HINO Trucks 155, 155h, 195, 195h & 238, 258LP, 268, 338, 358 Models Repair Service Manual 2013
Complete repair service manual with electrical wiring diagrams for MY2013 HINO Trucks 155, 155h, 195, 195h & 238, 258LP, 268, 338, 358 Series, with all the technical information to maintain, diagnose, repair, and service like professional mechanics.
HINO Trucks 155, 155h, 195, 195h & 238, 258LP, 268, 338, 358 Models Trucks 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.
S1-LXJE12A.pdf
S1-LXJE12A_EWD.pdf
S1-UNAE12A-1.pdf
S1-UNAE12A-2.pdf
S7-LXJE12A_1.pdf
S7-LXJE12A_2.pdf
S7-LXJE12A_3.pdf
S7-LXJE12A_4.pdf
S7-LXJE12A_5.pdf
S7-UNAE12A-1.pdf
S7-UNAE12A-2.pdf
S7-UNAE12A-3.pdf
Total Pages: 9,321 pages
File Format: PDF (Windows & Mac & Linux)
Language: English
Applicable for HINO 155, 155h, 195, 195h series, equipped with J05E engine
Applicable for HINO 238, 258LP, 268, 338, 358 series, equipped with J08E-VB and J08E-VC engine
...
TABLE OF CONTENTS
GENERAL INTRODUCTION
CLUTCH EQUIPMENT
CLUTCH MAIN UNIT
CLUTCH CONTROL
TRANSMISSION EQUIPMENT
TRANSMISSION MAIN UNIT
TRANSFER MAIN UNIT
AUTOMATIC TRANSMISSION
PTO (POWER TAKE-OFF)
TRANSMISSION / TRANSFER CONTROL
PROPELLER SHAFT EQUIPMENT
PROPELLER SHAFT
DIFFERENTIAL EQUIPMENT
DIFFERENTIAL CARRIER
BRAKE EQUIPMENT
SERVICE BRAKE
ABS
ES START (EASY & SMOOTH START) SYSTEM
EXHAUST BRAKE
RETARDER BRAKE
PARKING BRAKE
STEERING EQUIPMENT
STEERING UNIT
POWER STEERING
AXLE EQUIPMENT
FRONT AXLE
REAR AXLE
WHEEL & TIRE
SUSPENSION EQUIPMENT
SUSPENSION
CHASSIS EQUIPMENT
CHASSIS FRAME
COUPLER (5TH WHEEL)
PINTLE HOOK
CAB EQUIPMENT
CAB
ELECTRICAL EQUIPMENT
ELECTRIC WIRE
HYBRID SYSTEM
...
2013 Hino-155-195-155h-195h Body Build Manual....2
index....2
US cover....3
COVER ....3
BACK COVER ....4
BACK COVER ....5
US WARNING....6
US XZU Chap01....7
Chapter 1....7
PURPOSE....8
RELATION TO OTHER HINO MANUALS....8
NON-GUARANTEE....8
CERTIFICATION AND COMPLIANCE WITH SAFETY REGULATIONS AND STANDARDS....9
INSTALLATION, MODIFICATION AND ALTERATION....9
CHANGE OF THIS BOOK....9
RELATION BETWEEN THIS BOOK AND THE VEHICLE WARRANTY....10
FURTHER INFORMATION....10
US XZU Chap02....11
Chapter 2....0
SAFETY STANDARDS....12
VEHICLE NOISE REGULATIONS INFORMATION....16
EMISSION CONTROL REGULATIONS....17
US XZU Chap03....19
Chapter 3....19
MODEL LINE-UP....20
WEIGHTS AND DIMENSIONS....21
WEIGHT DISTRIBUTION OF THE OPTION EQUIPMENT....29
BODY TYPES....30
US XZU Chap04....31
Chapter 4....31
WARNING....32
GENERAL PRECAUTIONS....35
WEIGHT DISTRIBUTION AND CENTER OF GRAVITY....39
FIRE SHIELD....40
CLEARANCE BETWEEN CAB AND REAR BODY OR EQUIPMENT....41
SPACE FOR MAINTENANCE OF BATTERY....45
FUEL FILLER FOR FUEL TANK....46
PRECAUTION FOR CAUTION LABEL OF FUEL TANK....46
INSTALLATION OF FENDER AND MUDGUARD....48
CAUTIONS ON WELDING....48
PROTECTION OF INTERFERENCE WITH REAR SPRING AND REAR SPRING HANGE....55
NOTES ON SYSTEM CONTROL COMPUTERS....56
PROCESS FOR REMOVING THE INSTRUMENT PANEL....58
PRECAUTION FOR REINSTALLING WASHER TANK INLET....62
NOTES ON ADDITIONAL WIRING IN THE ENGINE COMPARTMENT....65
CAUTION ON VEHICLE STORAGE....65
PRECAUTIONS FOR EXHAUST SYSTEM....66
DPR MUFFLER....69
PRECAUTION FOR DEF - SCR SYSTEM....71
INSTALLATION OF FUEL INLET PIPE....75
PRECAUTIONS FOR THE FUEL HOSE AND PIPE....79
PRECAUTION ON BODY MOUNTING WORK....81
PROVISION FOR AM RADIO NOISE....85
FOR THE INSTALLING EQUIPMENT ON THE CAB ROOF....87
US XZU Chap05....88
Chapter 5....88
GENERAL CAUTIONS....89
PRECAUTION FOR THE TIGHTENING BOLT AND NUT OF THE CHASSIS FRAME....90
MATERIAL FOR CHASSIS FRAME MODIFICATIONS....90
CHASSIS FRAME HOLE PATTERN....91
CHASSIS FRAME DRILLING....92
FLANGE CUTTING....93
CHASSIS FRAME WELDING....93
REAR OVERHANG EXTENSION....95
STIFFENING OF SIDE RAILS....97
PROPELLER SHAFT MODIFICATION AND ALTERATION....102
SERVICE BRAKE MODIFICATIONS....102
ELECTRIC WIRING MODIFICATIONS....118
ALTERATION OF EXHAUST SYSTEM....119
CAUTIONS NEEDED IN ADDITIONAL MACHINING AND ALTERATION OF THE CAB....120
US XZU Chap06....121
Chapter 6....121
MAIN SILL (OR SUB-FRAME)....122
REAR AXLE....127
REAR BODY LENGTH AND MAIN SILL (SUB-FRAME) DIMENSIONS....128
U-BOLTS....128
MOUNTING SUB-FRAME WITH U-BOLT....132
MOUNTING OF REAR FENDER AND MUDGUARD....133
US XZU Chap07....135
Chapter 7....135
WARNING....136
LAMPS, REFLECTIVE DEVICES AND ASSOCIATED EQUIPMENT....137
FUSE BLOCK, RELAY PANEL AND FUSIBLE LINK BLOCK....140
ALTERNATOR OUTPUT CHARACTERISTIC....151
ELECTRICAL POWER SOURCES....152
BACK-UP BUZZER....159
HARNESS WIRING....160
US XZU Chap08....173
Chapter 8....173
GENERAL CAUTIONS....174
CAUTIONS FOR USE OF THINNER AND SOLVENTS CONTAINING THINNER....174
THE PARTS WHICH HAVE NO RESISTANCE TO HIGH TEMPERATURE AND THEIR TEMPERATURE LIMIT....176
CAUTIONS ON THE TOP COAT OF PAINT....176
CAUTIONS FOR FORCED DRYING....177
PRINCIPAL PARTS AND ALLOWABLE HEAT LIMIT....178
HOW TO DISMOUNTING & REMOUNTING THE PARTS OF CAB....182
THE KIND AND THE ATTACHING POSITION OF MARK AND ORNAMENT....191
PRECAUTIONS FOR FITTING AND STORING THE CAUTION PLATE....194
HANDLING OF COMPUTERS (ECU)....195
CAUTIONS FOR PAINTING THE TIRE WHELS....196
PRECAUTION FOR INSTALLING TIRE WHEL ONTO THE VEHICLE....197
TIGHTENING TORQUE OF WHEL NUT....197
US XZU Chap09....198
Chapter 9....198
CAB DRAWINGS....199
CAB BACK DRAWINGS....201
CHASSIS DRAWINGS....213
CHASSIS FRAME DRAWINGS....235
US XZU Chap10....253
Chapter 10....253
FUEL TANK....254
BATTERY....256
EXHAUST SYSTEM....258
US XZU Chap11....259
Chapter 11....259
HINO GENUINE P.T.O.....260
TRANSMISSION MODELS TO BE INSTALLED HINO?S VEHICLES....260
OTHER NOTICES....261
MOUNTING POSITION OF TRANSMISSION P.T.O. ASSY....262
ENGINE REV. CONTROL FOR MOUNTING OF BODY OR EQUIPMENT....263
US XZU Chap12....267
Chapter 12....267
DIAGRAM OF FRAME SECTION MODULUS....268
SUSPENSION DEFLECTION CHART....273
BRAKE PIPING DIAGRAM....277
ELECTRIC WIRING DIAGRAM....279
CONNECTORS....322
METRIC/U.S. CUSTOMARY UNIT EQUIVALENTS....417
2013 Hino-238-258-268-338 Body Build Manual....418
S1-LXJE12A....991
FOREWORD....991
CHAPTER REFERENCES....992
INDEX....993
GENERAL INTRODUCTION....995
HOW TO IDENTIFY VEHICLE TYPE....996
HOW TO IDENTIFY VEHICLE TYPE....996
VEHICLE MODEL....996
VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE....997
APPEARANCE OF VEHICLE....998
APPEARANCE....998
APPEARANCE OF VEHICLE....998
SAFETY INSTRUCTIONS AND READINESS TO WORK....999
WARNING....999
GENERAL PRECAUTIONS....999
IDENTIFICATION INFORMATION....1003
SAFETY INSTRUCTIONS FOR WORK....1006
PRECAUTIONS....1006
INTRODUCTION TO WORKSHOP MANUAL....1010
GENERAL....1010
INTRODUCTION TO DESCRIPTIONS....1011
DEFINITION OF TERM....1013
TIGHTENING OF BOLTS AND NUTS....1014
BOLTS AND NUTS....1014
PURPOSES OF TIGHTENING TORQUE....1014
CAUTIONS TO PREVENT LOOSENESS....1014
TYPES AND IDENTIFICATION....1015
COMPATIBILITY (NO COMPATIBILITY IN BOLTS AND NUTS)....1016
STRENGTH CLASSES AND SYMBOLS....1017
PART No.....1018
LIST OF TIGHTENING TORQUE....1019
TIGHTENING OF FLARE NUTS AND HOSES....1021
HANDLING OF LIQUID GASKET....1022
LIQUID GASKET....1022
GLOSSARY....1023
DEFINITION OF ABBREVIATION IN THIS MANUAL....1023
LIST OF ABBREVIATION....1023
GLOSSARY OF SAE AND HINO TERMS....1026
LUBRICANTS....1029
LUBRICANTS....1029
RECOMMENDED LUBRICANTS....1029
HYBRID....1031
STANDARD VALUE....1032
HYBRID SYSTEM....1032
SERVICE PLUG....1032
PCU....1032
HV BATTERY....1033
HV BATTERY COOLING FAN....1033
HV BATTERY ECU....1033
SYSTEM MAIN RELAY JUNCTION BLOCK....1033
INVERTER....1034
HV-ECU....1034
HYBRID JUNCTION BLOCK....1034
WATER PUMP....1035
INVERTER RADIATOR....1035
COOLANT....1035
MOTOR CABLE....1035
REQUIRED ITEMS....1036
HYBRID SYSTEM....1036
HYBRID SYSTEM....1036
SERVICE PLUG....1036
COOLANT....1036
HYBRID SYSTEM....1037
HYBRID SYSTEM....1037
CAUTIONS....1037
SERVICE PLUG....1041
COMPONENT LOCATOR....1041
UNIT CHECK....1041
REPLACEMENT....1042
PCU....1044
COMPONENT LOCATOR....1044
REPLACEMENT....1048
HV BATTERY....1053
COMPONENT LOCATOR....1053
REPLACEMENT....1055
HV BATTERY COOLING FAN....1060
COMPONENT LOCATOR....1060
REPLACEMENT....1062
HV BATTERY ECU....1065
COMPONENT LOCATOR....1065
REPLACEMENT....1066
SYSTEM MAIN RELAY JUNCTION BLOCK....1069
COMPONENT LOCATOR....1069
REPLACEMENT....1070
INVERTER....1072
COMPONENT LOCATOR....1072
REPLACEMENT....1073
HV-ECU....1077
COMPONENT LOCATOR....1077
REPLACEMENT....1078
HYBRID JUNCTION BLOCK....1080
COMPONENT LOCATOR....1080
REPLACEMENT....1081
WATER PUMP....1084
COMPONENT LOCATOR....1084
REPLACEMENT....1085
INVERTER RADIATOR....1088
COMPONENT LOCATOR....1088
REPLACEMENT....1089
COOLANT....1092
REPLACEMENT....1092
MOTOR CABLE....1094
COMPONENT LOCATOR....1094
REPLACEMENT....1097
TRANSMISSION (A465)....1103
STANDARD VALUE....1104
ATTACHING AND DETACHING THE TRANSMISSION....1104
AUTOMATIC TRANSMISSION ASSEMBLY....1104
TRANSMISSION CONTROL....1106
SHIFT LEVER ASSEMBLY....1106
TRANSMISSION MECHANICAL....1106
TURBINE SENSOR....1106
SPEED SENSOR....1106
NEUTRAL SWITCH....1107
EOP....1107
VALVE BODY ASSEMBLY....1107
REQUIRED ITEMS....1108
ATTACHING AND DETACHING THE TRANSMISSION....1108
AUTOMATIC TRANSMISSION ASSEMBLY....1108
NEUTRAL SWITCH....1108
FRONT OIL SEAL....1108
ATTACHING AND DETACHING THE TRANSMISSION....1109
AUTOMATIC TRANSMISSION ASSEMBLY....1109
REPLACEMENT....1109
TRANSMISSION CONTROL....1150
CONTROL COMPUTER ASSEMBLY ....1150
COMPONENT LOCATOR....1150
OVERHAUL....1151
SHIFT LEVER ASSEMBLY....1157
COMPONENT LOCATOR....1157
OVERHAUL....1158
TRANSMISSION MECHANICAL....1162
OIL PAN GASKET....1162
COMPONENT LOCATOR....1162
OVERHAUL....1163
REAR CASE GASKET....1165
COMPONENT LOCATOR....1165
OVERHAUL....1166
TURBINE SENSOR....1169
COMPONENT LOCATOR....1169
OVERHAUL....1170
SPEED SENSOR....1171
COMPONENT LOCATOR....1171
OVERHAUL....1172
NEUTRAL SWITCH....1173
COMPONENT LOCATOR....1173
OVERHAUL....1174
EOP....1176
OVERHAUL....1176
VALVE BODY ASSEMBLY....1183
OVERHAUL....1183
FRONT OIL SEAL....1192
OVERHAUL....1192
PROPELLER SHAFT (LD)....1194
STANDARD VALUE....1195
PROPELLER SHAFT MECHANICAL....1195
PROPELLER SHAFT ASSEMBLY....1195
REQUIRED ITEMS....1196
PROPELLER SHAFT MECHANICAL....1196
PROPELLER SHAFT ASSEMBLY....1196
PROPELLER SHAFT MECHANICAL....1198
PROPELLER SHAFT ASSEMBLY....1198
COMPONENT LOCATOR....1198
PROPELLER SHAFT ASSEMBLY....1200
OVERHAUL....1200
AXLE....1215
STANDARD VALUE....1216
FRONT AXLE....1216
STEERING KNUCKLE....1216
FRONT AXLE HUB....1217
REAR AXLE....1218
REAR AXLE HUB....1218
REAR AXLE SHAFT....1219
REQUIRED ITEMS....1220
FRONT AXLE....1220
STEERING KNUCKLE....1220
FRONT AXLE HUB....1221
REAR AXLE....1224
REAR AXLE HUB....1224
REAR AXLE SHAFT....1225
WHEEL AND TIRE....1226
FRONT AXLE....1227
STEERING KNUCKLE....1227
COMPONENT LOCATOR....1227
OVERHAUL....1231
FRONT AXLE HUB....1246
COMPONENT LOCATOR....1246
OVERHAUL....1248
FRONT AXLE HUB BOLT....1259
COMPONENT LOCATOR....1259
OVERHAUL....1260
REAR AXLE....1262
REAR AXLE HUB....1262
COMPONENT LOCATOR....1262
OVERHAUL....1264
REAR AXLE SHAFT....1274
COMPONENT LOCATOR....1274
OVERHAUL....1275
WHEEL AND TIRE....1277
WHEEL AND TIRE....1277
COMPONENT LOCATOR....1277
INSPECTION....1278
REPLACEMENT....1280
OVERHAUL (TUBELESS TIRE)....1283
DIFFERENTIAL (SH13)....1290
STANDARD VALUE....1291
DIFFERENTIAL....1291
DIFFERENTIAL CARRIER....1291
REQUIRED ITEMS....1293
DIFFERENTIAL....1293
DIFFERENTIAL CARRIER....1293
DIFFERENTIAL....1296
DIFFERENTIAL CARRIER....1296
COMPONENT LOCATOR....1296
OVERHAUL....1304
BRAKE....1341
STANDARD VALUE....1343
BRAKE CONTROL....1343
SERVICE BRAKE....1343
BRAKE FLUID....1343
BRAKE ACTUATOR....1344
SPEED SENSOR....1344
BRAKE PEDAL....1345
BRAKE MASTER CYLINDER....1345
BRAKE BOOSTER....1345
HYDRO BOOSTER....1346
ELECTRIC VACUUM PUMP....1346
VACUUM PUMP....1346
HYDRO PUMP....1347
VACUUM RESERVOIR....1347
FRONT FLEXIBLE HOSE....1347
REAR FLEXIBLE HOSE....1347
VACUUM WARNING BUZZER....1347
VACUUM SENSOR (FOR SKID CONTROL)....1348
DISC BRAKE ....1348
FRONT DISC CALIPER....1348
REAR DISC CALIPER....1349
PARKING BRAKE....1350
PARKING BRAKE....1350
PARKING BRAKE CABLE No.2....1350
PARKING BRAKE CABLE No.3....1350
PARKING BRAKE LEVER....1350
PARKING BRAKE DRUM....1351
PARKING BRAKE SWITCH....1351
REQUIRED ITEMS....1352
SERVICE BRAKE....1352
SERVICE BRAKE....1352
BRAKE FLUID....1352
SPEED SENSOR....1352
BRAKE PEDAL....1352
BRAKE BOOSTER....1352
HYDRO BOOSTER....1353
VACUUM RESERVOIR....1353
DISC BRAKE....1353
FRONT DISC CALIPER....1353
REAR DISC CALIPER....1353
PARKING BRAKE....1354
PARKING BRAKE DRUM....1354
BRAKE CONTROL....1355
SERVICE BRAKE....1355
INSPECTION AND ADJUSTMENT....1355
BRAKE FLUID....1360
REPLACEMENT....1360
ABS ACTUATOR....1363
COMPONENT LOCATOR....1363
REPLACEMENT....1364
UNIT CHECK....1366
SPEED SENSOR....1367
COMPONENT LOCATOR....1367
UNIT CHECK....1369
REPLACEMENT....1370
BRAKE PEDAL....1373
COMPONENT LOCATOR....1373
REPLACEMENT....1374
BRAKE MASTER CYLINDER....1377
COMPONENT LOCATOR....1377
REPLACEMENT....1378
BRAKE BOOSTER....1381
COMPONENT LOCATOR....1381
REPLACEMENT....1382
HYDRO BOOSTER....1390
COMPONENT LOCATOR....1390
REPLACEMENT....1391
ELECTRIC VACUUM PUMP....1396
COMPONENT LOCATOR....1396
OVERHAUL....1397
VACUUM PUMP....1401
COMPONENT LOCATOR....1401
OVERHAUL....1402
HYDRO PUMP....1404
COMPONENT LOCATOR....1404
OVERHAUL....1405
VACUUM RESERVOIR....1406
COMPONENT LOCATOR....1406
REPLACEMENT....1407
FRONT FLEXIBLE HOSE....1409
COMPONENT LOCATOR....1409
REPLACEMENT....1410
REAR FLEXIBLE HOSE....1412
COMPONENT LOCATOR....1412
REPLACEMENT....1413
VACUUM WARNING BUZZER....1415
BEHIND-THE-WHEEL INSPECTION....1415
REPLACEMENT....1415
VACUUM SENSOR (FOR SKID CONTROL)....1416
COMPONENT LOCATOR....1416
REPLACEMENT....1417
DISC BRAKE....1420
FRONT BRAKE CALIPER....1420
COMPONENT LOCATOR....1420
OVERHAUL....1421
REAR BRAKE CALIPER....1428
COMPONENT LOCATOR....1428
OVERHAUL....1429
PARKING BRAKE....1436
PARKING BRAKE....1436
INSPECTION AND ADJUSTMENT....1436
PARKING BRAKE CABLE No.2....1438
COMPONENT LOCATOR....1438
REPLACEMENT....1439
PARKING BRAKE CABLE No.3....1445
COMPONENT LOCATOR....1445
REPLACEMENT....1446
PARKING BRAKE LEVER....1451
COMPONENT LOCATOR....1451
REPLACEMENT....1452
PARKING BRAKE DRUM....1456
COMPONENT LOCATOR....1456
OVERHAUL....1458
PARKING BRAKE SWITCH....1468
COMPONENT LOCATOR....1468
REPLACEMENT....1469
STEERING....1471
STANDARD VALUE....1472
STEERING CONTROL....1472
POWER STEERING SYSTEM....1472
STEERING WHEEL....1472
STEERING COLUMN....1472
STEERING LINKAGE....1473
POWER STEERING GEAR....1473
POWER STEERING PUMP....1473
REQUIRED ITEMS....1474
STEERING CONTROL....1474
POWER STEERING SYSTEM....1474
STEERING WHEEL....1474
STEERING COLUMN....1475
STEERING LINKAGE....1475
POWER STEERING GEAR....1476
POWER STEERING PUMP....1476
STEERING CONTROL....1477
POWER STEERING SYSTEM....1477
PERFORMANCE INSPECTION....1477
STEERING WHEEL....1480
COMPONENT LOCATOR....1480
REPLACEMENT....1481
STEERING COLUMN....1484
COMPONENT LOCATOR....1484
REPLACEMENT....1485
STEERING LINKAGE....1492
COMPONENT LOCATOR....1492
REPLACEMENT....1493
POWER STEERING GEAR....1500
COMPONENT LOCATOR....1500
REPLACEMENT....1501
POWER STEERING PUMP....1512
COMPONENT LOCATOR....1512
REPLACEMENT ....1513
SUSPENSION....1515
STANDARD VALUE....1516
FRONT SUSPENSION....1516
SHOCK ABSORBER....1516
LEAF SPRING....1516
STABILIZER....1517
WHEEL ALIGNMENT....1517
REAR SUSPENSION....1518
SHOCK ABSORBER....1518
LEAF SPRING....1518
REQUIRED ITEMS....1519
FRONT SUSPENSION....1519
SHOCK ABSORBER....1519
LEAF SPRING....1519
WHEEL ALIGNMENT....1520
REAR SUSPENSION....1521
SHOCK ABSORBER....1521
LEAF SPRING....1521
FRONT SUSPENSION....1522
SHOCK ABSORBER....1522
COMPONENT LOCATOR....1522
REPLACEMENT....1523
LEAF SPRING....1526
COMPONENT LOCATOR....1526
OVERHAUL....1527
STABILIZER....1535
COMPONENT LOCATOR....1535
REPLACEMENT....1536
WHEEL ALIGNMENT....1538
ADJUSTMENT....1538
REAR SUSPENSION....1542
SHOCK ABSORBER....1542
COMPONENT LOCATOR....1542
REPLACEMENT....1543
LEAF SPRING....1546
COMPONENT LOCATOR....1546
OVERHAUL....1548
FRAME AND FRAME ACCESSORY....1557
STANDARD VALUE....1558
FRAME....1558
CHASSIS FRAME....1558
FRONT BUMPER....1559
REQUIRED ITEMS....1560
FRAME....1560
CHASSIS FRAME & CHASSIS FRAME ACCESSORIES....1560
FRAME....1561
FRAME AND FRAME ACCESSORIES....1561
COMPONENT LOCATOR....1561
FRAME....1562
INSPECTION....1562
REPAIR....1563
FRONT BUMPER....1568
COMPONENT LOCATOR....1568
REPLACEMENT....1569
CAB MOUNTING AND CAB SUSPENSION....1574
STANDARD VALUE....1575
CAB MOUNTING AND CAB SUSPENSION....1575
ASSEMBLY....1575
CAB MOUNTING....1575
TILT CAB STAY....1576
MOUNTING AND DISMOUNTING CAB....1577
CAB ASSEMBLY....1577
REPLACEMENT....1577
CAB MOUNTING AND CAB SUSPENSION....1591
CAB MOUNTING....1591
COMPONENT LOCATOR....1591
PRECAUTIONS IN TILTING AND LOWERING THE CAB....1595
REPLACEMENT....1596
CAB TILT STAY....1607
COMPONENT LOCATOR....1607
PRECAUTIONS IN TILTING AND LOWERING THE CAB....1610
REPLACEMENT....1611
CAB DIMENSIONAL DRAWING....1616
CAB ASSEMBLY....1616
SINGLE CAB....1616
CREW CAB....1618
BODY INSIDE ACCESSORY....1620
STANDARD VALUE....1621
INSTRUMENT PANEL AND DRIVER INFORMATION....1621
INSTRUMENT PANEL....1621
INTERIOR ACCESSORY....1621
ROOF ACCESSORY....1621
SEAT....1621
DRIVER'S SEAT....1621
ASSISTANT'S SEAT....1622
REAR SEAT....1622
INSTRUMENT PANEL AND DRIVER INFORMATION....1623
INSTRUMENT PANEL....1623
COMPONENT LOCATOR....1623
REPLACEMENT....1625
COMBINATION METER....1635
REPLACEMENT....1635
INTERIOR ACCESSORY....1636
INTERIOR ACCESSORY....1636
COMPONENT LOCATOR....1636
REPLACEMENT....1638
FLOOR ACCESSORY....1641
COMPONENT LOCATOR....1641
REPLACEMENT....1642
ROOF ACCESSORY....1643
COMPONENT LOCATOR....1643
REPLACEMENT....1644
SEAT....1651
DRIVER'S SEAT....1651
COMPONENT LOCATOR....1651
OVERHAUL....1653
ASSISTANT'S SEAT....1665
COMPONENT LOCATOR....1665
OVERHAUL (THREE-SEATER)....1668
OVERHAUL (CREW CAB)....1676
REAR SEAT....1682
COMPONENT LOCATOR....1682
OVERHAUL....1684
BODY OUTSIDE ACCESSORY....1694
STANDARD VALUE....1695
DOOR....1695
DOOR HINGE....1695
DOOR ACCESSORIES....1695
REQUIRED ITEMS....1696
DOOR....1696
DOOR ACCESSORIES....1696
POWER WINDOW....1696
AUTO DOOR LOCK SYSTEM....1696
WINDOW GLASS....1697
GLASS....1697
MIRROR....1698
POWER MIRROR....1698
DOOR....1699
DOOR HINGE....1699
INSPECTION AND ADJUSTMENT....1699
DOOR ACCESSORY....1703
COMPONENT LOCATOR....1703
OVERHAUL....1709
POWER WINDOW....1731
SINGLE UNIT INSPECTION....1731
AUTO DOOR LOCK SYSTEM....1734
PERFORMANCE INSPECTION....1734
SINGLE UNIT INSPECTION....1734
KEYLESS ENTRY....1736
PERFORMANCE INSPECTION....1736
WINDOW GLASS....1737
GLASS....1737
COMPONENT LOCATOR....1737
REPLACEMENT....1739
MIRROR....1750
REAR VIEW MIRROR....1750
COMPONENT LOCATOR....1750
REPLACEMENT....1751
POWER MIRROR....1752
SINGLE UNIT INSPECTION....1752
ACCESSORY....1753
OUTSIDE ACCESSORY....1753
COMPONENT LOCATOR....1753
REPLACEMENT....1754
AIR BAG AND SEAT BELT....1759
STANDARD VALUE....1760
SEAT BELT....1760
SEAT BELT....1760
CENTER SEAT BELT....1760
REAR SEAT BELT....1761
SEAT BELT....1762
SEAT BELT....1762
COMPONENT LOCATOR....1762
REPLACEMENT....1763
CENTER SEAT BELT....1765
COMPONENT LOCATOR....1765
REPLACEMENT....1766
REAR SEAT BELT....1767
COMPONENT LOCATOR....1767
REPLACEMENT....1768
HEATER AND AIR CONDITIONER....1771
STANDARD VALUE....1772
AIR CONDITIONER....1772
AIR CONDITIONER....1772
V-BELT....1773
COOLER COMPRESSOR....1773
CONDENSER....1773
HVAC (HEATING, VENTILATING AND AIR CONDITIONING UNIT)....1774
HEATER CONTROL....1774
REAR HEATER (CREW CAB)....1774
REAR COOLER (CREW CAB)....1775
REQUIRED ITEMS....1776
AIR CONDITIONER....1776
AIR CONDITIONER....1776
V-BELT....1776
COOLER COMPRESSOR....1777
CONDENSER....1777
AIR CONDITIONER....1778
AIR CONDITIONER....1778
SAFETY INSTRUCTIONS FOR WORK....1778
COLLECTION/FILLING OF REFRIGERANT....1782
MAINTENANCE....1790
V-BELT....1793
COMPONENT LOCATOR....1793
REPLACEMENT....1794
COOLER COMPRESSOR....1799
COMPONENT LOCATOR....1799
REPLACEMENT....1800
CONDENSER....1804
COMPONENT LOCATOR....1804
REPLACEMENT....1805
HVAC (HEATING, VENTILATING AND AIR CONDITIONING UNIT)....1809
COMPONENT LOCATOR....1809
REPLACEMENT....1811
HEATER CONTROL....1818
COMPONENT LOCATOR....1818
REPLACEMENT....1819
REAR HEATER (CREW CAB)....1822
COMPONENT LOCATOR....1822
REPLACEMENT....1823
REAR HEATER BLOWER SWITCH (CREW CAB)....1829
COMPONENT LOCATOR....1829
REPLACEMENT....1830
REAR COOLER (CREW CAB)....1832
COMPONENT LOCATOR....1832
REPLACEMENT....1833
COOLER CONTROL SWITCH (CREW CAB)....1840
COMPONENT LOCATOR....1840
REPLACEMENT....1841
ELECTRICAL....1845
STANDARD VALUE....1846
LIGHTING....1846
HEADLIGHT....1846
WIPER AND WASHER....1846
WIPER....1846
WASHER....1846
REQUIRED ITEMS....1847
LIGHTING....1847
COMBINATION SWITCH....1847
LIGHTING....1848
HEADLIGHT....1848
COMPONENT LOCATOR....1848
OPTICAL AXIS ADJUSTMENT....1849
REPLACEMENT....1850
FOG LIGHT....1851
REPLACEMENT....1851
ID LIGHT....1852
COMPONENT LOCATOR....1852
REPLACEMENT....1853
ROOM LIGHT....1854
COMPONENT LOCATOR....1854
REPLACEMENT....1855
COMBINATION SWITCH....1856
COMPONENT LOCATOR....1856
REPLACEMENT....1857
INSPECTION....1857
WIPER AND WASHER....1860
WIPER....1860
COMPONENT LOCATOR....1860
REPLACEMENT....1861
WASHER....1864
COMPONENT LOCATOR....1864
REPLACEMENT ....1865
COMPUTER....1867
COMPUTER....1867
MOUNTING POSITION....1867
SWITCH....1869
SWITCH....1869
MOUNTING POSITION....1869
FUSE AND RELAY....1870
FUSE BLOCK....1870
MOUNTING POSITION....1870
RELAY....1872
MOUNTING POSITION....1872
CONTROL SYSTEM....1873
REQUIRED ITEMS....1874
HINO STOP&START SYSTEM....1874
SLOPE LEARNING....1874
HINO STOP&START SYSTEM....1875
HINO STOP&START SYSTEM....1875
SLOPE LEARNING....1875
CRUISE CONTROL....1877
CRUISE MAIN SWITCH....1877
COMPONENT LOCATOR....1877
REPLACEMENT....1878
SINGLE UNIT INSPECTION....1879
S1-LXJE12A_EWD....1881
FOREWORD....1881
CHAPTER REFERENCES....1882
INDEX....1883
GENERAL INTRODUCTION....1884
HOW TO USE THIS MANUAL....1885
GRAPHICAL SYMBOLS FOR WIRING DIAGRAMS, ABBREVIATIONS AND TERMS....1885
WIRING DIAGRAM....1890
WIRE TO WIRE CONNECTOR....1891
JUNCTION CONNECTOR....1892
LOCATION....1893
RELAY LOCATION / FUSE AND RELAY BLOCK....1894
ABOUT CONNECTOR....1898
WIRING DIAGRAM ACCORDING TO SYSTEM....1900
WIRING DIAGRAM....1901
WIRING HARNESS CODE....1901
AC. POWER SUPPLY CIRCUIT....1903
AF. GROUND CIRCUIT....1907
AH. CHARGING CIRCUIT....1909
AK. ENGINE STARTING CIRCUIT....1911
AN. CAN COMMUNICATION CIRCUIT....1913
AO. CAN COMMUNICATION CIRCUIT [HV]....1915
BG. ENGINE ECU CIRCUIT [J05] 1/2....1919
BH. ENGINE ECU CIRCUIT [J05] 2/2....1923
BI. DEF SCR CIRCUIT....1931
BJ. HYDRO BOOST SYSTEM CIRCUIT....1933
BN. GLOW PLUG CIRCUIT....1935
BP. FUEL HEATER CIRCUIT....1937
CC. AT CIRCUIT [A465]....1939
CE. CLUTCH ECU CIRCUIT....1945
CF. HV PCU CIRCUIT....1949
DA. ABS/PAB+VSC CIRCUIT....1951
DD. VEHICLE CONTROL ECU CIRCUIT....1953
EC. POWER DOOR LOCK CIRCUIT....1955
ED. KEYLESS ENTRY CIRCUIT....1957
EG. POWER WINDOW CIRCUIT [FRONT]....1959
EH. POWER WINDOW CIRCUIT [REAR]....1961
FA. COMBINATION METER CIRCUIT....1963
FB. PARKING BRAKE WARNING CIRCUIT....1967
FC. WEAR INDICATOR CIRCUIT....1969
FD. HORN RELAY CIRCUIT....1971
FE. COOLANT LEVEL WARNING CIRCUIT....1973
FF. DIAGNOSIS MONITOR CIRCUIT....1975
FJ. RHEOSTAT CIRCUIT....1977
FK. TELEMATICS CIRCUIT....1979
GA. HEADLIGHT CIRCUIT....1981
GD. HEADLIGHT SUB CIRCUIT ....1983
GG. TAIL LIGHT CIRCUIT....1985
GH. STOP LIGHT CIRCUIT....1987
GJ. TURN / HAZARD CIRCUIT....1989
GL. COMBINATION LIGHT CIRCUIT....1991
GM. FOG LIGHT CIRCUIT [FRONT]....1993
HA. ROOM LIGHT CIRCUIT....1995
JA. WIPER AND WASHER CIRCUIT....1997
JD. MIRROR HEATER CIRCUIT....1999
JE. REMOTE CONTROL MIRROR CIRCUIT....2001
KA. RADIO CIRCUIT....2003
KB. CIGAR LIGHTER CIRCUIT....2005
LB. HEATER AND AIR CONDITIONER CIRCUIT....2007
LF. REAR HEATER AND AIR CONDITIONER CIRCUIT....2011
MA. OUTLET POWER SUPPLY CIRCUIT....2013
WIRE TO WIRE CONNECTOR....2015
WIRE TO WIRE CONNECTOR....2016
WIRE TO WIRE CONNECTOR LIST....2016
JUNCTION CONNECTOR....2033
JUNCTION CONNECTOR....2034
JUNCTION CONNECTOR LIST....2034
LOCATION....2051
CONNECTOR LOCATION....2052
CONTENTS....2052
QUICK REFERENCE....2053
IP-1 [INSTRUMENT PANEL (1 of 6)]....2054
IP-2 [INSTRUMENT PANEL (2 of 6)]....2056
IP-3 [INSTRUMENT PANEL (3 of 6)]....2058
IP-4 [INSTRUMENT PANEL (4 of 6)]....2060
IP-5 [INSTRUMENT PANEL (5 of 6)]....2064
IP-6 [INSTRUMENT PANEL (6 of 6)]....2066
CA-1 [CAB (1 of 2)] (Models: Single cab (Floor / Cowl))....2068
CA-2 [CAB (2 of 2)] (Models: Single cab (Roof / Door))....2070
CA-3 [CAB (1 of 2)] (Models: Crew cab (Floor))....2072
CA-4 [CAB (2 of 2)] (Models: Crew cab (Roof / Door))....2074
EG-1 [ENGINE (1 of 4)] (Models: J05E Engine)....2076
EG-2 [ENGINE (2 of 4)] (Models: J05E Engine)....2078
EG-3 [ENGINE (3 of 4)] (Models: J05E Engine)....2080
EG-4 [ENGINE (4 of 4)] (Models: J05E Engine)....2082
EG-5 [ENGINE] (Models: J05E Engine (Right rear))....2084
EG-6 [ENGINE (1 of 4)] (Models: J05E Engine HV)....2086
EG-7 [ENGINE (2 of 4)] (Models: J05E Engine HV)....2088
EG-8 [ENGINE (3 of 4)] (Models: J05E Engine HV)....2090
EG-9 [ENGINE (4 of 4)] (Models: J05E Engine HV)....2092
EG-10 [ENGINE] (Models: J05E Engine HV (Right rear))....2094
RR-1 [REAR] (Models: Except HV)....2096
RR-2 [REAR] (Models: HV)....2098
RELAY LOCATION/FUSE AND RELAY BLOCK....2100
RELAY LOCATION....2101
INSTRUMENT PANEL....2101
CHASSIS....2102
FUSE AND RELAY BLOCK....2103
CHASSIS RELAY BLOCK....2103
CAB RELAY....2106
RELAY BLOCK No.2....2107
JUNCTION BLOCK....2108
JUNCTION BLOCK....2108
WIRE TO WIRE BOX....2110
WIRE TO WIRE ALIGNMENT....2110
INDEX....2111
CONNECTOR INDEX....2112
ELECTRICAL EQUIPMENT CONNECTOR....2112
WIRE TO WIRE CONNECTOR....2128
JUNCTION CONNECTOR....2131
S1-UNAE12A-1....2135
FOREWORD....2135
CHAPTER REFERENCES....2136
INDEX....2137
GENERAL INTRODUCTION (CHASSIS)....2141
GENERAL INTRODUCTION....2142
GENERAL PRECAUTIONS....2142
IDENTIFICATION INFORMATION....2145
HOW TO USETHIS WORKSHOP MANUAL....2152
PRECAUTIONS....2155
SEALANT ON THE TAPERED SCREWFOR PIPING....2158
NYLON TUBE REPLACEMENT METHOD....2159
METRIC INFORMATION....2161
SPECIFIED TORQUE....2163
SPECIFIED TORQUE....2163
RECOMMENDED LUBRICANTS....2165
VEHICLE LIFTAND SUPPORT LOCATIONS....2167
INFORMATION DISPLAY....2169
SYMPTOM SIMULATION....2174
GLOSSARY....2176
GLOSSARY OF SAE AND HINO TERMS....2179
CLUTCH MAIN UNIT (EATON 1401)....2182
CLUTCH ASSEMBLY....2183
DATA AND SPECIFICATIONS....2183
DESCRIPTION....2183
TROUBLESHOOTING....2184
SPECIAL TOOL....2186
COMPONENT LOCATOR....2187
OVERHAUL....2188
CLUTCH ASSEMBLY....2195
DATA AND SPECIFICATIONS....2195
COMPONENT LOCATOR....2195
OVERHAUL....2196
INSPECTION AND REPAIR....2203
CLUTCH MAIN UNIT (EATON 1402)....2206
CLUTCH ASSEMBLY....2207
DATA AND SPECIFICATIONS....2207
DESCRIPTION....2207
TROUBLESHOOTING....2208
SPECIAL TOOL....2210
COMPONENT LOCATOR....2211
OVERHAUL....2212
CLUTCH ASSEMBLY ....2221
DATA AND SPECIFICATIONS....2221
COMPONENT LOCATOR....2221
OVERHAUL....2222
INSPECTION AND REPAIR....2232
CLUTCH CONTROL....2235
CLUTCH CONTROL UNIT....2236
DESCRIPTION....2236
INSPECTION AND ADJUSTMENT....2237
CLUTCH PEDAL AND RELEASE UNIT....2240
COMPONENT LOCATOR....2240
OVERHAUL....2241
INSPECTION AND REPAIR....2243
CLUTCH MASTER CYLINDER....2244
COMPONENT LOCATOR....2244
OVERHAUL....2245
INSPECTION AND REPAIR....2245
TRANSMISSION MAIN UNIT....2246
TRANSMISSION ASSEMBLY....2247
DATA AND SPECIFICATION....2247
DISMOUNTING AND MOUNTING....2248
AUTOMATIC TRANSMISSION(ALLISON 2200RDS, 2500RDS, 2200HS)....2250
AUTOMATIC TRANSMISSION ASSEMBLY....2251
TROUBLESHOOTING....2251
SPECIAL TOOL....2251
DISMOUNTING AND MOUNTING....2251
AUTOMATIC TRANSMISSION....2259
AUTOMATIC TRANSMISSION ASSEMBLY....2260
TROUBLESHOOTING....2260
SPECIAL TOOL....2260
DISMOUNTING AND MOUNTING....2260
TRANSMISSION/TRANSFER CONTROL....2267
TRANSMISSION CONTROL UNIT....2268
TROUBLESHOOTING....2268
COMPONENT LOCATOR....2269
OVERHAUL....2270
TRANSMISSION/TRANSFER CONTROL....2271
TRANSMISSION CONTROL UNIT....2272
TROUBLESHOOTING....2272
COMPONENT LOCATOR....2272
OVERHAUL....2274
PROPELLER SHAFT (SPL 100, 140)....2275
PROPELLER SHAFT ASSEMBLY....2276
DATA AND SPECIFICATIONS....2276
DESCRIPTION....2276
TROUBLESHOOTING....2277
COMPONENT LOCATOR....2277
OVERHAUL....2279
DIFFERENTIAL CARRIER(MERITOR RS17.19.21&23)....2295
DIFFERENTIAL CARRIER ASSEMBLY....2296
DATA AND SPECIFICATIONS....2296
DESCRIPTION....2298
TROUBLESHOOTING....2301
SPECIAL TOOL....2302
COMPONENT LOCATOR....2304
OVERHAUL....2308
INSPECTION AND REPAIR....2348
DRIVER-CONTROLLEDMAIN DIFFERENTIAL LOCK....2357
OVERHAUL....2357
INSPECTION AND REPAIR....2360
BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE)....2361
SERVICE BRAKE ASSEMBLY....2362
DESCRIPTION....2362
DIAGRAM....2363
TROUBLESHOOTING....2365
BRAKE SYSTEM AIR BLEEDING....2369
POWER STEERINGSYSTEM AIR BLEEDING....2371
BRAKE TEST....2372
BRAKE EQUIPMENT....2373
SERVICE BRAKE ASSEMBLY....2374
DESCRIPTION....2374
DATA AND SPECIFICATIONS....2375
DIAGRAM....2376
TROUBLESHOOTING....2377
SERVICE BRAKE (HYDRAULIC BRAKE)....2379
HYDRAULIC BRAKE....2380
INSPECTION AND ADJUSTMENT....2380
HYDRO-MAX HYDRAULIC BRAKE BOOSTERAND MASTER CYLINDER....2383
DATA AND SPECIFICATIONS....2383
DESCRIPTION....2383
PRINCIPLE OF OPERATION....2385
COMPONENT LOCATOR....2387
HYDRO-MAX BOOSTER....2388
OVERHAUL....2388
MASTER CYLINDER....2394
OVERHAUL....2394
PRESSURE TESTS....2396
ABS MODULATOR....2397
DATA AND SPECIFICATIONS....2397
DESCRIPTION....2397
WHEEL BRAKE (TYPE: 4 PISTON)....2398
DATA AND SPECIFICATIONS....2398
DESCRIPTION....2399
TROUBLESHOOTING....2400
SERVICE BRAKE (FULL AIR BRAKE)....2413
AIR DRYER AND RESERVOIR SYSTEM(MODEL: BENDIX AD-IS)....2414
DESCRIPTION....2414
AD-IS AIR DRYER RESERVOIR SYSTEMTROUBLESHOOTING CHART....2425
CHECK VALVE....2429
DATA AND SPECIFICATIONS....2429
DESCRIPTION....2429
INSPECTION AND REPAIR....2430
BRAKE PEDAL....2432
OVERHAUL....2432
BRAKE VALVE....2435
DATA AND SPECIFICATIONS....2435
DESCRIPTION....2435
COMPONENT LOCATOR....2436
INSPECTION AND REPAIR....2437
RELAY VALVE....2441
DATA AND SPECIFICATIONS....2441
DESCRIPTION....2441
INSPECTION AND REPAIR....2441
SPRING BRAKE MODULATING VALVE....2445
DESCRIPTION....2445
COMPONENT LOCATOR....2446
INSPECTION AND REPAIR....2447
SPRING BRAKE CONTROL VALVE....2449
DESCRIPTION....2449
COMPONENT LOCATOR....2450
INSPECTION AND REPAIR....2451
BRAKE CHAMBER (FRONT)....2454
DATA AND SPECIFICATIONS....2454
DESCRIPTION....2454
COMPONENT LOCATOR....2455
OVERHAUL....2455
BRAKE CHAMBER (REAR)....2457
DATA AND SPECIFICATIONS....2457
DESCRIPTION....2458
COMPONENT LOCATOR....2459
INSPECTION AND REPAIR....2460
PROTECTION VALVE....2471
DATA AND SPECIFICATIONS....2471
DESCRIPTION....2471
INSPECTION....2472
WHEEL BRAKE....2474
DATA AND SPECIFICATIONS....2474
DESCRIPTION....2475
COMPONENT LOCATOR....2476
OVERHAUL....2478
INSPECTION AND REPAIR....2495
AUTOMATIC SLACK ADJUSTER....2497
DESCRIPTION....2497
DIAGNOSTICS....2498
COMPONENT LOCATOR....2499
OVERHAUL....2501
INSTALLING THE SLACK ADJUSTERONTO THE CAMSHAFT....2509
CHECK & ADJUSTMENT....2511
ABS (ABS : HYDRAULIC (E VERSION))....2518
ABS....2519
OVERVIEW....2519
COMPOSITION AND OPERATION....2520
FUNCTION....2523
PRECAUTIONS WHEN DRIVING VEHICLESEQUIPPED WITH ABS....2524
OVERVIEW AND FUNCTION....2525
ABS (ABS : FULL AIR)....2537
ABS....2538
OVERVIEW....2538
COMPOSITION AND OPERATION....2539
FUNCTION....2542
PRECAUTIONS WHEN DRIVING VEHICLESEQUIPPED WITH ABS....2543
OVERVIEW AND FUNCTION....2544
INSPECTION (FRONT WHEEL BRAKE)....2549
INSPECTION (REAR WHEEL BRAKE)....2551
EXHAUST BRAKE....2557
EXHAUST BRAKE SYSTEM....2558
SYSTEM DIAGRAM....2558
TROUBLESHOOTING....2559
ADJUSTMENT....2559
BRAKE CYLINDER....2561
DATA AND SPECIFICATIONS....2561
DESCRIPTION....2561
PARKING BRAKE (BOSCH 12")....2562
PARKING BRAKE ASSEMBLY....2563
DATA AND SPECIFICATIONS....2563
DESCRIPTION....2563
TROUBLESHOOTING....2564
COMPONENT LOCATOR....2565
OVERHAUL....2567
INSPECTION AND REPAIR....2581
ADJUSTMENT....2582
S1-UNAE12A-2....2585
FOREWORD....2585
CHAPTER....2586
INDEX....2587
STEERING EQUIPMENT....2591
STEERING SYSTEM....2592
TROUBLESHOOTING....2592
STEERING UNIT....2597
STEERING LINKAGE....2598
DESCRIPTION....2598
COMPONENT LOCATOR....2599
SPECIAL TOOL....2600
OVERHAUL....2601
INSPECTION AND REPAIR....2606
POWER STEERING....2608
POWER STEERING GEAR UNIT....2609
DATA AND SPECIFICATIONS....2609
DESCRIPTION....2610
OPERATION....2611
COMPONENT LOCATOR....2613
TORQUE CHART....2615
HAZARD WARNING DEFINITIONS....2615
DISCLAIMER....2616
PATENTS....2616
MAINTENANCE TIPS....2616
ON-VEHICLE SERVICE....2618
RESEAL & REPAIR....2628
POWER STEERING PUMP....2662
DATA AND SPECIFICATIONS....2662
DESCRIPTION....2662
OPERATION....2663
COMPONENT LOCATOR....2664
OVERHAUL....2666
INSPECTION AND REPAIR....2672
FRONT AXLE (MFS)....2674
FRONT AXLE (MFS)....2675
DATA AND SPECIFICATIONS....2675
TROUBLESHOOTING....2677
COMPONENT LOCATOR....2679
SERVICE NOTES....2683
SPECIAL TOOLS....2684
INTRODUCTION....2689
INSPECTION....2690
DISASSEMBLY....2696
PREPARE PARTS FOR ASSEMBLY....2703
ASSEMBLY....2711
ADJUSTMENT....2723
LUBRICATION AND MAINTENANCE....2732
MAINTENANCE....2736
REAR AXLE....2737
REAR AXLE....2738
DATA AND SPECIFICATIONS....2738
COMPONENT LOCATOR....2745
SPECIAL TOOL....2748
DISASSEMBLY....2750
PREPARE PARTS FOR ASSEMBLY....2752
ASSEMBLY....2756
ADJUSTMENT....2766
LUBRICATION AND MAINTENANCE....2768
WHEEL & TIRE....2770
WHEEL AND TIRE....2771
DATA AND SPECIFICATIONS....2771
DESCRIPTION....2775
SPECIAL TOOL....2776
PRECAUTIONS....2777
INSPECTION....2778
INSPECTION AND REPAIR....2779
WHEEL....2780
OVERHAUL....2780
SUSPENSION....2785
LEAF SUSPENSION ASSEMBLY....2786
DATA AND SPECIFICATIONS....2786
DESCRIPTION....2788
TROUBLESHOOTING....2790
COMPONENT LOCATOR....2791
OVERHAUL....2795
INSPECTION AND REPAIR....2800
AIR SUSPENSION ASSEMBLY....2803
DATA AND SPECIFICATIONS....2803
SYSTEM DIAGRAM FOR HEIGHT CONTROL....2803
DESCRIPTION....2804
TROUBLESHOOTING....2805
COMPONENT LOCATOR....2806
OVERHAUL....2807
INSPECTION AND REPAIR....2811
CHASSIS FRAME....2813
CHASSIS FRAME....2814
TROUBLESHOOTING....2814
INSPECTION....2814
REPAIRS....2815
CAB....2820
CAB ASSEMBLY....2821
DATA AND SPECIFICATIONS....2821
TROUBLESHOOTING....2822
DISMOUNTING AND MOUNTING....2823
INSPECTION AND REPAIR....2826
HOOD....2827
COMPONENT LOCATOR....2827
OVERHAUL....2828
FRP REPAIR PROCEDURE....2831
RADIATOR GRILLE....2836
COMPONENT LOCATOR....2836
OVERHAUL....2837
DOOR....2838
COMPONENT LOCATOR....2838
OVERHAUL....2839
SEAT....2842
COMPONENT LOCATOR....2842
INSTRUMENT PANEL....2845
COMPONENT LOCATOR....2845
DISMOUNTING AND MOUNTING....2846
HEATER AND AIR CONDITIONER....2847
COMPONENT LOCATOR....2847
SPECIAL TOOL....2847
AIR CONDITIONING SYSTEM....2848
SPECIFICATION DATA....2848
PRECAUTIONS REGARDINGREFRIGERANT (HFC134a)....2848
PRECAUTIONS FOR REPLENISHING THE REFRIGERANT GAS....2849
TROUBLESHOOTING(FAULT DIAGNOSIS BY SYMPTOMS)....2850
GAS LEAKAGE INSPECTION....2859
PRECAUTIONS FOR REMOVING/INSTALLINGTHE AIR CONDITIONER....2862
RECOVERY AND REPLENISHMENT OFREFRIGERANT....2864
MAINTENANCE....2868
REPLACEMENT....2870
DISMOUNTING AND MOUNTING....2872
WINDSHIELD....2873
COMPONENT LOCATOR....2873
REPLACEMENT....2874
AFFIXING WEATHERSTRIPPROCEDURE....2875
FRONT BUMPER....2879
COMPONENT LOCATOR....2879
ELECTRICAL....2881
ELECTRICAL PARTS....2882
DATA AND SPECIFICATIONS....2882
COMPONENT LOCATOR....2883
TROUBLESHOOTING....2892
GENERAL INSTRUCTION....2893
HANDLING PRECAUTION....2898
INSPECTION....2900
INSPECTION AND ADJUSTMENT....2921
SPEEDOMETERCONVERSION RATE LIST....2922
ELECTRIC WIRE....2923
DIAGRAM....2924
HOW TO USE THIS CHAPTER....2924
SPECIFICATION SYMBOL LIST....2930
TERMS CONTRADISTINCTION LIST....2938
DIAGRAM....2940
POSITION OF CONNECTOR....3078
CONNECTOR....3103
PIN LIST OF WIRE TO WIRE CONNECTOR (IN THE BULK HEADCONNECTOR BOX)....3128
PIN LIST OF WIRE TO WIRE CONNECTOR (OUT OF THE BULK HEADCONNECTOR BOX)....3131
PIN LIST OF SIGNAL CHECK ....3134
CONNECTOR LIST....3135
S7-LXJE12A_1....3147
FOREWORD....3147
CHAPTER REFERENCES....3148
INDEX....3149
GENERAL INTRODUCTION....3151
HOW TO IDENTIFY VEHICLE TYPE....3152
HOW TO IDENTIFY VEHICLE TYPE....3152
VEHICLE TYPE ....3152
VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE....3153
APPEARANCE OF VEHICLE....3154
APPEARANCE....3154
APPEARANCE OF VEHICLE....3154
SAFETY INSTRUCTIONS AND READINESS TO WORK....3155
WARNING....3155
GENERAL PRECAUTIONS....3155
IDENTIFICATION INFORMATION....3160
SAFETY INSTRUCTIONS FOR WORK....3163
PRECAUTIONS....3163
INTRODUCTION TO WORKSHOP MANUAL....3167
GENERAL....3167
INTRODUCTION TO DESCRIPTIONS....3168
DEFINITION OF TERM....3171
TROUBLE SHOOTING....3172
TROUBLESHOOTING WITH DIAGNOSIS MONITOR....3172
TROUBLESHOOTING PROCEDURE....3172
APPARATUS FOR TROUBLE SHOOTING....3174
TROUBLE DIAGNOSIS USING THE COMPUTER (HINO DXII)....3175
STEP OF TROUBLE DIAGNOSIS....3175
APPARATUS FOR TROUBLE DIAGNOSIS....3176
GLOSSARY....3177
DEFINITION OF ABBREVIATION....3177
LIST OF ABBREVIATION....3177
GLOSSARY OF SAE AND HINO TERMS....3180
ENGINE (J05E)....3183
TROUBLESHOOTING....3186
ENGINE ECU (J05E)....3186
PRECAUTIONS FOR DIAGNOSIS....3186
ELECTRICAL....3188
PRECAUTIONS....3189
COMPUTER (ECU) PIN ASSIGNMENT....3193
ENGINE ECU CONNECTOR....3199
INSPECTION....3203
TROUBLE DIAGNOSIS USING THE COMPUTER (HINO DX?)....3204
DIAGNOSTIC TROUBLE CODE (DTC) TABLE....3205
GROUP SHARING THE SENSOR SUPPLY TERMINAL....3232
GROUP SHARING THE SENSOR GND TERMINAL....3233
MALFUNCTION CODES IN CASE OF DISRUPTION OF CAN COMMUNICATION....3234
PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (250 k)....3237
DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (250 k) [DIESEL]....3242
DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (250 k) [HYBRID]....3252
PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (500 k) [DIESEL]....3263
PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (500 k) [HYBRID]....3268
DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (500 k) [DIESEL]....3274
DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (500 k) [HYBRID]....3279
MALFUNCTION CODES FOR FAULTY ACTUATOR POWER RELAY....3284
ENG BASIC INSPECTION SHEET (ENGINE INSPECTION CHECK SHEET)....3285
NO DTC....3289
DTC: P0005....3293
DTC: P0006 and P0007....3297
DTC: P0016....3302
DTC: P0027....3305
DTC: P003A....3310
DTC: P0045....3315
DTC: P0047....3319
DTC: P0048....3323
DTC: P006E....3327
DTC: P006F....3331
DTC: P007B....3335
DTC: P007C and P007D....3349
DTC: P0088....3357
DTC: P0096....3365
DTC: P0097 and P0098 ....3376
DTC: P00AF....3385
DTC: P0101....3389
DTC: P0104....3398
DTC: P0106....3405
DTC: P0107....3411
DTC: P0108....3417
DTC: P0111....3423
DTC: P0112 and P0113....3429
DTC: P0115....3437
DTC: P0117 and P0118....3446
DTC: P011A....3454
DTC: P0122 and P0123....3463
DTC: P0126....3473
DTC: P0128....3477
DTC: P0148 ....3483
DTC: P016E and P016F ....3495
DTC: P0182 and P0183 ....3505
DTC: P0191....3513
DTC: P0192 and P0193 ....3522
DTC: P01A5....3532
DTC: P01A6....3539
DTC: P0200....3546
DTC: P0201, P0202, P0203 and P0204....3549
DTC: P0217....3554
DTC: P0219....3559
DTC: P0222 and P0223....3567
DTC: P0234....3577
DTC: P0263, P0266, P0269 and P0272....3583
DTC: P026C and P026D....3594
DTC: P0299....3607
DTC: P0300....3613
DTC: P0301, P0302, P0303 and P0304....3621
DTC: P0335....3630
DTC: P0336....3637
DTC: P0340....3644
DTC: P0341....3648
DTC: P0381....3656
DTC: P0401....3662
DTC: P0402....3678
DTC: P0404....3689
DTC: P0405 and P0406....3694
DTC: P041B....3700
DTC: P041C and P041D....3713
DTC: P0420....3721
DTC: P0421....3723
DTC: P0422....3736
DTC: P0489 and P0490....3739
DTC: P049D....3745
DTC: P04D5 and P04D6....3750
DTC: P04DA....3758
DTC: P04DB....3768
DTC: P0500 and P0501....3776
DTC: P0504....3783
DTC: P0506....3788
DTC: P0507....3792
DTC: P0521....3796
DTC: P0524....3800
DTC: P0545 and P0546....3805
DTC: P054E....3813
DTC: P054F....3817
DTC: P0562 and P0563....3821
DTC: P0603....3826
DTC: P0605....3830
DTC: P0606....3832
DTC: P0607....3834
DTC: P0610....3836
DTC: P0611....3839
DTC: P0617....3841
DTC: P0628 and P0629....3845
DTC: P062F....3853
DTC: P0630....3857
DTC: P0642....3861
DTC: P0643....3866
DTC: P064C....3872
DTC: P0652....3877
DTC: P0653....3883
DTC: P0671 and P0672 ....3890
DTC: P0673 and P0674....3896
DTC: P0683....3902
DTC: P0686....3908
DTC: P0698....3913
DTC: P0699....3916
DTC: P06A4....3919
DTC: P06A5....3922
DTC: P06D3 and P06D4....3925
DTC: P0700....3934
DTC: P073D....3936
DTC: P081A....3940
DTC: P081B....3946
DTC: P0A7B....3950
DTC: P0AC4....3952
DTC: P0CA1....3954
DTC: P1133....3956
DTC: P119F....3963
DTC: P1426....3969
DTC: P1427....3976
DTC: P1428....3983
DTC: P1458....3991
DTC: P1459....3996
DTC: P14B0....4001
DTC: P14B2....4005
DTC: P14B3 and P14B4....4009
DTC: P14B7 and P14B8....4015
DTC: P14BC and P14BD....4021
DTC: P14BF....4027
S7-LXJE12A_2....4033
FOREWORD....4033
CHAPTER REFERENCES....4034
INDEX....4035
ENGINE (J05E)....4037
TROUBLESHOOTING....4040
ENGINE ECU (J05E)....4040
DTC: P1515....4040
DTC: P1530....4045
DTC: P2002....4049
DTC: P200C....4070
DTC: P2032 and P2033....4079
DTC: P203F....4087
DTC: P204F....4091
DTC: P206B....4094
DTC: P207F....4119
DTC: P2080....4127
DTC: P2084....4135
DTC: P20CD....4143
DTC: P20CE....4147
DTC: P20CF....4150
DTC: P20D8....4156
DTC: P20DE....4162
DTC: P20DF....4166
DTC: P20E0....4172
DTC: P20EE....4178
DTC: P20EF....4186
DTC: P2100....4188
DTC: P2101....4194
DTC: P2103....4201
DTC: P2120....4206
DTC: P2122 and P2123....4210
DTC: P2127 and P2128....4220
DTC: P2135....4229
DTC: P2138....4234
DTC: P2146....4239
DTC: P2147 and P2148....4246
DTC: P2149....4254
DTC: P2150 and P2151....4261
DTC: P2184 and P2185....4269
DTC: P2201....4277
DTC: P2227....4323
DTC: P2228 and P2229....4327
DTC: P2269....4332
DTC: P226C....4336
DTC: P229F....4342
DTC: P22D3....4389
DTC: P240F....4393
DTC: P2428....4403
DTC: P242B....4407
DTC: P242C and P242D....4415
DTC: P244A....4423
DTC: P244B....4443
DTC: P2457....4460
DTC: P2458....4475
DTC: P2459....4486
DTC: P2463....4489
DTC: P246F....4497
DTC: P2470 and P2471....4505
DTC: P2481 and P2482....4513
DTC: P2483....4521
DTC: P24A0....4529
DTC: P24A1....4532
DTC: P24A2....4534
DTC: P24A3 (2 digit diagnosis code: 01)....4544
DTC: P24AE (2 digit diagnosis code: 04, 05, 06, 14, 25, 26, 27, 28)....4548
DTC: P24AF (2 digit diagnosis code: 23)....4550
DTC: P24B0 (2 digit diagnosis code: 19, 20, 21)....4553
DTC: P24B1 (2 digit diagnosis code: 18)....4555
DTC: P24B4 (2 digit diagnosis code: 10, 11, 15, 17)....4557
DTC: P24B7 (2 digit diagnosis code: 08)....4559
DTC: P24C7 (2 digit diagnosis code: 09)....4562
DTC: P24D0 (2 digit diagnosis code: 02)....4566
DTC: P24D1 (2 digit diagnosis code: 12)....4570
DTC: P24DA (2 digit diagnosis code: 07)....4572
DTC: P2562....4576
DTC: P259E....4580
DTC: P259F....4586
DTC: P2635....4591
DTC: P268A and P2696....4600
DTC: P26C8....4606
DTC: P2A00....4608
DTC: P2A01....4612
DTC: P2BA9....4616
DTC: U0073....4621
DTC: U010A....4624
DTC: U010C....4630
DTC: U010E....4636
DTC: U0293....4642
DTC: U029D (DIESEL)....4647
DTC: U029D (HYBRID)....4653
DTC: U029E (DIESEL)....4659
DTC: U029E (HYBRID)....4665
DTC: U02A2....4671
DTC: U02A3....4677
DTC: U0301....4680
DTC: U1001....4683
DTC: U110A....4690
ENGINE (COMMON ITEMS)....4697
TROUBLESHOOTING....4699
DCU....4699
PRECAUTIONS FOR DIAGNOSIS....4699
DIAGRAM....4701
SIGNAL CHECK HARNESS....4702
INSPECTION....4702
TROUBLE DIAGNOSIS USING THE COMPUTER (HINO DX?)....4704
DTC: P0071....4711
DTC: P0072....4721
DTC: P0073....4727
DTC: P0562....4733
DTC: P0563....4737
DTC: P060B....4741
DTC: P060C....4744
DTC: P062F....4746
DTC: P0667....4748
DTC: P068A....4750
DTC: P06AD....4755
DTC: P06AE....4757
DTC: P142A....4759
DTC: P142B....4770
DTC: P14C1....4781
DTC: P14C2....4794
DTC: P14C3....4799
DTC: P202E....4804
DTC: P203C....4808
DTC: P203D....4811
DTC: P2044....4814
DTC: P2045....4817
DTC: P2047....4820
DTC: P2048....4823
DTC: P2049....4828
DTC: P204B....4833
DTC: P204C....4836
DTC: P204D....4841
DTC: P205B....4846
DTC: P205C....4855
DTC: P205D....4858
DTC: P206A....4861
DTC: P206C....4864
DTC: P206D....4867
DTC: P208A....4870
DTC: P208B....4876
DTC: P208C....4879
DTC: P208D....4884
DTC: P20A0....4889
DTC: P20A1....4894
DTC: P20A2....4898
S7-LXJE12A_3....4904
FOREWORD....4904
CHAPTER REFERENCES....4905
INDEX....4906
ENGINE (COMMON ITEMS)....4908
TROUBLESHOOTING....4910
DCU....4910
DTC: P20A3....4910
DTC: P20B1....4915
DTC: P20B2....4920
DTC: P20B3....4930
DTC: P20B4....4935
DTC: P20BD, P20B9 and P20C1....4940
DTC: P20C0, P20BC and P20C4....4948
DTC: P20E8....4954
DTC: P20E9....4965
DTC: P20F4....4971
DTC: P21C2....4975
DTC: P21C3....4979
DTC: P21C4....4984
DTC: P2201....4989
DTC: P2202....5032
DTC: P2203....5035
DTC: P2204....5038
DTC: P2209....5045
DTC: P229F....5053
DTC: P22A0....5095
DTC: P22A1....5098
DTC: P22A2....5101
DTC: P22A7....5108
DTC: P2510....5116
DTC: P2BAE....5121
DTC: U0029....5128
DTC: U0038....5134
DTC: U0100....5140
DTC: U029D (DIESEL)....5144
DTC: U029D (HYBRID)....5150
DTC: U029E (DIESEL)....5156
DTC: U029E (HYBRID)....5162
DTC: U02A2....5168
VEHICLE CONTROL ECU....5175
CAUTIONS ON TROUBLESHOOTING....5175
SYSTEM BLOCK DIAGRAM....5176
COMPUTER PIN ASSIGNMENT....5177
TROUBLESHOOTING WITH COMPUTER (HINO DXII)....5181
DIAGNOSIS CODE TABLE....5182
DTC: C1244....5184
DTC: C1245....5189
DTC: C1249....5191
DTC: C1418....5197
DTC: C1491....5201
DTC: P0335....5203
DTC: P0501....5206
DTC: P0503....5212
DTC: P0555....5217
DTC: P0562....5219
DTC: P0563....5223
DTC: P0572....5226
DTC: P0573....5233
DTC: P0577....5239
DTC: P05BF....5243
DTC: P0604....5246
DTC: P0605 ....5248
DTC: P0605 ....5250
DTC: P0606....5252
DTC: P0617....5254
DTC: P062F....5257
DTC: P0702....5259
DTC: P081D....5261
DTC: P161F....5266
DTC: P1649....5271
DTC: P165A....5275
DTC: P165B....5278
DTC: P2525....5281
DTC: P2526....5284
DTC: P258D....5287
DTC: U0101....5290
DTC: U0105....5293
DTC: U0121....5296
DTC: U0155....5299
DTC: U0293....5302
DTC: U0418....5305
DTC: U1136....5308
HYBRID....5311
TROUBLE SHOOTING....5314
HYBRID CONTROL SYSTEM....5314
TROUBLE SHOOTING STEPS FOR HYBRID SYSTEM....5314
SAFETY MEASURES FOR HIGH-VOLTAGE WORK....5323
LIST OF CONNECTOR SYMBOLS....5326
HV SYSTEM WIRING DIAGRAM....5330
HEARING SHEET....5332
HYBRID ECU....5333
DIAGNOSIS CODE TABLE....5333
FREEZE FRAME DATA LIST....5343
LIST OF DATA MONITOR ITEMS....5346
ACTIVE TEST....5349
COMMON INSPECTION CHART....5350
DTC: C0081 (TCA0)....5355
DTC: P0500 (TC51)....5357
DTC: P0501 (TC5B)....5364
DTC: P0562 (TC71)....5368
DTC: P060B (TCB2)....5374
DTC: P0617 (TC59)....5376
DTC: P062F (TCB3)....5382
DTC: P0810 (TC9C)....5384
DTC: P0810 (TC9D)....5387
DTC: P0A01 (TC7B)....5390
DTC: P0A02 (TC78)....5396
DTC: P0A03 (TC79)....5402
DTC: P0A06 (TC7F)....5407
DTC: P0A07 (TC7E)....5415
DTC: P0A0F (TC31) ....5418
DTC: P0A1D (TC12)....5421
DTC: P0A1D (TC17)....5423
DTC: P0A78 (TC21)....5425
DTC: P0A78 (TC22)....5427
DTC: P0A7E (TC48)....5429
DTC: P0A82 (TC67)....5433
DTC: P0A84 (TC66)....5443
DTC: P0A85 (TC65)....5454
DTC: P0A90 (TC2A)....5459
DTC: P0A92 (TC29)....5468
DTC: P0A93 (TC7A)....5477
DTC: P0AFD (TC6B)....5482
DTC: P0BC9 (TC69)....5485
DTC: P0BCA (TC68)....5497
DTC: P0C73 (TC80)....5503
DTC: P3000 (TC42)....5508
DTC: P3001 (TC41)....5514
DTC: P3001 (TC43)....5516
DTC: P3001 (TC44)....5518
DTC: P3001 (TC45)....5520
DTC: P3001 (TC46)....5522
DTC: P3001 (TC47)....5525
DTC: P3001 (TC4A)....5528
DTC: P3001 (TC4B)....5531
DTC: P3001 (TC4C)....5533
DTC: P3001 (TC4D)....5535
DTC: P3009 (TC49)....5538
DTC: P3010 (TC4E)....5548
DTC: P3010 (TC4F)....5550
DTC: P3128 (TC7D)....5553
DTC: P3129 (TC7C)....5561
DTC: P314C (TC82)....5565
DTC: P314D (TC81)....5569
DTC: P324B (TC62)....5577
DTC: P324C (TC61)....5581
DTC: P33B1 (TC64)....5586
DTC: P33B2 (TC63)....5590
DTC: U0073 (TC11)....5594
DTC: U0074 (TC16)....5598
DTC: U0100 (TC13)....5601
DTC: U0101 (TC18)....5604
DTC: U0110 (TC14)....5609
DTC: U0111 (TC15)....5615
DTC: U0121 (TC24)....5621
DTC: U0155 (TC25)....5626
DTC: U110A (TC26)....5631
DTC: U1136 (TC27)....5636
INVERTER....5641
DIAGNOSIS CODE TABLE....5641
FREEZE FRAME DATA LIST....5647
DATA MONITOR ITEM LIST....5649
CONNECTION DIAGRAM....5652
INSULATION RESISTANCE MEASUREMENT PROCEDURE FOR HYBRID MOTOR [ROTATION MACHINE]....5653
DTC: P0562 (TC96) ....5655
DTC: P0562 (TCA0) ....5662
DTC: P0604 (TC18) ....5669
DTC: P0604 (TCD2)....5671
DTC: P0605 (TC17) ....5673
DTC: P0605 (TCD1) ....5675
DTC: P060B (TC1A)....5677
DTC: P060C (TC1C)....5680
DTC: P062F (TC41)....5682
DTC: P0A0D (TC20)....5684
DTC: P0A1B (TC16)....5689
DTC: P0A1B (TC92)....5694
DTC: P0A1B (TC97)....5696
DTC: P0A1B (TC3F)....5698
DTC: P0A1B (TCA1)....5700
DTC: P0A1B (TCA2)....5702
DTC: P0A1B (TCA3)....5704
DTC: P0A1B (TCA4)....5706
DTC: P0A1B (TCA5)....5708
DTC: P0A1B (TCA6)....5710
DTC: P0A1B (TCA7)....5712
DTC: P0A1B (TCA8) ....5714
DTC: P0A1B (TCA9)....5716
DTC: P0A1B (TCAA)....5718
DTC: P0A1B (TCBB)....5722
DTC: P0A1B (TCBC)....5724
DTC: P0A1B (TCBD)....5726
DTC: P0A1B (TCBE)....5728
DTC: P0A1B (TCBF)....5730
DTC: P0A1B (TCD3)....5732
DTC: P0A1B (TCD4)....5734
DTC: P0A1B (TCD5)....5736
DTC: P0A1D (TC21)....5738
DTC: P0A2B (TCE9)....5741
DTC: P0A2B (TCED)....5748
DTC: P0A2C (TCDA)....5755
DTC: P0A2D (TCDB)....5761
S7-LXJE12A_4....5769
FOREWORD....5769
CHAPTER REFERENCES....5770
INDEX....5771
HYBRID....5773
TROUBLE SHOOTING....5776
INVERTER....5776
DTC: P0A2F (TC33) ....5776
DTC: P0A3C (TC34)....5781
DTC: P0A3F (TCB7)....5794
DTC: P0A41 (TCC0)....5800
DTC: P0A42 (TCC1)....5808
DTC: P0A51 (TCD6)....5816
DTC: P0A51 (TCD7)....5818
DTC: P0A78 (TC13)....5820
DTC: P0A78 (TC14)....5827
DTC: P0A78 (TC15)....5838
DTC: P0AA1 (TCD8)....5843
DTC: P0AA4 (TCD9)....5847
DTC: P0ADB (TC1F)....5851
DTC: P0ADC (TC93)....5856
DTC: P0ADF (TC1E)....5862
DTC: P0AE0 (TC95)....5867
DTC: P0AE6 (TC1D)....5873
DTC: P0AE7 (TC94)....5878
DTC: P0AEE (TC22)....5884
DTC: P0AEE (TC23)....5886
DTC: P0AEF (TC24)....5888
DTC: P0AF0 (TC25)....5891
DTC: P0BEA (TCB3)....5894
DTC: P0BEA (TCB4)....5896
DTC: P0BEB (TC9A)....5898
DTC: P0BEC (TC9B)....5900
DTC: P0BEE (TCB5)....5902
DTC: P0BEE (TCB6)....5904
DTC: P0BEF (TC9C)....5906
DTC: P0BF0 (TC9D)....5908
DTC: P3126 (TC12)....5910
DTC: U0073 (TC91)....5917
DTC: U0074 (TC3E)....5921
DTC: U0293 (TC31)....5924
BATTERY ECU....5931
DIAGNOSIS CODE TABLE....5931
LIST OF FREEZE FRAME DATA....5935
LIST OF DATA MONITOR ITEMS....5937
CONNECTION DIAGRAM....5940
DTC: P0562....5941
DTC: P0604....5945
DTC: P0605....5947
DTC: P060B....5949
DTC: P062F....5951
DTC: P0A1F....5953
DTC: P0A7D....5955
DTC: P0A7F....5958
DTC: P0A80....5963
DTC: P0A95....5968
DTC: P0A9C....5972
DTC: P0A9D....5977
DTC: P0A9E....5981
DTC: P0ABF....5985
DTC: P0AC0....5990
DTC: P0AC1....5995
DTC: P0AC2....6000
DTC: P0AC6....6005
DTC: P0AC7....6010
DTC: P0AC8....6014
DTC: P0ACB....6018
DTC: P0ACC....6023
DTC: P0ACD....6027
DTC: P0AE9....6031
DTC: P0AEA....6036
DTC: P0AEB....6040
DTC: P0AFC....6044
DTC: P0B25....6046
DTC: P0B3D....6049
DTC: P0B42....6053
DTC: P0B47....6057
DTC: P0B4C....6061
DTC: P0B51....6065
DTC: P0B56....6069
DTC: P0B5B....6073
DTC: P0B60....6077
DTC: P0B65....6081
DTC: P0B6A....6085
DTC: P0B6F....6089
DTC: P0B74....6093
DTC: P0B79....6097
DTC: P0B7E....6101
DTC: P0B83....6105
DTC: P0B88....6109
DTC: P0B8D....6113
DTC: P0B92....6117
DTC: P0B97....6121
DTC: P0B9C....6125
DTC: P0BA1....6129
DTC: P0C30....6133
DTC: P3004....6140
DTC: P3011....6142
DTC: P3012....6147
DTC: P3013....6152
DTC: P3014....6157
DTC: P3015....6162
DTC: P3016....6167
DTC: P3017....6172
DTC: P3018....6177
DTC: P3019....6182
DTC: P301B....6187
DTC: P3020....6189
DTC: P3021....6194
DTC: P3022....6199
DTC: P3023....6204
DTC: P3024....6209
DTC: P3025....6214
DTC: P3026....6219
DTC: P3027....6224
DTC: P3028....6229
DTC: P3029....6234
DTC: P302F....6239
DTC: P3065....6244
DTC: P308A....6249
DTC: U0074....6253
DTC: U0293....6256
TRANSMISSION....6260
TROUBLESHOOTING....6262
TROUBLE SHOOTING BY TRANSMISSION SYMPTOM....6262
AUTOMATIC TRANSMISSION....6262
TROUBLESHOOTING....6264
AUTOMATIC TRANSMISSION....6264
PRECAUTIONS FOR DIAGNOSIS....6264
AT LEARNED VALUE INITIALIZATION....6265
INSPECTING/CLEARING DIAGNOSIS CODES....6269
SYSTEM BLOCK DIAGRAM....6272
COMPUTER PIN ASSIGNMENT....6273
DIAGNOSIS CODE TABLE....6276
DTC: P0500/DIAGNOSIS MONITOR CODE: 42....6278
DTC: P0562/DIAGNOSIS MONITOR CODE: 11....6284
DTC: P0705/DIAGNOSIS MONITOR CODE: 43....6287
DTC: P0706/DIAGNOSIS MONITOR CODE: 44....6295
DTC: P0710/DIAGNOSIS MONITOR CODE: 38....6300
DTC: P0715/DIAGNOSIS MONITOR CODE: 12....6307
DTC: P0720/DIAGNOSIS MONITOR CODE: 61....6313
DTC: P0725/DIAGNOSIS MONITOR CODE: 86....6319
DTC: P0730/DIAGNOSIS MONITOR CODE: 37....6325
DTC: P0746/DIAGNOSIS MONITOR CODE: 31....6333
DTC: P0748/DIAGNOSIS MONITOR CODE: 25....6339
DTC: P0751/DIAGNOSIS MONITOR CODE: 45....6344
DTC: P0756/DIAGNOSIS MONITOR CODE: 46....6350
DTC: P0761/DIAGNOSIS MONITOR CODE: 47.48....6356
DTC: P0776/DIAGNOSIS MONITOR CODE: 32....6366
DTC: P0778/DIAGNOSIS MONITOR CODE: 26....6372
DTC: P0810/DIAGNOSIS MONITOR CODE: 88....6377
DTC: P0973/DIAGNOSIS MONITOR CODE: 62....6381
DTC: P0974/DIAGNOSIS MONITOR CODE: 62....6386
DTC: P0976/DIAGNOSIS MONITOR CODE: 63....6391
DTC: P0977/DIAGNOSIS MONITOR CODE: 63....6396
DTC: P0979/DIAGNOSIS MONITOR CODE: 64....6401
DTC: P0980/DIAGNOSIS MONITOR CODE: 64....6406
DTC: P0985/DIAGNOSIS MONITOR CODE: 65....6411
DTC: P0986/DIAGNOSIS MONITOR CODE: 65....6416
DTC: P0A40/DIAGNOSIS MONITOR CODE: 88....6421
DTC: P1604/DIAGNOSIS MONITOR CODE: 24....6425
DTC: P1604/DIAGNOSIS MONITOR CODE: 54....6429
DTC: P2545/DIAGNOSIS MONITOR CODE: 88....6433
DTC: P2716/DIAGNOSIS MONITOR CODE: 28....6437
DTC: P2740/DIAGNOSIS MONITOR CODE: 17....6443
DTC: P2757/DIAGNOSIS MONITOR CODE: 33....6448
DTC: P2759/DIAGNOSIS MONITOR CODE: 27....6454
DTC: P2764/DIAGNOSIS MONITOR CODE: 36....6460
DTC: U0100/DIAGNOSIS MONITOR CODE: 88....6464
DTC: U110A/DIAGNOSIS MONITOR CODE: 88....6473
TROUBLESHOOTING....6482
CLUTCH ECU....6482
SYSTEM BLOCK DIAGRAM....6482
COMPUTER PIN ASSIGNMENT....6483
DIAGNOSIS CODE TABLE....6485
CAUTIONS ON HV DAMPER REPLACEMENT....6487
DTC: P0560....6488
DTC: P0563....6492
DTC: P0604....6494
DTC: P0605....6496
DTC: P062F....6498
DTC: P0775....6500
DTC: P0778....6505
DTC: P0811....6510
DTC: P081E....6512
DTC: P0883....6514
DTC: P0948....6518
DTC: P1538....6523
DTC: P1539....6533
DTC: P18F2....6540
DTC: P18F3....6550
DTC: P18F5....6560
DTC: P18F7....6570
DTC: P18F8....6580
DTC: P18F9....6590
DTC: P18FB....6600
DTC: P18FC....6605
DTC: P18FD....6610
DTC: P191A....6615
DTC: P2859....6617
DTC: P3156....6619
DTC: P3157....6629
DTC: U0073....6633
DTC: U0101....6636
DTC: U0110....6639
DTC: U0293....6642
DTC: U110A....6645
AXLE....6648
TROUBLESHOOTING....6649
TROUBLE SHOOTING BY AXLE SYMPTOM....6649
FRONT AXLE....6649
REAR AXLE....6650
WHEEL AND TIRE....6650
DIFFERENTIAL....6652
TROUBLESHOOTING....6653
TROUBLE SHOOTING BY DIFFERENTIAL SYMPTOM....6653
REAR DIFFERENTIAL....6653
S7-LXJE12A_5....6655
FOREWORD....6655
CHAPTER REFERENCES....6656
INDEX....6657
BRAKE....6659
TROUBLESHOOTING....6660
TROUBLE SHOOTING BY BRAKE SYMPTOM....6660
BRAKE....6660
ABS WITH EBD....6662
CAUTIONS....6662
TROUBLESHOOTING PROCEDURE....6663
ACT PART No. CORRESPONDENCE....6665
HEARING TABLE....6665
PRIOR CHECK....6666
LIST OF DIAGNOSIS CODE....6678
PARTS ARRANGEMENT....6681
ECU TERMINAL ARRANGEMENT....6683
SYMPTOM LIST....6686
ELECTRIC CIRCUIT DIAGRAM....6687
ABS WARNING LIGHT ALWAYS ON....6688
BRAKE WARNING LIGHT ALWAYS ON....6692
ABS ACTIVATION TOO FAST (ABS OPERATES BEFORE THE WHEEL LOCKS)....6696
THE BRAKE PEDAL GETS STUCK....6697
DTC: C1203 (Diagnosis monitor code 59)....6699
DTC: C1225 (Diagnosis monitor code 25)....6703
DTC: C1241 (Diagnosis monitor code 41)....6707
DTC: C1249 (Diagnosis monitor code 49)....6719
DTC: C1265 (Diagnosis monitor code 65)....6723
DTC: C1300 (Diagnosis monitor code 62)....6733
DTC: C1337 (Diagnosis monitor code 37)....6736
DTC: C1361 (Diagnosis monitor code 91)....6740
DTC: C1401 (Diagnosis monitor code 31)....6748
DTC: C1402 (Diagnosis monitor code 32)....6757
DTC: C1403 (Diagnosis monitor code 33)....6766
DTC: C1404 (Diagnosis monitor code 34)....6775
DTC: C1405 (Diagnosis monitor code 31)....6784
DTC: C1406 (Diagnosis monitor code 32)....6793
DTC: C1407 (Diagnosis monitor code 33)....6802
DTC: C1408 (Diagnosis monitor code 34)....6811
DTC: C1413 (Diagnosis monitor code 35)....6820
DTC: C1414 (Diagnosis monitor code 36)....6827
DTC: C1415 (Diagnosis monitor code 38)....6833
DTC: C1416 (Diagnosis monitor code 39)....6842
DTC: C1417 (Diagnosis monitor code 41)....6851
DTC: C1421 (Diagnosis monitor code 46)....6863
DTC: C1422 (Diagnosis monitor code 46)....6867
DTC: C1423 (Diagnosis monitor code 46)....6871
DTC: C1424 (Diagnosis monitor code 46)....6875
DTC: C1425 (Diagnosis monitor code 49)....6879
DTC: C1427 (Diagnosis monitor code 51)....6883
DTC: C1428 (Diagnosis monitor code 51)....6887
DTC: C1468 (Diagnosis monitor code 21)....6891
DTC: C1469 (Diagnosis monitor code 22)....6895
DTC: C146A (Diagnosis monitor code 23)....6899
DTC: C146B (Diagnosis monitor code 24)....6903
DTC: C146C (Diagnosis monitor code 13)....6907
DTC: C146D (Diagnosis monitor code 14)....6914
DTC: C146E (Diagnosis monitor code 11)....6921
DTC: C146F (Diagnosis monitor code 12)....6927
DTC: U0073 (Diagnosis monitor code 94)....6933
ELECTRIC VACUUM PUMP SYSTEM....6936
CAUTIONS FOR TROUBLESHOOTING....6936
SYSTEM BLOCK DIAGRAM....6937
ELECTRIC CIRCUIT DIAGRAM....6938
CONNECTOR TERMINAL ARRANGEMENT....6939
SYSTEM SELF-DIAGNOSTIC....6940
RESETTING THE ELECTRIC VACUUM PUMP OPERATION COUNT AND OPERATION TIME AND THE ELECTRIC VACUUM PUMP RELAY ACTUATION COUNT....6941
ACTIVE TEST....6941
DATA MONITOR....6941
DIAGNOSIS CODE TABLE....6942
EXCESSIVE OPERATION OF ELECTRIC VACUUM PUMP (DIAGNOSIS CODE P165A)....6943
EXCESSIVE OPERATION OF ELECTRIC VACUUM PUMP RELAY (DIAGNOSIS CODE P165B)....6944
ABNORMALITY IN VACUUM SENSOR CIRCUIT (DIAGNOSIS CODE P2525)....6945
FALSE DETECTION OF VACUUM SENSOR PRESSURE (DIAGNOSIS CODE P2526)....6949
ELECTRIC VACUUM PUMP RELAY CONTACT STUCK AT ON (DIAGNOSIS CODE P258D)....6961
HOW TO VERIFY AND CHANGE VEHICLE INFORMATION VALUES....6963
STEERING....6965
TROUBLESHOOTING....6966
TROUBLE SHOOTING BY STEERING SYMPTOM....6966
STEERING....6966
SUSPENSION....6972
TROUBLESHOOTING....6973
TROUBLE SHOOTING BY SUSPENSION SYMPTOM....6973
LEAF SUSPENSION....6973
ELECTRICAL....6974
TROUBLESHOOTING....6975
TROUBLE SHOOTING BY ELECTRICAL SYMPTOM....6975
SIMULTANEOUS MALFUNCTION OF MULTIPLE ELECTRIC SYSTEMS....6975
INTEGRATED UNIT....6980
SYSTEM BLOCK DIAGRAM....6980
COMPUTER PIN ASSIGNMENT....6983
TROUBLE SHOOTING....6984
CONTROL SYSTEM....6991
TROUBLESHOOTING....6994
CAN COMMUNICATION....6994
INSPECTION IN THE EVENT OF ABNORMALITY IN CAN COMMUNICATION LINE....6994
ECU INDIVIDUAL CODELIST (DIESEL)....6996
ECU INDIVIDUAL CODELIST (HYBRID)....6997
BASIC TROUBLESHOOTING PROCEDURE ON CAN COMMUNICATION....7000
ENGINE CAN COMMUNICATION LINE (DIESEL)....7002
ENGINE CAN LINE....7002
PRIOR INSPECTION OF THE CAN COMMUNICATION LINE....7004
INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION....7008
INSPECTING THE CAN H LINE FOR SHORT CIRCUIT....7013
INSPECTING THE CAN L LINE FOR SHORT CIRCUIT....7023
INSPECTING THE ENGINE ECU CAN COMMUNICATION LINE....7033
INSPECTING THE EGR CONTROLLER CAN COMMUNICATION LINE....7038
INSPECTING THE NOx SENSOR 1 CAN COMMUNICATION LINE....7041
INSPECTING THE NOx SENSOR 2 CAN COMMUNICATION LINE....7048
INSPECTING THE VNT CONTROLLER CAN COMMUNICATION LINE....7055
INSPECTING THE DEF SENSOR CAN COMMUNICATION LINE....7058
INSPECTING THE PM SENSOR CAN COMMUNICATION LINE....7062
ENGINE CAN COMMUNICATION LINE (HYBRID)....7068
ENGINE CAN LINE....7068
PRIOR INSPECTION OF THE CAN COMMUNICATION LINE....7070
INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION....7074
INSPECTING THE CAN H LINE FOR SHORT CIRCUIT....7079
INSPECTING THE CAN L LINE FOR SHORT CIRCUIT....7090
INSPECTING THE ENGINE ECU CAN COMMUNICATION LINE....7101
INSPECTING THE EGR CONTROLLER CAN COMMUNICATION LINE....7106
INSPECTING THE NOx SENSOR 1 CAN COMMUNICATION LINE....7109
INSPECTING THE NOx SENSOR 2 CAN COMMUNICATION LINE....7116
INSPECTING THE VNT CONTROLLER CAN COMMUNICATION LINE....7123
INSPECTING THE DEF SENSOR CAN COMMUNICATION LINE....7126
INSPECTING THE PM SENSOR CAN COMMUNICATION LINE....7130
DIAGNOSIS CAN COMMUNICATION LINE (DIESEL)....7137
DIAGNOSIS CAN LINE....7137
PRIOR INSPECTION OF THE CAN COMMUNICATION LINE....7139
INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION....7145
INSPECTING THE CAN H LINE FOR SHORT CIRCUIT....7148
INSPECTING THE CAN L LINE FOR SHORT CIRCUIT....7156
INSPECTING THE ABS ECU CAN COMMUNICATION LINE....7163
INSPECTING THE AT ECU CAN COMMUNICATION LINE....7166
INSPECTING THE ENGINE ECU CAN COMMUNICATION LINE....7169
INSPECTING THE VEHICLE CONTROL ECU CAN COMMUNICATION LINE....7174
DIAGNOSIS CAN COMMUNICATION LINE (HYBRID)....7178
DIAGNOSIS CAN LINE....7178
PRIOR INSPECTION OF THE CAN COMMUNICATION LINE....7181
INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION....7188
INSPECTING THE CAN H LINE FOR SHORT CIRCUIT....7194
INSPECTING THE CAN L LINE FOR SHORT CIRCUIT....7205
INSPECTING THE ABS ECU CAN COMMUNICATION LINE....7216
INSPECTING THE AT ECU CAN COMMUNICATION LINE....7219
INSPECTING THE ENGINE ECU CAN COMMUNICATION LINE....7222
INSPECTING THE INVERTER CAN COMMUNICATION LINE....7225
INSPECTING THE CLUTCH ECU CAN COMMUNICATION LINE....7228
INSPECTING THE BATTERY ECU CAN COMMUNICATION LINE....7231
INSPECTING THE VEHICLE CONTROL ECU CAN COMMUNICATION LINE....7234
CONTROL CAN COMMUNICATION LINE (DIESEL)....7237
CONTROL CAN LINE....7237
PRIOR INSPECTION OF THE CAN COMMUNICATION LINE....7239
INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION....7244
INSPECTING THE CAN H LINE FOR SHORT CIRCUIT....7248
INSPECTING THE CAN L LINE FOR SHORT CIRCUIT....7254
INSPECTING THE ABS ECU CAN COMMUNICATION LINE....7260
INSPECTING THE AT ECU CAN COMMUNICATION LINE....7263
INSPECTING THE VEHICLE CONTROL ECU CAN COMMUNICATION LINE....7266
CONTROL CAN COMMUNICATION LINE (HYBRID)....7269
CONTROL CAN LINE....7269
PRIOR INSPECTION OF THE CAN COMMUNICATION LINE....7273
INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION....7278
INSPECTING THE CAN H LINE FOR SHORT CIRCUIT....7285
INSPECTING THE CAN L LINE FOR SHORT CIRCUIT....7296
INSPECTING THE ABS ECU CAN COMMUNICATION LINE....7307
INSPECTING THE AT ECU CAN COMMUNICATION LINE....7310
INSPECTING THE HV ECU CAN COMMUNICATION LINE....7313
INSPECTING THE INVERTER CAN COMMUNICATION LINE....7316
INSPECTING THE CLUTCH ECU CAN COMMUNICATION LINE....7320
INSPECTING THE VEHICLE CONTROL ECU CAN COMMUNICATION LINE....7323
CAN COMMUNICATION (HYBRID SYSTEM)....7326
SAFETY MEASURES TO BE TAKEN IN HIGH VOLTAGE WORK....7326
LIST OF CONNECTOR MARKINGS....7329
CONNECTION DIAGRAM....7330
LIST OF DTC CODES FOR CAN SYSTEM-RELATED ABNORMALITIES....7331
CAN COMMUNICATION FAILURE....7333
BASIC INSPECTION ITEMS IN CASE OF ABNORMALITY IN DIAG CAN SYSTEM....7337
BASIC INSPECTION ITEMS IN CASE OF ABNORMALITY IN CONTROL CAN SYSTEM....7352
ABNORMALITY IN INVERTER (ECU SYSTEM) / DIAG CAN RESISTER SEIZURE (DTC CODE P0A1B / TC3F)....7361
ABNORMALITY IN THE INVERTER (ECU SYSTEM) / CONTROL CAN RESISTER SEIZURE (DTC CODE P0A1B / TC92)....7362
ABNORMALITY IN HV ECU FUNCTION / CONTROL CAN REGISTER SEIZURE (DTC CODE P0A1D / TC12)....7363
ABNORMALITY IN HV ECU FUNCTION / DIAG CAN REGISTER SEIZURE (DTC CODE P0A1D / TC17)....7364
HV ECU CAN COMMUNICATION FAILURE (CONTROL CAN) / CONTROL CAN COMMUNICATION SHUTDOWN DUE TO BUS OFF (DTC CODE U0073 / TC11)....7365
CAN COMMUNICATION FAILURE (CONTROL CAN) / CONTROL CAN COMMUNICATION SHUTDOWN DUE TO BUS OFF (DTC CODE U0073 / TC91)....7367
HV ECU CAN COMMUNICATION FAILURE (DIAG CAN) / DIAG CAN COMMUNICATION SHUTDOWN DUE TO BUS OFF (DTC CODE U0074 / TC16)....7369
CAN COMMUNICATION FAILURE (DIAG CAN) / COMMUNICATION SHUTDOWN DUE TO DIAG CAN BUS OFF (DTC CODE U0074 / TC3E)....7370
ENGINE ECU CAN COMMUNICATION BLACKOUT / ENGINE ECU CAN COMMUNICATION BLACKOUT (DTC CODE U0100 / TC13)....7371
TCM ECU CAN COMMUNICATION BLACKOUT / AT ECU CAN COMMUNICATION BLACKOUT (DTC CODE U0101 / TC18)....7372
INVERTER CAN COMMUNICATION BLACKOUT / INVERTER CAN COMMUNICATION BLACKOUT (DTC CODE U0110 / TC14)....7374
BATTERY ECU CAN COMMUNICATION BLACKOUT / BATTERY ECU CAN COMMUNICATION BLACKOUT (DTC CODE U0111 / TC15)....7377
ABS ECU CAN COMMUNICATION BLACKOUT / ABS ECU CAN COMMUNICATION BLACKOUT (DTC CODE U0121/TC24)....7380
METER CAN COMMUNICATION BLACKOUT / METER CAN COMMUNICATION BLACKOUT (DTC CODE U0155 / TC25)....7382
HV ECU COMMUNICATION FAILURE (DTC CODE U0293)....7384
HV ECU CAN COMMUNICATION BLACKOUT / HV ECU CAN COMMUNICATION BLACKOUT (DTC CODE U0293 / TC31)....7386
VEHICLE CONTROL ECU CAN COMMUNICATION BLACKOUT / VEHICLE CONTROL ECU CAN COMMUNICATION BLACKOUT (DTC CODE U110A / TC26)....7390
CLUTCH ECU CAN COMMUNICATION BLACKOUT / CLUTCH ECU CAN COMMUNICATION BLACKOUT (DTC CODE U1136 / TC27)....7392
COMMUNICATION DISABLED DUE TO DIAG CAN BUS OFF (DTC CODE U0074)....7394
S7-UNAE12A-1....7396
FOREWORD....7396
CHAPTER REFERENCES....7397
INDEX....7398
GENERAL INTRODUCTION....7399
GENERAL INTRODUCTION....7400
GENERAL PRECAUTIONS....7400
IDENTIFICATION INFORMATION....7403
HOW TO USE THIS WORKSHOP MANUAL....7410
INTRODUCTION TO DESCRIPTIONS....7410
PRECAUTIONS....7413
SEALANT ON THE TAPERED SCREW FOR PIPING....7416
METRIC INFORMATION....7417
SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS....7419
SPECIFIED TORQUE FOR FLANGE BOLTS AND NUTS....7420
RECOMMENDED LUBRICANTS....7421
INFORMATION DISPLAY....7423
GLOSSARY....7428
GLOSSARY OF SAE AND HINO TERMS....7431
TERMS CONTRADISTINCTION LIST....7434
TROUBLE SHOOTING - COMPONENTS....7436
ENGINE BASIC....7437
ENGINE ASSEMBLY....7437
ENGINE ASSEMBLY (COMMON RAIL SYSTEM)....7444
TURBOCHARGER (J08E)....7445
TURBOCHARGER....7445
ALTERNATOR (J08E: REMY 12V-130A, 135A, 180A, 200A)....7454
ALTERNATOR....7454
STARTER (J08E)....7455
STARTER....7455
AIR COMPRESSOR (J08E: 340 cm3)....7456
AIR COMPRESSOR....7456
CLUTCH MAIN UNIT....7457
CLUTCH ASSEMBLY (EATON SAS1401)....7457
CLUTCH ASSEMBLY (EATON SAS1402)....7459
AUTOMATIC TRANSMISSION....7461
AUTOMATIC TRANSMISSION ASSEMBLY....7461
TRANSMISSION/TRANSFER CONTROL (EATON MANUAL TRANSMISSION) ....7462
TRANSMISSION CONTROL UNIT....7462
TRANSMISSION/TRANSFER CONTROL (ALLISON AUTOMATIC TRANSMISSION)....7463
TRANSMISSION CONTROL UNIT....7463
PROPELLER SHAFT (SPL 100, 140)....7463
PROPELLER SHAFT ASSEMBLY....7463
DIFFERENTIAL CARRIER (MERITOR RS-17, 19, 21 AND 23)....7464
DIFFERENTIAL CARRIER ASSEMBLY....7464
BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE)....7465
SERVICE BRAKE ASSEMBLY....7465
BRAKE EQUIPMENT (MODELS WITH FULL AIR BRAKE)....7470
SERVICE BRAKE ASSEMBLY....7470
SERVICE BRAKE (HYDRAULIC BRAKE)....7472
WHEEL BRAKE (TYPE: 4 PISTON)....7472
SERVICE BRAKE (FULL AIR BRAKE)....7474
AIR DRYER AND RESERVOIR SYSTEM (MODEL: BENDIX AD-IS)....7474
EXHAUST BRAKE....7477
EXHAUST BRAKE SYSTEM....7477
PARKING BRAKE (BOSCH 12)....7478
PARKING BRAKE ASSEMBLY....7478
STEERING EQUIPMENT....7479
STEERING SYSTEM....7479
FRONT AXLE (MFS)....7483
FRONT AXLE (MFS)....7483
REAR AXLE....7485
REAR AXLE....7485
WHEEL AND TIRE....7486
WHEEL AND TIRE....7486
SUSPENSION....7488
LEAF SUSPENSION ASSEMBLY....7488
AIR SUSPENSION ASSEMBLY....7488
CHASSIS FRAME....7489
CHASSIS FRAME....7489
CAB....7490
AIR SUSPENSION DUMP SYSTEM....7490
CAB ASSEMBLY....7490
AIR CONDITIONING SYSTEM....7492
ELECTRICAL EQUIPMENT....7502
ELECTRICAL PARTS....7502
TROUBLE SHOOTING - ELECTRICAL CONTROL SYSTEM....7504
ABOUT HINO DX?....7505
About HINO DX?....7505
BASIC PROCEDURE FOR TROUBLESHOOTING....7507
BASIC PROCEDURE FOR TROUBLESHOOTING....7507
SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE....7509
SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE....7509
SYMPTOM SIMULATION....7512
SYMPTOM SIMULATION....7512
TROUBLE CODE DIAGNOSTIC INSPECTION FLOW CHART....7514
TROUBLE CODE DIAGNOSTIC INSPECTION FLOW CHART....7514
ELECTRONIC CIRCUIT INSPECTION PROCEDURE....7515
ELECTRONIC CIRCUIT INSPECTION PROCEDURE....7515
INSPECTION PROCEDURE FOR MULTIPLE DTCS....7520
INSPECTION PROCEDURE FOR MULTIPLE DTCS....7520
ENGINE CONTROL SYSTEM (J08E)....7521
ENGINE CONTROL SYSTEM....7524
PRECAUTIONS FOR DIAGNOSIS....7524
SYSTEM BLOCK DIAGRAM....7526
SYSTEM DIAGRAM....7527
PRECAUTIONS....7529
SENSOR LOCATION....7533
COMPUTER (ECU) PIN ASSIGNMENT....7542
ENGINE ECU CONNECTOR....7548
INSPECTION....7552
DIAGNOSIS USING THE PC DIAGNOSIS TOOL....7553
DIAGNOSTIC TROUBLE CODE (DTC) TABLE....7554
GROUP SHARING THE SENSOR POWER SUPPLY TERMINAL....7572
GROUP SHARING THE SENSOR GND TERMINAL....7573
ENGINE BASIC INSPECTION SHEET (ENGINE INSPECTION CHECK SHEET)....7574
NO DTC....7578
DTC: P0005....7581
DTC: P0006 and P0007....7585
DTC: P0016....7590
DTC: P0027....7593
DTC: P003A....7598
DTC: P0045....7603
DTC: P0047....7608
DTC: P0048....7613
DTC: P006E....7618
DTC: P006F....7622
DTC: P007B....7626
DTC: P007C and P007D....7639
DTC: P0088....7646
DTC: P0096....7655
DTC: P0097 and P0098 ....7666
DTC: P00AF....7673
DTC: P0101....7677
DTC: P0104....7684
DTC: P0106....7690
DTC: P0108....7696
DTC: P0112 and P0113....7702
DTC: P0115....7708
DTC: P0117 and P0118....7716
DTC: P011A....7723
DTC: P011C....7731
DTC: P0122 and P0123....7736
DTC: P0128....7746
DTC: P0148 ....7751
DTC: P016E and P016F ....7762
DTC: P0182 and P0183 ....7772
DTC: P0191....7779
DTC: P0192 and P0193 ....7787
DTC: P01A5....7795
DTC: P01A6....7802
DTC: P0200....7809
DTC: P0201, P0202, P0203, P0204, P0205 and P0206....7811
DTC: P0217....7816
DTC: P0219....7821
DTC: P0222 and P0223....7826
DTC: P0234....7836
DTC: P0237....7842
DTC: P0263, P0266, P0269, P0272, P0275 and P0278....7849
DTC: P026C and P026D....7860
DTC: P0299....7871
DTC: P0300....7876
DTC: P0301, P0302, P0303, P0304, P0305 and P0306....7883
DTC: P0335....7890
DTC: P0336....7895
DTC: P0340....7901
DTC: P0341....7906
DTC: P0381....7913
DTC: P0401....7918
DTC: P0402....7932
DTC: P0404....7942
DTC: P0405 and P0406....7947
DTC: P041B....7953
DTC: P041C and P041D....7961
DTC: P0420....7968
DTC: P0421....7970
DTC: P0422....7980
DTC: P0489 and P0490....7983
DTC: P049D....7989
DTC: P04DA....7994
S7-UNAE12A-2....8006
FOREWORD....8006
CHAPTER REFERENCES....8007
INDEX....8008
ENGINE CONTROL SYSTEM (J08E)....8009
ENGINE CONTROL SYSTEM....8012
DTC: P0500 and P0501....8012
DTC: P0504....8018
DTC: P0506 and P0507....8024
DTC: P0524....8027
DTC: P0545 and P0546....8032
DTC: P054E and P054F....8040
DTC: P0562 and P0563....8043
DTC: P05F1....8049
DTC: P0603....8057
DTC: P0605....8061
DTC: P0606....8063
DTC: P0607....8065
DTC: P0610....8067
DTC: P0611....8070
DTC: P0617....8072
DTC: P0628 and P0629....8076
DTC: P062F....8083
DTC: P0630....8087
DTC: P0642....8090
DTC: P0643....8094
DTC: P064C....8099
DTC: P0652....8104
DTC: P0653....8109
DTC: P0671, P0672, P0675 and P0676 ....8114
DTC: P0683....8124
DTC: P0686....8129
DTC: P0698....8133
DTC: P0699....8135
DTC: P06A4....8137
DTC: P06A5....8139
DTC: P06D3 and P06D4....8141
DTC: P0704....8147
DTC: P073D....8151
DTC: P081A....8157
DTC: P081B....8161
DTC: P0850....8165
DTC: P1133....8169
DTC: P119F....8175
DTC: P1426....8180
DTC: P1427....8186
DTC: P1428....8192
DTC: P1458....8198
DTC: P1459....8203
DTC: P14B0....8208
DTC: P14B2....8212
DTC: P14B3 and P14B4....8216
DTC: P14B7 and P14B8....8222
DTC: P14BC and P14BD....8228
DTC: P14BF....8234
DTC: P1515....8239
DTC: P1530....8244
DTC: P1681 and P1682....8247
DTC: P200C....8255
DTC: P2032 and P2033....8261
DTC: P203F....8269
DTC: P204F....8273
DTC: P206B....8275
DTC: P207F....8290
DTC: P2080....8305
DTC: P2084....8313
DTC: P20CD....8321
DTC: P20CE....8325
DTC: P20CF....8329
DTC: P20D8....8332
DTC: P20DE....8337
DTC: P20DF....8340
DTC: P20E0....8346
DTC: P20EE....8352
DTC: P2100....8369
DTC: P2101....8375
DTC: P2103....8381
DTC: P2120....8387
DTC: P2122 and P2123....8391
DTC: P2127 and P2128....8399
DTC: P2135....8408
DTC: P2138....8413
DTC: P2146....8417
DTC: P2147 and P2148....8423
DTC: P2149....8430
DTC: P2150 and P2151....8436
DTC: P2184 and P2185....8443
DTC: P2201....8450
DTC: P2214....8480
DTC: P2227....8510
DTC: P2228 and P2229....8514
DTC: P2269....8519
DTC: P226C....8523
DTC: P22D3....8530
DTC: P240F....8534
DTC: P2428....8543
DTC: P242B....8547
DTC: P242C and P242D....8555
DTC: P244A....8563
DTC: P244B....8580
DTC: P2457....8593
DTC: P2458....8607
DTC: P2459....8615
DTC: P2463....8617
DTC: P246F....8622
DTC: P2470 and P2471....8630
DTC: P24A0....8638
DTC: P24A1....8641
DTC: P24A2....8643
DTC: P2563....8652
DTC: P2564 and P2565....8657
DTC: P259E....8664
DTC: P259F....8669
DTC: P2635....8674
DTC: P268A and P2696....8683
DTC: P2BA9....8689
DTC: U0073....8693
DTC: U010A....8696
DTC: U010C....8699
DTC: U010E....8702
DTC: U029D....8705
DTC: U029E....8708
DTC: U02A2....8711
DTC: U0301....8714
DTC: U1001....8717
DTC: U110A....8720
S7-UNAE12A-3....8724
FOREWORD....8724
CHAPTER REFERENCES....8725
INDEX....8726
DEF SCR SYSTEM (DCU)....8727
DEF SCR SYSTEM....8728
PRECAUTIONS FOR DIAGNOSIS....8728
SYSTEM BLOCK DIAGRAM....8730
SYSTEM DIAGRAM....8731
SENSOR LOCATION....8732
COMPUTER (DCU) WIRE HARNESS CONNECTOR PIN ASSIGNMENT....8735
SIGNAL CHECK HARNESS....8736
INSPECTION....8736
MALFUNCTION INDICATOR LIGHT ILLUMINATION PATTERN....8737
DIAGNOSIS USING THE PC DIAGNOSIS TOOL....8738
DIAGNOSTIC TROUBLE CODE (DTC) TABLE....8739
DTC: P0071....8745
DTC: P0072....8756
DTC: P0073....8764
DTC: P0562....8771
DTC: P0563....8774
DTC: P060C....8777
DTC: P062F....8779
DTC: P0667....8781
DTC: P0668....8783
DTC: P0669....8785
DTC: P068A....8787
DTC: P142A....8792
DTC: P142B....8801
DTC: P202E....8811
DTC: P203C....8815
DTC: P203D....8818
DTC: P2044....8821
DTC: P2045....8824
DTC: P2047....8827
DTC: P2048....8830
DTC: P2049....8835
DTC: P204B....8841
DTC: P204C....8844
DTC: P204D....8850
DTC: P205B....8856
DTC: P205C....8865
DTC: P205D....8868
DTC: P206C....8871
DTC: P206D....8874
DTC: P208A....8877
DTC: P208B....8881
DTC: P208C....8884
DTC: P208D....8888
DTC: P20A0....8892
DTC: P20A1....8898
DTC: P20A2....8901
DTC: P20A3....8907
DTC: P20B1....8913
DTC: P20B2....8918
DTC: P20B3....8926
DTC: P20B4....8931
DTC: P20BD, P20B9 and P20C1....8936
DTC: P20C0, P20BC and P20C4....8942
DTC: P20FC....8948
DTC: P20FD....8952
DTC: P20FE....8955
DTC: P20E8....8958
DTC: P20E9....8969
DTC: P20F4....8974
DTC: P2202....8978
DTC: P2203....8981
DTC: P2204....8984
DTC: P2209....8991
DTC: P2212....8998
DTC: P2215....9006
DTC: P2216....9009
DTC: P2222....9012
DTC: P2481....9020
DTC: P2482....9025
DTC: P2483....9031
DTC: P2510....9044
DTC: P2BAE....9049
DTC: U0029....9052
DTC: U0038....9055
DTC: U0100....9058
DTC: U029D....9062
DTC: U029E....9065
DTC: U02A2....9068
DTC: U0597....9071
BRAKE CONTROL SYSTEM (ABS:HYDRAULIC (E VERSION))....9073
ABS....9074
TROUBLESHOTTING....9074
BRAKE CONTROL SYSTEM (ABS:FULL AIR)....9096
ABS....9097
TROUBLESHOTTING....9097
VEHICLE CONTROL SYSTEM (VCS)....9126
VEHICLE CONTROL SYSTEM....9127
PRECAUTIONS FOR DIAGNOSIS....9127
SYSTEM BLOCK DIAGRAM....9129
SIGNAL CHECK HARNESS....9130
DIAGNOSIS USING THE PC DIAGNOSIS TOOL....9138
VEHICLE CONTROL ECU INSPECTION....9139
DIAGNOSIS MONITOR CODE AND DIAGNOSIS TROUBLE CODE TABLE....9145
DTC: P0500....9146
DTC: P0501....9150
DTC: P0562....9154
DTC: P0563....9157
DTC: P0617....9160
DTC: P0704....9163
DTC: P0850....9169
DTC: P1565....9175
DTC: U0101....9181
DTC: U0105 ....9184
DTC: U0155....9187
NO ACTIVATION OF AUXILIARY BRAKE....9189
NO ACTIVATION/RELEASE OF ENGINE REVOLUTION CONTROL....9195
NO ACTIVATION/RELEASE OF CRUISE FUNCTION....9200
NO ACTIVATION/RELEASE OF ECO MODE....9208
CAN COMMUNICATION....9212
CAN COMMUNICATION TROUBLESHOOTING....9213
Outline....9213
Definition of Terms....9213
Troubleshooting Procedure....9214
Work Flow....9214
ECU individual code list....9215
CAN communication circuit diagram....9216
CAN communication relation connector location....9219
ENGINE CAN COMMUNICATION LINE....9223
ABNORMAL CAN COMMUNICATION DTC DETECTED....9223
CONNECTION DIAGRAM....9223
CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE....9223
PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE....9225
DISCONNECTION INSPECTION FOR ENGINE CAN_H/L_COMMUNICATION LINE....9228
INSPECTION FOR SHORT-CIRCUIT IN CAN H-LINE....9233
INSPECTION FOR SHORT-CIRCUIT IN CAN L-LINE....9241
INSPECTION FOR EGR CONTROLLER CAN COMMUNICATION LINE....9249
INSPECTION FOR VNT CONTROLLER CAN COMMUNICATION LINE....9254
INSPECTION FOR DCU CAN COMMUNICATION LINE (ENGINE CAN COMMUNICATION LINE)....9259
INSPECTION FOR NOx sensor 1 CAN COMMUNICATION LINE....9264
INSPECTION FOR NOx sensor 2 CAN COMMUNICATION LINE....9270
INSPECTION FOR DEF SENSOR CAN COMMUNICATION LINE....9276
DIAGNOSIS CAN COMMUNICATION LINE....9282
ABNORMAL CAN COMMUNICATION DTC DETECTED....9282
CONNECTION DIAGRAM....9282
CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE....9282
PRE-INSPECTION FOR DIAGNOSIS CAN COMMUNICATION LINE....9284
DISCONNECTION INSPECTION FOR DIAGNOSIS CAN_H/L_COMMUNICATION LINE....9287
INSPECTION FOR SHORT-CIRCUIT IN DIAGNOSIS CAN H-LINE....9291
INSPECTION FOR SHORT-CIRCUIT IN DIAGNOSIS CAN L-LINE....9295
INSPECTION FOR DCU CAN COMMUNICATION LINE (DIAGNOSIS CAN COMMUNICATION LINE)....9300
INSPECTION FOR ENGINE ECU CAN COMMUNICATION LINE....9304
CONTROL CAN COMMUNICATION LINE....9309
ABNORMAL CAN COMMUNICATION DTC DETECTED....9309
CONNECTION DIAGRAM (ALLISON AUTOMATIC TRANSMISSION)....9309
CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE (ALLISON AUTOMATIC TRANSMISSION)....9309
CONNECTION DIAGRAM (MANUAL TRANSMISSION)....9310
CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE (MANUAL TRANSMISSION)....9310
PRE-INSPECTION FOR CAN COMMUNICATION LINE....9311
DISCONNECTION INSPECTION FOR CAN_H/L_COMMUNICATION LINE....9315
INSPECTION FOR SHORT-CIRCUIT IN CAN H-LINE....9318
INSPECTION FOR SHORT-CIRCUIT IN CAN L-LINE....9320
INSPECTION FOR AUTOMATIC TRANSMISSION ECU CAN COMMUNICATION LINE....9322
