Hino Trucks Repair Service Manual + Owners Manual MY2001-MY2016
Complete service repair manual with Electrical Wiring Diagrams for Hino Trucks MY01-MY16, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
HINO TRUCKS all models MY2001-MY2016 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
2001
S1-134E-16-1_pdf
Document
01-218E-04.pdf
03-228E-04.pdf
15-180E-03.pdf
21-126E-05.pdf
22-114E-03.pdf
23-54E-06.pdf
23-55E-07.pdf
51-28E-07.pdf
78-07E-03.pdf
S-6E-15.pdf
S1-134E-16-1 .pdf
S1-134E-16-2_pdf
2001 Workshop Manual_S1-134E-16-2 .pdf
Document
01-218E-04.pdf
05-85E-05.pdf
05-86E-05.pdf
06-133E-06.pdf
07-141E-06.pdf
07-142E-06.pdf
07-164E-05.pdf
08-183E-06.pdf
09-105E-06.pdf
09-48E-13.pdf
10-108E-06.pdf
11-64E-12.pdf
12-233E-04.pdf
13-243E-07.pdf
13-340E-03.pdf
14-144E-04.pdf
16-27E-10.pdf
17-191E-05.pdf
17-192E-04 .pdf
18-28E-08.pdf
19-57E-04.pdf
20-260E-06.pdf
66-24E-03.pdf
67-124E-06.pdf
75-01E-12.pdf
77-04E-04.pdf
S-7E-15.pdf
W-17E-07.pdf
W-18E-07.pdf
S1-239E-12_pdf
Document
01-217E-04.pdf
03-229E-03.pdf
05-54E-10.pdf
06-66E-10.pdf
07-144E-06.pdf
08-98E-08.pdf
09-167E-04.pdf
10-81E-14.pdf
11-73E-11.pdf
12-232E-04.pdf
13-339E-04.pdf
13-379E-02.pdf
14-142E-04.pdf
14-143E-04.pdf
15-181E-04.pdf
15-195E-02.pdf
16-27E-10.pdf
17-89E-10.pdf
18-28E-08.pdf
19-56E-04.pdf
20-340E-04.pdf
21-126E-05.pdf
22-114E-03.pdf
23-89E-01.pdf
51-28E-07.pdf
67-61E-13.pdf
75-09E-11.pdf
77-05E-02.pdf
77-07E-02.pdf
78-07E-03.pdf
S-12E-13.pdf
W-27E-05.pdf
S1-239E-12 .pdf
2002
2002 Engine Manual J08E-TA, TB_S5UJ08E02B.pdf
2002 Engine Manual_S5UJ05E02B.pdf
S1-134E-17-1_pdf
Document
01-218E-05.pdf
03-228E-05.pdf
15-180E-03.pdf
21-174E-02.pdf
22-114E-03.pdf
23-54E-06.pdf
23-55E-07.pdf
51-28E-08.pdf
78-07E-04.pdf
S-6E-16.pdf
S1-134E-17-1 .pdf
S1-134E-17-2_pdf
Document
01-218E-05.pdf
05-162E-01.pdf
05-86E-05.pdf
06-133E-07.pdf
07-141E-07.pdf
07-142E-07.pdf
07-164E-06.pdf
07-279E-01.pdf
08-183E-07.pdf
09-105E-06.pdf
09-48E-13.pdf
10-108E-07.pdf
11-64E-13.pdf
12-233E-05.pdf
13-243E-08.pdf
13-340E-04.pdf
14-144E-04.pdf
16-27E-11.pdf
17-191E-05.pdf
17-192E-04 .pdf
18-28E-09.pdf
19-57E-05.pdf
20-260E-07.pdf
66-24E-03.pdf
67-124E-07.pdf
67-203E-04.pdf
75-01E-13.pdf
77-04E-05.pdf
S-7E-16.pdf
W-44E-01.pdf
S1-134E-17-2 .pdf
S1-239E-13_pdf
Document
01-217E-05.pdf
03-229E-04.pdf
05-54E-10.pdf
06-66E-10.pdf
07-144E-07.pdf
08-98E-08.pdf
09-167E-05.pdf
10-81E-14.pdf
11-73E-12.pdf
12-232E-04.pdf
13-339E-05.pdf
13-379E-03.pdf
14-142E-05.pdf
14-143E-05.pdf
15-181E-04.pdf
15-195E-02.pdf
16-27E-10.pdf
17-89E-11.pdf
18-28E-09.pdf
19-56E-04.pdf
20-340E-05.pdf
21-174E-02.pdf
22-114E-03.pdf
23-89E-02.pdf
51-28E-08.pdf
67-61E-13.pdf
75-09E-12.pdf
77-05E-03.pdf
77-07E-02.pdf
78-07E-04.pdf
S-12E-14.pdf
Icon[013]
S1-239E-13 .pdf
2003
2003 Engine Manual FD FE SG COVER.pdf
2003 Engine Manual FD FE SG.pdf
2003 Owner's Manual_H1795E01.pdf
S1-134E-18-1.pdf
S1-134E-18-2.pdf
S1-239E-14.pdf
2004
S1-134E-19-1.pdf
S1-134E-19-2.pdf
S1-239E-16-1.pdf
2005
2005 Engine Manual_S5-UJ05E04C.pdf
2005 Engine Manual_S5-UJ08E04C.pdf
2005 Owner's Manual_H1A015E04.pdf
2005 Workshop Manual_S1-UNAE01B_1.pdf
2005 Workshop Manual_S1-UNAE01B_2.pdf
2005 Workshop Manual_S1-UNAE01B_3.pdf
2005 Workshop Manual_S1-UNAE01B_4.pdf
2006
2006 J05_ Engine Manual_S5UJ05E02B.pdf
2006 Owner's Manual_H1A016E01.pdf
2007
2007 Engine Manual_S5-UJ05E03A.pdf
2007 Owner's Manual H1-A017E01.pdf
2007 Workshop Manual_S1-UNAE03A-1.pdf
2007 Workshop Manual_S1-UNAE03A-2.pdf
2008
2008 HINO ENGINE J05 MANUAL.pdf
2008 HINO ENGINE J08 6 CYLINDER MANUAL_S5-UJ08E04A.pdf
2008 HINO OWNERS MANUAL.pdf
2008 HINO WORKSHOP MANUAL CHASSIS 1 OF 2.pdf
2008 HINO WORKSHOP MANUAL CHASSIS 2 OF 2.pdf
2009
2009 CHASSIS WORKSHOP PART 1.pdf
2009 CHASSIS WORKSHOP PART 2.pdf
2009 DRIVERS OWNERS MANUAL.pdf
2009 WORKSHOP ENGINE J08E.pdf
2009 WORKSHOP ENGINE JO5D-TF.pdf
2010
2010 CHASSIS_1 of 2.pdf
2010 CHASSIS_ 2 of 2 .pdf
2010 ENGINE_J05D.pdf
2010 ENGINE_J08E.pdf
2010 Owners Manual.pdf
2011_2013
11_12_13 BCU-DCU Codes.pdf
11_12_13 CHASSIS-1.pdf
11_12_13 CHASSIS-2(ver1).pdf
11_12_13 DX MANUAL.pdf
11_12_13 ECU Codes.pdf
11_12_13 J08 ENGINE.pdf
11-13MY Check Sheet (modK)rev_6_15_12.pdf
2014
COE_HEV
2014 COE Chassis DT_SA_BE_HEV_AC.pdf
2014 COE Engine.pdf
2014 COE EWD.pdf
2014 COE Owner's Manual_H1-L047E01.pdf
2014 COE Troubleshooting 1_ENG.pdf
2014 COE Troubleshooting 2_ENG.pdf
2014 COE Troubleshooting 3_ENG.pdf
2014 COE Troubleshooting 4_HEV_ATM_DT.pdf
2014 COE Troubleshooting 5_HEV_ATM_DT.pdf
2014 COE Troubleshooting 6_SA_BRAKE_ELEC.pdf
2014 COE Troubleshooting_DX.pdf
Conventional
2014 CONV Chassis 1_DT_ABS.pdf
2014 CONV Chassis 2_EWD.pdf
2014 CONV Engine.pdf
2014 Conventional Owner's Manual_H1-A034E01.pdf
2014 CONV Troubleshooting 1_ELEC_ENG_DPF.pdf
2014 CONV Troubleshooting 2_ENGINE.pdf
2014 CONV Troubleshooting 3_DEF_DPF_ABS_VCS.pdf
2014 CONV Troubleshooting_DX.pdf
2015
Conventional
2015 CONV Chassis 1_DT_ABS.pdf
2015 CONV Chassis 2_EWD.pdf
2015 CONV Engine.pdf
2015 Conventional Owner's Manual H1-A035E01.pdf
2015 CONV Troubleshooting 1_ELEC_ENG_DPF.pdf
2015 CONV Troubleshooting 2_ENGINE.pdf
2015 CONV Troubleshooting 3_DEF_DPF.pdf
2016
COE_HEV
16MY COE Owners Manual_H1-L053E01.pdf
2016 COE Chassis DT_SA_BE_HEV_AC.pdf
2016 COE Engine.pdf
2016 COE EWD.pdf
2016 COE Troubleshooting 1_ENG.pdf
2016 COE Troubleshooting 2_ENG.pdf
2016 COE Troubleshooting 3_ENG.pdf
2016 COE Troubleshooting 4_HEV_ATM_DT.pdf
2016 COE Troubleshooting 5_SA_BRAKE_ELEC.pdf
COE Keyless Conversion.ppt
Conventional
16MY Conv Owners Manual_H1-A036E01.pdf
2016 CONV Chassis 1_DT_ABS.pdf
2016 CONV Chassis 2_EWD.pdf
2016 CONV Engine.pdf
2016 CONV Troubleshooting 1_ELEC_ENG_DPF.pdf
2016 CONV Troubleshooting 2_ENGINE.pdf
2016 CONV Troubleshooting 3_DEF_DPF.pdf
Bulkhead JB Connector ID.pdf
PRODUCT DETAILS:
Total Pages: 21,212 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
16MY COE Owners Manual_H1-L053E01....1
16MY Conv Owners Manual_H1-A036E01....343
2016 COE Chassis DT_SA_BE_HEV_AC....811
FOREWORD....811
CHAPTER REFERENCES....812
INDEX....813
GENERAL INTRODUCTION....815
HOW TO IDENTIFY VEHICLE TYPE....816
HOW TO IDENTIFY VEHICLE TYPE....816
VEHICLE MODEL....816
VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE....817
APPEARANCE OF VEHICLE....818
APPEARANCE....818
APPEARANCE OF VEHICLE....818
SAFETY INSTRUCTIONS AND READINESS TO WORK....819
WARNING....819
GENERAL PRECAUTIONS....819
IDENTIFICATION INFORMATION....823
SAFETY INSTRUCTIONS FOR WORK....826
PRECAUTIONS....826
INTRODUCTION TO WORKSHOP MANUAL....830
GENERAL....830
INTRODUCTION TO DESCRIPTIONS....831
DEFINITION OF TERM....833
TIGHTENING OF BOLTS AND NUTS....834
BOLTS AND NUTS....834
PURPOSES OF TIGHTENING TORQUE....834
CAUTIONS TO PREVENT LOOSENESS....834
TYPES AND IDENTIFICATION....835
COMPATIBILITY (NO COMPATIBILITY IN BOLTS AND NUTS)....836
STRENGTH CLASSES AND SYMBOLS....837
PART No...838
LIST OF TIGHTENING TORQUE....839
TIGHTENING OF FLARE NUTS AND HOSES....841
HANDLING OF LIQUID GASKET....842
LIQUID GASKET....842
GLOSSARY....843
DEFINITION OF ABBREVIATION IN THIS MANUAL....843
LIST OF ABBREVIATION....843
GLOSSARY OF SAE AND HINO TERMS....846
LUBRICANTS....849
LUBRICANTS....849
RECOMMENDED LUBRICANTS....849
HYBRID....850
STANDARD VALUE....851
HYBRID SYSTEM....851
SERVICE PLUG....851
PCU....851
HV BATTERY....852
HV BATTERY COOLING FAN....852
HV BATTERY ECU....852
SYSTEM MAIN RELAY JUNCTION BLOCK....852
INVERTER....853
HV-ECU....853
HYBRID JUNCTION BLOCK....853
WATER PUMP....854
INVERTER RADIATOR....854
COOLANT....854
MOTOR CABLE....854
REQUIRED ITEMS....855
HYBRID SYSTEM....855
HYBRID SYSTEM....855
SERVICE PLUG....855
COOLANT....855
HYBRID SYSTEM....856
HYBRID SYSTEM....856
CAUTIONS....856
SERVICE PLUG....860
COMPONENT LOCATOR....860
UNIT CHECK....860
REPLACEMENT....861
PCU....863
COMPONENT LOCATOR....863
REPLACEMENT....867
HV BATTERY....872
COMPONENT LOCATOR....872
REPLACEMENT....874
HV BATTERY COOLING FAN....879
COMPONENT LOCATOR....879
REPLACEMENT....881
HV BATTERY ECU....884
COMPONENT LOCATOR....884
REPLACEMENT....885
SYSTEM MAIN RELAY JUNCTION BLOCK....888
COMPONENT LOCATOR....888
REPLACEMENT....889
INVERTER....891
COMPONENT LOCATOR....891
REPLACEMENT....892
HV-ECU....896
COMPONENT LOCATOR....896
REPLACEMENT....897
HYBRID JUNCTION BLOCK....899
COMPONENT LOCATOR....899
REPLACEMENT....900
WATER PUMP....903
COMPONENT LOCATOR....903
REPLACEMENT....904
INVERTER RADIATOR....907
COMPONENT LOCATOR....907
REPLACEMENT....908
COOLANT....911
REPLACEMENT....911
MOTOR CABLE....913
COMPONENT LOCATOR....913
REPLACEMENT....916
TRANSMISSION (A465)....922
STANDARD VALUE....923
ATTACHING AND DETACHING THE TRANSMISSION....923
AUTOMATIC TRANSMISSION ASSEMBLY....923
TRANSMISSION CONTROL....925
SHIFT LEVER ASSEMBLY....925
TRANSMISSION MECHANICAL....925
TURBINE SENSOR....925
SPEED SENSOR....925
NEUTRAL SWITCH....926
REQUIRED ITEMS....927
ATTACHING AND DETACHING THE TRANSMISSION....927
AUTOMATIC TRANSMISSION ASSEMBLY....927
NEUTRAL SWITCH....927
ATTACHING AND DETACHING THE TRANSMISSION....928
AUTOMATIC TRANSMISSION ASSEMBLY....928
REPLACEMENT....928
TRANSMISSION CONTROL....971
CONTROL COMPUTER ASSEMBLY....971
COMPONENT LOCATOR....971
OVERHAUL....972
SHIFT LEVER ASSEMBLY....978
COMPONENT LOCATOR....978
OVERHAUL....979
TRANSMISSION MECHANICAL....983
OIL PAN GASKET....983
COMPONENT LOCATOR....983
OVERHAUL....984
REAR CASE GASKET....986
COMPONENT LOCATOR....986
OVERHAUL....987
TURBINE SENSOR....990
COMPONENT LOCATOR....990
OVERHAUL....991
SPEED SENSOR....992
COMPONENT LOCATOR....992
OVERHAUL....993
NEUTRAL SWITCH....994
COMPONENT LOCATOR....994
OVERHAUL....995
PROPELLER SHAFT (LD)....998
STANDARD VALUE....999
PROPELLER SHAFT MECHANICAL....999
PROPELLER SHAFT ASSEMBLY....999
REQUIRED ITEMS....1000
PROPELLER SHAFT MECHANICAL....1000
PROPELLER SHAFT ASSEMBLY....1000
PROPELLER SHAFT MECHANICAL....1002
PROPELLER SHAFT ASSEMBLY....1002
COMPONENT LOCATOR....1002
OVERHAUL....1004
AXLE....1019
STANDARD VALUE....1020
FRONT AXLE....1020
STEERING KNUCKLE....1020
FRONT AXLE HUB....1021
REAR AXLE....1022
REAR AXLE HUB....1022
REAR AXLE SHAFT....1022
REQUIRED ITEMS....1023
FRONT AXLE....1023
STEERING KNUCKLE....1023
FRONT AXLE HUB....1024
REAR AXLE....1027
REAR AXLE HUB....1027
REAR AXLE SHAFT....1028
WHEEL AND TIRE....1029
FRONT AXLE....1030
STEERING KNUCKLE....1030
COMPONENT LOCATOR....1030
OVERHAUL....1034
FRONT AXLE HUB....1049
COMPONENT LOCATOR....1049
OVERHAUL....1051
FRONT AXLE HUB BOLT....1062
COMPONENT LOCATOR....1062
OVERHAUL....1063
REAR AXLE....1065
REAR AXLE HUB....1065
COMPONENT LOCATOR....1065
OVERHAUL....1067
REAR AXLE SHAFT....1077
COMPONENT LOCATOR....1077
OVERHAUL....1078
WHEEL AND TIRE....1079
WHEEL AND TIRE....1079
COMPONENT LOCATOR....1079
INSPECTION....1080
REPLACEMENT....1082
OVERHAUL (TUBELESS TIRE)....1085
DIFFERENTIAL (SH13)....1092
STANDARD VALUE....1093
DIFFERENTIAL....1093
DIFFERENTIAL CARRIER....1093
REQUIRED ITEMS....1095
DIFFERENTIAL....1095
DIFFERENTIAL CARRIER....1095
DIFFERENTIAL....1098
DIFFERENTIAL CARRIER....1098
COMPONENT LOCATOR....1098
OVERHAUL....1104
BRAKE....1136
STANDARD VALUE....1138
BRAKE CONTROL....1138
SERVICE BRAKE....1138
BRAKE FLUID....1138
BRAKE ACTUATOR....1139
SPEED SENSOR....1139
BRAKE PEDAL....1140
BRAKE MASTER CYLINDER....1140
BRAKE BOOSTER....1140
HYDRO BOOSTER....1141
ELECTRIC VACUUM PUMP....1141
VACUUM PUMP....1141
HYDRO PUMP....1142
VACUUM RESERVOIR....1142
FRONT FLEXIBLE HOSE....1142
REAR FLEXIBLE HOSE....1142
VACUUM WARNING BUZZER....1142
DISC BRAKE....1143
FRONT DISC CALIPER....1143
REAR DISC CALIPER....1144
PARKING BRAKE....1145
PARKING BRAKE....1145
PARKING BRAKE CABLE No.2....1145
PARKING BRAKE CABLE No.3....1145
PARKING BRAKE LEVER....1145
PARKING BRAKE DRUM....1146
PARKING BRAKE SWITCH....1146
REQUIRED ITEMS....1147
SERVICE BRAKE....1147
SERVICE BRAKE....1147
BRAKE FLUID....1147
SPEED SENSOR....1147
BRAKE PEDAL....1147
BRAKE BOOSTER....1147
HYDRO BOOSTER....1148
VACUUM RESERVOIR....1148
DISC BRAKE....1148
FRONT DISC CALIPER....1148
REAR DISC CALIPER....1148
PARKING BRAKE....1149
PARKING BRAKE DRUM....1149
BRAKE CONTROL....1150
SERVICE BRAKE....1150
INSPECTION AND ADJUSTMENT....1150
BRAKE FLUID....1155
REPLACEMENT....1155
ABS ACTUATOR....1158
COMPONENT LOCATOR....1158
REPLACEMENT....1159
UNIT CHECK....1161
SPEED SENSOR....1162
COMPONENT LOCATOR....1162
UNIT CHECK....1164
REPLACEMENT....1165
BRAKE PEDAL....1168
COMPONENT LOCATOR....1168
REPLACEMENT....1169
BRAKE MASTER CYLINDER....1172
COMPONENT LOCATOR....1172
REPLACEMENT....1173
BRAKE BOOSTER....1177
COMPONENT LOCATOR....1177
REPLACEMENT....1178
HYDRO BOOSTER....1186
COMPONENT LOCATOR....1186
REPLACEMENT....1187
ELECTRIC VACUUM PUMP....1192
COMPONENT LOCATOR....1192
OVERHAUL....1193
VACUUM PUMP....1197
COMPONENT LOCATOR....1197
OVERHAUL....1198
HYDRO PUMP....1200
COMPONENT LOCATOR....1200
OVERHAUL....1201
VACUUM RESERVOIR....1202
COMPONENT LOCATOR....1202
REPLACEMENT....1203
FRONT FLEXIBLE HOSE....1205
COMPONENT LOCATOR....1205
REPLACEMENT....1206
REAR FLEXIBLE HOSE....1208
COMPONENT LOCATOR....1208
REPLACEMENT....1209
VACUUM WARNING BUZZER....1211
BEHIND-THE-WHEEL INSPECTION....1211
REPLACEMENT....1211
VACUUM SENSOR (FOR SKID CONTROL)....1212
COMPONENT LOCATOR....1212
REPLACEMENT....1213
DISC BRAKE....1216
FRONT BRAKE CALIPER....1216
COMPONENT LOCATOR....1216
OVERHAUL....1217
REAR BRAKE CALIPER....1224
COMPONENT LOCATOR....1224
OVERHAUL....1225
PARKING BRAKE....1232
PARKING BRAKE....1232
INSPECTION AND ADJUSTMENT....1232
PARKING BRAKE CABLE No.2....1234
COMPONENT LOCATOR....1234
REPLACEMENT....1235
PARKING BRAKE CABLE No.3....1241
COMPONENT LOCATOR....1241
REPLACEMENT....1242
PARKING BRAKE LEVER....1247
COMPONENT LOCATOR....1247
REPLACEMENT....1248
PARKING BRAKE DRUM....1252
COMPONENT LOCATOR....1252
OVERHAUL....1254
PARKING BRAKE SWITCH....1264
COMPONENT LOCATOR....1264
REPLACEMENT....1265
STEERING....1267
STANDARD VALUE....1268
STEERING CONTROL....1268
POWER STEERING SYSTEM....1268
STEERING WHEEL....1268
STEERING COLUMN....1268
STEERING LINKAGE....1269
POWER STEERING GEAR....1269
POWER STEERING PUMP....1269
REQUIRED ITEMS....1270
STEERING CONTROL....1270
POWER STEERING SYSTEM....1270
STEERING WHEEL....1270
STEERING COLUMN....1271
STEERING LINKAGE....1271
POWER STEERING GEAR....1272
POWER STEERING PUMP....1272
STEERING CONTROL....1273
POWER STEERING SYSTEM....1273
PERFORMANCE INSPECTION....1273
STEERING WHEEL....1276
COMPONENT LOCATOR....1276
REPLACEMENT....1277
STEERING COLUMN....1280
COMPONENT LOCATOR....1280
REPLACEMENT....1281
STEERING LINKAGE....1288
COMPONENT LOCATOR....1288
REPLACEMENT....1289
POWER STEERING GEAR....1296
COMPONENT LOCATOR....1296
REPLACEMENT....1297
POWER STEERING PUMP....1308
COMPONENT LOCATOR....1308
REPLACEMENT....1309
SUSPENSION....1311
STANDARD VALUE....1312
FRONT SUSPENSION....1312
SHOCK ABSORBER....1312
LEAF SPRING....1312
STABILIZER....1313
WHEEL ALIGNMENT....1313
REAR SUSPENSION....1314
SHOCK ABSORBER....1314
LEAF SPRING....1314
REQUIRED ITEMS....1315
FRONT SUSPENSION....1315
SHOCK ABSORBER....1315
LEAF SPRING....1315
WHEEL ALIGNMENT....1316
REAR SUSPENSION....1317
SHOCK ABSORBER....1317
LEAF SPRING....1317
FRONT SUSPENSION....1318
SHOCK ABSORBER....1318
COMPONENT LOCATOR....1318
REPLACEMENT....1319
LEAF SPRING....1322
COMPONENT LOCATOR....1322
OVERHAUL....1323
STABILIZER....1331
COMPONENT LOCATOR....1331
REPLACEMENT....1332
WHEEL ALIGNMENT....1334
ADJUSTMENT....1334
REAR SUSPENSION....1338
SHOCK ABSORBER....1338
COMPONENT LOCATOR....1338
REPLACEMENT....1339
LEAF SPRING....1342
COMPONENT LOCATOR....1342
OVERHAUL....1344
FRAME AND FRAME ACCESSORY....1353
STANDARD VALUE....1354
FRAME....1354
CHASSIS FRAME....1354
FRONT BUMPER....1354
REQUIRED ITEMS....1355
FRAME....1355
CHASSIS FRAME & CHASSIS FRAME ACCESSORIES....1355
FRAME....1356
FRAME AND FRAME ACCESSORIES....1356
COMPONENT LOCATOR....1356
FRAME....1357
INSPECTION....1357
REPAIR....1358
FRONT BUMPER....1363
COMPONENT LOCATOR....1363
REPLACEMENT....1364
CAB MOUNTING AND CAB SUSPENSION....1367
STANDARD VALUE....1368
CAB MOUNTING AND CAB SUSPENSION....1368
ASSEMBLY....1368
CAB MOUNTING....1368
TILT CAB STAY....1369
MOUNTING AND DISMOUNTING CAB....1370
CAB ASSEMBLY....1370
REPLACEMENT....1370
CAB MOUNTING AND CAB SUSPENSION....1384
CAB MOUNTING....1384
COMPONENT LOCATOR....1384
PRECAUTIONS IN TILTING AND LOWERINGTHE CAB....1388
REPLACEMENT....1389
CAB TILT STAY....1400
COMPONENT LOCATOR....1400
PRECAUTIONS IN TILTING AND LOWERINGTHE CAB....1403
REPLACEMENT....1404
CAB DIMENSIONAL DRAWING....1409
CAB ASSEMBLY....1409
SINGLE CAB....1409
CREW CAB....1411
BODY INSIDE ACCESSORY....1413
STANDARD VALUE....1414
INSTRUMENT PANEL AND DRIVER INFORMATION....1414
INSTRUMENT PANEL....1414
INTERIOR ACCESSORY....1414
ROOF ACCESSORY....1414
SEAT....1414
DRIVER'S SEAT....1414
ASSISTANT'S SEAT....1415
REAR SEAT....1415
INSTRUMENT PANEL AND DRIVER INFORMATION....1416
INSTRUMENT PANEL....1416
COMPONENT LOCATOR....1416
REPLACEMENT....1418
COMBINATION METER....1428
REPLACEMENT....1428
INTERIOR ACCESSORY....1429
INTERIOR ACCESSORY....1429
COMPONENT LOCATOR....1429
REPLACEMENT....1431
FLOOR ACCESSORY....1434
COMPONENT LOCATOR....1434
REPLACEMENT....1435
ROOF ACCESSORY....1436
COMPONENT LOCATOR....1436
REPLACEMENT....1437
SEAT....1444
DRIVER'S SEAT....1444
COMPONENT LOCATOR....1444
OVERHAUL....1446
ASSISTANT'S SEAT....1458
COMPONENT LOCATOR....1458
OVERHAUL (THREE-SEATER)....1461
OVERHAUL (CREW CAB)....1469
REAR SEAT....1475
COMPONENT LOCATOR....1475
OVERHAUL....1477
BODY OUTSIDE ACCESSORY....1487
STANDARD VALUE....1488
DOOR....1488
DOOR HINGE....1488
DOOR ACCESSORIES....1488
REQUIRED ITEMS....1489
DOOR....1489
DOOR ACCESSORIES....1489
POWER WINDOW....1489
AUTO DOOR LOCK SYSTEM....1489
WINDOW GLASS....1490
GLASS....1490
MIRROR....1491
POWER MIRROR....1491
DOOR....1492
DOOR HINGE....1492
INSPECTION AND ADJUSTMENT....1492
DOOR ACCESSORY....1496
COMPONENT LOCATOR....1496
OVERHAUL....1502
POWER WINDOW....1524
SINGLE UNIT INSPECTION....1524
AUTO DOOR LOCK SYSTEM....1527
PERFORMANCE INSPECTION....1527
SINGLE UNIT INSPECTION....1527
KEYLESS ENTRY....1529
PERFORMANCE INSPECTION....1529
WINDOW GLASS....1530
GLASS....1530
COMPONENT LOCATOR....1530
REPLACEMENT....1532
MIRROR....1542
REAR VIEW MIRROR....1542
COMPONENT LOCATOR....1542
REPLACEMENT....1543
POWER MIRROR....1544
SINGLE UNIT INSPECTION....1544
ACCESSORY....1545
OUTSIDE ACCESSORY....1545
COMPONENT LOCATOR....1545
REPLACEMENT....1546
AIR BAG AND SEAT BELT....1551
STANDARD VALUE....1552
SEAT BELT....1552
SEAT BELT....1552
CENTER SEAT BELT....1552
REAR SEAT BELT....1553
SEAT BELT....1554
SEAT BELT....1554
COMPONENT LOCATOR....1554
REPLACEMENT....1555
CENTER SEAT BELT....1557
COMPONENT LOCATOR....1557
REPLACEMENT....1558
REAR SEAT BELT....1559
COMPONENT LOCATOR....1559
REPLACEMENT....1560
HEATER AND AIR CONDITIONER....1561
STANDARD VALUE....1562
AIR CONDITIONER....1562
AIR CONDITIONER....1562
V-BELT....1563
COOLER COMPRESSOR....1563
CONDENSER (WIDE CAB MODEL TYPE WITH FAN)....1564
HVAC (WIDE CAB MODEL)....1564
HEATER CONTROL....1564
REAR HEATER (CREW CAB)....1565
REAR COOLER (CREW CAB)....1565
REQUIRED ITEMS....1566
AIR CONDITIONER....1566
AIR CONDITIONER....1566
V-BELT....1566
COOLER COMPRESSOR....1566
CONDENSER (REGULAR CAB MODEL TYPE WITH FAN)....1567
CONDENSER (WIDE CAB MODEL TYPE WITH FAN)....1567
AIR CONDITIONER....1568
AIR CONDITIONER....1568
SAFETY INSTRUCTIONS FOR WORK....1568
COLLECTION/FILLING OF REFRIGERANT....1572
MAINTENANCE....1580
V-BELT....1583
COMPONENT LOCATOR....1583
REPLACEMENT....1584
COOLER COMPRESSOR....1588
COMPONENT LOCATOR....1588
REPLACEMENT....1589
CONDENSER (WIDE CAB MODEL TYPE WITH FAN)....1593
COMPONENT LOCATOR....1593
REPLACEMENT....1594
HVAC (WIDE CAB MODEL)....1598
COMPONENT LOCATOR....1598
REPLACEMENT....1600
HEATER CONTROL....1607
COMPONENT LOCATOR....1607
REPLACEMENT....1608
REAR HEATER (CREW CAB)....1611
COMPONENT LOCATOR....1611
REPLACEMENT....1612
REAR HEATER BLOWER SWITCH (CREW CAB)....1618
COMPONENT LOCATOR....1618
REPLACEMENT....1619
REAR COOLER (CREW CAB)....1621
COMPONENT LOCATOR....1621
REPLACEMENT....1622
COOLER CONTROL SWITCH (CREW CAB)....1629
COMPONENT LOCATOR....1629
REPLACEMENT....1630
ELECTRICAL....1633
STANDARD VALUE....1634
LIGHTING....1634
HEADLIGHT....1634
WIPER AND WASHER....1634
WIPER....1634
WASHER....1634
REQUIRED ITEMS....1635
LIGHTING....1635
COMBINATION SWITCH....1635
LIGHTING....1636
HEADLIGHT....1636
COMPONENT LOCATOR....1636
OPTICAL AXIS ADJUSTMENT....1637
REPLACEMENT....1638
ID LIGHT....1639
COMPONENT LOCATOR....1639
REPLACEMENT....1640
ROOM LIGHT....1641
COMPONENT LOCATOR....1641
REPLACEMENT....1642
COMBINATION SWITCH....1643
COMPONENT LOCATOR....1643
REPLACEMENT....1644
INSPECTION....1644
WIPER AND WASHER....1647
WIPER....1647
COMPONENT LOCATOR....1647
REPLACEMENT....1648
WASHER....1651
COMPONENT LOCATOR....1651
REPLACEMENT....1652
COMPUTER....1654
COMPUTER....1654
MOUNTING POSITION....1654
SWITCH....1656
SWITCH....1656
MOUNTING POSITION....1656
FUSE AND RELAY....1657
FUSE BLOCK....1657
MOUNTING POSITION....1657
RELAY....1659
MOUNTING POSITION....1659
CONTROL SYSTEM....1660
REQUIRED ITEMS....1661
IDLING STOP....1661
SLOPE LEARNING....1661
IDLING STOP....1662
IDLING STOP SYSTEM....1662
SLOPE LEARNING....1662
CRUISE CONTROL....1664
CRUISE MAIN SWITCH....1664
COMPONENT LOCATOR....1664
REPLACEMENT....1665
SINGLE UNIT INSPECTION....1666
2016 COE EWD....1668
FOREWORD....1668
CHAPTER REFERENCES....1669
INDEX....1670
GENERAL INTRODUCTION....1671
HOW TO USE THIS MANUAL....1672
GRAPHICAL SYMBOLS FOR WIRING DIAGRAMS, ABBREVIATIONS AND TERMS....1672
WIRING DIAGRAM....1677
WIRE TO WIRE CONNECTOR....1678
JUNCTION CONNECTOR....1679
LOCATION....1680
RELAY LOCATION / FUSE AND RELAY BLOCK....1681
ABOUT CONNECTOR....1685
WIRING DIAGRAM ACCORDING TO SYSTEM....1687
WIRING DIAGRAM....1688
WIRING HARNESS CODE....1688
AC. POWER SUPPLY CIRCUIT....1690
AF. GROUND CIRCUIT....1694
AH. CHARGING CIRCUIT....1696
AK. ENGINE STARTING CIRCUIT....1698
AN. CAN COMMUNICATION CIRCUIT....1700
AO. CAN COMMUNICATION CIRCUIT [HV]....1702
BG. ENGINE ECU CIRCUIT [J05] 1/2....1706
BH. ENGINE ECU CIRCUIT [J05] 2/2....1710
BI. DEF SCR CIRCUIT....1718
BJ. HYDRO BOOST SYSTEM CIRCUIT....1720
BN. GLOW PLUG CIRCUIT....1722
BP. FUEL HEATER CIRCUIT....1724
CC. AT CIRCUIT [A465]....1726
CE. CLUTCH ECU CIRCUIT....1732
CF. HV PCU CIRCUIT....1736
DA. ABS/PAB+VSC CIRCUIT....1738
DD. VEHICLE CONTROL ECU CIRCUIT....1740
EC. POWER DOOR LOCK CIRCUIT....1742
ED. KEYLESS ENTRY CIRCUIT....1744
EG. POWER WINDOW CIRCUIT [FRONT]....1746
EH. POWER WINDOW CIRCUIT [REAR]....1748
FA. COMBINATION METER CIRCUIT....1750
FB. PARKING BRAKE WARNING CIRCUIT....1754
FC. WEAR INDICATOR CIRCUIT....1756
FD. HORN RELAY CIRCUIT....1758
FE. COOLANT LEVEL WARNING CIRCUIT....1760
FF. DIAGNOSIS MONITOR CIRCUIT....1762
FJ. RHEOSTAT CIRCUIT....1764
FK. TELEMATICS CIRCUIT....1766
GA. HEADLIGHT CIRCUIT....1768
GD. HEADLIGHT SUB CIRCUIT ....1770
GG. TAIL LIGHT CIRCUIT....1772
GH. STOP LIGHT CIRCUIT....1774
GJ. TURN / HAZARD CIRCUIT....1776
GL. COMBINATION LIGHT CIRCUIT....1778
HA. ROOM LIGHT CIRCUIT....1780
JA. WIPER AND WASHER CIRCUIT....1782
JD. MIRROR HEATER CIRCUIT....1784
JE. REMOTE CONTROL MIRROR CIRCUIT....1786
KA. RADIO CIRCUIT....1788
KB. CIGAR LIGHTER CIRCUIT....1790
LB. HEATER AND AIR CONDITIONER CIRCUIT....1792
LF. REAR HEATER AND AIR CONDITIONER CIRCUIT....1796
MA. OUTLET POWER SUPPLY CIRCUIT....1798
WIRE TO WIRE CONNECTOR....1800
WIRE TO WIRE CONNECTOR....1801
WIRE TO WIRE CONNECTOR LIST....1801
JUNCTION CONNECTOR....1817
JUNCTION CONNECTOR....1818
JUNCTION CONNECTOR LIST....1818
LOCATION....1834
CONNECTOR LOCATION....1835
CONTENTS....1835
QUICK REFERENCE....1836
IP-1 [INSTRUMENT PANEL (1 of 6)]....1837
IP-2 [INSTRUMENT PANEL (2 of 6)]....1839
IP-3 [INSTRUMENT PANEL (3 of 6)]....1841
IP-4 [INSTRUMENT PANEL (4 of 6)]....1843
IP-5 [INSTRUMENT PANEL (5 of 6)]....1847
IP-6 [INSTRUMENT PANEL (6 of 6)]....1849
CA-1 [CAB (1 of 2)] (Models: Single cab (Floor / Cowl))....1851
CA-2 [CAB (2 of 2)] (Models: Single cab (Roof / Door))....1853
CA-3 [CAB (1 of 2)] (Models: Crew cab (Floor))....1855
CA-4 [CAB (2 of 2)] (Models: Crew cab (Roof / Door))....1857
EG-1 [ENGINE (1 of 4)] (Models: J05E Engine)....1859
EG-2 [ENGINE (2 of 4)] (Models: J05E Engine)....1861
EG-3 [ENGINE (3 of 4)] (Models: J05E Engine)....1863
EG-4 [ENGINE (4 of 4)] (Models: J05E Engine)....1865
EG-5 [ENGINE] (Models: J05E Engine (Right rear))....1867
EG-6 [ENGINE (1 of 4)] (Models: J05E Engine HV)....1869
EG-7 [ENGINE (2 of 4)] (Models: J05E Engine HV)....1871
EG-8 [ENGINE (3 of 4)] (Models: J05E Engine HV)....1873
EG-9 [ENGINE (4 of 4)] (Models: J05E Engine HV)....1875
EG-10 [ENGINE] (Models: J05E Engine HV (Right rear))....1877
RR-1 [REAR] (Models: Except HV)....1879
RR-2 [REAR] (Models: HV)....1881
RELAY LOCATION/FUSE AND RELAY BLOCK....1883
RELAY LOCATION....1884
INSTRUMENT PANEL....1884
CHASSIS....1885
FUSE AND RELAY BLOCK....1886
CHASSIS RELAY BLOCK....1886
CAB RELAY....1889
RELAY BLOCK No.2....1890
JUNCTION BLOCK....1891
JUNCTION BLOCK....1891
WIRE TO WIRE BOX....1893
WIRE TO WIRE ALIGNMENT....1893
INDEX....1894
CONNECTOR INDEX....1895
ELECTRICAL EQUIPMENT CONNECTOR....1895
WIRE TO WIRE CONNECTOR....1911
JUNCTION CONNECTOR....1914
2016 COE Engine....1918
FOREWORD....1918
CHAPTER REFERENCES....1919
INDEX....1920
GENERAL INTRODUCTION....1922
HOW TO IDENTIFY VEHICLE TYPE....1923
VEHICLE MODEL....1923
VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE....1924
APPEARANCE OF VEHICLE....1925
APPEARANCE OF VEHICLE....1925
SAFETY INSTRUCTIONS AND READINESS TO WORK....1926
WARNING....1926
IDENTIFICATION INFORMATION....1930
SAFETY INSTRUCTIONS FOR WORK....1933
INTRODUCTION TO WORKSHOP MANUAL....1936
TIGHTENING OF BOLTS AND NUTS....1940
HANDLING OF LIQUID GASKET....1950
GLOSSARY....1951
DEFINITION OF ABBREVIATION IN THIS MANUAL....1951
LUBRICANTS....1957
RECOMMENDED LUBRICANTS....1957
STANDARD VALUE (J05E)....1958
MOUNTING AND DISMOUNTING THE ENGINE....1960
ENGINE ASSEMBLY....1960
ENGINE CONTROL....1961
ENGINE ECU....1961
ENGINE SPEED MAIN SENSOR....1961
ENGINE SPEED SUB SENSOR....1961
ACCELERATOR PEDAL....1962
BLOCK HEATER....1962
FUEL SYSTEM....1963
FUEL TANK....1963
FUEL SENDER GAUGE....1963
ENGINE-SIDE FUEL FILTER & CASE....1964
WATER LEVEL WARNING SWITCH....1964
SUPPLY PUMP....1965
INJECTOR....1965
COMMON RAIL....1966
VEHICLE-SIDE FUEL FILTER....1966
FUEL COOLER....1966
EMISSION CONTROL....1967
EGR VALVE & COOLER....1967
CLOSED VENTILATOR....1967
INTAKE....1968
INTAKE MANIFOLD....1968
DIESEL THROTTLE....1968
INTAKE PIPE (EXHAUST SIDE)....1968
STACK DUCT....1968
AIR CLEANER....1969
INTAKE TEMPERATURE SENSOR....1969
BOOST PRESSURE SENSOR....1969
AIR FLOW SENSOR....1969
ENGINE MECHANICAL....1970
HEAD COVER....1970
ROCKER ARM ASSEMBLY....1970
CAMSHAFT ASSEMBLY....1971
CYLINDER HEAD ASSEMBLY....1972
VALVE SYSTEM....1973
CRANKSHAFT PULLEY....1974
FRONT OIL SEAL RETAINER....1974
FLYWHEEL ASSEMBLY....1974
FLYWHEEL HOUSING....1974
TIMING GEAR & CAM IDLE GEAR....1975
PISTON & CONNECTING ROD....1976
CRANKSHAFT....1977
CYLINDER LINER....1978
CYLINDER BLOCK....1978
ENGINE MOUNTING AND BRACKET....1979
GLOW PLUG....1979
EXHAUST....1980
EXHAUST MANIFOLD....1980
EXHAUST PIPE....1980
EXHAUST PIPE (ATC)....1980
DEF-SCR....1981
DPR CLEANER....1981
FUEL ADDITION VALVE....1982
FUEL CUTOFF VALVE....1982
DEF PUMP....1982
DEF INJECTOR....1983
DEF TANK....1983
COOLANT CUTOFF VALVE....1983
DCU....1984
DPR DIFFERENTIAL PRESSURE SENSOR....1984
SCR UPSTREAM NOx SENSOR....1984
SCR DOWNSTREAM NOx SENSOR....1984
ATC UPSTREAM TEMPERATURE SENSOR....1985
DOC UPSTREAM TEMPERATURE SENSOR....1985
DPR UPSTREAM TEMPERATURE SENSOR....1985
DPR DOWNSTREAM TEMPERATURE SENSOR....1986
SCR UPSTREAM TEMPERATURE SENSOR....1986
EXHAUST BRAKE....1987
EXHAUST BRAKE MAGNETIC VALVE....1987
COOLING....1988
RADIATOR....1988
RADIATOR CAP....1988
RESERVE TANK....1988
INTERCOOLER....1989
THERMOSTAT CASE & THERMOSTAT....1989
COOLANT PUMP....1989
COOLING FAN & FAN CLUTCH....1990
COOLANT TEMPERATURE SENSOR....1990
LUBRICATION....1991
OIL COOLER....1991
OIL PUMP....1991
OIL PAN....1992
OIL STRAINER....1992
OIL PRESSURE SWITCH....1992
OIL LEVEL GAUGE AND GUIDE....1992
STARTING/CHARGING....1993
STARTER....1993
V-BELT....1993
ALTERNATOR (130 A)....1994
TURBOCHARGER....1995
TURBOCHARGER ASSEMBLY....1995
REQUIRED ITEMS (J05E)....1996
MOUNTING AND DISMOUNTING THE ENGINE....1997
ENGINE ASSEMBLY....1997
ENGINE CONTROL....1998
ENGINE ECU....1998
ENGINE MAIN REVOLUTION SENSOR....1998
ENGINE SUB REVOLUTION SENSOR....1999
ACCELERATOR PEDAL....2000
IDLE SET VOLUME....2000
FUEL SYSTEM....2001
FUEL SENDER GAUGE....2001
WATER LEVEL WARNING SWITCH....2001
SUPPLY PUMP....2002
INJECTOR....2003
COMMON RAIL....2004
FUEL FILTER AND CASE (VEHICLE SIDE)....2004
EMISSION CONTROL....2005
EGR VALVE AND COOLER....2005
INTAKE....2006
DIESEL THROTTLE....2006
BOOST PRESSURE SENSOR....2007
AIR FLOW SENSOR....2008
ENGINE MECHANICAL....2009
HEAD COVER....2009
ROCKER ARM ASSEMBLY....2009
CAMSHAFT ASSEMBLY....2009
CYLINDER HEAD ASSEMBLY....2010
VALVE SYSTEM....2011
CRANKSHAFT FRONT OIL SEAL....2012
FRONT OIL SEAL RETAINER....2012
FLYWHEEL ASSEMBLY....2012
CRANKSHAFT REAR OIL SEAL....2013
FLYWHEEL HOUSING....2013
TIMING GEAR AND CAM IDLE GEAR....2014
PISTON AND CONNECTING ROD....2015
CRANKSHAFT....2017
CYLINDER LINER....2018
CYLINDER BLOCK....2019
GLOW PLUG....2019
EXHAUST....2020
EXHAUST MANIFOLD....2020
DPR....2020
FUEL ADDITION VALVE....2021
DEF PUMP....2021
DEF INJECTOR....2021
DEF TANK....2022
DPR DIFFERENTIAL PRESSURE SENSOR....2022
SCR UPSTREAM NOx SENSOR....2022
SCR DOWNSTREAM NOx SENSOR....2022
ATC UPSTREAM TEMPERATURE SENSOR....2023
DOC UPSTREAM TEMPERATURE SENSOR....2023
DPR UPSTREAM TEMPERATURE SENSOR....2023
DPR DOWNSTREAM TEMPERATURE SENSOR....2024
SCR UPSTREAM TEMPERATURE SENSOR....2024
DPR EXHAUST GAS TEMPERATURE SENSOR....2024
EXHAUST BRAKE....2025
EXHAUST BRAKE MAGNETIC VALVE....2025
COOLING....2026
RADIATOR CAP....2026
THERMOSTAT CASE AND THERMOSTAT....2026
COOLANT PUMP....2027
COOLANT TEMPERATURE SENSOR....2027
LUBRICATION....2028
OIL FILTER....2028
OIL COOLER....2028
OIL PUMP....2029
OIL PAN....2029
OIL PRESSURE SWITCH....2029
STARTING/CHARGING....2030
STARTER....2030
V-BELT....2030
ALTERNATOR (130A)....2030
TURBOCHARGER....2031
TURBOCHARGER ASSEMBLY....2031
MOUNTING AND DISMOUNTING THE ENGINE....2033
ENGINE ASSEMBLY....2034
PRECAUTIONS IN TILTING AND LOWERING THE CAB....2034
MEASUREMENT OF COMPRESSION PRESSURE....2034
ADJUSTING THE VALVE CLEARANCE....2037
REPLACEMENT....2039
ENGINE CONTROL (J05E)....2048
CONTROL PARTS....2049
SYSTEM BLOCK DIAGRAM....2049
ENGINE ECU....2050
COMPONENT LOCATOR....2050
REPLACEMENT....2051
VEHICLE CONTROL ECU....2057
REPLACEMENT....2057
ENGINE SPEED MAIN SENSOR....2058
COMPONENT LOCATOR....2058
INSPECTION....2059
REPLACEMENT....2059
ENGINE SPEED SUB SENSOR....2060
COMPONENT LOCATOR....2060
INSPECTION....2061
REPLACEMENT....2061
ACCELERATOR PEDAL....2062
COMPONENT LOCATOR....2062
REPLACEMENT....2063
BLOCK HEATER....2064
COMPONENT LOCATOR....2064
REPLACEMENT....2065
FUEL SENDER GAUGE....2066
REPLACEMENT....2066
INTAKE TEMPERATURE SENSOR....2066
REPLACEMENT....2066
DIESEL THROTTLE....2066
REPLACEMENT....2066
BOOST PRESSURE SENSOR....2067
REPLACEMENT....2067
AIR FLOW SENSOR....2067
REPLACEMENT....2067
DPR DIFFERENTIAL PRESSURE SENSOR....2068
REPLACEMENT....2068
SCR UPSTREAM NOx SENSOR....2068
REPLACEMENT....2068
SCR DOWNSTREAM NOx SENSOR....2068
REPLACEMENT....2068
ATC UPSTREAM TEMPERATURE SENSOR....2069
REPLACEMENT....2069
DOC UPSTREAM TEMPERATURE SENSOR....2069
REPLACEMENT....2069
DPR UPSTREAM TEMPERATURE SENSOR....2070
REPLACEMENT....2070
DPR DOWNSTREAM TEMPERATURE SENSOR....2070
REPLACEMENT....2070
SCR UPSTREAM TEMPERATURE SENSOR....2071
REPLACEMENT....2071
OUTSIDE TEMPERATURE SENSOR....2071
REPLACEMENT....2071
COOLANT TEMPERATURE SENSOR....2072
REPLACEMENT....2072
OIL PRESSURE SWITCH....2072
REPLACEMENT....2072
FUEL SYSTEM (J05E)....2073
FUEL SYSTEM....2074
FUEL SYSTEM DIAGRAM....2074
FUEL TANK....2075
COMPONENT LOCATOR....2075
REPLACEMENT (30 GALLON)....2076
REPLACEMENT (33 GALLON)....2079
FUEL SENDER GAUGE....2083
COMPONENT LOCATOR....2083
REPLACEMENT....2084
FUEL FILTER AND CASE (ENGINE SIDE)....2086
COMPONENT LOCATOR....2086
REPLACEMENT....2087
WATER LEVEL WARNING SWITCH....2096
COMPONENT LOCATOR....2096
REPLACEMENT....2097
SUPPLY PUMP....2099
COMPONENT LOCATOR....2099
REPLACEMENT....2100
INJECTOR....2110
COMPONENT LOCATOR....2110
REPLACEMENT....2111
COMMON RAIL....2120
COMPONENT LOCATOR....2120
INSPECTION....2121
REPLACEMENT....2122
FUEL FILTER AND CASE (VEHICLE SIDE)....2127
COMPONENT LOCATOR....2127
REPLACEMENT....2128
FUEL COOLER....2135
COMPONENT LOCATOR....2135
REPLACEMENT....2136
EMISSION CONTROL (J05E)....2138
EGR VALVE & COOLER....2139
COMPONENT LOCATOR....2139
INSPECTION....2140
REPLACEMENT....2140
CLOSED VENTILATOR....2147
COMPONENT LOCATOR....2147
REPLACEMENT....2149
INTAKE (J05E)....2153
INTAKE MANIFOLD....2154
COMPONENT LOCATOR....2154
REPLACEMENT....2155
DIESEL THROTTLE....2160
COMPONENT LOCATOR....2160
INSPECTION....2161
REPLACEMENT....2161
INTAKE PIPE (EXHAUST SIDE)....2163
COMPONENT LOCATOR....2163
REPLACEMENT....2164
INTERCOOLER....2170
OVERHAUL....2170
STACK DUCT....2171
COMPONENT LOCATOR....2171
CLEANING THE PRECLEANER HOUSING....2172
REPLACEMENT....2173
AIR CLEANER....2175
COMPONENT LOCATOR....2175
REPLACEMENT....2177
CLEANING THE AIR CLEANER ELEMENT....2181
INTAKE TEMPERATURE SENSOR....2182
COMPONENT LOCATOR....2182
REPLACEMENT....2184
BOOST PRESSURE SENSOR....2185
COMPONENT LOCATOR....2185
INSPECTION....2186
REPLACEMENT....2186
AIR FLOW SENSOR....2188
COMPONENT LOCATOR....2188
INSPECTION....2189
REPLACEMENT....2191
ENGINE MECHANICAL (J05E)....2192
HEAD COVER....2193
COMPONENT LOCATOR....2193
REPLACEMENT....2194
ROCKER ARM ASSEMBLY....2197
COMPONENT LOCATOR....2197
OVERHAUL....2198
CAMSHAFT ASSEMBLY....2205
COMPONENT LOCATOR....2205
OVERHAUL....2207
CYLINDER HEAD ASSEMBLY....2212
COMPONENT LOCATOR....2212
REPLACEMENT....2213
OVERHAUL....2222
VALVE SYSTEM....2228
COMPONENT LOCATOR....2228
OVERHAUL....2229
CRANKSHAFT PULLEY....2238
COMPONENT LOCATOR....2238
REPLACEMENT....2239
CRANKSHAFT FRONT OIL SEAL....2241
COMPONENT LOCATOR....2241
REPLACEMENT....2242
FRONT OIL SEAL RETAINER....2245
COMPONENT LOCATOR....2245
REPLACEMENT....2246
FLYWHEEL ASSEMBLY....2248
COMPONENT LOCATOR....2248
OVERHAUL....2249
CRANKSHAFT REAR OIL SEAL....2253
COMPONENT LOCATOR....2253
REPLACEMENT....2254
FLYWHEEL HOUSING....2257
COMPONENT LOCATOR....2257
REPLACEMENT....2258
TIMING GEAR & CAM IDLE GEAR....2262
COMPONENT LOCATOR....2262
CONFIGURATION DIAGRAM....2263
OVERHAUL....2264
PISTON AND CONNECTING ROD....2278
COMPONENT LOCATOR....2278
OVERHAUL....2279
CRANKSHAFT....2295
COMPONENT LOCATOR....2295
REPLACEMENT....2297
CYLINDER LINER....2306
COMPONENT LOCATOR....2306
REPLACEMENT....2307
CYLINDER BLOCK....2310
COMPONENT LOCATOR....2310
OVERHAUL....2311
ENGINE MOUNTING AND BRACKET....2319
COMPONENT LOCATOR....2319
REPLACEMENT....2320
GLOW PLUG....2322
COMPONENT LOCATOR....2322
REPLACEMENT....2323
GCU....2326
COMPONENT LOCATOR....2326
REPLACEMENT....2326
EXHAUST (J05E)....2327
EXHAUST MANIFOLD....2329
COMPONENT LOCATOR....2329
REPLACEMENT....2330
EXHAUST PIPE....2334
COMPONENT LOCATOR....2334
REPLACEMENT....2335
EXHAUST PIPE (ATC)....2342
COMPONENT LOCATOR....2342
REPLACEMENT....2343
DEF-SCR & DPR....2345
CONFIGURATION DIAGRAM....2345
CAUTIONS ON DEF/COOLANT PIPING ATTACHING AND DETACHING ....2346
DEF-SCR....2347
COMPONENT LOCATOR....2347
REPLACEMENT....2348
DPR CLEANER....2352
COMPONENT LOCATOR....2352
DPR MAINTENANCE....2353
DPR INSPECTION....2353
INSPECTION PROCEDURE FOLLOWED WHEN “EXHAUST GAS AFTER TREATMENT SYSTEM MAINTENANCE REQUIREMENT LIGHT” LIGHT UP....2354
INSPECTION BY WAY OF HINO DXⅡ....2355
INSPECTION PROCEDURE FOLLOWED WHEN MALFUNCTION INDICATOR LIGHT ILLUMINATES (ABNORMAL)....2359
DETERMINATION BY WAY OF DPR STATE DETERMINATION MONITOR OF HINO DXⅡ....2362
CHECKING THE DPR STATE....2362
REPLACEMENT....2363
OVERALL OPERATION FLOW....2367
AIR CLEANING FLOW....2374
FUEL ADDITION VALVE....2375
COMPONENT LOCATOR....2375
REPLACEMENT....2376
FUEL CUTOFF VALVE....2384
COMPONENT LOCATOR....2384
REPLACEMENT....2385
DEF PUMP....2386
COMPONENT LOCATOR....2386
REPLACEMENT....2387
DEF INJECTOR....2395
COMPONENT LOCATOR....2395
REPLACEMENT....2396
DEF TANK....2401
COMPONENT LOCATOR....2401
INSPECTION....2402
REPLACEMENT....2403
DEF SENSOR....2412
COMPONENT LOCATOR....2412
REPLACEMENT....2413
COOLANT CUTOFF VALVE....2415
COMPONENT LOCATOR....2415
REPLACEMENT....2416
DCU....2418
COMPONENT LOCATOR....2418
REPLACEMENT....2419
DPR DIFFERENTIAL PRESSURE SENSOR....2425
COMPONENT LOCATOR....2425
REPLACEMENT....2426
SCR UPSTREAM NOx SENSOR....2428
COMPONENT LOCATOR....2428
REPLACEMENT....2429
SCR DOWNSTREAM NOx SENSOR....2431
COMPONENT LOCATOR....2431
REPLACEMENT....2432
ATC UPSTREAM TEMPERATURE SENSOR....2434
COMPONENT LOCATOR....2434
REPLACEMENT....2435
DOC UPSTREAM TEMPERATURE SENSOR....2437
COMPONENT LOCATOR....2437
REPLACEMENT....2438
DPR UPSTREAM TEMPERATURE SENSOR....2440
COMPONENT LOCATOR....2440
REPLACEMENT....2441
DPR DOWNSTREAM TEMPERATURE SENSOR....2443
COMPONENT LOCATOR....2443
REPLACEMENT....2444
SCR UPSTREAM TEMPERATURE SENSOR....2446
COMPONENT LOCATOR....2446
REPLACEMENT....2447
OUTSIDE TEMPERATURE SENSOR....2450
COMPONENT LOCATOR....2450
REPLACEMENT....2451
EXHAUST BRAKE....2452
COMPONENT LOCATOR....2452
REPLACEMENT....2453
EXHAUST BRAKE MAGNETIC VALVE....2456
COMPONENT LOCATOR....2456
REPLACEMENT....2457
COOLING (J05E)....2459
COOLING SYSTEM....2460
COOLING SYSTEM DIAGRAM....2460
RADIATOR....2461
COMPONENT LOCATOR....2461
INSPECTION....2462
REPLACEMENT....2463
RADIATOR CAP....2473
COMPONENT LOCATOR....2473
REPLACEMENT....2474
RESERVE TANK....2476
COMPONENT LOCATOR....2476
REPLACEMENT....2477
INTERCOOLER....2478
COMPONENT LOCATOR....2478
OVERHAUL....2479
THERMOSTAT CASE AND THERMOSTAT....2481
COMPONENT LOCATOR....2481
OVERHAUL....2482
COOLANT PUMP....2488
COMPONENT LOCATOR....2488
REPLACEMENT....2489
COOLING FAN AND FAN CLUTCH....2491
COMPONENT LOCATOR....2491
OVERHAUL....2492
COOLANT TEMPERATURE SENSOR....2495
COMPONENT LOCATOR....2495
REPLACEMENT....2496
LUBRICATION (J05E)....2498
LUBRICATION SYSTEM....2499
LUBRICATION SYSTEM DIAGRAM....2499
OIL FILTER....2500
COMPONENT LOCATOR....2500
REPLACEMENT....2501
OIL COOLER....2503
COMPONENT LOCATOR....2503
OVERHAUL....2504
OIL PUMP....2511
COMPONENT LOCATOR....2511
OVERHAUL....2512
OIL PAN....2520
COMPONENT LOCATOR....2520
REPLACEMENT....2521
OIL STRAINER....2525
COMPONENT LOCATOR....2525
REPLACEMENT....2526
OIL PRESSURE SWITCH....2527
COMPONENT LOCATOR....2527
REPLACEMENT....2528
OIL LEVEL GAUGE AND GUIDE....2530
COMPONENT LOCATOR....2530
REPLACEMENT....2531
STARTING/CHARGING (J05E)....2533
STARTER....2534
COMPONENT LOCATOR....2534
REPLACEMENT....2535
V-BELT....2540
COMPONENT LOCATOR....2540
REPLACEMENT....2541
ALTERNATOR (130A)....2544
COMPONENT LOCATOR....2544
OVERHAUL....2545
TURBOCHARGER (J05E)....2558
TURBOCHARGER ASSEMBLY....2559
COMPONENT LOCATOR....2559
INSPECTION....2560
REPLACEMENT....2562
2016 COE Troubleshooting 1_ENG....2571
FOREWORD....2571
CHAPTER REFERENCES....2572
INDEX....2573
GENERAL INTRODUCTION....2575
HOW TO IDENTIFY VEHICLE TYPE....2576
HOW TO IDENTIFY VEHICLE TYPE....2576
VEHICLE TYPE ....2576
VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE....2577
APPEARANCE OF VEHICLE....2578
APPEARANCE....2578
APPEARANCE OF VEHICLE....2578
SAFETY INSTRUCTIONS AND READINESS TO WORK....2579
WARNING....2579
GENERAL PRECAUTIONS....2579
IDENTIFICATION INFORMATION....2584
SAFETY INSTRUCTIONS FOR WORK....2587
PRECAUTIONS....2587
INTRODUCTION TO WORKSHOP MANUAL....2591
GENERAL....2591
INTRODUCTION TO DESCRIPTIONS....2592
DEFINITION OF TERM....2595
TROUBLE SHOOTING....2596
TROUBLESHOOTING WITH DIAGNOSIS MONITOR....2596
TROUBLESHOOTING PROCEDURE....2596
APPARATUS FOR TROUBLE SHOOTING....2598
TROUBLE DIAGNOSIS USING THE COMPUTER (HINO DXⅡ)....2599
STEP OF TROUBLE DIAGNOSIS....2599
APPARATUS FOR TROUBLE DIAGNOSIS....2600
GLOSSARY....2601
DEFINITION OF ABBREVIATION....2601
LIST OF ABBREVIATION....2601
GLOSSARY OF SAE AND HINO TERMS....2604
ENGINE (J05E)....2607
TROUBLESHOOTING....2610
ENGINE ECU (J05E)....2610
PRECAUTIONS FOR DIAGNOSIS....2610
ELECTRICAL....2612
PRECAUTIONS....2613
COMPUTER (ECU) PIN ASSIGNMENT....2617
ENGINE ECU CONNECTOR....2623
INSPECTION....2627
TROUBLE DIAGNOSIS USING THE COMPUTER (HINO DXⅡ)....2628
DIAGNOSTIC TROUBLE CODE (DTC) TABLE....2629
GROUP SHARING THE SENSOR SUPPLY TERMINAL....2651
GROUP SHARING THE SENSOR GND TERMINAL....2652
MALFUNCTION CODES IN CASE OF DISRUPTION OF CAN COMMUNICATION....2653
PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (250 k)....2656
DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (250 k) [DIESEL]....2661
DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (250 k) [HYBRID]....2670
PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (500 k) [DIESEL]....2680
PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (500 k) [HYBRID]....2685
DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (500 k) [DIESEL]....2691
DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (500 k) [HYBRID]....2696
MALFUNCTION CODES FOR FAULTY ACTUATOR POWER RELAY....2701
ENG BASIC INSPECTION SHEET (ENGINE INSPECTION CHECK SHEET)....2702
NO DTC....2706
DTC: P0005....2710
DTC: P0006 and P0007....2714
DTC: P0016....2719
DTC: P0027....2722
DTC: P003A....2727
DTC: P0045....2732
DTC: P0047....2736
DTC: P0048....2740
DTC: P006E....2744
DTC: P006F....2748
DTC: P007B....2752
DTC: P007C and P007D....2766
DTC: P0088....2774
DTC: P0096....2782
DTC: P0097 and P0098 ....2793
DTC: P00AF....2801
DTC: P0101....2805
DTC: P0104....2814
DTC: P0106....2821
DTC: P0108....2827
DTC: P0112 and P0113....2833
DTC: P0115....2841
DTC: P0117 and P0118....2850
DTC: P011A....2858
DTC: P011C....2867
DTC: P0122 and P0123....2873
DTC: P0128....2882
DTC: P0148 ....2888
DTC: P016E and P016F ....2900
DTC: P0182 and P0183 ....2910
DTC: P0191....2918
DTC: P0192 and P0193 ....2927
DTC: P01A5....2937
DTC: P01A6....2944
DTC: P0200....2951
DTC: P0201, P0202, P0203 and P0204....2954
DTC: P0217....2959
DTC: P0219....2964
DTC: P0222 and P0223....2972
DTC: P0234....2982
DTC: P0237....2988
DTC: P0263, P0266, P0269 and P0272....2994
DTC: P026C and P026D....3005
DTC: P0299....3018
DTC: P0300....3024
DTC: P0301, P0302, P0303 and P0304....3032
DTC: P0335....3041
DTC: P0336....3048
DTC: P0340....3055
DTC: P0341....3059
DTC: P0381....3067
DTC: P0401....3073
DTC: P0402....3089
DTC: P0404....3100
DTC: P0405 and P0406....3105
DTC: P041B....3111
DTC: P041C and P041D....3124
DTC: P0420....3132
DTC: P0421....3134
DTC: P0422....3137
DTC: P0489 and P0490....3140
DTC: P049D....3146
DTC: P04D5 and P04D6....3151
DTC: P04DA....3159
DTC: P0500 and P0501....3169
DTC: P0504....3176
DTC: P0506....3181
DTC: P0507....3185
DTC: P0521....3189
DTC: P0524....3193
DTC: P0545 and P0546....3198
DTC: P054E....3206
DTC: P054F....3210
DTC: P0562 and P0563....3214
DTC: P05F1....3219
DTC: P0603....3227
DTC: P0605....3231
DTC: P0606....3233
DTC: P0607....3235
DTC: P0610....3237
DTC: P0611....3240
DTC: P0617....3242
DTC: P0628 and P0629....3246
DTC: P062F....3254
DTC: P0630....3258
DTC: P0642....3262
DTC: P0643....3267
DTC: P064C....3273
DTC: P0652....3278
DTC: P0653....3284
DTC: P0671 and P0672 ....3291
DTC: P0673 and P0674....3297
DTC: P0683....3303
DTC: P0686....3309
DTC: P0698....3314
DTC: P0699....3317
DTC: P06A4....3320
DTC: P06A5....3323
DTC: P06D3 and P06D4....3326
DTC: P0700....3335
DTC: P073D....3337
DTC: P081A....3341
DTC: P081B....3347
DTC: P0A7B....3351
DTC: P0AC4....3353
DTC: P0CA1....3355
DTC: P1133....3357
DTC: P119F....3363
DTC: P1426....3369
DTC: P1427....3376
DTC: P1428....3383
DTC: P1458....3391
DTC: P1459....3396
DTC: P14B0....3401
DTC: P14B2....3405
DTC: P14B3 and P14B4....3409
DTC: P14B7 and P14B8....3415
DTC: P14BC and P14BD....3421
DTC: P14BF....3427
DTC: P1515....3432
DTC: P1530....3437
2016 COE Troubleshooting 2_ENG....3442
FOREWORD....3442
CHAPTER REFERENCES....3443
INDEX....3444
ENGINE (J05E)....3446
TROUBLESHOOTING....3449
ENGINE ECU (J05E)....3449
DTC: P200C....3449
DTC: P2032 and P2033....3458
DTC: P203F....3466
DTC: P204F....3470
DTC: P207F....3473
DTC: P2080....3481
DTC: P2084....3489
DTC: P20CD....3497
DTC: P20CE....3501
DTC: P20CF....3504
DTC: P20D8....3507
DTC: P20DE....3513
DTC: P20DF....3517
DTC: P20E0....3523
DTC: P20EE....3529
DTC: P2100....3537
DTC: P2101....3542
DTC: P2103....3549
DTC: P2120....3554
DTC: P2122 and P2123....3558
DTC: P2127 and P2128....3568
DTC: P2135....3576
DTC: P2138....3581
DTC: P2146....3586
DTC: P2147 and P2148....3593
DTC: P2149....3601
DTC: P2150 and P2151....3608
DTC: P2184 and P2185....3616
DTC: P2214....3624
DTC: P2227....3635
DTC: P2228 and P2229....3639
DTC: P2269....3644
DTC: P226C....3649
DTC: P22D3....3655
DTC: P240F....3659
DTC: P2428....3669
DTC: P242B....3673
DTC: P242C and P242D....3681
DTC: P244A....3689
DTC: P244B....3709
DTC: P2457....3726
DTC: P2458....3741
DTC: P2459....3751
DTC: P2463....3754
DTC: P246F....3762
DTC: P2470 and P2471....3770
DTC: P24A0....3778
DTC: P24A1....3781
DTC: P24A2....3783
DTC: P2562....3792
DTC: P259E....3796
DTC: P259F....3802
DTC: P2635....3807
DTC: P268A and P2696....3816
DTC: P26C8....3822
DTC: P2BA9....3824
DTC: U0073....3829
DTC: U010A....3832
DTC: U010C....3838
DTC: U010E....3844
DTC: U0293....3850
DTC: U029D (DIESEL)....3855
DTC: U029D (HYBRID)....3861
DTC: U029E (DIESEL)....3867
DTC: U029E (HYBRID)....3873
DTC: U02A2....3879
DTC: U0301....3885
DTC: U1001....3888
DTC: U110A....3895
ENGINE (COMMON ITEMS)....3902
TROUBLESHOOTING....3904
DCU....3904
PRECAUTIONS FOR DIAGNOSIS....3904
DIAGRAM....3906
SIGNAL CHECK HARNESS....3907
INSPECTION....3907
TROUBLE DIAGNOSIS USING THE COMPUTER (HINO DXⅡ)....3909
DTC: P0071....3917
DTC: P0072....3927
DTC: P0073....3933
DTC: P0562....3939
DTC: P0563....3943
DTC: P060C....3947
DTC: P062F....3949
DTC: P0667....3951
DTC: P0668....3953
DTC: P0669....3955
DTC: P068A....3957
DTC: P142A....3962
DTC: P142B....3973
DTC: P202E....3984
DTC: P203C....3988
DTC: P203D....3991
DTC: P2044....3994
DTC: P2045....3997
DTC: P2047....4000
DTC: P2048....4003
DTC: P2049....4008
DTC: P204B....4013
DTC: P204C....4016
DTC: P204D....4021
DTC: P205B....4026
DTC: P205C....4035
DTC: P205D....4038
DTC: P206A....4041
DTC: P206B....4044
DTC: P206C....4061
DTC: P206D....4064
DTC: P208A....4067
DTC: P208B....4073
DTC: P208C....4076
DTC: P208D....4081
DTC: P20A0....4086
DTC: P20A1....4091
DTC: P20A2....4095
DTC: P20A3....4100
DTC: P20B1....4105
DTC: P20B2....4110
DTC: P20B3....4120
DTC: P20B4....4125
DTC: P20BD, P20B9 and P20C1....4130
DTC: P20C0, P20BC and P20C4....4138
DTC: P20EE....4144
DTC: P20FC....4164
DTC: P20FD....4168
DTC: P20FE....4173
DTC: P20E8....4178
DTC: P20E9....4189
DTC: P20F4....4195
DTC: P2201....4199
DTC: P2202....4233
DTC: P2203....4236
DTC: P2204....4239
DTC: P2209....4246
DTC: P2212....4254
DTC: P2214....4261
DTC: P2215....4294
DTC: P2216....4297
DTC: P2222....4300
DTC: P2481....4308
DTC: P2482....4313
DTC: P2483....4318
DTC: P2510....4331
DTC: P2BAE....4336
DTC: U0029....4343
DTC: U0038....4349
DTC: U0100....4355
DTC: U029D (DIESEL)....4359
DTC: U029D (HYBRID)....4365
DTC: U029E (DIESEL)....4371
DTC: U029E (HYBRID)....4377
DTC: U02A2....4383
DTC: U0597....4390
2016 COE Troubleshooting 3_ENG....4394
FOREWORD....4394
CHAPTER REFERENCES....4395
INDEX....4396
ENGINE (COMMON ITEMS)....4398
TROUBLESHOOTING....0
VEHICLE CONTROL ECU....4400
CAUTIONS ON TROUBLESHOOTING....4400
SYSTEM BLOCK DIAGRAM....4401
COMPUTER PIN ASSIGNMENT....4402
TROUBLESHOOTING WITH COMPUTER (HINO DXⅡ)....4406
DIAGNOSIS CODE TABLE....4407
DTC: C1244....4409
DTC: C1245....4414
DTC: C1249....4416
DTC: C1418....4422
DTC: C1491....4426
DTC: P0335....4428
DTC: P0501....4431
DTC: P0501....4433
DTC: P0503....4437
DTC: P0555....4442
DTC: P0562....4444
DTC: P0563....4448
DTC: P0572....4451
DTC: P0573....4458
DTC: P0577....4464
DTC: P05BF....4468
DTC: P0604....4471
DTC: P0605 ....4473
DTC: P0605 ....4475
DTC: P0606....4477
DTC: P0617....4479
DTC: P062F....4482
DTC: P0702....4484
DTC: P081D....4486
DTC: P1143....4491
DTC: P161F....4495
DTC: P1649....4498
DTC: P165A....4502
DTC: P165B....4505
DTC: P2525....4508
DTC: P2526....4511
DTC: P258D....4514
DTC: U0101....4517
DTC: U0105....4520
DTC: U0121....4523
DTC: U0155....4526
DTC: U0293....4529
DTC: U0418....4532
DTC: U1136....4535
HYBRID....4538
TROUBLE SHOOTING....4541
HYBRID CONTROL SYSTEM....4541
TROUBLE SHOOTING STEPS FOR HYBRID SYSTEM....4541
SAFETY MEASURES FOR HIGH-VOLTAGE WORK....4549
LIST OF CONNECTOR SYMBOLS....4552
HV SYSTEM WIRING DIAGRAM....4556
HEARING SHEET....4558
HYBRID ECU....4559
DIAGNOSIS CODE TABLE....4559
FREEZE FRAME DATA LIST....4567
LIST OF DATA MONITOR ITEMS....4570
COMMON INSPECTION CHART....4573
DTC: C0081 (TCA0)....4578
DTC: P0500 (TC51)....4580
DTC: P0501 (TC5B)....4587
DTC: P0562 (TC71)....4591
DTC: P060B (TCB2)....4597
DTC: P0617 (TC59)....4599
DTC: P062F (TCB3)....4605
DTC: P0810 (TC9C)....4607
DTC: P0810 (TC9D)....4610
DTC: P0A01 (TC7B)....4613
DTC: P0A02 (TC78)....4619
DTC: P0A03 (TC79)....4625
DTC: P0A06 (TC7F)....4630
DTC: P0A07 (TC7E)....4638
DTC: P0A0F (TC31) ....4641
DTC: P0A1D (TC12)....4644
DTC: P0A1D (TC17)....4646
DTC: P0A78 (TC21)....4648
DTC: P0A78 (TC22)....4650
DTC: P0A7E (TC48)....4652
DTC: P0A82 (TC67)....4656
DTC: P0A84 (TC66)....4665
DTC: P0A85 (TC65)....4674
DTC: P0A90 (TC2A)....4678
DTC: P0A92 (TC29)....4687
DTC: P0A93 (TC7A)....4696
DTC: P0AFD (TC6B)....4701
DTC: P0BCA (TC68)....4704
DTC: P0C73 (TC80)....4708
DTC: P3000 (TC42)....4713
DTC: P3001 (TC41)....4719
DTC: P3001 (TC43)....4721
DTC: P3001 (TC44)....4723
DTC: P3001 (TC45)....4725
DTC: P3001 (TC46)....4727
DTC: P3001 (TC47)....4730
DTC: P3001 (TC4A)....4733
DTC: P3001 (TC4B)....4736
DTC: P3001 (TC4C)....4738
DTC: P3009 (TC49)....4740
DTC: P3128 (TC7D)....4750
DTC: P3129 (TC7C)....4758
DTC: P314C (TC82)....4762
DTC: P314D (TC81)....4766
DTC: P324B (TC62)....4774
DTC: P324C (TC61)....4778
DTC: P33B1 (TC64)....4783
DTC: P33B2 (TC63)....4787
DTC: U0073 (TC11)....4791
DTC: U0074 (TC16)....4795
DTC: U0100 (TC13)....4798
DTC: U0101 (TC18)....4801
DTC: U0110 (TC14)....4806
DTC: U0111 (TC15)....4812
DTC: U0121 (TC24)....4818
DTC: U0155 (TC25)....4823
DTC: U110A (TC26)....4828
DTC: U1136 (TC27)....4833
INVERTER....4838
DIAGNOSIS CODE TABLE....4838
FREEZE FRAME DATA LIST....4844
DATA MONITOR ITEM LIST....4846
CONNECTION DIAGRAM....4849
INSULATION RESISTANCE MEASUREMENT PROCEDURE FOR HYBRID MOTOR [ROTATION MACHINE]....4850
DTC: P0562 (TC96) ....4852
DTC: P0562 (TCA0) ....4859
DTC: P0604 (TC18) ....4866
DTC: P0604 (TCD2)....4868
DTC: P0605 (TC17) ....4870
DTC: P0605 (TCD1) ....4872
DTC: P060B (TC1A)....4874
DTC: P060C (TC1C)....4877
DTC: P062F (TC41)....4879
DTC: P0A0D (TC20)....4881
DTC: P0A1B (TC16)....4886
DTC: P0A1B (TC92)....4891
DTC: P0A1B (TC97)....4893
DTC: P0A1B (TC3F)....4895
DTC: P0A1B (TCA1)....4897
DTC: P0A1B (TCA2)....4899
DTC: P0A1B (TCA3)....4901
DTC: P0A1B (TCA4)....4903
DTC: P0A1B (TCA5)....4905
DTC: P0A1B (TCA6)....4907
DTC: P0A1B (TCA7)....4909
DTC: P0A1B (TCA8) ....4911
DTC: P0A1B (TCA9)....4913
DTC: P0A1B (TCAA)....4915
DTC: P0A1B (TCBB)....4918
DTC: P0A1B (TCBC)....4920
DTC: P0A1B (TCBD)....4922
DTC: P0A1B (TCBE)....4924
DTC: P0A1B (TCBF)....4926
DTC: P0A1B (TCD3)....4928
DTC: P0A1B (TCD4)....4930
DTC: P0A1B (TCD5)....4932
DTC: P0A1D (TC21)....4934
DTC: P0A2B (TCE9)....4937
DTC: P0A2B (TCED)....4944
DTC: P0A2C (TCDA)....4951
DTC: P0A2D (TCDB)....4957
DTC: P0A2F (TC33) ....4964
DTC: P0A3C (TC34)....4969
DTC: P0A3F (TCB7)....4982
DTC: P0A41 (TCC0)....4988
DTC: P0A42 (TCC1)....4996
DTC: P0A51 (TCD6)....5004
DTC: P0A51 (TCD7)....5006
DTC: P0A78 (TC13)....5008
DTC: P0A78 (TC14)....5016
DTC: P0A78 (TC15)....5028
DTC: P0AA1 (TCD8)....5033
DTC: P0AA4 (TCD9)....5038
DTC: P0ADB (TC1F)....5044
DTC: P0ADC (TC93)....5049
DTC: P0ADF (TC1E)....5055
DTC: P0AE0 (TC95)....5060
DTC: P0AE6 (TC1D)....5066
DTC: P0AE7 (TC94)....5071
DTC: P0AEE (TC22)....5077
DTC: P0AEE (TC23)....5079
DTC: P0AEF (TC24)....5081
DTC: P0AF0 (TC25)....5084
DTC: P0BEA (TCB3)....5087
DTC: P0BEA (TCB4)....5089
DTC: P0BEB (TC9A)....5091
DTC: P0BEC (TC9B)....5093
DTC: P0BEE (TCB5)....5095
DTC: P0BEE (TCB6)....5097
DTC: P0BEF (TC9C)....5099
DTC: P0BF0 (TC9D)....5101
DTC: P3126 (TC12)....5103
DTC: U0073 (TC91)....5111
DTC: U0074 (TC3E)....5115
DTC: U0293 (TC31)....5118
2016 COE Troubleshooting 4_HEV_ATM_DT....5126
FOREWORD....5126
CHAPTER REFERENCES....5127
INDEX....5128
HYBRID....5130
TROUBLE SHOOTING....5133
BATTERY ECU....5133
DIAGNOSIS CODE TABLE....5133
LIST OF FREEZE FRAME DATA....5136
LIST OF DATA MONITOR ITEMS....5138
CONNECTION DIAGRAM....5141
DTC: P0562....5142
DTC: P0604....5146
DTC: P0605....5148
DTC: P060B....5150
DTC: P062F....5152
DTC: P0A1F....5154
DTC: P0A7D....5156
DTC: P0A7F....5159
DTC: P0A80....5163
DTC: P0A95....5167
DTC: P0A9D....5171
DTC: P0A9E....5174
DTC: P0AAE....5177
DTC: P0AAF....5180
DTC: P0ABF....5183
DTC: P0AC0....5188
DTC: P0AC1....5193
DTC: P0AC2....5198
DTC: P0AC7....5203
DTC: P0AC8....5206
DTC: P0ACC....5209
DTC: P0ACD....5212
DTC: P0AEA....5215
DTC: P0AEB....5218
DTC: P0AFC....5221
DTC: P0B25....5223
DTC: P0B3D....5226
DTC: P0B42....5230
DTC: P0B47....5234
DTC: P0B4C....5238
DTC: P0B51....5242
DTC: P0B56....5246
DTC: P0B5B....5250
DTC: P0B60....5254
DTC: P0B65....5258
DTC: P0B6A....5262
DTC: P0B6F....5266
DTC: P0B74....5270
DTC: P0B79....5274
DTC: P0B7E....5278
DTC: P0B83....5282
DTC: P0B88....5286
DTC: P0B8D....5290
DTC: P0B92....5294
DTC: P0B97....5298
DTC: P0B9C....5302
DTC: P0BA1....5306
DTC: P0C30....5310
DTC: P3004....5314
DTC: P3011....5316
DTC: P3012....5320
DTC: P3013....5324
DTC: P3014....5328
DTC: P3015....5332
DTC: P3016....5336
DTC: P3017....5340
DTC: P3018....5344
DTC: P3019....5348
DTC: P301B....5352
DTC: P3020....5354
DTC: P3021....5358
DTC: P3022....5362
DTC: P3023....5366
DTC: P3024....5370
DTC: P3025....5374
DTC: P3026....5378
DTC: P3027....5382
DTC: P3028....5386
DTC: P3029....5390
DTC: P302F....5394
DTC: P3065....5398
DTC: P308A....5402
DTC: U0074....5406
DTC: U0293....5409
TRANSMISSION....5413
TROUBLESHOOTING....5415
TROUBLE SHOOTING BY TRANSMISSION SYMPTOM....5415
AUTOMATIC TRANSMISSION....5415
TROUBLESHOOTING....5417
AUTOMATIC TRANSMISSION....5417
PRECAUTIONS FOR DIAGNOSIS....5417
AT LEARNED VALUE INITIALIZATION....5418
INSPECTING/CLEARING DIAGNOSIS CODES....5422
SYSTEM BLOCK DIAGRAM....5425
COMPUTER PIN ASSIGNMENT....5426
DIAGNOSIS CODE TABLE....5429
DTC: P0500/DIAGNOSIS MONITOR CODE: 42....5431
DTC: P0562/DIAGNOSIS MONITOR CODE: 11....5437
DTC: P0705/DIAGNOSIS MONITOR CODE: 43....5440
DTC: P0706/DIAGNOSIS MONITOR CODE: 44....5447
DTC: P0710/DIAGNOSIS MONITOR CODE: 38....5451
DTC: P0715/DIAGNOSIS MONITOR CODE: 12....5455
DTC: P0720/DIAGNOSIS MONITOR CODE: 61....5460
DTC: P0725/DIAGNOSIS MONITOR CODE: 86....5466
DTC: P0730/DIAGNOSIS MONITOR CODE: 37....5471
DTC: P0746/DIAGNOSIS MONITOR CODE: 31....5477
DTC: P0748/DIAGNOSIS MONITOR CODE: 25....5482
DTC: P0751/DIAGNOSIS MONITOR CODE: 45....5486
DTC: P0756/DIAGNOSIS MONITOR CODE: 46....5491
DTC: P0761/DIAGNOSIS MONITOR CODE: 47, 48....5496
DTC: P0776/DIAGNOSIS MONITOR CODE: 32....5501
DTC: P0778/DIAGNOSIS MONITOR CODE: 26....5506
DTC: P0810/DIAGNOSIS MONITOR CODE: 88....5510
DTC: P0973/DIAGNOSIS MONITOR CODE: 62....5514
DTC: P0974/DIAGNOSIS MONITOR CODE: 62....5518
DTC: P0976/DIAGNOSIS MONITOR CODE: 63....5522
DTC: P0977/DIAGNOSIS MONITOR CODE: 63....5526
DTC: P0979/DIAGNOSIS MONITOR CODE: 64....5530
DTC: P0980/DIAGNOSIS MONITOR CODE: 64....5534
DTC: P0985/DIAGNOSIS MONITOR CODE: 65....5538
DTC: P0986/DIAGNOSIS MONITOR CODE: 65....5542
DTC: P0A40/DIAGNOSIS MONITOR CODE: 88....5546
DTC: P1604/DIAGNOSIS MONITOR CODE: 24....5550
DTC: P1604/DIAGNOSIS MONITOR CODE: 54....5554
DTC: P2545/DIAGNOSIS MONITOR CODE: 88....5558
DTC: P2716/DIAGNOSIS MONITOR CODE: 28....5562
DTC: P2740/DIAGNOSIS MONITOR CODE: 17....5566
DTC: P2757/DIAGNOSIS MONITOR CODE: 33....5570
DTC: P2759/DIAGNOSIS MONITOR CODE: 27....5575
DTC: P2764/DIAGNOSIS MONITOR CODE: 36....5579
DTC: U0100/DIAGNOSIS MONITOR CODE: 88....5583
DTC: U110A/DIAGNOSIS MONITOR CODE: 88....5589
TROUBLESHOOTING....5595
CLUTCH ECU....5595
SYSTEM BLOCK DIAGRAM....5595
COMPUTER PIN ASSIGNMENT....5596
DIAGNOSIS CODE TABLE....5598
CAUTIONS ON HV DAMPER REPLACEMENT....5600
DTC: P0560....5601
DTC: P0563....5605
DTC: P0604....5607
DTC: P0605....5609
DTC: P062F....5611
DTC: P0775....5613
DTC: P0778....5618
DTC: P0811....5623
DTC: P081E....5625
DTC: P0883....5627
DTC: P0948....5631
DTC: P1538....5636
DTC: P1539....5646
DTC: P18F2....5653
DTC: P18F3....5663
DTC: P18F5....5673
DTC: P18F7....5683
DTC: P18F8....5693
DTC: P18F9....5703
DTC: P18FB....5713
DTC: P18FC....5718
DTC: P18FD....5723
DTC: P191A....5728
DTC: P2859....5730
DTC: P3156....5732
DTC: P3157....5742
DTC: U0073....5746
DTC: U0101....5749
DTC: U0110....5752
DTC: U0293....5755
DTC: U110A....5758
AXLE....5761
TROUBLESHOOTING....5762
TROUBLE SHOOTING BY AXLE SYMPTOM....5762
FRONT AXLE....5762
REAR AXLE....5763
WHEEL AND TIRE....5763
DIFFERENTIAL....5765
TROUBLESHOOTING....5766
TROUBLE SHOOTING BY DIFFERENTIAL SYMPTOM....5766
REAR DIFFERENTIAL....5766
2016 COE Troubleshooting 5_SA_BRAKE_ELEC....5768
FOREWORD....5768
CHAPTER REFERENCES....5769
INDEX....5770
BRAKE....5772
TROUBLESHOOTING....5773
TROUBLE SHOOTING BY BRAKE SYMPTOM....5773
BRAKE....5773
ABS WITH EBD....5775
CAUTIONS....5775
TROUBLESHOOTING PROCEDURE....5776
ACT PART No. CORRESPONDENCE....5778
HEARING TABLE....5778
PRIOR CHECK....5779
LIST OF DIAGNOSIS CODE....5791
PARTS ARRANGEMENT....5794
ECU TERMINAL ARRANGEMENT....5796
SYMPTOM LIST....5799
ELECTRIC CIRCUIT DIAGRAM....5800
ABS WARNING LIGHT ALWAYS ON....5801
BRAKE WARNING LIGHT ALWAYS ON....5804
ABS ACTIVATION TOO FAST (ABS OPERATES BEFORE THE WHEEL LOCKS)....5808
THE BRAKE PEDAL GETS STUCK....5809
DTC: C1203 (Diagnosis monitor code 59)....5811
DTC: C1225 (Diagnosis monitor code 25)....5815
DTC: C1241 (Diagnosis monitor code 41)....5819
DTC: C1249 (Diagnosis monitor code 49)....5831
DTC: C1265 (Diagnosis monitor code 65)....5835
DTC: C1300 (Diagnosis monitor code 62)....5845
DTC: C1337 (Diagnosis monitor code 37)....5848
DTC: C1361 (Diagnosis monitor code 91)....5852
DTC: C1401 (Diagnosis monitor code 31)....5860
DTC: C1402 (Diagnosis monitor code 32)....5869
DTC: C1403 (Diagnosis monitor code 33)....5878
DTC: C1404 (Diagnosis monitor code 34)....5886
DTC: C1405 (Diagnosis monitor code 31)....5894
DTC: C1406 (Diagnosis monitor code 32)....5903
DTC: C1407 (Diagnosis monitor code 33)....5912
DTC: C1408 (Diagnosis monitor code 34)....5920
DTC: C1413 (Diagnosis monitor code 35)....5928
DTC: C1414 (Diagnosis monitor code 36)....5935
DTC: C1415 (Diagnosis monitor code 38)....5941
DTC: C1416 (Diagnosis monitor code 39)....5947
DTC: C1417 (Diagnosis monitor code 41)....5953
DTC: C1421 (Diagnosis monitor code 46)....5965
DTC: C1422 (Diagnosis monitor code 46)....5969
DTC: C1423 (Diagnosis monitor code 46)....5973
DTC: C1424 (Diagnosis monitor code 46)....5977
DTC: C1425 (Diagnosis monitor code 49)....5981
DTC: C1427 (Diagnosis monitor code 51)....5985
DTC: C1428 (Diagnosis monitor code 51)....5989
DTC: C1468 (Diagnosis monitor code 21)....5993
DTC: C1469 (Diagnosis monitor code 22)....5997
DTC: C146A (Diagnosis monitor code 23)....6001
DTC: C146B (Diagnosis monitor code 24)....6005
DTC: C146C (Diagnosis monitor code 13)....6009
DTC: C146D (Diagnosis monitor code 14)....6016
DTC: C146E (Diagnosis monitor code 11)....6023
DTC: C146F (Diagnosis monitor code 12)....6029
DTC: U0073 (Diagnosis monitor code 94)....6035
ELECTRIC VACUUM PUMP SYSTEM....6038
CAUTIONS FOR TROUBLESHOOTING....6038
SYSTEM BLOCK DIAGRAM....6039
ELECTRIC CIRCUIT DIAGRAM....6040
CONNECTOR TERMINAL ARRANGEMENT....6041
SYSTEM SELF-DIAGNOSTIC....6042
RESETTING THE ELECTRIC VACUUM PUMP OPERATION COUNT AND OPERATION TIME AND THE ELECTRIC VACUUM PUMP RELAY ACTUATION COUNT....6043
ACTIVE TEST....6043
DATA MONITOR....6043
DIAGNOSIS CODE TABLE....6044
EXCESSIVE OPERATION OF ELECTRIC VACUUM PUMP (DIAGNOSIS CODE P165A)....6045
EXCESSIVE OPERATION OF ELECTRIC VACUUM PUMP RELAY (DIAGNOSIS CODE P165B)....6046
ABNORMALITY IN VACUUM SENSOR CIRCUIT (DIAGNOSIS CODE P2525)....6047
FALSE DETECTION OF VACUUM SENSOR PRESSURE (DIAGNOSIS CODE P2526)....6051
ELECTRIC VACUUM PUMP RELAY CONTACT STUCK AT ON (DIAGNOSIS CODE P258D)....6063
HOW TO VERIFY AND CHANGE VEHICLE INFORMATION VALUES....6065
STEERING....6067
TROUBLESHOOTING....6068
TROUBLE SHOOTING BY STEERING SYMPTOM....6068
STEERING....6068
SUSPENSION....6074
TROUBLESHOOTING....6075
TROUBLE SHOOTING BY SUSPENSION SYMPTOM....6075
LEAF SUSPENSION....6075
ELECTRICAL....6076
TROUBLESHOOTING....6077
INTEGRATED UNIT....6077
SYSTEM BLOCK DIAGRAM....6077
COMPUTER PIN ASSIGNMENT....6080
TROUBLE SHOOTING....6081
CONTROL SYSTEM....6088
TROUBLESHOOTING....6091
CAN COMMUNICATION....6091
INSPECTION IN THE EVENT OF ABNORMALITY IN CAN COMMUNICATION LINE....6091
ECU INDIVIDUAL CODELIST (DIESEL)....6093
ECU INDIVIDUAL CODELIST (HYBRID)....6094
BASIC TROUBLESHOOTING PROCEDURE ON CAN COMMUNICATION....6097
ENGINE CAN COMMUNICATION LINE (DIESEL)....6099
ENGINE CAN LINE....6099
PRIOR INSPECTION OF THE CAN COMMUNICATION LINE....6101
INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION....6105
INSPECTING THE CAN H LINE FOR SHORT CIRCUIT....6110
INSPECTING THE CAN L LINE FOR SHORT CIRCUIT....6119
INSPECTING THE EGR CONTROLLER CAN COMMUNICATION LINE....6128
INSPECTING THE NOx SENSOR 1 CAN COMMUNICATION LINE....6131
INSPECTING THE NOx SENSOR 2 CAN COMMUNICATION LINE....6138
INSPECTING THE VNT CONTROLLER CAN COMMUNICATION LINE....6145
INSPECTING THE DEF SENSOR CAN COMMUNICATION LINE....6148
ENGINE CAN COMMUNICATION LINE (HYBRID)....6152
ENGINE CAN LINE....6152
PRIOR INSPECTION OF THE CAN COMMUNICATION LINE....6154
INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION....6158
INSPECTING THE CAN H LINE FOR SHORT CIRCUIT....6163
INSPECTING THE CAN L LINE FOR SHORT CIRCUIT....6173
INSPECTING THE EGR CONTROLLER CAN COMMUNICATION LINE....6183
INSPECTING THE NOx SENSOR 1 CAN COMMUNICATION LINE....6186
INSPECTING THE NOx SENSOR 2 CAN COMMUNICATION LINE....6193
INSPECTING THE VNT CONTROLLER CAN COMMUNICATION LINE....6200
INSPECTING THE DEF SENSOR CAN COMMUNICATION LINE....6203
DIAGNOSIS CAN COMMUNICATION LINE (DIESEL)....6207
DIAGNOSIS CAN LINE....6207
PRIOR INSPECTION OF THE CAN COMMUNICATION LINE....6209
INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION....6215
INSPECTING THE CAN H LINE FOR SHORT CIRCUIT....6218
INSPECTING THE CAN L LINE FOR SHORT CIRCUIT....6226
INSPECTING THE ABS ECU CAN COMMUNICATION LINE....6233
INSPECTING THE AT ECU CAN COMMUNICATION LINE....6236
INSPECTING THE ENGINE ECU CAN COMMUNICATION LINE....6239
INSPECTING THE VEHICLE CONTROL ECU CAN COMMUNICATION LINE....6244
DIAGNOSIS CAN COMMUNICATION LINE (HYBRID)....6248
DIAGNOSIS CAN LINE....6248
PRIOR INSPECTION OF THE CAN COMMUNICATION LINE....6251
INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION....6258
INSPECTING THE CAN H LINE FOR SHORT CIRCUIT....6264
INSPECTING THE CAN L LINE FOR SHORT CIRCUIT....6275
INSPECTING THE ABS ECU CAN COMMUNICATION LINE....6286
INSPECTING THE AT ECU CAN COMMUNICATION LINE....6289
INSPECTING THE ENGINE ECU CAN COMMUNICATION LINE....6292
INSPECTING THE INVERTER CAN COMMUNICATION LINE....6295
INSPECTING THE CLUTCH ECU CAN COMMUNICATION LINE....6298
INSPECTING THE BATTERY ECU CAN COMMUNICATION LINE....6301
INSPECTING THE VEHICLE CONTROL ECU CAN COMMUNICATION LINE....6304
CONTROL CAN COMMUNICATION LINE (DIESEL)....6307
CONTROL CAN LINE....6307
PRIOR INSPECTION OF THE CAN COMMUNICATION LINE....6309
INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION....6314
INSPECTING THE CAN H LINE FOR SHORT CIRCUIT....6317
INSPECTING THE CAN L LINE FOR SHORT CIRCUIT....6323
INSPECTING THE ABS ECU CAN COMMUNICATION LINE....6329
INSPECTING THE AT ECU CAN COMMUNICATION LINE....6332
INSPECTING THE VEHICLE CONTROL ECU CAN COMMUNICATION LINE....6335
CONTROL CAN COMMUNICATION LINE (HYBRID)....6338
CONTROL CAN LINE....6338
PRIOR INSPECTION OF THE CAN COMMUNICATION LINE....6342
INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION....6347
INSPECTING THE CAN H LINE FOR SHORT CIRCUIT....6354
INSPECTING THE CAN L LINE FOR SHORT CIRCUIT....6365
INSPECTING THE ABS ECU CAN COMMUNICATION LINE....6376
INSPECTING THE AT ECU CAN COMMUNICATION LINE....6379
INSPECTING THE HV ECU CAN COMMUNICATION LINE....6382
INSPECTING THE INVERTER CAN COMMUNICATION LINE....6385
INSPECTING THE CLUTCH ECU CAN COMMUNICATION LINE....6389
INSPECTING THE VEHICLE CONTROL ECU CAN COMMUNICATION LINE....6392
CAN COMMUNICATION (HYBRID SYSTEM)....6395
SAFETY MEASURES TO BE TAKEN IN HIGH VOLTAGE WORK....6395
LIST OF CONNECTOR MARKINGS....6398
CONNECTION DIAGRAM....6399
LIST OF DTC CODES FOR CAN SYSTEM-RELATED ABNORMALITIES....6400
CAN COMMUNICATION FAILURE....6402
BASIC INSPECTION ITEMS IN CASE OF ABNORMALITY IN DIAG CAN SYSTEM....6406
BASIC INSPECTION ITEMS IN CASE OF ABNORMALITY IN CONTROL CAN SYSTEM....6421
ABNORMALITY IN INVERTER (ECU SYSTEM) / DIAG CAN RESISTER SEIZURE (DTC CODE P0A1B / TC3F)....6430
ABNORMALITY IN THE INVERTER (ECU SYSTEM) / CONTROL CAN RESISTER SEIZURE (DTC CODE P0A1B / TC92)....6431
ABNORMALITY IN HV ECU FUNCTION / CONTROL CAN REGISTER SEIZURE (DTC CODE P0A1D / TC12)....6432
ABNORMALITY IN HV ECU FUNCTION / DIAG CAN REGISTER SEIZURE (DTC CODE P0A1D / TC17)....6433
HV ECU CAN COMMUNICATION FAILURE (CONTROL CAN) / CONTROL CAN COMMUNICATION SHUTDOWN DUE TO BUS OFF (DTC CODE U0073 / TC11)....6434
CAN COMMUNICATION FAILURE (CONTROL CAN) / CONTROL CAN COMMUNICATION SHUTDOWN DUE TO BUS OFF (DTC CODE U0073 / TC91)....6436
HV ECU CAN COMMUNICATION FAILURE (DIAG CAN) / DIAG CAN COMMUNICATION SHUTDOWN DUE TO BUS OFF (DTC CODE U0074 / TC16)....6438
CAN COMMUNICATION FAILURE (DIAG CAN) / COMMUNICATION SHUTDOWN DUE TO DIAG CAN BUS OFF (DTC CODE U0074 / TC3E)....6439
ENGINE ECU CAN COMMUNICATION BLACKOUT / ENGINE ECU CAN COMMUNICATION BLACKOUT (DTC CODE U0100 / TC13)....6440
TCM ECU CAN COMMUNICATION BLACKOUT / AT ECU CAN COMMUNICATION BLACKOUT (DTC CODE U0101 / TC18)....6441
INVERTER CAN COMMUNICATION BLACKOUT / INVERTER CAN COMMUNICATION BLACKOUT (DTC CODE U0110 / TC14)....6443
BATTERY ECU CAN COMMUNICATION BLACKOUT / BATTERY ECU CAN COMMUNICATION BLACKOUT (DTC CODE U0111 / TC15)....6446
ABS ECU CAN COMMUNICATION BLACKOUT / ABS ECU CAN COMMUNICATION BLACKOUT (DTC CODE U0121/TC24)....6449
METER CAN COMMUNICATION BLACKOUT / METER CAN COMMUNICATION BLACKOUT (DTC CODE U0155 / TC25)....6451
HV ECU COMMUNICATION FAILURE (DTC CODE U0293)....6453
HV ECU CAN COMMUNICATION BLACKOUT / HV ECU CAN COMMUNICATION BLACKOUT (DTC CODE U0293 / TC31)....6455
VEHICLE CONTROL ECU CAN COMMUNICATION BLACKOUT / VEHICLE CONTROL ECU CAN COMMUNICATION BLACKOUT (DTC CODE U110A / TC26)....6459
CLUTCH ECU CAN COMMUNICATION BLACKOUT / CLUTCH ECU CAN COMMUNICATION BLACKOUT (DTC CODE U1136 / TC27)....6461
COMMUNICATION DISABLED DUE TO DIAG CAN BUS OFF (DTC CODE U0074)....6463
2016 CONV Chassis 1_DT_ABS....6465
FOREWORD....6465
CHAPTER REFERENCES....6466
INDEX....6467
GENERAL INTRODUCTION (CHASSIS)....6471
GENERAL INTRODUCTION....6472
GENERAL PRECAUTIONS....6472
IDENTIFICATION INFORMATION....6475
HOW TO USETHIS WORKSHOP MANUAL....6482
PRECAUTIONS....6485
SEALANT ON THE TAPERED SCREWFOR PIPING....6488
NYLON TUBE REPLACEMENT METHOD....6489
METRIC INFORMATION....6491
SPECIFIED TORQUE....6493
SPECIFIED TORQUE....6493
RECOMMENDED LUBRICANTS....6495
VEHICLE LIFTAND SUPPORT LOCATIONS....6497
INFORMATION DISPLAY....6499
SYMPTOM SIMULATION....6504
GLOSSARY....6506
GLOSSARY OF SAE AND HINO TERMS....6509
CLUTCH MAIN UNIT (EATON 1401)....6512
CLUTCH ASSEMBLY....6513
DATA AND SPECIFICATIONS....6513
DESCRIPTION....6513
TROUBLESHOOTING....6514
SPECIAL TOOL....6516
COMPONENT LOCATOR....6517
OVERHAUL....6518
CLUTCH ASSEMBLY....6525
DATA AND SPECIFICATIONS....6525
COMPONENT LOCATOR....6525
OVERHAUL....6526
INSPECTION AND REPAIR....6533
CLUTCH MAIN UNIT (EATON 1402)....6536
CLUTCH ASSEMBLY....6537
DATA AND SPECIFICATIONS....6537
DESCRIPTION....6537
TROUBLESHOOTING....6538
SPECIAL TOOL....6540
COMPONENT LOCATOR....6541
OVERHAUL....6542
CLUTCH ASSEMBLY ....6551
DATA AND SPECIFICATIONS....6551
COMPONENT LOCATOR....6551
OVERHAUL....6552
INSPECTION AND REPAIR....6562
CLUTCH CONTROL....6565
CLUTCH CONTROL UNIT....6566
DESCRIPTION....6566
INSPECTION AND ADJUSTMENT....6567
CLUTCH PEDAL AND RELEASE UNIT....6570
COMPONENT LOCATOR....6570
OVERHAUL....6571
INSPECTION AND REPAIR....6573
CLUTCH MASTER CYLINDER....6574
COMPONENT LOCATOR....6574
OVERHAUL....6575
INSPECTION AND REPAIR....6575
TRANSMISSION MAIN UNIT....6576
TRANSMISSION ASSEMBLY....6577
DATA AND SPECIFICATION....6577
DISMOUNTING AND MOUNTING....6578
AUTOMATIC TRANSMISSION(ALLISON 2200RDS, 2500RDS, 2200HS)....6580
AUTOMATIC TRANSMISSION ASSEMBLY....6581
TROUBLESHOOTING....6581
SPECIAL TOOL....6581
DISMOUNTING AND MOUNTING....6581
AUTOMATIC TRANSMISSION....6589
AUTOMATIC TRANSMISSION ASSEMBLY....6590
TROUBLESHOOTING....6590
SPECIAL TOOL....6590
DISMOUNTING AND MOUNTING....6590
TRANSMISSION/TRANSFER CONTROL....6597
TRANSMISSION CONTROL UNIT....6598
TROUBLESHOOTING....6598
COMPONENT LOCATOR....6599
OVERHAUL....6600
TRANSMISSION/TRANSFER CONTROL....6601
TRANSMISSION CONTROL UNIT....6602
TROUBLESHOOTING....6602
COMPONENT LOCATOR....6602
OVERHAUL....6604
PROPELLER SHAFT (SPL 100, 140)....6605
PROPELLER SHAFT ASSEMBLY....6606
DATA AND SPECIFICATIONS....6606
DESCRIPTION....6606
TROUBLESHOOTING....6607
COMPONENT LOCATOR....6607
OVERHAUL....6609
DIFFERENTIAL CARRIER(MERITOR RS17.19.21&23)....6625
DIFFERENTIAL CARRIER ASSEMBLY....6626
DATA AND SPECIFICATIONS....6626
DESCRIPTION....6628
TROUBLESHOOTING....6631
SPECIAL TOOL....6632
COMPONENT LOCATOR....6634
OVERHAUL....6638
INSPECTION AND REPAIR....6678
DRIVER-CONTROLLEDMAIN DIFFERENTIAL LOCK....6687
OVERHAUL....6687
INSPECTION AND REPAIR....6690
BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE)....6691
SERVICE BRAKE ASSEMBLY....6692
DESCRIPTION....6692
DIAGRAM....6693
TROUBLESHOOTING....6695
BRAKE SYSTEM AIR BLEEDING....6699
POWER STEERINGSYSTEM AIR BLEEDING....6701
BRAKE TEST....6702
BRAKE EQUIPMENT....6703
SERVICE BRAKE ASSEMBLY....6704
DESCRIPTION....6704
DATA AND SPECIFICATIONS....6705
DIAGRAM....6706
TROUBLESHOOTING....6707
SERVICE BRAKE (HYDRAULIC BRAKE)....6709
HYDRAULIC BRAKE....6710
INSPECTION AND ADJUSTMENT....6710
HYDRO-MAX HYDRAULIC BRAKE BOOSTERAND MASTER CYLINDER....6713
DATA AND SPECIFICATIONS....6713
DESCRIPTION....6713
PRINCIPLE OF OPERATION....6715
COMPONENT LOCATOR....6717
HYDRO-MAX BOOSTER....6718
OVERHAUL....6718
MASTER CYLINDER....6724
OVERHAUL....6724
PRESSURE TESTS....6726
ABS MODULATOR....6727
DATA AND SPECIFICATIONS....6727
DESCRIPTION....6727
WHEEL BRAKE (TYPE: 4 PISTON)....6728
DATA AND SPECIFICATIONS....6728
DESCRIPTION....6729
TROUBLESHOOTING....6730
SERVICE BRAKE (FULL AIR BRAKE)....6743
AIR DRYER AND RESERVOIR SYSTEM(MODEL: BENDIX AD-IS)....6744
DESCRIPTION....6744
AD-IS AIR DRYER RESERVOIR SYSTEMTROUBLESHOOTING CHART....6755
CHECK VALVE....6759
DATA AND SPECIFICATIONS....6759
DESCRIPTION....6759
INSPECTION AND REPAIR....6760
BRAKE PEDAL....6762
OVERHAUL....6762
BRAKE VALVE....6765
DATA AND SPECIFICATIONS....6765
DESCRIPTION....6765
COMPONENT LOCATOR....6766
INSPECTION AND REPAIR....6767
RELAY VALVE....6771
DATA AND SPECIFICATIONS....6771
DESCRIPTION....6771
INSPECTION AND REPAIR....6771
SPRING BRAKE MODULATING VALVE....6775
DESCRIPTION....6775
COMPONENT LOCATOR....6776
INSPECTION AND REPAIR....6777
SPRING BRAKE CONTROL VALVE....6779
DESCRIPTION....6779
COMPONENT LOCATOR....6780
INSPECTION AND REPAIR....6781
BRAKE CHAMBER (FRONT)....6784
DATA AND SPECIFICATIONS....6784
DESCRIPTION....6784
COMPONENT LOCATOR....6785
OVERHAUL....6785
BRAKE CHAMBER (REAR)....6787
DATA AND SPECIFICATIONS....6787
DESCRIPTION....6788
COMPONENT LOCATOR....6789
INSPECTION AND REPAIR....6790
PROTECTION VALVE....6801
DATA AND SPECIFICATIONS....6801
DESCRIPTION....6801
INSPECTION....6802
WHEEL BRAKE....6804
DATA AND SPECIFICATIONS....6804
DESCRIPTION....6805
COMPONENT LOCATOR....6806
OVERHAUL....6808
INSPECTION AND REPAIR....6825
AUTOMATIC SLACK ADJUSTER....6827
DESCRIPTION....6827
DIAGNOSTICS....6828
COMPONENT LOCATOR....6829
OVERHAUL....6831
INSTALLING THE SLACK ADJUSTERONTO THE CAMSHAFT....6839
CHECK & ADJUSTMENT....6841
ABS (ABS : HYDRAULIC (E VERSION))....6848
ABS....6849
OVERVIEW....6849
COMPOSITION AND OPERATION....6850
FUNCTION....6853
PRECAUTIONS WHEN DRIVING VEHICLESEQUIPPED WITH ABS....6854
OVERVIEW AND FUNCTION....6855
ABS (ABS : FULL AIR)....6867
ABS....6868
OVERVIEW....6868
COMPOSITION AND OPERATION....6869
FUNCTION....6872
PRECAUTIONS WHEN DRIVING VEHICLESEQUIPPED WITH ABS....6873
OVERVIEW AND FUNCTION....6874
INSPECTION (FRONT WHEEL BRAKE)....6879
INSPECTION (REAR WHEEL BRAKE)....6881
EXHAUST BRAKE....6887
EXHAUST BRAKE SYSTEM....6888
SYSTEM DIAGRAM....6888
TROUBLESHOOTING....6889
ADJUSTMENT....6889
BRAKE CYLINDER....6891
DATA AND SPECIFICATIONS....6891
DESCRIPTION....6891
PARKING BRAKE (BOSCH 12")....6892
PARKING BRAKE ASSEMBLY....6893
DATA AND SPECIFICATIONS....6893
DESCRIPTION....6893
TROUBLESHOOTING....6894
COMPONENT LOCATOR....6895
OVERHAUL....6897
INSPECTION AND REPAIR....6911
ADJUSTMENT....6912
2016 CONV Chassis 2_EWD....6915
FOREWORD....6915
CHAPTER....6916
INDEX....6917
STEERING EQUIPMENT....6921
STEERING SYSTEM....6922
TROUBLESHOOTING....6922
STEERING UNIT....6927
STEERING LINKAGE....6928
DESCRIPTION....6928
COMPONENT LOCATOR....6929
SPECIAL TOOL....6930
OVERHAUL....6931
INSPECTION AND REPAIR....6936
POWER STEERING....6938
POWER STEERING GEAR UNIT....6939
DATA AND SPECIFICATIONS....6939
DESCRIPTION....6940
OPERATION....6941
COMPONENT LOCATOR....6943
TORQUE CHART....6945
HAZARD WARNING DEFINITIONS....6945
DISCLAIMER....6946
PATENTS....6946
MAINTENANCE TIPS....6946
ON-VEHICLE SERVICE....6948
RESEAL & REPAIR....6958
POWER STEERING PUMP....6992
DATA AND SPECIFICATIONS....6992
DESCRIPTION....6992
OPERATION....6993
COMPONENT LOCATOR....6994
OVERHAUL....6996
INSPECTION AND REPAIR....7002
FRONT AXLE (MFS)....7004
FRONT AXLE (MFS)....7005
DATA AND SPECIFICATIONS....7005
TROUBLESHOOTING....7007
COMPONENT LOCATOR....7009
SERVICE NOTES....7013
SPECIAL TOOLS....7014
INTRODUCTION....7019
INSPECTION....7020
DISASSEMBLY....7026
PREPARE PARTS FOR ASSEMBLY....7033
ASSEMBLY....7041
ADJUSTMENT....7053
LUBRICATION AND MAINTENANCE....7062
MAINTENANCE....7066
REAR AXLE....7067
REAR AXLE....7068
DATA AND SPECIFICATIONS....7068
COMPONENT LOCATOR....7075
SPECIAL TOOL....7078
DISASSEMBLY....7080
PREPARE PARTS FOR ASSEMBLY....7082
ASSEMBLY....7086
ADJUSTMENT....7096
LUBRICATION AND MAINTENANCE....7098
WHEEL & TIRE....7100
WHEEL AND TIRE....7101
DATA AND SPECIFICATIONS....7101
DESCRIPTION....7105
SPECIAL TOOL....7106
PRECAUTIONS....7107
INSPECTION....7108
INSPECTION AND REPAIR....7109
WHEEL....7110
OVERHAUL....7110
SUSPENSION....7115
LEAF SUSPENSION ASSEMBLY....7116
DATA AND SPECIFICATIONS....7116
DESCRIPTION....7118
TROUBLESHOOTING....7120
COMPONENT LOCATOR....7121
OVERHAUL....7125
INSPECTION AND REPAIR....7130
AIR SUSPENSION ASSEMBLY....7133
DATA AND SPECIFICATIONS....7133
SYSTEM DIAGRAM FOR HEIGHT CONTROL....7133
DESCRIPTION....7134
TROUBLESHOOTING....7135
COMPONENT LOCATOR....7136
OVERHAUL....7137
INSPECTION AND REPAIR....7141
CHASSIS FRAME....7143
CHASSIS FRAME....7144
TROUBLESHOOTING....7144
INSPECTION....7144
REPAIRS....7145
CAB....7150
CAB ASSEMBLY....7151
DATA AND SPECIFICATIONS....7151
TROUBLESHOOTING....7152
DISMOUNTING AND MOUNTING....7153
INSPECTION AND REPAIR....7156
HOOD....7157
COMPONENT LOCATOR....7157
OVERHAUL....7158
FRP REPAIR PROCEDURE....7161
RADIATOR GRILLE....7166
COMPONENT LOCATOR....7166
OVERHAUL....7167
DOOR....7168
COMPONENT LOCATOR....7168
OVERHAUL....7169
SEAT....7172
COMPONENT LOCATOR....7172
INSTRUMENT PANEL....7175
COMPONENT LOCATOR....7175
DISMOUNTING AND MOUNTING....7176
HEATER AND AIR CONDITIONER....7177
COMPONENT LOCATOR....7177
SPECIAL TOOL....7177
AIR CONDITIONING SYSTEM....7178
SPECIFICATION DATA....7178
PRECAUTIONS REGARDINGREFRIGERANT (HFC134a)....7178
PRECAUTIONS FOR REPLENISHING THE REFRIGERANT GAS....7179
TROUBLESHOOTING(FAULT DIAGNOSIS BY SYMPTOMS)....7180
GAS LEAKAGE INSPECTION....7189
PRECAUTIONS FOR REMOVING/INSTALLINGTHE AIR CONDITIONER....7192
RECOVERY AND REPLENISHMENT OFREFRIGERANT....7194
MAINTENANCE....7198
REPLACEMENT....7200
DISMOUNTING AND MOUNTING....7202
WINDSHIELD....7203
COMPONENT LOCATOR....7203
REPLACEMENT....7204
AFFIXING WEATHERSTRIPPROCEDURE....7205
FRONT BUMPER....7209
COMPONENT LOCATOR....7209
ELECTRICAL....7211
ELECTRICAL PARTS....7212
DATA AND SPECIFICATIONS....7212
COMPONENT LOCATOR....7213
TROUBLESHOOTING....7222
GENERAL INSTRUCTION....7223
HANDLING PRECAUTION....7228
INSPECTION....7230
INSPECTION AND ADJUSTMENT....7251
SPEEDOMETERCONVERSION RATE LIST....7252
ELECTRIC WIRE....7253
DIAGRAM....7254
HOW TO USE THIS CHAPTER....7254
SPECIFICATION SYMBOL LIST....7260
TERMS CONTRADISTINCTION LIST....7268
DIAGRAM....7270
POSITION OF CONNECTOR....7408
CONNECTOR....7433
PIN LIST OF WIRE TO WIRE CONNECTOR (IN THE BULK HEADCONNECTOR BOX)....7458
PIN LIST OF WIRE TO WIRE CONNECTOR (OUT OF THE BULK HEADCONNECTOR BOX)....7461
PIN LIST OF SIGNAL CHECK ....7464
CONNECTOR LIST....7465
2016 CONV Engine....7477
FO REWORD....7477
CHAPTER REFERENCES....7478
INDEX....7479
GENERAL INTRODUCTION (ENGINE)....7481
GENERAL INTRODUCTION (ENGINE) ....7482
GENERAL PRECAUTIONS....7482
HOW TO USE THIS WORKSHOP MANUAL....7485
IDENTIFICATION INFORMATION....7487
PRECAUTIONS....7488
SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS....7491
DISMOUNTING AND MOUNTING....7492
SYMPTOM SIMULATION....7495
GLOSSARY OF SAE AND HINO TERMS....7497
ENGINE INTRODUCTION (J08E)....7500
ENGINE ASSEMBLY....7501
DATA AND SPECIFICATIONS....7501
TROUBLESHOOTING....7503
TROUBLESHOOTING (COMMON RAIL SYSTEM)....7510
ENGINE TUNEUP....7511
SPECIAL TOOL....7517
OVERHAUL CRITERIA....7518
DISMOUNTING AND MOUNTING....7519
LIQUID GASKET AND APPLICATION POINTS....7521
ENGINE MECHANICAL (J08E)....7526
CYLINDER HEAD....7527
COMPONENT LOCATOR....7527
SPECIAL TOOL....7530
OVERHAUL....7531
INSPECTION AND REPAIR....7542
CRANKSHAFT FRONT END....7546
COMPONENT LOCATOR....7546
SPECIAL TOOL....7547
OVERHAUL....7548
FLYWHEEL AND FLYWHEEL HOUSING....7550
COMPONENT LOCATOR....7550
SPECIAL TOOL....7551
OVERHAUL....7551
INSPECTION AND REPAIR....7557
TIMING GEAR....7558
COMPONENT LOCATOR....7558
SPECIAL TOOL....7559
OVERHAUL....7560
INSPECTION AND REPAIR....7562
MAIN MOVING PARTS AND CYLINDER BLOCK....7564
COMPONENT LOCATOR....7564
SPECIAL TOOL....7567
OVERHAUL....7569
INSPECTION AND REPAIR....7582
AIR INTAKE SYSTEM (J08E)....7586
AIR INTAKE MANIFOLD AND PIPE....7587
COMPONENT LOCATOR....7587
DISMOUNTING AND MOUNTING....7588
AIR INTAKE....7589
COMPONENT LOCATOR....7589
AIR CLEANER....7590
DESCRIPTION....7590
OVERHAUL....7591
AIR HOSE....7592
COMPONENT LOCATOR....7592
OVERHAUL....7593
AIR FLOW SENSOR....7594
COMPONENT LOCATOR....7594
REPLACEMENT....7595
BOOST PRESSURE SENSOR....7596
COMPONENT LOCATOR....7596
REPLACEMENT....7597
EXHAUST SYSTEM (J08E)....7598
EXHAUST MANIFOLD AND PIPE....7599
COMPONENT LOCATOR....7599
DISMOUNTING AND MOUNTING....7600
EXHAUST PIPE AND MUFFLER UNIT....7601
DESCRIPTION....7601
COMPONENT LOCATOR....7602
REPLACEMENT OF ATC....7608
OVERHAUL....7610
DPR (DIESEL PARTICULATE REDUCTION SYSTEM)....7619
SYSTEM CONFIGURATION....7619
STRUCTURE OF DPR-CLEANER....7620
DPR MAINTENANCE....7621
DPR INSPECTION....7621
INSPECTION PROCEDURE FOLLOWED WHEN "DPR MAINTENANCE" IS DISPLAYED ON THE INFORMATION DISPLAY....7622
INSPECTION BY WAY OF HINO DXⅡ....7623
INSPECTION PROCEDURE FOLLOWED WHEN CHECK ENGINE LIGHT ILLUMINATES (ABNORMAL)....7627
DETERMINATION BY WAY OF DPR STATE DETERMINATION MONITOR OF HINO DXⅡ....7630
CHECKING THE DPR STATE....7630
REPLACEMENT OF DPR FILTER....7631
OVERALL OPERATION FLOW....7633
DIFFERENTIAL PRESSURE SENSOR....7641
COMPONENT LOCATOR....7641
DISMOUNTING AND MOUNTING....7642
INSPECTION AND REPAIR....7642
FUEL ADDITION VALVE....7645
COMPONENT LOCATOR....7645
OVERHAUL....7646
EXHAUST CONTROL CYLINDER....7656
SYSTEM CONFIGURATION....7656
DPR INSPECTION CHECK SHEET....7657
ATC UPSTREAM TEMPERATURE SENSOR....7660
COMPONENT LOCATOR....7660
OVERHAUL....7661
LUBRICATING SYSTEM (J08E)....7662
LUBRICATING SYSTEM....7663
DIAGRAM....7663
OIL PUMP AND OIL STRAINER....7665
COMPONENT LOCATOR....7665
OVERHAUL....7666
INSPECTION AND REPAIR....7667
OIL FILTER AND OIL COOLER....7669
COMPONENT LOCATOR....7669
SPECIAL TOOL....7670
DISMOUNTING AND MOUNTING....7671
INSPECTION AND REPAIR....7672
COOLING SYSTEM (J08E)....7673
COOLING SYSTEM....7674
DIAGRAM....7674
COOLANT PUMP....7675
COMPONENT LOCATOR....7675
THERMOSTAT....7676
COMPONENT LOCATOR....7676
OVERHAUL....7677
RADIATOR AND INTERCOOLER....7679
COMPONENT LOCATOR....7679
OVERHAUL....7679
RADIATOR....7681
COMPONENT LOCATOR....7681
SPECIAL TOOL....7682
OVERHAUL....7682
INSPECTION AND REPAIR....7686
COOLING FAN....7687
COMPONENT LOCATOR....7687
INSPECTION AND REPAIR....7688
FUEL SYSTEM (J08E)....7689
FUEL SYSTEM....7690
DIAGRAM....7690
COMPONENT LOCATOR....7691
SUPPLY PUMP....7692
DESCRIPTION....7692
COMPONENT LOCATOR....7693
SPECIAL TOOL....7693
OVERHAUL....7694
COMMON RAIL....7703
DESCRIPTION....7703
INSPENTION....7704
REPLACEMENT....7705
INJECTOR....7709
DESCRIPTION....7709
REPLACEMENT....7710
PRE FUEL FILTER....7718
DESCRIPTION....7718
AIR BLEEDING....7719
FUEL FILTER....7721
DESCRIPTION....7721
OVERHAUL....7722
FUEL TANK....7725
COMPONENT LOCATOR....7725
FUEL CUTOFF VALVE....7727
COMPONENT LOCATOR....7727
OVERHAUL....7728
TURBOCHARGER (J08E)....7729
TURBOCHARGER....7730
DESCRIPTION....7730
TROUBLESHOOTING....7731
REPLACEMENT....7740
INSPECTION AFTER MOUNTING....7746
EMISSION CONTROL (J08E)....7747
EGR VALVE AND EGR PIPE....7748
COMPONENT LOCATOR....7748
EGR VALVE....7749
DESCRIPTION....7749
DISMOUNTING AND MOUNTING....7750
CLOSED VENTILATOR....7753
DESCRIPTION....7753
REPLACEMENT OF CLOSED VENTILATOR....7753
SELECTIVE CATALYTIC REDUCTION (SCR)....7755
GENERAL DESCRIPTION....7755
COMPONENT LOCATOR....7757
INSPECTION....7758
SPECIAL TOOL....7759
DISMOUNTING AND MOUNTING....7760
INSPECTION AND REPAIR....7775
ALTERNATOR (J08E: REMY 12V-130A,135A,180A,200A)....7776
ALTERNATOR....7777
DATA AND SPECIFICATIONS....7777
TROUBLESHOOTING....7777
COMPONENT LOCATOR....7778
OVERHAUL....7779
INSPECTION AND REPAIR....7782
STARTER (J08E)....7783
STARTER....7784
DATA AND SPECIFICATIONS....7784
DESCRIPTION....7784
TROUBLESHOOTING....7785
COMPONENT LOCATOR....7786
OVERHAUL....7787
INSPECTION AND REPAIR....7791
AIR COMPRESSOR (J08E: 340 cm3)....7794
AIR COMPRESSOR....7795
DATA AND SPECIFICATIONS....7795
DESCRIPTION....7796
TROUBLESHOOTING....7797
COMPONENT LOCATOR....7798
SPECIAL TOOL....7799
OVERHAUL....7799
INSPECTION AND REPAIR....7807
ENGINE CONTROL (J08E)....7810
ACCELERATOR PEDAL....7811
DESCRIPTION....7811
ENGINE ECU....7812
COMPONENT LOCATOR....7812
REPLACEMENT....7813
2016 CONV Troubleshooting 1_ELEC_ENG_DPF....7820
FOREWORD....7820
CHAPTER REFERENCES....7821
INDEX....7822
GENERAL INTRODUCTION....7823
GENERAL INTRODUCTION....7824
GENERAL PRECAUTIONS....7824
IDENTIFICATION INFORMATION....7827
HOW TO USE THIS WORKSHOP MANUAL....7834
INTRODUCTION TO DESCRIPTIONS....7834
PRECAUTIONS....7837
SEALANT ON THE TAPERED SCREW FOR PIPING....7840
METRIC INFORMATION....7841
SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS....7843
SPECIFIED TORQUE FOR FLANGE BOLTS AND NUTS....7844
RECOMMENDED LUBRICANTS....7845
INFORMATION DISPLAY....7847
GLOSSARY....7852
GLOSSARY OF SAE AND HINO TERMS....7855
TERMS CONTRADISTINCTION LIST....7858
TROUBLE SHOOTING - COMPONENTS....7860
ENGINE BASIC....7861
ENGINE ASSEMBLY....7861
ENGINE ASSEMBLY (COMMON RAIL SYSTEM)....7868
TURBOCHARGER (J08E)....7869
TURBOCHARGER....7869
ALTERNATOR (J08E: REMY 12V-130A, 135A, 180A, 200A)....7878
ALTERNATOR....7878
STARTER (J08E)....7879
STARTER....7879
AIR COMPRESSOR (J08E: 340 cm3)....7880
AIR COMPRESSOR....7880
CLUTCH MAIN UNIT....7881
CLUTCH ASSEMBLY (EATON SAS1401)....7881
CLUTCH ASSEMBLY (EATON SAS1402)....7883
AUTOMATIC TRANSMISSION....7885
AUTOMATIC TRANSMISSION ASSEMBLY....7885
TRANSMISSION/TRANSFER CONTROL (EATON MANUAL TRANSMISSION) ....7886
TRANSMISSION CONTROL UNIT....7886
TRANSMISSION/TRANSFER CONTROL (ALLISON AUTOMATIC TRANSMISSION)....7887
TRANSMISSION CONTROL UNIT....7887
PROPELLER SHAFT (SPL 100, 140)....7887
PROPELLER SHAFT ASSEMBLY....7887
DIFFERENTIAL CARRIER (MERITOR RS-17, 19, 21 AND 23)....7888
DIFFERENTIAL CARRIER ASSEMBLY....7888
BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE)....7889
SERVICE BRAKE ASSEMBLY....7889
BRAKE EQUIPMENT (MODELS WITH FULL AIR BRAKE)....7894
SERVICE BRAKE ASSEMBLY....7894
SERVICE BRAKE (HYDRAULIC BRAKE)....7896
WHEEL BRAKE (TYPE: 4 PISTON)....7896
SERVICE BRAKE (FULL AIR BRAKE)....7898
AIR DRYER AND RESERVOIR SYSTEM (MODEL: BENDIX AD-IS)....7898
EXHAUST BRAKE....7901
EXHAUST BRAKE SYSTEM....7901
PARKING BRAKE (BOSCH 12)....7902
PARKING BRAKE ASSEMBLY....7902
STEERING EQUIPMENT....7903
STEERING SYSTEM....7903
FRONT AXLE (MFS)....7907
FRONT AXLE (MFS)....7907
REAR AXLE....7909
REAR AXLE....7909
WHEEL AND TIRE....7910
WHEEL AND TIRE....7910
SUSPENSION....7912
LEAF SUSPENSION ASSEMBLY....7912
AIR SUSPENSION ASSEMBLY....7912
CHASSIS FRAME....7913
CHASSIS FRAME....7913
CAB....7914
AIR SUSPENSION DUMP SYSTEM....7914
CAB ASSEMBLY....7914
AIR CONDITIONING SYSTEM....7916
ELECTRICAL EQUIPMENT....7926
ELECTRICAL PARTS....7926
TROUBLE SHOOTING - ELECTRICAL CONTROL SYSTEM....7928
ABOUT HINO DXⅡ....7929
About HINO DXⅡ....7929
BASIC PROCEDURE FOR TROUBLESHOOTING....7931
BASIC PROCEDURE FOR TROUBLESHOOTING....7931
SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE....7933
SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE....7933
SYMPTOM SIMULATION....7936
SYMPTOM SIMULATION....7936
TROUBLE CODE DIAGNOSTIC INSPECTION FLOW CHART....7938
TROUBLE CODE DIAGNOSTIC INSPECTION FLOW CHART....7938
ELECTRONIC CIRCUIT INSPECTION PROCEDURE....7939
ELECTRONIC CIRCUIT INSPECTION PROCEDURE....7939
INSPECTION PROCEDURE FOR MULTIPLE DTCS....7944
INSPECTION PROCEDURE FOR MULTIPLE DTCS....7944
ENGINE CONTROL SYSTEM (J08E)....7945
ENGINE CONTROL SYSTEM....7948
PRECAUTIONS FOR DIAGNOSIS....7948
SYSTEM BLOCK DIAGRAM....7950
SYSTEM DIAGRAM....7951
PRECAUTIONS....7953
SENSOR LOCATION....7957
COMPUTER (ECU) PIN ASSIGNMENT....7966
ENGINE ECU CONNECTOR....7972
INSPECTION....7976
DIAGNOSIS USING THE PC DIAGNOSIS TOOL....7977
DIAGNOSTIC TROUBLE CODE (DTC) TABLE....7978
GROUP SHARING THE SENSOR POWER SUPPLY TERMINAL....7996
GROUP SHARING THE SENSOR GND TERMINAL....7997
ENGINE BASIC INSPECTION SHEET (ENGINE INSPECTION CHECK SHEET)....7998
NO DTC....8002
DTC: P0005....8005
DTC: P0006 and P0007....8009
DTC: P0016....8014
DTC: P0027....8017
DTC: P003A....8022
DTC: P0045....8027
DTC: P0047....8032
DTC: P0048....8037
DTC: P006E....8042
DTC: P006F....8046
DTC: P007B....8050
DTC: P007C and P007D....8063
DTC: P0088....8070
DTC: P0096....8079
DTC: P0097 and P0098 ....8090
DTC: P00AF....8097
DTC: P0101....8101
DTC: P0104....8108
DTC: P0106....8114
DTC: P0108....8120
DTC: P0112 and P0113....8126
DTC: P0115....8132
DTC: P0117 and P0118....8140
DTC: P011A....8147
DTC: P011C....8155
DTC: P0122 and P0123....8160
DTC: P0128....8170
DTC: P0148 ....8175
DTC: P016E and P016F ....8186
DTC: P0182 and P0183 ....8196
DTC: P0191....8203
DTC: P0192 and P0193 ....8211
DTC: P01A5....8219
DTC: P01A6....8226
DTC: P0200....8233
DTC: P0201, P0202, P0203, P0204, P0205 and P0206....8235
DTC: P0217....8240
DTC: P0219....8245
DTC: P0222 and P0223....8250
DTC: P0234....8260
DTC: P0237....8266
DTC: P0263, P0266, P0269, P0272, P0275 and P0278....8273
DTC: P026C and P026D....8284
DTC: P0299....8295
DTC: P0300....8300
DTC: P0301, P0302, P0303, P0304, P0305 and P0306....8307
DTC: P0335....8314
DTC: P0336....8319
DTC: P0340....8325
DTC: P0341....8330
DTC: P0381....8337
DTC: P0401....8342
DTC: P0402....8356
DTC: P0404....8366
DTC: P0405 and P0406....8371
DTC: P041B....8377
DTC: P041C and P041D....8385
DTC: P0420....8392
DTC: P0421....8394
DTC: P0422....8404
DTC: P0489 and P0490....8407
DTC: P049D....8413
DTC: P04DA....8418
2016 CONV Troubleshooting 2_ENGINE....8430
FOREWORD....8430
CHAPTER REFERENCES....8431
INDEX....8432
ENGINE CONTROL SYSTEM (J08E)....8433
ENGINE CONTROL SYSTEM....8436
DTC: P0500 and P0501....8436
DTC: P0504....8442
DTC: P0506 and P0507....8448
DTC: P0524....8451
DTC: P0545 and P0546....8456
DTC: P054E and P054F....8464
DTC: P0562 and P0563....8467
DTC: P05F1....8473
DTC: P0603....8481
DTC: P0605....8485
DTC: P0606....8487
DTC: P0607....8489
DTC: P0610....8491
DTC: P0611....8494
DTC: P0617....8496
DTC: P0628 and P0629....8500
DTC: P062F....8507
DTC: P0630....8511
DTC: P0642....8514
DTC: P0643....8518
DTC: P064C....8523
DTC: P0652....8528
DTC: P0653....8533
DTC: P0671, P0672, P0675 and P0676 ....8538
DTC: P0683....8548
DTC: P0686....8553
DTC: P0698....8557
DTC: P0699....8559
DTC: P06A4....8561
DTC: P06A5....8563
DTC: P06D3 and P06D4....8565
DTC: P0704....8571
DTC: P073D....8575
DTC: P081A....8581
DTC: P081B....8585
DTC: P0850....8589
DTC: P1133....8593
DTC: P119F....8599
DTC: P1426....8604
DTC: P1427....8610
DTC: P1428....8616
DTC: P1458....8622
DTC: P1459....8627
DTC: P14B0....8632
DTC: P14B2....8636
DTC: P14B3 and P14B4....8640
DTC: P14B7 and P14B8....8646
DTC: P14BC and P14BD....8652
DTC: P14BF....8658
DTC: P1515....8663
DTC: P1530....8668
DTC: P1681 and P1682....8671
DTC: P200C....8679
DTC: P2032 and P2033....8685
DTC: P203F....8693
DTC: P204F....8697
DTC: P206B....8699
DTC: P207F....8714
DTC: P2080....8729
DTC: P2084....8737
DTC: P20CD....8745
DTC: P20CE....8749
DTC: P20CF....8753
DTC: P20D8....8756
DTC: P20DE....8761
DTC: P20DF....8764
DTC: P20E0....8770
DTC: P20EE....8776
DTC: P2100....8793
DTC: P2101....8799
DTC: P2103....8805
DTC: P2120....8811
DTC: P2122 and P2123....8815
DTC: P2127 and P2128....8823
DTC: P2135....8832
DTC: P2138....8837
DTC: P2146....8841
DTC: P2147 and P2148....8847
DTC: P2149....8854
DTC: P2150 and P2151....8860
DTC: P2184 and P2185....8867
DTC: P2201....8874
DTC: P2214....8904
DTC: P2227....8934
DTC: P2228 and P2229....8938
DTC: P2269....8943
DTC: P226C....8947
DTC: P22D3....8954
DTC: P240F....8958
DTC: P2428....8967
DTC: P242B....8971
DTC: P242C and P242D....8979
DTC: P244A....8987
DTC: P244B....9004
DTC: P2457....9017
DTC: P2458....9031
DTC: P2459....9039
DTC: P2463....9041
DTC: P246F....9046
DTC: P2470 and P2471....9054
DTC: P24A0....9062
DTC: P24A1....9065
DTC: P24A2....9067
DTC: P2563....9076
DTC: P2564 and P2565....9081
DTC: P259E....9088
DTC: P259F....9093
DTC: P2635....9098
DTC: P268A and P2696....9107
DTC: P2BA9....9113
DTC: U0073....9117
DTC: U010A....9120
DTC: U010C....9123
DTC: U010E....9126
DTC: U029D....9129
DTC: U029E....9132
DTC: U02A2....9135
DTC: U0301....9138
DTC: U1001....9141
DTC: U110A....9144
2016 CONV Troubleshooting 3_DEF_DPF....9148
FOREWORD....9148
CHAPTER REFERENCES....9149
INDEX....9150
DEF SCR SYSTEM (DCU)....9151
DEF SCR SYSTEM....9152
PRECAUTIONS FOR DIAGNOSIS....9152
SYSTEM BLOCK DIAGRAM....9154
SYSTEM DIAGRAM....9155
SENSOR LOCATION....9156
COMPUTER (DCU) WIRE HARNESS CONNECTOR PIN ASSIGNMENT....9159
SIGNAL CHECK HARNESS....9160
INSPECTION....9160
MALFUNCTION INDICATOR LIGHT ILLUMINATION PATTERN....9161
DIAGNOSIS USING THE PC DIAGNOSIS TOOL....9162
DIAGNOSTIC TROUBLE CODE (DTC) TABLE....9163
DTC: P0071....9169
DTC: P0072....9180
DTC: P0073....9188
DTC: P0562....9195
DTC: P0563....9198
DTC: P060C....9201
DTC: P062F....9203
DTC: P0667....9205
DTC: P0668....9207
DTC: P0669....9209
DTC: P068A....9211
DTC: P142A....9216
DTC: P142B....9225
DTC: P202E....9235
DTC: P203C....9239
DTC: P203D....9242
DTC: P2044....9245
DTC: P2045....9248
DTC: P2047....9251
DTC: P2048....9254
DTC: P2049....9259
DTC: P204B....9265
DTC: P204C....9268
DTC: P204D....9274
DTC: P205B....9280
DTC: P205C....9289
DTC: P205D....9292
DTC: P206C....9295
DTC: P206D....9298
DTC: P208A....9301
DTC: P208B....9305
DTC: P208C....9308
DTC: P208D....9312
DTC: P20A0....9316
DTC: P20A1....9322
DTC: P20A2....9325
DTC: P20A3....9331
DTC: P20B1....9337
DTC: P20B2....9342
DTC: P20B3....9350
DTC: P20B4....9355
DTC: P20BD, P20B9 and P20C1....9360
DTC: P20C0, P20BC and P20C4....9366
DTC: P20FC....9372
DTC: P20FD....9376
DTC: P20FE....9379
DTC: P20E8....9382
DTC: P20E9....9393
DTC: P20F4....9398
DTC: P2202....9402
DTC: P2203....9405
DTC: P2204....9408
DTC: P2209....9415
DTC: P2212....9422
DTC: P2215....9430
DTC: P2216....9433
DTC: P2222....9436
DTC: P2481....9444
DTC: P2482....9449
DTC: P2483....9455
DTC: P2510....9468
DTC: P2BAE....9473
DTC: U0029....9476
DTC: U0038....9479
DTC: U0100....9482
DTC: U029D....9486
DTC: U029E....9489
DTC: U02A2....9492
DTC: U0597....9495
BRAKE CONTROL SYSTEM (ABS:HYDRAULIC (E VERSION))....9497
ABS....9498
TROUBLESHOTTING....9498
BRAKE CONTROL SYSTEM (ABS:FULL AIR)....9520
ABS....9521
TROUBLESHOTTING....9521
VEHICLE CONTROL SYSTEM (VCS)....9550
VEHICLE CONTROL SYSTEM....9551
PRECAUTIONS FOR DIAGNOSIS....9551
SYSTEM BLOCK DIAGRAM....9553
SIGNAL CHECK HARNESS....9554
DIAGNOSIS USING THE PC DIAGNOSIS TOOL....9562
VEHICLE CONTROL ECU INSPECTION....9563
DIAGNOSIS MONITOR CODE AND DIAGNOSIS TROUBLE CODE TABLE....9569
DTC: P0500....9570
DTC: P0501....9574
DTC: P0562....9578
DTC: P0563....9581
DTC: P0617....9584
DTC: P0704....9587
DTC: P0850....9593
DTC: P1565....9599
DTC: U0101....9605
DTC: U0105 ....9608
DTC: U0155....9611
NO ACTIVATION OF AUXILIARY BRAKE....9613
NO ACTIVATION/RELEASE OF ENGINE REVOLUTION CONTROL....9619
NO ACTIVATION/RELEASE OF CRUISE FUNCTION....9624
NO ACTIVATION/RELEASE OF ECO MODE....9632
CAN COMMUNICATION....9636
CAN COMMUNICATION TROUBLESHOOTING....9637
Outline....9637
Definition of Terms....9637
Troubleshooting Procedure....9638
Work Flow....9638
ECU individual code list....9639
CAN communication circuit diagram....9640
CAN communication relation connector location....9643
ENGINE CAN COMMUNICATION LINE....9647
ABNORMAL CAN COMMUNICATION DTC DETECTED....9647
CONNECTION DIAGRAM....9647
CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE....9647
PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE....9649
DISCONNECTION INSPECTION FOR ENGINE CAN_H/L_COMMUNICATION LINE....9652
INSPECTION FOR SHORT-CIRCUIT IN CAN H-LINE....9657
INSPECTION FOR SHORT-CIRCUIT IN CAN L-LINE....9665
INSPECTION FOR EGR CONTROLLER CAN COMMUNICATION LINE....9673
INSPECTION FOR VNT CONTROLLER CAN COMMUNICATION LINE....9678
INSPECTION FOR DCU CAN COMMUNICATION LINE (ENGINE CAN COMMUNICATION LINE)....9683
INSPECTION FOR NOx sensor 1 CAN COMMUNICATION LINE....9688
INSPECTION FOR NOx sensor 2 CAN COMMUNICATION LINE....9694
INSPECTION FOR DEF SENSOR CAN COMMUNICATION LINE....9700
DIAGNOSIS CAN COMMUNICATION LINE....9706
ABNORMAL CAN COMMUNICATION DTC DETECTED....9706
CONNECTION DIAGRAM....9706
CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE....9706
PRE-INSPECTION FOR DIAGNOSIS CAN COMMUNICATION LINE....9708
DISCONNECTION INSPECTION FOR DIAGNOSIS CAN_H/L_COMMUNICATION LINE....9711
INSPECTION FOR SHORT-CIRCUIT IN DIAGNOSIS CAN H-LINE....9715
INSPECTION FOR SHORT-CIRCUIT IN DIAGNOSIS CAN L-LINE....9719
INSPECTION FOR DCU CAN COMMUNICATION LINE (DIAGNOSIS CAN COMMUNICATION LINE)....9724
INSPECTION FOR ENGINE ECU CAN COMMUNICATION LINE....9728
CONTROL CAN COMMUNICATION LINE....9733
ABNORMAL CAN COMMUNICATION DTC DETECTED....9733
CONNECTION DIAGRAM (ALLISON AUTOMATIC TRANSMISSION)....9733
CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE (ALLISON AUTOMATIC TRANSMISSION)....9733
CONNECTION DIAGRAM (MANUAL TRANSMISSION)....9734
CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE (MANUAL TRANSMISSION)....9734
PRE-INSPECTION FOR CAN COMMUNICATION LINE....9735
DISCONNECTION INSPECTION FOR CAN_H/L_COMMUNICATION LINE....9739
INSPECTION FOR SHORT-CIRCUIT IN CAN H-LINE....9742
INSPECTION FOR SHORT-CIRCUIT IN CAN L-LINE....9744
INSPECTION FOR AUTOMATIC TRANSMISSION ECU CAN COMMUNICATION LINE....9746
Bulkhead JB Connector ID....9749
...
Hino Trucks Repair Service Manual + Owners Manual MY2001-MY2016
