S1 - YFCE18B - 2 (Chassis Vol 2 Euro 2)
S1 - YFCE18B - 2 (Chassis Vol 2 Euro 2)
S1 - YFCE18B - 2 (Chassis Vol 2 Euro 2)
FOREWORD
This workshop manual has been prepared to provide information regarding repair procedures on Hino Vehicles.
Applicable for FC9J, FD8J, GD8J, FG8J, GH8J, FL8J, FM8J, FM2P, SG8J series,
equipped with J05E-TI, J08E-TI, P11C-TI engine
When making any repairs on your vehicle, be careful not to be injured through improper procedures.
As for maintenance items, refer to the Owner’s Manual.
All information and specifications in this manual are based upon the latest product information available at the time of print-
ing.
Hino Motors reserves the right to make changes at any time without prior notice.
This manual is divided into 15 sections with a thumb index for each section at the edge of the pages.
Please note that the publications below have also been prepared as relevant service manuals for the components and sys-
tems in this vehicles.
BR07-001 BR07-002
PARKING BRAKE
(MODELS: FC, FD, GD) (MODELS: FG, GH, FL, FM, SG)
SU02-001 SU02-004
SU02-002 SU02-003
SUSPENSION (MODELS: FC, FD, (HENDRICKSON
(MODELS: FL, FM) (MODEL: SG)
GD, FG, GH) HAS 230)
CAB CA02-001
DN03-004
DN03-001
DN03-002 DN03-003 (ELECTROMAG-
BRAKE CONTROL (ABS+ES START:
(ABS: WABCO) (ES START) NETIC
DENSO)
RETARDER)
DN06-001 DN06-002
OTHERS
(CAN COMMUNICATION) (HEADLIGHT AUTOLEVELING)
+0&':HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧣ᤨ㧠㧤ಽ
EXHAUST BRAKE
RETARDER BRAKE
PARKING BRAKE
POWER STEERING
AXLE EQUIPMENT
FRONT AXLE
REAR AXLE
SUSPENSION EQUIPMENT
SUSPENSION
CHASSIS EQUIPMENT
CHASSIS FRAME
PINTLE HOOK
CAB EQUIPMENT
ELECTRICAL EQUIPMENT
ELECTRIC WIRE
+0&':HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧣ᤨ㧠㧤ಽ
+0&':HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧣ᤨ㧠㧤ಽ
ENGINE CONTROL
FUEL CONTROL
BRAKE CONTROL
SUSPENSION CONTROL
OTHERS
+0&':HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧣ᤨ㧠㧤ಽ
2A$4AAOQMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧢ᣣᦐޓᣣޓඦ೨㧝㧜ᤨ㧠㧝ಽ
EXHAUST BRAKE
BR05
BR05-001
BRAKE CYLINDER
(MODELS: EXCEPT FOR FM2P) .............BR05-4
DATA AND SPECIFICATIONS........................ BR05-4
DESCRIPTION ................................................ BR05-4
COMPONENT LOCATOR ............................... BR05-5
OVERHAUL ..................................................... BR05-6
INSPECTION AND REPAIR ............................ BR05-6
ADJUSTMENT................................................. BR05-7
SHTS06Z080500001
TROUBLESHOOTING
EN06Z0805F300001
ADJUSTMENT
EN06Z0805H300001
SHTS06Z080500002
SHTS06Z080500003
SHTS06Z080500004
2A$4AAOQMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧞ಽ
DESCRIPTION
EN06Z0805C100001
SHTS06Z080500005
COMPONENT LOCATOR
EN06Z0805D100001
SHTS06Z080500006
1 Arm 8 Lever
2 Bushing 9 Cover
3 Seal ring 10 Valve
4 Plate 11 Shaft
5 Control cylinder 12 Stud
6 Pin 13 Body
7 Clevis
OVERHAUL
EN06Z0805H200001
SHTS06Z080500007
SHTS06Z080500008
9.81 N·m (3) Mark the bolt heads and shaft in the same direction with paint.
SHAFT
(4) Tighten the bolts 60° (1/6 turn) as in step 2.
(5) Make sure that the paint marks face the same direction.
PAINT MARK
SHTS06Z080500009 NOTICE
When adding torque, never untighten the nuts, even if they have
been overtightened.
ADJUSTMENT
EN06Z0805H300003
SHTS06Z080500011
SHTS06Z080500012
SHTS06Z080500013
SHTS06Z080500014
2A$4AAOQMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧢ᣣᦐޓᣣޓඦ೨㧥ᤨ㧡㧢ಽ
DESCRIPTION
EN06Z0805C100002
SHTS06Z080500015
COMPONENT LOCATOR
EN06Z0805D100002
SHTS06Z080500016
1 Bushing 13 O-ring
2 Piston rod 14 Poppet valve
3 Spring seat 15 Poppet valve cover
4 Cylinder 16 Connector
5 Spring 17 Valve housing
6 Collar 18 Valve
7 Piston 19 Liner guide
8 Piston packing 20 Liner
9 Washer 21 Stopper
10 Taper washer 22 Gasket
11 Wave washer 23 Adapter plate
12 Retainer
OVERHAUL
EN06Z0805H200002
(2) Remove the grease, anti-loose agent, anti-seizing agent and car-
bon completely with a scraper or emery paper.
NOTICE
Do not damage the parts.
DIAGRAM
EN06Z0806J100001
SYSTEM DIAGRAM
5
2 3
1 4
8 SCR
To STARTER SW
CIRCUIT
12
5A
5 8
4 6 7
FIELD COIL 2
GND
CONNECTOR
4P
1 TEMP.
SENSOR 1
3 TEMP.
2 SENSOR 2
4 SHILED
CABLE GND
SHTS06Z080600001
2A$4AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧣ᤨ㧡㧞ಽ
DESCRIPTION
EN06Z0806C100001
RETARDER DRUM
POLE
FIELD COIL
EXCITER COIL
EXCITER MAGNET
PROPELLER SHAFT
COIL BRACKET
SHTS06Z080600002
2A$4AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧣ᤨ㧡㧞ಽ
COMPONENT LOCATOR
EN06Z0806D100001
ACCELERATOR SWITCH
CONTROL LEVER
CLUTCH SWITCH
CONTROL UNIT
DRIVE UNIT
SHTS06Z080600003
2A$4AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧣ᤨ㧡㧞ಽ
SHTS06Z080600004
OVERHAUL
EN06Z0806H200001
NOTICE
• The main unit is very hot immediately after operating the
retarder. So, cool down enough the unit before starting the
work.
• If the retarder main unit is fouled with mud or sand, cool the
unit down to about ambient temperature. And then wash the
unit by washer with water or hot water.
SHTS06Z080600007
2A$4AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧣ᤨ㧡㧞ಽ
(2) Remove the universal joint flange fitting nut of transmission and
remove the universal joint flange from the retarder coil assembly.
(3) Remove the retarder coil fitting nut and remove the retarder coil
assembly from the transmission.
SHTS06Z080600008
SHTS06Z080600008
SHTS06Z080600009
SHTS06Z080600010
2A$4AA(%A(&A)&A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧣ᤨ㧡㧞ಽ
PARKING BRAKE
BR07
Parking brake control type Lever type control with control cable
DESCRIPTION
EN06Z0807C100001
SHTS06Z080700001
SHTS06Z080700002
TROUBLESHOOTING
EN06Z0807F300001
SPECIAL TOOL
EN06Z0807K100001
Prior to starting a parking brake adjustment, it is necessary to have the special tool.
COMPONENT LOCATOR
EN06Z0807D100001
PARKING BRAKE
SHTS06Z080700004
1 Grommet 8 Bracket
2 Brake drum 9 Cam lever
3 Return spring 10 Lock pin
4 Camshaft 11 Dust cover
5 Anchor pin retainer 12 Cam lever return spring
6 Anchor bracket 13 Brake shoe assembly
7 Shoe adjuster
SHTS06Z080700005
SHTS06Z080700006
1 Knob 6 Spacer
2 Compression spring 7 Pawl
3 Lever assembly 8 Pawl release rod
4 Bushing 9 Parking brake sensor assembly (If so equipped)
5 Parking brake switch
OVERHAUL
EN06Z0807H200001
SHTS06Z080700007
SHTS06Z080700008
SHTS06Z080700009
2A$4AA(%A(&A)&A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧝㧢ಽ
SHTS06Z080700010
SHTS06Z080700011
DIMENSION A
SHTS06Z080700012
2A$4AA(%A(&A)&A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧣ᤨ㧡㧞ಽ
Unit: mm {in.}
ADJUSTMENT
EN06Z0807H300002
INSPECTION HOLE
SHTS06Z080700016
SHTS06Z080700017
SHTS06Z080700018
(5) Pull the parking brake lever fully to three times and release the
lever. Turn the drum by hand to see that the shoes are not drag-
ging. If there is any dragging, repeat the operation from step 1.
SHTS06Z080700019
2A$4AA(%A(&A)&A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧣ᤨ㧡㧞ಽ
SHTS06Z080700019
(2) Adjust the clearance "A" between cable and cam lever on the
parking brake to 1-2 mm {0.040-0.078 in.} by turning the adjusting
CAM LEVER
A
nut.
LOCK NUT
CABLE
ADJUSTING
NUT
SHTS06Z080700020
(3) Pull the parking brake lever with 294 N {30 kgf, 66.14 lbf} force
and make sure that the lever stroke is within assembly standard.
Then lock the adjusting nut with the lock nut.
Assembly standard: 8-11 notches
SHTS06Z080700019
(4) Pull the parking brake lever fully to three times and release the
lever. Turn the drum by hand to see that the shoes are not drag-
ging. If there is any dragging, repeat the operation from step 1.
SHTS06Z080700021
2A$4AA()A)*A(.A(/A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧢ᣣᦐޓᣣޓඦ೨㧝㧜ᤨ㧜ಽ
BR07-002
PARKING BRAKE.....................................BR07-2
DATA AND SPECIFICATIONS........................ BR07-2
DESCRIPTION ................................................ BR07-2
TROUBLESHOOTING..................................... BR07-6
SPECIAL TOOL ............................................... BR07-6
COMPONENT LOCATOR ............................... BR07-7
OVERHAUL ................................................... BR07-12
INSPECTION AND REPAIR .......................... BR07-14
ADJUSTMENT............................................... BR07-15
2A$4AA()A)*A(.A(/A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧞㧠ಽ
PARKING BRAKE
DATA AND SPECIFICATIONS
EN06Z0807I200001
Parking brake control type Lever type control with control cable
DESCRIPTION
EN06Z0807C100001
SHTS06Z080700001
SHTS06Z080700002
SHTS06Z080700003
SHTS06Z080700004
TROUBLESHOOTING
EN06Z0807F300001
SPECIAL TOOL
EN06Z0807K100001
Prior to starting a parking brake adjustment, it is necessary to have the special tool.
COMPONENT LOCATOR
EN06Z0807D100001
A
10
5
6
3 1
13
4
2
3
9 3
3
11 13
B
7
8
12
SHTS06Z080700006
D
10
6
3 1
13
4
2
3
9 3
3
11 13
B
7
8
12
SHTS06Z080700007
SHTS06Z080700008
SHTS06Z080700009
SHTS06Z080700010
OVERHAUL
EN06Z0807H200001
SHTS06Z080700011
SHTS06Z080700012
SHTS06Z080700012
2A$4AA()A)*A(.A(/A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧞㧠ಽ
2. LUBRICATION
(1) Apply heat resistance grease on rubbing or matching faces of
brake shoes, camshaft, shoe adjuster and position the adjuster in
place.
SHTS06Z080700013
SHTS06Z080700014
SHTS06Z080700015
SHTS06Z080700016
2A$4AA()A)*A(.A(/A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧞㧠ಽ
DIMENSION A
SHTS06Z080700017
Unit: mm {in.}
5.75 3.1
{0.2264} {0.1220}
Model: FM2P
ADJUSTMENT
EN06Z0807H300002
SHTS06Z080700022
SHTS06Z080700023
(5) Pull the parking brake lever fully to three times and release the
lever. Turn the drum by hand to see that the shoes are not drag-
ging. If there is any dragging, repeat the operation from step 1.
SHTS06Z080700024
2A$4AA()A)*A(.A(/A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧞㧠ಽ
SHTS06Z080700024
(2) Adjust the clearance "A" between cable and cam lever on the
parking brake to 1-2 mm {0.040-0.078 in.} by turning the adjusting
CAM LEVER
A
nut.
LOCK NUT
CABLE
ADJUSTING
NUT
SHTS06Z080700025
(3) Pull the parking brake lever with 294 N {30 kgf, 66.14 lbf} force
and make sure that the lever stroke is within assembly standard.
Then lock the adjusting nut with the lock nut.
Assembly standard: 8-11 notches
SHTS06Z080700024
(4) Pull the parking brake lever fully to three times and release the
lever. Turn the drum by hand to see that the shoes are not drag-
ging. If there is any dragging, repeat the operation from step 1.
SHTS06Z080700026
2A54AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧣ᤨ㧡㧢ಽ
STEERING EQUIPMENT
SR01
SR01-001
STEERING SYSTEM
TROUBLESHOOTING
EN07Z0701F300001
STEERING UNIT
SR02
SR02-001
STEERING LINKAGE
DESCRIPTION
EN07Z0702C100001
SHTS07Z070200001
(REPRESENTATIVE TYPE)
1
3
SHTS07Z070200002
SPECIAL TOOL
EN07Z0702K100001
Prior to starting a steering linkage overhaul, it is necessary to have these special tools.
2 pieces
S0965-71790 GUIDE Models: except for
FC, FD, GD
COMPONENT LOCATOR
EN07Z0702D100001
SHTS07Z070200009
2A54AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧣ᤨ㧡㧢ಽ
G
16
4
6 5 17
3
18
9 19
7
8 20
10
A
F
15 14
13
D
12
C B
11
SHTS07Z070200010
OVERHAUL
EN07Z0702H200001
SHTS07Z070200011
SHTS07Z070200012
SHTS07Z070200013 (6) Fix the rotating part of spiral cable with tape etc. to prevent the
spiral cable from rotating.
NOTICE
Do not use wedges or hit with a hammer.
SHTS07Z070200014
2A54AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
FRONT
SHTS07Z070200016
NOTICE
When there is no lock pin though the spiral cable is new, or when
the seal is cut though there is a lock pin, or when the neutral posi-
tion of the spiral cable gets out of position in reuse, turn the spiral
cable counterclockwise lightly. And turn it back clockwise by 4
rotations at the point of beginning of the hard steering. Then
match the neutral position marks on the upper side of the spiral
cable assembly.
(3) Pass the spiral cable through the steering wheel opening area
and set the steering wheel straight to install it with nut. When the
NEUTRAL POSITION MARK
spiral cable is new, remove the lock pin. When it is reused,
SHTS07Z070200017 remove the tape etc. for fixing the rotation of the spiral cable.
(4) Tighten the set screw for fixing the horn button after pushing it in
by using a torx wrench.
Tightening Torque:
6.5-13.5 N⋅m {66-138 kgf⋅cm, 4.8-9.9 lbf⋅ft}
SHTS07Z070200011
2A54AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧣ᤨ㧡㧢ಽ
SHTS07Z070200018
(4) Put a dust seal on the end and fit it into the groove. Screw in a
A clamp mounting special tool so that its end plane "A" is located 5
5 mm mm {0.1969 in.} above the upper end of the ball stud screw. At
{0.1969 in.} this moment, make sure that the pointed end of the tool is posi-
tioned to the seal groove as the illustration to the left shows.
B
SPECIAL TOOL SST: Guide (S0965-72050)
(5) Insert a clamp from "A" side of the tool and move it to the direction
of B down to the plane "C". Then drop the clamp slowly into the
C
dust seal groove.
(6) After mounting the clamp, make sure that there is no deformation
SHTS07Z070200019 under torsion or running off the edge of the clamp. If such defor-
mation or running out is found, touch it up by using a flat head
screw driver or its equivalent.
NOTICE
• If the dust seal is damaged or the clamp is deformed, replace
them with new one.
• Do not reuse the clamp once used.
(7) After mounting the clamp, fill the lubrication fitting of the drag link
ball joint with chassis grease.
NOTICE
Fill with grease until it flows out from the hole of dust seal.
6. IF NECESSARY, REPLACE THE DRUG LINK DUST SEAL AND
RELAY ROD. (MODELS: EXCEPT FC, FD, GD)
(1) Observe the following procedure when changing the dust seal.
a. Pry off the dust seal with a screw driver.
b. Put 6.5 g {0.23 oz.} of lithium molybdenum grease in the seal.
c. Use the special tools to install the dust seal onto the socket
without damaging it.
SST:
Dust Cover Guide Inner (S0965-71790)
Dust Cover Guide Outer (S0965-71800)
Dust Cover Guide Nut (SZ179-20001)
SHTS07Z070200020
SHTS07Z070200021
2A54AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧣ᤨ㧡㧢ಽ
SHTS07Z070200023
(3) Check the steering wheel free play while engine is idling.
FREE PLAY Wheel Free Play: 15-35 mm {0.591-1.377 in.}
(4) If wheel free play exceeds 15-35 mm {0.591-1.377 in.}, turn the
set screw clockwise to decrease wheel free play and counter-
clockwise to increase it.
! CAUTION
Excessive steering wheel free play may adversely affect vehicle
handling. This can result in personal injury and/or property dam-
age.
SHTS07Z070200024
(5) Measure the steering wheel turning force. Use a spring balancer
to measure the steering wheel turning force.
NOTICE
Measure the steering wheel turning force while the engine is
idling.
Turning force: 20 N {2.0 kgf, 4.4 lbf}
SHTS07Z070200025
2A54AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧣ᤨ㧡㧢ಽ
(6) The steering wheel must be locked securely in any position up,
down, forward and backward.
! CAUTION
Before moving the vehicle, tighten the lever securely and try to
ADJUSTING
LEVER move the steering wheel up and down, and forward and backward
to make sure that it is locked securely. Never try to adjust the
RELEASE steering wheel position while the vehicle is moving. Any adjust-
ment of the steering wheel while driving can cause the driver to
lose control, and result in personal injury and/or property dam-
LOCK age.
SHTS07Z070200026
(7) Check to see that the combination switch is operating properly.
2A54AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧣ᤨ㧡㧢ಽ
POWER STEERING
SR03
SR03-001
AIR BLEEDING
EN07Z0703H200001
SHTS07Z070300001
SHTS07Z070300002
SHTS07Z070300003
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧢ᣣᦐޓᣣޓඦ೨㧝㧜ᤨ㧟ಽ
SHTS07Z070300004
NORMAL
HYDRAULIC TEST
EN07Z0703H300001
SHTS07Z070300006
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
HYDRAULIC TEST
SHTS07Z070300001
SHTS07Z070300007
MODEL "A"
FC, FD 13.5 MPa {138 kgf/cm2, 1,963 lbf/in.2}
GD 13.7 MPa {140 kgf/cm2, 1,992 lbf/in.2}
FG, GH, FL, FM, SG 12.8 MPa {131 kgf/cm2, 1,861 lbf/in.2}
NOTICE
Be careful not to exceed "A".
SHTS07Z070300009
MODEL "B"
12.7-13.5 MPa
FC, FD
{130-138 kgf/cm2, 1,849-1,963 lbf/in.2}
13.0-13.7 MPa
GD
{133-140 kgf/cm2, 1,890-1,992 lbf/in.2}
12.1-12.8 MPa
FG, GH, FL, FM, SG
{124-131 kgf/cm2, 1,759-1,861 lbf/in.2}
(4) If pressure is higher, stop the engine and replace the flow control
valve assembly.
SHTS07Z070300009
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
SHTS07Z070300011
SHTS07Z070300012
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
DESCRIPTION
EN07Z0703C100001
SHTS07Z070300013
SHTS07Z070300014
OPERATION
EN07Z0703C100002
SHTS07Z070300015
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
SHTS07Z070300016
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
SPECIAL TOOL
EN07Z0703K100001
Prior to starting a power steering gear unit overhaul, it is necessary to have this special tool.
COMPONENT LOCATOR
EN07Z0703D100001
SHTS07Z070300018
SHTS07Z070300019
OVERHAUL
EN07Z0703H200002
NOTICE
Observe the following instructions before disassembly and
assembly.
1. All functional parts should be clean. Blow dirty parts off with
dry compressed air, then clean them with volatile metal
cleanser. Never use brushes or cloth.
2. Handle rubber parts, seals, etc., in clean condition. Any worn
part should be replaced immediately.
Volatile metal cleanser may attack rubber parts, so they
should never be used. Always use fluid.
3. For disassembling and assembling, only use the specified
fluid.
4. Never use standard tools in place of special tools and when
using the special tools, read the instruction carefully.
SHTS07Z070300020
SHTS07Z070300197
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
(2) Turn the worm ball nut valve assembly counterclockwise until it
locks so that valve housing raised from gear housing.
(3) Use a spatula to pry open the valve housing and remove the
worm ball nut valve assembly from gear housing.
SHTS07Z070300023
SHTS07Z070300024
SHTS07Z070300025
SHTS07Z070300026
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
(2) Align the center of the ball nut tooth and sector shaft center tooth
then install the sector shaft assembly.
NOTICE
Apply fluid to the serrated part of the sector shaft so that the
housing oil seal will not be damaged.
(3) Tighten the side cover fitting bolt.
(4) Install the adjusting screw lock nut temporary.
(5) Turn the adjusting screw clockwise until the sector shaft tooth
contact with ball nut tooth then hold the adjusting screw lock nut.
SHTS07Z070300027
(6) Turn the adjusting screw counterclockwise fully once then lock
the adjusting screw lock nut.
SHTS07Z070300028
L Backlash
RHD model 197 mm {7.76 in.} 0.04-0.20 mm
LHD model 194 mm {7.64 in.} {0.0016-0.0078 in.}
SHTS07Z070300030
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
Unit: mm {in.}
GD 19.05: 1
Gear ratio Models:
FG, GH, FL, FM, SG 20.2: 1
GD 90 mm {3.543 in.}
Cylinder inside diameter Models:
FG, GH, FL, FM, SG 100 mm {3.937 in.}
DESCRIPTION
EN07Z0703C100003
4 3 2 1
10 9 8 7 6
SHTS07Z070300035
4 3 2 1
6 7 8 9 10
SHTS07Z070300036
OPERATION
EN07Z0703C100004
SHTS07Z070300037
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
SHTS07Z070300038
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
SPECIAL TOOL
EN07Z0703K100002
Prior to starting a power steering gear unit overhaul, it is necessary to have the following special tools.
TOOL ASSEMBLY
S0965-71870
• For 85 mm {3.346 in.}
• For 90-110 mm
{3.544-4.330 in.}
(Used together with tool assem-
bly)
INSERTER ASSEMBLY
A:
For 40 mm {1.575 in.}
S0965-71860
For 45 mm {1.772 in.}
For 48 mm {1.890 in.}
For 53 mm {2.087 in.}
For 58 mm {2.283 in.}
(Used together with inserter
assembly)
A
S0969-91360 NEEDLE
S0965-71840 INSERTER
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
S0965-71850 INSERTER
S0971-21130 BAR
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
COMPONENT LOCATOR
EN07Z0703D100002
A
2
6
B
8
7
7
7
9
10 C
9
11
7
12
3
17
13
14
E 18 15
22 16
19 D
17 13 14 20
7
21
F
SHTS07Z070300049
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
A
2
7
8
7 7
7
9
C 10
9
11
7
12
3 17
13
14
15 18 E
16 22
19
D
20 14 13 17
7
21
F
SHTS07Z070300050
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
OVERHAUL
EN07Z0703H200003
NOTICE
Observe the following instructions before disassembly and
assembly.
1. All functional parts should be clean. Blow dirty parts off with
dry compressed air, then clean them with volatile metal
cleanser. Never use brushes or cloth.
2. Handle rubber parts, seals, etc., in clean condition. Any worn
part should be replaced immediately.
Volatile metal cleanser may attack rubber parts, so they
should never be used. Always use fluid.
3. For disassembling and assembling, only use the specified
fluid.
4. Never use standard tools in place of special tools and when
using the special tools, read the instruction carefully.
SHTS07Z070300051
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
NUT
SHTS07Z070300052
(3) Confirm that the power piston is located in the center, and then
gently tap the output end of the sector shaft with a plastic (or
wooden) hammer to remove the sector shaft assembly and the
side cover together from the steering body.
NOTICE
Never use a steel hammer when removing the sector shaft (as the
PLASTIC HAMMER threads will be damaged).
SHTS07Z070300053
SECTOR SHAFT
SHTS07Z070300054
(5) Remove the O-ring from the groove around the outside of the side
BACK-UP RING cover using the special tool. Then remove the Y-packing from
behind the needle roller bearing and the back-up ring using the
Y-PACKING special tool.
NOTICE
O-RING
It is not necessary to remove the needle bearing unless it is dam-
aged.
SIDE COVER SST: Needle (S0969-91360)
SHTS07Z070300055
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
SHTS07Z070300056
(3) Remove the bolts to remove the worm shaft assembly and valve
housing assembly from the steering body.
NOTICE
• Do not damage the internal surface of the steering body
when removing the worm shaft assembly and valve housing
assembly.
• Do not let the steel balls spring out.
• Never damage the power piston.
BOLT
SHTS07Z070300057
SHTS07Z070300058
(2) Remove the retainer using the special tool. Remove the adjusting
RETAINER screw at the same time.
BAR SST: Bar (S0971-21130)
ADJUSTING SCREW
SHTS07Z070300059
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
SHTS07Z070300060
WRENCH (4) Remove the O-rings fitted on the contact surfaces of the steering
ASSEMBLY
ATTACHMENT body of the valve housing.
ASSEMBLY (5) Attach the valve housing to the attachment assembly, and
remove the previously loosened plug and seal assembly.
SST: Wrench assembly (S0960-31560)
SHTS07Z070300061
(6) Remove the ball bearing and oil seal from the plug and seal
BEARING assembly.
OIL SEAL
PLUG AND
SEAL ASSEMBLY
SHTS07Z070300062
(2) Remove the rotor from the worm shaft assembly, and then
remove the seal ring from the rotor using the special tool.
SEAL RING SST: Needle (S0969-91360)
ROTOR
SHTS07Z070300064
(3) Remove the three seal rings and three O-rings from the valve
SEAL RING (3) housing using the special tool.
SST: Needle (S0969-91360)
O-RING (3)
VALVE HOUSING
SHTS07Z070300065
(3) Remove the seal ring and O-ring from the power piston using the
PISTON
special tool.
SEAL RING SST: Needle (S0969-91360)
O-RING
SHTS07Z070300067
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
SHTS07Z070300068
SHTS07Z070300069
NOTICE
How to tighten the retainer; After fully tightening, back off the
CAULKING TOOL
retainer 180° and then, after retightening it to 4 kgf⋅m, back it off
20°. Ensure the adjusting screw rotates smoothly.
SHTS07Z070300070
SHTS07Z070300071
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
NOTICE
INSERTER ASSEMBLY There are five kinds of inserters as below, and install the back-up
ring using the inserter for the diameter 48 mm {1.890 in.}.
INSERTER
SIDE COVER
Unit: mm {in.}
INSERTER DIAMETER
40 {1.575}
45 {1.772}
SHTS07Z070300072
48 {1.890}
53 {2.087}
58 {2.283}
SEAL RING
SHTS07Z070300073
SHTS07Z070300074
(2) Apply grease to the oil seal and then install the ball bearing.
OIL SEAL
GREASE
SHTS07Z070300075
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
SEAL RING
ROTOR
SHTS07Z070300076
(2) Insert the rotor between the stub shaft and the worm shaft. At this
ROTOR time, assemble it so that the straight pin in the bottom fits in the
rotor notch.
ROTOR NOTCH
SHTS07Z070300077
(3) Fit the guide into the special tool and insert the previously assem-
bled worm shaft assembly into the guide with the input side down.
SST: Tool assembly (S0965-71870)
WORM SHAFT
BEARING CAGE NOTICE
GUIDE
There are two kinds of guide as below, and install worm shaft
STEEL BALL
assembly using the guide for power piston diameter 90-110 mm
TOOL {3.544-4.330 in.}.
ASSEMBLY
Unit: mm {in.}
POWER PISTON DIAMETER
SHTS07Z070300078
85 {3.346}
90-110 {3.544-4.330}
(4) Install the race of bearing side (one side), the bearing cage and
the steel balls, and allow the tool assembly to slide down and set
the balls in position.
(5) Remove the guide and fit the other side race.
SIDE RACE
SIDE RACE
BEARING CAGE
STEEL BALL
SHTS07Z070300079
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
(6) Assemble the valve housing to the worm shaft assembly and pre-
viously assembled bearing sub-assembly by inserting it from the
worm shaft side.
NOTICE
VALVE HOUSING
• When fitting the valve housing, do not damage the seal ring
in the valve housing.
• Inserter (S0965-71850) can be used to form the seal rings of
the valve housing part.
SHTS07Z070300080
(9) Tighten the plug and seal assembly using the special tool.
LOOSEN THE PLUG SST: Wrench assembly (S0960-31560)
AND SEAL ASSEMBLY
BY 180 FOR STUB SHAFT
SUBSEQUENT WORK NOTICE
Check that the stub shaft rotates smoothly and uniformly while
holding the valve housing.
(10) Loosen the plug and seal assembly by approx 180°.
SHTS07Z070300082
(11) Install O-rings in the groove around the outside of the valve hous-
ing and in the oil port recess.
NOTICE
Do not twist the O-rings.
O-RING
O-RING
SHTS07Z070300083
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
SHTS07Z070300084
STEEL BALL
SHTS07Z070300085
(4) Insert the worm shaft and valve housing assembly in the center
PUNCH STEEL BALL hole of the power piston, align the power piston and worm shaft
STUB SHAFT ball races, and drop the remaining steel balls one by one through
PISTON the piston's ball tube hole.
NOTICE
• Drop the steel balls while turning the stub shaft to facilitate
assembly.
• Steel balls sometimes come out of the hole on the other side
of the ball tube after a certain number are inserted. Plug the
hole with a punch to prevent the steel balls from coming out.
• When installing the steel balls, the worm shaft and valve
SHTS07Z070300086 housing assembly must not be drawn out to its extreme posi-
tion, as the steel balls may drop outside the ball race.
(5) After inserting the steel balls in the power piston, insert the ball
BALL TUBE tube into the power piston and fix it using the clip, washer, and
screw.
NOTICE
Always push in the ball tube by hand. Never force or strike it. If
forced or struck, the ball tube may be deformed, the edge may be
nipped, or otherwise damaged, causing malfunctions.
(6) Tighten the screw to the specified torque.
CLIP
SHTS07Z070300087
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
(7) Measure the axial play between the power piston and the worm
B (AXIAL PLAY) shaft assembly.
A
NEUTRAL POSITION F
SHTS07Z070300088
STEERING BODY
SHTS07Z070300089
INSERTER ASSEMBLY
NOTICE
INSERTER There are five kinds of inserters as below, and install the back-up
ring using the inserter for the diameter 58 mm {2.283 in.}.
Unit: mm {in.}
INSERTER DIAMETER
40 {1.575}
45 {1.772}
SHTS07Z070300090
48 {1.890}
53 {2.087}
58 {2.283}
(3) Press fit the oil seal into the steering body using the special tool.
SST: Inserter assembly (S0965-71860)
INSERTER ASSEMBLY
SHTS07Z070300091
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
SHTS07Z070300092
(3) Align the steering body and valve housing oil passage holes and
tighten the bolt to the specified torque.
NOTICE
Insert a bar into the bolt hole to align the body and housing oil
passage holes. Prevent housing rotation to prevent the O-ring
from being cut or dislodged.
SHTS07Z070300200
(4) Tighten the plug and seal assembly (which was previously loos-
ened through 180°) to the specified torque using the wrench
assembly.
WRENCH ASSEMBLY SST: Wrench assembly (S0960-31560)
NOTICE
After applying a thin and uniform coat of liquid gasket to 3-5 whole
threads of the screw part of the plug and seal assembly and tight-
ening it with the indicated torque, apply turning stopper punches
every 180°.
SHTS07Z070300201
Liquid gasket: Equivalent to ThreeBond 1102
DUST COVER
NUT
SHTS07Z070300202
SECTOR SHAFT
SHTS07Z070300203
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
(2) Insert the sector shaft into the steering body so that its gear and
the power piston gear engage in the center.
NOTICE
When inserting the sector shaft, do not let the sector shaft serra-
tion damage the lip of the Y-packing. Damage may affect oil tight-
ness.
SHTS07Z070300204
(3) Assemble the side cover to the steering body using the bolts.
STEERING BODY Tighten them to the specified torque.
SIDE COVER
SHTS07Z070300205
NEUTRAL
POSITION
SHTS07Z070300206
NOTICE
If measurement is not within specification, readjust the backlash
with adjusting screw.
SHTS07Z070300100
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
SHTS07Z070300101
(3) Use a dial gauge to check to see that the sector shaft backlash in
neutral position.
Model L Backlash
GD 226 mm {8.90 in.} 0.05-0.25 mm
FG, GH, FL, FM, SG 270 mm {10.63 in.} {0.002-0.009 in.}
SHTS07Z070300102
SHTS07Z070300103
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
METALLIC PARTS
Steering body • The internal surface of the cyl- Repair or replace the steering body if there is evi-
inder dence of abrasion or stepped wear. Check visu-
ally and by touch for any flaws that may affect
smooth piston stroke.
• Side cover assembly surface Repair or replace the steering body if there is evi-
dence of any flaws, rust or gouging that may
affect oil tightness (check visually and by touch).
• Y-packing groove in the sector Repair or replace the steering body if there is evi-
shaft hole dence of any flaws, rust or gouging that may
affect oil tightness (check visually and by touch).
• Gear shaft and serrations Check for cracks using magnetic-particle test
equipment and a color penetration test. Replace
any cracked parts.
• Needle roller bearing contact Check for wear, flaws or gouging (visually and by
surface touch). Repair or replace if necessary.
Power piston • Cylinder contact surface Any wear or abrasion that affects smooth piston
stroke must be corrected, or the power piston
must be replaced.
• Steel ball race surface Any wear or flaw that disturbs smooth rotation
and movement of steel balls must be corrected,
or the race must be replaced. (Visual inspection)
• Seal ring and O-ring Replace the seal ring or O-ring if any flaws or
tears affecting oil tightness are found.
Ball tube • Steel ball rotation surface Replace the ball tube if any wear, flaws or goug-
ing that affect smooth ball rotation are found on
the inside at the tube.
Worm shaft • Steel ball race surface Repair or replace the race if any wear, flaws or
(stub shaft) pits that affect smooth ball rotation are found.
• Y-packing contact surface Any wear, flaw, rust, or gouge which may affect
oil tightness must be corrected or the packing
must be replaced.
• Thrust bearing (steel ball) con- Check the bearing for wear, flaws or pits if shaft
tact surface rotation is stiff or uneven. Repair or replace if
found.
Thrust bearing • Bearing race and steel ball Check the bearing for wear, flaws or pits if shaft
(steel ball) rotation is stiff or uneven. Repair or replace if
and bearing cage found.
Rotor • External surface Repair or replace the rotor if any wear, flaws or
gouging affecting smooth rotation are found.
• Seal ring groove Replace the seal ring if any flaws or tears affect-
ing oil tightness are found.
Side cover • Steering body contact surface Repair or replace the side cover if any flaws,
gouging or rust affecting oil tightness are found.
Plug and seal • Thrust bearing side race con- Repair or replace the plug and seal assembly if
assembly tact surface any flaws, rust or gouging affecting uniform tight-
ening are found.
• Y-packing press fitted section Replace the plug and seal assembly if any flaws,
rust or gouging affecting oil tightness are found.
• O-ring contact surface Replace the plug and assembly if any flaws, rust
or gouging affecting oil tightness are found.
Flow rate 11-13 L/min. {2.91-3.42 U.S.gal., 2.42-2.85 lmp.gal.} at 1,000 r/min.
DESCRIPTION
EN07Z0703C100005
SHTS07Z070300104
OPERATION
EN07Z0703C100006
SHTS07Z070300105
COMPONENT LOCATOR
EN07Z0703D100003
SHTS07Z070300106
SHTS07Z070300107
OVERHAUL
EN07Z0703H200004
SHTS07Z070300108
SHTS07Z070300109
(5) Remove the rotor, vane, cam ring and dowel from the pump body.
SHTS07Z070300110
(6) Lightly tap the pump body on the wooden block and remove the
side plate and spring seat.
SHTS07Z070300111
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
SHTS07Z070300208
(2) Using a press, press out the pump shaft with drive gear and ball
bearing.
SHTS07Z070300113
SHTS07Z070300114
(2) Using a retainer ring pliers, remove the retainer ring from the
pump shaft.
(3) Using a press, press out the ball bearing.
SHTS07Z070300115
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
(4) Using a press, press the pump shaft into the ball bearing.
Press fit dimension: 21.4-21.7 mm {0.8426-0.8543 in.}
NOTICE
Install the ball bearing with the blue oil seal facing outside of the
pump.
(5) Install the retainer ring.
NOTICE
Make sure that the retainer ring seats in place.
SHTS07Z070300116
(6) Using a press, press the pump shaft into the drive gear.
NOTICE
• Bring the pump shaft flush with the drive gear.
• Take care to prevent tilt of the pump shaft.
SHTS07Z070300117
SHTS07Z070300118
(2) Using a suitable rod and a press, press the oil seal into the pump
body.
Press fit depth: 3.6-3.9 mm {0.1418-0.1535 in.}
NOTICE
• Make sure that oil seal is installed in the correct direction.
• To prevent oil leakage from oil seal due to lip wear, apply lith-
ium base grease to "A" and "B".
SHTS07Z070300119
SHTS07Z070300120
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
SHTS07Z070300121
SHTS07Z070300122
SHTS07Z070300123
SHTS07Z070300124
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
SHTS07Z070300125
SHTS07Z070300127
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
Unit: mm {in.}
Thickness:
1.965-1.972
{0.0774-0.0776}
Length:
15.953-15.973
{0.6281-0.6288}
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧢ᣣᦐޓᣣޓඦ೨㧝㧜ᤨ㧡ಽ
DESCRIPTION
EN07Z0703C100007
SHTS07Z070300138
OPERATION
EN07Z0703C100008
SHTS07Z070300105
COMPONENT LOCATOR
EN07Z0703D100004
SHTS07Z070300139
OVERHAUL
EN07Z0703H200005
SHTS07Z070300140
SHTS07Z070300141
SHTS07Z070300142
SHTS07Z070300143
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
REPLACEMENT
SHTS07Z070300144
SHTS07Z070300145
SHTS07Z070300146
(4) Using a pair of snap ring pliers, install the retainer ring.
SHTS07Z070300147
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
SHTS07Z070300148
SHTS07Z070300149
SHTS07Z070300150
SHTS07Z070300151
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
SHTS07Z070300152
SHTS07Z070300153
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
Flow rate 15-19 L/min. {3.97-5.01 U.S.gal, 3.30-4.17 lmp.gal} at 2,000 r/min.
DESCRIPTION
EN07Z0703C100009
SHTS07Z070300160
OPERATION
EN07Z0703C100010
SHTS07Z070300161
COMPONENT LOCATOR
EN07Z0703D100005
SHTS07Z070300162
OVERHAUL
EN07Z0703H200006
SHTS07Z070300163
SHTS07Z070300164
SHTS07Z070300165
SHTS07Z070300166
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧢ᣣᦐޓᣣޓඦ೨㧝㧜ᤨ㧣ಽ
SHTS07Z070300167
REPLACEMENT
SHTS07Z070300168
(2) Use a press, press out the ball bearing.
SHTS07Z070300169
(3) Use a press to press in the ball bearing.
SHTS07Z070300170
(4) Use a pair of snap ring pliers to install the retainer ring.
SHTS07Z070300171
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧢ᣣᦐޓᣣޓඦ೨㧝㧜ᤨ㧣ಽ
SHTS07Z070300209
SHTS07Z070300173
I A B C
Match mark
II A B C
SHTS07Z070300210
(2) Install the spring and the flow control valve assembly, and tighten
the plug.
NOTICE
Apply lithium base grease to an O-ring.
SHTS07Z070300175
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧢ᣣᦐޓᣣޓඦ೨㧝㧜ᤨ㧣ಽ
SHTS07Z070300176
SHTS07Z070300177
SHTS07Z070300178
SHTS07Z070300179
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧢ᣣᦐޓᣣޓඦ೨㧝㧜ᤨ㧣ಽ
SHTS07Z070300180
(3) Using a press, press in the pump cover and then install the
retainer ring securely.
NOTICE
• Be careful to see that the O-ring is not pinched by the rear
cover.
• With the pump cover pressed in completely fit the retainer
ring to pump body.
SHTS07Z070300181
SHTS07Z070300182
2A54AA0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧤ᤨ㧡㧢ಽ
SHTS07Z070300190
COMPONENT LOCATOR
EN07Z0703D100006
SHTS07Z070300191
OVERHAUL
EN07Z0703H200007
SHTS07Z070300193
COMPONENT LOCATOR
EN07Z0703D100007
SHTS07Z070300194
OVERHAUL
EN07Z0703H200008
AX02-001
Camber 0°-2°
DESCRIPTION
EN0860802C100001
SHTS086080200001
TROUBLESHOOTING
EN0860802F300001
SPECIAL TOOL
EN0860802K100001
Prior to starting a front axle overhaul, it is necessary to have these special tools.
S0984-92001 HANDLE
S0965-41080 PLATE
SL110-01210 NUT
2A#:AA.(HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟ಽ
S0971-21080 BAR
2A#:AA.(HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟ಽ
COMPONENT LOCATOR
EN0860802D100001
SHTS086080200011
SHTS086080200012
OVERHAUL
EN0860802H200001
SHTS086080200013
SHTS086080200014
SHTS086080200015
SHTS086080200016
2A#:AA.(HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟ಽ
SHTS086080200017
SHTS086080200018
SHTS086080200019
2A#:AA.(HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟ಽ
SHTS086080200020
LEFT L Silver
SHTS086080200021
SHTS086080200022
SHTS086080200024
8. GREASING
(1) Before assembling, apply wheel hub bearing grease to the follow-
ing parts as shown in the figure.
SHTS086080200026
SHTS086080200027
2A#:AA.(HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧢ᤨ㧞㧞ಽ
SHTS086080200028
SHTS086080200029
(2) Strike the wheel hub with a copper hammer to properly seat the
wheel hub, and check the return of the bearing. (Check that the
hub can be turned by hands, and the nut cannot be turned by
hands.)
(3) Measure the wheel bearing preload and adjust the preload with
the lock nut, if it exceeds or is less than that specified below.
Assembly standard:
Turning Torque
1.97-4.90 {20-50, 1.5-3.6}
N⋅m {kgf⋅cm, lbf⋅ft}
Spring balancer reading
17.6-43.1 {1.8-4.4, 4.0-9.7}
N {kgf, lbf}
SHTS086080200030
SHTS086080200031
2A#:AA.(HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟ಽ
SHTS086080200032
SHTS086080200034
SHTS086080200035
SHTS086080200036
SHTS086080200037
2A#:AA.(HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟ಽ
Unit: mm {in.}
AX02-002
Camber 0°-2°
DESCRIPTION
EN0861302C100001
SHTS086130200001
TROUBLESHOOTING
EN0861302F300001
SPECIAL TOOL
EN0861302K100001
Prior to starting a front axle overhaul, it is necessary to have these special tools.
S0984-92001 HANDLE
S0965-41080 PLATE
SL110-01210 NUT
S0971-21100 BAR
2A#:AA.(KHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟ಽ
COMPONENT LOCATOR
EN0861302D100001
SHTS086130200012
2A#:AA.(KHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟ಽ
OVERHAUL
EN08613022300001
SHTS086130200013
SHTS086130200014
SHTS086130200015
SHTS086130200016
2A#:AA.(KHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟ಽ
SHTS086130200017
SHTS086130200018
SHTS086130200019
SHTS086130200020
2A#:AA.(KHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟ಽ
SHTS086130200021
NOTICE
When assembling the brake drum and wheel hub, make sure that
their aligning marks are oriented as closely to each other as pos-
sible.
SHTS086130200022
SHTS086130200023
SHTS086130200025
SHTS086130200026
9. GREASING
(1) Before assembling, apply wheel hub bearing grease to the follow-
ing parts as shown in the figure.
SHTS086130200028
2A#:AA.(KHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧣ᤨ㧞㧢ಽ
SHTS086130200029
SHTS086130200030
SHTS086130200031
(2) Strike the wheel hub with a copper hammer to properly seat the
wheel hub, and check the return of the bearing. (Check that the
hub can be turned by hands, and the nut cannot be turned by
hands.)
(3) Measure the wheel bearing preload. If it exceeds or it is less than
the standard value shown below, adjust the preload with the lock
nut.
Assembly Standard:
Turning Torque
3.93-6.37 {40-65, 2.9-4.6}
N⋅m {kgf⋅cm, lbf⋅ft}
Spring balancer reading
23.5-38.0 {2.4-3.9, 5.3-8.6}
N {kgf, lbf}
SHTS086130200032
2A#:AA.(KHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟ಽ
SHTS086130200033
SHTS086130200034
SHTS086130200036
SHTS086130200037
SHTS086130200038
SHTS086130200039
2A#:AA.(KHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟ಽ
Unit: mm {in.}
AX02-003
Camber 0°-2°
DESCRIPTION
EN0861102C100001
SHTS086110200001
TROUBLESHOOTING
EN0861102F300001
SPECIAL TOOL
EN0861102K100001
Prior to starting a front axle overhaul, it is necessary to have these special tools.
S0984-92001 HANDLE
S0965-41080 PLATE
SL110-01210 NUT
S0971-21100 BAR
2A#:AA.(HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧠ಽ
COMPONENT LOCATOR
EN0861102D100001
SHTS086110200013
OVERHAUL
EN08611022300001
SHTS086110200014
SHTS086110200015
SHTS086110200016
SHTS086110200017
2A#:AA.(HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧠ಽ
SHTS086110200018
SHTS086110200019
SHTS086110200020
LEFT L Silver
NOTICE
• After tightening the hub bolts and nuts, caulk each at 2
points with a punch.
• If the wheel hub and brake drum are disassembled to replace
the hub bolts, reassemble them so that their aligning marks
are oriented as closely to each other as possible.
SHTS086110200021
2A#:AA.(HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧠ಽ
SHTS086110200022
SHTS086110200024
SHTS086110200025
2A#:AA.(HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧠ಽ
8. GREASING
(1) Before assembling, apply wheel hub bearing grease to the follow-
ing parts as shown in the figure.
SHTS086110200027
SHTS086110200028
2A#:AA.(HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧠ಽ
SHTS086110200029
SHTS086110200030
(2) Strike the wheel hub with a copper hammer to properly seat the
wheel hub, and check the return of the bearing. (Check that the
hub can be turned by hands, and the nut cannot be turned by
hands.)
(3) Measure the wheel bearing preload. If it exceeds or it is less than
the standard value shown below, adjust the preload with the lock
nut.
Assembly Standard:
Turning Torque
3.93-6.37 {40-65, 2.9-4.6}
N⋅m {kgf⋅cm, lbf⋅ft}
Spring balancer reading
27.5-44.1 {2.8-4.5, 6.2-9.9}
N {kgf, lbf}
SHTS086110200031
SHTS086110200032
SHTS086110200033
SHTS086110200034
SHTS086110200035
SHTS086110200036
SHTS086110200037
SHTS086110200038
2A#:AA.(HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧠ಽ
Unit: mm {in.}
AX02-004
Camber 0°-2°
DESCRIPTION
EN0861202C100001
SHTS086120200001
TROUBLESHOOTING
EN0861202F300001
SPECIAL TOOL
EN0861202K100001
Prior to starting a front axle overhaul, it is necessary to have these special tools.
S0984-92001 HANDLE
S0965-41080 PLATE
SL110-01210 NUT
S0971-21100 BAR
2A#:AA.(A+HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧢ᤨ㧞㧤ಽ
COMPONENT LOCATOR
EN0861202D100001
SHTS086120200013
OVERHAUL
EN08612022300001
SHTS086120200014
SHTS086120200015
SHTS086120200016
SHTS086120200017
2A#:AA.(A+HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧢ᤨ㧞㧤ಽ
SHTS086120200018
SHTS086120200019
SHTS086120200020
SHTS086120200018
NOTICE
When assembling the brake drum and wheel hub, make sure that
their aligning marks are oriented as closely to each other as pos-
sible.
SHTS086120200022
SHTS086120200023
SHTS086120200025
SHTS086120200026
9. GREASING
(1) Before assembling, apply wheel hub bearing grease to the follow-
ing parts as shown in the figure.
SHTS086120200028
SHTS086120200029
2A#:AA.(A+HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧢ᤨ㧞㧤ಽ
SHTS086120200031
SHTS086120200030
(2) Strike the wheel hub with a copper hammer to properly seat the
wheel hub, and check the return of the bearing. (Check that the
hub can be turned by hands, and the nut cannot be turned by
hands.)
(3) Measure the wheel bearing preload. If it exceeds or it is less than
the standard value shown below, and adjust the preload with the
lock nut.
Assembly Standard:
Turning Torque
3.93-6.37 {40-65, 2.9-4.6}
N⋅m {kgf⋅cm, lbf⋅ft}
Spring balancer reading
23.5-38.0 {2.4-3.9, 5.3-8.6}
N {kgf, lbf}
SHTS086120200032
SHTS086120200033
SHTS086120200034
SHTS086120200035
SHTS086120200036
SHTS086120200037
SHTS086120200038
SHTS086120200039
2A#:AA.(A+HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧢ᤨ㧞㧤ಽ
Unit: mm {in.}
AX02-005
Camber 0°-2°
DESCRIPTION
EN0861402C100001
SHTS086140200001
TROUBLESHOOTING
EN0861402F300001
SPECIAL TOOL
EN0861402K100001
Prior to starting a front axle overhaul, it is necessary to have these special tools.
S0984-92001 HANDLE
S0965-41080 PLATE
SL110-01210 NUT
S0971-21100 BAR
2A#:AA/(HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧡ಽ
COMPONENT LOCATOR
EN0861402D100001
SHTS086140200013
2A#:AA/(HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧡ಽ
SHTS086140200014
OVERHAUL
EN08614022300001
SHTS086140200015
SHTS086140200016
SHTS086140200017
SHTS086140200018
2A#:AA/(HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧡ಽ
SHTS086140200019
SHTS086140200020
SHTS086140200021
LEFT L Silver
NOTICE
• After tightening the hub bolts and nuts, caulk each at 2
points with a punch.
• If the wheel hub and brake drum are disassembled to replace
the hub bolts, reassemble them so that their aligning marks
are oriented as closely to each other as possible.
SHTS086140200022
2A#:AA/(HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧡ಽ
SHTS086140200023
SHTS086140200025
SHTS086140200026
2A#:AA/(HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧡ಽ
8. GREASING
(1) Before assembling, apply wheel hub bearing grease to the follow-
ing parts as shown in the figure.
SHTS086140200028
SHTS086140200029
2A#:AA/(HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧡ಽ
SHTS086140200031
SHTS086140200030
(2) Strike the wheel hub with a copper hammer to properly seat the
wheel hub.
(3) Measure the wheel bearing preload. If it exceeds or it is less than
the standard value shown below, and adjust the preload with the
lock nut.
Assembly Standard:
Turning Torque
3.93-6.37 {40-65, 2.9-4.6}
N⋅m {kgf⋅cm, lbf⋅ft}
Spring balancer reading
27.5-44.1 {2.8-4.5, 6.2-9.9}
N {kgf, lbf}
SHTS086140200032
SHTS086140200033
SHTS086140200034
SHTS086140200036
SHTS086140200037
SHTS086140200038
SHTS086140200039
2A#:AA/(HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧡ಽ
Unit: mm {in.}
AX02-006
Camber 0°-2°
DESCRIPTION
EN0861502C100001
SHTS086150200001
TROUBLESHOOTING
EN0861502F300001
SPECIAL TOOL
EN0861502K100001
Prior to starting a front axle overhaul, it is necessary to have these special tools.
S0984-92001 HANDLE
S0965-41080 PLATE
SL110-01210 NUT
S0971-21100 BAR
2A#:AA/(A+HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧢ಽ
COMPONENT LOCATOR
EN0861502D100001
SHTS086150200013
2A#:AA/(A+HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧢ಽ
SHTS086150200014
OVERHAUL
EN08615022300001
SHTS086150200015
SHTS086150200016
SHTS086150200017
SHTS086150200018
2A#:AA/(A+HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧢ಽ
SHTS086150200019
SHTS086150200020
SHTS086150200021
SHTS086150200022
2A#:AA/(A+HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧢ಽ
SHTS086150200019
NOTICE
When assembling the brake drum and wheel hub, make sure that
their aligning marks are oriented as closely to each other as pos-
sible.
SHTS086150200023
SHTS086150200024
SHTS086150200026
SHTS086150200027
9. GREASING
(1) Before assembling, apply wheel hub bearing grease to the follow-
ing parts as shown in the figure.
SHTS086150200029
2A#:AA/(A+HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧢ᤨ㧟㧞ಽ
SHTS086150200030
SHTS086150200032
SHTS086150200031
(2) Strike the wheel hub with a copper hammer to properly seat the
wheel hub, and check the return of the bearing. (Check that the
hub can be turned by hands, and the nut cannot be turned by
hands.)
(3) Measure the wheel bearing preload. If it exceeds or it is less than
the standard value shown below, and adjust the preload with the
lock nut.
Assembly Standard:
Turning Torque
3.93-6.37 {40-65, 2.9-4.6}
N⋅m {kgf⋅cm, lbf⋅ft}
Spring balancer reading
23.5-38.0 {2.4-3.9, 5.3-8.6}
N {kgf, lbf}
SHTS086150200033
2A#:AA/(A+HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧢ᤨ㧟㧞ಽ
SHTS086150200034
SHTS086150200035
SHTS086150200037
SHTS086150200038
SHTS086150200039
SHTS086150200040
2A#:AA/(A+HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧢ಽ
Unit: mm {in.}
REAR AXLE
DATA AND SPECIFICATIONS
EN0850403I200001
DESCRIPTION
EN0850403C100001
SHTS085040300001
TROUBLESHOOTING
EN0850403F300001
SPECIAL TOOL
EN0850403K100001
Prior to starting a rear axle overhaul, it is necessary to have these special tools.
S0984-91601
HANDLE
S0984-92001
COMPONENT LOCATOR
EN0850403D100001
SHTS085040300006
OVERHAUL
EN0850403H200001
SHTS085040300007
NOTICE
The wheel hub assembly is heavy, therefore be careful when han-
dling it.
SHTS085040300008
SHTS085040300009
SHTS085040300010
(2) Using a tapping rod and a hammer or a press, install the outer
race.
SHTS085040300011
NOTICE
Caulk the lock nuts at two points after tightening to the specified
SHTS085040300012
torque.
2A#:AA5*A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧣ಽ
3. GREASING
(1) Pack sufficient amount of wheel hub bearing grease between the
bearing rollers.
NOTICE
"1": Fill the grease to spaces among the inner race, rollers and
retainer to the extent that there is not any vacancy remained.
SHTS085040300013
SHTS085040300015
(2) Install the wheel hub assembly and the outer wheel hub bearing.
NOTICE
• Using a tool as shown simplifies installation.
• The wheel hub assembly is heavy, therefore be careful when
handling it.
SHTS085040300016
2A#:AA5*A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧢ᤨ㧟㧠ಽ
Tightening Torque:
588-882 N⋅m {6,000-9,000 kgf⋅cm, 433-650 lbf⋅ft}
SHTS085040300007
(2) Strike the wheel hub with a copper hammer to properly seat the
wheel hub.
SHTS085040300017
(3) Measure the wheel bearing preload and adjust the preload with
the lock nut, if it exceeds or is less than that specified below.
Assembly standard:
Turning Torque
4.0-5.4 {39-53, 2.9-4.0}
N⋅m {kgf⋅cm, lbf⋅ft}
Spring balancer reading
36.0-48.6 {3.6-4.8, 7.9-10.5}
N {kgf, lbf}
SHTS085040300018
SHTS085040300019
AX03-002
REAR AXLE
DATA AND SPECIFICATIONS
EN0851403I200001
DESCRIPTION
EN0851403C100001
SHTS085140300001
TROUBLESHOOTING
EN0851403F300001
SPECIAL TOOL
EN0851403K100001
Prior to starting a rear axle overhaul, it is necessary to have these special tools.
S0984-91601
HANDLE
S0984-92001
COMPONENT LOCATOR
EN0851403D100001
1
2
3
X
5
12 10 6
7
8
14 1
13 9
B
A
11
E
D
14
15
16
X
18
C G
17
SHTS085140300006
OVERHAUL
EN0851403H200001
SHTS085140300007
SHTS085140300008
NOTICE
The wheel hub assembly is heavy, therefore be careful when han-
dling it.
SHTS085140300009
SHTS085140300010
2A#:AA5*A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧣ಽ
SHTS085140300011
(2) Using a tapping rod and a hammer or a press, install the outer
race.
SHTS085140300012
3. GREASING.
(1) Pack sufficient amount of wheel hub bearing grease between the
bearing rollers.
NOTICE
"1": Fill the grease to spaces among the inner race, rollers and
retainer to the extent that there is not any vacancy remained.
SHTS085140300014
2A#:AA5*A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧞ᣣᦐᧁޓᣣޓඦᓟ㧢ᤨ㧟㧣ಽ
SHTS085140300016
(2) Install the wheel hub assembly and the outer wheel hub bearing.
NOTICE
• Using a tool as shown simplifies installation.
• The wheel hub assembly is heavy, therefore be careful when
handling it.
SHTS085140300017
Tightening Torque:
588-882 N⋅m {6,000-9,000 kgf⋅cm, 434-650 lbf⋅ft}
SHTS085140300018
2A#:AA5*A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧢ᣣᦐޓᣣޓඦ೨㧝㧝ᤨ㧞㧞ಽ
(2) Strike the wheel hub with a copper hammer to properly seat the
wheel hub.
SHTS085140300019
(3) Measure the wheel bearing preload and adjust the preload with
the lock nut, if it exceeds or is less than that specified below.
Assembly standard:
Turning Torque 3.9-5.9
N⋅m {kgf⋅cm, lbf⋅ft} {40-60, 2.9-4.4}
ISO type 23.3-35.2
Spring balancer reading wheel hub {2.4-3.5, 5.2-7.9}
N {kgf, lbf} JIS type 27.4-41.4
wheel hub {2.8-4.2, 6.2-9.3}
SHTS085140300020
SHTS085140300021
SHTS085140300007
REAR AXLE
DATA AND SPECIFICATIONS
EN0851203I200001
DESCRIPTION
EN0851203C100001
SHTS085120300001
TROUBLESHOOTING
EN0851203F300001
SPECIAL TOOL
EN0851203K100001
Prior to starting a rear axle overhaul, it is necessary to have these special tools.
S0984-91601
HANDLE
S0984-92001
2A#:AA5*A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧝㧝ಽ
COMPONENT LOCATOR
EN0851203D100001
(REPRESENTATIVE TYPE)
21
1
2 9 4
3
20 G
4 5
6
11 7 8
H
F
12
14
10 13
16
15
1
9
B
11 5
12 6
13
E 7
8
D A
16 17
18
X
19 C
SHTS085120300006
OVERHAUL
EN0851203H200001
SHTS085120300007
SHTS085120300008
NOTICE
The wheel hub assembly is heavy, therefore be careful when han-
dling it.
SHTS085120300009
SHTS085120300010
2A#:AA5*A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧝㧝ಽ
SHTS085120300011
(2) Using a tapping rod and a hammer or a press, install the outer
race.
SHTS085120300012
NOTICE
SHTS085120300013 Caulk the lock nuts at two points after tightening to the specified
torque. (Only models for Hong Kong and Taiwan)
2A#:AA5*A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧝㧝ಽ
3. GREASING
(1) Pack sufficient amount of wheel hub bearing grease between the
bearing rollers.
NOTICE
"1": Fill the grease to spaces among the inner race, rollers and
retainer to the extent that there is not any vacancy remained.
SHTS085120300014
SHTS085120300016
(2) Install the wheel hub assembly and the outer wheel hub bearing.
NOTICE
• Using a tool as shown simplifies installation.
• The wheel hub assembly is heavy, therefore be careful when
handling it.
SHTS085120300017
2A#:AA5*A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧢ᣣᦐޓᣣޓඦ೨㧝㧝ᤨ㧞㧠ಽ
Tightening Torque:
588-1,176 N⋅m {6,000-12,000 kgf⋅cm, 434-868 Ibf⋅ft}
SHTS085120300008
(2) Strike the wheel hub with a copper hammer to properly seat the
wheel hub.
SHTS085120300018
SHTS085120300020
REAR AXLE
DATA AND SPECIFICATIONS
EN0851503I200001
DESCRIPTION
EN0851503C100001
SHTS085150300001
SHTS085150300002
TROUBLESHOOTING
EN0851503F300001
SPECIAL TOOL
EN0851503K100001
Prior to starting a rear axle overhaul, it is necessary to have these special tools.
S0984-91601
HANDLE
S0984-92001
COMPONENT LOCATOR
EN0851503D100001
22
1 4
9
3
21 4 5 G
6
7
11 8
12
F 10 13
8
1 9
H 16
11 5
12 6
7
13
B
D A
15 14
20 15
19
C
18
E
17
SHTS085150300007
SHTS085150300008
DEAD AXLE
SHTS085150300009
OVERHAUL
EN0851503H200001
SHTS085150300010
SHTS085150300011
NOTICE
The wheel hub assembly is heavy, therefore be careful when han-
dling it.
SHTS085150300012
SHTS085150300013
2A#:AA5*A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧝㧝ಽ
SHTS085150300014
(2) Using a tapping rod and a hammer or a press, install the outer
race.
SHTS085150300015
NOTICE
SHTS085150300016 Caulk the lock nuts at two points after tightening to the specified
torque. (Only models for Taiwan FG, GH and Thailand FG)
3. GREASING
(1) Pack sufficient amount of wheel hub bearing grease between the
bearing rollers.
NOTICE
"1": Fill the grease to spaces among the inner race, rollers and
retainer to the extent that there is not any vacancy remained.
SHTS085150300017
2A#:AA5*A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧝㧝ಽ
SHTS085150300019
(2) Install the wheel hub assembly and the outer wheel hub bearing.
NOTICE
• Using a tool as shown simplifies installation.
• The wheel hub assembly is heavy, therefore be careful when
handling it.
SHTS085150300020
Tightening Torque:
588-1,176 N⋅m {6,000-12,000 kgf⋅cm, 434-868 lbf⋅ft}
SHTS085150300011
2A#:AA5*A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧢ᣣᦐޓᣣޓඦ೨㧝㧜ᤨ㧝㧣ಽ
(2) Strike the wheel hub with a copper hammer to properly seat the
wheel hub.
SHTS085150300021
SHTS085150300023
SHTS085150300010
AX03-005
REAR AXLE
DATA AND SPECIFICATIONS
EN0851803I200001
DESCRIPTION
EN0851803C100001
SHTS085180300001
TROUBLESHOOTING
EN0851803F300001
SPECIAL TOOL
EN0851803K100001
Prior to starting a rear axle overhaul, it is necessary to have these special tools.
S0984-91601
HANDLE
S0984-92001
COMPONENT LOCATOR
EN0851803D100001
SHTS085180300006
OVERHAUL
EN0851803H200001
SHTS085180300007
SHTS085180300008
NOTICE
The wheel hub assembly is heavy, therefore be careful when han-
dling it.
SHTS085180300009
SHTS085180300010
2A#:AA6*&A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧝㧡ಽ
SHTS085180300011
(2) Using a tapping rod and a hammer or a press, install the outer
race.
SHTS085180300012
SHTS085180300013
3. GREASING
(1) Pack sufficient amount of wheel hub bearing grease between the
bearing rollers.
NOTICE
"1": Fill the grease to spaces among the inner race, rollers and
retainer to the extent that there is not any vacancy remained.
SHTS085180300014
2A#:AA6*&A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧝㧡ಽ
SHTS085180300016
(2) Install the wheel hub assembly and the outer wheel hub bearing.
NOTICE
• Using a tool as shown simplifies installation.
• The wheel hub assembly is heavy, therefore be careful when
handling it.
SHTS085180300017
SHTS085180300008
2A#:AA6*&A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧢ᣣᦐޓᣣޓඦ೨㧝㧝ᤨ㧞㧡ಽ
(2) Strike the wheel hub with a copper hammer to properly seat the
wheel hub, and check the return of the bearing. (Check that the
hub can be turned by hands, and the nut cannot be turned by
hands.)
SHTS085180300018
SHTS085180300020
AX04-001
The figures given in the table are based on the recommendation by European Tire and Rim Technical Organiza-
tion. (E.T.R.T.O.)
*(1). Tire radius given is dynamic effective radius for dual tires, for single tire, deduct 1.0 mm {0.039 in.} from the
figure given.
*(2). The rims with mark (•) are standard and others may be used.
*(3). The max. air pressure and max. load refer to the recommendation by Japan Automobile Tire Manufacturers'
Association. (J.A.T.M.A.)
*(4). The tire is certified by ECE.
*(5). Some vehicle specifications are not applicable to the following table. Refer to the Owner's Manual for
details.
*(6). The tire is certified by GB.
1. Diagonal tires
• 16 x 6.40H
650 1,800 1,700 404
8.25-16-14PR 16 x 6.00S SDC
{6.63, 94} {3,968} {3,747} {15.91}
16 X 6.00GS
*(1)
*(3) 575 1,710 1,630
404 • 16 x 6.00GS
8.25-16-14PR {5.75, 83.4} {3,770} {3,593}
{15.91}
• 20 x 7.00T
725 2,500 2,300 494
9.00R-20-14PR 20 x 6.50T
{7.39, 105} {5,511} {5,071} {19.45}
20 x 7.50V
• 20 x 7.50V
725 2,650 2,430 508 20 x 6.50T
10.00R-20-14PR
{7.39, 105} {5,842} {5,357} {20.00} 20 x 7.00T
20 x 8.00V
• 20 x 8.00V
725 3,000 2,725 523
11.00R-20-14PR 20 x 7.50V
{7.39, 105} {6,614} {6,007} {20.59}
20 x 8.50V
• 20 x 8.00V
800 3,250 2,900 525
11.00R-20-16PR 20 x 7.50V
{8.16, 116} {7,165} {6,393} {20.67}
20 x 8.50V
• 17.5 x 6.00
205/75R17.5 675 1,500 1,400 366
17.5 x 5.25
122/120 {6.88, 81} {3,307} {3,086} {14.41}
17.5 x 6.75
• 22.5 x 7.50
900 2,725 2,500 452
255/70R22.5 22.5 x 6.75
{9.18, 131} {6,007} {5,511} {17.80}
22.5 x 8.25
* *
(3) (1)
900 2,725 2,500
255/70R22.5 453 22.5 x 7.50
{9.18, 131} {6,007} {5,511}
-143/140 {17.83}
• 17.5 x 5.25
600 1,285 1,250 381
8R17.5 117/116 • 17.5 x 6.00
{6.12, 87} {2,833} {2,756} {15.00}
17.5 x 6.75
*
* (1) • 17.5 x 6.00
(3) 625 1,450 1,400
389 16 x 6.00GS
8.5R17.5-12PR {6.25, 91} {3,196} {3,086}
{15.31} SDC
*
* (1)
(3) 725 2,030 1,930 • 22.5 x 6.75
470
9R22.5-14PR {7.25, 105} {4,475} {4,255} 22.5 x 6.00
{18.50}
DESCRIPTION
EN08Z0904C100001
SHTS08Z090400001
SHTS08Z090400002
SHTS08Z090400003
SHTS08Z090400004
SHTS08Z090400005
TROUBLESHOOTING
EN08Z0904F300001
SPECIAL TOOL
EN08Z0904K100001
Prior to starting a wheel and tire overhaul, it is necessary to have these special tools.
S0967-21010 LEVER
S0967-21020 LEVER
S0967-21040 LEVER
S0960-91210 LEVER
PRECAUTIONS
EN08Z0904C100002
! CAUTION
Failure to comply with the following procedures may result in faulty positioning of the tire and/or rim parts, and
can cause the assembly to burst with a explosive force sufficient to cause serious physical injury or death.
2. RIM INSPECTION
(1) Always select the proper tire size and construction to match the rim or wheel rating and size.
(2) Never use damaged, worn, or corroded rims, wheels, or mounting hardware.
(3) Always clean and repaint lightly rusted rims.
(4) Never use a rim or wheel component you cannot identify.
INSPECTION
EN08Z0904H300001
1. GENERAL INSPECTION
(1) Check the tire tread wear (groove depth) and tire damage. If the
slip sign on the tire tread comes out, replace the tire.
Groove depth (Remaining groove)
General running: 1.6 mm {0.063 in.}
High-speed running: 3.2 mm {0.126 in.}
SHTS08Z090400011
SHTS08Z090400012
SHTS08Z090400013
(2) If the wheel rim does not conform to the runout limits, try re-
mounting the wheel in a different position.
(3) If the wheel rim is still not within 1.8 mm {0.072 in.} of runout, then
replace it with a new rim.
(4) If the tire does not conform to runout standards, reinstall it in dif-
ferent position on the rim.
(5) With the special tool, pry the side ring from its groove in the rim by
prying progressively around the tire until the ring is freed.
SST: Lever (S0967-21040)
SHTS08Z090400024
(6) Turn the assembly over and unseat the second tire bead from the
rim. Lift the rim from the tire.
Remove the tube and flap, if any, from the tire.
SHTS08Z090400025
2A#:AA/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧝㧢ಽ
SHTS08Z090400026
(3) With the wide side of the rim down, lubricate the top bead.
(4) With the stops toward the rim, insert the spoon ends of the special
tools about 250 mm {10 in.} apart. Holding the bead in the well
with one foot, pull one tool towards the center of the rim.
SST: Lever (S0960-91210)
SHTS08Z090400027
(5) Hold the tool in position with one foot and pull the second tool
toward the center of the rim. Progressively work the bead off the
rim, taking additional bites with the tools as necessary.
SHTS08Z090400028
SHTS08Z090400029
2A#:AA/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧝㧢ಽ
SHTS08Z090400030
(2) Place the side-ring on the rim base so that the ring split is oppo-
site to the valve stem. Place the leading end of the ring into the
groove in the rim as shown.
SHTS08Z090400031
(3) Starting at the valve side progressively walk the side-ring into
place. Check to ensure that the ring is fully seated in the groove.
SHTS08Z090400032
(4) Place the tire assembly in a safety cage and inflate the tire as pre-
viously described in this chapter. Again check the side-ring, tap-
ping lightly with a mallet to ensure the proper engagement. Check
to see that the beads are properly seated. Completely deflate the
tire to prevent the tube from the buckling. Reinflate according to
the recommended pressure, and check the tire assembly.
SHTS08Z090400033
2A#:AA/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧝㧢ಽ
SHTS08Z090400034
(4) Push the first bead into the well of the rim and onto the rim as far
as possible.
With the special tool, hammer the first bead so that the bead gets
over the rim flange.
SST: Rubber hammer (S0960-91220)
SHTS08Z090400035
(5) Insert the lever between the rim flange and the tire bead and then
raise the lever so that the bead gets over the rim flange.
SST: Lever (S0960-91210)
SHTS08Z090400036
(6) With the special tool, hammer the tire tread so that the bead and
the rim will be seated.
SST: Rubber hammer (S0960-91220)
(7) Inflate the tire as described in this chapter, making certain that all
the safety precautions are followed. Check for the leakage.
SHTS08Z090400037
2A#:AA/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧝㧢ಽ
SHTS08Z090400038
(2) Apply lubricant (engine oil or grease) to the thread part of the hub
bolts and wheel nuts.
SHTS08Z090400039
(3) Rotate the wheel if necessary and check to see that the hub bolts
are in the center of the wheel's hub bolt holes, then tighten the
wheel nuts lightly.
NOTICE
The wheel nuts on the right side of the vehicle have right hand
threads, and those on the left side have left hand threads.
SHTS08Z090400040
2A#:AA/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧝㧢ಽ
(4) Using a wheel nut wrench, tighten the wheel nuts in accordance
with specified torque using diagonal method.
Tightening torque
N⋅m {kgf⋅cm, lbf⋅ft}
490.34-588.39
DIN type
{5,000-6,000, 362-434}
10 stud
392.27-470.71
8 stud
SAE and {4,000-4,800, 290-347}
JIS type 6 stud
235.36-294.19
5 stud
{2,400-3,000, 174-217}
490-539
ISO type
{5,000-5,500, 362-497}
NOTICE
Tighten the wheel nuts with several repetitions in the tightening
order so as to reach the proper torque evenly and gradually.
! CAUTION
SHTS08Z090400041 The specified torque should be referred to the torque tightening
wheel nuts. Tightening it with incorrect can cause the wheel to
come off while driving. This can result in physical injury and/or
property damage due to the loss of vehicle control.
When the vehicle, wheels, or wheel nuts are new, the wheel nuts
should be checked and tightened with specified torque at 50-100
km {30-60 miles} since they may not be well tightened. The tight-
ening torque should be checked with the proper torque wrench.
NOTICE
Block the wheels.
SHTS08Z090400042
(4) On the dual tires, the band spacer will also have to be removed
and then remove the inner wheel.
SHTS08Z090400043
SHTS08Z090400044
(4) Continue prying progressively around the tire until the bead is
completely freed from the rim.
(5) Make a matching marks on the segments.
(6) Place the special tool in the rim joint groove and pry the rim seg-
ments apart.
SST: Lever (S0967-21010)
SHTS08Z090400045
2A#:AA/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧝㧢ಽ
SHTS08Z090400046
(4) Place the other segment on the first one as shown in the figure.
NOTICE
Align the matching marks on the segments.
SHTS08Z090400047
(5) Place the other segment together with the first one.
Fit the segment so that the valve lies against the side of the hole
marked with an arrow.
SHTS08Z090400048
(6) With the special tool, pry the segments to fit the last segment in
position.
SST: Lever (S0967-21020)
NOTICE
Do not pull upwards.
(7) Install the valve core and then inflate the tire as previously
described in this chapter, making sure that all the safety precau-
tions are followed. Check for the leakage.
SHTS08Z090400049
2A#:AA/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧝㧢ಽ
SHTS08Z090400050
SHTS08Z090400051
SHTS08Z090400052
(4) Install the band spacer over the spokes so that it may tightened
up against the inner wheel rim.
The band spacer stopper must be between two spokes. Make
sure that the band spacer stopper does not cover the inner wheel
valve.
SHTS08Z090400053
2A#:AA/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧝㧢ಽ
(5) Install the outer wheel and press it, and then tighten up against
the band spacer. Make sure that the rim stopper and valve are
between two spokes and diagonally to the inner wheel valve.
Install two top clamps and nuts as indicated by the arrows on the
drawing and tighten the nuts lightly.
SHTS08Z090400054
SHTS08Z090400055
SUSPENSION SU02
MODELS: FC, FD
FRONT SUSPENSION
REAR SUSPENSION
MODEL: GD
FRONT SUSPENSION
REAR SUSPENSION
MODELS: FG, GH
FRONT SUSPENSION (MULTI LEAF SPRING)
13 mm 13 mm 13 mm 13 mm
{0.512 in.} {0.512 in.} {0.512 in.} {0.512 in.}
Dimensions of leaf springs:
10 mm 12 mm 10 mm 16 mm
Thickness of leaves
{0.394 in.} {0.472 in.} {0.394 in.} {0.629 in.}
10 mm 10 mm
— —
{0.394 in.} {0.394 in.}
19.5 mm 19.5 mm 21 mm 21 mm
{0.768 in.} {0.768 in.} {0.827 in.} {0.827 in.}
Dimensions of leaf springs:
10 mm 16 mm 10 mm 16 mm
Thickness of leaves
{0.394 in.} {0.629 in.} {0.394 in.} {0.629 in.}
10 mm 10 mm
— —
{0.394 in.} {0.394 in.}
REAR SUSPENSION
DESCRIPTION
EN09A0102C100001
FRONT SUSPENSION
SHTS09A010200001
SHTS09A010200002
SHTS09A010200003
TROUBLESHOOTING
EN09A0102F300001
SPECIAL TOOL
EN09A0102K100001
MODELS: FG, GH
S0983-93202
SOCKET WRENCH For rear U-bolt
S0983-93203
COMPONENT LOCATOR
EN09A0102D100001
SHTS09A010200009
2A57AA(%A(&A)&A()A)*A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧝㧤ಽ
SHTS09A010200010
2A57AA(%A(&A)&A()A)*A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧝㧤ಽ
1 U-bolt 15 Clip
2 Spring pad 16 Rivet
3 Spring bumper 17 Stabilizer link rod
4 Thrust washer 18 Holder
5 Spring pin 19 Stabilizer
6 Shackle 20 Rubber bushing
7 Lubrication fitting 21 Stabilizer lever
8 Leaf spring assembly 22 Stabilizer link pin
9 Shock absorber 23 Caster shim
10 Cushion washer 24 Spacer
11 Shock absorber pin 25 Center bolt
12 Lock washer 26 Cushion
13 Nut 27 Spacer (Driver's seat side only)
14 Bushing
SHTS09A010200011
D
B
9
7
4 12 8
3
5 11 7
8
6
9
F
5
A 7
8 10
9 13
10
C
14
13
SHTS09A010200012
OVERHAUL
EN09A0102H200001
SHTS09A010200013
(3) Jack up the axle, and support the frame with stands.
(4) Remove the tires.
SHTS09A010200014
SHTS09A010200016
2A57AA(%A(&A)&A()A)*A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧝㧤ಽ
(3) Use a brass rod to remove the spring pins from the shackle and
spring bracket.
SHTS09A010200017
SHTS09A010200018
(2) Use a brass rod to remove the spring pins from the shackle and
spring bracket.
SHTS09A010200019
SHTS09A010200020
2A57AA(%A(&A)&A()A)*A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧝㧤ಽ
SHTS09A010200021
SHTS09A010200022
(2) Align the leaf holes and silencers (Front suspension only), then
secure the leaves with a vise or an arbor press.
(3) Insert the center bolt and tighten the lock nut.
NOTICE
When reassembling the leaf spring, replace the center bolt with a
new one.
SHTS09A010200023
SHTS09A010200024
2A57AA(%A(&A)&A()A)*A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧝㧤ಽ
SHTS09A010200025
SHTS09A010200029 To Front
(2) Put the spacer between the caster shim and leaf spring of the
driver's seat side. (For front suspension)
(3) Lift the axle using a jack and align the hole of the leaf spring cen-
ter bolt and the hole of the axle I-beam.
NOTICE
Axle and suspension assembly are heavy, therefore be careful
when handling them.
(4) Put the spring bumper or the spring pad on the leaf spring.
(5) Set the U-bolts so that they catch the spring bumper or the spring
pad and tighten the U-bolt nuts temporarily.
SHTS09A010200030
(6) Using the special tool, tighten the U-bolt nuts (4 pieces) alter-
nately right and left and equally.
After repeating this operation 3 to 5 times, tighten the nuts to the
1 3 specified torque.
FRONT
SST:
Name Part No. Model
S0983-92204 FC, FD, GD
Socket Wrench for Front U-bolt
2 4 S0960-31160 FG, GH
S0960-31160 FC, FD, GD
SHTS09A010200031
Socket Wrench for Rear U-bolt S0983-93202
FG, GH
S0984-12560
2A57AA(%A(&A)&A()A)*A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧝㧤ಽ
4. LUBRICATION
(1) Lubricate the following parts with chassis grease.
1. Spring pins
SHTS09A010200032
SHTS09A010200033
2A57AA(%A(&A)&A()A)*A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧝㧤ಽ
Clearance between spring pin 0.125 0.5 Replace the pin Measure
and eye bushing {0.0049} {0.0197} and/or bushing.
Cushion: — —
Damage and wear
Stabilizer Sleeve:
Wear
(If so equipped)
Stabilizer Bushing:
Wear
(If so equipped)
2A57AA(%A(&A)&A()A)*A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧝㧤ಽ
MODELS: FG, GH
Unit: mm {in.}
38 {1.496} 3.5
{0.138}
Clearance between spring pin 0.020-0.125 0.5 Replace the pin Measure
and eye bushing {0.0008-0.0049} {0.0196} and/or bushing.
Cushion: — —
Damage and wear
Stabilizer Sleeve:
Wear
(If so equipped)
Stabilizer Bushing:
Wear
(If so equipped)
2A57AA(.A(/HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧝㧥ಽ
SU02-002
FRONT SUSPENSION
252 mm 260 mm
Stroke 249 mm {9.803 in.}
{9.921 in.} {10.236 in.}
Shock absorbers: 382 mm 390 mm
Min. length 381 mm {15.000 in.}
{15.039 in.} {15.354 in.}
634 mm 650 mm
Max. length 630 mm {24.803 in.}
{24.961 in.} {25.590 in.}
REAR SUSPENSION
DESCRIPTION
EN09A0102C100001
FRONT SUSPENSION
SHTS09A010200001
REAR SUSPENSION
SHTS09A010200002
TROUBLESHOOTING
EN09A0102F300001
SPECIAL TOOL
EN09A0102K100001
S0940-41060 HANDLE
2A57AA(.A(/HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧝㧥ಽ
COMPONENT LOCATOR
EN09A0102D100001
FRONT SUSPENSION
SHTS09A010200006
REAR SUSPENSION
SHTS09A010200007
OVERHAUL
EN09A0102H200001
SHTS09A010200008
(3) Jack up the axle, and support the frame with stands.
(4) Remove the tires.
SHTS09A010200009
SHTS09A010200011
2A57AA(.A(/HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧝㧥ಽ
SHTS09A010200012
(3) Remove the spring pin lock bolt. (Rear side of spring)
(4) Use a brass rod to remove the spring pins from the shackle and
spring bracket.
SHTS09A010200013
SHTS09A010200014
SHTS09A010200015
2A57AA(.A(/HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧝㧥ಽ
SHTS09A010200016
SHTS09A010200017
SHTS09A010200018
SHTS09A010200019
2A57AA(.A(/HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧝㧥ಽ
(2) Align the leaf holes and silencers (Front suspension only), then
secure the leaves with a vise or an arbor press.
(3) Insert the center bolt and tighten the lock nut.
NOTICE
When reassembling the leaf spring, replace the center bolt with a
new one.
SHTS09A010200020
SHTS09A010200021
SHTS09A010200022
(3) Inspect the clearance between the clamp plate and trunnion seat.
Standard clearance: 0.05-0.1 mm {0.0020-0.0039 in.}
Service limit: 0.4 mm {0.0157 in.}
NOTICE
If the standard clearance is not correct, adjust the clearance by
decreasing or increasing the shim.
The following shims are available.
0.30 mm {0.0118 in.}, 0.40 mm {0.0157 in.},
0.45 mm {0.0177 in.}, 0.50 mm {0.0197 in.}.
(4) Lock the clamp plate bolts with the lock plate.
SHTS09A010200024
SHTS09A010200028
(2) Place the caster shim between the spring seat and leaf spring.
NOTICE
When installing the caster shim, the thick end should face the rear
of the vehicle.
To Front
SHTS09A010200027
(3) Lift the axle using a jack and align the hole of the leaf spring cen-
ter bolt and the hole of the axle I-beam.
NOTICE
Axle and suspension assembly are heavy, therefore be careful
when handing them.
SHTS09A010200010
2A57AA(.A(/HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧢ᣣᦐޓᣣޓඦ೨㧝㧜ᤨ㧝㧤ಽ
(6) Using the special tool, tighten the U-bolt nuts (4 pieces) alter-
nately right and left and equally.
After repeating this operation 3 to 5 times, tighten the nuts to the
1 3 specified torque.
FRONT SST:
Socket Wrench for Front U-bolt (S0960-31160)
Socket Wrench for Rear U-bolt (S0960-31010)
Handle (S0940-41060)
5. LUBRICATION
(1) Lubricate the following parts with chassis grease.
a. Spring pins
b. Spring surface of the spring and axle housing
c. Trunnion shaft
SHTS09A010200030
SHTS09A010200031
NOTICE
Use the lubrication fitting to chassis grease the trunnion shaft,
until the grease flows out from the breather valve of trunnion seat
and trunnion cover.
SHTS09A010200032
2A57AA(.A(/HOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧢ᣣᦐޓᣣޓඦ೨㧝㧜ᤨ㧡㧤ಽ
Unit: mm {in.}
Clearance between spring pin 0.02-0.125 0.5 Replace the pin Measure
and eye bushing {0.0008-0.0049} {0.0196} and/or bushing.
Cushion: — —
Damage and wear
SU02-003
Width 80 {3.149}
Dimensions of leaf springs:
11 {0.433}
Thickness of leaves
12 {0.472}
Width 90 {3.543}
Dimensions of main leaf springs:
10 {0.394}
Thickness of leaves
12 {0.472}
DESCRIPTION
EN09A0102C100001
FRONT SUSPENSION
SHTS09A010200001
REAR SUSPENSION
SHTS09A010200002
TROUBLESHOOTING
EN09A0102F300001
SPECIAL TOOL
EN09A0102K100001
S0983-93202
SOCKET WRENCH For rear U-bolt
S0983-93203
COMPONENT LOCATOR
EN09A0102D100001
FRONT SUSPENSION
SHTS09A010200006
2A57AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧟ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
1 U-bolt 15 Clip
2 Spring pad 16 Rivet
3 Spring bumper 17 Cushion washer (If so equipped)
4 Thrust washer 18 Stabilizer link rod (If so equipped)
5 Spring pin 19 Holder (If so equipped)
6 Shackle 20 Stabilizer (If so equipped)
7 Lubrication fitting 21 Rubber bushing (If so equipped)
8 Leaf spring assembly 22 Stabilizer lever (If so equipped)
9 Shock absorber 23 Stabilizer link pin (If so equipped)
10 Cushion washer 24 Caster shim
11 Shock absorber pin 25 Spacer (Driver's seat side only)
12 Lock washer 26 Center bolt
13 Nut 27 Cushion (If so equipped)
14 Bushing
REAR SUSPENSION
SHTS09A010200007
2A57AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧟ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
OVERHAUL
EN09A0102H200001
SHTS09A010200008
(3) Jack up the axle, and support the frame with stands.
(4) Remove the tires.
SHTS09A010200009
2A57AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧟ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
SHTS09A010200011
(3) Remove the spring pin lock bolt. (Rear side of spring)
(4) Use a brass rod to remove the spring pins from the shackle and
spring bracket.
SHTS09A010200012
SHTS09A010200013
2A57AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧟ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
(2) Use a brass rod to remove the spring pins from the shackle and
spring bracket.
SHTS09A010200014
SHTS09A010200015
SHTS09A010200016
SHTS09A010200017
2A57AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧟ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
(2) Align the leaf holes and secure the leaves with a vise or an arbor
press.
(3) Insert the center bolt and tighten the lock nut.
NOTICE
When reassembling the leaf spring, replace the center bolt with a
new one.
SHTS09A010200018
SHTS09A010200019
SHTS09A010200020
To Front
SHTS09A010200023
(2) Put the spacer between the caster shim and leaf spring of the
driver's seat side. (For front suspension)
(3) Lift the axle using a jack and align the hole of the leaf spring cen-
ter bolt and the hole of the axle I-beam.
NOTICE
Axle and suspension assembly are heavy, therefore be careful
when handling them.
(4) Put the spring bumper and the spring pad on the leaf spring.
2A57AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧟ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
(5) Set the U-bolts so that they catch the spring bumper and the
spring pad and tighten the U-bolt nuts temporarily.
SHTS09A010200010
(6) Using the special tool, tighten the U-bolt nuts (4 pieces) alter-
nately right and left and equally.
After repeating this operation 3 to 5 times, tighten the nuts to the
1 3 specified torque.
FRONT SST:
Socket Wrench for Front U-bolt (S0960-31160)
Socket Wrench for Rear U-bolt (S0983-93202)
Socket Wrench for Rear U-bolt (S0983-93203)
Bar (S0984-12560)
2 4
SHTS09A010200024
4. LUBRICATION
(1) Lubricate the following parts with chassis grease.
a. Spring pins
SHTS09A010200025
SHTS09A010200026
2A57AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧟ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
Unit: mm {in.}
Clearance between spring pin 0.020-0.125 0.5 Replace the pin Measure
and eye bushing {0.0008-0.0049} {0.0196} and/or bushing.
Cushion: — —
Damage and wear
Stabilizer Sleeve:
Wear
Stabilizer Bushing:
Wear
SUSPENSION SU02
SUSPENSION ASSEMBLY
DATA AND SPECIFICATIONS
EN09A0202I200001
MODEL FG, GH
DESCRIPTION
EN09A0202C100001
6 4 5
7
3
1
2
SHTS09A020200001
TROUBLESHOOTING
EN09A0202F300001
SPECIAL TOOL
EN09A0202K100001
COMPONENT LOCATOR
EN09A0202D100001
J
F
B D A
B A
10 9 2 18
1 C
17 15
16
8
5 D G
B
D
14 A C
7
H
6
13
A
E
11 12
4
B
SHTS09A020200003
OVERHAUL
EN09A0202H200001
SHTS09A020200004
(3) Jack up the axle, and support the frame with the stand.
SHTS09A020200005
AIR SPRING
SHTS09A020200006
(3) Remove the rebound bolts, lock nuts, washers, spacer tube, and
REBOUND BOLT rebound roller from the frame hanger.
ROLLER
SPACER TUBE
SHTS09A020200007
2A57AA*#5A0QAVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧞ಽ
(4) Raise the rear of frame, high enough to remove the load from
main support member.
SHTS09A020200008
SHTS09A020200009
SHTS09A020200010
LOCK NUTS
SHTS09A020200011
(4) Push out oil bushings. Use a vertical shop press with a capacity of
at least 10 tons. Steel tube receiving tool is required. These bush-
ings are not cartridge type bushings. They do not have outer met-
als. Support the torque rod end on receiving tool with the end tube
of torque rod centered on tool. Push directly on the bushing strad-
dle mount bar pin until the bushing clears the torque rod end tube.
! CAUTION
Be sure the torque rod is securely supported on the press bed for
RECEIVING TOOL safety.
Do not use heat or cutting torch to remove the bushings from the
torque rod. The use of heat will adversely affect a strength of the
SHTS09A020200012
torque rod.
2A57AA*#5A0QAVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧞ಽ
(5) Clean and inspect the torque rod ends, removing any nick with
emery cloth.
(6) Lubricate the torque rod ends and the new rubber bushings with a
vegetable base oil (cooking oil or lard). Do not use a petroleum or
soap base lubricant.
(7) Press in new bushings. Support the torque rod end on receiving
tool with end tube of torque rod centered on receiving tool. Strad-
dle mount bar pin bushing must have mounting flats positioned
zero degrees to shank of torque rod as shown in the figure. Press
RECEIVING TOOL directly straddle mount bar pin of bushing. Bushing must be cen-
tered within torque rod end tubes. When pressing in new bush-
SHTS09A020200013
ings, overshoot desired final position by approximately 3/16 and
press bushing again from opposite side to center bushing within
torque rod end.
PIN
SLIPPER PAD
SHTS09A020200014
LOCK NUT
SHTS09A020200015
SHTS09A020200016
2A57AA*#5A0QAVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧞ಽ
SHOCK ABSORBER
SHTS09A020200017
LOWER BRACKET
SHTS09A020200018
SHTS09A020200019
SHTS09A020200020
2A57AA*#5A0QAVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧞ಽ
(2) If the shock absorber length is not the assembly standard, adjust
the extension rod length, so that the shock absorber length is the
assembly standard.
DIMENSION "A"
SHTS09A020200022
2A57AA*#5A0QAVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧟ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧣ಽ
Pad: — —
Wear, damage and crack
Slipper pad: — —
Wear, damage and crack
2A57AA*#5A0QAVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧞ಽ
Channel reinforcement: — —
Crack and damage
Back up plate: — —
Crack and damage
2A57AA*#5A0QAVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧞ಽ
2A(%AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧟ಽ
CHASSIS FRAME
FC02
FC02-001
CHASSIS FRAME
TROUBLESHOOTING
EN10Z1102F300001
REPAIR
EN10Z1102H200001
SHTS10Z110200001
(2) Drill out the head of the loosened rivets with a drill or grind.
NOTICE
When drilling, do not use the gloves. They can get caught up in
the drill.
SHTS10Z110200002
2A(%AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧟ಽ
SHTS10Z110200003
(5) If it is impossible to tighten with rivets, finish the rivet hole with a
reamer and tighten with reamer bolts.
NOTICE
The tensile strength of the bolts must be above 686 MPa {70 kgf/
mm2, 99,562 lbf/in.2}
Tightening Torque:
10 mm {0.39 in.} Bolt: 37.27-49.03 N⋅m {380-500 kgf⋅cm, 28-36
lbf⋅ft}
12 mm {0.47 in.} Bolt: 63.74-85.32 N⋅m {650-870 kgf⋅cm, 47-62
lbf⋅ft}
14 mm {0.55 in.} Bolt: 107.88-147.09 N⋅m {1,100-1,500 kgf⋅cm,
SHTS10Z110200005
80-108 lbf⋅ft}
16 mm {0.63 in.} Bolt: 166.72-225.55 N⋅m {1,700-2,300 kgf⋅cm,
123-166 lbf⋅ft}
18 mm {0.71 in.} Bolt: 245.17-323.61 N⋅m {2,500-3,300 kgf⋅cm,
181-238 lbf⋅ft}
20 mm {0.79 in.} Bolt: 343.24-460.91 N⋅m {3,500-4,700 kgf⋅cm,
254-339 lbf⋅ft}
22 mm {0.87 in.} Bolt: 470.72-627.62 N⋅m {4,800-6,400 kgf⋅cm,
348-462 lbf⋅ft}
2A(%AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧟ಽ
SHTS10Z110200006
(2) Make the V-shape groove with a grinder along the frame crack
according the following table.
Unit: mm {in.}
t x° s a
4.5 {0.18} 90 1.0 {0.039} 0
6 {0.24} 70 1.0 {0.039} 0
7 {0.28} 70 1.5 {0.059} 1 {0.039}
8 {0.31} 70 1.5 {0.059} 1 {0.039}
9 {0.35} 70 1.5 {0.059} 1 {0.039}
SHTS10Z110200007 10 {0.39} 60 1.5 {0.059} 1 {0.039}
12 {0.47} 60 1.5 {0.059} 1 {0.039}
16 {0.63} 60 2.0 {0.079} 1 {0.039}
(4) After welding, shake the grinder crosswise the bead line "A",
CORRECT WRONG
along direction "B", to polish the welded area as illustrated in "C".
Grind and polish the bead line "A" so that the frame surface
becomes even.
C B
SHTS10Z110200009
LESS
THAN 30º
SHTS10Z110200010
CORRECT WRONG
SHTS10Z110200011
CORRECT WRONG
SHTS10Z110200012
2A(%AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧟ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧥ಽ
(6) Be sure to fasten the bolts at the hole locations of ups and downs
(use rivets or perform the plug welding).
CORRECT WRONG
SHTS10Z110200013
SHTS10Z110200014
a ≥ 50 mm {1.969 in.}+d/2
e1 e1 b ≥ 3d
e1e2 ≥ 701 mm {27.598 in.}+a
a d
dφ: 20 or less
b b d
e2
SHTS10Z110200015
SHTS10Z110200016
2A(%AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧟ಽ
30
25
30
SHTS10Z110200017
CORRECT WRONG
PROHIBIT WELDING
THE BRACKET
AROUND THE HOLE
SHTS10Z110200018
(11) In welding, be sure that there is no undercut "A" or the overlap "B"
CORRECT WRONG of the bead and a pin hole.
NOTICE
An experienced professional welder should always perform the
A
welding since a poor welding job on the frame can cause damage.
SHTS10Z110200019
2A(%AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧟ಽ
WELDING CONDITION
(WHEN WELDING ROD IS USED)
NOTICE
• Diameter of welding rod φ3.2 mm {0.126 in.} or φ4 mm {0.157
in.} - plate thinner than 5 mm {0.197 in.}
• Diameter of welding rod φ4 mm {0.157 in.} or φ5 mm {0.197
in.} - plate thicker than 6 mm {0.236 in.}
CAB CA02–1
CAB
CA02
CA02-001
DOOR ......................................................CA02-14
COMPONENT LOCATOR ............................. CA02-14
OVERHAUL ................................................... CA02-15
SEAT .......................................................CA02-18
COMPONENT LOCATOR ............................. CA02-18
WINDSHIELD ..........................................CA02-30
COMPONENT LOCATOR ............................. CA02-30
REPLACEMENT ............................................ CA02-31
2A%#AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧠ಽ
CA02–2 CAB
CAB ASSEMBLY
DATA AND SPECIFICATIONS
EN11Z1202I200001
Type All steel welded construction, safety glass fitted to all windows
CAB CA02–3
TROUBLESHOOTING
EN11Z1202F300001
CAB TILT
Symptom Possible cause Remedy/Prevention
Cab does not tilt up. Cab mounting hook does not release. Inspection of cab mounting hook
mechanism.
Safety rod does not release. Inspection of safety rod mechanism.
Damaged torsion bar Replace torsion bar.
Cab tilting is difficult. Heavy items in or attached to cab Adjustment of shim for anchor lever or
removal of the heavy items.
Tilt up force is weak. Adjustment of shim for anchor lever.
Replace torsion bar.
Cab does not lock to cab mounting Mounting hook does not operate. Adjustment of mounting hook mecha-
member. nism.
Cab mounting cushion is not correctly Correct installation of cab mounting.
installed.
DOOR
Symptom Possible cause Remedy/Prevention
Door does not close properly. Door is not adjusted Adjust door installing.
Striker is not adjusted Adjustment of shim for door lock striker
Damaged door lock Replace door lock.
Door does not lock by inside lock Deformation of rod Replace rod.
knob. Rod is disconnected Connect rod.
Damaged door lock Replace door lock.
Door does not lock by key. Rod is disconnected Connect rod.
Damaged door lock Replace door lock.
Damaged lock cylinder Replace lock cylinder.
Door does not open by outside han- Outside handle push rod is not Adjust push rod.
dle. adjusted.
Damaged door lock Replace door lock.
Door does not open by inside han- Inside handle is not installed properly. Install inside handle properly.
dle. Deformation of rod Replace rod.
Rod is disconnected. Connect rod.
Damaged door lock Replace door lock.
Inside handle does not return to its Interference between rods. Replace rod.
normal position. Inside handle is not installed properly. Adjust inside handle.
Return spring is damaged. Replace inside handle.
Door window goes down while driv- Window is not in the glass holder. Repair.
ing. Regulator is damaged. Replace regulator.
Regulator makes abnormal noise Window sill weather strip is installed Install properly or replace clips.
while driving. improperly.
2A%#AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧠ಽ
CA02–4 CAB
BLOWER
Symptom Possible cause Remedy/Prevention
Malfunction of blower when power Blown fuse Change fuse or check for short circuit.
is ON. Malfunction in heater relay Inspect relay.
Malfunction of heater blower switch Inspect power switch.
Malfunction of register Check register.
Blower motor malfunction Replace motor.
Damaged electrical wiring or poor Repair as necessary.
grounding
2. CAB INSIDE
(1) Remove the parking brake cable retainer spring and pin. (Models
with center parking brake)
SHTS11Z120200001
SHTS11Z120200002
CONNECTOR
SHTS11Z120200003
2A%#AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧠ಽ
CAB CA02–5
SHTS11Z120200004
(2) Remove the harness clips located under the floor of the cab. Dis-
GROMMET connect the air brake hoses and clutch hose.
(3) Remove the cab stopper release cable (If so equipped).
CONTROL
CABLE
SHTS11Z120200005
! CAUTION
Do not raise cab excessively, because the cab will fall forward.
SHTS11Z120200006
(2) Remove the set screws of the anchor lever, and pull out the
anchor levers.
Remove the cab stopper stay.
Slowly lower the cab with crane or hoist.
! DANGER
Never go under the cab when lowering the cab. It is very danger-
ous.
SHTS11Z120200007
2A%#AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧠ಽ
CA02–6 CAB
SHTS11Z120200008
(2) Initially raise the cab so that most of its weight is borne by the lift-
ing device, then remove the bolts of the tilt hinge brackets.
SHTS11Z120200009
(3) Pull the cab tilt latch rod and lift the cab slowly.
NOTICE
Make sure that all of connecting parts are disconnected.
(4) Set the cab on a cab stand.
SHTS11Z120200010
7. CAB MOUNTING
(1) Pay attention to the points below, and mount in the reverse order
of dismounting.
1. Steering sliding shaft inserting
2. Anchor lever fitting position
3. Damage or interference of harness wire, cable and hose
2A%#AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧠ಽ
CAB CA02–7
FRONT SIDE
SHTS11Z120200011
Tightening torques:
CA02–8 CAB
REAR SIDE
SHTS11Z120200012
Tightening torques:
CAB CA02–9
SHTS11Z120200013
CA02–10 CAB
OVERHAUL
EN11Z1202H200001
SHTS11Z120200015
SHTS11Z120200016
UP DOWN
255 N 510 N
{26 kgf, 57 lbf} {52 kgf, 114.6 lbf}
or less or less
SHTS11Z120200017
2A%#AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧠ಽ
CAB CA02–11
SHTS11Z120200018
c. Pull out the pin at the lower part of cab stopper stay bracket.
SHTS11Z120200019
d. Align the hole on the cab stopper stay with the hole for OVER-
TILT at the upper part of the cab stopper stay bracket and
insert 12 mm {0.472 in.} pin.
Use a cotter pin so that the pin does not come out.
! CAUTION
Make sure that the cab stopper pin is locked. If it is not properly
locked, the cab may fall.
SHTS11Z120200020
CA02–12 CAB
SHTS11Z120200022
Unit: mm {in.}
Position Related parts Dimensions
A: Eye bolt, crank pin off set * Mark bolts 9-13 {0.36-0.51}
B: Tilt latch, pin clearance Tilt latch adjusting bolt 3-6 {0.12-0.23}
C: Hook, eye bolt clearance Mounting member attaching bolt 12-22 {0.48-0.86}
D: Hook, eye bolt clearance Mounting member attaching bolt 20-30 {0.79-1.18}
E: Mounting member, tilt latch clearance Mounting member attaching bolt 20-22 {0.79-0.86}
F: Mounting member, tilt latch clearance Mounting member attaching bolt 9-11 {0.36-0.43}
2A%#AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧠ಽ
CAB CA02–13
SHTS11Z120200023
SHTS11Z120200024
4. INSPECTION
(1) Operate the cab lock lever, and confirm that each part operates
smoothly, that the hook and eye bolt fit in the lock position, and
that the stopper pin is securely inserted.
! CAUTION
If the stopper pin is not inserted securely in place while driving,
external shock such as road bumps or collision may cause a tilt-
STOPPER PIN ing of the cab. This can result in personal injury and/or property
damage. If the stopper pin is lost, immediately install a new stop-
per pin. Make sure that the hook engages with the eye bolt
securely.
SHTS11Z120200025
2A%#AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧠ಽ
CA02–14 CAB
DOOR
COMPONENT LOCATOR
EN11Z1202D100002
SHTS11Z120200026
CAB CA02–15
OVERHAUL
EN11Z1202H200002
SHTS11Z120200027
SHTS11Z120200028
3. REMOVE WINDOW.
(1) Disconnect regulator from window channel.
SHTS11Z120200029
SHTS11Z120200030
2A%#AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧠ಽ
CA02–16 CAB
SHTS11Z120200031
SHTS11Z120200032
SHTS11Z120200033
(3) Make depth adjustments by loosening the hinge bolts on the body.
SHTS11Z120200034
2A%#AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧠ಽ
CAB CA02–17
7. STRIKER ADJUSTMENT
(1) Check the engagement between the door lock and the striker.
Make the top and bottom contact even.
(2) Perform adjustment so that the outside of the door and the out-
side of the rear quarter panel are flush with each other. After
adjustment, properly tighten the bolts.
NOTICE
When adjusting the door in the vertical direction, do not force in
into alignment by using the door lock striker.
SHTS11Z120200035
G
E
A B B
D D
C C
I I
SECTION OF D-D SECTION OF C-C
SHTS11Z120200036
CA02–18 CAB
SEAT
COMPONENT LOCATOR
EN11Z1202D100003
SHTS11Z120200037
CAB CA02–19
SHTS11Z120200038
CA02–20 CAB
ASSISTANT'S SEAT
SHTS11Z120200039
CAB CA02–21
SHTS11Z120200040
CA02–22 CAB
SHTS11Z120200041
CAB CA02–23
SHTS11Z120200042
CA02–24 CAB
SHTS11Z120200043
CAB CA02–25
INSTRUMENT PANEL
COMPONENT LOCATOR
EN11Z1202D100004
SHTS11Z120200044
CA02–26 CAB
! CAUTION
• When pulling the upper right cover, be careful not to damage
the clips.
• Be sure to remove the 4 clips of this side previously because
pulling out the upper right cover at one time may damage it.
SHTS11Z120200045
(3) Pull the upper right cover straight with both hands to remove the
(EXAMPLE: RHD MODEL)
inner clip and remove the upper right cover.
SHTS11Z120200046
PIN
SHTS11Z120200047
SHTS11Z120200048
2A%#AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧠ಽ
CAB CA02–27
SHTS11Z120200049
CA02–28 CAB
SHTS11Z120200050
SHTS11Z120200051
2A%#AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧠ಽ
CAB CA02–29
SHTS11Z120200052
(2) Hold the blower assembly up 15 mm {0.59 in.} to align it with the
installation hole.
SHTS11Z120200053
(3) Slide the blower assembly to the vehicle front until it is inserted
into the installation hole.
SHTS11Z120200054
2A%#AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧠ಽ
CA02–30 CAB
WINDSHIELD
COMPONENT LOCATOR
EN11Z1202D100006
SHTS11Z120200055
CAB CA02–31
REPLACEMENT
EN11Z1202H100004
SHTS11Z120200056
STRING
WEATHERSTRIP
SHTS11Z120200057
(4) Pull the working string from the interior of the cab, and gradually
install the lip of the weatherstrip on the mounting flange.
(5) During this operation, knock the glass from outside. Use soapy
water as necessary.
(6) After install the glass properly, knock the glass from inside and
outside.
SHTS11Z120200058
A
ASSISTANT'S SIDE DRIVER'S SIDE
SHTS11Z120200059
2A%#AHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧠ಽ
ELECTRICAL EQUIPMENT EL01–1
ELECTRICAL EQUIPMENT
EL01
EL01-001
ELECTRICAL PARTS
DATA AND SPECIFICATIONS
EN12Z1601I200001
ELECTRICAL SYSTEM
Headlight 75/70W
Clearance light 5W
GAUGE TYPE
TROUBLESHOOTING
EN12Z1601F300001
STARTING SYSTEM
Symptom Possible cause Remedy/Prevention
Engine does not operate Poor contact condition Clean or replace contacts.
(Starter switch)
Engine does not operate (Battery) Open circuit in harness Check and correct.
Short circuit between electrodes Replace battery.
Poor contact condition of battery termi- Clean or retighten.
nal
Engine does not operate Improper viscosity oil Change oil.
(Engine oil)
Engine does not operate Defective or poor contact of starter Repair or replace.
(Starter relay) relay
Engine does not operate (Starter) Starter does not operate Repair or replace. Refer to the chapter
"STARTER".
HEADLIGHT CIRCUIT
Symptom Possible cause Remedy/Prevention
Headlight does not turn on Bulb burned out Replace bulb.
(Headlight) Not grounded Check the grounding.
Headlight does not turn on (Fuse) Fuse burned out Replace fuse.
Headlight does not turn on Defective relay Replace relay.
(Headlight relay)
Headlight does not turn on Broken wire between relay and switch Repair wire.
(Lighting switch) Defective switch Replace switch.
GENERAL INSTRUCTION
EN12Z1601C100001
! CAUTION
Be sure to disconnect the ground cable before servicing the elec-
trical circuits except for testing on-vehicle.
1. WIRING CODE
(1) Wiring colors are indicated by a code.
(2) The first letter indicates the ground wire color and second letter
indicated the strip color.
(3) Arabic numerals indicates the cross sectional area of wire.
Example: 3 indicates 3 mm2 {0.0047 in.2}
SHTS12Z160100001
2. CONNECTOR
(1) The connector consists of the male and female connectors.
Male and female connectors are classified according to the shape
of the terminals in the connector.
Male and female connectors are provided with a lock, so that they
can not be separated easily.
To separate the connectors, unlock the lock, then hold one con-
nector with one hand and the other one with the other hand, and
pull each other.
NOTICE
When the connector is disconnected by pulling the wires, the con-
nection between the terminals and the wires will be damaged.
SHTS12Z160100002
2A'.AA/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧡ಽ
SHTS12Z160100003
3. FUSE
(EXAMPLE: RIGHT-HAND DRIVE) (1) The power supply must be switched off for fuse replacement.
Use a proper amperage fuse.
NOTICE
Wire burning may be caused when a fuse with an excessively
large current capacity is used.
If the fuse should blow frequently, investigate the cause and cor-
rect it.
SHTS12Z160100004
4. FUSIBLE LINK
(1) The cause of an overload current should be determined and cor-
rected before a melted fusible link is replaced.
A melted fusible link can be determined swollen or melted insula-
tion of the link.
SHTS12Z160100005
2A'.AA/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧡ಽ
5. DIODE
(1) Diode allows the flow of electric current in only one direction.
SHTS12Z160100006
6. SOLENOID VALVE
(1) Solenoid valve controls the current of compressed air by electric.
Check the continuity between terminals. If there is no continuity,
replace the solenoid valve.
SHTS12Z160100007
2A'.AA/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧡ಽ
SHTS12Z160100008
Horn relay
TYPE-7 Light brown S8592-02510 Engine stop motor relay (If so equipped)
1. TYPE-1 INSPECTION
(1) Apply voltage to terminals;
24V to terminal 1,
S8592-02660 Ground to terminal 2.
5 3 (2) Under normal condition, terminals 3 and 5 switch on.
2 5 3
1 2
SHTS12Z160100009
2. TYPE-2 INSPECTION
(1) Apply voltage to terminals;
24V to terminal 1,
S8592-02650 Ground to terminal 2.
5 3 (2) Under normal condition, terminals 3 and 5 switch on.
2 5 3
1 2
SHTS12Z160100010
3. TYPE-3 INSPECTION
(1) Apply voltage to terminals;
24V to terminal 1,
S8592-02570 Ground to terminal 2.
5 3 (2) Under normal condition, terminals 3 and 5 switch on.
5
1 2 1 2
SHTS12Z160100011
4. TYPE-4 INSPECTION
(1) Apply voltage to terminals;
24V to terminal 1,
S8592-02680 4 Ground to terminal 2.
2 5 3 3 (2) Under normal condition, relay switches the continuity from termi-
4 5 nals 3 and 4 to 3 and 5.
1 2
1
SHTS12Z160100012
2A'.AA/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧡ಽ
5. TYPE-5 INSPECTION
(1) Apply voltage to terminals;
24V to terminal 2,
S8592-02700 Ground to terminal 1.
5 3 (2) Under normal condition, terminal 3 and 5 switch on.
1
3 5 1 2
SHTS12Z160100013
6. TYPE-6 INSPECTION
(1) Apply voltage to terminals;
24V to terminal 2,
S8592-02710 Ground to terminal 1.
5 3 (2) Under normal condition, terminal 3 and 5 switch on.
1
3 5 1 2
SHTS12Z160100014
7. TYPE-7 INSPECTION
(1) Apply voltage to terminals;
S8592-02510 24V to terminal 1,
4 Ground to terminal 2.
5 4
3 (2) Under normal condition, relay switches the continuity from termi-
1 5 nals 3 and 4 to 3 and 5.
2
1 2
3
SHTS12Z160100015
8. TYPE-8 INSPECTION
(1) Apply voltage to terminals;
24V to terminal 1,
S8592-02670 4 Ground to terminal 2.
2 5 3 3 (2) Under normal condition, relay switches the continuity from termi-
4 5 nals 3 and 4 to 3 and 5.
1 2
1
SHTS12Z160100016
2A'.AA/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧡ಽ
HANDLING PRECAUTION
EN12Z1601C100002
BATTERY
2. BATTERY CHARGING
• Be careful of the following points.
(1) While the battery is being charged, ensure that the temperature of
the electrolyte does not rise above 45°C {113°F}.
(2) While the battery is being charged, be particularly careful to keep
it away from sources of fire.
(3) The amount of electrolyte must be within the specified level.
Specific gravity when battery is fully charged:
1.270-1.290 at 20°C {68°F}
INSPECTION
EN12Z1601H300001
SHTS12Z160100019
ST B M1
Terminals
B ACC M2 M1 ST
Switch position
LOCK
ACC
SHTS12Z160100021 ON
ST
SHTS12Z160100023
SHTS12Z160100024
SHTS12Z160100025
2A'.AA/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧡ಽ
Between terminals
Float position UP No continuity
Float position DOWN Continuity
SHTS12Z160100026
Between terminals
PUSH Continuity
FREE No continuity
Engine stop
Engine running
SHTS12Z160100029
2A'.AA/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧡ಽ
SHTS12Z160100031
Terminals
A B C D
Switch position
PUSH
FREE
SHTS12Z160100032
HEADLIGHT CIRCUIT
Terminals
EL LT LH
Switch position
OFF
TAIL
TAIL AND HEAD
Terminals
ED DL DU EP
Switch position
PASSING
LOW BEAM
HIGH BEAM
SHTS12Z160100036
2A'.AA/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧡ಽ
Turn signal:
Terminals
BT TL TR
Switch position
LEFT
OFF
RIGHT
Hazard warning:
Terminals
HF HL HR HT
Switch position
OFF
ON
Terminals
EB E1 E3 BE E2
SHTS12Z160100037 Switch position
OFF
Terminals
WW EW WI WL WH
Switch position
OFF
WIPER: INT
MEDIUM
HIGH
WASHER: ON
SHTS12Z160100042
P1 Terminals
B2 T P B2 TB P1
Switch position
P
OFF
TB
ON
SHTS12Z160100044
Terminals
1 2
Switch position
PUSH
FREE
SHTS12Z160100046
Terminals
1 1 2
Switch position
OFF
ON
SHTS12Z160100048
Between terminals
PUSH Continuity
FREE No continuity
SHTS12Z160100050
2A'.AA/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧡ಽ
SHTS12Z160100051
Between terminals
PUSH No continuity
FREE Continuity
SHTS12Z160100052
Terminals
1 2
Switch position
OFF
2 ON
SHTS12Z160100053
2A'.AA/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧡ಽ
DRIVER'S SIDE:
Terminals
+B DU DD E
Switch position
AUTO CLOSE
CLOSE
OFF
IG PU PD
OPEN
+B DD DU B2 E WL
AUTO OPEN
SHTS12Z160100054
CLOSE
OFF
OPEN
OFF
OPEN
2A'.AA/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧡ಽ
Terminals
SU U IG D SD
Switch position
CLOSE
OFF
OPEN
D SD U SU IG
SHTS12Z160100058
Terminals
Direction of rotation 1 2
(View from out put shaft)
CLOCKWISE + -
COUNTERCLOCKWISE - +
1 2
SHTS12Z160100060
(LEFT-HAND DRIVE)
2 1
SHTS12Z160100061
2A'.AAPQAVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧟ᣣޓ㊄ᦐᣣޓඦᓟ㧠ᤨ㧡㧞ಽ
SHTS12Z160100063 Terminals
LW LB L LR
Switch position
OFF
LOW
HIGH
SHTS12Z160100065
Electric current
+ -
Lever position
PULL G W
RETURN G B
NOTICE
Connect a 10A fuse between the terminal and the 24V power
source. If the fuse is burned out or the motor does not operate,
replace the motor.
SHTS12Z160100066
Terminals
1 2 3
Lever position
LOCK
SHTS12Z160100068 UNLOCK
SHTS12Z160100069
SHTS12Z160100071
Terminals
1 2
Lever position
LOCK + -
UNLOCK - +
SHTS12Z160100072
2A'.AAPQAVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧟ᣣޓ㊄ᦐᣣޓඦᓟ㧠ᤨ㧡㧞ಽ
Less than T
DOOR KNOB SWITCH
LOCK
UNLOCK
LOCK OUTPUT ON
"8"
OFF
T
UNLOCK OUTPUT ON
"7"
OFF
T T
SHTS12Z160100074
1 2 3 4
Terminals
1 2 3 4
Lever position
CLOSE
SHTS12Z160100076
OFF
SET
2A'.AA/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧡ಽ
3 2 1
8 7 6 5 4
SHTS12Z160100076
SET
4
1
SET
M STARTER
CLOSE SWITCH
3 POWER MIRROR
SWITCH
POWER MIRROR
MOTOR
8
CLOSE
BATTERY
(24V)
2 6
SHTS12Z160100077
2A'.AAPQAVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧟ᣣޓ㊄ᦐᣣޓඦᓟ㧠ᤨ㧡㧞ಽ
Terminals
Direction of rotation 1 2
(View from out put shaft)
COUNTERCLOCKWISE + -
CLOCKWISE - +
SHTS12Z160100080
Terminals
E C M1 M2 H P P
Switch position
OFF
1
2 LIGHT
3
4
SHTS12Z160100082
Terminals
A/C 5 6
Switch position
OFF
6 5 ON
SHTS12Z160100084
2A'.AA/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧡ಽ
Terminal
LB WB LY
Switch position
OFF
LO
HIGH
SHTS12Z160100084
4. POWER RELAY No.2 INSPECTION
(1) Refer to "RELAY (TYPE, COLOR, PART No., NAME AND
INSPECTION)" in the section "GENERAL INSTRUCTION".
Terminals
1 2
Switch position
PUSH
FREE
SHTS12Z160100046
Between terminals
PUSH Continuity
FREE No continuity
SHTS12Z160100086
2A'.AA/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧡ಽ
5 Terminals
5 6 7
1 Switch position
OFF
ON
SHTS12Z160100087
Terminals
5 1 2
Switch position
FAST
SLOW
Terminals
1 2
Switch position
PUSH
FREE
SHTS12Z160100090
3
2 Terminal
1 2 3 4
Switch position
1
4 OFF
ON
SHTS12Z160100091
Between terminals
PUSH Continuity
FREE No continuity
SHTS12Z160100093
2A'.AA/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧡ಽ
3
1. INTER-AXLE DIFFERENTIAL LOCK
2
(1) Check the continuity between terminals.
1
Terminal
1 2 3
Switch position
OFF
SHTS12Z160100094
ON
2A'.AAPQAVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧟ᣣޓ㊄ᦐᣣޓඦᓟ㧠ᤨ㧡㧠ಽ
SHTS12Z160100099
Thailand S7658-84080
SHTS12Z160100100
Except Thailand S7658-83800
(3) Remove the screws and then the cover of pulse adjust computer.
(4) If you disconnected the wire harness connector of the vehicle
when removing the cover of pulse adjust computer, connect again
the wire harness connector.
(5) Connect the input tool connector.
SST: Input tool (S0963-02400)
SHTS12Z160100102
SHTS12Z160100104
2A'.AAPQAVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧟ᣣޓ㊄ᦐᣣޓඦᓟ㧠ᤨ㧡㧠ಽ
SHTS12Z160100105
2A'.AAPQAVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧟ᣣޓ㊄ᦐᣣޓඦᓟ㧠ᤨ㧡㧠ಽ
SHTS12Z160100106
2A'.AAPQAVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧟ᣣޓ㊄ᦐᣣޓඦᓟ㧠ᤨ㧡㧠ಽ
SHTS12Z160100107
2A'.AAPQAVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧟ᣣޓ㊄ᦐᣣޓඦᓟ㧠ᤨ㧡㧠ಽ
SHTS12Z160100108
2A'.AAPQAVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧟ᣣޓ㊄ᦐᣣޓඦᓟ㧠ᤨ㧡㧠ಽ
SHTS12Z160100109
2A'.AAPQAVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧟ᣣޓ㊄ᦐᣣޓඦᓟ㧠ᤨ㧡㧠ಽ
SHTS12Z160100110
2A'.AAPQAVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧟ᣣޓ㊄ᦐᣣޓඦᓟ㧠ᤨ㧡㧠ಽ
SHTS12Z160100111
2A'.AAPQAVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧟ᣣޓ㊄ᦐᣣޓඦᓟ㧠ᤨ㧡㧠ಽ
SHTS12Z160100112
2A'.AAPQAVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧟ᣣޓ㊄ᦐᣣޓඦᓟ㧠ᤨ㧡㧠ಽ
SHTS12Z160100113
2A'.AAPQAVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧟ᣣޓ㊄ᦐᣣޓඦᓟ㧠ᤨ㧡㧠ಽ
SHTS12Z160100114
2A'.AAPQAVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧟ᣣޓ㊄ᦐᣣޓඦᓟ㧠ᤨ㧡㧠ಽ
ZF TRANSMISSION
SHTS12Z160100115
2A'.AAPQAVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧟ᣣޓ㊄ᦐᣣޓඦᓟ㧠ᤨ㧡㧠ಽ
SHTS12Z160100116
2A'.AAPQAVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧟ᣣޓ㊄ᦐᣣޓඦᓟ㧠ᤨ㧡㧠ಽ
SHTS12Z160100117
2A'.AAPQAVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧟ᣣޓ㊄ᦐᣣޓඦᓟ㧠ᤨ㧡㧠ಽ
SHTS12Z160100118
2A'.AAPQAVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧟ᣣޓ㊄ᦐᣣޓඦᓟ㧠ᤨ㧡㧠ಽ
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧟ᣣޓ㊄ᦐᣣޓඦᓟ㧠ᤨ㧡㧢ಽ
BRAKE CONTROL
DN03
ANTI-LOCK BRAKE
HANDLING PRECAUTIONS
EN16Z0803F200001
1. ABOUT CONNECTORS
(1) When vehicle placed on speed meter tester, or jacked up to rotate
the tires, there is a case that ECU memorize failure code. But, this
is not abnormal. Clear the failure code on ECU in any case of hav-
ing done that type of maintenance service.
(2) Before performing an inspection work, check that each connector
is surely connected.
(3) When taking off connector, do it without fail at the "LOCK" position
of starter key.
(4) Any parts presumed to be abnormal should not be repaired, but
change it.
(5) After clearing the failure memories recorded in the past, perform
SHTS16Z080300001
failure diagnosis again and check the current failure.
(6) After completing the diagnosis analysis, clear the diagnosis mem-
ories in the past.
(7) Unless otherwise specified, the drawing of connector is one
viewed from connected surface. But, test bar should be inserted
from back side for measuring.
However, check the terminals at the connected part of such water
proof connectors as ABS actuator, etc. In this case, be careful not
to short the terminals.
(8) The connector is displayed from the view of the mating surface
when the connector lock is positioned above.
Reference
• Female connector: The terminal is female.
• Male connector: The terminal is male.
SHTS16Z080300002
(9) As for the terminal numbers of the connector, the first terminal is
located on the top right terminal of the male connector and the top
left terminal of the female connector.
Reference:
When viewed from the mating surface, the terminal numbers
of both connectors are located symmetrically (reversed hori-
zontally).
(10) When disconnecting the connectors, be sure to position the
starter switch "LOCK".
SYSTEM DIAGRAM
EN16Z0803J100001
Front right wheel sensor ABS control function ABS solenoid valve
for front right wheel
Rear left wheel sensor ABS solenoid valve ABS solenoid valve
control function for rear left wheel
Courtesy switch
(For alarming while ES solenoid valve SM1
driver not seated)
SHTS16Z080300004
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
22 PIN CONNECTOR
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15
VIEW CHASSIS HARNESS
16 17 18 19 20 21 22
SHTS16Z080300005
9 — 20 —
10 — 21 —
11 — 22 —
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
31 PIN CONNECTOR
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
VIEW CHASSIS HARNESS
22 23 24 25 26 27 28 29 30 31
SHTS16Z080300006
3 Ground 2 19 —
4 Clutch pedal stroke sensor power supply 20 Rear retaining solenoid valve
5 — 21 —
6 — 22 —
7 — 23 —
13 — 29 —
24 PIN CONNECTOR
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
VIEW CHASSIS HARNESS
17 18 19 20 21 22 23 24
SHTS16Z080300007
5 Buzzer output 17 —
8 — 20 —
12 — 24 —
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
28 PIN CONNECTOR
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19
VIEW CHASSIS HARNESS
20 21 22 23 24 25 26 27 28
SHTS16Z080300008
2 Courtesy switch 16 —
9 — 23 —
12 — 26 —
13 — 27 —
NOTICE
ABS warning light will continue to be lit even when any abnormal condition is seen in ABS mechanism for a while
and come back to the normal condition.
In this case, it can be reset by stopping the vehicle and turning the starter key on "LOCK".
1. LIGHTING AND FLASHING ON/OFF OF WARNING LIGHT IN CONNECTION WITH DIAGNOSIS MONITOR.
• Lighting and flashing on/off of warning light in connection with diagnosis monitor.
Lighting and flashing on/off of warning light in connection with diagnosis monitor.
ABS 1
ABS+ES start 2
ON
ABS
warning light
OFF
3.0 second 0.13 second 0.13 second
(Initial check) 0.5 0.5
second second
Identification by frequency of flashing on/off (Example) Code 2 Test mode display.
SHTS16Z080300009
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
"ON"
ABS warning light
"OFF"
SHTS16Z080300010
NOTICE
When ABS warning light does not go on even with enough pedal effort, malfunction of fluid sensor may be its
cause.
(2) Speed sensor check
a. Starting engine, check that ABS warning light be put into "test mode" flashing on/off.
b. By taking off the vehicle in straight direction without making wheel-spin and speeding up to more than 45 km/h,
keeping it at a given speed for 1 second, check that ABS warning light went off.
NOTICE
• When making wheel-spin, there is a case that speed sensor check will not be completed.
• There is a case that by starting sensor check in steered condition, ABS warning light does not go off after
the check.
45
Vehicle speed
"ON"
ABS warning light
"OFF"
Light goes on when Light goes on and off Light goes off
the check is completed, when the vehicle is while the vehicle
running at a given speed stopping. running.
of more than 45km/h {28 mile/h}.
SHTS16Z080300011
NOTICE
When the sensor is abnormal and the check is not completed, different from the above mentioned condition, light
flashes on and off even under the vehicle running condition.
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
4. CHECKING COMPLETION
(1) When speed sensor check is correctly completed, ABS warning light goes to the following lighting condition:
• While the vehicle stopping: ABS warning light goes on and off. "Test mode display"
(It flashes on and off even when it is not correctly completed)
• While the vehicle is running: ABS warning light goes off.
NOTICE
• When the sensor check is not completed or the sensor is abnormal, it goes on.
even under the vehicle running condition.
• When the sensor check is correctly completed (light goes off while the vehicle running), ABS will become
possible to operate. When it is not completed or it is abnormal, ABS will not operate.
"ON"
ABS warning light
"OFF"
0.25 sec. 0.25 sec.
Abnormal code: Example "73"
"ON"
ABS warning light
"OFF"
0.5 sec. 0.5 sec. 1.5 sec. 2.5 sec.
* Abnormal code is found in Diagnosis monitor code and Sensor check code.
When there exist more than 2 abnormal codes, the display will be repeated in the order from smaller number of the codes.
SHTS16Z080300012
Sensor
check Description Contents Counter-measure
code
Abnormal voltage output on front The check for voltage output at vehi- Check diagnosis monitor code 31.
71
RH wheel sensor cle speed of less than 5 km/h is not
completed.
Abnormal voltage output on front Check diagnosis monitor code 32.
72
LH wheel sensor
Abnormal frequency output on The check for "noise" or "frequency Check diagnosis monitor code 31.
75
front RH wheel sensor change" at vehicle speed of more
than 45 km/h {28 mile/h} is not com-
Abnormal frequency output on pleted. Check diagnosis monitor code 32.
76
front LH wheel sensor
Abnormal voltage output on G sen- The check for sensor output is not Check diagnosis monitor code 43.
79
sor. completed.
Abnormal output on fluid sensor The check for sensor output is not Check diagnosis monitor code 46.
81
(ABS actuator) completed.
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
SHTS16Z080300013
ES start is operating
Lighting 1 short beeping
(After engine starting)
Operation
ES start is released Lighting off No beeping
Perform failure
Defects of signal
Failure alarm Blinking Beeping continuously diagnosis by diagnosis
switches or sensors
Warning function.
Initialization is
Non-adjustment alarm Blinking No beeping Initialize.
not completed.
2. OPERATION CHECK
(1) Normal operation check
a. Turn starter key "ON" position.
b. ES start indicator light in the meter goes on for 3 second.
c. Then, when only ES start light flashes on and off, it means that 0-point adjustment of clutch and initial setting of
release position are not made. Accordingly, make them. At the same time, when ES start indicator light flashes
on and off and the buzzer beeps continuously, it means that the switch or the sensor is not good. Checking those
defective parts through diagnosis function, repair them.
(2) 0-point adjustment of clutch and initial setting of release position.
a. Make 0-point adjustment of clutch and initial setting of release position.
(3) Operation check
NOTICE
This check should be performed on "brake tester" or at place where protective device against the vehicle taking
off since vehicle taking off operation is needed.
a. The followings should be fulfilled.
• Starter key: "ON".
• ES start main switch: "ON".
• Parking switch: "RELEASE".
• Vehicle speed: 0 km/h {0 mile/h}
b. After depressing the brake pedal for approx. 1 second, check that the buzzer beeps once, ES start indicator light
flashes on and off, and ES start will operate.
c. Check that braking force is retained.
d. By normal operation for taking off (by shifting gear for clutch connection), check that ES start will be released.
.
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
3. WARNING FUNCTION
(1) ES start system alerts by beeping the warning buzzer and lighting or blinking the indicator light to classify the alarms
when dangerous operations or failures occur.
NOTICE
When a failure alarm is displayed, perform the failure diagnosis by using diagnosis function.
Indicator
Warning buzzer Item Warning content Treatment
light
Non-adjustment
Blinking No beeping Initialization is not completed. Initialize.
alarm
It was made.
Table of warning kinds.
It was not made.
SHTS16Z080300015
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
It was made.
Table of warning kinds.
SHTS16Z080300017
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
It was made.
Table of warning kinds.
SHTS16Z080300018
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
It was made.
Table of warning kinds.
SHTS16Z080300019
SHTS16Z080300020
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
1. DIAGNOSIS MONITOR
(1) Diagnosis monitor alerts the failure location with sound and light
by being connected to the special diagnosis connector of the
ABS+ES start system.
SHTS16Z080300021
WHITE CONNECTOR
SHTS16Z080300022
SHTS16Z080300023
OPT:AIRSUS
SHTS16Z080300024
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
"ON"
ABS warning light
"OFF"
0.25 sec. 0.25 sec.
Incorrect code: Example "73 "
"ON"
ABS warning light
"OFF"
0.5 sec. 0.5 sec. 1.5 sec. 2.5 sec.
* Abnormal code is formed by diagnosis monitor code and sensor check one.
When more than 2 abnormal codes are found, they will be displayed in the order from smaller number of the codes.
SHTS16Z080300025
DIAGNOSIS
TROUBLE CONTENTS REFER PAGE
CODE
35 Abnormality of front right wheel sensor: Excessive air gap, or adhesion of iron piece. DN03-61
36 Abnormality of front left wheel sensor: Excessive air gap, or adhesion of iron piece. DN03-61
38 Abnormality of rear right wheel sensor: Excessive air gap, or adhesion of iron piece. DN03-61
39 Abnormality of rear left wheel sensor: Excessive air gap, or adhesion of iron piece. DN03-61
B5 Sticking at "ON" position of release timing switch (only vehicle with ES start) DN03-74
NOTICE
Diagnosis code "A" means "10", "B" means "11".
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
1. FUSE CHECK
(1) Set the starter switch to "LOCK", check the ABS solenoid 30A
RIGHT-HAND DRIVE fuse.
Standard: No abnormality
LEFT-HAND DRIVE
SHTS16Z080300026
.
NO
Replace the ABS solenoid fuse.
YES
2. RELAY CHECK
(1) Disconnect the 31 pin connector of the ECU.
(2) Measure the resistance between 1st and 24th terminals of the 31
pin connector (chassis harness side).
Standard: 160-340 Ω
SHTS16Z080300027
.
NO
Go to the item "6".
YES
(3) Remove the ABS solenoid relay, measure the resistance between
3rd and 5th terminals of the relay.
1
Standard: More than 500 Ω
3 5
SHTS16Z080300028
.
NO
Abnormality of the ABS solenoid relay.
YES
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
SHTS16Z080300029
.
NO
Abnormality of the wire harness.
YES
4. RELAY CHECK
(1) Remove the ABS solenoid relay, check the continuity between 3rd
1 and 5th terminals of relay when a battery voltage was applied
between 1st and 2nd terminals of relay.
Standard:
3 5 Turning on electricity between 1st and 2nd terminals:
It is conducted between 3rd and 5th terminals.
Not turning on electricity:
2 It is not conducted between 3rd and 5th terminals.
SHTS16Z080300030
.
NO
Abnormality of the ABS solenoid relay.
YES
5. ECU CHECK
ECU VIEW (1) Connect all the connector and relay, turn the starter switch to
"ON".
(2) Measure the voltage between 1st and 2nd terminals of the 31 pin
connector of ECU. (Leaving the connector connected with ECU.)
Standard: 20-28V
SHTS16Z080300031
.
NO
Abnormality of the ECU power supply circuit.
YES
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
(3) Measure the voltage between 24th and 2nd terminals of the 31
ECU VIEW pin connector. (Leaving the connector connected with ECU.)
Standard: Less than 2V
SHTS16Z080300032
.
NO
Abnormality of the ECU power supply circuit.
YES
(4) Measure the voltage between 6th terminal of the 22 pin connector
ECU VIEW and 2nd terminal of the 31 pin connector. (Leaving the connector
connected with ECU.)
Standard: 20-28V
SHTS16Z080300033
.
NO
Abnormality of the ECU power supply circuit.
YES
Normal.
SHTS16Z080300034
.
NO
Abnormality of the wire harness.
YES
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
(3) Measure the voltage between 24th terminal of the 31 pin connec-
tor of ECU (chassis harness side) and 1st terminal of the ABS
1 solenoid relay (socket side).
3
Standard: Less than 5 Ω
2
SHTS16Z080300035
.
NO
Abnormality of the wire harness.
YES
7. RELAY CHECK
(1) Remove the ABS solenoid relay, measure the resistance between
1 1st and 2nd terminals.
Standard: 160-340 Ω
3 5
SHTS16Z080300036
.
NO
Abnormality of the ABS solenoid relay.
YES
Normal.
.
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
1. RELAY CHECK
(1) Set the starter switch to "LOCK", remove the ABS solenoid relay
1
from the relay block.
(2) Measure the resistance between 3rd and 5th terminals.
Standard: More than 500 Ω
3 5
SHTS16Z080300037
.
NO
Abnormality of the ABS solenoid relay.
YES
(3) Measure the resistance between 1st and 2nd terminals of the
ABS solenoid relay.
1
Standard: 160-340 Ω
3 5
SHTS16Z080300038
.
NO
Abnormality of the ABS solenoid relay.
YES
(4) Check the continuity between 3rd and 5th terminals ABS solenoid
relay when a battery voltage was applied between 1st and 2nd
1 terminals.
Standard:
Turning on electricity between 1st and 2nd terminals:
3 5 It is conducted between 3rd and 5th terminals.
Not turning on electricity:
It is not conducted between 3rd and 5th terminals.
2
SHTS16Z080300039
.
NO
Abnormality of the ABS solenoid relay.
YES
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
2. ECU CHECK
ECU VIEW (1) Install the ABS solenoid relay, turn the starter switch to "ON".
(2) Measure the voltage between 1st and 2nd terminals of the 31 pin
connector of ECU. (Leaving the connector connected with ECU.)
Standard: 20-28V
SHTS16Z080300040
.
NO
Abnormality of the ECU power supply circuit.
YES
(3) Measure the voltage between 24th and 2nd terminals of the 31
ECU VIEW pin connector. (Leaving the connector connected with ECU.)
Standard: Less than 2V
SHTS16Z080300041
.
NO
Abnormality of the ECU power supply circuit.
YES
Normal.
.
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
1. FUSE CHECK
(1) Set the starter switch to "LOCK", check the ABS 50A fusible link.
Standard: No abnormality
.
NO
Replace the fusible link.
YES
2. RELAY CHECK
(1) Disconnect the 31 pin connector of ECU.
(2) Measure the resistance between 1st and 12th terminals of the 31
pin connector.
Standard: 100-210 Ω
SHTS16Z080300042
.
NO
Go to the item "6".
YES
(3) Remove the ABS motor relay, measure the resistance between
3rd and 5th terminals.
1
Standard: more than 500 Ω
3 5
SHTS16Z080300043
.
NO
Abnormality of the ABS motor relay.
YES
SHTS16Z080300044
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
NO
Abnormality of the wire harness.
YES
4. RELAY CHECK
(1) Check the continuity between 3rd and 5th terminals of ABS motor
1 relay when a battery voltage was applied between 1st and 2nd
terminals.
Standard:
3 5 Turning on electricity between 1st and 2nd terminals:
It is conducted between 3rd and 5th terminals.
Not turning on electricity:
2 It is not conducted between 3rd and 5th terminals.
SHTS16Z080300045
.
NO
Abnormality of the ABS motor relay.
YES
5. ECU CHECK
ECU VIEW (1) Connect the connector and relay, turn the starter switch to "ON".
(2) Measure the voltage between 1st and 2nd terminals of the 31 pin
connector of ECU. (Leaving the connector connected with ECU.)
Standard: 20-28V
SHTS16Z080300046
.
NO
Abnormality of the ECU power supply circuit.
YES
(3) Measure the voltage between 12th and 2nd terminals of the 31
ECU VIEW pin connector. (Leaving the connector connected with ECU.)
Standard: Less than 2V
SHTS16Z080300047
.
NO
Abnormality of the ECU power supply circuit.
YES
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
(4) Measure the voltage between 18th and 2nd terminals of the 31
ECU VIEW pin connector. (Leaving the connector connected with ECU.)
Standard: 20-28V
SHTS16Z080300048
.
NO
Abnormality of the ECU power supply circuit.
YES
Normal.
SHTS16Z080300049
.
NO
Abnormality of the wire harness.
YES
(2) Measure the resistance between 12th terminal of the 31 pin con-
nector of ECU (chassis harness side) and 3rd terminal of the ABS
3
motor relay (socket side).
1 4 Standard: Less than 5 Ω
SHTS16Z080300050
.
NO
Abnormality of the wire harness.
YES
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
7. RELAY CHECK
(1) Remove the ABS solenoid relay, measure the resistance between
1
1st and 2nd terminals.
Standard: 160-340 Ω
3 5
SHTS16Z080300051
.
NO
Abnormality of the ABS solenoid relay.
YES
Normal.
.
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
1. RELAY CHECK
(1) Set the starter switch to "LOCK", remove the ABS motor relay
1
from the relay block.
(2) Measure the resistance between 3rd and 5th terminals.
Standard: More than 500 Ω
3 5
SHTS16Z080300052
.
NO
Abnormality of the ABS motor relay.
YES
(3) Measure the resistance between 1st and 2nd terminals of the
ABS motor relay.
1
Standard: 100-210 Ω
3 5
SHTS16Z080300053
.
NO
Abnormality of the ABS motor relay.
YES
(4) Check the continuity between 3rd and 5th terminals of the ABS
motor relay when a battery voltage was applied between 1st and
1 2nd terminals.
Standard:
Turning on electricity between 1st and 2nd terminals:
3 5 It is conducted between 3rd and 5th terminals.
Not turning on electricity:
It is not conducted between 3rd and 5th terminals.
2
SHTS16Z080300054
.
NO
Abnormality of the ABS motor relay.
YES
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
2. ECU CHECK
ECU VIEW (1) Install the ABS motor relay, turn the starter switch to "ON".
(2) Measure the voltage between 1st and 2nd terminals of the 31 pin
connector of ECU. (Leaving the connector connected with ECU.)
Standard: 20-28V
SHTS16Z080300055
.
NO
Abnormality of ECU power supply circuit.
YES
(3) Measure the voltage between 12th and 2nd terminals of the 31
ECU VIEW pin connector. (Leaving the connector connected with ECU.)
Standard: Less than 2V
SHTS16Z080300056
.
NO
Abnormality of the ECU power supply circuit.
YES
Normal.
.
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
1. CHECK ITEM
(1) Firstly, perform the check of "DISCONNECTION OF SOLENOID
RELAY (DIAGNOSIS CODE 11)".
2. ACTUATOR CHECK
(1) Set the starter switch to "LOCK", disconnect the 24 pin connector
of ABS actuator.
(2) Measure the resistance between 16th and 19th terminals of the
24 pin connector (actuator side).
Standard: 26-40 Ω
SHTS16Z080300057
.
NO
Abnormality of the ABS actuator.
YES
(3) Measure the resistance between 14th and 16th terminals of the
24 pin connector (actuator side).
Standard: 13-20 Ω
SHTS16Z080300058
.
NO
Abnormality of the ABS actuator.
YES
SHTS16Z080300059
.
NO
Abnormality of the wire harness.
YES
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
(3) Measure the resistance between 8th terminal of the 22 pin con-
nector of ECU (chassis harness side) and 14th terminal of the 24
pin connector of ABS actuator (chassis harness side).
Standard: Less than 5 Ω
SHTS16Z080300060
.
NO
Abnormality of the wire harness.
YES
4. ECU CHECK
ECU VIEW (1) Connect all the connector, turn the starter switch to "ON".
(2) Measure the voltage between 16th terminal of the 22 pin connec-
tor and 2nd terminal of the 31 pin connector of ECU. (Leaving the
connector connected with ECU.)
Standard: 20-28V
SHTS16Z080300061
.
NO
Abnormality of the ECU power supply voltage.
YES
(3) Measure the voltage between 8th terminal of the 22 pin connector
ECU VIEW and 2nd terminal of the 31 pin connector. (Leaving the connector
connected with ECU.)
Standard: 20-28V
SHTS16Z080300062
.
NO
Abnormality of the ECU power supply voltage.
YES
Normal.
.
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
1. CHECK ITEM
(1) Firstly, perform the check of "DISCONNECTION OF SOLENOID
RELAY (DIAGNOSIS CODE 11)".
2. ACTUATOR CHECK
(1) Set the starter switch to "LOCK", disconnect the 24 pin connector
of ABS actuator.
(2) Measure the resistance between 16th and 22th terminals of the
24 pin connector (actuator side).
Standard: 26-40 Ω
SHTS16Z080300063
.
NO
Abnormality of the ABS actuator.
YES
(3) Measure the resistance between 15th and 16th terminals of the
24 pin connector (actuator side).
Standard: 13-20 Ω
SHTS16Z080300064
.
NO
Abnormality of the ABS actuator.
YES
SHTS16Z080300065
.
NO
Abnormality of the wire harness.
YES
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
(3) Measure the resistance between 9th terminal of the 31 pin con-
nector of ECU (chassis harness side) and 15th terminal of the 24
pin connector of ABS actuator (chassis harness side).
Standard: Less than 5 Ω
SHTS16Z080300066
.
NO
Abnormality of the wire harness.
YES
4. ECU CHECK
ECU VIEW (1) Connect all the connector, turn the starter switch to "ON".
(2) Measure the voltage between 8th and 2nd terminals of the 31 pin
connector of ECU. (Leaving the connector connected with ECU.)
Standard: 20-28V
SHTS16Z080300067
.
NO
Abnormality of the ECU power supply voltage.
YES
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
(3) Measure the voltage between 9th and 2nd terminals of the 31 pin
ECU VIEW connector. (Leaving the connector connected with ECU.)
Standard: 20-28V
SHTS16Z080300068
.
NO
Abnormality of the ECU power supply voltage.
YES
Normal.
.
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
1. CHECK ITEM
(1) Firstly, perform the check of "DISCONNECTION OF SOLENOID
RELAY (DIAGNOSIS CODE 11)".
2. ACTUATOR CHECK
(1) Set the starter switch to "LOCK", disconnect the 24 pin connector
of ABS actuator.
(2) Measure the resistance between 6th and 16th terminals of the 24
pin connector (actuator side).
Standard: 26-40 Ω
SHTS16Z080300069
.
NO
Abnormality of the ABS actuator.
YES
(3) Measure the resistance between 12th and 16th terminals of the
24 pin connector (actuator side).
Standard: 13-20 Ω
SHTS16Z080300070
.
NO
Abnormality of the ABS actuator.
YES
SHTS16Z080300071
.
NO
Abnormality of the wire harness.
YES
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
(3) Measure the resistance between 30th terminal of the 31 pin con-
nector of ECU (chassis harness side) and 12th terminal of the 24
pin connector of ABS actuator (chassis harness side).
Standard: Less than 5 Ω
SHTS16Z080300072
.
NO
Abnormality of the wire harness.
YES
4. ECU CHECK
ECU VIEW (1) Connect all the connector, turn the starter switch to "ON".
(2) Measure the voltage between 20th and 2nd terminals of the 31
pin connector of ECU. (Leaving the connector connected with
ECU.)
Standard: 20-28V
SHTS16Z080300073
.
NO
Abnormality of the ECU power supply voltage.
YES
(3) Measure the voltage between 30th and 2nd terminals of the 31
ECU VIEW pin connector. (Leaving the connector connected with ECU.)
Standard: 20-28V
SHTS16Z080300074
.
NO
Abnormality of the ECU power supply voltage.
YES
Normal.
.
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
1. CHECK ITEM
(1) Firstly, perform the check of "DISCONNECTION OF SOLENOID
RELAY (DIAGNOSIS CODE 11)".
2. ACTUATOR CHECK
(1) Set the starter switch to "LOCK", disconnect the 24 pin connector
of ABS actuator.
(2) Measure the resistance between 16th and 18th terminals of the
24 pin connector (actuator side).
Standard: 26-40 Ω
SHTS16Z080300075
.
NO
Abnormality of the ABS actuator.
YES
(3) Measure the resistance between 7th and 16th terminals of the 24
pin connector (actuator side).
Standard: 13-20 Ω
SHTS16Z080300076
.
NO
Abnormality of the ABS actuator.
YES
SHTS16Z080300077
.
NO
Abnormality of the wire harness.
YES
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
(3) Measure the resistance between 1st terminal of the 22 pin con-
nector of ECU (chassis harness side) and 7th terminal of the 24
pin connector of ABS actuator (chassis harness side).
Standard: Less than 5 Ω
SHTS16Z080300078
.
NO
Abnormality of the wire harness.
YES
4. ECU CHECK
ECU VIEW (1) Connect all the connector, turn the starter switch to "ON".
(2) Measure the voltage between 7th terminal of the 22 pin connector
of ECU and 2nd terminal of the 31 pin connector of ECU. (Leaving
the connector connected with ECU.)
Standard: 20-28V
SHTS16Z080300079
.
NO
Abnormality of the ECU power supply voltage.
YES
(3) Measure the voltage between 1st terminal of the 22 pin connector
ECU VIEW and 2nd terminal of the 31 pin connector. (Leaving the connector
connected with ECU.)
Standard: 20-28V
SHTS16Z080300080
.
NO
Abnormality of the ECU power supply voltage.
YES
Normal.
.
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
1. CHECK ITEM
(1) Firstly, perform the check of "DISCONNECTION OF SOLENOID
RELAY (DIAGNOSIS CODE 11)".
2. ACTUATOR CHECK
(1) Set the starter switch to "LOCK", disconnect the 24 pin connector
of ABS actuator.
(2) Measure the resistance between 8th and 21th terminals of the 24
pin connector (actuator side).
Standard: 26-40 Ω
SHTS16Z080300081
.
NO
Abnormality of the ABS actuator.
YES
SHTS16Z080300082
.
NO
Abnormality of the ABS actuator.
YES
SHTS16Z080300083
.
NO
Abnormality of the wire harness.
YES
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
(3) Measure the resistance between 2nd terminal of the 22 pin con-
nector of ECU (chassis harness side) and 8th terminal of the 24
pin connector of ABS actuator (chassis harness side).
Standard: Less than 5 Ω
SHTS16Z080300084
.
NO
Abnormality of the wire harness.
YES
(4) Measure the resistance between 5th terminal of the 22 pin con-
nector of ECU (chassis harness side) and 20th terminal of the 24
pin connector of ABS actuator (chassis harness side).
Standard: Less than 5 Ω
SHTS16Z080300085
.
NO
Abnormality of the wire harness.
YES
(5) Measure the resistance between 4th terminal of the 22 pin con-
nector of ECU (chassis harness side) and 13th terminal of the 24
pin connector of ABS actuator (chassis harness side).
Standard: Less than 5 Ω
SHTS16Z080300086
.
NO
Abnormality of the wire harness.
YES
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
4. ECU CHECK
ECU VIEW (1) Connect all the connector, turn the starter switch to "ON".
(2) Measure the voltage between 3rd terminal of the 31 pin connector
of ECU and 2nd terminal of the 31 pin connector of ECU. (Leaving
the connector connected with ECU.)
Standard: 20-28V
SHTS16Z080300087
.
NO
Abnormality of the ECU power supply voltage.
YES
(3) Measure the voltage between 5th terminal of the 22 pin connector
ECU VIEW and 2nd terminal of the 31 pin connector. (Leaving the connector
connected with ECU.)
Standard: 20-28V
SHTS16Z080300088
.
NO
Abnormality of the ECU power supply voltage.
YES
Normal.
.
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
1. SENSOR CHECK
(1) Perform the following checks:
• No damage at the sensor tip.
• No adhesion of foreign material of more than 1 mm3.
• No clearance between sensor and the face to be installed.
• No air gap expansion between sensor and sensor rotor.
Standard: No abnormality
.
NO
Repair or replace the sensor installing part.
YES
(2) Set the starter switch to "LOCK", disconnect the 31 pin connector
of ECU.
(3) Measure the resistance between 25th and 26th terminals of the
31 pin connector (chassis harness side).
Standard: 0.8-2.0 kΩ
SHTS16Z080300089
.
NO
Go to the item "3".
YES
2. ECU CHECK
(1) Connect the connector, check the continuity between 2nd and
ECU VIEW 25th terminals of the 31 pin connector of ECU. (Leaving the con-
nector connected with ECU.)
Standard: Continuity
SHTS16Z080300090
.
NO
Abnormality of the ECU.
YES
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
SHTS16Z080300091
.
NO
Abnormality of the ECU.
YES
Normal.
SHTS16Z080300092
.
NO
Abnormality of the wire harness.
YES
(3) Measure the resistance between 25th terminal of the 31 pin con-
nector of ECU (chassis harness side) and 2nd terminal of the
sensor connector (chassis harness side).
Standard: Less than 5 Ω
SHTS16Z080300093
.
NO
Abnormality of the wire harness.
YES
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
4. SENSOR CHECK
(1) Measure the resistance between 1st and 2nd terminals of the
connector of front right wheel sensor (sensor side).
Standard: 0.8-2.0 kΩ
SHTS16Z080300094
.
NO
Abnormality of the sensor.
YES
Normal.
.
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
1. SENSOR CHECK
(1) Perform the following checks:
• No damage at the sensor tip.
• No adhesion of foreign material of more than 1 m m3.
• No clearance between sensor and the face to be installed.
• No air gap expansion between sensor and sensor rotor.
Standard: No abnormality
.
NO
Repair or replace the sensor installing part.
YES
(2) Set the starter switch to "LOCK", disconnect the 31 pin connector
of ECU.
(3) Measure the resistance between 27th and 28th terminals of the
31 pin connector (chassis harness side).
Standard: 0.8-2.0 kΩ
SHTS16Z080300095
.
NO
Go to the item "3".
YES
2. ECU CHECK
(1) Connect the connector, check the continuity between 2nd and
ECU VIEW 28th terminals of the 31 pin connector of ECU. (Leaving the con-
nector connected with ECU.)
Standard: Continuity
SHTS16Z080300096
.
NO
Abnormality of the ECU.
YES
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
SHTS16Z080300097
.
NO
Abnormality of the ECU.
YES
Normal.
SHTS16Z080300098
.
NO
Abnormality of the wire harness.
YES
(3) Measure the resistance between 28th terminal of the 31 pin con-
nector of ECU (chassis harness side) and 2nd terminal of the
sensor connector (chassis harness side).
Standard: Less than 5 Ω
SHTS16Z080300099
.
NO
Abnormality of the wire harness.
YES
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
4. SENSOR CHECK
(1) Measure the resistance between 1st and 2nd terminals of the
connector of front left wheel sensor (sensor side).
Standard: 0.8-2.0 kΩ
SHTS16Z080300100
.
NO
Abnormality of the sensor.
YES
Normal.
.
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
1. SENSOR CHECK
(1) Perform the following checks:
• No damage at the sensor tip.
• No adhesion of foreign material of more than 1 m m3.
• No clearance between sensor and the face to be installed.
• No air gap expansion between sensor and sensor rotor.
Standard: No abnormality
.
NO
Repair or replace the sensor installing part.
YES
(2) Set the starter switch to "LOCK", disconnect the 24 pin connector
of ECU.
(3) Measure the resistance between 15th and 16th terminals of the
24 pin connector (chassis harness side).
Standard: 0.8-2.0 kΩ
SHTS16Z080300101
.
NO
Go to the item "3".
YES
2. ECU CHECK
ECU VIEW (1) Connect the connector, check the continuity between 15th termi-
nal of the 24 pin connector of ECU and 2nd terminal of the 31 pin
connector of ECU. (Leaving the connector connected with ECU.)
Standard: Continuity
SHTS16Z080300102
.
NO
Abnormality of the ECU.
YES
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
SHTS16Z080300103
NO
Abnormality of the ECU.
YES
Normal.
SHTS16Z080300104
.
NO
Abnormality of the wire harness.
YES
(3) Measure the resistance between 15th terminal of the 24 pin con-
nector of ECU (chassis harness side) and 1st terminal of the sen-
sor connector (chassis harness side).
Standard: Less than 5 Ω
SHTS16Z080300105
.
NO
Abnormality of the wire harness.
YES
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
4. SENSOR CHECK
(1) Measure the resistance between 1st and 2nd terminals of the
connector of rear right wheel sensor.
Standard: 0.8-2.0 kΩ
SHTS16Z080300106
.
NO
Abnormality of the sensor.
YES
Normal.
.
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
1. SENSOR CHECK
(1) Perform the following checks:
• No damage at the sensor tip.
• No adhesion of foreign material of more than 1 m m3.
• No clearance between sensor and the face to be installed.
• No air gap expansion between sensor and sensor rotor.
Standard: No abnormality
.
NO
Repair or replace the sensor installing part.
YES
(2) Set the starter switch to "LOCK", disconnect the 24 pin connector
of ECU.
(3) Measure the resistance between 22th and 23th terminals of the
24 pin connector (chassis harness side).
Standard: 0.8-2.0 kΩ
SHTS16Z080300107
.
NO
Go to the item "3".
YES
2. ECU CHECK
ECU VIEW (1) Connect the connector, check the continuity between 23th termi-
nal of the 24 pin connector of ECU and 2nd terminal of the 31 pin
connector of ECU. (Leaving the connector connected with ECU.)
Standard: Continuity
SHTS16Z080300108
.
NO
Abnormality of the ECU.
YES
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
OSCILLOSCOPE
SHTS16Z080300109
.
NO
Abnormality of the ECU.
YES
Normal.
SHTS16Z080300110
.
NO
Abnormality of the wire harness.
YES
(3) Measure the resistance between 23th terminal of the 31 pin con-
nector of ECU (chassis harness side) and 1st terminal of the sen-
sor connector (chassis harness side).
Standard: Less than 5 Ω
SHTS16Z080300111
.
NO
Abnormality of the wire harness.
YES
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
4. SENSOR CHECK
(1) Measure the resistance between 1st and 2nd terminals of the
connector of rear left wheel sensor (sensor side).
Standard: 0.8-2.0 kΩ
SHTS16Z080300112
.
NO
Abnormality of the sensor.
YES
Normal.
.
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
1. CHECK ITEM
(1) Perform the check of "ABNORMALITY OF FRONT RIGHT
WHEEL SENSOR (DIAGNOSIS CODE 31)".
.
1. CHECK ITEM
(1) Perform the check of "ABNORMALITY OF FRONT LEFT WHEEL
SENSOR (DIAGNOSIS CODE 32)".
.
1. CHECK ITEM
(1) Perform the check of "ABNORMALITY OF REAR RIGHT WHEEL
SENSOR (DIAGNOSIS CODE 33)".
.
1. CHECK ITEM
(1) Perform the check of "ABNORMALITY OF REAR LEFT WHEEL
SENSOR (DIAGNOSIS CODE 34)".
.
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
SHTS16Z080300113
.
NO
Abnormality of the power supply circuit.
YES
SHTS16Z080300114
.
NO
Abnormality of the power supply circuit.
YES
.
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
1. SENSOR CHECK
ECU VIEW (1) Set the starter switch to "ON", measure the voltage between 24th
and 15th terminal of the 28 pin connector of ECU. (Leaving the
connector connected with ECU.)
Standard: 4.5-5.5V
SHTS16Z080300115
.
NO
Go to the item "5".
YES
(2) Measure the voltage between 24th and 14th terminal of the 28 pin
ECU VIEW connector. (Leaving the connector connected with ECU.)
Standard: 4.5-5.5V
SHTS16Z080300116
.
NO
Go to the item "5".
YES
SHTS16Z080300117
.
NO
Abnormality of the wire harness.
YES
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
SHTS16Z080300118
.
NO
Abnormality of the ABS actuator.
YES
4. ECU CHECK
ECU VIEW (1) Measure the voltage between 24th terminal of the 28 pin connec-
tor of ECU and 2nd terminal of the 31 pin connector of ECU.
(Leaving the connector connected with ECU.)
Standard: 4.85-5.15V
SHTS16Z080300119
.
NO
Abnormality of the ECU.
YES
(2) Measure the voltage between 25th terminal of the 28 pin connec-
ECU VIEW tor and 2nd terminal of the 31 pin connector. (Leaving the connec-
tor connected with ECU.)
Standard: 0.3-0.7V
SHTS16Z080300120
.
NO
Abnormality of the ECU.
YES
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
(3) Turn the starter switch to "LOCK", check the continuity between
ECU VIEW 15th terminal of the 28 pin connector and 2nd terminal of the 31
pin connector. (Leaving the connector connected with ECU.)
Standard: Continuity
SHTS16Z080300121
.
NO
Abnormality of the ECU.
YES
(4) Check the continuity between 14th terminal of the 28 pin connec-
ECU VIEW tor and 2nd terminal of the 31 pin connector. (Leaving the connec-
tor connected with ECU.)
Standard: Continuity
SHTS16Z080300122
.
NO
Abnormality of the ECU.
YES
Normal.
SHTS16Z080300123
.
NO
Abnormality of the wire harness.
YES
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
(3) Measure the resistance between 15th terminal of the 28 pin con-
nector of ECU (chassis harness side) and 3rd terminal of the 3 pin
connector of ABS actuator (chassis harness side).
Standard: Less than 5 Ω
SHTS16Z080300124
.
NO
Abnormality of the wire harness.
YES
Normal.
.
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
SHTS16Z080300125
.
NO
Disconnection of the wire harness.
YES
(3) Connect all the connector, turn the starter switch to "ON".
ECU VIEW (4) Measure the voltage between 1st terminal of the 24 pin connector
of ECU and 2nd terminal of the 31 pin connector of ECU. (Leaving
the connector connected with ECU.)
Standard: 20-28V
SHTS16Z080300126
.
NO
Ground short of the wire harness.
YES
SHTS16Z080300127
.
NO
Abnormality of the stop light switch.
YES
NO
Abnormality of the motor.
YES
SHTS16Z080300129
.
NO
Abnormality of the motor.
YES
.
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
SHTS16Z080300130
.
NO
Disconnection of the wire harness.
YES
SHTS16Z080300131
.
NO
Ground short of the wire harness.
YES
NO
Abnormality of the exhaust brake cut relay.
YES
Normal.
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
1. CHECK ITEM
(1) Check if any abnormality on meter display (Indicator of air pres-
sure) is seen or not. When any abnormality found, check low
pressure warning switch and air gauge sensor.
.
SHTS16Z080300133
.
NO
Disconnection of the wire harness.
YES
.
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
SHTS16Z080300134
.
NO
Disconnection of the wire harness.
YES
(3) Check the continuity between 15th terminal of the 31 pin connec-
tor of ECU (chassis harness side) and 2nd terminal of the sensor
connector (chassis harness side).
Standard: Continuity
SHTS16Z080300135
.
NO
Disconnection of the wire harness.
YES
(4) Check the continuity between 16th terminal of the 31 pin connec-
tor of ECU (chassis harness side) and 3rd terminal of the sensor
connector (chassis harness side).
Standard: Continuity
SHTS16Z080300136
.
NO
Disconnection of the wire harness.
YES
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
SHTS16Z080300137
.
NO
Abnormality of the clutch stroke sensor.
YES
.
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
SHTS16Z080300138
.
NO
Disconnection of the wire harness.
YES
SHTS16Z080300139
.
NO
Replace the wire harness, or abnormality of
the power supply "M".
YES
SHTS16Z080300140
.
NO
Abnormality of the neutral switch.
YES
SHTS16Z080300141
.
NO
Short circuit of the wire harness.
YES
5 Standard:
NO
Abnormality of the release timing switch.
YES
.
2A&0AA&'051A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧞㧤ಽ
SHTS16Z080300143
.
NO
Disconnection the wire harness.
YES
(3) Check the continuity between 3rd terminal of the 28 pin connector
of ECU (chassis harness side) and 6th terminal of the switch con-
nector (chassis harness side).
Standard: Continuity
SHTS16Z080300144
.
NO
Disconnection the wire harness.
YES
7 6 5 Standard:
SHTS16Z080300145
.
NO
Abnormality of the ES start main switch.
YES
1. CHECK ITEM
(1) Perform the initial setting of ES start.
Refer to "INITIAL SETTING OF ES START" in the section
"ADJUSTMENT" in the chapter "ES START (EASY & SMOOTH
START SYSTEM) (DENSO)".
.
SHTS16Z080300146
.
NO
Disconnection the wire harness.
YES
NO
Abnormality of the engine ECU.
YES
.
2A&0AA9#$%1A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧝ಽ
DN03-002
ANTI-LOCK BRAKE
SYSTEM DIAGRAM
EN16Z0803J100001
Fail-safe function
(safety function)
ABS warning light
SHTS16Z080300001
2A&0AA9#$%1A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧝ಽ
HANDLING PRECAUTIONS
EN16Z0803F200001
1. ABOUT CONNECTORS
(1) Before performing the inspection operation, make sure that all
connectors are connected securely.
(2) Do not contact the tester bar to the connection surface of the con-
nector. This may cause terminal damage or a short-circuit.
(3) All connectors in the connector diagram are observed from the
contact surfaces. However, the tester bar is put from the rear side.
SHTS16Z080300002
(4) The connector is displayed from the view of the mating surface
when the connector lock is positioned above.
Reference
• Female connector: The terminal is female.
• Male connector: The terminal is male.
SHTS16Z080300003
(5) As for the terminal numbers of the connector, the first terminal is
located on the top right terminal of the male connector and the top
left terminal of the female connector.
Reference:
When viewed from the mating surface, the terminal numbers
of both connectors are located symmetrically (reversed hori-
zontally).
(6) When disconnecting the connectors, be sure to position the
starter switch "LOCK".
INSPECTION
(ABS SYSTEM OPERATION AND FAILURE DIAGNOSTICS)
EN16Z0803F200002
NOTICE
The ABS warning light may remain lit if the ABS system experiences a temporary malfunction and then recovers.
Should this occur, reset it by turn "LOCK" the starter switch temporarily while the vehicle is stopped. Then start
driving the vehicle. If the light goes off when a speed of vehicle exceeds 7 km/h {4.3 mile/h}, ABS is working nor-
mally.
2A&0AA9#$%1A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧝ಽ
No
Yes
Is the fuse burned out? Replace the fuse.
Start driving
(driving speed more than 7 km/h {4.3 mile/h}
Yes
Does the ABS warning light go off? Normal
No
No
Are the ABS ECU harness connectors Yes Check the harness
loose or disconnected? connectors.
No
Is there anything wrong with the solenoid Yes Replace ABS control
coil of the ABS control valve? valve.
Yes
Does the ABS warning light keeping go off. Normal
Does the light lit when the brakes Yes Broken wire or short in the ABS Inspect the ABS control
are applied? control valve system valve system.
No
Is there a broken wire or short in the wheel Yes Inspect the wheel sensor
sensor system? system.
No
Is there a broken wire or short in the power Yes Inspect power supply
supply system? system.
No
ABS ECU malfunction Replace the ABS ECU.
SHTS16Z080300006
P P
NOTICE
ABS diagnosis switch reverts automatically to "OFF" position.
2A&0AA9#$%1A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧝ಽ
ON
CONNECTING FOR 0.5-3.0 SECONDS
ABS DIAGNOSIS SWITCH
ON 0.5 SECONDS
ABS WARNING LIGHT
1.5 SECONDS 1.5 SECONDS 4.0 SECONDS 1.5 SECONDS 4.0 SECONDS 1.5 SECONDS
1a 1b 1a 1b 1a 1b
ERROR CODE 1a-1b = 3-4 : Left wheel sensor of rear axle: air gap large.
SHTS16Z080300008
ON
CONNECTING FOR 0.5-3.0 SECONDS
ABS DIAGNOSIS SWITCH
ON 0.5 SECONDS
1a 1b 2a 2b
ERROR CODE
Lastly occurred error 1a-1b = 2-2 : Abnormality in modulator valve of left wheel on front axle.
Second error from the last 2a-2b = 7-3 : Abnormality in the cut relay of sub brake.
SHTS16Z080300009
ON
CONNECTING FOR 3.0-6.3 SECONDS
ABS DIAGNOSIS SWITCH
ON 0.5 SECONDS 0.5 SECONDS
After ABS warning light flashes on/off quickly by 8 times, the system cord will be displayed repeatedly.
SHTS16Z080300010
2A&0AA9#$%1A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧝ಽ
1 1 Normal — —
2 ABS wheel sensor Front axle left wheel abnormal 18 pin connector-14th, 15th
3
3 air gap Rear axle right wheel abnormal 18 pin connector-7th, 13th
2 ABS wheel sensor Front axle left wheel abnormal 18 pin connector-14th, 15th
4 disconnection and
3 short-circuit Rear axle right wheel abnormal 18 pin connector-7th, 13th
4 Internal abnormality —
NOTICE
Different terminal numbers from below listed figure are stamped on the connector unit. However, verify it in refer-
ence to this figure.
ABS ECU
18-PIN CONNECTORS
1 2 3 4 5 6
7 8 9 10 11 12
A
VIEW A
15-PIN CONNECTORS
1 2 3 4 5
6 7 8 9 10 B
VIEW B
1 2
C
3 4 CAB SIDE HARNESS
VIEW C
2 1 D
VIEW D
SHTS16Z080300011
2A&0AA9#$%1A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧝ಽ
SHTS16Z080300012
.
NO
Abnormality of harness
YES
(3) Measure the voltage 5th terminal of 18 pin connectors and 13th
ECU VIEW one of 15 pin ones.
18 PIN CONNECTORS 15 PIN CONNECTORS Standard: 1V or less
SHTS16Z080300013
.
NO
Abnormality of harness
YES
SHTS16Z080300014
.
NO
Go to the item 3.
YES
SHTS16Z080300015
.
NO
Go to the item 3.
YES
SHTS16Z080300016
.
NO
Abnormality of control valve
YES
Abnormality of harness
2A&0AA9#$%1A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧝ಽ
SHTS16Z080300017
.
NO
Abnormality of harness
YES
SHTS16Z080300018
.
NO
Abnormality of harness
YES
.
2A&0AA9#$%1A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧝ಽ
SHTS16Z080300019
.
NO
Abnormality of harness
YES
(3) Measure the voltage 17th terminal of 18 pin connectors and 13th
ECU VIEW one of 15 pin ones.
18 PIN CONNECTORS 15 PIN CONNECTORS Standard: 1V or less
SHTS16Z080300020
.
NO
Abnormality of harness
YES
SHTS16Z080300021
.
NO
Go to the item 3.
YES
SHTS16Z080300022
.
NO
Go to the item 3.
YES
SHTS16Z080300016
.
NO
Abnormality of control valve
YES
Abnormality of harness
SHTS16Z080300023
.
NO
Abnormality of harness
YES
SHTS16Z080300024
.
NO
Abnormality of harness
YES
SHTS16Z080300025
.
NO
Abnormality of harness
YES
(3) Measure the voltage 16th terminal of 18 pin connectors and 13th
ECU VIEW one of 15 pin ones.
18 PIN CONNECTORS 15 PIN CONNECTORS Standard: 1V or less
SHTS16Z080300026
.
NO
Abnormality of harness
YES
SHTS16Z080300027
.
NO
Go to the item 3.
YES
SHTS16Z080300028
.
NO
Go to the item 3.
YES
SHTS16Z080300016
.
NO
Abnormality of control valve
YES
Abnormality of harness
SHTS16Z080300029
.
NO
Abnormality of harness
YES
SHTS16Z080300030
.
NO
Abnormality of harness
YES
SHTS16Z080300031
.
NO
Abnormality of harness
YES
(3) Measure the voltage 11th terminal of 18 pin connectors and 13th
ECU VIEW one of 15 pin ones.
18 PIN CONNECTORS 15 PIN CONNECTORS Standard: 1V or less
SHTS16Z080300032
.
NO
Abnormality of harness
YES
SHTS16Z080300033
.
NO
Go to the item 3.
YES
SHTS16Z080300034
.
NO
Go to the item 3.
YES
SHTS16Z080300016
.
NO
Abnormality of control valve
YES
Abnormality of harness
SHTS16Z080300035
.
NO
Abnormality of harness
YES
SHTS16Z080300036
.
NO
Abnormality of harness
YES
SHTS16Z080300037
SHTS16Z080300039
.
NO
Go to the item 5.
YES
SHTS16Z080300040
.
NO
Go to the item 6.
YES
SHTS16Z080300041
.
NO
Abnormality wheel sensor
YES
.
2A&0AA9#$%1A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧝ಽ
SHTS16Z080300037
SHTS16Z080300042
.
NO
Go to the item 5.
YES
SHTS16Z080300043
.
NO
Go to the item 6.
YES
SHTS16Z080300041
.
NO
Abnormality wheel sensor
YES
.
2A&0AA9#$%1A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧝ಽ
SHTS16Z080300045
.
NO
Go to the item 5.
YES
SHTS16Z080300046
.
NO
Go to the item 6.
YES
SHTS16Z080300041
.
NO
Abnormality wheel sensor
YES
.
2A&0AA9#$%1A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧝ಽ
SHTS16Z080300047
.
NO
Go to the item 5.
YES
SHTS16Z080300048
.
NO
Go to the item 6.
YES
SHTS16Z080300041
.
NO
Abnormality of wheel sensor
YES
.
2A&0AA9#$%1A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧝ಽ
SHTS16Z080300049
.
NO
Abnormality of harness
YES
SHTS16Z080300050
.
NO
Abnormality of harness
YES
SHTS16Z080300051
.
NO
Go to the item 4.
YES
SHTS16Z080300052
.
NO
Go to the item 5.
YES
SHTS16Z080300053
.
NO
Abnormality of wheel sensor
YES
.
2A&0AA9#$%1A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧝ಽ
SHTS16Z080300054
.
NO
Abnormality of harness
YES
SHTS16Z080300055
.
NO
Abnormality of harness
YES
SHTS16Z080300042
.
NO
Go to the item 4.
YES
SHTS16Z080300043
.
NO
Go to the item 5.
YES
SHTS16Z080300053
.
NO
Abnormality of wheel sensor
YES
.
2A&0AA9#$%1A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧝ಽ
SHTS16Z080300056
.
NO
Abnormality of harness
YES
SHTS16Z080300057
.
NO
Abnormality of harness
YES
SHTS16Z080300045
.
NO
Go to the item 4.
YES
SHTS16Z080300046
.
NO
Go to the item 5.
YES
SHTS16Z080300053
.
NO
Abnormality of wheel sensor
YES
.
2A&0AA9#$%1A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧝ಽ
SHTS16Z080300058
.
NO
Abnormality of harness
YES
SHTS16Z080300059
.
NO
Abnormality of harness
YES
SHTS16Z080300047
.
NO
Go to the item 4.
YES
SHTS16Z080300048
.
NO
Go to the item 5.
YES
SHTS16Z080300053
.
NO
Abnormality of wheel sensor
YES
(3) Measure the voltage terminal of sub brake cut relay and ground
bolt.
Standard: 20V or more
GROUND BOLT
SHTS16Z080300061
.
NO
Abnormality of harness
YES
SHTS16Z080300062
NO
Abnormality of harness
YES
2A&0AA9#$%1A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧝ಽ
SHTS16Z080300063
.
NO
Abnormality of sub brake cut relay
YES
SHTS16Z080300064
NO
Abnormality of ABS ECU
YES
Normality
SHTS16Z080300065
.
NO
Abnormality of harness
YES
.
2A&0AA9#$%1A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧝ಽ
2A&0AA'55A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧠ಽ
DN03-003
ES START
(EASY & SMOOTH START) SYSTEM ......DN03-2
HANDLING PRECAUTIONS ........................... DN03-2
SYSTEM DIAGRAM ........................................ DN03-3
ARRANGEMENT OF CONNECTOR PIN........ DN03-4
PRE-INSPECTION .......................................... DN03-5
TROUBLESHOOTING..................................... DN03-6
FAILURE DIAGNOSIS BY
USING DIAGNOSIS MONITOR..................... DN03-10
HOW TO DELETE
THE DIAGNOSIS CODE 8 ............................ DN03-12
HOW TO DELETE
THE DIAGNOSIS CODE 12 .......................... DN03-13
HOW TO DELETE
THE DIAGNOSIS CODE 13 .......................... DN03-14
DAMAGE ANALYSIS BY
DIAGNOSIS CODE ....................................... DN03-16
POWER MALFUNCTION
(NO DIAGNOSIS CODE)............................... DN03-16
POWER SUPPLY VOLTAGE MALFUNCTION
(DIAGNOSIS CODE 2) .................................. DN03-19
CLUTCH STROKE SENSOR SYSTEM DAMAGE
(DIAGNOSIS CODE 3) .................................. DN03-20
SPEED SENSOR SYSTEM DAMAGE
(DIAGNOSIS CODE 4) .................................. DN03-21
ES START CONTROL VALVE DAMAGE
(DIAGNOSIS CODE 7) .................................. DN03-22
CLUTCH FLUID PRESSURE SWITCH DAMAGE
(DIAGNOSIS CODE 8) .................................. DN03-24
CLUTCH STROKE SENSOR POWER SYSTEM
MALFUNCTION (DIAGNOSIS CODE 9) ....... DN03-26
NEUTRAL SWITCH AND
BACK-UP LIGHT SWITCH MALFUNCTION
(DIAGNOSIS CODE 11) ................................ DN03-27
NEUTRAL SWITCH SYSTEM OR
SPEED SENSOR SYSTEM MALFUNCTION
(DIAGNOSIS CODE 12) ................................ DN03-29
STOP LIGHT SWITCH DAMAGE
(DIAGNOSIS CODE 13) ................................ DN03-31
ES START CONTROLLER MALFUNCTION
(DIAGNOSIS CODE 16) ................................ DN03-32
ES MAIN SWITCH DAMAGE
(DIAGNOSIS CODE 18) ................................ DN03-33
ES START RELEASE TIMING SWITCH
(DIAGNOSIS CODE 21) ................................ DN03-35
2A&0AA'55A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧠ಽ
1. ABOUT CONNECTORS
(1) Before performing the inspection operation, make sure that all
connectors are connected securely.
(2) Do not contact the tester bar to the connection surface of the con-
nector. This may cause terminal damage or a short-circuit.
(3) All connectors in the connector diagram are observed from the
contact surfaces. However, the tester bar is put from the rear side.
SHTS16Z080300001
(4) The connector is displayed from the view of the mating surface
when the connector lock is positioned above.
Reference
• Female connector: The terminal is female.
• Male connector: The terminal is male.
SHTS16Z080300002
(5) As for the terminal numbers of the connector, the first terminal is
located on the top right terminal of the male connector and the top
left terminal of the female connector.
Reference:
When viewed from the mating surface, the terminal numbers
of both connectors are located symmetrically (reversed hori-
zontally).
(6) When disconnecting the connectors, be sure to position the
starter switch "LOCK".
SYSTEM DIAGRAM
EN16Z0803F200002
ES MAIN SWITCH
RELEASE TIMING
SWITCH
ES START CONTROL
STOP LIGHT SWITCH VALVE
ES START
CONTROLLER
NEUTRAL SWITCH
COURTESY SWITCH
PARKING BRAKE
SWITCH 2
BUZZER
BACK UP LIGHT
SWTCH
CLUTCH FLUID
PRESSURE SWITCH
CLUTCH STROKE
SENSOR
SPEED SENSOR
DIAGNOSIS MONITOR
SHTS16Z080300004
2A&0AA'55A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧠ಽ
ES START CONTROLLER
26-PIN CONNECTOR
1 2 3 4 5 6 7 8 9 10 11
A
15 16 18 19 20 2122 24
CAB SIDE HARNESS
VIEW A
12-PIN CONNECTOR
1 2 3
B
7
CAB SIDE HARNESS
VIEW B
PRE-INSPECTION
EN16Z0803F200004
SHTS16Z080300006
Perform failure
Defects of signal
Failure alarm Blinking Beeping continuously diagnosis by diagnosis
switches or sensors
Warning function.
Initialization is
Non-adjustment alarm Blinking No beeping Initialize.
not completed.
TROUBLESHOOTING
EN16Z0803F300001
2 Set the starter key to [ON] and check the main power.
SHTS16Z080300009
SHTS16Z080300012
2A&0AA'55A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧠ಽ
SHTS16Z080300015
ON
SHTS16Z080300025
BLACK CONNECTOR
WHITE CONNECTOR
SHTS16Z080300017
SHTS16Z080300018
2A&0AA'55A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧠ಽ
SHTS16Z080300019
(3) Wait for several seconds. Then connect the diagnosis monitor to
output the present failure.
.
2A&0AA'55A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧠ಽ
1. DELETING PROCEDURE
(1) Turn the starter switch to "ON" position and ES main switch
"OFF".
OFF (2) After having repaired the failure, step and release the clutch pedal
for more than three times to make the controller recognize the
ON/OFF of hydraulic switch.
HINT
Until the controller recognizes the ON/OFF of hydraulic switch, the
diagnosis code cannot be deleted.
SHTS16Z080300021
SHTS16Z080300022
(5) Disconnect the diagnosis monitor while keeping the starter switch
at "ON" position.
(6) Wait for several seconds. Then connect the diagnosis monitor to
check that the diagnosis code 8 has been deleted.
.
SHTS16Z080300023
2A&0AA'55A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧠ಽ
1. DELETING PROCEDURE
(1) Turn the starter switch to "ON" position and ES main switch
"OFF".
OFF (2) After having repaired the failure, engage and disengage the trans-
mission for more than three times to make the controller recog-
nize the ON/OFF of neutral switch.
HINT
Until the controller recognizes the ON/OFF of neutral switch, the
diagnosis code cannot be deleted.
SHTS16Z080300024
SHTS16Z080300025
(5) Disconnect the diagnosis monitor while keeping the starter key at
"ON" position.
(6) Wait for several seconds. Then connect the diagnosis monitor to
check that the diagnosis code 12 has been deleted.
.
SHTS16Z080300026
2A&0AA'55A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧠ಽ
1. DELETING PROCEDURE
(1) Turn the stater switch to "ON" position and ES main switch "OFF".
(2) After having repaired the failure, step and release the brake pedal
OFF for more than three times to make the controller recognize the
ON/OFF of stop light switch.
HINT
Until the controller recognizes the ON/OFF of stop light switch, the
diagnosis code cannot be deleted.
SHTS16Z080300021
SHTS16Z080300027
(5) Disconnect the diagnosis monitor while keeping the starter key at
"ON" position.
(6) Wait for several seconds. Then connect the diagnosis monitor to
check that the diagnosis code 13 has been deleted.
.
SHTS16Z080300028
2A&0AA'55A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧠ಽ
Diagnosis
Inspection item Diagnosis monitor and indicator light output
code No.
1 Normal
NOTICE
1. When replacing the clutch hydraulic switch, always initialize the brake releasing position.
2. When replacing the clutch stroke sensor, always initialize the brake releasing position.
3. When replacing ES start controller, always initialize the brake releasing position and perform 0 point adjust-
ment of slope sensor.
SHTS16Z080300042
.
NO
• Less than 20 V: Go to the item 3.
• 0 V: Go to the item 4.
YES
NO
ES start controller malfunction
YES
SHTS16Z080300043
.
NO
Battery malfunction
YES
NO
Go to the item 6.
YES
SHTS16Z080300043
.
NO
Battery malfunction
YES
NO
Go to the item 7.
YES
Normal
2A&0AA'55A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧠ಽ
SHTS16Z080300044
.
NO
Short-circuit in the harness
YES
NO
ES start controller malfunction
YES
.
2A&0AA'55A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧠ಽ
SHTS16Z080300045
.
NO
Go to the item 3.
YES
SHTS16Z080300043
.
NO
Battery malfunction
YES
SHTS16Z080300046
.
NO
ES start controller malfunction
YES
SHTS16Z080300047
.
NO
Install the sensor correctly.
YES
SHTS16Z080300048
.
NO
Harness disconnection
YES
SHTS16Z080300049
.
NO
Clutch stroke sensor damage
YES
Go to diagnosis code 9.
2A&0AA'55A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧠ಽ
SHTS16Z080300050
.
NO
Speed sensor or pulse adjust computer mal-
function
YES
SHTS16Z080300051
.
NO
Harness disconnection
YES
SHTS16Z080300052
.
NO
Connector or harness contact failure
YES
SHTS16Z080300053
.
NO
Harness disconnection
YES
SHTS16Z080300054
.
NO
Short-circuit in the harness
YES
2A&0AA'55A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧠ಽ
SHTS16Z080300055
.
NO
ES start control valve malfunction
YES
SHTS16Z080300056
.
NO
ES start control valve malfunction
YES
SHTS16Z080300057
.
NO
Faulty contact in harness or connector
YES
.
2A&0AA'55A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧠ಽ
SHTS16Z080300058
.
NO
Harness disconnection
YES
SHTS16Z080300059
.
NO
Supply the clutch fluid.
YES
SHTS16Z080300060
.
NO
Clutch fluid pressure switch malfunction
YES
2A&0AA'55A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧠ಽ
SHTS16Z080300061
.
NO
Install the sensor correctly.
YES
SHTS16Z080300062
.
NO
Faulty contact in connector or harness
YES
.
2A&0AA'55A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧠ಽ
SHTS16Z080300063
.
NO
Short-circuit in the harness
YES
SHTS16Z080300064
.
NO
Go to the item 3.
YES
SHTS16Z080300065
.
NO
Connector or harness contact failure.
YES
SHTS16Z080300066
.
NO
Neutral switch malfunction, disconnection or
installation error
YES
2A&0AA'55A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧠ಽ
SHTS16Z080300067
.
NO
Back-up light switch malfunction, disconnec-
tion or installation error
YES
SHTS16Z080300068
.
NO
Connector or harness contact failure.
YES
.
2A&0AA'55A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧠ಽ
SHTS16Z080300069
.
NO
Harness disconnection
YES
SHTS16Z080300070
.
NO
Harness or power supply malfunction
YES
SHTS16Z080300071
.
NO
Neutral switch malfunction
YES
2A&0AA'55A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧠ಽ
SHTS16Z080300050
.
NO
Go to the item 5 after checking the speed sen-
sor and pulse adjust computer.
YES
SHTS16Z080300072
.
NO
Connector or harness contact failure
YES
.
2A&0AA'55A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧠ಽ
SHTS16Z080300073
.
NO
Harness contact failure or disconnection
YES
SHTS16Z080300074
.
NO
Short-circuit in the harness
YES
SHTS16Z080300075
.
NO
Go to the item 4.
YES
Go to the item 5.
2A&0AA'55A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧠ಽ
NO
Stop light switch malfunction
YES
SHTS16Z080300076
.
NO
Connector or harness contact failure
YES
SHTS16Z080300077
.
NO
ES start controller malfunction
YES
Normal
.
2A&0AA'55A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧠ಽ
SHTS16Z080300078
.
NO
Harness disconnection
YES
SHTS16Z080300079
.
NO
Short-circuit in the harness
YES
SHTS16Z080300080
.
NO
Go to the item 4.
YES
Go to the item 5.
2A&0AA'55A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧠ಽ
NO
ES main switch malfunction
YES
ON
SHTS16Z080300025
(2) More than 10 seconds later, output the diagnosis code again.
Standard: Diagnosis code: 18
SHTS16Z080300081
.
NO
Connector or harness contact failure
YES
.
2A&0AA'55A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧠ಽ
SHTS16Z080300082
.
NO
Harness disconnection
YES
SHTS16Z080300083
.
NO
Short-circuit in the harness
YES
SHTS16Z080300084
.
NO
Go to the item 4.
YES
Go to the item 5.
2A&0AA'55A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧠ಽ
NO
Release timing switch malfunction
YES
SHTS16Z080300085
.
NO
Connector or harness contact failure
YES
.
2A&0AA46&A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧢ಽ
ELECTROMAGNETIC RETARDER
HANDLING PRECAUTIONS
EN16Z0803F200001
1. ABOUT CONNECTORS
(1) Before performing the inspection operation, make sure that all
connectors are connected securely.
(2) Do not contact the tester bar to the connection surface of the con-
nector. This may cause terminal damage or a short-circuit.
(3) All connectors in the connector diagram are observed from the
contact surfaces. However, the tester bar is put from the rear side.
SHTS16Z080300001
(4) The connector is displayed from the view of the mating surface
when the connector lock is positioned above.
Reference
• Female connector: The terminal is female.
• Male connector: The terminal is male.
SHTS16Z080300002
(5) As for the terminal numbers of the connector, the first terminal is
located on the top right terminal of the male connector and the top
left terminal of the female connector.
Reference:
When viewed from the mating surface, the terminal numbers
of both connectors are located symmetrically (reversed hori-
zontally).
(6) When disconnecting the connector, be sure to set the starter
switch to "LOCK".
SYSTEM DIAGRAM
EN16Z0803F200002
5
2 3
1 4
8 SCR
To STARTER SW
CIRCUIT
12
5A
5 8
4 6 7
FIELD COIL 2
GND
CONNECTOR
4P
1 TEMP.
SENSOR 1
3 TEMP.
2 SENSOR 2
4 SHILED
CABLE GND
SHTS16Z080300004
2A&0AA46&A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧢ಽ
1 2 3 4
5 6 7 8
A
9 10 11 12
13 14 15 16 CAB SIDE HARNESS
VIEW A
SHTS16Z080300005
3 — 11 Diagnosis switch
5 Ground 13 —
6 Lever switch Hi 14 —
7 — 15 —
8 Temperature sensor 2 16 —
2A&0AA46&A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧢ಽ
1 2 3 4
A
5 6 7 8
CAB SIDE HARNESS
VIEW A
SHTS16Z080300006
CIRCUIT A
3 Exciter 2 7 Exciter 6
4 Exciter 1 8 Exciter 5
CIRCUIT B
3 Exciter 4 7 Exciter 8
4 Exciter 3 8 Exciter 7
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PRE-INSPECTION
EN16Z0803F200004
INDICATOR
LIGHT CONDI- SYSTEM STATUS
TION
SHTS16Z080300008
.
NO
Replace the harness.
YES
SHTS16Z080300009
NO
Check the fuse.
YES
SHTS16Z080300010
NO
Check the fuse.
YES
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SHTS16Z080300011
NO
Check the fuse.
YES
SHTS16Z080300012
NO
Check the clutch switch, accelerator switch
and retarder control lever.
YES
SHTS16Z080300013
NO
Check the clutch switch, accelerator switch
and retarder control lever.
YES
Test OK.
.
2A&0AA46&A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧢ಽ
INSPECTION OF FUSE
1. Remove the lower cover of the assistant seat side. check the
fuse for electromagnetic retarder. if it is blown out, replace it
with new one.
2. Remove the lower cover of the assistant seat side. check the
fuse for power supply. if it is blown out, replace it with new
one.
.
The electromagnetic retarder stores the history of failures and its contents up to the present in its computer. Connecting
the diagnosis monitor to the special connector can monitor the failure contents.
1. DIAGNOSIS MONITOR
(1) Diagnosis monitor alerts the failure location with sound and light
by being connected to the special diagnosis connector of electro-
magnetic retarder.
SST: Diagnosis monitor (S0963-01370)
SHTS16Z080300014
BLACK CONNECTOR
WHITE CONNECTOR
SHTS16Z080300015
SHTS16Z080300016
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NOTICE
The intensive diagnosis connector is usually connected to the fix-
ing dummy connector. So, disconnect the connector from the
dummy connector and pull it to use. When the connector is not in
use, connect it firmly to the fixing dummy connector.
(3) Wait for several seconds. Then connect the diagnosis monitor to
output the present failure.
.
SHTS16Z080300018
Diagnosis
Inspection item Diagnosis monitor and indicator light output
code No.
SHTS16Z080300025
.
NO
Replace the retarder main unit (Except for
retarder drum).
YES
SHTS16Z080300026
.
NO
Replace the harness.
YES
NO
Couple the connector properly.
YES
SHTS16Z080300027
NO
Replace the retarder main unit (Except for
retarder drum).
YES
SHTS16Z080300028
NO
Replace the harness.
YES
.
2A&0AA46&A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧢ಽ
NO
Replace the retarder main unit (Except for
retarder drum).
YES
Reference: Conductivity
.
NO
Replace the harness.
YES
.
2A&0AAOQMWLKAMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧣ಽ
CAN COMMUNICATION
CAN COMMUNICATION LINE
EN16Z1606F200001
HANDLING PRECAUTIONS
EN16Z1606F200002
1. ABOUT CONNECTORS
(1) Before performing the inspection operation, make sure that all
connectors are connected securely.
(2) Do not contact the tester bar to the connection surface of the con-
nector. This may cause terminal damage or a short-circuit.
(3) All connectors in the connector diagram are observed from the
contact surfaces. However, the tester bar is put from the rear side.
SHTS16Z160600002
(4) The connector is displayed from the view of the mating surface
when the connector lock is positioned above.
Reference
• Female connector: The terminal is female.
• Male connector: The terminal is male.
SHTS16Z160600003
(5) As for the terminal numbers of the connector, the first terminal is
located on the top right terminal of the male connector and the top
left terminal of the female connector.
Reference:
When viewed from the mating surface, the terminal numbers
of both connectors are located symmetrically (reversed hori-
zontally).
(6) When disconnecting the connector, be sure to set the starter
switch to "LOCK".
SHTS16Z160600004
2A&0AAOQMWLKAMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧣ಽ
KRG
SHTS16Z160600005
NO
Replace the harness.
YES
KRH
SHTS16Z160600006
NO
Replace the harness.
YES
Proceed to 3.
2A&0AAOQMWLKAMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧣ಽ
SHTS16Z160600007
NO
Replace the harness.
YES
MMT-
SHTS16Z160600008
NO
Replace the harness.
YES
Proceed to 7.
SHTS16Z160600009
NO
Replace the harness.
YES
2A&0AAOQMWLKAMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧣ಽ
CANL
SHTS16Z160600010
NO
Replace the harness.
YES
Proceed to 7.
SHTS16Z160600011
(2) With the connector plugged, check the continuity between termi-
nals of joint connector.
L LINE H LINE
• Between terminals of CAN communication L line.
• Between terminals of CAN communication H line.
Standard: Continuity
SHTS16Z160600012
NO
Replace or repair the connector.
YES
Proceed to 8.
2A&0AAOQMWLKAMCKHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧣ಽ
SHTS16Z160600013
NO
Proceed to 9.
YES
Replace all the CAN harness in case that either or both continu-
ities between terminals "CA2H" and "+24V", "GND".
SHTS16Z160600014
NO
Proceed to 10.
YES
Replace all the CAN harness in case that either or both continu-
ities between terminals "CA2L" and "+24V", "GND".
OTHERS DN 06
(HEADLIGHT AUTOLEVELING)
DN06
DN06-002
HEADLIGHT AUTOLEVELING
OVERVIEW
EN16Z1606C100001
FUNCTION
• Headlight autoleveling is a system which will be installed on models with discharge headlights, with which the upper
or lower direction of the light axis will be ensured at a given level, regardless of vehicle posture change to be influ-
enced by the loading condition on the rear body.
• The system will not only assure excellent visibility at night time, but will also prevent dazzling ray being shone against
vehicle running ahead or oncoming vehicle.
SYSTEM
• Vehicle speed signal to be output by the speed sensor as well as vehicle height signal to be output by the vehicle
height sensors installed on the LH front and LH rear wheels of the vehicle are inputted into the autoleveling ECU.
• The ECU will control the light axis of the headlight by computing a change of pitch angle of the vehicle posture with
these signals and also wheelbase information memorized in the ECU, and by activating headlight actuator to respond
against changing amount of the vehicle posture.
Autoleveling ECU
Headlight
Headlight relay Judgement for Judgement for actuator
ON/OFF operation (IG-ON on operation
Input of headlight on/off while Vehicle stopping or
signal. driving at a constant speed.)
Fr. Vehicle height sensor
Computation
Input of Fr.vehicle height Actuator LH
for vehicle
signal.
posture.
Rr.vehicle height sensor Voltage output indicated
by actuator operation.
Input of Rr.vehicle height
signal.
Actuator RH
Initial setting tool Memory of vehicle
height sensor value Voltage output indicated
Input of initial setting by actuator operation.
(0 point adjustment) signal
Hino-DX
SHTS16Z160600001
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Running at
constant speed 60km/h
Always controlled : vehicle stopping
Accelerated/
Decelerated
Not controlled : while accelerating/decelerating
Vehicle stopping 0km/h
SHTS16Z160600003
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COMPONENT LOCATOR
EN16Z1606D100001
LOCATION OF COMPONENTS
HEADLIGHT ACTUATOR
SHTS16Z160600004
AUTOLEVELING ECU
• Controls the autoleveling function.
• Controls the headlight actuator, by judging from the vehicle posture and running status with signals from the vehicle
height sensor and the speed sensor.
• Once the system failure is detected, the autoleveling warning light will turn on at the meter-panel.
SHTS16Z160600005
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INTERFACE ECU
• For the autoleveling ECU, writing-in of the constant per vehicle model will be needed.
• The interface ECU will function between the autoleveling ECU and the writing-in tool (Hino-DX) as an interface when
writing the constant.
SHTS16Z160600006
HEADLIGHT ACTUATOR
• By activating the low-beam headlights the toward upper/lower directions with control signals from the autoleveling
ECU, light axis direction will be controlled.
HEADLIGHT ACTUATOR
SHTS16Z160600007
(REPRESENTATIVE TYPE)
FRONT REAR
SHTS16Z160600008
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SHTS16Z160600009
SHTS16Z160600010
P
P
WRITING-IN OF CONTROLLED
CONSTANT FOR AUTOLEVELING ECU
EN16Z1606H200001
INTRODUCTION
2. Hino-DX
(1) Writing-in of the controlled constant of autoleveling ECU should
be performed by Hino-DX.
To connect with the vehicle, an interface box (Hino Bowie) will be
needed.
SST: Interface Box (Hino-Bowie) (S0912-11040)
Cable between vehicle & Hino-Bowie (S0904-21220)
Diagnosis software:
Hino Diagnostic eXplorer (Hino-DX)
HINT
• Cable between Hino-Bowie & PC is packed in a set with the
SHTS16Z160600012 Hino Bowie. Use either for RS-232 or for USB.
• Read the manual, attached to the Hino-Bowie.
• Install the software of Hino Diagnostic eXplorer (Hino-DX) on
the PC unit. Refer to the manual attached to CD for installing
procedures.
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1. CONNECTION OF HINO-DX.
(1) Connect the Hino Bowie with the trouble diagnosis connector,
located at the lower part of LH under the instrument panel of the
driver's seat.
(2) Connect Hino Bowie with the PC unit, on which the Hino DX is
installed.
(3) Turn the starter switch to "ON" position.
(4) Turn on the power of the PC to start up the Hino-DX.
TROUBLE DIAGNOSIS CONNECTOR
HINT
When using the Hino-Bowie, the power will come "ON" the
moment it is connected with the vehicle and the power light (Red)
SHTS16Z160600013 on Hino-Bowie unit will turn on.
SHTS16Z160600014
(2) Select vehicle specifications with the appropriate vehicle type and
wheel-base code from the pull down menu. Refer to the vehicle
specification code chart that corresponds to the wheel-base
length (The wheel-base code corresponds to the wheel-base on
the production code), then click on "Over write" to set the variable
headlight projection angle.
NOTICE
• The correct vehicle specifications must be entered for the
system to function properly.
• Please note that the variable headlight projection angle also
SHTS16Z160600015
differs by the vehicle grade (with high intensity discharge
headlights).
(3) Click on "Read-out" to confirm the setting.
SHTS16Z160600016
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MODEL: FD
SHTS16Z160600017
MODELS: FG, GH
SHTS16Z160600018
OVERHAUL
EN16Z1606H200002
NOTICE
When changing and adjusting a front vehicle height sensor (Sen-
sor itself, Dimension relating to Link Rod), make sure to write in
"Controlled constant".
Refer to "WRITING-IN OF CONTROLLED CONSTANT FOR
AUTOLEVELING ECU".
VEHICLE HEIGHT (2) Connect the connector with the vehicle height sensor.
SENSOR LINK ROD (3) Install the harness clamp on the vehicle height sensor bracket.
SHTS16Z160600020 (4) Perform "LENGTH ADJUSTMENT OF THE LINK ROD"
described in next page.
(5) Installing the link rod on the link rod bracket, tighten the nut.
Tightening Torque:
18-26 N⋅m {184-244 kgf⋅cm, 14-17 lbf⋅ft}
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FD 140 {5.5}
MODEL: FD
VEHICLE HEIGHT
SENSOR
LINK ROD
SHTS16Z160600021
MODELS: FG, GH
LINK ROD
VEHICLE HEIGHT
SENSOR
SHTS16Z160600022
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MODEL: FD
SHTS16Z160600023
MODELS: FG, GH
SHTS16Z160600024
REPLACEMENT
EN16Z1606H200004
FD 160 {6.3}
MODEL: FD
LINK ROD
MODELS: FG, GH
LINK ROD
SHTS16Z160600028
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FAILURE DIAGNOSIS
HANDLING PRECAUTIONS
EN16Z1606F200001
1. ABOUT CONNECTORS
(1) When vehicle placed on speed meter tester, or jacked up to rotate
the tires, there is a case that ECU memorize failure code. But, this
is not abnormal. Clear the failure code on ECU in any case of hav-
ing done that type of maintenance service.
(2) Before performing an inspection work, check that each connector
is surely connected.
(3) When taking off connector, do it without fail at the "LOCK" position
of starter key.
(4) Any parts presumed to be abnormal should not be repaired, but
change it.
(5) After clearing the failure memories recorded in the past, perform
SHTS16Z160600029
failure diagnosis again and check the current failure.
(6) After completing the diagnosis analysis, clear the diagnosis mem-
ories in the past.
(7) Unless otherwise specified, the drawing of connector is one
viewed from connected surface. But, test bar should be inserted
from back side for measuring.
However, check the terminals at the connected part of such water
proof connectors as ABS actuator, etc. In this case, be careful not
to short the terminals.
(8) The connector is displayed from the view of the mating surface
when the connector lock is positioned above.
Reference
• Female connector: The terminal is female.
• Male connector: The terminal is male.
SHTS16Z160600030
(9) As for the terminal numbers of the connector, the first terminal is
located on the top right terminal of the male connector and the top
left terminal of the female connector.
Reference:
When viewed from the mating surface, the terminal numbers
of both connectors are located symmetrically (reversed hori-
zontally).
(10) When disconnecting the connectors, be sure to position the
starter switch "LOCK".
AUTOLEVELING ECU
22 pin connector
VIEW
CHASSIS HARNESS
SHTS16Z160600032
1 IG Power 12 E1 Ground
3 — — 14 — —
6 — — 17 — —
9 SGR Rear vehicle height sensor ground 20 SGF Front vehicle height sensor ground
10 SHR Rear vehicle height sensor signal 21 SHF Front vehicle height sensor signal
11 SBR Rear vehicle height sensor power 22 SBF Front vehicle height sensor power
INTERFACE ECU
22 pin connector
VIEW
CHASSIS HARNESS
SHTS16Z160600033
1 — — 12 — —
2 — — 13 — —
3 — — 14 — —
4 — — 15 — —
5 — — 16 — —
6 — — 17 — —
7 PCGD PC-ground 18 — —
10 — — 21 — —
SHTS16Z160600034
SHTS16Z160600035
NO
Short in the wire.
YES
SHTS16Z160600036
(2) Check electrical continuity between 9th, 10th, 11th and 1st termi-
nals of 22 pin connector (Vehicle harness side).
Standard: No electrical continuity
SHTS16Z160600037
NO
Short in the wire.
YES
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SHTS16Z160600039
.
NO
Short in the wire.
YES
SHTS16Z160600040
SHTS16Z160600041
2A&0AA*#.8A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧤ಽ
(4) Remove link rod out of the lever of front/rear vehicle height sen-
(REPRESENTATIVE TYPE) sors.
LEVER
LINK ROD
SHTS16Z160600042
(5) Checking voltage between 21st and 20th terminals of 22 pin con-
nector (Vehicle harness side), check voltage change when operat-
ing the lever at low/high position.
Standard: As shown in the figure, voltage should change.
NOTICE
Connector in the drawing is a view from mating face.
SHTS16Z160600043
(REPRESENTATIVE TYPE)
Vehicle height
goes down.
Vehicle height
goes up.
4.5
Output voltage
2.5
0.5
(V) 50 Std. vehicle 50
height position
Vehicle height Vehicle height
going down Shaft rotation angle ( ) going up
direction direction
Electrical operation range
SHTS16Z160600044
2A&0AA*#.8A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧤ಽ
(6) Checking voltage between 10th and 9th terminals of 22 pin con-
nector (Vehicle harness side), Check voltage change when oper-
ating the lever at low/high position.
Standard: As shown in the Figure, voltage should change.
NOTICE
Connector in the drawing is a view from mating face.
SHTS16Z160600045
(REPRESENTATIVE TYPE)
Vehicle height
goes down.
Vehicle height
goes up.
4.5
Output voltage
2.5
0.5
50 Std. vehicle 50
(V) height position
Vehicle height Vehicle height
going down Shaft rotation angle ( ) going up
direction Electrical operation range direction
SHTS16Z160600046
.
NO
Abnormality of vehicle height sensor.
YES
SHTS16Z160600047
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SHTS16Z160600048
NO
Short in the wire.
YES
SHTS16Z160600049
(2) Check electrical continuity between 4th, 15th and 1st terminals of
22 pin connector (Vehicle harness side).
Standard: No electrical continuity.
SHTS16Z160600050
NO
Short in the wire.
YES
2A&0AA*#.8A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧤ಽ
SHTS16Z160600051
SHTS16Z160600052
.
NO
Short in the wire.
YES
12V 3 1
SHTS16Z160600053
NO
Failure in Headlight levelling actuator.
YES
.
2A&0AA*#.8A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧤ಽ
SHTS16Z160600054
NO
Short in the wire.
YES
SHTS16Z160600055
NO
Short in the wire.
YES
NO
Short in the wire.
YES
2A&0AA*#.8A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧤ಽ
SHTS16Z160600057
NO
Abnormality of DC/DC convertor or short in the
wire.
YES
SHTS16Z160600058
NO
Failure in signal system of Headlight.
(Such as Harness disconnected)
YES
SHTS16Z160600059
2A&0AA*#.8A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧤ಽ
SHTS16Z160600060
NO
Short in the wire.
YES
SHTS16Z160600061
(2) Check electrical continuity between 4th, 15th and 1st terminals of
AUTOLEVELING ECU 22 pin connector (Vehicle harness side) of autoleveling ECU.
Standard: No electrical continuity.
SHTS16Z160600062
NO
Short in the wire.
YES
2A&0AA*#.8A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧤ಽ
SHTS16Z160600063
AUTOLEVELING
ECU
SHTS16Z160600064
.
NO
Short in the wire.
YES
12V 3 1
SHTS16Z160600065
NO
Failure in Headlight levelling actuator.
YES
.
2A&0AA*#.8A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧤ಽ
SHTS16Z160600066
SHTS16Z160600067
(5) Checking voltage between 21st and 20th terminals of 22 pin con-
AUTOLEVELING ECU nector (Vehicle harness side) of autoleveling ECU, check voltage
change when operating the lever at low/high position.
Standard: As shown in the Figure, voltage should change.
NOTICE
Connector in the drawing is a view from mating face.
SHTS16Z160600068
(REPRESENTATIVE TYPE)
Vehicle height
goes down.
Vehicle height
goes up.
4.5
Output voltage
2.5
0.5
(V) 50 0 (Std. vehicle 50
height position)
Vehicle height Vehicle height
going down Shaft rotation angle ( ) going up
direction direction
Electrical operation range
SHTS16Z160600069
2A&0AA*#.8A0QVTGGHOࡍࠫ㧞㧜㧜㧢ᐕ㧝㧝㧝ᣣޓ᳓ᦐᣣޓඦᓟ㧤ᤨ㧟㧤ಽ
(6) Checking voltage between 10th and 9th terminals of 22 pin con-
nector (Vehicle harness side) of autoleveling ECU, check voltage
AUTOLEVELING ECU
change when operating the lever at low/high position.
Standard: As shown in the figure, voltage should change.
NOTICE
Connector in the drawing is a view from mating face.
SHTS16Z160600070
(REPRESENTATIVE TYPE)
Vehicle height
goes down.
Vehicle height
goes up.
4.5
Output voltage
2.5
0.5
50 0 (Std. vehicle 50
(V) height position)
Vehicle height Vehicle height
going down Shaft rotation angle ( ) going up
direction Electrical operation range direction
SHTS16Z160600071
.
NO
Abnormality of vehicle height sensor.
YES
.
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SHTS16Z160600072
NO
Short in the wire.
YES
SHTS16Z160600073
NO
Short in the wire.
YES
NO
Failure in vehicle speed sensor system.
YES
NO
Go to the item 2.
YES
Normal.
2. OPERATION CHECK
(1) Check all items (Warning light to be on/off) that are not operating.
Standard: No abnormality.
SHTS16Z160600075
NO
Correction of all abnormal items.
YES
SHTS16Z160600076
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(3) Check voltage between 10th and 9th terminals of 22 pin connec-
tor (Vehicle harness side) of autoleveling ECU. (Do it under no
load on the body)
AUTOLEVELING ECU
HINT
When initial setting performed while not within the range of volt-
age, it will flash 2 times even when initial setting performed and
warning light turn off.
Standard: 0.85-4.15V
NOTICE
Connector in the drawing is a view from mating face.
SHTS16Z160600077
NO
Abnormality of vehicle height sensor.
YES
SHTS16Z160600078
NO
Failure in vehicle speed sensor system.
YES
.
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NO
No power is supplied to autolevelling ECU
(Connector is not connected. Harness is dis-
connected due to broken DC/DC converter or
YES
no electrical power) or failure in autolevelling
ECU.
SHTS16Z160600079
NO
Failure in DC/DC converter for autoleveling or
malfunction of harness.
YES
SHTS16Z160600080
NO
Short in the wire.
YES
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SHTS16Z160600081
NO
Short in the wire.
YES
SHTS16Z160600082
NO
Short in the wire.
YES
SHTS16Z160600083
NO
Short in the wire.
YES
.
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