - 850 rpm 720 - 820 rpm engine om661la engine om662la engine tools required 667 589 00 21 00 tdc pulse generato commercial tool idle speed adjustment service data e.G. Bosch, mot 001.03 sun, dit 9000 digital tester adjustment procedure 1. Connect the digit...

  • Page 748

    Om600 engine controls 1f3-17 6. After adjustment, tighten the locking nut and place the position marking with different color of paint. Notice if there are no changes in idle speed with pla unit adjustment, perform the service at a bosch service center. 7. Connect the vacuum pump to the pla vacuum u...

  • Page 749: Fuel Pump Test

    1f3-18 om600 engine controls min. Volume 150cm for 30 seconds fuel pump test notice before test, replace the fuel filter cartridge and fuel prefilter. Fuel feed test 1. Disconnect the fuel return line (1) and seal up it with plug. 2. Insert the plastic hose (5) and put the end into the measuring bea...

  • Page 750

    Om600 engine controls 1f3-19 fuel pressure test.

  • Page 751

    1f3-20 om600 engine controls tools required 617 589 04 21 00 tester 1. Disconnect the fuel line (2) from the fuel filter. 2. Remove the banjo bolt (4) from the fuel injection pump and remove the seals (3) and fuel line (2). 3. Connect the tester (5). 4. Start the engine and read off the fuel pressur...

  • Page 752: Fuel Pump

    Om600 engine controls 1f3-21 fuel pump 1 fuel injection pump 2 pressure line ............................................ 13nm 3 suction line 4 hose clip ............................................... Replace 5 gasket ................................................... Replace 6 spring lock washer ...

  • Page 753: Injection Nozzle Test

    1f3-22 om600 engine controls injection nozzle test preceding work : removal of fuel injection nozzle 1. Fuel injection nozzle ............. New : 115 - 125bar used : min. 100bar a closed spray = good b stringy spray = poor 2 tester 3 valve.

  • Page 754

    Om600 engine controls 1f3-23 tools required 000 589 14 27 00 tester notice when testing the injection nozzle, do not place your hand into the spray of a nozzle. The spray will penetrate deep into the skin and destroy the tissue. 1. Connect the fuel injection nozzle to the tester (2). Tester 000 589 ...

  • Page 755

    1f3-24 om600 engine controls 5. Opening pressure test : open the valve (3) and slowly operate the hand lever at tester (approx. 1 stroke / second) and measure opening pressure. Notice if out of standard, repair the injection nozzle. New nozzle used nozzle difference between nozzles 115 - 125bar min....

  • Page 756: Injection Nozzles

    Om600 engine controls 1f3-25 injection nozzles 1 fuel injection nozzle ............................. 35-40nm 2 fuel return hose 3 plug 4 nozzle washer ....................................... Replace 5 fuel injection pipe ..................................... 18nm.

  • Page 757

    1f3-26 om600 engine controls tools required 001 589 65 09 00 serration wrench removal & installation procedure 1. Remove the plastic clip from the injection pipe 2. Remove the fuel return hose. 3. Disconnect the injection pipes from the injection nozzles and push them to the side. 4. Remove the fuel...

  • Page 758: Injection Nozzle Repair

    Om600 engine controls 1f3-27 injection nozzle repair preceding work : removal of fuel injection nozzle 1 nozzle holder 2 steel washer 3 compression spring 4 thrust pin 5 intermediate disc 6 nozzle needle 7 nozzle body 8 nozzle tensioning nut ................................ 80nm.

  • Page 759

    1f3-28 om600 engine controls tools required 001 589 65 09 00 socket wrench insert 000 589 00 68 00 cleaning set repair procedure 1. Clamp the nozzle holder (1) in a vice and remove the nozzle tensioning nut (8). Notice use protective jaws for clamping. 2. Disassemble the fuel injection nozzle. Socke...

  • Page 760

    Om600 engine controls 1f3-29 7. Check the fuel injection nozzle and adjust opening pressure if necessary. Opening pressure adjustment disassemble the fuel injection nozzle and replace the steel washer (2). Notice each 0.05mm thickness of the washer results in a pressure difference of approx. 3bar..

  • Page 761

    1f3-30 om600 engine controls removal and installation of injection timing device preceding work : removal of vacuum pump 1 cylinder head cover 2 bolt ............................................................ 10nm 3 gasket ................................................... Replace 4 fuel injectio...

  • Page 762

    Om600 engine controls 1f3-31 tools required 601 589 00 08 00 flange 601 589 05 21 00 locking screw 116 589 20 33 00 sliding hammer 116 589 02 34 00 threaded bolt 667 589 04 63 00 retaining plate removal & installation procedure 1. Remove the bolts (2) and then remove the cylinder head cover (1) and ...

  • Page 763

    1f3-32 om600 engine controls 5. Remove the plug (6) and seal (5) from the fuel injection pump and collect oil in a suitable vessel. Installation notice notice replace the seal. Tightening torque 30 nm 6. Install the locking screw (18) into the injection pump. Notice before tightening the bolts for t...

  • Page 764

    Om600 engine controls 1f3-33 9. Pull out the 12-sided stretch bolt (14) and washer and remove the camshaft sprocket (12). Tightening torque 46 nm 11. Using special tool (24, 25), remove the locking pin (8). Sliding hammer 116 589 20 33 00 threaded bolt 116 589 02 34 00 8. Remove the chain tensioner ...

  • Page 765

    1f3-34 om600 engine controls 12. Push back the timing chain with retaining plate (26) and remove the injection timing device (9). Retaining plate 667 589 04 63 00 13. Installation should follow the removal procedure in the reverse order. 14. After assembling the engine, check start of delivery and a...

  • Page 766: Injection Timing Device

    Om600 engine controls 1f3-35 injection timing device preceding work : removal of injection timing device 1 cam sprocket ........................................... Check 2 bushing .................................................... Check 3 governor weights 4 segment flange and drive hub 5 compressi...

  • Page 767

    1f3-36 om600 engine controls disassembly & assembly 1. Remove the governor weights (3). 2. Pull out the compression springs (5) and cam sprocket (1) from the segment flange (4). 3. Knock out the bushing with a proper drift. 4. Installation should follow the removal procedure in the reverse order..

  • Page 768

    Om600 engine controls 1f3-37 start of delivery test (position sensor, riv method) 1 position sensor 2 battery 3 fuel injection pump 4 seal ....................................................... Replace 5 screw plug ................................................. 30nm service data start of deliver...

  • Page 769

    1f3-38 om600 engine controls tools required 617 589 08 21 00 position sensor test procedure 1. Remove the screw plug (5) and seal (4) and collect oil in a suitable vessel. 2. Install the position sensor (1) into the governor housing of the injection pump to be the guide pin of the position sensor fa...

  • Page 770

    Om600 engine controls 1f3-39 digital tester, riv method (connection diagram for testers without adapter) 1 fuel injection pump 2 rl sensor 3 digital tester 4 tdc pulse sender unit 5 battery.

  • Page 771

    1f3-40 om600 engine controls start of delivery (riv) idle speed (connection diagram for testers with adapter) 1 fuel injection pump 2 rl sensor 3 digital tester 4 tdc pulse sender unit 5 battery 6 rl pulse generator service data atdc 14° - 16° om661la : 720 - 820 rpm, om662la : 750 - 850 rpm.

  • Page 772

    Om600 engine controls 1f3-41 with pulse generator tools required 617 589 09 21 00 rl sensor 617 589 10 21 00 timing tester 667 589 00 21 00 tdc pulse generator commercial tools item digital tester without pulse generator tools bosch, mot 001.03 hartmann & braun, eomt3 bosch, etd 019.00 sun, dit 9000...

  • Page 773

    1f3-42 om600 engine controls after testing preceding work : start of delivery test position sensor (riv method) 1 adjusting screw 2 bolt ............................................................ 23nm 3 fuel injection pump 4 bolt ............................................................ 23nm 5 ...

  • Page 774

    Om600 engine controls 1f3-43 tools required 617 589 08 21 00 position sensor adjustment procedure 1. Position the no. 1 cylinder at atdc 15° notice do not rotate the engine in opposite direction of engine rotation. 2. Remove the bolt (2) at the supporting bracket. 3. Remove the bolt (4). 4. Turn the...

  • Page 775

    1f3-44 om600 engine controls tools required 617 589 09 21 00 rl sensor 617 589 10 21 00 timing tester 667 589 00 21 00 tdc pulse generator commercial tools item digital tester with pulse generator without pulse generator tools bosch, mot 001.03 hartmann & braun, eomt3 bosch, etd 019.00 sun, dit 9000...

  • Page 776

    Om600 engine controls 1f3-45 adjustment procedure 1. Remove the bolt (3) at the supporting bracket. 2. Remove the bolts (1) at the timing case cover. 3. Run the engine at idle speed. 4. Turn the adjusting screw (2) until the specification (15° ± 1° atdc) is indicated on the digital tester. To the ri...

  • Page 777: Fuel Injection Pump

    1f3-46 om600 engine controls tools required 000 589 77 03 00 box wrench insert 601 589 00 08 00 flange 601 589 05 21 00 locking screw 601 589 05 14 00 assembly cageremoval fuel injection pump preceding work : removal of vacuum pump removal of air cleaner housing removal of intake manifold 18 chain t...

  • Page 778

    Om600 engine controls 1f3-47 2. Remove the connecting rod (9). 3. Disconnect the vacuum lines (13, 14). 4. Remove the accelerator control damper (10). (manual transmission vehicle) 5. Remove the suction line (16) and pressure line (4). 6. Remove the banjo bolt (1) and then remove the seal (2) and fu...

  • Page 779

    1f3-48 om600 engine controls 10. Install the assembly cage (29) and remove the bolt (20) and pull off the washer (21). Notice be careful that the bolt (20) is left hand thread. Assembly cage 601 589 05 14 00 11. Remove the chain tensioner (18) and seal (19). 12. Remove the bolt (12) and pull off the...

  • Page 780

    Om600 engine controls 1f3-49 installation procedure 1. Remove the screw plug (27) and seal (26) and collect oil in a vessel. 2. Insert flange (31) onto the injection pump camshaft and turn until the cam of the governor is visible in the hole. Flange 601 589 00 08 00 3. Tighten the locking screw. Loc...

  • Page 781

    1f3-50 om600 engine controls 10. Connect the fuel pipes notice replace the seal. Box wrench insert 000 589 77 03 00 return line fuel injection line fuel feed line suction and pressure line 46 nm 18 nm 13 nm 13 nm 5. Coat the new seal (23) with engine oil and install it. 6. Insert the fuel injection ...

  • Page 782

    Om600 engine controls 1f3-51 12. Connect the vacuum line (13, 14). 13. Connect the connecting rod (9). 14. Connect the accelerator control damper (10). (manual transmission vehicle) 15. Install the chain tensioner. 16. Install the vacuum pump. 17. Check the start of delivery. 18. Adjust the idle spe...

  • Page 783: Section 1G1

    Section 1g1 m162 engine intake & exhaust specifications . . . . . . . . . . . . . . . . . . . . . . . 1g1-1 fastener tightening specifications . . . . . . . . 1g1-1 maintenance and repair . . . . . . . . . . . . . . 1g1-2 on-vehicle service . . . . . . . . . . . . . . . . . . . . . 1g1-2 air cleaner...

  • Page 784: Maintenance and Repair

    1g1-2 m162 engine intake & exhaust maintenance and repair on-vehicle service air cleaner 1 air - cleaner assembly 2 air - cleaner shield upper cover 3 blot 4 blot 5 air intake shield.

  • Page 785

    M162 engine intake & exhaust 1g1-3 removal & installation procedure 1. Release the clamp securing hfm sensor and air cleaner. 2. Disengage the air cleaner assembly and hfm sensor assembly. 3. Unserew the mounting bolt(6) from the bracket. Installation notice tightening torque 22.5 - 27.5 nm 4. Relea...

  • Page 786: Intake Air Duct

    1g1-4 m162 engine intake & exhaust intake air duct 1 clamp 2 sleeve 3 nut 4 clamp 5 intake air duct 3. Remove the clamp (4). 4. Remove the intake air duct (5) carefully. Installation notice exactly seat the pin of intake air duct onto the crankcase ventilation rubber mount. 5. Installation should fo...

  • Page 787: Intake Manifold

    M162 engine intake & exhaust 1g1-5 intake manifold preceding work : removal of fuel distributor and injection valve 1 bolt (m6 x 40, 4 pieces) ......................... 9-11 nm 2 softcap 3 resonance flap 4 gasket ................................................... Replace 5 upper intake manifold 6 b...

  • Page 788

    1g1-6 m162 engine intake & exhaust removal & installation procedure l upper intake manifold 1. Disconnect the vacuum hose (8,9). 2. Loosen the clip (22). 3. Remove the upper intake manifold (5) after unscrewing the bolt (6). Installation notice notice check the gasket and replace it if necessary. 4....

  • Page 789: Resonance Flap

    M162 engine intake & exhaust 1g1-7 resonance flap 1 soft cap (2) 2 bolt (m6 x 25, 4 pieces) ......................... 9-11 nm 3 o-ring removal & installation procedure 1. Remove the 2 soft caps (1). 2. Remove the upper resonance flap coupling after removing 4 bolts (2). Notice connect carefully the ...

  • Page 790

    1g1-8 m162 engine intake & exhaust function description a pneumatically actuated resonance flap (5) is located on the intake manifold, and will be opened and closed by load, which operates resonance flap according to engine and controlled by ecu and rpm. 1. Resonance flap closed (at idle/partial loa...

  • Page 791: Exhaust Manifold

    M162 engine intake & exhaust 1g1-9 exhaust manifold preceding work : removal of air cleaner 1 nut ....................................................... 36-44 nm 2 gasket ................................................... Replace 3 exhaust manifold.

  • Page 792

    1g1-10 m162 engine intake & exhaust tools required 103 589 01 39 00 caulking bolt removal & installation procedure 1. Remove the flange bolt from the exhaust manifold, and disconnect the front exhaust pipe. Installation notice notice check for nut damages and replace the nut if necessary. 2. Remove ...

  • Page 793

    M162 engine intake & exhaust 1g1-11 removal and installation of exhaust line 1 exhaust manifold 2 rivet nut 3 bolt ........................................................... 30 nm 4 front pipe 5 oxygen sensor 6 bolt ...................................................... 28-47 nm 7 rubber pad 8 cata...

  • Page 794: Section 1G2

    Section 1g2 m161 engine intake & exhaust table of contents specifications fastener tightening specifications n l m 9 - 11 22.5 - 27.5 22.5 - 27.5 9.5 - 12.5 15 - 28 28 - 47 application air cleaner housing cover nut intake manifold bolt (m8 x 20) intake manifold bolt (m8) exhaust mainfold stud bolt e...

  • Page 795: Maintenance and Repair

    1g2-2 m161 engine intake & exhaust maintenance and repair on-vehicle service air cleaner 1 air cleaner assembly 2 element assembly 3 insulator 4 air duct hose 5 air inlet duct 6 bolt (m8 × 30 ) ................................... 22.5-27.5 nm 7 bolt (m6 × 35 ) ..........................................

  • Page 796

    M161 engine intake & exhaust 1g2-3 removal & installation procedure 1. Release the clamp securing hfm sensor and air cleaner. 2. Disengage the air cleaner assembly and hfm sensor assembly. 3. Unserew the mounting bolt(6) from the bracket. Installation notice tightening torque 22.5 - 27.5 nm 4. Relea...

  • Page 797: Air Intake Shield

    1g2-4 m161 engine intake & exhaust air intake shield preceding work : removal of air cleaner removal & installation procedure 1. Remove the upper cover (3) from the air intake shield (5) upper mounting pin. 2. Remove the bolts (4 and 6). 3. Remove the air intake shield (5). 4. Installation should fo...

  • Page 798: Intake Air Duct

    M161 engine intake & exhaust 1g2-5 intake air duct 1 clamp 2 sleeve 3 hfm sensor 4 intake air duct 5 blow-by hose 7 clamp(2 pieces) 8 intake air duct mounting bracket removal & installation procedure 1. Release the clamp (1) and intake air duct. 2. Remove the blow-by hose (5) (arrow)..

  • Page 799

    1g2-6 m161 engine intake & exhaust 3. Release the clamp (7) and remove the intake air duct. Notice completely fit the intake air duct with the mounting bracket (8)..

  • Page 800: Intake Manifold

    M161 engine intake & exhaust 1g2-7 intake manifold preceding work : removal of intake air duce removal of fuel distributor and injector 1 bolt (m6 x 40, 6 pieces) ................. 22.5-27.5 nm 2 intake manifold 3 gasket (2 pieces) .................................. Replace 4 bolt (m8 x 40, 3 pieces...

  • Page 801

    1g2-8 m161 engine intake & exhaust removal & installation procedure 1. Disconnect the battery ground cable. 2. Remove idle speed control plug connector (arrow). 3. Disconnect the brake booster vacuum line and other vacuum lines. 4. Disconnector the rod from bearing bracket assembly and remove the co...

  • Page 802: Exhaust Manifold

    M161 engine intake & exhaust 1g2-9 exhaust manifold 1 oxygen sensor .............................. 49.5-60.5 nm 2 bolt (4 pieces) ........................................ 9-11 nm 3 upper cover 4 nut (11 pieces) ............................... 31.5-38.5 nm 5 exhaust manifold 6 flange bolt & exhaust p...

  • Page 803

    1g2-10 m161 engine intake & exhaust 4. Unscrew the eleven nuts (4) and remove the exhaust manifold (5) and gasket (7). Installation notice tightening torque 31.5 - 38.5 nm 5. Replace the gasket (7) with new one. 6. Installation should follow the removal procedure in the reverse order..

  • Page 804

    M161 engine intake & exhaust 1g2-11 removal and installation of exhaust line 1 heat protector-floor 2 pipe assembly-front exhaust 3 gasket 4 heat protector-rear exhaust 5 road assembly-muffler mounting rear 6 heat pro-tector dash 7 heat pro-tector floor 8 heat pro-tector rear exhaust.

  • Page 805: Section 1G3

    Section 1g3 om600 engine intake & exhaust specifications . . . . . . . . . . . . . . . . . . . . . . . 1g3-1 fastener tightening specifications . . . . . . . . 1g3-1 schematic and routing diagrams . . . . . . . 1g3-2 egr circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 1g3-2 maintenance a...

  • Page 806: Egr Circuit

    1g3-2 om600 engine intake & exhaust schematic and routing diagrams egr circuit.

  • Page 807: Maintenance and Repair

    Om600 engine intake & exhaust 1g3-3 air cleaner and inlet duct & hose maintenance and repair on-vehicle service 1 air intake shield assembly 2 air cleaner assembly 3 mounting bracket 4 air cleaner element ........... Clean : 20,000km replace : 60,000km 5 bolt ...........................................

  • Page 808

    1g3-4 om600 engine intake & exhaust removal & installation procedure 1. Loosen the air duct hose clamp and then remove the air cleaner and air duct hose. 2. Disconnect the air cleaner housing cover clamp and remove the cover and element. Tightening torque 9 - 11 nm 3. Loosen the nut (4ea) and remove...

  • Page 809: Intake and Exhaust Manifold

    Om600 engine intake & exhaust 1g3-5 intake and exhaust manifold 1 nut ................................................. 22.5-27.5 nm 2 washer 3 support assembly bar 4 nut ................................................. 22.5-27.5 nm 5 exhaust manifold assembly 6 exhaust gasket 7 stud bolt ............

  • Page 810

    1g3-6 om600 engine intake & exhaust exhaust line 1 heat protector assembly 2 heat protector floor 3 exhaust front pipe assembly 4 ring 5 exhaust rear pipe assembly 6 muffler 7 mounting 8 heat protector front floor 9 tail exhaust pipe assembly.

  • Page 811

    Om600 engine intake & exhaust 1g3-7 removal & installation procedure 1. Remove the bolt from the exhaust manifold and then remove the front exhaust pipe. Installation notice tightening torque 15 - 18 nm notice when tightening the nut(3), maintain the clearance between exhaust manifold(1) and front e...

  • Page 812: Turbocharger

    1g3-8 om600 engine intake & exhaust 1 turbocharger oil inlet 2 turbine wheel 3 waste gate 4 oil outlet 5 compressor wheel 6 air inlet 7 exhaust gas outlet 8 compressed air flow 9 intercooler 10 cylinder turbocharger charge air system diagram.

  • Page 813: Intercooler

    Om600 engine intake & exhaust 1g3-9 intercooler 1 hoses 2 pipes 3 hoses 4 intercooler 5 cover 6 bolts 7 screws 8 bolts.

  • Page 814

    1g3-10 om600 engine intake & exhaust removal & installation procedure 1. Remove the hose connected to turbocharger and intake duct. 2. Remove the protective cover. 3. Loosen the clamps and remove the pipe and hose connected to intercooler. 4. Unscrew the mounting bolts and remove the intercooler. 5....

  • Page 815: Turbocharger Assembly

    Om600 engine intake & exhaust 1g3-11 turbocharger assembly 1 oil supply line 2 oil return line 3 nuts 4 turbocharger.

  • Page 816

    1g3-12 om600 engine intake & exhaust removal & installation procedure 1. Remove the 2 hoses connected to intercooler. 2. Remove the hose(air cleaner to turbocharger) with blow by hose. 3. Disconnect the oil supply pipe. 4. Remove the oil return pipe. 5. Remove the support assembly. 6. Remove the 3 n...

  • Page 817

    Om600 engine intake & exhaust 1g3-13 7. Remove the turbocharger disconnecting the exhaust pipe from the turbocharger. 8. Installation should follow the removal procedure in the reverse order..

  • Page 818: Section 2A

    Section 2a suspension diagnosis table of contents specifications . . . . . . . . . . . . . . . . . . . . . . . . 2a-1 general specifications . . . . . . . . . . . . . . . . . . 2a-1 diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 2a-3 general diagnosis . . . . . . . . . . . . . . . ....

  • Page 819

    2a-2 suspension diagnosis application description 4.75 - 5.25 power voltage (v) axle vertical acceleration sensor (wheel g sensor) less than 10 consuming current (ma) less than 2.0 output current (ma) operating characteristics type damping force switching actuator 3-stage rotary step motor type volt...

  • Page 820: Diagnosis

    Suspension diagnosis 2a-3 diagnosis general diagnosis checks loosened mountings damaged or worn wheel bearing damaged shock absorber damaged tire action retightening replace replace replace abnormal noises checks broken stabilizer bar faulty shock absorber action replace replace vehicle rolling chec...

  • Page 821

    2a-4 suspension diagnosis checks worn or broken coil spring checks incorrect front wheel alignment worn or loosened lower arm bushing action replace repair or replace steering instability action replace vehicle bottoming.

  • Page 822: Control Logic

    Suspension diagnosis 2a-5 input & output devices and damping force control logic input & output devices damping force of shock absorber will rotate shock absorber control rod in 3 modes by driving actuator on the upper shock absorber when signaled from ecs. Rotary valve in the shock absorber will co...

  • Page 823: Damping Force Control Logic

    2a-6 suspension diagnosis damping force control logic control logic that applies on damping force variable suspension is comprised of road sensing driving comfort control logic to increase driving comfort and vehicle speed sensing control logic, anti-roll control logic and anti-dive control logic to...

  • Page 824: Self-Diagnosis

    Suspension diagnosis 2a-7 self-diagnosis ecs-ecu indicates ecs circuit defectives to the driver by flickering ecs indicator lamp in the meter cluster 0.5 second of interval if there are defectives. Code body vertical acceleration sensor defects when sensor output voltage is less than 0.5-4.5v, more ...

  • Page 825: Actuator Inspection

    2a-8 suspension diagnosis - actuator inspection output position of the actuator should be changed as below when battery voltage is applied between actuator connector terminals. Connector terminal battery voltage position of the actuator output remark 1 (white) - 2 (black) open 3 (red) + 1 (white) + ...

  • Page 826: Ecs Circuit

    Suspension diagnosis 2a-9 ecs circuit schematic and routing diagrams.

  • Page 827

    2a-10 suspension diagnosis.

  • Page 828

    Suspension diagnosis 2a-11 connector pin number and circuits 2 15 3 16 4 17 5 18 6 19 7 20 8 21 9 22 10 23 11 24 12 25 13 26 ignition actuator r-medium actuator r-soft actuator f-head select switch speed sensor wheel g sensor wheel g sensor ground - vertical g sensor sensor +5v chassis ground indica...

  • Page 829: Self Diagnosis Test

    2a-12 suspension diagnosis self diagnosis test diagnosis test special tool requirements : scanner 1. Position the ignition switch to 'off'. 2. Connect scanner harness connector to the engine compartment diagnosis socket. 3. Turn the ignition switch to 'on' position. 4. Select "electronic control veh...

  • Page 830

    Suspension diagnosis 2a-13 self - diagnosis list fault code defects service hint 01 vertical acceleration sensor 02 lateral acceleration sensor 03 wheel acceleration sensor 04 05 rear step motor 06 ecu front step motor 1. Check sensor supply voltage l condition - ign on l standard value - voltage be...

  • Page 831: Section 2B

    Section 2b wheel alignment table of contents specifications wheel alignment specifications application camber caster toe-in king pin inclination description 0 ° ± 30' 2 ° 30' ± 30' 0 - 4 mm 12 ° 30' specifications . . . . . . . . . . . . . . . . . . . . . . . . 2b-1 wheel alignment specifications . ...

  • Page 832: Diagnosis

    2b-2 wheel alignment diagnosis tire diagnosis irregular and premature wear irregular and premature tire wear has many causes. Some of them are incorrect inflation pressures, lack of regular rotation, poor driving habits, or improper wheel alignment. Rotate the tires if : l the front tire wear is dif...

  • Page 833: Radial Tire Lead/pull

    Wheel alignment 2b-3 3. Road test the vehicle. If there is improvement, install the original tires to find the offending tire. If there is no a straight improvement, install good tires in place of all four offending tires. 4. Install original tires one at a time to find the offending tire. Radial ti...

  • Page 834

    2b-4 wheel alignment 1. Perform wheel alignment preliminary inspection. 2. Check the brakes for dragging. 3. Road test the vehicle. Does the vehicle lead/pull? 1. Cross switch the front tire and wheel assemblies. 2. Road test the vehicle. Does the vehicle lead/pull? 1. Check the front wheel alignmen...

  • Page 835: Vibration Diagnosis

    Wheel alignment 2b-5 vibration diagnosis wheel imbalance causes most highway speed vibration problems. A vibration can remain after dynamic balancing because: l a tire is out of round. L a rim is out of round. L a tire stiffness variation exists. Measuring tire and wheel free runout will uncover onl...

  • Page 836: Maintenance and Repair

    2b-6 wheel alignment maintenance and repair on vehicle service wheel alignment vehicle height 1. Check the tire for proper inflation. 2. Measure ‘a’ from the center of the lower arm rear mounting bolt end to the ground. 3. Measure ‘b’ from the center of the steering knuckle shaft to the ground. 4. I...

  • Page 837

    Wheel alignment 2b-7 camber 1. Remove the free wheel hub. 2. Measure camber with a wheel alignment equipment. 3. If camber measurements are not within specification, adjust it by increasing or decreasing the number of adjusting shims (1) inserted between the upper arm shaft and cross bracket. Camber...

  • Page 838

    2b-8 wheel alignment increasing 1ea - 11’ - 43’ 3. If caster measurements are not within specification, adjust it by increasing 1ea (rear) or decreasing 1ea (front). Caster change notice difference between the left and right should be adjusted within 30’. 0.4 small 1.6 small decreasing 1ea + 11’ + 4...

  • Page 839: Four Wheel Alignment

    Wheel alignment 2b-9 general description and system operation four wheel alignment caster caster is the tilting 91 the uppermost point of the steering axis either forward or backward from the vertical when viewed from the side of the vehicle. A backward tilt is positive, and a forward tilt is negati...

  • Page 840: Section 2C

    Section 2c front suspension table of contents specifications general specifications type spring type torsion bar shock absorber stabilizer type double wishbone torsion bar spring 1,040 mm 24.5 mm cylindrical reciprocation type torsion bar spring specifications . . . . . . . . . . . . . . . . . . . ....

  • Page 841

    2c-2 front suspension application torque arm bolt n l m 40 - 60 60 - 80 fastener tightening specifications stabilizer bar application stabilizer bar retaining nut stabilizer bar link nut lower arm nut n l m 30 - 45 60 - 80 16 - 22 torsion bar lower and upper arm application upper arm nut upper arm e...

  • Page 842: Component Locator

    Front suspension 2c-3 component locator front suspension 1 shock absorber 2 upper arm 3 steering knuckle 4 lower arm 5 stabilizer bar link 6 stabilizer bar 7 suspension bumper.

  • Page 843: Maintenance and Repair

    2c-4 front suspension maintenance and repair on-vehicle service front stabilizer bar 1 front stabilizer bar 2 bolt ...................................................... 30-45 nm 3 fixing cap 4 bushing 5 nut ....................................................... 60-80 nm 6 stabilizer bar link assem...

  • Page 844

    Front suspension 2c-5 removal & installation procedure 1. Remove the connecting nuts (1) from stabilizer bar link. Installation notice 2. Remove the connecting nuts (2) of the stabilizer bar and link and then remove the link. Installation notice 3. Remove the stabilizer bar fixing cap bolts (arrow) ...

  • Page 845: Torsion Bar

    2c-6 front suspension torsion bar 1 nut 2 torque arm 3 washer 4 bolt ............................................ M10 : 40-60 nm m12 : 60-80 nm 5 torsion bar end seat 6 dust cover 7 torsion bar 8 dust cover 9 height control arm assembly 10 height control bolt end piece 11 height control bolt 12 heig...

  • Page 846

    Front suspension 2c-7 removal & installation procedure 1. Remove the fixing nuts and bolts of the shock absorber and lower arm connection. Installation notice 2. Remove the connecting nuts of the stabilizer bar link to the lower arm. Installation notice 3. Turn the height control bolt until the dist...

  • Page 847: Front Lower and Upper Arm

    2c-8 front suspension front lower and upper arm 1 nut ................................................... 120-140 nm 2 fulcrum pin and upper arm assembly 3 camber/caster adjusting shim 4 bolt 5 bolt 6 washer 7 upper arm end 8 nut ....................................................... 16-22 nm 9 cas...

  • Page 848

    Front suspension 2c-9 removal & installation procedure 1. Remove the shock absorber. Installation notice 2. Remove the fulcrum pin mounting bolts and nuts and remove the upper arm assembly. Notice be careful not to damage or lose the adjusting shims. Upper lower distance between the nut end and the ...

  • Page 849: Front Shock Absorber

    2c-10 front suspension front shock absorber 1 front shock absorber 2 washer 3 bush 4 center washer 5 actuator mounting bracket 6 nut ........................................................ 40-60nm.

  • Page 850

    Front suspension 2c-11 removal & installation procedure 1. Disconnect actuator connector and unscrew bolt and remove actuator assembly. Notice when installing the actuator to the mounting bracket, the wiring should face the front of the frame. 2. Unscrew the upper nut (6). Notice when screwing the n...

  • Page 851

    2c-12 front suspension 1 axle vertical acceleration sensor (wheel g sensor) removal & installation procedure 1. Disconnect extension wiring connector (2) from the axle vertical acceleration sensor. Notice installation of wiring connector should be as shown in the right drawing. 2. Unscrew bolts (3) ...

  • Page 852: Vertical and Lateral Sensor

    Front suspension 2c-13 vertical and lateral sensor removal & installation procedure 1. Disconnect vertical sensor and lateral sensor connectors. Notice when connecting the connectors, connector connection of the lateral sensor (2) should be in the right and connector connection of the vertical senso...

  • Page 853: Ecs (Ecu)

    2c-14 front suspension ecs (ecu) 1 electronically controlled suspension (ecu) 2 connector 3 bolts (2 pieces) removal & installation procedure 1. Disconnect each connectors from the console box and remove the console box. 2. Disconnect ecu connector. 3. Unscrew 10mm x 2 bolts and remove ecs (ecu). 4....

  • Page 854: Section 2D

    Type spring type coil spring shock absorber stabilizer type description 5-link coil spring 13.8 mm 126.8 mm 384.5 mm f 139.6 mm 2.58 kg cylindrical reciprocation type torsion bar type section 2d rear suspension table of contents specifications general specifications wire diameter (mm) diameter (mm) ...

  • Page 855: Diagnosis

    2d-2 rear suspension diagnosis noise (during straight driving) check lack of oil low viscosity of oil insufficient oil excessive backlash of ring gear worn or damaged tooth of ring and pinion gear worn or damaged drive pinion bearing worn spline of side bearing and side gear bent axle housing bent d...

  • Page 856: Heating

    Rear suspension 2d-3 heating check lack of oil insufficient backlash of gears excessive preload of bearing action replenish adjust adjust.

  • Page 857: Component Locator

    2d-4 rear suspension 1 spring seat 2 coil spring 3 lateral rod 4 shock absorber 5 upper arm 6 lower arm 7 connecting link 8 stabilizer bar component locator.

  • Page 858: Maintenance and Repair

    Rear suspension 2d-5 maintenance and repair on-vehicle serivce rear suspension (5 - link) 1 spring seat 2 coil spring 3 lateral rod 4 shock absorber 5 upper arm 6 lower arm 7 connecting link 8 stabilizer bar.

  • Page 859

    2d-6 rear suspension removal & installation procedure l stabilizer bar 1. Remove the upper nut of the connecting link. Installation notice 2. Remove the stabilizer bar cap fixing bolts (arrow) and remove the stabilizer bar. Installation notice tightening torque 16 - 22 nm distance between the nut en...

  • Page 860

    Rear suspension 2d-7 l shock absorber. 1. Remove the lower mounting nut. Installation notice 2. Remove the upper mounting nut and remove the shock absorber. Installation notice tightening torque 50 - 65 nm l upper arm 1. Remove the upper arm fixing nut from the frame. Installation notice 2. Remove t...

  • Page 861

    2d-8 rear suspension 2. Remove the lower arm fixing nut from the frame. Installation notice 3. Remove the lower arm fixing nut from the rear axle and remove the lower arm. Installation notice tightening torque 150 - 180 nm tightening torque 150 - 180 nm.

  • Page 862: Rear Shock Absorber

    Rear suspension 2d-9 rear shock absorber 1 rear shock absorber 2 washer 3 bush 4 center washer 5 actuator mounting bracket 6 nut (m12 x 1.25) ................................. 40 - 60nm.

  • Page 863

    2d-10 rear suspension removal & installation procedure 1. Disconnect actuator connector and unscrew bolt and remove actuator assembly. Notice l when installing the actuator to the mounting bracket, the wiring should face outward of the frame. L actuator wiring should be fixed 40 - 50mm away from the...

  • Page 864: Section 2E

    Description alumimun 7jj x 15 radial tire p215 / 75r 15 - 30psi p235 / 75r 15 - 30psi p255 / 70r 15 - 30psi application wheel section 2e tires and wheels table of contents specifications general specifications fastener tightening specifications application wheel bolt n l m 80 - 120 110 - 130 specifi...

  • Page 865: Diagnosis

    2e-2 tires and wheels diagnosis wear pattern diagnosis wear pattern possible cause remedy wear on both tread shoulders under inflation wear on tread center over inflation tread torn out under inflation one-sided tread wear incorrect camber or toe-in feather edging of tread incorrect toe-in spotty tr...

  • Page 866: Identification

    Tires and wheels 2e-3 identification radial tire wheel disc 7 j x 16 et 39 wheel offset (mm) (distance from rim center to wheel nave contacting surface) rim diameter (inch) identification for one-piece well-base rim code letter for height and profile of rim flange rim width (inch) et : distance from...

  • Page 867: Component Locator

    2e-4 tires and wheels component locator wheel and tire 1 wheel bolts ................. Steel wheel : 80-120 nm .......................... Aluminium wheel : 110-130 nm 2 steel wheel 3 aluminium wheel 4 tire 5 steel wheel weight balance 6 hub cap.

  • Page 868: Maintenance and Repair

    Tires and wheels 2e-5 maintenance and repair on-vehicle service wheels and tires removal & installation procedure 1. Inspection of tire check tread area for tread surface, crack, damage by nail in or stones. Replace or repair if necessary. L replace the tire if tread-wear indicator of the tread groo...

  • Page 869

    2e-6 tires and wheels 4. Tire pressure inspection. L tire pressure. L check tread contact with road. Notice l if underinflated, tire may come away from the wheel during rapid steering. L an overinflated tire will cause a hard riding and uneven wear. Front & rear (p235/75r15) 2.1kg/cm (30psi) 2 5. Wh...

  • Page 870

    Tires and wheels 2e-7 l to correct unbalance, install equal weights 180° opposite each other, one on the inside of the wheel and one on the outside, at the point of unbalance. L balance weight 6. Cautions for installation and removal. L clean the mounting surfaces of hub and wheel. L do not apply gr...

  • Page 871: Section 3A

    M/t m/t a/t (mb) m/t a/t (btra) m/t a/t (btra) m/t a/t (mb) m/t a/t (mb) a/t (btra) m/t a/t (mb) a/t (btra) section 3a front drive axle table of contents specifications general specifications specifications . . . . . . . . . . . . . . . . . . . . . . . . 3a-1 general specifications . . . . . . . . ....

  • Page 872

    3a-2 front drive axle fastener tightening specifications steering knuckle and drive shaft application drive shaft to front axle inner shaft wheel speed sensor drive shaft cover bolt locking hub washer screw hub flange bolt hub nut n l m 25 - 35 85 - 105 50 - 60 2 - 4 70 - 90 15.

  • Page 873: Component Locator

    Front drive axle 3a-3 1 drive shaft 2 axle housing mounting bolt 3 axle housing 4 cross member component locator front axle 5 brake disc 6 hub-wheel 7 locking hub.

  • Page 874: Auto-Locking Hub

    3a-4 front drive axle auto-locking hub 1 cap 2 filter 3 vacuum diaphragm 4 diaphragm retainer 5 piston 6 bolt (m10) 7 lock washer 8 o-ring 9 retaining ring 10 clutch ring 11 body 12 return spring 13 bearing 14 o-ring 15 retaining ring 16 inner drive gear 17 oil seal 18 oil seal race 19 axle retainin...

  • Page 875: Vacuum Circuit

    Front drive axle 3a-5 vacuum circuit 1 engine 2 vacuum pump 3 3-way connector 4 t-connector 5 check valve 6 auto locking hub solenoid valve 7 t-connector hose 8 hub hose (left) 9 hub hose (right).

  • Page 876: Maintenance and Repair

    3a-6 front drive axle maintenance and repair on-vehicle service vacuum line 1 vacuum auto-locking hub assembly 2 bolt ...................................................... 50-60 nm 3 cam washer 4 auto-locking hub cap 5 retainer ring 6 shim 7 locking hub 8 band 9 hose (l : 400) 10 t-connector 11 hos...

  • Page 877

    Front drive axle 3a-7 removal & installation procedure 1. Be careful not to change the valve when connecting the check valve and each hose. 2. Adjust the clearance between the retainer ring (5) and locking hub (7) using the shim(6). Notice shim thickness : 0.1, 0.2, 0.3, 0.5, 1.0 mm normal max. 0.2 ...

  • Page 878

    3a-8 front drive axle steering knuckle and drive shaft 1 front axle inner shaft 2 front axle drive shaft 3 spring washer 4 bolt ...................................................... 45-60 nm 5 steering knuckle.

  • Page 879

    Front drive axle 3a-9 removal & installation procedure 1. Remove the tire. Installation notice steel wheel aluminum wheel tightening torque 80 - 120 nm 110 - 130 nm 2. Remove the autolocking hub vacuum hose. 3. With abs remove the wheel speed sensor from the steering knuckle. Installation notice 4. ...

  • Page 880

    3a-10 front drive axle 5. With part time transfer case. 5-1. Remove the cover mounting bolts and pull off the cover. Installation notice 5-2. Remove the snap ring of the drive shaft and pull off the hub body. Notice for assembly, adjust the clearance between the snap ring and hub not to exceed 0.2 m...

  • Page 881

    Front drive axle 3a-11 8. Remove the hub and disk assembly. 9. Remove the disk brake dust shield. Installation notice tightening torque 4 - 6 nm 6-2. Unscrew the bolts and remove hub flange. Installation notice tightening torque 70 - 90 nm before installation, apply loctite on the mating surface. 7....

  • Page 882

    3a-12 front drive axle 10. Remove the cotter pin and slotted nut and then remove the steering knuckle arm and tie-rod. Installation notice replace the cotter pin with new one. Tightening torque 35 - 45 nm 11. Remove the cotter pin and nut from the steering knuckle arm and upper arm ball joint connec...

  • Page 883

    Front drive axle 3a-13 14. Remove the drive shaft mounting bolts and remove the drive shaft. Installation notice tightening torque 45 - 60 nm 15. Installation should follow the removal precedure in the reverse order. Observe the tighening torque and sequence..

  • Page 884: Front Axle

    3a-14 front drive axle 1 axle mounting bracket 2 breather hose 3 bolt (rear) 4 nut ..................................................... 95-142 nm 5 cross member 6 bolt (front) 7 bushing 8 spacer front axle 9 bushing 10 nut ..................................................... 95-142 nm 11 front axl...

  • Page 885

    Front drive axle 3a-15 removal & installation procedure 1. Remove the propeller shaft from the front axle input shaft. Notice before removal, place the alignment marks. Installation notice 2. Remove the breather hose. 3. Remove the axle housing mounting nuts (1) from the cross member. Installation n...

  • Page 886: Unit Repair

    3a-16 front drive axle unit repair axle housing preceding work : removal of the axle housing.

  • Page 887

    Front drive axle 3a-17 1 front axle housing mounting bracket 2 inner shaft (left) 3 bolt ...................................................... 55-65 nm 4 oil seal .................................................. Replace apply grease to the sealing rib 5 snap ring 6 bearing 7 snap ring 8 oil drain...

  • Page 888

    3a-18 front drive axle disassembly procedure 1. Remove the drain plug and drain the oil. Reinstall the drain plug. Installation notice tightening torque 28 - 41 nm 2. Unscrew the axle housing and housing mounting bracket bolts and remove the bracket and inner shaft assembly. 3. Remove the bearing fi...

  • Page 889

    Front drive axle 3a-19 5. Unscrew the bearing cap bolts and remove the bearing caps. Pull out the differential carrier assembly. Notice place alignment marks on the bearing cap not to change the caps before removal. When pulling out the differential carrier assembly, be careful not to damage the axl...

  • Page 890

    3a-20 front drive axle 2. Assemble the parts of the drive pinion. 3. Assemble the parts of the differential carrier. 4. Measure backlash of the side gear and pinion. 5. Install the differential carrier assembly into the axle housing. Notice be careful not to change the caps. Be sure to keep the orig...

  • Page 891

    Front drive axle 3a-21 6. Measure backlash of the drive pinion and ring gear. 7. Install the axle housing cover. 8. Assemble the parts of the front axle shaft and housing mounting bracket. Notice apply grease to the oil seal rib. 9. Align the axle shaft and differential carrier spline and insert the...

  • Page 892

    3a-22 front drive axle inspection of ring gear tooth contact pattern normal contact apply gear-marking compound (prussian blue / red lead) on the ring gear teeth. Rotate the ring gear and check the tooth contact pattern. Abnormal contact tooth contact pattern possible cause remedy 1. Heel contact 2....

  • Page 893: Section 3C

    Diesel gasoline (m161) gasoline (m162) diesel gasoline application joint type number of spider front front rear front rear front (full-time) front (part-time) rear front rear section 3c propeller shaft table of contents specifications . . . . . . . . . . . . . . . . . . . . . . . . 3c-1 general spec...

  • Page 894: Component Locator

    3c-2 propeller shaft 1 flange yoke 2 cross and bearing assembly (with snap ring) 3 cross and bearing assembly (with snap ring) 4 slip yoke assembly 5 grease nipple 6 dust cap 7 oil seal 8 split washer 9 slip tube shaft 10 tube notice only the length of shaft is different and the components of front/...

  • Page 895: Maintenance and Repair

    Propeller shaft 3c-3 1 front axle 2 bolt ...................................................... 70-80 nm 3 front propeller shaft (661la/662la) 4 front propeller shaft (e32) 5 bolt ...................................................... 81-89 nm 6 transfer case maintenance and repair on-vehicle servic...

  • Page 896

    3c-4 propeller shaft removal procedure 1. Place alignment marks and remove the propeller shaft. 2. Place alignment marks before removing the spider. 3. Using a snap ring pliers, remove the snap ring. Gasoline diesel.

  • Page 897

    Propeller shaft 3c-5 5. If difficult to remove, clamp the yoke side in a vise and tap off the needle bearing, using a proper tool. 6. Disassemble the universal joint parts. L as axles move up and down, universal joints allow drive angles to change without binding propeller shaft. 1 grease nipple 2 f...

  • Page 898

    3c-6 propeller shaft 3. Clearance between the spider and bearing. 4. Propeller shaft runout l using a dial indicator, measure propeller shaft runout by turning the shaft. If runout exceeds limit, replace the propeller shaft or correct it using a press. Standard 0.03 - 0.098 mm limit 0.25 mm inspecti...

  • Page 899

    Propeller shaft 3c-7 installation procedure clean the disassembled parts and replace them if damaged. 1. Align the alignment marks of the yoke and assemble the spider, bearing and snap ring. 2. Apply grease to the inner of the bearing cap of the needle roller bearing and assemble the needle roller. ...

  • Page 900

    3c-8 propeller shaft 3. Install the bearing cap to the yoke and insert the spider. Install the opposite side cap by tapping with a plastic hammer. Adjust clearance of the spider pin to be within 0.1 mm and install the snap ring. 4. Align the alignment marks and install the front and rear propeller s...

  • Page 901: Section 3D

    Section 3d rear drive axle table of contents specifications . . . . . . . . . . . . . . . . . . . . . . . . 3d-1 general specifications . . . . . . . . . . . . . . . . . . 3d-1 fastener tightening specifications . . . . . . . . . 3d-2 diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 3...

  • Page 902

    3d-2 rear drive axle fastener tightening specifications application inner bracket mounting nut propeller shaft to rear axle input shaft lower arm mounting nut lower shock absorber to axle housing upper arm mounting nut stabilizer bar mounting bolt lateral rod mounting nut drive pinion lock nut oil d...

  • Page 903: Diagnosis

    Rear drive axle 3d-3 checks worn or damaged tooth of pinion or side gear worn pinion shaft excessive backlash of pinion gear and side gear excessive end-play of rear axle shaft incorrect contact of side gear and differential case axle housing crack bent or poor installation of drive pinion oil seal ...

  • Page 904: Vibration

    3d-4 rear drive axle vibration checks faulty connection of sliding joint bent propeller shaft symmetry of universal joint snap ring loosened yoke bolts action adjust replace adjust tighten noise checks worn or damaged universal joint bearing fallen off universal joint snap ring loosened yoke connect...

  • Page 905: Component Locator

    Rear drive axle 3d-5 1 spring seat 2 coil spring 3 lateral rod 4 shock absorber 5 upper arm 6 lower arm 7 connecting link 8 stabilizer bar component locator.

  • Page 906: Maintenance and Repair

    3d-6 rear drive axle maintenance and repair on-vehicle service axle shaft 1 brake disc 2 dust plug 3 rear axle shaft 4 nut ....................................................... 50-65 nm 5 washer 6 parking brake cable 7 parking brake lining and back plate assembly 8 caliper assembly 9 gasket 10 bol...

  • Page 907

    Rear drive axle 3d-7 removal & installation procedure 1. Remove the tire. Installation notice 2. Release the parking brake. Steel wheel aluminum wheel tightening torque 3. Remove the bolts and the brake caliper. Installation notice be careful not to damage the brake hose. Tightening torque 85 - 100 ...

  • Page 908

    3d-8 rear drive axle tightening torque 50 - 65 nm 6. Remove the plug from the axle shaft flange and remove the inner shaft mounting nuts. Installation notice 7. Remove the axle shaft, parking brake lining and back plate assembly. 8. Installation should follow the removal precedure in the reverse ord...

  • Page 909: Axle

    Rear drive axle 3d-9 axle removal & installation procedure 1. Lift up the vehicle and support the frame safely. 2. Remove the axle shaft. Tightening torque 150 - 180 nm 3. Remove the propeller shaft from the rear axle input shaft. Installation notice notice place alignment marks before removal. Tigh...

  • Page 910

    3d-10 rear drive axle 6. Separate the lower shock absorber from the axle housing. Installation notice 7. Remove the upper arm mounting nuts and remove the upper arm form the axle housing. Installation notice tightening torque 50 - 65 nm 8. Remove the stabilizer bar. Installation notice tightening to...

  • Page 911: Unit Repair

    Rear drive axle 3d-11 unit repair axle housing preceding work : removal of the axle shaft removal of the axle housing 1 drive pinion lock nut ...................... 240-310 nm 2 washer 3 companion flange 4 pinion oil seal 5 bearing slinger 6 bearing 7 shim 8 shim 9 bearing cup 10 breather nipple 11 ...

  • Page 912

    3d-12 rear drive axle disassembly procedure 1. Remove the drain plug and drain the oil. Reinstall the drain plug. 2. Remove the axle housing cover. Notice clean the cover and housing contact surface. 3. Remove the bearing cap bolts and remove the bearing caps. Pull out the differential carrier assem...

  • Page 913

    Rear drive axle 3d-13 5. Remove the drive pinion lock nut. Disassemble the parts of the drive pinion. Assembly procedure 1. Clean the all parts and check the followings. L check the ring gear and drive pinion for wear or damage. If damaged, replace it as set. L check the bearing for sticks, wear, no...

  • Page 914

    3d-14 rear drive axle 4. Measure backlash of the side gear and pinion gear. Specified value 0 - 0.05 mm 5. Install the differential carrier assembly into the axle housing. Tightening torque of the bearing cap bolts 48 - 69 nm notice be careful no to change the caps. Be sure to keep the original posi...

  • Page 915

    Rear drive axle 3d-15 inspection of ring gear tooth contact pattern normal contact apply gear-marking compound (prussian blue / red lead) on the ring gear teeth. Rotate the ring gear and check the tooth contact pattern. Abnormal contact tooth contact pattern possible cause remedy 1. Heel contact 2. ...

  • Page 916

    3d-16 rear drive axle lsd (limited slip differential) 1 limited slip differential assembly 2 shaft, hub (left) 3 shim 4 thrust washer 5 face cam (left) 6 cam whillom 7 thrust bearing 8 radial bearing 9 shaft, hub (right) 10 thrust washer 11 face cam (right) 12 cage 13 thrust bearing 14 plate spring ...

  • Page 917

    Rear drive axle 3d-17 inspection l remove the lsd assembly and check the pre-load torque. L if necessary, replace lsd assembly. Procedure 1. Fix the right shaft of lsd to the special tool (a). 2. Install the special tool (b) to the left shaft and rotate counterclockwise and check the pre-load torque...

  • Page 918: Section 4A

    Section 4a hydraulic brakes specifications . . . . . . . . . . . . . . . . . . . . . . . . 4a-1 general specifications . . . . . . . . . . . . . . . . . . 4a-1 diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 4a-2 noise or vehicle vibration when applied brake . . . . . . . . . . . . ....

  • Page 919: Dignosis

    4a-2 hydraulic brakes check dirty or lack of fluid air in brake system faulty brake booster poor contact of pad or lining oil or grease on pad faulty auto adjuster over heated rotor due to dragging pad or lining clogging brake line faulty proportioning valve check incorrect tire pressure between lef...

  • Page 920: Or Brake Dragging

    Hydraulic brakes 4a-3 check air in brake system fluid leaking excessive clearance between push rod and m/cylinder parking brake is not fully released incorrect adjustment of parking brake weak return spring of brake pedal incorrect pedal freeplay broken rear drum brake shoe return spring lack of lub...

  • Page 921: Component Locator

    4a-4 hydraulic brakes component locator abs 1 actuation assembly (booster+tmc) 2 abs control unit 3 master cylinder 2nd tube (secondary) 4 master cylinder 1st tube (primary) 5 front tube (lh) 6 front tube (rh) 7 brake hose 8 rear tube 9 bolt ...................................................... 25-...

  • Page 922: Abs / Abd

    Hydraulic brakes 4a-5 abs / abd 1 actuation assembly (booster+tmc) 2 master cylinder 1st tube (primary) 3 master cylinder 2nd tube (secondary) 4 hydraulic modulator 5 front tube (lh) 6 front tube (rh) 7 rear tube (rh) 8 rear tube (lh) 9 2-way connector.

  • Page 923: Non-Abs/abd

    4a-6 hydraulic brakes non-abs/abd 1 actuation assembly (booster+tmc) 2 3-way connector 3 front tube (lh) 4 front tube (rh) 5 2-way connector 6 rear tube 7 3-way connector 8 lcrv.

  • Page 924: Maintenance and Repair

    Hydraulic brakes 4a-7 maintenance and repair on-vehicle service bleeding the brakes for master cylinder replacement 1. Add oil after master cylinder replacement. 2. Run the engine and depress the brake pedal several times to build pressure and then keep the pedal fully depressed. 3. Loosen the screw...

  • Page 925

    4a-8 hydraulic brakes for hydraulic unit replacement 1. Add oil after hydraulic unit replacement. 2. Run the engine and depress the pedal several times to build pressure and then keep the pedal fully depressed. 3. Loosen hydraulic pipe screws at the hydraulic unit outlets to bleed air. 4. Repeat abo...

  • Page 926: Brake Pedal

    Hydraulic brakes 4a-9 brake pedal 1 clevis pin 2 brake pedal 3 stop lamp switch 4 pad 5 nut ....................................................... 21-35 nm 6 yoke pin 7 fulcrum pin 8 return spring 9 pedal mounting bracket 10 washer 11 nut ....................................................... 16-3...

  • Page 927

    4a-10 hydraulic brakes removal & installation procedure 1. Remove the stop lamp switch connector. 2. Remove the clevis pin and disconnect the brake booster push rod. Notice l install in the upper hole (1), in case of mando brake and in the below hole (2), incase of pbr brake. L install the snap pin ...

  • Page 928

    Hydraulic brakes 4a-11 adjustment procedure 1. Pedal height notice if pedal height is not in specified value, loosen the stop lamp nut (b) and adjust the pedal height. 2. Pedal stroke height (a) 150 mm (from the carpet) notice if pedal stroke is not in specified value, loosen the stop bolt and lock ...

  • Page 929

    4a-12 hydraulic brakes lcrv (load conscious reducing valve) 1 brake tube (from the master cylinder) 2 brake tube (from the rear brake) 3 lcrv bracket 4 bolt ........................................................... 12 nm 5 lcrv assembly 6 connecting link 7 spring washer 8 nut ........................

  • Page 930

    Hydraulic brakes 4a-13 construction lcrv consists of sensing part and hydraulic control part. 1. Sensing part it detects the changes of vehicle height caused by vehicle load. It consists of load sensing spring and control lever which change according to vehicle load. 2. Hydraulic control part it con...

  • Page 931: Lcrv Setting Method

    4a-14 hydraulic brakes lcrv setting method 1. Lcrv setting should be performed with unladen vehicle condition. 2. Install the connecting rod (a) to the no.1 hole. Tightening torque 14 - 18 nm 3. Adjust the clearance “x” to be 0 mm and tighten the bolt (c) using the lock nut (b). Tightening torque 14...

  • Page 932: Section 4B

    Section 4b master cylinder specifications . . . . . . . . . . . . . . . . . . . . . . . . 4b-1 fastener tightening specifications . . . . . . . . . 4b-1 maintenance and repair . . . . . . . . . . . . . . . 4b-2 table of contents specifications fastener tightening specifications application master cy...

  • Page 933: Maintenance and Repair

    4b-2 master cylinder 1 nut ....................................................... 14-22 nm 2 washer 3 master cylinder assembly 4 oil level sensor 5 check valve 6 booster 7 clevis pin 8 snap pin 9 seal 10 spacer 11 nut ......................................................... 8-18 nm 12 front tube (...

  • Page 934

    Master cylinder 4b-3 removal & installation procedure 1. Remove the oil level sensor connector. 2. Remove the tube from the master cylinder. Installation notice notice l be careful not to drop the oil when removing the tube. L if the oil is dropped, promptly sweep up. 3. Remove the booster vacuum ho...

  • Page 935

    4b-4 master cylinder 6. Loosen the nut of booster and remove the booster from the dash panel. Installation notice tightening torque 8 - 18 nm 7. Installation should follow the removal procedure in the reverse order. 8. Add the fluid and bleed. 9. If necessary, adjust the pedal height, pedal stroke a...

  • Page 936: Section 4C

    Section 4c power booster specifications . . . . . . . . . . . . . . . . . . . . . . . . 4c-1 general specifications . . . . . . . . . . . . . . . . . . 4c-1 maintenance and repair . . . . . . . . . . . . . . . 4c-2 table of contents specifications general specifications application type ratio n · · ...

  • Page 937: Maintenance and Repair

    4c-2 power booster 1 nut ....................................................... 14-22 nm 2 washer 3 master cylinder assembly 4 oil level sensor 5 check valve 6 booster 7 clevis pin 8 snap pin maintenance and repair on-vehicle service booster and brake master cylinder 9 seal 10 spacer 11 nut ..........

  • Page 938

    Power booster 4c-3 removal & installation procedure 1. Remove the oil level sensor connector. 2. Remove the tube from the master cylinder. Installation notice notice l be careful not to drop the oil when removing the tube. L if the oil is dropped, promptly sweep up. 3. Remove the booster vacuum hose...

  • Page 939

    4c-4 power booster 6. Loosen the nut of booster and remove the booster from the dash panel. Installation notice tightening torque 8 - 18 nm 7. Installation should follow the removal procedure in the reverse order. 8. Add the fluid and bleed. 9. If necessary, adjust the pedal height, pedal stroke and...

  • Page 940: Pedal Stroke Inspection

    Power booster 4c-5 pedal stroke inspection 1. Start the engine and stop it after one or two minutes. Depress the brake pedal several times. If the pedal goes down furthest the first time, but gradually rises after the second or third time, brake booster is normal. If there is no change in pedal stro...

  • Page 941: Section 4D

    Section 4d front disc brakes table of contents specifications . . . . . . . . . . . . . . . . . . . . . . . . 4d-1 fastener tightening specifications . . . . . . . . . 4d-1 maintenance and repair . . . . . . . . . . . . . . . 4d-2 on-vehicle service . . . . . . . . . . . . . . . . . . . . . 4d-2 spe...

  • Page 942: Maintenance and Repair

    4d-2 front disc brakes 1 eye-hose bolt ...................................... 25-35 nm 2 gasket ................................................... Replace 3 brake hose 4 brake caliper 5 bolt ........................................................... 20 nm 6 washer maintenance and repair on-vehicle...

  • Page 943

    Front disc brakes 4d-3 removal & installation procedure 1. Mando brake tightening torque 25 - 35 nm 2. Pbr brake remove the eye-hose bolt and disconnect the hose. Installation notice tightening torque 15 - 18 nm 3. Remove the wheel speed sensor (for abs vehicies). Installation notice tightening torq...

  • Page 944

    4d-4 front disc brakes 5. Pull out the brake pads. Replace pads if necessary. Notice always change the all pads on one wheel at a time. 6. Installation should follow the removal procedure in the reverse order. 7. Bleed the air from the system..

  • Page 945: Unit Repair

    Front disc brakes 4d-5 4. Measure rotor disc thickness. Unit repair front disc brake inspection procedure 1. Clean all components and visually check the followings. L check the cylinder and piston for wear, rust or damage. L check the caliper body and guide pin for wear, damage or crank. L check the...

  • Page 946: Section 4E

    Section 4e rear disc brakes table of contents specifications . . . . . . . . . . . . . . . . . . . . . . . . 4e-1 fastener tightening specifications . . . . . . . . . 4e-1 maintenance and repair . . . . . . . . . . . . . . . 4e-2 on-vehicle service . . . . . . . . . . . . . . . . . . . . . 4e-2 spec...

  • Page 947: Maintenance and Repair

    4e-2 rear disc brakes 1 rear brake disc assembly 2 brake pad 3 brake caliper 4 gasket ................................................... Replace 5 bolt ........................................................... 20 nm 6 gasket ................................................... Replace maintenance ...

  • Page 948

    Rear disc brakes 4e-3 tightening torque 15 - 18 nm tightening torque 85 - 105 nm removal & installation procedure 1. Remove the eye-hose bolt and disconnect the hose. Installation notice 2. Unscrew the mounting bolts and remove the brake caliper assembly. Installation notice 3. Pull out the brake pa...

  • Page 949: Unit Repair

    4e-4 rear disc brakes standard 10.4 mm wear limit 9.3 mm unit repair rear disc brake inspection procedure 1. Clean all components and visually check the followings. L check the cylinder and piston for wear, rust or damage. L check the caliper body and guide pin for wear, damage or crank. L check the...

  • Page 950: Section 4F

    Front rear front rear section 4f antilock brake system table of contents caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help pre...

  • Page 951: Abs 5.0

    4f-2 antilock brake system abs 5.0 schematic and routing diagrams 5.0w 5.0w 30a 30a eng.

  • Page 952: Abs/abd 5.0

    Antilock brake system 4f-3 abs/abd 5.0 abd active.

  • Page 953: Abs 5.3

    4f-4 antilock brake system abs 5.3 5.0w 5.0w 30a 30a no.21 k2.

  • Page 954: Abs/abd 5.3

    Antilock brake system 4f-5 abs/abd 5.3 5.0w 5.0w.

  • Page 955: Abs,abs/abd

    4f-6 antilock brake system abs,abs/abd component locator 1 abs hydraulic unit 2 abs/abd hydraulic unit 3 diagnosis socket 4 front wheel speed sensor 5 front impulse ring 6 rear wheel speed sensor 7 rear impulse ring 8 abs warning indicator light 9 tcs indicator light 10 abs/abd ecu.

  • Page 956: Abd System Description

    Antilock brake system 4f-7 abd system description general: the automatic brake differential lock (abd) is a traction system by means of brake intervention only, available in a low speed range ( it workes on m -split roads with sidewise different friction coefficients. The spinning driven wheel is br...

  • Page 957

    4f-8 antilock brake system temperature model: abd operation is a high thermal load for the brakes. To avoid any damages at the brakes, the disk temperature is calculated with a mathematical model for each driven wheel separately. After ignition on, the calculation starts with 30 ° c and then three d...

  • Page 958: Self Diagnosis

    Antilock brake system 4f-9 self diagnosis abs, abs/abd 5.3 initialization 1. Turn the ignition switch to "on" position. 2. Using a service connector, ground the no.13 terminal of diagnosis socket and no.1 ground terminal for 3 - 4 seconds. Notice if it is over 5 seconds, initialization will not be p...

  • Page 959

    4f-10 antilock brake system diagnosis the flash code [ex] l time differences of normal code 01 : tw1 l time differences of fault code 15 : tw1 time characteristics 1. Initialization tba tba 1.8 - 2.2 sec. 2. Output of fault code tw1 = 1.8 - 2.2 sec. Tw2 = 1.8 - 2.2 sec. T = 0.75 sec., te ³ 0.25 sec....

  • Page 960: Abs, Abs/abd 5.0

    Antilock brake system 4f-11 abs, abs/abd 5.0 initializing 1. Set the ignition switch n “on” position. 2. Connect the no.1 terminal (ground) and the no.13 (abs) from diagnosis socket located in e/g room by use of service connector for 3 - 4 seconds and initialize the flash code. Notice be careful not...

  • Page 961

    4f-12 antilock brake system diagnosis the flash code [ex] l time differences of nromal code 01 : tw1 l time differences of fault code 15 : tw1 time characteristics 1. Initialization tba tba 1.8 - 2.2 sec. 2. Output of fault code tw1 = 1.8 - 2.2 sec. Tw2 = 1.8 - 2.2 sec. T = 0.75 sec., te ³ 0.25 sec....

  • Page 962: Defect Codes

    Antilock brake system 4f-13 defect codes description - replace the ecu l check resistance of the wheel speed sensor : 1.280k w - 1.920k w l check wire for ground and open. L replace the sensor. L check resistance of the wheel speed sensor : 1.280k w - 1.920k w l check wire for ground and open. L rep...

  • Page 963

    4f-14 antilock brake system description - when measured by multi - meter (ac) : output voltage > 70 mv - when measured in oscilloscope : output voltage ³ 120 mv/p-p l replace the sensor. L check wire for ground and open. L check connection of the wheel speed sensor con- nector and ecu side connector...

  • Page 964

    Antilock brake system 4f-15 description l check each valve by using scanner's solenoid valve overriding function. L check connection of connector and terminals in the ecu hydraulic modulator. L check each valve by using scanner's solenoid valve overriding function. L check connection of connector an...

  • Page 965

    4f-16 antilock brake system description l check terminals for open or short. (when connector is removed) l replace the hydraulic modulator. L check each valve by using scanner's solenoid valve overriding function. L check connection of connector and terminals in the ecu hydraulic modulator. L check ...

  • Page 966

    Antilock brake system 4f-17 application power voltage residual temperature measurement (abd only) acceleration sensor signal (wire) defect code 28 29 42 description when switch knob (planger) is pressed by 3mm : ¥ - each ends resistance value of the switch when switch knob(plunger) is not pressed : ...

  • Page 967

    4f-18 antilock brake system application defect code description l check connection between connectors. L check relevant wires for open or short. (when connector is removed) l check and replace the acceleration sensor. L replace the ecu. L check voltage between ecu side ground (abd:no.1, abs:no.15 pi...

  • Page 968: Maintenance and Repair

    Antilock brake system 4f-19 maintenance and repair on-vehicle service wheel speed sensor 1 bolt 2 front wheel speed sensor 3 knuckle 4 bolt 5 rear wheel speed sensor 6 rear axle.

  • Page 969

    4f-20 antilock brake system removal & installation procedure abs hydraulic unit 1. Release the abs wiring connector locking lever in arrow direction and remove the connector. Notice l do not force the connector when releasing in arrow direction. L for installation of the connetor, align and firmly s...

  • Page 970: Hydraulic Circuit

    Antilock brake system 4f-21 hydraulic circuit abs 5.3 pressure increased 1 master cylinder 2 hydraulic unit 3 damping chamber 4 return pump 5 return pump motor 6 accumulator chamber 7 inlet valve for each wheel 8 outlet valve for each wheel 9 front wheel 10 rear wheel.

  • Page 971

    4f-22 antilock brake system pressure decreased 1 master cylinder 2 hydraulic unit 3 damping chamber 4 return pump 5 return pump motor 6 accumulator chamber 7 inlet valve for each wheel 8 outlet valve for each wheel 9 front wheel 10 rear wheel.

  • Page 972

    Antilock brake system 4f-23 pressure maintained 1 master cylinder 2 hydraulic unit 3 damping chamber 4 return pump 5 return pump motor 6 accumulator chamber 7 inlet valve for each wheel 8 outlet valve for each wheel 9 front wheel 10 rear wheel.

  • Page 973: Abs/abd 5.3

    4f-24 antilock brake system abs/abd 5.3 pressure increased 1 master cylinder 2 hydraulic unit 3 damping chamber 4 return pump 5 return pump motor 6 accumulator chamber 7 inlet valve for each wheel 8 outlet valve for each wheel 9 wheel 10 prime valve (asv) 11 pilot valve (usv) 12 check valve 13 isd (...

  • Page 974

    Antilock brake system 4f-25 pressure decreased 1 master cylinder 2 hydraulic unit 3 damping chamber 4 return pump 5 return pump motor 6 accumulator chamber 7 inlet valve for each wheel 8 outlet valve for each wheel 9 wheel 10 prime valve (asv) 11 pilot valve (usv) 12 check valve 13 isd (integrated s...

  • Page 975

    4f-26 antilock brake system pressure maintained (hold) 1 master cylinder 2 hydraulic unit 3 damping chamber 4 return pump 5 return pump motor 6 accumulator chamber 7 inlet valve for each wheel 8 outlet valve for each wheel 9 wheel 10 prime valve (asv) 11 pilot valve (usv) 12 check valve 13 isd (inte...

  • Page 976: Section 4G

    Section 4g parking brake specifications . . . . . . . . . . . . . . . . . . . . . . . . 4g-1 general specifications . . . . . . . . . . . . . . . . . . 4g-1 fastener tightening specifications . . . . . . . . . 4g-1 component locator . . . . . . . . . . . . . . . . . . . 4g-2 table of contents parkin...

  • Page 977: Component Locator

    4g-2 parking brake component locator parking brake 1 parking brake lever 2 praking brake lamp switch 3 bolt 4 bolt ........................................................ 8-18 nm 5 front parking brake cable 6 equalizer 7 nut 8 bolt ........................................................ 8-18 nm 9 ...

  • Page 978: Maintenance and Repair

    Parking brake 4g-3 maintenance and repair on-vehicle service parking brake removal & installation procedure 1. Disconnect the parking brake indicator switch connector. 2. Disconnect the right and left cable from equalizer while parking brake lever is released. 3. Unscrew 8 bolts and remove the parki...

  • Page 979

    4g-4 parking brake 5. Remove the retainer with a screwdriver and disconnect the brake cable. 6. Installation should follow the removal procedure in the reverse order..

  • Page 980: Section 5A

    Section 5a automatic transmission table of contents specifications . . . . . . . . . . . . . . . . . . . . . . . . 5a-2 model part numbers and applications . . . . . . 5a-2 model specifications . . . . . . . . . . . . . . . . . . . . 5a-2 clutch pack details . . . . . . . . . . . . . . . . . . . . ....

  • Page 981: Specifications

    5a-2 automatic transmission specifications model part numbers and applications transmission 0574-000001 (9) 0574-000002 (8) 0574-000004 (10) 0574-000005 (7) torque converter 179k 160k 160k 179k engine version 661la e32 662la(turbo) e23 model specifications application torque converter mean diameter ...

  • Page 982: Clutch Pack Details

    Automatic transmission 5a-3 clutch pack details c1 composition steel c2 composition steel c3 composition steel c4 composition steel 0574-000002 5 5(2) 5 4(2) 4 4(2) 3 4(1) 0574-000001, 0574-000004, 0574-000005 4 6(2) 4 5(2) 3 5(2) 3 4(1) note : numbers in brackets indicate number of selective thickn...

  • Page 983: Special Tools

    5a-4 automatic transmission special tools special tools table part number 0555 - 332083 0555 - 336046 0555 - 336256 0555 - 336257 0555 - 336258 0555 - 336259 0555 - 336260 0555 - 336261 0555 - 336262 0555 - 336263 0555 - 336264 0555 - 336265 0555 - 336266 0555 - 336267 0555 - 336268 0555 - 336269 05...

  • Page 984: Tcu Circuit (4Wd-Diesel)

    Automatic transmission 5a-5 schematic and routing diagrams tcu circuit (4wd-diesel).

  • Page 985: Tcu Circuit (4Wd-Gasoline)

    5a-6 automatic transmission tcu circuit (4wd-gasoline).

  • Page 986: Shift Pattern Diagram

    Automatic transmission 5a-7 shift pattern diagram 661la normal mode.

  • Page 987: 661La Power Mode

    5a-8 automatic transmission 661la power mode.

  • Page 988: 662La Normal Mode

    Automatic transmission 5a-9 662la normal mode.

  • Page 989: 662La Power Mode

    5a-10 automatic transmission 662la power mode.

  • Page 990: 662La Low Mode

    Automatic transmission 5a-11 662la low mode.

  • Page 991: E32 Power Mode

    5a-12 automatic transmission e32 power mode.

  • Page 992: E32 Normal Mode

    Automatic transmission 5a-13 e32 normal mode.

  • Page 993: E32 Low Mode

    5a-14 automatic transmission e32 low mode.

  • Page 994: E23 Power Mode

    Automatic transmission 5a-15 e23 power mode.

  • Page 995: E23 Normal Mode

    5a-16 automatic transmission e23 normal mode.

  • Page 996: E23 Low Mode

    Automatic transmission 5a-17 e23 low mode.

  • Page 997: Introduction

    5a-18 automatic transmission introduction the btr automotive model 74 four speed automatic transmission is an electronically controlled overdrive four speed unit with a lock-up torque converter. The lock-up torque converter results in lower engine speeds at cruise and eliminates unnecessary slippage...

  • Page 998

    Automatic transmission 5a-19 figure 1.1 - conventional vs electronic transmission control system.

  • Page 999: Operator Interfaces

    5a-20 automatic transmission operator interfaces there are three operator interfaces associated with the four speed transmission. They are: l the gear select lever l the driving mode selector l the indicator light these operator interfaces are described below. Gear select lever operation the transmi...

  • Page 1000: Driving Mode Selector

    Automatic transmission 5a-21 downshift type range ‘1’ (manual ‘1’): range ‘2’ (manual ‘2’): range ‘3’ (manual ‘3’): range ‘d’ (drive): range ‘n’ (neutral): range ‘r’ (reverse): range ‘p’ (park): inhibited above first gear operation only with inhibited engagement as a function of vehicle speed. Engin...

  • Page 1001: Control Systems

    5a-22 automatic transmission control systems general there are two control systems associated with the transmission. The electronic control system monitors vehicle parameters and adjusts the transmission performance. The hydraulic control system implements the electronic control system commands. Ele...

  • Page 1002

    Automatic transmission 5a-23 temperature ( ° ° ° ° ° c) -20 0 20 100 135 (overheat mode threshold) maximum 17,287 6,616 2,723 196 85 minimum 13,638 5,177 2,278 177 75 resistance (ohms) table 3.1 - temperature / resistance characteristics figure 3.2 - temperature / resistance characteristics.

  • Page 1003

    5a-24 automatic transmission transmission control unit(tcu) the tcu is an in-vehicle micro-processor based transmission management system. It is usually mounted in the vehicle cabin, under the instrument panel, under the seat, behind the side kick panels or under the floor in the footwell on the pas...

  • Page 1004

    Automatic transmission 5a-25 producing a low resistance. Temperature/resistance characteristics and location within the solenoid wiring loom are given in tables 3-1 and 3- 2, and figures 3.2 and 3.3. If the transmission sump temperature exceeds 135°c, the tcu will impose converter lock-up at lower v...

  • Page 1005

    5a-26 automatic transmission i n h i b i t o r switch throttle position sensor the throttle position sensor(tps) is a resistance potentiometer mounted on the throttle body of the engine. It transmits a signal to the tcu proportional to the throttle plate opening. The potentiometer is connected to th...

  • Page 1006

    Automatic transmission 5a-27 shift lever position manual 1 manual 2 manual 3 drive netural reverse park resistance (ohms) 1k - 1.4k 1.8k - 2.2k 3k - 3.4k 4.5k - 4.9k 6.8k - 7.2k 10.8k - 11.2k 18.6k - 19k table 3.3 - readings for resistance/shift lever positions diagnostics inputs the diagnostics con...

  • Page 1007

    5a-28 automatic transmission table 3.4 - solenoid states and functions table 3.5 - solenoid logic for static gear states solenoids 1 and 2 solenoids 3 and 4 solenoid 5 solenoid 6 solenoid 7 s1 and s2 are normally open on/off solenoids that set the selected gear. These solenoids determine static gear...

  • Page 1008

    Automatic transmission 5a-29 table 3.6- solenoid operation during gearshifts to initiate shift s1 off s4 on s1 off s2 off s3 on s4 on s2 off s3 on s4 on s2 off s3 on s4 on s1 on s4 on s4 on s3 on s3 on s4 on s2 on s4 on s3 on s4 on s4 on s7 on to complete shift s4 off s3 off s4 off s3 off s4 off s3 ...

  • Page 1009

    5a-30 automatic transmission solenoid valve symbols (on/off solenoids) the solenoid symbol shown adjacent to each solenoid on the hydraulic system schematics indicates the state of the oil flow through the solenoid valve with the power on or 0ff. Refer to figure 3.6 for the on/off operational detail...

  • Page 1010: Hydraulic Control System

    Automatic transmission 5a-31 k-line the k-line is typically used for obtaining diagnostic information from the tcu. A computer with a special interface is connected to the tcu and all current faults, stored faults, runtime parameters are then available. The stored fault codes can also be cleared. Th...

  • Page 1011

    5a-32 automatic transmission figure 3.7 - hydraulic control circuit.

  • Page 1012

    Automatic transmission 5a-33 figure 3.8 - valve body figure 3.9 - pump cover valve body figure 3.8 depicts the valve body as a unit as viewed from the transmission sump. Figure 3.9 depicts the pump cover..

  • Page 1013

    5a-34 automatic transmission figure 3.10 - manual valve 1-2 shift valve the 1-2 shift valve (refer to figure 3.11) is a two position valve that must be switched to the (2,3,4) position in order to get any forward gear other than first gear. It is used for all 1-2 and 2-1 gearshifts. The switching of...

  • Page 1014

    Automatic transmission 5a-35 2-3 shift valve the 2-3 shift valve (refer to figure 3.12) is a two position valve. It is used on all 2-3 and 3-2 gearshifts. The switching of this valve is achieved by s2 which is located at the end of the valve spool. When in the (1,2) position, second gear oil from th...

  • Page 1015

    5a-36 automatic transmission 4-3 sequence valve the 4-3 sequence valve (refer figure 3.14) is a two position spring loaded valve. It switches during 3-4 and 4-3 gearshifts although it performs no function during the 3-4 shift. During the 4-3 shift the 4-3 sequence valve delays the connection of the ...

  • Page 1016

    Automatic transmission 5a-37 figure 3.16 - clutch apply regulator valve clutch apply regulator valve the clutch apply regulator valve (refer figure 3.16) is a fixed ratio valve. This valve provides a regulated pressure to the c1 clutch and controls the rate of change of state of the clutch to give t...

  • Page 1017

    5a-38 automatic transmission reverse lockout valve the reverse lockout valve (refer figure 3.18) is a two position valve contained in the upper valve body. This valve uses 51-52 pressure as a signal pressure and controls the application of the rear band (b2). While the manual valve is in d,3,2, or 1...

  • Page 1018

    Automatic transmission 5a-39 primary regulator valve the primary regulator valve (prv) (refer to figure 3.19) regulates the transmission line pressure (or pump output pressure). This valve gives either high or low line pressure depending on whether s6 is switched off or on, when s6 is switched on,s6...

  • Page 1019

    5a-40 automatic transmission converter clutch regulator valve the converter clutch regulator valve (refer figure 3.20) regulates the pressure of the oil which applies the converter clutch. Input oil from the line 500 circuit is regulated within the valve, with the output pressure being variable acco...

  • Page 1020

    Automatic transmission 5a-41 c1 bias valve the c1 bias valve (refer figure 3.22) ensures that the converter lock-up clutch is only applied in third and fourth gears. It uses c1 clutch oil pressure as the switching signal since c1 is only applied in third and fourth gears. Line to 500 oil is routed t...

  • Page 1021: Power Train System

    5a-42 automatic transmission power train system the power train system consists of: l a torque converter with single face lock-up clutch l four multi-plate clutch assemblies l two brake bands l two one-way clutches l planetary gearset l parking mechanism a conventional six pinion ravigneaux compound...

  • Page 1022: Torque Converter

    Automatic transmission 5a-43 figure 4.1 - power flow diagram torque converter the torque converter (refer figure 4.2) consists of a turbine, stator pump, impeller and a lock-up damper and piston assembly. As in conventional torque converters, the impeller is attached to the converter cover, the turb...

  • Page 1023: Clutch Packs

    5a-44 automatic transmission clutch packs there are four clutch packs (refer to figure 4.3). All clutch packs are composed of multiple steel and friction plates. C1 clutch when applied, this clutch pack allows the input shaft to drive the planet carrier. This occurs in third and fourth gears. C2 clu...

  • Page 1024: Bands

    Automatic transmission 5a-45 bands the transmission utilises two bands, the b1 band (sometimes known as the 24 band), and the b2 band (sometimes known as the low-reverse band). Refer to figure 4.4. The b1 band is a flexible band which is engaged by the front servo piston. B1 is activated in second a...

  • Page 1025: Parking Mechanism

    5a-46 automatic transmission parking mechanism when park is selected the manual lever extends the park rod rearwards to engage the parking pawl (refer to (figure 4.5). The pawl will engage the external teeth on the ring gear thus locking the output shaft to the transmission case. When park is not se...

  • Page 1026: Power Flows

    Automatic transmission 5a-47 power flows introduction the power flows for the various transmission selections are listed below: l power flow - neutral and park l power flow - reverse l power flow - manual 1 l power flow - drive 1 l power flow - drive 2 l power flow - drive 3 l power flow - drive 3 l...

  • Page 1027

    5a-48 automatic transmission power flow - park and neutral in park and neutral, there is no drive to the planetary gear set. The rear band is applied to eliminate ‘clunk’ on engagement of the reverse gear, and to improve the low range engagement for 4wd applications. No other clutches or bands are a...

  • Page 1028: Power Flow - Reverse

    Automatic transmission 5a-49 power flow - reverse in reverse, transmission drive is via the input shaft and the forward clutch cylinder to the hub of the c3 clutch. The elements of the transmission function as follows : l the c3 clutch is engaged and drives the reverse sun gear in a clock-wise direc...

  • Page 1029: Power Flow - Manual 1

    5a-50 automatic transmission power flow - manual 1 in manual 1, transmission drive is via the input shaft to the forward clutch cylinder. The elements of the transmission function as follows : l the c2 clutch is engaged to drive the forward sun gear, via the 3-4 owc. L the b2 band is engaged to hold...

  • Page 1030: Power Flow - Drive 1

    Automatic transmission 5a-51 power flow - drive 1 in drive 1, transmission drive is via the input shaft to the forward clutch cylinder. The elements of the transmission function as follows : l the c2 clutch is engaged to drive the forward sun gear. L the forward sun gear drives the short pinion anti...

  • Page 1031

    5a-52 automatic transmission power flow - drive 2 and manual 2 in drive 2 and manual 2, transmission drive is via the input shaft and forward clutch cylinder. The elements of the transmission function as follows : l the c2 clutch is applied to drive the forward sun gear. L the forward sun gear drive...

  • Page 1032

    Automatic transmission 5a-53.

  • Page 1033

    5a-54 automatic transmission power flow - drive 3 and manual 3 in drive 3 and manual 3, transmission drive is via the input shaft to the forward clutch cylinder. The elements of the transmission function as follows : l the c2 clutch is engaged to drive the forward sun gear. L the c1 clutch is engage...

  • Page 1034

    Automatic transmission 5a-55.

  • Page 1035

    5a-56 automatic transmission power flow - drive 3 lock up and manual 3 lock up in drive 3 lock up and manual 3 lock up, transmission drive is the same as for drive 3 but with the application of the converter lock up clutch to provide positive no-slip converter drive. Control control for drive 3 lock...

  • Page 1036

    Automatic transmission 5a-57 power flow - drive 4 (overdrive) in drive 4 (overdrive), transmission drive is via the input shaft to the forward clutch cylinder. The elements of the transmission function as follows : l the c1 clutch is applied to drive the planet carrier clockwise. L the b1 band is ap...

  • Page 1037

    5a-58 automatic transmission.

  • Page 1038: Power Flow - Drive 4 Lock Up

    Automatic transmission 5a-59 power flow - drive 4 lock up in drive 4 lock up, transmission drive is the same as for drive 4 but with the application of the converter lock up clutch to provide positive no-slip converter drive. Control control for drive 4 lock up is the same as for drive 4 with the ad...

  • Page 1039: Diagnosis

    5a-60 automatic transmission diagnosis diagnostic system recommended test equipment and procedure the test equipment is designed to be used with the control modules in all vehicles. The components used in the transmission application are: l multi function tester, and l appropriate vehicle for testin...

  • Page 1040

    Automatic transmission 5a-61 pin no. 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 identification mode indicator lamp - ‘power ’ throttle position sensor output as pulse width modulation for tod air conditioner input signal kickdown switch mode switch transfer case input (high) -4...

  • Page 1041

    5a-62 automatic transmission identification gear lever position transmission oil temperature solenoid 4 solenoid 1 do not use solenoid 5 return (-ve) gear lever position - ground transmission oil temperature - ground solenoid 6 solenoid 2 solenoid 3 solenoid 7 do not use solenoid 5 (+ve) type ip ip ...

  • Page 1042

    Automatic transmission 5a-63 ten pin plug pin numbers figure 6.1.1 - wiring loom pins.

  • Page 1043

    5a-64 automatic transmission default transmission operating modes the tcu relies on accurate information from its inputs and complete control of its outputs to effectively control the transmission. To ensure that it has both valid inputs and functioning outputs, the tcu carries out both hardware and...

  • Page 1044

    Automatic transmission 5a-65 if the gear lever is incorrectly adjusted, the transmission may shift gears on bumpy road surfaces. 6 transmission oil temperature sensing fault l all shifts will be firm until the transmission has warmed up, because a high transmission oil temperature is assumed. If a f...

  • Page 1045

    5a-66 automatic transmission diagnostic trouble messages the diagnostic trouble messages generated by the tcu and their possible causes are listed in table 6.1.3. Table 6.1.2 - transmission operations for on/off solenoid faults transmission operation first gear instead of second and fourth gear inst...

  • Page 1046

    Automatic transmission 5a-67 table 6.1.3 - diagnostic trouble messages description / cause there have been no faults recorded since the tcu was last cleared. If the fault history has never been cleared, then there have been no faults recorded since the tcu was originally powered up. There is an inte...

  • Page 1047

    5a-68 automatic transmission description / cause the signal from the mode switch is unreliable. This fault is caused by too many changes in the mode input signal over a period of time. Typical causes would be an intermittent connec tion in the switch or wiring or an intermittent short to ground in t...

  • Page 1048: Mechanical Tests

    Automatic transmission 5a-69 mechanical tests in vehicle transmission checks carry out the following tests before removing the transmission. L see checking transmission fluid level, section 7.2.1. L check that the transmission oil is not burnt (colour and smell are correct). L ensure that the transm...

  • Page 1049

    5a-70 automatic transmission action inspect s1. Repair or replace as necessary. Check for 12 volts applied to s1 at all times or for wiring fault. Inspect s1. Repair or replace as necessary. Check for 12 volts applied to s1 at all times or for wiring fault. Inspect s2. Repair or replace as necessary...

  • Page 1050

    Automatic transmission 5a-71 table 6.2.2 - faulty shift patterns action inspect inhibitor switch. Repair or replace as necessary. Inspect the 3-4 shift valve. Repair or replace as necessary. Inspect the release valve. Repair or replace as necessary. Inspect s3 or s2. Repair or replace as neces- sary...

  • Page 1051

    5a-72 automatic transmission action drain and fill with specified atf. Check that s5 is fitted correctly, or replace s5. Inspect band apply and clutch apply regulator springs. Refit or replace as necessary. Inspect the ball. Refit or replace as necessary. Inspect c4 clutch. Replace or repair as nece...

  • Page 1052

    Automatic transmission 5a-73 table 6.2.3 - shift quality faults action check the resistance. Replace the inhibitor switch as necessary. Inspect and replace the sensor as necessary. Inspect and adjust the band as necessary. Inspect and replace the’0’rings as necessary. Inspect, repair or replace s5 a...

  • Page 1053

    5a-74 automatic transmission action inspect, repair c2 and adjust the linkage as neces- sary. Repair c2. Inspect, repair or replace s6 as neces- sary. Repair c2. Inspect, replace the sealing rings and/ or shaft as necessary. Repair c2. Inspect, repair or replace the c2 piston as necessary. Inspect c...

  • Page 1054: Self Diagnosis Test

    Automatic transmission 5a-75 self diagnosis test 1. Turn the ignition switch to “off” position. 2. Connect the scanner harness connector to the engine compartment diagnosis socket. 3. Turn the ignition switch to “on” position. 4. Select “electronics control vehicle diagnosis” from the function selec...

  • Page 1055

    5a-76 automatic transmission action l check cable for open / short. L check connection of other connectors. L check voltage between terminal 27 and 29 of tcu, - standard value : 0.2 - 4.7v l check tps. L check cable for open / short. L check connection of other connectors. L check engine speed senso...

  • Page 1056

    Automatic transmission 5a-77 action l check cable for open / short. L check connection of other connectors. L check voltage between terminal 4 and 11 of tcu. - standard value : when the a/c compressor is on : 12v when the a/c compressor is off : 0v l check cable for open / short, l check connection ...

  • Page 1057

    5a-78 automatic transmission action l check solenoid. L check cable for open / short. L check connection of other connectors. L check resistance between terminal 36 and 44 of tcu (when the connector is disconnected). - standard value : 3.6 - 4.2 w l check solenoid. L check cable for open / short. L ...

  • Page 1058: Adjustments

    Automatic transmission 5a-79 adjustments hydraulic system the procedures detailed below should be followed in the event that the self test procedure detailed in section 6, or a defect symptom, indicates that there is a fault in the hydraulic system. When making adjustments to the transmission, selec...

  • Page 1059: Electronic Adjustments

    5a-80 automatic transmission 6. Switch off the engine and raise the vehicle on the hoist, if applicable, ensuring that the vehicle is level. 7. Three minutes after the engine has stopped, but no longer than one hour, remove the filler pump, the correct level is reached when atf is aligned with the b...

  • Page 1060

    Automatic transmission 5a-81 throttle clearing the leant throttle clearing routine uses the mode switch and gear lever. Carry out the following steps to complete the automated throttle clearing procedure: 1. Switch ignition ‘on’ with handbrake applied and engine ‘off’. 2. Select ‘m1’ and ‘winter’ mo...

  • Page 1061: Maintenance and Repair

    5a-82 automatic transmission maintenance and repair on-vehicle service tightening torque 70 - 80 nm 5. Remove the rear propeller shaft . Installation notice removal & installation of transmission 1. Disconnect the negative battery cable. 2. Disconnect the connectors from transfer case. 3. Disconnect...

  • Page 1062

    Automatic transmission 5a-83 tightening torque 70 - 80 nm 11. Remove the two pipes for oil cooler. Installation notice tightening torque 24.5 - 34.3 nm 12. Remove the service hall cover on torque converter. 13. Put the alignment mark for installation, and unscrew the six mounting bolts for torque co...

  • Page 1063

    5a-84 automatic transmission tightening torque 55 - 65 nm 14. Remover the starter. 15. Unscrew the eight transmission housing bolts and remove the transmission assembly. Installation notice be careful not to drop the torque converter while removing the transmission. 16. Installation should follow th...

  • Page 1064: Unit Repair

    Automatic transmission 5a-85 unit repair rebuild warnings prior to rebuilding a transmission system, the following warnings are to be noted. L ensure that, before replacing a transmission the cooler lines are flushed out to remove any debris. This can be done by applying compressed air to the rear c...

  • Page 1065

    5a-86 automatic transmission 9. Remove the pump to case bolts using a multi-hex 8 mm spanner. 10. Using the pump puller no. 0555-332941, remove the pump. 11. Remove the input shaft, forward clutch cylinder, and the overdrive shaft as an assembly, withdrawing them through the front of the case. 12. R...

  • Page 1066

    Automatic transmission 5a-87 transmission case to teardown the transmission case, proceed as follows: 1. Remove the pin from the cross shaft inhibitor switch side (4wd models) using tool no.0555-332942. 2. Remove the inhibitor switch from the case. Remove the cross shaft seals with special tool no.0...

  • Page 1067

    5a-88 automatic transmission 8. Detach the no.7 solenoid wire from the front of the case. 9. Remove the parking pawl pivot pin and the pawl and spring from the case. 10. Remove the shaft and the rear servo lever. 11. Remove the rear servo cover and piston assembly. 12. Remove the b1r circlip, valve ...

  • Page 1068

    Automatic transmission 5a-89 forward clutch cylinder to remove the forward clutch cylinder, refer to figure 8.4, proceed as follows. 1. Place the assembly in a horizontal position. 2. Remove the thrust bearing and adjustment shims from the input shaft. 3. Remove the circlip from the front of the clu...

  • Page 1069

    5a-90 automatic transmission 10. Remove the thrust block from the c4 clutch cylinder hub. Notice make sure that the spring keeper is not caught in the circlip groove, and that all the spring pressure is released, before removing the tool. 11. Mount the clutch cylinder on tool no.0555-331899 with the...

  • Page 1070

    Automatic transmission 5a-91 c3 clutch cylinder to remove the c3 clutch cylinder, proceed as follows: 1. Remove the forward sun gear and thrust bearing from the c3 clutch cylinder. 2. Remove the nylon thrust bearing, bearing support, needle thrust bearing and thrust block from the clutch cylinder hu...

  • Page 1071

    5a-92 automatic transmission planet carrier and centre support to remove the planet carrier and centre support, proceed as follows. 1. Separate the planet carrier and centre support from the output shaft. Remove the thrust bearings from the output shaft and the planet carrier. 2. Separate the centre...

  • Page 1072

    Automatic transmission 5a-93 valve body to disassemble the valve body, proceed as follows. 1. Remove the detent spring and retainer plate using a t40 torx bit. Notice be aware that the manual valve will fall out of the valve body. 2. Take note of the angular relationship of the solenoid terminals to...

  • Page 1073: Assembly Procedure

    5a-94 automatic transmission assembly procedure the transmission is assembled in modular fashion and details of assembly for each module are given under the appropriate subject. Refer to table 8.1 (at the end of section 8.3) for the torque specifications to be applied, and to table 9.10 in section 9...

  • Page 1074

    Automatic transmission 5a-95 notice care must be taken when applying sealant to ensure that it is not applied between the pin and the lever. 5. Assemble the park rod lever, complete with the return spring and pivot pin, applying a small amount of sealant to the outer end of the pivot pin. Notice tha...

  • Page 1075

    5a-96 automatic transmission 9. Check that the cam collar slides freely on the rod. 10. Insert the cross shaft into the case, from the side opposite to the inhibitor switch, then install the anti-rattle spring on the shaft. 11. Position the manual valve detent lever, aligning it with the cross-shaft...

  • Page 1076

    Automatic transmission 5a-97 20. Install the ten pin connector in the case engaging the tangs on the connector in the notches in case. 4wd models only 21. Route the portion of the wiring loom coming out of the case down between the inhibitor switch and the case. Position the ten pin plug on the wiri...

  • Page 1077

    5a-98 automatic transmission rear band assembly to assemble the rear band assembly proceed as follows: 1. Check the rear band for any cracks or damage along the lining and metal backing. 2. Install the reaction anchor strut into the main case, without shims. Notice if fitting a new band, soak the ne...

  • Page 1078

    Automatic transmission 5a-99 output shaft and gear assembly to assemble the output shaft and gear assembly (refer to (figure 8.19), proceed as follows: 1. Check that the output shaft bush is not won or damaged. Replace if necessary. 2. Check for damage to parking pawl teeth on the ring gear. Replace...

  • Page 1079

    5a-100 automatic transmission planet carrier assembly and centre support to assemble the planet carrier assembly and centre support, proceed as follows. 1. Check the carrier and planet assembly for any damage or irregularity and ensure that all pinions rotate freely and that the pinion end float is ...

  • Page 1080

    Automatic transmission 5a-101 extension housing assembly to assemble the extension housing assembly, proceed as follows. 1. Check the condition of the extension housing roller bearing. Replace if necessary (rwd models). Install the new bearing from rear of extension housing. Press on the branded fac...

  • Page 1081

    5a-102 automatic transmission front band assembly to assemble the front band assembly, proceed as follows. 1. Install the reaction anchor strut to the case. 2. Check the band for ally cracks or damage along its lining and metal backing. 3. Position the strut retainers on the band (refer to figure 8....

  • Page 1082

    Automatic transmission 5a-103 11. Assemble the piston return spring to the piston, and fit the spring retainer over the spring. Notice the wire diameter of this spring is 4.3 mm. 12. Using special tool no. 0555-331899, compress the spring sufficiently to enable the installation of the retaining circ...

  • Page 1083

    5a-104 automatic transmission figure 8.25 - c4 clutch pack clearance.

  • Page 1084

    Automatic transmission 5a-105 21. Holding the cylinder horizontal, install the sleeve and clutch plate assembly into the cylinder, with the crest of one wave of the washer in line with one of the holes in the outside of the cylinder, until the sleeve contacts the c2 wave washer. 22. Check the c4 clu...

  • Page 1085

    5a-106 automatic transmission 29. Align the tangs and fit the nylon thrust washer onto the c4 hub. Refer to figure 8.27. 30. Align and fit the c4 hub to the c2 clutch and the owc assembly. 31. Check the rotation of the c2 hub. While holding the c4 hub, the c2 hub should rotate in the clockwise direc...

  • Page 1086

    Automatic transmission 5a-107 c3 clutch and reverse sun gear assembly to assemble the c3 clutch and reverse sun gear assembly (refer to figure 8.28), proceed as follows. 1. Check the orifices in the cylinder are clear of obstructions. 2. Check the c3 cylinder bush outside diameter and the centre sup...

  • Page 1087

    5a-108 automatic transmission 12. Install the circlip. 13. Check the c3 clutch clearance (refer to figure 8.29) using special tool no.0555-331900 in the following manner (weight only). A. Place the weight on the pressure plate and measure the distance from the end of the cylinder to the top of the p...

  • Page 1088

    Automatic transmission 5a-109 forward sun gear and c3 clutch pack assembly to assemble the forward sun gear and c3 clutch pack assembly (refer to figure 8.30), proceed as follows: 1. Fit the no. 7 needle thrust bearing assembly over the forward sun gear, ensuring that the thrust washer is between th...

  • Page 1089

    5a-110 automatic transmission c1 clutch overdrive shaft and input shaft assembly notice 1. Ensure that the snap rings are fitted correctly. 2. Check pistons for cracks, especially the c1 piston. 3. Do not mix clutch piston return springs. 4. If the c1/c2 clutch packs separate from the c3 clutch pack...

  • Page 1090

    Automatic transmission 5a-111 7. Coat the small nylon thrust spacer with petroleum jelly and install it over the overdrive shaft. Refer to figure 8.19. 8. Carefully fit the overdrive shaft into the c1 cylinder so as not to damage the sealing ring. 9. Fit the small bronze c1 hub thrust washer in plac...

  • Page 1091

    5a-112 automatic transmission pump cover and converter support notice 1. Do not wash the nose of solenoids in solvent. 2. Ensure that the correct ‘o’ ring is fitted for the application. 3. Do not mix up the low first blow-off and the torque converter blow-off ball springs. 4. Be careful not to damag...

  • Page 1092

    Automatic transmission 5a-113 9. Assemble the primary regulator valve and plunger (refer to figure 8.36) to the pump cover, ensuring that the regulator valve slides freely, then fit the regulator valve plug and ‘o’ ring. 10. Install the retaining pin. 11. Install the converter clutch regulator valve...

  • Page 1093

    5a-114 automatic transmission 13. Install the converter clutch control valve (refer to figure 8.38), spring, plug, and ‘o’ ring. 14. Install the retaining pin. Refer to figure 8.39. Figure 8.39 - valve retaining plugs and pins figure 8.38 - converter clutch control valve 12. Install the retaining pi...

  • Page 1094

    Automatic transmission 5a-115 15. Install the c1 bias valve spring, valve, plug and ‘o’ ring. Refer to figure 8.40. 16. Install the retaining pin. Refer to figure 8.39. 17. Install the converter release check ball and spring and the feed ball. Refer to figures 8.41, 8.42 and 8.43. Figure 8.40 - c1 b...

  • Page 1095

    5a-116 automatic transmission 18. Install the gasket on the pump cover. 19. Install the cover plate, solenoid 7 with the retainer and the solenoid wiring retainer to the pump cover, ensuring that the periphery of the cover plate is flush with the periphery of the pump cover. Refer to figure 8.34. Ti...

  • Page 1096

    Automatic transmission 5a-117 25. Check that the transmission end float is set to the tolerance stated in section 9.2. Refer to figure 8.46. If the unshimmed end float clearance is greater than specification, shims are to be placed between the no. 4 bearing and the input shaft bearing surface. Refer...

  • Page 1097

    5a-118 automatic transmission valve bodies notice 1. Do not wash the nose of solenoids in solvent. 2. Be aware of ball positions in the upper valve body. 3. Be aware of 1-2 and 3-4 shift valve positions, they can be swapped. 4. Check the 4-3 sequence valve and spring orientation. 5. Check that the 1...

  • Page 1098

    Automatic transmission 5a-119 6. Install the lo-1st spring, ball check valve and roll pin. Refer to figure 8.49. 7. Install the solenoid 5 damper guide spring, piston and retaining pin. Refer to figure 8.49. Figure 8.49 - solenoid 5 and damper, lo-1st check valve assemblies figure 8.50 - 1-2 shift v...

  • Page 1099

    5a-120 automatic transmission 9. Install the 3-4 shift valve and retaining pin. Refer to figure 8.51. Figure 8.51 - 3-4 shift valve 10. Install the 2-3 shift valve and retaining pin. Refer to figure 8.52. Figure 8.52 - solenoid 2 and 2-3 shift valve 11. Install the 4-3 sequence valve, spring, plug a...

  • Page 1100

    Automatic transmission 5a-121 12. Install the band apply regulator (bar) valve (refer to figure 8.54), springs, plunger and retainer pin. Figure 8.54 - band apply regulator valve and solenoid 4 13. Install the clutch apply regulator (car) valve (refer to figure 8.55), springs, plunger and retainer p...

  • Page 1101

    5a-122 automatic transmission 15. Install solenoid 6 plunger, spring and retaining pin. 16. Position the third feed ball (large nylon) in the valve body and install the solenoid 5 filter and the solenoid 6 filter. Refer to figures 8.5 and 8.56. 17. Check the separator plate for burrs and damage. Rep...

  • Page 1102

    Automatic transmission 5a-123 23. Holding the separator plate to the upper valve body to prevent the check balls from falling out, install the upper valve body on the lower valve body. Install all screws finger tight then tighten the screws to specification in the prescribed sequence. Refer to figur...

  • Page 1103

    5a-124 automatic transmission 27. Install the line pressure plug and tighten to specification. Refer to figure 8.62. 28. Install the detent spring assembly (spring, support plate and screw), ensuring that the screw is tightened to specification. Check the spring for wear or damage. 29. Install the m...

  • Page 1104

    Automatic transmission 5a-125 30. Align the valve body assembly on the transmission case and install the manual valve lever to manual valve link. Fit the long end of the link to the manual valve first. Install the securing bolts and tighten to specification in the specified sequence. Refer to figure...

  • Page 1105

    5a-126 automatic transmission oil filter and pan assembly notice 1. Replace the filter whenever rebuilding a transmission where a significant amount of mechanical damage has occurred. 2. To aid the assembly of the pan gasket, use a small amount of vaseline at the pan/gasket interface. This ensures t...

  • Page 1106

    Automatic transmission 5a-127 torque converter and housing assembly to assemble the torque converter and housing assembly, proceed as follows. 1. Locate the torque converter housing on the transmission main case. 2. Install and tighten the securing bolts to specification. Notice all the hardware mus...

  • Page 1107

    5a-128 automatic transmission front and rear band adjustment front band setting procedure to set the front band, proceed as follows. 1. Measure the projection of the front servo push rod from the transmission case. Refer to figure 8.66, dimension a. A. Apply air at 650/700 kpa to the front servo app...

  • Page 1108

    Automatic transmission 5a-129 figure 8.68 - rear band settings rear band setting procedure to set the rear band, proceed as follows. 1. Measure distance ‘a’ from the rear servo piston to the inner face of the transmission case using vernier calipers. Refer to figure 8.68. A. Apply air at 650/700 kpa...

  • Page 1109

    5a-130 automatic transmission table 8.2 - thickness of available shims thickness 0.95/1.05 1.15/1.25 1.44/1.56 1.73/1.87 part number 0574-037017 0574-037018 0574-037019 0574-037020 thickness 1.93/2.07 2.12/2.28 2.42/2.58 2.61/2.79 part number 0574-037021 0574-037022 0574-037023 0574-037024 figure 8....

  • Page 1110: Section 5B

    Model type gear ratio oil weight (dry) section 5b manual transmission table of contents specifications . . . . . . . . . . . . . . . . . . . . . . . . 5b-1 general specifications . . . . . . . . . . . . . . . . . . 5b-1 fastener tightening specifications . . . . . . . . . 5b-2 external view . . . . ...

  • Page 1111

    5b-2 manual transmission fastener tightening specifications application transmission oil filler plug transmission mounting bolt (housing) oil drain plug front propeller shaft (t/c) rear propeller shaft (t/c) cross member bolt (center) cross member bolt (side) control cable shift lever bolt n l m 25 ...

  • Page 1112: External View

    Manual transmission 5b-3 external view gear train.

  • Page 1113: Power Flow

    5b-4 manual transmission power flow.

  • Page 1114: Diagnosis

    Manual transmission 5b-5 check clutch not releasing. Improper or low transmission oil. Shift or shift rail binding. Binding of sliding synchronizers or gears. If reverse only, faulty backup switch. Worn or damaged flywheel pilot bushing. Check control lever assembly broken or damaged. Damaged offset...

  • Page 1115: Transmission Jumps Out

    5b-6 manual transmission check loosened transmission or flywheel housing bolts, improper alignment. Synchronizer damaged or excessively worn. Blocking ring damaged, worn index slots or friction surfaces worn or damaged. Excessive countershaft end play. Worn or damaged fork due to loosened shaft, rai...

  • Page 1116: Transmission Leakage

    Manual transmission 5b-7 transmission leakage check leakage from transmission. Vent or breather clogged. Too much oil. Loose bolts at sealing faces. Improperly applied sealant. Worn or damaged oil seal. Action clean all exposed surfaces, then check for leaks. Clean or replace vent or breather. Check...

  • Page 1117: Diagnosis Table

    5b-8 manual transmission 1 shift hop-out 2 shift gear crash 3 shift block-out 4 hard shift 5 noise in reverse gear 6 noise in 5th gear 7 noise in 4th gear 8 noise in 3rd gear 9 noise in 2nd gear 10 noise in 1st gear 11 noise in all speeds 12 leak at transmission rear part 13 leak at transmission cen...

  • Page 1118: Component Locator

    Manual transmission 5b-9 component locator.

  • Page 1119

    5b-10 manual transmission 1 filler/drain plug 2 shift mechanism cover 3 shift shaft lever 4 outer select lever 5 inner select lever 6 offset control lever 7 bias spring 8 bolt 9 pin 10 washer 11 bolt 12 bolt 13 extension and plate assembly 14 o-ring & steel ring 15 oiling funnel 16 bolt 17 alignment...

  • Page 1120: Maintenance and Repair

    Manual transmission 5b-11 maintenance and repair on-vehicle service shift control cable 1 shift lever assembly 2 bolt ...................................................... 20-30 nm 3 select cable 4 shift cable 5 snap pin 6 snap pin 7 transmission 8 shift cable 9 select cable 10 clip 11 clip 12 snap...

  • Page 1121

    5b-12 manual transmission removal & installation procedure 1. Position the shift lever in neutral and remove the knob. 2. Remove the screw from the console box side and remove the shift lever cover. 3. Disconnect the cables by removing the snap pins from the control cable connections to the select l...

  • Page 1122

    Manual transmission 5b-13 5. Pull out the clip from the bracket and remove the shift cable and select cable. 6. Installation is reverse order of the removal. Inspection procedure 1. The shift lever should be positioned in neutral. 2. Apply liquid gasket on the cable contact surface. 3. Keep 130 mm b...

  • Page 1123: Transmission

    5b-14 manual transmission transmission preceding work : removal of the shift control cable 1 clutch housing 2 oil filler plug ............................................ 25 nm 3 transmission assembly 4 back-up switch 5 washer 6 bolt ...................................................... 77-87 nm 7 ...

  • Page 1124

    Manual transmission 5b-15 removal & installation procedure 1. Disconnect the negative terminal from the battery. 2. Lift up the vehicle and fix it safely. 3. Remove the drain plug from the transmission housing and drain the oil. Reinstall the drain plug. Installation notice tightening torque 25 nm 4...

  • Page 1125

    5b-16 manual transmission 7. Remove the front and rear propeller shafts from the transfercase. Installation notice tightening torque 81 - 89 nm 70 - 90 nm front rear 8. Support the transmission on an suitable jack. Unscrew the center mounting nuts and each sides mounting bolts and remove the cross m...

  • Page 1126: Unit Repair

    Manual transmission 5b-17 unit repair major unit preceding work : removal of the transmission removal of the transfer case disassembly procedure 1. Install the removed transmission into a fixture. 2. Remove the drain plug and drain the oil. Using a 13 mm wrench, remove the clamp bolt and position th...

  • Page 1127

    5b-18 manual transmission 8. Remove the counter shaft thrust race and bearing. 9. Carefully remove the oiling funnel from the end of the counter shaft. 10. Using a 10 mm wrench, remove the 10 bolts from the shift cover. Notice for assembly, note the location of the two bolts. 11. Lift up the shift c...

  • Page 1128

    Manual transmission 5b-19 13. Using a 21 mm wrench or a t-50 bit, remove the 5-r lever pivot bolt. Notice apply sealer bond to this bolt during assembly. 14. Using a 22 mm wrench, remove the back-up lamp switch from the 5-r lever side. Notice apply sealer to the threads. 15. Pull out the 5-r lever o...

  • Page 1129

    5b-20 manual transmission 18. Remove the slip yoke snap ring from the main shaft. 19. Remove the 5th speed drive gear snap ring from the main shaft. 20. Make alignment marks on the case and input bearing retainer and remove the 4 input shaft bearing retainer bolts, using a 13 mm wrench. Notice apply...

  • Page 1130

    Manual transmission 5b-21 23. Remove the main shaft in 2 steps. L to remove the rear bearing outer race, push the main shaft rearward. L tilt and lift the main shaft from the case. 24. Remove the reverse fork and spring from the case. 25. Remove the counter shaft as follows: l using a punch and hamm...

  • Page 1131

    5b-22 manual transmission 26. Using a pin punch and a hammer, remove the roll pin fixed on the reverse idler shaft. 27. By pushing the reverse idler shaft rearward and out of the case, remove the reverse idler gear and o-ring. 28. Using a puller, remove the rear bearing assembly from the counter sha...

  • Page 1132

    Manual transmission 5b-23 assembly procedure 1. Using a hydraulic press and a supporting tool, press the counter shaft rear bearing into the case. Be sure that the supporting tool inside of the case should support the counter shaft. 2. Without the shim, install the retainer and counter shaft rear be...

  • Page 1133

    5b-24 manual transmission 7. Install the counter shaft rear bearing outer race, shim and retainer. Tightening torque 39 - 52 nm l using a punch and hammer, bend the lock tabs on the retainer. 8. Install the following parts : l install the main shaft into case. L install the main shaft rear bearing o...

  • Page 1134

    Manual transmission 5b-25 14. Using a needle nose pliers, install the reverse fork spring to its pin inside the case. Check the operation of the 5-r shift mechanism at this time. 15. Using a snap ring piers, install the slip yoke snap ring onto the end of the main shaft. 16. Make sure that the 1-2 a...

  • Page 1135

    5b-26 manual transmission 21. Completely compress the detent spring. 22. To install the extension housing to the case, apply sealer to the top two bolts and tighten them and tighten the 6 bolts. 23. Apply sealer to the back-up lamp switch and drain plug and tighten them. 24. Using a hammer, install ...

  • Page 1136: Main Shaft

    Manual transmission 5b-27 main shaft disassembly procedure 1. For correct reassemble, place an alignment mark on the 3- 4 synchronizer hub and sleeve. 2. Using a hydraulic press and puller plate, remove the 3-4 synchronizer assembly and the 3rd speed gear. 3. Remove the 3rd speed gear bearing and sp...

  • Page 1137

    5b-28 manual transmission 7. Using a screwdriver, remove the spiral retaining ring. 8. Remove the thrust washer and three-piece 2nd speed blocking ring assembly. 9. For correct reassembly, place an alignment mark on the 1-2 synchronizer hub and sleeve. 10. Remove the 1-2 synchronizer sleeve from the...

  • Page 1138

    Manual transmission 5b-29 12. Remove the main shaft rear bearing assembly from the shaft. 13. Remove the 1st speed gear and bearing. 14. Remove the inner race. 15. Remove the tree-piece 1st speed blocking ring assembly and remaining synchronizer spring. 16. Check and clean all removed parts and repl...

  • Page 1139

    5b-30 manual transmission assembly procedure 1. When assemble the synchronizer, make sure that the hubs and sleeves are matched and the 3 keys are installed properly. Also align blocking rings with keys during installation. Notice before assembly, coat all parts with lubricant. In case of the paper-...

  • Page 1140

    Manual transmission 5b-31 6. Using a hydraulic press and installer, install the 3-4 synchronizer hub onto the main shaft. Notice align the blocking ring with the synchronizer keys while installing the hub..

  • Page 1141: Input Shaft

    5b-32 manual transmission input shaft disassembly procedure 1. Remove the following parts from the input shaft : l main shaft thrust race and bearing. L main shaft pilot bearing rollers (15 rollers). 2. Using a hydraulic press and puller plate, remove the input shaft bearing assembly from the shaft....

  • Page 1142

    Manual transmission 5b-33 assembly procedure 1. Using a hydraulic press and installer, press the input shaft bearing onto the input shaft. 2. Apply grease to the thrust bearing inner roller (15 rollers) and install the main shaft thrust bearing and its race in the rear of the input shaft. 3. Using a...

  • Page 1143: Counter Shaft

    5b-34 manual transmission counter shaft disassembly procedure 1. Using a hydraulic press and special tool, remove the front bearing assembly from the counter shaft. 2. Check and clean all removed parts and replace if necessary. Assembly procedure 1. Using a hydraulic press and installer, press the f...

  • Page 1144: Extension Housing

    Manual transmission 5b-35 extension housing disassembly procedure 1. Remove the vent from the extension housing. 2. Remove the o-ring and steel ring from the rear of the extension housing. 3. Check and clean all removed parts and replace if necessary. Assembly procedure 1. Install the o-ring and ste...

  • Page 1145: Shift Cover

    5b-36 manual transmission shift cover disassembly procedure 1. Using a hammer and a pin punch (3/16) remove the selector arm roll pin. 2. Before removal, note the correct position of the interlock plate and selector arm and remove the shift shaft. 3. Check and clean all removed parts and replace if ...

  • Page 1146

    Manual transmission 5b-37 l install the 1-2 shift fork and its selector plate. L push the shift shaft through the 1-2 shift fork. L place the selector arm and interlock plate in the cover note the position of the interlock plate and selector arm. L push the shift shaft through the 3-4 shift fork..

  • Page 1147

    5b-38 manual transmission l install the 3-4 shift fork and its selector plate. L push the shift shaft through the 3-4 shift fork. L install the roll pin that fixes the selector arm to the shift shaft. 4. Check the shift cover parts for proper assembly as follows : l insert a pin punch (3/16) into th...

  • Page 1148

    Manual transmission 5b-39 l selector arm should be aligned with the 3/4 shift fork selector plate. 5. Lubricate and install the o-ring on the rear of the shift cover..

  • Page 1149: Inspection of Components

    5b-40 manual transmission inspection of components inspection procedure 1. Clean all parts with solvent and dry them with compressed air. Check the following parts for cracks and damaged sealing surfaces. L case l extension housing l shift cover l input bearing retainer l counter shaft rear bearing ...

  • Page 1150

    Manual transmission 5b-41 5. Check the shift mechanism parts as follows : l wear of the shift shaft. L wear of the detent/guide plate and offset lever. L check worn edges on the following parts : - selector arm. - interlock plate. - selector plates for the 1-2 and 3-4 shift forks. - 5-r shift lever ...

  • Page 1151

    5b-42 manual transmission 6. Check the following bearing for excessive war: l crankshaft pilot bushing for the front of the input shaft. L clutch release bearing. L input shaft bearing. L main shaft pilot bearing rollers. L main shaft thrust bearing and its surfaces. L speed gear roller bearing on t...

  • Page 1152

    Manual transmission 5b-43 9. Take apart the three synchronizer assemblies and check : l the 1-2 synchronizer. L the 5th blocking ring. 10. Check the fit between the hub and sleeve of each synchronizer l excessively tight or loose hub-to-sleeve fit. L wear of the cone clutch surfaces of brass blockin...

  • Page 1153

    5b-44 manual transmission 12. Check for gear clash on the synchronizer sleeve teeth or the clutch teeth on the speed gear. 13. Check the synchronizer sleeve and gear clutch tooth for hop-out..

  • Page 1154: Pre-Installation Checks

    Manual transmission 5b-45 pre-installation checks checking procedure 1. Separate the clutch release fork from the pivot and remove the pivot from the clutch housing. 2. Check the pivot. Fork and release bearing. 3. Check the pressure plate spring. Notice inspect each parts and replace the excessivel...

  • Page 1155

    5b-46 manual transmission l check the housing face alignment. - place the dial indicator on the housing face. - by rotating the crankshaft one revolution, record the dial indicator reading. Notice if the reading is greater than 0.010 inch, insert the shim between the engine and clutch housing and ad...

  • Page 1156: Section 5C

    Type clutch pedal clutch disc clutch master cylinder clutch release cylinder clutch fluid description hydraulic suspended 158 mm 5 - 10 mm single dry diaphragm 9.85 - 10.2 mm 9.2 mm 19.8 mm f 15.87 mm 14.0 mm f 17.46 mm sae j1703 / dot3 section 5c clutch table of contents specifications . . . . . . ...

  • Page 1157

    5c-2 clutch fastener tightening specifications application clutch cover bolt clutch housing bolt clutch release cylinder master cylinder nut clutch tube nut pedal push rod nut pedal mounting n · · · · · m 37 47 30 - 40 8 - 18 15 - 18 16 - 22 8 - 18 21 - 25 bracket bolt stopper bolt.

  • Page 1158: Special Tools

    Clutch 5c-3 special tools special tools table 602 589 00 40 00 engine lock 661 589 00 15 00 centering pin.

  • Page 1159: Diagnosis

    5c-4 clutch checks oily facing hard or faulty facing burnt torsion spring faulty pressure plate bent clutch diaphragm spring hard or bent flywheel engine mounts loose or burnt lever action adjust pedal freeplay repair release cylinder repair or replace repair as necessary replace checks excessive cl...

  • Page 1160: Difficult Pedal Operation

    Clutch 5c-5 checks poor lubrication on clutch cable poor lubrication on pedal shaft poor lubrication on clutch pedal not using the clutch after disengagement when disengaging difficult pedal operation action lubricate or replace lubricate or replace repair clutch noisy checks action adjust replace r...

  • Page 1161: Component Locator

    5c-6 clutch component locator clutch assembly 1 clutch disc 2 clutch cover 3 clutch housing 4 release bearing 5 release fork pivot 6 release cylinder 7 release fork boot 8 bolt 9 release fork 10 bolt 11 spring lock washer 12 transmission input spline 13 release bearing contacting surface 14 contacti...

  • Page 1162: Pedal and Master Cylinder

    Clutch 5c-7 pedal and master cylinder 1 clutch pedal 2 clutch master cylinder 3 clutch tube 4 clutch oil chamber 5 clutch tube 6 clutch hose 7 clutch release cylinder.

  • Page 1163: Maintenance and Repair

    5c-8 clutch maintenance and repair on-vehicle service bleeding of clutch system bleeding procedure notice keep the fluid level over ‘max’ in reservoir during bleeding operation. Do not let fluid contact a painted surface. 1. Remove the air bolt cap of the release cylinder. Connect a vinyl tube to th...

  • Page 1164: Clutch Disc

    Clutch 5c-9 clutch disc preceding work : removal of the transmission 1 clutch disc 2 clutch cover assembly 3 release bearing 4 clutch housing tools 602 589 00 40 00 engine lock 661 589 00 15 00 centering pin 5 washer 6 bolt ........................................................... 23 nm 7 washer 8...

  • Page 1165

    5c-10 clutch removal & installation procedure 1. Remove the starter motor. Install the special tool to the flywheel through the starter motor mounting holes. Tightening torque 47 nm engine lock 602 589 00 40 00 2. Unscren the release cylinder mounting bolts and remove the release cylinder. Installat...

  • Page 1166

    Clutch 5c-11 5. Unscrew the bolts and remove the clutch cover, pressure plate and clutch disc. Notice be careful not to drop the pressure plate and clutch disc. Installation notice tightening torque 21 - 27 nm 6. Installation should follow the removal procedure in the reverse order. Notice l before ...

  • Page 1167

    5c-12 clutch inspection procedure 1. Clutch cover l check the diaphragm spring tip for wear and height unevenness. L check the pressure plate surface for wear, crack and discoloration. L check the strap plate rivet for looseness and replace the clutch cover if loosened. Unevenness limit 0.8 mm 2. Cl...

  • Page 1168: Master Cylinder

    Clutch 5c-13 master cylinder 1 snap pin 2 clevis pin 3 clevis 4 lock nut 5 flange nut ........................................... 30-40 nm 6 push rod 7 cylinder body 8 oil pipe ................................................ 15-18 nm 9 clamp 10 reservoir 11 spring 12 piston assembly 13 boot 14 plat...

  • Page 1169

    5c-14 clutch removal & installation procedure 1. Draw out the fluid. 2. Pull out the snap pin and clevis pin from the clutch pedal connection. 3. Remove the clutch tube. Installation notice tightening torque 15 - 18 nm notice be careful not the fluid contact a painted surface. 4. Remove the master c...

  • Page 1170: Clutch Pedal

    Clutch 5c-15 clutch pedal 1 snap pin ................................................ Replace 2 clevis pin ...................................... Apply grease 3 master cylinder push rod 4 gasket 5 nut ....................................................... 16-22 nm 6 spring washer 7 bolt ..............

  • Page 1171

    5c-16 clutch inspection procedure 1. Pedal stroke (a). Notice to adjust the pedal stroke, loosen the lock nut (h) of the interlock switch (g) and turn the two lock auto until the stroke is correct. Max. Stroke 158 mm 2. Pedal height (b). Notice to adjust the pedal height, loosen the lock nut (c) of ...

  • Page 1172: Clutch Oil Chamber

    Clutch 5c-17 clutch oil chamber 1 clutch master cylinder 2 hydraulic tube 3 bolt 4 clutch oil chamber 5 hydraulic tube 6 clutch release cylinder notice l installation should follow the removal procedure in the reverse order. L when installing, perform the bleeding procedures from chamber cylinder an...

  • Page 1173: Section 5D1

    Model type gear ratio oil manufacturer weight part-time 4408 (e) e.S.O.F. Type 1 : 1 2.48 : 1 atf s-3, s-4 or dexron ii, iii 1.2 l check : every 15,000 km replace : every 50,000 km borg warner 30 kg section 5d1 transfer case (part time 4408) table of contents specifications general specifications ca...

  • Page 1174

    5d1-2 transfer case (part time 4408) schematic and routing diagram part time transfer case - 4408.

  • Page 1175: Diagnosis

    Transfer case (part time 4408) 5d1-3 cannot front wheel drive when shifted 4h,4l diagnosis electric shift problems action overhaul and check, replace if necessary. Overhaul and check for wear and damage. Replace if necessary. Check sliding parts, replace if necessary. Checks faulty or damaged tccu, ...

  • Page 1176: Self-Diagnosis

    5d1-4 transfer case (part time 4408) self-diagnosis system description 1. Tccu detects transfer case system malfunctions and indicates malfunctioning part(s) through flashing 4h,4l indicator lights. Using a service connector, connect it to the diagnosis box in the engine room and read the flashing o...

  • Page 1177

    Transfer case (part time 4408) 5d1-5 defective code reading 1. Position the ignition switch to ‘off’ 2. Using a service connector, connect the no.2 pin ( lgnition ) and no.6 pin (tccu) of the diagnosis socket in the engine room. 3. Position the ignition switch to 'on'. 4. Read the flashing ‘4wd chec...

  • Page 1178

    5d1-6 transfer case (part time 4408) diagnostic table connect a service connector. If turn the ignition switch ‘on’ ‘4wd check’ indicator light will come on for 0.6 second and turn off for 3 seconds and then display a defective code 3 times continuously. No. Defective code malfunctioning part 1 2 3 ...

  • Page 1179

    Transfer case (part time 4408) 5d1-7 no. Defective code malfunctioning part 6 7 selector switch motor positon sensor 4wd check light on off defective code 4wd check light on off defective code.

  • Page 1180: Self-Diagnosis Test

    5d1-8 transfer case (part time 4408) self-diagnosis test test procedure 1. Connect the scanner harness connector to the engine compartment diagnosis socket. 2. Turn the ignition switch to "on" position. 3. Select "electronic control vehicle diagnosis" from the function selection display and press "e...

  • Page 1181: Diagnostic Diagram

    Transfer case (part time 4408) 5d1-9 diagnostic diagram.

  • Page 1182: Maintenance and Repair

    5d1-10 transfer case (part time 4408) maintenance and repair on-vehicle service maintenance of transfer case lubricant oil level check l clean the oil level plug and surrounding area. L remove the oil level plug and check whether oil is drip out or not. L tighten the oil level plug. Oil change l cle...

  • Page 1183: Transfer Case

    Transfer case (part time 4408) 5d1-11 transfer case 1 rear companion flange 2 cover 3 front companion flange 4 breather plug 5 case 6 input shaft 7 mounting bolt ..................................... 38-52 nm 8 transmission adapter 9 bolt ..................................................... 81-59 n...

  • Page 1184

    5d1-12 transfer case (part time 4408) removal & installation procedure 1. Disconnect the negative terminal from the battery. 2. Lift up the vehicle and fix it safely. 3. Remove the drain plug and drain the oil. Reinstall the drain plug. * if planar damper is installed, unscrew 4 bolts and remove the...

  • Page 1185

    Transfer case (part time 4408) 5d1-13 7. Remove the center mounting nuts and end sides mounting bolts of the cross member and then remove the cross member. Installation notice tightening torque(1) tightening torque(2) 21 - 35 nm 62 - 93 nm 8. Remove the transfer case by removing the bolts attaching ...

  • Page 1186: Unit Repair

    5d1-14 transfer case (part time 4408) unit repair transfer case preceding work : removal of the transfer case.

  • Page 1187

    Transfer case (part time 4408) 5d1-15 1 nut 2 spring washer 3 oil seal 4 companion flange 5 snap ring 6 torsional damper 7 pipe plug 8 bolt 9 bolt 10 speed sensor and harness bracket 11 speed sensor assembly 12 speed sensor 13 o-ring 14 locking clip 15 connector 16 motor assembly 17 oil seal 18 bear...

  • Page 1188

    5d1-16 transfer case (part time 4408) disassembly procedure 1. Holding the companion flange, remove the nut and washer and then remove the companion flange and oil seal. 2. Remove the 2 plugs from the cover. 1 nut 2 washer 3 oil seal 4 companion flange 5 plug 25 cover 6 bolt 7 washer 8 bolt 9 sensor...

  • Page 1189

    Transfer case (part time 4408) 5d1-17 1. Remove the 9 bolts, wiring harness clip and identification tag. Notice identification tag has information required for ordering replacement parts, so be careful not to lose it. 2. Using a ‘-‘ driver, pry and disconnect the sealant bond of the cover and requir...

  • Page 1190

    5d1-18 transfer case (part time 4408) 1. Remove the retaining ring and clutch housing from the shift collar hub. 2. Remove the shift collar hub from the output shaft. 3. Separate the 2wd - 4wd lock-up assembly and lock-up fork from the output shaft and remove the rail shaft. 4. To remove the 2wd - 4...

  • Page 1191

    Transfer case (part time 4408) 5d1-19 1. Holding the companion flange, remove the nut and washer and then remove the companion flange and oil seal. 2. Remove the output shaft. 65 nut 66 washer 67 oil seal 70 companion flange 71 output shaft (front) 111 case 57 reduction hub 58 shift fork facing 59 r...

  • Page 1192

    5d1-20 transfer case (part time 4408) 72 breather 73 bolt 74 adapter assembly 75 snap ring 76 oil seal 77 spiral pin 78 front adapter 79 retaining ring 80 bearing 81 input shaft assembly 1. Remove the breather. 2. After removing 6 bolts, remove the front adopter by separating the adapter sealer bond...

  • Page 1193

    Transfer case (part time 4408) 5d1-21 1. Remove the electric shift cam parts from the case assembly. 2. Separate the electric shift cam from the shift shaft. 3. Holding the shift shaft in a vise, remove the torsion spring and spacer from the shift shaft using a screw driver. 100 electric shift cam 1...

  • Page 1194

    5d1-22 transfer case (part time 4408) cleaning procedure notice before cleaning, check the magnet for the presence of metal particles which indicate internal chipping of the transfer case. 1. Using cleaning solvent, clean the residual oil and dirt deposits. Notice during cleaning, be careful not to ...

  • Page 1195

    Transfer case (part time 4408) 5d1-23 3. Specific inspection l referring to normal gear tooth face, specifically inspect the uneven wear and chips of gear tooth. Replace or repair if necessary. 4. Inspection of contact patterns description normal abnormal normal wear end face wear traveling face wea...

  • Page 1196

    5d1-24 transfer case (part time 4408) description repair description repair corner chip at drive face edge chip at drive face corner chip at coast face side edge chip at drive face chip within contact pattern chip completely through tooth.

  • Page 1197

    Transfer case (part time 4408) 5d1-25 electric shift cam parts 1. Insert the spacer into torsion spring. 2. Insert the end of the shift shaft into the spacer smoothly. 100 electric shift cam 101 torsion spring 102 spacer 103 shift shaft assembly procedure general information 1. Use special tools dur...

  • Page 1198

    5d1-26 transfer case (part time 4408) 101 torsion spring 102 spacer 103 shift shaft 3. Slide the torsion spring and spacer to the left of the shift shaft and position the end of the first spring to fix on the drive tang. 4. Push the end of the second spring to right and fix it on the drive tang. 101...

  • Page 1199

    Transfer case (part time 4408) 5d1-27 adapter, input shaft and carrier 72 breather 73 bolt 74 adapter assembly 75 snap ring 76 oil seal 77 spiral pin 78 front adapter 79 retaining ring 80 bearing 81 input shaft assembly 1. Place the planet carrier assembly on work bench to be the retaining ring moun...

  • Page 1200

    5d1-28 transfer case (part time 4408) 6. Install the planet carrier assembly onto the input shaft and install the thrust washer. Press the bearing over input shaft. 7. After pressing the bearing, install the retaining ring. 8. Press the pin into the front adapter. 9. Slowly press the oil seal into t...

  • Page 1201

    Transfer case (part time 4408) 5d1-29 front output shaft 1. Position the output shaft in transfer case and install the companion flange assembly, oil seal, washer and nut. 2. Holding the companion flange, tighten the nut. 65 nut 66 washer 67 oil seal 70 companion flange 71 output shaft (front) 111 c...

  • Page 1202

    5d1-30 transfer case (part time 4408) oil pump 1. Install the pump front cover to be the ‘top’ mark down and turn the cover to be the ‘top’ mark up when installed in vehicle. 2. Install the 2 pump pins and spring to the output shaft. Notice flat surface of the pins must point out and align the cente...

  • Page 1203

    Transfer case (part time 4408) 5d1-31 lockup shift 1. Install the lockup hub and return spring to the lockup collar and insert the snap ring. 2. Install the rail shaft through reduction shift fork assembly previously installed and into the blind hole in case. 3. Engage the lockup fork into the 2wd/4...

  • Page 1204

    5d1-32 transfer case (part time 4408) cover 1. Position the cover to be the open end up on the work table. 2. Position the end of needle bearing to be identification mark up and press into the cover until upper end of bearing is 40.47 - 40.97mm below cover face that contacts with transfer case. 3. P...

  • Page 1205

    Transfer case (part time 4408) 5d1-33 4. Install the cover onto the transfer case as follows : l align the cover bores with transfer case pins. L align the cover bearings with output shafts. L align the cover blind hole with rail shaft and make sure that return spring is not cocked. 29 return spring...

  • Page 1206

    5d1-34 transfer case (part time 4408) external electric shift 1. Align the motor with shift shaft and position the motor assembly onto the cover. 2. Install the motor to the shift shaft and contact cover androtate the motor clockwise direction to check correctengagement. 6 bolt 7 washer 8 bolt 9 sen...

  • Page 1207

    Transfer case (part time 4408) 5d1-35 companion flange 1. Install the 2 plugs to the cover. 2. Install the companion flange, oil seal and washer. 3. Holding the companion flange, tighten the nut. 1 nut 2 washer 3 oil seal 4 companion flange 5 plug 25 cover notice apply loctite 262 to nut before inst...

  • Page 1208: Transfer Case Control Unit

    5d1-36 transfer case (part time 4408) transfer case control unit (tccu) system description tccu is located under the front left handed seat and permits the vehicle to shift from two-wheel drive to four-wheel drive (and back shift) according to driver’s switch operation during driving (for the shifti...

  • Page 1209

    Transfer case (part time 4408) 5d1-37 inspection and repair 1. 4h and 4l indicator light inspection l when turn the ignition switch to "on" position, 4h and 4l indicator light will turn on for 0.6 second and will turn off immediately. Notice if indicator light does not turn on, check bulb, wiring ha...

  • Page 1210: Section 5D2

    Section 5d2 transfer case (tod) specifications . . . . . . . . . . . . . . . . . . . . . . . 5d2-1 general specifications . . . . . . . . . . . . . . . . . 5d2-1 schematic and routing diagrams . . . . . . . 5d2-2 tod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5d2-2 t.C.C.U . . . ....

  • Page 1211: Tod

    5d2-2 transfer case (tod) schematic and routing diagrams tod.

  • Page 1212: .C.C.U

    Transfer case (tod) 5d2-3 t .C.C.U.

  • Page 1213: Function Description

    5d2-4 transfer case (tod) function description l tod system select mode (4h and 4l) 4h is the mode when drive normally of which gear ratio is 1:1 and 4l mode distributes power to front and rear wheels 50:50 of which gear ratio is 2.48:1. L tod system function (select 4h mode) tod system controls clu...

  • Page 1214

    Transfer case (tod) 5d2-5 definitions rear speed sensor a hall effect speed sensor which produces a square wave. 0-5vdc signal in response to a rotating 30 tooth wheel coupled to the rear propshaft inside the transfer case. Each rotation of the rear propshaft will result in 30 speed sensor pulse. Fr...

  • Page 1215

    5d2-6 transfer case (tod) input/output diagram tod control unit and main wiring harness is linked by 30 pin connector. Each pin joins with switche and actuator whose details refer to the below diagram. Battery power ignition on/off position encoder 1 position encoder 2 position encoder 3 position en...

  • Page 1216

    Transfer case (tod) 5d2-7 1. K-line : communication line for coding and diagnosis with scanner. Classification of pin no. Classification pin no. Pin name description power supply 17,18 ground tod control unit ground 4,19 battery tod control unit battery supply : (fuse no 13,20a) 5 ignition ignition ...

  • Page 1217

    5d2-8 transfer case (tod) position code 1/2/3/4 1110 1010 0010 0000 1110 initial operation of tod control unit when ignition “on”, “4l” and "4wd check" lamps illuminates for 0.6second to check bulb in instrument panel, then perform diagnosis of system. Position encoder the position encoder is used b...

  • Page 1218

    Transfer case (tod) 5d2-9 4h/4l switch input 4h 4h 4h 4h 4h 4h 4h 4h 4h 4l 4l 4l 4l 4l 4l 4l 4l 4l position sensor interpretation 1. When the module powers up, it will read the position sensor and the 4h/4l switch input and respond to the possible codes as follows 2. A command to shift will only be ...

  • Page 1219

    5d2-10 transfer case (tod) electric shift system operation the electric shift system is responsible for changing the transfer case gear ratio by controlling the electric shift motor. The tccu monitors the 4h/4l switch, neutral switch, speed sensors, position encoder, and ignition switch. A range cha...

  • Page 1220

    Transfer case (tod) 5d2-11 4. Electric shift default mode if the motor fails to reach its destination, the tccu will attempt the following (in order): a. The tccu will wait 3 seconds then attempt the shift again. B. If the second attempt to reach the destination fails the tccu will wait 3 seconds th...

  • Page 1221: Tod Control Unit

    5d2-12 transfer case (tod) pin 1 2 3 4 5 6 7 8 function motor hi-lo motor lo-hi emc battery (+) ignition position return diagnosis display - pin 9 10 11 12 13 14 15 16 function hi / lo switch position 2 front speed tps supply (diesel) speed/tps return motor hi-lo motor lo-hi speed reference pin 17 1...

  • Page 1222

    Transfer case (tod) 5d2-13 speed sensor/clutch coil and motor connector speed senso /clutch coil and shift motor connector locate upper backside transfer case (upper part of shift motor). - shift motor connector : black - speed sensor and clutch coil connector : white shift mtor connector speed sens...

  • Page 1223: Control Unit Diagram

    5d2-14 transfer case (tod) motor hi-lo(clockwise) motor lo-hi(counterclockwise) pin 13 control unit diagram tod control unit 14.

  • Page 1224: Diagnosis

    Transfer case (tod) 5d2-15 diagnosis while the tccu is active it periodically monitors its inputs and outputs. If a fault is detected the “4wd check” lamp is illuminated and a fault code is stored in the tccu memory. When requested, fault codes are downloaded to a diagnostic connector (k-line) seria...

  • Page 1225

    5d2-16 transfer case (tod) g. If the shift motor/position encoder assembly failure (other than a motor failure which occurs when the motor is energized) recovers continuously for one second the tccu will function normally. The “4wd check” lamp is turned off but the fault code will remain in memory. ...

  • Page 1226: Diagnostic Trouble Codes

    Transfer case (tod) 5d2-17 classification tccu emc speed sensor shift motor position encoder diagnostic trouble codes (dtc’s) 1. Diagnostic trouble code retention the first time a fault is detected a dtc is stored in the tccu’s non-volatile memory. This dtc will remain in memory until the tccu is in...

  • Page 1227: Coding

    5d2-18 transfer case (tod) coding coding tool scanner connection of coding tool construct scanner into diagnosis connector (20 pins) near fuse box in engine room as below figure. 1 diagnosis connector 2 scanner notice coding ; an input activity of data for the proper performance by matching specific...

  • Page 1228

    Transfer case (tod) 5d2-19 classification engine type transmission/vehicle type axle ratio tire size coding required 1. Replacement of tod control unit. 2. Adjustment by input error. 3. Change of tire specification. Items gasoline engine (e32) 661 diesel engine 661la diesel turbo engine 662 diesel e...

  • Page 1229: Code

    5d2-20 transfer case (tod) eliminate the memorized fault code when diagnose by scanner, it is required that you make adequate service on defects against all fault codes. And then you should delete the memorized fault codes in tod control unit using scanner as follows; 1. Connect scanner with diagnos...

  • Page 1230: Diagnosis

    Transfer case (tod) 5d2-21 diagnosis malfunction interior tod control unit ; fault code 1714 l phenomenon 1. When ignition “on”, “4wd check” lamp illuminates continuously. 2. On diagnosis by scan-100, it displays fault code “1714”. L cause ; error of eeprom checksum in tod control unit test stage / ...

  • Page 1231

    5d2-22 transfer case (tod) check function of tod control unit. 1. Even a1, a2, a3 and a4 test, if you could not find defect, it is required to replace tod control unit on basis of below phenomena. A. ”4wd check” lamp illuminates continuously when ignition “on”. B. Shift is not possible even 4h/4l sw...

  • Page 1232

    Transfer case (tod) 5d2-23 error of signal in engine throttle position ; fault code 1715, 1716 l phenomenon 1. Upon diagnosis by scan-100, it display on 1715, 1716 codes. L cause 1. Bad communication line between e/g ecu and can. 2. Defect of tod control unit. 3. Defect of e/g ecu. Check connection ...

  • Page 1233

    5d2-24 transfer case (tod) yes no b4 b5 yes no b6 4.75-5.25vdc yes no b7 0.3-0.9vdc 4.6-4.9vdc yes no 4.6-4.9vdc 0.3-0.9vdc yes no test stage / contents result stage test contents and procedure specified value /yes/no countermeasure check can communication line by diagnosis of e/g ecu. 1. Diagnose e...

  • Page 1234

    Transfer case (tod) 5d2-25 error in electro - magnetic clutch : fault code “1721”, “1722” l phenomenon 1. Upon diagnosis by scan-100, it displays on fault codes “1721,1722”. L cause 1. Defect in electro - magnetic clutch 2. Defect in connector or wiring - open or short from emc to the supply : 1721 ...

  • Page 1235

    5d2-26 transfer case (tod) 0vdc 11 - 15vdc yes no 2.5 w yes no c3 test stage / contents result stage test contents and procedure specified value /yes/no countermeasure check resistance of electro-magnetic clutch. 1. Disconnect 30 pin connector from tod control unit. 2. Measure resistance between pin...

  • Page 1236

    Transfer case (tod) 5d2-27 defect in speed sensor : fault code 1731, 1732, 1733, 1734, 1735,1736 l phenomenon 1. Upon diagnosis by scanner, it displays on fault code 1731, 1732, 1733, 1734, 1735 and 1736. 2. “4wd check” lamp illuminates continuously when ignition “on”. L cause 1. Defect of speed sen...

  • Page 1237

    5d2-28 transfer case (tod) yes no d4 test stage / contents result stage test contents and procedure specified value /yes/no countermeasure check output voltage of front and rear speed sensor. 1. Upon driving mode 2. Measure output voltage of front and rear speed sensor by multi-tester. Check voltage...

  • Page 1238

    Transfer case (tod) 5d2-29 shift motor malfunction : fault code ® 1741, 1742, 1743 l phenomenon 1. When change the 4h/4l switch from 4h to 4l, ‘4l’ indicator lamp turn off after blinking for a time and then ‘4wd check’ indicator lamp turn on. 2. Fault codes display by diagnosis of scan-100 : 1741, 1...

  • Page 1239

    5d2-30 transfer case (tod) yes no yes no yes no e3 yes no e4 yes no e5 test stage / contents result stage test contents and procedure specified value /yes/no countermeasure check the wiring of shift motor whether it is shorted or not. 1. Turn off the ignition switch. 2. Detach the 30pin connector fr...

  • Page 1240

    Transfer case (tod) 5d2-31 position incoder and position 1,2,3,4 malfunction :fault code®1750,1751,1752,1753, 1754 l phenomenon the ‘4wd check’ lamp can not go out when the ignition switch positioned to ‘on’. The fault code display 1750, 1751, 1752, 1753, 1754 by diagnosis of scan-100. L cause the p...

  • Page 1241

    5d2-32 transfer case (tod) l phenomenon “4l” lamp on cluster continuous blinking and can not go off, when operated 4h/4l switch as 4l« 4h. L cause shifting failure. 1. Stop the vehicle 2. Return the 4h/4l switch to first position (before operating). - the blinking of 4l indicator lamp is stopped. No...

  • Page 1242: Maintenance and Repair

    Transfer case (tod) 5d2-33 9 - 16 vdc 6 - 16 vdc 2 ma 1 a 7 a 20 a removal & installation procedure 1. Turn the ignition switch to "off" position. 2. Remove 30 pin connector from tod control unit. 3. Unscrew 2 bolts (1). Installation notice 1 bolt (m6 x 16, 2pieces) ................ 9-11 nm 2 tod co...

  • Page 1243: Transfer Case (Tod)

    5d2-34 transfer case (tod) transfer case (tod) 1 transmission 2 tod transfer case 3 extension housing 4 bolt ....................................................... 35-60nm 5 front propeller shaft 6 bolt ....................................................... 81-89nm 7 rear propeller shaft 8 bolt .....

  • Page 1244

    Transfer case (tod) 5d2-35 removal & installation procedure 1. Disconnect (-) cable from battery. 2. Lift on vehicle and make sure on safety. Notice be careful for catalytic converter due to high temperature after driving or engine running. 3. Prepare a vessel to drain transfer case and manual trans...

  • Page 1245

    5d2-36 transfer case (tod) 11. Unscrew 4 units of m12 bolts from case flange then disconnect front propeller shaft from transfer case. Installation notice tightening torque 81 - 89 nm 12. Unscrew 4 units of m12 bolts from case flange then disconnect rear propeller shaft from transfer case. Installat...

  • Page 1246

    Transfer case (tod) 5d2-37 replacement of shift motor 1. Disconnect (-) cable from battery. 2. Disconnect shift motor/clutch coil connector (black pin7) upper backside. 3. Unscrew 3 units of shift motor mounting bolts (m10). 4. Unscrew 1unit of bracket mounting bolt (m10). Installation notice tighte...

  • Page 1247: Speed Sensor In Front and

    5d2-38 transfer case (tod) speed sensor in front and rear propeller shaft replacement procedure 1. Disconnect (-) cable from battery. 2. Detach shift motor assembly. 3. Disconnect front and rear speed sensor connector (white 3 pin) upper backside transfer case. 4. Disconnect speed sensor connect fro...

  • Page 1248

    Transfer case (tod) 5d2-39 10. Disconnect pin and wire from speed sensor connector by pulling sticking long-nose plier into “l” pin in connector. 11. On the same way, disconnect pin and wire “m” and “n” from connector. Notice do not touch the wires related with emc. 12. Prepare new speed sensor. 13....

  • Page 1249: Replacement of Oil

    5d2-40 transfer case (tod) replacement of oil oil specification specified oil level specification standard capacity service a.T.F s-3, s-4 or dexron ii, iii 1.4 litre inspection every 15,000km, replacement every 50,000km = oil replacement 1. Lift on vehicle then make sure on safety. 2. Prepare a ves...

  • Page 1250: Unit Repair

    Transfer case (tod) 5d2-41 unit repair transfer case transfer case, diassembled view.

  • Page 1251

    5d2-42 transfer case (tod) 1 bearing 2 bushing 3 carrier assembly 4 sun gear 5 thrust plate 6 input shaft 7 output shaft thrust washer 8 bearing 9 retaining ring 10 snap ring 11 high-low collar 12 rear output shaft 13 oil strainer 14 coupling hose 15 hose clamp 16 pump assembly 17 thrust washer 18 s...

  • Page 1252

    Transfer case (tod) 5d2-43 disassembly procedure 1. Disconnect transfer case from vehicle 2. Using a 30mm thin-wall socket, first remove the rear output nut, output shaft yoke washer, oil seal then the case flange. Installation notice 27 nut 28 washer 30 case flange tightening torque 137 - 196 nm 3....

  • Page 1253

    5d2-44 transfer case (tod) 9. Remove the bolts that retain the front case to the rear case. Make sure that the front case is facing downward so that the rear cover is facing upwards. Pry on the bosses and separate the front case from the rear case. Remove all traces of gasket sealant from the mating...

  • Page 1254

    Transfer case (tod) 5d2-45 19 clutch pack assembly 22 snap ring 23 wave washer 24 apply cam 14. Remove the chain, driven sprocket and drive sprocket as an assembly. 15. Remove thrust washer from output shaft. 16. Remove the magnet from the slot in the front of the case bottom. Remove the output shaf...

  • Page 1255

    5d2-46 transfer case (tod) 23. Remove the internal snap ring from the planetary carrier and separate the front planet from the input shaft. 24. Remove the external snap ring from the input shaft. Place the input shaft in a vise and remove the bearing. Remove the thrust washer, thrust plate and the s...

  • Page 1256

    Transfer case (tod) 5d2-47 assembly procedure assembly before assembly, lubricate all parts with automatic transmission fluid or equivalent. 1. If removed, drive the bearing into the front output case bore. Drive the bearing in staight, making sure it is not cocked in the bore. Install the internal ...

  • Page 1257

    5d2-48 transfer case (tod) 6. Install the front planet to the sun gear and input shaft. Install the internal snap ring to the planetary carrier. 7. Place the tanged snap ring in the case. Expand snap ring with snap ring pliers and install planetary carrier assembly. Check installation by holding the...

  • Page 1258

    Transfer case (tod) 5d2-49 12. Install the output shaft and oil pump in the input shaft. Make sure that the internal splines of the ouput shaft engage the internal splines of the high-low shift collar. Make sure that the oil pump retainer arm and oil filter leg are in the groove and slot of the fron...

  • Page 1259

    5d2-50 transfer case (tod) 19. Install wave spring, insulator washer and armature. (three offset slots must align with housing to be installed) notice three slots on the thrust washer must be aligned with the three tabs on the clutch pack housing. 20. Install apply cam onto the rear output shaft, in...

  • Page 1260

    Transfer case (tod) 5d2-51 25. Install the pin on the tang end of the helical cam into the hole in the front case. Position the torsion spring tangs so that they are pointing toward the top side of the transfer case and just touching the high-low shift fork. Caution do not bend the helical cam durin...

  • Page 1261

    5d2-52 transfer case (tod) 32. Install shift shaft oil seal if it is not installed. 33. Using pliers equipped with soft jaws, rotate the triangular shaft so it is aligned with the triangular slot in the transfer case shift motor. If triangular shaft will not rotate, rotate the rear output shaft. 34....

  • Page 1262

    Transfer case (tod) 5d2-53 40. Install the rear case flange on the output shaft. Install the rubber seal, output shaft yoke washer and nut. Tighten the nut. Tightening torque 137 - 196 nm 41. Install the drainplug and tighten. 42. Fill the transfer case with 1.4 liters of automatic transmission flui...

  • Page 1263: Section 6A

    Application steering wheel steering gear box oil pump steering column minmum turning radius oil section 6a power steering system table of contents specifications . . . . . . . . . . . . . . . . . . . . . . . . 6a-1 general specifications . . . . . . . . . . . . . . . . . . 6a-1 fastener tightening s...

  • Page 1264: Diagnosis

    6a-2 power steering system checks damaged or binding steering ball joint improper preload of steering pinion damaged wheel or tire faulty suspension system checks worn steering gear worn or damaged steering ball joint loosened steering gearbox bolts checks damaged steering linkage damaged wheel and ...

  • Page 1265: Steering Wheel Shimmy

    Power steering system 6a-3 checks loosened steering gearbox mounting bolt faulty steering gear steering column linterference loosened steering linkage damaged or loosened oil pump drive belt loosened oil pump bracket loosened oil pump mounting bolt air-in system faulty oil pump checks damaged steeri...

  • Page 1266: Component Locator

    6a-4 power steering system 1 steering wheel 2 steering column shaft 3 steering gear box 4 end ass'y - tie rod component locator steering system 5 lower shaft 6 oil reservoir 7 oil pump 8 steering knuckle.

  • Page 1267: Maintenance and Repair

    Power steering system 6a-5 maintenance and repair on-vehicle service inspection steering wheel freeplay inspection procedure 1. Start the engine and set the wheels in straight ahead position. 2. Slightly move the steering wheel to the left and right and measure steering wheel free play when the fron...

  • Page 1268: Oil Pump Pressure Check

    6a-6 power steering system oil pump pressure check oil pump pressure check 1. Disconnect the pressure hose from the oil pump connect a pressure gauge between the oil pump and pressure hose 2. Bleed the system . Start the engine and turn the steering wheel form lock several times until oil temperatur...

  • Page 1269: Steering Gear Box

    Power steering system 6a-7 steering gear box 1 bolt ....................................................... 30-40nm 2 spring washer 3 lower shaft 4 pressure hose ...................................... 12-18nm 5 return pipe .......................................... 12-18nm 6 cotter pin 7 slotted nut...

  • Page 1270

    6a-8 power steering system tightening torque 35 - 45 nm removal & installation procedure 1. Remove the cotter pin and nut and separate the steering gear box tie rod from the steering knuckle arm using the puller. Installation notice 2. Remove the bolt and separate the lower sha from the steering gea...

  • Page 1271

    Power steering system 6a-9 inspection procedure 1. Check the distance of tie rod and toe-in data and, if necessary, adjust as below. 2. Adjustment l unscrew the adjuster nut (1) and adjust the distance by turning the rod (2) counterclockwise. Distance of tie rod 152mm toe-in 0 - 4 mm tightening torq...

  • Page 1272: Section 6E

    Section 6e steering wheel and column table of contents specification . . . . . . . . . . . . . . . . . . . . . . . . 6e-1 fastener tightening specifications . . . . . . . . . 6e-1 maintenance and repair . . . . . . . . . . . . . . . 6e-2 specifications fastener tightening specifications application ...

  • Page 1273: Maintenance and Repair

    6e-2 steering wheel and column maintenance and repair on-vehicle service steering column 1 horn pad 2 nut ....................................................... 50-80 nm 3 washer 4 steering wheel 5 combination switch assembly 6 combination switch lower cover 7 combination switch upper cover 8 bolt ...

  • Page 1274

    Steering wheel and column 6e-3 removal & installation procedure 1. Remove the horn pad from the steering wheel and disconnect the connectors . 2. Place an alignment marks on the column shaft end and fixing nut and then remove the fixing nut. Installation notice 3. Remove the steering wheel. 4. Remov...

  • Page 1275

    6e-4 steering wheel and column 6. Disconnect each connectors. 7. Remove the vacuum hose from the ignition switch(diesel only) . 9. Remove the lower shaft by removing the bolt of the steering column shaft. Installation notice tightening torque 9 - 14 nm 8. Remove the combination switch assembly. 10. ...

  • Page 1276

    Steering wheel and column 6e-5 tightening torque 30 - 40 nm 11. Remove the steering column upper mounting bolt and pull out steering column assembly. Installation notice 12. Installation is reverse order of the removal..

  • Page 1277: Section 7B/c

    Section 7b/c manual control / semiauto temperature control heating, ventilation and air conditioning system caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Dis...

  • Page 1278: Condenser

    7b/c-2 manual & semiauto-hvac application type capacity condenser fan motor output description parallel type (multi flow condenser) 11,000 kcal/h 160w condenser application desiccant type capacity description xh - 9 (30g) aluminum type 240cc receiver drier application high low description off: 27±2k...

  • Page 1279: Evaporator

    Manual & semiauto-hvac 7b/c-3 application type expansion valve resistance thermo amp description tank laminated uniform external pressure type (1.5 rt) 4 stage (coil resistance) sensor type off : 2±0.5°c, diff : 2±0.5°c evaporator application heater core type heating capacity heater core size (lxwxt...

  • Page 1280: Diagnosis

    7b/c-4 manual & semiauto-hvac diagnosis m.

  • Page 1281

    Manual & semiauto-hvac 7b/c-5 action clean oily plate using cleaning agent. Charge battery or check for cause. Check wire continuity check a/c switch and fan switch for continuity and ground. Defectives in fan motor circuit fan motor does not run checks blown fuse battery voltage is low faulty wirin...

  • Page 1282: Component Locator

    7b/c-6 manual & semiauto-hvac component locator ventilation.

  • Page 1283

    Manual & semiauto-hvac 7b/c-7 switch door vent door foot door def door intake door air mix door air flow mode switch vent a c d recirculation switch temperature control lever [manual] [semi auto] - - - - b/l b b d foot c a d d/f c b b def c c a rec fre - - a b c indi. On - - - a indi. Off - - - b.

  • Page 1284: Air Conditioner System

    7b/c-8 manual & semiauto-hvac air conditioner system diesel engine 1 compressor 2 high pressure hose 3 condenser fan 4 condenser 5 liquid pipe (a) 6 receiver drier 7 liquid (b) 8 evaporator assembly 9 low pressure hose 10 water inlet hose 11 water outlet hose 12 control assembly 13 heater unit ampli...

  • Page 1285: Gasoline  Engine

    Manual & semiauto-hvac 7b/c-9 gasoline engine 1 compressor 2 high pressure hose 3 condenser 4 main condenser fan 5 sub condenser fan 6 condenser fan resistor 7 liquid pipe(a) 8 receiver dryer 9 liquid pipe(b) 10 grommet 11 evaporator assembly 12 control assembly 13 heater unit amp 14 mix actuator 15...

  • Page 1286: Refrigerant Charging

    7b/c-10 manual & semiauto-hvac refrigerant charging installation of manifold gauge 1. Close both high/low pressure hand valve of gauge before installation of gauge to the charging valve. 2. Connect the low pressure hose of the gauge to the low pressure charging valve and the high pressure hose of th...

  • Page 1287

    Manual & semiauto-hvac 7b/c-11 evacuating refrigeration system 1. Connect the manifold gauge to the charging valves. 2. Connect the center hose of the gauge to the vacuum pump. 3. Run the vacuum pump and open both high and low pressure hand valves. 4. Run the vacuum pump 15-20 minutes. 5. Check that...

  • Page 1288

    7b/c-12 manual & semiauto-hvac charging refrigerant 1. Connect the manifold gauge to the charging valve and evacuate the system. 2. Connect the center hose of the gauge to the refrigerant tank. 3. Open the high pressure valve and charge the system with 350g of refrigerant. 4. Close the high pressure...

  • Page 1289

    Manual & semiauto-hvac 7b/c-13 replacement of refrigerant connection (o-ring type) 1. When connecting a o-ring type, apply compressor oil to portions shown in illustration. Be careful not to apply oil to threaded portion. Notice use specified compressor oil. 2. O-rings must be closely attached to in...

  • Page 1290: Condenser

    7b/c-14 manual & semiauto-hvac condenser preceding work : removal of the radiator 1 bolt 2 condenser fan 3 bolt 4 condenser diesel engine.

  • Page 1291

    Manual & semiauto-hvac 7b/c-15 removal & installation procedure 1. Disconnect the inlet and outlet pipes of condenser. Notice before disconnection, evacuate the refrigerant from the system. 2. Remove the mounting bolts (4 ea) and condenser assembly. 3. Installation should follow the removal procedur...

  • Page 1292

    7b/c-16 manual & semiauto-hvac 1 main condenser fan 2 auxiliary condenser fan 3 bolt 4 condenser gasoline engine.

  • Page 1293

    Manual & semiauto-hvac 7b/c-17 removal & installation procedure 1. Disconnect the inlet and outlet pipes of condenser. Notice before disconnection, evacuate the refrigerant from the system. 2. Remove the mounting bolts (4bolts) and condenser assembly. 3. Remove the main condenser fan from condenser....

  • Page 1294: Receiver Drier

    7b/c-18 manual & semiauto-hvac receiver drier diesel engine 1 condenser 2 receiver drier 3 bolt ......................................................... 4-6 nm 4 bolt .......................................................... 5-8 nm 5 bracket.

  • Page 1295

    Manual & semiauto-hvac 7b/c-19 removal & installation procedure 1. Disconnect the negative(-) terminal from the battery. 2. Discharge refrigerant from the system. Notice by connecting a manifold gauge connection hose to high/ low pressure line, discharge the refrigerant. 3. Disconnect the inlet and ...

  • Page 1296

    7b/c-20 manual & semiauto-hvac 1 condenser 2 receiver drier 3 bracket removal & installation procedure 1. Disconnect the dual pressure switch connector from the receiver drier. 2. Discharge refrigerant from the system. 3. Remove the high pressure pipe from the inlet / outlet of receiver drier. 4. Re...

  • Page 1297: Compressor

    Manual & semiauto-hvac 7b/c-21 compressor preceding work : removal of the poly v-belt diesel engine 1 low pressure pipe 2 high pressure pipe 3 compressor bracket 4 compressor.

  • Page 1298

    7b/c-22 manual & semiauto-hvac removal & installation procedure 1. Disconnect the negative(-) terminal from the battery. 2. Discharge refrigerant from the system. Notice by connecting a manifold gauge connection hose to high/ low pressure line, discharge the refrigerant. 3. Disconnect the high / low...

  • Page 1299

    Manual & semiauto-hvac 7b/c-23 gasoline engine 1 low pressure pipe 2 high pressure pipe 3 compressor bracket 4 compressor removal & installation procedure 1. Disconnect the negative(-) terminal from the battery. 2. Discharge refrigerant from the system. Notice by connecting a manifold gauge connecti...

  • Page 1300

    7b/c-24 manual & semiauto-hvac 4. Remove the mounting bolt from the compressor bracket and remove compressor assembly. Notice place the removed compressor in vertical position. 5. Installation should follow the removal procedure in the reverse order..

  • Page 1301

    Manual & semiauto-hvac 7b/c-25 heater and air conditioner control box 1 blower switch 2 recirculation switch 3 mode switch 4 a/c switch 5 temperature control lever 6 in-vehicle sensor manual satc.

  • Page 1302

    7b/c-26 manual & semiauto-hvac removal & installation procedure 1. Remove the switch panel. Notice be careful not to damage the switch panel. 2. Remove the fixing screws (4 screws) of the control box. 3. Disconnect the wire connectors and remove the control box. 4. Installation should follow the rem...

  • Page 1303: Section 8A

    Section 8a seat belts specifications . . . . . . . . . . . . . . . . . . . . . . . . 8a-1 fastener tightening specifications . . . . . . . . . 8a-1 component locator . . . . . . . . . . . . . . . . . . . 8a-2 front seat belt . . . . . . . . . . . . . . . . . . . . . . . . 8a-2 rear seat belt . . . ....

  • Page 1304: Component Locator

    8a-2 seat belt component locator front seat belt 1 seat belt assembly (3-point) 2 buckle assembly 3 seat belt dust cover 4 seat belt webbing guide 5 seat belt reel assembly 6 anchor bolt .......................................... 35-55 nm 7 anchor bolt .......................................... 35-5...

  • Page 1305: Rear Seat Belt

    Seat belts 8a-3 rear seat belt 1 seat belt assembly (3-point) 2 seat belt stalk plate assembly 3 seat belt assembly (2-point) 4 webbing buckle assembly (center) 5 webbing buckle assembly (rear) 6 webbing hanger 7 seat belt dust cover 8 webbing guide.

  • Page 1306: General Description

    8a-4 seat belt general description and system operation driver seat belt warning the driver's safety belt incorporates a safety belt reminder light in the instment cluster remind the driver if the safety belt is not fastened when the ignition is turnd on. Operation and functional checks caution: l k...

  • Page 1307: Section 8B

    Section 8b supplemental restraint system(srs) specifications . . . . . . . . . . . . . . . . . . . . . . . . 8b-1 general specifications . . . . . . . . . . . . . . . . . . 8b-1 schematic and routing diagrams . . . . . . . . 8b-2 air bag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8b...

  • Page 1308: Air Bag

    8b-2 supplemental restraint system(srs) schematic and routing diagrams air bag.

  • Page 1309: Cautions

    Supplemental restraint system(srs) 8b-3 cautions failure to follow the correct service procedure can cause air bag damage or personal injury due to unexpected air bag deployment. Before service (removal and installation of part, check for replacement), please be weal noticed of following items for y...

  • Page 1310: Function Description

    8b-4 supplemental restraint system(srs) function description air bag control unit (ac4) air bag control unit (ac4) is installed on the center portion of the front floor tunnel. It is a central control unit that control all functions and determines whether deploy the air bag or not with the collision...

  • Page 1311

    Supplemental restraint system(srs) 8b-5 input & output function electronic air bag control and diagnosis module is connected by full 30-pin connectors. Input : ground output : 1 squib line, warning lamp input/output : communication, diagnosis 16 shorting bar 17 shorting bar 18 shorting bar 19 shorti...

  • Page 1312: Air Bag Module

    8b-6 supplemental restraint system(srs) air bag module air bag module is installed in the pad of steering wheel center and inflator is consisted of igniter, explosives, gas generating material and bag. When crashed, the air bag control unit sends current to the air bag module through squib line and ...

  • Page 1313: Diagnosis

    Supplemental restraint system(srs) 8b-7 diagnosis description air bag control unit continuously controls system function as follows during ignition on or driving. - recognition of collision - internal diagnosis - external diagnosis if recognize or detect defects, warning lamp will turn on. If there ...

  • Page 1314

    8b-8 supplemental restraint system(srs) energy reserve system energy reserve system is consisted of condensor and energy switch and will check following items continuously during system operation. - high voltage - low voltage - low rating capacity - function of the energy reserve switch if there is ...

  • Page 1315

    Supplemental restraint system(srs) 8b-9 diagnosis air bag control unit diagnoses each function in the intervals of 250ms - 20 sec. During start-up or driving to prevent unwanted air bag deployment. If there is defect, it turns on or blinks warning lamp to indicate defects in the air bag system to th...

  • Page 1316: Self Diagnosis

    8b-10 supplemental restraint system(srs) 1. Position the ignition switch to ‘off’. 2. Connect the harness connector of scanner to the diagnosis socket in engine compartment. 3. Turn the ignition switch to ‘on’ position. 4. Select “electronic control vehicle diagnosis” from function selection display...

  • Page 1317

    Supplemental restraint system(srs) 8b-11 self-diagnosis list fault code defects service hint 01 driver’s squib (+) side no. 1 l short of (+) side no. 1 in the driver’s squib circuit. L check connection of connector. L check the ecu. Appli- cation 02 driver’s squib (+) side no. 2 l short of (+) side ...

  • Page 1318

    8b-12 supplemental restraint system(srs) fault code defects service hint appli- cation 17 squib no. 1 resistance 18 squib no. 2 resistance x 19 squib no. 3 resistance x 20 squib no. 4 resistance x 21 squib no. 1 resistance 22 squib no. 2 resistance x l driver’s squib resistance is higher than standa...

  • Page 1319

    Supplemental restraint system(srs) 8b-13 fault code defects service hint appli- cation 24 squib no. 4 resistance x 25 energy reserve no. 1 voltage 26 energy reserve no. 2 voltage x 27 energy reserve no. 3 voltage x 28 energy reserve no. 4 voltage x 29 energy reserve no. 5 voltage 30 energy reserve n...

  • Page 1320

    8b-14 supplemental restraint system(srs) fault code defects service hint appli- cation 42 over heat 43 sens 44 standard band gap 45 temperature sensor 46 warning lamp 47 battery voltage 49 fault code list 50 usa communication 51 lsa communication 52 no eeprom program 53 eeprom checksum 54 eeprom map...

  • Page 1321

    Supplemental restraint system(srs) 8b-15 fault code defects service hint appli- cation 127 collision signal 128 collision number l air bag control unit internal defects. L check and replace the ecu. L air bag control unit internal defects. L check and replace the ecu..

  • Page 1322: Circuit Diagram

    8b-16 supplemental restraint system(srs) circuit diagram.

  • Page 1323: Air Bag Diagram

    Supplemental restraint system(srs) 8b-17 air bag diagram.

  • Page 1324: Maintenance and Repair

    8b-18 supplemental restraint system(srs) maintenance and repair on-vehicle service air bag module removal & installation procedure 1. Remove the steering wheel rid (lh,rh) with a screwdriver. Installation notice each position mark (lh,rh) is stamped on the inner surface of the rids. Tightening torqu...

  • Page 1325: Clock Spring

    Supplemental restraint system(srs) 8b-19 air bag horn (relay) remote control (electronic circuit) clock spring general specification voltage rating operating voltage current rating air bag circuit resistance isolating resistance rotating range dc 12v dc 6 - 18v 10 - 30ma(6a,0.1second) 200 - 220ma 15...

  • Page 1326

    8b-20 supplemental restraint system(srs) removal & installation procedure preceding work : removal of steering wheel 1. Turn the ignition switch to “off” position and disconnect the battery negative cable. Start the procedure after waiting over 3oseconds. 2. Unscrew 3 screws from lower cover on stee...

  • Page 1327: Air Bag Control Unit(Ac4)

    Supplemental restraint system(srs) 8b-21 air bag control unit(ac4) removal & installation procedure ac4 is installed on the center portion of the front floor tunnel. Built-in accelerometer sensor detects collision and determines action or non-action and ignition time. Notice do not disassemble the a...

  • Page 1328: General Description

    8b-22 supplemental restraint system(srs) general description and system operation introduction srs (supplemental restraint system) air bag protects driver and passenger by inflating air bag under collision and seat belt pre - tensioner is a supplemental equipment for seat belt reducing shocks from t...

  • Page 1329: Section 9A

    Section 9a body wiring system schematic and routing diagrams . . . . . . . . 9a-2 power distribution . . . . . . . . . . . . . . . . . . . . . . 9a-2 starting & charging (gasoline hfm) . . . . . . . 9a-3 starting & charging (diesel) . . . . . . . . . . . . . . 9a-4 fuse box and relay . . . . . . . ....

  • Page 1330: Power Distribution

    9a-2 body wiring system schematic and routing diagrams power distribution.

  • Page 1331

    Body wiring system 9a-3 starting & charging (gasoline hfm).

  • Page 1332

    9a-4 body wiring system starting & charging (diesel).

  • Page 1333: Fuse Box and Relay

    Body wiring system 9a-5 fuse box and relay 1 interior relay box 2 interior fuse box 3 engine compartment fuse and relay box.

  • Page 1334

    9a-6 body wiring system engine room fuse (ef) and relay box 1 fuse (15a) : abs, abd 2 fuse (20a) : sun roof 3 fuse (10a) : air bag 4 fuse (15a) : audio, clock, out side mirror 5 fuse (30a) : cigarette lighter, power socket 6 fuse (30a) : heater 7 fuse (15a) : door lock 8 fuse (30a) : rear heated 9 f...

  • Page 1335: Main

    Body wiring system 9a-7 location of connectors by wiring harness main.

  • Page 1336

    9a-8 body wiring system 1 fuse box 2 door lock relay 3 relay box 3.1 front wiper relay 3.2 abs warning lamp relay .................................... Abd 5.0 3.3 flasher unit 3.4 fuel pump relay ................................................. Gasoline e/g 3.5 shift lock relay .......................

  • Page 1337

    Body wiring system 9a-9 44 joint connector .................................................... Ground 45 door unlock switch 46 front fog lamp switch 47 rear defogger switch 48 ecs switch 49 rear fog lamp switch ........................................ Rear fog lamp 50 digital clock 51 thermo amplif...

  • Page 1338

    9a-10 body wiring system 94 seat belt switch (driver) 95 seat belt switch (dirver) 96 parking brake switch 97 rear cigarette lighter 98 ovpr ................................................................. Gasoline e/g 99 lh side repeater ............................................... Rear fog lam...

  • Page 1339: Engine Room

    Body wiring system 9a-11 engine room 1 engine room relay box 1.1 main wiring connector 1.2 main wiring connector 1.3 main wiring connector ........................................ Gasoline e/g 1.4 joint 1.5 compressor, condenser fan relay ..................... Diesel e/g 1.6 condenser fan relay 2 1....

  • Page 1340

    9a-12 body wiring system 15 lh damper ........................................................... Ecs 16 ground 1 17 ground 2 18 locking hub solenoid 19 condenser fan relay ......................................... Gasoline e/g 20 lh position lamp 21 lh head lamp 22 lh head lamp leveling device .......

  • Page 1341: Floor

    Body wiring system 9a-13 floor 1 ecs main wiring connector ........................ Ecs 2 main wiring connector 3 main wiring connector 4 main wiring connector 5 abd main wiring connector ........................ Abd 6 lh front door switch 7 lh tension reducer 8 ground 1 9 lh rear door wiring connec...

  • Page 1342: Roof

    9a-14 body wiring system roof 1 main wiring connector 2 room lamp 3 inside mirror 4 sun roof motor 5 map lamp.

  • Page 1343: Driver'S Door

    Body wiring system 9a-15 driver's door 1 main wiring connector 2 main wiring connector 3 main wiring connector 4 main wiring connector 5 speaker 6 door lock actuator 7 outside mirror motor 8 tweeter speaker wiring connector 9 power window motor 10 power window switch 11 door courtesy lamp passenger'...

  • Page 1344: Rear Left Door

    9a-16 body wiring system rear left door rear right door 1 floor wiring connector 2 door lock actuator 3 power window motor 4 power window switch 1 floor wiring connector 2 door lock actuator 3 power window motor 4 power window switch.

  • Page 1345: Tail Gate

    Body wiring system 9a-17 tail gate 1 floor wiring connector 2 floor wiring connector 3 floor wiring connector 4 lh rear combination lamp 5 lh rear fog lamp 6 joint connector (ground) 7 rear wiper motor 8 lh license lamp 9 tail gate switch 10 door lock actuator 11 high mounted stop lamp 12 rh license...

  • Page 1346

    9a-18 body wiring system semi automatic air conditioner 1 main connector 2 air conditioner relay 2 3 lo relay 4 ml relay 5 mh relay 6 hi relay 7 intake actuator 8 blower motor 9 resistor 10 diode 11 amplifier 12 amplifier 13 temp actuator 14 blower relay 15 water temperature sensor 16 air conditione...

  • Page 1347

    Body wiring system 9a-19 full automatic air conditioner 1 main connector 2 intake actuator 3 blower relay 4 hi relay 5 power tr 6 water temperature sensor 7 temp actuator 8 blower relay 9 control (a) 10 control (b) 11 sun sensor 12 mode actuator 13 in car sensor.

  • Page 1348: Gasoline Engine (Mse)

    9a-20 body wiring system gasoline engine (mse) 1 ecu main wiring connector 2 ecu main wiring connector 3 crankshaft position sensor 4 oil pressure switch 5 knock sensor 2 6 hot-film air mass sensor 7 injector 6 8 injector 5 9 injector 4 10 injector 3 11 injector 2 12 injector 1 13 camshaft adjustmen...

  • Page 1349: Gasoline Engine (Hfm)

    Body wiring system 9a-21 gasoline engine (hfm) 1 ecu 2 main wiring connector 3 crankshaft position sensor 4 knock sensor 5 hot-film air mass sensor 6 aspiration sensor 7 throttle regulating unit 8 knock sensor 9 camshaft position sensor 10 ignition coil 3 11 ignition coil 2 12 ignition coil 1 13 inj...

  • Page 1350: Diesel Engine

    9a-22 body wiring system diesel engine 1 preheating unit 2 main wiring connector 3 glow plug 1 4 glow plug 2 5 glow plug 3 6 glow plug 4 7 glow plug 5 8 water temperature sensor (gauge).

  • Page 1351: Manual Transmission

    Body wiring system 9a-23 manual transmission 1 main wiring connector ...................... Diesel e/g 2 main wiring connector .................. Gasoline e/g 3 main wiring connector ......................... Gasoline (e32, e23) e/g 4 back up switch 5 oil pressure switch 6 start motor solenoid 7 mic...

  • Page 1352

    9a-24 body wiring system automatic transmission (benz) 1 main wiring connector 2 start lock switch 3 automatic transmission change over valve 4 transmission overload protection switch ........................... Gasoline e/g 5 oil pressure switch 6 start solenoid 7 micro switch ........................

  • Page 1353

    Body wiring system 9a-25 automatic transmission (btra) 1 main wiring connector 2 main wiring connector 3 transmission 4 transmission lever 5 oil pressure switch ............................ Diesel e/g 6 start motor solenoid 7 throttle position sensor .................... Diesel e/g 8 speed sensor .....

  • Page 1354: Driver'S Seat

    9a-26 body wiring system driver's seat 1 main wiring connector 2 tilt motor 3 heater control unit 4 height motor 5 slide motor 6 back seat wiring connector 7 seat heater 8 driver seat switch.

  • Page 1355: Section 9B

    Low (philips h4) tail lamp brake lamp high mounted stop lamp reverse lamp fog lamp* turn signal lamp position lamp front lamp rear lamp luggage lamp door courtesy lamp section 9b lighting system caution: disconnect the negative battery cable before removing or installing any electrical unit or when ...

  • Page 1356: Tail Lamp & B/o Lamp

    9b-2 lighting system tail lamp & b/o lamp schematic and routing diagrams 15 (no.15) ovpr.

  • Page 1357: Head Lamp

    Lighting system 9b-3 head lamp.

  • Page 1358

    9b-4 lighting system head lamp leveling device.

  • Page 1359

    Lighting system 9b-5 turn signal lamp and hazard lamp 3.0bg.

  • Page 1360

    9b-6 lighting system back-up lamp and stop lamp.

  • Page 1361

    Lighting system 9b-7 front and rear fog lamp.

  • Page 1362: Room Lamp

    9b-8 lighting system room lamp.

  • Page 1363: Front and Rear Lamps

    Lighting system 9b-9 front and rear lamps 1 low-beam head lamp 2 high-beam head lamp 3 turn signal lamp 4 position lamp 5 back-up lamp 6 tail / stop lamp 7 turn signal lamp 8 tail / stop lamp maintenance and repair on-vehicle service.

  • Page 1364

    9b-10 lighting system head lamp focusing when using the beam setting device 1. The head lamp focus should be adjusted by using a proper beam setting device. 2. Adjust the head lamp focus by using up/down, left/right adjusting screws. When using the screen 1. Put the vehicle on the leveling surface. ...

  • Page 1365

    Lighting system 9b-11 head lamp removal & installation procedure 1. Unscrew upper 2(10mm) bolts and lower 1(10mm) bolt of head lamp. 2. Disconnect connector and remove the headlamp. 3. Installation should follow the removal procedure in the reverse order. Bulb replacement 1. Turn the dust cap of the...

  • Page 1366

    9b-12 lighting system tail/stop and turn signal lamp tail/stop lamp and backup lamp rear combination lamp removal & installation procedure 1. Open the tailgate and remove the inner cover of the rear combination lamp. 2. Unscrew 4(8mm) nuts of tail/stop lamp and turn signal lamp assembly. 3. Unscrew ...

  • Page 1367: Section 9C

    Section 9c horns caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The igni...

  • Page 1368: Horn

    9c-2 horn horn schematic and routing diagrams.

  • Page 1369: Section 9D

    Section 9d wipers/washer system caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the ve...

  • Page 1370: Rear Wiper and Washer

    9d-2 wipers/washer system schematic and routing diagrams rear wiper and washer.

  • Page 1371: Front Wiper and Washer

    Wipers/washer syatem 9d-3 front wiper and washer 1 windshield linkage 2 wiper arm 3 wiper blade (left) 4 wiper blade (right) 5 washer nozzle 6 reservoir tank guide 7 reservoir tank 8 washer hose 9 cap 10 washer motor 11 hose connector (y- type) 12 washer hose (left) 13 nozzle pipe 14 washer hose mai...

  • Page 1372

    9d-4 wipers/washer system removal & installation procedure 1. Remove the wiper arm and blade. 2. Remove the linkage connected to the wiper motor. 3. Disconnect the connector from the wiper motor. 4. Unscrew the locking bolts from wiper motor. 5. Installation is reverse order of removal connector app...

  • Page 1373: Rear Wiper and Washer

    Wipers/washer system 9d-5 rear wiper and washer 1 wiper arm 2 wiper cap 3 wiper blade 4 washer nozzle 5 reservoir tank 6 wiper hose 7 cap 8 washer motor 9 wiper hose socket 10 outer joint notice removal and installation is as shown in upper drawings..

  • Page 1374

    9d-6 wipers/washer system removal & installation procedure 1. Remove the spare tire. 2. Unscrew the locking nut and remove the wiper. 3. Unscrew the locking nut of wiper motor. 4. Remove the tailgate trim panel. 5. Dieconnect the connector from the wiper motor. 6. Unscrew four screws(arrows) and rem...

  • Page 1375

    Wipers/washer system 9d-7 connector appearance and connecting circuit connector terminal b+ e wp battery power source ground from switch diagram for connecting circuit.

  • Page 1376: Section 9E

    Section 9e instrumentation/driver information caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and da...

  • Page 1377: Cluster

    9e-2 instrumentation/driver information cluster schematic and routing diagrams.

  • Page 1378: Combination Meter

    Instrumentation/driver information 9e-3 combination meter component locator 1. Speedometer 2. Odometer 3. Trip odometer 4. Tachometer 5. Coolant temperature gauge 6. Fuel gauge 7. Low fuel level warning light 8. Turn signal indicator (left) 9. Turn signal indicator (right) 10. Outside rearview mirro...

  • Page 1379: Combination Meter

    9e-4 instrumentation/driver information combination meter diesel 1. Speedometer (km/h) 2. Tachometer revolution tolerance 1000 +137 -63 2000 3000 +261 -39 4000 +298 -2 5000 - +199 -51 gasolin 1 windshield linkage speed tolerance 40 +3 +0 60 80 +5 +0 100 +5 +0 140 +5.5 +0.5 160 +5.5 +0.5 180 - +4 +0 ...

  • Page 1380

    Instrumentation/driver information 9e-5 3. Fuel gauge resistance tolerance e 97 2.5' 1/2 (32.5) ±5° f 6 ±2.5 temperature 50 °c 86 °c 105.5 °c 120 °c resistance( w ) 156.9 w 44.5 w 27.3 w 19.4 w 4. Temperature gauge(temperature sensor) speed tolerance 1000 ±100 2000 3000 ±150 4000 ±150 6000 ±180 7000...

  • Page 1381: Section 9F

    Section 9f audio system caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. T...

  • Page 1382: Audio

    9f-2 audio system audio schematic and routing diagrams 0.3 gb rheo(exp) ly no.13.

  • Page 1383: Diagnosis

    Audio system 9f-3 diagnosis general diagnosis no sounds.

  • Page 1384: Section 9H

    Section 9h seats caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The igni...

  • Page 1385: Diagnosis

    9h-2 seats diagnosis when the power seat does not work :.

  • Page 1386: Power Sea

    Seats 9h-3 power sea t schematic and routing diagrams.

  • Page 1387: Sea

    9h-4 seats sea t w armer 0.5 gw.

  • Page 1388

    Seats 9h-5 seat belt & tension reducer.

  • Page 1389: Component Locator

    9h-6 seats component locator front seat & rear seat 1 front seat (driver’s) 2 front seat (passenger’s) 3 headrest 4 under tray assembly 5 front seat mounting rear outer cover 6 front seat mounting rear inner cover 7 rear seat assembly 8 headrest notice removal and installation is as shown in upper d...

  • Page 1390: Maintenance and Repair

    Seats 9h-7 maintenance and repair on-vehicle service 1 slide adjusting motor 2 height adjusting motor 3 tilt adjusting motor 4 recline adjusting motor 5 driver's power seat recline switch 6 driver's power seat switch(slide, height, tilt) 7 seat heater control unit 8 seat heater switch.

  • Page 1391

    9h-8 seats power seat connector and connection circuit driver's power seat switch size and color 1.25lb 1.25br 1.25y 1.25br 1.25b 1.25bw 1.25lb 1.25ly 1.25g 1.25by connection circuit tilt (up) tilt (down) slide (rr) slide (frt) ground battery (+) recline (rr) recline (frt) height (up) height (down) ...

  • Page 1392

    Seats 9h-9 seat heater connector and connection circuit seat heater switch connector circuit connection circuit.

  • Page 1393: Section 9L

    Section 9l glass and mirrors caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehic...

  • Page 1394: Outside Mirror

    9l-2 glass and mirrors outside mirror schematic and routing diagrams.

  • Page 1395

    Glass and mirrors 9l-3 auto dimming room mirror.

  • Page 1396: Maintenance and Repair

    9l-4 glass and mirrors maintenance and repair on-vehicle service front & side glass.

  • Page 1397

    Glass and mirrors 9l-5 installation of windshield 1. Cleaning of windshield mounting flange. L do not reuse a gauze over 20 times. L saturate the gauze in solvent (lsoprophyl alcohol). L keep the cleaned surface to be cleaned. L apply body primer to the cleaned and dry body flange. L if body flange ...

  • Page 1398

    9l-6 glass and mirrors 4. Installation of glass dam rubber. L using a double - faced adhesive tape, install the dam rubber keeping 10mm from the edge of glass. If intervals are irregular, primers and sealants can be applied unevenly. L if need to remove the improper dam rubber, do not remain the dou...

  • Page 1399

    Glass and mirrors 9l-7 installation of side glass for installation, refer to 'installation of windshield'. 1. Clean as the same procedure of windshield mounting flange (apply primer). L clean as the same procedure of windshield cleaning, however keep 20mm from the edge of glass. 2. Apply primer to t...

  • Page 1400

    9l-8 glass and mirrors tightening torque 7.7 nm 4. Before installation, ensure that the stay bolt washer is inserted. 5. Using suction holders, install the side glass within 5minutes after application of sealant..

  • Page 1401: Tailgate Glass

    Glass and mirrors 9l-9 tailgate glass 1 wiper arm and blade assembly 2 heating lines 3 tailgate trim 4 tailgate glass notice removal and installation is as shown in upper drawings..

  • Page 1402

    9l-10 glass and mirrors installation of tailgate glass 1. Clean the tailgate flange. L do not reuse a gauze over 20 times. L saturate the gauze in solvent (isoprophyl alcohol). L keep the cleaned surface to be cleaned. L apply body primer to the cleaned and dry flange. - if flange is oiled or contam...

  • Page 1403

    Glass and mirrors 9l-11 5. Apply sealant to the glass. L turn over the glass and apply sealant. L uneven application of sealant may cause water leakage after installation of glass. L do not touch the glass moldings and dam rubber while applying sealant. 6. Using suction holders, install the tailgate...

  • Page 1404: Auto Dimming Room Mirror

    9l-12 glass and mirrors 1 auto dimming room mirror assembly 2 sensor (front) 3 sensor (rear) auto dimming room mirror layout 4 switch 5 cover 6 lamp.

  • Page 1405

    Glass and mirrors 9l-13 check & service if reflection ratio is not adjusted automatically during night driving when auto switch is pressed, check each connectors for proper connection and power flow to the auto dimming room mirror using multi tester. 1. Yellow (connected to back-up lamp) 2. Blue (gr...

  • Page 1406

    9l-14 glass and mirrors removal & installation procedure 1. Removal the room mirror cover (arrow). 2. Disconnect 3-pin connector. 3. Removal the mirror assembly. 4. Installation should follow the removal procedure in the reverse order..

  • Page 1407: Section 9N

    Section 9n frame and underbody table of contents dimension . . . . . . . . . . . . . . . . . . . . . . . . . . 9n-2 frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9n-2 component locator . . . . . . . . . . . . . . . . . . . 9n-3 body mountings . . . . . . . . . . . . . . . . . ....

  • Page 1408: Dimension

    9n-2 frame and underbody dimension frame.

  • Page 1409: Component Locator

    Frame and underbody 9n-3 component locator body mountings 1 upper insulator 2 lower insulator 3 washer tube 4 plain washer 5 bolt 6 grommet 7 nut 8 plate 9 upper insulator 10 lower insulator 11 bolt 12 nut 13 washer.

  • Page 1410: Body Mounting-Sectional View

    9n-4 frame and underbody body mounting-sectional view.

  • Page 1411: Skid Plate

    Frame and underbody 9n-5 1 mounting bolt ....................................... 28-47 nm skid plate . 2 skid plate removal & installation procedure 1. Remove 6 mounting bolts and carefully remove the skid plate. Installation notice 2. Installation should follow the removal procedure in the reverse ...

  • Page 1412: Section 9O

    Section 9o bumpers and fascias table of contents maintenance and repair . . . . . . . . . . . . . . . 9o-2 on-vehicle service . . . . . . . . . . . . . . . . . . . . . . 9o-2 front bumper . . . . . . . . . . . . . . . . . . . . . . . . . 9o-2 rear bumper . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 1413: Maintenance and Repair

    9o-2 bumpers and fascias maintenance and repair on-vehicle service front bumper notice removal and installation is as shown in upper drawings..

  • Page 1414

    Bumpers and fascias 9o-3 mounting inspection 1. Clearance between the upper bumper and radiator grille. 2. Clearance between the upper bumper and headlamp moding. Clearance 12 ± 1.0 mm clearance 9 mm 2. Clearance between the bumper and wheel arch. Clearance 10 mm.

  • Page 1415: Rear Bumper

    9o-4 bumpers and fascias rear bumper notice removal and installation is as shown in upper drawings..

  • Page 1416

    Bumpers and fascias 9o-5 mounting inspection 1. Clearance between the upper bumper facia and tailgate. 2. Clearance between the rear bumper facia and rear bumper molding. Clearance 12 ± 1.0 mm clearance 11.0 mm 3. Clearance between the quarter outer panel and rear bumper facia. Clearance 10.0 mm.

  • Page 1417: Section 9P

    Section 9p doors caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The igni...

  • Page 1418: Power Window

    9p-2 doors schematic and routing diagrams power window.

  • Page 1419: Maintenance and Repair

    Doors 9p-3 maintenance and repair on-vehicle service front door removal & installation procedure 1. Remove the pin from the center hinge of the door. 2. Remove the upper/lower hinge bolts from the body and remove the door assembly. 3. Installation should follow the removal procedure in the reverse o...

  • Page 1420: Rear Door

    9p-4 doors rear door removal & installation procedure 1. Remove the pin from the center hinge of the door. 2. Remove the upper/lower hinge bolts from the body and remove the door assembly. 3. Installation should follow the removal procedure in the reverse order..

  • Page 1421: Tail Gate

    Doors 9p-5 tail gate removal & installation procedure 1. Remove the shock absorber mounting bolts. 2. Disconnect the tailgate wiring harness. 3. Remove the tailgate by removing the tailgate bracket bolts. 4. Installation should follow the removal procedure in the reverse order..

  • Page 1422

    9p-6 doors adjustment procedure 1. Adjust the striker in forward / rearward and left / right directions. Adjust striker height by increasing / decreasing the shims. 2. Adjust the position of the striker as described above. 3. Adjust the position of the safety hook as described above..

  • Page 1423: Section 9Q

    Section 9q roof table of contents schematic and routing diagrams . . . . . . . . 9q-2 sun roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9q-2 maintenance and repair . . . . . . . . . . . . . . . 9q-3 on-vehicle service . . . . . . . . . . . . . . . . . . . . . . 9q-3 sun roof . . . . ....

  • Page 1424: Sun Roof

    9q-2 roof sun roof schematic and routing diagrams.

  • Page 1425: Maintenance and Repair

    Roof 9q-3 maintenance and repair on-vehicle service sun roof 1 inner sliding sun roof assembly 2 sun roof body mounting bracket 3 drain hose rear grommet 4 sun roof motor spanner 5 mounting clip 6 mounting bracket 7 mounting bracket assembly 8 sun roof mounting bracket 11 sun roof module assembly.

  • Page 1426

    9q-4 roof removal & installation procedure 1. Disconnect the connector and remove the sun roof module assembly. 2. Disconnect the front and rear drain hose. 3. Unscrew the sun roof mounting bracket bolts(arrows) and remove the inner sliding and sun roof assembly.

  • Page 1427: Section 9R

    Section 9r body front end table of contents maintenance and repair . . . . . . . . . . . . . . . 9r-2 on-vehicle service . . . . . . . . . . . . . . . . . . . . . . 9r-2 hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9r-2 fender . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 1428: Maintenance and Repair

    9r-2 body front end maintenance and repair on-vehicle service hood 1 hood 2 sping 3 hood hinge assembly 4 bolt.

  • Page 1429

    Body front end 9r-3 removal & installation procedure 1. Remove the hood striker assembly. Notice when installing, tighten the bolt after setting the hole between wratch and hood striker assembly. Installation notice tightening toque 8 - 11 nm 2. Remove the hood mounting bolt and hood lifter assembly...

  • Page 1430

    9r-4 body front end adjustment procedure 1. Alignment between hood striker and latch hole. L loosen the mounting bolt of hood latch slightly and adjust hood in forward/rearward and left/right directions. Then align the center between hood striker and latch hole. Notice tighten the bolt fully after a...

  • Page 1431: Fender

    Body front end 9r-5 fender removal procedure 1. Remove the screws. 2. Remove the mudguard and wheel guard. 3. Disconnect the front lamps connectors. 4. Remove the front lamps..

  • Page 1432

    9r-6 body front end 5. Remove the fender mounting bolts. Notice be careful not to damage the paintwork. Installation procedure 1. Installation should follow the removal procedure in the reverse order. Notice apply a tape sealer to the fender and body panel to prevent rust in fender mounting bolts ar...

  • Page 1433: Section 9T

    Section 9t remote keyless entry and anti-theft system caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injur...

  • Page 1434: Rekes

    9t-2 remote keyless entry and anti-theft system rekes schematic and routing diagrams.

  • Page 1435: Diagnosis Test

    Remote keyless entry and anti-theft system 9t-3 diagnosis test introduction using the service connector, possible defects in power section, input·output section of internal stics unit can be detected and each normal status and defect mode can be checked. Diagnosis method 1. Use buzzer for diagnosis ...

  • Page 1436

    9t-4 remote keyless entry and anti-theft system 6. Buzzer output is as follows. T1 : 0.3±0.1 sec. T2 : 0.3±0.1 sec. T : 0.6±0.2 sec. Notice l in case of checking related devices, diagnosis switch should always be on. L when operating the diagnosing related devices, there will be buzzer sound if it i...

  • Page 1437: Maintenance and Repair

    Remote keyless entry and anti-theft system 9t-5 maintenance and repair on-vehicle service rekes 1 rekes receiver 2 antenna 3 bolt 4 wiring connector (6p).

  • Page 1438

    9t-6 remote keyless entry and anti-theft system input memory l when the rekes transmitter is lost 1. Connect the battery terminal no.3 and rekes terminal no.4 which are on the diagnosis socket in engine room with service lead wire. 2. Push the lock or unlock button on the rekes transmitter. 3. Input...

  • Page 1439

    Remote keyless entry and anti-theft system 9t-7 characteristic signal 1. Lock or unlock all doors according to the rekes signal when the key is removed from the key hole. 2. Characteristic signal : right picture 3. Time interval t1 : 0.05 ± 0.02sec.(lock signal) t2 : 0.1 ± 0.02sec.(unlock signal) t3...

  • Page 1440: Section 9U

    Section 9u control units and system caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to th...

  • Page 1441: Stics

    9u-2 control units and system stics schematic and routing diagrams.

  • Page 1442: Function Description

    Control units and system 9u-3 function description stics operating functions no. Application deseription 1 wiper int sensing vehicle speed l by operating int time control volume, variable time will be changed within 1.5 - 20 seconds. 2 washer relating wiper l wiper begins to operate within 0.6 - 1 s...

  • Page 1443

    9u-4 control units and system no. Application deseription 13 ignition key hole illumination l coupled with door switch, ignition key hole illumination lamp will turn on when the driver’s door is opened and will dim off after 10 sec. After closing the door. 14 auto door lock l all doors will be locke...

  • Page 1444

    Control units and system 9u-5 operating characteristics 1. Wiper int sensing vehicle speed t1 : within 0.5 sec. T2 : wiper motor 1 revolution time t3 : 1.5±0.2 sec. - 20±2 sec. 2. Washer relating wiper t1 : 0.6 - 1.0 sec. T2 : motor 3 revolution (including motor revolution time) 3. Dimming room lamp...

  • Page 1445

    9u-6 control units and system 5. Rear defogger timer t1 : 12±2 min. T2 : within 10±1 min. T3 : 6±1 min. 6. Seat belt warning timer t1 : 6±1 sec. T2 : 0.3±0.1 sec. T3 : 0.6±0.1 sec. 7. Parking brake warning t1 : 0.3±0.1 sec. T2 : 0.3±0.1 sec. V1 : 3km/h - 5km/h 8. Tail lamp lighting warning l when th...

  • Page 1446

    Control units and system 9u-7 l after 1), the driver’s or passenger’s door should be unlocked when it locked. T1 : within 0.2±5 sec. T2 : 5±0.5 sec. 9. Door ajar warning t1 : 0.3±0.1 sec. T2 : 0.3±0.1 sec. V1 : 3 - 5km/h 10. Ign key reminder warning t1 : within 0.2 sec. T2 : 5±0.5 sec. T3 : 0.3±0.1 ...

  • Page 1447

    9u-8 control units and system 11. Central door lock t1 : within 0.2 sec. T2 : 0.5±0.1 12. Coupled with rekes mode t1 : 0.05±0.02 sec. (lock signal) t2 : 0.1±0.02 sec. (unlock signal) t3 : within 0.2±5 sec. T4 : 0.5±0.1 sec. T5 : within 0.3 sec. T6, t7 : 0.5±0.1 sec. T8 : 1±0.25 sec. 13. Ignition key...

  • Page 1448

    Control units and system 9u-9 14. Auto door lock v1 : 50±5km/h t1 : 0.5±0.1 sec. 15. Auto door unlock t1 : 0.5±0.1 sec. V1 : 15km/h.

  • Page 1449: Maintenance and Repair

    9u-10 control units and system maintenance and repair on-vehicle service stics stics, electonic control warning device, controls 16 functions and contains the self diagnostic function detecting any malfunctions in the sensors and load. Removal & installation procedure 1. Disconnector the battery neg...

  • Page 1450: Section 9W

    Section 9w immobilizer system function description . . . . . . . . . . . . . . . . . . 9w-2 system description . . . . . . . . . . . . . . . . . . . . . 9w-3 diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 9w-8 gasoline engine . . . . . . . . . . . . . . . . . . . . . . . 9w-8 diesel...

  • Page 1451: Function Description

    9w-2 immobilizer system notice l if vehicle is equipped with immobilizer system and the engine cranks normally but not start, check immobilizer system first rather than ignition and other electrical systems because it can be disabled fuel supply of injectors by ecu due to defective immobilizer syste...

  • Page 1452: System Description

    Immobilizer system 9w-3 system description gasoline version the immobilizer system consists of an electronic device with integrated coil, called ‘active antenna’, the crypto transponder, which is integrated in the ignition key, and the engine management system (ems). The active antenna is mounted at...

  • Page 1453

    9w-4 imm obilizer system active antenna l connector 1 2 3 4 1 : ign (red) 2 : ground (brown) 3 : data in (yellow) 4 : data out (green) notice pin arrangement and spec. Of connector is same for gasoline and diesel vehicles. L wire circuit diagram 3 4 ant. 14 13 e/g ecu ign ground 13 : crypto read 14 ...

  • Page 1454

    Immobilizer system 9w-5 diesel version the immobilizer system consists of an electronic device with integrated coil, called ‘active antenna’, the crypto transponder, which is integrated in the ignition key, and the immobilizer-control-unit (icu). The active antenna is mounted at the ignition lock an...

  • Page 1455

    9w-6 immobilizer system.

  • Page 1456

    Immobilizer system 9w-7 system integration the med 98.2 immobilizer is an anti-theft protection device allowing the start of the engine only if a specific authorization is obtained during the start up phase. The med 98.2 will allow (prohibit) the start of the engine by driving on (off) an internal s...

  • Page 1457: Diagnosis

    9w-8 immobilizer system defects possible cause remedy no communication with transponder 1. Defective wiring harness - power supply/open/short of ground - open/short of signal terminal or mis-conneting(between ecu terminal no. 13 and 14) 1. Connect/replace the wire correctly. 2.1 replace the transpon...

  • Page 1458

    Immobilizer system 9w-9 check and remedy when engine does not start starter operates normally? Yes no l check fuses (no. 8 and 27) l check ecu and antenna power ecu terminal - no. 12 (power) - no. 11 (ignition) - no.5/10 (ground) l check battery voltage l check battery wiring l check signal wires be...

  • Page 1459: Diesel Engine

    9w-10 immobilizer system 1. Connect/replace the wire correctly 2. Replace the transponder 3.1 replace the valve 3.2 turn ign sw on 3.3 turn ign sw off & on defects possible cause remedy no communication with transponder 1. Defective wiring harness - power supply/open/short of ground - open/short of ...

  • Page 1460

    Immobilizer system 9w-11 check and remedy when engine does not start starter operates normally? Yes no l check fuses (no. 19) l check ecu and antenna power and solenoid valve ecu terminal - no. 9 (ignition) - no. 6 (ground) l check battery voltage l check battery wiring l check signal wires between ...

  • Page 1461

    9w-12 immobilizer system schematic and routing diagrams gasoline engine (hfm) immobilizer.

  • Page 1462: Diesel Engine Immobilizer

    Immobilizer system 9w-13 diesel engine immobilizer.

  • Page 1463

    9w-14 immobilizer system diesel engine immobilizer - crypto type.

  • Page 1464: Immobilizer Antenna

    Immobilizer system 9w-15 notice for circuit diagram of gasoline vehicle, refer to the ecu diagram. Immobilizer antenna immobilizer antenna is installed in key set outer surface (it is installed in the location of key hall illumination).(see the figure) 1 immobilizer antenna 2 key 3 transponder maint...

  • Page 1465

    9w-16 immobilizer system 4. Remove the transponder. Carefully remove the old shock absorbing sealant with a razor blade if applied. 5. Replace the transponder with new one, and apply the small amount of shock absorbing sealant. 6. Installation should follow the removal procedure in the reverse order...