Tài liệu hướng dẫn sửa chữa xe Nissan navara np300 (d23) esm tai lieu sua chua phan 4 . Cung cấp các thông tin cần thiết cho Kỹ thuật viên tiến hành chẩn đoán, sửa chữa nhanh chóng, chính xác, hiệu quả
ENGINE SECTION EC ENGINE CONTROL SYSTEM A EC C D E CONTENTS QR25DE Heated Oxygen Sensor 29 Knock Sensor 29 Engine Oil Pressure Sensor 29 Engine Oil Temperature Sensor 30 EVAP Canister 30 EVAP Canister Purge Volume Control Solenoid Valve 30 Battery Current Sensor (With Battery Temperature Sensor) .30 Atmospheric Pressure Sensor 31 Refrigerant Pressure Sensor 32 Power Steering Pressure Sensor 32 Stop Lamp Switch & Brake Pedal Position Switch 32 Clutch Pedal Position Switch 32 Park/Neutral position Switch 32 ASCD Steering Switch .33 PRECAUTION 12 PRECAUTIONS 12 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" 12 Precautions Necessary for Steering Wheel Rotation After Battery Disconnection 12 Precaution for Procedure without Cowl Top Cover 13 Precautions for Removing Battery Terminal 13 On Board Diagnostic (OBD) System of Engine and A/T 13 General Precautions 14 PREPARATION 17 PREPARATION 17 STRUCTURE AND OPERATION 34 COMPONENT PARTS .19 Component Parts Location 19 ECM 23 Accelerator Pedal Position Sensor 23 Electric Throttle Control Actuator 24 Ignition Coil With Power Transistor 25 Fuel Injector 25 Fuel Pump 25 Mass Air Flow Sensor (With Intake Air Temperature Sensor) 25 Engine Coolant Temperature Sensor 26 Crankshaft Position Sensor (POS) 27 Camshaft Position Sensor (PHASE) 27 Intake Valve Timing Control Solenoid Valve 27 Exhaust Valve Timing Control Position Sensor 27 Exhaust Valve Timing Control Solenoid Valve 28 Air Fuel Ratio (A/F) Sensor 28 Revision: 2014 December G H I J K Positive Crankcase Ventilation 34 On Board Refueling Vapor Recovery (ORVR) 35 Special Service Tools 17 Commercial Service Tools 17 SYSTEM DESCRIPTION 19 F SYSTEM 36 ENGINE CONTROL SYSTEM 36 ENGINE CONTROL SYSTEM : System Description 36 ENGINE CONTROL SYSTEM : Circuit Diagram 38 ENGINE CONTROL SYSTEM : Fail Safe 40 MULTIPORT FUEL INJECTION SYSTEM 42 MULTIPORT FUEL INJECTION SYSTEM : System Description 42 ELECTRIC IGNITION SYSTEM 45 ELECTRIC IGNITION SYSTEM : System Description 45 INTAKE VALVE TIMING CONTROL 46 INTAKE VALVE TIMING CONTROL : System Description 46 EXHAUST VALVE TIMING CONTROL .47 EC-1 D23 L M N O P EXHAUST VALVE TIMING CONTROL : System Description 47 ENGINE PROTECTION CONTROL AT LOW ENGINE OIL PRESSURE 48 ENGINE PROTECTION CONTROL AT LOW ENGINE OIL PRESSURE : System Description 48 AIR CONDITIONING CUT CONTROL 49 AIR CONDITIONING CUT CONTROL : System Description 49 ECM 77 Reference Value 77 Fail Safe 89 DTC Inspection Priority Chart 91 DTC Index 93 Test Value and Test Limit 96 WIRING DIAGRAM 104 ENGINE CONTROL SYSTEM 104 Wiring Diagram 104 EVAPORATIVE EMISSION SYSTEM 50 EVAPORATIVE EMISSION SYSTEM : System Description 51 BASIC INSPECTION 120 AUTOMATIC SPEED CONTROL DEVICE (ASCD) 52 AUTOMATIC SPEED CONTROL DEVICE (ASCD) : System Description 52 Work Flow 120 Diagnostic Work Sheet 123 CAN COMMUNICATION 53 CAN COMMUNICATION : System Description 53 INFORMATION DISPLAY (COMBINATION METER) 53 INFORMATION DISPLAY (COMBINATION METER) : Indicator/Information 53 INFORMATION DISPLAY (COMBINATION METER) : Engine Oil Pressure Warning 53 WARNING/INDICATOR/CHIME LIST 55 WARNING/INDICATOR/CHIME LIST : Warning lamps/Indicator lamps 55 WARNING/INDICATOR/CHIME LIST : Warning/ Indicator (On Information Display) 55 DIAGNOSIS AND REPAIR WORKFLOW 120 BASIC INSPECTION 125 Work Procedure 125 ADDITIONAL SERVICE WHEN REPLACING ECM 129 Description 129 Work Procedure 129 VIN REGISTRATION 131 Description 131 Work Procedure 131 ACCELERATOR PEDAL RELEASED POSITION LEARNING 132 Description 132 Work Procedure 132 OPERATION 56 THROTTLE VALVE CLOSED POSITION LEARNING 133 AUTOMATIC SPEED CONTROL DEVICE (ASCD) 56 AUTOMATIC SPEED CONTROL DEVICE (ASCD) : Switch Name and Function 56 Description 133 Work Procedure 133 ON BOARD DIAGNOSTIC (OBD) SYSTEM 57 Diagnosis Description 57 GST (Generic Scan Tool) 57 DIAGNOSIS SYSTEM (ECM) 58 DIAGNOSIS DESCRIPTION 58 DIAGNOSIS DESCRIPTION : 1st Trip Detection Logic and Two Trip Detection Logic 58 DIAGNOSIS DESCRIPTION : DTC and Freeze Frame Data 58 DIAGNOSIS DESCRIPTION : Counter System 59 DIAGNOSIS DESCRIPTION : Driving Pattern 62 DIAGNOSIS DESCRIPTION : System Readiness Test (SRT) Code 63 DIAGNOSIS DESCRIPTION : Malfunction Indicator Lamp (MIL) 64 On Board Diagnosis Function 65 CONSULT Function 68 ECU DIAGNOSIS INFORMATION 77 Revision: 2014 December IDLE AIR VOLUME LEARNING 134 Description 134 Work Procedure 134 MIXTURE RATIO SELF-LEARNING VALUE CLEAR 136 Description 136 Work Procedure 136 FUEL PRESSURE 137 Work Procedure 137 HOW TO SET SRT CODE 139 Description 139 SRT Set Driving Pattern 140 Work Procedure 142 DTC/CIRCUIT DIAGNOSIS 144 TROUBLE DIAGNOSIS - SPECIFICATION VALUE 144 Description 144 EC-2 D23 Component Function Check 144 Diagnosis Procedure 145 Component Inspection 190 P0130 A/F SENSOR 191 POWER SUPPLY AND GROUND CIRCUIT 152 A Diagnosis Procedure 152 DTC Description 191 Diagnosis Procedure 192 U0101 CAN COMM CIRCUIT 156 P0131 A/F SENSOR 195 DTC Description 156 Diagnosis Procedure 156 DTC Description 195 Diagnosis Procedure 196 U1001 CAN COMM CIRCUIT 157 P0132 A/F SENSOR 198 DTC Description 157 Diagnosis Procedure 157 DTC Description 198 Diagnosis Procedure 199 P0011 IVT CONTROL 158 P0137 HO2S2 201 DTC Description 158 Diagnosis Procedure 159 Component Inspection 160 DTC Description 201 Diagnosis Procedure 203 Component Inspection 204 E P0014 EVT CONTROL 162 P0138 HO2S2 207 F DTC Description 162 Diagnosis Procedure 163 Component Inspection 165 DTC Description 207 Diagnosis Procedure 209 Component Inspection 212 G P0031, P0032 A/F SENSOR HEATER 166 P0139 HO2S2 215 DTC Description 166 Diagnosis Procedure 166 Component Inspection 167 DTC Description 215 Diagnosis Procedure 217 Component Inspection 219 H P0037, P0038 HO2S2 HEATER 169 P014C, P014D A/F SENSOR 221 DTC Description 169 Diagnosis Procedure 170 Component Inspection 170 DTC Description 221 Diagnosis Procedure 223 I P0075 INTAKE VALVE TIMING CONTROL 172 DTC Description 172 Diagnosis Procedure 172 Component Inspection 173 P0171 FUEL INJECTION SYSTEM FUNCTION 226 DTC Description 226 Diagnosis Procedure 227 P0078 EVT CONTROL SOLENOID VALVE 175 P0172 FUEL INJECTION SYSTEM FUNCTION 231 DTC Description 175 Diagnosis Procedure 175 Component Inspection 176 DTC Description 231 Diagnosis Procedure 232 P0102, P0103 MAF SENSOR 178 P0197, P0198 EOT SENSOR 236 DTC Description 236 Diagnosis Procedure 236 Component Inspection 237 DTC Description 178 Diagnosis Procedure 179 Component Inspection 180 P0112, P0113 IAT SENSOR 183 DTC Description 185 Diagnosis Procedure 185 Component Inspection 186 P0122, P0123 TP SENSOR 188 D J K L M N DTC Description 239 Diagnosis Procedure 239 Component Inspection 241 O P0300, P0301, P0302, P0303, P0304 MISFIRE 242 P DTC Description 242 Diagnosis Procedure 244 P0327, P0328 KS 248 DTC Description 188 Diagnosis Procedure 188 Revision: 2014 December C P0222, P0223 TP SENSOR 239 DTC Description 183 Diagnosis Procedure 183 Component Inspection 184 P0117, P0118 ECT SENSOR 185 EC EC-3 DTC Description 248 Diagnosis Procedure 248 Component Inspection 249 D23 P0335 CKP SENSOR (POS) 250 P0606 ECM 288 DTC Description 250 Diagnosis Procedure .250 Component Inspection 252 DTC Description 288 Diagnosis Procedure 289 P0340 CMP SENSOR (PHASE) 254 DTC Description 254 Diagnosis Procedure .254 Component Inspection 256 P0607 ECM 290 DTC Description 290 Diagnosis Procedure 290 P060A ECM 291 P0420 THREE WAY CATALYST FUNCTION 258 DTC Description 291 Diagnosis Procedure 291 DTC Description 258 Diagnosis Procedure .259 P060B ECM 293 P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE 263 DTC Description 263 Diagnosis Procedure .263 Component Inspection 264 P0452, P0453 ATMOSPHERIC PRESSURE SENSOR 266 DTC Description 266 Diagnosis Procedure .266 Component Inspection 268 P0500 VSS 269 A/T MODELS 269 A/T MODELS : DTC Description 269 A/T MODELS : Diagnosis Procedure 270 M/T MODELS 270 M/T MODELS : DTC Description 270 M/T MODELS : Diagnosis Procedure 272 DTC Description 293 Diagnosis Procedure 293 P0643 SENSOR POWER SUPPLY 294 DTC Description 294 Diagnosis Procedure 295 P0850 PNP SWITCH 297 A/T MODELS 297 A/T MODELS : DTC Description 297 A/T MODELS : Diagnosis Procedure 298 M/T MODELS 298 M/T MODELS : DTC Description 299 M/T MODELS : Diagnosis Procedure 300 M/T MODELS : Component Inspection 301 P1078 EVT CONTROL POSITION SENSOR 302 DTC Description 302 Diagnosis Procedure 302 Component Inspection 304 P0520 EOP SENSOR 274 P1212 TCS COMMUNICATION LINE 305 DTC Description 274 Diagnosis Procedure .274 Component Inspection 275 P1217 ENGINE OVER TEMPERATURE 307 P0524 ENGINE OIL PRESSURE 277 DTC Description 277 Diagnosis Procedure .278 Component Inspection 279 P0550 PSP SENSOR 280 DTC Description 305 Diagnosis Procedure 305 DTC Description 307 Diagnosis Procedure 308 P1225 TP SENSOR 310 DTC Description 310 Diagnosis Procedure 310 DTC Description 280 Diagnosis Procedure .280 Component Inspection 282 P1226 TP SENSOR 311 P0603 ECM 283 P1550 BATTERY CURRENT SENSOR 312 DTC Description 283 Diagnosis Procedure .283 DTC Description 311 Diagnosis Procedure 311 P0604 ECM 285 DTC Description 312 Diagnosis Procedure 312 Component Inspection 314 DTC Description 285 Diagnosis Procedure .285 P1551, P1552 BATTERY CURRENT SENSOR 315 P0605 ECM 286 DTC Description 315 Diagnosis Procedure 315 Component Inspection 317 DTC Description 286 Diagnosis Procedure .286 Revision: 2014 December EC-4 D23 P1553 BATTERY CURRENT SENSOR 318 P2122, P2123 APP SENSOR 353 DTC Description 318 Diagnosis Procedure 318 Component Inspection 320 DTC Description 353 Diagnosis Procedure 353 Component Inspection 355 P1554 BATTERY CURRENT SENSOR 321 P2127, P2128 APP SENSOR 356 EC DTC Description 321 Diagnosis Procedure 322 Component Inspection 323 DTC Description 356 Diagnosis Procedure 356 Component Inspection 358 P1556, P1557 BATTERY TEMPERATURE SENSOR 324 P2135 TP SENSOR 359 DTC Description 324 Diagnosis Procedure 324 Component Inspection 325 D P2138 APP SENSOR 362 E DTC Description 362 Diagnosis Procedure 362 Component Inspection 364 F BRAKE PEDAL POSITION SWITCH 366 P1572 ASCD BRAKE SWITCH 330 DTC Description 330 Diagnosis Procedure 331 Component Inspection (Brake Pedal Position Switch) 335 Component Inspection (Stop Lamp Switch) 336 Component Inspection (Clutch Pedal Position Switch) 336 Component Inspection (Stop Lamp Relay) 337 Component Function Check 366 Diagnosis Procedure 366 Component Inspection (Brake Pedal Position Switch) 368 Component Inspection (Clutch Pedal Position Switch) 369 CLUTCH PEDAL POSITION SWITCH 370 Component Function Check 370 Diagnosis Procedure 370 Component Inspection (Brake Pedal Position Switch) 372 Component Inspection (Clutch Pedal Position Switch) 372 P1574 ASCD VEHICLE SPEED SENSOR 338 DTC Description 338 Diagnosis Procedure 339 P1805 BRAKE SWITCH 340 DTC Description 340 Diagnosis Procedure 340 Component Inspection (Stop Lamp Switch) 342 Component Inspection (Stop Lamp Relay) 342 ELECTRICAL LOAD SIGNAL 374 P2100, P2103 THROTTLE CONTROL MOTOR RELAY 343 FUEL INJECTOR 376 Description 374 Component Function Check 374 Diagnosis Procedure 374 Component Function Check 376 Diagnosis Procedure 376 Component Inspection 377 DTC Description 343 Diagnosis Procedure 344 P2101 ELECTRIC THROTTLE CONTROL FUNCTION 346 FUEL PUMP 379 DTC Description 346 Diagnosis Procedure 346 Component Inspection 348 Description 379 Component Function Check 379 Diagnosis Procedure 379 Component Inspection 381 P2118 THROTTLE CONTROL MOTOR 349 IGNITION SIGNAL 382 Component Function Check 382 Diagnosis Procedure 382 Component Inspection (Ignition Coil with Power Transistor) 385 Component Inspection (Condenser) 386 DTC Description 349 Diagnosis Procedure 349 Component Inspection 350 P2119 ELECTRIC THROTTLE CONTROL ACTUATOR 351 DTC Description 351 Diagnosis Procedure 352 Revision: 2014 December C DTC Description 359 Diagnosis Procedure 359 Component Inspection 361 P1564 ASCD STEERING SWITCH 327 DTC Description 327 Diagnosis Procedure 327 Component Inspection 329 A INFORMATION DISPLAY (ASCD) 387 EC-5 Component Function Check 387 D23 G H I J K L M N O P Diagnosis Procedure .387 MALFUNCTION INDICATOR LAMP 388 Component Function Check 388 Diagnosis Procedure .388 REFRIGERANT PRESSURE SENSOR 389 APPLICATION NOTICE 406 How to Check Vehicle Type 406 PRECAUTION 407 PRECAUTIONS 407 SYMPTOM DIAGNOSIS 393 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" 407 Precaution for Procedure without Cowl Top Cover 407 Precautions for Removing Battery Terminal 407 On Board Diagnosis (OBD) System of Engine and A/T 408 Precaution 409 ENGINE CONTROL SYSTEM 393 PREPARATION 412 Symptom Table .393 PREPARATION 412 INFORMATION DISPLAY IS MALFUNCTIONING 397 Special Service Tool 412 Commercial Service Tool 412 Diagnosis Procedure .397 SYSTEM DESCRIPTION 413 NORMAL OPERATING CONDITION 398 COMPONENT PARTS 413 Component Function Check 389 Diagnosis Procedure .389 SENSOR POWER SUPPLY CIRCUIT 391 Description .391 Diagnosis Procedure .391 Description .398 PERIODIC MAINTENANCE 399 IDLE SPEED 399 Inspection 399 IGNITION TIMING 400 Inspection 400 EVAPORATIVE EMISSION SYSTEM 401 Inspection 401 POSITIVE CRANKCASE VENTILATION 402 Inspection 402 REMOVAL AND INSTALLATION 403 ECM 403 Exploded View .403 Removal and Installation .403 ATMOSPHERIC PRESSURE SENSOR 404 Exploded View .404 Removal and Installation .404 SERVICE DATA AND SPECIFICATIONS (SDS) 405 SERVICE DATA AND SPECIFICATIONS (SDS) 405 Idle Speed .405 Ignition Timing .405 Calculated Load Value 405 Mass Air Flow Sensor 405 YD25DDTi STRUCTURE AND OPERATION 426 Crankcase Ventilation System 426 HOW TO USE THIS MANUAL 406 Revision: 2014 December Component Parts Location 413 ECM 418 Accelerator Pedal Position Sensor 418 ASCD Steering Switch 418 Barometric Pressure Sensor 418 Battery Current Sensor (With Battery Temperature Sensor) 419 Camshaft Position Sensor 419 Clutch Pedal Position Switch 419 Crankshaft Position Sensor 420 EGR Cooler Bypass Valve 420 EGR Cooler Bypass Valve Control Solenoid Valve 420 EGR Volume Control Valve 420 Engine Coolant Temperature Sensor 421 Exhaust Gas Pressure Sensor 421 Exhaust Gas Temperature Sensor 421 Fuel Injector 422 Fuel Temperature Sensor 422 Fuel Pump (With fuel pump suction control valve) 422 Fuel Rail Pressure Sensor 422 Glow Control Unit 422 Glow Plug 423 Intake air control Valve actuator 423 Intake Air Temperature Sensor 423 Mass Air Flow Sensor (With Intake Air Temperature Sensor 1) 423 Refrigerant Pressure Sensor 424 Stop Lamp Switch & Brake Pedal Position Switch 424 Turbocharger Boost Control Actuator 424 Turbocharger Boost Sensor 425 SYSTEM 427 EC-6 D23 ENGINE CONTROL SYSTEM 427 ENGINE CONTROL SYSTEM : System Description 427 ENGINE CONTROL SYSTEM : Circuit Diagram 430 ENGINE CONTROL SYSTEM : Fail safe 433 FUEL INJECTION CONTROL SYSTEM 434 FUEL INJECTION CONTROL SYSTEM : System Description 434 TURBOCHARGER BOOST CONTROL 436 TURBOCHARGER BOOST CONTROL : System Description 436 DIAGNOSIS DESCRIPTION : DTC And Freeze Frame Data 448 DIAGNOSIS DESCRIPTION : Malfunction Indicator Lamp (MIL) 450 On Board Diagnosis Function 450 OBD System Operation Chart 452 CONSULT Function 454 ECU DIAGNOSIS INFORMATION 461 AIR CONDITIONING CUT CONTROL 440 AIR CONDITIONING CUT CONTROL : System Description 441 AUTOMATIC SPEED CONTROL DEVICE (ASCD) 441 AUTOMATIC SPEED CONTROL DEVICE (ASCD) : System Description 442 THROTTLE CONTROL 442 THROTTLE CONTROL : System Description 443 CAN COMMUNICATION 443 CAN COMMUNICATION : System Description 443 EC C ECM 461 Reference Value 461 Fail safe 473 DTC Inspection Priority Chart 474 DTC Index 476 Test Value and Test Limit 480 GLOW CONTROL 437 GLOW CONTROL : System Description 438 EGR SYSTEM 438 EGR SYSTEM : System Description 438 A D E WIRING DIAGRAM 488 ENGINE CONTROL SYSTEM 488 F Wiring Diagram 488 BASIC INSPECTION 539 G DIAGNOSIS AND REPAIR WORK FLOW 539 Work Flow 539 Diagnostic Work Sheet 541 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT 543 H I Description 543 Diagnosis Procedure 543 J INFORMATION DISPLAY (COMBINATION METER) 443 INFORMATION DISPLAY (COMBINATION METER) : Indicator/Information 443 INFORMATION DISPLAY (COMBINATION METER) : Engine Oil Pressure Warning 444 SERVICE AFTER REPLACING OR REMOVING ENGINE PARTS 544 WARNING/INDICATOR/CHIME LIST 445 WARNING/INDICATOR/CHIME LIST : Warning lamps/Indicator lamps 445 WARNING/INDICATOR/CHIME LIST : Warning/ Indicator (On Information Display) 445 Description 545 Work Procedure 545 L EGR VOLUME CONTROL VALVE CLOSED POSITION LEARNING VALUE CLEAR 547 M Description 544 Description 547 Work Procedure 547 OPERATION 446 AUTOMATIC SPEED CONTROL DEVICE (ASCD) 446 AUTOMATIC SPEED CONTROL DEVICE (ASCD) : Switch Name and Function 446 ON BOARD DIAGNOSTIC (OBD) SYSTEM 447 Diagnosis Description 447 Diagnostic Tool Function 447 DIAGNOSIS SYSTEM (ECM) 448 EGR VOLUME CONTROL VALVE CLOSED POSITION LEARNING 548 Description 548 Work Procedure 548 N O FUEL INJECTION QUANTITY LEARNING 549 Description 549 Work Procedure 549 FUEL PUMP LEARNING VALUE CLEARING 551 DIAGNOSIS DESCRIPTION 448 DIAGNOSIS DESCRIPTION : Introduction 448 DIAGNOSIS DESCRIPTION : Three Trip Detection Logic And One Trip Detection Logic 448 Revision: 2014 December K ADDITIONAL SERVICE WHEN REPLACING ECM 545 EC-7 Description 551 Work Procedure 551 D23 P INJECTOR ADJUSTMENT VALUE REGISTRATION 552 Description .552 Work Procedure .552 BASIC INSPECTION 553 Component Inspection (Intake Air Temperature Sensor 1) 581 Component Inspection (Turbocharger Boost Sensor) 581 Component Inspection (Mass Air Flow Sensor) 581 Work Procedure .553 P0102, P0103 MAF SENSOR 583 DTC/CIRCUIT DIAGNOSIS 555 DTC Description 583 Diagnosis Procedure 583 Component Inspection (Mass Air Flow Sensor) 584 POWER SUPPLY AND GROUND CIRCUIT 555 Diagnosis Procedure .555 P0112, P0113 IAT SENSOR1 586 DTC Description 559 Diagnosis Procedure .559 DTC Description 586 Diagnosis Procedure 586 Component Inspection (Intake Air Temperature Sensor 1) 587 U1025 ENG COMMUNICATION 560 P0117, P0118 ECT SENSOR 588 U1000 CAN COMM CIRCUIT 559 Description .560 DTC Description 560 Diagnosis Procedure .560 P0016 CKP - CMP CORRELATION 563 DTC Description 563 Diagnosis Procedure .563 Component Inspection (Crankshaft Position Sensor) 564 Component Inspection (Camshaft Position Sensor) 565 P0088 FUEL SYSTEM 566 DTC Description 566 Diagnosis Procedure .566 Component Inspection (Fuel Rail Pressure Sensor) 567 Component Inspection (Fuel Injector) 568 Component Inspection (Fuel Pump Suction Control Valve) 568 P0089 FUEL PUMP 569 DTC Description 588 Diagnosis Procedure 588 Component Inspection (Engine Coolant Temperature Sensor) 589 P0122, P0123 APP SENSOR 590 DTC Description 590 Diagnosis Procedure 590 Component Inspection (Accelerator Pedal Position Sensor) 591 P012B INTAKE AIR SYSTEM 593 DTC Description 593 Diagnosis Procedure 593 Component Inspection (Turbocharger Boost Sensor) 594 P0182, P0183 FUEL TEMPERATURE SENSOR 595 DTC Description 595 Diagnosis Procedure 595 DTC Description 569 Diagnosis Procedure .569 Component Inspection (Fuel Rail Pressure Sensor) 570 Component Inspection (Fuel Pump Suction Control Valve) 570 P0192, P0193 FRP SENSOR 597 P0093 FUEL SYSTEM 572 Description 600 DTC Description 600 Diagnosis Procedure 600 DTC Description 572 Diagnosis Procedure .573 Component Inspection (Fuel Rail Pressure Relief Valve) 574 P0097, P0098 IAT SENSOR 576 DTC Description 597 Diagnosis Procedure 597 Component Inspection (Fuel Rail Pressure Sensor) 598 P0200 FUEL INJECTOR 600 P0201, P0202, P0203, P0204 FUEL INJECTOR 601 DTC Description 601 Diagnosis Procedure 601 DTC Description 576 Diagnosis Procedure .576 Component Inspection (IAT sensor 2) 578 P0217 ENGINE OVER TEMPERATURE 602 P0101 MAF SENSOR 579 DTC Description 602 Diagnosis Procedure 603 DTC Description 579 Diagnosis Procedure .579 P0222, P0223 APP SENSOR 604 Revision: 2014 December EC-8 D23 DTC Description 604 Diagnosis Procedure 604 Component Inspection (Accelerator Pedal Position Sensor) 605 P0501, P0502, P0503 VEHICLE SPEED SIGNAL 632 A Description 632 DTC Description 632 Diagnosis Procedure 632 EC P0234 TC SYSTEM 607 DTC Description 607 Diagnosis Procedure 607 P0504 ASCD BRAKE SWITCH 634 DTC Description 634 Diagnosis Procedure 634 Component Inspection (Brake Pedal Position Switch) 638 Component Inspection (Stop Lamp Switch) 639 Component Inspection (Stop Lamp Relay) 639 Component Inspection (Clutch Pedal Position Switch) 639 P0237, P0238 TC BOOST SENSOR 609 DTC Description 609 Diagnosis Procedure 609 P0301, P0302, P0303, P0304 MISFIRE 611 Description 611 DTC Description 611 Diagnosis Procedure 611 C D E P0545, P0546 EGT SENSOR 640 DTC Description 640 Diagnosis Procedure 640 Component Inspection (EGT Sensor 1) 642 P0335, P0336 CRANKSHAFT POSITION SENSOR 613 F DTC Description 613 Diagnosis Procedure 613 Component Inspection (Crankshaft Position Sensor) 614 P0563 BATTERY VOLTAGE 643 P0340, P0341 CAMSHAFT POSITION SENSOR 616 P0580, P0581 ASCD STEERING SWITCH 644 H DTC Description 644 Diagnosis Procedure 644 Component Inspection (ASCD Steering Switch) 646 I DTC Description 643 Diagnosis Procedure 643 DTC Description 616 Diagnosis Procedure 616 Component Inspection (Camshaft Position Sensor) 618 P0605, P0606 ECM 647 P0380, P0670 GLOW CONTROL UNIT 619 DTC Description 647 Diagnosis Procedure 647 DTC Description 619 Diagnosis Procedure 619 Component Inspection (Glow Plug) 620 Description 648 DTC Description 648 Diagnosis Procedure 648 P0628, P0629 FUEL PUMP 649 P0405, P0406 EGR VOLUME CONTROL VALVE POSITION SENSOR 624 DTC Description 649 Diagnosis Procedure 649 Component Inspection (Fuel Pump Suction Control Valve) 650 DTC Description 624 Diagnosis Procedure 624 P0642, P0643 SENSOR POWER SUPPLY 651 P0409 EGR VOLUME CONTROL VALVE 626 DTC Description 651 Diagnosis Procedure 651 DTC Description 626 Diagnosis Procedure 626 P0652, P0653 SENSOR POWER SUPPLY 653 P0473 EXHAUST GAS PRESSURE SENSOR 628 DTC Description 653 Diagnosis Procedure 653 DTC Description 628 Diagnosis Procedure 628 Component Inspection (Exhaust Gas Pressure Sensor 1) 630 P0668, P0669 BAROMETRIC PRESSURE SENSOR 655 P0488 EGR SYSTEM 631 P0686 ECM RELAY 656 DTC Description 631 Diagnosis Procedure 631 DTC Description 656 Diagnosis Procedure 656 Revision: 2014 December J P0607 ECM 648 P0403 EGR VOLUME CONTROL VALVE 622 DTC Description 622 Diagnosis Procedure 622 Component Inspection 623 G DTC Description 655 Diagnosis Procedure 655 EC-9 D23 K L M N O P P1020, P1022, P1023, P1024, P1025, P1026 TC BOOST CONTROL ACTUATOR 658 DTC Description 658 Diagnosis Procedure .658 P1028 EXHAUST GAS PRESSURE SENSOR 659 Description .659 DTC Description 659 Diagnosis Procedure .659 P1029 TC BOOST SENSOR 661 Description .661 DTC Description 661 Diagnosis Procedure .661 Component Inspection (Turbocharger Boost Sensor) 662 P102A BARO SENSOR 664 Description .664 DTC Description 664 Diagnosis Procedure .664 Component Inspection (Fuel Pump Suction Control Valve) 682 Component Inspection (Fuel Rail Pressure Sensor) 682 P1409 EGR COOLER BYPASS VALVE 684 DTC Description 684 Diagnosis Procedure 684 P1550, P1551, P1552, P1553, P1554 BATTERY CURRENT SENSOR 686 DTC Description 686 Diagnosis Procedure 687 Component Inspection (Battery Current Sensor) 688 P1556, P1557 BATTERY TEMPERATURE SENSOR 690 DTC Description 690 Diagnosis Procedure 690 Component Inspection (Battery Temperature Sensor) 692 P1616 ECM 693 P102B EXHAUST GAS PRESSURE SENSOR 666 DTC Description 693 Diagnosis Procedure 693 DTC Description 666 Diagnosis Procedure .666 P1622 INJECTOR ADJUSTMENT VALUE 694 P1268 P1269, P1270, P1271 FUEL INJECTOR 668 DTC Description 668 Diagnosis Procedure .669 Component Inspection (Fuel Injector) 670 P1272 FUEL PUMP 671 DTC Description 671 Diagnosis Procedure .671 Component Inspection (Fuel Pump Suction Control Valve) 673 Component Inspection (Fuel Rail Pressure Sensor) 673 Component Inspection (Fuel Rail Pressure Relief Valve) 674 P1273 FUEL PUMP 675 DTC Description 694 Diagnosis Procedure 694 P1623 INJECTOR ADJUSTMENT VALUE 695 DTC Description 695 Diagnosis Procedure 695 P1805 BRAKE SWITCH 697 DTC Description 697 Diagnosis Procedure 698 Component Inspection (Stop Lamp Switch) 699 Component Inspection (Stop Lamp Relay) 699 P2135 APP SENSOR 701 DTC Description 701 Diagnosis Procedure 701 Component Inspection (Accelerator Pedal Position Sensor) 702 DTC Description 675 Diagnosis Procedure .675 Component Inspection (Fuel Pump Suction Control Valve) 677 P2146, P2149 FUEL INJECTOR POWER SUPPLY 704 P1274 FUEL PUMP 678 P2147, P2148 FUEL INJECTOR 705 DTC Description 678 Diagnosis Procedure .678 Component Inspection (Fuel Pump Suction Control Valve) 679 Component Inspection (Fuel Rail Pressure Sensor) 679 P1275 FUEL PUMP 681 DTC Description 681 Diagnosis Procedure .681 Revision: 2014 December DTC Description 704 Diagnosis Procedure 704 DTC Description 705 Diagnosis Procedure 705 P2228, P2229 BARO SENSOR 706 DTC Description 706 Diagnosis Procedure 706 P2426, P2427 EGR COOLER BYPASS VALVE CONTROL SOLENOID VALVE 707 EC-10 D23 SERVICE DATA AND SPECIFICATIONS (SDS) [YD25DDTi] < SERVICE DATA AND SPECIFICATIONS (SDS) Unit: mm (in) A EM C D JPBIA0229ZZ SEM645 Main journal dia “Dm” 62.951 - 62.975 (2.4784 - 2.4793) Pin journal dia “Dp” 51.956 - 51.974 (2.0455 - 2.0462) Center distance “r” 49.97 - 50.03 (1.9673 - 1.9697) Out-of-round (Difference between and Taper (Difference between ) and ) Runout [TIR*] Standard 0.003 (0.0001) Limit 0.005 (0.0002) Standard 0.003 (0.0001) Limit 0.005 (0.0002) Standard 0.05 (0.0020) Limit F G 0.10 (0.0039) Standard End play E H 0.085 - 0.25 (0.0033 - 0.0098) Limit 0.30 (0.0118) I *: Total indicator reading Main Bearing INFOID:0000000010521067 J MAIN BEARING Unit: mm (in) Grade number Thickness Width Identification color Remarks K L M N O P Revision: 2014 December EM-287 D23 SERVICE DATA AND SPECIFICATIONS (SDS) [YD25DDTi] < SERVICE DATA AND SPECIFICATIONS (SDS) 01 12 23 34 45 56 67 1.812 - 1.809 (0.0713 - 0.0712) Black 1.815 - 1.812 (0.0715 - 0.0713) Brown 1.818 - 1.815 (0.0716 - 0.0715) Green 1.821 - 1.818 (0.0717 - 0.0716) Yellow 1.824 - 1.821 (0.0718 - 0.0717) Blue 1.827 - 1.824 (0.0719 - 0.0718) Pink 1.830 - 1.827 (0.0720 - 0.0719) Purple 1.833 - 1.830 (0.0722 - 0.0720 Red UPR 1.812 - 1.809 (0.0715 - 0.0712) Black LWR 1.815 - 1.812 (0.0715 - 0.0713) Brown UPR 1.815 - 1.812 (0.0715 - 0.0713) LWR 1.818 - 1.815 (0.0716 - 0.0715) UPR 1.818 - 1.815 (0.0716 - 0.0715) Green LWR 1.821 - 1.818 (0.0717 - 0.0716) Yellow UPR 1.821 - 1.818 (0.0717 - 0.0716) Yellow LWR 1.824 - 1.821 (0.0718 - 0.0717) Blue UPR 1.824 - 1.821 (0.0718 - 0.0717) Blue LWR 1.827 - 1.824 (0.0719 - 0.0718) Pink UPR 1.827 - 1.824 (0.0719 - 0.0718) Pink Grade and color are the same for upper and lower bearings Brown 19.9 - 20.1 (0.783 - 0.791) Green LWR 1.830 - 1.827 (0.0720 - 0.0719) Purple UPR 1.830 - 1.827 (0.0720 - 0.0719) Purple LWR 1.833 - 1.830 (0.0722 - 0.0720 Red Grade and color are different between upper and lower bearings UNDERSIZE Unit: mm (in) Size Thickness Main journal diameter “Dm” 0.25 (0.0098) 1.949 - 1.953 (0.0767 - 0.0769) Grind so that bearing clearance is the specified value MAIN BEARING OIL CLEARANCE Unit: mm (in) Items Standard Main bearing oil clearance Limit 0.056 - 0.066 (0.0022 - 0.0026) * 0.066 (0.0026) *: Actual clearance Connecting Rod Bearing INFOID:0000000010521068 CONNECTING ROD BEARING Grade number Thickness Revision: 2014 December mm (in) Width EM-288 Identification color Remarks D23 SERVICE DATA AND SPECIFICATIONS (SDS) [YD25DDTi] < SERVICE DATA AND SPECIFICATIONS (SDS) 1.488 - 1.485 (0.0586 - 0.0585) Green 1.491 - 1.488 (0.0585 - 0.0587) Yellow 1.494 - 1.491 (0.0588 - 0.0585) Blue 1.497 - 1.494 (0.0589 - 0.0588) Pink 1.500 - 1.497 (0.0591 - 0.0589) Purple 01 12 23 34 UPR 1.488 - 1.485 (0.0586 - 0.0585) A Grade and color are the same for upper and lower bearings EM Green 22.9 - 23.1 (0.902 - 0.909) LWR 1.491 - 1.488 (0.0585 - 0.0587) UPR 1.491 - 1.488 (0.0585 - 0.0587) Yellow LWR 1.494 - 1.491 (0.0588 - 0.0585) Blue UPR 1.494 - 1.491 (0.0588 - 0.0585) Blue LWR 1.497 - 1.494 (0.0589 - 0.0588) Pink UPR 1.497 - 1.494 (0.0589 - 0.0588) Pink LWR 1.500 - 1.497 (0.0591 - 0.0589) Purple C Yellow Grade and color are different between upper and lower bearings D E UNDERSIZE F Unit: mm (in) Size 0.08 (0.0031) 0.12 (0.0047) 0.25 (0.0098) Thickness Crank pin journal diameter “Dp” UPR 1.534 - 1.542 (0.0604 - 0.0607) LWR 1.536 - 1.540 (0.0605 - 0.0606) UPR 1.554 - 1.562 (0.0612 - 0.0615) LWR 1.556 - 1.560 (0.0613 - 0.0614) UPR 1.619 - 1.627 (0.0637 - 0.0641) LWR 1.621 - 1.625 (0.0638 - 0.0640) G Grind so that bearing clearance is the specified value H I CONNECTING ROD BEARING OIL CLEARANCE Unit: mm (in) Items Connecting rod bearing oil clearance Standard Limit 0.051 - 0.061 (0.002 - 0.0024)* 0.061 (0.0024) J K *: Actual clearance L M N O P Revision: 2014 December EM-289 D23 ENGINE SECTION EX EXHAUST SYSTEM A EX C D E CONTENTS F QR25DE YD25DDTi PRECAUTION PRECAUTION PRECAUTIONS PRECAUTIONS Precautions for Removing Battery Terminal Removal and Installation Precautions for Removing Battery Terminal Removal and Installation PREPARATION PREPARATION PREPARATION PREPARATION Special Service Tools Commercial Service Tools Commercial Service Tools PERIODIC MAINTENANCE REMOVAL AND INSTALLATION H I PERIODIC MAINTENANCE EXHAUST SYSTEM EXHAUST SYSTEM Inspection G J Inspection REMOVAL AND INSTALLATION 10 K EXHAUST SYSTEM 10 EXHAUST SYSTEM Exploded View Removal and Installation Inspection Exploded View 10 Removal and Installation 11 Inspection 12 L M N O P Revision: 2014 December EX-1 D23 PRECAUTIONS [QR25DE] < PRECAUTION > PRECAUTION PRECAUTIONS Precautions for Removing Battery Terminal INFOID:0000000011578334 When disconnecting the battery terminal, pay attention to the following • Always use a 12V battery as power source • Never disconnect battery terminal while engine is running • When removing the 12V battery terminal, turn OFF the ignition switch and wait at least 30 seconds • For vehicles with the engine listed below, remove the battery terminal after a lapse of the specified time: D4D engine : 20 minutes ZD30DDTi : 60 seconds HRA2DDT : 12 minutes ZD30DDTT : 60 seconds K9K engine : minutes M9R engine : minutes R9M engine : minutes V9X engine : minutes YD25DDTi : minutes SEF289H NOTE: ECU may be active for several tens of seconds after the ignition switch is turned OFF If the battery terminal is removed before ECU stops, then a DTC detection error or ECU data corruption may occur • After high-load driving, if the vehicle is equipped with the V9X engine, turn the ignition switch OFF and wait for at least 15 minutes to remove the battery terminal NOTE: • Turbocharger cooling pump may operate in a few minutes after the ignition switch is turned OFF • Example of high-load driving - Driving for 30 minutes or more at 140 km/h (86 MPH) or more - Driving for 30 minutes or more on a steep slope • For vehicles with the 2-batteries, be sure to connect the main battery and the sub battery before turning ON the ignition switch NOTE: If the ignition switch is turned ON with any one of the terminals of main battery and sub battery disconnected, then DTC may be detected • After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC NOTE: The removal of 12V battery may cause a DTC detection error Removal and Installation INFOID:0000000011578335 CAUTION: • Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat resistance, corrosion resistance, and shape • Perform the operation with the exhaust system fully cooled down because the system will be hot just after engine stops • Be careful not to cut your hand on the heat insulator edge Revision: 2014 December EX-2 D23 PREPARATION [QR25DE] < PREPARATION > PREPARATION A PREPARATION Special Service Tools INFOID:0000000011731327 Tool number Tool name Description KV10117100 Heated oxygen sensor wrench Loosening or tightening heated oxygen sensors with 22 mm (0.87 in) hexagon nut EX C D E NT379 Commercial Service Tools INFOID:0000000011578337 Tool name Description Power tool Loosening nuts and bolts F G H I PBIC0190E J K L M N O P Revision: 2014 December EX-3 D23 EXHAUST SYSTEM [QR25DE] < PERIODIC MAINTENANCE > PERIODIC MAINTENANCE EXHAUST SYSTEM Inspection INFOID:0000000011578339 Check exhaust pipes, muffler, and mounting for improper attachment, leakage, cracks, damage or deterioration • If anything is found, repair or replace damaged parts SMA211A Revision: 2014 December EX-4 D23 EXHAUST SYSTEM [QR25DE] < REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION A EXHAUST SYSTEM Exploded View INFOID:0000000011578341 EX C D E F G H I J K L M JPBIA7009GB Mounting rubber Mounting rubber Main muffler Mounting bracket Mounting rubber Gasket Stud bolt Mounting bracket Mounting rubber Heated oxygen sensor Ring gasket Exhaust front tube N O Insulator Do not loosen these nuts : Always replace after every disassembly P : N·m (kg-m, ft-lb) : N·m (kg-m, ft-lb) Removal and Installation INFOID:0000000011578342 CAUTION: Revision: 2014 December EX-5 D23 EXHAUST SYSTEM [QR25DE] < REMOVAL AND INSTALLATION > • Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat resistance, corrosion resistance and shape • Perform the operation with the exhaust system fully cooled down because the system will be hot just after engine stops • Be careful not to cut your hand on the insulator edge REMOVAL NOTE: Heated oxygen sensor can be removed without exhaust front tube removal Disconnect harness connector of heated oxygen sensor 2 Disconnect each joint and mounting and then remove exhaust system CAUTION: • Never disassemble main muffler at the portion shown in the exploded view • Be careful not to damage three way catalyst Remove heated oxygen sensor if necessary • Using heated oxygen sensor wrench [SST: KV10117100] (A), remove heated oxygen sensor : Vehicle front CAUTION: • Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one • Before installing new heated oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner (commercial service tool) and approved Antiseize lubricant (commercial service tool) JPBIA7070ZZ INSTALLATION Note the following, and install in the reverse order of removal CAUTION: • Always replace exhaust gaskets with new ones when reassembling • Discard any heated oxygen sensor which has been dropped onto a hard surface such as a concrete floor Use a new one • Before installing a new heated oxygen sensor 2, clean exhaust system threads using the heated oxygen sensor thread cleaner (commercial service tool) and apply anti-seize lubricant (commercial service tool) • Never over torque heated oxygen sensor Doing so may cause damage to the heated oxygen sensor 2, resulting in the “MIL” coming on • If heat insulator is badly deformed, repair or replace it If deposits such as mud pile up on the heat insulator, remove them • Prevent rust preventives from adhering to the sensor body • When installing heat insulator avoid large gaps or interference between heat insulator and each exhaust pipe • Remove deposits from the sealing surface of each connection Connect them securely to avoid gas leakage • When installing each mounting rubber, use silicon oil to avoid twisting • Temporarily tighten mounting nuts and bolts Check each part for unusual interference and mounting rubber interference, and then tighten them to the specified torque • When installing each mounting rubber and flex tube, avoid twisting or unusual extension in up/ down, front/rear and right/left directions Inspection INFOID:0000000011578343 INSPECTION AFTER INSTALLATION • Check the clearance between tailtube and rear bumber is even • With the engine running, check exhaust tube joints for gas leakage and unusual noises • Check to ensure that mounting brackets and mounting rubbers are installed properly and free from undue stress Improper installation could result in excessive noise and vibration Revision: 2014 December EX-6 D23 PRECAUTIONS [YD25DDTi] < PRECAUTION > PRECAUTION A PRECAUTIONS Precautions for Removing Battery Terminal INFOID:0000000010502001 When disconnecting the battery terminal, pay attention to the following • Always use a 12V battery as power source • Never disconnect battery terminal while engine is running • When removing the 12V battery terminal, turn OFF the ignition switch and wait at least 30 seconds • For vehicles with the engine listed below, remove the battery terminal after a lapse of the specified time: D4D engine : 20 minutes ZD30DDTi : 60 seconds HRA2DDT : 12 minutes ZD30DDTT : 60 seconds K9K engine : minutes M9R engine : minutes R9M engine : minutes V9X engine : minutes YD25DDTi : minutes EX C D E F SEF289H G NOTE: ECU may be active for several tens of seconds after the ignition switch is turned OFF If the battery terminal is removed before ECU stops, then a DTC detection error or ECU data corruption may occur • After high-load driving, if the vehicle is equipped with the V9X engine, turn the ignition switch OFF and wait for at least 15 minutes to remove the battery terminal NOTE: • Turbocharger cooling pump may operate in a few minutes after the ignition switch is turned OFF • Example of high-load driving - Driving for 30 minutes or more at 140 km/h (86 MPH) or more - Driving for 30 minutes or more on a steep slope • For vehicles with the 2-batteries, be sure to connect the main battery and the sub battery before turning ON the ignition switch NOTE: If the ignition switch is turned ON with any one of the terminals of main battery and sub battery disconnected, then DTC may be detected • After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC NOTE: The removal of 12V battery may cause a DTC detection error Removal and Installation H I J K L INFOID:0000000010502000 M CAUTION: • Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat resistance, corrosion resistance, and shape • Perform the operation with the exhaust system fully cooled down because the system will be hot just after engine stops • Be careful not to cut your hand on the heat insulator edge N O P Revision: 2014 December EX-7 D23 PREPARATION [YD25DDTi] < PREPARATION > PREPARATION PREPARATION Commercial Service Tools INFOID:0000000010501998 Tool name Description Power tool Loosening nuts and bolts PBIC0190E Revision: 2014 December EX-8 D23 EXHAUST SYSTEM [YD25DDTi] < PERIODIC MAINTENANCE > PERIODIC MAINTENANCE A EXHAUST SYSTEM Inspection INFOID:0000000010501999 Check exhaust pipes, muffler, and mounting for improper attachment, leakage, cracks, damage or deterioration • If anything is found, repair or replace damaged parts EX C D E SMA211A F G H I J K L M N O P Revision: 2014 December EX-9 D23 EXHAUST SYSTEM [YD25DDTi] < REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION EXHAUST SYSTEM Exploded View INFOID:0000000010501993 For Thailand double cab and king cab JSBIA5450GB Mounting rubber Mounting rubber Main muffler Gasket Ground cable Exhaust front tube Ring gasket Do not loosen these nuts : Always replace after every disassembly : N·m (kg-m, ft-lb) Revision: 2014 December EX-10 D23 EXHAUST SYSTEM < REMOVAL AND INSTALLATION > Except for Thailand double cab and king cab [YD25DDTi] A EX C D E F G H I J K JPBIA7008GB Mounting rubber Mounting rubber Main muffler Bracket Ground cable Mounting rubber Gasket Exhaust front tube Ring gasket L Do not loosen these nuts M : Always replace after every disassembly : N·m (kg-m, ft-lb) N Removal and Installation INFOID:0000000010501994 CAUTION: • Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat resistance, corrosion resistance and shape • Perform the operation with the exhaust system fully cooled down because the system will be hot just after engine stops • Be careful not to cut your hand on the insulator edge REMOVAL Disconnect each joints and mounting by using power tool CAUTION: Never disassemble main muffler at the portion shown in the exploded view INSTALLATION Revision: 2014 December EX-11 D23 O P EXHAUST SYSTEM [YD25DDTi] < REMOVAL AND INSTALLATION > Note the following, and install in the reverse order of removal CAUTION: • Always replace exhaust gaskets with new ones when reassembling • If insulator is badly deformed, repair or replace it If deposits such as mud pile up on insulator, remove them • When installing insulator avoid large gaps or interference between insulator and each exhaust pipe • Remove deposits from the sealing surface of each connection Connect them securely to avoid gas leakage • Temporarily tighten mounting nuts on the exhaust manifold side and mounting bolts on the vehicle side Check each part for unusual interference, and then tighten them to the specified torque • When installing each mounting rubber and flex tube, avoid twisting or unusual extension in up/down and right/left directions Inspection INFOID:0000000010501995 INSPECTION AFTER INSTALLATION • Check the clearance between tailtube and rear bumber is even • With the engine running, check exhaust tube joints for gas leakage and unusual noises • Check to ensure that mounting brackets and mounting rubbers are installed properly and free from undue stress Improper installation could result in excessive noise and vibration Revision: 2014 December EX-12 D23