Mitsubishi Fuso Canter 2010 2013 Service Repair Manual Part3

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320 TAIL, PARKING AND LICENSE PLATE LAMPS CIRCUIT 54-03
54-03-5
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325 STOP LAMP CIRCUIT
54-03-6
330 TURN SIGNAL AND HAZARD LAMP CIRCUIT 54-03
54-03-7
340 BACKUP LAMP CIRCUIT
54-03-8
54-03
M E M O
54-03-9
345 CAB LAMP CIRCUIT
54-03-10
54-03
54-03-11
348 ILLUMINATION LAMP CIRCUIT
54-03-12
349 IDENTIFICATION AND SIDE MARKER LAMP CIRCUIT 54-03
54-03-13
352 VAN BODY DOME LIGHT CIRCUIT
54-03-14
54-04 METER CIRCUIT
54-04-1
401 METER CLUSTER INTERNAL CIRCUIT
54-04-2
54-04
54-04-3
410 TACHOMETER CIRCUIT
54-04-4
412 SPEEDOMETER CIRCUIT 54-04
54-04-5
415 TACHOGRAPH CIRCUIT
54-04-6
420 FUEL GAUGE CIRCUIT 54-04
54-04-7
425 WATER TEMPERATURE GAUGE CIRCUIT
54-04-8
54-05 INDICATOR AND WARNING LAMP

CIRCUIT
54-05-1
510 PARKING BRAKE INDICATOR CIRCUIT
54-05-2
515 BRAKE WARNING CIRCUIT 54-05
54-05-3
536 ENGINE OIL PRESSURE WARNING CIRCUIT
54-05-4
537 OVERHEATING WARNING CIRCUIT 54-05
54-05-5
550 CAB TILT WARNING CIRCUIT
54-05-6
554 STARTER KEY REMOVAL REMINDER ALARM CIRCUIT 54-05
54-05-7
566 FUEL FILTER CIRCUIT
54-05-8
54-06 CAB SIDE ELECTRICAL CIRCUIT
54-06-1
610 CIGARETTE LIGHTER CIRCUIT
54-06-2
612 AUDIO CIRCUIT 54-06
54-06-3
614 WIPER AND WASHER CIRCUIT
54-06-4
616 HORN CIRCUIT 54-06
54-06-5
620 HEATER AND AIR-CONDITIONER CIRCUIT
54-06-6
54-06
54-06-7
622 POWER WINDOW AND CENTRAL DOOR LOCK CIRCUIT
54-06-8
629 MIRROR HEATER CIRCUIT 54-06
54-06-9
654 KEYLESS ENTRY CIRCUIT
54-06-10
54-08 ENGINE AND TRANSMISSION

SIDE ELECTRICAL CIRCUIT
54-08-1
810 FOUR-WHEEL DRIVE CIRCUIT
54-08-2
850 TRANSMISSION POWER TAKE-OFF CIRCUIT 54-08
54-08-3
54-09 OTHER CIRCUIT
54-09-1
905 JOINT CONNECTOR (J/C)
54-09-2
54-09
54-09-3
54-10 ELECTRICAL EQUIPMENT

INSTALLATION POSITIONS
54-10-1
A SWITCH AND SENSOR

Cab side
54-10-2
54-10
54-10-3
A SWITCH AND SENSOR
54-10-4
54-10
54-10-5
B RELAY AND ELECTRONIC CONTROL UNIT
54-10-6
54-10
54-10-7
B RELAY AND ELECTRONIC CONTROL UNIT
54-10-8
54-10
54-10-9
C METER AND MOTOR
54-10-10
54-10
M E M O
54-10-11
D AIR-CONDITIONER
54-10-12
54-10
54-10-13
D AIR-CONDITIONER
54-10-14
54-10
M E M O
54-10-15
E DOOR
54-10-16
F ROOF 54-10
54-10-17
G CAB
54-10-18
H TILT 54-10
54-10-19
J JOINTS OF MAIN HARNESS CONNECTORS
54-10-20
54-10
54-10-21
J JOINTS OF MAIN HARNESS CONNECTORS
54-10-22
54-10
54-10-23
P OTHERS
54-10-24
54-10
M E M O
54-10-25
R ENGINE
Engine and transmission
54-10-26
54-10
54-10-27
S TRANSMISSION
54-10-28
54-10
54-10-29
T SWITCH AND SENSOR

Chassis side
54-10-30
54-10
54-10-31
T SWITCH AND SENSOR
54-10-32
54-10
54-10-33
T SWITCH AND SENSOR
54-10-34
54-10
M E M O
54-10-35
U FUSE, RELAY AND ELECTRONIC CONTROL UNIT
54-10-36
54-10
54-10-37
V MAGNETIC VALVE, MOTOR AND BUZZER
54-10-38
54-10
54-10-39
W JOINTS OF MAIN HARNESS CONNECTORS
54-10-40
54-10
54-10-41
W JOINTS OF MAIN HARNESS CONNECTORS
54-10-42
54-10
M E M O
54-10-43
X OTHERS
54-10-44
54-10
R
54-10-45
X OTHERS
54-10-46
54-10
R
54-10-47
54-11 INSPECTION OF ELECTRICAL

EQUIPMENT
54-11-1
#001 to #179 SWITCH

#001 Inspection of combination switch
• Because it is not easy to independently check the switch for the
function, determine the quality of the switch indirectly by check-
ing the related parts, such as the harness, horn switch, etc. in
the system.
• If there is nothing abnormal in the related parts, but the problem
remains in the system, then replace the switch. (See Gr37.)
#002 Inspection of starter switch

• Perform the following checks, and if any fault is found, replace
the switch. (See Gr37.)
(1) Starter switch
Switch position Continuity terminal
without key –
LOCK
with key (1)–(2)
ACC (1)–(2), 4–5
ON (1)–(2), 4–5–6
START (1)–(2), 3–4–5–6
(2) Key interlock solenoid
• Confirm that applying battery voltage between the terminals 1
and 2 prevents the key from turning toward the LOCK position.
#023 Inspection of vacuum switch

(1) Inspection without applying negative pressure

• Make sure that there is no continuity between terminals 1 and 2
(body).
(2) Inspection by applying negative pressure
• Gradually apply negative pressure to the switch starting from 0
kPa {0 psi, 0 kgf/cm2}.
• Measure the degree of air pressure at the moment when conti-
nuity is detected between terminals 1 and 2 (body), and make
sure to confirm if the value meets the standard.
Standard
–(47 +3.3 +0.98 +25
–4.0 ) kPa {–(13.8 –1.18 ) in.Hg, –(350 –30 ) mmHg}
value
54-11-2
54-11
#027 Inspection of power window switch
• Because it is not easy to check these switches individually, de-
termine the quality of the switches indirectly by checking related
parts, such as harnesses, power window motor, etc. in the sys-
tem.
• If there is nothing abnormal in related parts, but there is still
something wrong with the system, then replace the switches.
(See Gr43.)
#034 Inspection of rear heater switch

HI 2–4
OFF –
LO 1–2
• If any fault is found, replace the switch.
#035 Inspection of door switch

OFF –
ON 1-body, 2-body
• If any fault is found, replace the switch. (See Gr43.)
#038 Inspection of parking brake switch

• Measure continuity between terminals 1 and 2 (body) ground.
Pull the parking brake lever Continuity exists
Release the parking brake lever Continuity does not exist
#039 Inspection of cab tilt lock switch

OFF –
ON 1–2
54-11-3
#001 to #179 SWITCH

#041 Inspection of brake fluid level switch
• Gradually drain brake fluid from the brake fluid reservoir.
CAUTION
• Brake fluid contains ingredients that dissolve the vehicle’s
paint. Quickly wipe off brake fluid when it is spilled.
• Measure height of the switch when continuity is detected be-

tween terminals 1 and 2.
Standard value 18 to 20 mm {0.71 to 0.79 in.}
• If the measured value deviates from the standard value, replace
the brake fluid reservoir. (See Gr52.)
#042 Inspection of stop lamp switch

A 1–2
B 3–4
#044 Inspection of oil pressure switch

(1) Inspection without applying air pressure
• Make sure that there is continuity between terminals 1 and the
body.
(2) Inspection by applying air pressure
• Gradually apply air pressure to the switch starting from 0 kPa {0
psi, 0 kgf/cm2}.
• Measure the degree of air pressure at the moment when conti-

nuity is not detected between terminals 1 and body, and make
sure to confirm if the value meets the standard.
Standard value
50 ± 10 kPa {7.1 ± 1.4 psi, 0.5 ± 0.1 kgf/cm2}
(operating pressure)
#054 Inspection of switch

the switch.
OFF –
ON 1–2
54-11-4
54-11
• Transfer four-wheel drive switch. <FG>
• Parking gear switch. (See Gr22.)
• Power take-off control switch. (See Gr22.)
#081 Inspection of hazard switch

Switch position Continuity terminal Night illumination
OFF –
(+) 4-1 (–)
ON 2–3
#089 Inspection of switch

the switch.
• Fog lamp switch
• DPF cleaning switch
• Transmission power take-off switch
OFF –
(+) 1–10 (–)
ON 3–7
• Font drive switch
54-11-5
#001 to #179 SWITCH

• ECO mode switch
OFF 5–7
(+) 1–10 (–)
ON 3–7
• Van body dome light switch
Continuity Operation Night
Switch position
terminal illumination illumination
OFF – –
(+) 1–10 (–)
ON 3–7 (+) 9–10 (–)
• Door lock switch
LOCK 3–7, 4–6
Neutral 4–6, 5–7 (+) 1–10 (–)
UNLOCK 4–8, 5–7
• Cruise control main switch
Switch position
OFF 4–8, 5–7 –
Neutral 4–6, 5–7 – (+) 1–10 (–)
ON 3–7, 4–6 (+) 9–10 (–)
54-11-6
#180 to #249 RELAY 54-11

#187 Inspection of starter relay
• Perform continuity and operation checks, and if any fault is
found, replace the relay.
#201 Inspection of relay (normally open type 5 pin)

• Perform continuity and operation checks, and if any fault is
54-11-7
#250 to #349 SENSOR

#251 Inspection of photo sensor
• With the photo sensor connected to the control panel at the sen-
sor connector, turn the starter switch ON.
• With the exposed portion of the sensor exposed to light, mea-
sure the output voltage between terminal 2 and body ground.
Inspection condition: Move a lit
bulb of about 60 watts toward
1 to 5 V
Standard and away from right above the
(voltage lowers as
value photo sensor (approx. 150 mm
light nears sensor)
{5.91 in.} from sensor at closest
point).
the sensor. (See Gr52.)
#252 Inspection of pressure sensor

termine the quality of the sensors indirectly by checking related
parts, such as harnesses, etc. in the system.
• If there is nothing abnormal in the related parts, but there is still
something wrong with the system, then replace the sensors.
#253 Inspection of air inlet sensor

• Change the ambient temperature of the sensor and measure the
resistance between terminals 1 and 2.
• If the measured value deviates from the characteristic shown in
the table at left, replace the sensor. (See Gr55.)
54-11-8
54-11
#256 Inspection of in car sensor
• If the measured value deviates from the characteristics shown in
#258 Inspection of fuel level sensor

• Measure resistance values between terminals 1 and 2 when
bringing the float arm into contact with stoppers (at EMPTY and
FULL positions) and placing it at the midpoint position.
at FULL position 0 +20 Ω
Standard value at 1/2 position 50 ± 3 Ω
at EMPTY position 150 ± 10 Ω
#259 Inspection of water level sensor

• Remove the water level sensor from the radiator.
• Turn the starter switch ON.
• Dip the water level sensor in a container filled with engine cool-
ant, and check that the meter cluster LED illuminates and extin-
guishes under the following conditions.
Condition Meter cluster LED
When water level sensor is out of
Illuminates
the water
When water level sensor is in the
Extinguishes
water
• If any fault is found, replace the sensor. (See Gr14.)
54-11-9
#250 to #349 SENSOR

#262 Inspection of water temperature sensor
• Dip the sensor in a container filled with engine oil.
• Raise the oil temperature to each specification below while stir-
ring the oil.
• Measure resistance values between terminals 1 and 2.
–30°C {–22°F} 22.307 to 310.194 kΩ
Standard 20°C {68°F} 2.262 to 2.760 kΩ
value 80°C {176°F} 0.304 to 0.342 kΩ
120°C {248°F} 0.106 to 0.119 kΩ
#263 Inspection of engine speed sensor
• Measure the resistance value between terminals 1 and 2.
Standard value (at 20°C {68°F}) 860 ± 86 Ω
#265 Inspection of vehicle speed sensor

• While applying a voltage of 6.5 to 9 V between terminals 1 and
2, rotate the sensor shaft.
• Check the signals of terminal 3 (SPEED SIG IN) and terminal 4
(SPEED DATA). If no signals are found, replace the sensor.
(See Gr22.)
#323 Inspection of fuel filter (fuel temperature sensor)

• Measure the resistance between terminals 8 and 9.
–30°C {–22°F} 26.114 ± 2.533 Ω
0°C {32°F} 5.896 ± 0.430 Ω
Standard 25°C {77°F} 2.057 ± 0.115 Ω
value 60°C {140°F} 596 ± 23 Ω
100°C {212°F} 186 ± 4 Ω
110°C {230°F} 144 ± 3.456 Ω
• If the measurement is out of specification, replace the fuel filter.
(See Gr13.)
54-11-10
#350 to #409 CONTROL UNIT 54-11

#350 Inspection of control unit and other units
• Since the units alone cannot be readily checked off the vehicle,
check the harness, switch and other related parts in each sys-
tem.
• If faults are not found in the related parts, and the problem still
remains in the system, replace the control units or other units.
54-11-11
#410 to #509 MOTOR

#411 Inspection of blower motor
• Make sure that the motor operates when 12 volts DC is applied
between each terminal.
• If any fault is found, replace the motor. (See Gr55.)
#413 Inspection of air mixing motor

the motor. (See Gr55.)
(1) Inspection of motor
Lever position Continuity terminal
MAX HOT (+) 6–7 (–)
MAX COOL (+) 7–6 (–)
CAUTION
• Stop voltage application when the lever stops.
• After inspection of the motor, return the lever to a position
within the range of MAX HOT to MAX COOL.
(2) Inspection of potentiometer

• Apply 5 volts DC between the terminals 1 and 3 and measure
the voltage between the terminals 1 and 5.
Lever position Standard value
MAX HOT 4 ± 0.03
MAX COOL 1 ± 0.03
54-11-12
54-11
#414 Inspection of mode motor
<Fully automatic air-conditioner>
FACE (+) 6–7 (–)
DEF (+) 7–6 (–)
CAUTION
• Stop voltage application when the lever stops.
• After inspection of the motor, return the lever to a position
within the range of FACE to DEF.

FACE 4.5 ± 0.03
DEF 0.5 ± 0.03
#415 Inspection of fresh/recirculation changeover motor

REC (inside air) (+) 3–2 (–)
FRE (outside air) (+) 3–1 (–)
CAUTION
• Stop applying 12 volts DC if the lever stops spontaneously
at the REC or FRE position.
54-11-13
#410 to #509 MOTOR

#422 Inspection of wiper motor
termine the quality of the motor indirectly by checking related
parts, such as harnesses, power window motor, etc. in the sys-
tem.
• If there is nothing abnormal in related parts, but there is still
something wrong with the system, then replace the motor. (See
Gr51.)
#423 Inspection of power window motor

Rotation direction Continuity terminal
Left (+) 2–1 (–)
Right (+) 1–2 (–)
• If any fault is found, replace the motor and the regulator as a set.
(See Gr43.)
#428 Inspection of windshield washer motor

#431 Inspection of condenser fan motor

• If any fault is found, replace the condenser. (See Gr55.)
54-11-14
#510 to #539 ACTUATOR 54-11
#510 Inspection of door lock actuator (passenger’s seat side)
• Make sure that the actuator operates when 12 volts DC is ap-
plied between each terminal.
Switch position Terminal
LOCK (+) 1–2 (–)
UNLOCK (+) 2–1 (–)
• If any fault is found, replace the actuator. (See Gr43.)
#511 Inspection of door lock actuator (driver’s seat side)

Switch position Continuity terminal Terminal
LOCK 1–2 (+) 3–4 (–)
UNLOCK 1–5 (+) 4–3 (–)
#512 Inspection of rear door lock actuator

Switch position Terminal
LOCK (+) 2–3 (–)
UNLOCK (+) 3–2 (–)
54-11-15
#560 to #609 MAGNETIC VALVE
#565 Inspection of 3-way magnetic valve
<Type-1>
the 3-way magnetic valve.
(1) Operation check
• Gradually apply DC current between each terminal starting from
0 V.
• Measure the voltage when the 3-way magnetic valve operates.
(Determine ON/OFF of the magnetic valve by operating noises.)
Standard value
11 V or less
(minimum operating voltage)
(2) Inspection of continuity and air tightness

• Negative pressure when inspected: –99.99 kPa {–29.5 in.Hg, –
750 mmHg}
<Type-2>
the 3-way magnetic valve.
(1) Operation check
• Gradually apply DC current between each terminal starting from
0 V.
• Measure the voltage at which the 3-way magnetic valve oper-
ates. (Determine ON/OFF of the magnetic valve by operating
noises.)
Standard value
8 V or less
(minimum operating voltage)
(2) Inspection of continuity and air tightness

• Negative pressure when inspected: –60 kPa {–17.7 in.Hg, –450
mmHg}
54-11-16
#610 to #649 BUZZER, HORN 54-11
#614 Inspection of backup buzzer
[Inspection]
• Make sure to confirm if the buzzer intermittently sounds by ap-
plying the 12 volts DC between each terminal.
• If any fault is found, replace the buzzer.
[Installation]
• Install the backup buzzer to the frame in the range of angles as
illustrated.
CAUTION
• Be aware that if the installed angle of the buzzer is out of
the range as illustrated, water in the buzzer will not drain
normally.
#615 Inspection of electric horn

CAUTION
• Bending the stay changes the sound quality of the horn, de-
grading the horn performance.
• Never bend or damage the stay.
[Inspection]
• Make sure to confirm whether the horn sounds by applying the 12
volts DC between terminals 1 and body.
• Remove foreign substances adhered to the resonator and dia-
phragm.
• If any fault is found, replace the horn.
[Installation]
• Install in the direction as illustrated.
54-11-17
#650 to #699 LAMP

#656 Inspection of cab and spot lamp
• If any fault is found, replace the lamp.
54-11-18
#750 to #859 OTHER 54-11

#750 Inspection of blower resistor
<Front air-conditioner (manual)>
• Measure resistance values between each terminals.
Fan speed Terminal Standard value
MEDIUM HIGH 2–4 0.56 ± 0.0392 Ω
MEDIUM LOW 3–4 1.56 ± 0.109 Ω
LOW 1–4 3.36 ± 0.235 Ω
the blower resistor. (See Gr55.)
<With rear heater>

• Measure resistance value between terminals 1 and 4.
Fan speed Terminal Standard value
LOW 1–4 3Ω
the blower resistor. (See Gr55.)
#751 Inspection of thermostat

• Measure the output voltage between terminals 1 and 2 at the
specified temperatures.
#752 Inspection of power MOS-FET (transistor)

the power transistor. (See Gr55.)
• Start the engine and operate the blower in the HI mode.
Check that a high blower output equivalent to HI is obtained.
• Operate the control to step down the flow of air. Check that
the blower output equally decreases gradually.
• Check that nothing is abnormal with the blower motor, wiring,
air conditioner electronic control unit, control panel and relat-
ed parts. If the blower motor is inoperative in that state, the
power MOS-FET (transistor) should be faulty.
54-11-19
#750 to #859 OTHER

#754 Inspection of cigarette lighter
the cigarette lighter. (See Gr52.)
• Make sure that there is continuity between heater element and
body.
• Make sure that when plug is pushed in by hand, it immediately

returns to its original position.
• Place the starter switch at ACC or ON position.
• Push plug into the socket in the cab.
• Measure the time required for plug to automatically return.
Standard value 15 ± 5 seconds
• Check to see that heater element is red-hot.
#763 Inspection of heater control panel

the heater control panel. (See Gr52.)
(1) Blower switch <AN6A connector>
0: OFF –
1: LO (LOW) 1–2–4
2: ML (MEDIUM LOW) 1–3–4
3: MH (MEDIUM HIGH) 1–4–6
4: HI (HIGH) 1–4–5
(2) Fresh/recirculation changeover switch

Switch position
OFF: Fresh air 6–12 –
ON: (+) 9–10 (–)
5–12 (+) 1–12 (–)
Recirculation air
(3) Air-conditioner switch

Switch position
OFF – –
(+) 9–10 (–)
ON 3–7 (+) 1–7 (–)
54-11-20
54-11
#764 Inspection of glow plug
• Measure the resistance between the housing and the connec-
tion pin using a multimeter.
Standard value
0.6 to 1.0 Ω
(at 20°C {68°F})
the glow plug. (See Gr11.)
#771 Inspection of immobilizer antenna

• Measure the resistance between terminals 1 and 2.
Standard value
20 ± 2 Ω
(at 25°C {77°F})
the immobilizer antenna.
54-11-21
#860 BATTERY
DANGER
• Since flammable hydrogen gas is generated by the battery be sure to obey the following warnings:
• Do not short-circuit the (+) and (–) terminals on the battery.
• Keep sparks and lit cigarettes away from the battery.
• Do not wear metal objects on your arms and lean over battery.
• Because the battery electrolyte is made of diluted sulfuric acid and is corrosive, when handling battery
wear safety glasses and rubber gloves to protect the eyes and hands.
WARNING
• Make sure that you disconnect battery cable (–) first when you disconnect battery cables.
CAUTION
• Make sure that all electrical switches of the vehicle are OFF before connecting battery cables.
• Make sure that you connect battery cable (+) before you connect battery cable (–).
• To prevent a short-circuit be sure that disconnected battery cables do not accidentally touch the battery
terminals.
Service standards
Location Maintenance item Standard value Limit Remedy
Charge or
– Specific gravity of battery electrolyte (20°C {68°F}) 1.280 1.220
replace
Service procedure
Inspection of battery
(1) Visual inspection
• If a terminal is corroded, remove the corrosion from it using a
wire brush.
• If cracks or defects are found on battery, replace it since the
cracks or defects can cause liquid spills.
• If vent plug bleed hole is clogged, clean the hole.
54-11-22
54-11
(2) Inspection of fluid level
• Make sure that the battery electrolyte level is between UPPER
and LOWER.
• If the level is below LOWER, remove the vent plug and fill the
battery with distilled water or battery replenisher to UPPER.
(3) Measurement of specific gravity

Measure the specific gravity of the battery electrolyte. If the mea-
sured value is lower than the limit, charge the battery.
NOTE
• The specific gravity of the battery electrolyte depends on
the liquid temperature. Use the following formula to convert
the actual value to the value for a temperature of 20°C
{68°F}.
S20 = St + 0.0007 (t–20)
S20 : Specific gravity at a temperature of 20°C {68°F}

St : Specific gravity actually measured with the temperature
at t°C
t : Temperature of battery electrolyte
54-11-23
#860 BATTERY
(4) Charging
• Although, as a rule, battery charging should be done with the
battery removed from the vehicle, if you have to charge the bat-
tery while it is on the vehicle, make sure that you stop the engine
and disconnect battery cable (–).
• Remove vent plugs before charging the battery.
• For the recommended charge time and current, see the follow-
ing table to avoid overcharging.
Upper limit
Charge current of fluid
Charge time (H)
(A) temperature
(°C {°F})
*Amount of
Value of 5-hour
Normal discharge (Ah) 45
rating capacity ×1.2
charge Charge {113}
10 (to 1.5)
current (A)
Value of 5-hour
Quick rating capacity 55
0.5
charge {131}
1.5
* Amount of discharge (Ah) =

Amount of
discharge(%)
5-hour rating capacity (Ah) ×
100
• Use the graph shown on the left to calculate the amount of dis-
charge (%).
• Use diluted sulfuric acid, made up of sulfuric acid and refined or
distilled water, as the battery electrolyte.
DANGER
• Keep naked light away from the battery while charging to
prevent explosion.
• It is dangerous to generate sparks while charging the bat-
tery.
• Do not charge battery if the electrolyte level is below LOW-
ER LEVEL, since it can cause early deterioration, heating,
or explosion. Make sure to add the fluid to the specified lev-
el before charging.
WARNING
• Do not let the battery electrolyte level rise and overflow
while charging the battery.
• After charging the battery, tighten vent plug, wash away sul-
furic acid from the battery using water, and dry the surface.
54-11-24
#890 METER 54-11
#890 Meter cluster
• Each sensor signal is converted into digital signal in the meter
cluster and then the value is indicated by the corresponding
meter on the cluster. Therefore, a single meter inspection cannot
be performed.
• Check for meter cluster faults with diagnosis codes. (See #986.)
54-11-25
54-12 STARTER AND ALTERNATOR
54-12-1
#930 STARTER
WARNING
• Before removing the starter, dis-
connect the (–) battery cable and in-
sulate the cable and the (–) battery
terminal with tape.
• It is dangerous to leave the (–) bat-
tery cable connected since the bat-
tery cable voltage is always present
at terminal B.
Tightening torque (Unit: N·m {ft.lbs, kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Bolt (starter mounting) 22 to 30 {16 to 22, 2.2 to 3.1} –
Assembly procedure
Assembly: Bracket
• Install the bracket at the angle shown in the illustration.
54-12-2
54-12
M E M O
54-12-3
#930 STARTER
Disassembly sequence
1 Magnetic switch 8 Yoke 15 Stop ring
2 Shim 9 Packing A 16 Overrunning clutch
3 Rear bracket 10 Planetary gear 17 Internal gear
4 Rear bearing 11 Packing B 18 Planetary gear holder
5 Brush holder 12 Plate 19 Front bracket
6 Armature 13 Lever
7 Ball 14 Snap ring : Non-reusable parts
CAUTION
• When the armature is removed, the ball may come out with it. Take care not to lose the ball.
54-12-4
54-12
• Do not remove the rear bearing unless defects are evident.
Assembly sequence
Follow the disassembly sequence in reverse.
CAUTION
• Do not immerse parts in any kind of solvent for cleaning.
• Immersing the armature in a solvent will damage the insulation. Wipe parts clean with a cloth.
• Immersion cleaning of the drive unit is prohibited.
• The overrunning clutch is filled with grease at the factory. Immersion cleaning will wash away the grease
from the clutch. To clean the drive unit, use a cleaning solvent-moistened brush and then wipe it dry with
a cloth.
• Whenever the magnetic switch is replaced, the pinion gap must be adjusted.
• The packing A is serviceable if any defect is not found.
Service standards (Unit: mm {in.})

– Pinion gap 0.5 to 2.0 {0.02 to 0.079} – Adjust
No-load char- Current 120 A or less – Correct or

– With 11 V applied
acteristics Rotation speed 2870 rpm or higher – replace
Difference between inside diameter of rear bearing

4,6 0.1 {0.0039} or less – Replace
and outside diameter of armature shaft
23.4 to 31.6 N
10 N
Brush spring pressure {5.3 to 7.1 lbs, Replace
5 {2.2 lbs, 1.0 kgf}
2.4 to 3.2 kgf}
Brush length 17.6 {0.69} 12.1 {0.48} Replace
Commutator outside diameter 29.4 {1.16} 28.8 {1.13}
Replace
Runout of commutator periphery – 0.1 {0.0039} or higher
6
Correct or
Mold depth between segments 0.5 {0.02} 0.2 {0.0079} or less
replace
13 Overrunning clutch contact surface of lever 8 {0.31} or higher – Replace

Screw (magnetic switch mounting) 4.1 to 7.6 {3.0 to 5.6, 0.4 to 0.8} –
Through bolt (rear bracket mounting) 5.0 to 7.1 {3.7 to 5.2, 0.5 to 0.7} –
Screw (rear bracket mounting) 2.4 to 4.4 {1.8 to 3.2, 0.2 to 0.4} –
54-12-5
#930 STARTER
Lubricant and/or sealant
Mark Points of application Specified lubricant and/or sealant Quantity
Armature contact surface of rear bearing
Sliding surfaces of lever and overrunning clutch and lever
supporting point Multipurpose grease
As required
Internal gear contact surface and spline of planetary gear [NLGI No. 2 (Li soap)]
holder
Gear shaft contact surface of front bracket
Sliding surfaces of armature and gear shaft
Ball
Molykote AG650 As required
Teeth of planetary gear
Internal gear and gear shaft contact surfaces
Multemp OA-171
Splines of planetary gear holder As required
(Kyodo Yushi Co., Ltd.)
Work before disassembly

Mating mark: Front bracket and yoke
CAUTION
• Make sure that the motor body is free of damage and that
the magnet switch terminals S, B and M are normal.
CAUTION
• A permanent magnet is used in the field section. Do not
strike at the yoke hard with a hammer or equivalent, drop it
nor squeeze it with a vise.
Disassembly procedure
Disassembly: Magnet switch
• Remove the terminal M nut from the magnet switch and discon-
nect the field coil line.
54-12-6
54-12
• Remove screws and remove the magnet switch.
Disassembly: Rear bracket

• Remove through bolts and screws, and then remove the rear
bracket.
Disassembly: Rear bearing

• To remove the rear bearing, press it out of the rear bracket using
a round bar slightly thinner than the bearing and a hand press to
apply force from outside of the rear bracket.
Disassembly: Brush holder, armature and yoke

• Separate the brushes from the commutator. Then, hold each
brush with the brush spring applied against the flank of brush.
54-12-7
#930 STARTER
• Pull the brush spring at A to draw up the brush.
• Hold the drawn-up brush with the brush spring as shown.
• With the brushes held, remove in this order: the brush holder, ar-
mature and yoke.
Disassembly: Packing A, B, plate and planetary gear

• Remove packing A, three planetary gears, packing B and plate
from the front bracket.
Disassembly: Planetary gear holder, internal gear, overrun-

ning clutch and lever
• Remove the planetary gear holder, internal gear, overrunning
clutch and lever from the front bracket.
CAUTION
• Confirm the lever direction before removal.
54-12-8
54-12
• Apply a pipe of the same size to the stop ring, and then hammer
the pipe moderately to release the stop ring from the snap ring.
• Remove the snap ring, stop ring, overrunning clutch and internal
gear from the planetary gear holder.
Inspection procedure
Inspection: Magnetic switch
the switch.
(1) Test for coil open circuit
• Confirm that continuity exists between terminals S and M.
• Confirm that continuity exists between terminal M and the body.
54-12-9
#930 STARTER
(2) Test for fused-together contacts
• Confirm that continuity does not exist between terminals B and
M.
(3) Test for contact-to-contact continuity

• Push in the end of the magnetic switch to close the internal con-
tacts. Then, confirm that continuity exists between terminals B
and M.
Inspection: Brush holder

(1) Test for insulation
• Thoroughly clean the (+) side connector and (–) side base and
check for continuity between them.
• If continuity exists, there is a short circuit and the brush holder
must be replaced.
(2) Manual and visual inspections
• Perform the following inspections. If any fault is found, replace
the brush holder.
• The brush holder should be free of deformation, cracks, loos-
ening of swaged joints and rusted base.
• The brushes should be able to move smoothly in the brush
holder.
• The brush springs should be free of rust.
Inspection: Brush spring

• Using new brushes, measure the load required to separate each
brush spring from its brush.
• If either measurement is lower than the specified limit, replace
the brush springs.
54-12-10
54-12
Inspection: Brush (+) (–)
• If either brush is shorter than the limit, it must be replaced.
Inspection: Armature
(1) Test for coil short circuit
• Hold an iron rod parallel with the armature.
• Slowly rotate the armature by hand.
• If the iron rod vibrates or is pulled toward the armature, the coil
is short-circuited and the armature must be replaced.
(2) Test for coil grounding

• Confirm that continuity does not exist between the commutator
and the core (or shaft).
• If continuity exists, the coil is grounded and the armature must
be replaced.
(3) Test for coil open circuit

• Check for continuity between commutator segments.
• If continuity does not exist, replace the armature.
(4) Commutator outside diameter

• If the measurement is out of specification, replace the armature.
54-12-11
#930 STARTER
(5) Runout of commutator periphery
• If the reading exceeds the specified limit, rectify the commutator
of the armature, making sure the outside diameter stays within
specification.
(6) Condition of commutator surface
• If the surface is rough or has stepped wear, rectify it with emery
paper (#300 to 500).
• After rectifying the surface, check the extent of commutator
runout.
(7) Undercut depth between segments

• If the measurement is lower than the specified limit, rectify or re-
place the armature.
• To rectify the armature, grind the illustrated portions.
• If the undercut is worn as illustrated, rectify or replace the arma-

ture.
: Acceptable
× : Unacceptable
Inspection: Yoke
• Inspect the ferrite magnet in the yoke for damages and cracks. If
any fault is found, replace the yoke.
54-12-12
54-12
Inspection: Overrunning clutch
If the following inspections reveal any abnormality, replace the
overrunning clutch.
• While holding the housing, give a turn to the pinion. The pinion
should not turn at all in one direction but should turn smoothly in
the other direction with some resistance felt.
• Confirm that the pinion teeth are free of chips and not abnormal-
ly worn.
• Confirm that the pinion metal is not abnormally worn.
CAUTION
• The overrunning clutch is filled with grease inside. Do not
use immersion cleaning.
Inspection: Lever
• Measure the overrunning clutch contact surface of the lever to
see if it meets the standard value.
• If the measurement is out of the standard value, replace the le-
ver.
Inspection: Rear bearing

• Confirm that the difference between the inside diameter of the
rear bearing and outside diameter of the armature shaft meets
the standard value.
• If the measurement is out of the standard value, replace the rear
bearing.
Assembly procedure
Assembly: Planetary gear holder, internal gear and overrun-
ning clutch
• Install the internal gear, overrunning clutch and stop ring onto
the planetary gear holder.
54-12-13
#930 STARTER
• Set a new snap ring in the groove of the planetary gear holder.
• Using a puller, draw the stop ring toward the snap ring and then
fit the snap ring into the stop ring by pressing with a screwdriver.
Assembly: Lever
• Paying attention to its direction, install the lever onto the over-
running clutch.
Assembly: Front bracket

• Install the planetary gear holder, internal gear, overrunning
clutch and lever on the front bracket.
Assembly: Packing A, B, plate and planetary gear

• Install in this order: plate, packing B, three planetary gears and
packing A.
54-12-14
54-12
Assembly: Front bracket and yoke
• Using the mating marks provided before disassembly for align-
ment, install the yoke to the front bracket.
Assembly: Ball and armature

• Insert the ball, and then install the armature on the planetary
gear holder side.
Assembly: Brush holder

• Install the brush holder on the armature.
• Set the brush springs in the regular state.
Assembly: Rear bearing and rear bracket

• Install the rear bearing to the rear bracket.
54-12-15
#930 STARTER
• Install the rear bracket on the yoke. Make sure that the parts are
fitted at the grommet section of the rear bracket.
• Tighten the through bolts and screws.
Assembly: Magnetic switch

• Install the magnet switch onto the lever with its terminal S in the
illustrated direction.
• Tighten the screws.
• Connect the field coil line to terminal M of the magnet switch,

and then tighten the nut.
54-12-16
54-12
Inspection after assembly
Inspection: Performance and pinion gap
• After assembling the starter, perform inspections with current
supplied to it.
WARNING
• When the starter is energized, the pinion will spring out and
rotate. Be careful not to touch it with your hands.
• The magnetic switch may become very hot during inspec-
tions. Be careful when touching it.
CAUTION
• Do not energize the pull-in coil P for longer than 10 sec-
onds, and do not energize the holding coil H for longer than
30 seconds. If these periods are exceeded, the coils may
overheat and burn out.
• When current is supplied to the starter, a large current (100
A or higher) will flow. For inspection purposes, booster ca-
bles or similarly thick cables must therefore be used. It is
also important to ensure that all connections are secure.
(1) Performance test

• Connect the starter as illustrated.
• Set the voltage to 11 volts DC.
CAUTION
• The voltage applied must not exceed 12 V.
• The following operations are performed with current supplied to

the starter. Thus, the entire test (consisting of measurement of
the current flowing through the starter and measurement of the
starter’s rotational speed) must be completed within 30 seconds.
• Turn ON the switch to supply current to the starter. The pinion
will spring out and rotate.
CAUTION
• When the switch is turned ON, the pull-in coil P and holding
coil H are both energized. When the large current from the
DC power supply flows from terminal B to terminal M, the
supply of current to the pull-in coil P is cut; only the holding
coil H remains energized. To prevent the holding coil from
burning out, it is essential to complete all operations within
30 seconds.
• Measure the current, then measure the starter’s rotational

speed with a digital tachometer.
• Turn OFF the switch to de-energize the starter.
• If either measurement is out of specification, disassemble and
inspect the starter again.
54-12-17
#930 STARTER
(2) Pinion gap
• Connect the starter as illustrated.
• The following operations are performed with current supplied to
the starter. Thus, the entire procedure for measurement of the
pinion gap must be completed within 30 seconds.
• Turn ON switches 1 and 2 to supply current to the starter. The
pinion will spring out and rotate.
• After the pinion starts to rotate, quickly (within five seconds)

turn OFF switch 2 to stop the pinion’s rotation.
CAUTION
• When switches 1 and 2 are turned ON, the pull-in coil P and
holding coil H are both energized. The circuit is connected
such that no voltage is applied to starter terminal B, so cur-
rent flows to the pull-in coil while the pinion rotates. To pre-
vent the pull-in coil from burning out, it is essential to turn
OFF switch 2 quickly (within five seconds) after the pinion
starts to rotate.
• Pull out the end of the pinion by hand, and then lightly push it
back by hand. Measure the amount of axial movement (pinion
gap).
• Turn OFF switch 1 to de-energize the starter.
• If the measurement is out of specification, replace the lever.
54-12-18
54-12
M E M O
54-12-19
#940 ALTERNATOR
Removal sequence
1 Belt
2 Alternator
WARNING
• Before removing the alternator, disconnect the (–) battery cable and insulate the cable and the (–) battery
terminal with tape.
• It is dangerous to leave the (–) battery cable connected since the battery cable voltage is always present
at terminal B.
Installation sequence
Follow the removal sequence in reverse.
Service standards
At 1800 rpm 55 A or more –
110A
Alternator output current At 6000 rpm 110 A or more – Correct or
(*when alternator is hot and
producing 13.5 V) At 1800 rpm 75 A or more – replace
2 140A
At 6000 rpm 140 A or more –
Adjustment voltage of regulator 14.5 ± 0.25 V – Replace
(at 6000 rpm, 5 A is loaded)
* The hot condition occurs after the alternator has been running at normal ambient temperature at 6000 rpm and
maximum output for 30 minutes.
54-12-20
54-12
Inspection: Alternator
(1) Alternator output current (bench test)
• Connect the alternator as illustrated.
CAUTION
• Wires with sufficient thickness should be used for wiring
and each connection should be securely fastened.
• Increase load resistance to the maximum (condition under which

the load current hardly flows).
• Turn switch 1 and 2 ON.
• Run alternator at 6000 rpm for 30 minutes by adjusting load re-
sistance so that electric current can conform to the following
standard.
Alternator nominal current
Alternator Current
110A Approx. 110A
140A Approx. 140A
• Measure the current at each specified revolution of alternator.
• If the measured value is lower than the standard value, disas-
semble and check alternator.
(2) Adjustment voltage of regulator (bench test)

• Connect the alternator as illustrated.
• Turn switch ON.
• Run alternator at low speeds.
• Increase the speed of alternator to 6000 rpm and measure the
voltage (adjustment voltage) at this speed. At the same time,
make sure that the current is 5 amperes or less at 6000 rpm.
• If the measured value deviates from the standard value, do as
follows:
• If higher than the standard value: Replace the regulator.
• If lower than the standard value: Inspect the alternator related
parts before replacing the regulator.
54-12-21
54-13 ON-VEHICLE INSPECTION AND

ADJUSTMENT
54-13-1
#950 INSPECTION OF ALTERNATOR

Performance test
• The on-vehicle inspection is only a simplified check. Use a test
bench for accurate checking.
• Connect the meters to the alternator as shown.
WARNING
• To prevent possible injury, be sure to disconnect the nega-
tive battery cable and insulate the cable and the negative
battery terminal with tape before working on the wiring.
With the negative (–) battery cable connected, battery volt-
age is always applied to terminal B.
• To connect to switch, use a lead wire with the same or larg-
er diameter than that of the chassis harness connected to
terminal B.
• Turn on switch and make sure that voltmeter indicates battery

voltage.
• Start the engine.
• Immediately turn on the switches for all lamps on the vehicle.
• Immediately accelerate the engine to the speed indicated below
and measure the alternator’s output current.
Approx. 2200 rpm
• The alternator is considered to be good if the measured value is
70% or more of the nominal output current.
Alternator nominal output
Voltage Output current
12 V 110 A
12 V 140 A
54-13-2
#951 INSPECTION OF REGULATOR 54-13

Service standards
12V-110A 14.5 ± 0.2 V
– Adjusting voltage – Replace
12V-140A 14.5 ± 0.25 V
• Connect the meters to the alternator as shown.

WARNING
• To prevent possible injury, be sure to disconnect the nega-
tive battery cable and insulate the cable and the negative
battery terminal with tape before working on the wiring.
With the negative (–) battery cable connected, battery volt-
age is always applied to terminal B.
• To connect to switch, use a lead wire with the same or larg-
er diameter than that of the chassis harness connected to
terminal B.
• Turn off the switches for lamps, heater, etc. so that electric loads
may not be applied during the inspection.
• Turn on switch and then start the engine.
• If the output current is 5 amperes or less when the engine speed
is raised to the appropriate speed indicated below, then mea-
sure the voltage at terminal B.
Approx. 2200 rpm
• If the output current is not less than 5 amperes, the measured
value (regulated voltage) will be slightly lower.
• If the output current is 5 amperes or more, do one of the follow-
ing:
• Run the engine for a while to charge the battery.
• Replace the battery with a fully-charged one.
• If the measured value deviates from the standard value, conduct
checking again on the test bench.
54-13-3
#960 HEADLAMP AIMING

1. Preparation for Aiming
• Park the vehicle on a level flat place and apply chocks to the
wheels.
• Empty the vehicle.
• Adjust the tire inflation pressure to the specified value.
• Place a mass of 68 kg {150 lb} (corresponding to a mean weight
of one man) on the driver’s seat.
• On vehicles with headlamp leveling device, set the headlamp
leveling switch to 0.
• Start the engine to charge the battery.
• Locate a lamp tester at a place opposite to the vehicle front end
face as illustrated.
• Turn on the headlamps and aim the headlamps such that the
passing beam lamp center is aligned with the beam convergent
lens center of the lamp tester. (Shown here is the left-hand
headlamp.)
• Mask other lamps than that next subjected to adjustment in such
a way that no light may leak.
CAUTION
• Headlamp lenses are made of plastic. Do not keep the
masked headlamps illuminated for longer than 2 minutes.
Sustained illumination of these lamps can cause heat gen-
eration, possibly resulting in deformed headlamp lens.
2. Aiming
2.1 Adjustment of passing beam
• Turn on the passing beam.
• Perform the following procedure to adjust the passing beam
such that the elbow point of the cut-off line between the lighted
and shaded areas is positioned as shown in the figure:
• Adjustment in vertical direction: Turn screws A and B the same
amount in this order.
• Adjustment in horizontal direction: Turn screw B.
• The position of the cut-off line between the lighted and shaded
areas must correspond to the adjustment value.
54-13-4
54-13
• The adjustment value can be known from the headlamp initial
beam angle indication label attached on the rear pillar on assis-
tant driver side.
The label shows the light beam inclination in percentage (%).
The inclination of 1% is equivalent to an ascent (descent) of 1 m
{3.3 ft.} per a travel distance of 100 m {330 ft.}.
To adjust the beam inclination, therefore, the specified value in
percentage must be converted into that in angle.
Adjustment value
Value on label indicat-
Beam inclination ad-
ing initial beam angle
justment angle
of headlamp
FE 1.0% 0.57°
FG 1.5% 0.86°
Beam adjustment direction

Right-hand headlamp Left-hand headlamp
Up Down Left Right Up Down Left Right
Screw A CCW CW – – CCW CW – –
Screw B CCW CW CCW CW CCW CW CW CCW
54-13-5
#961 FOG LAMP AIMING

1. Preparation for Aiming
• Park the vehicle on a level flat place and apply chocks to the
wheels.
• Empty the vehicle.
• Adjust the tire inflation pressure to the specified value.
• Place a mass of 68 kg {150 lb} (corresponding to a mean weight
of one man) on the driver’s seat.
• Start the engine to charge the battery.
• Locate a lamp tester at a place opposite to the vehicle front end
face as illustrated.
• Mask other lamps than that next subjected to adjustment in such
a way that no light may leak.
CAUTION
• Fog lamp lenses are made of plastic. Do not keep the
masked fog lamp illuminated for longer than 2 minutes.
Sustained illumination of these lamps can cause heat gen-
eration, possibly resulting in deformed fog lamp lens.
2. Aiming
• Turn on fog lamp.
• Make adjustment with the aiming gear to bring for lamp cut-off
line into the illustrated position.
Standard value
Cut-off line position
1.5% or less
Adjusting direction for optical axis

Upward Downward
Screwdriver rotation
Clockwise Counter-clockwise
direction
54-13-6
54-13
M E M O
54-13-7
#984 INSPECTION OF IMMOBILIZER

• Since the FUSO diagnostics data are updated from time to time, descriptions or wording may not agree with the
workshop manual. The FUSO diagnostics will have the latest data.
1. List of Diagnosis Codes
Warning lamp indication

Code Message Remarks
521742-12 Immobilizer fault O

521742-31 Watchdog reset O
521743-2 Missing transponder modulation O
521744-2 Invalid secret key O
521745-2 Bad ECM authentication O
521746-2 No ECM challenge/acknowledge O
521747-2 Transponder authentication failed O
521748-2 Transponder ID table empty O
521749-2 Transponder data format error O
521750-19 CAN bus performance O
521750-31 Lost communication with SAM O
2. Details of Diagnosis Codes

521742-12: Immobilizer fault
Generation condition • Some abnormality has occurred in immobilizer electronic control unit.
Recoverability • System recovers when relevant diagnosis code is erased.
Control effected by electronic control unit • Engine is disabled from starting.
Possible causes • Defective immobilizer electronic control unit
521742-31: Watchdog reset

Generation condition • CPU has been reset.
• System recovers if no abnormal conditions are present when starter switch is
Recoverability
placed in ON again.
Control effected by electronic control unit • None
521743-2: Missing transponder modulation

• No communication takes place between transponder key (starter key) and
Generation condition
immobilizer electronic control unit.
• System recovers if no abnormal conditions are present when starter switch is
Recoverability
placed in ON again.
• Defective transponder key (starter key)
• Defective harness between immobilizer antenna and immobilizer electronic
Possible causes control unit
• Defective immobilizer antenna
• Defective immobilizer electronic control unit
54-13-8
54-13
521744-2: Invalid secret key
Generation condition • Secret key is not registered in immobilizer electronic control unit.
Recoverability • None
521745-2: Bad ECM authentication

• Collation between engine electronic control unit and immobilizer electronic
control unit is not successfully made.
• System recovers if collation is made successfully when starter switch is
Recoverability
placed in ON again.
• Defective engine electronic control unit
Possible causes • Incorrect engine electronic control unit in use
• Engine electronic control unit transferred from another vehicle
521746-2: No ECM challenge/acknowledge

• No communication is possible between engine electronic control unit and im-
mobilizer electronic control unit.
• System recovers if normal communication is established when starter switch
Recoverability
is placed in ON again.
• Controller area network communication line is open or short-circuited to
Possible causes
power, ground or another circuit.
• Incorrect engine electronic control unit in use
521747-2: Transponder authentication failed

• Collation between transponder key (starter key) and immobilizer electronic
control unit is made unsuccessfully.
• System recovers if collation is made successfully when starter switch is
Recoverability
placed in ON again.
• Unauthorized transponder key (starter key) is used.
Possible causes
• Transponder key (starter key) not registered yet is used.
521748-2: Transponder ID table empty

• Transponder key (starter key) ID is not stored in immobilizer electronic con-
trol unit.
Recoverability • System recovers when initial key registration is executed.
• Transponder key (starter key) used is not a one registered in immobilizer
Possible causes
electronic control unit.
521749-2: Transponder data format error

• Immobilizer electronic control unit has received an implausible data from
transponder key (starter key) through communication line.
• System recovers if a plausible data is obtained when starter switch is placed
Recoverability
in ON again.
• Faulty transponder key (starter key)
Possible causes • Faulty immobilizer antenna
• Faulty immobilizer electronic control unit
54-13-9
#984 INSPECTION OF IMMOBILIZER

521750-19: CAN bus performance
Generation condition • Controller area network error message is received.
• System recovers if any normal signal is received when starter switch is
Recoverability
placed in ON position.
• Controller area network communication line is open or shorted to power,
ground or another circuit.
Possible causes • Faulty controller area network resistor
• Faulty signal detect and actuation module
521750-31: Lost communication with SAM

Generation condition • No controller area network message is receivable.
Recoverability
placed in ON position.
• Controller area network communication line is open or shorted to power,
Possible causes • Faulty controller area network resistor
3. FUSO Diagnostics Service Data (Measured Values)

• Since the contents of the FUSO Diagnostics are regularly updated, the descriptions and expressions may differ
from those given in the service manuals. Check the latest information with the FUSO Diagnostics.
Current Value
Description Value Explanation
Group
Number of regis- Shows the number of registered starter keys
0 to 6
tered key (transponder keys) for the engine immobilizer.
Shows the type of the starter key (transponder
Vehicle key Transponder key
Registered/Unregistered key) for the engine immobilizer that is currently
type
inserted in the starter switch.
Ignition status ON/OFF Shows the ignition status.
Normal mode/
Transponder key ID initial registration
mode/
Shows the current state of the immobilizer
Immobilizer mode Transponder key ID additional registra-
ECU.
Immobilizer tion mode/
status Transponder key deletion mode/
Secret key registration mode
Immobilizer indicator ON/OFF Shows the immobilizer indicator lamp state.
Immobilizer status ACTIVE/NOT ACTIVE Shows the immobilizer system state.
4. Initial Settings of Immobilizer

4.1 Connecting the FUSO Diagnostics (See Gr00.)
54-13-10
54-13
4.2 Selection of system
• From the control unit list screen, select [IMMO-Immobilizer Con-
trol unit (A12)].
Screen of [IMMO-Immobilizer Control unit (A12)]

• Select the “Actuations” tab and then select [Vehicle key]. Then,
the [Vehicle key] screen appears.
• Using the “S” button of “Start immobilizer functions”, display the
various registration/deletion screens.
4.3 Initial key registration, Additional key registration, Key deletion, Secret key registration
• Following the instructions given on the screen of the FUSO Di-
agnostics, perform necessary steps to register and delete data.
Function buttons Functions invoked Outline

“Initial key registration” Initial key registra- Register key information at replacement of the immobilizer electronic control
button tion unit.
Register additional key information in the immobilizer electronic control unit.
“Additional key registra- Additional key regis-
(Up to 6 sets of the key information can be registered in the immobilizer elec-
tion” button tration
tronic control unit.)
Erase key information registered in the immobilizer electronic control unit,
“Key deletion” button Key deletion
excepting the engine immobilizer starter key inserted in the starter switch.
Register the secret key that has previously been registered in the immobiliz-
er electronic control unit in the engine electronic control unit.
A collation check is made by using the secret key registered in both the im-
“Secret key registration” Select key registra-
mobilizer electronic control unit and engine electronic control unit and, if it is
button tion
checked okay, the engine is started. This function should be performed
whenever either one of the electronic control units is replaced with a new
one or remounted from other vehicles.
CAUTION
• The secret key can be registered only when the initial key has previously been registered.
• If registration of the secret key is yet to be completed, the collation check with the engine electronic con-
trol unit is NG and the engine cannot be started.
54-13-11
#985 INSPECTION OF SIGNAL DETECT AND ACTUATION MODULES



(red) (orange)
2372-4 Left rear brake light - Insufficient voltage or short circuit to ground - O
Left rear brake light - The current strength is too low or there is an
2372-5 - O
open circuit.
2374-4 Right rear brake light - Insufficient voltage or short circuit to ground - O
Right rear brake light - The current strength is too low or there is an
2374-5 - O
open circuit.
521985-4 BBC Side turn lamp LH - Insufficient voltage or short circuit to ground - -
BBC Side turn lamp LH - The current strength is too low or there is an
521985-5 - -
open circuit.
521986-4 BBC Side turn lamp RH - Insufficient voltage or short circuit to ground - -
BBC Side turn lamp RH - The current strength is too low or there is an
521986-5 - -
open circuit.
521987-4 BBC Body illumination - Insufficient voltage or short circuit to ground - -
BBC Chassis illumination - Insufficient voltage or short circuit to
521988-4 - -
ground
521989-4 BBC Backup Alarm - Insufficient voltage or short circuit to ground - -
Transmission power take-off 3-way magnetic valve - Insufficient volt-
521990-4 - -
age or short circuit to ground
Transmission power take-off 3-way magnetic valve - The current
521990-5 - -
strength is too low or there is an open circuit.
521992-4 Driver mirror heater - Insufficient voltage or short circuit to ground - -
521994-4 Backup lamp - Insufficient voltage or short circuit to ground - -

Backup lamp - The current strength is too low or there is an open cir-
521994-5 - -
cuit.
521995-4 Left high beam - Insufficient voltage or short circuit to ground - -
Left high beam - The current strength is too low or there is an open cir-
521995-5 - -
cuit.
521996-4 Right high beam - Insufficient voltage or short circuit to ground - -
Right high beam - The current strength is too low or there is an open
521996-5 - -
circuit.
521997-4 Left low beam - Insufficient voltage or short circuit to ground - -
Left low beam - The current strength is too low or there is an open cir-
521997-5 - -
cuit.
521998-4 Right low beam - Insufficient voltage or short circuit to ground - -
Right low beam - The current strength is too low or there is an open
521998-5 - -
circuit.
522003-4 Left standing light - Insufficient voltage or short circuit to ground - O
Left standing light - The current strength is too low or there is an open
522003-5 - O
circuit.
54-13-12
54-13

(red) (orange)
522004-4 Right standing light - Insufficient voltage or short circuit to ground - O

Right standing light - The current strength is too low or there is an
522004-5 - O
open circuit.
522005-4 Left tail lamp - Insufficient voltage or short circuit to ground - O
Left tail lamp - The current strength is too low or there is an open cir-
522005-5 - O
cuit.
522006-4 Right tail lamp - Insufficient voltage or short circuit to ground - O
Right tail lamp - The current strength is too low or there is an open cir-
522006-5 - O
cuit.
Left rear turn signal lamp - Insufficient voltage or short circuit to
522007-4 - -
ground
Left rear turn signal lamp - The current strength is too low or there is
522007-5 - -
an open circuit.
Right rear turn signal lamp - Insufficient voltage or short circuit to
522008-4 - -
ground
Right rear turn signal lamp - The current strength is too low or there is
522008-5 - -
an open circuit.
Left turn signal lamp (front) - Insufficient voltage or short circuit to
522009-4 - -
ground
Left turn signal lamp (front) - The current strength is too low or there is
522009-5 - -
an open circuit.
Right turn signal lamp (front) - Insufficient voltage or short circuit to
522010-4 - -
ground
Right turn signal lamp (front) - The current strength is too low or there
522010-5 - -
is an open circuit.
522011-4 Right front fog lamp - Insufficient voltage or short circuit to ground - -
Right front fog lamp - The current strength is too low or there is an
522011-5 - -
open circuit.
522014-4 Passenger exit lamp - Insufficient voltage or short circuit to ground - -
Passenger exit lamp - The current strength is too low or there is an
522014-5 - -
open circuit.
522015-4 Driver exit lamp - Insufficient voltage or short circuit to ground - -
Driver exit lamp - The current strength is too low or there is an open
522015-5 - -
circuit.
522016-4 Cabin button illumination - Insufficient voltage or short circuit to ground - -
522017-4 Washer motor - Insufficient voltage or short circuit to ground - -

Washer motor - The current strength is too low or there is an open cir-
522017-5 - -
cuit.
522020-4 Left license plate lamp - Insufficient voltage or short circuit to ground - O
Left license plate lamp - The current strength is too low or there is an
522020-5 - O
open circuit.
522022-4 Left front fog lamp - Insufficient voltage or short circuit to ground - -
Left front fog lamp - The current strength is too low or there is an open
522022-5 - -
circuit.
522026-4 Passenger mirror heater - Insufficient voltage or short circuit to ground - -
54-13-13


(red) (orange)
522027-3 Interior lamp - Excessive voltage or short circuit to positive - -
522028-4 Mirror heater Switches - Insufficient voltage or short circuit to ground - -
522030-4 Backup buzzer - Insufficient voltage or short circuit to ground - -

Connected electrical equipment - Insufficient voltage or short circuit to
522032-4 - -
ground
522033-4 - -
ground
522034-4 - -
ground
Air conditioner blower - The current strength is too low or there is an
522038-5 - O
open circuit.
Accessory 12V/24V relay - The current strength is too low or there is
522039-5 - O
an open circuit.
Ignition relay - The current strength is too low or there is an open cir-
522040-5 O -
cuit.
Accessory relay - The current strength is too low or there is an open
522041-5 O -
circuit.
Ignition 12V/24V relay - The current strength is too low or there is an
522042-5 - O
open circuit.
Air conditioner compressor relay - The current strength is too low or
522043-5 - O
there is an open circuit.
522064-25 Transmission current gear signal - Received network data is in error. - -
522067-25 Main light switch request signal - Received network data is in error. - O
522069-25 High beam switch request signal - Received network data is in error. - -
High beam flash switch request signal - Received network data is in
522070-25 - -
error.
522071-25 Transmission Control unit - Received network data is in error. - -
522074-25 Combustion engine Control unit - Received network data is in error. - -
522077-25 Combination switch - Received network data is in error. - O
522078-25 Combination switch - Received network data is in error. - -
522079-25 Selector lever - Received network data is in error. - -
522080-25 Keyless entry unit - Received network data is in error. - -
522081-25 Driver power window Switches - Received network data is in error. - -

Passenger power window Switches - Received network data is in er-
522082-25 - -
ror.
522097-2 Starter Switches - Data erratic, intermittent or incorrect O -
54-13-14
54-13

(red) (orange)
The battery voltage is too high. - Excessive voltage or short circuit to

522112-3 O -
positive
The battery voltage is too low. - Insufficient voltage or short circuit to
522112-4 O -
ground
522115-25 Driver power window Switches - Received network data is in error. - -

Passenger power window Switches - Received network data is in er-
522116-25 - -
ror.
522117-25 Keyless entry unit - Received network data is in error. - -
522118-25 Selector lever - Received network data is in error. - -

Power take-off is not connected when the Power take-off Switches are
522133-17 - -
turned ON. - Occurring
Power take-off is not disconnected when the Power take-off Switches
522134-17 - -
are turned OFF. - Occurring
Power take-off was disconnected when the Transmission power take-
522135-17 - -
off 3-way magnetic valve was ON. - Occurring
Power take-off was connected when Transmission power take-off 3-
522136-17 - -
way magnetic valve was OFF. - Occurring
522142-4 Wiper internal circuit - Insufficient voltage or short circuit to ground - -

Wiper internal circuit - The current strength is too low or there is an
522143-5 - -
open circuit.
522144-3 Wiper internal circuit - Excessive voltage or short circuit to positive - -
522147-4 Key interlock solenoid - Insufficient voltage or short circuit to ground - -
522148-17 Faulty part CPU inside component “SAM” - Occurring - -
522149-17 Faulty part Memory inside component “SAM” - Occurring O -
522150-17 Faulty component “SAM” - Occurring O -
54-13-15

2372-4: Left rear brake light - Insufficient voltage or short circuit to ground
• Output current to stop lamp (left-hand) rises to range of 2.3 to 3.7 A or high-
er.
• System recovers when output current to stop lamp (left-hand) falls within
Recoverability
range of 2.3 to 3.7 A or lower.
Control effected by electronic control unit • Output to stop lamp (left-hand) is stopped.
• Short-circuit to power, ground or another circuit in SIG harness between stop
lamp (left-hand) and signal detect and actuation module
Possible causes
• Faulty stop lamp (left-hand)
• Defective signal detect and actuation module
2372-5: Left rear brake light - The current strength is too low or there is an open circuit.
Generation condition • Output current to stop lamp (left-hand) falls to range of 0.5 to 1.1 A or lower.
• System recovers when output current to stop lamp (left-hand) rises to range
Recoverability
of 0.5 to 1.1 A or higher.
Control effected by electronic control unit • Normal control is effected.
• Open-circuit or short-circuit to power or ground in SIG harness between stop
• Open-circuit in Plus harness between stop lamp (left-hand) and signal detect
Possible causes
and actuation module
• Faulty stop lamp (left-hand)
2374-4: Right rear brake light - Insufficient voltage or short circuit to ground
• Output current to stop lamp (right-hand) rises to range of 2.3 to 3.7 A or high-
er.
• System recovers when output current to stop lamp (right-hand) falls within
Recoverability
Control effected by electronic control unit • Output to stop lamp (right-hand) is stopped.
• Short-circuit to power, ground or another circuit in SIG harness between stop
lamp (right-hand) and signal detect and actuation module
Possible causes
• Faulty stop lamp (right-hand)
2374-5: Right rear brake light - The current strength is too low or there is an open circuit.
Generation condition • Output current to stop lamp (right-hand) falls to range of 0.5 to 1.1 A or lower.
• System recovers when output current to stop lamp (right-hand) rises to
Recoverability
range of 0.5 to 1.1 A or higher.
• Open-circuit or short-circuit to power or ground in SIG harness between stop
• Open-circuit in Plus harness between stop lamp (right-hand) and signal de-
Possible causes
tect and actuation module
• Faulty stop lamp (right-hand)
521985-4: BBC Side turn lamp LH - Insufficient voltage or short circuit to ground
• Output current to side turn signal lamp (left-hand) rises to range of 2.3 to 3.7
A or higher.
• System recovers when output current to side turn signal lamp (left-hand) falls
Recoverability
within range of 2.3 to 3.7 A or lower.
Control effected by electronic control unit • Output to side turn signal lamp (left-hand) is stopped.
• Short-circuit to power, ground or another circuit in SIG harness between side
turn signal lamp (left-hand) and signal detect and actuation module
Possible causes
• Faulty side turn signal lamp (left-hand)
54-13-16
54-13
521985-5: BBC Side turn lamp LH - The current strength is too low or there is an open circuit.
• Output current to side turn signal lamp (left-hand) falls to range of 0.5 to 1.1
A or lower.
• System recovers when output current to side turn signal lamp (left-hand) ris-
Recoverability
es to range of 0.5 to 1.1 A or higher.
• Open-circuit or short-circuit to power or ground in SIG harness between side
• Open-circuit in Plus harness between side turn signal lamp (left-hand) and
Possible causes
signal detect and actuation module
• Faulty side turn signal lamp (left-hand)
521986-4: BBC Side turn lamp RH - Insufficient voltage or short circuit to ground
• Output current to side turn signal lamp (right-hand) rises to range of 2.3 to
3.7 A or higher.
• System recovers when output current to side turn signal lamp (right-hand)
Recoverability
falls within range of 2.3 to 3.7 A or lower.
Control effected by electronic control unit • Output to side turn signal lamp (right-hand) is stopped.
• Short-circuit to power, ground or another circuit in SIG harness between side
turn signal lamp (right-hand) and signal detect and actuation module
Possible causes
• Faulty side turn signal lamp (right-hand)
521986-5: BBC Side turn lamp RH - The current strength is too low or there is an open circuit.
• Output current to side turn signal lamp (right-hand) falls to range of 0.5 to 1.1
A or lower.
• System recovers when output current to side turn signal lamp (right-hand)
Recoverability
rises to range of 0.5 to 1.1 A or higher.
• Open-circuit or short-circuit to power or ground in SIG harness between side
• Open-circuit in Plus harness between side turn signal lamp (right-hand) and
Possible causes
• Faulty side turn signal lamp (right-hand)
521987-4: Body illumination - Insufficient voltage or short circuit to ground

• Output current to body illumination lamp rises to range of 3.8 to 7.3 A or
higher.
• System recovers when output current to body illumination lamp falls within
Recoverability
Control effected by electronic control unit • Output to body illumination lamp is stopped.
• Short-circuit to power, ground or another circuit in SIG harness between
body illumination lamp (12 V) and signal detect and actuation module
Possible causes
• Faulty body illumination lamp (12 V)
521988-4: Chassis illumination - Insufficient voltage or short circuit to ground

• Output current to chassis illumination lamp rises to range of 3.8 to 7.3 A or
higher.
• System recovers when output current to chassis illumination lamp falls within
Recoverability
Control effected by electronic control unit • Output to chassis illumination lamp is stopped.
chassis illumination lamp (12 V) and signal detect and actuation module
Possible causes
• Faulty chassis illumination lamp (12 V)
54-13-17

521989-4: BBC Backup Alarm - Insufficient voltage or short circuit to ground
Generation condition • Output current to backup lamp rises to range of 0.4 to 0.7 A or higher.
• System recovers when output current to backup lamp falls within range of
Recoverability
0.4 to 0.7 A or lower.
Control effected by electronic control unit • Output to backup lamp is stopped.
backup lamp and signal detect and actuation module
Possible causes
• Faulty backup lamp
521990-4: Transmission power take-off 3-way magnetic valve - Insufficient voltage or short circuit to ground
• Output current to transmission power take-off 3-way magnetic valve rises to
• System recovers when output current to transmission power take-off 3-way
Recoverability
magnetic valve falls within range of 1.0 to 1.7 A or lower.
Control effected by electronic control unit • Output to transmission power take-off 3-way magnetic valve is stopped.
transmission power take-off 3-way magnetic valve and signal detect and ac-
Possible causes tuation module
• Faulty transmission power take-off 3-way magnetic valve
521990-5: Transmission power take-off 3-way magnetic valve - The current strength is too low or there is an
open circuit.
• Output current to transmission power take-off 3-way magnetic valve falls to
• System recovers when output current to transmission power take-off 3-way
Recoverability
magnetic valve rises to range of 0.2 to 0.4 A or higher.
• Open-circuit or short-circuit to power or ground in SIG harness between
transmission power take-off 3-way magnetic valve and signal detect and ac-
tuation module
Possible causes • Open-circuit in Plus harness between transmission power take-off 3-way
magnetic valve and signal detect and actuation module
521992-4: Right mirror heater - Insufficient voltage or short circuit to ground

• Output current to mirror heater (driver side) rises to range of 7.7 to 13.5 A or
higher.
• System recovers when output current to mirror heater (right-hand) falls with-
Recoverability
in range of 7.7 to 13.5 A or lower.
Control effected by electronic control unit • Output to mirror heater (right-hand) is stopped.
• Short-circuit to power, ground or another circuit in SIG harness between mir-
ror heater (right-hand) and signal detect and actuation module
Possible causes
• Faulty mirror heater (right-hand)
521994-4: Backup lamp - Insufficient voltage or short circuit to ground

Generation condition • Output current to backup lamp rises to range of 4.7 to 8.2 A or higher.
• System recovers when output current to backup lamp falls within range of
Recoverability
Control effected by electronic control unit • Output to backup lamp is stopped.
Possible causes
54-13-18
54-13
521994-5: Backup lamp - The current strength is too low or there is an open circuit.
Generation condition • Output current to backup lamp falls to range of 1.1 to 2.2 A or lower.
• System recovers when output current to backup lamp rises to range of 1.1 to
Recoverability
2.2 A or higher.
• Open-circuit in Plus harness between backup lamp and signal detect and ac-
Possible causes
tuation module
521995-4: Left high beam - Insufficient voltage or short circuit to ground

• Output current to headlamp Hi (left-hand) rises to range of 6.5 to 11.7 A or
higher.
• System recovers when output current to headlamp Hi (left-hand) falls within
Recoverability
Control effected by electronic control unit • Output to headlamp Hi (left-hand) is stopped.
headlamp Hi (left-hand) and signal detect and actuation module
Possible causes
• Faulty headlamp Hi (left-hand)
521995-5: Left high beam - The current strength is too low or there is an open circuit.
• Output current to headlamp Hi (left-hand) falls to range of 0.8 to 2.9 A or low-
er.
• System recovers when output current to headlamp Hi (left-hand) rises to
Recoverability
headlamp Hi (left-hand) and signal detect and actuation module
• Open-circuit in Plus harness between headlamp Hi (left-hand) and signal de-
Possible causes
• Faulty headlamp Hi (left-hand)
521996-4: Right high beam - Insufficient voltage or short circuit to ground

• Output current to headlamp Hi (right-hand) rises to range of 6.5 to 11.7 A or
higher.
• System recovers when output current to headlamp Hi (right-hand) falls within
Recoverability
Control effected by electronic control unit • Output to headlamp Hi (right-hand) is stopped.
headlamp Hi (right-hand) and signal detect and actuation module
Possible causes
• Faulty headlamp Hi (right-hand)
54-13-19

521996-5: Right high beam - The current strength is too low or there is an open circuit.
• Output current to headlamp Hi (right-hand) falls to range of 0.8 to 2.9 A or
lower.
• System recovers when output current to headlamp Hi (right-hand) rises to
Recoverability
headlamp Hi (right-hand) and signal detect and actuation module
• Open-circuit in Plus harness between headlamp Hi (right-hand) and signal
Possible causes
detect and actuation module
• Faulty headlamp Hi (right-hand)
521997-4: Left low beam - Insufficient voltage or short circuit to ground

• Output current to headlamp Lo (left-hand) rises to range of 6.0 to 10.9 A or
higher.
• System recovers when output current to headlamp Lo (left-hand) falls within
Recoverability
Control effected by electronic control unit • Output to headlamp Lo (left-hand) is stopped.
headlamp Lo (left-hand) and signal detect and actuation module
Possible causes
• Faulty headlamp Lo (left-hand)
521997-5: Left low beam - The current strength is too low or there is an open circuit.
• Output current to headlamp Lo (left-hand) falls to range of 0.8 to 2.9 A or
lower.
• System recovers when output current to headlamp Lo (left-hand) rises to
Recoverability
headlamp Lo (left-hand) and signal detect and actuation module
• Open-circuit in Plus harness between headlamp Lo (left-hand) and signal
Possible causes
• Faulty headlamp Lo (left-hand)
521998-4: Right low beam - Insufficient voltage or short circuit to ground

• Output current to headlamp Lo (right-hand) rises to range of 6.0 to 10.9 A or
higher.
• System recovers when output current to headlamp Lo (right-hand) falls with-
Recoverability
Control effected by electronic control unit • Output to headlamp Lo (right-hand) is stopped.
headlamp Lo (right-hand) and signal detect and actuation module
Possible causes
• Faulty headlamp Lo (right-hand)
54-13-20
54-13
521998-5: Right low beam - The current strength is too low or there is an open circuit.
• Output current to headlamp Lo (right-hand) falls to range of 0.8 to 2.9 A or
lower.
• System recovers when output current to headlamp Lo (right-hand) rises to
Recoverability
headlamp Lo (right-hand) and signal detect and actuation module
• Open-circuit in Plus harness between headlamp Lo (right-hand) and signal
Possible causes
• Faulty headlamp Lo (right-hand)
522003-4: Left standing light - Insufficient voltage or short circuit to ground

• Output current to parking lamp (left-hand) rises to range of 0.5 to 1.0 A or
higher.
• System recovers when output current to parking lamp (left-hand) falls within
Recoverability
Control effected by electronic control unit • Output to parking lamp (left-hand) is stopped.
parking lamp (left-hand) and signal detect and actuation module
Possible causes
• Faulty parking lamp (left-hand)
522003-5: Left standing light - The current strength is too low or there is an open circuit.
• Output current to parking lamp (left-hand) falls to range of 0.1 to 0.3 A or low-
er.
• System recovers when output current to parking lamp (left-hand) rises to
Recoverability
parking lamp (left-hand) and signal detect and actuation module
• Open-circuit in Plus harness between parking lamp (left-hand) and signal de-
Possible causes
• Faulty parking lamp (left-hand)
522004-4: Right standing light - Insufficient voltage or short circuit to ground

• Output current to parking lamp (right-hand) rises to range of 0.5 to 1.0 A or
higher.
• System recovers when output current to parking lamp (right-hand) falls with-
Recoverability
Control effected by electronic control unit • Output to parking lamp (right-hand) is stopped.
parking lamp (right-hand) and signal detect and actuation module
Possible causes
• Faulty parking lamp (right-hand)
54-13-21

522004-5: Right standing light - The current strength is too low or there is an open circuit.
• Output current to parking lamp (right-hand) falls to range of 0.1 to 0.3 A or
lower.
• System recovers when output current to parking lamp (right-hand) rises to
Recoverability
parking lamp (right-hand) and signal detect and actuation module
• Open-circuit in Plus harness between parking lamp (right-hand) and signal
Possible causes
• Faulty parking lamp (right-hand)
522005-4: Left tail lamp - Insufficient voltage or short circuit to ground

Generation condition • Output current to tail lamp (left-hand) rises to range of 1.3 to 2.4 A or higher.
• System recovers when output current to tail lamp (left-hand) falls within
Recoverability
Control effected by electronic control unit • Output to tail lamp (left-hand) is stopped.
• Short-circuit to power, ground or another circuit in SIG harness between tail
Possible causes
• Faulty tail lamp (left-hand)
522005-5: Left tail lamp - The current strength is too low or there is an open circuit.
Generation condition • Output current to tail lamp (left-hand) falls to range of 0.1 to 0.3 A or lower.
• System recovers when output current to tail lamp (left-hand) rises to range of
Recoverability
0.1 to 0.3 A or higher.
• Open-circuit or short-circuit to power or ground in SIG harness between tail
• Open-circuit in Plus harness between tail lamp (left-hand) and signal detect
Possible causes
• Faulty tail lamp (left-hand)
522006-4: Right tail lamp - Insufficient voltage or short circuit to ground

• Output current to tail lamp (right-hand) rises to range of 1.3 to 2.2 A or high-
er.
• System recovers when output current to tail lamp (right-hand) falls within
Recoverability
Control effected by electronic control unit • Output to tail lamp (right-hand) is stopped.
• Short-circuit to power, ground or another circuit in SIG harness between tail
Possible causes
• Faulty tail lamp (right-hand)
522006-5: Right tail lamp - The current strength is too low or there is an open circuit.
Generation condition • Output current to tail lamp (right-hand) falls to range of 0.0 to 0.3 A or lower.
• System recovers when output current to tail lamp (right-hand) rises to range
Recoverability
• Open-circuit or short-circuit to power or ground in SIG harness between tail
• Open-circuit in Plus harness between tail lamp (right-hand) and signal detect
Possible causes
• Faulty tail lamp (right-hand)
54-13-22
54-13
522007-4: Left rear turn signal lamp - Insufficient voltage or short circuit to ground
• Output current to rear turn signal lamp (left-hand) rises to range of 2.3 to 3.7
A or higher.
• System recovers when output current to rear turn signal lamp (left-hand) falls
Recoverability
Control effected by electronic control unit • Output to rear turn signal lamp (left-hand) is stopped.
• Short-circuit to power, ground or another circuit in SIG harness between rear
Possible causes
• Faulty rear turn signal lamp (left-hand)
522007-5: Left rear turn signal lamp - The current strength is too low or there is an open circuit.
• Output current to rear turn signal lamp (left-hand) falls to range of 0.5 to 1.1
A or lower.
Generation condition <In case of LED>
• Output current to rear turn signal lamp (left/right-hand) falls to range of 0.007
to 0.03 A or lower.
• System recovers when output current to rear turn signal lamp (left-hand) ris-
es to range of 0.5 to 1.1 A or higher.
Recoverability <In case of LED>
• System recovers when output current to rear turn signal lamp (left/right-
hand) rises to range of 0.007 to 0.03 A or higher.
• Open-circuit or short-circuit to power or ground in SIG harness between rear
• Open-circuit in Plus harness between rear turn signal lamp (left-hand) and
Possible causes
• Faulty rear turn signal lamp (left-hand)
522008-4: Right rear turn signal lamp - Insufficient voltage or short circuit to ground
• Output current to rear turn signal lamp (right-hand) rises to range of 2.3 to
3.7 A or higher.
• System recovers when output current to rear turn signal lamp (right-hand)
Recoverability
Control effected by electronic control unit • Output to rear turn signal lamp (right-hand) is stopped
• Short-circuit to power, ground or another circuit in SIG harness between rear
Possible causes
• Faulty rear turn signal lamp (right-hand)
522008-5: Right rear turn signal lamp - The current strength is too low or there is an open circuit.
• Output current to rear turn signal lamp (right-hand) falls to range of 0.5 to 1.1
A or lower.
Generation condition <In case of LED>
• Output current to rear turn signal lamp (left/right-hand) falls to range of 0.007
to 0.03 A or lower.
• System recovers when output current to rear turn signal lamp (right-hand)
rises to range of 0.5 to 1.1 A or higher.
Recoverability <In case of LED>
• System recovers when output current to rear turn signal lamp (left/right-
• Open-circuit or short-circuit to power or ground in SIG harness between rear
• Open-circuit in Plus harness between rear turn signal lamp (right-hand) and
Possible causes
• Faulty rear turn signal lamp (right-hand)
54-13-23

522009-4: Left turn signal lamp (front and side) - Insufficient voltage or short circuit to ground
• Output current to front side turn signal lamp (left-hand) rises to range of 2.3
to 3.7 A or higher.
• System recovers when output current to front side turn signal lamp (left-
Recoverability
hand) falls within range of 2.3 to 3.7 A or lower.
Control effected by electronic control unit • Output to front side turn signal lamp (left-hand) is stopped.
• Short-circuit to power, ground or another circuit in SIG harness between front
side turn signal lamp (left-hand) and signal detect and actuation module
Possible causes
• Faulty front side turn signal lamp (left-hand)
522009-5: Left turn signal lamp (front and side) - The current strength is too low or there is an open circuit.
• Output current to front side turn signal lamp (left-hand) falls to range of 0.5 to
1.1 A or lower.
• System recovers when output current to front side turn signal lamp (left-
Recoverability
• Open-circuit or short-circuit to power or ground in SIG harness between front
side turn signal lamp (left-hand) and signal detect and actuation module
• Open-circuit in Plus harness between front side turn signal lamp (left-hand)
Possible causes
and signal detect and actuation module
• Faulty front side turn signal lamp (left-hand)
522010-4: Right turn signal lamp (front and side) - Insufficient voltage or short circuit to ground
• Output current to front side turn signal lamp (right-hand) rises to range of 2.3
to 3.9 A or higher.
• System recovers when output current to front side turn signal lamp (right-
Recoverability
hand) falls within range of 2.3 to 3.9 A or lower.
Control effected by electronic control unit • Output to front side turn signal lamp (right-hand) is stopped.
• Short-circuit to power, ground or another circuit in SIG harness between front
side turn signal lamp (right-hand) and signal detect and actuation module
Possible causes
• Faulty front side turn signal lamp (right-hand)
522010-5: Right turn signal lamp (front and side) - The current strength is too low or there is an open circuit.
• Output current to front side turn signal lamp (right-hand) falls to range of 0.5
to 1.1 A or lower.
• System recovers when output current to front side turn signal lamp (right-
Recoverability
• Open-circuit or short-circuit to power or ground in SIG harness between front
side turn signal lamp (right-hand) and signal detect and actuation module
• Open-circuit in Plus harness between front side turn signal lamp (right-hand)
Possible causes
and signal detect and actuation module
• Faulty front side turn signal lamp (right-hand)
522011-4: Right front fog lamp - Insufficient voltage or short circuit to ground
• Output current to fog lamp (right-hand) rises to range of 6.0 to 10.9 A or high-
er.
• System recovers when output current to fog lamp (right-hand) falls within
Recoverability
Control effected by electronic control unit • Output to fog lamp (right-hand) is stopped.
• Short-circuit to power, ground or another circuit in SIG harness between fog
Possible causes
• Faulty fog lamp (right-hand)
54-13-24
54-13
522011-5: Right front fog lamp - The current strength is too low or there is an open circuit.
Generation condition • Output current to fog lamp (right-hand) falls to range of 0.8 to 2.9 A or lower.
• System recovers when output current to fog lamp (right-hand) rises to range
Recoverability
• Open-circuit or short-circuit to power or ground in SIG harness between fog
• Open-circuit in Plus harness between fog lamp (right-hand) and signal detect
Possible causes
• Faulty fog lamp (right-hand)
522014-4: Left exit lamp - Insufficient voltage or short circuit to ground

• Output current to step lamp (left-hand) rises to range of 0.5 to 0.9 A or high-
er.
• System recovers when output current to step lamp (left-hand) falls within
Recoverability
Control effected by electronic control unit • Output to step lamp (left-hand) is stopped.
• Short-circuit to power, ground or another circuit in SIG harness between step
Possible causes
• Faulty step lamp (left-hand)
522014-5: Left exit lamp - The current strength is too low or there is an open circuit.
Generation condition • Output current to step lamp (left-hand) falls to range of 0.1 to 0.3 A or lower.
• System recovers when output current to step lamp (left-hand) rises to range
Recoverability
• Open-circuit or short-circuit to power or ground in SIG harness between step
• Open-circuit in Plus harness between step lamp (left-hand) and signal detect
Possible causes
• Faulty step lamp (left-hand)
522015-4: Right exit lamp - Insufficient voltage or short circuit to ground

• Output current to step lamp (right-hand) rises to range of 0.5 to 0.9 A or high-
er.
• System recovers when output current to step lamp (right-hand) falls within
Recoverability
Control effected by electronic control unit • Output to step lamp (right-hand) is stopped.
• Short-circuit to power, ground or another circuit in SIG harness between step
Possible causes
• Faulty step lamp (right-hand)
522015-5: Right exit lamp - The current strength is too low or there is an open circuit.
Generation condition • Output current to step lamp (right-hand) falls to range of 0.1 to 0.3 A or lower.
• System recovers when output current to step lamp (right-hand) rises to
Recoverability
• Open-circuit or short-circuit to power or ground in SIG harness between step
• Open-circuit in Plus harness between step lamp (right-hand) and signal de-
Possible causes
• Faulty step lamp (right-hand)
54-13-25

522016-4: Cabin button illumination - Insufficient voltage or short circuit to ground
Generation condition • Output current to illumination lamp rises to range of 3.9 to 6.7 A or higher.
• System recovers when output current to illumination lamp falls within range
Recoverability
of 3.9 to 6.7 A or lower.
Control effected by electronic control unit • Output to illumination lamp is stopped.
• Short-circuit to ground in harness between battery and signal detect and ac-
tuation module
Possible causes • Malfunction of battery
• Faulty alternator
522017-4: Washer motor - Insufficient voltage or short circuit to ground

Generation condition • Output current to washer motor rises to range of 4.9 to 8.9 A or higher.
• System recovers when output current to washer motor falls within range of
Recoverability
Control effected by electronic control unit • Output to washer motor is stopped.
washer motor and signal detect and actuation module
Possible causes
• Faulty washer motor
522017-5: Washer motor - The current strength is too low or there is an open circuit.
Generation condition • Output current to washer motor falls to range of 0.4 to 1.7 A or lower.
• System recovers when output current to washer motor rises to range of 0.4
Recoverability
to 1.7 A or higher.
washer motor and signal detect and actuation module
• Open-circuit in Plus harness between washer motor and signal detect and
Possible causes
actuation module
• Faulty washer motor
522020-4: Left license plate lamp - Insufficient voltage or short circuit to ground
• Output current to license plate lamp (left-hand) rises to range of 1.1 to 1.8 A
or higher.
• System recovers when output current to license plate lamp (left-hand) falls
Recoverability
Control effected by electronic control unit • Output to license plate lamp (left-hand) is stopped.
• Short-circuit to power, ground or another circuit in SIG harness between li-
cense plate lamp (left-hand) and signal detect and actuation module
Possible causes
• Faulty license plate lamp (left-hand)
522020-5: Left license plate lamp - The current strength is too low or there is an open circuit.
• Output current to license plate lamp (left-hand) falls to range of 0.1 to 0.3 A
or lower.
• System recovers when output current to license plate lamp (left-hand) rises
Recoverability
to range of 0.1 to 0.3 A or higher.
• Open-circuit or short-circuit to power or ground in SIG harness between li-
cense plate lamp (left-hand) and signal detect and actuation module
• Open-circuit in Plus harness between license plate lamp (left-hand) and sig-
Possible causes
nal detect and actuation module
• Faulty license plate lamp (left-hand)
54-13-26
54-13
522022-4: Left front fog lamp - Insufficient voltage or short circuit to ground
• Output current to fog lamp (left-hand) rises to range of 6.0 to 10.9 A or high-
er.
• System recovers when output current to fog lamp (left-hand) falls within
Recoverability
Control effected by electronic control unit • Output to fog lamp (left-hand) is stopped.
• Short-circuit to power, ground or another circuit in SIG harness between fog
Possible causes
• Faulty fog lamp (left-hand)
522022-5: Left front fog lamp - The current strength is too low or there is an open circuit.
Generation condition • Output current to fog lamp (left-hand) falls to range of 0.8 to 2.9 A or lower.
• System recovers when output current to fog lamp (left-hand) rises to range
Recoverability
• Open-circuit or short-circuit to power or ground in SIG harness between fog
• Open-circuit in Plus harness between fog lamp (left-hand) and signal detect
Possible causes
• Faulty fog lamp (left-hand)
522026-4: Left mirror heater - Insufficient voltage or short circuit to ground

• Output current to mirror heater (passenger side) rises to range of 7.7 to 13.5
A or higher.
• System recovers when output current to mirror heater (left-hand) falls within
Recoverability
Control effected by electronic control unit • Output to mirror heater (left-hand) is stopped.
ror heater (left-hand) and signal detect and actuation module
Possible causes
• Faulty mirror heater (left-hand)
522027-3: Interior lamp - Excessive voltage or short circuit to positive

Generation condition • Output current to room lamp rises to range of 6.0 to 12.0 A or higher.
• System recovers when output current to room lamp falls within range of 6.0
Recoverability
to 12.0 A or lower.
Control effected by electronic control unit • Output to room lamp is stopped.
room lamp and signal detect and actuation module
Possible causes
• Faulty room lamp
522028-4: Mirror heater Switches - Insufficient voltage or short circuit to ground

• Output current to mirror heater switch (illuminated) rises to range of 0.4 to
0.9 A or higher.
• System recovers when output current to mirror heater switch (illuminated)
Recoverability
Control effected by electronic control unit • Output to mirror heater switch (illuminated) is stopped.
ror heater switch (illuminated) and signal detect and actuation module
Possible causes
• Faulty mirror heater switch (illuminated)
54-13-27

522030-4: Backup buzzer - Insufficient voltage or short circuit to ground
• Chip internal temperature rises abnormally high due to overcurrent generat-
ed by full or partial short-circuit to ground.
Recoverability • System recovers when normal current flow is detected.
Control effected by electronic control unit • Output to back buzzer is stopped.
• Open-circuit or short-circuit to power or ground in SIG harness between back
buzzer and signal detect and actuation module
• Open-circuit in Plus harness between back buzzer and signal detect and ac-
Possible causes
tuation module
• Faulty back buzzer
522032-4: Connected electrical equipment - Insufficient voltage or short circuit to ground

• Output current to option connector (transmission power take-off output) rises
• System recovers when output current to option connector (transmission
Recoverability
power take-off output) falls within range of 0.4 to 0.9 A or lower.
Control effected by electronic control unit • Output to option connector (transmission power take-off output) is stopped.
• Short-circuit to power, ground or another circuit in SIG harness between op-
tion connector (transmission power take-off output) and signal detect and ac-
• Faulty option connector (transmission power take-off output)

• Output current to option connector (transmission neutral switch signal) rises
• System recovers when output current to option connector (transmission neu-
Recoverability
tral switch signal) falls within range of 0.4 to 0.9 A or lower.
Control effected by electronic control unit • Output to option connector (transmission neutral switch signal) is stopped.
tion connector (transmission neutral switch signal) and signal detect and ac-
• Faulty option connector (transmission neutral switch signal)

• Output current to option connector (parking brake switch signal) rises to
• System recovers when output current to option connector (parking brake
Recoverability
switch signal) falls within range of 0.4 to 0.9 A or lower.
Control effected by electronic control unit • Output to option connector (parking brake switch signal) is stopped.
tion connector (parking brake switch signal) and signal detect and actuation
Possible causes module
• Faulty option connector (parking brake switch signal)
522038-5: Air conditioner blower - The current strength is too low or there is an open circuit.
Generation condition • A/C blower relay in signal detect and actuation module is malfunctioning.
• System recovers when A/C blower relay in signal detect and actuation mod-
Recoverability
ule resumes normal control.
Possible causes • Defective signal detect and actuation module (faulty A/C blower relay)
54-13-28
54-13
522039-5: Accessory 12V/24V relay - The current strength is too low or there is an open circuit.
Generation condition • A/C relay in signal detect and actuation module is malfunctioning.
• System recovers when A/C relay in signal detect and actuation module re-
Recoverability
sumes normal control.
Possible causes • Defective signal detect and actuation module (faulty A/C relay)
522040-5: Ignition relay - The current strength is too low or there is an open circuit.
Generation condition • IGN relay in signal detect and actuation module is malfunctioning.
• System recovers when IGN relay in signal detect and actuation module re-
Recoverability
Possible causes • Defective signal detect and actuation module (faulty IGN relay)
522041-5: Accessory relay - The current strength is too low or there is an open circuit.
Generation condition • ACC relay in signal detect and actuation module is malfunctioning.
• System recovers when ACC relay in signal detect and actuation module re-
Recoverability
Possible causes • Defective signal detect and actuation module (faulty ACC relay)
522042-5: Ignition 12V/24V relay - The current strength is too low or there is an open circuit.
Generation condition • IGN relay (option) in signal detect and actuation module is malfunctioning.
• System recovers when IGN relay (option) in signal detect and actuation
Recoverability
module resumes normal control.
Possible causes • Defective signal detect and actuation module (faulty IGN relay)
522043-5: Air conditioner compressor relay - The current strength is too low or there is an open circuit.
• A/C compressor/condenser relay in signal detect and actuation module is
malfunctioning.
• System recovers when A/C compressor/condenser relay in signal detect and
Recoverability
actuation module resumes normal control.
• Defective signal detect and actuation module (faulty A/C compressor/con-
Possible causes
denser relay)
522064-25: Transmission current gear signal - Received network data is in error.

• Controller area network communication data (gear information) from DUON-
ICTM electronic control unit are abnormal.
Recoverability • System recovers when normal controller area network signals are received.
• Controller area network line is open or shorted to power, ground or another
circuit.
Possible causes
• Faulty DUONICTM electronic control unit
54-13-29

522067-25: Main light switch request signal - Received network data is in error.
• Local interconnect network communication data (headlight and markers in-
formation) from combination switch are abnormal.
• System recovers when normal local interconnect network signals are re-
Recoverability
ceived.
• Open-circuit or short-circuit to power, ground or another circuit in local inter-
connect network line between combination switch and signal detect and ac-
• Faulty combination switch
522069-25: High beam switch request signal - Received network data is in error.
• Local interconnect network communication data (high beam switch informa-
tion) from combination switch are abnormal.
Recoverability
ceived.
522070-25: High beam flash switch request signal - Received network data is in error.
• Local interconnect network communication data (high beam flash switch in-
formation) from combination switch are abnormal.
Recoverability
ceived.
522071-25: Transmission current gear signal - Received network data is in error.

• Controller area network communication data from DUONICTM electronic
control unit are abnormal.
circuit.
Possible causes
• Faulty DUONICTM electronic control unit
522074-25: Combustion engine Control unit - Received network data is in error.

• Controller area network communication data from engine electronic control
unit are abnormal.
circuit.
Possible causes
54-13-30
54-13
unit are abnormal.
circuit.
Possible causes

unit are abnormal.
circuit.
Possible causes
522077-25: Combination switch - Received network data is in error.

• Local interconnect network communication data (lighting information) from
combination switch are abnormal.
Recoverability
ceived.
Control effected by electronic control unit • Headlamps and Marker Lights automatically turns on when IGN=ON.
• Local interconnect network line is open or shorted to power, ground or anoth-
er circuit.
Possible causes
• Defective combination switch

• Local interconnect network communication data (wiper information) from
Recoverability
ceived.
Control effected by electronic control unit • Wiper slow mode automatically turns on when IGN=ON.
er circuit.
Possible causes
• Defective combination switch
522079-25: Selector lever - Received network data is in error.

• Local interconnect network communication data from gear shift lever unit are
abnormal.
Recoverability
ceived.
er circuit.
Possible causes
• Faulty gear shift lever unit
54-13-31

522080-25: Keyless entry unit - Received network data is in error.
• Local interconnect network communication data from keyless entry electron-
ic control unit are abnormal.
Recoverability
ceived.
er circuit.
Possible causes
• Faulty keyless entry electronic control unit
522081-25: Right power window Switches - Received network data is in error.

• Local interconnect network communication data from power window switch
driver side are abnormal.
Recoverability
ceived.
er circuit.
Possible causes
• Faulty power window switch right-hand
522082-25: Left power window Switches - Received network data is in error.

passenger side are abnormal.
Recoverability
ceived.
er circuit.
Possible causes
• Faulty power window switch left-hand
522097-2: Starter Switches - Data erratic, intermittent or incorrect

• Starter key position disagrees with starter switch signal (the key is OFF but
the signal is ACC); there is a trouble in starter switch internal circuit.
• Starter key position corresponds with starter switch signal (both are ACC);
there is a trouble in key reminder switch (stuck at OFF position).
Recoverability • System recovers when normal signals are received.
• Faulty key reminder switch (sticking in OFF position or open-circuit)
• Open-circuit in harness between key reminder switch and signal detect and
actuation module
Possible causes • Short-circuit in harness between signal detect and actuation module and
starter switch
• Faulty starter switch
54-13-32
54-13
• Starter key position disagrees with starter switch signal (the key is OFF or
ACC but the signal is ON); there is a trouble in starter switch internal circuit.
• Starter key position corresponds with starter switch signal (both are ON);
actuation module
starter switch

• Starter key position disagrees with starter switch signal (the key is OFF, ACC
or ON but the signal is ON); there is a trouble in starter switch internal circuit.
• Starter key position corresponds with starter switch signal (both are ON);
actuation module
starter switch
522112-3: The battery voltage is too high. - Excessive voltage or short circuit to positive
Generation condition • Battery voltage (12 V) is too high.
Recoverability • System recovers when normal voltage is applied.
Possible causes
522112-4: The battery voltage is too low. - Insufficient voltage or short circuit to ground
Generation condition • Battery voltage (12 V) is too low.
• Open-circuit or short-circuit to ground in harness between battery and signal
Possible causes

• Local interconnect network communication data (lighting information) from
Recoverability
ceived.
Control effected by electronic control unit • Headlamps and Marker Lights automatically turns on when IGN=ON.
54-13-33

• Local interconnect network communication data from combination switch are
abnormal.
Recoverability
ceived.
522115-25: Right power window Switches - Received network data is in error.

driver side are abnormal.
Recoverability
ceived.
• Faulty power window switch right-hand
522116-25: Left power window Switches - Received network data is in error.

passenger side are abnormal.
Recoverability
ceived.
• Faulty power window switch left-hand
522117-25: Keyless entry unit - Received network data is in error.

• Local interconnect network communication data from keyless entry unit are
abnormal.
Recoverability
ceived.
• Faulty keyless entry unit
54-13-34
54-13
522118-25: Selector lever - Received network data is in error.
• Local interconnect network communication data from gear shift lever unit are
abnormal.
Recoverability
ceived.
• Faulty gear shift lever unit
522133-17: Power take-off is not connected when the Power take-off Switches are turned ON. - Occurring
• Power take-off control switch does not turn ON even in 5 seconds after
transmission power take-off switch is turned ON.
• Open-circuit in SIG harness between transmission power take-off 3-way
• Open-circuit in Plus harness between transmission power take-off 3-way
Possible causes
522134-17: Power take-off is not disconnected when the Power take-off Switches are turned OFF. - Occurring
• Transmission power take-off switch (cabin switch) does not turn OFF even in
5 seconds after power take-off control switch (chassis switch) is turned OFF.
• Short-circuit to power or ground in SIG harness between transmission power
take-off 3-way magnetic valve and signal detect and actuation module
Possible causes
522135-17: Power take-off was disconnected when the Transmission power take-off 3-way magnetic valve
was ON. - Occurring
• Power take-off control switch turns OFF before transmission power take-off
Generation condition switch is turned OFF with transmission power take-off 3-way magnetic valve
ON.
• Open-circuit in SIG harness between power take-off control switch and sig-
• Open-circuit in Plus harness between power take-off control switch and sig-
Possible causes
• Faulty power take-off control switch
54-13-35

522136-17: Power take-off was connected when Transmission power take-off 3-way magnetic valve was
OFF. - Occurring
• Power take-off control switch turns ON before transmission power take-off
Generation condition switch is turned ON with transmission power take-off 3-way magnetic valve
OFF.
power take-off control switch and signal detect and actuation module
Possible causes
• Faulty power take-off control switch

• Local interconnect network communication data (turn signal left-hand) from
Recoverability
ceived.

• Local interconnect network communication data (turn signal right-hand) from
Recoverability
ceived.

• Local interconnect network communication data (wiper signal) from combi-
nation switch are abnormal.
Recoverability
ceived.
Control effected by electronic control unit • Wiper slow mode automatically turns on when IGN=ON.
54-13-36
54-13
• Local interconnect network communication data (interval wiper signal) from
Recoverability
ceived.
522142-4: Wiper motor - Insufficient voltage or short circuit to ground

Generation condition • Voltage output to wiper motor is abnormal.
• Short-circuit to ground in SIG harness between wiper motor and signal de-
Possible causes
• Faulty wiper motor
522143-5: Wiper motor - The current strength is too low or there is an open circuit.
Generation condition • Current output to wiper motor is abnormal.
Recoverability • System recovers when normal current is applied.
• Open-circuit in SIG harness between wiper motor and signal detect and ac-
tuation module
• Open-circuit in Plus harness between wiper motor and signal detect and ac-
Possible causes
tuation module
522144-3: Wiper motor - Excessive voltage or short circuit to positive

Generation condition • Voltage input from wiper motor is abnormal.
• Short-circuit to power in SIG harness between wiper motor and signal detect
Possible causes
522147-4: Key interlock solenoid - Insufficient voltage or short circuit to ground

• Output current to key interlock solenoid rises to range of 4.2 to 7.4 A or high-
er.
• System recovers when output current to key interlock solenoid falls within
Recoverability
Control effected by electronic control unit • Output to key interlock solenoid is stopped.
• Short-circuit to power, ground or another circuit in SIG harness between key
interlock solenoid and signal detect and actuation module
Possible causes
• Faulty key interlock solenoid
54-13-37

522148-17: Faulty part CPU inside component “SAM” - Occurring
• Watch dog of signal detect and actuation module generation condition is de-
tected and resetting takes place.
• Watch dog of signal detect and actuation module generation condition is
Recoverability
cleared after resetting.
• Defective CPU of signal detect and actuation module
Possible causes
• Defective software of signal detect and actuation module
522149-17: Faulty part Memory inside component “SAM” - Occurring

• Checksum of signal detect and actuation module calculated at data rewriting
is not correct.
• Checksum of signal detect and actuation module calculated at data rewriting
Recoverability
becomes correct.
Possible causes • Abnormality of signal detect and actuation module
522150-17: Faulty component “SAM” - Occurring

Generation condition • Memory unit is in an abnormal condition.
Recoverability • Normal operations of memory unit are resumed after restarting.
Possible causes • Defective software of signal detect and actuation module

Current
Value Description Value Explanation
Group
Shows the state of voltage supply to the license plate
lamp.
Left license plate lamp ON/OFF
ON: 12 V
OFF: 0 V
Shows the state of voltage supply to the daytime running
light (RH).
Right daytime running light ON/OFF
ON: 12 V
OFF: 0 V
Shows the state of voltage supply to the daytime running
light (LH).
Left daytime running light ON/OFF
ON: 12 V
Lighting: OFF: 0 V
Outputs Shows the state of voltage supply to the parking lamp
(RH).
Clearance lamp RIGHT ON/OFF
ON: 12 V
OFF: 0 V
Shows the state of voltage supply to the parking lamp
(LH).
Clearance lamp LEFT ON/OFF
ON: 12 V
OFF: 0 V
Shows the state of voltage supply to the headlamp high
beam (RH).
Right high beam ON/OFF
ON: 12 V
OFF: 0 V
54-13-38
54-13
Current
Group
Shows the state of voltage supply to the headlamp high
beam (LH).
Left high beam ON/OFF
ON: 12 V
OFF: 0 V
Shows the state of voltage supply to the option connector
(right turn signal on trailer).
Right turn signal on trailer ON/OFF
ON: 12 V
OFF: 0 V
(left turn signal on trailer).
Left turn signal on trailer ON/OFF
ON: 12 V
OFF: 0 V
Shows the state of voltage supply to the rear turn signal
lamp (RH).
Right turn signal REAR ON/OFF
ON: 12 V
OFF: 0 V
Shows the state of voltage supply to the rear turn signal
lamp (LH).
Left turn signal REAR ON/OFF
ON: 12 V
OFF: 0 V
Shows the state of voltage supply to the front turn signal
lamp (RH).
Right turn signal ON/OFF
ON: 12 V
OFF: 0 V
Shows the state of voltage supply to the front turn signal
lamp (LH).
Left turn signal ON/OFF
ON: 12 V
OFF: 0 V
Lighting:
Outputs Shows the state of voltage supply to front fog lamp (RH).
Right front fog lamp ON/OFF ON: 12 V
OFF: 0 V
Shows the state of voltage supply to front fog lamp (LH).
Left front fog lamp ON/OFF ON: 12 V
OFF: 0 V
Shows the state of voltage supply to the stop lamp (LH).
Right rear brake light ON/OFF ON: 12 V
OFF: 0 V
Shows the state of voltage supply to the stop lamp (RH).
Left rear brake light ON/OFF ON: 12 V
OFF: 0 V
Shows the state of voltage supply to the tail lamp (RH).
Right tail lamp ON/OFF ON: 12 V
OFF: 0 V
Shows the state of voltage supply to the tail lamp (LH).
Left tail lamp ON/OFF ON: 12 V
OFF: 0 V
Shows the state of voltage supply to the step lamp (LH).
Left exit lamp ON/OFF ON: 12 V
OFF: 0 V
Shows the state of voltage supply to the step lamp (RH).
Right exit lamp ON/OFF ON: 12 V
OFF: 0 V
Shows the state of voltage supply to the illumination
lamp.
Switch and controls illumination ON/OFF
ON: 12 V
OFF: 0 V
54-13-39

Current
Group
(body illumination).
Body illumination ON/OFF
ON: 12 V
Lighting: OFF: 0 V
Outputs Shows the state of voltage supply to the option connector
(chassis illumination).
Chassis illumination ON/OFF
ON: 12 V
OFF: 0 V
Shows the state of voltage supply to the wiper motor (Lo).
Windshield wiper Stage ON ON/OFF ON: 12 V
Wipe and OFF: 0 V
wash: Out-
puts Shows the state of voltage supply to the wiper motor (Hi).
Windshield wiper Stage HIGH ON/OFF ON: 12 V
OFF: 0 V
Output
Shows the state of voltage supply to the wiper washer
'Pump of
motor.
windshield Windshield washer system ON/OFF
ON: 12 V
washer
OFF: 0 V
system'
Shows the state of voltage supply to the mirror heater
switch illumination.
Mirror heater Switches ON/OFF
ON: 12 V
OFF: 0 V
Door mod-
(LH).
ule: Out- Right mirror heater ON/OFF
ON: 12 V
puts
OFF: 0 V
(RH).
Left mirror heater ON/OFF
ON: 12 V
OFF: 0 V
Shows the state of voltage supply to the accessory relay
connected equipment.
• Gearshift lever unit relay
• ETC accessory
• Audio accessory
Starter signal Relays (ACC) ON/OFF
• DUONICTM accessory
• Cigarette lighter accessory
• Power mirror accessory
ON: 12 V
OFF: 0 V
Shows the state of voltage supply to the accessory relay
(option) connected equipment.
• Option connector (accessory body)
Option relay (ACC) ON/OFF
• Option connector (accessory chassis)
Ignition:
ON: 12 V
Outputs
OFF: 0 V
Shows the state of voltage supply to the ignition relay
connected equipment.
• Meter cluster (M power supply)
• Anti-skid brake system electronic control unit (M pow-
er supply)
• Engine electronic control unit (M power supply)
Starter signal Relays (IGN) ON/OFF • DUONICTM electronic control unit (M power supply 1)
• DUONICTM electronic control unit (M power supply 2)
• Gearshift lever unit (M power supply 1)
• Gearshift lever unit (M power supply 2)
• Starter relay
ON: 12 V
OFF: 0 V
54-13-40
54-13
Current
Group
Shows the state of voltage supply to the ignition relay
(option) connected equipment.
• Option connector (M power supply, body)
Ignition:
Option relay (IGN) ON/OFF • Option connector (M power supply, chassis)
Outputs
• Alternator (R terminal)
ON: 12 V
OFF: 0 V
Shows the state of voltage supply to the air conditioner
compressor condenser relay connected equipment.
• Dual pressure switch
Refrigerant compressor Relays ON/OFF
• Condenser fan relay
Air condi- ON: 12 V
tioning: OFF: 0 V
Outputs Shows the state of voltage supply to the air conditioner
blower relay connected equipment.
Blower motor Relays ON/OFF • Blower fan relay
ON: 12 V
OFF: 0 V
Brake sys-
(parking brake cut).
tem: Out- Parking brake Switches Release ON/OFF
ON: 12 V
puts
OFF: 0 V
Shows the state of voltage supply to the neutral position
switch.
Transmission neutral position switch ON/OFF
ON: 12 V
OFF: 0 V
Transmis- Shows the state of voltage supply to the backup lamp
sion: Out- switch.
Transmission backup light Switches ON/OFF
puts ON: 12 V
OFF: 0 V
Shows the state of voltage supply to the backup buzzer.
Backup buzzer ON/OFF ON: 12 V
OFF: 0 V
Shows the state of voltage supply to the power-take off
Transmission power take-off 3-way magnetic valve.
ON/OFF
Status of magnetic valve ON: 12 V
power OFF: 0 V
take-off: Shows the state of voltage supply to the option connector
Outputs (power-take off magnetic valve).
Power take-off outputs ON/OFF
ON: 12 V
OFF: 0 V
Shows the state of supply voltage to the cab lamp.
Interior lamp Door OPEN 0 to 100%
Driving duty cycle: 0 to 100%
Shows the state of supply voltage to the headlamp low
Left low beam 0 to 100% beam (LH).
PWM Shows the state of supply voltage to the headlamp low
Right low beam 0 to 100% beam (RH).
Shows the state of supply voltage to the key interlock so-
Key interlock solenoid 0 to 100% lenoid.
Shows the ON/OFF state of the front fog lamp switch.
Front fog lamp Switches ON/OFF OFF: 12 V
Lighting: ON: 0 V (unlatched)
Inputs Shows the ON/OFF state of the hazard switch.
Hazard warning flasher Switches ON/OFF OFF: 12 V
ON: 0 V (unlatched)
54-13-41

Current
Group
Shows the ON/OFF state of the automatic stop position
Wipe and
Windshield wiper Switch 'Rest posi- of the wiper motor.
wash: In- ON/OFF
tion' OFF: 12 V
puts
ON: 0 V
Shows the ON/OFF state of the mirror heater.
Mirror heater ON/OFF OFF: 12 V
ON: 0 V (unlatched)
OPEN/
Right rear door / Left rear door Shows the open/closed state of the rear door.
CLOSED
Door mod- OPEN/
ule: Inputs Passenger door CLOSED
Shows the open/closed state of the passenger door.
OPEN/
Driver door Shows the open/closed state of the driver door.
CLOSED
Door Lock Switch OFF ON/OFF Shows the ON/OFF state of the door lock switch.
Door Lock Switch ON ON/OFF Shows the ON/OFF state of the door lock switch.
Shows the ON/OFF state of the starter switch (START
position).
Starter Switches (START) ON/OFF
OFF: 0 V
ON: 12 V
Shows the ON/OFF state of the starter insert switch.
Starter Switches (LOCK) ON/OFF OFF: 0 V
ON: 12 V
Shows the ON/OFF state of the starter switch (ACC posi-
tion).
Starter Switches (ACC) ON/OFF
OFF: 0 V
ON: 12 V
Shows the ON/OFF state of the starter switch (M posi-
tion).
Starter Switches (ON) ON/OFF
OFF: 0 V
ON: 12 V
Shows the state of supply voltage from the alternator (L
Ignition: In-
terminal).
puts Alternator ON/OFF
ON: 12 V
OFF: 0 V
Shows the operating state of the accessory relay output.
Starter signal Relays (ACC) ON/OFF ON: 12 V
OFF: 0 V
Shows the operating state of the accessory relay (option)
output.
Option relay (ACC) ON/OFF
ON: 12 V
OFF: 0 V
Shows the operating state of the ignition relay output.
Starter signal Relays (IGN) ON/OFF ON: 12 V
OFF: 0 V
Shows the operating state of the ignition relay (option)
output.
Option relay (IGN) ON/OFF
ON: 12 V
OFF: 0 V
Shows the ON/OFF state of the air conditioning switch.
Air conditioning switch ON/OFF OFF: 12 V
Air condi- ON: 0 V
tioning: In-
puts Shows the ON/OFF state of the blower fan.
Refrigerant compressor Relays ON/OFF OFF: 0 V
ON: 12 V
54-13-42
54-13
Current
Group
Shows the ON/OFF state of the refrigerant compressor
Air condi-
relays.
tioning: In- Blower fan output ON/OFF
OFF: 0 V
puts
ON: 12 V
Shows the ON/OFF state of the vacuum switch.
Vacuum Switches ON/OFF OFF: 12 V
ON: 0 V
Shows the ON/OFF state of the brake fluid level switch.
Brake fluid level Switches ON/OFF OFF: 12 V
ON: 0 V
Shows the ON/OFF state of the parking brake switch.
Parking brake Switches ON/OFF OFF: 12 V
Brake sys-
ON: 0 V
tem: Inputs
Shows the ON/OFF state of the brake switch (normal
close).
Brake light Switches 2 ON/OFF
OFF: 12 V
ON: 0 V
Shows the ON/OFF state of the brake switch (normal
open).
Brake light Switches 1 ON/OFF
OFF: 12 V
ON: 0 V
Shows the ON/OFF state of the backup lamp switch.
Backup light Switches ON/OFF OFF: 12 V
ON: 0 V
Transmis- Shows the ON/OFF state of the neutral switch.
sion: In- Transmission neutral position switch ON/OFF OFF: 0 V
puts ON: 12 V
Shows the ON/OFF state of the clutch switch.
Clutch Switches ON/OFF OFF: 12 V
ON: 0 V
Shows the ON/OFF state of the option connector (power
take-off control switch).
Power take-off Inputs ON/OFF
OFF: 0 V
ON: 12 V
Status of Shows the ON/OFF state of the power take-off control
power switch.
Switch for power take-off on body ON/OFF
take-off: In- OFF: 12 V
puts ON: 0 V
Shows the ON/OFF state of the transmission power take-
off switch.
Switch for power take-off in cab ON/OFF
OFF: 12 V
ON: 0 V
Shows the fuel level in the fuel tank.
Fill level of
Fuel level 0 Fuel tank empty: Approx. 0
fuel tank
Fuel tank full: Approx. 242
Shows the input voltage from the battery (high-current
Battery
Battery voltage 0 fuse box) to the SAM (signal detect and actuation mod-
voltage
ules).
54-13-43

4. Actuator Test (Control) Using FUSO Diagnostics
• The basic conditions for performing the actuator test: Vehicle stopped, engine stopped and starter switch ON.
Selection Explanation
Illuminates the stop lamp (LH).
Illuminates the headlamp high beam (LH).
Illuminates the parking lamp (LH).
Illuminates the turn signal lamp (LH).
Exterior illumination
Illuminates the stop lamp (RH).
Illuminates the headlamp high beam (RH).
Illuminates the parking lamp (RH).
Illuminates the turn signal lamp (RH).
M7 (Washer motor) Activates the windshield washer system.
Activates the ignition relay.
[Additional condition for performing actuator test]
Starter switch position: ACC
Activates the ignition relay (option)
K22 (Starter relay) [Additional condition for performing actuator test]
Starter switch position: ACC
Activates the accessory relay.
Activates the accessory relay (option).
Door module –
Activates the air conditioner compressor condenser relay.
Air conditioning
Activates the air blower relay.
5. Electronic Control Unit Coding

• The signal detect and actuation module has various kinds of information such as technical data of vehicle and
equipment registered as coding data.
• Therefore, each time the signal detect and actuation module is replaced or some setting changes are made, the
coding data must surely be rewritten using FUSO Diagnostics. Otherwise, the data stored in the signal detect and
actuation module could deviate from the actual conditions of the vehicles, resulting in occurrence of diagnosis
codes.
5.1 Rewriting of coding data

• If one of the following changes has been made, be sure to rewrite the relevant coding data. For details of the re-
writing procedure, consult an authorized dealer or distributor.
• Depending on the specifications of the rear body to be mounted, coding data other than those listed below may
have to be rewritten. For further information, consult an authorized dealer or distributor.
Standards for rewriting signal detect and actuation module in-
Rewriting coding data required
ternal data
When signal detect and actuation module is replaced –
When additional turn signal lamps are installed –
If an optional connector for rear body mounting is used, the fol-
lowing diagnosis/actuator functions must be set valid:
• Illumination
When rear body is mounted • Backup buzzer
• Power take-off
• Neutral switch
• Parking brake switch
When additional LED rear lamps are installed –
When additional mirror with heater is installed –
54-13-44
54-13
6. Electronic Control Unit Input/Output Table
• See the Electronic Control Unit Schematic Diagram for the pin locations of each signal and ground. (See Gr54-
00C)
Input/
Devices to be connected Terminal Voltage and wave form
output
License plate lamp 13C-9-Ground Output ON: 12 V/OFF: 0 V
Parking lamp (RH) 15B-11-Ground Output ON: 12 V/OFF: 0 V
Parking lamp (LH) 15B-10-Ground Output ON: 12 V/OFF: 0 V
Head lamp high beam (RH) 14B-7-Ground Output ON: 12 V/OFF: 0 V
Head lamp high beam (LH) 16B-2-Ground Output ON: 12 V/OFF: 0 V
Option connector (side turn lamp (RH)) 13C-4-Ground Output ON: 12 V/OFF: 0 V
Option connector (side turn lamp (LH)) 12C-7-Ground Output ON: 12 V/OFF: 0 V
Rear turn lamp (RH) 13C-5-Ground Output ON: 12 V/OFF: 0 V
Rear turn lamp (LH) 12C-4-Ground Output ON: 12 V/OFF: 0 V
Front turn lamp (RH) 14B-4-Ground Output ON: 12 V/OFF: 0 V
Front turn lamp (LH) 16B-4-Ground Output ON: 12 V/OFF: 0 V
Front fog lamp (RH) 12C-6-Ground Output ON: 12 V/OFF: 0 V
Front fog lamp (LH) 13C-2-Ground Output ON: 12 V/OFF: 0 V
Stop lamp (RH) 13C-7-Ground Output ON: 12 V/OFF: 0 V
Stop lamp (LH) 12C-1-Ground Output ON: 12 V/OFF: 0 V
Tail lamp (RH) 12C-3-Ground Output ON: 12 V/OFF: 0 V
Tail lamp (LH) 13C-8-Ground Output ON: 12 V/OFF: 0 V
Step lamp (RH) 15B-12-Ground Output ON: 12 V/OFF: 0 V
Step lamp (LH) 15B-14-Ground Output ON: 12 V/OFF: 0 V
Illumination lamp 14B-8-Ground Output ON: 12 V/OFF: 0 V
Wiper motor (Hi) 16B-5-Ground Output ON: 12 V/OFF: 0 V
Wiper motor (Lo) 16B-1-Ground Output ON: 12 V/OFF: 0 V
Wiper washer motor 17B-5-Ground Output ON: 12 V/OFF: 0 V
Mirror heater switch illumination 15B-27-Ground Output ON: 12 V/OFF: 0 V
Mirror heater (LH) 14B-5-Ground Output ON: 12 V/OFF: 0 V
Mirror heater (RH) 14B-1-Ground Output ON: 12 V/OFF: 0 V
Backup lamp 13C-6-Ground Output ON: 12 V/OFF: 0 V
Backup buzzer 11C-6-Ground Output ON: 12 V/OFF: 0 V
Cab lamp 17B-15-Ground Output PWM
Key interlock solenoid 17B-17-Ground Output PWM
Front fog lamp switch 15B-16-Ground Input OFF: 12 V/ON: 0 V (Unlatched type)
Hazard switch 15B-4-Ground Input OFF: 12 V/ON: 0 V (Unlatched type)
Wiper motor stop position switch 17B-16-Ground Input OFF: 12 V/ON: 0 V
Heater mirror switch 18B-11-Ground Input OFF: 12 V/ON: 0 V (Unlatched type)
Rear door switch 15B-2-Ground Input OFF: 12 V/ON: 0 V
Front door switch (assistant driver's seat side) 15B-3-Ground Input OFF: 12 V/ON: 0 V
Front door switch (driver's seat side) 15B-18-Ground Input OFF: 12 V/ON: 0 V
Starter switch (START position) 15B-15-Ground Input OFF: 0 V/ON: 12 V
Starter switch (key insert switch) 18B-18-Ground Input OFF: 0 V/ON: 12 V
Starter switch (ACC position) 18B-17-Ground Input OFF: 0 V/ON: 12 V
Starter switch (M position) 18B-3-Ground Input OFF: 0 V/ON: 12 V
54-13-45

Input/
Devices to be connected Terminal Voltage and wave form
output
Engine running: 12 V
Alternator (L terminal) 11C-8-Ground Input
Engine stopped: 0 V
3B-8, 7C-8, 3B-10, Activated: 12 V
Accessory relay Output
3B-13-Ground Not activated: 0 V
Activated: 12 V
Accessory relay (option) 6X-1-Ground Output
Not activated: 0 V
1B-11, 5C-2, 5C-4,
5C-11, 5C-9, 1B-1, Activated: 12 V/24 V
Ignition relay Output
1B-4, 1B-5, 1B-13, Not activated: 0 V
1B-14-Ground
Activated: 12 V
Ignition relay (option) 6X-5-Ground Output
Not activated: 0 V
Air conditioner switch 15B-17-Ground Input OFF: 12 V/ON: 0 V
7C-11, 7C-12- Activated: 12 V
Air conditioner compressor condenser relay Output
Ground Not activated: 0 V
Active (with air conditioner compres-
Air conditioner blower relay 2B-14-Ground Output sor operating): 12 V
Not activated: 0 V
Vacuum switch 15B-1-Ground Input OFF: 12 V/ON: 0 V
Brake fluid level switch 18B-7-Ground Input OFF: 12 V/ON: 0 V
Parking brake switch 18B-6-Ground Input OFF: 12 V/ON: 0 V
Stop lamp switch (normal close) 15B-19-Ground Input OFF: 12 V/ON: 0 V
Stop lamp switch (normal open) 18B-4-Ground Input OFF: 12 V/ON: 0 V
Power-take off control switch 11C-9-Ground Input OFF: 12 V/ON: 0 V
Cab tilt lock switch 18B-10-Ground Input OFF: 12 V/ON: 0 V
Diesel particulate filter cleaning switch 15B-20-Ground Input OFF: 12 V/ON: 0 V (Unlatched type)
Fuel tank empty: 150 ± 3.5Ω or more
Fuel level sensor 11C-1-Ground Input
Full: 5 ± 2Ω
Battery voltage 10C-1-Ground Input Shows the battery voltage (12 V).
54-13-46
54-13
7. Inspection of Relays in Signal Detect and Actuation Module
E: Ignition relay
H: Engine relay
J: ACC relay (normally open 4-pin)
• Replace the relay if any abnormal conditions are found during
checking for conductivity or operation.
A: A/C blower relay

B: Horn relay
C: ACC relay (option)
D: IGN relay (option)
F: Fuel pump relay
G: A/C compressor (normally open 4-pin)
• Replace the relay if any abnormal conditions are found during
checking for conductivity or operation.
54-13-47
#986 INSPECTION OF METER CLUSTER


The battery voltage is too high. - Voltage above normal or shorted to

158-3 O
high source
The battery voltage is too low. - Voltage below normal or shorted to
158-4 O
low source
629-31 Watchdog reset condition exists O
639-4 CAN bus OFF fault - Voltage below normal or shorted to low source O
1213-14 MIL lamp internal LED circuit failure O
521751-7 Stopper motor internal circuit failure O
521768-19 EEPROM internal access failure O

158-3: The battery voltage is too high. - Voltage above normal or shorted to high source
• In meter cluster is indicated a battery voltage higher than 16 V for 10 sec-
onds.
• System recovers if normal reading is obtained when starter switch is turned
Recoverability
to OFF and then to ON.
Possible causes • Faulty signal detect and actuation module
• Defective meter cluster
158-4: The battery voltage is too low. - Voltage below normal or shorted to low source
Generation condition • In meter cluster is indicated a battery voltage lower than 10 V for 10 seconds
• System recovers if normal reading is obtained when starter switch is turned
Recoverability
to OFF and then to ON.
• Open-circuit or short-circuit to ground in harness between battery and meter
cluster
• Malfunction of battery
Possible causes
629-31: Watchdog reset condition exists

Generation condition • CPU in meter cluster is reset.
Recoverability
turned to OFF and then to ON.
Possible causes • Faulty alternator
54-13-48
54-13
639-4: CAN bus OFF fault - Voltage below normal or shorted to low source
Generation condition • Controller area network communication bus off condition is detected.
Recoverability
• Controller area network communication bus is open or shorted to power,
Possible causes
• Faulty resistor in meter cluster
1213-14: MIL lamp internal LED circuit failure

Generation condition • Internal circuit is malfunctioning.
Recoverability
Control effected by electronic control unit • Error message is sent through controller area network.
Possible causes • Defective meter cluster
521751-7: Stopper motor internal circuit failure

Generation condition • Internal circuit is malfunctioning.
Recoverability
521768-19: EEPROM internal access failure

Generation condition • Access to EEPROM is impossible.
Recoverability

Current
Group
0.000 to
255.000 km/h Shows the vehicle speed as determined by the ta-
– Vehicle speed Tachograph
{0.000 to 158.4 chograph.
mph}
0.000 to
255.000 km/h
– Vehicle speed ECU Shows the vehicle speed as determined by the ECU.
{0.000 to 158.4
mph}
54-13-49
#986 INSPECTION OF METER CLUSTER

• The basic conditions for performing the actuator test: Vehicle stopped, engine stopped and starter switch ON.
Selection Explanation
[Test method]
Operate each indication in the meter cluster.
[Checking method]
• The speedometer operates from 0 to maximum. It stops on the way for about 5 seconds at
the 40 km/h {40 mph} point.
• The tachometer operates from 0 to maximum. It stops on the way for about 5 seconds at
Instrument cluster the 2000 rpm point.
• The fuel level gauge operates from 0 to full. It stops on the way for about 5 seconds at the
one half point.
• The indicator lamp, illumination, multi-information display and buzzer cycle ON/OFF.
[Note]
The test stops automatically when three rounds of inspection are completed. (Or, terminated
using the stop button.)
5. Electronic Control Unit Coding

• The meter cluster has various kinds of information such as technical data of vehicle and equipment registered as
coding data.
• Therefore, each time the meter cluster is replaced or some specification changes are made, the coding data must
surely be rewritten using FUSO Diagnostics. Otherwise, the data stored in the meter cluster could deviate from
the actual conditions of the vehicles, resulting in incorrect alarms.
6. Rewriting of Coding Data

• If specification changes have been made, be sure to rewrite the relevant coding data. For details of the rewriting
procedure, consult an authorized dealer or distributor.
Rewriting coding data required Standards for rewriting meter cluster internal data
Final gear When the final gear is changed, the meter cluster internal data must be updated.
Rear tire When the tire size is changed, the meter cluster internal data must be updated.
When specifications of this system are changed, the meter cluster internal data must
Anti-lock brake system
be updated.
54-13-50
54-14 CONNECTOR CONFIGURATION

CHART
54-14-1
CONNECTOR CONFIGURATION CHART

AA type
Number shows
Female connector Male connector
number of pins
AA1A
AA2A
AA2B
AA3A
AA3B
AA4A
AA4B
AA6A
54-14-2
54-14
Number shows
number of pins
AA6B
AA8A
AA10A
AA12A
AB type
Number shows
number of pins
AB1A
AB2A
AB2B
AB2C
54-14-3

Number shows
number of pins
AB3A
AB3B
AB4A
AB6A
AB6B
AB8A
AB8B
AB12A
54-14-4
54-14
Number shows
number of pins
AB12B
AB14A
AB14B
AB16A
AB16B
AB52A
AB52B
54-14-5

AC type
Number shows
number of pins
AC1A
AC1B
AC2A
AC2B
AC2C
AC2D
AC3A
AC4A
AC4B
54-14-6
54-14
AD type
Number shows
number of pins
AD1A
AD2A
AD2B
AE type
Number shows
number of pins
AE2A
AE3A
AE5A
AE7A
AE9A
54-14-7

Number shows
number of pins
AE11A
AE13A
AE15A
AE16A
AE16B
AE16C
AE17A
AG type
Number shows
number of pins
AG16A
54-14-8
54-14
Number shows
number of pins
AG20A
AH type
Number shows
number of pins
AH10A
AH12A
AH12B
AH16A
54-14-9

Number shows
number of pins
AH18A
AH18B
AH22A
AH24A
54-14-10
54-14
Number shows
number of pins
AH26A
AJ type
Number shows
number of pins
AJ2A
AJ4A
AJ8A
AJ10A
54-14-11

Number shows
number of pins
AJ12A
AJ16A
AJ20A
54-14-12
54-14
AK type
Number shows
number of pins
AK2A
AK3A
AK4A
AK6A
AK8A
AK10A
AK12A
54-14-13

Number shows
number of pins
AK14A
AK18A
AK20A
AK20B
AK22A
54-14-14
54-14
Number shows
number of pins
AK22B
AL type
Number shows
number of pins
AL1A
AL2A
AL2B
AL3A
54-14-15

Number shows
number of pins
AL3B
AL3C
AL3D
AL3E
AL4A
54-14-16
54-14
Number shows
number of pins
AL4B
AL6A
AL6B
AL8A
AL8B
54-14-17

AM type
Number shows
number of pins
AM1A
AM1B
AM2A
AM2B
AM2C
AM4A
AM4B
AM6A
AM6B
54-14-18
54-14
Number shows
number of pins
AM8A
AM8B
AM10A
AM10B
AN type
Number shows
number of pins
AN1A
AN2A
AN2B
AN3A
54-14-19

Number shows
number of pins
AN4A
AN4B
AN6A
AN6B
AN8A
AN8B
AP type
Number shows
number of pins
AP1A
AP1B
54-14-20
54-14
Number shows
number of pins
AP2A
AP2B
AP2C
AQ type
Number shows
number of pins
AQ1A
AQ3A
AQ3B
AQ5A
AQ6A
54-14-21

Number shows
number of pins
AQ8A
AQ12A
AR type
Number shows
number of pins
AR2A
AR2B
AR2C
AR2D
AR2E
AR2F
54-14-22
54-14
Number shows
number of pins
AR2G
AR2H
AR3A
AS type
Number shows
number of pins
AS1A
AS2A
AS2B
AT type
Number shows
number of pins
AT4A
54-14-23

AU type
Number shows
number of pins
AU2A
AU6A
AU8A
AU10A
AU12A
AU13A
AU16A
AU16B
AU16C
54-14-24
54-14
AV type
Number shows
number of pins
AV1A
AV2A
AW type
Number shows
number of pins
AW1A
AW1B
AW1C
AW2A
AX type
Number shows
number of pins
AX2A
54-14-25

Number shows
number of pins
AX3A
AX4A
AY type
Number shows
number of pins
AY2A
AZ type
Number shows
number of pins
AZ2A
BA type
Number shows
number of pins
BA3A
BB type
Number shows
number of pins
BB2A
54-14-26
54-14
Number shows
number of pins
BB3A
BC type
Number shows
number of pins
BC3A
BD type
Number shows
number of pins
BD6A
BD8A
BD12A
BD16A
BD20A
54-14-27

BE type
Number shows
number of pins
BE6A
BF type
Number shows
number of pins
BF6A
BF8A
BF10A
BF12A
BG type
Number shows
number of pins
BG10A
BG12A
54-14-28
54-14
Number shows
number of pins
BG16A
BJ type
Number shows
number of pins
BJ5A
BJ7A
BJ9A
BM type
Number shows
number of pins
BM2A
BM2B
BM2C
54-14-29

Number shows
number of pins
BM3A
BM4A
BN type
Number shows
number of pins
BN1A
BQ type
Number shows
number of pins
BQ1A
BQ2A
BQ3A
BQ3B
54-14-30
54-14
BR type
Number shows
number of pins
BR1A
BR2A
BR4A
BR4B
BS type
Number shows
number of pins
BS1A
BS2A
54-14-31

Number shows
number of pins
BS3A
BS4A
BS6A
BS8A
BT type
Number shows
number of pins
BT2A
BT3A
BT4A
54-14-32
54-14
Number shows
number of pins
BT6A
BT8A
BT10A
BT12A
BT16A
BT16B
BT16C
BT20A
BT20B
54-14-33

Number shows
number of pins
BT20C
BU type
Number shows
number of pins
BU4A
BU6A
BW type
Number shows
number of pins
BW2A
BW2B
BW3A
BW3B
54-14-34
54-14
Number shows
number of pins
BW4A
BW4B
BW6A
BW6B
BW8A
BW10A
BX type
Number shows
number of pins
BX2A
54-14-35

Number shows
number of pins
BX3A
BX5A
BX7A
BX9A
54-14-36
54-14
Number shows
number of pins
BX11A
BX13A
BX15A
BX17A
54-14-37

Number shows
number of pins
BX19A
BY type
Number shows
number of pins
BY4A
BZ type
Number shows
number of pins
BZ12A
BZ16A
BZ22A
54-14-38
54-14
Number shows
number of pins
BZ26A
CA type
Number shows
number of pins
CA2A
CB type
Number shows
number of pins
CB16A
CD type
Number shows
number of pins
CD35A
CD55A
54-14-39

CE type
Number shows
number of pins
CE2A
CE4A
CE12A
CE16A
CE20A
CF type
Number shows
number of pins
CF21A
CH type
Number shows
number of pins
CH2A
54-14-40
54-14
Number shows
number of pins
CH2B
CH3A
CK type
Number shows
number of pins
CK3A
CL type
Number shows
number of pins
CL14A
CM type
Number shows
number of pins
CM28A
CM30A
54-14-41

Number shows
number of pins
CM35A
CN type
Number shows
number of pins
CN2A
CN12A
CN16A
CP type
Number shows
number of pins
CP40A
54-14-42
54-14
Number shows
number of pins
CP40B
CP80A
CQ type
Number shows
number of pins
CQ2B
CQ3A
CQ8A
54-14-43

CR type
Number shows
number of pins
CR16A
CS type
Number shows
number of pins
CS2A
CT type
Number shows
number of pins
CT3A
CT3B
CT10A
CU type
Number shows
number of pins
CU6A
54-14-44
54-14
Number shows
number of pins
CU9A
CU12A
CU15A
CU17A
CU18A
CV type
Number shows
number of pins
CV8A
CW type
Number shows
number of pins
CW16A
54-14-45

Number shows
number of pins
CW25A
CW31A
CW32A
CX type
Number shows
number of pins
CX30A
CX32A
CX32B
CX32C
54-14-46
54-14
CY type
Number shows
number of pins
CY17A
CY22A
CY24A
CY28A
CY31A
DA type
Number shows
number of pins
DA20A
DA22A
DA25A
54-14-47

DB type
Number shows
number of pins
DB2A
DC type
Number shows
number of pins
DC3A
DD type
Number shows
number of pins
DD1A
DD2A
DD2B
DD2C
DD2E
54-14-48
54-14
Number shows
number of pins
DD2F
DD3A
DD4A
DD4C
DD5A
DD6A
DD6B
DD6C
DD6E
54-14-49

Number shows
number of pins
DD7A
DD8A
DD9A
DD10A
DD10B
DD11A
DD12A
DD12B
DD12C
54-14-50
54-14
Number shows
number of pins
DD13A
DD13B
DD14A
DD14B
DD15A
DD15B
DD16A
DD16B
DD18A
54-14-51

Number shows
number of pins
DD20A
DD22A
DE type
Number shows
number of pins
DE3A
DE7A
DF type
Number shows
number of pins
DF3A
DG type
Number shows
number of pins
DG1A
54-14-52
54-14
Number shows
number of pins
DG1B
DG1C
DG1D
DG2A
DG2B
DG2C
DG2D
DG2E
DG2F
54-14-53

Number shows
number of pins
DG2G
DG2H
DG2J
DG2K
DG2L
DG2M
DG3A
DG3B
DG4A
54-14-54
54-14
Number shows
number of pins
DG4B
DG4C
DG5A
DG5B
DG5C
DG5D
DG6A
DG6B
DG6C
54-14-55

Number shows
number of pins
DG8A
DG8B
DG10A
DG12A
DH type
Number shows
number of pins
DH2A
DH5A
DH6A
DH10A
54-14-56
54-14
Number shows
number of pins
DH14A
DH18A
DH20A
DH22A
DJ type
Number shows
number of pins
DJ10A
DJ10B
DK type
Number shows
number of pins
DK2A
54-14-57

Number shows
number of pins
DK2B
DK3A
DK4A
DL type
Number shows
number of pins
DL4A
DM type
Number shows
number of pins
DM3A
DM4A
54-14-58
54-14
DN type
Number shows
number of pins
DN4A
DP type
Number shows
number of pins
DP5A
DQ type
Number shows
number of pins
DQ2A
DQ2B
DQ2C
DQ2D
DQ2E
54-14-59

Number shows
number of pins
DQ2F
DQ3A
DQ3B
DQ3D
DQ4A
DQ4B
DQ8A
DR type
Number shows
number of pins
DR2A
54-14-60
54-14
DS type
Number shows
number of pins
DS2A
DS6A
DT type
Number shows
number of pins
DT1A
DT2A
DT3A
DT4A
54-14-61

DU type
Number shows
number of pins
DU2A
DV type
Number shows
number of pins
DV4A
DW type
Number shows
number of pins
DW2A
DX type
Number shows
number of pins
DX2A
DY type
Number shows
number of pins
DY1A
54-14-62
54-14
DY1B
DZ type
Number shows
number of pins
DZ1A
EA type
Number shows
number of pins
EA8A
EA8B
EB type
Number shows
number of pins
EB8A
EC type
Number shows
number of pins
EC2A
54-14-63

ED type
Number shows
number of pins
ED2A
EE type
Number shows
number of pins
EE2A
EF type
Number shows
number of pins
EF2A
EG type
Number shows
number of pins
EG4A
EH type
Number shows
number of pins
EH2A
54-14-64
54-14
EJ type
Number shows
number of pins
EJ9A
EK type
Number shows
number of pins
EK2A
EL type
Number shows
number of pins
EL2A
EM type
Number shows
number of pins
EM40A
EM81A
54-14-65

EN type
Number shows
number of pins
EN4A
EN5A
EP type
Number shows
number of pins
EP34A
EQ type
Number shows
number of pins
EQ4A
EQ4B
EQ5A
54-14-66
54-14
Number shows
number of pins
EQ5B
ER type
Number shows
number of pins
ER2A
ER6A
ER8A
ES type
Number shows
number of pins
ES2A
ES2B
ES2C
54-14-67

Number shows
number of pins
ES3A
ES3B
ES4A
ET type
Number shows
number of pins
ET1A
ET1B
ET1D
ET2A
ET2B
54-14-68
54-14
Number shows
number of pins
ET2C
ET2D
ET2F
ET2G
ET2L
ET3A
ET3B
ET3C
ET4A
54-14-69

Number shows
number of pins
ET4B
ET5A
ET5B
ET5D
ET6A
ET6B
ET6C
ET8A
ET8B
54-14-70
54-14
Number shows
number of pins
ET10A
ET32A
EU type
Number shows
number of pins
EU1A
EV type
Number shows
number of pins
EV2A
EW type
Number shows
number of pins
EW12A
EX type
Number shows
number of pins
EX5A
54-14-71

EY type
Number shows
number of pins
EY3A
EZ type
Number shows
number of pins
EZ3A
FA type
Number shows
number of pins
FA2B
FA3A
FA5A
FB type
Number shows
number of pins
FB55A
54-14-72
54-14
GA type
Number shows
number of pins
GA1A
GA2A
GA2B
GA3A
GA3B
GA4A
GA4B
GA6A
54-14-73

Number shows
number of pins
GA6B
GA8A
GA10A
GA12A
GB type
Number shows
number of pins
GB1A
GB2A
GB2B
GB3A
54-14-74
54-14
Number shows
number of pins
GB3B
GB4A
GB4B
GB6A
GB6B
GB8A
GB10A
GB12A
54-14-75

GC type
Number shows
number of pins
GC32A
GD type
Number shows
number of pins
GD1A
GD2A
GD3A
GD3B
54-14-76
54-14
GE type
Number shows
Female connector
number of pins
GE58A
GE96A
GF type
Number shows
number of pins
GF31A
GF32A
GF34A
GF35A
54-14-77

Number shows
number of pins
GF35B
GG type
Number shows
number of pins
GG12A
GG16A
GG22A
GG26A
GH type
Number shows
number of pins
GH3A
54-14-78
54-14
GJ type
Number shows
number of pins
GJ2A
GJ2B
GK type
Number shows
number of pins
GK7A
GL type
Number shows
number of pins
GL2A
GM type
Number shows
number of pins
GM2A
54-14-79

GN type
Number shows
number of pins
GN2A
GP type
Number shows
number of pins
GP8A
GP8B
GQ type
Number shows
number of pins
GQ9A
GR type
Number shows
number of pins
GR13A
GR15A
54-14-80
54-14
GS type
Number shows
number of pins
GS2A
GS2B
GS2C
GS2D
GS3A
GT type
Number shows
number of pins
GT24A
GT28A
GT32A
54-14-81

GU type
Number shows
number of pins
GU24A
GV type
Number shows
number of pins
GV12A
GV16A
GV20A
GW type
Number shows
number of pins
GW3A
54-14-82
54-14
Number shows
number of pins
GW3B
GW4A
GX type
Number shows
number of pins
GX1A
GX2A
GY type
Number shows
number of pins
GY4A
GZ type
Number shows
number of pins
GZ2A
54-14-83

HA type
Number shows
number of pins
HA2A
HA4A
HA7A
HA15A
HA36A
HA46A
HB type
Number shows
number of pins
HB4A
54-14-84
54-14
HC type
Number shows
number of pins
HC11A
HD type
Number shows
number of pins
HD2A
HD2B
HD3A
HD4A
HD4B
HD5A
54-14-85

HE type
Number shows
number of pins
HE2A
HE3A
HF type
Number shows
number of pins
HF3A
HG type
Number shows
number of pins
HG2A
HG3A
HG3B
HG4A
54-14-86
54-14
HH type
Number shows
number of pins
HH2A
HH2B
HH3A
HH3B
HH8A
HH10A
HH10B
HH12A
HH12B
54-14-87

Number shows
number of pins
HH16A
HH18A
HH18B
HH18C
HH20A
HH28A
HH28B
HH38A
HH40A
54-14-88
54-14
Number shows
number of pins
HH40B
HH60A
HH81A
HJ type
Number shows
number of pins
HJ2A
HJ2B
HJ2C
HJ3A
HJ3B
54-14-89

Number shows
number of pins
HJ3C
HJ4A
HJ4B
HJ6A
HJ94A
HK type
Number shows
number of pins
HK2A
HK2B
54-14-90
54-14
Number shows
number of pins
HK6A
HK11A
HL type
Number shows
number of pins
HL3A
HM type
Number shows
number of pins
HM5A
HN type
Number shows
number of pins
HN3A
HN5A
54-14-91

Number shows
number of pins
HN5B
HN6A
HN14A
HN14B
HN14C
HN14D
HP type
Number shows
number of pins
HP23A
54-14-92
54-14
HQ type
Number shows
number of pins
HQ1A
HQ2A
HQ4A
HQ4B
HQ5A
HQ5B
HQ8A
HQ8B
HQ8C
54-14-93

Number shows
number of pins
HQ10A
HQ10B
HQ10C
HR type
Number shows
number of pins
HR3A
HS type
Number shows
number of pins
HS2A
HS3A
HS4A
54-14-94
54-14
Number shows
number of pins
HS5A
HS5B
HT type
Number shows
number of pins
HT7A
HU type
Number shows
number of pins
HU2A
HU2B
HU2C
HU2D
54-14-95

Number shows
number of pins
HU3A
PC type
Number shows
number of pins
PC4A
PE type
Number shows
number of pins
PE8A
PE10A
PE10B
54-14-96
54-14
Number shows
number of pins
PE12A
PE12B
PE14A
54-14-97

Number shows
number of pins
PE18A
PE20A
54-14-98
Group 55
Heater, Air-conditioner
And Ventilation
Pub.No.00ELT0001-55
INDEX
SPECIFICATIONS .............................................................................. 55-2
STRUCTURE AND OPERATION

1. Heater .......................................................................................... 55-3
2. Air Conditioner ............................................................................. 55-4
3. Compressor .................................................................................. 55-5
4. Air Duct ........................................................................................ 55-8
5. Heater Control .............................................................................. 55-9
6. Rear Heater <Crew Cab> ............................................................ 55-13
TROUBLESHOOTING ...................................................................... 55-14
ON-VEHICLE INSPECTION AND ADJUSTMENT

1. Operation Check of Air Conditioner ........................................... 55-17
2. Recovery of Refrigerant ............................................................. 55-21
3. Recharging the System with Refrigerant .................................... 55-22
CONNECTING AIR CONDITIONER PIPING ................................... 55-24
COMPRESSOR ................................................................................ 55-25
CONDENSER, RECEIVER ............................................................... 55-26
HEATER CONTROL <MANUAL AIR CONDITIONER> ................... 55-28
AIR DUCT ......................................................................................... 55-32
HEATER AND COOLING UNIT, BLOWER ...................................... 55-33
REAR HEATER <CREW CAB> ........................................................ 55-34
55-1
SPECIFICATIONS
Specifications
Item Fully automatic air conditioner
Manual air conditioner
<option>
Type HFC134a
Refrigerant
Charged quantity g {oz} Indicated on the label
Mode selection
Damper change- Manual cable type
Air mixing Servomotor
over system
Fresh/recirculation changeover Servomotor
Servomotor rated voltage V 12
Manufacturer DENSO
Heating capacity W {kcal/h} 4600 ± 460 {3956 ± 396}
Blower and Heater
Cooling capacity W {kcal/h} 3650 ± 365 {3139 ± 314}
and cooling unit
Temperature control system Air mixing type
Rated voltage V 12
Manufacturer DENSO
Model 10S15C
Discharge cm3 {cu.in.}/1 rotation 167.3 {10.2}
Compressor Type ND-OIL8
without rear air
120 +15 +0.92
0 {7.32 0 }
Lubricant Quantity conditioner
cm3 {cu.in.} with rear air
200 +15 +0.92
0 {12.2 0 }
conditioner
Manufacturer Valeo Thermal Systems Japan Corporation
Condenser Rated voltage V 12
Rated current A 9.0 ± 0.5
Receiver
Capacity cm3 {cu.in.} 300 {18.3}
Rear heater unit Manufacturer DENSO
<crew cab> Heating capacity W {kcal/h} 1760 ± 180 {1514 ± 151}
55-2
STRUCTURE AND OPERATION 55

1. Heater
• The air intake box sends air to the blower and heater and cooling unit, where the air is heated by the heater core
(heat exchanger). The warmed-up air is then sent through the ducts into the cab.
• Water (engine coolant) warmed up by the heat from the engine circulates permanently through the heater core, ir-
respective of whether the thermostat is open or closed.
55-3

2. Air Conditioner
• The air intake box sends air to the
blower and heater and cooling unit,
where the air is cooled by the evapo-
rator. The cooled air is then sent
through the ducts into the cab.
• Refrigerant in gas form is compressed
by the compressor. The compressed
gas is then sent to the side condenser,
where it is cooled by outside air and
condenses into liquid form.
• The liquid refrigerant is sprayed into
the evaporator, where it quickly evapo-
rates into gas form while at the same
time absorbing heat from the sur-
rounding air.
• The refrigerant in gas form is again
sent to the compressor and is com-
pressed there.
• When the refrigerant pressure in the
high pressure line reaches the speci-
fied limit, the dual pressure switch
senses this and turns itself OFF. At
the same time, the magnet clutch is
turned OFF.
55-4
55
3. Compressor
• The compressor draws low-temperature, low-pressure refrigerant gas from the evaporator, compresses it, and
discharges a high-temperature, high-pressure refrigerant gas into the condenser.
• The compressor is driven by the engine via a belt and magnetic clutch.
• The swash plate compressor is equipped with a piston and a swash plate that is secured at an angle to the shaft.
• Rotation of the swash plate integrated with the shaft converts the rotary motion of the shaft into the reciprocating
motion of the piston, thereby drawing, compressing and discharging the gas refrigerant.
(1) Operation
• When the piston moves to the left, the
difference in pressure between the re-
frigerant that has been sent into the
compressor and the space inside the
cylinder opens the suction valve in the
compressor, feeding the refrigerant
into the cylinder.
55-5

• When the piston moves to the right,
the suction valve closes and the refrig-
erant is compressed.
• When the pressure of the refrigerant
reaches a certain level as the com-
pression progresses, the discharge
valve in the compressor opens the dis-
charge valve to discharge the com-
pressed refrigerant.
• The suction and discharge valves pre-
vent the refrigerant from flowing back-
ward.
3.1 Magnetic clutch

• The magnetic clutch is installed in the
shaft of the air compressor to operate
and stop the compressor.
55-6
55
(1) Operation
• When the stator coil in the stator is en-
ergized, the generated electromagnet-
ic force strongly attracts the armature
plate until it comes in contact with the
rotor to rotate the compressor.
• De-energizing the coil releases the ar-
mature plate from the rotor to stop the
rotation of the compressor.
55-7

4. Air Duct
• The air intake box sends outside air A or inside air B through the blower and heater and cooling unit to the ducts.
The flow of air is dependent on the open/closed positions of the various dampers.
55-8
55
5. Heater Control
5.1 Mode selection
<Manual air conditioner>
• Mode selection (opening/closing the dampers) is achieved by the operation of the mode selection control cables
and the resultant movement of the related parts linked to the cables.
55-9

<Fully automatic air conditioner>
• Mode selection (opening/closing the dampers) is achieved by the operation of the mode motor and the resultant
movement of the related parts linked to the motor.
55-10
55
5.2 Air mix selection
<Manual air conditioner>
• Air mix selection is achieved by controlling the positions of the dampers, thereby proportioning the volumes of
warm and cool air that is and is not sent through the heater core.
<Fully automatic air conditioner>
• Air mix selection is achieved by controlling the positions of the dampers, thereby proportioning the volumes of
warm and cool air that is and is not sent through the heater core.
55-11

5.3 Fresh/recirculation changeover
• The fresh/recirculation changeover damper is operated by a motor.
55-12
55
6. Rear Heater <Crew Cab>
55-13
TROUBLESHOOTING
Front Heater, Front Air Conditioner
Symptoms
Controls require too much effort

Air volume from vents unstable
No fresh/recirculation selection
No temperature setting
Reference Gr
No mode selection
No air from vents
Draft from vents

Poor heating
Poor cooling
Possible causes
Blower motor coil open, shorted O
Blower motor relay contacts stuck closed, coil open, shorted O
Gr54
Power transistor malfunction <F-A/C> O
Blower resistor malfunction <M-A/C> O
Compressor seized, malfunction O
Magnetic clutch of compressor fault O
Refrigerant charge low O O
Air conditioner relay contacts stuck closed, coil open, shorted O
Mode motor coil open, shorted <F-A/C> O Gr54
Mode damper malfunction, not fully closed O O O
Air mix motor coil open, shorted <F-A/C> O Gr54
Air mix damper malfunction, not fully closed O O O
Fresh/recirculation selection motor coil open, shorted O Gr54
Fresh/recirculation selection damper malfunction, not fully
O O O
closed
Condenser fan motor coil open, shorted O
Condenser relay contacts stuck closed, coil open, shorted O
In car sensor coil open, shorted <F-A/C> O O O
Air inlet sensor coil open, shorted <F-A/C> O O O
Thermostat coil open, shorted <F-A/C> O O O
Gr54
Dual pressure switch coil open, shorted O
Photo sensor coil open, shorted <F-A/C> O O O
Something placed on sensitive portion of photo sensor
O O O
<F-A/C>
Heater control malfunction <M-A/C> O O O O O O O
Air conditioner electronic control unit and control panel fault
O O O O O O O O
<F-A/C>
Gr14
Thermostat stays open O
Coolant level low O
Connector poor contact, harness open, faulty earth O O O O O O
Gr54
Fuse blown O O
Air conditioner piping clogged, loose, incorrectly connected O
Heater piping clogged, loose, incorrectly connected O
Duct incorrectly connected O
Heater and cooling unit clogged O
55-14
55
Symptoms
Controls require too much effort

No fresh/recirculation selection
Reference Gr
No mode selection
No air from vents
Draft from vents

Poor heating
Poor cooling
Possible causes
Condenser clogged O
Condenser core restricted, accumulation of foreign matter O
Receiver clogged, inefficient desiccant O
Evaporator clogged O
Control wire jammed, incorrectly installed <M-A/C> O O O O
Lever bent O O O O
Lever sliding section worn, out of grease O O O O
<M-A/C>: Manual air conditioner

<F-A/C>: Fully automatic air conditioner
55-15
TROUBLESHOOTING
Rear Heater, Rear Air Conditioner
Symptoms

Reference Gr
No mode selection
No air from vents
Poor heating
Poor cooling
Possible causes
Rear blower motor coil open, shorted O
Rear blower motor relay contacts stuck closed, coil open, shorted O
Rear blower resistor malfunction O
Rear heater switch malfunction <R-H> O O O
Connector poor contact, harness open, faulty ground O O O O O
Fuse blown O O
<R-H>: Rear heater
55-16
ON-VEHICLE INSPECTION AND ADJUSTMENT 55

1. Operation Check of Air Conditioner
• Check the operation using the following flow chart.
Air conditioner is not effective
Within standard performance range
1.1 Check cooling performance (See later section.) Air conditioner operation is normal
Out of standard performance range
Abnormal
1.2 Check compressor operation (See later section.) Correct the problem
Normal
Abnormal
1.3 Check condenser operation (See later section.) Correct the problem
Normal
1.4 Measure refrigerant pressure (See later section.)
1.4 Remedy in accordance with measurement results

(See later section.)
Abnormal refrigerant
Equipment failure
quantity or trapped air
Repair air conditioner piping Correct the problem
2. Recover refrigerant (See later section.)
3. Charge refrigerant (See later section.)
Check air conditioner operation
55-17

1.1 Checking the cooling performance
• In the cooling performance check, measure the temperature dif-
ference between the outside air and air outlet, and the ambient
humidity, and check if the measurement is within the normal
range (shaded area in the graph).
• This check should be done under the following conditions:
• Engine speed: 1400 rpm
• Air conditioner switch: ON
• Fan switch: MAX
• Temperature control: MAX COOL
• Fresh/recirculation selection: Recirculation
• Doors: Fully opened
• Environment: No wind, in the shade
1.2 Checking compressor operation
• Check the following:
• Seizure or failure of compressor (See COMPRESSOR.)
• Magnet clutch failure (See COMPRESSOR.)
• Fusing of air conditioner relay contacts, open or short circuit in
relay coil (See Gr54.)
• Open or short circuit in dual pressure switch coil (See Gr54.)
• Heater control failure (See AIR CONDITIONING CONTROL,
FULLY AUTOMATIC AIR CONDITIONER SYSTEM.)
1.3 Checking condenser operation

• Check the following:
• Open or short circuit in condenser fan motor (See Gr54.)
• Fusing of condenser relay contacts, open or short circuit in re-
lay coil (See Gr54.)
• Clogging, crushed fins or contamination of condenser (See
CONDENSER, RECEIVER.)
55-18
55
1.4 Measuring refrigerant pressure
• The measurement should be performed under the following conditions:

• Engine speed: 825 rpm
• Air conditioner switch: ON
• Fan switch: MAX
• Temperature control: MAX COOL
• Fresh/recirculation selection: Recirculation
• Doors: Fully closed
• Environment: No wind, in the shade, humidity 50%
• Check if the measured pressure is within the limit range shown

in the characteristics graph. The pressure values in the graph
should be regarded as a reference since pressure values vary
depending on the measurement environment and vehicle condi-
tions.
A: Upper limit on the high pressure side
B: Lower limit on the high pressure side
C: Upper limit on the low pressure side
D: Lower limit on the low pressure side
• If the measurement is out of the standard value, take the neces-
sary measures by referring to the following table.
55-19

Measurement results Possible cause Remedy
Check for refrigerant leaks from piping
Pressure is too low on both the low and connections, and repair as required. (See
Refrigerant leakage
high pressure sides CONNECTING AIR CONDITIONER PIP-
ING.)
• Check the heater and cooling unit, and
repair as required. (See HEATER
Negative pressure on the low pressure • Clogged expansion valve AND COOLING UNIT, BLOWER.)
side • Clogged condenser • Check the condenser, and repair or re-
place as required. (See CONDENS-
ER, RECEIVER.)
• Too much refrigerant • Check the condenser, and repair or re-
• Poor cooling performance of condens- place as required. (See CONDENS-
Pressure is too high on both the low and er ER, RECEIVER.)
high pressure sides • Air trapped in refrigerant line • Check the compressor, and repair or
• Contamination or abnormal quantity of replace as required. (See COMPRES-
compressor lubricant SOR.)
Check the compressor, and repair or re-
Almost no difference in pressure between
Compressor failure place as required. (See COMPRES-
the low and high pressure sides
SOR.)
• After correcting the problem, recover all refrigerant and charge the specified quantity of refrigerant.
55-20
55
2. Recovery of Refrigerant
• Recover refrigerant from the air conditioning system in accordance with the following flow chart.
• Installation of the refrigerant recovery unit
Close both the low pressure and high pressure valves.
Connect the charge hose to the low pressure service valve.
Connect the charge hose to the high pressure service valve.
Connect the charge hose to the adapter valve.
Open both the low pressure and high pressure valves.
Open the adapter valve.
Run the recovery unit to collect the refrigerant.
55-21

3. Recharging the System with Refrigerant
Recharge
Continue
Prepare the system
Install the Start filling recharging
the air Vacuum with refrig- Refrigerant OK
refrigerant the system Airtightness OK to the
Start conditioner filling is erant until leakage Finish
charge with test specified
for completed. saturation test
unit. vacuum. charge
recharging. pressure is
level.
reached.
NG
Retighten the NG
pipe connections.
• Recharge the system with refrigerant in accordance with the following flow chart.
• Installation of the refrigerant charge unit
Connect the charge hose to the low pressure service valve.
Connect the charge hose to the high pressure service valve.
Connect the charge hose to the adapter valve.
Fill the system with vacuum.
Open both the low pressure and high pressure valves.
Open the adapter valve.
55-22
55
Run the vacuum pump.
Continue to run the pump for a minimum of 10 to 15 minutes. Close the adapter valve.
Stop the vacuum pump.
CAUTION
• Make sure that the adapter valve is closed before stopping the vacuum pump.
Wait for 5 minutes. During this interval, the readings on the gauges installed on the gauge manifold should stay where they are and should
not move towards zero.
Vacuum filling is now completed.
Recharging the system with refrigerant
With the adapter valve still closed, remove it from the vacuum pump. Connect the valve to the refrigerant container via the container valve.
Open the container valve and then the adapter valve.
Open the low pressure valve to fill refrigerant in gas form.
CAUTION
• Filling refrigerant into the system in liquid form may damage the compressor. To prevent this,
keep the refrigerant container in the upright position so that refrigerant is filled in gas form.
When the refrigerant container is empty, close the adapter valve and install a new container. Continue filling the system.
When the air conditioning system is saturated, start the engine. Turn on the air conditioner to run the compressor, and continue recharging
until the specified charge level is reached.
CAUTION
• Remove the refrigerant completely and charge the system with refrigerant of the quantity indicated on the
label. If the label is damaged or defaced, replace it with a new one.
• Charge the system with small amounts of refrigerant (approxi-

mately 25g) at a time while checking the air outlet temperature
and the change in pressure relative to the amount of charge of
refrigerant. Consider the system to be properly charged when
the pressure stops changing as shown in the graph.
• After the refrigerant charging has completed, perform cooling
performance check and refrigerant pressure measurement. (See
“1. Checking Air Conditioner Operation”.)
55-23
CONNECTING AIR CONDITIONER PIPING

1 Flange (pipe end) <Flange type>
2 Flange (mating end)
<Flange type>
3 O-ring
4 Pipe
5 Pipe <Nut type>
6 Union <Nut type>
7 Nut <Nut type>
A: Refrigerant oil application area

: Non-reusable parts

11.8 to 14.7
Fluid pipes –
{8.7 to 11.0, 1.2 to 1.5}
19.6 to 24.5
Nut High-pressure pipes –
{14 to 18, 2.0 to 2.5}
29.4 to 34.2
Low-pressure pipes –
{22 to 25, 3.0 to 3.5}
Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
O-ring
Refrigerant machine oil ND-OIL8 As required
Outer periphery of pipe end (area A)
• There are 2 types of air conditioner pipe/hose connections: flange type and nut type. When connecting/tightening
the connections, observe the following precautions.
CAUTION
• The connected parts are sealed by the O-ring. Be careful not to damage the O-ring, such as by twisting.
• The O-rings are exclusively designed for HFC-134a refrigerant and are not reusable.
• Never tighten the nut-type connection by rotating the union. This will deform the piping, allowing refrig-
erant to leak out. Tighten by rotating the nut while holding the union in position.
55-24
COMPRESSOR 55
Removal sequence
1 Discharge hose (high pressure
side)
2 Suction hose (low pressure side)
3 Belt (See Gr14.)
4 Compressor
5 Knock bushing
• Recover the refrigerant before discon-

necting the hose. (See “On-Vehicle In-
spection and Adjustment”.)
• See the CONNECTING AIR CONDI-

TIONER PIPING section for the instal-
lation of hose and pipe.
• After installation, tension the belt to
specification. (See Gr14.)
Inspection: Compressor
• Perform the following inspections. If any abnormality is found,
replace the compressor.
(1) Operation and oil leakage
• Check the compressor proper for malfunction and oil leakage.
(2) Magnetic clutch

• Disconnect the magnetic clutch harness connector and supply
power from the positive terminal of the battery to check if the
magnetic clutch operates normally.
CAUTION
• Do not allow the lead wire connected to the positive termi-
nal of the battery to touch any other component around the
connector. Otherwise, a short circuit will occur and the
component may fail.
55-25
CONDENSER, RECEIVER
Removal sequence
1 Side baffle plate 9 Condenser bracket
2 Upper baffle plate 10 Rubber plate
3 Lower baffle plate 11 Rubber plate
4 Discharge hose (compressor end) 12 Condenser rear bracket
5 Liquid hose (heater and cooling unit end) 13 Condenser
6 Liquid pipe (condenser end) 14 Condenser front bracket
7 Receiver
8 Condenser bracket
*a: Front shield panel
• Recover the refrigerant before disconnecting the hose and the pipe. (See “On-Vehicle Inspection and Adjust-
ment”.)
• See the CONNECTING AIR CONDITIONER PIPING section for the installation of hose and pipe.

Bolt (condenser rear bracket mounting) 50 to 65 {37 to 48, 5.1 to 6.6} –
55-26
55
Inspection: Condenser
• If the condenser fins are clogged with dirt, dust or other foreign
material wash it out. Any deformed fins should be straightened
using a spatula or the like.
55-27
HEATER CONTROL <MANUAL AIR CONDITIONER>
Removal sequence
1 Air mix control cable (NATURAL)
2 Mode selection control cable (LIGHT BLUE)
3 Heater controls
CAUTION
• Never remove the cable(s) from the heater controls except when the control cable(s) needs to be re-
placed. Failure to observe this may damage the hooks on the cable clip.
55-28
55
Work before removal
Adjustment: Temperature control knob
• Before disconnecting the control cables, turn the temperature
control knob of the heater controls to the MAX-COOL position.
Removal procedure
Removal: Control cables
• Before disconnecting the cables from the levers, put pairing
marks on each cable and its lever.
• Disconnect the control cables from the heater and cooling unit.
• In order that the control cables can be pulled back during instal-
lation, attach a string to the rings on the cables as shown in the
illustration.
55-29
HEATER CONTROL <MANUAL AIR CONDITIONER>

• Remove the heater controls from the instrument panel.
• Use snap ring pliers to disconnect the cable(s) from the heater
controls.
Work before installation

Adjustment: Heater controls knobs
• At the heater controls, turn the temperature control knob to the
MAX-HOT position and turn the mode selector knob to the DEF
position before reconnecting the control cables.
55-30
55
Installation procedure
Installation: Air mix control cable
• Connect the air mix control inner cable to the lever in the heater
control unit.
• Insert the air mix control outer cable into the clip on the heater
control while lightly pulling on the cable, and securely fasten the
cable with the clip.
• Turn the heater control unit’s temperature control knob to the
MAX-COOL position. Hold the knob at that position.
• Using the string attached to the control cable during the removal
procedure, pull the cable back.
• Connect the air mix control inner cable to the pin on the link le-
ver in the heater and cooling unit.
• Insert the air mix control outer cable into the clip on the heater
and cooling unit while lightly pulling on the cable, and securely
fasten the cable with the clip.
• Set the heater control unit’s temperature control knob to the
MAX-COOL and MAX-HOT positions to check that the link lever
properly moves to the corresponding positions. If the lever fails
to move correctly, repeat the cable installation steps from the be-
ginning.
Installation: Mode selection control cable

• Connect the end of the mode selection control inner cable to the
lever in the heater control unit.
• Insert the mode selection control outer cable into the clip on the
heater control unit while lightly pulling on the cable, and securely
fasten the cable with the clip.
• Move the control unit’s mode control knob to the DEF position.
Hold the knob in that position.
• Pull the control cable back using the string attached to the cable
during the removal procedure.
• Connect the other end of the mode selection control inner cable
to the pin on the link lever of the heater and cooling unit.
• Put the mode selection control outer cable positioning ring to the
side of the clip on the heater and cooling unit, and securely fas-
ten the cable with the clip.
• Set the heater control unit’s mode control knob to the FACE and
DEF positions to check that the lever properly moves to the cor-
responding positions. If the lever fails to move correctly, repeat
the cable installation steps from the beginning.
55-31
AIR DUCT
Removal sequence
1 Driver face duct 4 Defroster duct
2 Passenger face duct 5 Passenger foot duct
3 Center face duct 6 Driver foot duct
55-32
HEATER AND COOLING UNIT, BLOWER 55
Removal sequence
1 Heater hose (outlet) 8 Fresh/recirculation changeover motor
2 Heater hose (return) 9 Air inlet sensor <F-A/C>
3 Drain hose 10 Air intake box
4 Liquid hose (high pressure) 11 Blower and heater and cooling unit
5 Suction hose (low pressure)
6 Air filter F-A/C: Fully automatic air conditioner
7 Air filter
• Recover the refrigerant before disconnecting the hose. (See “On-Vehicle Inspection and Adjustment”.)
• See the CONNECTING AIR CONDITIONER PIPING section for the installation of hose and pipe.
55-33
REAR HEATER <CREW CAB>
Removal sequence
1 Rear heater switch 5 Heater hose (outlet)
2 Switch box 6 Plate
3 Foot duct 7 Joint duct
4 Heater hose (return) 8 Rear heater unit
55-34
Group 55E
Full Automatic
Air-conditioner
Pub.No.00ELT0001-55E
INDEX
SPECIFICATIONS ........................................................................... 55E-2

1. Overview .................................................................................... 55E-4
2. Electronic Control System ........................................................ 55E-5
3. Electronic Control Unit Schematic Diagram .............................. 55E-7
TROUBLESHOOTING
1. Inspection According to Diagnosis Code (Trouble Codes) ........ 55E-8
2. FUSO Diagnostics Service Data (Measured Values) ................ 55E-14
3. Actuator Test (Control) Using FUSO Diagnostics .................... 55E-16
4. Electronic Control Unit Input/Output Table .............................. 55E-18
INSPECTION OF ELECTRICAL PARTS ....................................... 55E-20
INSTALLED LOCATIONS OF PARTS .......................................... 55E-26
ELECTRICAL CIRCUIT DIAGRAM ............................................... 55E-44
55E-1
SPECIFICATIONS
Item Specifications
Type HFC134a
Refrigerant
Charged quantity g {oz} Indicated on the label
Mode selection
Damper change-
Air mixing Servomotor
over system
Fresh/recirculation changeover
Servomotor rated voltage V 12
Manufacturer DENSO
Heater and cool- Heating capacity W {kcal/h} 4600 ± 460 {3956 ± 396}
ing unit Cooling capacity W {kcal/h} 3650 ± 365 {3139 ± 314}
Temperature control system Air mixing type
Manufacturer DENSO
Blower
Rated voltage V 12
Manufacturer DENSO
Model 10S15C
3
Discharge cm {cu.in.}/1 rotation 167.3 {10.2}
Compressor Type ND-OIL8
without rear air
120 +15 +0.92
0 {7.32 0 }
Lubricant Quantity conditioner
cm3 {cu.in.} with rear air
200 +15 +0.92
0 {12.2 0 }
conditioner
Condenser Rated voltage V 12
Rated current A 9.0 ± 0.5
Receiver 3
Capacity cm {cu.in.} 300 {18.3}
55E-2
55E
M E M O
55E-3

1. Overview
• The fully automatic air conditioner system automatically determines the following parameters to always maintain
the optimum condition for a selected temperature.
• Blow-off air temperature
• Air outlets
• Air flow rate
• Air intake port (inside and outside air changeover)
• Compressor ON/OFF
• These controls are achieved by the control unit built in air conditioner control unit and control panel; it calculates
the temperature control command value using the information from the various sensors provided indoors and out-
doors and the temperature control map to determine the operating amount of each actuator.
1.1 System composition
55E-4
55E
2. Electronic Control System
2.1 System block diagram
Input Air conditioner control unit and Output

control panel
Thermostat Mode motor

Temperature control
Air inlet sensor Air flow rate control Air mixing motor
Air outlet control
Photo sensor Air inlet control Fresh/recirculation changeover motor
Compressor control
In car sensor Warmup control Power transistor
Backup mode function

Blower motor
Diagnosis function
Condenser fan motor
Electric signal Signal detect and Condenser fan relay

actuation modules
Controller area
network signal
Dual pressure switch
Diagnostics connector Engine electronic control unit Magnetic clutch
Part name Major function or operation

Thermostat Detection of temperature of air passed through evaporator
Air inlet sensor Detection of outside air temperature
Photo sensor Detection of sunlight intensity
In car sensor Detection of inside air temperature
Mode motor Changeover of mode damper
Air mixing motor Changeover of air mixing damper
Fresh/recirculation changeover motor Changeover of inside and outside air damper
Power transistor Regulator of blower motor operating voltage
Blower motor Operation of blower fan
Condenser fan motor Refrigerant cooling
Condenser fan relay Operation of blower fan motor
Dual pressure switch Detection of refrigerant pressure
Magnetic clutch Operation of compressor
Engine electronic control unit Detection of engine coolant temperature
Control of power supply to relevant devices
SAM * Repeating of signals transmitted via controller area network
from airbag electronic control unit to send them to relevant de-
vices
Communication with air conditioner electronic control unit and
FUSO Diagnostics (diagnostics connector)
control panel
* : SAM (Signal detect and actuation modules)
55E-5

2.2 Fully automatic air conditioner control functions
(1) Temperature control
• The air conditioner control unit & control panel operates air mixing motor to adjust the opening of the air mixing
damper.
(2) Air flow rate control
• In the auto fan mode, the air conditioner control unit & control panel changes the base voltage of power transistor,
thereby changing the drive voltage of blower motor to control the air delivery rate.
• In the warmup control mode, it controls the blower motor depending on the signals from water temperature sen-
sor.
(3) Air outlet control
• In the auto air outlet control mode, the air conditioner control unit & control panel operates mode motor to adjust
the openings of the individual dampers (DEF, FACE, FOOT).
• There are 5 selectable positions: FACE, FACE/FOOT, FOOT, FOOT/DEF, and DEF. They are numbered as -1, -2,
-3, -4, and -5 in this order.
(4) Air inlet control
• The air selector motor switches the air mode between inside air recirculation and outside air introduction accord-
ing to the conditions established as a result of manual selections.
Condition Damper position
MAX COOL is selected when both the mode and fan speed controls are in
Inside air recirculation Inside air position
AUTO.
• MAX HOT is selected when both the mode and fan speed controls are
Outside air introduction in AUTO. Outside air position
• DEF position is selected.
• If the above conditions are not met when both the mode and fan speed controls are in AUTO, the damper posi-
tion is automatically adjusted between the inside air and outside air positions according to the temperature.
(5) Compressor control
• In the auto mode, the air conditioner control unit & control panel operates compressor in economy mode (ON/
OFF).
(6) Warmup control
• When the following conditions are satisfied, the air conditioner control unit & control panel interrupts air outlet and
air flow rate controls, initiating warmup control.
<Automatic mode control>
• Mode: AUTO
• Engine coolant temperature: 60°C {140°F}
<Automatic fan speed control>
• Fan speed: AUTO
• Mode: Other position than FACE and DEF
• Engine coolant temperature: 50°C {122°F}
After warmup control, the air conditioner control unit & control panel enters the auto mode.
(7) Backup function
• The air conditioner control unit & control panel in air conditioner control unit and control panel keeps the set tem-
perature and the setting conditions of all the switches in the memory unless the battery terminals are disconnect-
ed.
2.3 Diagnosis function

• Each time the starter switch is set to ON, the air conditioner control unit & control panel performs a self-diagnostic
to ensure that all the sensors, etc. are in order. If any of them is found to be defective, the air conditioner control
unit & control panel stores the defective element in memory, and enters the backup mode.
• The air conditioner control unit limits the function of the system to keep the vehicle safety when the system is fail-
ing. The defective element stored in memory can be called out in terms of a diagnosis code by an Multi-Use
Tester or the diagnosis switch. (See Gr00.)
55E-6
55E
3. Electronic Control Unit Schematic Diagram
55E-7
TROUBLESHOOTING
1. Inspection According to Diagnosis Code (Trouble Codes)
1.1 List of diagnosis code
warning lamp
indication
Interior temperature sensor open circuit - Voltage above normal or shorted to
170-3 -
high source
Interior temperature sensor short circuit - Voltage below normal or shorted to
170-4 -
low source
Ambient temperature sensor open circuit - Voltage above normal or shorted to
171-3 -
high source
Ambient temperature sensor short circuit - Voltage below normal or shorted to
171-4 -
low source
Communication with the CAN-bus has a malfunction. - Received network data
639-19 -
is in error
Evaporator temperature sensor open circuit - Voltage above normal or shorted
1547-3 -
to high source
Evaporator temperature sensor short circuit - Voltage below normal or shorted
1547-4 -
to low source
Solar radiation sensor short circuit - Voltage below normal or shorted to low
2610-4 -
source
Mode door feedback potentiometer open circuit - Voltage above normal or
3981-3 -
shorted to high source
Mode door feedback potentiometer short circuit - Voltage below normal or
3981-4 -
shorted to low source
Mode door actuator stuck - Mechanical system not responding or out of adjust-
3981-7 -
ment
3985-12 The control unit has an internal fault. - Bad intelligent device or component -
Air mix door feedback potentiometer open circuit - Voltage above normal or
3986-3 -
shorted to high source
Air mix door feedback potentiometer short circuit - Voltage below normal or
3986-4 -
shorted to low source
Air mix door actuator stuck - Mechanical system not responding or out of ad-
3986-7 -
justment
CAN: Controller Area Network communication
55E-8
55E
1.2 Code generation criteria and inspection item
170-3: Interior temperature sensor open circuit - Voltage above normal or shorted to high source
Generation condition • Output voltage of inside air temperature sensor is 4.9 V or higher.
Recoverability • System recovers normal state when sensor voltage becomes normal.
• If starter switch is turned to ON when faulty condition exists: Default values
are invariably assumed.
Control effected by electronic control unit
• If faulty condition occurs while starter switch is in ON position: Values just
before occurrence of fault are invariably assumed.
• Open signal harness between air conditioner electronic control unit & control
panel and inside air temperature sensor
• Open ground harness between air conditioner electronic control unit & con-
trol panel and inside air temperature sensor
Possible causes
• Short circuit to power supply of signal harness between air conditioner elec-
tronic control unit & control panel and inside air temperature sensor
• Faulty inside air temperature sensor
• Faulty air conditioner electronic control unit & control panel
170-4: Interior temperature sensor short circuit - Voltage below normal or shorted to low source
Generation condition • Output voltage of inside air temperature sensor is 0.1 V or lower.
Recoverability • System recovers normal state when sensor output voltage becomes normal.
• Shorted signal harness between air conditioner electronic control unit & con-
trol panel and inside air temperature sensor
Possible causes
• Faulty inside air temperature sensor
171-3: Ambient temperature sensor open circuit - Voltage above normal or shorted to high source
Generation condition • Output voltage of outside air temperature sensor is 4.9 V or higher.
panel and outside air temperature sensor
trol panel and outside air temperature sensor
Possible causes
tronic control unit & control panel and outside air temperature sensor
• Faulty outside air temperature sensor
171-4: Ambient temperature sensor short circuit - Voltage below normal or shorted to low source
Generation condition • Output voltage of outside air temperature sensor is 0.1 V or lower.
trol panel and outside air temperature sensor
Possible causes
• Faulty outside air temperature sensor
55E-9
TROUBLESHOOTING
639-19: Communication with the CAN-bus has a malfunction. - Received network data is in error
Generation condition • There is some controller area network communications problem.
• System recovers normal state when all of the following conditions are met.
• Communication bus is not in off state.
Recoverability
• Message indicating normal speed range is being received.
• Message indicating normal coolant temperature range is being received.
• Default value is invariably assumed for non-received controller area network
message.
• Controller area network communications bus is open, shorted to power sup-
ply, shorted to ground, or otherwise shorted.
Possible causes • Faulty malfunction signal detect and actuation modules for resistors in air
conditioner electronic control unit & control panel.
• Faulty air conditioner electronic control unit & control panel.
1547-3: Evaporator temperature sensor open circuit - Voltage above normal or shorted to high source
Generation condition • Output voltage of thermostat is 4.9 V or higher.
• System recovers normal state when thermostat output voltage becomes nor-
Recoverability
mal.
panel and thermostat
trol panel and thermostat
Possible causes
tronic control unit & control panel and thermostat
• Faulty thermostat
1547-4: Evaporator temperature sensor short circuit - Voltage below normal or shorted to low source
Generation condition • Output voltage of thermostat is 0.1 V or lower.
• System recovers normal state when thermostat output voltage becomes nor-
Recoverability
mal.
trol panel and thermostat
Possible causes
• Faulty thermostat
2610-4: Solar radiation sensor short circuit - Voltage below normal or shorted to low source
Generation condition • Output voltage of photo sensor is 0.1 V or lower.
• System recovers normal state when photo sensor output voltage becomes
Recoverability
normal.
Control effected by electronic control unit • Photo sensor output voltage is invariably assumed to be 0 W.
trol panel and photo sensor
Possible causes
• Faulty photo sensor
CAN: Controller Area Network communication
55E-10
55E
3981-3: Mode door feedback potentiometer open circuit - Voltage above normal or shorted to high source
Generation condition • Output voltage of potentiometer inside the mode motor is 4.9 V or higher.
• System recovers normal state when potentiometer output voltage becomes
Recoverability
normal.
Control effected by electronic control unit • Air mixing actuator is not driven any further.
• Short circuit to power supply (5 V and/or 24 V) of signal harness between air
conditioner electronic control unit & control panel and mode motor
Possible causes
trol panel and mode motor
• Faulty potentiometer inside the mode motor
3981-4: Mode door feedback potentiometer short circuit - Voltage below normal or shorted to low source
Generation condition • Output voltage of potentiometer inside the mode motor is 0.1 V or lower.
• System recovers normal state when potentiometer output voltage becomes
Recoverability
normal.
Control effected by electronic control unit • Mode actuator is not driven any further.
• Short circuit to ground of signal harness between air conditioner electronic
control unit & control panel and mode motor
• Open power harness between air conditioner electronic control unit & control
Possible causes
panel and mode motor
• Faulty potentiometer inside the mode motor
3981-7: Mode door actuator stuck - Mechanical system not responding or out of adjustment
• Mode motor is stopped from being driven if potentiometer output does not
Generation condition vary 12 bits or more. This code is set after consecutive 5 stop-and-restart cy-
cles of mode motor after it is first stopped.
• System recovers normal state when potentiometer varies more than 12 bits
Recoverability
when air mixing motor is driven.
• Repeats stop-and-restart cycles as many time as required to reach the tar-
get.
• Foreign material caught in mode dampers (DEF, FACE, and FOOT) and
Possible causes
links.
3985-12: The control unit has an internal fault. - Bad intelligent device or component
Generation condition • There is some problem inside electronic control unit.
• System recovers normal state when all of the following conditions are met.
Recoverability • Both writing and reading into EEPROM complete successfully.
• Resetting completes successfully.
• When EEPROM is faulty: Battery backup data is used as substitute.
• When reset circuit is faulty: Normal resetting is impossible.
Possible causes • Faulty air conditioner electronic control unit & control panel.
3986-3: Air mix door feedback potentiometer open circuit - Voltage above normal or shorted to high source
Generation condition • Output voltage of air mixing motor is 4.9 V or higher.
• System recovers normal state when output voltage of air mixing motor be-
Recoverability
comes normal.
Control effected by electronic control unit • Electronic control unit causes air mixing motor to stop.
• Short circuit to power supply (5 V and/or 24 V) of signal harness between air
conditioner electronic control unit & control panel and air mixing motor
Possible causes
trol panel and air mixing motor
• Faulty potentiometer inside the air mixing motor
55E-11
TROUBLESHOOTING
3986-4: Air mix door feedback potentiometer short circuit - Voltage below normal or shorted to low source
Generation condition • Output voltage of air mixing motor is 0.1 V or lower.
• System recovers normal state when air mixing motor output voltage be-
Recoverability
comes normal.
Control effected by electronic control unit • Air mixing actuator is not driven any further.
• Short circuit to ground of signal harness between air conditioner electronic
control unit & control panel and air mixing motor
• Open power harness between air conditioner electronic control unit & control
Possible causes
panel and air mixing motor
• Faulty potentiometer inside the air mixing motor
3986-7: Air mix door actuator stuck - Mechanical system not responding or out of adjustment
• Air mixing motor is stopped from being driven if potentiometer output does
Generation condition not vary 12 bits or more. This code is set after consecutive 5 stop-and-restart
cycles of mode motor after it is first stopped.
• System recovers normal state when potentiometer output varies more than
Recoverability
12 bits.
• Repeats stop-and-restart cycles of air mixing motor as many time as re-
quired to reach the target.
Possible causes • Foreign material caught in air mixing damper and links.
55E-12
55E
M E M O
55E-13
TROUBLESHOOTING
Current value
group
Detected by the in-car sensor.
Ambient temperature -20.20 to 117.5°F
0.12 to 4.86 V
Detected by the air inlet sensor.
Vehicle interior temperature -20.20 to 117.5°F
0.12 to 4.86 V
Temperature
values Detected by the thermostat.
Evaporator temperature -20.20 to 117.5°F
0.12 to 4.86 V
Detected by the photo sensor.
Solar value 0 to 1559W 0.12 to 5 V
Measured values are changed by direct sunlight only.
Temperature motor output Shows the value of the photometer in the air mixing motor.
0 to 100%
Feedback 0.12 to 4.86 V
Mode B/L1
Mode B/L2
Mode B/L3
Mode Def/Foot1 Shows the damper value of the photometer in the mode
Mode motor output Feed-
Mode Def/Foot2 motor.
back
Mode Def/Foot3 0.12 to 4.86 V
Mode Foot
Mode Def
Mode Face
Shows the output value of the air conditioner.
ON: Approx. 0 V
Compressor output ON/OFF
OFF: Supply voltage from SAM (Signal detect and actua-
tion modules)
Shows the output value of the fresh/recirculation
Fresh/Recirculate motor changeover motor.
Fresh/Recirculate
output Fresh mode Pin 23: Approx. 0 V
Recirc. mode Pin 24: Approx. 0 V
Status of elec-
Shows the output value of the air mixing motor.
tric motor
Temperature motor output 0 to 100% When the air mixing motor is running:
Voltage between pins 1 and 2: Approx. -11 to 11 V
Fan OFF/
Fan speed 1/
Fan speed 2/
Fan speed 3/
Shows the output value of the blower motor.
Blower fan output Fan speed 4/
Voltage between pins 14 and 31: Approx. 0 to 12 V
Fan speed 5/
Fan speed 6/
Fan speed 7/
Fan speed 8
Mode B/L1
Mode B/L2
Mode B/L3
Mode Def/Foot1 Shows the output value of the mode motor.
Mode motor output Mode Def/Foot2 When the mode motor is running:
Mode Def/Foot3 Voltage between pins 21 and 22: Approx. -11 to 11 V
Mode Foot
Mode Def
Mode Face
55E-14
55E
Current value
group
Auto/
Fresh/Recirculate switch Fresh/ Shows the state of the fresh/recirculate switch.
Recirculate
Air conditioning switch Auto/OFF/ON Shows the state of the air conditioning switch.
Mode B/L1
Mode B/L2
Mode B/L3
Mode Def/Foot1
Mode Def/Foot2
Mode dial position Shows the mode dial position.
Mode Def/Foot3
Mode Auto
Mode Foot
Mode Def
Switch status
Mode Face
Fan speed Auto/
Fan OFF/
Fan speed 1
Fan speed 2
Fan speed 3
Fan dial position Shows the fan dial position.
Fan speed 4
Fan speed 5
Fan speed 6
Fan speed 7
Fan speed 8
Shows the temperature dial position.
Temperature dial position 19 to 31°F
19 (max. cool) to 31 (max. hot)
Coolant temperature -40.00 to 210.0°F Shows the coolant temperature data.
Other actual Reserved/ Shows the switch illumination state.
values Switch illumination OFF/ Voltage between pins 27 and 28: Approx. 12 V when ON,
ON Approx. 0 V when OFF
55E-15
TROUBLESHOOTING
Selection Description
Drives the compressor output (pin 26).
The actuator test cannot be performed when the blower motor is OFF.

+12V (M): ON
Compressor outlet
Blower fan: ON
[Checking method]
Confirm that cold air comes out after the activation sound of the magnetic
clutch is heard.
Drives the fresh/recirculation changeover motor output (pins 23 and 24).
Wait for 1.5 seconds before switching the motor.

+12V (M): ON
Fresh/recirculation changeover motor output Turn off the blower fan and drive the vehicle.
Switch the motor between the fresh air and recirculation modes.
[Checking method]
Confirm that air comes out from the outlet in the fresh air mode.
Confirm that air does not come out from the outlet in the recirculation mode.
Drives the air mixing motor output (pins 1 and 2).

+12V (M): ON
Temperature motor output: Low (2 to 18%)
Temperature motor output
Temperature motor output: Center (42 to 58%)
Temperature motor output: High (82 to 98%)
[Checking method]
Confirm that the motor output feedback follows the motor output.
Drives the condenser fan motor output (pin 13).

+12V (M): ON
Blower motor: OFF
Blower motor speed setting: 1 to 8
Blower fan outlet
[Checking method]
When the blower motor is OFF, confirm that air does not come out from the
outlet.
When a blower motor speed is selected, confirm that air comes out from the
outlet and that the airflow rate corresponds to the selected speed.
Drives the mode motor output (pins 21 and 22).

+12V (M): ON
1=Face
2=BL1
3=BL2
4=BL3
Mode motor outlet
5=Foot
6=DF1
7=DF2
8=DF3
9=Front windshield
[Checking method]
Confirm that air comes out from the same outlet as the selected mode.
55E-16
55E
M E M O
55E-17
TROUBLESHOOTING
4. Electronic Control Unit Input/Output Table
• See the Electronic Control Unit Schematic Diagram for the pin locations of each signal and ground.
Devices to be connected Terminal Input/output Voltage and wave form

[Measurement condition]
Disconnect the electronic control unit and har-
In car sensor 37-9 In ness, then inspect on the vehicle-side connector.
[Judgment criteria]
See 54-#256.
Air inlet sensor 35-9 In ness, then inspect on the vehicle-side connector.
[Judgment criteria]
See 54-#253.
Thermostat 36-9 In ness, then inspect on the vehicle-side connector.
[Judgment criteria]
See 54-#751.
[Judgment criteria]
Potentiometer of air mixing motor 34-9 Out • Lever position Max. hot: 4.0 ± 0.03 V
• Lever position Max. cool: 1.0 ± 0.03 V
[Judgment criteria]
Potentiometer of mode motor 33-9 Out • Lever position Face: 4.5 ± 0.03 V
• Lever position Def.: 0.5 ± 0.03 V
55E-18
55E
M E M O
55E-19
INSPECTION OF ELECTRICAL PARTS

#201 Inspection of relay (normally open type 5 pin)
• Perform continuity check and operation check, and if any fault is
#251 Inspection of photo sensor

• Turn the starter switch to the ON position with the photo sensor
connected to the control panel connector.
• Measure the voltage output from between terminal 2 and body
ground while shining light on the light receiving part of the sen-
sor.
Inspection condition: Move an
1 to 5V
electric lamp of approx. 60 watts
Standard (Voltage decreases
up and down right above the
value when the lamp is
photo sensor (150 mm {5.91 in.}
closer.)
at closest point).
#253 Inspection of air inlet sensor

55E-20
55E
#256 Inspection of in car sensor
#411 Inspection of blower motor

#413 Inspection of air mixing motor

MAX HOT (+) 6–7 (–)
MAX COOL (+) 7–6 (–)
CAUTION
• Stop applying voltage when the lever has stopped.
• After inspecting the motor, return the lever to a position be-
tween MAX HOT and MAX COOL.
55E-21

MAX HOT 4 ± 0.03
MAX COOL 1 ± 0.03
#414 Inspection of mode motor

FACE (+) 6–7 (–)
DEF (+) 7–6 (–)
CAUTION
• Stop applying voltage when the lever has stopped.
• After inspecting the motor, return the lever to a position be-
tween FACE and DEF.

FACE 4.5 ± 0.03
DEF 0.5 ± 0.03
#415 Inspection of fresh/recirculation changeover motor

REC (inside air) (+) 3–2 (–)
FRE (outside air) (+) 3–1 (–)
CAUTION
• Stop applying 12 volts DC if the lever stops spontaneously
at the REC or FRE position.
55E-22
55E
#431 Inspection of condenser fan motor
• If any fault is found, replace condenser. (See Gr55.)
#751 Inspection of thermostat

• Measure the output voltage between terminals 1 and 2 at the
specified temperatures.
the table at left, replace the sensor.
#752 Inspection of power MOS-FET (transistor)

the power transistor. (See Gr55.)
• Start the engine and operate the blower with the HI setting.
Confirm that the rate of air flow from the blower corresponds
to the HI level.
• Next, gradually decrease the air flow rate by operating the
control panel and confirm that the rate of air flow from the
blower gradually decreases.
• Confirm that there is no problem in the blower motor, wiring,
air conditioner electronic control unit and control panel. If the
blower motor does not rotate in this condition, the power
MOS-FET (transistor) is faulty.
55E-23

#828 Inspection of controller area network resistor
• Measure the resistance of the resistor number marked on the
controller area network resistor.
1 270 ± 13.5 Ω
2 510 ± 25.5 Ω
3 820 ± 41 Ω
4 1300 ± 65 Ω
5 2000 ± 100 Ω
6 3300 ± 165 Ω
Standard value 7 5600 ± 280 Ω
Resistor No.
(at 20°C {68°F})
8 15000 ± 750 Ω
9 390 ± 19.5 Ω
10 4300 ± 215 Ω
11 9100 ± 455 Ω
120 ± 6 Ω
12 (for controller area
network resistor)
• If the measurement is out of specification, replace the controller
area network resistor with one that has the same resistor num-
ber and same specified resistance.
CAUTION
The controller area network resistor are matched to the en-
gine. If you replace any of them, be sure to replace it with one
that has the same resistor number.
55E-24
55E
M E M O
55E-25
INSTALLED LOCATIONS OF PARTS
55E-26
55E
M E M O
55E-27
55E-28
55E
55E-29
55E-30
55E
55E-31
55E-32
55E
M E M O
55E-33
55E-34
55E
55E-35
55E-36
55E
55E-37
55E-38
55E
55E-39
55E-40
55E
55E-41
INSTALLED LOCATION OF PARTS
Wire diameter -
Location Circuit No. Destination Remarks
wire color
[12] CFE1 1.25-B Condenser fan motor
[13] EAB1 8-B SAM ECU (8C)
SAM : Signal detect and actuation modules
55E-42
55E
M E M O
55E-43
ELECTRICAL CIRCUIT DIAGRAM
55E-44
55E
55E-45

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320 TAIL, PARKING AND LICENSE PLATE LAMPS CIRCUIT 54-03

325 STOP LAMP CIRCUIT

330 TURN SIGNAL AND HAZARD LAMP CIRCUIT 54-03

340 BACKUP LAMP CIRCUIT

345 CAB LAMP CIRCUIT

348 ILLUMINATION LAMP CIRCUIT

349 IDENTIFICATION AND SIDE MARKER LAMP CIRCUIT 54-03

352 VAN BODY DOME LIGHT CIRCUIT

54-04 METER CIRCUIT

401 METER CLUSTER INTERNAL CIRCUIT

410 TACHOMETER CIRCUIT

412 SPEEDOMETER CIRCUIT 54-04

415 TACHOGRAPH CIRCUIT

420 FUEL GAUGE CIRCUIT 54-04

425 WATER TEMPERATURE GAUGE CIRCUIT

54-05 INDICATOR AND WARNING LAMP

510 PARKING BRAKE INDICATOR CIRCUIT

515 BRAKE WARNING CIRCUIT 54-05

536 ENGINE OIL PRESSURE WARNING CIRCUIT

537 OVERHEATING WARNING CIRCUIT 54-05

550 CAB TILT WARNING CIRCUIT

554 STARTER KEY REMOVAL REMINDER ALARM CIRCUIT 54-05

566 FUEL FILTER CIRCUIT

54-06 CAB SIDE ELECTRICAL CIRCUIT

610 CIGARETTE LIGHTER CIRCUIT

612 AUDIO CIRCUIT 54-06

614 WIPER AND WASHER CIRCUIT

616 HORN CIRCUIT 54-06

620 HEATER AND AIR-CONDITIONER CIRCUIT

622 POWER WINDOW AND CENTRAL DOOR LOCK CIRCUIT

629 MIRROR HEATER CIRCUIT 54-06

654 KEYLESS ENTRY CIRCUIT

54-08 ENGINE AND TRANSMISSION

810 FOUR-WHEEL DRIVE CIRCUIT

850 TRANSMISSION POWER TAKE-OFF CIRCUIT 54-08

54-09 OTHER CIRCUIT

905 JOINT CONNECTOR (J/C)

54-10 ELECTRICAL EQUIPMENT

A SWITCH AND SENSOR

A SWITCH AND SENSOR

B RELAY AND ELECTRONIC CONTROL UNIT

B RELAY AND ELECTRONIC CONTROL UNIT

C METER AND MOTOR

J JOINTS OF MAIN HARNESS CONNECTORS

J JOINTS OF MAIN HARNESS CONNECTORS

T SWITCH AND SENSOR

T SWITCH AND SENSOR

T SWITCH AND SENSOR

U FUSE, RELAY AND ELECTRONIC CONTROL UNIT

V MAGNETIC VALVE, MOTOR AND BUZZER

W JOINTS OF MAIN HARNESS CONNECTORS

W JOINTS OF MAIN HARNESS CONNECTORS

54-11 INSPECTION OF ELECTRICAL

#001 to #179 SWITCH

#002 Inspection of starter switch

#023 Inspection of vacuum switch

(1) Inspection without applying negative pressure

#034 Inspection of rear heater switch

#035 Inspection of door switch