Opel Frontera 1998 2002 Workshop Manual Vol 2

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7A1–8 TRANSMISSION CONTROL SYSTEM (4L30–E)

Gear Shift Control

F07RT034
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–9

Winter Drive Mode


1. Operation
The winter switch will operate when switched on after
all of the following conditions are present:
a. The gear select position is “D”, “N”, “R” and “P”
range.
b. Vehicle speed is 7 mph (11 km/h) or less.
c. Transmission oil temperature is 130 C (266 F) or
less.
d. Kickdown switch is off.
e. Accelerator opening is at 8% or less.
2. Cancel Release
1. Cancellation by driver
a. Turning off the winter drive mode switch
b. Shifting select position to “3”, “2”, or “L” (Winter
drive mode is not canceled by selecting “N”, “R”,
or “P” from “D”)
c. Ignition key is turned off.
2. Automatic cancellation
a. When vehicle runs at 19mph (30 km/h) (6VD1) or
21 mph (34 km/h) (6VE1) or more for 1 second or
more
b. When transmission oil temperature reaches
130 C (266 F) or above
NOTE: The mode returns to normal drive mode or power
drive mode after the winter drive mode is canceled.

Backup Mode
If a major system failure occurs which could affect safety
or damage the transmission under normal vehicle
operation, the diagnostic system detects the fault and
overrides the Powertrain Control Module (PCM).
The “CHECK TRANS” light flashes to alert the driver, and
the transmission must be manually shifted as follows:
Select lever position Gear Ratio Selected
D 4 (Fourth)
Manual 3 4 (Fourth)
Manual 2 3 (Third)
Manual L 1 (First)
R Reverse

Shifts are firmer to prevent clutch slip and consequent


wear. The fault should be corrected as soon as possible.
7A1–10 TRANSMISSION CONTROL SYSTEM (4L30–E)

Functions of Input / Output Components


Components Function
Speed sensor Senses rotation of output shaft and feeds the data to Powertrain Control Module
(fixed to transmission (PCM).
(T/M))
Throttle position sensor Senses the extent of throttle valve opening and the speed of the throttle valve
(TPS) lever motion to open the valve. Feeds the data to PCM.
(fixed to engine)
Brake Switch (SW) Senses whether the driver has pressed the brake pedal or not and feeds the
I (fixed to brake pedal) information to PCM.
N Kickdown SW Senses whether the driver has pushed the accelerator pedal fully or not, and
P (fixed to accelerator pedal) feeds the information to PCM.
U
T Mode SW (fixed to T/M) Senses the select lever position, and feeds the information to PCM.
Power drive SW Senses whether the driver has selected the power mode, and feeds the
S (fixed to front console) information to PCM.
I
G T/M oil temp. sensor Senses the T/M oil temperature and feeds the data to PCM
N Engine coolant tempera- Senses the engine coolant temperature, and feeds the data to PCM.
A ture sensor
L
Engine speed signal Feeds the signals monitoring engine speed to PCM from crank angle sensor.
Air conditioning information Senses whether the air conditioner has been switched on or not, and feeds the
information to PCM.
Winter switch (fixed to front Senses whether the driver has selected the winter mode, and feeds the informa-
console) tion to PCM.
Cruise controller * (Over- Downshift takes place when Overdrive OFF signal is received from auto cruise
drive OFF signal) control unit.
Shift solenoid A, B Selects shift point and gear position suited to the vehicle running condition on
the basis of PCM output.
S
O Band apply solenoid Controls oil flow suited to the vehicle running condition on the basis of PCM
O L output.
U E Torque Converter Controls clutch engagement/disengagement suited to the vehicle running
T N Clutch solenoid condition on the basis of PCM output.
P O
Force motor Adjusts the oil pump delivery pressure to line pressure suited to the vehicle
U I
(Pressure regulator running condition on the basis of PCM output.
T D
valve)
S Power drive mode lamp Informs the driver whether the vehicle is in power mode or not.
I
Winter drive mode lamp Informs the driver whether the vehicle is in winter mode or not.
G
N T/M monitor lamp Informs the driver of failure in the system.
A (“CHECK TRANS”)
L ATF warning lamp Lights when ATF oil temperature rises.
ABS signal * When the select lever is at “Reverse” or “L” range, sends a signal to the ABS
controller as one of the ABS control conditions.

* If equipped
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–11

Diagnosis 3. Push “F2” on Tech2 to see the Diagnostic Trouble


Code (DTC):
Electronic Diagnosis 4. Do you have a DTC?
How To Diagnose The Problem YES: write down all code numbers and do the DTC
CHECK
1. To avoid incorrect diagnostics, this book needs to be NO: the DTC can not help you finding the problem.
followed accurately. Unless stated, do not jump
directly to a section that could contain the solution. 1. GOTHROUGH “CHECK TRANS” CHECK
Some important information may be missed. 2. IF it is flashing and the flash is 0.2 seconds ON
2. The sections in CAPITALS and bold are the main and 0.2 seconds OFF, this means that you should
sections that can be found in the contents. have a DTC stored. Please recheck GOTO
DIAGNOSTIC CHECK and if you find the same
3. The GOTO “SECTION” means to continue to check
problem, replace the Powertrain Control Module
going to the “section”.
(PCM).
4. The GOTHROUGH “SECTION” means to go
through the “section” and then to go back to the place Normal
the GOTHROUGH was written.
5. BASIC ELECTRIC CIRCUITS:
You should understand the basic theory of electricity.
This includes the meaning of voltage, amps, ohms,
and what happens in a circuit with an open or shorted
wire. You should also be able to read and understand
wiring diagrams.

Check Trans Indicator


Find CHECK TRANS indicator and verify if it is
A. Flashing: GOTO DIAGNOSTIC CHECK.
B. Staying on: GOTHROUGH CHECK TRANS
CHECK.
C. Is never ON when the ignition key is turned on:
GOTHROUGH CHECK TRANS CHECK
D. Is ON during 2 seconds at ignition but OFF after:
Normal operation. No DTC or malfunction.
C07RW047

Abnormal

821RW261

Diagnostic Check
C07RW048
This test determines if the transmission or its inputs,
outputs, connections, or sensors are failing.
1. Connect the Tech2: GOTHROUGH Tech2 OBD II
CONNECTION.
2. Turn on the ignition but not the engine.
7A1–12 TRANSMISSION CONTROL SYSTEM (4L30–E)

“Check Trans” Check Abnormal


1. Indicator it is ON during 2 seconds at ignition (or when
the engine is cranked) but it is OFF after the engine
starts. The indicator is working normally GOTO
DIAGNOSTIC CHECK.

C07RW048

3. Indicator it is staying ON always when Ignition is ON.


1. This means that connection between the lamp
and the PCM is shorted to ground.
821RW261
2. Verify if instrument panel terminal 3 of connector
I–9 is shorted to ground.
Normal
3. Verify if the PCM connector J1 (RED) terminal
A14 is shorted to ground.
4. Verify that the instrument panel terminal 15 of
connector I–9 is connected to battery.
5. IF problem solved: GOTO CHECK TRANS
INDICATOR.
NO:Replace Powertrain Control Module (PCM).
4. Indicator it is staying OFF with the ignition ON (engine
OFF).
1. This means that connection between the lamp
and the PCM is shorted to battery or opened.
2. Verify if instrument panel terminal 3 of connector
I–9 is shorted to battery or open.
3. Verify if the PCM connector J1 (RED) terminal
A14 is shorted to battery or open.
4. Verify that the instrument panel terminal 15 of
C07RW047
connector I–9 is connected to battery. If not,
2. Indicator it is flashing and the flash is 0.2 seconds ON check the fuses and the connections voltage.
and 0.2 seconds OFF always when ignition is on 5. IF problem solved: GOTO CHECK TRANS
(engine cranked or not). This means that there is a INDICATOR.
malfunction. GOTO DIAGNOSTIC CHECK.
NO: Replace Powertrain Control Module (PCM).
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–13

D07RW028

Tech2 OBD II Connection 2. SAE 16/19 adapter (3000098) (1), RS 232 loop
In order to access OBD II Powertrain Control Module back connector (3000112) (2), and PCMCIA card
(3000117) (3).
(PCM) data, use of the Tech2 scan tool kit (7000086) is
required.
1. The electronic diagnosis equipment is composed of:
1. Tech2 (7000057) hand–held scan tool unit and
DLC cable (3000095).

F07RW033

901RW176
7A1–14 TRANSMISSION CONTROL SYSTEM (4L30–E)
2. Connecting the TECH2

901RW180

Legend (3) SAE 16/19 Adapter


(1) PCMCIA Card (4) DLC Cable
(2) RS 232 Loop Back Connector (5) Tech2

Before operating the Isuzu PCMCIA card with the 2. Connect the SAE 16/19 adapter (3) to the DLC
Tech 2, the following steps must be performed: cable (4).
1. The Isuzu 2000 System PCMCIA card (1) inserts 3. Connect the DLC cable to the Tech 2 (5)
into the Tech 2 (5).
4. Make sure the vehicle ignition is off.
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–15
5. Connect the Tech 2 SAE 16/19 adaptor to the 6. The vehicle ignition turns on.
vehicle DLC.
7. Verify the Tech 2 power up display.

821RW262
060RW009

NOTE: The RS232 Loop back connector is only to use for


diagnosis of Tech 2 and refer to user guide of the Tech 2.
8. The power up screen is displayed when you
power up the tester with the Isuzu systems
PCMCIA card. Follow the operating procedure
below.

821RW263
7A1–16 TRANSMISSION CONTROL SYSTEM (4L30–E)

060RY00042 060RY00041
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–17
Once the test vehicle has been identified an “Application Function Tests (Reset Oil Life Monitor)
(Powertrain) Menu” screen appears. Please select the When F4: Function Tests is selected from the “Powertrain
appropriate application. Menu”, a “Reset Oil Life Monitor Menu” screen appears.
Data Display When the ATF has been replaced, select “F0” and reset
When F1: Data Display is selected, a “Data Display “Oil Life Monitor” data.
Menu” screen appears.
Please select either “Transmission Data” or “PC Solenoid
Data”.

060RX056

060RX009
7A1–18 TRANSMISSION CONTROL SYSTEM (4L30–E)

F0: Transmission Data


Item Unit Engine running at idle
Engine Speed RPM 750 900 RPM
Vehicle Speed km/h, MPH 0 MPH
Throttle Position % 0%
Throttle Position Sensor V 0.5 1.0 V
Manifold Absolute Pressure kPa approx. 40 kPa
Barometric Pressure kPa approx. 102 kPa
AT Output Speed (Automatic Transmission) RPM 0 RPM
AT Input Speed Ratio (Automatic Transmission) 0.0
Ignition Voltage V 12.8 14.1 V
AT Oil Temperature (Automatic Transmission) C, F 70 80 C (158 176 F)
AT Oil Life Monitor (Automatic Transmission) % 100 %
Commanded Gear 1
Current Gear 1
Mode Switch C Inactive, Active Inactive
Mode Switch B Inactive, Active Inactive
Mode Switch A Inactive, Active Active
Mode Switch G Inactive, Active Active
Actual Gear Park
1–2 Shift Solenoid A Off, On Off
2–3 Shift Solenoid B Off, On On
Brake Switch Off, On Off
Solenoid Brake Band Off, On Off
TCC Slip Speed RPM 750 900 RPM
TCC Status Disabled, Enabled Enabled
TCC Solenoid Off, On Off
TCC Duty Cycle % 0%
TCC Apply Mode No Apply, In Apply No Apply
TCC Release Mode No, Yes No
TCC On Mode No, Yes No
TCC Off Mode No, Yes Yes
Default Gear No, Yes No
Engine Warm No, Yes Yes
A/C Request Yes, No Yes
A/C Clutch Relay Off, On On
Winter Switch Off, On Off
Winter Drive Lamp Off, On Off
Kickdown Switch Off, On Off
ATF Lamp (Automatic Transmission) Off, On Off
Power Switch Normal, Power Normal
Power Drive Lamp Off, On Off
ABS Status On, Off Off
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–19

F1: PC Solenoid Data


Item Unit Engine running at idle
Engine Speed RPM 750 900 RPM
Vehicle Speed km/h, MPH 0 MPH
Throttle Position % 0%
Throttle Position Sensor V 0.5 1.0 V
Manifold Absolute Pressure kPa approx. 40 kPa
Barometric Pressure kPa approx. 102 kPa
PCS Current (Pressure Control Solenoid) A approx. 1.0 A
PCS Actual Current (Pressure Control Solenoid) A approx. 1.0 A
PCS Duty Cycle (Pressure Control Solenoid) % approx. 45 %
Desired PCS Pressure (Pressure Control Solenoid) kPa 43 52 kPa
Shift Pressure (Line Pressure) kPa 43 52 kPa
Transmission Temperature C, F 75 110 C (167 230 F)
7A1–20 TRANSMISSION CONTROL SYSTEM (4L30–E)

OBD II Diagnostic Management System


Powertrain Control Module (PCM) Location

C07RW005

Class 2 Serial Data Bus TROOPER previously used a 5 volt data bus called
OBD II technology requires a much more sophisticated UART, which is an acronym for “Universal Asynchronous
PCM than does OBD I technology. The OBD II PCM Receive and Transmit”. When neither the vehicle’s
diagnostic management system not only monitors control module nor the diagnostic tool, such as a Tech2,
systems and components that can impact emissions, but are “talking,” the voltage level of the bus at rest is 5 volts.
they also run active tests on these systems and The two computers talk to each other at a rate of 8,192
components. The decision making functions of OBD II bits per second, by toggling or switching the voltage on
PCMs have also greatly increased. To accommodate this the data bus from 5 volts to ground.
expansion in diagnostic complexity, Isuzu engineers have Class 2 data, which is used on OBD II vehicles, is quite
designed the Class 2 serial data bus, which meets SAE different. Data is transferred at a rate of 10.4 kilobits per
J1850 recommended practice for serial data. second, and the voltage is toggled between zero and 7
“Serial Data” refers to information which is transferred in a volts.
linear fashion – over a single line, one bit at a time. A “Data
Bus” is an electronic pathway through which serial data
travels.
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–21

C07RT006

Class 2 data is also pulse width modulated. Each bit of


information can have one of two lengths: long or short. On
the other hand, UART data bits come in only one length
(short). The pulse width modulation of Class 2 data allows
better utilization of the data line.
The message carried on Class 2 data streams are also
prioritized. This means that if two devices try to
communication on the data line at the same time, only the
higher priority message will continue. The device with the
lower priority message must wait.
NOTE: The Class 2 data wire is always terminal 2 of the
new 16–terminal Data Link Connector (DLC).

16 – Terminal Data Link Connector (DLC)


OBD II standardizes Data Link Connector (DLC)
configurations. The DLC, formerly referred to as the
ALDL, will be a 16–terminal connector found on the lower
left side of the driver’s side instrument panel. All
manufacturers must conform to this 16–terminal 821RW262

standard.
7A1–22 TRANSMISSION CONTROL SYSTEM (4L30–E)

Malfunction Indicator Lamp (MIL)


The Malfunction Indicator Lamp (MIL) looks the same as
the MIL you are already familiar with (“CHECK ENGINE”
lamp). However, OBD II requires that it illuminate under a
strict set of guidelines. Basically, the MIL is turned on
when the PCM detects a DTC that will impact the vehicle’s
emissions.
The MIL is under the control of the Diagnostic Executive.
The MIL will be turned on if a component or system which
has an impact on vehicle emissions indicates a
malfunction or fails to pass an emissions–related
diagnostic test. It will stay on until the system or
component passes the same test, for three consecutive
trips, with no emissions–related faults.

Types Of Diagnostic Trouble Codes (DTCs)


The Diagnostic Executive classifies Diagnostic Trouble
Codes (DTCs) into certain categories. Each type has
821RW263 different requirements to set the code, and the Diagnostic
Executive will only illuminate the Malfunction Indicator
Lamp (MIL) for emissions–related DTCs. DTCs fall into
four categories: A, B, C, and D; only types A and B are
emission–related The following descriptions define these
categories:
TYPE A
Will store the DTC and turn on the MIL (“Check Engine”
lamp) on the first trip in which an emission–related
diagnostic test has run and reported a “test failed” to the
Diagnostic Executive.
TYPE B
Will store the DTC and turn on the MIL on the second
consecutive trip in which an emission–related diagnostic
test has run and reported a “test failed” to the Diagnostic
Executive. After one failure, the type B DTC is “armed,”
or prepared to store a history code and turn on the MIL if
a second failure occurs. One passed test will disarm a
type B DTC. Some special conditions apply to misfire and
fuel trim DTCs. For a type B DTC to store and turn on the
810RT022
MIL, two ignition cycles are required.
PIN 1 – (Not used)
PIN 2 – J1850 Bus + L line on 2–wire systems, or TYPE C
single wire (Class 2) Will store the DTC and turn on a “SERVICE” lamp
(“Check Trans” lamp) on the first trip that a
PIN 3 – (Not used) non–emission–related diagnostic test has run and
PIN 4 – Chassis ground pin reported a “test failed” to the Diagnostic Executive. This
PIN 5 – Signal ground pin type of DTC will be used in future applications.
PIN 6 – PCM diagnostic enable
TYPE D
PIN 7 – (Not used) Will store a DTC but will not turn on the MIL on the first
PIN 8 – (Not used) trip that a non–emission–related diagnostic test has run
PIN 9 – Primary UART and reported a “test failed” to the Diagnostic Executive.
PIN 10 – (Not used) These codes can be very helpful for vehicle service when
PIN 11 – (Not used) the driver may comment about a condition, but the MIL did
PIN 12 – ABS diagnostic or CCM diagnostic enable not turn on.
PIN 13 – SIR diagnostic enable
PIN 14 – (Not used) Clear DTC
PIN 15 – (Not used) NOTE: If you clear the DTC (Diagnostic Trouble Codes)
PIN 16 – Battery power from vehicle unswitched (4 you will not be able to read any codes recorded during the
AMP MAX.) last occurrence.
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–23
NOTE: To use the DTC again to identify a problem, you 2. There are several ways for a person to become
will need to reproduce the fault or the problem. This may statically charged. The most common methods of
require a new test drive or just turning the ignition on (this charging are by friction and induction. An example of
depends on the nature of the fault). charging by friction is a person sliding across a car
seat, in which a charge of as much as 25,000 volts
1. IF you have a Tech2:
can build up. Charging by induction occurs when a
1. Connect the Tech2 if it is still not connected person with well insulated shoes stands near a highly
GOTHROUGH Tech2 OBD II CONNECTION. charged object and momentarily touches ground.
2. Push “F1= Clear DTC Info” in the Application Charges for the same polarity are drained off, leaving
Menu and answer “Yes” to the question “Do you the person highly charged with the opposite polarity.
want to clear DTC’s?” Static charges of either type can cause damage,
therefore, it is important to use care when handling
a. When a malfunction remains as it is the Tech2 and testing electronic components.
displays “4L30E CODES NOT CLEARED”. This
means that the problem is still there or that the NOTICE: To prevent possible electrostatic
recovery was not done. Please GOTO DTC discharge damage:
CHECK.
1. Do not touch the PCM connector pins or soldered
b. When a malfunction has been repaired and the
components on the PCM circuit board.
recovery is done. The Tech2 displays “4L30E
CODES CLEARED”. 2. Be sure to follow the guidelines listed below if
servicing any of these electronic components:
2. IF you have no Tech2:
To clear the DTC, remove Fuse “Stop, A/T CONT” 3. Do not open the replacement part package until it is
(C–14, 15A) for at least 10 seconds. time to install the part.
4. Avoid touching electrical terminals of the part.
DTC Check 5. Before removing the part from its package, ground
the package to a known good ground on the vehicle.
1. Diagnostic Trouble Codes (DTC) have been identified
by Tech2. 6. Always touch a known good ground before handling
the part. This step should be repeated before
2. You have written the list of the DTCs. The order of the installing the part if the part has been handled while
malfunctions has no meanings for this PCM. Usually sliding across the seat, while sitting down from a
only one or two malfunctions should be set for a given standing position or while walking some distance.
problem.
3. Check directly the DTCs you identified. The DTCs are Information On PCM
sorted by number. Refer to Diagnostic Trouble Code
(DTC) Identification in this section. 1. The Powertrain Control Module (PCM) is located in
the center console and is the control center of the
PCM Precaution electronic transmission control system.
2. The PCM must be maintained at a temperature below
The PCM can be damaged by: 85 C (185 F) at all times. This is most essential if the
1. Electrostatic discharge vehicle is put through a paint baking process. The
2. The short circuit of some terminals to voltage or to PCM will become inoperative if its temperature
ground. exceeds 85 C (185 F). Therefore, it is
recommended that the PCM be removed or that
Electrostatic Discharge Damage Description: temporary insulation be placed around the PCM
1. Electronic components used to control systems are during the time the vehicle is in a paint oven or other
often designed to carry very low voltage, and are very high temperature process.
susceptible to damage caused by electrostatic 3. The PCM is designed to process the various inputs
discharge. It is possible for less than 100 volts of and then respond by sending the appropriate
static electricity to cause damage to some electronic electrical signals to control transmission upshift,
components. By comparison, it takes as much as downshift, shift feel and torque converter clutch
4,000 volts for a person to even feel the zap of a static engagement.
discharge. 4. The PCM constantly interprets information from the
various sensors, and controls the systems that affect
transmission and vehicle performance. By analyzing
operational problems, the PCM is able to perform a
diagnostic function by displaying DTC(s) and aid the
technician in making repairs.

Intermittent Conditions
If the Tech2 displays a diagnostic trouble code as
intermittent, or if after a test drive a DTC does not
reappear though the detection conditions for this DTC are
present, the problem is most likely a faulty electrical
connection or loose wiring. Terminals and grounds should
7A1–24 TRANSMISSION CONTROL SYSTEM (4L30–E)
always be the prime suspect. Intermittents rarely occur Use the F3 SNAPSHOT mode of the Tech2 to help isolate
inside sophisticated electronic components such as the the cause of an intermittent fault. The snapshot mode will
PCM. record information before and after the problem occurs.
Use the DTC information to understand which wires and Set the snapshot to “trigger” on the suspect DTC. If you
sensors are involved. notice the reported symptom during the test drive, trigger
When an intermittent problem is encountered, check the snapshot manually.
suspect circuits for: After the snapshot has been triggered, command the
1. Poor terminal to wire connection. Tech2 to play back the flow of data recorded from each of
the various sensors. Signs of an intermittent fault in a
2. Terminals not fully seated in the connector body
(backed out). sensor circuit are sudden unexplainable jump in data
values out of the normal range.
3. Improperly formed or damaged terminals.
4. Loose, dirty, or corroded ground connections: Transmission And PCM Identification
HINT: Any time you have an intermittent in more than The chart below contains a list of all important information
one circuit, check whether the circuits share a concerning rear axle ratio, Powertrain Control Module
common ground connection. (PCM), and transmission identification.
5. Pinched or damaged wires.
6. Electro–Magnetic Interference (EMI):
HINT: Check that all wires are properly routed away
from spark plug wires, distributor wires, coil, and
generator. Also check for improperly installed
electrical options, such as lights, 2–way radios, etc.
VEHICLE PCM TRANSMISSION
Rr axle
Ratio Calibration
Type Engine ISUZU Parts No. Isuzu Part No. Model Code
Code
8–16254–949–0
3.2L V6 4.555 8–16254–749–0 G20 8–96018–272–3 FP (4X4)
Isuzu / 8–16253–989–0
Trooper 8–16254–019–1
3.5L V6 4.300 8–16254–959–1 G21 8–96018–270–4 FK (4X4)
8–09376–619–1
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–25

Isuzu Trooper

240RY00031
7A1–26 TRANSMISSION CONTROL SYSTEM (4L30–E)

Diagnostic Trouble Code (DTC)


Identification
DTC “CHECK
DTC NAME DTC TYPE
NUMBER TRANS”
P0218 Transmission Fluid Over Temperature D
P0560 System Voltage Malfunction C Flash
P0705 Transmission Range Switch (Mode Switch) Illegal Position D
P0706 Transmission Range Switch (Mode Switch) Performance D
Transmission Fluid Temperature Sensor Circuit Low Input
P0712 D
(TFT)
Transmission Fluid Temperature (TFT) Sensor Circuit High
P0713 D
Input
P0719 TCC Brake Switch Circuit High (Stuck ON) D
P0722 Transmission Output Speed Sensor (OSS) Low Input C Flash
P0723 Transmission Output Speed Sensor (OSS) Intermittent C Flash
P0730 Transmission Incorrect Gear Ratio C Flash
Pressure Control Solenoid (PCS) (Force Motor) Circuit
P0748 C Flash
Electrical
P0753 Shift Solenoid A Electrical C Flash
P0758 Shift Solenoid B Electrical C Flash
P1790 ROM Transmission Side Bad Check Sum C Flash
P1792 EEPROM Transmission Side Bad Check Sum C Flash
P1835 Kickdown Switch Always ON D
P1850 Brake Band Apply Solenoid Malfunction D
P1860 TCC Solenoid Electrical D

DTC TYPE DEFINITION


C Flashing Check Trans on 1st failure
D No lamps

NOTE: On the following charts, refer to the Powertrain


Control Module (PCM) section for the Wiring System, and
the Body and Accessories section for circuit diagram
details, parts location, and connector configuration.
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–27

DTC P0218 Transmission Fluid Over Temperature

D07RW029

Circuit Description Diagnostic Aids


The Transmission Fluid Temperature (TFT) sensor is a Inspect the wiring for poor electrical connections at
thermister that controls the signal voltage to the PCM. the PCM and at the transmission 16–way connector.
The PCM supplies a 5–volt reference to the sensor on Look for possible bent, backed out, deformed, or
circuit RED/BLK–GRN/RED. When the transmission fluid damaged terminals. Check for weak terminal tension
is cold, the sensor resistance is high and the PCM will as well.
sense high signal voltage. As the fluid temperature Also check for a chafed wire that could short to bare
warms to a normal transmission operating temperature of metal or other wiring. Inspect for a broken wire inside
100 C (212 F), the sensor resistance becomes less and the insulation.
the voltage decreases to 1.5 to 2.0 volts.
When diagnosing for a possible intermittent short or
This DTC detects a high transmission temperature for a
open condition, move the wiring harness while
long period of time. This is a type “D” DTC. observing test equipment for a change.
Conditions For Setting The DTC Check harness routing for a potential short to ground
in circuit RED/BLK–GRN/RED.
No TFT DTCs P0712 or P0713.
Scan tool TFT sensor temperature should rise
TFT is greater than 135 C (275 F). steadily to about 100 C (212 F), then stabilize.
All conditions met for 21 seconds. Check for a “skewed” (mis–scaled) sensor by
comparing the TFT sensor temperature to the
Action Taken When The DTC Sets ambient temperature after a vehicle cold soak. A
Hot mode TCC Shift Pattern. “skewed” sensor can cause delayed garage shifts or
The PCM will not illuminate the CHECK TRANS TCC complaints.
Lamp. Check for a possible torque converter stator problem.
ATF Lamp ON. (TFT is greater than 145 C (293 F).) Verify customer driving habits, trailer towing, etc.
Disable E–side TCC OFF request.
Test Description
Conditions For Clearing The DTC The numbers below refer to the step numbers on the
diagnostic chart.
The DTC can be cleared from the PCM history by
using a scan tool. 2. This test checks for a “skewed” sensor or shorted
circuit.
The DTC will be cleared from history when the vehicle
has achieved 40 warm–up cycles without a failure 3. This test simulates a TFT DTC P0713.
reported.
The PCM will cancel the DTC default actions when
the fault no longer exists and the ignition is cycled “off”
long enough to power down the PCM.
7A1–28 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0218 Transmission Fluid Over Temperature


Step Action Yes No
1 Perform the following checks:
Check for possible engine system problems.
Transmission fluid checking procedure. Refer to Checking
Transmission Fluid Level and Condition in Automatic
Transmission (4L30–E) Section.
Were the checks performed? Go to Step 2 —
2 1. Install the scan tool.
2. With the engine “off”, turn the ignition switch “on”.
NOTE: Before clearing DTC(s), use the scan tool to record “Failure
Records” for reference, as data will be lost when “Clear Info”
function is used.
3. Record the DTC “Failure Records”.
Go to Diagnostic
Is the TFT sensor signal voltage less than 1.54 volts? Go to Step 3 Aids
3 1. Turn the ignition “off”.
2. Disconnect the transmission 16–way connector H–53
Go to Internal
(additional DTCs may set).
Wiring Harness
Is the TFT sensor signal voltage greater than 4.92 volts? Check. Go to Step 4
4 Inspect/repair circuit RED/BLK–GRN/RED for a short to ground.
Was a problem found? Go to Step 6 Go to Step 5
5 1. Inspect the PCM for poor connections.
2. Replace the PCM if no poor connections were found.
Is the replacement complete? Go to Step 6 —
6 1. After the repair is complete, use the scan tool to select “DTC”,
then “Clear Info” function and ensure the following conditions
are met:
TFT is less than 125 C (257 F) for at least 10 seconds.
Begin diagnosis
2. Review the scan tool “DTC Info”. again Repair verified
Has the last test failed or is the current DTC displayed? Go to Step 1 Exit DTC table
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–29

DTC P0560 System Voltage Malfunction

D07RW030

Circuit Description The PCM will turn off the CHECK TRANS Lamp after
Circuit WHT is the battery voltage feed for the PCM. three consecutive ignition cycles without a failure
reported.
Circuit RED/BLU is the ignition voltage feed for the PCM.
This DTC detects a low voltage or a high voltage. This is a The DTC will be cleared from history when the vehicle
type “C” DTC. has achieved 40 warmup cycles without a failure
reported.
Conditions For Clearing The DTC The PCM will cancel the DTC default actions when
System Voltage Low: the fault no longer exists and the ignition is cycled “off”
long enough to power down the PCM.
Engine speed is greater than 1,000 rpm.
System voltage is less than 10 volts at a maximum Diagnostic Aids
transmission temperature of 150 C (302 F).
Charging the battery with a battery charger and jump
System voltage is less than 7.3 volts at a minimum
starting an engine may set DTC(s). If DTC(s) set
transmission temperature of –40 C (–40 F).
when an accessory is operated, check for faulty
All conditions met for 4 seconds. connections or excessive current draw.
System Voltage High: Check for faulty connections at the starter solenoid or
System voltage is greater than 16 volts for 2 seconds. fusible link.
Check for loose/damaged terminals at generator.
Action Taken When The DTC Sets
Check belt wear/tension.
Fixed to 4th gear.
Maximum line pressure. Test Description
Inhibit TCC engagement. The numbers below refer to the step numbers on the
The PCM will illuminate the CHECK TRANS Lamp. diagnostic chart.
3. This test checks charging system voltage.
Conditions For Clearing The DTC/CHECK 4. This test checks battery voltage input at the PCM.
TRANS Lamp 6. This test checks ignition voltage input at the PCM.
The DTC can be cleared from the PCM history by
using a scan tool.
7A1–30 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0560 System Voltage Malfunction


Step Action Yes No
1 1. Install the scan tool.
2. With the engine “off”, turn the ignition switch “on”.
NOTE: Before clearing DTC(s), use the scan tool to record “Failure
Records” for reference, as data will be lost when the “Clear Info”
function is used.
3. Record the DTC “Failure Records”. Note: If any other DTCs
are present, refer to their applicable diagnostic charts before
continuing.
4. Using the J–39200 DVOM, measure the battery voltage
across the battery terminals. Record the measurement for
Go to Engine
future reference.
Electrical in
Is the voltage higher than 10.5 volts? Go to Step 2 Engine section
2 Start the engine and warm to normal operating temperature. Go to Starting
and Charging
Is the generator/check engine light “on”?
System in Engine
section Go to Step 3
3 1. Increase the engine speed to 1,000–1,500 rpm. Go to Starting
2. Observe scan tool system voltage. and Charging
System in Engine
Is the system voltage within 13–15 volts.
Go to Step 4 section
4 1. Turn the ignition switch “off”.
2. Disconnect the J1(RED) and J3 (BLUE) PCM connector
(additional DTCs will set).
3. With the engine “off”, turn the ignition switch “on”.
4. Using the J39200 DVOM, measure the battery voltage input at
PCM connector terminals J1–A4 and J3–E16.
Is there a voltage variance between the voltage measured at the
battery (taken in Step 1) and at terminals J1–A4 and J3–E16 that
is greater than 0.5 volts? Go to Step 5 Go to Step 6
5 Repair the high resistance condition in circuit WHT.
Was the circuit repaired? Go to Step 10 —
6 1. Disconnect the J3 (BLUE) PCM connector.
2. Measure the ignition voltage input at PCM connector terminals
J3–E16 and J3–F16.
Is there a voltage variance between the voltage measured at the
battery (taken in Step 1) and at terminals J3–E16 and J3–F16 that
is greater than 0.5 volts? Go to Step 7 Go to Step 8
7 Repair the high resistance condition is circuit RED/BLU.
Was the circuit repaired? Go to Step 10 —
8 Check PCM connector terminals J1–A4, J3–E16 and J3–F16 for
bent, damaged, or backed out connector pins. Also check for
weak terminal tension.
Was a problem found? Go to Step 10 Go to Step 9
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–31

DTC P0560 System Voltage Malfunction (Cont’d)


Step Action Yes No
9 Replace the PCM.
Is the replacement complete? Go to Step 10 —
10 1. After the repair is complete, use the scan tool to select “DTC”,
then “Clear Info” function and operate the vehicle under the
following conditions:
Start the vehicle and warm to normal operating temperature.
The PCM must see a system voltage between 10 and 16 volts.
Begin diagnosis
2. Review the scan tool “DTC Info”. again Repair verified
Has the last test failed or is the current DTC displayed? Go to Step 1 Exit DTC table
7A1–32 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position

D07RW031

Circuit Description The PCM will not illuminate the CHECK TRANS
Lamp.
The range switch supplies the Powertrain Control
Module (PCM) with information regarding the selector
lever position: P, R, N, D 3, 2 or L. The selector lever
Conditions For Clearing The DTC
position is indicated by the state of four ON/OFF The DTC can be cleared from the PCM history by
contracts. The range switch is located on one side of using a scan tool.
the transmission. It is on the transmission manual The DTC will be cleared from history when the vehicle
shaft and is fixed to the main case. has achieved 40 warmup cycles without a failure
The range switch is also used to provide the reported.
information P or N to the engine crank wiring. The The PCM will cancel the DTC default actions when
engine can be cranked only if connector M–25 the fault no longer exists and the ignition is cycled “off”
terminal 4(H) is connected to terminal 1(E) which is long enough to power down the PCM.
connected to ground.
The range switch is also used to provide the backup Diagnostic Aids
lamp power in reverse. This is why the range switch is Refer to accompanying chart for the normal range
supplied through a 10A fuse (C–3). This fuse can signals and the illegal combinations.
burn due to a short circuit in the backup lamp.
Inspect the wiring for poor electrical connections at
This DTC detects when a fuse is open or the range switch
the PCM and at the transmission 8–way connector.
circuit does not work. This is a type “D” DTC.
Look for possible bent, backed out, deformed or
damaged terminals. Check for weak terminal tension
Conditions For Setting The DTC as well. Also check for a chafed wire that could short
Range switch illegal positions met for 5 seconds. to bare metal or other wiring. Inspect for a broken wire
inside the insulation.
Action Taken When The DTC Sets When diagnosing for a possible intermittent short or
Default to D position. open condition, move the wiring harness while
Inhibit torque management. observing test equipment for a change.
Maximum line pressure.
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–33
Refer to the “Range Switch Logic Table” or Range Switch Logic Table
“Functional Test Procedure” for further information.
Rangeg Range Switch Pin
Test Description Position A B C P(G)
The numbers below refer to the step numbers on the
Park ON OFF OFF ON
diagnostic chart:
2. This test checks the indicated range signal to the Reverse ON ON OFF OFF
manual valve actually selected. Neutral OFF ON OFF ON
5. This test checks for continuity between each
D4 OFF ON ON OFF
selected range switch connector terminals.
D3 ON ON ON ON
2 ON OFF ON OFF
L OFF OFF ON ON
Illegal OFF OFF OFF OFF
Illegal OFF OFF OFF ON

DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position


Step Action Yes No
1 Perform the following checks:
The transmission linkage from the select lever to the manual
valve is adjusted properly.
Diagnostic circuit check.
Were the checks performed? Go to Step 2 —
2 1. Install the scan tool.
2. With the engine “off”, turn the ignition switch “on”.
NOTE: Before clearing DTC(s), use the scan tool to record “Failure
Records” for reference, as data will be lost when the “Clear Info”
function is used.
3. Record the DTC “Failure Records”.
4. Select each transmission range: DL, D2, D3, D4, N, R, and P.
Does each selected transmission range match the scan tool Go to Diagnostic
“Range Switch” display? Aids Go to Step 3
3 Are all range switch pin displays incorrect? Go to Step 4 Go to Step 5
4 Check fuse and wiring to the 8–way connector terminal 5(D) for
opens.
Refer to Mode Switch in Automatic Transmission (4L30–E)
section.
If no problem was found, replace the range switch.
Is the replacement complete? Go to Step 8 —
5 1. Disconnect the 8–way range switch connector.
2. Using ohmmeter, check continuity between terminal 5(D) and
respectively terminals 3(G), 6(C), 7(B) and 8(A) of the 8–way
range switch connector.
3. Move shift selector lever through all positions and compare
results with “Range Switch Logic Table”.
Is one range switch pin display incorrect? Go to Step 6 Go to Step 7
6 Check the affected wiring and connector, and repair.
Is the repair complete? Go to Step 8 —
7A1–34 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position (Cont’d)
Step Action Yes No
7 Check the Powertrain Control Module (PCM) connectors for poor
connection.
If no problem was found, replace the PCM.
Is the replacement complete? Go to Step 8 —
8 1. After the repair is complete, use the scan tool to select “DTC”,
then “Clear Info” function and road test the vehicle. Begin diagnosis
2. Review the scan tool “DTC Info”. again Repair verified
Has the last test failed or is the current DTC displayed? Go to Step 1 Exit DTC table
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–35

DTC P0706 Transmission Range Switch (Mode Switch) Performance

D07RW031

Circuit Description Output speed greater than 3,200 RPM.


The range switch supplies the Powertrain Control Range switch indicates “R”.
Module (PCM) with information regarding the selector All conditions met for 4 seconds.
lever position: P, R, N, D, 3, 2 or L. The selector lever
position is indicated by the state of four ON/OFF Condition 2 (“P” or “N” bad position):
contracts. The range switch is located on one side of Engine is running.
the transmission. It is on the transmission manual
shaft and is fixed to the main case. No TPS codes.
The range switch is also used to provide the Engine speed is less than 3,000 RPM.
information P or N to the engine crank wiring. The TP angle is greater than 20%.
engine can be cranked only if connector M–25 Range switch indicates “P” or “N”.
terminal 4(H) is connected to terminal 1(E) which is All conditions met for 4 seconds.
connected to ground.
The range switch is also used to provide the backup Action Taken When The DTC Sets
lamp power in reverse. This is why the mode switch is
supplied through a 10A fuse (C–3). This fuse can Default to “D” position.
burn due to a shot circuit in the backup lamp. The PCM will not illuminate the CHECK TRANS
This DTC detects an invalid state of the range switch Lamp.
or the range switch circuit by deciphering the range
switch inputs. This is a type “D” DTC. Conditions For Clearing The DTC
The DTC can be cleared from the PCM history by
Conditions For Setting The DTC using a scan tool.
This DTC will set if any of the following conditions occurs: The DTC will be cleared from history when the vehicle
has achieved 40 warmup cycles without a failure
Condition 1 (“R” bad position): reported.
Engine is running. The PCM will cancel the DTC default actions when
No output speed DTCP0722, P0723. the fault no longer exists and the ignition is cycled “off”
long enough to power down the PCM.
7A1–36 TRANSMISSION CONTROL SYSTEM (4L30–E)

Diagnostic Aids 5. This test checks for continuity between each


selected range switch connector terminals.
Refer to the accompanying chart for the normal range
signals and the illegal combinations. Range Switch Logic Table
Inspect the wiring for poor electrical connections at Range Switch Pin
the PCM and at the transmission 8–way connector. Rangeg
Look for possible bent, backed out, deformed or Position A B C P(G)
damaged terminals. Check for weak terminal tension Park ON OFF OFF ON
as well. Also check for a chafed wire that could short
to bare metal or other wiring. Inspect for a broken wire Reverse ON ON OFF OFF
inside the insulation. Neutral OFF ON OFF ON
When diagnosing for a possible intermittent short or
open condition, move the wiring harness while D4 OFF ON ON OFF
observing test equipment for a change. D3 ON ON ON ON
Refer to the “Range Switch Logic Table” for further 2 ON OFF ON OFF
information.
L OFF OFF ON ON
Test Description Illegal OFF OFF OFF OFF
The numbers below refer to the step numbers on the
Illegal OFF OFF OFF ON
diagnostic chart:
2. This test checks the indicated range signal to the
manual valve actually selected.

DTC P0706 Transmission Range Switch (Mode Switch) Performance


Step Action Yes No
1 Perform the following checks:
The transmission linkage from the select lever to the manual
valve is adjusted properly.
Diagnostic circuit check.
Were the checks performed? Go to Step 2 —
2 1. Install the scan tool.
2. With the engine “off”, turn the ignition switch “on”.
NOTE: Before clearing DTC(s), use the scan tool to record “Failure
Records” for reference, as data will be lost when the “Clear Info”
function is used.
3. Record the DTC “Failure Records”.
4. Select each transmission range: DL, D2, D3, D4, N, R, and P.
Does each selected transmission range match the scan tool Go to Diagnostic
“Range Switch” display? Aids Go to Step 3
3 Are all range switch pin displays incorrect? Go to Step 4 Go to Step 5
4 Check fuse and wiring to the 8–way connector terminal 5(D) for
opens.
Refer to Mode Switch in Automatic Transmission (4L30–E)
section.
If no problem was found, replace the range switch.
Is the replacement complete? Go to Step 8 —
5 1. Disconnect the 8–way range switch connector.
2. Using ohmmeter, check continuity between terminal 5(D) and
respectively terminals 3(G), 6(C), 7(B) and 8(A) of the 8–way
range switch connector.
3. Move shift selector lever through all positions and compare
results with “Range Switch Logic Table”.
Is one range switch pin display incorrect? Go to Step 6 Go to Step 7
6 Check the affected wiring and connector, and repair.
Is the repair complete? Go to Step 8 —
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–37

DTC P0706 Transmission Range Switch (Mode Switch) Performance (Cont’d)


Step Action Yes No
7 Check the Powertrain Control Module (PCM) connectors for poor
connection.
If no problem was found, replace the PCM.
Is the replacement complete? Go to Step 8 —
8 1. After the repair is complete, use the scan tool to select “DTC”,
then “Clear Info” function and road test the vehicle. Begin diagnosis
2. Review the scan tool “DTC Info”. again Repair verified
Has the last test failed or is the current DTC displayed? Go to Step 1 Exit DTC table
7A1–38 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input

D07RW029

Circuit Description The DTC will be cleared from history when the vehicle
The TFT sensor is a thermister that controls the signal has achieved 40 warmup cycles without a failure
reported.
voltage to the PCM. The PCM supplies a 5–volt reference
signal to the sensor on circuit RED/BLK–GRN/RED. The PCM will cancel the DTC default actions when
When the transmission fluid is cold, the sensor resistance the fault no longer exists and the ignition is cycled “off”
is high. The PCM detects high signal voltage. As the long enough to power down the PCM.
transmission fluid temperature increases to the normal
operating temperature of 100 C (212 F), the sensor Diagnostic Aids
resistance becomes less and the voltage decreases to Check harness routing for a potential short to ground
1.5 to 2 volts. With transmission fluid over temperature in circuit RED/BLK–GRN/RED. Scan tool TFT
and DTC P0218 also set, check the transmission cooling display should rise steadily to about 100 C (212 F),
system. then stabilize.
This DTC detects a continuous short to ground in the TFT Inspect the wiring for poor electrical connection at the
signal circuit or the TFT sensor. This is a type “D” DTC. PCM and at the transmission 16–way connector.
Look for possible bent, backed out, deformed or
Conditions For Setting The DTC damaged terminals. Check for weak terminal tension
Battery voltage is between 10 and 16 volts. as well. Also check for a chafed wire that could short
to bare metal or other wiring. Inspect for a broken wire
Ignition is “on”. inside the insulation.
TFT sensor indicating a voltage less than 0.4 volts. When diagnosing for a possible intermittent short or
All conditions met for 20 seconds. open condition, move the wiring harness while
observing test equipment for a change.
Action Taken When The DTC Sets The temperature to resistance value scale may be
Transmission default temperature will be: used to test the TFT sensor at the various
temperature levels to evaluate the possibility of a
80 C (176 F) if engine temperature code is set.
“skewed” (mis–scaled) sensor.
100 C (212 F) if engine temperature is warm. A “skewed” sensor could result in delayed garage
80 C (176 F) if engine run time is greater than 5 shifts or TCC complaints.
minutes. Verify customer driving habits, trailer towing, etc.
21 C (69.8 F) if engine run time is less than 5
minutes. Test Description
The PCM will not illuminate the CHECK TRANS The numbers below refer to the step numbers on the
Lamp. diagnostic chart:
2. This test checks for a short to ground or a “skewed”
Conditions For Clearing The DTC sensor.
The DTC can be cleared from the PCM history by 3. This test checks for an internal fault within the
using a scan tool. transmission by creating an open.
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–39
Resistance Chart
C F Resistance (k )
–40 –40 672
0 32 65
20 68 25
80 176 2.5
120 248 0.78
150 304 0.37

DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input
Step Action Yes No
1 Perform the transmission fluid checking procedure. Refer to Refer to
Checking Transmission Fluid Level and Condition in Automatic Checking
Transmission (4L30–E) section. Transmission
Fluid Level and
Was the fluid checking procedure performed?
Condition in
Automatic
Transmission
Go to Step 2 (4L30–E) section
2 1. Install the scan tool.
2. With the engine “off”, turn the ignition switch “on”.
NOTE: Before clearing DTC(s), use the scan tool to record “Failure
Records” for reference, as data will be lost when the “Clear Info”
function is used.
3. Record the DTC “Failure Records”.
Does the scan tool display a TFT sensor signal voltage less than Go to Diagnostic
0.4 volts? Go to Step 3 Aids
3 1. Turn the ignition “off”.
2. Disconnect the transmission 16–way connector H–53.
3. Turn the ignition “on”.
Does the TFT signal voltage change to match the voltage 4.92
volts? Go to Step 4 Go to Step 9
4 Using the J39200 DVOM, measure the resistance between
terminals 3(C) and 5 (D).
Go to Diagnostic
Is the resistance within specifications? (See Resistance Chart.) Aids Go to Step 5
5 1. Disconnect the transmission 5–way connector M–6.
2. Using the J39200 DVOM, measure the resistance between
terminals 3(C) and 5(D).
Go to Diagnostic
Is the resistance within specifications? (See Resistance Chart.) Aids Go to Step 6
6 1. Remove the transmission oil pan. Refer to Transmission Oil
Temperature Sensor (Adapter Case) in Automatic
Transmission (4L30–E) section.
2. Check the internal wiring harness for a short to ground.
Was a problem found? Go to Step 8 Go to Step 7
7 1. Disconnect the internal wiring harness at the TFT sensor.
2. Measure the resistance of the TFT sensor.
Go to Diagnostic
Is the resistance within specifications? (See Resistance Chart.) Aids Go to Step 8
8 Replace the TFT Sensor.
Is the replacement complete? Go to Step 12 —
7A1–40 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input (Cont’d)
Step Action Yes No
9 Check circuit RED/BLK–GRN/RED for a short to ground.
Was a problem found? Go to Step 12 Go to Step 10
10 Check the PCM for faulty connections.
Was a problem found? Go to Step 12 Go to Step 11
11 Replace the PCM. Refer to Powertrain Control Module (PCM) in
Automatic Transmission (4L30–E) section.
Is the replacement complete? Go to Step 12 —
12 1. After the repair is complete, use the scan tool to select “DTC”,
then “Clear Info” function and ensure the following conditions
are met:
TFT sensor indicates a voltage greater than 0.33 volts for 2
seconds.
Begin diagnosis
2. Review the scan tool “DTC info”. again Repair verified
Has the last test failed or is the current DTC displayed? Go to Step 1 Exit DTC table
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–41

DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input

D07RW029

Circuit Description The DTC will be cleared from history when the vehicle
The TFT sensor is a thermistor that controls the signal has achieved 40 warmup cycles without a failure
reported.
voltage to the PCM. The PCM supplies a 5–volt reference
signal to the sensor on circuit RED/BLK–GRN/RED. The PCM will cancel the DTC default actions when
When the transmission fluid is cold, the sensor resistance the fault no longer exists and the ignition is cycled “off”
is high and the PCM will sense high signal voltage. As the long enough to power down the PCM.
transmission fluid temperature warms to the normal
operating temperature of 100 C (212 F), the sensor Diagnostic Aids
resistance becomes less and the voltage decreases to Inspect the wiring for poor electrical connection at the
about 1.5 to 2 volts. PCM and at the transmission 16–way connector.
This DTC detects a continuous open or short to power in Look for possible bent, backed out, deformed or
the TFT signal circuit or the TFT sensor. This is a type “D” damaged terminals. Check for weak terminal tension
DTC. as well. Also check for a chafed wire that could short
to bare metal or other wiring. Inspect for a broken wire
Conditions For Setting The DTC inside the insulation.
Battery voltage is between 10 and 16 volts. When diagnosing for a possible intermittent short or
open condition, move the wiring harness while
Ignition is “on”. observing test equipment for a change.
TFT sensor indicating a voltage greater than 4.86 Scan tool displays transmission fluid temperature in
volts. degrees. After transmission is operating, the
All conditions met for 20 seconds. temperature should rise steadily to about 100 C
(212 F), then stabilize.
Action Taken When The DTC Sets The temperature to resistance value scale may be
Transmission default temperature will be: used to check the TFT sensor at the various
temperature levels to evaluate the possibility of a
80 C (176 F) if engine temperature code is set.
“skewed” (mis–scaled) sensor.
100 C (212 F) if engine temperature is warm. A “skewed” sensor could result in hard shifts or TCC
80 C (176 F) if engine run time is greater than 5 complaints.
minutes.
21 C (69.8 F) if engine run time is less than 5
Test Description
minutes. The numbers below refer to the step numbers on the
diagnostic chart:
The PCM will not illuminate the CHECK TRANS
Lamp. 2. This check verifies problem in the TFT sensor circuit.
3. This test simulates a TFT sensor DTC P0712. If the
Conditions For Clearing The DTC PCM recognizes the low signal voltage (high
temperature), and the scan tool displays 146 C
The DTC can be cleared from the PCM history by
(295 F) or greater, the PCM and wiring are OK.
using a scan tool.
7A1–42 TRANSMISSION CONTROL SYSTEM (4L30–E)
5. This test checks the TFT sensor and internal wiring
harness.
Resistance Chart
C F Resistance (k )
–40 –40 672
0 32 65
20 68 25
80 176 2.5
120 248 0.78
150 304 0.37

DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input
Step Action Yes No
1 Perform the transmission fluid checking procedure. Refer to
Refer to Checking Transmission Fluid Level and Condition in Checking
Automatic Transmission (4L30–E) section. Transmission
Fluid Level and
Was the fluid checking procedure performed?
Condition in
Automatic
Transmission
Go to Step 2 (4L30–E) section
2 1. Install the scan tool.
2. With the engine “off”, turn the ignition switch “on”.
NOTE: Before clearing DTC(s), use the scan tool to record “Failure
Records” for reference, as data will be lost when the “Clear Info”
function is used.
3. Record the DTC “Failure Records”.
Does the scan tool display a TFT sensor signal voltage greater Go to Diagnostic
than 4.86 volts? Go to Step 3 Aids
3 1. Turn the ignition “off”.
2. Disconnect the transmission 16–way connector H–53.
3. Install a fused jumper wire from terminal 3(C) to 5(D) on the
engine harness.
4. Turn the ignition “on”.
Does the TFT signal voltage drop to less than 0.4 volts? Go to Step 4 Go to Step 9
4 1. Turn the ignition “off”.
2. Using the J39200 DVOM, measure the resistance between
terminals 3(C) and 5(D).
Go to Diagnostic
Is the resistance within specifications? (See Resistance Chart.) Aids Go to Step 5
5 1. Disconnect the transmission 5–way connector M–6.
2. Using the J39200 DVOM, measure the resistance between
terminals 3(C) and 5(D).
Go to Diagnostic
Is the resistance within specifications? (See Resistance Chart.) Aids Go to Step 6
6 1. Remove the transmission oil pan.
2. Check the internal wiring harness for an open. Refer to
Transmission Oil Temperature Sensor (Adapter Case) in
Automatic Transmission (4L30–E) section.
Was a problem found and corrected? Go to Step 13 Go to Step 7
7 1. Disconnect the internal wiring harness at the TFT sensor.
2. Measure the resistance of the TFT sensor.
Go to Diagnostic
Is the resistance within specifications? (See Resistance Chart.) Aids Go to Step 8
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–43

DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input (Cont’d)
Step Action Yes No
8 Replace TFT sensor. Refer to Transmission Oil Temperature
Sensor (Adapter Case) in Automatic Transmission (4L30–E)
section.
Is the replacement complete? Go to Step 13 —
9 Check circuit RED/BLK–GRN/RED for an open or short to B+.
Was a problem found? Go to Step 13 Go to Step 10
10 Check circuit GRY–GRN for an open.
Was a problem found? Go to Step 13 Go to Step 11
11 Check the PCM for faulty or intermittent connections.
Was a problem found? Go to Step 13 Go to Step 12
12 Replace the PCM. Refer to Powertrain Control Module (PCM) in
Automatic Transmission (4L30–E) section.
Is the replacement complete? Go to Step 13 —
13 1. After the repair is complete, use the scan tool to select “DTC”,
then “Clear Info” function and ensure the following conditions
are met:
2. TFT sensor indicates a voltage less than 4.92 volts for 2
seconds. Begin diagnosis
3. Review the scan tool “DTC Info”. again Repair verified
Has the last test failed or is the current DTC displayed? Go to Step 1 Exit DTC table
7A1–44 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0719 TCC Brake Switch Circuit High (Stuck On)

D07RW032

Circuit Description The DTC will be cleared from history when the vehicle
The TCC brake switch is used to indicate brake pedal has achieved 40 warmup cycles without a failure
reported.
status. The normally opened brake switch signal voltage
circuit is opened. The PCM will cancel the DTC default actions when
Brake switch supplies a B+ signal on circuit GRN/YEL to the fault no longer exists and the ignition is cycled “off”
the PCM when the brakes are applied. The PCM uses long enough to power down the PCM.
this signal to deenergize the TCC solenoid when the
brakes are applied. Diagnostic Aids
This DTC detects a closed brake switch during Inspect the wiring for poor electrical connections at
accelerations. This is a type “D” DTC. the PCM and TCC brake switch. Look for possible
bent, backed out, deformed or damaged terminals.
Conditions For Setting The DTC Check for weak terminal tension as well. Also check
for a chafed wire that could short to bare metal or
No OSS DTCs P0722 or P0723.
other wiring. Inspect for a broken wire inside the
The PCM detects a closed brake switch/circuit (12 insulation.
volts) for 2 seconds, and the following events occur
When diagnosing for a possible intermittent short or
seven consecutive times: vehicle speed is less than 8
open condition, move the wiring harness while
km/h (5 mph); then vehicle speed is between 8 and 32
observing test equipment for a change.
km/h (5 and 20 mph) for 4 seconds; then vehicle
speed is greater than 32 km/h (20 mph) for 4 seconds. Check customer driving habits and/or unusual driving
conditions (i.e. stop and go, highway).
Action Taken When The DTC Sets Check brake switch for proper mounting and
If throttle opening is greater than 10% and vehicle adjustment.
speed is greater than 45 km/h (28 mph), then
disregard brake switch contingency for TCC off Test Description
mode. The numbers below refer to the step numbers on the
The PCM will not illuminate the CHECK TRANS diagnostic chart:
Lamp. 2. This test checks for voltage at the brake switch.
5. This test checks the brake switch.
Conditions For Clearing The DTC 8. This test checks circuit GRN/YEL at the PCM.
The DTC can be cleared from the PCM history by
using a scan tool.
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–45

DTC P0719 TCC Brake Switch Circuit High (Stuck On)


Step Action Yes No
1 1. Install the scan tool.
2. With the engine “off”, turn the ignition switch “on”. If ABS code
is set, check applicable fuse.
NOTE: Before clearing DTC(s), use the scan tool to record “Failure
Records” for reference, as data will be lost when the “Clear Info”
function is used.
3. Record the DTC “Failure Records”.
4. Apply then release the brake pedal.
Does the scan tool display “TCC Brake Switch” as “closed” with
the brake pedal applied, and then display “open” when the brake Go to Diagnostic
pedal is released? Aids Go to Step 2
2 1. Connect the test light to ground.
2. Back probe ignition feed circuit terminal B13–1 at the brake
switch.
Is the test light “on”? Go to Step 3 Go to Step 4
3 1. Connect the test light to ground.
2. Back probe circuit terminal B13–4 at the brake switch.
Is the test light “off”? Go to Step 7 Go to Step 5
4 Repair the open in battery feed circuit terminal B13–1 to the brake
switch.
If fuse is open, check circuit terminal B13–4 for a short to ground.
Is the repair complete? Go to Step 13 —
5 Disconnect brake switch connector B–13 and ignition switch “on”.
Is the test light “on”? Go to Step 8 Go to Step 6
6 Check the brake switch short (B13–1 and B13–4).
Was a problem found? Go to Step 9 Go to Step 10
7 Check circuit terminal B13–4 for a short to voltage.
Ignition switch “on”.
Is the test light “on”? Go to Step 8 Go to Step 10
8 1. Disconnect the J3 (BLUE) PCM connector.
2. Check circuit terminal B13–4 for a short to voltage.
Was a problem found? Go to Step 13 Go to Step 10
9 Replace the brake switch.
Is the replacement complete? Go to Step 13 —
10 1. Turn the ignition “off”.
2. Reconnect the J3 (BLUE) PCM connector.
3. Turn the ignition “on”.
Does the scan tool display “TCC Brake Switch” as “open” with the
brake applied, then display “closed” with the brake pedal Go to Diagnostic
released? Aids Go to Step 11
11 Check the PCM for faulty or intermittent connections.
Was a problem found and corrected? Go to Step 13 Go to Step 12
7A1–46 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0719 TCC Brake Switch Circuit High (Stuck On) (Cont’d)
Step Action Yes No
12 Replace the PCM. Refer to Powertrain Control Module (PCM) in
Automatic Transmission (4L30–E) section.
Is the replacement complete? Go to Step 13 —
13 1. After the repair is complete, use the scan tool to select “DTC”,
then “Clear Info” function and ensure the following conditions
are met:
The PCM brake switch signal must indicate 0 volts for 1
seconds with the brake pedal applied.
Begin diagnosis
2. Review the scan tool “DTC Info”. again Repair verified
Has the last test failed or is the current DTC displayed? Go to Step 1 Exit DTC table
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–47

DTC P0722 Transmission Output Speed Sensor (OSS) Low Input

D07RW006

Circuit Description Conditions For Clearing The DTC/CHECK


Output speed information is provided to the PCM by the TRANS Lamp
OSS, which is a permanent magnet (PM) generator. The The PCM will turn off the CHECK TRANS Lamp after
PM generator produces a pulsing AC voltage. The AC three consecutive ignition cycles without a failure
voltage level and number of pulses increases as the reported.
speed of the vehicle increases. The PCM then converts The DTC can be cleared from the PCM history by
the pulsing voltage to output speed, which is used for using a scan tool. The DTC will be cleared from
calculations. The vehicle speed can be displayed with a history when the vehicle has achieved 40 warmup
scan tool. cycles without a failure reported.
This DTC detects a low output speed when there is a high
The PCM will cancel the DTC default actions when
engine speed in a drive gear range. This is a type “C” the fault no longer exists and the ignition is cycled “off”
DTC. long enough to power down the PCM.
Conditions For Setting The DTC Diagnostic Aids
No MAP DTCs P0107 or P0108, P0106, P1106, An OSS DTC P0722 will set when no output speed is
P1107.
at detected at start off.
No TPS DTCs P0122 or P0123.
Inspect the wiring for poor electrical connection at the
Not in Park or Neutral. PCM. Look for possible bent, backed out, deformed
TP angle is greater than 10%. or damaged terminals. Check for weak terminal
Engine vacuum is between 0 and 70kPa. tension as well. Also check for a chafed wire that
could short to bare metal or other wiring. Inspect for a
Engine speed is between 3,000 and 7,000 rpm. broken wire inside the insulation.
Transmission output speed is less than 0 rpm. When diagnosing for a possible intermittent short or
All conditions met for 5 seconds. open condition, move the wiring harness while
observing test equipment for a change.
Action Taken When The DTC Sets
Fixed to 4th gear. Test Description
Maximum line pressure. The numbers below refer to the step numbers on the
Inhibit TCC engagement. diagnostic chart:
4. This test checks the OSS circuit.
The PCM will illuminate the CHECK TRANS Lamp.
5. This test checks the integrity of the OSS.
7. This test checks the 5–volt and ground circuit of the
PCM.
7A1–48 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0722 Transmission Output Speed Sensor (OSS) Low Input


Step Action Yes No
1 1. Install the scan tool.
2. With the engine “off”, turn the ignition switch “on”.
NOTE: Before clearing DTC(s), use the scan tool to record “Failure
Records” for reference, as data will be lost when the “Clear Info”
function is used.
3. Record the DTC “Failure Records”.
4. Raise the drive wheels.
5. Start the engine.
6. Place the transmission in any drive range.
With the drive wheels rotating, does the “Trans Output Speed” Go to Diagnostic
increase with the drive wheel speed? Aids Go to Step 2
2 Does the speedometer work? Go to Step 3 Go to Step 4
3 Check for the most current and/or incorrect calibration.
Is the calibration current? Go to Step 16 Go to Step 4
4 1. Turn the ignition “off”.
2. Disconnect the J3 (BLUE) PCM connector.
3. Using the J39200 DVOM, measure the resistance between
harness connector terminals J3–E1 and J3–E2.
Is the reading 3,000 ohms? Go to Step 5 Go to Step 6
5 1. Select AC volts.
2. Rotate the rear wheels, ensuring the driveshaft is turning.
Is the voltage greater than 0.5 volts? Go to Step 7 Go to Step 8
6 Inspect circuits RED and WHT for a poor connection or an open
circuit.
Was a problem found? Go to Step 17 Go to Step 8
7 1. Reconnect the J3 (BLUE) PCM connector.
2. Disconnect the OSS harness from the OSS.
3. With the engine “off”, turn the ignition “on”.
4. Using the J 39200 DVOM, measure the voltage at the OSS
harness connector terminals M15–1 and M15–2.
Is the reading between 4.0 to 5.1 volts? Go to Step 16 Go to Step 10
8 1. Remove the OSS.
2. Check the output shaft speed sensor rotor for damage or
misalignment. Refer to Speed Sensor (Extension Housing) in
Automatic Transmission (4L30–E) section.
Was a problem found? Go to Step 17 Go to Step 9
9 Replace the OSS.
Is the replacement complete? Go to Step 17 —
10 Was the reading in step 7 less than 4.0 volts? Go to Step 12 Go to Step 11
11 Was the reading in step 7 greater than 5.1 volts? Go to Step 15 —
12 Using the J 39200 DVOM to chassis ground, measure the voltage
on circuit RED.
Is the reading between 4.0 to 5.1 volts? Go to Step 13 Go to Step 14
13 Repair the open in circuit WHT.
Is the repair complete? Go to Step 17 —
14 Check circuit RED for a short to ground or open.
Was a problem found and corrected? Go to Step 17 Go to Step 16
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–49

DTC P0722 Transmission Output Speed Sensor (OSS) Low Input (Cont’d)
Step Action Yes No
15 Repair the short to B+ in circuit RED.
Is the repair complete? Go to Step 17 —
16 Replace the PCM. Refer to Powertrain Control Module (PCM) in
automatic Transmission (4L30–E) section.
Is the replacement complete? Go to Step 17 —
17 1. After the repair is complete, use the scan tool to select “DTC”,
then “Clear Info” function and operate the vehicle under the
following conditions:
Transmission output speed is greater than 101 rpm for 3
seconds.
Begin diagnosis
2. Review the scan tool “DTC Info”. again Repair verified
Has the last test failed or is the current DTC displayed? Go to Step 1 Exit DTC table
7A1–50 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0723 Transmission Output Speed Sensor (OSS) Intermittent

D07RW006

Circuit Description The PCM will illuminate the CHECK TRANS Lamp.
Output speed information is provided to the PCM by the
OSS, which is a permanent magnet (PM) generator. The Conditions For Clearing The DTC/CHECK
PM generator produces a pulsing AC voltage. The AC TRANS Lamp
voltage level and number of pulses increases as the The PCM will turn off the CHECK TRANS Lamp after
speed of the vehicle increases. The PCM then converts three consecutive ignition cycles without a failure
the pulsing voltage to output speed, which is used for reported.
calculations. The vehicle speed can be displayed with a The DTC can be cleared from the PCM history by
scan tool. using a scan tool.
This DTC detects a low output speed when there is a high The DTC will be cleared from history when the vehicle
engine speed in a drive gear range. This is a type “C” has achieved 40 warmup cycles without a failure
DTC. reported.
Conditions For Setting The DTC The PCM will cancel the DTC default actions when
the fault no longer exists and the ignition is cycled “off”
In Park or Neutral: long enough to power down the PCM.
Transmission output speed change is greater than
10,000 rpm. Diagnostic Aids
Conditions met for 6 seconds. A OSS DTC P0723 will set when output speed has
Engine running time is greater than 2 seconds. been detected and is lost.
Not in Park or Neutral: Inspect the wiring for poor electrical connection at the
Transmission output speed change is greater than PCM. Look for possible bent, backed out, deformed
512 rpm. or damaged terminals. Check for weak terminal
Conditions met for 0.075 seconds tension as well. Also check for a chafed wire that
could short to bare metal or other wiring. Inspect for a
Engine running time is greater than 2 seconds.
broken wire inside the insulation.
Engine vacuum is less than 70 kPa.
When diagnosing for a possible intermittent short or
Output speed is greater than 1,380 rpm for 1 second. open condition, move the wiring harness while
NORAW–NOLAST < 60 rpm for 6 seconds. observing test equipment for a change.
NORAW: Latest raw data of output shaft speed.
Test Description
NOLAST: Filtered pervious data of output speed. The numbers below refer to the step numbers on the
diagnostic chart:
Action Taken When The DTC Sets 4. This test checks the OSS circuit.
Fixed to 4th gear. 5. This test checks the integrity of the OSS.
Maximum line pressure. 7. This test checks the 5–volt and ground circuit of the
Inhibit TCC engagement. PCM.
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–51

DTC P0723 Transmission Output Speed Sensor (OSS) Intermittent


Step Action Yes No
1 1. Install the scan tool.
2. With the engine “off”, turn the ignition switch “on”.
NOTE: Before clearing DTC(s), use the scan tool to record “Failure
Records” for reference, as data will be lost when the “Clear Info”
function is used.
3. Record the DTC “Failure Records”.
4. Raise the drive wheels.
5. Start the engine.
6. Place the transmission in any drive range.
With the drive wheels rotating, does the “Trans Output Speed” Go to Diagnostic
increase with the drive wheel speed? Aids Go to Step 2
2 Does the speedometer work? Go to Step 3 Go to Step 4
3 Check for the most current and/or incorrect calibration.
Is the calibration current? Go to Step 16 Go to Step 4
4 1. Turn the ignition “off”.
2. Disconnect the J3 (BLUE) PCM connector.
3. Using the J39200 DVOM, measure the resistance between
harness connector terminals J3–E1 and J3–E2.
Is the reading 3,000 ohms? Go to Step 5 Go to Step 6
5 1. Select AC volts.
2. Rotate the rear wheels, ensuring the driveshaft is turning.
Is the voltage greater than 0.5 volts? Go to Step 7 Go to Step 8
6 Inspect circuits RED and WHT for a poor connection or an open
circuit.
Was a problem found? Go to Step 17 Go to Step 8
7 1. Reconnect the J3 (BLUE) PCM connector.
2. Disconnect the OSS harness from the OSS.
3. With the engine “off”, turn the ignition “on”.
4. Using the J 39200 DVOM, measure the voltage at the OSS
harness connector terminals M15–1 and M15–2.
Is the reading between 4.0 to 5.1 volts? Go to Step 16 Go to Step 10
8 1. Remove the OSS.
2. Check the output shaft speed sensor rotor for damage or
misalignment. Refer to Speed Sensor (Extension Housing) in
Automatic Transmission (4L30–E) section.
Was a problem found? Go to Step 17 Go to Step 9
9 Replace the OSS.
Is the replacement complete? Go to Step 17 —
10 Was the reading in step 7 less than 4.0 volts? Go to Step 12 Go to Step 11
11 Was the reading in step 7 greater than 5.1 volts? Go to Step 15 —
12 Using the J 39200 DVOM to chassis ground, measure the voltage
on circuit RED.
Is the reading between 4.0 to 5.1 volts? Go to Step 13 Go to Step 14
13 Repair the open in circuit WHT.
Is the repair complete? Go to Step 17 —
14 Check circuit RED for a short to ground or open.
Was a problem found and corrected? Go to Step 17 Go to Step 16
7A1–52 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0723 Transmission Output Speed Sensor (OSS) Intermittent (Cont’d)


Step Action Yes No
15 Repair the short to B+ in circuit RED.
Is the repair complete? Go to Step 17 —
16 Replace the PCM. Refer to Powertrain Control Module (PCM) in
Automatic Transmission (4L30–E) section.
Is the replacement complete? Go to Step 17 —
17 1. After the repair is complete, use the scan tool to select “DTC”,
then “Clear Info” function and operate the vehicle under the
following conditions:
Transmission output speed is greater than 101 rpm for 3
seconds.
Begin diagnosis
2. Review the scan tool “DTC Info”. again Repair verified
Has the last test failed or is the current DTC displayed? Go to Step 1 Exit DTC table
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–53

DTC P0730 Transmission Incorrect Gear Ratio

D07RT015

Circuit Description 3 seconds since upshift.


The Powertrain Control Module (PCM) calculates the 3 seconds since downshift.
slippage of the converter and transmission based 3 seconds since garage shift (N D).
upon the engine speed, the output speed, and the And one of the following conditions occur:
current gear ratio.
– Slip is greater than 508 rpm in 1st gear.
The slippage of the converter at a high enough engine
speed is low. The transmission should not slip more – Slip is greater than 468 rpm in 2nd gear.
than a given value when there is no shift. – Slip is greater than 449 rpm on 3rd gear.
This DTC detects a slip at each gear. This is a type
“C” DTC. – Slip is greater than 440 rpm on 4th gear.
All conditions met for 5.5 seconds.
Conditions For Setting The DTC
No Output Speed Sensor DTC(s) P0722, P0723. Action Taken When The DTC Sets
Not in Park, Neutral, or Reverse. Maximum line pressure.
Engine speed is greater than 3,500 rpm. The PCM will illuminate the CHECK TRANS Lamp.
7A1–54 TRANSMISSION CONTROL SYSTEM (4L30–E)

Conditions For Clearing The DTC/CHECK Diagnostic Aids


TRANS Lamp Check for intermittent output speed sensor circuit
The PCM will turn “off” the CHECK TRANS Lamp problems.
after three consecutive ignition cycles without a Check for possible incorrect calibration. (PCM part
failure reported. No., tire specification, and rear axle ratio)
The DTC can be cleared from PCM memory by using
a scan tool. Test Description
The DTC can also be cleared from memory when the The numbers below refer to the step numbers on the
vehicle has made 40 warmup cycles without a failure diagnostic chart:
reported. 2. This step checks for possible low fluid level causing
The PCM will cancel the DTC Actions Taken items slipping resulting in an undefined gear ratio.
when the fault conditions no longer exist and the 3. This step checks for correct gear ratios for
ignition is cycles “off” long enough to power down the commanded gears.
PCM. 4. This step checks for low line pressure.

DTC P0730 Transmission Incorrect Gear Ratio


Step Action Yes No
1 Visually inspect the transmission cooling system for fluid leaks.
Refer to Chart 16: Possible Causes of Transmission Fluid
Leaks of Mechanical/Hydraulic Diagnosis Symptoms Index in
Automatic Transmission (4L30–E) section
Was condition found and corrected? Go to Step 6 Go to Step 2
2 Refer to Checking Transmission Fluid Level and Condition in Go to Checking
Automatic Transmission (4L30–E) section. Transmission
Fluid Level and
Has transmission fluid checking procedure been performed?
Condition in
Automatic
Transmission
Go to Step 3 (4L30–E) section
3 1. Install the scan tool.
2. Turn the ignition switch to the “on” position.
3. Engine not running.
NOTE: Before clearing DTC(s) use the scan tool to record the
“Failure Records” for reference, as data will be lost when the “Clear
Info” function is used.
4. Record the Failure Record data.
5. Use the scan tool snapshot mode to record transmission gear
ratios.
6. Drive vehicle in transmission gear ranges L, 2, 3, and D with
the engine speed is greater than 3,500 rpm for 5.5 seconds.
7. Record each transmission gear.
1st:2.73 – 2.99
2nd:1.54 – 1.71
3rd:0.93 – 1.05
4th:0.66 – 0.78
Refer to
Does commanded gear ratio match ranges as shown? Diagnostic Aids Go to Step 4
4 Perform line pressure check.
Refer to Line Pressure Test in Automatic Transmission
(4L30–E) section.
Was condition found and corrected? Go to Step 6 Go to Step 5
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–55

DTC P0730 Transmission Incorrect Gear Ratio (Cont’d)


Step Action Yes No
5 Check for possible clutch slippage.
Refer to Chart 6: Diagnostic Trouble Code (DTC) P0730 of
Mechanical/Hydraulic Diagnosis Symptoms Index in
Automatic Transmission (4L30–E) section.
Was condition found and corrected? Go to Step 6 —
6 1. After the repair is complete, use the scan tool to select “DTC”,
then “Clear info” function.
2. Operate the vehicle under the following conditions:
Drive the vehicle in D4 with the engine speed greater than
3,500 rpm to obtain anyone of the following gear ratios for
seven seconds.
1st 1:2.73 – 1:2.99
2nd 1:1.54 – 1:1.71
3rd 1:0.93 – 1:1.05
Begin diagnosis
4th 1:0.66 – 1:0.78
again Repair verified
Has the last test failed? Go to Step 1 Exit DTC table
7A1–56 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical

D07RW008

Circuit Description The DTC will be cleared from memory when the
The PCS is a PCM–controlled device used to regulate vehicle has achieved 40 warmup cycles without a
failure reported.
transmission line pressure. The PCM compares TPS
voltage, engine rpm, and other inputs to determine the The PCM will cancel the DTC default actions when
line pressure appropriate for a given load. The PCM will the fault no longer exists and the ignition is cycled “off”
regulate the pressure by applying a varying amperage to long enough to power down the PCM.
the PCS. The applied amperage can vary from 0.1 to 1
amp, and is monitored by the PCM. Diagnostic Aids
This DTC detects a continuous open or short to ground in Inspect the wiring for poor electrical connection at the
the PCS circuit or the PCS. This is a type “C” DTC. PCM and at the transmission 5–way connector. Look
for possible bent, backed out, deformed or damaged
Conditions For Setting The DTC terminals. Check for weak terminal tension as well.
Also check for a chafed wire that could short to bare
Battery voltage is between 10 and 16 volts.
metal or other wiring. Inspect for a broken wire inside
The PCM detects that the different between the insulation.
commanded and actual current is 200 milliampere
When diagnosing for a possible intermittent short or
(mA) for over 1 second.
open condition, move the wiring harness while
observing test equipment for a change.
Action Taken When the DTC Sets
Maximum line pressure. Test Description
The PCM will illuminate the CHECK TRANS Lamp. The numbers below refer to the step numbers on the
diagnostic chart:
Conditions For Clearing The DTC/CHECK 1. This test checks the ability of the PCM to command
TRANS Lamp the PCS.
The PCM will turn “off” the CHECK TRANS Lamp 2. This test checks the PCS and internal wiring harness
after three consecutive ignition cycles without a for incorrect resistance.
failure reported.
The DTC can be cleared from PCM history by using a
scan tool.
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–57

DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical
Step Action Yes No
1 1. Install the scan tool.
2. With the engine “off”, turn the ignition switch “on”.
NOTE: Before clearing DTC(s), use the scan tool to record “Failure
Records” for reference, as data will be lost when the “Clear Info”
function is used.
3. Record the DTC “Failure Records”.
4. While the engine is operating, put the transmission in Park.
5. Using the scan tool, apply 0.1 amp through 1.0 amp while
observing “PC Ref. Current” and “PC Act. Current”.
Go to Diagnostic
Is the “PC Act. Current” reading always within 0.16 amp? Aids Go to Step 2
2 1. Turn the ignition “off”.
2. Disconnect the transmission 5–way connector M–6.
3. Using the J39200 DVOM, measure the resistance between
terminals M6–2(B) and M6–1(E).
Is the resistance within 3–7 ohms? Go to Step 6 Go to Step 3
3 1. Remove the transmission oil pan. Refer to Solenoid (Adapter
Case Valve Body) in Automatic Transmission (4L30–E)
section.
2. Disconnect the internal wiring harness at the PCS.
3. Measure the resistance of the PCS.
Is the resistance within 3–7 ohms? Go to Step 5 Go to Step 4
4 Replace the PCS.
Is the replacement complete? Go to Step 9 —
5 Repair the internal wiring harness for an open.
Is the repair complete? Go to Step 9 —
6 Inspect/repair circuits J3–E4, M6–2(B), J3–E3, and M6–1(E).
Was a problem found? Go to Step 9 Go to Step 7
7 Inspect/repair circuits J3–E4, M6–2(B), J3–E3, and M6–1(E) for
a short to ground or poor connections.
Was a problem found? Go to Step 9 Go to Step 8
8 Replace the PCM. Refer to Powertrain Control Module (PCM) in
Automatic Transmission (4L30–E) section.
Is the replacement complete? Go to Step 9 —
9 1. After the repair is complete, use the scan tool to select “DTC”,
then “Clear Info” function and ensure the following conditions
are met:
The PCS duty cycle is not at its electrical high or low limit.
Begin diagnosis
2. Review the scan tool “DTC Info”. again Repair verified
Has the last test failed or is the current DTC displayed? Go to Step 1 Exit DTC table
7A1–58 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0753 Shift Solenoid A Electrical

D07RW009

Circuit Description Action Taken When The DTC Sets


The shift solenoid A is a simple on/off solenoid Maximum line pressure.
located in the main case valve body. The solenoid is Immediate landing to 4th gear.
the normally closed type. In second or third gear, the
Inhibit TCC engagement.
Powertrain Control Module (PCM) energizes the
solenoid to open a fluid inlet port. When the port is The PCM will illuminate the CHECK TRANS Lamp.
open, fluid pressure actuates the shift valve.
The solenoid is activated by current. This current is Conditions For Clearing The DTC/CHECK
produced by applying a voltage to one side (the High TRANS Lamp
side) and a ground to the other side (Low side). The PCM will turn off the CHECK TRANS Lamp after
The High Side Driver (HSD) is a circuit of the PCM three consecutive ignition cycles without a failure
that acts as a switch between the solenoids and the reported.
supply voltage. The High side of the solenoid is The DTC can be cleared from the PCM history by
permanently supplied with voltage, except in using a scan tool.
BACKUP MODE or when ignition is off the HSD is The DTC will be cleared from history when the vehicle
turned off. has achieved 40 warmup cycles without a failure
This DTC detects a continuous open or short to ground in reported.
the shift solenoid A circuit or the shift solenoid A. This is a
The PCM will cancel the DTC default actions when
type “C” DTC.
the fault no longer exists and the ignition is cycled “off”
long enough to power down the PCM.
Conditions For Setting The DTC
Ignition is “on”, Engine “run”. Diagnostic Aids
Battery voltage is between 10 and 16 volts. Inspect the wiring for poor electrical connection at the
The PCM commands the solenoid “on” and the PCM and at the transmission 16–way connector.
voltage remains high (B+) or the PCM commands the Look for possible bent, backed out, deformed or
solenoid “off” and the voltage remains low (zero damaged terminals. Check for weak terminal tension
volts). as well. Also check for a chafed wire that could short
All conditions met for 0.33 seconds. to bare metal or other wiring. Inspect for a broken wire
inside the insulation.
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–59
When diagnosing for a possible intermittent short or 8. This test checks the function of the shift solenoid A
open condition, move the wiring harness while and the transmission internal wiring harness.
observing test equipment for a change. Shift Solenoid Status Chart
An open ignition feed circuit can cause multiple DTCs
to set. Gear Shift solenoid A Shift solenoid B
1st OFF ON
Test Description
The numbers below refer to the step numbers on the 2nd ON ON
diagnostic chart: 3rd ON OFF
2. This test checks for power to the shift solenoid A 4th OFF OFF
from the ignition through the PCM.
4. This test measures the resistance of the component.

DTC P0753 Shift Solenoid A Electrical


Step Action Yes No
1 1. Install the scan tool.
2. With the engine “on”, turn the ignition switch “on”.
NOTE: Before clearing DTC(s), use the scan tool to record “Failure
Records” for reference, as data will be lost when the “Clear Info”
function is used.
3. Record the DTC “Failure Records”.
Go to Diagnostic
Were DTCs P0753, P0758, P1860 set? Go to Step 2 Aids
2 1. Turn the ignition “on”.
2. Using the J39200 DVOM, measure the voltage between PCM
connector terminals J3–E14 and J2–C8 (GND).
Is the voltage within 10–12 volts? Go to Step 3 Go to Step 4
3 1. Turn the ignition “off”.
2. Disconnect the J3 (BLUE) PCM connector.
3. Turn the ignition “on”.
4. Using the J39200 DVOM, measure the voltage between PCM
connector terminals J3–F14 and ground.
Is the voltage within 10 – 12 volts? Go to Step 10 Go to Step 4
4 1. Turn the ignition “off”.
2. Disconnect the J3 (BLUE) PCM connector.
3. Using the J39200 DVOM, measure the resistance between
PCM connector terminals J3–E14 and J3–F14.
Is the resistance within 18 – 20 ohms? Go to Step 5 Go to Step 6
5 1. Disconnect the J1 (RED) and J2 (WHITE) PCM connectors.
2. Using the J39200 DVOM, check a continuity between PCM
terminals J3–F14 and ground.
Is there a continuity? Go to Step 11 Go to Step 7
6 1. Disconnect the 16–way harness connector H–53.
2. Using the J39200 DVOM, measure the resistance between
terminals H53–14 and H53–15.
Is the resistance within 18–20 ohms? Go to Step 13 Go to Step 8
7 Using the J39200 DVOM, check a continuity between J3 (BLUE)
PCM terminal E14 and ground.
Is there a continuity? Go to Step 12 Go to Step 9
8 1. Disconnect the transmission main case 4 pin connector M–7.
2. Using the J39200 DVOM, measure the resistance between
terminals M7–3(D) and M7–4(C).
Is the resistance within 18–20 ohms? Go to Step 14 Go to Step 15
7A1–60 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0753 Shift Solenoid A Electrical (Cont’d)


Step Action Yes No
9 Check every connection at the PCM connector.
Was a problem found? Go to Step 17 Go to Step 16
10 The wiring harness between PCM connector terminals J3–F14
and transmission harness terminal M7–3(D) is shorted to voltage.
Was a problem found and corrected? Go to Step 18 —
11 The wiring harness between PCM connector terminal
J3–F14 and transmission harness terminal M7–3(D) is shorted to
ground.
Was a problem found and corrected? Go to Step 18 —
12 The wiring harness between PCM connector terminals J3–E14
and transmission harness terminal M7–4(C) is shorted to ground.
Was a problem found and corrected? Go to Step 18 —
13 The wiring harness between PCM connector J3 and transmission
16–way connector H–53 is open or poor connection.
Was a problem found and corrected? Go to Step 18 —
14 The wiring harness between transmission 16–way connector
H–53 and transmission main case connector M–7 is open or has a
poor connection.
Was a problem found and corrected? Go to Step 18 —
15 The shift solenoid A is faulty.
Replace the shift solenoid A. Refer to Solenoid (Main Case Valve
Body) in Automatic Transmission (4L30–E) section.
Is the replacement complete? Go to Step 18 —
16 The PCM may be faulty.
Replace the PCM. Refer to Powertrain Control Module (PCM) in
Automatic Transmission (4L30–E) section.
Is the replacement complete? Go to Step 18 —
17 Repair the PCM connector connection.
Was a problem found and corrected? Go to Step 18 —
18 1. After the repair is complete, use the scan tool to select “DTC”,
then “Clear Info” function and operate the vehicle under the
following conditions:
The shift solenoid A is commanded “on” and voltage drops to
zero.
The shift solenoid A is commanded “off” and voltage
increases to B+. Begin diagnosis
2. Review the scan tool “DTC Info”. again Repair verified
Has the last test failed or is the current DTC displayed? Go to Step 1 Exit DTC table
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–61

DTC P0758 Shift Solenoid B Electrical

D07RW009

Circuit Description Action Taken When The DTC Sets


The shift solenoid B is a simple on/off solenoid Fixed to 4th gear.
located in the main case valve body. It is normally Maximum line pressure.
open. When the port is open, fluid pressure actuates
Inhibit TCC engagement.
the shift valve. In first or second gear, the Powertrain
Control Module (PCM) energizes the solenoid to The PCM will illuminate the CHECK TRANS Lamp.
close a fluid inlet port.
The solenoid is activated by current. This current is Conditions For Clearing The DTC/CHECK
procuded by applying a voltage to one side (the High TRANS Lamp
side) and a ground to the other side (Low side). The PCM will turn off the CHECK TRANS Lamp after
The High Side Driver (HSD) is a circuit of the PCM three consecutive ignition cycles without a failure
that acts as a switch between the solenoids and the reported.
supply voltage. The High side of the solenoid is The DTC can be cleared from the PCM history by
permanently supplied with voltage. In BACKUP using a scan tool.
MODE or when the ignition is off, the HSD is turned The DTC will be cleared from history when the vehicle
off. has achieved 40 warmup cycles without a failure
This DTC detects a continuous open or short to ground in reported.
the shift solenoid B circuit or shift solenoid B. This is a
The PCM will cancel the DTC default actions when
type “C” DTC.
the fault no longer exists and the ignition is cycled “off”
long enough to power down the PCM.
Conditions For Setting The DTC
Ignition is “on”, Engine “run”. Diagnostic Aids
Battery voltage is between 10 and 16 volts. Inspect the wiring for poor electrical connections at
The PCM commands the solenoid “on” and the the PCM and at the transmission 16–way connector.
voltage remains high (B+)or the PCM commands the Look for possible bent, backed out, deformed or
solenoid “off” and the voltage remains low (zero damaged terminals. Check for weak terminal tension
volts). as well. Also check for a chafed wire that could short
All conditions met for 0.33 seconds. to bare metal or other wiring. Inspect for a broken wire
inside the insulation.
7A1–62 TRANSMISSION CONTROL SYSTEM (4L30–E)
When diagnosing for a possible intermittent short or Shift Solenoid Status Chart
open condition, move the wiring harness while
observing test equipment for a change. Gear Shift solenoid A Shift solenoid B
1st OFF ON
Test Description
2nd ON ON
The numbers below refer to the step numbers on the
diagnostic chart: 3rd ON OFF
4. This test measures the resistance of the component. 4th OFF OFF
6. This test checks the function of the shift solenoid B
and the transmission internal wiring harness.
10.This test checks for power to the shift solenoid B
from the ignition through the PCM.

DTC P0758 Shift Solenoid B Electrical


Step Action Yes No
1 1. Install the scan tool.
2. With the engine “on”, turn the ignition switch “on”.
NOTE: Before clearing DTC(s), use the scan tool to record “Failure
Records” for reference, as data will be lost when the “Clear Info”
function is used.
3. Record the DTC “Failure Records”.
Were DTCs P0753, P0758, P1860 set? Go to Step 3 Go to Step 2
2 1. The engine “on”.
2. Apply brake pedal and select transmission range “D”.
3. Press and hold down the winter switch and select transmission
mode “winter”.
Go to Diagnostic
Does the scan tool display DTC P0758 at 3rd gear? Go to Step 7 Aids
3 1. Turn the ignition “off”.
2. Disconnect the J2 (WHITE) and J3 (BLUE) PCM connectors.
3. Turn the ignition “on”.
4. Using the J39200 DVOM, measure the voltage between PCM
connector terminals J2–C2 and J2–C8.
Is the voltage within 10 – 12 volts? Go to Step 14 Go to Step 4
4 1. Turn the ignition “off”.
2. Using the J39200 DVOM, measure the resistance between
PCM connector terminals J2–C2 and J3–E14.
Is the resistance within 18 – 20 ohms? Go to Step 15 Go to Step 5
5 1. Disconnect the transmission 16–way connector H–53.
2. Using the J39200 DVOM, measure the resistance between
terminals H53–16 and H53–15.
Is the resistance within 18 – 20 ohms? Go to Step 16 Go to Step 6
6 1. Disconnect the transmission main case connector M–7.
2. Using the J39200 DVOM, measure the resistance between
terminals M7–1(A) and M7–4(C).
Is the resistance within 18 – 20 ohms? Go to Step 17 Go to Step 18
7 1. Turn the ignition “off”.
2. Disconnect the J2 (WHITE) and J3 (BLUE) PCM connectors.
3. Using the J39200 DVOM, measure the resistance between
PCM connector terminals J2–C2 and J3–E14.
Is the resistance within 18 – 20 ohms? Go to Step 8 Go to Step 9
8 Using the J39200 DVOM, check a continuity between PCM
connector terminal J2–C2 and ground.
Is there a continuity? Go to Step 19 Go to Step 10
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–63

DTC P0758 Shift Solenoid B Electrical (Cont’d)


Step Action Yes No
9 1. Disconnect the transmission 16–way connector H–53.
2. Using the J39200 DVOM, measure the resistance between
terminals H53–16 and H53–15.
Is the resistance within 18–20 ohms? Go to Step 20 Go to Step 11
10 Using the J39200 DVOM, check a continuity between PCM
connector terminal J3–E14 and ground.
Is there a continuity? Go to Step 21 Go to Step 12
11 1. Disconnect the transmission main case connector M–7.
2. Using the J39200 DVOM, measure the resistance between
terminals M7–1(A) and M7–4(C).
Is the resistance within 18 – 20 ohms? Go to Step 22 Go to Step 23
12 Check every connection of the PCM and transmission 16–way
connector H–53.
Was a problem found and corrected? Go to Step 25 Go to Step 13
13 1. Connect the J2 (WHITE) and J3 (BLUE) PCM connectors to
the PCM.
2. Turn the ignition “on”, the engine “on”.
3. Repeat Step 2.
Go to Diagnostic
Does the scan tool display DTC P0758 at 3rd gear? Go to Step 24 Aids
14 The wiring harness between PCM connector terminal
J2–C2 and transmission main case terminal M7–1(A) is shorted
to voltage.
Was a problem found and corrected? Go to Step 25 —
15 The PCM internal terminal J2–C2 is shorted to voltage.
Replace the PCM. Refer to Powertrain Control Module (PCM) in
Automatic Transmission (4L30–E) section.
Is the replacement complete? Go to Step 25 —
16 The wiring harness between PCM connector and transmission
16–way connector is shorted.
Was a problem found and corrected? Go to Step 25 —
17 The wiring harness between transmission 16–way connector and
transmission main case connector is shorted.
Was a problem found and corrected? Go to Step 25 —
18 The shift solenoid B is faulty, or the internal wiring harness from
the shift solenoid B is shorted.
Was a problem found and corrected? Go to Step 25 —
19 The wiring harness between PCM connector terminal
J2–C2 and transmission main case connector terminal M7–1(A)
is shorted to ground.
Was a problem found and corrected? Go to Step 25 —
20 The wiring harness between PCM connector terminal J2–C2 and
transmission 16–way connector terminal H53–16, or between
PCM connector terminal J3–E14 and 16–way connector terminal
H53–15 is open.
Was a problem found and corrected? Go to Step 25 —
7A1–64 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0758 Shift Solenoid B Electrical (Cont’d)


Step Action Yes No
21 The wiring harness between PCM connector terminal J3–E14
and transmission main case connector terminal M7–4(C) is
shorted to ground.
Was a problem found and corrected? Go to Step 25 —
22 The wiring harness between transmission 16–way connector
terminal H53–16 and transmission main case connector terminal
M7–1(A), or between H53–15 and M7–4(C) is open.
Was a problem found and corrected? Go to Step 25 —
23 The internal wiring harness from the shift solenoid B is open, or
the shift solenoid B is faulty.
Was a problem found and corrected? Go to Step 25 —
24 Replace the PCM.
Is the replacement complete? Go to Step 25 —
25 1. After the repair is complete, use the scan tool to select “DTC”,
then “Clear Info” function and operate the vehicle under the
following conditions:
The shift solenoid B is commanded “on” and voltage drop to
zero.
The shift solenoid B is commanded “off” and voltage
increases to B+. Begin diagnosis
2. Review the scan tool “DTC Info”. again Repair verified
Has the last test failed or is the current DTC displayed? Go to Step 1 Exit DTC table
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–65

DTC P1790 ROM Transmission Side Immediate landing to 4th gear.


Inhibit TCC engagement.
Bad Check Sum
The PCM will illuminate the CHECK TRANS Lamp.
Circuit Description
Transmission Side Read Only Memory (ROM) and Conditions For Clearing The DTC/CHECK
Electronically Erasable Programmable Read Only TRANS Lamp
Memory (EEPROM) is an electronic circuit that controls The PCM will turn off the CHECK TRANS Lamp after
the transmission control in the Powertrain Control Module three consecutive ignition cycles without a failure
(PCM). reported.
This DTC detects a check sum error. This is a type “C” The DTC can be cleared from the PCM history by
DTC. using a scan tool.
Conditions For Setting The DTC The DTC will be cleared from history when the vehicle
has achieved 40 warmup cycles without a failure
Detects check sum error for 1 second. reported.
The PCM will cancel the DTC default actions when
Action Taken When The DTC Sets the fault no longer exists and the ignition is cycled “off”
Maximum line pressure. long enough to power down the PCM.

DTC P1790 ROM Transmission Side Bad Check Sum


Step Action Yes No
1 1. Install the scan tool.
2. With the engine “off”, turn the ignition switch “on”.
NOTE: Before clearing DTC(s), use the scan tool to record “Failure
Records” for reference, as data will be lost when the “Clear Info”
function is used.
3. Record the DTC “Failure Records”.
Was DTC P1790 set? Go to Step 4 Go to Step 2
2 Was DTC P1792 set? Go to Step 3 —
3 1. Remove the PCM. Refer to Powertrain Control Module (PCM)
in Automatic Transmission (4L30–E) section.
2. Using the ITCS, make a reprogramming the transmission
EEPROM.
Was the reprogramming complete? Go to Step 5 —
4 Replace the PCM.
Is the replacement complete? Go to Step 5 —
5 1. After the repair is complete, use the scan tool to select “DTC”,
then “Clear Info” function and operate the vehicle. Begin diagnosis
2. Review the scan tool “DTC Info”. again Repair verified
Has the last test failed or is the current DTC displayed? Go to Step 1 Exit DTC table
7A1–66 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P1792 EEPROM Transmission Immediate landing to 4th gear.


Inhibit TCC engagement.
Side Bad Check Sum
The PCM will illuminate the CHECK TRANS Lamp.
Circuit Description
Transmission Side Read Only Memory (ROM) and Conditions For Clearing The DTC/CHECK
Electronically Erasable Programmable Read Only TRANS Lamp
Memory (EEPROM) is an electronic circuit that controls The PCM will turn off the CHECK TRANS Lamp after
the transmission control in the Powertrain Control Module three consecutive ignition cycles without a failure
(PCM). reported.
This DTC detects a check sum error. This is a type “C” The DTC can be cleared from the PCM history by
DTC. using a scan tool.
Conditions For Setting The DTC The DTC will be cleared from history when the vehicle
has achieved 40 warmup cycles without a failure
Detects check sum error for 1 second. reported.
The PCM will cancel the DTC default actions when
Action Taken When The DTC Sets the fault no longer exists and the ignition is cycled “off”
Maximum line pressure. long enough to power down the PCM.

DTC P1792 EEPROM Transmission Side Check Bad Check Sum


Step Action Yes No
1 1. Install the scan tool.
2. With the engine “off”, turn the ignition switch “on”.
NOTE: Before clearing DTC(s), use the scan tool to record “Failure
Records” for reference, as data will be lost when the “Clear Info”
function is used.
3. Record the DTC “Failure Records”.
Was DTC P1790 set? Go to Step 4 Go to Step 2
2 Was DTC P1792 set? Go to Step 3 —
3 1. Remove the PCM. Refer to Powertrain Control Module (PCM)
in Automatic Transmission (4L30–E) section.
2. Using the ITCS, make a reprogramming the transmission
EEPROM.
Was the reprogramming complete? Go to Step 5 —
4 Replace the PCM.
Is the replacement complete? Go to Step 5 —
5 1. After the repair is complete, use the scan tool to select “DTC”,
then “Clear Info” function and operate the vehicle. Begin diagnosis
2. Review the scan tool “DTC Info”. again Repair verified
Has the last test failed or is the current DTC displayed? Go to Step 1 Exit DTC table
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–67

DTC P1835 Kickdown Switch Always On

D07RW033

Circuit Description Conditions For Clearing The DTC


When the driver presses the accelerator pedal down The DTC can be cleared from the PCM history by
fully, the kickdown switch closes, sending a ground using a scan tool.
signal to the Powertrain Control Module (PCM). The DTC will be cleared from history when the vehicle
This information is used to perform shifts at high has achieved 40 warmup cycles without a failure
engine speed. reported.
When the kickdown switch is closed, the Throttle The PCM will cancel the DTC default actions when
Position Sensor (TPS) is already is at 100%. the fault no longer exists and the ignition is cycled “off”
This DTC detects a closed kickdown switch when TP long enough to power down the PCM.
angle is less than 70%.
This is a type “D” DTC.
Diagnostic Aids
Check the wiring harness for a short to ground
Conditions For Setting The DTC between the PCM and kickdown switch.
No TPS DTCs P0122 or P0123. Check the kickdown switch for failure.
TP angle is less than 70%. Check kickdown adjustment.
Kickdown switch is “on”.
Test Description
All conditions met for 1 second.
The numbers below refer to the step numbers on the
Action Taken When The DTC Sets. diagnostic chart:
1. This test checks for short to ground or kickdown
Kickdown mode control is off. switch failure.
The PCM will not illuminate the CHECK TRANS 3. This test checks for regulation kickdown switch.
Lamp.
7A1–68 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P1835 Kickdown Switch Always On


Step Action Yes No
1 1. Install the scan tool.
2. With the engine “on”, turn the ignition switch “on”.
NOTE: Before clearing DTC(s), use the scan tool to record “Failure
Records” for reference, as data will be lost when the “Clear Info”
function is used.
3. Record the DTC “Failure Records”.
Does the scan tool display “Kickdown switch” “low” (closed
switch)? Go to Step 2 Go to Step 3
2 1. Turn the ignition “off”.
2. Disconnect the J3 (BLUE) PCM connector.
3. Using the J39200 DVOM, check a continuity between PCM
connector terminal J3–F11 and ground.
Is there a continuity? Go to Step 4 Go to Step 7
3 The TP angle goes from 0% to 100% with the accelerator pedal
depressed.
Go to Diagnostic
Is the kickdown switch “on” when TP angle is below 70%? Go to Step 5 Aids
4 1. Disconnect the kickdown switch connector B–10.
2. Using the J39200 DVOM, check a continuity between
terminals B10–1 and B10–2.
Is there a continuity? Go to Step 6 Go to Step 8
5 Adjust the kickdown switch.
Is the kickdown switch “on” when TP angle is above 95%? Go to Step 9 —
6 Replace the kickdown switch.
Is the replacement complete? Go to Step 9 —
7 Replace the PCM. Refer to Powertrain Control Module (PCM) in
Automatic Transmission (4L30–E) section.
Is the replacement complete? Go to Step 9 —
8 Repair the short to ground in circuit LT BLUE.
Is the repair complete? Go to Step 9 —
9 1. After the repair is complete, use the scan tool to select “DTC”,
then “Clear Info” function and ensure the following condition is
met:
The torque converter stator temperature switch circuit does not
indicate a hot mode when the transmission fluid temperature is
less than 60 C (140 F) for at least 5 seconds.
Begin diagnosis
2. Review the scan tool “DTC Info”. again Repair verified
Has the last test failed or is the current DTC displayed? Go to Step 1 Exit DTC table
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–69

DTC P1850 Brake Band Apply Solenoid Malfunction

D07RW009

Circuit Description This DTC detects a continuous open or short to ground in


the brake band apply solenoid circuit or the brake band
The brake band apply solenoid is a normally open
apply solenoid. This is a type “D” DTC.
solenoid which controls the flow of fluid for brake band
application. The Powertrain Control Module (PCM)
uses Pulse Width Modulation (PWM) and changes
Conditions For Setting The DTC
the duty cycle to control the solenoid. The PCM turns Battery voltage is between 10 and 16 volts.
the solenoid on (energized) and off (deenergized) at a Ignition is “on”, Engine “run”.
constant frequency. The length of time the solenoid is The PCM commands the solenoid “on” and the
energized during each on/off cycle is called the pulse voltage remains high (B+) or the PCM commands the
width. By varying or “modulating” the pulse width, the solenoid “off” and the voltage remains low (zero
solenoid output pressure is changed. Since the volts).
solenoid is normally open, increasing the pulse width
increases the duty cycle and decreases the output All conditions met in 1.3 seconds.
pressure. PWM control provides smooth band
application without an accumulator. The band is only Action Taken When The DTC Sets
applied in first and second gears. Inhibit brake band apply solenoid.
In the event of an electrical failure (open), the The PCM will not illuminate the CHECK TRANS
solenoid regulates at the maximum oil flow (0% duty Lamp.
cycle).
The solenoid is activated by current. This current is Conditions For Clearing The DTC
produced by applying a voltage to one side (the High The DTC can be cleared from the PCM history by
side) and a ground to the other side (Low side). using a scan tool.
The High Side Driver (HSD) is a circuit of the PCM The DTC will be cleared from history when the vehicle
that acts as a switch between the solenoids and the has achieved 40 warmup cycles without a failure
supply voltage. The High side of the solenoid is reported.
permanently supplied with voltage. When the ignition
is off, the HSD is turned off. The PCM will cancel the DTC default actions when
the fault no longer exists and the ignition is cycled “off”
long enough to power down the PCM.
7A1–70 TRANSMISSION CONTROL SYSTEM (4L30–E)

Diagnostic Aids Test Description


Inspect the wiring for poor electrical connection at the The numbers below refer to the step numbers on the
PCM and at the transmission 16–way connector. diagnostic chart:
Look for possible bent, backed out, deformed or 2. This test checks for power to the brake band apply
damaged terminals. Check for weak terminal tension solenoid from the ignition through the PCM.
as well. Also check for a chafed wire that could short 3. This test checks the resistance of the transmission
to bare metal or other wiring. Inspect for a broken wire internal wiring harness and brake band apply
inside the insulation. solenoid.
When diagnosing for a possible intermittent short or 4. This test checks the ability of the PCM and wiring to
open condition, move the wiring harness while control the ground circuit.
observing test equipment for a change.

DTC P1850 Brake Band Apply Solenoid Malfunction


Step Action Yes No
1 1. Install the scan tool.
2. With the engine “on”, turn the ignition switch “on”.
NOTE: Before clearing DTC(s), use the scan tool to record “Failure
Records” for reference, as data will be lost when the “Clear Info”
function is used.
3. Record the DTC “Failure Records”.
Were DTCs P0753, P0758 set? Go to Step 2 Go to Step 3
2 Using the J39200 DVOM, back probe between PCM connector
terminals J3–E14 and J2–C8.
Is the voltage between 10 to 12 volts? Go to Step 4 Go to Step 5
3 1. Turn the ignition “off”.
2. Disconnect the J1 (RED) and J3 (BLUE) PCM connectors.
3. Using the J39200 DVOM, measure the resistance between
PCM connector terminals J1–A16 and J3–E14.
Is the resistance within 10–12 ohms? Go to Step 11 Go to Step 12
4 Using the J39200 DVOM, back probe between PCM connector
terminals J1–A16 and J2–C8.
Is the voltage between 10 to 12 volts? Go to Step 25 Go to Step 3
5 1. Turn the ignition “off”.
2. Disconnect the J1 (RED) and J3 (BLUE) PCM connectors.
3. Using the J39200 DVOM, check continuity between PCM
terminal J3–E14 and ground.
Is there a continuity? Go to Step 6 Go to Step 8
6 1. Disconnect the transmission 16–way connector H–53.
2. Using the J39200 DVOM, check continuity between connector
H53–13 and ground.
Is there a continuity? Go to Step 7 Go to Step 16
7 1. Disconnect the transmission main case connector M–7.
2. Using the J39200 DVOM, check continuity between the
terminal M7–2(B) and ground.
Is there a continuity? Go to Step 17 Go to Step 18
8 1. Disconnect the J1 (RED) PCM Connector.
2. Using the J39200 DVOM, measure the resistance between
PCM connector terminals J1–A16 and J3–E14.
Is the resistance within 10–12 ohms? Go to Step 25 Go to Step 9
9 1. Disconnect the transmission 16–way connector H–53.
2. Using the J39200 DVOM, measure the resistance between
terminal H53–13 and H53–15.
Is the resistance within 10–12 ohms? Go to Step 16 Go to Step 10
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–71

DTC P1850 Brake Band Apply Solenoid Malfunction (Cont’d)


Step Action Yes No
10 1. Disconnect the transmission main case connector M–7.
2. Using the J39200 DVOM, measure the resistance between
terminals M7–2(B) and M7–4(C).
Is the resistance within 10–12 ohms? Go to Step 19 Go to Step 20
11 Using the J39200 DVOM, check continuity between PCM
terminal J1–A16 and ground.
Is there a continuity? Go to Step 13 Go to Step 25
12 1. Disconnect the transmission 16–way connector H–53.
2. Using the J39200 DVOM, measure the resistance between
terminal H53–13 and H53–15.
Is the resistance within 10–12 ohms? Go to Step 23 Go to Step 14
13 1. Disconnect the transmission 16–way connector H–53.
2. Using the J39200 DVOM, check continuity between terminal
H53–13 and ground.
Is there a continuity? Go to Step 15 Go to Step 21
14 1. Disconnect the transmission main case connector M–7.
2. Using the J39200 DVOM, measure the resistance between
terminals M7–2(B) and M7–4(C).
Is the resistance within 10–12 ohms? Go to Step 24 Go to Step 20
15 1. Disconnect the transmission main case connector M–7.
2. Using the J39200 DVOM, check continuity between the
terminal M7–2(B) and ground.
Is there a continuity? Go to Step 17 Go to Step 22
16 The wiring harness between PCM terminal J3–E14 and
transmission 16–way connector terminal H53–15 is open.
Was a problem found and corrected? Go to Step 26 —
17 The brake band apply solenoid is faulty, or the internal wiring
harness from the brake band apply solenoid is shorted to ground.
Was a problem found and corrected? Go to Step 26 —
18 The wiring harness between the transmission 16–way connector
terminal H53–15 and the transmission main case connector
terminal M7–4(C) is shorted to ground.
Was a problem found and corrected? Go to Step 26 —
19 The wiring harness between the transmission 16–way connector
terminal H53–15 and the transmission main case connector
terminal M7–4(C) is open.
Was a problem found and corrected? Go to Step 26 —
20 The brake band apply solenoid is faulty, or the internal wiring
harness from the brake band apply solenoid is open.
Was a problem found and corrected? Go to Step 26 —
21 The wiring harness between the PCM connector terminal J1–A16
and transmission 16–way connector terminal H53–13 is shorted
to ground.
Was a problem found and corrected? Go to Step 26 —
22 The wiring harness between the transmission 16–way connector
terminal H53–13 and the transmission main case connector
terminal M7–2(B) is shorted to ground.
Was a problem found and corrected? Go to Step 26 —
7A1–72 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P1850 Brake Band Apply Solenoid Malfunction (Cont’d)


Step Action Yes No
23 The wiring harness between the PCM connector terminal J1–A16
and the 16–way connector terminal H53–13 is open.
Was a problem found and corrected? Go to Step 26 —
24 The wiring harness between the transmission 16–way connector
terminal H53–13 and the transmission main case connector
terminal M7–2(B) is open.
Was a problem found and corrected? Go to Step 26 —
25 Check every connection at the PCM.
If OK, replace the PCM. Refer to Powertrain Control Module
(PCM) in Automatic Transmission (4L30–E) section.
Is the replacement complete? Go to Step 26 —
26 1. After the repair is complete, use the scan tool to select “DTC”,
then “Clear Info” function and ensure the following conditions
are met:
The brake band apply solenoid is commanded “on” and the
volts drop to zero.
The brake band apply solenoid is commanded “off” and the
volts increase to B+. Begin diagnosis
2. Review the scan tool “DTC Info”. again Repair verified
Has the last test failed or is the current DTC displayed? Go to Step 1 Exit DTC table
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–73

DTC P1860 TCC Solenoid Electrical

D07RW010

Circuit Description The PCM will not illuminate the CHECK TRANS
The PCM allows current to flow through the solenoid coil Lamp.
according to the duty cycle (percentage of “on” and “off”
time). This current flow through the solenoid coil creates
Conditions For Clearing The DTC
a magnetic field that magnetizes the solid core. The The DTC can be cleared from the PCM history by
magnetized core attracts the check ball to seat against using a scan tool.
spring pressure. This blocks the exhaust for the TCC The DTC will be cleared from history when the vehicle
signal fluid and allows 2–3 drive fluid to feed to TCC signal has achieved 40 warmup cycles without a failure
circuit. The TCC signal fluid pressure acts on the TCC reported.
regulator valve to regulate line pressure and to apply fluid The PCM will cancel the DTC default actions when
pressure to the torque converter clutch shift valve. When the fault no longer exists and the ignition is cycled “off”
the TCC shift valve is in the apply position, regulated long enough to power down the PCM.
apply fluid pressure is directed through the TCC valve to
apply the torque converter clutch. The TCC solenoid is Diagnostic Aids
used in conjunction with the TCC solenoid to regulate fluid Inspect the wiring for poor electrical connections at
to the torque converter. The TCC solenoid is attached to the PCM and at the transmission 16–way connector.
the valve body within the transmission. Look for possible bent, backed out, deformed or
This DTC detects a continuous open or short to ground or damaged terminals. Check for weak terminal tension
ignition in the TCC circuit or the TCC solenoid. This is a as well. Also check for a chafed wire that could short
type “D” DTC. to bare metal or other wiring. Inspect for a broken wire
inside the insulation.
Conditions For Setting The DTC When diagnosing for a possible intermittent short or
Battery voltage is between 10 and 16 volts. open condition, move the wiring harness while
No shift solenoid A DTC P0753. observing test equipment for a change.
No shift solenoid B DTC P0758.
Test Description
Ignition is “on”, Engine “run”.
The numbers below refer to the step numbers on the
The PCM commands the solenoid “on” and the diagnostic chart:
voltage remains low (zero volts).
2. This test checks for voltage to the solenoid.
The PCM commands the solenoid “off” and the
voltage remains high (B+). 3. This test checks the ability of the PCM and wiring to
control the ignition circuit.
All conditions met for 0.25 seconds.
8. This test checks the resistance of the TCC solenoid
Action Taken When The DTC Sets and the internal wiring harness.

Inhibit TCC engagement.


7A1–74 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P1860 TCC Solenoid Electrical


Step Action Yes No
1 1. Install the scan tool.
2. With the engine “on”, turn the ignition switch “on”.
NOTE: Before clearing DTC(s), use the scan tool to record “Failure
Records” for reference, as data will be lost when the“Clear Info”
function is used.
3. Record the DTC “Failure Records”.
Go to Step 2 Go to Step 3
2 Using the J39200 DVOM, back probe between PCM connector
terminals J2–D2 and J2–C8.
Is the voltage 0 ? Go to Step 4 Go to Step 5
3 1. Apply brake pedal and select transmission range “D”.
2. Do a test drive, and increase the vehicle speed to TCC “on” at
4th.
Go to Diagnostic
Does the scan tool display DTC P1860 at TCC “ON”? Go to Step 9 Aids
4 1. Turn the ignition “off”.
2. Disconnect the J2 (WHITE) PCM connector.
3. Using the J39200 DVOM, measure the resistance between
PCM connector terminals J2–D2 and J2–C8.
Is the resistance within 18 – 20 ohms? Go to Step 6 Go to Step 7
5 The wiring harness between PCM connector terminal J2–D2 and
transmission adapter case connector terminal M6–4(A) is shorted
to voltage.
Was a problem found and corrected? Go to Step 18 Go to Step 19
6 Intermittent condition.
Check the wiring harness and terminals between PCM connector
J2 and transmission adapter case connector M–6.
Was a problem found and corrected? Go to Step 18 Go to Step 19
7 1. Disconnect the transmission 16–way connector H–53.
2. Using the J39200 DVOM, measure the resistance between
terminal H53–8 and ground.
Is the resistance within 18 – 20 ohms? Go to Step 15 Go to Step 8
8 1. Disconnect the transmission adapter case connector M–6.
2. Using the J39200 DVOM, measure the resistance between
terminal M6–4(A) and ground.
Is the resistance within 18 – 20 ohms? Go to Step 16 Go to Step 17
9 1. Turn the ignition “off”.
2. Disconnect the J2 (WHITE) PCM connector.
3. Using the J39200 DVOM, measure the resistance between
terminals J2–D2 and J2–C8.
Is the resistance within 18 – 20 ohms? Go to Step 18 Go to Step 10
10 1. Disconnect the transmission 16–way connector H–53.
2. Using the J39200 DVOM, measure the resistance between
terminal H53–8 and ground.
Is the resistance within 18–20 ohms? Go to Step 12 Go to Step 11
11 1. Disconnect the transmission adapter case connector M–6.
2. Using the J39200 DVOM, measure the resistance between
terminal M6–4(A) and ground.
Is the resistance within 18–20 ohms? Go to Step 13 Go to Step 14
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–75

DTC P1860 TCC Solenoid Electrical (Cont’d)


Step Action Yes No
12 The wiring harness between PCM connector terminal J2–D2 and
transmission 16–way connector terminal H53–8 is shorted to
ground.
Was a problem found and corrected? Go to Step 20 —
13 The wiring harness between transmission 16–way connector
H–53 and adapter case connector M–6 is shorted to ground.
Was a problem found and corrected? Go to Step 20 —
14 The TCC solenoid is faulty, or the internal wiring harness from the
TCC solenoid is shorted to ground.
Was a problem found and corrected? Go to Step 20 —
15 The wiring harness between PCM connector terminal J2–D2 and
transmission 16–way connector terminal H53–8 is open.
Was a problem found and corrected? Go to Step 20 —
16 The wiring harness between transmission 16–way connector
terminal H53–8 and adapter case terminal M6–4(A) is open.
Was a problem found and corrected? Go to Step 20 —
17 The TCC solenoid is faulty, or the internal wiring harness from the
TCC solenoid is open.
Was a problem found and corrected? Go to Step 20 —
18 Check every connection at the PCM.
If OK, replace the PCM. Refer to Powertrain Control Module
(PCM) in Automatic Transmission (4L30–E) section.
Is the replacement complete? Go to Step 20 —
19 Check the PCM connector terminal J2–D2, transmission 16–way
connector terminal H53–8 and transmission adapter case
connector terminal M6–4(A).
Was a problem found and corrected? Go to Step 20 —
20 1. After the repair is complete, use the scan tool to select “DTC”,
then “Clear Info” function and ensure the following conditions
are met:
The TCC solenoid is commanded “on” and the volts increase
to B+.
The TCC solenoid is commanded “off” and the volts drop to
zero. Begin diagnosis
2. Review the scan tool “DTC Info”. again Repair verified
Has the last test failed or is the current DTC displayed? Go to Step 1 Exit DTC table
7A1–76 TRANSMISSION CONTROL SYSTEM (4L30–E)

Transmission Fluid Temperature (TFT) Sensor Specifications


Temperature Temperature Minimum Nominal Maximum Signal
Resistance Resistance Resistance
C F Volts
-40 -40 600500 664200 731100 5.00
-30 -22 319800 350400 382400 4.65
-20 -4 177400 192700 208600 4.41
-10 14 102200 110100 118300 4.00
0 32 60870 65110 69450 3.52
10 50 37410 39750 42120 2.98
20 68 23660 24980 26300 2.40
30 86 15270 16120 16970 1.85
40 104 10040 10660 11290 1.43
50 122 6758 7211 7673 4.29
60 140 4645 4980 5324 4.04
70 158 3255 3506 3765 3.69
80 176 2323 2513 2710 3.34
90 194 1685 1831 1982 3.04
100 212 1242 1355 1472 2.58
110 230 929 1017 1109 2.24
120 248 704 773 846 1.97
130 266 540 595 653 1.67
140 284 419 464 511 1.42
150 302 329 365 403 1.16
MANUAL TRANSMISSION 7B–1

TRANSMISSION
MANUAL TRANSMISSION
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 7B–1 Transmission (AR-5) . . . . . . . . . . . . . . . . . . . . . 7B–18
General Description . . . . . . . . . . . . . . . . . . . . . 7B–2 Disassembled View . . . . . . . . . . . . . . . . . . . . 7B–18
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–4 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–21
Manual Transmission Assembly . . . . . . . . . . . 7B–5 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–39
Transmission and Associated Parts . . . . . . 7B–5 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–41
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–6 Main Data and Specifications . . . . . . . . . . . . . 7B–68
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–11 General Specifications . . . . . . . . . . . . . . . . . 7B–68
Rear Oil Seal (Transfer Adapter) . . . . . . . . . . 7B–17 Torque Specifications . . . . . . . . . . . . . . . . . . 7B–69
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–17 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–72
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–17

Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
7B–2 MANUAL TRANSMISSION

General Description
(6VE1)

A07RW044
MANUAL TRANSMISSION 7B–3

(4JX1)

A07RW043
7B–4 MANUAL TRANSMISSION

Diagnosis
Condition Possible cause Correction
Abnormal noise Flywheel pilot bearing worn Replace
Bearings worn or broken (Mainshaft, Replace
counter shaft, and transfer shaft)
Gear tooth contact surfaces worn or Replace
scuffed (Mainshaft, counter shaft,
reverse idler gear and transfer gears)
Splines worn (Mainshaft, Replace
synchronizer clutch hub)
Gear or bearing thrust face seized Replace
Lack of backlash between meshing Replace
gears
Hard Shifting Improper clutch pedal free play Readjust
Change lever sliding portions worn Repair or replace
Regrease
Shift block, shift rod and/or control Replace
box sliding faces worn
Shift arm and synchronizer sleeve Replace worn parts
groove worn
Thrust washer, collar, and/or gear Replace worn parts
thrust faces worn (Mainshaft and
counter shaft thrust play)
Synchronizer parts worn Replace
Walking or Jumping out of gear Detent ball worn Replace
Detent spring weakened or broken Replace
Shift rod and/or control box sliding Replace
faces worn
Shift arm and synchronizer sleeve Replace worn parts
groove worn
Thrust washer, collar, and/or gear Replace worn parts
thrust faces worn (Mainshaft and
counter shaft thrust play)
Bearings worn or broken Replace
Splines worn (Mainshaft, Replace
synchronizer hub)
Synchronizer spring weakened or Replace
broken
Oil leakage Loose drain plug(s) and/or filler Tighten
plug(s) Replenish oil
Defective or improperly installed Replace
gasket(s)
Oil seal worn or scratched Replace
MANUAL TRANSMISSION 7B–5

Manual Transmission Assembly


Transmission and Associated Parts

220RW108

Legend (11) Slave Cylinder Heat Protector


(1) Gear Control Lever and Knob (12) Harness Heat Protector
(2) Transfer Control Lever and Knob (13) Slave Cylinder
(3) Front Console Assembly (14) Dust Cover
(4) Grommet Assembly (15) Engine Rear Mount Nut
(5) Transfer Protector (16) Engine Rear Mount Bolt
(6) Rear Propeller Shaft (17) Engine Rear Mount
(7) Front Propeller Shaft (18) Third Crossmember
(8) Exhaust Pipe (19) Flywheel Under Cover
(9) Backup Lamp, 4WD Indicator, and 1–2 (20) Transmission Retaining Bolt
Indicator Switch Harness Connector (21) Transmission Assembly with Transfer Case
(10) Speedometer Sensor and 2WD–4WD Actuator
Harness Connector
7B–6 MANUAL TRANSMISSION

Removal 10. Remove the front propeller shaft.


NOTE: Apply alignment marks on the flange at both the
NOTE: Before remove the transmission and transfer
front and rear sides.
assembly from the vehicle, change the transfer mode to
2WD using push button on dash panel.
1. Remove engine hood.
2. Disconnect battery ground cable.
3. Remove the gear control lever knob.
4. Remove the front console assembly.
5. Remove the grommet assembly.
6. Remove the transmission control lever and transfer
control lever.

401RS003

11. Disconnect two oxygen sensor connectors from the


transmission harness (6VE1).
12. Remove the front and 3 way exhaust pipe (6VE1).
Remove the exhaust pipe with catalytic converter
(4JX1).
(4JX1)

235RW014

7. Raise and support the vehicle with suitable jack


stand.
8. Remove transfer protector.
9. Remove the rear propeller shaft.
NOTE: Apply alignment marks on the flange at the both
front and rear side.
(4JX1)

150RW041

401RW060
MANUAL TRANSMISSION 7B–7
13. Disconnect the backup lamp switch, 4WD indicator
switch and 1–2 indicator switch harness connectors.

826RW023

14. Disconnect the speedometer sensor and 2WD-4WD


actuator harness connectors.

826RW024
7B–8 MANUAL TRANSMISSION
15. Remove four fuel pipe bracket from the transmission
case (6VE1).

141RW024
MANUAL TRANSMISSION 7B–9
16. Remove the slave cylinder heat protector. 22. Remove two engine rear mount nuts.
17. Remove the harness heat protector (6VE1). (6VE1)
(6VE1)

022RT002

225RW006
23. Remove third crossmember (6VE1).
18. Remove two transmission harness clamps and 24. Remove third crossmember with rear mount rubber
bracket (6VE1). (4JX1).
19. Remove the slave cylinder. (4JX1)

206RW002 022RW013

20. Remove the two dust cover from transmission case. 25. Remove two engine rear mount bolts (6VE1).
21. Support the transfer case with a jack. 26. Remove the rear mount from the transmission
(6VE1).
27. Remove three flywheel under cover (6VE1).
7B–10 MANUAL TRANSMISSION
28. Support the transmission with a transmission jack 3. Turn the remover to separate the release bearing.
and then remove jack from the transfer case side.
NOTE: Be sure not to insert the remover between the
wedge collar and the clutch.

220RS001

29. Use the clutch release bearing remover


5–8840–2291–0 (J–39207) to disconnect the clutch
release bearing from the clutch pressure plate.

220RW063

220RW109

Release bearing disconnection


1. Pull the shift fork toward the transmission to press
the clutch release bearing against the clutch.
2. Insert the clutch release bearing remover
between the wedge collar and the release
bearing.

220RW064
MANUAL TRANSMISSION 7B–11

220RW119 220RS005

Legend 4. Install the transmission to the engine.


(1) Pressure Plate Assembly Tighten the transmission retaining nuts and bolts.
(2) Release Bearing
(3) Wedge Collar

30. Remove the transmission retaining nuts and bolts.


31. Remove the transmission assembly with transfer
case from the vehicle.
NOTE: Remove the transfer case from the transmission
assembly if the transmission disassembly required.
Refer to Transfer Case in Drive Line/Axle section.

Installation
1. Apply a thin coat of molybdenum disulfide grease to
the top gear shaft spline.
2. Slowly operate the transmission jack until the front of
transmission is aligned with the rear of the engine.
The slope of the engine and the transmission must be
the same.
3. Align the top gear shaft spline with the clutch driven
plate spline.
7B–12 MANUAL TRANSMISSION

(6VE1)

225RW019
MANUAL TRANSMISSION 7B–13

(4JX1)

225RW020

5. Apply a force of about 113N (26 Ib) to the tip of the


shift fork in the direction of the transmission to engage
the clutch pressure plate and release bearing.
NOTE: A clicking sound is heard when the release
bearing and the tip of the diaphragm spring engage each
other.
Check to see if they are securely engaged by pushing the
tip of the shift fork toward the engine while applying a
force of about 25 N (5.5 lb). If the shift fork will not move,
then they are securely engaged.

220RS006

6. Install three flywheel under cover (6VE1).


7B–14 MANUAL TRANSMISSION
7. Install the engine rear mount to the transmission case (6VE1)
and tighten the fixing bolts specified torque (6VE1).
Torque: 41 Nꞏm (4.2kgꞏm/30 Ib ft)
8. Install the third crossmember to the frame and tighten
the fixing bolts specified torque.
Torque: 50 Nꞏm (5.1kgꞏm/37 Ib ft)
9. Tighten the engine rear mount nuts specified torque.
Torque: 50 Nꞏm (5.1kgꞏm/37 Ib ft)
10. Remove the transmission jack.
11. Apply the grease to top hole portion of the shift fork.
12. Install the slave cylinder and tighten the fixing bolts
specified torque.
Torque: 43 Nꞏm (4.4kgꞏm/32 Ib ft)
13. Install the clutch dust cover to the clutch housing and
tighten the fixing bolts specified torque.
Torque: 8 Nꞏm (0.8kgꞏm/69 Ib in)
225RW006

17. Install four fuel pipe bracket (6VE1).

220RS007

14. Install the slave cylinder heat protector to the slave


cylinder.
15. Install bracket and two transmission harness clamps
to the transmission case (6VE1).
16. Install harness heat protector (6VE1).
MANUAL TRANSMISSION 7B–15

141RW024

18. Connect the speedometer sensor and 2WD–4WD


actuator harness connector.

826RW024
7B–16 MANUAL TRANSMISSION
19. Connect the backup lamp switch, 4WD indicator 24. Install transfer protector and tighten the fixing bolts
switch, and 1-2 indicator switch harness connectors. specified torque.
Torque: 37 Nꞏm (3.8 kgꞏm/27 Ib ft)
25. Install the transmission control lever and transfer
control lever.

826RW023

20. Install the front and 3 way exhaust pipe (6VE1).


Install the exhaust pipe with catalytic converter
(4JX1).
235RW014

Torque: 26. Install the grommet assembly.


Exhaust pipe to exhaust manifold: 27. Install the front console assembly.
67 Nꞏm (6.8 kgꞏm/49 Ib ft) 28. Install the gear control lever knob.
Exhaust pipe flange bolt: 29. Connect battery ground cable.
43 Nꞏm (4.4 kgꞏm/32 Ib ft) 30. Install engine hood.
(4JX1)

150RW041

21. Connect two oxygen sensor connectors to the


transmission harness (6VE1).
22. Install the front propeller shaft and tighten the fixing
bolts and nuts specified torque.
Torque: 63 Nꞏm (6.4 kgꞏm/46 Ib ft)
23. Install the rear propeller shaft and tighten the fixing
bolts and nuts specified torque.
Torque: 63 Nꞏm (6.4 kgꞏm/46 Ib ft)
MANUAL TRANSMISSION 7B–17

Rear Oil Seal (Transfer Adapter)


Removal Installation
1. Remove the transfer case assembly from the vehicle. 1. Use 5–8840–2558–0 (J–42802) transfer adapter oil
Refer to Transfer Case in Drive Line/Axle section. seal installer, and install the rear oil seal to the transfer
adapter.
2. Remove the rear oil seal from the transfer adapter.
2. Apply grease to the oil seal lip.
3. Install the transfer case assembly to the vehicle.
Refer to Transfer Case in Drive Line/Axle section.

220RW090

220RW115
7B–18 MANUAL TRANSMISSION

Transmission (AR-5)
Disassembled View

226RW182

Legend (16) Clutch Hub No.1 Assembly


(1) Snap Ring (17) Snap Ring
(2) Bearing (18) Synchronizer Assembly
(3) Top Gear Shaft (19) 1st Gear
(4) Block Ring (20) 1st Gear Bearing Spacer
(5) Roller Bearing (21) 1st Gear Needle Roller Bearing
(6) Snap Ring (22) 1st Gear Thrust Washer
(7) Clutch Hub No.2 Assembly (23) Mainshaft Bearing
(8) 3rd Block Ring (24) Snap Ring
(9) 3rd Gear (25) 5th Gear
(10) 3rd Gear Needle Roller Bearing (26) Snap Ring
(11) Mainshaft (27) Intermediate Plate
(12) Thrust Washer Pin (28) Bearing Retainer
(13) 2nd Gear Needle Roller Bearing (29) Snap Ring
(14) 2nd Gear (30) Front Bearing Assembly
(15) Synchronizer Assembly (31) Counter Gear Shaft
MANUAL TRANSMISSION 7B–19
(32) Thrust Washer Pin (39) Counter 5th Gear
(33) Reverse Idle Gear (40) Reverse Block Ring
(34) Reverse Idle Gear Shaft (41) Synchronizer Assembly
(35) Counter Gear Shaft Center Bearing (42) Hub Sleeve No.3
(36) Snap Ring (43) 5th Gear Spline Piece
(37) Thrust Washer (44) Snap Ring
(38) Roller Bearing

226RW00001

Legend (9) Reverse Shift Arm Bracket


(1) 3rd-4th Shift Arm (10) E–Ring
(2) 1st-2nd Shift Arm (11) Reverse Shift Arm No.2
(3) 3rd-4th Shift Rod (12) Reverse Shift Arm No.1
(4) Ball (13) 5th Reverse Shift Rod
(5) Spring (14) Spring Pin
(6) 1st-2nd Shift Rod (15) 5th Shift Arm
(7) Snap Ring (16) Reverse Shift Rod
(8) Interlock Pin
7B–20 MANUAL TRANSMISSION

220RW095

Legend (10) Filler Plug


(1) Release Bearing and Shift Fork (11) Gear Control Rod
(2) Clutch Housing (12) Reverse Restrict Pin
(3) Front Cover (13) Oil Receiver Pipe
(4) Snap Ring (14) Transfer Adapter
(5) Snap Ring (15) Plug (6VE1) or Neutral Switch (4JX1)
(6) 1st and 2nd Switch (16) Gear Control Box
(7) Drain Plug (17) Shift Lever Housing
(8) Backup Light Switch (18) Oil Seal
(9) Transmission Case (19) Plug
MANUAL TRANSMISSION 7B–21

Disassembly 3. Remove the switch.


1. Remove backup light switch (6) and gasket.
1. Remove the drain plug and filler plug.
2. Remove neutral switch (7) and gasket (4JX1).
1. Remove the drain plug (1) and gasket.
2. Remove the filler plug (2) and gasket. 3. Remove 1st and 2nd switch (8) and gasket.

(6VE1) (4JX1)

220RW093
220RW007

2. Remove the clutch release bearing and shift fork. 4. Remove the clutch housing.
1. Remove the clutch release bearing (3) from the 1. Remove the 9 bolts.
front cover.
2. Remove the split pin (4). Remove the shaft from
the under. Remove the shift fork (5).

241RW001

220RW086
7B–22 MANUAL TRANSMISSION
2. Using a plastic hammer, carefully tap the clutch 6. Remove transfer adapter.
housing. 1. Using a hexagon wrench, remove the plug (1).
(6VE1)

220RW010

220RW008 2. Using a pin punch and hammer, drive out the


5. Remove gear control box and gasket. slotted spring pin (2).
1. Remove the 6 bolts, gear control box and gasket.
(6VE1)

230RW002

230RW001
MANUAL TRANSMISSION 7B–23
3. Using the M8 1.25 bolt, remove the gear control 5. Using a plastic hammer, tap the transfer adapter.
rod and the shift lever hausing.
NOTE:
NOTE: Turn the M8 bolt a few times, before remove the Be careful not to lose the pin.
gear control rod.
Cover the mainshaft splines with adhesive tape.
This will prevent damage to the oil seal lip.

220RW098

4. Remove the 10 bolts and clamp.


220RW015

7. Disassemble the transfer adapter assembly.


1. Using a torx socket wrench(T40), remove the
plug.

220RW016

220RW013
7B–24 MANUAL TRANSMISSION
2. Using a pin punch and hammer, drive out the 4. Remove the oil seal.
slotted spring pin. Remove the reverse restrict
5. Using socket hexagon wrench, remove the plug.
pin.

220RW014
220RW012
8. Remove the front cover.
3. Remove the oil receiver pipe.
1. Remove the 8 bolts.

220RW011
220RW018
MANUAL TRANSMISSION 7B–25
2. Using a plastic hammer, carefully tap the front 10. Remove the transmission case.
cover. 1. Using a snap ring expander, remove the 2 snap
rings (1)(2).

220RW017

9. Remove the front cover oil seal. 226RW004

1. Mount the front cover through the aluminum plate 2. Using a plastic hammer, carefully tap the
in a vise. transmission case.
2. Using screwdriver, remove oil seal (1).

220RW020

220RW019
7B–26 MANUAL TRANSMISSION
11. Mount the intermediate plate. 13. Remove the shift arm set bolt.
1. Mount the intermediate plate through the 1. Remove the 2 bolts from the shift arm.
aluminum plate in a vise.

226RW023

226RW005 14. Remove the counter 5th gear.


12. Remove the slotted spring pin. 1. Using 2 screwdrivers and hammer, tap out the
1. Using a pin punch and hammer, drive out the pin snap ring.
from the arm.

226RW024

226RW025
MANUAL TRANSMISSION 7B–27
2. Using remover 5–8840–2550–0 (J–42794) and 4. Remove the synchronizer pull ring, synchronizer
attachment 5–8840–2560–0 (J–42988), remove cone ring, and synchronizer outer ring from hub
the 5th gear spline piece. sleeve No.3.

226RW201 226RW066

3. Remove the hub sleeve No.3, block ring set, 5. Remove the reverse block ring from the hub
counter 5th gear, bearing and 5th shift arm. sleeve No.3. Remove the 3 inserts and 3
compression springs.

220RW101

226RW067
7B–28 MANUAL TRANSMISSION
15. Remove the thrust washer. 17. Remove the reverse idle gear.
1. Remove the thrust washer from counter gear 1. Pull out the shaft foward the rear and remove the
shaft. reverse idle gear.
2. Remove the thrust washer pin from counter gear
shaft.

226RW020

18. Remove the counter gear shaft.


226RW018
1. Using snap ring plier, remove counter gear shaft
16. Remove the bearing plate. center bearing snap ring.
1. Remove the 4 bolts and bearing retainer.

226RW015

226RW016
MANUAL TRANSMISSION 7B–29
2. Using remover 5–8840–2551–0 (J–42795) and 19. Disassemble the counter gear shaft assembly.
attachment 5–8840–2560–0 (J–42988), remove 1. Using snap ring pliers, remove the counter gear
counter gear shaft center bearing. shaft front bearing snap ring.
NOTE: Be careful not to drop the counter gear, when
removing the bearing.

226RW065

2. Using bearing separator 5–8840–0015–0


226RW199
(J–22912–01) and a press, remove the bearing.
3. Remove the counter gear from intermediate
plate.

226RW200

226RW030
7B–30 MANUAL TRANSMISSION
20. Remove the top gear shaft. 21. Disassemble the top gear shaft assembly.
1. Remove the top gear shaft from mainshaft. 1. Check for wear or damage.
NOTE: Don’t fall needle roller bearing.

226RW033

2. Remove the front bearing shaft snap ring.


226RW029

2. Remove the 4th block ring and roller bearing.

226RW062

226RW031
MANUAL TRANSMISSION 7B–31
3. Using bearing separator 5–8840–0015–0 2. Using a plastic hammer, tap the 5th-reverse shift
(J–22912–01) and a press, remove the bearing. rod at the reverse shift side.

226RW202 226RW034

22. Remove the mainshaft. 3. Remove the intermediate plate from a vise.
1. Remove mainshaft bearing snap ring. 4. Remove the mainshaft, 1st-2nd shift arm and
3rd-4th shift arm.

226RW035

226RW014
7B–32 MANUAL TRANSMISSION
23. Disassemble the mainshaft assembly. 2. Inspect each gear radial clearance
1. Inspect each gear thrust clearance. 1. Using a dial indicator, measure the radial
1. Using thickness gauge, inspect thrust clearance of each gear.
clearance (1st gear, 3rd gear).
Gear Standard Clearanse
1st 0.020 – 0.074 mm (0.00078 – 0.00291 in)
2nd 0.015 – 0.068 mm (0.00059 – 0.00268 in)
3rd 0.015 – 0.068 mm (0.00059 – 0.00268 in)

226RW077

2. Mount the mainshaft through the aluminum


plate in a vise.
3. Using a dial indicator, measure each gear
thrust clearance.
Gear Standard Clearanse 226RW071

1st 0.15 – 0.45 mm (0.0059 – 0.0177 in) 3. Using 2 screwdrivers and hammer, tap out the
snap ring.
2nd 0.10 – 0.25 mm (0.0039 – 0.0098 in)
3rd 0.10 – 0.25 mm (0.0039 – 0.0098 in)

226RW053

226RW070
MANUAL TRANSMISSION 7B–33
4. Using bearing separator 5–8840–0015–0 6. Using 2 screwdrivers and hammer, tap out snap
(J–22912–01) and a press, remove the following ring.
parts.
1. 5th gear (1).
2. Mainshaft bearing (2).
3. 1st gear thrust washer (3).
4. 1st gear (4).

226RW073

7. Using bearing separator 5–8840–0015–0


(J–22912–01) and a press, remove the following
parts.
1. Clutch hub No.1 assembly (1).
2. Synchronizer assembly (2).
226RW197
3. 2nd gear (3).
5. Remove following parts from mainshaft.
1. Synchronizer assembly (1). 4. 2nd gear needle roller bearing (4).
2. 1st gear thrust washer pin (3).
3. 1st gear needle roller bearing (4).
4. 1st gear bearing spacer (2).

226RW198

226RW146
7B–34 MANUAL TRANSMISSION
8. Remove the reverse gear from clutch hub No.1. 11. Using a press, remove following parts.
9. Remove the 3 inserts and 3 compression springs. 1. Clutch hub No.2 assembly (1).
When removing the inserts, push the insert 2. 3rd block ring (2).
spring with a screwdriver. 3. 3rd gear (3).
4. 3rd gear needle roller bearing (4).

226RW075

10. Remove the snap ring.


226RW091

NOTE: Don’t damage the bearing surface. 12. Using screwdriver, remove the 2 insert springs,
hub sleeve No.2, clutch hub No.2 and 3 inserts.

226RW076

226RW090
MANUAL TRANSMISSION 7B–35
24. Remove the shift parts and interlock parts. 4. Using a magnetic finger, remove 3 springs and
1. Mount the intermediate plate through the balls.
aluminum plate in a vise.
2. Using a plastic hammer, tap the 5th shift rod on
the neutral.

226RW049

5. Using 2 screwdrivers and a hammer, remove 2


snap rings from each shift fork rod.
226RW052

3. Using a torx socket wrench(T40), remove the 4


plugs.

226RW048

226RW050
7B–36 MANUAL TRANSMISSION
6. Pull out the 3rd–4th shift rod at the rear. 8. Pull out the 1st–2nd shift rod at the rear.

226RW047 226RW045

7. Using a magnetic finger, remove the interlock pin 9. Using a magnetic finger, remove the interlock pin.
and straight pin.

226RW042

226RW043
MANUAL TRANSMISSION 7B–37
10. Using 2 screwdrivers and a hammer, remove 2 12. Using a magnetic finger, remove the interlock pin
snap rings. from the intermediate plate. Remove the ball
from the reverse shift arm No.1.

226RW041

11. Pull out the 5th-reverse shift rod at the front. 226RW039

13. Pull out at the rear reverse shift rod, reverse shift
arm No.1 and reverse shift arm No.2 at the same
time.

226RW040

226RW038
7B–38 MANUAL TRANSMISSION
14. Pull out reverse shift rod from reverse shift arm 16. Remove the reverse shift arm No.2 E–ring.
No.1. Remove the reverse shift arm No.2 from reverse
shift arm No.1.
NOTE: Be sure remove at the rear.

226RW089

17. Remove the 2 bolts and reverse shift arm bracket.


226RW055

15. Using a magnetic finger, remove the ball and


spring from reverse shift arm No.1.

226RW054

226RW056
MANUAL TRANSMISSION 7B–39

Inspection 4. Using a inside dial indicator, measure the gear


inside diameter.
1. Counter 5th gear radial clearance.
1. Install the following parts to the counter gear Standard: 38.015 – 38.040 mm
shaft. (1.49665 – 1.49763 in)
1. Counter 5th gear thrust washer pin (1).
2. Counter 5th gear thrust washer (2).
3. Counter 5th gear needle bearing( 3).
4. Counter 5th gear (4).

226RW085

2. 5th-reverse shift arm and hub sleeve No.3 clearance.


1. Using a vernier caliper, measure the 5th-reverse
shift arm thickness.
Reference: 10.2 mm (0.402 in)
226RW088

2. Mount the counter gear shaft through the 2. Using a vernier caliper, measure the center
aluminum plate in vise. groove of hub sleeve No.3. Calculate the
clearance between the hub sleeve No.3 and shift
3. Using a dial indicator, measure the counter 5th arm.
gear radial clearance.
Standard: 0.26 – 0.84 mm (0.0102 – 0.0331 in)
Standard: 0.015 – 0.068 mm
(0.00059 – 0.00268 in) Reference: Center groove dimension 10.5mm
(0.413 in)

226RW183
226RW086
7B–40 MANUAL TRANSMISSION
3. Reverse block ring set. 3. If the clearance exceeds the maximum, measure
1. Using a thickness gauge, measure the clearance the gear inside diameter and shaft diameter.
between the counter 5th gear spline piece and Standard
reverse block ring.
Shaft Diameter: 23.979 – 24.000 mm
Standard: 0.7 – 1.7 mm (0.028 – 0.067 in) (0.94405 – 0.94488 in)
Gear Diameter: 24.040 – 24.061 mm
(0.94645 – 0.94728 in)

226RW084

4. Reverse idle gear and reverse idle gear shaft.


1. Mount the reverse idle gear and reverse idle gear 226RW082

shaft in a vise. 5. Reverse shift arm No.2 thrust clearance.


2. Using a dial indicator, measure the reverse idle 1. Using a thickness gauge, measure the clearance
gear radial clearance. between the reverse idle gear and shift arm No.2.
Standard: 0.040 – 0.082 mm (0.0016 – 0.0032 in) Standard: 0.05 – 0.35 mm (0.002 – 0.014 in)

226RW081
226RW083
MANUAL TRANSMISSION 7B–41

Reassembly 3. Using a snap ring expander, install the new snap


ring.
1. Install the top gear shaft assembly.
1. Using installer 5–8840–2559–0 (J–42904) and a
press, install a new bearing.
NOTE: Outer race snap ring groove (1) toward front.

226RW062

4. Install the 4th block ring.

226RW196

2. Select a snap ring that will allow minimum axial


play.

Mark Thickness
A 2.10 – 2.15 mm (0.083 – 0.085 in)
B 2.15 – 2.20 mm (0.085 – 0.087 in)
C 2.20 – 2.25 mm (0.087 – 0.089 in)
D 2.25 – 2.30 mm (0.089 – 0.091 in)
E 2.30 – 2.35 mm (0.091 – 0.093 in)
F 2.35 – 2.40 mm (0.093 – 0.095 in)
G 2.40 – 2.45 mm (0.095 – 0.097 in)

226RW063

226RW061
7B–42 MANUAL TRANSMISSION
5. Using a thickness gauge, measure the clearance 3. Inspect block ring
between the 4th block ring back and gear spline 1. Using a thickness gauge, measure the clearance
end. between the synchronizer ring back and gear
Standard: 0.75 – 1.65 mm (0.030 – 0.065 in) spline end.
Gear Standard Clearanse
1st 0.80 – 1.60 mm (0.032 – 0.063 in)
2nd 0.65 – 1.75 mm (0.026 – 0.069 in)
3rd 0.75 – 1.65 mm (0.030 – 0.065 in)

226RW064

6. Check the braking effect of the block ring. Turn


the block ring in one direction while pushing it to
the gear cone. Check that the ring locks. If it does
not lock, replace the block ring.

226RW105

2. Turn the synchronizer ring in one direction while


pushing it to the gear cone. Check that the ring
locks.

226RW060

7. Install the needle roller bearing.


2. Reassemble the mainshaft assembly.
NOTE: Apply all parts with engine oil before installing
them.
226RW106
MANUAL TRANSMISSION 7B–43
4. Inspect hub sleeve and shift arm.
1st–2nd shift arm
1. Using a vernier caliper, measure center groove of
the 1st–2nd shift arm.
Reference: 5.28 mm (0.208 in)
2. Using a vernier caliper, measure flange of the
reverse gear. Calculate the clearance between
the reverse gear and shift arm.
Reference: Reverse gear flange thickness 5.0
mm. (0.197 in)
Standard: 0.15 – 0.41 mm (0.006 – 0.016 in)

226RW095

5. Inspect clutch hub and hub sleeve.


1. Check for wear or damage.
2. Install the hub sleeve to the clutch hub, and check
sliding smoothly.

226RW093

3rd–4th shift arm


1. Using a vernier caliper, measure tip of the shift
arm thickness.
Reference: 10.0mm (0.39 in)
2. Using a vernier caliper, measure center groove of
the hub sleeve No.2. Calculate the clearance
between the hub sleeve No.2 and shift arm.
Reference: Center groove dimension 10.2 mm
(0.402 in)
226RW094

Standard: 0.15 – 0.35 mm (0.006 – 0.014 in) 6. Inspect gear inside diameter.
1. Using a inside dial indicator, measure the gear
inside diameter.
Gear Standard Diameter
1st 46.015 – 46.040 mm (1.8116 – 1.8126 in)
2nd 53.015 – 53.040 mm (2.0872 – 2.0882 in)
3rd 44.015 – 44.040 mm (1.7329 – 1.7339 in)
7B–44 MANUAL TRANSMISSION
2. Using a micrometer, measure the mainshaft
flange thickness.
Standard: 5.0 mm (0.197 in)

226RW096

7. Inspect mainshaft.
1. Using a micrometer, measure the outer diameter
of the mainshaft journal.
226RW079

Measure 3. Install the mainshaft to V-blocks.


Standard
Position
4. Use a dial indicator to measure the mainshaft
A 37.984 – 38.000 mm (1.4954 – 1.4961 in) central portion run-out.
B 46.984 – 47.000 mm (1.8498 – 1.8504 in) Standard: less than 0.015 mm (0.0006 in)
C 38.979 – 38.995 mm (1.5346 – 1.5352 in)

226RW097

226RW078
MANUAL TRANSMISSION 7B–45
8. Install 3rd gear. NOTE:
1. Install the 3rd gear needle bearing, 3rd gear and Align the brock ring slots with the inserts.
3rd block ring to the mainshaft. Check that the gear rotates smoothly.

226RW098
226RW206
9. Install the clutch hub No.2.
4. Select a snap ring that will allow minimum axial
1. Install the clutch hub No.2 and hub sleeve No.2. play.
NOTE: Be careful the direction of the clutch hub No.2, as
shown. Mark Thickness

2. Using a screwdriver, install 3 inserts and 2 A 1.80 – 1.85 mm (0.071 – 0.073 in)
springs. B 1.85 – 1.90 mm (0.073 – 0.075 in)
NOTE: Position the insert springs so that their end gaps C 1.90 – 1.95 mm (0.075 – 0.077 in)
are not in line.
D 1.95 – 2.00 mm (0.077 – 0.079 in)
E 2.00 – 2.05 mm (0.079 – 0.081 in)
F 2.05 – 2.10 mm (0.081 – 0.083 in)
G 2.10 – 2.15 mm (0.083 – 0.085 in)

226RW099

3. Using installer 5–8840–2553–0 (J–42797) and a


press, install the clutch nob No.2 and hub sleeve
No.2 to the mainshaft.

226RW102
7B–46 MANUAL TRANSMISSION
5. Using a snap ring expander, install the new snap 10. Install the 2nd gear.
ring. 1. Install the synchronizer ring set No.1 to the 2nd
NOTE: Be careful not to damage the bearing surface. gear.
NOTE: Align the nail of middle ring with gear spline slots.

226RW101

6. Using a thickness gauge, inspect the 3rd gear 226RW104

thrust clearance. 2. Install the needle roller bearing, 2nd gear and 2nd
Standard: 0.10 – 0.25mm (0.004 – 0.010 in) gear block ring set to the mainshaft.

226RW107
226RW103
MANUAL TRANSMISSION 7B–47
11. Install the clutch hub No.1. NOTE:
1. Install the 3 inserts and 3 insert springs to the Align the projection of inner ring with hub No.1 slots.
clutch hub No.1. Check that the gear rotates smoothly.
Reference: While pushing the insert spring
with a screwdriver, install the inserts.

226RW205

4. Select a snap ring that will allow minimum axial


226RW108
play.
2. Install the clutch hub No.1 to the reverse gear.
NOTE: Check the clutch hub No.1 installing direction, as Mark Thickness
shown. A 2.30 – 2.35 mm (0.091 – 0.093 in)
B 2.35 – 2.40 mm (0.093 – 0.095 in)
C 2.40 – 2.45 mm (0.095 – 0.097 in)
D 2.45 – 2.50 mm (0.097 – 0.098 in)
E 2.50 – 2.55 mm (0.098 – 0.100 in)
F 2.55 – 2.60 mm (0.100 – 0.102 in)
G 2.60 – 2.65 mm (0.102 – 0.104 in)

226RW109

3. Using installer 5–8840–2554–0 (J–42798) and a


press, install the hub No.1 by retaining the
reverse gear.

226RW111
7B–48 MANUAL TRANSMISSION
5. Using a screwdriver and hammer, install the snap 1. Install the following parts:
ring. 1. 1st gear bearing spacer (4).
NOTE: Be careful not to damage the bearing surface. 2. 1st gear needle roller bearing (3).
6. Check that the gear rotates smoothly. 3. Synchronizer assembly (2).
4. 1st gear (1).
NOTE:
Align the projection of inner ring with hub No.1 slots.
Check that the gear rotates smoothly.

226RW112

7. Using a dial indicator, measure the 2nd gear


thrust clearance.
Standard: 0.10 – 0.25mm (0.004 – 0.010 in)
226RW114

2. Install the 1st gear thrust washer pin and 1st gear
thrust washer to the mainshaft.
NOTE: Align the straight pin with the thrust washer slot.

226RW113

12. Install the 1st gear.

226RW115
MANUAL TRANSMISSION 7B–49
13. Install the mainshaft center bearing. Mark Thickness
1. Using installer 5–8840–2555–0 (J–42799) and a
C 2.75 – 2.80 mm (0.108 – 0.110 in)
press, install the mainshaft center bearing.
D 2.80 – 2.85 mm (0.110 – 0.112 in)
NOTE: Center bearing snap ring groove toward rear.
E 2.85 – 2.90 mm (0.112 – 0.114 in)
F 2.90 – 2.95 mm (0.114 – 0.116 in)
G 2.95 – 3.00 mm (0.116 – 0.118 in)
H 3.00 – 3.05 mm (0.118 – 0.120 in)
J 3.05 – 3.10 mm (0.120 – 0.122 in)
K 3.10 – 3.15 mm (0.122 – 0.124 in)
L 3.15 – 3.20 mm (0.124 – 0.126 in)
M 3.20 – 3.25 mm (0.126 – 0.128 in)
N 3.25 – 3.30 mm (0.128 – 0.130 in)
P 3.30 – 3.35 mm (0.130 – 0.132 in)

226RW195

2. Using a thickness gauge, measure 1st gear thrust


clearance.
Standard: 0.10 – 0.45mm (0.004 – 0.018 in)

226RW203

3. Using a screwdriver and hammer, install the new


snap ring.

226RW118

14. Install the 5th gear.


1. Using installer 5–8840–2555–0 (J–42799) and a
press, install the 5th gear.
2. Select a snap ring that will allow minimum axial
play.

226RW127
7B–50 MANUAL TRANSMISSION
15. Inspect each gear radial clearance. 3. Select a snap ring that will allow minimum axial
1. Mount the mainshaft through the aluminum plate play.
in a vise.
Mark Thickness
2. Using a dial indicator, measure the radial
clearance of each gear. A 2.00 – 2.05 mm (0.079 – 0.081 in)
B 2.05 – 2.10 mm (0.081 – 0.083 in)
Gear Standard Clearanse
C 2.10 – 2.15 mm (0.083 – 0.085 in)
1st 0.020 – 0.073 mm (0.0008 – 0.0029 in)
D 2.15 – 2.20 mm (0.085 – 0.087 in)
2nd 0.015 – 0.068 mm (0.0006 – 0.0027 in)
E 2.20 – 2.25 mm (0.087 – 0.089 in)
3rd 0.015 – 0.068 mm (0.0006 – 0.0027 in)
F 2.25 – 2.30 mm (0.089 – 0.091 in)

226RW071

16. Install the counter gear shaft. 226RW128

1. Check the new counter front bearing inner race 4. Using a snap ring expander, install the new snap
and the side race, as shown. ring.
2. Using installer 5–8840–2556–0 (J–42800) and a
press, install the counter gear shaft front bearing.

226RW129

226RW194
MANUAL TRANSMISSION 7B–51
17. Install the front cover. 3. Install the oil receiver pipe.
1. Using installer 5–8840–2557–0 (J–42801), grip
5–8840–0007–0 (J–8092) and a hammer, drive in
a new oil seal.
Drive in depth (from cover end): 11.7 0.5 mm
(0.46 0.02 in)
2. Apply grease to the seal lip.

220RW011

4. Install the reverse restrict to the transfer adapter.

220RW113

18. Install the transfer adapter.


1. Using installer 5–8840–2558–0 (J –42802), and a
hammer drive in a new oil seal.
Drive in depth (from transfer adapter):
10.95 0.5 mm (0.431 0.02 in)
2. Apply grease to the oil seal lip.

226RW059

220RW114
7B–52 MANUAL TRANSMISSION
5. Using a pin punch and hammer, drive in the 9. Using hexagon wrench, install and torque the
slotted spring pin. plug.
Torque: 37 Nꞏm (3.8 kgꞏm/27 lb ft)

226RW058

6. Clean up the plug and plug hole. 220RW014

7. Apply sealant to the plug threads. (THREE BOND 19. Install the reverse shift arm No.1 and reverse shift
1344 or equivalent) arm No.2.
8. Using a torx socket wrench(T40), install and 1. Mount the intermediate plate through the
torque the plug. aluminum plate in a vise.

Torque: 19 Nꞏm (1.9 kgꞏm/14 lb ft)

226RW057

220RW013
MANUAL TRANSMISSION 7B–53
2. Using 2 bolts, install reverse shift arm bracket. 4. Install reverse shift arm No.2 to the reverse shift
arm bracket.
Torque: 18 Nꞏm (1.8 kgꞏm/13 lb ft)

226RW012

20. Install the reverse shift rod.


226RW054

3. Install reverse shift arm No.2 to the reverse shift


arm No.1. Using screwdriver and a hammer, 1. Install the reverse shift arm No.1 compression
install the new E-ring. spring and ball to the reverse shift arm No.1.

226RW125
226RW138
7B–54 MANUAL TRANSMISSION
2. Install the reverse shift rod from the rear side by 3. Put in the reverse-5th shift rod from the front.
pushing the ball on using a screwdriver.

226RW011

226RW126 4. Using a screwdriver and a hammer, install the 2


21. Install the reverse-5th shift rod. new shift rod snap rings to the 5th-reverse shift
1. Install the reverse shift arm No.1 lock ball to the rod and reverse shift rod.
reverse shift arm No.1.
2. Install the interlock pin to the intermediate plate.

226RW037

226RW039
MANUAL TRANSMISSION 7B–55
22. Install 1st–2nd shift rod. 23. Install 3rd–4th shift rod.
1. Install the interlock pin to the intermediate plate. 1. Install the straight pin and interlock pin to the
intermediate plate.

226RW042

2. Put in the 1st–2nd shift rod from the rear. 226RW043

2. Put in the 3rd–4th shift rod from the rear.

226RW044

226RW046
7B–56 MANUAL TRANSMISSION
24. Install the interlock parts. 5. Using a torx socket wrench(T40), install and
1. Using a screwdriver and hammer, 2 new shift rod torque the 4 plugs.
snap rings to the 1st–2nd and 3rd–4th shift rod. Torque: 19 Nꞏm (1.9 kgꞏm/14 lb ft)

226RW051
226RW050

2. Install the 3 shift detent ball and springs to the 25. Install mainshaft assembly.
intermediate plate.
NOTE: Coat all parts with gear oil before installing them.
1. Using a plastic hammer, tap the 5th-reverse shift
rod at the reverse shift.

226RW049

3. Clean up the plug hole.


4. Apply sealant to the plug threads. 226RW180

sealant: THREE BOND 1344 or equivalent


MANUAL TRANSMISSION 7B–57
2. Install the shift arm No.1 and No.2 to the 4. Using a snap ring expander, install the snap ring.
mainshaft.

226RW035

226RW010 5. Using a plastic hammer, tap the 5th-reverse shift


3. Using a plastic hammer, tap the intermediate rod at the neutral shift.
plate and install the mainshaft. Through the shift
arm No.1 and No.2 to the shift rod.

226RW008

226RW009
7B–58 MANUAL TRANSMISSION
26. Install the top gear shaft. 2. Using installer 5–8840–2552–0 (J–42796) and a
1. Align the projection of the hub No.2 with the hammer, drive in the center bearing as shown.
synchronizer ring slots, and install the top gear NOTE: Outer race snap ring groove toward rear.
shaft assembly to the mainshaft.
2. Check that the gear rotates smoothly.

226RW192

Reference: Drive in the counter rear bearing


226RW006 by tapping on the front end of the counter
27. Install the counter gear shaft. shaft.
1. Temporarily install the counter gear shaft to the
intermediate plate.

226RW022

226RW028
MANUAL TRANSMISSION 7B–59
28. Install the reverse idle gear. 30. Install the 5th gear thrust washer.
1. Install the reverse idle gear and reverse idle gear 1. Install the 5th gear thrust washer pin to the
shaft. counter gear shaft.
NOTE: 2. Install the 5th gear thrust washer to the counter
gear shaft.
Insert the reverse idle gear shaft with the slot toward
rear. NOTE: Thrust washer must be assembled with the
Install the reverse idle gear with the reverse shift arm chamfered face of the washer toward the front.
No.2.

226RW185

226RW019 31. Install the counter 5th gear.


29. Install the bearing plate. 1. Install the 3 inserts and 3 compression springs to
1. Align the bearing plate to groove of the reverse the reverse block ring.
idle gear shaft. Reference: Push the 3 inserts with the 3 com-
Torque: 13 Nꞏm (1.3 kgꞏm/113 lb in) pression springs to the reverse synchronizer
ring.

226RW016
226RW120
7B–60 MANUAL TRANSMISSION
2. Install the synchronizer outer ring, synchronizer 4. Install the hub sleeve No.3 and reverse block ring
cone ring, and synchronizer pull ring to the set to the counter 5th gear.
reverse block ring.
NOTE: Check the hub sleeve No.3 direction, as shown.
Reference: While pushing the 3 inserts,
install the synchronizer ring assembly to the
hub sleeve No.3.

226RW121

3. Turn to 30 degree the reverse synchronizer pull


ring.
226RW184

5. Slide the hub sleeve No.3.

226RW080

226RW123
MANUAL TRANSMISSION 7B–61
6. Install the counter 5th gear bearing, counter 5th 8. Using thickness gauge, measure the counter 5th
gear and reverse block ring set to the counter gear thrust clearance.
gear shaft, through the 5th reverse shift arm to the
Standard: 0.10 – 0.35mm (0.004 – 0.014 in)
5th reverse shift rod.

220RW100
220RW101
9. Select a snap ring that will allow minimum axial
7. Using installer 5–8840–2552–0 (J–42796) and a
play.
press, install counter 5th gear spline piece.
NOTE: Mark Thickness
Align the projection of the cone ring to the holes of the A 2.80 – 2.85 (0.110 – 0.112 in)
5th gear spline piece. B 2.85 – 2.90 (0.112 – 0.114 in)
Check that the gear rotates smoothly.
C 2.90 – 2.95 (0.114 – 0.116 in)
D 2.95 – 3.00 (0.116 – 0.118 in)
E 3.00 – 3.05 (0.118 – 0.120 in)
F 3.05 – 3.10 (0.120 – 0.122 in)
G 3.10 – 3.15 (0.122 – 0.124 in)

226RW193

226RW027
7B–62 MANUAL TRANSMISSION
10. Install the new snap ring. 33. Install the shift arm slotted pin.
1. Using a pin punch and a hammer, drive in the
slotted pin to the shift arm.

226RW026

32. Install the shift arm bolts.


1. Install and torque the 2 shift arm bolts. 226RW025

34. Install the transmission case.


Torque: 20 Nꞏm (2.0 kgꞏm/14 lb ft)
1. Clean up the fitting surface.
2. Apply recommended liquid gasket (THREE
BOND 1281 or equivalent), as shown.
NOTE:
Don’t dry the liquid gasket.

226RW023

220RW024
MANUAL TRANSMISSION 7B–63
3. Stand the transmission by the wood blocks. NOTE:
4. Using a plastic hammer, tap the transmission Don’t dry the liquid gasket.
case and attach it to the intermediate plate.
NOTE: Be careful not to add over force to bearing.

220RW025

3. Clean up and dry the bolts.


220RW022
4. Apply thread sealant (THREE BOND 1344 or
5. Using a snap ring expander, install the front equivalent) to the 8 bolts.
bearing shaft snap ring (1) and counter gear shaft 5. Using 8 bolts, install the front cover to the
bearing snap ring (2). transmission case.
Torque: 17 Nꞏm (1.7 kgꞏm/12 lb ft)
NOTE:
Tighten the all bolts evenly.
Be careful not to damage the oil seal.

226RW004

6. Turn over the transmission.


35. Install the front cover.
1. Clean up the fitting surface.
2. Apply recommended liquid gasket (THREE
BOND 1281 or equivalent), as shown. 220RW018
7B–64 MANUAL TRANSMISSION
6. Check that the top gear shaft and mainshaft 4. Using 10 bolts, install the transfer adapter.
rotate.
Torque: 37 Nꞏm (3.8 kgꞏm/27 lb ft)
36. Install the transfer adapter.
NOTE:
1. Clean up the fitting surface.
Tighten the all bolts evenly.
2. Apply recommended liquid gasket (THREE
BOND 1281 or equivalent), as shown. Don’t damage the lip of the oil seal.
Install the wire clamp (9) to the transfer adapter.
NOTE:
Don’t dry the liquid gasket.

220RW083

37. Install the gear control box.


220RW026
1. Align the projection of the shift lever housing to
3. Using a plastic hammer, tap the transfer adapter the shaft rod groove, and install the gear control
and attach it to the intermediate plate. rod.

220RW034 230RW003
MANUAL TRANSMISSION 7B–65
2. Using a pin punch and hammer, drive in the 5. Clean up the bolts and bolt hole.
slotted spring pin (2) to the shift lever housing.
6. Using 6 bolts, install the gear control box through
NOTE: Be carefull not to drop the slotted spring pin. the gasket.
Torque 18 Nꞏm (1.8 kgꞏm/13 lb ft)
(6VE1)

230RW002

3. Apply sealant (THREE BOND 1344 or


equivalent) to the plug (1) thread. 230RW001

4. Using hexagon wrench, install and torque the (4JX1)


plug (1).
Torque: 18 Nꞏm (1.8 kgꞏm/13 lb ft)

220RW097

220RW010
7B–66 MANUAL TRANSMISSION
38. Install clutch housing. 40. Install the clutch release bearing (3) and clutch shift
1. Install the clutch housing to the transmission fork (5).
case. 1. Apply the clutch release grease.
Torque: 36 Nꞏm (3.7 kgꞏm/27 lb ft) 1. Fitting surface of the cylinder push rod.
2. Fitting surface of the release bearing hub.
NOTE: Tighten the all bolts evenly.
3. The hole of the fork split pin (4).
2. Apply the clutch release grease.
1. The spline surface of the top gear shaft.
3. Install the clutch shift fork (5).
4. Install the snap pin.
5. Install the clutch release bearing (3) to the clutch
shift fork (5).

241RW001

39. Install the switches.


1. Install the new gasket to the 1st and 2nd switch.
2. Install the 1st and 2nd switch assembly (8).
Torque: 39 Nꞏm (4.0 kgꞏm/29 lb ft)
3. Install the new gasket to the backup light switch.
4. Install the backup light switch assembly (6).
220RW086

Torque: 44 Nꞏm (4.5 kgꞏm/33 lb ft)


5. Install the new gasket to the neutral switch.
6. Install the neutral switch (7) to the transfer
adapter (4JX1).
Torque: 37 Nꞏm (3.8 kgꞏm/27 lb ft)
(4JX1)

220RW093
MANUAL TRANSMISSION 7B–67
41. Install the drain plug and filler plug.
1. Install the drain plug (1) through the new gasket.
Torque: 37 Nꞏm (3.8 kgꞏm/27 lb ft)
2. Install the filler plug (2) through the new gasket.
Reference: Plug after the gear oil fill in.
Torque: 37 Nꞏm (3.8 kgꞏm/27 lb ft)
(6VE1)

220RW007
7B–68 MANUAL TRANSMISSION

Main Data and Specifications


General Specifications
Transmission type Fully synchronized forward and reverse gears
Control method Direct control with the gear shift lever on the floor
Gear ratio 1st 3.954
2nd 2.330
3rd 1.436
4th 1.000
5th 0.788
Rev 3.918
Oil capacity lit (US qt) 2.7 (2.86)
Type of lubricant Engine oil : Refer to the chart in “SECTION 0”
MANUAL TRANSMISSION 7B–69

Torque Specifications

E07RW049
7B–70 MANUAL TRANSMISSION
Torque Specifications (Cont’d)

E07RW050
MANUAL TRANSMISSION 7B–71

Torque Specifications (Cont’d)

E07RW051
7B–72 MANUAL TRANSMISSION

Special Tools
TOOL NO. TOOL NO.
ILLUSTRATION ILLUSTRATION
TOOL NAME TOOL NAME

5–8840–2550–0
5–8840–2555–0
(J–42794)
(J–42799)
Gear spline pieace
Installer
remover

5–8840–2556–0
5–8840–2551–0
(J–42800)
(J–42795)
Counter gear shaft front
Center bearing remover
bearing installer

5–8840–2559–0
5–8840–2560–0
(J–42904)
(J–42988)
Top gear shaft front
Attachment
bearing installer

5–8840–2552–0 5–8840–2557–0
(J–42796) (J–42801)
Counter gear shaft Front rerainer oil seal
center bearing installer installer

5–8840–2553–0 5–8840–2558–0
(J–42797) (J–42802)
Clutch hub (No.2) Transfer adapter oil seal
installer installer

5–8840–2554–0
5–8840–0007–0
(J–42798)
(J–8092)
Clutch hub (No.1)
Driver handle
installer
MANUAL TRANSMISSION 7B–73

Special Tools (Cont’d)


TOOL NO.
ILLUSTRATION
TOOL NAME

5–8840–0015–0
(J–22912–01)
Bearing separator
235RT004
220R200001

220LV019
220LV019

220R200001
220LV018

235RT004
CLUTCH 7C–1

TRANSMISSION
CLUTCH
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 7C–1 Inspection and Repair . . . . . . . . . . . . . . . . . . 7C–23
General Description . . . . . . . . . . . . . . . . . . . . . 7C–2 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–23
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–8 Slave Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–24
Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . 7C–9 Disassembled View . . . . . . . . . . . . . . . . . . . . 7C–24
Clutch Assembly and Associated Parts . . . 7C–9 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–9 Inspection and Repair . . . . . . . . . . . . . . . . . . 7C–24
Inspection and Repair . . . . . . . . . . . . . . . . . . 7C–10 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–15 Damper Cylinder . . . . . . . . . . . . . . . . . . . . . . . . 7C–26
Clutch Control . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–17 Disassembled View . . . . . . . . . . . . . . . . . . . . 7C–26
Clutch Control Parts . . . . . . . . . . . . . . . . . . . 7C–17 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–18 Inspection and Repair . . . . . . . . . . . . . . . . . . 7C–26
Inspection and Repair . . . . . . . . . . . . . . . . . . 7C–18 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–19 Main Data and Specifications . . . . . . . . . . . . . 7C–27
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–19 General Specifications . . . . . . . . . . . . . . . . . 7C–27
Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . 7C–22 Torque Specifications . . . . . . . . . . . . . . . . . . 7C–27
Disassembled View . . . . . . . . . . . . . . . . . . . . 7C–22 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–30
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–23

Service Precaution CAUTION: Always use the correct fastner in the


proper location. When you reolace a fastener, use
WARNING: IF SO EQUIPPED WITH A ONLY the exact part number for that application.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS), ISUZU will call out those fasteners that requir a
REFER TO THE SRS COMPONENT AND WIRING replacement after removal. ISUZU will also call out
LOCATION VIEW IN ORDER TO DETERMINE the fasteners that requir thread lockers or thread
WHETHER YOU ARE PERFORMING SERVICE ON OR sealant. UNLESS OTHERWISE SPECIFIED , do not
NEAR THE SRS COMPONENTS OR THE SRS use supplemental coatings (Paints, greases, or other
WIRING. WHEN YOU ARE PERFOMING SERVICE ON corrosion inhibitors) on threaded fastners or fastner
OR NEAR THE SRS COMPONENTS OR THE SRS joint interfaces. Generally,such coatings adversely
WIRING, REFER TO THE SRS SERVICE affect the fastner torque and the joint clamping force,
INFORMATION. FAILURE TO FOLLOW WARNINGS and may damage the fastner. When you install
COULD RESULT IN POSSIBLE AIR BAG fasteners, use the correct tightening sequence and
DEPLOYMENT, PERSONAL INJURY, OR specifications. Following these instructions can
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. help you avoid damage to parts and systems.
7C–2 CLUTCH

General Description
Clutch
(6VE1)

A07RW046

For 6VE1 (3.5L) and 4JX1 (3.0L) engine models, the disengaged by pulling the release lever (release bearing)
pull-type clutch is employed. The pull-type clutch is to disengage the pressure plate.
CLUTCH 7C–3

Master Cylinder
(6VE1 LHD)

A07RW007

(6VE1 RHD)

A07RW066
7C–4 CLUTCH

(4JX1)

A07RW067

Damper Cylinder
(Except 6VE1 LHD)

A07RS004

In order to reduce the occurrence of noises at the clutch clutch hydraulic line between the master cylinder and
hydraulic system, the damper cylinder is used in the slave cylinder.
CLUTCH 7C–5

Slave Cylinder

A07RS005

Pressure Plate Assembly

A07RS006
7C–6 CLUTCH
Driven Plate Assembly
(6VE1)

A07RS007
CLUTCH 7C–7

(4JX1)

A07RW045
7C–8 CLUTCH

Diagnosis
Condition Possible cause Correction
Dragging Fluid leakage. Repair
Air in hydraulic line. Bleed
Master cylinder and slave cylinder Replace master cylinder.
seals worn. Replace slave cylinder seals.
Driven plate warped. Replace driven plate.
Diaphragm spring weakened or tip of Replace pressure plate
fingers worn.
Driven plate sticking on splines. Lubricate with grease or replace.
Clutch spline worn. Repair
Release bearing worn or damaged. Replace release bearing.
Slipping Driven plate facing worn or Replace driven plate and check for
oil–soaked. leaks.
Diaphragm spring weakened. Replace pressure plate.
Pressure plate or flywheel warped. Correct or replace.
Master cylinder and slave cylinder Replace master cylinder.
seals worn. Replace slave cylinder seals.
Chattering Engine mounts loose or damaged. Tighten or replace.
Driven plate facing warped. Replace driven plate.
Surface of facing hardened. Replace driven plate
Driven plate facing oil soaked. Replace driven plate and check for
leaks.
Damper springs weakened or Replace.
broken.
Pressure plate or flywheel warped. Correct or replace.
Noisy Replace bearing binding. Correct, or replace if damaged, and
lubricate.
Replace bearing worn or damaged. Replace release bearing.
Release bearing poorly lubricated. Lubricate.
Pilot bearing worn. Replace pilot bearing.
Damper springs weakened or Replace driven plate.
broken.
Rivets of driven plate exposed. Replace driven plate.
Replace driven plate. Hydraulic line blocked. Clean out or replace.
Master or slave cylinders binding. Repair or replace as needed.
CLUTCH 7C–9

Clutch Assembly
Clutch Assembly and Associated Parts

201RW029

Legend (5) Transmission Assembly


(1) Flywheel Assembly and Crankshaft Bearing (6) Front Cover
(2) Driven Plate Assembly (6VE1) (7) Shift Fork
(3) Driven Plate Assembly (4JX1) (8) Release Bearing
(4) Pressure Plate Assembly

Removal
1. Remove transmission assembly, refer to ”MANUAL
TRANSMISSION” of Section 7B for ”Removal AND
INSTALLATION” procedure.
2. Mark the flywheel, clutch cover and pressure plate lug
for alignment when installing.
3. Remove pressure plate assembly (3).
4. Remove driven plate assembly (1) or (2). Use the pilot
aligner 5-85253-001-0 (J-24547) to prevent the
driven plate assembly from falling free.

201RW031
7C–10 CLUTCH
5. Mark the flywheel, clutch cover and pressure plate lug Inspection and Repair
for alignment when installing.
Make necessary correction or parts replacement if wear,
6. Remove the release bearing (3) from the damage, or any other abnormal condition are found
transmission case . through inspection.
7. Remove the shift fork snap pin.
Pressure Plate Assembly
8. Remove the shift fork pin and shift fork (4) from the
front cover.
9. Remove the front cover bolts.
10. Remove the front cover (5) from the transmission
case.

201RS002

1. Visually check the pressure plate friction surface for


excessive wear and heat cracks.
2. If excessive wear or deep heat cracks are present,
the pressure plate must be replaced.
220RW088

11. Remove flywheel assembly and crankshaft bearing. Pressure Plate Warpage
Do not remove except for replacement.
12. Use the remover 5–8840–2000–0 (J–5822) and
sliding hammer 5–8840–0019–0 (J–23907) to
remove the crankshaft bearing

201RS003

015RW053
CLUTCH 7C–11
1. Use a straight edge and a feeler gauge to measure 2. Place a new driven plate over the pressure plate. A
the pressure plate friction surface flatness in four metal sheet with “A” thickness of 8.3 mm (0.327 in)
directions. may be used in place of the driven plate.
2. If any of the measured values exceeds the specified 3. Compress the pressure plate assembly until the
limit, the pressure plate must be replaced. distance “B” becomes 12 mm (0.472 in).
Pressure Plate Warpage 4. Note the pressure gauge reading.
Limit: 0.3 mm (0.012 in) 5. If the measured value is less than the specified limit,
the pressure plate assembly must be replaced.
Clutch Cover Clutch Set Force
Standard: 7208 N ( 1621 lb)
Limit: 6468 N (1454 lb)

Diaphragm Spring Finger Height

201RS004

1. Visually check the entire clutch cover for excessive


wear, cracking, and other damage.
2. The clutch cover must be replaced if any of these
conditions are present. 201RW009

Clutch Set Force Legend


(1) Release Side

1. Place a new driven plate or a 8.3 mm (0.327 in)


spacer beneath the pressure plate.
2. Fully compress the pressure plate and diaphragm
spring.
3. There are two ways to do this.
4. Use a bench press to press down on the assembly
from the top.
5. Tighten the fixing bolts.
NOTE: Preload on diaphragm spring finger must be 49 –
98 N (11 – 22 lb) in direction of release, when clutch cover
assembly is bolted to the flywheel.
6. Measure the spring height from base to spring tip “A”.
If the measured value exceeds the specified limit, the
pressure plate assembly must be replaced.
Diaphragm Spring Finger Height
Standard: 49.9 mm – 51.9 mm (1.965 in –
201RS005
2.043 in)
1. Invert the pressure plate assembly.
7C–12 CLUTCH
Driven Plate Assembly Driven Plate Warpage

201RW033 201RW034

Legend Legend
(1) Driven Plate Assembly (6VE1) (1) Driven Plate Assembly (6VE1)
(2) Driven Plate Assembly (4JX1) (2) Driven Plate Assembly (4JX1)

1. Visually check the torsion spring for looseness, 1. Insert the clutch pilot aligner into the driven plate
breakage, and weakening. splined hub.
2. If any of these conditions are discovered, the driven 2. The clutch pilot aligner J-24547 must be held
plate assembly must be replaced. perfectly horizontal.
3. Visually check the facing surfaces for cracking and 3. Set a dial indicator to the driven plate outside
excessive scorching. circumference.
4. Visually inspect the facing surfaces for the presence 4. Slowly turn the driven plate.
of oil or grease. 5. Read the dial indicator as you turn the driven plate.
5. If any of these conditions are discovered, the facing 6. If the measured value exceeds the specified limit, the
must be cleaned or replaced. driven plate assembly must be replaced.
6. Check that the driven plate moves smoothly on the Driven Plate Warpage
transmission top gear shaft spline.
Standard: 0.7 mm (0.028 in)
7. Minor ridges on the top gear shaft spline may be
removed with an oil stone. Limit: 1.0 mm (0.039 in)
CLUTCH 7C–13

Driven Plate Splined Hub Spline Wear Rivet Head Depression

201RW032 201RS010

Legend 1. Use a depth gauge or a straight edge with steel rule to


(1) Driven Plate Assembly (6VE1) measure the rivet head depression 1 from the facing
surface 2.
(2) Driven Plate Assembly (4JX1)
2. Be sure to measure the rivet head depression on both
sides of the driven plate.
1. Clean the driven plate splined hub.
3. If the measured value is less than the specified limit,
2. Install the driven plate to the transmission top gear
the driven plate assembly must be replaced.
shaft spline.
3. Set a surface gauge to the driven plate outside Rivet Head Depression
circumference. Standard:
4. Slowly turn the driven plate counterclockwise.
5. Measure the spline rotation play as you turn the
Flywheel side Pressure plate side
driven plate.
6. If the measured value exceeds the specified limit, the 6VE1 1.95mm (0.077 in) 1.95mm (0.077 in)
driven plate assembly must be replaced. 4JX1 1.60mm (0.063 in) 1.60mm (0.063 in)
Driven Plate Splined Hub Spline Wear
Standard: 0.5 mm (0.020 in) Limit: 0.2 mm (0.008 in)
Limit: 1.0 mm (0.039 in)
7C–14 CLUTCH
Release Bearing Wedge Collar

201RS011 201RS013

1. Visually check the release bearing for excessive play, 1. Visually check the surfaces of the wedge collar
noise and breakage. making contact with the release bearing for excessive
2. If any of these conditions are discovered, the release wear and damage.
bearing must be replaced. 2. Replace any exhibiting excessive wear or damage.
3. When replacing the release bearing, replace both the
wedge collar and wire ring at the same time. Shift Fork

201RW010 201RS014

Legend 1. Visually check the surfaces of the shift fork making


(1) Wire Ring contact with the release bearing for excessive wear
and damage.
(2) Pressure Plate Assembly
(3) Wedge Collar 2. Remove any minor stepping or abrasion from shift
fork with an oil stone.
(4) T/M Side
(5) Release Bearing 3. Replace any exhibiting excessive wear or damage.
(6) Engine Side
CLUTCH 7C–15

Installation 3. Install the front cover (5) to the transmission case.


To install, follow the removal steps in the reverse order, 4. Tighten eight front cover bolts to the specified torque.
noting the following points: Torque: 17 Nꞏm (1.7 kgꞏm/12 lb ft)
1. Install flywheel assembly and crankshaft bearing.
Use the installer 5-8840-0125-0 (J-26516-A) and
driver handle 5-8840-0007-0 (J-8092) to install the
crankshaft bearing then clean and lubricate with
grease.

220RW088

5. Apply molybednum disulfide type grease to the pin


hole inner circumferences and thrust surfaces.
6. Attach the shift fork to the front cover and insert the
pin from below of the front cover.
015RW054
7. Install the washer and snap pin.
2. Install new flywheel fixing bolts in the order illustrated
and tighten them to the specified torque.
Torque:
6VE1: 54 Nꞏm (5.5 kgꞏm/40 lb ft)
4JX1: 60 Nꞏm (6.1 kgꞏm/44 lb ft)+60
NOTE: Do not reuse the bolt and do not apply oil or thread
lock to the bolt.

015RS047

201RW019
7C–16 CLUTCH
8. Apply molybdenum disulfide type grease to the areas 10. Install driven plate assembly. Use the pilot aligner
shown in illustration. 5-85253-001-0 (J-24547) to install the driven plate
assembly.

201RW012

9. Install the release bearing in the proper direction. 201RW027

11. Install pressure plate assembly and tighten the bolts


NOTE: Ensure release bearing is properly positioned
holding the pressure plate assembly in the order
during installation, as shown in illustration.
shown in illustration.
Torque: 18 Nꞏm (1.8 kgꞏm/13 lb ft)

201RW020

201RS017

12. Remove the aligner.


NOTE: Do not strike the aligner with a hammer to remove
it.
13. Install transmission assembly.
CLUTCH 7C–17

Clutch Control
Clutch Control Parts
(6VE1 LHD)

203RW017

Legend (3) Pin and Jaw Joint Pin


(1) Master Cylinder Assembly (4) Oil Line Pipe
(2) Pedal Assembly (5) Slave Cylinder Assembly and Heat Protector
7C–18 CLUTCH

(Except 6VE1 LHD)

203RW009

Legend (4) Oil Line Pipe


(1) Master Cylinder Assembly (5) Slave Cylinder Assembly and Heat Protector
(2) Pedal Assembly (6) Damper Cylinder Assembly
(3) Pin and Joint Pin

Removal Inspection and Repair


1. Remove pin and jaw joint pin. Make necessary adjustments, repairs, and part
replacement if wear, damage or other problems are
2. Remove pedal assembly.
discovered during inspection.
3. Remove oil line pipe.
4. Remove slave cylinder assembly and heat protector.
5. Remove master cylinder assembly.
6. Remove damper cylinder assembly (except V6 LHD).
CLUTCH 7C–19

Installation
1. Install damper cylinder assembly (except V6 LHD).
2. Install master cylinder assembly.
3. Install slave cylinder assembly and heat protector.
4. Install oil line pipe.
5. Install pedal assembly.
6. Install pin and jaw joint pin.

Adjustment
Clutch Pedal Adjustment
1. Loosen the clutch pedal adjusting bolt so that there is
enough gap between the clutch pedal and the
adjusting bolt to allow push rod adjustment.

203RW004

Legend
(3) Floor Panel
(4) Pedal Free Play
(5) Clutch Pedal Height

3. Tighten push rod lock nut.


4. Adjusting bolt adjustment.
1. Turn the adjusting bolt until it just touches the
clutch pedal arm.

203RW011

Legend
(1) Push Rod
(2) Adjusting Bolt

2. Loosen clutch master cylinder push rod lock nut. Turn


push rod by hand to set clutch pedal height (5) to
within specification.
Clutch pedal height (5):
LHD: 217 mm – 227 mm (8.543 in – 8.937 in)
RHD:
(6VE1) 238.5 mm – 248.5 mm (9.390 in – 9.783 in) 203RW012

Legend
(4JX1) 231 mm – 241 mm (9.094 in – 9.488 in)
(6) Blacket
(7) Adjusting Bolt
(8) Clutch Pedal Arm
7C–20 CLUTCH
2. Adjust clutch padel adjusting bolt by backing it out 6. Clutch pedal engagement height inspection:
half a turn, and measure the clearance ( ) 1. Operate the parking brake lever and block the
between the clutch pedal arm and the adjusting wheels.
bolt.
2. Start the engine, fully step on the clutch pedal,
and move the shift lever to 1st position.
3. With the engine idling, release the clutch pedal
slowly and measure its stroke just prior to its
clutching position.
Clutch Pedal Engagement Height (14)
MIN. 30 mm (1.18 in)
7. If the measured value exceeds the specified limit,
check the following points. Repair if necessary:
Hydraulic circuit for fluid leakage or air in circuit.
Clutch disc warped.
Diaphragm spring weakened or tip of fingers worn.
Driven plate sticking on sprines.
Release bearing worn or damaged.
Master cylinder and slave cylinder worn.

203RW010

Legend
(9) Bracket
(10) Clutch Pedal Adjusting Bolt
(11) Lock Nut
(12) Clutch Pedal Arm

3. Lock the lock nut.


Clutch Switch and Clutch Pedal Clearance ( )
0.5 mm – 1.5 mm (0.020 in – 0.059 in)
5. After adjusting the clutch pedal height, push the
clutch pedal by hand rightly to check the clutch pedal
free play (4) to within specification.
Pedal Free Play (4)
5 mm – 15 mm (0.20 in – 0.59 in)

203RW007

Legend
(3) Floor Panel
(14) Clutch Pedal Engagement Height

203RW004
CLUTCH 7C–21

Torque Specifications 5. Release the clutch pedal carefully. Repeat the above
Master cylinder to dash panel operation until air bubbles disappear from the clutch
fluid being pumped out into the container. During the
Torque: 16 Nꞏm (1.6 kgꞏm/12 lb ft)
bleeding operation, keep the clutch fluid reservoir
Clutch pedal to dash panel filled to the specified level. Reinstall the rubber cap.
Torque: 21 Nꞏm (2.1 kgꞏm/15 lb ft) Bleeding the slave cylinder
Master cylinder push rod to yoke 6. Repeat step 2 through 5 for bleeding the slave
Torque: 17 Nꞏm (1.7 kgꞏm/12 lb ft) cylinder.
Clutch pipe to master cylinder
Torque: 20 Nꞏm (2.0 kgꞏm/14 lb ft)
Clutch pipe to flex, hose
Torque:
M 10: 16 Nꞏm (1.6 kgꞏm/12 lb ft)
M 12: 20 Nꞏm (2.0 kgꞏm/14 lb ft)
Slave cylinder to case
Torque: 43 Nꞏm (4.4 kgꞏm/32 lb ft)
Slave cylinder bleeder screw
Torque: 8 Nꞏm (0.8 kgꞏm/69 lb in)
Flexible hose to slave cylinder
Torque: 20 Nꞏm (2.0 kgꞏm/14 lb ft)
Clutch pipe to damper cylinder
Torque: 12 Nꞏm (1.2 kgꞏm/104 lb in)
Damper cylinder bleeder screw
Torque: 8 Nꞏm (0.8 kgꞏm/69 lb in)

Bleeding 206RW003

1. Check the level of clutch fluid in the reservoir and Legend


replenish if necessary. (1) Slave Cylinder
Bleeding the damper cylinder (except V6 LHD (2) Bleeder Screw
model).
(3) Vinyl Tube
2. Remove the rubber cap from the bleeder screw and
wipe clean the bleeder screw. Connect a vinyl tube to
the bleeder screw and insert the other end of the vinyl
tube into a transparent container.
3. Pump the clutch pedal repeatedly and hold it
depressed.

203RS005

4. Loosen the bleeder screw to release clutch fluid with


air bubbles into the container, then tighten the bleeder
screw immediately.
7C–22 CLUTCH

Master Cylinder
Disassembled View

208RW016

Legend (3) Damper Cylinder Assembly


(1) Master Cylinder Assembly (4) Nut
(2) Gasket (5) Push Rod Damper
CLUTCH 7C–23

Disassembly
(4JX1)
1. Remove damper cylinder assembly and gasket.
2. Remove push rod damper.
NOTE: The master cylinder assembly cannot be
disassembled because of point–staked rod stopper.

Inspection and Repair


Clean and inspect the removed parts.
Make necessary parts replacement if any abnormalities
such as wear, oil leaks or other damage are found through
inspection.

Reassembly
To reassemble, follow the disassembly steps in the
reverse order, noting the following points:
1. Push rod set length
RHD: 117.5 mm (4.626 in)
LHD: 119 mm (4.685 in)
2. Push rod nut torque
17 Nꞏm (1.7 kgꞏm/12 Ib ft)
3. Damper cylinder torque
47 Nꞏm (4.8 kgꞏm/35 Ib ft)
7C–24 CLUTCH

Slave Cylinder
Disassembled View

206RW004

Legend (3) Piston and Piston Cup


(1) Cylinder Body (4) Boot
(2) Spring (5) Push Rod

Disassembly Cylinder Body


1. Remove boot.
2. Remove push rod.
3. Remove piston and piston cup.
4. Remove spring.

Inspection and Repair


Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is discovered
during inspection.

206RS003

1. Clean the cylinder body.


2. Check the fluid return port for restrictions and clean it
if necessary.
CLUTCH 7C–25

Piston and Piston Cup Reassembly


1. Visually inspect the disassembled piston and piston To reassemble, follow the disassembly steps in the
cup for excessive wear and damage. reverse order, noting the following points:
2. Replace the inner parts with new parts shown in the 1. Before installing the parts, apply a thin coat of rubber
illustration. grease.
2. Install cup in groove in piston with the lip turned to the
front of cylinder. Use care so as not to scratch the
cylinder.

206RS004

3. Measure the clearance between slave cylinder wall


and piston.
4. If the measured value exceeds the specified limit, the 206RS006

slave cylinder assembly must be replaced.


Standard: 0.07 mm (0.0028 in)
Limit: 0.15 mm (0.0059 in)

206RS005
7C–26 CLUTCH

Damper Cylinder
Disassembled View

205RW005

Legend (4) Spacer


(1) Cylinder Body (5) Damper Rubber
(2) Spring (6) Cover and Gasket
(3) Piston Assembly

Disassembly Reassembly
1. Remove cover and gasket. To assemble, follow the disassembly steps in the reverse
order.
2. Remove damper rubber.
3. Remove spacer.
4. Remove piston assembly.
5. Remove spring.

Inspection and Repair


Check damper rubber and piston cup for cracks,
deformation or damage.
Replace the damper cylinder assembly if necessary.
CLUTCH 7C–27

Main Data and Specifications


General Specifications
Type Dry single plate type with diaphragm spring
Size 275 mm (10.83 in)
Pressure plate Outside diameter 332 mm (13.07 in)
Pressure plate Clamping force 7208 N (1621 lb)
Pressure plate Spring finger height 49.9 – 51.9 mm (1.965 – 2.043 in)
Driven plate Outside diameter x inside diameter 275 180 mm (10.83 6.69 in)
Thickness Clutch disengaged 8.8 mm (0.346 in)
Thickness Clutch engaged 8.3 mm (0.327 in)
Total friction area 339 2 cm (52 2 in )
Clutch control type Hydraulic
Clutch pedal free play 5 – 15 mm (0.20 – 0.59 in)
Clutch pedal height LHD: 217 – 227 mm (8.543 – 8.937 in)
RHD:
(6VE1) 238.5 mm – 248.5 mm (9.390 in – 9.783 in)
(4JX1) 231 mm – 241 mm (9.094 in – 9.488 in)
Clutch pedal stroke 152.5 – 162.5 mm (6.004 – 6.398 in)
4JX1, RHD: 145 – 155mm (5.709 – 6.102 in)

Torque Specifications

E07RW053
7C–28 CLUTCH
Torque Specifications (Cont’d)
(6VE1 LHD)

E07RW054
CLUTCH 7C–29

Torque Specifications (Cont’d)


(Except 6VE1 LHD)

E07RW055
7C–30 CLUTCH

Special Tools
TOOL NO.
ILLUSTRATION
TOOL NAME

5-85253-001-0
(J-24547)
Driven plate aligner

5-8840-2000-0 and
5-8840-0019-0
(J-5822 and J-23907)
Pilot bearing remover
and Sliding hammer

5-8840-0125-0
(J-26516-A)
Crankshaft pilot bearing
installer

5-8840-0007-0
(J-8092)
Driver handle
LIGHTING SYSTEM 8A–1

BODY AND ACCESSORIES


CONTENTS
Lighting System . . . . . . . . . . . . . . . . . . . . . . . . . 8A Body Structure . . . . . . . . . . . . . . . . . . . . . . . . . . 8F
Wiper/Washer System . . . . . . . . . . . . . . . . . . . 8B Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G
Entertainment . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C Security and Locks . . . . . . . . . . . . . . . . . . . . . . 8H
Wiring System . . . . . . . . . . . . . . . . . . . . . . . . . . 8D Sun Roof/Convertible Top . . . . . . . . . . . . . . . . 8I
Meter and Gauge . . . . . . . . . . . . . . . . . . . . . . . 8E Exterior/Interior Trim . . . . . . . . . . . . . . . . . . . . . 8J

LIGHTING SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 8A–2 High Mount Stoplight . . . . . . . . . . . . . . . . . . . . 8A–10
Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–3 Front Turn Signal Light Bulb . . . . . . . . . . . . . . 8A–10
Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–10
Headlight and Associated Parts . . . . . . . . . 8A–4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–4 Side Turn Signal Light Bulb . . . . . . . . . . . . . . . 8A–11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–11
Headlight Adjustment . . . . . . . . . . . . . . . . . . 8A–4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–11
Fog Light Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–5 Rear Turn Signal Light Bulb . . . . . . . . . . . . . . 8A–11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–11
Fog Light Assembly . . . . . . . . . . . . . . . . . . . . . 8A–6 Backup Light Bulb . . . . . . . . . . . . . . . . . . . . . . . 8A–12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–12
Fog Light Adjustment . . . . . . . . . . . . . . . . . . 8A–6 Dome Light Bulb . . . . . . . . . . . . . . . . . . . . . . . . 8A–12
Clarence Light Bulb . . . . . . . . . . . . . . . . . . . . . . 8A–6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–6 Luggage Room Light Bulb . . . . . . . . . . . . . . . . 8A–13
Rear Fog Light Bulb (RHD) . . . . . . . . . . . . . . . 8A–7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–7 Courtesy Light Bulb . . . . . . . . . . . . . . . . . . . . . . 8A–13
Taillight Bulb (Body) . . . . . . . . . . . . . . . . . . . . . 8A–7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–7 Map Light Switch/Bulb . . . . . . . . . . . . . . . . . . . 8A–14
Taillight Bulb (Bumper) . . . . . . . . . . . . . . . . . . . 8A–8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–8 Ashtray Illumination Bulb . . . . . . . . . . . . . . . . . 8A–15
License Plate Light Bulb (Body) . . . . . . . . . . . 8A–8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–8 Glove Box Illumination Bulb . . . . . . . . . . . . . . . 8A–15
License Plate Light Bulb (Bumper) . . . . . . . . . 8A–9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–9 Vanity Mirror Illumination Bulb . . . . . . . . . . . . . 8A–16
Stoplight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–16
Removal and Installation . . . . . . . . . . . . . . . 8A–9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–16
8A–2 LIGHTING SYSTEM
Starter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–17 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–17 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–17 Door Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–23
Lighting Switch (Combination Switch) . . . . . . 8A–18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–18 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–18 Rear Defogger Switch . . . . . . . . . . . . . . . . . . . 8A–24
Fog Light Switch . . . . . . . . . . . . . . . . . . . . . . . . 8A–19 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–19 Seat Heater Switch . . . . . . . . . . . . . . . . . . . . . . 8A–25
Stoplight Switch (W/O Cruise Control) . . . . . . 8A–20 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–20 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–20 Key Remind Switch (Starter Switch) . . . . . . . 8A–25
Brake Switch (W/Cruise Control) . . . . . . . . . . 8A–21 Removal and Installation . . . . . . . . . . . . . . . 8A–25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–21 Illumination Controller . . . . . . . . . . . . . . . . . . . . 8A–26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–21 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–26
Turn Signal Switch (Combination Switch) . . . 8A–21 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–26
Removal and Installation . . . . . . . . . . . . . . . 8A–21 Power/Winter Switch . . . . . . . . . . . . . . . . . . . . . 8A–27
Hazard Warning Switch . . . . . . . . . . . . . . . . . . 8A–22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–22 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–22 Main Data and Specifications . . . . . . . . . . . . . 8A–28
Tailgate Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–23

Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
LIGHTING SYSTEM 8A–3

Headlight Bulb
Removal
1. Disconnect the battery ground cable.
2. Disconnect the connector.
3. Remove the cap(3) while turning it counter clockwise.
4. Remove the cover(2).
5. Pull the bulb(1) out from the headlight body.
CAUTION: The halogen bulb develops a very high
temperature. Do not touch the glass portion. If any
stain is on the glass surface, It will scorch and the
glass will be damaged.

801RW014

Installation
To install, follow the removal steps in the reverse order.
8A–4 LIGHTING SYSTEM

Headlight
Headlight and Associated Parts

801RW003

Legend (5) Headlight Rim


(1) Radiator Grille (6) Headlight Bulb
(2) Front End Lower Panel (7) Rear Cover
(3) Headlight Assembly (8) Bracket
(4) Headlight (9) Front Combination Light

Removal Headlight Adjustment


1. Disconnect the battery ground cable. Preparation
2. Remove the screw and pull out the two projecting Place the unloaded vehicle on a level surface and check
portions on the fender to remove the front to see if the inflation pressure of the tires is correct, the
combination light. lenses are clean, and the battery is sufficiently charged.
3. Remove five clips and two screws to remove the Adjust the aim with the headlight tester, if necessary.
radiator grille. When adjusting, follow the procedure of the tester
4. Remove two screws to remove the front end lower manufacturer’s.
panel(2).
5. Remove two bolts and two nuts to remove the
headlight assembly (with bracket).
6. Remove the headlight bulb.
7. Remove two screws, two nuts and the spring for the
headlight aim adjustment to remove the bracket.
8. Remove four screws to remove the rear cover.
9. Remove the headlight rim.
10. Remove the headlight.

Installation
To install, follow the removal steps in the reverse order.
CAUTION: After installing the headlight, be sure to
adjust the headlight aim.

801RS009
LIGHTING SYSTEM 8A–5

Vertical adjustment Horizontal adjustment


Use a screwdriver for vertical adjustment. Use a screwdriver for horizontal adjustment.

801RW004 801RW005

Fog Light Bulb


Removal Installation
1. Disconnect the battery ground cable. 1. Install the fog light bulb(1).
2. Open the rear cover(1) of the case. 2. Install the clip(2).
3. Remove the dust cover. 3. Connect the bulb connector.
4. Disconnect the bulb connector. 4. Install the dust cover.
5. Remove the clip(3). 5. Close the rear cover(3) of the case.
6. Remove the fog light bulb(2).

801RW017

801RW012
6. Connect the battery ground cable.
8A–6 LIGHTING SYSTEM

Fog Light Assembly


Removal CAUTION: After installing the fog light, be sure to
adjust the fog light aim.
1. Disconnect the battery ground cable.
2. Remove two nuts from the bracket.
Fog Light Adjustment
3. Disconnect the connector.
Turn the adjusting screw with a screwdriver to adjust the
4. Remove the fog light assembly (1). aim of the fog light vertically.

825RW104
801RW007

Installation
To install, follow the removal steps in the reverse order.

Clarence Light Bulb


Removal
1. Disconnect the battery ground cable.
2. Remove the screw at the upper portion of the light
bracket and then remove the bracket from the fender.
3. Remove the front combination light assembly(1).
4. Remove the front side marker light socket(2) by
turning it counterclockwise.
5. Pull out the bulb(3) from the socket.

801RW015

Installation
To install, follow the removal steps in the reverse order.
LIGHTING SYSTEM 8A–7

Rear Fog Light Bulb (RHD)


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Remove three screws and release locks at two
locations to remove the rear combination light
assembly(2).
3. Remove the socket(3) by turning it counterclockwise.
4. Turn the bulb(1) counterclockwise while pushing it to
remove it from the socket.

803RS005

Taillight Bulb (Body)


Removal
1. Disconnect the battery ground cable.
2. Remove three screws and release locks at two
locations to remove the rear combination light
assembly(2).
3. Remove the socket(3) by turning it counterclockwise.
4. Turn the bulb(1) counterclockwise while pushing it to
remove it from the socket.

803RS005

Installation
To install, follow the removal steps in the reverse order.
8A–8 LIGHTING SYSTEM

Taillight Bulb (Bumper)


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Remove two screws to remove the rear combination
light assembly(2).
3. Remove the socket(1) by turning it counterclockwise.
4. Remove the bulb(3) by turning it counterclockwise
while pushing.

803RW004

License Plate Light Bulb (Body)


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Remove two screws to remove the lens(2).
3. Pull out the bulb(1) from the socket.

803RS006
LIGHTING SYSTEM 8A–9

License Plate Light Bulb (Bumper)


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Remove two screws to remove the license plate
light(1).
3. Pull out the bulb(3) from the socket(2).

803RW003

Stoplight Bulb
Removal and Installation
Refer to the Taillight Bulb in this section.
8A–10 LIGHTING SYSTEM

High Mount Stoplight


Removal Installation
1. Disconnect the battery ground cable. 1. Insert the clips(1)(3) into the high mount stoplight(2).
2. Remove the clips(2). 2. Reconnect the connector.
3. Pull out the high mount stoplight(1). 3. Install the high mount stoplight.
4. Remove the connector.
5. Remove the high mount stoplight.

803RS004

803RS003

Front Turn Signal Light Bulb


Removal
1. Disconnect the battery ground cable.
2. Remove the screw at the upper portion of the light
bracket, and remove the bracket from the fender.
3. Remove the front combination light(1).
4. Remove the turn signal light socket(3) by turning it
counterclockwise.
5. Remove the bulb(2) by turning it counterclockwise
while pushing it at the same time.

801RS002

Installation
To install, follow the removal steps in the reverse order.
LIGHTING SYSTEM 8A–11

Side Turn Signal Light Bulb


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Pull the light/bulb(1) toward you while pushing the
light housing in the rear direction of the vehicle to
release its lock.
3. Remove the bulb by turning it counterclockwise while
pushing it at the same time.

801RW013

Rear Turn Signal Light Bulb


Removal
1. Disconnect the battery ground cable.
2. Remove the three screws and release the lock at two
positions.
3. Remove the rear combination light(3).
4. Remove the turn signal light socket/bulb(1) by turning
it counterclockwise.
5. Remove the bulb(2) by turning it counterclockwise
while pushing it at the same time.

803RS002

Installation
To install, follow the removal steps in the reverse order.
8A–12 LIGHTING SYSTEM

Backup Light Bulb


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Remove three screws and release the lock at two
positions.
3. Remove the rear combination light(3).
4. Remove the backup light socket/bulb(1) by turning it
counterclockwise.
5. Remove the bulb(2) by turning it counterclockwise
while pushing it at the same time.

803RS001

Dome Light Bulb


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Remove the lens(2) by releasing the locks at three
locations.
3. Remove the bulb(1).

805RS005
LIGHTING SYSTEM 8A–13

Luggage Room Light Bulb


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Remove the lens(2) by releasing the locks at four
locations.
3. Remove the bulb(1).

803RS007

Courtesy Light Bulb


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Remove two screws to remove the lens(1).
3. Pull out the bulb(2) from the socket.

805RS006
8A–14 LIGHTING SYSTEM

Map Light Switch/Bulb


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Pull the map light body downward to release the lock.
3. Disconnect the connectors of the map light and the
sun roof switch.
4. Remove the map light switch.
5. Turn the socket counterclockwise to remove it.
6. Pull out the bulb from the socket.

805RS008
LIGHTING SYSTEM 8A–15

Ashtray Illumination Bulb


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Removal eight screws to remove the instrument
cluster panel(1).
3. Remove the ashtray(5).
4. Remove four screws to remove the audio box(4).
5. Remove two screws to remove the ashtray guide(2).
6. Turn the socket counterclockwise to remove it then
pull out the bulb(3).

742RS001

Glove Box Illumination Bulb


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Open the glove box lid, and then pull out the bulb(1).

805RS004
8A–16 LIGHTING SYSTEM

Vanity Mirror Illumination Bulb


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Remove the lens(2).
3. Remove the bulb(1).

743RW007
LIGHTING SYSTEM 8A–17

Starter Switch
Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order
noting the following point.
2. Remove the front console assembly(1).
Refer to Instrument Panel Assembly in Body 1. When installing the steering cowl(10), be sure to pass
Structure section. the harnesses through the route as shown in the
figure so that the starter switch harness(7), the
3. Remove the lower cluster assembly(2). combination switch harness(8) and the inflator
Refer to the Instrument Panel Assembly in Body module harness(9) will not get caught.
Structure section.
4. Remove the instrument panel driver lower cover
assembly(3).
Refer to the Instrument Panel Assembly in Body
Structure section.

431RW008

821RW024

5. Remove seven screws to remove the steering


cowl(6).
6. Disconnect the connector, remove the screw(4) and
then remove the starter switch(5).

431RW005
8A–18 LIGHTING SYSTEM

Lighting Switch (Combination Switch)


Removal 1. Check to see if the vehicle is in the straight driving
condition and turn the rotary section of the SRS coil
1. Disconnect the battery ground cable. assembly provided to the upper surface of the lighting
2. Remove the instrument panel driver lower cover(5). switch (combination switch) counterclockwise fully
Refer to the Instrument Panel Assembly in Body until it stops.
Structure section. Then from where it stops, turn it back about 3
rotations to set the alignment marks(7) together
3. Remove seven screws to remove the steering
before installing the steering wheel.
cowl(4).
4. Disconnect the SDM (air bag controller) connector
located at lower of the instrument panel driver lower
cover.
5. Remove four fixing screws and disconnect the driver
inflator module connector to remove the driver inflator
module(3).
CAUTION: When carrying a live inflator module,
make sure the bag opening is pointed away from
you. In case of an accidental deployment, the bag will
then deploy with minimal chance of injury. Never
carry the inflator module by the wires or connector
on the underside of the module.
When placing a live inflator module on a bench or
other surface, always face the bag and trim cover up,
away from the surface. This is necessary so that a
free space is provided to allow the air bag to expand
in the unlikely event of accidental deployment.
6. Remove the steering wheel(2).
Refer to the Steering Wheel in Steering section. 825RW099

7. Disconnect the SRS coil assembly connector, 2. Tighten the steering shaft nut to the specified torque.
remove four fixing screws to remove the SRS coil Torque: 34 Nꞏm (3.5 kgꞏm/25 lb ft)
assembly(1). 3. When connect the double lock type of inflator module
8. Disconnect the lighting switch connector, remove four connector, insert the connector completely and lock
fixing screws to remove the lighting switch(6). at outside.
Imperfect locking may cause malfunction of SRS
system circuit.
4. When installing the steering cowl(11), be sure to pass
the harnesses through the route as shown in the
figure so that the starter switch harness(8), the
combination switch harness(9) and inflator module
harness(10) will not get caught.

825RS039

Installation
To install, follow the removal steps in the reverse order,
noting the following points.

431RW014
LIGHTING SYSTEM 8A–19

Fog Light Switch


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order,
noting the following point:
2. Remove the front console assembly(1).
Refer to the Instrument Panel Assembly in Body 1. Push in the switch with your fingers until the switch is
Structure section. locked securely.
3. Remove the lower cluster assembly(2).
Refer to the Instrument Panel Assembly in Body
Structure section.
4. Remove the instrument panel driver lower cover
assembly(3).
Refer to the Instrument Panel Assembly in Body
Structure section.

821RW024

5. Remove the instrument panel cluster assembly(4).


Refer to the Instrument Panel Assembly in Body
Structure section.
6. Disconnect the connector and push the lock from the
back side of the instrument panel cluster assembly to
remove the fog light switch(5).

825RW027
8A–20 LIGHTING SYSTEM

Stoplight Switch (W/O Cruise Control)


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order,
noting the following points.
2. Disconnect the connector(3), loosen the lock nut(1)
and then remove the stoplight switch(2) by turning it. 1. Check to see if the brake pedal has been returned by
the return spring to the specified position.
2. Turn the stoplight switch(1) clockwise until the tip of
the threaded portion of the switch contacts the pedal
arm(2).
3. Turn the switch counterclockwise until the space
between the tip of the threaded portion and the pedal
arm is 0.5 to 1.0 mm (0.02 – 0.04 in.).

310RS007

310RS006
LIGHTING SYSTEM 8A–21

Brake Switch (W/Cruise Control)


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order,
noting the following points.
2. Disconnect the connector(1), loosen the lock nut(3)
and then remove the brake switch(2) by turning it. 1. Check to see if the brake pedal has been returned by
the return spring to the specified position.
2. Turn the switch clockwise until the tip of the threaded
portion of the brake switch contacts the pedal arm.
3. Turn the switch counterclockwise until the space
between the tip of the threaded portion and the pedal
arm is 0.5 to 1.0 mm (0.02 – 0.04 in.).

310RW010

310RS003

Turn Signal Switch (Combination Switch)


Removal and Installation
Refer to the removal and installation steps of the Lighting
Switch (Combination Switch) in this section.
8A–22 LIGHTING SYSTEM

Hazard Warning Switch


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order,
noting the following point.
2. Remove the front console assembly(1).
Refer to the Instrument Panel Assembly in Body 1. Push in the switch with your fingers until it locks
Structure section. securely.
3. Remove the lower cluster assembly(2).
Refer to the Instrument Panel Assembly in Body
Structure section.
4. Remove the instrument panel driver lower cover
assembly(3).
Refer to the Instrument Panel Assembly in Body
Structure section.

821RW024

5. Remove the instrument panel cluster assembly(4).


Refer to the Instrument Panel Assembly in Body
Structure section.
6. Disconnect the connector and push the lock from the
back side of the instrument panel cluster assembly to
remove the hazard warning switch(5).

825RW024
LIGHTING SYSTEM 8A–23

Tailgate Switch
Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Remove the screw and disconnect the connector(1)
to remove the tailgate switch(2).

683RS014

Door Switch
Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Remove the screw and disconnect the connector to
remove the door switch(1).

825RS043
8A–24 LIGHTING SYSTEM

Rear Defogger Switch


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order,
noting the following point.
2. Remove the front console assembly(1).
Refer to the Instrument Panel Assembly in Body 1. Push in the switch with your fingers until it locks
Structure section. securely.
3. Remove the lower cluster assembly(2).
Refer to the Instrument Panel Assembly in Body
Structure section.
4. Remove the instrument panel driver lower cover
assembly(3).
Refer to the Instrument Panel Assembly in Body
Structure section.

821RW024

5. Remove the instrument panel cluster assembly(4).


Refer to the Instrument Panel Assembly in Body
Structure section.
6. Disconnect the connector and push the lock from the
back side of the instrument panel cluster assembly to
remove the rear defogger switch(5).

825RW023
LIGHTING SYSTEM 8A–25

Seat Heater Switch


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order,
noting the following point.
2. Remove four fixing screws and disconnect the switch
connectors to remove the front console assembly(4). 1. Push the switch with your fingers until it locks
securely.
3. Push the lock from the back side of the front console
assembly to remove the seat heater switch(5).

825RW025

Key Remind Switch (Starter Switch)


Removal and Installation
Refer to the removal and installation on steps of the
Starter Switch in this section.
8A–26 LIGHTING SYSTEM

Illumination Controller
Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order,
noting the following point.
2. Remove the front console assembly(1).
Refer to the Instrument Panel Assembly in Body 1. Push in the switch with your fingers until the switch is
Structure section. locked securely.
3. Remove the lower cluster assembly(2).
Refer to the Instrument Panel Assembly in Body
Structure section.
4. Remove the instrument panel driver lower cover
assembly(3).
Refer to the Instrument Panel Assembly in Body
Structure section.

821RW024

5. Remove the instrument panel cluster assembly(4).


Refer to the Instrument Panel Assembly in Body
Structure section.
6. Disconnect the connector and push the lock from the
back side of the instrument panel cluster assembly to
remove the illumination controller(5).

825RW026
LIGHTING SYSTEM 8A–27

Power/Winter Switch
Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order,
noting the following point.
2. Remove four fixing screws and disconnect the switch
connectors to remove the front console assembly(4). 1. Push the switch with your fingers until it locks
securely.
3. Push the lock from the back side of the front console
assembly to remove the power/winter switch(5).

825RW204
8A–28 LIGHTING SYSTEM

Main Data and Specifications


Light and Bulb Specifications

D08RW539

Legend (10) Meter


(1) Dome Light (11) Map Light
(2) Luggage Room Light (12) High Mount Step Light
(3) Courtesy Light (13) License Plate Light
(4) Side Turn Signal Light (14) Rear combination Light
(5) Front Turn Signal Light (15) Taillight/Stoplight
(6) Clearance Light (16) Rear Fog Light
(7) Front Combination Light (17) Backup Light
(8) Headlight (18) Rear Turn Signal Light.
(9) Fog Light
LIGHTING SYSTEM 8A–29

Number of
Light Name Rated Power Lens Color Remarks
Bulbs
Headlight 60w/55w 2 White Halogen
Front Turn signal light 21w 2 White
combination
light Clearance light 5w 2 Amber

FRT fog light 55w 2 White Halogen


Taillight/Stoplight 5w/21w 2 Red
Rear Bumper
Bum er
Turn signal light 21w 2 Amber
combination
light
g Taillight/Stoplight 5w/21w 2 Red
Body
Turn signal light 21w 2 Amber
Backup light 21w 2 White
RR fog light 21w 2 Red
Side turn signal light 5w 2 Amber
License plate light Bumper 5w 2 White
Body 5W 1 White
High mount stoplight — — Red LED
Map light 5w 2 White
Dome light 10w 1 White
Luggage room light 8w 1 White
Courtesy light 3.8w 2 White
A/C SW 60mA 1
RR defogger SW 0.84w 1
Mirror defogger SW 0.84w 1
FRT fog light SW 0.7w 1
RR fog light SW 0.7w 1
Cruise (Set) 1.4w 1 Meter
Cruise (Main) 1.4w 1 Meter
Check trans 3w 1 Meter
Anti-theft 3w 1 Warning box
Turn signal 1.4w 2 Meter
Glow 1.4w 1 Meter
Water sedimenter 1.4w 1 Meter
Indicator/ High beam 1.4w 1 Meter
Warning
light
g ABS 1.4w 1 Meter
Check engine 1.4w 1 Meter
Low fuel 1.4w 1 Meter
4WD 1.4w 1 Meter
Oil Pressure 1.4w 1 Meter
Brake system 1.4w 1 Meter
Charge 1.4w 1 Meter
Seat belt 2w 1 Meter
A/T shift position 0.91w 7 Meter
A/T oil temp 3w 1 Meter
8A–30 LIGHTING SYSTEM

Power drive 1.4w 1 Meter


Winter drive 1.4w 1 Meter
Air bag 2w 1 Meter
Engine warming SW 0.84w 1
FRT fog light SW 0.84w 1
RR fog light SW 0.84w 1
Glove box 1.2w 1
Ashtray 1.4w 1
Illumination controller 0.7w 1
Heater bezel 150mA 2
Hazard warning light SW 0.84w 1
Illumination Meter 3.4w 4 Meter ASM
Light Rear wiper & washer SW 0.84w 1
Rear defogger SW 0.84w 1
Mirror control SW 45mA 1
Mirror defogger SW 0.7w 1
Mirror folding SW 0.7w 1
A/T select lever 1.2w 1
Power & Winter SW 50mA 2
Cruise control main SW 0.84w 1
Headlight wiper SW 0.84w 1

Torque Specifications
Application Nꞏm kgꞏm Lb Ft Lb In
Steering Shaft Nut 34 3.5 25 —
WIPER/WASHER SYSTEM 8B–1

WIPER / WASHER SYSTEM


CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 8B–2 Alarm & Relay Control Unit . . . . . . . . . . . . . . . 8B–9
Windshield Wiper/Washer System . . . . . . . . . 8B–2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–9
General Description . . . . . . . . . . . . . . . . . . . . . 8B–2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–9
Windshield Wiper And Washer Switch . . . . . 8B–2 Rear Washer Motor . . . . . . . . . . . . . . . . . . . . . . 8B–9
Removal and Installation . . . . . . . . . . . . . . . 8B–2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–9
Windshield Wiper Motor . . . . . . . . . . . . . . . . . . 8B–2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–2 Rear Wiper Arm/Blade . . . . . . . . . . . . . . . . . . . 8B–10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–10
Windshield Washer Motor . . . . . . . . . . . . . . . . 8B–3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–3 Rear Washer Nozzle . . . . . . . . . . . . . . . . . . . . . 8B–10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–10
Windshield Wiper Linkage . . . . . . . . . . . . . . . . 8B–4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–10
Windshield Wiper Linkage and Rear Washer Nozzle Angle Adjustment . . . 8B–10
Associated Parts . . . . . . . . . . . . . . . . . . . . . . 8B–4 Rear Wiper Blade Rubber . . . . . . . . . . . . . . . . 8B–11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–4 Removal and Installation . . . . . . . . . . . . . . . 8B–11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–4 Headlight Wiper/Washer . . . . . . . . . . . . . . . . . 8B–11
Windshield Wiper Arm/Blade . . . . . . . . . . . . . . 8B–5 General Description . . . . . . . . . . . . . . . . . . . . . 8B–11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–5 Headlight Wiper and Washer Switch . . . . . . . 8B–12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–12
Windshield Wiper Blade Rubber . . . . . . . . . . . 8B–6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–6 Headlight Wiper Arm & Blade . . . . . . . . . . . . . 8B–13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–13
Rear Wiper/Washer System . . . . . . . . . . . . . . 8B–7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–13
General Description . . . . . . . . . . . . . . . . . . . . . 8B–7 Headlight Wiper Motor . . . . . . . . . . . . . . . . . . . 8B–13
Rear Wiper and Washer Switch . . . . . . . . . . . 8B–7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–7 Headlight Washer Motor . . . . . . . . . . . . . . . . . 8B–14
Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . 8B–8 Removal and Installation . . . . . . . . . . . . . . . 8B–14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–8 Main Data and Specifications . . . . . . . . . . . . . 8B–14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–8
8B–2 WIPER/WASHER SYSTEM

Service Precaution CAUTION: Always use the correct fastener in the


proper location. When you replace a fastener, use
WARNING: IF SO EQUIPPED WITH A ONLY the exact part number for that application.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS), ISUZU will call out those fasteners that require a
REFER TO THE SRS COMPONENT AND WIRING replacement after removal. ISUZU will also call out
LOCATION VIEW IN ORDER TO DETERMINE the fasteners that require thread lockers or thread
WHETHER YOU ARE PERFORMING SERVICE ON OR sealant. UNLESS OTHERWISE SPECIFIED, do not
NEAR THE SRS COMPONENTS OR THE SRS use supplemental coatings (Paints, greases, or other
WIRING. WHEN YOU ARE PERFORMING SERVICE corrosion inhibitors) on threaded fasteners or
ON OR NEAR THE SRS COMPONENTS OR THE SRS fastener joint interfaces. Generally, such coatings
WIRING, REFER TO THE SRS SERVICE adversely affect the fastener torque and the joint
INFORMATION. FAILURE TO FOLLOW WARNINGS clamping force, and may damage the fastener. When
COULD RESULT IN POSSIBLE AIR BAG you install fasteners, use the correct tightening
DEPLOYMENT, PERSONAL INJURY, OR sequence and specifications. Following these
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. instructions can help you avoid damage to parts and
systems.

Windshield Wiper/Washer System


General Description When the wiper & washer switch is turned on with the
starter switch on, the battery voltage is applied to the
The circuit consists of the starter switch, windshield wiper wiper motor to activate the wiper.
& washer switch, windshield wiper motor, windshield The washer motor squirts glass cleaning fluid while the
washer motor and windshield intermittent relay. washer switch is being pushed. The intermittent relay is
used to control motion of the wiper.

Windshield Wiper And Washer Switch


Removal and Installation
Refer to the Lighting Switch (Combination Switch) in
Lighting System section.

Windshield Wiper Motor


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Disconnect the connector.
3. Remove 4 mounting bolts.
4. Remove the windshield wiper motor(1).

880RW007
WIPER/WASHER SYSTEM 8B–3

Windshield Washer Motor


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Remove the fender inner liner (right side) (1).
3. Remove the screws and then remove the front
combination light(2).
4. Remove 2 screws, the filler neck and the hose.
5. Disconnect the windshield washer motor connector
and remove the washer tank (4).
6. Pull the windshield washer motor(3) from the washer
tank(4).

880RS006
8B–4 WIPER/WASHER SYSTEM

Windshield Wiper Linkage


Windshield Wiper Linkage and Associated Parts

880RW008

Legend (3) Windshield Wiper Linkage Assembly


(1) Windshield Wiper Arm/Blade (4) Windshield Wiper Motor
(2) Vent Cowl Cover

Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Remove the windshield wiper arm/blade.
3. Remove the windshield wiper motor.
4. Remove the pivot assembly mounting nuts, fixing
screws and then remove the vent cowl cover.
5. Take out the windshield wiper linkage assembly from
the opening of the cowl.
WIPER/WASHER SYSTEM 8B–5

Windshield Wiper Arm/Blade


Removal Installation
1. Pry the cap(2) off with the tip of a screwdriver. To install, follow the removal steps in the reverse order,
noting the following points.
2. Remove the nut(3).
3. Remove the wiper/blade(1).

880RS004

1. Wiper arm/blade
Before installing the wiper arm/blade to the shaft,
880RS005

confirm that the motor stops at the auto-stop


position.
Set the wiper arm/blade so that the tips of both
blades are positioned about 35 mm (1.37 in) from
the upper edge of the cowl cover as shown in the
figure.
Tighten the nuts to the specified torque.
Torque: 31 Nꞏm (3.2 kgꞏm/23 lb ft)
8B–6 WIPER/WASHER SYSTEM

Windshield Wiper Blade Rubber


Removal Installation
1. Push the wiper blade lock(1) while pulling the wiper To install, follow the removal steps in the reverse order,
blade in the arrow direction as shown in the figure. noting the following points.
1. Install the click of the blade stay in the groove of the
CAUTION: When the wiper blade has been
new rubber and slide it in. Complete wiper blade
removed, wrap the tip of the wiper arm with cloth, to
installation by pushing the click.
avoid damaging the glass.

885RS002

2. Finally, check that the click of the stay has caught in


880RS011

2. Pull the end of rubber and remove the projection(3)


the hole of the rubber.
from the click of the blade stay (2).

885RS001
880RS010

3. Pull the rubber out in the same direction.


WIPER/WASHER SYSTEM 8B–7

Rear Wiper/Washer System


General Description When the wiper & washer switch is turned on with the
starter switch on, the battery voltage is applied to the
The circuit consists of the starter switch, rear wiper & wiper motor to activate the wiper.
washer switch, rear wiper motor, rear washer motor and The washer motor squirts glass cleaning fluid while the
rear intermittent relay. washer switch is being pushed. The intermittent relay is
used to control motion of the wiper.

Rear Wiper and Washer Switch


Removal
1. Disconnect the battery ground cable.
2. Remove the front console assembly(1).
Refer to the Instrument Panel Assembly in Body
Structure section.
3. Remove the lower cluster assembly(2).
Refer to the Instrument Panel Assembly in Body
Structure section.
4. Remove the instrument panel driver lower cover(3).
Refer to the Instrument Panel Assembly in Body
Structure section.

821RW023

Installation
To install, follow the removal steps in the reverse order,
noting the following point:
1. Push the switch with your fingers until it locks
securely.

821RW024

5. Remove the instrument panel cluster assembly(4).


Refer to the Instrument Panel Assembly in Body
Structure section.
6. Disconnect the connector and push the lock from the
back side of the instrument panel cluster assembly to
remove the rear wiper & washer switch(5).
8B–8 WIPER/WASHER SYSTEM

Rear Wiper Motor


Removal
1. Disconnect the battery ground cable.
2. Remove the tailgate trim pad.
3. Remove the wiper arm/blade.
Refer to the removal steps of the Rear Wiper
Arm/Blade in this section.
4. Disconnect the connector remove the wiper shaft nut,
remove the fixing screws and then remove the rear
wiper motor(1).

885RS012

885RS013

Installation
To install, follow the removal steps in the reverse order,
noting the following points.
1. Before installing the wiper arm/blade to the motor
shaft, confirm that the motor stops at the auto-stop
position.
2. Install the wiper arm so that the blade gets parallel to 885RS011

the lowermost heat wire(2) of the rear defogger 3. Tighten the motor shaft nut to the specified torque.
(w/rear defogger), or position the blade 20 mm
Torque: 6 Nꞏm (0.6 kgꞏm/52 lb in)
(0.79 in) from edge of tailgate glass (W/O rear
defogger). 4. Tighten the wiper arm nut to the specified torque.
Torque: 9 Nꞏm (0.9 kgꞏm/78 lb in)
WIPER/WASHER SYSTEM 8B–9

Alarm & Relay Control Unit


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Remove the glove box.
3. Remove the instrument panel passenger lower cover
assembly.
4. Remove the passenger Knee bolster reinforcement
assembly.
5. Remove the fixing bolts, disconnect the connectors
and then remove the alarm & relay control unit (1).

826RW020

Rear Washer Motor


Removal
1. Disconnect the battery ground cable.
2. Remove the tailgate trim pad(2).
3. Remove two screws, disconnect the connector,
remove the washer hose and then remove the rear
washer tank(3).
4. Pull out the rear washer motor(1) from the washer
tank.

885RS009

Installation
To install, follow the removal steps in the reverse order.
8B–10 WIPER/WASHER SYSTEM

Rear Wiper Arm/Blade


Removal Installation
1. Remove the arm nut(2). Refer to the installation steps of the Rear Wiper Motor in
Wiper/Washer System section.
2. Remove the wiper arm/blade(1).

885RS008

Rear Washer Nozzle


Removal Rear Washer Nozzle Angle
1. Disconnect the hose(3). Adjustment
2. Remove the lock nut(2), and then remove the washer Loosen the lock nut(2) of the washer nozzle(1) to adjust
nozzle(1). the injection angle of the cleaning fluid, and then retighten
the lock nut(2).

885RS005
885RS004

Installation
To install, follow the removal steps in the reverse order.
WIPER/WASHER SYSTEM 8B–11

Rear Washer Spray Pattern

885RS003

Legend
(1) Washer Nozzle
(2) Spray Target

Rear Wiper Blade Rubber


Removal and Installation
Refer to the Windshield Wiper Blade Rubber in this
section.

Headlight Wiper/Washer
General Description
The circuit consists of the starter switch, headlight
wiper/washer switch, headlight wiper motor and washer
motor. By pushing the headlight wiper/washer switch with
the starter switch on, the wiper will make 5 strokes with
washer solution applied between each of the first 4
strokes, regardless of the length of time the switch is held
down.
The washer nozzle is installed to the wiper blade, and the
tank to which the washer motor is installed shared among
the headlight washer and the windshield washer.
8B–12 WIPER/WASHER SYSTEM

Headlight Wiper and Washer Switch


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order,
noting the following point:
2. Remove the front console assembly(1).
Refer to the Instrument Panel Assembly in Body 1. Push the switch with your fingers until it locks
Structure section. securely.
3. Remove the lower cluster assembly(2).
Refer to the Instrument Panel Assembly in Body
Structure section.
4. Remove the instrument panel driver lower cover(3).
Refer to the Instrument Panel Assembly in Body
Structure section.

821RW024

5. Remove the instrument panel cluster assembly(4).


Refer to the Instrument Panel Assembly in Body
Structure section.
6. Disconnect the connector and push the lock from the
back side of the instrument panel cluster assembly to
remove the headlight wiper switch(5).

825RW245
WIPER/WASHER SYSTEM 8B–13

Headlight Wiper Arm & Blade


Removal Installation
1. Remove the wiper arm nut and the wiper arm & To install, follow the removal steps in the reverse order,
blade(1). noting the following point:
2. Disconnect the washer hose. 1. Tighten the wiper arm nut to the specified torque.
Torque: 5 Nꞏm (0.5 kgꞏm/44 Ib ft)

808RW001

Headlight Wiper Motor


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order,
noting the following point:
2. Remove the headlight wiper arm/blade(1).
1. Make sure that the motor stops at auto stop position
3. Remove the headlight assembly(2).
prior to installing the wiper arm & blade to the motor
Refer to the Headlight removal steps in this section. shaft.
4. Remove 2 nuts and screws, the remove headlight
wiper motor(3).

808RW002
8B–14 WIPER/WASHER SYSTEM

Headlight Washer Motor


Removal and Installation
Refer to the removal and installation steps of the
windshield washer tank/motor under »Windshield
Wiper/Washer And Rear Wiper/Washer” in this section.

Main Data and Specifications


Torque Specifications
Application Nꞏm kgꞏm Lb Ft Lb In
Windshield Wiper Motor Shaft Nut 14 1.4 — 122
Windshield Wiper Arm Nuts 31 3.2 23 —
Rear Wiper Motor Shaft Nut 6 0.6 — 52
Rear Wiper Arm Nut 9 0.9 — 78
Headlight Wiper Arm Nuts 5 0.5 — 44
ENTERTAINMENT 8C–1

ENTERTAINMENT
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 8C–1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–5
Cigarette Lighter . . . . . . . . . . . . . . . . . . . . . . . . 8C–2 Antenna Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–6
General Description . . . . . . . . . . . . . . . . . . . . . 8C–2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–2 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–7
Digital Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–3 Front Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–8
Rod Type Antenna . . . . . . . . . . . . . . . . . . . . . . 8C–4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–4 Rear Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–9
Auto Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–9
General Description . . . . . . . . . . . . . . . . . . . . . 8C–5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–5

Service Precaution CAUTION: Always use the correct fastener in the


proper location. When you replace a fastener, use
WARNING: IF SO EQUIPPED WITH A ONLY the exact part number for that application.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS), ISUZU will call out those fasteners that require a
REFER TO THE SRS COMPONENT AND WIRING replacement after removal. ISUZU will also call out
LOCATION VIEW IN ORDER TO DETERMINE the fasteners that require thread lockers or thread
WHETHER YOU ARE PERFORMING SERVICE ON OR sealant. UNLESS OTHERWISE SPECIFIED, do not
NEAR THE SRS COMPONENTS OR THE SRS use supplemental coatings (Paints, greases, or other
WIRING. WHEN YOU ARE PERFORMING SERVICE corrosion inhibitors) on threaded fasteners or
ON OR NEAR THE SRS COMPONENTS OR THE SRS fastener joint interfaces. Generally, such coatings
WIRING, REFER TO THE SRS SERVICE adversely affect the fastener torque and the joint
INFORMATION. FAILURE TO FOLLOW WARNINGS clamping force, and may damage the fastener. When
COULD RESULT IN POSSIBLE AIR BAG you install fasteners, use the correct tightening
DEPLOYMENT, PERSONAL INJURY, OR sequence and specifications. Following these
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. instructions can help you avoid damage to parts and
systems.
8C–2 ENTERTAINMENT

Cigarette Lighter
General Description
When the cigarette lighter is pushed in with the starter
switch at either “ACC” or “ON” position, a circuit is formed
in the cigarette lighter case to heat the lighter coil.
The cigarette lighter is sprung back to its original position
after the lighter coil is heated.

Removal
1. Disconnect the battery ground cable.
2. Remove the lower cluster assembly(1).
Refer to the Instrument Panel Assembly removal
steps in Body Structure section.
3. Disconnect the connectors, remove the socket, the
retaining ring(7), the outer case(6), the cigarette
lighter(3) and socket(4), the bezel(5) and then
remove the cigarette lighter assembly(2).

826RS007

Installation
To install, follow the removal steps in the reverse order,
noting the following point.
1. When installing the bezel, align the projected portion
of the socket with the notch of the bezel.
ENTERTAINMENT 8C–3

Digital Clock
Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order,
noting the following point.
2. Remove the front console assembly(1).
Refer to the Instrument Panel Assembly in Body 1. Push in the switch with your fingers until it locks
Structure section. securely.
3. Remove the lower cluster assembly(2).
Refer to the Instrument Panel Assembly in Body
Structure section.
4. Remove the instrument panel driver lower cover
assembly(3).
Refer to the Instrument Panel Assembly in Body
Structure section.

821RW024

5. Remove the instrument panel cluster assembly(4).


Refer to the Instrument Panel Assembly in Body
Structure section.
6. Disconnect the connector and push the lock from the
back side of the instrument panel cluster assembly to
remove the digital clock(5).

821RW034
8C–4 ENTERTAINMENT

Rod Type Antenna


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Turn the antenna rod(1) counterclockwise to remove
it.
3. Remove three screws and nine clips to remove the
fender inner liner(2).
4. Disconnect the feeder cable connector at the inside of
the vehicle, remove the housing bracket screw, turn
the lock nut counterclockwise to remove it together
with the base mold and then remove the housing(3).

890RS004
ENTERTAINMENT 8C–5

Auto Antenna
General Description Installation
The auto antenna is interlocked with the radio switch. The To install, follow the removal steps in the reverse order.
antenna rod goes up when the switch is on, and goes
down when the switch is off. The antenna rod also goes
down when the starter switch is turned off with the radio
on.
The antenna rod goes up or down when the cable
connected to the uppermost rod is let out or taken up by
the rotation of motor.
The motor is provided with a built-in limit switch. When the
up/down motion of the antenna is completed, the limit
switch is activated to cut off the circuit.

Removal
1. Disconnect the battery ground cable.
2. Remove three screws and nine clips to remove the
fender inner liner(4).
3. Disconnect the feeder cord and the antenna motor
connector at the inside of the vehicle.
4. Remove the lock nut(1) and base mold(2).
5. After taking off the clips and screws, remove the
motor bracket(5).

890RW075
8C–6 ENTERTAINMENT

Antenna Rod
Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order,
nothing the following points.
2. Remove the antenna nut(1).
1. Rotate the antenna motor in a descend way, and push
3. Until the lower part of the antenna rod(4) is removed in vertically until the antenna rod is in the complete
from the bezel part, rotate the antenna motor in an state of storage.
ascending way, and expand the rod.
2. After ending the installation, confirm that the antenna
4. Turn the antenna top(2) counterclockwise. rod works correctly.
5. Remove the contact sleeve(3).
6. Remove the antenna rod(4).

890RW076
ENTERTAINMENT 8C–7

Radio
Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Remove the front console assembly (1).
Refer to the Instrument Panel Assembly in Body
Structure section.
3. Remove the lower cluster assembly (2).
Refer to the Instrument Panel Assembly in Body
Structure section.
4. Remove the instrument panel driver lower cover
assembly (3).
Refer to the Instrument Panel Assembly in Body
Structure section.

821RW024

5. Remove the instrument panel cluster assembly(4).


Refer to the Instrument Panel Assembly in Body
Structure section.
6. Remove two screws and disconnect the radio
connector(5) and antenna feeder plug(6) to remove
the radio(7).

825RW039
8C–8 ENTERTAINMENT

Front Speaker
Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Pull the grille(1) to release the locks and then remove
it.
3. Remove four screws and disconnect the
connector(3) to remove the speaker(2).

890RW013
ENTERTAINMENT 8C–9

Rear Speaker
Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Pull the grille(1) to release the locks and then remove
it.
3. Remove four screws and disconnect the
connector(3) to remove the speaker(2).

890RW015
8C–10 ENTERTAINMENT

MEMO
General Description
The chassis electrical system is a 12–volt system with a CAUTION: Clean the battery terminal and apply a
negative ground polarity. light coat of grease to prevent terminal corrosion.
Wire size are appropriate to respective circuits, and
classified by color. (The classification of harnesses by
color is shown on the circuit diagram for ease of harness Disconnecting the Connector
identification.) Some connectors have a tang lock to hold the connectors
The wire size is determined by load capacity and the together during vehicle operation.
length of wire required. Some tang locks are released by pulling them towards
The vehicle harnesses are: body harness, chassis you (1).
harness, engine room harness, instrument harness, Other tang locks are released by pressing them forward
transmission harness, engine ECGI harness, dome light (2).
harness, door harness, rear body harness, tailgate Determine which type of tang lock is on the connector
harness, SRS harness and battery cables. being handled.
The harnesses are protected either by tape or corrugated
tube, depending on harness location.
The circuit for each system consists of the power source,
wire, fuse, relay, switch, load parts and ground, all of
which are shown on the circuit diagram.
In this section, each electrical device is classified by
system.
For major parts shown on the circuit based on the circuit
diagram for each system, a summary, diagnosis of
troubles and inspection procedures are detailed. 1
2

Notes for Working on Electrical


Items
Disconnecting the Battery Cable
1. All switches should be in the “OFF” position.
2. Disconnect the battery ground cable (2).
3. Disconnect the battery positive cable (1).
CAUTION: It is important that the battery ground
cable be disconnected first. Disconnecting the
battery positive cable first can result in a short circuit. Firmly grasp both sides (male and female) of the
connector (3).
Release the tang lock and carefully pull the two halves of
the connector apart.
1 Never pull on the wires to separate the connectors (4).

Connecting the Battery Cable


Follow the disconnecting procedure in the reverse order.
When removing the connector for relay (MR5B type) (5), Connector Inspection
unfasten the tang lock of the connector by using a
screwdriver, then pull the relay out as shown in the figure. Use a circuit tester to check the connector for continuity.
Insert the test probes (1) from the connector wire side.

Connecting the Connector


Never insert the circuit tester test probes (2) into the
Firmly grasp both sides (male and female) of the connector open end to test the continuity.
connectors. Be sure that both sides of the connectors are Broken or open connector terminals will result.
aligned with each other.
Firmly but carefully push the two sides of the connectors
together until a distinct click is heard (2).
Do not connect them by force if they can not be connected
smoothly (1).

2
Waterproof Connector Inspection Connector Pin Removal – Pin Tang Lock
It is not possible to insert the test probes (2) into the Type
connector wire side of a waterproof connector. 1. Insert a slender shaft (1) into the connector housing
Use one side of a connector (1) with its wires cut to make open end (5).
the test. Connect the test connector to the connector to 2. Push the tang lock (2) flat (toward the wire (3) side of
be tested (3). Connect the test probes to the cut wires to the connector.
check the connector continuity.
Pull the wire with pin (4) free from the wire side of the
connector.

1 1
2
3

2
5 4

Connector Pin Removal – Connector


Housing Tang Lock Type
1. Insert a slender shaft (1) into the connector housing
Connector Pin Insertion
open end (5). 1. Check that the tang lock (1) is fully up.
2. Push the tang lock (2) up (in the direction of the arrow 2. Insert the pin (3) from the connector wire (2) side.
in the illustration). Push the pin in until the tang lock closes firmly.
Pull the wire (3) with pin (4) free from the wire side of 3. Gently pull on the wires to make sure that the
the connector. connector pin is firmly set in place.

1
2 1 2

5 4 3 3
Parts Handling 3. Use a grommet or guard tube (1) to protect the wiring
harness from contacting a sharp edge or surface (2).
Be careful when handling electrical parts. They should not
be dropped or thrown, because short circuit or other
damage may result.
2

4. Position the wiring harness with enough clearance


from the other parts and guard the wiring harness with
Cable Harness a vinyl tube (2) and clips (1) to avoid direct contact.
1. When installing the parts, be careful not to pinch or
wedge the wiring harness.
2. All electrical connections must be kept clean and tight.

2
1
5. The wiring harness between engine and chassis
should be long enough (2). Tension of the wire (1) may
causes chafing or damage due to various vibrations.

2
Open the crimping tool to its full width and rest one
handle on a firm flat surface.
Center the back of the splice clip on the proper anvil
and close the crimping tool to the point where the back
Splicing Wire of the splice clip touches the wings of the clip.
1. If the harness is taped, remove the tape. To avoid wire Make sure that the clip and wires are still in the correct
insulation damage, use a sewing “seam ripper” position. Then, apply steady pressure until the
(available from sewing supply stores) to cut open the crimping tool closes as shown in the figure.
harness.
If the harness has a black plastic conduit, simply pull
out the desired wire.
2. Begin by cutting as little wire off the harness as
possible. You may need the extra length of wire later
if you decide to cut more wire off to change the location
of a splice. You may have to adjust splice locations to
make certain that each splice is at least 1–1/2”
(40 mm) away from other splices, harness branches,
or connectors.
3. When replacing a wire, use a wire of the same size as
the original wire.
Check the stripped wire for nicks or cut stands. If the
wire is damaged, repeat the procedure on a new
section of wire. The two stripped wire ends should be
equal in length.
4. Select the proper clip to secure the splice.
To determine the proper clip size for the wire being
spliced, follow the directions included with your clips.
Select the correct anvil on the crimper. (On most
crimpers your choice is limited to either a small or
large anvil.)
Overlap the two stripped wire ends and hold them
between your thumb and forefinger as shown in the
figure.
The center the spline clip (1) under the stripped wires
and hold it in place.
Before crimping the ends of the clip (1), be sure that: 6. Center and roll the splicing tape.
The wires extend beyond the clip in each direction. The tape should cover the entire splice.
No strands of wire are cut loose, and Roll on enough tape (1) to duplicate the thickness of
No insulation is caught under the clip. the insulation on the existing wires.
Crimp the splice again, once on each end. Does not flag the tape (2). Flagged tape may not
Does not let the crimping tool (2) extend beyond the edge provide enough insulation, and the flagged ends will
of the clip or you may damage or nick the wires as shown tangle with the other wires in the harness as shown in
in the figure. the figure.

1 2

5. Apply 60/40 resin core solder to the opening in the If the wire does not belong in a conduit or other
back of the clip as shown in the figure. harness covering, tape the wire again. use a winding
Follow the manufacturer’s instructions for the solder motion to cover the first piece of tape as shown in the
equipment you are using. figure.
Symbols and Abbreviations
Symbols
Abbreviations
Parts for Electrical Circuit
Wiring – Wire color
All wires have color–coded insulation.
Wires belonging to a system’s main harness will have a
single color (1). Wires belonging to a system’s subcircuits
will have a colored stripe (2). Striped wires use the
following code to show wire size and colors. 1

Example: 0.5 G / R

Red (Stripe color)

Green (Base color)


2
Wire size (0.5 mm2)

Wiring – Wire Color Coding


Abbreviations are used to indicate wire color within a circuit diagram.
Refer to the following table.

Color Coding Meaning Color Coding Meaning

B Black BR Brown

W White LG Light green

R Red GR Grey

G Green P Pink

Y Yellow LB Light blue

L Blue V Violet

O Orange
Wiring – Wire Size
The size of wire used in a circuit is determined by the
amount of current (amperage), the length of the circuit,
and the voltage drop allowed. The following wire size and
load capacity are specified. (Nominal size means
approximate cross sectional area (1).)

Wiring – Wire Size Table

Nominal size Cross sectional Outside diameter Allowable


area (mm2) (mm) current (A)

0.3 0.372 1.5 9


0.5 0.563 1.7 12
0.85 0.885 1.9 16
1.25 1.287 2.2 21
2 2.091 2.7 28
3 3.296 3.6 37.5
5 5.227 4.4 53
8 7.952 5.5 67
15 13.36 7.0 75
20 20.61 8.2 97
Fuse
Fuses are the most common form of circuit protection
used in vehicle wiring. A fuse is a thin piece of wire or strip
of metal encased in a glass or plastic housing. It is wired
in series with the circuit it protects. When there is an
overload of current in a circuit, such as a short of a ground,
the metal strip is designed to burn out and interrupt the
flow of current. This prevents a surge of high current from
reaching and damaging other components in the circuit.
Determine the cause of the overloaded before replacing
the fuse.
The replacement fuse must have the same amperage
specification as the original fuse.
Never replace a blown fuse with a fuse of a different
amperage specification.
Doing so can result in an electrical fire or other serious
circuit damage. A blown fuse is easily identified as shown
in the figure.
Fusible Link
The fusible link is primarily used to protect circuits where
high amounts of current flow and where it would not be
practical to use a fuse. For example, the starter circuit.
When a current overload occurs, the fusible link melts
open and interrupts the flow of current so as to prevent
the rest of the wiring harness from burning.
Determine the cause of the overload before replacing the
fusible link. the replacement fusible link must have the
same amperage specification as the original fusible link.
Never replace a blown fusible link with fusible link of a
different amperage specification. Doing so can result in
an electrical fire or other serious circuit damage.
A blown fusible link is easily identified as shown in the
figure.

Fusible Link Specifications

Type Rating Case Color Maximum Circuit Current (A)

Connector 30A Pink 15


Connector 40A Green 20
Bolted 50A Red 25
Bolted 60A Yellow 30

Bolted 80A Black 40


Circuit Breaker
The circuit breaker is a protective device designed to
open the circuit when a current load is in excess of rated
breaker capacity. If there is a short or other type of
overload condition in the circuit, the excessive current will
open the circuit between the circuit breaker terminals.
The reset knob (1) pops out when the circuit is open. Push
the reset knob in place to restore the circuit after repairing
it.

Relay
Battery and load location may require that a switch be
placed some distance from either component. This
means a longer wire and a higher voltage drop (1).
The installation of a relay between the battery and the
load reduces the voltage drop (2).
Because the switch controls the relay, amperage through
the switch can be reduced.

LOAD LOAD

RELAY

D08RW404
Relay Specifications and Configurations

* Relay contact shown in the wiring diagram indicates condition before actuation.
Diode – Diode Specifications and Configurations

Diode – Maximum Rating (Temp. = 77°F (25°C))

Items Rating Remarks


Peak reverse voltage 400V

Transient peak reverse voltage 500V


Average output current 1.5A Temp. = 104°F (40°C)
Working ambient temperature –22°F~176°F (–30°C~80°C)
Storage temperature –40°F~212°F (–40°C~100°C)
Connector Connector is identified with a connector number (6)
The connector pin shape (2) determines whether the
connector is male (3) or female (1).

6
1 2 3

The applicable terminal number (7) is shown for each


connector.
The symbol illustrated in the figure is used as connector,
in the circuit of this section.

Legend
(4) Female Side Connector
(5) Male Side Connector
Connector terminal numbers (10) are clearly shown. 2. The connectors used for relays have their own terminal
Male side connector (9) terminal numbers are in number assignment, irrespective of the above rule.
sequence from upper right to lower left. Refer to the following figure.
Female side connector (8) terminal numbers are in
sequence from upper left to lower right.

8 9
5 6
5 6
1 4 3
2 4
2
1 3
1 2 3 4 4 3 2 1
5 6 7 8 8 7 6 5

10

Double Lock Type Connector


NOTE: Double lock type yellow color connectors are used for
1. For those connectors on which specific terminal supplemental restraint system–air bag circuit. When
numbers or symbols are shown (such as PCM), the removing the cable harness, disconnect the connector by
terminal numbers or symbols are used in the circuit unlocking at two places, outside (1) and inside (2). In such
diagram, irrespective of the above rule. a case, do not pull the cables. Otherwise, cable
Refer to the following figure. disconnection may occur.
When connecting the connector, insert the connector
completely and lock at outside. Imperfect locking may
cause malfunction of SRS system circuit.

C1 C2 C3 C4 C5 C6 C7 C8 C9 C10C11C12C13C14C15C16 2
D1 D2 D3 D4 D5 D6 D7 D8 D9 D10D11D12D13D14D15D16

1
Reading the Circuit Diagram
In this section, each system has its own parts location
illustration and circuit diagram.
And harness connector faces used in the circuit diagram
are shown at the end of this section.

Parts Location
The parts location shows the location of the connectors
(1) and the harness (2) used in each harness routing.

1 2

D08RWB11
Circuit Diagram
The circuit diagram shows the power supply (1), the load
or loads (2) and the grounding point(s) (3).

STARTER SW
1 BATT.(+) (IG1)

5.0 3.0
W B/Y
C-17 15A C-4 10A
RR DEF ELEC.IGN.

3.0 0.5
L/O L/W
2 3
B-38 RR DEFOGGER RELAY B-38

0.5
L/W

B-38 B-38
5
4 1
3.0 H-25
B/L 0.5
2 O/L
H-31 3
3.0 H-25
0.5
B/L TAIL RELAY(4)
2 L/W
H-37 0.5
O/L 0.85
G/R
3.0 4 1 6
B/L
I-17 I-17 I-17
1
G-3 RR DEFOGGER
SW
RR DEFOGGER
TIMER
2
I-17 I-17
G-7
5 2
1 0.3 0.3
B R/G
3.0
B 2.0
4 B 15 ILLUMINATION
CONTROLLER(3)
H-37 H-48

3.0 2.0
B B

R-3 B-2

3
BODY-RR BODY-RH

D08RW425
Harness Connector Faces
The harness connector faces show each connector’s
number (1), configuration (2) and the pin number (3).

No. Connector face No. Connector face


B-21 B-31

NOT USED

B-22 B-32

B-23 B-33

NOT USED

1 2 3

D08RW424
Main Data and Specifications
Fuse, Fusible Link and Circuit Breaker Location

1 2

D08RWA03

Legend
(1) Relay and Fuse Box
(2) Fuse Box
810RS027
810RV026
810RS029
4

2 3
1

810RW330

Legend
4

3
2
1

810RW331

Legend
1 4

3 5

D08RWA22

Legend
5
4

3
2

D08RWA24

Legend
1 2 5

3
7

D08RWA23

Legend
1

D08RWA30

Legend
4

39
38 40
37
5 6 7
36

33 35 45
34 43 44 17 16
8
32 42 13
41 18
29 19
28 9
30 15 14
31 27 10

11
12
25

24 26
23
22
21
20

D08RWA34
6

3 5
7

2
8
1 9

10
33 26 12
25 11
32
29
31 28 24 13
14
30 15
23
27 16
17
19 18
22

20
21

D08RWA35
1 2

10

7
6
5 4

D08RWA33
5

4
3 6 7
2

1
8
53
54
55
51
50 52
12
47 39
38
49 40
41 24 16 14
46 48
13
45 42 37 26 25 9
36 27 23
35 28 21 15
44 34 22 10
43

29 11

17

33 18
32 30
19
31
20

D08RWB04
4 6
3

2 5

13
29
30 7
26
28 22 8
11
21
9
27 24 20
25 10
14
23
15
18 12
17

16

19

D08RWB03
8
10
1
11

7
2
9

4
6 5

D08RWB02
8.0
B/R

BATTERY P-2 RELAY & FUSE BOX


+�
P-1 30.0 FL-1 80A
B/R
MAIN
P-5 5.0
STARTER
−� (B) W

5.0
W
8.0
8.0 30.0 B
B B
FL-2 50A FL-3 30A FL-4 30A FL-6 40A
P-6 P-10 P-7 KEY SW PCM CONDENSER ABS
FAN

BODY ENGINE FRAME 3.0


1.25
W/B
2.0 L/O
3.0 W 3.0
W/B 2 W/G
3.0 1
W/B H-14
X-19
3.0 CONDENSER
3.0 W/B PCM EHCU
FAN
W/B (A4)
STARTER RELAY
RELAY
2 4
(3)
B-11 B-11 X-19
3
STARTER B1 B2
SW
OFF

IG1 ST IG2 ACC


1.25
B-11 B-11 B-11 B-11 L
7 3 5 1

3.0 3.0 3.0 3.0


B/Y W/G B/R L/B

CONDENSER
FAN

D08RWC56
RELAY & FUSE BOX

5.0 5.0 5.0 5.0 5.0 5.0 3.0


W W W W W W W

F-1 10A F-3 15A F-6 10A F-7 20A F-8 20A F-11 15A F-12 15A
RR HORN RR ACC FRT FOG ANTI TAIL 3.0
SUB HAZARD COOLER SOCKET THEFT ILLUMI W
3.0
W
1 4
X-1 X-1
0.85 2.0 0.5 0.85 3.0 0.85 0.85 LIGHTING 5.0 5.0 5.0
G/W G/O LG/Y O Y/R G/O R/B RELAY W W W

X-1
TAIL HORN RR COOLER ANTI-THEFT FOG ANTI THEFT TAIL RELAY 3 1 2 1
LIGHT RELAY(2) HORN LIGHT RELAY (5) (1)(2) H-14 H-2 H-2

5.0 5.0
3.0 5.0 W W
R/B W

5.0
HEADLIGHT W

5.0 3.0
W W AC GENERATOR
(B)

D08RY000189
RELAY & FUSE BOX

5.0 5.0 5.0


W W W

F-3 15A F-1 15A F-8 20A


HORN ANTI- FRT FOG 3.0
HAZARD THEFT W
RR COOLER 3.0
W
1 4
X-1 X-1
2.0 0.5 0.85 3.0 LIGHTING 5.0 5.0 5.0
G/O LG O Y/R RELAY W W W

X-1
HORN RR COOLER ANTI-THEFT FOG 3 1 2 1
RELAY(2) HORN LIGHT H-14 H-2 H-2

5.0 5.0
3.0 5.0
W W
R/B W

5.0
HEADLIGHT W

5.0 3.0
W W
AC GENERATOR
(B)

D08RY00188
3.0
B/Y
1
H-63

3.0 3.0
3.0
3.0 W/G B/R
B/Y
B/Y
3
H-63
3.0 3.0
B/Y B/R
3.0
B/Y
FUSE BOX

C-3 10A C-4 15A C-8 15A C-9 15A C-10 10A C-21 10A C-1 10A C-2 15A C-5 15A C-6 10A C-7 10A
TURN ELEC. ENGINE IG COIL METER SRS STARTER SEAT FRT WIPER RR WIPER H/LAMP
BACK IGN. GAUGE RELAY HEATER & WASHER & WASHER WIPER

0.5 0.5 0.85 1.25 0.5 0.75 0.5 1.25 0.85 0.5 0.5
R/B L/W B/Y B/O L/Y B/R W/R G/R W/L L/B R

0.85
B/Y

HAZARD ALARM & RELAY PCM IGNITION METER SDM STARTER SEAT WINDSHIELD RR HEADLIGHT
WARNING CONTROL UNIT MAIN COIL (12) RELAY HEATER WIPER WIPER WIPER
SW RELAY (6) MOTOR MOTOR MOTOR
(8) (1)

AC GENERATOR
(IG)

D08RY00187
3.0
W 5.0
W

2 HEATER &
3.0 B-36 A/C RELAY
L/B

B-36 3.0 5.0 5.0


W W W
4

3.0
FUSE BOX
L/R

C-11 10A C-12 20A C-19 25A C-20 10A C/B-2 30A C-14 15A C-15 20A C-16 10A C-17 25A C-18 20A
AUDIO CIGAR BLOWER AIR CON P/W,P/S, STOP AUDIO (B) CLOCK (B) RR DOOR
(ACC) S/R A/T CONT ROOM DEFOG LOCK
MIRROR

0.5 1.25 3.0 0.5 3.0 0.85 1.25 0.5 3.0 1.25
O/G O/B L BR B/L G/W R/W R/W L/O LG/W

AUDIO MAGNETIC POWER STOPLIGHT AUDIO RR DEFOGGER


CLUTCH WINDOW (14)
RELAY
(2)

CIGARETTE BLOWER DOME LIGHT FRT DOOR LOCK &


LIGHTER MOTOR POWER WINDOW SW

D08RWB16
8.0
B/R

BATTERY P-2 FUSE & RELAY BOX



P-1 FL-1 80A
30.0 MAIN
B/R
P-5
− E
STARTER
(B) F
8.0
8.0 30.0 B
B B G
FL-2 50A FL-4 50A
P-6 P-10 P-7 KEY SW ECM

BODY ENGINE FRAME 3.0


W/B 3.0
W/B
3.0 3.0
W/B W/B
2
3.0 2 2
W/B H-14
X-11 X-10
3.0 ECM ECM
3.0 W/B RELAY-1 RELAY-2
STARTER W/B
RELAY
2 4
(4)
B-11 B-11 X-11 X-10
4 4
STARTER B1 B2
SW
OFF

IG1 ST IG2 ACC


3.0 3.0
B-11 B-11 B-11 B-11 R R/W
7 3 5 1

3.0 3.0 3.0 3.0


B/Y W/G B/R L/B

ECM ECM
(J3-1) (J3-2)
A B C D

D08RWB17
8.0
B/R

BATTERY P-2 FUSE & RELAY BOX



P-1 FL-1 80A
30.0 MAIN
B/R
P-5
− E
STARTER
(B) F
8.0
8.0 30.0 B
B B G
FL-2 50A FL-4 30A
P-6 P-10 P-7 KEY SW CONDENSER
FAN

BODY ENGINE FRAME 3.0


W/B 1.25
L/O
3.0
W/B 2
3.0 1
W/B H-14
X-19
3.0 CONDENSER
3.0 W/B FAN
STARTER W/B RELAY
RELAY
2 4
(4)
B-11 B-11 X-19
3
STARTER B1 B2
SW
OFF

IG1 ST IG2 ACC


1.25
B-11 B-11 B-11 B-11 L
7 3 5 1

3.0 3.0 3.0 3.0


B/Y W/G B/R L/B

CONDENSER
FAN
A B C D

D08RWC54
RELAY & FUSE BOX

E H

F I

G
FL-3 40A FL-5 50A FL-6 40A
CERAMIC GLOW ABS
HEATER

3.0
W
3.0
W
3.0 3.0 3.0 1 4
W/L W/R W/G X-1 X-1
LIGHTING
RELAY

X-1

CERAMIC GLOW EHCU 3


HEATER PLUG

3.0
R/B

HEADLIGHT

D08RWB45
RELAY & FUSE BOX

E H

F I

G
FL-5 50A FL-6 40A
GLOW ABS

3.0
W
3.0
W
3.0 3.0 1 4
W/R W/G X-1 X-1
LIGHTING
RELAY

X-1

GLOW EHCU 3
PLUG

3.0
R/B

HEADLIGHT

D08RWC53
RELAY & FUSE BOX

I
5.0 5.0 5.0 5.0 5.0
W W W W W

F-1 10A F-3 15A F-6 10A F-7 15A F-8 20A F-12 15A
RR HORN RR COOLER ANTI-THEFT FRT FOG TAIL
SUB HAZARD ILLUMI

0.85 2.0 0.5 0.85 3.0 0.85


5.0 5.0 5.0
G/W G/O LG/Y O Y/R R/B
W W W

TAIL HORN RR COOLER ANTI-THEFT FOG TAIL RELAY 1 2 1


LIGHT RELAY(2) HORN LIGHT (1) (2) H-14 H-2 H-2

5.0 5.0
5.0 W W
W

5.0
W

5.0 3.0
W W AC GENERATOR
(B)
J K

D08RY00190
RELAY & FUSE BOX

I
5.0 5.0 5.0
W W W

F-3 15A F-1 15A F-8 20A


HORN ANTI-THEFT FRT FOG
HAZARD

2.0 0.85 3.0


5.0 5.0 5.0
G/O O Y/R
W W W

HORN ANTI-THEFT FOG 1 2 1


HORN LIGHT H-14 H-2 H-2

5.0 5.0
5.0 W W
W

5.0
W

5.0 3.0
W W AC GENERATOR
(B)
J K

D08RWC52
3.0
B/Y
1
H-63

3.0 3.0
3.0
3.0 W/G B/R
B/Y
B/Y
3
H-63
3.0 3.0
B/Y B/R
3.0
B/Y
FUSE BOX

C-3 10A C-4 10A C-8 15A C-10 10A C-21 10A C-1 10A C-2 15A C-5 15A C-6 10A C-7 10A
TURN ELEC. ENGINE METER SRS STARTER SEAT FRT WIPER RR WIPER H/LAMP
BACK IGN. GAUGE RELAY HEATER & WASHER & WASHER WIPER

0.5 0.5 0.85 0.5 0.75 0.5 1.25 0.85 0.5 0.5
R/B L/W B/Y L/Y B/R W/R G/R W/L L/B R

HAZARD ALARM & RELAY ECM METER SDM STARTER SEAT WINDSHIELD RR HEADLIGHT
WARNING CONTROL UNIT (J2-9) (12) RELAY HEATER WIPER WIPER WIPER
SW (6) MOTOR MOTOR MOTOR
(8)

D08RWB20
3.0
W 5.0
W

2 HEATER &
3.0 B-36 A/C RELAY
L/B

B-36 3.0 5.0 5.0


W W W
4

3.0
FUSE BOX
L/R

C-11 10A C-12 20A C-19 25A C-20 10A C/B-2 30A C-14 15A C-15 20A C-16 10A C-17 25A C-18 20A
AUDIO CIGAR BLOWER AIR CON P/W,P/S, STOP AUDIO (B) CLOCK (B) RR DOOR
(ACC) S/R A/T CONT ROOM DEFOG LOCK
MIRROR

0.5 1.25 3.0 0.5 3.0 0.85 1.25 0.5 3.0 1.25
O/G O/B L BR B/L G/W R/W R/W L/O LG/W

AUDIO CIGARETTE BLOWER MAGNETIC POWER STOPLIGHT AUDIO RR DEFOGGER


LIGHTER MOTOR CLUTCH WINDOW (14)
RELAY
(2)

DOME LIGHT FRT DOOR LOCK &


POWER WINDOW SW

D08RWB21
STARTER SW STARTER SW
(ST) FL-1 (IG1) FL-1

3.0 3.0 5.0


W/G B/Y W
C-1 10A FL-2 50A C-8 15A
STARTER RELAY KEY SW ENGINE
0.5 0.85 5.0 5.0
W/R 2 B/Y W W
19 1 2
H-12
PCM(C12) H-15 H-2 H-2
0.5 (M/T)
W/L 0.85
15 3.0 B/Y
5.0 5.0
H-10 W/B 3 2
W W
1.25 H-3 H-3
W/L 0.5 0.75
4
W/L B/Y 5.0
M-25
3 2 W
P-8 P-8 P-9
MODE SW
0.5 3.0 C IG B
(A/T) AC GENERATOR
W/R W/B 2
H-14 L

M-25 P-8

1.25 1 0.75 1
W/R 16 3.0 STARTER SW(B2) W/G 1
H-10 W/B H-3 1
0.5 0.85 H-14
W/R 4 W/G
H-42
0.85
0.5 0.85 0.85
W/G
W/R W/G W/G
6 3 2 13 10
X-17 X-17 X-17 H-15 H-16

STARTER
RELAY
SHIFT LOCK CHARGE 5.0
X-17 X-17 X-17 CONTROLLER(5) WARNING W
LIGHT
5 4 1
3.0 0.85 (METER)
B/Y Y
1 10
0.5 H-1 H-13
L

A B C D

D08RY00094
FUSE
C-8 BATT.(+)

0.5
L 0.5
(THAILAND) (SOUTH AFRICA) 5.0
B/Y
W
3 0.5
L 0.85
2 1
H-41 W/R
X-20 X-20
3.0
0.5 30.0 3.0 W
L B/R B/W 1 2
5
B-36 B-36
H-42
X-20 X-20 HEATER &
A/C RELAY
0.5 4 0.5 3
L/B G/Y
12 B-36 B-36
1 3 4
H-15 IMMOBILIZER
CONTROL UNIT P-4 P-3
0.5 (10)
L/B STARTER
(W/O ANTI-THEFT) 3.0
L/R

22 0.5
B
B-22 0.3
B C-19 25A C-20 10A
ANTI-THEFT & KEYLESS
BLOWER AIR CON
ENTRY CONTROL UNIT
0.5 0.3
BR 16 BR 10
B-22
H-26 H-26
17 BLOWER
MOTOR

0.85
A/C THERMO MAX HI
B
RELAY RELAY
(2)

2.0
B 1.25
B

1.25
B

B-19 B-2 B-18 B-19

BODY-RH BODY-LH BODY-RH BODY-RH

D08RY00087
1

13 14

12

11
10

7
6
5 4

D08RW617
STARTER SW
BATT.(+) (ST)

8.0 3.0
B/R W/G

FL-1 80A C-1 10A


MAIN STARTER RELAY

0.5
5.0 BATT.(+)
W/R
FL-2 50A W
KEY SW 2
H-12

3.0 5.0
W/B B/W
2.0 0.5
W/B W/R
1 0.5
30.0 L
B/R 0.5
4 H-6
B
H-41

3.0
0.5 B/W
W/R
22
1 1 B-22
C-56 C-57 1
ANTI-THEFT
P-4 E-35 & KEYLESS
STARTER
RELAY STARTER ENTRY
B-22

C-56 C-57 17
2 2
5.0 0.5
0.85
B/Y L
1 12 B
2.0 2.0
H-43 H-15 B B

5.0 0.5
B/W L
1.25
B

B-19 B-2 B-18

BODY-RH BODY-LH BODY-RH

D08RW632
STARTER SW
(IG1)

3.0
B/Y
C-8 15A 2.0 5.0
ENGINE W/B W 5.0
2 1 W 2
0.85 H-3 H-2 H-2
B/Y
1
5.0
H-3 3.0 5.0 W
0.85 W/B W
0.85 B/Y 3 2
B/Y 5.0
P-8 P-8 P-9 W
19 IG S B AC
H-15 GENERATOR
L
P-8
0.85 1 1
0.85 W/G 3
B/Y H-14
0.5 H-3
B 0.85
2 3 W/L 5
X-17 X-17 X-17
5.0
CHARGE W
RELAY

X-17 X-17
0.5
1 4 B
0.85 0.5
0.85 0.85 0.85 W/G 10 B 1 3.0
W/G W/G W/G W
H-13 C-39
12 13 10
0.85
H-42 H-15 H-16 W/G 1 2
B-36 FENDER-RH B-36
HEATER & A/C
QOS III CONTROL A/T SHIFT CHARGE RELAY
UNIT(6) CONTROLLER WARNING
or (5) LIGHT
QOS/EGR (METER) B-36 B-36
CONTROL UNIT(18)
3 4
0.3 3.0
B L/R

1.25 C-19 25A C-20 10A


B
BLOWER AIR CON
B-19
3.0 0.5
L BR

BODY-RH BLOWER A/C THERMO


MOTOR RELAY(2)

D08RW633
15 16 2 3
14 1
13

12

11

10

9 5
8 7 6

D08RW839
STARTER SW STARTER SW
(ST) FL-1 (IG1) FL-1

3.0 3.0 5.0


W/G B/Y W
C-1 10A FL-2 50A C-8 15A
STARTER RELAY KEY SW ENGINE
0.5 0.85 5.0 5.0
W/R 1 B/Y W W
3 1 2
H-8
PCM(C12) H-13 H-2 H-2
0.5 (M/T)
W/L 0.85
15 3.0 B/Y
5.0 5.0
H-10 W/B 3 2
W W
1.25 H-3 H-3
W/L 0.5 0.75
4
W/L B/Y 5.0
M-25 3 2 W
P-8 P-8 P-9
MODE SW
0.5 3.0 C IG B
(A/T) AC GENERATOR
W/R W/B 2
H-14 L

M-25 P-8

1.25 1 0.75 1
W/R 16 3.0 STARTER SW(B2) W/G 1
H-10 W/B H-3 1
0.5 0.85 H-14
W/R 4 W/G
H-42

0.5 0.85 0.85


W/R W/G W/G
6 3 11 5
X-17 X-17 H-15 H-16

STARTER
RELAY
SHIFT LOCK CHARGE 5.0
X-17 X-17 CONTROLLER(5) WARNING W
LIGHT
5 4
3.0 (METER)
B/Y
1
0.5 H-1
L

A B C

D08RY00088
BATT.(+) STARTER SW
(ACC)

0.3
L/B
C-11
0.5 10A
L AUDIO 5.0
(ACC) W
3
H-41
0.5
O/G 3.0
0.5 30.0 3.0 W
L B/R B/W 1 2
5
B-36 B-36
H-42
HEATER &
A/C RELAY
0.5
L/B
3 B-36 B-36
1 3 4
H-15
P-4 P-3
0.5
L/B STARTER
(W/O ANTI-THEFT) 3.0
L/R

22
B-22 0.3
B C-19 25A C-20 10A
ANTI-THEFT & KEYLESS
ENTRY CONTROL UNIT BLOWER AIR CON
0.5
B
B-22
17 BLOWER PRESSURE SW
MOTOR (A/C)

0.85
B

1.25
B
1.25
1.25 B
B

B-19 B-18 B-19

BODY-LH BODY-LH BODY-LH

D08RW895
1

15
14

13

3
12

5
11

6
10 9 8 7

D08RW896
STARTER SW
BATT.(+) (ST)

8.0 3.0
B/R W/G

FL-1 80A C-1 10A


MAIN STARTER RELAY

5.0 BATT.(+)
FL-2 50A W 0.5
KEY SW
W/R

3.0 5.0
W/B B/Y
6
2.0 H-12
W/B (W/O ANTI-THEFT)
30.0 1
B/R H-6

0.5
0.5 L
W/R 3.0 0.5
B/W B
22
1 1 B-22
C-56 C-57 1
ANTI-THEFT
P-4 E-35 & KEYLESS
STARTER
RELAY STARTER ENTRY
B-22

C-56 C-57 17
2 2
5.0 0.5
0.85
B/Y L
1 3 B

H-43 H-15
1.25
5.0 B
B/Y
1.25
B

B-19 B-18

BODY-LH BODY-LH

D08RW899
STARTER SW STARTER SW
(IG1) (IG1)
B A
3.0 3.0
B/Y L/B
2.0
5.0
C-8 15A W/B C-11 10A
W
ENGINE 5.0 AUDIO(ACC)
2 1 W 2 5.0
H-3 H-2 H-2 W
0.85 1
5.0 0.5
B/Y
0.85 O/G
W H-14
B/Y 3.0 5.0
1 W/B W
3
H-13 H-3 5.0
W
3 2
P-8 P-8 P-9
0.85 IG S B A/C
B/Y 0.5
GENERATOR
3.0 O/G
L W
0.85
P-8
B/Y
1 2 1
0.85 B-36 B-36
W/G
3 HEATER & A/C
H-3 RELAY
0.5
B 0.85
E W/L B-36 B-36
2 3 5
X-17 X-17 X-17 4 3
3.0
CHARGE L/R
RELAY
0.3
C-19 25A C-20 10A B
E BLOWER AIR CON
X-17 X-17
1 4 3.0 0.5
0.85 L BR
W/G 0.5
0.85 B
W/G
BLOWER A/C THERMO
0.5
CHARGE QOS III MOTOR RELAY(2)
B
WARNING CONTROL UNIT(6) 1.25
LIGHT OR B
(METER) QOS/EGR
CONTROL UNIT(18) 2
C-39 B-19

FENDER-RH BODY-LH

D08RY00086
1
16
15
14
13

12

11 2

10

7 4

6 5

D08RW900
STARTER SW
BATT.(+) (IG1)

3.0
B/Y

FL-3 30A C-8 15A


PCM ENGINE

0.85
2.0 B/Y
W 19
H-15
2.0
0.85
W
B/Y
2 1
X-12 X-12 0.85
2.0
B/Y
W PCM MAIN
1.25
W
RELAY
0.5
R/L
X-12 X-12
0.5 0.5 0.5 0.5 0.5 4 3
R/L R/L R/L R/L R/L 1.25
8
1 1 1 1 1 1 R/L
16
H-41
E-26 E-11 E-25 E-12 E-24 E-13
H-42
FUEL NO.1 NO.2 NO.3 NO.4 NO.5 NO.6
INJECTOR 1.25
R/L
E-26 E-11 E-25 E-12 E-24 E-13
2 2 2 2 2 2
1.25
0.5 0.5 0.5 0.5 0.5 0.5
1.25 R/L
G/W G/O G G/R G/B G/Y 10 0.5
W B
8 7 6 5 12 11 H-4
1.25 1.25
H-4 H-4 H-4 H-4 H-4 H-4
R/L R/L

0.85 0.85 0.85 0.85 0.85 0.85


G/W G/O G G/R G/B G/Y

C-1 C-2 C-2 C-3 C-2 C-3 C-2 C-3 C-3


A4 D3 D1 F13 C1 F15 C3 E16 F16

P C M
7
C-39

PCM : POWERTRAIN CONTROL MODULE


FENDER-RH

D08RW587
PCM : POWERTRAIN CONTROL MODULE

P C M
E13 C9 C7 C8 A2 B11
C-3 C-2 C-2 C-2 C-1 C-1
0.5
R/W 7
H-42 2.0
0.5 W
0.85
1 4 0.5 0.5
R/W B/L Y G/Y
X-11 X-11

FUEL PUMP
RELAY 16
1.25 1.25
B/L B/P H-6
X-11 X-11
3 2 2.0
2.0 R
R 0.5
B
0.5
F-10 15A F-2 10A G/Y
FUEL PUMP OXYGEN SENSOR
HEATER
2.0 10 6
B/R 15 14 C-88 13 1
0.85
H-13 R/W H-5 H-6 E-4
JOINT
2.0 CONNECTOR
B/R 20 1 POWER
STEERING
H-46 PRESSURE
0.5 0.5
B 2.0 8 (EXCEPT SOUTH AFRICA) SW
B/R 1.25 Y
2 (SOUTH AFRICA) B/P
H-33
2.0 1
B/R 1 13
1.0 E-14
F-4 B/L H-5

KNOCK
FUEL
7 SENSOR
PUMP
H-33 1.0
F-4 B/R

2.0 2 2.0
B B
7
C-39 R-4 E-30 E-29

FENDER-RH BODY-RR COMMON CHAMBER COMMON CHAMBER

D08RY00101
PCM : POWERTRAIN CONTROL MODULE HO2S : HEATED OXYGEN SENSOR

P C M
D14 D15 C15 C14
C-2 C-2 C-2 C-2

0.5 0.5 0.5 0.5


10 G R L P

H-41

1.25 5 2 1 3 8 4
R/W
10 H-11 H-11 H-11 H-11 H-11 H-11
H-11

1.25
R/W

0.5 1.25 0.5 1.25


R R/W P R/W
2 4 2 4
M-17 M-17 M-18 M-18

0.5 HO2S 0.5 0.5 HO2S


G B L
(A) (B)

M-17 M-17 M-18 M-18


1 3 1 3
1.25 1.25
B B

C-88 8 9
1.25
JOINT
B
CONNECTOR
1 11
1.25 H-11
B/P
13
H-5
0.85
1.0 B
B/R
2
E-29 C-16

COMMON CHAMBER FENDER-LH

D08RW589
PCM : POWERTRAIN CONTROL MODULE

P C M
E13 C9 C7 C8 A2 B11
C-3 C-2 C-2 C-2 C-1 C-1
0.5
R/W 7
H-42 2.0
0.5 W
0.85 0.5 0.5
R/W 1 4 B/L
Y G/Y
X-11 X-11

FUEL PUMP
RELAY 16
1.25 1.25
B/L B/P H-6
X-11 X-11
3 2 2.0
2.0 R
R 0.5
B
0.5
F-10 15A F-2 10A
G/Y
FUEL PUMP OXYGEN SENSOR
2.0 HEATER
10 6
B/R 15 14 C-88 13 1
0.85
H-13 R/W H-5 H-6 E-4
JOINT
2.0 CONNECTOR
B/R 20 1 POWER
STEERING
H-46 PRESSURE
0.5 0.5
B 2.0 8 (EXCEPT SOUTH AFRICA) SW
B/R 1.25 Y
2 (SOUTH AFRICA) B/P
H-33
2.0 1
B/R 1 13
1.0 E-14
F-4 B/L H-5

KNOCK
FUEL
7 SENSOR
PUMP
H-33 1.0
F-4 B/R

2.0 2 2.0
B B
7
C-39 R-4 E-30 E-29

FENDER-RH BODY-RR COMMON CHAMBER COMMON CHAMBER

D08RY00101
2
H-41

8
H-6

THROTTLE
0.8 INTAKE AIR POSITION
B/Y TEMPERATURE SENSOR
0.8 0.5 5
SENSOR
B/Y B/Y E-33

2 1
EGR VALVE
E-8 E-44
VSV ; VSV ; E-33 E-33 E-33 E-33 E-43 E-43 E-5 E-5 E-5
DUTY INTAKE 1 3 4 2 2 1 1 3 2
SOLENOID AIR 0.8 0.8 0.8
16 0.8
G Y/G G 0.8
H-4 G 0.8
E-8 E-44 L R
0.8 0.8 0.8
1 2 Y Y/R R

0.8 0.5
R/L W/L 15 14 13 9 6 5
H-4 H-4 H-4 H-5 H-6 H-6
0.85 7 9
B/Y H-6 H-4 0.5
B/R
0.5
0.85 0.85 0.85
B
0.5 0.5 Y Y/R R 0.85 0.75 0.75 3
R/L Y/B Y/G G L C-88

C-3 C-1 C-2 C-3 C-1 C-1 C-1 C-2 C-3


1
E5 A15 C11 E6 B7 A1 B8 D8 E8 1.25
B/P 13
P C M
H-5

1.0
B/R

E-29
VSV : VACUUM SWITCHING VALVE
PCM : POWERTRAIN CONTROL MODULE
COMMON CHAMBER

D08RY00186
0.85
B/Y

CRANK POSITION CAM POSITION


1 SENSOR SENSOR
C-87

MASS AIR FLOW


SENSOR

C-87 C-87 E-27 E-27 E-27 E-32 E-32 E-32


2 3 3 1 2 2 3 1
0.5
G 0.5 0.5
0.85 0.5 0.5 0.5
Y/R L
B/L Y Y/R G

0.5 10 11 6 5
Y H-5 H-5 H-5 H-5

1.25
0.85
B/L
Y/R
0.5
14 B
0.85
H-5 2 4 0.5
5 0.5 Y/R
W
C-88 Y

JOINT
CONNECTOR
1
1.25
1.0 B/P
C-2 C-2 C-3 C-2
B/L 13
D10 C5 E11 D11
H-5
P C M

1.0
B/P

E-30 E-29

COMMON CHAMBER COMMON CHAMBER PCM : POWERTRAIN CONTROL MODULE

D08RY00185
PCM : POWERTRAIN CONTROL MODULE

P C M (W/ IMMOBILIZER)
B1 D9 F8 E9 B10 A5 A6 A8 A7 D7
C-1 C-2 C-3 C-3 C-1 C-1 C-1 C-1 C-1 C-2

0.5
0.85 0.85 0.5 W/B
R/Y GR L/R 6
0.5 C-65 0.5
20 15 12 GR/B LG/W
0.85 0.85 0.85 0.85
L L/W L/R L/B IMMOBILIZER
C-88 CONTROL
16 10 UNIT 12
JOINT H-8 C-65 H-9
CONNECTOR 4 3 2 1
8
H-4
C-2 H-4
C-2 H-4
C-2 H-4
C-2 0.5
18 14 13 17 LG/W
11
0.85 0.85 0.85 0.5 0.5 0.5
GR L/P H-10 LG/W
R/Y GR GR/B (W/TOD)
2 3 4 15 16 0.5
0.8 0.8 0.8 0.8 LG/W
H-6 H-6 H-6
C-2 H-5 H-5
C-2 2 3 5 5
L L/W L/R L/B
B-60 M-10 I-10 I-10
0.8 0.8 0.8 0.8 0.8 VEHICLE
G/W G R G L/R CO
SPEED
ADJUST (T/M)
3 1 2 2 1 1 2 3 4 SENSOR
RESISTOR
(METER)
E-7 E-7 E-7
C-2 E-20 E-20
C-2 E-6
C-2 C-2
E-6 C-2
E-6 C-2
E-6
B-60 M-10 I-9 I-10
1 2 19 21
A B 0.5
0.5 B/R 0.85
GR 4 B/P
MAP SENSOR ENGINE
COOLANT IDLE AIR H-10
TEMPERATURE 9 CONTROL VALVE 18
SENSOR H-8 0.5 H-16
B/R
10
0.5 H-42 0.85
GR B/P
0.5
B/R
3 5
C-39 C-39

FENDER-RH

D08RY00104
BATT. (+)

5.0
W
F-12 15A
TAIL

0.85
R/B

0.85 0.85
R/B R/B
2 1
X-9 X-9

TAIL
RELAY

X-9 X-9
4 3
0.85
G/R
0.3
G
RR 3
COMBINATION
H-15
LIGHT-RH
A/C A/C
TACHO- CHECK COMPRESSOR THERMO
METER ENGINE RELAY (3) RELAY (4) 0.3
G

15 10 5 6 4 0.3
H-9 H-9 H-41 H-41 G
H-7

LIGHTING
0.5 0.5 0.5 SW
V G/B G/O 0.3
G

C-2 C-1 C-1 C-3 C-1


C10 A13 B14 E15 B12

P C M

PCM : POWERTRAIN CONTROL MODULE

D08RY00184
STARTER SW STARTER SW
(IG1) (ST)

3.0 3.0
B/Y W/G
C-3 10A C-1 10A
TURN, BACK STARTER RELAY

0.85 0.5
R/B W/R

17 2
H-7 H-12

0.85 0.5
R/B W/L
6 15

H-11 H-10

0.75 1.25
R/B W/L
5 4
M-25 M-25
A/T MODE SW

M-25 M-25 M-25 M-25 M-25 M-25 CRUISE CONTROL


EHCU (6) UNIT (5)
2 8 7 6 3 1
0.75 0.5 0.5 0.5 0.5 1.25
R/L L/W L/Y L/B Y/G W/R 8 7

16 H-42 H-8
7 1 2 3 4
H-11 H-53 H-53 H-53 H-53 H-10

0.5 0.5
0.5 0.5 0.5 0.5 0.5 GR GR/L
BACKUP L/W L/Y L/B L/B Y/G STARTER
LIGHT 3 RELAY (6)

C-3 C-3 C-3 H-8 C-3 C-1 C-3


E12 E7 F2 F3 A12 F10
P C M CRUISE P C M
CONTROL
UNIT (12)
EHCU : ELECTRONIC HYDRAULIC CONTROL UNIT
PCM : POWERTRAIN CONTROL MODULE

D08RY00106
STARTER SW
(IG1) BATT. (+)

3.0 5.0
B/Y W
C-10 10A C-14 15A
METER,GAUGE STOP,A/T CONT

0.5 0.85
L/Y G/W

6
H-26

(W/CRUISE CONTROL)
0.5 (W/TOD)
L/Y 0.85
G/W
15 26 1 1

I-9 METER I-9 B-14 B-13

STOP BRAKE
LIGHT SW
SW

TEMP
TEMP

TRANS
TRANS

A/T OIL
A/T OIL

CHECK
CHECK

POWER
POWER

WINTER
WINTER
B-14 B-13
I-9 I-9 I-9 I-9 I-9 I-9 I-9 I-9
2 4
25 21 3 1 29 28 6 3 0.85
G/Y
0.5 0.5 0.5 0.5 0.85
P/W P/G O/B O/L G/Y

8
2 4 16 5
H-12
H-9 H-9 H-9 H-24

0.5 0.5 0.5 0.5 0.85


GR/W P/G O/B O/L G/Y

C-1 C-1 C-1 C-1 C-3


A11 A10 A14 A9 F4
P C M

PCM:POWERTRAIN CONTROL MODULE

D08RW596
PCM:POWERTRAIN CONTROL MODULE

P C M
A16 F14 C2 E14 D9 F7 D2 E3 E4 E1 E2
C-1 C-3 C-2 C-3 C-2 C-3 C-2 C-3 C-3 C-3 C-3

0.85
GR 0.5 0.5
15 R W
0.5 0.5 0.5 1.25 C-88
BR/Y BR/R BR/B BR/W 0.5 0.5 1.25 1.25
JOINT R/B BR/L V/R V/W
CONNECTOR
17
13 14 16 15 0.5 6 7 5
GR
H-53 H-53 H-53 H-53 9 10 8 11 12 H-53 H-53 H-53
H-53 H-53 H-53 H-53 H-53

1.25 0.75 0.75 1.25 7


0.75 0.75 0.75 1.25 1.25
BR/Y BR/R BR/B BR/W C-88
G R/B BR/L V/R V/W 0.5 0.5
R W JOINT
2 3 1 4 5 3 4 1 2 1 2 CONNEC-
1 TOR
M-7 M-7 M-7 M-7 M-6 M-6 M-6 M-6 M-6 M-15 M-15
(—) (+)
1.25
B/P
(+) (—)
FORCE
MOTOR

1-2,3-4
SOLENOID
2-3
SOLENOID
TCC
SOLENOID
OIL TEMP. SPEED

BAND APPLY
SENSOR SENSOR 13
(TRANSMISSION) H-5
MAIN CASE
(TRANSMISSION)
ADAPTER CASE
(TRANSMISSION) 1.0
B/R

E-29

COMMON CHAMBER

D08RY00107
PCM:POWERTRAIN CONTROL MODULE

P C M
F11 F5 F6 B13 F12 D4
C-3 C-3 C-3 C-1 C-3 C-2

0.5 0.5 0.5


LB V/R V/G
0.85
G/W
6 11 12 0.5 0.5 0.5 9
H-8 H-8 H-8 O/G O/L O H-7

TAIL REAY
(4)
0.85
0.5 0.5 0.5 G/W
LB V/R V/G
0.85
G/R 2 6 9 16
2 1 3 5 C-63 C-63 C-63 C-63
B-10 B-30 B-30 B-30
DATA LINK CONNECTOR
KICK DOWN
SW POWER/
C-63 C-63
WINTER SW
B-10 0.5 4 0.5 5
B/L B/L
1
B-30 B-30
0.5 1.25
B 4 2 B/L
0.5 14
0.3
B H-5
R/G

1.25 1.0
2.0 2.0 2.0 ILLUMINATION
B B/L
B B B CONTROLLER (3)

B-19 B-2 B-18 B-26 E-30

BODY-RH BODY-LH BODY-RH BODY-CTR COMMON


CHAMBER

D08RW598
29 38
40
39 41
28
30
27 37 42
26 31 1 2 3
32 36 43
33 23
35
44 45 22
34 4
21
51
20
50
49 48 19
47 46
52
18
17

24
5
15

25
16
14

7
8
13
12
11 10
9

D08RY00195
3
1 2

21

20
19

18

17

16

15
22

6
14

13
12
11 7
10
8
9

D08RW615
STARTER SW
BATT.(+) (IG1)

3.0
B/Y

FL-3 30A C-8 15A


PCM ENGINE

0.85
2.0 B/Y
W 3
H-13
2.0
0.85
W
B/Y
2 1
X-12 X-12 0.85
2.0
B/Y
W PCM MAIN
1.25
W
RELAY
0.5
R/L
X-12 X-12
0.5 0.5 0.5 0.5 0.5 4 3
R/L R/L R/L R/L R/L 1.25
8
1 1 1 1 1 1 R/L
16
H-41
E-26 E-11 E-25 E-12 E-24 E-13
H-42
FUEL NO.1 NO.2 NO.3 NO.4 NO.5 NO.6
INJECTOR 1.25
R/L
E-26 E-11 E-25 E-12 E-24 E-13
2 2 2 2 2 2
1.25
0.5 0.5 0.5 0.5 0.5 0.5
1.25 R/L
G/W G/O G G/R G/B G/Y 10 0.5
W B
8 7 6 5 12 11 H-4
1.25 1.25
H-4 H-4 H-4 H-4 H-4 H-4
R/L R/L

0.85 0.85 0.85 0.85 0.85 0.85


G/W G/O G G/R G/B G/Y

C-1 C-2 C-2 C-3 C-2 C-3 C-2 C-3 C-3


A4 D3 D1 F13 C1 F15 C3 E16 F16

P C M
7
C-39

PCM : POWERTRAIN CONTROL MODULE


FENDER-RH

D08RW901
PCM : POWERTRAIN CONTROL MODULE

P C M
E13 C9 C7 C8 A2 B11
C-3 C-2 C-2 C-2 C-1 C-1
0.5
R/W 7
H-42 2.0
0.5 W
0.85
1 4 0.5 0.5
R/W B/L
Y G/Y
X-11 X-11

FUEL PUMP
RELAY 16
1.25 1.25
B/L B/P H-6
X-11 X-11
3 2 2.0
2.0 R
R 0.5
B
0.5
F-10 15A F-2 10A G/Y
FUEL PUMP OXYGEN SENSOR
HEATER
2.0 10 6
B/R 5 14 C-88 13 1
0.85
H-13 R/W H-5 H-6 E-4
JOINT
2.0 CONNECTOR
B/R 20 1 POWER
STEERING
H-46 PRESSURE
0.5 0.5
B 2.0 SW
B/R 1.25 Y
8
B/P
H-33
2.0 1
B/R 1 13
1.0 E-14
F-4 B/L H-5

KNOCK
FUEL
7 SENSOR
PUMP
H-33 1.0
F-4 B/R

2.0 2 2.0
B B
7
C-39 R-4 E-30 E-29

FENDER-RH BODY-RR COMMON CHAMBER COMMON CHAMBER

D08RY00095
PCM : POWERTRAIN CONTROL MODULE HO2S : HEATED OXYGEN SENSOR

P C M
D14 D15 C15 C14
C-2 C-2 C-2 C-2

0.5 0.5 0.5 0.5


10 G R L P

H-41

0.85 5 2 1 3 8 4
R/W
10 H-11 H-11 H-11 H-11 H-11 H-11
H-11

1.25
R/W

0.5 1.25 0.5 1.25


R R/W P R/W
2 4 2 4
M-17 M-17 M-18 M-18

0.5 HO2S 0.5 0.5 HO2S


G B L
(A) (B)

M-17 M-17 M-18 M-18


1 3 1 3
1.25 1.25
B B

C-88 8 9
1.25
JOINT
B
CONNECTOR
1 11
1.25 H-11
B/P
13
H-5
0.85
1.0 B
B/R
7
E-29 C-16

COMMON CHAMBER FENDER-LH

D08RY00096
STARTER SW
(IG1)

3.0
B/Y
C-9 15A
IGN. COIL

1.25
B/O
16
H-8

1.25
B/O
1
H-6

1.0
B/O
1.0 1.0 1.0 1.0 1.0
B/O B/O B/O B/O B/O
2 2 2 2 2 2
E-37 E-40 E-38 E-41 E-39 E-42

IGNITION IGNITION IGNITION IGNITION IGNITION IGNITION


COIL NO.1 COIL NO.2 COIL NO.3 COIL NO.4 COIL NO.5 COIL NO.6
14 14 14 14 14 14
E-37 E-37 E-40 E-40 E-38 E-38 E-41 E-41 E-39 E-39 E-42 E-42
3 1 3 1 3 1 3 1 3 1 3 1
1.0 1.0 1.0 1.0 1.0 1.0
B B B B B B
0.5
R
0.5 0.5 0.5 0.5 0.5
R/B R/L R/W R/Y R/G
4 3 2 1 8 7
H-5 H-5 H-5 H-5 H-5 H-5

0.5 0.5 0.5 0.5 0.5 0.5


R R/B R/L R/W R/Y R/G 1.0 1.0
B B
C-2 C-1 C-2 C-1 C-2 C-1
C4 B3 D6 B2 D5 B4
P C M

E-30 E-28
PCM : POWERTRAIN CONTROL MODULE

COMMON CHAMBER

D08RW905
2
H-41

8
H-6

THROTTLE
0.8 INTAKE AIR POSITION
B/Y TEMPERATURE SENSOR
0.8 0.5 5
SENSOR
B/Y B/Y E-33

2 1
EGR VALVE
E-8 E-44
VSV ; VSV ; E-33 E-33 E-33 E-33 E-43 E-43 E-5 E-5 E-5
DUTY INTAKE 1 3 4 2 2 1 1 3 2
SOLENOID AIR 0.8 0.8 0.8
16 0.8
G Y/G G 0.8
H-4 G 0.8
E-8 E-44 L R
0.8 0.8 0.8
1 2 Y Y/R R

0.8 0.5
R/L W/L 15 14 13 9 6 5
H-4 H-4 H-4 H-5 H-6 H-6
0.85 7 9
B/Y H-6 H-4 0.5
B/R
0.5
0.85 0.85 0.85
B
0.5 0.5 Y Y/R R 0.85 0.75 0.75 3
R/L Y/B Y/G G L C-88

C-3 C-1 C-2 C-3 C-1 C-1 C-1 C-2 C-2


1
E5 A15 C11 E6 B7 A1 B8 D8 E8 1.25
B/P 13
P C M
H-5

1.0
B/R

E-29
VSV : VACUUM SWITCHING VALVE
PCM : POWERTRAIN CONTROL MODULE
COMMON CHAMBER

D08RY00098
0.85
B/Y

CRANK POSITION CAM POSITION


3 SENSOR SENSOR
C-87

MASS AIR FLOW


SENSOR

C-87 C-87 E-27 E-27 E-27 E-32 E-32 E-32


2 1 3 1 2 2 3 1
0.5
G
0.85 0.5 0.5 0.5
0.5 0.5
B/L Y Y/R G
Y/R L

0.5 10 11 6 5
Y H-5 H-5 H-5 H-5

1.25
0.85
B/L
Y/R
0.5
14 B
0.85
H-5 2 0.5
4 0.5 Y/R
W
C-88 Y

JOINT
CONNECTOR
1
1.25
1.0 B/P
C-2 C-2 C-3 C-2
B/L 13
D10 C5 E11 D11
H-5
P C M

1.25
B/P

E-30 E-29

COMMON CHAMBER COMMON CHAMBER PCM : POWERTRAIN CONTROL MODULE

D08RY00097
PCM : POWERTRAIN CONTROL MODULE
HO2S : HEATED OXYGEN SENSOR

P C M
B1 D9 F8 E9 B10 A5 A6 A8 A7 D7
C-1 C-2 C-3 C-3 C-1 C-1 C-1 C-1 C-1 C-2

0.85 0.85 0.5


R/Y GR L/R
0.5 0.5
20 15 12 GR/B LG/W
0.85 0.85 0.85 0.85
L L/W L/R L/B
C-88
16 13 14
JOINT H-7 H-9
CONNECTOR 4 3 2 1
H-4
C-2 H-4
C-2 H-4
C-2 H-4
C-2
18 14 13 17
0.5 0.5 0.5
0.85 0.85 0.85
GR L/P LG/W
R/Y GR GR/B
2 3 4 15 16
H-6 H-6 H-6
C-2 H-5 H-5
C-2 0.8 0.8 0.8 0.8
2 L L/W L/R L/B 5
B-60 I-10
0.8 0.8 0.8 0.8 0.8 VEHICLE
G/W G R G L/R CO SPEED
ADJUST SENSOR
3 1 2 2 1 1 2 3 4
RESISTOR (METER)
E-7 E-7 C-2
E-7 E-20 C-2
E-20 C-2
E-6 C-2
E-6 C-2
E-6 C-2
E-6
B-60 I-9
1 19
A B
0.5 0.85
MAP SENSOR ENGINE GR B/P
COOLANT IDLE AIR
TEMPERATURE CONTROL VALVE 1
SENSOR H-7 H-16
5
0.5 0.85
GR B/P

3
C-39
(W/O HO2S)

FENDER-RH

D08RY00099
BATT. (+)

8.0
B/R
FL-1 80A
MAIN

5.0
W

3.0 3.0
W W
2 1
X-9 X-9

TAIL
RELAY

X-9 X-9
4 3
3.0
G/Y
0.3
G
F-12 F-11 1
10A 10A
TAIL TAIL H-12
A/C A/C -RH -LH
TACHO- COMPRESSOR THERMO CHECK
METER MIL RELAY (3) RELAY (4) TRANS 0.3
TAIL TAIL G
LIGHT LIGHT
15 3 5 6 -RH -LH 5 0.3
0.5
H-9 H-9 H-41 H-41 O/B G
H-8
3
H-24 LIGHTING
0.5 0.5 0.5 0.5 SW
B/R V G/B G/O 0.5 0.3
O/B G

C-2 C-1 C-1 C-3 C-1 C-1


C10 A13 B14 E15 A14 B12

P C M

PCM : POWERTRAIN CONTROL MODULE

D08RY00173
STARTER SW STARTER SW
(IG1) (ST)

3.0 3.0
B/Y W/G
C-3 10A C-1 10A
TURN, BACK STARTER RELAY

0.5 0.5
R/B W/R

4 1
H-8 H-8

0.85 0.5
R/B W/L
6 15

H-11 H-10

0.75 1.25
R/B W/L
8 1
M-25 M-25
MODE SW

M-25 M-25 M-25 M-25 M-25 M-25 CRUISE CONTROL


EHCU (6) UNIT (5)
3 5 6 7 2 4
0.75 0.5 0.5 0.5 0.5 1.25
R/L L/W L/Y L/B Y/G W/R 8 2

16 H-42 H-7
7 1 2 3 4
H-11 H-53 H-53 H-53 H-53 H-10

0.5 0.5
0.5 0.5 0.5 0.5 GR GR/L
BACKUP L/W L/Y L/B Y/G STARTER
LIGHT RELAY (6)

C-3 C-3 C-3 C-3 C-1 C-3


E12 E7 F2 F3 A12 F10
P C M

EHCU : ELECTRONIC HYDRAULIC CONTROL UNIT


PCM : POWERTRAIN CONTROL MODULE

D08RW909
STARTER SW
(IG1) BATT. (+)

3.0 5.0
B/Y W
C-10 10A C-14 15A
METER,GAUGE STOP,A/T CONT

0.5 0.85
L/Y G/W

10
H-25

(W/CRUISE CONTROL)
0.5
L/Y 0.85
G/W
15 1 1

I-9 METER B-14 B-13

STOP BRAKE
LIGHT SW

TEMP
SW

TRANS
A/T OIL

CHECK

POWER
WINTER
B-14 B-13
I-9 I-9 I-9 I-9
2 4
25 21 3 1 0.85
G/Y
0.5 0.5 0.5 0.5 0.85
P/W P/G O/B O/L G/Y

12
9 2 3 11
H-7
H-24 H-24 H-24 H-24

0.5 0.5 0.5 0.5 0.85


GR/W P/G O/B O/L G/Y

C-1 C-1 C-1 C-1 C-3


A11 A10 A14 A9 F4
P C M

PCM:POWERTRAIN CONTROL MODULE

D08RW910
PCM:POWERTRAIN CONTROL MODULE

P C M
A16 F14 C2 E14 D9 F7 D2 E3 E4 E1 E2
C-1 C-3 C-2 C-3 C-2 C-3 C-2 C-3 C-3 C-3 C-3

0.85
GR 0.5 0.5
15 R W
0.5 0.5 0.5 1.25 C-88
BR/Y BR/R BR/B BR/W 0.5 0.5 1.25 1.25
JOINT R/B BR/L V/R V/W
CONNECTOR
17
13 14 16 15 0.5 6 7 5
GR
H-53 H-53 H-53 H-53 9 10 8 11 12 H-53 H-53 H-53
H-53 H-53 H-53 H-53 H-53

1.25 0.75 0.75 1.25 7


0.75 0.5 0.75 1.25 1.25 C-88
BR/Y BR/R BR/B BR/W G G/R BR/L V/R V/W 0.5 0.5
R W JOINT
2 3 1 4 5 3 4 1 2 2 1 CONNEC-
1 TOR
M-7 M-7 M-7 M-7 M-6 M-6 M-6 M-6 M-6 M-15 M-15
(–) (+)
1.25
B/P
(+) (–)
FORCE
MOTOR

1-2,3-4
SOLENOID
2-3
SOLENOID
TCC
SOLENOID
SPEED

BAND APPLY
OIL TEMP.
SENSOR SENSOR 13
(TRANSMISSION) H-5
MAIN CASE
(TRANSMISSION)
ADAPTER CASE
(TRANSMISSION) 1.0
B/R

E-29

COMMON CHAMBER

D08RW597
PCM:POWERTRAIN CONTROL MODULE

P C M
F11 F5 F6 B13 F12 D4
C-3 C-3 C-3 C-1 C-3 C-2

0.5 0.5 0.5


LB V/R V/G
0.85
G/W
1 7 16 0.5 0.5 0.5 9
H-7 H-7 H-7 O/G O/L O H-7

TAIL REAY
(4)
0.85
0.5 0.5 0.5 G/W
LB V/R V/G
0.85
G/R 2 6 9 16
2 1 3 5 C-63 C-63 C-63 C-63
B-10 B-30 B-30 B-30
DATA LINK CONNECTOR
KICK DOWN
SW POWER/
C-63 C-63
WINTER SW
B-10 0.5 4 0.5 5
B/L B/L
1
B-30 B-30
0.5 1.25
B 4 2 B/L
0.5 14
0.3
B H-5
R/G

1.25 1.0
2.0 2.0 2.0 ILLUMINATION
B B/L
B B B CONTROLLER (3)

B-19 B-2 B-18 B-26 E-30

BODY-LH BODY-RH BODY-LH BODY-CTR COMMON


CHAMBER

D08RW911
28
37 39
38 40
27
29
26
36 41
25 30
31 35
42
32
34
43 44
33

50
49
48
47 46 45 2 3
51
1 4
22 23 24

21
5
20 6

19 7

10

9
11
18

12

17 13
16

15 14
D08RW912
2
1

26

4
6
25
3
24 5

7
8
9

23
10

22 11
12
13

21

14
15
20
19
18 16
17

D08RW913
STARTER SW STARTER SW
(IG1) (ST)

3.0 3.0
B/Y W/G
C-1 10A
C-8 15A C-10 10A C-9 15A STARTER
ENGINE METER, GAUGE FUEL CUT RELAY

0.85
B/Y
AC GENERATOR 0.5 0.85
(L) 19 L/Y B/O
H-15

3 6 7
0.85 0.5 H-26 H-7
H-3 A
B/Y B/Y

0.85
W/L 0.5 0.85
0.5
12 L/Y B/O
W/R
5 3 2
H-7
X-17 X-17 X-17 15 7
CHARGE
I-9 H-5
RELAY
GLOW
INDICATOR
X-17 X-17 LIGHT
0.5 0.85
(METER)
4 1 B B/O
I-9
26
1 VEHICLE SPEED
4
0.85 E-37 SENSOR(3)
H-7
W/G 0.85 0.5
B/Y P/W FUEL CUT
SOLENOID 15
0.5 H-5
14
B
H-9
0.5
0.5 LG/W
12 W/R
H-41 0.3
P/W 0.3
0.85
LG/W
W/G
6 1 13 11 9
C-66 C-66 C-66 C-66 C-66
1
C-39
QOS III CONTROL UNIT

FENDER-RH

D08RW982
BATT.(+)
A

FL-5 50A
GLOW

0.85
B/Y
3.0
R/W

0.85 3.0 0.85


B/Y R/W B/Y
1 1 1 1
C-53 C-55 C-51 C-52
GLOW GLOW
RELAY-2 RELAY-1

C-54 C-55 C-51 C-52

3.0 1 2 2 2 QOS III CONTROL UNIT


B/Y 2 0.5
C-59 B/G 0.5 C-66 C-66 C-66
B/L
DROPPING 8 4 10
16 3.0
RESISTOR 0.5 0.5
H-42 B/R Y B/Y
7
8 12
H-41
H-4 H-4
C-59
0.5
1 B/G 0.5
0.5 0.5
Y B B
3.0 0.5
B/L 1 2
B/R
E-41 E-41
1
C-60 12 5
GLOW C-66 C-66
PLUG 7
QOS THERMO SENSOR C-16
QOS III CONTROL UNIT (ENGINE)

FENDER
-LH

D08RW980
Parts Location (RHD)

2
1

19 20
18

17

16

15

14

13
3
12

11

10

8
7
6

D08RWA27
STARTER SW STARTER SW
(IG1) (ST)

3.0 3.0
B/Y W/G
C-1 10A
C-8 15A C-10 10A C-9 15A STARTER
ENGINE METER, GAUGE FUEL CUT RELAY

0.85
B/Y
AC GENERATOR 0.5 0.85
(L) 3 L/Y B/O
H-13

3 10 7
0.85 0.5 H-25 H-8
H-3 A
B/Y B/Y

0.85
W/L 0.5 0.85
0.5
13 L/Y B/O
W/R
5 3 2
H-8
X-17 X-17 X-17 15 7
CHARGE
I-9 H-5
RELAY
GLOW
INDICATOR
X-17 X-17 LIGHT
0.5 0.85
(METER)
4 1 B B/O
I-9
26
1 VEHICLE SPEED
6
0.85 E-37 SENSOR(3)
0.85 H-8
W/G 0.5
B/Y P/W FUEL CUT
SOLENOID 15
0.5 H-5
1
B
H-24
0.5
0.5 LG/W
12 W/R
H-41 0.3
P/W 0.3
0.85
LG/W
W/G
6 1 13 11 9
C-66 C-66 C-66 C-66 C-66
2
C-39
QOS III CONTROL UNIT

FENDER-RH

D08RY00297
BATT.(+)
A

FL-5 50A
GLOW

0.85
B/Y
3.0
R/W

0.85 3.0 0.85


B/Y R/W B/Y
1 1 1 1
C-53 C-55 C-51 C-52
GLOW GLOW
RELAY-2 RELAY-1

C-54 C-55 C-51 C-52

3.0 1 2 2 2 QOS III CONTROL UNIT


B/Y 2 0.5
C-59 B/G 0.5 C-66 C-66 C-66
B/L
8 4 10
DROPPING
16 3.0
RESISTOR 0.5 0.5
H-42 B/R Y B/Y
7
8 12
H-41
H-4 H-4
C-59
0.5
1 B/G 0.5
0.5 0.5
Y B B
3.0 0.5
B/L 1 2
B/R
E-41 E-41
1
C-60 12 5
GLOW C-66 C-66
PLUG 8
QOS THERMO SENSOR C-16
QOS III CONTROL UNIT (ENGINE)

FENDER
-LH

D08RW981
Parts Location (LHD)

19 1

18
17

16
2

15

14

13
3

12
4

11 5

10

9
8 7

D08RWA26
STARTER SW STARTER SW HEATER & A/C
(IG1) (ST) RELAY(4)
C
3.0 3.0 3.0
B/Y W/G L/R
C-1 10A 0.5
C-8 15A C-10 10A C-9 15A STARTER BR C-20 10A
ENGINE METER, GAUGE FUEL CUT RELAY 2 AIR CON

H-41 0.5
0.85 BR
16
B/Y 0.5
AC GENERATOR 0.5 0.85 BR H-26
(L) 19 L/Y B/O 7
H-15 0.5
H-4 BR
7
3 6 7
0.85 0.5 H-26 H-7 0.5 H-16
H-3 A
B/Y B/Y BR
0.5
2
BR
0.85 E-40
C
W/L 0.5 0.85
0.5
12 L/Y B/O QWS
W/R
5 3 2
H-7 THERMO SW
X-17 X-17 X-17 15 7 (ENGINE)
CHARGE
I-9 H-5
RELAY E-40
GLOW
INDICATOR 1
0.5
X-17 X-17 0.85 LIGHT
0.5 0.85 LG/Y
B/Y (METER) 11
4 1 B B/O
I-9
H-4
26
1 0.5 VEHICLE SPEED
4
0.85 E-37 G/B SENSOR(3)
H-7
W/G 0.5 2
P/W FUEL CUT C-74
SOLENOID 15
0.85
0.5 B/Y AMBIENT H-5
14
B THERMO
H-9
B SW 0.5
0.5 0.5 LG/W
12 B/Y W/R
H-41 C-74
0.3
P/W 1
0.5 0.3
0.5
G/W LG/W
W/G
18 9 5 17 20 16
C-66 C-66 C-66 C-66 C-66 C-66
1
C-39
QOS/EGR CONTROL UNIT

FENDER-RH

D08RW695
BATT.(+)
A B

FL-5 50A
GLOW
0.85
B/Y
0.85
B/Y
3.0
R/W

0.85 0.85
B/Y B/Y
0.85 3.0 0.85
B/Y R/W B/Y
1 1 1 1 1 1
C-53 C-55 C-51 C-52 C-73 C-72
GLOW GLOW VSV; VSV;
RELAY-2 RELAY-1 EGR EVRV

C-54 C-55 C-51 C-52 C-73 C-72

3.0 1 2 2 2 2 2
B/Y 2 0.5
C-59 B/G 0.5
B/L
DROPPING
16 3.0
RESISTOR
H-42 B/R
7
0.5 0.5
H-41
G R
C-59
0.5
1 B/G

3.0 0.5
B/R B/L

1
C-60 6 7 4 10
GLOW C-66 C-66 C-66 C-66
PLUG

QOS/EGR CONTROL UNIT

D08RW696
QOS/EGR CONTROL UNIT

C-66 C-66 C-66 C-66 C-66 C-66 C-66 C-66


3 14 15 2 1 12 11 13
0.5 0.5 0.5 0.5 0.5 0.5
B/R R/G R/W Y/L Y B/Y
6 1 9 5 8 12
H-4 H-4 H-4 H-4 H-4 H-4

0.5 0.5 0.5 0.5 0.5 0.5


B/R R/G R/W Y/L Y B
1 1 2 3 1 2
E-36 E-5 E-5 E-5 E-41 E-41

TACHO
SENSOR
(INJECTION
PUMP)
QOS THERMO SENSOR
E-36 THROTTLE POSITION (ENGINE)
SENSOR
2
(INJECTION PUMP)
0.5 0.5
B B/P
10
H-4

0.5
B/P
0.5
B/P

4
H-41

0.5
B/P

7 6
C-16 C-39

FENDER FENDER
-LH -RH

D08RW697
Parts Location (RHD)

2
1

24
23
22
21

20
19

18
25
17

16
3

15 5
14

13 12
11 7
10 9 8

D08RW846
STARTER SW STARTER SW HEATER & A/C
(IG1) (ST) RELAY(4)
C
3.0 3.0 3.0
B/Y W/G L/R
C-1 10A 0.5
C-8 15A C-10 10A C-9 15A STARTER BR C-20 10A
ENGINE METER, GAUGE FUEL CUT RELAY 2 AIR CON

H-41 0.5
0.85 BR
14
B/Y 0.5
AC GENERATOR 0.5 0.85 BR H-26
(L) 3 L/Y B/O 7
H-13 0.5
H-4 BR
17
3 10 7
0.85 0.5 H-25 H-8 0.5 H-16
H-3 A
B/Y B/Y BR
0.5
2
BR
0.85 E-40
C
W/L 0.5 0.85
0.5
13 L/Y B/O QWS
W/R
5 3 2
H-8 THERMO SW
X-17 X-17 X-17 15 7 (ENGINE)
CHARGE
I-9 H-5
RELAY E-40
GLOW
INDICATOR 1
0.5
X-17 X-17 0.85 LIGHT
0.5 0.85 LG/Y
B/Y (METER) 11
4 1 B B/O
I-9
H-4
26
1 0.5 VEHICLE SPEED
6
0.85 E-37 G/B SENSOR(3)
H-8
W/G 0.5 2
P/W FUEL CUT C-74
SOLENOID 15
0.85
0.5 B/Y AMBIENT H-5
1
B THERMO
H-24
B SW 0.5
0.5 0.5 LG/W
12 B/Y W/R
H-41 C-74
0.3
P/W 1
0.5 0.3
0.5
G/W LG/W
W/G
18 9 5 17 20 16
C-66 C-66 C-66 C-66 C-66 C-66
2
C-39
QOS/EGR CONTROL UNIT

FENDER-RH

D08RW984
BATT.(+)
A B

FL-5 50A
GLOW
0.85
B/Y
0.85
B/Y
3.0
R/W

0.85 0.85
B/Y B/Y
0.85 3.0 0.85
B/Y R/W B/Y
1 1 1 1 1 1
C-53 C-55 C-51 C-52 C-73 C-72
GLOW GLOW VSV; VSV;
RELAY-2 RELAY-1 EGR EVRV

C-54 C-55 C-51 C-52 C-73 C-72

3.0 1 2 2 2 2 2
B/Y 2 0.5
C-59 B/G 0.5
B/L
DROPPING
16 3.0
RESISTOR
H-42 B/R
7
0.5 0.5
H-41
G R
C-59
0.5
1 B/G

3.0 0.5
B/R B/L

1
C-60 6 7 4 10
GLOW C-66 C-66 C-66 C-66
PLUG

QOS/EGR CONTROL UNIT

D08RW985
QOS/EGR CONTROL UNIT

C-66 C-66 C-66 C-66 C-66 C-66 C-66 C-66


3 14 15 2 1 12 11 13
0.5 0.5 0.5 0.5 0.5 0.5
B/R R/G R/W Y/G Y B/Y
6 1 9 5 8 12
H-4 H-4 H-4 H-4 H-4 H-4

0.5 0.5 0.5 0.5 0.5 0.5


B/R R/G R/W Y/L Y B
1 1 2 3 1 2
E-36 E-5 E-5 E-5 E-41 E-41

TACHO
SENSOR
(INJECTION
PUMP)
QOS THERMO SENSOR
E-36 THROTTLE POSITION (ENGINE)
SENSOR
2
(INJECTION PUMP)
0.5 0.5
B B/P
10
H-4

0.5
B/P
0.5
B/P

4
H-41

0.5
B/P

8 7
C-16 C-39

FENDER FENDER
-LH -RH

D08RW986
Parts Location (LHD)

2
1

3
24
23

22

21

20
4

19

18
5

17

8
16
15 14 9
13
12 11 10

D08RWA25
BATT.(+)

FL-1 80A
MAIN

5.0
W
TAIL 3.0 3.0
RELAY(4) W W
1 4
X-1 X-1
LIGHTING
F-8 20A 0.85 0.85 RELAY
FRT FOG G/R G/R
7 3
I-43 I-43 X-1 X-1
FOG 3 5
LIGHT 3.0
SW R/B 0.5
V/R
RR FRT F-4 15A F-5 15A
3.0 I-43 I-43 I-43 5
H/LAMP-LH H/LAMP-RH
Y/R H-15
8 6 2
0.85
G
1 0.3
H-16 0.85 0.3 V/R
G/Y R/G 0.85
0.85 0.85
LG/R
G R/L
2 1 13
0.3
X-23 X-23 H-25 0.3
V/R
V/R
FOG LIGHT
RELAY ILLUMINATION D E F
CONTROLLER
(3)
X-23 X-23 0.85
G/Y 0.85 0.85
4 3
R/L R/L
1.25 0.5
V B
15 13 4
H-41 H-16 H-41
0.5 RR FOG LIGHT
B CONTROL UNIT
7
C-39

A B C

FENDER
-RH

D08RY00084
0.85 0.85 0.85
R/L 15 R/L LG/R
I-10
HIGH
3 3
BEAM
INIDI- C-21 C-32 0.3
CATOR HEAD HEAD V/R
1.25
V (METER) I-10 LIGHT LIGHT
-LH C-21 C-21 -RH C-32 C-32
14
0.85 1 2 1 2
1.25 R/Y 9
V 0.85 1.25
H-9
Y R/Y
0.85 1
0.85
1 1 R/Y Y 1.25 B-12
R/Y
C-24 C-29
13 16
FOG FOG H-41 H-41
LIGHT LIGHT LIGHTING
-LH -RH 0.85 SW
Y
C-24 C-29 1.25
2 2 R/Y B-12
7
10 16
0.5
B H-15 H-13

0.85 1.25 0.3


Y R/Y V/R
0.5 13 15 14
B
B-12 B-12 B-12
0.5
B
PASS
DIMMERꞏPASSING
SW LOW HIGH
(COMBINATION
SW)

B-12
16
1.25
B
5
C-16 B-19

FENDER-LH BODY-RH

D08RW609
Parts Location (RHD)

7 8

3 4

1
5

15

9
14

10

13

11

12

D08RW607
BATT.(+)

FL-1 80A
MAIN

5.0
W
TAIL 3.0 3.0
RELAY(4) W W
1 4
X-1 X-1
LIGHTING
F-8 20A 0.85 0.85 RELAY
FRT FOG GR GR
4 6
I-5 I-5 X-1 X-1
FOG 3 5
LIGHT
SW 3.0 0.5
R/B V/R
1.25
3.0 R/B
I-5 I-5 I-5 1 4 4
Y/R
5 3 2 X-3 X-3 H-12
0.85
G DIMMER
1 RELAY
0.5 0.3 G
H-16
B R/G
0.85
G X-3 X-3 X-3
2 1 5 2 3 5
X-23 X-23 H-26
0.5
FOG LIGHT R
RELAY ILLUMINATION 2.0
0.5 CONTROLLER Y/G
(3) F
B
2.0
X-23 X-23 Y/R
4 3
F-5 10A
1.25 0.5 F-4 10A
H/LAMP-RH
V B H/LAMP-LH
(HI)
15 (HI)
1.25
H-41 B
0.5 F-6 10A F-7 10A
H/LAMP-LH H/LAMP-RH 0.85
B
7 (LOW) 0.85 (LOW) R/L
0.85 R/Y 0.85
C-39 B-19
Y R/G
A B C D E

FENDER BODY
-RH -RH

D08RW805
A B C D E F G

0.85 0.85
Y R/Y

(4JG2) (4JG2)
0.5 0.5
0.5
R/Y V/R
R
11 13 16 14
12 0.85 0.85
1.25 H-41 H-41 H-41 H-41 R/G R/L
V H-16

10
1.25 H-15
0.85
V
R/Y
0.85 0.85
Y R/Y
1 1 14
2 1 2 1
C-24 C-29 I-10
C-21 C-21 HIGH C-32 C-32
FOG FOG HEAD- HEAD- 1.25 0.3 0.5
BEAM V/R V/R
LIGHT LIGHT LIGHT LIGHT R
INIDI-
-LH -RH -LH CATOR -RH
C-21 C-32
C-24 C-29 I-10 (METER)
3 3
2 2 15
15 14
B-12 B-12 1
0.5
B-12
B
DIMMER/
(4JG2) 0.85
PASSING PASS LIGHTING
R/L
SW SW
0.5 0.85 0.85 LOW HIGH
B B B

4 3 10 0.85
H-41 H-41 H-16 B B-12
B-12 7
16
0.5
B
0.85 0.85 (4JG2)
B B 1.25
B
0.5 0.5
B B

5 1 4 4 8 7
C-16 C-39 C-39 C-39 C-39 C-39 B-19

FENDER-LH FENDER-RH FENDER-RH FENDER-RH BODY-LH

D08RY00424
Parts Location (LHD)

1 2 3 4

14
13

12

11

10

D08RW806
Diagnosis
Quick Chart for Check Points
1. Headlight (RHD)
2. Headlight (LHD)
BATT.(+)

FL-1 80A
MAIN

5.0
W 3.0
W
F-8 20A F-12 15A
FRT FOG TAIL

0.85
R/B 0.85
3.0 2 R/B 1
Y/R
X-9 X-9
TAIL
RELAY
2.0
Y/R
G X-9 X-9
1.25
Y/R 4 3
0.85
G/R
2 3 14
X-22 X-22 H-16
RR FOG 0.3
LIGHT G
RELAY

X-22 X-22 0.85


4 1 G/R
1.25 7 3 3
BR/Y
14 I-43 I-43 H-15
H-15 0.3
BR/R FRT & RR
FOG LIGHT
0.85 SW FRT RR
11
BR/Y
H-13 I-43 I-43 I-43
4 0.3
8 6 2
0.85 0.85 G
H-46 0.85 G G/Y
21 13
BR/Y 0.3 0.3
BR/R H-25 H-25 R/G
1.25
BR/Y

A B C D E F ILLUMINATION H
CONTROLLER (3)

D08RY00081
A B C

1.25 0.5
BR/Y BR/Y

8 1
H-33 H-27

1.25
BR/Y 1.25 0.5
BR/Y BR/Y
(W/TOD)

3 3 2 10 22
R-13 R-12 H-44 I-10 I-10
RR FOG RR FOG TRAILER RR FOG LIGHT
LIGHT—LH LIGHT—RH HARNESS INDICATOR
CONNECTOR (METER)
R-13 R-12 H-44
I-9 I-10
1 1 4
30 10
0.3
1.25
B
B

20
H-33 1.25
1.25
B B
20
1.25 H-27
B
1.25
B

1.25
B 1.25
B

R-4 B-18

BODY—RR BODY—RH

D08RY00198
FUSE F-5
D E F G H

0.85 0.85 0.3


2.0
G LG/R G
Y/R

1 3 8
B-45 X-14 3 B-12
DIODE DIODE H-16
LIGHTING
SW

0.3 B-45 X-14 0.85 2.0 B-12


BR/R G/Y Y/R
2 4 7
0.85
LG 5
13
0.85 H-27
H-15
LG 0.5
0.85 B
LG
2.0
Y/R

6 4 3 1
B-70 B-70 B-70 B-70
RR FOG RELAY H/L & FRT FOG RR FOG BATT(+) RR FOG
SW-ON SW-ON LIGHT
CONTROL
UNIT
GND
B-70
5

0.5
B

1.25
B

B-19

BODY—RH

D08RY00083
2
1

3
14
13

12

11

4
10

15

D08RY00199
Diagnosis
General Description
STARTER SW
(IG1)

3.0
B/Y

C-4 15A
ELEC. IG

0.5
Circuit Diagram

L/W

0.5
20
L/W
H-25
6
H-12 0.85 TAIL
L/W RELAY(4)

0.85
L/W 0.5 0.85
L/W G/R
A B C D
6 9
I-30 I-30
HEADLIGHT
LEVELING
SWITCH
0.5
L/W I-30 I-30 I-30 I-30 I-30
0.5
P/L 0.5
0.5 1 2 3 4 7
O/L 0.5 0.5 0.5 0.5 0.50.5
L/O 0.3
O/B L/W P/L O/L O/B L/O R/G
4 5 1 2 3 4 5 1 2 3
C-77 C-77 C-77 C-77 C-77 C-76 C-76 C-76 C-76 C-76 0.5 0.5 0.5 0.5
P/L O/L L/O O/B ILLUMINATION
CONTROLLER(3)
HEADLIGHT LEVELING HEADLIGHT LEVELING
ACTUATOR-LH ACTUATOR-RH
12 3 13 11
H-24 H-24 H-9 H-9
C-77 C-76
6 6

0.5 0.5
B B 0.5 0.5 0.5 0.5
P/L O/L L/O O/B
6 (4JX1)
7 (6V*1) 6
C-16 C-16
A B C D

FENDER-LH FENDER-LH

D08RY00136
Parts Location

1
2

10

3
7
4
6

D08RW999
Diagnosis
2. Actuator On The Left (Or Right) Side Inoperative
BATT.(+)

3.0
W

F-12 15A
TAIL,ILLUMI.

0.85
R/B
0.85
R/B
1 2
X-9 X-9
TAIL RELAY

X-9 X-9
3 4
0.3
G
3 0.85
G/R
H-15

0.3 1 0.85
G 0.85 G/R
H-41
8 G/R
B-12
INTERIOR
LIGHTING 0.85 4 ILLUMINATION
SW G/R H-15 LIGHT
(COMBINATION
SW) 2 2
C-22 C-31
B-12 0.85
7 FRT FRT G/R
COMBINATION COMBINATION 0.85
0.5 G/R
B
LIGHT LIGHT
-LH -RH 10 9

CLEARANCE
CLEARANCE

H-32 H-32

C-22 C-31
1.25 1 1
B 0.5 0.5 0.85 0.85
B B G/O G/R
1 1
B-19 C-16 C-16

A B

BODY-RH FENDER-LH FENDER-LH

D08RW619
A B

0.85
G/R

0.85
G/O

0.85
G/R
1
0.85 H-39
G/R

0.5
G/R
6 6 1
R-13 R-12 G-8
TAIL TAIL LICENSE
LIGHT LIGHT PLATE
-LH -RH LIGHT
(BODY) (BODY)
R-13 R-12 G-8
1 1 2
0.5
W/L
2
1.25
B H-39

0.5
B
1.25
B

R-4

BODY-RR

D08RW799
A B

0.85 0.85
G/O
G/R

18 17
H-33 H-33

0.85
O/B
0.85
G/R
0.85
O/B
4 4
F-7 F-8
0.85 0.85 TRAILER
G/R O/B HARNESS
CONNECTOR
(TAIL LIGHT)
1 1
6 1
F-9 F-10
LICENSE TAIL H-44 H-44 TAIL LICENSE
PLATE LIGHT LIGHT PLATE
LIGHT -LH -RH LIGHT
-LH (BUMPER) H-44 (BUMPER) -RH
F-9 F-10
4
2 2
1.25
B
2 20 2
F-7 H-33 F-8

1.25 1.25
B/L B/L

1.25
B/L 6 1.25
H-33 B

1.25
B

R-4

BODY-RR

D08RWB46
1 2 3
4

5
18

17 6
16

15

10

14
11

13

12

D08RW620
BATT.(+)

8.0
B/R

FL-1 80A
MAIN

5.0
W

3.0 3.0
W W
1 2
X-9 X-9
TAIL RELAY

X-9 X-9
3 4
0.3 3.0
G G/Y
1
H-12 F-11 10A F-12 10A
TAIL-LH TAIL-RH
0.3
G 0.85 0.85
8 G/O G/R
B-12 1 13
H-42 0.85
H-41
0.85 0.85 G/R
LIGHTING
0.85 G/O 0.85 G/R
SW
(COMBINATION G/O G/R
2 2 2 6 INTERIOR
SW)
C-22 H-15 C-31 H-13 ILLUMINATION
B-12 LIGHT
7 FRT FRT
COMBINATION 0.85 COMBINATION 0.85
0.5 G/O G/R
LIGHT LIGHT
B
-LH -RH

CLEARANCE
CLEARANCE

10 9

C-22 H-32 C-31 H-32


1.25 1 1
B 0.5 0.85 0.5 0.85
B G/O B G/R
1 1
B-19 C-16 C-16

A B

BODY-LH FENDER-LH FENDER-LH

D08RW798
A B

0.85
G/R

0.85
G/O

0.85
G/R
1
0.85 H-39
G/R

0.5
G/R
6 6 1
R-13 R-12 G-8
TAIL TAIL LICENSE
LIGHT LIGHT PLATE
-LH -RH LIGHT
(BODY) (BODY)
R-13 R-12 G-8
1 1 2
0.5
W/L
2
1.25
B H-39

0.5
B
1.25
B

R-4

BODY-RR

D08RW799
A B

0.85 0.85
G/O G/R

18 17
H-33 H-33

0.85 0.85
G/R O/B

4 4
F-7 F-8

1 1
F-9 F-10
LICENSE TAIL TAIL LICENSE
PLATE LIGHT LIGHT PLATE
LIGHT -LH -RH LIGHT
-LH (BUMPER) (BUMPER) -RH
F-9 F-10
2 2

2 2
F-7 F-8

1.25 1.25
B/L B/L

1.25
B/L 6
H-33

1.25
B

R-4

BODY-RR

D08RW800
2 3
1 4 5 6
7

20

19

10
11

12

13

14

15

18

17
16

D08RW801
BATT.(+)

5.0
W

F-12 15A
TAIL,ILLUMI.

0.85
R/B
0.85
R/B
1 2
X-9 X-9
TAIL RELAY

X-9 X-9
3 4
0.3 0.85
G/R 0.85
G G/R
3 A
H-15 0.85
G/R
0.3 4
G H-15
8
0.85
B-12 G/R 0.85
G/R
LIGHTING B
SW 0.85 0.85 0.85 0.85 0.85 0.85
(COMBINATION G/R G/R G/R G/R G/R G/R 5
1 9 1
SW) 2 3 6 B-30
H-41 H-32 B-33
B-12 B-55 B-56 B-57 POWER/
SHIFT MIRROR MIRROR MIRROR WINTER
7 LEVER CONTROL FOLD DEFOGGER SW
(A/T) SW SW SW
0.5 FRT TAIL B-55 B-56 B-57
B COMBINATION LIGHT B-33
3 2 2
LIGHT 2 B-30
0.3 0.3 0.3 0.3 2
0.3
R/G R/G R/G R/G
1.25 R/G
B

B-19

BODY-RH

D08RW657
A

0.85
G/R
14
H-16
B
0.5
G/R 1
H-21

0.5
0.85 D
G/R
0.5 G/R
G/R
1 1
0.85 0.85 0.85 0.85
L-4 L-6 G/R G/R G/R G/R
1
VANITY VANITY 3 6 6 11
MIRROR MIRROR I-20
I-11 I-5 FOG I-17 RR I-15
CIGARE-
-LH -RH HAZARD LIGHT DEFOGGER TTE AUDIO
SW SW SW LIGHTER
I-11 I-5 I-17 I-15
I-20
1 2 2 3
2
L-4 L-6
0.3 0.3 0.3 0.3 0.3
2 2 R/G R/G R/G R/G R/G
0.5
B E
0.5
B

(W/SUN ROOF)

0.5 2.0
B 4 B 4
H-21 H-21

2.0
B

B-2

BODY-LH

D08RW656
D F

0.85 0.85 0.85 0.85


G/R G/R G/R G/R (W/TOD)

3 3 7 24
I-23 I-16 I-9 I-9
6
HEATER RR WIPER/ METER
I-6 CRUISE BEZEL WASHER
CONTROL SW
MAIN
I-6 SW
2
I-16 I-9 I-9
I-23
2 8 25
5

0.3 0.3 0.3 0.3


R/G R/G R/G R/G

0.3
R/G

D08RW655
C G

0.3
R/G

0.5 0.5 0.3


G/R G/R R/G
3
H-26
0.85
1 2 G/R

I-24 I-19
0.3
GLOVE R/G
ASH TRAY
BOX
I-24 I-19 1 3
2 1 I-7 I-7
ILLUMINATION
0.3 0.3
B B
CONTROLLER

I-7
2
0.5
0.5 B
B

5
H-26

0.5
B

1.25
B

B-19

BODY-RH

D08RW654
7 8 9 10
6
5
4

25 11

24

12

13

23
22

14

21 15

16

17
20 18
19

D08RW651
BATT.(+)

8.0
B/R

FL-1 80A
MAIN

5.0
W

3.0 3.0
W W
1 2
X-9 X-9
TAIL RELAY

X-9 X-9
3 4
0.3 3.0
G G/Y
1 F-1110A F-12 10A
H-12 TAIL-LH TAIL-RH

0.3 0.85
G G/O
8
B-12
0.85 0.85 0.85
LIGHTING G/O G/R G/R
0.85
SW 2 6 G/R
(COMBINATION 0.85 H-15 0.85 H-13 B
SW) G/O G/R 1
B-12 0.85 0.85 H-15
7 G/O G/R

0.5 1 10 13 10 0.85
B H-32 H-32 G/R
H-41 H-42

A
1.25 FRT TAIL FRT TAIL
B COMBINATION LIGHT COMBINATION LIGHT
LIGHT-LH -LH LIGHT-RH -RH

B-19

BODY-LH

D08RW888-1
A

0.85 0.85 0.85 0.85 0.85


G/R G/R G/R G/R G/R

1
2 3 6 5
B-33
SHIFT B-55 MIRROR B-56 MIRROR B-57 MIRROR B-30
LEVER CONTROL FOLD DEFOGGER POWER/
(A/T) SW SW SW WINTER
B-55 B-56 B-57 SW
B-33
3 2 2
2

B-30
2
0.3 0.3 0.3 0.3
0.3
R/G R/G R/G R/G
R/G

D08RW889-1
B

0.85
G/R
6
H-16

0.85 D
G/R

0.85 0.85 0.85 0.85 0.85 0.85 0.85


G/R G/R G/R G/R G/R G/R G/R

1 6
3 6 6 11 3 3
I-20 I-25
I-11 I-5 FOG I-17 RR I-15 I-16 RR I-4
CIGARE- ENGINE HEAD LIGHT
HAZARD LIGHT DEFOGGER WIPER &
TTE AUDIO WARMING WIPER
SW SW SW WASHER
LIGHTER SW
I-11 I-5 I-17 I-15 I-16 SW I-4
I-20 I-25
1 2 2 3 2 2
2 2

0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3


R/G R/G R/G R/G R/G R/G R/G R/G

D08RW890-1
D F

0.85 0.85 0.85 0.85 0.85


G/R G/R G/R G/R G/R

3 3 7
I-23 I-16 I-9
6 2
HEATER RR WIPER/ 4WD METER
I-6 CRUISE I-12
BEZEL WASHER SW
CONTROL SW
MAIN
I-6 SW I-12
2 3
I-16 I-9
I-23
2 8
5

0.3 0.3 0.3 0.3 0.3


R/G R/G R/G R/G R/G

0.3
R/G

D08RW891
C G

0.3
R/G

0.5 0.5 0.3


G/R G/R R/G
2
H-26
0.85
1 2 G/R
0.3
I-24 I-19 R/G

GLOVE
ASH TRAY
BOX 0.5
R/G
I-24 I-19 1 3
2 1 I-7 I-7
ILLUMINATION
0.3 0.3
B B
CONTROLLER

I-7
2
0.5
0.5 B
B

16
H-25

0.5
B

1.25
B

B-19

BODY-LH

D08RW892
1 2 3 4 7
8
5 9
6
20 18
19
17
16
15
14
12 11
10
13

31
30 32
29

28

21

22
23

24

27

26
25

D08RW893
STARTER SW
(IG1) BATT.(+)

3.0 5.0
B/Y W

C-3 10A
F-3 15A
TURN
HORN,HAZARD
BACK

1
B-53
B FLASHER 2.0
UNIT B/R 0.85 2.0
R/B G/O
E L 0.85 0.85
B-53 B-53 R/B G/O
3 2 7 10
H-25 H-25 BACK UP HORN RELAY
2.0 LIGHT (2)
LG/B

0.5
B 2.0 0.85 TAIL RELAY
2.0
B/R R/B (4)
LG/B
16
2.0
LG/B H-27
0.85 12
2.0 G/R H-16
3 LG/B
HAZARD 5 7 8 3
B-12
WARNING I-11 I-11 I-11 I-11
SW
TURN SIGNAL
LIGHT SW
L R
I-11 I-11 I-11 I-11
B-12 B-12
6 4 2 1
1.25 4 5 0.85 0.85
B G/B P/B 0.3
0.85 10 6 R/G
0.85 P/B H-27 H-27 2.0
G/B G/O
ILLUMINATION
0.85
CONTROLLER
G/B
0.85 (3)
P/B
B-19

A B

BODY-RH

D08RW683
A B

0.85 0.85 0.85 0.85 0.85


G/B G/B TURN SIGNAL P/B P/B P/B
INDICATOR
14 LIGHT
H-7 (METER)
21 22 1 7
H-32 H-32 H-7 H-15

0.85 0.85 0.85 0.85 0.85


G/B G/B P/B P/B P/B
0.85
G/B

1 3 4 4 3 1
C-70 C-22 R-13 R-12 C-31 C-61
SIDE TURN FRT TURN RR TURN RR TURN FRT TURN SIDE TURN
SIGNAL SIGNAL SIGNAL SIGNAL SIGNAL SIGNAL
LIGHT-LH LIGHT-LH LIGHT-LH LIGHT-RH LIGHT-RH LIGHT-RH
(BODY) (BODY)
C-70 C-22 R-13 R-12 C-31 C-61
2 1 1 1 1 2

1.25
B

0.5 0.5 1.25 0.5 0.5


B B B B B

8 1 1 7
C-16 C-16 R-4 C-16 C-39

FENDER-LH FENDER-LH BODY-RR FENDER-LH FENDER-RH

D08RWC67
A B

0.85 0.85
G/B P/B
0.85 0.85 0.85
G/B 21 TURN SIGNAL 22 P/B P/B
INDICATOR
19 14 H-32 H-32
LIGHT
H-7 H-7 (METER)
1 7
0.85 0.85
H-7 H-15
0.85 G/O P/L 0.85
2 1
G/B P/B
H-59 H-59
11 5
0.85 0.85
H-33 G/O P/L H-33
7 3
0.85 H-44 H-44 0.85 0.85
G/B P/B P/B
0.85 TRAILER HARNESS 0.85
0.85
G/B CONNECTOR P/B
G/B
H-44
1 3 1 1 3 1
4
C-70 C-22 F-7 F-8 C-31 C-61
SIDE TURN FRT TURN RR TURN RR TURN FRT TURN SIDE TURN
SIGNAL SIGNAL SIGNAL 1.25
SIGNAL SIGNAL SIGNAL
LIGHT-LH LIGHT-LH LIGHT-LH B
LIGHT-RH LIGHT-RH LIGHT-RH
(BUMPER) (BUMPER)
C-70 C-22 F-7 F-8 C-31 C-61
20
2 1 2 H-33 2 1 2
1.25
B
1.25
B
0.5 0.5 0.5 0.5
B B 1.25 B B
6
B
H-33

1.25
B
8 1 1 7
C-16 C-16 R-4 C-16 C-39

FENDER-LH FENDER-LH BODY-RR FENDER-LH FENDER-RH

D08RWC66
1
2 3 4 5
6
29
7
8

28 10

27
26
11
25

24

16 12

23 13

14

15

22

21
20
19
18

17

D08RW678
STARTER SW
(IG1) BATT.(+)

3.0 5.0
B/Y W

C-3 10A
F-3 15A
TURN
HORN,HAZARD
BACK

1
B-53
B FLASHER 2.0
UNIT B/R 0.85 2.0
R/B G/O
E L 0.85 0.85
B-53 B-53 R/B G/O
3 2 2 17
H-20 H-25 BACK UP HORN RELAY
2.0 LIGHT (2)
LG/B

0.5
B 2.0 0.85 TAIL RELAY
2.0
B/R R/B (4)
LG/B
4
2.0
LG/B H-20
0.85 14
2.0 G/R H-16
3 LG/B
HAZARD 5 7 8 3
B-12
WARNING I-11 I-11 I-11 I-11
SW
TURN SIGNAL
LIGHT SW
L R
I-11 I-11 I-11 I-11
B-12 B-12
6 4 2 1
1.25 4 5 0.85 0.85
B G/B P/B 0.3
0.85 20 19 R/G
0.85 P/B H-25 H-25 2.0
G/B G/O
ILLUMINATION
0.85
CONTROLLER
G/B
0.85 (3)
P/B
B-19

A B

BODY-LH

D08RW872
A B

0.85 0.85 0.85 0.85 0.85


G/B G/B TURN SIGNAL P/B P/B P/B
INDICATOR
14 LIGHT
H-7 (METER)
21 22 6 4
H-32 H-32 H-7 H-13

0.85 0.85 0.85 0.85 0.85


G/B G/B P/B P/B P/B
0.85
G/B

1 3 4 4 3 1
C-70 C-22 R-13 R-12 C-31 C-61
SIDE TURN FRT TURN RR TURN RR TURN FRT TURN SIDE TURN
SIGNAL SIGNAL SIGNAL SIGNAL SIGNAL SIGNAL
LIGHT-LH LIGHT-LH LIGHT-LH LIGHT-RH LIGHT-RH LIGHT-RH
(BODY) (BODY)
C-70 C-22 R-13 R-12 C-31 C-61
2 1 1 1 1 2

1.25
B

0.5 (4JG2) 0.5 1.25 0.5 0.5 (4JG2)


B B B B B

0.5
B

8 6 1 1 4 1
C-16 C-16 C-16 R-4 C-16 C-39 C-39

FENDER-LH FENDER-LH BODY-RR FENDER-LH FENDER-RH

D08RW867
A B

0.85 0.85
G/B P/B
0.85 0.85 0.85
G/B 21 TURN SIGNAL 22 P/B P/B
INDICATOR
14 H-32 H-32
LIGHT
H-7 (METER)
6 4
0.85 0.85 H-7 H-13
G/B P/B

11 5
H-33 H-33

0.85 0.85 0.85


G/B P/B P/B
0.85 0.85
0.85
G/B P/B
G/B

1 3 1 1 3 1
C-70 C-22 F-7 F-8 C-31 C-61
SIDE TURN FRT TURN RR TURN RR TURN FRT TURN SIDE TURN
SIGNAL SIGNAL SIGNAL SIGNAL SIGNAL SIGNAL
LIGHT-LH LIGHT-LH LIGHT-LH LIGHT-RH LIGHT-RH LIGHT-RH
(BUMPER) (BUMPER)
C-70 C-22 F-7 F-8 C-31 C-61
2 1 2 2 1 2
1.25
B
1.25
B
0.5 0.5 0.5 0.5
B B B B
6
H-33

1.25
B
8 1 1 4
C-16 C-16 R-4 C-16 C-39

FENDER-LH FENDER-LH BODY-RR FENDER-LH FENDER-RH

D08RW868
1 2
3
30
4

29 5

28 6

27
26
25

24

23 8
18
9
17
10
16

11

12
22

13

14

15
21
20
19

D08RW873
BATT.(+)

5.0
W

C-14 15A
STOP,A/T CONT
(W/CRUISE CONTROL)
(W/O RR WIPER
AND/OR RR DEFOGGER) 0.85 0.85
G/W G/W
A 1 1 2
B-14 B-13 B-13
0.5 STOPLIGHT BRAKE SW
B SW
4
H-37
B-14 B-13 B-13
3.0 2 4 3
B 0.85 0.85
G/Y G/Y
R-3
7
H-32
BODY-RR
0.85
G/Y

0.85 0.85 0.85


G/Y G/Y G/Y
1
A H-37 5 5
R-13 R-12
0.5 0.85
B G/Y STOPLIGHT STOPLIGHT
1 -LH(BODY) -RH(BODY)
G-9
R-13 R-12
3.0
B HIGH MOUNTED 1 1
4 STOPLIGHT 1.25
H-37 B
G-9
1.25
3.0 2 B
B 0.5
B
R-3 R-4
A

BODY-RR BODY-RR

D08RW989
BATT.(+)

5.0
W

C-14 15A
STOP,A/T CONT
(W/CRUISE CONTROL)
(W/O RR WIPER
AND/OR RR DEFOGGER) 0.85 0.85
G/W G/W
A 1 1 2
B-14 B-13 B-13
0.5 STOPLIGHT BRAKE SW
B SW
4
H-37
B-14 B-13 B-13
3.0 2 4 3
B 0.85 0.85
G/Y G/Y
R-3
7
H-32
BODY-RR
0.85
G/Y
A

0.85 0.85 0.85


G/Y G/Y G/Y
1
A H-37 5 5
R-13 R-12
0.5 0.85
B G/Y STOPLIGHT STOPLIGHT
1 -LH(BODY) -RH(BODY)
G-9
R-13 R-12
3.0
B HIGH MOUNTED 1 1
4 STOPLIGHT 1.25
H-37 B
G-9
1.25
3.0 2 B
B
B 0.5
B
R-3 R-4
A

BODY-RR BODY-RR

D08RW658
A

0.85
G/Y

0.85
10 G/Y
H-33

6
0.85 H-33
G/Y

0.85
G/Y
0.85
G/Y
0.85
G/Y 3 3
F-7 F-8

STOPLIGHT STOPLIGHT
5 -LH(BUMPER) -RH(BUMPER)
H-44 F-7 F-8
2 2
TRAILER HARNESS
CONNECTOR 1.25
(STOP LIGHT) B

1.25
H-44
B
4

1.25
B

20 6
H-33 H-33

1.25 1.25
B B

D08RW874
2
1

15

14

13 3

12

11
4

10
9
8

7
6 5

D08RW877
BATT.(+)

5.0
W

C-14 15A
STOP,A/T CONT
(W/CRUISE CONTROL)
(W/O RR WIPER
AND/OR RR DEFOGGER) 0.85 0.85
G/W G/W
A 1 1 2
B-14 B-13 B-13
0.5 STOPLIGHT BRAKE SW
B SW
4
H-37
B-14 B-13 B-13
3.0 2 4 3
B 0.85 0.85
G/Y G/Y
R-3
7
H-32
BODY-RR
0.85
G/Y

0.85 0.85 0.85


G/Y G/Y G/Y
1 5 5
A H-37 R-13 R-12

0.5 0.85 STOPLIGHT STOPLIGHT


B G/Y -LH -RH
1
G-9 R-13 R-12
3.0 1 1
B HIGH MOUNTED 1.25
4 STOPLIGHT B
H-37
1.25
G-9 B
3.0 2
B 0.5
B
R-3 R-4
A

BODY-RR BODY-RR

D08RW953
BATT.(+)

5.0
W

C-14 15A
STOP,A/T CONT
(W/CRUISE CONTROL)
(W/O RR WIPER
AND/OR RR DEFOGGER) 0.85 0.85
G/W G/W
A 1 1 2
B-14 B-13 B-13
0.5 STOPLIGHT BRAKE SW
B SW
4
H-37
B-14 B-13 B-13
3.0 2 4 3
B 0.85 0.85
G/Y G/Y
R-3
7
H-32
BODY-RR
0.85
G/Y
0.85 0.85
G/Y 10 G/Y 1
0.85
H-33 H-33
G/Y
1 0.85 0.85
A H-37 G/Y 3 G/Y 3
F-7 F-8

0.5 0.85
B G/Y STOPLIGHT STOPLIGHT
1 -LH(BUMPER) -RH(BUMPER)
G-9
F-7 F-8
3.0
B HIGH MOUNTED 2 1.25 2
4 STOPLIGHT 1.25 B/L
H-37 B/L
G-9 6
3.0 2 H-33
B 0.5 1.25
B B
R-3 R-4
A

BODY-RR BODY-RR

D08RW939
16

1
2

3
15

14

13

5
6
12
7
11 10 9 8

D08RW940
STARTER SW
(IG1)
A
3.0
B/Y
C-3 10A
TURN,BACK 0.5
R/L

0.5
R/B 16
H-7

0.5 0.5 0.85


R/B R/B R/L

17 17
8
H-25 H-7
H-32

0.85 0.85 0.5


HAZARD R/B R/B R/B
6 6 6
WARNING
SWITCH (8) H-11 H-11 H-5
0.5
0.75 0.75 0.85 R/L
R/B R/B R/B
0.5
8 1 1
R/L
M-25 M-8 E-42
3 3
MODE BACKUP BACKUP
SW LIGHT SW LIGHT SW R-13 R-12
(A/T) (6VD1 M/T) (4JG2) BACKUP BACKUP
LIGHT LIGHT
-LH -RH
M-25 M-9 E-43 R-13 R-12
3 1 1 1 1
0.75 0.75 0.85
R/L R/L R/L
7 7 5 1.25
H-11 H-11 H-5 B

0.5 0.5 1.25


0.5
R/L R/L B
R/L

R-4

BODY-RR

D08RWC64
STARTER SW
(IG1)
A
3.0
B/Y
C-3 10A
TURN,BACK 0.5
R/L

0.5
R/B 16
H-7

0.5 0.5 0.85


R/B R/B R/L

17 17
8
H-25 H-7
H-32

0.85 0.85 0.5


HAZARD R/B R/B R/B
6 6 13
WARNING
SWITCH (8) H-11 H-11 H-4
0.5
0.75 0.75 0.5 R/L
R/B R/B R/B
0.5
8 1 1
R/L
M-25 M-8 E-15
2 2
MODE BACKUP BACKUP
SW LIGHT SW LIGHT SW R-13 R-12
(A/T) (6VE1 M/T) (4JX1) BACKUP BACKUP
LIGHT LIGHT
M-8 E-15 -LH -RH
M-25 R-13 R-12
3 2 2 1 1
0.75 0.75 0.5
R/L R/L R/L
7 7 14 1.25
H-11 H-11 H-4 B

0.5 0.5 1.25


0.5
R/L R/L B
R/L

R-4

BODY-RR

D08RWC65
12 1
2

11

10

D08RW881
STARTER SW
(IG1)
A
3.0
B/Y
C-3 10A
TURN,BACK 0.5
R/L

0.5
R/B 12
H-8

0.5 0.5 0.85


R/B R/B R/L

17 4
8
H-25 H-8
H-32

0.85 0.85 0.5


HAZARD R/B R/B R/B
6 6 6
WARNING
SWITCH (8) H-11 H-11 H-5
0.5
0.75 0.75 0.85 R/L
R/B R/B R/B
0.5
8 1 1
R/L
M-25 M-8 E-42
3 3
MODE BACKUP BACKUP
SW LIGHT SW LIGHT SW R-13 R-12
(A/T) (6VD1 M/T) (4JG2) BACKUP BACKUP
LIGHT LIGHT
-LH -RH
M-25 M-9 E-43 R-13 R-12
3 1 1 1 1
0.75 0.75 0.85
R/L R/L R/L
7 7 5 1.25
H-11 H-11 H-5 B

0.5 0.5 1.25


0.5
R/L R/L B
R/L

R-4

BODY-RR

D08RW942
STARTER SW
(IG1)
A
3.0
B/Y
C-3 10A
TURN,BACK 0.5
R/L

0.5
R/B 12
H-8

0.5 0.5 0.85


R/B R/B R/L

17 4
8
H-25 H-8
H-32

0.85 0.85 0.5


HAZARD R/B R/B R/B
6 6 6
WARNING
SWITCH (8) H-11 H-11 H-5
0.85
0.75 0.75 0.85 R/L
R/B R/B R/B
0.85
8 1 1
R/L
M-25 M-8 E-42
2 2
MODE BACKUP BACKUP
SW LIGHT SW LIGHT SW R-13 R-12
(A/T) (6VD1 M/T) (4JG2) BACKUP BACKUP
LIGHT LIGHT
-LH -RH
M-25 M-9 E-43 R-13 R-12
3 1 1 1 1
0.75 0.75 0.85
R/L R/L R/L
7 7 5 1.25
H-11 H-11 H-5 B

0.5 0.5 1.25


0.5
R/L R/L B
R/L

R-4

BODY-RR

D08RW943
1
13

12

11
9
10

D08RW371
BATT.(+)

FL-1 80A
MAIN

5.0
W

F-3 15A
HORN, HAZARD

2.0
G/O

0.85
2.0 G/O
2
G/O
12 X-8
H-16 HORN RELAY

HAZARD
X-8 X-8
WARNING SW
(2) 1 3

0.3
B/O

16
0.85
H-15 G/Y

0.85
0.3 G/Y
B/O

1 1
12 C-28 C-27
B-12 HORN HORN
(LOW NOTE) (HIGH NOTE)
HORN SW

D08RW660
1

5
4
3

D08RW880
BATT.(+)

FL-1 80A
MAIN

5.0
W

F-3 15A
HORN, HAZARD

2.0
G/O

0.85
2.0 G/O
2
G/O
14 X-8
H-16 HORN RELAY

HAZARD
X-8 X-8
WARNING SW
(2) 1 3

0.3
B/O

16
0.85
H-12 G/Y

0.85
0.3 G/Y
B/O

1 1
12 C-28 C-27
B-12 HORN HORN
(LOW NOTE) (HIGH NOTE)
HORN SW

D08RW954
1

5 4
3

D08RW398
STARTER SW
BATT. (+) (IG1)

5.0 3.0
W B/Y
C-16 10A C-4 15A
CLOCK(B), ROOM ELEC. IGN

0.5
R/W
0.5
0.5
2 R/W 2
R/W
H-18 H-22
7 6
H-21 H-32 0.5 0.5
R/W R/W
1 1
D-18 D-7
0.5
R/W 0.5 FRT FRT
R/W
0.5 COURTESY COURTESY
R/W LIGHT-LH LIGHT-RH

A D-18 D-7 0.5


1 3
2 2 L/W
L-2 R-6 0.5 0.5
GR/W GR/W 0.5
10 10
R/W
H-18 H-22

MAP LUGGAGE
0.5
LIGHT ROOM GR/W
LIGHT 0.5
GR/W
TAIL
RELAY
(4)

R-6 R-6 14 4
1 2
H-46 H-15
0.5
B 0.5 0.5
0.5
R/Y GR/W
GR/R
0.85
1 G/R
1
R-2
1.25 R-8
4 2 1 10
B
TAIL FRT DOOR B-6 B-6 B-6 B-6
GATE SW SW-LH
R-3
ALARM & RELAY CONTROL UNIT

BODY-RR

D08RY00214
A

0.5
R/W
4
H-45
A
0.5
R
0.5 2
R/W S-1
1
DOME
L-3
LIGHT
(W/ TIMER)
DOME
LIGHT S-1
(W/O TIMER) 1
ON 0.5
GR/G
OFF 5
DOOR H-45

L-3 0.5
2 GR/G ALARM & RELAY CONTROL UNIT
0.5
GR/G
5
B-6 B-6
H-21
3 6
0.5
GR/G 0.5 0.5
5
GR/R GR/B
B-6

5 11
ALARM & RELAY CONTROL UNIT H-47 H-32

B-7
9 0.5 0.5
GR/W GR/B
0.85 0.5
B GR/B
1 1 1
K-2 R-1 R-11
2.0 2.0 2.0
B B B FRT RR RR
DOOR SW DOOR SW DOOR SW
-RH -LH -RH
B-2 B-18 B-26

BODY-LH BODY-RH BODY-CTR

D08RW780
1 2
25

24

23 3

14

22

21

20
13

4
5
12
26
10 6
11
9

19
18
17
16
15

D08RW653
STARTER SW
BATT. (+) (IG1)

5.0 3.0
W B/Y
C-16 10A C-4 15A
CLOCK(B), ROOM ELEC. IGN

0.5
R/W
0.5 0.5
0.5 R/W
2 R/W 2
R/W
H-22 H18
7 6
H-21 H-32 0.5 0.5
R/W R/W
1 1
D-7 D-18
0.5
R/W 0.5 FRT FRT
R/W
0.5 COURTESY COURTESY
R/W LIGHT-LH LIGHT-RH

A D-7 D-18 0.5


1 3
2 2 L/W
L-2 R-6 0.5 0.5
GR/W GR/W 0.5
10 10
R/W
H-22 H-18

MAP LUGGAGE
0.5
LIGHT ROOM GR/W
LIGHT 0.5
GR/W
TAIL
RELAY
(4)

R-6 R-6 5 1
1 2 H-47
H-15
0.5
B 0.5 0.5
0.5
R/Y GR/W
GR/W
0.85
1 G/R
1
K-2
1.25 R-8
4 2 1 10
B
TAIL FRT DOOR B-6 B-6 B-6 B-6
GATE SW SW-RH
R-3
ALARM & RELAY CONTROL UNIT

BODY-RR

D08RY00426
A

0.5
R/W
4
H-45
A
0.5
R
0.5 2
R/W S-1
1
DOME
L-3
LIGHT
(W/ TIMER)
DOME
LIGHT S-1
(W/O TIMER) 1
ON 0.5
GR/G
OFF 5
DOOR H-45

L-3 0.5
2 GR/G ALARM & RELAY CONTROL UNIT
0.5
GR/G
5
B-6 B-6
H-21
3 6
0.5
GR/G 0.5 0.5
5
GR/R GR/B
B-6

14 11
ALARM & RELAY CONTROL UNIT H-46 H-32

B-7
9 0.5 0.5
GR/W GR/B
0.85 0.5
B GR/B
1 1 1
R-2 R-1 R-11
2.0 2.0 2.0
B B B FRT RR RR
DOOR SW DOOR SW DOOR SW
-LH -LH -RH
B-2 B-18 B-26

BODY-RH BODY-LH BODY-CTR

D08RW813
21 22
20 23 24
1

19

18
2

3
17

16

15 8
14
13
9
12
10
11

D08RY00425
BATT. (+)

5.0 FRT DOOR LOCK &


W POWER WINDOW SW-RH
LOCK UNLOCK
C-18 20A
DOOR LOCK D-5 D-5
9 8
1.25
LG/W POWER WINDOW
RELAY (4) 1.25
8 LG
H-23
2.0 1.25
1.25 L/B LG/B
LG/W 1.25 1.25
10 7 LG LG/B
3 5
D-5 D-5
H-23 H-23

1.25
LG
FRT DOOR LOCK &
POWER WINDOW SW-RH
1.25
LG/B
1.25 1.25 1.25 1.25 1.25 1.25
LG LG/B LG LG/B LG LG/B
15 13 4 10 15 13
H-32 H-32 H-47 H-47 H-32 H-32
3 5
H-19 H-19 1.25 1.25 1.25 1.25 1.25 1.25
LG LG/B LG LG/B LG LG/B
6 3 6 3 2 8
1.25 1.25 H-28 H-28 H-34 H-34 H-38 H-38
LG LG/B
1.25 1.25 1.25 1.25 1.25 1.25
LG LG/B LG LG/B LG LG/B
2 4 2 4 2 4 2 4 4 2
D-9 D-9 D-19 D-19 D-21 D-21 D-26 D-26 G-4 G-4

FRT DOOR LOCK FRT DOOR LOCK RR DOOR LOCK RR DOOR LOCK TAIL GATE
ACTUATOR-RH ACTUATOR-LH ACTUATOR-LH ACTUATOR-RH ACTUATOR

D08RW759
FRT DOOR LOCK & POWER WINDOW SW-RH

LOCK

UNLOCK
D-30 D-30 D-5
1 2 1
0.3 0.5
LG/L LG/R
14 2
H-22 H-23
0.5
0.5 LG/R
LG/L 0.5
0.5
14 2 LG/L 7 0.5
LG/L LG/R
H-18 H-19 H-19 7
H-23
0.3 0.5 1.25
LG/L LG/R 0.5 B
3 4 0.5 0.5
L/Y LG/R L/Y
D-14 D-14 2 1 2 1
FRT DOOR LOCK & D-17 D-17 D-8 D-8
POWER WINDOW
SW-LH
DOOR LOCK DOOR LOCK

LOCK

UNLOCK
LOCK
LOCK

KEY SW-LH KEY SW-RH

UNLOCK
UNLOCK

D-17 D-8
D-14 3 3
0.5
0.5
7 B
B
1.25 1.25
B B 1
1
H-23
H-19
1.25
B 1.25
B
2.0
B
B-1 B-18

BODY-LH BODY-RH

D08RW760
BATT. (+)

5.0 FRT DOOR LOCK &


W POWER WINDOW SW-RH
LOCK UNLOCK
C-18 20A
DOOR LOCK D-5 D-5
9 8
1.25 1.25 1.25
LG/W POWER WINDOW LG LG/B
RELAY (4) 13 6
8
H-22 H-23
H-23
1.25
2.0
1.25 LG
L/B 1.25
LG/W LG/B
10 7
D-5 D-5

1.25
LG
FRT DOOR LOCK &
POWER WINDOW SW-RH
1.25
LG/B
1.25 1.25 1.25 1.25 1.25 1.25
1.25
LG LG/B LG LG/B LG LG/B
LG/B 15 13 4 10 15 13
H-32 H-32 H-47 H-47 H-32 H-32
3 5
H-19 H-19 1.25 1.25 1.25 1.25 1.25 1.25
LG LG/B LG LG/B LG LG/B
3 5 6 3 6 3 2 8
H-23 H-23 1.25 1.25 H-28 H-28 H-34 H-34 H-38 H-38
LG LG/B
1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25
LG LG/B LG LG/B LG LG/B LG LG/B
2 4 2 4 2 4 2 4 4 2
D-9 D-9 D-19 D-19 D-21 D-21 D-26 D-26 G-4 G-4

FRT DOOR LOCK FRT DOOR LOCK RR DOOR LOCK RR DOOR LOCK TAIL GATE
ACTUATOR-RH ACTUATOR-LH ACTUATOR-LH ACTUATOR-RH ACTUATOR

D08RW761
FRT DOOR LOCK & POWER WINDOW SW-RH

LOCK

UNLOCK
D-30 D-30 D-5
1 2 1
0.3 0.5
LG/L LG/R A
14 15
H-22 H-22 B
A 7 2 7 2
0.3 0.5 H-23 H-23 H-19 H-19
LG/L LG/R
B
14 15 0.5 0.5 0.5 0.5
H-18 H-18 L/Y LG/R L/Y LG/R
0.3 0.5
LG/L LG/R
0.3 0.5 2 1 2 1
LG/L LG D-8 D-8 D-17 D-17
3 4 15 5
D-14 D-14 B-22 B-22
FRT DOOR LOCK & ANTI-THEFT & DOOR LOCK DOOR LOCK
LOCK

KEYLESS ENTRY KEY SW-RH


LOCK

POWER WINDOW KEY SW-LH


UNLOCK
UNLOCK

SW-LH CONTROL UNIT

LOCK

UNLOCK
D-8 D-17
3 3
0.5
B
0.5
D-14
1.25 B
7 B
1.25
B
1 1
H-19 H-23
1.25
B 1.25
2.0 B
B
B-1 B-18

BODY-LH BODY-RH

D08RW762
FRT DOOR LOCK & POWER WINDOW SW-RH

LOCK

UNLOCK
D-30 D-30 D-5
1 2 1
0.3 0.5
LG/L LG/R A
14 15
H-22 H-22 B
A 7 2 7 2
0.3 0.5 H-23 H-23 H-19 H-19
LG/L LG/R
B
14 15 0.5 0.5 0.5 0.5
H-18 H-18 L/Y LG/R L/Y LG/R
0.3 0.5
LG/L LG/R
0.3 0.5 2 1 2 1
LG/L LG D-8 D-8 D-17 D-17
3 4 7 11
D-14 D-14 B-20 B-20
FRT DOOR LOCK & ANTI-THEFT & DOOR LOCK DOOR LOCK
LOCK

KEYLESS ENTRY KEY SW-RH


LOCK

POWER WINDOW KEY SW-LH


UNLOCK
UNLOCK

SW-LH CONTROL UNIT

LOCK

UNLOCK
D-8 D-17
3 3
0.5
B
0.5
D-14
1.25 B
7 B
1.25
B
1 1
H-19 H-23
1.25
B 1.25
2.0 B
B
B-1 B-18

BODY-LH BODY-RH

D08RW763
1

21

20

19
2
18
17
3
16

7
8
9
15

14
10

13
12
11

D08RW677
BATT. (+)

5.0 FRT DOOR LOCK &


W POWER WINDOW SW-LH
LOCK UNLOCK
C-18 20A
DOOR LOCK D-5 D-5
9 8
1.25
LG/W POWER WINDOW
RELAY (4) 1.25
8 LG
H-23
2.0 1.25
1.25 L/B LG/B
LG/W 1.25 1.25
10 7 LG LG/B
3 5
D-5 D-5
H-23 H-23

1.25
LG
FRT DOOR LOCK &
POWER WINDOW SW-LH
1.25
LG/B
1.25 1.25 1.25 1.25 1.25 1.25
LG LG/B LG LG/B LG LG/B
15 13 4 10 15 13
H-32 H-32 H-47 H-47 H-32 H-32
3 5
H-19 H-19 1.25 1.25 1.25 1.25 1.25 1.25
LG LG/B LG LG/B LG LG/B
6 3 6 3 2 8
1.25 1.25 H-28 H-28 H-34 H-34 H-38 H-38
LG LG/B
1.25 1.25 1.25 1.25 1.25 1.25
LG LG/B LG LG/B LG LG/B
2 4 2 4 2 4 2 4 4 2
D-9 D-9 D-19 D-19 D-21 D-21 D-26 D-26 G-4 G-4

FRT DOOR LOCK FRT DOOR LOCK RR DOOR LOCK RR DOOR LOCK TAIL GATE
ACTUATOR-LH ACTUATOR-RH ACTUATOR-LH ACTUATOR-RH ACTUATOR

D08RW884
FRT DOOR LOCK & POWER WINDOW SW-LH

LOCK

UNLOCK
D-30 D-30 D-5
1 2 1
0.3 0.5
LG/L LG/R
14 2
H-22 H-23
0.5
0.5 LG/R
LG/L 0.5
0.5 0.5
14 2 LG/L 7 LG/R
H-18 H-19 LG/L
H-19 7
H-23
0.3 0.5 1.25
LG/L LG/R B
0.5 0.5 0.5
3 4
L/Y LG/R L/Y
D-14 D-14 2 1 2 1
FRT DOOR LOCK & D-17 D-17 D-8 D-8
POWER WINDOW
SW-RH
DOOR LOCK DOOR LOCK

LOCK

UNLOCK
LOCK
LOCK

KEY SW-RH KEY SW-LH

UNLOCK
UNLOCK

D-17 D-8
D-14 3 3
0.5
0.5
7 B
B
1.25 1.25
B B 1
1
H-23
H-19

1.25 1.25
B B

B-1 B-18

BODY-RH BODY-LH

D08RW885-1
BATT. (+)

5.0 FRT DOOR LOCK &


W POWER WINDOW SW-LH
LOCK UNLOCK
C-18 20A
DOOR LOCK D-5 D-5
9 8
1.25 1.25 1.25
LG/W POWER WINDOW LG LG/B
RELAY (4) 13 6
8
H-22 H-23
H-23
1.25
2.0
1.25 LG
L/B 1.25
LG/W LG/B
10 7
D-5 D-5

1.25
LG
FRT DOOR LOCK &
POWER WINDOW SW-RH
1.25
LG/B
1.25 1.25 1.25 1.25 1.25 1.25
1.25
LG LG/B LG LG/B LG LG/B
LG/B 15 13 4 10 15 13
H-32 H-32 H-47 H-47 H-32 H-32
3 5
H-19 H-19 1.25 1.25 1.25 1.25 1.25 1.25
LG LG/B LG LG/B LG LG/B
3 5 6 3 6 3 2 8
H-23 H-23 1.25 1.25 H-28 H-28 H-34 H-34 H-38 H-38
LG LG/B
1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25
LG LG/B LG LG/B LG LG/B LG LG/B
2 4 2 4 2 4 2 4 4 2
D-9 D-9 D-19 D-19 D-21 D-21 D-26 D-26 G-4 G-4

FRT DOOR LOCK FRT DOOR LOCK RR DOOR LOCK RR DOOR LOCK TAIL GATE
ACTUATOR-LH ACTUATOR-RH ACTUATOR-LH ACTUATOR-RH ACTUATOR

D08RW886
FRT DOOR LOCK & POWER WINDOW SW-LH

LOCK

UNLOCK
D-30 D-30 D-5
1 2 1
0.3 0.5
LG/L LG/R A
14 15
H-22 H-22 B
A 7 2 7 2
0.3 0.5 H-23 H-23 H-19 H-19
LG/L LG/R
B
14 15 0.5 0.5 0.5 0.5
H-18 H-18 L/Y LG/R L/Y LG/R
0.3 0.5
LG/L LG/R
0.3 0.5 2 1 2 1
LG/L LG D-8 D-8 D-17 D-17
3 4 15 5
D-14 D-14 B-22 B-22
FRT DOOR LOCK & ANTI-THEFT & DOOR LOCK DOOR LOCK
LOCK

KEYLESS ENTRY KEY SW-LH


LOCK

POWER WINDOW KEY SW-RH


UNLOCK
UNLOCK

SW-RH CONTROL UNIT

LOCK

UNLOCK
D-8 D-17
3 3
0.5
B
0.5
D-14
1.25 B
7 B
1.25
B
1 1
H-19 H-23
1.25
B 1.25
2.0 B
B
B-1 B-18

BODY-RH BODY-LH

D08RW887
1
21

20

19

18

17

16 2

8
9

10

11

12
15

14

13

D08RW392
STARTER SW A
(IG1) BATT.(+)

3.0 3.0
B/Y W
C-4 C/B-2
15A 30A
ELEC. P/W,P/S,S/R
IGN.
0.5
L/W 2.0 0.3
3.0 L/B
B/L 2.0 0.3 2.0 R/Y
0.5 L/B R/Y L/B
L/W 1 2 15 13 13 6
0.3 2.0 0.3 H-46 H-46 H-47 H-47
B-37 B-37
R/Y L/B R/Y
POWER WINDOW
RERAY 2.0 0.3 2.0 0.3
L/B R/Y L/B R/L
4 12 4 12 1 2 1 2
B-37 B-37 H-23 H-22 H-19 H-18 H-29 H-28 H-35 H-34

3 4
2.0 0.3 2.0 0.3 2.0 0.3 2.0 0.3
L/B R/Y L/B R/Y L/B R/Y L/B R/Y
2.0 7 5 5 2 4 2 4 2
L/B
D-5 D-30 D-14 D-14 D-22 D-22 D-27 D-27

A
0.3 FRT POWER WINDOW FRT POWER WINDOW RR POWER WINDOW RR POWER WINDOW SW-RH
B & DOOR LOCK SW-RH & DOOR LOCK SW-LH SW-LH

UP DOWN UP DOWN UP DOWN UP DOWN


D-5 D-5 D-5 D-14 D-14 D-14 D-22 D-22 D-22 D-27 D-27 D-27 D-27
5 6 1 10 1 7 5 6 3 5 6 3 1
2.0 2.0 1.25 2.0 2.0 1.25 2.0 2.0 1.25 2.0 2.0 1.25 0.3
L/W L B L/Y BR/Y B L/R BR/R B L/R BR/R B B
2 1 1 2 1 1 2 1 2 2 1 2 3
D-2 D-2 H-23 D-11 D-11 H-19 D-20 D-20 H-29 D-25 D-25 H-35 H-35
1.25
1.25 B 1.25 1 8
FRT POWER B FRT POWER 2.0 RR POWER B RR POWER
1.25 H-47 H-47
B
B WINDOW WINDOW WINDOW WINDOW
0.3
MOTOR-RH B-18 MOTOR-LH B-1 MOTOR-LH R-3 MOTOR-RH B
1.25
B
BODY-RH BODY-LH BODY-RR
2.0 2.0 2.0
B B B
B-19 B-2 B-26 B-18

BODY-RH BODY-LH BODY-CTR BODY-RH

D08RY00216
1
20 2

19

18

17

7
8
9

10

11

16
15 14
13 12

D08RW883
STARTER SW A
(IG1) BATT.(+)

3.0 3.0
B/Y W
C-4 C/B-2
15A 30A
ELEC. P/W,P/S,S/R
IGN.
0.5
L/W 2.0 0.3
3.0 L/B
B/L 2.0 0.3 2.0 R/Y
0.5 L/B R/Y L/B
L/W 1 2 15 13 13 6
0.3 2.0 0.3 H-46 H-46 H-47 H-47
B-37 B-37
R/Y L/B R/Y
POWER WINDOW
RERAY 2.0 0.3 2.0 0.3
L/B R/Y L/B R/L
4 12 4 12 1 2 1 2
B-37 B-37 H-23 H-22 H-19 H-18 H-29 H-28 H-35 H-34

3 4
2.0 0.3 2.0 0.3 2.0 0.3 2.0 0.3
L/B R/Y L/B R/Y L/B R/Y L/B R/Y
2.0 7 5 5 2 4 2 4 2
L/B
D-5 D-30 D-14 D-14 D-22 D-22 D-27 D-27

A
0.3 FRT POWER WINDOW FRT POWER WINDOW RR POWER WINDOW RR POWER WINDOW SW-RH
B & DOOR LOCK SW-LH & DOOR LOCK SW-RH SW-LH

UP DOWN UP DOWN UP DOWN UP DOWN


D-5 D-5 D-5 D-14 D-14 D-14 D-22 D-22 D-22 D-27 D-27 D-27 D-27
5 6 1 10 1 7 5 6 3 5 6 3 1
2.0 2.0 1.25 2.0 2.0 1.25 2.0 2.0 1.25 2.0 2.0 1.25 0.3
L/W L B L/Y BR/Y B L/R BR/R B L/R BR/R B B
2 1 1 2 1 1 2 1 2 2 1 2 3
D-2 D-2 H-23 D-11 D-11 H-19 D-20 D-20 H-29 D-25 D-25 H-35 H-35
1.25 1.25 0.3
M M B M M B 1 B 8
1.25 1.25
FRT POWER B FRT POWER 2.0 RR POWER B RR POWER
1.25 H-47 H-47
B
B WINDOW WINDOW WINDOW WINDOW
0.5
MOTOR-LH B-18 MOTOR-RH B-1 MOTOR-LH R-3 MOTOR-RH B
1.25
B
BODY-LH BODY-RH BODY-RR
2.0 2.0 2.0
B B B
B-18 B-18 B-26 B-2

BODY-LH BODY-LH BODY-CTR BODY-RH

D08RY00217
1 2

18

17

16

15

3
14

10
13

12 11

D08RW882
STEP ACTION VALUE(S) YES NO
1 Is the fuse C–4 normal? – Go to Replace
step 2 the fuse

2 Is the circuit breaker C/B–2 normal? – Go to Replace


step 3 the circuit
breaker

3 Is B–19 grounded securely? – Go to Ground it


step 4 securely

4 Disconnect the power window relay connector B–37. Approx. 12V Go to Go to


Is the battery voltage applied between harness side step 6 step 5
connector B–37 terminal 2 and the ground?

5 Repair an open circuit between the circuit breaker C/B–2 and – Go to –


connector B–37 terminal 2. step 4
Is the action complete?

6 Turn the starter switch on Approx. 12V Go to Go to


Is the battery voltage applied between harness side step 8 step 7
connector B–37 terminal 1 and the ground?

7 Repair an open circuit between the fuse C–4 and connector – Go to –


B–37 terminal 1. step 6
Is the action complete?

8 Is there continuity between harness side connector B–37 – Replace Go to


terminal 3 and the ground B–19? the relay step 9

9 Repair an open circuit between connector B–37 terminal 3 – Verify –


and the ground B–19. repair
Is the action complete?
STEP ACTION VALUE(S) YES NO
1 Is B–18 grounded securely? – Go to Ground it
step 2 securely

2 Is there continuity between harness side connector D–5 – Go to Go to


terminal 1 and the ground B–18? step 4 step 3

3 Repair an open circuit between connector D–5 terminal 1 – Go to –


and the ground B–18. step 2
Is the action complete?

4 Turn the starter switch on. Approx. 12V Go to Go to


Is the battery voltage applied between harness side step 6 step 5
connector D–5 terminal 7 and the ground?

5 Repair an open circuit between connector B–37 terminal 4 – Go to –


and connector D–5 terminal 7. step 4
Is the action complete?

6 Connect the battery positive terminal with harness side – Replace Go to


connector D–5 terminal 5 or 6, and the negative terminal with the front step 7
harness side connector D–5 terminal 6 or 5. power
Does the motor operate? window &
door lock
switch–RH

7 1. Disconnect the front power window motor–RH connector – Go to Replace


D–2. step 8 the motor
2. Connect the battery positive terminal with the motor side
connector D–2 terminal 1 or 2, and connect the battery
negative terminal with the motor side connector D–2
terminal 2 or 1.
Does the motor operate?

8 Repair an open circuit between the front power window & – Verify –
door lock switch–RH and the front power window motor–RH. repair
Is the action complete?
STEP ACTION VALUE(S) YES NO
1 Is B–1 grounded securely? – Go to Ground it
step 2 securely

2 Disconnect the front power window & door lock switch–LH – Go to Go to


connector D–14. step 4 step 3
Is there continuity between harness side connector D–14
terminal 7 and the ground B–1?

3 Repair an open circuit between connector D–14 terminal 7 – Go to –


and the ground B–1. step 2
Is the action complete?

4 Turn the starter switch on. Approx. 12V Go to Go to


Is the battery voltage applied between harness side step 6 step 5
connector D–14 terminal 5 and the ground?

5 Repair an open circuit between connector B–37 terminal 4 – Go to –


and connector D–14 terminal 5. step 4
Is the action complete?

6 Connect the battery positive terminal with harness side – Replace Go to


connector D–14 terminal 10 or 1, and connect the battery the front step 7
negative terminal with harness side connector D–14 terminal power
1 or 10. window &
Does the motor operate? door lock
switch–LH

7 1. Disconnect the front power window motor–LH connector – Go to Replace


D–11. step 8 the motor
2. Connect the battery positive terminal with the motor side
connector D–11 terminal 1 or 2, and connect the battery
negative terminal with the motor side connector D–11
terminal 2 or 1.
Does the motor operate?

8 Repair an open circuit between the front power window & – Verify –
door lock switch–LH and the front power window motor–LH. repair
Is the action complete?
STEP ACTION VALUE(S) YES NO
1 1. Disconnect the rear power window switch–LH connector Approx. 12V Go to Go to
D–22 or the rear power window & door lock switch–RH step 3 step 2
connector D–27.
2. Turn the starter switch on.
Is the battery voltage applied between harness side
connector D–22 terminal 4 and the ground, or harness side
connector D–27 terminal 4 and the ground?

2 Repair an open circuit between connector B–37 terminal 4 – Go to –


and connector D–22 terminal 4 or connector D–27 terminal 4. step 1
Is the action complete?

3 Is there continuity between harness side connector D–22 – Go to Go to


terminal 3 and the ground, or harness side connector step 5 step 4
D–27 terminal 3 and the ground?

4 Repair an open circuit between connector D–22 terminal 3 or – Go to –


connector D–27 terminal 3 and the ground. step 3
Is the action complete?

5 Connect the battery positive terminal with harness side – Replace Go to


connector D–22 terminals 5 or harness side connector D–27 the rear step 6
terminal 5, and connect the battery negative terminal with power
harness side connector D–22 terminal 6 or harness side window
connector D–27 terminal 6. switch–LH
Does the motor operate? or –RH

6 1. Disconnect the rear power window motor connector D–20 – Go to Replace


or D–25. step 7 the motor
2. Connect the battery positive terminal with motor side
connector D–20 or D–25 terminal 1 or 2, and connect the
battery negative terminal with the motor side connector
D–20 or D–25 terminal 2 or 1.
Does the motor operate?

7 Repair an open circuit between the rear power window – Verify –


switch and the rear power window motor. repair
Is the action complete?
STEP ACTION VALUE(S) YES NO
1 Disconnect the front power window & door lock switch–RH – Replace Go to
connector D–30 and the front power window & door lock the front step 2
switch–RH connector D–14. power
Is there continuity between harness side connector D–30 window &
terminal 5 and harness side connector D–14 terminal 2? door lock
switch–RH

2 Repair an open circuit between connector D–30 terminal 5 Verify –


and connector D–14 terminal 2. – repair
Is the action complete?
STEP ACTION VALUE(S) YES NO
1 Repair or replace the front power window & door lock – Verify –
switch–RH. repair
Is the action complete?
STARTER SW
(IG1)
(A/T)
3.0
B/Y
C-4 15A C-3 10A
ELEC.IGN. TURN,BACK
0.85 0.5
L/W R/B 17
H-7
0.5
L/W 0.85
20 TAIL RELAY
0.5 0.5 R/B 6
(4) 0.5
H-25 L/W L/W
L/W H-11
0.85 0.85 0.75
9 12
L/W G/R R/B 8
4 6 B-52 B-52 2
M-25
I-6 I-6 B-16
COMBINATION MODE
CRUISE SW CLUTCH SW
0.5 MAIN SW

SET
L/W SW (M/T)

CANCEL

RESUME
M-25
I-6 I-6 B-16
0.5 7
5 2 B-52 B-52 B-52 1
L/B 3
0.5 0.3
10 11 13 H-53
P/B R/G
12 0.5
0.5
H-26 ILLUMINATION 0.5 0.5 0.5 L/B 3
L/B 0.5
CONTROLLER(3) LG BR/Y GR/G H-8 L/B
0.5
P/B 0.5
L/B PCM
1 11 4 3 10 12 12
(F2)
B-9 B-9 B-9 B-9 B-9 B-9 B-9

CRUISE CONTROL UNIT

B-9
16
0.5
B

2.0
B

B-1

BODY-LH

D08RW661
STARTER SW
BATT.(+) (IG1)

5.0 3.0
W B/Y
C-14 15A C-10 10A
STOP, METER,GAUGE
A/T CONT
0.85
G/W
1 3 0.5
B-13 B-13 L/Y

BRAKE
6
SW
H-26

B-13 B-13
4 2
0.5 (W/T.O.D.)
0.5
BR/R L/Y
12
0.85 H-7
G/Y INDICATOR
15 LIGHT 26
0.5 I-9 I-9
(METER)
BR/R 0.5
3 O
C-37 ACTUATOR

MAIN
MAIN

CRUISE
CRUISE
CRUISE
CRUISE

0.85
G/Y VEHICLE
7 I-9 I-9 I-9 I-9 SPEED SENSOR
H-32 16 17 18 19 (3)

0.5 0.5 11
STOP B/O GR/L H-10
LIGHT
0.5 C-37 C-37 C-37 PCM
G/Y 14 15 (F10) 0.5
4 1 2
H-26 H-26 LG/W
0.5 0.5 0.5
BR/B BR/W BR 7 2
14 11 19 H-8 H-8
H-8 H-7 H-7
0.3 0.3
B/O GR/L 0.5 0.5
0.5 0.5 0.5
GR/L LG/W
BR/B BR/W BR
2 8 7 15 6 14 13 5 9
B-9 B-9 B-9 B-9 B-9 B-9 B-9 B-9 B-9

CRUISE CONTROL UNIT

D08RW662
2 3
1

15

14

13

12
11
10
8
9

D08RW941
STARTER SW
(IG1)
(A/T)
3.0
B/Y
C-4 15A C-3 10A
ELEC.IGN. TURN,BACK
0.5 0.85
L/W R/B 4
H-8
0.85
L/W 0.85
5 TAIL RELAY
0.5 0.5 R/B 6
(4) 0.5
H-25 L/W L/W
L/W H-11
0.85 0.85 0.75
9 12
L/W G/R R/B 8
4 6 B-52 B-52 2
M-25
I-6 I-6 B-16
COMBINATION MODE
CRUISE SW CLUTCH SW
0.5 MAIN SW

SET
L/W SW (M/T)

CANCEL

RESUME
M-25
I-6 I-6 B-16
0.5 7
5 2 B-52 B-52 B-52 1
0.5 0.3 L/B 3
10 11 13 H-53
P/B R/G
6 0.5
0.5
H-48 ILLUMINATION 0.5 0.5 0.5 L/B 2
L/B 0.5
CONTROLLER(3) LG BR/Y GR/G H-8 L/B
0.5
P/B 0.5
L/B PCM
1 11 4 3 10 12 12
(F2)
B-9 B-9 B-9 B-9 B-9 B-9 B-9

CRUISE CONTROL UNIT

B-9
16
0.5
B

2.0
B

B-2

BODY-RH

D08RY00218
STARTER SW
BATT.(+) (IG1)

5.0 3.0
W B/Y
C-14 15A C-10 10A
STOP, METER,GAUGE
A/T CONT
0.85
G/W
1 3 0.5
B-13 B-13 L/Y

BRAKE
10
SW
H-25

B-13 B-13
4 2
0.5 0.5
BR/R L/Y
6
0.85 H-12
G/Y
INDICATOR
15 LIGHT
0.5 I-9 (METER)
BR/R 0.5
3 O
C-37 ACTUATOR

MAIN

CRUISE
CRUISE
0.85
G/Y VEHICLE
10 I-9 I-9 SPEED SENSOR
H-32 16 17 (3)

0.3 0.3 11
STOP B/O GR/L H-10
LIGHT
0.5 C-37 C-37 C-37 PCM
G/Y 13 12 (F10) 0.5
4 1 2
H-48 H-48 LG/W
0.5 0.5 0.5
BR/B BR/W BR 2 8
7 3 15 H-7 H-8
H-12 H-12 H-12
0.3 0.3
B/O GR/L 0.5 0.5
0.5 0.5 0.5
GR/L LG/W
BR/B BR/W BR
2 8 7 15 6 14 13 5 9
B-9 B-9 B-9 B-9 B-9 B-9 B-9 B-9 B-9

CRUISE CONTROL UNIT

D08RW958
15

14

13
12 1

11

10
5
9
8
7 6

D08RW394
Diagnosis

PART POSIBLE CAUSE DETECTION PERIOD DTC


Motor system short circuit Energizing motor 1–1
Clutch system short circuit Energizing clutch 1–2
Actuator Clutch system open circuit Energizing clutch 1–2
Mechanical defect Cruise controlling 1–3

Close side of motor system open circuit Cruise controlling 1–1

Cruise Open side of motor system continuously energizing While starter sw on 1–4
control unit Clutch output abnormality While starter sw on 1–4

Vehicle Signal of vehicle speed disconnection Cruise controlling 2–1


speed sensor Signal of vehicle speed abnormality Cruise controlling 2–1
Turning on switch at all times While starter sw on 3–1
Switch
Turning on switch at the same time. While starter sw on 3–1

DTC: Diagnostic Trouble Code

DTC Display Condition


1. While starter swi

erased with the starter switch turned off.

DTC Display Format


1. When no DTCs are detected. (The unit : sec.)

0.25 0.25
2. When two or more DTCs are detected. (The unit ; sec.)

0.5

4 1 1 1 2 1 1 1 1 1

Code 1–1 Code 2–2


DTC 1–1 Motor System Short Circuit

STEP ACTION VALUE(S) YES NO


1 1. Turn the starter switch off. More than 4.2 Go to Replace
2. Disconnect the actuator connector C–37. step 2 the
3. Measure resistance between actuator side connector actuator
terminal 1 and 2.
NOTE: If control plate position is fully opened or fully
closed, resistance can not be measured.
Is the resistance within range specified in the value(s)
column?

2 Measure continuity between harness side connector C–37 No continuity Replace Repair or
terminal 1 and the ground, terminal 2 and the ground, and the control replace
terminal 1 and 2. unit the
Are the results same as specified in the value(s) columns? harness
DTC 1–2 Clutch System Open or Short Circuit

STEP ACTION VALUE(S) YES NO


1 1. Turn the starter switch off. 34.7 – 42.4 Go to Replace
2. Disconnect the actuator connector C–37. step 2 the
3. Measure resistance between actuator side connector actuator
terminal 3 and 4.
Is the resistance within range specified in the value(s)
column?

2 1. Disconnect the brake switch connector B–13. – Go to Adjust the


2. Check continuity between switch side connector terminal 2 step 3 switch or
and 3. replace it
Is there continuity between terminals?

3 1. Reconnect the brake switch connector B–13. – Go to Repair


2. Check continuity between harness side connector B–9 step 4 open
terminal 6 and connector C–37 terminal 3, connector C–37 circuit
terminal 4 and connector B–9 terminal 8.
Is there continuity between terminals?

4 Is there continuity between harness side connector C–37 No continuity Replace Repair
terminal 3 and the ground, connector C–37 terminal 4 and the control short
the ground, connector B–9 terminal 6 and the ground? unit circuit
Are the results same as specified in the value(s) column?
DTC 1–3 Mechanical Defect

STEP ACTION VALUE(S) YES NO


1 1. Turn the starter switch off. – Replace Go to
2. Disconnect the actuator connector C–37. the step 2
3. Connect the battery positive terminal with the actuator side actuator
connector terminal 3 and the battery negative terminal with
terminal 4.
Does the control plate move by hand?

2 Connect the battery positive terminal with the actuator side – Go to Replace
connector terminal 1 and 3, and the battery negative terminal step 3 the
with terminal 2 and 4. actuator
Does the control plate move to full open side?

3 Connect the battery positive terminal with the actuator side – Go to Replace
connector terminal 2 and 3, and the battery negative terminal step 4 the
with terminal 1 and 4. actuator
Does the control plate move to full close side?

4 Is there continuity between harness side connector C–37 – Replace Repair or


terminal 1 and connector B–9 terminal 7, connector C–37 the control replace
terminal 2 and connector B–9 terminal 15? unit harness
DTC 1–4 Open Side of Motor System Continuously Energizing

STEP ACTION VALUE(S) YES NO


1 1. Turn the starter switch off. More than 4.2 Go to Replace
2. Disconnect the actuator connector C–37. step 2 the
3. Measure resistance between actuator side connector actuator
terminal 1 and 2.
NOTE: If control plate position is fully opened or fully
closed, resistance can not be measured.
Is there resistance within range specified in the value(s)
column?

2 Is there continuity between harness side connector C–37 – Replace Repair or


terminal 1 and connector B–9 terminal 7, harness side the control replace
connector C–37 terminal 2 and connector B–9 terminal 15? unit harness
STARTER SW STARTER SW
BATT.(+) (IG1) (IG1) BATT.(+)

3.0 3.0 5.0


B/Y B/Y W
FL-6 40A C-4 15A C-10 10A C-14 15A
ABS ELEC.IGN. METER,GAUGE STOP,A/T CONT.

0.5
0.5 L/Y 0.85
3.0 6
L/W 0.85 G/W
W/G H-26 A
G/W

F-9 20A 0.5 (W/CRUISE CONTROL)


ABS 0.5 L/Y
0.85
L/W
15 G/W
INDICATOR
2 1 1
0.5 I-9 LIGHT(METER)
B-25 L/W B-14 B-13
G- STOP BRAKE
SENSOR LIGHT SW

ABS
4WD
SW

B-25 1 I-10 I-9 B-14 B-13


2.0 2.0 H-13
1 16 18 2 4
Y/G W/G 0.5 0.85
0.5 LG G/Y
0.5
Y 19
Y/B
H-27
1 2
0.85
H-15 0.85 H-16 G/Y 0.85
L/W
3 G/Y

0.5 0.5 H-13 STOP LIGHT


4WD CONTROL
Y/B Y UNIT(19) 0.85
G/Y
14 13 26 8 16 10
C-4 C-4 C-4 C-4 C-4 C-4
BATTERY BATTERY G-SENSOR POWER SILA BRAKE LIGHT ELECTRONIC
SUPPLY SWITCH HYDRAULIC
CONTROL UNIT
GROUND GROUND GROUND
C-4 C-4 C-4
12 15 15
2.0 2.0 2.0 (DIESEL)
B B B
6 5
C-85 C-39 C-39

ENG.ROOM-FRT FENDER-RH FENDER-RH

D08RY00219
(A/T) T.O.D. T.O.D. (W/O T.O.D.)
CONTROL UNIT CONTROL UNIT 4WD
PCM CONTROL
B
(A12) UNIT(20)

20 9
0.5 0.5 H-15 H-15
GR GR 0.5
P
0.5 0.5
LG/R P
6 6 27 9 9
C-4 C-4 C-4 C-4 C-4
ELECTRONIC TMM TMM ABS TFM2 TFM2
STATUS
HYDRAULIC
CONTROL DIAG DIAG
UNIT GND RLS GND RRS GND FLS GND FRS SDL2 K L
C-4 C-4 C-4 C-4 C-4 C-4 C-4 C-4 C-4 C-4 C-4
23 22 3 2 21 20 5 4 25 24 17 A
0.5 0.5 0.5
0.5 0.5 0.5 0.5 O/G O/B O/W
W/L O/L W O 0.5 0.5 3 9 1 9
8 5 4 14 13 0.5 0.5 0.5 L G H-42 H-42 H-42 H-7
H-13 H-13 B/L W R
H-13 H-13 H-13
11 15 14 0.5 0.5 0.5 0.85
0.5 0.5 0.5 0.5 O/G O/B O/W G/W
W/L O/L W O H-42 H-42 H-42
8 6 7 11 12
2 7 12 16
H-46 H-46 H-46 H-46 H-46
0.5 0.5 0.5 C-63 C-63 C-63 C-63
B/L W R
0.5 0.5 0.5 0.5
W/L O/L W O
DATA LINK CONNECTOR
6 4 5 2 3
H-33 H-33 H-33 H-33 H-33 1 2 1 2
C-63 C-63
C-13 C-13 C-41 C-41
0.5 0.5 0.5 0.5 4 5
0.5 0.5
W/L O/L W O B/L B/L
SPEED SPEED
SENSOR SENSOR 1.25
1 2 1 2 B/L 14
FRT-LH FRT-RH
F-3 F-3 F-2 F-2 H-5

SPEED SPEED C 1.0


SENSOR SENSOR B/L
C RR-LH RR-RH 8
C-39 E-30

FENDER-RH COMMON
CHAMBER

D08RW786
4WD
CONTROL
B
UNIT(20)

0.5
GR 0.5
P

6 9
C-4 C-4
ELECTRONIC TMM TFM2
HYDRAULIC
CONTROL DIAG DIAG
UNIT GND RLS GND RRS GND FLS GND FRS K L
C-4 C-4 C-4 C-4 C-4 C-4 C-4 C-4 C-4 C-4
23 22 3 2 21 20 5 4 24 17 A
0.5 0.5
0.5 0.5 0.5 0.5 O/B O/W
W/L O/L W O 0.5 0.5 9 1 9
8 5 4 14 13 0.5 0.5 0.5 L G H-42 H-42 H-7
B/L W R
H-13 H-13 H-13 H-13 H-13
0.5 0.5 0.5 0.5 11 15 14 0.5 0.5 0.85
W/L O/L W O H-42 H-42 H-42 O/B O/W G/W
8 6 7 11 12
7 12 16
H-46 H-46 H-46 H-46 H-46
0.5 0.5 0.5 C-63 C-63 C-63
B/L W R
0.5 0.5 0.5 0.5
W/L O/L W O
6 4 5 2 3 DATA LINK CONNECTOR
H-33 H-33 H-33 H-33 H-33
1 2 1 2
C-63 C-63
0.5 0.5 0.5 0.5 C-13 C-13 C-41 C-41
4 5
W/L O/L W O

SPEED SPEED 0.5


1 2 1 2 SENSOR SENSOR B

F-3 F-3 F-2 F-2


FRT-LH FRT-RH 0.5
B
SPEED SPEED
SENSOR SENSOR C
0.5
RR-LH RR-RH B
8 7
C-39 C-16
C

FENDER-RH FENDER-LH

D08RW788
STARTER SW
(IG1)
D E
3.0
B/Y
C-3 10A C-4 15A
TURN,BACK ELEC.IGN.
0.75 0.75
0.5 R/L GR
L/W
0.5
R/B
7 15
0.5
H-11 H-10
L/W
17 7
H-7 H-12 0.5
R/L
0.85 0.5
L/W GR
0.85
R/B 0.5 0.5
0.5 R/L R/L
L/W 6 8
6 16 H-42 H-42
H-11 H-10
BACK UP
LIGHT

0.75 0.75 0.5


R/B L/W R/L

1 1
3
M-8 M-1
X-15 0.5
BACK UP TRANSMISSION GR
LIGHT SW-1, 2
SW
X-15
M-9 M-2 4
1 1

0.75 0.75 0.5


R/L GR GR

D E B

D08RY00220
STARTER SW
(IG1)
D E
3.0
B/Y
C-3 10A C-4 15A
TURN,BACK ELEC.IGN.
0.75 0.75
0.5 R/L GR
L/W
0.5
R/B
7 15
0.5
H-11 H-10
L/W
17 7
H-7 H-12 0.5
R/L
0.85 0.5
L/W GR
0.85
R/B 0.85 0.5
R/L R/L
0.5
L/W 6 8
6 16 H-42 H-42
H-11 H-10
BACK UP
LIGHT

0.75 0.75 0.5


R/B L/W R/L

1 1
3
M-8 M-1
X-15 0.5
BACK UP TRANSMISSION GR
LIGHT SW-1,2
SW
X-15
M-8 M-1 4
2 2

0.75 0.75 0.5


R/L GR GR

D E B

D08RY00221
STARTER SW
(IG1)
D E
3.0
B/Y
C-3 10A C-4 15A
TURN,BACK ELEC.IGN.
0.85 0.85
0.5 R/L R
L/W
0.5
R/B
5 13
0.5
L/W H-5 H-5
17 7
H-7 H-12 0.5
R/L
0.85 0.5
L/W GR
0.5
R/B 0.85 0.5
0.5 R/L R/L
L/W 6 8
6 8 H-42 H-42
H-5 H-5
BACK UP
LIGHT

0.85 0.85 0.5


R/B R/G R/L

1 1
3
E-42 E-47
X-15 0.5
BACK UP TRANSMISSION GR
LIGHT SW-1, 2
SW
X-15
E-43 E-48 4
1 1

0.85 0.85 0.5


R/L R GR

D E B

D08RY00222
2
1
26
25
24
23
22
21
20

19 3

18

17 4

6
16
7

15 8

9
14

13

10
12
11

D08RW807
STARTER SW STARTER SW
BATT.(+) (IG1) (IG1) BATT.(+)

3.0 3.0 5.0


B/Y B/Y W
FL-6 40A C-4 15A C-10 10A C-14 15A
ABS ELEC.IGN. METER,GAUGE STOP,A/T CONT.

0.5
0.5 L/Y 0.85
3.0 10
L/W 0.85 G/W
W/G H-25 A
G/W

F-9 20A 0.5 (W/CRUISE CONTROL)


ABS 0.5 L/Y
0.85
L/W
15 G/W
INDICATOR
2 1 1
0.5 I-9 LIGHT(METER)
B-25 L/W B-14 B-13
STOP BRAKE
G- LIGHT SWITCH

ABS
4WD
SENSOR SWITCH

B-25 5 I-10 I-9 B-14 B-13


2.0 2.0 H-12
1 16 18 2 4
Y/G W/G 0.5 0.85
0.5 LG G/Y
0.5
Y 22
Y/B
H-25
4 18
0.85
H-15 0.85 H-16 G/Y 0.85
L/W
2 G/Y

0.5 0.5 H-13 STOP LIGHT


4WD CONTROL
Y/B Y UNIT(19) 0.85
G/Y
14 13 26 8 16 10
C-4 C-4 C-4 C-4 C-4 C-4
BATTERY BATTERY G-SENSOR POWER SILA BRAKE LIGHT ELECTRONIC
SUPPLY SWITCH HYDRAULIC
CONTROL
GROUND GROUND GROUND UNIT
C-4 C-4 C-4
12 15 15
2.0 2.0 2.0
B B B
(4JG2)
6 5
C-85 C-39 C-39

ENG. ROOM-FRT FENDER-RH FENDER-RH

D08RY00223
(A/T)
4WD
PCM CONTROL
B
(A12) UNIT(20)

0.5 0.5
GR GR 0.5
P

6 6 9
C-4 C-4 C-4
ELECTRONIC TMM TMM TFM2
HYDRAULIC
CONTROL DIAG DIAG
UNIT GND RLS GND RRS GND FLS GND FRS SDL2 K L
C-4 C-4 C-4 C-4 C-4 C-4 C-4 C-4 C-4 C-4 C-4
23 22 3 2 21 20 5 4 25 24 17 A
0.5 0.5 0.5
0.5 0.5 0.5 0.5 O/G O/B O/W
W/L O/L W O 0.5 0.5 3 9 1 9
19 8 18 10 9 0.5 0.5 0.5 L G H-42 H-42 H-42 H-7
H-12 H-12 B/L W R
H-12 H-12 H-12
11 15 14 0.5 0.5 0.5 0.85
0.5 0.5 0.5 0.5 O/G O/B O/W G/W
W/L O/L W O H-42 H-42 H-42
8 6 7 11 12
2 7 12 16
H-46 H-46 H-46 H-46 H-46
0.5 0.5 0.5 C-63 C-63 C-63 C-63
B/L W R
0.5 0.5 0.5 0.5
W/L O/L W O
DATA LINK CONNECTOR
6 4 5 2 3
H-33 H-33 H-33 H-33 H-33 1 2 1 2
C-63 C-63
C-13 C-13 C-41 C-41
0.5 0.5 0.5 0.5 4 5
0.5 0.5
W/L O/L W O B/L B/L
SPEED SPEED
SENSOR SENSOR 1.25
1 2 1 2 B/L 14
FRT-LH FRT-RH
F-3 F-3 F-2 F-2 H-5

SPEED SPEED C 1.0


SENSOR SENSOR B/L
C RR-LH RR-RH 2
C-39 E-30

FENDER-RH COMMON
CHAMBER

D08RW790
4WD
CONTROL
B
UNIT(20)

0.5
GR 0.5
P

6 9
C-4 C-4
ELECTRONIC TMM TFM2
HYDRAULIC
CONTROL DIAG DIAG
UNIT GND RLS GND RRS GND FLS GND FRS K L
C-4 C-4 C-4 C-4 C-4 C-4 C-4 C-4 C-4 C-4
23 22 3 2 21 20 5 4 24 17 A
0.5 0.5
0.5 0.5 0.5 0.5 O/B O/W
W/L O/L W O 0.5 0.5 9 1 9
19 8 18 10 9 0.5 0.5 0.5 L G H-42 H-42 H-7
B/L W R
H-12 H-12 H-12 H-12 H-12
0.5 0.5 0.5 0.5 11 15 14 0.5 0.5 0.85
W/L O/L W O H-42 H-42 H-42 O/B O/W G/W
8 6 7 11 12
7 12 16
H-46 H-46 H-46 H-46 H-46
0.5 0.5 0.5 C-63 C-63 C-63
B/L W R
0.5 0.5 0.5 0.5
W/L O/L W O
6 4 5 2 3 DATA LINK CONNECTOR
H-33 H-33 H-33 H-33 H-33
1 2 1 2
C-63 C-63
0.5 0.5 0.5 0.5 C-13 C-13 C-41 C-41
4 5
W/L O/L W O

SPEED SPEED 0.5


1 2 1 2 SENSOR SENSOR B

F-3 F-3 F-2 F-2


FRT-LH FRT-RH 0.5
B
SPEED SPEED
SENSOR SENSOR C
0.5
RR-LH RR-RH B
4 8
C-39 C-16
C

FENDER-RH FENDER-LH

D08RW792
STARTER SW
(IG1)
D E
3.0
B/Y
C-3 10A C-4 15A
TURN,BACK ELEC.IGN.
0.75 0.75
R/L GR

0.85 0.5
R/B L/W 7 15
H-11 H-10
4 10
H-8 H-8 0.5
R/L
0.85 0.5
L/W GR
0.85
R/B 0.5 0.5
0.5 R/L R/L
L/W 6 8
6 16 H-42 H-42
H-11 H-10
BACK UP
LIGHT

0.75 0.75 0.5


R/B L/W R/L

1 1
3
M-8 M-1
X-15 0.5
BACK UP TRANSMISSION GR
LIGHT SW-1, 2
SW
X-15
M-9 M-2 4
1 1

0.75 0.75 0.5


R/L GR GR

D E B

D08RY00224
STARTER SW
(IG1)
D E
3.0
B/Y
C-3 10A C-4 15A
TURN,BACK ELEC.IGN.
0.75 0.85
0.85 R/L R
R/B
0.5
L/W 5 13
0.5
R/B H-5 H-5
4 10
H-8 H-8 0.5
R/L
0.5
0.85 GR
0.5
R/B L/W 0.5 0.5
R/L R/L
6 8
6 8 H-42 H-42
H-5 H-5
BACK UP
LIGHT

0.85 0.85 0.5


R/B R/G R/L

1 1
3
E-42 E-47
X-15 0.5
BACK UP TRANSMISSION GR
LIGHT SW-1, 2
SW
X-15
E-43 E-48 4
1 1

0.85 0.85 0.5


R/L R GR

D E B

D08RY00225
1
2

22
21 24
23
20

19 3

18
25

17
4

16

7
15

14 8
9
13

10
12 11

D08RW808
STARTER SW
(IG1) BATT.(+)

3.0 5.0
B/Y W
C-4 15A C-14 15A
ELEC. IGN. STOP, A/T CONT

0.85
G/W
0.85 0.85 0.85
L/W G/W G/W
1 1
B-14 B-13
STOPLIGHT BRAKE
AC GENERATOR
SW SW
(L) (W/O CRUISE (W/ CRUISE
CONTROL) CONTROL)
B-14 B-13
13 2 4
0.85 0.85
H-15
G/Y G/Y
0.5
L/W
0.85
0.85
W/G
G/Y

1 5 4 2 7
B-32 B-32 B-32 B-32 H-32

SHIFT LOCK CONTROLLER STOPLIGHT

B-32
6

0.5
B

SHIFT LOCK PARKING POSITION


SOLENOID DETECTING SW
2.0 2.0 2.0
B B B

B-2 B-26 B-18

BODY-LH BODY-CTR BODY-RH

D08RY00226
2

1
10
9
8

D08RWA08
STARTER SW
(IG1) BATT.(+)

3.0 5.0
B/Y W
C-4 15A C-14 15A
ELEC. IGN. STOP, A/T CONT

0.85
G/W
0.5 0.85 0.85
L/W G/W G/W
1 1
B-14 B-13
STOPLIGHT BRAKE
AC GENERATOR
SW SW
(L) (W/O CRUISE (W/ CRUISE
CONTROL) CONTROL)
B-14 B-13
11 2 4
0.85 0.85
H-15
G/Y G/Y
0.5
L/W
0.85
0.85
W/G
G/Y

1 5 4 2 7
B-32 B-32 B-32 B-32 H-32

SHIFT LOCK CONTROLLER STOPLIGHT

B-32
6

0.5
B

SHIFT LOCK PARKING POSITION


SOLENOID DETECTING SW
2.0
B

B-26

BODY-CTR

D08RY00227
1

D08RW395
STARTER SW
(IG2)

3.0
B/R
C-5 15A
FRT WIPER & WASHER

0.85
W/L
0.85
1 W/L 3 WINDSHIELD WIPER & WASHER SW 0.85
B-52 B-52 (COMBINATION SW) W/L

WASHER INT LOW HIGH OFF 2


H-15

B-52 B-52 B-52 B-52 B-52 B-52 B-52


7 2 5 4 6 8 14
0.85 0.85 0.85
0.85 R/Y L W/L
L/Y 9 2
H-13 H-13
0.85
0.85 0.85 0.85 W/L
L/Y R/Y 2 L 1 6
7
C-38 C-38 C-38 0.5
H-13
B 1

0.85 0.85 WIND- B-7


L/Y LG/R SHIELD 0.85 0.85
1
WIPER O L/R
C-35 MOTOR
0.85
WIND- L/Y C-38 C-38 B-7
SHIELD
WASHER 3 5 9
0.85
MOTOR L/O 0.85
C-35 12
1.25 B
2 0.85 H-13 B
B
0.5 0.85
B 19 20 L/O 12 11 14 2.0 2.0
B B
B-7 B-7 B-7 B-7 B-6
4 2
C-39 C-39 ALARM & RELAY B-19 B-2 B-18
CONTROL UNIT

FENDER-RH FENDER-RH BODY-RH BODY-LH BODY-RH

D08RW644
1

11

10

6
5

D08RWA06
STARTER SW
(IG2)

3.0
B/R
C-5 15A
FRT WIPER & WASHER

0.85
W/L
0.85
1 W/L 3 WINDSHIELD WIPER & WASHER SW 0.85
B-52 B-52 (COMBINATION SW) W/L

WASHER INT LOW HIGH OFF 13


H-15

B-52 B-52 B-52 B-52 B-52 B-52 B-52


7 2 5 4 6 8 14
0.85 0.85 0.85
0.85 R/Y L W/L
L/Y 14 8
H-15 H-15
0.85
0.85 0.85 0.85 W/L
L/Y R/Y 2 L 1 6
7
C-38 C-38 C-38 0.5
H-15
B

0.85 0.85 WIND-


L/Y LG/R SHIELD M 0.85 0.85
1
WIPER O L/R
C-35 MOTOR
1
0.85
WIND- L/Y B-7
C-38 C-38
M SHIELD
WASHER 3 5
0.85
MOTOR L/O
C-35 6
1.25
2 0.85 H-15 B B-7
B
0.5 0.85 0.85 9
B 19 20 L/O 12 11 14 B

B-7 B-7 B-7 B-7 B-6 2.0


1 2 B
C-39 C-39 ALARM & RELAY B-19 B-2
CONTROL UNIT

FENDER-RH FENDER-RH BODY-LH BODY-RH

D08RW955
1

5 6

D08RW381
1 Windshield Wiper Does Not Operate At Any Switch Position
2 Windshield Wiper Does Not Operate At “INT” Position
3 Intermittent Interval Does Not Change

4 Windshield Wiper Does Not Operate At “LO” Position


5 Windshield Wiper Does Not Operate At “HI” Position
6 Auto-Stop Function of The Windshield Wiper Motor Does Not Operate
7 Rotation of The Windshield Wiper Motor Does Not Stop
8 Windshield Washer Motor Does Not Operate
STARTER SW
(IG2)

3.0
B/R
C-6 10A
RR WIPER&WASHER

TAIL RELAY
(4)

0.5
0.5 L/B
L/B 3 14
H-25 H-16
A
0.5 0.85
L/B G/R
7 3
I-16 I-16
RR WIPER/
WASHER SW

RR
WIPER
RR
WASHER

0.5
L/B
I-16 I-16 I-16
8 6 2

0.5 0.5 0.3


LB LG/W R/G

22 11
H-25 H-26
ILLUMINATION
0.5 CONTROLLER(3)
LB
0.5
LG/W
4 18 8
B-7 B-7 B-7
ALARM & RELAY WIPER WASHER
CONTROL UNIT
AUTO STOP MOTOR
B-7 B-7 B-7

0.85 9 2 3
B
2.0 2.0 0.5 0.5 0.5
B B LG/L LG/R LG/W

B-2 B-18

B C D

BODY-LH BODY-RH

D08RW643
A C D
B

0.5 0.5 0.5 0.5


L/B LG/L LG/R LG/W

2 1 3 4
H-32 H-32 H-32 H-32

0.5 0.5 0.5 0.5


L/B LG/L LG/R LG/W

7 6 9 3
H-38 H-38 H-38 H-38

0.5 0.5 0.5


L/B LG/Y LG/R
0.5
LG/W
3 1 2
G-6 G-6 G-6
1
RR WIPER
G-2
MOTOR
RR WASHER
MOTOR

G-2
2
G-6
0.5
4
B

0.5
B

5
H-38

0.5
B

1.25
B

R-3

BODY-RR

D08RW642
1 2 3

11

10

9 8 7

D08RWA07
STARTER SW
(IG2)

3.0
B/R
C-6 10A
RR WIPER&WASHER

TAIL RELAY
(4)

0.5
0.5 L/B
L/B 21 13
H-25 H-16
A
0.5 0.85
L/B G/R
7 3
I-16 I-16
RR WIPER/
WASHER SW

RR
WIPER
RR
WASHER

0.5
L/B
I-16 I-16 I-16
8 6 2

0.5 0.5 0.3


LB LG/W R/G

4 13
H-25 H-25
ILLUMINATION
0.5 CONTROLLER(3)
LB
0.5
LG/W
4 18 8
B-7 B-7 B-7
ALARM & RELAY WIPER WASHER
CONTROL UNIT
AUTO STOP MOTOR
B-7 B-7 B-7
9 2 3
0.85
B 0.5 0.5 0.5
LG/L LG/R LG/W

B-2

C D
B
BODY-RH

D08RW072
A C D
B

0.5 0.5 0.5 0.5


L/B LG/L LG/R LG/W

2 1 8 7
H-32 H-32 H-32 H-32

0.5 0.5 0.5 0.5


L/B LG/L LG/R LG/W

7 6 9 3
H-38 H-38 H-38 H-38

0.5 0.5 0.5


L/B LG/Y LG/R
0.5
LG/W
3 1 2
G-6 G-6 G-6
1
RR WIPER
G-2
MOTOR
RR WASHER
MOTOR

G-2
2
G-6
0.5
4
B

0.5
B

5
H-38

0.5
B

R-3

BODY-RR

D08RW071
10 1
9

3
4

D08RW396
1 Rear Wiper Motor Does Not Operate
2 Auto-Stop Function of The Rear Wiper Motor Does Not Operate
3 Rear Wiper Motor Does Not Operate at “Wiper” Position

4 Rear Wiper Motor Does Not Operate at “Washer” Position


5 Rotation of The Rear Wiper Motor Does Not Stop
6 Rear Washer Motor Does Not Operate
STATER SW STATER SW
(IG1) (IG2)

3.0
B/Y
C-4 15A C-7 10A
ELEC,IG H/LAMP
WIPER
0.5 0.5
R 15
L/W
H-7
0.5
L/W 1 0.5
R
B-6

ALARM&RELAY 10
CONTROL UNIT 0.5 H-41
R
B-6 0.5
R
0.5 12 1
R/Y
C-36
5
H-7 H/LIGHT
0.5 0.5 M WASHER
R 0.5 R MOTOR
R/Y
6 5 6 C-36
C-23 C-23 C-30 2
0.5
R/G
HEADLIGHT HEADLIGHT 15
WIPER WIPER H-15
MOTOR-LH MOTOR-RH
0.5
R/G
10
B-7

ALARM&RELAY
M M CONTROL UNIT

B-7
9
0.85
B
2.0 2.0 2.0
C-23 C-23 C-23 C-30 C-30 C-30 B B B
0.5 3 0.5 4 0.5 2 0.5 3 0.5 4 0.5 2
B-2 B-26 B-18
R/B L/R B O/W L/W B
A B C D E F

BODY BODY BODY


-LH -CTR -RH

D08RY00228
A D C F
B E

0.5 0.5 0.5 0.5


R/B L/R O/W L/W

TAIL RELAY 20 11 1 6
(4) H-9 H-24 H-9 H-9

0.5 0.5
B B

0.85 0.5 0.5 0.5 0.5


G/R R/B L/R O/W L/W

3 7 8 5 4
I-4 I-4 I-4 I-4 I-4
HEAD LIGHT
WIPER SW

I-4 I-4
2 6

0.3 0.5
R/G B

5
ILLUMINATION
H-26 0.5
CONTROLLER
B
(3)
0.5
B

1.25
B
4
B-19 C-16

BODY-RH FENDER-LH

D08RW932
2
1

17
16

15

14

13

12
3

11
5

10

9 6

8
7
D08RW938
STATER SW STATER SW
(IG1) (IG2)

3.0
B/Y
C-4 15A C-7 10A
ELEC,IG H/LAMP
WIPER
0.5 0.5
R 11
L/W
H-8
0.5
L/W 1 0.5
R
B-6
(4JG2)

ALARM&RELAY 11 9
CONTROL UNIT 0.5 H-41 H-41
R
B-6 0.5
R
0.5 12 1
R/Y
C-36
10
H-7 H/LIGHT
0.5 0.5 M WASHER
R 0.5 R MOTOR
R/Y
6 5 6 C-36
C-23 C-23 C-30 2
0.5
R/G
HEADLIGHT HEADLIGHT 12
WIPER WIPER H-15
MOTOR-LH MOTOR-RH
0.5
R/G
10
B-7

ALARM&RELAY
M M CONTROL UNIT

B-7
9
0.85
B
2.0 2.0 2.0
C-23 C-23 C-23 C-30 C-30 C-30 B B B
0.5 3 0.5 4 0.5 2 0.5 3 0.5 4 0.5 2
B-2 B-26 B-18
R/B L/R B O/W L/W B
A C D F
B E
BODY BODY BODY
-RH -CTR -LH

D08RY00229
A D C F
B E

0.5 0.5 0.5 0.5


R/B L/R O/W L/W

TAIL RELAY 10 9 6 5
(4) H-9 H-9 H-9 H-9

0.5 0.5
B B

0.85 0.5 0.5 0.5 0.5


G/R R/B L/R O/W L/W

3 7 8 5 4
I-4 I-4 I-4 I-4 I-4
HEAD LIGHT
WIPER SW

I-4 I-4
2 6

0.3 0.5
R/G B

16
ILLUMINATION
H-25 0.5
CONTROLLER
B
(3)
0.5
B

1.25
B
4
B-19 C-16

BODY-LH FENDER-LH

D08RW933
1

17
2

16
15

14

3
13

12

4
11

9
10 6

8 7

D08RW937
STARTER SW
BATT.(+) (IG1)

5.0 3.0
W B/Y

C-17 25A C-4 15A


RR DEFOG ELEC. IGN.

0.5
L/W
3.0
L/W TAIL RELAY(4)
0.5 0.5
L/W L/W 20
2 3
H-25 0.85
B-38 B-38 G/R
0.85
RR DEFOGGER L/W 5 6
RELAY I-17 I-17
RR DEFOGGER
B-38 B-38 SW

3.0 4 1
B/L
2 I-17 I-17 I-17
H-31 3 4 2
0.5 0.5
3.0 O/L 0.3
O/L 0.5
B/L 2 R/G
2 O/G
H-26
H-37 1
0.5 H-25 ILLUMINATION
3.0
O/L CONTROLLER(3)
B/L
1
0.5
G-3 0.5 O/G
O/L
RR DEFOGGER 5 8
B-7 B-6
ALARM & RELAY
CONTROL UNIT
TIMER
G-7 (RR DEFOGGER)
1
3.0 B-7
B
4 9
0.85
H-37 B

3.0
2.0 2.0 2.0
B B B B
R-3 B-2 B-26 B-18

BODY-RR BODY-LH BODY-CTR BODY-RH

D08RY00230
2
13 14 1

12

11 4

10

D08RW811
STARTER SW
BATT.(+) (IG1)

5.0 3.0
W B/Y

C-17 25A C-4 15A


RR DEFOG ELEC. IGN.

0.5
L/W
3.0
L/O TAIL RELAY(4)
0.5 0.5
L/W L/W 5
2 3
H-25 0.85
B-38 B-38 G/R
0.85
RR DEFOGGER L/W 5 6
RELAY I-17 I-17
RR DEFOGGER
B-38 B-38 SW

3.0 4 1
B/L
2 I-17 I-17 I-17
H-31 3 4 2
0.5 0.5
3.0 O/L 0.3
O/L 0.5
B/L 3 R/G
2 O/G
H-25
H-37 1
0.5 H-48 ILLUMINATION
3.0 O/L
B/L CONTROLLER(3)
1
0.5
G-3 0.5 O/G
O/L
RR DEFOGGER 5 8
B-7 B-6
ALARM & RELAY
CONTROL UNIT
TIMER
G-7 (RR DEFOGGER)
1
3.0 B-7
B
4 9
0.85
H-37 B

3.0
2.0 2.0 2.0
B B B B
R-3 B-2 B-26 B-18

BODY-RR BODY-RH BODY-CTR BODY-LH

D08RY00231
16 1
15 2
14

13
3

12

11

10

4
6 5

D08RW810
STARTER SW
(ACC) BATT.(+)

3.0 5.0
L/B W
C-11 10A C-15 20A
AUDIO(ACC) AUDIO(B)
MIRROR

TAIL RELAY
(4) 0.5 1.25
O/G R/W

14 4 19
H-16 H-27 H-25

0.85 0.5 1.25


G/R O/G R/W

11 4 14
I-15 I-15 I-15

AUDIO

I-15 I-15 I-15 I-15 I-15 I-15 I-15 I-15 I-15


3 1 8 6 15 7 16 2 9

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5


0.3
Y L W R GR G O B
R/G
8 7 12 11 18 17 14 13
H-27 H-27 H-27 H-27 H-27 H-27 H-27 H-27

ILLUMINATION
CONTROLLER(3) 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Y L W R GR G O B

20 19 3 11 3 11 18 17
H-32 H-32 H-18 H-18 H-22 H-22 H-32 H-32

0.5 0.5 0.5 0.5


Y L O B

2 1 2 1 2 1 2 1
R-5 R-5 D-10 D-10 1 2 D-1 D-1 1 2 R-10 R-10
+� −� +� −� +� −� +� −�
D-13 D-13 D-4 D-4
+� −� +� −�
RR SPEAKER FRT SPEAKER FRT SPEAKER RR SPEAKER
-LH -LH -RH -RH
TWEETER-LH TWEETER-RH

D08RW765
BATT.(+)

5.0
AUDIO
W

I-15 I-15 C-16 10A


10 12 CLOCK(B), ROOM

0.5
BR/R

6
0.5
H-25 R/W

0.5
BR/R

1 2
0.85
B/L B-8 B-8

AUTO ANTENNA

LIMIT LIMIT
SW SW
(UP) (DOWN)

UP

M
DOWN

I-39

BODY-FRT

D08RW681
STARTER SW
BATT.(+) (ACC)

5.0 3.0
W L/B
C-15 20A C-11 10A
AUDIO(B) AUDIO(ACC)
MIRROR

TAIL RELAY
(4) 1.25 0.5
A
R/W O/G

14 19 4
H-16 H-25 H-27

0.85 1.25 0.5


G/R R/W O/G

11 14 4
I-15 I-15 I-15

AUDIO

I-15 I-15 I-15 I-15 I-15 I-15 I-15 I-15 I-15 I-15
3 1 8 6 15 7 16 2 9 10

0.3 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5


Y L W R GR G O B
R/G
8 7 12 11 18 17 14 13
H-27 H-27 H-27 H-27 H-27 H-27 H-27 H-27

ILLUMINATION
CONTROLLER(3) 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.85
Y L W R GR G O B B/L

20 19 3 11 3 11 18 17
H-32 H-32 H-18 H-18 H-22 H-22 H-32 H-32

0.5 0.5 0.5 0.5


Y L O B

2 1 2 1 2 1 2 1
R-5 R-5 D-10 D-10 D-1 D-1 R-10 R-10 I-39
1 2 1 2
+� −� +� −� +� −� +� −�
D-13 D-13 D-4 D-4
+� −� +� −�
RR SPEAKER FRT SPEAKER FRT SPEAKER RR SPEAKER
-LH -LH -RH -RH BODY-FRT
TWEETER-LH TWEETER-RH

D08RWB90
A BATT.(+)

TAIL RELAY 5.0


(4) W
0.5
0.85 O/G
C-16 10A
G/R
3 4 CLOCK(B), ROOM

B-59 B-59

AUTO
ANTENNA
SW

B-59 B-59
6 2 0.5
0.3
R/G R/W

ILLUMINATION 0.5
CONTROLLER BR/R
(3)

1 2
B-8 B-8

AUTO ANTENNA

LIMIT LIMIT
SW SW
(UP) (DOWN)

UP

M
DOWN

D08RWB89
1
18

17

16

15

14 3
13
12
4

5
6

8
11
10

D08RWB91
STARTER SW
(ACC) BATT.(+)

3.0 5.0
L/B W
C-11 10A C-15 20A
AUDIO(ACC) AUDIO(B)
MIRROR

TAIL RELAY
(4) 0.5 1.25
O/G R/W

6 8 7
H-16 H-26 H-25

0.85 0.5 1.25


G/R O/G R/W

11 4 14
I-15 I-15 I-15

AUDIO

I-15 I-15 I-15 I-15 I-15 I-15 I-15 I-15 I-15


3 1 8 6 15 7 16 2 9

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5


0.3
Y L W R GR G O B
R/G
6 7 3 8 9 8 18 19
H-26 H-26 H-26 H-25 H-48 H-48 H-26 H-26

ILLUMINATION
CONTROLLER(3) 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Y L W R GR G O B

20 19 3 11 3 11 18 17
H-32 H-32 H-22 H-22 H-18 H-18 H-32 H-32

0.5 0.5 0.5 0.5


Y L O B

2 1 2 1 2 1 2 1
R-5 R-5 D-1 D-1 1 2 D-10 D-10 1 2 R-10 R-10
+� −� +� −� +� −� +� −�
D-4 D-4 D-13 D-13
+� −� +� −�
RR SPEAKER FRT SPEAKER FRT SPEAKER RR SPEAKER
-LH -LH -RH -RH
TWEETER-LH TWEETER-RH

D08RW764
BATT.(+)

5.0
AUDIO
W

I-15 I-15 C-16 10A


10 12 CLOCK(B), ROOM

0.5
BR/R

7
0.5
H-48 R/W

0.5
BR/R

0.85
1 2
B/L
B-8 B-8

AUTO ANTENNA

LIMIT LIMIT
SW SW
(UP) (DOWN)

UP

M
DOWN

I-39

BODY-FRT

D08RW682
1

17
16
15 2
14

13

12
3

9
11
10

D08RW676
STARTER SW STARTER SW
BATT(+) (IG2) BATT(+) (ACC)

5.0 3.0 5.0 3.0


W B/R W L/B
C-15 20A C-2 15A C-16 10A C-11 10A C-12 20A
AUDIO SEAT CLOCK(B) AUDIO(ACC), TAIL RELAY CIGAR
TEL HEATER ROOM MIRROR (4)
1.25
O/B 3
H-20
0.5 0.5
R/W O/G 0.85 1.25
G/R O/B
9 4 1
1.25 1.25 1
R/W GR H-26 H-27 I-20
0.5 I-21
O/G 0.85 CIGARETTE
G/R
LIGHTER
0.5 0.5
R/W O/G
I-22
I-20
1
4 2 1 2 5 4 2
B-58 B-58 B-58 I-27 I-27 I-27
0.3
CAR DIGITAL
R/G 1.25
TELEPHONE CLOCK
B

I-27 ILLUMINATION
B-58
CONTROLLER(3)
3 3
20
H-27
0.3
B

1.25
B 5
1.25
H-26 B

0.5
B

2.0 2.0 2.0 1.25


B B B B

B-2 B-26 B-18 B-19

BODY-LH BODY-CTR BODY-RH BODY-RH

D08RWA62
1

11

10

8
7
6

D08RWA52
STARTER SW STARTER SW
BATT(+) (IG2) BATT(+) (ACC)

5.0 3.0 5.0 3.0


W B/R W L/B
C-15 20A C-2 15A C-16 10A C-11 10A C-12 20A
AUDIO SEAT CLOCK(B) AUDIO(ACC), TAIL RELAY CIGAR
TEL HEATER ROOM MIRROR (4)
1.25
O/B 16
H-48
0.5 0.5
R/W O/G 0.85 1.25
G/R O/B
5 8 1
1.25 1.25 1
R/W GR H-26 H-26 I-20
0.5 I-21
O/G 0.85 CIGARETTE
G/R
LIGHTER
0.5 0.5
R/W O/G
I-22
I-20
1
4 2 1 2 5 4 2
B-58 B-58 B-58 I-27 I-27 I-27
0.3
CAR DIGITAL
R/G
TELEPHONE CLOCK
1.25
B
I-27 ILLUMINATION
B-58
CONTROLLER(3)
3 3

0.3
B

1.25
B
2.0
B
15
H-48

2.0
2.0 2.0 2.0 B
B B B

B-18 B-26 B-2 B-2

BODY-LH BODY-CTR BODY-RH BODY-RH

D08RWA63
10

5
6

D08RWA50
STARTER SW
(ACC)

3.0
L/B
C-11 10A
AUDIO(ACC), MIRROR
TAIL RELAY
(4)

0.5
0.5 O/G
A
O/G 0.85
G/R

4 2
MIRROR CONTROL SW
B-55 B-55

LH LV RH RV
B-55 B-55 B-55 B-55 B-55 B-55 B-55
10 8 5 7 1 9 3
0.5
0.3
B/W
R/G
0.5 0.5 0.5 0.5
B/G W/B B/L W/G H
0.5
0.5 0.5
B
B/W B/W
8 6 8 6 18 18 0.5
B ILLUMINATION
H-18 H-18 H-22 H-22 H-18 H-22 CONTROLLER (3)

0.5 0.5 0.5 0.5 0.5 0.5 2.0 2.0 2.0


B/G W/B B/L W/G B/W B/W B B B

B-2 B-26 B-18

B C D E F G

BODY-LH BODY-CTR BODY-RH

D08RW652
0.5 0.5 0.5 0.5
B/G W/B B/L W/G

5 4 5 4
D-12 D-12 D-3 D-3

MIRROR MIRROR
-LH -RH

UP
UP

LEFT
LEFT

RIGHT
RIGHT

DOWN
DOWN

D-12 D-3
6 6

0.5 0.5
B/W B/W

D08RW646
STARTER SW
(IG1)

0.5 3.0
O/G B/Y
C-4 15A
6 ELEC. IGN.
B-56
0.5
L/W
MIRROR
FOLDING SW 0.5
L/W 4

B-57 MIRROR DEFOGGER SW

CLOSE OPEN

I B-56 B-56 B-56 B-56


5 8 7 4 B-57 B-57
0.5 5 3
0.5 0.5
B 0.5
B B 0.5 0.5
GR/G
P/W B
0.5
0.5 7 P/W 7
0.5 I
GR/L GR/G
0.5 H-18 H-22
17 GR/L
16 17 16 0.5 0.5
2.0 P/W P/W
B H-18 H-18 H-22 H-22
3 3

D-12 D-3
0.5 0.5 0.5 0.5
H GR/L GR/L GR/L GR/G
MIRROR MIRROR
2 7 2 7 DEFOGGER DEFOGGER
-LH -RH
D-12 D-12 D-3 D-3

D-12 D-3
8 8
0.5 0.5
B B
5 5

H-18 H-22
0.5 0.5
B B
MIRROR-LH MIRROR-RH 2.0 1.25
B B
B-1 B-18

BODY-LH BODY-RH

D08RY00232
1 2
3

13

12

11

10

4
5
6

9 7
8

D08RWA05
STARTER SW
(ACC)

3.0
L/B
C-11 10A
AUDIO(ACC), MIRROR
TAIL RELAY
(4)

0.5
0.5 O/G
A
O/G 0.85
G/R

4 2
MIRROR CONTROL SW
B-55 B-55

LH LV RH RV
B-55 B-55 B-55 B-55 B-55 B-55 B-55
10 8 5 7 1 9 3
0.5
0.3
B/W
R/G
0.5 0.5 0.5 0.5
B/L W/G B/G W/B H
0.5 0.5
0.5
B/W B
B/W
8 6 8 6 18 18 2.0
B ILLUMINATION
H-22 H-22 H-18 H-18 H-22 H-18 CONTROLLER (3)

0.5 0.5 0.5 0.5 0.5 0.5 2.0 2.0 2.0


B/L W/G B/G W/B B/W B/W B B B

B-18 B-26 B-2

B C D E F G

BODY-LH BODY-CTR BODY-RH

D08RW945
0.5 0.5 0.5 0.5
B/L W/G B/G W/B

5 4 5 4
D-3 D-3 D-12 D-12

MIRROR MIRROR
-LH -RH

UP
UP

LEFT
LEFT

RIGHT
RIGHT

DOWN
DOWN

D-3 D-12
6 6

0.5 0.5
B/W B/W

D08RW088
STARTER SW
(IG1)
A

0.5 3.0
O/G B/Y
C-4 15A
6 ELEC. IGN.
B-56
0.5
L/W
MIRROR
FOLDING SW 0.5
L/W 4

B-57 MIRROR DEFOGGER SW

CLOSE OPEN

I B-56 B-56 B-56 B-56


5 8 7 4 B-57 B-57
0.5 5 3
0.5 0.5
B 0.5
B B 0.5 0.5
GR/G
P/W B
0.5
0.5 7 P/W 7
0.5 I
GR/L GR/G
0.5 H-22 H-18
GR/L
17 16 17 16 0.5 0.5
2.0 P/W P/W
B H-22 H-22 H-18 H-18
3 3

D-3 D-12
0.5 0.5 0.5 0.5
H GR/L GR/G GR/L GR/G
MIRROR MIRROR
2 7 2 7 DEFOGGER DEFOGGER
-LH -RH
D-3 D-3 D-12 D-12

D-3 D-12
8 8
M M 0.5 0.5
B B
5 5

H-22 H-18
0.5 0.5
B B
MIRROR-LH MIRROR-RH 1.25 1.25
B B
B-18 B-1

BODY-LH BODY-RH

D08RY00233
1

12

11
10

8 9

4
6

D08RW380
STARTER SW STARTER SW
(SW) BATT.(+) (ACC) BATT.(+)

3.0 5.0 3.0 5.0


W/G W L/B W
C-1 10A C-16 C-13 C-18 20A
STARTER 10A 10A DOOR LOCK
RELAY CLOCK(B) ANTI
ROOM THEFT
0.5
W/R 2 1.25
H-12 LG/W

0.5 (M/T)
W/L 20
15 H-26
H-10
1.25
W/L 1 1.25
M-25 LG/W

MODE 2
SW 0.5 I-8
(A/T) W/R
ANTI-THEFT
INDICATOR
M-25 0.5 0.5 LIGHT
R/W O/L
4
1.25
W/R
16
H-10 I-8
1.25 1
W/R 4
H-42 0.3
0.5 DOME LG/B
W/R A LIGHT
6
7
X-17 0.5 5 H-26
STARTER L
12 H-21
RELAY
H-15
0.3
0.5 LG/B
X-17 0.5 GR/G
0.5 5 L
L
22 10 18 20 19
A
B-22 B-22 B-22 B-22 B-22

ANTI-THEFT & KEYLESS ENTRY CONTROL UNIT

D08RW704
STARTER SW
STARTER SW
(ST) BATT.(+)
BATT.(+) (ACC)

3.0 5.0 3.0 5.0


W/G W L/B W
C-16 C-13 C-18 20A
C-1 10A
10A 10A DOOR LOCK
STARTER
CLOCK(B) ANTI
RELAY
ROOM THEFT

0.5 1.25
W/R LG/W

2
H-12 20
H-26

0.5
W/R 1.25
LG/W
4
H-42
2
I-8
ANTI-THEFT
0.5
INDICATOR
W/R
0.5 0.5 LIGHT
R/W O/L
1
C-57
STARTER
RELAY I-8
1

C-57
0.3
2 DOME LG/B
0.5 LIGHT
L 7
12 5 H-26
H-15 H-21

0.3
0.5 0.5 LG/B
L GR/G

22 10 18 20 19
B-22 B-22 B-22 B-22 B-22

ANTI-THEFT & KEYLESS ENTRY CONTROL UNIT

D08RW703
BATT.(+) BATT.(+)

5.0
W

FL-1 80A F-11 15A


MAIN ANTI THEFT

5.0 0.85
W G/O

F-3 15A
HORN, HAZARD
0.85 0.85 0.85 0.85
2.0 G/O G/O G/O G/O
G/O
2 5 4 2
0.85 C-19 X-16 X-16 X-16
2.0 G/O ANTI-THEFT ANTI-THEFT
2
G/O HORN RELAY
12 X-8
C-19
H-16 HORN RELAY
1 X-16 X-16 X-16
6 1 3
0.85 0.85
P/B G/B
HAZARD 0.5
X-8 X-8
WARNING SW O/B
(2) 1 3 0.5
G/Y SIDE REAR
0.85 TURN TURN
0.3
G/Y SIGNAL SIGNAL
B/O
LIGHT LIGHT
16 6 17
H-15 HORN H-13 H-15

0.3
B/O 0.5
O/B 0.5
G/Y
0.3
12 B/O
B-12
7 8 21
HORN SW
B-22 B-22 B-22

ANTI-THEFT & KEYLESS ENTRY CONTROL UNIT

D08RY00493
ANTI-THEFT & KEYLESS ENTRY CONTROL UNIT

B-22 B-22 B-22 B-22


17 12 13 16
0.5 0.5
0.5 O/B BR/R
BR/W

13 0.5 0.5
H-7 O/B BR/R
12 16 0.5 0.5 0.5 0.5
0.85 H-32 H-32 O/B BR/R O/B BR/R
B
0.5
BR/W 0.5 0.5 4 1 4 1
O/B BR/R H-22 H-22 H-18 H-18
10 3
1
H-38 H-37
C-20
0.5 0.5 0.5 0.5
0.5 0.5 O/B BR/R O/B BR/R
ENGINE
O/B BR/R
HOOD
1 2 1 2 1 2
SW
G-5 G-5 D-6 D-6 D-16 D-16

TAIL GATE FRT DOOR FRT DOOR


KEY SW KEY SW KEY SW
-RH -LH

DETECT
DETECT
DETECT

TAMPER
TAMPER
TAMPER

G-5 G-5 D-6 D-6 D-16 D-16


3 4 3 4 3 4
0.5 0.5
0.5 0.5 0.5 0.5 B B
B B B B
1.25 1.25
B 0.5 B
B 1.25 1
5
B H-19
H-38
1
1.25
0.5
H-23 B
B

1.25
1.25 2.0 2.0 2.0
B
B B B B

B-19 R-3 B-18 B-2 B-18 B-26

BODY-RH BODY-RR BODY-RH BODY-LH BODY-RH BODY-CTR

D08RW706
ANTI-THEFT & KEYLESS ENTRY CONTROL UNIT

B-22
11

0.5
BR/B
0.5
BR/B
14 0.5 0.5
14 BR/B BR/B
H-32
H-47
9 9
0.5 0.5
BR/B BR/B H-18 H-22
4 0.5 1
BR/B 1
H-38 H-34
H-28 0.5 0.5
0.5 0.5 BR/B BR/B
BR/B 0.5 BR/B
1 2 BR/B 1 4 1 4 1 4 1 4
G-4 G-4 D-21 D-21 D-26 D-26 D-19 D-19 D-9 D-9
TAIL GATE RR DOOR RR DOOR FRT DOOR FRT DOOR
ACTUATOR LOCK LOCK LOCK LOCK
ACTUATOR ACTUATOR ACTUATOR ACTUATOR
-LH -RH -LH -RH
G-4 G-4 D-21 D-21 D-26 D-26 D-19 D-19 D-9 D-9
3 4 3 2 0.5 3 2 3 2 3 2
0.5 0.5 0.5
B B B B
0.5 1.25
B B
1.25 2 1.25 1.25
B H-35 B B
5 2 1 1
H-38 H-29 1.25 H-19 H-23
B 1
0.5 1.25 H-47 1.25
B B B
1.25 1.25
B B
1.25
B 2.0
2.0 2.0 2.0 B
R-3 B B B

B-26 B-18 B-2 B-1 B-18

BODY-RR
BODY-CTR BODY-RH BODY-LH BODY-LH BODY-RH

D08RW707
ANTI-THEFT & KEYLESS ENTRY CONTROL UNIT

B-22 B-22 B-22 B-22 B-22


15 5 1 2 6
0.5 0.5 0.5
GR/W GR/B R/Y
0.5
LG/R
0.5 0.5
LG/R LG/R FRT RR TAIL
0.5 DOOR SW DOOR GATE
LG/L SW SW
0.5
LG/R
0.5 0.5 0.5
LG/L LG/L LG/L

14 15 14 15 7 2 7 2
H-22 H-22 H-18 H-18 H-23 H-23 H-19 H-19

0.3 0.5 0.3 0.5 0.5 0.5 0.5 0.5


LG/L LG LG/L LG L/Y LG/R L/Y LG/R

2 1 2 1
1 2 3 4
D-8 D-8 D-17 D-17
D-30 D-30 D-14 D-14
FRT DOOR FRT DOOR DOOR LOCK DOOR LOCK
LOCK SW-RH LOCK SW-LH KEY SW-RH KEY SW-LH
(FRT DOOR LOCK (FRT DOOR LOCK

LOCK
LOCK
LOCK
LOCK

UNLOCK
UNLOCK
UNLOCK
UNLOCK

& POWER WIN- & POWER WIN-


D-5 DOW SW-RH) D-14 DOW SW-LH)
D-8 D-17
1 7
3 3
0.5
B 0.5
1.25 B
B 1.25
B
1 1

H-23 H-19
1.25
B
1.25
B 2.0 2.0 2.0
B B B

B-18 B-2 B-18 B-26

BODY-RH BODY-LH BODY-RH BODY-CTR

D08RW708
STARTER SW
BATT.(+) BATT.(+) (ACC) BATT.(+) BATT.(+)

5.0 5.0 3.0 5.0 5.0


W W L/B W W

C-16 10A C-18 20A C-13 10A F-3 15A F-11 15A
CLOCK(B) DOOR ANTI-THEFT HORN ANTI-THEFT/
ROOM LOCK
ACC SOCKET
2.0
G/O

0.85 0.85
G/O G/O
2 HORN
X-8 RELAY 0.85 0.85 0.85
G/O G/O G/O

5 4 2
X-16 X-16 X-16
X-8 X-8 ANTI-THEFT
1 3 RELAY
0.3
B/O 0.85
16 G/Y
5.0 1.25 0.5 X-16 X-16 X-16
R/W LG/W O/L H-15 1 6 1 3
0.3 C-19
HORN 0.85 0.85
B/O P/B G/B
ANTI-THEFT
HORN
0.5
0.3 C-19 G/Y
0.3
B/O TURN TURN
B/O 3 2 SIGNAL SIGNAL
B-46 LIGHT LIGHT
0.85 17
DIODE -RH -LH
HORN SW O/B
H-15
6
H-13
B-46
4 0.5
0.3 0.5
O/B
O/B G/Y

0.5
O/B
18 9 3 19 14
B-21 B-20 B-20 B-21 B-21

ANTI-THEFT & KEYLESS ENTRY CONTROL UNIT

D08RY00494
ANTI-THEFT & KEYLESS ENTRY CONTROL UNIT

B-21 B-20 B-20 B-21


25 11 12 20
0.5 0.5
0.5
O/B BR/R
LG/W

20
B-26 0.5 0.5 0.5
BR/R O/B BR/R
13 12 16 0.5 0.5 0.5 0.5
H-32 H-32 O/B BR/R O/B BR/R
H-7
1.25 0.85
LG/W B 4 1 4 1
0.5 0.5
0.5
O/B BR/R H-22 H-22 H-18 H-18
BR/W
2 10 3
1
I-8 H-38 H-37
C-20
ANTI-THEFT 0.5 0.5 0.5 0.5
INDICATOR 0.5 0.5 O/B BR/R O/B BR/R
ENGINE
LIGHT O/B BR/R
HOOD
1 2 1 2 1 2
SW
G-5 G-5 D-6 D-6 D-16 D-16

TAIL GATE FRT DOOR FRT DOOR


I-8 KEY SW KEY SW KEY SW
1 -RH -LH

DETECT
DETECT
DETECT

TAMPER
TAMPER
TAMPER

G-5 G-5 D-6 D-6 D-16 D-16

0.3 3 4 3 4 3 4
LG/B 0.5 0.5 0.5 0.5 0.5 0.5
B B B B B B
7 1.25
0.5 1.25 1.25
H-26 B B
B B
5 1 1
0.3 H-38 H-23 H-19
B
1.25
B
0.5 1.25
1.25 B B
B 2.0
B
B-18 B-19 R-3 B-18 B-1

BODY-RH BODY-RH BODY-RR BODY-RH BODY-LH

D08RW687
ANTI-THEFT & KEYLESS ENTRY CONTROL UNIT

B-21 B-20 B-21 B-20


3 8 4 7

0.5
BR/B
0.5
BR
1.25
LG/B 1.25 0.5 1.25
LG/B BR/B LG/B 0.5 1.25 0.5
5 13 14 13 14 10 1.25
BR/B LG/B BR/B LG/B
H-46 H-32 H-32 H-32 H-47 H-47
9 5 9 5 1.25
0.5 1.25 0.5 1.25 0.5 1.25
LG/B LG/B LG/B H-18 H-19 H-22 H-23 LG
BR/B BR/B BR/B
4 8 1 3 1 3
H-38 H-38 H-28 H-28 H-34 H-34 0.5 1.25 0.5 1.25
BR/B LG/B BR/B LG/B
0.5 1.25 0.5 1.25 0.5 1.25
BR/B LG/B BR/B LG/B BR/B LG/B
1 2 1 4 1 4 1 4 1 4
G-4 G-4 D-21 D-21 D-26 D-26 D-19 D-19 D-9 D-9
TAIL GATE RR DOOR RR DOOR FRT DOOR FRT DOOR
ACTUATOR LOCK LOCK LOCK LOCK
M M ACTUATOR
M ACTUATOR
M ACTUATOR
M ACTUATOR
-LH -RH -LH -RH
G-4 G-4 D-21 D-21 D-26 D-26 D-19 D-19 D-9 D-9
3 4 0.5 3 2 0.5 3 2 0.5 3 2 0.5 3 2
0.5 1.25 B 1.25 B 1.25 B 1.25 B 1.25
B LG LG LG LG LG
1.25 1.25 1.25 1.25
5 2 B 2 6 B 2 6 B 1 3 B 1 3
H-38 H-38 H-29 H-28 H-35 H-34 H-19 H-19 H-23 H-23

1.25 1.25 1.25 1.25 1.25


LG 15 LG 15 B 1 LG 4 B
1.25 1.25 1.25 1.25
0.5 H-32 H-32 H-47 H-47
B LG B LG
B 2.0
1.25 1.25 1.25 1.25 B
LG LG B LG

1.25
2.0 2.0 2.0
B
B B B

R-3 B-2 B-26 B-18 B-1 B-18

BODY-RR BODY-LH BODY-CTR BODY-RH BODY-LH BODY-RH

D08RW688
ANTI-THEFT & KEYLESS ENTRY CONTROL UNIT

B-20 B-20 B-21 B-21


6 2 2 1

0.5
LG/R

0.5
0.5 LG/R
LG/L
0.3
LG/L 0.5
14 15 14 15 O
H-22 H-22 H-18 H-18 0.5 0.5
G 0.5 O
7 2 G 7 2
H-23 H-23 H-19 H-19

0.3 0.5 0.3 0.5


LG/L LG/R LG/L LG/R 0.5 0.5 0.5 0.5
L/Y LG/R L/Y LG/R

2 1 2 1
1 2 3 4
D-8 D-8 D-17 D-17
D-30 D-30 D-14 D-14
FRT DOOR FRT DOOR DOOR LOCK DOOR LOCK
LOCK SW-RH LOCK SW-LH KEY SW-RH KEY SW-LH
(FRT DOOR LOCK (FRT DOOR LOCK

LOCK
LOCK
LOCK
LOCK

UNLOCK
UNLOCK
UNLOCK
UNLOCK

& POWER WIN- & POWER WIN-


D-5 DOW SW-RH) D-14 DOW SW-LH)
D-8 D-17
1 7
3 3
0.5
B 0.5
1.25 B
B
1.25
B
1 1
H-23 H-19

1.25
B
1.25
B 2.0
B

B-18 B-1

BODY-RH BODY-LH

D08RW689
ANTI-THEFT & KEYLESS ENTRY ANTI-THEFT & KEYLESS ENTRY
CONTROL UNIT DOME LIGHT CONTROL UNIT

B-21 B-21 B-21 B-21


26 15 5 17 21
H-21 0.5 0.5
0.5 R/Y O/B
RR DEFOGGER ALARM & RELAY
B/L RELAY(4) CONTROL UNIT 0.5 5 4
FUSE
GR/G 0.5 H-12
3.0 0.5 H-32 C-14
GR/G
B/L 0.5 GR/R
GR/R ALARM & RELAY 0.5 0.85
3.0 CONTROL UNIT O/B G/W
B/L LUGGAGE
2 5 ROOM 7 16
H-47 LIGHT
H-31 16 C-63 C-63
0.5
B-21
0.5 R/Y
3.0 0.5
R/Y C-63 C-63
B/L GR/W
ANTI-THEFT & KEYLESS ENTRY
2 1 CONTROL UNIT 4 5
1
H-37 K-2 0.5 0.5
R-8 B/L B/L
FRT TAIL GATE
3.0 DOOR SW SW
B/L
-RH
1
1.25
G-3
B/L
RR
DEFOGGER 14
H-5

1.0
G-7
B/L
1
3.0
E-30
B
4
H-37
COMMON
CHAMBER
3.0
B

R-3

BODY-RR

D08RW691
2 3
1
36 37
35
34
33 4
32
31 5
30

29
6
28
7
27
8

10

11
12
13
14
15
16
17
26

25
24 18
23 19
22
21
20

D08RW680
STARTER SW STARTER SW
BATT.(+) (ACC) (ST) BATT.(+) BATT.(+)

5.0 3.0 3.0 5.0 5.0


W L/B W/G W W
C-16 C-13 C-110A F-1 15A C-18 20A
10A 10A STARTER RR COOLER/ DOOR LOCK
CLOCK(B) ANTI RELAY ANTI THEFT
ROOM THEFT 1
H-8 0.85
1.25
0.5 (M/T) G/O
LG/W
W/L 15
H-10
1.25 12
W/L 1 0.85 H-26
M-25 G/O

1
MODE A
C-19 1.25
SW 0.5 LG/W
(A/T) W/R
ANTI-THEFT
HORN 0.5
2 W/R
C-19
M-25 I-8 6
4 2
1.25 ANTI-THEFT X-17
B/W INDICATOR STARTER
16
0.5 0.5 LIGHT RELAY
R/W O/L H-10
0.5
O/B
1.25
W/R X-17
4
H-42 5
I-8 0.5
L
0.5 9 1
3
W/R H-15 H-41
0.3
A LG/B 0.5
DOME
LIGHT L
5
1 H-42
5 H-26
0.5 0.5
H-21
O/B L/B
3
0.3 H-15
0.5 LG/B
GR/G 0.5
L
10 18 20 8 19 22
B-22 B-22 B-22 B-22 B-22 B-22

ANTI-THEFT & KEYLESS ENTRY CONTROL UNIT

D08RW920
STARTER SW
STARTER SW
(ST) BATT.(+)
BATT.(+) (ACC)

3.0 5.0 3.0 5.0


W/G W L/B W
C-16 C-13 C-18 20A
C-1 10A
10A 10A DOOR LOCK
STARTER
CLOCK(B) ANTI
RELAY
ROOM THEFT

1.25
LG/W
0.5
W/R
12
H-26

6
H-12 1.25
LG/W

2
I-8
0.5
W/R ANTI-THEFT
INDICATOR
0.5 0.5
LIGHT
R/W O/L

1
C-57
STARTER I-8
RELAY
1

C-57 0.3
LG/B
2 DOME
0.5 LIGHT 1
L
H-26
12 5
H-15 H-21
0.3
0.5 LG/B
0.5
L GR/G

22 10 18 20 19
B-22 B-22 B-22 B-22 B-22

ANTI-THEFT & KEYLESS ENTRY CONTROL UNIT

D08RW709
ANTI-THEFT & KEYLESS ENTRY CONTROL UNIT

B-22 B-22 B-22 B-22


17 12 13 16
0.5 0.5
O/B BR/R
0.5
BR/W

9 0.5 0.5
O/B BR/R
H-8
12 16 0.5 0.5 0.5 0.5
H-32 H-32 O/B BR/R O/B BR/R
0.85
B 0.5 4 1 4 1
0.5 0.5
BR/W
O/B BR/R H-22 H-22 H-18 H-18
10 3
1
H-38 H-37
C-20
0.5 0.5 0.5 0.5
0.5 0.5 O/B BR/R O/B BR/R
ENGINE
O/B BR/R
HOOD
1 2 1 2 1 2
SW
G-5 G-5 D-6 D-6 D-16 D-16

TAIL GATE FRT DOOR FRT DOOR


KEY SW KEY SW KEY SW
-LH -RH

DETECT
DETECT
DETECT

TAMPER
TAMPER
TAMPER

G-5 G-5 D-6 D-6 D-16 D-16


3 4 3 4 3 4
0.5 0.5 0.5 0.5 0.5 0.5
B B B B B B

1.25
0.5 1.25 1.25
B
B B B
5 1 1
H-38 H-23 H-19

0.5
B
1.25 1.25
B B
1.25
B

B-19 R-3 B-18 B-1

BODY-LH BODY-RR BODY-LH BODY-RH

D08RW921
ANTI-THEFT & KEYLESS ENTRY CONTROL UNIT

B-22
11

0.5
BR/B
0.5
BR/B
14 14 0.5 0.5
H-47 BR/B BR/B
H-32

9 9
0.5 0.5
BR/B BR/B H-18 H-22
4 0.5 1
BR/B 1
H-38 H-34
H-28 0.5 0.5
0.5 0.5 BR/B BR/B
BR/B 0.5 BR/B
1 2 BR/B 1 4 1 4 1 4 1 4
G-4 G-4 D-21 D-21 D-26 D-26 D-19 D-19 D-9 D-9
TAIL GATE RR DOOR RR DOOR FRT DOOR FRT DOOR
ACTUATOR LOCK LOCK LOCK LOCK
M M ACTUATOR
M ACTUATOR
M ACTUATOR
M ACTUATOR
-LH -RH -RH -LH
G-4 G-4 D-21 D-21 D-26 D-26 D-19 D-19 D-9 D-9
3 4 3 2 3 2 3 2 3 2
0.5 0.5 0.5 0.5
B B B B
0.5
B 1.25
1.25 1.25 1.25
B
B 2 B B
5 2 1 1
H-35
H-38 H-29 H-19 H-23
1.25
0.5 1.25 B
B B 1
H-47 1.25 1.25
B B
1.25 1.25
B B

R-3 B18 B-1 B-18

BODY-RR BODY-LH BODY-RH BODY-LH

D08RW922
ANTI-THEFT & KEYLESS ENTRY CONTROL UNIT

B-22 B-22 B-22 B-22 B-22


15 5 1 2 6
0.5 0.5 0.5
0.5 GR/W GR/B R/Y
LG/R

0.5 FRT RR TAIL


LG/L DOOR SW DOOR GATE
SW SW
0.5 0.5 0.5 0.5 0.5 0.5
LG/L LG/R LG/L LG/R LG/L LG/R

14 15 14 15 7 2 7 2
H-22 H-22 H-18 H-18 H-23 H-23 H-19 H-19

0.3 0.5 0.3 0.5 0.5 0.5 0.5 0.5


LG/L LG LG/L LG L/Y LG/R L/Y LG/R

2 1 2 1
1 2 3 4
D-8 D-8 D-17 D-17
D-30 D-30 D-14 D-14
FRT DOOR FRT DOOR DOOR LOCK DOOR LOCK
LOCK SW-LH LOCK SW-RH KEY SW-LH KEY SW-RH
(FRT DOOR LOCK (FRT DOOR LOCK

LOCK
LOCK
LOCK
LOCK

UNLOCK
UNLOCK
UNLOCK
UNLOCK

& POWER WIN- & POWER WIN-


D-5 DOW SW-LH) D-14 DOW SW-RH)
D-8 D-17
1 7
3 3
0.5
B 0.5
1.25 B
B
1.25
B
1 1
H-23 H-19

1.25 1.25
B B

B-18 B-1

BODY-LH BODY-RH

D08RW923
38 1 2 3
37 4
5
36

35

34

33
6
32

31

7
30
8

9
10
11

12

13

14

15
18 17 16
29
19

20
28
27
26
25
24
23
22
21

D08RW679
WIRING SYSTEM 8D–401

1. Check to see if the battery voltage is normal.


2. Check to see if the fuse is normal.
3. Replace the anti–theft & keyless entry control unit with one reserved for test. If a trouble recurs even after replacing
the control unit, find out the cause of the trouble by referring to “System check procedure” and the following list.

ITEM MALFUNCTION POSSIBLE CAUSE DETECTING METHOD REMARKS


Defective contact of door switch, With door open, dome light and Burnt out indicator
or open circuit in door switch courtesy light do not come on. light bulb possible.
ANTI–THEFT wiring.
A indicator light
does not flash Short circuit in the detect switch. Check the control unit connector. Refer to “Connector
check table” in this
system.

Engine hood, doors and tailgate Check to see if doors are closed
are not fully closed and locked. and locked.

Defective door switch, or short Dome light and courtesy light


circuit in switch wiring. remain lit on after closing doors.

Defective tamper switch, or short Check the control unit connector. Refer to “Connector
Indicator light circuit in wiring. check table” in this
does not change system.
to fully ON
B
condition, or does Defective lock switch, or short Check the control unit connector. Refer to “Connector
not come on at circuit in wiring. check table” in this
all. system.

Defective engine hood switch, or Check the control unit connector. Refer to “Connector
short circuit in wiring. check table” in this
system.

Defective tailgate switch, or short Luggage room light remains lit


circuit in wiring. after closing tailgate.

ANTI–THEFT Defective control unit.


indicator light
C
does not turn off.
(Steadily on)

Poor contact of lock switch, or Check alarm operation (See No.


open circuit in wiring. 46 of “System check procedure”),
When door is possible cause is a poor contact
opened by pulling of lock switch of an open circuit in
D up locking knob, wiring.
alarm does not
operate Broken wire in wiring to headlight Check to see if headlights go out. Refer to “Connector
and horn, or a blown fuse. Check the control unit connector. check table” in this
system.

Defective contact of detect Check the control unit connector. Refer to “Connector
Alarm does not switch, or damaged switch wiring. check table” in this
E
stop. system.
8D–402 WIRING SYSTEM

ITEM MALFUNCTION POSSIBLE CAUSE DETECTING METHOD REMARKS


Defective contact of detect Check the control unit connector. Refer to “Connector
switch, or damaged switch wiring. check table” in this
Even when door system.
unlocked with
F
key, alarm Door detect switch is assembled When key is turned to lock
operates. to wrong door. position, alarm stops.

Defective contact of tailgate When luggage room light switch


Alarm does not
switch, or defective wiring. is turned on with tailgate open,
G operate even with luggage room light does not
tailgate open. come on.

Even when Defective contact of tailgate Check the control unit connector. Refer to “Connector
tailgate is opened detect switch, or damage wiring. check table” in this
H system.
with key, alarm
does not stop.

Even when Damaged engine hood switch or


engine hood is wiring.
opened with
I
remote release,
alarm does not
operate

Even when Defective contact of starter With starter switch turned to


starter switch is switch. “ACC” position, audio, cigarette
J lighter and door mirrors (on
turned, alarm
does not stop “ACC” circuit) do not operate.

Damaged door switch, or a short After closing door, dome light and
circuit in wiring. courtesy light remain on.
Indicator light
K continues
Damaged tamper switch, or a Check the control unit connector. Refer to “Connector
flashing
short circuit in wiring. check table” in this
system.
WIRING SYSTEM 8D–403

ITEM OF
STEP OPERATION ITEM TO BE CHECKED MALFUNCTION REMARKS

1 Turn starter key to “ON” position. Check to see if engine hood,


tailgate and doors are closed and
2 Open windows fully. locked.

3 Pull out starter key after turning it Check to see if indicator light K
back to “OFF” position. remains lit off.

4 Unlock left front door with locking


knob.

Check to see if indicator light


flashes.
Open left front door. (And get out
5 A
of the vehicle.)
Check to see if dome light and
courtesy light illuminate.

6 Close left front door.


Be sure to lock door
Check to see if indicator light
with locking knob.
7 Lock left front door. changes from flashing to steadily
B
on.

Check to see if indicator light C Activate alarm


8 Wait about 10 seconds
turns off in about 10 seconds. device.

Check to see if alarm operates


Unlock left front door with locking All doors are
9 (with headlight flashing, and horn D
knob. unlocked.
blaring intermittently.)

Insert key into key cylinder of left With key set at unlock
10 front door and turn it in unlock Check to see if alarm stops. E position, check to see
direction. if alarm stops.

Check to see if indicator light All doors are


11 Lock left front door. B
turns on. locked.

Check to see if indicator light Activate alarm


12 Wait for about 10 seconds. C
goes off after about 10 seconds. device.

Check to see if alarm does not


13 Unlock left front door with key. F
operate.

Check to see if indicator light


14 Lock left front door with key. B
turns on.

Check to see if indicator light Activate alarm


15 Wait for about 10 seconds. C
goes off after about 10 seconds. device.

Unlock left rear door with locking Only left rear door
16 Check to see if alarm starts. D
knob. is unlocked.
8D–404 WIRING SYSTEM

ITEM OF
STEP OPERATION ITEM TO BE CHECKED MALFUNCTION REMARKS

With key set at


Insert key into key cylinder of left unlock position,
17 front door and turn it to unlock Check to see if alarm stops. E check to see if
direction. alarm stops. (All
doors are unlocked.)

Check to see if indicator light


flashes.
18 Open left rear door. A
Check to see if dome light and
courtesy light come on.

With one person in vehicle, close


19
left rear door.

Lock left front door with locking Check to see if indicator light is All doors are
20 B
knob. steadily on. locked.

Check to see if indicator light Activate alarm


21 Wait about 10 seconds. C
turns off in about 10 seconds. device.

Unlock tailgate from inside with Only tailgate is


22 Check to see if alarm operates. D
locking knob. unlocked.

With key set at


Open tailgate, insert key into key
unlock position,
23 cylinder of tailgate and turn it in Check to see if alarm stops. H
check to see if
lock direction.
alarm stops.

Check to see if indicator light


A
flashes.
24 Leave tailgate open.
Check to see if luggage room
G
light on.

25 Close tailgate

Insert key into tailgate key Check to see if indicator light


26 cylinder and turn it in lock changes over from flashing into B
direction. lighting condition.

Check to see if indicator light Activate alarm


27 Wait about 10 seconds. C
goes off after about 10 seconds. device.

Check to see if alarm does not


28 Unlock tailgate with key. F
operate.

Check to see if indicator light


29 Lock tailgate with key. B
come on.

Check to see if indicator light Activate alarm


30 Wait about 10 seconds. C
goes off after about 10 seconds. device.
WIRING SYSTEM 8D–405

ITEM OF
STEP OPERATION ITEM TO BE CHECKED MALFUNCTION REMARKS

Unlock right rear door with Only right rear door


31 Check to see if alarm operates. D
locking knob. is unlocked.

With key at unlock


Insert key into key cylinder of position, check to
32 right front door and turn it in Check to see if alarm stops. E see if alarm stops.
unlock direction. (With all doors
unlocked.)

Check to see if indicator light


flashes.
33 Open right rear door. A
Check to see if dome light and
courtesy light come on.

34 Close right rear door.

Insert key into key cylinder of Check to see if indicator light


35 right front door and turn it in lock stays on steadily. B
direction.

Check to see if indicator light Activate alarm


36 Wait about 10 seconds. C
goes off after about 10 seconds. device.

Unlock right front door with Only right front door


37 Check to see if alarm operates. D
locking knob. is unlocked.

With key at unlock


Insert key into key cylinder of position, check to
38 right front door and turn it in Check to see if alarm stops. E see if alarm stops.
unlock direction. (With all doors
unlocked.)

Check to see if indicator light


flashes.
39 Open right front door. A
Check to see if dome light and
courtesy light come on.

40 Close right front door.

Check to see if indicator light


41 Lock right front door with key. B
stays on steadily.

Check to see if indicator light Activate alarm


42 Wait about 10 seconds. C
goes off after about 10 seconds. device.

Check to see if alarm does not


43 Unlock right front door with key. F
operate.

Check to see if indicator light


44 Lock right front door with key. B
stays on steadily.
8D–406 WIRING SYSTEM

ITEM OF
STEP OPERATION ITEM TO BE CHECKED MALFUNCTION REMARKS

Check to see if indicator light Activate alarm


45 Wait about 10 seconds. C
goes off after about 10 seconds. device.

Open engine hood with engine Check to see if alarm operates.


46 I
hood release handle.

Insert key into starter switch and Check to see if alarm stops.
47 J
turn it to “ACC” position.

NOTE: When the connector of the anti–theft & keyless entry control unit is disconnected, the starter is inoperative.
In the checking of short wheel base model, Step Nos. 16 through 21 and Step Nos. 31 through 36 are omitted.
WIRING SYSTEM 8D–407

Check the anti–theft & keyless entry control unit harness side connector B–20 by using a circuit tester.

TERMINAL CHECK CIRCUIT


CONNECTION OPERATION
NO. ITEM CONDITION

Open door Continuity


1 FRT door switch–LH, RH Continuity
Close door No continuity
Open door Continuity
2 RR door switch–LH, RH Continuity
Close door No continuity
3 — — – –

4 Door lock key switch–LH, RH Continuity Lock with key Continuity


5 FRT door lock switch–LH, RH Continuity Lock Continuity
Open tailgate Continuity
6 Tailgate switch Continuity
Close tailgate No continuity
8 Anti–theft horn Voltage – Approx. 12V

10 Battery Voltage – Approx. 12V


Unlock with locking knob Continuity
11 Door switch Continuity
Lock with locking knob No continuity
Open engine hood Continuity
12 Engine hood switch Continuity
Close engine hood No continuity
Unlock with key Continuity
13 Detect switch Continuity
Lock with key No continuity

14 Door lock key switch Continuity Unlock Continuity


15 FRT door lock switch–LH, RH Continuity Unlock Continuity

16 Tamper switch Continuity – No continuity

17 Ground Continuity – Continuity


18 Starter switch Voltage Starter switch “ACC” Approx. 12V
19 Indicator light Voltage – Approx. 12V
20 Dome light Voltage Dome light “DOOR” position Approx. 12V

21 Anti-theft relay Voltage – Approx. 12V


Mode switch “P” or “N” Approx. 12V
22 Starter relay Voltage
Clutch pedal depressed Approx. 12V
8D–408 WIRING SYSTEM

There are four kinds of ID codes which can be registered,


for which these three modes, ID code new registration, ID
code additional registration and ID code check, are
available.

This procedure erases all registered ID codes and


registers a new received ID code instead.

Step Action Yes No


1 1. Open the driver’s side door.
2. Turn the starter switch off.
Is the action complete? Go to Step 2 —
2 Turn the starter switch to ACC position and then off three times
within five seconds after step 1.
Is the action complete within five seconds? Go to Step 3 Finished
3 Close the door and then open it two times within ten seconds after
step 2.
Is the action complete within ten seconds? Go to Step 4 Finished
4 1. Turn the starter switch to ACC position and then off five times.
2. Close the door and then open it.
NOTE: This step must be performed within ten seconds after step
3.
Is the action complete? Go to Step 5 Finished
5 The control unit makes lock/unlock response once with interval of
one second.
Is the response complete? Go to Step 6 —
6 Operate the lock or unlock button of transmitter within twenty
seconds after step 5.
Is the action complete? Go to Step 7 Finished
7 The control unit makes lock/unlock response once with interval of
one second as ID temporary registration.
Is the response complete? Go to Step 8 —
8 Operate the lock or unlock button of transmitter within twenty
seconds after step 7.
Is the action complete? Go to Step 9 Finished
9 The control unit compares temporary registered ID code with
receiving ID code.
Is temporary registered ID code the same as receiving ID code? Go to Step 11 Go to Step 11
10 The control unit makes lock/unlock response three times with
interval of one second.
Is the response complete? Finished —
11 The control unit erases all registered ID codes and registers new
ID code.
Is the registration complete? Go to Step 12 Go to Step 13
WIRING SYSTEM 8D–409

Step Action Yes No


12 The control unit makes lock/unlock response once with interval of
one second.
Is the response complete? Finished —
13 The control unit makes lock/unlock response three times with
interval of one second.
Is the response complete? Finished —

This procedure additionally registers a new received ID


code with holding registered ID codes. When total
number of registered ID codes and newly registered ID
code exceeds four, they are erased in order of older one.
Step Action Yes No
1 1. Open the driver’s side door.
2. Turn the starter switch off.
Is the action complete? Go to Step 2 —
2 Turn the starter switch to ACC position and then off three times
within five seconds after step 1.
Is the action complete within five seconds? Go to Step 3 Finished
3 Close the door and then open it two times within ten seconds after
step 2.
Is the action complete within ten seconds? Go to Step 4 Finished
4 1. Turn the starter switch to ACC position and then off three
times.
2. Close the door and then open it.
NOTE: This step must be performed within ten seconds after step
3.
Is the action complete? Go to Step 5 Finished
5 The control unit makes lock/unlock response two times with
interval of one second.
Is the response complete? Go to Step 6 —
6 Operate the lock or unlock button of transmitter within twenty
seconds after step 5.
Is the action complete? Go to Step 7 Finished
7 The control unit makes lock/unlock response two times with
interval of one second as ID temporary registration.
Is the response complete? Go to Step 8 —
8 Operate the lock or unlock transmitter within twenty seconds after
step 7.
Is the action complete? Go to Step 9 Finished
9 The control unit compares temporary registered ID code with
receiving ID code.
Is temporary registered ID code the same as receiving ID code? Go to Step 11 Go to Step 10
10 The control unit makes lock/unlock response three times with
interval of one second.
Is the response complete? Finished —
11 The control unit registers new ID code.
Is the registration complete? Go to Step 12 Go to Step 13
8D–410 WIRING SYSTEM

Step Action Yes No


12 The control unit makes lock/unlock response once with interval of
one second.
Is the response complete? Finished —
13 The control unit makes lock/unlock response three times with
interval of one second.
Is the response complete? Finished —

This procedure checks how many kinds of ID code are


registered.
Step Action Yes No
1 1. Open the driver’s side door.
2. Turn the starter switch off.
Is the action complete? Go to Step 2 —
2 Turn the starter switch to ACC position and then off three times
within five seconds after step 1.
Is the action complete within five seconds? Go to Step 3 Finished
3 Close the door and then open it two times within ten seconds after
step 2.
Is the action complete within ten seconds? Go to Step 4 Finished
4 1. Turn the starter switch to ACC position and then off.
2. Close the door and then open it.
NOTE: This step must be performed within ten seconds after step
3.
Is the action complete? Go to Step 5 Finished
The control unit makes lock/unlock response twice as many the
5 number of registered ID code with interval of two seconds. (In case
of no registered code, the response is made ten times.)
Is the response complete? Finished —

Anti–theft horn, as an answer back function for the


transmitter operation, changes from available into
unavailing or from unavailing into available by this
procedure.

Step Action Yes No


1 Open the driver’s side door.
Is the action complete? Go to Step 2 —
2 Lock the door and then unlock it three times within ten seconds
after step 1.
Is the action complete within five seconds? Go to Step 3 Finished
3 Close the door and then open it two times within ten seconds after
step 2.
Is the action complete within ten seconds? Go to Step 4 Finished
WIRING SYSTEM 8D–411

Step Action Yes No


4 1. Lock the door and unlock it three times.
2. Close the door and then open it.
NOTE: This step must be performed within ten seconds after step
3.
Is the action complete? Go to Step 5 Finished
5 Answer back mode changes.
Is this step complete? Go to Step 6 Go to Step 7
6 The control unit makes lock/unlock response once with interval of
one second.
Is the response complete? Finished —
7 The control unit makes lock/unlock response three times with
interval of one second.
Is the response complete? Finished —

1. Remove and install the control unit.


Refer to Anti–theft & Keyless Entry Control Unit
Removal and Installation in this section.
2. Register ID code.
Refer to ID Code Registration in this section.
3. Check that the keyless entry system works normally.

1. Prepare a new transmitter.


2. Register ID code.
Refer to ID Code Registration in this section.
3. Check that the keyless entry system works normally.

1. Remove a screw to remove the cover.


2. Remove the batteries.
3. Set the new batteries into the transmitter.
4. Install the cover to the transmitter.
5. Check that the keyless entry system works normally.
8D–412 WIRING SYSTEM

Programing With Tech 2 (SOUTH AFRICA)


General Description
When the anti-theft and keyless entry control unit and / or
the transmitters (remote keys) are replaced, the security
codes and / or transmitter ID codes must be programed
by using the Tech 2. The following pages show the
procedures to program in regard to the anti-theft and
keyless entry system. Please refer to Tech 2 scan tool
user`s guide in detail.

3
4

901RW180

Legend (3) SAE 16/19 Adaptor


(1) PCMCIA Card (4) DLC Cable
(2) RS 232 Loop Back Connector (5) Tech 2
WIRING SYSTEM 8D–413

Programing Anti-Theft Warning Programing Remote Key


When the anti-theft and keyless entry control unit is When the anti-theft and keyless entry control unit is
replaced, the security code must be programed after replaced and / or the new transmitter (remote key) is
installation. supplied, the ID code of the transmitter must be
1. Insert the Isuzu system PCMCIA card into the Tech 2. programed by the following procedure.
2. Connect the SAE 16/19 adaptor to the data link 1. Perform the step 1. to 15. of " Programing Anti Theft
connector (DLC) cable. Warning ".
3. Connect the DLC cable to the Tech 2. 2. Select " F1 : Program Remote Key " and press the
4. Confirm that the starter switch is off. enter key.
5. Connect the Tech 2 SAE 16/19 adaptor to the vehicle 3. Press the confirm key (soft key).
DLC. 4. Press the lock button of the transmitter until the
6. Verify the Tech 2 power up display. display changes.
5. Press the confirm key (soft key).
6. Press the Yes or No key (soft key).

Erasing Remote Keys


All the ID code stored in the control unit can be erased by
the following procedure.
1. Perform the step 1. to 15. of " Programing Anti Theft
Warning ".
2. Select " F0 : Erase Remote Keys " and press the enter
key.
3. Press the confirm key (soft key).
4. Press the confirm key (soft key).
Press (ENTER) To Continue 5. Press the confirm key (soft key).

060RW009

7. Press the enter key.


8. Select " F0 : Diagnostics " and press the enter key.
9. Select the model year and press the enter key.
10. Select the vehicle type and press the enter key.
11. Select " F2 : Body " and press the enter key.
12. Select " Anti Theft Warning " and press the enter key.
13. Turn the starter switch on and press the confirm key
(soft key).
14. Confirm " Partnumber " , " Country Code " and "
Production Date " and press the confirm key (soft key).
15. Select " F4 : Programing " and press the enter key.
16. Select " F2 : Program Anti Theft Warning " and press
the enter key.
17. Press the confirm key (soft key).
18. Press the confirm key (soft key).
19. Enter the security code and press the enter key.
20. Press the okey key (soft key).
21. Enter the security code and press the enter key.
22. Press the okey key (soft key).
23. Press the soft key to select " Remote Key ".
24. Select country code and press the enter key.
25. Press the confirm key (soft key).
B FUSE C-15
0.5
R/W
8
I-10 METER

0.5 C
L/Y ENGINE
OIL
SPEEDO- COOLANT FUEL
TACHOMETER PRESSURE
METER TEMPERATURE GAUGE
GAUGE
GAUGE

3
H-9

RESET ODO/TRIP
SW METER

0.5
D
L/Y

I-10 I-9 I-10 I-10 I-10


5 9 4 20 19
9 0.5
LG/W 0.5 0.5 0.5 0.5
H-10 12 B/R Y/R
Y/B Y/B
H-9
15 1 14 17
0.5 H-9 H-24 H-25 H-9
LG/W
0.5 11 0.5
LG/W 0.5 0.5
L/Y H-10 I
0.5 2 Y/B Y/V
LG/W PCM
0.5 H-8 11 10
(C10)
LG/W 3 H-6 H-6
1
M-10 M-10
PCM CRUISE CONTROL 0.5 0.5
VEHICLE (D7) UNIT(9) Y/B Y/G
A
SPEED SENSOR
1 1
0.5 M-10 E-19 E-2
B/R
10 2 ENGINE
0.5 OIL
H-42 B/R
COOLANT
4 TEMPERATURE PRESSURE
0.5 H-10 UNIT UNIT
B/R
3
C-39
A

FENDER-RH

D08RW722
STARTER SW MIL:MALFUNCTION INDICATOR LIGHT
(IG1)

3.0
B/Y
C-10 10A
METER, GAUGE

0.5
L/Y

B
0.5
L/Y
6
H-26

0.5
L/Y
15
I-9 METER

C E

VOLT CHECK A/T OIL


FUEL MIL POWER WINTER
METER TRANS. TEMP.

I-9 I-10 I-9 I-9 I-9 I-9 I-9


19 18 5 25 21 3 1
0.85 0.3 0.5 0.5 0.5 0.5 0.5
B/P Y/G V P/W P/G O/B O/L
18 15 10 2 4 16 5
H-16 H-25 H-9 H-9 H-9 H-9 H-24

0.85
B/P
PCM PCM PCM PCM PCM
5 (A13) (A11) (A10) (A14) (A9)
C-39 J

FENDER-RH

D08RW723
EHCU:ELECTRONIC HYDRAULIC CONTROL UNIT

METER

E F

CRUISE CRUISE OIL


AIR BAG ABS 4WD BRAKE
SET MAIN PRESSURE

I-9 I-9 I-9 I-10 I-9 I-9 I-9


16 17 24 16 18 22 4
0.5 0.5 0.5 0.5 0.5 0.5 0.5
B/O GR/L W/R Y LG LB B/P 0.5
14 15 2 2 19 22 9 B/P 13
H-26 H-26 H-62 H-16 H-27 H-9 H-16 H-26

0.5 0.5 0.5


LB B/P B/P
CRUISE CRUISE SDM EHCU 4WD
CONTROL CONTROL (7) (16) CONTROL 12 2 1
UNIT(14) UNIT(13) UNIT(19)/ H-6 C-15 B-27
FRT
AXLESW(2) BRAKE PARKING
OR 0.5 FLUID BRAKE
4WDSW(1) LB SW SW
1
C-15
E-1
1

OIL PRESSURE 0.5


SW B
8
C-39

FENDER-RH

D08RW725
TAIL RELAY TURN SIGNAL/ REAR
(4) LIGHT SW FOG LIGHT

14 10 6 1
H-16 H-27 H-27 H-27

0.85 0.85 0.85 0.5


G/R G/B P/B BR/Y
7 28 1 10
METER I-9 I-9 I-10 I-10

ODO/ REAR
TURN TURN FOG
CHARGE TRIP METER
-LH -RH LIGHT
METER

I-9 I-9 I-9


6 8 30
0.85 0.5 0.3
W/G R/G B
10
H-16
1.25
ILLUMINAITON B
0.85 CONTROLLER(3)
W/G 20
1 H-27
H-3

1.25
AC GENERATOR
B
(L)

B-19

BODY-RH

D08RW727
FUSE F-4
I J

13 18
H-16 (SOUTH AFRICA)
H-46

0.85 0.5
R/L Y/R
15 13 7
I-10
H-33 H-33

0.5 0.5
Y/R Y/R
2 2
HIGH
BEAM F-5 F-5
FUEL FUEL
TANK TANK
UNIT UNIT

I-10
14
0.85
R/Y 0.3
Y/G
9
H-9

DIMMER•
PASSING F-5 F-5 F-5 F-5
SW
1 4 1 4
0.3 0.3
Y/BR Y/BR
0.5 14 9
0.5
B/P H-33 H-33
B/P

0.3 0.3
12 Y/BR Y/BR
H-33 17 19 17
H-46 H-33 H-46
0.5
B 0.3
Y/BR
7 6
1.25 B-6 B-7
B
ALARM&RELAY
R-4 CONTROL UNIT

BODY-RR

D08RW729
STARTER SW
(ACC)

3.0
L/B
TAIL RELAY
C-11 10A (4)
AUDIO(ACC), MIRROR

0.5 0.5
O/G G/R
3 1
H-21 H-21

0.5 0.5
O/G G/R
3 1
L-5 L-5

MULTI METER

L-5 L-5 L-5


4 5 6
(W/O SUNROOF)
0.5 0.5
P/L P/G 0.85
2 8 B
0.5
H-21 H-21
B
2.0
B
0.5 0.5 4 4
P/L P/G
H-21 H-21
8 3
H-7 H-7

0.5 0.5 2.0 2.0


P/L P/G B B
1 2
C-9 C-9

B-2 B-2

AMBIENT TEMPERATURE BODY-LH BODY-LH


SENSOR

D08RW730
B FUSE C-15
0.5
R/W
8
I-10 METER

0.5 C
L/Y ENGINE
SPEEDO- COOLANT FUEL
METER TACHOMETER
TEMPERATURE GAUGE
GAUGE

3
H-9

RESET ODO/TRIP
SW METER

0.5
D
L/Y

I-10 I-9 I-10 I-10


5 9 9 20
9 0.5
LG/W 0.5 0.5 0.5
H-10 12 B/R Y/R
Y/B
H-9
15 1 14
0.5 H-9 H-24 H-25
LG/W
0.5 11 0.5
LG/W 0.5
L/Y H-10 0.5 I
2 Y/B
LG/W PCM
0.5 H-8 11
(C10)
LG/W 3 H-6
1
M-10 M-10
PCM CRUISE CONTROL 0.5
VEHICLE (D7) UNIT(9) Y/B
A
SPEED SENSOR
1
0.5 M-10 E-19
B/R
10 2 ENGINE
0.5
COOLANT
H-42 B/R
4 TEMPERATURE
0.5 H-10 UNIT
B/R
3
C-39
A

FENDER-RH

D08RW731
STARTER SW MIL:MALFUNCTION INDICATOR LIGHT
(IG1)

3.0
B/Y
C-10 10A
METER, GAUGE

0.5
L/Y

B
0.5
L/Y
6
H-26

0.5
L/Y
26
I-9 METER

C E

CHECK A/T OIL


FUEL MIL POWER WINTER
TRANS. TEMP.

I-10 I-10 I-10 I-9 I-9 I-9 I-9


21 18 4 29 28 6 3
0.85 0.3 0.5 0.5 0.5 0.5 0.5
B/P Y/G V P/W P/G O/B O/L
18 15 10 2 4 16 5
H-16 H-25 H-9 H-9 H-9 H-9 H-24

0.85
B/P J
PCM PCM PCM PCM PCM
5 (A13) (A11) (A10) (A14) (A9)
C-39

FENDER-RH

D08RW732
EHCU:ELECTRONIC HYDRAULIC CONTROL UNIT

METER

E F

CRUISE CRUISE OIL


AIR BAG ABS BRAKE
SET MAIN PRESSURE

I-9 I-9 I-9 I-10 I-9 I-9


18 19 2 16 20 7
0.5 0.5 0.5 0.5 0.5 0.5
B/O GR/L W/R Y LB B/P 0.5
14 15 2 2 22 9 B/P 13
H-26 H-26 H-62 H-16 H-9 H-16 H-26

0.5 0.5 0.5


LB B/P B/P
CRUISE CRUISE SDM EHCU
CONTROL CONTROL (7) (16) 12 2 1
UNIT(14) UNIT(13) H-6 C-15 B-27

BRAKE PARKING
0.5 FLUID BRAKE
LB SW SW
1
C-15
E-1
1

OIL PRESSURE 0.5


SW B
8
C-39

FENDER-RH

D08RW733
TAIL RELAY TURN SIGNAL/CORNERING
(4) LIGHT SW FUSE F-4

14 10 6 13
H-16 H-27 H-27 H-16

0.85 0.85 0.85 0.85


G/R G/B P/B R/L
24 11 1 15
METER I-9 I-9 I-10 I-10

F
HIGH
BEAM
ODO/
TURN TURN
CHARGE TRIP METER
-LH -RH
METER

I-9 I-9 I-10 I-10


4 25 10 14
0.85 0.5 0.3 0.85
W/G R/G B R/Y
10 9
H-16 H-9
1.25
ILLUMINAITON B
0.85 CONTROLLER(3)
W/G 20
DIMMER•
1 H-27
PASSING
H-3 SW

1.25
AC GENERATOR
B
(L)

B-19

BODY-RH

D08RW735
FUSE F-4
I J

13 18
H-16 (SOUTH AFRICA)
H-46

0.85 0.5
R/L Y/R
15 13 7
I-10
H-33 H-33

0.5 0.5
Y/R Y/R
2 2
HIGH
BEAM F-5 F-5
FUEL FUEL
TANK TANK
UNIT UNIT

I-10
14
0.85
R/Y 0.3
Y/G
9
H-9

DIMMER•
PASSING F-5 F-5 F-5 F-5
SW
1 4 1 4
0.3 0.3
Y/BR Y/BR
0.5 14 9
0.5
B/P H-33 H-33
B/P

0.3 0.3
12 Y/BR Y/BR
H-33 17 19 17
H-46 H-33 H-46
0.5
B 0.3
Y/BR
7 6
1.25 B-6 B-7
B
ALARM&RELAY
R-4 CONTROL UNIT

BODY-RR

D08RW729
STARTER SW
(ACC)

3.0
L/B
TAIL RELAY
C-11 10A (4)
AUDIO(ACC), MIRROR

0.5 0.5
O/G G/R
3 1
H-21 H-21

0.5 0.5
O/G G/R
3 1
L-5 L-5

MULTI METER

L-5 L-5 L-5


4 5 6
(W/O SUNROOF)
0.5 0.5
P/L P/G 0.85
2 8 B
0.5
H-21 H-21
B
2.0
B
0.5 0.5 4 4
P/L P/G
H-21 H-21
8 3
H-7 H-7

0.5 0.5 2.0 2.0


P/L P/G B B
1 2
C-9 C-9

B-2 B-2

AMBIENT TEMPERATURE BODY-LH BODY-LH


SENSOR

D08RW730
FUSE C-15
0.5
R/W
8
I-10 METER

0.5
L/Y ENGINE
OIL
SPEEDO- COOLANT FUEL
TACHOMETER PRESSURE
METER TEMPERATURE GAUGE
GAUGE
GAUGE

H-9

RESET ODO/TRIP
SW METER

0.5
L/Y

I-10 I-9 I-10 I-10 I-10


5 9 4 20 19
16 0.5 0.5
LG/W BR 0.5 0.5 0.5
H-5 12 Y/R
15 Y/B Y/B
H-9 H-9 1 14 17
0.5 0.5 H-24 H-25 H-9
LG/W BR
0.5 15 6
0.5 0.5
Y H-5 0.3 0.3 H-4 Y/B Y/V
LG/W LG/W
0.5 0.5 4 2 3
LG/W 3 BR H-5 H-5 H-5
1 1
E-20 E-20 E-36
QOS-III QOS/EGR 0.5 0.5 0.5
VEHICLE CONTROL CONTROL TACHO Y/B Y/V LB
SPEED SENSOR UNIT UNIT SENSOR 1 1 2
(9) (16)
0.5 E-20 E-19 E-2 E-2
B/R
10 2 ENGINE
0.5 0.5 OIL
H-41 E-36 BP
COOLANT
B PRESSURE
14 2 4 TEMPERATURE
0.5 H-5 0.5 UNIT UNIT
H-42
B/R BP
6 10 0.5
C-39 H-4 BP
6
C-39

FENDER-RH

FENDER-RH

D08RW738
STARTER SW
(IG1) EHCU : ELECTRONIC HYDRAULIC UNIT

3.0
B/Y
C-10 10A
METER, GAUGE

0.5
L/Y

B
0.5
L/Y
6
H-26

0.5
L/Y
15
I-9 METER

D H

VOLT OIL
FUEL GLOW AIR BAG ABS
METER PRESSURE

I-9 I-9 I-10 I-9 I-9 I-10


19 22 18 26 24 16
0.5 0.3 0.5 0.5 0.5
0.85
LB Y/G P/W W/R Y
B/P
22 15 14 2 2
18
H-9 H-25 H-9 H-62 H-16
H-16

0.85 G I
B/P QOS/EGR CONTROL SDM EHCU
UNIT(5) (7) (16)
4 QOS III CONTROL
C-39 UNIT(13)

FENDER-RH

D08RY00427
METER

4WD SEDIMENTER BRAKE

I-9 I-9 I-9


18 23 4
0.5 0.5 0.5
LG V B/P
0.5
19 7 9
B/P
H-27 H-9 H-16 13
H-26
0.5
0.3 B/P 0.85 0.5
V
0.5 0.5 0.5 B/P 1 B/P
2 2 1
LG LG LG C-68
C-67 C-15 B-27

4WD FRT AXLE 4WD FUEL BRAKE VACUUM PARKING


SW(1) SW(2) CONTROL FILTER FLUID SW BRAKE
UNIT(19) SW SW SW

C-67 C-15
1 1

0.5 0.5
B B
2 8
C-16 C-39

FENDER-L H FENDER-RH

D08RY00428
TAIL RELAY
(4) TURN SIGNAL LIGHT SW

14 10 6
H-16 H-27 H-27

0.85 0.85 0.85


G/R G/B P/B
7 28 1
METER I-9 I-9 I-10

ODO/
TURN TURN
CHARGE TRIP METER
-LH -RH
METER

I-9 I-9 I-9


6 8 30
0.85 0.5
W/G R/G 0.3
B
10
H-16
ILLUMINAITON
0.85 CONTROLLER(3)
W/G
1.25
B

CHARGE
RELAY 20
(1) H-27

1.25
B

B-19

BODY-RH

D08RW740
FUSE F-4
F I

13
18
H-16
H-46
0.85
0.5
R/L
15 Y/R 13
I-10 H-33
0.5
Y/R
2
HIGH
BEAM F-5
FUEL
TANK
UNIT

I-10
14
0.85 0.3
R/Y Y/G

9
H-9

DIMMERꞏ
PASSING F-5 F-5
SW 1 4
0.3
Y/BR
14
0.5 H-33
B/P
0.3
Y/BR
12 17
H-33 H-46

0.3
0.5
Y/BR
B 7 6
B-6 B-7

1.25 ALARM & RELAY


B CONTROL UNIT

R-4

BODY-RR

D08RW741
STARTER SW
(ACC)

3.0
L/B
TAIL RELAY
C-11 10A (4)
AUDIO(ACC), MIRROR

0.5 0.5
O/G G/R
3 1
H-21 H-21

0.5 0.5
O/G G/R
3 1
L-5 L-5

MULTI METER

L-5 L-5 L-5


4 5 6
(W/O SUNROOF)
0.5 0.5
P/L P/G 0.85
2 8 B
0.5
H-21 H-21
B
2.0
B
0.5 0.5 4 4
P/L P/G
H-21 H-21
8 3
H-7 H-7

0.5 0.5 2.0 2.0


P/L P/G B B
1 2
C-9 C-9

B-2 B-2

AMBIENT TEMPERATURE BODY-LH BODY-LH


SENSOR

D08RW730
1 2
27
26
25
24
23
22 3

21

20

19

4
18

8
17
9

16 10
15
14 11

13 12

D08RW747
1 2
27
26
25

24
23 3

22

21

20

4
19

18 8
9
17
10
16 15
14
13
12
11

D08RW748
B FUSE C-15
0.5
R/W
8
I-10 METER

0.5 C
L/Y ENGINE
OIL
SPEEDO- COOLANT FUEL
TACHOMETER PRESSURE
METER TEMPERATURE GAUGE
GAUGE
GAUGE

5
H-24

RESET ODO/TRIP
SW METER

0.5
D
L/Y

I-10 I-9 I-10 I-10 I-10


5 9 4 20 19
9 0.5
LG/W 0.5 0.5 0.5 0.5
H-10 14 B/R Y/R
Y/B Y/B
H-9
18 1 13 12
0.5 H-9 H-9 H-26 H-9
LG/W
0.5 11 0.5
LG/W 0.5 0.5
L/Y H-10 0.5 I
8 Y/B Y/B
LG/W PCM
0.5 H-8 11 10
(C10)
LG/W 3 H-6 H-6
1
M-10 M-10
PCM CRUISE CONTROL 0.5 0.5
VEHICLE (D7) UNIT(9) Y/B Y/G
A
SPEED SENSOR
1 1
0.5 M-10 E-19 E-2
B/R
10 2 ENGINE
0.5 OIL
COOLANT
H-42 B/R PRESSURE
4 TEMPERATURE
0.5 H-10 UNIT UNIT
B/R
8
C-39
A

FENDER-RH

D08RW924
STARTER SW MIL:MALFUNCTION INDICATOR LIGHT
(IG1)

3.0
B/Y
C-10 10A
METER, GAUGE

0.5
L/Y

B
0.5
L/Y
10
H-25

0.5
L/Y
15
I-9 METER

C E

VOLT CHECK A/T OIL


FUEL MIL POWER WINTER
METER TRANS. TEMP.

I-9 I-10 I-9 I-9 I-9 I-9 I-9


19 18 5 25 21 3 1
0.85 0.3 0.5 0.5 0.5 0.5 0.5
B/P Y/G V GR/W P/G O/B O/L
1 9 3 9 2 3 11
H-16 H-25 H-9 H-24 H-24 H-24 H-24

0.85
B/P J
PCM PCM PCM PCM PCM
3 (A13) (A11) (A10) (A14) (A9)
C-39

FENDER-RH

D08RW925
EHCU:ELECTRONIC HYDRAULIC CONTROL UNIT

METER

E F

CRUISE CRUISE SEAT OIL


AIR BAG ABS 4WD BRAKE
SET MAIN BELT PRESSURE

I-9 I-9 I-9 I-9 I-10 I-9 I-9 I-9


16 17 24 2 16 18 22 4
0.3
0.3 0.3 0.5 0.5 0.5 0.5 0.5
L
B/O GR/L W/R Y LG LB B/P 0.5
11
13 12 2 18 22 16 17 B/P 15
H-25
H-48 H-48 H-62 H-16 H-25 H-9 H-9 H-25
0.5
L 0.5 0.5 0.5
1
LB B/P B/P
CRUISE CRUISE SDM EHCU 4WD
B-62 12 2 1
CONTROL CONTROL (7) (16) CONTROL
UNIT(14) UNIT(13) SEAT UNIT(19)/ H-6 C-15 B-27
FRT AXLE
BELT
SW(2) BRAKE PARKING
SW OR 0.5 FLUID BRAKE
4WD SW(1) LB SW SW
B-62 1
C-15
2 E-1
0.5 1
B
OIL PRESSURE 0.85
2.0 2.0 2.0 SW B
B B B 2
B-26 B-18 B-2 C-16

BODY-CTR BODY-LH BODY-RH FENDER-LH

D08RY00429
TAIL RELAY TURN SIGNAL/CORNERING
(4) LIGHT SW

13 20 19
H-16 H-25 H-25

0.85 0.85 0.85


G/R G/B P/B
7 28 1
METER I-9 I-9 I-10

ODO/
TURN TURN
CHARGE TRIP METER
-LH -RH
METER

I-9 I-9 I-9


6 8 30
0.85 0.5 0.3
W/G R/G B
5
H-16
2.0
ILLUMINAITON B
0.85 CONTROLLER(3)
W/G 15
1 H-48
H-3

2.0
AC GENERATOR B
(L)

B-2

BODY-RH

D08RW927
FUSE F-4
I J

12 18
H-16 H-46

0.85 0.5
R/Y Y/R
14 13
I-10
H-33

0.5
Y/R
2
HIGH
BEAM F-5
FUEL
TANK
UNIT

I-10
15

0.3
Y/G

0.85
R/L

F-5 F-5
1 4
10 0.3
Y/BR
H-16 14
0.5
B/P H-33

0.3
12 Y/BR
H-33 17
H-46
0.5
B 0.5
B 0.3
Y/BR
7 6
1.25 B-6 B-7
B
4 ALARM&RELAY
C-39 R-4 CONTROL UNIT

FENDER-RH BODY-RR

D08RW928
STARTER SW
(ACC)

3.0
L/B
TAIL RELAY
C-11 10A (4)
AUDIO(ACC), MIRROR

0.5 0.5
O/G G/R
3 1
H-21 H-21

0.5 0.5
O/G G/R
3 1
L-5 L-5

MULTI METER

L-5 L-5 L-5


4 5 6
(W/O SUNROOF)
0.5 0.5
P/L P/G 0.85
2 8 B
0.5
H-21 H-21
B
2.0
B
0.5 0.5 4 4
P/L P/G
H-21 H-21
11 20
H-7 H-7

0.5 0.5 2.0 2.0


P/L P/G B B
1 2
C-9 C-9

B-1 B-1

AMBIENT TEMPERATURE BODY-RH BODY-RH


SENSOR

D08RW929
FUSE C-15
0.5
R/W
8
I-10 METER

0.5
L/Y ENGINE
OIL
SPEEDO- COOLANT FUEL
TACHOMETER PRESSURE
METER TEMPERATURE GAUGE GAUGE
GAUGE

5
H-24

RESET ODO/TRIP
SW METER

0.5
L/Y

I-10 I-9 I-10 I-10 I-10


5 9 4 20 19
16 0.5 0.5
LG/W BR 0.5 0.5 0.5
H-5 14 Y/R
18 Y/B Y/B
H-9 H-9 1 13 12
0.5 0.5 H-9 H-26 H-9
LG/W BR
0.5 15 6
0.5 0.5
Y H-5 0.3 0.3 H-4 Y/B Y/V
LG/W LG/W
0.5 0.5 4 2 3
LG/W 3 BR H-5 H-5 H-5
1 1
E-20 E-20 E-36
QOS-III QOS/EGR 0.5 0.5 0.5
VEHICLE CONTROL CONTROL TACHO Y/B Y/V LB
SPEED SENSOR UNIT UNIT SENSOR 1 1 2
(9) (16)
0.5 E-20 E-19 E-2 E-2
B/R
10 2 ENGINE
0.5 0.5 OIL
H-41
E-36 BP
COOLANT
B PRESSURE
14 2 4 TEMPERATURE
0.5 H-5 0.5 UNIT UNIT
H-42
B/R BP
8 10 0.5
C-39 H-4 BP
7
C-39

FENDER-RH

FENDER-RH

D08RW915
STARTER SW
EHCU : ELECTRONIC HYDRAULIC UNIT
(IG1)

3.0
B/Y
C-10 10A
METER, GAUGE

0.5
L/Y

B
0.5
L/Y
10
H-25

0.5
L/Y
15
I-9 METER

D H

VOLT OIL
FUEL GLOW AIR BAG ABS
METER PRESSURE

I-9 I-9 I-10 I-9 I-9 I-10


19 22 18 26 24 16
0.85 0.5 0.3 0.5 0.5 0.5
B/P LB Y/G P/W W/R Y
1 16 9 1 2 18
H-16 H-9 H-25 H-24 H-62 H-16

0.85
B/P G I
QOS/EGR SDM EHCU
6 CONTROL (7) (16)
C-39 UNIT(5)

FENDER-RH

D08RY00430
EHCU:ELECTRONIC HYDRAULIC CONTROL UNIT

METER

SEAT 4WD SEDIMENTER BRAKE


BELT

I-9 I-9 I-9 I-9


0.3 2 18 23 4
L 11 0.5 0.5 0.5
H-25 LG V B/P
0.5
0.5 22 20 17
B/P
L 1 H-25 H-9 H-9 15
B-62 H-25
0.5
0.3 B/P
SEAT 0.85 0.5
V
BELT 0.85 0.5 0.5 B/P 1 B/P
SW 2 2 1
LG LG LG C-68
C-67 C-15 B-27
B-62 4WD FRT AXLE 4WD FUEL BRAKE VACUUM PARKING
2 SW(1) SW(2) CONTROL FILTER FLUID SW BRAKE
0.5 UNIT(19) SW SW SW
B
C-67 C-15
1 1
2.0 2.0 2.0 0.5 0.5
B B B B B
2 3
B-26 B-18 B-2 C-16 C-16

BODY-CTR BODY-LH BODY-RH FENDER-L H FENDER-LH

D08RY00431
TAIL RELAY TURN SIGNAL/CORNERING
(4) LIGHT SW

6 20 19
H-16 H-25 H-25

0.85 0.85 0.85


G/R G/B P/B
7 28 1
METER I-9 I-9 I-10

ODO/
TURN TURN
CHARGE TRIP METER
-LH -RH
METER

I-9 I-9 I-9


6 8 30
0.85 0.5 0.3
W/G R/G B
5
H-16
2.0
ILLUMINAITON B
0.85 CONTROLLER(3)
W/G 15
H-48

CHAGE
RELAY
(1)
2.0
B

B-2

BODY-RH

D08RW917
FUSE F-4
F I

10 18
H-16 H-46

0.85 0.5
R/L Y/R
15 13
I-10
H-33

0.5
Y/R
2
HIGH
BEAM F-5
FUEL
TANK
UNIT

I-10
14
0.85
R/Y 0.3
Y/G
12
H-16

DIMMER•
PASSING F-5 F-5
SW
1 4
0.3
Y/BR
0.5 14
B/P H-33

0.3
12 Y/BR
H-33 17
H-46
0.5
B 0.3
Y/BR
7 6
1.25 B-6 B-7
B
ALARM&RELAY
R-4 CONTROL UNIT

BODY-RR

D08RW918
STARTER SW
(ACC)

3.0
L/B
TAIL RELAY
C-11 10A (4)
AUDIO(ACC), MIRROR

0.5 0.5
O/G G/R
3 1
H-21 H-21

0.5 0.5
O/G G/R
3 1
L-5 L-5

MULTI METER

L-5 L-5 L-5


4 5 6
(W/O SUN ROOF)
0.5 0.5
P/L P/G 0.85
2 8 B
0.5
H-21 H-21
B
2.0
B
0.5 0.5 4 4
P/L P/G
H-21 H-21
11 20
H-7 H-7

0.5 0.5 2.0 2.0


P/L P/G B B

1 2
C-9 C-9

B-1 B-1

AMBIENT TEMPERATURE BODY-RH BODY-RH


SENSOR

D08RW919
2 3
4
1

27

26

25
24
23 5

22

9
21
10
20
19 11
18
17 12
16
15 14 13

D08RW930
28 2 3
1

27 4

26
5

6
25
7

8
24
9

10

11

12

13

14

15
23

22 16
20
21

19 17
18

D08RW897
STARTER SW
(IG1)

3.0
B/Y
C-3 10A
TURN,BACK

0.85
R/B
17
H-7
STARTER SW
(ST)

0.5
R/B 16
6
H-10
H-11
1.25
0.75
W/R
R/B
8 4
M-25 M-25

MODE
SW

0.85
R/B
M-25 M-25 M-25 M-25 M-25 M-25
5 6 7 2 3 1
0.5 0.5 0.5 0.5 0.75 1.25
TAIL RELAY L/W L/Y L/B Y/G R/L W/L
(4) 1 2 3 4 7 15
H-53 H-53 H-53 H-53 H-11 H-10
1
H-41
PCM BACK UP STARTER
0.5 0.5 0.5
(F3) LIGHT RELAY
L/W L/Y L/B
0.85 (5)
0.5 0.5 0.5
G/R L/W L/Y L/B
PCM PCM PCM
(E12) (E7) (F2)
12 13 1 2 3
C-93 C-93 C-93 C-93 C-93

A/T SHIFT INDICATOR CONTROL UNIT

D08RW639
A/T SHIFT INDICATOR CONTROL UNIT

C-93 C-93 C-93 C-93 C-93 C-93 C-93 C-93 C-93


11 10 9 8 7 6 5 4 14

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5


R/G R/L Y/V Y P/W P/B Y/G YB/R 0.5
B/L
10 2 7 21 8 18 4 14
H-24 H-24 H-24 H-9 H-9 H-9 H-24 H-24

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5


R/G R/L Y/V Y P/W P/B Y/G YB/R

11 3 12 10 13 14 2 12
I-10 I-10 I-10 I-9 I-10 I-9 I-10 I-9
1.25
A/T B/L
SHIFT
INDICATOR
P R N D 3 2 L
(METER)

14
(W/T.O.D.) H-5

14 13 13
I-9 I-10 I-9
1.0
B/L

D 3 2

E-30

COMMON CHAMBER

D08RW650
2
1

11

10

9
5

6
7

D08RWA10
STARTER SW
(IG1)

3.0
B/Y
C-3 10A
TURN,BACK

0.85
R/B
4
H-8
STARTER SW
(ST)

0.85
R/B 15
6
H-10
H-11
1.25
0.75
W/L
R/B
8 1
M-25 M-25

MODE
SW

0.85
R/B
M-25 M-25 M-25 M-25 M-25 M-25
5 6 7 2 3 4
0.5 0.5 0.5 0.5 0.75 1.25
TAIL RELAY L/W L/Y L/B Y/G R/L W/R
(4) 1 2 3 4 7 16
H-53 H-53 H-53 H-53 H-11 H-10
13
H-42
PCM BACK UP STARTER
0.5 0.5 0.5
(F3) LIGHT RELAY
L/W L/Y L/B
0.85 (6)
0.5 0.5 0.5
G/R L/W L/Y L/B
PCM PCM PCM
(E12) (E7) (F2)
12 13 1 2 3
C-93 C-93 C-93 C-93 C-93

A/T SHIFT INDICATOR CONTROL UNIT

D08RW949
A/T SHIFT INDICATOR CONTROL UNIT

C-93 C-93 C-93 C-93 C-93 C-93 C-93 C-93 C-93


11 10 9 8 7 6 5 4 14

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5


R/G R/L Y/V Y P/W P/B Y/G Y/BR 0.5
B/L
18 7 16 15 14 13 8 12
H-24 H-24 H-24 H-24 H-24 H-24 H-24 H-24

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5


R/G R/L Y/V Y P/W P/B Y/G Y/BR
1.25
11 3 12 10 13 14 2 12 B/L
I-10 I-10 I-10 I-9 I-10 I-9 I-10 I-9

A/T 14
SHIFT H-5
INDICATOR
P R N D 3 2 L
(METER)

1.0
B/L

E-30

COMMON
CHAMBER

D08RW950
1
2

12

11 4

10
5
9
8 6
7

D08RWA09
FL-1 FL-4
80A MAIN 30A CONDENSER FAN
8B / R 1.25 L/O
+ P-2

P-1 F-6
15A RR COOLER

5W
0.5 LG/Y

P-5
_
30B
8B

0.5 LG
5B

5W
7
0.5 BR 0.5 BR
P-6 P - 10 P-7 1 H-16

H-14
BODY ENG. FRAME

0.5 BR
RELAY;STARTER (1)

5W

0.5 BR
2

I-23 A/C SW

10 6 13 1
0.5 LG 0.5 LG
16 I-23 H-24 H-51
H-13
3W

H-26
0.85W/G

0.5 LG
I-23
1

1 2 3
0.5 BR

B-36 B-36 I-42

RELAY ; 1 16
ELECTRONIC 0.5 P/G
HEATER AND I-42 H-16
THERMOSTAT
A/C

I-42
B-36 B-36
3 4 2
3L/R

C-20 10A
AIR CON.

0.3 G/Y
C-19
25A BLOWER
3L

0.3 G/Y 0.3 G/Y


2
B-5
0.3B

BLOWER
M MOTOR
CONTROLLER (3)
RELAY ; TAIL (4)

B-5
ILLUMINATION

1
HEATER BEZEL
2L/B

ILLUMINATION
0.3 G/Y

2
H-20
0.85 G/R
2L/B

3
0.3 R/G

2
BLOWER I-23
I-41 RESISTOR
5
I-23
3 6 4
1.25B

2 L/R
I-41 I-18 I-18
6 3
1.25 L/O 1
I-41 I-18
I-18
4 5
1.25 L/Y
I-41 I-18
1 2
0.85 L/W
2B

I-41 I-18

FAN SW
1
H-20
2B

BODY-RH B-19

BODY-LH B -1

D08RY00128
0.5 LG

2
H-51

0.5 LG
(IF EQUIPPED)

C-25

TRIPLE SW
0.5 BR C-25

0.5 LG/Y
PRESSURE SW 4

0.5 BR
1 (CONDENSER) 2 0.5 4 0.5 12
0.5 LG G/W G/W
C - 25 C - 25 H-51 H-41

0.5 W/G
0.5
G/W
3 2
3
X-5 X-5 0.5 BR
H-51

1.25 L/O
RELAY ;
0.5 BR

0.5 BR

A/C THERMO

0.5 W/G
X-5 X-5 2 1
A/C COMPRESSOR

2
1 4 X-7 X-7
0.5 P/G H-42
0.5 G/O

0.5 BR

0.5 W/G
RELAY;

6
H-41 X-7 X-7

RELAY; CONDENSER FAN


4 3 1 2 4 1
RELAY ; RR COOLER
0.5BR/Y

0.5G/B

X-6 X-6 X-19 X-19


PCM (E15)

7 5

H - 41 H - 41
0.5BR/Y

0.5G/B

X-6 X-6 X-19 X-19


0.5LG/B

3 4 5 3
9
6
H-6
H-15
1.25L
0.5B
PCM (B14)
0.5BR/Y

0.5LG/B

7 1
1 1
C-39 H-31
E-3 C-75
0.5LG/B

1
0.3G/Y
MAGNETIC CLUTCH

CONDENSER FAN

H-50

RR COOLER
CONNECTOR
M
H-50
2
0.5B

C-75
3B

R-3 3
H - 16
1.25B

BODY-RR

0.3 G/Y

1.25 B
FENDER-RH C - 39
1

D08RY00129
2 3 4
1

21
20

19 5

18 6

17 10
16
15

14 11
13 12

D08RWA15
D08RY00130
(IF EQUIPPED)

2
0.5 LG 0.5 LG
H-51

0.5 BR 3

C-25

TRIPLE SW
C-25

0.5 LG/Y
0.5 BR

0.5 BR
4

0.5 W/R
DUAL PRESSURE SW
or
TRIPLE SW 3
1 2 4 12
0.5G/W 0.5G/W

1.25 L/O
C - 25 C - 25 H-51 H-41 H-51
0.5G/W

0.5 W/R
3 2
X-5 X-5

RELAY ; 2
A/C THERMO H-42
0.5 BR

0.5 BR

0.5 BR

0.5 W/R
X-5 X-5
1 4
0.5 G/O

0.5 P/G

RELAY; CONDENSER FAN


1 2 4 1
RELAY ; RR COOLER

6 2 1 X-6 X-6 X-19 X-19


A/C COMPRESSOR

H-41 X-7 X-7


RELAY;

X-6 X-6 X-19 X-19


PCM (E15)

0.5LG/B

X-7 X-7 3 4 5 3

4 3 5
0.5BR/Y

0.5G/B

H-15
1.25L
0.5B

0.5LG/B

7 5
7 1
H - 41 H - 41 1
C-39 H-31
C-75
0.5LG/B
0.5BR/Y

1
0.3G/Y

9
CONDENSER FAN

H-50
PCM (B14)

H-6
RR COOLER
CONNECTOR
0.5BR/Y

M
H-50
1 2
0.5B

E-3

C-75
MAGNETIC CLUTCH

3B

R-3 17
H - 12
1.25B

BODY-RR

0.3 G/Y
2
FENDER-RH C-39

D08RY00131
4

27
25 5

26
6
24

28
23 7
17
16
13
8

22 9

10

11

21
20
19
18
15
14 12

D08RWA14
FL-1 FL-4 30A
80A MAIN CONDENSER FAN
8B / R 1.25 L/O
+ P-2

P-1 F-6 10A

5W
RR COOLER
0.5 LG/Y

P-5
_ 7
0.5 BR 0.5 BR
H-16

5W

0.5BR
30B

2
8B

5B
I-23 A/C SW
1

P-6 P - 10 P-7 H-14


6 13
0.5LG 0.5LG 0.5 LG

0.5BR
BODY ENG. FRAME I-23 H-24

LG
0.5
1
H-51
5W

BR
0.5
I-23 1

RELAY ; CHARGE (1) 1 C-25


PRESSURE SW
(CONDENSER)
10
3W

H-13 16 C-25

0.5 BR
H-26 2

G/W
0.5
0.85W/G

4
H-51

G/W
0.5
10
1 2
H-41
B-36 B-36

G/W
0.5
1 2
RELAY ;
0.5 LG
0.3G/Y

HEATER AND X-5 X-5


A/C
RELAY ;
B-36 B-36 A/C THERMO

3 4 3
C-20 10A
3L/R

AIR CON. I-42 X-5 X-5

C-19 1 16 3 4
ELECTRONIC 0.5 P/G 0.5 P/G
25A BLOWER

0.5 G/O
THERMOSTAT I-42 H-16

I-42 6
3L

2 2 H-41
0.3G/Y

B-5
0.5G/O

1
BLOWER
0.3B

MOTOR H-5
0.5G/O

B-5
CONTROLLER (3)

1 1
RELAY ; TAIL (4)

ILLUMINATION
2L/B

E-3

2 HEATER BEZEL
0.5G/O

ILLUMINATION
MAGNETIC CLUTCH

H-20
0.3G/Y
2L/B

0.85 G/R

3
0.3 R/G

2 BLOWER I-23
I-41 RESISTOR
5
I-23
3 6 4
2L/R 0.3GY
I-41 I-18 I-18
6 3
1.25L/O 1
0.5 G/O

I-41 I-18
I-18
4 5
1.25L/Y
I-41 I-18
1
1 2
0.85L/W C-69
2B

I-41 I-18
1.25B

FAN SW
1 VSV; FICD
H-20
C-69
2
2B

0.5 B

BODY-RH B-19
7
FENDER-LH C-16
BODY-LH B-1

D08RY00124
(IF EQUIPPED)

2
0.5 LG 0.5 LG
H-51

3
C-25

TRIPLE SW
C-25

0.5 LG/Y
4

0.5 W/R
3

1.25 L/O
H-51

0.5 W/R
2
0.5 BR H-42

0.5 W/G

RELAY; CONDENSER FAN


1 2 4 1
RELAY ; RR COOLER

X-6 X-6 X-19 X-19

X-6 X-6 X-19 X-19


0.5LG/B

3 4 5 3
6
H-15
1.25L
0.5B

0.5LG/B

1 1
1
C-39 H-31
C-75
0.5LG/B

1
0.5B

CONDENSER FAN

H-50

RR COOLER
CONNECTOR
M
H-50
2
0.5B

C-75
3B

R-3
1.25B

BODY-RR

7
C-39

FENDER-RH 3
C-39

D08RY00125
D08RWA29
D08RY00126
(IF EQUIPPED)

2
0.5 LG 0.5 LG
H-51

0.5 BR 3

C-25

TRIPLE SW
0.5 BR C-25
4

0.5 W/R
0.5 LG/Y
DUAL PRESSURE SW
or
TRIPLE SW 3
1 2 4 10

0.5 BR
0.5G/W 0.5G/W

1.25 L/O
H-51
C - 25 C - 25 H-51 H-41
0.5G/W

0.5 W/R
1 2
X-5 X-5

RELAY ; 2
A/C THERMO H-42

0.5 W/R
X-5 X-5
3 4
0.5 G/O

0.5 P/G

RELAY; CONDENSER FAN


1 2 4 1
RELAY ; RR COOLER

6 X-6 X-6 X-19 X-19

H-41

X-6 X-6 X-19 X-19


0.5 G/O

0.5LG/B

3 4 5 3
5
H-15
1.25L
0.5B
0.5 G/O

0.5LG/B

1 2 1
1
H-5 C-39 H-31
C-75
0.5LG/B

1
C-69 1
0.3B

CONDENSER FAN

H-50
VSV;FICD
0.5 G/O

RR COOLER
CONNECTOR
M
H-50
C-69
1 2
2
0.5B

E-3

C-75
0.5B
MAGNET CLUTCH

3B

2
3
R-3
C-16
1.25B

BODY-RR

2
FENDER-RH C-39

D08RY00127
D08RWA28
STARTER SW
(IG1) BATT.(+)
3.0
B/Y
C-4 15A C/B-2 30A 2.0
ELEC. P/W, P/S, S/R L/B
2
IGN.
S-4 SUN ROOF CONTROL UNIT
0.85
L/W
3.0
B/L

0.5
L/W 1 2 OPEN

B-37 B-37
POWER
WINDOW
CLOSE
RELAY

B-37 B-37
S-5 S-5 S-5 S-4 S-5 S-5
3 4
5 3 6 4 1 4
0.5 0.5 0.5
2.0 Y/B L/Y 1.25 1.25 B
1 2 L Y
L/B 2.0
2.0 H-45 H-45 1 2 B
L/B
6 4 0.5 0.5 0.5 S-3 S-3
0.3 Y/R
B H-21 H-23 Y/B L/Y
1 3 6
H-45
L-1 L-1
2.0 SUN ROOF
POWER WINDOW 3 SUN ROOF MOTOR
L/B
SW S-2 SW

OPEN
CLOSE

3
2.0
H-45 B
L-1
SAFETY LIMIT 2
2.0 STOP SW 0.5
L/B SW B

1.25
B 4
H-21
S-2
1 2.0
0.5 B
B

B-19 B-2

BODY-RH BODY-LH

D08RY00234
1 2 3
12 4

11

10

8
7

D08RW995
STARTER SW
(IG1) BATT.(+)
A
3.0
B/Y
C-4 15A C/B-2 30A 2.0
ELEC. P/W, P/S, S/R L/B
2
IGN.
S-4 SUN ROOF CONTROL UNIT
0.5
L/W
3.0
B/L

0.5
L/W 1 2 OPEN

B-37 B-37
POWER
WINDOW
CLOSE
RELAY

B-37 B-37 B
S-5 S-5 S-5 S-4 S-5 S-5
3 4
5 3 6 4 1 4
0.5 0.5 0.5
2.0 Y/B L/Y 1.25 1.25 B
1 2 L Y
L/B 2.0
2.0 H-45 H-45 1 2 B
L/B
6 4 0.5 0.5 0.5 S-3 S-3
0.3 Y/R
B H-21 H-23 Y/B L/Y
1 3 6
M H-45
L-1 L-1
2.0 SUN ROOF
POWER WINDOW 3 SUN ROOF MOTOR
L/B
SW S-2 SW

OPEN
CLOSE

3
2.0
H-45 B
L-1
SAFETY LIMIT 2
2.0 STOP SW 0.5
L/B SW B

1.25
B 4
A
H-21
S-2
1 2.0
0.5 B
B

B-18 B B-1

BODY-LH BODY-RH

D08RY00235
2
1
3 4
12
11

10
9

D08RW388
STARTER SW
(IG2)

3.0
B/R
C-2 15A
SEAT HEATER
0.85 0.85 0.85 0.85
W W/R W W/R
1.25
G/R
0.85
G/R 1 3 1 3
2 2
SEAT T-8 T-8 SEAT T-10 T-10
B-29 SEAT HEATER SW-RH B-31 SEAT HEATER SW-LH HEATER-RH HEATER-LH
SEAT SEAT
BACK BACK

H H

H K H K H K H K

B-29 B-29 B-29 B-31 B-31 B-31


SEAT CUSHION SEAT CUSHION
1 4 3 1 4 3
0.85 0.85 0.85 0.85
GR/L Y/V L/G Y/G T-8 T-10
4 4
2 5 2 5
H-57 H-57 H-58 H-58 0.85 0.85
0.85 0.85 B/W B/W
B B 3 3
0.85 0.85 0.85 0.85
W W/R W W/R H-57 H-58

0.85 0.85
B B

2.0 2.0 2.0


B B B

B-18 B-2 B-26

BODY-RH BODY-LH BODY-CTR

D08RW648
1

11

10

9
2

8 7 6
3
4

D08RW993
STARTER SW
(IG2)
A B C D
3.0
B/R
C-2 15A
SEAT HEATER
0.85 0.85 0.85 0.85
W W/R W W/R
1.25
GR
0.85
GR 1 3 1 3
2 2
SEAT T-8 T-8 SEAT T-10 T-10
B-29 SEAT HEATER SW-LH B-31 SEAT HEATER SW-RH HEATER-LH HEATER-RH
SEAT SEAT
BACK BACK

H H

H K H K H K H K

B-29 B-29 B-29 B-31 B-31 B-31


SEAT CUSHION SEAT CUSHION
1 4 3 1 4 3
0.85 0.85 0.85 0.85
GR/L Y/V L/G Y/G T-8 T-10
4 4
2 5 2 5
H-57 H-57 H-58 H-58 0.85 0.85
0.85 0.85 B/W B/W
B B 3 3
0.85 0.85 0.85 0.85
W W/R W W/R H-57 H-58

A B C D 0.85 0.85
B B

2.0 2.0 2.0


B B B

B-18 B-26 B-2

BODY-LH BODY-CTR BODY-RH

D08RW948
1

11

10

8 7 6

5
3

D08RW992
C/B-2
3.0
3.0 B/L
B/L 1
H-57

2.0
R
1
T-2
POWER SEAT SW-RH

UP DOWN UP DOWN

FRT RR FRT RR

T-1 T-1 T-1 T-1 T-1 T-1 T-1 T-1 T-1 T-1 1.25 1.25 1.25 1.25
B/W W BR LG
8 1 6 3 9 2 7 4 5 10 5 3 6 2
1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25
Y/B Y Y/R Y/W L/B L L/R L/W G G/R T-11 T-11 T-11 T-11
2 1 2 1 2 1 2 1 1 2
T-3 T-4 T-4 T-3 T-5 T-6 T-6 T-5 T-7 T-7

DRIVER'S SEAT T-5 DRIVER'S SEAT SLIDE MOTOR T-11 RECLINER


T-3
TILT MOTOR TILT MOTOR -LH MOTOR & SW
3 & SW-FRT 3 & SW-RR 4 -LH
2.0
B
2.0 2
B
T-2

2.0
B
4
H-57
2.0
B 2.0 2.0
B B
B-26 B-2 B-18

BODY-CTR BODY-LH BODY-RH

D08RW640
3.0
B/L
1
H-58

2.0
R
1
T-9
POWER SEAT SW-LH

FRT RR FRT RR

1.25 1.25 1.25 1.25 1.25 1.25


G G/R B/W W BR LG
1 2 5 3 6 2
T-13 T-13 T-12 T-12 T-12 T-12

SLIDE MOTOR RECLINER


T-12
-RH MOTOR & SW
4 -RH
2.0
B
2
T-9
2.0
B 4
H-58
2.0
B

D08RW641
1

14

13
2

10

12 7
3 9
11
8
6

D08RW996
C/B-2
3.0
3.0 B/L
A
B/L 1
H-57

2.0
R
1
T-2
POWER SEAT SW-LH

UP DOWN UP DOWN

FRT RR FRT RR

T-1 T-1 T-1 T-1 T-1 T-1 T-1 T-1 T-1 T-1 1.25 1.25 1.25 1.25
B/W W BR LG
8 1 6 3 9 2 7 4 5 10 5 3 6 2
1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25
Y/B Y Y/R Y/W L/B L L/R L/W G G/R T-11 T-11 T-11 T-11
2 1 2 1 2 1 2 1 1 2
T-3 T-4 T-4 T-3 T-5 T-6 T-6 T-5 T-7 T-7

M M M M

DRIVER'S SEAT T-5 DRIVER'S SEAT SLIDE MOTOR T-11 RECLINER


T-3
TILT MOTOR TILT MOTOR -LH MOTOR & SW
3 & SW-FRT 3 & SW-RR 4 -LH
2.0
B
2.0 2
B
T-2

2.0
B
4
H-57
2.0
B B

B-18 B-26 B-2

BODY-LH BODY-CTR BODY-RH

D08RW951
A
3.0
B/L
1
H-58

2.0
R
1
T-9
POWER SEAT SW-RH

FRT RR FRT RR

1.25 1.25 1.25 1.25 1.25 1.25


G G/R B/W W BR LG
1 2 5 3 6 2
T-13 T-13 T-12 T-12 T-12 T-12

M M

SLIDE MOTOR RECLINER


T-12
-RH MOTOR & SW
4 -RH
2.0
B
2
T-9
2.0
B 4
H-58
2.0
B
B

D08RW952
1

13

12
14

11
10 8

9
7
6

D08RW994
STARTER SW STARTER SW
(IG1) (IG1)

3.0 3.0
B/Y B/Y

C-10 10A C-4 15A


METER, GAUGE ELEC.IGN

0.5 0.5
L/Y L/W
6 1
H-26 H-13

0.5
L/Y 0.85
L/W
15 0.85
L/W
I-9 1 4
4WD X-18 X-18
INDICATOR
LIGHT SHIFT ON THE
(METER) FLY RELAY
I-9
18 X-18 X-18
0.5 2 5
LG
0.5 0.5
19 L/Y Y/B
H-27 18 9
H-15 H-41
0.5
LG
0.5 0.5
18 L/B Y/B
H-7
2 1
0.5 H-7 H-10
LG
0.5
0.5
0.5 Y/B
L/Y
Y
5 3
C
H-10 H-10

0.5 0.5
Y L/Y

A B

D08RY00236
A B C

0.5 0.5
Y Y/B
2 0.5 1
M-22 L/Y
M-11
0.5
FRT AXLE L/Y 4WD SW
SW 1 1 (TRANSFER)
M-23 M-24
VSV; VSV;
M-22 FRT AXLE(C) FRT AXLE(D) M-12
1 1

M-23 M-24 0.5


2 2 B

0.5 0.5
14
B B
H-10
0.5
B

0.5
B

8
C-16
2
H-10
FENDER-LH

0.85
B

3
C-16

FENDER-LH

D08RW716
2
1

16
15
14

13

12
3
11 4

10 5
9
8 6
7

D08RW624
STARTER SW STARTER SW
(IG1) (IG1)

3.0 3.0
B/Y B/Y

C-10 10A C-4 15A


METER, GAUGE ELEC.IGN

0.5 0.5
L/Y L/W
6 1
H-26 H-13

0.5
L/Y 0.85
L/W
15 0.85
L/W
I-9 1 4
4WD X-18 X-18
INDICATOR
LIGHT SHIFT ON THE
(METER) FLY RELAY
I-9
18 X-18 X-18
0.5 2 5
LG
0.5 0.5
19 L/Y Y/B
H-27 18 8
H-15 H-41
0.5
LG
0.5 0.5
18 L/B Y/B
H-7
2 10
0.5 H-7 H-5
LG
0.5
0.5
0.5 L/G
L/Y
Y
3 1
C
H-60 H-60

0.5 0.5
LG L/Y

A B

D08RY00237
A B C

0.85 0.5
LG L/G
2 0.5 1
P-17 B/R
E-45
0.5
FRT AXLE B/R 4WD SW
SW 1 1 (TRANSFER)
P-18 P-19
VSV; VSV;
P-17 FRT AXLE(C) FRT AXLE(D) E-46
1 1

P-18 P-19 0.85


2 2 B

0.5 0.5
9
B B
H-5
0.85
B

0.5
B

2
C-16
4
H-60
FENDER-LH

0.85
B

3
C-16

FENDER-LH

D08RW720
2 3 4
1

16
15

14

13

12

7
11

10 9 8

D08RW830
STARTER SW STARTER SW
(IG1) (IG1)

3.0 3.0
B/Y B/Y

C-10 10A C-4 15A


METER, GAUGE ELEC.IGN

0.5 0.5
L/Y L/W
10 5
H-25 H-12

0.5
L/Y 0.85
L/W
15 0.85
L/W
I-9 1 4
4WD X-18 X-18
INDICATOR
LIGHT SHIFT ON THE
(METER) FLY RELAY
I-9
18 X-18 X-18
0.5 2 5
LG
0.5 0.5
22 L/Y Y/B
H-25 20 9
H-12 H-41
0.5
LG
0.5 0.5
18 L/B Y/B
H-7
3 1
0.5 H-8 H-10
LG
0.5
0.5
0.5 Y/B
L/Y
Y
5 3
C
H-10 H-10

0.5 0.5
Y L/Y

A B

D08RY00238
A B C

0.5 0.5
Y Y/B
2 0.5 1
M-22 L/Y M-11
0.5
FRT AXLE L/Y 4WD SW
SW 1 1 (TRANSFER)
M-23 M-24
VSV; VSV;
M-22 FRT AXLE(C) FRT AXLE(D) M-12
1 1

M-23 M-24 0.5


2 2 B

0.5 0.5
14
B B
H-10
0.5
B

0.5
B

8
C-16
2
H-10
FENDER-LH

0.85
B

3
C-16

FENDER-LH

D08RW716
1

11

10

9 6
8 7

D08RW833
STARTER SW STARTER SW
(IG1) (IG1)

3.0 3.0
B/Y B/Y

C-10 10A C-4 15A


METER, GAUGE ELEC.IGN

0.5 0.5
L/Y L/W
10 5
H-25 H-12

0.5
L/Y 0.85
L/W
15 0.85
L/W
I-9 1 4
4WD X-18 X-18
INDICATOR
LIGHT SHIFT ON THE
(METER) FLY RELAY
I-9
18 X-18 X-18
0.5 2 5
LG
0.5 0.5
22 L/Y Y/B
H-25 20 8
H-12 H-41
0.5
LG
0.5 0.5
18 L/B Y/B
H-7
3 10
0.5 H-8 H-5
LG
0.5
0.5
0.5 L/G
L/Y
Y
3 1
C
H-60 H-60

0.85 0.5
LG B/R

A B

D08RY00239
A B C

0.85 0.5
LG L/G
2 0.5 1
P-17 B/R
E-45
0.5
FRT AXLE B/R 4WD SW
SW 1 1 (TRANSFER)
P-18 P-19
VSV; VSV;
P-17 FRT AXLE(C) FRT AXLE(D) E-46
1 1

P-18 P-19 0.85


2 2 B

0.5 0.5
9
B B
H-5
0.85
B

0.5
B

2
C-16
4
H-60
FENDER-LH

0.85
B

3
C-16

FENDER-LH

D08RW720
1

14

13

12

11

10

4
9
8 7 6
5

D08RW829
STARTER SW STARTER SW
(IG1) (IG1)

3.0 3.0
B/Y B/Y
C-4 15A C-10 10A
ELEC.IGN. METER,GAUGE
0.5 TAIL RELAY
L/W 0.5
(4)
L/Y
6
0.5
L/W H-26
20 14
H-25 H-16 0.5
0.5 L/Y
L/W 0.85 0.85 15 (4JG2)
L/W G/R I-9
6 2
INDICATOR/
I-12 I-12 WARNING LIGHT
7 4WD SW (METER)

4WD
CHARGE
CHARGE

H-12 (INSTRUMENT
PANEL)

I-12 I-12 I-9 I-9 I-9


4 3 0.5 18 6 6
0.5 0.3 LG 19 0.85 0.85
0.85 R/W R/G W/G W/G
H-27
L/W 5
ILLUMINATION 0.5 AC GENERATOR CHARGE RELAY
H-9 LG
CONTROLLER(3) 18 (L) (1)
0.5 H-7
R/W 0.5
17 8 LG 19
C-94 C-94 C-94

4WD CONTROL UNIT

C-94 C-94

0.5 16 16
B/L

1.25
B/L 0.5
14
B
H-5 (4JG2)
1.0
B/L 7
E-30 C-16

COMMON FENDER-LH
CHAMBER

D08RY00240
EHCU : ELECTRONIC HYDRAULIC CONTROL UNIT

4WD CONTROL UNIT

C-94 C-94 C-94 C-94 C-94 C-94 C-94 C-94 C-94


20 14 15 9 10 5 4 21 22
0.5
L/Y
0.5
0.5 0.5 0.5 0.85 0.85 0.5 0.5
Y/B
P L/Y Y GR GR/L R/L R

10 5 1 7 8 13 10
3
H-12 H-10 H-10 H-10 H-10 H-10 H-10
H-10

0.5 0.5 0.75 0.75 0.5 0.5


0.5 0.5 Y Y/B GR GR/L R/L R
LG L/Y
0.5
9 L/Y 2 1 3 2 6 5
1 1
H-15 M-22 M-11 M-26 M-26 M-26 M-26
M-23 M-24
VSV; VSV; FRT AXLE 4WD SW
FRT AXLE(C) FRT AXLE(D) SW (TRANSFER)
EHCU
(9)
M-23 M-24
M-22 M-12
2 2 ACTUATOR M-26
0.5 0.5 1 1
(TRANSFER)
B B 0.5 4
0.5 B 0.5
B B

0.5
2 B 14
H-10
H-10

0.85 0.5
B B

3 8
C-16 C-16

FENDER-LH FENDER-LH

D08RW638
2
1

17
16

15

14

4
13
12 5
11
10 6
9 8 7

D08RW853
STARTER SW STARTER SW
(IG1) (IG1)

3.0 3.0
B/Y B/Y
C-4 15A C-10 10A
ELEC.IGN. METER,GAUGE
0.5 TAIL RELAY
L/W 0.5
(4)
L/Y
6
0.5
L/W H-26
20 14
H-25 H-16 0.5
0.5 L/Y
L/W 0.85 0.85 15 (4JG2)
L/W G/R I-9
6 2
INDICATOR/
I-12 I-12 WARNING LIGHT
7 4WD SW (METER)

4WD
CHARGE
CHARGE

H-12 (INSTRUMENT
PANEL)

I-12 I-12 I-9 I-9 I-9


4 3 0.5 18 6 6
0.5 0.3 LG 19 0.85 0.85
0.85 R/W R/G W/G W/G
H-27
L/W 5
ILLUMINATION 0.5 AC GENERATOR CHARGE RELAY
H-9 LG
CONTROLLER(3) 18 (L) (1)
0.5 H-7
R/W 0.5
17 8 LG 19
C-94 C-94 C-94

4WD CONTROL UNIT

C-94 C-94

0.5 16 16
B/L

1.25
B/L 0.5
14
B
H-5 (4JG2)
1.0
B/L 7
E-30 C-16

COMMON FENDER-LH
CHAMBER

D08RY00240
EHCU : ELECTRONIC HYDRAULIC CONTROL UNIT

4WD CONTROL UNIT

C-94 C-94 C-94 C-94 C-94 C-94 C-94 C-94 C-94


20 14 15 9 10 5 4 21 22
0.5
L/Y
0.5
0.5 0.5 0.5 0.85 0.85 0.5 0.5
Y/B
P L/Y Y GR GR/L R/L R

10 3 10 13 14 16 15
1
H-12 H-60 H-5 H-4 H-4 H-4 H-4
H-60

0.85 0.5 0.85 0.85 0.5 0.5


0.5 0.5 LG L/G GR GR/L R/L R
LG BR
0.5
9 BR 2 1 3 2 6 5
1 1
H-15 P-17 E-45 E-21 E-21 E-21 E-21
P-18 P-19
VSV; VSV; FRT AXLE 4WD SW
FRT AXLE(C) FRT AXLE(D) SW (TRANSFER)
EHCU
(9)
P-18 P-19
P-17 E-46
2 2 ACTUATOR E-21
0.5 0.5 1 1
(TRANSFER)
B B 0.85 4
0.5 B 0.5
B B

0.85
4 B 9
H-60
H-5

0.85 0.5
B B

3 2
C-16 C-16

FENDER-LH FENDER-LH

D08RW842
2 3 4
1

16
15

14

13

12

7
11

10 9 8

D08RW830
STARTER SW STARTER SW
(IG1) (IG1)

3.0 3.0
B/Y B/Y
C-4 15A C-10 10A
ELEC.IGN. METER,GAUGE
0.5 TAIL RELAY
L/W 0.5
(4)
L/Y
10
0.5
L/W H-25
5 6
H-25 H-16 0.5
0.5 L/Y
L/W 0.85 0.85 15 (4JG2)
L/W G/R I-9
6 2
INDICATOR/
I-12 I-12 WARNING LIGHT
10 4WD SW (METER)

4WD
CHARGE
CHARGE

H-8 (INSTRUMENT
PANEL)

I-12 I-12 I-9 I-9 I-9


4 3 0.5 18 6 6
0.5 0.3 LG 21 0.85 0.85
0.85 R/W R/G W/G W/G
H-25
L/W 4
0.5 AC GENERATOR CHARGE RELAY
H-24 ILLUMINATION LG
CONTROLLER(3) 18 (L) (1)
0.5 H-7
R/W 0.5
17 8 LG 19
C-94 C-94 C-94

4WD CONTROL UNIT

C-94 C-94

0.5 16 16
B/L

1.25
B/L 0.5
14
B
H-5 (4JG2)
1.0
B/L 8
E-30 C-16

COMMON FENDER-LH
CHAMBER

D08RY00241
EHCU : ELECTRONIC HYDRAULIC CONTROL UNIT

4WD CONTROL UNIT

C-94 C-94 C-94 C-94 C-94 C-94 C-94 C-94 C-94


20 14 15 9 10 5 4 21 22
0.5
L/Y
0.5
0.5 0.5 0.5 0.85 0.85 0.5 0.5
Y/B
P L/Y Y GR GR/L R/L R

15 5 1 7 8 13 10
3
H-7 H-10 H-10 H-10 H-10 H-10 H-10
H-10

0.5 0.5 0.75 0.75 0.5 0.5


0.5 0.5 Y Y/B GR GR/L R/L R
LG L/Y
0.5
2 L/Y 2 1 3 2 6 5
1 1
H-12 M-22 M-11 M-26 M-26 M-26 M-26
M-23 M-24
VSV; VSV; FRT AXLE 4WD SW
FRT AXLE(C) FRT AXLE(D) SW (TRANSFER)
EHCU
(9)
M-23 M-24
M-22 M-12
2 2 ACTUATOR M-26
0.5 0.5 1 1
(TRANSFER)
B B 0.5 4
0.5 B 0.5
B B

0.5
2 B 14
H-10
H-10

0.85 0.5
B B

3 8
C-16 C-16

FENDER-LH FENDER-LH

D08RW843
2
1

16

15

14

13

5
6
7
8

12 9
11 10

D08RW854
STARTER SW STARTER SW
(IG1) (IG1)

3.0 3.0
B/Y B/Y
C-4 15A C-10 10A
ELEC.IGN. METER,GAUGE
0.5 TAIL RELAY
L/W 0.5
(4)
L/Y
10
0.5
L/W H-25
5 6
H-25 H-16 0.5
0.5 L/Y
L/W 0.85 0.85 15 (4JG2)
L/W G/R I-9
6 2
INDICATOR/
I-12 I-12 WARNING LIGHT
10 4WD SW (METER)

4WD
CHARGE
CHARGE

H-8 (INSTRUMENT
PANEL)

I-12 I-12 I-9 I-9 I-9


4 3 0.5 18 6 6
0.5 0.3 LG 21 0.85 0.85
0.85 R/W R/G W/G W/G
H-25
L/W 4
ILLUMINATION 0.5 AC GENERATOR CHARGE RELAY
H-24 LG
CONTROLLER(3) 18 (L) (1)
0.5 H-7
R/W 0.5
17 8 LG 19
C-94 C-94 C-94

4WD CONTROL UNIT

C-94 C-94

0.5 16 16
B/L

1.25
B/L 0.5
14
B
H-5 (4JG2)
1.0
B/L 8
E-30 C-16

COMMON FENDER-LH
CHAMBER

D08RY00241
EHCU : ELECTRONIC HYDRAULIC CONTROL UNIT

4WD CONTROL UNIT

C-94 C-94 C-94 C-94 C-94 C-94 C-94 C-94 C-94


20 14 15 9 10 5 4 21 22
0.5
L/Y
0.5
0.5 0.5 0.5 0.85 0.85 0.5 0.5
Y/B
P L/Y Y GR GR/L R/L R

15 3 10 13 14 16 15
1
H-7 H-60 H-5 H-4 H-4 H-4 H-4
H-60

0.85 0.5 0.85 0.85 0.5 0.5


0.5 0.5 LG L/G GR GR/L R/L R
LG BR
0.5
2 BR 2 1 3 2 6 5
1 1
H-12 P-17 E-45 E-21 E-21 E-21 E-21
P-18 P-19
VSV; VSV; FRT AXLE 4WD SW
FRT AXLE(C) FRT AXLE(D) SW (TRANSFER)
EHCU
(9)
P-18 P-19
P-17 E-46
2 2 ACTUATOR E-21
0.5 0.5 1 1
(TRANSFER)
B B 0.85 4
0.5 B 0.5
B B

0.85
4 B 9
H-60
H-5

0.85 0.5
B B

3 2
C-16 C-16

FENDER-LH FENDER-LH

D08RW841
2
1

15

14
13

12

5
11

6
7

8
10 9

D08RW852
STARTER SW STARTER SW
(IG1) (IG1) BATT.(+)

3.0 3.0 5.0


B/Y B/Y W
C-4 10A C-10 10A C-14 15A
ELEC.IGN. METER,GAUGE STOP,
A/T CONT.

0.5 0.85
0.5 L/Y G/W
A
L/W
6
H-26

0.85 (W/ CRUISE CONTROL)


G/W
0.5 0.5
L/W TAIL RELAY L/Y
0.85
20 (4)
G/W
H-25 26 T.O.D. INDICATOR 1 1
I-9 (METER) B-14 B-13
0.85
0.5 G/R
STOP BRAKE
L/W LIGHT SW
6 2 SW
I-12 I-12
B-14 B-13
4WD
SW 2 4
0.85
RR 1 2 3 AUTO CHECK
0.5 G/Y
L/W I-12 I-12 I-9 I-9 I-9 I-9 I-9 I-9
4 3 15 21 22 23 16 17
0.3
0.5 R/G 0.5 0.5 0.5 0.5 0.5 0.5
B/W BR/R BR/G BR BR/Y BR/W R
0.85
5 9 2 15 3 16 G/Y 0.85
9 ILLUMINATION
G/Y 7
H-25 CONTROLLER H-27 H-27 H-27 H-27 H-27 H-25
(3) H-32

0.5 0.5 0.5 0.5 0.5 0.5 0.5


B/W BR/R BR/G BR BR/Y BR/W R STOP LIGHT

1 7 17 15 14 13 16 18 2
B-67 B-68 B-68 B-68 B-68 B-68 B-68 B-68 B-68

T.O.D. CONTROL UNIT

D08RW610
T.O.D. CONTROL UNIT

B-68 B-67 B-67 B-68 B-67 B-68 B-67


5 5 7 12 10 11 4

0.5 0.5
BR/R L/Y 0.5 0.5 0.5
G/W G/R G/Y
10 2 0.5
H-12 H-7 0.5 LB
G
0.5
P 0.5
L/Y 0.5 4
0.5 G H-49
0.5 3 G/R
Y H-10 3 14 13 2 12 7
5 H-49 H-49 H-49 H-49 H-49 H-49
H-10 0.5
0.5
LB
0.5 L/Y
0.5 L/Y
Y 0.5 0.5 0.5 0.5 0.5 0.5
2 8
1 1 G G/W G/R G/R G/Y G
M-22 A-3
M-23 M-24
FRT AXLE VSV; VSV; CLUTCH
SW FRT AXLE(C) FRT AXLE(D) SOLENOID
2 6 10 9 5 1
(TRANSFER)
A-3 A-3 A-3 A-3 A-3 A-3
M-23 M-24
M-22
2 2
1
0.5 0.5
B B
0.5 FRT SPEED RR SPEED
B SENSOR SENSOR
(TRANSFER) (TRANSFER)
2
H-10

0.85
B

3
C-16

FENDER-LH

D08RW611
TAIL RELAY EHCU EHCU EHCU : ELECTRONIC
(3) (27) (9) HYDRAULIC
CONTROL UNIT

3 20 9
H-15 H-15 H-15

0.3 0.5 0.5


G LG/R P
1 6 3
B-68 B-68 B-67

T.O.D. CONTROL UNIT

B-67 B-68 B-68 B-67 B-67 B-67 B-68 B-68 B-68


12 3 4 11 6 9 9 10 8 A

0.5 0.85 0.5 0.3


R/W PCM O/B W 0.85
GR/L
0.5 (E8) G/W
GR/R 6 8 1 9
5 0.5 0.5 H-7 H-8 H-8 H-7
H-49 B/L B/L
0.85 0.75
0.85 6 L L 0.5 0.3 0.85
B
H-49 0.5 O/B W G/W
0.75
GR/L L 5 7 8 16
PCM PCM C-63 C-63 C-63
12 0.5 H-6
(D8) (A1)
0.5 B/L
A-3 DATA LINK
GR/R
9 4L SW 0.8 0.8 0.8 CONNECTOR
(TRANSFER) G L R
H-49 C-63 C-63
4 1 3 2
A-3 E-5 E-5 E-5 5 4
B 0.5 0.5
4H SW A-3
B/L B/L
(TRANSFER) 3 0.5
B/L 4
0.5
H-8
B THROTTLE POSITION
0.85 0.5 SENSOR 1.25
8
B B/P B/L
H-49
14
1.25
B/P 13 H-5
0.5
H-5
B/L 1.0
1.0 B/L
7 0.5 B/R
B/L
A-3 E-29 E-30
B

TRANSFER COMMON COMMON


CHAMBER CHAMBER

D08RW612
5 6
4
3
2
1

23

22

21

20

19

18 7

17

9
16

15 14 13 12 11 10

D08RW621
STARTER SW (W/T.O.D)
(IG1) FUSE C-10
FUSE C-10
3.0 0.5
B/Y L/Y 0.5
15 L/Y 26
C-21 10A I-9
SRS I-9
SRS
WARNING
WARNING
LIGHT
LIGHT
(METER)
I-9 (METER)
I-9
24
2
0.75 0.5 0.5
B/R W/R W/R
2 2
H-62 H-62

0.5 0.5
W/R W/R
12 7 7
U-5 U-5 U-5

S D M

U-5 U-5 U-5 U-5 U-5 U-5 U-5


FUSE C-14
3 4 15 16 6 0.5 1 0.5 24
GR 2 O 1 0.85
0.75 0.75 0.75 0.75 H-61 H-61 G/W
9
Y Y/B Y/G Y/R
0.5 0.5 H-7
GR 2 O 1
H-65 H-65
2 1 1 2 0.85
U-6 U-6 U-1 U-1 0.5 0.5 G/W
GR 13 O 9 16
SRS COIL
PASSENGER
ASSEMBLY 0.5 C-63 C-63 C-63
INFLATOR B
MODULE DATA LINK
C-63 C-63 CONNECTOR
DRIVER 4 0.5 5
0.5
B/L B/L
INFLATOR
MODULE 1.25
B/L 14
H-5
1.0
B/L

U-2 E-30
•Terminals marked with a star ( ) are gold plated.

BODY-FRT COMMON
CHAMBER

D08RW605
STARTER SW
(IG1) FUSE C-10

3.0 0.5
B/Y L/Y 15
C-21 10A I-9
SRS
WARNING
LIGHT
(METER)
I-9
24
0.75 0.5
B/R W/R
2
H-62

0.5
W/R
12 7
U-5 U-5

S D M

U-5 U-5 U-5 U-5 U-5 U-5 U-5


FUSE C-14
3 4 15 16 6 0.5 1 0.5 24
GR 2 O 1 0.85
0.75 0.75 0.75 0.75 H-61 H-61 G/W
9
Y Y/B Y/G Y/R
0.5 0.5 H-7
GR 2 O 1
H-65 H-65
2 1 1 2 0.85
U-6 U-6 U-1 U-1 0.5 0.5 G/W
GR 13 O 9 16
SRS COIL
PASSENGER
ASSEMBLY 0.5 C-63 C-63 C-63
INFLATOR B
MODULE DATA LINK
C-63 C-63 CONNECTOR
DRIVER 4 5
0.5
INFLATOR B/L
MODULE 0.5
B

8
C-16
•Terminals marked with a star ( ) are gold plated. U-2

FENDER
BODY-FRT -LH

D08RW990
STARTER SW (W/T.O.D)
(IG1) FUSE C-10
FUSE C-10
3.0 0.5
B/Y L/Y 0.5
15 L/Y 26
C-21 10A I-9
SRS I-9
SRS
WARNING
WARNING
LIGHT
LIGHT
(METER)
I-9 (METER)
I-9
24
2
0.75 0.5 0.5
B/R W/R W/R
2 2
H-62 H-62

0.5 0.5
W/R W/R
12 7 7
U-5 U-5 U-5

S D M

U-5 U-5 U-5 U-5 U-5 U-5 U-5


FUSE C-14
3 4 15 16 6 0.5 1 0.5 24
GR 2 O 1 0.85
0.75 0.75 0.75 0.75 H-61 H-61 G/W
9
Y Y/B Y/G Y/R
0.5 0.5 H-7
GR 2 O 1
H-65 H-65
2 1 1 2 0.85
U-6 U-6 U-1 U-1 0.5 0.5 G/W
GR 13 O 9 16
SRS COIL
PASSENGER
ASSEMBLY 0.5 C-63 C-63 C-63
INFLATOR B
MODULE DATA LINK
C-63 C-63 CONNECTOR
4 0.5 5
DRIVER 0.5
B/L
INFLATOR B/L
MODULE 1.25
B/L 14
H-5
1.0
B/L

U-2 E-30
•Terminals marked with a star ( ) are gold plated.

BODY-FRT COMMON
CHAMBER

D08RWB41
S D M

U-5 U-5 U-5 U-5


9 10 21 22

0.5 0.5 0.5 0.5


L/B L/O L/R L/Y

1 2 1 2
H-66 H-66 H-64 H-64

0.5 0.5 0.5 0.5


L/B L/O L/R L/Y

1 2 1 2
B-34 B-34 B-23 B-23

SEAT BELT BUCKLE SEAT BELT BUCKLE


SQUIB-LH SQUIB-RH

D08RWB43
4 5
3
2
1

14

13

12

11

6
10

7
9

D08RW622
1

14

13
10 8 3

12 9
4
7
6
11

D08RW997
8D–554 WIRING SYSTEM

Connector List
No. Connector face No. Connector face
WIRING SYSTEM 8D–555

No. Connector face No. Connector face


8D–556 WIRING SYSTEM

No. Connector face No. Connector face


WIRING SYSTEM 8D–557

No. Connector face No. Connector face


8D–558 WIRING SYSTEM

No. Connector face No. Connector face


WIRING SYSTEM 8D–559

No. Connector face No. Connector face


8D–560 WIRING SYSTEM

No. Connector face No. Connector face


WIRING SYSTEM 8D–561

No. Connector face No. Connector face


8D–562 WIRING SYSTEM

No. Connector face No. Connector face


WIRING SYSTEM 8D–563

No. Connector face No. Connector face


8D–564 WIRING SYSTEM

No. Connector face No. Connector face


WIRING SYSTEM 8D–565

No. Connector face No. Connector face


8D–566 WIRING SYSTEM

No. Connector face No. Connector face


WIRING SYSTEM 8D–567

No. Connector face No. Connector face


8D–568 WIRING SYSTEM

No. Connector face No. Connector face


WIRING SYSTEM 8D–569

No. Connector face No. Connector face


8D–570 WIRING SYSTEM

No. Connector face No. Connector face


WIRING SYSTEM 8D–571

No. Connector face No. Connector face


8D–572 WIRING SYSTEM

No. Connector face No. Connector face


WIRING SYSTEM 8D–573

No. Connector face No. Connector face


8D–574 WIRING SYSTEM

No. Connector face No. Connector face


WIRING SYSTEM 8D–575

No. Connector face No. Connector face


8D–576 WIRING SYSTEM

No. Connector face No. Connector face


WIRING SYSTEM 8D–577

No. Connector face No. Connector face


8D–578 WIRING SYSTEM

No. Connector face No. Connector face


WIRING SYSTEM 8D–579

No. Connector face No. Connector face


8D–580 WIRING SYSTEM

No. Connector face No. Connector face


WIRING SYSTEM 8D–581

No. Connector face No. Connector face


8D–582 WIRING SYSTEM

No. Connector face No. Connector face


WIRING SYSTEM 8D–583

No. Connector face No. Connector face


8D–584 WIRING SYSTEM

No. Connector face No. Connector face


WIRING SYSTEM 8D–585

No. Connector face No. Connector face


8D–586 WIRING SYSTEM

No. Connector face No. Connector face


WIRING SYSTEM 8D–587

No. Connector face No. Connector face


8D–588 WIRING SYSTEM
METER AND GAUGE 8E–1

BODY AND ACCESSORIES


METER AND GAUGE
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 8E–1 Vehicle Speed Sensor . . . . . . . . . . . . . . . . . . . 8E–17
General Description . . . . . . . . . . . . . . . . . . . . . 8E–1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–17
Meter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 8E–2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–17
General Description . . . . . . . . . . . . . . . . . . . . . 8E–2 Fuel Tank Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–17
Layout for Meters/Gauges, Warning Lights, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–17
Indicator Lights and Illumination Lights . . . 8E–2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–17
Table for Meter/Gauge Connector Terminal Multi Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–18
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–16
Ambient Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 8E–18
Warning Light Bulb, Indicator Light Bulb, Illumination Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–18
Light Bulb, A/T Indicator Light Bulb . . . . . . . . 8E–16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–16
Main Data and Specifications . . . . . . . . . . . . . 8E–19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–16

Service Precaution General Description


The circuit consists of the starter switch, meter assembly,
WARNING: IF SO EQUIPPED WITH A
vehicle speed sensor, transmission switch, lighting
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
switch, turn signal switch, thermo unit, oil pressure unit,
REFER TO THE SRS COMPONENT AND WIRING
Powertrain Control Module (PCM), fuel tank unit, 4WD
LOCATION VIEW IN ORDER TO DETERMINE
switch, oil pressure switch, parking brake switch, brake
WHETHER YOU ARE PERFORMING SERVICE ON OR
fluid switch, seat belt switch, illumination controller, multi
NEAR THE SRS COMPONENTS OR THE SRS
meter and ambient sensor.
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
8E–2 METER AND GAUGE

Meter Assembly
General Description
The meter assembly has the speedometer, tachometer,
engine coolant temperature gauge, fuel gauge and
warning/indicator lights. In addition, the meter assembly
containing TOD (Torque on Demand) has the TOD
indicator light, or the meter assembly not containing TOD
has the voltmeter and oil pressure gauge instead of the
TOD indicator.

Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination


Lights
Meter Assembly–Gasoline W/O TOD (Front View)

821R200045

Legend (5) Oil Pressure Gauge & Fuel Gauge


(1) Voltmeter & Engine Coolant Temperature (6) Warning Light Lens
Gauge (7) Reset Knob
(2) Tachometer (8) A/T Shift Indicator
(3) Warning Light Lens (9) Warning Light Lens
(4) Speedometer
METER AND GAUGE 8E–3

Meter Assembly–Gasoline W/O TOD (Rear View)

821R200046

Legend (12) Illumination Light


(10) LCD Light (13) Illumination Light
(11) Illumination Light (14) Illumination Light
8E–4 METER AND GAUGE
Meter Assembly–Gasoline W/TOD (Front View)

821R200047

Legend (5) Coolant Temperature Gauge & Fuel Gauge


(1) TOD Indicator (6) Warning Light Lens
(2) Tachometer (7) Reset Knob
(3) Warning Light Lens (8) A/T Shift Indicator
(4) Speedometer (9) Warning Light Lens
METER AND GAUGE 8E–5

Meter Assembly–Gasoline W/TOD (Rear View)

821R200048

Legend (12) Illumination Light


(10) LCD Light (13) Illumination Light
(11) Illumination Light (14) Illumination Light
8E–6 METER AND GAUGE
Meter Assembly–Diesel (Front View)

821R200049

Legend (5) Coolant Temperature Gauge & Fuel Gauge


(1) TOD Indicator (6) Warning Light Lens
(2) Tachometer (7) Reset Knob
(3) Warning Light Lens (8) A/T Shift Indicator
(4) Speedometer (9) Warning Light Lens
METER AND GAUGE 8E–7

Meter Assembly–Diesel (Rear View)

821R200050

Legend (11) Illumination Light


(9) LCD Light (12) Illumination Light
(10) Illumination Light (13) Illumination Light
8E–8 METER AND GAUGE

Table for Meter/Gauge Connector Terminal Connections


Meter Assembly–Gasoline W/O TOD–1

825RW206
METER AND GAUGE 8E–9

Meter Assembly–Gasoline W/O TOD–2


Connector No. I–9 Connector No. I–10
Terminal Function Terminal Function
1 A/T oil temp warning light 1 Turn signal indicator light (Right)
2 Seat belt warning light 2 L position (A/T)
3 Check trans warning light 3 R position (A/T)
4 Brake warning light 4 Engine coolant temperature gauge
5 Check engine warning light 5 Speedometer
6 Charge warning light 6 —
7 Meter illumination light 7 —
8 Illumination controller 8 Battery (+)
9 Tachometer 9 —
10 D position (A/T) 10 Rear fog light
11 — 11 P position (A/T)
12 A/T shift indicator control unit 12 N position (A/T)
13 — 13 3 position (A/T)
14 2 position (A/T) 14 High-beam indicator light (–)
15 Starter switch 15 High-beam indicator light (+)
16 Ground (Gauge) 16 ABS indicator light
17 Cruise set indicator light 17 —
18 Cruise main indicator light 18 Fuel warning light
19 4WD indicator light 19 Oil pressure gauge
20 — 20 Fuel gauge
21 Winter drive indicator light 21 —
22 Oil pressure warning light 22 —
23 Front fog light
24 Air bag warning light
25 Power drive indicator light
26 —
27 —
28 Turn signal indicator light (Left)
29 —
30 Ground
8E–10 METER AND GAUGE
Meter Assembly–Gasoline W/TOD–1

825RW209
METER AND GAUGE 8E–11

Meter Assembly–Gasoline W/TOD–2


Connector No. I–9 Connector No. I–10
Terminal Function Terminal Function
1 Front fog light 1 Turn signal indicator light (Right)
2 Air bag warning light 2 L position (A/T)
3 A/T oil temp warning light 3 R position (A/T)
4 Charge warning light 4 Ground
5 Seat belt warning light 5 Speedometer
6 Check trans warning light 6 —
7 Brake warning light 7 —
8 — 8 Ground (Gauge)
9 Tachometer 9 Check engine warning light
10 — 10 Battery (+)
11 Turn signal indicator light (Left) 11 P position (A/T)
12 A/T shift indicator control unit 12 N position (A/T)
13 2 position (A/T) 13 3 position (A/T)
14 D position (A/T) 14 High beam indicator light (–)
15 Rear (TOD) 15 High beam indicator light (+)
16 Auto (TOD) 16 ABS indicator light
17 Check (TOD) 17 —
18 Cruise set indicator light 18 Fuel warning light
19 Cruise main indicator light 19 —
20 Oil pressure warning light 20 Fuel gauge
21 Front “1” (TOD) 21 Rear fog light
22 Front “2” (TOD) 22 Engine coolant temperature
23 Front “3” (TOD)
24 Cigarette lighter illumination light
25 Illumination controller
26 Starter switch
27 —
28 Winter drive indicator light
29 Power drive indicator light
30 —
8E–12 METER AND GAUGE
Meter Assembly–Diesel W/O TOD–1

821R200051
METER AND GAUGE 8E–13

Meter Assembly–Diesel W/O TOD–2


Connector No. I–9 Connector No. I–10
Terminal Function Terminal Function
1 A/T oil temp warning light 1 Turn signal indicator light (Right)
2 Seat belt warning light 2 O/D OFF position (A/T)
Water sedimenter
3 R position (A/T)
3 Check trans warning light
4 Engine coolant temperature gauge
4 Brake warning light
5 Speedometer
5 Check engine warning light
6 —
6 Charge warning light
7 —
7 Meter illumination light
8 Battery (+)
8 Illumination controller
9 —
9 Tachometer
10 Rear fog light
10 D position (A/T)
11 P position (A/T)
11 —
12 N position (A/T)
12 —
13 2 position (A/T)
13 —
14 High-beam indicator light (–)
14 L position (A/T)
15 High-beam indicator light (+)
15 Starter switch
16 ABS indicator light
16 Ground (Gauge)
17 —
17 —
18 Fuel warning light
18 Front fog light
19 Oil pressure gauge
19 4WD indicator light
20 Fuel gauge
20 —
21 —
21 Winter drive indicator light
22 —
22 Oil pressure warning light
23 Water sedimenter
24 Air bag warning light
25 Power drive indicator light
26 Glow indicator light
27 —
28 Turn signal indicator light (Left)
29 —
30 Ground
8E–14 METER AND GAUGE
Meter Assembly–Diesel W/TOD–1

821R200052
METER AND GAUGE 8E–15

Meter Assembly–Diesel W/TOD–2


Connector No. I–9 Connector No. I–10
Terminal Function Terminal Function
1 — 1 Turn signal indicator light (Right)
2 Air bag warning light 2 O/D OFF position (A/T)
3 A/T oil temp warning light 3 R position (A/T)
4 Charge warning light 4 Ground
5 Seat belt warning light 5 Speedometer
Water sedimenter
6 —
6 Check trans warning light
7 —
7 Brake warning light
8 Ground (Gauge)
8 —
9 Check engine warning light
9 Tachometer
10 Battery (+)
10 —
11 P position (A/T)
11 Turn signal indicator light (left)
12 N position (A/T)
12 —
13 2 position (A/T)
13 L position (A/T)
14 High-beam indicator light (–)
14 D position (A/T)
15 High-beam indicator light (+)
15 Rear (TOD)
16 ABS indicator light
16 Auto (TOD)
17 —
17 Check (TOD)
18 Fuel warning light
18 —
19 —
19 —
20 Fuel gauge
20 Oil pressure warning light
21 Rear fog light
21 Front “1” (TOD)
22 Engine coolant temperature
22 Front “2” (TOD)
23 Front “3” (TOD)
24 Meter illumination light
25 Illumination controller
26 Starter switch
27 —
28 Winter drive indicator light
29 Power drive indicator light
30 Glow indicator light
8E–16 METER AND GAUGE

Removal 5. Remove four fixing screws and disconnect the meter


connectors to remove the meter assembly(5).
1. Disconnect the battery ground cable.
2. Remove the front console assembly(1).
Refer to the Instrument Panel Assembly in Body
Structure section.
3. Remove the lower cluster assembly(2).
Refer to the Instrument Panel Assembly in Body
Structure section.
4. Remove the instrument panel driver lower cover(3).
Refer to the Instrument Panel Assembly in Body
Structure section.

825RW031

CAUTION: The removed meter assembly should be


placed upright or with its face side up.

Installation
To install, follow the removal steps in the reverse order.

740RS004

Warning Light Bulb, Indicator Light Bulb, Illumination Light Bulb,


A/T Indicator Light Bulb
Removal
1. Disconnect the battery ground cable.
2. Remove the meter assembly(1).
Refer to the Meter Assembly removal steps in this
section.
3. Hold the bulb socket by hand and rotate it
counterclockwise to remove the socket & bulb(2)
from the meter body.

825RW032

Installation
To install, follow the removal steps in the reverse order.
METER AND GAUGE 8E–17

Vehicle Speed Sensor


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order,
noting the following point.
2. Disconnect the connector, remove the vehicle speed
sensor body by rotating it and then remove the vehicle 1. Tighten the vehicle speed sensor to the specified
speed sensor(1). torque.
Torque: 27 Nꞏm (2.8 kgꞏm/20 lb ft)

826RS009

Fuel Tank Unit


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Remove the fuel tank(1).
Refer to the Fuel Tank removal steps in Engine
section
3. Disconnect the connectors, remove five screws and
then remove the fuel tank unit(2).

140RS006
8E–18 METER AND GAUGE

Multi Meter
Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Remove two caps, two screws and disconnect the
connector to remove the multi meter(1).

821RW036

Ambient Sensor
Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Disconnect the connector and remove the nut to
remove the ambient sensor(1).

821RW035
METER AND GAUGE 8E–19

Main Data and Specifications


Torque Specifications
Application Nꞏm kgꞏm Lb Ft Lb In
Vehicle Speed Sensor Fixing 27 2.8 20 —
BODY STRUCTURE 8F–1

BODY AND ACCESSORIES


BODY STRUCTURE
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 8F–3 Radiator Grille And Front End Lower Panel . 8F–18
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–3 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–18
General Description . . . . . . . . . . . . . . . . . . . . . . 8F–3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–18
Frame Dimensions (L W B) . . . . . . . . . . . . . . . 8F–4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–19
Frame Dimensions (S W B) . . . . . . . . . . . . . . . 8F–5 Front Fender Panel . . . . . . . . . . . . . . . . . . . . . . 8F–20
General Description . . . . . . . . . . . . . . . . . . . . . 8F–6 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–20
Front Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–20
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–7 Body Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–7 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–22
Front Bumper Slider Bracket . . . . . . . . . . . . . . 8F–7 Removal (No.1 – No. 2) . . . . . . . . . . . . . . . . 8F–22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–7 Removal (No. 3 — No. 6) . . . . . . . . . . . . . . . 8F–23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–24
Rear Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–8 General Description . . . . . . . . . . . . . . . . . . . . . 8F–25
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–8 Body Dimension . . . . . . . . . . . . . . . . . . . . . . . . 8F–26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–8 Instrument Panel Assembly . . . . . . . . . . . . . . . 8F–46
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–9 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–46
Parts Location (W/Rear Combination Light Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–47
and License Light) . . . . . . . . . . . . . . . . . . . . 8F–10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–51
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–10 Cross Beam Assembly . . . . . . . . . . . . . . . . . . . 8F–52
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–11 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–52
Rear Bumper Slider . . . . . . . . . . . . . . . . . . . . . 8F–12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–52
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–53
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–12 Front Door Assembly . . . . . . . . . . . . . . . . . . . . 8F–54
General Description . . . . . . . . . . . . . . . . . . . . . 8F–13 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–54
Cowl Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–13 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–54
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–13 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–54
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–13 Rear Door Assembly . . . . . . . . . . . . . . . . . . . . . 8F–55
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–14 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–55
Engine Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–56
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–14 Door Strikers . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–56
Air Bulge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–15 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–56
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–15 Door Check Arm Assembly (Front & Rear) . . 8F–57
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–15 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–57
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–57
Engine Hood Hinge . . . . . . . . . . . . . . . . . . . . . . 8F–16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–58
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–16 Front Window Regulator, Glass And Glass
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–16 Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–58
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–16 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–58
Engine Hood Lock . . . . . . . . . . . . . . . . . . . . . . . 8F–17 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–58
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–17 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–60
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–17 Rear Window Regulator And Glass . . . . . . . . 8F–61
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–18 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–61
8F–2 BODY STRUCTURE
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–61 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–79
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–62 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–79
Rear Door Fixed Glass And Glass Run . . . . . 8F–63 Tailgate Dove-Tail Striker . . . . . . . . . . . . . . . . . 8F–80
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–63 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–80
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–63 Tailgate Frame Cover (LH) . . . . . . . . . . . . . . . 8F–81
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–64 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–81
Front Door Sash Moulding . . . . . . . . . . . . . . . . 8F–65 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–81
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–65 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–81
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–65 Tailgate Frame Cover (RH) . . . . . . . . . . . . . . . 8F–82
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–65 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–82
Rear Door Moulding . . . . . . . . . . . . . . . . . . . . . 8F–66 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–82
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–66 Tailgate Sash Trim Cover . . . . . . . . . . . . . . . . . 8F–83
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–66 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–83
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–66 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–83
Front Door Waist Seal . . . . . . . . . . . . . . . . . . . 8F–67 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–83
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–67 Tailgate Outer Weatherstrip . . . . . . . . . . . . . . . 8F–84
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–67 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–84
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–67 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–84
Rear Door Waist Seal . . . . . . . . . . . . . . . . . . . . 8F–68 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–84
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–68 Tailgate Center Weatherstrip . . . . . . . . . . . . . . 8F–85
Removal and Installation . . . . . . . . . . . . . . . 8F–68 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–85
Front Door Weatherstrip . . . . . . . . . . . . . . . . . . 8F–69 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–85
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–69 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–85
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–69 Tailgate Main Weatherstrip . . . . . . . . . . . . . . . 8F–86
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–70 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–86
Rear Door Weatherstrip . . . . . . . . . . . . . . . . . . 8F–71 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–86
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–71 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–86
Removal and Installation . . . . . . . . . . . . . . . 8F–71 Spare Tire Carrier . . . . . . . . . . . . . . . . . . . . . . . 8F–87
Front Door Seal Finisher . . . . . . . . . . . . . . . . . 8F–72 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–87
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–72 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–87
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–72 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–87
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–72 Headlining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–88
Rear Door Seal Finisher . . . . . . . . . . . . . . . . . . 8F–73 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–88
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–73 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–88
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–73 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–89
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–73 Rear Air Deflector . . . . . . . . . . . . . . . . . . . . . . . 8F–90
Tailgate Assembly (LH) . . . . . . . . . . . . . . . . . . 8F–74 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–90
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–74 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–90
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–74 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–90
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–75 Roof Moulding . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–92
Tailgate Assembly (RH) . . . . . . . . . . . . . . . . . . 8F–76 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–92
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–76 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–92
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–76 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–93
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–77 Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–94
Tailgate Strikers . . . . . . . . . . . . . . . . . . . . . . . . . 8F–78 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–94
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–78 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–94
Tailgate Stopper Assembly . . . . . . . . . . . . . . . 8F–78 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–95
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–78 Rear Quarter Side Glass . . . . . . . . . . . . . . . . . 8F–99
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–78 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–99
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–78 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–99
Tailgate Dove-Tail . . . . . . . . . . . . . . . . . . . . . . . 8F–79 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–100
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–79 Tailgate Glass . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–102
BODY STRUCTURE 8F–3
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–102 Main Data and Specifications . . . . . . . . . . . . . 8F–104
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–102 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–115
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–103

Service Precaution CAUTION: Always use the correct fastener in the


proper location. When you replace a fastener, use
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL ONLY the exact part number for that application.
RESTRAINT SYSTEM (SRS). REFER TO THE SRS ISUZU will call out those fasteners that require a
COMPONENT AND WIRING LOCATION VIEW IN replacement after removal. ISUZU will also call out
ORDER TO DETERMINE WHETHER YOU ARE the fasteners that require thread lockers or thread
PERFORMING SERVICE ON OR NEAR THE SRS sealant. UNLESS OTHERWISE SPECIFIED, do not
COMPONENTS OR THE SRS WIRING. WHEN YOU use supplemental coatings (Paints, greases, or other
ARE PERFORMING SERVICE ON OR NEAR THE SRS corrosion inhibitors) on threaded fasteners or
COMPONENTS OR THE SRS WIRING, REFER TO fastener joint interfaces. Generally, such coatings
THE SRS SERVICE INFORMATION. FAILURE TO adversely affect the fastener torque and the joint
FOLLOW WARNINGS COULD RESULT IN POSSIBLE clamping force, and may damage the fastener. When
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR you install fasteners, use the correct tightening
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.

Frame
General Description
Proper frame alignment is important to assure normal
vehicle life and performance of many other parts of the
vehicle. If the vehicle has been involved in a fire, collision
or has been overloaded, it is necessary to check the
frame alignment.
8F–4 BODY STRUCTURE

Frame Dimensions (L W B)
This illustration is based on the gasoline engine and A/T
model.

501RW013
BODY STRUCTURE 8F–5

Frame Dimensions (S W B)
This illustration is based on the gasoline engine and A/T
model.

501RW014
8F–6 BODY STRUCTURE

General Description frame, a slider is used to fasten the bumper fascia to the
fender panel. The bumpers can be removed by taking
This section describes how to remove and install front them out forward or backward after removing the two
and rear bumpers. Each bumper is installed with two fixing bolts on either side.
fixing bolts used on either side to fasten the backbar to the

Front Bumper
Parts Location

601RX001

Legend (8) Front Bumper Slider


(1) Front Bumper Assembly (9) Front Bumper Slider Fixing Nut
(2) Front Bumper Retainer Bolt (10) Bumper Fascia Lower Bolt
(3) Support Fixing Clip (11) Front Fog Light Assembly
(4) Bumper Spacer Support (12) Reinforce Assembly
(5) Back Bar Fixing Bolt (13) Reinforce Lower Bolt
(6) Front Fog Light Connector (14) Front Bumper Fixing Bolt
(7) Front Bumper Slider Fixing Clip (15) Back Bar
BODY STRUCTURE 8F–7

Removal 9. Remove backbar fixing bolts.


Remove the four bolts at each backbar.
1. Disconnect battery ground cable.
10. Remove front fog light assembly.
2. Remove front fog light connector.
11. Remove the front bumper slider(1).
3. Remove front bumper assembly fixing bolt.
Remove the two clips(4) and the two nuts(3), and
Remove the two bolts from both sides of the front release the claw from the washer(2).
bumper.

601RW009
601RW010

4. Remove front bumper assembly.


5. Remove bumper fascia lower bolts. Installation
6. Remove front bumper retainer. To install, follow the removal steps in reverse order noting
the following points:
7. Remove reinforce lower bolts.
1. Tighten the front bumper assembly fixing bolts to the
Loosen the five bolts and release claws. specified torque.
8. Remove reinforce assembly.
Torque: 132 N m (13.5kgꞏm/98 lb ft)

Front Bumper Slider Bracket


Removal
1. Disconnect battery ground cable.
2. Remove the Front bumper.
Refer to Front Bumper in this section.
3. Remove the three nuts(1) and draw out the slider
bracket(2).

601RW003

Installation
To install, follow the removal steps in reverse order.
8F–8 BODY STRUCTURE

Rear Bumper
Parts Location

690RW001

Legend (8) Rear Bumper Fascia Bracket Screws


(1) Back Bars (9) Rear Bumper Assembly
(2) Reinforce Assembly (10) Rear Bumper Side Covers
(3) Rear Bumper Slider Brackets (11) Mud Flaps
(4) Rear Step Clips (12) Rear Bumper Assembly Fixing Bolts
(5) Reinforce Lower Screws (13) Rear Bumper Retainers
(6) Reinforce Upper Bolts (14) Clips
(7) Rear Bumper Fascia Brackets

Removal 2. Remove mud flaps.


Remove three screws.
1. Remove rear bumper side covers.
3. Remove bumper fascia bracket screws.
BODY STRUCTURE 8F–9
4. Remove rear bumper assembly fixing bolts. 14. Remove bumper fascia brackets.
Remove two bolts from each side. Remove the fixing nut on the back side of the fender
panel.

Installation
To install, follow the removal steps in reverse order noting
the following points:
1. Tighten the rear bumper assembly fixing bolts to the
specified torque.
Torque: 132 N m (13.5kgꞏm/98 lb ft)
2. Apply chassis grease to the slider and the slider
bracket moving surface.

690RW002

5. Remove rear bumper assembly.


6. Remove rear bumper retainers.
7. Remove reinforce upper bolts.
Remove the rear bumper retainer from each side,
and then remove two upper bolts.
8. Remove reinforce lower screws.
9. Remove clips.
10. Remove rear step clips.
11. Remove reinforce assembly.
Pull out both ends of the bumper fascia and take out
the reinforce assembly.
12. Remove backbars.
Remove the three bolts from each backbar.
13. Remove rear bumper slider brackets(4).
Remove the two clips(1) and two screws(3), and
then remove claw caught in the washer(2).

690RS003
8F–10 BODY STRUCTURE

Parts Location (W/Rear Combination Light and License Light)

690RW010

Legend (9) Reinforce Upper Bolts


(1) Back Bar (10) Rear Step
(2) Rear Combination Light Back Plate (11) Rear Step Clips
(3) Rear Bumper Retainer (12) Rear Bumper Fascia Bracket Screws
(4) Reinforce Assembly (13) Rear Bumper Assembly
(5) Rear Bumper Slider Brackets (14) Rear Bumper Side Covers
(6) Rear Combination Light Assembly (15) Rear Bumper Fascia Brackets
(7) License Light (16) Mud Flaps
(8) Reinforce Lower Screws (17) Rear Bumper Assembly Fixing Bolts

Removal 3. Remove mud flaps.


Remove three screws.
1. Disconnect battery ground cable.
4. Remove rear bumper fascia bracket screws.
2. Remove rear bumper side covers.
BODY STRUCTURE 8F–11
5. Remove rear bumper assembly fixing bolts. 16. Remove bumper fascia brackets.
Remove two bolts from each side. Remove the fixing nut on the back side of the fender
panel.
17. Remove rear combination light assembly.
18. Remove license light.

Installation
To install, follow the removal steps in reverse order noting
the following points:
1. Tighten the rear bumper assembly fixing bolts to the
specified torque.
Torque: 132 N m (13.5kgꞏm/98 lb ft)
2. Apply chassis grease to the slider and the slider
bracket moving surface.

690RW002

6. Remove rear bumper assembly.


7. Remove rear bumper retainers.
8. Remove rear combination light back plate.
9. Remove reinforce upper bolts.
Remove the rear bumper retainer from each side,
and then remove two upper bolts.
10. Remove reinforce lower screws.
11. Remove rear step clips.
12. Remove rear step.
13. Remove reinforce assembly.
Pull out both ends of the bumper fascia and take out
the reinforce assembly.
14. Remove backbars.
Remove the three bolts from each backbar.
15. Remove rear bumper slider brackets(4).
Remove the two clips(1) and two screws(3), and
then remove claw caught in the washer(2).

690RS003
8F–12 BODY STRUCTURE

Rear Bumper Slider


Removal
1. Remove the rear bumper.
Refer to Rear Bumper removal in this section.
2. Remove the three bolts (2).
3. Remove rear bumper slider (1).

690RS004

Installation
To install, follow the removal steps in reverse order noting
the following points:
1. Apply chassis grease to the slider and the slider
bracket moving surface.
BODY STRUCTURE 8F–13

General Description Anti-corrosion materials have been applied to the interior


surfaces of some metal panels to provide rust resistance.
This section includes items of front end sheet metal that When servicing these panels, areas on which this
are attached by bolts, screws or clips and related material has been disturbed should be properly recoated
accessory components. with service-type anti-corrosion material.

Cowl Cover
Parts Location

605RW009

Legend (4) Cowl Cover Stoppers


(1) Front Wiper Arms (5) Cowl Cover Seals
(2) Cowl Cover (6) Front Window Lower Molding
(3) Cowl Cover Brackets

Removal 3. Remove front wiper arms.


Refer to Windshield Wiper Arm/Blade in
1. Open the hood. Wiper/Washer System section.
2. Support the hood.
8F–14 BODY STRUCTURE
4. Remove cowl cover brackets. 7. Remove front window lower molding.
Disconnect two screws each side. 8. Remove cowl cover stoppers.
5. Remove cowl cover.
Disconnect three screws. Installation
6. Remove cowl cover seals. To install, follow the removal steps in reverse order.

Engine Hood
Removal Installation
1. Open the hood. To install, follow the removal steps in the reverse order
noting the following points:
2. Support the hood.
1. Tighten the engine hood fixing bolts to the specified
3. Remove windowshield washer nozzle tube.
torque.
Torque: 13 N m (1.3kgꞏm/113 lb in)
2. Adjust the engine hood mounting gap with reference
to Body Dimension in this section.
3. Check and see if the engine hood lock operates
normally.

880RS001

4. Remove hood hinge bolts (3).


Before removing the hinges from the engine hood
(1), scribe a mark (2) showing location of the hinges
to facilitate installation in the original position.

610RS003

5. Remove engine hood.


BODY STRUCTURE 8F–15

Air Bulge
Parts Location

610RW013

Legend (2) Intercooler Seal


(1) Air Bulge (3) Engine Hood Insulator

Removal 1. Tighten the air bulge fixing nuts to the specified


torgue.
1. Remove engine food insulator.
Torque 8 N m (0.8kgꞏm/ 69 lb in)
Remove the sixteen clips.
2. Remove Intercooler seal.
Remove the six clips.
3. Remove air bulge.
Remove the six nuts.

Installation
To install, follow the removal steps in the reverse order
noting the following points:
8F–16 BODY STRUCTURE

Engine Hood Hinge


Parts Location

610RW012

Legend (3) Engine Hood Hinge


(1) Hinge Fixing Bolts And Nuts (4) Engine Hood
(2) Hood End Seal (5) Cowl Cover

Removal Installation
1. Remove cowl cover. To install, follow the removal steps in reverse order noting
the following points:
Refer to Cowl Cover in this section.
1. Tighten the hood hinge fixing bolt and nut to the
2. Remove engine hood.
specified torque.
Refer to Engine Hood in this section.
Torque 13 N m (1.3kgꞏm/113 lb in)
3. Remove hinge fixing bolt and nut.
4. Remove engine hood hinge.
5. Remove hood end seal.
BODY STRUCTURE 8F–17

Engine Hood Lock


Parts Location

610RW011

Legend (3) Engine Hood Lock Assembly


(1) Hood Lock Control Lever (4) Radiator Grille
(2) Control Cable (5) Inner Liner

Removal
1. Remove hood lock control lever.
2. Remove inner liner.
3. Remove control cable.
Remove the cable fixing clips from the body panel.
4. Remove radiator grille.
Refer to Radiator Grille And Front End Lower Panel
in this section.
5. Remove engine hood lock assembly.
Apply setting marks (1) to the hood lock assembly
and the body prior to removal.

610RW009
8F–18 BODY STRUCTURE

Installation 2. Tighten the hood lock assembly fixing bolts to the


specified torque.
To install, follow the removal steps in reverse order noting
the following points: Torque : 10 N m (1.0kgꞏm/87 lb in)
1. Reroute the control cable to its original position, and
check and see if the lock assembly and control lever
work normally.

Radiator Grille And Front End Lower Panel


Parts Location

603RY00002

Legend (3) Radiator Grille


(1) Front End Lower Panel (4) For ISUZU Brand Vehicle Only
(2) Head Light Wiper

Removal
1. Open the hood.
2. Support the hood.
3. Remove headlight wiper.
Refer to Headlight Wiper Arm & Blade in
Wiper/Washer System section.
BODY STRUCTURE 8F–19
4. Remove radiator grille.
Raise the clips (1) on the radiator grille and remove
two screws.

603RW012

5. Remove front end lower panel.


Remove two fixing bolts and remove the panel from
the fender.

Installation
To install, follow the removal steps in reverse order, noting
the following point.
1. Install the radiator grille clips remaining on the body
side in the radiator grille, and then install the radiator
grille on the body.
8F–20 BODY STRUCTURE

Front Fender Panel


Parts Location

605RW008

Legend (4) Side Turn Signal Light


(1) Cowl Cover (5) Front Fender Panel
(2) Front Mud Flap (6) Front Combination Light Assembly
(3) Antenna Bezel (7) Inner Liner

Removal 6. Remove front mud flap.


Disconnect three fixing screws and four clips.
1. Open the hood.
7. Remove inner liner.
2. Support the hood.
8. Remove antenna bezel.
3. Disconnect the battery ground cable.
Refer to Antenna in Entertainment section.
4. Remove cowl cover.
9. Remove side turn signal light.
Refer to Cowl Cover in this section.
Refer to Side Turn Signal Light Bulb in Lighting
5. Remove front combination lamp assembly. System section.
Disconnect fixing screw and connector.
BODY STRUCTURE 8F–21
10. Remove front fender panel.
Disconnect ten fixing bolts and two nuts.

605RW001

Installation
To install, follow the removal steps in the reverse order
noting the following points:
1. Tighten the front fender panel fixing bolts to the
specified torque.
(1) Torque : 9 N m (0.9kgꞏm/78 lb in)
(2) Torque : 7 N m (0.7kgꞏm/61 lb in)
8F–22 BODY STRUCTURE

Body Mounting
Parts Location

E02RW006

Removal (No.1 – No. 2)


1. Remove the front bumper.
2. Jack up the vehicle by the frame.
3. Support the front side sill and rear axle with stands.
Further, support the front jack up point with a jack.
BODY STRUCTURE 8F–23
4. Remove the mounting bolts (No. 1-4) on either side.
No. 1 – Hold in check not to turn from the inside of
the front fender.
No. 2 – Remove the front door sill plate and dash
side trim panel, turn over the floor carpet and hold
the bolt in check not to turn.
No. 3 (LWB only)– Remove the rear door sill plate
and center pillar lower trim cover, turn over the floor
carpet and hold the bolt in check not to turn.
No. 4 (SWB)– Remove the luggage side trim cover,
turn over the floor carpet and hold the bolt in chek
not to turn.
No. 4 (LWB)– Remove the bolt from under the
frame.
5. Loosen the mounting bolts (No. 5-6) on either side.
6. Remove the frame side mounting and washer.
7. Gently lower the jack supporting the front axle until
620RS001
the cab side mounting can be removed.
8. Remove the cab side mounting.
Be sure to use a splice bar around the mounting to
be removed.

420RS001

501RS001

Removal (No. 3 — No. 6)


1. Remove the rear bumper.
2. Jack up the vehicle by the frame.

545RS001
8F–24 BODY STRUCTURE
3. Support the rear side sill and frame stands, and 4. Remove the mounting bolts (No. 3-6) on either side.
support the rear axle with a jack. No. 3 (LWB only) — Remove the rear door sill plate
and center pillar lower-trim cover, turn over the floor
carpet and hold the bolt in check not to turn.
No. 4 (SWB) — Remove the luggage side trim
cover, turn over the floor carpet and hold the bolt in
check not to turn.
No. 4 (LWB) and No. 5 – 6
5. Remove the frame side mounting and washer.
6. Gently lower the jack supporting the rear axle until the
cab side mounting can be removed.
7. Remove the cab side mounting.
Be sure to use a splice bar around the mounting to
be removed.
As for No. 5 and 6, remove the frame side bracket
fixing bolts after lowering the frame gently.

620RS002

510RS001

Installation
501RS003 To install, follow the removal steps in the reverse order,
noting the following point:
1. Tighten each mounting bolt to the specified torque.
Torque : 50 N m (5.1kgꞏm/37 lb ft)

420RS002
BODY STRUCTURE 8F–25

General Description
This section describes major items of the removal,
installation and servicing procedures pertaining to the
TROOPER body. Each servicing instruction is applicable
to all models of the TROOPER, unless otherwise
specifically mentioned. For those differing by specific
models from the common procedures, they are detailed
for each model.
8F–26 BODY STRUCTURE

Body Dimension
Upper Body

A10RW001
BODY STRUCTURE 8F–27

A10RY00001
8F–28 BODY STRUCTURE

A10RY00002
BODY STRUCTURE 8F–29

A10RY00007
8F–30 BODY STRUCTURE

Front Section

A10RW031
BODY STRUCTURE 8F–31

A10RW004
8F–32 BODY STRUCTURE

Room Section (LWB)

A10RW030
BODY STRUCTURE 8F–33

A10RW005
8F–34 BODY STRUCTURE

A10RW006
BODY STRUCTURE 8F–35

A10RW024
8F–36 BODY STRUCTURE

A10RW025
BODY STRUCTURE 8F–37

Rear Section

A10RW032
8F–38 BODY STRUCTURE

A10RW008
BODY STRUCTURE 8F–39

Side Body

A10RW026
8F–40 BODY STRUCTURE

A10RW009
BODY STRUCTURE 8F–41

A10RW027
8F–42 BODY STRUCTURE

Window Glass

A10RW028
BODY STRUCTURE 8F–43

A10RW011
8F–44 BODY STRUCTURE

A10RW029
BODY STRUCTURE 8F–45

A10RW013
8F–46 BODY STRUCTURE

Instrument Panel Assembly


Parts Location
This illustration is based on RHD and W/SRS.

740RY00028

Legend (10) Lower Cluster Assembly


(1) Front Defroster Grille (11) Front Console Assembly
(2) Vent Duct Assembly (12) Glove Box
(3) Instrument Harness Assembly (13) Instrument Panel Passenger Lower Cover
(4) Side Defroster Grille Assembly
(5) Meter Assembly (14) Passenger Knee Bolster Reinforcement
(6) Instrument Panel Cluster Assembly Assembly
(7) Driver Knee Bolster Assembly (W/SRS) (15) Control Lever Assembly
(8) Instrument Panel Driver Lower Cover (16) Passenger Inflator Module (W/SRS)
Assembly (17) Instrument Panel Assembly
(9) Radio Assembly
BODY STRUCTURE 8F–47

Removal 5. Remove instrument panel passenger lower cover


assembly.
CAUTION: For precautions on installation or Remove the 7 fixing screws (1) and 1 clip (2).
removal of SRS—air bag system, refer to
Supplemental Restraint System (SRS) — AIR BAG in
Restraint section.
1. Disconnect the battery ground cable.
2. Remove front console assembly.
Remove the 4 fixing screws and disconnect the
switch connectors.
3. Remove lower cluster assembly.
Remove the 3 fixing screws (1) in order to
disconnect the cigarette lighter (3) and the
illumination (2) connectors.

740RW103

6. Remove passenger knee bolster reinforcement


assembly.
Remove the 4 fixing bolts (2) and 4 nuts (1).

740RS014

4. Remove glove box.


Remove the 2 fixing screws.

740RS011

740RW104
8F–48 BODY STRUCTURE
7. Remove instrument panel driver lower cover 9. Remove front defroster grille.
assembly. Pry 8 claws on the front side toward you side (room
Remove the engine hood opener fixing screws. side) and raise the grille upward.
Remove the 2 fixing screws (2), 1 fixing bolt (3), and 10. Remove instrument panel assembly.
1 clip (4). Pull out the fasteners at the 4 positions Remove the 2 fixing bolts on the SRS adjust bracket
(1). and the cross beam under the passenger inflator
module (W/SRS).
CAUTION: For precautions on installation or
removal of SRS — air bag system, refer to
Supplemental RestraintSystem (SRS) — AIR BAG in
Restraint section.

740RW105

8. Remove driver knee bolster assembly (W/SRS).


Remove the 6 fixing nuts.

827RW031

Disconnect the 3 air conditioner control cables on


the unit side.
Remove the instrument harness connectors (5
connectors on the drivers side and 3 connectors on
the passenger side), the passenger inflator module
connector, the radio antenna cable plug, and the
ground cable fixing bolt on the center bracket.
Remove the 4 bolts (4) and the 2 nuts (3) under the
instrument panel assembly, and the upper left and
the upper right bolts (2) and the center nut (1).

740RW122
BODY STRUCTURE 8F–49

740RW106

11. Remove passenger inflator module (W/SRS). 12. Remove instrument panel cluster assembly.
From the back of the instrument panel, remove the Remove the 5 fixing screws (2) and pull the main
4 fixing nuts (2) on the passenger inflator module (3) unit toward you and remove the clips at the 4
and the 2 fixing nuts (1) and washers on the support positions (1). Disconnect the switch connectors.
bracket (4), then disengage the 2 clips in order to
remove the passenger inflator module.

740RW107

827RW032
8F–50 BODY STRUCTURE
13. Remove meter assembly.
Remove the 4 meter assembly fixing screws and
disconnect the meter harness connectors.

821RS034

14. Remove control lever assembly.


Refer to Control Lever Assembly And/Or Control
Cables in Heating And Ventilation section.
15. Remove radio assembly.
Remove 2 fixing screws.
16. Remove vent duct assembly.
Remove 5 fixing screws.
17. Remove instrument harness assembly.
Remove the 4 fixing screws, fasteners at the 4
positions and the clips at the 7 positions.
18. Remove side defroster grille.
NOTE: For the order of removal steps in which each
items contained in the instrument panel assembly are
removed individually, refer to the chart.
BODY STRUCTURE 8F–51

Installation
To install, follow the removal steps in the reverse order.
Order Of Removal/Installation Steps For Each Item
Removal Item Removal Procedure Removal Step
Front console Shift knob (M/T), Power & Winter SW (A/T), Transfer knob, Seat 1, 2
assembly heater/Miller SW conn. and 4 screws
Lower cluster 3 screws, Ciger lighter conn. and Ashtray illumination conn. 1 3
assembly
Glove box 2 screws 4
Instrument panel 7 screws and 1 clip 1 5
passenger lower cover
Passenger knee 4 nuts and 4 bolts 1 6
bolster reinforcement
Instrument panel driver Engine hood opening fixing screw, 2 screws, 1 bolt, 1 clip and 1 3, 7
lower cover fasteners at 4 positions
Driver knee bolster 6 nuts 1 3, 7, 8
Front defroster grille Claws at 8 positions 9
Instrument panel 2 bolts (SRS adjust bracket cross beam), A/C control cable (Unit 1 10
assembly side at 3 position), Instrument harness connector (Driver side 5
position, assist side 3 position), SRS module conn., Radio antenna
jack, Earth cable, 9 bolts and 3 nuts
Passenger inflator 4 nuts (SRS module Instrument panel), 2 nuts 0 and 2 washers 1 6, 11
module (SRS module support bracket) and 2 clips
Instrument panel 5 Screws, fastener at 4 position and each SW conn. 1 3, 7, 12
cluster
Meter assembly 4 screws and connectors 1 3, 7, 12, 13
A/C control panel 4 screws and connectors 1 3, 7, 12, 14
assembly
Radio assembly 2 screws 1 3, 15
Vent duct assembly 5 screws 1 10, 16
Instrument harness 4 screws, fasteners at 4 position, and clips at 7 position 1 10, 17
assembly
Side defroster grille 18

M/T = Manual Transmission


A/T = Automatic Transmission
SRS = Supplemental Restraint System
A/C = Air Conditioning
8F–52 BODY STRUCTURE

Cross Beam Assembly


Parts Location
This illustration is based on RHD and W/SRS

740RW100

Legend (5) Steering Support Bracket Assembly


(1) Instrument Panel Assembly (6) Instrument Panel Center Bracket
(2) Cross Beam Assembly (7) Side Support Bracket Assembly (LH)
(3) Side Support Bracket Assembly (RH) (8) Steering Column Fixing Bolts
(4) Brake Pedal Mounting Bracket Assembly (9) Cross Beam Center Bracket

Removal 5. Remove instrument panel center bracket.


Disconnect the PCM and EBCM connector.
1. Disconnect battery ground cable.
Remove the DERM (SRS) with 3 fixing nuts.
2. Remove instrument panel assembly.
Refer to Instrument Panel Assembly in this section. CAUTION: For precautions on installation or
3. Remove side support bracket assembly (LH/RH). removal of SRS — air bag system, refer to
Supplemental Restraint System (SRS) — AIR BAG in
Remove the 4 fixing bolts on both sides. Restraint section.
4. Remove cross beam center bracket
Remove the 2 fixing nuts (upper) and the 4 fixing
Remove 2 fixing nuts. bolts (lower).
BODY STRUCTURE 8F–53

740RW101 310RW014

6. Remove steering column fixing bolts. 8. Remove steering support bracket assembly.
Remove 2 fixing bolts. Remove the 2 fixing bolts (upper side) (1) and the 3
fixing nuts (lower side) (2).

431RW007

7. Remove brake pedal mounting bracket assembly. 740RW102

Disconnect the 2 brake pedal mounting bracket 9. Remove cross beam assembly.
assembly fixing nuts, and remove the antitheft Disconnect the harness clips from the crossbeam
controller. assembly, and remove 2 fixing bolts on both sides
Disconnect the brake pedal link and the brake and 2 fixing nuts in the center.
switch, and remove the 4 fixing bolts and the nuts
on the bracket. Installation
To install, follow the removal steps in the reverse order.
8F–54 BODY STRUCTURE

Front Door Assembly


Parts Location

630RS001

Legend (3) Door Hinge Assembly


(1) Door Check Arm Pin (4) Hinge Bolt
(2) Front Door Assembly (5) Door Harness Connection

Removal
1. Disconnect the battery ground cable.
2. Remove door check arm pin (1).

810RS001

5. Remove front door assembly.

Installation
630RS002
To install, follow the removal steps in the reverse order,
3. Remove hinge bolt.
noting the following points:
Align the hinge bolt to the door side hinge and put a
1. Align the door fitting to the body by referring to Body
marker on it.
Dimensions in this section.
4. Remove door harness connection (2).
2. Tighten the door hinge bolts to the specified torque.
Pull the door harness grommet out in order to
disconnect the harness connection. Torque : 34 N m (3.5kgꞏm/25 lb ft)
3. Apply chassis grease to the door check arm pin and
the door hinge moving surface.
BODY STRUCTURE 8F–55

Rear Door Assembly


Parts Location

650RW007

Legend (3) Rear Door Assembly


(1) Door Check Arm Pin (4) Hinge Bolt
(2) Door Harness Connection

Removal 4. Remove hinge bolt.


Open the front door and remove the body side hinge
1. Disconnect the battery ground cable. bolts (2).
2. Apply a setting mark on the body side hinge.
3. Remove door check arm pin (1).

650RS002

630RS002
8F–56 BODY STRUCTURE
5. Remove door harness connection (3). Installation
Pull the door harness grommet out in order to To install, follow the removal steps in the reverse order,
disconnect the door harness connection. noting the following points.
1. Align the door fitting to the body by refer to Body
Dimensions in this section.
2. Tighten the door hinge bolts to the specified torque.
Torque : 34 N m (3.5kgꞏm/25 lb ft)
3. Apply chassis grease to the check arm pin and the
door hinge moving surface.

810RS002

6. Remove door assembly

Door Strikers
Adjustment

632RS001

1. Loosen the striker (1) screws.


2. Tap with a plastic hammer to align.
3. Tighten the striker screws.
Torque : 15 N m (1.5kgꞏm/11 lb ft)
BODY STRUCTURE 8F–57

Door Check Arm Assembly (Front & Rear)


Parts Location

630RS003

Legend (4) Check Arm Pin Bracket


(1) Front or Rear Door (5) Check Arm Pin
(2) Door Trim Panel (6) Front or Center Pillar
(3) Check Arm Assembly

Removal
1. Disconnect the battery ground cable.
2. Remove door trim panel.
Refer to Front Door Trim Panel in Exterior / Interior
Trim section.
3. Remove check arm pin (1).

630RS002
8F–58 BODY STRUCTURE
4. Remove check arm assembly. 1. When installing the check arm assembly, note its
Carefully peel off the water proof sheet as much as marking to ensure using the appropriate part.
necessary, for check arm removal. 2. Tighten the check arm fixing nuts to the specified
torque.
Installation Torque : 13 N m (1.3kgꞏm/113 lb in)
To install, follow the removal steps in the reverse order, 3. Apply chassis grease to the check arm pin moving
noting the following point. surface.

Front Window Regulator, Glass And Glass Run


Parts Location

631RS002

Legend (5) Window Regulator


(1) Speaker Box (6) Window Regulator with Power Window
(2) Glass Run (7) Window Regulator Motor Connector
(3) Glass (8) Door Trim Panel
(4) Rear Guide Rail (9) Waterproof Sheet

Removal 2. Remove door trim panel.


Refer to Front Door Trim Panel in Exterior / Interior
1. Disconnect the battery ground cable. section.
3. Remove speaker box.
BODY STRUCTURE 8F–59
4. Remove waterproof sheet. When the front side of the glass comes off the glass
Take notice of the door harness and the grommet, run (3), turn the glass inside out and pull it up from
peel the waterproof sheet off the door panel its rear side.
carefully.

631RS005

631RS003 6. Remove window regulator.


5. Remove glass. Remove the window regulator fixing bolts (4) and
Bring the glass (1) down to the position where the the rear guide rail fixing bolt (5).
fixing bolts can be seen. Disconnect the window regulator motor harness
Remove the glass fixing bolts from the window connector, if equipped with power windows.
regulator (2) and lower the front side of the glass.

631RS006

631RS004
8F–60 BODY STRUCTURE
7. Remove glass run. 4. Check to see of the window regulator operates
Pull the glass run (6) out from the door frame smoothly and the glass opens and closes properly.
groove. Install the waterproof sheet with no clearance
between the door panel and the waterproof sheet.

631RS007

8. Remove rear guide rail.

Installation
To install, follow the removal steps in the reverse order,
noting the following points.
1. Apply soap and water to the door frame groove. Insert
the glass run (1) to the door frame from the A corner in
the arrow–marked directions.
Install the glass run with its wider end pointed to the
inside of the vehicle.

A10RS023

2. Set the glass into the door panel with the front side of
the glass lowered and insert the rear side of the glass
into the glass run (1). Then insert the front side of the
glass into the glass run in order to install the glass to
the glass run while raising it up along the glass run.
3. Tighten the window regulator and the glass fixing
bolts and nuts to the specified torque.
Torque : 8 N m (0.8kgꞏm/69 lb in)
BODY STRUCTURE 8F–61

Rear Window Regulator And Glass


Parts Location

651RW018

Legend (4) Window Regulator Motor Connector


(1) Window Regulator (5) Door Trim Panel
(2) Glass (6) Waterproof Sheet
(3) Cable Fixing Clip

Removal
1. Disconnect the battery ground cable.
2. Remove door trim panel.
Refer to Rear Door Trim Panel in Exterior / Interior
Trim section.
3. Remove waterproof sheet (1).
Taking notice of the door harness, peel the
waterproof sheet off the door panel carefully.

651RS002
8F–62 BODY STRUCTURE
4. Remove glass. 5. Remove window regulator.
Bring the glass down to the position where the bolt Disconnect the regulator motor connector (4) and
can be seen. remove the window regulator cable fixing clip (3)
Remove the sash division 2 fixing bolts (1) and then from the door panel, if model is equipped with power
remove the glass fixing bolt to remove the glass windows.
upwards. Remove the window regulator 7 fixing bolts (2) and
pull the regulator out from the lower hole of the door
panel.

651RS003

651RW011

Installation
To install, follow the removal steps in the reverse order,
noting the following points.
1. Tighten the window regulator and the glass fixing
bolts to the specified torque.
Torque : 8 N m (0.8kgꞏm/69 lb in)
2. Install the waterproof sheet with no clearance
between the door panel and the waterproof sheet.

651RW010
BODY STRUCTURE 8F–63

Rear Door Fixed Glass And Glass Run


Parts Location

651RW019

Legend (4) Sash Division Fixing Bolts


(1) Glass Run (5) Door Trim Panel
(2) Rear Fixed Glass (6) Waterproof Sheet
(3) Sash Division (7) Glass

Removal
1. Disconnect the battery ground cable.
2. Remove door trim panel.
3. Remove waterproof sheet.
4. Remove glass.
Refer to Window Regulator and Glass in this
section.
5. Remove glass run.
Pull the glass run (1) out from the door frame.

651RS007
8F–64 BODY STRUCTURE
6. Remove sash division (2).

651RS008

7. Remove door fixed glass.

Installation
To install, follow the removal steps in the reverse order,
noting the following points.
1. Apply soap and water to the fixed glass.
2. Apply soap and water to the door groove and insert
the glass run (3) to the frame from the corner in the
arrow-marked directions.
3. Be sure to install the glass run with its end pointed to
the inside of the vehicle.

A10RW019
BODY STRUCTURE 8F–65

Front Door Sash Moulding


Parts Location

645RS001

Legend
(1) Front Door Sash Moulding

Removal Installation
1. Remove front door slash moulding. 1. Install the front door sash moulding.
To avoid the weatherstrip (1) and pry the door sash Assemble the edge portion (A portion) of the
moulding (2) out from the door panel. moulding so that the clearance between the
moulding and the waist seal becomes 1 mm (0.04
in).

645RS002
8F–66 BODY STRUCTURE

Rear Door Moulding


Parts Location

645RS003

Legend (2) Rear Door Corner Moulding


(1) Rear Door Side Moulding (3) Rear Door Upper Moulding

Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order,
noting the following points.
2. Remove rear door side moulding.
1. Install each moulding with no clearance between
3. Remove rear door upper moulding.
each piece of moulding.
4. Remove rear door corner moulding.
2. Assemble the edge portion (A portion) of the
Avoiding the weatherstrip (3), pry the moulding (2) moulding so that the clearance between the rear side
out from the door frame (1). moulding and the waist seal is 1 mm (0.04 in).

645RS004
BODY STRUCTURE 8F–67

Front Door Waist Seal


Parts Location

631RS009

Legend (2) Door Mirror


(1) Nylon Washer (3) Front Door Waist Seal

Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order,
noting the following points.
2. Remove door mirror.
1. Apply soap and water to the inside of the waist seal
Refer to Door Mirror in Exterior / Interior Trim
and align the screw hole of the waist seal to the door
section.
panel hole, and gently tap the seal with a rubber
3. Remove front door waist seal. hammer.
Remove the fixing screw and pull out the waist seal Be sure not to tap the seal hard. This may result in
(1) from the door frame while prying it up. deforming the seal.

631RS010
8F–68 BODY STRUCTURE

Rear Door Waist Seal


Parts Location

651RW013

Legend
(1) Rear Door Waist Seal

Removal and Installation


Refer to Front Door Waist Seal in this section.
BODY STRUCTURE 8F–69

Front Door Weatherstrip


Parts Location

631RS008

Legend (3) Weather Strip


(1) Check Arm Pin (4) Clip
(2) Bracket

Removal
1. Remove check arm pin.
2. Remove front door weatherstrip.
Pull the weatherstrip (1) out from the door frame.

631RS011
8F–70 BODY STRUCTURE
Carefully remove the weatherstrip (2) from the door 3. After positioning the weatherstrip (4) corner, insert
panel. the weatherstrip into the door frame groove from A
point in the arrow–marked direction.
4. Insert the weatherstrip clip (5) into the door panel up
to its base.

631RW003

Installation
To install, follow the removal steps in the reverse order,
noting the following points.
1. Apply soapy water to the door frame groove when
installing the front door weather strip (2).
2. Apply the sealing adhesive (3) to the upper A portion
of the door frame (1) and press it for installation after
assembling the weatherstrip (2).

631RW009

631RS013
BODY STRUCTURE 8F–71

Rear Door Weatherstrip


Parts Location

655RW010

Legend (2) Rear Door Weather Strip


(1) Check Arm Pin (3) Clip

Removal and Installation


Refer to Front Door Weatherstrip in this section.
8F–72 BODY STRUCTURE

Front Door Seal Finisher


Parts Location

635RS002

Legend
(1) Front Door Sill Plate
(2) Front Door Seal Finisher

Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order,
noting the following points.
2. Remove front door sill plate.
1. Insert the finisher into the A corner and install the
3. Remove front door seal finisher (1).
finisher (2) in the arrow–marked directions.
Pull the finisher out from the body panel.
2. Take care not to allow the sill plate (1) to distort or twist
the finisher.

635RS003

635RS002
BODY STRUCTURE 8F–73

Rear Door Seal Finisher


Parts Location

655RS002

Legend
(1) Rear Door Sill Plate and Luggage Side Lower
Cover
(2) Rear Door Seal Finisher

Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order,
noting the following points.
2. Remove rear door sill plate and the luggage side
lower cover. 1. Insert the rear door seal finisher (2) into the A corner
and install the finisher in the arrow-marked directions.
3. Remove rear door seal finisher (1).
2. Be careful not to allow the sill plate and cover (1) to
Pull the rear door seal finisher (1) out from the body
distort or twist the finisher.
panel.

655RS002
635RS003
8F–74 BODY STRUCTURE

Tailgate Assembly (LH)


Parts Location

681RW008

Legend (4) Tailgate Stopper Assembly


(1) Tailgate Fixing Bolt (5) Tailgate Trim Panel (LH)
(2) Tailgate Hinge (6) Tailgate Assembly (LH)
(3) Tailgate Harness Connection

Removal
1. Disconnect the battery ground cable.
2. Remove tailgate time panel (LH).
Refer to Tailgate Trim Panel (LH) in Exterior /
Interior Trim section.
3. Remove tailgate stopper assembly
4. Remove tailgate harness connection.
Open the luggage trim panel lid and disconnect the
tailgate harness connection.

810RS003
BODY STRUCTURE 8F–75
5. Remove tailgate fixing bolts.

681RS002

6. Remove tailgate assembly (LH).


7. Remove tailgate hinge.
Apply a setting mark (1) on the body side hinge and
remove the hinge fixing bolts.

681RW007

Installation
To install, follow the removal steps in the reverse order,
noting the following points.
1. Apply chassis grease to the tailgate hinge and the
tailgate stopper moving surface.
2. Align the tailgate fitting to the body by referring to
Body Dimension in this section.
3. Tighten the hinge bolts to the specified torque.
Torque : 34 N m (3.5kgꞏm/25 lb ft)
8F–76 BODY STRUCTURE

Tailgate Assembly (RH)


Parts Location

681RS004

Legend (4) Rear Combination Light (RH)


(1) Tailgate Assembly (RH) (5) Tailgate Fixing Bolt
(2) Tailgate Trim Panel (RH) (6) Tailgate Hinge
(3) Tailgate Harness Connection

Removal
1. Disconnect the battery ground cable.
2. Remove rear combination light (RH).
3. Remove tailgate trim panel (RH).
Refer to Tailgate Trim Panel (RH) in Exterior /
Interior section.
4. Remove tailgate harness connection.
Disconnect the tailgate harness connection.

810RS004
BODY STRUCTURE 8F–77
5. Remove tailgate fixing bolt.

681RS005

6. Remove tailgate assembly (RH).


7. Remove tailgate hinge.
Apply a setting mark (1) on the body side hinge and
remove the hinge fixing bolts.

681RW006

Installation
To install, follow the removal steps in the reverse order,
noting the following point.
1. Apply chassis grease to the tailgate hinge moving
surface.
2. Align the tailgate fitting to the body. Refer to Body
Dimension in this section.
3. Tighten the hinge bolts to the specified torque.
Torque : 34 N m (3.5kgꞏm/25 lb ft)
8F–78 BODY STRUCTURE

Tailgate Strikers
Adjustment 1. Loosen the striker screws (3) (or bolts (2)).
2. Tap the striker (1) with a plastic hammer to align.
3. Tighten the striker screws (3) (or bolts (2)).
Screw Torque : 15 N m (1.5kgꞏm/11 lb ft)
Bolt Torque : 12 N m (1.2kgꞏm/104 lb in)

683RW012

Tailgate Stopper Assembly


Parts Location

683RS010

Legend (2) Rear Bumper


(1) Tailgate (3) Tailgate Stopper Assembly

Removal Installation
1. Remove tailgate stopper assembly. To install, follow the removal steps in the reverse order,
noting the following points.
1. Tighten the fixing bolts to the specified torque.
Torque : 12 N m (1.2kgꞏm/104 lb in)
2. Apply chassis grease to the stopper moving surface.
BODY STRUCTURE 8F–79

Tailgate Dove-Tail
Parts Location

683RW011

Legend (3) Tailgate Striker


(1) Dove-Tail (4) Rear Bumper
(2) Fixing Bolt (5) Tailgate (LH)

Removal
1. Remove tailgate dove-tail.

Installation
To install, follow the removal steps in the reverse order,
noting the following points.
1. Apply chassis grease to the dove–tail (A) moving
surface.
2. Tighten the fixing bolts to the specified torque.
Torque : 12 N m (1.2kgꞏm/104 lb in)
8F–80 BODY STRUCTURE

Tailgate Dove-Tail Striker


Adjustment

683RS012

1. Loosen the striker bolts.


2. Tap with a plastic hammer to align.
Gaps between Dove–Tail Striker (2) and bracket (1)
are 0 mm (No clearance).

683RS013

3. Tighten striker bolts.


Torque : 12 N m (1.2kgꞏm/104 lb in)
BODY STRUCTURE 8F–81

Tailgate Frame Cover (LH)


Parts Location

684RW001

Legend (2) Washer Tube


(1) High Mount Stop Light (3) Tailgate Frame Cover

Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order,
noting the following points.
2. Remove tailgate frame cover.
1. Hit the lower A edge portion of the cover (1) to the
Pull the tailgate frame cover (2) out.
tailgate flange.
Disconnect the washer tube (1) at the nozzle and 2. Clearance between the frame cover and the tailgate
pull the washer tube out from the frame cover (2). panel (B portion) is 1 mm (0.04 in).
Disconnect the rear defogger and pull the harness
from the cover.

684RS008

684RW002
8F–82 BODY STRUCTURE

Tailgate Frame Cover (RH)


Removal
1. Remove tailgate frame cover (RH).
Pull the frame cover out from the tailgate frame.

684RS011

Installation
To install, follow the removal steps in the reverse order,
noting the following points.
1. Hit the lower A edge portion (2) of the tailgate frame
cover (1).
2. Clearance between the frame cover and the tailgate
panel (B portion) is 1 mm (0.04 in).

684RS010
BODY STRUCTURE 8F–83

Tailgate Sash Trim Cover


Parts Location

684RS012

Legend
(1) Tailgate Sash Trim Cover

Removal Installation
1. Remove tailgate sash trim cover (1). 1. Install the tailgate sash trim cover (1).
Pry the tailgate trim cover retainers free from the Insert the trim cover retainers into the tailgate hole
tailgate panel. securely so that there are no gaps between them.

684RS013
8F–84 BODY STRUCTURE

Tailgate Outer Weatherstrip


Parts Location

682RW001

Legend
(1) Tailgate Outer Weatherstrip

Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order,
noting the following point.
2. Remove tailgate outer weatherstrip (1).
1. Insert the tailgate outer weatherstrip clip into the body
Pry the tailgate outer weatherstrip clips (2) free from
panel hole securely in order to install the tailgate outer
the body panel.
weatherstrip with the gap between the body panel
and the weatherstrip.

682RS002
BODY STRUCTURE 8F–85

Tailgate Center Weatherstrip


Parts Location

682RS003

Legend
(1) Clip
(2) Tailgate Center Weatherstrip

Removal Clean the tailgate center weatherstrip (4) adhesive


tape (2) and the butyl seal (3) fitting position of the
1. Remove tailgate center weatherstrip. tailgate panel.
Remove the fixing clips in order to pull the tailgate Affix new adhesive tape and the butyl seal to the
center weatherstrip out from the tailgate panel. weatherstrip (lower side) in order to install the
tailgate center weatherstrip to the tailgate panel
Installation with no gap between them.

1. Install the tailgate center weatherstrip (1).


Start assembling at the A portion.

682RS004

682RW006
8F–86 BODY STRUCTURE

Tailgate Main Weatherstrip


Parts Location

682RS005

Legend
(1) Tailgate Main Weatherstrip

Removal
1. Remove tailgate main weatherstrip.
Pull the tailgate main weatherstrip out from the
body panel.

Installation
1. Install the tailgate main weatherstrip.
Align the A and B positions to the corners of the
body panel. Install the tailgate main weatherstrip to
the body panel by gently tapping with a plastic
hammer. There should be not clearance between
the body panel the tailgate main weatherstrip.
BODY STRUCTURE 8F–87

Spare Tire Carrier


Parts Location

530RS001

Legend
(1) Spare Tire
(2) Spare Tire Carrier

Removal Installation
1. Remove spare tire. 1. Install the spare tire carrier.
2. Remove spare tire carrier. Tighten the carrier fixing bolts to the specified
Remove the special bolts by using special tool (If so torque.
equipped). Torque : 31 N m (3.2kgꞏm/23 lb ft)
Spare tire carrier bolt wrench 5–8840–2095–0 2. Install the spare tire.
(J–34355). Tighten the spare tire fixing bolts to the specified
torque.
Torque : 118 N m (12.0kgꞏm/87 lb ft)

530RS002
8F–88 BODY STRUCTURE

Headlining
Parts Location

666RW003

Legend (6) Sunvisors


(1) Clip (7) Map Light
(2) Interior Trim Panels (8) Sunvisor Holder
(3) Sun Roof Finisher (W/Sun Roof) (9) Rear View Mirror
(4) Headlining (10) Multi Meter
(5) Dome Light

Removal
1. Disconnect the battery ground cable.
2. Remove interior trim panels.
Refer to the Exterior / Interior Trim section.
3. Remove dome light.
Remove the dome light lens and the fixing screws.
Disconnect the dome light connectors.
4. Remove multi meter (4) (If so equipped).
Remove two caps (2), two screws (3) and
disconnect the connector (1).

821RW241
BODY STRUCTURE 8F–89
5. Remove rear view mirror.
Remove the rubber stopper (1).
Pry off the mirror stay cover (2) and remove 3
screws.

743RW008

8. Remove sun roof finisher (W/Sun roof).


9. Remove headlining.
Remove the headlining fixing clips.
720RW004

6. Remove map light/sun roof switch. Installation


Pry the map light clip free from the map light/sun To install, follow the removal steps in the reverse order,
roof switch bracket and disconnect the connector. noting the following points.
1. Install the headlining so that the fixing clips will not
come off.
2. To install the sun roof finisher (3), first fit in at one
place with the head lining (2) close to the sun roof
frame complete (1), then install the entire finisher
tightly by hitting it with a plastic hammer, not allowing
it to move up.

805RS001

7. Remove sunvisors.
Remove the fixing screw and turn the sunvisor
holder (1) to remove it.
Disconnect the vanity mirror illumination connector.

665RS001
8F–90 BODY STRUCTURE

Rear Air Deflector


Parts Location

667RW001

Legend (7) Rear Outer Roof Panel


(1) Rear Roof Trim Cover (8) Grommet
(2) Rear Air Deflector (9) Fixing Nut
(3) Roof Rail (10) Rear Pillar Upper Reinforcement
(4) Rear Inner Roof Rail (11) Rear Outer Roof Rail
(5) Fixing Bolt (12) Roof Panel
(6) Nylon Washer (13) Grommet

Removal Installation
1. Disconnect the battery ground cable To install, follow the removal steps in the reverse order,
noting the following points.
2. Remove rear roof trim cover.
Refer to Luggage Side and Quarter Upper Trim
Cover in Exterior / Interior section.
3. Remove rear air deflector.
Take notice of the grommet and the nylon washer.
BODY STRUCTURE 8F–91
1. Install the grommet (1) to the air deflector (2) drain 3. Install the air deflector (5) to the roof by referring to the
hole. specified values shown in the illustration.

667RW002 667RW003

2. Use a new nylon washer (4). Peel off the adhesive 4. Tighten the deflector fixing to the specified torque.
tape of the washer to install the nylon washer to the air Bolt Torque : 6 N m (0.6kgꞏm/52 lb in)
deflector (3).
Nut Torque : 8 N m (0.8kgꞏm/69 lb in)

667RW004
8F–92 BODY STRUCTURE

Roof Moulding
Parts Location

645RW009

Legend (4) Roof Moulding Clip


(1) LꞏWꞏB (5) Roof End Moulding
(2) Windshield Side Moulding Upper Clip (6) SꞏWꞏB
(3) Roof Moulding

Removal 3. Remove roof end moulding.


Remove the sealing adhesive and the adhesive
1. Disconnect the battery ground cable. tape of the roof end moulding from the panel using a
2. Remove roof moulding. knife or scraper while you peel them off.
4. Remove roof moulding clips.
BODY STRUCTURE 8F–93

Installation
1. Install the moulding roof clips (1).
Install the clips on roof panel flange (2) to refer the
illustration.

645RW003

2. Install the roof end moulding (3).


Clean the body panel where the roof end moulding
is installed.
Install the roof end moulding and the rear air
deflector (2) so that the installation clearance 645RW001

between them is within the specified values. 3. Install the roof moulding (9).
Securely fix it with the adhesive tape (4) and sealing Assemble the windshield side moulding upper clip
adhesive (5). (8) to the roof panel with the clip positioning rib (6)
(oblique lines portion) attached to the roof panel
flange (7). Assemble the roof moulding (9) while
you attach the front edge portion of the roof molding
to the windshield side moulding (10).

645RX001
8F–94 BODY STRUCTURE

Windshield
Parts Location

607RW006

Legend (6) Windshield Support


(1) Windshield Upper Moulding (7) Cowl Upper Rail Flange
(2) Moulding Clip (8) Windshield Wiper
(3) Windshield Side Seal (9) Front Cowl Cover
(4) Windshield Side Moulding (10) Windshield
(5) Spacer

Removal 4. Remove windshield side moulding.


Pull the moulding out from the windshield side
1. Disconnect the battery ground cable. moulding clip.
2. Remove windshield wiper. 5. Remove windshield support.
Refer to Windshield Wiper Arm/Blade in 6. Remove windshield side seal.
Wiper/Washer System section.
7. Remove windshield (2).
3. Remove front cowl cover.
Use a knife or pick to make a hole in part of the
Refer to Cowl Cover in this section. adhesive caulking material.
BODY STRUCTURE 8F–95
Secure one end of a piece of steel piano wire (1) (0.02 9. Remove moulding clip.
inches in diameter) to a piece of wood that can serve 10. Remove spacer.
as a handle.

Installation
1. Install the spacer (1).
Clean the bonding surfaces of both the windshield
and the body panel.
When installing the spacers, align the lower side
spacer to the R stop of the body panel and the side
spacer to the end of the body panel. Be sure to
always use a new spacer.

607RS002

Use a pair of needle nose pliers to insert the other end


of the piano wire through the adhesive caulking
material at the edge of the windshield glass.
Secure the other end of the piano wire to another
piece of wood.
With the aid of an assistant, carefully move the piano
wire with a sawing motion to cut through the adhesive
caulking material around the entire circumference of
the windshield glass.
Clean the remaining adhesive caulking material from 607RS003

the area of the body which holds the windshield. Be absolutely sure to apply glass primer and body
primer to the body panel as shown in the illustration.
8. Remove windshield upper moulding.
Taking notice of the adhesive tape, and peel the
moulding off the windshield upper portion.
8F–96 BODY STRUCTURE

607RW005

Legend (7) Cowl Upper Panel


(1) Front Cowl Cover (8) Body Primer
(2) Windshield Lower Moulding (9) Roof Panel
(3) The portion of the cowl upper rail flange where (10) Sealing Adhesive
sealing adhesive is additionally filled (11) Windshield Upper Moulding
(4) Apply primer to the glass and portion where (12) Moulding Clip
sealing adhesive is additionally filled (13) Front Pillar Outer Panel
(5) Windshield (14) Windshield Side Moulding
(6) Cowl Upper Rail (15) Sealing Adhesive

2. Install the moulding clip (2).


Install new moulding clips to the fixed position of the
windshield (3).
Always use new moulding clips (4).

607RS004
BODY STRUCTURE 8F–97
3. Install the windshield upper moulding (1).
Peel off the adhesive tape (2) and install the
moulding to the fixed position of the windshield (3).
Always use new upper moulding (1).

607RS005

4. Install the windshield.

607RW005
8F–98 BODY STRUCTURE
Legend (7) Cowl Upper Panel
(1) Front Cowl Cover (8) Body Primer
(2) Windshield Lower Moulding (9) Roof Panel
(3) The portion of the cowl upper rail flange where (10) Sealing Adhesive
sealing adhesive is additionally filled (11) Windshield Upper Moulding
(4) Apply primer to the glass and portion where (12) Moulding Clip
sealing adhesive is additionally filled (13) Front Pillar Outer Panel
(5) Windshield (14) Windshield Side Moulding
(6) Cowl Upper Rail (15) Sealing Adhesive

5. Install the windshield side seal.


6. Install the windshield support (2).

607RS007

7. Install the windshield side moulding.


631RS014
Insert the windshield (5) side moulding (1) into the
Apply a sealing adhesive to the circumference of moulding clip (2).
the windshield.
Apply the sealing adhesive to the frange portion of
the cowl upper rail.
Adjust the gap clearance of the windshield.
Install the windshield to the body panel by applying
pressure to the windshield.
Cure the adhesive at a temperature of 20~30 C
(68 86 F) for 24 hours.
Check that the windshield does not leak water.

607RS008

Take care not to damage the side moulding when


you install it.
8. Install the front cowl cover.
9. Install the windshield wiper.
BODY STRUCTURE 8F–99

Rear Quarter Side Glass


Parts Location

641RS005

Legend (6) Side Outer Panel


(1) Rear Quarter Upper Trim Panel (7) Ventilation Assembly
(2) Fastener (8) Ventilation Fixing Clip
(3) Rear Quarter Side Glass (9) Rear Quarter Side
(4) Valve Assembly (10) Glass Fixing Clip
(5) Ventilation Assembly

Removal
1. Disconnect the battery ground cable.
2. Remove rear quarter upper trim panel.
Refer to Laggage Side and Quarter Upper Trim
Cover in Exterior / Interior Trim section.
3. Remove ventilation assembly.
4. Remove valve assembly.
Refer to Ventilation Assembly in Exterior / Interior
Trim section.
5. Remove rear quarter side glass.
Refer to Windshield in this section.
8F–100 BODY STRUCTURE

Installation Always use new fasteners.


Be absolutely sure to apply glass primer (2) to the side
1. Install the rear quarter side glass. glass.
Clean the bonding surfaces of both the glass and the Apply a sealing adhesive (1) to the glass
body panel. circumference.
Install the fasteners (1) to the fixed positions of the
glass and the body panel.

641RS006

641RS007
BODY STRUCTURE 8F–101
Apply PVC primer (4) to the A clip portion.

641RS008

Insert the fixing clip on the side glass into the body
panel.
Push the side glass against the body panel and bond
them.
Cure the adhesive at a temperature of 20~30 C
(68~86 F) for 24 hours.
Check that the rear quarter side glass does not leak
water.
2. Install the valve assembly.
3. Install the ventilation assembly.
4. Install the rear quarter upper trim panel.
8F–102 BODY STRUCTURE

Tailgate Glass
Parts Location

682RW008

Legend (4) Glass Moulding


(1) Tailgate Glass Moulding (5) Clip
(2) Tailgate Glass (6) Body Panel
(3) Tailgate Glass Clip

Removal
1. Remove battery ground cable.
2. Remove tailgate trim panel.
3. Remove tailgate sash trim cover (RH only).
Refer to Tailgate Sash Trim Cover in this section.
4. Remove the tailgate frame cover (LH only).
Refer to Tailgate Frame Cover (LH) in this section.
5. Remove tailgate glass.
Refer to Windshield in this section.

682RS007
BODY STRUCTURE 8F–103
6. Remove tailgate glass clip. Installation

682RW009

Legend (4) Sealing Adhesive


(1) Glass Moulding (5) Body Panel
(2) Tailgate Glass (6) Tailgate Frame
(3) Clip

1. Install the tailgate glass clip. 2. Install the tailgate glass (2).
Clean the bonding surfaces of both the tailgate
glass and the tailgate panel.
Be absolutely sure to apply glass primer to the
tailgate glass and PCV primer to the glass moulding
(1).
Apply a sealing adhesive to the circumference of
the tailgate glass as shown.
Insert the clip of the tailgate glass A portion into the
tailgate panel hole to position the glass.
Install the new tailgate glass clip to the clip of the
tailgate glass B portion while sliding it, and bond the
glass to the tailgate panel by applying pressure.
Always use new tailgate glass clips.
Cure the bonding at a temperature of 20~30 C
(68 86 F) for 24 hours.
Check that the tailgate glass does not leak water.
682RS008
8F–104 BODY STRUCTURE

Main Data and Specifications


Torque Specifications

E10RW020
BODY STRUCTURE 8F–105

E10RW019
8F–106 BODY STRUCTURE

E10RX007
BODY STRUCTURE 8F–107

E10RW021
8F–108 BODY STRUCTURE

E10RW028
BODY STRUCTURE 8F–109

E10RW029
8F–110 BODY STRUCTURE

E10RW027
BODY STRUCTURE 8F–111

E10RW024
8F–112 BODY STRUCTURE

E10RW025
BODY STRUCTURE 8F–113

E10RW026
8F–114 BODY STRUCTURE

E10RW022
BODY STRUCTURE 8F–115

Special Tools
TOOL NO.
ILLUSTRATION
TOOL NAME

5–8840–2095–0
(J–34355)
Spare Tire Carrior Bolt
Wrench
SEATS 8G–1

BODY AND ACCESSORIES


SEATS
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 8G–1 Heat Unit Parts Location . . . . . . . . . . . . . . . . 8G–14
Front Seat Assembly . . . . . . . . . . . . . . . . . . . . 8G–2 Heat Unit Removal and Installation . . . . . . 8G–14
Front Seat Assembly and Associated Parts 8G–2 Rear Seat Assembly . . . . . . . . . . . . . . . . . . . . . 8G–15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–2 Rear Seat Assembly and Associated Parts 8G–15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–15
Disassembled View (LWB) . . . . . . . . . . . . . . 8G–3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–15
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–4 Disassembled View (Split Type) . . . . . . . . . 8G–16
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–5 Disassembly (Split Type) . . . . . . . . . . . . . . . 8G–17
Disassembled View (SWB) . . . . . . . . . . . . . 8G–6 Reassembly (Split Type) . . . . . . . . . . . . . . . . 8G–18
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–6 Disassembled View (SWB) . . . . . . . . . . . . . 8G–19
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–8 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–19
Power Seat Assembly . . . . . . . . . . . . . . . . . . . 8G–9 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–20
General Description . . . . . . . . . . . . . . . . . . . . . 8G–9 Disassembled View (Bench Type) . . . . . . . 8G–21
Disassembled View . . . . . . . . . . . . . . . . . . . . 8G–9 Disassembly (Bench Type) . . . . . . . . . . . . . 8G–22
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–10 Reassembly (Bench Type) . . . . . . . . . . . . . . 8G–23
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–12 Third Seat Assembly . . . . . . . . . . . . . . . . . . . . . 8G–23
Power Seat Switch . . . . . . . . . . . . . . . . . . . . . . 8G–12 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8G–23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–24
Front Tilt Motor / Rear Tilt Motor / Disassembled View . . . . . . . . . . . . . . . . . . . . 8G–24
Slide Motor / Recliner Motor . . . . . . . . . . . . . . 8G–13 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–25
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8G–13 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–25
Removal and Installation . . . . . . . . . . . . . . . 8G–13 Rear Seat Foot Rest . . . . . . . . . . . . . . . . . . . . . 8G–25
Seat Heater System . . . . . . . . . . . . . . . . . . . . . 8G–14 Rear Seat Foot Rest and Associated Parts 8G–25
General Description . . . . . . . . . . . . . . . . . . . . . 8G–14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–26
Seat Heater Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–14 Main Data and Specifications . . . . . . . . . . . . . 8G–26

Service Precaution CAUTION: Always use the correct fastener in the


proper location. When you replace a fastener, use
WARNING: IF SO EQUIPPED WITH A ONLY the exact part number for that application.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS), ISUZU will call out those fasteners that require a
REFER TO THE SRS COMPONENT AND WIRING replacement after removal. ISUZU will also call out
LOCATION VIEW IN ORDER TO DETERMINE the fasteners that require thread lockers or thread
WHETHER YOU ARE PERFORMING SERVICE ON OR sealant. UNLESS OTHERWISE SPECIFIED, do not
NEAR THE SRS COMPONENTS OR THE SRS use supplemental coatings (Paints, greases, or other
WIRING. WHEN YOU ARE PERFORMING SERVICE corrosion inhibitors) on threaded fasteners or
ON OR NEAR THE SRS COMPONENTS OR THE SRS fastener joint interfaces. Generally, such coatings
WIRING, REFER TO THE SRS SERVICE adversely affect the fastener torque and the joint
INFORMATION. FAILURE TO FOLLOW WARNINGS clamping force, and may damage the fastener. When
COULD RESULT IN POSSIBLE AIR BAG you install fasteners, use the correct tightening
DEPLOYMENT, PERSONAL INJURY, OR sequence and specifications. Following these
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. instructions can help you avoid damage to parts and
systems.
8G–2 SEATS

Front Seat Assembly


Front Seat Assembly and Associated Parts

750RX016

Legend (5) Seat Rail Cover (SWB)


(1) Rear Cover (6) Door Sill Plate
(2) Front Seat Assembly (7) Riser Cover (LWB)
(3) Seat Belt Warning Connector/Pretensioner (8) Seat Slide Cover (SWB)
Harness Connector (9) Front Cover
(4) Rear Seat Foot Rest (LWB) (10) Seat Rail Cover and Hole Cover (SWB)

Removal 5. Remove the rear seat foot rest.


Refer to the Rear Seat Foot Rest in this section.
1. Disconnect the battery ground cable.
6. Remove the riser cover.
2. Remove the front cover.
7. Remove the seat belt warning connector (Driver’s
3. Remove the rear cover. side only) or pretensioner harness connector.
Remove the cover fixing screw from the rear inner 8. Remove the front seat assembly.
cover, if this model is equipped with the power
seats. Disconnect the power seat connector, if this model
is equipped with the power seats.
4. Remove the door sill plate.
SEATS 8G–3

Installation 1. Tighten the front seat assembly fixing bolts to the


specified torque.
To install, follow the removal steps in the reverse order,
noting the following points: Torque: 40 Nꞏm (4.1 kgꞏm/30 lb ft)
2. Install the longest bolt to the rear inner side fixing
location, if this model is equipped with power seats.
Disassembled View (LWB)

750RX017

Legend (13) Seat Heater Assembly


(1) Head Rest (14) Pad Assembly
(2) Seat Back Assembly (15) Trim Cover
(3) Back Board Assembly (16) Spacer (W/O Height Adjuster)
(4) Guide Holder (17) Release Wire
(5) Trim Cover (18) Seat Adjuster/Seat Adjuster (W/Pretensioner)
(6) Pad & Frame Assembly (19) Seat Belt Buckle Assembly
(7) Seat Heater Assembly (20) Height Adjuster
(8) Reclining Device (21) Seat Cushion Assembly
(9) Slide Cover (22) Hinge Cover
(10) Reclining Knob (23) Pad & Frame Assembly
(11) Dial (W/Height Adjuster) (24) Trim Cover
(12) Frame Assembly (25) Armrest Assembly
8G–4 SEATS

Disassembly 6. Remove the trim cover.


7. Remove the pad and frame assembly.
1. Remove the head rest.
8. Remove the hinge cover.
2. Remove the reclining knob.
9. Remove the back board assembly(3).
3. Remove the dial(1) (W/height adjuster).
Pull out the back board while prying the clip (4) of
Remove the side cover fixing screws and the dial the back board free from the seat back assembly.
lock spring(2).

750RW032
750RW025
10. Remove the reclining device.
4. Remove the side cover.
Turn up the seat back trim cover in order to remove
5. Remove the armrest assembly. the reclining device fixing bolts.
Open the armrest fastener and remove the armrest
fixing bolt.

750RS006

750RS004
SEATS 8G–5
11. Remove the seat back assembly. 14. Remove the pad and frame assembly.
Remove the clips (2) from the seat heater harness 15. Remove the seat heater assembly.
(1), and separate the seat heater connector (3) 16. Remove the seat adjuster.
(models with the seat heater).
Disconnect the release wire(4) and remove the
fixing bolts.

750RW029

Remove the seat back assembly fixing nut on the 750RW006


opposite side of the reclining device.
Remove the seat belt buckle assembly.
17. Remove the height adjuster.
18. Remove the spacer (W/O height adjuster).
19. Remove the seat cushion assembly.
20. Remove the trim cover.
Remove the trim cover hog rings from the back side
of the seat cushion assembly.
With close attention paid to the hog rings and the
wire which connect the trim cover and the pad and
frame assembly, remove the trim cover while
turning it up.
21. Remove the frame assembly.
22. Remove the pad assembly.
23. Remove the seat heater assembly.

Reassembly
To reassembly, follow the disassembly steps in the
750RS007 reverse order, noting the following point.
12. Remove the guide holder. 1. Tighten the armrest assembly fixing bolts to the
Pull the guide holder out by holding the bottom end specified torque.
of it from the seat back assembly.
Torque: 18 Nꞏm (1.8 kgꞏm/13 lb ft)
13. Remove the trim cover.
2. Tighten the reclining device fixing bolts to the
Remove the trim cover hog rings from the back side specified torque.
of the seat back.
Torque: 47 Nꞏm (4.8kgꞏm/35 lb ft)
With close attention paid to the hog rings and the
wire which connect the trim cover and the pad and
frame assembly, remove the trim cover while
turning it up.
8G–6 SEATS

Disassembled View (SWB)

750RX018

Legend (11) Pad Assembly


(1) Head Rest (12) Trim Cover
(2) Seat Back Assembly (13) Walk–in Cover
(3) Back Board Assembly (14) Walk–in Assembly
(4) Pad & Frame Assembly (15) Seat Adjuster/Seat Adjuster (W/Pretensioner)
(5) Trim Cover (16) Release Wire
(6) Guide Holder (17) Seat Belt Buckle Assembly
(7) Reclining Device (18) Spacer
(8) Slide Cover (19) Seat Cushion Assembly
(9) Reclining Knob (20) Hinge Cover
(10) Frame Assembly

Disassembly 5. Remove the back board assembly.


Pull out the back board while prying the clip of the
1. Remove the head rest. back board free from the seat back assembly.
2. Remove the reclining knob.
3. Remove the side cover.
4. Remove the hinge cover.
SEATS 8G–7
6. Remove the reclining device. 7. Remove the seat back assembly.
Turn up the seat back trim cover in order to remove Remove the seat back assembly fixing nut on the
the reclining device fixing bolts. opposite side of the reclining device.

750RS006 750RS007

Remove the push nut (2) and disconnect walk-in 8. Remove the guide holder.
cable (3) from reclining device (1). Pull the guide holder out by holding the bottom end
of it from the seat back assembly.
9. Remove the trim cover.
Remove the trim cover hog rings from the back side
of the seat back.
With close attention paid to the hog rings and the
wire which connect the trim cover and the pad and
frame assembly, remove the trim cover while
turning it up.
10. Remove the pad and frame assembly.
11. Remove the walk-in cover.
12. Remove the seat adjuster.
Disconnect the release wire (4) and remove the
fixing bolts.

750RW034

750RW006

Remove the seat belt buckle assembly.


8G–8 SEATS
13. Remove the walk-in assembly (passenger side).
14. Remove the spacer (driver side).
15. Remove the seat cushion assembly.
16. Remove the trim cover.
Remove the trim cover hog rings from the back side
of the seat cushion assembly.
With close attention paid to the hog rings and the
wire which connect the trim cover and the pad and
frame assembly, remove the trim cover while
turning it up.
17. Remove the frame assembly.
18. Remove the pad assembly.

Reassembly
To reassembly, follow the disassembly steps in the
reverse order, noting the following point.
1. Tighten the armrest assembly fixing bolts to the
specified torque.
Torque: 18 Nꞏm (1.8 kgꞏm/13 lb ft)
2. Tighten the reclining device fixing bolts to the
specified torque.
Torque: 47 Nꞏm (4.8kgꞏm/35 lb ft)
SEATS 8G–9

Power Seat Assembly


General Description The power seat switch has a tilt & slide switch and a
recliner switch.
The circuit consists of the power seat switch, front tilt The motor built in the seat can be actuated by operating
motor (driver’s seat only), rear tilt motor (driver’s seat these switches to move the seat to desired position,
only), slide motor and the recliner motor. independent of the position of the starter switch.
Disassembled View

750RS011

Legend (12) Adjuster Assembly


(1) Reclining Device (13) Seat Cushion Assembly
(2) Inner Cover (14) Connecting Shaft
(3) Rear Cover (15) Outer Cover Fixing Screws
(4) Armrest Assembly (16) Switch Assembly
(5) Inner Lower Cover (17) Outer Cover
(6) Pad & Frame Assembly (18) Switch Knob
(7) Trim Cover (19) Outer Cover Cap
(8) Front Lower Cover (20) Back Board Assembly
(9) Front Cover (21) Guide Holder
(10) Power Seat Harness (22) Trim Cover
(11) Outer Lower Cover (23) Pad Assembly
8G–10 SEATS
(24) Seat Heater (28) Seat Heater
(25) Frame Assembly (29) Frame Assembly
(26) Pad Assembly (30) Head Rest
(27) Trim Cover (31) Seat Back Assembly

Disassembly
1. Disconnect the battery ground cable.
2. Remove the head rest.
3. Remove the switch knob.
Pull the switch knob out.
4. Remove the outer cover cap.
5. Remove the outer cover fixing screws.
Pull up the outer cover(1) to remove the cover from
the reclining device(2).

750RS004

12. Remove the trim cover.


13. Remove the pad & frame assembly.
14. Remove the inner cover
Remove the cover fixing screw.
Pull up the inner cover to remove the cover from the
reclining device(3).

750RS012

6. Remove the front cover.


7. Remove the front lower cover.
8. Remove the rear cover.
9. Remove the outer cover.
Disconnect the switch connectors and remove the
harness fixing clips.
10. Remove the switch assembly.
Remove the switch fixing screws from the outer
cover.
11. Remove the armrest assembly.
Open the armrest fastener and remove the fixing
bolt.

750RW007
SEATS 8G–11
15. Remove the back board assembly(4).
Remove the board fixing screws.
Pull the back board downward and remove the
board from the seat back frame(5).

750RW009

17. Remove the seat back assembly.


18. Remove the guide holder(8).
Remove the trim cover fixing hog rings(9) from the
backside of the seat back assembly.
Hold the tip end of the guide holder and pull the
holder out from the seat back assembly.

750RW008

16. Remove the reclining device(7).


Remove the device lower side fixing bolt in order to
separate the seat back from the seat cushion.
Disconnect the seat heater connector.
Remove the trim cover(6) hog rings from the
backside of the seat back assembly.
Turn up the seat back trim cover to remove the
reclining device upper side fixing bolt.
Disconnect the connecting shaft and the reclining
device connectors.
750RW010

19. Remove the trim cover.


Remove the trim cover hog rings from the backside
of the seat back.
With close attention paid to the hog rings and the
wire which connect the trim cover and pad & frame
assembly, remove the trim cover while turning it up.
20. Remove the seat heater.
21. Remove the pad assembly.
22. Remove the frame assembly.
23. Remove the outer lower cover.
24. Remove the inner lower cover.
25. Remove the adjuster assembly.
Disconnect the connectors and remove the fixing
bolts.
8G–12 SEATS
Remove the power seat harness from the adjuster 28. Remove the seat heater.
assembly. 29. Remove the frame assembly.
26. Remove the seat cushion assembly. 30. Remove the pad assembly.
27. Remove the trim cover.
Remove the trim cover hog rings from the backside Reassembly
of the seat cushion assembly.
To reassemble, follow the disassembly steps in the
With close attention paid to the hog rings and the reverse order, noting the following point.
wire which connect the trim cover and the pad &
1. Tighten the fixing bolts to the specified torque.
frame assembly, remove the trim cover while
turning it up. Refer to the Torque Specifications in this section.

Power Seat Switch


Removal Installation
1. Remove the side cover(3). To install, follow the removal steps in the reverse order.
Refer to the Power Seat Assembly disassembly
steps in this section.
2. Remove the tilt & slide switch lever(4).
Hold the switch lever with your fingers and pull it
toward you.
3. Remove the tilt & slide switch(2).
Remove two screws.
4. Remove the recliner switch(1).
Remove two screws.

750RS025
SEATS 8G–13

Front Tilt Motor / Rear Tilt Motor / Slide Motor / Recliner Motor
Parts Location

750RS027

Legend
(1) Tilt Motor
(2) Slide Motor
(3) Tilt Motor

750RS028

Legend
(4) Recliner Motor

Removal and Installation


Refer to the Power Seat Assembly in this section.
8G–14 SEATS

Seat Heater System


General Description
The circuit consists of the starter switch, seat heater
switch and the heat unit.
The seat heater is provided in driver’s and front
passenger seats (as option).
When the seat heater switch is ON, the seat heat built in
the seat back and cushion is switched on to warm the
seats.
To prevent the seats from being overheated, the circuit is
fitted with a thermostat.

Seat Heater Switch Removal and


Installation
Refer to the Seat Heater Switch in Lighting System
section.

Heat Unit Parts Location


750RS019

Legend
(2) Heat Unit (Seat Cushion Side)

Heat Unit Removal and Installation


Refer to the Power Seat Assembly in this section.

750RS018

Legend
(1) Heat Unit (Seat Back Side)
SEATS 8G–15

Rear Seat Assembly


Rear Seat Assembly and Associated Parts

755RW031

Legend (2) Rear Seat Assembly


(1) Fixing Bolts (3) Mounting Bracket Cover

Removal 4. Remove the rear seat assembly.

1. Unlock the rear seat(1) lock to remove it.


2. Remove the mounting bracket cover. Installation
3. Remove the fixing bolts. To install, follow the removal steps in the reverse order,
noting the following point.
1. Tighten the rear seat fixing bolts to the specified
torque.
Torque: 19 Nꞏm (1.9kgꞏm/14 lb ft)

755RS002
8G–16 SEATS

Disassembled View (Split Type)

755RW056

Legend (16) Linkage Bush


(1) Free Hinge Cover (17) Device Cover
(2) Back Board (18) Trim Cover
(3) Seat Back Assembly (19) Seat Lock Cover
(4) Armrest Assembly (20) Rear Seat Belt Buckle and Lock Assembly
(5) Bush (21) Frame Assembly
(6) Armrest Set Bracket (22) Stopper Rubber
(7) Clip (23) Spring Collar
(8) Armrest Board (24) Return Spring
(9) Pillow Assembly (25) Mounting Bracket
(10) Band Hook Cover (26) Pad Assembly
(11) Trim Cover (27) Reclining Device
(12) Pad & Frame Assembly (28) Seat Cushion Assembly
(13) Release Knob (29) Linkage Bush
(14) Connecting Shaft (30) Bush
(15) Release Rod
SEATS 8G–17

Disassembly (Split Type)


1. Remove the back board.
Remove the clips and the back board.
2. Remove the device cover.
3. Remove the release knob.
Turn the knob counterclockwise to remove it.
4. Remove the release rod.
Disconnect the rod from the linkage bush.
5. Remove the reclining device.

755RS017

9. Remove the band hook cover.


10. Remove the armrest assembly.
Turn up the seat back trim cover and remove the
fixing nuts.
11. Remove the armrest set bracket.
12. Remove the armrest board.
13. Remove the trim cover.
Remove the trim cover fixing hog rings from the
backside of the seat back.
755RS004 With close attention paid to the hog rings and the
6. Remove the connecting shaft. wire which connect the trim cover and the pad and
7. Remove the seat back assembly. frame assembly, remove the trim cover while
turning it up.
8. Remove the pillow assembly.
14. Remove the pad & frame assembly.
Turn up the seat back trim cover and slit the pad
from the back around to the place where the lock 15. Remove the seat cushion assembly.
spring(2) of the guide bush(1) is. 16. Remove the seat lock cover.
Then insert a finger through the slit and pull out the 17. Remove the rear seat belt buckle and lock assembly.
pillow while you are pressing down on the lock spring. 18. Remove the mounting bracket.
19. Remove the return spring.
20. Remove the spring collar.
21. Remove the trim cover.
Remove the hog rings and pull the trim cover out
from the frame assembly groove.
With close attention paid to the hog rings and the
wire which connect the trim cover and the pad &
frame assembly, remove the trim cover while
turning it up.
22. Remove the frame assembly.
23. Remove the pad assembly.
24. Remove the stopper rubber.
8G–18 SEATS

Reassembly (Split Type)


To reassemble, follow the disassembly steps in the
reverse order, noting the following point.
1. Tighten the reclining device fixing bolts to the
specified torque.
Torque: 27 Nꞏm (2.8kgꞏm/20 lb ft)
2. Loosen the rubber stopper lock nut(1). Adjust the
stopper(3) so there is no clearance between the
bottom of the stopper and the carpet(2) while you
make sure the rear seat is firmly locked.
Then tighten the lock nut securely.

755RS005
SEATS 8G–19

Disassembled View (SWB)

755RW036

Legend (13) Armrest Set Bracket


(1) Back Board (14) Bush
(2) Release Knob (15) Armrest Assembly
(3) Release Rod (16) Trim Cover
(4) Device Cover (17) Mounting Bracket
(5) Reclining Device (18) Frame Assembly
(6) Linkage Bush (19) Stopper Rubber
(7) Pillow Assembly (20) Pad Assembly
(8) Pad & Frame Assembly (21) Seat Lock Cover
(9) Armrest Board (22) Rear seat Belt Bukle and Lock Assembly
(10) Clip (23) Seat Cushion Assembly
(11) Band Hook Cover (24) Free Hinge Cover
(12) Trim Cover (25) Seat Back Assembly

Disassembly 2. Remove the device cover.


3. Remove the release knob.
1. Remove the back board.
Turn the knob counterclockwise to remove it.
Remove the clips and the back board.
8G–20 SEATS
4. Remove the release rod. With close attention paid to the hog rings and the
Disconnect the rod from the linkage bush. wire which connect the trim cover and the pad and
frame assembly, remove the trim cover while
5. Remove the reclining device.
turning it up.
13. Remove the pad & frame assembly.
14. Remove the free hinge cover.
15. Remove the seat cushion assembly.
16. Remove the seat lock cover.
17. Remove the rear seat belt buckle and lock assembly.
18. Remove the mounting bracket.
19. Remove the trim cover.
Remove the hog rings and pull the trim cover out
from the frame assembly groove.
With close attention paid to the hog rings and the
wire which connect the trim cover and the pad &
frame assembly, remove the trim cover while
turning it up.
20. Remove the frame assembly.
21. Remove the pad assembly.
22. Remove the stopper rubber.
755RS004

6. Remove the seat back assembly.


7. Remove the pillow assembly.
Reassembly
To reassemble, follow the disassembly steps in the
Turn up the seat back trim cover and slit the pad
reverse order, noting the following point.
from the back around to the place where the lock
spring(2) of the guide bush(1) is. 1. Tighten the reclining device fixing bolts to the
Then insert a finger through the slit and pull out the specified torque.
pillow while you are pressing down on the lock spring. Torque: 27 Nꞏm (2.8kgꞏm/20 lb ft)
2. Loosen the rubber stopper lock nut(1). Adjust the
stopper(3) so there is no clearance between the
bottom of the stopper and the carpet(2) while you
make sure the rear seat is firmly locked.
Then tighten the lock nut securely.

755RS017

8. Remove the band hook cover.


9. Remove the armrest assembly.
Turn up the seat back trim cover and remove the
fixing nuts.
10. Remove the armrest set bracket. 755RS005

11. Remove the armrest board.


12. Remove the trim cover.
Remove the trim cover fixing hog rings from the
backside of the seat back.
SEATS 8G–21

Disassembled View (Bench Type)

755RW033

Legend (12) Seat Cushion Assembly


(1) Trim Cover (13) Connecting Link
(2) Pillow Assembly (14) Seat Lock Cover
(3) Band Hook Cover (15) Rear Seat Belt Buckle and Lock Assembly
(4) Pad & Frame Assembly (16) Trim Cover
(5) Seat Back Assembly (17) Stopper Rubber
(6) Release Knob (18) Mounting Bracket
(7) Release Rod (19) Frame Assembly
(8) Device Cover (20) Pad Assembly
(9) Linkage Bush (21) LꞏWꞏB
(10) Reclining Device (22) SꞏWꞏB
(11) Connecting Shaft
8G–22 SEATS

Disassembly (Bench Type) 9. Remove the trim cover.


Open the fastener(3), and with close attention paid
1. Remove the device cover. to the hog rings and wire which connect the trim
2. Remove the release knob. cover and the pad and frame assembly, remove the
Turn the knob to the counterclockwise to remove it. trim cover as you turn it up.
3. Remove the release rod.
Disconnect the rod from the linkage bush.
4. Remove the reclining device.

750RW011

10. Remove the pad & frame assembly.


11. Remove the seat cushion assembly.
755RS004
12. Remove the seat lock cover.
5. Remove the connecting shaft. 13. Remove the rear seat belt buckle and lock assembly.
6. Remove the seat back assembly. 14. Remove the mounting bracket.
7. Remove the band hook cover. 15. Remove the trim cover.
8. Remove the pillow assembly. Remove the hog rings and pull the trim cover out
Refer to the Disassembly (Split Type) in this from the frame assembly groove.
section. With close attention paid to the hog rings and the
wire which connect the trim cover and the pad and
frame assembly, remove the trim cover while
turning it up.
16. Remove the frame assembly.
17. Remove the pad assembly.
18. Remove the stopper rubber.

755RS017
SEATS 8G–23

Reassembly (Bench Type)


To reassemble, follow the disassembly steps in the
reverse order, noting the following point.
1. Tighten the reclining device fixing bolts to the
specified torque.
Torque: 27 Nꞏm (2.8kgꞏm/20 lb ft)
2. Loosen the rubber stopper lock nut(1) and adjust the
stopper rubber(3) so there is no clearance between
the bottom of the stopper and the carpet(2), while
ensuring the rear seat is firmly locked.
Tighten the lock nut securely.

755RS005

Third Seat Assembly


Parts Location

755RW034

Legend (2) Rear Side of LH


(1) Cover (3) Third Seat Assembly

Removal 2. Remove the cover.


3. Remove the third seat assembly.
1. Disconnect the battery ground cable.
8G–24 SEATS

Installation 1. Tighten the reclining device fixing bolts to the


specified torque.
To reassemble, follow the disassembly steps in the
reverse order, noting the following point. Torque: 19 Nꞏm (1.9kgꞏm/14 lb ft)

Disassembled View

755RW035

Legend (14) Board Assembly


(1) Seat Back Assembly (15) E–Ring
(2) Pad & Frame Assembly (16) Cam Bracket
(3) Trim Cover (17) Tension Spring
(4) Hinge Knob (18) Leg Pipe Assembly
(5) Hinge Cover (19) Hing Pin
(6) Hinge Assembly (20) Lock Cover
(7) Trim Cover (21) Floor Lock Assembly
(8) Arm Bracket (22) Lock Cover
(9) Bush (23) Band Assembly
(10) Bracket (24) Arm Bracket
(11) Arm Bracket Cover (25) Free Hinge
(12) Pad & Frame Assembly (26) Free Hinge Bolt
(13) Seat Cushion Assembly
SEATS 8G–25

Disassembly 7. Remove the pad & frame assembly.


8. Remove the seat cushion assembly.
1. Remove the hinge knob.
9. Remove the free hinge.
Pull the knob out from hinge assembly.
10. Remove the lock cover.
2. Remove the hinge cover.
11. Remove the floor lock assembly.
3. Remove the hinge assembly.
12. Remove the leg cover.
4. Remove the free hinge bolt.
13. Remove the leg pipe assembly.
5. Remove the seat back assembly.
Remove the E-ring and pull the hinge pin from cam
6. Remove the trim cover. bracket.
Turn up the trim cover from under the seat back 14. Remove the cam bracket.
while taking notice of the hog ring and wire.
15. Remove the tension spring.
16. Remove the band assembly.
17. Remove the board assembly.
18. Remove trim cover.
Remove the hog ring from back side seat cushion.
Turn up the trim cover from under the seat back
while taking notice of the hog ring.
19. Remove the arm bracket.
20. Remove the arm bracket cover.
21. Remove the pad & frame assembly.

Reassembly
To reassemble, follow the disassembly steps in the
reverse order.

755RW032

Rear Seat Foot Rest


Rear Seat Foot Rest and Associated Parts

676RY001

Legend (3) Rear Seat Foot Rest


(1) Fixing Nut (4) Foot Rest Pad
(2) Front Seat
8G–26 SEATS

Removal Installation
1. Remove the foot rest pad. To install, follow the removal steps in the reverse order.

676RS002

2. Remove the fixing nuts.


3. Remove the rear seat foot rest.

Main Data and Specifications


Torque Specifications

E10RX006
SEATS 8G–27

E10RW031
SECURITY AND LOCKS 8H–1

BODY AND ACCESSORIES


SECURITY AND LOCKS
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 8H–2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–15
Front Door Lock Assembly . . . . . . . . . . . . . . . 8H–2 Tailgate Inside Handle . . . . . . . . . . . . . . . . . . . 8H–16
Front Door Lock Assembly and Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8H–16
Associated Parts . . . . . . . . . . . . . . . . . . . . . . 8H–2 Removal and Installation . . . . . . . . . . . . . . . 8H–16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–2 Tailgate Outside Handle and/or Tailgate
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–3 Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–17
Front Outside Handle and Door Lock Cylinder 8H–4 Tailgate Outside Handle and/or Tailgate
Front Outside Handle, Door Lock Cylinder Lock Cylinder and Associated Parts . . . . . 8H–17
and Associated Parts . . . . . . . . . . . . . . . . . . 8H–4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–5 Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–19
Rear Door Lock Assembly . . . . . . . . . . . . . . . . 8H–7 Key Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–19
Rear Door Lock Assembly and Associated Key Styles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–19
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–7 Power Door Lock System . . . . . . . . . . . . . . . . 8H–20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–7 General Description . . . . . . . . . . . . . . . . . . . . . 8H–20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–8 Front Door Lock Actuator Removal . . . . . . 8H–20
Rear Outside Handle . . . . . . . . . . . . . . . . . . . . 8H–9 Front Door Lock Actuator Installation . . . . . 8H–20
Rear Outside Handle and Associated Parts 8H–9 Rear Door Lock Actuator Removal . . . . . . . 8H–20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–9 Rear Door Lock Actuator Installation . . . . . 8H–21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–10 Tailgate Lock Actuator Removal . . . . . . . . . 8H–21
Rear Door Inside Lock Knob Link . . . . . . . . . . 8H–10 Tailgate Lock Actuator Installation . . . . . . . 8H–21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–10 Anti-theft System . . . . . . . . . . . . . . . . . . . . . . . . 8H–22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–10 General Description . . . . . . . . . . . . . . . . . . . . . 8H–22
Door Inside Lock Knob . . . . . . . . . . . . . . . . . . . 8H–11 Anti-theft & Keyless Entry Control Unit
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–11 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–11 Anti-theft & Keyless Entry Control Unit
Door Inside Handle . . . . . . . . . . . . . . . . . . . . . . 8H–11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–22
Removal and Installation . . . . . . . . . . . . . . . 8H–11 Anti-theft Indicator Removal . . . . . . . . . . . . . 8H–22
Anti-theft Indicator Installation . . . . . . . . . . . 8H–23
Tailgate Lock Assembly (LH) . . . . . . . . . . . . . . 8H–12
Anti-theft Horn Removal . . . . . . . . . . . . . . . . 8H–23
Tailgate Lock Assembly (LH) and
Associated Parts . . . . . . . . . . . . . . . . . . . . . . 8H–12 Anti-Theft Horn Installation . . . . . . . . . . . . . . 8H–23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–12 Engine Hood Switch Removal . . . . . . . . . . . 8H–23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–13 Engine Hood Switch Installation . . . . . . . . . 8H–23
Tailgate Lock Assembly (RH) . . . . . . . . . . . . . 8H–14 Keyless Entry System . . . . . . . . . . . . . . . . . . . . 8H–24
Tailgate Lock Assembly (RH) and ID Code Registration (Except South Africa) 8H–24
Associated Parts . . . . . . . . . . . . . . . . . . . . . . 8H–14 Anti–theft & Keyless Entry Control
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–14 Unit/Transmitter Replacement . . . . . . . . . . 8H–26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–15 Programming With Tech 2 (For South
Africa) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–27
Tailgate Inside Lock Knob . . . . . . . . . . . . . . . . 8H–15
Main Data and Specifications . . . . . . . . . . . . . 8H–29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–15
8H–2 SECURITY AND LOCKS

Service Precaution CAUTION: Always use the correct fastener in the


proper location. When you replace a fastener, use
WARNING: IF SO EQUIPPED WITH A ONLY the exact part number for that application.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS), ISUZU will call out those fasteners that require a
REFER TO THE SRS COMPONENT AND WIRING replacement after removal. ISUZU will also call out
LOCATION VIEW IN ORDER TO DETERMINE the fasteners that require thread lockers or thread
WHETHER YOU ARE PERFORMING SERVICE ON OR sealant. UNLESS OTHERWISE SPECIFIED, do not
NEAR THE SRS COMPONENTS OR THE SRS use supplemental coatings (Paints, greases, or other
WIRING. WHEN YOU ARE PERFORMING SERVICE corrosion inhibitors) on threaded fasteners or
ON OR NEAR THE SRS COMPONENTS OR THE SRS fastener joint interfaces. Generally, such coatings
WIRING, REFER TO THE SRS SERVICE adversely affect the fastener torque and the joint
INFORMATION. FAILURE TO FOLLOW WARNINGS clamping force, and may damage the fastener. When
COULD RESULT IN POSSIBLE AIR BAG you install fasteners, use the correct tightening
DEPLOYMENT, PERSONAL INJURY, OR sequence and specifications. Following these
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. instructions can help you avoid damage to parts and
systems.

Front Door Lock Assembly


Front Door Lock Assembly and Associated Parts

632RS003

Legend (4) Rear Guide Rail


(1) Door Trim Panel (5) Door Lock Assembly
(2) Waterproof Sheet (6) Door Lock Switch Connector (W/Power Door
(3) To Outside Handle Lock)

Removal 3. Remove the waterproof sheet.


Refer to the Front Window Regulator, Glass And
1. Disconnect the battery ground cable. Glass Run in Body Structure section.
2. Remove the door trim panel.
SECURITY AND LOCKS 8H–3
4. Raise the glass up to the uppermost position, and
then remove the rear guide rail.
5. Disconnect the door lock switch connector (w/power
door lock) and locking links (arrow marks positions),
then remove the door lock assembly fixing screws
and door lock assembly.

632RS004

Legend
(1) To Inside Lock Knob
(2) Door Lock Assembly
(3) To Actuator
(4) Door Lock Switch Connector
(5) To Inside Handle
(6) Outside Handle

Installation
To install, follow the removal steps in the reverse order,
noting the following points.
1. Apply chassis grease to the lock assembly and striker
moving surface.
2. Tighten the door lock assembly fixing screws to the
specified torque.
Torque: 7 Nꞏm (0.7kgꞏm/61 lb in)
3. Check that the door lock operates smoothly.
8H–4 SECURITY AND LOCKS

Front Outside Handle and Door Lock Cylinder


Front Outside Handle, Door Lock Cylinder and Associated Parts

632RS006

Legend (4) Door Lock Cylinder


(1) Door Trim Panel (5) Clip
(2) Waterproof Sheet (6) Key Switch (W/Anti-Theft)
(3) Outside Handle

Removal
1. Disconnect the battery ground cable.
2. Remove the door trim panel.
3. Remove the waterproof sheet.
Refer to the Front Window Regulator, Glass And
Glass Run in Body Structure section.
SECURITY AND LOCKS 8H–5
4. Disconnect the locking links (arrow marks positions) 6. Remove the fixing clip(1) to remove the door lock
and key switch connector (w/anti-theft) to remove the cylinder(2).
outside handle.

632RS009

632RS005

Legend Installation
(1) Outside Handle To install, follow the removal steps in the reverse order,
(2) To Door Lock Assembly noting the following points.
(3) Key Switch Connector (W/Anti–Theft) 1. Be sure to install the door lock cylinder(2) at a right
angle to the outside handle(1).
5. Remove the key Switch.

632RS008

632RS007

Legend
(1) Outside Handle
(2) Lock Cylinder
(3) Key Switch
8H–6 SECURITY AND LOCKS
2. For the anti-theft system, be sure to install the push
rod(3) of key switch while pressing it to the door lock
cylinder(5) so that there is no continuity between the
key switch(4) side connector terminal No. D6–2 and
D6–4 (No. D16–2 and D16–4: passenger side).

632RS010

3. Tighten the outside handle and key switch fixing bolts


to the specified torque.
Torque: 9 Nꞏm (0.9kgꞏm/78 lb in)
4. Check for smooth outside handle and lock cylinder
operation.
SECURITY AND LOCKS 8H–7

Rear Door Lock Assembly


Rear Door Lock Assembly and Associated Parts

652RW004

Legend (2) Waterproof Sheet


(1) Door Trim Panel (3) Door Lock Assembly

Removal
1. Disconnect the battery ground cable.
2. Remove the door trim panel.
3. Remove the waterproof sheet.
Refer to the Rear Window Regulator And Glass in
Body Structure section.
8H–8 SECURITY AND LOCKS
4. Disconnect the locking links (arrow marks positions)
and remove the fixing screws to remove the door lock
assembly.

652RS002

Legend
(1) Outside Handle
(2) To Inside Lock Knob
(3) To Inside Handle
(4) To Actuator

Installation
To install, follow the removal steps in the reverse order,
noting the following points.
1. Apply chassis grease to the lock assembly and striker
moving surface.
2. Tighten the door lock assembly fixing screws to the
specified torque.
Torque: 7 Nꞏm (0.7kgꞏm/61 lb in)
3. Check that the door lock operates smoothly.
SECURITY AND LOCKS 8H–9

Rear Outside Handle


Rear Outside Handle and Associated Parts

652RW003

Legend (2) Waterproof Sheet


(1) Door Trim Panel (3) Outside Handle

Removal
1. Disconnect the battery ground cable.
2. Remove the door trim panel.
3. Remove the waterproof sheet.
Refer to the Rear Window Regulator And Glass in
Body Structure section.
4. Disconnect the locking link (arrow mark position) and
remove three fixing bolts to remove the outside
handle.

652RS003
8H–10 SECURITY AND LOCKS

Installation 1. Tighten the outside handle fixing bolts to the specified


torque.
To install, follow the removal steps in the reverse order,
noting the following points. Torque: 9 Nꞏm (0.9kgꞏm/78 lb in)
2. Check that the outside handle operates smoothly.

Rear Door Inside Lock Knob Link


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Remove the door trim panel(3).
3. Remove the waterproof sheet(2).
Refer to the Rear Window Regulator And Glass in
Body Structure section.
4. Remove the fixing screw(4) and disconnect the
locking link at the door lock assembly to remove the
rear door inside lock knob link(1).

655RW009
SECURITY AND LOCKS 8H–11

Door Inside Lock Knob


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Remove the door trim panel(1).
Refer to the Front & Rear Door Trim Panel in
Exterior/Interior Trim section.
3. Turn the door inside lock knob counterclockwise and
then remove the door inside lock knob (2).

632RS011

Door Inside Handle


Removal and Installation
Refer to the Front & Rear Door Trim Panel in
Exterior/Interior Trim section.

635RS008
8H–12 SECURITY AND LOCKS

Tailgate Lock Assembly (LH)


Tailgate Lock Assembly (LH) and
Associated Parts

684RW008

Legend (2) Waterproof Sheet


(1) Tailgate Trim Panel(LH) (3) Tailgate Lock Assembly

Removal
1. Disconnect the battery ground cable.
2. Remove the tailgate trim panel (LH).
Refer to the Tailgate Trim Panel (LH) in
Exterior/Interior Trim section.
3. Taking notice of the tailgate harness, peel the
waterproof sheet off the tailgate panel carefully and
then remove the waterproof sheet.

684RS005
SECURITY AND LOCKS 8H–13
4. Disconnect the locking links (arrow marks positions),
remove three fixing screws and then remove the
tailgate lock assembly (LH).

683RW015

Legend
(1) To Inside Lock Knob
(2) To Actuator
(3) To Inside Handle

Installation
To install, follow the removal steps in the reverse order,
noting the following points.
1. Apply chassis grease to the lock assembly and striker
moving surface.
2. Tighten the tailgate lock assembly fixing screws to the
specified torque.
Torque: 7 Nꞏm (0.7kgꞏm/61 lb in)
3. Check that the tailgate lock operates correctly after
installing it.
8H–14 SECURITY AND LOCKS

Tailgate Lock Assembly (RH)


Tailgate Lock Assembly (RH) and Associated Parts

684RW006

Legend (4) Clip


(1) Tailgate Trim Panel (RH) (5) Screw
(2) Waterproof Sheet (6) Tailgate Lock Assembly (RH)
(3) Tailgate Lock Seal

Removal
1. Disconnect the battery ground cable.
2. Remove the tailgate trim panel (RH).
Refer to the Tailgate Trim Panel (RH) in
Exterior/Interior Trim section.
3. Peel the waterproof sheet off the tailgate panel
carefully and then remove the waterproof sheet.
4. Remove three fixing bolts and then remove the
tailgate lock assembly (RH).

683RW009
SECURITY AND LOCKS 8H–15
5. Remove the tailgate lock seal fixing clip(1) and then Installation
remove the tailgate lock seal(2).
To install, follow the removal steps in the reverse order,
noting the following points.
1. Apply chassis grease to the lock assembly and striker
moving surface.
2. Tighten the tailgate lock assembly fixing bolts to the
specified torque.
Torque: 11 Nꞏm (1.1kgꞏm/95 lb in)
3. Check that the tailgate lock operates correctly after
installing it.

683RW008

Tailgate Inside Lock Knob


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Remove the tailgate trim panel (LH)(2).
Refer to the Tailgate Trim Panel (LH) in
Exterior/Interior Trim section.
3. Take care of cushion to turn the lock knob
counterclockwise and then remove the tailgate inside
lock knob(1).

683RW014
8H–16 SECURITY AND LOCKS

Tailgate Inside Handle


Parts Location

683RW013

Legend
(1) Tailgate Inside Handle

Removal and Installation


Refer to the Tailgate Trim Panel (LH) in
Exterior/Interior Trim section.
SECURITY AND LOCKS 8H–17

Tailgate Outside Handle and/or Tailgate Lock Cylinder


Tailgate Outside Handle and/or Tailgate Lock Cylinder and Associated Parts

684RW007

Legend (4) Tailgate Lock Cylinder


(1) Tailgate Trim Panel (LH) (5) Tailgate Outside Handle
(2) Waterproof Sheet (6) Key Switch (W/Anti–Theft)
(3) Grommet

Removal
1. Disconnect the battery ground cable.
2. Remove the tailgate trim panel.
3. Remove the waterproof sheet.
Refer to the Tailgate Lock Assembly (LH) in this
section.
4. Remove the grommet.
8H–18 SECURITY AND LOCKS
5. Disconnect the locking links (arrow marks positions), Installation
key switch connector (w/anti-theft) and remove three
fixing bolts to remove the tailgate outside handle. To install, follow the removal steps in the reverse order,
noting the following points.
1. For the anti-theft system, install the push rod(1) of the
key switch(3) to the key cylinder(2) while pressing it
so that there is not continuity between the key switch
side connector terminals No. G5–2 and G5–4 as
shown in the figure.

683RW016

Legend
(1) To Actuator
(2) Key Switch Connector (W/Anti–Theft)
(3) To Lock Assembly
683RS009

6. Remove the key switch fixing bolt(3) to remove the 2. Tighten the outside handle and key cylinder fixing
key switch (w/anti-theft) (4) from the tailgate lock bolts to the specified torque.
cylinder (1). Torque: 9 Nꞏm (0.9kgꞏm/78 lb in)
And remove the tailgate lock cylinder fixing bolt(2) to
remove the tailgate lock cylinder. 3. Check that the outside handle and key cylinder
operate correctly after installing them.

683RS008
SECURITY AND LOCKS 8H–19

Key

Key Coding

730RY00001

Legend (3) Position


(1) Key(Actual Size) (4) Level
(2) Key Code Tag

One key is used for the ignition, door, and tailgate lock Key Styles
cylinders. The keys are cut on both edges to make them
reversible.
Key identification is obtained from the five character key
code stamped on the key code tag. From this key code,
the key code cutting combination can be determined from
a code list (available to owners of key cutting equipment
from suppliers).
If key codes are not available from records or tags, the
key code can be obtained from the right hand door lock
cylinder (if lock has not been replaced). Lock cylinders
supplied by the factory as service parts are unmarked.
If the original key is available, the key code cutting
combination can be determined by laying the key on the
diagram shown in the figure.

730RY00001

Legend
(1) Blank Key Style “A”
(2) Blank Key Style “B”

The keys come in styles A or B depending on the key code


cutting combination. When the first position in the
combination is a 1, 2 or 3, Style A is used. When the first
position is a 4, Style B (factory pre-cut key) is used.
8H–20 SECURITY AND LOCKS

Power Door Lock System


General Description
The circuit consists of the door lock (& power window)
switch, door lock actuator for the front and rear door,
tailgate lock actuator and the door lock key switch. The
front door lock switch –LH is always provided with battery
voltage.
The key or the inside lock button on the both driver’s and
the front passenger’s door can activate the lock
mechanism of all the doors (including the tailgate).
When the driver’s door lock switch or the front
passenger’s door lock switch is turned on, current flows
for about one second to the door lock actuator of each
door connected in parallel with the front door lock (&
power window) switch –LH to activate the actuator to lock
and unlock the doors.

Front Door Lock Actuator Removal


1. Refer to the Front Door Lock Assembly removal
procedure in this section. 632RS020

2. Remove the door lock actuator(1).


Front Door Lock Actuator Installation
To install, follow the removal steps in the reverse order.

Rear Door Lock Actuator Removal


1. Refer to the Rear Door Lock Assembly removal
procedure in this section.
2. Removal the door lock actuator(1).

632RS021

632RS019
SECURITY AND LOCKS 8H–21

Rear Door Lock Actuator Installation


To install, follow the removal steps in the reverse order.

Tailgate Lock Actuator Removal


1. Refer to the Tailgate Lock Assembly removal
procedure in this section.
2. Remove the tailgate lock actuator(1).

632RY00002

Tailgate Lock Actuator Installation


To install, follow the removal steps in the reverse order.
8H–22 SECURITY AND LOCKS

Anti-theft System
General Description
The circuit consists of the starter switch, anti-theft &
keyless entry control unit, anti-theft horn, front door and
tailgate key switch (detect and tamper switch), door lock
(& power window) switch, door lock actuator for each
door, engine hood switch, clutch start switch (M/T),
ANTI-THEFT indicator light and mode switch (A/T).
The system operates as follows: After locking the starter
switch and removing the starter key (this sets the alarm),
if the door is unlocked in any way other than with the
proper key, the headlights start flashing, the horn sounds,
and the starter circuit is disabled. (However, the engine
hood and all the doors must be locked and closed.)
Once the system has been placed in the warning or alarm
condition, it can be released only when the starter switch
is shifted from “OFF” to “ACC” by the starter key, or when
the lock of the front door or the tailgate is released (to
activate the detect switch) by the starter key.

Anti-theft & Keyless Entry Control 825RW028

Unit Removal Anti-theft & Keyless Entry Control


1. Disconnect the battery ground cable. Unit Installation
2. Remove the front console assembly. To install, follow the removal steps in the reverse order.
Refer to the Instrument Panel Assembly in Body
Structure section.
3. Remove the lower cluster assembly.
Anti-theft Indicator Removal
Refer to the Instrument Panel Assembly in Body 1. Disconnect the battery ground cable.
Structure section. 2. Remove the front console assembly(1).
4. Disconnect the connector(2). Refer to the Instrument Panel Assembly in Body
5. Remove four screws to remove the anti-theft & Structure section.
keyless entry control unit with bracket(1). 3. Remove the lower cluster assembly(2).
Refer to the Instrument Panel Assembly in Body
Structure section.
4. Remove the instrument panel driver lower cover
assembly(3).
Refer to the Instrument Panel Assembly in Body
Structure section.

825RW029

6. Remove two nuts from the anti-theft & keyless entry


control unit with bracket(3) to remove the anti-theft &
keyless entry controller(4).

821RW024
SECURITY AND LOCKS 8H–23
5. Remove the instrument panel cluster assembly(4). Engine Hood Switch Removal
Refer to the Instrument Panel Assembly in Body
Structure section. 1. Disconnect the battery ground cable.
6. Remove two screws and then remove the anti-theft 2. Remove the cap(1).
indicator(5). 3. Remove the lock nut(2).
4. Disconnect the connector(4).
5. Remove the engine hood switch(3).

821RW032

Anti-theft Indicator Installation 828RS011

To install, follow the removal steps in the reverse order.


Engine Hood Switch Installation
Anti-theft Horn Removal To install, follow the removal steps in the reverse order.
1. Disconnect the battery ground cable.
2. Disconnect the connector and remove the fixing bolt
to remove the anti-theft horn(1).

828RS007

Anti-Theft Horn Installation


To install, follow the removal steps in the reverse order.
8H–24 SECURITY AND LOCKS

Keyless Entry System


ID Code Registration (Except South ID Code New Registration
Africa) This procedure erases all registered ID codes and
registers a new received ID code instead.
There are four kinds of ID codes which can be registered,
for which these two modes, ID code new registration and
ID code additional registration, are available.
Step Action Yes No
1 1. Confirm that all the doors are closed and unlocked.
2. Open the driver’s side door.
3. Insert the key into the starter switch.
Is the action complete? Go to Step 2 Go to Step 1
2 Turn the starter switch to ACC position and then to OFF position
three times.
NOTE: This step must be carried out within five seconds after
step 1.
Is the action complete? Go to Step 3 Go to Step 1
3 Close the driver’s side door and then open it two times.
NOTE: This step must be carried out within ten seconds after
step 2.
Is the action complete? Go to Step 4 Go to Step 1
4 1. Turn the starter switch to ACC position and then to OFF
position five times.
2. Close the driver’s side door and then open it.
NOTE: This step must be carried out within ten seconds after
step 3.
Is the action complete? Go to Step 5 Go to Step 1
5 The control unit locks and unlocks the doors one time.
Does the control unit work normally? Go to Step 6 Go to Step 1
6 Operate the lock or unlock button of the transmitter.
NOTE: This step must be carried out within twenty seconds
after step 5.
Is the action complete? Go to Step 7 Go to Step 1
7 The control unit locks and unlocks the doors one time.
Does the control unit work normally? Go to Step 8 Go to Step 1
8 Operate the lock or unlock button of the transmitter.
NOTE: This step must be carried out within twenty seconds
after step 7.
Is the action complete? Go to Step 9 Go to Step 1
9 The control unit compares the two codes sent from the
transmitter.
If the code succeeds in registration, the control unit locks and
unlocks the doors one time.
If the two codes are different from each other or fails in
registration, the control unit locks and unlocks the doors three
times.
NOTE: In any case, this procedure is finished.
Go to Step 1 Go to Step 1
SECURITY AND LOCKS 8H–25

ID Code Additional Registration


This procedure additionally registers a new received ID
code with holding registered ID codes. When total
number of registered ID codes and newly registered ID
code exceeds four, they are erased in order of older one.

Step Action Yes No


1 1. Confirm that all the doors are closed and unlocked.
2. Open the driver’s side door.
3. Insert the key into the starter switch.
Is the action complete? Go to Step 2 Go to Step 1
2 Turn the starter switch to ACC position and then to OFF position
three times.
NOTE: This step must be carried out within five seconds after
step 1.
Is the action complete? Go to Step 3 Go to Step 1
3 Close the driver’s side door and then open it two times.
NOTE: This step must be carried out within ten seconds after
step 2.
Is the action complete? Go to Step 4 Go to Step 1
4 1. Turn the starter switch to ACC position and then to OFF
position three times.
2. Close the driver’s side door and then open it.
NOTE: This step must be carried out within ten seconds after
step 3.
Is the action complete? Go to Step 5 Go to Step 1
5 The control unit locks and unlocks the doors two times.
Does the control unit work normally? Go to Step 6 Go to Step 1
6 Operate the lock or unlock button of the transmitter.
NOTE: This step must be carried out within twenty seconds
after step 5.
Is the action complete? Go to Step 7 Go to Step 1
7 The control unit locks and unlocks the doors one time.
Does the control unit work normally? Go to Step 8 Go to Step 1
8 Operate the lock or unlock button of the transmitter.
NOTE: This step must be carried out within twenty seconds
after step 7.
Is the action complete? Go to Step 9 Go to Step 1
9 The control unit compares the two codes sent from the
transmitter.
If the code succeeds in registration, the control unit locks and
unlocks the doors one time.
If the two codes are different from each other or fails in
registration, the control unit locks and unlocks the doors three
times.
NOTE: In any case, this procedure is finished.
Go to Step 1 Go to Step 1
8H–26 SECURITY AND LOCKS

Anti–theft & Keyless Entry Control


Unit/Transmitter Replacement
Anti–theft & Keyless Entry Control Unit
Replacement
1. Remove and install the control unit.
Refer to Anti–theft & Keyless Entry Control Unit
Removal and Installation in this section.
2. Register ID code.
Refer to ID Code Registration in this section.
3. Check that the keyless entry system works normally.

Transmitter Replacement
1. Prepare a new transmitter.
2. Regiter ID code.
Refer to ID Code Registration in this section.
3. Check that the keyless entry system works normally.

Transmitter Battery Replacement


1. Remove a screw to remove the cover.
2. Remove the batteries.
3. Set the new batteries into the transmitter.
4. Install the cover to the transmitter.
5. Check that the keyless entry system works normally.
SECURITY AND LOCKS 8H–27

Programming With Tech 2 (For South Africa)


General Description
When the anti-theft and keyless entry control unit and/or
the transmitters (remote keys) are replaced, the security
codes and/or transmitter ID codes must be programmed
by using the Tech 2. The following pages show the
procedures to program in regard to the anti-theft and
keyless entry system. Please refer to Tech 2 scan tool
user’s guide in detail.

901RW180

Legend (3) SAE 16/19 Adaptor


(1) PCMCIA Card (4) DLC Cable
(2) RS 232 Loop Back Connector (5) Tech 2
8H–28 SECURITY AND LOCKS
Programming Anti-Theft Warning Programming Remote Key
When the anti-theft and keyless entry control unit is When the anti-theft and keyless entry control unit is
replaced, the security code must be programmed after replaced and/or the new transmitter (remote key) is
installation. supplied, the ID code of the transmitter must be
1. Insert the Isuzu system PCMCIA card into the Tech 2. programmed by the following procedure.
2. Connect the SAE 16/19 adaptor to the data link 1. Perform the step 1. to 15. of “Programming Anti Theft
connector (DLC) cable. Warning”.
3. Connect the DLC cable to the Tech 2. 2. Select “F1: Program Remote Key” and press the
enter key.
4. Confirm that the starter switch is off.
3. Press the confirm key (soft key).
5. Connect the Tech 2 SAE 16/19 adaptor to the vehicle
DLC. 4. Press the lock button of the transmitter until the
display changes.
6. Verify the Tech 2 power up display.
5. Press the confirm key (soft key).
6. Press the Yes or No key (soft key).

Erasing Remote Keys


All the ID code stored in the control unit can be erased by
the following procedure.
1. Perform the step 1. to 15. of “Programming Anti Theft
Warning”.
2. Select “F0: Erase Remote Keys” and press the enter
key.
3. Press the confirm key (soft key).
4. Press the confirm key (soft key).
5. Press the confirm key (soft key).

060RW009

7. Press the enter key.


8. Select “F0 : Diagnostics” and press the enter key.
9. Select the model year and press the enter key.
10. Select the vehicle type and press the enter key.
11. Select “F2 : Body” and press the enter key.
12. Select “Anti Theft Warning” and press the enter key.
13. Turn the starter switch on and press the confirm key
(soft key).
14. Confirm “Partnumber” , “Country Code” and
“Production Date” and press the confirm key (soft
key).
15. Select “F4 : Programming” and press the enter key.
16. Select “F2 : Program Anti Theft Warning” and press
the enter key.
17. Press the confirm key (soft key).
18. Press the confirm key (soft key).
19. Enter the security code and press the enter key.
20. Press the okey key (soft key).
21. Enter the security code and press the enter key.
22. Press the okey key (soft key).
23. Press the soft key to select “Remote Key”.
24. Select country code and press the enter key.
25. Press the confirm key (soft key).
SECURITY AND LOCKS 8H–29

Main Data and Specifications


Torque Specifications
Application Nꞏm Kgꞏm Lb Ft Lb In
Front Door Lock Assembly Fixing Screws 7 0.7 — 61
Front Outside Handle and Key Switch Fixing Bolts 9 0.9 — 78
Rear Door Lock Assembly Fixing Screws 7 0.7 — 61
Rear Outside Handle Fixing Bolts 9 0.9 — 78
Tailgate Lock Assembly (LH) Fixing Screws 7 0.7 — 61
Tailgate Lock Assembly (RH) Fixing Bolts 11 1.1 — 95
Tailgate Outside Handle and Key Cylinder Fixing Bolts 9 0.9 — 78
SUN ROOF/CONVERTIBLE TOP 8I–1

BODY AND ACCESSORIES


SUN ROOF/CONVERTIBLE TOP
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 8I–1 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–8
Sun Roof Glass . . . . . . . . . . . . . . . . . . . . . . . . . 8I–2 Sun Roof Drain Hose (Front Side) . . . . . . . . . 8I–9
Sun Roof Glass and Associated Parts . . . . 8I–2 Sun Roof Drain Hose (Front Side) and
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–2 Associated Parts . . . . . . . . . . . . . . . . . . . . . . 8I–9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–9
Sun Roof Deflector . . . . . . . . . . . . . . . . . . . . . . 8I–4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–4 Sun Roof Drain Hose (Rear Side) . . . . . . . . . 8I–10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–4 Sun Roof Drain Hose (Rear Side) and
Sunshade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–4 Associated Parts . . . . . . . . . . . . . . . . . . . . . . 8I–10
Disassembled View . . . . . . . . . . . . . . . . . . . . 8I–4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–5 Sun Roof Switch . . . . . . . . . . . . . . . . . . . . . . . . 8I–11
Sun Roof Frame Complete Assembly . . . . . . 8I–6 General Description . . . . . . . . . . . . . . . . . . . . . 8I–11
Sun Roof Frame Complete Assembly and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–11
Associated Parts . . . . . . . . . . . . . . . . . . . . . . 8I–6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–6 Sun Roof Motor . . . . . . . . . . . . . . . . . . . . . . . . . 8I–12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–12
Disassembled View . . . . . . . . . . . . . . . . . . . . 8I–7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–7 Main Data and Specifications . . . . . . . . . . . . . 8I–12

Service Precaution CAUTION: Always use the correct fastener in the


proper location. When you replace a fastener, use
WARNING: IF SO EQUIPPED WITH A ONLY the exact part number for that application.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS), ISUZU will call out those fasteners that require a
REFER TO THE SRS COMPONENT AND WIRING replacement after removal. ISUZU will also call out
LOCATION VIEW IN ORDER TO DETERMINE the fasteners that require thread lockers or thread
WHETHER YOU ARE PERFORMING SERVICE ON OR sealant. UNLESS OTHERWISE SPECIFIED, do not
NEAR THE SRS COMPONENTS OR THE SRS use supplemental coatings (Paints, greases, or other
WIRING. WHEN YOU ARE PERFORMING SERVICE corrosion inhibitors) on threaded fasteners or
ON OR NEAR THE SRS COMPONENTS OR THE SRS fastener joint interfaces. Generally, such coatings
WIRING, REFER TO THE SRS SERVICE adversely affect the fastener torque and the joint
INFORMATION. FAILURE TO FOLLOW WARNINGS clamping force, and may damage the fastener. When
COULD RESULT IN POSSIBLE AIR BAG you install fasteners, use the correct tightening
DEPLOYMENT, PERSONAL INJURY, OR sequence and specifications. Following these
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. instructions can help you avoid damage to parts and
systems.
8I–2 SUN ROOF/CONVERTIBLE TOP

Sun Roof Glass


Sun Roof Glass and Associated Parts

665RS002

Legend (3) Decoration Cover


(1) Sun Roof Weatherstrip (4) Sun Roof Shim
(2) Sun Roof Glass

Removal
1. Open the sun roof and pull the sun roof weatherstrip
out from the roof panel.
2. Close the sun roof and open the sunshade(1). Then,
remove the decoration cover fixing screws and
decoration cover(2).

665RS003
SUN ROOF/CONVERTIBLE TOP 8I–3
3. Disconnect the battery ground cable. 3. Temporarily install the glass to the sun roof frame.
4. Remove eight sun roof glass fixing screws to remove 4. Open and shut the sun roof four to five times to
the sun roof glass(3). position correctly the sun roof weatherstrip and the
glass in the longitudinal and latitudinal setting
NOTE: If shims are used between the sun roof set plate
positions.
and the glass, note the number of shims used.
5. Insert the original shims between the sun roof set
plate and the glass.
6. Tighten the sun roof glass fixing screws to the
specified torque.
Torque: 10 Nꞏm (1.0 kgꞏm/87 lb in)
7. After the sun roof glass is installed, check the roof
panel and sun roof glass for vertical install position.
If out of standard, adjust with shim.
For the installation standard, refer to the Body
Dimension in Body Structure section.
8. Install the decoration cover.

665RS004

Installation
To install, follow the removal steps in the reverse order,
noting the following points.
1. Clean the body panel of the weatherstrip fixing
portion.
If the protective film(1) of the body panel is peeled, it
cannot be reused.
Install the new protective film around the body
panel(2).
2. Install the new weatherstrip(3).
Always replace with a new one.
Be sure to install the sun roof weatherstrip so that
the white marking location(4) of the weatherstrip is
on the front side of the vehicle.

665RW016
8I–4 SUN ROOF/CONVERTIBLE TOP

Sun Roof Deflector


Removal Installation
1. Open the sun roof. To install, follow the removal steps in the reverse order.
2. Remove the fixing screws(2) to remove the sun roof
deflector(1).

665RS006

Sunshade
Disassembled View

665RS007
SUN ROOF/CONVERTIBLE TOP 8I–5
Legend (3) Decoration Cover
(1) Sunshade (4) Sun Roof Deflector
(2) Sunshade Stopper

Removal Installation
1. Remove the decoration cover. To install, follow the removal steps in the reverse order.
2. Open the sun roof half position, remove the sunshade
stopper screw and pull out the sunshade(6) until its
front side protrudes a little from the sun roof glass(2)
to remove the sunshade stopper.
3. Remove the sun roof deflector.
Refer to the Sun Roof Deflector in this section.
4. Open the sun roof completely.
5. Remove the sunshade guide rail stopper(5), and pull
out the sunshade up to the rail edge.
6. Remove the guide pin(4) in the sunshade through the
notch(7) of guide rail(1) and then draw the sunshade
out of the roof by pushing inward the retaining clips(3)
on both sides.

665RS008
8I–6 SUN ROOF/CONVERTIBLE TOP

Sun Roof Frame Complete Assembly


Sun Roof Frame Complete Assembly and Associated Parts

665RS009

Legend (3) Headlining


(1) Sun Roof Drain Hose (4) Sun Roof Drain Hose
(2) Sun Roof Frame Complete Assembly

Removal
1. Disconnect the battery ground cable.
2. Remove the headlining.
Refer to the Headlining in Body Structure section.
3. Disconnect the sun roof drain hose at the sun roof
frame side as shown in the figure.

665RS010

4. Disconnect the sun roof harness connection.


SUN ROOF/CONVERTIBLE TOP 8I–7
5. Remove two sun roof frame complete assembly fixing 1. Tighten the sun roof frame complete assembly fixing
nuts (front side) and four fixing bolts (each side) from bolts and nuts to the specified torque.
the frame complete, and then remove the sun roof Torque: 10 Nꞏm(1.0 kgꞏm/87 lb in)
frame complete assembly.
2. After installing the frame complete, loosen the sun
NOTE: Be sure to remove the frame complete while roof glass fixing nuts and adjust the sun roof glass
supporting it. setting position.
Refer to the Sun Roof Glass in this section.
Installation
To install, follow the removal steps in the reverse order,
noting the following points.

Disassembled View

665RW035

Legend (4) Sun Roof Drive Unit Assembly


(1) Sunshade (5) Outer Tube Fixing Screw
(2) Sun Roof Glass (6) Sun Roof Frame Assembly
(3) Sun Roof Motor (7) Sun Roof Deflector

Disassembly 6. Disconnect the sun roof motor connector, remove the


sun roof fixing nuts and screws, and then remove the
1. Open the sun roof. sun roof motor.
2. Remove the sun roof deflector fixing screws and then
remove the sun roof deflector.
3. Remove the sunshade.
Refer to the Sunshade in this section.
4. Close the sun roof, remove the decoration cover and
the fixing screws and then remove the sun roof glass.
5. If the shims are used between the sun roof set plate
and the glass, note the number of the shims.
8I–8 SUN ROOF/CONVERTIBLE TOP
7. Remove the cable outer tube(2) fixing screws.
8. Remove the cable outer tube fixing clamps(1) and
guide rail fixing nuts(5).
9. Prying the guide rail a little with a screwdriver, draw
the outer tube out of the grommet(3).
At this time, the inner cable(4) remains on the frame
assembly.
10. Remove the sun roof frame assembly.

665RS012

Reassembly
To reassembly, follow the disassembly steps in the
reverse order, noting the following points.
1. When installing the motor or drive unit, set the sun
roof set plate in the full closed position by pushing the
link(3) portion using the screwdriver(2).
2. When installing the sun roof glass(1) to the sun roof
set plate, insert the original shims in the same position
before removing the sun roof glass.

665RS013
SUN ROOF/CONVERTIBLE TOP 8I–9

Sun Roof Drain Hose (Front Side)


Sun Roof Drain Hose (Front Side) and Associated Parts

665RW017

Legend (4) Instrument Panel Assembly


(1) Clip (5) Front Inner Liner
(2) Sun Roof Drain Hose (6) Headlining
(3) Grommet

Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order,
noting the following points.
2. Remove the front inner liner.
1. Apply the soap and water to the body panel grommet.
3. Remove the headlining.
2. Install the drain hose from inside of the vehicle by
Refer to the Headlining in Body Structure section.
utilizing, as a guide, the string passed during removal
4. Remove the instrument panel assembly. step.
Refer to the Instrument Panel Assembly in Body 3. The body panel grommet must not be twisted or
Structure section. caught in during installation.
5. Disconnect the drain hose at the frame complete 4. Complete routing, avoiding extreme bends or curves.
side.
5. After routing, install the trim with care not to allow the
6. Apply the soap and water to the body panel grommet. drain hose to be caught in.
7. Pass the string from the sun roof frame side through 6. Test the drain condition.
the drain port side, and remove the drain hose from
7. The protrusion of drain hose from the body panel
the hose fixing clips. Taking care not to allow the body
must be within 50 mm (2.0 in). If it exceeds 50 mm
panel grommet to be removed together with the hose,
(2.0 in) after correct routing, cut the leading edge so
pull the drain hose only to the inside of the vehicle.
that the protrusion is within 50 mm (2.0 in).
(The string should be kept as it is.)
8I–10 SUN ROOF/CONVERTIBLE TOP

Sun Roof Drain Hose (Rear Side)


Sun Roof Drain Hose (Rear Side) and Associated Parts

665RS015

Legend (6) Tape


(1) Soft Tape (7) Grommet
(2) Pipe (8) Grommet
(3) Clip (9) Clip
(4) Soft Tape (10) Headlining
(5) Sun Roof Drain Hose (11) Rear Fender Inner Liner

Removal 5. Apply the soap and water to the body panel grommet.
6. Remove the hose fixing tapes and clips.
1. Disconnect the battery ground cable.
7. Pull the drain hose to the inside of the vehicle.
2. Remove the rear fender inner liner.
3. Remove the headlining.
Refer to the Headlining in Body Structure section. Installation
4. Disconnect the drain hose at the frame complete To install, follow the removal steps in the reverse order,
side. noting the following points.
1. Apply the soap and water to the body panel grommet.
SUN ROOF/CONVERTIBLE TOP 8I–11
2. Insert the drain hose from inside of vehicle, restore 4. Test the drain condition.
routing, and fix with new soft tape and clip. 5. The protrusion of the drain hose from the body panel
If the grommet is removed during removal of drain must be within 50 mm (2.0 in). If it exceeds 50 mm
hose, insert the grommet into drain hose from outside (2.0 in) after correct routing, cut the leading edge so
of the vehicle, and install on the body panel, avoiding that the protrusion is within 50 mm (2.0 in).
any twisting.
3. After installing the drain hose, install the trim while
taking care not to crush the drain hose.
Also, care should be taken not to allow the drain hose
connected to the pipe to be caught in.

Sun Roof Switch


General Description Installation
Sun roof operation can be controlled by pushing To install, follow the removal steps in the reverse order.
continuously the sun roof switch to activate the sun roof
control unit and sun roof motor.
While the switch is being pushed to the “OPEN” side, the
sun roof stops about 165 mm (6.5 in) before fully open
position. Push the switch again to the “OPEN” side to
open it fully. When the switch is being continuously
pushed to the “CLOSE” side, the sun roof stops about
180 mm (7.1 in) short of the fully closed position and
remains in this state. Push the switch again to the
“CLOSE” side to close it completely.

Removal
1. Disconnect the battery ground cable.
2. Pull down the switch housing(2) and disconnect the
sun roof switch and map light connectors to remove
the sun roof switch(1).

805RS002
8I–12 SUN ROOF/CONVERTIBLE TOP

Sun Roof Motor


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order,
noting the following point.
2. Remove the headlining(2).
1. When installing the sun roof motor, close the sun roof
Refer to the Headlining removal steps in Body
glass completely.
Structure section.
3. Disconnect the connector, and remove three nuts and
two screws to remove the sun roof motor(1).

665RW034

Main Data and Specifications


Torque Specifications
Application Nꞏm kgꞏm lb ft lb in
Sun Roof Frame Complete Assembly Fixing Bolts 10 1.0 — 87
Sun Roof Glass Fixing Screws 10 1.0 — 87
EXTERIOR/INTERIOR TRIM 8J–1

BODY AND ACCESSORIES


EXTERIOR / INTERIOR TRIM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 8J–2 Roof Side Trim Cover and Associated
Dash Side Trim Panel . . . . . . . . . . . . . . . . . . . . 8J–3 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–22
Assist Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–3 Front Pillar Trim Cover . . . . . . . . . . . . . . . . . . . 8J–23
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8J–3 Front Pillar Trim Cover and Associated
Removal and Installation . . . . . . . . . . . . . . . 8J–3 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–23
Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–23
Consoles and Associated Parts . . . . . . . . . 8J–4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–4 Center Pillar Assist Grip . . . . . . . . . . . . . . . . . . 8J–24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–5 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8J–24
Removal and Installation . . . . . . . . . . . . . . . 8J–24
Front Door Trim Panel . . . . . . . . . . . . . . . . . . . 8J–6
Front Door Trim Panel and Associated Assist Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–24
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–6 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8J–24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–6 Removal and Installation . . . . . . . . . . . . . . . 8J–24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–9 Fuel Filler Lid Opener Cable . . . . . . . . . . . . . . 8J–25
Rear Door Trim Panel . . . . . . . . . . . . . . . . . . . . 8J–10 Fuel Filler Lid Opener Cable and
Rear Door Trim Panel and Associated Associated Parts . . . . . . . . . . . . . . . . . . . . . . 8J–25
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–11 Fuel Filler Door . . . . . . . . . . . . . . . . . . . . . . . . . 8J–26
Door Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–13 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8J–26
Door Mirror and Associated Parts . . . . . . . . 8J–13 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–13 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–13 Rocker Protector (Without Wheel Opening
Luggage Side and Quarter Upper Trim Cover Extension) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–27
(LWB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–14 Rocker Protector (Without Wheel Opening
Luggage Side, Quarter Upper Trim Cover Extension) and Associated Parts . . . . . . . . 8J–27
and Associated Parts . . . . . . . . . . . . . . . . . . 8J–14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–16 Wheel Opening Extension and Rocker Protector
Luggage Side and Quarter Upper Trim Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–28
(SWB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–17 Wheel Opening Extension, Rocker Protector
Luggage Side, Quarter Upper Trim Cover Assembly and Associated Parts . . . . . . . . . 8J–28
and Associated Parts . . . . . . . . . . . . . . . . . . 8J–17 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–17 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–19 Mud Flaps (With Wheel Opening Extension) 8J–31
Center Pillar and Roof Side Trim Cover Mud Flaps (With Wheel Opening Extension)
(LWB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–20 and Associated Parts . . . . . . . . . . . . . . . . . . 8J–31
Center Pillar, Roof Side Trim Cover and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–31
Associated Parts . . . . . . . . . . . . . . . . . . . . . . 8J–20 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–20 Ventilation Assembly . . . . . . . . . . . . . . . . . . . . . 8J–32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–21 Ventilation Assembly and Associated Parts 8J–32
Roof Side Trim Cover (SWB) . . . . . . . . . . . . . 8J–22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–32
8J–2 EXTERIOR/INTERIOR TRIM
Quarter Flipper Glass Assembly (SWB) . . . . 8J–33 Rope Hook Set and Associated Parts . . . . 8J–37
Quarter Flipper Glass Assembly and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–37
Associated Parts . . . . . . . . . . . . . . . . . . . . . . 8J–33 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–37
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–33 Power Door Mirror System . . . . . . . . . . . . . . . 8J–38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–33 General Description . . . . . . . . . . . . . . . . . . . . . 8J–38
Tailgate Trim Panel (LH) . . . . . . . . . . . . . . . . . 8J–34 Door Mirror Switch Assembly (Control
Tailgate Trim Panel (LH) and Associated Switch, Folding Switch and Defogger
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–34 Switch) Removal . . . . . . . . . . . . . . . . . . . . . . 8J–38
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–34 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–35 Power Door Mirror . . . . . . . . . . . . . . . . . . . . . . . 8J–38
Tailgate Trim Panel (RH) . . . . . . . . . . . . . . . . . 8J–36 General Description . . . . . . . . . . . . . . . . . . . . 8J–38
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8J–36 Removal and Installation . . . . . . . . . . . . . . . 8J–38
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–36 Power Window System . . . . . . . . . . . . . . . . . . 8J–39
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–36 General Description . . . . . . . . . . . . . . . . . . . . . 8J–39
Luggage Floor Box . . . . . . . . . . . . . . . . . . . . . . 8J–37 Power Window Switch Removal and
Luggage Floor Box and Associated Parts . 8J–37 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–39
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–37 Power Window Motor Removal and
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–37 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–40
Rope Hook Set . . . . . . . . . . . . . . . . . . . . . . . . . 8J–37 Main Data and Specifications . . . . . . . . . . . . . 8J–41

Service Precaution CAUTION: Always use the correct fastener in the


proper location. When you replace a fastener, use
WARNING: IF SO EQUIPPED WITH A ONLY the exact part number for that application.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS), ISUZU will call out those fasteners that require a
REFER TO THE SRS COMPONENT AND WIRING replacement after removal. ISUZU will also call out
LOCATION VIEW IN ORDER TO DETERMINE the fasteners that require thread lockers or thread
WHETHER YOU ARE PERFORMING SERVICE ON OR sealant. UNLESS OTHERWISE SPECIFIED, do not
NEAR THE SRS COMPONENTS OR THE SRS use supplemental coatings (Paints, greases, or other
WIRING. WHEN YOU ARE PERFORMING SERVICE corrosion inhibitors) on threaded fasteners or
ON OR NEAR THE SRS COMPONENTS OR THE SRS fastener joint interfaces. Generally, such coatings
WIRING, REFER TO THE SRS SERVICE adversely affect the fastener torque and the joint
INFORMATION. FAILURE TO FOLLOW WARNINGS clamping force, and may damage the fastener. When
COULD RESULT IN POSSIBLE AIR BAG you install fasteners, use the correct tightening
DEPLOYMENT, PERSONAL INJURY, OR sequence and specifications. Following these
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. instructions can help you avoid damage to parts and
systems.
EXTERIOR/INTERIOR TRIM 8J–3

Dash Side Trim Panel


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order,
noting the following point.
2. Remove the front door sill plate(2).
1. Lap the door inner seal over the trim panel to install
3. Remove the dash side trim panel(3).
them securely to the body panel.
Turn up the door inner seal(1) of the body panel to
remove the clips of the trim panel.
Take care not to damage the harness and the
controller on the back of the trim panel.

643RW005

Assist Grip
Parts Location Removal and Installation
Refer to the Consoles in this section.

745RW006

Legend
(1) Assist Grip
8J–4 EXTERIOR/INTERIOR TRIM

Consoles
Consoles and Associated Parts
This illustration is based on RHD

745RW009

Legend (4) Center Console Assembly


(1) Shift Knob (M/T) / Transfer Knob (A/T) (5) Front Seat Assembly (RH)
(2) Assist Grip (6) Front Console Assembly
(3) Fuel Filler Lid Opener

Removal
1. Disconnect the battery ground cable.
2. Remove the shift knob (M/T) / transfer knob (A/T).
3. Remove the front console assembly.
Remove four fixing screws and disconnect the
switch connectors.
4. Remove the front seat assembly(RH).
Refer to the Front Seat Assembly in Seats section.
5. Remove the assist grip.
Remove three bolts.
6. Remove the fuel filler lid opener.
Remove the fuel filter lid opener(1) and disconnect
the cable(2).

686RW007
EXTERIOR/INTERIOR TRIM 8J–5
7. Remove the center console assembly(2).
Remove two fixing screws on the front side.
Open the rear cover, remove two nuts, then the
center console assembly.
Remove the rear heater duct(1) from the center
console.

745RS005

Installation
To install, follow the removal steps in the reverse order.
8J–6 EXTERIOR/INTERIOR TRIM

Front Door Trim Panel


Front Door Trim Panel and Associated Parts

635RW011

Legend (7) Regulator Handle


(1) Power Window Switch (8) Inside Handle Fixing Screw
(2) Door Mirror Cover (9) Inside Handle
(3) Door Trim Panel (10) Hook
(4) Courtesy Light (11) Washer
(5) Front Speaker (12) Inside Pull Handle
(6) Speaker Cover (13) Inside Pull Handle (W/O Power Window)

Removal
1. Disconnect the battery ground cable.
EXTERIOR/INTERIOR TRIM 8J–7
2. Remove the door mirror cover (1). 4. Remove the power window switch(1).
Pry the power window switch out and disconnect
the switch connector.

720RW011

3. Remove the regulator handle(3).


Pull the hook(4) out and remove the regulator 825RW174

handle. 5. Remove the speaker cover.


6. Remove the front speaker.
Remove the front speaker fixing screws in order to
disconnect the speaker connector.
7. Remove the inside handle fixing screw.
Remove the screw that fixes the inside handle(7),
slide the inside handle to the position illustrated,
and leave it there for the moment.
CAUTION: Take care not to impose excessive force
on the inside handle link(6), lest this link is
elongated, which could make it impossible to
operate the door with the inside handle.

631RW001
8J–8 EXTERIOR/INTERIOR TRIM
Disconnect the courtesy light connector(13) to lift
the door trim panel(14) and unlock the engagement
of the waist seal(12) section. Then, pass the inside
handle(11) through the mounting hole of the trim
panel, and detach the trim panel.

632RW001

8. Remove the door trim panel(9).


Remove two fixing screws(8) in order to take off
seven clips(10) from the door panel.

632RS015

9. Remove the inside handle.

635RS007
EXTERIOR/INTERIOR TRIM 8J–9

Installation
To install, follow the removal steps in the reverse order,
noting the following point.
1. When installing the inside handle(2), assemble it
temporarily to the inside handle link(1).

632RW006

3. Fit the claw(10) of the inside handle(11) securely into


the hole of the door panel and fix the inside handle
with the screw.

632RS014

2. Pass the inside handle(4) through the mounting hole


of the trim panel and assemble the trim panel.
Engage seven clips(8) into the door panel. Also,
connect the courtesy light connector(5) and leave the
connectors of the speaker(7), tweeter(9) and power
window(3) drawn out to their prescribed positions, so
that they will not be caught.
Then, put the inside handle(4) to the normal position
of the inside handle link(6).

632RW007
8J–10 EXTERIOR/INTERIOR TRIM

Rear Door Trim Panel


Rear Door Trim Panel and Associated Parts

655RW006

Legend (4) Clip


(1) Power Window Switch (5) Regulator Handle
(2) Door Trim Panel (6) Inside Handle Fixing Screw
(3) Washer (7) Inside Handle

Removal
1. Disconnect the battery ground cable.
2. Remove the regulator handle(1).
Pull the hook(2) out and remove the regulator
handle.

631RW002
EXTERIOR/INTERIOR TRIM 8J–11
3. Remove the power window switch(3). 5. Remove the door trim panel(6).
Pry the power window switch out and disconnect Remove two fixing screws(8) to take off seven
the switch connector. clips(7) from the door panel.

825RS084 655RW007

4. Remove the inside handle fixing screw. Lift the trim panel and unlock the engagement of the
Remove the screw that fixes the inside handle(5), waist seal section. Then, pass the inside lever
slide the inside handle to the position illustrated, through the mounting hole of the trim panel, and
and leave it there for the moment. detach the trim panel.
CAUTION: Take care not to impose excessive force 6. Remove the inside handle.
on the inside handle link(4), lest this link be
elongated, which could make it impossible to Installation
operate the door with the inside handle.
To install, follow the removal steps in the reverse order,
noting the following point.
1. When installing the inside handle(1), assemble
temporarily to the inside handle link(2).

652RS006

632RW002
8J–12 EXTERIOR/INTERIOR TRIM
2. Pass the inside handle through the mounting hole of
the trim panel. Assemble the trim panel. Engage
securely seven clips into the door panel. Also, leave
the connector of the power window drawn out to its
prescribed position, so that it will not caught.
3. Put back the inside handle(3) to the original position
of the link(5). Fit the claw(4) of the inside handle
securely into the hole of the door panel. Fix the
handle with the screw.

632RW011
EXTERIOR/INTERIOR TRIM 8J–13

Door Mirror
Door Mirror and Associated Parts Installation
To install, follow the removal steps in the reverse order,
noting the following points.
1. When you install the door mirror, install the bolt(1) to
the mirror temporarily, hook the bolt to the door side
hole and tighten the bolt from the inside.

720RS012

Legend
(1) Door Mirror Cover
(2) Door Mirror Connector
(3) Door Mirror
720RS001

2. When installing the door mirror, hold the glass run


lip(2) between the door mirror base(3) and the center
Removal sash(4).
1. Disconnect the battery ground cable.
2. Remove the door mirror cover(1).

A10RS001

3. Tighten the door mirror fixing bolts to the specified


torque.
720RW011

3. Remove the door mirror connector. Torque: 8 Nꞏm (0.8kgꞏm/69 lb in)


4. Remove the door mirror.
8J–14 EXTERIOR/INTERIOR TRIM

Luggage Side and Quarter Upper Trim Cover (LWB)


Luggage Side, Quarter Upper Trim Cover and Associated Parts

760RW017

Legend (8) Third Seat Belt Anchor Bolt Cover and Anchor
(1) Assist Grip Bolt
(2) Rear Seat Belt Anchor Bolt Cover and Anchor (9) Rear End Floor Trim Cover
Bolt (10) Luggage Side Cap
(3) Quarter Upper Trim Cover (11) Speaker Grille
(4) Anchor Bolt (12) Rear Speaker
(5) Luggage Side Trim Cover (13) Luggage Room Light
(6) Luggage Side Lower Cover (14) Rear Roof Trim Cover
(7) Third Seat Assembly and seat Bracket

Removal 4. Remove the luggage side cap.


5. Remove the luggage side lower cover.
1. Disconnect the battery ground cable.
2. Remove the third seat assembly and seat bracket.
3. Remove the rear end floor trim cover.
EXTERIOR/INTERIOR TRIM 8J–15
6. Remove the luggage side trim cover (1). 9. Remove the speaker grille.
Remove the rear side fixing screws and pry the trim
cover retainers free from the body panel and the
upper trim cover.

687RS003

10. Remove the rear speaker.


Remove the rear speaker fixing screws and
687RS002 disconnect the connector.
7. Remove the luggage room light. 11. Remove the rear seat belt anchor bolt cover (2) and
Remove the luggage room light lens and the fixing the anchor bolt (3).
screws.
Disconnect the luggage room light connector.
8. Remove the rear roof trim cover.
Pry the trim cover retainers free from the body
panel.

760RW005

12. Remove the third seat belt anchor bolt cover and
anchor bolt.
Refer to the Third Seat Belt removal procedure in
Seat Belt System section.
13. Remove the assist grip.
666RS001
8J–16 EXTERIOR/INTERIOR TRIM
14. Remove the quarter upper trim cover.
Remove the rear side clips of the trim cover and pry
the quarter upper trim cover retainers free from the
body panel.

687RS004

Installation
To install, follow the removal steps in the reverse order,
noting the following point.
1. Tighten the seat belt anchor bolt to the specified
torque.
Torque: 39 Nꞏm (4.0kgꞏm/29 lb ft)
EXTERIOR/INTERIOR TRIM 8J–17

Luggage Side and Quarter Upper Trim Cover (SWB)


Luggage Side, Quarter Upper Trim Cover and Associated Parts

760RW021

Legend (7) Rear End Floor Trim Cover


(1) Rear Assist Grip (8) Luggage Side Cap
(2) Quater Upper Trim Cover (9) Speaker Grill
(3) Seat belt adjust Shoulder Anchor Plate (10) Rear Speaker
(4) Front Seat Belt Anchor Bolt Cover and Anchor (11) Luggage Room Light
Bolt (12) Rear Roof Trim Cover
(5) Luggage Side Trim Cover
(6) Rear Seat Belt Anchor Bolt Cover and Anchor
Bolt

Removal
1. Disconnect the battery ground cable.
2. Remove the rear end floor trim cover.
3. Remove the luggage side cap.
8J–18 EXTERIOR/INTERIOR TRIM
4. Remove the luggage side trim cover (1). 7. Remove the speaker grille.
Remove the rear side fixing screws and pry the trim
cover retainers free from the body panel and the
upper trim cover.
Remove the cover by pulling the front seat belt out
of the slit on the lower side of the trim cover.

687RS003

8. Remove the rear speaker.


Remove the rear speaker fixing screws and
disconnect the connector.
9. Remove the rear assist grip (7).
687RS002 Open the both side of the assist grip cover (8) and
5. Remove the luggage room light. remove two fixing screws.
Remove the luggage room light lens and the fixing
screws.
Disconnect the luggage room light connector.
6. Remove the rear roof trim cover.
Pry the trim cover retainers free from the body
panel.

743RW004

666RS001
EXTERIOR/INTERIOR TRIM 8J–19
10. Remove the rear seat belt anchor bolt cover (1) and 12. Remove the quarter upper trim cover.
the anchor bolt (2). Remove the rear side clips of the trim cover and pry
the quarter upper trim cover retainers free from the
body panel.

755RW037

11. Remove the front seat belt anchor bolt cover (3) and
the anchor bolt (4). 687RW001

13. Remove the seat belt adjust shoulder anchor plate.

Installation
To install, follow the removal steps in the reverse order,
noting the following point.
1. Tighten the seat belt anchor bolts to the specified
torque.
Torque: 39 Nꞏm (4.0kgꞏm/29 lb ft)

760RW006
8J–20 EXTERIOR/INTERIOR TRIM

Center Pillar and Roof Side Trim Cover (LWB)


Center Pillar, Roof Side Trim Cover and Associated Parts

643RW007

Legend (6) Door Sill Plate (Front and Rear)


(1) Roof Side Trim Cover (7) Center Pillar Lower Trim Cover
(2) Front Pillar Trim Cover (8) Front Seat Anchor Bolt Cover and Anchor Bolt
(3) Assist Grip (Passenger Seat Side) (9) Center Pillar Assist Grip
(4) Adjust Shoulder Anchor Assembly/Seat Belt (10) Assist Grip
Anchor Plate (11) Rear Quarter Upper Trim Cover
(5) Center Pillar Upper Trim Plate

Removal
1. Disconnect the battery ground cable.
2. Remove the door sill plate (front and rear).
3. Remove the center pillar lower trim cover (2).
Turn up the finisher (1) and pry the trim cover
retainers free from the body panel, then slide the
trim cover downward.

643RS003
EXTERIOR/INTERIOR TRIM 8J–21
4. Remove the front seat belt anchor bolt cover (3) and 8. Remove the assist grip (7).
the anchor bolt (4). Open the both side of the assist grip cover (8) and
remove two fixing screws.

760RW006

5. Remove the center pillar upper trim cover (6). 743RW004

Turn up the finisher (5) and pry the trim cover 9. Remove the roof side trim cover (9).
retainers free from the body panel. Turn up the finisher (10) and pry the trim cover
retainers free from the body panel.

643RS004

6. Remove the center pillar assist grip. 643RS005

7. Remove the seat belt anchor plate/adjusut shoulder


anchor assembly. Installation
To install, follow the removal steps in the reverse order,
noting the following point.
1. Install the seat belt anchor bolts to the specified
torque.
Torque: 39 Nꞏm (4.0kgꞏm/29 lb ft)
8J–22 EXTERIOR/INTERIOR TRIM

Roof Side Trim Cover (SWB)


Roof Side Trim Cover and Associated
Parts

643RW006

Legend
(1) Front Pillar Trim Cover
(2) Roof Side Trim Cover
(3) Assist Grip (Passenger Seat Side)
(4) Rear Quarter Upper Trim Cover

Removal
1. Remove the assist grip.
2. Remove the roof side trim cover (9).
Turn up the finisher (10) and pry the trim cover
retainers free from the body panel.

643RS005

Installation
To install, follow the removal steps in the reverse order.
EXTERIOR/INTERIOR TRIM 8J–23

Front Pillar Trim Cover


Front Pillar Trim Cover and 2. Remove the front pillar trim cover (3).
Associated Parts Turn up the finisher (4) and pry the trim cover
retainers free from the body panel.

743RS003
635RW001

Legend
(1) Roof Side Trim Panel Installation
(2) Assist Grip
To install, follow the removal steps in the reverse order.
(3) Front Pillar Trim Panel

Removal
1. Remove the front pillar assist grip(1).
Open the both sides of the assist grip cover (2) and
remove the fixing screws and the front pillar assist
grip.

743RW003
8J–24 EXTERIOR/INTERIOR TRIM

Center Pillar Assist Grip


Parts Location Removal and Installation
Refer to the Center Pillar and Roof Side Trim Cover in this
section.

743RS004

Legend
(1) Center Pillar Assist Grip

Assist Grip
Parts Location Removal and Installation
Refer to the Front Pillar Trim Cover in this section.

743RS005

Legend
(1) Assist Grip
EXTERIOR/INTERIOR TRIM 8J–25

Fuel Filler Lid Opener Cable


Fuel Filler Lid Opener Cable and Associated Parts

686RW008

Legend (8) Fuel Filler Lid Opener Cable (SWB)


(1) Rear End Floor Trim Cover (9) Chassis Harness
(2) Fuel Filler Lid Opener Cable (LWB) (10) Center Console Assembly
(3) To Lever (11) Fuel Filler Lid Opener
(4) Cable (12) Front Seat (RH)
(5) Marking (13) Center Pillar Lower Trim Cover
(6) Clip (14) Rear Door Sill Plate (RH)
(7) To Door (15) Luggage Side Trim Panel (RH)

Removal 5. Remove the rear end floor trim panel.


6. Remove the luggage side trim panel (RH).
1. Disconnect the battery ground cable.
Refer to the Luggage Side and Quarter Upper Trim
2. Remove the front seat (RH). Cover in this section.
3. Remove the rear door sill plate (RH).
4. Remove the center pillar lower trim cover.
8J–26 EXTERIOR/INTERIOR TRIM
7. Remove the fuel filler lid opener(1). Installation
Remove two opener fixing screws and disconnect To install, follow the removal steps in the reverse order,
the cable(2). noting the following points.
1. Insert the opener cable(2) into the body panel(1)
securely.

686RW007

8. Remove the center console assembly.


9. Remove the fuel filler lid opener cable. 686RS002

Roll up the floor carpet and remove the clips of the 2. Install the cable and clips to its original position to the
chassis harness and body panel to pull out the chassis harness and the body panel.
cable toward the fuel filler lid. 3. Check that the opener operates smoothly.

Fuel Filler Door


Parts Location Removal
1. Remove the fuel filler door.

Installation
1. Install the fuel filler door.

686RS003

Legend
(1) Fuel Filler Door
EXTERIOR/INTERIOR TRIM 8J–27

Rocker Protector (Without Wheel Opening Extension)


Rocker Protector (Without Wheel Opening Extension) and Associated Parts

603RW015

Legend (8) Fixing Clip


(1) Rear Rocker Protector (9) Outer Rocker Panel
(2) Inner Liner (10) Door Panel
(3) Spare Nut (11) Front Rocker Protector
(4) Fixing Screw (12) Clip (W/Rocker Protector)
(5) Rocker Protector (13) Fender Panel
(6) Outer Side Panel (14) SWB
(7) Outer Wheel House Panel

Removal Installation
1. Remove the rear rocker protector. To install, follow the remove steps in the reverse order.
2. Remove the front rocker protector.
8J–28 EXTERIOR/INTERIOR TRIM

Wheel Opening Extension and Rocker Protector Assembly


Wheel Opening Extension, Rocker Protector Assembly and Associated Parts

620RW005

Legend (5) Rear Quarter Wheel Opening Extension


(1) Front Wheel Opening Extension Assembly Assembly (Only LWB)
(2) Front Rocker Protector Assembly (6) Rear Wheel Opening Extension Assembly
(3) Rear Rocker Protector Assembly (Only LWB) (Only SWB)
(4) Rear Door Wheel Opening Extension
Assembly (Only LWB)

Removal
1. Remove the front wheel opening extension(2).
Let a 5mm drill(3) go through four blind rivets(5) to
disengaged riveted portions.
Remove two screws and disengage five clips (6),
then remove the front wheel opening extension
assembly.
EXTERIOR/INTERIOR TRIM 8J–29

Installation
To install, follow the removal steps in the reverse order,
noting the following points.
1. Use a new 2–sided adhesive tape whenever installing
each wheel opening extension assembly and rocker
protector assembly. Using a white gasoline, clean the
places in advance where a 2–sided adhesive tape is
affixed. Also, install the clips, screws and blind rivets
in the order specified as shown in the figure.

620RS005

2. Remove the rear quarter wheel opening extension


assembly (Only LWB).
Let a 5mm drill go through six blind rivets to
disengage riveted portions.
Disengage four clips, remove two screws, and
remove the rear quarter wheel opening extension
assembly.
3. Remove the rear wheel opening extension assembly
(Only SWB).
Let a 5mm drill go through four blind rivets to
disengage riveted portions. Remove two screws,
disengage eight clips, and remove the rear wheel
opening extension assembly.
Remove two fixing nuts (upper) and four fixing bolts
(lower).
4. Remove the rear door wheel opening extension
assembly (Only LWB).
Let a 5mm drill go through a blind rivet to disengage
riveted portions.
Disengage three clips, peel off the bonded portions
with two double surface adhesive tape and the rear
door wheel opening extension assembly.
5. Remove the rear rocker protector assembly (Only
LWB).
Loosen and pull three clips, remove a rear screw,
and remove the rear rocker protector assembly.
6. Remove the front rocker protector assembly.
Loosen and pull four clips, and remove the front
rocker protector assembly.
8J–30 EXTERIOR/INTERIOR TRIM

620RW006
EXTERIOR/INTERIOR TRIM 8J–31

Mud Flaps (With Wheel Opening Extension)


Mud Flaps (With Wheel Opening Extension) and Associated Parts

620RW003

Legend (3) Front Mud Flap


(1) Front Bumper Assembly (4) Bumper Side Cover
(2) Front Bumper Slider (5) Rear Mud Flap

Removal 3. Remove the front mud flap.


Remove four nuts and a clip.
Front Side
1. Remove the front bumper assembly.
Disconnect the front fog light connector and remove
two bolts from both sides of the front bumper.
2. Remove the front bumper slider(1).
Remove two clips(4) and two nuts(3), release the
claw from the washer(2).

601RW013

Rear Side
1. Remove the bumper side cover.
2. Remove the rear mud flap.
Remove four bolts and two nuts.

601RW009
Installation
To install, follow the removal steps in the reverse order.
8J–32 EXTERIOR/INTERIOR TRIM

Ventilation Assembly
Ventilation Assembly and Associated Parts

641RS001

Legend
(1) Outlet Valve Assembly
(2) Ventilation Assembly

Removal Installation
1. Remove the ventilation assembly(1). 1. Install the outlet valve assembly.
Pry the ventilation assembly retainers free from the Insert the upper and lower catches of the outlet
body panel. valve into the body panel flange and fix them
securely.
2. Install the ventilation assembly.
Fix the clips to the body panel securely so that the
ventilation assembly will not come off the body
panel.

641RS002

2. Remove the outlet valve assembly.


EXTERIOR/INTERIOR TRIM 8J–33

Quarter Flipper Glass Assembly (SWB)


Quarter Flipper Glass Assembly and Removal
Associated Parts 1. Remove the quarter flipper glass assembly (3).
Remove the fixing screws (2) and rivet (5).
2. Remove the fastener (1).
3. Remove the hinge assembly (4).

641RW003

Legend
(1) Hinge Assembly
(2) Quarter Flipper Glass Assembly 641RW002

(3) Fastener
Installation
To install, follow the removal steps in the reverse order.
8J–34 EXTERIOR/INTERIOR TRIM

Tailgate Trim Panel (LH)


Tailgate Trim Panel (LH) and Associated Parts

683RW017

Legend (3) Tailgate Panel


(1) Tailgate Trim Panel (LH) (4) Inside Handle
(2) Clip (5) Tailgate Assist Grip

Removal
1. Disconnect the battery ground cable.
2. Remove the tailgate assist grip.
Open the assist covers (1) and remove two fixing
screws.

683RW019
EXTERIOR/INTERIOR TRIM 8J–35
3. Remove the inside handle (2). Installation
Remove the fixing screw and disconnect the locking To install, follow the removal steps in the reverse order,
link (1). noting the following point.
1. Install the inside handle (1), connect the link to the
handle, insert the catch portion of the handle into the
tailgate side hole securely and fix it with a screw.

683RW020

4. Remove the tailgate trim panel (LH).


Pry the trim panel retainers free from the tailgate
panel. 683RW018

684RS001
8J–36 EXTERIOR/INTERIOR TRIM

Tailgate Trim Panel (RH)


Parts Location

684RS002

Legend
(1) Tailgate Trim Panel

Removal
1. Disconnect the battery ground cable.
2. Remove the tailgate trim panel (RH).
Pry trim panel retainer free from the tailgate panel.

684RS003

Installation
To install, follow the removal steps in the reverse order,
noting the following points.
1. Insert the retainer of the trim panel into the tailgate
panel and fix it securely.
EXTERIOR/INTERIOR TRIM 8J–37

Luggage Floor Box


Luggage Floor Box and Associated Remove
Parts 1. Fold the rear seat assembly to the front direction.
2. Remove the luggage floor box cover.
Remove the clips which connect the floor carpet
and the luggage floor box cover.
3. Remove the luggage floor box.

Installation
To install, follow the removal steps in the reverse order.

643RS006

Legend
(1) Rear Seat
(2) Floor Carpet
(3) Luggage Floor Box
(4) Luggage Floor Box Cover

Rope Hook Set


Rope Hook Set and Associated Parts Legend
(1) Rope Hook Set
(2) Cover
(3) Luggage Floor Carpet
(4) Hook

Removal
1. Remove the rope hook set.
Open the hook cover and hook fixing bolt.

Installation
1. Install the rope hook set.
Tighten the hook fixing bolt to the specified torque.
Torque: 13 Nꞏm (1.3kgꞏm/113 lb in)

676RS003
8J–38 EXTERIOR/INTERIOR TRIM

Power Door Mirror System


General Description Disconnect the power & winter switch connectors.
(A/T only)
The circuit consists of the starter switch, door mirror
control switch, folding switch, defogger switch and door 3. Remove the door mirror switch assembly(1).
mirrors on both sides. Push the lock from the back side of the front
The door mirror switch consists of the control switch, console.
folding switch and defogger switch.
When the control switch is operated with the starter
switch at either “ACC” or “ON” position, the motors
incorporated in the door mirrors on both sides rotates to
allow the horizontal and vertical adjustment of mirror
angles.
The folding switch can be used to fold the mirror and
return it to its original position.
When turning on the door mirror defogger switch with the
starter switch at “ON” position, built-in heater in the mirror
is activated to perform the defogger function.

Door Mirror Switch Assembly


(Control Switch, Folding Switch and
Defogger Switch) Removal
1. Disconnect the battery ground cable.
2. Remove the front console assembly(2).
Remove four screws.
825RS005

Remove the transmission shift lever knob.


Remove the transfer shift lever knob. Installation
Disconnect the seat heater switch connectors (if so To install, follow the removal steps in the reverse order,
equipped). noting the following point.
Disconnect the door mirror switch connectors. 1. Depress the switch with your fingers until it locks
securely.

Power Door Mirror


General Description
Mirrors contain two driving motors for the horizontal and
vertical movement of the mirror and one motor for folding
the mirror.
The movement of the mirror is controlled by the direction
of current running through these motors.
The housing portion of the mirror is provided with the
auto-stop mechanism which is interlocked with the motor
for folding the mirror. When the mirror moves to the stop
position (with the mirror folded or returned to its original
position), the current to the motor is shut off.
When the mirror cannot operate due to some obstacle
and the motor stops its rotation, the resistor prevents
current overflow.

720RS004

Removal and Installation


Refer to the Door Mirror removal and installation steps in
this section.
EXTERIOR/INTERIOR TRIM 8J–39

Power Window System


General Description 2. Remove the switch(1).
The circuit consists of the starter switch, (door lock &) Pull out the switch by pushing the spring with the tip
power window switch for each of the front windows, of a screwdriver.
power window switch for rear windows and power window Disconnect the connector.
motors.
When the starter switch is turned on, the battery voltage is
applied to each of the power window switches through the
circuit breaker and the power window relay on the circuit.
The “Down” switch of the driver’s power window switch
has a built-in function which can be operated by just
touching it.
Accordingly, the window will roll down automatically by
just setting the switch to the “AUTO” position.
When the driver’s power lock switch at the driver side is
depressed, the power source to the passenger’s power
window switches are shut off. So, even if these switches
are operated, the power window motor will not operate.

Power Window Switch Removal and


Installation
Driver Seat Side
Removal
825RW046
1. Disconnect the battery ground cable.
Installation
2. Remove the switch(1).
To install, follow the removal steps in the reverse order.
Pull out the switch by pushing the spring with the tip
of a screwdriver. Rear-Left and Right Sides
Disconnect two connectors. Removal
1. Disconnect the battery ground cable.
2. Remove the switch(1).
Pull out the switch by pushing the spring with the tip
of a screwdriver.
Disconnect the connector.

825RS052

Installation
To install, follow the removal steps in the reverse order.

Front Passenger Seat Side


Removal 825RS057

1. Disconnect the battery ground cable. Installation


To install, follow the removal steps in the reverse order.
8J–40 EXTERIOR/INTERIOR TRIM

Power Window Motor Removal and


Installation
Driver Seat Side
Removal
1. Disconnect the battery ground cable.
2. Remove the window regulator assembly (1).
Refer to the Front Window Regulator, Glass And
Glass Run in Body Structure section.
3. Remove the power window motor(2).
Remove three screws.
CAUTION: When removing the motor from the
regulator(1), be careful not to get injured by the
strong repellent force of the regulator spring.

631RS015

Installation
To install, follow the removal steps in the reverse order.

Rear-Left Side
Removal
1. Disconnect the battery ground cable.
2. Remove the rear window regulator assembly.
Refer to the Rear Window Regulator And Glass in
Body Structure section.
3. Remove the power window motor(1).
Remove four screws.

631RS018

Installation
To install, follow the removal steps in the reverse order.

Front Passenger Seat Side


Removal
1. Disconnect the battery ground cable.
2. Remove the window regulator assembly (1).
Refer to the Front Window Regulator, Glass And
Glass Run in Body Structure section.
3. Remove the power window motor(2).
Remove three screws.
CAUTION: When removing the motor from the
regulator(1), be careful not to get injured by the
strong repellent force of the regulator spring. 651RW014

Installation
To install, follow the removal steps in the reverse order.

Rear-Right Side
Removal and Installation
Refer to the Rear Power Window Motor-Left Side in this
section.
EXTERIOR/INTERIOR TRIM 8J–41

Main Data and Specifications


Torque Specifications
Application Nꞏm kgꞏm lb ft lb in
Door Mirror Fixing Bolts 8 0.8 — 69
Seat Belt Anchor Bolts 39 4.0 29 —
Hook Fixing Bolt 13 1.3 — 113
SEAT BELT SYSTEM 9A–1

RESTRAINTS
CONTENTS
Seat Belt System . . . . . . . . . . . . . . . . . . . . . . 9A–1 Restraint Control System . . . . . . . . . . . . . . . . 9J1–1
Supplemental Restraint System (SRS) . . . . . 9J–1

SEAT BELT SYSTEM


CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . 9A–1 Front Seat Buckle Assembly . . . . . . . . . . . . . 9A–12
Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–12
Front Seat Belt and Associated Parts Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–12
(Long Wheel Base) . . . . . . . . . . . . . . . . . . 9A–2 Front Seat Buckle Assembly (W/Pretensioner) 9A–12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–3 Rear Center Seat Belt Buckle Assembly . . . 9A–13
Front Seat Belt and Associated Parts Rear Center Seat Belt Buckle Assembly
(Short Wheel Base) . . . . . . . . . . . . . . . . . . 9A–4 and Associated Parts . . . . . . . . . . . . . . . . . 9A–13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–13
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–5 Third Seat Belt Buckle and Lock Assembly . 9A–14
Rear Seat Belt and Associated Parts Third Seat Belt Buckle and Lock Assembly
(Long Wheel Base) . . . . . . . . . . . . . . . . . . 9A–6 and Associated Parts . . . . . . . . . . . . . . . . . 9A–14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–7 Rear Seat Lock Assembly . . . . . . . . . . . . . . . 9A–15
Rear Seat Belt and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–15
(Short Wheel Base) . . . . . . . . . . . . . . . . . . 9A–8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–8 Rear Seat Lock Assembly (Bench Type) . . . 9A–15
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–15
Third Seat Belt and Associated Parts Rear Seat Strikers . . . . . . . . . . . . . . . . . . . . . 9A–16
(Long Wheel Base) . . . . . . . . . . . . . . . . . . 9A–10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–11 Third Seat Striker . . . . . . . . . . . . . . . . . . . . . . 9A–16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–11 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–16
Main Data and Specifications . . . . . . . . . . . . 9A–17

Service Precaution CAUTION: Always use the correct fastener in the


proper location. When you replace a fastener, use
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL ONLY the exact part number for that application.
RESTRAINT SYSTEM (SRS). REFER TO THE SRS ISUZU will call out those fasteners that require a
COMPONENT AND WIRING LOCATION VIEW IN replacement after removal. ISUZU will also call out
ORDER TO DETERMINE WHETHER YOU ARE the fasteners that require thread lockers or thread
PERFORMING SERVICE ON OR NEAR THE SRS sealant. UNLESS OTHERWISE SPECIFIED, do not
COMPONENTS OR THE SRS WIRING. WHEN YOU use supplemental coatings (Paints, greases, or other
ARE PERFORMING SERVICE ON OR NEAR THE SRS corrosion inhibitors) on threaded fasteners or
COMPONENTS OR THE SRS WIRING, REFER TO fasteners joint interfaces. Generally, such coatings
THE SRS SERVICE INFORMATION. FAILURE TO adversely affect the fastener torque and the joint
FOLLOW WARNINGS COULD RESULT IN POSSIBLE clamping force, and may damage the fasteners.
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR When you install fasteners, use the correct tightening
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
9A–2 SEAT BELT SYSTEM

Seat Belt
Front Seat Belt and Associated Parts (Long Wheel Base)

1
2

10

3
8

760RW022

Legend (6) Anchor Bolt (Lower)


(1) Center Pillar Upper Trim Cover (7) Door Sill Plate (Front & Rear)
(2) Adjust Shoulder Anchor Assembly/Seat Belt (8) Center Pillar Lower Trim Cover
Anchor Plate (9) Front Seat Belt Assembly
(3) Center Pillar (10) Front Seat Belt Anchor Bolt Cover and Anchor
(4) Dust Cover Bolt
(5) Retractor

Removal Inspection
1. Disconnect the battery ground cable. If any of the following abnormalities is found, replace on
2. Remove the door sill plate (Front & Rear). an assembly basis;
3. Remove the center pillar lower trim cover. Deform and malfunction of adjustable shoulder
anchor/seat belt anchor plate.
4. Remove the front seat belt anchor bolt cover and
anchor bolt (Upper Side). No smooth move of upper/lower anchors in the
Refer to Center Pillar and Roof Side Trim Cover in circumferential direction.
Exterior/Interior Trim section. Damaged and/or deformed through ring.
5. Remove the seat belt lower anchor bolt and screw, Damaged and/or deformed tongue.
and then remove the front seat belt. Damaged and/or frayed of webbing.
6. Remove the adjust shoulder anchor assembly/seat Deformed retractor bracket.
belt anchor plate. Seat belt not rewound up.
Refer to Center Pillar and Roof Side Trim Cover in Resistance or abnormal sound when seat belt is
Exterior/Interior Trim section. wound out and rewound.
Retractor abnormality.
SEAT BELT SYSTEM 9A–3
Inspection of retractor Installation
1. ELR (Emergency Locking Retractor) lock inclining To install, follow the removal steps in the reverse order,
angle check. noting the following points;
When the retractor is moved gently from its installing 1. Pass the seat belt through the lower trim cover hole,
position, make sure it is not locked within 15° in any and tighten the seat belt anchor bolts to the specified
directions, and it remains locked at 45° or larger. torque.
2. ELR lock check. Torque: 39 Nꞏm (4.0 kgꞏm/29 lb ft)
When the seat belt is drawn slowly with the retractor 2. After installing the trim cover to the body panel
installed, make sure it is not locked. And when it is securely, close the lower trim cover.
drawn quickly, make sure it is locked.
3. ALR (Automatic Locking Retractor)/ELR check
(Except for driver’s seat).
When rewound after winding out the seat belt, make
sure the seat belt cannot be taken out. After
rewinding, make sure it has returned to its normal
operation.
CAUTION: Do not disassemble the retractor.
9A–4 SEAT BELT SYSTEM

Front Seat Belt and Associated Parts (Short Wheel Base)

1 3

4
5
6

9 8

760RW024

Legend (4) Front Seat Belt Assembly


(1) Quarter Upper Trim Cover (5) Retractor
(2) Front Seat Belt Anchor Bolt Cover and Anchor (6) Dust Cover
Bolt (Upper Side) (7) Anchor Bolt (Lower)
(3) Adjust Shoulder Anchor Assembly/Seat Belt (8) Luggage Side Trim Cover
Anchor Plate (9) Rear End Floor Trim Cover

Removal Inspection
1. Disconnect the battery ground cable. If any of the following abnormalities is found, replace on
2. Remove the rear end floor trim cover. an assembly basis;
3. Remove the luggage side trim cover. Deform and malfunction of adjustable shoulder
anchor/seat belt anchor plate.
Refer to Luggage Side and Quarter Upper Trim
Panel removal steps in Exterior/Interior Trim No smooth move of upper/lower anchors in the
section. circumferential direction.
4. Remove the front seat belt anchor bolt cover and Damaged and/or deformed through ring.
anchor bolt (Upper Side). Damaged and/or deformed tongue.
5. Remove the seat belt lower anchor bolt and the Damaged and/or frayed of webbing.
retractor and then remove the front seat belt. Deformed retractor bracket.
6. Remove the adjust shoulder anchor assembly/seat Seat belt not rewound up.
belt anchor plate.
Resistance or abnormal sound when seat belt is
Refer to Luggage Side and Quarter Upper Trim wound out and rewound.
Cover remove steps in Exterior/Interior Trim
Retractor abnormality.
section.
SEAT BELT SYSTEM 9A–5
Inspection of retractor Installation
1. ELR (Emergency Locking Retractor) lock inclining To install, follow the removal steps in the reverse order,
angle check. noting the following points;
When the retractor is moved gently from its installing 1. Pass the seat belt through the lower trim cover hole,
position, make sure it is not locked within 15° in any and tighten the seat belt anchor bolts to the specified
directions, and it remains locked at 45° or larger. torque.
2. ELR lock check. Torque: 39 Nꞏm (4.0 kgꞏm/29 lb ft)
When the seat belt is drawn slowly with the retractor 2. After installing the trim cover to the body panel
installed, make sure it is not locked. And when it is securely, close the lower trim cover.
drawn quickly, make sure it is locked.
3. ALR (Automatic Locking Retractor)/ELR check
(Except for driver’s seat).
When rewound after winding out the seat belt, make
sure the seat belt cannot be taken out. After
rewinding, make sure it has returned to its normal
operation.
CAUTION: Do not disassemble the retractor.
9A–6 SEAT BELT SYSTEM

Rear Seat Belt and Associated Parts (Long Wheel Base)

2
1

7
8

6
760RS006

Legend (4) Dust Cover


(1) Rear Seat Belt Anchor Bolt Cover and Anchor (5) Retractor
Bolt (Upper Side) (6) Anchor Bolt (Lower Side)
(2) Quarter Upper Trim Cover (7) Luggage Side Trim Cover
(3) Rear Seat Belt Assembly (8) Rear End Floor Trim Cover

Removal Inspection
1. Disconnect the battery ground cable. If any of the following abnormalities is found, replace on
2. Remove the rear end floor trim cover. an assembly basis;
3. Remove the luggage side trim cover. No smooth move of upper/lower anchors in the
circumferential direction.
Refer to Luggage Side and Quarter Upper Trim
Panel removal steps in Exterior/Interior Trim Damaged and/or deformed through ring.
section. Damaged and/or deformed tongue.
4. Remove the rear seat belt anchor bolt cover and Damaged and/or frayed of webbing.
anchor bolt (Upper Side). Deformed retractor bracket.
5. Remove the seat belt lower anchor bolt and remove Seat belt not rewound up.
the retractor from dust cover slit to remove the rear
Resistance or abnormal sound when seat belt is
seat belt.
wound out and rewound.
Retractor abnormality.
SEAT BELT SYSTEM 9A–7
Inspection of retractor Installation
1. ELR (Emergency Locking Retractor) lock inclining To install, follow the removal steps in the reverse order,
angle check. noting the following point.
When the retractor is moved gently from its installing 1. Tighten the seat belt anchor bolts to the specified
position, make sure it is not locked within 15° in any torque.
directions, and it remains locked at 45° or larger. Torque: 39 Nꞏm (4.0 kgꞏm/29 lb ft)
2. ELR lock check.
When the seat belt is drawn slowly with the retractor
installed, make sure it is not locked. And when it is
drawn quickly, make sure it is locked.
3. ALR (Automatic Locking Retractor)/ELR check
(Except for driver’s seat).
When rewound after winding out the seat belt, make
sure the seat belt cannot be taken out. After
rewinding, make sure it has returned to its normal
operation.
CAUTION: Do not disassemble the retractor.
9A–8 SEAT BELT SYSTEM

Rear Seat Belt and Associated Parts (Short Wheel Base)

3
4

6 5
7

760RW025

Legend (5) Rear Seat Belt Lower Anchor Bolt Cover and
(1) Rear Seat Belt Upper Anchor Bolt Cover and Anchor Bolt
Anchor Bolt (6) Luggage Side Trim Cover
(2) Quarter Upper Trim Cover (7) Rear End Floor Trim Cover
(3) Dust Cover (8) Rear Seat Belt Assembly
(4) Retractor

Removal
1
1. Disconnect the battery ground cable.
2. Remove the rear seat belt lower anchor bolt cover (1)
and anchor bolt (2). 2

755RW038
SEAT BELT SYSTEM 9A–9
3. Remove the rear end floor trim cover. 6. Remove the rear seat belt assembly.
4. Remove the luggage side trim cover. Remove the seat belt lower anchor bolt and screw.
Refer to Luggage Side and Quarter Upper Trim Remove the retractor from the dust cover slit.
Panel removal steps in Exterior/Interior Trim
section. Inspection
5. Remove the rear seat belt upper anchor bolt cover (1) If any of the following abnormalities is found, replace on
and anchor bolt. an assembly basis;
No smooth move of upper/lower anchors in the
circumferential direction.
Damaged and/or deformed through ring.
Damaged and/or deformed tongue.
Damaged and/or frayed of webbing.
Deformed retractor bracket.
Seat belt not rewound up.
Resistance or abnormal sound when seat belt is
wound out and rewound.
Retractor abnormality.
1 Inspection of retractor
1. ELR (Emergency Locking Retractor) lock inclining
angle check.
When the retractor is moved gently from its installing
position, make sure it is not locked within 15° in any
directions, and it remains locked at 45° or larger.
2. ELR lock check.
755RW039
When the seat belt is drawn slowly with the retractor
installed, make sure it is not locked. And when it is
drawn quickly, make sure it is locked.
3. ALR (Automatic Locking Retractor)/ELR check
(Except for driver’s seat).
When rewound after winding out the seat belt, make
sure the seat belt cannot be taken out. After
rewinding, make sure it has returned to its normal
operation.
CAUTION: Do not disassemble the retractor.
Installation
To install, follow the removal steps in the reverse order,
noting the following point.
1. Be sure to install the lower side anchor plate straight
horizontally, with mounting hole of the plate at the
center.
2. Tighten the seat belt anchor bolts to the specified
torque.
Torque: 39 Nꞏm (4.0 kgꞏm/29 lb ft)
9A–10 SEAT BELT SYSTEM

Third Seat Belt and Associated Parts (Long Wheel Base)

1
2

760RW027

Legend (4) Retractor


(1) Third Seat Belt Upper Anchor Bolt Cover and (5) Luggage Side Trim Cover
Anchor Bolt (6) Third Seat Belt Lower Anchor Bolt Cover and
(2) Third Seat Belt Assembly Anchor Bolt
(3) Dust Cover (7) Rear End Floor Trim Cover

Removal
1. Disconnect the battery ground cable.
2. Remove the rear end floor trim cover. 1
3. Remove the luggage side trim cover.
Refer to Luggage Side and Quarter Upper Trim
Panel removal steps in Exterior/Interior Trim
section.
4. Remove the third seat belt anchor bolt cover and
anchor bolt (Upper Side).
5. Remove the seat belt lower anchor bolt and remove
the retractor from dust cover slit to remove the third
seat belt.

755RW043
SEAT BELT SYSTEM 9A–11

Inspection Installation
If any of the following abnormalities is found, replace on To install, follow the removal steps in the reverse order,
an assembly basis; noting the following point.
No smooth move of upper/lower anchors in the 1. Be sure to install the lower side anchor plate (1)
circumferential direction. straight against the longitudinal direction of the
Damaged and/or deformed through ring. vehicle with mounting hole of the plate at the center.
Damaged and/or deformed tongue. 2. Tighten the seat belt anchor bolts to the specified
torque.
Damaged and/or frayed of webbing.
Torque: 39 Nꞏm (4.0 kgꞏm/29 lb ft)
Deformed retractor bracket.
Seat belt not rewound up.
Resistance or abnormal sound when seat belt is
wound out and rewound.
Retractor abnormality.
Inspection of retractor
1. ELR (Emergency Locking Retractor) lock inclining
angle check.
When the retractor is moved gently from its installing
position, make sure it is not locked within 15° in any
directions, and it remains locked at 45° or larger.
2. ELR lock check.
When the seat belt is drawn slowly with the retractor
installed, make sure it is not locked. And when it is
drawn quickly, make sure it is locked.
CAUTION: Do not disassemble the retractor.
9A–12 SEAT BELT SYSTEM

Front Seat Buckle Assembly


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order,
2. Disconnect the seat belt warning connector (If so noting the following points.
equipped). 1. Fix the buckle to the rotation – stop position(2)
3. Remove the front seat buckle assembly(1). securely to install the front seat buckle assembly(1).

760RW023 760RS005

2. Tighten the buckle anchor bolt to the specified torque.


Torque: 39 Nꞏm (4.0 kgꞏm/29 lb ft)
Front Seat Buckle Assembly (W/Pretensioner)
Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order,
2. Disconnect the pretensioner harness connector(3). noting the following points.
3. Remove the pretensioner cover(1). 1. Fix the buckle to the rotation – stop position securely
to install the front seat buckle assembly.
4. Remove the front seat buckle assembly(2).
2. Connect the pretensioner harness connector.

2
1

760RW030
760RW029

3. Tighten the buckle anchor bolt to the specified torque.


Torque: 39 Nꞏm (4.0 kgꞏm/29 lb ft)
SEAT BELT SYSTEM 9A–13

Rear Center Seat Belt Buckle Assembly


Rear Center Seat Belt Buckle Assembly and Associated Parts

2
1 2 4

3
3

760RW026

Legend (3) Seat Lock Cover


(1) Long Wheel Base (4) Short Wheel Base
(2) Rear Seat Belt Buckle Assembly

Removal Installation
1. Remove the catch portions(2) & (3) of the seat lock 1. Fix the rear seat belt buckle assembly(1) to the
assembly(4) from the cover, and then remove the seat rotation stopper and tighten the anchor bolt to the
lock cover(1). specified torque.
Torque: 39 Nꞏm (4.0 kgꞏm/29 lb ft)

4 1

760RW016

2. Remove the rear seat buckle assembly. 760RW013

2. Install the seat lock cover.


9A–14 SEAT BELT SYSTEM

Third Seat Belt Buckle and Lock Assembly


Third Seat Belt Buckle and Lock Removal
Assembly and Associated Parts 1. Disconnect the battery ground cable.
2. Remove seat lock cover.
3. Remove third seat belt buckle assembly.
4. Remove third seat lock assembly.

Installation
1
To install, follow the removal steps in the reverse order,
noting the following point.
1. Tighten the lock assembly fixing bolts to the specified
torque.
Torque: 39 Nꞏm (4.0 kgꞏm/29 lb ft)
4
2. Tighten the buckle assembly fixing bolt to the
specified torque.
3
Torque: 39 Nꞏm (4.0 kgꞏm/29 lb ft)

755RW042

Legend
(1) Third Seat Belt Buckle Assembly
(2) Third Seat Lock Assembly
(3) Third Seat
(4) Seat Lock Cover
SEAT BELT SYSTEM 9A–15

Rear Seat Lock Assembly Rear Seat Lock Assembly


Removal (Bench Type)
1. Remove the seat lock cover(3). Removal
2. Remove the rear seat belt buckle assembly(1). 1. Remove the seat lock cover(3).
3. Remove the rear seat lock assembly(2). 2. Remove the rear seat belt/buckle assembly(1).
3. Disconnect the link connecting the lock assemblies on
L.W.B the both sides, and then remove the rear seat lock
assembly(2).

1
1

S.W.B
3
1 2

760RW003
2

3
Installation
To install, follow the removal steps in the reverse order,
noting the following point.
1. Tighten the seat lock fixing bolts to the specified
torque.
755RW040 Torque: 42 Nꞏm (4.3 kgꞏm/31 lb ft)

Installation
To install, follow the removal steps in the reverse order,
noting the following point.
1. Tighten the seat lock fixing bolts to the specified
torque.
Torque: 42 Nꞏm (4.3 kgꞏm/31 lb ft)
9A–16 SEAT BELT SYSTEM

Rear Seat Strikers Third Seat Striker


Removal Removal
1. Fold the rear seat assembly to the front direction. 1. Disconnect the battery ground cable.
2. Remove the luggage floor box(1) (LꞏWꞏB). 2. Remove the striker cover (1).
Remove the striker cover(3) (SꞏWꞏB). 3. Remove the third seat striker (2).
3. Remove the rear seat striker(2).

1
L.W.B

S.W.B

755RW041
3
Installation
To install, follow the removal steps in the reverse order,
noting the following point.
2
1. Tighten the striker fixing nuts to the specified torque.
Torque: 39 Nꞏm (4.0 kgꞏm/29 lb ft)

755RW045

Installation
To install, follow the removal steps in the reverse order,
noting the following point.
1. Tighten the striker fixing bolts to the specified torque.
Torque: 40 Nꞏm (4.1 kgꞏm/30 lb ft)
SEAT BELT SYSTEM 9A–17

Main Data and Specifications


Torque Specifications
Application Nꞏm kgꞏm Lb Ft
Front Seat Belt Anchor Bolts 39 4.0 29
Rear Seat Belt Anchor Bolts 39 4.0 29
Front Seat Buckle Anchor Bolt 39 4.0 29
Rear Seat Buckle Anchor Bolt 39 4.0 29
Rear Seat Lock Fixing Bolts 42 4.3 31
Third Seat Belt Anchor Bolts 39 4.0 29
Third Seat Lock Fixing Bolts 39 4.0 29
Third Seat Buckle Anchor Bolt 39 4.0 29
Third Seat Striker Fixing Nuts 39 4.0 29
Rear Seat Striker Fixing Bolts 40 4.1 30
SUPPLEMENTAL RESTRAINT SYSTEM 9J–1

RESTRAINTS
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 9J–1 Service Precautions . . . . . . . . . . . . . . . . . . . 9J–37
General Description . . . . . . . . . . . . . . . . . . . . . 9J–2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–37
SRS Component And Wiring Location View . 9J–4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–38
Component Description . . . . . . . . . . . . . . . . . . 9J–4 SRS Coil Assembly . . . . . . . . . . . . . . . . . . . . . . 9J–39
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–7 Service Precautions . . . . . . . . . . . . . . . . . . . 9J–39
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–39
SRS Connector Body Face Views . . . . . . . . . 9J–9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–41
Repairs And Inspections Required After SRS Coil Replacement Procedure . . . . . . . . . 9J–42
An Accident . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–42
On–Vehicle Service . . . . . . . . . . . . . . . . . . . . . . 9J–10 How to Disconnect the horn terminal . . . . . 9J–43
Air Bag Assembly Handling / Shipping How to Connect Horn Terminal . . . . . . . . . . 9J–43
/ Scrapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–44
Pretensioner Seat Belt Handling / Shipping
/ Scrapping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–11 Steering Column . . . . . . . . . . . . . . . . . . . . . . . . 9J–44
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–26 Service Precautions . . . . . . . . . . . . . . . . . . . 9J–44
Service Precautions for SRS Component Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–44
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–30 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–46
SRS Connectors . . . . . . . . . . . . . . . . . . . . . . . . 9J–31 Passenger Air Bag Assembly . . . . . . . . . . . . . 9J–48
Sensing And Diagnostic Module (SDM) . . . . 9J–33 Service Precautions . . . . . . . . . . . . . . . . . . . 9J–48
Service Precautions . . . . . . . . . . . . . . . . . . . 9J–33 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–48
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–33 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–48
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–33 Pretensioner Seat Belt (If so equipped) . . . . 9J–49
Driver Air Bag Assembly . . . . . . . . . . . . . . . . . 9J–35 Service Precaution . . . . . . . . . . . . . . . . . . . . 9J–49
Service Precautions . . . . . . . . . . . . . . . . . . . 9J–35 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 9J–49
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–35 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–49
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–36 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–49
Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . 9J–37 Main Data and Specifications . . . . . . . . . . . . . 9J–50

Service Precaution CAUTION: Always use the correct fastener in the


proper location. When you replace a fastener, use
WARNING: IF SO EQUIPPED WITH A ONLY the exact part number for that application.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS), ISUZU will call out those fasteners that require a
REFER TO THE SRS COMPONENT AND WIRING replacement after removal. ISUZU will also call out
LOCATION VIEW IN ORDER TO DETERMINE the fasteners that require thread lockers or thread
WHETHER YOU ARE PERFORMING SERVICE ON OR sealant. UNLESS OTHERWISE SPECIFIED, do not
NEAR THE SRS COMPONENTS OR THE SRS use supplemental coatings (Paints, greases, or other
WIRING. WHEN YOU ARE PERFORMING SERVICE corrosion inhibitors) on threaded fasteners or
ON OR NEAR THE SRS COMPONENTS OR THE SRS fastener joint interfaces. Generally, such coatings
WIRING, REFER TO THE SRS SERVICE adversely affect the fastener torque and the joint
INFORMATION. FAILURE TO FOLLOW WARNINGS clamping force, and may damage the fastener. When
COULD RESULT IN POSSIBLE AIR BAG you install fasteners, use the correct tightening
DEPLOYMENT, PERSONAL INJURY, OR sequence and specifications. Following these
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. instructions can help you avoid damage to parts and
systems.
9J–2 SUPPLEMENTAL RESTRAINT SYSTEM

General Description
CAUTION: When fasteners are removed, always
reinstall them at the same location from which they
were removed. If a fastener needs to be replaced, use
the correct part number fastener for that application.
If the correct part number fastener is not available, a
fastener of equal size and strength (or stronger) may
be used. Fasteners that are not reused, and those
requiring thread locking compound will be called
out. The correct torque value must be used when
installing fasteners that require it. If the above
conditions are not followed, parts or system damage
could result.
Restraint Devices

827RW005

827RW006

Legend
(1) Deployed Air Bag
(2) Knee Bolster
(3) Seat Belt

The Supplemental Restraint System (SRS) helps


supplement the protection offered by the driver and front
passenger seat belts by deploying an air bag from the
center of the steering wheel and from the top of the right
side of the instrument panel.
The air bag deploys when the vehicle is involved in a
frontal crash of sufficient force up to 30 degrees off the
centerline of the vehicle. To further absorb the crash
energy there is a knee bolster located beneath the
instrument panel for both the driver and passenger, and
the steering column is collapsible.
SUPPLEMENTAL RESTRAINT SYSTEM 9J–3
System Description degrees off the centerline of the vehicle. The air bag
The SRS consists of the Sensing and Diagnostic Module assemblies are only supplied enough current to deploy
(SDM), the driver air bag assembly, the SRS coil when the SDM detects vehicle velocity changes severe
assembly, the passenger air bag assembly and the “AIR enough to warrant deployment.
BAG” warning lamp in the instrument cluster. The SDM, The SDM contains a sensing device which converts
SRS coil assembly (driver side only), driver air bag vehicle velocity change to an electrical signal. The
assembly, passenger air bag assembly and connector electrical signal generated is processed by the SDM and
wire make up the deployment loops. The function of the then compared to a value stored in memory. When the
deployment loops is to supply current through air bag generated signal exceeds the stored value, the SDM will
assembly, which will cause deployment of the air bags in cause current to flow through the air bag assembly
the event of a frontal crash of sufficient force, up to 30 deploying the air bags.

D09RW014
9J–4 SUPPLEMENTAL RESTRAINT SYSTEM

SRS Component And Wiring Location View

810RW298

Legend (8) Starter Switch


(1) Battery (9) Fuse Box, C–21
(2) Relay & Fuse Box (10) SRS Body Earth
(3) Passenger Air Bag Assembly (11) Body Harness Connector
(4) SDM (12) Instrument Harness Connector
(5) Meter Assembly (13) Engine Haness Connector
(6) SRS Coil Assembly (14) Pretensioner, LH (If so equipped)
(7) Driver Air Bag Assembly (15) Pretensioner, RH (If so equipped)

Component Description FASTENERS MUST BE CAREFULLY TORQUED AND


THE ARROW MUST BE POINTED TOWARD THE
SDM (Sensing and Diagnostic Module) FRONT OF THE VEHICLE TO ENSURE PROPER
OPERATION OF THE SRS. THE SDM COULD BE
WARNING: DURING SERVICE PROCEDURES, BE ACTIVATED WHEN POWERED WHILE NOT RIGIDLY
VERY CAREFUL WHEN HANDLING A SENSING AND ATTACHED TO THE VEHICLE WHICH COULD CAUSE
DIAGNOSTIC MODULE (SDM). NEVER STRIKE OR DEPLOYMENT AND RESULT IN PERSONAL INJURY.
JAR THE SDM. NEVER POWER UP THE SRS WHEN
The Sensing and Diagnostic Module (SDM) is designed
THE SDM IS NOT RIGIDLY ATTACHED TO THE
to perform the following functions in the SRS:
VEHICLE. ALL SDM AND MOUNTING BRACKET
SUPPLEMENTAL RESTRAINT SYSTEM 9J–5
1. Energy Reserve — The SDM maintains 24–Volt Loop “Air Bag” Warning Lamp
Reserve (24VLR) energy supply to provide Ignition voltage is applied to the “AIR BAG” warning lamp
deployment energy when ignition voltage is lost in a
when the ignition switch is at the ON or START positions.
frontal crash.
The SDM controls the lamp by providing ground with a
2. Frontal Crash Detection — The SDM monitors lamp driver. The “AIR BAG” warning lamp is used in the
vehicle velocity changes to detect frontal crashes SRS to do the following:
which are severe enough to warrant deployment.
1. Verify lamp and SDM operation by turn on 3.5
3. Air Bag Deployment — When a frontal crash of seconds and then turns “OFF” when the ignition
sufficient force is detected, the SDM will cause switch is first turned “ON”.
enough current to flow through the air bag assembly
to deploy the air bag. 2. Warn the vehicle driver of SRS electrical system
malfunctions which could potentially affect the
4. Malfunction Detection — The SDM performs operation of the SRS. These malfunctions could
diagnostic monitoring of SRS electrical components result in nondeployment in case of a frontal crash or
and sets a diagnostic trouble code when a deployment for conditions less severe than intended.
malfunction is detected.
The “AIR BAG ” warning lamp is the key to driver
5. Frontal Crash Recording — The SDM records notification of SRS malfunctions. For proper lamp
information regarding SRS status during frontal operation, refer to the “SRS Diagnostic System Check” in
crash. this section.
6. Malfunction Diagnosis — The SDM displays SRS
diagnostic trouble codes and system status
information through the use of a scan tool.
7. Driver Notification — The SDM warns the vehicle
driver of SRS malfunctions by controlling the “Air
Bag” warning lamp.
The SDM is connected to the SRS wiring harness by a
24–pin connector. This harness connector uses a
shorting clip across certain terminals in the contact area.
This shorting clip connects the “AIR BAG” warning lamp
to ground when the SDM harness connector is
disconnected or CPA (Connector Position Assurance) is
not inserted even if completely connected. This will
cause the “AIR BAG” warning lamp to come “ON” steady
whenever the ignition switch is at the ON or START
positions with the SDM disconnected.

821RW037

SRS Coil Assembly


The SRS coil assembly consists of two current carrying
coils. This is attached to the steering column and allow
rotation of the steering wheel while maintaining
continuous contact of the driver deployment loop to the
driver air bag assembly.
There is a shorting clip on the yellow 2–pin connector near
the base of steering column which connects the SRS coil
to the SRS wiring harness.
The shorting clip shorts to the SRS coil and driver air bag
assembly when the yellow 2–pin connector is
disconnected. The circuit to the driver air bag assembly is
shorted in this way to help prevent unwanted deployment
of the air bag when servicing the steering column or other
827RW044 SRS components.
Legend
(1) SDM
(2) SRS Harness
(3) Connector Position Assurance
9J–6 SUPPLEMENTAL RESTRAINT SYSTEM
The shorting clip shorts across the passenger air bag
assembly circuit when the passenger air bag assembly
connector is disconnected. The circuit to the passenger
air bag assembly is shorted in this way to help prevent
unwanted deployment of the air bag when servicing the
passenger air bag assembly, the instrument panel or
other SRS components.

825RS017

Air Bag Assemblies


The air bag assembly consist of an inflatable air bag
assembly and an inflator (a canister of gas–generating
material and an initiating device). When the vehicle is in a
frontal crash of sufficient force.
The SDM causes current flow through the deployment 827RS001

loops. Current passing through the inflator ignites the


material in the air bag assembly. The gas produced from Seat Belt with Pretensioner (If so
this reaction rapidly inflates the air bag assembly. equipped)
There is a shorting clip on the driver air bag assembly The seat belt comprises a seat belt and a cylinder (a
connector which connects the SRS coil assembly. The cylinder filled with powder and an ignition device). In
shorting clip shorts across the driver air bag assembly cases of frontal collision which cause a shock exceeding
circuits when driver air bag assembly connector is a specified level, the controller lets current flow to the
disconnected. inflation circuit. The current ignites the cylinder of the seat
The circuit to the driver air bag assembly is shorted in this belt, producing gas. The gas helps tighten the seat belt to
way to help prevent unwanted deployment of the air bag restrain firmly the driver’s upper half in his seat.
when servicing the driver air bag assembly, the steering
column or other SRS components.

760RW033

827RS008

There is a shorting clip on the passenger air bag


assembly connector which connects to the SRS harness.
SUPPLEMENTAL RESTRAINT SYSTEM 9J–7
Steering Column B+
The steering column absorbs energy and is designed to Battery voltage, (B+) The voltage available at the battery
at the time of the indicated measurement. With the key
compress in a frontal crash to decrease the chance of
“ON” and the engine not running, the system voltage will
injury to the driver.
likely be between 12 and 12.5 volts. At idle, the voltage
may be 14 to 16 volts. The voltage could be as low as 10
volts during engine cranking.
Bulb Check
The SDM will cause the “AIR BAG” warning lamp to turn
on 3.5 seconds and then go “OFF” whenever the ignition
switch transitions to the ON position from any other
ignition switch position and no malfunctions are detected.
“Continuous Monitoring”
Tests performed by the SDM on the SRS every 100
milliseconds while “Ignition 1” voltage is in the normal
operating voltage range at the SDM.
Data Link Connector (DLC)
Formerly “DLC” a connector which allows communication
with an external computer, such as a scan tool.
Datum Line
A base line parallel to the plane of the underbody or frame
from which all vertical measurements originate.
431RW019 Deploy
To inflate the air bag.
Knee Bolster
The knee bolsters are used to absorb energy to protect Deployment Loops
knees and control the forward movement of the vehicle’s The circuits which supply current to the air bag
assemblies to deploy the air bag.
front seat occupants during a frontal crash, by limiting leg
movement. Diagnostic Trouble Code (DTC)
Formerly “Code”, a numerical designator used by the
SDM to indicate specific SRS malfunctions.
Driver Current Source
An output of the SDM which applies current into the driver
air bag assembly circuit during the “Initiator Assembly
Resistance Test”.
Driver Air Bag Assembly
An assembly located in the steering wheel hub consisting
of an inflatable bag, an inflator and an initiator.
EEPROM
Electrically Erasable Programmable Read Only Memory.
Memory which retains its contents when power is
removed from the SDM.
Ignition Cycle
The voltage at the SDM “Ignition 1” inputs, with ignition
switch “ON”, is within the normal operating voltage range
for at least ten seconds before turning ignition switch
“OFF”.
740RT015
Ignition 1
A battery voltage (B+) circuit which is only powered with
Definitions the ignition switch in the ON, or START positions.
Air Bag Initiator
An inflatable cloth cushion designed to deploy in certain The electrical component inside the air bag assembly
frontal crashes. It supplements the protection offered by which, when sufficient current flows, sets off the chemical
the seat belts by distributing the impact load more evenly reaction that inflates the air bag.
over the vehicle occupant’s head and torso. “Initiator Assembly Resistance Test”
Asynchronous Tests performed once each ignition cycle when no
Performed in a nonperiodic fashion, (i.e., no defined time malfunctions are detected during “Turn–ON” or
or interval). “Continuous Monitoring”. This test checks for the correct
SDM configuration for the vehicle, shorts to “Ignition 1” in
9J–8 SUPPLEMENTAL RESTRAINT SYSTEM
the deployment loops, high resistance or opens in the Diagnostic Trouble Codes
“Driver Side High”, “Driver Side Low”, “Passenger Side The “SRS Diagnostic System Check” must always be the
High” and “Passenger Side Low” circuits and measures
starting point of any SRS diagnosis. The “SRS
the resistance of the inflator assembly consisting of 1)
Diagnostic System Check” checks for proper “AIR BAG”
Initiators, 2) SRS coil assembly (driver side only), 3)
Connectors and associated wiring. warning lamp operation and checks for SRS diagnostic
trouble codes using the scan tool.
Normal Operating Voltage Range 1. Current diagnostic trouble codes – Malfunctions that
The voltage measured between the SDM “Ignition 1” are presently being detected. Current diagnostic
terminals and “Ground” terminals is between 9 and 16 trouble codes are stored in RAM (Random Access
volts. Memory).
Passenger Current Source 2. History diagnostic trouble codes – All malfunctions
An output of the SDM which applies current into the detected since the last time the history memory was
passenger air bag assembly circuit during the “Initiator cleared. History diagnostic trouble codes are stored
Assembly Resistance Test”. in EEPROM.
Passenger Air Bag Assembly
An assembly located in the right side of the instrument Scan Tool Diagnostics
panel consisting of an inflatable bag, an inflator and an A scan tool is used to read current and history diagnostic
initiator. trouble codes and to clear all diagnostic trouble codes
Scan Tool after a repair is completed. The scan tool must be
An external computer used to read diagnostic information updated to communicate with the SRS through a
from on–board computers via the data link connector. replaceable cartridge before it can be used for SRS
diagnostics. To use the scan tool, connect it to the data
SDM link connector and turn the ignition switch “ON”. The scan
Sensing and Diagnostic Module which provides reserve tool reads serial data from the SDM “Serial Data” line
energy to the deployment loops, deploys the air bags terminal “24” to the data link connector terminal “9”.
when required and performs diagnostic monitoring of all
SRS components. Use Of Special Tools
Serial Data WARNING: TO AVOID DEPLOYMENT WHEN
Information representing the status of the SRS. TROUBLESHOOTING THE SRS, DO NOT USE
SRS ELECTRICAL TEST EQUIPMENT SUCH AS A
Supplemental Restraint System. BATTERY–POWERED OR AC–POWERED
VOLTMETER, OHMMETER, ETC, OR ANY TYPE OF
SRS Coil Assembly ELECTRICAL EQUIPMENT OTHER THAN THAT
An assembly of two current–carrying coils in the driver SPECIFIED IN THIS MANUAL. DO NOT USE A NON
deployment loop that allows the rotation of the steering POWERED PROBE–TYPE TESTER. INSTRUCTIONS
wheel while maintaining the continuous contact of the IN THIS MANUAL MUST BE FOLLOWED
driver deployment loop to the driver air bag assembly. CAREFULLY, OTHERWISE PERSONAL INJURY MAY
SRS Wiring Harness RESULT. YOU SHOULD BE FAMILIAR WITH THE
The wires and connectors that electrically connect the TOOLS LISTED IN THIS SECTION UNDER THE
components in the SRS. HANDLING SRS SPECIAL TOOLS.
“Turn–ON” You should be able to measure voltage and resistance.
Test which the SDM performs on the SRS once during You should be familiar with proper use of a scan tool such
each ignition cycle immediately after “Ignition 1” voltage as the Tech 2 Diagnostic Computer, SRS
is applied to the SDM and before “Continuous Driver/Passenger Load Tool 5–8840–2421–0, Connector
Monitoring”. Test Adapter Kit 5–8840–0385–0, and the DVM (Digital
Multimeter) 5–8840–0285–0.
Diagnosis
WARNING: TO AVOID DEPLOYMENT WHEN
TROUBLESHOOTING THE SRS, DO NOT USE
ELECTRICAL TEST EQUIPMENT SUCH AS A
BATTERY–POWERED OR AC–POWERED
VOLTMETER, OHMMETER, ETC., OR ANY TYPE OF
ELECTRICAL EQUIPMENT OTHER THAN THAT
SPECIFIED IN THIS MANUAL. DO NOT USE A
NONPOWERED PROBE–TYPE TESTER.
INSTRUCTIONS IN THIS MANUAL MUST BE
FOLLOWED CAREFULLY, OTHERWISE PERSONAL
INJURY MAY RESULT.
SUPPLEMENTAL RESTRAINT SYSTEM 9J–9

SRS Connector Body Face Views

D09RW016

Legend (8) Connector between Chassis Harness and


(1) SDM Pretensioner Harness for Passenger Seat Belt
(2) Driver Air Bag Assembly (If so equipped)
(3) Passenger Air Bag Assembly (9) Connector between Pretensioner Harness and
(4) “Air Bag” Warning Lamp driver side Pretensioner Seat Belt (If so
equipped)
(5) SRS Coil Assembly
(10) Connector between Pretensioner Harness and
(6) DLC
passenger side Pretensioner Seat Belt (If so
(7) Connector between Chassis Harness and equipped)
Pretensioner Harness for Driver Seat Belt (If so
equipped)

Repairs And Inspections Required CAUTION: Never use the air bag assembly from
another vehicle. Use only the air bag assembly for
After An Accident Trooper.
NOTE: If any SRS components are damaged, they must CAUTION: Proper operation of the sensors and
be replaced. If SRS component mounting points are supplemental restraint system (SRS) requires that
damaged, they must be replaced. any repairs to the vehicle structure return it to the
Never use SRS parts from another vehicle. This does original production configuration. Deployment
not include remanufactured parts purchased from an requires, at a minimum, replacement of the SDM, air
authorized dealer; they may be used for SRS repairs. bag assembly and dimensional inspection of the
steering column. Any visible damage to the SDM
Do not attempt to service the SDM, the SRS coil
mounting bracket (s) requires replacement, and the
assembly, or the air bag assembly. Service of these
steering column must be dimensionally inspected,
items is by replacement only.
whether deployment occurred or not.
Verify the part number of replacement air bag
assembly.
9J–10 SUPPLEMENTAL RESTRAINT SYSTEM
Accident With Deployment – Component On–Vehicle Service
Replacement And Inspections
Service Precaution
Certain SRS components must be replaced or inspected
for damage after a frontal crash involving air bag WARNING: WHEN PERFORMING SERVICE ON OR
deployment. Those components are: AROUND SRS COMPONENTS OR SRS WIRING,
Air bag assembly FOLLOW THE PROCEDURES LISTED BELOW TO
SDM TEMPORARILY DISABLE THE SRS. FAILURE TO
FOLLOW PROCEDURES COULD RESULT IN
CAUTION: Refer to “SDM Replacement Guidelines” POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
below for important information on SDM INJURY OR OTHERWISE UNNEEDED SRS REPAIRS.
replacement in both deployment and non The SDM in Driver–Passenger SRS can maintain
deployment crashes.
sufficient voltage to cause a deployment for up to 15
SRS coil assembly — Inspect wiring and connector seconds after the ignition switch is turned “OFF,” the
for any signs of scorching, melting, or damage due to battery is disconnected, or the fuse powering the SDM is
excessive heat. Replace if damaged. Refer to removed.
section “SRS Coil Assembly” in this manual. Many of the service procedures require removal of the
“C–21” fuse, and disconnection of the air bag assembly
Accident With or Without Deployment – from the deployment loop to avoid an accidental
Component Inspection deployment. If the air bag assembly is disconnected from
Certain SRS system components and rotation parts must the deployment loop as noted in the “Disabling the SRS”
be inspected after any crash, whether the air bag procedure that follows, service can begin immediately
deployed or not. Those components are: without waiting for the 15 second time period to expire.
Steering column — Refer to Inspection Required
“After an Accident” in this manual. Disabling The SRS
Knee bolsters and mounting points — Inspect for any Removal
distortion, bending, cracking, or other damage.
Turn the ignition switch to “LOCK” and remove key.
I/P steering column reinforcement plate — Inspect for
any distortion, bending, cracking, or other damage. 1. Remove SRS fuse C–21, from left dash side lower
fuse block or disconnect battery.
I/P braces — Inspect for any distortion, bending,
cracking, or other damage. 2. Disconnect yellow 2–pin connector at the base of
steering column.
Seat belts and mounting points — Refer to “Seat
Belts” in Section “Seat Belt” of this workshop manual. 3. Remove glove box assembly, refer to “Passenger Air
Bag Assembly Replacement” in this manual.
SDM Replacement Guidelines 4. Disconnect yellow 2–pin connector behind the glove
box assembly.
SDM replacement policy requires replacement of SDM,
after crash involving air bag deployment when “SRS CAUTION: With the “C–21” fuse removed and
Warning Lamp” turn “ON”, “SRS Diagnosis” should be ignition switch “ON”, the “AIR BAG” warning lamp
done according to Section “Restraint Control System.” will be “ON”. This is normal operation and does not
If accident without deployment air bag, it is not necessary indicate an SRS malfunction.
replacement of SDM when do not indicate to replace the
SDM by scan tool after SRS system check. Enabling The SRS
Wiring Damage Installation
If any SRS wire harness is damaged, it should be CAUTION: Never use the air bag assembly from
replaced. Don’t repair SRS harness. It is replace only. another vehicle. Use only the air bag assembly for
Trooper.
SRS Connector (Plastic Body And Turn ignition switch to “LOCK” and remove key.
Terminal Metal Pin) Damage 1. Connect yellow 2–pin connector passenger air bag
If any connector or terminal in the SRS wire harness assembly.
(except pigtails) is damaged, it should be replaced. 2. Install glove box assembly. Refer to “Passenger air
bag assembly replacement” in this manual.
SRS Wire Pigtail Damage 3. Connect yellow 2–pin connector at the base of
If the wiring pigtail (a wire or wires attached directly to the steering column.
device, not by a connector) is damaged, the entire 4. Install “AIR BAG” fuse C–21 to left dash side lower
component (with pigtail) must be replaced. Examples of fuse block or connect battery.
“pigtail” components are the driver air bag assembly, the Turn ignition switch to “ON” and verify that the “AIR BAG”
passenger air bag assembly, and the SRS coil assembly. warning lamp turn on 3.5 seconds and then turns “OFF.” If
it does not operate as described, perform the “SRS
Diagnostic System Check” in this manual.
SUPPLEMENTAL RESTRAINT SYSTEM 9J–11
Handling / Installation / Diagnosis WIRES OR CONNECTOR ON THE UNDERSIDE OF
THE MODULE.
1. Air bag assembly should not be subjected to
temperatures above 93 C (200 F).
2. Air bag assembly, and SDM should not be used if they Pretensioner Seat Belt Handling /
have been dropped from a height of 100 centimeters Shipping / Scrapping.
(3.28 feet) or more.
3. When a SDM is replaced, it must be oriented with the Live (undeployed) pretensioner seat belt.
arrow on the sensor pointing toward the front of the Special care is necessary when handling and storing a
vehicle. It is very important for the SDM to be located live (undeployed) pretensioner seat belt.
flat on the mounting surface, parallel to the vehicle The rapid gas generation produced during deployment of
datum line. It is important that the SDM mounting the pretensioner seat belt (could cause the pretensioner
surface is free of any dirt or other foreign material. seat belt), or an object around of pretensioner seat belt, to
4. Do not apply power to the SRS unless all components be thrown through the air in the unlikely event of an
are connected or a diagnostic chart requests it, as this accidental deployment.
will set a diagnostic trouble code.
WARNING: WHEN CARRYING A LIVE
5. The “SRS Diagnostic System Check” must be the PRETENSIONER SEAT BELT, MAKE SURE THE
starting point of any SRS diagnostics. The “SRS PRETENSIONER SEAT BELT CYLINDER IS POINTED
Diagnostic System Check” will verify proper “AIR AWAY FROM YOU. IN CASE OF AN ACCIDENTAL
BAG” warning lamp operation and will lead you to the DEPLOYMENT, THE PRETENSIONER SEAT BELT
correct chart to diagnose any SRS malfunctions. WILL THEN DEPLOY WITH MINIMAL CHANCE OF
Bypassing these procedures may result in extended INJURY. NEVER CARRY THE PRETENSIONER SEAT
diagnostic time, incorrect diagnosis, and incorrect BELT BY THE CYLINDER OR WIRES ON THE
parts replacement. UNDERSIDE OF THE MODULE.

Air Bag Assembly Handling /


Shipping / Scrapping
Live (Undeployed) Air Bag Assembly
Special care is necessary when handling and storing a
live (undeployed) air bag assembly. The rapid gas
generation produced during deployment of the air bag
could cause the air bag assembly, or an object in front of
the air bag assembly, to be thrown through the air in the
unlikely event of an accidental deployment.

827RS044
827RV004

WARNING: WHEN CARRYING A LIVE AIR BAG Air Bag Assembly and/or Pretensioner
ASSEMBLY, MAKE SURE THE BAG OPENING IS Seat Belt Shipping Procedure For
POINTED AWAY FROM YOU. IN CASE OF AN Live(Undeployed) Them.
ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN
DEPLOY WITH MINIMAL CHANCE OF INJURY. Service personnel should refer to the Service Bulletins for
NEVER CARRY THE AIR BAG ASSEMBLY BY THE proper SRS composition parts shipping procedures.
9J–12 SUPPLEMENTAL RESTRAINT SYSTEM
Deployed Air Bag Assembly (Driver Side) 4. Place the air bag with its trim cover up.
“You should wear gloves and glasses. After the air bag 5. Do not let the air bag deploy directly on the floor. (The
assembly has been deployed, the surface of the air bag air bag may be blown off 2 3 m (6.5 or 10 feet)).
may contain solid particulate. This solid particulate 6. Be sure to install the air bag firmly to a deployment
consists primarily of by products of the chemical reaction, tool (fixing tool).
Potassium Chloride and copper metal dust. Compounds 7. Set a battery 10 m (33 feet) or more away from the air
of Potassium Borate, Strontium Chloride, Copper bag.
Chloride, and Ammonium Chloride may be found in 8. Before disconnecting air bag harness, ground the
amounts of about 1% (each) of the total particulate.” worker by touching the vehicle outer panel with bare
hand.
Deployed Pretensioner Seat Belt.
9. When connecting or disconnecting the harness, do
You should wear gloves and safety glasses. After the not work just in front of the air bag.
pretensioner seat belt has been deployed, the surface of
10. As deployment gives rise to big sound, warn the
the pretensioner seat belt cylinder may heating up. people around against it. Further, try to reduce the
sound by covering the steering wheel or tires, and
Air Bag Assembly and/or Pretensioner shut the vehicle windows in case of deployment
Seat Belt Scrapping Procedure. inside the vehicle.
During the cause of vehicle’s useful life, certain situations 11. As deployment generates smoke, select a well
may arise which will necessitate the disposal of a live air ventilated place. (In case of deployment indoors,
bag and/or pretensioner seat belt. (This information avoid deployment just under a fire alarm, smoke
covers proper procedures for disposing of a live air bag sensor, and fluorescent lamps).
assembly and/or pretensioner seat belt.) 12. Be careful not to inhale the smoke after deployment.
Before a live air bag assembly can be dispose off, it must
13. If part of the vehicle glass is damaged, cover the
be deployed.
vehicle with a car cover to prevent the glass from
A live air bag assembly and/or pretensioner seat belt
braking at the time of deployment.
must not be disposed of though normal refuse channels.
14. Do not touch the air bag immediately after
WARNING: FAILURE TO FOLLOW PROPER deployment, since it remains hot for 30 minutes.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR
15. Do not water the air bag immediately after
BAG ASSEMBLY DISPOSAL PROCEDURES CAN
deployment.
RESULT IN AIR BAG DEPLOYMENT WHICH MAY
CAUSE PERSONAL INJURY. AN UNDPLOYED AIR 16. Wear safety glasses and gloves throughout the work
BAG ASSEMBLY MUST NOT BE DISPOSED OF and wash the glasses and gloves after the work.
THROUGH NORMAL REFUSE CHANNELS. THE 17. Do not reuse the removed air bag for another vehicle.
UNDEPLOYED AIR BAG ASSEMBLY CONTAINS (Deployment characteristic is different with vehicle
SUBSTANCES THAT CAN CAUSE SEVERE ILLNESS types).
OR PERSONAL INJURY IF THE SEALED CONTAINER
IS DAMAGED DURING DISPOSAL. DISPOSAL IN Deployment Outside Vehicle (Driver Air
ANY MANNER INCONSISTENT WITH PROPER Bag Assembly)
PROCEDURES MAY BE A VIOLATION OF LOCAL
Deployment outside the vehicle is proper when the
LAW.
vehicle is to be returned to service. This includes, for
In situations which require deployment of a live air bag example, situations in which the vehicle will be returned to
assembly, deployment may be accomplished inside or useful service after a functionally or cosmetically deficient
outside the vehicle. The method employed depends air bag assembly is replaced. Deployment and disposal
upon the final disposition of the particular vehicle, as of a malfunctioning air bag assembly is, of course, subject
noted in “Deployment Outside Vehicle” and “Deployment to any required retention period.
Inside Vehicle” in this section. For deployment of a live (undeployed) air bag assembly
outside the vehicle, the deployment procedure must be
Cautions About Air Bag Deployment And followed exactly. Always wear safety glasses during this
Disposal deployment procedure until a deployed air bag assembly
Failure to follow proper procedures could result in is scrapped or until an undeployed air bag assembly is
erroneous air bag deployment which may cause personal shipped. Before performing the procedures you should
injury be sure to follow proper procedures. be familiar with servicing the SRS and with proper
1. Turn off (Lock) the ignition switch and disconnect the handling of the air bag assembly. Procedures should be
minus terminal of the battery, then start the work 15 or read fully before they are performed.
more sec later. (Air bag is designed to work by the The following procedure requires use of 5–8840–2468–0
back-up power source even if the battery power SRS deployment harness with appropriate pigtail
source is cut off at vehicle collision). adapter. Do not attempt procedure without
2. Be sure not to disassemble the air bag. 5–8840–2468–0 adapter.
3. Do not give an impact to the air bag and bring the air WARNING: FAILURE TO FOLLOW PROCEDURES IN
bag close to magnet. (The air bag could deploy THE ORDER LISTED MAY RESULT IN PERSONAL
unexpectedly). INJURY. NEVER CONNECT DEPLOYMENT
SUPPLEMENTAL RESTRAINT SYSTEM 9J–13
HARNESS TO ANY POWER SOURCE BEFORE 6. Place the driver air bag assembly on a work bench or
CONNECTING DEPLOYMENT HARNESS TO THE other surface away from all loose or flammable
DRIVER AIR BAG ASSEMBLY. DEPLOYMENT objects with its trim cover facing up, away from the
HARNESS SHALL REMAIN SHORTED AND NOT BE surface.
CONNECTED TO A POWER SOURCE UNTIL THE AIR
BAG IS TO BE DEPLOYED. THE AIR BAG
ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR
BAG WHEN A POWER SOURCE IS CONNECTED TO
IT. WEAR SAFETY GLASSES THROUGHOUT THIS
ENTIRE DEPLOYMENT AND DISPOSAL
PROCEDURE.
NOTE: This information applies only to driver air bag
assembly . Refer to “Deployment Outside Vehicle
(Passenger Air Bag assembly)” in this section for
information on passenger air bag assembly scrapping.
1. Turn ignition switch to “LOCK”, remove key.
2. Inspect 5–8840–2468–0 SRS Deployment Harness
and appropriate pigtail adapter for damage. If
harness or pigtail adapter is damaged, discard and
obtain a replacement.
3. Short the two SRS deployment harness leads
together by fully seating one banana plug into the
other. SRS deployment harness shall remain shorted 827RV003
and not be connected to a power source until the air 7. Clear a space on the ground about 183 cm (six feet) in
bag is to be deployed. clearance where the driver air bag assembly is to be
deployed. A paved, outdoor location where there is
no activity is preferred. If an outdoor location is not
available, a space on the shop floor where there is no
activity and sufficient ventilation is recommended.
Ensure no loose or flammable objects are within the
deployment area.

827RS004

4. Connect the appropriate pigtail adapter to the SRS


deployment harness.
5. Remove the driver air bag assembly from vehicle.
Refer to “Inflator Module Removal” in this manual.
WARNING: WHEN STORING A LIVE AIR BAG
ASSEMBLY OR WHEN LEAVING A LIVE AIR BAG
827RX032

8. Place the driver air bag assembly, with its trim cover
ASSEMBLY UNATTENDED ON A BENCH OR OTHER
facing up, on the ground in the space just cleared.
SURFACE, ALWAYS FACE THE AIR BAG AND TRIM
COVER UP AND AWAY FROM THE SURFACE. THIS 9. Stretch the SRS deployment harness and pigtail
IS NECESSARY SO THAT A FREE SPACE IS adapter from the driver air bag assembly to its full
PROVIDED TO ALLOW THE AIR BAG TO EXPAND IN length.
THE UNLIKELY EVENT OF ACCIDENTAL
DEPLOYMENT. FAILURE TO FOLLOW
PROCEDURES MAY RESULT IN PERSONAL INJURY.
9J–14 SUPPLEMENTAL RESTRAINT SYSTEM
10. Place a power source near the shorted end of the 19. In the unlikely event that the driver air bag assembly
SRS deployment harness. Recommended did not deploy after following these procedures,
application: 12 volts minimum, 2 amps minimum. A proceed immediately with Steps 24 through 26. If the
vehicle battery is suggested. driver air bag assembly did deploy, proceed with
11. Connect the driver air bag assembly to the pigtail Steps 20 through 23.
adapter on the SRS deployment harness. 20. Put on a pair of shop gloves and safety glasses to
Deployment harness shall remain shorted and not be protect your hands and eyes from possible irritation
connected to a power source until the air bag is to be and heat when handling the deployed driver air bag
deployed. The driver air bag assembly will assembly. After the air bag assembly has been
immediately deploy the air bag when a power source deployed, the surface of the air bag may contain a
is connected to it. powdery residue. This solid particulate consists
primarily of by products of the chemical reaction,
NOTE: Ensure that the pigtail adapter is firmly seated into
Potassium Chloride and copper metal dust.
the driver air bag assembly connector. Failure to fully
Compounds of Potassium Borate, Strontium
seat the connectors may leave the shorting bar located in
Chloride, Copper Chloride, and Ammonium Chloride
the driver air bag assembly connector functioning
may be found in amounts of about 1 % (each) of the
(shorted) and may result in nondeployment of the driver
total particulate.
air bag assembly.
12. Verify that the area around the driver air bag WARNING: SAFETY PRECAUTIONS MUST BE
assembly is clear of all people and loose or flammable OBSERVED WHEN HANDING A DEPLOYED AIR BAG
objects. ASSEMBLY. AFTER DEPLOYMENT, THE METAL
SURFACES OF THE AIR BAG ASSEMBLY WILL BE
13. Verify that the driver air bag assembly is resting with VERY HOT. ALLOW THE INFLATOR MODULE TO
its trim cover facing up. COOL BEFORE HANDLING ANY METAL PORTION
14. Notify all people in the immediate area that you intend OF IT. DO NOT PLACE THE DEPLOYED AIR BAG
to deploy the driver air bag. The deployment will be ASSEMBLY NEAR ANY FLAMMABLE OBJECTS.
accompanied by a substantial noise which may FAILURE TO FOLLOW PROCEDURES MAY RESULT
startle the uninformed. IN FIRE OR PERSONAL INJURY.
15. Separate the two banana plugs on the SRS AFTER A DRIVER AIR BAG ASSEMBLY HAS BEEN
deployment harness. DEPLOYED, THE METAL CANISTER AND
NOTE: When the air bag deploys, the driver air bag SURROUNDING AREAS OF THE DRIVER AIR BAG
assembly may jump about 3 m (ten feet) vertically. This ASSEMBLY WILL BE VERY HOT. DO NOT TOUCH
is a normal reaction of the driver air bag to the force of the THE METAL AREAS OF THE DRIVER AIR BAG
rapid gas expansion inside the air bag. ASSEMBLY FOR ABOUT TEN MINUTES AFTER
NOTE: When the air bag deploys, the rapid gas DEPLOYMENT. IF THE DEPLOYED DRIVER AIR BAG
expansion will create a substantial noise. Notify all ASSEMBLY MUST BE MOVED BEFORE IT IS COOL,
people in the immediate area that you intend to deploy the WEAR GLOVES AND HANDLE BY THE AIR BAG OR
driver air bag. TRIM COVER.
21. Disconnect the pigtail adapter from the driver air bag
WARNING: DEPLOYMENT HARNESS SHALL
assembly as soon after deployment as possible. This
REMAIN SHORTED AND NOT BE CONNECTED TO A will prevent damage to the pigtail adapter or SRS
POWER SOURCE UNTIL THE AIR BAG IS TO BE deployment harness due to possible contact with the
DEPLOYED. THE AIR BAG ASSEMBLY WILL hot driver air bag assembly canister. The pigtail
IMMEDIATELY DEPLOY THE AIR BAG WHEN A adapter can be reused. They should, however, be
POWER SOURCE IS CONNECTED TO IT.
inspected for damage after each deployment and
CONNECTING THE DEPLOYMENT HARNESS TO replaced if necessary.
THE POWER SOURCE SHOULD ALWAYS BE THE
LAST STEP IN THE AIR BAG ASSEMBLY 22. Dispose of the deployed driver air bag assembly
DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW through normal refuse channels after it has cooled for
PROCEDURES IN THE ORDER LISTED MAY RESULT at least 30 minutes.
IN PERSONAL INJURY. 23. Wash your hands with mild soap and water afterward.
16. Connect the SRS deployment harness wires to the NOTE: The remaining steps are to be followed in the
power source to immediately deploy the driver air unlikely event that the driver air bag assembly did not
bag. Recommended application: 12 volts minimum, 2 deploy after following these procedures.
amps minimum. A vehicle battery is suggested. 24. Ensure that the SRS deployment harness has been
17. Disconnect the SRS deployment harness from the disconnected from the power source and that its two
power source. banana plugs have been shorted together by fully
18. Short the two SRS deployment harness leads seating one banana plug into the other.
together by fully seating one banana plug into the 25. Disconnect the pigtail adapter from the driver air bag
other. assembly.
WARNING: WHEN STORING A LIVE AIR BAG
ASSEMBLY OR WHEN LEAVING A LIVE INFLATOR
MODULE UNATTENDED ON A BENCH OR OTHER
SUPPLEMENTAL RESTRAINT SYSTEM 9J–15
SURFACE, ALWAYS FACE THE BAG AND TRIM SAFETY GLASSES THROUGHOUT THIS ENTIRE
COVER UP AND AWAY FROM THE SURFACE. THIS DEPLOYMENT AND DISPOSAL PROCEDURE.
IS NECESSARY SO THAT A FREE SPACE IS
PROVIDED TO ALLOW THE AIR BAG TO EXPAND IN NOTE: This information applies only to passenger air bag
THE UNLIKELY EVENT OF ACCIDENTAL assembly. Information for disposing of a live driver air bag
DEPLOYMENT. FAILURE TO FOLLOW assembly can be found in “Deployment Outside Vehicle”
PROCEDURES MAY RESULT IN PERSONAL INJURY. (Driver Air Bag Assembly) in this section.
26. Temporarily store the driver air bag assembly with its 1. Turn ignition switch to “LOCK” remove key, and put on
trim cover facing up, away from the surface upon safety glasses.
which it rests. 2. Inspect 5–8840–2468–0 SRS Deployment Harness
and appropriate pigtail adapter for damage. If
Deployment Outside Vehicle (Passenger harness or pigtail is damaged, discard and obtain a
Air Bag Assembly) replacement.
3. Short the two SRS Deployment Harness leads
WARNING: FAILURE TO FOLLOW PROPER SRS AIR together by fully seating one banana plug into the
BAG ASSEMBLY DISPOSAL PROCEDURES CAN other. The SRS Deployment Harness shall remain
RESULT IN AIR BAG DEPLOYMENT WHICH MAY shorted and not be connected to a power source until
CAUSE PERSONAL INJURY. UNDEPLOYED AIR the air bag is to be deployed.
BAG ASSEMBLIES MUST NOT BE DISPOSED OF
THROUGH NORMAL REFUSE CHANNELS. THE
UNDEPLOYED AIR BAG ASSEMBLY CONTAINS
SUBSTANCES THAT CAN CAUSE SEVERE ILLNESS
OR PERSONAL INJURY IF THE SEALED CONTAINER
IS DAMAGED DURING DISPOSAL. DISPOSAL IN
ANY MANNER INCONSISTENT WITH PROPER
PROCEDURES MAY BE A VIOLATION OF FEDERAL,
STATE AND/OR LOCAL LAWS.
Deployment out of the vehicle is proper when the vehicle
is to be returned to service. This includes, for example,
situations in which a functionally or cosmetically deficient
air bag assembly is replaced. Deployment and disposal
of an air bag assembly is, of course, subject to any
required retention period.
For deployment of a live air bag assembly out of the
vehicle, the deployment procedure must be followed
exactly. Always wear safety glasses during this
deployment procedure until the deployed air bag
assembly is scrapped. Before performing the 827RS003
procedures, you should be familiar with servicing the SRS 4. Connect the appropriate pigtail adapter to the SRS
system and with proper handling of the air bag assembly. Deployment Harness
Procedures should be read fully before they are
performed.
The following procedure requires use of 5–8840–2468–0
SRS Deployment Harness with the appropriate pigtail
adapter. The procedure also requires the use of
5–8840–2420–0 Passenger Side SRS Module
Deployment Fixture. Do not attempt this procedure
without 5–8840–2468–0 and adapter, and
5–8840–2420–0.
WARNING: FAILURE TO FOLLOW PROCEDURES IN
THE ORDER LISTED MAY RESULT IN PERSONAL
INJURY. NEVER CONNECT DEPLOYMENT
HARNESS TO ANY POWER SOURCE BEFORE
CONNECTING DEPLOYMENT HARNESS TO THE AIR
BAG ASSEMBLY. DEPLOYMENT HARNESS SHALL
REMAIN SHORTED AND NOT BE CONNECTED TO A
POWER SOURCE UNTIL THE AIR BAG IS TO BE
DEPLOYED. THE AIR BAG ASSEMBLY WILL
IMMEDIATELY DEPLOY THE AIR BAG WHEN A
POWER SOURCE IS CONNECTED TO IT. WEAR 827RS004
9J–16 SUPPLEMENTAL RESTRAINT SYSTEM
5. Remove passenger air bag assembly from vehicle. 13. Verify that the passenger air bag assembly is firmly
Refer to “Passenger Air Bag Assembly Removal ” in and properly in 5–8840–2420–0.
this Section 9J–3. 14. Notify all people in the immediate area of your
6. Clear a space on the ground approximately 183 cm intention to deploy the passenger air bag assembly.
(six feet) in clearance where the fixture with attached The deployment will be accompanied by a substantial
air bag assembly is to be placed for deployment. A noise which may startle the uninformed.
paved outdoor location where there is no activity is 15. Separate the two banana plugs on the SRS
preferred. If an outdoor location is not available, a deployment harness.
space on the shop floor where is no activity and
sufficient ventilation is recommended. Ensure that no NOTE: When air bag deploys, the rapid gas expansion
loose or flammable objects are within the deployment will create a substantial noise. Notify all people in the
area. immediate area that you intend to deploy the air bag
assembly.
7. Place the 5–8840–2420–0 on the bench vice. This is
necessary to provide sufficient stabilization of the WARNING: DEPLOYMENT HARNESS SHALL
fixture during deployment. REMAIN SHORTED AND NOT BE CONNECTED TO A
8. Attach the passenger air bag assembly in the POWER SOURCE UNTIL THE AIR BAG IS TO BE
5–8840–2420–0. An air bag assembly must be DEPLOYED. THE AIR BAG ASSEMBLY WILL
mounted such that the bag will deploy upward. IMMEDIATELY DEPLOY THE AIR BAG WHEN A
SECURELY HAND–TIGHTEN ALL FASTENERS POWER SOURCE IS CONNECTED TO IT.
PRIOR TO DEPLOYMENT. CONNECTING THE DEPLOYMENT HARNESS TO
THE POWER SOURCE SHOULD ALWAYS BE THE
LAST STEP IN THE AIR BAG ASSEMBLY
DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW
PROCEDURES IN THE ORDER LISTED MAY RESULT
IN PERSONAL INJURY.
16. Connect the SRS deployment harness wires to the
power source to immediately deploy the air bag
assembly. Recommended application : 12 volts
minimum, 2 amps minimum. A vehicle battery is
suggested.
17. Disconnect the SRS deployment harness from the
power source.
18. Short the two SRS deployment harness leads
together by fully seating one banana plug into the
other.
19. In the unlikely event that the passenger air bag
assembly did not deploy after following these
procedures, proceed immediately with Steps 24
through 26. If the passenger air bag assembly
901RW199
deployed as intended, proceed with Steps 20 through
9. Stretch the SRS Deployment Harness and pigtail 23.
adapter from the air bag assembly to its full length.
20. Put on a pair of shop gloves and safety glasses to
10. Place a power source near the shorted end of the protect your hands and eyes from possible irritation
SRS deployment harness. (Recommended and heat when handling the deployed air bag
application: 12 volts minimum, 2 amps minimum. A assembly.
vehicle battery is suggested.) After the air bag assembly has been deployed, the
11. Connect the air bag assembly to the pigtail adapter on surface of the air bag may contain a powdery residue.
the SRS deployment harness. The SRS Deployment This powder consists primarily of cornstarch (used to
Harness shall remain shorted and not be connected lubricate the bag as it inflates) and by products of the
to a power source until the air bag is to be deployed. chemical reaction. Sodium hydroxide dust (similar to
The air bag assembly will immediately deploy the air lye soap) is produced as a by product of the
bag when a power source is connected to it. deployment reaction. The sodium hydroxide then
NOTE: Ensure that the pigtail adapter is firmly seated into quickly reacts with atmospheric moisture and is
the air bag assembly connector. Failure to fully seat the converted to sodium carbonate and sodium
connectors may leave the shorting bar located in the air bicarbonate (baking soda). Therefore, it is unlikely
bag assembly connector functioning (shorting the that sodium hydroxide will be present after
deployment circuit) and may result in nondeployment of deployment.
the air bag assembly. WARNING: SAFETY PRECAUTIONS MUST BE
12. Verify that the area around the passenger air bag OBSERVED WHEN HANDLING A DEPLOYED AIR
assembly is clear of all people and loose or flammable BAG ASSEMBLY. AFTER DEPLOYMENT, THE
objects. METAL SURFACES OF THE AIR BAG ASSEMBLY
WILL BE HOT. ALLOW THE AIR BAG ASSEMBLY TO
SUPPLEMENTAL RESTRAINT SYSTEM 9J–17
COOL BEFORE HANDLING ANY METAL PORTION 2. Inspect J–41434 Supplemental Restraint System
OF IT. DO NOT PLACE THE DEPLOYED INFLATOR (SRS) Deployment Harness and appropriate pigtail
MODULE NEAR ANY FLAMMABLE OBJECTS. adapter for damage. If harness or pigtail is damaged,
FAILURE TO FOLLOW PROCEDURES MAY RESULT discard and obtain a replacement.
IN FIRE OR PERSONAL INJURY. AFTER AN AIR BAG 3. Extend double pole extension cord to a position far
ASSEMBLY HAS BEEN DEPLOYED, THE METAL away 10 m (33 feet) from the air bag assembly.
CANISTER AND SURROUNDING AREAS OF THE AIR
4. Place a power source near the extended end of SRS
BAG ASSEMBLY WILL BE HOT. DO NOT TOUCH THE
air bag deployment harness. (Use of 12V battery is
METAL AREAS OF THE AIR BAG ASSEMBLY FOR
recommended).
ABOUT THIRTY MINUTES AFTER DEPLOYMENT. IF
THE DEPLOYED AIR BAG ASSEMBLY MUST BE
MOVED BEFORE IT IS COOL, WEAR GLOVES AND
HANDLE BY THE AIR BAG ITSELF.
21. Disconnect the pigtail adapter from the air bag
assembly as soon after deployment as possible to
avoid damage to the pigtail adapter or SRS
deployment harness from contacting the hot air bag
assembly canister. The pigtail adapter and SRS
deployment harness are designed to be reused.
They should, however, be inspected for damage after
each deployment and replaced if necessary.
22. Dispose of the deployed air bag assembly through
normal refuse channels after it has cooled for at least
30 minutes.
23. Wash your hands with mild soap and water afterward.
NOTE: The remaining steps are to be followed in the
unlikely event that the air bag assembly did not deploy
after following the above procedures.
24. Ensure that the SRS deployment harness has been 827RW057

disconnected from the power source and that its two Legend
banana plugs have been shorted together by fully (A) 10 m (33 feet) or more
seating one banana plug into the other.
25. Disconnect the pigtail adapter from the air bag 5. Insert one of the banana plugs into the other banana
assembly. plug to short the two SRS air bag deployment
harness. Do not the harness to a power source until
WARNING: WHEN STORING A LIVE AIR BAG deployment.
ASSEMBLY OR WHEN LEAVING A LIVE AIR BAG
ASSEMBLY UNATTENDED ON A BENCH OR OTHER
SURFACE, ALWAYS FACE THE BAG UP AND AWAY
FROM THE SURFACE. THIS IS NECESSARY SO
THAT A FREE SPACE IS PROVIDED TO ALLOW THE
AIR BAG TO EXPAND IN THE UNLIKELY EVENT OF
ACCIDENTAL DEPLOYMENT. FAILURE TO FOLLOW
PROCEDURES MAY RESULT IN PERSONAL INJURY.
26. Temporarily store the air bag assembly with the bag
facing up, away from the surface upon which it rests.

Deployment Outside Vehicle (Fixing Air


Bag on Tire)
Read and understand the items of “CAUTIONS ABOUT
AIR BAG DEPLOYMENT AND DISPOSAL
PROCEDURES” and “Usage of Deployment Tool” for
safe deployment of air bag.
1. Remove air bag assembly from vehicle. Refer to air
bag assembly Removal “in this section”.
827RW055
9J–18 SUPPLEMENTAL RESTRAINT SYSTEM
6. Prepare four 15 inch or larger tires without wheel and 3. Place three tires without wheel on the tire on
two same size tires with wheels. which air bag is fixed and a tire with a wheel on
top.
Bind the five tires with a rope so that the tires may
not collapse.

827RW056

7. How to fix Driver air bag.


1. Fix the air bag with its trim cover up on a tire with a
wheel using an automobile use wire harness, 827RW053

(core size: 0.05 inch) or a wire trebly at two or Legend


more points. (A) 10 m (33 feet) or more
2. Connect SRS air bag assembly to the double pole
extension cord of the air bag deployment 8. How to fix Passenger air bag.
harness. 1. Fix the air bag with its trim cover side fixing the
Do not connect the deployment harness to a pow- center of a tire without a wheel using an
er source until air bag deployment. automobile use wire harness, (core size: 0.05
(If connected the SRS air bag assembly deploys inch) or a wire trebly at two or more points.
immediately)
NOTE: Ensure that the pigtail adapter is firmly seated into
the air bag assembly connector. Failure to fully seat the
connectors may leave the shorting bar located in the air
bag assembly connector functioning (shorting the
deployment circuit) and may result in non deployment of
the air bag assembly.

901RX045

2. Connect Supplemental Restraint System (SRS)


air bag assembly to the deployment harness
double pole extension cord end. Be sure not to
connect the deployment harness to a power
source. (If connected the SRS air bag assembly
deploys immediately).
827RW054
SUPPLEMENTAL RESTRAINT SYSTEM 9J–19
NOTE: Ensure that the pigtail adapter is firmly seated into THE AIR BAG ASSEMBLY WILL IMMEDIATELY
the air bag assembly connector. Failure to fully seat the DEPLOY THE AIR BAG WHEN A CONNECTING THE
connectors may leave the shorting bar located in the air DEPLOYMENT HARNESS TO THE POWER SOURCE
bag assembly connector functioning (shorting the SHOULD ALWAYS BE THE LAST STEP IN THE AIR
deployment circuit) and may result in non deployment of BAG ASSEMBLY DEPLOYMENT PROCEDURE.
the air bag assembly. FAILURE TO FOLLOW PROCEDURES IN THE
ORDER LISTED MAY RESULT IN PERSONAL
INJURY.
10. Connect the Supplemental Restraint System (SRS)
deployment harness wires to the power source to
immediately deploy the air bag assembly.
Recommended application : 12 volts minimum, 2
amps minimum. A vehicle battery is suggested.

827RW054

3. Put a tire without wheel on another, put the tire on


which the air bag is fixing, put a tire without a
wheel, and finally put a tire with a wheel on top.
Bind the tires with a rope so that the tires pile may
not collapse.

827LW011

WARNING: SAFETY PRECAUTIONS MUST BE


OBSERVED WHEN HANDING A DEPLOYED AIR BAG
ASSEMBLY. AFTER DEPLOYMENT, THE METAL
SURFACES OF THE AIR BAG ASSEMBLY WILL BE
VERY HOT. ALLOW THE AIR BAG ASSEMBLY TO
COOL BEFORE HANDLING ANY METAL PORTION
OF IT. DO NOT PLACE THE DEPLOYED INFLATOR
MODULE NEAR ANY FLAMMABLE OBJECTS.
FAILURE TO FOLLOW PROCEDURES MAY RESULT
IN FIRE OR PERSONAL INJURY. AFTER AN AIR BAG
ASSEMBLY HAS BEEN DEPLOYED, THE METAL
CANISTER AND SURROUNDING AREAS OF THE AIR
BAG ASSEMBLY WILL BE HOT. DO NOT TOUCH THE
METAL AREAS OF THE AIR BAG ASSEMBLY FOR
ABOUT THIRTY MINUTES AFTER DEPLOYMENT. IF
THE DEPLOYED AIR BAG ASSEMBLY MUST BE
MOVED BEFORE IT IS COOL, WEAR GLOVES AND
HANDLE BY THE AIR BAG IT SELF.
827RW050

Legend 11. Disconnect the pigtail adapter from the air bag
assembly as soon after deployment as possible to
(A) 10 m (33 feet) or more avoid damage to the pigtail adapter or SRS
deployment harness from contacting the hot air bag
9. Notify all people in the immediate area of your assembly canister. The pigtail adapter and SRS
intention to deploy the passenger air bag assembly. deployment harness are designed to be reused. They
The deployment will be accompanied by a substantial should, however, be inspected for damage after each
noise which may startle the uninformed. deployment and replaced if necessary.
WARNING: DEPLOYED HARNESS SHALL REMAIN 12. Dispose of the deployed air bag assembly through
SHORTED AND NOT BE CONNECTED TO A POWER normal refuse channels after it has cooled for at least
SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. 30 minutes.
9J–20 SUPPLEMENTAL RESTRAINT SYSTEM
13. Wash your hands with mild soap and water afterward. Deployment Inside Vehicle (Vehicle
NOTE: The remaining steps are to be followed in the Scrapping Procedure)
unlikely event that the air bag assembly did not deploy Deployment inside vehicle is proper when the vehicle is to
after following the above procedures. be destroyed or salvaged for component parts. This
14. Ensure that the SRS deployment harness has been includes, but is not limited to, the following situations:
disconnected from the power source and that its two 1. The vehicle has completed its useful life.
banana plugs have been shorted together by fully 2. The vehicle has been damaged beyond repair in a
seating one banana plug into the other. nondeployment type accident.
3. The vehicle has been stripped or damaged beyond
repair in a theft.
4. The vehicle will be salvaged for component parts to
be used on a vehicle with a different Vehicle
Identification Number (VIN) as opposed to being
rebuilt as same VIN. Never use SRS components
from another vehicle.
WARNING: FAILURE TO FOLLOW PROPER SRS AIR
BAG ASSEMBLY DISPOSAL PROCEDURES CAN
RESULT IN AIR BAG DEPLOYMENT WHICH MAY
CAUSE PERSONAL INJURY. UNDEPLOYED AIR
BAG ASSEMBLIES MUST NOT BE DISPOSED OF
THROUGH NORMAL REFUSE CHANNELS. THE
UNDEPLOYED AIR BAG ASSEMBLY CONTAINS
SUBSTANCES THAT CAN CAUSE SEVERE ILLNESS
OR PERSONAL INJURY IF THE SEALED CONTAINER
IS DAMAGED DURING DISPOSAL. DISPOSAL IN
ANY MANNER INCONSISTENT WITH PROPER
PROCEDURES MAY BE A VIOLATION OF FEDERAL,
827RW055
STATE AND/OR LOCAL LAWS.
15. Disconnect the pigtail adapter from the air bag
assembly. 1. Turn ignition switch to “LOCK,” remove key and put
on safety glasses.
WARNING: WHEN STORING A LIVE AIR BAG
ASSEMBLY OR WHEN LEAVING A LIVE AIR BAG 2. Remove all loose objects from front seats.
ASSEMBLY UNATTENDED ON A BENCH OR OTHER 3. Disconnect driver air bag assembly, yellow 2–pin
SURFACE, ALWAYS FACE THE BAG UP AND AWAY connector located at the base of the steering column.
FROM THE SURFACE. THIS IS NECESSARY SO 4. Cut the driver air bag assembly yellow 2–pin harness
THAT A FREE SPACE IS PROVIDED TO ALLOW THE connector from the vehicle leaving at least 15 cm (six
AIR BAG TO EXPAND IN THE UNLIKELY EVENT OF inches) of wire at the connector.
ACCIDENTAL DEPLOYMENT. FAILURE TO FOLLOW
5. Strip 13 mm (1/2 inch) of insulation from yellow –
PROCEDURES MAY RESULT IN PERSONAL INJURY.
green and yellow – black wire lead of the connector.
16. Temporarily store the air bag assembly with the bag 6. Cut two 900 cm (30 feet) deployment wires from 0.8
facing up, away from the surface upon which it rests. mm (18 gauge) or thicker multi–strand wire. These
wires will be used to fabricate the driver deployment
harness.
7. Strip 13 mm (1/2 inch) of insulation from both ends of
the wires cut in the previous step.
8. Short the wires by twisting together one end from
each. Deployment wires shall remain shorted and not
be connected to a power source until the air bag is to
be deployed.
WARNING: FAILURE TO FOLLOW PROCEDURES IN
THE ORDER LISTED COULD RESULT IN PERSONAL
INJURY. NEVER CONNECT DEPLOYMENT WIRES
TO ANY POWER SOURCE BEFORE CONNECTING
DEPLOYMENT WIRES TO THE AIR BAG ASSEMBLY
LEADS. DEPLOYMENT WIRES SHALL REMAIN
SHORTED AND BE NOT CONNECTED TO A POWER
SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED.
THE AIR BAG ASSEMBLY WILL IMMEDIATELY
DEPLOY THE AIR BAG WHEN A POWER SOURCE IS
CONNECTED TO IT. WEAR SAFETY GLASSES
066RW030
SUPPLEMENTAL RESTRAINT SYSTEM 9J–21
THROUGHOUT THIS ENTIRE DEPLOYMENT AND 19. Twist together one connector wire lead to one
DISPOSAL PROCEDURE. deployment wire. The connection should be
mechanically secure.
9. Twist together one connector wire lead to one
deployment wire. The connection should be 20. Bend twisted connection made in the previous step
mechanically secure. flat and wrap tightly with electrical tape to insulate and
secure.
10. Bend twisted connection made in the previous step
flat and wrap tightly with electrical tape to insulate and 21. Twist together, bend and tape the remaining
secure. connector wire lead to the remaining deployment
wire.
11. Twist together, bend and tape the remaining
connector wire lead to the remaining deployment 22. Connect the deployment harness to the passenger air
wire. bag assembly, yellow 2–pin connector located behind
the glove box assembly. Route deployment harness
12. Connect the deployment harness to the driver air bag
out the passenger side of the vehicle.
assembly, yellow 2–pin connector at the base of the
steering column. Route deployment harness out the WARNING: DEPLOYMENT WIRES SHALL REMAIN
driver side of the vehicle. SHORTED AND NOT BE CONNECTED TO A POWER
SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED.
WARNING: DEPLOYMENT WIRES SHALL REMAIN
THE AIR BAG ASSEMBLY WILL IMMEDIATELY
SHORTED AND NOT BE CONNECTED TO A POWER
DEPLOY THE AIR BAG WHEN A POWER SOURCE IS
SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED.
CONNECTED TO IT. CONNECTING THE
THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOYMENT WIRES SHOULD ALWAYS BE THE
DEPLOY THE AIR BAG WHEN A POWER SOURCE IS FINAL STEP IN THE AIR BAG ASSEMBLY
CONNECTED TO IT. DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW
PROCEDURES IN THE ORDER LISTED COULD
CONNECTING THE DEPLOYMENT WIRES TO THE RESULT IN PERSONAL INJURY.
POWER SOURCE SHOULD ALWAYS BE THE FINAL
STEP IN THE AIR BAG ASSEMBLY DEPLOYMENT 23. Verify that the inside of the vehicle and the area
PROCEDURE. surrounding the vehicle are clear of all people and
loose or flammable objects.
FAILURE TO FOLLOW PROCEDURES IN THE
24. Stretch the driver and passenger deployment
ORDER LISTED COULD RESULT IN PERSONAL
harness to their full length.
INJURY.
25. Completely cover windshield area and front door
13. Disconnect passenger air bag assembly, yellow 2–pin window openings with a drop cloth, blanket or similar
connector located behind glove box assembly. item. This reduces the possibility of injury due to
14. Cut the passenger air bag assembly harness possible fragmentation of the vehicle’s glass or
connector from the vehicle leaving at least 15 cm (six interior.
inches) of wire at the connector. 26. Notify all people in the immediate area that you intend
15. Strip 13 mm (1/2 inch) of insulation from blue–white to deploy the air bags. The deployment will be
and pink–blue wire lead of the connector. accompanied by a substantial noise which may
16. Cut two 900 cm (30 feet) deployment wires from 0.8 startle the uninformed.
mm (18 gauge) or thicker multi–strand wire. These 27. Separate the two ends of the driver deployment
wires will be used to fabricate the passenger harness wires.
deployment harness.
WARNING: DEPLOYMENT WIRES SHALL REMAIN
17. Strip 13 mm (1/2 inch) of insulation from both ends of SHORTED AND NOT BE CONNECTED TO A POWER
the wires cut in the previous step. SOURCE UNTIL THE AIR BAG IS TO A POWER
18. Short the wires by twisting together one end from SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED.
each. Deployment wires shall remain shorted and not THE AIR BAG ASSEMBLY WILL IMMEDIATELY
be connected to a power source until the air bag is to DEPLOY THE AIR BAG WHEN A POWER SOURCE IS
be deployed. CONNECTED TO IT. CONNECTING THE
WARNING: FAILURE TO FOLLOW PROCEDURES IN DEPLOYMENT WIRES TO THE POWER SOURCE
THE ORDER LISTED COULD RESULT IN PERSONAL SHOULD ALWAYS BE THE FINAL STEP IN THE AIR
INJURY. NEVER CONNECT DEPLOYMENT WIRES BAG ASSEMBLY DEPLOYMENT PROCEDURE.
TO ANY POWER SOURCE BEFORE CONNECTING FAILURE TO FOLLOW PROCEDURES IN THE
DEPLOYMENT WIRES TO THE AIR BAG ASSEMBLY ORDER LISTED COULD RESULT IN PERSONAL
LEADS. DEPLOYMENT WIRES SHALL REMAIN INJURY.
SHORTED AND NOT BE CONNECTED TO A POWER NOTE: When the air bag deploys, the rapid gas
SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. expansion will create a substantial noise. Notify all
THE AIR BAG ASSEMBLY WILL IMMEDIATELY people in the immediate area that you intend to deploy the
DEPLOY THE AIR BAG WHEN A POWER SOURCE IS air bags.
CONNECTED TO IT. WEAR SAFETY GLASSES
THROUGHOUT THIS ENTIRE DEPLOYMENT AND
DISPOSAL PROCEDURE.
9J–22 SUPPLEMENTAL RESTRAINT SYSTEM
28. Connect the driver deployment harness wires to a PROCEDURES COULD RESULT IN FIRE OR
power source to immediately deploy the driver air bag PERSONAL INJURY.
assembly. Recommended application: 12 volts After an air bag assembly has been deployed, the
minimum, 2 amps minimum. A vehicle battery is metal canister and surrounding areas of the air bag
suggested. assembly will be very hot. Do not touch the metal
29. Separate the two ends of the passenger deployment areas of the air bag assembly for about 30 minutes
harness wires. after deployment. If the deployed air bag assembly
WARNING: DEPLOYMENT WIRES SHALL REMAIN must be moved before it is cool, wear gloves and
SHORTED AND NOT BE CONNECTED TO A POWER handle by the air bag or trim cover.
SOURCE UNTIL THE AIR BAG IS TO A POWER 31. Short the driver deployment harness wires by twisting
SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. together one end from each. Repeat this procedure
THE AIR BAG ASSEMBLY WILL IMMEDIATELY for the passenger deployment harness.
DEPLOY THE AIR BAG WHEN A POWER SOURCE IS 32. Carefully remove drop cloth from vehicle and clean off
CONNECTED TO IT. CONNECTING THE any fragments or discard drop cloth entirely.
DEPLOYMENT WIRES TO THE POWER SOURCE
33. Disconnect driver deployment harness and
SHOULD ALWAYS BE THE FINAL STEP IN THE AIR
passenger deployment harness from vehicle and
BAG ASSEMBLY DEPLOYMENT PROCEDURE.
discard.
FAILURE TO FOLLOW PROCEDURES IN THE
ORDER LISTED COULD RESULT IN PERSONAL 34. In the unlikely event that either or both of the air bag
INJURY. assemblies did not deploy after following these
procedures, proceed immediately with Steps 36
30. Connect the passenger deployment harness wires to through 37. If the air bag assembly deployed, proceed
a power source to immediately deploy the passenger to step 35.
air bag assembly. Recommended application: 12
35. With both air bags deployed, the vehicle may be
volts minimum, 2 amps minimum. A vehicle battery is
scrapped in the same manner as a non–SRS
suggested.(Driver air bag assembly) Put on a pair of
equipped vehicle.
shop gloves and safety glasses to protect your hands
and eyes from possible irritation and heat when NOTE: The remaining steps are to be followed in the
handling the deployed air bag assembly. After the air unlikely event that the air bag assembly did not deploy
bag assembly has been deployed, the surface of the after following these procedures.
air bag may contain solid particulate. This solid 36. Remove the undeployed air bag assembly (s) from
particulate consists primarily of by products of the the vehicle. For driver air bag assembly refer to in the
chemical reaction, Potassium Chloride and copper “Passenger Air Bag Assembly Removal” in this
metal dust. Compounds of Potassium Borate, manual.
Strontium Chloride, Copper Chloride, and
Ammonium Chloride may be found in amounts of WARNING: WHEN STORING A LIVE AIR BAG
about 1 % (each) of the total particulate. ASSEMBLY OR WHEN LEAVING A LIVE AIR BAG
(Passenger air bag assembly) ASSEMBLY UNATTENDED ON A BENCH OR OTHER
Put on a pair of shop gloves and safety glasses to SURFACE, ALWAYS FACE THE BAG AND TRIM
protect your hands and eyes from possible irritation COVER UP, AWAY FROM THE SURFACE. THIS IS
and heat when handling the deployed air bag NECESSARY SO THAT A FREE SPACE IS PROVIDED
assembly. TO ALLOW THE AIR BAG TO EXPAND IN THE
UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT.
After the air bag assembly has been deployed, the FAILURE TO FOLLOW PROCEDURES COULD
surface of the air bag may contain a powdery residue. RESULT IN PERSONAL INJURY.
This powder consists primarily of cornstarch (used to
lubricate the bag as it inflates) and by products of the 37. Temporarily store the air bag assembly with the air
chemical reaction. Sodium hydroxide dust (similar to bag opening facing up, away from the surface upon
lye soap) is produced as a by product of the which it rests.
deployment reaction. The sodium hydroxide then
quickly reacts with atmospheric moisture and is Deployed Air Bag Assembly Handling
converted to sodium carbonate and sodium Put on a pair of shop gloves and safety glasses to protect
bicarbonate (baking soda). Therefore, it is unlikely your hands and eyes from possible irritation and heat
that sodium hydroxide will be present after when handling the deployed air bag assembly.
deployment. After the air bag assembly has been deployed, the
WARNING: SAFETY PRECAUTIONS MUST BE surface of the air bag may contain a powdery residue.
OBSERVED WHEN HANDLING A DEPLOYED AIR (Passenger air bag assembly)
BAG ASSEMBLY. AFTER DEPLOYMENT, THE After the air bag assembly has been deployed, the
METAL SURFACES OF THE AIR BAG ASSEMBLY surface of the air bag may contain a powdery residue.
WILL BE VERY HOT. ALLOW THE AIR BAG This powder consists primarily of cornstarch (used to
ASSEMBLY TO COOL BEFORE HANDLING ANY lubricate the bag as it inflates) and by products of the
METAL PORTION OF IT. DO NOT PLACE THE HOT chemical reaction. Sodium hydroxide dust (similar to lye
DEPLOYED AIR BAG ASSEMBLY NEAR ANY soap) is produced as a by product of the deployment
FLAMMABLE OBJECTS. FAILURE TO FOLLOW reaction. The sodium hydroxide then quickly reacts with
atmospheric moisture and is converted to sodium
SUPPLEMENTAL RESTRAINT SYSTEM 9J–23
carbonate and sodium bicarbonate (baking soda).
Therefore, it is unlikely that sodium hydroxide will be
present after deployment.
(Driver air bag assembly)
After the air bag assembly has been deployed, the
surface of the air bag may contain solid particulate. This
solid particulate consists primarily of by products of the
chemical reaction, Potassium Chloride and copper metal
dust. Compounds of Potassium Borate, Strontium
Chloride, Copper Chloride, and Ammonium Chloride may
be found in amounts of about 1 % (each) of the total
particulate.

Deployment Outside Vehicle (Pretensioner


Seat Belt Assembly)
Deployment outside the vehicle is proper when the
vehicle is to be returned to service. This includes, for
example, situations in which the vehicle will be returned to
useful service after a functionally or cosmetically deficient
901HV009
pretensioner seat belt assembly is replaced. Deployment
4. Short the two SRS deployment harness leads
and disposal of a malfunctioning pretensioner seat belt together by fully seating one banana plug into the
assembly is, of course, subject to any required retention other. SRS deployment harness shall remain shorted
period. and not be connected to a power source until the
For deployment of a live (undeployed) pretensioner seat pretensioner seat belt is to be deployed.
belt assembly outside the vehicle, the deployment
5. Place the pretensioner seat belt assembly on a work
procedure must be followed exactly. Always wear gloves bench or other surface away from all loose or
and safety glasses during this deployment procedure until flammable objects.
a deployed pretensioner seat belt assembly is scrapped
or until an undeployed pretensioner seat belt assembly is WARNING: WHEN FIXING THE DEPLOYMENT
shipped. Before performing the procedures you should DEVICE OF PRETENSIONER SEAT BELT, THE
be familiar with servicing the system and with proper DEPLOYMENT DEVICE SHOULD BE FIXED AWAY
handling of the pretensioner seat belt assembly. FROM OTHER PERSON
Procedures should be read fully before they are 6. Clear a space on the ground about 183 cm (six feet) in
performed. diameter where the pretensioner seat belt assembly
The following procedure requires use of SRS deployment is to be deployed. A paved, outdoor location where
harness with appropriate pigtail adapter. Do not attempt there is no activity is preferred. If an outdoor location
procedure without adapter. is not available, a space on the shop floor where there
WARNING: FAILURE TO FOLLOW PROCEDURES IN is no activity and sufficient ventilation is
THE ORDER LISTED MAY RESULT IN PERSONAL recommended. Ensure no loose or flammable
INJURY. NEVER CONNECT DEPLOYMENT objects are within the deployment area.
HARNESS TO ANY POWER SOURCE BEFORE 7. Stretch the SRS deployment harness and pigtail
CONNECTING DEPLOYMENT HARNESS TO THE adapter from the pretensioner seat belt assembly to
PRETENSIONER SEAT BELT ASSEMBLY. its full length.
DEPLOYMENT HARNESS SHALL REMAIN 8. Place a power source near the shorted end of the
SHORTED AND NOT BE CONNECTED TO A POWER SRS deployment harness. Recommended
SOURCE UNTIL THE PRETENSIONER SEAT BELT IS application: 12 volts minimum, 2 amps minimum. A
TO BE DEPLOYED. THE PRETENSIONER SEAT vehicle battery is suggested.
BELT ASSEMBLY WILL IMMEDIATELY DEPLOY THE 9. Deployment harness shall remain shorted and not be
PRETENSIONER SEAT BELT WHEN A POWER connected to a power source until the pretensioner
SOURCE IS CONNECTED TO IT. WEAR GLOVES seat belt is to be deployed. The pretensioner seat belt
AND SAFETY GLASSES THROUGHOUT THIS assembly will immediately deploy the pretensioner
ENTIRE DEPLOYMENT AND DISPOSAL seat belt when a power source is connected to it.
PROCEDURE.
10. Verify that the area around the pretensioner seat belt
1. Turn ignition switch to “LOCK”, remove key. assembly is clear of all people and loose or flammable
2. Remove the pretensioner seat belt assembly from objects.
vehicle. Refer to “Pretensioner Seat Belt Removal” in 11. Notify all people in the immediate area that you intend
this manual. to deploy the driver air bag. The deployment will be
3. Prepare SRS deployment harness. accompanied by a substantial noise which may
startle the uninformed.
12. Connect the pretensioner seat belt to the pigtail
adapter on the SRS deployment harness.
9J–24 SUPPLEMENTAL RESTRAINT SYSTEM
NOTE: Ensure that the pigtail adapter is firmly seated into SEAT BELT ASSEMBLY MUST BE MOVED BEFORE
the pretensioner seat belt assembly connector. Failure to IT IS COOL, WEAR GLOVES AND HANDLE BY THE
fully seat the connectors may leave the shorting bar PRETENSIONER SEAT BELT OR TRIM COVER.
located in the pretensioner seat belt assembly connector
19. Disconnect the pigtail adapter from the pretensioner
functioning (shorted) and may result in nondeployment of
seat belt assembly as soon after deployment as
the pretensioner seat belt assembly.
possible. This will prevent damage to the pigtail
13. Separate the two banana plugs on the SRS adapter or SRS deployment harness due to possible
deployment harness. contact with the hot pretensioner seat belt assembly
NOTE: When the pretensioner seat belt deploys, the canister. The pigtail adapter can be reused. They
rapid gas expansion will create a substantial noise. Notify should, however, be inspected for damage after each
all people in the immediate area that you intend to deploy deployment and replaced if necessary.
the pretensioner seat belt. 20. Dispose of the deployed pretensioner seat belt
assembly through normal refuse channels after it has
WARNING: DEPLOYMENT HARNESS SHALL cooled for at least 30 minutes.
REMAIN SHORTED AND NOT BE CONNECTED TO A 21. Wash your hands with mild soap and water afterward.
POWER SOURCE UNTIL THE PRETENSIONER SEAT
BELT IS TO BE DEPLOYED. THE PRETENSIONER NOTE: The remaining steps are to be followed in the
SEAT BELT ASSEMBLY WILL IMMEDIATELY unlikely event that the pretensioner seat belt assembly
DEPLOY THE PRETENSIONER SEAT BELT WHEN A did not deploy after following these procedures.
POWER SOURCE IS CONNECTED TO IT. 22. Ensure that the SRS deployment harness has been
CONNECTING THE DEPLOYMENT HARNESS TO disconnected from the power source and that its two
THE POWER SOURCE SHOULD ALWAYS BE THE banana plugs have been shorted together by fully
LAST STEP IN THE PRETENSIONER SEAT BELT seating one banana plug into the other.
ASSEMBLY DEPLOYMENT PROCEDURE. FAILURE
TO FOLLOW PROCEDURES IN THE ORDER LISTED 23. Disconnect the pigtail adapter from the pretensioner
MAY RESULT IN PERSONAL INJURY. seat belt assembly.
24. Remove the undeployed pretensioner seat belt from
14. Connect the SRS deployment harness wires to the the special tool.
power source to immediately deploy the pretensioner
seat belt. Recommended application: 12 volts WARNING: WHEN STORING A LIVE
minimum, 2 amps minimum. A vehicle battery is PRETENSIONER SEAT BELT ASSEMBLY OR WHEN
suggested. LEAVING A LIVE INFLATOR MODULE UNATTENDED
15. Disconnect the SRS deployment harness from the ON A BENCH OR OTHER SURFACE, ALWAYS PUT
power source. THE PRETENSIONER SEAT BELT HORIZONTAL
PLACE. THIS IS NECESSARY SO THAT A FREE
16. Short the two SRS deployment harness leads SPACE IS PROVIDED TO ALLOW THE
together by fully seating one banana plug into the PRETENSIONER SEAT BELT TO SHRINK IN THE
other. UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT.
17. In the unlikely event that the pretensioner seat belt FAILURE TO FOLLOW PROCEDURES MAY RESULT
assembly did not deploy after following these IN PERSONAL INJURY.
procedures, proceed immediately with Steps 21
through 24. If the pretensioner seat belt assembly did 25. Temporarily store the pretensioner seat belt
deploy, proceed with Steps 15 through 20. assembly with its deployment device facing up, away
from the surface upon which it rests.
18.
WARNING: SAFETY PRECAUTIONS MUST BE Deployment Inside Vehicle (Pretensioner
OBSERVED WHEN HANDING A DEPLOYED Seat Belt Vehicle Scrapping Procedure)
PRETENSIONER SEAT BELT ASSEMBLY. AFTER Deployment inside vehicle is proper when the vehicle is to
DEPLOYMENT, THE METAL SURFACES OF THE be destroyed. This includes, but is not limited to, the
PRETENSIONER SEAT BELT ASSEMBLY WILL BE following situations:
VERY HOT. ALLOW THE INFLATOR MODULE TO
COOL BEFORE HANDLING ANY METAL PORTION 1. The vehicle has completed its useful life.
OF IT. DO NOT PLACE THE DEPLOYED 2. The vehicle has been damaged beyond repair in a
PRETENSIONER SEAT BELT ASSEMBLY NEAR ANY nondeployment type accident.
FLAMMABLE OBJECTS. FAILURE TO FOLLOW 3. The vehicle has been stripped or damaged beyond
PROCEDURES MAY RESULT IN FIRE OR PERSONAL repair in a theft.
INJURY.
NOTE: The vehicle will be salvaged for component parts
AFTER A DRIVER PRETENSIONER SEAT BELT to be used on a vehicle with a different Vehicle
ASSEMBLY HAS BEEN DEPLOYED, THE METAL Identification Number (VIN) as opposed to being rebuilt
CANISTER AND SURROUNDING AREAS OF THE as same VIN. Never use pretensioner seat belt
DRIVER PRETENSIONER SEAT BELT ASSEMBLY components from another vehicle.
WILL BE VERY HOT. DO NOT TOUCH THE METAL
WARNING: FAILURE TO FOLLOW PROCEDURES IN
AREAS OF THE PRETENSIONER SEAT BELT THE ORDER LISTED COULD RESULT IN PERSONAL
ASSEMBLY FOR ABOUT TEN MINUTES AFTER INJURY. NEVER CONNECT DEPLOYMENT WIRES
DEPLOYMENT. IF THE DEPLOYED PRETENSIONER
SUPPLEMENTAL RESTRAINT SYSTEM 9J–25
TO ANY POWER SOURCE BEFORE CONNECTING 13. Connect the SRS deployment harness wires to a
DEPLOYMENT WIRES TO THE PRETENSIONER power source to immediately deploy the pretensioner
SEAT BELT ASSEMBLY LEADS. DEPLOYMENT seat belt assembly. Recommended application: 12
WIRES SHALL REMAIN SHORTED AND NOT BE volts minimum, 2 amps minimum. A vehicle battery is
CONNECTED TO A POWER SOURCE UNTIL THE suggested.
PRETENSIONER SEAT BELT IS TO BE DEPLOYED.
WARNING: DEPLOYMENT WIRES SHALL REMAIN
THE PRETENSIONER SEAT BELT ASSEMBLY WILL
SHORTED AND NOT BE CONNECTED TO A POWER
IMMEDIATELY DEPLOY THE PRETENSIONER SEAT
SOURCE UNTIL THE PRETENSIONER SEAT BELT IS
BELT WHEN A POWER SOURCE IS CONNECTED TO
TO IS TO BE DEPLOYED. THE PRETENSIONER
IT. WEAR SAFETY GLASSES THROUGHOUT THIS
SEAT BELT ASSEMBLY WILL IMMEDIATELY
ENTIRE DEPLOYMENT AND DISPOSAL
DEPLOY THE PRETENSIONER SEAT BELT WHEN A
PROCEDURE.
POWER SOURCE IS CONNECTED TO IT.
1. Turn ignition switch to “LOCK,” remove key and put CONNECTING THE DEPLOYMENT WIRES SHOULD
on safety glasses. ALWAYS BE THE FINAL STEP IN THE
2. Remove all loose objects from front seats. PRETENSIONER SEAT BELT ASSEMBLY
DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW
3. Disconnect pretensioner seat belt assembly, yellow PROCEDURES IN THE ORDER LISTED COULD
2–pin connector located at the base of the seat. RESULT IN PERSONAL INJURY.
4. Prepare SRS deployment harness.
14. Short the two SRS deployment harness leads
5. Short the two SRS deployment harness leads together by fully seating one banana plug into the
together by fully seating one banana plug into the other.
other.
15. Disconnect the deployment harness to the
6. Deployment harness shall remain shorted and not be pretensioner seat belt assembly, yellow 2-pin
connected to a power source until the pretensioner connector at the base of the seat.
seat belt is to be deployed.
16. In the unlikely event that the pretensioner seat belt
7. Route deployment harness out the driver side of the assembly did not deploy after following these
vehicle. procedures, proceed immediately with Steps 18
8. Verify that the inside of the vehicle and the area through 19. If the pretensioner seat belt assembly
surrounding the vehicle are clear of all people and deployed as intended, proceed with Steps 14 through
loose or flammable objects. 17.
9. Stretch the SRS deployment harness to their full 17. With both air bags and pretensioner seat belt
length. deployed, the vehicle may be scrapped in the same
10. Connect the deployment harness to the pretensioner manner as a non–SRS equipped vehicle.
seat belt assembly, yellow 2-pin connector at the NOTE: The remaining steps are to be followed in the
base of the seat. unlikely event that the pretensioner seat belt assembly
WARNING: DEPLOYMENT WIRES SHALL REMAIN did not deploy after following these procedures.
SHORTED AND NOT BE CONNECTED TO A POWER 18. Remove the undeployed pretensioner seat belt
SOURCE UNTIL THE PRETENSIONER SEAT BELT IS assembly (s) from the vehicle. For pretensioner seat
TO BE DEPLOYED. THE PRETENSIONER SEAT belt assembly refer to in the “Pretensioner Seat Belt
BELT ASSEMBLY WILL IMMEDIATELY DEPLOY THE Assembly Removal” in this manual.
PRETENSIONER SEAT BELT WHEN A POWER
19. Temporarily store the pretensioner seat belt
SOURCE IS CONNECTED TO IT. CONNECTING THE
assembly with the deployment device facing up, away
DEPLOYMENT WIRES TO THE POWER SOURCE
from the surface upon which it rests.
SHOULD ALWAYS BE THE FINAL STEP IN THE
PRETENSIONER SEAT BELT ASSEMBLY
DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW
PROCEDURES IN THE ORDER LISTED COULD
RESULT IN PERSONAL INJURY.
11. Notify all people in the immediate area that you intend
to deploy the pretensioner seat belt. The deployment
will be accompanied by a substantial noise which may
startle the uninformed.
12. Separate the two banana plugs on the SRS
deployment harness.
NOTE: When the pretensioner seat belt deploys, the
rapid gas expansion will create a substantial noise. Notify
all people in the immediate area that you intend to deploy
the pretensioner seat belt.
9J–26 SUPPLEMENTAL RESTRAINT SYSTEM

Special Tools
WARNING: TO AVOID DEPLOYMENT WHEN tool should be used only when specifically called for in the
TROUBLESHOOTING THE SRS, DO NOT USE diagnostic procedures.
ELECTRICAL TEST EQUIPMENT SUCH AS A
NOTE: If comand to use 5–8840–2421–0 load tool when
BATTERY–POWERED OR AC–POWERED
repair the pretensioner seat belt, connect load tool
VOLTMETER, OHMMETER, ETC., OR ANY TYPE OF
connector to use for driver air bag and/or passenger air
ELECTRICAL EQUIPMENT OTHER THAN THAT
bag connector.
SPECIFIED IN THIS MANUAL. DO NOT USE A
NONPOWERED PROBE–TYPE TESTER.
INSTRUCTIONS IN THIS MANUAL MUST BE 5–8840–0285–0 DVM
FOLLOWED CAREFULLY, OTHERWISE PERSONAL
INJURY MAY RESULT.
5–8840–2421–0 SRS Driver/Passenger
Load Tool

901RS153

The 5–8840–0285–0 DVM is the preferred DVM for use in


SRS diagnosis and repair. However, 5–8840–0366–0
may be used if 5–8840–0285–0 is not available. No other
DVMs are approved for SRS diagnosis and repair.

Scan Tool
901RS146

The SRS Driver/Passenger Load Tool 5–8840–2421–0 is


used only when called for in this section. It is used as a
diagnostic aid and safety device to prevent inadvertent air
bag assembly deployment.
The load tool has three yellow connectors attached to its
case.
The three small connectors are electrically functional and
serve as resistive load substitutions.
No more than two connectors are used at any time. One
of the small connectors is used to substitute for the load of
the driver air bag assembly when it is connected at the top
of the column to the SRS coil assembly. Another small
connector is used to substitute for the load of the driver air
bag assembly and the SRS coil assembly when it is
connected at the base of the column to the SRS wiring
harness. The third small connector is used to substitute
for the load of the passenger air bag assembly and
pretensioner seat belt assembly when connected to the
passenger air bag assembly and pretensioner seat belt
assembly harness connector.
By substituting the resistance of the load tool when called 901RW176

for, a determination can be made as to whether an inflator The Tech 2 is used to read and clear SRS Diagnostic
circuit component is causing system malfunction and Trouble Codes (DTCs). Refer to the Tech 2 Operators,
which component is causing the malfunction. The load Manual for specific information on how to use the Tech 2.
SUPPLEMENTAL RESTRAINT SYSTEM 9J–27
5–8840–0385–0 Connector Test Adapter 5–8840–2420–0 SRS Deployment Fixture
Kit

901RW199

901RS151
The 5–8840–2420–0 SRS Deployment Fixture must be
The 5–8840–0385–0 Connector Test Adapter Kit must be used for deployment of the undeployed passenger side
used whenever a diagnostic procedure requests air bag.
checking or probing a terminal. Using the appropriate
adapter will ensure that no damage to the terminal will 5–8840–2469–0 SRS Adapter for Load
occur from the DVM prove, such as spreading or bending. Tool.
The adapter will also give an idea of whether contact
tension is sufficient, helping to find an open or intermittent
open due to poor terminal contact.

5–8840–2468–0 SRS Deployment Tool

901RW107

The 5–8840–2469–0 SRS Adapter for Load Tool must be


used with 5–8840–2421–0 SRS Driver/Passenger Load
Tool.

901RW106

The 5–8840–2468–0 SRS Deployment Tool must be


used for deployment of the undeployed air bag, and/or
pretensioner seat belt.
9J–28 SUPPLEMENTAL RESTRAINT SYSTEM
Tech 2 Scan Tool 3. Connect the DLC cable to the Tech 2 (5)
From 98 MY, Isuzu dealer service departments are 4. Make sure of the vehicle ignition is off.
recommended to use Tech 2. Please refer to Tech 2 scan 5. Connect the Tech 2 SAE 16/19 adapter to the vehicle
tool user guide. ALDL/DLC connector.

901RW200 060RW220

Legend Legend
(1) PCMCIA Card (1) For RHD model
(2) RS 232 Loop Back Connector (2) For LHD model
(3) SAE 16/19 Adaptor
(4) DLC Cable 6. Turn on the vehicle ignition switch.
(5) Tech–2 7. Verify the Tech 2 power up display.

Getting Started
Before operating the Isuzu PCMCIA card with the
Tech 2, the following steps must be performed:
1. Insert the Isuzu 98 System PCMCIA card (1) into the
Tech 2 (5).
2. Connect the SAE 16/19 adapter (3) to the DLC cable
(4).

060RW009

NOTE: The RS232 Loop back connector is only used to


diagnosis Tech 2. Refer to user guide of the Tech 2.
SUPPLEMENTAL RESTRAINT SYSTEM 9J–29
Operating Procedure
The power up screen is displayed when you power up the
tester with the Isuzu systems PCMCIA card. Follow the
operating procedure below.

060RW019

060RX038
9J–30 SUPPLEMENTAL RESTRAINT SYSTEM

Service Precautions for SRS 2. Install glove box assembly. Refer to “Passenger Air
Bag Assembly Replacement” in this section.
Component Service 3. Connect yellow 2–pin connector at the base of the
CAUTION: When fasteners are removed, always steering column.
reinstall them at the same location from which they 4. Install “AIR BAG” fuse “C–21” to left dash side lower
were removed. If a fastener needs to be replaced, use fuse block or connect battery.
the correct part number fastener for that application. Turn ignition switch to “ON” and verify that the “AIR BAG”
If the correct part number fastener is not available, a warning lamp turn on 3.5 seconds and then turns “OFF.” If
fastener of equal size and strength (or stronger) may it does not operate as described, perform the “SRS
be used. fasteners that are not reused, and those Diagnostic System Check” in this section.
requiring thread locking compound will be called
out. The correct torque value must be used when Handling / Installation / Diagnosis
installing fasteners that require it. If the above
conditions are not followed, parts or system damage 1. Air bag assembly should not be subjected to
could result. temperatures above 93 C (200 F).
2. Air bag assembly, and SDM should not be used if they
WARNING: WHEN PERFORMING SERVICE ON OR have been dropped from a height of 100 centimeters
AROUND SRS COMPONENTS OR SRS WIRING, (3.28 feet) or more.
FOLLOW THE PROCEDURES LISTED BELOW TO
TEMPORARILY DISABLE THE SRS. FAILURE TO 3. When a SDM is replaced, it must be oriented with the
FOLLOW PROCEDURES COULD RESULT IN arrow on the SDM pointing toward the front of the
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL vehicle. It is very important for the SDM to be located
INJURY OR OTHERWISE UNNEEDED SRS REPAIRS. flat on the mounting surface, parallel to the vehicle
datum line. It is important that the SDM mounting
The SDM in Driver–Passenger SRS can maintain surface is free of any dirt or other foreign material.
sufficient voltage to cause a deployment for up to 15
seconds after the ignition switch is turned “OFF,” the 4. Do not apply power to the SRS unless all components
battery is disconnected, or the fuse powering the SDM is are connected or a diagnostic chart requests it, as
removed. this will set a diagnostic trouble code.
Many of the service procedures require removal of the 5. The “SRS Diagnostic System Check” must be the
“C–21” fuse, and disconnection of the air bag assembly starting point of any SRS diagnostics. The “SRS
from the deployment loop to avoid an accidental Diagnostic System Check” will verify proper “AIR
deployment. If the air bag assembly is disconnected from BAG” warning lamp operation and will lead you to the
the deployment loop as noted in the “Disabling the SRS” correct chart to diagnose any SRS malfunctions.
procedure that follows, service can begin immediately Bypassing these procedures may result in extended
without waiting for the 15 second time period to expire. diagnostic time, incorrect diagnosis, and incorrect
parts replacements.
Disabling The SRS
Removal Inspections Required After An Accident
Turn the ignition switch to “OFF” and turn the steering CAUTION: Certain SRS components must be
wheel so that the vehicle’s wheels are pointing straight replaced after a frontal crash involving air bag
ahead. deployment.
1. Remove SRS fuse “C–21” from left dash side lower In all types of accidents regardless of “Air Bag”
fuse block or disconnect battery. deployment, visually inspect all of the following
2. Disconnect yellow 2–pin connector at the base of components and replace as required:
steering column. — Driver air bag assembly
3. Remove glove box assembly; Refer to “Passenger air — Passenger air bag assembly
bag assembly replacement” in this section. — Driver pretensioner assembly
4. Disconnect passenger air bag assembly yellow 2–pin — Passenger pretensioner assembly
connector behind the glove box assembly. — Steering wheel
CAUTION: With the “C–21” fuse removed and — SRS coil assembly
ignition switch “ON,” the “AIR BAG” warning lamp — Steering column
will be “ON.” This is normal operation and does not
indicate an SRS malfunction. — Knee bolster and instrument panel mounting
attachments
Enabling The SRS — Driver seat and belt
— Passenger seat and belt
Installation
— SDM
Turn ignition switch to “LOCK” and remove key.
SDM always should be checked according to “SDM
1. Connect yellow 2–pin connector passenger air bag
Replacement Guidelines.”
assembly.
SUPPLEMENTAL RESTRAINT SYSTEM 9J–31
CAUTION: Refer to “SDM Replacement Guidelines”
below for important information on SDM
replacement in both deployment and
non–deployment crashes.
Inspect SRS coil assembly wiring and steering wheel for
any sign of scorching, melting, or damage due to
excessive heat. If coil assembly wire or steering wheel is
damaged, replace them. The steering column and wheel
must be dimensionally checked to determine if they are
damaged. Refer to steering wheel of in this manual.
Never use SRS parts from another vehicle. This does not
include remanufactured parts purchased from an
authorized Isuzu Retailer; they may be used for SRS
repairs.
Do not attempt to repair the SDM, the SRS harness, the
SRS coil assembly, the air bag assembly, the steering
wheel, or the steering column. Service of these items is
replacement only. Verify replacement part numbers.
CAUTION: Proper operation of the SDM and
supplemental restraint system (SRS) requires that
any repairs to the vehicle structure return it to its
original production configuration.
SRS Connectors
CAUTION: The special yellow color connectors are
used for supplemental restraint system air bag circuit.
When removing the oable harnese, do not pull the cables
otherwile, cable disconnection may occur. When connect
the SRS connector, insert the connector completely.
Imperfect locking may cause malfunction of SRS circuit.
Removal
To remove the connector, hold the cover insulator (1) and
pull it. The cover insulator slides and lock will be released.
Do not hold the socket insulator (2).

827RW028
9J–32 SUPPLEMENTAL RESTRAINT SYSTEM
Installation
To install the connector, hold the socket insulator (1) and
insert it. The cover insulator slides and connector will be
locked. Do not hold the cover insulator (2).

827RW027
SUPPLEMENTAL RESTRAINT SYSTEM 9J–33

Sensing And Diagnostic Module (SDM)


Service Precautions
WARNING: DURING SERVICE PROCEDURES, BE
VERY CAREFUL WHEN HANDLING SDM. NEVER
STRIKE OR JAR SDM. UNDER SOME
CIRCUMSTANCES, IT COULD CAUSE
DEPLOYMENT AND RESULT IN PERSONAL INJURY
OR IMPROPER OPERATION OF THE
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) . SDM
MOUNTING BRACKET BOLTS MUST BE
CAREFULLY TORQUED TO ASSURE PROPER
OPERATION. NEVER POWER UP THE SRS WHEN
SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE.
THE SDM COULD BE ACTIVATED WHEN POWERED
WHILE NOT RIGIDLY ATTACHED TO THE VEHICLE
WHICH COULD CAUSE DEPLOYMENT AND RESULT
IN PERSONAL INJURY.
WARNING: PROPER OPERATION OF THE SENSING
AND DIAGNOSTIC MODULE (SDM) REQUIRES THE
SDM TO BE RIGIDLY ATTACHED TO THE VEHICLE 827RW044

STRUCTURE AND THAT THE ARROW ON THE Legend


SENSOR BE POINTING TOWARD THE FRONT OF (1) SDM
THE VEHICLE. (2) SRS Harness
SDM is specifically calibrated and is keyed to the SDM (3) Connector Position Assurance
location SRS wiring harness. Caution should be used to
ensure proper location of the SDM. The keying of the
SDM to its location and wiring harness connectors should
never be modified in the field. Installation
1. Install the SDM on bracket and fixing bolts and tighten
Removal the fixing bolts to the specified torque.
Torque: 10 Nꞏm (1.0 Kgꞏm/87 Ib in)
1. Disable the SRS (Refer to “Disabling the SRS” in this
section). 2. Connect the SDM harness connector and after that,
2. Remove the transmission knob (for M/T) and transfer put CPA into connector.
lever knob. 3. Install the front console.
3. Remove the front console assembly and disconnect 4. Install the transmission knob (for M/T) and transfer
wiring harness connector. lever knob.
4. Pull CPA (Connector Position Assurance) out and
push connector lock down to disconnect the SDM
harness connector.
5. Remove the three SDM fixing bolts and remove SDM.
9J–34 SUPPLEMENTAL RESTRAINT SYSTEM
5. Enable the SRS (Refer to “Enabling the SRS” in this
section).

827RW044

Legend
(1) SDM
(2) SRS Harness
(3) Connector Position Assurance
SUPPLEMENTAL RESTRAINT SYSTEM 9J–35

Driver Air Bag Assembly


Service Precautions
WARNING: SAFETY PRECAUTIONS MUST BE
FOLLOWED WHEN HANDLING A DEPLOYED AIR
BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR
BAG ASSEMBLY SURFACE MAY CONTAIN A SMALL
AMOUNT OF SODIUM HYDROXIDE, A BY–PRODUCT
OF THE DEPLOYMENT REACTION, THAT IS
IRRITATING TO THE SKIN AND EYES. MOST OF THE
POWER ON THE AIR BAG ASSEMBLY IS
HARMLESS. AS A PRECAUTION, WEAR GLOVES
AND SAFETY GLASSES WHEN HANDLING A
DEPLOYED AIR BAG ASSEMBLY, AND WASH YOUR
HANDS WITH MILD SOAP AND WATER
AFTERWARDS.
WARNING: WHEN CARRYING A LIVE AIR BAG
ASSEMBLY, MAKE SURE THE BAG AND TRIM
COVER ARE POINTED AWAY FROM YOU. NEVER
CARRY AIR BAG ASSEMBLY BY THE WIRES OR
CONNECTOR ON THE UNDERSIDE OF MODULE. IN 827RT008

THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE 3. Disconnect the yellow 2–pin connector located
BAG WILL THEN DEPLOY WITH MINIMAL CHANCE behind the air bag assembly and remove air bag
OF INJURY. WHEN PLACING ALIVE AIR BAG assembly. Refer to “SRS Connectors” in this section
ASSEMBLY ON A BENCH OR OTHER SURFACE, for removal and installation.
ALWAYS FACE BAG AND TRIM COVER UP, AWAY
FROM THE SURFACE. NEVER REST A STEERING
COLUMN ASSEMBLY ON THE STEERING WHEEL
WITH THE AIR BAG ASSEMBLY FACE DOWN AND
COLUMN VERTICAL. THIS IS NECESSARY SO THAT
A FREE SPACE IS PROVIDED TO ALLOW THE AIR
BAG ASSEMBLY TO EXPAND IN THE UNLIKELY
EVENT OF ACCIDENTAL DEPLOYMENT.
OTHERWISE, PERSONAL INJURY COULD RESULT.
NOTE: In the event deployment has occurred, inspect
coil assembly wire for any signs of scorching, melting or
any other damage due to excessive heat. If the coil has
been damaged, replace it.

Removal
1. Disable the SRS (Refer to “Disabling the SRS” in this
section).
2. Loosen the air bag assembly fixing bolts from behind 827RT009
the steering wheel assembly using a TORX driver or
equivalent until the air bag assembly can be released
from steering wheel.
9J–36 SUPPLEMENTAL RESTRAINT SYSTEM

Installation
1. Connect air bag to wiring harness connector.
NOTE: Pass the lead wire through the tabs on the plastic
cover (wire protector) of air bag to prevent lead wire from
being pinched.

827RT009

2. Install air bag into steering wheel and tighten bolts to


specified sequence as shown in figure.
Torque: 8.8 Nꞏm (0.9 Kgꞏm/78 Ib in)
CAUTION: Never use the air bag assembly from
another vehicle. Use only new air bag assembly
proper to the Trooper which is being repaired.

827RT008

3. Enable the SRS (Refer to “Enabling the SRS” in this


section).
SUPPLEMENTAL RESTRAINT SYSTEM 9J–37

Steering Wheel
Service Precautions
WARNING: SAFETY PRECAUTIONS MUST BE
FOLLOWED WHEN HANDLING A DEPLOYED AIR
BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR
BAG ASSEMBLY SURFACE MAY CONTAIN A SMALL
AMOUNT OF SODIUM HYDROXIDE, A BY–PRODUCT
OF THE DEPLOYMENT REACTION, THAT IS
IRRITATING TO THE SKIN AND EYES. MOST OF THE
POWER ON THE AIR BAG ASSEMBLY IS
HARMLESS. AS A PRECAUTION, WEAR GLOVES
AND SAFETY GLASSES WHEN HANDLING A
DEPLOYED AIR BAG ASSEMBLY, AND WASH YOUR
HANDS WITH MILD SOAP AND WATER
AFTERWARDS.
WARNING: WHEN CARRYING A LIVE AIR BAG
ASSEMBLY, MAKE SURE THE BAG AND TRIM
COVER ARE POINTED AWAY FROM YOU. NEVER
CARRY AIR BAG ASSEMBLY BY THE WIRES OR
CONNECTOR ON THE UNDERSIDE OF MODULE. IN 827RT008

THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE 3. Disconnect the yellow 2–pin connector located
BAG WILL THEN DEPLOY WITH MINIMAL CHANCE behind the air bag assembly and remove air bag
OF INJURY. WHEN PLACING ALIVE AIR BAG assembly.Refer to “SRS Connectors” in this section
ASSEMBLY ON A BENCH OR OTHER SURFACE, for removal and installation.
ALWAYS FACE BAG AND RIM COVER UP, AWAY 4. Disconnect horn lead.
FROM THE SURFACE. NEVER REST A STEERING
COLUMN ASSEMBLY ON THE STEERING WHEEL
WITH THE AIR BAG ASSEMBLY FACE DOWN AND
COLUMN VERTICAL. THIS IS NECESSARY SO THAT
A FREE SPACE IS PROVIDED TO ALLOW THE AIR
BAG ASSEMBLY TO EXPAND IN THE UNLIKELY
EVENT OF ACCIDENTAL DEPLOYMENT.
OTHERWISE, PERSONAL INJURY COULD RESULT.
NOTE: In the event deployment has occurred, inspect
coil assembly wire for any signs of scorching, melting or
any other damage due to excessive heat. If the coil has
been damaged, replace it.

Removal
1. Disable the SRS (Refer to “Disabling the SRS” in this
section).
2. Loosen the air bag assembly fixing bolts from behind
the steering wheel assembly using a TORX driver or
equivalent until the air bag assembly can be released 827RT009

from steering wheel. 5. Remove steering wheel attachment nut.


9J–38 SUPPLEMENTAL RESTRAINT SYSTEM
6. Apply a setting mark across the steering wheel and Installation
shaft so parts can be reassembled in their original
position. 1. Install the steering wheel and align the setting marks.

430RS004 430RS004

7. Move the tires to the straight ahead position before 2. Tighten the steering wheel fixing nut to the specified
removing the steering wheel. Install steering wheel torque.
puller onto steering wheel and remove steering wheel Torque : 34 Nꞏm (3.5 Kgꞏm/25 Ib ft)
with 5–8521–0016–0.
3. Connect horn lead.
4. Connect air bag to wiring harness connector.
NOTE: Pass the lead wire through the tabs on the plastic
cover (wire protector) of air bag to prevent lead wire from
being pinched.

430RT009

8. Feed wiring through the wheel and remove wheel.


CAUTION: Never apply force to the steering wheel
in direction of the shaft by using a hammer or other
impact tools in an attempt to remove the steering
wheel. The steering shaft is designed as an energy 827RT009

absorbing unit.
SUPPLEMENTAL RESTRAINT SYSTEM 9J–39
5. Install air bag into steering wheel and tighten bolts to 6. Enable the SRS (Refer to “Enabling the SRS” in this
specified sequence as show in figure. section).
Torque: 8.8 Nꞏm (0.9 Kgꞏm/78 Ib in)
CAUTION: Never use the air bag assembly from
another vehicle. Use only new air bag assembly
proper to the Trooper which is being repaired.

827RT008

SRS Coil Assembly


Service Precautions NOTE: In the event deployment has occurred, inspect
coil assembly wire for any signs of scorching, melting or
WARNING: SAFETY PRECAUTIONS MUST BE any other damage due to excessive heat. If the coil has
FOLLOWED WHEN HANDLING A DEPLOYED AIR been damaged, replace it.
BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR
BAG ASSEMBLY SURFACE MAY CONTAIN A SMALL
AMOUNT OF SODIUM HYDROXIDE, A BY–PRODUCT Removal
OF THE DEPLOYMENT REACTION, THAT IS 1. Disable the SRS (Refer to “Disabling the SRS” in this
IRRITATING TO THE SKIN AND EYES. MOST OF THE section).
POWER ON THE AIR BAG ASSEMBLY IS 2. Loosen the air bag assembly fixing bolts from behind
HARMLESS. AS A PRECAUTION, WEAR GLOVES the steering wheel assembly using a TORX driver or
AND SAFETY GLASSES WHEN HANDLING A equivalent until the air bag assembly can be released
DEPLOYED AIR BAG ASSEMBLY, AND WASH YOUR from steering wheel.
HANDS WITH MILD SOAP AND WATER
AFTERWARDS.
WARNING: WHEN CARRYING A LIVE AIR BAG
ASSEMBLY, MAKE SURE THE BAG AND TRIM
COVER ARE POINTED AWAY FROM YOU. NEVER
CARRY AIR BAG ASSEMBLY BY THE WIRES OR
CONNECTOR ON THE UNDERSIDE OF MODULE. IN
THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE
BAG WILL THEN DEPLOY WITH MINIMAL CHANCE
OF INJURY. WHEN PLACING ALIVE AIR BAG
ASSEMBLY ON A BENCH OR OTHER SURFACE,
ALWAYS FACE BAG AND RIM COVER UP, AWAY
FROM THE SURFACE. NEVER REST A STEERING
COLUMN ASSEMBLY ON THE STEERING WHEEL
WITH THE AIR BAG ASSEMBLY FACE DOWN AND
COLUMN VERTICAL. THIS IS NECESSARY SO THAT
A FREE SPACE IS PROVIDED TO ALLOW THE AIR
BAG ASSEMBLY TO EXPAND IN THE UNLIKELY
EVENT OF ACCIDENTAL DEPLOYMENT.
OTHERWISE, PERSONAL INJURY COULD RESULT.
827RT008
9J–40 SUPPLEMENTAL RESTRAINT SYSTEM
3. Disconnect the yellow 2–pin connector located 7. Move the tires to the straight ahead position before
behind the air bag assembly and remove air bag removing the steering wheel and remove wheel with
assembly.Refer to “SRS Connectors” in this section 5–8521–0016–0.
for removal and installation.
4. Disconnect horn lead connector.

430RT009

8. Feed wiring though the wheel and remove wheel.


827RT009 9. Remove the steering lower cover and engine hood
5. Remove the steering wheel attachment nut. opening lever.
6. Apply a setting mark across the steering wheel and 10. Remove the driver knee bolster assembly.
shaft so parts can be reassembled in their original 11. Remove the steering column cover.
position.
12. Remove air conditioning lower duct.
13. Disconnect the 12–pin wiring harness connectors
located at the base of steering column.
CAUTION: Never apply force to the steering wheel
in the direction of the shaft by using a hammer or
other impact tools in an attempt to remove the
steering wheel. The steering shaft is designed as an
energy absorbing unit.
14. Remove the combination switch assembly with SRS
coil.

430RS004
SUPPLEMENTAL RESTRAINT SYSTEM 9J–41

Installation 6. Install the driver knee bolster assembly.


7. Install the steering lower cover and engine hood
1. Install the combination switch assembly with SRS opening lever.
coil.
8. Install the steering wheel and align the setting marks.
2. Turn the SRS coil counterclockwise to full, return
about 3 turns and align the neutral mark (1).
CAUTION: When turning the SRS coil
counterclockwise to full, stop turning if resistance is
felt. Forced further turning may damage the cable in
the SRS coil.

430RS004

9. Tighten the steering wheel fixing nut to the specified


torque.
Torque: 34 Nꞏm (3.5 Kgꞏm/25 Ib ft)
10. Connect horn lead.
826RW014 11. Connect air bag to wiring harness connector.
3. Connect the wiring harness connectors located at the NOTE: Pass the lead wire through the tabs on the plastic
base of steering column. cover (wire protector) of air to prevent lead wire from
4. Install the air conditioning lower duct. being pinches.
5. Install the steering column cover.
CAUTION: When installing the steering column
cover, be sure to wire (through each harness) as
illustrated so that the harness starter switch,
combination switch and SRS coil may not catch
wiring.

827RT009

12. Install air bag into steering wheel and tighten bolts to
specified sequence as shown in figure.
Torque: 8.8 Nꞏm (0.9 Kgꞏm/78 Ib in)

825RS048
9J–42 SUPPLEMENTAL RESTRAINT SYSTEM
CAUTION: Never use the air bag assembly from 13. Enable the SRS (Refer to “Enabling the SRS” in this
another vehicle. Use only new air bag assembly section).
proper to the Trooper which is being repaired.

827RT008

SRS Coil Replacement Procedure


Removal 3. Remove four bolts of SRS coil assembly and remove
the SRS coil assembly from the combination switch.
1. Same removal steps until step 13 of SRS Coil
Assembly Removal.
2. Disconnect the horn terminal NO.12 from connector
and remove the tape binding harness. (Refer to How
to Disconnect the horn terminal in this section.)

825RX033

827RX029
SUPPLEMENTAL RESTRAINT SYSTEM 9J–43

How to Disconnect the horn terminal How to Connect Horn Terminal


1. Lift the terminal lock plate from upper portion of 1. Insert horn terminal from behind black connector
connector with a minitenes screw driver (-) and NO.12 until connector lock works.
release connector terminal lock.

827RX047

827RX045
Legend
Legend (1) Terminal
(1) Minitenes screw driver (-) (2) Connector lock knob
(2) Connector lock knob
2. Push terminal lock plate into the connector for a duble
2. Pull out the terminal of lead wire coming to connector lock.
NO.12 while lifting the lock part with a minitenes
screw driver (-).

827RX048

827RX046

Legend
(1) Lock
(2) Minitenes screw driver (-)
(3) Terminal
9J–44 SUPPLEMENTAL RESTRAINT SYSTEM

Installation 2. Insert the horn terminal into the connector NO.12 and
bind the combination switch harness and SRS coil
1. Set cancel cam and SRS coil in position and install the harness with a tape. (Refer to How to Connect the
SRS coil to combination switch by tightening the four Horn Terminal in this section.)
bolts to a specified tightening torque with four bolts. 3. After installation steps above, same steps as SRS
Torque: 0.5 Nꞏm (0.05 kgꞏm/4 Ib ft) Coil Assembly installation step 2 to step 13.

825RX033

Steering Column
Service Precautions NOTE: In the event deployment has occurred, inspect
coil assembly wire for any signs of scorching, melting or
WARNING: SAFETY PRECAUTIONS MUST BE any other damage due to excessive heat. If the coil has
FOLLOWED WHEN HANDLING A DEPLOYED AIR been damaged, replace it.
BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR
BAG ASSEMBLY SURFACE MAY CONTAIN A SMALL
AMOUNT OF SODIUM HYDROXIDE, A BY–PRODUCT Removal
OF THE DEPLOYMENT REACTION, THAT IS 1. Disable the SRS (Refer to “Disabling the SRS ” in this
IRRITATING TO THE SKIN AND EYES. MOST OF THE section).
POWER ON THE AIR BAG ASSEMBLY IS
HARMLESS. AS A PRECAUTION, WEAR GLOVES 2. Loosen the air bag assembly fixing bolts from behind
AND SAFETY GLASSES WHEN HANDLING A the steering wheel assembly using a TORX driver or
DEPLOYED AIR BAG ASSEMBLY, AND WASH YOUR equivalent until the air bag assembly can be released
HANDS WITH MILD SOAP AND WATER from steering wheel.
AFTERWARDS.
WARNING: WHEN CARRYING A LIVE AIR BAG
ASSEMBLY, MAKE SURE THE BAG AND TRIM
COVER ARE POINTED AWAY FROM YOU. NEVER
CARRY AIR BAG ASSEMBLY BY THE WIRES OR
CONNECTOR ON THE UNDERSIDE OF MODULE. IN
THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE
BAG WILL THEN DEPLOY WITH MINIMAL CHANCE
OF INJURY. WHEN PLACING ALIVE AIR BAG
ASSEMBLY ON A BENCH OR OTHER SURFACE,
ALWAYS FACE BAG AND RIM COVER UP, AWAY
FROM THE SURFACE. NEVER REST A STEERING
COLUMN ASSEMBLY ON THE STEERING WHEEL
WITH THE AIR BAG ASSEMBLY FACE DOWN AND
COLUMN VERTICAL. THIS IS NECESSARY SO THAT
A FREE SPACE IS PROVIDED TO ALLOW THE AIR
BAG ASSEMBLY TO EXPAND IN THE UNLIKELY
EVENT OF ACCIDENTAL DEPLOYMENT.
OTHERWISE, PERSONAL INJURY COULD RESULT.
827RT008
SUPPLEMENTAL RESTRAINT SYSTEM 9J–45
3. Disconnect the yellow 2–pin connector located 7. Move the tires to the straight ahead position before
behind the air bag assembly and remove air bag removing the steering wheel and removing wheel with
assembly.Refer to “SRS Connectors” in this section 5–8521–0016–0.
for removal and installation.

430RT009

827RT009 8. Feed wiring though the wheel and remove wheel.


4. Disconnect horn lead connector. 9. Remove the steering lower cover and engine hood
5. Remove the steering wheel attachment nut. opening lever.
6. Apply a setting mark across the steering wheel and 10. Remove the driver knee bolster assembly.
shaft so parts can be reassembled in their original
position.

740RT015

11. Remove the steering column cover.


430RS004
12. Remove air conditioning lower duct.
13. Disconnect the wiring harness connectors located at
the base of steering column.
CAUTION: Never apply force to the steering wheel
in direction of the shaft by using a hammer or other
impact tools in an attempt to remove the steering
wheel. The steering shaft is designed as an energy
absorbing unit.
14. Remove the combination switch assembly with SRS
coil.
9J–46 SUPPLEMENTAL RESTRAINT SYSTEM
NOTE: SRS coil is a part of combination switch 2. Tighten the steering column fixing bolts (dash panel
assembly, which cannot be replaced separately. side) to the specified torque.
Therefore, be sure not to remove the SRS coil from the Torque: 19 Nꞏm (1.9 Kgꞏm/14 Ib ft)
combination switch assembly.
3. Tighten the steering column fixing bolts (Pedal
15. Remove the snap ring. bracket) to the specified torque.
16. Remove the cushion rubber.
Torque: 17 Nꞏm (1.7 Kgꞏm/13 Ib ft)
17. Disconnect shift lock cable (A/T only).
4. Tighten the universal joint to the specified torque.
18. Disconnect the starter switch harness connector
located base of steering column. Torque: 25 Nꞏm (2.6 Kgꞏm/18 Ib ft)
19. Remove steering lock cylinder assembly. 5. Install steering lock cylinder assembly.
20. Apply a setting mark across the universal joint and 6. Connect shift lock cable (For A/T)
steering shaft to reassemble the parts in their original 7. Install cushion rubber.
position. 8. Install snap ring.
9. Install the combination switch assembly with SRS
coil.
10. Connect the wiring harness connector located on the
base of steering column.
11. Turn the SRS coil counterclockwise to full, return
about 3 turns and align the neutral mark (1).
CAUTION: When turning the SRS coil
counterclockwise to full, stop turning if resistance is
felt. Forced further turning may damage to the cable
in the SRS coil.

431RS013

21. Remove steering column assembly.

Installation
1. Install the steering column assembly and align the
setting marks on the universal joint and steering shaft
made during removal.

826RW014

431RS013
SUPPLEMENTAL RESTRAINT SYSTEM 9J–47
12. Install steering column cover. 15. Connect horn lead.
CAUTION: When installing the steering column 16. Connect air bag wiring harness connector.
cover, be sure to wire (through each harness) as NOTE: Pass the lead wire through the tabs on the plastic
illustrated so that the harness starter switch, cover (wire protector) of air bag to prevent lead wire from
combination switch and SRS coil may not catch being pinched.
wiring.

827RT009
825RS048
17. Install air bag into steering wheel and tighten bolts to
13. Install the steering wheel and align the setting marks. specified sequence as shown in figure.
Torque: 8 Nꞏm (0.8 Kgꞏm/69 Ib in)
CAUTION: Never use the air bag assembly from
another vehicle. Use only the air bag assembly
proper to the Trooper which is being repaired.

430RS004

14. Tighten the steering wheel fixing nut to the specified


torque.
Torque: 34 Nꞏm (3.5 Kgꞏm/25 Ib ft)

827RT008

18. Enable the SRS (Refer to “Enabling the SRS” in this


section).
9J–48 SUPPLEMENTAL RESTRAINT SYSTEM

Passenger Air Bag Assembly


Service Precautions 1. Disable the SRS (Refer to “Disabling the SRS ” in this
section).
WARNING: SAFETY PRECAUTIONS MUST BE 2. Remove gear control knob.
FOLLOWED WHEN HANDLING A DEPLOYED AIR
3. Remove front console assembly.
BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR
BAG ASSEMBLY SURFACE MAY CONTAIN A SMALL 4. Remove rear console assembly and disconnect
AMOUNT OF SODIUM HYDROXIDE, A BY–PRODUCT harness connector.
OF THE DEPLOYMENT REACTION, THAT IS 5. Remove ECM and SDM cover.
IRRITATING TO THE SKIN AND EYES. MOST OF THE 6. Remove glove box assembly with lid.
POWER ON THE AIR BAG ASSEMBLY IS
7. Remove glove box cover.
HARMLESS. AS A PRECAUTION, WEAR GLOVES
AND SAFETY GLASSES WHEN HANDLING A 8. Remove instrument panel assist side lower cover.
DEPLOYED AIR BAG ASSEMBLY, AND WASH YOUR 9. Disconnect engine hood opener lever.
HANDS WITH MILD SOAP AND WATER 10. Remove instrument panel door side lower cover.
AFTERWARDS.
11. Remove lower cluster with ashtray.
WARNING: WHEN CARRYING A LIVE AIR BAG 12. Remove meter cluster assembly and disconnect
ASSEMBLY, MAKE SURE THE BAG AND TRIM harness connector.
COVER ARE POINTED AWAY FROM YOU. NEVER 13. Remove instrument panel lower center cover.
CARRY AIR BAG ASSEMBLY BY THE WIRES OR
CONNECTOR ON THE UNDERSIDE OF MODULE. IN 14. Disconnect passenger air bag assembly harness
THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE connector.
BAG WILL THEN DEPLOY WITH MINIMAL CHANCE 15. Remove air bag assembly fixing bolts and nuts.
OF INJURY. WHEN PLACING ALIVE AIR BAG 16. Remove passenger air bag assembly.
ASSEMBLY ON A BENCH OR OTHER SURFACE,
ALWAYS FACE BAG AND RIM COVER UP, AWAY
FROM THE SURFACE. NEVER REST A STEERING Installation
COLUMN ASSEMBLY ON THE STEERING WHEEL
WITH THE AIR BAG ASSEMBLY FACE DOWN AND
COLUMN VERTICAL. THIS IS NECESSARY SO THAT
A FREE SPACE IS PROVIDED TO ALLOW THE AIR
BAG ASSEMBLY TO EXPAND IN THE UNLIKELY
EVENT OF ACCIDENTAL DEPLOYMENT.
OTHERWISE, PERSONAL INJURY COULD RESULT.
NOTE: IN THE EVENT DEPLOYMENT HAS
OCCURRED, INSPECT COIL ASSEMBLY WIRE FOR
ANY SIGNS OF SCORCHING, MELTING OR ANY
OTHER DAMAGE DUE TO EXCESSIVE HEAT. IF THE
COIL HAS BEEN DAMAGED, REPLACE IT.

Removal

827RS001

1. Install passenger air bag assembly.


2. Install air bag assembly fixing bolts, nuts and tighten
to specified torque.
Torque: 6 Nꞏm (0.6 Kgꞏm/52 Ib in)
3. Connect air bag assembly harness connector.
4. Install instrument panel lower center cover.
5. Install meter cluster assembly and connect harness
connector.
6. Install lower cluster with ashtray.
7. Install instrument panel door side lower cover.
8. Connect engine hood opener lever.
9. Install instrument panel assist side lower cover.
827RS001
SUPPLEMENTAL RESTRAINT SYSTEM 9J–49
10. Install glove box cover. 14. Install front console assembly.
11. Install glove box assembly with lid. 15. Install gear control knob.
12. Install ECM and SDM cover. 16. Enable the SRS (Refer to “Enabling the SRS” in this
13. Install rear console assembly and connect harness section).
connector.

Pretensioner Seat Belt (If so equipped)


Service Precaution Legend
(1) Seat
WARNING: WHEN PERFORMING SERVICE ON OR (2) Pretensioner Cover
AROUND THE PRETENSIONER SEAT BELT OR THE
(3) Bolt
PRETENSIONER SEAT BELT WIRING, FOLLOW THE
PROCEDURES LISTED BELOW TO TEMPORARILY (4) Pretensioner Harness
DISABLE THE PRETENSIONER SEAT BELT. (5) Pretensioner
FAILURE TO FOLLOW PROCEDURES COULD
RESULT IN POSSIBLE THE PRETENSIONER SEAT
BELT DEPLOYMENT, PERSONAL INJURY OR Removal
OTHERWISE UNNEEDED THE PRETENSIONER
SEAT BELT REPAIR. 1. Turn ignition switch to “LOCK”, remove key.
AS A PRECAUTION, WEAR GLOVES AND SAFETY 2. Remove the foot rest located behind the seat.
GLASSES WHEN PERFORMING THE 3. Remove the cover on seat slide.
PRETENSIONER SEAT BELT. WHEN DEPLOY A LIVE 4. Disconnect the 2-pin connector at the base of the
PRETENSIONER SEAT BELT AT OUTSIDE THE seat.
VEHICLE, DEPLOYMENT HARNESS SHALL REMAIN 5. Remove four fixing bolts the seat slide and remove
SHORTED AND NOT BE CONNECTED TO A POWER seat.
SOURCE UNTIL THE PRETENSIONER SEAT BELT IS 6. Remove the pretensioner seat belt cover.
TO BE DEPLOYED. THE PRETENSIONER SEAT
7. Remove the pretensioner seat belt assembly.
BELT WILL IMMEDIATELY DEPLOY WHEN A POWER
SOURCE IS CONNECTED TO IT. CONNECTING THE
DEPLOYMENT HARNESS SHOULED ALWAYS BE Installation
THE FINAL STEP IN THE PRETENSIONER SEAT
1. Install the pretensioner seat belt assembly.
BELT DEPLOYMENT PROCEDURE. FAILURE TO
FOLLOW PROCEDURES IN THE ORDER LISTED 2. Install the pretensioner seat belt cover.
COULD RESULT IN PERSONAL INJURY. 3. Install the seat on seat slide and four fixing bolts.
4. Connect the yellow 2-pin connector at the base of the
seat.
Parts Location
5. Install the cover on seat slide.
6. Install the foot rest located behind the seat.

760RW028
9J–50 SUPPLEMENTAL RESTRAINT SYSTEM

Main Data and Specifications


Fastener Tightening Specification
Application Nꞏm Kgꞏm Lb Ft Lb In.
SDM 10 1.0 — 87
Driver air bag fixing bolt 8.8 0.9 — 78
Steering wheel fixing bolt 34 3.5 25 —
Steering column (dash panel side fixing bolts) 19 1.9 14 —
Steering column (Pedal bracket fixing bolt) 17 1.7 13 —
Steering column (Universal joint fixing bolt) 25 2.6 18 —
Passenger Air Bag fixing bolts and nuts 6 0.6 — 52
RESTRAINT CONTROL SYSTEM 9J1–1

RESTRAINT CONTROL SYSTEM


CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 9J1–1 DTC 51 Air Bag Deployment Event
Diagnostic Information . . . . . . . . . . . . . . . . . . . 9J1–2 Commanded . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J1–35
System Schematic . . . . . . . . . . . . . . . . . . . . . . 9J1–4 DTC 53 Deployment Commanded With
SRS Diagnostic System Check . . . . . . . . . . . . 9J1–4 Deployment Loop Fault Or Energy
Chart A SDM Integrity Check . . . . . . . . . . . . . 9J1–6 Reserves Out Of Range . . . . . . . . . . . . . . . . . 9J1–37
Chart B “AIR BAG” Warning Lamp DTC 61 Warning Lamp Circuit Failure . . . . . 9J1–39
Comes “ON” Steady . . . . . . . . . . . . . . . . . . . . 9J1–8 DTC 71 Internal SDM Fault . . . . . . . . . . . . . . 9J1–41
Chart C “AIR BAG” Warning Lamp DTC 29 Passenger Pretensioner Loop
Does Not Come “ON” Steady . . . . . . . . . . . . . 9J1–10 Short To Ground . . . . . . . . . . . . . . . . . . . . . . . . 9J1–43
DTC 15 Passenger Deployment Loop DTC 31 Passenger Pretensioner Loop
Resistance High . . . . . . . . . . . . . . . . . . . . . . . . 9J1–13 Resistance High . . . . . . . . . . . . . . . . . . . . . . . . 9J1–45
DTC 16 Passenger Deployment loop DTC 32 Passenger Pretensioner loop
Resistance Low . . . . . . . . . . . . . . . . . . . . . . . . 9J1–15 Resistance Low . . . . . . . . . . . . . . . . . . . . . . . . 9J1–47
DTC 17 Passenger Deployment Loop DTC 33 Passenger Pretensioner Loop
Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J1–17 Short To Voltage . . . . . . . . . . . . . . . . . . . . . . . . 9J1–49
DTC 18 Passenger Deployment Loop DTC 34 Passenger Pretensioner Loop
Short To Ground . . . . . . . . . . . . . . . . . . . . . . . . 9J1–19 Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J1–51
DTC 19 Passenger Deployment Loop DTC 41 Driver Pretensioner Loop
Short To B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J1–21 Resistance High . . . . . . . . . . . . . . . . . . . . . . . . 9J1–53
DTC 21 Driver Deployment Loop DTC 42 Driver Pretensioner Loop
Resistance High . . . . . . . . . . . . . . . . . . . . . . . . 9J1–23 Resistance Low . . . . . . . . . . . . . . . . . . . . . . . . 9J1–55
DTC 22 Driver Deployment Loop DTC 44 Driver Pretensioner Loop
Resistance Low . . . . . . . . . . . . . . . . . . . . . . . . 9J1–26 Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J1–57
DTC 24 Driver Deployment Loop DTC 45 Driver Pretensioner Loop
Short To Ground . . . . . . . . . . . . . . . . . . . . . . . . 9J1–29 Short To Ground . . . . . . . . . . . . . . . . . . . . . . . . 9J1–59
DTC 25 Driver Deployment Loop DTC 46 Driver Pretensioner Loop
Short To B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J1–31 Short To Voltage . . . . . . . . . . . . . . . . . . . . . . . . 9J1–61
DTC 26 Driver Deployment Loop Open . . . . 9J1–33 DTC 52 Pretensioner Deployment
Event Commanded . . . . . . . . . . . . . . . . . . . . . 9J1–63

Service Precaution CAUTION: Always use the correct fastener in the


proper location. When you replace a fastener, use
WARNING: IF SO EQUIPPED WITH A ONLY the exact part number for that application.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS), ISUZU will call out those fasteners that require a
REFER TO THE SRS COMPONENT AND WIRING replacement after removal. ISUZU will also call out
LOCATION VIEW IN ORDER TO DETERMINE the fasteners that require thread lockers or thread
WHETHER YOU ARE PERFORMING SERVICE ON OR sealant. UNLESS OTHERWISE SPECIFIED, do not
NEAR THE SRS COMPONENTS OR THE SRS use supplemental coatings (Paints, greases, or other
WIRING. WHEN YOU ARE PERFORMING SERVICE corrosion inhibitors) on threaded fasteners or
ON OR NEAR THE SRS COMPONENTS OR THE SRS fastener joint interfaces. Generally, such coatings
WIRING, REFER TO THE SRS SERVICE adversely affect the fastener torque and the joint
INFORMATION. FAILURE TO FOLLOW WARNINGS clamping force, and may damage the fastener. When
COULD RESULT IN POSSIBLE AIR BAG you install fasteners, use the correct tightening
DEPLOYMENT, PERSONAL INJURY, OR sequence and specifications. Following these
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. instructions can help you avoid damage to parts and
systems.
9J1–2 RESTRAINT CONTROL SYSTEM

Diagnostic Information detected since the SRS codes were last cleared during
service.
CAUTION: When fasteners are removed, always 1. Active Codes — Faults that are presently detected
reinstall them at the same location from which they this ignition cycle. Active codes are stored in RAM
were removed. if a fastener needs to be replaced, use (Random Access Memory).
the correct part number fastener for that application. 2. History Codes — All faults detected since the last
if the correct part number fastener is not available, a time the history fault memory was cleared. History
fastener of equal size and strength (or stronger) may codes are stored in EEPROM. (Electronically
be used. fasteners that are not reused, and those Erasable Programmable Read only Memory)
requiring thread locking compound will be called
out. the correct torque value must be used when How To Read Trouble Codes
installing fasteners that require it. if the above
conditions are not followed, parts or system damage All codes (Active and history) can be read (or cleared) by
could result. using a scan tool or equivalent.
If a PDT is not available, have the vehicle serviced by
Diagnostic Procedures ISUZU dealer.
WARNING: TO AVOID DEPLOYMENT WHEN
TROUBLESHOOTING THE SRS, DO NOT USE How To Clear Trouble Codes
ELECTRICAL TEST EQUIPMENT SUCH AS A Trouble codes can only be cleared by using a Scan Tool.
BATTERY–POWERED OR AC–POWERED If a “scan tool” is not available then inform the owner of the
VOLTMETER, OHMMETER, ETC., OR ANY TYPE OF stored codes and suggest that the codes are cleared
ELECTRICAL EQUIPMENT OTHER THAN THAT upon the next visit to an Isuzu dealership.
SPECIFIED IN THIS MANUAL. DO NOT USE A NON
POWERED, PROBE–TYPE TESTER. Scan Tool Diagnostics
INSTRUCTIONS IN THIS MANUAL MUST BE A scan tool can be used to read current and history codes
FOLLOWED CAREFULLY, OTHERWISE PERSONAL and to clear all history codes after a repair is complete.
INJURY MAY RESULT. The scan tool must be updated to communicate with the
The diagnostic procedures used in this section are SRS through a memory card or a manufacturer’s update
designed to aid in finding and repairing SRS problems. before it can be used for SRS diagnostics. To use the
Outlined below are the steps to find and repair SRS scan tool, connect it to the DLC connector and turn the
problems quickly and effectively. Failure to carefully ignition switch “ON”. Then follow the manufacturer’s
follow these procedures may result in extended directions for communication with the SRS. The scan tool
diagnostic time, incorrect diagnosis and incorrect parts reads serial data from the SDM “Serial Data” output
replacement. (terminal 24) to the DLC connector (terminal 9).
1. Perform The “SRS Diagnostic System Check”.
The “SRS Diagnostic System Check” should always Basic Knowledge Required
be the starting point of any SRS diagnostics. The Before using this section of the Service Manual, there is
“SRS Diagnostic System Check” checks for proper some basic knowledge which will be required. Without
“AIR BAG” warning lamp operation and checks for this knowledge, you will have trouble using the diagnostic
SRS trouble codes using both “Flash Code” and procedures in this section. Use care to prevent harm or
“Scan Tool” Methods. unwanted deployment. Read all cautions in the service
2. Refer To The Proper Diagnostic Chart As Directed manual and on warning labels attached to SRS
By The “SRS Diagnostic System Check”. components.
The “SRS Diagnostic System Check” will lead you to
the correct chart to diagnose any SRS problems. Basic Electrical Circuits
Bypassing these procedures may result in extended You should understand the basic theory of electricity
diagnostic time, incorrect diagnosis and incorrect including series and parallel circuits, and understand the
parts replacement. voltage drops across series resistors. You should know
3. Repeat The “SRS Diagnostic System Check” the meaning of voltage (volts), current (amps), and
After Any Repair Or Diagnostic Procedures Have resistance (ohms). You should understand what happens
Been Performed. in a circuit with an open or a shorted wire. You should be
Preforming the “SRS Diagnostic System Check” after able to read and understand a wiring diagram.
all repair or diagnostic procedures will assure that the
repair has been made correctly and that no other “Flash Code” Diagnostics
conditions exist. Flash code diagnostics can be used to read active codes
and to determine if history codes are present but cannot
Diagnostic Codes be used to clear codes or read history codes. Flash code
The Sensing and Diagnostic Module (SDM) maintains a diagnostics is enabled by grounding by terminal 4
history record of all diagnostic codes that have been shorting to terminal 13 of the DLC connector with the
ignition switch “ON”. Grounding terminal 4 of the DLC
connector pulls the “Diagnostics Request” input (Terminal
1) of the SDM low and signals the SDM to enter the flash
code diagnostic display mode.
RESTRAINT CONTROL SYSTEM 9J1–3
The SDM displays the trouble codes by flashing the
warning lamp. Each code that is displayed will consist of a
number of flashes which represents the tens digit, a 1.2
second pause, following by a number of flashes which
represents the ones digit of the code. Each code is
displayed one time before moving on to the next code.
After all of the codes have been displayed, the entire code
sequence will continually by repeated until ground is
removed from terminal 4 of the DLC connector.
Two special codes exist when reading in the flash code
mode (Flash Code 12 and Flash Code 13). “Flash Code
12“ will always be the first code displayed when the flash
code mode is enable Code 12 is not an indication of a SRS
problem but an indication that the flash code mode has
been enabled. If there are no active or history codes
present, the SDM will display code 12 until ground is
removed from the DLC connector at terminal 4. “flash
Code 13” will be displayed if history codes are present. To
read the history codes a scan tool must be used.
9J1–4 RESTRAINT CONTROL SYSTEM

System Schematic

D09RW014

SRS Diagnostic System Check Circuit Description


The diagnostic procedures used in this section are When the ignition switch is first turned “ON”, “Ignition 1”
designed to find and repair SRS malfunctions. To get the voltage is applied from the “C–21” fuse to the SDM at the
best results, it is important to use the diagnostic charts “Ignition 1” input terminals “12”. The SDM responds by
and follow the sequence listed below: flashing the “AIR BAG” warning lamp turn on 3.5 seconds,
A. Perform the “SRS Diagnostic System Check.” while performing tests on the SRS.
The “SRS Diagnostic System Check” must be the
starting point of any SRS diagnostics. The “SRS Notes On System Check Chart:
Diagnostic System Check” checks for proper “AIR 1. The “AIR BAG” warning lamp should turn on 3.5
BAG” warning lamp operation, the ability of the SDM seconds after ignition is first turned “ON”.
to communicate through the “Serial Data” line and 2. After the “AIR BAG” warning lamp turn on 3.5
whether SRS diagnostic trouble codes exist. seconds, it should turn “OFF”
B. Refer to the proper diagnostic chart as directed by the 3. This test checks for the proper operation of the
“SRS Diagnostic System Check.” “Serial Data” line. This test will also determine
The “SRS Diagnostic System Check” will lead you to whether history diagnostic trouble codes are stored
the correct chart to diagnose any SRS malfunctions. and, if so, identify them.
Bypassing these procedures may result in extended 4. Improper operation of the “AIR BAG” warning lamp
diagnostic time, incorrect diagnosis and incorrect is indicated. This test differentiates a warning lamp
parts replacement. stays “ON” condition from a warning lamp does not
C. Repeat the “SRS Diagnostic System Check” after any come “ON” condition.
repair or diagnostic procedures have been 5. This test checks for proper operation of the “Serial
preformed. Data” line. This test will also identify the stored
Performing the “SRS Diagnostic System Check” after diagnostic trouble codes and whether they are
all repair or diagnostic procedures will ensure that the current or history.
repair has been made correctly and that no other
malfunctions exist Diagnostic Aids:
The order in which diagnostic trouble codes are
diagnosed is very important. Failure to diagnose the
RESTRAINT CONTROL SYSTEM 9J1–5
diagnostic trouble codes in the order specified may result in extended diagnostic time, incorrect diagnosis and
incorrect parts replacement.

SRS Diagnostic System Check


Step Action Yes No
1 Note the “Air Bag” warning lamp as ignition switch is turned “ON.”
Does the “AIR BAG” warning lamp turn on 3.5 seconds? Go to Step 2 Go to Step 3
2 Note the “AIR BAG” warning lamp after it turn on 3.5 seconds.
Does the “AIR BAG” warning lamp go “OFF”? Go to Step 4 Go to Step 5
3 Note the “AIR BAG” warning lamp as ignition switch is turned
“ON”.
Does the “AIR BAG” warning lamp come “ON” steady? Go to Chart B Go to Chart C
4 1. Note the “AIR BAG” warning lamp as that ignition switch is Ignition switch
turned “ON.” “OFF”
Ignition switch “OFF.” When DTC 71 is
2. Connect a scan tool to data link connector. set, go to DTC 71
3. Follow direction given in the scan tool instruction manual. Chart
Ignition switch “ON.” For all other SRS is functional
4. Request the SRS diagnostic trouble code display, recode all history codes and free of
history diagnostic trouble code(s). specify as such, on repair refer to malfuncitons, no
order “Diagnostic Aids” further diagnosis
For that specific is required
Is (are) diagnostic trouble code(s) displayed?
DTC If scan tool
A history DTC indicated “NO
indicates the DATA
malfunction has RECEIVED,”
been repaired or refer to chassis
is intermittent electrical section8
5 1. Ignition switch “OFF.” Ignition switch
2. Connect a scan tool to data link connector. “OFF”
3. Follow directions as given in the scan tool instruction manual. When DTC 53 is
4. Ignition switch “ON.” set, go to DTC 53
5. Request the SRS diagnostic trouble code display, Recode all chart
diagnostic trouble code(s), specifying as current or history on
When DTC 51 is
repair order.
set, go to DTC 51
Is (are) diagnostic trouble code (s) displayed? chart
When DTC 19 is
set, go to DTC 19
chart
When DTC 25 is
set, go to DTC 25
chart
Diagnose
remaining current
DTCs from
lowest to highest
When only history
DTCs exist, refer
to “Diagnostics
Aids” for that
specific DTC
A history DTC If scan tool
indicates the indicates “No
malfunction has Data Received,”
been repaired or refer to chassis
is intermittent electrical section8
9J1–6 RESTRAINT CONTROL SYSTEM

Chart A SDM Integrity Check

D09RW014

Circuit Description: Chart Test Description:


When the SDM recognizes “Ignition 1” voltage, applied to Number(s) below refer to step number(s) on the
terminals “12”, is greater than 9 volts, the “AIR BAG” diagnostic chart:
warning lamp is turned on 3.5 seconds to verify operation. 1. This test confirms a current malfunction. If no
At this time the SDM performs “Turn–ON” tests followed current malfunction is occurring (history DTC set)
by “Continuous Monitoring” tests. When a malfunction is the “Diagnostic Aids” for the appropriate diagnostic
detected, the SDM sets a current diagnostic trouble code trouble code should be referenced. The SDM
and illuminates the “AIR BAG” warning lamp. The SDM should not be replaced for a history diagnostic
will clear current diagnostic trouble codes and move them trouble code.
to a history file when the malfunction is no longer detected 2. This test checks for a malfunction introduced into the
and/or the ignition switch is cycled, except for DTCs 19, SRS during the diagnostic process. It is extremely
25, 51, 53 and 71. DTC 71 can only be cleared using a unlikely that a malfunctioning SDM would cause a
scan tool “Clear Codes” command. If DTCs 51, 53 are not new malfunction to occur during the diagnostic
indicated then DTC 71 is not existing. DTCs 51, 53 and 71 process.
can not be cleared after a “Clear Codes” command is 3. When all circuitry outside the SDM has been found
issued. to operate properly, as indicated by the appropriate
diagnostic chart, then and only then should the SDM
be replaced.
RESTRAINT CONTROL SYSTEM 9J1–7

Chart A SDM Integrity Check


WARNING: DURING SERVICE PROCEDURES. BE VERY CAREFUL WHEN HANDLING A SENSING AND
DIAGNOSTIC MODULE (SDM). NEVER STRIKE OR JAR THE SDM. NEVER POWER UP THE SRS WHEN THE
SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SDM AND MOUNTING BRACKET FASTENERS MUST
BE CAREFULLY TORQUED AND THE ARROW MUST BE POINTING TOWARD THE FRONT OF THE VEHICLE
TO ENSURE PROPER OPERATION OF THE SRS. THE SDM COULD BE ACTIVATED WHEN POWERED WHILE
NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH COULD CAUSE DEPLOYMENT AND RESULT IN
PERSONAL INJURY.

Step Action Yes No


1 1. This chart assumes that the “SRS Diagnostic System Check”
and either a symptom chart or a diagnostic trouble code chart
diagnosis have been performed. When all circuitry outside the
SDM has been found to operate properly, as indicated by the
appropriate diagnostic chart, and the symptom or DTC
remains current, the following
2. Diagnostic procedures must be performed to verify the need
for SDM replacement. The symptom or
3. Ignition switch “OFF”. DTC is no longer
4. Reconnect all SRS components, ensure all components are occurring
properly mounted. Clear SRS
5. Ensure the ignition switch has been “OFF” for at least 15 diagnostic trouble
seconds. codes
6. Note “AIR BAG” warning lamp as ignition switch is turned
Repeat “SRS
“ON.”
Diagnostic
Does warning lamp turn on 3.5 seconds then go “OFF”? System Check” Go to Step 2
2 Using a scan tool request diagnostic trouble code display Ignition switch
“OFF”
Is the same symptom or DTC occurring as was when the “SRS
Diagnostic System Check ” was first performed? Go to the
appropriate chart
for the indicated
Go to Step 3 malfunction
3 1. Clear “SRS Diagnostic Trouble Codes”. SRS is functional
2. Ignition switch “OFF” for at least two minutes. and free of
3. Note “AIR BAG” warning lamp as ignition switch is turned malfunctions
“ON.” No further Ignition switch
diagnosis is “OFF”
Does warning lamp turn on 3.5 seconds then go “OFF”?
required Replace SDM
Go to Step 4 Go to Step 4
4 Reconnect all SRS components, ensure all components are
Repeat the “SRS
properly mounted.
Diagnostic
Was this step finished? System Check” Go to Step 4
9J1–8 RESTRAINT CONTROL SYSTEM

Chart B “AIR BAG” Warning Lamp Comes “ON” Steady

D09RW014

Circuit Description: Chart Test Description:


When the ignition switch is first turned “ON”, “Ignition 1” Number(s) below refer to step number(s) on the
voltage is applied from the “C–10” fuse to “AIR BAG”, diagnostic chart.
warning lamp which is connected to “SRS Warning 2. This test checks for an open in the “Ignition 1” circuit
Lamp”, terminal “7”. The “C–21” fuses apply system to the SDM.
voltage to the “Ignition 1” inputs, terminals “12”. The SDM 3. This test checks for the voltage of “IGNITION 1”.
responds by turning on the “AIR BAG” warning lamp 3.5
4. This test determines whether the malfunction is a
seconds. If “Ignition 1” is less than 9 volts, the “AIR BAG”
short to ground in IB04–WHT/RED.
warning lamp will come “ON” solid with no DTCs set.
RESTRAINT CONTROL SYSTEM 9J1–9

Chart B “AIR BAG” warning lamp comes “ON” Steady


Step Action Yes No
1 1. When measurements are requested in this chart use
5–8840–0285–0 DVM with correct terminal adapter from
5–8840–0385–0.
2. Ignition switch “OFF.”
3. Connect scan tool to data link connector, follow directions as
given in the scan tool instruction MANUAL.
4. Ignition switch “ON.”
5. Request SRS diagnostic trouble code display.
Dose scan tool indicate “No Data Received”? Go to Step 2 Go to Step 3
2 1. Ignition switch “OFF”. Connect SDM
2. Inspect SDM harness connector connection to SDM. securely to
de–activate
Is it securely connected to the SDM? Ignition switch shorting clip in
“OFF” SDM harness
Replace SDM connector
Go to Step 5 Go to Step 5
3 Using scan tool, request SRS data list. Ignition switch
“OFF”
Is “ignition” less than 9 volts?
Replace SDM
Go to Step 4 Go to Step 5
4 1. Ignition switch “OFF.”
2. Disconnect SRS coil and passenger air bag assemblies.
yellow 2–pin connector located at base of steering column and
behind the glove box assembly.
Disconnect SDM.
3. Disconnect the connector of “SRS Warning Lamp” of
instrument cluster.
4. Measure resistance from SDM harness connector terminal “7” Replace SRS
to ground “6”. harness
Does 5–8840–0285–0 display “OL” (Infinite)? Go to Chart A Go to Step 5
5 Reconnect all SRS components, ensure all components are
Repeat the “SRS
properly mounted.
Diagnostic
Was this step finished? System Check” Go to Step 5
9J1–10 RESTRAINT CONTROL SYSTEM

Chart C “AIR BAG” Warning Lamp Does Not Come “ON” Steady

D09RW014

Circuit Description: 2. This test determines whether the voltage is present


When the ignition switch is first turned “ON”, “Ignition 1” in the warning lamp circuit.
voltage is applied from the “C–10” fuse to the “AIR BAG” 3. This test determines if the malfunction is in the
warning lamp which is connected to “SRS Warning instrument cluster.
Lamp”, terminal “7”. The “C–21” fuse apply system 4. This test checks for open in the warning lamp
voltage to the “Ignition 1” inputs, terminals “12”. The SDM circuitry.
responds by turning on the “AIR BAG” warning lamp 3.5 5. This test isolates the IB04–WHT/RED circuit and
seconds. If “Ignition 1” is more than 16 volts, the “AIR checks for a short in the IB04–WHT/RED circuit to
BAG” warning lamp will be still “OFF” solid with no DTCs B+.
set. 8. This test checks for a short from the SDM warning
lamppower feed circuit to ground.
Chart Test description: 9. This test determines whether the short to ground is
Number(s) below refer to step number(s) on the due to a short in the wiring.
diagnostic chart:
1. This test decides whether power is available to SDM
warning lamp power feed circuit.
RESTRAINT CONTROL SYSTEM 9J1–11

Chart C “AIR BAG” Warning Lamp Does Not Come “ON” Steady
Step Action Yes No
1 1. When measurements are requested in this chart,use
5–8840–0285–0 DVM with correct terminal adapter from
5–8840–0385–0.
2. Ignition switch “OFF.”
3. Remove and inspect “C–10” fuse (meter) to the “AIR BAG”
warning lamp.
Is fuse good? Go to Step 2 Go to Step 7
2 1. Ignition switch “OFF.”
2. Disconnect SRS coil and passenger air bag assemblies.
Yellow 2–pin connector located at base of steering column and
behind the glove box assembly.
3. Disconnect SDM.
4. Ignition switch “ON.”
5. Measure voltage on SDM harness connector from terminal “7”
to terminal “6” (ground).
Is system voltage present on terminal “7”? Go to Step 4 Go to Step 3
3 1. Ignition switch “OFF.”
2. Remove instrument meter cluster.
3. Check for proper connection to instrument cluster at
IB04–WHT/RED terminal.
4. If ok, then remove and inspect “AIR BAG” bulb. Replace bulb
Is bulb good? Go to Step 5 Go to Step 6
4 1. Ignition switch “OFF.”
2. Disconnect instrument meter cluster harness connector.
3. Ignition switch “ON.”
4. Measure voltage on SDM harness connector from terminal “7” Replace SRS
to terminal “6” (GROUND). harness
Is voltage 1 volt or less? Go to Chart A Go to Step 6
5 1. Install bulb. Service
2. Measure resistance from instrument meter cluster harness instrument meter
connector IB04–WHT/RED terminal to SDM harness cluster
connector terminal “7”. Install instrument Replace SRS
Is resistance 5.0 ohms or less? meter cluster harness
Go to Step 6 Go to Step 6
6 Reconnect all SRS components, ensure all components are
Repeat the “SRS
properly mounted.
Diagnostic
Was this step finished? System Check” Go to Step 6
7 Perform chart C.
Was this step finished? Go to Step 8 Go to Step 1
8 1. Replace “C–10” fuse.
2. Ignition switch “ON” wait 10 Seconds then ignition switch “Off.” Install “C–10”
3. Remove and inspect “C–10” fuse. fuse
Is fuse good? Go to Step 10 Go to Step 9
9J1–12 RESTRAINT CONTROL SYSTEM

Chart C “AIR BAG” Warning Lamp Does Not Come “ON” Steady (Cont’d)
Step Action Yes No
9 1. Disconnect SRS coil and passenger air bag assemblies.
Yellow 2–pin connectors located at base of steering column
and behind the glove box assembly.
2. Disconnect SDM.
3. Replace “C–10” fuse. Replace SRS
4. Ignition switch “ON” wait 10 seconds. harness
5. Ignition switch “OFF”. Replace “C–10”
6. Remove and inspection “C–10” fuse. Install“C–10” fuse fuse
Is fuse good? Go to Chart A Go to Step 10
10 Reconnect all SRS components, ensure all components are
Repeat the “SRS
properly mounted.
Diagnostic
Was this step finished? System Check” Go to Step 10
RESTRAINT CONTROL SYSTEM 9J1–13

DTC 15 Passenger Deployment Loop Resistance High

D09RW014

Circuit Description: Action Taken:


When the ignition switch is turned “ON”, the SDM will SDM turns “ON” the “AIR BAG” warning lamp and sets a
perform tests to diagnose critical malfunctions within diagnostic trouble code.
itself. Upon passing these tests “Ignition 1”, and
deployment loop voltages are measured to ensure they DTC Will Clear When:
are within their respective normal voltage ranges. The The ignition switch is turned “OFF.”
SDM then proceeds with the “Resistance Measurement
Test”. “Passenger Bag Low” terminal “16” is grounded DTC Chart Test Description:
through a resister and the passenger current source Number(s) below refer to step number(s) on the
connected to “Passenger Bag High” terminal “15” allows a diagnostic chart:
known amount of current to flow. By monitoring the 2. This test determines whether the malfunction is in
voltage difference between “Passenger Bag High” and the SDM.
“Passenger Bag Low” the SDM calculates the combined
3. This test verifies proper connection of the yellow
resistance of the passenger air bag assembly, harness
2–pin connector.
wiring IB07–YEL/GRN and IB08–YEL/RED connector
terminal contact. 4. This test checks for proper contact and/or corrosion
of the yellow 2–pin connector terminals.
DTC Will Set When: 5. The test checks for a malfunctioning passenger air
The combined resistance of the passenger air bag bag assembly.
assembly, harness wiring IB07–YEL/GRN and 6. This test determines whether the malfunction is due
IB08–YEL/RED, and connector terminal contact is above to high resistance in the wiring.
a specified value. This test is run once each ignition cycle
during the “Resistance Measurement Test” when: Diagnostic Aids:
1. No “higher priority faults” are detected during An intermittent condition is likely to be caused by a poor
“Turn–ON”, connection at the passenger air bag assembly harness
2. “Ignition 1” voltage is in the specified value. connector terminals “1” and “2”, SDM terminal “15” and
“16”, or a poor wire to terminal connection in
IB07–YEL/GRN and IB08–YEL/RED. This test for this
diagnostic trouble code is only run while the “AIR BAG”
9J1–14 RESTRAINT CONTROL SYSTEM
warning lamp is performing the bulb check, unless DTC present, the DTC will not reappear until the next ignition
17 or DTC 26 is detected. When a scan tool “Clear cycle.
Codes” command is issued and the malfunction is still

DTC 15 Passenger Deployment loop Resistance High


Step Action Yes No
1 Was the “SRS Diagnostic System Check” Performed? Go to The “SRS
Diagnostic
Go to Step 2 System Check”
2 1. When measurements are requested in this chart use
5–8840–0285–0 DVM with correct terminal adapter from
5–8840–0385–0.
2. Use scan tool data list function, read and record the passenger
deployment loop resistance.
Is passenger resist. more than 2.9 ohms? Go to Step 3 Go to Chart A
3 1. Ignition switch “Off.” Seat passenger
2. Make sure the passenger air bag assembly yellow 2–pin Air Bag assembly
connector located behind the glove box assembly is seated yellow 2–pin
properly. connector
properly
Is the yellow 2–pin connector connected properly?
Go to Step 4 Go to Step 7
4 1. Disconnect and inspect the passenger air bag assembly
yellow 2–pin connector located behind the glove box
assembly.
2. If ok, reconnect the passenger air bag assembly 2–pin
connector.
3. Ignition switch “ON.”
Is DTC 15 current? Go to Step 5 Go to Step 7
5 1. Ignition switch “Off.”
2. Disconnect SRS coil and passenger air bag assembly, yellow
2–pin connector located at the base of the steering column and
behind the glove box assembly. Ignition switch
3. Connect 5–8840–2421–0 SRS driver / passenger load tool “Off”
and appropriate adapters to SRS coil and passenger air bag Replace the
assembly harness connectors. passenger air
4. Ignition switch “ON.” bag assembly
Is DTC 15 Current? Go to Step 6 Go to Step 7
6 1. Ignition switch “Off.”
2. There has been an increase in the total circuit resistance of the
passenger inflator deployment loop.
3. Use the high resolution ohmmeter mode of the DVM while
checking IB07–YEL/GRN and IB08–YEL/RED, and SDM Replace SRS
connector terminal “15” and “16” to locate the root cause. harness
Was a fault found? Go to Step 7 Go to Chart A
7 1. Reconnect all components ensure all component are properly
mounted.
Repeat the “SRS
2. Clear diagnostic trouble codes.
Diagnostic
Was This step finished? System Check” Go to Step 7
RESTRAINT CONTROL SYSTEM 9J1–15

DTC 16 Passenger Deployment loop Resistance Low

D09RW014

Circuit Description: Action Taken:


When the ignition switch is turned “ON”, the SDM will SDM turns “ON” the “AIR BAG” warning lamp and sets a
perform tests to diagnose critical malfunctions within diagnostic trouble code.
itself. Upon passing these tests “Ignition 1”, and
deployment loop voltages are measured to ensure they DTC Will Clear When:
are within their respective normal voltage ranges. The The ignition switch is turned “OFF.”
SDM then proceeds with the “Resistance Measurement
Test”. “Passenger Bag Low” terminal “16” is grounded DTC Chart Test Description:
through a resistor and the passenger current source Number(s) below refer to step number(s) on the
connected to “Passenger Bag High” terminal “15” allows a diagnostic chart:
known amount of current to flow. By monitoring the 2. This test determines whether the malfunction is in
voltage difference between “Passenger Bag High” and the SDM.
“Passenger Bag Low”, the SDM calculates the combined
3. This test verifies connection of the yellow 2–pin
resistance of the passenger air bag assembly, harness
connector.
wiring IB07–YEL/GRN and IB08–YEL/RED connector
terminal contact. 4. This test cheeks for proper operation of the shorting
clip in the yellow 2–pin connector.
DTC Will Set When: 5. The test checks for a malfunction passenger air bag
The combined resistance of the passenger air bag assembly.
assembly, harness wiring IB07–YEL/GRN and 6. This test determines whether the malfunctioning is
IB08–YEL/RED, and connector terminal contact is above due to shortening in the wiring.
a specified value. This test is run once each ignition cycle
during the “Resistance Measurement Test” when: Diagnostic Aids:
1. No “higher priority faults” are detected during An intermittent condition is likely to be caused by a short
“Turn–ON”, between IB07–YEL/GRN and IB08–YEL/RED, or a
2. “Ignition 1” voltage is in the specified value. malfunctioning shorting clip on the passenger air bag
assembly which would require replacement of the air bag
assembly. The test for this diagnostic trouble code is only
run while “AIR BAG” warning lamp is performing the bulb
9J1–16 RESTRAINT CONTROL SYSTEM
check, unless DTC 17 or DTC 26 is detected. When a malfunction is still present, the DTC will not reappear until
scan tool “Clear Codes” command is issued and the the next ignition cycle.

DTC 16 Passenger Deployment loop Resistance Low


Step Action Yes No
1 Was the “SRS Diagnostic System Check” performed? Repeat the “SRS
Diagnostic
Go to Step 2 System Check”
2 1. When measurements are requested in this chart use
5–8840–0285–0 DVM with correct terminal adapter from
5–8840–0385–0.
2. Using scan tool data list function, read and record the
passenger deployment loop resistance.
Is passenger resist. less than 1.4 ohms? Go to Step 3 Go to Chart A
3 1. Ignition switch “Off.” Seat passenger
2. Make sure the passenger air bag assembly yellow 2–pin air bag assembly
connector located behind the glove box assembly is seated yellow 2–pin
properly. connector
properly
Is the yellow 2–pin connector connected properly?
Go to Step 4 Go to Step 7
4 1. Disconnect and inspect the passenger air bag assembly
yellow 2–pin connector located behind the glove box
assembly.
2. If ok, reconnect the passenger air bag assembly 2–pin
connector.
3. Ignition switch “ON.”
Is DTC 16 Current? Go to Step 5 Go to Step 7
5 1. Ignition switch “Off.”
2. Disconnect SRS coil and passenger air bag assembly, yellow
2–pin connector located at the base of the steering column and
behind the glove box assembly. Ignition switch
3. Connect 5–8840–2421–0 SRS driver/passenger load tool and “Off”
appropriate adapters to SRS coil and passenger air bag Replace the
assembly harness connectors. passenger air
4. Ignition switch “ON.” bag assembly
Is DTC 16 current? Go to Step 6 Go to Step 7
6 1. Ignition switch “Off.”
2. There has been a decrease in the total circuit resistance of the
passenger inflator deployment loop.
3. Use the high resolution ohmmeter mode of the DVM while
checking IB07–YEL/GRN and IB08–YEL/RED, and SDM Replace SRS
connector terminal “15” and “16” to locate the root cause. harness
Was a fault found? Go to Step 7 Go to Chart A
7 1. Reconnect all components, ensure all component are properly
mounted.
Repeat the “SRS
2. Clear diagnostic trouble codes.
Diagnostic
Was this step finished? System Check” Go to Step 7
RESTRAINT CONTROL SYSTEM 9J1–17

DTC 17 Passenger Deployment Loop Open

D09RW014

Circuit Description: DTC Will Clear When:


When the ignition switch is turned “ON”, the SDM will The voltage difference between “Passenger Bag High”
perform tests to diagnose critical malfunctions within terminal “15” and “Passenger Bag Low” terminal “16” is
itself. Upon passing these tests, “Ignition 1”, and below a specified value for 500 milliseconds during
deployment loop voltages are measured to ensure they “Continuous Monitoring”.
are within their respective normal voltage ranges. During
“Continuous Monitoring” diagnostics, a fixed amount of DTC Chart Test Description:
current is flowing in the deployment loop. This produces Number(s) below refer to step number(s) on the
proportional voltage drops in the loop. By monitoring the diagnostic chart:
voltage difference between “Passenger Bag High” and 2. This test determines whether the malfunction is in
“Passenger Bag Low”, the SDM calculates the combined the SDM.
resistance of the passenger air bag assembly, harness 3. This test verifies proper connection of the yellow
wiring IB07–YEL/GRN AND IB08–YEL/RED, and 2–pin connector.
connector terminal contact.
4. This test cheeks for proper contact and/or corrosion
DTC Will Set When: of the shorting clip in the yellow 2–pin connector
terminals.
The voltage difference between “Passenger Bag High”
terminal “15” and “Passenger Bag Low” terminal “16” is 5. The test checks for a malfunctioning passenger air
bag assembly.
above or equal to a specified value for 500 milliseconds
during “Continuous Monitoring”. 6. This test determines whether the open in the wiring.

Action Taken: Diagnostic Aids:


SDM turns “ON” the “AIR BAG” warning lamp and sets a An intermittent condition is likely to be caused by a poor
diagnostic trouble code. connection at the passenger air bag assembly harness
connector terminals“2” and “3”, SDM terminals “15” and
“16”, or an open in IB07–YEL/GRN and IB08–YEL/RED.
9J1–18 RESTRAINT CONTROL SYSTEM

DTC 17 Passenger Deployment Loop Open


Step Action Yes No
1 Was the “SRS Diagnostic System Check” performed? Go to the “SRS
Diagnostic
Go to Step 2 System Check”
2 1. When measurements are requested in this chart use
5–8840–0285–0 DVM with correct terminal adapter from
5–8840–0385–0.
2. Using scan tool data list function, read and record the
passenger differential voltage.
Is passenger VDIF 0.425 volts or more? Go to Step 3 Go to Chart A
3 1. Ignition switch “OFF”. Seat passenger
2. Make sure the passenger air bag assembly yellow 2–pin air bag assembly
connector located behind the glove box assembly is seated yellow 2–pin
properly. connector
properly
Is the yellow 2–pin connector connected properly?
Go to Step 4 Go to Step 7
4 1. Disconnect and inspect the passenger air bag assembly
yellow 2–pin connector located behind the glove box
assembly.
2. If ok, reconnect the passenger air bag assembly 2–pin
connector.
3. Ignition switch “ON”.
Is DTC 17 current? Go to Step 5 Go to Step 7
5 1. Ignition switch “Off.”
2. Disconnect SRS coil and passenger air bag assembly, yellow
2–pin connector located at the base of the steering column and
behind the glove box assembly. Ignition switch
3. Connect 5–8840–2421–0 SRS driver / passenger load tool “Off”
and appropriate adapters to SRS coil and passenger air bag Replace the
assembly harness connectors. passenger air
4. Ignition switch “ON.” bag assembly
Is DTC 17 current? Go to Step 6 Go to Step 7
6 1. Ignition switch “Off.”
2. There has been an open circuit resistance in the passenger
deployment loop.
3. Use the high resolution ohmmeter mode of the DVM while
checking IB07–YEL/GRN and IB08–YEL/RED, and SDM Replace SRS
connector terminal “15” and “16” to locate the root cause. harness
Was a fault found? Go to Step 7 Go to Chart A
7 1. Reconnect all components ensure all component are properly
mounted.
Go to the “SRS
2. Clear diagnostic trouble codes.
Diagnostic
Was this step finished? System Check” Go to Step 7
RESTRAINT CONTROL SYSTEM 9J1–19

DTC 18 Passenger Deployment Loop Short To Ground

D09RW014

Circuit Description: DTC Chart Test Description:


When the ignition switch is turned “ON”, the SDM will Number(s) below refer to circled number(s) on the
perform tests to diagnose critical malfunctions within diagnostic chart.
itself. Upon passing these tests, “Ignition 1”, and 2. This test determines whether the SDM is
deployment loop voltages are measured to ensure they malfunctioning.
are within their respective normal voltage ranges. 3. This test isolates the malfunction to one side of the
The SDM monitors the voltages at “Driver Bag Low” passenger air bag assembly yellow 2–pin connector
terminal “4” and “Passenger Bag Low” terminal “16” to behind glove box assembly.
detect short to ground in the air bag assembly circuits. 4. This test determines whether the malfunction is in
IB07–YEL/GRN.
DTC Will Set When:
5. This test determines whether the malfunction is in
Neither of the two air bag assemblies is open. IB08–YEL/RED.
“Ignition 1” is within the normal operating voltage range.
Once these conditions are met and the voltage at Diagnostic Aids:
“Passenger Bag Low” is below a specified value, DTC 18
will set. This test is run once each ignition cycle and An intermittent condition is likely to be caused by a short
“Continuous Monitoring”. to ground in the passenger air bag assembly circuit.
Inspect IB07–YEL/GRN and IB08–YEL/RED carefully for
Action Taken: cutting or chafing. If the wiring pigtail of the passenger air
bag assembly is damaged, the component must be
SDM turns “ON” the “AIR BAG” warning lamp and sets a
replaced.
diagnostic trouble code.

DTC Will Clear When:


This malfunction is no longer occurring and the ignition
switch is turned “OFF”.
9J1–20 RESTRAINT CONTROL SYSTEM

DTC 18 Passenger Deployment Loop Short To Ground


Step Action Yes No
1 Was the “SRS Diagnostic System Check” performed? Go to the “SRS
Diagnostic
Go to Step 2 System Check”
2 1. When measurements are requested in this chart use
5–8840–0285–0 DVM with correct terminal adapter from
5–8840–0385–0.
2. Ignition switch “OFF.”
3. Connect scan tool data link connector. follow directions as
given in the scan tool operator’s MANUAL.
4. Ignition switch “ON.”
5. Read passenger bag sense LO.
Is passenger bag sense LO less than 1.5 volts? Go to Step 3 Go to Chart A
3 1. Ignition switch “OFF.”
2. Disconnect passenger air bag assembly yellow 2–pin
connector behind the glove box assembly.
3. Leave driver air bag assembly connected. Ignition switch
4. Connect SRS driver / passenger load tool 5–8840–2421–0 “OFF”
and appropriate adapter to passenger air bag assembly Replace
harness connector. passenger air
5. Ignition switch “ON.” bag assembly
Is DTC 18 current? Go to Step 4 Go to Step 6
4 1. Ignition switch “OFF”.
2. Disconnect SRS driver / passenger load tool
3. Measure resistance on SDM harness connector from terminal Replace SRS
“15” to terminal “16” (ground). Harness
Does 5–8840–0285–0 display “OL” (Infinite)? Go to Step 5 Go to Step 6
5 Measure resistance on SDM harness connector from terminal Replace SRS
“16” to terminal “6” (ground). Harness.
Does 5–8840–0285–0 display “OL” (Infinite)? Go to Chart A Go to Step 6
6 1. Reconnect all components and ensure all component are
properly mounted.
Go to the “SRS
2. Clear diagnostic trouble codes.
Diagnostic
Was this step finished? system Check” Go to Step 6
RESTRAINT CONTROL SYSTEM 9J1–21

DTC 19 Passenger Deployment Loop Short To B+

D09RW014

Circuit Description: DTC Chart Test Description:


When the ignition switch is turned “ON”, the SDM will Number(s) below refer to step number(s) on the
perform tests to diagnose critical malfunctions within diagnostic chart:
itself. Upon passing these tests, “Ignition 1”, and 2. This test determines whether the malfunction is in
deployment loop voltages are measured to ensure they the SDM.
are within their respective normal voltage ranges. 3. This test isolates the malfunction to one side of the
The SDM monitors the voltages at “Driver Bag Low” passenger air bag assembly yellow 2–pin connector
terminal “4” and “Passenger Bag Low” terminal “16” to behind glove box assembly.
detect short to B+ in the air bag assembly circuits. 4. This test determines whether the malfunction is in
IB07–YEL/GRN.
DTC Will Set When:
5. This test determines whether the malfunction is in
“Ignition 1” is within the normal operating voltage range. IB08–YEL/RED.
Once these conditions are met and the voltage at
“Passenger Bag Low” is above a specified value, DTC 19 Diagnostic Aids:
will set. This test is run once each ignition cycle and
“Continuous Monitoring”. An intermittent condition is likely to be caused by a short
to B+ in the passenger air bag assembly circuit. Inspect
Action Taken: IB07–YEL/GRN and IB08–YEL/RED carefully for cutting
or chafing. If the wiring pigtail of the passenger air bag
SDM turns “ON” the “AIR BAG” warning lamp and sets
assembly is damaged, the component must be replaced.
DTC 19 and also DTC 71.
A careful inspection of IB07–YEL/GRN and
DTC Will Clear When: IB08–YEL/RED, including the passenger air bag
assembly pigtail is essential to ensure that the
The SDM is replaced. replacement SDM will not be damaged.
9J1–22 RESTRAINT CONTROL SYSTEM

DTC 19 Passenger Deployment Loop Short To B+


CAUTION: When DTC 19 has been set, it is necessary to replace the SDM. Setting DTC 19 will also cause DTC
71 to set. When a scan tool “CLEAR CODES” command is issued and the malfunction is no longer present,
DTC 71 will remain current. Ensure that the short to voltage condition is repaired prior to installing a
replacement SDM to avoid damaging the SDM.

Step Action Yes No


1 Perform the “SRS Diagnostic System Check” Repeat the “SRS
Diagnostic
Was the “SRS Diagnostic System Check” performed?
Go to Step 2 System Check”
2 1. When measurements are requested in this chart use
5–8840–0285–0 DVM With correct terminal adapter from
5–8840–0385–0.
2. Ignition switch “OFF.”
3. Connect scan tool data link connector. follow directions as
given in the scan tool operator’s manual.
4. Ignition switch “ON.”
5. Read passenger bag sense LO.
Is passenger bag sense LO more than 3.5 volts? Go to Step 3 Go to Chart A
3 1. Ignition switch “OFF”.
2. Disconnect passenger air bag assembly yellow 2–pin
connector behind the glove box assembly.
3. Leave driver air bag assembly connected. Ignition switch
4. Connect SRS driver / passenger load tool 5–8840–2421–0 “OFF”
and appropriate adapter to passenger air bag assembly Replace
harness connector. passenger air
5. Ignition switch “ON.” bag assembly
Is passenger bag sense LO more than 3.5 volts? Go to Step 4 Go to Step 6
4 1. Ignition switch “OFF.”
2. Disconnect SDM.
3. Disconnect SRS driver / passenger load tool.
4. Measure resistance on SDM harness connector from terminal Replace SRS
“15” to terminal “12” (ignition). harness
Does 5–8840–0285–0 display “OL” (infinite)? Go to Step 5 Go to Step 6.
5 Measure resistance on SDM harness connector from terminal replace SRS
“16” and terminal “12” (ignition). harness
Does 5–8840–0285–0 display “OL” (infinite)? Go to Chart A Go to Step 6
6 1. Reconnect all components ensure all component are properly Ignition switch
mounted. “OFF”
2. Ignition switch “ON”. Replace SDM
Is passenger bag senslo less than 3.5 volts? Go to Step 7 Go to Chart A
7 1. Reconnect all components ensure all component are properly
mounted.
Repeat the “SRS
2. Clear diagnostic trouble codes.
Diagnostic
Was this step finished? System Check” Go to Step 7
RESTRAINT CONTROL SYSTEM 9J1–23

DTC 21 Driver Deployment Loop Resistance High

D09RW014

Circuit Description: Action Taken:


When the ignition switch is turned “ON”, the SDM will SDM turns “ON” the “AIR BAG” warning lamp and sets
perform tests to diagnose critical malfunctions within DTC 21.
itself. Upon passing these tests, “Ignition 1”, and
deployment loop voltages are measured to ensure they DTC Will Clear When:
are within their respective normal voltage ranges. The ignition switch is turned “OFF”.
The SDM then proceeds with the “Resistance
Measurement Test” “Driver Bag Low” terminal “4” is DTC Chart Test Description:
grounded through a current sink and the driver current Number(s) below refer to step number(s) on the
source connected to “Driver Bag High” terminal “3” allows diagnostic chart:
a known amount of current to flow. By monitoring the 2. This test determines whether the malfunction is in
voltage difference between “Driver Bag High” and “Driver the SDM.
Bag Low”, the SDM calculates the combined resistance
3. This test verifies proper connection of the yellow
of the driver air bag assembly, SRS coil assembly,
2–pin connector at the base of the steering column.
harness wiring IB05–YEL and IB06–YEL/BLK, and
connector terminal contact. 4. This test checks for proper contact and/or corrosion
of the 2–pin connector terminals at the base of
DTC Will Set When: steering column.
The combined resistance of the driver air bag assembly, 5. This test isolate the malfunction to one side of the
SRS Coil assembly, harness wiring IB05–YEL and SRS coil assembly yellow 2–pin connector located
IB06–YEL/BLK, and connector terminal contact is above at the base of the steering column.
a specified value. This test run once each ignition cycle 6. This test determines whether the malfunction is due
during the “Resistance Measurement Test” when: to high resistance in the wiring.
1. No “higher priority faults” are detected during 7. This test determines whether the malfunction is in
“Turn–ON” the SRS coil assembly or the driver air bag
2. “Ignition 1” voltage is in the specified value. assembly.
9J1–24 RESTRAINT CONTROL SYSTEM
Diagnostic Aids: IB06–YEL/BLK. The test for this diagnostic trouble code
An intermittent condition is likely to be caused by a poor is only run while the “AIR BAG” warning lamp is
connection at terminals “1” and “2” of the SRS coil 2–pin performing the bulb check, unless DTC 17 or DTC 26 is
connector at the base of the steering column, terminal “1” detected. When a scan tool “Clear Codes” command is
and “2” of the driver air bag assembly 2–pin connector at issued and the malfunction is still present, the DTC will not
the top of the steering column, SDM terminals “3” and “4” reappear until the next ignition cycle.
or a poor wire to terminal connection in IB05–YEL or

DTC 21 Driver Deployment Loop Resistance High


Step Action Yes No
1 Perform the “SRS Diagnostic System Check”. Repeat the “SRS
Diagnostic
Was the “SRS Diagnostic System Check” performed?
Go to Step 2 System Check”
2 1. When measurements are requested in this chart use
5–8840–0285–0 DVM with correct terminal adapter from
5–8840–0385–0.
2. Use scan tool data list function, read and record the driver
deployment loop resistance.
Is driver resistance more than 3.7 ohms? Go to Step 3 Go to Chart A
3 1. Ignition switch “OFF.” Seat SRS coil
2. Disconnect SRS coil assembly yellow 2–pin connector located assembly 2–pin
at base of steering column is seated properly. connector
properly
Is the 2–pin connector connected properly?
Go to Step 4 Go to Step 8
4 1. Disconnect and inspect the SRS coil assembly yellow 2–Pin
connector located base of steering column.
2. If ok, reconnect the SRS coil assembly yellow 2–pin
connector.
3. Ignition switch “ON.”
Is DTC 21 current? Go to Step 5 Go to Step 8
5 1. Ignition switch “OFF.”
2. Disconnect SRS coil and passenger air bag assembly, yellow
2–pin connector located at the base of steering column and
behind the glove box assembly.
3. Connect SRS driver / passenger load tool 5–8840–2421–0
and appropriate adapter to SRS coil and passenger air bag
assembly harness connectors.
4. Ignition switch “ON.”
Is DTC 21 current? Go to Step 6 Go to Step 7
6 1. Ignition switch “Off.”
2. There has been a increase in the total circuit resistance of the
driver deployment loop.
3. Use the high resolution ohmmeter mode of the DVM while
checking IB05–YEL and IB06–YEL/BLK, and SDM connector Replace SRS
terminal “3” and “4” to locate the root cause. harness
Was a fault found? Go to Step 8 Go to Chart A
RESTRAINT CONTROL SYSTEM 9J1–25

DTC 21 Driver Deployment Loop Resistance High (Cont’d)


Step Action Yes No
7 1. Ignition switch “OFF.”
2. Disconnect SRS driver / passenger load tool from SRS coil
assembly harness connector.
3. Connect SRS driver / passenger load tool 5–8840–2421–0 on
the top of steering column. Ignition switch Ignition switch
4. Reconnect SRS coil assembly harness connector as the base “OFF” “OFF”
of steering column. Replace SRS coil Replace driver air
5. Ignition switch “ON.” assembly bag assembly
Is DTC 21 current? Go to Step 8 Go to Step 8
8 1. Reconnect all components ensure all component are properly
mounted.
Repeat the “SRS
2. Clear diagnostic trouble codes.
Diagnostic
Was this step finished? System Check” Go to Step 8
9J1–26 RESTRAINT CONTROL SYSTEM

DTC 22 Driver Deployment Loop Resistance Low

D09RW014

Circuit Description: Action Taken:


When the ignition switch is turned “ON”, the SDM will SDM turns “ON” the “AIR BAG” warning lamp and sets
perform tests to diagnose critical malfunctions within DTC 22.
itself. Upon passing these tests “Ignition 1”, and
deployment loop voltages are measured to ensure they DTC Will Clear When:
are within their respective normal voltage ranges. The ignition switch is turned “OFF.”
The SDM then proceeds with the “Resistance
Measurement Test” “Driver Bag Low” terminal “4” is DTC Chart Test Description:
grounded through a current sink and the driver current Number(s) below refer to circled number(s) on the
source connected to “Driver Bag High” terminal “3” allows diagnostic chart:
a known amount of current to flow. By monitoring the 2. This test determines whether the malfunction is in
voltage difference between “Driver Bag High” and “Driver the SDM.
Bag Low” the SDM calculates the combined resistance of
3. This test verifies proper connection of the yellow
the driver air bag assembly, SRS coil assembly, harness
2–pin connector at the base of the steering column.
wiring IB05–YEL and IB06–YEL/BLK and connector
terminal contact. 4. This test checks for proper operation of the shorting
clip in the yellow 2–pin connector.
DTC Will Set When: 5. This test isolate the malfunction to one side of the
The combined resistance of the driver air bag assembly, SRS coil assembly yellow 2–pin connector located
SRS Coil assembly, harness wiring IB05–YEL and at the base of steering column.
IB06–YEL/BLK and connector terminal contact is above a 6. This test determines whether the malfunction is due
specified value. This test is run once each ignition cycle to shortening in the wiring.
during the “Resistance Measurement Test” when: 7. This test determines whether the malfunction is in
1. No “higher priority faults” are detected during the SRS coil assembly or the driver air bag
“Turn–ON” assembly.
2. “Ignition 1” voltage is in the specified value.
Diagnostic Aids:
An intermittent condition is likely to be caused by a short
between IB05–YEL or IB06–YEL/BLK or a
RESTRAINT CONTROL SYSTEM 9J1–27
malfunctioning shorting clip on the driver air bag 17 or DTC 26 is detected. When a scan tool “Clear
assembly or SRS coil assembly which would require Codes” command is issued and the malfunction is still
replacement of the component. The test for this present, the DTC will not reappear until the next ignition
diagnostic trouble code is only run while the “AIR BAG” cycle.
warning lamp is performing the bulb check, unless DTC

DTC 22 Driver Deployment Loop Resistance Low


Step Action Yes No
1 Perform the “SRS Diagnostic System Check.” Go to the “SRS
Diagnostic
Was the “SRS Diagnostic System Check” performed?
Go to Step 2 System Check”
2 1. When measurements are requested in this chart use
5–8840–0285–0 DVM with correct terminal adapter from
5–8840–0385–0.
2. Use scan tool data list function, read and record the driver
deployment loop resistance.
Is driver deployment loop resistance less than 1.7 OHMS? Go to Step 3 Go to Chart A
3 1. Ignition switch “OFF.” Seat driver air
2. Make sure the SRS coil assembly yellow 2–pin connector bag assembly
located at the base of steering column is seated properly. 2–pin connector
properly
Is the 2–pin connector connected properly?
Go to Step 4 Go to Step 8
4 1. Disconnect and inspect the SRS coil assembly yellow 2–pin
connector located base of steering column.
2. If ok, reconnect the SRS coil assembly yellow 2–pin
connector.
3. Ignition switch “ON.”
Is DTC 22 current? Go to Step 5 Go to Step 8
5 1. Ignition switch “OFF.”
2. Disconnect SRS coil and passenger air bag assembly, yellow
2–pin connector located at the base of steering column and
behind the glove box assembly.
3. Connect SRS driver / passenger load tool 5–8840–2421–0
and appropriate adapter to SRS coil and passenger air bag
assembly harness connectors.
4. Ignition switch “ON.”
Is DTC 22 current? Go to Step 6 Go to Step 7
6 1. Ignition switch “OFF.”
2. There has been a decrease in the total circuit resistance of the
driver deployment loop.
3. Use the high resolution ohmmeter mode of the DVM while
checking IB05–YEL and IB06–YEL/BLK, and SDM connector Replace SRS
terminal “3” and “4” to locate the root cause. harness
Was a fault found? Go to Step 8 Go to Chart A
9J1–28 RESTRAINT CONTROL SYSTEM

DTC 22 Driver Deployment Loop Resistance Low (Cont’d)


Step Action Yes No
7 1. Ignition switch “OFF.”
2. Disconnect SRS driver / passenger load tool from driver air
bag assembly harness connector.
3. Connect SRS driver / passenger load tool 5–8840–2421–0 to
the top of steering column 2–pin connector. Ignition switch Ignition switch
4. Reconnect SRS coil assembly harness connector as the base “off” “OFF”
of steering column. Replace SRS coil Replace driver air
5. Ignition switch “ON.” assembly bag assembly
Is DTC 22 current? Go to Step 8 Go to Step 8
8 1. Reconnect all components, ensure all component are properly
mounted.
Go to the “SRS
2. Clear diagnostic trouble codes.
Diagnostic
Was this step finished? System Check” Go to Step 8
RESTRAINT CONTROL SYSTEM 9J1–29

DTC 24 Driver Deployment Loop Short To Ground

D09RW014

Circuit Description: DTC Chart Test Description:


When the ignition switch is turned “ON”, the SDM will Number(s) below refer to step number(s) on the
perform tests to diagnose critical malfunctions within diagnostic chart:
itself. Upon passing these tests, “Ignition 1”, and 2. This test determines whether the SDM is
deployment loop voltages are measured to ensure they malfunctioning
are within their respective normal voltage ranges. 3. This test isolates the malfunction to one side of the
The SDM monitors the voltage at “Driver Bag Low” SRS coil assembly yellow 2–pin connector at the
terminal “4” and “passenger Bag Low” terminal “16” to base of the steering column.
detect shorts to ground in the air bag assembly circuits. 4. This test determines whether the malfunction is in
IB05–YEL.
DTC Will Set When:
5. This test determines whether the malfunction is in
Neither of the two air bag assemblies is open. IB06–YEL/BLK.
“Ignition 1” is within the normal operating voltage range.
This test is run once each ignition cycle and “Continuous 6. This test determines whether the malfunction is in
the SRS coil assembly or the driver air bag
Monitoring”. Once these conditions are met and the
assembly.
voltage at “Driver Bag Low” is below a specified value,
DTC 24 will set.
Diagnostic Aids:
Action Taken: An intermittent condition is likely to be caused by a short
SDM turns “ON” the “AIR BAG” warning lamp and sets a to ground in the driver air bag assembly circuit. Inspect
diagnostic trouble code. IB05–YEL and IB06–YEL/BLK carefully for cutting or
chafing.
DTC Will Clear When:
The malfunction is no longer occurring and the ignition is
turned “OFF”.
9J1–30 RESTRAINT CONTROL SYSTEM

DTC 24 Driver Deployment Loop Short To Ground


Step Action Yes No
1 Was the “SRS Diagnostic System Check” performed? Go to the “SRS
Diagnostic
Go to Step 2 System Check”
2 1. When measurements are requested in this chart use
5–8840–0285–0 DVM with correct terminal adapter from
5–8840–0385–0.
2. Ignition switch “OFF.”
3. Connect scan tool data link connector. follow directions as
given in the scan tool operator’s manual.
4. Ignition switch “ON.”
5. Read driver bag sense LO.
Is driver bag sense LO less than 1.5 volts? Go to Step 3 Go to Chart A
3 1. Ignition switch “OFF.”
2. Disconnect SRS coil assembly yellow 2–pin connector located
at base of the steering column. leave passenger air bag
assembly connected.
3. Connect SRS driver / passenger load tool 5–8840–2421–0
and appropriate adapter to SRS coil assembly harness
connector.
4. ignition switch “ON.”
Is DTC 24 current? Go to Step 4 Go to Step 6
4 1. Ignition switch “OFF.”
2. Disconnect SDM.
3. Disconnect SRS driver / passenger load tool.
4. Measure resistance on SDM harness connector “3” to terminal Replace SRS
“6” (ground). harness
Does 5–8840–0285–0 display “OL” (infinite)? Go to Step 5 Go to Step 7
5 Measure resistance on SDM harness connector from terminal “4” Replace SRS
to terminal “6” (ground). harness
Does 5–8840–0285–0 display “OL” (infinite)? Go to Chart A Go to Step 7
6 1. Ignition switch “OFF.”
2. Disconnect SRS driver / passenger load tool 5–8840–2421–0
from SRS coil assembly harness connector.
3. Connect SRS driver / passenger load tool 5–8840–2421–0
and appropriate adapter 5–8840–0385–0 to driver air bag
assembly harness connector. located top of the steering
column 2–pin connector. Ignition switch Ignition switch
4. Reconnect SRS coil assembly harness connector as the base “OFF” “OFF”
of steering column. Replace SRS coil Replace driver air
5. Ignition switch “ON.” assembly bag assembly
Is DTC 24 current? Go to Step 7 Go to Step 7
7 1. Reconnect all components ensure all component are properly
mounted.
Go to the “SRS
2. Clear diagnostic trouble codes.
Diagnostic
Was this step finished? System Check” Go to Step 7
RESTRAINT CONTROL SYSTEM 9J1–31

DTC 25 Driver Deployment Loop Short To B+

D09RW014

Circuit Description: 2. This test determines whether the SDM is


When the ignition switch is turned “ON”, the SDM will malfunctioning.
perform tests to diagnose critical malfunctions within 3. This test isolates the malfunction to one side of the
itself. Upon passing these tests, “Ignition 1”, and driver air bag assembly yellow 2–pin connector at
deployment loop voltages are measured to ensure they the base of steering column.
are within their respective normal voltage ranges. 4. This test determines whether the malfunction is in
The SDM monitors the voltage at “Driver Bag Low” IB05–YEL.
terminal “4” and “Passenger Bag Low” terminal “16” to 5. This test determines whether the malfunction is in
detect shorts to B+ in the air bag assembly circuits. IB06–YEL/BLK.
6. This test determines whether the malfunction is in
DTC Will Set When: the SRS coil assembly or the driver air bag
“Ignition 1” is in the normal operating voltage range. This assembly.
test is run once each ignition cycle and “Continuous
monitoring”. Once these conditions are met and the Diagnostic Aids:
voltage at “Driver Bag Low” is above a specified value, An intermittent condition is likely to be caused by a short
DTC 25 will set. to B+ in the driver air bag assembly circuit. Inspect
IB05–YEL and IB06–YEL/BLK carefully for cutting or
Action Taken: chafing. If the wiring pigtail of the driver air bag assembly
SDM turns “ON” the “AIR BAG” warning lamp and sets and SRS coil assembly is damaged, the components
DTC 25 and also DTC 71 must be replaced. A careful inspection of IB05–YEL and
IB06–YEL/BLK, including the SRS coil assembly and
DTC Will Clear When: driver air bag assembly is essential to ensure that the
The SDM is replaced. replacement SDM will not be damaged.

DTC Chart Test Description:


Number(s) below refer to step number(s) on the
diagnostic chart:
9J1–32 RESTRAINT CONTROL SYSTEM

DTC 25 Driver Deployment Loop Short To B+


CAUTION: When DTC 25 has been set, it is necessary to replace the SDM. Setting DTC 25 will also cause DTC
71 to set. When a scan tool “CLEAR CODES” command is issued and the malfunction is no longer present,
DTC 71 will remain current. Ensure that the short to B+ condition is repaired prior to installing a replacement
SDM to avoid damaging the SDM.

Step Action Yes No


1 Was the “SRS Diagnostic System Check” performed? Go to the “SRS
Diagnostic
Go to Step 2 System Check”
2 1. When measurements are requested in this chart use
5–8840–0285–0 DVM with correct terminal adapter from
5–8840–0385–0.
2. Ignition switch “OFF.”
3. Connect scan tool data link connector. follow directions as
given in the scan tool operator’s manual.
4. Ignition switch “ON.”
5. Read driver bag sense LO .
Is driver bag sense LO more than 3.5 volts? Go to Step 3 Go to Chart A
3 1. Ignition switch “OFF.”
2. Disconnect SRS coil assembly yellow 2–pin connector at the
base of the steering column. Leave passenger air bag
assembly connected.
3. Connect SRS driver /passenger load tool 5–8840–2421–0 and
appropriate adapter to SRS coil assembly harness connector.
4. Ignition switch “ON.”
Is driver bag sense LO more than 3.5 volts? Go to Step 4 Go to Step 6
4 1. Ignition switch “OFF.”
2. Disconnect SDM.
3. Disconnect SRS driver /passenger load tool.
4. Measure resistance on SDM harness connector “3” to terminal Replace SRS
“12” (ignition). harness
Does 5–8840–0285–0 display “OL” (infinite)? Go to Step 5 Go to Step 7
5 Measure resistance on SDM harness connector from terminal “4” Replace SRS
to terminal “12” (ignition). harness
Does 5–8840–0285–0 display “OL” (infinite)? Go to Chart A Go to Step 7
6 1. Ignition switch “OFF”
2. Connect SRS driver / passenger load tool 5–8840–2421–0
and appropriate adapter 5–8840–0385–0 to driver air bag
assembly harness 2-pin connector located at top of the
steering column. Ignition switch Ignition switch
3. Reconnect SRS coil assembly harness connector as the base “OFF” “OFF”
of steering column. Replace SRS coil Replace driver air
4. Ignition switch “ON.” assembly bag assembly
Is driver bag sense LO more than 3.5 volts? Go to Step 7 Go to Step 7
7 1. Reconnect all components, ensure all component are properly Ignition switch
mounted. “OFF”
2. Ignition switch “ON.” Replace SDM
Is driver bag senslo less than 3.5 volts? Go to Step 8 Go to Chart A
8 1. Reconnect all components ensure all component are properly
mounted.
Go to the “SRS
2. Clear diagnostic trouble codes.
Diagnostic
Was this step finished? System Check” Go to Step 8
RESTRAINT CONTROL SYSTEM 9J1–33

DTC 26 Driver Deployment Loop Open

D09RW014

Circuit Description: specified value for 500 milliseconds during “Continuous


When the ignition switch is turned “ON”, the SDM will Monitoring”.
perform tests to diagnose critical malfunctions within
itself. Upon passing these tests, “Ignition 1”, and
DTC Chart Test Description:
deployment loop voltages are measured to ensure they Number(s) below refer to step number(s) on the
are within their respective normal voltage ranges. diagnostic chart:
During “Continuous Monitoring” diagnostics, a fixed 2. This test determines whether the malfunction is in
amount of current is following in the deployment loop. the SDM.
This produces proportional voltage drops in the loop. By 3. This test verifies proper connection of the yellow
monitoring the voltage difference between “Driver Bag 2–pin connector at the base of the steering column.
High” and “Driver Bag Low”, the SDM calculates the 4. This test checks for proper contact and/or corrosion
combined resistance of the driver air bag assembly, SRS of the yellow 2–pin connector at the base of the
coil assembly, harness wiring IB05–YEL and steering column.
IB06–YEL/BLK, and connector terminal contact. 5. This test isolates the malfunction to one side of the
SRS coil assembly yellow 2–pin connector located
DTC Will Set When: at the base of steering column.
The voltage difference between “Driver Bag High” 6. This test determines whether the open is in the
terminal “3” and “Driver Bag Low” terminal “4” is above or wiring.
equal to a specified value for 500 milliseconds during
7. This test determines whether the malfunction is in
“Continuous Monitoring”. the SRS coil assembly or the driver air bag
assembly.
Action Taken:
SDM turns “ON” the “AIR BAG” warning lamp and sets a Diagnostic Aids:
diagnostic trouble code.
An intermittent condition is likely to be caused by a poor
DTC Will Clear When: connection at the driver air bag assembly harness 2–pin
connector terminals “1” and “2” at the top of the steering
The voltage difference between “Driver Bag High” column, SRS coil assembly harness 2–pin connection
terminal “3” and “Driver Bag Low” terminal “4” is below a terminals “1” and “2”, SDM terminals “3” and “4”, or an
open in IB05–YEL and IB06–YEL/BLK.
9J1–34 RESTRAINT CONTROL SYSTEM

DTC 26 Driver Deployment Loop Open


Step Action Yes No
1 Was the “SRS Diagnostic System Check” performed? Go to the “SRS
Diagnostic
Go to Step 2 System Check”
2 1. When measurements are requested in this chart use
5–8840–0285–0 DVM with correct terminal adapter from
5–8840–0385–0.
2. Use scan tool data list function, read and record the driver
differential voltage.
Is driver VDIF more than 4.25 volts? Go to Step 3 Go to Chart A
3 1. Ignition switch “OFF.” Seat driver air
2. Make sure the SRS coil assembly yellow 2–pin connector bag assembly
located at the base of steering column is seated properly. 2–pin connector
Is the yellow 2–pin connector connected properly? Go to Step 4 Go to Step 8
4 1. Disconnect and inspect the SRS coil assembly yellow 2–pin
connector located base of steering column.
2. If ok, reconnect the SRS coil assembly yellow 2–pin
connector.
3. Ignition switch “ON.”
Is DTC 26 current? Go to Step 5 Go to Step 8
5 1. Ignition switch “OFF”.
2. Disconnect SRS coil and passenger air bag assembly, yellow
2–pin connectors located at the base of steering column and
behind the glove box assembly.
3. Connect SRS driver/passenger load tool 5–8840–2421–0 and
appropriate adapter to SRS coil and passenger air bag
assembly harness connectors.
4. Ignition switch “ON.”
Is DTC 26 current? Go to Step 6 Go to Step 7
6 1. Ignition switch “OFF.”
2. There has been an open circuit in the driver inflator
deployment loop.
3. Use the high resolution ohmmeter mode of the DVM while
checking IB05–YEL and IB06–YEL/BLK, and SDM connector Replace SRS
terminal “3” and “4” to locate the root cause. harness
Was a fault found? Go to Step 8 Go to Chart A
7 1. Ignition switch “OFF.”
2. Disconnect SRS driver / passenger load tool from SRS coil
assembly harness connector.
3. Connect SRS driver / passenger load tool 5–8840–2421–0 on
steering column 2–pin connector. Ignition switch Ignition switch
4. Reconnect SRS coil assembly harness connector at the base “OFF” “OFF”
of steering column. Replace SRS coil Replace driver air
5. Ignition switch “ON.” assembly bag assembly
Is DTC 26 current? Go to Step 8 Go to Step 8
8 1. Reconnect all components ensure all component are properly
mounted.
Repeat the “SRS
2. Clear diagnostic trouble codes.
Diagnostic
Was this step finished? System Check” Go to Step 8
RESTRAINT CONTROL SYSTEM 9J1–35

DTC 51 Air Bag Deployment Event Commanded

D09RW014

Circuit Description: Action Taken:


The SDM contains a sensing device which converts SDM turns “ON” the “AIR BAG” warning lamp records
vehicle velocity changes to an electrical signal. The “Crash Data”, and sets a diagnostic trouble code.
electrical signal generated is processed by the SDM and
then compared to a value stored in memory. When the DTC Will Clear When:
generated signal exceeds the stored value, the SDM will The SDM is replaced.
cause current to flow through the air bag assembly
deploying the air bags and causing DTC 51 to set. DTC Chart Test Description:
Number(s) below refer to step number(s) on the
DTC Will Set When: diagnostic chart:
The SDM detects a frontal crash, up to 30 degrees off the 2. If air bag assembly (s) has not deployed, DTC 51
centerline of the vehicle, of sufficient force to warrant may have falsely set.
deployment of the air bags. 3. If DTC 51 has set with no signs of frontal impact, the
diagnostic trouble code has falsely set.
9J1–36 RESTRAINT CONTROL SYSTEM

DTC 51 Air Bag Deployment Event Commanded


WARNING: DURING SERVICE PROCEDURES. BE VERY CAREFUL WHEN HANDLING A SENSING AND
DIAGNOSTIC MODULE (SDM). NEVER STRIKE OR JAR THE SDM. NEVER POWER UP THE SRS WHEN THE
SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SDM AND MOUNTING BRACKET FASTENERS MUST
BE CAREFULLY TORQUED AND THE ARROW MUST BE POINTING TOWARD THE FRONT OF THE VEHICLE
TO ENSURE PROPER OPERATION OF THE SRS. THE SDM COULD BE ACTIVATED WHEN POWERED WHILE
NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH COULD CAUSE DEPLOYMENT AND RESULT IN
PERSONAL INJURY.

Step Action Yes No


1 Was the “SRS Diagnostic System Check” performed? Go to the “SRS
Diagnostic
Go to Step 2 System Check”
2 Ignition switch “OFF.” Replace
components and
Have air bag assemblies deployed?
perform
inspections as
directed in
“repairs and
inspections
required after an
accident” in this
section
Clear diagnostic
trouble codes
Repeat “SRS
Diagnostic
System Check” Go to Step 3
3 Inspect front of vehicle and undercarriage for sings of impact. Replace
components and
Were signs of impact found?
perform
inspections as Ignition switch
directed in “OFF”
“Repairs and Replace SDM
Inspections Reconnect all
Required After An SRS system
Accident” in this components,
section ensure all
Clear diagnostic components are
trouble codes properly mounted
Repeat “SRS Repeat “SRS
Diagnostic Diagnostic
System Check” System Check”
RESTRAINT CONTROL SYSTEM 9J1–37

DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy


Reserves Out Of Range

D09RW014

Circuit Description: Action Taken:


The SDM contains a sensing drive which converts vehicle SDM turns “ON” the “AIR BAG” warning lamp records
velocity changes to an electrical signal. The electrical “Crash Data”, and sets a diagnostic trouble code.
signal generated is processed by the SDM and then
compared to a value stored in memory. When the DTC Will Clear When:
generated signal exceeds the stored value, the SDM will The SDM is replaced. If DTC 53 is set, one or more DTCs
cause current to flow through the air bag assembly will be set in addition to DTC 53. Malfunction(s) setting
deploying the air bags. DTC 53 is set accompanying with DTC(s) (other than DTC 71) must be repaired so that
DTC 51 when a deployment occurs while an air bag DTC(s) will not be set when a new SDM is installed.
assembly circuit fault is present that could possible result
in a no deployment situation in one or both air bag DTC Chart Test Description:
assemblies. Number(s) below refer to step number(s) on the
diagnostic chart:
DTC Will Set When: 2. If air bag assembly have not deployed, DTC 53 may
The SDM detects a frontal crash, up to 30 degrees off the have falsely set.
centerline of the vehicle, of sufficient force to warrant 3. If DTC 53 has set with no signs of frontal impact, the
deployment of the air bags and an inflator circuit fault is diagnostic trouble code has falsely set.
present..
9J1–38 RESTRAINT CONTROL SYSTEM

DTC 53 Deployment Commanded WITH Deployment Loop Fault Or Energy Reserves Out
Of Range
WARNING: DURING SERVICE PROCEDURES. BE VERY CAREFUL WHEN HANDLING A SENSING AND
DIAGNOSTIC MODULE (SDM). NEVER STRIKE OR JAR THE SDM. NEVER POWER UP THE SRS WHEN THE
SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SDM AND MOUNTING BRACKET FASTENERS MUST
BE CAREFULLY TORQUED AND THE ARROW MUST BE POINTING TOWARD THE FRONT OF THE VEHICLE
TO ENSURE PROPER OPERATION OF THE SRS. THE SDM COULD BE ACTIVATED WHEN POWERED WHILE
NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH COULD CAUSE DEPLOYMENT AND RESULT IN
PERSONAL INJURY.

Step Action Yes No


1 Was the “SRS Diagnostic System Check” performed? Go to the “SRS
Diagnostic
Go to Step 2 System Check”
2 Ignition switch “OFF.” Replace
components and
Have air bag assembles deployed?
perform
inspections as
directed in
“Repairs And
Inspections
Required After An
Accident” in this
section
Clear diagnostic
trouble codes
Repeat the “SRS
Diagnostic
System Check” Go to Step 3
3 Inspect front of vehicle and undercarriage for signs of impact. Replace
components and
Were signs of impact found?
perform
inspections as Ignition switch
directed in “OFF”
“Repairs And Replace SDM
Inspections Reconnect all
Required After An SRS system
Accident” in this components,
section ensure all
Clear diagnostic components are
trouble codes properly mounted
Repeat “SRS Repeat the “SRS
Diagnostic Diagnostic
System Check” System Check”
RESTRAINT CONTROL SYSTEM 9J1–39

DTC 61 Warning Lamp Circuit Failure

D09RW014

Circuit Description: the commanded state of the lamp driver for 500
When the ignition switch is turned “ON”, battery voltage is milliseconds. This test is run every 100 milliseconds
applied to the “AIR BAG” warning lamp and to the “Ignition during “Continuous Monitoring” tests and once per each
1” input terminal “12”. The SDM responds by turning on ignition cycle at the beginning.
the “AIR BAG” warning lamp 3.5 seconds. The SDM
monitors the lamp driver output by comparing the output
Action Taken:
state at “SRS Warning Lamp” terminal “7” to the SDM attempts to turn “ON” the “AIR BAG” warning lamp
microprocessor commanded state. When “Ignition 1” is in and sets a diagnostic trouble code.
the specified value, and the output state does not match
the commanded state of the lamp driver for 500 DTC Will Clear When:
milliseconds, DTC 61 is set. The ignition switch is turned “OFF.”

DTC Will Set When: Diagnostic Aids:


“Ignition 1” voltage is in the specified value and the output Refer to Charts B and C to diagnose warning lamp circuit
state at the “SRS Warning Lamp” terminal does not match malfunctions.
9J1–40 RESTRAINT CONTROL SYSTEM

DTC 61 Warning Lamp Circuit Failure


Step Action Yes No
1 Was the “SRS Diagnostic System Check” performed? Go to the “SRS
Diagnostic
Go to Step 2 System Check”
2 1. Malfunctions within the “AIR BAG” warning lamp circuitry will
set this diagnostic trouble code.
2. These malfunctions are addressed in the “SRS Diagnostic
System Check” via Chart B and Chart C.
3. Failure to properly perform the “SRS Diagnostic System
Check” may result in misdiagnosis.
4. Ignition switch “ON.” Ignition switch Repeat the “SRS
5. Clear SRS diagnostic trouble codes. “OFF” Diagnostic
IS DTC 61 set? Go to Chart A System Check”
RESTRAINT CONTROL SYSTEM 9J1–41

DTC 71 Internal SDM Fault

D09RW014

Circuit Description: DTC Will Set When:


DTC 71 is an indication of a potential internal SDM Any of the above indicated malfunctions are detected by
malfunction and will set if any of the following conditions the SDM. The malfunctions described above are tested
are detected: mainly during “Continuous Monitoring” and some ones
1) Deployment or microprocessor energy reserve failure. run each ignition cycle.
2) EEPROM failure.
3) ROM failure. Action Taken:
4) RAM failure. SDM turns “ON” the “AIR BAG” warning lamp and sets a
5) Calibration check sum failure. diagnostic trouble code.
6) Deployment switch faults.
7) Accelerometer fault. DTC Will Clear When:
8) Arming sensor fault. A scan tool “Clear Codes” commanded is received by the
9) Diagnostic current faults. SDM. Some of the indicated malfunctions will only allow
10) DTC 19 the “AIR BAG” warning lamp to go out.
11) DTC 25 But when DTC 19, 25, 51, 53 are also set, SDM is
12) DTC 51 replaced.
13) DTC 53
9J1–42 RESTRAINT CONTROL SYSTEM

DTC 71 Internal SDM Fault


WARNING: DURING SERVICE PROCEDURES. BE VERY CAREFUL WHEN HANDLING A SENSING AND
DIAGNOSTIC MODULE (SDM). NEVER STRIKE OR JAR THE SDM. NEVER POWER UP THE SRS WHEN THE
SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SDM AND MOUNTING BRACKET FASTENERS MUST
BE CAREFULLY TORQUED AND THE ARROW MUST BE POINTING TOWARD THE FRONT OF THE VEHICLE
TO ENSURE PROPER OPERATION OF THE SRS. THE SDM COULD BE ACTIVATED WHEN POWERED WHILE
NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH COULD CAUSE DEPLOYMENT AND RESULT IN
PERSONAL INJURY.

CAUTION: When DTC 19 or 25 has been set, it is necessary to replace the SDM. Setting DTC 19 and 25 or 51
or 53 will also cause DTC 71 to set. When a scan tool “CLEAR CODES” command is issued and the
malfunction is no longer present, DTC 51 or 53 and DTC 71 will remain current. Ensure that the short to voltage
condition DTC 19, 25 is repaired prior to installing a replacement SDM to avoid damaging the SDM.

Step Action Yes No


1 Was the “SRS Diagnostic System Check” performed? Go to the “SRS
Diagnostic
Go to Step 2 System Check”
2 Note SRS “Diagnostic System Check.” Go to DTC 19 if
DTC 19 is set
IS DTC 19 OR 25 OR 51 OR 53 ALSO SET (CURRENT OR
HISTORY)? (REFER TO NOTICE ABOVE.) Go to DTC 25 if Ignition switch
DTC 25 is set “OFF”
Go to DTC 51 if Replace SDM
DTC 51 is set Repeat the “SRS
Go to DTC 53 if Diagnostic
DTC 53 is set System Check”
RESTRAINT CONTROL SYSTEM 9J1–43

DTC 29 Passenger Pretensioner Loop Short To Ground

D09RW014

Circuit Description: DTC Chart Test Description:


When the ignition switch is turned “ON”, the SDM will Number(s) below refer to circled number(s) on the
perform tests to diagnose critical malfunctions within diagnostic chart.
itself. Upon passing these tests, “Ignition 1”, and 2. This test determines whether the SDM is
pretensioner loop voltages are measured to ensure they malfunctioning.
are within their respective normal voltage ranges. 3. This test isolates the malfunction to one side of the
The SDM monitors the voltages at “Driver Belt Low” passenger pretensioner assembly yellow 2–pin
terminal “10” and “Passenger Belt Low” terminal “22” to connector at the base of the passenger seat.
detect short to ground in the pretensioner assembly 4. This test determines whether the malfunction is in
circuits. IB15–BLU/BLK.
DTC Will Set When: 5. This test determines whether the malfunction is in
IB16–BLU/ORG.
Neither of the air bag and the pretensioner belt are open.
“Ignition 1” is within the normal operating voltage range. Diagnostic Aids:
Once these conditions are met and the voltage at
“Passenger Belt Low” is below a specified value, DTC 29 An intermittent condition is likely to be caused by a short
will set. This test is run once each ignition cycle and to ground in the passenger pretensioner assembly circuit.
“Continuous Monitoring”. Inspect IB15–BLU/BLK and IB16–BLU/ORG carefully for
cutting or chafing. If the wiring pigtail of the passenger
Action Taken: pretensioner assembly is damaged, the component must
be replaced.
SDM turns “ON” the “AIR BAG” warning lamp and sets a
diagnostic trouble code.

DTC Will Clear When:


This malfunction is no longer occurring and the ignition
switch is turned “OFF”.
9J1–44 RESTRAINT CONTROL SYSTEM

DTC 29 Passenger Pretensioner Loop Short To Ground


Step Action Yes No
1 Was the “SRS Diagnostic System Check” performed? Go to the “SRS
Diagnostic
Go to Step 2 System Check”
2 1. When measurements are requested in this chart use
5–8840–0285–0 DVM with correct terminal adapter from
5–8840–0385–0.
2. Ignition switch “OFF.”
3. Connect scan tool data link connector. follow directions as
given in the scan tool operator’s MANUAL.
4. Ignition switch “ON.”
5. Read passenger sense LO.
Is passenger sense LO less than 1.5 volts? Go to Step 3 Go to Chart A
3 1. Ignition switch “OFF.”
2. Disconnect passenger pretensioner assembly yellow 2–pin
connector at the base of the passenger seat. Ignition switch
3. Leave driver pretensioner assembly connected. “OFF”
4. Connect SRS driver / passenger load tool 5–8840–2421–0 Replace
and appropriate adapter to passenger pretensioner assembly passenger
harness connector. pretensioner
5. Ignition switch “ON.” assembly
Is DTC 29 current? Go to Step 4 Go to Step 6
4 1. Ignition switch “OFF”.
2. Disconnect SRS driver / passenger load tool Replace SRS
3. Measure resistance on SDM harness connector from terminal harness or repair
“9” to terminal “6” (ground). chassis harness
Does 5–8840–0285–0 display “OL” (Infinite)? Go to Step 5 Go to Step 6
5 Measure resistance on SDM harness connector from terminal Replace SRS
“10” to terminal “6” (ground). harness or repair
chassis harness
Does 5–8840–0285–0 display “OL” (Infinite)?
Go to Chart A Go to Step 6
6 1. Reconnect all components and ensure all component are
properly mounted.
Go to the “SRS
2. Clear diagnostic trouble codes.
Diagnostic
Was this step finished? system Check” Go to Step 6
RESTRAINT CONTROL SYSTEM 9J1–45

DTC 31 Passenger Pretensioner Loop Resistance High

D09RW014

Circuit Description: Action Taken:


When the ignition switch is turned “ON”, the SDM will SDM turns “ON” the “AIR BAG” warning lamp and sets a
perform tests to diagnose critical malfunctions within diagnostic trouble code.
itself. Upon passing these tests “Ignition 1”, and
deployment loop voltages are measured to ensure they DTC Will Clear When:
are within their respective normal voltage ranges. The The ignition switch is turned “OFF.”
SDM then proceeds with the “Resistance Measurement
Test”. “Passenger Belt Low” terminal “10” is grounded DTC Chart Test Description:
through a resister and the passenger current source Number(s) below refer to step number(s) on the
connected to “Passenger Belt High” terminal “9” allows a diagnostic chart:
known amount of current to flow. By monitoring the 2. This test determines whether the malfunction is in
voltage difference between “Passenger Belt High” and the SDM.
“Passenger Belt Low” the SDM calculates the combined
3. This test verifies proper connection of the yellow
resistance of the passenger air bag assembly, harness
2–pin connector.
wiring IB15–BLU/BLK and IB16–BLU/ORG connector
terminal contact. 4. This test checks for proper contact and/or corrosion
of the yellow 2–pin connector terminals.
DTC Will Set When: 5. The test checks for a malfunctioning passenger
The combined resistance of the passenger pretensioner pretensioner assembly.
assembly, harness wiring IB15–BLU/BLK and 6. This test determines whether the malfunction is due
IB16–BLU/ORG, and connector terminal contact is to high resistance in the wiring.
above a specified value. This test is run once each
ignition cycle during the “Resistance Measurement Test” Diagnostic Aids:
when: An intermittent condition is likely to be caused by a poor
1. No “higher priority faults” are detected during connection at the passenger air bag assembly harness
“Turn–ON”, connector terminals “1” and “2”, SDM terminal “9” and
2. “Ignition 1” voltage is in the specified value. “10”, or a poor wire to terminal connection in
IB15–BLU/BLK and IB16–BLU/ORG. This test for this
diagnostic trouble code is only run while the “AIR BAG”
9J1–46 RESTRAINT CONTROL SYSTEM
warning lamp is performing the bulb check. When a scan malfunction is still present, the DTC will not reappear until
tool “Clear Codes” command is issued and the the next ignition cycle.

DTC 31 Passenger Pretensioner loop Resistance High


Step Action Yes No
1 Was the “SRS Diagnostic System Check” Performed? Go to The “SRS
Diagnostic
Go to Step 2 System Check”
2 1. When measurements are requested in this chart use
5–8840–0285–0 DVM with correct terminal adapter from
5–8840–0385–0.
2. Use scan tool data list function, read and record the passenger
pretensioner loop resistance.
Is passenger resist. more than 3.7 ohms? Go to Step 3 Go to Chart A
3 1. Ignition switch “Off.” Seat passenger
2. Make sure the passenger pretensioner assembly yellow 2–pin pretensioner
connector located at the base of the passenger seat. assembly yellow
2–pin connector
Is the yellow 2–pin connector connected properly?
properly
Go to Step 4 Go to Step 7
4 1. Disconnect and inspect the passenger pretensioner assembly
yellow 2–pin connector located at the base of the passenger
seat.
2. If ok, reconnect the passenger pretensioner assembly 2–pin
connector.
3. Ignition switch “ON.”
Is DTC 31 current? Go to Step 5 Go to Step 7
5 1. Ignition switch “Off.”
2. Disconnect passenger pretensioner assembly, yellow 2–pin Ignition switch
connector located at the base of the passenger seat. “Off”
3. Connect 5–8840–2421–0 SRS driver / passenger load tool Replace the
and appropriate adapters to passenger pretensioner passenger
assembly harness connectors. pretensioner
4. Ignition switch “ON.” assembly
Is DTC 31 Current? Go to Step 6 Go to Step 7
6 1. Ignition switch “Off.”
2. There has been an increase in the total circuit resistance of the
passenger loop.
3. Use the high resolution ohmmeter mode of the DVM while Replace SRS
checking IB15–BLU/BLK and IB16–BLU/ORG, and SDM harness or repair
connector terminal “9” and “10” to locate the root cause. chassis harness
Was a fault found? Go to Step 7 Go to Chart A
7 1. Reconnect all components ensure all component are properly
mounted.
Repeat the “SRS
2. Clear diagnostic trouble codes.
Diagnostic
Was This step finished? System Check” Go to Step 7
RESTRAINT CONTROL SYSTEM 9J1–47

DTC 32 Passenger Pretensioner loop Resistance Low

D09RW014

Circuit Description: Action Taken:


When the ignition switch is turned “ON”, the SDM will SDM turns “ON” the “AIR BAG” warning lamp and sets a
perform tests to diagnose critical malfunctions within diagnostic trouble code.
itself. Upon passing these tests “Ignition 1”, and
pretensioner loop voltages are measured to ensure they DTC Will Clear When:
are within their respective normal voltage ranges. The The ignition switch is turned “OFF.”
SDM then proceeds with the “Resistance Measurement
Test”. “Passenger Belt Low” terminal “10” is grounded DTC Chart Test Description:
through a resistor and the passenger current source Number(s) below refer to step number(s) on the
connected to “Passenger Belt High” terminal “9” allows a diagnostic chart:
known amount of current to flow. By monitoring the 2. This test determines whether the malfunction is in
voltage difference between “Passenger Belt High” and the SDM.
“Passenger Belt Low”, the SDM calculates the combined
3. This test verifies connection of the yellow 2–pin
resistance of the passenger air bag assembly, harness
connector.
wiring IB15–BLU/BLK and IB16–BLU/ORG connector
terminal contact. 4. This test cheeks for proper operation of the shorting
clip in the yellow 2–pin connector.
DTC Will Set When: 5. The test checks for a malfunction passenger
The combined resistance of the passenger air bag pretensioner assembly.
assembly, harness wiring IB15–BLU/BLK and 6. This test determines whether the malfunctioning is
IB16–BLU/ORG, and connector terminal contact is due to shortening in the wiring.
above a specified value. This test is run once each
ignition cycle during the “Resistance Measurement Test” Diagnostic Aids:
when: An intermittent condition is likely to be caused by a short
1. No “higher priority faults” are detected during between IB15–BLU/BLK and IB16–BLU/ORG, or a
“Turn–ON”, malfunctioning shorting clip on the passenger
2. “Ignition 1” voltage is in the specified value. pretensioner assembly which would require replacement
of the pretensioner assembly. The test for this diagnostic
trouble code is only run while “AIR BAG” warning lamp is
9J1–48 RESTRAINT CONTROL SYSTEM
performing the bulb check. When a scan tool “Clear present, the DTC will not reappear until the next ignition
Codes” command is issued and the malfunction is still cycle.

DTC 32 Passenger Pretensioner loop Resistance Low


Step Action Yes No
1 Was the “SRS Diagnostic System Check” performed? Repeat the “SRS
Diagnostic
Go to Step 2 System Check”
2 1. When measurements are requested in this chart use
5–8840–0285–0 DVM with correct terminal adapter from
5–8840–0385–0.
2. Using scan tool data list function, read and record the
passenger pretensioner loop resistance.
Is passenger resist. less than 1.4 ohms? Go to Step 3 Go to Chart A
3 1. Ignition switch “Off.” Seat passenger
2. Make sure the passenger pretensioner assembly yellow 2–pin pretensioner
connector located at the base of the passenger seat. assembly yellow
2–pin connector
Is the yellow 2–pin connector connected properly?
properly
Go to Step 4 Go to Step 7
4 1. Disconnect and inspect the passenger pretensioner assembly
yellow 2–pin connector located at the base of the passenger
seat.
2. If ok, reconnect the passenger pretensioner assembly 2–pin
connector.
3. Ignition switch “ON.”
Is DTC 32 Current? Go to Step 5 Go to Step 7
5 1. Ignition switch “Off.”
2. Disconnect passenger pretensioner assembly, yellow 2–pin Ignition switch
connector located at the base of the passenger seat. “Off”
3. Connect 5–8840–2421–0 SRS driver/passenger load tool and Replace the
appropriate adapters to passenger pretensioner assembly passenger
harness connectors. pretensioner
4. Ignition switch “ON.” assembly
Is DTC 32 current? Go to Step 6 Go to Step 7
6 1. Ignition switch “Off.”
2. There has been a decrease in the total circuit resistance of the
passenger pretensioner loop.
3. Use the high resolution ohmmeter mode of the DVM while Replace SRS
checking IB15–BLU/BLK and IB16–BLU/ORG, and SDM harness or repair
connector terminal “9” and “10” to locate the root cause. chassis harness
Was a fault found? Go to Step 7 Go to Chart A
7 1. Reconnect all components, ensure all component are properly
mounted.
Repeat the “SRS
2. Clear diagnostic trouble codes.
Diagnostic
Was this step finished? System Check” Go to Step 7
RESTRAINT CONTROL SYSTEM 9J1–49

DTC 33 Passenger Pretensioner Loop Short To Voltage

D09RW014

Circuit Description: DTC Chart Test Description:


When the ignition switch is turned “ON”, the SDM will Number(s) below refer to step number(s) on the
perform tests to diagnose critical malfunctions within diagnostic chart:
itself. Upon passing these tests, “Ignition 1”, and 2. This test determines whether the malfunction is in
pretensioner loop voltages are measured to ensure they the SDM.
are within their respective normal voltage ranges. 3. This test isolates the malfunction to one side of the
The SDM monitors the voltages at “Driver Belt Low” passenger pretensioner assembly yellow 2–pin
terminal “10” and “Passenger Belt Low” terminal “22” to connector at the base of the passenger seat.
detect short to B+ in the pretensioner assembly circuits. 4. This test determines whether the malfunction is in
IB15–BLU/BLK.
DTC Will Set When:
5. This test determines whether the malfunction is in
“Ignition 1” is within the normal operating voltage range. IB16–BLU/ORG.
Once these conditions are met and the voltage at
“Passenger pretensioner Low” is above a specified value, Diagnostic Aids:
DTC 33 will set. This test is run once each ignition cycle
and “Continuous Monitoring”. An intermittent condition is likely to be caused by a short
to B+ in the passenger pretensioner assembly circuit.
Action Taken: Inspect IB15–BLU/BLK and IB16–BLU/ORG carefully for
cutting or chafing. If the wiring pigtail of the passenger
SDM turns “ON” the “AIR BAG” warning lamp and sets
pretensioner assembly is damaged, the component must
DTC 33.
be replaced. A careful inspection of IB15–BLU/BLK and
DTC Will Clear When: IB16–BLU/ORG, including the passenger pretensioner
assembly pigtail is essential to ensure that the
The malfunction is no longer occurring and the ignition is replacement SDM will not be damaged.
turned “OFF”.
9J1–50 RESTRAINT CONTROL SYSTEM

DTC 33 Passenger Pretensioner Loop Short To Voltage


Step Action Yes No
1 Perform the “SRS Diagnostic System Check” Repeat the “SRS
Diagnostic
Was the “SRS Diagnostic System Check” performed?
Go to Step 2 System Check”
2 1. When measurements are requested in this chart use
5–8840–0285–0 DVM With correct terminal adapter from
5–8840–0385–0.
2. Ignition switch “OFF.”
3. Connect scan tool data link connector. follow directions as
given in the scan tool operator’s manual.
4. Ignition switch “ON.”
5. Read passenger belt sense LO.
Is passenger belt sense LO more than 3.5 volts? Go to Step 3 Go to Chart A
3 1. Ignition switch “OFF”.
2. Disconnect passenger pretensioner assembly yellow 2–pin
connector at the base of the passenger seat. Ignition switch
3. Leave driver pretensioner assembly connected. “OFF”
4. Connect SRS driver / passenger load tool 5–8840–2421–0 Replace
and appropriate adapter to passenger air bag assembly passenger
harness connector. pretensioner
5. Ignition switch “ON.” assembly
Is DTC 33 current? Go to Step 4 Go to Step 6
4 1. Ignition switch “OFF.”
2. Disconnect SRS driver / passenger load tool.
3. Measure resistance on SDM harness connector from terminal Replace SRS
“9” to terminal “12” (ignition). harness
Does 5–8840–0285–0 display “OL” (infinite)? Go to Step 5 Go to Step 6.
5 Measure resistance on SDM harness connector from terminal Replace SRS
“10” and terminal “12” (ignition). harness
Does 5–8840–0285–0 display “OL” (infinite)? Go to Chart A Go to Step 6
6 1. Reconnect all components ensure all component are properly
mounted.
Repeat the “SRS
2. Clear diagnostic trouble codes.
Diagnostic
Was this step finished? System Check” Go to Step 6
RESTRAINT CONTROL SYSTEM 9J1–51

DTC 34 Passenger Pretensioner Loop Open

D09RW014

Circuit Description: below a specified value for 500 milliseconds during


When the ignition switch is turned “ON”, the SDM will “Continuous Monitoring”.
perform tests to diagnose critical malfunctions within
itself. Upon passing these tests, “Ignition 1”, and
DTC Chart Test Description:
pretensioner loop voltages are measured to ensure they Number(s) below refer to step number(s) on the
are within their respective normal voltage ranges. During diagnostic chart:
“Continuous Monitoring” diagnostics, a fixed amount of 2. This test determines whether the malfunction is in
current is flowing in the deployment loop. This produces the SDM.
proportional voltage drops in the loop. By monitoring the 3. This test verifies proper connection of the yellow
voltage difference between “Passenger Belt High” and 2–pin connector.
“Passenger Belt Low”, the SDM calculates the combined 4. This test cheeks for proper contact and/or corrosion
resistance of the passenger pretensioner assembly, of the shorting clip in the yellow 2–pin connector
harness wiring IB15–BLU/BLK AND IB16–BLU/ORG, terminals.
and connector terminal contact. 5. The test checks for a malfunctioning passenger
pretensioner assembly.
DTC Will Set When:
6. This test determines whether the open in the wiring.
The voltage difference between “Passenger pretensioner
High” terminal “9” and “Passenger pretensioner Low” Diagnostic Aids:
terminal “10” is above or equal to a specified value for 500
An intermittent condition is likely to be caused by a poor
milliseconds during “Continuous Monitoring”.
connection at the passenger pretensioner assembly
Action Taken: harness connector terminals“1” and “2”, SDM terminals
“9” and “10”, or an open in IB15–BLU/BLK and
SDM turns “ON” the “AIR BAG” warning lamp and sets a IB16–BLU/ORG.
diagnostic trouble code.

DTC Will Clear When:


The voltage difference between “Passenger Belt High”
terminal “9” and “Passenger Belt Low” terminal “10” is
9J1–52 RESTRAINT CONTROL SYSTEM

DTC 34 Passenger Pretensioner Loop Open


Step Action Yes No
1 Was the “SRS Diagnostic System Check” performed? Go to the “SRS
Diagnostic
Go to Step 2 System Check”
2 1. When measurements are requested in this chart use
5–8840–0285–0 DVM with correct terminal adapter from
5–8840–0385–0.
2. Using scan tool data list function, read and record the
passenger pretensioner differential voltage.
Is passenger pretensioner VDIF 0.425 volts or more? Go to Step 3 Go to Chart A
3 1. Ignition switch “OFF”. Seat passenger
2. Make sure the passenger pretensioner assembly yellow 2–pin pretensioner
connector located at the base of the passenger seat. assembly yellow
2–pin connector
Is the yellow 2–pin connector connected properly?
properly
Go to Step 4 Go to Step 7
4 1. Disconnect and inspect the passenger pretensioner assembly
yellow 2–pin connector located at the base of the passenger
seat.
2. If ok, reconnect the passenger pretensioner assembly 2–pin
connector.
3. Ignition switch “ON”.
Is DTC 34 current? Go to Step 5 Go to Step 7
5 1. Ignition switch “Off.”
2. Disconnect the passenger pretensioner assembly, yellow Ignition switch
2–pin connector located at the base of the passenger seat. “Off”
3. Connect 5–8840–2421–0 SRS driver / passenger load tool Replace the
and appropriate adapters to passenger pretensioner passenger
assembly harness connectors. pretensioner
4. Ignition switch “ON.” assembly
Is DTC 34 current? Go to Step 6 Go to Step 7
6 1. Ignition switch “Off.”
2. There has been an open circuit resistance in the passenger
pretensioner loop.
3. Use the high resolution ohmmeter mode of the DVM while Replace SRS
checking IB15–BLU/BLK and IB16–BLU/ORG, and SDM harness or repair
connector terminal “9” and “10” to locate the root cause. chassis harness
Was a fault found? Go to Step 7 Go to Chart A
7 1. Reconnect all components ensure all component are properly
mounted.
Go to the “SRS
2. Clear diagnostic trouble codes.
Diagnostic
Was this step finished? System Check” Go to Step 7
RESTRAINT CONTROL SYSTEM 9J1–53

DTC 41 Driver Pretensioner Loop Resistance High

D09RW014

Circuit Description: Action Taken:


When the ignition switch is turned “ON”, the SDM will SDM turns “ON” the “AIR BAG” warning lamp and sets
perform tests to diagnose critical malfunctions within DTC 41.
itself. Upon passing these tests, “Ignition 1”, and
pretensioner loop voltages are measured to ensure they DTC Will Clear When:
are within their respective normal voltage ranges. The ignition switch is turned “OFF”.
The SDM then proceeds with the “Resistance
Measurement Test” “Driver Belt Low” terminal “22” is DTC Chart Test Description:
grounded through a current sink and the driver current Number(s) below refer to step number(s) on the
source connected to “Driver Belt High” terminal “21” diagnostic chart:
allows a known amount of current to flow. By monitoring 2. This test determines whether the malfunction is in
the voltage difference between “Driver Belt High” and the SDM.
“Driver Belt Low”, the SDM calculates the combined
3. This test verifies proper connection of the yellow
resistance of the driver pretensioner assembly, harness
2–pin connector at the base of the driver seat.
wiring IB13–BLU/RED and IB14–BLU/YEL, and
connector terminal contact. 4. This test checks for proper contact and/or corrosion
of the 2–pin connector terminals at the base of the
DTC Will Set When: driver seat.
The combined resistance of the driver pretensioner 5. This test isolate the malfunction to one side of the
assembly, harness wiring IB13–BLU/RED and pretensioner assembly yellow 2–pin connector
IB14–BLU/YEL, and connector terminal contact is above located at the base of the driver seat.
a specified value. This test run once each ignition cycle 6. This test determines whether the malfunction is due
during the “Resistance Measurement Test” when: to high resistance in the wiring.
1. No “higher priority faults” are detected during
“Turn–ON”
2. “Ignition 1” voltage is in the specified value.
9J1–54 RESTRAINT CONTROL SYSTEM
Diagnostic Aids: IB14–BLU/YEL. The test for this diagnostic trouble code
An intermittent condition is likely to be caused by a poor is only run while the “AIR BAG” warning lamp is
connection at terminals “3” and “4” of the driver performing the bulb check. When a scan tool “Clear
pretensioner assembly 2–pin connector at the base of the Codes” command is issued and the malfunction is still
driver seat. SDM terminals “21” and “22” or a poor wire to present, the DTC will not reappear until the next ignition
terminal connection in IB13–BLU/RED or cycle.

DTC 41 Driver Pretensioner Loop Resistance High


Step Action Yes No
1 Perform the “SRS Diagnostic System Check”. Repeat the “SRS
Diagnostic
Was the “SRS Diagnostic System Check” performed?
Go to Step 2 System Check”
2 1. When measurements are requested in this chart use
5–8840–0285–0 DVM with correct terminal adapter from
5–8840–0385–0.
2. Use scan tool data list function, read and record the driver
pretensioner loop resistance.
Is driver resistance more than 3.7 ohms? Go to Step 3 Go to Chart A
3 1. Ignition switch “OFF.” Driver
2. Disconnect driver pretensioner assembly yellow 2–pin pretensioner
connector located at base of the driver seat. assembly 2–pin
connector
Is the 2–pin connector connected properly?
properly
Go to Step 4 Go to Step 7
4 1. Disconnect and inspect the driver pretensioner assembly
yellow 2–Pin connector located base of the driver seat.
2. If ok, reconnect the driver pretensioner assembly yellow 2–pin
connector.
3. Ignition switch “ON.”
Is DTC 41 current? Go to Step 5 Go to Step 7
5 1. Ignition switch “OFF.”
2. Disconnect driver pretensioner assembly, yellow 2–pin
connector located at the base of the driver seat.
3. Connect SRS driver / passenger load tool 5–8840–2421–0
and appropriate adapter to driver pretensioner assembly
harness connectors.
4. Ignition switch “ON.”
Is DTC 41 current? Go to Step 6 Go to Step 7
6 1. Ignition switch “Off.”
2. There has been a increase in the total circuit resistance of the
driver pretensioner loop.
3. Use the high resolution ohmmeter mode of the DVM while Replace SRS
checking IB13–BLU/RED and IB14–BLU/YEL, and SDM harness or repair
connector terminal “21” and “22” to locate the root cause. chassis harness
Was a fault found? Go to Step 7 Go to Chart A
7 1. Reconnect all components ensure all component are properly
mounted.
Repeat the “SRS
2. Clear diagnostic trouble codes.
Diagnostic
Was this step finished? System Check” Go to Step 7
RESTRAINT CONTROL SYSTEM 9J1–55

DTC 42 Driver Pretensioner Loop Resistance Low

D09RW014

Circuit Description: Action Taken:


When the ignition switch is turned “ON”, the SDM will SDM turns “ON” the “AIR BAG” warning lamp and sets
perform tests to diagnose critical malfunctions within DTC 42.
itself. Upon passing these tests “Ignition 1”, and
pretensioner loop voltages are measured to ensure they DTC Will Clear When:
are within their respective normal voltage ranges. The ignition switch is turned “OFF.”
The SDM then proceeds with the “Resistance
Measurement Test” “Driver Belt Low” terminal “22” is DTC Chart Test Description:
grounded through a current sink and the driver current Number(s) below refer to circled number(s) on the
source connected to “Driver Belt High” terminal “21” diagnostic chart:
allows a known amount of current to flow. By monitoring 2. This test determines whether the malfunction is in
the voltage difference between “Driver Belt High” and the SDM.
“Driver Belt Low” the SDM calculates the combined
3. This test verifies proper connection of the yellow
resistance of the driver pretensioner assembly, harness
2–pin connector at the base of the driver seat.
wiring IB13–BLU/RED and IB14–BLU/YEL and
connector terminal contact. 4. This test checks for proper operation of the shorting
clip in the yellow 2–pin connector.
DTC Will Set When: 5. This test isolate the malfunction to one side of the
The combined resistance of the driver pretensioner pretensioner assembly yellow 2–pin connector
assembly, harness wiring IB13–BLU/RED and located at the base of driver seat.
IB14–BLU/YEL and connector terminal contact is above 6. This test determines whether the malfunction is due
a specified value. This test is run once each ignition cycle to shortening in the wiring.
during the “Resistance Measurement Test” when:
1. No “higher priority faults” are detected during Diagnostic Aids:
“Turn–ON” An intermittent condition is likely to be caused by a short
2. “Ignition 1” voltage is in the specified value. between IB13–BLU/RED or IB14–BLU/YEL or a
malfunctioning shorting clip on the driver pretensioner
assembly which would require replacement of the
component. The test for this diagnostic trouble code is
9J1–56 RESTRAINT CONTROL SYSTEM
only run while the “AIR BAG” warning lamp is performing command is issued and the malfunction is still present,
the bulb check. When a scan tool “Clear Codes” the DTC will not reappear until the next ignition cycle.

DTC 42 Driver Pretensioner Loop Resistance Low


Step Action Yes No
1 Perform the “SRS Diagnostic System Check.” Go to the “SRS
Diagnostic
WAS THE “SRS Diagnostic System Check” performed?
Go to Step 2 System Check”
2 1. When measurements are requested in this chart use
5–8840–0285–0 DVM with correct terminal adapter from
5–8840–0385–0.
2. Use scan tool data list function, read and record the driver
pretensioner loop resistance.
Is driver pretensioner loop resistance less than 1.4 OHMS? Go to Step 3 Go to Chart A
3 1. Ignition switch “OFF.” Seat driver
2. Make sure the driver pretensioner assembly yellow 2–pin pretensioner
connector located at the base of the driver seat is connected assembly 2–pin
properly. connector
properly
Is the 2–pin connector connected properly?
Go to Step 4 Go to Step 7
4 1. Disconnect and inspect the driver pretensioner assembly
yellow 2–pin connector located base of the driver seat.
2. If ok, reconnect the driver pretensioner assembly yellow 2–pin
connector.
3. Ignition switch “ON.”
Is DTC 42 current? Go to Step 5 Go to Step 7
5 1. Ignition switch “OFF.”
2. Disconnect driver pretensioner assembly, yellow 2–pin
connector located at the base of driver seat.
3. Connect SRS driver / passenger load tool 5–8840–2421–0
and appropriate adapter to driver pretensioner assembly
harness connectors.
4. Ignition switch “ON.”
Is DTC 42 current? Go to Step 6 Go to Step 7
6 1. Ignition switch “OFF.”
2. There has been a decrease in the total circuit resistance of the
driver pretensioner loop.
3. Use the high resolution ohmmeter mode of the DVM while Replace SRS
checking IB13–BLU/RED and IB14–BLU/YEL, and SDM harness or repair
connector terminal “21” and “22” to locate the root cause. chassis harness
Was a fault found? Go to Step 7 Go to Chart A
7 1. Reconnect all components, ensure all component are properly
mounted.
Go to the “SRS
2. Clear diagnostic trouble codes.
Diagnostic
Was this step finished? System Check” Go to Step 7
RESTRAINT CONTROL SYSTEM 9J1–57

DTC 44 Driver Pretensioner Loop Open

D09RW014

Circuit Description: a specified value for 500 milliseconds during “Continuous


When the ignition switch is turned “ON”, the SDM will Monitoring”.
perform tests to diagnose critical malfunctions within
itself. Upon passing these tests, “Ignition 1”, and
DTC Chart Test Description:
pretensioner loop voltages are measured to ensure they Number(s) below refer to step number(s) on the
are within their respective normal voltage ranges. diagnostic chart:
During “Continuous Monitoring” diagnostics, a fixed 2. This test determines whether the malfunction is in
amount of current is following in the pretensioner loop. the SDM.
This produces proportional voltage drops in the loop. By 3. This test verifies proper connection of the yellow
monitoring the voltage difference between “Driver Belt 2–pin connector at the base of the driver seat.
High” and “Driver Belt Low”, the SDM calculates the 4. This test checks for proper contact and/or corrosion
combined resistance of the driver pretensioner assembly, of the yellow 2–pin connector at the base of the
harness wiring IB13–BLU/RED and IB14–BLU/YEL, and driver seat.
connector terminal contact. 5. This test isolates the malfunction to one side of the
driver pretensioner assembly yellow 2–pin
DTC Will Set When: connector located at the base of driver seat.
The voltage difference between “Driver Belt High” 6. This test determines whether the open is in the
terminal “21” and “Driver Belt Low” terminal “22” is above wiring.
or equal to a specified value for 500 milliseconds during
“Continuous Monitoring”. Diagnostic Aids:
Action Taken: An intermittent condition is likely to be caused by a poor
connection at the driver pretensioner assembly harness
SDM turns “ON” the “AIR BAG” warning lamp and sets a 2–pin connector terminals “3” and “4” at the top of the
diagnostic trouble code. steering column, SDM terminals “21” and “22”, or an open
in IB13–BLU/RED and IB14–BLU/YEL.
DTC Will Clear When:
The voltage difference between “Driver Belt High”
terminal “21” and “Driver Belt Low” terminal “22” is below
9J1–58 RESTRAINT CONTROL SYSTEM

DTC 44 Driver Pretensioner Loop Open


Step Action Yes No
1 Was the “SRS Diagnostic System Check” performed? Go to the “SRS
Diagnostic
Go to Step 2 System Check”
2 1. When measurements are requested in this chart use
5–8840–0285–0 DVM with correct terminal adapter from
5–8840–0385–0.
2. Use scan tool data list function, read and record the driver
pretensioner circuit differential voltage.
Is driver pretensioner VDIF more than 4.25 volts? Go to Step 3 Go to Chart A
3 1. Ignition switch “OFF.” Seat driver
2. Make sure the driver pretensioner assembly yellow 2–pin pretensioner
connector located at the base of the driver seat is seated assembly 2–pin
properly. connector
Is the yellow 2–pin connector connected properly? Go to Step 4 Go to Step 7
4 1. Disconnect and inspect the driver pretensioner assembly
yellow 2–pin connector located base of the driver seat.
2. If ok, reconnect the driver pretensioner assembly yellow 2–pin
connector.
3. Ignition switch “ON.”
Is DTC 44 current? Go to Step 5 Go to Step 7
5 1. Ignition switch “OFF”.
2. Disconnect driver pretensioner assembly, yellow 2–pin
connectors located at the base of the driver seat.
3. Connect SRS driver/passenger load tool 5–8840–2421–0 and
appropriate adapter to driver pretensioner assembly harness
connectors.
4. Ignition switch “ON.”
Is DTC 44 current? Go to Step 6 Go to Step 7
6 1. Ignition switch “OFF.”
2. There has been an open circuit in the driver pretensioner loop.
3. Use the high resolution ohmmeter mode of the DVM while Replace SRS
checking IB13–BLU/RED and IB14–BLU/YEL, and SDM harness or repair
connector terminal “21” and “22” to locate the root cause. chassis harness
Was a fault found? Go to Step 7 Go to Chart A
7 1. Reconnect all components ensure all component are properly
mounted.
Repeat the “SRS
2. Clear diagnostic trouble codes.
Diagnostic
Was this step finished? System Check” Go to Step 7
RESTRAINT CONTROL SYSTEM 9J1–59

DTC 45 Driver Pretensioner Loop Short To Ground

D09RW014

Circuit Description: DTC Will Clear When:


When the ignition switch is turned “ON”, the SDM will The malfunction is no longer occurring and the ignition is
perform tests to diagnose critical malfunctions within turned “OFF”.
itself. Upon passing these tests, “Ignition 1”, and
pretensioner loop voltages are measured to ensure they DTC Chart Test Description:
are within their respective normal voltage ranges. Number(s) below refer to step number(s) on the
The SDM monitors the voltage at “Driver Belt Low” diagnostic chart:
terminal “22” and “passenger Belt Low” terminal “10” to 2. This test determines whether the SDM is
detect shorts to ground in the air bag assembly circuits. malfunctioning
3. This test isolates the malfunction to one side of the
DTC Will Set When: driver pretensioner assembly yellow 2–pin
Neither of the air bag and the pretensioner belt are open. connector at the base of the driver seat.
“Ignition 1” is within the normal operating voltage range. 4. This test determines whether the malfunction is in
This test is run once each ignition cycle and “Continuous IB13–BLU/RED.
Monitoring”. Once these conditions are met and the
5. This test determines whether the malfunction is in
voltage at “Driver Belt Low” is below a specified value,
IB14–BLU/YEL.
DTC 45 will set.

Action Taken: Diagnostic Aids:


SDM turns “ON” the “AIR BAG” warning lamp and sets a An intermittent condition is likely to be caused by a short
diagnostic trouble code. to ground in the driver pretensioner assembly circuit.
Inspect IB13–BLU/RED and IB14–BLU/YEL carefully for
cutting or chafing.
9J1–60 RESTRAINT CONTROL SYSTEM

DTC 45 Driver Pretensioner Loop Short To Ground


Step Action Yes No
1 Was the “SRS Diagnostic System Check” performed? Go to the “SRS
Diagnostic
Go to Step 2 System Check”
2 1. When measurements are requested in this chart use
5–8840–0285–0 DVM with correct terminal adapter from
5–8840–0385–0.
2. Ignition switch “OFF.”
3. Connect scan tool data link connector. follow directions as
given in the scan tool operator’s manual.
4. Ignition switch “ON.”
5. Read driver belt sense LO.
Is driver belt sense LO less than 1.5 volts? Go to Step 3 Go to Chart A
3 1. Ignition switch “OFF.”
2. Disconnect driver pretensioner assembly yellow 2–pin
connector located at base of the driver seat, leave passenger
pretensioner assembly connected.
3. Connect SRS driver / passenger load tool 5–8840–2421–0
and appropriate adapter to driver pretensioner assembly
harness connector.
4. Ignition switch “ON.”
Is DTC 45 current? Go to Step 4 Go to Step 6
4 1. Ignition switch “OFF.”
2. Disconnect SDM.
3. Disconnect SRS driver / passenger load tool. Replace SRS
4. Measure resistance on SDM harness connector “21” to harness or repair
terminal “6” (ground). chassis harness
Does 5–8840–0285–0 display “OL” (infinite)? Go to Step 5 Go to Step 6
5 Measure resistance on SDM harness connector from terminal Replace SRS
“22” to terminal “6” (ground). harness or repair
chassis harness
Does 5–8840–0285–0 display “OL” (infinite)?
Go to Chart A Go to Step 6
6 1. Reconnect all components ensure all component are properly
mounted.
Go to the “SRS
2. Clear diagnostic trouble codes.
Diagnostic
Was this step finished? System Check” Go to Step 6
RESTRAINT CONTROL SYSTEM 9J1–61

DTC 46 Driver Pretensioner Loop Short To Voltage

D09RW014

Circuit Description: DTC Chart Test Description:


When the ignition switch is turned “ON”, the SDM will Number(s) below refer to step number(s) on the
perform tests to diagnose critical malfunctions within diagnostic chart:
itself. Upon passing these tests, “Ignition 1”, and 2. This test determines whether the SDM is
pretensioner loop voltages are measured to ensure they malfunctioning.
are within their respective normal voltage ranges. 3. This test isolates the malfunction to one side of the
The SDM monitors the voltage at “Driver Belt Low” driver pretensioner assembly yellow 2–pin
terminal “22” and “Passenger Belt Low” terminal “10” to connector at the base of the driver seat.
detect shorts to B+ in the pretensioner assembly circuits. 4. This test determines whether the malfunction is in
IB13–BLU/RED.
DTC Will Set When:
5. This test determines whether the malfunction is in
“Ignition 1” is in the normal operating voltage range. This IB14–BLU/YEL.
test is run once each ignition cycle and “Continuous
monitoring”. Once these conditions are met and the Diagnostic Aids:
voltage at “Driver Belt Low” is above a specified value,
DTC 46 will set. An intermittent condition is likely to be caused by a short
to B+ in the driver pretensioner assembly circuit. Inspect
Action Taken: IB13–BLU/RED and IB14–BLU/YEL carefully for cutting
or chafing. If the wiring pigtail of the driver pretensioner
SDM turns “ON” the “AIR BAG” warning lamp and sets
assembly is damaged, the components must be
DTC 46.
replaced. A careful inspection of IB13–BLU/RED and
DTC Will Clear When: IB14–BLU/YEL, including the driver pretensioner
assembly is essential to ensure that the replacement
The malfunction is no longer occurring and the ignition is SDM will not be damaged.
turned “OFF”.
9J1–62 RESTRAINT CONTROL SYSTEM

DTC 46 Driver Pretensioner Loop Short To Ignition


Step Action Yes No
1 Was the “SRS Diagnostic System Check” performed? Go to the “SRS
Diagnostic
Go to Step 2 System Check”
2 1. When measurements are requested in this chart use
5–8840–0285–0 DVM with correct terminal adapter from
5–8840–0385–0.
Ignition switch “OFF.”
Connect scan tool data link connector. follow directions as
given in the scan tool operator’s manual.
2. Ignition switch “ON.”
3. Read driver belt sense LO .
Is driver belt sense LO more than 3.5 volts? Go to Step 3 Go to Chart A
3 1. Ignition switch “OFF.”
2. Disconnect driver pretensioner assembly yellow 2–pin
connector at the base of the driver seat, leave passenger
pretensioner assembly connected. Ignition switch
3. Connect SRS driver /passenger load tool 5–8840–2421–0 and “OFF”
appropriate adapter to driver pretensioner assembly harness Replace driver
connector. pretensioner
4. Ignition switch “ON.” assembly
Is DTC 46 current? Go to Step 4 Go to Step 6
4 1. Ignition switch “OFF.”
2. Disconnect SDM.
3. Disconnect SRS driver /passenger load tool. Replace SRS
4. Measure resistance on SDM harness connector “21” to harness or repair
terminal “12” (ignition). chassis harness
Does 5–8840–0285–0 display “OL” (infinite)? Go to Step 5 Go to Step 6
5 Measure resistance on SDM harness connector from terminal Replace SRS
“22” to terminal “12” (ignition). harness or repair
chassis harness
Does 5–8840–0285–0 display “OL” (infinite)?
Go to Chart A Go to Step 6
6 1. Reconnect all components ensure all component are properly
mounted.
Go to the “SRS
2. Clear diagnostic trouble codes.
Diagnostic
Was this step finished? System Check” Go to Step 6
RESTRAINT CONTROL SYSTEM 9J1–63

DTC 52 Pretensioner Deployment Event Commanded

D09RW014

Circuit Description: Action Taken:


The SDM contains a sensing device which converts SDM turns “ON” the “AIR BAG” warning lamp records
vehicle velocity changes to an electrical signal. The “Crash Data”, and sets a diagnostic trouble code.
electrical signal generated is processed by the SDM and
then compared to a value stored in memory. When the DTC Will Clear When:
generated signal exceeds the stored value, the SDM will The SDM is replaced.
cause current to flow through the pretensioner assembly
deploying the pretensioners and causing DTC 52 to set. DTC Chart Test Description:
Number(s) below refer to step number(s) on the
DTC Will Set When: diagnostic chart:
The SDM detects a frontal crash, up to 30 degrees off the 2. If pretensioner assembly (s) has not deployed, DTC
centerline of the vehicle, of sufficient force to warrant 52 may have falsely set.
deployment of the air bags and pretensioner seat belt. 3. If DTC 52 has set with no signs of frontal impact, the
diagnostic trouble code has falsely set.
9J1–64 RESTRAINT CONTROL SYSTEM

DTC 52 Deployment Event Commanded


WARNING: DURING SERVICE PROCEDURES. BE VERY CAREFUL WHEN HANDLING A SENSING AND
DIAGNOSTIC MODULE (SDM). NEVER STRIKE OR JAR THE SDM. NEVER POWER UP THE PRETENSIONER
WHEN THE SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SDM AND MOUNTING BRACKET
FASTENERS MUST BE CAREFULLY TORQUED AND THE ARROW MUST BE POINTING TOWARD THE FRONT
OF THE VEHICLE TO ENSURE PROPER OPERATION OF THE PRETENSIONER. THE SDM COULD BE
ACTIVATED WHEN POWERED WHILE NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH COULD CAUSE
DEPLOYMENT AND RESULT IN PERSONAL INJURY.

Step Action Yes No


1 Was the “SRS Diagnostic System Check” performed? Go to the “SRS
Diagnostic
Go to Step 2. System Check”
2 Ignition switch “OFF.” Replace
components and
Have pretensioner assemblies deployed?
perform
inspections as
directed in
“repairs and
inspections
required after an
accident” in this
section
clear diagnostic
trouble codes
Repeat “SRS
Diagnostic
System Check” Go to Step 3
3 Inspect front of vehicle and undercarriage for sings of impact. Replace
components and
Were signs of impact found?
perform
inspections as Ignition switch
directed in “OFF”
“Repairs and Replace SDM
Inspections Reconnect all
Required After An SRS system
Accident” in this components,
section ensure all
Clear diagnostic components are
trouble codes properly mounted
Repeat “SRS Repeat “SRS
Diagnostic Diagnostic
System Check” System Check”
CRUISE CONTROL SYSTEM 10A–1

CONTROL SYSTEM
CRUISE CONTROL SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 10A–1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A–5
General Description . . . . . . . . . . . . . . . . . . . . . 10A–1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A–5
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A–2 Cruise Control Switch (Combination Switch) 10A–5
Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A–2 Removal and Installation . . . . . . . . . . . . . . . 10A–5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A–2 Cruise Control Unit . . . . . . . . . . . . . . . . . . . . . . 10A–6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A–2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A–6
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A–3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A–6
Clutch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A–3 Cruise Actuator . . . . . . . . . . . . . . . . . . . . . . . . . 10A–7
Removal and Installation . . . . . . . . . . . . . . . 10A–3 Actuator Cable Diagram (LHD) . . . . . . . . . . 10A–7
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A–3 Actuator Cable Diagram (RHD) . . . . . . . . . . 10A–7
Starter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A–4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A–8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A–4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A–8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A–4 Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A–8
Cruise Control Main Switch . . . . . . . . . . . . . . . 10A–5 Removal and Installation . . . . . . . . . . . . . . . 10A–8

Service Precaution General Description


WARNING: IF SO EQUIPPED WITH A The cruise control keeps the vehicle running at a fixed
SUPPLEMENTAL RESTRAINT SYSTEM (SRS), speed until a signal canceling this fixed speed is received .
REFER TO THE SRS COMPONENT AND WIRING When the main switch “AUTO CRUISE” is turned on with
LOCATION VIEW IN ORDER TO DETERMINE the vehicle in the running mode, the battery voltage is
WHETHER YOU ARE PERFORMING SERVICE ON OR applied to the control unit. When a signal from the control
NEAR THE SRS COMPONENTS OR THE SRS switch is input to the control unit while the vehicle is in this
WIRING. WHEN YOU ARE PERFORMING SERVICE state, the cruise control actuator is activated to operate
ON OR NEAR THE SRS COMPONENTS OR THE SRS the system. Also, while the system is operating, the
WIRING, REFER TO THE SRS SERVICE “AUTO CRUISE” indicator light in the meter assembly
INFORMATION. FAILURE TO FOLLOW WARNINGS lights up.
COULD RESULT IN POSSIBLE AIR BAG 1. SET/COAST Switch Function
DEPLOYMENT, PERSONAL INJURY, OR 1. Set Function: When the SET/COAST switch is
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. pressed and released with the main switch on, the
CAUTION: Always use the correct fastener in the speed at which the vehicle is running at that moment
proper location. When you replace a fastener, use is stored in the memory, and the vehicle automatically
ONLY the exact part number for that application. runs at the stored speed.
ISUZU will call out those fasteners that require a 2. Coast-down Function: When the SET/COAST
replacement after removal. ISUZU will also call out switch is kept on while the vehicle in running, the
the fasteners that require thread lockers or thread vehicle decelerates during that time. The speed at
sealant. UNLESS OTHERWISE SPECIFIED, do not which vehicle is running when the control switch is
use supplemental coatings (Paints, greases, or other turned off is stored in the memory, and the vehicle
corrosion inhibitors) on threaded fasteners or automatically returns to the stored speed.
fastener joint interfaces. Generally, such coatings 3. Tap-down Function: When the SET/COAST switch
adversely affect the fastener torque and the joint is turned on and off instantaneously while the vehicle
clamping force, and may damage the fastener. When is running, the vehicle decelerates a mile for each
you install fasteners, use the correct tightening on/off operation. The vehicle speed at which the
sequence and specifications. Following these vehicle was running when the SET/COAST was
instructions can help you avoid damage to parts and turned off last is stored in the memory, and the vehicle
systems. automatically returns to this stored speed.
10A–2 CRUISE CONTROL SYSTEM

2. RESUME/ACCEL Switch Function 3. CANCEL Function


1. Resume Function: When the RESUME/ACCEL 1. Temporary Cancellation:
switch is turned on/off after the system is temporarily When the brake pedal is pressed.
deactivated by pressing the brake or clutch pedal
When the clutch pedal is pressed. (M/T)
while the vehicle is running, the vehicle resumes the
speed stored before the system was released, and When the select lever is shifted to any position other
the vehicle automatically runs at the stored speed . than “D”, “3”, “2” or “L”. (A/T)
2. Accelerate Function: When the RESUME/ACCEL When the cancel switch is operated.
switch is kept on after the system is released When the vehicle speed exceeds about 20 km/h
completely, the vehicle accelerates its speed during over the vehicle speed stored in the memory.
that time. The vehicle speed at which the vehicle was Turning the RESUME/ACCEL switch will return the
running when the switch was turned off is stored in the vehicle to the speed stored in the cruise control
memory, and the vehicle automatically returns to this memory.
speed.
2. Complete Cancellation:
3. Tap-up Function: When the RESUME/ACCEL
switch is turned on and off instantaneously while the When the starter switch or the main switch is turned
vehicle is running, the vehicle decelerates a mile for off.
each on/off operation. The vehicle speed at which the When the fail-safe function is activated.
vehicle was running when the switch was turned off When the vehicle speed is about 38.5 km/h.
last is stored in the memory, and the vehicle
automatically returns to this stored speed. Diagnosis
Refer to the Cruise Control System Diagnosis in Wiring
System section.

Brake Switch
Removal 2. Turn the switch clockwise until the tip of the threaded
portion of the brake switch contacts the pedal arm.
1. Disconnect the battery ground cable. 3. Turn the switch counterclockwise until the space
2. Remove the brake switch (1). between the tip of the threaded portion and the pedal
Disconnect the connector. arm is 0.5 to 1.0 mm (0.02-0.04 in.) as shown in the
figure.
Loosen the lock nuts of the switch.
Remove the switch by turning it.

310RS003

310RS004

Installation
To install, follow the removal steps in the reverse order,
noting the following points.
1. Check to see if the brake pedal has been returned by
the return spring to the specified position.
CRUISE CONTROL SYSTEM 10A–3

Adjustment
1. Check to be sure that the brake pedal (3) has been
completely returned by the return spring.
2. Disconnect the switch connector.
3. Loosen the lock nut (1) of the switch (2).
4. Turn the switch clockwise until the tip of screw portion
of the brake pedal hits the pedal arm.
5. Turn the switch counterclockwise until the clearance
between the tip of the screw portion and the pedal arm
becomes 0.5 to 1.0 mm (0.02-0.04 in).
6. Tighten the lock nut.
7. Connect the switch connector.

310RW006

Clutch Switch
Removal and Installation
Refer to the Clutch Control removal and installation steps
in Clutch section.

Adjustment
1. Check to be sure that the clutch pedal (1) has been
completely returned by the return spring.
2. Disconnect the switch connector.
3. Loosen the lock nut (2) of the switch (3).
4. Push the switch by hand until the push rod cannot be
seen from the tip portion of the switch.
5. Give the switch one reverse rotation.
6. Tighten the lock nut.
7. Connect the switch connector.

203RW002
10A–4 CRUISE CONTROL SYSTEM

Starter Switch
Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order,
noting the following point.
2. Remove the front console assembly (1). Refer to the
Instrument Panel Assembly in Body Structure 1. When installing the steering cowl (10), be sure to pass
section. the harnesses through the route as shown in the
figure so that the starter switch harness (7), the
3. Remove the lower cluster assembly (2). Refer to the
combination switch harness (8) and the inflator
Instrument Panel Assembly in Body Structure
module harness (9) will not catch.
section.
4. Remove the instrument panel driver lower cover
assembly (3). Refer to the Instrument Panel
Assembly in Body Structure section.

821RW024

5. Remove seven screws to remove the steering cowl


(6).
6. Disconnect the connector, remove the screw (4) and
then remove the starter switch (5).

825RW058

431RW005
CRUISE CONTROL SYSTEM 10A–5

Cruise Control Main Switch


Removal 5. Remove the instrument panel cluster assembly (5).
Refer to the Instrument Panel Assembly in Body
1. Disconnect the battery ground cable. Structure section.
2. Remove the front console assembly (1). Refer to the 6. Disconnect the and push the lock from the side of the
Instrument Panel Assembly in Body Structure instrument panel cluster assembly to remove the
section. cruise control main switch (4).
3. Remove the lower cluster assembly (2). Refer to the
Instrument Panel Assembly in Body Structure
section.
4. Remove the instrument panel driver lower cover
assembly (3). Refer to the Instrument Panel
Assembly in Body Structure section.

821RW079

Installation
To install, follow the removal steps in the reverse order,
noting the following point.
821RW024
1. Push in the switch with your fingers until the switch is
locked securely.

Cruise Control Switch (Combination Switch)


Removal and Installation
Refer to the Lighting Switch (Combination Switch)
removal and installation steps of Lighting System in Body
and Accessories section.
10A–6 CRUISE CONTROL SYSTEM

Cruise Control Unit


Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Remove the dash side trim panel (RH)(2).
3. Disconnect the connector.
4. Remove a fixing nut to remove the cruise control unit
(1).

825RW050
CRUISE CONTROL SYSTEM 10A–7

Cruise Actuator
Actuator Cable Diagram (LHD)

825RW051

Legend (3) Accel Control Cable


(1) Cruise Actuator Assembly (4) Cam Link (Cruise Control Side)
(2) Cruise Control Cable

Actuator Cable Diagram (RHD)

825RW221

Legend (3) Accel Control Cable


(1) Cruise Actuator Assembly (4) Cam Link (Cruise Control Side)
(2) Cruise Control Cable
10A–8 CRUISE CONTROL SYSTEM

Removal
1. Disconnect the battery ground cable. Installation
2. Remove the cruise actuator Assembly (4). To install, follow the removal steps in the reverse order,
Disconnect the connector (3). noting the following point.
1. Take care not to bend the cable excessively.
Remove the cable end (1) from the cam link (cruise
control side).
Loosen two fixing nuts (2).
Remove three actuator fixing screws.

825RW049

Mode Switch
Removal and Installation
Refer to the Mode Switch removal and installation steps
in Automatic Transmission section.
HOME

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THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:

SECTION No. CONTRNTS


0A GENERAL INFORMATION
0B MAINTENANCE AND LUBRICATION
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THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:

SECTION No. CONTRNTS


1A HEATING AND VENTILATION
1B AIR CONDITIONING
1D COMPRESSOR OVERHAUL
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THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:

SECTION No. CONTRNTS


00 SERVICE INFORMATION
2A FRONT END ALIGNMENT
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THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:

SECTION No. CONTRNTS


3C FRONT SUSPENSION
3D REAR SUSPENSION; COIL SPRING
3E WHEELS AND TIRES
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THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:

SECTION No. CONTRNTS


4A1 DIFFERENTIAL (FRONT)
4A2A DIFFERENTIAL (Rear 220mm)
4A2B DIFFERENTIAL (REAR 244mm)
4B1 DRIVELINE CONTROL SYSTEM (SHIFT ON
THE FLY)
4B2 DRIVELINE CONTROL SYSTEM (TOD)
4C DRIVE SHAFT SYSTEM
4D1 TRANSFER CASE (STANDARD TYPE)
4D2 TRANSFER CASE (TOD)
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THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:

SECTION No. CONTRNTS


5A BRAKE CONTROL SYSTEM
5B ANTI-LOCK BRAKE SYSTEM
5C POWER ASSISTED BRAKE SYSTEM
5D PARKING BRAKES
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THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:

8bit
SECTION No. CONTRNTS
6A ENGINE MECHANICAL
6B ENGINE COOLING
6C ENGINE FUEL
6D1 ENGINE ELECTRICAL
6D2 IGNITION SYSTEM
6D3 STARTING AND CHARGING SYSTEM
6E ENGINE DRIVEABILITY AND EMISSIONS
6F ENGINE EXHAUST
6G ENGINE LUBRICATION
6H ENGINE SPEED CONTROL SYSTEM
6J INDUCTION
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32bit
SECTION No. CONTRNTS
6A ENGINE MECHANICAL
6B ENGINE COOLING
6C ENGINE FUEL
6D1 ENGINE ELECTRICAL
6D2
6D2 IGNITION SYSTEM
6D3 STARTING AND CHARGING SYSTEM
6E ENGINE DRIVEABILITY AND EMISSIONS
6F
6F ENGINE EXHAUST
6G ENGINE LUBRICATION
6H ENGINE SPEED CONTROL SYSTEM
6J
6J INDUCTION
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4JX1
SECTION No. CONTRNTS
6A ENGINE MECHANICAL
6B ENGINE COOLING
6C ENGINE FUEL
6D ENGINE ELECTRICAL
6E ENGINE DRIVEABILITY AND EMISSIONS
6F ENGINE EXHAUST
6G ENGINE LUBRICATION
6H ENGINE SPEED CONTROL
6J INDUCTION
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THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:

SECTION No. CONTRNTS


7A AUTOMATIC TRANSMISSION (4L30-E, 8bit
Type)
7A AUTOMATIC TRANSMISSION (AW30-40LE,
32bit Type)
7A AUTOMATIC TRANSMISSION (AW30-40LE,
Semi Type)
7A1 TRANSMISSION CONTROL SYSTEM (4L30-
E, 8bit Type)
7A1 TRANSMISSION CONTROL SYSTEM (4L30-
E, 32bit Type)
7B MANUAL TRANSMISSION (AR-5)
7B MANUAL TRANSMISSION (MUA)
7C CLUTCH
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THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:

SECTION No. CONTRNTS


8A LIGHTING SYSTEM
8B WIPER / WASHER SYSTEM
8C ENTERTAINMENT
8D WIRING SYSTEM
8E METER AND GAUGE
8F BODY STRUCTURE
8G SEATS
8H SECURITY AND LOCKS
8I SUN ROOF/CONVERTIBLE TOP
8J EXTERIOR / INTERIOR TRIM
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THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:

SECTION No. CONTRNTS


9A SEAT BELT SYSTEM
9J SUPPLEMENTAL RESTRAINT SYSTEM
9J1 RESTRAINT CONTROL SYSTEM
HOME

PAGE BACK

THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:

SECTION No. CONTRNTS


10A CRUISE CONTROL SYSTEM
Service Precaution CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL ONLY the exact part number for that application.
RESTRAINT SYSTEM (SRS). REFER TO THE SRS ISUZU will call out those fasteners that require a
COMPONENT AND WIRING LOCATION VIEW IN replacement after removal. ISUZU will also call out
ORDER TO DETERMINE WHETHER YOU ARE the fasteners that require thread lockers or thread
PERFORMING SERVICE ON OR NEAR THE SRS sealant. UNLESS OTHERWISE SPECIFIED, do not
COMPONENTS OR THE SRS WIRING. WHEN YOU use supplemental coatings (Paints, greases, or
ARE PERFORMING SERVICE ON OR NEAR THE other corrosion inhibitors) on threaded fasteners
SRS COMPONENTS OR THE SRS WIRING, REFER or fasteners joint interfaces. Generally, such
TO THE SRS SERVICE INFORMATION. FAILURE coatings adversely affect the fastener torque and
TO FOLLOW WARNINGS COULD RESULT IN the joint clamping force, and may damage the
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL fastener. When you install fasteners, use the
INJURY, OR OTHERWISE UNNEEDED SRS correct tightening sequence and specification.
SYSTEM REPAIRS. Following these instructions can help you avoid
damage to parts and systems.
4JG2
905RY00014

905RW014
6VE1
and
6VD1
905RY00013

905RW015

905RW018

905RW007
Service Precaution CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL ONLY the exact part number for that application.
RESTRAINT SYSTEM (SRS). REFER TO THE SRS ISUZU will call out those fasteners that require a
COMPONENT AND WIRING LOCATION VIEW IN replacement after removal. ISUZU will also call out
ORDER TO DETERMINE WHETHER YOU ARE the fasteners that require thread lockers or thread
PERFORMING SERVICE ON OR NEAR THE SRS sealant. UNLESS OTHERWISE SPECIFIED, do not
COMPONENTS OR THE SRS WIRING. WHEN YOU use supplemental coatings (Paints, greases, or
ARE PERFORMING SERVICE ON OR NEAR THE other corrosion inhibitors) on threaded fasteners
SRS COMPONENTS OR THE SRS WIRING, REFER or fasteners joint interfaces. Generally, such
TO THE SRS SERVICE INFORMATION. FAILURE coatings adversely affect the fastener torque and
TO FOLLOW WARNINGS COULD RESULT IN the joint clamping force, and may damage the
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL fastener. When you install fasteners, use the
INJURY, OR OTHERWISE UNNEEDED SRS correct tightening sequence and specification.
SYSTEM REPAIRS. Following these instructions can help you avoid
damage to parts and systems.
II III
II
III
II
II
III
II II
II
III III
− − 0 15 38
− 5 32 60 100

( )

905RW017
− − 5 10 20 35
− 14 41 50 68 95

− − 0 15 30 35
− 14 32 59 86 95
5

740RW168

871RY00011

871RY00012

852RW031
1

874RY00003

875RY00003
1 2

1
4

874RX022

874RY00003
11
12
1

5
1

10

4
2

6
8

3
7

852RY00006
852RY00008
13 14

11 1

12 4
6
5

10

8
852RY00005
12

13

1
5

11

2
6
10

3
9

852RY00012
13

12

11
2

4
5

3
10

7
8

852RW009
852RY00014

◯� ×� ×�

852RY00015

852RY00016
1

3
2

852RW010
3
4

1
5

8 6
7

850RY00001
852RY00007
3
4

1
5

8 6
7

850RX003
871RY00013

850RY00002
852RY00011
850RY00007
850RY00007
1

3
4

875RW001
1 2

5
3

7 6

875RY00002
1
1
1

2
875RW002
1
3

875RW005
850RW00001
11

10
2

9 3

8
7

6 5

874RY00012
874RY00006

874RS006

SENSOR TO BE LOCATED
AT 7TH LINE FROM LEFT

1
Lower case Upper case

2 57.5mm(2.26 in.)

874RX021

874RY00005
SENSOR TO BE LOCATED
AT 7TH LINE FROM LEFT

1 2

Lower case Upper case


3

2 57.5mm(2.26 in.)

4
874RX021

874RX022

852RY00009
855RY00002
16
1
15
14
2

13

3 5
4
11

12

10

855RY00001
D08RY00303
25(2.5/18)

15(1.5/11)
25(2.5/18)

15(1.5/11)

15(1.5/11)

15(1.5/11)

25(2.5/18)

25(2.5/18) 15(1.5/11)

E06RY00003
25 (2.5/18)

25 (2.5/18)
15 (1.5/11)

15 (1.5/11)

15 (1.5/11)

15 (1.5/11)

25 (2.5/18)

25 (2.5/18)

15 (1.5/11)

E06RY00002
825RY00058

826RY00016
872RY00001
872RY00002
1 2

13

12
10
3
11

4
9
7
5

8
ZE
XE
6
L

AUT
O

20
25
30

AUTO
F

LO
OF

A/C
HI

865RY0004
FL-1
80A HEATER & A/C RELAY
2 4
MAIN 5W 3W 3L/R
P-2 H-14 B-36 B-36
C-19 25A C-20 10A
1 3 BLOWER AIR CON
B-36 B-36
0.85W/G
BATT

5W

3L

0.3BR
2
10
H-13 B-5
1 BLOWER
H-14 MOTOR
M
STARTER RELAY(1)

H-26
B-5
10
1
5W

2L/B

0.3BR
C-16
2
10A CLOCK ROOM
H-20
0.5R/W

2L/B

0.5BR
9
H-26

1 2 1
I-50 I-51 I-51
POWER MAX HI
2 TRANSISTOR RELAY
I-50
0.5R/W

I-50 I-51 I-51


TAIL RELAY(4)

3 4 3

2B
2/B
0.5L/B

0.3GR
0.3B

H-20

0.3GR/L
1
14
H-16
2/B
0.85G/R
0.3R/W

0.5G/R

H-20
1
8 10 17 19 12 7
I-32 I-32 I-33 I-33 I-32 I-32
21 35 14 12 33 22

AUTO A/C CONTROL UNIT AUTO A/C CONTROL UNIT

6 29
I-32 I-32
9 16
0.5P/G

0.5B
ILLUMINATION
CONTROLLER

1.25B

BODY-LH B-1

B-19

BODY-RH
20
1.25B 1.25B
B-18 H-27

D08RY00118
0.5BR

13
H-24
0.5LG

0.5RB

1
H-51
0.5BR

1
C-25
PRESSURE
SW

C-25 7
H-16
2
0.5G/W

4
H-51
0.5G/W

0.5BR

12
0.5BR

0.5BR

H-41
0.5G/W

3 2 1 2
X -5 X-5 X -7 X-7
A/C TEHRMO A/C COMPRESSOR
RELAY RELAY

0.3B/L

0.3B/L
X-5 X-5 X -7 X-7
1 4 3 4
THERMO
0.5BR
0.5BR/Y

UNIT
0.5G/O

0.5G/B

0.5BR
6
H-41
H-41
E-19 3 5 1 4
0.5BR/Y
0.5P/G

0.5G/O

I-49 I-49 I-34 I-34


9
INTAKE INCAR
H-6 ACTUATOR SENSOR
11
M M
PCM(E15)

0.5G/B

0.5BR/Y

H-6
0.5G/B

5 1
16 I-49 I-49 I-49 I-49 I-34 I-34
H-41 E-3
0.5Y/B

H-16 4 6 1 2 2 3

MAGNETIC
PCM(B14)

0.5B

CLUTCH
1 17
H-24 H-16
0.3BR/B
0.5L/W
0.5L/O

0.3L/R

0.3L/Y
0.5P/G

1.25B
0.5Y/B

0.3G/B

4 14 18 11 12 13 14 1
I-33 I-32 I-33 I-32 I-33 I-33 I-33 I-33
7 31 13 34 19 18 17 10

AUTO A/C CONTROL UNIT

1.25B

D08RY00293
0.3B/L

4
0.3B/L
0.3B/L

H-26

9
0.3B/L

8
0.3B/L

0.3B/L

H-24 H-67

9
0.3B/L

MODE ACTUATOR
0.3B/L

B-69

VENT B/L FOOT D/F DEF

0.3B/L
0.3B/L
2 2
AMBIENT SENSOR

2 3
I-40
MIX ACTUATOR
DUCT SENSOR

C-86
SUN SENSOR

I-35 I-45
C

M M
H 8
I-35 I-45 I-45 I-45 I-45 B-69 B-69 B-69 B-69 B-69 B-69 B-69 B-69 H-25
C-86 I-40 1 6 8 2 7 1 5 4 3 8 7 2 6
1 1
0.3GR/G

0.3GR/G
0.3GR/R

0.3GR/R
0.3GR/L
0.3GR
0.3LG/B

0.3V/W

0.3V/G
0.3V/R

0.3V

0.3Y/BR

0.3Y/G
0.3LG/W

0.3LG/W

8 4 5 6 7
0.3B/L

H-24 H-67 H-67 H-67 H-67


11 12 18 19 5 1
H-25 H-25 H-26 H-26 H-25 H-26
0.3LG/B

0.3V/W

0.3V/G
0.3V/R

0.3Y/BR

0.3GR/L
0.3GR/G
0.3GR/R
0.3V

0.3Y/G

0.3GR

2 20 3 6 5 15 5 4 3 10 9 8 7 6 11
I-33 I-33 I-33 I-32 I-32 I-33 I-33 I-32 I-32 I-33 I-33 I-33 I-33 I-33 I-33
9 11 8 23 24 16 6 25 26 1 2 3 4

AUTO A/C CONTROL UNIT

D08RY00120
FL-1
80A HEATER A/C RELAY C-20 10A
2 4 AIR CON
MAIN 3L/R 14
5W 3W
P-2 H-14 B-36 B-36 H-26
C-19 25A
1 3 BLOWER
B-36 B-36

3L
0.85W/R
BATT.

5W

B-5
BLOWER
C-11 10A

0.3BR
MOTOR
1
AUDIO
M
H-14

B-5
5W

2L/B
STARTER SW (ACC)

11
4 H-48
H-48

C-16 10A
CLOCK ROOM

2L/B
0.5R/W

0.3BR
5
H-26

0.5BR
1 2 1
POWER I-50 I-51 I-51
TAIL REAY(4)

TRANSISTOR
MAX HI
0.5R/W

2 RELAY
I-50

I-50 I-51 I-51


3 4 3

F-12 10A
0.3B

0.3GR/W

TAIL-RH
0.5L/B

2B

6
0.3GR/L

H-16
15
H-48
0.85R/W
0.3R/W

2B
0.5G/R

8 10 17 19 12 7
I-32 I-32 I-33 I-33 I-32 I-32
21 35 14 12 33 22

AUTO A/C CONTORL UNIT AUTO A/C CONTORL UNIT


36 29
I-32 I-32
9 16
0.5R/G

0.5B
ILLUMINATION
CONTROLLER

1.25B

15
H-48

BODY-LH 1.25B
B-19

2B 15 1.25B
BODY-RH B-2 H-48

D08RY00121
0.5BR 19
H-9

0.5BR
0.5LG

1 17
H-51 H-16
0.5BR

1
C-25
PURESSURE
0.5BR

SW
0.5BR

0.5BR
C-25

0.3B/L

0.3B/L
2
0.5G/W

1 2
4
X -7 X-7
H-51 A/C

0.5BR
COMPRESSOR
0.5G/W

RELAY
12

0.5BR
THERMO H-41 X -7 X-7
SENSOR 3 4 3 5 1 4
0.5G/W

0.5BR/Y
0.5G/B

I-49 I-49 I-34 I-34


3 2
7
X -5 X-5 INTAKE IN CAR
E-19 H-41 ACTUATOR SENSOR
A/C THERMO
M M
0.5G/B

RELAY
0.5BR/Y
0.5Y/B

0.3G/B

5 9
X-5 X-5 I-49 I-49 I-49 I-49 I-34 I-34
H-41 H-6
1 4 4 6 1 2 2 3
0.5BR/Y
0.5G/O

11
H-16
PCM(B14)

6
0.5P/G

19 1
H-41
H-16 E-3
0.5Y/B

0.5G/O

21

0.3BR/B
0.3L/W
0.5L/O

0.3L/R

0.3L/Y

MAGNETIC
H-16
1 CLUTCH
1.25B
PCM(E15)

H-9
0.3G/B
0.5P/G
0.5Y/B

4 14 18 11 12 13 14 1
I-33 I-32 I-33 I-32 I-33 I-33 I-33 I-33

7 31 13 34 19 18 17 10

ATUO A/C CONTROL UNIT

1.25B

D08RY00122
0.3B/L
6
0.3B/L
0.3B/L

H-25

9 8

0.3B/L
0.3B/L

0.3B/L

H-24 H-67

9
0.3B/L

0.3B/L

B-69 MODE ACTUATOR

VENT B/L FOOT D/F DEF

0.3B/L
0.3B/L
2 2
2 3
C-86 I-40
I-35 I-45
AMBIENT SENSOR

MIX ACTUATOR
DUCT SENSOR

SUN SENSOR

M M
H 18
I-35 I-45 I-45 I-45 I-45 B-69 B-69 B-69 B-69 B-69 B-69 B-69 B-69 H-25
C-86 I-40
1 6 8 2 7 1 5 4 3 8 7 2 6
1 1
0.3GR/G

0.3GR/G
0.3GR/R

0.3GR/R
0.3GR/L
0.3GR
0.3LG/B

0.3V/W

0.3V/G
0.3V/R

0.3V

0.3Y/BR

0.3Y/G

4 4 2 6 3
0.3LG/W
0.3G/W

0.3B/L
H-9 H-67 H-67 H-67 H-63

1 3 2 10 5 4
0.3LG/B

0.3V/W

0.3V/G
0.3V/R

H-20 H-20 H-48 H-48 H-48 H-48


0.3V

0.3Y/BR

0.3GR/L
0.3GR/G
0.3GR/R
0.3Y/G

0.3GR

2 20 3 6 5 15 5 4 3 10 9 8 7 6 11
I-33 I-33 I-33 I-32 I-32 I-33 I-33 I-32 I-32 I-33 I-33 I-33 I-33 I-33 I-33
9 11 8 23 24 16 6 25 26 1 2 3 4 5 20

AUTO A/C CONTROL UNIT

D08RY00123
FL-3
40A C/HEAT 3W/L

THERMO SW RELAY
2 4
0.5BR 0.5G/B
X-21 X-21 5
1 7 1 3 H-41
5W 5W 3W 0.5BR 0.5BR
H-14 H-16 X-21 X-21 QWS THERMO SW

0.5G/Y
2
10 0.5G/Y
FL-1 CHARGE 0.85W/G 0.85W/G H-41 ECM(J1-23)
80A MAIN H-13
RELAY(1)

0.5BR
1 2

B-36 B-36
P-2
5W

HEATER
& A/C RELAY PRESSURE SW
13
8B/R

0.5BR 0.5LG 0.5G/W


B-36 B-36 H-24 C-25 C-25
1 2
3 4

0.5BR
+

3L/R
0.5B
P-1
C-20 10A
C-19 25A A/C 16
P-5 BLOWER
ー� H-26

3L

5B
C-16
30B
8B

0.3B/L

0.3BR
CLOCK, ROOM
10A 2

B-5 0.5BR
P-6 P-10 P-7
BLOWER
MOTOR H-26
0.5R/W

BODY ENG. FRAME


M 10
0.3B

B-5
THERMO UNIT

3 5
1
I-49 I-49
2L/B

INTAKE
ACTUATOR
0.5R/W

0.3BR

H-20
E-23
2
M
0.5Y/B

9
12
2L/B
2L/B

H-26
H-17
TAIL RELAY (4)

I-49 I-49 I-49 I-49


ILLUMINATION
CONTROLLER

1 2 1
0.5Y/B

4 6 1 2
0.5L/B

POWER I-50 I-51 I-51


0.5BR
MAX HI RELAY
0.5R/W

3 TRANSISTOR
2
H-4
I-50
0.5Y/B

0.5G/R

0.3GR/W

I-50 I-51 I-51


1
0.5L/W
0.5L/O

0.3L/R

0.3L/Y

3 4 3
H-24
0.5R/G

2B

2B
0.5Y/B
0.3R/W

1
0.3GR/L
0.5G/R

H-20
1.25B

0.5Y/B

8 4 9 10 17 19 12 7 11 12 13 14

I-32 I-33 I-32 I-32 I-33 I-33 I-32 I-32 I-32 I-33 I-33 I-33
21 7 36 35 14 12 33 22 34 19 18 17
2B

AUTO A/C CONTROL UNIT


29
I-32
16
B-1
0.5B

20
1.25B 1.25B
BODY-RH B-19 H-27

BODY-RH B-18

D08RY00114
CERAMIC CERAMIC
HEATER RELAY HEATER
2 4 15 1 2
3W/L 3W/G 3W/G 2B
X-12 X-12 H-13 B-48 B-48
1 3 11 1 2
0.5G/B 0.5Y/G 0.5Y/G 0.3G/W
X-12 X-12 H-15 B-44 B-44

DIODE
B-1

0.3G/W
BODY-LH
ECM(J1-31)

A/C THERMO MAGNETIC


RELAY CLUTCH
7 2 4 1
0.5BR 0.5G/O 0.5G/O 0.5G/O 4
X-5 X-5 H-41 H-6 H-17 E-27
2 4 0.5G/O H-25
11 16
0.5G/W 0.5P/G 0.5P/G
H-41 X-5 X-5 H-16
1 3

0.3G/W
0.5P/G

0.3B/L

H-26
9 8

0.3B/L
0.3B/L

H-24
0.3B/L

0.3B/L

H-67
9
MODE
B-69 ACTUATOR

VENT B/L FOOT D/F DEF


1 4 2 2 2 3
MIX 6
I-34 I-34 C-86 I-35 I-40 ACTUATOR I-45 H-16
AMBIENT SENSOR
INCAR SENSOR

DUCT SENSOR
SUN SENSOR

M M M

0.3B/L

0.3B/L
I-34 I-34 C-86 I-40 I-45 I-45 I-45 I-45 B-69 B-69 B-69 B-69 B-69 B-69 B-69 B-69
I-35
2 3 1 1 1 6 8 2 7 1 5 4 3 8 7 2 6
0.3GR/G
0.3GR/R

0.3GR/R
0.3GR/L
0.3GR/G
0.3Y/BR
0.3LG/B

0.3V/W

0.3V/G

0.3Y/G
0.3V/R

0.3GR

17
0.3V

H-16
0.3LG/W
0.3LG/W
0.3BR/B

8 4 5 6 7 11 12 18 19 5 1
0.5B

H-24 H-67 H-67 H-67 H-67 H-25 H-25 H-26 H-26 H-25 H-26
0.3G/B
0.3LG/B

0.3GR/G
0.3GR/R

0.3GR/L
0.3Y/BR

0.3GR
0.3V/W

0.3V/G
0.3V/R

0.3Y/G
0.3V

1 2 3 20 6 5 15 5 4 3 10 9 8 7 13 14 11 18

I-33 I-33 I-33 I-33 I-32 I-32 I-33 I-33 I-32 I-32 I-33 I-33 I-33 I-33 I-32 I-32 I-33 I-33
10 9 8 11 23 24 16 6 25 26 1 2 3 4 32 31 20 13
AUTO A/C CONTROL UNIT

D08RY00115
FL-3
40A C/HEATER 3W/L
THERMO SW RELAY
2 4
0.5BR 0.5G/B
X-21 X-21
1 1 3
5W 5W 3W 0.5BR
H-14 X-21 X-21 QWS THERMO SW

0.5G/Y
2
0.5G/Y
FL-1 STARTER 0.5O/G H-42 ECM(J1-23)
80A MAIN SW (ACC)
1 2

B-36 B-36
P-2 7
5W

HEATER AND 0.5BR 0.5BR


H-16
A/C RELAY
PRESSURE SW
19
8B/R

0.5BR 0.5LG 0.5G/W


B-36 B-36 H-9 C-25 C-25
1 2
3 4

0.5BR
+ 3L/R
P-1
0.3B
P-5 14
ー� C-19 H-26
25A C-20
BLOWER 10A A/C
3L

5B 1
0.3BR

C-16
30B
8B

B-5 0.3B/L
CLOCK, ROOM
BLOWER

10A
MOTOR

M 0.5BR
P-6 P-10 P-7
ENGINE

BODY ENG FRAME B-5


0.5R/W

11
2 H-48
0.5BR
0.3B

2L/B

3 5
0.3BR

4
THERMO UNIT

I-49 I-49 INTAKE


H-48
ACTUATOR
0.5R/W

2L/B
E-23 M
ELECTRONIC 1 2 1
7 THERMOSTAT I-50 I-51 I-51
12
H-26 2 MAX
H-17 HI I-49 I-49 I-49 I-49
I-50
RELAY
4 6 1 2
I-50 I-51 I-51
0.5R/W

3 3 4 3
H-4
0.5L/B
0.5Y/B

0.3GR/W

2B

1
0.3GR/L

0.5L/W
0.5L/O

0.3L/R

0.3L/Y
0.5BR

H-9
15
0.5Y/B
0.3R/W

H-48
0.5Y/B
1.25B

8 4 17 19 12 7 11 12 13 14

I-32 I-33 I-33 I-33 I-32 I-32 I-32 I-33 I-33 I-33
21 7 14 12 33 22 34 19 18 17
AUTO A/C CONTROL UNIT

I-32
16
0.5B

BODY-LH B-19
15
1.25B 1.25B
BODY-RH B-2 H-48

D08RY00116
CERAMIC HEATER
RELAY CERAMIC HEATER
2 4 15 1 2
3W/L 3W/G 3W/G 2B
X-12 X-12 H-13 B-48 B-48
5 1 3 11 1 2
0.5G/B 0.5G/B 0.5Y/G 0.5Y/G 0.3G/W
H-41 X-12 X-12 H-15 B-44 B-44
DIODE
B-2

0.3G/W
BODY-RH
ECM(J1-31)

MAGNETIC
A/C THERMO RELAY CLUTCH
7 2 4 1
0.5G/W 0.5G/O 0.5G/O 0.5G/O 12
X-5 X-5 H-41 H-6 H-17 E-27
2 4 0.5G/O H-25
12 21
0.5G/W 0.5PG 0.5PG
H-41 X-5 X-5 H-16
1 3

0.3G/W
0.5P/G

0.3B/L
0.3B/L

H-25
2 6
0.3B/L

0.3B/L
0.3B/L

H-9
0.3B/L

0.3B/L

H-25
9
0.3B/L

0.3B/L

B-69 MODE ACTUATOR

VENT B/L FOOT D/F DEF


1 4 2 2 2 3
MIX 8
I-34 I-34 C-86 I-35 I-40 ACTUATOR I-45 H-16
AMBIENT SENSOR
INCAR SENSOR

DUCT SENSOR
SUN SENSOR
(ASPILATOR)

M M

C-86 I-40 I-45 I-45 I-45 I-45 B-69 B-69 B-69 B-69 B-69 B-69 B-69 B-69

0.3B/L
I-34 I-34 I-35
2 3 1 1 1 6 8 2 7 1 5 4 3 8 7 2 6
0.3GR/G
0.3GR/R

0.3GR/R
0.3GR/L
0.3GR/G
0.3Y/BR
0.3LG/B

0.3V/W

0.3V/G

0.3Y/G
0.3V/R

0.3GR

19
0.3V

H-16
0.3LG/W
0.3LG/W
0.3BR/B

4 4 2 6 3 11 12 2 10 5 4
0.5B

H-9 H-67 H-67 H-67 H-67 H-20 H-20 H-48 H-48 H-48 H-48
0.3G/B
0.3LG/B

0.3GR/G
0.3GR/R

0.3GR/L
0.3Y/BR

0.3GR
0.3V/W

0.3V/G
0.3V/R

0.3Y/G
0.3V

1 2 3 20 6 5 15 5 4 3 10 9 8 7 13 14 11 18

I-33 I-33 I-33 I-33 I-32 I-32 I-33 I-33 I-32 I-32 I-33 I-33 I-33 I-33 I-32 I-32 I-33 I-33
10 9 8 11 23 24 16 6 25 26 1 2 3 4 32 31 20 13
AUTO A/C CONTROL UNIT
35 36
I-32 I-32

10 9

0.5G/R 0.5R/G ILLUMINATION


TAIL RELAY
CONTROLLER

D08RY00117
FULL AUTO display MIX ACTUATOR
AIR MIX DOOR
POTENTIOMETER

MODE indication
(LED) (Blow port)

INTAKE indication MODE ACTUATOR


MODE DOOR
(LED) POTENTIOMETER
(switching between
fresh and interior air)
AUTOMATIC HEATER/AIR CONDITIONER CONTROL UNIT (with the built-in micro-computer)

AC display (LED)
INTAKE ACTUATOR
INTAKE DOOR
REC MIX FRESH
FAN indication (LED)

FAN KNOB
AUTO SET
POWER
TRANSISTOR FAN MOTOR

REC FRESH SWITCH


MAX HI RELAY

TEMP LEVER
(temperature control)

MODE SWITCH
(blow port selection)
PRESSURE AIR CONDITIONER
SWITCH THERMO RELAY PCM

AC SWITCH

MAGNET COMPRESSOR
CLUTCH SWITCH
IN CAR SENSOR

AMBIENT SENSOR

PRESSURE AIR CONDITIONER MAGNET


SUN SENSOR SWITCH THERMO RELAY CLUTCH

(4JX1engine)

DUCT SENSOR

F01RY00009
12
13
1

6
1

11

10

5
2

7
9

4
8

852RY00001
13

12

11
2

3
4

9
10

7
8 6

852RY00002
14 15

12 1

13 5
7
6

11

10

9 4

852RY00003
12

11

5
7
6

10

9 4

852RY00004
1 2 3 4 5

8 7 6

865RY00026
2
3 4
1 A 5 6

B A
B
C
C
B
A B 7
B
A A
C

13 B
12 11 A
10
9
8

Mode Position Display of Intake Status Set Temperature

VENT BI-LEVEL FOOT DEF/FOOT DEF Blue White Red


ON OFF FULL 20~30℃ FULL
COLD HOT
Vent Door A B C C C
Foot Door C B A B C
DEF Door A A A C B
Intake Door A B
Air Mix Door A A 〜 B B
Sub Air Mix Door B B 〜 A A

C01RY00001
1

845RY00001

ZE
X EL

AUT
O

20
25
30

AUTO
F

LO
OF

A/C
HI

865RY00006
1

860RX013

2
5

4 3
860RX012

826RY00001
2

4 3

860RW026

4 3 2 1 Automatic Heater / Air


9 8 7 6 5
Conditioner Control Unit
Position
Potentiometer Detection
Block Controller
3
2
7

Heat Side

Cool Side
N

Connection
M

8
Driver

Sliding Contact Full Cool Position


Terminal Plate
Full Heat Position
C01RY00016

1.0
Voltage ratio VM/VDD

Full heat
VDD
+
VM 0.5


Full cool 0
0 50 100%
Full cool Full heat

Aperture of air mix door

C01RX016
2 1

Control unit 6 5 4 3
Sliding (Actuator Side)
contact Position
DEF 6 detection
block Controller Auto A/C
2 7 Sliding Contact
Control Unit
VENT
DEF side

side

7 8
6 REC

Controller
8 9 1 MIX
3 10 2 FRESH
4 Com 5
VENT +
9 + 3 +

Driver
Connected — 4
M
Interconnected
motor
5
1

Actuator side Terminal Plate


4 3 2 1
9 8 7 6 5 Driver C01RX006

7 8 9 10
VENT H L H L
Mid point between VENT - B/L H H H L
B/L H H L L
Mid point between B/L - FOOT H H L H
FOOT H L L H
Mid point between FOOT - D/F H L H H
D/F L L H H
Mid point between D/F - DEF L H H H
DEF L H L H
C01RX017
Set temperature
signal

In car sensor
Mix

Air mix door


actuator

Control unit
Ambient sensor

Sun sensor Potentio


meter
Air conditioning
switch
Set up temperature
signal

Full heat

Air conditioning
ON mode

Air mix door aperture


Air conditioning
OFF mode
50

Restriction on the
aperture enabied
in the VENT mode

0
Full cool 140 104 68 32
Heater Total signal Cooler
side side
C01RY00011
Set up temperature
signal
Set up
temperature signal In car sensor
M
In car sensor Mode actuator

Mode door
Control unit
Ambient sensor
Control unit

Ambient sensor MAX Position


Sun sensor
HI Relay detection
Sun sensor Air conditioning switch
switch
Fan switch
Mode control
Mode control signal
signal Power
transistor
Blower fan motor terminal voltage

DEF / FOOT
(V)
Mode control

12 MAX HI
FOOT
10.5 AUTO HI
BI-LEVEL

VENT
4.8
4.5 VENT mode Heater Mode total signal Cooler
side side
Heater Cooler
side Total signal side

C01RY00009

C01RY00008
Ambient sensor

Thermo switch relay

Compressor relay
Pressure switch

Compressor
Control unit
Electronic
thermostat

ECM
Air conditioning
switch
Setup temperature Set up temperature
signal signal
In car sensor
Intake
Ambient sensor actuator
Control unit

Intake door

Sun sensor
Position
Compressor detection
switch
ON / OFF C01RY00010

Fan ON / OFF

Intake switch
Intake door open / close

RECIRC

MIX

FRESH

Heater Total mode signal Cooler


side side

C01RY00012
100%
(MAX HI)
3 SEC

Blower voltage to turn


5.32%/S

on the cooling
DEF
Mode

Auto
33.5%
Mode
(LO)
7 SEC maximum
100%
(MAX HI)
Ignition swich
"ON"
2.63%/S Time
33.5%
(LO) C06RY00001

Ignition
switch "ON" Time

Thermo Unit 58¡C(Gasoline)


52¡C(Diesel)

840RY00009
Occurrence of a trouble

Check if the automatic Check the power supply and


heater / air conditioner NG circuit on the automatic
Correction
control unit indicator LED heater / air conditioner control
is turned on. unit.
OK

Refer to the check list for NG


Locate the failed location.
the inspection.
OK
NG Reference the "Check
Troubleshooting by the
Procedure by Failed Correction
self-diagnosis function.
Location" for the inspection.
OK

Troubleshooting not relying Reference the "Check


on the self-diagnosis NG
Procedure by Failed Correction
function(troubleshooting Location" for the inspection.
by failure type).
OK

Check the cooling / heating NG


Check the failed part. Correction
cycles.
OK

End

F01RX009
1 0.3R/W 9 8
H-14 H-26 Backup
FL-1 Main C-16
80A 10A

B-36
C-20
10A A/C 14 7
2 4 0.5BR
H-26 I-32 Power supply (12V)

1 3
20 16
Relay: H-27 Unit ground
Heater and air
conditioner

2B 1.25B 0.5B
B-18

10
Lighting switch

I-32

14 0.5G/R
Lighting switch H-16

Automatic heater/air conditioner control unit

B-18 B-36 H-14 H-16

H-26 H-27 I-32

D08RY00175
F01RX002

(VENT) (BI-LEVEL) (FOOT)


F01RX003

F01RX004
Indication for presence
of a trouble Indication for normal state
LED on

LED off

0.5 0.5 0.5 3 seconds interval


F01RX010

Display pattern Failed part


ON
Normal pattern
OFF

In car sensor

Ambient sensor

Sun sensor (Note 1)

Duct sensor

Temperature control lever (Note 2)

Fan switch (Note 3)

Mix actuator

Mode (blow port) control

Intake (fresh air/interior air switching) control

F01RY00008
Indication for presence of a trouble Indication for normal state

LED on

LED off

0.5 0.5 0.5 3 second interval


F01RX011

Display pattern Failed part

ON
Normal pattern
OFF

In car sensor

Ambient sensor

Sun sensor

Duct sensor

Mix actuator

F01RY00007

100

FAN (%)

33.5
F/H

MIX (%)

F/C
VENT
B/L
MODE
FOOT
DOOR
D/F
DEF

REC
INTAKE
MIX
DOOR
FRE

SET UP
TEMPERATURE F/C 20 21 22 23 24 25 26 27 28 29 30 F/H
F01RY00001
Independent check of sensors

YES

NO
Normal ? Replace the sensors.

Check the related harness and


connector

NO Replace the harness and


Normal ? connector.

YES

Replace the control unit.

Sensors Allowable range Check method

In car sensor Refer to the sensor resistance curve. Chart 1

Ambient sensor Refer to the sensor resistance curve. Chart 2

Sun sensor 100 ohms maximum in forward and 0.02 mA Chart 3


minimum when exposed to 60W incandescent lamp.

F01RY00005
Auto A/C Control Unit

In car Sensor
1 0.3 BR/B 3
(In car Sensor)

I-33 I-34
11 0.5 B/L 4
(Sensor GND)

I-33 I-34

D08RY00174
Auto A/C Control Unit

Ambient Sensor
2 0.3 LG/B 8 0.3 LG/B 1
(Ambient Sensor) H-24 C-86

I-33
11 0.3 B/L 9 0.3 B/L 2
(Sensor GND) H-24 C-86

C-86 I-33

H-24

D08RY00176
Auto A/C Control Unit

Sun Sensor
3 0.3 LG/W 1
(Sun Sensor) I-35

I-33
11 0.3 B/L 2
(Sensor GND) I-35

I-33 I-35

D08RY00177
B-36
10 Intake Actuator
STARTER RELAY H-13 1 3
B-19

3.0 L/R 0.5 BR 14 0.5 BR 3


BATT. H-26 I-49
FL-1 80A 2 4 C-20 10A
Auto A/C Control Unit MAIN A/C M
11 0.5 L/O 4
(Intake Actuator) I-32 I-49

11 0.3 B/L 5
GND(COM) I-49
12 0.5 L/W 6
CIRC I-49
I-33 0.3 L/R 1
13
MIX I-49
0.3 L/Y 2
14
FRESH I-49

B-19 I-32 I-33 I-49 B-36

H-26 H-13

D08RY00178
Auto A/C Control Unit Mix Actuator

(HEAT TO COOL) 0.3 V/W 4 0.3 V/W 6


23 6
+ Cool side H-67

I-32

+ Heat side 5 0.3 V/R 5 0.3 V/R 8


(COOL TO HEAT)�
24 H-67 M
Heat Cool
I-45

11 0.5 B/L 8 0.3 B/L 3


(GND)� 20 H-67 Cool
5 0.3 V 7 0.3 V 7
(Mix Potentio Meter) 6 I-33 H-67 3 KW

15 0.3 V/G 6 0.3 V/G 2


(+5 V)� 16 H-67 Heat

(Potentio Meter)

I-32 I-33 I-45 H-67

D08RY00179
Mode Actuator
Auto A/C Control Unit (Heater Unit)
(DEF TO VENT) 25 4 0.3Y/BR 11 H-25 0.3Y/BR 1
+ VENT side
I-32
(VENT TO DEF)� 3 0.5Y/G 12 0.3Y/G
26 5
+ DEF side H-25 M
0.3GR/G 4
VENT

1 10 0.3GR 18 0.3GR 3
MODE1 H-26 B/L

B-69
MODE2 2 9 0.5GR/R 19 0.5GR/R 8
H-26 FOOT

MODE3
3 8 0.5GR/G 5 0.3GR/G 7
I-33 H-25 D/F
MODE4

7 0.3GR/L 1 0.3GR/L 2
MODE5 4 H-26 DEF

S.GND 6
20 11 0.5B/L 4 0.3B/L
H-26
9

5 6 0.5B/L 8
H-25

B-69 I-32 I-33

H-25 H-26

D08RY00180
B-36

3.0 L/R 3.0 L

C-19 25A
FUSE

C-20 10A
FUSE 10
2
H-26
B-5

0.3 BR
Blower Motor M

B-5
1

0.5 L/B 2 2 L/B

2 L/B
H-20
2.0L/B

17
14
I-33 1 2 1
I-50 I-51 I-51

Auto A/C 19 0.3 GR 2


I-50
Power Max High
12
Control Unit
I-33 Transistor Relay
I-50
3 I-51 I-51
12
33 4 3
I-32

2B
2B

0.3 GR/L

1
2.0 B
B-1 H-20

B-1 B-5 B-36 I-32 I-33 I-50 I-51

H-20 H-26

D08RY00181
STARTER 0.5 0.5
RELAY(1) BR BR
BATT.(+) A
7
H-16
13
H-24
0.85
W/R FL-1 0.5
80A LG
MAIN 1
10 C-25
H-13 Triple
1 Pressure 0.5
0.5 0.5
BR BR
0.85
H-14 Switch BR
W/G C-25
3.0
W 2
1 2 12
B-36 B-36 H-41
Heater ENGINE COOLANT
0.5
G/W 3 2 1 2
Relay TEMPERATURE GAUGE
X-5 X-5 X-7 X-7

B-36 B-36 A/C A/C


3 4 Thermo Relay Compressor
3.0
L/R Relay
C-20 X-5 X-5 X-5 X-7 X-7
0.3
B C-19 10A 0.5 1 1 4 3 4
25A A/C BR 0.5
A H-24 0.5
BLOWER 0.5 G/O 0.5
G/B BR/Y
MOTOR P/G 6
7
0.5 H-41
Y/B 0.5 16 5 H-41
17
Y/B H-16
0.5 H-16 H-41
Blower Intake 11 9
G/O
Motor Actuator H-6
H-6
0.5 0.3
P/G G/B PCM
0.5 PCM 0.5
Y/B (C3-E15) (C-1-B14) BR/Y
1.25 4 14 18 1
1
B
E-19 I-33 I-32 I-33 E-3
7 31 13
Engine COMP-F/B Magnetic
Coolant clutch
Auto A/C Control Unit
Temperature
B-19
Sensor

BODY-LH

B-19 B-36 X-5 X-7 C-25 E-3 E-19 H-6 H-41

H-13 H-14 H-16 I-32

I-33 H-24 C-1 C-3

D08RY00182
B-36
Relay:
FL-1 MAIN Air conditioning C-20
80A 10A A/C 0.5 BR 0.5 BR

1
C-25

Pressure

0.5 G/W
switch

C-25
2

1 2
X-5 X-5

Relay:
Air conditioning
thermostat

X-5 X-5
Automatic heater/air conditioner 3 4
control unit

0.5 G/O
0.5 P/G
14 16
Fan ON I-32 H-16
1
E-27

Magnet
clutch

C-25 E-27 H-16

I-32 X-5 B-36

D08RY00183
A

4 3 2 1

1 2

Testing rod Current


— + value
30
2
AUTO
20
25 1
1 2 40 A or more
30.69
30
D06RY00001

25
17.09
Sensor Resistance

20

15
9.93
Value(k‰)

10 6.0
3.75
5 2.24 1.6
0
-20 -10 0 10 20 30 40
Temperature on the Sensor ‰
Temperature Detector(¡C)

865RX007

30.69
17.09
30
9.93
Sensor Resistance

25
6.0
20
Value(k‰)

15 3.75

2.24
10
1.6
5

0
-20 -10 0 10 20 30 40
Temperature on the Sensor
Temperature Detector(¡C)
C01RX012
2 3

3
1

Terminal 4 3 2 1
No. 1 2 3 Conduction

−� +� Conducted (50‰ maximum)


−� +� Conducted (100‰ maximum)
Testing
rod +� −� Not conducted
+� −� Conducted (220‰ maximum)
−� +� Not conducted

C01RY00002

AUTO 30
25
20

C01RW020

2 1 2 1

4 3
4 3

No continuity between terminals (2) and (4).


Continuity between terminal (2) and (4) when battery
voltage is applied between (1) and (3).

C01RY00003
1
1

7
ZEX EL

2
AUTO

20
25
30
AUTO
LO

F
OF

HI
A/C

6
2

3
5

4
3

874RY00001

865RY00007
1 2

ZE
X EL

AUT
O

20
25
30

AUTO
F

LO
OF

A/C
HI

865RY00006 875RY00001
1
1

826RY00001

874RY00002
1

3
4
860RW030 860RY00004
1

3
860RX018
871RY00014
871RX020
871RX013
SERVICE PROCEDURE
DKV-14D TYPE COMPRESSOR

7
5
4

2
3

1
6

871RX012

Legend (4) Pulley Assembly


(1) Drive Plate Bolt (5) Field Coil
(2) Drive Plate (6) Shim(s)
(3) Snap Ring (7) Lead Wire

Removal 2. Remove drive plate by using drive plate puller


J-33944-A (2) and forcing screw J-33944-4 (1).
1. Remove drive plate bolt by using drive plate holder
J-7624 (1) to prevent the drive plate from rotating.

871RX016

901RX055
3. Remove shim(s). 6. Loosen screw and disconnect the coil lead wire
4. Remove snap ring (1) by using snap ring pliers. connector.

871RW016 871RS010

5. Remove pulley assembly by using pulley puller pilot 7. Loosen three screws and remove the field coil.
J-38424 (2), pulley puller J-8433 (1) and pulley
puller leg J-24092-2 (3).

871RS011

871RX031
Inspection and Repair 3. Install pulley assembly by using pulley installer
J-33940-A (2) and drive handle J-8092 (1).
Drive Plate
If the frictional surface shows signs of damage due to
excessive heat, the drive plate and pulley should be
replaced.
Pulley Assembly
1
Check the appearance of the pulley assembly. If the
frictional surface of the pulley shows signs of excessive
grooving due to slippage, both the pulley and drive
plate should be replaced. The frictional surfaces of the
pulley assembly should be cleaned with a suitable
solvent before reinstallation. 2

Coil
Check coil for loose connector or cracked insulation.

Installation
1. Install field coil. 871RX032

Align the located portion (1) of the field coil and


4. Install snap ring.
compressor.
5. Install shim(s).
6. Install the drive plate to the compressor drive shaft
together with the original shim(s)(1). Press the drive
plate by hand.

871RX010

Tighten the mounting screw to the specified torque.


Torque: 5Nꞏm (44 lb in)
2. Connect the lead wire connector with the rubber 871RX015

hold and tighten the screw.


7. Install drive plate bolt by using drive plate holder
J-7624 (1) to prevent the drive plate from rotating.

901RX055

Tighten the drive plate bolt to the specified torque.


Torque: 13 Nꞏm (113 lb in)
After tightening the drive plate bolt, check to be
sure the pulley rotates smoothly.
Check to be sure that the clutch clearance is
between 0.3-0.6 mm (0.01-0.02 in.)

871RX014

If necessary, install adjusting shim(s).


Adjusting shims are available in the following
thickness.

Thickness
0.1 mm (0.0039 in.)
0.3 mm (0.0118 in.)
0.5 mm (0.0197 in.)
DKS-15CH TYPE COMPRESSOR

(’98)

7
6
5
3 4
2
1
20
12
19
18
15
21
17
16
15
14
13
12
11
10
8
22
23

16

7
6
5
3 4
2
1
(’99~)

871RY00015

Legend (12) O-Ring


(1) Drive Plate Bolt (13) Gasket
(2) Drive Plate (14) Front Valve Plate
(3) Shim (15) Front Suction Valve
(4) Snap Ring (16) Pin
(5) Pulley Assembly (17) Cylinder and Shaft Assembly
(6) Screw (18) Rear Valve Plate
(7) Field Coil (19) Gasket
(8) Through Bolt (20) Rear Cylinder Head
(9) Shaft Seal Assembly (21) Bolt
(10) Gasket (22) Oil Drain Plug
(11) Front Cylinder Head (23) O-Ring
Removal 3. Remove shim(s).
1. Remove drive plate bolt by using drive plate holder 4. Remove snap ring (1) by using snap ring pliers.
J-7624 (1) to prevent the drive plate from rotating.

871RY00004

901RX055
5. Remove pulley assembly by using pulley puller pilot
2. Remove drive plate by using drive plate puller J-38424 (2), pulley puller J-8433 (1) and pulley
J-33944-A (2) and forcing screw J-33944-4 (1). puller leg J-24092-2 (3).

2
3

871RY00005
871RY00003
6. Loosen three screws and remove the field coil. 8. Remove shaft seal assembly (2) by using shaft seal
remover J-33942 (1).

871RY00006

871RY00018

7. Remove snap ring by using snap ring pliers.


Engage the remover hook with the shaft seal
assembly groove and slowly draw the shaft seal
assembly out.
NOTE
The shaft seal is precision-machined and its
critical parts are finished to extremely close
tolerances. The assembly must be handled
with great care, it slips face demanding
particularly careful handling.
The shaft seal can not be reused. Install a new
shaft seal at reassembly.
Take care not to scratch or otherwise damage
the shaft seal face.
Keep the shaft seal free from lint and dirt.

9. Remove through bolt.

871RY00017
10. Remove front cylinder head. 15. Remove rear cylinder head.

871RY00019 871RY00020

11. Remove o-ring. 16. Remove o-ring.


Alternately tap the projections on the Alternately tap the projections on the
circumference of the front cylinder head with a circumference of the rear cylinder head with a
screwdriver and a plastic hammer to remove the screwdriver and a plastic hammer to remove the
front cylinder head. rear cylinder head.
12. Remove gasket. 17. Remove gasket.
13. Remove front valve plate. 18. Remove rear valve plate.
14. Remove front suction valve. 19. Remove rear suction valve.
NOTE 20. Remove cylinder and shaft assembly.
Check the front valve plate for scratching and NOTE
bending. Check the rear valve plate for scratching and
Check the front valve plate and the front bending.
cylinder head for nicks and burrs on the Check the rear valve plate and the rear
sealing surface. cylinder head for nicks and burrs on the
Buff or replace the valve plate and cylinder sealing surface.
head if nicks and burrs are present. Buff or replace the valve plate and cylinder
Check that the front valve plate passage is free head if nicks and burrs are present.
from obstructions. Check that the rear valve plate passage is free
Check the front valve plate and the cylinder from obstructions.
head for cracks. Check the rear valve plate and the cylinder
Replace the valve plate and cylinder head if head for cracks.
cracks are present. Replace the valve plate and cylinder head if
cracks are present.
Installation 6. Install rear cylinder head (1).
1. Install cylinder and shaft assembly. Apply a coat of new compressor oil to the new o-
ring (2).
Clamp the cylinder shaft assembly in a vise.
Install the o-ring (2) to the rear cylinder head (1).
The rear side of the cylinder shaft assembly must
Install the rear cylinder head.
be facing up.
Top the rear cylinder head (1) into place with a
2. Install rear suction valve. plastic hammer.
Apply a coat of new compressor oil to the new
suction valve (2).
Install the suction valve by aligning it with the
spring pin and the cylinder valve relief grooves.

1
2
3
4
5

871RY00022

3 7. Install front suction valve.


Set the cylinder shaft assembly with the front side
871RY00021 facing up.
Apply a coat of new compressor oil to the new
Legend suction valve (2).
(1) Escape Groove Install the suction valve (2) by aligning it with the
(2) Suction Valve spring pin and the cylinder valve relief grooves.
(3) Piston

3. Install rear valve plate. 1


Apply a coat of new compressor oil to the new
valve plate.
Install the valve plate to the suction valve by
aligning it with the spring pin. 2

NOTE
Do not mix up the front and rear valve plate.
4. Install gasket.
Apply a coat of new compressor oil to the new
gasket.
Install the gasket (3) to the valve plate (4).
5. Install o-ring (2).
3

871RY00021

Legend
(1) Escape Groove
(2) Suction Valve
(3) Piston
8. Install front valve plate. 12. Install through bolt.
Apply a coat of new compressor oil to the new Gaskets cannot reused. Always replace new
valve plate. ones. Tighten the bolts to the specified torque a
Install the valve plate to the suction valve by little at a time in the sequence shown in the
aligning it with the spring pin. illustration.
Torque: 22Nꞏm (16 lbꞏft)
NOTE
Do not mix up the front and rear valve plates. NOTE
9. Install gasket Rotate the compressor drive shaft two or three
Apply new compressor oil to the new gasket. times to make sure that it moves smoothly.
Install the gasket to the valve plate by a aligning it
with the spring pin.
10. Install o-ring.
11. Install front cylinder head.
Apply a coat of new compressor oil to the new O-
ring.
Install the O-ring to the front cylinder head. 6
Install the front cylinder head.
Tap the front cylinder head into place with a
plastic hammer. 1
3

NOTE
When installing the cylinder head, be careful
that the end of the drive shaft does not 4
damage the shaft seal assembly surface in the 2
cylinder head.
5

871RY00016

871RY00023
13. Install shaft seal assembly. 17. Install pulley assembly.
Clean the sealing portion of the compressor and Using pulley installer J-33940 (2) and drive handle
shaft seal (2). J-8092 (1) to install the pulley assembly.
Install the shaft seal guide J-34614 (1) onto the
end of the drive shaft.
Apply new compressor oil to the shaft seal guide.
Install the shaft seal (2) onto the compressor drive
shaft head by using shaft seal installer J-33942 (3).

1 1
2

871RY00008

18. Install snap ring.


Install the snap ring with the inside indented
portion facing out.
871RY00024

14. Install snap ring.


15. Install field coil.
16. Install lead wire connector.
Install the field coil to the compressor.
Lead wire must be facing up.
Tighten the field coil fixing screws to the specified
torque.
Torque: 5Nꞏm (44 lbꞏin) A

871RY00025

871RY00006
19. Install shim(s). Check to be sure that the clutch clearance is
20. Install drive plate. between 0.3–0.6 mm (0.01–0.02 in.)
Install the drive plate to the compressor drive
shaft together with the original shim(s)(1) press
the drive plate by hand.

871RY00007

If necessary, install adjusting shim(s).


Adjusting shims are available in the following
thickness.
871RY00009

21. Install drive plate bolt by using drive plate holder Thickness
J-7624 (1) to prevent the drive plate from rotating. 0.1 mm (0.0039 in.)
Tighten the bolt to the specified torque. 0.3 mm (0.0118 in.)
Torque: 15Nꞏm (11 lbꞏin) 0.5 mm (0.0197 in.)
NOTE
After tightening the bolt, check to be sure the
pulley rotates smoothly.

901RY00010
HD6 TYPE COMPRESSOR
Metric Thread Size Information
Compressor to mounting bracket bolts (Front) Compressor shaft
M10 1.5 – 6H M9 1.25 – 6H
Compressor to mounting bracket bolts (Rear) Internal hub-clutch drive assembly
M8 1.25 – 6H M22 1.5 – 6H
Suction-discharge port screw
M10 1.5 – 6H

COMPRESSOR CLUTCH PLATE AND HUB 2. Be sure the frictional surface of the clutch plate and
ASSEMBLY the clutch rotor (2) are clean before installing the
clutch plate and hub assembly (1).
Removal 3. Align the shaft key (4) with the shaft keyway (3) and
1. Clamp the holding fixture J-33026 in a vise and place the clutch plate and the hub assembly onto
attach compressor to holding fixture with thumb the compressor shaft.
screws J-33026-1.
2. With center screw forcing tip in place to thrust
against the end of the shaft, thread the Clutch Plate 4 1
and Hub Assembly Installer-Remover J-33013-B into
the hub. Hold the body of the remover with a wrench
and turn the center screw into the remover body to
remove the clutch plate and hub assembly (1).
3
CAUTION: Do not drive or pound on the clutch hub
or shaft. Internal damage to compressor may
result. The forcing tip on J-33013-B remover-
installer center screw must be flat or the end of the
2
shaft/axial plate assembly will be damaged.

J-33013-B 871RW003

4. Remove the forcing tip on J-33013-B clutch plate


and hub assembly installer-remover center screw
and reverse the body direction on the center screw,
as shown in Figure.
5. Install the clutch plate and hub installer-remover J-
J-33026-1 33013-B with bearing as shown in Figure.
The body of the J-33013-B installer-remover should
J-33026 be backed off sufficiently to allow the center screw to
be threaded onto the end of the compressor shaft.
6. Hold the center screw with a wrench. Tighten the
901RW001
hex portion of the installer-remover J-33013-B body
to press the hub onto the shaft. Tighten the body
3. Remove the shaft key and retain for reassembly. several turns, remove the installer and check to see
that the shaft key is still in place in the keyway
Installation before installing the clutch plate and hub
1. Install the shaft key into the hub key groove. Allow assembly to its finial position. The air gap (2)
the key to project approximately 3.2 mm (1/8 in) out between frictional surfaces of the clutch plate and
of the keyway. The shaft key is curved slightly to clutch rotor should be 0.50–0.76 mm (.020–.030 in).
provide an interference fit in the hub key groove.
CAUTION: If the center screw is threaded fully onto 7. Remove installer J-33013-B, check for proper
the end of the compressor shaft. or if the body of positioning of the shaft key (even or slightly above
the installer is held and the center screw is rotated, the clutch hub).
the key will wedge and will break the clutch hub. 8. Spin the pulley rotor by hand to see that the rotor is
not rubbing the clutch drive plate.

J-33013-B

901RW002

COMPRESSOR CLUTCH ROTOR AND/OR 4. Hold the J-41552 puller in place and tighten the
BEARING puller screw against the puller guide to remove the
pulley rotor and bearing assembly.
Removal
1. Remove the clutch plate and hub assembly as
described previously.
2. Remove rotor (1) and bearing assembly retaining
ring (2), using snap ring pliers.

J-41552
1

2
871RW007

Installation
1. With the compressor mounted to the J-34992
holding fixture, position the rotor and bearing
901RW003
assembly on the front head.
3. Install pulley rotor and bearing puller guide J-33023-A 2. Position the J-33017 pulley, rotor and bearing
to the front head and install J-41552 pulley rotor and installer and J-33023-A puller pilot directly over the
bearing puller down into the inner circle of slots (1) in inner race of the bearing.
the rotor. Turn the J-41552 puller clockwise in the
slots in the rotor.
3. Position puller crossbar J-8433-1 on the puller pilot 5. Install rotor and bearing assembly retainer ring,
J-33023-A and assemble the two J-33026 through using snap ring pliers.
bolts and washers through the puller bar slots and 6. Reinstall clutch plate and hub assembly as
thread them into the J-33026 holding fixture. The described previously.
thread of the through bolts should engage the full
thickness of the holding fixture.
4. Tighten the center screw in the J-8433-1 puller
crossbar to force the pulley rotor (1) and bearing
assembly onto the compressor front head. Should
the J-33017 pulley rotor and bearing installer slip off
direct in-line contact with the inner race of the
bearing, loosen the J-8433-1 center forcing screw
and realign the installer and pilot so that the J-
33017 installer will properly clear the front head.

J-8433-3

J-8433-1 J-33023

J-33017

J-33026

901RW005

COMPRESSOR CLUTCH COIL J-8433-3


Removal J-33023-A
J-8433-1
1. Perform Steps 1 through 4 of "Clutch Rotor and/or
Bearings" removal procedure. Mark clutch coil
terminal location (1) on compressor front head.
2. Install J-33023-A puller pilot on front head of J-33025
compressor. Also install J-8433-1 puller crossbar
with J-33025 puller legs as shown in figure.
3. Tighten J-8433-3 forcing screw against the puller
pilot to remove the clutch coil (2).

2
1

901RW006
Installation
1. Place the clutch coil assembly (1) on the front head
with the terminals positioned at the "marked" location. 2
3
2. Place the J-33024 clutch coil installer over the
internal opening of the clutch coil housing and align
installer with the compressor front head.
3. Center the J-8433-1 puller crossbar in the counter-
sunk center hole of the J-33024 clutch coil installer.
Install the J-33026 through bolts and washers
through the crossbar slots and thread them into the
holding fixture J-33026 to full fixture thickness.

J-8433-3
J-8433-1

871RW004

Stake size should be only one-half the area of the


J-33024
punch tip and be only approximately 0.28–0.35
mm (.010–.015 in) deep.

1 1
3

901RW007

4. Turn the center forcing screw of J-8433-1 puller


crossbar to force the clutch coil onto the front head.
Be sure clutch coil and J-33024 installer stay "in-
line" during installation.
5. When coil is fully seated on the front head, use a
1/8 in diameter drift punch (2) and stake the front
head at three places 120 degrees apart, to ensure 2
clutch coil (3) remains in position.

871RW005

Legend
(1) Stake Front Head 0.28–0.35 mm Deep
(0.10–015 in)
(2) Clutch Coil Housing
(3) Front Head Surface

6. Install rotor and bearing assembly and the clutch


plate and hub assembly as described previously.
COMPRESSOR SHAFT SEAL Seal Leak Detection
Service Precaution A shaft seal should not be changed because of small
amounts of oil found on an adjacent surface but only
When replacing the shaft seal assembly, pressure relief
after actual refrigerant leakage is found using an
valve or control switches, it will be necessary to recover
approved leak detector.
the refrigerant. Other than clutch repair procedures, the
same holds true for any disassembly of the compressor. CAUTION: Handling and care of seal protector is
A clean workbench covered with a sheet of clean important. If seal protector is nicked or the bottom
paper, and a place (clean trays, etc) for all parts being flared, the new seal may be damaged during
removed and replaced is important, as is the use of installation.
proper clean service tools.
Removal
CAUTION: Any attempt to use makeshift or
inadequate service tools or equipment may result 1. Recover the refrigerant using Refrigerant Recovery
in damage and/or improper compressor operation. System.
All parts required for servicing the internal compressor 2. Loosen and reposition compressor in mounting
are protected by a preservative process and packaged brackets, if necessary.
in a manner which will eliminate the necessity of 3. Remove clutch plate and hub assembly from
cleaning, washing or flushing of the parts. The parts compressor as described previously.
can be used in the internal assembly just as they are 4. Remove the shaft seal retainer ring, using snap ring
removed from the service package. Seals and pliers.
protective packaging should be left intact until just 5. Thoroughly clean inside of compressor neck area
prior to installation. surrounding the shaft, the exposed portion of the
If the compressor rear head, front head or cylinder and seal, the retainer ring groove and the shaft itself.
shaft assembly is to be serviced or replaced, the oil in Any dirt or foreign material getting into compressor
the compressor must be drained, measured, recorded may cause damage.
and replaced. 6. Fully engage the knurled tangs of Seal Remover-
Installer J-23128-A into the recessed portion of the
Seal (1) by turning the handle clockwise. Remove
6 the Seal from the compressor with a rotary-pulling
1 motion.
Discard the seal. The handle must be hand-
5 tightened securely. Do not use a wrench or pliers.
2

3
4

871RW006

Legend
(1) Suction Port J-23128-A
(2) Discharge Port
(3) Mounting Boss
(4) Mounting Boss
(5) Pressure Relief Valve 901RW008

(6) Mounting Boss


7. Remove and discard the seal seat O-ring (2) from the 2. Insert the O-ring installer J-33011 into the
compressor neck using O-ring remover J-9553-01. compressor neck until the installer "bottoms". Lower
the moveable slide of the O-ring installer to release
the O-ring into the seal O-ring lower groove (The
compressor neck top groove is for the shaft seal
retainer ring.) Rotate the installer to seat the O-ring
and remove the installer.
J-9553-01
3. Dip the new seal in clean 525 viscosity refrigerant oil
and assemble seal to Seal Installer J-23128-A, by
turning handle clockwise. The stamped steel case
side of the lip seal must be engaged with knurled
tangs of installer so that flared-out side of lip seal is
facing and installed towards the compressor. Install
seal protector J-34614, in the seal lip and place over
the compressor shaft, and push the seal in place with
a rotary motion or place the seal protector J-34614
over end of compressor shaft, and slide the new seal
2 onto the shaft with a rotary motion until it stops. Take
care not to dislodge the O-ring. Be sure the seal (2)
makes good contact with the O-ring. Disengage the
installer from the seal and remove the installer
901RW009
J-23128-A and the seal protector J-34614.
CAUTION: Handling and care of seal protector is
8. Recheck the shaft and inside of the compressor important. If seal protector is nicked or the bottom
neck for dirt or foreign material and be sure these flared, the new seal may be damaged during
areas are perfectly clean before installing new parts. installation.
Cleaning
Thoroughly clean O-ring seal groove in front head.
CAUTION: Seals should not be re-used. Always use
a new specification service seal on rebuild. Be sure
that the seal to be installed is not scratched or
damaged in anyway. Make sure that the seal seat J-34614
and seal are free of lint and dirt that could damage 2
the seal surface or prevent sealing.

Installation
1. Dip the new seal seat O-ring (1) in clean 525
viscosity refrigerant oil and assemble onto O-ring
installer J-33011.
J-23128-A

901RW011

1
4. Install the new seal retainer ring with its flat side
against the Seal, using Snap-Ring Pliers. Use the
sleeve from O-ring installer J-33011 to press in on
the seal retainer ring so that it snaps into its groove.
5. To leak test, install compressor leak test fixture
J-39893 on rear head of compressor and connect
gage charging lines and Refrigerant Recovery
System. Pressurize suction and high-side of
compressor with R-134a Refrigerant. Temporarily
install (M9 1.25 thread on shaft) nut and, with the
J-33011 compressor in horizontal position, rotate the
compressor shaft in normal direction of rotation
several times by hand. Leak test the seal area and
correct and leak found. Recover the refrigerant.
901RW010 Remove shaft nut.
6. Remove any excess oil resulting from installing the 8. Reinstall compressor belt and tighten bracket.
new seal parts from the shaft and inside the 9. Evacuate and charge the refrigerant system.
compressor neck.
7. Install the clutch plate and hub assembly as
described previously.

COMPRESSOR PRESSURE RELIEF VALVE 2. Lubricate O-ring of new pressure relief valve and
O-ring assembly with new 525 viscosity refrigerant
Removal oil. Install new valve and torque in place, 9.0 Nꞏm
1. Recover the refrigerant using Refrigerant Recovery (6.1 ft lbs)
System. 3. Evacuate and recharge the system.
2. Remove old pressure relief valve. 4. Leak test system.
Installation
1. Clean valve seat area on rear head.

COMPRESSOR OIL 7. Install the compressor, then evacuate, charge and


perform the oil return operation.
Compressor Oil Check
8. Check system operation.
The oil used to lubricate the compressor is circulating
with the refrigerant. When it is impossible to preform oil return
Whenever replacing any component of the system or a operation, the compressor oil should be checked in
large amount of gas leakage occurs, add oil to maintain the following order:
the original amount of oil. 1. Discharge and recover refrigerant and remove the
compressor.
(Oil Capacity) 2. Drain the compressor oil and measure the extracted
Capacity total in system 150 cc (5.0 fl.oz) oil with a measuring cylinder.
Compressor (Service 150 cc (5.0 fl.oz) 3. Check the oil for contamination.
parts) charging amount 4. If more than 90 cc (3.0 fl. oz.) of oil is extracted from
the compressor, supply the same amount of oil to
Checking and Adjusting Oil Quantity for the compressor to be installed. If the amount of oil
extracted is less than 90 cc (3.0 fl. oz.), recheck the
Used Compressor compressor oil in the following order:
1. Perform oil return operation. Refer to Oil Return 5. Supply 90 cc (3.0 fl. oz.) of oil to the compressor
Operation in this section. and install it onto the vehicle.
2. Discharge and recover refrigerant and remove the 6. Evacuate and recharge with the proper amount of
compressor. refrigerant.
3. Drain the compressor oil and measure the extracted 7. Perform the oil return operation.
oil with a measuring cylinder.
8. Remove the compressor and recheck the amount of
4. If the amount of oil drained is much less than 90 cc oil.
(3.0 fl. oz.), some refrigerant may have leaked out.
9. Adjust the compressor oil, if necessary.
Conduct a leak tests on the connections of each
system, and if necessary, repair or replace faulty (Collected Amount) (Charging Amount)
parts.
more than 90 cc same as collected
5. Check the compressor oil contamination. (Refer to (3.0 fl.oz) amount
Contamination of Compressor Oil in this section.)
less than 90 cc (3.0 fl.oz) 90 cc (3.0 fl.oz)
6. Adjust the oil level following the next procedure
below.
Checking and Adjusting for Compressor
(Collected Amount) (Charging Amount)
Replacement
more than 90 cc same as collected The oil is not charged in compressor (service parts). So
(3.0 fl.oz) amount
it is necessary to charge the proper amount of oil to the
less than 90 cc (3.0 fl.oz) 90 cc (3.0 fl.oz) new compressor.
1. Perform oil return operation. (Component parts to be (Amount of Oil)
2. Discharge and recover the refrigerant and remove installed)
the compressor. Evaporator 50 cc (1.7 fl. oz.)
3. Drain the compressor oil and measure the extracted
Condenser 30 cc (1.0 fl. oz.)
oil.
4. Check the compressor oil for contamination. Receiver/dryer 30 cc (1.0 fl. oz.)
5. Adjust the oil level as required. Refrigerant line (one 10 cc (0.3 fl. oz.)
piece)
(Amount of oil drained (Charging amount of oil
from used compressor) to new compressor)
Compressor Leak Testing (External and
more than 90 cc same as drained amount
(3.0 fl.oz) Internal)
less than 90 cc (3.0 fl.oz) 90 cc (3.0 fl.oz) Bench-Check Procedure
1. Install test plate J-39893 on rear head of compressor.
6. Evacuate, charge and perform the oil return 2. Using Refrigerant Recovery System, attach center
operation. hose of manifold gage set on charging station to a
7. Check the system operation. refrigerant drum standing in an upright drum.
3. Connect charging station high and low pressure
Contamination of Compressor Oil lines to corresponding fittings on test plate J-39893.
Unlike engine oil, no cleaning agent is added to the Suction port (low-side) of compressor has large
compressor oil. Even if the compressor runs for a long internal opening. Discharge port (high-side) has
period of time (approximately one season), the oil never smaller internal opening into compressor and
becomes contaminated as long as there is nothing deeper recess.
wrong with the compressor or its method of use. 4. Open low pressure control, high pressure control
Inspect the extracted oil for any of the following and refrigerant control on charging station to allow
conditions: refrigerant vapor to flow into compressor.
The capacity of the oil has increased. 5. Using a leak detector, check for leaks at pressure
The oil has changed to red. relief valve, rear head switch location, compressor
front and rear head seals, center cylinder seal,
Foreign substances, metal powder, etc., are present through bolt head gaskets and compressor shaft
in the oil. seal. After checking, shut off low pressure control
If any of these conditions exists, the compressor and high-pressure control on charging station.
oil is contaminated. Whenever contaminated 6. If an external leak is present, perform the necessary
compressor oil is discovered, the receiver/drier corrective measures and recheck for leaks to make
must be replaced. certain the leak has been connected.
7. Recover the refrigerant.
Oil Return Operation 8. Disconnect both hoses from the test plate J-39893.
There is close affinity between the oil and the 9. Add 90 ml (3 oz.) new PAG lubricant to the
refrigerant. During normal operation, part of the oil compressor assembly. Rotate the complete
recirculates with the refrigerant in the system. When compressor assembly (not the crankshaft or drive
checking the amount of oil in the system, or replacing plate hub) slowly several turns to distribute oil to all
any component of the system, the compressor must be cylinder and piston areas.
run in advance for oil return operation. The procedure 10. Install a M9 1.25 threaded nut on the compressor
is as follows: crankshaft if the drive plate and clutch assembly are
1. Open all the doors and the engine hood. not installed.
2. Start the engine and air conditioning switch to "ON" 11. Using a box-end wrench or socket and handle,
and set the fan control knob at its highest position. rotate the compressor crankshaft or clutch drive
3. Run the compressor for more than 20 minutes plate on the crankshaft several turns to insure
between 800 and 1,000 rpm in order to operate the piston assembly to cylinder wall lubrication.
system. 12. Using Refrigerant Recovery System, connect the
4. Stop the engine. charging station high-pressure line to the test plate
J-39893 high-side connector.
Replacement of Component Parts 13. Using Refrigerant Recovery System, connect the
When replacing the system component parts, supply charging station low-pressure line to the low
the following amount of oil to the component parts to be pressure port of the test plate J-39893. Oil will drain
installed. out of the compressor suction port if the compressor
is positioned with the suction port downward.
14. Attach the compressor to the J-34992 holding
fixture and mount the compressor in a vise so that
the compressor will be in a horizontal position and
the shaft can be turned with a wrench.
15. Using a wrench, rotate the compressor crankshaft
or drive plate hub ten complete revolutions at a
speed of approximately one-revolution per second
turning the compressor at less than one-revolution
per second can result in a lower pump-up pressure
and disqualify a good pumping compressor.
16. Observe the reading on high-pressure gauge at the
completion of the tenth revolution of the
compressor. The pressure reading for a good
pumping compressor should be 690 kPa (100 psi)
or above. A pressure reading of less than 620 kPa
(90 psi) would indicate one or more suction and/or
discharge valves leaking an internal leak, or an
inoperative valve, and the refrigerant must be
recovered and the compressor disassembled and
checked for cause of leak. Repair as needed,
reassemble and repeat the pump-up test. Externally
leak test.
17. When the pressure pump-up test is completed,
recover the refrigerant from the high-side and
remove the test plate J-39893.
18. Tilt the compressor so that the compressor suction
and discharge ports are down. Drain the PAG
lubricant from the compressor.
19. Allow the compressor to drain for 10 minutes, then
refill with the proper amount of PAG lubricant, per
oil balance procedure described previously. The
PAG lubricant may be poured into the suction port.
If further assembly or processing is required, a
shipping plate or test plate J-39893 should be
installed to keep out air, dirt and moisture until the
compressor is installed.
Ⅱ Ⅲ
E03RW015
E03RW011
25 (2.5/18)

34 (3.5/25)

8 (0.8/69 lbꞏin)

19 (1.9/14)

17 (1.7/12)
E03RW010
436RW006

436RW005
436RW009
440RW004
412RW055
412RW048
433RW004
433RW005
イラスト区分� B K T G S
資料区分� W O Y T
資料番号(Pub.No.)
ユニットタイプ�
いすゞ品番�
J−No.�
イラスト番号・追番� 4 3 1 R T
対⽶ Sec.3 F4
品名 ⼜は�
電装タイトル�
431RW021
C03RW003
5

460RW024
461RW003
460RW025
460RW026
460RW027
460RW028
480RV004
DIFFERENTIAL (FRONT) 4A1–1

DRIVELINE/AXLE
CONTENTS
Differential (Front) . . . . . . . . . . . . . . . . . . . . . . . 4A1 Driveline Control System (TOD) . . . . . . . . . . . 4B2
Differential (Rear/220mm) . . . . . . . . . . . . . . . . 4A2A Driveshaft System . . . . . . . . . . . . . . . . . . . . . . . 4C
Differential (Rear/244mm) . . . . . . . . . . . . . . . . 4A2B Transfer Case (Standard Type) . . . . . . . . . . . 4D1
Driveline Control System (Shift on the Fly) . . 4B1 Transfer Case (TOD) . . . . . . . . . . . . . . . . . . . . 4D2

DIFFERENTIAL (FRONT)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 4A1–1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A1–7
Front Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . 4A1–2 Differential Assembly . . . . . . . . . . . . . . . . . . . . 4A1–9
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A1–2 Disassembled View . . . . . . . . . . . . . . . . . . . . 4A1–9
Pinion Shaft Oil Seal . . . . . . . . . . . . . . . . . . . . . 4A1–3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4A1–10
Pinion Shaft Oil Seal and Associated Parts 4A1–3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4A1–12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A1–3 Differential Cage Assembly . . . . . . . . . . . . . . . 4A1–21
Inspection and Repair . . . . . . . . . . . . . . . . . . 4A1–4 Disassembled View . . . . . . . . . . . . . . . . . . . . 4A1–21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A1–4 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4A1–21
Front Drive Axle Assembly . . . . . . . . . . . . . . . 4A1–5 Inspection and Repair . . . . . . . . . . . . . . . . . . 4A1–22
Front Drive Axle Assembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4A1–23
Associated Parts . . . . . . . . . . . . . . . . . . . . . . 4A1–5 Main Data and Specifications . . . . . . . . . . . 4A1–25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A1–5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 4A1–28

Service Precaution CAUTION: Always use the correct fastener in the


proper location. When you replace a fastener, use
WARNING: IF SO EQUIPPED WITH A ONLY the exact part number for that application.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS), ISUZU will call out those fasteners that require a
REFER TO THE SRS COMPONENT AND WIRING replacement after removal. ISUZU will also call out
LOCATION VIEW IN ORDER TO DETERMINE the fasteners that require thread lockers or thread
WHETHER YOU ARE PERFORMING SERVICE ON OR sealant. UNLESS OTHERWISE SPECIFIED , do not
NEAR THE SRS COMPONENTS OR THE SRS use supplemental coatings (Paints, greases, or other
WIRING. WHEN YOU ARE REFORMING SERVICE ON corrosion inhibitors) on threaded fasteners or
OR NEAR THE SRS COMPONENTS OR THE SRS fastener joint interfaces. Generally,such coatings
WIRING, REFER TO THE SRS SERVICE adversely affect the fastener torque and the joint
INFORMATION. FAILURE TO FOLLOW WARNINGS clamping force, and may damage the fastener. When
COULD RESULT IN POSSIBLE AIR BAG you install fasteners, use the correct tightening
DEPLOYMENT, PERSONAL INJURY, OR sequence and specification. Following these
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. instructions can help you avoid damage to parts and
systems.
4A1–2 DIFFERENTIAL (FRONT)

Front Drive Axle


Diagnosis
Condition Possible cause Correction
Oil Leak At Front Axle Worn or defective oil seal. Replace the oil seal.
Front axle housing cracked. Repair or replace.
Oil Leak At Pinion Shaft Too much gear oil. Correct the oil level.
Oil seal worn or defective. Replace the oil seal.
Pinion flange loose or damaged. Tighten or replace.
Noises In Front Axle Drive Shaft Broken or worn drive shaft joints and Replace the drive shaft joints and
Joint bellows (BJ and DOJ). bellows.
“Clank” When Accelerating From Loose drive shaft joint to output shaft Tighten.
“Coast” bolts.
Damaged inner drive shaft joint. Replace.
Shudder or Vibration During Excessive drive shaft joint angle. Repair.
Acceleration
Worn or damaged drive shaft joints. Replace.
Sticking spider assembly (inner drive Lubricate or replace.
shaft joint).
Sticking joint assembly (outer drive Lubricate or replace.
shaft joint).
Vibration At Highway Speeds Out of balance or out of round tires. Balance or replace.
Front end out of alignment. Align.
Noises in Front Axle Insufficient gear oil. Replenish the gear oil.
Wrong or poor grade gear oil. Replace the gear oil.
Drive pinion to ring gear backlash Adjust the backlash.
incorrect.
Worn or chipped ring gear, pinion Replace the ring gear, pinion gear or
gear or side gear. side gear.
Pinion shaft bearing worn. Replace the pinion shaft bearing.
Wheel bearing worn. Replace the wheel bearing.
Differential bearing loose or worn. Tighten or replace.
Wanders and Pulls Wheel bearing preload too tight. Adjust the wheel bearing preload.
Incorrect front alignment. Adjust the front alignment.
Steering linkage loose or worn. Tighten or replace.
Steering gear out of adjustment. Adjust or replace the steering gear.
Tire worn or improperly inflated. Adjust the inflation or replace.
Front or rear suspension parts loose Tighten or replace.
or broken.
Front Wheel Shimmy Wheel bearing worn or improperly Adjust or replace.
adjusted.
Incorrect front alignment. Adjust the front alignment.
Worn ball joint or bush. Replace the ball joint or bush.
Steering linkage loose or worn. Tighten or replace.
Steering gear out of adjustment. Tighten or replace.
Tire worn or improperly inflated. Replace or adjust the inflation.
Shock absorber worn. Replace the shock absorber.
DIFFERENTIAL (FRONT) 4A1–3

Pinion Shaft Oil Seal


Pinion Shaft Oil Seal and Associated Parts

415RW015

Legend (3) Oil Seal


(1) Flange Nut (4) Outer Bearing
(2) Flange (5) Collapsible Spacer

Removal
1. Raise the vehicle and support it at the frame.
The hoist must remain under the front axle housing.
2. Drain the front axle oil by loosening the drain plug(1).

412RS001
4A1–4 DIFFERENTIAL (FRONT)
3. Remove the front propeller shaft. Refer to Front Inspection and Repair
Propeller Shaft in this section.
Make necessary correction or parts replacement if wear,
4. Remove flange nut by using pinion flange holder damage, corrosion or any other abnormal conditions are
5–8840–2157–0. found through inspection.
Check the following parts:
1. Seal surface of the pinion.
2. Cage bore for burns.

Installation
1. Install collapsible spacer. Discard the used
collapsible spacer and install a new one.
2. Install outer bearing.
NOTE: Do not drive in, but just temporarily set in the outer
bearing by hand, which should be indirectly pressed in
finally by tightening the flange nut.
3. Install oil seal, use oil seal installer 9–8522–1275–0 to
install a new oil seal that has been soaked in axle
lubricant.

425RW045

5. Remove flange.
6. Remove oil seal.
7. Remove outer bearing by using remover
5–8840–2323–0.

415RW021

4. Install flange.
5. Install flange nut, refer to Differential Assembly for
flange nut reassembly in this section.
NOTE: Discard the used nut and install a new one.

415RW022

8. Remove collapsible spacer.


DIFFERENTIAL (FRONT) 4A1–5

Front Drive Axle Assembly


Front Drive Axle Assembly and Associated Parts

412RY00001

Legend (6) Front Axle Case Assembly and Front Drive


(1) Mounting Bolt and Nut Shaft Assembly (LH side)
(2) Washer and Spacer (7) Hub Assembly (Disc, Back Plate and Knuckle)
(3) Breather Hose (8) Front Drive Shaft Assembly (RH side)
(4) Shift Switch Connector (with Shift on the Fly) (9) Propeller Shaft
(5) Protector (with Shift on the Fly) (10) Bolt

Removal
1. Jack up the vehicle and support it using jack stands.
2. Remove the tire and wheel.
4A1–6 DIFFERENTIAL (FRONT)
3. Remove the drain bolt to drain differential oil. 13. Disconnect shift switch connector (Shift on the fly
model).
NOTE:
a. During the work, be sure that the diff case is
supported by the jack.

412RS031

14. Remove VSV assembly (1) (Shift on the fly model).

412RS003
NOTE: Be sure not to remove hose and connector from
b. Remove the brake caliper fixing bolt and hang the VSV asm.
caliper. Refer to Front Disc Brake Caliper Assembly
in Brake section.
c. Remove the antilock brake system speed sensor (if
equipped). Refer to Front Wheel Speed Sensor in
Brakes section.
4. Remove the hub assembly (Disc, back plate and
knuckle), refer to Front Hub and Disc in this section.
5. Disconnect the knuckle and the suspension arm.
Refer to Suspension section.
6. Remove steering link and arm assembly, refer to
Steering Linkage in Steering section.
7. Remove suspension crossmember.
8. Remove propeller shaft, refer to Front Propeller Shaft
in this section.
9. Remove protector (Shift on the fly model).
10. Remove the hose clip.
11. Disconnect breather hose from front drive axle tube.
(and disconnect housing : Shift on the fly model). 412RW002

12. Disconnect vacuum hose from actuator (Shift on the


fly model).
DIFFERENTIAL (FRONT) 4A1–7
15. Remove mounting bolt and nut. 18. Lower the vehicle and disconnect the RH front drive
shaft assembly, then remove the front axle case
assembly and front drive shaft assembly (LH).

412RS004

16. Remove washer and spacer.


17. Remove the mounting bracket fixing bolt. 412RS006

19. Remove front drive shaft assembly (RH).

Installation
1. Install front drive shaft assembly (RH) and lay the
assembly on the lower arm.
2. Install front axle case assembly and front drive shaft
assembly (LH) and place the axle case on the jack,
connect to the front drive shaft assembly (RH) before
installing to the vehicle.
3. Install bolt and tighten the mounting bracket fixing bolt
to the specified torque.
Torque: 116 Nꞏm (11.8kgꞏm/85 lb ft)
4. Install washer and spacer.

412RS005
4A1–8 DIFFERENTIAL (FRONT)
5. Tighten the mounting bolt and nut to the specified
torque.
Torque: 152 Nꞏm (15.5kgꞏm/112 lb ft)

412RW005

Legend
(1) Frame
(2) Spacer
(3) Washer
(4) Bolt
(5) Nut

6. Install VSV assembly and tighten nuts to specified


torque (Shift on the fly model).
Torque: 8 Nꞏm (0.8kgꞏm/69 lb in)
7. Install the shift switch connector (Shift on the fly
model).
NOTE: Be careful not to permit the entry of dust into the
connector.
8. Install the actuator side of vacuum hose (Shift on the
fly model).
NOTE: Be careful not to permit the entry of dust into the
hose.
9. Connect breather hose and install the hose clip.
10. Install protector and tighten bolts to specified torque
(Shift on the fly model).
Torque: 26 Nꞏm (2.7kgꞏm/20 lb ft)
11. Install propeller shaft, refer to Front Propeller Shaft in
this section.
12. Install suspension crossmember.
13. Steering link and arm assembly, refer to Steering
Linkage in Steering section.
14. Install hub assembly (Disc, back plate and knuckle),
refer to Front Hub and Disc in this section.
DIFFERENTIAL (FRONT) 4A1–9

Differential Assembly
Disassembled View

415RW001

Legend (12) Bolt


(1) Differential Assembly (13) Inner Bearing Outer Race
(2) Flange Nut (14) Collapsible Spacer
(3) Flange (15) Pinion Gear
(4) Dust Cover (16) Inner Bearing
(5) Oil Seal (17) Adjust Shim
(6) Outer Bearing (18) Diff Cage Assembly
(7) Outer Bearing Outer Race (19) Side Bearing Outer Race
(8) Damper (20) Side Bearing
(9) Bracket (21) Adjust Shim
(10) Differential Carrier (22) Bolt
(11) Bearing Cap (23) Axle Case
4A1–10 DIFFERENTIAL (FRONT)

Disassembly 7. Remove side bearing outer race, after removal, keep


the right and left hand side bearing assemblies
1. Remove differential carrier fixing bolt. separate to maintain inner and outer race
2. Remove differential assembly. combinations.
3. Using holding fixture 5–8840–0275–0 and holding 8. Remove side bearing, using remover
fixture base 5–8840–0003–0, fix the differential 5–8840–0013–0, 5–8840–0014–0 and adapter
assembly to the bench. 9–8521–1743–0.

425RW046 415RW023

4. Remove bearing cap bolt. 9. Remove adjust shim, note the thickness and position
5. Apply a setting mark to the side bearing cap and the of the shims removed.
differential carrier then remove bearing cap. 10. Remove the flange nut using holding wrench
5–8840–2157–0 after raising up its staked parts
completely.

425RS009

6. Remove differential cage assembly.


425RW047

11. Remove flange.


DIFFERENTIAL (FRONT) 4A1–11
12. Remove dust cover. 20. Remove the inner bearing outer race (1) and the outer
13. Remove the drive pinion assembly using a soft metal bearing outer race (2) by using a brass bar and a
rod and a hammer. hammer.

425RS014
425RW041

14. Remove collapsible spacer.


15. Remove the inner bearing using a separator
5–8840–0015–0 and a press.

425RS015

415RW033

16. Remove adjust shim.


17. Remove inner bearing outer race.
18. Remove oil seal.
19. Remove outer bearing.
4A1–12 DIFFERENTIAL (FRONT)

21. Remove damper and bracket. 2. Using installer 9–8522–1274–0 and grip
5–8840–0007–0, install Inner bearing outer race.

425RW042

415RW017

Reassembly 3. Install adjust shim and adjust drive pinion mounting


distance
1. Using installer 9–8522–1141–0 and grip 1. Apply gear oil to the inner and outer drive pinion
5–8840–0007–0, install outer bearing outer race. bearing.
Clean the pinion setting gauge set.
Then install the gauge set together with the inner
and outer bearings.
2. Tighten the nut to the specified torque.
Torque: 2.3 Nꞏm (0.23kgꞏm/20 lb in)

415RW018

415RS009

Legend
(1) Pilot : 5–8840–2085–0
(2) Nut and Bolt : 5–8840–2089–0
(3) Gauge Plate : 5–8840–2087–0
DIFFERENTIAL (FRONT) 4A1–13
3. Clean the side bearing bores. Install the dial Legend
indicator with the discs and arbor. Install and (1) Dial Indicator
tighten the bearing caps to the specified torque. (2) Gauging Arbor
Torque: 98 Nꞏm (10kgꞏm/72 lb ft) (3) Plunger
(4) Gauge Plate

5. Position the plunger on the gauge plate. Move the


gauging arbor slowly back and forth and locate
the position at which the dial indicator shows the
greatest defection. At this point, once again set
the dial indicator to “0”.
Repeat the procedure to verify the “0” setting.

415RS010

Legend
(1) Dial Indicator: 5–8840–0126–0
(2) Disc (2 pcs.): 5-8840-2088-0
(3) Arbor: 5–8840–0128–0
(4) Gauge Plate: 5–8840–2087–0

4. Set the dial indicator to “0”. Place it on the 425RS021

mounting post of the gauging arbor with the 6. After the ZERO setting is obtained, rotate the
contact button touching the indicator pad. Force gauging arbor until the dial indicator rod does not
the dial indicator downward until the needle has touch the gauging plate.
made a half turn clockwise. Tighten down the dial
indicator in this position. Record the number the dial indicator needle
points to.

425RS020
425RS022

Legend
(1) Example=Dial indicator reading of 0.085
4A1–14 DIFFERENTIAL (FRONT)

7. Record the pinion depth code on the head of the


drive pinion.
The number indicates a necessary change in the
pinion mounting distance. A plus number indi-
cates the need for a greater mounting distance
(which can be achieved by decreasing the shim
thickness). A minus number indicates the need
for a smaller mounting distance (which can be
achieved by increasing the shim thickness). If ex-
amination reveals pinion depth code “0”, the pin-
ion is “nominal”.

425RS023
DIFFERENTIAL (FRONT) 4A1–15
8. Select the shim using the chart;
Pinion marking +10 +8 +6 +4 +2 0 –2 –4 –6 –8 –10

Dial indicator
reading mm mm mm mm mm mm mm mm mm mm mm
(Inches) (Inches) (Inches) (Inches) (Inches) (Inches) (Inches) (Inches) (Inches) (Inches) (Inches) (Inches)

2.18
0.081
(0.0858)

2.18 2.20
0.082
(0.0858) (0.0866)

2.18 2.20 2.23


0.083
(0.0858) (0.0866) (0.0882)

2.18 2.20 2.24 2.26


0.084
(0.0858) (0.0866) (0.0882) (0.0890)

2.18 2.20 2.24 2.26 2.28


0.085
(0.0858) (0.0866) (0.0882) (0.0890) (0.0898)

2.18 2.20 2.24 2.26 2.28 2.32


0.086
(0.0858) (0.0866) (0.0882) (0.0890) (0.0898) (0.0914)

2.18 2.20 2.24 2.26 2.28 2.32 2.34


0.087
(0.0858) (0.0866) (0.0882) (0.0890) (0.0898) (0.0914) (0.0921)

2.18 2.20 2.24 2.26 2.28 2.32 2.34 2.36


0.088
(0.0858) (0.0866) (0.0882) (0.0890) (0.0898) (0.0914) (0.0921) (0.0929)

2.18 2.20 2.24 2.26 2.28 2.32 2.34 2.36 2.38


0.089
(0.0858) (0.0866) (0.0882) (0.0890) (0.0898) (0.0914) (0.0921) (0.0929) (0.0937)

2.18 2.20 2.24 2.26 2.28 2.32 2.34 2.36 2.38 2.42
0.090
(0.0858) (0.0866) (0.0882) (0.0890) (0.0898) (0.0914) (0.0921) (0.0929) (0.0937) (0.0953)

2.18 2.20 2.24 2.26 2.28 2.32 2.34 2.36 2.38 2.42 2.44
0.091
(0.0858) (0.0866) (0.0882) (0.0890) (0.0898) (0.0914) (0.0921) (0.0929) (0.0937) (0.0953) (0.0961)

2.20 2.24 2.26 2.28 2.32 2.34 2.36 2.38 2.42 2.44 2.46
0.092
(0.0866) (0.0882) (0.0890) (0.0898) (0.0914) (0.0921) (0.0929) (0.0937) (0.0953) (0.0961) (0.0969)

2.24 2.26 2.28 2.32 2.34 2.36 2.38 2.42 2.44 2.46 2.48
0.093
(0.0882) (0.0890) (0.0898) (0.0914) (0.0921) (0.0929) (0.0937) (0.0953) (0.0961) (0.0969) (0.0977)

2.26 2.28 2.32 2.34 2.36 2.38 2.42 2.44 2.46 2.48 2.52
0.094
(0.0890) (0.0898) (0.0914) (0.0921) (0.0929) (0.0937) (0.0953) (0.0961) (0.0969) (0.0977) (0.0992)

2.28 2.32 2.34 2.36 2.38 2.42 2.44 2.46 2.48 2.52 2.54
0.095
(0.0898) (0.0914) (0.0921) (0.0929) (0.0937) (0.0953) (0.0961) (0.0969) (0.0977) (0.0992) (0.1000)

2.32 2.34 2.36 2.38 2.42 2.44 2.46 2.48 2.52 2.54 2.56
0.096
(0.0914) (0.0921) (0.0929) (0.0937) (0.0953) (0.0961) (0.0969) (0.0977) (0.0992) (0.1000) (0.1008)

2.34 2.36 2.38 2.42 2.44 2.46 2.48 2.52 2.54 2.56
0.097
(0.0921) (0.0929) (0.0937) (0.0953) (0.0961) (0.0969) (0.0977) (0.0992) (0.1000) (0.1008)

2.36 2.38 2.42 2.44 2.46 2.48 2.52 2.54 2.56


0.098
(0.0929) (0.0937) (0.0953) (0.0961) (0.0969) (0.0977) (0.0992) (0.1000) (0.1008)

2.38 2.42 2.44 2.46 2.48 2.52 2.54 2.56


0.099
(0.0937) (0.0953) (0.0961) (0.0969) (0.0977) (0.0992) (0.1000) (0.1008)

2.42 2.44 2.46 2.48 2.52 2.54 2.56


0
(0.0953) (0.0961) (0.0969) (0.0977) (0.0992) (0.1000) (0.1008)

2.44 2.46 2.48 2.52 2.54 2.56


0.001
(0.0961) (0.0969) (0.0977) (0.0992) (0.1000) (0.1008)

2.46 2.48 2.52 2.54 2.56


0.002
(0.0969) (0.0977) (0.0992) (0.1000) (0.1008)

2.48 2.52 2.54 2.56


0.003
(0.0977) (0.0992) (0.1000) (0.1008)

2.52 2.54 2.56


0.004
(0.0992) (0.1000) (0.1008)

2.54 2.56
0.005
(0.1000) (0.1008)

2.56
0.006
(0.1008)

NOTE: When ordering shims, find the part number in the 4. Place the shim on the drive pinion, with the chamfered
parts catalog by using the thickness of shims listed in the side turned towards the pinion head then install the
above table. inner bearing onto the pinion using an installer
9–8522–1165–0 and a press.
4A1–16 DIFFERENTIAL (FRONT)

NOTE: Do not apply pressure to the roller cage and apply NOTE: Discard used flange nut and install new one and
pressure only to the inner race. do not over tighten the flange nut.

425RW048 425RW047

5. Discard the used collapsible spacer and install a new 3. Adjust pinion bearing preload.
one.
a. Measure the bearing preload by using a torque
6. Install pinion gear. meter. Note the scale reading required to
7. Install outer bearing. rotate the flange.
8. Use oil seal installer 9–8522–1275–0 to install a new b. Continue tightening flange nut until the
oil seal that has been soaked in rear axle lubricant. specified starting torque is obtained.
NOTE: Take care to use a front differential oil seal, NOT Starting torque:
the rear differential oil seal. New bearing
0.7–1.1 Nꞏm(0.065–0.115kgꞏm/5.64–9.98 lb in)
Used bearing
0.4–0.5Nꞏm(0.033–0.057kgꞏm/2.86–4.94 Ib in)

415RW024

9. Install dust cover.


10. Install flange.
11. Install flange nut. 425RS027

1. Apply lubricant to the pinion threads. 4. Using punch 5-8840-2293-0, stake the flange nut
at two points.
2. Tighten the nut to the specified torque using the
pinion flange holder 5–8840–2157–0.
Torque: 177–275Nꞏm (18–28kgꞏm/130–203 lb ft)
DIFFERENTIAL (FRONT) 4A1–17
NOTE: When staking, be sure to turn the nut to insure 2. Insert the differential cage assembly with bearing
that there is no change in bearing preload. Make sure of outer races into the side bearing bores of the
preload again as instructed in 3). carrier.

415RW019 425RS030

Legend 3. Using two sets of feeler gauges, insert a feeler


(1) 1.3mm or less stock of sufficient thickness between each
bearing outer race and the carrier to remove all
12. Install adjust shim. end play. Make certain the feeler stock is pushed
to the bottom of the bearing bores.
1. Attach the side bearing to the differential
assembly without shims. Support the opposite Mount the dial indicator 5–8840–0126–0 on the
side using a pilot to prevent bearing damage. carrier so that the indicator stem is at right angles
to a tooth on the ring gear.

425RS029
425RW049

Legend
(1) Drive handle:5–8840–0007–0
(2) Installer:9–8522–1164–0
(3) Pilot:9–8521–1743–0
4A1–18 DIFFERENTIAL (FRONT)

4. Adjust feeler gauge thickness from side to side 13. Install the side bearings together with the selected
until ring gear backlash is in the specified range. shims.
Backlash: 0.13–0.18 mm(0.005 –0.007 in)

425RS029

425RS032
Legend
With zero end play and correct backlash estab- (1) Drive Handle:5–8840–0007–0
lished, remove the feeler gauge packs, determine (2) Installer: 9–8522–1164–0
the thickness of the shims required and add 0.05 (3) Pilot: 9–8521–1743–0
mm (0.002 in) to each shim pack to provide side
bearing preload. Always use new shims. 14. Install side bearing outer race.
5. Use bearing remover 5–8840–0013–0 and 15. Install differential cage assembly.
5–8840–0014–0 and pilot 9–8521–1743–0 to
remove side bearing. 16. Install bearing cap then align the setting marks(1)
applied at disassembly.

415RW020
425RS035
DIFFERENTIAL (FRONT) 4A1–19
17. Tighten the cap bolt to the specified torque. Gear Tooth Contact Pattern Check and Adjustment
Torque: 98 Nꞏm (10kgꞏm/72 lb ft) 1. Apply a thin coat of prussian blue or equivalent
to the faces of the 7–8 teeth of the ring gear.
Check the impression of contact on the ring
gear teeth and make necessary adjustment as
described in illustration if the contact is
abnormal.

425RS036

1. Measure the amount of run–out of the ring gear at


its rear face.
Standard: 0.02 mm ( 0.001 in)
Limit: 0.05 mm ( 0.002 in) 425RS038

Legend
(1) Heel
(2) Toe
(3) Concave Side(Coast)
(4) Convex Side(Drive)

425RS037
4A1–20 DIFFERENTIAL (FRONT)

425RS039

18. Install differential assembly. 3. Fill the axle case with hypoid gear lubricant, to just
1. Clean the faces of the front axle case and below the filler hole.
differential carrier. Lubricant capacity: 1.4 liter(1.2 Imp qt/1.5 US qt)
Apply Three Bond TB1215 or equivalent to the
19. Install damper.
sealing side of the axle case and the carrier.
1. Clean the faces and bolt thread hole of differential
2. Attach the differential case and the carrier
carrier.
assembly to the front axle case and tighten the
nuts and bolts. 2. Install the bracket with new bolts.
Torque: 25 Nꞏm (2.5kgꞏm/19 lb ft) 3. Install the damper to the bracket with new bolts.
Torque: 25 Nꞏm (2.5kgꞏm/19 lb ft)

415RS014

425RW042
DIFFERENTIAL (FRONT) 4A1–21

Differential Cage Assembly


Disassembled View

415RS015

Legend (5) Ring Gear


(1) Pinion Gear (6) Bolt
(2) Thrust Washer (7) Differential Cage
(3) Side Gear (8) Lock Pin
(4) Cross Pin

Disassembly
1. Remove bolt.
2. Remove ring gear.
3. Remove lock pin, break staking on the lock pin, using
a 5 mm (0.20 in) diameter drill.

425RS042
4A1–22 DIFFERENTIAL (FRONT)

4. Remove the cross pin, using a soft metal rod and a 5. Tighten the fixing bolts in a diagonal sequence as
hammer. illustrated.

425RS043 415RS016

5. Remove pinion gear.


6. Remove side gear.
Clearance between the differential pinion
and the cross pin measurement:
7. Remove thrust washer.
Standard: 0.06 – 0.12 mm (0.002–0.005 in)
Inspection and Repair Limit: 0.2 mm (0.008 in)
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal conditions are
found through inspection.
Check the following parts:
1. Ring gear, pinion gear
2. Bearing
3. Side gear, pinion gear, cross pin
4. Differential cage, carrier
5. Thrust washer
6. Oil seal
Ring gear replacement:
1. The ring gear should always be replaced with the
drive pinion as a set.
2. Clean the ring gear threaded holes to remove the
locking agent.
3. When installing the ring gear, apply LOCTITE 271 or
equivalent to all the threaded area and half of the
unthreaded area of the bolt. 425RS045

4. Discard used bolts and install new ones.


Torque: 108 Nꞏm (11kgꞏm/80 lb ft)
DIFFERENTIAL (FRONT) 4A1–23
Clearance between the side gear and the Reassembly
differential box:
1. Install thrust washer.
Standard: 0.03–0.10 mm (0.001–0.004 in) 2. Install side gear.
Limit: 0.15 mm(0.006 in) 3. Install the pinion gear by engaging it with the side
gears while turning both pinion gears simultaneously
in the same direction.

425RS046

Legend
425RS048
(1) Side Gear 4. Install cross pin.
(2) Differential Box
1. Be sure to install the cross pin so that it is in
alignment with the lock pin hole in the differential
Play in splines between the side gear and cage.
the axle shaft:
Standard: 0.08–0.36 mm(0.003 –0.014 in)
Limit:0.5m (0.02 in)

425RS049

2. Adjust the backlash between the side gear and


the pinion gear.
Backlash:0.03 – 0.08 mm (0.001– 0.003 in)
425RS047
4A1–24 DIFFERENTIAL (FRONT)

Thickness of thrust washers available: 7. Tighten the bolts in diagonal sequence as illustrated.
1.00 mm, 1.05 mm, 1.10 mm (0.039 in, 0.041 in, Torque: 108 Nꞏm (11kgꞏm/80 lb ft)
0.043 in)
NOTE: Discard used bolts and install new ones.

425RS050

5. Install lock pin. After lock pin installation, stake the 415RS016

cage to secure the lock pin.

425RS051

Legend
(1) Staked Portion
(2) Lock Pin

6. Clean the ring gear threaded holes to remove the


locking agent. When installing the ring gear, apply
LOCTITE 271 or equivalent to all the threaded area
and half of the unthreaded area of the bolt.
DIFFERENTIAL (FRONT) 4A1–25

Main Data and Specifications


General Specifications
Axle tube Type It consists of the duct, a cast iron housing and the axle
tube.
Gear type Hypoid
Gear ratio (to 1) 4.100(6VE1)
4.300(4JX1, 6VE1)
4.555(4JG2–TC, 6VD1)
4.777(4JG2)
Differential type Two pinion
Oil capacity liter (Imp qt/US 1.4 (1.2/1.5) (Differential)
qt) 0.12 (0.11/0.13) (Actuator Housing: Shift on the fly)
Type of lubricant 75W–90 GL–5 (Multi grade type)
Refer to General Information
Axle shaft type Constant velocity joint
(Birfield joint type and double offset joint)
4A1–26 DIFFERENTIAL (FRONT)

Torque Specifications

E04RW014
DIFFERENTIAL (FRONT) 4A1–27

E04RW015
4A1–28 DIFFERENTIAL (FRONT)

Special Tools
TOOL NO. TOOL NO.
ILLUSTRATION ILLUSTRATION
TOOL NAME TOOL NAME

5–8840–2157–0 5–8840–0015–0
(J–37221) (J–22912–01)
Holder; Pinion flange Separator

9–8522–1275–0 9–8522–1141–0
(J–24250) (J–24256)
Installer; Oil seal Installer; Outer bearing
outer race

5–8840–0275–0
(J–37264)
Differential holding 5–8840–0007–0
fixture (J–8092)
(Use with Driver handle
5–8840–0003–0 base)

5–8840–0003–0 9–8522–1274–0
(J–3289–20) (J–24252)
Holding fixture base Installer; Inner bearing
outer race

5–8840–0013–0
5–8840–0014–0 5–8840–2085–0
(J–22888) (J–21777–42)
Puller; Side bearing Pilot

9–8521–1743–0
(J–8107–2) 5–8840–2089–0
Adapter; Side bearing (J–23597–9)
plug Nut and bolt
DIFFERENTIAL (FRONT) 4A1–29

TOOL NO. TOOL NO.


ILLUSTRATION ILLUSTRATION
TOOL NAME TOOL NAME

5–8840–2087–0 9–8522–1164–0
(J–23597–7) (J–24244)
Gauge plate Installer; Side bearing

5–8840–0126–0 5–8840–2323–0
(J–8001) (J–39602)
Dial indicator Remover; Outer bearing

5–8840–2088–0
(J–23597–8)
Disc

5–8840–0128–0
(J–23597–1)
Arbor

9–8522–1165–0
(J–6133–01)
Installer; Pinion bearing

5–8840–2293–0
(J–39209)
Punch; End nut lock
DIFFERENTIAL (REAR 220mm) 4A2A–1

DRIVELINE/AXLE
DIFFERENTIAL (Rear 220mm)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 4A2A–1 Differential Assembly . . . . . . . . . . . . . . . . . . . . 4A2A–11
General Description . . . . . . . . . . . . . . . . . . . . . 4A2A–2 Differential Assembly and Associated Parts 4A2A–11
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2A–3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2A–11
Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2A–4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2A–12
Axle Housing and Associated Parts . . . . . . 4A2A–4 Disassembled View . . . . . . . . . . . . . . . . . . . . 4A2A–13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2A–4 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2A–14
Oil Seal Replacement . . . . . . . . . . . . . . . . . . 4A2A–5 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2A–16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2A–5 Differential Cage Assembly . . . . . . . . . . . . . . . 4A2A–24
Axle Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2A–6 Disassembled View . . . . . . . . . . . . . . . . . . . . 4A2A–24
Axle Shaft and Associated Parts . . . . . . . . . 4A2A–6 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2A–24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2A–6 Inspection and Repair . . . . . . . . . . . . . . . . . . 4A2A–25
Inspection and Repair . . . . . . . . . . . . . . . . . . 4A2A–7 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2A–26
Oil Seal Replacement . . . . . . . . . . . . . . . . . . 4A2A–8 Limited Slip Differential . . . . . . . . . . . . . . . . . . . 4A2A–28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2A–8 Disassembled View . . . . . . . . . . . . . . . . . . . . 4A2A–28
Pinion Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2A–9 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2A–29
Pinion Oil Seal and Associated Parts . . . . . 4A2A–9 Inspection and Repair . . . . . . . . . . . . . . . . . . 4A2A–29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2A–9 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2A–31
Inspection and Repair . . . . . . . . . . . . . . . . . . 4A2A–10 Main Data and Specifications . . . . . . . . . . . 4A2A–35
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2A–10 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2A–37

Service Precaution CAUTION: Always use the correct fastener in the


proper location. When you replace a fastener, use
WARNING: IF SO EQUIPPED WITH A ONLY the exact part number for that application.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS), ISUZU will call out those fasteners that require a
REFER TO THE SRS COMPONENT AND WIRING replacement after removal. ISUZU will also call out
LOCATION VIEW IN ORDER TO DETERMINE the fasteners that require thread lockers or thread
WHETHER YOU ARE PERFORMING SERVICE ON OR sealant. UNLESS OTHERWISE SPECIFIED , do not
NEAR THE SRS COMPONENTS OR THE SRS use supplemental coatings (Paints, greases, or other
WIRING. WHEN YOU ARE REFORMING SERVICE ON corrosion inhibitors) on threaded fasteners or
OR NEAR THE SRS COMPONENTS OR THE SRS fastener joint interfaces. Generally,such coatings
WIRING, REFER TO THE SRS SERVICE adversely affect the fastener torque and the joint
INFORMATION. FAILURE TO FOLLOW WARNINGS clamping force, and may damage the fastener. When
COULD RESULT IN POSSIBLE AIR BAG you install fasteners, use the correct tightening
DEPLOYMENT, PERSONAL INJURY, OR sequence and specification. Following these
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. instructions can help you avoid damage to parts and
systems.
4A2A–2 DIFFERENTIAL (REAR 220mm)

General Description
The rear axle assembly is of the semi–floating type in driving force at a 90 degree angle from the propeller shaft
which the vehicle weight is carried on the axle housing . to the drive shafts.
The center line of the pinion gear is below the center line The axle shafts are supported at the wheel end of the
of the ring gear (hypoid drive). shaft by a roller bearing.
All parts necessary to transmit power from the propeller The pinion gear is supported by two tapered roller
shaft to the rear wheels are enclosed in a banjo type axle bearings. The pinion depth is set by a shim pack located
housing. between the gear end of the pinion and the roller bearing
The 8.7 inch ring gear rear axle uses a conventional ring that is pressed onto the pinion. The pinion bearing
and pinion gear set to transmit the driving force of the preload is set by crushing a collapsible spacer between
engine to the rear wheels. This gear set transfers this the bearings in the axle housing.

A04RS001

The ring gear is bolted onto the differential cage with 12 are pressed onto the differential cage. Two bearing caps
bolts. are used to hold the differential into the rear axle housing.
The differential cage is supported in the axle housing by The differential is used to allow the wheels to turn at
two tapered roller bearings. The differential and ring gear different rates of speed while the rear axle continues to
are located in relationship to the pinion by using selective transmit the driving force. This prevents tire scuffing
shims and spacers between the bearing and the axle when going around corners and prevents premature wear
housing. To move the ring gear, shims are deleted from on internal axle parts.
one side and an equal amount are added to the other side. The rear axle is sealed with a pinion seal, a seal at each
These shims are also used to preload the bearings which axle shaft end, and by a liquid gasket between the
differential carrier and the axle housing.
DIFFERENTIAL (REAR 220mm) 4A2A–3

Diagnosis Gear Noise


Many noises that seem to come from the rear axle Gear noise (whine) is audible from 32 to 89 km/h (20 to 55
actually originate from other sources such as tires, road mph) under four driving conditions.
surface, wheel bearings, engine, transmission, muffler, or 1. Driving under acceleration or heavy pull.
body drumming. Investigate to find the source of the 2. Driving under load or under constant speed.
noise before disassembling the rear axle. Rear axles, like
any other mechanical device, are not absolutely quiet but 3. When using enough throttle to keep the vehicle from
should be considered quiet unless some abnormal noise driving the engine while the vehicle slows down
is present. gradually (engine still pulls slightly).
To make a systematic check for axle noise, observe the 4. When coasting with the vehicle in gear and the throttle
following: closed. The gear noise is usually more noticeable
1. Select a level asphalt road to reduce tire noise and between 48 and 64 km/h (30 and 40 mph) and 80 and
body drumming. 89 km/h (50 and 55 mph).
2. Check rear axle lubricant level to assure correct level, Bearing Noise
and then drive the vehicle far enough to thoroughly
warm up the rear axle lubricant. Bad bearings generally produce a rough growl or grating
sound, rather than the whine typical of gear noise.
3. Note the speed at which noise occurs. Stop the
Bearing noise frequently “wow–wows” at bearing rpm,
vehicle and put the transmission in neutral. Run the
indicating a bad pinion or rear axle side bearing. This
engine speed slowly up and down to determine if the
noise is caused by exhaust, muffler noise, or other noise can be confused with rear wheel bearing noise.
engine conditions.
Rear Wheel Bearing Noise
4. Tire noise changes with different road surfaces; axle
noises do not. Temporarily inflate all tires to 344 kPa Rear wheel bearing noise continues to be heard while
(3.5kg/cm2, 50 psi) (for test purposes only). This will coasting at low speed with transmission in neutral. Noise
change noise caused by tires but will not affect noise may diminish by gentle braking. Jack up the rear wheels,
caused by the rear axle. spin them by hand and listen for noise at the hubs.
Rear axle noise usually stops when coasting at Replace any faulty wheel bearings.
speeds under 48 km/h (30 mph); however, tire noise
continues with a lower tone. Rear axle noise usually Knock At Low Speeds
changes when comparing pull and coast, but tire Low speed knock can be caused by worn universal joints
noise stays about the same. or a side gear hub counter bore in the cage that is worn
Distinguish between tire noise and rear axle noise by oversize. Inspect and replace universal joints or cage and
noting if the noise changes with various speeds or side gears as required.
sudden acceleration and deceleration. Exhaust and
axle noise vary under these conditions, while tire Backlash Clunk
noise remains constant and is more pronounced at Excessive clunk on acceleration and deceleration can be
speeds of 32 to 48 km/h (20 to 30 mph). Further check caused by a worn rear axle pinion shaft, a worn cage,
for tire noise by driving the vehicle over smooth excessive clearance between the axle and the side gear
pavements or dirt roads (not gravel) with the tires at splines, excessive clearance between the side gear hub
normal pressure. If the noise is caused by tires, it will and the counterbore in the cage, worn pinion and side
change noticeably with changes in road surface. gear teeth, worn thrust washers, or excessive drive pinion
5. Loose or rough front wheel bearings will cause noise and ring gear backlash. Remove worn parts and replace
which may be confused with rear axle noise; however, as required. Select close–fitting parts when possible.
front wheel bearing noise does not change when Adjust pinion and ring gear backlash.
comparing drive and coast. Light application of the
brake while holding vehicle speed steady will often
cause wheel bearing noise to diminish. Front wheel
bearings may be checked for noise by jacking up the
wheels and spinning them or by shaking the wheels to
determine if bearings are loose.
6. Rear suspension rubber bushings and spring
insulators dampen out rear axle noise when correctly
installed. Check to see that there is no link or rod
loosened or metal–to–metal contact.
7. Make sure that there is no metal–to–metal contact
between the floor and the frame.
After the noise has been determined to be in the axle, the
type of axle noise should be determined, in order to make
any necessary repairs.
4A2A–4 DIFFERENTIAL (REAR 220mm)

Axle Housing
Axle Housing and Associated Parts

420RW022

Legend (9) Nut


(1) Coil Spring and Insulator (10) Differential Assembly
(2) Axle Housing Assembly (11) Axle Shaft Assembly
(3) ABS Speed Sensor and Harness(if equipped) (12) Brake Disc
(4) Nut (13) Brake Pipe
(5) Parking Brake Cable (14) Brake Caliper
(6) Bolt and Nut (15) Nut
(7) Antilock Brake System (ABS) Connector and (16) Breather Hose
Bracket (if equipped) (17) Flare Nut
(8) Bolt and Nut

Removal 4. Remove propeller shaft. Refer to Rear Propeller


Shaft in this section.
1. Raise the vehicle and support it with suitable safety 5. Drain the rear axle oil into a proper container.
stands.
6. Remove parking brake cable, release the connection
The hoist must remain under the rear axle housing.
between the cable fixing clip equalizer. Refer to
2. Drain brake fluid. Refer to Hydraulic Brakes in Brake Parking Brakes in Brake section.
section. 7. Move the clip aside and pull out the breather hose.
3. Remove rear wheels and tires. Refer to Wheel in
Suspension section.
DIFFERENTIAL (REAR 220mm) 4A2A–5
8. Disconnect the ABS connectors (1) and remove the 18. Remove brake disc.
brackets (2) attached to the frame and center link 19. Remove antilock brake system speed sensor fixing
(ABS model only). bolt and the clip and bracket on the axle housing
(ABS model only).
20. Remove the brake pipe clip and fixing bolt on the axle
housing and take out the brake pipe.
21. Remove the bearing holder fixing nut and take out the
axle shaft assembly, be sure not to damage the oil
seal by the spline of the shaft, Refer to Axle Shaft in
this section.
22. Remove differential assembly, refer to Differential
Assembly in this section.

Oil Seal Replacement


Remove the oil seal, carefully not to damage the housing,
and mount new oil seal using oil seal installer
5–8840–2294–0.

350RS001

9. Loosen the brake tube flare nut, remove the clip and
take out the brake tube.
10. Remove the shock absorber fixing nut from the axle
housing.
11. Remove the stabilizer linkage mounting nut from the
axle housing.
12. Remove the lateral rod fixing nut from the axle
housing.
13. Remove the center link mounting bolt and nut from
the axle housing.
14. Remove the trailing link fixing bolt and nut from the
axle housing.
15. Jack down and remove the coil spring and insulator.
16. Axle housing assembly can be separated from the 420RW028

vehicle on completion of steps 1 – 11.


17. Remove the brake caliper fixing bolt (3), loosen the Installation
flare nut (1), release the clip (2) and take out the brake
caliper together with the flexible hose. 1. Install differential assembly, refer to Differential
Assembly in this section.
2. Install axle shaft assembly then tighten the bearing
holder mounting nut to the specified torque. Be sure
not to damage the oil seal by the spline of the shaft.
Torque: 74Nꞏm (7.5kgꞏm/54lb ft)
3. Install brake pipe.
4. Connect antilock brake system (ABS) speed sensor
and harness, refer to 4–Wheel Anti–Lock Brake
System (ABS) in Brake section (ABS model only).
5. Install brake disc.
6. Install brake caliper. Refer to Disk Brakes in Brake
section.
7. Install axle housing assembly.
8. Install coil spring and insulator.
9. Install the trailing link fixing bolt and nut to the axle
housing. For the procedures in items 9–13, refer to
Suspension section.
306RS001
10. Install the center link bolt and nut to the axle housing.
4A2A–6 DIFFERENTIAL (REAR 220mm)
11. Install the lateral rod fixing nut to the axle housing. 15. Install ABS connector and bracket (ABS model only).
12. Install the stabilizer linkage mounting nut to the axle 16. Connect breather hose.
housing. 17. Install parking brake cable, Refer to Parking Brakes in
13. Install the shock absorber fixing nut to the axle Brake section.
housing. 18. Bleed brakes. Refer to Hydraulic Brakes in Brake
14. Install brake tube flare nut, Refer to Disk Brakes in section.
Brake section.

Axle Shaft
Axle Shaft and Associated Parts

420RY00005

Legend (7) Bearing Holder


(1) Brake Caliper (8) Bearing
(2) Brake Disc (9) Retainer
(3) Wheel Pin (10) Snap Ring
(4) Axle Shaft Assembly (11) Bolt
(5) Back Plate (12) Nut
(6) Parking Brake Assembly (13) Antilock Brake System (ABS) Speed Sensor

Removal 3. Remove brake caliper. Use a wire to attach the brake


caliper to the frame. Refer to Disk Brakes in Brake
1. Raise the vehicle. section.
2. Remove tires and wheels. Refer to Wheel in Steering 4. Remove brake disc.
section. 5. Remove ABS sensor.
6. Remove Parking brake assembly. Refer to Parking
Brakes in Brake section.
DIFFERENTIAL (REAR 220mm) 4A2A–7
7. Remove the parking brake cable mounting 15. Remove the wheel pins using a remover
bolts(Behind the back plate)(1). 5–8840–0029–0.

311RS001 420RY00011

8. Remove the bearing holder mounting nuts.


9. Remove axle shaft assembly. Inspection and Repair
NOTE: Be sure not to damage the oil seal. Make necessary correction or parts replacement if wear,
10. Remove snap ring. corrosion or any other abnormal conditions are found
through inspection.
11. Using a bearing remover 5–8840–2295–0 and press,
remove retainer together with the bearing holder. Visual Check:
Check the following parts for wear, damage, noise or any
other abnormal conditions:
1. Axle shaft
2. Bearing
When checking the axle shaft, pay special attention to the
splined portions and replace the shaft if distortion or step
wear is noticeable. Correct slight step wear with a grinder.

420RY00012

12. Remove bearing.


13. Remove bearing holder.
14. Remove back plate.

420RS008
4A2A–8 DIFFERENTIAL (REAR 220mm)

Axle Shaft Run–out Oil Seal Replacement


Limit: 1.0 mm (0.039 in) Remove the oil seal carefully not to damage the bearing
holder bore .
When installing, use oil seal installer 5–8840–2310–0.

420RS009

Axle Shaft Flange Run–out 420RY00009

Limit: 0.08 mm (0.003 in)


Installation
1. Install wheel pin.
2. Install back plate.
3. Install bearing holder.
4. Install bearing.
5. Install retainer by using a bearing installer
5–8840–2296–0, press fit together with the bearing.

420RS010

420RY00010
DIFFERENTIAL (REAR 220mm) 4A2A–9
6. Install snap ring. 10. Install parking brake assembly, refer to Parking
7. Install axle shaft assembly. Brakes in Brake section.
11. Install antilock brake system sensor.
NOTE: Be sure not to damage the oil seal.
12. Install brake disc.
8. Tighten the bearing holder mounting nut to the
specified torque. 13. Install brake caliper, refer to Disk Brakes in Brake
section.
Torque: 74Nꞏm (54 Ib ft)
9. Fix the parking brake cable mounting bolt (Behind the
back plate).

Pinion Oil Seal


Pinion Oil Seal and Associated Parts

425RW054

Legend (3) Oil Seal


(1) Flange Nut and Washer (4) Outer Bearing
(2) Flange (5) Collapsible Spacer

Removal
1. Remove the rear propeller shaft. Refer to Rear
Propeller Shaft in this section.
2. Drain the rear axle oil.
4A2A–10 DIFFERENTIAL (REAR 220mm)
3. Remove flange nut and washer by using pinion flange Inspection and Repair
holder 5–8840–2157–0 after raising up its staked
parts completely. Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal conditions are
found through inspection.
Check the following parts:
1. Seal surface of the pinion.
2. Cage bore for burns.

Installation
1. Install collapsible spacer, discard the used collapsible
spacer and install a new one.
2. Install outer bearing.
NOTE: Do not drive in, but just temporarily set in the outer
bearing by hand, which should be indirectly pressed in
finally by tightening the flange nut.
3. By using the seal installer 5–8840–2165–0, install a
new oil seal (1) that has grease on seal lip.

415RW028

4. Remove flange.
5. Remove oil seal.
6. Remove outer bearing by using remover
5–8840–2323–0.

425RW050

4. Install flange.
5. Install flange nut and washer. Refer to Differential
Assembly in this section for flange nut reassembly.
NOTE: Discard the used nut and install a new one.

425RW066

7. Remove collapsible spacer.


DIFFERENTIAL (REAR 220mm) 4A2A–11

Differential Assembly
Differential Assembly and Associated Parts

425RW055

Legend (3) Parking Brake Cable


(1) Bolt and Nut (4) Differential Assembly
(2) Axle Shaft Assembly (5) Nut

Removal 6. Remove the parking brake cable fastening clip and


disconnect the equalizer section. Refer to Parking
1. Jack up and support the frame with stands. Brakes in Brake section.
2. Remove the wheel and tire. Refer to Wheel in 7. Remove the bearing holder fixing nuts.
Steering section. 8. Remove axle shaft assembly, be sure not to damage
3. Drain the differential oil. the oil seal by axle shaft.
4. Remove the propeller shaft. Refer to Rear Propeller 9. Remove differential carrier mounting bolts and nuts.
Shaft in this section. 10. Remove differential assembly.
5. Remove the ABS speed sensor(ABS model only).
Refer to 4–Wheel Anti–lock Brake System (ABS) in
Brake section.
4A2A–12 DIFFERENTIAL (REAR 220mm)

Installation 2. Install bolt and nut. Tighten the differential carrier


mounting bolts and nuts to the specified torque.
1. Clean the contact surfaces of the axle and differential
Torque:Nuts 44Nꞏm (4.5kgꞏm/33lb ft)
carrier. As shown in the drawing, apply Three Bond
TB1215 or equivalent then install differential Bolts 64Nꞏm (6.5kgꞏm/47lb ft)
assembly. 3. Install axle shaft assembly. Be sure not to damage
the oil seal by axle shaft.
4. Install nut, refer to Axle Shaft in this section.
5. Install parking brake cable, refer to Parking Brakes in
Brake section.
NOTE: After completing the assembling work, fill the
prescribed gear oil to the filler hole.
Lubricant capacity: 1.8 liter (1.6 Imp qt/1.9US
qt)
6. Tighten the oil filler plug to the specified torque.
Torque: 78Nꞏm (8.0kgꞏm/58lb ft)

425RS006
DIFFERENTIAL (REAR 220mm) 4A2A–13

Disassembled View

415RW035

Legend (10) Inner Bearing Outer Race


(1) Bolt (11) Collapsible Spacer
(2) Bearing Cap (12) Differential Carrier
(3) Side Bearing (13) Outer Bearing Outer Race
(4) Adjust Shim (14) Outer Bearing
(5) Diff Cage Assembly (15) Oil Seal
(6) Side Bearing Outer Race (16) Dust Cover
(7) Pinion Gear (17) Flange
(8) Adjust Shim (18) Flange Nut
(9) Inner Bearing
4A2A–14 DIFFERENTIAL (REAR 220mm)

Disassembly 6. Remove side bearing, using remover


5–8840–0013/0014–0 and adapter 5–8840–2196–0.
1. Using holding fixture 5–8840–0275–0 and holding
fixture base 5–8840–0003–0, fix the differential
assembly to the bench.

415RW031

7. Remove adjust shim, note the thickness and position


of the shims removed.
425RW046
8. Remove the flange nut using holding wrench
2. Remove bearing cap bolt. 5–8840–2157–0 after raising up its staked parts
3. Apply a setting mark to the side bearing cap and the completely.
differential carrier then remove bearing cap.

425RW057

425RS009 9. Remove flange.


4. Remove differential cage assembly. 10. Remove dust cover.
5. Remove side bearing outer race, after removal, keep
the right and left hand side bearing assemblies
separate to maintain inner and outer race
combinations.
DIFFERENTIAL (REAR 220mm) 4A2A–15
11. Remove the drive pinion assembly using a soft metal 18. Remove the inner bearing outer race (1) and the outer
rod and a hammer. bearing outer race (2) by using a brass bar and a
hammer.

425RW056

12. Remove collapsible spacer. 425RS014

13. Remove the inner bearing using a separator


5–8840–2197–0 and a press.

425RS015

415RW039

14. Remove adjust shim.


15. Remove inner bearing outer race.
16. Remove oil seal.
17. Remove outer bearing.
4A2A–16 DIFFERENTIAL (REAR 220mm)

Reassembly 2. Tighten the nut to the specified torque.

1. Using installer 5–8840–2164–0 and grip Torque: 2.3 Nꞏm (0.23kgꞏm/20 lb in)
5–8840–0007–0, install outer bearing outer race.

415RW037

415RW025 Legend
2. Using installer 5–8840–2163–0 and grip (1) Front Pilot: 5–8840–2085–0
5–8840–0007–0, install Inner bearing outer race. (2) Rear Pilot: 5–8840–0129–0
(3) Gauge Plate: 5–8840–2166–0
(4) Bolt and Nut: 5–8840–0127–0

3. Clean the side bearing bores. Install the dial


indicator with the discs and arbor. Install and
tighten the bearing caps to the specified torque.
Torque: 108 Nꞏm (11.0kgꞏm/80 lb ft)

415RW026

3. Install adjust shim and adjust drive pinion mounting


distance
1. Apply gear oil to the inner and outer drive pinion
bearing.
Clean the pinion setting gauge set.
Then install the gauge set together with the inner
and outer bearings.
415RW038

Legend
(1) Dial Indicator: 5–8840–0126–0
(2) Disc (2 pcs.): 5–8840–2167–0
(3) Arbor: 5–8840–0128–0
(4) Gauge Plate: 5–8840–2166–0
DIFFERENTIAL (REAR 220mm) 4A2A–17
4. Set the dial indicator to “0”. Place it on the 6. After the ZERO setting is obtained, rotate the
mounting post of the gauging arbor with the gauging arbor until the dial indicator rod does not
contact button touching the indicator pad. Force touch the gauging plate.
the dial indicator downward until the needle has Record the number the dial indicator needle
made a half turn clockwise. Tighten down the dial points to.
indicator in this position.

425RS022

425RS020
Legend
Legend (1) Example=Dial indicator reading of 0.085
(1) Dial Indicator
(2) Ganging Arbor 7. Record the pinion depth code on the head of the
(3) Plunger drive pinion.
(4) Gauge Plate The number indicates a necessary change in the
pinion mounting distance. A plus number indi-
5. Position the plunger on the gauge plate. Move the cates the need for a greater mounting distance
gauging arbor slowly back and forth and locate (which can be achieved by decreasing the shim
the position at which the dial indicator shows the thickness). A minus number indicates the need
greatest defection. At this point, once again set for a smaller mounting distance (which can be
the dial indicator to “0”. achieved by increasing the shim thickness). If ex-
Repeat the procedure to verify the “0” setting. amination reveals pinion depth code “0”, the pin-
ion is “nominal”.

425RS021
425RS023
4A2A–18 DIFFERENTIAL (REAR 220mm)
8. Select the shim using the chart;
Pinion
marking
Dial +10 +8 +6 +4 +2 0 –2 –4 –6 –8 –10
indicator
reading
(Inches)
1.94 1.96
0.073
(0.0764) (0.0772)
1.94 1.96 1.98
0.074
(0.0764) (0.0772) (0.0779)
1.94 1.96 1.98 2.00
0.075
(0.0764) (0.0772) (0.0779) (0.0787)
1.94 1.96 1.98 2.00 2.02 2.04
0.076
(0.0764) (0.0772) (0.0779) (0.0787) (0.0795) (0.0803)
1.96 1.98 2.00 2.02 2.04 2.06
0.077
(0.0772) (0.0779) (0.0787) (0.0795) (0.0803) (0.0811)
1.94 1.96 1.98 2.00 2.02 2.04 2.06 2.08
0.078
(0.0764) (0.0772) (0.0779) (0.0787) (0.0795) (0.0803) (0.0811) (0.0819)
1.94 1.96 1.98 2.00 2.02 2.04 2.06 2.08 2.10
0.079
(0.0764) (0.0772) (0.0779) (0.0787) (0.0795) (0.0803) (0.0811) (0.0819) (0.0827)
1.94 1.96 1.98 2.00 2.02 2.04 2.06 2.08 2.10 2.12 2.14
0.080
(0.0764) (0.0772) (0.0779) (0.0787) (0.0795) (0.0803) (0.0811) (0.0819) (0.0827) (0.0835) (0.0842)
1.96 1.98 2.00 2.02 2.04 2.06 2.08 2.10 2.12 2.14 2.16
0.081
(0.0772) (0.0779) (0.0787) (0.0795) (0.0803) (0.0811) (0.0819) (0.0827) (0.0835) (0.0842) (0.0850)
1.98 2.00 2.02 2.04 2.06 2.08 2.10 2.12 2.14 2.16 2.18
0.082
(0.0779) (0.0787) (0.0795) (0.0803) (0.0811) (0.0819) (0.0827) (0.0835) (0.0842) (0.0850) (0.0858)
2.00 2.02 2.04 2.06 2.08 2.10 2.12 2.14 2.16 2.18 2.20
0.083
(0.0787) (0.0795) (0.0803) (0.0811) (0.0819) (0.0827) (0.0835) (0.0842) (0.0850) (0.0858) (0.0866)
2.04 2.06 2.08 2.10 2.12 2.14 2.16 2.18 2.20 2.22 2.24
0.084
(0.0803) (0.0811) (0.0819) (0.0827) (0.0835) (0.0842) (0.0850) (0.0858) (0.0866) (0.0874) (0.0882)
2.06 2.08 2.10 2.12 2.14 2.16 2.18 2.20 2.22 2.24 2.26
0.085
(0.0811) (0.0819) (0.0827) (0.0835) (0.0842) (0.0850) (0.0858) (0.0866) (0.0874) (0.0882) (0.0890)
2.08 2.10 2.12 2.14 2.16 2.18 2.20 2.22 2.24 2.26 2.28
0.086
(0.0819) (0.0827) (0.0835) (0.0842) (0.0850) (0.0858) (0.0866) (0.0874) (0.0882) (0.0890) (0.0898)
2.12 2.14 2.16 2.18 2.20 2.22 2.24 2.26 2.28 2.30 2.32
0.087
(0.0835) (0.0842) (0.0850) (0.0858) (0.0866) (0.0874) (0.0882) (0.0890) (0.0898) (0.0906) (0.0913)
2.14 2.16 2.18 2.20 2.22 2.24 2.26 2.28 2.30 2.32 2.34
0.088
(0.0842) (0.0850) (0.0858) (0.0866) (0.0874) (0.0882) (0.0890) (0.0898) (0.0906) (0.0913) (0.0921)
2.16 2.18 2.20 2.22 2.24 2.26 2.28 2.30 2.32 2.34 2.36
0.089
(0.0850) (0.0858) (0.0866) (0.0874) (0.0882) (0.0890) (0.0898) (0.0906) (0.0913) (0.0921) (0.0929)
2.18 2.20 2.22 2.24 2.26 2.28 2.30 2.32 2.34 2.36
0.090
(0.0858) (0.0866) (0.0874) (0.0882) (0.0890) (0.0898) (0.0906) (0.0913) (0.0921) (0.0929)
2.22 2.24 2.26 2.28 2.30 2.32 2.34 2.36
0.091
(0.0874) (0.0882) (0.0890) (0.0898) (0.0906) (0.0913) (0.0921) (0.0929)
2.24 2.26 2.28 2.30 2.32 2.34 2.36
0.092
(0.0882) (0.0890) (0.0898) (0.0906) (0.0913) (0.0921) (0.0929)
2.26 2.28 2.30 2.32 2.34 2.36
0.093
(0.0890) (0.0898) (0.0906) (0.0913) (0.0921) (0.0929)
2.28 2.30 2.32 2.34 2.36
0.094
(0.0898) (0.0906) (0.0913) (0.0921) (0.0929)
2.32 2.34 2.36
0.095
(0.0913) (0.0921) (0.0929)
2.34 2.36
0.096
(0.0921) (0.0929)
2.36
0.097
(0.0929)

NOTE: When ordering shims, find the part number in the


parts catalog by using the thickness of shims listed in the
above table.
DIFFERENTIAL (REAR 220mm) 4A2A–19
4. Place the shim on the drive pinion, with the chamfered 2. Tighten the nut to the specified torque using the
side turned towards the pinion head then install the pinion flange holder 5–8840–2157–0.
inner bearing onto the pinion using an installer
Torque: 245–294Nꞏm (25.0–28.0kgꞏm/181–217 lb f
9–8522–1165–0 and a press.
t)
NOTE: Do not apply pressure to the roller cage and apply
pressure only to the inner race. NOTE: Discard used flange nut and install new one and
do not over tighten the flange nut.

425RW048

5. Discard the used collapsible spacer and install a new 425RW057

one. 3. Adjust pinion bearing preload.


6. Install pinion gear. a. Measure the bearing preload by using a torque
7. Install outer bearing. meter. Note the scale reading required to
rotate the flange.
8. Use oil seal installer 5–8840–2165–0 to install a new
oil seal that has been soaked in rear axle lubricant. b. Continue tightening flange nut until the
specified starting torque is obtained.
NOTE: Take care to use a front differential oil seal, NOT
Starting torque:
the rear differential oil seal.
New bear-
ing 0.7–1.3 Nꞏm(0.07-0.13kgꞏm/6.08–11.28 lb in)
Used bear-
ing 0.4–0.6Nꞏm(0.04–0.06kgꞏm/3.04-5.64 Ib in)

415RW029

9. Install dust cover.


10. Install flange.
11. Install flange nut. 425RS027

1. Apply lubricant to the pinion threads. 4. Using punch 5–8840–2293–0, stake the flange
nut at two points.
4A2A–20 DIFFERENTIAL (REAR 220mm)
NOTE: When staking, be sure to turn the nut to insure 2. Insert the differential cage assembly with bearing
that there is no change in bearing preload. Make sure of outer races into the side bearing bores of the
preload again as instructed in 3). carrier.

415RW019 425RS030

Legend 3. Using two sets of feeler gauges, insert a feeler


(1) 1.5mm or less stock of sufficient thickness between each
bearing outer race and the carrier to remove all
12. Install adjust shim. end play. Make certain the feeler stock is pushed
to the bottom of the bearing bores.
1. Attach the side bearing to the differential
assembly without shims. Support the opposite Mount the dial indicator 5–8840–0126–0 on the
side using a pilot to prevent bearing damage. carrier so that the indicator stem is at right angles
to a tooth on the ring gear.

425RS029
425RW049

Legend
(1) Drive handle: 5–8840–0007–0
(2) Installer: 5–8840–2162–0
(3) Pilot: 5–8840–2196–0
DIFFERENTIAL (REAR 220mm) 4A2A–21
4. Adjust feeler gauge thickness from side to side 13. Install the side bearings together with the selected
until ring gear backlash is in the specified range. shims.
Backlash: 0.15–0.2 mm(0.006 –0.008 in)

425RS029

425RS032
Legend
With zero end play and correct backlash estab- (1) Drive Handle: 5–8840–0007–0
lished, remove the feeler gauge packs, determine (2) Installer: 5–8840–2162–0
the thickness of the shims required and add 0.05 (3) Pilot: 5–8840–2196–0
mm (0.002 in) to each shim pack to provide side
bearing preload. Always use new shims. 14. Install side bearing outer race.
5. Use bearing remover 5–8840–0013/0014–0 and 15. Install differential cage assembly.
pilot 5–8840–2196–0 to remove side bearing.
16. Install bearing cap then align the setting marks(1)
applied at disassembly.

415RW032

425RS035
4A2A–22 DIFFERENTIAL (REAR 220mm)
17. Tighten the cap bolt to the specified torque. Gear Tooth Contact Pattern Check and Adjustment
Torque: 108 Nꞏm (11.0kgꞏm/80 lb ft) 1. Apply a thin coat of prussian blue or equivalent
to the faces of the 7–8 teeth of the ring gear.
Check the impression of contact on the ring
gear teeth and make necessary adjustment as
described in illustration if the contact is
abnormal.

425RS036

1. Measure the amount of run–out of the ring gear at


its rear face.
Standard: 0.02 mm ( 0.001 in)
Limit: 0.05 mm ( 0.002 in) 425RS038

Legend
(1) Heel
(2) Toe
(3) Concave Side(Coast)
(4) Convex Side(Drive)

425RS037
DIFFERENTIAL (REAR 220mm) 4A2A–23

425RS039
4A2A–24 DIFFERENTIAL (REAR 220mm)

Differential Cage Assembly


Disassembled View

415RW034

Legend (5) Ring Gear


(1) Pinion Gear (6) Bolt
(2) Thrust Washer (7) Differential Cage
(3) Side Gear (8) Lock Pin
(4) Cross Pin

Disassembly
1. Remove bolt.
2. Remove ring gear.
3. Remove lock pin, break staking on the lock pin, using
a 5 mm (0.20 in) diameter drill.

425RS042
DIFFERENTIAL (REAR 220mm) 4A2A–25
4. Remove the cross pin, using a soft metal rod and a 5. Tighten the fixing bolts in a diagonal sequence as
hammer. illustrated.

425RS043 415RW036

5. Remove pinion gear.


6. Remove side gear.
Clearance between the differential pinion
and the cross pin measurement:
7. Remove thrust washer.
Standard: 0.06 – 0.12 mm (0.002–0.005 in)
Inspection and Repair Limit: 0.2 mm (0.008 in)
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal conditions are
found through inspection.
Check the following parts:
1. Ring gear, pinion gear
2. Bearing
3. Side gear, pinion gear, cross pin
4. Differential cage, carrier
5. Thrust washer
6. Oil seal
Ring gear replacement:
1. The ring gear should always be replaced with the
drive pinion as a set.
2. Clean the ring gear threaded holes to remove the
locking agent.
3. When installing the ring gear, apply LOCTITE 271 or
equivalent to all the threaded area and half of the
unthreaded area of the bolt. 425RS045

4. Discard used bolts and install new ones.


Torque: 108 Nꞏm (11.0kgꞏm/80 lb ft)
4A2A–26 DIFFERENTIAL (REAR 220mm)

Clearance between the side gear and the Reassembly


differential box:
1. Install thrust washer.
Standard: 0.05–0.12 mm (0.002–0.005 in) 2. Install side gear.
Limit: 0.15 mm(0.006 in) 3. Install the pinion gear by engaging it with the side
gears while turning both pinion gears simultaneously
in the same direction.

425RS046

Legend
425RS048
(1) Side Gear 4. Install cross pin.
(2) Differential Box
1. Be sure to install the cross pin so that it is in
alignment with the lock pin hole in the differential
Play in splines between the side gear and cage.
the axle shaft:
Standard: 0.07–0.38 mm(0.003 –0.014 in)
Limit:0.5m (0.02 in)

425RS049

2. Adjust the backlash between the side gear and


the pinion gear.
Backlash:0.13 – 0.18 mm (0.005– 0.007 in)
425RS047
DIFFERENTIAL (REAR 220mm) 4A2A–27
Thickness of thrust washers available: 7. Tighten the bolts in diagonal sequence as illustrated.
0.80 mm, 0.90 mm, 1.00 mm 1.10 mm, 1.20 mm, Torque: 108 Nꞏm (11.0kgꞏm/80 lb ft)
1.30 mm (0.031 in, 0.035 in, 0.039 in,0.043 in,
0.047 in, 0.051 in) NOTE: Discard used bolts and install new ones.

415RW036
425RS050

5. Install lock pin. After lock pin installation, stake the


cage to secure the lock pin.

425RS051

Legend
(1) Staked Portion
(2) Lock Pin

6. Clean the ring gear threaded holes to remove the


locking agent. When installing the ring gear, apply
LOCTITE 271 or equivalent to all the threaded area
and half of the unthreaded area of the bolt.
4A2A–28 DIFFERENTIAL (REAR 220mm)

Limited Slip Differential


Disassembled View

425RY001

Legend (14) Pinion and Pinion shaft


(1) Screw (15) Side gear
(2) Differential cage A (16) Pressure ring
(3) Thrust washer (17) Friction Plate
(4) Spring disc (18) Friction disc
(5) Friction Plate (19) Friction Plate
(6) Friction plate (20) Friction disc
(7) Friction Plate (21) Friction Plate
(8) Friction disc (22) Friction Plate
(9) Friction Plate (23) Friction Plate
(10) Friction disc (24) Spring disc
(11) Friction Plate (25) Thrust washer
(12) Pressure ring (26) Differential cage B
(13) Side gear
DIFFERENTIAL (REAR 220mm) 4A2A–29

Disassembly 9. Remove Friction plate.


Differential Cages A and B 10. Remove Friction disc.
1. To ensure installation of the parts in original position 11. Remove Friction plate.
apply a setting mark before removing the differential 12. Remove Friction disc.
cages A and B. 13. Remove Friction plate.
2. Using special tool, 5–8840–2682–0, grip it with a vice, 14. Remove Pressure ring.
and set the differential. 15. Remove Side gear.
16. Remove Pinion and pinion shaft.
17. Remove Side gear.
18. Remove Pressure ring.
19. Remove Friction plate.
20. Remove Friction disc.
21. Remove Friction plate.
22. Remove Friction disc.
23. Remove Friction plate.
24. Remove Friction plate.
25. Remove Friction plate.
26. Remove Friction disc.
27. Remove Thrust washer.
28. Remove Differential cage B.

Inspection and Repair


425RS054 Make necessary correction or parts replacement if wear,
3. Gradually and evenly loosen the 3 fixing screws of the damage, corrosion or any other abnormal condition is
differential cages A and B. found through inspection.
Visual check
Check the following parts for wear, damage, noise or any
other abnormal conditions.
Friction disc, friction plate and spring disc

425RS055

4. Remove Differential cage A.


5. Remove Thrust washer.
6. Remove Spring disc.
NOTE: When removing the spring disc, friction disc, and 425RS056

friction plate, place them in order for clear distinction of Legend


left and right use. (1) Sliding surfaces
7. Remove Spring disc. (2) Projections
8. Remove Friction plate.
4A2A–30 DIFFERENTIAL (REAR 220mm)
Pressure ring Case

425RY003 425RS059

Legend Legend
(3) Sliding surface with the friction disc. When (11) Contact surface with the spring disc.
nicks or scratches are found, polish with an oil (12) Inner groove of the differential cage B.
stone and repair on a level block using a Repair light nicks and burrs using an oil stone.
compound.
(4) Sliding spherical surface with the pinion gear.
(5) Sliding surface with the side gear.
(6) V–shaped groove of the pressure ring and V
–shaped section of the pinion shaft.
(7) Fitting section with the case.
(8) Face contacting the inner surface of the
differential case. Repair burrs and nicks using
an oil stone.

Thrust washer

425RS060

Legend
(7) Fitting section with the case.
(8) Face contacting the inner surface of the
differential case.
Repair burrs and nicks using an oil stone.
(9) Sliding surface with the side gear or case.
(11) Contact surface with spring disc.

425RS058

Legend
(9) Sliding surface with the side gear or case.
(10) Peripheral groove of the side gear.
Repair light nicks and burrs using an oil stone.
DIFFERENTIAL (REAR 220mm) 4A2A–31
Measure the Deformation of the friction disc & plate. Measure the wear of the thrust washer
Limit: 0.1 mm (0.004 in) Limit: 1.3 mm (0.05 in)

425RS061 425RS063

Measure the wear of the friction plate & disc


Limit(A–B): 0.1 mm (0.004 in) Reassembly
Remarks:
A=Inner or outer projections Adjust the clearance between the friction disc and plate.
B=Sliding surface subjected to abrasion 1. Measuring the depth of the differential cage.
Standard (A–B): 89.13 mm (3.51 in)
(C): 9.13 mm (0.36 in)

425RS062

425RS064
4A2A–32 DIFFERENTIAL (REAR 220mm)
2. Measuring the overall length of the pressurering,
friction disc and friction plate.
Mount the pinion shaft in the pressurering and then
install the friction disc & plate.
Measure the length between the plates over the
V–groove. (D)

425RS066

2. Measuring the dimension between the thrust washers


at both ends.
Assemble the side gear, pinion, pinion shaft,
pressure ring and thrust washer, and pressing the
pressure ring to–the pinion shaft in the direction of
the shaft to make the clearance 0.
Have the side gear contact to the pinion to make the
425RS065

3. After measuring dimensions A,B,C and D, make


backlash 0.
adjustment in the following manner:
Measure the thickness (E) of the spring disc. Measure the dimension (H) between thrust
1.75mm (0.069in) 2 discs washers at both ends.
4. Select the friction disc & plate so as to satisfy the
following equation:
{(A-B)+C}-(D+E)=0.06-0.20mm (0.002-0.008in)
Also, the total size difference of the friction disc &
plate and spring disc should be 0.05mm (0.02in) or
less.
Thickness
:1.65–1.75–1.85mm(0.065–0.069–0.073 in)

Backlash adjustment of the side gear in


the direction of the shaft
1. Measuring the depth of the differential cage.
(F–B): 95.63 mm (3.76 in)
(G): 15.63 mm (0.62 in)

425RS067
DIFFERENTIAL (REAR 220mm) 4A2A–33
3. After measuring dimensions of each of the above 6. Install Friction plate.
sections, proceed with the adjustment in the following 7. Install Friction disc.
manner:
8. Install Friction plate.
Adjust the clearance to satisfy the equation below.
9. Install Friction disc.
{(F – B) + G – H}=0.05 – 0.20 mm
10. Install Friction plate.
Also, select the thrust washers so that the
dimensional difference between the back surfaces of 11. Install Pressure ring.
the left and right pressure rings to the thrust washers 12. Install Side gear.
is 0.05mm or less. 13. Install Pinion and pinion shaft.
14. Install Side gear.
Thickness : 1.5mm (0.059 in)
15. Install Pressure ring.
1.6 mm(0.063 in)
16. Install Friction plate.
1.7 mm(0.067 in) 17. Install Friction disc.
18. Install Friction plate.
NOTE: When assembling the parts, apply recommended 19. Install Friction disc.
gear oil sufficiently to each of the parts, especially, to the 20. Install Friction plate.
contact surfaces and sliding surfaces.
21. Install Friction plate.
1. Install Differential cage B.
22. Install Friction plate.
2. Install Thrust washer.
23. Install Spring disc.
3. Install Spring disc.
When assembling the spring disc, make sure the
When assembling the spring disc, make sure the mounting direction is correct.
mounting direction is correct as shown in figure.
24. Install Spring disc.
25. Install Thrust washer.
26. Install Differential cage A.
27. Install Screw.
Matching the guide marks of the differential cages A
and B, tighten the screws evenly in the diagonal
order.

425RY004

Legend
(1) Friction Plate
(2) Spring Disc
(3) Friction Disc

4. Install Friction disc.


425RS055
5. Install Friction plate.
4A2A–34 DIFFERENTIAL (REAR 220mm)
28. Check the operation.
Measure the starting torque using the side gear
holder.
Starting torque:
29 – 45 Nꞏm (3.0 – 4.6 kgꞏm/ 22 – 33Ib ft)

425RW065

Legend
(1) Side Gear Holder : 5–8840–2381–0
DIFFERENTIAL (REAR 220mm) 4A2A–35

Main Data and Specifications


General Specifications
Rear axle
Type Banjo, Semi–floating
Rear axle Size 220mm(8.66in)
Gear type Hypoid
Gear ratio (to 1) 4.555(6VD1,4JG2–TC)
4.777(4JG2)
Differential type Pinion (STD), Four pinion (LSD)
Lubricant Grade GL–5: (Standard differential)
GL–5, LSD: (Limited slip differential)
Locking Differential Lubricant 80W90 GL–5 Limited Slip Differential Gear Lubricant
together with Limited Slip Differential Lubricant Additive
(Part No. 8–01052–358–0) or equivalent.
Capacity 1.8liter(1.6 Imp qt/1.9 US qt)
4A2A–36 DIFFERENTIAL (REAR 220mm)

Torque Specifications

420RY00008
DIFFERENTIAL (REAR 220mm) 4A2A–37

Special Tools
TOOL NO. TOOL NO.
ILLUSTRATION ILLUSTRATION
TOOL NAME TOOL NAME

5–8840–2157–0 5–8840–2197–0
(J–37221) (J–22912–01)
Holder; Pinion flange Separator

5–8840–2294–0 5–8840–2164–0
(J–24250) (J–24256)
Installer; Oil seal Installer; Outer bearing
outer race

5–8840–0275–0
(J–37264)
Differential holding 5–8840–0007–0
fixture (J–8092)
(Use with Driver handle
5–8840–0003–0)

5–8840–0003–0 5–8840–2163–0
(J–3289–20) (J–24252)
Holding fixture base Installer; Inner bearing
outer race

5–8840–0013–0
5–8840–0014–0 5–8840–2085–0
(J–22888) (J–21777–42)
Puller; Side bearing Front Pilot

5–8840–2196–0
(J–8107–2) 5–8840–0127–0
Adapter; Side bearing (J–23597–9)
plug Nut and bolt
4A2A–38 DIFFERENTIAL (REAR 220mm)

TOOL NO. TOOL NO.


ILLUSTRATION ILLUSTRATION
TOOL NAME TOOL NAME

5–8840–2166–0 5–8840–2162–0
(J–23597–7) (J–24244)
Gauge plate Installer; Side bearing

5–8840–0126–0 5–8840–2323–0
(J–8001) (J–39602)
Dial indicator Remover; Outer bearing

5–8840–2167–0 5–8840–2165–0
(J–23597–8) (J–37263)
Disc Installer; Pinion oil seal

5–8840–0128–0 5–8840–2682–0
(J–23597–1) (J–44450)
Arbor Holder; Side gear

9–8522–1165–0 5–8840–0129–0
(J–6133–01) (J–23597–12)
Installer; Pinion bearing Rear pilot

5–8840–2293–0
(J–39209)
Punch; End nut lock
DIFFERENTIAL (REAR 244mm) 4A2B–1

DRIVELINE/AXLE
DIFFERENTIAL (REAR 244mm)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 4A2B–1 Differential Assembly . . . . . . . . . . . . . . . . . . . . 4A2B–12
General Description . . . . . . . . . . . . . . . . . . . . . 4A2B–3 Differential Assembly and Associated Parts 4A2B–12
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2B–4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2B–12
Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2B–5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2B–13
Axle Housing and Associated Parts . . . . . . 4A2B–5 Disassembled View . . . . . . . . . . . . . . . . . . . . 4A2B–14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2B–5 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2B–15
Oil Seal Replacement . . . . . . . . . . . . . . . . . . 4A2B–6 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2B–17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2B–6 Differential Cage Assembly . . . . . . . . . . . . . . . 4A2B–24
Axle Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2B–7 Disassembled View . . . . . . . . . . . . . . . . . . . . 4A2B–24
Axle Shaft and Associated Parts . . . . . . . . . 4A2B–7 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2B–25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2B–7 Inspection and Repair . . . . . . . . . . . . . . . . . . 4A2B–25
Inspection and Repair . . . . . . . . . . . . . . . . . . 4A2B–8 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2B–26
Oil Seal Replacement . . . . . . . . . . . . . . . . . . 4A2B–9 Limited Slip Differential . . . . . . . . . . . . . . . . . . . 4A2B–28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2B–9 Disassembled View . . . . . . . . . . . . . . . . . . . . 4A2B–28
Pinion Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2B–10 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2B–29
Pinion Oil Seal and Associated Parts . . . . . 4A2B–10 Inspection and Repair . . . . . . . . . . . . . . . . . . 4A2B–29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2B–10 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2B–31
Inspection and Repair . . . . . . . . . . . . . . . . . . 4A2B–11 Main Data and Specifications . . . . . . . . . . . . . 4A2B–35
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2B–11 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2B–37

Service Precaution CAUTION: Always use the correct fastener in the


proper location. When you replace a fastener, use
WARNING: IF SO EQUIPPED WITH A ONLY the exact part number for that application.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS), ISUZU will call out those fasteners that require a
REFER TO THE SRS COMPONENT AND WIRING replacement after removal. ISUZU will also call out
LOCATION VIEW IN ORDER TO DETERMINE the fasteners that require thread lockers or thread
WHETHER YOU ARE PERFORMING SERVICE ON OR sealant. UNLESS OTHERWISE SPECIFIED , do not
NEAR THE SRS COMPONENTS OR THE SRS use supplemental coatings (Paints, greases, or other
WIRING. WHEN YOU ARE REFORMING SERVICE ON corrosion inhibitors) on threaded fasteners or
OR NEAR THE SRS COMPONENTS OR THE SRS fastener joint interfaces. Generally,such coatings
WIRING, REFER TO THE SRS SERVICE adversely affect the fastener torque and the joint
INFORMATION. FAILURE TO FOLLOW WARNINGS clamping force, and may damage the fastener. When
COULD RESULT IN POSSIBLE AIR BAG you install fasteners, use the correct tightening
DEPLOYMENT, PERSONAL INJURY, OR sequence and specification. Following these
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. instructions can help you avoid damage to parts and
systems.
The 244 differential has two N types A-type and B-
type.
A-type: the sticker with bar code is attached.
B-type: the sticker with no bar code on the lower part
of carrier is attached.
4A2B–2 DIFFERENTIAL (REAR 244mm)

In case of Work Shop Manual;


A-type: Refer to ’98 UBS Work Shop Manual.
B-type: Described in ’00UBS Work Shop Manual.

425RY00018
DIFFERENTIAL (REAR 244mm) 4A2B–3

General Description
The rear axle assembly is of the semi–floating type in driving force at a 90 degree angle from the propeller shaft
which the vehicle weight is carried on the axle housing . to the drive shafts.
The center line of the pinion gear is below the center line The axle shafts are supported at the wheel end of the
of the ring gear (hypoid drive). shaft by a roller bearing.
All parts necessary to transmit power from the propeller The pinion gear is supported by two tapered roller
shaft to the rear wheels are enclosed in a banjo type axle bearings. The pinion depth is set by a shim pack located
housing. between the gear end of the pinion and the roller bearing
The 9.61 inch ring gear rear axle uses a conventional ring that is pressed onto the pinion. The pinion bearing
and pinion gear set to transmit the driving force of the preload is set by crushing a collapsible spacer between
engine to the rear wheels. This gear set transfers this the bearings in the axle housing.

420RY00006

The ring gear is bolted onto the differential cage with 12 are pressed onto the differential cage. Two bearing caps
bolts. are used to hold the differential into the rear axle housing.
The differential cage is supported in the axle housing by The differential is used to allow the wheels to turn at
two tapered roller bearings. The differential and ring gear different rates of speed while the rear axle continues to
are located in relationship to the pinion by using selective transmit the driving force. This prevents tire scuffing
shims and spacers between the bearing and the axle when going around corners and prevents premature wear
housing. To move the ring gear, shims are deleted from on internal axle parts.
one side and an equal amount are added to the other side. The rear axle is sealed with a pinion seal, a seal at each
These shims are also used to preload the bearings which axle shaft end, and by a liquid gasket between the
differential carrier and the axle housing.
4A2B–4 DIFFERENTIAL (REAR 244mm)

Diagnosis Gear Noise


Many noises that seem to come from the rear axle Gear noise (whine) is audible from 32 to 89 km/h (20 to 55
actually originate from other sources such as tires, road mph) under four driving conditions.
surface, wheel bearings, engine, transmission, muffler, or 1. Driving under acceleration or heavy pull.
body drumming. Investigate to find the source of the 2. Driving under load or under constant speed.
noise before disassembling the rear axle. Rear axles, like
any other mechanical device, are not absolutely quiet but 3. When using enough throttle to keep the vehicle from
should be considered quiet unless some abnormal noise driving the engine while the vehicle slows down
is present. gradually (engine still pulls slightly).
To make a systematic check for axle noise, observe the 4. When coasting with the vehicle in gear and the throttle
following: closed. The gear noise is usually more noticeable
1. Select a level asphalt road to reduce tire noise and between 48 and 64 km/h (30 and 40 mph) and 80 and
body drumming. 89 km/h (50 and 55 mph).
2. Check rear axle lubricant level to assure correct level, Bearing Noise
and then drive the vehicle far enough to thoroughly
warm up the rear axle lubricant. Bad bearings generally produce a rough growl or grating
sound, rather than the whine typical of gear noise.
3. Note the speed at which noise occurs. Stop the
Bearing noise frequently “wow–wows” at bearing rpm,
vehicle and put the transmission in neutral. Run the
indicating a bad pinion or rear axle side bearing. This
engine speed slowly up and down to determine if the
noise is caused by exhaust, muffler noise, or other noise can be confused with rear wheel bearing noise.
engine conditions.
Rear Wheel Bearing Noise
4. Tire noise changes with different road surfaces; axle
noises do not. Temporarily inflate all tires to 344 kPa Rear wheel bearing noise continues to be heard while
(3.5kg/cm2, 50 psi) (for test purposes only). This will coasting at low speed with transmission in neutral. Noise
change noise caused by tires but will not affect noise may diminish by gentle braking. Jack up the rear wheels,
caused by the rear axle. spin them by hand and listen for noise at the hubs.
Rear axle noise usually stops when coasting at Replace any faulty wheel bearings.
speeds under 48 km/h (30 mph); however, tire noise
continues with a lower tone. Rear axle noise usually Knock At Low Speeds
changes when comparing pull and coast, but tire Low speed knock can be caused by worn universal joints
noise stays about the same. or a side gear hub counter bore in the cage that is worn
Distinguish between tire noise and rear axle noise by oversize. Inspect and replace universal joints or cage and
noting if the noise changes with various speeds or side gears as required.
sudden acceleration and deceleration. Exhaust and
axle noise vary under these conditions, while tire Backlash Clunk
noise remains constant and is more pronounced at Excessive clunk on acceleration and deceleration can be
speeds of 32 to 48 km/h (20 to 30 mph). Further check caused by a worn rear axle pinion shaft, a worn cage,
for tire noise by driving the vehicle over smooth excessive clearance between the axle and the side gear
pavements or dirt roads (not gravel) with the tires at splines, excessive clearance between the side gear hub
normal pressure. If the noise is caused by tires, it will and the counterbore in the cage, worn pinion and side
change noticeably with changes in road surface. gear teeth, worn thrust washers, or excessive drive pinion
5. Loose or rough front wheel bearings will cause noise and ring gear backlash. Remove worn parts and replace
which may be confused with rear axle noise; however, as required. Select close–fitting parts when possible.
front wheel bearing noise does not change when Adjust pinion and ring gear backlash.
comparing drive and coast. Light application of the
brake while holding vehicle speed steady will often
cause wheel bearing noise to diminish. Front wheel
bearings may be checked for noise by jacking up the
wheels and spinning them or by shaking the wheels to
determine if bearings are loose.
6. Rear suspension rubber bushings and spring
insulators dampen out rear axle noise when correctly
installed. Check to see that there is no link or rod
loosened or metal–to–metal contact.
7. Make sure that there is no metal–to–metal contact
between the floor and the frame.
After the noise has been determined to be in the axle, the
type of axle noise should be determined, in order to make
any necessary repairs.
DIFFERENTIAL (REAR 244mm) 4A2B–5

Axle Housing
Axle Housing and Associated Parts

420RY00007

Legend (8) Bolt and Nut


(1) Coil Spring and Insulator (9) Nut
(2) Axle Housing Assembly (10) Differential Assembly
(3) ABS Speed Sensor and Harness (if so (11) Axle Shaft Assembly
equipped) (12) Brake Disc
(4) Nut (13) Brake Pipe
(5) Parking Brake Cable (14) Brake Caliper
(6) Bolt and Nut (15) Nut
(7) Antilock Brake System (ABS) Connector and (16) Breather Hose
Bracket (if so equipped) (17) Flare Nut

Removal 4. Remove propeller shaft. Refer to Rear Propeller


Shaft in this section.
1. Raise the vehicle and support it with suitable safety 5. Drain the rear axle oil into a proper container.
stands.
6. Remove parking brake cable, release the connection
The hoist must remain under the rear axle housing.
between the cable fixing clip equalizer. Refer to
2. Drain brake fluid. Refer to Hydraulic Brakes in Brakes Parking Brakes in Brakes section.
section. 7. Move the clip aside and pull out the breather hose.
3. Remove rear wheels and tires. Refer to Wheel in
Suspension section.
4A2B–6 DIFFERENTIAL (REAR 244mm)
8. Disconnect the ABS connectors (1) and remove the 18. Remove brake disc.
brackets (2) (if so equipped) attached to the frame 19. Remove antilock brake system speed sensor fixing
and center link. bolt and the clip and bracket (if so equipped) on the
axle housing.
20. Remove the brake pipe clip and fixing bolt on the axle
housing and take out the brake pipe.
21. Remove the bearing holder fixing nut and take out the
axle shaft assembly, be sure not to damage the oil
seal by the spline of the shaft, Refer to Axle Shaft in
this section.
22. Remove differential assembly, refer to Differential
Assembly in this section.

Oil Seal Replacement


Remove the oil seal, carefully not to damage the housing,
and mount new oil seal using oil seal installer
5–8840–2294–0

350RS001

9. Loosen the brake tube flare nut, remove the clip and
take out the brake tube.
10. Remove the shock absorber fixing nut from the axle
housing.
11. Remove the stabilizer linkage mounting nut from the
axle housing.
12. Remove the lateral rod fixing nut from the axle
housing.
13. Remove the center link mounting bolt and nut from
the axle housing.
14. Remove the trailing link fixing bolt and nut from the
axle housing.
15. Jack down and remove the coil spring and insulator.
16. Axle housing assembly can be separated from the 420RW028

vehicle on completion of steps 1 – 11.


17. Remove the brake caliper fixing bolt (3), loosen the Installation
flare nut (1), release the clip (2) and take out the brake
caliper together with the flexible hose. 1. Install differential assembly, refer to Differential
Assembly in this section.
2. Install axle shaft assembly then tighten the bearing
holder mounting nut to the specified torque. Be sure
not to damage the oil seal by the spline of the shaft.
Torque: 74Nꞏm (7.5kgꞏm/54 lb ft)
3. Install brake pipe.
4. Connect antilock brake system (ABS) speed sensor
and harness (if so equipped), refer to Anti–Lock
Brake System in Brake section.
5. Install brake disc.
6. Install brake caliper. Refer to Disk Brakes in Brake
section.
7. Install axle housing assembly.
8. Install coil spring and insulator.
9. Install the trailing link fixing bolt and nut to the axle
housing. For the procedures in items 9–13, refer to
Suspension section.
306RS001
10. Install the center link bolt and nut to the axle housing.
DIFFERENTIAL (REAR 244mm) 4A2B–7
11. Install the lateral rod fixing nut to the axle housing. 15. Install ABS connector and bracket (if so equipped).
12. Install the stabilizer linkage mounting nut to the axle 16. Connect breather hose.
housing. 17. Install parking brake cable, Refer to Parking Brakes in
13. Install the shock absorber fixing nut to the axle Brake section.
housing. 18. Bleed brakes. Refer to Hydraulic Brakes in Brake
14. Install brake tube flare nut, Refer to Disk Brakes in section.
Brake section.

Axle Shaft
Axle Shaft and Associated Parts

420RY00005

Legend (7) Bearing Holder


(1) Brake Caliper (8) Bearing
(2) Brake Disc (9) Retainer
(3) Wheel Pin (10) Snap Ring
(4) Axle Shaft Assembly (11) Bolt
(5) Back Plate (12) Nut
(6) Parking Brake Assembly (13) Antilock Brake System (ABS) Speed Sensor

Removal 3. Remove brake caliper. Use a wire to attach the brake


caliper to the frame. Refer to Disk Brakes in Brake
1. Raise the vehicle. section.
2. Remove tires and wheels. Refer to Wheel in Steering 4. Remove brake disc.
section. 5. Remove ABS sensor.
6. Remove Parking brake assembly. Refer to Parking
Brakes in Brake section.
4A2B–8 DIFFERENTIAL (REAR 244mm)
7. Remove the parking brake cable mounting 15. Remove the wheel pins using a remover
bolts(Behind the back plate)(1). 5–8840–0029–0.

311RS001 420RY00011

8. Remove the bearing holder mounting nuts.


9. Remove axle shaft assembly. Inspection and Repair
NOTE: Be sure not to damage the oil seal. Make necessary correction or parts replacement if wear,
10. Remove snap ring. corrosion or any other abnormal conditions are found
through inspection.
11. Using a bearing remover 5–8840–2295–0 and press,
remove retainer together with the bearing holder. Visual Check:
Check the following parts for wear, damage, noise or any
other abnormal conditions:
1. Axle shaft
2. Bearing
When checking the axle shaft, pay special attention to the
splined portions and replace the shaft if distortion or step
wear is noticeable. Correct slight step wear with a grinder.

420RY00012

12. Remove bearing.


13. Remove bearing holder.
14. Remove back plate.

420RS008
DIFFERENTIAL (REAR 244mm) 4A2B–9

Axle Shaft Run–out Oil Seal Replacement


Limit: 1.0 mm (0.039 in) Remove the oil seal carefully not to damage the bearing
holder bore .
When installing, use oil seal installer 5–8840–2310–0.

420RS009

Axle Shaft Flange Run–out 420RY00009

Limit: 0.08 mm (0.003 in)


Installation
1. Install wheel pin.
2. Install back plate.
3. Install bearing holder.
4. Install bearing.
5. Install retainer by using a bearing installer
5–8840–2296–0, press fit together with the bearing.

420RS010

420RY00010
4A2B–10 DIFFERENTIAL (REAR 244mm)
6. Install snap ring. 10. Install parking brake assembly, refer to Parking
7. Install axle shaft assembly. Brakes in Brake section.
11. Install antilock brake system sensor.
NOTE: Be sure not to damage the oil seal.
12. Install brake disc.
8. Tighten the bearing holder mounting nut to the
specified torque. 13. Install brake caliper, refer to Disk Brakes in Brake
section.
Torque: 74Nꞏm (54 Ib ft)
9. Fix the parking brake cable mounting bolt (Behind the
back plate).

Pinion Oil Seal


Pinion Oil Seal and Associated Parts

425RY00010

Legend (3) Oil Seal


(1) Flange Nut and Washer (4) Outer Bearing
(2) Flange (5) Collapsible Spacer

Removal
1. Remove the rear propeller shaft. Refer to Rear
Propeller Shaft in this section.
2. Drain the rear axle oil.
DIFFERENTIAL (REAR 244mm) 4A2B–11
3. Remove flange nut and washer by using pinion flange Inspection and Repair
holder 5–8840–0133–0 after raising up its staked
parts completely. Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal conditions are
found through inspection.
Check the following parts:
1. Seal surface of the pinion.
2. Cage bore for burns.

Installation
1. Install collapsible spacer, discard the used collapsible
spacer and install a new one.
2. Install outer bearing.
NOTE: Do not drive in, but just temporarily set in the outer
bearing by hand, which should be indirectly pressed in
finally by tightening the flange nut.
3. By using the seal installer 5–8840–2165–0, install a
new oil seal (1) that has grease on seal lip.

415RW040

4. Remove flange.
5. Remove oil seal.
6. Remove outer bearing by using remover
5–8840–2323–0.

425RW050

4. Install flange.
5. Install flange nut and washer. Refer to Differential
Assembly in this section for flange nut reassembly.
NOTE: Discard the used nut and install a new one.

425RY00003

7. Remove collapsible spacer.


4A2B–12 DIFFERENTIAL (REAR 244mm)

Differential Assembly
Differential Assembly and Associated Parts

425RY00016

Legend (3) Parking Brake Cable


(1) Bolt and Nut (4) Differential Assembly
(2) Axle Shaft Assembly (5) Nut

Removal 6. Remove the parking brake cable fastening clip and


disconnect the equalizer section. Refer to Parking
1. Jack up and support the frame with stands. Brakes in Brake section.
2. Remove the wheel and tire. Refer to Wheel in 7. Remove the bearing holder fixing nuts.
Steering section. 8. Remove axle shaft assembly, be sure not to damage
3. Drain the differential oil. the oil seal by axle shaft.
4. Remove the propeller shaft. Refer to Rear Propeller 9. Remove differential carrier mounting bolts and nuts.
Shaft in this section. 10. Remove differential assembly.
5. Remove the ABS speed sensor. Refer to Anti–lock
Brake System in Brakes section.
DIFFERENTIAL (REAR 244mm) 4A2B–13

Installation 2. Install bolt and nut. Tighten the differential carrier


mounting bolts and nuts to the specified torque.
1. Clean the contact surfaces of the axle and differential
Torque:Nuts 44Nꞏm (4.5kgꞏm/33 lb ft)
carrier. As shown in the drawing, apply Three Bond
TB1215 or equivalent then install differential Bolts 64Nꞏm (6.5kgꞏm/47 lb ft)
assembly. 3. Install axle shaft assembly. Be sure not to damage
the oil seal by axle shaft.
4. Install nut, refer to Axle Shaft in this section.
5. Install parking brake cable, refer to Parking Brakes in
Brake section.
NOTE: After completing the assembling work, fill the
prescribed gear oil to the filler hole.
Lubricant capacity: 3.0 liter (2.6 Imp qt/3.2
US qt)
6. Tighten the oil filler plug to the specified torque.
Torque: 78Nꞏm (8.0kgꞏm/58 lb ft)

425RS006
4A2B–14 DIFFERENTIAL (REAR 244mm)

Disassembled View

415RY00002

Legend (9) Inner Bearing Outer Race


(1) Flange Nut and Washer (10) Collapsible Spacer
(2) Flange (11) Inner Bearing
(3) Oil Seal (12) Adjust Shim (Pinion Position)
(4) Outer Bearing (13) Drive Pinion Shaft
(5) Outer Bearing Outer Race (14) Adjust Shim (Diff Cage Assembly)
(6) Diff Carrier (15) Diff Preload/Backlash
(7) Bearing Cap (16) Side Bearing
(8) Bolt (17) Side Bearing Outer Race
DIFFERENTIAL (REAR 244mm) 4A2B–15

Disassembly 3. Remove differential cage assembly.


4. Remove side bearing outer race. After removal, keep
1. Using holding fixture 5–8840–2029–0 and holding the right and left hand side bearing assemblies
fixture base 5–8840–0003–0, fix the differential separate to maintain inner and outer race
assembly to the bench. combinations.
5. Remove side bearing by using remover
5–8840–2587–0 and adapter 5–8840–2576–0.
Select collet halves 44803 in remover kit
5–8840–2587–0 for side bearing removal and insert
is not required for this operation.

425RW058

2. Apply a setting mark to the side bearing cap and the


differential carrier then remove bearing cap.

415RW041

6. Note the thickness and position of the shims then


remove adjust shim.
7. Remove the flange nut and washer by using pinion
flange holder 5–8840–0133–0 after raising up its
staked parts completely.

425RS009

415RW040
4A2B–16 DIFFERENTIAL (REAR 244mm)
8. Removed flange assembly. 12. Remove adjust shim.
9. Remove the drive pinion assembly using a soft metal 13. Remove oil seal.
rod and a hammer. 14. Remove oil seal slinger.
15. Remove outer bearing.
16. Remove the inner bearing outer race (1) and the outer
bearing outer race (2) by using a brass bar and a
hammer.

425RY005

10. Remove collapsible spacer.


11. Remove the inner bearing by using remover
5–8840–2587–0. Select insert 303174 and collet
halves 44803 in remover kit 5–8840–2587–0 for inner
bearing removal.
425RS014

425RS015

415RW042
DIFFERENTIAL (REAR 244mm) 4A2B–17

Reassembly 2. Tighten the nut to the specified torque.

1. Install outer bearing outer race by using installer Torque: 2.3 Nꞏm (23kgꞏcm/20 lb in)
5–8840–2689–0 and grip 5–8840–0007–0.

425RW030

425RY00014 3. Clean the side bearing bores. Place discs and dial
2. Install inner bearing outer race by using installer indicator on to arbor, and place tool into position in
5–8840–2690–0 and grip 5–8840–0007–0. side bearing bores. Install and tighten the bearing
caps to the specified torque.

425RY00013

3. Adjust the drive pinion mounting distance as follows: 425RW031

1. Apply gear oil to the inner and outer drive pinion Legend
bearing. Clean the pinion setting gauge set. (1) Dial Indicator: 5–8840–0126–0
Then install the gauge set together with the inner (2) Gauge Plate: 5–8840–2678–0
and outer bearings.
(3) Disc (2 pcs.): 5–8840–2679–0
Install gauge plate 5–8840–2678–0 (3), inner pilot
5–8840–2680–0 (2) ,bolt and nut 5–8840–0127–0 (4) Arbor: 5–8840–0128–0
(4) and outer pilot 5–8840–2681–0 (1) through inner
and outer bearings.
4A2B–18 DIFFERENTIAL (REAR 244mm)
4. Set the dial indicator 5–8840–0126–0 to “0”. 6. After the ZERO setting is obtained, rotate the
Place it on the mounting post of the gauging arbor gauging arbor until the dial indicator rod does not
with the contact button touching the indicator pad. touch the gauging plate. Record the number the
Force the dial indicator downward until the needle dial indicator needle points to.
has made a half turn clockwise. Tighten down the
dial indicator in this position.

425RS022

Legend
(1) Example=Dial indicator reading od 0.085
425RS020

Legend
(1) Dial Indicator 7. Record the pinion depth code on the head of the
(2) Ganging Arbor drive pinion. The number indicates a necessary
(3) Plunger change in the pinion mounting distance. A plus
(4) Gauge Plate number indicates the need for a greater mounting
distance (which can be achieved by decreasing
5. Position the plunger on the gauge plate. Move the the shim thickness). A minus number indicates
gauging arbor slowly back and forth and locate the need for a smaller mounting distance (which
the position at which the dial indicator shows the can be achieved by increasing the shim
greatest defection. At this point, once again set thickness). If examination reveals pinion depth
the dial indicator to “0”. Repeat the procedure to code “0”, the pinion is “nominal”.
verify the “0” setting.

425RS023

425RS021
DIFFERENTIAL (REAR 244mm) 4A2B–19
8. Select the shim thickness using the chart;
Pinion
marking
Dial +10 +9 +8 +7 +6 +5 +4 +3 +2 +1 0 –1 –2 –3 –4 –5 –6 –7 –8 –9 –10
indicator
reading
(inches)

0.080 2.12 2.12


(0.0835) (0.0835)

0.081 2.12 2.12 2.14 2.14 2.16


(0.0835) (0.0835) (0.0843) (0.0843) (0.0850)

0.082 2.12 2.12 2.14 2.14 2.16 2.16 2.18 2.18


(0.0835) (0.0835) (0.0843) (0.0843) (0.0850) (0.0850) (0.0858) (0.0858)

0.083 2.12 2.12 2.14 2.14 2.16 2.16 2.18 2.18 2.20 2.20
(0.0835) (0.0835) (0.0843) (0.0843) (0.0850) (0.0850) (0.0858) (0.0858) (0.0866) (0.0866)

0.084 2.12 2.12 2.14 2.14 2.16 2.16 2.18 2.18 2.20 2.20 2.22 2.22
(0.0835) (0.0835) (0.0843) (0.0843) (0.0850) (0.0850) (0.0858) (0.0858) (0.0866) (0.0866) (0.0874) (0.0874)

0.085 2.12 2.12 2.14 2.14 2.16 2.16 2.18 2.18 2.20 2.20 2.22 2.22 2.24 2.24 2.26
(0.0835) (0.0835) (0.0843) (0.0843) (0.0850) (0.0850) (0.0858) (0.0858) (0.0866) (0.0866) (0.0874) (0.0874) (0.0822) (0.0822) (0.0890)

0.086 2.12 2.12 2.14 2.14 2.16 2.16 2.18 2.18 2.20 2.20 2.22 2.22 2.24 2.24 2.26 2.26 2.28 2.28
(0.0835) (0.0835) (0.0843) (0.0843) (0.0850) (0.0850) (0.0858) (0.0858) (0.0866) (0.0866) (0.0874) (0.0874) (0.0882) (0.0882) (0.0890) (0.0890) (0.0898) (0.0898)

0.087 2.12 2.12 2.14 2.14 2.16 2.16 2.18 2.18 2.20 2.20 2.22 2.22 2.24 2.24 2.26 2.26 2.28 2.28 2.30 2.30
(0.0835) (0.0835) (0.0843) (0.0843) (0.0850) (0.0850) (0.0858) (0.0858) (0.0866) (0.0866) (0.0874) (0.0874) (0.0882) (0.0882) (0.0890) (0.0890) (0.0898) (0.0898) (0.0905) (0.0905)

0.088 2.14 2.14 2.16 2.16 2.18 2.18 2.20 2.20 2.22 2.22 2.24 2.24 2.26 2.26 2.28 2.28 2.30 2.30 2.32 2.32 2.34
(0.0843) (0.0843) (0.0850) (0.0850) (0.0858) (0.0858) (0.0866) (0.0866) (0.0874) (0.0874) (0.0882) (0.0882) (0.0890) (0.0890) (0.0898) (0.0898) (0.0905) (0.0905) (0.0914) (0.0914) (0.0921)

0.089 2.16 2.18 2.18 2.20 2.20 2.22 2.22 2.24 2.24 2.26 2.26 2.28 2.28 2.30 2.30 2.32 2.32 2.34 2.34 2.36 2.36
(0.0850) (0.0858) (0.0858) (0.0866) (0.0866) (0.0874) (0.0874) (0.0882) (0.0882) (0.0890) (0.0890) (0.0898) (0.0898) (0.0905) (0.0905) (0.0914) (0.0914) (0.0921) (0.0921) (0.0929) (0.0929)

0.090 2.18 2.20 2.20 2.22 2.22 2.24 2.24 2.26 2.26 2.28 2.28 2.30 2.30 2.32 2.32 2.34 2.34 2.36 2.36 2.38 2.38
(0.0858) (0.0866) (0.0866) (0.0874) (0.0874) (0.0882) (0.0882) (0.0890) (0.0890) (0.0898) (0.0898) (0.0905) (0.0905) (0.0914) (0.0914) (0.0921) (0.0921) (0.0929) (0.0929) (0.0937) (0.0937)

0.091 2.20 2.22 2.22 2.24 2.24 2.26 2.26 2.28 2.28 2.30 2.30 2.32 2.32 2.34 2.34 2.36 2.36 2.38 2.38 2.40 2.40
(0.0866) (0.0874) (0.0874) (0.0882) (0.0882) (0.0890) (0.0890) (0.0898) (0.0898) (0.0905) (0.0905) (0.0914) (0.0914) (0.0921) (0.0921) (0.0929) (0.0929) (0.0937) (0.0937) (0.0945) (0.0945)

0.092 2.24 2.24 2.26 2.26 2.28 2.28 2.30 2.30 2.32 2.32 2.34 2.34 2.36 2.36 2.38 2.38 2.40 2.40 2.42 2.42 2.44
(0.0882) (0.0882) (0.0890) (0.0890) (0.0898) (0.0898) (0.0905) (0.0905) (0.0914) (0.0914) (0.0921) (0.0921) (0.0929) (0.0929) (0.0937) (0.0937) (0.0945) (0.0945) (0.0953) (0.0953) (0.0961)

0.093 2.26 2.28 2.28 2.30 2.30 2.32 2.32 2.34 2.34 2.36 2.36 2.38 2.38 2.40 2.40 2.42 2.42 2.44 2.44 2.46 2.46
(0.0890) (0.0898) (0.0898) (0.0905) (0.0905) (0.0914) (0.0914) (0.0921) (0.0921) (0.0929) (0.0929) (0.0937) (0.0937) (0.0945) (0.0945) (0.0953) (0.0953) (0.0961) (0.0961) (0.0969) (0.0969)

0.094 2.28 2.30 2.30 2.32 2.32 2.34 2.34 2.36 2.36 2.38 2.38 2.40 2.40 2.42 2.42 2.44 2.44 2.46 2.46 2.48 2.48
(0.0898) (0.0905) (0.0905) (0.0914) (0.0914) (0.0921) (0.0921) (0.0929) (0.0929) (0.0937) (0.0937) (0.0945) (0.0945) (0.0953) (0.0953) (0.0961) (0.0961) (0.0969) (0.0969) (0.0977) (0.0977)

0.095 2.30 2.32 2.32 2.34 2.34 2.36 2.36 2.38 2.38 2.40 2.40 2.42 2.42 2.44 2.44 2.46 2.46 2.48 2.48 2.50 2.50
(0.0905) (0.0914) (0.0914) (0.0921) (0.0921) (0.0929) (0.0929) (0.0937) (0.0937) (0.0945) (0.0945) (0.0953) (0.0953) (0.0961) (0.0961) (0.0969) (0.0969) (0.0977) (0.0977) (0.0987) (0.0987)

0.096 2.34 2.34 2.36 2.36 2.38 2.38 2.40 2.40 2.42 2.42 2.44 2.44 2.46 2.46 2.48 2.48 2.50 2.50 2.52 2.52 2.54
(0.0921) (0.0921) (0.0929) (0.0929) (0.0937) (0.0937) (0.0945) (0.0945) (0.0953) (0.0953) (0.0961) (0.0961) (0.0969) (0.0969) (0.0977) (0.0977) (0.0987) (0.0987) (0.0992) (0.0992) (0.1000)

0.097 2.36 2.38 2.38 2.40 2.40 2.42 2.42 2.44 2.44 2.46 2.46 2.48 2.48 2.50 2.50 2.52 2.52 2.54 2.54 2.56 2.56
(0.0929) (0.0937) (0.0937) (0.0945) (0.0945) (0.0953) (0.0953) (0.0961) (0.0961) (0.0969) (0.0969) (0.0977) (0.0977) (0.0984) (0.0984) (0.0992) (0.0922) (0.1000) (0.1000) (0.1008) (0.1008)

0.098 2.38 2.40 2.40 2.42 2.42 2.44 2.44 2.46 2.46 2.48 2.48 2.50 2.50 2.52 2.52 2.54 2.54 2.56 2.56 2.58 2.58
(0.0937) (0.0945) (0.0945) (0.0953) (0.0953) (0.0961) (0.0961) (0.0969) (0.0969) (0.0977) (0.0977) (0.0984) (0.0984) (0.0992) (0.0922) (0.1000) (0.1000) (0.1008) (0.1008) (0.1016) (0.1016)

0.099 2.42 2.42 2.44 2.44 2.46 2.46 2.48 2.48 2.50 2.50 2.52 2.52 2.54 2.54 2.56 2.56 2.58 2.58
(0.0953) (0.0953) (0.0961) (0.0961) (0.0969) (0.0969) (0.0977) (0.0977) (0.0984) (0.0984) (0.0992) (0.0922) (0.1000) (0.1000) (0.1008) (0.1008) (0.1016) (0.1016)

0.000 2.44 2.46 2.46 2.48 2.48 2.50 2.50 2.52 2.52 2.54 2.54 2.56 2.56 2.58 2.58
(0.0961) (0.0969) (0.0969) (0.0977) (0.0977) (0.0984) (0.0984) (0.0992) (0.0922) (0.1000) (0.1000) (0.1008) (0.1008) (0.1016) (0.1016)

0.001 2.46 2.48 2.48 2.50 2.50 2.52 2.52 2.54 2.54 2.56 2.56 2.58 2.58
(0.0969) (0.0977) (0.0977) (0.0984) (0.0984) (0.0992) (0.0922) (0.1000) (0.1000) (0.1008) (0.1008) (0.1016) (0.1016)

0.002 2.48 2.50 2.50 2.52 2.52 2.54 2.54 2.56 2.56 2.58 2.58
(0.0977) (0.0984) (0.0984) (0.0992) (0.0922) (0.1000) (0.1000) (0.1008) (0.1008) (0.1016) (0.1016)

0.003 2.52 2.52 2.54 2.54 2.56 2.56 2.58 2.58


(0.0992) (0.0922) (0.1000) (0.1000) (0.1008) (0.1008) (0.1016) (0.1016)

0.004 2.54 2.56 2.56 2.58 2.58


(0.1000) (0.1008) (0.1008) (0.1016) (0.1016)

0.005 2.56 2.58 2.58


(0.1008) (0.1016) (0.1016)

0.006 2.58
(0.1016)
4A2B–20 DIFFERENTIAL (REAR 244mm)
4. Place the shim (1) on the drive pinion, then install the 10. Install flange nut and washer.
inner bearing (2) onto the pinion by using installer 1. Apply lubricant to the pinion threads.
5–8840–2574–0 and a press .
2. Using the pinion flange holder 5–8840–0133–0,
NOTE: Do not apply pressure to the roller cage. Apply tighten the nut only enough to remove the shaft
pressure only to the inner race. end play.
NOTE: Discard used flange nut and install new one.

425RW061

5. Install collapsible spacer. Discard the used


collapsible spacer and install a new one. 415RW006

6. Install drive pinion shaft assembly. 3. Adjust pinion bearing preload.


7. Install outer bearing and oil seal slinger. a. Measure the bearing preload by using a torque
meter and note the scale reading required to
8. Use oil seal installer 5–8840–2165–0 to install a new
rotate the flange.
oil seal that has grease on seal lip.
b. Continue tightening flange nut until the specified
starting torque is obtained.
Starting torque: 1.1–1.6 Nꞏm (11–16kgꞏcm/10–14
lb in)
NOTE:
a. Do not overtighten or loosen and then retighten the
nut.
b. Pinion nut torque should be in the range of
298–380 Nꞏm (30.4–38.8kgꞏm/220–281 Ib ft).

415RW029

9. Install flange assembly.

425RW018
DIFFERENTIAL (REAR 244mm) 4A2B–21
4. Using punch 5–8840–2293–0, stake the flange 2. Insert the differential cage assembly with bearing
nut at two points. outer races into the side bearing bores of the
carrier.
NOTE: When staking, be sure to turn the nut to ensure
that there is no change in bearing preload. Make sure of
preload again as instructed in 3).

425RS030

3. Using two sets of feeler gauges, insert a feeler


stock of sufficient thickness between each
bearing outer race and the carrier to remove all
425RW062

11. Adjust ring gear backlash.


end play. Make certain the feeler stock is pushed
1. Attach the side bearing to the differential to the bottom of the bearing bores.
assembly without shims by using installer
Mount the dial indicator 5–8840–0126–0 on the
5–8840–2050–0 and grip 5–8840–0007–0.
carrier so that the indicator stem is at right angles to
a tooth on the ring gear.

425RW063

425RW049
4A2B–22 DIFFERENTIAL (REAR 244mm)
4. Adjust feeler gauge thickness from side to side 12. Install the side bearings together with the selected
until ring gear backlash is in the specified range. shims by using installer 5–8840–2050–0 (2) and grip
5–8840–0007–0 (1).
Backlash: 0.13– 0.2mm (0.005– 0.008in)

425RW032
425RS032
13. Install side bearing outer race.
With zero end play and correct backlash
established, remove the feeler gauge packs, 14. Install differential cage assembly.
determine the thickness of the shims required and 15. Align the setting marks (1) applied at disassembly
add 0.05 mm (0.002 in) to each shim pack to then install the bearing cap.
provide side bearing preload. Always use new
shims.
5. Remove side bearing by using remover
5–8840–2587–0 and adapter 5–8840–2576–0.

425RS035

415RW041
DIFFERENTIAL (REAR 244mm) 4A2B–23
16. Tighten the bolt to the specified torque.
Torque:108Nꞏm (11.0kgꞏm/80 lb ft)

425RS038

Legend
425RS036
(1) Heel
(2) Toe
(3) Concave Side(Coast)
Gear Tooth Contact Pattern Check and Adjustment (4) Convex Side(Drive)
1. Apply a thin coat of Prussian blue or equivalent to the
faces of the 7–8 teeth of the ring gear. Check the
impression of contact on the ring gear teeth and make
necessary adjustment as described in illustration if
the contact is abnormal.

425RS039
4A2B–24 DIFFERENTIAL (REAR 244mm)

Differential Cage Assembly


Disassembled View

415RY00001

Legend (5) Ring Gear


(1) Pinion Mate Gear (6) Bolt
(2) Thrust Washer(for Side Gear) (7) Differention Cage
(3) Side Gear (8) Lock Pin
(4) Differential Shaft
DIFFERENTIAL (REAR 244mm) 4A2B–25

Disassembly Differential cage, carrier


Thrust washer
1. Remove bolt.
Oil seal
2. Remove ring gear.
Ring gear replacement:
3. Remove lock pin using a small drift.
1. The ring gear should always be replaced with the
drive pinion as a set.
2. Clean the ring gear threaded holes to remove the
locking argent.
3. Discard used bolts and install new ones.
4. When installing the ring gear, apply LOCTITE 271 or
equivalent to all the threaded area and ha of the
unthreaded area of the bolt.
Torque: 127Nꞏm (13.0kgꞏm/94 lb ft)

425RY00002

4. Remove the differential shaft by using a hard metal


rod and a hammer.

425RW033

Clearance between the differential pinion and the


pinion shaft measurement.
Standard: 0.07 – 0.13 mm (0.003 – 0.005 in)
Limit: 0.2 mm (0.008 in)

425RS043

5. Remove pinion mate gear and thrust washer.


6. Remove side gear and thrust washer.

Inspection and Repair


Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal conditions are
found through inspection.
Check the following parts:
Ring gear, pinion gear
Bearing
Side gear, pinion mate gear, differential shaft 425RY00007
4A2B–26 DIFFERENTIAL (REAR 244mm)
Clearance between the side gear and the differential Reassembly
box.
Differential cage
Standard: 0.032 – 0.105 mm (0.001 – 0.004 in) Thrust washer
Limit: 0.105 mm (0.004 in) Side gear
Pinion gear
1. Install the pinion gear by engaging it with the side
gears while turning both pinion gears simultaneously
in the same direction.
2. Install the pinion mate gear with thrust washer by
engaging it with the side gears while turning both
pinion mate gears simultaneously in the same
direction.

425RY00005

Legend
(1) Side gear
(2) Differential box

Play in splines between the side gear and the axle


shaft.
Standard: 0.07 – 0.38 mm (0.003 – 0.014 in) 425RS048

Limit: 0.5 mm (0.02 in) 3. Install differential shaft.


1. Be sure to install the differential shaft so that it is in
alignment with the lock pin hole in the differential
cage.

425RY00006

425RS049
DIFFERENTIAL (REAR 244mm) 4A2B–27
2. Adjust the backlash between the side gear and 5. Install exciter ring (If equipped with rear wheel
the pinion gear. antilock).
Backlash: 0.15 – 0.20 mm (0.006 – 0.008 in) Press the exciter ring on the differential cage using
the ring gear as a pilot.
Thickness of thrust washers available
NOTE: Discard used exciter ring and install new one.
mm 0.80 0.90 1.00 1.10 1.20 1.30
in 0.031 0.035 0.039 0.043 0.047 0.051

425RS052

6. Tighten the bolts in diagonal sequence as illustrated.


Torque: 127Nꞏm (13.0kgꞏm/94 lb ft)
425RY00008
NOTE: Discard used bolts and install new ones.
4. Install lock pin.
Install the lock pin using small drift.

425RW033

425RY00009
4A2B–28 DIFFERENTIAL (REAR 244mm)

Limited Slip Differential


Disassembled View

425RY001

Legend (14) Pinion and Pinion shaft


(1) Screw (15) Side gear
(2) Differential cage A (16) Pressure ring
(3) Thrust washer (17) Friction Plate
(4) Spring disc (18) Friction disc
(5) Friction Plate (19) Friction Plate
(6) Friction plate (20) Friction disc
(7) Friction Plate (21) Friction Plate
(8) Friction disc (22) Friction Plate
(9) Friction Plate (23) Friction Plate
(10) Friction disc (24) Spring disc
(11) Friction Plate (25) Thrust washer
(12) Pressure ring (26) Differential cage B
(13) Side gear
DIFFERENTIAL (REAR 244mm) 4A2B–29

Disassembly 9. Remove Friction plate.


Differential Cages A and B 10. Remove Friction disc.
1. To ensure installation of the parts in original position 11. Remove Friction plate.
apply a setting mark before removing the differential 12. Remove Friction disc.
cages A and B. 13. Remove Friction plate.
2. Using special tool, 5–8840–2682–0, grip it with a vice, 14. Remove Pressure ring.
and set the differential. 15. Remove Side gear.
16. Remove Pinion and pinion shaft.
17. Remove Side gear.
18. Remove Pressure ring.
19. Remove Friction plate.
20. Remove Friction disc.
21. Remove Friction plate.
22. Remove Friction disc.
23. Remove Friction plate.
24. Remove Friction plate.
25. Remove Friction plate.
26. Remove Friction disc.
27. Remove Thrust washer.
28. Remove Differential cage B.

Inspection and Repair


425RS054 Make necessary correction or parts replacement if wear,
3. Gradually and evenly loosen the 3 fixing screws of the damage, corrosion or any other abnormal condition is
differential cages A and B. found through inspection.
Visual check
Check the following parts for wear, damage, noise or any
other abnormal conditions.
Friction disc, friction plate and spring disc

425RS055

4. Remove Differential cage A.


5. Remove Thrust washer.
6. Remove Spring disc.
NOTE: When removing the spring disc, friction disc, and 425RS056

friction plate, place them in order for clear distinction of Legend


left and right use. (1) Sliding surfaces
7. Remove Spring disc. (2) Projections
8. Remove Friction plate.
4A2B–30 DIFFERENTIAL (REAR 244mm)
Pressure ring Case

425RY003 425RS059

Legend Legend
(3) Sliding surface with the friction disc. When (11) Contact surface with the spring disc.
nicks or scratches are found, polish with an oil (12) Inner groove of the differential cage B.
stone and repair on a level block using a Repair light nicks and burrs using an oil stone.
compound.
(4) Sliding spherical surface with the pinion gear.
(5) Sliding surface with the side gear.
(6) V–shaped groove of the pressure ring and V
–shaped section of the pinion shaft.
(7) Fitting section with the case.
(8) Face contacting the inner surface of the
differential case. Repair burrs and nicks using
an oil stone.

Thrust washer

425RS060

Legend
(7) Fitting section with the case.
(8) Face contacting the inner surface of the
differential case.
Repair burrs and nicks using an oil stone.
(9) Sliding surface with the side gear or case.
(11) Contact surface with spring disc.

425RS058

Legend
(9) Sliding surface with the side gear or case.
(10) Peripheral groove of the side gear.
Repair light nicks and burrs using an oil stone.
DIFFERENTIAL (REAR 244mm) 4A2B–31
Measure the Deformation of the friction disc & plate. Measure the wear of the thrust washer
Limit: 0.1 mm (0.004 in) Limit: 1.3 mm (0.05 in)

425RS061 425RS063

Measure the wear of the friction plate & disc


Limit(A–B): 0.1 mm (0.004 in) Reassembly
Remarks:
A=Inner or outer projections Adjust the clearance between the friction disc and plate.
B=Sliding surface subjected to abrasion 1. Measuring the depth of the differential cage.
Standard (A–B): 89.13 mm (3.51 in)
(C): 9.13 mm (0.36 in)

425RS062

425RS064
4A2B–32 DIFFERENTIAL (REAR 244mm)
2. Measuring the overall length of the pressurering,
friction disc and friction plate.
Mount the pinion shaft in the pressurering and then
install the friction disc & plate.
Measure the length between the plates over the
V–groove. (D)

425RS066

2. Measuring the dimension between the thrust washers


at both ends.
Assemble the side gear, pinion, pinion shaft,
pressure ring and thrust washer, and pressing the
pressure ring to–the pinion shaft in the direction of
the shaft to make the clearance 0.
Have the side gear contact to the pinion to make the
425RS065

3. After measuring dimensions A,B,C and D, make


backlash 0.
adjustment in the following manner:
Measure the thickness (E) of the spring disc. Measure the dimension (H) between thrust
1.75mm (0.069in) 2 discs washers at both ends.
4. Select the friction disc & plate so as to satisfy the
following equation:
{(A-B)+C}-(D+E)=0.06-0.20mm (0.002-0.008in)
Also, the total size difference of the friction disc &
plate and spring disc should be 0.05mm (0.02in) or
less.
Thickness
:1.65–1.75–1.85mm(0.065–0.069–0.073 in)

Backlash adjustment of the side gear in


the direction of the shaft
1. Measuring the depth of the differential cage.
(F–B): 95.63 mm (3.76 in)
(G): 15.63 mm (0.62 in)

425RS067
DIFFERENTIAL (REAR 244mm) 4A2B–33
3. After measuring dimensions of each of the above 6. Install Friction plate.
sections, proceed with the adjustment in the following 7. Install Friction disc.
manner:
8. Install Friction plate.
Adjust the clearance to satisfy the equation below.
9. Install Friction disc.
{(F – B) + G – H}=0.05 – 0.20 mm
10. Install Friction plate.
Also, select the thrust washers so that the
dimensional difference between the back surfaces of 11. Install Pressure ring.
the left and right pressure rings to the thrust washers 12. Install Side gear.
is 0.05mm or less. 13. Install Pinion and pinion shaft.
14. Install Side gear.
Thickness : 1.5mm (0.059 in)
15. Install Pressure ring.
1.6 mm(0.063 in)
16. Install Friction plate.
1.7 mm(0.067 in) 17. Install Friction disc.
18. Install Friction plate.
NOTE: When assembling the parts, apply recommended 19. Install Friction disc.
gear oil sufficiently to each of the parts, especially, to the 20. Install Friction plate.
contact surfaces and sliding surfaces.
21. Install Friction plate.
1. Install Differential cage B.
22. Install Friction plate.
2. Install Thrust washer.
23. Install Spring disc.
3. Install Spring disc.
When assembling the spring disc, make sure the
When assembling the spring disc, make sure the mounting direction is correct.
mounting direction is correct as shown in figure.
24. Install Spring disc.
25. Install Thrust washer.
26. Install Differential cage A.
27. Install Screw.
Matching the guide marks of the differential cages A
and B, tighten the screws evenly in the diagonal
order.

425RY004

Legend
(1) Friction Plate
(2) Spring Disc
(3) Friction Disc

4. Install Friction disc.


425RS055
5. Install Friction plate.
4A2B–34 DIFFERENTIAL (REAR 244mm)
28. Check the operation.
Measure the starting torque using the side gear
holder.
Starting torque:
29 – 45 Nꞏm (3.0 – 4.6 kgꞏm/ 22 – 33Ib ft)

425RW065

Legend
(1) Side Gear Holder : 5–8840–2381–0
DIFFERENTIAL (REAR 244mm) 4A2B–35

Main Data and Specifications


General Specifications
Rear axle
Type Banjo, Semi–floating
Rear axle Size 244 mm (9.61 in)
Gear type Hypoid
Gear ratio (to 1) 4.100(6VE1 with A/T)
4.300(6VE1 with M/T,4JX1)
Differential type Pinion (STD), Four pinion (LSD)
Lubricant Grade GL–5: (Standard differential)
GL–5, LSD: (Limited slip differential)
Locking Differential Lubricant 80W90 GL–5 Limited Slip Differential Gear Lubricant
together with Limited Slip Differential Lubricant Additive
(Part No. 8–01052–358–0) or equivalent.
Capacity 3.0 liter (2.6 Imp qt/3.2 US qt)
4A2B–36 DIFFERENTIAL (REAR 244mm)

Torque Specifications

420RY00002
DIFFERENTIAL (REAR 244mm) 4A2B–37

Special Tools
TOOL NO. TOOL NO.
ILLUSTRATION ILLUSTRATION
TOOL NAME TOOL NAME

5–8840–2294–0 5–8840–2576–0
(J–39210) (J–8107–3)
Installer; Axle shaft inner Adapter; Side bearing
seal plug

5–8840–2689–0
5–8840–0133–0
(J–44461)
(J–8614–01)
Installer; Outer bearing
Pinion flange holder
outer race

5–8840–2165–0 5–8840–0007–0
(J–37263) (J–8092)
Installer; Pinion oil seal Grip

5–8840–2690–0
5–8840–2029–0
(J–44462)
(J–42832)
Installer; Inner bearing
Holding fixture
outer race

5–8840–0003–0 5–8840–2681–0
(J–3289–20) (J–42824)
Holding fixture base Pilot;Outer

5–8840–2587–0 5–8840–0127–0
(J–42379) (J–21777–43)
Remover; Bearing Nut & Bolt
4A2B–38 DIFFERENTIAL (REAR 244mm)

TOOL NO. TOOL NO.


ILLUSTRATION ILLUSTRATION
TOOL NAME TOOL NAME

5–8840–2680–0 5–8840–2574–0
(J–44453) (J–42828)
Pilot; Inner Installer; Pinion bearing

5–8840–2681 5–8840–2293–0
(J–44449) (J–39209)
Pilot; Outer bearing Punch; End nut lock

5–8840–2678–0 5–8840–2570–0
(J–44451) (J–42829)
Gage plate Installer; Side bearing

5–8840–0126–0 5–8840–2323–0
(J–8001) (J–39602)
Dial indicator Remover; Outer bearing

5–8840–2586–0
5–8840–2679–0 (J–39858)
(J–44452) Clutch pack unloading
Disc (2 required) tool kit Includes
Screw cap, Cap and
Forcing screw

5–8840–0128–0
(J–23597–1)
Arbor
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–1

DRIVELINE/AXLE
DRIVELINE CONTROL SYSTEM (SHIFT ON THE FLY)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 4B1–1 Functions of Indicator Lamp . . . . . . . . . . . . . . . 4B1–11
Shift on the Fly System (Lever Type) . . . . . . . 4B1–2 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B1–11
Outline of Shift on the Fly System Front Axle Diagnosis . . . . . . . . . . . . . . . . . . . 4B1–30
(Lever Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B1–2 Shift on the Fly Vacuum Piping and Electric
Shift on the Fly Vacuum Piping and Electric Equipment (For Push Button Type) . . . . . . . . 4B1–32
Equipment (For Lever Control Type) . . . . . . 4B1–3 Vacuum Piping Diagram . . . . . . . . . . . . . . . . 4B1–32
Vacuum Piping Diagram . . . . . . . . . . . . . . . . 4B1–3 Inspection and Repair . . . . . . . . . . . . . . . . . . 4B1–33
Inspection and Repair . . . . . . . . . . . . . . . . . . 4B1–4 4WD Control Unit (For Push Button Type) . . 4B1–36
Shift on the Fly System (Push Button Type) . 4B1–7 4WD Control Unit Associated Parts . . . . . . 4B1–36
Outline of Shift on the Fly System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B1–37
(Push Button Type) . . . . . . . . . . . . . . . . . . . . 4B1–7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B1–37

Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
4B1–2 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)

Shift on the Fly System (Lever Type)


Outline of Shift on the Fly System
(Lever Type)
The shift on the fly system (Lever type) switches between
2 wheel drive (2WD) and 4 wheel drive (4WD) by driver’s
shifting the transfer control lever on the floor.
This system controls below operations.
1. Connecting front wheels to, and disconnecting them
from, the front axles by vacuum actuator.
2. Indicator on instrument panel.
3. 4WD signal to Electronic Hydraulic Control Unit for
brake system (If anti–lock brake system is equipped).
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–3

Shift on the Fly Vacuum Piping and Electric Equipment


(For Lever Control Type)

Vacuum Piping Diagram

C04RW015

VSV Assembly, Actuator Assembly Vacuum Tank

412RS032 412RS033
4B1–4 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)

Inspection and Repair


Vacuum Piping

C04RW016

1. Pull out the Hose A in figure and install a vacuum Check Valve
gauge.
2. Plug up Hose B in figure to prevent the leak of
vacuum.
3. Start the engine and measure vacuum 2 or 3 minutes
afterward.
4. Repeat 1) and 2) but with Hose A plugged and Hose B
pulled out.
5. If vacuum measures –400mmHg, or if it shows a
sudden drop immediately after engine stop, inspect
the hose, tank, and pipe for damage.
NOTE: Be careful not to permit the entry of dust and
water during inspection.
6. Pull out Hose D in above illustration.
7. Plug Hose E in above illustration.
8. Make sure that Hose D in above illustration is under
atmospheric pressure.
9. Pull out Hose E and plug Hose D, and make sure that
Hose E is under atmospheric pressure.
C04RS004
10. If Check 8) or 9) has revealed stoppage, check and 1. Apply vacuum from the orange colored side(1).
see that there is no bend, foreign matter in the hose or
in the filter. If there is trouble, repair or replace. Vacuum:–400mmHg
2. Check leakage of vacuum.
3. Make sure that vacuum cannot be applied from the
black colored side(2).
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–5
4. If vacuum is not applicable as much as –400mmHg, 1. With battery not connected (Usual).
and if there is resistance on the intake side, replace A–C:There is continuity
with a new check valve.
B:Closed
VSV Assembly 2. With battery connected
Inspect the vehicle side harness as follows: A – B:There is continuity
C:Closed
3. If 1) and 2) fail, replace with a new VSV.

Axle Position Switch

412RS071

Legend
(1) Grey
(2) Blue
412RS048

1. Remove connector. 1. With ball (1) being free


2. Shift transfer lever to 2H and start the engine.
A – B:There is continuity
NOTE: Do not move the vehicle while inspection. 2. With ball forced into the switch
3. Make sure that there is continuity in the vehicle side of A – B:No continuity
harness. If there is no continuity, check transfer shift
switch and wiring. 3. If 1) and 2) fail, replace with a new switch.
Inspect both VSVs as follows:

F04RS004
4B1–6 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)

Transfer Position Switch

412RW040

Legend
(1) Ball

1. With ball being free.


A–B : There is continuity.
2. With ball forced into the switch.
A–B : No continuity.
3. If 1) and 2) fail, replace with a new switch.
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–7

Shift on the Fly System (Push Button Type)

Outline of Shift on the Fly System (Push Button Type)


The shift on the fly system switches between 2 wheel 2. Retrial of shifting the transfer front output gear.
drive (2WD) and 4 wheel drive (4WD) electrically by 3. Connecting front wheels to, and disconnecting them
driver’s pressing the 4WD switch (push button type) on from, the front axles by vacuum actuator.
instrument panel.
4. Indicator on instrument panel.
This system controls below operations. (Shifting between
“4H” and “4L” must be performed by transfer control lever 5. 4WD out signal to other Electronic Hydraulic Control
on the floor.) Unit (If anti–lock brake system is equipped).
1. Shifting the transfer front output gear (Connecting to,
and disconnecting from, front propeller shaft by motor
actuator).
System Diagrams

412RW050
4B1–8 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)

Normal Operation
The motor actuator mounted on transfer rear case is of the transfer position switch changes. The vacuum
driven by signal from 4WD switch on instrument panel. solenoid valve (VSV) is driven by the signal from transfer
After complete the connecting transfer front output gear position switch and the vacuum actuator connects front
to, or disconnecting it from, front propeller shaft, condition wheels to, or disconnect them from, front axles.
Time Chart of Shifting Under Normal Condition

F04RW002
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–9
Retrial
The motor actuator starts transfer gear shifting after gear. This procedure is repeated 3 times in maximum.
signal from 4WD switch on instrument panel has been While this procedure, 4WD indicator lamp blinks by 2 Hz.
received. But the shifting may be impossible in cold If the transfer position switch does not turn on after
weather or under high speed condition. When 2 seconds aforementioned procedure has been repeated 3 times,
have passed since transfer gear shifting started and the the gear shifting is stopped and 4WD indicator lamp’s
transfer position switch dose not turn on (the gear blinking changes from 2Hz to 4Hz to notify driver that the
engagement is not completed), the motor reverses its gear shifting is stopped. This blinking of indicator lamp
rotation for 1.2 seconds and tries again to shift transfer continues until 4WD switch is returned from 4WD to 2WD.
Time Chart of Shifting Under Severe Condition (re-
trial)

F04RW003
4B1–10 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
Warning at “4L” position :In view of the shifting switch when vehicle is in “4L” condition. In the case this
mechanism of transfer, the gear shifting from 4WD to condition continues for 2 seconds, the shifting to 2WD is
2WD at “4L” condition is impossible. Therefore, the stopped and the indicator lamp’s blinking changes from
transfer position switch can not be turned off by 4WD 2Hz to 4Hz to notify driver of wrong operation.
Time Chart of Shifting from 4WD to 2WD at “4L”
Condition

F04RW005

4WD out signal to other Electronic Hydraulic Control


Unit : 4WDcontrol unit sends 4WD out signal to other
Electronic Hydraulic Control Unit as below.
4WD out signal Vehicle Condition Transfer position switch Front axle switch
(Period)
120 ms 2WD 2WD (Open) 2WD (Open)
240 ms 4WD 4WD (Close) 4WD (Close)
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–11

Functions of Indicator Lamp


Indication of vehicle condition : Indicator lamp is
controlled by 4WD control unit and shows vehicle
conditions as below.
Indicator Vehicle condition 4WD switch Transfer position Front axle switch
switch
Off 2WD Off (Close) 2WD (Open) 2WD (Open)
On 4WD On (Open) 4WD (Close) 4WD (Close)
Blink (2Hz) Operating On (Open) 4WD (Close) 2WD (Open)
Off (Close) 2WD (Open) 4WD (Close)
Blink (4Hz) Stop operating On (Open) 2WD (Open) 2WD (Open)
Off (Close) 4WD (Close) 4WD (Close)

Bulb check :To check the bulb of indicator lamp, the sometimes does not complete by 3 trials. In such case,
indicator lamp comes on when ignition key is turned on, the indicator lamp inform driver of this incident as
and goes off when the engine is started. aforementioned chart (shown at Retrial in Outline of shift
Retrials from 2WD to 4WD :In cold weather or under on the fly system).
high speed condition, the gear shifting (engagement)

Diagnosis
Before Judging That Troubles Occur When switching from 4WD to 2WD
(Unfaulty mode) 1. In case that the 4WD indicator continues blinking
When Switching from 2WD to 4WD by 2Hz .
The 4WD indicator continues blinking by 2Hz until
1. In case that blinking frequency of the 4WD both shifting the transfer gear and disconnecting the
indicator changes from 2Hz to 4Hz. front wheels are completed when switching 4WD to
When heavy synchronization load is needed, the 2WD. When driveline is loaded with torsional torque,
motor actuator tries the shifting transfer gear three the shifting transfer gear and disconnecting front
times including the activation shifting. While the wheels are impossible. In this case, removal of
motor actuator tries shifting, the indicator blinks by torsional torque on driveline make the shifting
2Hz. If the third shifting fails, the indicator’s blinking transfer gear and disconnecting front wheels
changes from 2Hz to 4Hz at the same time that the possible.
motor actuator shifted back to 2WD. Solution 3: When vehicle is running, drive
Heavy synchronization load occurs by: straight ahead while accelerating and
extremely lower temperature. decelerating. When vehicle is at a stop, move the
vehicle forward and backward from 2 to 3 meters.
higher speed, rotation difference of wheels during
cornering. 2. In case that the 4WD indicator’s blinking changes
from 2Hz to 4Hz.
Solution 1: Operate again after stop the vehicle or
slow down. Check the position of transfer lever. Is it at “4L”
position? In view of the shifting mechanism of
2. In case that the 4WD indicator continues blinking transfer, the gear shifting from 4WD to 2WD at “4L”
by 2Hz for more than 11.5 seconds. condition is impossible.
When there is rotation difference of wheels or there Solution 4: Push the 4WD switch to 4WD, shift the
is phase difference between front wheels and axles, transfer lever to “High” position and re–operate
it is difficult to connect front wheels to front axles. The the 4WD switch to 2WD.
blinking by 2Hz shows that shifting the transfer gear
or connecting the front wheels is in the middle of
operating. In above case, the indicator’s blinking by
2Hz shows that connecting the front wheels is not
completed (because the indicator’s blinking changes
to 4Hz when the shifting transfer gear is impossible.).
And removal of rotation or phase difference make
connecting the front wheels possible.
Solution 2: When vehicle is running, drive
straight ahead while accelerating and
decelerating. When vehicle is at a stop, move the
vehicle forward and backward from 2 to 3 meters.
4B1–12 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)

Parts Location (LHD / Diesel Engine Model)

D08RW852

Legend (8) P–17


(1) I–12 (9) P–18
(2) I–9 (10) P–19
(3) H–7, H–8, H–24, H–25 (11) H–60
(4) Fuse Box (12) Relay & Fuse Box
(5) C–16 (13) H–12, H–16
(6) C–94 (14) E–21
(7) H–4, H–5 (15) E–45
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–13

Parts Location (LHD / Gasoline Engine Model)

D08RW854

Legend (9) M–22


(1) I–12 (10) M–23
(2) I–9 (11) M–24
(3) H–7, H–8, H–24, H–25 (12) H–10
(4) Fuse Box (13) M–26
(5) C–16 (14) Relay & Fuse Box
(6) C–94 (15) H–12, H–16
(7) H–5 (16) E–30
(8) M–11, M–12
4B1–14 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)

Parts Location (RHD / Diesel Engine Model)

D08RW831

Legend (8) H–4, H–5


(1) I–9 (9) P–17
(2) I–12 (10) P–18
(3) E–45 (11) P–19
(4) E–21 (12) H–60
(5) H–7, H–9 (13) Relay & Fuse Box
(6) C–16 (14) H–15, H–16, H–25, H–26, H–27
(7) C–94 (15) Fuse Box
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–15

Parts Location (RHD / Gasoline Engine Model)

D08RW853

Legend (9) M–22


(1) I–9 (10) M–23
(2) I–12 (11) M–24
(3) H–7, H–9 (12) H–10
(4) C–16 (13) H–12
(5) H–5 (14) Relay & Fuse Box
(6) C–94 (15) E–30
(7) M–26 (16) H–15, H–16, H–25, H–26, H–27
(8) M–11, M–12 (17) Fuse Box
4B1–16 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)

Wiring Diagram (LHD Model)

D08RW845
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–17

Wiring Diagram (LHD / Diesel Engine Model)

D08RW841
4B1–18 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)

Wiring Diagram (LHD / Gasoline Engine Model)

D08RW843
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–19

Wiring Diagram (RHD Model)

D08RW844
4B1–20 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)

Wiring Diagram (RHD / Diesel Engine Model)

D08RW842
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–21

Wiring Diagram (RHD / Gasoline Engine Model)

D08RW638
4B1–22 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)

Connector List
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–23
4B1–24 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–25

Diagnosis of the Faults Based on the


Status of 4WD Indicator Lamp, 4WD
Switch and T/F Change Lever
Diagnosis charts are shown on below. If troubles can not
be solved after every chart was traced, troubles may
occur in the 4WD control unit. In this case, replace the
4WD control unit and trace every chart again.
Fault on switching from 2WD to 4WD
1. In case that 4WD indicator’s blinking changes
from 2Hz to 4Hz after Solution 1 is carried out.
Faults occur in the motor actuator or the transfer case
assembly. Remove the motor actuator and check
function. If problem was found and it was repaired, try
Solution 1 again. After that, disassemble the
transfer case assembly for check and repair or
replace. If incident is not improved after above
mentioned actions were taken, replace the 4WD
control unit.
2. In case that 4WD indicator does not blink nor
light, when switching from 2WD to 4WD.
Step Action Yes No
1 Is ignition turned on? Turn on the
ignition and trace
this chart from
Go to Step 2 start.
2 Burning out of
indicator lamp or
Does the indicator light comes on when the engine is not started?
disconnection of
harness wire.
Trace this chart
from the start
after repair or
Go to Step 3 replace.
3 Start the engine. Short-circuit
(body short) on
Is the 4WD switch turned from 2WD to 4WD?
harness of the
4WD switch.
Fault of the 4WD
switch (holding
the closed
condition).
Trace this chart
from the start
after repair or Push the 4WD
replace. switch to 4WD.
4B1–26 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
3. Case that the indicator keeps blinking by 2Hz
after aforementioned Solution 2 is carried out.
Step Action Yes No
1 Check the air pressure and wear of all tires. Try Solution 2
after adjust the
Were problems found?
air pressure and
replace worn
tires. Go to Step 2
2 Disconnection of
the motor
Can the transfer lever be operated from High to 4L or vice versa?
actuator harness
wiring. Trace this
chart from the
start after repair
or replace.
Faults on the
motor actuator.
Trace this chart
from the start
after replace.
Internal faults of
transfer case.
Disassemble the
transfer case for
check. Trace this
chart from the
start after repair
Go to Step 3 or replace.
3 Pull out the hoses from vacuum actuator and operate 4WD Faults on the
switch. transfer position
switch or its
Is there negative pressure on either of hoses?
harness. Trace
this chart from
the start after
repair or replace.
Faults on the
VSV main body,
its harness or
vacuuming
system. Trace
the front axle
diagnosis chart in
this section.
After that, trace
this chart from
Go to Step 4 the start.
4 Check the axle switch. Disconnection on
the axle harness.
Were problems found?
Trace this chart
from the start
after repair or
replace.
Faults on Front
Axle ASM. Trace
the front axle
Internal faults on diagnosis chart in
axle switch. this section.
Trace this chart After that, trace
from the start this chart from
after replace. the start.
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–27
Fault on switching from 4WD to 2WD
1. Case that indicator does not blink nor turn out.
Step Action Yes No
1 Short circuit of
the indicator
Does the indicator turn out by ignition off?
Go to Step 2 harness.
2 Disconnection on
the 4WD switch
Is the 4WD switch on 2WD position?
harness or
breakdown of the
4WD switch in
open state. Turn the 4WD
Trace this chart switch to 2WD
from the start position. Trace
after repair or this chart from
replace. the start.
4B1–28 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
2. Case that indicator keeps 2Hz blinking after
aforementioned Solution 3 is carried out.
Step Action Yes No
1 Check the air pressure and wear of all tires. Try Solution 3
after adjust the
Were problems found?
air pressure and
replace worn
tires. Go to Step 2
2 Faults on the
harness wiring of
Can the transfer lever be operated from High to 4L or vice versa?
motor actuator.
Trace this chart
from the start
after repair or
replace.
Internal faults on
transfer case.
Disassemble the
transfer case for
check. Trace this
chart from the
start after repair
or replace.
Faults on the
motor actuator.
Trace this chart
from the start
after or replace. Go to Step 3
3 Pull out the hoses from vacuum actuator and operate 4WD Faults on the
switch. transfer position
switch or its
Is there negative pressure on either of hoses?
harness. Trace
this chart from
the start after
repair or replace.
Faults on the
VSV main body,
its harness or
vacuuming
system. Trace
the front axle
diagnosis chart in
this section.
After that, trace
this chart from
Go to Step 4 the start.
4 Check the axle switch. Internal faults on
axle switch.
Were problems found?
Trace this chart
from the start
after replace.
Faults on Front Short circuit
Axle ASM. Trace (body short) or
the front axle disconnection of
diagnosis chart in the axle harness.
this section. Trace this chart
After that, trace from the start
this chart from after repair or
the start. replace.
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–29
3. Case that indicator’s blinking changes to 4Hz
after aforementioned Solution 4 is carried out.
Step Action Yes No
1 Faults on the
harness wiring of
Can the transfer lever be operated from High to 4L or vice versa?
motor actuator.
Trace this chart
from the start
after repair or
replace.
Faults on the
motor actuator.
Trace this chart
from the start
after replace.
Internal faults on
transfer case.
Disassemble the
transfer case for Faults on the
check. Trace this 4WD control unit.
chart from the Trace this chart
start after repair from the start
or replace. after replace.
4B1–30 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)

Front Axle Diagnosis


When the 4WD switch is operated from 4H to 2H,
indicator light does not go out.
Step Action Yes No
1 Drive slow 100 — 200m after a few minutes” idling.
Has indicator light gone out? All right. Go to Step 2
2 Jack up front tires.
Does the right side of front wheel rotate when the left side of front
wheel is rotated? Go to Step 4 Go to Step 3
3 1. Check the actuator switch. Disassemble axle
2. Check the circuit to indicator. ASM for check.
Trace this chart Trace this chart
Was a problem found?
from the start from the start
after repair or after repair or
replace. replace.
4 1. Check the VSV valve. Trace this chart
2. Check the circuit to VSV valve. from the start
after repair or
Was a problem found?
replace. Go to Step 5
5 Is vacuum piping all right? (tank, hose, & pipe damage or trouble) Trace this chart
from the start
after repair or
Go to Step 6 replace.
6 Does actuator work all right? Disassemble axle
ASM for check.
Trace this chart
from the start
Trace this chart after repair or
from the start. replace.
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–31
When the 4WD switch is operated from 2H to 4H,
indicator light is not actuated.
Step Action Yes No
1 Drive slow 100 — 200m after a few minutes” idling.
Has indicator light actuated? All right. Go to Step 2
2 Jack up front tires.
Does not the right side of front wheel rotate when the left side of
front wheel is rotated? Go to Step 4 Go to Step 3
3 1. Check the actuator switch. Disassemble axle
2. Check the circuit to indicator. ASM for check.
Trace this chart Trace this chart
Was a problem found?
from the start from the start
after repair or after repair or
replace. replace.
4 1. Check the VSV valve. Trace this chart
2. Check the circuit to VSV valve. from the start
after repair or
Was a problem found?
replace. Go to Step 5
5 Is vacuum piping all right? (tank, hose, & pipe damage or trouble) Trace this chart
from the start
after repair or
Go to Step 6 replace.
6 Does actuator work all right? Disassemble axle
ASM for check.
Trace this chart
from the start
Trace this chart after repair or
from the start. replace.
4B1–32 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)

Shift on the Fly Vacuum Piping and Electric Equipment


(For Push Button Type)

Vacuum Piping Diagram

C04RW013

VSV Assembly, Actuator Assembly Vacuum Tank

412RS032 412RS033
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–33

Inspection and Repair


Vacuum Piping

C04RW014

1. Pull out the Hose A in figure and install a vacuum Check Valve
gauge.
2. Plug up Hose B in figure to prevent the leak of
vacuum.
3. Start the engine and measure vacuum 2 or 3 minutes
afterward.
4. Repeat 1) and 2) but with Hose A plugged and Hose B
pulled out.
5. If vacuum measures –400mmHg, or if it shows a
sudden drop immediately after engine stop, inspect
the hose, tank, and pipe for damage.
NOTE: Be careful not to permit the entry of dust and
water during inspection.
6. Pull out Hose D in above illustration.
7. Plug Hose E in above illustration.
8. Make sure that Hose D in above illustration is under
atmospheric pressure.
9. Pull out Hose E and plug Hose D, and make sure that
Hose E is under atmospheric pressure.
C04RS004
10. If Check 8) or 9) has revealed stoppage, check and 1. Apply vacuum from the orange colored side(1).
see that there is no bend, foreign matter in the hose or
in the filter. If there is trouble, repair or replace. Vacuum:–400mmHg
2. Check leakage of vacuum.
3. Make sure that vacuum cannot be applied from the
black colored side(2).
4B1–34 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
4. If vacuum is not applicable as much as –400mmHg, 1. With battery not connected (Usual).
and if there is resistance on the intake side, replace A–C:There is continuity
with a new check valve.
B:Closed
VSV Assembly 2. With battery connected
Inspect the vehicle side harness as follows: A – B:There is continuity
C:Closed
3. If 1) and 2) fail, replace with a new VSV.

Axle Position Switch

412RS071

Legend
(1) Grey
(2) Blue
412RS048

1. Remove connector. 1. With ball (1) being free


2. Shift transfer lever to 2H and start the engine.
A – B:There is continuity
NOTE: Do not move the vehicle while inspection. 2. With ball forced into the switch
3. Make sure that there is continuity in the vehicle side of A – B:No continuity
harness. If there is no continuity, check transfer shift
switch and wiring. 3. If 1) and 2) fail, replace with a new switch.
Inspect both VSVs as follows: Motor Actuator Assembly
Inspect the function of the motor actuator assembly as
follows:

F04RS004
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–35
1. Disassemble the motor actuator from transfer rear Shift rod of the motor actuator moves and stops
case. at 2WD position.

412RW037 412RW039

Legend Legend
(3) Shift Rod (1) 2WD
(4) Connector (2) 4WD
(3) Shift Rod
2. Connect the terminals as shown in figure. (4) Connector
Shift rod of the motor actuator moves and stops
at 4WD position. 4. If 2) and 3) fail, replace with a new motor actuator.

Transfer Position Switch

412RW038

Legend
(1) 2WD 412RW040

(2) 4WD Legend


(3) Shift Rod (1) Ball
(4) Connector
1. With ball being free.
3. Connect the terminals as shown in figure. A–B : There is continuity.
2. With ball forced into the switch.
A–B : No continuity.
3. If 1) and 2) fail, replace with a new switch.
4B1–36 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)

4WD Control Unit (For Push Button Type)


4WD Control Unit Associated Parts

412RW044

Legend (3) Harness Connector


(1) Lower Cluster Assembly (4) Nut
(2) Front Console Assembly (5) 4WD Control Unit
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–37

Removal
1. Remove lower cluster assembly and front console
assembly.
Refer to Interior Trim in Body and Accessories
section.
2. Remove nut.
3. Remove 4WD control unit.
4. Disconnect harness connector (1).

412RW045

Legend
(1) Harness Connector

Installation
1. Connect harness connector, then install 4WD control
unit.
2. Install lower cluster assembly and front console
assembly.
4B1–38 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)

MEMO
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–1

DRIVELINE/AXLE
DRIVELINE CONTROL SYSTEM (TOD)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 4B2–1 Connector List . . . . . . . . . . . . . . . . . . . . . . . . . . 4B2–34
General Description . . . . . . . . . . . . . . . . . . . . . 4B2–2 Checking Failed Pin . . . . . . . . . . . . . . . . . . . . . 4B2–36
System Components . . . . . . . . . . . . . . . . . . . . 4B2–4 Checking Failed TOD Control Unit Pin . . . . . 4B2–39
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 4B2–4 Diagnostic Trouble Codes . . . . . . . . . . . . . . . . 4B2–43
Functions of Indicator Lamp . . . . . . . . . . . . . . 4B2–8 Diagnosis from Trouble Codes . . . . . . . . . . . . 4B2–44
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B2–13 Trouble Diagnosis Depending on The Status
Basic Diagnostic Flow Chart . . . . . . . . . . . . . . 4B2–17 of TOD Indicator . . . . . . . . . . . . . . . . . . . . . . . . 4B2–74
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . . . 4B2–18 Diagnosis from Symptom . . . . . . . . . . . . . . . . . 4B2–114
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 4B2–22

Service Precaution CAUTION: Always use the correct fastener in the


proper location. When you replace a fastener, use
WARNING: IF SO EQUIPPED WITH A ONLY the exact part number for that application.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS), ISUZU will call out those fasteners that require a
REFER TO THE SRS COMPONENT AND WIRING replacement after removal. ISUZU will also call out
LOCATION VIEW IN ORDER TO DETERMINE the fasteners that require thread lockers or thread
WHETHER YOU ARE PERFORMING SERVICE ON OR sealant. UNLESS OTHERWISE SPECIFIED, do not
NEAR THE SRS COMPONENTS OR THE SRS use supplemental coatings (Paints, greases, or other
WIRING. WHEN YOU ARE PERFORMING SERVICE corrosion inhibitors) on threaded fasteners or
ON OR NEAR THE SRS COMPONENTS OR THE SRS fastener joint interfaces. Generally, such coatings
WIRING, REFER TO THE SRS SERVICE adversely affect the fastener torque and the joint
INFORMATION. FAILURE TO FOLLOW WARNINGS clamping force, and may damage the fastener. When
COULD RESULT IN POSSIBLE AIR BAG you install fasteners, use the correct tightening
DEPLOYMENT, PERSONAL INJURY, OR sequence and specifications. Following these
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. instructions can help you avoid damage to parts and
systems.
4B2–2 DRIVE LINE CONTROL SYSTEM (TOD)

General Description

C07RW014–1

TOD (Torque on Demand) system is traction state control


system to vehicle.
Transfer Position and Drive Mode
Three drive modes can be selected through operation of
4WD AUTO switch and transfer lever.
Transfer Position 4WD AUTO SW Mode Drive mode
HIGH ON (NORMAL) 2H Rear wheel drive
OFF (PUSHED) TOD Electronically controlled torque split
four wheel drive
4L ON/OFF 4L Low-speed mechanical lock-up four
wheel drive

The electronic control unit (ECU) judges the signals from pressing force of the clutch is controlled by changing the
the transfer lever and 4WD AUTO switch, and controls duty cycle to the electromagnetic coil mounted to the rear
the transfer drive mode and shift-on-the-fly system of the clutch. When the clutch is completely disengaged,
status. the rear wheels are driven. When the clutch is completely
engaged, a rigid four wheel drive mode is obtained. The
TOD Control torque split status is controlled continuously between the
The TOD position usually drives the rear wheels, and rear wheel and four wheel drive modes. This system
transmits the torque to the front wheels with the help of includes front and rear speed sensors, and receives
electronically controlled torque split mechanism throttle position sensor information from ECM.
according to running conditions encountered. The driving The control unit receives signals sent from these sensors
force is directly transmitted to the rear wheels. This force and changes the pressing force of the multi plate disk
is split by the transfer and delivered to the front wheels. clutch to determine the torque distribution on the front and
The magnitude of the torque transmitted to the front rear wheels. Therefore, when the slip of the rear wheels is
wheels is controlled by changing the pressing force of the increased against the current torque level in the normal
multi plate disk clutch built in the transfer unit. The rear wheel drive mode, the control unit detects the slip
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–3
condition, determines the optimum torque based on the
feedback control logic, and increases the torque to the
front wheels.
The control unit uses the signal from the throttle position
sensor to predict the future vehicle condition and the
intention of the driver with respect to acceleration and
deceleration, and determines the initial torque distribution
using these data and the information from the speed
sensors.
In case of small circle turning in the parking lot, for
example, the control unit minimizes the clutch pressing
force to restrict a braking phenomenon. When the ABS
becomes active, the control unit optimizes the clutch
pressing force to ensure stable braking.

TOD Indicator Control


The TOD indicator on the instrument panel informs the
driver of the current working status of the transfer unit.
The information consists of two items: the drive mode
(2H, TOD, 4L, transition) and the torque split status of the
TOD (torque distribution level). The indicator can display
occasional errors and corresponding error codes.
4B2–4 DRIVE LINE CONTROL SYSTEM (TOD)

System Components
Parts Location

A07RY00002

Legend (5) Multi Plate Disk Clutch Pack


(1) T/F Connector (6) Electromagnetic Coil
(2) 4H and 4L Switch (7) Rear Speed Sensor
(3) High-Low Planetary Gear Set (8) Front Speed Sensor
(4) Mechanical Lock
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–5
Front and Rear Speed Sensors Multi Plate Disk Clutch Pack
The sensors are built in the transfer case, detect the Transmits the torque determined by the clutch pressing
rotation of rotors directly coupled to the propeller shafts. force to the front propeller shaft via the front drive chain.
Thirty rectangular pulses are output per one rotation of
the propeller shaft.

262RW029

261RW045
Mechanical Lock Sleeve
Couples the front and rear propeller shaft mechanically
Electromagnetic Coil when the transfer shaft is in the 4L position.
Receives the duty signals from the TOD control unit and
controls the pressing force of the clutch pressure cam.

262RW028

261RW044
4B2–6 DRIVE LINE CONTROL SYSTEM (TOD)
High-Low Planetary Gear Set Transfer Connector
Establishes an auxiliary transmission mechanism. When Transmits the input and output signals of the speed
the transfer shift lever is set to the 2H or TOD position, the sensors, electromagnetic coil, and 4H and 4L switche to
reduction gear ratio is 1.000 and the corresponding the vehicle harness. A waterproof 12-pin type is used.
driving force is generated. When the transfer shift lever is
set to the 4L position, the reduction gear ratio is 2.480 and
the corresponding driving force is generated.

261RW046

TOD Indicator Lamps (on the instrument


262RW030 panel)
Inform the following items.
4H and 4L Switch Bulb check
Detects the shift position of the transfer from the
Drive mode
movement of the transfer lever and outputs signals to the
TOD control unit. ABS IN status
BRAKE ON status

261RW002

821RW049
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–7
Check Lamp
Inform the following items.
Bulb check
Fail (fail alarm)
Trouble code
Diesel/gasoline MAP

821RW078

TOD ECU
This control unit is mounted to the front right hand seat via
a special bracket.

F07RW029
4B2–8 DRIVE LINE CONTROL SYSTEM (TOD)

Functions of Indicator Lamp


TOD Indicator Lamps

C04RY00014

Indication During Transition of Transfer Lever NOTE: After the 4WD AUTO SW and the transfer lever
When the 4WD AUTO SW is selected or the transfer lever is set to the specified position and the AXLE switch
is shifted, and the signals from the AXLE switch do not generates compliant signals, the normal output status is
comply with the signal conditions of the 4H and 4L switch, returned.
the transfer lever position signals generated by the 4H
and 4L switch and the N position signals are repeatedly
output at an interval of 0.8 second.
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–9

C07RW061

Bulb Check NOTE: Once the starter switch is turned on, all the TOD
When the starter switch is turned on, the TOD indicator indicator lamps are lit for two seconds even if the transfer
lamps go on as shown below. lever is in any position.

C07RW016
4B2–10 DRIVE LINE CONTROL SYSTEM (TOD)
Simplified checking method of ABS IN and BRAKE ON signals:
In the event that any of the signal inputs listed below are
observed while the self-diagnostic code is being
displayed (the self-diagnostic connector is short-circuited
to GND), you can simply check the ABS IN and BRAKE
ON signals as shown in the figures below.

C07RW017

Check Lamp
Check Lamp Bulb Check
When the starter switch is turned on in the normal state,
the control unit turns on the CHECK lamp to check the
bulb.

C07RW019
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–11
The CHECK lamp also has the following functions. NOTE: If the TPS has failed, this function might not work.
D-G MAP recognition and display (The control unit 1. When the control unit recognizes the vehicle as
displays what type of vehicle, diesel or gasoline gasoline type, the CHECK lamp is turned on for five
vehicle, it recognizes.) seconds and this mode is repeated at an interval of
1. Short-circuit the self-diagnostic connector. 0.3 second.
2. Turn on the starter switch. (Displays with respect to 2. When the control unit recognizes the vehicle as
the self-diagnosis begin to appear.) diesel type, the CHECK lamp is turned off for five
seconds and this mode is repeated at an interval of
NOTE: Do not start the engine. 0.3 seconds.
3. Shift the transfer lever to the neutral position between 3. Upon completion of step 4, the system resumes the
HIGH and 4L. self-diagnosis. (The self-diagnosis is executed
4. After all the conditions in 1 through 3 above are met, from the beginning.)
set the throttle to the WOT (wide open throttle) 5. Turn off the starter switch once. When above
position (i.e., full open position). The display of the conditions are met again in the future, the TPS MAP
self-diagnosis is temporarily suspended, and the control can be started.
CHECK lamp begins to display that MAP is
recognized by the TPS (throttle position sensor)
according to the current conditions.

C04RW010

If the accelerator wide–open–throttle(WOT) timing check


lamp is on, the subsequent timing will display immediately
after the WOT timing check lamp turns off. If the WOT
timing check lamp is off, the subsequent lamp timing will
display immediately.
4B2–12 DRIVE LINE CONTROL SYSTEM (TOD)

C04RY00011

If the WOT timing check lamp is off, the subsequent


timing will display immediately after the WOT timing
check lamp turns on.
If the WOT timing check lamp is on, the subsequent lamp
timing will display immediately.
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–13

Diagnosis
General Information Diagnosis
The troubles on TOD are classified into the group that can
be identified by the lighting status of the TOD indicator
lamps and those that can be recognized as abnormal
phenomena of the vehicle by the driver.
The troubles that can be identified by the lighting status of
the TOD indicator lamps are examined by the procedures
“Diagnosis from Trouble Codes” and “Trouble Diagnosis
Depending on The Status of TOD indicator”. The troubles
that can be recognized as abnormal phenomena of the
vehicle by the driver are examined by the procedure
“Diagnosis from symptom”.

Self-diagnosis
The control unit has a function of self-diagnosis. If a
trouble occurs in the course of system startup, the control
unit blinks the CHECK lamp and saves the trouble code.

C07RW021

NOTE: If an intermittent fault occurs, the control unit


stops blinking upon removal of the fault. The trouble code
is saved to the control unit.
4B2–14 DRIVE LINE CONTROL SYSTEM (TOD)
Indication Method of Trouble Code If no trouble codes exist, code “12” is displayed
Short-circuit terminal 8 of the self-diagnostic continuously.
connector to GND to display the trouble code on the If trouble codes exist, code “12” is displayed three
CHECK lamp. times, and the trouble codes, starting from the smaller
code number, are displayed three times respectively.

810RW308

C07RW013
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–15
How to Clear The Trouble Code Trouble Intermittently Observed
The trouble codes saved to the control unit can be deleted Troubles intermittently observed are mostly attributable
by the following procedure if the starter switch is being in to temporary imperfect connection of harnesses and
the OFF position. connectors.
1. Shift the transfer lever to the neutral position between When such troubles are found, check the associated
HIGH and 4L, and short-circuit the self-diagnostic circuit according to the following procedure.
connector. 1. Check whether improper connectors are plugged in
NOTE: The neutral position between HIGH and 4L refers or connector terminals are completely engaged.
to the point that turns off the TOD indicator lamps. 2. Check whether the terminals are deformed or
(However, be sure to check the position before damaged. If yes, remove the deformation or damage
short-circuiting the self-diagnostic connector.) and connect the terminals securely.
3. It is likely that wires in the harness are falsely broken.
Therefore, in examination of failed harness circuit,
shake the harness for check to such extent that the
harness will not be damaged.
Test Run of Failed TOD Vehicle
If the TOD indicator lamps experienced faulty operation
even once in the past, the failed portion can be identified
by use of the procedure “Diagnosis from Trouble Codes”
or “Trouble Diagnosis Depending on The Status of TOD
Indicator”. If the troubles that are only recognized as
abnormal phenomena of the vehicle by the driver are
observed, conduct the test run in the following procedure
to reproduce the faulty phenomena and diagnose the fault
for each phenomenon.
1. Start the engine, and check that the TOD indicator
lamps are turned on for about two seconds for initial
check; the CHECK lamp goes off; and the TOD
indicator lamps display the specified drive mode. (If
the CHECK lamp starts blinking, read the trouble
C07RW011 codes and identify the failed portion.)
2. Turn on the starter switch while maintaining the state 2. While keeping the vehicle standstill, operate the 4WD
of step 1, and step on the brake pedal five times within switch and shift the transfer lever to change the
five seconds from the first step on. (Note that “five modes: 2H mode TOD mode 4L mode TOD
times” includes the first step on). (The TOD indicator mode 2H mode. Check that the TOD indicator
lamps display the 4L mode whenever the brake pedal lamps correctly display the status whenever the
is stepped on.) mode is changed. If the transition status is displayed
3. If the conditions shown in steps 1 and 2 are met, the during the shift operation, run the vehicle a little to
trouble codes saved to the control unit are cleared. complete shifting.
(After the codes are completely deleted, the code 12 3. Slowly start the vehicle in the TOD mode, and add the
that indicates the normal condition is continuously power to accelerate to at least 40 km/h and maintain
displayed.) the speed for about two minutes. Apply the brake to
completely stop the vehicle. Repeat this test pattern
Precautions on Diagnosis at least three times.
Replacement of Control Unit 4. Turn the steering to the right end (or left end) in the
The control unit itself rarely fails. In most cases, the TOD mode, and slowly start the vehicle and make a
harnesses have failed (i.e. short-circuit) to cause circle five times. Next, conduct the same test in the 2H
secondary troubles. Other cases include that the cause mode.
has been unknown due to intermittent occurrence of 5. Slowly start the vehicle in the TOD mode, and
troubles and the troubles are removed accidentally along accelerate to at least 40 km/h. Keep the established
with replacement of control unit, resulting in misjudgment speed, carefully change the mode in the sequence
of cause. Therefore, before replacing the control unit, “TOD mode 2H mode TOD mode” while checking
check the connector joints and whether the unspecified that the shift is complete in each mode change. After
current flows in the control unit due to short-circuit the test, apply the brake to completely stop the
between harnesses. vehicle.
6. Slowly start the vehicle in the TOD mode, and
accelerate to at least 40 km/h. Apply the brake
strongly so that the ABS works, and completely stop
the vehicle.
4B2–16 DRIVE LINE CONTROL SYSTEM (TOD)
7. Slowly start the vehicle in the 4L mode, and
accelerate to at least 20 km/h. Apply the brake to
completely stop the vehicle.
If the CHECK lamp starts blinking during the test run, read
the trouble codes and give appropriate maintenance
according to the diagnostic procedure. If the TOD
indicator lamps are lit abnormally during the run, check
the lighting condition and give appropriate maintenance
according to the diagnostic procedure. Even if the
phenomena are not observed, try to reproduce the
abnormal state reported by the customer to the possible
extent.
Post-Repair Check
As long as the starter is not turned off, the TOD indicator
lamps continue blinking even after the failed portion
repaired. Therefore, upon completion of repair, be sure to
turn off the starter switch once and then turn on it to
conduct the test run sequence specified in steps 1
through 7 above and check that the TOD indicator lamps
no longer show any faulty status.
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–17

Basic Diagnostic Flow Chart

C04RY00015
4B2–18 DRIVE LINE CONTROL SYSTEM (TOD)

Parts Location (RHD 6VE1)

D08RW621

Legend (12) M–22


(1) I–9 (13) M–23
(2) B–13 or B–14 (14) M–24
(3) H–12 (15) H–10
(4) I–12 (16) E–5
(5) A–3 (17) E–29
(6) H–7, H–8 (18) H–42
(7) H–32 (19) E–30
(8) C–16 (20) Battery
(9) H–5, H–6 (21) H–13, H–15, H–25, H–26, H–27
(10) C–63 (22) Fuse Box
(11) H–49 (23) B–67, B–68
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–19

Parts Location (RHD 4JX1)

D08RW753

Legend (11) P–17


(1) I–9 (12) P–18
(2) B–13 or B–14 (13) P–19
(3) H–12 (14) A–3
(4) I–12 (15) B–67, B–68
(5) C–63 (16) H–49
(6) H–7, H–8 (17) H–60
(7) H–32 (18) Relay and Fuse Box
(8) C–16 (19) H–15, H–25, H–26, H–27
(9) H–5, H–6 (20) Fuse Box
(10) E–4
4B2–20 DRIVE LINE CONTROL SYSTEM (TOD)

Parts Location (LHD 6VE1)

D08RW367

Legend (11) M–24


(1) I–9 (12) H–10
(2) C–63 (13) H–49
(3) H–7, H–8, H–25, H–26 (14) E–5
(4) H–32 (15) E–30
(5) Fuse Box (16) Relay and Fuse Box
(6) C–6 (17) H–12, H–15
(7) B–13 or B–14 (18) B–67, B–68
(8) H–5, H–6 (19) Not Used
(9) M–22 (20) A–3
(10) M–23 (21) I–12
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–21

Parts Location (LHD 4JX1)

D08RY00610

Legend (10) P–17


(1) I–9 (11) P–18
(2) C–63 (12) P–19
(3) H–15, H–25, H–26 (13) A–3
(4) H–32 (14) Relay and Fuse Box
(5) Fuse Box (15) H–7, H–8
(6) C–16 (16) B–67, B–68
(7) B–14 (17) H–49
(8) H–5, H–6 (18) I–12
(9) E–4
4B2–22 DRIVE LINE CONTROL SYSTEM (TOD)

Circuit Diagram–1 (RHD 6VE1)

D04RY00041
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–23

Circuit Diagram–2 (RHD 6VE1)

D04RY00042
4B2–24 DRIVE LINE CONTROL SYSTEM (TOD)

Circuit Diagram–3 (RHD 6VE1)

D04RY00043
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–25

Circuit Diagram–1 (RHD 4JX1)

D04RY00044
4B2–26 DRIVE LINE CONTROL SYSTEM (TOD)

Circuit Diagram–2 (RHD 4JX1)

D04RY00045
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–27

Circuit Diagram–3 (RHD 4JX1)

D04RY00046
4B2–28 DRIVE LINE CONTROL SYSTEM (TOD)

Circuit Diagram–1 (LHD 6VE1)

D04RY00047
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–29

Circuit Diagram–2 (LHD 6VE1)

D04RY00048
4B2–30 DRIVE LINE CONTROL SYSTEM (TOD)

Circuit Diagram–3 (LHD 6VE1)

D04RY00049
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–31

Circuit Diagram–1 (LHD 4JX1)

D04RY00050
4B2–32 DRIVE LINE CONTROL SYSTEM (TOD)

Circuit Diagram–2 (LHD 4JX1)

D04RY00074
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–33

Circuit Diagram–3 (LHD 4JX1)

D04RY00052
4B2–34 DRIVE LINE CONTROL SYSTEM (TOD)

Connector List
No. Connector face No. Connector face
A-3 E-5
(6VE1)

B-13 E-29
(6VE1)

B-14 E-30
(6VE1)

B-67 H-5
(6VE1)
(4JX1
–A/T)

B-68 H-6

C-16 H-7

C-63 H-8

E-4 H-10
(6VE1)

E-4 H-12
(4JX1)
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–35

No. Connector face No. Connector face


H-13 I-9

H-15 I-12

H-25 M-22

H-26 M-23

H-27 M-24

H-32 P-17
(4JX1)

H-42 P-18
(4JX1)

H-49 P-19
(4JX1)

H-60
4B2–36 DRIVE LINE CONTROL SYSTEM (TOD)

Checking Failed Pin


Connector Pin Assignment
ECU pin assignment

D04RW032
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–37

No. NAME CONTENTS


1 VIG Power supply (IG)
2 N.C Not used
3 4WD OUT 4WD signal output
4 SOL (+) Electromagnetic solenoid
5 ADC (+) Axle disconnect output
6 LIGHTING SW Lighting SW input
7 BRAKE Brake SW input
8 4H SW 4H SW input
9 4L SW 4L SW input
10 AXEL SW AXEL SW input
11 ABS IN Operation signal input
12 TOD SW TOD SW input
13 DIAG Self-diagnosis input
14 D-G MAP D-G MAP recognition input (Only V6 engine)
15 Ref. Vehicle speed sensor supply
16 N.C Not used
17 N.C Not used
18 COM (–) Vehicle speed sensor GND
19 S-GND Sensor GND
20 P-GND Power GND
21 TPS Throttle position sensor
22 TECH 2 TECH 2 output
23 Rer. Sig Rear vehicle speed sensor input
24 Frt. Sig Front vehicle speed sensor input
25 IND.a 4WD display signal a
26 IND.b 4WD display signal b
27 IND.c 4WD display signal c
28 IND.AUTO AUTO display output
29 IND Rr Rear display output
30 CHECK TOD warning lamp
4B2–38 DRIVE LINE CONTROL SYSTEM (TOD)
Reference
Transfer connector pin assignment (connector on the
transfer case)
for inspection of transfer pins.

810RW310

No. NAME CONTENTS


1 Ref. (Rer. ) Rear speed sensor reference output
2 Ref. (Frt. ) Front speed sensor reference output
3 SW GND SW GND
4 4H SW (+) 4H SW plus terminal
5 Rer. (+) Rear speed sensor plus
6 Frt. (+) Front speed sensor plus
7 POWER GND Power GND
8 SOL (+) Electromagnetic solenoid
9 COM (–) (Rer. ) Rear speed sensor GND
10 COM (–) (Frt. ) Front speed sensor GND
11 NC Not used
12 4L SW (+) 4L SW plus terminal
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–39

Checking Failed TOD Control Unit Pin


NOTE: 2. Before removing the ECU, turn off the ignition switch.
1. Unplug the ECU connector and the pins, unless 3. If the standard values are not observed, check the
otherwise specified. pins with other testers.
Check Circuit to be Ignition Engine Multimeter Measure Standard Valve Note
Pin tested Switch State Scale/ between Pin
No. Position Range Number
14 D-G MAP OFF STOP 14, 19 Continuity : OK
(Gasoline)
No continuity : OK
(Diesel)
20 P-GND OFF STOP 20, 19 Continuity : OK
19 GND OFF STOP 19, GND Continuity : OK
8 4H SW OFF STOP 8, 19 No continuity (high,
4L) and continuity
(N) : OK
9 4L SW OFF STOP 9, 19 No continuity (high)
and continuity (4L,
N) : OK
10 AXLE SW ON RUN 10, 19 Continuity : OK Remove ECU and start the engine. Move
the vehicle forth and back to connect axle
surely.
13 DIAG OFF STOP 13 (TOD), 8 Continuity : OK DLC connector terminal 8
(DLC
Connector)
25 IND.a ON STOP DCV 25 (+), 19 (–) 8.0 14.5 V When the indicator lamp is turned off.
26 IND.b ON STOP DCV 26 (+), 19 (–) 8.0 14.5 V When the indicator lamp is turned off.
27 IND.c ON STOP DCV 27 (+), 19 (–) 8.0 14.5 V When the indicator lamp is turned off.
30 CHECK ON STOP DCV 30 (+), 19 (–) 8.0 14.5 V When the indicator lamp is turned off.
LAMP
11 ABS IN ON STOP DCV 11 (+), 19 (–) 11.5 14.5 V
15 Ref. ON STOP DCV 15 (+), 19 (–) 5 9V Connect ECU
24 Ft.(+) ON STOP DCV 24 (+), 19 (–) 0.7 6 V Connect ECU (off one tooth of speed
sensor ring) and move the vehicle making
sure of voltage change.
23 Rr.(+) ON STOP DCV 23 (+), 19 (–) 0.7 6 V Connect ECU (off one tooth of speed
sensor ring) and move the vehicle making
sure of voltage change.
18 COM(-) ON STOP DCV 18 (+), 19 (–) 0V Connect ECU
1 Vig ON STOP DCV 1 (+), 19 (–) 8 14.5 V
7 BRAKE OFF STOP DCV 7 (+), 19 (–) 8 14.5 V Press brake pedal
21 TPS ON STOP DCV 21 (+), 19 (–) 0.2 4.6 V Step on the accelerator pedal and make
sure that voltage changes.
3 4WD OUT OFF STOP 3, 19 7 12 k Disconnect battery GND terminal
5 ADC(+) OFF STOP 5, 19 10 30 Disconnect battery GND terminal
4 SOL(+) OFF STOP 4, 19 1.0 5.0 Disconnect battery GND terminal
12 4WD SW ON STOP DCV 12 (+), 19 (–) SW OFF : 0 V SW OFF : Contact point open
SW ON : 8.0 14.5 V SW ON : Contact point close
6 LIGHTING ON STOP DCV 6 (+), 19 (–) SW OFF : 8.0 14.5
V
SW ON : 0 V
28 AUTO INDI ON STOP DCV 28 (+), 19 (–) TOD : 0 V Connect ECU
2H & 4L : 8.0 14.5
V
29 RR INDI ON STOP DCV 29 (+), 19 (–) 0V Connect ECU. When the indicator lamp is
turned on.
4B2–40 DRIVE LINE CONTROL SYSTEM (TOD)
Tech 2 Scan Tool
From 98 MY, Isuzu dealer service departments are
recommended to use Tech 2. Please refer to Tech 2 scan
tool user guide.

901RW180

Legend (3) SAE 16/19 Adaptor


(1) PCMCIA Card (4) DLC Cable
(2) RS 232 Loop Back Connector (5) Tech–2
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–41

Getting Started Operating Procedure


Before operating the Isuzu PCMCIA card with the The power up screen is displayed when you power up the
Tech 2, the following steps must be performed: tester with the Isuzu systems PCMCIA card. Follow the
1. The Isuzu 00 System PCMCIA card (1) inserts into operating procedure below.
the Tech 2 (5).
2. Connect the SAE 16/19 adapter (3) to the DLC cable
(4).
3. Connect the DLC cable to the Tech 2 (5)
4. Mark sure the vehicle ignition is off.
5. Connect the Tech 2 SAE 16/19 adapter to the vehicle
ALDL/DLC connector.

810RW308

6. The vehicle ignition turns on.


7. Verify the Tech 2 power up display.

060RY027

060RW009

NOTE: The RS232 Loop back connector is only to use for


diagnosis of Tech 2 and refer to user guide of the Tech 2.
4B2–42 DRIVE LINE CONTROL SYSTEM (TOD)

060RY00269
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–43

Diagnostic Trouble Codes


Code Tech 2 code Item Diagnosis Check flow No.
(P code)
12 — Start code Normal —
13 P1735 Ref Shorted GND 6
14 P1731 Front speed sensor Input abnormality (open, sig or com) 2
15 P1736 Ref Shorted VB 6
16 P1737 Front speed sensor Input abnormality 3
21 P1716 TPS Shorted or disconnected wiring, abnormality in 7
input
23 — ECU CPU abnormality 1
24 P1733 Rear speed sensor Input abnormality (open, sig or com) 5
25 — CHECK lamp Shorted 14
26 — EMC (+) Shorted GND 10
27 P1738 Rear speed sensor Input abnormality 4
28 P1760 ADC (+) & AXLE SW Output abnormality 11
31 P1721 EMC (+) Shorted or disconnected coil/wiring 9
32 P1761 ADC (+) Shorted or disconnected coil/wiring 12
33 P1762 ADC (+) Shorted GND 13
34 — D-G MAP Input abnormality 8
35 — CHECK lamp Shorted or disconnected wiring 14
36 — ECU CPU abnormality 1
37 P1712 ECU CPU abnormality 1
38 P1714 ECU CPU abnormality 1

TPS : Throttle Position Sensor


EMC : Electromagnetic coil
ADC : Shift on the fly (Axle Dis Connect)
D-G MAP : Discrimination engine type
4B2–44 DRIVE LINE CONTROL SYSTEM (TOD)

Diagnosis from Trouble Codes


Diagnose the TOD based on the fault that has been
saved to the control unit according to the system
self-diagnostic function.

Check flow Trouble code Phenomenon Standard


1 23, 36, The ECU has failed. —
37(P1712),
38(P1714)

Step Action Yes No


1 Turn on the starter switch. Replace the ECU
and conduct the
Is the trouble reproduced?
test run.
Go to Step 3 Go to Step 2
2 1. Clear the trouble codes. The trouble is not
2. Conduct the test run. reproduced.
Replace the ECU Refer to
Is the trouble reproduced during the test run? and conduct the “Troubles
test run. intermittently
Go to Step 3 observed”.
3 1. Check that all the parts are mounted.
2. Clear the trouble codes.
Repeat the
Is this step complete? “Diagnosis Flow”. Return to Step 3
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–45

Check flow Trouble code Phenomenon Standard


2 14 Front speed sensor signal open or 0.3V > sensor voltage
(P1733) GND short, speed sensor com
open.

NOTE: The following procedure shows the case that the


front or rear sensor reference or common grounding line
is broken.

D04RY00059
4B2–46 DRIVE LINE CONTROL SYSTEM (TOD)

Step Action Yes No


1 1. Start the engine.
2. Select TOD mode.
Is there the memory except DTC 14(P1731)? Go to Step 4 Go to Step 2
2 1. Turn off the starter switch.
2. Disconnect the ECU connector (B–67) and (B–68).
Is there the continuity between the connector (B–68) terminal 12 Repair the circuit.
and connector (B–67) terminal 11? Go to Step 7 Go to Step 3
3 1. Disconnect the transfer connector (A–3).
Is there the continuity between the connector (B–68) terminal 12
and the connector (A–3) terminal 6, the connector (B–67) terminal Replace the front
7 and connector (A–3) terminal 2, and the connector (B–67) speed sensor. Repair the circuit.
terminal 10 and connector (A–3) terminal 10? Go to Step 7 Go to Step 7
4 Is the memory DTC 24(P1733)? Refer to other
trouble check
Go to Step 5 flow.
5 Is there the continuity between harnesses of terminal 24 and 23 Repair the circuit.
(vehicle side terminal of the front and rear speed sensor)? Go to Step 6 Go to Step 7
6 Is there the continuity between harnesses of terminal 18 and 15 Replace front and
(vehicle side terminal of the speed sensor COM(–) and ref)? rear speed
sensor. Repair the circuit.
Go to Step 7 Go to Step 7
7 1. Check that all the parts are mounted.
2. Clear the trouble code.
Is the step complete? Verify the repair. Return to Step 7
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–47

Check flow Trouble code Phenomenon Standard


3 16 The front speed sensor no pulse. Hi level : 4.5 6.0 V
(P1737) Lo level : 0.7 2.0 V
Frequency (F) =
700–850 Hz (at 50 km/h)

NOTE: Find the trouble in which the pulse corresponding


to the running speed is not input.

D04RY00059
4B2–48 DRIVE LINE CONTROL SYSTEM (TOD)

Step Action Yes No


1 1. Connect TECH 2. Repair and
inspection front
While running in TOD mode, does TECH–2’s front speed sensor
speed sensor
indication change with vehicle speed?
tone wheel.
Go to Step 2 Go to Step 6
2 1. Clear the trouble code. The trouble is not
reproduced.
While running at 40 km/h or 25 mph in TOD mode for 30
consecutive sec, is the trouble code reissued? Refer to
“Troubles
intermittently
Go to Step 3 observed”.
3 1. Turn off the starter switch.
2. Disconnect the ECU connector (B–67) and (B–68).
Is there the continuity between the connector (B–68) terminal 12 Repair the circuit.
and connector (B–67) terminal 11? Go to Step 6 Go to Step 4
4 1. Disconnect the transfer connector (A–3).
Is there the continuity between the connector (B–68) terminal 12
and the connector (A–3) terminal 6, the connector (B–67) terminal Replace the front
7 and connector (A–3) terminal 2, and the connector (B–67) speed sensor. Repair the circuit.
terminal 10 and connector (A–3) terminal 10? Go to Step 5 Go to Step 5
5 1. Clear the trouble code.
While running at 40 km/h or 25 mph in TOD mode for 30 Replace ECU.
consecutive sec, is the trouble code reissued? Go to Step 6 Go to Step 6
6 1. Check that all the parts are mounted.
2. Clear the trouble code.
Repeat the
Is this step complete? “Diagnosis Flow”. Return to Step 6
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–49

Check flow Trouble code Phenomenon Standard


4 27 The rear speed sensor no pulse. Hi level : 4.5 6.0 V
(P1738) Lo level : 0.7 2.0 V
Frequency (F) =
700–850 Hz (at 50 km/h)

NOTE: Find the trouble in which the pulse corresponding


to the running speed is not input.

D04RY00059
4B2–50 DRIVE LINE CONTROL SYSTEM (TOD)

Step Action Yes No


1 1. Connect TECH 2. Repair and
inspection front
While running in TOD mode, does TECH–2’s rear speed sensor
speed sensor
indication change with vehicle speed?
tone wheel.
Go to Step 2 Go to Step 6
2 1. Clear the trouble code. The trouble is not
reproduced.
While running at 40 km/h or 25 mph in TOD mode for 30
consecutive sec, is the trouble code reissued? Refer to
“Troubles
intermittently
Go to Step 3 observed”.
3 1. Turn off the starter switch.
2. Disconnect the ECU connector (B–67) and (B–68).
Is there the continuity between the connector (B–68) terminal 11 Repair the circuit.
and connector (B–67) terminal 11? Go to Step 5 Go to Step 4
4 1. Disconnect the transfer connector (A–3).
Is there the continuity between the connector (B–68) terminal 11
and the connector (A–3) terminal 5, the connector (B–67) terminal Replace the rear
7 and connector (A–3) terminal 1, and the connector (B–67) speed sensor. Repair the circuit.
terminal 10 and connector (A–3) terminal 9? Go to Step 5 Go to Step 5
5 1. Clear the trouble code.
While running at 40 km/h or 25 mph in TOD mode for 30 Replace ECU.
consecutive sec, is the trouble code reissued? Go to Step 6 Go to Step 6
6 1. Check that all the parts are mounted.
2. Clear the trouble code.
Repeat the
Is this step complete? “Diagnosis Flow”. Return to Step 6
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–51

Check flow Trouble code Phenomenon Standard


5 24 Rear speed sensor signal open or 0.3V > sensor voltage
(P1733) GND short, speed sensor COM
open.

NOTE: The following procedure shows the case that the


front or rear sensor reference or common grounding line
is broken.

D04RY00059
4B2–52 DRIVE LINE CONTROL SYSTEM (TOD)

Step Action Yes No


1 1. Start the engine.
2. Select TOD mode.
Is there the memory except DTC 24(P1733)? Go to Step 4 Go to Step 2
2 1. Turn off the starter switch.
2. Disconnect the ECU connector (B–67) and (B–68).
Is there the continuity between the connector (B–68) terminal 11 Repair the circuit.
and connector (B–67) terminal 11? Go to Step 7 Go to Step 3
3 1. Disconnect the transfer connector (A–3).
Is there the continuity between the connector (B–68) terminal 11
and the connector (A–3) terminal 5, the connector (B–67) terminal Replace the rear
7 and connector (A–3) terminal 1, and the connector (B–67) speed sensor. Repair the circuit.
terminal 10 and connector (A–3) terminal 9? Go to Step 7 Go to Step 7
4 Is the memory DTC 14(P1731)? Refer to other
trouble cheek
Go to Step 5 flow.
5 Is there the continuity between harnesses of terminal 24 and 23 Repair the circuit
(vehicle side terminal of the front and rear speed sensor)? Go to Step 6 Go to Step 7
6 Is there the continuity between harnesses of terminal 18 and 15 Replace front and
(vehicle side terminal of the speed sensor COM(–) and ref)? rear speed
sensor. Repair the circuit.
Go to Step 7 Go to Step 7
7 1. Check that all the parts are mounted.
2. Clear the trouble code.
Is the step complete? Verify the repair Return to Step 7
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–53

Check flow Trouble code Phenomenon Standard


6 13 The reference is short-circuited to Reference 5V
(P1735) GND.
15 The reference is short-circuited to
(P1736) Vb.

If the reference wire (15) is short-circuited to GND, the


speed signal is not generated. If the wire is short-circuited
to the battery voltage, the signal level becomes faulty.

D04RY00059
4B2–54 DRIVE LINE CONTROL SYSTEM (TOD)

Step Action Yes No


1 1. Start the engine. The trouble is not
reproduced.
Does the voltage between terminals 15 and 19 meet the standard
5V? Refer to “Trouble
intermittently
boserved”.
Or verify repair. Go to Step 2
2 Is the voltage below the standard? Go to Step 3 Go to Step 7
3 1. Turn off the starter switch. The ECU is
2. Disconnect the ECU connector. failed. Replace
Is the continuity established between vehicle harness terminals the ECU.
(B–67)7 and (B–67)11? Go to Step 4 Go to Step 8
4 1. Disconnect the H-49 connector. Short to GND
between (B–67)7
Is the continuity established between floor harness connector
and (H–49)3.
terminals (H-49)3 and (H-49)9?
Repair the circuit.
Go to Step 5 Go to Step 8
5 1. Disconnect the A–3 connector. The reference
harness for the
Is the continuity established between transfer harness connector
front speed
terminals (A–3)2 and (A–3)7?
sensor is
short–circuited to
Replace the front GND. Repair the
speed sensor. circuit.
Go to Step 8 Go to Step 6
6 1. Disconnect the A–3 connector. The reference
harness for the
Is the continuity established between transfer harness connector
rear speed
terminals (A–3)1 and (A–3)7?
sensor is
short–circuited to
Replace the rear GND. Repair the
speed sensor. circuit.
Go to Step 8 Go to Step 8
7 1. Turn off the starter switch.
2. Disconnect the ECU connector. The ECU has
3. Turn on the starter switch. Repair the failed. Replace
Is the battery voltage observed between harness connector harness circuit. the ECU.
terminals (B–67)7 and (B–67)11? Go to Step 8 Go to Step 8
8 1. Check that all the parts are mounted.
2. Clear the trouble code.
Repeat the
Is this step complete? “Diagnosis Flow” Go to Step 8
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–55

Check flow Trouble code Phenomenon Standard


7 21 The voltage of the throttle position
(P1716) sensor (TPS) is faulty.

The signal voltage from the TPS deviates from the stan-
dard range.

D04RY00053
4B2–56 DRIVE LINE CONTROL SYSTEM (TOD)

Step Action Yes No


1 1. Turn off the starter switch. Charge or
replace the
Is the battery voltage normal?
battery.
Go to Step 2 Go to Step 6
2 1. Turn on the starter switch.
Does the voltage between terminals 21 and 19 fall within the
standard range above? Go to Step 3 Go to Step 3
3 1. Turn off the starter switch.
2. Disconnect the ECU connector. The ECU has
3. Turn on the starter switch. failed. Replace
Does the voltage between terminals (B–68)9 and (B–67)11 fall the ECU.
within the standard range above? Go to Step 6 Go to Step 4
4 Is the harness healthy? Repair the
harness.
Go to Step 5 Go to Step 6
5 Is the TPS healthy? Replace the TPS.
Go to Step 6 Go to Step 6
6 1. Check that all the parts are mounted.
2. Clear the trouble code.
Repeat the
Is this step complete? “Diagnosis Flow”. Go to Step 6
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–57

Check flow Trouble code Phenomenon Standard


8 34 The diesel/gasoline engine identifi- 6VE1: Continuity established
cation signal is faulty. 4JX1: No continuity

The engine identification signals of 6VE1 and 4JX1 are


changed each other.

D04RY00053
4B2–58 DRIVE LINE CONTROL SYSTEM (TOD)
6VE1
Step Action Yes No
1 1. Turn off the starter switch. The harness is
broken. Repair
Is the continuity established between terminals 14 and 19?
the circuit.
Go to Step 2 Go to Step 3
2 1. Turn on the starter switch. The phenomenon
is not
Does the voltage between terminals 14 and 19 indicate 0V?
reproduced.
Refer to The ECU has
“Troubles failed. Replace
intermittently the ECU.
observed” Go to Step 3
3 1. Check that all the parts are mounted.
2. Clear the trouble code.
Repeat the
Is this step complete? “Diagnosis Flow”. Return to Step 3
4JX1
Step Action Yes No
1 1. Turn off the starter switch. The harness for
terminal 14 is
Is the continuity established between terminals 14 and 19?
short–circuited to
GND.
Repair the circuit.
Go to Step 3 Go to Step 2
2 1. Turn on the starter switch. The phenomenon
is not
Does the voltage between terminals 14 and 19 indicate 5V?
reproduced.
Refer to The ECU has
“Troubles failed. Replace
intermittently the ECU.
observed” Go to Step 3
3 1. Check that all the parts are mounted.
2. Clear the trouble code.
Repeat the
Is this step complete? “Diagnosis Flow”. Return to Step 3
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–59

Check flow Trouble code Phenomenon Standard


9 31 The electromagnetic coil is broken —
(P1721) or shorted to the battery or GND.

D04RY00060
4B2–60 DRIVE LINE CONTROL SYSTEM (TOD)

Step Action Yes No


1 1. Clear the trouble code.
2. Start the engine
Refer to “Trouble
3. Set the TOD mode.
intermittently
Is there DTC31 (P1721)? Go to Step 2 observed”.
2 1. Turn off the starter switch.
2. Disconnect the ECU connector from ECU.
Is the continuity established between terminals (B–67)4 and
(B–67)12? Go to Step 3 Go to Step 5
3 1. Connect the ECU connector.
2. Start the engine.
3. Set the TOD mode.
Does the voltage between terminals 4 and 20 indicate at least
0.4V? Go to Step 4 Go to Step 6
4 Is the battery voltage always observed between terminals 4 and The harness is
20? short–circuited on
the battery.
Repair the circuit.
Go to Step 8 Go to Step 6
5 1. Disconnect the A–3 connector. Replace the
transfer
Is the continuity established between transfer connector
The harness is electromagnetic
terminals (A–3)8 and (A–3)7?
broken. Repair coil (solenoid
the circuit. clutch).
Go to Step 8 Go to Step 8
6 1. Turn off the starter switch. The ECU has
2. Disconnect the ECU connector from ECU. failed. Replace
Is the resistance between the connector (B–67) terminal 4 and 12 the ECU
1.0 5.0 ? Go to Step 8 Go to Step 7
7 Is the resistance between the transfer connector (A–3) terminal 8 Replace the
and 7 1.0 5.0 ? The harness is transfer
disconnection or electromagnetic
short to GND. coil (solenoid
Repair the circuit. clutch).
Go to Step 8 Go to Step 8
8 1. Check that all the parts are mounted.
2. Clear the trouble code.
Repeat the
Is this step complete? “Diagnosis Flow”. Return to Step 8
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–61

Check flow Trouble code Phenomenon Standard


10 26 The electromagnetic coil is short- Resistance: 1.0 to 5.0 ohm (at
circuited to GND. ordinary temperature)

D04RY00060
4B2–62 DRIVE LINE CONTROL SYSTEM (TOD)

Step Action Yes No


1 1. Turn off the starter switch.
2. Disconnect the ECU connector from ECU.
Does the resistance between terminals (B–67)4 and (B–67)12?
indicate 1.0 to 5.0 ohm? Go to Step 2 Go to Step 3
2 1. Connect the ECU connector. The phenomenon
2. Start the engine. is not
3. Set the TOD mode. reproduced.
Refer to The ECU has
When the throttle is operated between full close and full open failed. Replace
“Troubles
positions, does the voltage between terminals 4 and 20 indicate the ECU.
intermittently
0.1 to 1.0 V? Go to Step 4
observed”.
3 Does the resistance between transfer connector terminals (A–3)8 Replace the
and (A–3)7 indicate 1.0 to 5.0ohm? The harness is transfer
broken. Repair electromagnetic
the circuit. coil.
Go to Step 4 Go to Step 4
4 1. Check that all the parts are mounted.
2. Clear the trouble code.
Repeat the
Is this step complete? “Diagnosis Flow”. Return to Step 4
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–63

Check flow Trouble code Phenomenon Standard


11 28 The shift on the fly system (front —
(P1760) axle disconnect) works incorrectly.

NOTE: The shift on the fly system is not changed


between 2WD and 4WD modes normally.
CAUTION: If code 32 or 33 is also observed, remove
the trouble associated with code 32 or 33 first.

D04RY00061
4B2–64 DRIVE LINE CONTROL SYSTEM (TOD)

D04RY00062
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–65

Step Action Yes No


1 1. Turn on the starter switch.
2. Set the transfer to the 2H mode.
Is the battery voltage observed between terminals 5 and 19? Go to Step 2 Go to Step 5
2 Is 5V observed between terminals 10 and 19? Go to Step 3 Go to Step 6
3 1. Set the transfer to the high (TOD) mode. The ECU has
failed. Replace
Does the voltage between terminals 5 and 19 indicate 0V?
the ECU.
Go to Step 4 Go to Step 7
4 Does the voltage between terminals 10 and 19 indicate 0V? The phenomenon
is not The shift on the
reproduced. fly system is
Refer to failed (refer to
“Troubles Section 4B and
intermittently 4C of Chassis
observed”. Repair Manual).
5 Does the TOD indicator show the 2H mode? See “Trouble
The ECU has Diagnosis
failed. Replace Depending on
the ECU. The Status of
Go to Step 7 TOD Indicator”.
6 Set the transfer to the high (TOD) mode. The shift on the
fly system has
Does the voltage between terminals 5 and 19 indicate 0V? The ECU has
failed (refer to
Section 4B1 and failed. Replace
4C of Chassis the ECU.
Repair Manual). Go to Step 7
7 1. Check that all the parts are mounted.
2. Clear the trouble code.
Repeat the
Is this step complete? “Diagnosis Flow”. Return to Step 7
4B2–66 DRIVE LINE CONTROL SYSTEM (TOD)

Check flow Trouble code Phenomenon Standard


12 32 The on/off signal (ADC) line of the
(P1761) shift on the fly system (front axle

disconnect) is broken, or the line is
short-circuited to the battery.

NOTE: The on/off signal line of the shift on the fly system
is broken, or the line is short–circuited to the battery.

D04RY00061
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–67

D04RY00062
4B2–68 DRIVE LINE CONTROL SYSTEM (TOD)

Step Action Yes No


1 1. Turn off the starter switch. The harness is
2. Disconnect the ECU connector from ECU. broken. Repair
Is the continuity established between terminals (B–67)5 and the circuit.
(B–67)11? Go to Step 2 Go to Step 3
2 Does the voltage between terminals (B–67) 5 and (B–67) 11 The battery is
indicate 0V? short-circuited.
Repair the circuit.
Go to Step 3 Go to Step 4
3 1. Turn off the starter switch. The phenomenon
2. Connect ECU connector. is not reproduced
3. Turn on the starter switch. Refer to The ECU has
4. Set the transfer to the 2H mode. “Troubles failed. Replace
intermittently the ECU.
Is the battery voltage observed between terminals 5 and 19?
observed”. Go to Step 4
4 1. Check that all the parts are mounted.
2. Clear the trouble code.
Repeat the
Is this step complete? “Diagnosis Flow”. Return to Step 4
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–69

Check flow Trouble code Phenomenon Standard


13 33 The ADC line is short-circuited to —
(P1762) GND.

NOTE:
The on/off signal line of the shift on the fly system is
short–circuited to GND.
The system enters into the fail-safe mode because of
fusing or system protection.
(If a short–circuit is observed on GND, the output to
the on/off signal line becomes 0V.)

D04RY00061
4B2–70 DRIVE LINE CONTROL SYSTEM (TOD)

D04RY00062
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–71

Step Action Yes No


1 1. Turn off the starter switch. The phenomenon
2. Disconnect the ECU connector from ECU. is not
reproduced.
Does the resistance between terminals (B–67) 5 and (B–67) 11
Refer to
meet the standard, 17<R<25 ohms?
“Troubles
intermittently
observed”. Go to Step 2
2 Is the resistance between terminals (B–67) 5 and (B–67) 11 R<2 The signal line
ohms? circuit of the shift
on the fly system
is short-circuited
to GND. Repair
the circuit.
Go to Step 4 Go to Step 3
3 Is the resistance between terminals (B–67) 5 and (B–67) 11 R= The signal line
9 7ohms? circuit of the shift
on the fly system
is layer
short-circuited*.
Replace the valve
(VSV).
Go to Step 4 Go to Step 4
4 1. Check that all the parts are mounted.
2. Clear the trouble code.
Repeat the
Is this step complete? “Diagnosis Flow”. Return to Step 4
*Layer short-circuit : The coil is damaged by overcurrent.
4B2–72 DRIVE LINE CONTROL SYSTEM (TOD)

Check flow Trouble code Phenomenon Standard


14 25 The CHECK lamp indicator line is —
short–circuited to the battery.
35 The line is broken or short–circuited —
to GND.

D04RY00063
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–73

Step Action Yes No


1 1. Turn on the starter switch.
Is the CHECK lamp always turned on? Go to Step 2 Go to Step 3
2 1. Turn off the starter switch. The CHECK
2. Disconnect the ECU connector. circuit is
3. Turn on the starter switch. short-circuited to The ECU has
GND. Repair the failed. Replace
Is the CHECK lamp always turned on?
circuit. the ECU.
Go to Step 7 Go to Step 7
3 Turn on the starter switch.
Is the CHECK lamp always turned off? Go to Step 4 Go to Step 6
4 Turn on the starter switch. The CHECK
circuit wires are
Is the battery voltage observed between terminals 30 and 19?
broken or the
CHECK lamp is
failed. Repair the
circuit.
Go to Step 5 Go to Step 7
5 Turn off the starter switch. The battery is
short–circuited.
Is the battery voltage observed between terminals 30 and 19?
Repair the The ECU has
CHECK lamp failed. Replace
circuit. the ECU.
Go to Step 7 Go to Step 7
6 Turn on the starter switch. The phenomenon
is not
Does the CHECK lamp go off two seconds after?
reproduced.Refer
to “Troubles
intermittently
observed”. Go to Step 7
7 1. Check that all the parts are mounted.
2. Clear the trouble code.
Repeat the
Is this step complete? “Diagnosis Flow”. Return to Step 7
4B2–74 DRIVE LINE CONTROL SYSTEM (TOD)

Trouble Diagnosis Depending on The


Status of TOD Indicator
Functional check with TOD indicator light is conducted
prior to check on Charts A–H.
After the starter is switched on, check and see if the
status has become as tabulated below.

C07RW012–1

If the status is as tabulated above, there is no


problem. If not as tabulated above, inspect the
harness.
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–75

Chart A Indicator drive circuit


Function of circuit The circuit informs the indicator of the working condition of the ECU.
Fail condition All the TOD indicator lamps and CHECK lamp are lit, and go off momentarily at an
interval of about two seconds.
Indicator lamp status

Transfer position 2H, TOD, 4L —

D04RY00114
4B2–76 DRIVE LINE CONTROL SYSTEM (TOD)

D04RY00115

Step Action Yes No


1 Turn on the starter switch. The ECU has
failed. Replace Check the battery
Is the battery voltage observed between terminals 1 and 19? circuit.
the ECU.
Go to Step 2 Go to Step 2
2 Check that all the parts are mounted.
Repeat the
Is this step complete? “Diagnosis Flow”. Return to Step 2
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–77

Chart B–1 The 4WD AUTO switch circuit wires are broken or short-circuited to the GND
Function of circuit —
Fail condition Even after the transfer mode is selected from TOD to 2H, the indicator lamp status is not
changed.
Indicator lamp status

Transfer position 2H —

D04RY00114
4B2–78 DRIVE LINE CONTROL SYSTEM (TOD)

D04RY00115
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–79

Step Action Yes No


1 1. Turn on the starter switch. Repair the 4WD
When the 4WD SW is selected to the 4WD position, is 0 V AUTO SW circuit.
observed between terminal 12 and 19? Go to Step 2 Go to Step 4
2 When the 4WD AUTO SW is selected to the 2WD position, is 12 V Repair the 4WD
observed between terminals 12 and 19? AUTO SW circuit.
Go to Step 3 Go to Step 4
3 When the transfer lever is shifted to the 4L position, is battery The phenomenon
voltage observed between terminals 28 and 19? is not
reproduced.
Refer to
“Troubles Replace the
intermittently ECU.
observed”. Go to Step 4
4 Check that all the parts are mounted.
Repeat the
Is this step complete? “Diagnosis Flow”. Return to Step 4
4B2–80 DRIVE LINE CONTROL SYSTEM (TOD)

Chart B–2 The 4WD AUTO switch circuit is short to battery.


Function of circuit —
Fail condition Even after the transfer mode is selected from 2H to TOD, the indicator lamp status dose
not change.
Indicator lamp status

Transfer position TOD

D04RY00114
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–81

D04RY00115
4B2–82 DRIVE LINE CONTROL SYSTEM (TOD)

Step Action Yes No


1 When the 4WD AUTO SW is selected to the 4WD position, is 0 V Repair the 4WD
observed between terminal 12 and 19? AUTO SW circuit.
Go to Step 2 Go to Step 7
2 When the 4WD AUTO SW is selected to the 2WD position, is 12 V Repair the 4WD
observed between terminals 12 and 19? AUTO SW circuit.
Go to Step 3 Go to Step 7
3 1. Disconnect the ECU connector. Replace TOD
indicator lamp
Is the continuity established between terminals (B–67)1 and
bulb.
(B–68)13?
Go to Step 4 Go to Step 7
4 Is the continuity established between terminals (B–67)1 and Replace TOD
(B–68)14? indicator lamp
bulb.
Go to Step 5 Go to Step 7
5 Is the continuity established between terminals (B–67)1 and Replace TOD
(B–68)15? indicator lamp
bulb.
Go to Step 6 Go to Step 7
6 Is the continuity established between terminals (B–67)1 and Replace TOD
(B–68)16? indicator lamp
Replace ECU. bulb.
Go to Step 7 Go to Step 7
7 Check that all the parts are mounted.
Repeat the
Is this step complete? “Diagnosis Flow”. Return to Step 7
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–83

Chart C–1 4H switch circuit wires are broken or the battery is short-circuited.
Function of circuit —
Fail condition When the 4WD AUTO SW is 4WD mode.
When the lever is shifted from 4L to HIGH, the 4L mode remains on the indicator and the
TOD mode is displayed without turning off the previous mode.
Indicator lamp status

Transfer position 4L <——> Neutral <——> TOD

D04RY00114
4B2–84 DRIVE LINE CONTROL SYSTEM (TOD)

D04RY00115
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–85

Step Action Yes No


1 1. Turn on the starter switch.
When the transfer lever is shifted to the high position, is 5V
observed between terminals 8 and 19 (4H switch)? Go to Step 2 Go to Step 4
2 When the transfer lever is shifted to the 4L position, is 5V
observed between terminals 8 and 19 (4H switch)? Go to Step 3 Go to Step 4
3 When the transfer lever is shifted to the neutral position, is 0V Replace the
observed between terminals 8 and 19 (4H switch)? ECU.
Go to Step 13 Go to Step 4
4 1. Turn off the starter switch.
2. Disconnect the ECU connector.
3. Turn on the starter switch.
When the transfer lever is shifted to the high position, is 12V
observed between terminals 8 and 19 (4H switch)? Go to Step 5 Go to Step 7
5 When the transfer lever is shifted to the neutral position, is 0V
observed between terminals 8 and 19 (4H switch)? Go to Step 6 Go to Step 7
6 When the transfer lever is shifted to the 4L position, is 12V The 4H switch
observed between terminals 8 and 19 (4H switch)? circuit is
short-circuited
between ECU
and transfer on
battery.Repair the
circuit.
Go to Step 13 Go to Step 7
7 Turn off the starter switch.
When the transfer lever is shifted to the neutral position, is the
continuity established between terminals 8 and 19 (4H switch)? Go to Step 8 Go to Step 10
8 When the transfer lever is shifted to the high position, is the
continuity established between terminals 8 and 19? Go to Step 11 Go to Step 9
9 When the transfer lever is shifted to the 4L position, is the The ECU has
continuity established between terminals 8 and 19? failed.
Replace the
ECU.
Go to Step 12 Go to Step 13
10 When the transfer lever is shifted to the neutral position, is the The 4H switch
continuity established between terminals (A–3)4 and (A–3)7? circuit is broken
between ECU
and Repair the
transfer.Repair transfer
the circuit. assembly.
Go to Step 13 Go to Step 13
11 When the transfer lever is shifted to the high position, is the Repair the
continuity established between transfer connector terminals transfer Repair the 4HSW
(A–3)4 and (A–3)7? assembly. circuit.
Go to Step 13 Go to Step 13
12 When the transfer lever is shifted to the 4L position, is the Repair the
continuity established between transfer connector terminals transfer Repair the 4H
(A–3)7 and (A–3)4? assembly. SW circuit.
Go to Step 13 Go to Step 13
4B2–86 DRIVE LINE CONTROL SYSTEM (TOD)

Step Action Yes No


13 Check that all the parts are mounted.
Repeat the
Is this step complete? “Diagnosis Flow”. Return to Step 13
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–87

Chart C–2 The 4H switch circuit is short-circuited to GND.


Function of circuit —
Fail condition When the transfer lever is shifted to 4L, the indicator lamp status is not changed.
Indicator lamp status

Transfer position 4L

D04RY00114
4B2–88 DRIVE LINE CONTROL SYSTEM (TOD)

D04RY00115
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–89

Step Action Yes No


1 When the transfer lever is shifted to the High position, is 5V
observed between terminals 8 and 19 (4H switch)? Go to Step 2 Go to Step 14
2 When the transfer lever is shifted to the neutral position, is 0V
observed between terminals 8 and 19 (4H switch)? Go to Step 3 Go to Step 14
3 When the transfer lever is shifted to the 4L position, is 5V
observed between terminals 8 and 19 (4H switch)? Go to Step 4 Go to Step 14
4 1. Turn off the starter switch. Replace TOD
indicator lamp
Is the continuity established between terminals 1 and 25?
bulb, or repair the
circuit.
Go to Step 5 Go to Step 23
5 Is the continuity established between terminals 1 and 26? Replace TOD
indicator lamp
bulb, or repair the
circuit.
Go to Step 6 Go to Step 23
6 Is the continuity established between terminals 1 and 27? Replace TOD
indicator lamp
bulb, or repair the
circuit.
Go to Step 7 Go to Step 23
7 Is the continuity established between terminals 1 and 28? Replace TOD
indicator lamp
bulb, or repair the
circuit.
Go to Step 8 Go to Step 23
8 Is the continuity established between terminals 1 and 29? Replace TOD
indicator lamp
bulb, or repair the
circuit.
Go to Step 9 Go to Step 23
9 1. Turn on the starter switch. The ECU has
2. Shift the transfer lever is shifted to the 4L position. failed. Replace
the ECU.
Is 0 V observed between terminals 25 and 20?
Go to Step 10 Go to Step 23
10 Is 0 V observed between terminals 26 and 20? The ECU has
failed. Replace
the ECU.
Go to Step 11 Go to Step 23
11 Is 0 V observed between terminals 27 and 20? The ECU has
failed. Replace
the ECU.
Go to Step 12 Go to Step 23
12 Is 12 V observed between terminals 28 and 20? The ECU has
failed. Replace
the ECU.
Go to Step 13 Go to Step 23
13 Is 0 V observed between terminals 29 and 20? The phenomenon
is not
reproduced.
Refer to The ECU has
“Troubles failed. Replace
intermittently the ECU.
observed”. Go to Step 23
4B2–90 DRIVE LINE CONTROL SYSTEM (TOD)

Step Action Yes No


14 1. Turn off the starter switch.
2. Disconnect the ECU connector.
When the transfer lever is shifted to the neutral position, is the
continuity established between terminals (B–68)3 and (B–67)11
(4H switch)? Go to Step 15 Go to Step 17
15 When the transfer lever is shifted to the high position, is the
continuity established between terminals (B–68)3 and (B–67)11? Go to Step 17 Go to Step 16
16 When the transfer lever is shifted to the 4L position, is the The ECU has
continuity established between terminals (B–68)3 and (B–67)11? failed. Replace
the ECU.
Go to Step 17 Go to Step 23
17 1. Disconnect the H–49 connector.
When the transfer lever is shifted to the neutral position between
high and 4L, is the continuity established between terminals
(H-49)6 and (B-67)11? Go to Step 18 Go to Step 20
18 When the transfer lever is shifted to the high position, is the
continuity established between transfer connector terminals
(H-49)6 and (B-67)11? Go to Step 20 Go to Step 19
19 When the transfer lever is shifted to the 4L position, is the GND is
continuity established between transfer connector terminals short-circuited
(H-49)6 and (B-67)11? between
terminals (B-68)3
and (H-49)6.
Repair the circuit.
Go to Step 20 Go to Step 23
20 1. Disconnect the A–3 connector. Repair the
When the transfer lever is shifted to the neutral position between transfer
high and 4L, is the continuity established between terminals assembly.
(A-3)4 and (A-3)7? Go to Step 21 Go to Step 23
21 When the transfer lever is shifted to the high position, is the Repair the
continuity established between terminals (A-3)4 and (A-3)7? transfer
assembly.
Go to Step 23 Go to Step 22
22 When the transfer lever is shifted to the 4L position, is the GND is
continuity established between terminals (A-3)4 and (A-3)7? short-circuited
between
Repair the terminals (B-68)3
transfer and (A–3)4.
assembly. Repair the circuit.
Go to Step 23 Go to Step 23
23 Check that all the parts are mounted.
Repeat the
Is this step complete? “Diagnosis Flow”. Return to Step 23
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–91

Chart D–1 4L switch circuit wires are broken or the battery is short-circuited.
Function of circuit —
Fail condition The TOD mode is displayed in the neutral position between high and 4L. When the lever
is shifted to the 4L position, the TOD mode is displayed.
Indicator lamp status

Transfer position 4L Neutral

D04RY00054
4B2–92 DRIVE LINE CONTROL SYSTEM (TOD)

Step Action Yes No


1 Turn on the starter switch.
When the transfer lever is shifted to the high position, is 5V
observed between terminals 9 and 19 (4L switch)? Go to Step 2 Go to Step 4
2 When the transfer lever is shifted to the neutral position, is 0V
observed between terminals 9 and 19 (4L switch)? Go to Step 3 Go to Step 4
3 When the transfer lever is shifted to the 4L position, is 0V The ECU has
observed between terminals 9 and 19 (4L switch)? failed. Replace
the ECU.
Go to Step 13 Go to Step 4
4 1. Turn off the starter switch.
2. Disconnect the ECU connector.
3. Turn on the starter switch.
When the transfer lever is shifted to the high position, is 12V
observed between terminals (B–68)4 and (B–67)11? Go to Step 5 Go to Step 7
5 When the transfer lever is shifted to the neutral position, is 0V
observed between terminals (B–68)4 and (B–67)11? Go to Step 6 Go to Step 7
6 When the transfer lever is shifted to the 4L position, is 0V The 4L switch
observed between terminals (B–68)4 and (B–67)11? circuit is
short-circuited on
battery between
ECU and
transfer.Repair
the circuit.
Go to Step 13 Go to Step 7
7 Turn off the starter switch.
When the transfer lever is shifted to the high position, is the
continuity established between terminals (B–68)4 and (B–67)11? Go to Step 12 Go to Step 8
8 When the transfer lever is shifted to the neutral position between
high and 4L, is the continuity established between terminals
(B–68)4 and (B–67)11? Go to Step 9 Go to Step 10
9 When the transfer lever is shifted to the 4L position, is the The phenomenon
continuity established between terminals (B–68)4 and (B–67)11? is not
reproduced.
Refer to
“Troubles
intermittently
observed”. Go to Step 11
10 1. Disconnect the A–3 connector. Wires are broken
between transfer
When the transfer lever is shifted to the neutral position between
connector
high and 4L, is the continuity established between transfer
(A–3)12 and
connector terminals (A–3)12 and GND?
connector Repair the
(B-68)4.Repair transfer
the circuit. assembly.
Go to Step 13 Go to Step 13
11 When the transfer lever is shifted to the 4L position, is the Wires are broken
continuity established between transfer connector terminals between transfer
(A–3)12 and GND? connector
(A–3)12 and
connector Repair the
(B-68)4.Repair transfer
the circuit. assembly.
Go to Step 13 Go to Step 13
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–93

Step Action Yes No


12 When the transfer lever is shifted to the high position, is the Wires are broken
continuity established between transfer connector terminals between transfer
(A–3)12 and GND? connector
(A–3)12 and
Repair the connector
transfer (B-68)4.Repair
assembly. the circuit.
Go to Step 13 Go to Step 13
13 Check that all the parts are mounted.
Repeat the
Is this step complete? “Diagnosis Flow”. Return to Step 13
4B2–94 DRIVE LINE CONTROL SYSTEM (TOD)

Chart D–2 The 4L switch circuit is short-circuited to GND.


Function of circuit —
Fail condition The 4L mode is displayed even in the 2H or TOD.
Indicator lamp status

Transfer position HIGH (2H or TOD)

D04RY00064
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–95

D04RY00065
4B2–96 DRIVE LINE CONTROL SYSTEM (TOD)

Step Action Yes No


1 When the transfer lever is shifted to the high position, is 5V
observed between terminals 9 and 19 (4L switch)? Go to Step 2 Go to Step 7
2 When the transfer lever is shifted to the neutral position, is 0V
observed between terminals 9 and 19 (4L switch)? Go to Step 3 Go to Step 7
3 When the transfer lever is shifted to the 4L position, is 0V
observed between terminals 9 and 19 (4L switch)? Go to Step 4 Go to Step 7
4 1. Shift the 4WD AUTO SW to the 2H position. The ECU has
failed. Replace
Is 12V observed between terminals 25 and 19?
the ECU.
Go to Step 5 Go to Step 16
5 Is 12V observed between terminals 26 and 19? The ECU has
failed. Replace
the ECU.
Go to Step 6 Go to Step 16
6 Is 12V observed between terminals 27 and 19? The phenomenon
is not
reproduced.
Refer to The ECU has
“Troubles failed. Replace
intermittently the ECU.
observed”. Go to Step 16
7 1. Turn off the starter switch.
2. Disconnect the ECU connector.
When the transfer lever is shifted to the neutral position between
High and 4L, is the continuity established between terminals
(B–68)4 and (B–67)11? Go to Step 8 Go to Step 10
8 When the transfer lever is shifted to the 4L position, is the
continuity established between terminals (B–68)4 and (B–67)11? Go to Step 9 Go to Step 10
9 When the transfer lever is shifted to the high position, is the The ECU has
continuity established between terminals (B–68)4 and (B–67)11? failed. Replace
the ECU.
Go to Step 10 Go to Step 16
10 1. Disconnect the H-49 connector.
When the transfer lever is shifted to the neutral position between
high and 4L, is the continuity established between terminals
(H-49)5 and (B-67)11? Go to Step 11 Go to Step 13
11 When the transfer lever is shifted to the 4L position, is the
continuity established between transfer connector terminals
(H-49)5 and (B-67)11? Go to Step 12 Go to Step 13
12 When the transfer lever is shifted to the high position, is the GND is
continuity established between terminals (H-49)5 and (B-67)11? short-circuited
between
terminals (B–68)4
and (H-49)5.
Repair the circuit.
Go to Step 13 Go to Step 16
13 1. Disconnect the A-3 connector. Repair the
When the transfer lever is shifted to the neutral position between transfer
high and 4L, is the continuity established between terminals assembly.
(A-3)12 and GND? Go to Step 14 Go to Step 16
14 When the transfer lever is shifted to the 4L position, is the Repair the
continuity established between terminals (A-3)12 and GND? transfer
assembly.
Go to Step 15 Go to Step 16
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–97

Step Action Yes No


15 When the transfer lever is shifted to the high position, is the GND is
continuity established between terminals (A-3)12 and GND? short-circuited
between
Repair the terminals (H–49)5
transfer and (A-3)12.
assembly. Repair the circuit.
Go to Step 16 Go to Step 16
16 Check that all the parts are mounted.
Repeat the
Is this step complete? “Diagnosis Flow”. Return to Step 16
4B2–98 DRIVE LINE CONTROL SYSTEM (TOD)

Chart E–1 AXLE switch circuit wires are broken.


Function of circuit —
Fail condition Both the TOD and 4L modes are disabled. (The transition status is not removed.)
Indicator lamp status

Transfer position TOD 4L

D04RY00068
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–99

D04RY00069
4B2–100 DRIVE LINE CONTROL SYSTEM (TOD)

D04RY00070
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–101

D04RY00071
4B2–102 DRIVE LINE CONTROL SYSTEM (TOD)

Step Action Yes No


1 Start the engine.
When the transfer lever is shifted to the neutral position between
high and 4L, is 5V observed between terminals 10 and 19? Go to Step 2 Go to Step 7
2 When the transfer lever is shifted to the high position and 4WD
AUTO SW is selected to the 4WD position, is 0V observed
between terminals 10 and 19? Go to Step 3 Go to Step 7
3 When the transfer lever is shifted to the 4L position, is 0V The ECU has
observed between terminals 10 and 19? failed. Replace
the ECU.
Go to Step 4 Go to Step 7
4 Shift the transfer lever to the 4L position. The ECU has
failed. Replace
Is 0V observed between terminals 25 and 19?
the ECU.
Go to Step 5 Go to Step 19
5 Is 0V observed between terminals 26 and 19? The ECU has
failed. Replace
the ECU.
Go to Step 6 Go to Step 19
6 Is 0V observed between terminals 27 and 19? The phenomenon
is not
reproduced.
Refer to The ECU has
“Troubles failed. Replace
intermittently the ECU.
observed”. Go to Step 19
7 When the transfer lever is shifted to the high position and 4WD
AUTO SW is selected to the 2H position, is the battery voltage
observed between terminals 5 and 19? Go to Step 8 Go to Step 11
8 When the transfer lever is shifted to the neutral position between
high and 4L, is the battery voltage observed between terminals 5
and 19? Go to Step 9 Go to Step 11
9 When the transfer lever is shifted to the high position and 4WD
AUTO SW is selected to the 4WD position (TOD mode), is 0V
observed between terminals 5 and 19? Go to Step 10 Go to Step 11
10 When the transfer lever is shifted to the 4L position, is 0V
observed between terminals 5 and 19? Go to Step 12 Go to Step 11
11 Is any of the trouble codes 28, 32 and 33 recorded? Examine the
trouble based on The ECU has
“Diagnosis from failed. Replace
Trouble Codes”. the ECU.
12 1. Turn off the starter switch. Repair the circuit
2. Disconnect the ECU connector. or replace the
Does the resistance between terminals (B–67)5 and (B–67)11 VSV.
meet the standard, 17< R < 25 ohm? Go to Step 13 Go to Step 19
13 1. Turn on the starter switch. Repair the circuit
or replace the
When the 4WD AUTO SW is selected to the 2WD position, is the
VSV.
battery voltage supplied to each VSV?
Go to Step 14 Go to Step 19
14 When the transfer lever is shifted to the neutral position between Repair the circuit
high and 4L, is the battery voltage supplied to each VSV? or replace the
VSV.
Go to Step 15 Go to Step 19
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–103

Step Action Yes No


15 When the transfer lever is shifted to the high position and 4WD Repair the circuit
AUTO SW is selected to the 4WD position, is 0V observed on or replace the
each VSV? VSV.
Go to Step 16 Go to Step 19
16 When the transfer lever is shifted to the 4L position, is 0V Repair the circuit
observed on each VSV? or replace the
VSV.
Go to Step 17 Go to Step 19
17 Is the vacuum pressure supplied to the VSV? Repair the
vacuum system.
Go to Step 18 Go to Step 19
18 Can the single AXLE switch enable and disable the continuity? Replace the
AXLE switch
Repair the shift (refer to Section
on the fly system 4B1 and 4C of
(refer to Section Chassis Repair
4B1 and 4C.) Manual).
19 Check that all the parts are mounted.
Repeat the
Is this step complete? “Diagnosis Flow”. Return to Step 19
4B2–104 DRIVE LINE CONTROL SYSTEM (TOD)

Chart E–2 The AXLE switch circuit is short-circuited to GND.


Function of circuit —
Fail condition Even after the 4WD AUTO SW is select to the 2WD position, the 2WD mode is not
enabled. (The transition status is not removed.)
Indicator lamp status

Transfer position 2H

D04RY00068
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–105

D04RY00069
4B2–106 DRIVE LINE CONTROL SYSTEM (TOD)

D04RY00070
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–107

D04RY00071
4B2–108 DRIVE LINE CONTROL SYSTEM (TOD)

Step Action Yes No


1 Start the engine.
When the transfer lever is shifted to the neutral position between
high and 4L, is 5V observed between terminals 10 and 19? Go to Step 2 Go to Step 7
2 When the transfer lever is shifted to the high position and 4WD
AUTO SW is selected to the 4WD position, is 0V observed
between terminals 10 and 19? Go to Step 3 Go to Step 7
3 When the transfer lever is shifted to the 4L position, is 0V
observed between terminals 10 and 19? Go to Step 4 Go to Step 7
4 Select the 4WD AUTO SW to the 2WD position. Replace the
ECU.
Is 12V observed between terminals 25 and 19?
Go to Step 5 Go to Step 19
5 Is 12V observed between terminals 26 and 19? Replace the
ECU.
Go to Step 6 Go to Step 19
6 Is 12V observed between terminals 27 and 19? The phenomenon
is not
reproduced.
Refer to The ECU has
“Troubles failed. Replace
intermittently the ECU.
observed”. Go to Step 19
7 When the 4WD AUTO SW is selected to the 2WD position, is the
battery voltage observed between terminals 5 and 19? Go to Step 8 Go to Step 11
8 When the transfer lever is shifted to the neutral position between
high and 4L, is the battery voltage observed between terminals 5
and 19? Go to Step 9 Go to Step 11
9 When the transfer lever is shifted to the high position and 4WD
AUTO SW is selected to the 4WD position, is 0V observed
between terminals (B–67)5 and (B–67)11? Go to Step 10 Go to Step 11
10 When the transfer lever is shifted to the 4L position, is 0V
observed between terminals 5 and 19? Go to Step 12 Go to Step 11
11 Is any of the trouble codes 28, 32 and 33 recorded? Examine the
trouble based on The ECU has
“Diagnosis from failed. Replace
Trouble Codes”. the ECU.
12 1. Turn off the starter switch. Repair the circuit
2. Disconnect the ECU connector. or replace the
Does the resistance between terminals 5 and 19 meet the VSV.
standard, 17< R < 25 ohm? Go to Step 13 Go to Step 19
13 1. Connect the ECU connector. Repair the circuit
2. Turn on the starter switch. or replace the
When the 4WD AUTO SW is selected to the 2WD position, is the VSV.
battery voltage supplied to each VSV? Go to Step 14 Go to Step 19
14 When the transfer lever is shifted to the neutral position between Repair the circuit
high and 4L, is the battery voltage supplied to each VSV? or replace the
VSV.
Go to Step 15 Go to Step 19
15 When the transfer lever is shifted to the high position and 4WD Repair the circuit
AUTO SW is selected to the 4WD position, is 0V observed on or replace the
each VSV? VSV.
Go to Step 16 Go to Step 19
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–109

Step Action Yes No


16 When the transfer lever is shifted to the 4L position, is 0V Repair the circuit
observed on each VSV? or replace the
VSV.
Go to Step 17 Go to Step 19
17 Is the vacuum pressure supplied to the VSV? Repair the
vacuum system.
Go to Step 18 Go to Step 19
18 Can the single AXLE switch enable and disable the continuity? Repair the shift Replace the
on the fly system AXLE switch
Refer to Section Refer to Section
4B1 and 4C. 4B1 and 4C.
Go to Step 19 Go to Step 19
19 Check that all the parts are mounted.
Repeat the
Is this step complete? “Diagnosis Flow”. Return to Step 19
4B2–110 DRIVE LINE CONTROL SYSTEM (TOD)

Chart G The trouble codes are displayed.


Function of circuit —
Fail condition

Indicator lamp status

Transfer position —
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–111

D04RY00072

Step Action Yes No


1 Disconnect the ECU connector from ECU. The ECU has
failed. Replace
Is the continuity established between terminals (B–68)8 and
the ECU.
(B–67)11?
Go to Step 2 Go to Step 3
2 Is the self-diagnostic connector short-circuited? Repair the
self-diagnostic
connector circuit.
Go to Step 3 Go to Step 3
3 1. Check that all the parts are mounted.
2. Clear the trouble codes.
Repeat the
Is this step complete? “Diagnosis Flow”. Return to Step 3
4B2–112 DRIVE LINE CONTROL SYSTEM (TOD)

Chart H lighting switch circuit


Function of circuit Reads in the status of lighting switch and reduces the indicator brightness at night.
Fail condition Even if the lighting switch is pressed on and off, brightness does not change.
Indicator lamp status

Transfer position All position (example TOD mode)

D04RY00073
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–113

Step Action Yes No


1 1. Disconnect ECU connector. Wirers are broken
2. Turn on the starter switch. lighting SW
circuit. Repair
Is battery voltage observed between ECU terminals (B–68)1 and
the circuit.
(B–67)11?
Go to Step 2 Go to Step 4
2 Turn lighting SW “ON”. Lighting SW
circuit battery
Is 0 V observed between ECU terminal (B–68)1 and (B–67)11?
short. Repair the
circuit.
Go to Step 3 Go to Step 4
3 Connect ECU terminal. The phenomenon
is not
While the lighting switch is pressed on and off, does the
reproduced.
brightness of the indicator change? The ECU has
Refer to
“Troubles failed. Replace
intermittently the ECU.
observed” Go to Step 4
4 Check that all the parts are mounted.
Repeat the
Is this step complete? “Diagnosis Flow”. Return to Step 4
4B2–114 DRIVE LINE CONTROL SYSTEM (TOD)

Diagnosis from Symptom


Troubles that are not indicated by the warning lamp are
listed in the table below. These troubles are caused by
the faults that cannot be detected by the self-diagnostic
function of the control unit.
If this type of trouble is observed, interview the customer
and conduct test runs to reproduce the trouble,
cross-check the reported trouble with the listed
phenomena, and diagnose and analyze the trouble on the
item by item basis.
Phenomena Major cause Corrective action
1 The tight corner braking is The standard tires are not used. Check and recondition the
observed when the vehicle is The tire pressure is incorrect. vehicle according to Chart 1.
subject to full steering.
The tires are worn inuniformity.
The transfer or wiring is
imperfect.
The limited slip differential is
failed.
2 Even if the 4WD AUTO SW is The transfer or wiring is Check and recondition the
select to the 4WD position, the imperfect. vehicle according to Chart 2.
4WD mode is not active, resulting The shift on the fly system is
in remarkable rear wheel spin. failed.
3 When the 4WD AUTO SW is The standard tires are not used. Check and recondition the
selected to the 4WD position, The tire pressure is incorrect. vehicle according to Chart 1.
the drive resistance of the 4WD
The tires are worn inuniformity.
system is too large to get
sufficient running speed. The transfer or wiring is
imperfect.
Noised drive line.
The limited slip differential is
failed.
4 The shift on the fly system (front The wiring is imperfect. Check and recondition the
axle) generates gear noises. The shift on the fly system is vehicle according to Chart 3.
failed.
5 The braking distance gets long The wiring is imperfect. Check and recondition the
even when the ABS is active. The ABS is failed. vehicle according to Chart 4.
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–115

Chart 1 The tight corner braking is observed.


Function of circuit —
Fail condition When the vehicle is subject to full steering in the TOD mode, the drive resistance gets
large or the judder occurs. Otherwise, the above phenomenon is observed only when the
brake is applied.

D04RY00073
4B2–116 DRIVE LINE CONTROL SYSTEM (TOD)

Step Action Yes No


1 Are the front and rear tires in specified size? Replace the tires
with specified
ones, and service
the new tires.
Go to Step 2 Go to Step 16
2 Is the tire pressure correct? In flate tries to
recommended
pressure.
Go to Step 3 Go to Step 16
3 Are the tires free from abnormal wear? Replace the tires
with specified
ones, and service
the new tires.
Go to Step 4 Go to Step 16
4 Are different types of tires used? Replace the tires
with specified
ones, and service
the new tires.
Go to Step 5 Go to Step 16
5 1. Start the engine.
2. Shift the transfer lever to the high position and switch the 4WD
AUTO SW to 4WD position.
3. Fully turn the steering to the left (or right) end, and select the D
range and start the creep run.
Does the tight corner braking occur? Is the judder with chug-chug
sound observed? * Use caution on the operation. Go to Step 6 Go to Step 11
6 1. Shift the transfer lever to the high position and switch the 4WD
AUTO SW to the 2H position.
2. Fully turn the steering to the left (or right) end, and select the D
range and start the creep run.
Does the tight corner braking occur? Is the judder with chug-chug
sound observed? * Use caution on the operation. Go to Step 7 Go to Step 14
7 Is an LSD mounted to the rear differential? Go to Step 8 Go to Step 9
8 Is the genuine LSD oil used in the rear differential? Replace the
differential oil.
Go to Step 9 Go to Step 16
9 Does the engine output the power correctly? Check the
engine.
Go to Step 10 Go to Step 16
10 Do the speed sensors work correctly? (Check trouble codes.) The ECU has
failed. Replace Replace the
the ECU. speed sensors.
Go to Step 16 Go to Step 16
11 Is the tight corner braking observed only when the brake is Conduct full
applied? steering under
WOT.
Go to Step 12 Go to Step 5
12 1. Turn on the starter switch. Repair the circuit
of terminal 11
Is the battery voltage observed between terminals 11 and 19?
(ABS IN).
Go to Step 13 Go to Step 16
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–117

Step Action Yes No


13 1. Apply the brake and fully turn the steering to the left (or right) Repair the The ECU has
end, and start the creep run. transfer failed. Replace
Does the voltage between terminals 4 and 20 range between 0.1 assembly. the ECU.
and 1.0V? Go to Step 16 Go to Step 16
14 1. Shift the transfer lever to the high position and switch the 4WD
AUTO SW to 4WD position.
2. Fully turn the steering to the left (or right) end, and select the D
range and start the creep run.
Does the voltage between terminals 4 and 20 range between 0.1
and 1.0V? Go to Step 15 Go to Step 10
15 1. Select the 4WD AUTO SW to the 2WD position. The phenomenon
2. Jack up the right front wheel. is not
reproduced.
Does the front tire rotate smoothly?
Refer to
“Troubles Repair the
intermittently transfer
observed”. assembly.
Go to Step 16 Go to Step 16
16 Check that all the parts are mounted.
Repeat the
Is this step complete? “Diagnosis Flow”. Return to Step 16
*NOTE: Before checking this item, run the vehicle more
than 10 meters with the steering wheel in straight position
so that the 4L mechanical lock sleeve can be released
certainly.
4B2–118 DRIVE LINE CONTROL SYSTEM (TOD)

Chart 2 The 4WD mode is not active.


Function of circuit —
Fail condition The rear wheels spin in the TOD mode, so the driving torque is not transmitted to the
front wheels. The indicator lamps will not show the 4L and TOD status.

D04RY00073
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–119

Step Action Yes No


1 Is the trouble code 31 or 26 recorded? Examine the
trouble based on
“Diagnosis from
Trouble Codes”. Go to Step 2
2 Is any of the trouble codes 28(P1760), 32(P1761) and 33(1762) Examine the
recorded? trouble based on
“Diagnosis from
Trouble Codes”. Go to Step 3
3 When the transfer lever is in the specified position, do the TOD Examine the
indicator lamps show the correct status? trouble based on
“Trouble
Diagnosis
Depending on
The Status of
Go to Step 4 TOD Indicator”.
4 Shift the transfer lever to the 4L position, fully turn the steering to Repair the
the left (or right) end, and start the creep run. Does the tight transfer
corner braking occur? assembly.
Go to Step 5 Go to Step 7
5 1. Shift the transfer lever to the high (TOD) position. The ECU has
2. Turn on the starter switch. failed. Replace
Does the voltage between terminals 4 and 20 indicate at least 3V the ECU.
while the throttle is completely open? Go to Step 6 Go to Step 7
6 Does the voltage between terminals 4 and 20 indicate at least The TOD clutch
0.1V while the throttle is completely closed? is worn. Repair The ECU has
the transfer failed. Replace
assembly. the ECU.
Go to Step 7 Go to Step 7
7 Check that all the parts are mounted.
Repeat the
Is this step complete? “Diagnosis Flow”. Return to Step 7
4B2–120 DRIVE LINE CONTROL SYSTEM (TOD)

Chart 3 The shift on the fly system generates gear noises.


(The fuel economy is bad in the 2H mode.)
Function of circuit —
Fail condition When the vehicle is run in the 2H mode, the shift on the fly system generates gear
noises or the front wheel gears are engaged to generate a shock.

D04RY00073
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–121

Step Action Yes No


1 Do the indicator lamps show the correct status? Examine the
trouble based on
“Touble Diagnosis
Depending on
The Status of
Go to Step 2 TOD Indicator”.
2 Is any of the trouble codes 28(P1760), 32(P1761) and 33(P1762) Examine the
recorded? trouble based on
“Diagnosis from
Trouble Codes”. Go to Step 3
3 Turn on the starter switch.
Is the battery voltage observed between terminals 1 and 20? Go to Step 4 Go to Step 5
4 When the 4WD AUTO SW is selected to the 2WD position, are the The phenomenon
front axle gears correctly disengaged (and when the left front tire is not The shift on the
is jacked up and turned, is the front propeller shaft standstill)? reproduced. fly system is
Refer to failed (refer to
“Troubles Section 4B1 and
intermittently 4C.)
observed”. Go to Step 6
5 Does the battery voltage maintain the correct level? Repair the battery
Repair the battery and charging
circuit. system.
Go to Step 6 Go to Step 6
6 Check that all the parts are mounted.
Repeat the
Is this step complete? “Diagnosis Flow”. Return to Step 6
4B2–122 DRIVE LINE CONTROL SYSTEM (TOD)

Chart 4 The braking distance gets long even when the ABS is active.
Function of circuit —
Fail condition Enough deceleration is not obtained and the braking distance gets long even when the
ABS is active in the 2H mode.

D04RY00073
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–123

Step Action Yes No


1 Are the brake and ABS systems healthy? Repair the
brake and ABS.
Refer to
Go to Step 2 section 5A.
2 Turn on the starter switch. Repair the
Is the battery voltage observed between terminals 1 and 20? battery system.
Go to Step 3 Go to Step 4
3 1. Select the 4WD AUTO SW to the 2WD position.
2. The voltage between terminals 3 and 19 range between 7.5
and 16V (0.12 seconds make a cycle)

The ECU has


failed. Replace
the ECU.
Does the voltage within the range specified? Go to Step 4 Go to Step 4
4 Check that all the parts are mounted. Repeat the
Is this step complete? “Diagnosis Flow". Return to Step 4
DRIVE SHAFT SYSTEM 4C–1

DRIVELINE/AXLE
DRIVE SHAFT SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 4C–2 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–26
General Description . . . . . . . . . . . . . . . . . . . . . 4C–2 Shift On The Fly System . . . . . . . . . . . . . . . . . 4C–28
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–3 Shift On The Fly System and Associated
Rear Axle Shaft . . . . . . . . . . . . . . . . . . . . . . . . . 4C–4 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–28
Rear Axle Shaft and Associated Parts . . . . 4C–4 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–4 Inspection and Repair . . . . . . . . . . . . . . . . . . 4C–30
Inspection and Repair . . . . . . . . . . . . . . . . . . 4C–5 Main Data and Specifications . . . . . . . . . . . 4C–35
Oil Seal Replacement . . . . . . . . . . . . . . . . . . 4C–6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–36
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–6 Front Propeller Shaft . . . . . . . . . . . . . . . . . . . . . 4C–37
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–8 General Description . . . . . . . . . . . . . . . . . . . . . 4C–37
Front Hub and Disc (with Shift on the Fly) . . 4C–9 Front Propeller Shaft and Associated Parts 4C–38
Disassembled View . . . . . . . . . . . . . . . . . . . . 4C–9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–38
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–39
Inspection and Repair . . . . . . . . . . . . . . . . . . 4C–10 Disassembly (Except TOD 4 4) . . . . . . . . . 4C–40
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–11 Universal Joint Disassembly . . . . . . . . . . . . 4C–41
Front Hub and Disc with Manual Locking Hub 4C–14 Inspection and Repair . . . . . . . . . . . . . . . . . . 4C–42
Disassembled View . . . . . . . . . . . . . . . . . . . . 4C–14 Universal Joint Reassembly . . . . . . . . . . . . . 4C–45
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–14 Reassembly (Except TOD 4 4) . . . . . . . . . . 4C–46
Inspection and Repair . . . . . . . . . . . . . . . . . . 4C–16 Main Data and Specifications . . . . . . . . . . . 4C–47
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–16 Rear Propeller Shaft . . . . . . . . . . . . . . . . . . . . . 4C–48
Main Data and Specifications . . . . . . . . . . . . . 4C–20 General Description . . . . . . . . . . . . . . . . . . . . . 4C–48
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–21 Rear Propeller Shaft and Associated Parts 4C–48
Front Drive Shaft Joint . . . . . . . . . . . . . . . . . . . 4C–22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–49
Front Drive Shaft Joints Replacement . . . . 4C–22 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–49
Front Axle Drive Shaft . . . . . . . . . . . . . . . . . . . 4C–23 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–50
Front Axle Drive Shaft and Associated Universal Joint Disassembly . . . . . . . . . . . . 4C–51
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–23 Inspection and Repair . . . . . . . . . . . . . . . . . . 4C–52
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–24 Universal Joint Reassembly . . . . . . . . . . . . . 4C–53
Inspection and Repair . . . . . . . . . . . . . . . . . . 4C–25 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–54
Bushing Replacement . . . . . . . . . . . . . . . . . . 4C–25 Main Data and Specifications . . . . . . . . . . . 4C–55
4C–2 DRIVE SHAFT SYSTEM

Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED , do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
General Description
This publication contains essential removal, installation,
adjustment and maintenance procedures.
The front axle utilizes a central disconnect type front
axle/transfer case system.
The drive axles are completely flexible assemblies,
consisting of inner and outer constant velocity (CV) drive
shaft joints connected by an axle shaft.
For description of propeller shaft and universal joint, refer
to Front/Rear Propeller Shaft in this section.
DRIVE SHAFT SYSTEM 4C–3

Diagnosis
Condition Possible cause Correction
Oil Leak At Front Axle Worn or defective oil seal. Replace the oil seal.
Front axle housing cracked. Repair or replace.
Oil Leak At Pinion Shaft Too much gear oil. Correct the oil level.
Oil seal worn or defective. Replace the oil seal.
Pinion flange loose or damaged. Tighten or replace.
Noises In Front Axle Drive Shaft Broken or worn drive shaft joints and Replace the drive shaft joints and
Joint bellows (BJ and DOJ). bellows.
“Clank” When Accelerating From Loose drive shaft joint to output shaft Tighten.
“Coast” bolts.
Damaged inner drive shaft joint. Replace.
Shudder or Vibration During Excessive drive shaft joint angle. Repair.
Acceleration
Worn or damaged drive shaft joints. Replace.
Sticking spider assembly (inner drive Lubricate or replace.
shaft joint).
Sticking joint assembly (outer drive Lubricate or replace.
shaft joint).
Vibration At Highway Speeds Out of balance or out of round tires. Balance or replace.
Front end out of alignment. Align.
Noises in Front Axle Insufficient gear oil. Replenish the gear oil.
Wrong or poor grade gear oil. Replace the gear oil.
Drive pinion to ring gear backlash Adjust the backlash.
incorrect.
Worn or chipped ring gear, pinion Replace the ring gear, pinion gear or
gear or side gear. side gear.
Pinion shaft bearing worn. Replace the pinion shaft bearing.
Wheel bearing worn. Replace the wheel bearing.
Differential bearing loose or worn. Tighten or replace.
Wanders and Pulls Wheel bearing preload too tight. Adjust the wheel bearing preload.
Incorrect front alignment. Adjust the front alignment.
Steering linkage loose or worn. Tighten or replace.
Steering gear out of adjustment. Adjust or replace the steering gear.
Tire worn or improperly inflated. Adjust the inflation or replace.
Front or rear suspension parts loose Tighten or replace.
or broken.
Front Wheel Shimmy Wheel bearing worn or improperly Adjust or replace.
adjusted.
Incorrect front alignment. Adjust the front alignment.
Worn ball joint or bush. Replace the ball joint or bush.
Steering linkage loose or worn. Tighten or replace.
Steering gear out of adjustment. Tighten or replace.
Tire worn or improperly inflated. Replace or adjust the inflation.
Shock absorber worn. Replace the shock absorber.
4C–4 DRIVE SHAFT SYSTEM

Rear Axle Shaft


Rear Axle Shaft and Associated Parts

420RW014

Legend (8) Bearing


(1) Brake Caliper (9) Retainer
(2) Brake Disc (10) Snap Ring
(3) Wheel Pin (11) Bolt
(4) Axle Shaft Assembly (12) Nut
(5) Back Plate (13) Antilock Brake System (ABS) Speed Sensor (if
(6) Parking Brake Assembly so equipped)
(7) Bearing Holder

Removal 3. Remove brake caliper. Use a wire to attach the brake


caliper to the frame. Refer to Disk Brakes in Brake
1. Raise the vehicle. section.
2. Remove tires and wheels. Refer to Wheel in Steering 4. Remove brake disc.
section. 5. Remove ABS sensor (if so equipped).
6. Remove Parking brake assembly. Refer to Parking
Brakes in Brake section.
DRIVE SHAFT SYSTEM 4C–5
7. Remove the parking brake cable mounting 15. Remove the wheel pins using a remover
bolts(Behind the back plate)(1). 5–8840–0079–0.

311RS001 420RW023

8. Remove the bearing holder mounting nuts.


9. Remove axle shaft assembly. Inspection and Repair
NOTE: Be sure not to damage the oil seal. Make necessary correction or parts replacement if wear,
10. Remove snap ring. corrosion or any other abnormal conditions are found
through inspection.
11. Using a bearing remover 5–8840–2295–0 and press,
remove retainer together with the bearing holder. Visual Check:
Check the following parts for wear, damage, noise or any
other abnormal conditions:
1. Axle shaft
2. Bearing
When checking the axle shaft, pay special attention to the
splined portions and replace the shaft if distortion or step
wear is noticeable. Correct slight step wear with a grinder.

420RW024

12. Remove bearing.


13. Remove bearing holder.
14. Remove back plate.

420RS008
4C–6 DRIVE SHAFT SYSTEM

Axle Shaft Run–out Oil Seal Replacement


Limit: 1.0 mm (0.039 in) Remove the oil seal carefully not to damage the bearing
holder bore .
When installing, use oil seal installer 5–8840–2310–0.

420RW025

Axle Shaft Flange Run–out 420RW026

Limit: 0.08 mm (0.003 in)


Installation
1. Install wheel pin.
2. Install back plate.
3. Install bearing holder.
4. Install bearing.
5. Install retainer by using a bearing installer
5–8840–2296–0, press fit together with the bearing.

420RS010

420RW027

6. Install snap ring.


7. Install axle shaft assembly.
NOTE: Be sure not to damage the oil seal.
8. Tighten the bearing holder mounting nut to the
specified torque.
Torque: 74Nꞏm (7.5kgꞏm/54 Ib ft)
DRIVE SHAFT SYSTEM 4C–7
9. Fix the parking brake cable mounting bolt (Behind the
back plate).
10. Install parking brake assembly, refer to Parking
Brakes in Brake section.
11. Install antilock brake system sensor (if so equipped).
12. Install brake disc.
13. Install brake caliper, refer to Disk Brakes in Brake
section.
4C–8 DRIVE SHAFT SYSTEM

Special Tools
TOOL NO.
ILLUSTRATION
TOOL NAME

5–8840–0079–0
(J–6627–A)
Wheel pin remover

5–8840–2295–0
(J–39211)
Remover; Axle shaft
bearing

5–8840–2296–0
(J–39212)
Installer; Axle shaft
bearing

5–8840–2310–0
(J–39379)
Installer; Outer axle seal
DRIVE SHAFT SYSTEM 4C–9

Front Hub and Disc (with Shift on the Fly)


Disassembled View

411RW001

Legend (7) Outer Bearing


(1) Bolt (8) Bolt
(2) Cap (9) Hub and Disc Assembly
(3) Snap Ring and Shim (10) Wheel Pin
(4) Hub Flange (11) ABS Sensor Ring (If equipped)
(5) Lock Washer and Lock Screw (12) Inner Bearing
(6) Hub Nut (13) Oil Seal

Disassembly 3. Remove the disc brake caliper assembly and hang it


on the frame with wires. Refer to Front Disc Brake
1. Before disassembly, select the 2WD position. Caliper Assembly in Brakes section.
2. Jack up the front of vehicle and support frame with 4. Remove bolt.
jack stands. 5. Remove cap.
6. Remove snap ring and shim.
7. Remove hub flange.
4C–10 DRIVE SHAFT SYSTEM
8. Remove lock washer and lock screw. Place hub on a suitable work surface and remove
9. Use wrench 5–8840–2117–0, remove hub nut. the studs by using a hammer.

411RS004
411RW005

10. Remove hub and disc assembly.


11. Remove ABS sensor ring (If equipped). Inspection and Repair
12. Remove outer bearing. Make necessary correction or parts replacement if wear,
13. Remove oil seal. damage, corrosion or any other abnormal conditions are
found through inspection.
14. Remove inner bearing.
Check the following parts:
15. Remove bolt , if necessary, replace the wheel pin in Hub
the following manner.
Hub bearing oil seal
Apply a scribe mark(1) to disc to hub.
Knuckle spindle
Clamp the hub and disc assembly in a vise, using
Disc
protective pads. Remove the 6 disc–to–hub
retaining bolts. Caliper
Shift on the fly system parts (Cap, Hub flange, Shim,
Snap ring)
ABS sensor ring (If equipped)
For inspection and servicing of disc caliper and related
parts, refer to Brakes section.

411RS003
DRIVE SHAFT SYSTEM 4C–11

Reassembly 3. Use installer 5–8840–2119–0 and grip


5–8840–0007–0, then install the inner bearing by
1. Install wheel pin. driving it into the hub.
Place the hub on a wood workbench or a block of
wood approx. 6” by 6” to protect the wheel stud
ends and threads.
Insert a wheel stud using a hammer.
Be sure the wheel stud is started squarely and
seats completely.

411RW006

4. Use installer 5–8840–2118–0 and grip


5–8840–0007–0, then install the outer bearing by
driving it into the hub.

411RS005

2. Align scribe marks(1) and attach the hub to the disc,


then tighten the bolts to the specified torque.
Torque: 103 Nꞏm (10.5 kgꞏm/76 lb ft)

411RW007

411RS003
4C–12 DRIVE SHAFT SYSTEM
5. Apply grease (NLGI No.2 or equivalent) to the lip 8. Install hub nut. Turn the place where there is a
portion, then install oil seal by using installer chamfer in the tapped hole to the outer side, then
5–8840–2120–0 and grip 5–8840–0007–0. attach the nut by using front hub nut wrench
5–8840–2117–0.

411RW008

6. Install ABS sensor ring, then tighten the bolts to the 411RW005

specified torque. Preload Adjustment


Torque: 18 Nꞏm (1.8 kgꞏm/13 lb ft) 1. Tighten the hub nut to 29 Nꞏm (3.0 kgꞏm/22 lb ft),
7. Install hub and disc assembly. then fully loosen the nut.
Apply grease in the hub. 2. Tighten the hub nut to the value given below,
using a spring scale on the wheel pin.
Apply wheel bearing type grease NLGI No. 2 or
equivalent to the outer and inner bearing. New bearing and New oil seal
Grease Amount Bearing Preload: 20 – 25 N (2.0–2.5 kg/4.4 –
5.5 lb)
Hub: 35 g (1.23 oz)
Outer bearing: 10 g (0.35 oz) Used bearing and New oil seal
Inner bearing: 15 g (0.53 oz) Bearing Preload: 12 – 18 N (1.2–1.8 kg/2.6 –
4.0 lb)
If the measured bearing preload is outside the
specifications, adjust it by loosening or tightening the
bearing nut.

411RS009

Legend
(1) Inner Bearing
(2) Hub 411RS011

(3) Outer Bearing


DRIVE SHAFT SYSTEM 4C–13
9. Install lock washer and lock screw in the following 12. Install hub cap.
manner. 13. Tighten the bolts to the specified torque.
Turn the side with larger diameter of the tapered Torque: 59 Nꞏm (6.0 kgꞏm/43 lb ft)
bore to the vehicle outer side, then attach the
washer.
If the bolt holes in the lock plate are not aligned with
the corresponding holes in the nut, reverse the lock
plate.
If the bolt holes are still out of alignment, turn in the
nut just enough to obtain alignment.
Screw is to be fastened tightly so its head may
come lower than the surface of the washer.

411RS012

10. Apply adhesive (LOCTITE 515 or equivalent) to both


joining flange faces then install hub flange.
11. Install snap ring and shim.
Adjust the clearance between the free wheeling hub
body and the snap ring.
Clearance: 0 mm–0.3 mm (0 in–0.012 in)
Shims Available: 0.2 mm, 0.3 mm, 0.5 mm,
1.0 mm (0.008 in, 0.012 in, 0.020 in, 0.039 in)

411RW002
4C–14 DRIVE SHAFT SYSTEM

Front Hub and Disc with Manual Locking Hub


Disassembled View

411RW009

Legend (13) Body Assembly


(1) Bolt (14) Inner Assembly
(2) Cover Assembly (15) Spacer
(3) Gasket (16) Ring
(4) Knob (17) Snap Ring
(5) X–ring (18) Snap Ring
(6) Detent Ball and Spring (19) Lock Washer and Lock Screw
(7) Snap Ring (20) Hub Nut
(8) Clutch Assembly (21) Hub and Disc Assembly
(9) Compression Spring (22) Outer Bearing Outer Race
(10) Follower (23) ABS Sensor Ring (if so equipped)
(11) Retaining Spring (24) Inner Bearing Outer Race
(12) Snap Ring and Shim (25) Oil Seal

Disassembly 2. Remove the disc brake caliper assembly and hang it


on the frame with wires. Refer to Front Disk Brake
1. Before disassembly, jack up the front of vehicle and Caliper Assembly in Brakes section.
support frame with jack stands.
DRIVE SHAFT SYSTEM 4C–15
3. Remove bolt. 13. Remove inner bearing outer race.
Before removal, shift transfer lever into “2H” position, 14. While pushing follower knob against cover, turn clutch
set free wheeling hub knob into “FREE” position (1), assembly clockwise and then remove clutch
and run the vehicle about 50m (160 ft). assembly from knob.

411RW010 411RW011

4. Remove cover assembly. 15. Remove gasket.


5. Remove snap ring and shim. 16. Remove snap ring.
6. Remove body assembly. 17. Remove knob.
7. Remove lock washer and lock screw. 18. Remove compression spring.
8. Remove hub nut by using wrench 5–8840–2117–0. 19. Remove follower.
20. Remove retaining spring from clutch assembly by
turning it counterclockwise.

411RW005

9. Remove hub and disc assembly.


10. Remove ABS sensor ring (If equipped). 411RW012

11. Remove outer bearing outer race. 21. Remove dedent ball and spring.
12. Remove oil seal. 22. Remove X–ring.
23. Remove snap ring.
24. Remove inner assembly.
25. Remove snap ring.
26. Remove ring.
27. Remove spacer.
4C–16 DRIVE SHAFT SYSTEM

Inspection and Repair 6. Install X–ring.


Apply wheel bearing grease to hub lock ring and fit it
Make necessary correction or parts replacement if wear,
in knob paying attention to mounting direction.
damage, corrosion or any other abnormal condition are
found through inspection. NOTE: After fitting, make sure that the hub lock ring is not
Check the following parts. twisted.
Hub 7. Apply wheel bearing grease to ball and spring and fit
Hub bearing, oil seal them in knob.
Knuckle spindle 8. Install knob.
Disc 1. Apply grease to outer circumference of knob and
Caliper inner circumference of cover.
Free wheeling hub parts (Clutch, knob, follower, 2. Align detent ball (1) to a groove cut in the cover.
inner, ring and spring)
ABS sensor ring (if so equipped)
For inspection and servicing of disc caliper, and relative
parts, refer to Brakes section.

Reassembly
1. Install spacer.
Apply about 1 g wheel bearing grease to both face of
spacer.
2. Install ring.
Apply about 3 g wheel bearing grease to inside face
of ring.
3. Install snap ring
Assembly with grease surplus being left unwiped up
as illustrated.

411RW014

9. Install snap ring.


Turn the smoother face to knob side.
10. Align the end of retaining spring (1) with clutch spring
groove (2) and fit in the spring.

411RW013

Legend
(1) Inner Assembly
(2) Apply Grease
(3) Body

4. Install inner assembly.


Apply grease to splined portion of body. 411RW015

5. Install snap ring.


DRIVE SHAFT SYSTEM 4C–17
11. Install follower to clutch so that follower nails (large) 14. Install gasket.
(1) will come closer to the bent portion of retaining Make sure that there is no breakage, etc.
spring by aligning follower stopper nail with outer
15. Install outer bearing outer race by driving it into the
teeth of clutch. Then, fit in with follower’s nails (small)
hub, by using installer 5–8522–2118–0 and grip
(2) caught in spring.
5–8840–0007–0.

411RW016

12. Install compression ring.


411RW007

16. Install inner bearing outer race by driving it into the


Turn the smaller diameter side toward follower and fit hub, by using installer 5–8840–2119–0 and grip
spring in clutch. 5–8840–0007–0.
13. Align follower nail (1) to handle groove (2). and then
assemble clutch with knob by pushing and turning
clutch counterclockwise to knob.

411RW006

411RW017
4C–18 DRIVE SHAFT SYSTEM
17. Install oil seal by using installer 5–8840–2120–0 and
grip 5–8840–0007–0.
Apply grease (NLGI No.2 or equivalent) to the lip
portion.

411RW005

Preload Adjustment
Tighten the hub nut to 29 Nꞏm (3.0 kgꞏm/22 lbꞏft),
then fully loosen the nut.
411RW008
Tighten the hub nut to the value given below, using
18. Install ABS sensor ring (if so equipped).
a spring scale on the wheel pin.
Tighten the bolts to the specified torque.
Bearing Preload
Torque: 18 Nꞏm (1.8 kgꞏm/13 lb ft)
New bearing and New oil seal:
19. Install hub and disc assembly. 20-25N (2-2.5 kg/4.4-5.5 lb)
1. Apply grease in the hub.
Used bearing and New oil seal:
2. Apply wheel bearing type grease NLGI No.2 or 12-18N (1.2-1.8 kg/2.6-4.0 lb)
equivalent to the outer and inner bearing.
If the measured bearing preload is outside the
Grease Amount specifications, adjust it by loosening or tightening
Hub: 35 g (1.23 oz) the bearing nut.
Outer bearing: 10 g (0.35 oz)
Inner bearing: 15 g (0.53 oz)
20. Install hub nut.
1. Turn the place where there is a chamfer in the
tapped hole to the outer side, and attach the nut
by using wrench 5–8840–2117–0.

411RS011
DRIVE SHAFT SYSTEM 4C–19
21. Install lock washer and lock screw in the following
manner.
Turn the side with larger diameter of the tapered
bore to the vehicle outer side, and attach the
washer.
If the bolt holes in the lock plate are not aligned with
the corresponding holes in the nut, reverse the lock
plate.
If the bolt holes are still out of alignment, trun in the
nut just enough to obtain alignment.
Screw is to be fastened tightly so its head may
come lower than the surface of the washer.

411RW002

24. Install cover assembly.


Align stopper nails (1) to grooves of body (2).

411RS012

22. Install body assembly.


Apply adhesive (LOCTITE 515 or equivalent) to
both joining faces.
Tighten the bolts to the specified torque.
Torque: 59 Nꞏm (6.0 kgꞏm/43 lb ft)
23. Install snap ring and shim.
Adjust the clearance between the free wheeling hub 411RW019
body and the snap ring. 25. Tighten the cover bolts to the specified torque.
Clearance: Torque: 12 Nꞏm (1.2 kgꞏm/104 lb in)
0-0.3mm (0-0.012in)
Shims Available:
0.2mm, 0.3mm, 0.5mm, 1.0mm, (0.008in, 0.012in,
0.020in, 0.039in)
4C–20 DRIVE SHAFT SYSTEM

Main Data and Specifications


Torque Specifications

E04RW022
DRIVE SHAFT SYSTEM 4C–21

Special Tools
TOOL NO.
ILLUSTRATION
TOOL NAME

5–8840–2117–0
(J–36827)
Wrench; Hub nut

5–8840–2119–0
(J–36829)
Installer; Inner bearing

5–8840–2118–0
(J–36828)
Installer; Outer bearing

5–8840–2120–0
(J–36830)
Installer; Oil seal

5–8840–0007–0
(J–8092)
Grip
4C–22 DRIVE SHAFT SYSTEM

Front Drive Shaft Joint


Front Drive Shaft Joints Replace- 1. Open filler plug and make sure that the oil is up to the
plug port.
ment If the level oil is low, replenish with gear oil GL–5
Refer to Front Drive Axle Assembly Replacement in grade.
this section, and refer to Front Hub and Disc in 2. Tighten the filler plug to specified torque.
Suspension section.
Torque: 7.8 Nꞏm (7.9 kgꞏcm/58 lb in)
Front Hub Bearing Preload Check
Check the hub bearing preload at the wheel pin.
New bearing and New oil seal
Preload: 20 – 25 N (2.0 – 2.5 kg/4.4–5.5 lb)
New bearing and New oil seal
Preload: 12 –18 N (1.2 – 1.8 kg/2.6–4.0 lb)

411RS001

Inspection Of Shift On The Fly System


Gear Oil

412RT002
DRIVE SHAFT SYSTEM 4C–23

Front Axle Drive Shaft


Front Axle Drive Shaft and Associated Parts
This illustration is based on the model equipped with shift on the fly system.

412RW003

Legend (13) Spacer


(1) Axle Case and Differential (14) Ball
(2) DOJ Case Assembly (15) Snap Ring
(3) Snap Ring (16) Ball Retainer
(4) Bearing (17) Ball Guide
(5) Snap Ring (18) Band
(6) Oil Seal (19) Bellows
(7) Bracket (20) Band
(8) DOJ Case (21) Band
(9) Circlip (22) Bellows
(10) Bolt (23) Band
(11) Drive Shaft Joint Assembly (24) BJ Shaft
(12) Snap Ring (25) Dust Seal
4C–24 DRIVE SHAFT SYSTEM

Disassembly 4. Remove drive shaft joint assembly.


5. Using snap ring pliers, remove the snap ring.
NOTE: For the left side, follow the same steps as right
side.
1. Raise the hooked end of the band (1) with a
screwdriver or equivalent.

412RS011

6. Remove spacer.
7. Remove the six balls (1) with a screwdriver or
equivalent.
412RS009

2. Remove band.
3. Pry off circlip (1) with a screwdriver or equivalent.

412RS012

412RS010
DRIVE SHAFT SYSTEM 4C–25
8. Using snap ring pliers, remove the snap ring (1) Inspection and Repair
fastening the ball retainer to the center shaft.
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal conditions are
found through inspection.
Check the following parts:
1. Drive shaft joint assembly
2. DOJ case, ball, ball guide, ball retainer
3. Bellows
4. Bearing
5. Dust seal, oil seal

Bushing Replacement
Remove the bushings using a remover
5–8840–2309–0 and hammer.

412RS013

9. Remove ball retainer, ball guide and bellows.


10. Raise the hooked end of the band (1) with a
screwdriver or equivalent.

412RW051

By using installer and base 5–8840–2309–0, press fit


the bushings into the bracket.

412RS014

11. Remove band.


12. Remove bellows.
13. Remove dust seal.
14. Remove BJ shaft assembly.
15. Remove the mounting bracket fixing bolts, and then
remove DOJ case assembly from the axle case.
16. Remove snap ring and bearing.
17. Remove snap ring and oil seal.
18. Remove bracket.

412RW052
4C–26 DRIVE SHAFT SYSTEM

Reassembly
1. Install DOJ case to bracket.
2. Install oil seal and fix snap ring.
3. Install bearing and fix snap ring.
4. Install bracket to axle case. Tighten the bracket bolt to
the specified torque.
Torque: 116 Nꞏm (11.8 kgꞏm/85 lb ft)
5. Apply 150g of the specified grease in BJ .
6. Install dust seal .
7. Apply a thin coat of grease to the shaft for smooth
installation then install bellows.
8. Install band. Note the setting direction. After
installation, check that the bellows is free from
distortion.

412RS013

13. Align the track on the ball (1) retainer with the window
in the cage, and install the six balls into position.

412RS017

9. Install another bellows and fix band.


10. Install the ball guide with the smaller diameter side
ahead onto the shaft.
11. Install ball retainer.
12. Using snap ring pliers, install the snap ring (1) 412RS018

securing the ball retainer to the shaft. 14. Install spacer.


15. Install snap ring.
16. Enclose 150g of the specified grease in DOJ case,
then install drive shaft joint assembly. After
reassembly, move the DOJ longitudinally several
times to get to fit.
17. Install the circlip (1) so that open ends are positioned
away from the ball groove.
DRIVE SHAFT SYSTEM 4C–27

412RS019 412RW053

19. Install Band. After installation, check that the bellows


is free from distortion.

412RS020

Legend
(1) Outer Case
(2) Circlip
(3) Open Ends

18. Install bellows. Adjust the air pressure within the


bellows by inserting a screwdriver or equivalent, so
that it equals atmospheric pressure.
4C–28 DRIVE SHAFT SYSTEM

Shift On The Fly System


Shift On The Fly System and Associated Parts

412RW004

Legend (8) Needle Bearing


(1) Filler Plug (9) Clutch Gear
(2) Bolt (10) Sleeve
(3) Oil Seal (11) Housing
(4) Snap Ring(External) (12) Front Axle Drive Shaft (LH side)with Bracket
(5) Inner Shaft Bearing (13) Bolt
(6) Snap Ring(Internal) (14) Actuator Assembly
(7) Inner Shaft (15) Bolt

Disassembly 3. Remove Actuator Assembly and draw out actuator


ASM.
1. Remove filler plug and gasket, drain oil. 4. Remove housing.
2. Loosen mounting bracket fitting bolts and remove 5. Remove sleeve.
front axle drive shaft from front axle case.
6. Remove clutch gear.
DRIVE SHAFT SYSTEM 4C–29
7. Remove snap ring from front axle case by using snap 10. Remove inner shaft bearing by using a remover
ring pliers. 5–8840–2197–0 and press.
NOTE: Be careful not to damage the shaft.

412RW017

8. Take out inner shaft from front axle case.


412RW015
9. Remove snap ring from inner shaft by using snap ring 11. Remove needle bearing from inner shaft by using a
pliers. remover 5–8840–0027–0 and sliding hammer
5–8840–0084–0.
NOTE: Be careful not to damage the shaft.

412RW016

412RS045

12. Remove oil seal from front axle case.


NOTE: Be careful not to damage the front axle case.
4C–30 DRIVE SHAFT SYSTEM

Inspection and Repair Inner Shaft Run–Out


Inspect the removed parts. If there are abnormalities With both end centers supported, rotate the shaft slowly
such as wear and damage, take corrective action or and measure deflection with a dial gauge.
replace. Limit: 0.5 mm (0.02 in)max.
Visual Check NOTE: Do not heat the shaft to correct its bend.
1. Check and see if the inner shaft has any
abnormalities such as wear and damage.

412RS026

412RW014
Inner Shaft Bearing
2. When inspecting the inner shaft, be sure to check and
see if its splined part is twisted, worn, or cracked. If so,
replace with a new shaft. In case of an abnormality in
its gear part (a slide with sleeve), replace the shaft.

412RW006

Legend
(1) Inner Shaft Bearing
420RS008
(2) Inner Shaft
(3) Clutch Gear

1. Inspect the state of inner shaft bearing. If any


abnormality such as roughness is found, replace with
a new inner shaft bearing.
2. Insert a clutch gear and check the state of needle
bearing.
3. If there is an abnormality such as roughness, replace
the needle bearing.
DRIVE SHAFT SYSTEM 4C–31
Sleeve Condition Clutch Gear Condition
Check and see that there is no wear, damage, or cracking Check and see that there is no wear, damage, cracking,
in the sleeve. or any other abnormality in the clutch gear.
NOTE: Close inspection of the groove and inner gear are
required because those are important parts.
Clutch Gear Function

Sleeve Function

412RW010

If there is an abnormality such as roughness when


operated in combination with sleeve, replace the clutch
412RW011
gear.
Operate the sleeve with the inner shaft combined with the
clutch gear. If roughness is felt, replace the sleeve. NOTE: When inspecting, gear oil should be applied to the
contact surface of gear.
NOTE: Gear oil should be applied to the contact surface
of gear.
Clutch Gear Journal Diameter
Check the width of sleeve center groove.
Make sure of the size illustrated.
Limit: 7.1 mm (0.28 in) max.
Limit: 36.98 mm (1.456 in) min.

412RW022
412RW009
4C–32 DRIVE SHAFT SYSTEM

Actuator
Check and see that there is no damage, cracking, or other
abnormality.
Functional Check

412RW007

Disconnect the shift position switch and make sure of


function with a vacuum of –400 mmHg applied to Ports A
and B, in accordance with the table below.

412RW021
State Port A Port B Function
C –400 mmHg A/P E
D A/P –400 mmHg F

If there is an abnormality, replace the actuator as an


assembly.
NOTE:
1. If the actuator works under –400mmHg or less, there
is no functional problem.
2. Be careful not to permit the entry of water or dust into
the ports of the actuator.
Dimensional Check
Measure illustrated sizes 1, 2, and 3.
Limit
1=64.3 mm (2.53 in) max.
2=6.7 mm (0.26 in) min.
3=6.7 mm (0.26 in) min.
412RW013
DRIVE SHAFT SYSTEM 4C–33

412RS037 412RS051

3. Place a new snap ring(internal) in inner shaft.


Reassembly Force a new inner shaft bearing into the inner shaft by
1. Install the new oil seal which has been immersed in using a installer 5–8840–2197–0 and press.
differential gear oil, by using an oil seal installer
5–8840–2407–0 and grip 5–8840–0007–0.

412RS044

4. Install snap ring(external).


412RS043
NOTE: Be careful not to damage the inner shaft.
2. Force a new needle bearing into inner shaft by using a
installer 5–8840–2408–0 and grip 5–8840–0007–0. 5. Clean the housing contact surface of the front axle
case and insert inner shaft assembly into the front
axle case.
4C–34 DRIVE SHAFT SYSTEM
NOTE: Be careful not to damage seal. 11. Clean the actuator contact surface with the housing
6. Install snap ring (internal) in the groove of front axle then Install and tighten shift position switch to
case. specified torque.
Torque: 39Nꞏm (4.0 kgꞏm/29 lb ft)
NOTE: Be sure to install the snap ring properly.
12. Apply liquid gasket to the contact surface on the
actuator side.

412RW017

7. Apply differential gear oil to clutch gear, then install


clutch gear. 412RW012

13. Align shift arm with the groove of sleeve and install the
8. Apply differential gear oil to sleeve, then install
actuator.
sleeve.
14. Tighten bolts to specified torque.
9. Clean contact surface with the front axle and actuator
mounting surface. Apply liquid gasket to the contact Torque: 13Nꞏm (1.3 kgꞏm/113 lb in)
surface on the front axle case, then install in the 15. Install front axle drive shaft and mounting bracket.
housing. Tighten fitting bolts to specified torque.
Torque: 116Nꞏm (11.8 kgꞏm/85 lb ft)
16. Pour specified amount of differential gear oil to filler
plug.
Front Differential
Oil Capacity: 1.4lit (1.23 Imp qt/1.48 US qt)
Actuator Housing
Oil Capacity: 0.12lit (0.10 Imp qt/0.13 US qt)
17. Install filler plug through gasket and tighten to
specified torque.
Torque: 78Nꞏm (58lb ft)

412RW023

10. Tighten bolts to specified torque.


Torque: 116Nꞏm (11.8 kgꞏm/85 lb ft)
DRIVE SHAFT SYSTEM 4C–35

Main Data and Specifications


General Specifications
Front drive axle oil capacity 1.4 liter (1.23 Imp qt/1.48 US qt)(Differential)
0.12 liter (0.10 Imp qt/0.13 US qt)(Actuator Housing:Shift on the fly)
Type of lubricant GL–5 (Multi grade type) Refer to chart in General Information
Axle shaft type Constant velocity joint(Birfield joint type and double offset joint)

Torque Specifications

E04RW020
4C–36 DRIVE SHAFT SYSTEM

Special Tools
TOOL NO. TOOL NO.
ILLUSTRATION ILLUSTRATION
TOOL NAME TOOL NAME

5–8840–2309–0
(J–39378) 5–8840–0007–0
Remover and Installer; (J–8092)
Front Axle mount Grip
bushing

5–8840–2197–0
(J–37452)
Remover and Installer;
Inner shaft bearing

5–8840–0027–0 (J–
26941)
Remover;Bearing needle

5–8840–0084–0
(J–2619–01)
Hammer; Sliding

5–8840–2407–0
(J–41693)
Installer; Oil seal

5–8840–2408–0
(J–41694)
Installer; Bearing needle
DRIVE SHAFT SYSTEM 4C–37

Front Propeller Shaft

General Description
Since the propeller shaft is balanced carefully, welding or Alignment marks should be applied to each propeller
any other modifications are not permitted. shaft before removal.

401RW002
4C–38 DRIVE SHAFT SYSTEM

Front Propeller Shaft and Associated Parts

401RW058

Legend (4) Front Propeller Shaft (with TOD)


(1) Bolt, Nut and Washer (Front Axle Side) (5) Coupling
(2) Front Propeller Shaft (6) LJ Constant Velocity Joint
(3) Bolt, Nut and Washer (Transfer Side) (7) BJ Constant Velocity Joint

Removal
1. Jack up the vehicle and support it on the chassis
stands.
2. Gear shift lever should be placed in neutral position
and parking brake released.
3. Remove the exhaust and transfer protectors.
NOTE: Apply alignment marks on the flange at the front
propeller shaft both front and rear side.

401RS020
DRIVE SHAFT SYSTEM 4C–39

401RW053 401RW051

Installation
NOTE: Never install the shaft assembly backwards.
Completely remove the black paint from the connecting
surface of flange coupling on each end of propeller shaft.
Clean so that no foreign matter will be caught in between.
1. Align the mark which was applied at removal. Install
front propeller shaft and tighten the bolts to the
specified torque.
Torque: 63 Nꞏm (6.4 kgꞏm/46 lb ft)
2. Install the exhaust and transfer protectors.
3. After installing the propeller shaft, be sure to apply
black paint (1) to exposed area (other than
connecting surface) of the entire surface of flange
coupling .

401RW052

4. Remove bolt, nut and washer (Front axle side).


5. Remove bolt, nut and washer (Transfer side).
6. Remove front propeller shaft.
NOTE: If equipped with torque on demand (TOD), when
removing, installing or carring for front propeller shaft, be
sure to wind a piece of cloth round the part of the boot with
which fittings may interfere so that the boot can be
protected. The boot may be damaged if bending force is
applied to the constant velocity joint of the shaft.

401RS019
4C–40 DRIVE SHAFT SYSTEM

Disassembly (Except TOD 4 4)

401RW057

Legend (2) Seal


(1) Sleeve Yoke (3) Tube Assembly

1. Apply alignment marks (1) on the sleeve yoke and 2. Remove seal.
tube assembly then remove sleeve yoke. 3. Remove tube assembly.

401RW056
DRIVE SHAFT SYSTEM 4C–41

Universal Joint Disassembly

401RW055

Legend (3) Snap Ring


(1) Flange Yoke (4) Needle Roller Bearing
(2) Spider (5) Grease Fitting

1. Apply alignment marks (1) on the yokes of the 2. Tap out the needle roller bearing by gently striking the
universal joint, then remove snap ring. shoulder of the yoke, using a mallet or a copper
hammer.

401RS028

401RS006
4C–42 DRIVE SHAFT SYSTEM
3. Make sure of proper position for reinstallation by
applying setting marks, then remove spider .

Inspection and Repair


Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition is
found through inspection.
NOTE: When any part of the journal assembly (spider,
needle roller bearing) requires replacement, be sure to
replace the entire assembly.
Check the following parts for wear, damage, noise or any
other abnormal conditions:
1. Spider
2. Needle roller bearing
3. Yoke
4. Flange
5. Constant velocity joint
401RS027

Outside Diameter of Spider Pin


Play in Splines in Normal Direction of
Standard: 17.00 mm (0.669 in)
Rotation
Limit: 16.90 mm (0.665 in) Check the amount of play between the sleeve yoke (1)
and the propeller shaft spline (2) in the direction of
rotation, using a pointed feeler gauge.
Standard: 0.073 – 0.156 mm (0.003 – 0.006 in)
Limit: 0.3 mm (0.012 in)

401RS007

Propeller Shaft Run–out


Support the ends of the propeller shaft on V-blocks (2)
and check for run–out by holding the probe of a dial
indicator (1) in contact with the center part of the shaft. If 401RS009

the amount of run–out is beyond the standard value for


assembly, correct with a bench press or replace the shaft
with a new propeller shaft assembly.
Standard: 0.3 mm (0.012 in)
Limit: 0.5 mm (0.02 in)
DRIVE SHAFT SYSTEM 4C–43
Play in Universal Joint
Limit: Less than 0.1 mm (0.004 in)

401RW049

Boot of Constant Velocity Joint


401RS010 Check the boot (2) for crack, damage and grease leak,
and the boot band (1) for loosening and damage. Check
Constant Velocity Joint the both sides of the joint and make sure that there is no
leak of grease from the cover press-in parts(3).
NOTE: LJ and BJ constant velocity joints are
unremovable types. Check the joint for play and the boot
for damage, wear, and leak of grease. If abnormality is
found, replace propeller shaft as an assembly.

Play in Constant Velocity Joint


Fix the shaft in a vise throrgh pieces of wood, and try to
move the joint vertically, right and left, and back and forth
to make sure of smooth motions and no remarkable play.

401RW048

401RW050
4C–44 DRIVE SHAFT SYSTEM
2. Set a dial gage at right angle near the inner
circumference and check the run-out of the flange.
Limit: 0.15 mm (0.006 in)

401RW047

Front Axle Flange Run-out


1. Set a dial gage at right angle near the outer
circumference of the flange face and check the 401RW045

run-out of the flange face. 3. If vibration is felt during the 4H AUTO drive, disconnct
the propeller shaft at the front axle. Reinstall the
Limit: 0.15 mm (0.006 in) propeller shaft at 60 , 120 , 180 , 240 , and 300
and conduct test drive in each position and check if
there is vibration.

401RW046

401RW044
DRIVE SHAFT SYSTEM 4C–45

Universal Joint Reassembly 4. Align setting marks (1) and join the yokes.

1. Install spider to flange yoke. Be sure to install the


spider by aligning the setting marks made during
disassembly.
2. Apply a molybdenum–disulfide grease or a
multi–purpose type grease NLGI No. 2 to inside of the
bearing cap.
Grease Amount: Approx. 1.2 g (0.042 oz)

401RS028

5. Install snap ring.


NOTE: Discard used snap rings and install new ones.
When the bearing cap is in position, select and attach a
snap ring of suitable thickness so that the end play of the
spider pin is held within 0.1 mm (0.004 in).
Snap ring thickness and Identification color
401RS011 1.5 mm (0.059 in); Blue
3. Using either a mallet (or copper hammer) or a press, 1.53 mm (0.060 in); White
install the needle roller bearing into the yoke so that 1.59 mm (0.063 in); Yellow
the snap ring can be installed in its groove.
1.62 mm (0.064 in); Green
CAUTION: The needle roller bearing cannot be 1.68 mm (0.066 in); Not colored
installed smoothly if it is set at an incorrect angle
with the flange and excessive hammering will NOTE: Be sure to use snap rings of the same thickness
damage the needle roller bearing. on both sides.

401RS012
4C–46 DRIVE SHAFT SYSTEM

Reassembly (Except TOD 4 4)

401RW057

Legend (2) Seal


(1) Sleeve Yoke (3) Tube Assembly

1. Discard used seal and install new one.


2. Align the alignment marks and install tube assembly
to sleeve yoke.
DRIVE SHAFT SYSTEM 4C–47

Main Data and Specifications


General Specifications
Engine 6VE1 (3.5L) 6VD1 (3.2L) 4JX1 (3.0L) 4JG2 (3.1L)
Transmission A/T A/T
M/T A/T with M/T A/T with M/T A/T M/T A/T
TOD TOD
Construction Hollow Hollow
steel steel
Hollow steel tube tube Hollow steel tube tube
with yoke and with with yoke and with Hollow steel tube with yoke and
spider type consta spider type consta spider type universal joint
universal joint nt universal joint nt
velocity velocity
joints joints
Outside
40.0mm (1.57 in)
diameter
Length 559mm 559mm 577mm 393mm 559mm 577mm 627mm 627mm 421mm 627mm
(22.01in) (22.01in) (22.72in) (15.47in) (22.01in) (22.72in) (24.69in) (24.69in) (16.57in) (24.69in)

Torque Specifications

E04RW021
4C–48 DRIVE SHAFT SYSTEM

Rear Propeller Shaft

General Description
Since the propeller shaft is balanced carefully, welding or Alignment marks should be applied to each propeller
any other modifications are not permitted. shaft before removal.

401RW003

Rear Propeller Shaft and Associated Parts

401RW059

Legend (2) Rear Propeller Shaft


(1) Bolt, Nut and Washer (3) Bolt, Nut and Washer
DRIVE SHAFT SYSTEM 4C–49

Removal 3. After installing the propeller shaft, be sure to apply


black paint (1) to exposed area (other than
1. Jack up the vehicle and support it on the chassis connecting surface) of the entire surface of flange
stands. coupling .
2. Gear shift lever should be placed in neutral position
and parking brake released.
NOTE: Apply alignment marks on the flange at the rear
propeller shaft both front and rear side.

401RS022

401RS023

3. Remove bolt, nut and washer (Rear axle side).


4. Remove bolt, nut and washer (Transfer side).
5. Remove rear propeller shaft.

Installation
NOTE: Never install the shaft assembly backwards.
1. Completely remove the black paint from the
connecting surface of flange coupling on each end of
propeller shaft. Clean so that no foreign matter will be
caught in between.
2. Align the mark which is applied at removal .
Install rear propeller shaft and tighten the bolts to the
specified torque.
Torque: 63 Nꞏm (6.4 kgꞏm/46 lb ft)
4C–50 DRIVE SHAFT SYSTEM

Disassembly

401RW057

Legend (2) Seal


(1) Sleeve Yoke (3) Tube Assembly

1. Apply alignment marks (1) on the sleeve yoke and 2. Remove seal.
tube assembly then remove sleeve yoke. 3. Remove tube assembly.

401RW056
DRIVE SHAFT SYSTEM 4C–51

Universal Joint Disassembly

401RW054

Legend (3) Snap Ring


(1) Flange Yoke (4) Needle Roller Bearing
(2) Spider with Grease Fitting (5) Grease Fitting

1. Apply alignment marks (1) on the yokes of the 2. Tap out the needle roller bearing by gently striking the
universal joint, then remove snap ring. shoulder of the yoke, using a mallet or a copper
hammer.

401RS028

401RS006
4C–52 DRIVE SHAFT SYSTEM
3. Make sure of proper position for reinstallation by
applying setting marks, then remove spider with
grease fitting.

Inspection and Repair


Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition is
found through inspection.
NOTE: When any part of the journal assembly (spider,
needle roller bearing, grease fitting) requires
replacement, be sure to replace the entire assembly.
Check the following parts for wear, damage, noise or any
other abnormal conditions:
1. Spider
2. Needle roller bearing
3. Yoke
4. Flange
Outside Diameter of Spider Pin
401RS008

Standard: 17.00 mm (0.669 in) Play in Splines in Normal Direction of


Rotation
Limit: 16.90 mm (0.665 in)
Check the amount of play between the sleeve yoke (1)
and the propeller shaft spline (2) in the direction of
rotation, using a pointed feeler gauge.
Standard: 0.073 – 0.156 mm (0.003 – 0.006 in)
Limit: 0.3 mm (0.012 in)

401RS007

Propeller Shaft Run-out


Support the ends of the propeller shaft on V-blocks (2)
and check for run-out by holding the probe of a dial
indicator (1) in contact with the center part of the shaft. If 401RS009

the amount of run-out is beyond the standard value for


assembly, correct with a bench press or replace the shaft
with a new propeller shaft assembly .
Standard: 0.3 mm (0.012 in)
Limit: 0.5 mm (0.02 in)
DRIVE SHAFT SYSTEM 4C–53
Play in Universal Joint
Limit: Less than 0.1 mm (0.004 in)

401RS012

4. Align setting marks (1) and join the yokes.


NOTE: Assemble the spider and spline yoke so that their
401RS010
grease fittings are arranged on the same side.

Universal Joint Reassembly


1. Install spider to flange yoke. Be sure to install the
spider by aligning the setting marks made during
disassembly.
2. Before installing needle roller bearing, apply a
molybdenum–disulfide grease or a multi–purpose
type grease NLGI No. 2 to inside of the bearing cap.
Grease Amount: Approx. 1.2 g (0.042 oz)

401RS028

5. Install snap ring.


NOTE: Discard used snap rings and install new ones.
When the bearing cap is in position, select and attach a
snap ring of suitable thickness so that the end play of the
spider pin is held within 0.1 mm (0.004 in).
Snap ring thickness and identification color
1.5 mm (0.059 in): Blue
1.545 mm (0.061 in): White
401RS011

3. Using either a mallet (or copper hammer) or a press, 1.59 mm (0.063 in): Yellow
install the needle roller bearing into the yoke so that 1.635 mm (0.064 in): Green
the snap ring can be installed in its groove. 1.68 mm (0.066 in): Not colored
CAUTION: The needle roller bearing cannot be NOTE: Be sure to use snap rings of the same thickness
installed smoothly if it is set at an incorrect angle on both sides.
with the flange and excessive hammering will
damage the needle roller bearing.
4C–54 DRIVE SHAFT SYSTEM

Reassembly

401RW057

Legend (2) Seal


(1) Sleeve Yoke (3) Tube Assembly

1. Discard used seal and install new one.


2. Align the alignment marks and install tube assembly
to sleeve yoke.
DRIVE SHAFT SYSTEM 4C–55

Main Data and Specifications


General Specifications
Engine 6VE1 (3.5L) 6VD1 (3.2L) 4JX1 (3.0L) 4JG2 (3.1L)
Transmission A/T A/T
M/T A/T with M/T A/T with M/T A/T M/T A/T
TOD TOD
Construction Hollow steel tube with yoke and spider type universal joint
Length S
846mm 678mm 810mm
W 668mm (26.30in) — (33.31in) (26.69in) — 604mm (23.78in)
(31.89in) —
B
L
1075mm 1271mm 1103mm 1083mm 1236mm 1037mm
W 1093mm (43.03in)
(42.32in) (50.04in) (43.43in) (42.64in)
1029mm (40.51in)
(48.66in) (40.83in)
B
Outside S
diamter W 68.9mm (2.71in) — 68.9mm (2.71in) — 68.9mm (2.71in) —
B
LW 68.9mm (2.71in)
82.6mm
68.9mm (2.71in)
82.6mm 68.9mm
B (3.25in) (3.25in) (2.71in)

Torque Specifications

E04RW023
TRANSFER CASE (STANDARD TYPE) 4D1–1

DRIVELINE/AXLE
TRANSFER CASE (STANDARD TYPE)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 4D1–1 Transfer Rear Cover Assembly and
General Description . . . . . . . . . . . . . . . . . . . . . 4D1–2 Associated Parts . . . . . . . . . . . . . . . . . . . . . . 4D1–19
Transfer Rear Oil Seal . . . . . . . . . . . . . . . . . . . 4D1–8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D1–20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D1–8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D1–20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D1–8 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D1–23
Transfer Case Assembly . . . . . . . . . . . . . . . . . 4D1–9 Inspection and Repair . . . . . . . . . . . . . . . . . . 4D1–24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D1–9 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D1–24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D1–10 Detent, Shift Arm, and Interlock Pin . . . . . . . . 4D1–26
Transfer Rear Cover Assembly Disassembled View . . . . . . . . . . . . . . . . . . . . 4D1–26
(4WD Switch Model) . . . . . . . . . . . . . . . . . . . . 4D1–11 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D1–26
Transfer Rear Cover Assembly and Inspection and Repair . . . . . . . . . . . . . . . . . . 4D1–28
Associated Parts . . . . . . . . . . . . . . . . . . . . . . 4D1–11 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D1–28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D1–12 Transfer Case Assembly . . . . . . . . . . . . . . . . . 4D1–30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D1–13 Disassembled View . . . . . . . . . . . . . . . . . . . . 4D1–30
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D1–16 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D1–31
Inspection and Repair . . . . . . . . . . . . . . . . . . 4D1–17 Inspection and Repair . . . . . . . . . . . . . . . . . . 4D1–33
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D1–17 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D1–37
Transfer Rear Cover Assembly Main Data and Specifications . . . . . . . . . . . . . 4D1–43
(Except 4WD Switch Model) . . . . . . . . . . . . . . 4D1–19 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D1–46

Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
4D1–2 TRANSFER CASE (STANDARD TYPE)

General Description
M/T, W/Shift On The Fly, W/4WD Switch, model

A07RW019
TRANSFER CASE (STANDARD TYPE) 4D1–3

M/T, W/Shift On The Fly, WO/4WD Switch, model

A07RW054
4D1–4 TRANSFER CASE (STANDARD TYPE)

M/T, WO/Shift On The Fly, WO/4WD Switch, model

A07RW053
TRANSFER CASE (STANDARD TYPE) 4D1–5

A/T, W/Shift On The Fly, W/4WD Switch, model

A07RW001
4D1–6 TRANSFER CASE (STANDARD TYPE)

A/T, W/Shift On The Fly, WO/4WD Switch, model

A07RW056
TRANSFER CASE (STANDARD TYPE) 4D1–7

A/T, WO/Shift On The Fly, WO/4WD Switch, model

A07RW055

The transfer case is used to provide a means of providing


power flow to the front axle. The transfer case also
provides a means of disconnecting the front axle,
providing better fuel economy and quieter operation when
the vehicle is driven on improved roads where four wheel
drive is not required. In addition, the transfer case
provides an additional gear reduction when placed in low
range, which is useful when difficult off–road conditions
are encountered.
A floor mounted shift lever is used to select the high–low
range. When four wheel drive switch has been turned on,
the four wheel drive indicator light is designed to come on
when the front axle has been engaged.
4D1–8 TRANSFER CASE (STANDARD TYPE)

Transfer Rear Oil Seal


Removal
1. Disconnect the rear propeller shaft from the transfer
case side.
2. Remove end nut and rear companion flange, using
the companion flange holder 5–8840–0133–0
(J–8614–11).

220RW105

4. Install the rear companion flange and O–ring.


5. Use the companion flange holder 5–8840–0133–0
(J–8614–11) to install a new end nut and tighten to the
specified torque.
Torque: 167 Nꞏm (17.0kgꞏm/123 lb ft)
6. Use the punch 5–8840–2293–0 (J–39209) to stake
266RW026
the end nut at two spots.
3. Use the universal puller to remove the rear
companion flange and O–ring. NOTE: Be sure to confirm that there is no crack at the
4. Remove the oil seal from the transfer case. staked portion of the end nut after staking.

Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. Install oil seal and apply engine oil to the oil seal outer
surfaces.
2. Apply the recommended grease (BESCO L2) or
equivalent to the oil seal lip.
3. Use the oil seal installer 5–8840–2292–0 (J–39208)
to install the rear seal to the transfer rear case.

266RW027
TRANSFER CASE (STANDARD TYPE) 4D1–9
7. Connect the rear propeller shaft to the transfer case
and tighten to the specified torque.
Torque: 63 Nꞏm (6.4kgꞏm/46 lb ft)

266RW002

Transfer Case Assembly


Removal 10. Support the transfer case with a transmission jack.
11. Remove the transmission–transfer bolts and the nut
NOTE: Before removing the transmission & transfer (M/T).
assembly from the vehicle, change the transfer mode to
12. Remove the transfer case assembly from the vehicle.
2WD by pushing button switch on dash panel. (4WD
Switch Model)
1. Disconnect the battery ground cable.
2. Drain the transfer case fluid, if overhauling the
transter case assembly.
3. Remove the exhaust and transfer protectors.
4. Remove the rear and front propeller shafts from the
transfer case side.
5. Remove the transfer control lever knob.
6. Disconnect the harness connectors and remove the
front console.
7. Remove the selector lever assembly. Refer to
Selector Lever in the Section 7A.
8. Remove the transfer control lever.
9. Disconnect the 4WD switch connector, speed sensor
harness connector and 2WD–4WD actuator harness
connector (4WD Switch Model) from the transmission
harness.
4D1–10 TRANSFER CASE (STANDARD TYPE)

Installation 2. Tighten the transmission–transfer bolts and the nut


(M/T) to the specified torque.
To install, follow the removal steps in the reverse order,
noting the following points: Torque: 46 Nꞏm (4.7kgꞏm/34 lb ft)
1. Apply a thin coat of molybdenum disulfide grease to 3. Tighten the propeller shaft bolts to the specified
the input shaft spline and install the transter case torque.
assembly to the vehicle. Torque: 63 Nꞏm (6.4kgꞏm/46 lb ft)
4. Tighten the transfer protector bolts to the specified
torque.
Torque: 37 Nꞏm (3.8kgꞏm/27 lb ft)

260RW001

256RW030
TRANSFER CASE (STANDARD TYPE) 4D1–11

Transfer Rear Cover Assembly (4WD Switch Model)


Transfer Rear Cover Assembly and Associated Parts

220RW102

Legend (4) Control Box Assembly


(1) Speedometer Sensor, Speedometer Driven (5) 2WD–4WD Actuator Heat Protector
Gear and Plate (6) 2WD–4WD Actuator Assembly
(2) Front Companion Flange (7) Transfer Rear Cover Assembly
(3) Rear Companion Flange (8) Transfer Case Assembly
4D1–12 TRANSFER CASE (STANDARD TYPE)

Removal 8. Remove the 2WD–4WD actuator assembly bolts.


9. Pull the 2WD–4WD actuator assembly with
1. Remove the speedometer sensor. 2WD–4WD shift rod.
2. Remove the plate.
3. Remove the speedometer driven gear bushing and
driven gear.
NOTE: Apply a reference mark to the driven gear bushing
before removal.
4. Remove the front companion flange and the rear
companion flange, using the flange companion holder
5–8840–0133–0 (J–8614–11) to remove the end
nuts.

262RW067

NOTE: Use a universal puller to remove the rear 220RW027

companion flange. Legend


5. Disconnect the actuator breather hose and the (1) Shift Rod: 2WD–4WD (Position: 2WD)
transfer breather hose from the control box. (2) 2WD–4WD Actuator Assembly
6. Remove the control box assembly. (3) Pull Cover
7. Disconnect the actuator breather hose and remove (4) Rear Cover Assembly
the 2WD–4WD actuator heat protector from the (5) Position: 4WD
2WD–4WD actuator assembly. (6) Mode: 2WD

220RW085
TRANSFER CASE (STANDARD TYPE) 4D1–13
10. Offset the actuator assembly.

220RS017

220RW028
2. Install the transfer rear cover assembly to the transfer
11. Remove the actuator assembly. case assembly.
3. Perform the following steps before fitting the transfer
rear case:
1. Shift the high–low shift rod to the 4H side.
2. The cut–away portion of the select rod head (9)
should align with that of the rear case hole’s
stopper (10).

220RW029

Legend
(7) Position: 4WD
(8) Mode: 2WD

12. Remove the transfer rear cover assembly from the


transfer case assembly. 230RW004

4. Tighten the transfer rear case bolts to the specified


torque.
Installation Torque: 37 Nꞏm (3.8kgꞏm/27 lb ft)
1. Apply the recommended liquid gasket (LOCTITE 5. Shift the 2WD–4WD shift rod (11) to the 4WD side.
17430) or its equivalent to the transfer rear cover
fitting faces.
4D1–14 TRANSFER CASE (STANDARD TYPE)
6. Join the rod grooves of 2WD–4WD actuator 11. Install the control box assembly.
assembly (12) and shift rod (11). Torque: 19 Nꞏm (1.9kgꞏm/14 lb ft)
12. Connect the breather hoses to the control box.
13. Install the rear companion flange and front
companion flange, using the companion flange holder
5–8840–0133–0 (J–8614–11) to tighten the flange
nuts to the transfer case.

220RW030

Legend
(11) Shift Rod: 2WD–4WD (Position: 4WD)
(12) 2WD–4WD Actuator Assembly (Mode: 2WD)
(13) Rear Cover Assembly
262RW067

7. Push the 2WD–4WD actuator assembly (12) with 14. Tighten the new transfer flange nuts to the specified
2WD–4WD shift rod (11) till the shift rod (11) reaches torque.
the 2WD position.
Torque
Rear companion flange: 167 Nꞏm (17.0kgꞏm/123
lb ft)
Front companion flange: 137 Nꞏm (14.0kgꞏm/101
lb ft)
15. Use the punch 5–8840–2293–0 (J–39209) to stake
the rear companion flange nut at two spots.

220RW031

Legend
(14) Position: 2WD
(15) Mode: 2WD

8. Tighten the 2WD–4WD actuator bolts to the specified


torque.
266RW027

Torque: 19 Nꞏm (1.9kgꞏm/14 lb ft)


9. Install the actuator heat protector.
10. Connect the actuator breather hose to the actuator.
TRANSFER CASE (STANDARD TYPE) 4D1–15
20. Install the plate (6) to the transfer rear case and
tighten to the specified torque.
Torque: 15 Nꞏm (1.5kgꞏm/11 lb ft)
21. Install the speedometer sensor and tighten to the
specified torque.
Torque: 27 Nꞏm (2.8kgꞏm/20 lb ft)

266RW002

16. Stake the front companion flange nut at one spot.


NOTE: Be sure to confirm that there is no crack at the
staked portion of the flange nut after staking.
17. Install the O–ring (8) to the speedometer driven gear
bushing (7).
18. Install the driven gear to the speedometer driven gear
bushing (7). 225RW014

19. Install the speedometer driven gear assembly to the


transfer rear cover.
4D1–16 TRANSFER CASE (STANDARD TYPE)

Disassembly

226RW154

Legend (5) Bearing Snap Ring


(1) Rear Output Shaft Assembly (6) Ball
(2) Rear Output Shaft (7) Speedometer Drive Gear
(3) Bearing Snap Ring (8) Ball Bearing
(4) Ball Bearing (9) Transfer Rear Cover (with oil seal)

1. Remove the bearing snap ring (3), using a pair of snap


ring pliers.

226RS060
TRANSFER CASE (STANDARD TYPE) 4D1–17
2. Remove the rear output shaft assembly (1) from the Reassembly
transfer rear cover (with oil seal).
3. Remove ball bearing (8), using a bench press and the 1. Install transfer rear cover (with oil seal).
bearing remover 5–8840–0015–0 (J–22912–01) . Oil seal replacement
Remove the oil seal from the transfer rear cover.
Apply engine oil to the oil seal outer surfaces.
Fill in recommended grease (BESCO L2) or
equivalent in the oil seal lip.
Use the oil seal installer 5–8840–2292–0 (J–39208)
to install the rear oil seal to the transfer rear cover.

226RW186

4. Remove the speedometer drive gear (7).


5. Remove the ball (6).
6. Remove the bearing snap ring (5), using a pair of snap
ring pliers.
7. Remove the ball bearing (4) from the rear output
shaft, using a bench press and the bearing remover
5–8840–0015–0 (J–22912–01). 220RW104

2. Set the snap ring (3), and install ball bearing (4) to the
rear output shaft (2), using the ball bearing installer
5–8840–2159–0 (J–37223) and the adapter
5–8840–2192–1 (J–37486–A).

226RW187

Inspection and Repair


Refer to “TRANSFER CASE ASSEMBLY” in this section 262RW068

for inspection and repair.


4D1–18 TRANSFER CASE (STANDARD TYPE)
3. Install the bearing snap ring (5).
4. Install the ball (6).
5. Install the speedometer drive gear (7).

226RS064

6. Install ball bearing (8), using the ball bearing installer


5–8840–2159–0 (J–37223).

226RW188

7. Install the rear output shaft assembly (1) to the


transfer rear cover.
8. Install the bearing snap ring (3).
NOTE: The snap ring must be fully inserted into the
transfer rear case snap ring groove.
TRANSFER CASE (STANDARD TYPE) 4D1–19

Transfer Rear Cover Assembly (Except 4WD Switch Model)


Transfer Rear Cover Assembly and Associated Parts

220RW116

Legend (3) Rear Companion Flange


(1) Speedometer Sensor, Speedometer Driven (4) Control Box Assembly
Gear and Plate (5) Transfer Rear Cover Assembly
(2) Front Companion Flange (6) Transfer Case Assembly
4D1–20 TRANSFER CASE (STANDARD TYPE)

Removal
1. Remove the speedometer sensor.
2. Remove the plate.
3. Remove the speedometer driven gear bushing and
driven gear.
NOTE: Apply a reference mark to the driven gear bushing
before removal.
4. Remove the front companion flange and the rear
companion flange, using the flange companion holder
5–8840–0133–0 (J–8614–11) to remove the end
nuts.

220RS017

2. Install the transfer rear cover assembly to the transfer


case assembly.
3. Perform the following steps before fitting the transfer
rear case:
1. Shift the high–low shift rod to the 4H side.
2. Turn the select rod counterclockwise so that the
select block projection may enter into the
2WD–4WD shift block.
3. The cut–away portion of the select rod head (9)
should align with that of the rear case hole’s
stopper (10).
262RW067

NOTE: Use a universal puller to remove the rear


companion flange.
5. Disconnect the transfer breather hose from the
control box.
6. Remove the control box assembly.
7. Remove the transfer rear cover assembly from the
transfer case assembly.

Installation
1. Apply the recommended liquid gasket (LOCTITE
17430) or its equivalent to the transfer rear cover
fitting faces.

230RW004

4. Tighten the transfer rear case bolts to the specified


torque.
Torque: 37 Nꞏm (3.8kgꞏm/27 lb ft)
TRANSFER CASE (STANDARD TYPE) 4D1–21
5. Install the control box assembly.
Torque: 19 Nꞏm (1.9kgꞏm/14 lb ft)
6. Connect the breather hoses to the control box.
7. Install the rear companion flange and front
companion flange, using the companion flange holder
5–8840–0133–0 (J–8614–11) to tighten the flange
nuts to the transfer case.

262RW067

8. Tighten the new transfer flange nuts to the specified


torque.
266RW002
Torque 10. Stake the front companion flange nut at one spot.
Rear companion flange: 167 Nꞏm (17.0kgꞏm/123
lb ft) NOTE: Be sure to confirm that there is no crack at the
staked portion of the flange nut after staking.
Front companion flange: 137 Nꞏm (14.0kgꞏm/101
lb ft) 11. Install the O–ring (8) to the speedometer driven gear
bushing (7).
9. Use the punch 5–8840–2293–0 (J–39209) to stake
the rear companion flange nut at two spots. 12. Install the driven gear to the speedometer driven gear
bushing (7).
13. Install the speedometer driven gear assembly to the
transfer rear cover.
14. Install the plate (6) to the transfer rear case and
tighten to the specified torque.
Torque: 15 Nꞏm (1.5kgꞏm/11 lb ft)

266RW027
4D1–22 TRANSFER CASE (STANDARD TYPE)
15. Install the speedometer sensor and tighten to the
specified torque.
Torque: 27 Nꞏm (2.8kgꞏm/20 lb ft)

225RW014
TRANSFER CASE (STANDARD TYPE) 4D1–23

Disassembly

226RW154

Legend (5) Bearing Snap Ring


(1) Rear Output Shaft Assembly (6) Ball
(2) Rear Output Shaft (7) Speedometer Drive Gear
(3) Bearing Snap Ring (8) Ball Bearing
(4) Ball Bearing (9) Transfer Rear Cover (with oil seal)

1. Remove the bearing snap ring (3), using a pair of snap


ring pliers.

226RS060
4D1–24 TRANSFER CASE (STANDARD TYPE)
2. Remove the rear output shaft assembly (1) from the Reassembly
transfer rear cover (with oil seal).
3. Remove ball bearing (8), using a bench press and the 1. Install transfer rear cover (with oil seal).
bearing remover 5–8840–0015–0 (J–22912–01) . Oil seal replacement
Remove the oil seal from the transfer rear cover.
Apply engine oil to the oil seal outer surfaces.
Fill in recommended grease (BESCO L2) or
equivalent in the oil seal lip.
Use the oil seal installer 5–8840–2292–0 (J–39208)
to install the rear oil seal to the transfer rear cover.

226RW186

4. Remove the speedometer drive gear (7).


5. Remove the ball (6).
6. Remove the bearing snap ring (5), using a pair of snap
ring pliers.
7. Remove the ball bearing (4) from the rear output
shaft, using a bench press and the bearing remover
5–8840–0015–0 (J–22912–01). 220RW104

2. Set the snap ring (3), and install ball bearing (4) to the
rear output shaft (2), using the ball bearing installer
5–8840–2159–0 (J–37223) and the adapter
5–8840–2192–1 (J–37486–A).

226RW187

Inspection and Repair


Refer to “TRANSFER CASE ASSEMBLY” in this section 262RW068

for inspection and repair.


TRANSFER CASE (STANDARD TYPE) 4D1–25
3. Install the bearing snap ring (5).
4. Install the ball (6).
5. Install the speedometer drive gear (7).

226RS064

6. Install ball bearing (8), using the ball bearing installer


5–8840–2159–0 (J–37223).

226RW188

7. Install the rear output shaft assembly (1) to the


transfer rear cover.
8. Install the bearing snap ring (3).
NOTE: The snap ring must be fully inserted into the
transfer rear case snap ring groove.
4D1–26 TRANSFER CASE (STANDARD TYPE)

Detent, Shift Arm, and Interlock Pin


Disassembled View

262RW074

Legend (9) Interlock Pin


(1) Detent Ball, Spring and Plug (10) Spring
(2) Spring Pin and Bridge (11) Select Rod Assembly
(3) Spring Pin (12) Spring Pin
(4) Spring (13) High–Low Shift Rod
(5) 2WD–4WD Shift Rod (14) Shift Arm
(6) Shift Arm (15) Shift Block
(7) Shift Block (16) Transfer Case
(8) 4WD Indicator Switch (17) Spring (Except Shift On The Fly Model)

Disassembly
1. Remove the detent ball, spring and plug (1).
TRANSFER CASE (STANDARD TYPE) 4D1–27
2. Use a spring pin remover to remove the spring pin (2) 8. Use a magnetic tool to remove the interlock pin (9)
from the bridge (2). and spring (10) from the transfer case (16).

262RW011 262RS005

3. Remove the spring (4). 9. Remove the select rod assembly (11).
4. Engage the 2WD–4WD sleeve with the front output 10. Use a spring pin remover to remove the shift arm
gear. Remove the spring pin (3) from the block (7). spring pins (12) from the shift arm (14) and shift block
Remove the 2WD–4WD shift rod (5). (15). Remove the high–low shift rod (13) from the
transfer case (16).

262RW022

5. Remove the shift arm (6). 262RS006

6. Remove the shift block (7). 11. Remove the shift arm (14).
7. Remove the 4WD indicator switch (8). 12. Remove the shift block (15) from the transfer case
(16).
4D1–28 TRANSFER CASE (STANDARD TYPE)

Inspection and Repair


Refer to “TRANSFER CASE ASSEMBLY” in this section
for inspection and repair.

Reassembly
1. Place the shift block (15) in the transfer case (16).
2. Set the shift arm (14) on the High–Low sleeve.
3. Push the High–Low shift rod (13) through the shift
arm (14) and block (14).
4. Engage the High–Low sleeve with the 4H (1) side.
5. Install the spring pins (12) to the shift block (15) and
shift arm (14).

262RW035

Legend
(18) 2WD–4WD
(19) 4H Side
262RW012

6. Install the select rod assembly (11), joining its lever to (20) Interlock pin
the shift block groove. (21) 2WD
7. Engage the High–Low sleeve with the 4H side and (22) 4WD
install the the interlock pin (9) and spring (10) in the (23) Rod: 2–4
proper direction. (24) Rod: H–L
8. Place the 2WD–4WD shift block (7) in the transfer (25) 4H
case (16). (26) 4L
9. Set the 2WD–4WD shift arm (6) on the 2WD–4WD (27) 4 2
sleeve. (28) 4 4
10. Push the 2WD–4WD shift rod (5) through the
2WD–4WD shift arm (6) and 2WD–4WD shift block 12. Install the 4WD indicator switch and gasket (8).
(7). Tighten to the specified torque.
11. Install the 2WD–4WD shift rod (5) with the interlock Torque: 39 Nꞏm (4.0kgꞏm/29 lb ft)
pin pushed in. 13. Install the spring (4).
TRANSFER CASE (STANDARD TYPE) 4D1–29
14. Engage the 2WD–4WD sleeve with the 4WD side and
install the spring pin (3).

262RW022

15. Install the spring pin and bridge (2).


16. Install the detent ball, spring and plug and tighten the
plug (1) to the specified torque.
Torque: 25 Nꞏm (2.5kgꞏm/18 lb ft)
4D1–30 TRANSFER CASE (STANDARD TYPE)

Transfer Case Assembly


Disassembled View

226RW132

Legend (22) Counter Gear


(1) Transfer Case (with oil seal) (23) Sub–Gear (anti–lash plate)
(2) Bearing Snap Ring (24) Belleville Spring
(3) Front Output Gear Assembly (25) Spacer
(4) Ball Bearing (26) Ball Bearing
(5) Front Output Shaft (27) Snap Ring
(6) Stopper Plate (Shift On The Fly model) (28) Counter Gear Assembly
(7) 2WD–4WD Clutch Hub and Sleeve Assembly (29) Bearing Snap Ring
(8) Block Ring (Shift On The Fly model) (30) Input Shaft Assembly
(9) Outside Ring (Shift On The Fly model) (31) Input Shaft
(10) Inside Ring (Shift On The Fly model) (32) Ball Bearing
(11) Front Output Gear (33) Snap Ring
(12) Needle Bearing (34) Plate
(13) Sub–Gear (anti–lash plate) (M/T) (35) Ball
(14) Belleville Spring (M/T) (36) Bearing Collar
(15) Spacer (M/T) (37) Needle Bearing
(16) Sub–Gear Snap Ring (M/T) (38) Transfer Input Gear
(17) Bearing Collar (39) High–Low Clutch Hub and Sleeve Assembly
(18) Ball Bearing (40) Lock Nut
(19) Bearing Snap Ring (41) Ball Bearing
(20) Snap Ring (42) Bearing Snap Ring
(21) Ball Bearing
TRANSFER CASE (STANDARD TYPE) 4D1–31

Disassembly 5. Remove the front companion flange.


6. Remove the snap ring (33) from the transfer case (1).
1. Use a pair of snap ring pliers to remove the snap ring
(42). 7. Remove the input shaft assembly (30) from the
transfer case.
2. Use a bearing remover 5–8840–2155–0 ( J–37217)
and puller 5–8840–2027–0 (J–37487) to remove the
ball bearing (41).

265RW001

8. Use a universal puller to remove the high–low clutch


hub and sleeve (39), and transfer input gear (38).
262RW069

3. Install the front companion flange temporarily.


4. Use the Companion flange holder 5–8840–0133–0
(J–8614–11) and lock nut wrench 5–8840–2156–0
(J–37219) to remove the lock nut (40).

226RS070

9. Remove needle bearing (37).

226RW189
4D1–32 TRANSFER CASE (STANDARD TYPE)
10. Remove the bearing collar (36). 15. Use a plastic hammer to tap the front output gear
assembly (3) free.

226RS071

11. Remove the ball (35). 262RS009

12. Remove the plate (34). 16. Remove the bearing snap ring (19). Remove the ball
bearing (18) and bearing collar (17) together with
13. Use a bench press and the ball bearing remover
front output gear assembly: including following parts.
5–8840–0015–0 (J–22912–01) to remove the ball
bearing (32) from input shaft (31). 17. Use a bench press and the bearing remover
5–8840–0015–0 (J–22912–01) to remove the
following parts.
18. Remove the sub–gear snap ring (16), spacer (15),
belleville spring (14), and sub–gear (anti–lash plate)
(13).(M/T)
19. Remove the front output gear (11) and needle bearing
(12).

265RW013

14. Remove the bearing snap ring (2) from the transfer
case, using a pair of snap ring pliers.

262RW070

20. Remove the inside ring (10). (Shift On The Fly model)
21. Remove the outside ring (9). (Shift On The Fly model)
22. Remove the block ring (8). (Shift On The Fly model)
23. Use a bench press and bearing remover
5–8840–0015–0 (J–22912–01) to remove the
2WD–4WD clutch hub and sleeve assembly (7) and
stopper plate (6). (Shift On The Fly model)
TRANSFER CASE (STANDARD TYPE) 4D1–33
NOTE: Do not reuse the stopper plate. (Shift On The Fly 29. Use a bench press and the bearing remover
model) 5–8840–0015–0 (J–22912–01) to remove the ball
bearing (21).
24. Disassemble the 2WD–4WD clutch hub and sleeve
assembly. 30. Use a pair of snap ring pliers to remove the snap ring
(27).
Springs (1) (Shift On The Fly model)
31. Use a bench press and the bearing remover
Inserts (2) (Shift On The Fly model) 5–8840–0015–0 (J–22912–01) to remove the ball
Clutch Hub (3) bearing (26).
Sleeve (4)

226RW191

32. Remove the spacer (25).


226RW133
33. Remove the belleville spring (24).
25. Use a bench press and the ball bearing remover
5–8840–0015–0 (J–22912–01) to remove the ball 34. Remove the sub–gear (anti–lash plate) (23) from the
bearing (4) from front output shaft (5). counter gear (22).

Inspection and Repair


1. Make the necessary repair or parts replacement if
wear, damage or any other abnormal conditions are
found during inspection.
2. Wash all parts thoroughly in clean solvent. Be sure all
old lubricant, metallic particles, dirt, or foreign
material are removed from the surfaces of every part.
Apply compressed air to each oil feed port and
channel in each case half to remove any obstructions
or cleaning solvent residue.
Gears
1. Inspect all the gear teeth for signs of excessive wear
or damage and check all the gear splines for burrs,
nicks, wear or damage. Remove the minor nicks or
scratches on an oil stone. Replace any part exhibiting
excessive wear or damage.
262RW071
Front Output Gear Inside Diameter
26. Remove bearing snap ring (29) from transfer case. 1. Use an inside dial indicator to measure the gear inside
27. Remove the counter gear assembly (28) from the diameter.
transfer case (1).
28. Use a pair of snap ring pliers to remove the snap ring
(20).
4D1–34 TRANSFER CASE (STANDARD TYPE)
2. If the measured value exceeds the specified limit, the Bearings
gear must be replaced.
1. Inspect the condition of all the needles and ball
Gear inside diameter bearings. Wash bearings thoroughly in a cleaning
Standard : 48.000–48.013 mm (1.8898–1.8903 in) solvent. Apply compressed air to the bearings.
Limit : 48.10 mm (1.894 in) NOTE: Do not allow the bearings to spin. Turn them
slowly by hand. Spinning bearings may damage the
rollers.
2. Lubricate the bearings with a light oil and check them
for roughness by slowly turning the race by hand.
Ball Bearing Play
1. Use a dial indicator to measure the ball bearing play.
2. If the measured value exceeds the specified limit, the
ball bearing must be replaced.
Limit : 0.2 mm (0.008 in)

226RS040

Clutch Hub Spline Play


1. Set a dial indicator to the clutch hub to measured.
2. Move the clutch hub as far as possible to both the right
and the left.
Note the dial indicator reading.
3. If the measured value exceeds the specified limit, the
clutch hub must be replaced.
Clutch hub spline play 226RS043

Standard : 0–0.1 mm (0–0.004 in)


Limit : 0.2 mm (0.008 in)
Synchronizers
The synchronizer hubs and sliding sleeves are a selected
assembly and should be kept together as originally
assembled.
Clean synchronizer components with clean solvent and
air dry.
Inspect the components for the following:
Teeth for wear, scuffs, nicks, burrs or breaks.
Keys and springs for wear, cracks or distortion,
replace if these conditions are present.
If scuffed, nicked or burred conditions cannot be
corrected with a soft stone or crocus cloth, replace the
component.

Block Ring and Insert Clearance


1. Use a vernier caliper to measure the clearance
between the block ring and the insert.
2. If the measured value exceeds the specified limit, the
block ring and the insert must be replaced.
226RS042 Block ring and insert clearance
Standard : 2.46–2.74 mm (0.097–0.108 in)
TRANSFER CASE (STANDARD TYPE) 4D1–35
Limit : 3.0 mm (0.118 in) Clutch Hub and Insert Clearance
1. Use a thickness gauge to measure the clearance
between the clutch hub and the insert.
2. If the measured value exceeds the specified limit, the
clutch hub and the insert must be replaced.
Clutch hub and insert clearance
Standard : 0.01–0.19 mm (0.0004–0.0075 in)
Limit : 0.3 mm (0.012 in)

226RS037

2WD–4WD 3–Cone Synchronizer (Shift On


The Fly model)
1. Use a thickness gauge to measure the clearance
between the block ring and the dog teeth.
2. If the measured value exceeds the specified limit, the
2WD–4WD synchronizer assembly must be
replaced. 226RS038

Block ring and insert clearance


Detent Springs
Standard : 1.5 mm (0.059 in)
1. Inspect the springs for distortion, cracks or wear.
Limit : 0.8 mm (0.031 in)
Replace if these conditions are present.
Detent Spring Free Length
1. Use a vernier caliper to measure the detent spring
free length.

226RW142
4D1–36 TRANSFER CASE (STANDARD TYPE)
2. If the measured value is less than the specified limit,
the detent spring must be replaced.
Detent spring free length
Detent ball
Standard : 23.4 mm (0.921 in)
Limit : 22.8 mm (0.898 in)
Interlock pin
Standard : 1.59 mm (0.063 in)
Limit : 1.53 mm (0.060 in)

220RS013

Shift Arm
1. Inspect the shift arms for wear, distortion or scoring.
Replace if these conditions are present.
Shift Arm Thickness
1. Use a micrometer to measure the shift arm thickness.
2. If the measured value is less than the specified limit,
the shift arm must be replaced.
Shift arm thickness
220RW035
Standard : 9.60–9.85 mm (0.378–0.388 in)
Detent Spring Tension
Limit : 9.0 mm (0.354 in)
1. Use a spring tester to measure the detent spring
tension.
2. If the measured value is less than the specified limit,
the detent spring must be replaced.
Detent spring free length
Detent ball
Compressed height : 18.7 mm (0.736 in)
Standard : 68.6–88.2 N (7.0–9.0kg/15.4–19.8 lb)
Interlock pin
Compressed height : 11.5 mm (0.453 in)
Standard : 9.8 N (1.0kg/2.2 lb)

230RS006
TRANSFER CASE (STANDARD TYPE) 4D1–37

Reassembly
1. Put the transfer case (with oil seal) as the following
illustration.
Input shaft oil seal (1) replacement
1. Remove the oil seal from the transfer case.
2. Apply engine oil to the oil seal outer surfaces.
3. Apply recommended grease (BESCO L2) or
equivalent to the oil seal lip.
4. Use the oil seal installer 5–8840–2279–0
(J–38592) to install the oil seal to the transfer
case.

220RW107

Legend
(2) Front output shaft oil seal

2. Apply chassis grease (3) to the sub–gear (23) and the


counter gear (22) thrust surfaces.

220RW106

Front output shaft oil seal (2) replacement


1. Remove the oil seal from the transfer case.
2. Apply engine oil to the oil seal outer surfaces.
3. Apply recommended grease (BESCO L2) or
equivalent to the oil seal lip.
4. Use the oil seal installer 5–8840–2281–0
(J–38594) to install the oil seal to the transfer
case.

226RW134
4D1–38 TRANSFER CASE (STANDARD TYPE)
3. Install the sub–gear (23) to the counter gear (22). Sub–Gear (anti–lash plate) Preload
4. Install the belleville spring (24). 1. Hook a length of piano wire (4) over one of the
5. Install the spacer (25) and put the snap ring (29) on sub–gear (5) teeth.
the sub–gear (23). 2. Attach the other end of the piano wire (4) to a
6. Install the ball bearing (26), using a bench press. spring balancer.
7. Select a snap ring that will allow the minimum axial 3. Measure the sub–gear preload.
play.
Preload : 59–98 N (6.0–10kg/13–22 lb)
Clearance : 0–0.1 mm (0–0.004 in)

Snap ring availability:


Thickness Color–coding
1.50 mm (0.059 in) White
1.55 mm (0.061 in) Yellow
1.60 mm (0.063 in) Blue

8. Use a pair of snap ring pliers to install the snap ring


(27) to the counter gear (22).

226RS075

9. Install ball bearing (21), using a bench press.


10. Install snap ring (20).
11. Install the counter gear assembly (28) to the transfer
case (1).
12. Use a pair of snap ring pliers to install the snap ring
(29) to the transfer case (1).
NOTE: The snap ring must be fully inserted into the
transfer case snap ring groove.
13. Use a bench press to install the ball bearing (4) to the
226RS170 front output shaft (5).

226RS021
262RS012
TRANSFER CASE (STANDARD TYPE) 4D1–39
14. Assemble the 2WD–4WD clutch hub and sleeve
assembly (7).

226RW135

Legend
226RW140 (6) Front Output Gear
15. Engage the springs in the same insert with the open
ends away from each other. (Shift On The Fly model) 17. The clutch hub face (with the heavy boss) must be
facing the front output gear side.
18. Use a bench press to slowly force the clutch hub and
sleeve assembly (7) together with the stopper plate
(6) (Shift On The Fly model) into place.
19. Align the inserts with the block ring insert grooves.
Install the block ring (8) (Shift On The Fly model) to
the clutch sleeve and hub assembly (7).
20. Install the outside ring (9) (Shift On The Fly model),
inside ring (10) (Shift On The Fly model) and needle
bearing (12) to the front output gear (11) and bearing
collar (17).
NOTE: Coat all parts with transmission oil before
installing them.

226RW141

16. Place the snap ring (2), a new stopper plate (6) (Shift
On The Fly model) and the clutch sleeve and hub
assembly (7) on the front output shaft (5).

226RW139
4D1–40 TRANSFER CASE (STANDARD TYPE)
21. Apply engine oil to the thrust surfaces of the sub–gear 26. Select a snap ring that will allow the minimum axial
(13), the belleville spring (14), and the spacer (15). play.
(M/T) Clearance : 0–0.1 mm (0–0.004 in)

Snap ring availability:


Snap ring thickness Color coding
1.55 mm (0.061 in) White
1.60 mm (0.063 in) Yellow
1.65 mm (0.065 in) Blue
1.70 mm (0.067 in) Pink
1.75 mm (0.069 in) Green
1.80 mm (0.071 in) Brown
1.85 mm (0.073 in) Red
1.90 mm (0.075 in) Orange

262RW060

22. Install the sub–gear (anti–lash plate) (13), belleville


spring (14), and spacer (15) to the front output gear
(11).(M/T)
23. Install the sub–gear snap ring (16). (M/T)
24. Use a bench press to install the needle bearing collar
(17) together with the front output gear, aligning inside
ring claw with block ring groove.

262RS015

262RS014

25. Install ball bearing (18), using a bench press.

226RS021
TRANSFER CASE (STANDARD TYPE) 4D1–41
27. Use a pair of snap ring pliers to install the snap ring 31. Install the plate (34), ball (35), and bearing collar (36)
(19) to the output shaft (5). and place the snap ring (33).
Sub gear (anti lash plate) preload (M/T) 32. Install the needle bearing (37) and input gear (38).
1. Hook a length of piano wire (4) over one of the 33. The clutch hub face (with the heavy boss) must be
sub–gear (5) teeth. facing the transfer input gear side (7).
2. Attach the other end of the piano wire to (4) a
spring balancer.
3. Measure the sub–gear preload.
Preload: 59–98 N (6.0–10.0kg/13–22 lb)
(M/T)

226RW136

34. Install the high–low clutch hub and sleeve (39), using
a bench press.
35. Install the input shaft assembly (30) to the transfer
case (1).
36. Install the snap ring (33) to the transfer case (1).
226RS075 NOTE: The snap ring must be fully inserted into the
28. Install front output gear assembly (3) to the transfer transfer case snap ring groove.
case (1).
37. Install the front companion flange temporarily and use
29. Use a pair of snap ring pliers to install the snap ring (2) the flange holder 5–8840–0133–0 (J–8614–11) and
to the transfer case (1). lock nut wrench 5–8840–2156–0 (J–37219) to install
NOTE: The snap ring must be fully inserted into the the lock nut (40).
transfer case snap ring groove. Torque: 137 Nꞏm (14.0kgꞏm/101 lb ft)
30. Use a bench press to install the ball bearing (32) to the
input shaft (31).

226RW190

38. Use the punch to stake the lock nut (40) at one spot.
265RS003
4D1–42 TRANSFER CASE (STANDARD TYPE)
39. Use a suitable drift and hammer to install the ball
bearing (41).

226RS079

40. Install the bearing snap ring (42).


TRANSFER CASE (STANDARD TYPE) 4D1–43

Main Data and Specifications


General Specifications
Type W/Shift On The Fly System model
Synchronized type gears shifting between the 2 and 4 wheel drive mode.
Constant mesh type gears shifting between “low” and “high”.
WO/Shift On The Fly System model
Constant mesh type gears shifting between the 2 and 4 wheel drive mode,
and between “low” and “high”.
Control method W/4WD Switch model
Electric control with the button switch on the instrument panel for gear
shifting between the 2 and 4 wheel drive mode.
Remote control with the gear shift lever on the floor for gear shifting
between “low and high” .
WO/4WD Switch model
Remote control with the gear shift lever on the floor for gear shifting.
Gear ratio High; 1.000
Low; 2.050
Oil capacity 1.45 lit. (1.53 U.S. quart)
Type of lubricant Engine oil
Refer to chart in Section 0

Torque Specifications

E07RW037
4D1–44 TRANSFER CASE (STANDARD TYPE)

E07RW039
TRANSFER CASE (STANDARD TYPE) 4D1–45

E07RW038
4D1–46 TRANSFER CASE (STANDARD TYPE)

Special Tools
PART NO. PART NO.
ILLUSTRATION ILLUSTRATION
PART NAME PART NAME

5–8840–0015–0
5–8840–2292–0
(J–22912–01)
(J–39208)
Bearing
Rear oil seal installer
remover/installer

5–8840–2279–0
5–8840–2192–1
(J–38592)
(J–37486–A)
Transfer case oil seal
Bearing installer adapter
installer

5–8840–2156–0 5–8840–0133–0
(J–37219) (J–8614–11)
Mainshaft nut wrench Flange holder

5–8840–2159–0 5–8840–2155–0
(J–37223) (J–37217)
Rear output shaft and Mainshaft end bearing
bearing installer remover

5–8840–2293–0 5–8840–2027–0
(J–39209) (J–37487)
Punch, end nut Puller

5–8840–2281–0
5–8840–0007–0
(J–38594)
(J–8092)
Front output shaft oil
Driver handle
seal installer
TRANSFER CASE (TOD) 4D2–1

DRIVELINE/AXLE
TRANSFER CASE (TOD)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 4D2–1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–16
Transfer Case Assembly . . . . . . . . . . . . . . . . . 4D2–2 Sprocket and Mechanical Lock . . . . . . . . . . . . 4D2–18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–2 Disassembled View . . . . . . . . . . . . . . . . . . . . 4D2–18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–18
Transfer Rear Oil Seal . . . . . . . . . . . . . . . . . . . 4D2–5 Output Shafts and Shift Control Shaft . . . . . . 4D2–20
Transfer Rear Oil Seal and Associated Disassembled View . . . . . . . . . . . . . . . . . . . . 4D2–20
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–5 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–5 Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–5 Disassembled View . . . . . . . . . . . . . . . . . . . . 4D2–23
TOD ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–7 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–7 Inspection and Repair . . . . . . . . . . . . . . . . . . 4D2–26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–7 Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–30
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–8 Disassembled View . . . . . . . . . . . . . . . . . . . . 4D2–30
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–8 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–30
Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–9 Output Shafts and Shift Control Shaft . . . . . . 4D2–34
Disassembled View . . . . . . . . . . . . . . . . . . . . 4D2–9 Disassembled View . . . . . . . . . . . . . . . . . . . . 4D2–34
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–9 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–34
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–10 Sprocket and Mechanical Lock . . . . . . . . . . . . 4D2–37
Transfer Cover Assembly . . . . . . . . . . . . . . . . 4D2–12 Disassembled View . . . . . . . . . . . . . . . . . . . . 4D2–37
Disassembled View . . . . . . . . . . . . . . . . . . . . 4D2–12 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–37
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–12 Clutch Pack and Clutch Cam . . . . . . . . . . . . . 4D2–39
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–14 Disassembled View . . . . . . . . . . . . . . . . . . . . 4D2–39
Transfer Case Assembly Clutch Pack and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–39
Clutch Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–16 Main Data and Specifications . . . . . . . . . . . . . 4D2–41
Disassembled View . . . . . . . . . . . . . . . . . . . . 4D2–16 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–43

Service Precaution CAUTION: Always use the correct fastener in the


proper location. When you replace a fastener, use
WARNING: IF SO EQUIPPED WITH A ONLY the exact part number for that application.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS), ISUZU will call out those fasteners that require a
REFER TO THE SRS COMPONENT AND WIRING replacement after removal. ISUZU will also call out
LOCATION VIEW IN ORDER TO DETERMINE the fasteners that require thread lockers or thread
WHETHER YOU ARE PERFORMING SERVICE ON OR sealant. UNLESS OTHERWISE SPECIFIED, do not
NEAR THE SRS COMPONENTS OR THE SRS use supplemental coatings (Paints, greases, or other
WIRING. WHEN YOU ARE PERFORMING SERVICE corrosion inhibitors) on threaded fasteners or
ON OR NEAR THE SRS COMPONENTS OR THE SRS fastener joint interfaces. Generally, such coatings
WIRING, REFER TO THE SRS SERVICE adversely affect the fastener torque and the joint
INFORMATION. FAILURE TO FOLLOW WARNINGS clamping force, and may damage the fastener. When
COULD RESULT IN POSSIBLE AIR BAG you install fasteners, use the correct tightening
DEPLOYMENT, PERSONAL INJURY, OR sequence and specifications. Following these
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. instructions can help you avoid damage to parts and
systems.
4D2–2 TRANSFER CASE (TOD)

Transfer Case Assembly


Removal

F07RW083

Legend (7) Breather Hose


(1) Transfer Protector (8) Exhaust Pipe
(2) Rear Propeller Shaft (9) Seat Belt Tension Rod
(3) Front Propeller Shaft (10) Speed Sensor Harness Connector
(4) Front Console (11) Transfer Harness Connector
(5) Selector Lever Assembly (12) Transfer Case Bolt
(6) Transfer Control Lever (13) Transfer Case

1. Disconnect the ground cable.


2. Remove the transfer protector.
3. Remove the rear propeller shaft from the transfer
case.
4. Remove the front propeller shaft from the transfer
case.
5. Remove the shift control rod from the selector lever
assembly.
TRANSFER CASE (TOD) 4D2–3
6. Disconnect the wiring harness connector, transfer Installation
control lever knob and shift lock cable and then
remove the front console. To install, follow the removal steps in the reverse order,
noting the following points:
7. Remove the selector lever assembly and put it aside.
1. Apply a thin coat of grease (Besco L2) or equivalent to
8. Remove the transfer control lever. the input shaft spline.
9. Disconnect the breather hose.
10. Remove the left front exhaust pipe fixing bolts and
nuts, and put the exhaust pipe aside.
11. Remove the left seat belt tension rod and put the rear
proper shaft aside.

261RW024

2. Mount the transfer case.

260RW006

12. Disconnect the transfer harness connector from the


top of the transfer case.
13. Disconnect the speed sensor harness connector.
14. Remove the fuel pipe clip fixing bolt on the transfer
case.
15. Support the transmission with a jack.
16. Remove the seven bolts from the transfer case.
17. Remove the transfer case assembly.
4D2–4 TRANSFER CASE (TOD)
3. Tighten the transfer case bolts (see the figure below).
Torque : 46 Nꞏm (4.7 kgꞏm/34 lb ft)

261RW004–1

4. Tighten the propeller shaft bolts.


Torque : 63 Nꞏm (6.4 kgꞏm/46 lb ft)
TRANSFER CASE (TOD) 4D2–5

Transfer Rear Oil Seal


Transfer Rear Oil Seal and Associated Parts

261RW005

Legend
(1) Oil Seal
(2) End Nut and Rear Companion Flange

Removal
1. Remove the rear propeller shaft from the transfer
case.
2. Using the flange holder 5-8840-0133-0 (J-8614-11),
remove the end nut.
3. Using the universal puller, remove the rear
companion flange, washer and O-ring.
4. Remove the oil seal from the transfer rear case.

Installation
1. Apply engine oil to the oil seal outer surfaces. Fill the
oil seal lip with grease (Besco L2).

261RW006

Legend
(1) Inside
(2) Outside
4D2–6 TRANSFER CASE (TOD)
2. Using the oil seal installer 5-8840-2412-0 (J-42804), 3. Mount the rear companion flange, O-ring , washer,
install the oil seal. and nut to the transfer case in this order.
NOTE: When installing the oil seal, pay attention to the 4. Using the flange holder 5-8840-0133-0 (J-8614-11),
direction. install a new end nut.
Torque : 167 Nꞏm (17 kgꞏm /123 lb ft)
5. Using the punch 5-8840-2293-0 (J-39209), stake the
end nut at two spots.
NOTE: Check the staked end nut is free from cracks.

261RW051

Rear Output Shaft Oil Seal


Distance between the transfer case end and oil seal.
NOTE: When installing the oil seal to the specified
dimension, be careful not to damage it. 266RW028

Distance : 9.85 — 10.35mm (0.39 — 0.41 in)

260RW007

6. Install the rear propeller shaft to the transfer case and


A04RW004 tighten to the specified torque.
Torque : 63 Nꞏm (6.4 kgꞏm /46 lb ft)
TRANSFER CASE (TOD) 4D2–7

TOD ECU
Removal Installation
1. Disconnect the ground cable. 1. Perform the removal step in reverse order.
2. Move the right-hand seat forward and remove the
second seat foot rest (1).
3. Disconnect the connector from the ECU (2).
4. Remove the bolts and detach the ECU (2) from the
bracket.

F07RW021
4D2–8 TRANSFER CASE (TOD)

Unit Repair
Inspection 4H and 4L switch
Before disassembling and after assembling, check the Check whether the 4H switch (terminals 4 and 7) and 4L
following items on the transfer connector terminals. switch (terminals 12 and 3 ) work as specified in the table
below. If yes, the continuity is established on these
No. NAME CONTENTS switches. If not, check the switches, shift rails, transfer
1 Ref . (Rr . ) Rear speed sensor case, and rear cover, and replace the failed parts.
reference output
SHIFT PIN 4 (4 to 7) PIN 12 (3 to 12)
2 Ref . (Frt . ) Front speed sensor POSITION 4H SW 4L SW
reference output
HIGH OFF OFF
3 SW GND SW GND
(NEUTRAL) ON ON
4 4H SW (+) 4H SW plus terminal
4L OFF ON
5 Rer . (+) Rear speed sensor plus
6 Frt . (+) Front speed sensor plus
Power GND
7 POWER GND Power GND
Check that there is a continuity between the power GND
8 EMC (+) Electromagnetic coil pin (terminal 7) and transfer case. If not, replace the
9 COM (–) (Rr .) Rear speed sensor GND grounding wire.

10 COM (–) (Frt .) Front speed sensor GND Resistance of electromagnetic coil
11 NC Not used Check the resistance between electromagnetic coil
(terminal 8) and power GND (terminal 7). If not, replace
12 4L SW (+) 4L SW plus terminal
the electromagnetic coil.
Standard : 1.4 2.0
Allowable : 1.0 5.0

810RW002
TRANSFER CASE (TOD) 4D2–9

Transfer Case
Disassembled View

266RW004

Legend (4) Spring Pin


(1) Front Companion Flange (5) Transfer Case Assembly
(2) 4H and 4L Switch, Ground Cable, and Center (6) Transfer Cover Assembly
Connector (7) Rear Companion Flange
(3) Offset Lever

Disassembly
1. Remove the drain plug from the transfer case and
drain the oil.
2. Disconnect the 4H and 4L switch and ground cable.
3. Remove the clip fixing the harness.
4. Using the flange holder 5-8840-0133-0 (J-8614-11),
remove the flange nut, and remove front companion
flange.
5. Using the flange folder 5-8840-0133-0 (J-8614-11),
remove the flange nut, and remove rear companion
flange.

266RW005
4D2–10 TRANSFER CASE (TOD)
6. Remove the offset lever set bolt on the right side. 8. Remove the offset lever.

261RW015 261RW017

7. Remove the offset lever lock spring pin. 9. Remove the sixteen bolts and detach the transfer
cover assembly from the transfer case assembly.
NOTE: When removing the spring pin, note the recess
position of the pin. NOTE: When removing the transfer cover assembly, be
careful not to damage the oil seal.

Reassembly
1. Apply liquid gasket (Loctite 598 or equivalent)
uniformly to the mating face that contacts the transfer
case.

261RW016

261RW023
TRANSFER CASE (TOD) 4D2–11
2. Tighten the sixteen bolts to the specified torque.
Torque : 31 Nꞏm (3.2 kgꞏm/23 lb ft)
3. Wind the sealing tape around the drain plug thread
and tighten the plug to the specified torque.
Torque : 25 Nꞏm (2.5 kgꞏm/18 lb ft)
4. Mount the offset lever to the transfer shift and install
the spring pin.

260RW007

9. Fix the harness with the clip.


10. Tighten the 4L and 4H switch to the specified torque.
Torque : 24 Nꞏm (2.4 kgꞏm/17 lb ft)
11. Fill the transfer case with ATF II or III (1.9 liters).
12. Wind the sealing tape around the filler plug thread and
tighten the plug to the specified torque.
261RW016
Torque : 25 Nꞏm (2.5 kgꞏm/18 lb ft)
5. Attach the O-ring and washer to the companion
flange.
NOTE: Securely push the O-ring to the hollow of the
companion flange, and then attach the washer.
6. Use the flange holder 5-8840-0133-0 (J-8614-11) to
tighten the flange nut.
7. Tighten the flange nut to the specified torque.
Torque : 167 Nꞏm (17.0 kgꞏm/123 lb ft)
8. Using the punch 5-8840-2293-0 (J-39209), securely
stake the flange nut at two spots.
NOTE: Check the staked flange nut is free from cracks.

266RW028
4D2–12 TRANSFER CASE (TOD)

Transfer Cover Assembly


Disassembled View

261RW007

Legend (4) Speed Gear and Tone Wheel


(1) Coil Assembly (5) Ball Bearing
(2) Snap Ring (6) Transfer Cover Assembly
(3) Ball Bearing (7) Front and Rear Speed Sensors

Disassembly
1. Using snap ring pliers, remove the snap ring.

261RW047
TRANSFER CASE (TOD) 4D2–13
2. Strike the speed gear and tone wheel with a rod or 4. Using a terminal pull-out tool or an equivalent tool,
other appropriate tool from the outside of the transfer push down the lock to unlatch the terminal for the coil
cover assembly, and remove the ball bearing and assembly, and pull the terminal out.
speed gear and tone wheel.
NOTE: Be careful not to damage other terminals.
NOTE: Be careful not to damage the speed gear teeth.

261RW032

266RW018 5. Remove the fixing nuts of the coil assembly from the
3. Remove the stopper plate on the back with a outside of the transfer cover assembly. Remove the
precision screwdriver or other appropriate tool coil assembly from the transfer cover.
starting from the small lock of the plate.
NOTE: Be careful not to damage the stopper plate during
the work.

261RW030

261RW042
4D2–14 TRANSFER CASE (TOD)
6. Using the bearing remover 5-8840-2409-0 (J-42805) Reassembly
and slide hammer 5-8840-0084-0 (J-2619-01),
remove the ball bearing for the front output shaft. 1. Remove the oil seal from the transfer cover assembly.
2. Apply oil to the circumference of the new oil seal and
fill the lip with grease (Besco L2 or equivalent).
3. Using the oil seal installer 5-8840-2412-0 (J-42804),
install the oil seal to the transfer cover assembly.

901RW234

7. Remove the bolts and front and rear speed sensors.


NOTE: Be careful not to damage the speed sensors
during the work.
261RW051

Rear Output Shaft Oil Seal


Distance between the transfer case end and oil seal.
NOTE: When installing the oil seal to the specified
dimension, be careful not to damage it.
Dimension : 9.85 — 10.35mm (0.39 — 0.41 in)

261RW033

A04RW004
TRANSFER CASE (TOD) 4D2–15
4. Apply a thin coat of grease to the seal ring of each NOTE: Securely install the snap ring to the groove of the
front and rear speed sensor, and mount the sensors transfer cover assembly.
carefully.
5. Tighten the bolts to the specified torque.
Torque : 5 Nꞏm (0.5 kgꞏm/43 lb in)
NOTE: Pay attention not to mount the front (or rear)
sensor to the rear (or front) sensor position.
6. Install the ball bearing (1) for the front output shaft as
flat as shown in the figure.

261RW008

7. Mount the coil assembly and tighten the nuts to the


specified torque.
Torque : 10 Nꞏm (1.0 kgꞏm/87 lb in)
8. Connect the terminal in the central connector.
NOTE: Be careful not to damage other terminals.
9. Install speed gear and tone wheel.
10. Mount the ball bearing (2) as flat as shown in the
figure.

261RW009–1

11. Using snap ring pliers, install the snap ring to the
transfer cover assembly.
4D2–16 TRANSFER CASE (TOD)

Transfer Case Assembly Clutch Pack and Clutch Cam


Disassembled View

266RW006

Legend (5) Wave Spring


(1) Clutch Pack Assembly (6) Cam Pulley
(2) Insulator Washer (7) Cam Ball
(3) Armature Plate (8) Cam and Coil Housing
(4) Snap Ring (9) Thrust Bearing

Disassembly
1. Remove the thrust bearing.
2. Remove the cam and coil housing.
NOTE: When the cam and coil housing is removed, the
cam balls may be detached together with the housing. Be
careful not to lose the ball.
3. Remove the cam ball.

266RW013
TRANSFER CASE (TOD) 4D2–17
4. Remove the cam pulley.
5. Remove the wave spring.
6. Using snap ring pliers, remove the snap ring.
NOTE: Be careful not to damage the snap ring.

266RW009

7. Remove the armature plate.


8. Remove the insulator washer.
9. Remove the clutch pack assembly as a package.

266RW017
4D2–18 TRANSFER CASE (TOD)

Sprocket and Mechanical Lock


Disassembled View

266RW008

Legend (7) Lock-up Fork


(1) Strainer (8) Chain
(2) Hose (9) Lower Driven Sprocket
(3) Oil Pump Assembly (10) Front Tone Wheel
(4) Thrust Washer (11) Drive Sprocket
(5) Mechanical Lock Hub (12) Sprocket Spacer
(6) Lock-up Sleeve

Disassembly
1. Remove the sprocket spacer.
2. Remove the front tone wheel.
TRANSFER CASE (TOD) 4D2–19
3. Remove the drive sprocket, lower driven sprocket,
and chain together from the front and rear output
shafts.

266RW010

4. Remove the mechanical lock hub.


5. Remove the lock-up fork.
6. Remove the spring retainers from the connection
between the rail shaft and lock-up fork.
7. Remove the lock-up sleeve.

261RW018

8. Remove the thrust washer.


9. Remove the magnet from the strainer set position
together with the oil pump assembly.
10. Remove the strainer from the oil pump assembly.
11. Remove the hose from the oil pump assembly.
4D2–20 TRANSFER CASE (TOD)

Output Shafts and Shift Control Shaft


Disassembled View

261RW010–1

Legend (10) Cam Assembly


(1) Transfer Case Assembly (11) Snap Ring
(2) Detent Spring (12) Washer
(3) Front Output Shaft (13) Cam
(4) Reduction Hub (14) Cam Pilot Block
(5) Output Shaft (15) Shifter Shaft Assembly
(6) Reduction Fork Assembly (16) Shifter Lever Shaft
(7) Lock-up Shaft (17) Snap Ring
(8) Spring Pin (18) Reduction Lever Assembly
(9) Reduction Fork (19) Snap Ring
TRANSFER CASE (TOD) 4D2–21

Disassembly 6. Remove the spring pin that fixes the reduction fork to
the lock-up shaft.
1. Remove the output shaft.

261RW020

266RW011 7. Remove the reduction fork.


2. Remove the detent spring. 8. Remove the lock-up shaft.
3. Remove the cam pilot block bolts. 9. Using snap ring pliers, remove the snap ring from cam
4. Remove the shifter shaft assembly and cam pilot block.
assembly.
5. Remove the reduction fork assembly together with
reduction hub.

261RW029

10. Remove the washer.


11. Remove the cam.
261RW019
12. Remove the cam pilot block.
4D2–22 TRANSFER CASE (TOD)
13. Using snap ring pliers, remove the snap ring from the
shifter shaft assembly.

261RW021

14. Remove the reduction lever assembly.


15. Remove the snap ring.
16. Remove the shifter lever shaft.
17. Remove the front output shaft.

266RW012

18. Remove the transfer case assembly.


TRANSFER CASE (TOD) 4D2–23

Transfer Case
Disassembled View

265RW015

Legend (7) Ball Bearing


(1) Transfer Case (8) Snap Ring
(2) Ball Bearing (9) Thrust Plate
(3) Ring Gear (10) Carrier Assembly
(4) Snap Ring (11) Snap Ring
(5) Input Shaft and Carrier Assembly (12) Circular Hub
(6) Snap Ring (13) Input Shaft
4D2–24 TRANSFER CASE (TOD)

Disassembly 4. Remove the snap ring from the transfer case.

1. Remove the ball bearing (for front output shaft).


2. Expand the snap ring through the opening in the
planetary gear assembly.

261RW036

5. Using snap ring pliers, remove the snap ring before


the ball bearing.

261RW040

3. While expanding the snap ring, remove the input


shaft, ball bearing, carrier assembly, and thrust plate
from the transfer case.

265RW009

261RW037
TRANSFER CASE (TOD) 4D2–25
6. Using the bearing remover 5-8840-0015-0 10. Remove the circular hub.
(J-22912-01), remove the ball bearing from the input 11. Remove the snap ring before the ring gear.
shaft.

261RW025

265RW014
12. Using the replacer 5-8840-2413-0 (J-42806), remove
7. Remove the thrust plate. the ring gear.
8. Remove the carrier assembly.
NOTE: Removing the ring gear needs a high-load press.
9. Remove the snap ring from the carrier assembly. This means the transfer case may be damaged. To
remove and replace the ring gear, it is recommended that
the transfer case assembly should be replaced.

265RW006

261RW050
4D2–26 TRANSFER CASE (TOD)
If the measurement exceeds the limit, replace the
reduction hub.
Standard : 3.05-3.30 mm (0.120-0.130 in)
Allowable limit : 2.5 mm (0.098 in)

265RW007

Inspection and Repair


When wear, damage, or any other defects are observed
during the inspection, the part or parts must be repaired or
replaced. Wash all the parts with clean solvent, and 265RW005

check that old oil, metallic particles, dirt, or foreign Lock-up Sleeve
materials are completely removed. Blow the air into oil Mount the mechanical lock hub, drive sprocket
holes and grooves to remove foreign materials or residual assembly, and lock-up sleeve to the output shaft.
detergent. If the lock-up sleeve does not move smoothly, replace
Chain the sleeve.
Check whether the face that contacts the sprocket is NOTE: Apply ATF to the area engaging the gear.
free from excessive wear or damage. If defects are
observed, replace the part. Thickness of Lock-up Sleeve
If the chain interference mark is found on the inside If the measurement exceeds the limit, replace the
wall of the transfer cover or the chain is so slack that a lock-up sleeve.
skipped engagement occurs between the chain and Standard : 7.16-7.32 mm (0.282-0.288 in)
sprocket, replace the chain.
Allowable limit : 7.9 mm (0.311 in)
Sprocket
Check whether the sprocket tooth surface is
excessively worn or damaged, and there is evidence
of burrs, chipping, wear, or damage on the gear
spline. Remove minor flaws or scratches with oil
stone. If excessive wear or damage is observed,
replace the part.
If excessive wear or damage is observed on the
sprocket inside sliding surface, replace the part.

Gear
Check whether the gear tooth surface is excessively
worn or damaged, and there is evidence of burrs,
chipping, wear, or damage on the gear spline.
Remove minor flaws or scratches with oil stone. If
excessive wear or damage is observed, replace the
part.
Thickness of Reduction Hub
Measure the thickness with a micrometer. 266RW014
TRANSFER CASE (TOD) 4D2–27
Reduction Fork Bearing
Check the reduction fork and shaft for wear, distortion, Check the profile of the needle, roller, ball, and thrust
and scratches. If defects are observed, replace the bearings. Wash the bearings with clean solvent
parts. completely, and dry with air.
Thickness of Reduction Fork NOTE: If the bearing is rotated excessively, the rollers
If the measurement exceeds the limit, replace the may be damaged. So, rotate the bearing slowly with your
reduction fork. hand. Apply grease to the bearing, and check the
smoothness of the bearing while slowly rotating the race
Standard : 3.41-3.79 mm (0.134-0.149 in) with your hand.
Allowable limit : 4.4 mm (0.173 in) Use a dial indicator to measure the ball bearing play.
Allowable limit : 0.23 mm (0.009 in)

261RW026

Lock-up Fork
226RW143

Check the lock-up fork and shaft for wear, distortion, Lock-up Fork Spring
and scratches. If defects are observed, replace the
parts. Check the lock-up fork spring for distortion, cracking,
and wear. If defects are observed, replace the part.
Thickness Lock-up Fork
Free Length of the Lock-up Fork Spring
If the measurement exceeds the limit, replace the
lock-up fork. If the measurement exceeds the limit, replace the
spring.
Standard : 6.99-7.09 mm (0.275-0.279 in)
Standard : 60.96 mm (2.40 in)
Allowable limit : 6.3 mm (0.248 in)
Allowable limit : 55.0 mm (2.17 in)

261RW027
220RW045
4D2–28 TRANSFER CASE (TOD)
Tension of Lock-up Fork Spring Multi Plate Disk Clutch
If the measurement exceeds the limit, replace the If the burned, mirror-surfaced clutch facing, or
spring. (When compressed to 41.4 mm) scraping is observed on the clutch plates, clutch
Standard : 27.1-33.8 N {2.76-3.45 kg/6.08-7.61 Ib} housing, armature plate, and insulator washer,
replace the part or parts.
Allowable limit : 24.5 N {2.5 kg/5.5 Ib}

266RW003

014RW048

Tension of Detent Spring Assembly Coil Assembly


If the measurement exceeds the limit, replace the Check the resistance of the coil with a tester. If
spring. N {kg} (When compressed by 3 mm from the defects are observed, replace the assembly.
free length) * (ordinary temperature)
Standard : 139 N -203 {14.2-20.7 kg/31.3-45.6 Ib} Standard : 1.4 2.0
Allowable limit : 130 N {13.3 kg/29.3 Ib} Allowable limit : 1.0 5.0

261RW041 261RW031

Oil Pump
Remove foreign materials from the strainer. If the
strainer is damaged, replace it.
If the area into which the shaft is inserted is
excessively worn or damaged, replace the pump.
TRANSFER CASE (TOD) 4D2–29

Cam Pulley, Cam Ball, and Cam&Coil


Housing
Check the cam balls and cam for excessive wear or
damage. If defective, replace the parts.

261RW049

Switch 4H Switch 4L Switch The


Stroke Signal Signal correspo
nding
osition
position
266RW016
B to Switch A to C of
Body transfer
The Parts 4H and 4L Switch
lever
Check the continuity of 4H and 4L switch.
1 Open Open High
2 Open Close 4L
3 Close Close Neutral

261RW003
4D2–30 TRANSFER CASE (TOD)

Transfer Case
Disassembled View

265RW015

Legend (7) Ball Bearing


(1) Transfer Case (8) Snap Ring
(2) Ball Bearing (9) Thrust Plate
(3) Ring Gear (10) Carrier Assembly
(4) Snap Ring (11) Snap Ring
(5) Input Shaft and Carrier Assembly (12) Circular Hub
(6) Snap Ring (13) Input Shaft

Reassembly
1. Remove the oil seal from the transfer case.
2. Apply engine oil to the circumference of the new oil
seal and fill the lip with grease (Besco L2 or
equivalent).
TRANSFER CASE (TOD) 4D2–31
3. Using the front output shaft oil seal installer 4. Using the input shaft (main) oil seal installer
5-8840-2410-0 (J-42807), install the oil seal to the 5-8840-2411-0 (J-42808), install the oil seal to the
transfer case. transfer case.

261RW053 261RW055

Front Output Shaft Oil Seal Input Shaft Oil Seal


Distance between the transfer case end and oil seal.
Distance between the transfer case end and oil seal.
NOTE: When installing the oil seal to the specified
NOTE: When installing the oil seal to the specified
dimension, be careful not to damage it.
dimension, be careful not to damage it.
Distance : 0.93 — 1.43mm (0.037 — 0.056 in)
Distance : 3.25 — 3.75mm (0.13 — 0.15 in)

A04RW003
A04RW002
4D2–32 TRANSFER CASE (TOD)
5. Using the installer 5-8840-2416-0 (J-42809), press-fit 6. Install the snap ring to the transfer case.
the ring gear. 7. Install the circular hub.
Pay attention to the following points. 8. Install the snap ring to the carrier.
Identify the correct direction of gear. 9. Mount the carrier assembly to the input shaft.
Do not damage the gear. 10. Check the direction of thrust plate and mount it to the
input shaft.
Do not press-fit the ring gear slantingly.
Press-fit the ring gear to the innermost.
Remove burrs generated by press-fitting.
If the transfer case has serrations, match them with
those of the gear and press-fit the gear.

265RW008

11. Mount the ball bearing to the input shaft so that the
snap ring will be installed to the input shaft.

261RW054

265RW003

12. Install the snap ring to the input shaft.


13. Install the snap ring to the transfer case.
261RW034
TRANSFER CASE (TOD) 4D2–33
14. Using the snap ring pliers, expand the snap ring
through the opening between the ring gear and carrier
assembly and securely install the input shaft and
carrier assembly.

261RW038

15. Install the ball bearing (for front output shaft)


4D2–34 TRANSFER CASE (TOD)

Output Shafts and Shift Control Shaft


Disassembled View

261RW010–1

Legend (10) Cam Assembly


(1) Transfer Case Assembly (11) Snap Ring
(2) Detent Spring (12) Washer
(3) Front Output Shaft (13) Cam
(4) Reduction Hub (14) Cam Pilot Block
(5) Output Shaft (15) Shifter Shaft Assembly
(6) Reduction Fork Assembly (16) Shifter Lever Shaft
(7) Lock-up Shaft (17) Snap Ring
(8) Spring Pin (18) Reduction Lever Assembly
(9) Reduction Fork (19) Snap Ring

Reassembly
1. Apply ATF to the inside of the ball bearing for the front
output shaft.
TRANSFER CASE (TOD) 4D2–35
2. Mount the front output shaft to the transfer case. 6. Install the cam to the cam pilot block.
7. Attach the washer to the cam pilot block and fix the
washer with the snap ring.

266RW012

3. Install the shifter lever shaft to the transfer case


assembly. 261RW029

4. Install the snap ring to the shifter lever shaft. 8. Mount the reduction fork to the lock-up shaft.
5. Install the reduction lever assembly to the shifter lever 9. Install the spring pin to the reduction fork and lock-up
shaft and fix the assembly with the snap ring. shaft.

261RW021 261RW020
4D2–36 TRANSFER CASE (TOD)
10. Install the reduction fork assembly together with
reduction hub to the transfer case assembly.

261RW019

11. Install the cam assembly and tighten the cam pilot
block set bolts to the specified torque.
Torque : 12 Nꞏm (1.2 kgꞏm/104 lb in)
12. Tighten the detent spring to the specified torque.
Torque : 24 Nꞏm (2.4 kgꞏm/17 lb in)

261RW022

13. Apply ATF to the needle bearing inside the input shaft
assembly.
14. Install the output shaft to the transfer case assembly.
TRANSFER CASE (TOD) 4D2–37

Sprocket and Mechanical Lock


Disassembled View

266RW008

Legend (7) Lock-up Fork


(1) Strainer (8) Chain
(2) Hose (9) Lower Drive Sprocket
(3) Oil Pump Assembly (10) Front Tone Wheel
(4) Thrust Washer (11) Drive Sprocket
(5) Mechanical Lock Hub (12) Sprocket Spacer
(6) Lock-up Sleeve

Reassembly
1. Connect the hose and strainer to the oil pump
assembly.
2. Install the oil pump assembly to the output shaft and
set the magnet to the strainer position.
3. Install the thrust washer.
4. Install the spring to the lock-up fork.
4D2–38 TRANSFER CASE (TOD)
5. Install the lock-up sleeve together with the lock-up
fork to the output shaft and lock-up shaft assembly.
6. Install the spring retainers to the lock-up fork.

261RW018

7. Install the mechanical lock hub.


8. Apply ATF to the chain.
9. Engage the chain to both sprockets.
10. Install the chain and sprocket assembly to both output
shafts.

266RW010

11. Install the front tone wheel and sprocket spacer.


TRANSFER CASE (TOD) 4D2–39

Clutch Pack and Clutch Cam


Disassembled View

266RW006

Legend (5) Wave Spring


(1) Clutch Pack Assembly (6) Cam Pulley
(2) Insulator Washer (7) Cam Ball
(3) Armature Plate (8) Cam and Coil Housing
(4) Snap Ring (9) Thrust Bearing

Reassembly
1. Mount the clutch pack assembly to which the multi
plate disk clutch is already installed to the output
shaft.
NOTE: Mount the clutch pack assembly while adjusting
the phase of both the clutch housing and drive sprocket.
2. Install the insulator washer.
3. Install the armature plate.
4D2–40 TRANSFER CASE (TOD)
4. Using snap ring pliers, install the snap ring.

266RW009

5. Install the wave spring.


6. Install the cam pulley.
7. Place a ball on each groove of the cam pulley.

266RW013

8. Install the cam and coil housing.


9. Install the thrust bearing.
TRANSFER CASE (TOD) 4D2–41

Main Data and Specifications


Leading Particulars
Type Transfer case with low range reduction mechanism
2H Rear wheel drive
TOD Electronically controlled torque split four wheel drive
4L Low-speed mechanical lock-up four wheel drive
Control system Floor direct control
Gear ratio H 1.000
L 2.480
Oil quantity, Lit 1.9
Oil ATF DEXRON -IIE or ATF DEXRON -III

Torque Specifications

E04RW012
4D2–42 TRANSFER CASE (TOD)

E04RW013
TRANSFER CASE (TOD) 4D2–43

Special Tools
TOOL NO. TOOL NO.
ILLUSTRATION ILLUSTRATION
TOOL NAME TOOL NAME

5–8840–0133–0 5–8840–2413–0
(J–8614–11) (J–42806)
Flange Holder Ring Gear Replacer

5–8840–2410–0
5–8840–2412–0
(J–42807)
(J–42804)
Front Out Oil Seal
Rear Oil Seal Installer
Installer

5–8840–2411–0
5–8840–2293–0
(J–42808)
(J–39209)
Input Shaft Oil Seal
Punch
Installer

5–8840–2409–0 5–8840–2416–0
(J–42805) (J–42809)
Bearing Remover Ring Gear Installer

5–8840–0084–0
(J–2619–01)
Slide Hammer

5–8840–0015–0
(J–22912–01)
Bearing Remover
BRAKE CONTROL SYSTEM 5A–1

BRAKES
CONTENTS
Brake Control System . . . . . . . . . . . . . . . . . . . . 5A Power–Assisted Brake System . . . . . . . . . . . . 5C
Anti–lock Brake System . . . . . . . . . . . . . . . . . . 5B Parking Brakes . . . . . . . . . . . . . . . . . . . . . . . . . 5D

BRAKE CONTROL SYSTEM


CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 5A–2 Circuit Diagram (RHD model / 4JX1) . . . . . 5A–27
General Description . . . . . . . . . . . . . . . . . . . . . 5A–3 Circuit Diagram (RHD model / 4JX1) . . . . . 5A–28
System Components . . . . . . . . . . . . . . . . . . . 5A–3 Circuit Diagram (RHD model / 6VE1) . . . . . 5A–29
Electronic Hydraulic Control Unit (EHCU) . 5A–3 Circuit Diagram (RHD model / 6VE1) . . . . . 5A–30
ABS Warning Light . . . . . . . . . . . . . . . . . . . . 5A–4 Connector List (RHD model) . . . . . . . . . . . . 5A–31
Wheel Speed Sensor . . . . . . . . . . . . . . . . . . 5A–4 Part Location (RHD model) . . . . . . . . . . . . . 5A–34
G-Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–4 Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . 5A–35
Normal and Anti-lock Braking . . . . . . . . . . . 5A–4 Chart A–1 ABS Works Frequently But
Vehicle Does Not Decelerate . . . . . . . . . . . 5A–35
Brake Pedal Travel . . . . . . . . . . . . . . . . . . . . 5A–4 Chart TA-1 ABS Works Frequently But
Acronyms and Abbreviations . . . . . . . . . . . . 5A–4 Vehicle Does Not Decelerate (Use
General Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 5A–5 TECH 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–36
Chart A-2 Uneven Braking Occurs While
General Information . . . . . . . . . . . . . . . . . . . . 5A–5 ABS Works . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–36
ABS Service Precautions . . . . . . . . . . . . . . . 5A–5 Chart A-3, TA-3 The Wheels Are Locked . 5A–36
Computer System Service Precautions . . . 5A–5 Chart A-4 Brake Pedal Feed Is Abnormal . 5A–37
General Service Precautions . . . . . . . . . . . . 5A–5 Chart A-5, TA-5 Braking Sound (From
EHCU) Is Heard While Not Braking . . . . . . 5A–38
Note on Intermittents . . . . . . . . . . . . . . . . . . . 5A–5
Diagnostic Trouble Codes . . . . . . . . . . . . . . . . 5A–39
Test Driving ABS Complaint Vehicles . . . . . 5A–6
Diagnosis By “ABS” Warning Light
“ABS” Warning Light . . . . . . . . . . . . . . . . . . . 5A–6 Illumination Pattern . . . . . . . . . . . . . . . . . . . . . 5A–40
Normal Operation . . . . . . . . . . . . . . . . . . . . . 5A–6 Diagnostic Trouble Codes (DTCs) . . . . . . . 5A–40
Basic Diagnostic Flow Chart . . . . . . . . . . . . 5A–6 Chart B-1 With the key in the ON position
Basic Inspection Procedure . . . . . . . . . . . . . 5A–7 (Before starting the engine). Warning light
Tech 2 Scan Tool . . . . . . . . . . . . . . . . . . . . . . 5A–8 (W/L) is not activated. . . . . . . . . . . . . . . . . . 5A–43
Getting Started . . . . . . . . . . . . . . . . . . . . . . . . 5A–9 Chart B-2 EHCU Abnormality (DTC 14) . . . 5A–43
Operating Procedure . . . . . . . . . . . . . . . . . . . 5A–10 Chart B-3 Power Voltage Drop (DTC 15) . . 5A–44
Data List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–11 Chart B-4 CLASS-2 Communication Line
Abnormality (DTC 16) . . . . . . . . . . . . . . . . . 5A–44
EHCU Connector Pin-out Checks . . . . . . . . 5A–12
Chart B-5 G-Sensor Circuit (DTC 21) . . . . . 5A–45
Circuit Diagram (LHD model / 6VD1 and Chart B-6 Abnormal Transmission Input
4JG2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–13 (DTC 23) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–46
Circuit Diagram (LHD model / 4JG2) . . . . . 5A–14 Chart B-7 Transfer Monitor (DTC 24) . . . . . 5A–47
Circuit Diagram (LHD model / 4JG2) . . . . . 5A–15 Chart B-8 EHCU Pump Motor And Motor
Circuit Diagram (LHD model / 6VD1) . . . . . 5A–16 Relay Circuit (DTC 32) . . . . . . . . . . . . . . . . . 5A–47
Chart B-9 EHCU Pump Valve And Valve
Circuit Diagram (LHD model / 6VD1) . . . . . 5A–17 Relay Circuit (DTC 35) . . . . . . . . . . . . . . . . . 5A–47
Connector List (LHD model) . . . . . . . . . . . . 5A–18 Chart B-10 FL Isolation Solenoid Valve
Part Location (LHD model) . . . . . . . . . . . . . . 5A–20 Abnormality (DTC 41) . . . . . . . . . . . . . . . . . 5A–48
Circuit Diagram (RHD model / 6VD1 and Chart B-11 FL Dump Solenoid Valve
4JG2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–21 Abnormality (DTC 42) . . . . . . . . . . . . . . . . . 5A–48
Circuit Diagram (RHD model / 4JG2) . . . . . 5A–22 Chart B-12 FR Isolation Solenoid Valve
Circuit Diagram (RHD model / 4JG2) . . . . . 5A–23 Abnormality (DTC 43) . . . . . . . . . . . . . . . . . 5A–48
Chart B-13 FR Dump Solenoid Valve
Circuit Diagram (RHD model / 6VD1) . . . . . 5A–24 Abnormality (DTC 44) . . . . . . . . . . . . . . . . . 5A–49
Circuit Diagram (RHD model / 6VD1) . . . . . 5A–25 Chart B-14 Rear Isolation Solenoid Valve
Circuit Diagram (RHD model / 6VE1 and Abnormality (DTC 45) . . . . . . . . . . . . . . . . . 5A–49
4JX1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–26 Chart B-15 Rear Dump Solenoid Valve
Abnormality (DTC 46) . . . . . . . . . . . . . . . . . 5A–49
5A–2 BRAKE CONTROL SYSTEM
Chart B-16 FL Speed Sensor Disconnection Sensor Signal Abnormality Criteria using
(DTC 51) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–50 TECH 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–56
Chart B-17 FR Speed Sensor Disconnection Unit Inspection Procedure . . . . . . . . . . . . . . . . 5A–57
(DTC 52) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–50
Chart B-18 RL Speed Sensor Disconnection Chart C-1-1 FL Sensor Output Inspection
(DTC 53) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–51 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–57
Chart C-1-2 FR Sensor Output Inspection
Chart B-19 RR Speed Sensor Disconnection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–58
(DTC 54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–51
Chart B-20 FL Speed Sensor Short Circuit Chart C-1-3 RL Sensor Output Inspection
(DTC 61) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–52 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–58
Chart B-21 FR Speed Sensor Short Circuit Chart C-1-4 RR Sensor Output Inspection
(DTC 62) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–53 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–59
Chart B-22 RL Speed Sensor Short Circuit Chart TC-1 Sensor Output Inspection
(DTC 63) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–54 Procedure (Use TECH 2) . . . . . . . . . . . . . . 5A–59
Chart B-23 RR Speed Sensor Short Circuit Chart C-2 Transmission Input Inspection
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–60
(DTC 64) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–55
Chart TC-2 Transmission Input Inspection
Chart B-24 Sensor Signal Input Abnormality Procedure (Use TECH 2) . . . . . . . . . . . . . . 5A–61
(DTC 65) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–56
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–62

Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
BRAKE CONTROL SYSTEM 5A–3

General Description
The Anti-lock Brake System (ABS) works on all four This system helps the driver maintain greater control of
wheels. A combination of wheel speed sensor and the vehicle under heavy braking conditions.
Electronic Hydraulic Control Unit (EHCU) can determine
when a wheel is about to stop turning and adjust brake
pressure to maintain best braking.

C05RW027

Legend (6) G-Sensor


(1) With P&B Valve Model (7) Proportioning and Bypass (P&B) Valve
(2) With LSPV Model (8) Load Sensing Proportioning Valve (LSPV)
(3) Electronic Hydraulic Control Unit (EHCU) (9) Electronic Line
(4) Front Wheel Speed Sensor (10) Hydraulic Line
(5) Rear Wheel Speed Sensor

System Components Electronic Hydraulic Control Unit (EHCU)


Electronic Hydraulic Control Unit (EHCU), four Wheel The EHCU consists of ABS control circuits, fault detector,
Speed Sensors, Warning Light, and G-sensor. and a fail-safe. It drives the hydraulic unit according to the
signal from each sensor, cancelling ABS to return to
5A–4 BRAKE CONTROL SYSTEM
normal braking when a malfunction has occurred in the The flux generated from electrodes magnetized by a
ABS. magnet in the sensor varies due to rotation of the rotor,
The EHCU has a self-diagnosing function which can and the electromagnetic induction generates alternating
indicate faulty circuits during diagnosis. voltage in the coil. This voltage draws a “sine curve” with
The EHCU is mounted on the engine compartment front the frequency proportional to rotor speed and it allows
right side. It consists of a Motor, Plunger Pump, Solenoid detection of wheel speed.
Valves and Check Valve.
On the outside, the relay box containing a motor relay and G-Sensor
a valve relay is installed. The G-sensor installed inside the center console detects
Solenoid Valves: Reduces or holds the caliper fluid the vehicle deceleration speed and sends a signal to the
pressure for each front disc brake or both rear disc brakes EHCU. In 4WD operation, all four wheels may be
according to the signal sent from the EHCU. decelerated in almost the same phase, since all wheels
Reservoir: Temporarily holds the brake fluid that returns are connected mechanically.
from the front and rear disc brake caliper so that pressure This tendency is noticeable particularly on roads with low
of front disc brake caliper can be reduced smoothly. friction coefficient, and the ABS control is adversely
Plunger Pump: Feeds the brake fluid held in the reservoir affected.
to the master cylinder. The G-sensor judges whether the friction coefficient of
Motor: Drives the pump according to the signal from road surface is low or high, and changes the EHCU’s
EHCU. operating system to ensure ABS control.
Check Valve: Controls the brake fluid flow.
Normal and Anti-lock Braking
ABS Warning Light Under normal driving conditions, the Anti-lock Brake
System functions the same as a standard power assisted
brake system. However, with the detection of wheel
lock-up, a slight bump or kick-back will be felt in the brake
pedal. This pedal “bump” will be followed by a series of
short pedal pulsations which occurs in rapid succession.
The brake pedal pulsation will continue until there is no
longer a need for the anti-lock function or until the vehicle
is stopped. A slight ticking or popping noise may be heard
during brake applications when the Anti-lock features is
being used.
When the Anti-lock feature is being used, the brake pedal
may rise even as the brakes are being applied. This is
also normal. Maintaining a constant force on the pedal
will provide the shortest stopping distance.

Brake Pedal Travel


Vehicles equipped with the Anti-lock Brake System may
be stopped by applying normal force to the brake pedal.
Although there is no need to push the pedal beyond the
821RW033
point where it stops or holds the vehicle, by applying more
Vehicles equipped with the Anti-lock Brake System have force the pedal will continue to travel toward the floor.
an amber “ABS” warning light in the instrument panel. This extra brake pedal travel is normal.
The “ABS” warning light will illuminate if a malfunction in
the Anti-lock Brake System is detected by the Electronic Acronyms and Abbreviations
Hydraulic Control Unit (EHCU). In case of an electronic
Several acronyms and abbreviations are commonly used
malfunction, the EHCU will turn “ON” the “ABS” warning
throughout this section:
light and disable the Anti-lock braking function.
The “ABS” light will turn “ON” for approximately three ABS
seconds after the ignition switch is to the “ON” position. Anti-lock Brake System
If the “ABS” light stays “ON” after the ignition switch is the CKT
“ON” position, or comes “ON” and stays “ON” while Circuit
driving, the Anti-lock Brake System should be inspected
for a malfunction according to the diagnosis procedure. DLC
Data Link Connector
Wheel Speed Sensor EHCU
It consists of a sensor and a rotor. The sensor is attached Electronic Hydraulic Control Unit
to the knuckle on the front wheels and to the axle shaft FL
bearing holder on the rear wheels. Front Left
The rotor is press-fit in the axle shaft.
BRAKE CONTROL SYSTEM 5A–5
FR RPS
Front Right Revolution per Second
GEN VDC
Generator Volts DC
MV VAC
Millivolts Volts AC
RL W/L
Rear Left Warning Light
RR WSS
Rear Right Wheel Speed Sensor

General Diagnosis
General Information observe these precautions may result in Anti-lock Brake
ABS malfunction can be classified into two types, those System damage.
which can be detected by the ABS warning light and those If welding work is to be performed on the vehicle using
which can be detected as a vehicle abnormality by the an electric arc welder, the EHCU and valve block
driver. connectors should be disconnected before the
In either case, locate the fault in accordance with the welding operation begins.
“BASIC DIAGNOSTIC FLOWCHART” and repair. The EHCU and valve block connectors should never
Please refer to Section 5C for the diagnosis of be connected or disconnected with the ignition “ON” .
mechanical troubles such as brake noise, brake judder EHCU of the Anti-lock Brake System are not
(brake pedal or vehicle vibration felt when braking), separately serviceable and must be replaced as
uneven braking, and parking brake trouble. assemblies. Do not disassemble any component
which is designated as non-serviceable in this
ABS Service Precautions Section.
Required Tools and Items: If only rear wheels are rotated using jacks or drum
Box Wrench tester, the system will diagnose a speed sensor
malfunction and the “ABS” warning light will
Brake Fluid illuminate. But actually no trouble exists. After
Special Tool inspection stop the engine once and re-start it, then
Some diagnosis procedures in this section require the make sure that the “ABS” warning light does not
installation of a special tool. illuminate.
J-39200 High Impedance Multimeter If the battery has been discharged
When circuit measurements are requested, use a circuit The engine may stall if the battery has been completely
tester with high impedance. discharged and the engine is started via jumper cables.
This is because the Anti-lock Brake System (ABS)
Computer System Service Precautions requires a large quantity of electricity. In this case, wait
The Anti-lock Brake System interfaces directly with the until the battery is recharged, or set the ABS to a
Electronic Hydraulic Control Unit (EHCU) which is a non-operative state by removing the fuse for the ABS
control computer that is similar in some regards to the (40A). After the battery has been recharged, stop the
Powertrain Control Module. These modules are designed engine and install the ABS fuse. Start the engine again,
to withstand normal current draws associated with and confirm that the ABS warning light does not light.
vehicle operation. However, care must be taken to avoid
overloading any of the EHCU circuits. In testing for opens Note on Intermittents
or shorts, do not ground or apply voltage to any of the As with virtually any electronic system, it is difficult to
circuits unless instructed to do so by the appropriate identify an intermittent failure. In such a case duplicating
diagnostic procedure. These circuits should only be the system malfunction during a test drive or a good
tested with a high impedance multimeter (J-39200) or description of vehicle behavior from the customer may be
special tools as described in this section. Power should helpful in locating a “most likely” failed component or
never be removed or applied to any control module with circuit. The symptom diagnosis chart may also be useful
the ignition in the “ON” position. in isolating the failure. Most intermittent problems are
Before removing or connecting battery cables, fuses or caused by faulty electrical connections or wiring. When
connectors, always turn the ignition switch to the “OFF” an intermittent failure is encountered, check suspect
position. circuits for:
Suspected harness damage.
General Service Precautions Poor mating of connector halves or terminals not fully
The following are general precautions which should be seated in the connector body (backed out).
observed when servicing and diagnosing the Anti-lock Improperly formed or damaged terminals.
Brake System and/or other vehicle systems. Failure to
5A–6 BRAKE CONTROL SYSTEM
Test Driving ABS Complaint Vehicles NOTE:
In case that there has been an malfunction in the lighting Be sure to give a test drive on a wide, even road with
pattern of “ABS” warning light, the fault can be located in little traffic.
accordance with the “DIAGNOSIS BY “ABS” WARNING If an abnormality is detected, be sure to suspend the
LIGHT ILLUMINATION PATTERN” . In case of such test and start trouble diagnosis at once.
trouble as can be detected by the driver as a vehicle
symptom, however, it is necessary to give a test drive “ABS” Warning Light
following the test procedure mentioned below, thereby When ABS trouble occurs and actuates when possible
reproducing the symptom for trouble diagnosis on a the “ABS” warning light, the trouble code corresponding
symptom basis: to the trouble is stored in the EHCU. Only the ordinary
1. Start the engine and make sure that the “ABS” W/L brake system is available when the ABS is turned off.
goes OFF. If the W/L remains ON, it means that the When the “ABS” warning light is actuated, if the starter
Diagnostic Trouble Code (DTC) is stored. Therefore, switch is set ON after setting it OFF once, the EHCU
read the code and locate the fault. checks up on the entire system and, if there is no
2. Start the vehicle and accelerate to about 30 km/h (19 abnormality, judges ABS to work currently and the
mph) or more. warning light works normally even though the trouble
3. Slowly brake and stop the vehicle completely. code is stored.
4. Then restart the vehicle and accelerate to about 40 NOTE: Illumination of the “ABS” warning light indicates
km/h (25 mph) or more. that anti-lock braking is no longer available. Power
5. Brake at a time so as to actuate the ABS and stop the assisted braking without anti-lock control is still available.
vehicle.
6. Be cautious of abnormality during the test. If the W/L Normal Operation
is actuated while driving, read the DTC and locate the “ABS” Warning Light
fault. When the ignition is first moved from “OFF” to “RUN” , the
7. If the abnormality is not reproduced by the test, make amber “ABS” warning light will turn “ON” . The “ABS”
best efforts to reproduce the situation reported by the warning light will turn “ON” during engine starting and will
customer. usually stay “ON” for approximately three seconds after
8. If the abnormality has been detected, repair in the ignition switch is returned to the “ON” position. The
accordance with the “SYMPTOM DIAGNOSIS” . warning light should remain “OFF” at all other times.

Basic Diagnostic Flow Chart


Step Action Yes No
1 1. Customer complaint.
2. Questioning to customer.
3. Basic inspection (Refer to “Basic inspection procedure”)
Using TECH 2? Go to Step 2 Go to Step 4
2 Make sure of DTC by mode “F0: Diagnostic Trouble Codes”.
Is EHCU including DTC? Go to Step 3 Go to Step 5
3 1. Repair of faulty part.
2. Elimination of DTC.
Repeat the
3. Inspection of “ABS” W/L Illumination pattern with ignition SW
diagnosis it the
“ON”.
symptom or DTC
4. Test drive.
appears again Go
Does repeat trouble? to Step 1 Go to Step 5
4 Check if the DTC is stored. Trouble diagnosis
based on
Is EHCU including DTC?
symptom (Refer
to “SYMPTOM
DIAGNOSIS”) Go
Go to Step 3 to Step 3
5 1. Reconnect all components and ensure all component are
properly mounted.
2. Clear diagnostic trouble code.
Was this step finished? Finished Go to Step 5
BRAKE CONTROL SYSTEM 5A–7
Basic Inspection Procedure

1. Basic Inspection of System Brake


Step Action Yes No
1 Is the fluid level normal? Replenish with
fluid.
Go to Step 2 Go to Step 2
2 Does fluid leak? Repair.
Go to Step 3 Go to Step 3
3 Is the booster functioning normal? Repair.
Go to Step 4 Go to Step 4
4 Is the pad and rotor normal? Repair.
Go to Step 5 Go to Step 5
5 Reconnect all components and ensure all component are
properly mounted.
Was this step finished? Finished Go to Step 5

2. Inspection of Front Axle Switch


Step Action Yes No

1 Turn the key switch on and shift the T/F to 4WD position. Repair.
Does the 4WD light come on? Go to Step 2 Go to Step 2
2 Reconnect all components and ensure all components are
properly mounted.
Was this step finished? Finished Go to Step 2

3. Ground Inspection
Step Action Yes No

1 Are ABS—related ground points ok? Repair.


Go to Step 2 Go to Step 2
2 Reconnect all components and ensure all components are
properly mounted.
Was this step finished? Finished Go to Step 2
5A–8 BRAKE CONTROL SYSTEM
Tech 2 Scan Tool
From 98 MY, Isuzu dealer service departments are
recommended to use Tech 2. Please refer to Tech 2 scan
tool user guide.

901RW257

Legend (3) DLC Cable


(1) PCMCIA Card (4) Tech–2
(2) SAE 16/19 Adaptor
BRAKE CONTROL SYSTEM 5A–9
Getting Started 8. Verify the Tech 2 power up display.
Before operating the Isuzu PCMCIA card with the
Tech 2, the following steps must be performed:
1. The Isuzu 98 System PCMCIA card (1) inserts into
the Tech 2 (4).
2. Connect the SAE 16/19 adapter (2) to the DLC cable
(3).
3. Connect the DLC cable to the Tech 2 (4).
4. Make sure the vehicle ignition is off.
5. Connect the Tech 2 SAE 16/19 adapter to the vehicle
DLC connector.

060RW009

350RV014

6. The vehicle ignition turns on.


7. Power up the Tech 2.
5A–10 BRAKE CONTROL SYSTEM
Operating Procedure
The power up screen is displayed when you power up the
tester with the Isuzu systems PCMCIA card. Follow the
operating procedure below.

060RW020

060RW014
BRAKE CONTROL SYSTEM 5A–11
Data List
Display Content OK/NG Criteria for Data
Battery Voltage Voltage Between 10-16.9V
Brake Light Switch Open/Close Open(0V) when pedal is released
Closed(12V) when pedal is depressed.
Front Left Wheel Speed MPH(km/h) Start the vehicle and make sure of linear change in each
Front Right Wheel Speed wheel speed.
Rear Left Wheel Speed Turn each wheel by hand and make sure that each
Rear Right Wheel Speed speed data change.
Wheel Sensor Status OK/NG To be OK usually
G-sensor Low/High To be Low usually
Transfer Monitor(TOD) 2 Wheel Drive When 2WD: 2 Wheel Drive
4 Wheel Drive When 4WD: 4 Wheel Drive
Off-Road Switch Active/Inactive When shift lever position is 1, 2 and R: Active (M/T)
(Transmission Input)
When shift lever position is L and R: Active (A/T)
Valve Relay Active/Inactive To be Active usually
ABS State ON/OFF To be OFF usually
ABS Relay Active/Inactive To be Active usually
Return Pump Relay Active/Inactive To be Inactive usually
Front Left Isolation Valve Active/Inactive To be Inactive usually
Front Left Dump Valve
Front Right Isolation Valve
Front Right Dump Valve
Rear Isolation Valve
Rear Dump Valve
ABS Warning Lamp ON/OFF To be ON usually (while engine stopped)
5A–12 BRAKE CONTROL SYSTEM
EHCU Connector Pin-out Checks
Disconnect Electronic Brake Control Module.
Perform checks with high impedance digital
multimeter (5-8840-0366-0) or equivalent.
No. Circuit to be Tested Ignition Multimeter Measure Nominal Value Note
Switch Scale/Range between
Position Pin Number
1 Ignition enable OFF 20DCV 8 (+), 15 (–) 0V to 0.1V
ON 20DCV 8 (+), 15 (–) 11.5V to 14.5V
2 Stop light switch OFF 20DCV 10, 15 10.5V to 14.5V Press brake pedal
3 Ground connection OFF 200 12, Ground Less than 2
15, Ground
4 FL speed sensor OFF 2k 20, 21 1.3k to 1.9k Internal Resistance
OFF 200k 20, 15 more than Insulation Resistance
100k
OFF 200mACV 20, 21 more than Turn wheel at 1RPS
200mV
5 FR speed sensor OFF 2k 4, 5 1.3k to 1.9k Internal Resistance
OFF 200k 4, 15 more than Insulation Resistance
100k
OFF 200mACV 4, 5 more than Turn wheel at 1RPS
200mV
6 RL speed sensor OFF 2k 22, 23 1.3k to 1.9k Insulation Resistance
OFF 200k 22, 15 more than Internal Resistance
100k
OFF 200mACV 22, 23 more than Turn wheel at 1RPS
200mV
7 RR speed sensor OFF 2k 2, 3 1.3k to 1.9k Internal Resistance
OFF 200k 2, 15 more than Insulation Resistance
100k
OFF 200mACV 2, 3 more than Turn wheel at 1RPS
200mV
8 G-sensor ON 26,8 1k to 2k Horizontal vehicle
9 Transmission Input ON 20DCV 6 (+), 15 (–) Less than 6V A/T
(Shift lever Battery voltage 12V
position – L, R)
6.6 to 9.0V
(other shift
position)
More than 9.6V M/T
(Shift lever Battery voltage 12V
position –
1, 2, R)
6.6 to 9.0V
(other shift
position)
BRAKE CONTROL SYSTEM 5A–13
Circuit Diagram (LHD model / 6VD1 and 4JG2)

D08RW793
5A–14 BRAKE CONTROL SYSTEM
Circuit Diagram (LHD model / 4JG2)

D08RW792
BRAKE CONTROL SYSTEM 5A–15
Circuit Diagram (LHD model / 4JG2)

D08RW791
5A–16 BRAKE CONTROL SYSTEM
Circuit Diagram (LHD model / 6VD1)

D08RW790
BRAKE CONTROL SYSTEM 5A–17
Circuit Diagram (LHD model / 6VD1)

D08RW789
5A–18 BRAKE CONTROL SYSTEM
Connector List (LHD model)
BRAKE CONTROL SYSTEM 5A–19
5A–20 BRAKE CONTROL SYSTEM
Part Location (LHD model)

D08RW808

Legend (13) E–30


(1) F–2 (14) C–41
(2) F–3 (15) H–42
(3) H–33 (16) C–85
(4) H–7, H–8, H–25 (17) C–4 (EHCU)
(5) H–46 (18) Relay & Fuse Box
(6) C–16 (19) C–39
(7) C–63 (20) H–12, H–13, H–15, H–16
(8) Fuse Box (21) E–47, E–48, M–1
(9) B–13 or B–14 (22) E–42, E–43, M–8
(10) C–13 (23) B–25
(11) H–5 (24) I–10
(12) H–10, H–11 (25) I–9
BRAKE CONTROL SYSTEM 5A–21
Circuit Diagram (RHD model / 6VD1 and 4JG2)

D08RW601
5A–22 BRAKE CONTROL SYSTEM
Circuit Diagram (RHD model / 4JG2)

D08RW788
BRAKE CONTROL SYSTEM 5A–23
Circuit Diagram (RHD model / 4JG2)

D08RW787
5A–24 BRAKE CONTROL SYSTEM
Circuit Diagram (RHD model / 6VD1)

D08RW786
BRAKE CONTROL SYSTEM 5A–25
Circuit Diagram (RHD model / 6VD1)

D08RW827
5A–26 BRAKE CONTROL SYSTEM
Circuit Diagram (RHD model / 6VE1 and 4JX1)

D08RW601
BRAKE CONTROL SYSTEM 5A–27
Circuit Diagram (RHD model / 4JX1)

D08RW600
5A–28 BRAKE CONTROL SYSTEM
Circuit Diagram (RHD model / 4JX1)

D08RW602
BRAKE CONTROL SYSTEM 5A–29
Circuit Diagram (RHD model / 6VE1)

D08RW604
5A–30 BRAKE CONTROL SYSTEM
Circuit Diagram (RHD model / 6VE1)

D08RW603
BRAKE CONTROL SYSTEM 5A–31
Connector List (RHD model)
5A–32 BRAKE CONTROL SYSTEM
BRAKE CONTROL SYSTEM 5A–33
5A–34 BRAKE CONTROL SYSTEM
Part Location (RHD model)

D08RW623

Legend (14) E–30 (4GJ2, 6VD1/6VE1)


(1) F–2 (15) Fuse Box
(2) F–3 (16) H–42
(3) H–33 (17) C–41
(4) H–7 (18) C–85
(5) H–46 (19) C–4 (EHCU)
(6) C–16 (20) Relay & Fuse Box
(7) E–42, E–43, M–8 (21) C–39
(8) E–47, E–48, M–1 (22) H–13, H–15, H–16, H–26, H–27
(9) B–13 or B–14 (23) I–10
(10) C–13 (24) I–9
(11) H–4, H–5, H–6 (25) H–12
(12) H–10, H–11 (26) C–63
(13) E–4 (4JX1) (27) B–25
BRAKE CONTROL SYSTEM 5A–35

Symptom Diagnosis 4. Brake pedal feel is abnormal.


5. Braking sound (from EHCU) is heard while not
The symptoms that cannot be indicated by the warning
braking.
light can be divided in the following five categories:
These are all attributable to problems which cannot be de-
1. ABS works frequently but vehicle does not
tected by EHCU self-diagnosis. Use the customer com-
decelerate.
plaint and a test to determine which symptom is present.
2. Uneven braking occurs while ABS works. Then follow the appropriate flow chart listed below.
3. The wheels lock during braking.
Diagnostic Flow Charts
No
No. Symptom
Sym tom
Without TECH 2 With TECH 2
1 ABS works frequently but vehicle does not decelerate. Chart A–1 Chart TA–1
2 Uneven braking occurs while ABS works. Chart A–2 —
3 The wheels are locked. Chart A–3 Chart TA–3
4 Brake pedal feel is abnormal. Chart A–4 —
5 Braking sound (from EHCU) is heard while not braking. Chart A–5 Chart TA–5

Chart A–1 ABS Works Frequently But Vehicle Does Not Decelerate
Step Action Yes No
1 1. Turn key off.
2. G Sensor connector and EHCU connector disconnected.
Is there continuity between EHCU terminals 26 and 8? Go to Step 2 Go to Step 3
2 Connect EHCU connector. Repair circuit.
Is there continuity between the G sensor and the EHCU? Go to Step 3 Go to Step 1
3 Is the G sensor normal? (Refer to chart B-5) Replace G
sensor.
Go to Step 4 Go to Step 11
4 Is braking force distribution normal between the front and rear of Repair brake
the vehicle? parts.
Go to Step 5 Go to Step 11
5 Are axle parts installed normally? Go to Step 6 Repair axle parts.
Go to Step 11
6 Is there play in each wheel speed sensor? Repair wheel
speed sensor.
Go to Step 11 Go to Step 7
7 Is there damage, or powered iron sticking to each wheel speed Replace sensor
sensor/sensor ring? or sensor ring.
Go to Step 11 Go to Step 8
8 Is the output of each wheel speed sensor normal? (Refer to chart Replace wheel
C-1 or TC-1) speed sensor or
repair harness.
Go to Step 9 Go to Step 11
9 Is the input of transmission normal? (Refer to chart C-2 or TC-2) Replace switch or
repair harness.
Go to Step 10 Go to Step 11
5A–36 BRAKE CONTROL SYSTEM

Step Action Yes No


10 Is the input of 4WD controller normal? Replace
controller or
repair harness.
Go to Step 11 Go to Step 11
11 Reconnect all components and ensure all components are
Repeat the “Basic
properly mounted.
diagnostic flow
Was this step finished? chart.” Go to Step 11

Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)
Step Action Yes No
1 1. Connect TECH 2.
2. Make sure of the output conditions of each wheel speed Replace wheel
sensor by mode “F1: Data Display”. speed sensor.
Is the output of each sensor normal? Go to Step 2 Go to Step 3
2 Return to Chart A-1.
Was the Chart A-1 finished? Go to Step 3 Go to Step 2
3 Reconnect all components, ensure all components are properly
Repeat the “Basic
mounted.
diagnostic flow
Was this step finished? chart.” Go to Step 3

Chart A-2 Uneven Braking Occurs While ABS Works


Step Action Yes No
1 Is there play in each sensor? Repair.
Go to Step 5 Go to Step 2
2 Is there damage or powdered iron sticking to each sensor/sensor Repair.
ring? Go to Step 5 Go to Step 3
3 Is the output of each sensor normal? (Refer to chart C-1 or TC-1) Replace sensor
or repair harness.
Go to Step 4 Go to Step 5
4 Is brake pipe connecting order correct? Reconnect brake
Replace EHCU. pipe correctly.
Go to Step 5 Go to Step 5
5 Reconnect all components, ensure all components are properly
Repeat the “Basic
mounted.
diagnostic flow
Was this step finished? chart.” Go to Step 5

Chart A-3, TA-3 The Wheels Are Locked


Step Action Yes No
1 Is ABS working? Go to Step 2 Go to Step 6
2 Is vehicle speed under 10 km/h (6mph)? Normal. Go to Step 3
3 Is sensor output normal? (Chart C-1 or TC-1) Replace sensor
or repair harness.
Go to Step 4 Go to Step 9
4 Is transmission input normal? (Chart C-2 or TC-2) Replace SW or
repair harness.
Go to Step 5 Go to Step 9
BRAKE CONTROL SYSTEM 5A–37

Step Action Yes No


5 Is front 4WD controller normal? Replace 4WD
controller or
Replace EHCU. repair harness.
Go to Step 9 Go to Step 9
6 Is transmission input normal? (Chart C-2 or TC-2) Replace SW or
repair harness
Go to Step 7 Go to Step 9
7 Is front 4WD controller normal? Replace 4WD
controller or
repair harness.
Go to Step 8 Go to Step 9
8 Is hydraulic unit grounded properly? Replace EHCU. Correct.
Go to Step 9 Go to Step 9
9 Reconnect all components, ensure all components are properly
Repeat the “Basic
mounted.
diagnostic flow
Was this step finished? chart.” Go to Step 9

Chart A-4 Brake Pedal Feed Is Abnormal


Step Action Yes No
1 Is the stop light actuated when the brake pedal is depressed? Go to Step 2 Go to Step 3
2 1. Turn the ignition switch off.
2. Disconnected EHCU connector. Harness NG
3. Measure voltage between the EHCU connector terminal 10 between brake
and 15 when brake pedal is depressed. SW and EHCU.
Is the voltage equal to the battery voltage? Go to Step 4 Go to Step 7
3 Is stop light fuse C-14 normal? Replace fuse
C-14.
Go to Step 5 Go to Step 7
4 Is there continuity between EHCU connector terminals, 12 and 15 Repair body
to body ground? grounded
harness.
Go to Step 6 Go to Step 7
5 Is the brake SW normal? Repair stop light Replace brake
harness. SW.
Go to Step 7 Go to Step 7
6 Is the check harness/connector for suspended disconnection? Hydraulic system
leakage or air
entry (Refer to
servicing
“Leakage or
brake fluid” ) Repair harness.
Go to Step 7 Go to Step 7
7 Reconnect all components and ensure all components are
Repeat the “Basic
properly mounted.
diagnostic flow
Was this step finished? chart.” Go to Step 7
5A–38 BRAKE CONTROL SYSTEM
Chart A-5, TA-5 Braking Sound (From EHCU) Is Heard While Not Braking
Step Action Yes No
1 Is this the first time the vehicle is being driven after starting the It is self checking
engine? sound.
Normal. Go to Step 2
2 Is vehicle speed under 10 km/h (6 mph)? It is self checking
sound.
Normal. Go to Step 3
3 Check for the following condition:
At the time of shift down or clutch operation.
At the time of low drive (ice or snow road) or rough road drive.
At the time of high-speed turn.
At the time of passing curb. ABS may
At the time of operating electrical equipment switches. sometime be
At the time of racing the engine (over 5000 rpm). actuated even
when brake pedal
Did it occur under any one condition above? is not applied. Go to Step 4
4 Is there play in each sensor/wheel speed sensor rings? Repair.
Go to Step 5 Go to Step 7
5 Damage or powdered iron sticking to each sensor/wheel speed Repair.
sensor ring? Go to Step 6 Go to Step 7
6 Is each sensor output normal?(Refer to chart C-1 or TC-1). Check harness/
connector for
suspected
disconnection.
If no
disconnection is
found, replace
EHCU. Repair.
Go to Step 7 Go to Step 7
7 Reconnect all components, ensure all components are properly
Repeat the “Basic
mounted.
diagnostic flow
Was this step finished? chart.” Go to Step 7
BRAKE CONTROL SYSTEM 5A–39

Diagnostic Trouble Codes


Choose and trace an appropriate flowchart by the
numbers listed below to find fault and repair.
Code Item Diagnosis Chart No.
12 Start Code Normal —
14 EHCU Function Abnormality in input/output, operational and B-2
control circuits
15 Power Voltage Drop B-3
16 CLASS–2 Communication Line Ab- B-4
normality
21 G-sensor Wiring disconnection B-5
23 Transmission Input Input abnormality B-6
24 Transfer Monitor B-7
32 Motor & Motor Relay Shorted or disconnected coil B-8
35 Valve Relay Shorted or disconnected coil/wiring B-9
41 FL Holding Solenoid Valve Shorted or disconnected coil/wiring B-10
42 FL Decompression Solenoid Valve Shorted or disconnected coil/wiring B-11
43 FR Holding Solenoid Valve Shorted or disconnected coil/wiring B-12
44 FR Decompression Solenoid Valve Shorted or disconnected coil/wiring B-13
45 Rear Holding Solenoid Valve Shorted or disconnected coil/wiring B-14
46 Rear Decompression Solenoid Valve Shorted or disconnected coil/wiring B-15
51 FL Wheel Speed Sensor Disconnected coil/wiring B-16
52 FR Wheel Speed Sensor Disconnected coil/wiring B-17
53 RL Wheel Speed Sensor Disconnected coil/wiring B-18
54 RR Wheel Speed Sensor Disconnected coil/wiring B-19
61 FL Wheel Speed Sensor Shorted coil/wiring B-20
62 FR Wheel Speed Sensor Shorted coil/wiring B-21
63 RL Wheel Speed Sensor Shorted coil/wiring B-22
64 RR Wheel Speed Sensor Shorted coil/wiring B-23
65 Sensor Signal Input Wrong number of teeth B-24
5A–40 BRAKE CONTROL SYSTEM

Diagnosis By “ABS” Warning Light


Illumination Pattern
In the event that there is abnormality in the “ABS” warning
light illumination pattern while the key is in the ON position
or if the warning light is actuated during driving, trouble
should be diagnosed on a illumination pattern basis as
follows:
No. Condition “ABS” Warning Light Illumination Pattern Diagnostic
1 Warning light is actu- Normal
ated normally

2 Warning light is not lit Warning light lighting circuit


trouble Go to Chart B-1

3 Warning light remains Diagnostic trouble codes are


ON stored.
Display diagnostic trouble
codes and diagnose on a
code basis according to the
flow charts.

4 Warning light is actu- Diagnostic trouble codes are


ated while driving stored.
Display diagnostic trouble
codes and diagnose on a
code basis according to the
flow charts.

Diagnostic Trouble Codes (DTCs) DTCs can be displayed also by TECH 2. Select mode
When the warning light in the meter remains ON, the “F0: Diagnostic Trouble Codes” from Application
Menu.
EHCU stores the fault identification and disables the
ABS. 1. How to start DTC display:
1. How to display and erase DTCs: Confirm that the vehicle has come to a complete
stop (with the wheels standing still) and that the
NOTE: brake pedal is not depressed. (Unless these two
If DTCs are not displayed, harness C-4 connector conditions are satisfied, DTC display cannot be
terminal 30 and I-10 connector terminal 2 may be started.)
disconnected. Repair the harness and try DTC With IGN OFF, connect #12 terminal with #4
display again. terminal or # 5 terminal (GND) . Then turn IGN ON.
BRAKE CONTROL SYSTEM 5A–41

The DLC is located behind the center console

350RV010

Keep #12 terminal connected with #4 terminal or # 5


terminal (GND) during DTC display. (If #12 terminal
is separated from #4 terminal or # 5 terminal (GND)
during display, display will stop.)
2. DTC display:
DTC is displayed by blinking warning light.
Double-digit display.
First, normal DTC 12 is displayed three times and
then any other DTCs are displayed three times. (If
no other DTCs have been stored, the display of DTC
12 will be repeated.)
3. How to erase code:
Conduct brake switch ON/OFF operation 6 or more
times within 3 seconds of self-diagnosis startup.
The code cannot be erased if more than 3 seconds
have passed since self-diagnosis startup, or if
self-diagnosis has started with brake switched on
(brake pedal depressed).

B05RW005
5A–42 BRAKE CONTROL SYSTEM
4. Notes
If the following should occurs during Diagnostic
Trouble Code (DTC) display the display will be
discontinued. After initial check, the status that is
under the control of ABS will be returned :
– The vehicle starts (The wheels turn) or the brake
pedal is depressed.
Up to 3 different codes can be stored.
If the ABS should turn OFF due to an intermittent
defect, the system will be restored at the next key
cycle, if the initial check finds no abnormality (when
IGN is switched from OFF to ON).
5. An example of DTC display
Display of DTC 23

B05RW006

After displaying DTC 12 three times, one DTC after


another is displayed, starting with the most recent
one. (However, display is discontinued after about 5
minutes.)

B05RS005

The DTC 12 is displayed repeatedly. (display is


discontinued after about 5 minutes)
BRAKE CONTROL SYSTEM 5A–43
Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L)
is not activated.
Step Action Yes No
1 Is W/L fuse C-10 disconnected? Replace fuse.
Go to Step 5 Go to Step 2
2 Is W/L burnt out? Replace W/L
bulb.
Go to Step 5 Go to Step 3
3 1. Turn the key off.
2. Disconnect EHCU connector.
3. Turn the key ON.
4. Measure the voltage between EHCU connector terminal 13 Repair harness
and 14. and connector.
Is the voltage equal to the battery voltage? Go to Step 4 Go to Step 5
4 Is there continuity between EHCU connector terminals, 12 and 15 Check harness
and body ground. for suspected
disconnection.
No fault found: Repair harness
Replace EHCU. and connector.
Go to Step 5 Go to Step 5
5 Reconnect all components, ensure all components are properly
Repeat the “Basic
mounted.
diagnostic flow
Was this step finished? chart.” Go to Step 5

Chart B-2 EHCU Abnormality (DTC 14)


Step Action Yes No
1 1. Turn the key off.
2. Disconnect the EHCU connector.
3. Inspect EHCU ground. Repair the body
Is there resistance between the EHCU connector terminals, 12 ground harness.
and 15 and body ground? Go to Step 2 Go to Step 3
2 1. Turn the key off, connect the EHCU.
2. Erase the trouble code.
Inspect in
3. Turn Ignition off, then on, to perform system self-check.
accordance with
4. If warning light remains on, display trouble codes once again. Replace EHCU. the DTC
Is the check trouble code 14? Go to Step 3 displayed.
3 1. Reconnect all components and ensure all components are
properly mounted.
Repeat the “Basic
2. Clear diagnostic trouble code.
diagnostic flow
Was this step finished? chart.” Go to Step 3
5A–44 BRAKE CONTROL SYSTEM
Chart B-3 Power Voltage Drop (DTC 15)
Step Action Yes No
1 Is the battery voltage normal? (Battery capacity check) Charge or
replace battery.
Go to Step 2 Go to Step 2
2 1. Turn the key off. Check harness
2. Disconnect EHCU connector. connector for
3. Turn the key on. suspected
disconnection.
Is the voltage between EHCU connector terminals 8 and 15,
higher than 10V? Fault found:
Repair, and
perform system
self-check.
No fault found: Repair harness or
replace EHCU. connector.
Go to Step 3 Go to Step 3
3 1. Reconnect all components, ensure all components are
properly mounted.
Repeat the “Basic
2. Clear diagnostic trouble code.
diagnostic flow
Was this step finished? chart.” Go to Step 3

Chart B-4 CLASS-2 Communication Line Abnormality (DTC 16)


Step Action Yes No
1 1. Turn the key off.
2. Disconnect EHCU and PCM connector. Repair harness or
Is there continuity between EHCU connector terminals 25 and connector.
ground? Go to Step 2 Go to Step 3
2 1. Connect EHCU connector. Check the PCM
2. Clear diagnostic trouble code. harness. Refer to
3. Turn the key on. 6E section. Replace EHCU.
Is the diagnostic trouble code 16 shown on the displayed? Go to Step 3 Go to Step 3
3 1. Reconnect all components, ensure all components are
properly mounted.
Repeat the “Basic
2. Clear diagnostic trouble code.
diagnostic flow
Was this step finished? chart.” Go to Step 3
BRAKE CONTROL SYSTEM 5A–45
Chart B-5 G-Sensor Circuit (DTC 21)
Step Action Yes No
1 Vehicle placed horizontal. Check harness
connector for
Is the resistance between the G sensor connector terminals 1 and
short.
2 within 4.0-6.0 k ?
Fault found :
Repair , and
perform system
self-check.
No fault found :
replace EHCU.
Go to Step 3 Go to Step 2
2 Is the bracket installed horizontally? Repair or replace
bracket.
Go to Step 4 Go to Step 4
3 Remove G sensor. Replace G
Is the resistance between the G sensor connector terminals 1 and sensor.
2 within 1.0-2.0 k when G sensor is horizontal? Go to Step 4 Go to Step 5
4 Measure resistance between G sensor connector terminals 1 and Harness between
2 within 4.0-6.0 k when G sensor tilted to 30 or more? EHCU and G
sensor is faulty
and short.
Repair the Replace G
harness sensor.
Go to Step 5 Go to Step 5
5 1. Reconnect all components and ensure all components are
properly mounted.
Repeat the “Basic
2. Clear diagnostic trouble code.
diagnostic flow
Was this step finished? chart.” Go to Step 5
5A–46 BRAKE CONTROL SYSTEM
Chart B-6 Abnormal Transmission Input (DTC 23)
Step Action Yes No
1 1. Turn the key off. Shorted switch
2. Disconnect EHCU connector. harness.
Is there continuity between EHCU connector terminal 6 to 15 Repair switch or
(Gear position-P(A/T), N(M/T))? harness.
Go to Step 6 Go to Step 2
2 Is the vehicle an A/T model? Go to Step 3 Go to Step 4
3 Turn the key on and measure the voltage between EHCU Transmission SW
connector terminal 6 and 15. trouble.
Is the 6V under when the gear position is L, and R(Battery voltage Disconnected
12V)? harness.
Repair SW and
harness.
Go to Step 5 Go to Step 6
4 Turn the key on and measure the voltage between EHCU Transmission SW
connector terminal 6 and 15. trouble.
Is the 9.6V over when the gear position is 1, 2, R(Battery voltage Disconnected
12V)? harness.
Repair SW and
harness.
Go to Step 5 Go to Step 6
5 Is there 6.6 to 9.0V when the gear position is 3, 4, 5 and N(M/T) or Suspected
2,3,D,N and P(A/T)(Battery voltage 12V)? harness/
connector short
power
source/GND.
Suspected
shorted
transmission SW.
Fault found: Transmission SW
repair, and trouble.
perform system Disconnected
self-check. harness.
No fault found: Repair SW and
replace EHCU. harness.
Go to Step 6 Go to Step 6
6 1. Reconnect all components, ensure all components are
properly mounted.
Repeat the “Basic
2. Clear diagnostic trouble code.
diagnostic flow
Was this step finished? chart.” Go to Step 6
BRAKE CONTROL SYSTEM 5A–47
Chart B-7 Transfer Monitor (DTC 24)
Step Action Yes No
1 1. Turn the key off.
2. Disconnect EHCU connector. Repair
Is the EHCU connector terminal 9 line normally? Go to Step 2 Go to Step 3
2 Is the TOD ECU or 4WD controller normal? Repair or replace
TOD ECU or
Replace EHCU. 4WD contrder.
Go to Step 3 Go to Step 3
3 1. Reconnect all components, ensure all components are
properly mounted.
Repeat the “Basic
2. Clear diagnostic trouble code.
diagnostic flow
Was this step finished? chart.” Go to Step 3

Chart B-8 EHCU Pump Motor And Motor Relay Circuit (DTC 32)
Step Action Yes No
1 1. Turn the key off. Repair
2. Disconnect EHCU connector. fuse/harness
3. Measure voltage between EHCU connector terminal 13 and between battery
body ground. and EHCU
connector
Is the voltage equal to battery voltage?
terminal 13.
Go to Step 2 Go to Step 3
2 Is there continuity between EHCU connector terminal 12 and Repair between
ground? EHCU connector
terminal 12 and
ground.
Go to Step 3 Go to Step 3
3 1. Reconnect all components and ensure all components are
properly mounted.
Repeat the “Basic
2. Clear diagnostic trouble code.
diagnostic flow
Was this step finished? chart.” Go to Step 3

Chart B-9 EHCU Pump Valve And Valve Relay Circuit (DTC 35)
Step Action Yes No
1 1. Turn the key off. Repair fuse and
2. Disconnect EHCU connector. harness EHCU
3. Measure voltage between EHCU connector terminal 14 and connector
body ground. terminal 14 and
Replace EHCU. battery.
Is the voltage equal to battery voltage?
Go to Step 2 Go to Step 2
2 1. Reconnect all components and ensure all components are
properly mounted.
Repeat the “Basic
2. Clear diagnostic trouble code.
diagnostic flow
Was this step finished? chart.” Go to Step 2
5A–48 BRAKE CONTROL SYSTEM
Chart B-10 FL Isolation Solenoid Valve Abnormality (DTC 41)
Step Action Yes No
1 Was the “EHCU Connector Pin-out Checks” performed? Go to “EHCU
Connector
Go to Step 2 Pin-out Checks”.
2 Is the EHCU connector free from damage or corrosion? Repair the
connector.
Repeat the “Basic
Diagnostic Flow
Go to Step 3 Chart”.
3 1. Replace the EHCU.
2. Reconnect all component, ensure all component are properly
Repeat the “Basic
mounted.
Diagnostic Flow
Was this step finished? Chart”. Go to Step 3

Chart B-11 FL Dump Solenoid Valve Abnormality (DTC 42)


Step Action Yes No
1 Was the “EHCU Connector Pin-out Checks” performed? Go to “EHCU
Connector
Go to Step 2 Pin-out Checks”.
2 Is the EHCU connector free from damage or corrosion? Repair the
connector.
Repeat the “Basic
Diagnostic Flow
Go to Step 3 Chart”.
3 1. Replace the EHCU.
2. Reconnect all component, ensure all component are properly
Repeat the “Basic
mounted.
Diagnostic Flow
Was this step finished? Chart”. Go to Step 3

Chart B-12 FR Isolation Solenoid Valve Abnormality (DTC 43)


Step Action Yes No
1 Was the “EHCU Connector Pin-out Checks” performed? Go to “EHCU
Connector
Go to Step 2 Pin-out Checks”.
2 Is the EHCU connector free from damage or corrosion? Repair the
connector.
Repeat the “Basic
Diagnostic Flow
Go to Step 3 Chart”.
3 1. Replace the EHCU.
2. Reconnect all component, ensure all component are properly
Repeat the “Basic
mounted.
Diagnostic Flow
Was this step finished? Chart”. Go to Step 3
BRAKE CONTROL SYSTEM 5A–49
Chart B-13 FR Dump Solenoid Valve Abnormality (DTC 44)
Step Action Yes No
1 Was the “EHCU Connector Pin-out Checks” performed? Go to “EHCU
Connector
Go to Step 2 Pin-out Checks”.
2 Is the EHCU connector free from damage or corrosion? Repair the
connector.
Repeat the “Basic
Diagnostic Flow
Go to Step 3 Chart”.
3 1. Replace the EHCU.
2. Reconnect all component, ensure all component are properly
Repeat the “Basic
mounted.
Diagnostic Flow
Was this step finished? Chart”. Go to Step 3

Chart B-14 Rear Isolation Solenoid Valve Abnormality (DTC 45)


Step Action Yes No
1 Was the “EHCU Connector Pin-out Checks” performed? Go to “EHCU
Connector
Go to Step 2 Pin-out Checks”.
2 Is the EHCU connector free from damage or corrosion? Repair the
connector.
Repeat the “Basic
Diagnostic Flow
Go to Step 3 Chart”.
3 1. Replace the EHCU.
2. Reconnect all component, ensure all component are properly
Repeat the “Basic
mounted.
Diagnostic Flow
Was this step finished? Chart”. Go to Step 3

Chart B-15 Rear Dump Solenoid Valve Abnormality (DTC 46)


Step Action Yes No
1 Was the “EHCU Connector Pin-out Checks” performed? Go to “EHCU
Connector
Go to Step 2 Pin-out Checks”.
2 Is the EHCU connector free from damage or corrosion? Repair the
connector.
Repeat the “Basic
Diagnostic Flow
Go to Step 3 Chart”.
3 1. Replace the EHCU.
2. Reconnect all component, ensure all component are properly
Repeat the “Basic
mounted.
Diagnostic Flow
Was this step finished? Chart”. Go to Step 3
5A–50 BRAKE CONTROL SYSTEM
Chart B-16 FL Speed Sensor Disconnection (DTC 51)
Step Action Yes No
1 1. Turn the key off. Check for faults
2. Disconnect EHCU connector. in harness
3. Measure the resistance between EHCU connector terminals between speed
20 and 21. sensor and
EHCU.
Is the resistance between 1.3k and 1.9k ohms?
Fault found:
Repair, and
perform system
self-check.
No fault found:
Replace EHCU.
Go to Step 3 Go to Step 2
2 Measure the FL speed sensor resistance at the sensor connector. Repair harness
abnormality
Is the resistance between 1.3k and 1.9k ohms?
between sensors
and EHCU. Replace sensor.
Go to Step 3 Go to Step 3
3 1. Reconnect all components, ensure all components are
properly mounted.
Repeat the “Basic
2. Clear diagnostic trouble code.
diagnostic flow
Was this step finished? chart.” Go to Step 3

Chart B-17 FR Speed Sensor Disconnection (DTC 52)


Step Action Yes No
1 1. Turn the key off. Check for faults
2. Disconnect EHCU connector. in harness
3. Measure the resistance between EHCU connector terminals 4 between speed
and 5. sensor and
EHCU.
Is the resistance between 1.3k and 1.9k ohms?
Fault found:
Repair, and
perform system
self-check.
No fault found:
Replace EHCU.
Go to Step 3 Go to Step 2
2 Measure the FR speed sensor resistance at the sensor Repair harness
connector. abnormality
between sensors
Is the resistance between 1.3k and 1.9k ohms?
and EHCU. Replace sensor.
Go to Step 3 Go to Step 3
3 1. Reconnect all components and ensure all components are
properly mounted.
Repeat the “Basic
2. Clear diagnostic trouble code.
diagnostic flow
Was this step finished? chart.” Go to Step 3
BRAKE CONTROL SYSTEM 5A–51
Chart B-18 RL Speed Sensor Disconnection (DTC 53)
Step Action Yes No
1 1. Turn the key off. Check for faults
2. Disconnect EHCU connector. in harness
3. Measure the resistance between EHCU connector terminals between speed
22 and 23. sensor and
EHCU.
Is the resistance between 1.3k and 1.9k ohms?
Fault found:
Repair, and
perform system
self-check.
No fault found:
Replace EHCU.
Go to Step 3 Go to Step 2
2 Measure the RL speed sensor resistance at the sensor Repair harness
connector. abnormality
between sensors
Is the resistance between 1.3k and 1.9k ohms?
and EHCU. Replace sensor.
Go to Step 3 Go to Step 3
3 1. Reconnect all components and ensure all components are
properly mounted.
Repeat the “Basic
2. Clear diagnostic trouble code.
diagnostic flow
Was this step finished? chart.” Go to Step 3

Chart B-19 RR Speed Sensor Disconnection (DTC 54)


Step Action Yes No
1 1. Turn the key off. Check for faults
2. Disconnect EHCU connector. in harness
3. Measure the resistance between EHCU connector terminals 2 between speed
and 3. sensor and
EHCU.
Is the resistance between 1.3K and 1.9k ohms?
Fault found:
Repair, and
perform system
self-check.
No fault found:
Replace EHCU.
Go to Step 3. Go to Step 2
2 Measure the RR speed sensor resistance at the sensor Repair harness
connector. abnormality
between sensors
Is the sensor resistance between 1.3k and 1.9k ohms?
and EHCU. Replace sensor.
Go to Step 3 Go to Step 3
3 1. Reconnect all components and ensure all components are
properly mounted.
Repeat the “Basic
2. Clear diagnostic trouble code.
diagnostic flow
Was this step finished? chart.” Go to Step 3
5A–52 BRAKE CONTROL SYSTEM
Chart B-20 FL Speed Sensor Short Circuit (DTC 61)
Step Action Yes No
1 1. Turn the key off.
2. Disconnect EHCU connector
3. Measure the FL speed sensor resistance between EHCU
connector terminals 20 and 21.
Is the resistance between 1.3k and 1.9k ohms? Go to Step 2 Go to Step 3
2 Is there play in the sensor/sensor rotor? Repair.
Go to Step 4 Go to Step 6
3 Measure the FL speed sensor resistance at the sensor connector. Repair harness
abnormality
Is the resistance between 1.3k and 1.9k ohms?
between sensors
and EHCU. Replace sensor.
Go to Step 6 Go to Step 6
4 Damage and powdered iron sticking to sensor/sensor ring? Repair.
Go to Step 5 Go to Step 6
5 Is sensor output normal? (Chart C-1-1 or TC-1) Check for faults
in harness
between speed
sensor and
EHCU.
Fault found:
repair, and
perform system
self-check.
No fault found:
replace EHCU. Replace sensor.
Go to Step 6 Go to Step 6
6 1. Reconnect all components and ensure all components are
properly mounted.
Repeat the “Basic
2. Clear diagnostic trouble code.
diagnostic flow
Was this step finished? chart.” Go to Step 6
NOTE: Even after repairing the faulty part the warning
light (W/L) does not go out if the vehicle is at a stop. Turn
the ignition switch to the ON position and drive the vehicle
at 12 km/h or higher to make sure that the warning light
goes out.
BRAKE CONTROL SYSTEM 5A–53
Chart B-21 FR Speed Sensor Short Circuit (DTC 62)
Step Action Yes No
1 1. Turn the key off.
2. Disconnect EHCU connector.
3. Measure the FR speed sensor resistance between EHCU
connector terminals 4 and 5.
Is the resistance between 1.3k and 1.9k ohms? Go to Step 2 Go to Step 3
2 Is there play in the sensor/sensor rotor? Repair.
Go to Step 4 Go to Step 6
3 Measure the FR speed sensor resistance at the sensor Repair harness
connector. abnormality
between sensors
Is the resistance between 1.3k and 1.9k ohms?
and EHCU. Replace sensor.
Go to Step 6 Go to Step 6
4 Damage and powdered iron sticking to sensor/sensor ring? Repair.
Go to Step 5 Go to Step 6
5 Is sensor output normal? (Chart C-1-2 or TC-1) Check for faults
in harness
between speed
sensor and
EHCU.
Fault found:
repair, and
perform system
self-check.
No fault found:
replace EHCU. Replace sensor.
Go to Step 6 Go to Step 6
6 1. Reconnect all components and ensure all components are
properly mounted.
Repeat “Basic
2. Clear diagnostic trouble code.
diagnostic flow
Was this step finished? chart.” Go to Step 6
NOTE: Even after repairing the faulty part the warning
light (W/L) does not go out if the vehicle is at a stop. Turn
the ignition switch to the ON position and drive the vehicle
at 12 km/h or higher to make sure that the warning light
goes out.
5A–54 BRAKE CONTROL SYSTEM
Chart B-22 RL Speed Sensor Short Circuit (DTC 63)
Step Action Yes No
1 1. Turn the key off.
2. Disconnect EHCU connector
3. Measure the RL speed sensor resistance between EHCU
connector terminals 22 and 23.
Is the resistance between 1.3k and 1.9k ohms? Go to Step 2 Go to Step 3
2 Is there play in the sensor/sensor rotor? Repair.
Go to Step 4 Go to Step 6
3 Measure the RL speed sensor resistance at the sensor Repair harness
connector. abnormality
between sensors
Is the resistance between 1.3k and 1.9k ohms?
and EHCU. Replace sensor.
Go to Step 6 Go to Step 6
4 Damage and powdered iron sticking to sensor/sensor ring? Repair.
Go to Step 5 Go to Step 6
5 Is sensor output normal? (Chart C-1-3 or TC-1)? Check for faults
in harness
between speed
sensor and
EHCU.
Fault found:
repair, and
perform system
self-check.
No fault found:
replace EHCU. Replace sensor.
Go to Step 6 Go to Step 6
6 1. Reconnect all components and ensure all components are
properly mounted.
Repeat the “Basic
2. Clear diagnostic trouble code.
diagnostic flow
Was this step finished? chart.” Go to Step 6
NOTE: Even after repairing the faulty part the warning
light (W/L) does not go out if the vehicle is at a stop. Turn
the ignition switch to the ON position and drive the vehicle
at 12 km/h or higher to make sure that the warning light
goes out.
BRAKE CONTROL SYSTEM 5A–55
Chart B-23 RR Speed Sensor Short Circuit (DTC 64)
Step Action Yes No
1 1. Turn the key off.
2. Disconnect EHCU connector.
3. Measure the RR speed sensor resistance between EHCU
connector terminals 2 and 3.
Is the resistance between 1.3k and 1.9k ohms? Go to Step 2 Go to Step 3
2 Is there play in the sensor/sensor rotor? Repair.
Go to Step 4 Go to Step 6
3 Measure the RR speed sensor resistance at the sensor Repair harness
connector. abnormality
between sensors
Is the resistance between 1.3k and 1.9k ohms?
and EHCU. Replace sensor.
Go to Step 6 Go to Step 6
4 Damage and powdered iron sticking to sensor/sensor ring? Repair.
Go to Step 5 Go to Step 6
5 Is sensor output normal? (Chart C-1-4 or TC-1) Check for faults
in harness
between speed
sensor and
EHCU.
Fault found:
repair, and
perform system
self-check.
No fault found:
replace EHCU. Replace sensor.
Go to Step 6 Go to Step 6
6 1. Reconnect all components and ensure all components are
properly mounted.
Repeat “Basic
2. Clear diagnostic trouble code.
diagnostic flow
Was this step finished? chart.” Go to Step 6
NOTE: Even after repairing the faulty part the warning
light (W/L) does not go out if the vehicle is at a stop. Turn
the ignition switch to the ON position and drive the vehicle
at 12 km/h or higher to make sure that the warning light
goes out.
5A–56 BRAKE CONTROL SYSTEM
Chart B-24 Sensor Signal Input Abnormality (DTC 65)
Step Action Yes No
1 Using TECH 2? Go to Step 2 Go to Step 3
2 1. Connect TECH 2.
2. Select Snap shot manual trigger. Go to Step 3
3. With wheel speed data displayed, run the vehicle when speed
All the sensors
has arrived at 30 km/h (18 mph).
should follow the
4. Check speed data on each wheel (refer to the criterion given
following
below). *1 Replace. flowchart (without
Is the abnormal sensor condition found? Go to Step 8 using TECH 2).
3 Is there play in sensor/sensor ring? Repair.
Go to Step 8 Go to Step 4
4 Is there powdered iron sticking to sensor/sensor ring? Repair.
Go to Step 8 Go to Step 5
5 Is there a broken tooth or indentation in sensor ring? Replace sensor
ring.
Go to Step 8 Go to Step 6
6 Is there play in wheel bearing? Adjust or repair.
Go to Step 8 Go to Step 7
7 Is the check wiring between sensor and EHCU normal? Repair, and
perform system
Replace EHCU. self-check.
Go to Step 8 Go to Step 8
8 1. Reconnect all components, ensure all components are
properly mounted.
Repeat “Basic
2. Clear diagnostic trouble code.
diagnostic flow
Was this step finished? chart.” Go to Step 8

Sensor Signal Abnormality Criteria using


TECH 2
1. While driving, the speed of one or two wheels 25% or
more higher than that of the other wheels.
2. The speed of one or two wheels is 10 km/h (6 mph) or
more higher than that of the other wheels.
3. During steady driving, wheel speed changes abruptly.
*1 The vehicle must run on a level paved road.
NOTE: Even after repairing the faulty part the warning
light (W/L) does not go out if the vehicle is at a stop.
Turn the ignition switch to the ON position and drive the
vehicle at 12 km/h or higher to make sure that the warning
light goes out.
It is important to verify that the correct tires are installed
on vehicle.
BRAKE CONTROL SYSTEM 5A–57

Unit Inspection Procedure


This section describes the following inspection
procedures referred to during “SYMPTOM DIAGNOSIS”
and “DIAGNOSIS BY ‘ABS’ WARNING LIGHT
ILLUMINATION PATTERN” :
without TECH 2 with TECH 2
Wheel Speed Sensor Output Inspection Chart C-1-1 to C-1-4 Chart TC-1
Transmission SW Inspection Chart C-2 Chart TC-2

Chart C-1-1 FL Sensor Output Inspection Procedure


Step Action Yes No
1 1. Turn the key off.
2. Disconnect EHCU connector.
3. Jack up the vehicle, With all four wheels off the ground.
Measure the AC voltage between EHCU connector terminals
while turning FL wheel at a speed of 1 RPS:
Is voltage between EHCU connector terminals 20 and 21 under Ok.
200 mV? Go to Step 2 Go to Step 3
2 1. Disconnect the wheel speed sensor. Connector is
2. Measure resistance between the wheel speed sensor faulty, or open or
connector terminals 1 and 2. short circuit in
harness between
Is resistance between connector (C-13) terminals 1 and 2 within
wheel speed
1.3k - 1.9k ohms?
sensor connector
and EHCU. Wheel speed
Inspect and sensor is faulty.
correct the Replace the
connector or wheel speed
harness sensor.
Go to Step 3 Go to Step 3
3 Reconnect all components and ensure all components are
Repeat the “Basic
properly mounted.
diagnostic flow
Was this step finished? chart.” Go to Step 3
5A–58 BRAKE CONTROL SYSTEM
Chart C-1-2 FR Sensor Output Inspection Procedure
Step Action Yes No
1 1. Turn the key off.
2. Disconnect EHCU connector.
3. Jack up the vehicle with all four wheels off the ground.
Measure the AC voltage between EHCU connector terminals
while turning FR wheel at a speed of 1 RPS:
Is voltage between EHCU connector terminals 4 and 5 under 200 Ok.
mV? Go to Step 2 Go to Step 3
2 1. Disconnect the wheel speed sensor. Connector is
2. Measure resistance between the wheel speed sensor faulty, or open or
connector terminals 1 and 2. short circuit of
harness between
Is resistance between connector (C-41) terminals 1 and 2 within
wheel speed
1.3k - 1.9k ohms?
sensor connector
and EHCU. Wheel speed
Inspect and sensor is faulty.
correct the Replace the
connector or wheel speed
harness sensor.
Go to Step 3 Go to Step 3
3 Reconnect all components and ensure all components are
Repeat the “Basic
properly mounted.
diagnostic flow
Was this step finished? chart.” Go to Step 3

Chart C-1-3 RL Sensor Output Inspection Procedure


Step Action Yes No
1 1. Turn the key off.
2. Disconnect EHCU connector.
3. Jack up the vehicle with all four wheels off the ground.
Measure the AC voltage between EHCU connector terminals
while turning RL wheel at a speed of 1 RPS:
Is voltage between EHCU connector terminals 22 and 23 under Ok.
200 mV? Go to Step 2 Go to Step 3
2 1. Disconnect the wheel speed sensor. Connector is
2. Measure resistance between the wheel speed sensor faulty, or open or
connector terminals 1 and 2. short circuit of
harness between
Is resistance between connector (F-3) terminals 1 and 2 within
wheel speed
1.3k - 1.9k ohms?
sensor connector
and EHCU. Wheel speed
Inspect and sensor is faulty.
correct the Replace the
connector or wheel speed
harness sensor.
Go to Step 3 Go to Step 3
3 Reconnect all components and ensure all components are
Repeat the “Basic
properly mounted.
diagnostic flow
Was this step finished? chart.” Go to Step 3
BRAKE CONTROL SYSTEM 5A–59
Chart C-1-4 RR Sensor Output Inspection Procedure
Step Action Yes No
1 1. Turn the key off.
2. Disconnect EHCU connector.
3. Jack up the vehicle with all four wheels off the ground.
Measure the AC voltage between EHCU connector terminals
while turning RR wheel at a speed of 1 RPS:
Is voltage between EHCU connector terminals 2 and 3 under 200 Ok.
mV? Go to Step 2 Go to Step 3
2 1. Disconnect the wheel speed sensor. Connector is
2. Measure resistance between the wheel speed sensor faulty, or open or
connector terminals 1 and 2. short circuit of
harness between
Is resistance between connector (F-2) terminals 1 and 2 within
wheel speed
1.3k - 1.9k ohms?
sensor connector
and EHCU. Wheel speed
Inspect and sensor is faulty.
correct the Replace the
connector or wheel speed
harness sensor.
Go to Step 3 Go to Step 3
3 Reconnect all components and ensure all components are
Repeat the “Basic
properly mounted.
diagnostic flow
Was this step finished? chart.” Go to Step 3

Chart TC-1 Sensor Output Inspection Procedure (Use TECH 2)


Step Action Yes No
1 1. Connect TECH 2.
2. While driving the vehicle, check the wheel speed of each
sensor by Data List.
Is the vehicle speed value is normal? Go to Step 6 Go to Step 2
2 Check the sensor harness for suspected disconnection (Check Replace speed
while shaking harness/connector). sensor. Repair.
Is the sensor harness connection normal? Go to Step 3 Go to Step 6
3 While driving the vehicle, check the wheel speed of each sensor
by Data List.
Is the vehicle speed value is normal? Go to Step 6 Go to Step 4
4 Check the sensor rotor. Replace sensor
rotor.
Is the sensor rotor normal?
Go to Step 6 Go to Step 5
5 While driving the vehicle, check the wheel speed of each sensor Repair harness or
by Data List. connector
between EHCU
Is the vehicle speed value is normal?
and speed
sensor.
Go to Step 6 Go to Step 6
6 Reconnect all components, ensure all components are properly
Repeat the “Basic
mounted.
diagnostic flow
Was this step finished? chart.” Go to Step 6
5A–60 BRAKE CONTROL SYSTEM
Chart C-2 Transmission Input Inspection Procedure
Step Action Yes No
1 1. Turn the key off. Shorted switch
2. Disconnect EHCU connector. harness.
Is there continuity between EHCU connector terminals 6 and 15 Repair switch or
(Gear position-P(A/T), N(M/T))? harness.
Go to Step 6 Go to Step 2
2 Is the vehicle an A/T model? Go to Step 3 Go to Step 5
3 Turn the key on and measure voltage between EHCU connector Transmission SW
terminals 6 and 15. trouble.
Is there less than 6V when the gear position is L, and R(Battery Disconnected
voltage 12V)? harness.
Repair SW and
harness.
Go to Step 5 Go to Step 6
4 Turn the key on and measure the voltage between EHCU Transmission SW
connector terminal 6 and 15. trouble.
Is there more than 9.6V when the gear position is 1, 2, R(Battery Disconnected
voltage 12V)? harness.
Repair SW and
harness.
Go to Step 5 Go to Step 6
5 Measure the voltage between EHCU connector terminals 6 and Transmission SW
15. trouble.
Is there 6.6 to 9.0V when the gear position is 3, 4, 5 and N(M/T) or Disconnected
2,3,D,N and P(A/T)(Battery voltage 12V)? harness.
Repair SW and
harness.
Go to Step 6 Go to Step 6
6 1. Reconnect all components and ensure all components are
properly mounted.
Repeat the “Basic
2. Clear diagnostic trouble code.
diagnostic flow
Was this step finished? chart.” Go to Step 6
BRAKE CONTROL SYSTEM 5A–61
Chart TC-2 Transmission Input Inspection Procedure (Use TECH 2)
Step Action Yes No
1 1. Connect TECH 2.
2. Select Data List.
Is this vehicle an A/T model ? Go to Step 2 Go to Step 4
2 Is “Off-Road Switch(Transmission Input): Active” when the shift
lever is the L and R? Go to Step 3 Go to Step 6
3 Is “Off-Road Switch(Transmission Input): Inactive” when the shift
lever is other than the L and R? Go to Step 7 Go to Step 6
4 Is “Off-Road Switch(Transmission Input): Active” when the shift
lever is in 1, 2 and R? Go to Step 5 Go to Step 6
5 Is “Off-Road Switch(Transmission Input): Inactive” when the shift
lever is other than the 1, 2 and R? Go to Step 7 Go to Step 6
6 1. Abnormal T/M SW, inhibitor SW, or harness.
2. Repair T/M SW, inhibitor SW, or harness.
Is the T/M SW, inhibitor SW, or harness repaired? Go to Step 7 Go to Step 6
7 Reconnect all components, ensure all components are properly
Repeat the “Basic
mounted.
diagnostic flow
Was this step finished? chart.” Go to Step 7
5A–62 BRAKE CONTROL SYSTEM

Special Tools
TOOL NO.
ILLUSTRATION
TOOL NAME

5–8840–0385–0
(J–35616)
Connector test adapter
kit

5–8840–0366–0
(J–39200)
High impedance
multimeter

(1) PCMCIA Card


(2) SAE 16/19 Adapter
(3) DLC Cable
(4) Tech–2
ANTI–LOCK BRAKE SYSTEM 5B–1

BRAKES
ANTI-LOCK BRAKE SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 5B–1 Front Wheel Speed Sensor and
Electronic Hydraulic Control Unit . . . . . . . . . . 5B–2 Associated Parts . . . . . . . . . . . . . . . . . . . . . . 5B–4
Electronic Hydraulic Control Unit and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B–4
Associated Parts . . . . . . . . . . . . . . . . . . . . . . 5B–2 Inspection and Repair . . . . . . . . . . . . . . . . . . 5B–5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B–2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B–5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B–2 Rear Wheel Speed Sensor . . . . . . . . . . . . . . . 5B–6
G-Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B–3 Rear Wheel Speed Sensor and
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B–3 Associated Parts . . . . . . . . . . . . . . . . . . . . . . 5B–6
Inspection and Repair . . . . . . . . . . . . . . . . . . 5B–3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B–6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B–3 Inspection and Repair . . . . . . . . . . . . . . . . . . 5B–6
Front Wheel Speed Sensor . . . . . . . . . . . . . . . 5B–4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B–6

Service Precaution CAUTION: Replace all components included in


repair kits used to service this system. Lubricate
WARNING: IF SO EQUIPPED WITH A rubber parts with clean, fresh brake fluid to ease
SUPPLEMENTAL RESTRAINT SYSTEM(SRS), assembly. Do not use shop air with in–line
REFER TO THE SRS COMPONENT AND WIRING lubricators on brake parts, as damage to rubber
LOCATION VIEW IN ORDER TO DETERMINE components may result. If any hydraulic component
WHETHER YOU ARE PERFORMING SERVICE ON OR is removed or brake line disconnected, it may be
NEAR THE SRS COMPONENTS OR THE SRS necessary to bleed part or all of the brake system.
WIRING. WHEN YOU ARE PERFORMING SERVICE
NOTE: The use of rubber hoses or parts other than those
ON OR NEAR THE SRS COMPONENTS OR THE SRS
furnished specifically for the Anti–lock Brake System may
WIRING, REFER TO THE SRS SERVICE
lead to functional problems requiring major overhaul.
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
5B–2 ANTI–LOCK BRAKE SYSTEM

Electronic Hydraulic Control Unit


Electronic Hydraulic Control Unit and Associated Parts

350RW013

Legend (3) Bolts


(1) Connector (4) Nut
(2) Hydraulic Unit ASM (5) Bolt

Removal Installation
1. Remove battery ASM. To install, follow the removal steps in the reverse order,
noting the following points:
2. Remove harness connector.
Torque
3. Remove EHCU fixing nuts.
Hydraulic unit fixing nuts : 22 Nꞏm (2.2kgꞏm/16
4. Remove brake pipes.
lb ft)
After disconnecting brake pipe, cap or tape the
Ground cable : 14 Nꞏm (1.4kgꞏm/10 lb ft)
openings of the brake pipe to prevent the entry of
foreign matter. Brake pipe (joint bolts) : 16 Nꞏm (1.6kgꞏm/12
lb ft)
5. Remove hydraulic unit fixing nuts.
After installing the hydraulic unit, bleed brakes
completely. Refer to Servicing in Power Assisted
Brake System section.
ANTI–LOCK BRAKE SYSTEM 5B–3

G-Sensor
Removal

350RX001

1. Remove center console.


Refer to Consoles in Body and Accessories
section.
2. Remove clip from G-sensor connector (1), then
disconnect connector.
3. Remove G-sensor assembly fixing bolt (2).
4. Remove G-sensor assembly (3).

Inspection and Repair


Refer to Chart B-5 in Brake Control System section.

Installation
1. Install G-sensor assembly (3).
Care should be taken so that the G-sensor is not
installed in the wrong direction.
2. Install G-sensor assembly fixing bolt (2).
Tighten the fixing bolt to the specified torque.
Torque : 10 Nꞏm (1.0kgꞏm/87 lb in)
3. Install G-sensor wiring connector (1).
4. Install center console.
Refer to Consoles in Body and Accessories
section.
5B–4 ANTI–LOCK BRAKE SYSTEM

Front Wheel Speed Sensor


Front Wheel Speed Sensor and Associated Parts

350RW012

Legend (3) Sensor Cable Fixing Bolt (Lower side)


(1) Speed Sensor Connector (4) Sensor Cable Fixing Bolt (Sensor side)
(2) Sensor Cable Fixing Bolt (Upper side) (5) Speed Sensor

Removal
1. Remove speed sensor connector.
2. Remove sensor cable fixing bolt (Upper side).
3. Remove sensor cable fixing bolt (Lower side).
4. Remove the speed sensor cable fixing bolts (1) and
caliper fixing bolt (2) from caliper side speed sensor
cable bracket (3).

350RW010

5. Remove speed sensor.


ANTI–LOCK BRAKE SYSTEM 5B–5

Inspection and Repair NOTE: Confirm that a white line marked on the cable is
not twisted when connecting the speed sensor cable.
1. Check the speed sensor pole piece for presence of
5. Install speed sensor connector.
foreign materials; remove any dirt, etc.
2. Check the pole piece for damage; replace speed
sensor if necessary.
3. Check the speed sensor cable for short or open
circuit, and replace with a new one if necessary.
To check for cable short or open, bend or stretch the
cable while checking for continuity.
4. Check the sensor ring for damage including tooth
chipping, and if damaged, replace the sensor ring
assembly. Refer to Front Hub and Disc in Drive Shaft
System section.

Installation
1. Install speed sensor and take care not to hit the speed
sensor pole piece during installation.
2. Install speed sensor fixing bolt and tighten the fixing
bolt to the specified torque.
Torque
Sensor side : 8 Nꞏm (0.8kgꞏm/69 lb in)
Caliper side : 155 Nꞏm (15.8kgꞏm/115 lb ft)

350RW011

Legend
(1) Caliper Fixing Bolt
(2) Bracket
(3) Sensor Fixing Bolt
(4) Sensor
(5) Knuckle
(6) Brake Caliper

3. Install speed sensor cable fixing bolt (Lower side) and


tighten the fixing bolt to the specified torque.
Torque : 24 Nꞏm (2.4kgꞏm/18 lb ft)
4. Install speed sensor cable fixing bolt (Upper side) and
tighten the fixing bolt to the specified torque.
Torque : 6 Nꞏm (0.6kgꞏm/52 lb in)
5B–6 ANTI–LOCK BRAKE SYSTEM

Rear Wheel Speed Sensor


Rear Wheel Speed Sensor and Associated Parts

350RW008

Legend (3) Clip (11 pieces)


(1) Speed Sensor Connector (4) Speed Sensor
(2) Sensor Cable Fixing Bolt (5) Sensor Fixing Bolt

Removal 2. Check the pole piece for damage, and replace the
speed sensor if necessary.
1. Remove speed sensor connector. 3. Check the speed sensor cable for a short or an open,
2. Remove clip. and replace with a new one if necessary. To check for
3. Remove sensor cable fixing bolt. cable short or open, bend or stretch the cable while
4. Remove sensor fixing bolt. checking for continuity.
5. Remove speed sensor. 4. Check the sensor ring for damage including tooth
chipping. If damaged replace the axle shaft assembly.
Refer to Front Hub and Disc in Drive Shaft System
section.

Installation
1. Install the speed sensor and take care not to hit the
speed sensor pole piece during installation.
2. Install the sensor fixing bolt and tighten it to the
specified torque.
Torque : 18 Nꞏm (1.8kgꞏm/13 lb ft)
3. Install the sensor cable fixing bolt and tighten it to the
specified torque.
Torque : 24 Nꞏm (2.4kgꞏm/18 lb ft)
NOTE: Confirm that the cable is not twisted when
connecting the speed sensor cable.
4. Install clip.
350RS035
5. Install speed sensor connector.

Inspection and Repair


1. Check the speed sensor pole piece for presence of
foreign materials; remove any dirt, etc.


330RW013
F05RW003
C05RW025

C05RW021

C05RW024
C05RW022
C05RW023
330RW015
331RW010
1

ENG

360RX001
331RW011
E05RW019
331RW007

331RW008
331RW009
ENGINE MECHANICAL 6A–1

ENGINE
CONTENTS
Engine Mechanical . . . . . . . . . . . . . . . . . . . . . . 6A Driveability and Emissions . . . . . . . . . . . . . . . . 6E
Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . . 6B Engine Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . 6F
Engine Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . 6G
Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . 6D1 Engine Speed Control System . . . . . . . . . . . . 6H
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . 6D2 Inducton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6J
Starting and Charging System . . . . . . . . . . . . 6D3

ENGINE MECHANICAL
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 6A–2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–40
General Description . . . . . . . . . . . . . . . . . . . . . 6A–3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–41
Engine Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 6A–4 Crankshaft and Main Bearings . . . . . . . . . . . . 6A–42
Cylinder Head Cover LH . . . . . . . . . . . . . . . . . 6A–18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–42
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–18 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–43
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–19 Rear Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–47
Cylinder Head Cover RH . . . . . . . . . . . . . . . . . 6A–21 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–47
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–21 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–47
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–22 Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . 6A–48
Common Chamber . . . . . . . . . . . . . . . . . . . . . . 6A–24 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–48
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–24 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–48
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–24 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–52
Exhaust Manifold LH . . . . . . . . . . . . . . . . . . . . . 6A–26 Cylinder Head and Associated Parts . . . . . 6A–52
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–26 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–52
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–26 Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–53
Exhaust Manifold RH . . . . . . . . . . . . . . . . . . . . 6A–27 Inspection and Repair . . . . . . . . . . . . . . . . . . 6A–53
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–27 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–53
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–27 Valve Spring, Oil Controller, Valve,
Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . . 6A–28 Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–56
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–28 Valve Spring, Oil Controller, Valve,
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–28 Valve Guide and Associated Parts . . . . . . . 6A–56
Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–29 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–56
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–29 Inspection and Repair . . . . . . . . . . . . . . . . . . 6A–57
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–30 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–60
Valve Clearance Adjustments . . . . . . . . . . . . . 6A–61
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–33 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–63
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–33 Camshaft and Associated Parts . . . . . . . . . 6A–63
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–63
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–37
Inspection and Repair . . . . . . . . . . . . . . . . . . 6A–64
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–37
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–66
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–37
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–69
Valve Stem Oil Controller , Valve Spring and
Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–39 Crankshaft and Associated Parts . . . . . . . . 6A–69
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–39 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–69
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–39 Inspection and Repair . . . . . . . . . . . . . . . . . . 6A–70
Inspection and Repair . . . . . . . . . . . . . . . . . . 6A–71
Piston, Piston Ring and Connecting Rod . . . 6A–40
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–73
6A–2 ENGINE MECHANICAL
Piston and Connecting Rod . . . . . . . . . . . . . . . 6A–77
Piston, Connecting Rod and Associate
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–77
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–77
Inspection and Repair . . . . . . . . . . . . . . . . . . 6A–78
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–82
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–85
Cylinder Block and Associated Parts . . . . . 6A–85
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–85
Inspection and Repair . . . . . . . . . . . . . . . . . . 6A–86
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–87
Main Data and Specification . . . . . . . . . . . . . . 6A–90
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–96
Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
ENGINE MECHANICAL 6A–3

General Description Cylinder Head


The cylinder head, made of aluminum alloy casting
Engine Cleanliness And Care employs a pent–roof type combustion chamber with a
An automobile engine is a combination of many spark plug in the center. The intake and exhaust valves
machined, honed, polished and lapped surfaces with are placed in V–type design. The ports are cross–flow
tolerances that are measured in the thousandths of a type.
millimeter (ten thousandths of an inch). Accordingly,
when any internal engine parts are serviced, care and Valve Train
cleanliness are important. Throughout this section, it Intake and exhaust camshaft on the both side of banks
should be understood that proper cleaning and protection are driven through an camshaft drive gear by timing belt.
of machined surfaces and friction areas is part of the The valves are operated by the camshaft and the valve
repair procedure. This is considered standard shop clearance is adjusted to select suitable thickness shim.
practice even if not specifically stated.
A liberal coating of engine oil should be applied to all Intake Manifold
friction areas during assembly to protect and lubricate The intake manifold system is composed of the aluminum
the surfaces on initial operation. cast common chamber and intake manifold attached with
Whenever valve train components, pistons, piston six fuel injectors.
rings, connecting rods, rod bearings, and crankshaft
journal bearings are removed for service, they should Exhaust Manifold
be retained in order.
The exhaust manifold is made of nodular cast iron.
At the time of installation, they should be installed in
the same locations and with the same mating Pistons and Connecting Rods
surfaces as when removed.
Aluminum pistons are used after selecting the grade that
Battery cables should be disconnected before any meets the cylinder bore diameter. Each piston has two
major work is performed on the engine. Failure to compression rings and one oil ring. The piston pin is made
disconnect cables may result in damage to wire of chromium steel is offset 1mm toward the thrust side,
harness or other electrical parts. and the thrust pressure of piston to the cylinder wall varies
The six cylinders of this engine are identified by gradually as the piston travels. The connecting rods are
numbers; Right side cylinders 1, 3 and 5, Left side made of forged steel. The connecting rod bearings are
cylinders 2, 4 and 6, as counted from crankshaft graded for correct seze selection.
pulley side to flywheel side.
Crankshaft and Bearings
General Information on Engine Service The crankshaft is made of Ductile cast–iron. Pins and
The following information on engine service should be journals are graded for correct size selection for their
noted carefully, as it is important in preventing damage bearing.
and contributing to reliable engine performance:
When raising or supporting the engine for any reason, Engine Lubrication
do not use a jack under the oil pan. Due to the small The oil discharged by a trochoid–type oil pump driven by
clearance between the oil pan and the oil pump the crankshaft is fed through full–flow oil filter and to the oil
strainer, jacking against the oil pan may cause gallery provided under the crankshaft bearing cap. The oil
damage to the oil pick–up unit. is then led to the crankshaft journals and cylinder head.
The 12–volt electrical system is capable of damaging The crank pins are lubricated with oil from crankshaft
circuits. When performing any work where electrical journals through oil holes. Also, an oil jet is fed to each
terminals could possibly be grounded, the ground cylinder from crankshaft juornals on the connecting rod
cable of the battery should be disconnected at the for piston cleaning. The oil pan flange is dealed with liquid
battery. packing only; do not deform or damage the flange surface
Any time the intake air duct or air cleaner is removed, during removal or installation.
the intake opening should be covered. This will
protect against accidental entrance of foreign
material into the cylinder which could cause extensive
damage when the engine is started.

Cylinder Block
The cylinder block is made of aluminum die–cast casting
for 75 V–type six cylinders. It has a rear plate integrated
structure and employs a deep skint. The cylinder liner is
cast and the liner inner diameter and crankshaft journal
diameter are classified into grades. The crankshaft is
supported by four bearings of which width of No.3 bearing
on the body side is different in order to support the thrust
bearing. The bearing cap is made of nodular cast iron and
each bearing cap uses four bolts and two side bolts.
6A–4 ENGINE MECHANICAL

Engine Diagnosis
Hard Starting
1. Starting Motor Does Not Turn Over
Troubleshooting Procedure
Turn on headlights and starter switch.
Condition Possible cause Correction
Headlights go out or dim Battery run down or under charged Recharge or replace battery
considerably
Terminals poorly connected Clean battery posts and terminals
and connect properly
Starting motor coil circuit shorted Overhaul or replace
Starting motor defective Overhaul or replace

2. Ignition Trouble — Starting Motor Turns Over But Engine Does Not Start
Spark Test
Disconnect an igniton coil from any spark plug. Connect tester is properly grounded. To avoid electrical shock, do
the spark plug tester 5–8840–0607–0, start the engine, not touch the part where insulation of the igniton coil is
and check if a spark is generated in the spark plug tester. broken while the engine is running.
Before starting the engine, make sure that the spark plug
Condition Possible cause Correction
Spark jumps across gap Spark plug defective Clean, adjust spark gap or replace
Ignition timing incorrect Refer to Ignition System
Fuel not reaching fuel injector(s) or Refer to item 3 (Trouble in fuel
engine system)
Valve timing incorrect Adjust
Engine lacks compression Refer to item 4 (Engine lacks
compression)
No sparking takes place Ignition coil disconnected or broken Connect properly or replace
Electronic Ignition System with Replace
module
Poor connections in engine harness Correct
Powertrain Control Module cable Correct or replace
disconnected or defective

3. Trouble In Fuel System

Condition Possible cause Correction


Starting motor turns over and spark Fuel tank empty Fill
occurs but engine does not start
start.
Water in fuel system Clean
Fuel filter clogged Replace filter
Fuel pipe clogged Clean or replace
Fuel pump defective Replace
Fuel pump circuit open Correct or replace
Evaporative Emission Control Correct or replace
System circuit clogged
Multiport Fuel Injection System faulty Refer to “Electronic Fuel Injection”
section
ENGINE MECHANICAL 6A–5
4. Engine Lacks Compression

Condition Possible cause Correction


Engine lacks compression Spark plug loosely fitted or spark Tighten to specified torque or replace
plug gasket defective gasket
Valve timing incorrect Adjust
Cylinder head gasket defective Replace gasket
Valve incorrectly seated Lap valve
Valve stem seized Replace valve and valve guide
Valve spring weakened or broken Replace
Cylinder or piston rings worn Overhaul engine
Piston ring seized Overhaul engine.

Engine Compression Test Procedure


1. Start and run the engine until the engine reaches 7. Install cylinder compression gauge into spark plug
normal operating temperature. hole.
2. Turn the engine off. 8. With the throttle valve opened fully, keep the starter
3. Remove all the spark plugs. engaged until the compression gage needle reaches
the maximum level. Note the reading.
4. Remove ignition coil fuse (15A) and disable the
ignition system. 9. Repeat the test with each cylinder.
5. Remove the fuel pump relay from the relay and fuse If the compression pressure obtained falls below the
box. limit, engine overhaul is necessary.
6. Engage the starter and check that the cranking speed Limit; 1000 kPa (145 psi)
is approximately 300 rpm.
6A–6 ENGINE MECHANICAL
Rough Engine Idling or Engine Stalling
Condition Possible cause Correction
Trouble in fuel injection system Idle air control valve defective Replace
Throttle shutting off incomplete Correct or replace
Throttle position sensor circuit open Correct or replace
or shorted
Fuel injector circuits open or shorted Correct or replace
Fuel injectors damaged Replace
Fuel pump relay defective Replace
Mass Airflow Sensor circuit open or Correct or replace
poor connections
Mass Airflow Sensor defective Replace
Manifold Absolute Pressure Sensor Correct or replace
circuit open or poor connections
Manifold Absolute Pressure Sensor Replace
defective
Engine Coolant Temperature Sensor Correct or replace
circuit open or poor connections
Engine Coolant Temperature Sensor Replace
defective
Intake Air Temperature sensor circuit Correct or replace
open or poor connections
Intake Air Temperature sensor Replace
defective
Knock Sensor (KS) cable broken or Correct or replace
poor connections
KS defective Replace
KS Module circuits open or ground Correct or replace
KS Module defective Replace
Vehicle Speed Sensor circuit open or Correct or replace
shorted
Vehicle Speed Sensor defective Replace
Trouble in emission control system Powertrain Control Module defective Replace
Exhaust Gas Recirculation Valve Correct or replace
circuit open or poor connections
Exhaust Gas Recirculation Valve Replace
faulty
Canister purge valve circuit open or Correct or replace
poor connections
Canister purge valve defective Replace
Evaporative Emission Canister Replace
Purge control valve defective
Trouble in ignition system Refer to “Hard Start”
ENGINE MECHANICAL 6A–7

Condition Possible cause Correction


Others Engine lacks compression Refer to “Hard Start”
Valve incorrectly seated Lap valve
Air Cleaner Filter clogged Replace filter element
Valve timing incorrect Readjust
Idle air control valve broken Replace
Fast idle solenoid defective Replace
Positive Crankcase Ventilation valve Replace
defective or clogged

Rough Engine Running


Condition Possible cause Correction
Engine misfires periodically Ignition coil layer shorted Replace
Spark plugs fouling Clean or install hotter type plug
Spark plug(s) insulator nose leaking Replace
Fuel injector(s) defective Replace
Powertrain control module faulty Replace
Engine knocks periodically Spark plugs running too hot Install colder type spark plugs
Powertrain control module faulty Replace
Engine lacks power Spark plugs fouled Clean
Fuel injectors defective Replace
Mass Airflow Sensor or Intake Correct or replace
Airflow Sensor circuit defective
Manifold Absolute Pressure (MAP) Correct or replace
Sensor or Manifold Absolute
Pressure Sensor circuit defective
Engine Coolant Temperature Sensor Correct or replace
or Engine Coolant Temperature
Sensor circuit defective
Powertrain Control Module faulty Replace
Intake Air Temperature Sensor or Correct or replace
Intake Air Temperature Sensor
circuit defective
Throttle Position Sensor or Throttle Correct or replace
Position Sensor circuit defective
Knock Sensor or Knock Sensor Correct or replace
circuits defective
Knock Sensor Module or Knock Correct or replace
Sensor Module circuits defective
6A–8 ENGINE MECHANICAL
Hesitation
Condition Possible cause Correction
Hesitation on acceleration Throttle Position Sensor adjustment Replace throttle valve assembly
incorrect
Throttle Position Sensor circuit open Correct or replace
or shorted
Excessive play in accelerator linkage Adjust or replace
Mass Airflow Sensor circuit open or Correct or replace
poor connections
Mass Airflow Sensor defective Replace
Manifold Absolute Pressure (MAP) Correct or replace
Sensor circuit open or shorted
MAP Sensor defective Replace
Intake Air Temperature (IAT) Sensor Correct or replace
circuit open or shorted
Knock Sensor (KS) Circuit open or Correct or replace
poor connections
KS defective Replace
KS Module circuits open or shorted Correct or replace
KS Module defective Replace
IAT Sensor defective Replace
Hesitation at high speeds Fuel tank strainer clogged Clean or replace
(Fuel pressure too low) Fuel pipe clogged Clean or replace
Fuel filter clogged Replace
Defective fuel pump system Check and replace
Fuel Pressure Control Valve leaking Replace
Hesitation at high speeds Power supply or ground circuit for Check and correct or replace
(Fuel injector not working normally) Multiport Fuel Injection System
shorted or open
Fuel Injector defective Replace
Cable of Multiport Fuel Injection Correct or replace
System circuit open or poor
connections
ENGINE MECHANICAL 6A–9

Condition Possible cause Correction


Hesitation at high speeds Powertrain Control Module defective Replace
Throttle Position Sensor cable Correct or replace
broken or poor connections
Throttle Position Sensor defective Replace
Engine Coolant Temperature Sensor Correct or replace
circuit open or shorted
Engine Coolant Temperature Sensor Replace
defective
Mass Airflow Sensor circuit open or Correct or replace
poor connections
Mass Airflow Sensor defective Replace
MAP Sensor cable broken or poor Correct or replace
connections
MAP Sensor defective Replace
IAT Sensor circuit open or poor Correct or replace
connections
IAT Sensor defective Replace
KS circuit open or poor connections Correct or replace
KS defective Replace
KS Module circuit open or shorted Correct or replace
KS Module defective Replace
Throttle valve not fully opened Check and correct or replace
Air Cleaner Filter clogged Replace filter element
Power supply voltage too low Check and correct or replace
6A–10 ENGINE MECHANICAL
Engine Lacks Power
Condition Possible cause Correction
Trouble in fuel system Fuel Pressure Control Valve not Replace
working normally
Fuel injector clogged Clean or replace
Fuel pipe clogged Clean
Fuel filter clogged or fouled Replace
Fuel pump drive circuit not working Correct or replace
normally
Fuel tank not sufficiently breathing Clean or replace
due to clogged Evaporative
Emission Control System circuit
Water in fuel system Clean
Inferior quality fuel in fuel system Use fuel of specified octane rating
Powertrain Control Module supplied Correct circuit
poor voltage
Throttle Position Sensor cable Correct or replace
broken or poor connections
Throttle Position Sensor defective Replace
Mass Airflow Sensor not working Replace
normally
Manifold Absolute Pressure Sensor Replace
not working normally
Intake Air Temperature Sensor not Replace
working normally
Engine Coolant Temperature Sensor Correct or replace
circuit open or shorted
Engine Coolant Temperature Sensor Replace
defective
Powertrain Control Module defective Replace
Trouble in intake or exhaust system Air Cleaner Filter clogged Replace filter element
Air duct kinked or flattened Correct or replace
Ignition failure ———— Refer to Hard Start Troubleshooting
Guide
Heat range of spark plug inadequate Install spark plugs of adequate heat
range
Ignition coil defective Replace
ENGINE MECHANICAL 6A–11

Condition Possible cause Correction


Engine overheating Level of Engine Coolant too low Replenish
Fan clutch defective Replace
Incorrect fan installed Replace
Thermostat defective Replace
Engine Coolant pump defective Correct or replace
Radiator clogged Clean or replace
Radiator filler cap defective Replace
Level of oil in engine crankcase too Change or replenish
low or wrong engine oil
Resistance in exhaust system Clean exhaust system or replace
increased defective parts
Throttle Position Sensor adjustment Replace with Throttle Valve ASM
incorrect
Throttle Position Sensor circuit open Correct or replace
or shorted
Cylinder head gasket damaged Replace
Engine overcooling Thermostat defective Replace (Use a thermostat set to
open at 82 C (180 F))
Engine lacks compression ———— Refer to Hard Start
Others Tire inflation pressure abnormal Adjust to recommended pressures
Brake drag Adjust
Clutch slipping Adjust or replace
Level of oil in engine crankcase too Correct level of engine oil
high
Exhaust Gas Recirculation Valve Replace
defective

Engine Noisy
Abnormal engine noise often consists of various noises moving parts of the engine. It is, therefore, advisable to
originating in rotating parts, sliding parts and other locate the source of noise systematically.
Condition Possible cause Correction
Noise from crank journals or from Oil clearance increased due to worn Replace crank bearings and
crank bearings crank journals or crank bearings crankshaft or regrind crankshaft and
(Faultyy crank journals
j and crank install the undersize bearing
bearings usually make dull noise that Crankshaft out of round Replace crank bearings and
becomes more evident when crankshaft or regrind crankshaft and
accelerating) install the undersize bearing
Crank bearing seized Crank bearing seized. Replace crank
bearings and crankshaft or regrind
crankshaft and install the undersize
bearing

Troubleshooting Procedure
Short out each spark plug in sequence using insulated bearing by listening for abnormal noise that stops when
spark plug wire removers. Locate cylinder with defective spark plug is shorted out.
6A–12 ENGINE MECHANICAL

Condition Possible cause Correction


Noise from connecting rods or from Bearing or crankshaft pin worn Replace connecting rod bearings
connecting rod bearings and crankshaft or regrind crankshaft
(Faulty
y connecting
g rods or pin and install the undersize bearing
connecting rod bearings usually Crankpin out of round Replace connecting rod bearings
make an abnormal noise slightly and crankshaft or regrind crankshaft
higher than the crank bearing noise, pin and install the undersize bearing
which becomes more evident when
engine
g is accelerated)) Connecting rod bent Correct or replace
Connecting rod bearing seized Replace connecting rod bearings
and crankshaft or regrind crankshaft
pin and install the undersize bearing

Troubleshooting Procedure
Abnormal noise stops when the spark plug on the cylinder
with defective part is shorted out.
Condition Possible cause Correction
Piston and cylinder noise Piston clearance increased due to Replace piston and cylinder body
(Faulty piston or cylinder usually cylinder wear
makes
k a combined
bi d mechanical
h i l
Piston seized Replace piston and cylinder body
thumpingg noise which increases
when engine is suddenly accelerated Piston ring broken Replace piston and cylinder body
but diminishes gradually as the
engine warms up) Piston defective Replace pistons and others

Troubleshooting Procedure
Short out each spark plug and listen for change in engine
noise.
Condition Possible cause Correction
Piston pin noise Piston pin or piston pin hole worn Replace piston, piston pin and
(Piston makes noise each time it connecting rod assy
goes up and down)

Troubleshooting Procedure
The slapping sound stops when spark plug on bad
cylinder is shorted out.
Condition Possible cause Correction
Timing belt noise Timing belt tension is incorrect Replace pusher or adjust the tension
pulley or replace timing belt
Tensioner bearing defective Replace
Timing belt defective Replace
Timing pulley defective Replace
Timing belt comes in contact with Replace timing belt and timing cover
timing cover
Valve noise Valve clearance incorrect Replace adjusting shim
Valve and valve guide seized Replace valve and valve guide
Valve spring broken or weakened Replace
Valve seat off–positioned Correct
Camshaft worn out Replace
Crankshaft noise Crankshaft end play excessive Replace thrust bearing
(noise occurs when clutch is
engaged)
ENGINE MECHANICAL 6A–13

Condition Possible cause Correction


Engine knocking Preignition due to use of spark plugs Install Spark Plugs of adequate heat
of inadequate heat range range
Carbon deposits in combustion Clean
chambers
Fuel too low in octane rating Replace fuel
Wide Open Throttle enrichment Refer to Section 6E
system failure
Selection of transmission gear Caution operator of incorrect gear
incorrect selection
Engine overheating Refer to “Engine Lacks Power”
Others Water pump defective Replace
Drive belt slipping Replace auto tentioner or drive belt

Abnormal Combustion
Condition Possible cause Correction
Trouble in fuel system Fuel pressure control valve defective Replace
Fuel filter clogged Replace
Fuel pump clogged Clean or replace
Fuel tank or fuel pipe clogged Clean or replace
Fuel injector clogged Clean or replace
Fuel pump relay defective Replace
Power supply cable for fuel pump Reconnect, correct or replace
broken or poor connections
Mass Airflow (MAF) sensor circuit Correct or replace
open or defective
MAF Sensor defective Replace
Manifold Absolute Pressure Sensor Correct or replace
circuit open or shorted
Manifold Absolute Pressure Sensor Replace
defective
Engine Coolant Temperature (ECT) Correct or replace
Sensor circuit open or shorted
ECT Sensor defective Replace
Throttle Position Sensor adjustment Readjust
incorrect
Throttle Position Sensor defective Replace
Throttle Position Sensor connector Reconnect
poor connections
Vehicle Speed Sensor cable poor Correct or replace
connections or defective
Vehicle Speed Sensor loosely fixed Fix tightly
Vehicle Speed Sensor in wrong Replace
contact or defective
Powertrain Control Module cable Correct or replace
poor connections or defective
6A–14 ENGINE MECHANICAL

Condition Possible cause Correction


Trouble in emission control system Heated Oxygen Sensor circuit open Correct or replace
Heated Oxygen Sensor defective Replace
Signal vacuum hose loosely fitted or Correct or replace
defective
EGR Valve circuit open or shorted Correct or replace
Exhaust Gas Recirculation Valve Replace
defective
ECT Sensor circuit open or shorted Correct or replace
Canister Purge Valve circuit open or Correct or replace
shorted
Canister Purge Valve defective Replace
ECT Sensor defective Replace
Positive Crankcase Ventilation Correct or replace
(PCV) valve and hose clogged
Evaporator system Refer to Section 6E
Trouble in ignition system ———— Refer to “Engine Lacks Power”
Trouble in cylinder head parts Carbon deposits in combustion Remove carbon
chamber
Carbon deposit on valve, valve seat Remove carbon
and valve guide

Engine Oil Consumption Excessive


Condition Possible cause Correction
Oil leaking Oil pan drain plug loose Retighten or replace gasket
Crankcase fixing bolts loosened Retighten
Oil pan setting bolts loosened Retighten
Oil pan gasket broken Replace gasket
Front cover retaining bolts loose or Retighten or replace gasket
gasket broken
Head cover fixing bolts loose or Retighten or replace gasket
gasket broken
Oil cooler adapter cracked Replace
Oil cooler center bolt loose Retighten
Oil cooler O–ring broken Replace
Oil cooler piping loose or broken Retighten or replace
Oil filter adapter cracked Replace
Oil filter attaching bolt loose or rubber Retighten or replace oil filter
gasket broken
Oil cooler broken Replace
Crankshaft front or rear oil seal Replace oil seal
defective
Oil pressure unit loose or broken Retighten or replace
Blow–by gas hose broken Replace hose
Positive Crankcase Ventilation Valve Clean
clogged
Engine/Transmission coupling failed Replace oil seal
ENGINE MECHANICAL 6A–15

Condition Possible cause Correction


Oil leaking into combustion Valve stem oil seal defective Replace
chambers due to poor
oor seal in valve
system Valve stem or valve guide worn Replace valve and valve guide

Oil leaking into combustion Cylinders and pistons worn Replace cylinder body assembly and
chambers due to poor seal in cylinder excessively pistons
t
parts Piston ring gaps incorrectly Correct
positioned
Piston rings set with wrong side up Correct
Piston ring sticking Replace cylinder body assembly and
pistons
Piston ring and ring groove worn Replace pistons and others
Return ports in oil rings clogged Clean piston and replace rings
Positive Crankcase Ventilation Positive Crankcase Ventilation Valve Clean
System malfunctioning clogged
Others Improper oil viscosity Use oil of recommended S.A.E.
viscosity
Continuous high speed driving Continuous high speed operation
and/or severe usage such as trailer and/or severe usage will normally
towing cause increased oil consumption

Fuel Consumption Excessive


Condition Possible cause Correction
Trouble in fuel system Mixture too rich or too lean due to Refer to “Abnormal Combustion”
trouble in fuel injection system
Fuel cut function does not work Refer to “Abnormal Combustion”
Trouble in ignition system Misfiring or abnormal combustion Refer to “Hard Start” or “Abnormal
due to trouble in ignition system Combustion”
Others Engine idle speed too high Reset Idle Air Control Valve
Returning of accelerator control Correct
sluggish
Fuel system leakage Correct or replace
Clutch slipping Correct
Brake drag Correct
Selection of transmission gear Caution operator of incorrect gear
incorrect selection
Excessive Exhaust Gas Refer to “Abnormal Combustion”
Recirculation flow due to trouble in
Exhaust Gas Recirculation system
6A–16 ENGINE MECHANICAL
Lubrication Problems
Condition Possible cause Correction
Oil pressure too low Wrong oil in use Replace with correct engine oil
Relief valve sticking Replace
Oil pump not operating properly Correct or replace
Oil pump strainer clogged Clean or replace strainer
Oil pump worn Replace
Oil pressure gauge defective Correct or replace
Crankshaft bearing or connecting Replace
rod bearing worn
Oil contamination Wrong oil in use Replace with correct engine oil
Oil filter clogged Replace oil filter
Cylinder head gasket damage Replace gasket
Burned gases leaking Replace piston and piston rings or
cylinder body assembly
Oil not reaching valve system Oil passage in cylinder head or Clean or correct
cylinder body clogged

Engine Oil Pressure Check


1. Check for dirt, gasoline or water in the engine oil. 3. Remove the oil pressure unit.
a. Check the viscosity of the oil. 4. Install an oil pressure gauge.
b. Change the oil if the viscosity is outside the 5. Start the engine and allow the engine to reach normal
specified standard. operating temperature (About 80 C).
c. Refer to the “Maintenance and Lubrication” section 6. Measure the oil pressure.
of this manual. Oil pressure should be:
2. Check the engine oil level.
392–550 kPa (56.9–80.4 psi) at 3000 rpm.
The level should fall somewhere between the “ADD”
and the “FULL” marks on the oil level dipstick. 7. Stop the engine.
If the oil level does not reach the “ADD” mark on the 8. Remove the oil pressure gauge.
oil level dipstick, engine oil must be added. 9. Install the oil pressure unit.
10. Start the engine and check for leaks.
ENGINE MECHANICAL 6A–17
Malfunction Indicator Lamp
The instrument panel “CHECK ENGINE” Malfunction system when the system checks the starting of engine, or
Indicator Lamp (MIL) illuminates by self diagnostic senses malfunctions.
Condition Possible cause Correction
“CHECK ENGINE” MIL does not Bulb defective Replace
illuminate at the starting of engine
MIL circuit open Correct or replace
Command signal circuit to operate Correct or replace
self diagnostic system shorted
Engine Control Module (PCM) cable Correct or replace
loosely connected, disconnected or
defective
PCM defective Replace
“CHECK ENGINE” MIL illuminates, Deterioration of heated oxygen Replace
and stays on sensor internal element
Heated oxygen sensor connector Reconnect properly
terminal improper contact
Heated oxygen sensor lead wire Correct
shorted
Heated oxygen sensor circuit open Correct or replace
Deterioration of engine coolant Replace
temperature sensor internal element
Engine coolant temperature sensor Reconnect properly
connector terminal improper contact
Engine coolant temperature sensor Correct
lead wire shorted
Engine coolant temperature sensor Correct or replace
circuit open
Throttle position sensor open or Correct or replace
shorted circuits
Deterioration of crankshaft position Replace
sensor
Crankshaft position sensor circuit Correct or replace
open or shorted
Vehicle speed sensor circuit open Correct or replace
Manifold absolute pressure sensor Correct or replace
circuit open or shorted
Intake air temperature sensor circuit Correct or replace
open or shorted
Fuel injector circuit open or shorted Correct or replace
PCM driver transistor defective Replace PCM
Malfunctioning of PCM RAM Replace PCM
(Random Access Memory) or ROM
(Read Only Memory)
6A–18 ENGINE MECHANICAL

Cylinder Head Cover LH


Removal 5. Disconnect following wiring connectors and bonding
cable:
1. Disconnect battery ground cable. Manifold Absolute Pressure (MAP) sensor
2. Drain engine coolant from faucet bottom of radiator.
Vacuum Switching Valve (VSV) for Induction Air
3. Remove engine cover from the dowels on the Control Valve (IACV) actuator
common chamber.
Ignition coils for left bank
Fuel injectors for left bank
Idle air control (IAC) valve
Throttle position sensor (TPS)
Bonding cable
Others as necessitated
6. Disconnect following vacuum hoses:
Brake master VAC
Canister
VSV for IACV actuator
Duty solenoid valve
PCV
7. Disconnect radiator upper and lower hoses
8. Remove engine harness from the cylinder head
F06RW018
cover.
4. Remove air cleaner duct assembly (3) and air cleaner 9. Remove the upper fan guide.
element (4). 10. Remove cooling fan and clutch assembly.
11. Remove drive belt by pushing down the auto
tensioner using spanner as illustrated.

130RW001

Legend
(1) Positive Crankcase Ventilation Hose Connector F06RW019

(2) Intake Air Temperature Sensor


(3) Air Cleaner Duct Assembly
(4) Air Cleaner Element
(5) Mass Air Flow Sensor

NOTE: Disconnect the mass air flow (MAF) sensor


connector, intake air temperature (IAT) sensor connector,
and positive crankcase ventilation (PCV) hose before
hand the air cleaner duct assembly is removed.
ENGINE MECHANICAL 6A–19
Legend The cylinder head cover must be installed within 5
(1) Crankshaft Pulley minutes after sealant application to prevent
(2) Generator premature hardening of sealant.
(3) Auto Tensioner
(4) Idle Pulley
(5) Cooling Fan Pulley
(6) Power Steering Oil Pump
(7) Drive Belt
(8) Air Conditioner Compressor

12. Remove power steering oil pump pulley.


13. Remove fan pulley and bracket assembly.
14. Remove idle pulley assembly.
15. Remove auto tensioner assembly.
16. Remove crankshaft pulley using 5–8840–0133–0
crankshaft holder.
17. Remove timing belt covers from the right bank side to
the left bank side in order.
18. Remove ignition coil assemblies for the left side bank.

014RW144

Tighten bolts to the specified torque.


Torque : 9 Nꞏm (0.9 Kgꞏm/78 lb in)

060RW018

Legend
(1) Ignition Coil Connectors
(2) Bolts
(3) Ignition Coil Assemblies 010RW008

2. Install ignition coil assemblies and tighten the fixing


19. Remove cylinder head cover assembly. bolts to the specified torque.
Torque : 4 Nꞏm (0.4 Kgꞏm/35 lb in)
Installation 3. Install timing belt covers from left bank side to right
1. Install cylinder head cover. bank side, and tighten the fixing bolts and nut to the
specified torque.
Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and sealing Torque : 19 Nꞏm (1.9 Kgꞏm/14 lb ft)
materials completely. 4. Install crankshaft pulley and tighten the fixing bolt
Apply sealant (TB-1207B or equivalent) of bead using 5–8840–0133–0 crankshaft holder to the
diameter 2-3 mm at eight place of arched area of specified torque.
camshaft bracket on front and rear sides. Torque : 167 Nꞏm (17.0 Kgꞏm/123 lb ft)
6A–20 ENGINE MECHANICAL
5. Install auto tensioner assembly and tighten the fixing
bolts to the specified torque.
Torque :
Shorter Bolt : 20 Nꞏm (2.0 Kgꞏm/14 lb ft)
Longer Bolt : 39 Nꞏm (4.0 Kgꞏm/29 lb ft)
6. Install idle pulley and bracket assembly and tighten
the fixing bolt to the specified torque.
Torque : 52 Nꞏm (5.3 Kgꞏm/38 lb ft)
7. Install fan pulley and bracket assembly and tighten
the fixing bolts and nut to the specified torque.
Torque : 22 Nꞏm (2.2 Kgꞏm/16 lb ft)
8. Install power steering oil pump pulley and tighten the
fixing bolt to the specified torque.
Torque : 78 Nꞏm (8.0 Kgꞏm/58 lb ft)
9. Install drive belt by pushing down the auto tensioner
using spanner as shown in the removal step of drive
belt.
10. Install cooling fan and clutch assembly and tighten
the fixing bolts to the specified torque.
Torque : 10 Nꞏm (1.0 Kgꞏm/87 lb in)
11. Install upper fan guide and clip both side and tighten
the fixing bolts to the specified torque.
Torque : 4 Nꞏm (0.4 Kgꞏm/35 lb in)
12. Install engine harness and tighten the fixing bolts of
the retaining clip and bracket to the specified torque.
Torque : 4 Nꞏm (0.4 Kgꞏm/35 lb in)
13. Connect radiator upper and lower hoses and clip
them securely.
14. Connect vacuum hoses of those which were
disconnected in the removal step.
15. Connect wiring connectors and bonding cable of
those which were disconnected in the removal step.
16. Install air cleaner element and air cleaner duct
assembly, and clip the both end securely.
17. Connect MAF sensor connector, IAT sensor
connector and PCV hose.
18. Install engine cover mating with the dowels.
ENGINE MECHANICAL 6A–21

Cylinder Head Cover RH


Removal NOTE: Disconnect the mass air flow (MAF) sensor
connector, intake air temperature (IAT) sensor connector,
1. Disconnect battery ground cable. and positive crankcase ventilation (PCV) hose before
2. Remove battery from the vehicle. hand the air cleaner duct assembly is removed.
3. Drain engine coolant from faucet bottom of radiator. 6. Disconnect following wiring connectors and bonding
4. Remove engine cover from the dowels on the cable:
common chamber. Exhaust Gas Recirculation (EGR) valve
Fuel injectors for right bank
Ignition coils for right bank
Bonding cable
Othres as necessitated
7. Disconnect radiator upper and lower hoses.
8. Remove engine harness from the cylinder head
cover.
9. Remove the upper fan guide.
10. Remove cooling fan and clutch assembly.
11. Remove drive belt by pushing down the auto
tensioner using spanner as illustrated.

F06RW018

5. Remove air cleaner duct assembly (3) and air cleaner


element (4).

F06RW019

Legend
(1) Crankshaft Pulley
(2) Generator
(3) Auto Tensioner
(4) Idle Pulley
(5) Cooling Fan Pulley
130RW001
(6) Power Steering Oil Pump
(7) Drive Belt
Legend
(8) Air Conditioner Compressor
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor 12. Remove fan pulley and bracket assembly.
(3) Air Cleaner Duct Assembly 13. Remove idle pulley assembly.
(4) Air Cleaner Element
14. Remove auto tensioner assembly.
(5) Mass Air Flow Sensor
15. Remove crankshaft pulley using 5–8840–0133–0
crankshaft holder.
6A–22 ENGINE MECHANICAL
16. Remove timing belt covers for right bank side.
17. Reomve timing belt covers for right bank side.

014RW143

Tighten bolts in turn to the specified torque.


060RW001 Torque : 8.8 Nꞏm (0.9 Kgꞏm/78 lb in)
Legend
(1) Ignition Coil Connectors
(2) Bolts
(3) Ignition Coil Assemblies

18. Remove ignition coil assemblies for the right side


bank.
19. Remove cylinder head cover assembly.

Installation
1. Install cylinder head cover.
Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and sealing
materials completely.
Apply sealant (TB-1207B or equivalent) of bead
diameter 2-3 mm at eight place of arched area of
camshaft bracket on front and rear sides.
The cylinder head cover must be installed within 5
010RW007

2. Install ignition coil assemblies and tighten the fixing


minutes after sealant application before the sealant
bolts to the specified torque.
hardens.
Torque : 4 Nꞏm (0.4 Kgꞏm/35 lb in)
3. Install timing belt cover and tighten the fixing bolts and
nut to the specified torque.
Torque : 19 Nꞏm (1.9 Kgꞏm/14 lb ft)
4. Install crankshaft pulley and tighten the fixing bolt
using 5–8840–0133–0 crankshaft holder to the
specified torque.
Torque : 167 Nꞏm (17 Kgꞏm/123 lb ft)
5. Install auto tensioner assembly and tighten the fixing
bolts to the specified torque.
Torque :
Shorter Bolt : 20 Nꞏm (2.0 Kgꞏm/14.8 lb ft)
Longer Bolt : 39 Nꞏm (4.0 Kgꞏm/28.8 lb ft)
ENGINE MECHANICAL 6A–23
6. Install idle pulley assembly and tighten the fixing bolt
to the specified torque.
Torque : 52 Nꞏm (5.3 Kgꞏm/38.4 lb ft)
7. Install fan pulley and bracket assembly and tighten
the fixing bolts and nut to the specified torque.
Torque : 22 Nꞏm (2.2 Kgꞏm/16.2 lb ft)
8. Install drive belt by pushing down the auto tensioner
using spanner as shown in the removal step of drive
belt.
9. Install cooling fan clutch assembly and tighten the
fixing bolts to the specified torque.
Torque : 10 Nꞏm (1.0 Kgꞏm/88.5 lb in)
10. Install upper fan guide and clip both side and tighten
the fixing bolts to the specified torque.
Torque : 4 Nꞏm (0.4 Kgꞏm/35.4 lb in)
11. Install engine harness and tighten the fixing bolts of
the retaining clip and brackets to the specified torque.
Torque : 4 Nꞏm (0.4 Kgꞏm/35.4 lb in)
12. Connect radiator upper and lower hoses and clip
them securely.
13. Connect wiring connectors and bonding cable of
those which were disconnected in the removal step.
14. Install air cleaner element and air cleaner duct
assembly, and the clip both end securely.
15. Connect MAF sensor connector, IAT sensor
connector and PCV hose.
16. Install engine cover mating with the dowels.
6A–24 ENGINE MECHANICAL

Common Chamber
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner duct assembly.

025RW001

Legend
(1) Common Chamber
(2) Throttle Valve Assembly
130RW001
(3) Bolt
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor Installation
(3) Air Cleaner Duct Assembly
1. Install common chamber and tighten bolts and nuts to
(4) Air Cleaner Element
the specified torque.
(5) Air Flow Sensor
Torque :
3. Disconnect accelerator pedal cable from throttle body Bolt : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
and cable bracket. Nut : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
4. Disconnect vacuum booster hose from common 2. Install fuel hose bracket and tighten bolts to specified
chamber. torque.
5. Disconnect connector from manifold absolute Torque : 10 Nꞏm (1.0 Kgꞏm/89 lb in)
pressure sensor, idle air control valve, throttle
3. Install exhaust gas recirculation valve assembly and
position sensor, solenoid valve, electric vacuum
tighten bolt and nut to the specified torque.
sensing valve, and EGR valve.
6. Disconnect vacuum hose on canister VSV and Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
positive crankcase ventilation hose, fuel rail 4. Install throttle body and tighten bolts to the specified
assembly with pressure control valve bracket. torque.
7. Remove ventilation hose from throttle valve and Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
intake duct and remove water hose.
5. Install ventilating hose to throttle valve and intake
8. Remove the four throttle body fixing bolts. duct.
9. Remove exhaust gas recirculation valve assembly 6. Connect vacuum hoses on canister VSV and positive
fixing bolt and nut on common chamber and remove crankcase ventilation hose. Tighten bolts for fuel rail
EGR valve assembly. assembly with pressure control valve bracket.
10. Remove two bolts from common chamber rear side Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
for remove fuel hose bracket.
11. Remove common chamber four bolts and four nuts 7. Connect each connector without fail.
then remove the common chamber. 8. Connect vacuum booster hose.
9. Connect accelerator pedal cable.
Accelerator pedal cable adjustment
1. Loosen the adjusting nut and screw cap.
2. Pull outer cable while fully closing the throttle
valve.
ENGINE MECHANICAL 6A–25
3. Tighten adjusting nut and lock nut temporarily.
4. Loosen adjusting nut by three turns and tighten
lock nut.
Then manually operating the throttle valve, make
sure that the valve lever returns up to the stopper
screw.
If it does not reach the stopper screw, repeat from
step 1.

035RW004

Legend
(1) Clearance
(2) Lock Nut
(3) Adjusting Nut

10. Install air cleaner duct assembly.

130RW001

Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Air Cleaner Element.
(5) Mass Air Flow Sensor
6A–26 ENGINE MECHANICAL

Exhaust Manifold LH
Removal 5. Remove a bolt on engine LH side for air conditioner
(A/C) compressor bracket and loosen two bolts for
1. Disconnect battery ground cable. A/C compressor then move A/C compressor to front
2. Remove air cleaner duct assembly. side.
6. Remove exhaust manifold eight fixing nuts and
remove exhaust manifold from the engine.

Installation
1. Install exhaust manifold and tighten exhaust manifold
fixing nuts to the specified torque with new nuts.
Torque: 57 Nꞏm (5.8 Kgꞏm/42 lb ft)
2. Install heat protector.
3. Install exhaust front pipe and tighten three stud nuts
and two nuts to the specified torque.
Torque :
Stud nuts: 67 Nꞏm (6.8 Kgꞏm/49 lb ft)
Nuts: 43 Nꞏm (4.4 Kgꞏm/32 lb ft)

130RW001

Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Air Cleaner Element
(5) Mass Air Flow Sensor

3. Remove exhaust front pipe three stud nuts from


exhaust side and two nuts from rear end of exhaust
front pipe.

150RW062

Legend
(1) Exhaust Front Pipe LH

4. Set A/C compressor to normal position and tighten


two bolts and a bolt to the specified torque.
Torque : 40 Nꞏm (4.1 Kgꞏm/30 lb ft)
5. Install air cleaner duct assembly.

150RW062

Legend
(1) Exhaust Front Pipe LH

4. Remove heat protector two fixing bolts then the heat


protector.
ENGINE MECHANICAL 6A–27

Exhaust Manifold RH
Removal
1. Disconnect battery ground cable.
2. Remove torsion bar. Refer to removal procedure in
Front Suspension section.
3. Remove exhaust front pipe three stud nuts and two
nuts then disconnect exhaust front pipe.

056RW001

Legend
(1) Exhaust Gas Recirculation (EGR) Valve
(2) EGR Pipe

6. Remove exhaust manifold eight fixing nuts then the


exhaust manifold.
150RW061

Legend Installation
(1) Exhaust Front Pipe RH
1. Install exhaust manifold and tighten bolts to the
(2) O2 Sensor (for IGM)
specified torque.
4. Remove heat protector two fixing bolts then the heat Torque : 57 Nꞏm (5.8 Kgꞏm/42 lb ft)
protector. 2. Install the EGR pipe, tighten bolt and nut on exhaust
5. Remove exhaust gas recirculation (EGR) pipe fixing manifold to specified torque.
bolt and nut from exhaust manifold, remove a nut Torque : 28 Nꞏm (2.9 Kgꞏm/21 lb ft)
from EGR valve and a bolt from rear side of cylinder
head for bracket of EGR pipe then remove the EGR Tighten nut to EGR valve to the specified torque.
pipe. Torque : 44 Nꞏm (4.5 Kgꞏm/33 lb ft)
Tighten the bolt for EGR pipe bracket to specified
torque.
Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
3. Install heat protector
4. Install exhaust front pipe and tighten three stud nuts
and two nuts to the specified torque.
Torque:
Stud nuts: 67 Nꞏm (6.8 Kgꞏm/49 lb ft)
Nuts: 43 Nꞏm (4.4 Kgꞏm/32 lb ft)
5. Install the torsion bar and readjust the vehicle height.
Refer to installation and vehicle height adjustment
procedure for Front Suspension.
6A–28 ENGINE MECHANICAL

Crankshaft Pulley
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner assembly.

850RW001

Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
130RW001 (3) Tensioner
Legend (4) Generator
(1) Positive Crankcase Ventilation Hose Connector (5) Air Conditioner Compressor
(2) Intake Air Temperature Sensor (6) Power Steering Oil Pump
(3) Air Cleaner Duct Assembly (7) Serpentine Belt
(4) Air Cleaner Element
(5) Mass Air Flow Sensor 5. Remove cooling fan assembly four fixing nuts, then
the cooling fan assembly.
3. Remove radiator upper fan shroud from radiator. 6. Remove crankshaft pulley assembly using J-8614-01
4. Move serpentine belt tensioner to loose side using crankshaft holder, hold crankshaft pulley then
wrench then remove serpentine belt. remove center bolt and pulley.

Installation
1. Install crankshaft pulley using J-8614-01 crankshaft
holder, hold the crankshaft pulley and tighten center
bolt to the specified torque.
Torque : 167 Nꞏm (17.0 Kgꞏm/123 lb ft)
2. Install cooling fan assembly and tighten bolts/nuts to
the specified torque.
Torque : 22 Nꞏm (2.2 Kgꞏm/16 lb ft) for fan pulley
and fan bracket.
Torque : 10 Nꞏm (1.0 Kgꞏm/88.5 lb in) for fan and
clutch assembly.
3. Move serpentine belt tensioner to loose side using
wrench, then install serpentine belt to normal
position.
4. Install radiator upper fan shroud.
5. Install air cleaner assembly.
ENGINE MECHANICAL 6A–29

Timing Belt
Removal CAUTION: The pusher prevents air from entering
the oil chamber. Its rod must always be facing
1. Disconnect battery ground cable. upward.
2. Remove air cleaner assembly.
3. Remove radiator upper fan shroud from radiator.
4. Move drive belt tensioner to loose side using wrench
then remove drive belt.

014RW011

Legend
(1) Up Side
(2) Down Side
850RW001 (3) Direction For Installation
Legend (4) Locking Pin
(1) Crankshaft Pulley
(2) Cooling Fan Pulley 14. Remove timing belt.
(3) Tensioner CAUTION:
(4) Generator 1. Do not bend or twist the belt, otherwise its core
(5) Air Conditioner Compressor could be damaged. The belt should not be bent at
(6) Power Steering Oil Pump a radius less than 30 mm.
(7) Drive Belt 2. Do not allow oil or other chemical substances to
come in contact with the belt. They will shorten
5. Remove cooling fan assembly four nuts, then the the life.
cooling fan assembly.
3. Do not attempt to pry or stretch the belt with a
6. Remove cooling fan drive pulley assembly. screw driver or any other tool during installation.
7. Remove idle pulley assembly.
4. Store timing belt in a cool and dark place. Never
8. Remove serpentine belt tensioner assembly. expose the belt direct sunlight or heat.
9. Remove power steering pump assembly.
10. Remove crankshaft pulley assembly using
5–8840–0133–0 crankshaft holder, hold crankshaft
pulley remove center bolt, then the pulley.
11. Remove right side timing belt cover then left side
timing belt cover.
12. Remove lower timing belt cover
13. Remove pusher.
6A–30 ENGINE MECHANICAL

Installation
NOTE: For correct belt installation, the letter on the belt
must be able to be read as viewed from the front of the
vehicle.

014RW006

Legend
(1) Timing Belt
(2) Engine Rotation Direction
(3) Cylinder Head Side
014RY00042

Legend 1. Install timing belt.


(1) Crankshaft Timing Pulley 1. Align the mark (notch) of crankshaft timing pulley
(2) RH Bank Camshaft Drive Gear Pulley (2) with mark on oil pump (1).
(3) Water Pump Pulley Align the mark (groove) on the crankshaft timing
(4) Idle Pulley pulley (3) with alignment mark (white dots line) on
(5) LH Bank Camshaft Drive Gear Pulley the timing belt (4).
(6) Tension Pulley NOTE: When timing marks are aligned, No.2 piston will
be on Top Dead Center.

014RY00043
014RW003

Legend Legend
(7) Alignment Mark on Oil Pump. (1) Alignment Mark on Oil Pump
(8) Alignment Mark on Timing Belt (2) Groove on Crankshaft Timing Pulley
(9) Alignment Mark (notch) on Crankshaft Timing (3) Alignment Mark on Crankshaft Timing Pulley
Pulley. (4) Alignment Mark on Timing Belt
(10) Alignment Mark (groove) on Crankshaft Timing
Pulley.
ENGINE MECHANICAL 6A–31
2. Align the alignment mark on the RH bank
camshaft drive gear pulley (2) to the alignment
mark of the cylinder head cover RH (3).
3. Align the alignment mark (white line) on the timing
belt (1) with alignment mark on the RH bank
camshaft drive gear pulley (2) (on the left side as
viewed from the front of the vehicle) and put the
timing belt on the camshaft drive gear pulley.
Secure the belt with a double clip or equivalent
clip.

014RW00005

Legend
(1) Alignment Mark on Timing Belt (White line).
(2) Alignment Mark on Camshaft Drive Gear
Pulley.
(3) Alignemnt Mark on Cylinder Head Cover LH.

6. Install crankshaft pulley temporarily and tighten


center bolt by hand (do not use a wrench).
Turn the crankshaft pulley clockwise to give some
014RW00004 belt slack between the crankshaft timing pulley
Legend and the RH bank camshaft drive gear pulley.
(1) Alignment Mark on Timing Belt (White line). 2. Install pusher and tighten bolt to the specified torque.
(2) Alignment Mark on Camshaft Drive Gear Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
Pulley. 1. Install the pusher while pushing the tension pulley
(3) Alignemnt Mark on Cylinder Head Cover RH. to the belt.
2. Pull out pin from the pusher.
4. Align the alignment mark on the LH bank
camshaft drive gear pulley (2) to the alignment NOTE: When reusing the pusher, press the pusher with
mark of the cylinder head cover LH (3). approximately 100Kg to retract the rod, and insert a pin
5. Align the alignment mark (white line) on the timing (1.4 mm piano wire).
belt (1) with the alignment mark on the LH bank
camshaft drive gear pulley (2).
When aligning the timing marks, use a wrench to
turn the camshaft drive gear pulley, then set the
timing mark between timing belt and camshaft
drive gear pulley and put the timing belt on the
camshaft drive gear pulley.
Secure the belt with a double clip or equivalent
clip.
NOTE: It is recommended for easy installation that the
belt be secured with a double clip or equivalent clip after
it is installed the timing belt to each pulley.

014RW011
6A–32 ENGINE MECHANICAL
Legend Legend
(1) Up Side (1) Timing Belt Cover
(2) Down Side (2) Rubber Bushing
(3) Direction for Installation (3) Sealing Rubber
(4) Locking Pin (4) Cylinder Body

3. Remove double clips or equivalent clips, from 4. Install crankshaft pulley using 5–8840–0133–0, hold
timing belt pulleys. the crankshaft pulley and tighten center bolt to the
Turn the crankshaft pulley clockwise by two turns. specified torque.
3. Install timing belt cover. Torque : 167 Nꞏm (17.0 Kgꞏm/123 lb ft)
Remove crankshaft pulley that was installed in step 5. Install fan pulley bracket and tighten fixing bolts to the
1 item 5. specified torque.
Tighten bolts to the specified torque. Torque : 22 Nꞏm (2.2 Kgꞏm/16 lb ft)
Torque: 19 Nꞏm (1.9 Kgꞏm/14 lb ft) 6. Install power steering pump assembly and tighten to
the specified torque.
Torque :
M8 bolt : 22 Nꞏm (2.2 Kgꞏm/16 lb ft)
M10 bolt : 46 Nꞏm (4.7 Kgꞏm/34 lb ft)
7. Install cooling fan assembly and tighten bolts/nuts to
the specified torque.
Torque : 22 Nꞏm (2.2 Kgꞏm/16 lb ft) for fan pulley
and fan bracket.
Torque : 10 Nꞏm (1.0 Kgꞏm/88.5 lb in) for fan and
clutch assembly.
8. Move drive belt tensioner to loose side using wrench,
then install drive belt to normal position.

020RW004

Legend
(1) Timing Belt Cover RH
(2) Timing Belt Cover LH
(3) Timing Belt Cover Lower

850RW001

Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Auto Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Idle Pulley
(8) Drive Belt
020RW003
9. Install radiator upper fan shroud.
10. Install air cleaner assembly.
ENGINE MECHANICAL 6A–33

Camshaft
Removal
1. Disconnect battery ground cable.
2. Remove crankshaft pulley.
Refer to removal procedure for Crankshaft Pulley in
this manual.
3. Remove timing belt.
Refer to removal procedure for Timing Belt in this
manual.
4. Remove cylinder head cover LH.
Refer to removal procedure for Cylinder Head
Cover LH in this manual.
5. Remove cylinder head cover RH.
Refer to removal procedure for Cylinder Head
Cover RH in this manual.
6. Remove twenty fixing bolts from inlet and exhaust
camshaft bracket on one side bank, then camshaft
brackets. 014RW026

Legend
(1) Right Bank
(2) Left Bank
(3) Timing Mark on Retainer

Installation
1. Install camshaft drive gear assembly and tighten
three bolts to the specified torque.
Torque : 10 Nꞏm (1.0 Kgꞏm/89 lb in)
2. Tighten bolt for camshaft drive gear assembly pulley
to the specified torque.
Torque : 98 Nꞏm (10.0 Kgꞏm/72 lb ft)
3. Tighten sub gear setting bolt.
1. Use the 5–8840–2443–0 gear spring lever to turn
sub gear to right direction until it aligns with the M5
014RW027 bolt hole between camshaft driven gear and sub
7. Remove camshaft assembly. gear.
8. Remove fixing bolt for camshaft drive gear pulley. 2. Tighten the M5 bolt to a suitable torque to prevent
9. Remove three fixing bolts from camshaft drive gear the sub gear from moving.
retainer, then camshaft drive gear assembly.
6A–34 ENGINE MECHANICAL

014RW041 014RW023

4. Install camshaft assembly and camshaft brackets, Legend


tighten twenty bolts on one side bank to the specified (1) Right Bank Camshaft Drive Gear
torque.
(2) Left Bank Camshaft Drive Gear
1. Apply engine oil to camshaft journal and bearing (3) Timing Mark on Drive Gear
surface of camshaft bracket.
(4) Dowel Pin
2. Align timing mark on intake camshaft (one dot for
right bank, two dot for left bank) and exhaust
camshaft (one dot for right bank, two dots for left
bank) to timing mark on camshaft drive gear (one
dot).

014RW020

Legend
(1) Intake Camshaft Timing Gear for Right Bank
(2) Intake Camshaft Timing Gear for Left Bank
(3) Exhaust Camshaft Timing Gear
(4) Discrimination Mark
(LI: Left bank intake, RI: Right bank intake)
(LE: Left bank exhaust, RE: Right bank
exhaust)
ENGINE MECHANICAL 6A–35

014RW024

Legend (3) Alignment Mark on Camshaft Drive Gear


(1) Right Bank (4) Alignment Mark on Camshaft
(2) Left Bank (5) Alignment Mark on Retainer

3. Tighten twenty bolts on numerical order an one 8. Install crankshaft pulley.


side bank as shown in the illustration. Refer to installation procedure for CRANKSHAFT
Torque : 10 Nꞏm (1.0 Kgꞏm/89 lb in) PULLEY in this manual.
Accelerator pedal cable adjustment
1. Loosen adjusting nut and lock nut.
2. Pull outer cable while closing fully the throttle
valve.
3. Tighten adjusting nut and lock nut temporarily.

014RW031

5. Install cylinder head cover RH.


Refer to installation procedure for CYLINDER
HEAD COVER RH in this manual.
6. Install cylinder head cover LH.
Refer to installation procedure for CYLINDER
HEAD COVER LH in this manual.
7. Install timing belt.
Refer to installation procedure for TIMING BELT in
this manual.
6A–36 ENGINE MECHANICAL
4. Loosen adjusting nut by three turns and tighten
lock nut.
Then, manually operating the throttle valve, make
sure that the valve lever returns up to the stopper
screw.
If it does not reach the stopper screw, repeat from
step 1.

035RW004

Legend
(1) Clearance
(2) Lock Nut
(3) Adjusting Nut
ENGINE MECHANICAL 6A–37

Cylinder Head
Removal NOTE: There is discrimination mark “R” for right bank
and “L” for left bank on the cylinder head gasket as shown
1. Remove engine hood. in the illustration.
2. Disconnect battery ground cable. Do not reuse cylinder head gasket.
3. Drain radiator coolant.
4. Drain engine oil.
5. Remove crankshaft pulley.
Refer to removal procedure for Crankshaft Pulley in
this manual.
6. Remove timing belt.
Refer to removal procedure for Timing Belt in this
manual.
7. Remove cylinder head cover LH.
Refer to removal procedure for Cylinder Head
Cover LH in this manual.
8. Remove cylinder head cover RH.
Refer to removal procedure for Cylinder Head
Cover RH in this manual.
9. Remove common chamber.
Refer to removal procedure for Common Chamber
in this manual.
10. Remove cylinder head assembly. 011RW005

1. Loosen eights bolts for tight cylinder head. 2. Align dowel pin hole to dowel pin on the cylinder
block.
2. Remove cylinder head assembly.
3. Tighten two bolts temporarily by hand to prevent
the cylinder head assembly from moving.
4. Using 9–8511–4209–0 cylinder head bolt wrench,
tighten bolts in numerical order as shown in the
illustration to the specified torque.
NOTE: Do not reuse cylinder head bolts.
Do not apply any lubricant to the cylinder head bolts.
Torque :
Temporary : 29 Nꞏm (3.0 Kgꞏm/21 lb ft)
Final : 64 Nꞏm (6.5 Kgꞏm/47 lb ft)

014RW028

Legend
(1) Cylinder Head
(2) Cylinder Head Bolt
(3) Camshaft

Installation
1. Install cylinder head assembly to cylinder block.
1. Put cylinder head gasket on the cylinder block.
014RW029
6A–38 ENGINE MECHANICAL
2. Install common chamber.
Refer to installation procedure for Common
Chamber in this manual.
3. Install cylinder head cover RH.
Refer to installation procedure for Cylinder Head
Cover RH in this manual.
4. Install cylinder head cover LH.
Refer to installation procedure for Cylinder Head
Cover LH in this manual.
5. Install timing belt.
Refer to installation procedure for Timing Belt in this
manual.
6. Install crankshaft pulley.
Refer to installation procedure for Crankshaft
Pulley in this manual.
Accelerator pedal cable adjustment
1. Loosen adjusting nut and lock nut.
2. Pull outer cable while closing fully the throttle
valve.
3. Tighten adjusting nut and lock nut temporarily.
4. Loosen adjusting nut by three turns and tighten
lock nut.
Then, manually operating the throttle valve, make
sure that the valve lever returns up to the stopper
screw.
If it does not reach the stopper screw, repeat from
step 1.

035RW004

Legend
(1) Clearance
(2) Lock Nut
(3) Adjusting Nut
ENGINE MECHANICAL 6A–39

Valve Stem Oil Controller , Valve Spring and Valve Guide


Removal
1. Disconnect battery ground cable.
2. Drain engine oil.
Drain engine coolant.
3. Remove cylinder head assembly.
Refer to removal procedure for Cylinder Head in
this manual.
4. Remove camshaft.
Refer to removal procedure for Camshaft in this
manual.
5. Remove tappets with shim.
NOTE: Do not damage shim surface.
6. Remove valve springs using 5–8840–2446–0 valve
spring compressor and 5–8840–2547–0 valve spring
compressor adapter then remove upper valve spring
seat and lower seat.
014RW042

4. Install tappet with shim.


5. Install camshaft assembly.
Refer to installation procedure for Camshaft in this
manual.
6. Install cylinder head assembly.
Refer to installation procedure for Cylinder Head in
this manual.
7. Fill engine oil until full level.
8. Fill engine coolant.

014RW042

7. Remove oil controller using 5–8840–0623–0 oil


controller remover, remove each valve stem oil
controller.
8. Remove valve guide using 5–8840–2549–0 valve
guide replacer.

Installation
1. Install valve guide using 5–8840–2442–0 valve guide
installer.
2. Install oil controller using 5–8840–0624–0 oil
controller installer.
3. Install lower valve spring seat, valve spring and upper
valve spring seat then put split collars on the upper
spring seat, using 5–8840–2446–0 valve spring
compressor and 5–8840–2547–0 valve spring
compressor adapter to install the split collars.
6A–40 ENGINE MECHANICAL

Piston, Piston Ring and Connecting Rod


Removal

F06RW011

Legend (4) Oil Strainer


(1) Cylinder Head (5) Oil Gallery
(2) Crankcase with Oil Pan (6) Piston with Connecting Rod Assembly
(3) Oil Pipe

1. Remove cylinder head assembly. 2. Remove crankcase with Oil Pan.


Refer to removal procedure for Cylinder Head in Refer to removal procedure for Oil Pan and
this manual. Crankcase in this manual.
ENGINE MECHANICAL 6A–41
3. Remove oil strainer fixing bolts, remove oil strainer
assembly with O-ring.

015RW003

Legend
050RW002 (1) Piston Front Mark
Legend (2) Piston Grade
(1) Oil Pump (3) Connecting Rod Front Mark
(2) Oil Strainer
(3) Oil Gallery 2. Install oil gallery and tighten the bolts in two steps, in
(4) From Oil Filter the order shown in illustration.
(5) To Oil Filter Torque :
1st step : 29 Nꞏm (3.0 Kgꞏm/21 lb ft)
4. Remove three fixing bolts, oil pipe with O-ring. 2nd step : 55 –65
5. Remove eight fixing bolts, oil gallery.
6. Remove piston with connecting rod assembly, before
removing the bearing cap, remove carbon on the top
of cylinder bore and push piston with connecting rod
out from the top of cylinder bore.

Installation
1. Install piston with connecting rod assembly.
Apply engine oil to cylinder bore, connecting rod
bearing and crank pin.
When installing the piston, its front mark must face
the engine front side.
The bearing cap number must be the same as
connecting rod number.
Apply engine oil to the thread and seating surface of
each nut.
Tighten nuts to the specified torque. 051RS009

Torque : 54 Nꞏm (5.5 Kgꞏm/40 lb ft) 3. Install oil pipe with O-ring.
After tightening the nuts, make sure that the Torque : 10 Nꞏm (1.0 Kgꞏm/89 lb in)
crankshaft rotates smoothly. 4. Install oil strainer assembly with O-ring.
NOTE: Do not apply engine oil to the bearing back faces Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
and connecting rod bearing fitting surfaces. 5. Install crankcase with Oil Pan.
Refer to installation procedure for Oil Pan and
Crankcase in this manual.
6. Install cylinder head assembly.
Refer to installation procedure for Cylinder Head in
this manual.
6A–42 ENGINE MECHANICAL

Crankshaft and Main Bearings


Removal

F06RW010

Legend (8) Oil Pump Assembly


(1) Engine Assembly (9) Cylinder Body Side Bolt
(2) Crankshaft Pulley (10) Oil Gallery
(3) Timing Belt Cover (11) Flywheel
(4) Timing Belt (12) Rear Oil Seal Retainer
(5) Crankcase with Oil Pan (13) Connecting Rod Cap
(6) Oil Pipe (14) Crankshaft Main Bearing Cap
(7) Oil Strainer (15) Crankshaft and Main Bearing

1. Remove engine assembly. 3. Remove oil pan and crankcase.


Refer to removal procedure for Engine Assembly in Refer to removal procedure for Oil Pan and
this manual. Crankcase in this manual.
2. Remove timing belt. 4. Remove oil pipe with O-ring.
Refer to removal procedure for Timing Belt in this 5. Remove oil strainer assembly with O-ring.
manual.
ENGINE MECHANICAL 6A–43
6. Remove oil pump assembly.
Refer to removal procedure for Oil Pump in this
manual.
7. Remove cylinder body side bolts.
8. Remove oil gallery.
9. Remove flywheel.
10. Remove rear oil seal retainer.
Refer to removal procedure for Rear Oil Seal in this
manual.
11. Remove connecting rod caps.
12. Remove crankshaft main bearing caps.
13. Remove crankshaft and main bearings.

Installation
1. Install crankshaft and main bearings.
Install main bearing in the cylinder block and main
bearing cap respectively. 015RS013

Apply new engine oil to upper and lower main 2. Install crankshaft main bearing caps.
bearings. Apply engine oil to the thread and seating surface of
each bearing cap fixing bolt.
NOTE:
NOTE:
Do not apply engine oil to the bearing back faces.
Do not apply engine oil to the bearing back faces.
Make sure that main bearings are in correct position.
Install bearing caps in the order of numbers, starting
Install crankshaft with care. with cylinder block front side.
Apply engine oil to the thrust washer. Tighten main bearing fixing bolts to the specified
Install thrust washer on No.3 journal. torque.
Oil grooves in thrust washer must face the Torque : 39 Nꞏm (4.0 Kgꞏm/29 lb ft)
crankshaft.
After tightening the bolts, make sure that the
crankshaft rotates smoothly.
3. Install connecting rod caps.
The cap number must be same as connecting rod
number.
Apply engine oil to the thread and seating surface of
each nut.
Tighten nuts to the specified torque.
Torque : 54 Nꞏm (5.5 Kgꞏm/40 lb ft)
After tightening the nuts, make sure that the
crankshaft rotates smoothly.
4. Install rear oil seal retainer.
Remove oil on cylinder block and retainer fitting
surface.
Apply sealant (TB1207B or equivalent) to retainer
fitting surface as shown in illustration.
015RS012
6A–44 ENGINE MECHANICAL
The oil seal retainer must be installed within 5 Tighten fixing bolts to the specified torque.
minutes after sealant application before the sealant Torque : 54 Nꞏm (5.5 Kgꞏm/40 lb ft)
hardens.

015RS018
015RW002
6. Install oil gallery.
Legend Clean contact surface of oil gallery and main
(1) Around Bolt Holes bearing cap.
(2) Around Dowel Pin Apply engine oil to oil gallery fixing bolts and tighten
the bolts in two steps, in the order shown in
Apply engine oil to oil seal lip and align a dowel pin illustration.
hole in the cylinder block with that in the retainer. Torque :
Tighten retainer fixing bolts to the specified torque. 1st step : 29 Nꞏm (3.0 Kgꞏm/21 lb ft)
Torque : 18 Nꞏm (1.8 Kgꞏm/13 lb ft) 2nd step : 55 –65
7. Install cylinder body side bolts and tighten bolts in
order to the specified torque.
Torque : 39 Nꞏm (4.0 Kgꞏm/29 lb ft)
NOTE: Do not apply the oil to the bolts.

015RW001

5. Install flywheel.
Clean tapped holes in the crankshaft.
Remove oil on crankshaft and flywheel fitting
surface. 012RS007

NOTE: 8. Install oil pump assembly.


Do not reuse the bolts. Remove oil on cylinder block and oil pump mounting
surface.
Do not apply oil or thread lock to the bolts.
ENGINE MECHANICAL 6A–45
Apply sealant (TB1207B or equivalent) to the oil 11. Install crankcase.
pump mounting surface. Remove oil on crankcase mounting surface and dry
The oil pump assembly must be installed within 5 the surface.
minutes after sealant application before the sealant Properly apply a 4.5 mm (0.7 in) wide bead of
hardens. sealant (TB1207C or equivalent) to the crankcase
Apply engine oil to oil seal lip. mounting surface. The bead must be continuous.

Install oil pump in the cylinder block and tighten The crankcase must be installed within 5 minutes
fixing bolts to the specified torque. after sealant application before the sealant
hardens.
Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
Tighten fixing bolts to the specified torque.
Torque : 10 Nꞏm (1.0 Kgꞏm/89 lb in)

051RW002

Legend
(1) Around Bolt Holes 013RW010

(2) Around Dowel Pin

013RW004

12. Install oil pan


051RW001
Remove oil on oil pan mounting surface and dry the
9. Install oil strainer with O-ring, tighten to the specified surface.
torque. Properly apply a 4.5 mm (0.7 in) wide bead of
Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft) sealant (TB1207C or equivalent) to the oil pan
mounting surface. The bead must be continuous.
10. Install oil pipe with O-ring, tighten fixing bolts to the
specified torque. The oil pan must be installed within 5 minutes after
sealant application to prevent premature hardening
Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft) of sealant.
6A–46 ENGINE MECHANICAL
Tighten fixing bolts to the specified torque.
Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)

013RW003

013RW002

13. Install timing belt.


Refer to installation procedure for Timing Belt in this
manual.
14. Install engine assembly.
Refer to installation procedure for Engine in this
manual.
ENGINE MECHANICAL 6A–47

Rear Oil Seal


Removal
1. Remove transmission assembly.
Refer to removal procedure for Transmission
section in this manual.
2. Remove flywheel.
3. Remove rear oil seal using a seal remover.
NOTE: Take care not to damage the crankshaft or oil seal
retainer when removing oil seal.

Installation
1. Apply engine oil to oil seal lip and install oil seal using
5–8840–2286–0.

015RS018

3. Install transmission.
See Transmission section in this manual.
CAUTION: When assembling the engine and
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side. Take care that dowel positions are different
between the manual transmission and the automatic
transmission.
Otherwise, the transmission may be damaged.

015RS017

2. Install flywheel.
Clean tapped holes in the crankshaft.
Remove oil on the crankshaft and flywheel
mounting surface.
Tighten fixing bolts to the specified torque.
NOTE: Do not reuse the bolts and do not apply oil or
thread lock to the bolts.
Torque : 54 Nꞏm (5.5 Kgꞏm/40 lb ft)

012RS009
6A–48 ENGINE MECHANICAL

Engine Assembly
Removal

035RW027

1. Disconnect battery ground and positive cable. 23. Remove power steering pump fixing bolts, then
2. Remove battery. power steering pump. Place the power steering pump
along with piping on the body side.
3. Make alignment mark on the engine hood and hinges
before removal in order to return the hood to original 24. Remove air conditioning compressor fixing bolts from
position exactly. bracket and place the compressor along with piping
on the body side.
4. Remove engine hood.
25. Remove O2 sensor harness connectors from exhaust
5. Drain radiator coolant.
front pipe.
6. Disconnect accelerator cable and automatic cruise
26. Remove three exhaust pipe fixing nuts from each
control cable from throttle valve on common
bank.
chamber.
27. Remove two exhaust pipe fixing nuts from each
7. Disconnect air duct with air cleaner cover.
exhaust pipe, then move exhaust pipe to rear side of
8. Remove air cleaner assembly. vehicle.
9. Disconnect canister vacuum hose. 28. Remove flywheel dust covers.
10. Disconnect vacuum booster hose. 29. Disconnect two heater hoses from engine.
11. Disconnect three engine harness connectors. 30. Disconnect fuel hoses from right side of transmission.
12. Disconnect harness connector to transmission (left
CAUTION: Plug fuel pipes on engine side and fuel
front side of engine compartment), disconnect shift
hoses from fuel tank.
on the fly harness connector from front side of front
axle and remove transmission harness bracket from 31. Remove transmission assembly. Refer to
engine left side. Transmission section in this manual.
13. Disconnect ground cable between engine and frame. 32. Support the engine by engine hoist.
14. Disconnect bonding cable connector on the back of 33. Remove two left side engine mount fixing bolts from
right dash panel. engine mount on chassis side.
15. Disconnect bonding cable terminal on the left bank. 34. Remove two right side engine mount fixing bolts from
engine mount on chassis side.
16. Disconnect starter harness connector from starter.
35. Remove engine assembly.
17. Disconnect generator harness connector from
generator.
18. Disconnect coolant reserve tank hose from radiator. Installation
19. Remove radiator upper and lower hoses. CAUTION: When assembling the engine and
20. Remove upper fan shroud. transmission, confirm that dowels have been
21. Remove cooling fan assembly four fixing nuts, then mounted in the specified positions at the engine
the cooling fan assembly. side. Take care that dowel positions are different
22. Move drive belt tensioner to loose side using wrench between the manual transmission and the automatic
then remove drive belt. transmission.
ENGINE MECHANICAL 6A–49
If the engine is assembled in the condition that the
dowels have not been mounted in the specified posi-
tions, the transmission may be damaged the trans-
mission.

150RW061

Legend
(1) Exhaust Front Pipe RH
(2) O2 Sensor (for IGM)
012RS009

1. Install engine assembly. Tighten engine mount fixing


bolts to frame to the specified torque.
Torque: 41 Nꞏm (4.2 Kgꞏm/30 lb ft)
2. Reconnect fuel hose to fuel pipe on engine.
3. Install transmission assembly. Refer to Transmission
section in this manual.
4. Reconnect two heater hoses to engine.
5. Install flywheel dust covers.
6. Install exhaust pipe and temporally tighten two (each
bank) rear exhaust flange nuts then tighten three stud
nuts (each bank) between exhaust manifold and
exhaust pipe, finally tighten rear side nuts to the
specified torque.
Torque:
Nuts: 43 Nꞏm (4.4 Kgꞏm/32 lb ft)
Stud nuts: 67 Nꞏm (6.8 Kgꞏm/49 lb ft)

150RW062

Legend
(1) Exhaust Front Pipe LH

7. Reconnect O2 sensor connector.


8. Install cooling fan assembly and tighten bolts/nuts to
the specified torque.
Torque : 22 Nꞏm (2.2 Kgꞏm/16 lb ft) for fan pulley
and fan bracket.
Torque : 10 Nꞏm (1.0 Kgꞏm/88.5 lb in) for fan and
clutch assembly.
6A–50 ENGINE MECHANICAL
9. Install air conditioner compressor to engine and 19. Reconnect ground cable between engine and
tighten to the specified torque. chassis.
Torque : 20. Reconnect harness connector to transmission and
M8 bolts : 22 Nꞏm (2.2 Kgꞏm/16 lb ft) install transmission harness bracket on engine left
side.
M10 bolts : 43 Nꞏm (4.4 Kgꞏm/32 lb ft)
21. Reconnect three engine harness connectors.
10. Install power steering pump, tighten fixing bolt to the
specified torque. 22. Reconnect vacuum booster hose.
Torque : 23. Reconnect canister vacuum hose.
M8 bolts : 22Nꞏm (2.2 Kgꞏm/16 lb ft) 24. Install air cleaner assembly.
M10 bolts : 46 Nꞏm (4.7 Kgꞏm/34 lb ft) 25. Reconnect air duct.
11. Move drive belt tensioner to loose side using wrench, 26. Reconnect accelerator cable and automatic cruise
then install drive belt to normal position. control cable to throttle valve on common chamber.

035RW007
850RW001

Legend Legend
(1) Crankshaft Pulley (1) Throttle Valve Assembly
(2) Cooling Fan Pulley (2) Throttle Lever
(3) Tensioner (3) Idle Air Control Valve
(4) Generator (4) Throttle Position Sensor
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump 27. Install engine hood to the original position.
(7) Drive Belt Refer to installation procedure for Body section in
this manual.
12. Install upper fan shroud. Accelerator pedal cable adjustment
13. Reconnect radiator upper and lower hoses. 1. Loosen adjusting nut and lock nut.
14. Reconnect coolant reserve tank hose to radiator. 2. Pull outer cable while fully closing the throttle
15. Reconnect generator harness connector. valve.
16. Reconnect starter harness connector. 3. Tighten adjusting nut and lock nut temporarily.
17. Reconnect bonding cable terminal on left bank 4. Loosen adjusting nut by three turns and tighten
18. Reconnect bonding cable terminal on the back of right lock nut.
dash panel. Then, manually operating the throttle valve, make
sure that the valve lever returns up to the stopper
screw.
ENGINE MECHANICAL 6A–51
If it does not reach the stopper screw, repeat from
step 1.

130RW004

Legend
(1) Clearance
(2) Lock Nut
(3) Adjusting Nut
6A–52 ENGINE MECHANICAL

Cylinder Head
Cylinder Head and Associated Parts

011RW008

Legend (8) Camshaft Intake


(1) Spark Plug (9) Retainer Fixing Bolt
(2) Cylinder Head Bolt (10) Retainer Assembly
(3) Camshaft Drive Gear Pulley Fixing Bolt (11) Tappet with Shim
(4) Camshaft Drive Gear Pulley (12) Split Collar
(5) Camshaft Bracket Fixing Bolt (13) Valve Spring and Spring Upper Seat
(6) Camshaft Bracket (14) Valve
(7) Camshaft Exhaust

Disassembly Before removing the cylinder head from the engine


and before disassembling the valve mechanism,
NOTE: perform a compression test and note the results.
During disassembly, be sure that the valve train 1. Remove camshaft drive gear pulley fixing bolt (3),
components are kept together and identified so that then pulley (4).
they can be reinstalled in their original locations.
ENGINE MECHANICAL 6A–53
2. Remove camshaft bracket fixing bolt (5), camshaft 3. Cylinder head deck for corrosion, sand particles in
bracket (6), then camshaft exhaust (7), and intake head and porosity.
side (8).
CAUTION:
3. Remove tappet with shim (11).
Do not attempt to weld the cylinder head. Replace
4. Use the 5–8840–2446–0 valve spring compressor it.
and 5–8840–2547–0 valve spring compressor
Do not reuse cylinder head bolts.
adapter to remove the split collar (12), valve spring
with upper seat (13) and valve (14). 4. Cylinder head deck, common chamber and exhaust
manifold mating surfaces for flatness. These
surfaces may be reconditioned by milling. If the
surfaces are “out of flat” by more than specification,
the surface should be ground to within specifications.
Replace the head if it requires machining beyond the
repairable limit.
Head surface and manifold surface
Standard: 0.05 mm (0.002 in) or less
Warpage limit: 0.2 mm (0.0079 in)
Maximum Repairable limit: 0.2 mm (0.0079 in)
Head height
Standard height : 133.2 mm (5.2441 in)
Warpage limit : 0.2 mm (0.0079 in)
Maximum Repairable limit : 133.0 mm (5.2362 in)

014RW042

5. Remove spark plug (1).


CAUTION: Do not remove the spark plugs when the
head and plugs are hot. Clean dirt and debris from
spark plug recess areas before removal.

Clean
Cylinder head
Carefully remove all varnish, soot and carbon from the
bare metal. Do not use a motorized wire brush on any
gasket sealing surface.

Inspection and Repair


1. Cylinder head gasket and mating surfaces for leaks,
011RW019

5. Water jacket sealing plugs seating surfaces.


corrosion and blow–by. If the gasket has failed,
determine the cause.
– Insufficient torque on head bolts. Reassembly
– Improper installation 1. Install Spark plug and tighten all the spark plugs to
– Loose or warped cylinder head specified torque.
– Missing dowel pins Torque: 18 Nꞏm (1.8 Kgꞏm/13 lb ft)
– Warped case surface 2. Tighten sub gear setting bolt.
2. Cylinder head for cracks, especially between valve 1. Use 5–8840–2443–0 gear spring lever to turn sub
seats and in the exhaust ports. gear to right direction until the M5 bolt aligns with
the hole between camshaft driven gear and sub
gear.
6A–54 ENGINE MECHANICAL
2. Tighten the M5 bolt to a suitable torque to prevent Legend
the sub gear from moving . (1) Intake Camshaft Timing Gear for Right Bank
(2) Intake Camshaft Timing Gear for Left Bank
(3) Exhaust Camshaft Timing Gear
(4) Discrimination Mark
LI: Left Bank Intake
RI: Right Bank Intake
LE: Left Bank Exhaust
RE: Right Bank Exhaust

014RW025

3. Install camshaft drive gear assembly and tighten


three bolts to the specified torque.
Torque: 10 Nꞏm (1.0 Kgꞏm/89 lb in)
4. Install camshaft assembly and camshaft brackets,
tighten twenty bolts on one side bank to the specified
torque.
1. Apply engine oil to camshaft journal and bearing
surface of camshaft bracket. 014RW023

2. Align timing mark on intake camshaft (one dot for Legend


right bank, two dots for left bank) and exhaust (1) Right Bank Camshaft Drive Gear
camshaft (one dot for right bank, two dots for left (2) Left Bank Camshaft Drive Gear
bank) to timing mark on camshaft drive gear (one (3) Timing Mark on Drive Gear
dot). (4) Dowel Pin

014RW020
ENGINE MECHANICAL 6A–55

014RW024

Legend (3) Alignment Mark on Camshaft Drive Gear


(1) Right Bank (4) Alignment Mark on Camshaft
(2) Left Bank (5) Alignment Mark on Retainer

3. Tighten twenty bolts in numerical order on one


side bank as shown in the illustration.
Torque: 10 Nꞏm (1.0 Kgꞏm/89 lb in)

014RW031

5. Tighten bolt for camshaft drive gear assembly pulley


to the specified torque.
Torque: 98 Nꞏm (10.0 Kgꞏm/72 lb ft)
6A–56 ENGINE MECHANICAL

Valve Spring, Oil Controller, Valve, Valve Guide


Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts

014RW039

Legend (7) Spring Upper Seat


(1) Camshaft Bracket Fixing Bolts (8) Valve Spring
(2) Camshaft Assembly Inlet (9) Oil Controller
(3) Camshaft Assembly Exhaust (10) Spring Lower Seat
(4) Shim (11) Valve Guide
(5) Tappet (12) Valve
(6) Split Collar

Disassembly 3. Remove camshaft assembly (Exhaust side).


4. Remove shim (4) and tappet (5).
1. Remove camshaft bracket fixing bolts (1).
2. Remove camshaft assembly (intake).
ENGINE MECHANICAL 6A–57
5. Use 5–8840–2446–0 valve spring compressor and 2. Measure the valve spring squareness with a steel
5–8840–2547–0 valve spring compressor adapter to square and replace the valve springs if the measured
remove split collar. value exceeds the specified limit.
Limit : 2 mm (0.0787 in)

014RW042

6. Remove valve spring.


014RS005

7. Remove valve. 3. Using a spring tester to compress the springs to the


8. Remove oil controller and spring lower seat. installed height, measure the compressed spring
9. Remove the valve guide using the 5–8840–2442–0 tension, and replace the springs if the measured
valve guide replacer. tension is below the specified limit.
At installed height: 35.0 mm (1.38 in)
Inspection and Repair Standard: 196 N (44 lb)
Limit: Less than 181 N (41 lb)
Valve Spring
CAUTION: Visually inspect the valve springs and
replace them if damage or abnormal wear is evident.
1. Measure the free height of the springs. The springs
must be replaced if the free height is below the
specified limit.
Standard : 44.6 mm (1.7559 in)
Limit : 43.6 mm (1.7165 in)

014RS006

Valve Guide
CAUTION: Take care not to damage the valve seat
contact surface, when removing carbon adhering to
the valve head. Carefully inspect the valve stem for
scratchs or abnormal wear. If these conditions are
present, the valve and the valve guide must be
replaced as a set.
014RS004
6A–58 ENGINE MECHANICAL
1. Measure the valve stem diameter with a micrometer.
If the valve stem diameter is less than the specified
limit, the valve and the valve guide must be replaced
as a set.
Diameter of Valve Stem
Intake
Standard : 5.977 mm–5.959 mm
(0.2353 in–0.2346 in)
Limit : 5.90 mm (0.2323 in)
Exhaust
Standard : 5.952 mm–5.970 mm
(0.2343 in–0.2350 in)
Limit : 5.90 mm (0.2323 in)

014RS008

2. Apply engine oil to the outside of the valve guide.


Using valve guide replacer 5–8840–2442–0, drive in
a new valve guide from the camshaft side, and check
the valve guide height.
Valve guide upper end height: 13.0 mm (0.5118
in)
(Measured from the cylinder head upper face)

014RS007

2. Measure the inside diameter of the valve guide with a


micrometer. Subtract the measured outer diameter of
the valve stem from the measured inner diameter of
the valve guide. If the value exceeds the specified
limit, the valve and the valve guide must be replaced
as a set.
Inside Diameter of the Vale Guide
Inlet clearance
Standard : 0.023 mm–0.056 mm
(0.0009 in–0.0002 in)
Limit : 0.20 mm (0.00787 in)
014RW046
Exhaust clearance
3. Check the clearance. If the clearance is less than the
Standard : 0.030 mm–0.063 mm specified value, ream the inside diameter of valve
(0.0012 in–0.0025 in) guide. Using a sharp 6 mm reamer, ream the valve
Limit : 0.20 mm (0.00787 in) guide to obtain the specified clearance.

Valve Guide Replacement Valve Seat


1. Using Valve guide replacer: 5–8840–2442–0, drive 1. Measure the protrusion of the valve stem when a new
out the valve guide from the combustion chamber valve is installed in the cylinder head. If the protrusion
side. of the valve stem exceeds the limit, replace the valve
seat insert or the cylinder head assembly.
Protrusion of valve stem
Intake
Standard: 39.32 mm (1.5480 in)
ENGINE MECHANICAL 6A–59
Limit: 39.47 mm (1.5539 in) 2. If the measured value exceeds the limit, replace
Exhaust valve, valve guide and valve seat as a set.
Standard: 39.30 mm (1.5472 in) Valve contact surface angle: 45
Limit: 39.45 mm (1.5531 in)

014RS012

2. Measure the valve seat contact width. Make the


014RW047
Valve Seat Insert Correction
necessary corrections if the seat contact surface is 1. Remove the carbon from the valve seat insert
damaged or rough or if the contact width wear surface.
exceeds the limit. 2. Use a valve cutter to minimize scratches and other
Valve seat contact width rough areas. This will bring the contact width back to
Standard: 1.1 mm (0.0433 in) the standard value. Remove only the scratches and
rough areas. Do not cut away too much. Take care not
Limit: 1.7 mm (0.0669 in) to cut away unblemished areas of the valve seat
surface.
Valve seat angle degree: 90

014RS011

Contact Surface Angle on Valve Seat on


Valve 014RW059

3. Apply abrasive compound to the valve seat insert


1. Measure contact surface angle on valve seat. surface.
4. Insert the valve into the valve guide.
5. Turn the valve while lapping it to fit the valve seat
insert.
6A–60 ENGINE MECHANICAL
6. Check that the valve contact width is correct. 7. After insertion, use a seat grinder to grind finish the
7. Check that the valve seat insert surface is in contact seating face. Carefully note the seating angle, the
with the entire circumference of the valve. contact width, and the depression.
8. Lap the valve and the seat.

Reassembly
1. Install valve guide (1) to cylinder head. Apply engine
oil to the outside of the valve guide. Using valve guide
replacer 5–8840–2442–0, drive in a new valve guide
from the camshaft side.
2. Install oil controller (3) and spring lower seat (2).
Using oil controller replacer 5–8840–0623–0, drive in
a new oil controller.

014RS014

Valve Seat Insert Replacement


1. Arc weld the rod at several points. Be careful not to
damage the aluminum section.
2. Allow the rod to cool for a few minutes. This will cause
the valve seat to shrink.
3. Strike the rod and pull it out.

014RW058

3. Install valve to valve guide. Before install valve guide


apply engine oil to the outside of the valve stem.
4. Install valve spring to cylinder head. Attach the valve
spring to the lower spring seat. The painted area of
the valve spring should be facing downward.

014RS015

4. Carefully clean the valve seat press–fit section on the


cylinder head side.
5. Heat the press–fit section with steam or some other
means to cause expansion. Cool the valve seat with
dry ice or some other means.
6. Insert the press–fit section into the valve seat
horizontally.
Standard fitting interference: 0.14 mm–0.09 mm 014RS020

(0.0055 in–0.0035 in)


ENGINE MECHANICAL 6A–61
5. Install lower valve spring seat, valve spring and upper Valve Clearance Adjustments
valve spring seat then put split collars on the upper
spring seat, using the 5–8840–2446–0 valve spring NOTE: To adjust valve clearance, apply engine oil to the
compressor and 5–8840–2547–0 valve spring cam as well as to the adjusting shim (2) with the cylinder
compressor adapter to install the split collars. head built on the cylinder block, give a few turns to the
camshaft by means of timing pulley tightening bolt, and
measure valve clearance when the nose of cam is just
opposite to maximum cam lift (1) as shown in illistration
below.

014RW042

6. Install tappet with shim.


7. Install camshaft assembly.
Refer to installation procedure for Camshaft in this
manual. 014RW081

Legend
(1) Cam
(2) Shim
(3) Tappet

Valve Clearance Standard Value (cold)


Intake: 0.23 mm–0.33 mm
(0.0091 in–0.0130 in)
Exhaust: 0.25 mm–0.35 mm
(0.0098 in–0.0138 in)

Selection of Adjusting Shim


Shim to be selected = (Thickness of removed shim) +
(Valve clearance measurement – Standard valve)
Based on the above formula, the best suited shim should
be selected from 41 sorts of shim (differently thick at
0.02mm (0.0008 in) intervals from 2.40mm (0.0945 in)
through 3.2mm (0.1260 in) thick). Install the shim and
check valve clearance.
6A–62 ENGINE MECHANICAL
Replacement of Shim
Let the cam push down the edge of tappet by using
5–8840–2444–0 valve clearance adjusting tool and push
out the shim with a flat blade screw driver as shown in
illustrations below.

014RW084

014RW082

014RW083
ENGINE MECHANICAL 6A–63

Camshaft
Camshaft and Associated Parts

014RW040

Legend (6) Camshaft Drive Gear Pulley


(1) Camshaft Bracket Fixing Bolt (7) Retainer Fixing Bolt
(2) Camshaft Bracket (8) Retainer
(3) Camshaft Assembly Intake (9) Camshaft Drive Gear
(4) Camshaft Assembly Exhaust (10) Oil Seal
(5) Pulley Fixing Bolt

Disassembly
1. Remove fixing bolt (5) for camshaft drive gear pulley
using the 5–8840–2447–0 universal holder.
6A–64 ENGINE MECHANICAL

014RW060 014RW043

2. Remove twenty fixing bolts from inlet and exhaust 2. Use a micrometer to measure the diameter and the
camshaft bracket on one side bank, then camshaft uneven wear of the camshaft journals.
brackets (2). Replace the camshaft if the diameter or the uneven
wear exceeds the specified limit.
Journal Diameter
Standard : 25.972 mm–25.993 mm
(1.0225 in–1.0233 in)
Limit : 25.8 mm (1.0157 in)
Uneven wear : 0.05 mm (0.0020 in)

014RW027

3. Remove camshaft assembly (3), (4).


4. Remove three fixing bolts (7) from camshaft drive
gear retainer (8), then camshaft drive gear assembly.

Inspection and Repair


1. Use a micrometer to measure the cam lobe height 014RS023

and uneven wear. Replace the camshaft if either the 3. Place the camshaft on V–blocks.
lobe height or the uneven wear exceeds the specified Slowly rotate the camshaft and measure the runout
limit. with a dial indicator.
Lobe height : 44.709 mm (1.7602 in) Replace the camshaft if the runout exceeds the
Uneven wear : 0.05 mm (0.0020 in) specified limit.
ENGINE MECHANICAL 6A–65
Runout
Limit : 0.1 mm (0.0039 in)

014RW037

5. Replace the cylinder head and/or camshaft if the


measured oil clearance exceeds the specified limit.
014RW044

4. Measure the camshaft journal oil clearance. 1. Carefully clean the camshaft journal, the
camshaft bracket, and the cylinder head.
1. Measure the camshaft bracket housing inside
diameter. 2. Install camshaft assembly and camshaft brackets
(2), tighten twenty bolts (1) on one side bank to
NOTE: Tighten camshaft bracket (2) to specified torque the specified torque.
before measuring the camshaft bracket inside diameter.
Torque: 10 Nꞏm (1.0 Kgꞏm/89 lb in)
Torque : 10 Nꞏm (1.0 Kgꞏm/89 lb in)

014RW031

014RW031
3. Measure the camshaft thrust clearance with a dial
2. Subtract the camshaft outside diameter from the indicator. Replace the camshaft and/or the
camshaft bracket housing inside diameter. cylinder head if the camshaft thrust clearance
Oil Clearance exceeds the specified limit.
Standard : 0.027 mm–0.078 mm Camshaft thrust Clearance
(0.0011 in–0.0031 in) Standard : 0.03 mm–0.08 mm
Limit : 0.11 mm (0.0043 in) (0.0012 in.–0.0031 in.)
6A–66 ENGINE MECHANICAL
Limit : 0.12 mm (0.0047 mm) 2. Align timing mark on intake camshaft (one dot for
right bank, two dots for left bank) and exhaust
camshaft (one dot for right bank, two dots for left
bank) to timing mark on camshaft drive gear (one
dot).

014RW035

Reassembly
1. Install camshaft drive gear assembly and tighten 014RW020

three bolts to specified torque. Legend


Torque: 10 Nꞏm (1.0 Kgꞏm/89 lb in) (1) Intake Camshaft Timing Gear for Right Bank
2. Tighten sub gear setting bolt. (2) Intake Camshaft Timing Gear for Left Bank
1. Use 5–8840–2443–0 to turn sub gear to right (3) Exhaust Camshaft Timing Gear
direction until the M5 bolt hole aligns between (4) Discerning Mark
camshaft driven gear and sub gear. LI: Left Bank Intake
2. Tighten M5 bolt suitable torque for prevent RI: Right Bank Intake
moving the sub gear. LE: Left Bank Exhaust
RE: Right Bank Exhaust

014RW041

3. Install camshaft assembly and camshaft brackets,


tighten twenty bolts on one side bank to the specified
torque.
1. Apply engine oil to camshaft journal and bearing
surface of camshaft bracket.
ENGINE MECHANICAL 6A–67
Legend
(1) Right Bank Camshaft Drive Gear
(2) Left Bank Camshaft Drive Gear
(3) Timing Mark on Drive Gear
(4) Dowel Pin

014RW023

014RW024

Legend (3) Alignment Mark on Camshaft Drive Gear


(1) Right Bank (4) Alignment Mark on Camshaft
(2) Left Bank (5) Alignment Mark on Retainer

3. Tighten twenty bolts in numerical order on one


side bank as shown in the illustration.
Torque: 10 Nꞏm (1.0 Kgꞏm/89 lb in)
6A–68 ENGINE MECHANICAL

014RW031 014RW060

4. If the oil seal requires replacement, use the


5–8840–2445–0 to install the oil seal.

014RW034

5. Tighten bolt for camshaft drive gear pulley to the


specified torque using the 5–8840–2447–0 universal
holder.
Torque: 98 Nꞏm (10.0 Kgꞏm/72 lb ft)
ENGINE MECHANICAL 6A–69

Crankshaft
Crankshaft and Associated Parts

013RW009

Legend (8) Piston and Connecting Rod Assembly


(1) Cylinder Head Assembly (9) Flywheel
(2) Crankcase with Oil Pan (10) Rear Oil Seal Retainer and Oil Seal
(3) Oil Pipe and O-Ring (11) Main Bearing Cap
(4) Oil Strainer and O-Ring (12) Crankshaft
(5) Oil Pump Assembly (13) Main Bearing Cap Fixing Bolts
(6) Cylinder Block Side Bolts (14) Oil Gallery Fixing Bolts
(7) Oil Gallery

Disassembly CAUTION: Take care not to damage or deform the


sealing flange surface of crankcase.
1. Remove cylinder head assembly (1). Refer to 3. Remove oil pipe and O-ring (3).
“Cylinder Head” in this manual.
4. Remove oil strainer and O-ring (4).
2. Remove crankcase with oil pan (2). Refer to “Oil Pan
and Crankcase” in this manual. 5. Remove oil pump assembly (5).
6. Remove crankcase side bolts (6).
6A–70 ENGINE MECHANICAL
7. Remove oil gallery (7).
8. Remove piston and connecting rod assembly (8).
Refer to “Piston, Piston Ring and Connecting Rod” in
this manual.
9. Remove flywheel (9).
10. Remove rear oil seal retainer (10).
11. Remove main bearing cap (11).
12. Remove crankshaft (12).

Inspection and Repair


1. Crankshaft
Set the dial indicator as shown in the illustration and
measure the crankshaft thrust clearance. If the thrust
clearance exceeds the specified limit, replace the
thrust bearings as a set.
Thrust Clearance
Standard : 0.06 mm–0.24 mm 015RS004

(0.0024 in–0.0094 in) 3. Remove the crankshaft.


Limit : 0.30 mm (0.0118 in) Remove the main bearings.
4. Clean the upper and lower bearings as well as the
crankshaft main journal.
5. Check the bearings for damage or excessive wear.
The bearings must be replaced as a set if damage or
excessive wear is discovered during inspection.
6. Set the upper bearings and the thrust washers to their
original positions.
Carefully install the crankshaft.
7. Set the lower bearings to the bearing cap original
position.
8. Apply plastigage to the crankshaft journal unit as
shown in the illustration.
NOTE: Do not set the plastigage on the oil hole.

015RS003

Main Bearing Clearance


1. Remove the bearing caps and measure the oil
clearance.
2. Remove the main bearing cap fixing bolts in the
sequence shown in the illustration.
Arrange the removed main bearing caps in the
cylinder number order.
Remove the main bearings.

015RS005

9. Install main bearing caps, oil gallery and crank case


bolts in the order shown, and tighten each bolt to the
specified torque.
ENGINE MECHANICAL 6A–71
NOTE: Do not apply engine oil to the crank case side Limit : 0.08 mm (0.0031 in)
bolts.
Main bearing cap bolts.
Torque: 39 Nꞏm (4.0 Kgꞏm/29 lb ft)
Oil gallery fixing bolts.
Torque:
1st step: 29 Nꞏm (3.0 Kgꞏm/21 lb ft)
2nd step 55 65
Crank case side bolts
Torque : 39 Nꞏm (4.0 Kgꞏm/29 lb ft)
NOTE: Do not allow the crankshaft to rotate.

015RS008

12. Clean the plastigage from the bearings and the


crankshaft.
Remove the crankshaft and the bearings.

Crankshaft (12) Inspection


Inspect the surface of the crankshaft journal and crank
pins for excessive wear and damage. Inspect the oil seal
fitting surfaces for excessive wear and damage. Inspect
the oil ports for obstructions.

Inspection and Repair


015RS006

10. Remove the main bearing caps in the sequence 1. Carefully set the crankshaft on the V–blocks. Slowly
shown in the illustration. rotate the crankshaft and measure the runout. If the
crankshaft runout exceeds the specified limit, the
crankshaft must be replaced.
Runout : 0.04 mm (0.0016 in)

015RS004

11. Measure the plastigage width and determine the oil


clearance. If the oil clearance exceeds the specified
limit, replace the main bearings as a set and/or 015RS007

replace the crankshaft.


Standard : 0.019 mm–0.043 mm
(0.0007 in–0.0017 in)
6A–72 ENGINE MECHANICAL
2. Measure the diameter and the uneven wear of main 2. Diameter size mark (1).
journal and crank pin. If the crankshaft wear exceeds The diameter size marks are stamped on the No.1
the specified limit, crankshaft must be replaced. crankshaft balancer as shown in the illustration.
Main journal diameter : 63.918 mm–63.933 mm
(2.5165 in–2.5170 in)
Crank pin diameter : 53.922 mm–53.937 mm
(2.1229 in.–2.1235 in.)
Uneven wear limit : 0.005 mm (0.0002 in)

015RS011

NOTE: Take care to ensure the bearings are positioned


correctly.

015RS009

Crankshaft Bearing Selection


When installing new crankshaft bearings or replacing
bearings, refer to the selection table below. Select and
install the new crankshaft bearings, paying close
attention to the cylinder block journal hole.
1. Diameter size mark (1) and the crankshaft journal.

015RS012

Legend
(1) Number 1 and 4 main bearing upper and lower
(2) Number 2 and 3 main bearing upper
(3) Number 2 and 3 main bearing lower

015RS010
ENGINE MECHANICAL 6A–73

Crank Shaft Crank Shaft


Bearing Bearing
1 Size Main Bearing Crank Shaft Main 2 Size Oil Clearance
Size Mark Size Mark
Mark Bore Diameter Journal Diameter Mark (Reference)
(Upper (Lower
Side) Side)
63.918-63.925 0.030-0.049
2 Blue Blue
68.994-69.000 (2.5165-2.5167) (0.0012-0.0019)
1
(2.7163-2.7165) 63.926-63.933 0.028-0.047
1
(2.5168-2.5170) (0.0011-0.0019)
Brown Brown
63.918-63.925 0.029-0.048
2
68.987-68.993 (2.5165-2.5167) (0.0011-0.0019)
2
(2.7160-2.7163) 63.926-63.933 0.027-0.046
1
(2.5168-2.5170) (0.0011-0.0018)
Green Green
63.918-63.925 0.028-0.047
2
68.980-68.986 (2.5165-2.5167) (0.0011-0.0019)
3
(2.7157-2.7160) 63.926-63.933 0.026-0.045
1 Yellow Yellow
(2.5168-2.5170) (0.0010-0.0018)

Reassembly Apply engine oil to the thrust washer.

1. Crankshaft (12) Assemble the thrust washer to the No.3 bearing


journal. The oil grooves must face the crankshaft.
Install the main bearings to the cylinder block and
the main bearing caps.
Be sure that they are positioned correctly.
Apply new engine oil to the upper and lower main
bearing faces.
NOTE: Do not apply engine oil to the main bearing back
faces.

015RS013

2. Rear oil seal (10)


Remove the oil from the cylinder block and the
retainer mounting surface.
Apply sealant (TB–1207B or equivalent) to the
retainer mounting surface, following the pattern
shown in the illustration.
015RS012
The retainer must be installed within 5 minutes after
Carefully mount the crankshaft. sealant application befor the sealant hardens.
6A–74 ENGINE MECHANICAL

015RW002 015RS017

Legend 3. Flywheel (9)


(1) Around Bolt Holes 1. Thoroughly clean and remove the oil from the
(2) Around Dowel Pin threads of crankshaft.
2. Remove the oil from the crankshaft and flywheel
Apply engine oil to the oil seal lip. mounting faces.
Align the cylinder block dowel pin holes with the rear 3. Mount the flywheel on the crankshaft and then
retainer dowel pins. install the washer.
Tighten the rear retainer fixing bolts. New bolts 4. Hold the crankshaft to prevent from rotating then
should be used when installing rear retainer. install the bolts in the order shown to the specified
torque.
Torque: 18 Nꞏm (1.8 Kgꞏm/13 lb ft)
Torque: 54 Nꞏm (5.5 Kgꞏm/40 lb ft)
NOTE: Be very careful not to disengage the oil seal garter
spring during installation of the rear retainer. NOTE: Do not reuse the bolt and do not apply oil or thread
If the seal was removed from retainer for lock to the bolt.
replacement, apply engine oil to the oil seal lip and
install the oil seal using 5–8840–2286–0 oil seal
installer.

015RS018

015RW001
ENGINE MECHANICAL 6A–75
4. Piston and connecting rod assembly (8)
Apply engine oil to the cylinder bores, the
connecting rod bearings and the crankshaft pins.
Check to see that the piston ring end gaps are
correctly positioned.

015RS020

5. Install oil gallery (7) and tighten the bolts in 2 steps, in


the order shown.
1st step: 29 Nꞏm (3.0 Kgꞏm/22 lb ft)
2nd step: 55 65
015RS019

Legend
(1) No.1 Compression Ring
(2) No.2 Compression Ring
(3) Oil Ring Side Rail Upper
(4) Oil Ring Side Rail Lower
(5) Piston Front Mark

Insert the piston/connecting rod assemblies into


each cylinder with the piston ring compressor. The
front marks must be facing the front of the engine.
Match the numbered caps with the numbers on the
connecting rods. Align the punched marks on the
connecting rods and caps.
Apply engine oil to the threads and seating faces of
the nuts.
Tighten the nuts.
Torque: 54 Nꞏm (5.5 Kgꞏm/40 lb ft)
051RS009

6. Cylinder block side bolts (6)


After tightening the cap nuts, check to see that the
Tighten all the bolts to the specified torque in the
crankshaft rotates smoothly.
order shown.
NOTE: Do not apply engine oil to the bearing back faces. NOTE: Do not apply engine oil to the crank case side
bolts.
Torque: 39 Nꞏm (4.0 Kgꞏm/29 lb ft)
6A–76 ENGINE MECHANICAL
Legend
(1) Portion Between Bolt Holes
(2) Bolt Hole Portion

11. Install cylinder head assembly, refer to “Cylinder


head” in this manual.

012RS001

7. Install oil pump assembly (5), refer to “Oil pump” in


this manual.
8. Install oil strainer and O-ring (4).
9. Install oil pipe and O-ring (3) and tighten the bolts.
Torque: 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
10. Install crankcase with oil pan (2).
1. Completely remove all residual sealant, lubricant
and moisture from the sealing surfaces. The
surfaces must be perfectly dry.
2. Apply a correct width bead of sealant (TB—
1207C or its equivalent) to the contact surfaces of
the oil pan. There must be no gaps in the bead.
3. The crankcase assembly must be installed within
5 minutes after sealant application to prevent
premature hardening of the sealant.
4. Tighten the bolts and nuts to the specified torque.
Torque : 10 Nꞏm (1.0 Kgꞏm/89 lb in)

013RW010
ENGINE MECHANICAL 6A–77

Piston and Connecting Rod


Piston, Connecting Rod and Associate Parts

015RW019

Legend (7) Piston and Connecting Rod Assembly


(1) Cylinder Head Assembly (8) Piston Ring
(2) Cylinder Head Gasket (9) Piston Pin
(3) Crankcase with Oil Pan (10) Piston
(4) Oil Pipe and O-Ring (11) Connecting Rod
(5) Oil Strainer and O-Ring (12) Connecting Rod Cap
(6) Oil Gallery

Disassembly 5. Remove oil strainer and O-ring (5).


6. Remove oil gallery (6).
1. Remove cylinder head assembly (1). Refer to
“Cylinder Head Removal” in this manual. 7. Remove connecting rod cap with connecting rod
lower bearing (12).
2. Remove cylinder head gasket (2).
8. Remove piston and connecting rod assembly (7).
3. Remove crankcase with oil pan (3). Refer to“Oil Pan
and Crankcase” in this manual. NOTE: Before removing piston and connecting rod
4. Remove oil pipe and O-ring (4). assembly, measure thrust clearance.
6A–78 ENGINE MECHANICAL

015RS031 015RX001

Remove any ridge or carbon build up from the top Legend


end of the cylinder.
(1) Press Ram
9. Remove the piston rings (8) with a piston ring (2) Piston
expander. Arrange the removed piston rings in the
(3) Connecting Rod
cylinder number order.
(4) Piston Pin

11. Piston (10)


12. Connecting rod (11)

Inspection and Repair


Pistons (10)
Carefully clean away all the carbon adhering to the piston
head and the piston ring grooves.
NOTE: Never use a wire brush to clean the pistons.
Damage will result. Visually check each piston for
cracking, scoring, and other signs of excessive wear. If
any of the above conditions are found, the piston must be
replaced.

Piston Diameter
1. Measure the piston outside diameter with micrometer
015RS022 at the piston grading position and a right angle to the
10. Remove the piston pin (9) using 5–8840–0551–0 piston pin.
piston pin service set and piston support with a press. Piston grading position (from piston head)
NOTE: Keep the parts removed from each cylinder Piston grading position : 43.0 mm (1.6929 in)
separate. All parts must be reinstalled in their original
positions. Heating the connecting rod will permit easy
removal of the piston pin.
ENGINE MECHANICAL 6A–79

015RV014 012RS002

The size mark (1) for piston outside diameter is


represented as shown in illustration below. Piston Rings (8)
Outside Diameter Any worn or damaged part discovered during engine
overhaul must be replaced with a new one.
Size Mark A : 93.360 mm–93.370 mm
(3.6756 in–3.6760 in) 1. Ring end gap measurement
Insert the piston ring into the bore.
Size Mark B : 93.371 mm–93.380 mm
(3.6760 in–3.6764 in) Push the ring by the piston, at a right angle to the
wall, into the point at which the cylinder bore
Size Mark C : 93.381 mm–93.390 mm diameter is the smallest.
(3.6764 in–3.6768 in)
Measure the ring end gap.

Compression Ring
1st ring
Standard: 0.300 mm–0.400 mm
(0.0118 in–0.0157 in)
Limit: 1.0 mm (0.0394 in)
2nd ring
Standard: 0.450 mm–0.600 mm
(0.0177 in–0.0236 in)
Limit: 1.2 mm (0.0472 in)
Oil ring
Standard: 0.150 mm–0.450 mm
(0.0059 in–0.0177 in)
Limit: 1.05 mm (0.0413 in)
015RS025

Measure the cylinder bore inside diameter (refer to


“Cylinder Block” in this manual).
6A–80 ENGINE MECHANICAL

015RS026 015RS028

Positioning mark (1) is painted as shown in the


illustration. Piston Pin (9)
Marked T : No.1 Compression ring NOTE: Do not reuse the old piston pin.
Marked T2 : No.2 Compression ring 1. Use a micrometer to measure the new piston pin
outside diameter in both directions at three different
positions.
2. Measure the inside diameter of the connecting rod
small end. If the fitting interference between the small
end and pin does not conform to the specified value,
the connecting rod must be replaced.
Standard : 0.023 mm–0.038 mm (0.0009
in–0.0015 in)

015RS027

2. Measure the clearance between the piston ring


groove and the piston ring with a feeler gauge. If the
piston ring groove / piston ring clearance exceeds the
specified limit, the piston must be replaced.
Compression Ring Clearance
Standard : 0.016 mm–0.038 mm
(0.0006 in.–0.0015 in)
015RS029
Limit : 0.15mm (0.0059 in) 3. Insert the new pin into the piston and rotate it. If the
pin rotates smoothly with no backlash, the clearance
is normal. If there is backlash or roughness, measure
the clearance. If the clearance exceeds the specified
limit, the piston must be replaced.
Clearance
Standard : 0.010 mm–0.017 mm
(0.0004 in.–0.0007 in)
Limit : 0.040 mm (0.0016 in)
ENGINE MECHANICAL 6A–81
Connecting Rods (11)
1. Check the connecting rod alignment If either the bend
or the twist exceeds the specified limit, the connecting
rod must be replaced.
Bend per 100 mm (3.937 in)
Limit: 0.15 (0.0059)
Twist per 100 mm (3.937 in)
Limit: 0.20 (0.0078)

015RS031

3. Measure the oil clearance between the connecting


rod and the crankshaft.
1. Remove the connecting rod cap nuts and the rod
caps (12).
Arrange the removed rod caps in the cylinder
number order.
2. Clean the rod bearings and the crankshaft pins.
3. Carefully check the rod bearings. If even one
015RS030 bearing is found to be damaged or badly worn, the
2. Measure the connecting rod thrust clearance. Use a entire bearing assembly must be replaced as a
feeler gauge to measure the thrust clearance at the set. Reinstall the bearings in their original
large end of the connecting rod If the clearance positions. Apply plastigage to the crank pin.
exceeds the specified limit, the connecting rod must
be replaced.
Standard : 0.16 mm–0.35 mm
(0.0063 in.–0.0138 in)
Limit : 0.40 mm (0.0157 in)

015RS032
6A–82 ENGINE MECHANICAL
4. Reinstall the rod caps (12) to their original 7. Clean the plastigage from the bearings and the
positions. crankshaft pins.
Tighten the rod cap nuts.
Torque: 54 Nꞏm (5.5 Kgꞏm/40 lb ft) Con–rod Bearing Selection
Select and install the new connecting rod bearings,
NOTE: Do not allow the crankshaft to rotate. paying close attention to the connecting rod big end
5. Remove the rod caps. diameter size mark (1).
6. Measure the width of the plastigage and NOTE: Take care not to confuse the alignment mark (2)
determine the oil clearance. If the oil clearance and the size mark (1) during the installation procedure.
exceeds the limit, replace the rod bearing as a
set.
Standard : 0.019 mm–0.043 mm
(0.0007 in–0.0017 in)
Limit : 0.08 mm (0.003 in)

015RS034

015RS008

Connecting Rod Color of


Big end Bore Crankshaft Pin Oil Clearance
1 Size Mark Bearing Thickness Size
Diameter Diameter (Reference)
(Reference) Mark
56.994-57.000 1.512-1.516 0.025-0.054
A Yellow
(2.2439-2.2441) (0.0595-0.0597) (0.0010-0.0021)
56.988-56.994 53.922-53.937 1.508-1.512 0.027-0.056
B Green
(2.2436-2.2439) (2.1229-2.1235) (0.0594-0.0595) (0.0011-0.0022)
56.982-56.988 1.504-1.508 0.029-0.058
C Pink
(2.2434-2.2436) (0.0592-0.0594) (0.0011-0.0023)

Reassembly 3. Install piston pin


Apply a thin coat of engine oil to the piston pin. Try to
1. Install connecting rod insert the piston pin into the piston pin hole with
2. Install piston normal finger pressure.
NOTE: When changing piston / connecting rod
combinations, do not change the piston / piston pin
combination and do not reuse the old piston pin.
ENGINE MECHANICAL 6A–83
Attach the piston to the connecting rod with the
piston front mark and the connecting rod front mark
on the same side.

015RS027

Install piston rings in the following sequence.


1. Oil ring
015RS036 1. Expander ring
With 5–8840–0551–0 Piston pin service set and a 2. Upper side rail
press, press fit the piston pin. 3. Lower side rail
NOTE: Heat the connecting rod small end to a suitable 2. 2nd compression ring
temperature to ensure smooth installation. 3. 1st compression ring
The compression rings must be set with the T or T2
mark facing up.
Marked T : No.1 Compression ring
Marked T2 : No.2 Compression ring
After installation, apply engine oil to the entire
circumference of the piston rings. Check to see that
all the rings rotate smoothly.

015RX001

Legend
(1) Press Ram
(2) Piston
(3) Connecting Rod
(4) Piston Pin

4. Install piston ring with the piston ring expander.


The compression ring must be set with the T mark (1) 015RS038

facing up. 5. Install piston and connecting rod assembly.


Marked T : No.1 Compression ring Insert the bearings into the connecting rods and
caps. Apply new engine oil to the bearing faces and
Marked T2 : No.2 Compression ring nuts.
6A–84 ENGINE MECHANICAL
Tighten the connecting rod cap nuts
Torque : 54 Nꞏm (5.5 Kgꞏm/40 lb ft)
NOTE: Do not apply engine oil to the bearing back faces.
6. Oil gallery, refer to “Crankshaft and main bearing” in
this manual.
7. Oil strainer and O-ring.
8. Oil pipe and O-ring.
9. Install crankcase with oil pan, refer to “Oil pan and
Crankcase” in this manual.
10. Install cylinder head gasket.
11. Install Cylinder head assembly.
Refer to “Cylinder head” in this manual.
ENGINE MECHANICAL 6A–85

Cylinder Block
Cylinder Block and Associated Parts

012RW010

Legend (8) Oil Gallery


(1) Cylinder Head Assembly (9) Piston and Connecting Rod Assembly
(2) Cylinder Head Gasket (10) Flywheel
(3) Crankcase with Oil Pan (11) Rear Oil Seal Retainer Assembly
(4) Oil Pipe and O-Ring (12) Main Bearing Cap
(5) Oil Strainer and O-Ring (13) Crankshaft
(6) Oil Pump Assembly (14) Cylinder Block
(7) Cylinder Block Side Bolts

Disassembly 5. Remove oil strainer and O-ring.


6. Remove oil pump assembly.
1. Remove cylinder head assembly.
7. Remove crankcase side bolts.
2. Remove cylinder head gasket.
8. Remove oil gallery.
3. Remove crankcase with oil pan.
9. Remove piston and connecting rod assembly.
4. Remove oil pipe and O-ring.
10. Remove flywheel.
6A–86 ENGINE MECHANICAL
11. Remove rear oil seal retainer assembly. CAUTION: Be very careful not to allow any material
12. Remove main bearing cap. to accidentally drop into the upper surface of the
cylinder block. Be very careful not to scratch the
13. Remove crankshaft.
upper surface of the cylinder block.
14. Remove cylinder block.
Cylinder Bore Inside Diameter
Limit : 93.530 (3.6823)
Inspection and Repair If the measurement exceed the specified limit, the
1. Remove the cylinder head gasket and any other cylinder block must be replaced.
material adhering to the upper surface of the cylinder Diameter
block. Be very careful not to allow any material to Grade A : 93.400 mm–93.410 mm
accidentally drop into the cylinder block. Be very (3.6772 in–3.6776 in)
careful not to scratch the cylinder block.
2. Carefully remove the oil pump, rear oil seal retainer, Grade B : 93.411 mm–93.420 mm
and crankcase assembly installation surface seal. (3.6776 in–3.6779 in)
3. Wipe the cylinder block clean. Grade C : 93.421 mm–93.430 mm
4. Visually inspect the cylinder block. If necessary, use a (3.6780 in–3.6783 in)
flaw detector to perform a dye penetrate and
hydraulic (or air pressure) test. If cracking or other
damage is discovered, the cylinder block must either
be repaired or replaced.
Flatness
1. Using a straight–edge and feeler gauge, check that
the upper surface of the cylinder block is not warped.
CAUTION: Be very careful not to allow any material
to accidentally drop into the upper surface of the
cylinder block. Be very careful not to scratch the
upper surface of the cylinder block.
2. The cylinder block must be reground or replaced if the
warpage exceeds the limit.
Warpage
Limit : 0.15 mm (0.0059 in)
Maximum repairable limit: 0.15 mm (0.0059 in)

012RS005

NOTE: For information on piston diameter, please refer


to the section ”Inspection of the Piston and Connecting
Rod Assembly” in this manual.
The ”Grade” mark (1) is stamped at the position
illustrated.

012RS004

Cylinder Bore
Use a cylinder gauge to measure the cylinder bore
diameter in both the axial and thrust directions. Each
measurement should be made at six points.
ENGINE MECHANICAL 6A–87
Assemble the thrust washer to the No. 3 bearing
journal. The oil grooves must face the crankshaft.

012RS006

Reassembly 015RS013

3. Install rear oil seal retainer.


1. Install cylinder block.
Remove oil on cylinder block and retainer fitting
2. Install crankshaft.
surface.
Install the main bearings to the cylinder block and
the main bearing caps. Apply sealant (TB1207B or equivalent) to retainer
fitting surface as shown in illustration.
Be sure that they are positioned correctly.
The oil seal retainer must be installed within 5
Apply new engine oil to the upper and lower main minutes after sealant application before the sealant
bearing faces. hardens.
NOTE: Do not apply engine oil to the bearing back faces.

015RW002

015RS012 Legend
Legend (1) Around Bolt Holes
(1) Number 1 and 4 main bearing upper and lower. (2) Around Dowel Pin
(2) Number 2 and 3 main bearing upper.
(3) Number 2 and 3 main bearing lower. Apply engine oil to oil seal lip and align a dowel pin
hole in the cylinder block with that in the retainer.
Carefully mount the crankshaft. Tighten retainer fixing bolts to the specified torque.
Apply engine oil to the thrust washer. Torque: 25 Nꞏm (2.5 Kgꞏm/18.4 lb ft)
6A–88 ENGINE MECHANICAL
Check to see that the piston ring end gaps are
correctly positioned.

015RW001

4. Install flywheel
1. Thoroughly clean and remove the oil from the 015RS019

threads of crankshaft.
Legend
2. Remove the oil from the crankshaft and flywheel (1) No.1 Compression Ring
mounting faces.
(2) No.2 Compression Ring
3. Mount the flywheel on the crankshaft and then (3) Oil Ring Side Rail Upper
install the washer. (4) Oil Ring Side Rail Lower
4. Holding the crankshaft stationary, tighten the (5) Piston Front Mark
flywheel bolts in the order shown.
Torque: 54 Nꞏm (5.5 Kgꞏm/40 lb ft) Insert the piston/connecting rod assemblies into
each cylinder with the piston ring compressor.
NOTE: Do not reuse the bolts and do not apply oil or The front marks (1) must be facing the front of the
thread lock to the bolts. engine.

015RS018
015RS020
5. Install piston and connecting rod assembly. 6. Install oil gallery and tighten the bolts in 2 steps in the
Apply engine oil to the cylinder bores, the order shown.
connecting rod bearings and the crankshaft pins.
1st step : 29 Nꞏm (3.0 Kgꞏm/22 lb ft)
NOTE: Do not apply engine oil to the bearing back faces. 2nd step : 55 65
ENGINE MECHANICAL 6A–89

012RS007 013RW010

7. Install cylinder block side bolts (1) and tighten Legend


crankcase bolts in sequence shown in the illustration.
(1) Portion Between Both Holes
Torque : 39 Nꞏm (4.0 Kgꞏm/29 lb ft) (2) Bolt Hole Portions

12. Install cylinder head gasket.


13. Install cylinder head assembly. Refer to “Cylinder
Head” in this manual.

012RW005

8. Install oil pump assembly. Refer to “Oil Pump” in this


manual.
9. Install oil strainer and O-ring.
10. Install oil pipe and O-ring.
11. Install crankcase with oil pan.
1. Completely remove all residual sealant, lubricant
and moisture from the sealing surfaces. The
surfaces must be perfectly dry.
2. Apply a correct width bead of sealant (TB– 1207C
or its equivalent) to the contact surfaces of the
crankcase. There must be no gaps in the bead.
3. The oil pan must be installed within 5 minutes
after sealant application to prevent premature
hardening of sealant.
4. Tighten the bolts and nuts to the specified torque.
Torque : 10 Nꞏm (1.0 Kgꞏm/89 lb in)
6A–90 ENGINE MECHANICAL

Main Data and Specification


General Specification
Specifications
Item
6VD1 6VE1
Engine type, number of cylinders and arrangement Water cooled, four cycle V6
Form of combustion chamber Pent roof type
Valve mechanism 4-Cams, 4-Valves, DOHC Gear & Belt Drive
Cylinder liner type Casted in cylinder drive
Total piston displacement 3165 cc 3494 cc
Cylinder bore x stroke 93.4mm x 77.0mm 93.4mm x 85.0mm
(3.6772 in x 3.0315 in) (3.6772 in x 3.3465 in)
Compression ratio 9.1 : 1
Compression pressure at 300rpm 14.0 Kg/cm
Engine idling speed rpm Non adjustable (750)
Valve clearance Intake: 0.28 mm (0.11 in)
Exhaust: 0.30mm (0.12in)
Oil capacity 5.3 liters
Ignition timing Non adjustable Non adjustable
16 BTDC at idle rpm) (20 BTDC at idle rpm)
Spark plug K16PR–P11, PK16PR11, RC10PYP4
Plug gap 1.0 mm–1.1 mm(0.0394 in – 0.0433 in)
ENGINE MECHANICAL 6A–91
Torque Specifications
Ignition coil, Spark plug, Crankshaft angle sensor and Under cover
Nꞏm (Kgꞏm/Ib ft)

E06RW038
6A–92 ENGINE MECHANICAL

Cylinder head cover, Cylinder head, Camshaft bracket, Common chamber, EGR valve and EGR pipe
Nꞏm (Kgꞏm/Ib ft)

E06RW043
ENGINE MECHANICAL 6A–93
Crankshaft main bearing, Flywheel, Crankcase, Oil pan, Timing belt tensioner, Timing pulley, Timing belt
cover, Oil pump, Oil gallery, Oil strainer and Water pump
Nꞏm (Kgꞏm/Ib ft)

E06RW039
6A–94 ENGINE MECHANICAL
Connecting rod and Water pump
Nꞏm (Kgꞏm/Ib ft)

E06RW042
ENGINE MECHANICAL 6A–95
Engine mount
Nꞏm (Kgꞏm/Ib ft)

E06RW040
6A–96 ENGINE MECHANICAL

Special Tool
TOOL NO. TOOL NO.
ILLUSTRATION ILLUSTRATION
TOOL NAME TOOL NAME

5–8840–0011–0 5–8840–0133–0
(J–21687–02) (J–8614–01)
Remover; tie rod end Holder; Crankshaft

5–8840–2441–0
Set Number of Valve
Compressor
5–8840–2446–0 5–8840–2153–0
(J–8062) (J–37228)
Compressor; Valve Seal cutter
Spring (1)
5–8840–2547–0
(J–42898)
Adapter; Compressor
Valve Spring (2)

5–8840–2286–0
(J–39201)
5–8840–0623–0 Installer; Real oil seal
(J–37281)
Remover; Oil controller

9–8511–4209–0
(J–24239–1)
5–8840–0624–0 Cylinder head bolt
(J–38537) wrench
Installer; Oil controller

5–8840–2442–0
(J–42899)
Replacer; Valve guide
(set) (1,2)
5–8840–2445–0 5–8840–2548–0
(J–42985) (J–42687)
Installer; Camshaft oil Installer; Valve guide (1)
seal 5–8840–2549–0
(J–37985–1)
Remover; Valve guide
(2)

5–8840–2444–0
5–8840–2545–0
(J–42689)
(J–39206)
Adjusting Tool: Valve
Installer; Pilot bearing
clearance
ENGINE MECHANICAL 6A–97

TOOL NO.
ILLUSTRATION
TOOL NAME

5–8840–2443–0
(J–42686)
Lever; Gear spring

5–8840–2447–0
(J–43041)
Holder; Universal
ENGINE COOLING 6B–1

ENGINE
ENGINE COOLING
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 6B–1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–8
General Description . . . . . . . . . . . . . . . . . . . . . 6B–2 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–9
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–5 Radiator and Associated Parts . . . . . . . . . . 6B–9
Draining and Refilling Cooling System . . . . . 6B–6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–9
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–7 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–10
Water Pump and Associated Parts . . . . . . . 6B–7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–7 Drive Belt and Cooling Fan . . . . . . . . . . . . . . . 6B–12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–7 Drive Belt and Associated Parts . . . . . . . . . 6B–12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–7 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–12
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–12
Thermostat and Associated Parts . . . . . . . . 6B–8 Main Data and Specifications . . . . . . . . . . . . . 6B–13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–8 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–8

Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
6B–2 ENGINE COOLING

General Description

030RW001

Legend (7) Cylinder Head


(1) Water Pump (8) Right Bank
(2) Thermostat (9) Throttle Body
(3) Radiator (10) Cylinder Block
(4) Reserve Tank (11) Cylinder Head
(5) Cooling Fan (12) Left Bank
(6) Cylinder Block (13) Heater

The cooling system is a pressurized Engine Coolant (EC)


forced circulation type which consists of a water pump,
thermostat cooling fan, radiator and other components.
The automatic transmission fluid is cooled by the EC in
radiator.
Water Pump
The EC pump is a centrifugal impeller type and is driven
by a timing belt.

030RS001
ENGINE COOLING 6B–3

Thermostat Anti Freeze Solution


The thermostat is a wax pellet type with a air hole(1) and is Relation between the mixing ratio and freezing
installed in the thermostat housing. temperature of the EC varies with the ratio of
anti–freeze solution in water. Proper mixing ratio can
be determined by referring to the chart. Supplemental
inhibitors or additives claiming to increase cooling
capability that have not been specifically approved by
Isuzu are not recommended for addition to the cooling
system.
Calculating mixing ratio

031RW002

Radiator
The radiator is a tube type with corrugated fins. In order to
raise the boiling point of the coolant, the radiator is fitted
with a cap in which the valve is operated at 88.2 117.6
kPa (12.8 17.0 psi) pressure. (No oil cooler provided for
M/T) F06RW005

110RS001
6B–4 ENGINE COOLING
NOTE: Antifreeze solution + Water = Total cooling
system capacity.
Total Cooling System Capacity
M/T 8.8Lit (2.32Us gal)
A/T 8.4Lit (2.22Us gal)

B06RW003

B06RW002

Mixing ratio
Check the specific gravity of engine coolant in the
cooling system temperature ranges from 0 C to 50 C
using a suction type hydrometer, then determine the
density of the engine coolant by referring to the table.
NOTE:
1. Even in the areas where the atmospheric
temperature is higher than 0 C, be sure not to use
antifreeze solution at a mixing ratio lower than 20% so
that the inside of the engine may not be corroded.
2. If antifreeze solution is used at a mixing ratio higher
than 60%, the specific heat of the coolant falls and the
engine may be overheated. Moreover, antifreeze
performance drop and the coolant may be frozen.
The density of the solution must be adjusted as
occasion calls.
Antifreeze solution lower than 20% may not have
sufficient anticorrosive performance, and therefore,
please never fail to adjust as occasion demands within
the range of 20% to 60%.
ENGINE COOLING 6B–5

Diagnosis
Engine Cooling Trouble
Condition Possible cause Correction
Engine overheating Low Engine Coolant level Replenish
Incorrect fan installed Replace
Thermo meter unit faulty Replace
Faulty thermostat Replace
Faulty Engine Coolant temperature Repair or replace
sensor
Clogged radiator Clean or replace
Faulty radiator cap Replace
Low engine oil level or use of Replenish or change oil
improper engine oil
Clogged exhaust system Clean exhaust system or replace
faulty parts
Faulty Throttle Position sensor Replace throttle valve assembly
Open or shorted Throttle Position Repair or replace
sensor circuit
Damaged cylinder head gasket Replace
Engine overcooling Faulty thermostat Replace
Engine slow to warm–up Faulty thermostat Replace
Thermo unit faulty Replace
6B–6 ENGINE COOLING

Draining and Refilling Cooling 9. After the engine has cooled, replenish with EC up to
the “MAX” line of the reserve tank.
System 10. Start the engine. With the engine running at 3,000
Before draining the cooling system, inspect the system rpm, make sure there is no running water sound from
and perform any necessary service to ensure that it is the heater core (behind the center console).
clean, does not leak and is in proper working order. The
11. If the running water sound is heard, repeat steps 8 to
engine coolant (EC) level should be between the “MIN”
10.
and “MAX” lines of reserve tank when the engine is cold.
If low, check for leakage and add EC up to the “MAX” line.
There should not be any excessive deposit of rust or
scales around the radiator cap or radiator filler hole, and
the EC should also be free from oil.
Replace the EC if excessively dirty.
1. Completely drain the cooling system by opening the
drain plug (2) at the bottom of the radiator.

110RW002

2. Remove the radiator cap.


WARNING: TO AVOID THE DANGER OF BEING
BURNED, DO NOT REMOVE THE CAP WHILE THE
ENGINE AND RADIATOR ARE STILL HOT.
SCALDING FLUID AND STEAM CAN BE BLOWN OUT
UNDER PRESSURE.
3. Disconnect all hoses from the EC reserve tank.
Scrub and clean the inside of the reserve tank with
soap and water. Flush it well with clean water, then
drain it. Install the reserve tank and hoses.
4. Refill the cooling system with the EC using a solution
that is at least 50 percent antifreeze but no more than
70 percent antifreeze.
5. Fill the radiator to the base of the filler neck.
Fill the EC reserve tank to “MAX” line when the engine
is cold.
6. Block the drive wheels and firmly apply the parking
brake. Shift an automatic transmission to “P” (Park)
or a manual transmission to neutral.
7. Remove the radiator cap. Start the engine and warm
it up at 2,500 3,000 rpm for about 30 minutes.
8. When the air comes out from the radiator filler neck
and the EC level has gone down, replenish with the
EC. Repeat this procedure until the EC level does not
go down. Then stop the engine and install the radiator
cap. Let the engine cool down.
ENGINE COOLING 6B–7

Water Pump
Water Pump and Associated Parts

030RS002

Legend (3) Water Pump Assembly


(1) Timing Belt (4) Gasket
(2) Idle Pulley

Removal 2. Install water pump assembly and tighten bolts to the


specified torque.
1. Disconnect battery ground cable.
Torque: 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
2. Drain coolant.
Tightening order
3. Radiator hose (on inlet pipe side).
The tightening order are in the illustrate.
4. Remove timing belt. Refer to “Timing Belt” in this
manual. NOTE: To prevent the oil leakage, apply the LOCTITE
5. Remove Idle pulley. 262 or an equivalent, to the arrow marked fixing bolt
thread.
6. Remove water pump assembly.
7. Remove gasket.

Inspection
Make necessary repair and parts replacement if extreme
wear or damage is found during inspection. Should any of
the following problems occur, the entire water pump
assembly must be replaced:
Crack in the water pump body
EC leakage from the seal unit
Play or abnormal noise in the bearing
Cracks or corrosion in the impeller.

Installation
1. Install gasket, clean the mating surface of gasket
before installation.

030RW008
6B–8 ENGINE COOLING
3. Idle pulley 4. Timing belt
Install idle pulley and tighten bolt to the specified Install timing belt. Refer to timing belt installation
torque. step in “Timing Belt” in this manual.
Torque: 52 Nꞏm (5.3 Kgꞏm/38 lb ft) 5. Connect radiator inlet hose and replenish EC.
6. Connect battery ground cable.

Thermostat
Thermostat and Associated Parts

031RS003

Confirm the temperature when the valve first begins to


031RW001 open.
Legend Valve opening temperature 74.5C 78.5 C
(1) Thermostat Housing (166.1 F 173.3 F)
(2) Thermostat Confirm the temperature when the valve is fully opened.
(3) Outlet Pipe Valve full open temperature and lift More than
8.5mm (0.33 in) at 90 C (194 F)
Make necessary repair and parts replacement if extreme
Removal wear or damage is found during inspection.

1. Disconnect battery ground cable.


2. Drain engine coolant from the radiator and engine.
Installation
3. Disconnect radiator hose from the inlet pipe. 1. Install thermostat into the outlet pipe(4) making sure
that the air hole is in the up position.
4. Remove thermostat housing.
2. Install thermostat housing and tighten bolts to the
5. Remove thermostat(2).
specified torque.
Torque: 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
Inspection 3. Installation rubber hose.
Suspend the thermostat in a water–filled container using
4. Replenish engine coolant (EC).
thin wire. Place a thermometer next to the thermostat.
Do not directly heat the thermostat. 5. Start engine and check for EC leakage.
Gradually increase the water temperature. Stir the water
so that the entire water is same temperature.
ENGINE COOLING 6B–9

Radiator
Radiator and Associated Parts

110RW003

Legend (4) Reserve Tank Hose


(1) Oil Cooler Hose For Automatic Transmission (5) Bracket
(2) Radiator Hose (6) Radiator Assembly
(3) Fan Guide, Lower (7) Reserve Tank

Removal 5. Remove fan guide(1), clips(3) on both sides and the


bottom lock, then remove lower fan guide(3) with fan
1. Disconnect battery ground cable. shroud(4).
2. Loosen a drain plug(2) to drain EC.
3. Disconnect oil cooler hose(1) on automatic
transmission (A/T).
4. Disconnect radiator inlet hose and outlet hose from
the engine.

110RW001

110RW002
6B–10 ENGINE COOLING
6. Disconnect the reserve tank hose(4) from radiator. Valve opening vacuum kPa (psi) 1.96 4.91
7. Remove bracket(5). (0.28 0.71)

110RW004 110RS006

8. Lift up and remove the radiator assembly with hose,


taking care not to damage the radiator core with a fan Radiator Core
blade. 1. A bent fin may result in reduced ventilation and
9. Remove rubber cushions on both sides at the bottom. overheating may occur. All bent fins must be
straightened. Pay close attention to the base of the fin
when it is being straightened.
Inspection 2. Remove all dust, bugs and other foreign material.
Radiator Cap
Measure the valve opening pressure of the pressurizing
Flushing the Radiator
valve with a radiator filler cap tester. Thoroughly wash the inside of the radiator and the engine
Replace the cap if the valve opening pressure is outside coolant passages with cold water and mild detergent.
the standard range. Remove all signs of scale and rust.
Valve opening pressure kPa (psi) 88.3 117.7 Cooling System Leakage Check
(12.8 17.1)
Use a radiator cap tester to force air into the radiator
Cap tester: 5–8840–0277–0
through the filler neck at the specified pressure of 196 kPa
Adapter: 5–8840–2603–0
(28.5 psi) with a cap tester:
Check the condition of the vacuum valve in the center of
the valve seat side of the cap. If considerable rust or dirt is Leakage from the radiator
found, or if the valve seat cannot be moved by hand, clean Leakage from the coolant pump
or replace the cap. Leakage from the water hoses
Check the rubber hoses for swelling.
ENGINE COOLING 6B–11
Cap tester: 5–8840–0277–0 8. Connect battery ground cable.
Adapter: 5–8840–2603–0 9. Pour engine coolant up to filler neck of radiator, and
up to MAX mark of reserve tank.

110RS005

111RS001

Installation Important operation (in case of 100% engine coolant


change) procedure for filling with engine coolant.
1. Install rubber cushions on both sides of radiator
1. Make sure that the engine is cool.
bottom.
2. Install radiator assembly with hose, taking care not to 2. Open radiator cap pour coolant up to filler neck.
damage the radiator core with a fan blade. 3. Pour coolant into reservoir tank up to “MAX” line.
3. Install bracket (6) and support the radiator upper tank 4. Tighten radiator cap and start the engine. After
with the bracket (5) and secure the radiator. idling for 2 to 3 minutes, stop the engine and
4. Connect reserve tank hose (4). reopen radiator cap. If the water level is lower,
5. Install lower fan guide (3). replenish.
6. Connect radiator inlet hose and outlet hose to the WARNING: WHEN THE COOLANT IS HEATED TO A
engine. HIGH TEMPERATURE, BE SURE NOT TO LOOSEN
7. Connect oil cooler hose (1) to automatic OR REMOVE THE RADIATOR CAP. OTHERWISE YOU
transmission. MIGHT GET SCALDED BY HOT VAPOR OR BOILING
WATER. TO OPEN THE RADIATOR CAP, PUT A
PIECE OF THICK CLOTH ON THE CAP AND LOOSEN
THE CAP SLOWLY TO REDUCE THE PRESSURE
WHEN THE COOLANT HAS BECOME COOLER.
5. After tightening radiator cap, warm up the engine
at about 2000 rpm. Set heater adjustment to the
highest temperature position, and let the coolant
circulate also into heater water system.
6. Check to see the thermostat has opened through
the needle position of water thermometer,
conduct a 5–minute idling again and stop the
engine.
7. When the engine has been cooled, check filler
neck for water level and replenish if required.
Should extreme shortage of coolant is found,
check the cooling system and reservoir tank hose
for leakage.
8. Pour coolant into reservoir tank up tp “MAX” line.
110RW004
6B–12 ENGINE COOLING

Drive Belt and Cooling Fan


Drive Belt and Associated Parts

015RW005

Legend (4) Water Pump and Cooling Fan Pulley


(1) Crankshaft Pulley (5) Idle Pulley
(2) Generator (6) Tension Pulley
(3) Power Steering Pump (7) Drive Belt

The drive belt adjustment is not required as automatic


drive belt tensioner is equipped.

Inspection
Check drive belt for wear or damage, and replace with a
new one as necessary.

Installation
Install cooling fan assembly and tighten bolts/nuts to the
specified torque.
Torque : 22 Nꞏm (2.2 Kgꞏm/16 lb ft) for fan pulley
and fan bracket.
Torque : 10 Nꞏm (1.0 Kgꞏm/88.5 lb in) for fan and
clutch assembly.
NOTE: Fan belts for 6VE1 Gasoline Engine mounted on
98MY (UX) have been brought into one. As a result, the
rotating direction of a fan belt is opposite to the direction
of cooling fan for 92 to 97MY 6VD1 with no
interchangeability.
Therefore, incorrect installation of a fan may cause the air
for cooling to flow in the opposite direction, this resulting
in the poor performance of the air-conditioner and a rise
temperature in engine cooling water.
ENGINE COOLING 6B–13

Main Data and Specifications


General Specifications
M/T A/T
Cooling system Engine coolant forced circulation
Radiator (1 tube in row) Tube type corrugated (2 tube in row)
Heat radiation capacity 68,000 kcal/h 77,000 kcal/h
Heat radiation area 9.445m (0.878ft ) 11.21m (1.04ft )
Radiator front area 0.302m (0.028ft )
Radiator dry weight 39N (8.8lb) 44N (9.9lb)
Radiator cap valve opening pressure 93.3 122.7kpa (13.5 17.8psi)
Engine coolant capacity 2.5lit (2.6U.S q.t.) 2.4lit (2.5U.S q.t.)
Engine coolant pump Centrifugal impeller type
Delivery 300 (317) or more
Pump speed 5000 50 rpm
Thermostat Wax pellet type with air hole
Valve opening temperature 74.5 78.5 C (166.1 173.3 F)
Engine coolant total capacity 10.4lit (11.0U.S qt) 10.5lit (11.1U.S qt)

Torque Specifications
Nꞏm (Kgꞏm/lb ft)

E06RW041
6B–14 ENGINE COOLING

Special Tool
TOOL NO.
ILLUSTRATION
TOOL NAME

5–8840–0277–0
(J–24460–01)
Tester; radiator cap

5–8840–2603–0
(J–33984–A)
Adapter; radiator cap
ENGINE FUEL 6C–1

ENGINE
ENGINE FUEL
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 6C–1 Fuel Tank and Associated Parts . . . . . . . . . 6C–7
General Description . . . . . . . . . . . . . . . . . . . . . 6C–2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–7
Fuel Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–8
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–4 Fuel Tube / Quick – Connect Fittings . . . . . . . 6C–8
Fuel Filter and Associated Parts . . . . . . . . . 6C–4 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–4 Cautions During Work . . . . . . . . . . . . . . . . . . 6C–8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–5 Reuse of Quick–Connector . . . . . . . . . . . . . . . 6C–10
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–5 Assembling Advice . . . . . . . . . . . . . . . . . . . . . . 6C–10
In–Tank Fuel Filter . . . . . . . . . . . . . . . . . . . . . 6C–5 Fuel Gauge Unit . . . . . . . . . . . . . . . . . . . . . . . . 6C–11
Fuel Pump Flow Test . . . . . . . . . . . . . . . . . . . 6C–5 Fuel Gauge Unit and Associated Parts . . . 6C–11
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–11
Fuel Pump and Associated Parts . . . . . . . . 6C–6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–6 Fuel Filler Cap . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–6 General Description . . . . . . . . . . . . . . . . . . . . . 6C–12
Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . . . 6C–7 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–12
General Description . . . . . . . . . . . . . . . . . . . . . 6C–7 Main Data and Specifications . . . . . . . . . . . . . 6C–12
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–7

Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
6C–2 ENGINE FUEL

General Description

140RW030

Legend (8) Fuel Rail Left


(1) Fuel Filler Cap (9) Left Bank
(2) Fuel Tank (10) Fuel Pressure Control Valve
(3) Rollover Valve (11) Common Chamber
(4) Fuel Pump (12) Duty Solenoid Valve
(5) Fuel Filter (13) Throttle Valve
(6) Fuel Rail Right (14) Canister
(7) Right Bank

When working on the fuel system, there are several Replace all pipes with the same pipe and fittings that
things to keep in mind: were removed.
Any time the fuel system is being worked on, Clean and inspect “O” rings. Replace if required.
disconnect the negative battery cable except for Always relieve the line pressure before servicing any
those tests where battery voltage is required. fuel system components.
Always keep a dry chemical (Class B) fire Do not attempt repairs on the fuel system until you
extinguisher near the work area. have read the instructions and checked the pictures
relating to that repair.
ENGINE FUEL 6C–3
Adhere to all Notices and Cautions.
All gasoline engines are designed to use only unleaded
gasoline. Unleaded gasoline must be used for proper
emission control system operation.
Its use will also minimize spark plug fouling and extend
engine oil life. Using leaded gasoline can damage the
emission control system and could result in loss of
emission warranty coverage.
All cars are equipped with an Evaporative Emission
Control System. The purpose of the system is to minimize
the escape of fuel vapors to the atmosphere.

Fuel Metering
The Engine Control Module (ECM) is in complete control
of this fuel delivery system during normal driving
conditions.
The intake manifold function, like that of a diesel, is used
only to let air into the engine. The fuel is injected by
separate injectors that are mounted over the intake
manifold.
The Manifold Absolute Pressure (MAP) sensor measures
the changes in the intake manifold pressure which result
from engine load and speed changes, which the MAP
sensor converts to a voltage output.
This sensor generates the voltage to change
corresponding to the flow of the air drawn into the engine.
The changing voltage is transformed into an electric
signal and provided to the ECM.
With receipt of the signals sent from the MAP sensor,
Intake Air Temperature sensor and others, the ECM
determines an appropriate fuel injection pulse width
feeding such information to the fuel injector valves to
effect an appropriate air/fuel ratio.
The Multiport Fuel Injection system utilizes an injection
system where the injectors turn on at every crankshaft
revolution. The ECM controls the injector on time so that
the correct amount of fuel is metered depending on
driving conditions.
Two interchangeable “O” rings are used on the injector
that must be replaced when the injectors are removed.
The fuel rail is attached to the top of the intake manifold
and supplies fuel to all the injectors.
Fuel is recirculated through the rail continually while the
engine is running. This removes air and vapors from the
fuel as well as keeping the fuel cool during hot weather
operation.
The fuel pressure control valve that is mounted on the fuel
rail maintains a pressure differential across the injectors
under all operating conditions. It is accomplished by
controlling the amount of fuel that is recirculated back to
the fuel tank based on engine demand.
See Section “Driveability and Emission” for more
information and diagnosis.
6C–4 ENGINE FUEL

Fuel Filter
Fuel Filter and Associated Parts

041RW014

Legend (3) Fuel Filter Fixing Bolt


(1) Fuel Filler Cap (4) Fuel Filter
(2) Fuel Hose

Removal Inspection
CAUTION: When repair to the fuel system has been 1. Replace the fuel filter if the fuel leaks from fuel filter
completed, start engine and check the fuel system body or if the fuel filter body itself is damaged.
for loose connection or leakage. For the fuel system 2. Replace the filter if it is clogged with dirt or sediment.
diagnosis, see Section “Driveability and Emission”. 3. Check the drain of receive rubber and if it is clogged
1. Disconnect battery ground cable. with dust, clean it up with air.
2. Remove Fuel filler cap(1).
3. Disconnect fuel hoses(2) from fuel filter on both
engine side and fuel tank side.
4. Fuel filter fixing bolt(3).
Remove the fuel filter fixing bolt(3) on fuel filter
holder.
5. Remove fuel filter(4).
ENGINE FUEL 6C–5

Installation 4. Connect the pump relay terminals with a jumper


wire(1) as shown and start the fuel pump to measure
1. Install the fuel filter in the proper direction. delivery.
2. Install fuel filter holder fixing bolt.
3. Connect fuel hoses on engine side(1) and fuel tank
side(2).

140RW002

CAUTION: Never generate sparks when connecting


a jumper wire.
041RW001

4. Install fuel filler cap Delivery Delivery


5. Connect the battery ground cable. 15 seconds 0.38 liters minimum

If the measure value is out of standard, conduct the


Inspection pressure test.
After installation, start engine and check for fuel leakage.
Pressure test
For the pressure test to the fuel system, see Section 6E
In–Tank Fuel Filter “Fuel Control System”.
The filter is located on the lower end of fuel pickup tube in
the fuel tank. It prevents dirt from entering the fuel pipe
and also stops water unless the filter is completely
submerged in the water. It is a self cleaning type, not
requiring scheduled maintenance. Excess water and
sediment in the tank restricts fuel supply to the engine,
resulting in engine stoppage. In such a case, the tank
must be cleaned thoroughly.

Fuel Pump Flow Test


If reduction of fuel supply is suspected, perform the
following checks:
1. Make sure that there is fuel in the tank.
2. With the engine running, check the fuel feed pipe and
hose from fuel tank to injector for evidence of
leakage. Retighten, if pipe or hose connection is
loose. Also, check pipes and hoses for squashing or
clogging.
3. Insert the hose from fuel feed pipe into a clean
container, and check for fuel pump flow rate.
6C–6 ENGINE FUEL

Fuel Pump
Fuel Pump and Associated Parts

035RW047

Removal Installation
CAUTION: When repair to the fuel system has been 1. Install FP assembly(2).
completed, start engine and check the fuel system 2. Install fuel tank assembly(1). Refer to “Fuel Tank
for loose connection or leakage. For the fuel system Installation”.
diagnosis, see Section “Driveability and Emission”. 3. Fill the tank with fuel and tighten fuel filler cap.
1. Disconnect battery ground cable. 4. Connect battery ground cable.
2. Loosen fuel filler cap.
3. Drain fuel.
Tighten drain plug to the specified torque after
draining fuel.
Torque: 20 Nꞏm (2.0 Kgꞏm/14 lb ft) — M8
4. Remove fuel tank assembly(1). Refer to “Fuel Tank
Removal” in this section.
5. Remove fuel pump (FP) assembly(2) fixing screws
and remove the FP assembly.
NOTE: After removing FP, cover fuel tank to prevent any
dust entering.
ENGINE FUEL 6C–7

Fuel Pump Relay


General Description When it is turned to “START” position, the Power Train
Control Module (PCM) receives the reference pulse from
In order to control the FP operation, the FP relay is the Ignition Control Module and it operates the relay,
provided. When the starter switch is turned to “ON” again causing the FP to feed fuel.
position, the FP relay operates the FP for 2 seconds.

Fuel Tank
Fuel Tank and Associated Parts

035RW048

Legend (4) Fuel Tank Wiring Connector


(1) Fender Liner (5) Evapo Fuel Hose
(2) Fuel Filler Hose and Air Breather Hose and (6) Fuel Feed Tube and Fuel Return
Evapo Hose Tube/Quick–Connect Fittings
(3) Undercover (7) Fuel Tank

Removal 3. Drain fuel.


Tighten drain plug to the specified torque after
CAUTION: When repair to the fuel system has been draining fuel.
completed, start engine and check the fuel system
for loose connection or leakage. For the fuel system Torque: 20 Nꞏm (2.0 Kgꞏm/14 lb ft) — M8
diagnosis, see Section “Driveability and Emission”. 4. Remove fender liner (1) of wheel well on rear right
1. Disconnect battery ground cable. side.
2. Loosen fuel filler cap. 5. Fuel filler hose, air breather hose and evapo hose (2).
6. Remove undercover fixing bolts on both sides and
remove under cover(3).
6C–8 ENGINE FUEL
7. Disconnect two fuel tank wiring connectors(4) on Install a flange on left side on the bracket from the
front right side of tank. bottom, and tighten bolts to the specified torque.
8. Disconnect evapo fuel hose(5). Torque: 36 Nꞏm (3.7 Kgꞏm/27 lb ft)
9. Disconnect fuel feed tube and fuel return tube(6). 2. Connect fuel feed tube and fuel return tube(6).
NOTE: Handling of the fuel tube, be sure to refer “Fuel 3. Connect evapo fuel hose(5).
Tube/Quick–Connect Fittings” in this section. 4. Connect fuel tank wiring connector(4).
10. Remove fuel tank fixing bolts on both sides and 5. Install undercover(3).
remove fuel tank(7). 6. Connect fuel filler hose, air breather hose and evapo
hose(2).
Installation 7. Install fender liner(1).
1. Install fuel tank(7). Mount fender liner to the wheel well.
Place a flange on right side of tank on the bracket. Fill the tank with fuel and tighten fuel filler cap.
Connect battery ground cable.

Fuel Tube / Quick – Connect Fittings


Precautions
Lighting of Fires Prohibited.
Keep flames away from your work area to prevent the
inflammable from catching fire.
Disconnect the battery negative cable to prevent
shorting during work.
When welding or conducting other heat-generating
work on other parts, be sure to provide pretreatment
to protect the piping system from thermal damage or
spattering.
Cautions During Work
Do not expose the assembly to battery electrolyte or do
not wipe the assembly with a cloth used to wipe off spilt
battery electorolyte.
The piping wet with battery electrolyte cannot be used.
Be careful not to give a bending or twisting force to the
piping during the work. If deformed, replace with a new
piping. 141RW016

As some pressure may remain in the piping, cover the


connector with a cloth, etc. to prevent the splashing
Removal of fuel in the first disconnection of the piping.
1. Open the fuel cap to relieve the fuel pressure in the
tank.
If the fuel quick-connect fittings are dusty, clean with
an air blower, etc. and then remove it.
ENGINE FUEL 6C–9
2. For removal of the delivery pipe (feeding fuel to the NOTE: This work should be done by hands. Do not use
engine), hold the connector in one hand, and hold the any tools. Should the pipe can hardly be removed from
retainer tab with the other hand and pull out the the connector, use a lubricant (light oil) and/or push and
connector, as illustrated. The pipe can be removed pull the connector longitudinally until the pipe is removed.
with the retainer attached.

141RW021

141RW019 When reusing the delivery pipe retainer, reuse


3. For removal of the return pipe (returning fuel to the without removing the retainer from the pipe. If the
tank), hold the pipe in one hand, and pull out the retainer is damaged or deformed, however, replace
connentor with the other hand while pressing the with a new retainer.
square relieve button of the retainer, as illustrated. Cover the connectors removed with a plastic bag, etc.
to prevent the entry of dust or rain water.

141RW020

141RW022
6C–10 ENGINE FUEL

Reuse of Quick–Connector
(Delivery Pipe)
Replace the pipe and connector if scratch, dent or
crack is found.
Remove mud and dust from the pipe and make sure
that the end including spool is free of defects, such as
scratch, rust, and dent, which may cause poor
sealability. If defective, replace with a new pipe.
If the retainer removed according to the removal step
above is attached to the pipe, clean and insert it
straight into the quick-connector till it clicks. After it
clicks, try pulling it out to make sure that it is not drawn
and is securely locked.
NOTE: The retainer, once removed from the pipe, cannot
be reused. Just replace with a new retainer. Insert the
new retainer into the connector side until it clicks, and
connect the pipe as inserting it into the retainer until it
clicks. 141RW017

Assembling Advice
Application of engine oil or light oil to the pipe facilitates
connecting work. The work should be started immediately
after lubrication, since dust may stick to the pipe surface
to cause poor sealability if a long time passes after
lubrication.
Test/Inspection After Assembling
1. Reconnect the battery negative cable.
2. Turn the ignition key to the “ON” position and check
pump startup sound. As the pump is actuated to raise
fuel pressure, check and see fuel leak from the piping
system.
3. Make sure of no fuel leakage by conducting the above
fuel leak check a few times.
4. Start the engine and make sure of stable idling speed
and normal vehicle run.The entry of dust during the
work may sometimes affect the fuel injection system.
141RW018

(Return Pipe)
Replace the pipe and connector if scratch, dent or
crack is found.
Remove mud or dust from the pipe and make sure
that the end including spool is free from defects, such
as scratch, rust, and dent, which may cause poor
sealability. If defective, replace with a new pipe.
After cleaning the pipe, insert it straight into the
connector until it clicks. After it clicks, try pulling it out
to make sure that it is not drawn and is securely
locked.
ENGINE FUEL 6C–11

Fuel Gauge Unit


Fuel Gauge Unit and Associated Parts

140RS004

Legend
(1) Wiring Connector
(2) Fuel Gauge Unit

Removal
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system
for loose connection or leakage. For the fuel system
diagnosis, see Section “Driveability and Emission”.
1. Disconnect battery ground cable.
2. Loosen fuel filler cap.
3. Drain fuel.
Tighten drain plug to the specified torque after
draining fuel.
Torque: 20 Nꞏm (2.0 Kgꞏm/14 lb ft) — M8
4. Wiring connector
Disconnect wiring connector(1) from the unit.
5. Fuel gauge unit
Remove the fixing screws, then the fuel gauge
unit(2).
NOTE: After removing fuel gauge unit, cover fuel tank to
prevent any dust entering

Installation
1. Fuel gauge unit(2).
2. Wiring connector(1).
Connect the wiring connector to the fuel gauge unit.
Fill the tank with fuel and tighten fuel filler cap.
Connect battery ground cable.
6C–12 ENGINE FUEL

Fuel Filler Cap


General Description Legend
(1) Vacuum Valve
Fuel filler cap includes vacuum valve and pressure valve.
(2) Pressure Valve
In case any high vacuum and any high pressure happen in
tank, each valve works to adjust the pressure to prevent
the tank from being damaged.
Inspection
Check the seal ring in the filler cap for presence of any
abnormality and for seal condition.
Replace the filler cap, if abnormal.
CAUTION: The fuel filler cap valves have
characteristics.
A defective valve, no valve at all or a valve with the
wrong characteristics will do a lot of harm to engine
operating characteristics; be sure to use the same
fuel filler cap as installed in this vehicle.

140RW021

Main Data and Specifications


Torque Specification
Nꞏm (Kgꞏm/lb ft)

035RW141
ENGINE ELECTRICAL 6D1–1

ENGINE
ENGINE ELECTRICAL
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 6D1–1 Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . 6D1–3
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D1–2 Battery Removal . . . . . . . . . . . . . . . . . . . . . . 6D1–4
General Description . . . . . . . . . . . . . . . . . . . . 6D1–2 Battery Installation . . . . . . . . . . . . . . . . . . . . . 6D1–4
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D1–2 Main Data and Specifications . . . . . . . . . . . 6D1–5
Battery Charging . . . . . . . . . . . . . . . . . . . . . . 6D1–3

Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
6D1–2 ENGINE ELECTRICAL

Battery
General Description 3. Fluid Level Check
There are six battery fluid caps on top of the battery. The fluid level should be between the upper level line(2)
These are covered by a paper label. and lower level line(3) on side of battery.
The battery is completely sealed except for the six small a. CORRECT FLUID LEVEL – Charge the battery.
vent holes on the side. These vent holes permit the b. BELOW LOWER LEVEL – Replace battery.
escape of small amounts of gas generated by the battery.
This type of battery has the following advantages over
conventional batteries:
1. There is no need to add water during the entire
service life of the battery.
2. The battery protects itself against overcharging.
The battery will refuse to accept an extensive charge.
(A conventional battery will accept an excessive
charge, resulting in gassing and loss of battery fluid.)
3. The battery is much less vulnerable to self discharge
than a conventional type battery.
Diagnosis
1. Visual Inspection
Inspect the battery for obvious physical damage, such as
a cracked or broken case, which would permit electrolyte
loss.
Replace the battery if obvious physical damage is
discovered during inspection. 061RW001

Check for any other physical damage and correct it as


4. Voltage Check
necessary.
1. Put voltmeter test leads to battery terminals.
2. Hydrometer Check a. VOLTAGE IS 12.4V OR ABOVE – Go to Step 5.
There is a built–in hydrometer (Charge test indicator(1)) b. VOLTAGE IS UNDER 12.4V – Go to procedure (2)
at the top of the battery. It is designed to be used during below.
diagnostic procedures. 2. Determine fast charge amperage from specification.
Before trying to read the hydrometer, carefully clean the (See Main Data and Specifications in this section).
upper battery surface.
Fast charge battery for 30 minutes at amperage rate
If your work area is poorly lit, additional light may be no higher than specified value.
necessary to read the hydrometer.
Take voltage and amperage readings after charge.
a. BLUE RING OR DOT VISIBLE(5) – Go to Step 4.
b. BLUE RING OR DOT NOT VISIBLE(4) – Go to Step a. VOLTAGE IS ABOVE 16V AT BELOW 1/3 OF
3. AMPERAGE RATE – Replace battery.
b. VOLTAGE IS ABOVE 16V AT ABOVE 1/3 OF
AMPERAGE RATE – Drop charging voltage to
15V and charge for 10 – 15 hours. Then go to Step
5.
c. VOLTAGE IS BETWEEN 12V AND 16V –
Continue charging at the same rate for an
additional 3–1/2 hours. Then go to Step 5.
d. VOLTAGE BELOW 12V – Replace Battery.

5. Load Test
1. Connect a voltmeter and a battery load tester across
the battery terminals.
2. Apply 300 ampere load for 15 seconds to remove
surface charge from the battery. Remove load.
3. Wait 15 seconds to let battery recover. Then apply
specified load from specifications (See Main Data
and Specifications in this section).
Read voltage after 15 seconds, then remove load.
061RW001
ENGINE ELECTRICAL 6D1–3
a. VOLTAGE DOES NOT DROP BELOW THE Treat both the discharged battery and the booster
MINIMUM LISTED IN THE TABLE – The battery is battery with great care when using jumper cables.
good and should be returned to service. Carefully follow the jump starting procedure, being
b. VOLTAGE IS LESS THAN MINIMUM LISTED – careful at all times to avoid sparking.
Replace battery. WARNING: FAILURE TO CAREFULLY FOLLOW THE
JUMP STARTING PROCEDURE COULD RESULT IN
ESTIMATED TEMPERATURE MINIMUM
THE FOLLOWING:
VOLTAGE
1. Serious personal injury, particularly to your eyes.
F C V
2. Property damage from a battery explosion, battery
70 21 9.6 acid, or an electrical fire.
60 16 9.5 3. Damage to the electronic components of one or both
50 10 9.4 vehicles particularly.
Never expose the battery to an open flame or electrical
40 4 9.3 spark. Gas generated by the battery may catch fire or
30 –1 9.1 explode.
Remove any rings, watches, or other jewelry before
20 –7 8.9 working around the battery. Protect your eyes by wearing
10 –12 8.7 an approved set of goggles.
Never allow battery fluid to come in contact with your eyes
0 –18 8.5
or skin.
The battery temperature must be estimated by feel Never allow battery fluid to come in contact with fabrics or
and by the temperature the battery has been painted surfaces.
exposed to for the preceding few hours. Battery fluid is a highly corrosive acid.
Should battery fluid come in contact with your eyes, skin,
fabric, or a painted surface, immediately and thoroughly
rinse the affected area with clean tap water.
Battery Charging Never allow metal tools or jumper cables to come in
Observe the following safety precautions when charging contact with the positive battery terminal, or any other
the battery: metal surface of the vehicle. This will protect against a
1. Never attempt to charge the battery when the fluid short circuit.
level is below the lower level line on the side of the Always keep batteries out of reach of young children.
battery. In this case, the battery must be replaced.
2. Pay close attention to the battery during charging Jump Starting Procedure
procedure. 1. Set the vehicle parking brake.
Battery charging should be discontinued or the rate of If the vehicle is equipped with an automatic
charge reduced if the battery feels hot to the touch. transmission, place the selector level in the “PARK”
Battery charging should be discontinued or the rate of position.
charge reduced if the battery begins to gas or spew If the vehicle is equipped with a manual transmission,
electrolyte from the vent holes. place the shift lever in the “NEUTRAL” position.
3. In order to more easily view the hydrometer blue dot Turn “OFF” the ignition.
or ring, it may be necessary to jiggle or tilt the battery.
Turn “OFF” all lights and any other accessory
4. Battery temperature can have a great effect on requiring electrical power.
battery charging capacity.
2. Look at the built–in hydrometer.
5. The sealed battery used on this vehicle may be either
If the indication area of the built–in hydrometer is
quick charged or slow charged in the same manner as
completely clear, do not try to jump start.
other batteries.
Whichever method you decide to use, be sure that 3. Attach the end of one jumper cable to the positive
you completely charge the battery. Never partially terminal of the booster battery.
charge the battery. Attach the other end of the same cable to the positive
terminal of the discharged battery.
Do not allow the vehicles to touch each other. This will
Jump Starting cause a ground connection, effectively neutralizing
Jump Starting with an Auxiliary (Booster) the charging procedure.
Battery Be sure that the booster battery has a 12 volt rating.

CAUTION: Never push or tow the vehicle in an


attempt to start it. Serious damage to the emission
system as well as other vehicle parts will result.
6D1–4 ENGINE ELECTRICAL
4. Attach one end of the remaining cable to the negative
terminal of the booster battery.
Attach the other end of the same cable to a solid
engine ground (such as the air conditioning
compressor bracket or the generator mounting
bracket) of the vehicle with the discharged battery.
The ground connection must be at least 450 mm (18
in.) from the battery of the vehicle whose battery is
being charged.
WARNING: NEVER ATTACH THE END OF THE
JUMPER CABLE DIRECTLY TO THE NEGATIVE
TERMINAL OF THE DEAD BATTERY.
5. Start the engine of the vehicle with the good battery.
Make sure that all unnecessary electrical accessories
have been turned “OFF”.
6. Start the engine of the vehicle with the dead battery.
7. To remove the jumper cables, follow the above
directions in reverse order.
Be sure to first disconnect the negative cable from the
vehicle with the discharged battery.

Battery Removal

061RS002

1. Remove negative cable (1).


2. Remove positive cable (2).
3. Remove retainer screw and rods (3).
4. Remove retainer (4).
5. Remove battery (5).

Battery Installation
1. Install battery (5).
2. Install retainer (4).
3. Instal retainer screw and rods (3).
NOTE: Make sure that the rod is hooked on the body
side.
4. Install positive cable (2).
5. Install negative cable (1).
ENGINE ELECTRICAL 6D1–5

Main Data and Specifications


General Specifications
Model (JIS) 95D31R–MF 80D26R–MF 75D26R–MF
Voltage (V) 12 12 12
Cold Cranking Performance (Amp) 622 582 490
Reserve Capacity (Min) 159 133 123
Load Test (Amp) 310 290 245
Fast Charge Maximum Amperage (Amp) 20 20 20
BCI Group No. 27 24 24
6D1–6 ENGINE ELECTRICAL

MEMO
IGNITION SYSTEM 6D2–1

ENGINE
IGNITION SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 6D2–1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D2–4
General Description . . . . . . . . . . . . . . . . . . . . . 6D2–2 Inspection and Repair . . . . . . . . . . . . . . . . . . 6D2–4
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D2–2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D2–4
Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D2–3 Crankshaft Angle Sensor . . . . . . . . . . . . . . . . . 6D2–5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D2–3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D2–5
Inspection and Repair . . . . . . . . . . . . . . . . . . 6D2–3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D2–5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D2–3 Main Data and Specifications . . . . . . . . . . . . . 6D2–6
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D2–4

Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
6D2–2 IGNITION SYSTEM

General Description
Ignition is done by the electronic ignition (El) that directly The ignition coils are connected with the PCM by means
fires the spark plugs from ignition coils through spark plug of a 32 pin connector.
wires without using a distributor. A pair of ignition coils for The ignition control module turns on/off the primary circuit
the cylinders having different phases by 360 (No.1 and of ignition coils, and also it controls the ignition timing at
No.4,No.2 and No.5,No.3 and No.6) are fired the engine speed below 538 rpm.
simultaneously. A notch in the timing disc on the crankshaft activates the
Since the cylinder on exhaust stroke requires less energy crank angle sensor which then sends information such as
to fire its ignition plug, energy from the ignition coils can be firing order and starting timing of each ignition coil to the
utilized to fire the mating cylinder on compression stroke. PCM.
After additional 360 rotation, respective cylinder strokes Further, the El employs ignition control (IC) to control
are reversed. similar to a distributor system.
The EI consists of six ignition coils,ignition control By receiving signals such as crank position,engine
module, crank angle sensor, powertrain control module speed, water temperature and Manifold Absolute
(PCM) and other components. Pressure (MAP), the PCM controls the ignition timing.

D06RW084

Diagnosis
Refer to Section Drivability and Emissions for the
diagnosis to electronic ignition system (El system).
IGNITION SYSTEM 6D2–3

Ignition Coil
Removal
1. Disconnect battery ground cable.
2. Ignition coil connector and ignition coil.
Disconnect three connector from ignition coil.
Remove harness bracket bolt on cylinder head
cover.
Remove fixing bolts on ignition coil.

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Installation
1. Install the ignition coil assembly (3).
Connect ignition coil connector (1) and ignition coil
(3), then tighten bolt (2) to the specified torque.
Torque: 4 Nꞏm (0.4 Kgꞏm/35 lb in)

060RW121

Legend
(1) Ignition Coil Connector
(2) Bolt
(3) Ignition Coil Assembly

Inspection and Repair


Check the ignition coil assembly for insulation. Check
terminals for corrosion or damage, and replace as
necessary.
Measuring resistance of ignition coil assembly.
Terminal No. Limit
1 to 2 Without 0 ohm or infinity
maximum ohm.
1 to 3 Same as above
060RW121

2 to 3 Same as above 2. Connect battery ground cable.

Measure resistance of ignition coil assembly, and replace


the ignition coil assembly if its value exceeds the
standard.
6D2–4 IGNITION SYSTEM

Spark Plug
Removal
1. Remove spark plugs.

Inspection and Repair


The spark plug affects entire engine performance and
therefore its inspection is very important.
Check electrode and insulator for presence of cracks,
and replace if any.
Check electrode for wear, and replace if necessary.
Check gasket for damage, and replace if necessary.
Measure insulation resistance with an ohmmeter, and
replace if faulty.
Adjust spark plug gap to 1.0 mm (0.04 in) 1.1 mm
(0.043 in).
Check fuel and electrical systems if spark plug is
extremely dirty.
Use spark plugs having low heat value (hot type plug) 011RS010

if fuel and electrical systems are normal.


Use spark plugs having high heat value (cold type
Cleaning Spark Plugs
plug) if insulator and electrode are extremely burned. Clean spark plugs with a spark plug cleaner.
Sooty Spark Plugs Raise the ground electrode to an angle of 45 to 60
degrees. If electrode is wet, dry it before cleaning.
Much deposit of carbon or oil on the electrode and
insulator of spark plug reduces the engine performance. After spark plug is thoroughly cleaned, check
insulator for presence of cracks.
Possible causes:
Clean threads and metal body with a wire brush.
Too rich mixture File the electrode tip if electrode is extremely worn.
Presence of oil in combustion chamber Bend the ground electrode to adjust the spark plug
Incorrectly adjusted spark plug gap gap.

Burning Electrodes
This fault is characterized by scorched or heavily oxidized
electrode or blistered insulator nose.
Possible causes:
Too lean mixture
Improper heat value

Measuring Insulation Resistance


Measure insulation resistance using a 500 volt
megaohm meter.
Replace spark plugs if measured value is out of
standard.
Insulation resistance: 50 M or more

011RS011

Installation
1. Spark plugs
Tighten spark plugs to the specified torque.
Torque: 18 Nꞏm (1.8 Kgꞏm/13 lb ft)
IGNITION SYSTEM 6D2–5

Crankshaft Angle Sensor


Removal
1. Disconnect battery ground cable
2. Wiring connector from crankshaft angle sensor.
3. Remove crankshaft angle sensor from cylinder block.

012RS008

Installation
1. Install crankshaft angle sensor into the cylinder block.
Before installation,apply small amount of engine oil to
the O–ring.
Torque: 10 Nꞏm (1.0 Kgꞏm/89 lb in)
2. Reconnect wiring connector to crankshaft angle
sensor.
6D2–6 IGNITION SYSTEM

Main Data and Specifications


General Specifications
Ignition System
Ignition Form Electronic Ignition System (El system) with Crankshaft angle Sensor
Spark Plug
Type K16PR–P11
RC10PYP4
PK16PR11
Plug gap 1.0 mm (0.04 in) – 1.1 mm (0.043 in)
Torque 18 Nꞏm (1.8 Kgꞏm/13 lb ft)

Torque Specifications
Nꞏm (Kgꞏm/lb ft)

E06RW038
STARTING AND CHARGING SYSTEM 6D3–1

ENGINE
STARTING AND CHARGING SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 6D3–1 General Description . . . . . . . . . . . . . . . . . . . . . 6D3–18
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . 6D3–2 General On–Vehicle Inspection . . . . . . . . . . . 6D3–18
General Description . . . . . . . . . . . . . . . . . . . . . 6D3–2 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3–19
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3–4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3–19
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3–5 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3–19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3–5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3–19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3–5 Disassembled View . . . . . . . . . . . . . . . . . . . . 6D3–20
Disassembled View . . . . . . . . . . . . . . . . . . . . 6D3–6 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3–21
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3–7 Inspection and Repair . . . . . . . . . . . . . . . . . . 6D3–23
Inspection and Repair . . . . . . . . . . . . . . . . . . 6D3–9 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3–24
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3–13 Bench Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3–25
Main Data and Specifications . . . . . . . . . . . 6D3–15 Main Data and Specifications . . . . . . . . . . . 6D3–26
Charging System . . . . . . . . . . . . . . . . . . . . . . . . 6D3–18

Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
6D3–2 STARTING AND CHARGING SYSTEM

Starting System

General Description
Cranking Circuit
The cranking system consists of a battery, starter, starter
switch, starter relay, etc. These main components are
connected.
Starter
The cranking system employs a magnetic type reduction
starter in which the motor shaft is also used as a pinion
shaft. When the starter switch is turned on, the contacts of
magnetic switch are closed, and the armature rotates. At
the same time, the plunger is attracted, and the pinion is
pushed forward by the shift lever to mesh with the ring
gear.
Then, the ring gear runs to start the engine. When the
engine starts and the starter switch is turned off, the
plunger returns, the pinion is disengaged from the ring
gear, and the armature stops rotation. When the engine
speed is higher than the pinion, the pinion idles, so that
the armature is not driven.
STARTING AND CHARGING SYSTEM 6D3–3

C06RW005
6D3–4 STARTING AND CHARGING SYSTEM

Diagnosis
Condition Possible cause Correction
Starter does not run Charging failure Repair charging system
Battery Failure Replace Battery
Terminal connection failure Repair or replace terminal connector
and/or wiring harness
Starter switch failure Repair or replace starter switch
Starter failure Repair or replace starter
STARTING AND CHARGING SYSTEM 6D3–5

Starter
Removal 2. Install mounting bolts and tighten bolts to specified
torque(5).
1. Battery ground cable.
Torque: 40 Nꞏm (4.1 Kgꞏm/30 lb ft)
2. Remove exhaust front left pipe(1).
3. Reconnect the connectors to terminals “B” and “S”
and tighten Terminals “B” to specified torque.
Torque: 9 Nꞏm (0.9 Kgꞏm/80 lb in)
4. Install heat protector(3).

150RW062

3. Remove heat protector(3).


4. Disconnect starter wiring connector from terminals
“B” and “S”(4).
5. Remove starter assembly mounting bolts on inside 065RW027

and outside(5). 5. Install exhaust front left pipe and tighten bolts and
6. Remove starter assembly toward the bottom of nuts to specified torque(2).
engine(6). Stud Nuts
Torque: 67 Nꞏm (6.8 Kgꞏm/49 lb ft)
Nuts
Torque: 43 Nꞏm (4.4 Kgꞏm/32 lb ft)

065RW027

Installation
1. Install starter assembly(6). 150RW062

6. Reconnect the battery ground cable.


6D3–6 STARTING AND CHARGING SYSTEM

Disassembled View

065RW002

Legend (14) Center Bracket


(1) Bolt (2 pcs) (15) Pinion Shaft
(2) Ball Bearing (16) Planet Gear (3)
(3) Pinion (17) Internal Gear
(4) Shift Lever (18) Center Bracket (A)
(5) Dust Cover (19) Yoke Assembly
(6) Torsion Spring (20) Armature
(7) Dust Cover (21) Brush
(8) Magnetic Switch (22) Brush Holder
(9) Nut (23) Thrust Washer
(10) Gear Case (24) Rear Cover
(11) Bearing Cover (25) Screw (2 pcs)
(12) E–Ring (26) Through Bolt (2 pcs)
(13) Thrust Washer (2)
STARTING AND CHARGING SYSTEM 6D3–7

Disassembly 9. Remove screws and through bolts, then the rear


cover(9) then remove thrust washer(10).
1. Loosen the nut(1) on terminal “M” of magnetic switch 10. Remove brush holder(6).
and disconnect the connector cable.
2. Remove bolt (2 pcs) (2).

065RW005

11. Raise a brush spring to detach brushes (4 pcs) from


065RW003 the commutator face and pull off the brush holder(12)
3. Remove magnetic switch(5). and brush(11).
4. Remove dust cover(4).
5. Remove torsion spring bolts, then the magnetic
switch assembly.
6. Remove torsion spring(3) from magnetic switch
assembly(5).

065RW006

12. Remove yoke assembly(14).


13. Remove armature(15).
14. Pull off the yoke assembly, then remove armature,
washer and center bracket.(A) (13).
065RW004

7. Remove screw (2 pcs) (8).


8. Remove through bolt (2 pcs) (7).
6D3–8 STARTING AND CHARGING SYSTEM
NOTE: In disassembling the yoke assembly, hold the 17. Remove ball bearing(19).
armature and pull off slowly the yoke assembly. Because 18. Remove bearing cover(20).
of strong magnetic force, avoid placing a metallic part
19. Remove a ball bearing and bearing cover from the
near armature.
gear case(18).

065RW007
065RW021
15. Remove dust cover(17). 20. Internal gear(21).
16. Remove a dust cover and shift lever(16) from the gear 21. Remove internal gear and planet gear(3) (22).
case.

065RW009
065RW008
STARTING AND CHARGING SYSTEM 6D3–9
22. Remove an E–ring(23) from the pinion shaft using a Inspection and Repair
flat blade screwdriver.
Repair or replace necessary parts if extreme wear or
damage is found during inspection.
Armature
Measure the outer diameter of commutator, and replace
with a new one if it is out of the limit.
Standard: 33.0 mm (1.30 in)
Limit: 32.0 mm (1.26 in)

065RW010

23. Holding the pinion shaft, push pinion toward the


center bracket. and turn the pinion clockwise or
counterclockwise by one tooth of spline, then pull off
the pinion.
24. Remove thrust washer(24).
25. Remove center bracket
26. Remove pinion shaft. 065RS014

Check for continuity between commutator and segment.


Replace commutator if there is no continuity (i.e.,
disconnected).

065RW011

065RS015
6D3–10 STARTING AND CHARGING SYSTEM
Check for continuity between commutator and shaft. Polish the commutator surface with sandpaper #500 to
Also, check for continuity between commutator and #600 if it is rough.
armature core,armature core and shaft. Replace
commutator if there is continuity (i.e., internally
grounded).

065RW012

Measure the depth of insulator in commutator. Repair, if it


is below the limit.
065RS016 Standard: 0.05 mm to 0.8 mm (0.02 in to 0.03 in)
Measure runout of armature core and commutator with a Limit: 0.2 mm (0.008 in)
dial gauge. Repair or replace, if it exceeds the limit.
Armature
Standard: 0.05 mm (0.002 in) Max.
Limit: 0.10 mm (0.004 in)
Commutator
Standard: 0.05 mm (0.002 in) Max.
Limit: 0.10 mm (0.004 in)

065RW013

Legend
(1) Steel Saw
(2) Insulator
(3) Commutator Segments

065RS017
STARTING AND CHARGING SYSTEM 6D3–11
Brush Magnetic Switch
Measure the length of brush. Check for continuity of shunt coil between terminals S and
Replace with a new one, if it is below the limit. M.
Standard: 16 mm (0.63 in) Replace, if there is no continuity (i.e., coil is
Limit: 11 mm (0.43 in) disconnected).

065RW016
065RW014

Brush Holder Continuity of Series Coil


Check for continuity between brush holder (+) (4) and Check for continuity between terminals S and M.
base (–). Replace, if there is continuity (i.e., insulation is Replace, if there is no continuity (i.e., coil is
broken). disconnected).

065RW017
065RW015
6D3–12 STARTING AND CHARGING SYSTEM
Continuity of Contacts Yoke Assembly
With the plunger faced downward, push down the Check a magnet inside the yoke.
magnetic switch. In this state, check for continuity Replace the yoke assembly if it is broken.
between terminals B and M. Replace, if there is no
continuity (i.e., contacts are faulty).

065RS026

065RW018
Ball Bearing
Clamp the inner race of the ball bearing with your finger,
Pinion and check for sticking or play when rotating the outer
Check if the pinion rotates smoothly in drive direction by race.
hand, or if it is locked when it is rotated in reverse. If not, Replace, if abnormality is found.
replace the pinion.

065RS027

065RS025
STARTING AND CHARGING SYSTEM 6D3–13
Measure inner diameter of bushing in the rear cover, and Reassembly
replace if it exceeds the limit.
To install, follow the removal steps in the reverse order,
Standard: 12.50 mm to 12.527 mm (0.492 in to noting the following points:
0.4932 in)
Grease application places
Limit: 12.60 mm (0.4961 in)
Bushing in rear cover and center bracket
Gears in reduction gear
Shift lever operating portion
Sliding portion of pinion
Plunger sliding portion of magnetic switch
Reassembling Yoke Assembly
Before reassembly, make sure that no metallic parts
attach to the yoke assembly. Because of strong magnetic
force, hold the yoke assembly and insert it slowly into the
armature.
Torque
Torque for each part (See Torque Specifications in
this section)

Pinion Jump–out Dimension


Connect the “+” cable of battery to terminal S and the “–”
cable to terminal M. Turn the switch on, and measure
065RS028
pinion travel dimension in thrust direction from the
Measure inner diameter of bushing in the center bracket jump–out position.
(P), and replace if it exceeds the limit. In measuring the dimension, pull the pinion out a little in
Standard: 18.01 mm to 18.127 mm (0.7091 in to the arrow direction.
0.7137 in) Dimension(L): 0.05 mm to 1.5 mm (0.002 in to
Limit: 18.15 mm (0.7146 in) 0.06 in)

065RS029 065RS030
6D3–14 STARTING AND CHARGING SYSTEM
If the measured value is out of standard, insert dust cover,
or disassemble and adjust.

065RW019

Characteristic Test
For easily confirming the characteristics, conduct the no
load test as follows:
Rating as short as 30 seconds requires rapid testing.
Fix the starter on the test bench, and wire as shown in
illustration. When the switch is closed, the current flows
and the starter runs under no load. At this time, measure
current, voltage and speed to check if they satisfy the
standard.

065RW020

Legend
(1) Volt Meter
(2) Tachometer
(3) Battery
(4) Ammeter
(5) Switch
STARTING AND CHARGING SYSTEM 6D3–15

Main Data and Specifications


General Specifications
Model HITACHI GD002350
Rating
Voltage 12 V
Output 1.4 Kw
Time 30 sec
Number of teeth of pinion 9
Rotating direction(as viewed from pinion) Clockwise
Weight(approx.) 34 N
No load characteristics
Voltage /Current 11V/90A or less
Speed 2700rpm or more
Load characteristics
Voltage/current 8.4V/250A
Torque 7.3Nꞏm(64lbꞏin.) or more
Speed 1200rpm or more
Locking characteristics
Voltage/current 3V/750A or less
Torque 19Nꞏm(14lbꞏin) or more
6D3–16 STARTING AND CHARGING SYSTEM
Torque Specifications
Nꞏm (Kgꞏm/lb ft)

E06RW044
STARTING AND CHARGING SYSTEM 6D3–17

Nꞏm (Kgꞏm/lb ft)

150RW100
6D3–18 STARTING AND CHARGING SYSTEM

Charging System
General Description General On–Vehicle Inspection
The IC integral regulator charging system and its main The operating condition of charging system is indicated
components are connected as shown in the illustration. by the charge warning lamp. The warning lamp comes on
The regulator is a solid state type and it is mounted along when the starter switch is turned to “ON” position. The
with the brush holder assembly inside the generator charging system operates normally if the lamp goes off
installed on the rear end cover. when the engine starts.
The generator does not require particular maintenance If the warning lamp shows abnormality or if undercharged
such as voltage adjustment. or overcharged battery condition is suspected, perform
The rectifier connected to the stator coil has eight diodes diagnosis by checking the charging system as follows:
to transform AC voltage into DC voltage. 1. Check visually the belt and wiring connector.
This DC voltage is connected to the output terminal of 2. With the engine stopped, turn the stator switch to
generator. “ON” position and observe the warning lamp.
If lamp does not come on:
Disconnect wiring connector from generator, and
ground the terminal “L” on connector side.
If lamp comes on:
Repair or replace the generator.

F06RW009
STARTING AND CHARGING SYSTEM 6D3–19

Generator
Removal
1. Disconnect battery ground cable.
2. Move drive belt tensioner to loose side using wrench
then remove drive belt (1).
3. Disconnect the wire from terminal “B” and disconnect
the connector (4).
4. Remove generator fixing bolt (3).
5. Remove generator assembly (2).

066RW001

If voltage is not present, the line between battery and


connector is disconnected and so requires repair.
3. Reconnect the wiring connector to the generator, run
the engine at middle speed, and turn off all electrical
devices other than engine.
4. Measure battery voltage. If it exceeds 16V, repair or
replace the generator.
5. Connect an ammeter to output terminal of generator,
and measure output current under load by turning on
the other electrical devices (eg., head lights). At this
060RW002

time, the voltage must not be less than 13V.


Inspection
1. Disconnect the wiring connector from generator. Installation
2. With the engine stopped, turn starter switch to “ON”
1. Install generator assembly to the position to be
and connect a voltmeter between connector terminal
installed.
L (2) and ground or between terminal IG (1) and
ground. 2. Install generator assembly and tighten the fixing bolts
to the specified torque.
Torque:
M10 bolt: 41 Nꞏm (4.2 Kgꞏm/30 lb ft)
M8 bolt: 21 Nꞏm (2.1 Kgꞏm/15 lb ft)
3. Connect wiring harness connector and direct terminal
“B”.
4. Move drive belt tensioner to loose side using wrench,
then install drive belt to normal position.
5. Reconnect battery ground cable.
6D3–20 STARTING AND CHARGING SYSTEM

Disassembled View

066RW007

Legend (6) Rectifier


(1) Pulley Nut (7) Terminal Insulator and Nut
(2) Pulley (8) Regulator Assembly
(3) Front Cover Assembly (9) Brush Holder Assembly
(4) Rotor Assembly (10) Rear Cover
(5) Rear End Cover
STARTING AND CHARGING SYSTEM 6D3–21

Disassembly 4. Remove three screws on the IC regulator, then the IC


regulator assembly(6).
1. Terminal insulator and nut(2).
2. Remove three nuts(1) on the rear cover and a nut on
terminal B and insulator, then remove the rear
cover(3).

060RW003

5. Remove four screws that fix rectifier(7) and stator


lead wires.

060RW005

3. Remove two screws that fix the brush holder(5) and


rectifier, then remove the brush holder assembly(4).

066RW004

060RW004
6D3–22 STARTING AND CHARGING SYSTEM
6. Secure the pulley directly in the vise between two 8. Use the puller to remove the rear end cover.
copper plates, and remove the nut and pulley. 9. Rotor assembly

066RS010
066RS012

7. Remove four nuts(8) that secure the front cover 10. Pull the rotor assembly(10) off the front cover
assembly and rear end cover, and an insulator(9). assembly(12) using a bench press(11).

066RW005
066RW006
STARTING AND CHARGING SYSTEM 6D3–23

Inspection and Repair 3. Check resistance between slip rings, and replace if
there is no continuity.
Repair or replace necessary parts if extreme wear or
damage is found during inspection.
Rotor Assembly
1. Check the rotor slip ring surfaces for contamination
and roughness. If rough, polish with #500—600
sandpaper.

066RS016

4. Check for continuity between slip ring and rotor core.


In case of continuity, replace the rotor assembly.

066RS014

2. Measure the slip ring diameter, and replace if it


exceeds the limit.

066RS017

066RS015
6D3–24 STARTING AND CHARGING SYSTEM
Stator Coil Rectifier Assembly
1. Measure resistance between respective phases. Check for continuity across “P” and “E” in the 100W
range of multimeter.
2. Measure insulation resistance between stator coil
and core with a mega–ohmmeter.
If less than standard, replace the coil.

066RW002

Change polarity, and make sure that there is continuity in


one direction, and not in the reverse direction. In case of
066RS018 continuity in both directions, replace the rectifier
assembly.
Brush
Measure the brush length. IC Regulator Assembly
If more than limit, replace the brush. Check for continuity across “B” and “F” in the 100W
Standard: 10.mm (0.4134 in) range of multimeter.
Limit: 8.4.mm (0.3307 in)

066RS021

Change polarity, and make sure that there is continuity in


066RS019
one direction, and not in the reverse direction. In case of
continuity in both directions, replace the IC regulator
assembly.

Reassembly
To reassemble, follow the disassembly steps in the
reverse order, noting the following points:
STARTING AND CHARGING SYSTEM 6D3–25
1. Using a press with a socket wrench attached, Bench Test
reassemble rotor and rear end cover assembly in the
front cover. Conduct a bench test of the generator.

066RS023
066RS022

2. Install pulley on the rotor. Preparation


Secure the pulley directly in the vise between two Remove generator from the vehicle (see “Generator
copper plates, and tighten nut to the specified torque. removal”).
Torque: 111 Nꞏm (11.3 Kgꞏm/82 lb ft) 1. Secure generator to the bench test equipment and
connect wires.
Terminal “IG” for energization
Terminal “L” for neutral (warning lamp)
Terminal “B” for output
2. Conduct the generator characteristic test.
Characteristics of generator are shown in illustration.
Repair or replace the generator if its outputs are
abnormal.

066RS010

B06RW001
6D3–26 STARTING AND CHARGING SYSTEM

Main Data and Specifications


General Specifications
Parts Number (Nippon denso) 102211—5030
Model ACHD04
Rated voltage 12 V
Rated output 75 A
Rotating direction (As viewed from pulley) Clockwise
Pulley effective diameter 50 mm (1.97 in)
Weight 44 N (33 lb)
ENGINE DRIVEABILITY AND EMISSIONS 6E–1

ENGINE
ENGINE DRIVEABILITY AND EMISSIONS
CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 6E–5 Engine Component Locator Table . . . . . . . . 6E–29
Tightening Specifications . . . . . . . . . . . . . . . 6E–5 Engine Component Locator Table . . . . . . . . 6E–31
Undercarriage Component Locator . . . . . . 6E–32
Vehicle Type Specifications . . . . . . . . . . . . . 6E–5
Undercarriage Component Locator Table
Diagrams and Schematics . . . . . . . . . . . . . . . . 6E–6 (Automatic Transmission) . . . . . . . . . . . . . . 6E–32
PCM Wiring Diagram (1 of 11) . . . . . . . . . . . 6E–6 Undercarriage Component Locator Table
PCM Wiring Diagram (2 of 11) For EC, (Manual Transmission) . . . . . . . . . . . . . . . . 6E–33
THAILAND, SOUTH EAST ASIA, LATIN Fuse and Relay Panel (Underhood
AMERICA, GULF, SAUDI, CHINA. . . . . . . 6E–7 Electrical Center) . . . . . . . . . . . . . . . . . . . . . 6E–33
PCM Wiring Diagram (3 of 11) For SOUTH Sensors and Miscellaneous Component
AFRICA and EXP. . . . . . . . . . . . . . . . . . . . . . 6E–8 Locators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–34
PCM Wiring Diagram (4 of 11) . . . . . . . . . . . 6E–9 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–37
PCM Wiring Diagram (5 of 11) . . . . . . . . . . . 6E–10 Strategy-Based Diagnostics . . . . . . . . . . . . . 6E–37
PCM Wiring Diagram (6 of 11) For Strategy-Based Diagnostics . . . . . . . . . . . . . 6E–37
AUSTRALIA, THAILAND, SOUTH EAST DTC Stored . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–37
ASIA, LATIN AMERICA, GULF, SAUDI, No DTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–37
LATIN AMERICA. . . . . . . . . . . . . . . . . . . . . . 6E–11 No Matching Symptom . . . . . . . . . . . . . . . . . 6E–37
PCM Wiring Diagram (7 of 11) For EC. . . . 6E–12 Intermittents . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–37
PCM Wiring Diagram (8 of 11) For EXPORT No Trouble Found . . . . . . . . . . . . . . . . . . . . . 6E–37
and SOUTH AFRICA. . . . . . . . . . . . . . . . . . 6E–13 Verifying Vehicle Repair . . . . . . . . . . . . . . . . 6E–37
PCM Wiring Diagram (9 of 11) Except EXP General Service Information . . . . . . . . . . . . . . 6E–38
and SOUTH AFRICA . . . . . . . . . . . . . . . . . . 6E–14
OBD Serviceablity Issues . . . . . . . . . . . . . . . 6E–38
PCM Wiring Diagram (10 of 11) For
Maintenance Schedule . . . . . . . . . . . . . . . . . 6E–38
EXPORT and SOUTH AFRICA . . . . . . . . . 6E–15
Visual / Physical Engine Compartment
PCM Wiring Diagram (11 of 11) . . . . . . . . . . 6E–16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–38
PCM Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–17
Basic Knowledge of Tools Required . . . . . . 6E–38
PCM Pinout Table, 32-Way Red
Connector – Row “A” . . . . . . . . . . . . . . . . . . 6E–17 Serial Data Communications . . . . . . . . . . . . . . 6E–38
PCM Pinout Table, 32-Way Red Class II Serial Data Communications . . . . . 6E–38
Connector – Row “B” . . . . . . . . . . . . . . . . . . 6E–19 On-Board Diagnostic (OBD) . . . . . . . . . . . . . . 6E–39
PCM Pinout Table, 32-Way White On-Board Diagnostic Tests . . . . . . . . . . . . . 6E–39
Connector – Row “C” (For EC) . . . . . . . . . . 6E–20
PCM Pinout Table, 32-Way White Comprehensive Component Monitor
Connector – Row “C” (For except EC) . . . 6E–21 Diagnostic Operation . . . . . . . . . . . . . . . . . . 6E–39
PCM Pinout Table, 32-Way White Common OBD Terms . . . . . . . . . . . . . . . . . . 6E–40
Connector – Row “D” The Diagnostic Executive . . . . . . . . . . . . . . . 6E–40
(For except EXPORT and SOUTH
AFRICA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–22 DTC Types . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–41
PCM Pinout Table, 32-Way White Verifying Vehicle Repair . . . . . . . . . . . . . . . . 6E–42
Connector – Row “D” Reading Diagnostic Trouble Codes Using
(For EXPORT and SOUTH AFRICA) . . . . . 6E–23 A Tech 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–42
PCM Pinout Table, 32-Way Blue
Connector – Row “E” Tech 2 Tech 2 . . . . . . . . . . . . . . . . . . . . . . . . . 6E–43
(For except EXPORT and SOUTH Tech 2 Features . . . . . . . . . . . . . . . . . . . . . . . 6E–43
AFRICA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–24 Getting Started . . . . . . . . . . . . . . . . . . . . . . . . 6E–44
PCM Pinout Table, 32-Way Blue
Connector – Row “E” Operating Procedure (For Example) . . . . . 6E–44
(For EXPORT and SOUTH AFRICA) . . . . . 6E–26 DTC Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–45
PCM Pinout Table, 32-Way Blue DTC Information Mode . . . . . . . . . . . . . . . . . 6E–46
Connector – Row “F” . . . . . . . . . . . . . . . . . . 6E–27 Injector Balance Test . . . . . . . . . . . . . . . . . . . 6E–46
Component Locators . . . . . . . . . . . . . . . . . . . . 6E–28 EGR Control Test . . . . . . . . . . . . . . . . . . . . . . 6E–47
Engine Component Locator (This illustration
is based on RHD model.) . . . . . . . . . . . . . . 6E–28 Idle Air Control System Test . . . . . . . . . . . . . 6E–48
6E–2 ENGINE DRIVEABILITY AND EMISSIONS
Primary System-Based Diagnostic . . . . . . . . . 6E–50 Diagnostic Trouble Code (DTC) P0117
Primary System-Based Diagnostic . . . . . . . 6E–50 ECT Sensor Circuit Low Voltage . . . . . . . . . . 6E–124
Fuel Control Heated Oxygen Sensor . . . . . 6E–50 Diagnostic Trouble Code (DTC) P0118
HO2S Heater . . . . . . . . . . . . . . . . . . . . . . . . . 6E–50 ECT Sensor Circuit High Voltage . . . . . . . . . 6E–127
Fuel Trim System Monitor Diagnostic Diagnostic Trouble Code (DTC) P0121
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–50 TP System Performance . . . . . . . . . . . . . . . . . 6E–130
Fuel Trim System Monitor Diagnostic Diagnostic Trouble Code (DTC) P0122
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–50 TP Sensor Circuit Low Voltage . . . . . . . . . . . 6E–133
Fuel Trim Cell Diagnostic Weights . . . . . . . 6E–50 Diagnostic Trouble Code (DTC) P0123
On-Board Diagnostic (OBD) System Check . 6E–51 TP Sensor Circuit High Voltage . . . . . . . . . . 6E–136
A/C Clutch Control Circuit Diagnosis . . . . . . . 6E–54 Diagnostic Trouble Code (DTC) P0131
HO2S Circuit Low Voltage Bank 1
Electronic Ignition System Diagnosis . . . . . . . 6E–60
Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–139
Fuel Metering System Check . . . . . . . . . . . . . 6E–60
Diagnostic Trouble Code (DTC) P0132
Idle Air Control (IAC) Valve . . . . . . . . . . . . . . . 6E–60 HO2S Circuit High Voltage Bank 1
Fuel System Pressure Test . . . . . . . . . . . . . . . 6E–60 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–142
Fuel Injector Coil Test Procedure and Fuel Diagnostic Trouble Code (DTC) P0134
Injector Balance Test Procedure . . . . . . . . . . 6E–60 HO2S Circuit Insufficient Activity Bank 1
Knock Sensor Diagnosis . . . . . . . . . . . . . . . . . 6E–65 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–145
Powertrain Control Module (PCM) Diagnosis 6E–65 Diagnostic Trouble Code (DTC) P0151
Multiple PCM Information Sensor DTCS Set 6E–65 HO2S Circuit Low Voltage Bank 2
Exhaust Gas Recirculation (EGR) Diagnosis Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–148
(For except EXPORT and Diagnostic Trouble Code (DTC) P0152
SOUTH AFRICA) . . . . . . . . . . . . . . . . . . . . . . . 6E–68 HO2S Circuit HIGH Voltage Bank 2
Engine Tech 2 Data Definitions and Ranges 6E–68 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–151
Typical Scan Data Values . . . . . . . . . . . . . . . . 6E–70 Diagnostic Trouble Code (DTC) P0171
No Malfunction Indicator Lamp (MIL) . . . . . . . 6E–74 Fuel Trim System Lean Bank 1 . . . . . . . . . . . 6E–154
Malfunction Indicator Lamp (MIL) “ON” Diagnostic Trouble Code (DTC) P0172
Steady . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–77 Fuel Trim System Rich Bank 1 . . . . . . . . . . . 6E–158
Engine Cranks But Will Not Run . . . . . . . . . . . 6E–79 Diagnostic Trouble Code (DTC) P0174
Fuel System Electrical Test . . . . . . . . . . . . . . . 6E–85 Fuel Trim System Lean Bank 2 . . . . . . . . . . . 6E–162
Fuel System Diagnosis . . . . . . . . . . . . . . . . . . . 6E–88 Diagnostic Trouble Code (DTC) P0175
Fuel Trim System Rich Bank 2 . . . . . . . . . . . 6E–166
Idle Air Control (IAC) System Check . . . . . . . 6E–93
Diagnostic Trouble Code (DTC) P0201
Knock Sensor (KS) System Check
Injector 1 Control Circuit . . . . . . . . . . . . . . . . . 6E–170
(Engine Knock, Poor Performance, or Poor
Economy) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–95 Diagnostic Trouble Code (DTC) P0202
Injector 2 Control Circuit . . . . . . . . . . . . . . . . . 6E–173
Exhaust Gas Recirculation (EGR) System
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–97 Diagnostic Trouble Code (DTC) P0203
Injector 3 Control Circuit . . . . . . . . . . . . . . . . . 6E–176
Manifold Absolute Pressure (MAP) Output
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–99 Diagnostic Trouble Code (DTC) P0204
Injector 4 Control Circuit . . . . . . . . . . . . . . . . . 6E–179
PCM Diagnostic Trouble Codes . . . . . . . . . . . 6E–101
Diagnostic Trouble Code (DTC) P0205
Diagnostic Trouble Code (DTC) P0101
Injector 5 Control Circuit . . . . . . . . . . . . . . . . . 6E–182
MAF System Performance . . . . . . . . . . . . . . . 6E–104
Diagnostic Trouble Code (DTC) P0206
Diagnostic Trouble Code (DTC) P0102
Injector 6 Control Circuit . . . . . . . . . . . . . . . . . 6E–185
MAF Sensor Circuit Low Frequency . . . . . . 6E–107
Diagnostic Trouble Code (DTC) P0325
Diagnostic Trouble Code (DTC) P0103
KS Module Circuit . . . . . . . . . . . . . . . . . . . . . . 6E–188
MAF Sensor Circuit High Frequency . . . . . . 6E–110
Diagnostic Trouble Code (DTC) P0327
Diagnostic Trouble Code (DTC) P0107
KS Sensor Circuit . . . . . . . . . . . . . . . . . . . . . . . 6E–190
MAP Sensor Circuit Low Voltage . . . . . . . . . . 6E–112
Diagnostic Trouble Code (DTC) P0336
Diagnostic Trouble Code (DTC) P0108
58X Reference Signal Circuit . . . . . . . . . . . . . 6E–193
MAP Sensor Circuit High Voltage . . . . . . . . . 6E–115
Diagnostic Trouble Code (DTC) P0337
Diagnostic Trouble Code (DTC) P0112
CKP Sensor Circuit Low Frequency . . . . . . . 6E–195
IAT Sensor Circuit Low Voltage . . . . . . . . . . . 6E–118
Diagnostic Trouble Code (DTC) P0341
Diagnostic Trouble Code (DTC) P0113
CMP Sensor Circuit Performance . . . . . . . . . 6E–198
IAT Sensor Circuit High Voltage . . . . . . . . . . 6E–121
Diagnostic Trouble Code (DTC) P0342
CMP Sensor Circuit Low . . . . . . . . . . . . . . . . . 6E–202
ENGINE DRIVEABILITY AND EMISSIONS 6E–3
Diagnostic Trouble Code (DTC) P0351 Mass Air Flow (MAF) Sensor . . . . . . . . . . . . . 6E–297
Ignition 1 Control Circuit . . . . . . . . . . . . . . . . . 6E–206 Manifold Absolute Pressure (MAP) Sensor . 6E–297
Diagnostic Trouble Code (DTC) P0352 Malfunction Indicator Lamp (MIL) . . . . . . . . . . 6E–298
Ignition 2 Control Circuit . . . . . . . . . . . . . . . . . 6E–209 Powertrain Control Module (PCM) . . . . . . . . . 6E–298
Diagnostic Trouble Code (DTC) P0353 EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–300
Ignition 3 Control Circuit . . . . . . . . . . . . . . . . . 6E–212 Power Steering Pressure (PSP) Switch . . . . 6E–300
Diagnostic Trouble Code (DTC) P0354 Throttle Position (TP) Sensor . . . . . . . . . . . . . 6E–301
Ignition 4 Control Circuit . . . . . . . . . . . . . . . . . 6E–215
Vehicle Speed Sensor (VSS) . . . . . . . . . . . . . 6E–302
Diagnostic Trouble Code (DTC) P0355
Air Cleaner/Air Filter . . . . . . . . . . . . . . . . . . . . . 6E–303
Ignition 5 Control Circuit . . . . . . . . . . . . . . . . . 6E–218
Idle Air Control (IAC) Valve . . . . . . . . . . . . . . . 6E–304
Diagnostic Trouble Code (DTC) P0356
Ignition 6 Control Circuit . . . . . . . . . . . . . . . . . 6E–221 Common Chamber . . . . . . . . . . . . . . . . . . . . . . 6E–305
Diagnostic Trouble Code (DTC) P0402 Accelerator Cable Assembly . . . . . . . . . . . . . . 6E–305
EGR Pintle Crank Error . . . . . . . . . . . . . . . . . . 6E–224 Accelerator Pedal Replacement . . . . . . . . . . . 6E–308
Diagnostic Trouble Code (DTC) P0404 Fuel Filter Cap . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–310
EGR Open Stuck . . . . . . . . . . . . . . . . . . . . . . . 6E–226 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–310
Diagnostic Trouble Code (DTC) P0405 Fuel Gauge Unit . . . . . . . . . . . . . . . . . . . . . . . . 6E–313
EGR Low Voltage . . . . . . . . . . . . . . . . . . . . . . . 6E–228 Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–314
Diagnostic Trouble Code (DTC) P0406 Fuel Pressure Regulator . . . . . . . . . . . . . . . . . 6E–315
EGR High Voltage . . . . . . . . . . . . . . . . . . . . . . 6E–231 Fuel Metering System . . . . . . . . . . . . . . . . . . . . 6E–317
Diagnostic Trouble Code (DTC) P0502 Fuel Pump Assembly . . . . . . . . . . . . . . . . . . . . 6E–318
VSS Circuit Low Input . . . . . . . . . . . . . . . . . . . 6E–234 Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . . . 6E–319
Diagnostic Trouble Code (DTC) P0562 Fuel Rail Assembly . . . . . . . . . . . . . . . . . . . . . . 6E–319
System Voltage Low . . . . . . . . . . . . . . . . . . . . 6E–237 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–321
Diagnostic Trouble Code (DTC) P0563 Throttle Body (TB) . . . . . . . . . . . . . . . . . . . . . . . 6E–323
System Voltage High . . . . . . . . . . . . . . . . . . . . 6E–239
Electronic Ignition System . . . . . . . . . . . . . . . . 6E–324
Diagnostic Trouble Code (DTC) P0601
Catalytic Converter . . . . . . . . . . . . . . . . . . . . . . 6E–325
PCM Memory . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–240
Air Conditioning Relay . . . . . . . . . . . . . . . . . . . 6E–325
Diagnostic Trouble Code (DTC) P1154
EVAP Canister Hoses . . . . . . . . . . . . . . . . . . . . 6E–326
HO2S Circuit Transition Time Ratio Bank 2
Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–241 EVAP Canister . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–326
Diagnostic Trouble Code (DTC) P1171 EVAP Canister Purge Solenoid . . . . . . . . . . . . 6E–327
Fuel System Lean During Acceleration . . . . 6E–245 Fuel Tank Vent Valve . . . . . . . . . . . . . . . . . . . . 6E–328
Diagnostic Trouble Code (DTC) P1380 Linear Exhaust Gas Recirculation
ABS Rough Road ABS System Fault . . . . . . 6E–248 (EGR) Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–328
Diagnostic Trouble Code (DTC) P1404 Positive Crankcase Ventilation (PCV) Valve . 6E–329
EGR Closed Stuck . . . . . . . . . . . . . . . . . . . . . . 6E–249 Wiring and Connectors . . . . . . . . . . . . . . . . . . . 6E–330
Diagnostic Trouble Code (DTC) P1508 PCM Connectors and Terminals . . . . . . . . . . . 6E–330
IAC System Low RPM . . . . . . . . . . . . . . . . . . . 6E–251 Wire Harness Repair: Twisted Shielded
Diagnostic Trouble Code (DTC) P1509 Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–330
IAC System High RPM . . . . . . . . . . . . . . . . . . 6E–254 Twisted Leads . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–331
Diagnostic Trouble Code (DTC) P1618 Weather-Pack Connector . . . . . . . . . . . . . . . . . 6E–332
Serial Peripheral Interface (SPI) PCM Com-Pack III . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–333
Interprocessor Communication Error . . . . . . 6E–257 Metri-Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–333
Diagnostic Trouble Code (DTC) P1625 General Description . . . . . . . . . . . . . . . . . . . . . 6E–335
PCM Unexpected Reset . . . . . . . . . . . . . . . . . 6E–258 General Description (PCM and Sensors) . . . 6E–335
Diagnostic Trouble Code (DTC) P1640 58X Reference PCM Input . . . . . . . . . . . . . . 6E–335
Driver-1-Input High Voltage . . . . . . . . . . . . . . 6E–259
A/C Request Signal . . . . . . . . . . . . . . . . . . . . 6E–335
Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . 6E–262
Crankshaft Position (CKP) Sensor . . . . . . . 6E–335
Default Matrix Table . . . . . . . . . . . . . . . . . . . . . 6E–288
Camshaft Position (CMP) Sensor and
Camshaft Position (CMP) Sensor . . . . . . . . . . 6E–291
Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–335
Crankshaft Position (CKP) Sensor . . . . . . . . . 6E–292
Engine Coolant Temperature (ECT) Sensor 6E–335
Engine Coolant Temperature (ECT) Sensor . 6E–292
Electrically Erasable Programmable Read
Heated Oxygen Sensor (HO2S) . . . . . . . . . . . 6E–293
Only Memory (EEPROM) . . . . . . . . . . . . . . 6E–336
Intake Air Temperature (IAT) Sensor . . . . . . . 6E–295
Fuel Control Heated Oxygen Sensors . . . . 6E–336
Knock Sensor (KS) . . . . . . . . . . . . . . . . . . . . . . 6E–296
Intake Air Temperature (IAT) Sensor . . . . . 6E–336
6E–4 ENGINE DRIVEABILITY AND EMISSIONS
Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 6E–337 Fuel Metering System Purpose . . . . . . . . . . 6E–342
Linear Exhaust Gas Recirculation (EGR) Fuel Pressure Regulator . . . . . . . . . . . . . . . . 6E–343
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–337 Fuel Pump Electrical Circuit . . . . . . . . . . . . . 6E–343
Mass Air Flow (MAF) Sensor . . . . . . . . . . . . 6E–337 Fuel Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–343
Manifold Absolute Pressure (MAP) Sensor 6E–338 Idle Air Control (IAC) Valve . . . . . . . . . . . . . 6E–343
Powertrain Control Module (PCM) . . . . . . . 6E–338 Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–344
PCM Function . . . . . . . . . . . . . . . . . . . . . . . . . 6E–338 Starting Mode . . . . . . . . . . . . . . . . . . . . . . . . . 6E–344
PCM Components . . . . . . . . . . . . . . . . . . . . . 6E–339 Throttle Body Unit . . . . . . . . . . . . . . . . . . . . . 6E–344
PCM Voltage Description . . . . . . . . . . . . . . . 6E–339 General Description (Electronic Ignition
PCM Input/Outputs . . . . . . . . . . . . . . . . . . . . 6E–339 System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–344
PCM Service Precautions . . . . . . . . . . . . . . 6E–339 Camshaft Position (CMP) Sensor . . . . . . . . 6E–344
Reprogramming The PCM . . . . . . . . . . . . . . 6E–339 Crankshaft Position (CKP) Sensor . . . . . . . 6E–345
Throttle Position (TP) Sensor . . . . . . . . . . . 6E–339 Electronic Ignition . . . . . . . . . . . . . . . . . . . . . 6E–345
Transmission Fluid Temperature (TFT) Ignition Coils . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–345
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–340 Ignition Control . . . . . . . . . . . . . . . . . . . . . . . . 6E–345
Transmission Range Switch . . . . . . . . . . . . . 6E–340 Ignition Control PCM Output . . . . . . . . . . . . 6E–347
Vehicle Speed Sensor (VSS) . . . . . . . . . . . . 6E–340 Knock Sensor (KS) PCM Input . . . . . . . . . . 6E–347
Use of Circuit Testing Tools . . . . . . . . . . . . . 6E–340 Powertrain Control Module (PCM) . . . . . . . 6E–347
Aftermarket Electrical and Vacuum Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–347
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–340 A/C Clutch Diagnosis . . . . . . . . . . . . . . . . . . . . 6E–349
Electrostatic Discharge Damage . . . . . . . . . 6E–341 A/C Clutch Circuit Operation . . . . . . . . . . . . 6E–349
Upshift Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 6E–341 A/C Clutch Circuit Purpose . . . . . . . . . . . . . 6E–349
General Description (Air Induction) . . . . . . . . 6E–341 A/C Request Signal . . . . . . . . . . . . . . . . . . . . 6E–349
Air Induction System . . . . . . . . . . . . . . . . . . . 6E–341 General Description (Exhaust Gas
General Description (Fuel Metering) . . . . . . . 6E–341 Recirculation (EGR) System) . . . . . . . . . . . . . 6E–349
Acceleration Mode . . . . . . . . . . . . . . . . . . . . . 6E–341 EGR Purpose . . . . . . . . . . . . . . . . . . . . . . . . . 6E–349
Accelerator Controls . . . . . . . . . . . . . . . . . . . 6E–341 Linear EGR Valve . . . . . . . . . . . . . . . . . . . . . 6E–349
Battery Voltage Correction Mode . . . . . . . . 6E–341 Linear EGR Control . . . . . . . . . . . . . . . . . . . . 6E–349
CMP Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–341 Linear EGR Valve Operation and Results
Clear Flood Mode . . . . . . . . . . . . . . . . . . . . . 6E–342 of Incorrect Operation . . . . . . . . . . . . . . . . . 6E–349
Deceleration Mode . . . . . . . . . . . . . . . . . . . . 6E–342 EGR Pintle Position Sensor . . . . . . . . . . . . . 6E–350
Engine Speed/Vehicle Speed/Fuel General Description (Positive Crankcase
Disable Mode . . . . . . . . . . . . . . . . . . . . . . . . 6E–342 Ventilation (PCV) System) . . . . . . . . . . . . . . . 6E–350
Fuel Cutoff Mode . . . . . . . . . . . . . . . . . . . . . . 6E–342 Crankcase Ventilation System Purpose . . . 6E–350
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–342 Crankcase Ventilation System Operation . 6E–350
Fuel Metering System Components . . . . . . 6E–342
ENGINE DRIVEABILITY AND EMISSIONS 6E–5

Specifications
Tightening Specifications
Application Nꞏm Lb Ft. Lb In.
Camshaft Position Sensor Retaining Screw 9 — 78
Crankshaft Position Sensor Mounting Bolt 10 — 87
EGR Bolt 28 21 —
EGR Nut 28 21 —
Engine Coolant Temperature Sensor 20 7.7 —
Fuel Drain Plug 29 22 —
Fuel Pressure Regulator Attaching Screw 6.5 — 60
Fuel Rail Bolts 25 18 —
Fuel Tank Undercover Retaining Bolts 36 27 —
Heated Oxygen Sensor 42 31 —
Lower Intake Manifold to Engine Block Bolts 25 18 —
Lower Intake Manifold to Engine Block Nuts 25 18 —
Spark Plugs 18 13 —
Throttle Body Mounting Bolts 25 18 —
Upper Intake Manifold to Lower Intake Manifold Bolts 25 18 —
VSS Retaining Bolt 13 — 120

Vehicle Type Specifications


THAILAND
GULF SOU
SOUTH-EA
CONTRIES TH
EC AUSTRALIA ST-ASIA EXPORT Specifications
SAUDI AFRI
LATIN
CHINA CA
AMERICA
UBS UBS UBS UBS UBS UBS O2
CAT
OBD SEN EGR
MT AT MT AT MT AT MT AT MT MT AT A
SOR
I 2 1
I 2 1
1 1
1 1
1 1
1 1
1
1

I
6E–6 ENGINE DRIVEABILITY AND EMISSIONS

Diagrams and Schematics


PCM Wiring Diagram (1 of 11)

D06RW00005
ENGINE DRIVEABILITY AND EMISSIONS 6E–7
PCM Wiring Diagram (2 of 11) For EC, THAILAND, SOUTH EAST ASIA, LATIN AMERICA,
GULF, SAUDI, CHINA.

D06RW134
6E–8 ENGINE DRIVEABILITY AND EMISSIONS
PCM Wiring Diagram (3 of 11) For SOUTH AFRICA and EXP.

D06RW140
ENGINE DRIVEABILITY AND EMISSIONS 6E–9
PCM Wiring Diagram (4 of 11)

D06RX00003
6E–10 ENGINE DRIVEABILITY AND EMISSIONS
PCM Wiring Diagram (5 of 11)

D06RW138
ENGINE DRIVEABILITY AND EMISSIONS 6E–11
PCM Wiring Diagram (6 of 11) For AUSTRALIA, THAILAND, SOUTH EAST ASIA, LATIN
AMERICA, GULF, SAUDI, LATIN AMERICA.

D06RW137
6E–12 ENGINE DRIVEABILITY AND EMISSIONS

PCM Wiring Diagram (7 of 11) For EC.

D06RW100
ENGINE DRIVEABILITY AND EMISSIONS 6E–13
PCM Wiring Diagram (8 of 11) For EXPORT and SOUTH AFRICA.

D06RW138
6E–14 ENGINE DRIVEABILITY AND EMISSIONS
PCM Wiring Diagram (9 of 11) Except EXP and SOUTH AFRICA

D06RW099
ENGINE DRIVEABILITY AND EMISSIONS 6E–15
PCM Wiring Diagram (10 of 11) For EXPORT and SOUTH AFRICA

D06RW141
6E–16 ENGINE DRIVEABILITY AND EMISSIONS
PCM Wiring Diagram (11 of 11)

D06RW136
ENGINE DRIVEABILITY AND EMISSIONS 6E–17

PCM Pinouts
PCM Pinout Table, 32-Way Red Connector – Row “A”

TS23344

PIN PIN Function Wire Color IGN ON ENG RUN Refer To


A1 5 Volt Reference “A” RED 5.0 V 5.0 V Appropriate Sensor
A2 Knock Sensor YEL 0.0 V DC 0.0 V DC General Description and
2mV AC 18mV AC Operation, Knock Sensor
(at idle)
A3 Not Used — — — —
A4 Battery Feed WHT B+ B+ Chassis Electrical
A5 Idle Air Control (IAC) “A” BLU B+/0.8 V B+/0.8 V General Description and
High Operation, IAC
A6 IAC “A” Low BLU/WHT B+/0.8 V B+/0.8 V General Description and
Operation, IAC
A7 IAC “B” Low BLU/BLK B+/0.8 V B+/0.8 V General Description and
Operation, IAC
A8 IAC “B” High BLU/RED B+/0.8 V B+/0.8 V General Description and
Operation, IAC
A9 Automatic Transmission ORN/BLU B+ B+ Automatic Transmission
Fluid (ATF) Lamp (4L30E)
A10 Winter Lamp PNK/GRN B+ B+ Automatic Transmission
(4L30E)
A11 Power Lamp GRY/WHT B+ B+ Automatic Transmission
(4L30E)
A12 Antilock Brake System GRY B+ B+ Antilock Brake System
(ABS)
A13 Malfunction Indicator BLU 0.0 V B+ Chassis Electrical
(Check Engine or MIL)
Lamp
A14 “Check Transmission” ORN/BLK B+ B+ Chassis Electrical
Lamp Driver (AT)
Up Shift Lamp Driver (MT) ORN/BLU
6E–18 ENGINE DRIVEABILITY AND EMISSIONS

PIN PIN Function Wire Color IGN ON ENG RUN Refer To


A15 EVAP RED/BLU B+ 5.0 V —
A16 Band Apply (AT) BRN/YEL B+ B+ Automatic Transmission
Air Pump (MT) (4L30E)
ENGINE DRIVEABILITY AND EMISSIONS 6E–19
PCM Pinout Table, 32-Way Red Connector – Row “B”

TS23344

PIN PIN Function Wire Color IGN ON ENG RUN Refer To


B1 5 Volt Reference “B” RED/YEL 5.0 V 5.0 V Appropriate Sensor
B2 lgnition coil RED/WHT 0.0 V 0.1 V General Description and
Operation
B3 lgnition coil RED/BLK 0.0 V 0.1 V General Description and
Operation
B4 lgnition coil RED/GRN 0.0 V 0.1 V General Description and
Operation
B5 Not Used — — — —
B6 Not Used — — — —
B7 Exhaust Gas Recirculation YEL/RED 0.6 V 0.6 V General Description and
(EGR) Operation, Linear EGR
Control
B8 Intake Air Temperature YEL/GRN 0.5-4.9 V 0.5-4.9 V General Description and
(IAT) Sensor (depends on (depends on Operation, IAT
temperature) temperature)
B9 Not Used — — — —
B10 Not Used — — — —
B11 Power Steering Pressure GRN/YEL B+ B+ General Description and
(PSP) Switch Operation, PSP
B12 Illuminated Switch GRN B+ B+ Chassis Electrical
B13 Class 2 Data ORN/GRN 0.0 V 0.0 V Diagnosis, Class 2 Serial
Data
B14 A/C Clutch GRN/BLK B+ B+ General Description and
(A/C OFF) (A/C OFF) Operation, A/C Clutch Circuit
Operation
B15 ECM to ECU Violet 0.0 V 0.1 V —
Communication
B16 Not Used — — — —
6E–20 ENGINE DRIVEABILITY AND EMISSIONS
PCM Pinout Table, 32-Way White Connector – Row “C” (For EC)

TS23345

PIN PIN Function Wire Color IGN ON ENG RUN Refer To


C1 Injector Cylinder #4 GRN/RED B+ B+ General Description and
Operation, Fuel Injector
C2 Shift “B” Solenoid BRN/BLK 0.0 V 0.0 V Automatic Transmission
(4L30E)
C3 Injector Cylinder #6 GRN/YEL B+ B+ General Description and
Operation, Fuel Injector
C4 Ignition Control (IC) RED 0.0 V 0.1 V General Description and
Cylinder #1 Operation, Fuel Injector
C5 Crankshaft Position YEL 0.3 V to 5 V 2.2 V General Description and
Sensor, “A” Circuit Operation, Crankshaft
Position Sensor
C6 Not Used — — — —
C7 PCM Ground YEL 0.0 V 0.0 V Chassis Electrical
C8 PCM Ground BLK/PNK 0.0 V 0.0 V Chassis Electrical
C9 PCM Ground BLK/BLU 0.0 V 0.0 V Chassis Electrical
C10 Tachometer BLK/RED 8.8 V 10.0 V Chassis Electrical
(at idle)
C11 Variable Intake Manifold YEL/BLK 0.0 V B+ (rpm Manual Transmission
3600 over)
C12 Alternator Control Gain WHT/BLU 10.5 V B+ Chassis Electrical
C13 Fuel PWM BLU/PNK B+ B+ —
C14 Bank 2 HO2S 1 High PNK 0.4 V 0.1-0.9 V General Description and
Operation, Fuel HO2S 1
C15 Bank 2 HO2S 1 Low BLU 0.0 V 0.1 V General Description and
Operation, Fuel HO2S 1
C16 Not Used — — — —
ENGINE DRIVEABILITY AND EMISSIONS 6E–21
PCM Pinout Table, 32-Way White Connector – Row “C” (For except EC)

TS23345

PIN PIN Function Wire Color IGN ON ENG RUN Refer To


C1 Injector Cylinder #4 GRN/RED B+ B+ General Description and
Operation, Fuel Injector
C2 Shift “B” Solenoid BRN/BLK 0.0 V 0.0 V Automatic Transmission
(4L30E)
C3 Injector Cylinder #6 GRN/YEL B+ B+ General Description and
Operation, Fuel Injector
C4 Ignition Control (IC) RED 0.0 V 0.1 V General Description and
Cylinder #1 Operation, Fuel Injector
C5 Crankshaft Position YEL 0.3 V to 5 V 2.2 V General Description and
Sensor, “A” Circuit Operation, Crankshaft
Position Sensor
C6 Not Used — — — —
C7 PCM Ground BLK/BLU 0.0 V 0.0 V Chassis Electrical
C8 PCM Ground BLK/PNK 0.0 V 0.0 V Chassis Electrical
C9 PCM Ground BLK/BLU 0.0 V 0.0 V Chassis Electrical
C10 Tachometer BLK/RED 8.8 V 10.0 V Chassis Electrical
(at idle)
C11 Variable Intake Manifold YEL/BLK 0.0 V B+ (rpm Manual Transmission
3600 over)
C12 Not Used — — — —
C13 Not Used — — — —
C14 Not Used — — — —
C15 Not Used — — — —
C16 Not Used — — — —
6E–22 ENGINE DRIVEABILITY AND EMISSIONS
PCM Pinout Table, 32-Way White Connector – Row “D”
(For except EXPORT and SOUTH AFRICA)

TS23345

PIN PIN Function Wire Color IGN ON ENG RUN Refer To


D1 Injector Cylinder #2 GRN/ORN B+ B+ General Description and
Operation, Fuel Injector
D2 Torque Converter Clutch BRN/BLU 0.0 V 0.0 V On-Vehicle Service, Torque
(TCC) Converter Clutch
D3 Injector Cylinder #1 GRN/WHT B+ B+ General Description and
Operation, Fuel Injector
D4 Serial Data (8192) ORN 5.0 V 5.0 V Chassis Electrical
D5 Ignition Control, Cylinder RED/YEL 0.0 V 0.1 V General Description and
#5 Operation, Ignition Coil
D6 Ignition Control, Cylinder RED/BLUE 0.0 V 0.0 V General Description and
#3 Operation, Ignition Coil
D7 VSS Input / IMOB WHT/BLK 0.0 V 0.1 V Chassis Electrical
Response (at rest)
D8 Sensor Ground 5V GRN 0.0 V 0.0 V Appropriate Sensor
Reference A Return
D9 Sensor Ground 5 V GRY 0.0 V 0.0 V Appropriate Sensor
Reference B Return
D10 Mass Air Flow (MAF) YEL 4.9 V 4.2 V General Description, Mass
Air Flow Sensor
D11 Camshaft Position Sensor WHT 5.0 V or less 4.6 V General Description and
than 1.0 V Operation, Camshaft
Position Sensor
D12 Not Used — — — —
D13 Not Used — — — —
D14 Bank 1 HO2S 1 Low GRN 0.0 V 0.1 V General Description and
Operation, Fuel HO2S 1
D15 Bank 1 HO2S 1 Signal RED 0.4 V 0.1-0.9 V General Description and
Operation, Fuel HO2S 1
D16 Not Used — — — —
ENGINE DRIVEABILITY AND EMISSIONS 6E–23
PCM Pinout Table, 32-Way White Connector – Row “D”
(For EXPORT and SOUTH AFRICA)

TS23345

PIN PIN Function Wire Color IGN ON ENG RUN Refer To


D1 Injector Cylinder #2 GRN/ORN B+ B+ General Description and
Operation, Fuel Injector
D2 Torque Converter Clutch BRN/BLU 0.0 V 0.0 V On-Vehicle Service, Torque
(TCC) Converter Clutch
D3 Injector Cylinder #1 GRN/WHT B+ B+ General Description and
Operation, Fuel Injector
D4 Serial Data (8192) ORN 5.0 V 5.0 V Chassis Electrical
D5 Ignition Control, Cylinder RED/YEL 0.0 V 0.1 V General Description and
#5 Operation, Ignition Coil
D6 Ignition Control, Cylinder RED/BLUE 0.0 V 0.0 V General Description and
#3 Operation, Ignition Coil
D7 VSS Input / IMOB LIGHT 0.0 V 0.1 V Chassis Electrical
Response GRN/WHT (at rest)
D8 Sensor Ground 5V GRN 0.0 V 0.0 V Appropriate Sensor
Reference A Return
D9 Sensor Ground 5 V GRY 0.0 V 0.0 V Appropriate Sensor
Reference B Return
D10 Mass Air Flow (MAF) YEL 4.9 V 4.2 V General Description, Mass
Air Flow Sensor
D11 Camshaft Position Sensor WHT 5.0 V or less 4.6 V General Description and
than 1.0 V Operation, Camshaft
Position Sensor
D12 Not Used — — — —
D13 Not Used — — — —
D14 Not Used — — — —
D15 Not Used — — — —
D16 Not Used — — — —
6E–24 ENGINE DRIVEABILITY AND EMISSIONS
PCM Pinout Table, 32-Way Blue Connector – Row “E”
(For except EXPORT and SOUTH AFRICA)

TS23346

PIN PIN Function Wire Color IGN ON ENG RUN Refer To


E1 Transmission Output Shaft RED 0.0 V 0.1 V Automatic Transmission
Sensor (TOSS) High (4L30E)
E2 Transmission Output Shaft WHT 0.0 V 0.0 V Automatic Transmission
Sensor (TOSS) Low (4L30E)
E3 Pressure Control Solenoid PPL/RED 0.0 V 1.1 V Automatic Transmission
Low (4L30E)
E4 Pressure Control Solenoid PPL/WHT 0.0 V 4.9 V Automatic Transmission
High (4L30E)
E5 Exhaust Gas Recirculation BLK/YEL B+ B+ General Description and
(EGR) Control High Operation, EGR Control
E6 Exhaust Gas Recirculation YEL B+ B+ General Description and
(EGR) Control Low Operation, EGR Control
E7 Transmission Range BLU/YEL 0.0 V 0.0 V Automatic Transmission
Signal “B” (4L30E)
E8 Throttle Position (TP) BLU 0.5-0.8 V 0.5-0.8 V General Description and
Sensor (at idle) Operation, Throttle Position
Sensor
E9 Engine Coolant BLU/RED 0.5-4.9 V 0.5-4.9 V General Description and
Temperature (ECT) (depends on (depends on Operation, Engine Coolant
Sensor temperature) temperature) Temperature (ECT) Sensor
E10 Not Used — — — —
E11 Crankshaft Position (CKP) YEL/RED 5.0 V or less 5.0 V General Description and
Sensor +5 Volt Reference than 1.0 V Operation, Crankshaft
Position Sensor
E12 Transmission Range BLU/WHT B+ B+ Automatic Transmission
Signal “A” (4L30E)
E13 Fuel Pump (FP) Relay RED/WHT 0.0 V B+ On-Vehicle Service, Fuel
Pump Relay
E14 Shift High (BAND APPLY) BRN/WHT B+ B+ Automatic Transmission
(4L30E)
ENGINE DRIVEABILITY AND EMISSIONS 6E–25

PIN PIN Function Wire Color IGN ON ENG RUN Refer To


E15 A/C Request GRN/ORN 0.0 V 0.0 V Electric Cooling Fans
E16 Ignition Feed (1 of 2 F16) RED/BLU B+ B+ —
6E–26 ENGINE DRIVEABILITY AND EMISSIONS
PCM Pinout Table, 32-Way Blue Connector – Row “E”
(For EXPORT and SOUTH AFRICA)

TS23346

PIN PIN Function Wire Color IGN ON ENG RUN Refer To


E1 Transmission Output Shaft RED 0.0 V 0.1 V Automatic Transmission
Sensor (TOSS) High (4L30E)
E2 Transmission Output Shaft WHT 0.0 V 0.0 V Automatic Transmission
Sensor (TOSS) Low (4L30E)
E3 Pressure Control Solenoid PPL/RED 0.0 V 1.1 V Automatic Transmission
Low (4L30E)
E4 Pressure Control Solenoid PPL/WHT 0.0 V 4.9 V Automatic Transmission
High (4L30E)
E5 Not Used — — — —
E6 Not Used — — — —
E7 Transmission Range BLU/YEL 0.0 V 0.0 V Automatic Transmission
Signal “B” (4L30E)
E8 Throttle Position (TP) BLU 0.5-0.8 V 0.5-0.8 V General Description and
Sensor (at idle) Operation, Throttle Position
Sensor
E9 Engine Coolant BLU/RED 0.5-4.9 V 0.5-4.9 V General Description and
Temperature (ECT) (depends on (depends on Operation, Engine Coolant
Sensor temperature) temperature) Temperature (ECT) Sensor
E10 Not Used — — — —
E11 Crankshaft Position (CKP) YEL/RED 5.0 V or less 5.0 V General Description and
Sensor +5 Volt Reference than 1.0 V Operation, Crankshaft
Position Sensor
E12 Transmission Range BLU/WHT B+ B+ Automatic Transmission
Signal “A” (4L30E)
E13 Fuel Pump (FP) Relay RED/WHT 0.0 V B+ On-Vehicle Service, Fuel
Pump Relay
E14 Shift High (BAND APPLY) BRN/WHT B+ B+ Automatic Transmission
(4L30E)
E15 A/C Request GRN/ORN 0.0 V 0.0 V Electric Cooling Fans
E16 Ignition Feed (1 of 2 F16) RED/BLU B+ B+ —
ENGINE DRIVEABILITY AND EMISSIONS 6E–27
PCM Pinout Table, 32-Way Blue Connector – Row “F”

TS23346

PIN PIN Function Wire Color IGN ON ENG RUN Refer To


F1 Not Used — — — —
F2 Transmission Range BLU/BLK 0.0 V 0.0 V Automatic Transmission
Signal “C” (4L30E)
F3 Transmission Range YEL/GRN B+ 0.0 V Automatic transmission
Signal “P” (4L30E)
F4 Brake Switch GRN/YEL 0.0 V 0.0 V Automatic transmission
(4L30E)
F5 Power Switch PPL/RED B+ B+ Automatic Transmission
(4L30E)
F6 Winter Switch PPL/GRN B+ B+ Automatic Transmission
(4L30E)
F7 Transmission Fluid RED/BLK 0.5-4.9 V 0.5-4.9 V Automatic Transmission
Temperature (depends on (depends on (4L30E)
temperature) temperature)
F8 Manifold Absolute GRY/BLK 3.5-4.9 V 0.6-1.3 V General Description and
Pressure (MAP) (depends on Operation, Manifold Absolute
altitude and Pressure
barometric
pressure)
F9 Not Used — — — —
F10 Cruise Control GRY/BLU B+ B+ Automatic transmission
(4L30E)
F11 Kickdown Switch LT BLU B+ B+ Automatic Transmission
(4L30E)
F12 DIAG ORN/BLU B+ B+ —
F13 Injector “C” Cylinder #3 GRN B+ B+ General Description and
Operation, Fuel Injector
F14 Shift “A” Solenoid BRN/RED B+ B+ Automatic Transmission
(4L30E)
F15 Injector Cylinder #5 GRN/BLK B+ B+ General Description and
Operation, Fuel Injector
F16 Ignition Feed (1 of 2 E16) RED/BLU B+ B+ —
6E–28 ENGINE DRIVEABILITY AND EMISSIONS

Component Locators
Engine Component Locator (This illustration is based on RHD model.)

060RW210
ENGINE DRIVEABILITY AND EMISSIONS 6E–29
Engine Component Locator Table

Number Name Location


1 Linear Exhaust Gas Recirculation (EGR) Valve Rear right side of the engine
2 Throttle Position (TP) Sensor On the rear of the throttle body
3 Intake Air Temperature (IAT) Sensor On the intake air duct near the throttle body
4 Check Engine (MIL) Light On the instrument panel beneath the
tachometer
5 Positive Crankcase Ventilation (PCV) Valve On the left of the cylinder head cover
6 Air Cleaner Left front of the engine bay
7 Mass Air Flow (MAF) Sensor Attached to the air filter box
8 Camshaft Position (CMP) Sensor On the rear right side at the left of the cylinder
head cover
9 Fuel Pressure Regulator Rear right side of the engine
10 Idle Air Control (IAC) Valve On the left of the throttle body
11 Upper Intake Manifold Top of the engine
12 Fuse/Relay Box Along the inside of the right fender
13 Manifold Absolute Pressure (MAP) Sensor Bolted to the top of the upper intake manifold
14 Throttle Body Between the intake air duct and the upper
intake manifold
15 Engine Coolant Temperature Sensor On the coolant crossover pipe at the front of
the engine, near the throttle body
6E–30 ENGINE DRIVEABILITY AND EMISSIONS
Engine Component Locator (This illustration is based on LHD model.)

755RW062
ENGINE DRIVEABILITY AND EMISSIONS 6E–31
Engine Component Locator Table

Number Name Location


1 Linear Exhaust Gas Recirculation (EGR) Valve Rear right side of the engine
2 Throttle Position (TP) Sensor On the rear of the throttle body
3 Intake Air Temperature (IAT) Sensor On the intake air duct near the throttle body
4 Check Engine (MIL) Light On the instrument panel beneath the
tachometer
5 Positive Crankcase Ventilation (PCV) Valve On the left of the cylinder head cover
6 Air Cleaner Left front of the engine bay
7 Mass Air Flow (MAF) Sensor Attached to the air filter box
8 Camshaft Position (CMP) Sensor On the rear right side at the left of the cylinder
head cover
9 Fuel Pressure Regulator Rear right side of the engine
10 Idle Air Control (IAC) Valve On the left of the throttle body
11 Upper Intake Manifold Top of the engine
12 Fuse/Relay Box Along the inside of the right fender
13 Manifold Absolute Pressure (MAP) Sensor Bolted to the top of the upper intake manifold
14 Throttle Body Between the intake air duct and the upper
intake manifold
15 Engine Coolant Temperature Sensor On the coolant crossover pipe at the front of
the engine, near the throttle body
6E–32 ENGINE DRIVEABILITY AND EMISSIONS
Undercarriage Component Locator

F00RW040

Undercarriage Component Locator Table (Automatic Transmission)

Number Name Location


1 Fuel Pump Assembly Installed in the top of the fuel tank
2 Fuel Gauge Unit Installed in the front edge of the fuel tank, on
the right side
3 Fuel Filter Located along the inside of the right frame rail,
ahead of the rear axle
4 Vehicle Speed Sensor (VSS) 2WD: Protrudes from the transmission
housing, just ahead of the propeller shaft.
4WD: Protrudes from the rear output shaft
housing of the transfer case.
5 Heated Oxygen Sensor (Bank 1, HO2S 1) Threaded into the exhaust pipe ahead of the
right-hand catalytic converter
6 Heated Oxygen Sensor (Bank 2, HO2S 1) Threaded into the exhaust pipe ahead the
left-hand catalytic converter
ENGINE DRIVEABILITY AND EMISSIONS 6E–33
Undercarriage Component Locator Table (Manual Transmission)

Number Name Location


1 Fuel Pump Assembly Installed in the top of the fuel tank
2 Fuel Gauge Unit Installed in the front edge of the right frame
rail, ahead of the rear axle
3 Fuel Filter Located along the inside of the right frame rail,
ahead of the rear axle
4 Vehicle Speed Sensor (VSS) 2WD: Protrudes from the transmission
housing, just ahead of the propeller shaft.
4WD: Protrudes from the rear output shaft
housing of the transfer case.
5 Heated Oxygen Sensor (Bank 1, HO2S 1) Threaded into the exhaust pipe ahead of the
right-hand catalytic converter
6 Heated Oxygen Sensor (Bank 2, HO2S 1) Threaded into the exhaust pipe ahead of the
left-hand catalytic converter

Fuse and Relay Panel (Underhood Electrical Center)

TS23336
6E–34 ENGINE DRIVEABILITY AND EMISSIONS
Sensors and Miscellaneous Component
Locators
For EC.

060RW194 T321066

For AUSTRALIA, THAILAND, SOUTH EAST ASIA,


LATIN AMERICA, GULF, SAUDI, CHINA.

T321067

150RW101
ENGINE DRIVEABILITY AND EMISSIONS 6E–35

140RW032 055RW003

014RW125 041RW004

T321070 025RW005
6E–36 ENGINE DRIVEABILITY AND EMISSIONS

T321078

060RW007

028RW001
ENGINE DRIVEABILITY AND EMISSIONS 6E–37

Diagnosis 3. Use a check sheet or other method to identify the


circuit or electrical system component.
Strategy-Based Diagnostics 4. Follow the suggestions for intermittent diagnosis
found in the service documentation.
Strategy-Based Diagnostics Most Tech 2s, such as the Tech II and the
5–8840–0285–0 (Fluke model 87 DVOM), have
The strategy-based diagnostic is a uniform approach to
data-capturing capabilities that can assist in detecting
repair all Electrical/Electronic (E/E) systems. The
intermittents.
diagnostic flow can always be used to resolve an E/E
system problem and is a starting point when repairs are No Trouble Found
necessary. The following steps will instruct the technician
how to proceed with a diagnosis: This condition exists when the vehicle is found to operate
normally. The condition described by the customer may
1. Verify the customer complaint.
be normal. Verify the customer complaint against another
To verify the customer complaint, the technician vehicle that is operating normally. The condition may be
should know the normal operation of the system. intermittent. Verify the complaint under the conditions
2. Perform preliminary checks. described by the customer before releasing the vehicle.
Conduct a thorough visual inspection. 1. Re-examine the complaint.
Review the service history. When the Complaint cannot be successfully found or
Detect unusual sounds or odors. isolated, a re-evaluation is necessary. The complaint
should be re-verified and could be intermittent as
Gather diagnostic trouble code information to defined in Intermittents, or could be normal.
achieve an effective repair.
2. Repair and verify.
3. Check bulletins and other service information.
After isolating the cause, the repairs should be made.
This includes videos, newsletters, etc. Validate for proper operation and verify that the
4. Refer to service information (manual) system symptom has been corrected. This may involve road
check(s). testing or other methods to verify that the complaint
“System checks” contain information on a system has been resolved under the following conditions:
that may not be supported by one or more DTCs. Conditions noted by the customer.
System checks verify proper operation of the
If a DTC was diagnosed, verify a repair by
system. This will lead the technician in an
duplicating conditions present when the DTC was
organized approach to diagnostics.
set as noted in the Failure Records or Freeze
5. Refer to service diagnostics. Frame data.

DTC Stored Verifying Vehicle Repair


Follow the designated DTC chart exactly to make an Verification of the vehicle repair will be more
effective repair. comprehensive for vehicles with OBD system
diagnostics. Following a repair, the technician should
No DTC perform the following steps:
Select the symptom from the symptom tables. Follow the
IMPORTANT: Follow the steps below when you verify
diagnostic paths or suggestions to complete the repair. repairs on OBD systems. Failure to follow these steps
You may refer to the applicable component/system check could result in unnecessary repairs.
in the system checks.
1. Review and record the Failure Records and the
No Matching Symptom Freeze Frame data for the DTC which has been
diagnosed (Freeze Frame data will only be stored for
1. Analyze the complaint. an A or B type diagnostic and only if the MIL(”Check
2. Develop a plan for diagnostics. Engine” lamp) has been requested).
3. Utilize the wiring diagrams and the theory of 2. Clear the DTC(S).
operation. 3. Operate the vehicle within conditions noted in the
Call technical assistance for similar cases where repair Failure Records and Freeze Frame data.
history may be available. Combine technician knowledge 4. Monitor the DTC status information for the specific
with efficient use of the available service information. DTC which has been diagnosed until the diagnostic
test associated with that DTC runs.
Intermittents
Conditions that are not always present are called
intermittents. To resolve intermittents, perform the
following steps:
1. Observe history DTCs, DTC modes, and freezeframe
data.
2. Evaluate the symptoms and the conditions described
by the customer.
6E–38 ENGINE DRIVEABILITY AND EMISSIONS

General Service Information Related System Faults


Many of the OBD system diagnostics will not run if the
OBD Serviceablity Issues PCM detects a fault on a related system or component.
One example would be that if the PCM detected a Misfire
The list of non-vehicle faults that could affect the
fault, the diagnostics on the catalytic converter would be
performance of the OBD system has been compiled.
suspended until Misfire fault was repaired. If the Misfire
These non-vehicle faults vary from environmental
fault was severe enough, the catalytic converter could be
conditions to the quality of fuel used.
damaged due to overheating and would never set a
The illumination of the MIL (“Check Engine” lamp) due to
Catalyst DTC until the Misfire fault was repaired and the
a non-vehicle fault could lead to misdiagnosis of the
Catalyst diagnostic was allowed to run to completion. If
vehicle, increased warranty expense and customer
this happens, the customer may have to make two trips to
dissatisfaction. The following list of non-vehicle faults
the dealership in order to repair the vehicle.
does not include every possible fault and may not apply
equally to all product lines. Maintenance Schedule
Fuel Quality Refer to the Maintenance Schedule.
Using fuel with the wrong octane rating for your vehicle
may cause driveability problems. Many of the major fuel Visual / Physical Engine Compartment
companies advertise that using “premium” gasoline will Inspection
improve the performance of your vehicle. Most premium Perform a careful visual and physical engine
fuels use alcohol to increase the octane rating of the fuel. compartment inspection when performing any diagnostic
Although alcohol-enhanced fuels may raise the octane procedure or diagnosing the cause of an emission test
rating, the fuel’s ability to turn into vapor in cold failure. This can often lead to repairing a problem without
temperatures deteriorates. This may affect the starting further steps. Use the following guidelines when
ability and cold driveability of the engine. performing a visual/physical inspection:
Low fuel levels can lead to fuel starvation, lean engine Inspect all vacuum hoses for punches, cuts,
operation, and eventually engine misfire. disconnects, and correct routing.
Inspect hoses that are difficult to see behind other
Non-OEM Parts
components.
All of the OBD diagnostics have been calibrated to run
Inspect all wires in the engine compartment for proper
with OEM parts. Something as simple as a connections, burned or chafed spots, pinched wires,
high-performance exhaust system that affects exhaust contact with sharp edges or contact with hot exhaust
system back pressure could potentially interfere with the manifolds or pipes.
operation of the EGR valve and thereby turn on the MIL
(“Check Engine” lamp). Small leaks in the exhaust Basic Knowledge of Tools Required
system near the post catalyst oxygen sensor can also
cause the MIL (“Check Engine” lamp) to turn on. NOTE: Lack of basic knowledge of this powertrain when
Aftermarket electronics, such as cellular phones, performing diagnostic procedures could result in an
stereos, and anti-theft devices, may radiate EMI into the incorrect diagnosis or damage to powertrain
control system if they are improperly installed. This may components. Do not attempt to diagnose a powertrain
cause a false sensor reading and turn on the MIL (“Check problem without this basic knowledge.
Engine” lamp). A basic understanding of hand tools is necessary to effec-
tively use this section of the Service Manual.
Environment
Temporary environmental conditions, such as localized
flooding, will have an effect on the vehicle ignition system.
Serial Data Communications
If the ignition system is rain-soaked, it can temporarily
cause engine misfire and turn on the MIL (“Check Engine” Class II Serial Data Communications
lamp). This vehicle utilizes the “Class II” communication system.
Each bit of information can have one of two lengths: long
Poor Vehicle Maintenance or short. This allows vehicle wiring to be reduced by
The sensitivity of OBD diagnostics will cause the MIL transmitting and receiving multiple signals over a single
(“Check Engine” lamp) to turn on if the vehicle is not wire. The messages carried on Class II data streams are
maintained properly. Restricted air filters, fuel filters, and also prioritized. If two messages attempt to establish
crankcase deposits due to lack of oil changes or improper communications on the data line at the same time, only
oil viscosity can trigger actual vehicle faults that were not the message with higher priority will continue. The device
previously monitored prior to OBD. Poor vehicle with the lower priority message must wait. The most
maintenance can not be classified as a “non-vehicle significant result of this regulation is that it provides Tech 2
fault”, but with the sensitivity of OBD diagnostics, vehicle manufacturers with the capability to access data from any
maintenance schedules must be more closely followed. make or model vehicle that is sold.
ENGINE DRIVEABILITY AND EMISSIONS 6E–39
The data displayed on the other Tech 2 will appear the In addition to the circuit continuity and rationality check,
same, with some exceptions. Some Tech 2s will only be the ECT sensor is monitored for its ability to achieve a
able to display certain vehicle parameters as values that steady state temperature to enable closed loop fuel
are a coded representation of the true or actual value. For control.
more information on this system of coding, refer to
Decimal/Binary/Hexadecimal Conversions. On this Output Components:
vehicle Tech 2 displays the actual values for vehicle Output components are diagnosed for proper response to
parameters. It will not be necessary to perform any control module commands. Components where
conversions from coded values to actual values. functional monitoring is not feasible will be monitored for
circuit continuity and out-of-range values if applicable.
On-Board Diagnostic (OBD) Output components to be monitored include, but are not
limited to, the following circuits:
On-Board Diagnostic Tests Idle Air Control (IAC) Motor
A diagnostic test is a series of steps, the result of which is Electronic Transmission controls
a pass or fail reported to the diagnostic executive. When A/C relays
a diagnostic test reports a pass result, the diagnostic Cooling fan relay
executive records the following data:
VSS output
The diagnostic test has been completed since the last
ignition cycle. MIL control
The diagnostic test has passed during the current Cruise control inhibit
ignition cycle. Refer to PCM and Sensors in General Descriptions.
The fault identified by the diagnostic test is not Passive and Active Diagnostic Tests
currently active.
A passive test is a diagnostic test which simply monitors a
When a diagnostic test reports a fail result, the diagnostic vehicle system or component. Conversely, an active test,
executive records the following data: actually takes some sort of action when performing
The diagnostic test has been completed since the last diagnostic functions, often in response to a failed passive
ignition cycle. test. For example, the EGR diagnostic active test will
The fault identified by the diagnostic test is currently force the EGR valve open during closed throttle decel
active. and/or force the EGR valve closed during a steady state.
The fault has been active during this ignition cycle. Either action should result in a change in manifold
The operating conditions at the time of the failure. pressure.
Remember, a fuel trim DTC may be triggered by a list of
Intrusive Diagnostic Tests
vehicle faults. Make use of all information available (other
DTCs stored, rich or lean condition, etc.) when This is any on-board test run by the Diagnostic
diagnosing a fuel trim fault. Management System which may have an effect on
vehicle performance or emission levels.
Comprehensive Component Monitor Warm-Up Cycle
Diagnostic Operation
A warm-up cycle means that engine at temperature must
Input Components: reach a minimum of 70 C (160 F) and rise at least 22 C
(40 F) over the course of a trip.
Input components are monitored for circuit continuity and
out-of-range values. This includes rationality checking. Freeze Frame
Rationality checking refers to indicating a fault when the Freeze Frame is an element of the Diagnostic
signal from a sensor does not seem reasonable, i.e. Management System which stores various vehicle
Throttle Position (TP) sensor that indicates high throttle information at the moment an emissions-related fault is
position at low engine loads or MAP voltage. Input stored in memory and when the MIL is commanded on.
components may include, but are not limited to the These data can help to identify the cause of a fault. Refer
following sensors: to Storing And Erasing Freeze Fame Data for more
Vehicle Speed Sensor (VSS) detailed information.
Crankshaft Position (CKP) sensor
Failure Records
Knock Sensor (KS)
Failure Records data is an enhancement of the OBD
Throttle Position (TP) sensor
Freeze Frame feature. Failure Records store the same
Engine Coolant Temperature (ECT) sensor vehicle information as does Freeze Frame, but it will store
Camshaft Position (CMP) sensor that information for any fault which is stored in on-board
Manifold Absolute Pressure (MAP) sensor memory, while Freeze Frame stores information only for
Mass Air Flow (MAF) sensor emission-related faults that command the MIL on.
6E–40 ENGINE DRIVEABILITY AND EMISSIONS
Common OBD Terms The Diagnostic Executive
The Diagnostic Executive is a unique segment of
Diagnostic software which is designed to coordinate and prioritize
When used as a noun, the word diagnostic refers to any the diagnostic procedures as well as define the protocol
on-board test run by the vehicle’s Diagnostic for recording and displaying their results. The main
Management System. A diagnostic is simply a test run on responsibilities of the Diagnostic Executive are listed as
a system or component to determine if the system or following:
component is operating according to specification. There Commanding the MIL (“Check Engine” lamp) on and
are many diagnostics, shown in the following list: off
Oxygen sensors DTC logging and clearing
Oxygen sensor heaters Freeze Frame data for the first emission related DTC
EGR recorded
Catalyst monitoring Non-emission related Service Lamp (future)
Operating conditions Failure Records buffer, (the
Enable Criteria number of records will vary)
The term “enable criteria” is engineering language for the Current status information on each diagnostic
conditions necessary for a given diagnostic test to run. The Diagnostic Executive records DTCs and turns on the
Each diagnostic has a specific list of conditions which MIL when emission-related faults occur. It can also turn
must be met before the diagnostic will run. “Enable off the MIL if the conditions cease which caused the DTC
criteria” is another way of saying “conditions required”. to set.
The enable criteria for each diagnostic is listed on the first
page of the DTC description under the heading Diagnostic Information
“Conditions for Setting the DTC”. Enable criteria varies The diagnostic charts and functional checks are designed
with each diagnostic, and typically includes, but is not to locate a faulty circuit or component through a process
limited to the following items: of logical decisions. The charts are prepared with the
engine speed requirement that the vehicle functioned correctly at the
vehicle speed time of assembly and that there are not multiple faults
ECT present.
MAF/MAP There is a continuous self-diagnosis on certain control
functions. This diagnostic capability is complemented by
barometric pressure the diagnostic procedures contained in this manual. The
IAT language of communicating the source of the malfunction
TP is a system of diagnostic trouble codes. When a
fuel trim malfunction is detected by the control module, a
TCC enabled diagnostic trouble code is set and the Malfunction
Indicator Lamp (MIL) (“Check Engine” lamp) is
A/C on illuminated.
Trip Malfunction Indicator Lamp (MIL)
Technically, a trip is a key on-run-key off cycle in which all The Malfunction Indicator Lamp (MIL) looks the same as
the enable criteria for a given diagnostic are met, allowing the MIL you are already familiar with (“Check Engine”
the diagnostic to run. Unfortunately, this concept is not lamp). However, OBD requires that the it illuminate under
quite that simple. A trip is official when all the enable a strict set of guide lines.
criteria for a given diagnostic are met. But because the Basically, the MIL is turned on when the PCM detects a
enable criteria vary from one diagnostic to another, the DTC that will impact the vehicle emissions.
definition of trip varies as well. Some diagnostic are run The MIL is under the control of the Diagnostic Executive.
when the vehicle is at operating temperature, some when The MIL will be turned on if an emissions-related
the vehicle first start up; some require that the vehicle be diagnostic test indicates a malfunction has occurred. It
cruising at a steady highway speed, some run only when will stay on until the system or component passes the
the vehicle is idle; some diagnostics function with the same test, for three consecutive trips, with no
TCC disables. Some run only immediately following a emissionsrelated faults.
cold engine start-up.
A trip then, is defined as a key on-run-key off cycle in Extinguishing the MIL
which the vehicle was operated in such a way as to satisfy When the MIL is on, the Diagnostic Executive will turn off
the enables criteria for a given diagnostic, and this the MIL after three consecutive trips that a “test passed”
diagnostic will consider this cycle to be one trip. However, has been reported for the diagnostic test that originally
another diagnostic with a different set of enable criteria caused the MIL to illuminate.
(which were not met) during this driving event, would not Although the MIL has been turned off, the DTC will remain
consider it a trip. No trip will occur for that particular in the PCM memory (both Freeze Frame and Failure
diagnostic until the vehicle is driven in such a way as to Records) until forty(40) warm-up cycles after no faults
meet all the enable criteria. have been completed.
ENGINE DRIVEABILITY AND EMISSIONS 6E–41
If the MIL was set by either a fuel trim or misfire-related Stores a Fail Record when the first test fails (not
DTC, additional requirements must be met. In addition to dependent on consecutive trip fails)
the requirements stated in the previous paragraph, these Updates the Fail Record each time the diagnostic
requirements are as follows: test fails
The diagnostic tests that are passed must occur with Type C (if the vehicle is so equipped)
375 RPM of the RPM data stored at the time the last
Non-Emissions related
test failed.
Requests illumination of the Service Lamp or the
Plus or minus ten (10) percent of the engine load that
service message on the Drive Information Center
was stored at the time the last failed.
(DIC) on the first trip with a fail
Similar engine temperature conditions (warmed up or
Stores a History DTC on the first trip with a fail
warming up ) as those stored at the time the last test
failed. Does not store a Freeze Frame
Meeting these requirements ensures that the fault which Stores Fail Record when test fails
turned on the MIL has been corrected. Updates the Fail Record each time the diagnostic
The MIL (“Check Engine” lamp) is on the instrument test fails
panel and has the following function: Type D (Type D non-emissions related are not utilized
It informs the driver that a fault affects vehicle emission on certain vehicle applications).
levels has occurred and that the vehicle should be Non-Emissions related
taken for service as soon as possible.
Dose not request illumination of any lamp
As a bulb and system check, the MIL will come “ON”
with the key “ON” and the engine not running. When Stores a History DTC on the first trip with a fail
the engine is started, the MIL will turn “OFF.” Does not store a Freeze Frame
When the MIL remains “ON” while the engine is Stores Fail Record when test fails
running, or when a malfunction is suspected due to a Updates the Fail Record each time the diagnostic
driveability or emissions problem, a Powertrain test fails
On-Board Diagnostic (OBD ll) System Check must be
IMPORTANT: Only four Fail Records can be stored.
performed. The procedures for these checks are given
Each Fail Record is for a different DTC. It is possible that
in On-Board Diagnostic (OBD) System Check. These
there will not be Fail Records for every DTC if multiple
checks will expose faults which may not be detected if
DTCs are set.
other diagnostics are performed first.
Storing and Erasing Freeze Frame Data and Failure
DTC Types Records
Each DTC is directly related to a diagnostic test. The The data captured is called Freeze Frame data. The
Diagnostic Management System sets DTC based on the Freeze Frame data is very similar to a single record of
failure of the tests during a trip or trips. Certain tests must operating conditions. Whenever the MIL is illuminated,
fail two (2) consecutive trips before the DTC is set. The the corresponding record of operating conditions is
following are the four (4) types of DTCs and the recorded to the Freeze Frame buffer.
characteristics of those codes: Data from these faults take precedence over data
Type A associated with any other fault. The Freeze Frame data
Emissions related will not be erased unless the associated history DTC is
Requests illumination of the MIL of the first trip with a cleared.
fail Each time a diagnostic test reports a failure, the current
Stores a History DTC on the first trip with a fail engine operating conditions are recorded in the Failure
Records buffer. A subsequent failure will update the
Stores a Freeze Frame (if empty)
recorded operating conditions. The following operating
Stores a Fail Record conditions for the diagnostic test which failed typically
Updates the Fail Record each time the diagnostic include the following parameters:
test fails Air Fuel Ratio
Type B Air Flow Rate
Emissions related Fuel Trim
“Armed” after one (1) trip with a fail Engine Speed
“Disarmed” after one (1) trip with a pass Engine Load
Requests illumination of the MIL on the second Engine Coolant Temperature
consecutive trip with a fail
Vehicle Speed
Stores a History DTC on the second consecutive trip
with a fail (The DTC will be armed after the first fail) TP Angle
Stores a Freeze Frame on the second consecutive MAP/BARO
trip with a fail (if empty) Injector Base Pulse Width
Loop Status
6E–42 ENGINE DRIVEABILITY AND EMISSIONS
Intermittent Malfunction Indicator Lamp Reading Diagnostic Trouble Codes Using
In the case of an “intermittent” fault, the MIL (“Check A Tech 2
Engine” lamp) may illuminate and then (after three trips) The procedure for reading diagnostic trouble code(s) is to
go “OFF”. However, the corresponding diagnostic trouble used a diagnostic Tech 2. When reading DTC(s), follow
code will be stored in the memory. When unexpected instructions supplied by Tech 2 manufacturer.
diagnostic trouble codes appear, check for an intermittent
malfunction. Clearing Diagnostic Trouble Codes
A diagnostic trouble code may reset. Consult the
IMPORTANT: Do not clear DTCs unless directed to do
“Diagnostic Aids” associated with the diagnostic trouble
so by the service information provided for each diagnostic
code. A physical inspection of the applicable sub-system procedure. When DTCs are cleared, the Freeze Frame
most often will resolve the problem. and Failure Record data which may help diagnose an
Data Link Connector (DLC) intermittent fault will also be erased from memory.
The provision for communication with the control module If the fault that caused the DTC to be stored into memory
is the Data Link Connector (DLC). The DLC is used to has been corrected, the Diagnostic Executive will begin to
connect to Tech 2. Some common uses of Tech 2 are count the “warm-up” cycles with no further faults
listed below: detected, the DTC will automatically be cleared from the
PCM memory.
Identifying stored Diagnostic Trouble Codes (DTCs).
To clear Diagnostic Trouble Codes (DTCs), use the
Clearing DTCs. diagnostic Tech 2 “clear DTCs”. When clearing DTCs
Performing output control tests. follow instructions supplied by the tool manufacturer.
Reading serial data. When Tech 2 is not available, DTCs can also be cleared
by disconnecting one of the following sources for at least
thirty (30) seconds.
NOTE: To prevent system damage, the ignition key must
be “OFF” when disconnecting or reconnecting battery
power.
The power source to the control module. Examples:
fuse, pigtail at battery PCM connectors etc.
The negative battery cable. (Disconnecting the
negative battery cable will result in the loss of other
on-board memory data, such as preset radio tuning).

TS24064

Verifying Vehicle Repair


Verification of vehicle repair will be more comprehensive
for vehicles with OBD system diagnostic. Following a
repair, the technician should perform the following steps:
1. Review and record the Fail Records and/or Freeze
Frame data for the DTC which has been diagnosed
(Freeze Frame data will only be stored for an A or B
type diagnostic and only if the MIL has been
requested).
2. Clear DTC(s).
3. Operate the vehicle within conditions noted in the Fail
Records and/or Freeze Frame data.
4. Monitor the DTC status information for the specific
DTC which has been diagnosed until the diagnostic
test associated with that DTC runs.
Following these steps are very important in verifying
repairs on OBD systems. Failure to follow these steps
could result in unnecessary repairs.
ENGINE DRIVEABILITY AND EMISSIONS 6E–43
Tech 2
From 98 MY, Isuzu dealer service departments are
recommended to use Tech 2. Please refer to Tech 2 Tech
2 user guide.

901RW180

Legend (3) SAE 16/19 Adaptor


(1) PCMCIA Card (4) DLC Cable
(2) RS 232 Loop Back Connector (5) Tech–2

Tech 2 Features 5. The Tech 2 has the capability of two snapshots.


1. Tech 2 is 12 volt system. Do not apply 24 volt. 6. The PCMCIA card is sensitive to magnetism and
static electricity, so care should be taken in the
2. After connect and/or install Tech 2 body, Vehicle handling of the card.
Communications Interface (VCI) module, PCMCIA
card and DLC connector, connect them to the vehicle 7. The Tech 2 can plot a graph when replaying a
DLC. snapshot.
3. After power off to the Tech 2, remove and reinstall the 8. Always return to the Main Menu to press EXIT key
PCMCIA card. several times before shutting down.
4. The PCMCIA card has a capacity of 10 Megabytes 9. To clear Diagnostic Trouble Codes (DTCs), open
which is 10 times greater than the memory of the Tech Application Menu and press “F1: Clear DTC Info”.
1 Mass Storage Cartridge.
6E–44 ENGINE DRIVEABILITY AND EMISSIONS
Getting Started Operating Procedure (For Example)
Before operating the Isuzu PCMCIA card with the Tech The power up screen is displayed when you power up the
2, the following steps must be performed: tester with the Isuzu systems PCMCIA card. Follow the
1. The Isuzu 98 System PCMCIA card (1) inserts into operating procedure below. (Ver. 5.471)
the Tech 2 (5).
2. Connect the SAE 16/19 adapter (3) to the DLC cable
(4).
3. Connect the DLC cable to the Tech 2 (5)
4. Make sure the vehicle ignition is off.
5. Connect the Tech 2 SAE 16/19 adapter to the vehicle
DLC.
1. For RHD model: Right front side in the console
box.
2. For LHD model: Left front side in the console box.

060RW220

6. The vehicle ignition turns on.


7. Verify the Tech 2 power up display.

060RW014

060RW009

NOTE: The RS232 Loop back connector is only to use for


diagnosis of Tech 2 and refer to user guide of the Tech 2.
ENGINE DRIVEABILITY AND EMISSIONS 6E–45
Menu
The following table shows, which functions are used
the available equipment versions.

060RW228

DTC Modes

060RW218

060RW229

On OBD passenger cars there are five options available


in Tech 2 DTC mode to display the enhanced information
available. A description of the new modes, DTC Info
follows. After selecting DTC, the following menu
appears:
DTC Info
Freeze Frame
Fail Records (not all applications)
Clear Info
6E–46 ENGINE DRIVEABILITY AND EMISSIONS
Fail This Ignition
This selection will display all DTCs that have failed during
the present ignition cycle.
History
This selection will display only DTCs that are stored in the
PCM’s history memory. It will not display Type B DTCs
that have not requested the MIL (“Check Engine” lamp). It
will display all type A and B DTCs that have requested the
MIL and have failed within the last 40 warm-up cycles. In
addition, it will display all type C and type D DTCs that
have failed within the last 40 warm-up cycles.
Last Test Failed
This selection will display only DTCs that have failed the
last time the test ran. The last test may have run during a
previous ignition cycle if a type A or type B DTC is
displayed. For type C and type D DTCs, the last failure
must have occurred during the current ignition cycle to
060RW223
appear as Last Test Fail.
The following is a brief description of each of the sub
menus in DTC Info and Specific DTC. The order in which MILSVC or Message Requested
they appear here is alphabetical and not necessarily the This selection will display only DTCs that are requesting
way they will appear on the Tech 2. the MIL. Type C and type D DTCs cannot be displayed
using this option. This selection will report type B DTCs
DTC Information Mode only after the MIL has been requested.
Use the DTC info mode to search for a specific type of Not Run Since Code Clear
stored DTC information. There are seven choices. The
service manual may instruct the technician to test for This option will display up to 33 DTCs that have not run
DTCs in a certain manner. Always follow published since the DTCs were last cleared. Since any displayed
service procedures. DTCs have not run, their condition (passing or failing) is
To get a complete description of any status, press the unknown.
“Enter” key before pressing the desired F-key. For Test Failed Since Code Clear
example, pressing “Enter” then an F-key will display a
definition of the abbreviated Tech 2 status. This selection will display all active and history DTCs that
have reported a test failure since the last time DTCs were
cleared. DTCs that last failed more than 40 warm-up
cycles before this option is selected will not be displayed.

Injector Balance Test


This test is conducted to make it sure that appropriate
electric signals are being sent to injectors Nos. 1–6.
Tech 2 must be used for this test.
Test Procedure:
1. Connect Tech 2 to the vehicle DLC.
2. Run the Engine at idle.

060RW221

DTC Status
This selection will display any DTCs that have not run
during the current ignition cycle or have reported a test
failure during this ignition up to a maximum of 33 DTCs.
DTC tests which run and pass will cause that DTC
number to be removed from Tech 2 screen.
ENGINE DRIVEABILITY AND EMISSIONS 6E–47
3. Select F3: Miscellaneous Test in the Application 5. Select injector number and push “injector off” of soft
Menu. key.

060RW228 060RW230

4. Select F7: Injector Balance Test in the Miscellaneous 6. Make sure of engine speed change.
Test. 7. In the engine speed whose change has been
confirmed, the injector electric circuit can be regard
as normal.
As for the engine speed whose change has not been
confirmed, the injector electric circuit or the injector
proper is faulty.

EGR Control Test


This test is conducted check EGR valve for its working.
Tech 2 must be used for this test.
Test Procedure:
1. Connect Tech 2 to the vehicle DLC.
2. Run the Engine at idle.
3. Select F3: Miscellaneous Test in the Application
Menu.

060RX006

060RW228
6E–48 ENGINE DRIVEABILITY AND EMISSIONS
4. Select F5: EGR Control Test in the Miscellaneous 3. Select F3: Miscellaneous Test in the Application
Test. Menu.

060RX008 060RW228

5. Instruct EGR Valve to check a data list. 4. Select F3: IAC System Test in the Miscellaneous
Test.

060RW234

6. If change in the data list shows a normal valve. 060RX007

Idle Air Control System Test


This test is conducted check IAC system for its working.
Tech 2 must be used for this test.
Test Procedure:
1. Connect Tech 2 to the vehicle DLC.
2. Run the Engine at idle.
ENGINE DRIVEABILITY AND EMISSIONS 6E–49
5. Select F1: IAC Control Test. F0: RPM Control

060RW235 060RW232

6. Instruct IAC system to check a data list. F2: IAC Reset

060RW233
060RW231

7. If change in the data list shows a normal IAC.


6E–50 ENGINE DRIVEABILITY AND EMISSIONS

Primary System-Based Diagnostic Fuel Trim System Monitor Diagnostic


Operation
Primary System-Based Diagnostic
There are primary system-based diagnostics which Fuel Trim System Monitor Diagnostic
evaluate system operation and its effect on vehicle Operation
emissions. The primary system-based diagnostics are This system monitors the averages of short-term and
listed below with a brief description of the diagnostic long-term fuel trim values. If these fuel trim values stay at
function: their limits for a calibrated period of time, a malfunction is
Oxygen Sensor Diagnosis indicated. The fuel trim diagnostic compares the
averages of short-term fuel trim values and long-term fuel
The fuel control heated oxygen sensors (Bank 1 HO2S 1
trim values to rich and lean thresholds. If either value is
and Bank 2 HO2S 1) are diagnosed for the following
within the thresholds, a pass is recorded. If both values
conditions:
are outside their thresholds, a rich or lean DTC will be
Inactive signal (output steady at bias voltage – approx. recorded.
450 mV) The fuel trim system diagnostic also conducts an intrusive
Signal fixed high test. This test determines if a rich condition is being
Signal fixed low caused by excessive fuel vapor from the EVAP canister.
If the oxygen sensor pigtail wiring, connector or terminal In order to meet OBD requirements, the control module
are damaged, the entire oxygen sensor assembly must uses weighted fuel trim cells to determine the need to set
be replaced. DO NOT attempt to repair the wiring, a fuel trim DTC. A fuel trim DTC can only be set if fuel trim
connector or terminals. In order for the sensor to function counts in the weighted fuel trim cells exceed
properly, it must have clean reference air provided to it. specifications. This means that the vehicle could have a
This clean air reference is obtained by way of the oxygen fuel trim problem which is causing a problem under
sensor wire(s). Any attempt to repair the wires, connector certain conditions (i.e., engine idle high due to a small
or terminals could result in the obstruction of the vacuum leak or rough idle due to a large vacuum leak)
reference air and degrade oxygen sensor performance. while it operates fine at other times. No fuel trim DTC
Refer to On-Vehicle Service, Heated Oxygen Sensors. would set (although an engine idle speed DTC or HO2S
DTC may set). Use a Tech 2 to observe fuel trim counts
Fuel Control Heated Oxygen Sensor while the problem is occurring.
The main function of the fuel control heated oxygen A fuel trim DTC may be triggered by a number of vehicle
sensors is to provide the control module with exhaust faults. Make use of all information available (other DTCs
stream oxygen content information to allow proper fueling stored, rich or lean condition, etc.) when diagnosing a fuel
and maintain emissions within mandated levels. After it trim fault.
reaches operating temperature, the sensor will generate
a voltage, inversely proportional to the amount of oxygen Fuel Trim Cell Diagnostic Weights
present in the exhaust gases. The control module uses No fuel trim DTC will set regardless of the fuel trim counts
the signal voltage from the fuel control heated oxygen in cell 0 unless the fuel trim counts in the weighted cells
sensors while in closed loop to adjust fuel injector pulse are also outside specifications. This means that the
width. While in closed loop, the PCM can adjust fuel vehicle could have a fuel trim problem which is causing a
delivery to maintain an air/fuel ratio which allows the best problem under certain conditions (i.e. engine idle high due
combination of emission control and driveability. to a small vacuum leak or rough due to a large vacuum
leak) while it operates fine at other times. No fuel trim
HO2S Heater DTC would set (although an engine idle speed DTC or
Heated oxygen sensors are used to minimize the amount HO2S DTC may set). Use a Tech 2 to observe fuel trim
of time required for closed loop fuel control to begin counts while the problem is occurring.
operation and to allow accurate catalyst monitoring. The
oxygen sensor heater greatly decreases the amount of
time required for fuel control sensors (Bank 1 HO2S 1 and
Bank2 HO2S 1) to become active. Oxygen sensor
heaters are required to maintain a sufficiently high
temperature which allows accurate exhaust oxygen
content readings further away from the engine.
ENGINE DRIVEABILITY AND EMISSIONS 6E–51

On-Board Diagnostic (OBD) System Check

TS321119

Circuit Description Test Description


The on-board diagnostic system check is the starting Number(s) below refer to the step number(s) on the
point for any driveability complaint diagnosis. Before Diagnostic Chart:
using this procedure, perform a careful visual/physical 1. The MIL (“Check Engine” lamp) should be “ON”
check of the PCM and engine grounds for cleanliness and steady with the ignition “ON”/engine “OFF.” If not,
tightness. Chart A-1 should be used to isolate the malfunction.
The on-board diagnostic system check is an organized 2. Checks the Class 2 data circuit and ensures that the
approach to identifying a problem created by an PCM is able to transmit serial data.
electronic engine control system malfunction.
3. This test ensures that the PCM is capable of
Diagnostic Aids controlling the MIL (“Check Engine” lamp) and the
MIL (“Check Engine” lamp) driver circuit is not
An intermittent may be caused by a poor connection, shorted to ground.
rubbed-through wire insulation or a wire broken inside the
4. If the engine will not start, the Cranks But Will Not
insulation. Check for poor connections or a damaged
Run chart should be used to diagnose the condition.
harness. Inspect the PCM harness and connector for
improper mating, broken locks, improperly formed or 7. A Tech 2 parameter which is not within the typical
damaged terminals, poor terminal-to-wire connection, range may help to isolate the area which is causing
and damaged harness. the problem.
6E–52 ENGINE DRIVEABILITY AND EMISSIONS
10.This vehicle is equipped with a PCM which utilizes
an electrically erasable programmable read only
memory (EEPROM). When the PCM is replaced,
the new PCM must be programmed. Refer to UBS
98 model year Immobilizer Workshop Manual.
ENGINE DRIVEABILITY AND EMISSIONS 6E–53

On-Board Diagnostic (OBD) System Check


Step Action Value(s) Yes No
1 1. Ignition “ON,” engine “OFF.”
2. Observe the malfunction indicator lamp (MIL or Go to No MIL
“Check Engine” lamp). (“Check
Is the MIL (“Check Engine” lamp)“ON?” — Go to Step 2 Engine” lamp)
2 1. Ignition “OFF.”
2. Install a Tech 2.
3. Ignition “ON.”
4. Attempt to display PCM engine data with the Tech 2.
Does the Tech 2 display PCM data? — Go to Step 3 Go to Step 8
3 1. Using the Tech 2 output tests function, select MIL
(“Check Engine” lamp) dash lamp control and
command the MIL (“Check Engine” lamp) “OFF.” Go to MIL
(“Check
2. Observe the MIL (“Check Engine” lamp). Engine” lamp)
Did the MIL (“Check Engine” lamp) turn “OFF?” — Go to Step 4 On Steady
4 Attempt to start the engine. Go to Cranks
But Will Not
Did the engine start and continue to run?
— Go to Step 5 Run
5 Select “Display DTCs” with the Tech 2.
Are any DTCs stored? — Go to Step 6 Go to Step 7
6 Are two or more of the following DTCs stored? P0107, Go to
P0108, P0113, P0118, P0122, P0123, P0712.? “Multiple
PCM
Information Go to
Sensor DTCs applicable
— Set” DTC table
7 Compare PCM data values displayed on the Tech 2 to Refer to
the typical engine scan data values. Refer indicated
toTypical Component
Are the displayed values normal or close to the typical
scan data System
values?
— value Checks
8 1. Ignition “OFF,” disconnect the PCM.
2. Ignition “ON,” engine “OFF.”
3. Check the Class 2 data circuit for an open, short to
ground, or short to voltage. Also, check the DLC
ignition feed circuit for an open or short to ground
and the DLC ground circuit for an open.
4. If a problem is found, repair as necessary.
Was a problem found? — Go to Step 2 Go to Step 9
9 Attempt to display PCM data with the Tech 2.
Does the Tech 2 display PCM engine data? — Go to Step 2 Go to Step 10
10 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to Powertrain Control Module
(PCM) in On-Vehicle Service.
Is the action complete? — Go to Step 2 —
6E–54 ENGINE DRIVEABILITY AND EMISSIONS

A/C Clutch Control Circuit Diagnosis

D06RW085

Circuit Description The throttle is greater than 90%.


When air conditioning and blower fan are selected, and if The ignition voltage is below 10.5 volts.
the system has a sufficient refrigerant charge, a 12-volt The engine speed is greater than 4500 RPM for 5
signal is supplied to the A/C request input of the seconds or 5400 RPM.
powertrain control module (PCM). The A/C request The engine coolant temperature (ECT) is greater than
signal may be temporarily canceled during system 125 C (257 F).
operation by the electronic thermostat in the evaporator The intake air temperature (IAT) is less than 5 C
case. The electronic thermostat may intermittently (41 F).
remove the control circuit ground for the A/C thermostat
The power steering pressure switch signals a cramped
relay to prevent the evaporator from forming ice. When
position.
the A/C request signal is received by the PCM, the PCM
supplies a ground from the compressor clutch relay if the Diagnostic Aids
engine operating conditions are within acceptable
ranges. With the A/C compressor relay energized, To diagnose an the intermittent fault, check for the
voltage is supplied to the compressor clutch coil. following conditions:
The PCM will enable the compressor clutch to engage Poor connection at the PCM–Inspect connections for
whenever A/C has been selected with the engine running, backed-out terminals, improper mating, broken locks,
unless any of the following conditions are present: improperly formed or damaged terminals, and poor
terminal-to-wire connection.
ENGINE DRIVEABILITY AND EMISSIONS 6E–55
Damaged harness–Inspect the wiring harness for 3. This a test determine is the problem is with the
damage. If the harness appears to OK, observe the refrigerant system. If the switch is open, A/C
A/C clutch while moving connectors and wiring pressure gauges will be used to determine if the
harnesses related to the A/C. A sudden clutch pressure switch is faulty or if the system is partially
malfunction will indicate the source of the intermittent discharged or empty.
fault. 4. Although the normal complaint will be the A/C clutch
failing to engage, it is possible for a short circuit to
A/C Clutch Diagnosis cause the clutch to run when A/C has not been
This chart should be used for diagnosing the electrical selected. This step is a test for that condition.
portion of the A/C compressor clutch circuit. A Tech 2 will 7. There is an extremely low probability that both relays
be used in diagnosing the system. The Tech 2 has the will fail at the same time, so the substitution process
ability to read the A/C request input to the PCM. The Tech is one way to check the A/C Thermostat relay. Use
2 can display when the PCM has commanded the A/C a known good relay to do a substitution check.
clutch “ON.” The Tech 2 should have the ability to
9. The blower system furnishes a ground for the A/C
override the A/C request signal and energize the A/C control circuit, and it also shares a power source
compressor relay. through the Heater and A/C Relay. The blower
must be “ON” in order to test the A/C system.
Test Description
IMPORTANT: Do not engage the A/C compressor
clutch with the engine running if an A/C mode is not
selected at the A/C control switch.
The numbers below refer to the step numbers on the
Diagnostic Chart:

A/C Clutch Control Circuit Diagnosis


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 Are any other DTCs stored? Go to the
other DTC
— chart(s) first Go to Step 3
3 1. Disconnect the electrical connector at the pressure Go to Air
switch located on the receiver/drier. Conditioning
2. Use an ohmmeter to check continuity across the to diagnose
pressure switch. the cause of
the open
Is the pressure switch open? pressure
— switch Go to Step 4
4 IMPORTANT: Before continuing with the diagnosis, the
following conditions must be met:
The intake air temperature must be greater than
15 C. (60 F).
The engine coolant temperature must be less
than 119 C (246 F).
1. A/C “OFF.”
2. Start the engine and idle for 1 minute.
3. Observe the A/C compressor.
Is the A/C compressor clutch engaged even though
A/C has not been requested? — Go to Step 45 Go to Step 5
5 1. Idle the engine.
2. A/C “ON”.
3. Blower “ON”.
Refer to
4. Observe the A/C compressor. Diagnostic
Is the A/C compressor magnetic clutch engaged? — Aids Go to Step 6
6E–56 ENGINE DRIVEABILITY AND EMISSIONS

A/C Clutch Control Circuit Diagnosis


Step Action Value(s) Yes No
6 1. Engine idling.
2. A/C “ON”.
3. Blower “ON”.
4. Observe the “A/C Request” display on the Tech 2.
Does the tool “A/C Request” display indicate “Yes?” — Go to Step 34 Go to Step 7
7 Temporarily substitute the A/C compressor relay in
place of the A/C thermostat relay, then repeat Step 5.
Did the “A/C Request” display indicate “Yes?” — Go to Step 8 Go to Step 9
8 Replace the original A/C thermostat relay.
Is the action complete? — Verify repair —
9 Dose the blower operate? — Go to Step 10 Go to Step 11
10 Repair the blower.
Is the action complete? — Verify repair —
11 Check for a faulty 10a A/C fuse in the underdash fuse
panel.
Was the 10A fuse OK? — Go to Step 13 Go to Step 12
12 Check for short circuit and make repairs if necessary.
Replace the 10A A/C fuse.
Is the action complete? — Verify repair —
13 1. Ignition “ON.”
2. Use a DVM to check voltage at the positive A/C
switch wire (BRN).
Was voltage equal to the specified value? +B Go to Step 15 Go to Step 14
14 Repair the open wire (BRN) between the A/C switch
and the A/C fuse.
Is the action complete? — Verify repair —
15 1. Remove the glove box to gain access to the A/C
thermostat.
2. Disconnect the thermostat connector.
3. Attach a fused jumper between ground and the
PNK/GRN wire at the thermostat.
4. A/C “ON.”
5. Blower “ON.”
Dose A/C request indicate “YES” on the Tech 2? — Go to Step 16 Go to Step 23
16 1. Ignition “ON.”
2. Use a DVM to check voltage at the electronic A/C
thermostat.
Was voltage equal to the specified value? +B Go to Step 20 Go to Step 17
17 Check for an open (LT GRN) between the thermostat
and the A/C switch.
Was the wire open? — Go to Step 18 Go to Step 19
18 Repair the open wire (LT GRN) between the thermostat
and the A/C switch.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–57

A/C Clutch Control Circuit Diagnosis


Step Action Value(s) Yes No
19 Replace the A/C switch.
Is the action complete? — Verify repair —
20 Use an ohmmeter to check continuity between the
electronic A/C thermostat and the blower switch.
Was there an open circuit? — Go to Step 21 Go to Step 22
21 Repair the open wire (GRN/YEL) between the
thermostat and the blower switch.
Is the action complete? — Verify repair —
22 Replace the electronic A/C thermostat.
Is the an action complete? — Verify repair —
23 Check for an open circuit between A/C thermostat relay
and PCM A/C request terminal (E-15).
Was there an open circuit? — Go to Step 24 Go to Step 25
24 Repair the open circuit between the PCM and A/C
thermostat relay.
Is the action complete? — Verify repair —
25 Check for an open circuit between the A/C switch (LT
GRN) and the A/C thermostat relay (LT GRN).
Was there an open circuit? — Go to Step 26 Go to Step 27
26 Repair the open circuit between the A/C switch and the
A/C thermostat relay.
Is the action complete? — Verify repair —
27 1. Ignition “ON.”
2. Use a DVM to check voltage at the A/C pressure
switch (BRN).
Was voltage equal to the specified value? +B Go to Step 29 Go to Step 28
28 Repair the open circuit between the 10A A/C fuse and
the pressure switch.
Is the action complete? — Verify repair —
29 Use an ohmmeter to check continuity between the
pressure switch (GRN/WHT) and the A/C thermostat
relay (GRN/WHT).
Was the circuit open? — Go to Step 30 Go to Step 31
30 Repair the open circuit between the pressure switch
and the A/C thermostat relay.
Is the action complete? — Verify repair —
31 Check for damaged pin or terminal at E-15 of the PCM.
Was a damaged pin or terminal found? — Go to Step 32 Go to Step 33
32 Repair the damaged pin or terminal.
Is the action complete? — Verify repair —
33 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
6E–58 ENGINE DRIVEABILITY AND EMISSIONS

A/C Clutch Control Circuit Diagnosis


Step Action Value(s) Yes No
34 1. Remove the A/C compressor relay.
2. Ignition “ON.”
3. Use a DVM to check voltage at both of the BRN
wires at the A/C compressor relay socket.
Is the voltage equal to the specified value? +B Go to Step 36 Go to Step 35
35 Repair the faulty BRN wire between the A/C fuse and
the A/C compressor relay .
Is the action complete? — Verify repair —
36 1. A/C compressor relay removed.
2. Engine idling.
3. A/C “ON.”
4. Blower “ON.”
5. Use a DVM to measure voltage between the
GRN/BLK wire at the A/C compressor relay socket
and battery .
Did the DVM indicate the specified value? +B Go to Step 40 Go to Step 37
37 Check for an open GRN/BLK wire between PCM
terminal B-14 and the A/C compressor relay.
Was the wire open? — Go to Step 38 Go to Step 39
38 Repair the open GRN/BLK wire between the PCM and
the A/C compressor relay.
Is the action complete? — Verify repair —
39 Check for a damaged pin or terminal at B-14 of the
PCM.
Was a damaged pin or a terminal found? — Go to Step 32 Go to Step 33
40 1. A/C compressor relay removed.
2. Connect a fused jumper at the A/C compressor
relay socket between either BRN wire and the
BRN/YEL wire.
3. Engine idling.
4. A/C “ON.”
5. Blower “ON.”
Did the compressor magnetic clutch engage? — Go to Step 41 Go to Step 42
41 Repair the A/C compressor relay.
Is the action complete? — Verify repair —
42 Check for an open circuit between the A/C compressor
relay and the A/C clutch.
Was an open circuit found? — Go to Step 43 Go to Step 44
43 Repair the open circuit between the compressor Clutch
and the A/C compressor relay.
Is the action complete? — Verify repair —
44 Service the compressor clutch or replace the
compressor due to a faulty internal overheat switch.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–59

A/C Clutch Control Circuit Diagnosis


Step Action Value(s) Yes No
45 1. Remove the A/C compressor relay.
2. Idle the engine.
Is the compressor clutch still engaged when A/C is not
selected? — Go to Step 46 Go to Step 47
46 Repair the short to voltage between the A/C clutch and
A/C compressor relay.
Is the action complete? — Verify repair —
47 1. Reinstall the A/C compressor relay.
2. Remove the A/C thermostat relay.
3. Engine idling.
Is the compressor clutch still engaged when A/C is not
selected? — Go to Step 48 Go to Step 50
48 Use a DVM to check for a short to ground between the
A/C compressor relay and B-14 of the PCM.
Was a short detected? — Go to Step 49 Go to Step 33
49 Repair the short to ground between the PCM and A/C
compressor relay.
Is the action complete? — Verify repair —
50 Repair the short to ground between the A/C thermostat
relay and the electronic thermostat.
Is the action complete? — Verify repair —
6E–60 ENGINE DRIVEABILITY AND EMISSIONS

Electronic Ignition System Diagnosis Fuel Injector Coil Test Procedure and
If the engine cranks but will not run or immediately stalls, Fuel Injector Balance Test Procedure
the Engine Cranks But Will Not Start chart must be used
to determine if the failure is the ignition system or the fuel
system. If DTC P0341, or P0336 is set, the appropriate
diagnostic trouble code chart must be used for diagnosis.
If a misfire is being experienced with no DTC set, refer to
the Symptoms section for diagnosis.

Fuel Metering System Check


Some failures of the fuel metering system will result in an
“Engine Cranks But Will Not Run” symptom. If this
condition exists, refer to the Cranks But Will Not Run
chart. This chart will determine if the problem is caused
by the ignition system, the PCM, or the fuel pump
electrical circuit.
Refer to Fuel System Electrical Test for the fuel system
wiring schematic.
If there is a fuel delivery problem, refer to Fuel System
Diagnosis, which diagnoses the fuel injectors, the fuel
pressure regulator, and the fuel pump. If a malfunction
occurs in the fuel metering system, it usually results in
either a rich HO2S signal or a lean HO2S signal. This T32003

condition is indicated by the HO2S voltage, which causes


the PCM to change the fuel calculation (fuel injector pulse Test Description
width) based on the HO2S reading. Changes made to the Number(s) below refer to the step number(s) on the
fuel calculation will be indicated by a change in the long Diagnostic Chart:
term fuel trim values which can be monitored with a Tech
2. Ideal long term fuel trim values are around 0%; for a 2. Relieve the fuel pressure by connecting the
lean HO2S signal, the PCM will add fuel, resulting in a fuel 5-8840-0378-0 Fuel Pressure Gauge to the fuel
trim value above 0%. Some variations in fuel trim values pressure connection on the fuel rail.
are normal because all engines are not exactly the same. CAUTION: In order to reduce the risk of fire and
If the fuel trim values are greater than +23%, refer to DTC personal injury, wrap a shop towel around the fuel
P0131, DTC P0151, DTC P0171, and DTC 1171 for items pressure connection. The towel will absorb any fuel
which can cause a lean HO2S signal. leakage that occurs during the connection of the fuel
pressure gauge. Place the towel in an approved
Idle Air Control (IAC) Valve container when the connection of the fuel pressure
The Tech 2 displays the IAC pintle position in counts. A gauge is complete.
count of “0” indicates the PCM is commanding the IAC Place the fuel pressure gauge bleed hose in an
pintle to be driven all the way into a fully-seated position. approved gasoline container.
This is usually caused by a large vacuum leak.
The higher the number of counts, the more air is being With the ignition switch “OFF,” open the valve on the
commanded to bypass the throttle blade. Refer to IAC fuel pressure gauge.
System Check in order to diagnose the IAC system. 3. Record the lowest voltage displayed by the DVM
Refer to Rough, Unstable, or Incorrect Idle, Stalling in after the first second of the test. (During the first
Symptoms for other possible causes of idle problems. second, voltage displayed by the DVM may be
inaccurate due to the initial current surge.)
Fuel System Pressure Test Injector Specifications:
A fuel system pressure test is part of several of the
diagnostic charts and symptom checks. To perform this Resistance Ohms Voltage Specification at
test, refer to Fuel Systems Diagnosis. 10 C-35 C (50 F-95 F)
11.8 – 12.6 5.7 – 6.6

The voltage displayed by the DVM should be within


the specified range.
The voltage displayed by the DVM may increase
throughout the test as the fuel injector windings
warm and the resistance of the fuel injector windings
changes.
ENGINE DRIVEABILITY AND EMISSIONS 6E–61
An erratic voltage reading (large fluctuations in 7. The Fuel Injector Balance Test portion of this chart
voltage that do not stabilize) indicates an (Step 7 through Step 11) checks the mechanical
intermittent connection within the fuel injector. (fuel delivery) portion of the fuel injector. An engine
5. Injector Specifications: cool-down period of 10 minutes is necessary in
order to avoid irregular fuel pressure readings due
Highest Acceptable Acceptable Subtracted to “Hot Soak” fuel boiling.
Voltage Reading Value
Above/Below 35 C/10 C
(95 F/50 F)
9.5 Volts 0.6 Volts

Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11)

R262001

CYLINDER 1 2 3 4 5 6
1st Reading (1) 296 kPa 296 kPa 296 kPa 296 kPa 296 kPa 296 kPa
(43 psi) (43 psi) (43 psi) (43 psi) (43 psi) (43 psi)
2nd Reading (2) 131 kPa 117 kPa 124 kPa 145 kPa 131 kPa 130 kPa
(19 psi) (17 psi) (18 psi) (21 psi) (19 psi) (19 psi)
Amount of Drop (1st 165 kPa 179 kPa 172 kPa 151 kPa 165 kPa 166 kPa
Reading–2nd Reading) (24 psi) (26 psi) (25 psi) (22 psi) (24 psi) (24 psi)
Av.drop = 166 kPa/24 psi OK Faulty, Rich OK Faulty, Lean OK OK
10 kPa/1.5 psi (Too Much (Too Little
= 156 – 176 kPa or Fuel Drop) Fuel Drop)
22.5 – 25.5 psi

NOTE: These figures are examples only.


6E–62 ENGINE DRIVEABILITY AND EMISSIONS

Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure
(Steps 7-11)
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Turn the engine “OFF.”
NOTE: In order to prevent flooding of a single cylinder
and possible engine damage, relieve the fuel pressure
before performing the fuel injector coil test procedure.
2. Relieve the fuel pressure. Refer to Test Description
Number 2.
3. Connect the 5-8840-2638-0 Fuel Injector Tester to
B+ and ground, and to the 5-8840-2619-0 Injector
Switch Box.
4. Connect the injector switch box to the grey fuel
injector harness connector located on the front of
the EVAP canister bracket.
5. Set the amperage supply selector switch on the fuel
injector tester to the “Coil Test” 0.5 amp position.
6. Connect the leads from the 5-8840-0285-0 Digital
Voltmeter (DVM) to the injector tester. Refer to the
illustrations associated with the test description.
7. Set the DVM to the tenths scale (0.0).
8. Observe the engine coolant temperature. 10 C (50 F)
Is the engine coolant temperature within the specified to 35 C
values? (95 F) Go to Step 3 Go to Step 5
3 1. Set injector switch box injector #1.
2. Press the “Push to Start Test” button on the fuel
injector tester.
3. Observe the voltage reading on the DVM.
IMPORTANT: The voltage reading may rise during the
test.
4. Record the lowest voltage observed after the first
second of the test.
5. Set the injector switch box to the next injector and
repeat steps 2, 3, and 4.
Did any fuel injector have an erratic voltage reading
(large fluctuations in voltage that did not stabilize) or a
voltage reading outside of the specified values? 5.7-6.6 V Go to Step 4 Go to Step 7
4 Replace the faulty fuel injector(s). Refer to Fuel
Injector.
Is the action complete? — Go to Step 7 —
ENGINE DRIVEABILITY AND EMISSIONS 6E–63

Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure
(Steps 7-11)
Step Action Value(s) Yes No
5 1. Set injector switch box injector #1.
2. Press the “Push to Start Test” button on the fuel
injector tester.
3. Observe the voltage reading on the DVM.
IMPORTANT: The voltage reading may rise during the
test.
4. Record the lowest voltage observed after the first
second of the test.
5. Set the injector switch box to the next injector and
repeat steps 2, 3, and 4.
Did any fuel injector have an erratic voltage reading
(large fluctuations in voltage that did not stabilize) or a
voltage reading above the specified value? 9.5 V Go to Step 4 Go to Step 6
6 1. Identify the highest voltage reading recorded (other
than those above 9.5 V).
2. Subtract the voltage reading of each injector from
the highest voltage selected in step 1. Repeat until
you have a subtracted value for each injector.
For any injector, is the subtracted Value in step 2
greater than the specified value? 0.6 V Go to Step 4 Go to Step 7
7 CAUTION: In order to reduce the risk of fire and
personal injury, wrap a shop towel around the
fuel pressure connection. The towel will absorb
any fuel leakage that occurs during the
connection of the fuel pressure gauge. Place the
towel in an approved container when the
connection of the fuel pressure gauge is
complete.
1. Connect the 5-8840-0378-0 Fuel Pressure Gauge
to the fuel pressure test port.
2. Energize the fuel pump using the scan tool.
3. Place the bleed hose of the fuel pressure gauge into
an approved gasoline container.
4. Bleed the air out of the fuel pressure gauge.
5. With the fuel pump running, observe the reading on Go to Fuel
the fuel pressure gauge. 296-376 kPa System
Is the fuel pressure within the specified values? (43-55 psi) Go to Step 8 Diagnosis
8 Turn the fuel pump “OFF.” Go to Fuel
System
Does the fuel pressure remain constant?
— Go to Step 9 Diagnosis
6E–64 ENGINE DRIVEABILITY AND EMISSIONS

Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure
(Steps 7-11)
Step Action Value(s) Yes No
9 1. Connect the 5-8840-2638-0 Fuel Injector Tester
and 5-8840-2619-0 Injector Switch Box the fuel
injector harness connector.
2. Set the amperage supply selector switch on the fuel
injector tester to the “Balance Test” 0.5–2.5 amp
position.
3. Using the scan tool turn the fuel pump “ON” then
“OFF” in order to pressurize the fuel system.
4. Record the fuel pressure indicated by the fuel
pressure gauge after the fuel pressure stabilizes.
This is the first pressure reading.
5. Energize the fuel injector by depressing the “Push
to Start Test” button on the fuel injector tester.
6. Record the fuel pressure indicated by the fuel
pressure gauge after the fuel pressure gauge
needle has stopped moving. This is the second
pressure reading.
7. Repeat steps 1 through 6 for each fuel injector.
8. Subtract the second pressure reading from the first
pressure reading for one fuel injector. The result is
the pressure drop value.
9. Obtain a pressure drop value for each fuel injector.
10.Add all of the individual pressure drop values. This
is the total pressure drop.
11. Divide the total pressure drop by the number of fuel
injectors. This is the average pressure drop.
Does any fuel injector have a pressure drop value that Go to OBD
is either higher than the average pressure drop or lower 10 kPa System
than the average pressure drop by the specified value? (1.5 psi) Go to Step 10 Check
10 Re-test any fuel injector that does not meet the
specification. Refer to the procedure in step 11.
NOTE: Do not repeat any portion of this test before
running the engine in order to prevent the engine from
flooding.
Does any fuel injector still have a pressure drop value
that is either higher than the average pressure drop or
lower than the average pressure drop by the specified 10 kPa Go to
value? (1.5 psi) Go to Step 11 Symptoms
11 Replace the faulty fuel injector(s). Refer to Fuel
Injector.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–65

Knock Sensor Diagnosis The PCM provides a sensor ground to all of the sensors.
The PCM applies 5 volts through a pull-up resistor, and
The Tech 2 has two data displays available for diagnosing
determines the status of the following sensors by
the knock sensor (KS) system. The two displays are
monitoring the voltage present between the 5-volt supply
described as follows:
and the resistor:
“Knock Retard” indicates the number of degrees that
the spark timing is being retarded due to a knock The engine coolant temperature (ETC) sensor
condition. The intake air temperature (IAT) sensor
“KS Noise Channel” indicates the current voltage level The transmission fluid temperature (TFT) sensor
being monitored on the noise channel. The PCM provides the following sensors with a 5-volt
DTCs P0325 and P0327 are designed to diagnose the KS reference and a sensor ground signal:
module, the knock sensor, and the related wiring. The The exhaust gas recirculating (EGR) pintle position
problems encountered with the KS system should set a sensor
DTC. However, if no DTC was set but the KS system is The throttle position (TP) sensor
suspect because of a detonation complaint, refer to
Detonation/Spark Knock in Symptoms. The manifold absolute pressure (MAP) sensor
The PCM monitors the separate feedback signals from
Powertrain Control Module (PCM) these sensors in order to determine their operating
status.
Diagnosis
To read and clear diagnostic trouble codes, use a Tech 2. Diagnostic Aids
IMPORTANT: Use of a Tech 2 is recommended to clear IMPORTANT: Be sure to inspect PCM and engine
diagnostic trouble codes from the PCM memory. grounds for being secure and clean.
Diagnostic trouble codes can also be cleared by turning
the ignition “OFF” and disconnecting the battery power A short to voltage in one of the sensor input circuits may
from the PCM for 30 seconds. Turning off the ignition and cause one or more of the following DTCs to be set:
disconnecting the battery power from the PCM will cause P0108
all diagnostic information in the PCM memory to be P0113
cleared. Therefore, all the diagnostic tests will have to be P0118
re-run.
P0123
Since the PCM can have a failure which may affect only
one circuit, following the diagnostic procedures in this P0560
section will determine which circuit has a problem and P0712
where it is. P0406
If a diagnostic chart indicates that the PCM connections
IMPORTANT: If a sensor input circuit has been shorted
or the PCM is the cause of a problem, and the PCM is
to voltage, ensure that the sensor is not damaged. A
replaced, but this does not correct the problem, one of the
damaged sensor will continue to indicate a high or low
following may be the reason:
voltage after the affected circuit has been repaired. If the
There is a problem with the PCM terminal connections. sensor has been damaged, replace it.
The terminals may have to be removed from the
connector in order to check them properly. An open in the sensor ground circuit between the PCM
and the splice will cause one or more of the following
The problem is intermittent. This means that the DTCs to be set:
problem is not present at the time the system is being
checked. In this case, refer to the Symptoms portion of P0108
the manual and make a careful physical inspection of P0113
all component and wiring associated with the affected P0118
system. P0123
There is a shorted solenoid, relay coil, or harness. P0712
Solenoids and relays are turned “ON” and “OFF” by the
PCM using internal electronic switches called drivers. P0406
A shorted solenoid, relay coil, or harness will not A short to ground in the 5-volt reference A or B circuit will
damage the PCM but will cause the solenoid or relay to cause one or more of the following DTCs to be set:
be inoperative. P0107
P0122
Multiple PCM Information Sensor In the 5-volt reference circuit A, between the PCM and the
DTCS Set splice, will cause one or more of the following DTCs to be
set:
Circuit Description P0122
The powertrain control module (PCM) monitors various In the 5-volt reference circuit B, between the PCM and the
sensors to determine the engine operating conditions. splice, will cause one or more of the following DTCs to be
The PCM controls fuel delivery, spark advance, set:
transmission operation, and emission control device P0107
operation based on the sensor inputs. Check for the following conditions:
6E–66 ENGINE DRIVEABILITY AND EMISSIONS
Poor connection at PCM. Inspect the harness IAT
connectors for backed-out terminals, improper mating, ECT
broken locks, improperly formed or damage terminals,
TP
and a poor terminal-to-wire connection.
MAP
Damaged harness. Inspect the wiring harness for
damage. If the harness is not damaged, observe an EGR
affected sensor’s displayed value on the Tech 2 with TFT
the ignition “ON” and the engine “OFF” while you move
the connectors and the wiring harnesses related to the
following sensors:

Multiple PCM Information Sensor DTCs Set


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Turn the ignition “OFF,” disconnect the PCM.
2. Turn the ignition “ON,” check the 5 volt reference A
circuit for the following conditions:
A poor connection at the PCM.
An open between the PCM connector and the
splice.
A short to ground.
A short to voltage.
Is there an open or short? — Go to Step 3 Go to Step 4
3 Repair the open or short.
Is the action complete? — Verify repair —
4 Check the sensor ground circuit for the following
conditions:
A poor connection at the PCM or the affected
sensors.
An open between the PCM connector and the
affected sensors.
Is there an open or a poor connection? — Go to Step 5 Go to Step 6
5 Repair the open or the poor connection.
Is the action complete? — Verify repair —
6 Measure the voltage between the EGR pintle position
sensor signal circuit at the PCM harness connector and
ground.
Does the voltage measure near the specified value? 0V Go to Step 7 Go to Step 12
7 Measure the voltage between the MAP sensor signal
circuit at the PCM harness connector and ground.
Does the voltage measure near the specified value? 0V Go to Step 8 Go to Step 15
8 Measure the voltage between the TP sensor signal
circuit at the PCM harness connector and ground.
Does the voltage measure near the specified value? 0V Go to Step 9 Go to Step 16
9 Measure the voltage between the IAT sensor signal
circuit at the PCM harness connector and ground.
Does the voltage measure near the specified value? 0V Go to Step 10 Go to Step 17
10 Measure the voltage between the ECT sensor signal
circuit at the PCM harness connector and ground.
Does the voltage measure near the specified value? 0V Go to Step 11 Go to Step 18
ENGINE DRIVEABILITY AND EMISSIONS 6E–67

Multiple PCM Information Sensor DTCs Set


Step Action Value(s) Yes No
11 1. Disconnect the EGR valve.
2. Measure the voltage between the EGR pintle
position sensor signal circuit at the PCM harness
connector and ground.
Does the voltage measure near the specified value? 0V Go to Step 13 Go to Step 18
12 Measure the voltage between the TFT sensor signal
circuit at the PCM harness connector and ground.
Does the voltage measure near the specified value? 0V Go to Step 20 Go to Step 19
13 Replace the EGR valve.
Is the action complete? — Verify repair —
14 Locate and repair the short to voltage in the MAP
sensor signal circuit.
Is the action complete? — Verify repair —
15 Locate and repair the short to voltage in the TP sensor
signal circuit.
Is the action complete? — Verify repair —
16 Locate and repair the short to voltage in the IAT sensor
signal circuit.
Is the action complete? — Verify repair —
17 Locate and repair the short to voltage in the ECT
sensor signal circuit.
Is the action complete? — Verify repair —
18 Locate and repair the short to voltage in the EGR pintle
position sensor signal circuit.
Is the action complete? — Verify repair —
19 Locate and repair the short to voltage in the TFT sensor
signal circuit.
Is the action complete? — Verify repair —
20 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Go to OBD
Workshop Manual. System
Is the action complete? — Check —
6E–68 ENGINE DRIVEABILITY AND EMISSIONS

Exhaust Gas Recirculation (EGR) ECT — (Engine Coolant Temperature) Tech 2


Range –40 C to 151 C (–40 F to 304 F) —
Diagnosis (For except EXPORT and The engine coolant temperature (ECT) is mounted in the
SOUTH AFRICA) coolant stream and sends engine temperature
Pintle position error diagnosis is covered by DTC P0402, information to the PCM. The PCM applies 5 volts to the
P0404, P1404, P0405, P0406. If EGR diagnostic trouble ECT sensor circuit. The sensor is a thermistor which
codes P0402, P0404, P1404, P0405, P0406 are changes internal resistance as temperature changes.
encountered, refer to the DTC charts. When the sensor is cold (high resistance), the PCM
monitors a high signal voltage and interprets that as a cold
Engine Tech 2 Data Definitions and engine. As the sensor warms (decreasing resistance),
the voltage signal will decrease and the PCM will interpret
Ranges the lower voltage as a warm engine.
A/C CLUTCH – Tech 2 Displays ON or OFF – EGR DUTY CYCLE — Tech 2 Range 0%-100% —
Indicates whether the PCM has commanded the A/C Represents the EGR valve driver PWM signal from the
clutch ON. Used in A/C system diagnostic. PCM. A duty cycle of 0% indicates that no EGR flow is
A/C REQUEST — Tech 2 Displays YES or NO — being commanded; a 100% duty cycle indicates
Indicates the state of the A/C request input circuit from the maximum EGR flow commanded.
HVAC controls. The PCM uses the A/C request signal to EGR FEEDBACK — Tech 2 Range 0.00-5.00 Volts —
determine whether A/C compressor operation is being Indicates the EGR pintle position sensor signal voltage
requested. being monitored by the PCM. A low voltage indicates a
AIR/FUEL RATIO — Tech 2 Range 0.0-25.5 — fully extended pintle (closed valve); a voltage near 5 volts
Air/fuel ratio indicates the PCM commanded value. In indicates a retracted pintle (open valve).
closed loop, the air/fuel ratio should normally be ENGINE LOAD — Tech 2 Range 0%-100% —
displayed around “14.2-14.7.” A lower air/fuel ratio Engine load is calculated by the PCM from engine speed
indicates a richer commanded mixture, which may be and MAF sensor readings. Engine load should increase
seen during power enrichment or TWC protection modes. with an increase in RPM or air flow.
A higher air/fuel ratio indicates a leaner commanded
mixture. This can be seen during deceleration fuel mode. ENGINE RUN TIME — Tech 2 Range
00:00:00-99:99:99 Hrs:Min:Sec —
BAROMETRIC PRESSURE — Tech 2 Range 10-105 Indicates the time elapsed since the engine was started.
kPa/0.00-5.00 Volts — If the engine is stopped, engine run time will be reset to
The barometric pressure reading is determined from the 00:00:00.
MAP sensor signal monitored during key up and wide
open throttle (WOT) conditions. The barometric pressure ENGINE SPEED — Range 0-9999 RPM —
is used to compensate for altitude differences and is Engine speed is computed by the PCM from the 58X
normally displayed around “61-104” depending on reference input. It should remain close to desired idle
altitude and barometric pressure. under various engine loads with engine idling.

CHECK TRANS LAMP — AUTO TRANSMISSION — FUEL PUMP — Tech 2 Displays ON or OFF —
Indicates the need to check for a DTC with the Tech 2 Indicates the PCM commanded state of the fuel pump
when the lamp is flashing 0.2 seconds ON and 0.2 relay driver circuit.
seconds OFF. FUEL TRIM CELL — Tech 2 Range 0-21 —
CMP ACT. COUNTER – Cam Position Activity The fuel trim cell is dependent upon engine speed and
DECEL FUEL MODE — Tech 2 Display ACTIVE or MAF sensor readings. A plot of RPM vs. MAF is divided
INACTIVE — into 22 cells. Fuel trim cell indicates which cell is currently
“ACTIVE” displayed indicates that the PCM has detected active.
conditions appropriate to operate in deceleration fuel FUEL TRIM LEARN — Tech 2 Displays NO or YES
mode. The PCM will command the deceleration fuel —
mode when it detects a closed throttle position while the When conditions are appropriate for enabling long term
vehicle is traveling over 20 mph. While in the deceleration fuel trim corrections, fuel trim learn will display “YES.”
fuel delivered by entering open loop and decreasing the This indicates that the long term fuel trim is responding to
injector pulse width. the short term fuel trim. If the fuel trim learn displays
DESIRED EGR POS. — Tech 2 Range 0%-100% — “NO,” then long term fuel trim will not respond to changes
Represents the EGR pintle position that the PCM is in short term fuel trim.
commanding. HO2S BANK 1, SEN. 1 — Tech 2 Range 0-1132 mV
DESIRED IDLE — Tech 2 Range 0-3187 RPM — —
The idle speed that the PCM is commanding. The PCM Represents the fuel control exhaust oxygen sensor
will compensate for various engine loads based on engine output voltage. Should fluctuate constantly within a range
coolant temperature, to keep the engine at the desired between 10 mV (lean exhaust) and 1000 mV (rich
speed. exhaust) while operating in closed loop.
ENGINE DRIVEABILITY AND EMISSIONS 6E–69
HO2S BANK2, SEN. 1—Tech 2 Range 0-1132 mV— KS NOISE CHANNEL (Knock Sensor) —
Represents the fuel control exhaust oxygen sensor Indicates the output from the KS noise channel. There is
output voltage. Should fluctuate constantly within a range always some electrical noise in an engine compartment
between 10mV (lean exhaust) and 1000 mV (rich and to avoid mistaking this as engine knock, the output
exhaust) while operating in closed loop. from the knock sensor is compared to the output from the
noise channel. A knock condition is not set unless the
HO2S BANK 1, SEN. 1—Tech 2 Displays NOT
knock sensor output is greater than the noise channel
READY or READY—
output.
Indicates the status of the exhaust oxygen sensor. The
Tech 2 will indicate that the exhaust oxygen sensor is LONG TERM FUEL TRIM BANK 1/BANK 2 —
ready when the PCM detects a fluctuating HO2S voltage The long term fuel trim is derived from the short term fuel
sufficient to allow closed loop operation. This will not trim values and represents a long term correction of fuel
occur unless the exhaust oxygen sensor is warmed up. delivery for the bank in question. A value of 0% indicates
that fuel delivery requires no compensation to maintain
HO2S BANK 2, SEN. 1 — Tech 2 Displays NOT
the PCM commanded air/fuel ratio. A negative value
READY or READY —
significantly below 0% indicates that the fuel system is
Indicates the status of the exhaust oxygen sensor. The
rich and fuel delivery is being reduced (decreased injector
Tech 2 will indicate that the exhaust oxygen sensor is
pulse width). A positive value significantly greater than
ready when the PCM detects a fluctuating HO2S voltage
0% indicates that a lean condition exists and the PCM is
sufficient to allow closed loop operation. This will not
compensating by adding fuel (increased injector pulse
occur unless the exhaust oxygen sensor is warmed up.
width). Because long term fuel trim tends to follow short
HO2S WARM UP TIME BANK 1, SEN. 1/BANK 2 term fuel trim, a value in the negative range due to
SEN. 1 — Tech 2 Range 00:00:00-99:99:99 canister purge at idle should not be considered unusual.
HRS:MIN:SEC — Fuel trim values at maximum authority may indicate an
Indicates warm-up time for each HO2S. The HO2S excessively rich or lean system.
warm-up time is used for the HO2S heater test. The PCM
LOOP STATUS — Tech 2 Displays OPEN or
will run the heater test only after a cold start (determined
CLOSED —
by engine coolant and intake air temperature at the time
“CLOSED” indicates that the PCM is controlling fuel
of start-up) and only once during an ignition cycle. When
delivery according to oxygen sensor voltage. In “OPEN”
the engine is started the PCM will monitor the HO2S
the PCM ignores the oxygen sensor voltage and bases
voltage. When the HO2S voltage indicates a sufficiently
the amount of fuel to be delivered on TP sensor, engine
active sensor, the PCM looks at how much time has
coolant, and MAF sensor inputs only.
elapsed since start-up. If the PCM determines that too
much time was required for the HO2S to become active, MAF — Tech 2 Range 0.0-512 gm/s —
a DTC will set. If the engine was warm when started, MAF (mass air flow) is the MAF input frequency
HO2S warm-up will the display “00:00:00”. converted to grams of air per second. This indicates the
amount of air entering the engine.
IAC POSITION — Tech 2 Range 0-255 Counts —
Displays the commanded position of the idle air control MAP — Tech 2 Range 10-105 kPa (0.00-4.97 Volts)
pintle in counts. A larger number of counts means that —
more air is being commanded through the idle air The manifold absolute pressure (MAP) sensor measures
passage. Idle air control should respond fairly quickly to the change in the intake manifold pressure from engine
changes in engine load to maintain desired idle RPM. load, EGR flow, and speed changes. As intake manifold
pressure increases, intake vacuum decreases, resulting
IAT (INTAKE AIR TEMPERATURE) — Tech 2 Range
in a higher MAP sensor voltage and kPa reading. The
–40 C to 151 C (–40 F to 304 F) —
MAP sensor signal is used to monitor intake manifold
The PCM converts the resistance of the intake air
pressure changes during the EGR flow test, to update the
temperature sensor to degrees. Intake air temperature
BARO reading, and as an enabling factor for several of
(IAT) is used by the PCM to adjust fuel delivery and spark
the diagnostics.
timing according to incoming air density.
MIL — Tech 2 Displays ON or OFF —
IGNITION 1 — Tech 2 Range 0-25.5 Volts —
Indicates the PCM commanded state of the malfunction
This represents the system voltage measured by the
indicator lamp.
PCM at its ignition feed.
POWER ENRICHMENT — Tech 2 Displays ACTIVE
INJ. PULSE BANK 1/INJ. PULSE BANK 2 — Tech 2
or INACTIVE —
Range 0-1000 msec. —
“ACTIVE” displayed indicates that the PCM has detected
Indicates the amount of time the PCM is commanding
conditions appropriate to operate in power enrichment
each injector “ON” during each engine cycle. A longer
mode. The PCM will command power enrichment mode
injector pulse width will cause more fuel to be delivered.
when a large increase in throttle position and load is
Injector pulse width should increase with increased
detected. While in power enrichment mode, the PCM will
engine load.
increase the amount of fuel delivered by entering open
loop and increasing the injector pulse width. This is done
to prevent a possible sag or hesitation from occurring
during acceleration.
6E–70 ENGINE DRIVEABILITY AND EMISSIONS
SPARK — Tech 2 Range –64 to 64 — Test Conditions
Displays the amount of spark advance being commanded Engine running, lower radiator hose hot, transmission in
by the PCM on the IC circuit.
park or neutral, closed loop, accessaries off, brake not
START-UP ECT — Tech 2 Range –40 C to 151 C applied and air conditioning off.
(–40 F to 304 F) —
Indicates the engine coolant temperature at the time that
the vehicle was started. Used by the HO2S diagnostic to
determine if the last start-up was a cold start.
START-UP IAT — Tech 2 Range –40 C to 151 C
(–40 F to 304 F) —
Indicates the intake air temperature at the time that the
vehicle was started. Used by the HO2S diagnostic to
determine if the last start-up was a cold start.
TP — Tech 2 Range 0%-100% —
TP (throttle position) angle is computed by the PCM from
the TP sensor voltage. TP angle should display “0%” at
idle and “100%” at wide open throttle.
TP SENSOR — Tech 2 Range 0.00-5.00 Volts —
The voltage being monitored by the PCM on the TP
sensor signal circuit.
CATALYST PROTECTION MODE — Tech 2 Displays
YES or NO —
“YES” displayed indicates that the PCM has detected
conditions appropriate to operate in TWC protection
mode. The PCM will decrease the air/fuel ratio to a value
that depends on mass air flow (higher mass air flow =
lower air/fuel ratio).
UPSHIFT LAMP (MANUAL TRANSMISSION)
VEHICLE SPEED — Tech 2 Range 0-255 km/h
(0-155 mph) —
The vehicle speed sensor signal is converted into km/h
and mph for display.
WEAK CYLINDER — Tech 2 Displays Cylinder
Number —
This indicates that the PCM has detected crankshaft
speed variations that indicate 2% or more cylinder firing
events are misfires.

Typical Scan Data Values


Use the Typical Scan Data Values Table only after the
On-Board Diagnostic System Check has been
completed, no DTC(s) were noted, and you have
determined that the on-board diagnostics are functioning
properly. Tech 2 values from a properly-running engine
may be used for comparison with the engine you are
diagnosing. The typical scan data values represent
values that would be seen on a normally-running engine.
NOTE: A Tech 2 that displays faulty data should not be
used, and the problem should be reported to the Tech 2
manufacturer. Use of a faulty Tech 2 can result in
misdiagnosis and unnecessary replacement of parts.
Only the parameters listed below are referred to in this
service manual for use in diagnosis. For further
information on using the Tech 2 to diagnose the PCM and
related sensors, refer to the applicable reference section
listed below. If all values are within the typical range
described below, refer to the Symptoms section for
diagnosis.
ENGINE DRIVEABILITY AND EMISSIONS 6E–71
3.2/3.5L V-6 Engine

Tech 2 Data List Units Typical Data Typical Data Refer To


Parameter Displayed Values (IDLE) Values
(2500 RPM)
A/C Clutch Engine On/Off Off Off General Description and
Operation, A/C Clutch
Circuit Operation
A/C Request Engine Yes/No No No General Description and
Operation, A/C Request
Signal
Air/Fuel Ratio Engine Ratio: _ to 14.7 14.7 General Description and
1 Operation, Fuel System
Metering Purpose
Barometric Engine kPa 61-104 (depends 61-104 (depends General Description and
Pressure on altitude and on altitude and Operation
barometric) barometric)
CMP Act. Engine Counts 0-255, always 0-255, always DTC P0341 and P0342
Counter (Cam increasing increasing
Position Activity)
Decel Fuel Engine Active/Inac Inactive Inactive General Description and
Mode tive Operation, Deceleration
Mode
Desired EGR Engine Percent 0% 0% General Description and
Position Operation, EGR Pintle
Position Sensor
Desired Idle Engine RPM 750 — General Description and
Operation, Idle Air Control
(IAC) Valve
ECT (Engine Engine Degrees C, 80-100 C 80-100 C General Description and
Coolant Temp) Degrees F (176-212 F) (176-212 F) Operation, Engine Coolant
Temperature (ECT) Sensor
EGR Closed Engine Steps 20-40 20-40 General Description and
Valve Pintle Operation, EGR Pintle
Position Position Sensor
EGR Duty Cycle Engine Percent 0% 0% General Description and
Operation, Linear EGR
Operation and Results of
Incorrect Operation
EGR Feedback Engine Volts 0.45-0.80 0.45-0.80 —
EGR Engine Percent 0% 0%

Normalized
Engine Load Engine Percent 2.0% - 5.5% 8.0% - 16.0% General Description and
Operation, Mass Air Flow
(MAF) Sensor
Time From Start Engine Sec Varies. Resets at Varies. Resets at
each engine each engine —
start. start.
Engine Speed Engine RPM Within –50 to Actual engine DTCs: P1508, P1509
+100 of “Desired speed
Idle”
Fuel Pump Engine On/Off On On Engine Fuel
HO2S Bank 1 O2 Sensor Millivolts 50-950 changing 50-950, always General Description and
Sen.1 (millivolts) Data quickly changing quickly Operation, Fuel control
HO2S
6E–72 ENGINE DRIVEABILITY AND EMISSIONS

Tech 2 Data List Units Typical Data Typical Data Refer To


Parameter Displayed Values (IDLE) Values
(2500 RPM)
HO2S Bank 2 O2 Sensor Millivolts 50-950 changing 50-950 changing General Description and
Sen.1 (millivolts) Data quickly quickly Operation, Fuel Control
HO2S
HO2S Bank 1 O2 Sensor Ready Ready Ready General Description and
Sen.1 Data Yes/No Yes Yes Operation, Fuel Control
(ready/not HO2S; DTC: P0135
ready)
HO2S Bank 2 O2 Sensor Ready Ready Ready General Description and
Sen.1 Data Yes/No Yes Yes Operation, Fuel Control
(ready/not HO2S
ready)
HO2S Warm-Up O2 Sensor Seconds 25-45 25-45 General Description and
Time Bank 1 Data Operation, Fuel Control
Sen.1 HO2S
HO2S Warm-Up O2 Sensor Seconds 25-45 25-45 General Description and
Time Bank 2 Data Operation, Fuel Control
Sen.1 HO2S
IAT (Intake Air Engine Degrees C, 0-100 C, 0-80 C, depends General Description and
Temp) Degrees F depends on on underhood Operation, Intake Air
underhood Temperature (IAT) Sensor
Ignition Voltage Engine Volts 12.8-14.1 12.8-14.1 General Description and
Operation, Electronic
Ignition System
Inj. Pulse Bank Engine Millisecond 2.0-4.0 2.5-4.0 General Description, Fuel
1 s Metering, Fuel Injector
Inj. Pulse Bank Engine Millisecond 2.0-4.0 2.5-4.0 General Description, Fuel
2 s Metering, Fuel Injector
KS Noise Engine Volts 0.10-0.40 0.50-1.75 General Description and
Channel (Knock Operation, Knock Sensor
Sensor) Purpose and Operation;
DTCs: P0352, P0327
Loop Status Engine Open/Clos Closed Closed General Description and
ed Operation, Fuel Metering
System; DTCs:
P0125-P0155
MAF (Mass Air Engine Grams per 2.85-6.65 9.5-16.5 General Description and
Flow) second Operation, MAF; DTCs:
P101, P0102, P0103
MAP kPa Engine Kilopascals General Description and
(Manifold Operation, Manifold
Absolute — — Absolute Pressure (MAP)
Pressure) Sensor; DTCs: P0106,
P0107, P0108
MIL Engine On/Off Off Off On-Board Diagnostic
System Check
Power Engine Inactive/Ac Inactive Inactive General Description and
Enrichment tive Operation, Acceleration
Mode
Spark Engine Degrees 15-22 34-44 General Description and
(Advance) Before Top Operation, Electronic
Dead Ignition System
Center
ENGINE DRIVEABILITY AND EMISSIONS 6E–73

Tech 2 Data List Units Typical Data Typical Data Refer To


Parameter Displayed Values (IDLE) Values
(2500 RPM)
Start-Up ECT Engine Degrees C, Depends on Depends on General Description and
(Engine Coolant Degrees F engine coolant engine coolant Operation, Engine Coolant
Temp) temperature at temperature at Temperature (ECT) Sensor
time of start-up time of start-up
Start-Up IAT Engine Degrees C, Depends on Depends on General Description and
(Intake Air Degrees F intake air intake air Operation, Intake Air
Temp) temperature at temperature at Temperature (IAT) Sensor
time of start-up time of start-up
TP Engine Percent 0 General Description and
(Throttle Operation, Throttle
Position) — Position (TP) Sensor;
DTCs: P0121,
P0122,P0123
TP Sensor Engine Volts 0.50-0.82 0.60-1.00 General Description and
(Throttle Operation, Throttle
Position) Position (TP) Sensor;
DTCs: P0121,
P0122,P0123
Catalyst Engine No/Yes No No General Description, Fuel
Protection Mode Metering, catalytic
Converter Protection Mode
Vehicle Speed Engine MPH / 0 0 4L30-E Automatic
km/h Transmission Diagnosis
EVAP Purge Engine Percent 65 99 General Description
Solenoid
VIM Solenoid Engine On/Off On On General Description
Security Wait Engine Active/Inac Inactive Inactive —
Time tive
6E–74 ENGINE DRIVEABILITY AND EMISSIONS

No Malfunction Indicator Lamp (MIL)

D06RW00006

Circuit Description If the engine cranks but will not run, check for an open
The “Check Engine” lamp (MIL) should always be PCM ignition or battery feed, or a poor PCM to engine
ground.
illuminated and steady with the ignition “ON” and the
engine stopped. Ignition feed voltage is supplied to the
MIL bulb through the meter fuse. The powertrain control
Test Description
module (PCM) turns the MIL “ON” by grounding the MIL Number(s) below refer to the step number(s) on the
driver circuit. Diagnostic Chart.
2. A “No MIL” condition accompanied by a no-start
Diagnostic Aids condition suggests a faulty PCM ignition feed or
An intermittent MIL may be cased by a poor connection, battery feed circuit.
rubbed-through wire insulation, or a wire broken inside 9. Using a test light connected to B+, probe each of the
the insulation. Check for the following items: PCM ground terminals to ensure that a good ground
Inspect the PCM harness and connections for is present. Refer to PCM Terminal End View for
improper mating, broken locks, improperly formed or terminal locations of the PCM ground circuits.
damaged terminals, poor terminal-to-wire connection, 12.In this step, temporarily substitute a known good
and damaged harness. relay for the PCM relay. The horn relay is nearby,
If the engine runs OK, check for a faulty light bulb, an and it can be verified as “good” simply by honking
open in the MIL driver circuit, or an open in the the horn. Replace the horn relay after completing
instrument cluster ignition feed. this step.
ENGINE DRIVEABILITY AND EMISSIONS 6E–75
17.This vehicle is equipped with a PCM which utilizes
an electrically erasable programmable read only
memory (EEPROM). When the PCM is replaced,
the new PCM must be programmed. Refer to UBS
98 model year Immobilizer Workshop Manual.

No Malfunction Indicator Lamp (MIL)


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 Attempt to start the engine.
Does the engine start? — Go to Step 3 Go to Step 6
3 Check the meter fuse for the instrument cluster ignition
feed circuit.
Is the fuse OK? — Go to Step 4 Go to Step 16
4 Ignition “ON,” probe the ignition feed circuit at the
cluster connector with a test light to ground.
Is the test light “ON?” — Go to Step 5 Go to Step 13
5 1. Ignition “OFF.”
2. Disconnect the PCM.
3. Jumper the MIL driver circuit at the PCM connector
to ground.
4. Ignition “ON.”
Is the MIL “ON?” — Go to Step 10 Go to Step 11
6 Check the PCM ignition feed and battery feed fuses (15
A engine fuse and 15 A PCM fuse).
Are both fuses OK? — Go to Step 7 Go to Step 15
7 1. Ignition “OFF.”
2. Disconnect the PCM.
3. Ignition “ON.”
4. Probe the ignition feed circuit at the PCM harness
connector with a test light to ground.
Is the test light “ON?” — Go to Step 8 Go to Step 12
8 Probe the battery feed circuit at the PCM harness
connector with a test light to ground.
Is the test light “ON?” — Go to Step 9 Go to Step 14
9 Check for a faulty PCM ground connection.
Was a problem found? — Verify repair Go to Step 10
10 Check for damaged terminals at the PCM.
Was a problem found? — Verify repair Go to Step 17
11 Check for an open MIL driver circuit between the PCM
and the MIL.
Was a problem found? — Verify repair Go to Step 18
12 Substitute a known “good” relay for the PCM main
relay.
Was the malfunction fixed? — Verify repair Go to Step 13
13 Repair the open in the ignition feed circuit.
Is the action complete? — Verify repair —
6E–76 ENGINE DRIVEABILITY AND EMISSIONS

No Malfunction Indicator Lamp (MIL)


Step Action Value(s) Yes No
14 Locate and repair the open PCM battery feed circuit.
Is the action complete? — Verify repair —
15 Locate and repair the short to ground in the PCM
ignition feed circuit or PCM battery feed circuit.
Is the action complete? — Verify repair —
16 Locate and repair the short to ground in the ignition
feed circuit to the instrument cluster, and replace the
fuse.
Is the action complete? — Verify repair —
17 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to PCM in ON-Vehicle Service for
procedures.
Is the action complete? — Verify repair —
18 Check the MIL driver circuit for a poor connection at the Go to
instrument panel connector. Instrument
Panel in
Was a problem found?
Electrical
— Verify repair Diagnosis
ENGINE DRIVEABILITY AND EMISSIONS 6E–77

Malfunction Indicator Lamp (MIL) “ON” Steady

D06RW00007

Circuit description Test Description


The malfunction indicator lamp (MIL) should always be Number(s) below refer to the step number(s) on the
illuminated and steady with ignition “ON” and the engine Diagnostic Chart.
stopped. Ignition feed voltage is supplied directly to the 2. If the MIL does not remain “ON” when the PCM is
MIL indicator. The powertrain control module (PCM) disconnected, the MIL driver wiring is not faulty.
turns the MIL “ON” by grounding the MIL driver circuit. 3. If the MIL driver circuit is OK, the instrument panel
The MIL should not remain “ON” with the engine running cluster is faulty.
and no DTC(s) set. A steady MIL with the engine running
6. This vehicle is equipped with a PCM which utilizes
and no DTC(s) suggests a short to ground in the MIL
an electrically erasable programmable read only
driver circuit.
memory (EEPROM). When the PCM is replaced,
the new PCM must be programmed. Refer to UBS
Diagnostic Aids 98 model year Immobilizer Workshop Manual.
An intermittent may be caused by a poor connection,
rubbed-through wire insulation, or a wire broken inside
the insulation. Check for the following items:
Poor connection or damaged harness – Inspect the
PCM harness and connectors for improper mating,
broken locks, improperly formed or damaged
terminals, poor terminal-to-wire connection, and
damaged harness.
6E–78 ENGINE DRIVEABILITY AND EMISSIONS

Malfunction Indicator Lamp (MIL) “ON” Steady


Step Action Value(s) Yes No
1 Was the “On-Board diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Ignition “OFF,” disconnect PCM.
2. Ignition “ON,” observe the MIL (Service Engine
Soon lamp).
Is the MIL “ON?” — Go to Step 3 Go to Step 5
3 1. Ignition “OFF,” disconnect the instrument panel
cluster.
2. Check the MIL driver circuit between the PCM and
the instrument panel cluster for a short to ground.
Go to OBD
3. If a problem is found, repair as necessary. System
Was the MIL driver circuit shorted to ground? — Check Go to Step 4
4 Replace the instrument panel cluster. Go to OBD
System
Is the action complete?
— Check —
5 1. Ignition “OFF,” reconnect the PCM.
2. Using Tech 2, select “Output Miscellaneous Test” Go to OBD
and command the MIL “OFF.” System
Did the MIL turn “OFF?” — Check Go to Step 6
6 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Go to OBD
Workshop Manual. System
Is the action complete? — Check —
ENGINE DRIVEABILITY AND EMISSIONS 6E–79

Engine Cranks But Will Not Run

D06RX00004
6E–80 ENGINE DRIVEABILITY AND EMISSIONS
Circuit Description Test Description
The electronic Ignition system uses a coil-at-plug method Number(s) below refer to the step number(s) on the
of spark distribution. In this type of ignition system, the Diagnostic Chart.
powertrain control module (PCM) triggers the correct 5. An obvious cause of low fuel pressure would be an
driver inside the ignition coil, which then triggers the empty fuel tank.
correct ignition coil based on the 58X signal received from 6. The engine will easily start and run if a few injectors
the crankshaft position sensor (CKP). The spark plug are disabled. It is not necessary to test all injectors
connected to the coil fires when the ICM opens the ground at this time since this step is only a test to verify that
circuit for the coil’s primary circuit. all of the injectors have not been disabled by fuel
During crank, the PCM monitors the CKP 58X signal. The contamination.
CKP signal is used to determine which cylinder will fire 7. A blinking test light verifies that the PCM is
first. After the CKP 58X signal has been processed by the monitoring the 58X crankshaft reference signal and
PCM, it will command all six injectors to allow a priming is capable of activating the injectors. If there is an
shot of fuel for all the cylinders. After the priming, the open or shorted driver circuit, DTCs 201-206 should
injectors are left “OFF” during the next six 58X reference be set.
pulses from the CKP. This allows each cylinder a chance
19.By using a spark tester, each ignition coil’s ability to
to use the fuel from the priming shot. During this waiting
produce 25,000 volts is verified.
period, a camshaft position (CMP) signal pulse will have
been received by the PCM. The CMP signal allows the 25.If there is an open or shorted driver circuit, DTCs
PCM to operate the injectors sequentially based on 201-206 should be set. All six injector driver circuits
camshaft position. If the camshaft position signal is not can be checked at one time without removing the
present at start-up, the PCM will begin sequential fuel intake manifold if a 5-8840-2636-0 test light is
delivery with a 1-in-6 chance that fuel delivery is correct. available. This is the alternative procedure:
The engine will run without a CMP signal, but will set a With the ignition “OFF,” disconnect the gray
DTC code. connector located at the rear of the air filter, attached
to a bracket on the purge canister.
Diagnostic Aids Connect test light 5-8840-2636-0 to the connector.
An intermittent problem may be caused by a poor Do any of the light constantly illuminate or fail to blink
connection, rubbed-through wire insulation or a wire when the engine is cranked? If so, repair the short or
broken inside the insulation. Check for the following open circuit, or replace the PCM if indicated.
items: This procedure only tests the driver circuit as far as the
Poor connection or damaged harness – Inspect the test connection, so step 31 is added to test the circuit all
PCM harness and connectors for improper mating, the way to the injector.
broken locks, improperly formed or damaged
terminals, poor terminal-to-wire connection, and
damaged harness.
Faulty engine coolant temperature sensor – Using
Tech 2, compare engine coolant temperature with
intake air temperature on a completely cool engine.
Engine coolant temperature should be within 10 C of
intake air temperature. If not, replace the ECT sensor.
ENGINE DRIVEABILITY AND EMISSIONS 6E–81

Engine Cranks But Will Not Run


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 Check the 15 A ignition coil fuse, the 15 A engine fuse,
and the 30 A PCM fuse.
Was a fuse blown? — Go to Step 3 Go to Step 4
3 Check for a short to ground and replace the fuse.
Is the action complete? — Verify repair —
4 1. Ignition “OFF,” install a fuel pressure gauge at the
test fitting on the fuel supply line in the engine
compartment. (Use a shop cloth to absorb any fuel
leakage while making the connection.)
2. Ignition “ON,” observe the fuel pressure.
Is the fuel pressure within the specified values, and 285-376 kPa
does it hold steady? (43-55 psi) Go to Step 6 Go to Step 5
5 Is any fuel pressure indicated? Go to Fuel Go to Fuel
System System
— Electrical Test Diagnosis
6 Install an injector switch box to the injector test
connector, and attempt to operate the injector.
Did the fuel pressure drop when the injector is
operated? — Go to Step 7 Go to Step 12
7 Install an injector test light at the #2 cylinder injector
harness connector.
Does the light blink when the engine is cranked? — Go to Step 8 Go to Step 18
8 1. Ignition “ON.”
2. While the coil connectors are disconnected, touch
each coil connector’s ignition feed terminal with a
grounded test light (the ignition feed wire is black
with orange tracer).
Did the test light illuminate? — Go to Step 10 Go to Step 9
9 Repair the open ignition feed circuit.
Is the action complete? — Verify repair —
10 While the coil connectors are disconnected, touch
each connector’s secondary ground terminal with a
test light to B+. (The ground wires are black.)
Did the test light illuminate at each coil connector? — Go to Step 12 Go to Step 11
11 Repair the open secondary ground circuit.
Is the action complete? — Verify repair —
12 1. Test the fuel for contamination.
2. If a problem is found, clean the fuel system and
correct the contaminated fuel condition as
necessary. Replace the fuel filter and replace any
injectors that are not delivering fuel (see Injector
Balance Test).
Was a problem found? — Verify repair Go to Step 13
6E–82 ENGINE DRIVEABILITY AND EMISSIONS

Engine Cranks But Will Not Run


Step Action Value(s) Yes No
13 1. Remove any ignition coil and install a spark tester at
the spark plug end of the coil.
2. Observe the tester while the engine is cranking.
Was a crisp, blue spark observed? Only one or two
sparks followed by no result is considered the same as
“No Spark.” — Go to Step 15 Go to Step 14
14 Replace the ignition coil, and return to Step 13 to test
the remaining coils.
Is the action complete? — Verify repair —
15 Repeat Step 13 for each coil. Remove only one coil at a
time, and reinstall each coil on its spark plug after
testing, but do not refasten coils with screws at this
time.
Refasten all
After all coils have passed the spark test, does the coils with
engine start? — their screws Go to Step 16
16 1. Remove the spark plugs from all cylinders.
2. Visually inspect the spark plug electrodes.
3. Replace any spark plugs with loose or missing
electrodes or cracked insulators. Correct the
Did your inspection reveal any spark plugs exhibiting fouling
excessive fouling? — condition Go to Step 17
17 Refer to Engine Mechanical Diagnosis to diagnose the
following conditions:
Faulty or incorrect camshaft drive belts
Leaking or sticky valves or rings
Excessive valve deposits
Loose or worn rocker arms
Weak valve springs
Incorrect valve timing
Leaking head gasket
Is the action complete? — Verify repair Go to Step 19
18 Observe the “Engine Speed” data display on the scan
tool while cranking the engine.
Is the engine RPM indicated? (If the scan tool is
normally powered from the cigarette lighter socket, and
if the scan tool display goes blank while cranking the
engine, it will be necessary to power the scan tool
directly from the vehicle battery.) — Go to Step 19 Go to Step 28
19 1. Disconnect the 7-pin gray connector at the rear of
the air filter beneath the point where the air duct
attaches to the MAF sensor.
2. Ignition “ON.”
3. Using a test light connected to ground, probe the
ignition terminal at the PCM (female) side of the
7-pin connector.
Is the test light “ON?” — Go to Step 20 Go to Step 26
ENGINE DRIVEABILITY AND EMISSIONS 6E–83

Engine Cranks But Will Not Run


Step Action Value(s) Yes No
20 1. At the PCM (female) side of the connector, connect
a test light between the ignition + terminal and one
of the injector driver circuits at the same connector.
2. Ignition “ON.”
3. Observe the test light, and repeat the test for each
injector driver circuit.
Did the test light stay on when checking any of the 6
injector driver circuits? — Go to Step 21 Go to Step 23
21 1. Ignition “OFF,” disconnect the PCM.
2. Ignition “ON,” observe the test light.
Is the test light “ON?” — Go to Step 22 Go to Step 27
22 Locate and repair the short to ground in the injector
driver circuit.
Is the action complete? — Verify repair —
23 1. Using the same test location as in step 20, connect
a test light between the ignition terminal and one of
the driver circuits.
2. Crank the engine and observe the test light.
3. Repeat for each injector driver circuit.
Did the light blink during the test for each circuit? — Go to Step 25 Go to Step 24
24 Check for an open injector driver circuit.
Was a problem found? — Verify repair Go to Step 27
25 1. At the injector (male) side of the gray connector,
connect an ohmmeter between the ignition pin and
one of the driver circuit pins.
2. Check for continuity in the circuit.
3. Repeat for each injector circuit. The readings
should be approximately equal to the specified
value for injector resistance.
Was a problem found? 12.5 ohms Verify repair Go to Step 8
26 Repair the ignition feed circuit.
Is the action complete? — Verify repair —
27 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
28 1. Raise the vehicle and disconnect the CKP sensor
harness.
2. Ignition “ON.”
3. With a test light to ground, probe the harness
ignition feed terminal.
Did the light illuminate? — Go to Step 30 Go to Step 29
29 Check the ignition feed wire between the sensor and
the PCM for a short to ground or open circuit.
Is the action complete? — Verify repair —
6E–84 ENGINE DRIVEABILITY AND EMISSIONS

Engine Cranks But Will Not Run


Step Action Value(s) Yes No
30 1. Ignition “ON.”
2. At the CKP harness connector, connect a test light
between the ignition and ground terminals.
Did the light illuminate? — Go to Step 32 Go to Step 31
31 Check the sensor ground circuit for an open or short to
voltage.
Is the action complete? — Verify repair —
32 Check the signal circuit between the sensor and the
PCM for a short to ground, short to voltage, or an open.
Was a problem found? — Verify repair Go to Step 33
33 Replace the CKP sensor.
Is the action complete? — Verify repair Go to Step 27
ENGINE DRIVEABILITY AND EMISSIONS 6E–85

Fuel System Electrical Test

D06RW101

Circuit Description Diagnostic Aids


When the ignition switch is first turned “ON,” the An intermittent may be caused by a poor connection,
powertrain control module (PCM) energizes the fuel rubbed-through wire insulation, or a wire broken inside
pump relay which applies power to the in-tank fuel pump. the insulation. Check for the following items:
The fuel pump relay will remain “ON” as long as the Poor connection or damaged harness – Inspect the
engine is running or cranking and the PCM is receiving PCM harness and connectors for improper mating,
58X crankshaft position pulses. If no 58X crankshaft broken locks, improperly formed or damaged
position pulses are present, the PCM de-energizes the terminals, poor terminal-to-wire connection, and
fuel pump relay within 2 seconds after the ignition is damaged harness.
turned “ON” or the engine is stopped.
The fuel pump delivers fuel to the fuel rail and injectors, Test Description
then to the fuel pressure regulator. The fuel pressure Number(s) below refer to the step number(s) on the
regulator controls fuel pressure by allowing excess fuel to Diagnostic Chart.
be returned to the fuel tank. With the engine stopped and 2. If the fuel pump is operating but incorrect pressure is
ignition “ON,” the fuel pump can be turned “ON” by using a noted, the fuel pump wiring is OK and the “Fuel
command by Tech 2. System Pressure Test” chart should be used for
diagnosis.
6E–86 ENGINE DRIVEABILITY AND EMISSIONS
CAUTION: To reduce the risk of fire and personal Fuel Pressure Relief Procedure
injury:
1. Remove the fuel cap.
It is necessary to relieve fuel system pressure 2. Remove the fuel pump relay from the underhood
before connecting a fuel pressure gauge. Refer to relay center.
Fuel Pressure Relief Procedure, below.
3. Start the engine and allow it to stall.
A small amount of fuel may be released when
disconnecting the fuel lines. Cover fuel line 4. Crank the engine for an additional 3 seconds.
fittings with a shop towel before disconnecting, to
catch any fuel that may leak out. Place the towel in Fuel Gauge Installation
an approved container when the disconnect is 1. Remove the shoulder fitting cap.
completed. 2. Install fuel gauge 5-8840-0378-0 to the fuel feed line
located in front of and above the right side valve train
cover .
3. Reinstall the fuel pump relay.

Fuel System Electrical Test


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Read the “Caution” above.
2. Relieve the fuel system pressure and install the fuel
pump pressure gauge to the test fitting.
3. Use Tech 2 to command the fuel pump “ON.”
Is there an immediate pressure build-up which
indicates the pump is running? — Go to Step 3 Go to Step 4
3 1. Verify that the pump is not running by removing the
fuel filler cap and listening.
2. Command the pump “ON” with Tech 2. Test
Did the pump turn “OFF” after 2 seconds? — completed Go to Step 12
4 1. Ignition “OFF.”
2. Remove the fuel pump relay.
3. Using a test light connected to ground, probe the
battery feed to the relay.
Did the light illuminate? — Go to Step 6 Go to Step 5
5 Repair short or open battery feed to fuel pump relay.
Is the action complete? — Verify repair —
6 1. Connect a test light between the two wires that
connect to the fuel pump relay pull-in coil.
2. Ignition “ON.”
Did the test light illuminate for 2 seconds and then turn
off? — Go to Step 12 Go to Step 7
7 1. With a test light connected to battery (–), probe the
fuel pump relay connector at the wire which runs
from the relay pull-in coil to the PCM.
2. Ignition “ON.”
Did the test light illuminate for 2 seconds and then turn
off? — Go to Step 8 Go to Step 9
8 Locate and repair open in the fuel pump relay ground
circuit.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–87

Fuel System Electrical Test


Step Action Value(s) Yes No
9 Check for short or open between the PCM and the fuel
pump relay.
Was a problem found? — Verify repair Go to Step 10
10 1. Check the fuel pump relay circuit for a poor terminal
connection at the PCM.
2. If a problem is found, replace terminal as necessary.
Was a problem found? — Verify repair Go to Step 11
11 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
12 1. Reconnect the fuel pump relay.
2. Disconnect the fuel pump electrical connector at the
fuel tank.
3. Using a test light connected to ground, probe the
fuel pump feed wire (harness side).
4. Command the fuel pump “ON” with Tech 2.
Did the light illuminate for 2 seconds? — Go to Step 15 Go to Step 13
13 1. Honk the horn to verify that the horn relay is
functioning.
2. Substitute the horn relay for the fuel pump relay.
3. Leave the test light connected as in step 12.
4. Command the fuel pump “ON” with Tech 2.
Did the test light illuminate for 2 seconds when the fuel
pump was commanded “ON?” — Go to Step 17 Go to Step 14
14 1. Re-connect the horn relay in its proper location.
2. Check for a short circuit, blown fuse or open circuit
between the relay and the fuel tank.
Is the action complete? — Verify repair —
15 1. With the fuel pump electrical connector at the fuel
tank disconnected, connect a test light between the
feed wire and the ground wire (harness side).
2. Command the fuel pump “ON” with Tech 2.
Did the test light illuminate for 2 seconds? — Go to Step 18 Go to Step 16
16 Repair the open circuit in the fuel pump ground wire.
Is the action complete? — Verify repair —
17 1. Re-connect the horn relay in its proper location.
2. Replace the fuel pump relay.
Is the action complete? — Verify repair —
18 Replace the fuel pump.
Is the action complete? — Verify repair —
6E–88 ENGINE DRIVEABILITY AND EMISSIONS

Fuel System Diagnosis

140RW020

Legend (8) Fuel Rail Left


(1) Fuel Filler Cap (9) Left Bank
(2) Fuel Tank (10) Fuel Pressure Control Valve
(3) Rollover Valve (11) Common Chamber
(4) Fuel Pump and Sender Assembly (12) Duty Solenoid Valve
(5) Fuel Filter (13) Throttle Valve
(6) Fuel Rail Right (14) Canister
(7) Right Bank (15) Evapo Shut Off Valve

Circuit Description Test Description


When the ignition switch is turned “ON,” the powertrain Number(s) below refer to the step number(s) on the
control module (PCM) will turn “ON” the in-tank fuel Diagnostic Chart.
pump. The in-tank fuel pump will remain “ON” as long as 2. Connect the fuel pressure gauge to the fuel feed line
the engine is cranking or running and the PCM is receiving as shown in the fuel system illustration. Wrap a
58X crankshaft position pulses. If there are no 58X shop towel around the fuel pressure connection in
crankshaft position pulses, the PCM will turn the in-tank order to absorb any fuel leakage that may occur
fuel pump “OFF” 2 seconds after the ignition switch is when installing the fuel pressure gauge. With the
turned “ON” or 2 seconds after the engine stops running. ignition switch “ON” and the fuel pump running, the
The in-tank fuel pump is an electric pump within an fuel pressure indicated by the fuel pressure gauge
integral reservoir. The in-tank fuel pump supplies fuel should be 333-376 kPa (48-55 psi). This pressure
through an in-line fuel filter to the fuel rail assembly. The is controlled by the amount of pressure the spring
fuel pump is designed to provide fuel at a pressure above inside the fuel pressure regulator can provide.
the pressure needed by the fuel injectors. A fuel pressure 3. A fuel system that cannot maintain a constant fuel
regulator, attached to the fuel rail, keeps the fuel available pressure has a leak in one or more of the following
to the fuel injectors at a regulated pressure. Unused fuel areas:
is returned to the fuel tank by a separate fuel return line. The fuel pump check valve.
The fuel pump flex line.
ENGINE DRIVEABILITY AND EMISSIONS 6E–89
The valve or valve seat within the fuel pressure 20.This test determines if the high fuel pressure is due
regulator. to a restricted fuel return line or if the high fuel
The fuel injector(s). pressure is due to a faulty fuel pressure regulator.
4. Fuel pressure that drops off during acceleration, 21.A lean condition may result from fuel pressure
cruise, or hard cornering may case a lean condition. below 333 kPa (48 psi). A lean condition may
A lean condition can cause a loss of power, surging, cause a DTC P0131 or a DTC P0171 to set.
or misfire. A lean condition can be diagnosed using Driveability conditions associated with lean
a Tech II Tech 2. If an extremely lean condition conditions can include hard starting (when the
occurs, the oxygen sensor(s) will stop toggling. The engine is cold ), hesitation, poor driveability, lack of
oxygen sensor output voltage(s) will drop below 500 power, surging , and misfiring.
mV. Also, the fuel injector pulse width will increase. 22.Restricting the fuel return line causes the fuel
IMPORTANT: Make sure the fuel system is not pressure to rise above the regulated fuel pressure.
operating in the “Fuel Cut-Off Mode.” Command the fuel pump “ON” with Tech 2. The fuel
pressure should rise above 376 kPa (55 psi) as the
When the engine is at idle, the manifold pressure is fuel return line becomes partially closed.
low (high vacuum). This low pressure (high vacuum)
is applied to the fuel pressure regulator diaphragm. NOTE: Do not allow the fuel pressure to exceed 414 kPa
The low pressure (high vacuum) will offset the (60 psi). Fuel pressure in excess of 414 kPa (60 psi) may
pressure being applied to the fuel pressure regulator damage the fuel pressure regulator.
diaphragm by the spring inside the fuel pressure
regulator. When this happens, the result is lower fuel CAUTION: To reduce the risk of fire and personal
pressure. The fuel pressure at idle will vary slightly as injury:
the barometric pressure changes, but the fuel
pressure at idle should always be less than the fuel It is necessary to relieve fuel system pressure
pressure noted in step 2 with the engine “OFF.” before connecting a fuel pressure gauge. Refer to
Fuel Pressure Relief Procedure, below.
16.Check the spark plug associated with a particular A small amount of fuel may be released when
fuel injector for fouling or saturation in order to disconnecting the fuel lines. Cover fuel line
determine if that particular fuel injector is leaking. If fittings with a shop towel before disconnecting, to
checking the spark plug associated with a particular catch any fuel that may leak out. Place the towel in
fuel injector for fouling or saturation does not an approved container when the disconnect is
determine that a particular fuel injector is leaking, completed.
use the following procedure:
Remove the fuel rail, but leave the fuel lines and Fuel Pressure Relief Procedure
injectors connected to the fuel rail. Refer to Fuel Rail
Assembly in On-Vehicle Service. 1. Remove the fuel cap.
Lift the fuel rail just enough to leave the fuel injector 2. Remove the fuel pump relay from the underhood
nozzles in the fuel injector ports. relay center.
3. Start the engine and allow it to stall.
CAUTION: In order to reduce the risk of fire and 4. Crank the engine for an additional 3 seconds.
personal injury that may result from fuel spraying on
the engine, verify that the fuel rail is positioned over Fuel Gauge Installation
the fuel injector ports and verify that the fuel injector
retaining clips are intact. 1. Remove the shoulder fitting cap.
2. Install fuel gauge 5-8840-0378-0 to the fuel feed line
Pressurize the fuel system by connecting a 10 amp located in front of and above the right side valve train
fused jumper between B+ and the fuel pump relay cover.
connector.
3. Reinstall the fuel pump relay.
Visually and physically inspect the fuel injector
nozzles for leaks.
17.A rich condition may result from the fuel pressure
being above 376 kPa (55 psi). A rich condition may
cause a DTC P0132 or a DTC P0172 to set.
Driveability conditions associated with rich
conditions can include hard starting (followed by
black smoke) and a strong sulfur smell in the
exhaust.
6E–90 ENGINE DRIVEABILITY AND EMISSIONS

Fuel System Diagnosis


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Turn the ignition “OFF.”
2. Turn the air conditioning system “OFF.”
3. Relieve fuel system pressure and install the fuel
pressure gauge.
4. Turn the ignition “ON.”
NOTE: The fuel pump will run for approximately 2
seconds. Use Tech 2 to command the fuel pump “ON”.
5. Observe the fuel pressure indicated by the fuel
pressure gauge with the fuel pump running. 290-376 kPa
Is the fuel pressure within the specified limits? (42-55 psi) Go to Step 3 Go to Step 17
3 NOTE: The fuel pressure will drop when the fuel pump
stops running, then it should stabilize and remain
constant.
Does the fuel pressure indicated by the fuel pressure
gauge remain constant? — Go to Step 4 Go to Step 12
4 1. When the vehicle is at normal operation
temperature, turn the ignition “ON” to build fuel
pressure and observe the measurement on the
gauge.
2. Start the engine and observe the fuel pressure
gauge.
Did the reading drop by the amount specified after the 21-105 kPa
engine was started? (3-15 psi) Go to Step 5 Go to Step 9
5 Is fuel pressure dropping off during acceleration, Check for
cruise, or hard cornering? — Go to Step 6 improper fuel
6 Visually and physically inspect the following items for a
restriction:
The in-pipe fuel filter.
The fuel feed line.
Was a restriction found? — Verify repair Go to Step 7
7 Remove the fuel tank and visually and physically
inspect the following items:
The fuel pump strainer for a restriction.
The fuel line for a leak.
Verify that the correct fuel pump is in the vehicle.
Was a problem found in any of these areas? — Verify repair Go to Step 8
8 Replace the fuel pump.
Is the action complete? — Verify repair —
9 1. Disconnect the vacuum hose from the fuel pressure
regulator.
2. With the engine idling, apply 12-14 inches of
vacuum to the fuel pressure regulator.
Does the fuel pressure indicated by the fuel pressure 21-105 kPa
gauge drop by the amount specified? (3-15 psi) Go to Step 10 Go to Step 11
ENGINE DRIVEABILITY AND EMISSIONS 6E–91

Fuel System Diagnosis


Step Action Value(s) Yes No
10 Locate and repair the loss of vacuum to the fuel
pressure regulator.
Is the action complete? — Verify repair —
11 Replace the fuel pressure regulator.
Is the action complete? — Verify repair —
12 1. Run the fuel pump with Tech 2.
2. After pressure has built up, turn off the pump and
clamp the supply hose shut with suitable locking
pliers.
Does the fuel pressure indicated by the fuel pressure
gauge remain constant? — Go to Step 13 Go to Step 15
13 Visually inspect the fuel supply line and repair any
leaks.
Was a problem found? — Verify repair Go to Step 14
14 Remove the fuel tank and inspect for leaky hose or
in-tank fuel line.
Was a problem found? — Verify repair Go to Step 8
15 1. If the pliers are still clamped to the fuel supply hose,
remove the locking pliers.
2. With suitable locking pliers, clamp the fuel return
line to prevent fuel from returning to the fuel tank.
3. Run the fuel pump with Tech 2.
4. After pressure has built up, remove power to the
pump.
Does the fuel pressure indicated by the fuel pressure
gauge remain constant? — Go to Step 11 Go to Step 16
16 Locate and replace any leaking fuel injector(s).
Is the action complete? — Verify repair —
17 Is the fuel pressure indicated by the fuel pressure 376 kPa
gauge above the specified limit? (55 psi) Go to Step 18 Go to Step 21
18 1. Relieve the fuel pressure. Refer to the Fuel
Pressure Relief.
2. Disconnect the fuel return line from the fuel rail.
3. Attach a length of flexible hose to the fuel rail return
outlet passage.
4. Place the open end of the flexible hose into an
approved gasoline container.
5. Run the fuel pump with Tech 2.
6. Observe the fuel pressure indicated by the fuel
pressure gauge with the fuel pump running. 290-376 kPa
Is the fuel pressure within the specified limits? (42-55 psi) Go to Step 19 Go to Step 20
19 Locate and correct the restriction in the fuel return line.
Is the action complete? — Verify repair —
20 Visually and physically inspect the fuel rail outlet
passages for a restriction.
Was a restriction found? — Verify repair Go to Step 11
21 Is the fuel pressure indicated by the fuel pressure
gauge above the specified value? 0 kPa (0 psi) Go to Step 22 Go to Step 23
6E–92 ENGINE DRIVEABILITY AND EMISSIONS

Fuel System Diagnosis


Step Action Value(s) Yes No
22 1. Command the fuel pump “ON” with Tech 2.
2. Using suitable pliers which will not damage the fuel
hose, gradually apply pressure with the pliers to
pinch the flexible fuel return hose closed.
CAUTION: Do not let the fuel pressure exceed
376 kPa
the second specified value.
(55 psi)
Does the fuel pressure indicated by the fuel pressure 414 kPa
gauge rise above the first specified value? (60 psi) Go to Step 11 Go to Step 7
23 1. Command the fuel pump “ON” with Tech 2.
2. Remove the fuel filler cap and listen for the sound of
the fuel pump running. Go to Fuel
System
3. Turn the pump off. Electrical Test
Was the fuel pump running? — Go to Step 7 Chart
ENGINE DRIVEABILITY AND EMISSIONS 6E–93

Idle Air Control (IAC) System Check


Circuit Description Throttle body – Remove the IAC valve and inspect the
The powertrain control module (PCM) controls engine bore for foreign material.
idle speed with the idle air control (IAC) valve. To increase IAC valve electrical connections – IAC valve
idle speed, the PCM retracts the IAC valve pintle away connections should be carefully checked for proper
from its seat, allowing more air to bypass the throttle bore. contact.
To decrease idle speed, it extends the IAC valve pintle PCV valve – An incorrect or faulty PCV valve may
towards its seat, reducing by pass air flow. Tech 2 will result in an incorrect idle speed. Refer to Diagnosis,
read the PCM commands to the IAC valve in counts. Rough Idle, Stalling. If intermittent poor driveability or
Higher counts indicate more air bypass (higher idle). idle symptoms are resolved by disconnecting the IAC,
Lower counts indicate less air is allowed to bypass (lower carefully recheck the connections and valve terminal
idle). resistance, or replace the IAC.

Diagnostic Aids Test Description


A slow, unstable, or fast idle may be caused by a non-IAC Number(s) below refer to the step number(s) on the
system problem that cannot be overcome by the IAC Diagnostic Chart.
valve. Out of control range IAC Tech 2 counts will be 1. The Tech 2 is used to extend and retract the IAC
above 60 if idle is too low, and zero counts if idle is too valve. Valve movement is verified by an engine
high. The following checks should be made to repair a speed change. If no change in engine speed
non-IAC system problem: occurs, the valve can be resettled when removed
from the throttle body.
Vacuum leak (high idle) – If idle is too high, stop the
engine. Fully extend (low) IAC with the Tech 2. Start 2. This step checks the quality of the IAC movement in
the engine. If idle speed is above 800 RPM, locate and step 1. Between 700 revolutions per minute (RPM)
correct the vacuum leak, including the PCV system. and about 1500 RPM, the engine speed should
Check for binding of the throttle blade or linkage. change smoothly with each flash of the tester light
Lean heated oxygen sensor signal (high air/fuel ratio) – in both extend and retract. If the IAC valve is
The idle speed may be too high or too low. Engine retracted beyond the control range (about 1500
speed may vary up and down, and disconnecting the RPM), it may take many flashes to extend the IAC
IAC valve does not help. Diagnostic trouble codes valve before engine speed will begin to drop. This
P0131, P0151, P0171, or P0174 may be set. Tech 2 is normal on certain engines. Fully extending the
oxygen (O2) voltage will be less than 100 mV (0.1 V). IAC may cause engine stall. This may be normal.
Check for low regulated fuel pressure, water in fuel, or
a restricted injector.
Rich heated oxygen sensor signal (low air/fuel ratio) –
The idle speed will be too low. Tech 2 IAC counts will
usually be above 80. The system is obviously rich and
may exhibit black smoke in the exhaust.
Tech 2 O2 voltage will be fixed at about 750 mV (0.75
V). Check for high fuel pressure, or a leaking or
sticking injector. A silicon-contaminated heated
oxygen sensor will show an O2 voltage slow to
respond on Tech 2.
6E–94 ENGINE DRIVEABILITY AND EMISSIONS

Idle Air Control (IAC) System Check


Step Action Value(s) Yes No
1 1. Ignition “OFF.”
2. Connect the Tech 2.
3. Set the parking brake.
4. Block the wheels.
5. Turn the air conditioning “OFF.”
6. Idle the engine in Park (A/T) or Neutral (M/T).
7. Operate the IAC test.
8. The engine speed should decrease and increase as
the IAC is cycled.
Does the RPM change? — Go to Step 2 Go to Step 3
2 RPM should change smoothly. 700-1500
Does the RPM change within the range specified? RPM — Go to Step 3
3 Check the IAC passages.
Are the IAC passages OK? — Go to Step 4 Go to Step 5
4 Clear any obstruction from the IAC passages.
Is the action complete? — Verify repair —
5 Replace the IAC. Refer to On-Vehicle Service, Idle Air
Control Valve.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–95

Knock Sensor (KS) System Check


(Engine Knock, Poor Performance, or Poor Economy)

D06RW035

Circuit Description Test Description


The knock sensor (KS) sends an AC voltage signal to the The numbers below refer to the step numbers on the
powertrain control module (PCM). As the KS detects Diagnostic Chart.
engine knock, the signal to the PCM changes in amplitude 9. The change in signal speed depends on how hard
and frequency. The PCM retards timing if the engine the tapping is done. Normally there is about 1.5 to
speed is over 900 RPM. 10 mV at PCM pin A2 with the engine off. Loud
tapping should be able to make the reading jump to
Diagnostic Aids 20-25 mV AC.
If the KS system checks OK, but detonation is the
complaint, refer to Diagnosis, Detonation/Spark Knock.
6E–96 ENGINE DRIVEABILITY AND EMISSIONS

Knock Sensor (KS) System Check


(Engine Knock, Poor Performance, or Poor Economy)
Step Action Value(s) Yes No
1 Is DTC P0325 or P0327 set? Go to DTC
P0325 or
— DTC P0327 Go to Step 2
2 Run the engine at 1500 RPM.
Is there an internal engine knock? — Go to Step 3 Go to Step 4
3 Repair the mechanical problem.
Is the action complete? — Verify repair —
4 1. Install Tech 2.
2. Turn the ignition “ON.”
3. Cycle through the list until “Knock Retard” is
displayed.
Is knock retard at the specified value? 0 Go to Step 6 Go to Step 7
5 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer toUBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
6 1. Start the engine.
2. Monitor the knock retard display on Tech 2 while
changing the throttle setting to place different loads
on the engine.
Is knock retard at the specified value? (Turn the ignition
“OFF.”) 0 Go to Step 9 Go to Step 7
7 1. At the rear of the engine, behind the rear fuel
injector on the lift side, disconnect the 2-wire knock
sensor harness connector.
2. Attach the positive lead of DVM to B+.
3. On the main harness side of the connector, use the
negative lead of the DVM to probe the connector pin
that is connected to the black wire.
Dose the DVM indicate the specified value?
(Reconnect the knock sensor harness.) B+ Go to Step 9 Go to Step 8
8 Repair the open black wire ground for the shield which
prevents stray electromagnetic pulses from affecting
the knock signal.
Is the action complete? — Verify repair —
9 1. Reconnect the wire harness.
2. Set a DVM to AC voltage.
3. With the DVM, backprobe the PCM connector at
A2.
4. Tap the engine lift brackprobe with a socket
extension.
Did the DVM show an increase in AC voltage while
tapping on the lift bracket? — System OK Go to Step 10
10 Replace the knock sensor.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–97

Exhaust Gas Recirculation (EGR) System Check

D06RW106

Circuit Description Diagnostic Aids


A properly operation exhaust gas recirculation (EGR) The EGR valve chart is a check of the EGR system. An
system will directly affect the air/fuel requirements of the EGR pintle constantly in the closed position could cause
engine. Since the exhaust gas introduced into the air/fuel detonation and high emissions of NOx. It could also result
mixture is an inert gas (contains very little or no oxygen), in high long term fuel trim values in the open throttle cell,
less fuel is required to maintain a correct air/fuel ratio. but not in the closed throttle cell. An EGR pintle
Introducing exhaust gas into the combustion chamber constantly in the open position would cause a rough idle.
lowers combustion temperatures and reduces the Also, an EGR mounted incorrectly (rotated 180 ) could
formation of oxides of nitrogen (NOx) in the exhaust gas. cause rough idle. Check for the following items:
Lower combustion temperatures also prevent detonation. EGR passages – Check for restricted or blocked EGR
If the EGR pintle were to stay closed, the inert exhaust passages.
gas would be replaced with air and the air/fuel mixture Manifold absolute pressure sensor – A manifold
would be leaner. The powertrain control module (PCM) absolute pressure sensor may shift in calibration
would compensate for the lean condition by adding fuel, enough to affect fuel delivery. Refer to Manifold
resulting in higher long term fuel trim values. Absolute Pressure Output Check.
6E–98 ENGINE DRIVEABILITY AND EMISSIONS

Exhaust Gas Recirculation (EGR) System Check


Step Action Value(s) Yes No
1 Check the EGR valve for looseness.
Is the EGR valve Loose? — Go to Step 2 Go to Step 3
2 Tighten the EGR valve.
Is the action complete? — Verify repair —
3 1. Place the transmission selector in Park or Neutral. EGR system
2. Start the engine and idle until warm. working
properly. No
3. Using Tech 2, command EGR “50% ON.”
problem
Does the engine idle rough and lose RPMs? — found. Go to Step 4
4 1. Engine “OFF.”
2. Ignition “ON.”
3. Using a test light to ground, check the EGR harness
between the EGR valve and the ignition feed.
Does the test light illuminate? — Go to Step 6 Go to Step 5
5 Repair the EGR harness ignition feed.
Was the problem corrected? — Verify repair Go to Step 6
6 1. Remove the EGR valve.
2. Visually and physically inspect the EGR valve
pintle, valve passages and adapter for excessive
deposits, obstructions or any restrictions.
Does the EGR valve have excessive deposits,
obstructions or any restrictions? — Go to Step 7 Go to Step 8
7 Clean or replace EGR system components as
necessary.
Was the problem corrected? — Verify repair Go to Step 8
8 1. Ground the EGR valve metal case to battery (–).
2. Using Tech 2, command EGR “ON” and observe the
EGR valve pintle for movement.
Does the EGR valve pintle move according to Go to DTC
command? — Go to Step 9 P1406 chart
9 1. Remove the EGR inlet and outlet pipes from the
intake and exhaust manifolds.
2. Visually and physically inspect manifold EGR ports
and EGR inlet and outlet pipes for blockage or
restriction caused by excessive deposits or other EGR system
damage. working
Do the manifold EGR ports or inlet and outlet pipes properly. No
have excessive deposits, obstructions, or any problem
restrictions? — Go to Step 10 found.
10 Clean or replace EGR system components as
necessary.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–99

Manifold Absolute Pressure (MAP) Output Check

D06RW102

Circuit Description Test Description


The manifold absolute pressure (MAP) sensor measures IMPORTANT: Be sure to used the same diagnostic test
the changes in the intake MAP which result from engine equipment for all measurements.
load (intake manifold vacuum) and engine speed The number(s) below refer to the step number(s) on the
changes; and converts these into a voltage output. The Diagnostic Chart.
powertrain control module (PCM) sends a 5-volt
2. Applying 34 kPa (10 Hg) vacuum to the MAP sensor
reference voltage to the MAP sensor. As the MAP should cause the voltage to be 1.5-2.1 volts less
changes, the output voltage of the sensor also changes. than the voltage at step 1. Upon applying vacuum
By monitoring the the sensor output voltage, the PCM to the sensor, the change in voltage should be
knows the MAP. A lower pressure (low voltage) output instantaneous. A slow voltage change indicates a
voltage will be about 1-2 volts at idle. Higher pressure faulty sensor.
(high voltage) output voltage will be about 4-4.8 volts at
3. Check the vacuum hose to the sensor for leaking or
wide open throttle. The MAP sensor is also used, under
restriction, Be sure that no other vacuum devices
certain conditions, to measure barometric pressure,
are connected to the MAP hose.
allowing the PCM to make adjustments for different
altitudes. The PCM uses the MAP sensor to diagnose IMPORTANT: Make sure the electrical connector
proper operation of the EGR system, in addition to other remains securely fastened.
functions. 4. Disconnect the sensor from the bracket. Twist the
sensor with your hand to check for an intermittent
connection. Output changes greater than 0.10 volt
indicate a bad sensor.
6E–100 ENGINE DRIVEABILITY AND EMISSIONS

Manifold Absolute Pressure (MAP) Output Check


Step Action Value(s) Yes No
1 1. Turn the ignition “OFF”and leave it “OFF” for 15
seconds.
2. Ignition “ON.” Don’t crank engine.
3. Tech 2 should indicate a manifold absolute pressure
(MAP) sensor voltage.
4. Compare this scan reading to scan reading of a
known good vehicle obtained using the exact same
procedure as in Steps 1-4.
Is the voltage reading the same +/–0.40 volt? — Go to Step 2 Go to Step 5
2 1. Disconnect the vacuum hose at the MAP sensor
and plug the hose.
2. Connect a hand vacuum pump to the MAP sensor.
3. Start the engine.
4. Apply 34 kPa (10 Hg) of vacuum and note the
voltage change.
Is the voltage change 1.5-2.1 volts less than Step 1? — Go to Step 3 Go to Step 4
3 No trouble found. Check the sensor cover for leakage
or restriction.
Does the hose supply vacuum to the MAP sensor only? — Go to Step 5 Go to Step 4
4 Repair the material to block.
Is the action complete? — Verify repair —
5 Check the sensor connection.
Is the sensor connection good? — Go to Step 6 Go to Step 7
6 Replace the sensor. Refer to On-Vehicle Service, MAP
Sensor.
Is the action complete? — Verify repair —
7 Repair the poor connection.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–101

PCM Diagnostic Trouble Codes


The following table lists the diagnostic trouble codes
supported by this vehicle application. If any DTCs not
listed here are displayed by a Tech 2, the Tech 2 data may
be faulty; notify the Tech 2 manufacturer of any DTCs
displayed that are not included in the following table.
A - Emission related P-code, check engine light on as
soon as a failure detected.
B - Emission related P-code, check engine light on if a
failure detected in two consecutive trips.
C - Non emission related P-code, check engine light on
if a failure detected in one trip.
D - Non emission related P-code, no check engine
light, but P-code will be set if a failure detected.
X - Do not check.
6E–102 ENGINE DRIVEABILITY AND EMISSIONS
PCM Diagnostic Trouble Codes
ENGINE DRIVEABILITY AND EMISSIONS 6E–103
PCM Diagnostic Trouble Codes (Cont’d)
6E–104 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0101 MAF System Performance

D06RW103

Circuit Description Action Taken When the DTC Sets


The mass air flow (MAF) sensor measures the amount of The PCM will illuminate the malfunction indicator lamp
air which passes through it into the engine during a given (MIL) after the second consecutive trip in which the
time. The powertrain control module (PCM) uses the fault is detected.
mass air flow information to monitor engine operating The PCM calculates an airflow value based on idle air
conditions for fuel delivery calculations. A large quantity control valve position, throttle position, RPM and
of air entering the engine indicates an acceleration or high barometric pressure.
load situation, while a small quantity or air indicates The PCM will store conditions which were present
deceleration or idle. when the DTC was set as Freeze Frame and in the
The MAF sensor produces a frequency signal which can Failure Records data.
be monitored using a Tech 2. DTC P0101 will be set if the
Conditions for Clearing the MIL/DTC
signal from the MAF sensor does not match a predicted
value based on throttle position and engine RPM. DTC P0101 can be cleared by using the Tech 2 “Clear
Info” function or by disconnecting the PCM battery
Conditions for Setting the DTC feed.
The engine is running. Diagnostic Aids
No TP sensor or MAP sensor DTCs are set. An intermittent may be caused by the following:
The throttle is steady, TP angle doesn’t change by Poor connections.
more than 1%.
Mis-routed harness.
System voltage is between 11.5 volts and 16 volts.
Rubbed through wire insulation.
Calculated air flow is between 25 g/second and 40
g/second. Broken wire inside the insulation.
Refer to Intermittents under service category Symptoms.
Above conditions present for at least 1 second.
Any un-metered air may cause this DTC to set. Check for
MAF signal frequency indicates an airflow significantly
higher or lower than a predicted value based on throttle the following:
position and engine RPM for a total of 12.5 seconds The duct work at the MAF sensor for leaks.
over a 25-second period of time. An engine vacuum leak.
The PCV system for vacuum leaks.
An incorrect PCV valve.
ENGINE DRIVEABILITY AND EMISSIONS 6E–105
The engine oil dip stick not fully seated. For any test that requires back probing the PCM or
The engine oil fill cap loose or missing. component harness connectors, use the Connector
Test Adapter Kit J 35616-A. Using this kit will
Test Description prevent any damage to the harness connector
Number(s) below refer to the step number(s) on the terminals.
Diagnostic Chart. 7. Any un-metered air may cause this DTC to set.
2. The MAF system performance or “rationality” Check the PVC system for vacuum leaks. Also
diagnostic uses the MAP sensor signal along with inspect the dip stick for being pulled out. Check the
other input to calculate an expected airflow rate that oil fill cap for being loose.
is then compared to the actual measured airflow 8. Verifies the signal circuit from the MAF sensor
from the MAF sensor. The first few steps of this electrical connector to the PCM.
table verify that the MAP sensor is working properly. 9. Verifies whether a ground and B+ circuit is available.
6. Using Freeze Frame and/or Failure Records data 10. Checks a signal circuit for an open.
may aid in locating an intermittent condition. If the
DTC cannot be duplicated, the information included 11. Checks for a signal circuit shorted to B+.
in the Freeze Frame and/or Failure Records data
can be useful in determining how many miles since
the DTC set. The Fail Counter and Pass Counter
can also be used to determine how many ignition
cycles the diagnostic reported a pass and/or a fail.
Operate the vehicle within the same Freeze Frame
conditions (RPM, load, vehicle speed , temperature,
etc.) that were noted. This will isolate when the
DTC failed.

DTC P0101 – MAF System Performance


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Ignition “ON,” engine “OFF.”
2. Using a Tech 2, select “MAP” from the Engine 1
Data List.
Is the value displayed greater than the value shown? 85 kPa Go to Step 3 Go toStep 13
3 1. Remove the MAP sensor from the intake manifold
but leave the electrical harness connected.
2. Connect a hand operated vacuum pump to the MAP
sensor.
3. Observe the MAP display while slowly applying
vacuum up to 20” Hg as indicated on the pump
gauge.
Each 1” of vacuum applied should result in a 3 to 4 kPa
drop in the MAP sensor value on the Tech 2 and the
value should change smoothly with each increase in
vacuum.
Did the MAP value change smoothly through the entire
range of the test without any erratic readings? — Go to Step 13 Go to Step 4
4 With 20” Hg vacuum applied to the MAP sensor, is the
MAF sensor reading the same or less than the value
shown? 34 kPa Go to Step 5 Go to Step 13
5 Disconnect the vacuum source from the MAP sensor.
Does the MAP sensor reading return to its original
value? — Go to Step 6 Go to Step 13
6E–106 ENGINE DRIVEABILITY AND EMISSIONS

DTC P0101 – MAF System Performance


Step Action Value(s) Yes No
6 1. Ignition “ON,” engine “OFF.”
2. Review the Freeze Frame and/or Failure Records
data for this DTC and note parameters.
3. Ignition “OFF” for 15 seconds.
4. Start the engine and operate the vehicle within the
conditions required for this diagnostic to run, and as
close to the conditions recorded in Freeze Frame
/Failure Records possible. (Special operating
conditions that need to be met before the PCM will
run this diagnostic (where applicable) are listed in
“Conditions for Setting the DTC”).
5. Using the Tech 2, select “DTC,” then enter the DTC
number which was set. Refer to
Does the Tech 2 indicate that this diagnostic failed this Diagnostic
ignition? — Go to Step 7 Aids
7 1. Check for the following conditions:
Objects blocking the MAF sensor inlet screen;
Intake manifold vacuum leaks;
Vacuum leaks at throttle body;
Vacuum leaks EGR value flange and pipes.
Crankcase ventilation valve faulty, missing, or
incorrectly installed.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go toStep 8
8 1. Ignition “OFF.”
2. Disconnect the MAF sensor connector.
3. Ignition “ON,” engine “OFF.”
4. Using DVM 5-8840-0285-0, measure voltage
between the MAF sensor signal circuit and chassis
ground.
Is the voltage near the specified value? 5V Go to Step 9 Go toStep 10
9 Connect a test light (5-8840-0607-0) between the MAF
sensor ignition feed and ground circuits at the MAF
sensor harness connector.
Is the test light “ON?” — Go to Step 13 Go toStep 12
10 Is the voltage less than the specified value? 4.5 V Go to Step 13 Go toStep 11
11 1. Ignition “OFF,” disconnect the PCM.
2. Ignition “ON,” engine “OFF.”
3. Measure voltage between the MAF signal circuit
and ground.
Does the voltage measure near the specified value? 0V Go to Step 13 Go toStep 12
12 Connect a test light (5-8840-0607-0) between the MAF
sensor ignition feed circuit and chassis ground.
Is the test light “ON?” — Go to Step 13 Go toStep 7
13 1. Check for a poor connection at the MAF sensor.
2. If a poor connection is found, replace faulty
terminal(s). Refer to Repair Procedures in
Electrical Diagnosis (8A Cell 5).
Was a poor connection found? — Verify repair Solved
ENGINE DRIVEABILITY AND EMISSIONS 6E–107

Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency

T321122

Circuit Description The PCM will store conditions which were present
when the DTC was set as Freeze Frame and in the
The mass air flow (MAF) sensor measures the amount of Failure Records data.
air which passes through it into the engine during a given
time. The powertrain control module (PCM) uses the Conditions for Clearing the MIL/DTC
mass air flow information to monitor engine operating
conditions for fuel delivery calculations. A large quantity DTC P0102 can be cleared by using the Tech 2 “Clear
Info” function or by disconnecting the PCM battery
of air entering the engine indicates an acceleration or high feed.
load situation, while a small quantity of air indicates
deceleration or idle. Diagnostic Aids
The MAF sensor produces a frequency signal which can
Check for the following conditions:
be monitored using a Tech 2. The frequency will vary
within a range of around 2500 Hz at idle to around Poor connection at PCM – Inspect harness connectors
for backed-out terminals, improper mating, broken
1900 Hz at maximum engine load. DTC P0102 will be set locks, improperly formed or damaged terminals, and
if the signal from the MAF sensor is below the possible poor terminal-to-wire connection.
range of a normally operating MAF sensor. Misrouted harness – Inspect the MAF sensor harness
to ensure that it is not routed too close to high voltage
Conditions for Setting the DTC wires.
The engine is running above 500 RPM for greater than Damaged harness – Inspect the wiring harness for
10 seconds. damage. If the harness appears to be OK, observe the
System voltage is above 11.5 volts. Tech 2 while moving connectors and wiring harnesses
related to the MAF sensor. A change in the display will
MAF signal frequency is below 1000 Hz for a total of indicate the location of the fault.
50-percent of the last 1000 samples monitored. A
sample is taken every cylinder event. Plugged intake air duct or filter element – A wide-open
throttle acceleration from a stop should cause the
mass air flow displayed on a Tech 2 to increase from
Action Taken When the DTC Sets about 3-6 g/second at idle to 100 g/second or greater
The PCM will illuminate the malfunction indicator lamp at the time of the 1-2 shift. If not, check for a restriction.
(MIL) the first time the fault is detected. If DTC P0102 cannot be duplicated, the information
The PCM calculates an air flow value based on idle air included in the Failure Records data can be useful in
control valve position, throttle position, RPM and determining vehicle mileage since the DTC was last set.
barometric pressure.
6E–108 ENGINE DRIVEABILITY AND EMISSIONS
Test Description 4. A voltage reading of less than 4 or over 5 volts at the
Number(s) below refer to the step number(s) on the MAF sensor signal circuit indicates a fault in the
wiring or a poor connection.
Diagnostic Chart.
2. This step verifies that the problem is present at idle. 5. This verifies that ignition feed voltage and a good
ground are available at the MAF sensor.

DTC P0102 – MAF Sensor Circuit Low Frequency


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Start the engine.
2. With the engine idling, monitor “MAF Frequency”
display on the Tech 2.
Is the “MAF Frequency” below the specified value? 3 g/Sec Go to Step 4 Go to Step 5
3 1. Ignition “ON,” engine “OFF.”
2. Review and record Tech 2 Failure Records data.
3. Operate the vehicle within Failure Records
conditions as noted.
4. Using a Tech 2, monitor “DTC” info for DTC P0102. Refer to
Does the Tech 2 indicate DTC P0102 failed this Diagnostic
ignition? — Go to Step 4 Aids
4 1. Ignition “OFF.”
2. Disconnect the MAF sensor connector.
3. Ignition “ON,” engine “OFF.”
4. Using a DVM, measure voltage between the MAF
sensor signal circuit and battery ground.
Is the voltage near the specified value? 5V Go to Step 5 Go to Step 8
5 Connect a test light between the MAF sensor ignition
feed and ground circuits at the MAF sensor harness
connector.
Is the test light “ON?” — Go to Step 13 Go to Step 6
6 Connect a test light between the MAF sensor ignition
feed circuit and battery ground.
Is the test light “ON?” — Go to Step 12 Go to Step 7
7 1. Check for a poor connection at the MAF sensor.
2. If a poor connection is found, replace the faulty
terminal(s).
Was a poor connection found? — Verify repair Go to Step 11
8 1. Ignition “OFF.”
2. Disconnect the MAF sensor.
3. Disconnect the PCM connector for the MAF signal
circuit.
4. Ignition “ON,” engine “OFF.”
5. With the DVM, measure the voltage between the
MAF signal terminal at the PCM and battery ground.
Is the voltage under the specified value? 4V Go to Step 9 Go to Step 10
ENGINE DRIVEABILITY AND EMISSIONS 6E–109

DTC P0102 – MAF Sensor Circuit Low Frequency


Step Action Value(s) Yes No
9 1. Ignition “OFF.”
2. Disconnect the PCM white connector.
3. Ignition “ON.”
4. Check the MAF sensor signal circuit for a short to 5
volts.
Is the action complete? — Verify repair —
10 1. Ignition “OFF.”
2. Disconnect the PCM white connector.
3. Ignition “ON.”
4. Check the MAF sensor signal circuit between the
PCM and the MAF sensor for an open, short to
ground, or short to the MAF ground circuit.
Is the action complete? — Verify repair Go to Step 13
11 Locate and repair the open in the ground circuit to the
MAF sensor.
Is the action complete? — Verify repair —
12 Locate and repair the open in the ignition feed circuit to
the MAF sensor.
Is the action complete? — Verify repair —
13 Replace the MAF sensor.
Is the action complete? — Verify repair Go to Step 14
14 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
6E–110 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency

T321122

Circuit Description The PCM calculates an airflow value based on idle air
control valve position, throttle position, RPM and
The mass air flow (MAF) sensor measures the amount of barometric pressure.
air which passes through it into the engine during a given
The PCM will store conditions which were present
time. The powertrain control module (PCM) uses the when the DTC was set as Freeze Frame and in the
mass air flow information to monitor engine operating Failure Records data.
conditions for fuel delivery calculations. A large quantity
of air entering the engine indicates an acceleration or high Conditions for clearing the MIL/DTC
load situation, while a small quantity of air indicates
DTC P0103 can be cleared by using the Tech 2 “Clear
deceleration or idle. Info” function or by disconnecting the PCM battery
The MAF sensor produces a frequency signal which can feed.
be monitored using a Tech 2. The frequency will vary
within a range of around 2500 Hz at idle to around Diagnostic Aids
9000 Hz at maximum engine load. DTC P0103 will be set If DTC P0103 cannot be duplicated, the information
if the signal from the MAF sensor is above the possible included in the Failure Records data can be useful in
range of a normally operating MAF sensor. determining vehicle mileage since the DTC was last set.
Conditions for Setting the DTC Test Description
The engine is running above 500 RPM for more than Number(s) below refer to the step number(s) on the
10 seconds. Diagnostic Chart.
System voltage is above 11.5 volts. 2. This step verifies that the problem is present at idle.
MAF signal frequency is above 10,000 Hz (10.0 kHz)
for a total of 50 percent of the last 200 samples 4. A frequency reading with the MAF sensor connector
monitored. A sample is taken every cylinder event. disconnected indicates an electromagnetic
interfernce (EMI) related fault.
Action Taken When the DTC Sets
The PCM will illuminate the malfunction indicator lamp
(MIL) the first time the fault is detected.
ENGINE DRIVEABILITY AND EMISSIONS 6E–111

DTC P0103 – MAF Sensor Circuit High Frequency


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Ignition “ON,” engine “OFF.”
2. Review and record Tech 2 Failure Records data.
3. Operate the vehicle within Failure Records
conditions as noted.
4. Using a Tech 2, monitor “DTC” info for DTC P0103. Refer to
Does the Tech 2 indicate DTC P0103 failed this Diagnostic
ignition? — Go to Step 3 Aids
3 1. Start the engine.
2. With the engine idling, monitor “MAF Frequency”
display on the Tech 2.
Is “MAF Frequency” above the specified value? 219 g/Sec Go to Step 4 Go to Step 7
4 1. Ignition “OFF.”
2. Disconnect the MAF sensor connector.
3. Ignition “ON,” engine idling.
4. Using a Tech 2, monitor “MAF Frequency.”
Does the Tech 2 indicate a “MAF Frequency” at the
specified value? 0.0 g/Sec Go to Step 5 Go to Step 6
5 Replace the MAF sensor.
Is the action complete? — Verify repair Go to Step 8
6 1. Check the MAF harness for incorrect routing near
high voltage components (solenoids, relays,
motors).
2. If incorrect routing is found, correct the harness
routing.
Was a problem found? — Verify repair Go to Step 7
7 1. With the engine idling, monitor “MAF Frequency”
display on the Tech 2.
2. Quickly snap open throttle to wide open throttle
while under a road load and record value.
Does the Tech 2 indicate “MAF Frequency” above the
specified value? 219 g/Sec Go to Step 5 Go to Step 8
8 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
6E–112 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage

D06RW102

Circuit Description Action Taken When the DTC Sets


The manifold absolute pressure (MAP) sensor responds The PCM will illuminate the malfunction indicator lamp
to changes in intake manifold pressure (vacuum). The (MIL) the first time the fault is detected.
MAP sensor signal voltage to the powertrain control The PCM will default to a BARO value of 79.3 kPa.
module (PCM) varies from below 2 volts at idle (high The PCM will store conditions which were present
vacuum) to above 4 volts with the ignition “ON,” engine when the DTC was set as Freeze Frame and in the
not running or at wide-open throttle (low vacuum). Failure Records data.
The MAP sensor is used to determine manifold pressure
changes while the exhaust gas recirculation (EGR) flow Conditions for Clearing the MIL/DTC
test diagnostic is being run (refer to DTC P0401), to DTC P0107 can be cleared by using the Tech 2 “Clear
determine engine vacuum level for some other Info” function or by disconnecting the PCM battery
diagnostics and to determine barometric pressure feed.
(BARO). The PCM monitors the MAP signals for voltages
outside the normal range of the MAP sensor. If the PCM Diagnostic Aids
detects a MAP signal voltage that is excessively low, DTC Check for the following conditions:
P0107 will be set. Check for intermittent codes.
The MAP sensor shares a 5 Volt reference with the
Conditions for Setting the DTC Rough Road Sensor. If these codes are also set, it
No TP sensor DTCs present. could indicate a problem with the 5 Volt reference
circuit .
Engine is running.
The MAP sensor shares a ground with the Rough Road
Throttle angle is above 1% if engine speed is less than Sensor, the ECT sensor, and the Transmission Fluid
1000 RPM. Temperature sensor.
Throttle angle is above 2% if engine speed is above Poor connection at PCM – Inspect harness connectors
1000 RPM. for backed-out terminals, improper mating, broken
The MAP sensor indicates manifold absolute pressure locks, improperly formed or damaged terminals, and
at or below 11 kPa for a total of approximately 10 poor terminal-to-wire connection.
seconds over a 16-second period. Damaged harness – Inspect the wiring harness for
Ignition voltage more than 11 volts. damage. If the harness appears to be OK, observe the
MAP display on the Tech 2 while moving connectors
ENGINE DRIVEABILITY AND EMISSIONS 6E–113
and wiring harnesses related to the sensor. A change determining vehicle mileage since the DTC was last set.
in the display will indicate the location of the fault. If it is determined that the DTC occurs intermittently,
If DTC P0107 cannot be duplicated, the information performing the DTC P0107 Diagnostic Chart may isolate
included in the Failure Records data can be useful in the cause of the fault.

DTC P0107 – MAP Sensor Circuit Low Voltage


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Ignition “ON,” engine “OFF.”
2. With the throttle closed, observe the MAP value
displayed on the Tech 2. 11 kPa at sea
Is the MAP value near the specified value? level Go to Step 4 Go to Step 3
3 1. Ignition “ON,” engine “OFF.”
2. Review and record Tech 2 Failure Records data.
3. Operate the vehicle within Failure Records
conditions as noted.
4. Using a Tech 2, monitor “Specific DTC” info for DTC Refer to
P0107. Diagnostic
Does the Tech 2 indicate DTC P0107 failed? — Go to Step 4 Aids
4 1. Ignition “OFF.”
2. Disconnect the MAP sensor electrical connector.
3. Jumper the 5 volt reference “A” circuit and the MAP
signal together at the MAP sensor harness
connector.
4. Ignition “ON.”
5. Observe the MAP value displayed on the Tech 2.
Is the MAP value near the specified value? 5 V 104 kPa Go to Step 10 Go to Step 5
5 1. Disconnect the jumper.
2. Connect a test light between B+ and the MAP
sensor signal circuit at the MAP sensor harness
connector.
3. Observe the MAP value displayed on the Tech 2.
Is the MAP value near the specified value. 5 V 104 kPa Go to Step 6 Go to Step 8
6 1. Ignition “OFF.”
2. Disconnect the PCM and check the 5 volt reference
“A” circuit for an open or short to ground.
3. If the 5 volt reference “A” circuit is open or shorted to
ground, repair it as necessary.
Was the 5 volt reference “A” circuit open or shorted to
ground? — Verify repair Go to Step 7
7 Check the 5 volt reference “A” circuit for a poor
connection at the PCM and replace the terminal if
necessary.
Did the terminal require replacement? — Verify repair Go to Step 11
8 1. Ignition “OFF.”
2. Disconnect the PCM, and check the MAP signal
circuit for an open, short to ground, or short to the
sensor ground circuit.
3. If the MAP sensor signal circuit is open or shorted to
ground, repair it as necessary.
Was the MAP signal circuit open or shorted to ground? — Verify repair Go to Step 9
6E–114 ENGINE DRIVEABILITY AND EMISSIONS

DTC P0107 – MAP Sensor Circuit Low Voltage


Step Action Value(s) Yes No
9 Check the MAP sensor signal circuit for a poor
connection at the PCM and the MAP sensor; replace
the terminal if necessary.
Did the terminal require replacement? — Verify repair Go to Step 11
10 Replace the MAP sensor.
Is the action complete? — Verify repair —
11 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–115

Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit High Voltage

D06RW102

Circuit Description The PCM will default to a BARO value of 79.3 kPa.
The manifold absolute pressure (MAP) sensor responds The PCM will store conditions which were present
to changes in intake manifold pressure (vacuum). The when the DTC was set as Freeze Frame and in the
Failure Records data.
MAP sensor signal voltage to the powertrain control
module (PCM) varies from below 2 volts at idle (high Conditions for Clearing the MIL/DTC
vacuum) to above 4 volts with the key “ON,” engine not
running or at wide-open throttle (low vacuum). DTC P0108 can be cleared by using the Tech 2 “Clear
The MAP sensor is used to determine manifold pressure Info” function or by disconnecting the PCM battery
feed.
changes while the linear EGR flow test diagnostic is being
run (refer to DTC P0401), to determine engine vacuum Diagnostic Aids
level for some other diagnostics and to determine
barometric pressure (BARO). The PCM monitors the Check for the following conditions:
MAP signals for voltages outside the normal range of the Poor connection at PCM – Inspect harness connectors
for backed-out terminals, improper mating, broken
MAP sensor. If the PCM detects a MAP signal voltage locks, improperly formed or damaged terminals, and
that is excessively high, DTC P0108 will be set. poor terminal-to-wire connection.
Damaged harness – Inspect the wiring harness for
Conditions for Setting the DTC damage. If the harness appears to be OK, observe the
No TP sensor DTCs present. MAP display on the Tech 2 while moving connectors
Engine is running for more than 10 seconds. and wiring harnesses related to the sensor. A change
in the display will indicate the location of the fault.
Throttle position is below 3% if engine speed is below If DTC P0108 cannot be duplicated, the information
1000 RPM.
included in the Failure Records data can be useful in
Throttle position is below 10% if engine speed is above determining vehicle mileage since the DTC was last set. If
1000 RPM.
it is determined that the DTC occurs intermittently,
The MAP sensor indicates an intermittent manifold
absolute pressure above 80 kPa for a total of performing the DTC P1108 Diagnostic Chart may isolate
approximately 10 seconds over a 16-second period. the cause of the fault.

Action Taken When the DTC Sets


The PCM will illuminate the malfunction indicator lamp
(MIL) the first time the fault is detected.
6E–116 ENGINE DRIVEABILITY AND EMISSIONS

DTC P0108 – MAP Sensor Circuit High Voltage


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. If the engine idle is rough, unstable or incorrect,
repair the idle problem before using this chart. Refer
to Symptoms section.
2. With the engine idling, note the MAP value on the
Tech 2.
Is the MAP reading above the specified value? 90 kPa Go to Step 4 Go to Step 3
3 1. Ignition “ON,” engine “OFF.”
2. Review and record Tech 2 Failure Records data.
3. Operate the vehicle within Failure Records
conditions as noted.
4. Using a Tech 2, monitor “Specific DTC” info for DTC
P0108. Refer to
Does the Tech 2 indicate DTC P0108 failed this Diagnostic
ignition? — Go to Step 4 Aids
4 1. Ignition “OFF.”
2. Disconnected the MAP sensor electrical connector.
3. Ignition “ON.”
4. Note the MAP sensor voltage displayed on the Tech
2.
Is the MAP sensor voltage at the specified value? 0.0 V 11 kPa Go to Step 5 Go to Step 6
5 Probe the sensor ground circuit with a test light to B+.
Is the test light “ON?” — Go to Step 7 Go to Step 9
6 1. Check the MAP signal circuit for a short to voltage or
a short to the 5 volt reference “A” circuit.
2. If the MAP sensor signal circuit is shorted, repair
circuit as necessary.
Was the MAP sensor signal circuit shorted? — Verify repair Go to Step 11
7 1. Check for a poor sensor ground terminal connection
at the MAP sensor electrical connector.
2. If a problem if found, replace the faulty terminal.
Did the terminal require replacement? — Verify repair Go to Step 8
8 Check for a plugged or leaking vacuum supply to the
MAP sensor.
Is the vacuum supply plugged or leaking? — Verify repair Go to Step 12
9 1. Check for a poor sensor ground terminal connection
at the PCM.
2. If a problem is found, replace the faulty terminal.
Did the terminal require replacement? — Verify repair Go to Step 10
10 1. Check the continuity of the MAP sensor ground
circuit.
2. If the MAP sensor ground circuit measures over 5
ohms, repair open or poor connection.
Was a condition found and corrected? — Verify repair Go to Step 11
ENGINE DRIVEABILITY AND EMISSIONS 6E–117

DTC P0108 – MAP Sensor Circuit High Voltage


Step Action Value(s) Yes No
11 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify Repair —
12 Replace the MAP sensor.
Is the action complete? — Verify repair —
6E–118 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage

D06RW026

Circuit Description Conditions for Clearing the MIL/DTC


The intake air temperature (IAT) sensor is a thermistor DTC P0112 can be cleared by using the Tech 2 “Clear
which measures the temperature of the air entering the Info” function or by disconnecting the PCM battery
engine. The powertrain control module (PCM) applies 5 feed.
volts through a pull-up resistor to the IAT sensor. When
the intake air is cold, the sensor resistance is high and the Diagnostic Aids
PCM will monitor a high signal voltage on the IAT signal Check for the following conditions:
circuit. If the intake air is warm, the sensor resistance is Poor connection at PCM – Inspect harness connectors
lower, causing the PCM to monitor a lower voltage. DTC for backed-bout terminals, improper mating, broken
P0112 will set when the PCM detects an excessively low locks, improperly formed or damaged terminals, and
signal voltage on the intake air temperature sensor signal poor terminal-to-wire connection.
circuit. Damaged harness – Inspect the wiring harness for
damage. If the harness appears to be OK, observe the
Conditions for Setting the DTC IAT display on the Tech 2 while moving connectors and
wiring harnesses related to the IAT sensor. A change
The engine has been running for over 2 minutes. in the IAT display will indicate the location of the fault.
Vehicle speed is greater than 30 mph (48 km/h) . If DTC P0112 cannot be duplicated, the information
IAT signal voltage indicates and intake air temperature included in the Failure Records data can be useful in
greater than 148 C (298 F) (about 5 volts) for a total determining vehicle mileage since the DTC was last set.
of 12.5 seconds over a 25-second period of time.
Test Description
Action Taken When the DTC Sets Number(s) below refer to the step number(s) on the
The PCM will illuminate the malfunction indicator lamp Diagnostic Chart:
(MIL) the first time the fault is detected. 2. Verifies that the fault is present.
The PCM will store conditions which were present
when the DTC was set as Freeze Frame and in the
Failure Records data.
ENGINE DRIVEABILITY AND EMISSIONS 6E–119
3. If DTC P0112 can be repeated only by duplicating
the Failure Records condition, refer to the
Temperature vs. Resistance Value table. The table
may be used to test the IAT sensor at various
temperatures to evaluate the possibility of a
“shifted” sensor that may be stored above or below
a certain temperature. If this is the case, replace
the IAT sensor. If the IAT sensor appears to be OK,
the fault is intermittent; refer to Diagnostic Aids.

Intake Air Temperature Sensor


C F OHMS
Temperature vs. Resistance Values
(approximate)
100 212 177
80 176 332
60 140 667
45 113 1188
35 95 1802
25 77 2796
15 59 4450
5 41 7280
–5 23 12300
–15 5 21450
–30 –22 52700
–40 –40 100700
6E–120 ENGINE DRIVEABILITY AND EMISSIONS

DTC P0112–IAT Sensor Circuit Low Voltage


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Ignition “ON,” engine “OFF.”
2. Using a Tech 2, monitor the intake air temperature
(IAT).
Is the intake air temperature greater than the specified 148 C
value? (283 F) Go to Step 4 Go to Step 3
3 1. Ignition “ON,” engine “OFF.” Review and record
Tech 2 Failure Records data.
2. Operate the vehicle within Failure Records
conditions as noted.
3. Using a Tech 2, monitor the “Specific DTC” info for
DTC P0112. Refer to
Does the Tech 2 indicate DTC P0112 failed this Refer to Test Diagnostic
ignition? — Description Aids
4 1. Ignition “OFF.”
2. Disconnect the IAT sensor electrical connector.
3. Ignition “ON.”
4. Observe the intake air temperature on the Tech 2. –38 C
Is the intake air temperature below the specified value? (–36 F) Go to Step 6 Go to Step 5
5 1. Ignition “OFF.”
2. Disconnect the PCM electrical connectors.
3. Check the IAT sensor signal circuit for a short to
ground.
Is the IAT sensor signal circuit shorted to ground? — Verify repair Go to Step 7
6 Replace the IAT sensor.
Is the action complete? — Verify repair —
7 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–121

Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage

D06RW026

Circuit Description Conditions for Clearing the MIL/DTC


The intake air temperature (IAT) sensor is a thermistor DTC P0113 can be cleared by using the Tech 2 “Clear
which measures the temperature of the air entering the Info” function or by disconnecting the PCM battery
engine. The powertrain control module (PCM) applies 5 feed.
volts through a pull-up resistor to the IAT sensor. When
the intake air is cold, the sensor resistance is high and the Diagnostic Aids
PCM will monitor a high signal voltage on the IAT signal Check for the following conditions:
circuit. If the intake air is warm, the sensor resistance is The IAT sensor shares a ground with the EGR position
lower causing the PCM to monitor a lower voltage. DTC sensor and the TP sensor. Check the ground if these
P0113 will set when the PCM detects an excessively high DTC’s are set.
signal voltage on the intake air temperature sensor signal Poor connection at PCM – Inspect harness connectors
circuit. for backed-out terminals, improper mating, broken
locks, improperly formed or damaged terminals, and
Conditions for Setting the DTC poor terminal-to-wire connection.
Damaged harness – Inspect the wiring harness for
The engine has been running for over 4 minutes. damage. If the harness appears to be OK, observe the
Vehicle speed is less than 20 mph (32 km/h). IAT display on the Tech 2 while moving connectors and
ECT signal temperature is above 60 C (140 F). wiring harnesses related to the IAT sensor. A change
Mass air flow is less then 20 g/second. in the IAT display will indicate the location of the fault.
If DTC P0113 cannot be duplicated, the information
IAT signal voltage indicates an intake air temperature
less than –39 C (–38 F) for total of 12.5 seconds over included in the Failure Records data can be useful in
a 25-second period. determining vehicle mileage since the DTC was last set.

Action Taken When the DTC Sets Test Description


The PCM will illuminate the malfunction indicator lamp Number(s) below refer to the step number(s) on the
(MIL) the first time the fault is detected. Diagnostic Chart:
The PCM will store conditions which were present 2. Verifies that the fault is present.
when the DTC was set as Freeze Frame and in the
Failure Records data.
6E–122 ENGINE DRIVEABILITY AND EMISSIONS
3. If DTC P0113 can be repeated only by duplicating Intake Air Temperature Sensor
the Failure Records conditions, refer to the
“Temperature vs. Resistance Values” table. The C F OHMS
table may be used to test the IAT sensor at various
temperatures to evaluate the possibility of a Temperature vs. Resistance Values
“shifted” sensor that may be open above or below a (approximate)
certain temperature. If this is the case, replace the 100 212 177
IAT sensor. If the IAT sensor appears to be OK, the
fault is intermittent; refer to Diagnostic Aids. 80 176 332
60 140 667
45 113 1188
35 95 1802
25 77 2796
15 59 4450
5 41 7280
–5 23 12300
–15 5 21450
–30 –22 52700
–40 –40 100700

DTC P0113 –IAT Sensor Circuit High Voltage


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 Ignition “ON,” engine “OFF.” Observe the “Intake Air
Temp” display on the Tech 2.
–38 C
Is the “Intake Air Temp” below the specified value? (–36 F) Go to Step 4 Go to Step 3
3 1. Ignition “ON,” engine “OFF.”
2. Review and record Tech 2 Failure Records data
parameters.
3. Operate the vehicle within Failure Records
conditions as noted.
4. Using a Tech 2, monitor “Specific DTC” info for DTC Refer to
P0113. Refer to Test Diagnostic
Does the Tech 2 indicate DTC P0113 failed? — Description Aids
4 1. Ignition “OFF.”
2. Disconnect the IAT sensor electrical connector.
3. Jumper the IAT signal circuit and the sensor ground
circuit together at the IAT sensor harness
connector.
4. Ignition “ON.”
5. Observe the “Intake Air Temp” display on the Tech
2. 140 C
Is the “Intake Air Temp” at the specified value? (284 F) Go to Step 6 Go to Step 5
5 1. Jumper the IAT signal circuit at the IAT sensor
harness connector to chassis ground.
2. Observe the “Intake Air Temp” display on the Tech
2. 140 C
Is the “Intake Air Temp” at the specified value? (284 F) Go to Step 7 Go to Step 8
ENGINE DRIVEABILITY AND EMISSIONS 6E–123

DTC P0113 –IAT Sensor Circuit High Voltage


Step Action Value(s) Yes No
6 Check for poor connections at the IAT sensor and
replace terminals if necessary.
Did any terminals require replacement? — Verify repair Go to Step 10
7 1. Ignition “OFF.”
2. Disconnect the PCM, and check the IAT sensor
ground circuit for an open.
3. If the IAT sensor ground circuit is open, repair it as
necessary.
Was the IAT sensor ground circuit open? — Verify repair Go to Step 9
8 1. Ignition “OFF.”
2. Disconnect the PCM, and check the IAT signal
circuit for an open.
3. If the IAT sensor signal circuit is open, repair it as
necessary.
Was the IAT signal circuit open? — Verify repair Go to Step 9
9 Check for a poor sensor ground or IAT signal circuit
terminal connection at the PCM and replace
terminal(s) if necessary.
Did any of the terminals need to be replaced? — Verify repair Go to Step 11
10 Replace the IAT sensor.
Is the action complete? — Verify repair —
11 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
6E–124 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage

060RY00304

Circuit Description The PCM will store conditions which were present
when the DTC was set as Freeze Frame and in the
The engine coolant temperature (ETC) sensor is a Failure Records data.
thermistor mounted on a coolant crossover pipe at the
rear of the engine. The powertrain control module (PCM) Conditions for Clearing the MIL/DTC
applies a voltage (about 5 volts) through a pull-up resistor
to the ECT signal circuit. When the engine coolant is cold, DTC P0117 can be cleared by using the Tech 2 “Clear
Info” function or by disconnecting the PCM battery
the sensor (thermistor) resistance is high, therefore the feed.
PCM will measure a high signal voltage. As the engine
coolant warms, the sensor resistance becomes lower, Diagnostic Aids
and the ECT signal voltage measured at the PCM drops.
Check for the following conditions:
With a fully warmed-up engine, the ECT signal voltage
should measure about 1.5 to 2.0 volts. Poor connection at PCM – Inspect harness connectors
for backed-out terminals, improper mating, broken
locks, improperly formed or damaged terminals, and
Conditions for Setting the DTC poor terminal-to-wire connection.
Engine running time is longer than one minute. Damaged harness – Inspect the wiring harness for
The ECT sensor signal indicates an engine coolant damage. If the harness appears to be OK, observe the
temperature greater than 150 C (302 F) (about 0.10 ECT display on the Tech 2 while moving connectors
V) for a total of 50 seconds over a 100–second period. and wiring harnesses related to the ECT sensor. A
change in the ECT display will indicate the location of
Action Taken When the DTC Sets the fault.
If DTC P0117 cannot be duplicated, the information
The PCM will illuminate the malfunction indicator lamp included in the Failure Records data can be useful in
(MIL) the first time the fault is detected. determining vehicle mileage since the DTC was last set.
The PCM will substitute the ECT reading with a default
engine coolant temperature value. The default value Test Description
is based on start-up intake air temperature and running
time. Number(s) below refer to the step number(s) on the
Diagnostic Chart.
ENGINE DRIVEABILITY AND EMISSIONS 6E–125
2. Verifies that the fault is present.
3. If DTC P0117 can be repeated only by duplicating
the Failure Records conditions, refer to the
“Temperature vs. Resistance Values” table. The
table may be used to test the ECT sensor at various
temperatures to evaluate the possibility of a
“shifted” sensor that may be shorted above or below
a certain temperature. If this is the case, replace
the ECT sensor. If the ECT sensor appears to be
OK, the fault is intermittent; refer to Diagnostic Aids.

Engine Coolant Temperature Sensor


C F OHMS
Temperature vs. Resistance Values
(approximate)
100 212 177
80 176 332
60 140 667
45 113 1188
35 95 1802
25 77 2796
15 59 4450
5 41 7280
–5 23 12300
–15 5 21450
–30 –22 52700
–40 –40 100700
6E–126 ENGINE DRIVEABILITY AND EMISSIONS

DTC P0117 – ECT Sensor Low Voltage


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Ignition “ON,” engine “OFF.”
2. Observe the “Eng Cool Temp” display on the Tech 2. 139 C
Is the “Eng Cool Temp” below the specified value? (282 F) Go to Step 4 Go to Step 3
3 1. Ignition “ON,” engine “OFF.”
2. Review and record Tech 2 Failure Records data.
3. Operate the vehicle within Failure Records
conditions as noted.
4. Using a Tech 2, monitor “Specific DTC” info for DTC
P0117. Refer to
Does the Tech 2 indicate DTC P0117 failed this Diagnostic
ignition? — Go to Step 4 Aids
4 1. Disconnect the ECT sensor electrical connector.
2. Observe the “Eng Cool Temp” display on the Tech 2. –39 C
Is the “Eng Cool Temp” at the specified value? (–38 F) Go to Step 6 Go to Step 5
5 1. Ignition “OFF.”
2. Disconnect the PCM and check the ECT signal
circuit for a short to ground or a short to the sensor
ground circuit.
3. If the ECT signal circuit is shorted. repair it as
necessary.
Was the ECT signal circuit shorted to ground? — Verify repair Go to Step 7
6 Replace the ECT sensor.
Is the action complete? — Verify repair —
7 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–127

Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage

060RY00304

Circuit Description Conditions for Clearing the MIL/DTC


The engine coolant temperature (ETC) sensor is a DTC P0118 can be cleared by using the Tech 2 “Clear
thermistor mounted in on a coolant crossover pipe at the Info” function or by disconnecting the PCM battery
rear of the engine. The powertrain control module (PCM) feed.
applies a voltage (about 5 volts) through a pull-up resistor
to the ECT signal circuit. When the engine coolant is cold, Diagnostic Aids
the sensor (thermistor) resistance is high, therefore the Check for the following conditions:
PCM will measure a high signal voltage. As the engine The ECT shares a ground with the Transmission Fluid
coolant warms, the sensor resistance becomes less, and Temperature sensor, the Rough Road sensor, and the
the ECT signal voltage measured at the PCM drops. With MAP sensor.
a fully warmed-up engine, the ECT signal voltage should Check the ground if these DTCs are also set.
measure about 1.5 to 2.0 volts. Poor connection at PCM – Inspect harness connectors
for backed-out terminals, improper mating, broken
Conditions for Setting the DTC locks, improperly formed or damaged terminals, and
poor terminal-to-wire connection.
Engine running time is longer than 1.5 minutes.
Damaged harness – Inspect the wiring harness for
The ECT sensor signal indicates an engine coolant damage. If the harness appears to be OK, observe the
temperature of –39 C (–38 F) or less (about 5 volts) ECT display on the Tech 2 while moving connectors
for a total of 50 seconds over a 100-second period. and wiring harnesses related to the ECT sensor. A
change in the ECT display will indicate the location of
Action Taken When the DTC Sets the fault.
The PCM will illuminate the malfunction indicator lamp If DTC P0118 cannot be duplicated, the information
(MIL) the first time the fault is detected. included in the Failure Records data can be useful in
The PCM will substitute the ECT reading with a default determining vehicle mileage since the DTC was last set.
engine coolant temperature value. The default value If it is determined that the DTC occurs intermittently,
is based on start-up intake air temperature and running performing the DTC P1115 Diagnostic Chart may isolate
time. the cause of the fault.
The PCM will store conditions which were present
when the DTC was set as Freeze Frame and in the
Failure Records data.
6E–128 ENGINE DRIVEABILITY AND EMISSIONS
Test Description Engine Coolant Temperature Sensor
Number(s) below refer to the step number(s) on the
Diagnostic Chart. C F OHMS
2. Verifies that the fault is present. Temperature vs. Resistance Values
(approximate)
3. If DTC P0118 can be repeated only by duplicating
the Failure Records conditions, refer to the 100 212 177
“Temperature vs. Resistance Value” table. The
80 176 332
table may be used to test the ECT sensor at various
temperatures to evaluate the possibility of a 60 140 667
“shifted” sensor that may be shorted above or below
45 113 1188
a certain temperature. If this is the case, replace
the ECT sensor. If the ECT sensor appears to be 35 95 1802
OK, the fault is intermittent; refer to Diagnostic Aids.
25 77 2796
15 59 4450
5 41 7280
–5 23 12300
–15 5 21450
–30 –22 52700
–40 –40 100700

DTC P0118 – ECT Sensor Circuit High Voltage


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Ignition “ON,” engine “OFF.”
2. Observe the “Eng Cool Temp” display on the Tech 2. –39 C
Is the “Eng Cool Temp” below the specified value? (–38 F) Go to Step 4 Go to Step 3
3 1. Ignition “ON,” engine “OFF.”
2. Review and record Tech 2 Failure Records data.
3. Operate the vehicle within Failure Records
conditions as noted.
4. Using a Tech 2, monitor the “Specific DTC” info for Refer to
DTC P0118. Refer to Test Diagnostic
Does the Tech 2 indicate DTC P0118 failed? — Description Aids
4 1. Disconnect the ECT sensor electrical connector.
2. Jumper the ECT signal circuit and the sensor
ground circuit together at the ECT sensor harness
connector.
3. Observe the “Eng Cool Temp” display on the Tech 2. 140 C
Is the “Eng Cool Temp” at the specified value? (284 F) Go to Step 6 Go to Step 5
5 1. Jumper the ECT signal circuit at the ECT sensor
harness connector to chassis ground.
2. Observe the “Eng Cool Temp” display on the Tech 2. 140 C
Is the “Eng Cool Temp” at the specified value? (284 F) Go to Step 7 Go to Step 8
6 Check for poor connections at the ECT sensor and
replace terminals if necessary.
Did any terminals require replacement? — Verify repair Go to Step 10
ENGINE DRIVEABILITY AND EMISSIONS 6E–129

DTC P0118 – ECT Sensor Circuit High Voltage


Step Action Value(s) Yes No
7 1. Ignition “OFF.”
2. Disconnect the PCM, and check the ECT sensor
ground circuit for an open.
3. If the ECT sensor ground circuit is open, repair it as
necessary.
Was the ECT sensor ground circuit open? — Verify repair Go to Step 9
8 1. Ignition “OFF.”
2. Disconnect the PCM, and check the ECT signal
circuit for an open.
3. If the ECT sensor signal circuit is open, repair it as
necessary.
Was the ECT signal circuit open? — Verify repair Go to Step 9
9 Check for a poor sensor ground or ECT signal circuit
terminal connection at the PCM and replace
terminal(s) if necessary.
Did any of the terminals need to be replaced? — Verify repair Go to Step 11
10 Replace the ECT sensor.
Is the action complete? — Verify repair —
11 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
6E–130 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0121 TP System Performance

D06RW028

Circuit Description The PCM will store conditions which were present
when the DTC was set as Freeze Frame and in the
The throttle position (TP) sensor circuit provides a voltage Failure Records data.
signal that changes relative to throttle blade angle. The
The PCM will use a default throttle position based on
signal voltage will vary from about 0.6 volts at closed mass air flow and RPM.
throttle to about 4.5 volts at wide open throttle (WOT).
The TP signal is used by the powertrain control module Conditions for Clearing the MIL/DTC
(PCM) for fuel control and many of the PCM-controlled
outputs. The PCM monitors throttle position and DTC P0121 can be cleared by using the Tech 2 “Clear
info ” function or by disconnecting the PCM battery
compares actual throttle position from the TP sensor to a feed.
predicted TP value calculated from engine speed. If the
PCM detects an out-of-range condition, DTC P0121 will Diagnostic Aids
set. Check for the following conditions:
Conditions for Setting the DTC Skewed MAP signal or faulty Map sensor – An
incorrect MAP signal may cause the PCM to incorrectly
The engine is running. calculate the predicted TP sensor value during high
No MAP DTCs, or P0121, P0122, P0123 are set. engine load situations. Check for an unusually low
MAP reading is below 55 kPa. MAP reading. This condition can cause DTC P0121 to
be set.
Throttle is steady, throttle angle is changing less than Poor connection at PCM – Inspect harness connectors
1%. for backed-out terminals, improper mating, broken
Predicted throttle angle is not close to actual throttle locks improperly formed or damaged terminals, and
angle. poor terminal-to-wire connection.
Above conditions are present for a total of 12.5 Damaged harness – Inspect the wiring harness for
seconds over a 25-second period of time. damage. If the harness appears to be OK, observe the
ECT display on the Tech 2 while moving connectors
Action Taken When the DTC Sets and wiring harnesses related to the sensor. A change
in the display will indicate the location of the fault.
The PCM will illuminate the malfunction indicator lamp
(MIL) after the second consecutive trip in which the If DTC P0121 cannot be duplicated, the information
fault is detected. included in the Failure Records data can be useful in
determining vehicle mileage since the DTC was last set.
ENGINE DRIVEABILITY AND EMISSIONS 6E–131

DTC P0121 –TP System Performance


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Ignition “ON,” engine not running.
2. Observe the MAP reading on the Tech 2.
Is the MAP reading less than the specified value? 65 kPa Go to Step 3 Go to Step 6
3 1. Disconnected the MAP sensor.
2. Connect a test light between the 5 volt reference “A”
circuit and the MAP signal circuit at the MAP sensor
harness connector.
3. Observe the MAP reading on the Tech 2.
Is the MAP reading less than the specified value? 65 kPa Go to Step 5 Go to Step 4
4 1. Check the MAP signal circuit between the PCM and
the MAP sensor for an open, short to ground, or
short to the MAP ground circuit.
2. If the MAP signal circuit is open or shorted, repair it
as necessary.
Was the MAP signal circuit open or shorted? — Verify repair Go to Step 12
5 Replace the MAP sensor.
Is the action complete? — Verify repair —
6 Observe the TP angle reading on the Tech 2 while Closed
slowly opening the throttle. throttle = 0%
Does the TP angle increase steadily and evenly from Wide open Refer to
the closed throttle value to the wide open throttle throttle = Diagnostic
value? 100% Aids Go to Step 7
7 1. Disconnect the TP sensor.
2. Observe the TP sensor reading on the Tech 2.
Is the TP sensor reading near the specified value? 0V Go to Step 8 Go to Step 9
8 1. Connect a test light between the 5 volt reference “A”
circuit and the TP sensor signal circuit at the TP
sensor harness connector.
2. Observe the TP sensor reading on the Tech 2.
Is the TP sensor reading at the specified value? 5V Go to Step 11 Go to Step 10
9 Check the following items:
1. TP signal circuit for a short to voltage.
2. TP sensor ground circuit for high resistance
between the PCM and the TP sensor.
3. TP sensor ground circuit for a poor connection.
4. If a problem is found, repair wiring harness as
necessary.
Was a problem found? — Verify repair Go to Step 12
6E–132 ENGINE DRIVEABILITY AND EMISSIONS

DTC P0121 –TP System Performance


Step Action Value(s) Yes No
10 Check the following items:
1. TP signal circuit or 5 volt reference “A” circuit for a
poor connection.
2. TP signal circuit or 5 volt reference “A” circuit for
high resistance between the PCM and the TP
sensor.
3. If a problem is found, repair wiring harness as
necessary.
Was a problem found? — Verify repair Go to Step 12
11 Replace the TP sensor.
Is the action complete? — Verify repair —
12 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–133

Diagnostic Trouble Code (DTC) P0122 TP Sensor Circuit Low Voltage

D06RW028

Circuit Description Diagnostic Aids


The throttle position (TP) sensor circuit provides a voltage Check for the following conditions:
signal that changes relative to throttle blade angle. The Check intermittent codes.
signal voltage will vary from below 0.6 volts at closed The TP sensor shares a 5 Volt reference with the EGR
throttle to about 4.5 volts at wide open throttle (WOT). position sensor. Check the 5 Volt reference if these
The TP signal is used by the powertrain control module DTCs are also set.
(PCM) for fuel control and many of the PCM–controlled The TP sensor shares a ground with the IAT sensor,
outputs. the EGR position sensor.
Poor connection at PCM – Inspect harness connectors
Conditions for Setting the DTC for backed-out terminals, improper mating, broken
The ignition is “ON.” locks, improperly formed or damaged terminals, and
poor terminal-to-wire connection.
TP sensor signal voltage is less than 0.22 volt for a total
of 0.78 second over a 1.5-second period. Damaged harness – Inspect the wiring harness for
damage. If the harness appears to be OK, observe the
throttle position display on the Tech 2 while moving
Action Taken When the DTC Sets connectors and wiring harnesses related to the TP
The PCM will illuminate the malfunction indicator lamp sensor. A change in the display will indicate the
(MIL) the first time the fault is detected. location of the fault.
The PCM will store conditions which were present If DTC P0122 cannot be duplicated, the information
when the DTC was set as Freeze Frame and in the included in the Failure Records data can be useful in
Failure Records data. determining vehicle mileage since the DTC was last set.
The PCM will use a default throttle position based on
mass air flow and RPM.

Conditions for Clearing the MIL/DTC


DTC P0122 can be cleared by using the Tech 2 “Clear
Info” function or by disconnecting the PCM battery
feed.
6E–134 ENGINE DRIVEABILITY AND EMISSIONS

DTC P0122 –TP Sensor Circuit Low Voltage


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Ignition “ON,” engine “OFF.”
2. With the throttle closed, observe the “TP Sensor”
display on the Tech 2.
Is the “TP Sensor” below the specified value? 0.22 V Go to Step 4 Go to Step 3
3 1. Ignition “ON,” engine “OFF.”
2. Review and record Tech 2 Failure Records data.
3. Operate the vehicle within Failure Records
conditions as noted.
4. Using a Tech 2, monitor the “DTC” info for DTC Refer to
P0122. Diagnostic
Does the Tech 2 indicate DTC P0122 failed? — Go to Step 4 Aids
4 1. Ignition “OFF.”
2. Disconnect the TP sensor electrical connector.
3. Jumper the 5 volt reference “A” circuit and the TP
signal together at the TP sensor harness connector.
4. Ignition “ON.”
Observe the “TP Sensor” display on the Tech 2.
Is the “TP Sensor” at the specified value? 5V Go to Step 10 Go to Step 5
5 1. Disconnect jumper.
2. Connect a test light between B+ and the TP sensor
signal circuit at the TP sensor harness connector.
Observe the “TP Sensor” display on the Tech 2.
Is the “TP Sensor” at the specified value? 5V Go to Step 6 Go to Step 8
6 1. Ignition “OFF.”
2. Disconnect the PCM and check the 5 volt reference
“A” circuit for an open or short to ground.
3. If the 5 volt reference “A” circuit is open or shorted to
ground, repair it as necessary.
Was the 5 volt reference “A” circuit open or shorted to
ground? — Verify repair Go to Step 7
7 Check the 5 volt reference “A” circuit for a poor
connection at the PCM and replace the terminal if
necessary.
Did the terminal require replacement? — Verify repair Go to Step 12
8 1. Ignition “OFF.”
2. Disconnect the PCM, and check the TP signal
circuit for an open, short to ground, or short to the
sensor ground circuit.
3. If the TP sensor signal circuit is open or shorted to
ground, repair it as necessary.
Was the TP signal circuit open or shorted to ground? — Verify repair Go to Step 9
9 Check the TP sensor signal circuit for a poor
connection at the PCM and replace the terminal if
necessary.
Did the terminal require replacement? — Verify repair Go to Step 12
ENGINE DRIVEABILITY AND EMISSIONS 6E–135

DTC P0122 –TP Sensor Circuit Low Voltage


Step Action Value(s) Yes No
10 Check the TP sensor signal circuit for a poor
connection at the TP sensor and replace the terminal if
necessary.
Did the terminal require replacement? — Verify repair Go to Step 11
11 Replace the TP sensor.
Is the action complete? — Verify repair —
12 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
6E–136 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0123 TP Sensor Circuit High Voltage

D06RW028

Circuit Description Check intermittent codes.


The throttle position (TP) sensor circuit provides a voltage The TP sensor shares a 5 Volt reference with the EGR
signal that changes relative to throttle blade angle. The position sensor. Check the 5 Volt reference if these
DTCs are also set.
signal voltage will vary from about 0.6 volts at closed
throttle to about 4.5 volts at wide open throttle (WOT). The TP sensor shares a ground with the IAT sensor
and the EGR position sensor. Check the ground if
The TP signal is one of the most important inputs used by these other DTCs are also set.
the powertrain control module (PCM) for fuel control and
Poor connection at PCM – Inspect harness connectors
many of the PCM-controlled outputs. for backed-out terminals, improper mating, broken
locks, improperly formed or damaged terminals, and
Conditions for Setting the DTC poor terminal-to-wire connection.
The ignition is “ON.” Damaged harness – Inspect the wiring harness for
TP sensor signal voltage is greater than 4.88 volts for damage. If the harness appears to be OK, observe the
a total of 0.78 second over a 1.5-second period. TP sensor display on the Tech 2 while moving
connectors and wiring harnesses related to the TP
sensor. A change in the display will indicate the
Action Taken When the DTC Sets location of the fault.
The PCM will illuminate the malfunction indicator lamp Faulty TP sensor – With the ignition key “ON,” engine
(MIL) the first time the fault is detected. “OFF,” observe the TP sensor display on the Tech 2
The PCM will store conditions which were present while slowly depressing the accelerator to wide open
when the DTC was set as Freeze Frame and in the throttle. If a voltage over 4.88 volts is seen at any point
Failure Records data. in normal accelerator travel, replace the TP sensor.
The PCM will use a default throttle position based on If DTC P0123 cannot be duplicated, the information
mass air flow and RPM. included in the Failure Records data can be useful in
determining vehicle mileage since the DTC was last set.
Conditions for Clearing the MIL/DTC
DTC P0123 can be cleared by using the Tech 2 “Clear Test Description
Info” function or by disconnecting the PCM battery Number (s) below refer to the step number(s) on the
feed. Diagnostic Chart.
7. Components that share the TP sensor 5 volt reference
Diagnostic Aids “A” circuit include the following device:
Check for the following conditions: EGR valve
ENGINE DRIVEABILITY AND EMISSIONS 6E–137
Disconnect the component while observing the TP disconnected, replace the component that affected
sensor display on the Tech 2. If the reading the reading.
changes drastically when this component is

DTC P0123 – TP Sensor Circuit High Voltage


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Ignition “ON,” engine “OFF.”
2. With the throttle closed, observe the “TP Sensor”
display on the Tech 2.
Is the “TP Sensor” above the specified value? 4.88 V Go to Step 4 Go to Step 3
3 1. Ignition “ON,” engine “OFF.”
2. Review and record Tech 2 Failure Records data.
3. Operate the vehicle within Failure Records
conditions as noted.
4. Using a Tech 2, monitor “Specific DTC” info for DTC Refer to
P0123. Diagnostic
Does the Tech 2 indicate DTC P0123 failed. — Go to Step 4 Aids
4 1. Disconnect the TP sensor electrical connector.
2. Observe the “TP Sensor” display on the Tech 2.
Is the “TP Sensor” near the specified value? 0V Go to Step 5 Go to Step 6
5 Probe the sensor ground circuit at the TP sensor
harness connector with a test light connected to B+.
Is the test light “ON?” — Go to Step 7 Go to Step 10
6 1. Ignition “OFF,” disconnect the PCM.
2. Ignition “ON,” engine “OFF.”
3. Check for a short to voltage on the TP sensor signal
circuit.
4. If the TP sensor signal circuit is shorted, repair it as
necessary.
Was the TP sensor signal circuit shorted? — Verify repair Go to Step 12
7 1. Ignition “ON.”
2. Monitor the “TP Sensor” Tech 2 display while
disconnecting each of the components that share
the 5 volt reference “A” circuit (one at a time).
3. If the “TP Sensor” Tech 2 display changes, replace
the component that caused the display to change
when disconnected.
Does disconnecting any of these components cause
the “TP Sensor” display to change? — Verify repair Go to Step 8
8 1. Ignition “OFF,” disconnect the PCM.
2. Ignition “ON,” engine “OFF.”
3. Check for a short to B+ on the 5 volt reference “A”
circuit.
4. If the 5 volt reference “A” circuit is shorted, repair it
as necessary.
Was the 5 volt reference “A” circuit shorted? — Verify repair Go to Step 9
9 Check for poor electrical connections at the TP sensor
and replace terminals if necessary.
Did any terminals require replacement? — Verify repair Go to Step 11
6E–138 ENGINE DRIVEABILITY AND EMISSIONS

DTC P0123 – TP Sensor Circuit High Voltage


Step Action Value(s) Yes No
10 1. Ignition “OFF.”
2. Disconnect the PCM, and check for an open sensor
ground circuit to the TP sensor.
3. If a problem is found, repair it as necessary.
Was the sensor ground circuit to the TP sensor open? — Verify repair Go to Step 12
11 Replace the TP sensor.
Is the action complete? — Verify repair —
12 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–139

Diagnostic Trouble Code (DTC) P0131 HO2S Circuit Low Voltage Bank 1
Sensor 1

060RW236

Circuit Description Action Taken When the DTC Sets


The powertrain control module (PCM) supplies a bias The PCM will illuminate the malfunction indicator lamp
voltage of about 450 mV between the heated oxygen (MIL) the first time the fault is detected.
sensor (HO2S) signal high and signal low circuits. When The PCM will store conditions which were present
measured with a 10 megaohm digital voltmeter, this may when the DTC was set as Freeze Frame and in the
display as low as 350 mV. The oxygen sensor varies the Failure Records data.
voltage within a range of about 1000 mV when the “Open loop” fuel control will be in effect.
exhaust is rich, down through about 10 mV when exhaust
is lean. The PCM constantly monitors the HO2S signal Conditions for Clearing the MIL/DTC
during “closed loop” operation and compensates for a rich DTC P0131 can be cleared by using the Tech 2 “Clear
or lean condition by decreasing or increasing injector Info” function or by disconnecting the PCM battery
pulse width as necessary. If the Bank 1 HO2S 1 voltage feed.
remains excessively low for an extended period of time,
DTC P0131 will be set. Diagnostic Aids
Check for the following conditions:
Conditions for Setting the DTC Heated oxygen sensor wiring – The sensor pigtail may
No related DTCs. be routed incorrectly and contacting the exhaust
system.
Vehicle is operating in “closed loop.”
Poor PCM to engine block grounds.
Engine coolant temperature is above 60 C (140 F).
Fuel pressure – The system will go lean if pressure is
“Closed loop” commanded air/fuel ratio is between too low. The PCM can compensate for some
14.5 and 14.8. decrease. However, If fuel pressure is too low, a DTC
Throttle angle is between 3% and 19%. P0131 may be set. Refer to Fuel System Diagnosis.
Bank 1 HO2S 1 signal voltage remains below 22 mV Lean injector(s) – Perform “Injector Balance Test.”
during normal “closed loop” operation for a total of 77 Vacuum leaks – Check for disconnected or damaged
seconds over a 90-second period of time. vacuum hoses and for vacuum leaks at the intake
manifold, throttle body, EGR system, and PCV system.
Exhaust leaks – An exhaust leak may cause outside air
to be pulled into the exhaust gas stream past the
6E–140 ENGINE DRIVEABILITY AND EMISSIONS
HO2S, causing the system to appear lean. Check for Test Description
exhaust leaks that may cause a false lean condition to
be indicated. Number(s) below refer to step numbers on the diagnostic
chart.
MAF sensor – The system can go lean if the MAF
sensor signal indicates an engine airfiow 3. DTC P0131 failing during operation may indicate a
measurement that is not correct. Disconnect the MAF condition described in the “Diagnostic Aids” above.
sensor to see if the lean condition is corrected. If so, If the DTC P0131 test passes while the Failure
replace the MAF sensor. Records conditions are being duplicated, an
Fuel contamination – Water, even in small amounts, intermittent condition is indicated.
can be delivered to the fuel injectors. The water can Reviewing the Failure Records vehicle mileage since the
cause a lean exhaust to be indicated. Excessive diagnostic test last failed may help determine how often
alcohol in the fuel can also cause this condition. Refer
to Fuel System Diagnosis for the procedure to check the condition that caused the DTC to be set occurs. This
for fuel contamination. may assist in diagnosing the condition.
If none of the above conditions are present, replace the
affected HO2S.

DTC P0131 –HO2S Circuit Low Voltage Bank 1 Sensor 1


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Install the Tech 2.
2. Run the engine at operating temperature.
3. Operate the vehicle within the parameters specified
under “Conditions for Setting the DTC” criteria
included in Diagnostic Support.
4. Using a Tech 2, monitor Bank 1 HO2S 1 voltage.
Does the Bank 1 HO2S 1 voltage remain below the
specified value? 22 mV Go to Step 4 Go to Step 3
3 1. Ignition “ON,” engine “OFF,” review and record Tech
2 Failure Records data and note parameters.
2. Operate the vehicle within Failure Records
conditions as noted.
3. Using a Tech 2, monitor “Specific DTC” info for DTC
P0131 until the DTC P0131 test runs.
Refer to
Note test result.
Diagnostic
Does Tech 2 indicate DTC P0131 failed this ignition? — Go to Step 4 Aids
4 1. Turn the ignition “OFF.”
2. Disconnect the PCM.
3. Check the Bank 1 HO2S 1 high and low circuits for a
short to ground or a short to the heater ground
circuit.
Are the Bank 1 HO2S 1 signal circuits shorted to
ground? — Go to Step 5 Go to Step 6
5 Repair the Bank 1 HO2S 1 signal circuit.
Is the action complete? — Verify repair —
6 1. Turn the ignition “OFF,” HO2S 1 and PCM
disconnected.
2. Check for continuity between the high and low
signal circuits.
Was there continuity between the high and low circuits? — Go to Step 7 Go to Step 8
7 Repair the short between the high and low circuits.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–141

DTC P0131 –HO2S Circuit Low Voltage Bank 1 Sensor 1


Step Action Value(s) Yes No
8 1. Ignition “OFF.”
2. Reconnect the PCM, leave the sensor
disconnected.
3. Ignition “ON.” Refer to
Does the Tech 2 indicate Bank 1 HO2S 1 voltage Diagnostic
between the specified values? 425-475 mV Aids Go to Step 9
9 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
6E–142 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0132 HO2S Circuit High Voltage Bank 1
Sensor 1

060RW236

Circuit Description Action Taken When the DTC Sets


The powertrain control module (PCM) supplies a bias The PCM will illuminate the malfunction indicator lamp
voltage of about 450 mV between the heated oxygen (MIL) the first time the fault is detected.
sensor (HO2S) signal and low circuits. When measured The PCM will store conditions which were present
with a 10 megaohm digital voltmeter, this may display as when the DTC was set as Freeze Frame and in the
low as 320 mV. The oxygen sensor varies the voltage Failure Records data.
within a range of about 1000 mV when exhaust is rich, “Open loop” fuel control will be in effect.
down through about 10 mV when exhaust is lean. The
PCM constantly monitors the HO2S signal during “closed Conditions for Clearing the MIL/DTC
loop” operation and compensates for a rich or lean DTC P0132 can be cleared by using the Tech 2 “Clear
condition by decreasing or increasing injector pulse width Info” function or by disconnecting the PCM battery
as necessary. If the Bank 1 HO2S 1 voltage remains feed.
excessively high for an extended period of time, DTC
P0132 will be set. Diagnostic Aids
Check the following items:
Conditions for Setting the DTC Fuel pressure – The system will go rich if pressure is
No related DTCs. too high. The PCM can compensate for some
increase. However, if fuel pressure is too high, a DTC
Engine coolant temperature is above 60 C (140 F) P0132 may be set. Refer to Fuel System Diagnosis.
“Closed loop” commanded air/fuel ratio is between Perform “Injector Balance Test” – Refer to Fuel System
14.5 and 14.8. Diagnosis.
Throttle angle is between 3% and 19%. MAF sensor –The system can go rich if MAF sensor
Bank 1 HO2S 1 signal voltage remains above 952 mV signal indicates an engine airflow measurement that is
during normal “closed loop” operation for a total of 77 not correct. Disconnect the MAF sensor to see it the
seconds over a 90-second period. rich condition is corrected. If so, replace the MAF
OR sensor.
Bank 1 HO2S 1 signal voltage remains above 500 mV Check for a leak in the fuel pressure regulator
during “deceleration fuel cutoff mode” operation for 3 diaphragm by checking the vacuum line to the
seconds. regulator for the presence of fuel. There should be no
fuel in the vacuum line.
ENGINE DRIVEABILITY AND EMISSIONS 6E–143
An intermittent TP sensor output will cause the system HO2S voltage is limited within a range between 300
to go rich due to a false indication of the engine mV to 600 mV, check the HO2S signal circuit wiring
accelerating. and associated terminal conditions.
Shorted Heated Oxygen Sensor (HO2S) –If the HO2S If none of the above conditions are present, replace the
is internally shorted, the HO2S voltage displayed on affected HO2S.
the Tech 2 will be over 1 volt. Try disconnecting the
affected HO2S with the key “ON,” engine “OFF.” If the Test Description
displayed HO2S voltage changes from over 1000 mV
to around 450 mV, replace the HO2S. Silicon Number(s) below refer to the step number(s) on the
contamination of the HO2S can also cause a high Diagnostic Chart.
HO2S voltage to be indicated. This condition is 3. DTC P0132 failing during “deceleration fuel cutoff
indicated by a powdery white deposit on the portion of mode” operation may indicate a condition described
the HO2S exposed to the exhaust stream. If in the “Diagnostic Aids” above. If the DTC P0132
contamination is noticed, replace the affected HO2S. test passes while the Failure Records conditions are
Open HO2S Signal Circuit or Faulty HO2S–A poor being duplicated, an intermittent condition is
connection or open in the HO2S signal circuit can indicated.
cause the DTC to set during deceleration fuel mode.
An HO2S which is faulty and not allowing a full voltage Reviewing the Failure Records vehicle mileage since the
swing between the rich and lean thresholds can also diagnostic test last failed may help determine how often
cause this condition. Operate the vehicle by the condition that caused the DTC to be set occurs. This
monitoring the HO2S voltage with a Tech 2. If the may assist in diagnosing the condition.

DTC P0132 – HO2S Circuit High Voltage Bank 1 Sensor 1


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Install the Tech 2.
2. Run the engine at operating temperature.
3. Operate the vehicle within parameters specified
under “Conditions for Setting the DTC” included in 952 mV (500
Diagnostic Support.
mV in
4. Using a Tech 2, monitor Bank 1 HO2S 1 voltage. deceleration
Does the Bank 1 HO2S 1 voltage remain above the fuel cutoff
specified value? mode) Go to Step 4 Go to Step 3
3 1. Ignition “ON,” review and record Tech 2 Failure
Records data.
2. Operate the vehicle within Failure Records
conditions as noted.
3. Using a Tech 2, monitor “Specific DTC” info for DTC
P0132 until the DTC P0132 test runs.
4. Note the test result. Refer to
Does the Tech 2 indicate DTC P0132 failed this Diagnostic
ignition? — Go to Step 4 Aids
4 1. Ignition “OFF.”
2. Disconnect Bank 1 HO2S 1.
3. Ignition “ON.”
4. At HO2S Bank 1 Sensor 1 connector (PCM side)
use a DVM to measure voltages at the high and low
signal terminals.
Are the voltages in the specified range? 3-4 V Go to Step 5 Go to Step 6
5 Repair short to voltage in signal circuit.
Is the action complete? — Verify repair —
6E–144 ENGINE DRIVEABILITY AND EMISSIONS

DTC P0132 – HO2S Circuit High Voltage Bank 1 Sensor 1


Step Action Value(s) Yes No
6 1. Ignition “ON,” engine“OFF.”
2. At Bank 1 HO2S 1 connector (PCM side) jumper
both the HO2S high and low signal circuits (PCM
side) to ground.
3. Using a Tech 2, monitor Bank 1 HO2S 1 voltage.
Is Bank 1 HO2S 1 voltage below the specified value? 10 mV Go to Step 7 Go to Step 8
7 1. Disconnect the jumpers to ground from Bank 1
HO2S 1 PCM-side connector.
2. With the HO2S 1 connector disconnected, monitor
Bank 1 HO2S 1 voltage. Refer to
Is Bank 1 HO2S 1 voltage between the specified Diagnostic
values? 425-475 mV Aids Go to Step 8
8 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–145

Diagnostic Trouble Code (DTC) P0134 HO2S Circuit Insufficient Activity Bank 1
Sensor 1

060RW237

Circuit Description Oxygen sensor heater has been determined to be


functioning properly.
The powertrain control module (PCM) supplies a bias
voltage of about 450 mV between the heated oxygen Bank 1 HO2S 1 signal voltage remains between
sensor (HO2S) high and low circuits. When measured 400 mV and 500 mV for a total of 77 seconds over a
with a 10 megaohm digital voltmeter, this may display 90-second period of time.
as low as 320 mV. The oxygen sensor varies the
voltage within a range of about 1000 mV when the Action Take When the DTC Sets
exhaust is rich, down through about 10 mV when The PCM will illuminate the malfunction indicator lamp
exhaust is lean. The PCM constantly monitors the (MIL) the first time the fault is detected.
HO2S signal during “closed loop” operation and
compensates for a rich or lean condition by decreasing The PCM will store conditions which were present
or increasing injector pulse width as necessary. If the when the DTC was set as Freeze Frame and in the
Bank 1 HO2S 1 voltage remains at or near the 450 mV Failure Records data.
bias for an extended period of time, DTC P0134 will be “Open loop” fuel control will be in effect.
set, indicating an open sensor signal or sensor low
circuit. Conditions for Clearing the MIL/DTC
Heated oxygen sensors are used to minimize the DTC P0134 can be cleared by using Tech 2 “Clear Info”
amount of time required for “closed loop” fuel control function or by disconnecting the PCM battery feed.
operation and to allow accurate catalyst monitoring.
The oxygen sensor heater greatly decreases the Diagnostic Aids
amount of time required for fuel control sensors Bank
1 HO2S 1 and Bank 2 HO2S 1 to become active. Check for the following conditions:
Oxygen sensor heaters are required by post-catalyst Poor connection or damaged harness – Inspect the
monitor sensors to maintain a sufficiently high harness connectors for backed-out terminals,
temperature for accurate exhaust oxygen content improper mating, broken locks, improperly formed or
readings further from the engine. damaged terminals, poor terminal-to-wire connection,
and damaged harness.
Conditions for Setting the DTC Faulty HO2S heater or heater circuit – With the ignition
“ON,” engine “OFF,” after a cool down period, the
No related DTCs. HO2S 1 voltage displayed on Tech 2 is normally
Battery voltage is above 10 volts. 455-460 mV. A reading over 1000 mV indicates a
Engine run time is longer than 40 seconds. signal line shorted to voltage. A reading under 5 mV
6E–146 ENGINE DRIVEABILITY AND EMISSIONS
indicates a signal line shorted to ground or signal lines Test Description
shorted together. Disconnect the HO2S and connect
a test light between the HO2S ignition feed and heater Number(s) below refer to the step number(s) on the
ground circuits. If the test light does not light for 2 Diagnostic Chart.
seconds when the ignition is turned on, repair the open 3. If the DTC P0134 test passes while the Failure
ignition feed or sensor ground circuit as necessary. If Records conditions are being duplicated, an
the test light lights and the HO2S signal and low circuits intermittent conditions is indicated.
are OK, replace the HO2S.
Reviewing the Failure Records vehicle mileage since the
Intermittent test – With the Ignition “ON,” monitor the diagnostic test last failed may help determine how often
HO2S signal voltage while moving the wiring harness
and related connectors. If the fault is induced, the the condition that caused the DTC to be set occurs. This
HO2S signal voltage will change. This may help isolate may assist in diagnosing the condition.
the location of the malfunction.

DTC P0134 –HO2S Circuit Insufficient Activity Bank 1 Sensor 1


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Install Tech 2.
2. Run the engine at operating temperature.
3. Operate the engine above 1200 RPM for two
minutes.
Does Tech 2 indicate Bank 1 HO2S 1 voltage varying
outside the specified values? 400-500 mV Go to Step 3 Go to Step 4
3 1. Ignition “ON,” engine “OFF,” review and record Tech
2 Failure Records data and note parameters.
2. Operate the vehicle within Failure Records
conditions as noted.
3. Using Tech 2, monitor “Specific DTC” info for DTC
P0134 until the DTC P0134 test runs.
Refer to
4. Note the test result. Diagnostic
Does Tech 2 indicate DTC P0134 failed this ignition? — Go to Step 4 Aids
4 Check for a damaged harness.
Was a problem found? — Verify repair Go to Step 5
5 Check for poor Bank 1 HO2S 1 high and low circuit
terminal connections at the Bank 1 HO2S 1 harness
connector and replace terminal(s) if necessary.
Did any terminals require replacement? — Verify repair Go to Step 6
6 Check for poor Bank 1 HO2S 1 high and low circuit
terminal connections at the PCM and replace terminals
if necessary.
Did any terminals require replacement? — Verify repair Go to Step 7
7 1. Ignition “OFF.”
2. With the PCM disconnected, check continuity of the
Bank 1 HO2S 1 high circuit.
3. If the Bank 1 HO2S 1 high circuit measures over 5.0
ohms, repair open or poor connection as necessary.
Was a Bank 1 HO2S 1 high circuit problem found and
corrected? — Verify repair Go to Step 8
ENGINE DRIVEABILITY AND EMISSIONS 6E–147

DTC P0134 –HO2S Circuit Insufficient Activity Bank 1 Sensor 1


Step Action Value(s) Yes No
8 1. Ignition “OFF.”
2. With the PCM disconnected, check continuity of the
Bank 1 HO2S 1 low circuit.
3. If the Bank 1 HO2S 1 low circuit measures over 5
ohms, repair open or poor connection as necessary.
Was a Bank 1 HO2S 1 low circuit problem found and
corrected? — Verify repair Go to Step 9
9 1. Ignition “ON,” engine “OFF.”
2. Disconnect Bank 1 HO2S 1 and jumper the HO2S
high and low circuits (PCM side) to ground.
3. Using Tech 2, monitor Bank 1 HO2S 1 voltage.
Is Bank 1 HO2S 1 voltage in the specified range? 0-10 mV Go to Step 10 Go to Step 11
10 Replace Bank 1 HO2S 1.
Is the action complete? — Verify repair —
11 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
6E–148 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0151 HO2S Circuit Low Voltage Bank 2
Sensor 1

060RW190

Circuit Description Action Taken When the DTC Sets


The powertrain control module (PCM) supplies a bias The PCM will illuminate the malfunction indicator lamp
voltage of about 450 mV between the heated oxygen (MIL) the first time the fault is detected.
sensor (HO2S) signal high and signal low circuits. When The PCM will store conditions which were present
measured with a 10 megaohm digital voltmeter, this may when the DTC was set as Freeze Frame and in the
display as low as 320 mV. The oxygen sensor varies the Failure Records data.
voltage within a range of about 1000 mV when the “Open loop” fuel control will be in effect.
exhaust is rich, down through about 10 mV when exhaust
is lean. The PCM constantly monitors the HO2S signal Conditions for Clearing the MIL/DTC
during “closed loop” operation and compensates for a rich DTC P0151 can be cleared by using Tech 2 “Clear Info”
or lean condition by decreasing or increasing injector function or by disconnecting the PCM battery feed.
pulse width as necessary. If the Bank 2 HO2S 1 voltage
remains excessively low for an extended period of time, Diagnostic Aids
DTC P0151 will be set. Check for the following conditions:
Heated oxygen sensor wiring – The sensor pigtail may
Conditions for Setting the DTC be mispositioned and contacting the exhaust system.
No related DTCs. Poor PCM to engine block grounds.
The engine is operating in “closed loop.” Fuel pressure – The system will go lean if pressure is
Engine coolant temperature is above 60 C (140 F). too low. The PCM can compensate for some
decrease. However, if fuel pressure is too low, a DTC
“Closed loop” commanded air/fuel ratio is between P0151 may be set. Refer to Fuel System Diagnosis.
14.5 and 14.8.
Lean injector(s) – Perform “Injector Balance Test.”
Throttle angle is between 3% and 19%.
Vacuum leaks – Check for disconnected or damaged
Bank 2 HO2S 1 signal voltage remains below 22 mV vacuum hoses and for vacuum leaks at the intake
during normal “closed loop” operation for a total of 77 manifold, throttle body, EGR system, and PCV system.
seconds over a 90-second period of time.
Exhaust leaks – An exhaust leak may cause outside air
to be pulled into the exhaust gas stream past the
HO2S, causing the system to appear lean. Check for
ENGINE DRIVEABILITY AND EMISSIONS 6E–149
exhaust leaks that may cause a false lean condition to Test Description
be indicated.
Number(s) below refer to the step number(s) on the
MAF sensor –The system can go lean if the MAF Diagnostic Chart.
sensor signal indicates an engine airflow
measurement that is not correct. Disconnect the MAF 3. DTC P0151 failing during operation may indicate a
sensor to see if the lean condition is corrected. If so, condition described in the “Diagnostic Aids” above.
replace the MAF sensor. If the DTC P0151 test passes while the Failure
Fuel contamination – Water, even in small amounts, Records conditions are being duplicated, an
can be delivered to the fuel injectors. The water can intermittent condition is indicate.
cause a lean exhaust to be indicated. Excessive Reviewing the Failure Records vehicle mileage since the
alcohol in the fuel can also cause this condition. Refer diagnostic test last failed may help determine how often
to Fuel System Diagnosis for the procedure to check
for fuel contamination. the condition that caused the DTC to be set occurs. This
may assist in diagnosing the condition.
If none of the above conditions are present, replace the
affected HO2S.

DTC P0151 – HO2S Circuit Low Voltage Bank 2 Sensor 1


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Install Tech 2.
2. Run the engine at operating temperature.
3. Operate the vehicle within the parameters specified
under “Conditions for Setting the DTC” criteria
included in Diagnostic Support.
4. Using Tech 2, monitor Bank 2 HO2S 1 voltage.
Does the Bank 2 HO2S 1 voltage remain below the
specified value? 22 mV Go to Step 4 Go to Step 3
3 1. Ignition “ON,” engine “OFF,” review and record Tech
2 Failure Records data and note parameters.
2. Operate the vehicle within Failure Records
conditions as noted.
3. Using Tech 2, monitor “Specific DTC” info for DTC
P0151 until the DTC P0151 test runs.
Refer to
4. Note test result. Diagnostic
Does Tech 2 indicate DTC P0151 failed this ignition? — Go to Step 4 Aids
4 1. Turn ignition “OFF.”
2. Disconnect the PCM.
3. Check the Bank 2 HO2S 1 high and low signal
circuits for a short to ground or a short to the heater
ground circuit.
Were Bank 2 HO2S 1 signal circuits shorted? — Go to Step 5 Go to Step 6
5 Repair the Bank 2 HO2S 1 signal circuit.
Is the action complete? — Verify repair —
6 1. Ignition “OFF.”
2. Leave the PCM and HO2S 1 disconnected.
3. Check for continuity between the high and low
signal circuits.
Was there continuity between the high and low circuits? — Go to Step 7 Go to Step 8
7 Repair the short between the high and low circuits.
Is the action complete? — Verify repair —
6E–150 ENGINE DRIVEABILITY AND EMISSIONS

DTC P0151 – HO2S Circuit Low Voltage Bank 2 Sensor 1


Step Action Value(s) Yes No
8 1. Ignition “OFF.”
2. Reconnect the PCM, leave HO2S 2 disconnected.
3. Ignition “ON.” Refer to
Does Tech 2 indicate Bank 2 HO2S 1 voltage near the Diagnostic
specified value? 425-475 mV Aids Go to Step 9
9 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–151

Diagnostic Trouble Code (DTC) P0152 HO2S Circuit HIGH Voltage Bank 2
Sensor 1

060RW190

Circuit Description Bank 2 HO2S 1 signal voltage remains above 500 mV


during deceleration fuel cutoff mode operation for up to
The powertrain control module (PCM) supplies a bias 3 seconds.
voltage of about 450 mV between the heated oxygen
sensor (HO2S) signal high and signal low circuits. When Action Taken When the DTC Sets
measured with a 10 megaohm digital voltmeter, this may
display as low as 320 mV. The oxygen sensor varies the The PCM will illuminate the malfunction indicator lamp
(MIL) the first time the fault is detected.
voltage within a range of about 1000 mV when the
exhaust is rich, down through about 10 mV when exhaust The PCM will store conditions which were present
when the DTC was set as Freeze Frame and in the
is lean. The PCM constantly monitors the HO2S signal Failure Records data.
during “closed loop” operation and compensates for a rich
“Open loop” fuel control will be in effect.
or lean condition by decreasing or increasing the injector
pulse width as necessary. If the Bank 2 HO2S 1 voltage Conditions for Clearing the MIL/DTC
remains excessively high for an extended period of time,
DTC P0152 will be set. DTC P0152 can be cleared by using Tech 2 “Clear Info”
function or by disconnecting the PCM battery feed.
Conditions for Setting the DTC
Diagnostic Aids
No related DTCs. Check for the following conditions:
The engine is operating in “closed loop.” Fuel pressure – The system will go rich if pressure is
The engine coolant temperature is above 60 C too high. The PCM can compensate for some
(140 F). increase. However, if fuel pressure is too high, a DTC
“Closed loop” commanded air/fuel ratio between 14.5 P0152 may be set. Refer to Fuel System Diagnosis.
and 14.8. Rich injector(s) – Perform “Injector Balance Test.”
Throttle angle between 3% and 19%. Leaking injector – Refer to Fuel System Diagnosis.
Bank 2 HO2S 1 signal voltage remains above 952 mV Evaporative emissions (EVAP) system – Check the
during normal “closed loop” operation for a total of 77 canister for fuel saturation. If the canister is full of fuel,
seconds over a 90-second period. check EVAP control system components and hoses.
OR Refer to Evaporative Emission (EVAP) Control
System.
6E–152 ENGINE DRIVEABILITY AND EMISSIONS
MAF sensor – The system can go rich if the MAF An HO2S which is faulty and not allowing a full voltage
sensor signal indicates an engine airflow switch between the rich and lean thresholds can also
measurement that is not correct. Disconnect the MAF cause the condition. Operate the vehicle while
sensor to see if rich condition is corrected. If so, monitoring the HO2S voltage with Tech 2. If the HO2S
replace MAF sensor. is limited within a range between 300 mV to 600 mV,
Check for leaking fuel pressure regulator diaphragm by check the HO2S signal circuit wiring and associated
checking vacuum line to regulator for the presence of terminal connections.
fuel. There should be no fuel in the vacuum line. If none of the above conditions are present, replace the
TP sensor – An intermittent TP sensor output will affected HO2S.
cause the system to go rich, due to a false indication
of the engine accelerating. Test Description
Shorted Heated Oxygen Sensor (HO2S)– If the HO2S Number(s) below refer to the step number(s) on the
is internally shorted, the HO2S voltage displayed on Diagnostic Chart.
Tech 2 will be over 1 volt. Try disconnecting the
affected HO2S with the key “ON,” engine “OFF.” If the 3. DTC P0152 failing during deceleration fuel cutoff
displayed HO2S voltage changes from over 1000 mV mode operation may indicate a condition described
to around 450 mV, replace the HO2S. Silicon in the “Diagnostic Aids” above. If the DTC P0152
contamination of the HO2S can cause a high HO2S test passes while the Failure Records conditions are
voltage to be indicated. This condition is indicated by being duplicated, an intermittent condition is
powdery white deposit on the portion of the HO2S indicated.
exposed to the exhaust stream. If contamination is Reviewing the Failure Records vehicle mileage since the
noticed, replace the affected HO2S. diagnostic test last failed may help determine how often
Open HO2S Signal Circuit of Faulty HO2S– A poor the condition that caused the DTC to be set occurs. This
connection or open in the HO2S signal circuit can may assist in diagnosing the condition.
cause the DTC to set during deceleration fuel mode.

DTC P0152 – HO2S Circuit High Voltage Bank 2 Sensor 1


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Install Tech 2.
2. Engine is at operating temperature.
3. Operate the vehicle within the parameters specified
under “Conditions for Setting the DTC” criteria 952 mV
included in Diagnostic Support.
(500 mV in
4. Using Tech 2, monitor Bank 2 HO2S 1 voltage. deceleration
Does the Bank 2 HO2S 1 voltage remain above the fuel cut-off
specified value? mode) Go to Step 4 Go to Step 3
3 1. Ignition “ON.”
2. Review and record Tech 2 Failure Records data.
3. Operate the vehicle within Failure Records
conditions as noted.
4. Using Tech 2, monitor “Specific DTC” info for DTC
P0152 until the DTC P0152 test runs.
Refer to
5. Note the test result. Diagnostic
Does Tech 2 indicate DTC P0152 failed this ignition? — Go to Step 4 Aids
4 1. Ignition “OFF.”
2. Disconnect Bank 2 HO2S 1.
3. Ignition “ON.”
4. At HO2S Bank 2 Sensor 1 connector (PCM side)
use a DVM to measure voltages at the high and low
signal terminals.
Are the voltages in the specified range? 3-4 V Go to Step 5 Go to Step 6
5 Repair short to voltage in signal circuit.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–153

DTC P0152 – HO2S Circuit High Voltage Bank 2 Sensor 1


Step Action Value(s) Yes No
6 1. Ignition “ON,” engine“OFF.”
2. At Bank 2 HO2S 1 connector (PCM side) jumper
both the HO2S high and low signal circuits (PCM
side) to ground.
3. Using Tech 2, monitor Bank 2 HO2S 1 voltage.
Is Bank 2 HO2S 1 voltage below the specified value? 10 mV Go to Step 7 Go to Step 8
7 1. Disconnect the jumpers to ground from Bank 2
HO2S 1 PCM-side connector.
2. With the HO2S 1 connector disconnected, monitor
Bank 2 HO2S 1 voltage. Refer to
Is the Bank 2 HO2S 1 voltage between the specified Diagnostic
values? 425-475 mV Aids Go to Step 8
8 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
6E–154 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0171 Fuel Trim System Lean Bank 1

D06RW030

Circuit Description speed/load fuel trim cells before determining the status of
To provide the best possible combination of driveability, the fuel trim diagnostic.
fuel economy, and emission control, a “closed loop”
air/fuel metering system is used. While in “closed loop,”
Conditions for Setting the DTC
the powertrain control module (PCM) monitors the Bank 1 No Tech 2 test is being run.
HO2S 1 and Bank 2 HO2S 1 signals and adjusts fuel None of the following: EGR DTCs, HO2S DTCs,
delivery based upon the HO2S signal voltages. A change (response, transition, open, low volts, no activity), MAF
made to fuel delivery will be indicated by the long and DTCs, TP sensor DTCs, MAP DTCs, IAT DTCs,
short term fuel trim values which can be monitored with a canister purge DTCs, EVAP DTCs, injector circuit
DTCs, or misfire DTCs.
Tech 2. Ideal fuel trim values are around 0%; if the HO2S
signals are indicating a lean condition the PCM will add Engine coolant temperature is between 25 C (77 F)
and 100 C (212 F).
fuel, resulting in fuel trim values above 0%. If a rich
condition is detected, the fuel trim values will be below Intake air temperature is between –40 C (–40 F) and
120 C (248 F).
0%, indicating that the PCM is reducing the amount of fuel
Manifold absolute pressure is between 24 kPa and 99
delivered. If an excessively lean condition is detected on kPa.
Bank 1, the PCM will set DTC P0171.
Throttle angle is steady below 95%.
The PCM’s maximum authority to control long term fuel
trim allows a range between –15% (automatic Vehicle speed is below 136 km/h (85 mph).
transmission) or –12% (manual transmission) and +20%. Engine speed is between 400 and 6,000 RPM.
The PCM monitors fuel trim under various engine Barometric pressure is greater than 72.5 kPa.
ENGINE DRIVEABILITY AND EMISSIONS 6E–155
Mass air flow is between 2 g/second and 200 g/second. Damaged harness – Inspect the wiring harness for
Ignition voltage is above 9.5 volts. damage. If the harness appears to be OK, observe the
Bank 1 HO2S 1 display on the Tech 2 while moving
Fuel system is in “closed loop.” connectors and wiring harnesses related to the engine
harness. A change in the display will indicate the
Action Taken When the DTC Sets location of the fault.
The PCM will illuminate the malfunction indicator lamp Reviewing the Failure Records vehicle mileage since the
(MIL) after the second consecutive trip in which the diagnostic test last failed may help determine how often
fault is detected. the condition that caused the DTC to be set occurs. This
The PCM will store conditions which were present may assist in diagnosing the condition.
when the DTC was set as Freeze Frame and in the
Failure Records data. Test Description
Number(s) below refer to the step number(s) on the
Conditions for Clearing the MIL/DTC
Diagnostic Chart.
DTC P0171 can be cleared by using the Tech 2 “Clear 2. DTCs other than P0171 and P0174 may indicate a
Info” function or by disconnecting the PCM battery condition present which may cause a lean condition.
feed.
If this is the case, repairing the condition which
Diagnostic Aids caused the other DTC will most likely correct the
DTC P0171/P0174.
Check for the following conditions:
4. If the DTC P0171 test passes while the Failure
Poor connection at PCM – Inspect harness connectors Records conditions are being duplicated, the lean
for backed-out terminals, improper mating, broken
locks, improperly formed or damaged terminals, and condition is intermittent. Refer to Diagnostic Aids or
poor terminal-to-wire connection. Symptoms for additional information on diagnosing
intermittent problems.
6E–156 ENGINE DRIVEABILITY AND EMISSIONS

DTC P0171 – Fuel Trim System Lean Bank 1


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 Are any DTCs set other than P0171 and P0174? Go to the
applicable
DTC charts
and repair the
other DTCs
before
proceeding
— with this chart Go to Step 3
3 1. Start the engine and operate the vehicle in “closed
loop.”
2. Observe the “BANK 1 L.T. FUEL TRIM” display on
the Tech 2. L.T. Fuel
Is the displayed value greater than the specified value? Trim: +20% Go to Step 5 Go to Step 4
4 1. Review and record the Tech 2 Failure Records data.
2. Clear the DTC P0171/P0174 and operate the
vehicle to duplicate the Failure Records conditions. The lean
3. Monitor the Tech 2 “Specific DTC” info for DTC condition is
P0171 while operating the vehicle to duplicate the not present.
Failure Records conditions. If a
driveability
4. Continue operating the vehicle until the DTC P0171 symptom still
test runs and note the test result. exists, refer
Does the Tech 2 indicate DTC P0171 failed this to Symptoms
ignition? — Go to Step 5 section.
5 Was DTC P0174 also set? — Go to Step 6 Go to Step 15
6 Visually and physically inspect the vacuum hoses for
disconnects, splits, kinks, improper routing and
improper connections and repair any problem found.
Did your inspection reveal a problem requiring repair? — Verify repair Go to Step 7
7 Visually and physically inspect the crankcase
ventilation valve for proper installation and repair any
problem found (refer to Crankcase Ventilation
System).
Did your inspection reveal a problem requiring repair? — Verify repair Go to Step 8
8 1. Inspect the MAF sensor inlet screen for damage or
for the presence of foreign objects which may
partially block the air flow sample through the MAF
sensor.
2. Correct any problem that is found as necessary.
Did your inspection of the MAF sensor reveal a
condition requiring repair? — Verify repair Go to Step 9
9 Start the engine and note the idle quality.
Is a high or unsteady idle being experienced? — Go to Step 10 Go to Step11
10 1. Visually and physically inspect the throttle body,
intake manifold, EGR valve and the EGR feed pipe
for vacuum leaks.
2. Repair any vacuum leaks as necessary.
Did your inspection reveal a vacuum leak? — Verify repair Go to Step 11
ENGINE DRIVEABILITY AND EMISSIONS 6E–157

DTC P0171 – Fuel Trim System Lean Bank 1


Step Action Value(s) Yes No
11 Check the fuel for excessive water, alcohol, or other
contaminants (see Diagnosis in Engine Fuel for the
procedure) and correct the contaminated fuel condition
if present (see Engine Fuel).
Was the fuel contaminated? — Verify repair Go to Step 12
12 1. Visually and physically inspect the PCM injector
grounds, power grounds and sensor grounds to
ensure that they are clean, tight, and in their proper
locations.
2. If a faulty ground condition is present, correct it as
necessary.
Did your inspection reveal a condition requiring repair? — Verify repair Go to Step 13
13 1. Disconnect the MAF sensor electrical connector.
2. Operate the vehicle in “closed loop” while
monitoring the “BANK 1 S.T. FUEL TRIM” displayed
on the Tech 2.
Does “BANK 1 S.T. FUEL TRIM” value decrease to
near the specified value? 0% Go to Step 19 Go to Step 14
14 Perform the procedure in the “Fuel System Pressure
Test” and repair fuel system problem if necessary.
Did Fuel System Pressure Test isolate a condition
requiring repair? — Verify repair Go to Step 15
15 1. Visually and physically inspect the intake manifold,
injector O-rings, EGR adapter, EGR valve and the
EGR feed pipes for vacuum leaks.
2. Repair any problem that is found.
Did your inspection reveal a problem? — Verify repair Go to Step 16
16 Visually and physically inspect the Bank 1 exhaust
manifold for leaks and loose or missing hardware and
correct any problem found.
Did your inspection reveal a problem? — Verify repair Go to Step 17
17 Perform the “Injector Balance Test,” and correct any
problem found (refer to Fuel Metering System).
Did Injector Balance Test isolate a problem? — Verify repair Go to Step 18
18 1. Visually and physically inspect the Bank 1 HO2S 1
to ensure that it is installed securely and that the
Bank 1 HO2S 1 pigtail and wiring harness are not
contacting the exhaust or otherwise damaged.
Refer to
2. If a problem is found, correct it as necessary. Diagnostic
Did your inspection reveal a problem? — Verify repair Aids
19 Replace the MAF sensor.
Is the action complete? — Verify repair —
6E–158 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0172 Fuel Trim System Rich Bank 1

D06RW030

Circuit Description The PCM’s maximum authority to control short term fuel
To provide the best possible combination of driveability, trim allows a range between –11% and +20%. The PCM
fuel economy, and emission control, a “closed loop” monitors fuel trim under various engine speed/load fuel
air/fuel metering system is used. While in “closed loop,” trim cells before determining the status of the fuel trim
the powertrain control module (PCM) monitors the Bank 1 diagnostic.
heated oxygen sensors (HO2S) 1 and Bank 2 HO2S 1
signals and adjusts fuel delivery based upon the HO2S
Conditions for Setting the DTC
signal voltages. A change made to fuel delivery will be No Tech 2 test is being run.
indicated by the long and short term fuel trim values which None of the following was set: EGR DTCs, HO2S
can be monitored with a Tech 2. Ideal fuel trim values are DTCs, (response, transition, open, low volts, no
around 0%; if the HO2S signals are indicating a lean activity), MAF DTCs, TPS DTCs, MAP DTCs, IAT
condition the PCM will add fuel, resulting in fuel trim DTCs, canister purge DTCs, EVAP DTCs, injector
circuit DTCs, or misfire DTCs.
values above 0%. If a rich condition is detected, the fuel
trim values will be below 0%, indicating that the PCM is Engine coolant temperature is between 25 C (77 F)
and 100 C (212 F).
reducing the amount of fuel delivered. If an excessively
Intake air temperature is between –40 C (–40 F) and
rich condition is detected on Bank 1, the PCM will set DTC 120 C (248 F).
P0172.
Manifold absolute pressure is between 24 kPa and 99
The PCM’s maximum authority to control long term fuel kPa.
trim allows a range between –15% (automatic
Throttle angle is steady below 95%.
transmission) or –12 (manual transmission) and +20%.
ENGINE DRIVEABILITY AND EMISSIONS 6E–159
Vehicle speed is below 136 km/h (85 mph). Damaged harness – Inspect the wiring harness for
Engine speed is between 400 and 6,000 RPM. damage. If the harness appears to be OK, observe the
Bank 1 HO2S 1 display on the Tech 2 while moving
Barometric pressure is greater than 72.5 kPa. connectors and wiring harnesses related to the engine
Mass air flow is between 2 g/second and 200 g/second. harness. A change in the display will indicate the
Ignition voltage is above 9.5 volts. location of the fault.
Fuel system is in “closed loop.” Reviewing the Failure Records vehicle mileage since the
diagnostic test last failed may help determine how often
Action Taken When the DTC Sets the condition that caused the DTC to be set occurs. This
may assist in diagnosing the condition.
The PCM will illuminate the malfunction indicator lamp
(MIL) after the second consecutive trip in which the
fault is detected. Test Description
The PCM will store conditions which were present Number(s) below refer to the step number(s) on the
when the DTC was set as Freeze Frame and in the Diagnostic Chart.
Failure Records data. 2. DTCs other than P0172 and P0175 may indicate a
condition present which may cause a lean condition.
Conditions for Clearing the MIL/DTC If this is the case, repairing the condition which
DTC P0172 can be cleared by using the Tech 2 “Clear caused the other DTC will most likely correct the
Info” function or by disconnecting the PCM battery DTC P0172/P0175.
feed. 4. If the DTC P0172 test passes while the Failure
Records conditions are being duplicated, the rich
Diagnostic Aids condition is intermittent. Refer to Diagnostic Aids or
Check for the following conditions: Symptoms for additional information on diagnosing
Poor connection at PCM – Inspect harness connectors intermittent problems.
for backed-out terminals, improper mating, broken
locks, improperly formed or damaged terminals, and
poor terminal-to-wire connection.
6E–160 ENGINE DRIVEABILITY AND EMISSIONS

DTC P0172 – Fuel Trim System Rich Bank 1


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 Are any DTCs set other than P0172 and P0175? Go to the
applicable
DTC charts
and repair the
other DTCs
before
proceeding
— with this chart Go to Step 3
3 1. Start the engine and operate the vehicle in “closed
loop.” L.T. Fuel
2. Observe “B1 Long Term Fuel Trim” display on the Trim: –15%
Tech 2. (auto. trans.)
Is the displayed value more negative than the specified OR –12%
value? (man. trans.) Go to Step 5 Go to Step 4
4 1. Review and record the Tech 2 Failure Records data.
2. Clear the DTC P0172/P0175 and operate the
vehicle to duplicate the Failure Records conditions.
3. Monitor the Tech 2 “DTC” info for DTC P0172 while The rich
operating the vehicle to duplicate the Failure condition is
Records conditions. not present.
If a
4. Continue operating the vehicle until the DTC P0172 driveability
test runs and note test result. symptom still
Does the Tech 2 indicate DTC P0172 failed this exists, refer
ignition? — Go to Step 5 to Symptoms.
5 Is DTC P0175 also set? — Go to Step 6 Go to Step 15
6 Visually and physically inspect the air filter element and
replace it if necessary.
Did the air filter require replacement? — Verify repair Go to Step 7
7 Visually and physically inspect the air intake duct for
collapse or restriction and repair if necessary.
Did your inspection reveal a condition requiring repair? — Verify repair Go to Step 8
8 Inspect the MAF sensor inlet screen for damage or for
the presence of foreign objects which may partially
block air flow through the screen and correct any
problem found.
Did your inspection of the MAF sensor reveal a
condition requiring repair or replacement? — Verify repair Go to Step 9
9 Start the engine and note the idle quality.
Is a low or unsteady idle being experienced? — Go to Step 10 Go to Step 11
10 1. Ignition “OFF.”
2. Physically inspect the throttle body bore, throttle
plate, and IAC passages for coking and foreign
objects.
3. If a problem was found, repair as necessary.
Did your inspection reveal a condition requiring repair? — Verify repair Go to Step 11
ENGINE DRIVEABILITY AND EMISSIONS 6E–161

DTC P0172 – Fuel Trim System Rich Bank 1


Step Action Value(s) Yes No
11 1. Disconnect the vacuum hose from the fuel pressure
regulator and inspect the hose for the presence of
fuel.
2. If fuel is present in the vacuum hose, replace the
fuel pressure regulator (refer to Fuel Metering
System).
Did the fuel pressure regulator require replacement? — Verify repair Go to Step 12
12 Ignition “ON,” engine “OFF,” monitor the TP Angle
display on the Tech 2 while slowly depressing the
accelerator pedal.
Does the TP Angle display increase steadily and Minimum 0%
evenly from minimum value at closed throttle to Maximum
maximum value at wide-open throttle? 100% Go to Step 13 Go to Step 18
13 1. Disconnect the MAF sensor electrical connector.
2. Operate the vehicle in “closed loop” while
monitoring the “BANK 1 L.T. FUEL TRIM” and
“BANK 1 S. T. FUEL TRIM” display on the Tech 2.
Did both values change to near the specified value? 0% Go to Step 19 Go to Step 14
14 1. Perform “Fuel System Pressure Test.”
2. If Fuel System Pressure Test isolates a problem,
repair as necessary (refer to Engine Fuel or Fuel
Metering System).
Did the Fuel System Pressure Test isolate a problem
requiring repair? — Verify repair Go to Step 16
15 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
16 1. Perform the “Injector Balance Test.”
2. If Injector Balance Test isolates a problem, repair as
necessary (refer to Fuel Metering System).
Did the Injector Balance Test isolate a problem
requiring repair? — Verify repair Go to Step 17
17 1. Remove and visually/physically inspect the Bank 1
HO2S 1 for silicon contamination. This will be
indicated by a powdery white deposit on the portion
of the HO2S that is exposed to the exhaust stream.
2. If contamination is evident on the Bank 1 HO2S 1, Refer to
replace the contaminated sensors. Diagnostic
Did the sensor require replacement? — Verify repair Aids
18 1. Check the TP sensor mounting screws and tighten
or replace them as necessary if they are loose or
missing.
2. If the screws are OK, replace the TP sensor.
Is the action complete? — Verify repair —
19 Replace the MAF sensor.
Is the action complete? — Verify repair —
6E–162 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0174 Fuel Trim System Lean Bank 2

D06RW031

Circuit Description speed/load fuel trim cells before determining the status of
To provide the best possible combination of driveability, the fuel trim diagnostic.
fuel economy, and emission control, a “closed loop”
air/fuel metering system is used. While in “closed loop,”
Conditions for Setting the DTC
the powertrain control module (PCM) monitors the Bank 1 No Tech 2 test is being run.
HO2S 1 and Bank 2 HO2S 1 signals and adjusts fuel None of the following DTCs are set: idle system, EGR,
delivery based upon the HO2S signal voltages. A change HO2S, (response, transition, open, low volts, no
made to fuel delivery will be indicated by the long and activity), MAF, TP sensor, MAP, IAT, canister purge,
short term fuel trim values which can be monitored with a EVAP, injector circuit, or misfire.
Tech 2. Ideal fuel trim values are around 0%; if the HO2S Engine coolant temperature is between 25 C (77 F)
signals are indicating a lean condition the PCM will add and 100 C (212 F).
fuel, resulting in fuel trim values above 0%. If a rich Intake air temperature is between –40 C (–40 F) and
condition is detected, the fuel trim values will be below 120 C (248 F).
0%, indicating that the PCM is reducing the amount of fuel Manifold absolute pressure is between 24 kPa and 99
kPa.
delivered. If an excessively lean condition is detected on
Bank 2, the PCM will set DTC P0174. Throttle angle is steady below 95%.
The PCM’s maximum authority to control long term fuel Vehicle speed is below 136 km/h (85 mph).
trim allows a range between –15%(automatic Engine speed is between 400 and 6,000 RPM.
transmission) or –12%(manual transmission) and +20%. Barometric pressure is greater than 72.5 kPa.
The PCM monitors fuel trim under various engine Mass air flow is between 2 g/second and 200 g/second.
ENGINE DRIVEABILITY AND EMISSIONS 6E–163
Ignition voltage is above 9.5 volts. Bank 2 HO2S 1 display on the Tech 2 while moving
Fuel system is in “closed loop.” connectors and wiring harnesses related to the engine
harness. A change in the display will indicate the
Action Taken When the DTC Sets location of the fault.
Reviewing the Failure Records vehicle mileage since the
The PCM will illuminate the malfunction indicator lamp diagnostic test last failed may help determine how often
(MIL) after the second consecutive trip in which the the condition that caused the DTC to be set occurs. This
failure is detected.
may assist in diagnosing the condition.
The PCM will store conditions which were present
when the DTC was set as Freeze Frame and in the Test Description
Failure Records data.
Number(s) below refer to the step number(s) on the
Conditions for Clearing the MIL/DTC Diagnostic Chart.
DTC P0174 can be cleared by using the Tech 2 “Clear 2. DTCs other than P0171 and P0174 may indicate a
Info” function or by disconnecting the PCM battery condition present which may cause a lean condition.
feed. If this is the case, repairing the condition which
caused the other DTC will most likely correct the
Diagnostic Aids DTC P0171/P0174.
Check for the following conditions: 4. If the DTC P0174 test passes while the Failure
Poor connection at PCM – Inspect harness connectors Records conditions are being duplicated, the lean
for backed-out terminals, improper mating, broken condition is intermittent. Refer to Diagnostic Aids or
locks, improperly formed or damaged terminals, and Symptoms for additional information on diagnosing
poor terminal-to-wire connection. intermittent problems.
Damaged harness – Inspect the wiring harness for
damage. If the harness appears to be OK, observe the
6E–164 ENGINE DRIVEABILITY AND EMISSIONS

DTC P0174 – Fuel Trim System Lean Bank 2


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 Are any DTCs set other than P0174 and P0171? Go to the
applicable
DTC charts
and repair the
other DTCs
before
proceeding
with this
— chart. Go to Step 3
3 1. Start the engine and operate the vehicle in “closed
loop.”
2. Observe the “BANK 2 L.T. FUEL TRIM” display on
the Tech 2.
Is the displayed values greater than the specified L.T. Fuel
values? Trim: +20% Go to Step 5 Go to Step 4
4 1. Review and record Tech 2 Failure Records data.
2. Clear the DTC P0171/P0174 and operate the
vehicle to duplicate the Failure Records conditions.
3. Monitor the Tech 2 “DTC” info for DTC P0174 while The lean
operating the vehicle to duplicate the Failure condition is
Records conditions. not present.
4. Continue operating the vehicle until the DTC P0174 If a
test runs. driveability
symptom still
5. Note the test result. exists, refer
Does the Tech 2 indicate DTC P0174 failed this to Symptoms
ignition? — Go to Step 5 section.
5 Was DTC P0171 also set? — Go to Step 6 Go to Step 15
6 Visually and physically inspect the vacuum hoses for
disconnects, splits, kinks, improper routing and
improper connections and repair any problem found.
Did your inspection reveal a problem requiring repair? — Verify repair Go to Step 7
7 Visually and physically inspect the crankcase
ventilation valve for proper installation and repair any
problem found (refer to Crankcase Ventilation
System).
Did your inspection reveal a problem requiring repair? — Verify repair Go to Step 8
8 1. Inspect the MAF sensor inlet screen for damage or
for the presence of foreign objects which may
partially block the air flow sample through the MAF
sensor.
2. Correct any problem that is found as necessary.
Did your inspection of the MAF sensor reveal a
condition requiring repair? — Verify repair Go to Step 9
9 Start the engine and note the idle quality.
Is a high or unsteady idle being experienced? — Go to Step 10 Go to Step 11
ENGINE DRIVEABILITY AND EMISSIONS 6E–165

DTC P0174 – Fuel Trim System Lean Bank 2


Step Action Value(s) Yes No
10 1. Visually and physically inspect the throttle body,
intake manifold, EGR valve and the EGR feed pipe
for vacuum leaks.
2. Repair any vacuum leaks as necessary.
Did your inspection reveal a vacuum leak? — Verify repair Go to Step 11
11 Check the fuel for excessive water, alcohol, or other
contaminants (see Diagnosis in Engine Fuel for
procedure) and correct the contaminated fuel condition
is present (see Engine Fuel).
Was the fuel contaminated? — Verify repair Go to Step 12
12 1. Visually and physically inspect the PCM injector
grounds, power grounds and sensor grounds to
ensure that they are clean, tight, and in their proper
locations.
2. If a faulty ground condition is present, correct it as
necessary.
Did your inspection reveal a condition requiring repair? — Verify repair Go to Step 13
13 1. Disconnect the MAF sensor electrical connector.
2. Operate the vehicle in “closed loop” while
monitoring the “BANK 1 S.T. FUEL TRIM” displayed
on the Tech 2.
Does the “BANK 1 S.T. FUEL TRIM” value decrease to
near the specified value? 0% Go to Step 19 Go to Step 14
14 Perform the procedure in the ”Fuel System Pressure
Test” and repair fuel system problem if necessary.
Did the Fuel System Pressure Test isolate a condition
requiring repair? — Verify repair Go to Step 15
15 1. Visually and physically inspect the intake manifold,
injector O-rings, EGR adapter, EGR valve and the
EGR feed pipes for vacuum leaks.
2. Repair any problem that is found.
Did your inspection reveal a problem? — Verify repair Go to Step 16
16 Visually and physically inspect the Bank 2 exhaust
manifold for leaks and loose or missing hardware and
correct any problem found.
Did your inspection reveal a problem? — Verify repair Go to Step 17
17 Perform the “Injector Balance Test,” and correct any
problem found (refer to Fuel Metering System).
Did the Injector Balance Test isolate a problem? — Verify repair Go to Step 18
18 1. Visually and physically inspect the Bank 2 HO2S 1
to ensure that it is installed securely and that the
Bank 2 HO2S 1 pigtail and wiring harness are not
contacting the exhaust or otherwise damaged.
Refer to
2. If a problem is found, correct it as necessary. Diagnostic
Did your inspection reveal a problem? — Verify repair Aids
19 Replace the MAF sensor.
Is the action complete? — Verify repair —
6E–166 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0175 Fuel Trim System Rich Bank 2

D06RW031

Circuit Description trim allows a range between –11% and +20%. The PCM
To provide the best possible combination of driveability, monitors fuel trim under various engine speed/load fuel
fuel economy, and emission control, a “closed loop” trim cells before determining the status of the fuel trim
air/fuel metering system is used. While in “closed loop,” diagnostic.
the powertrain control module (PCM) monitors the Bank 1
HO2S 1 and Bank 2 HO2S 1 signals and adjusts fuel
Conditions for Setting the DTC
delivery based upon the HO2S signal voltages. A change No Tech 2 test is being run.
made to fuel delivery will be indicated by the long and None of the following DTCs are set: idle system, EGR,
short term fuel trim values which can be monitored with a HO2S, (response, transition, open, low volts, no
Tech 2. Ideal fuel trim values are around 0%; if the HO2S activity), MAF, TPS, MAP, IAT, canister purge, EVAP,
signals are indicating a lean condition the PCM will add injector circuit, or misfire.
fuel, resulting in fuel trim values above 0%. If a rich Engine coolant temperature is between 25 C (77 F)
condition is detected, the fuel trim values will be below and 100 C (212 F).
0%, indicating that the PCM is reducing the amount of fuel Intake air temperature is between –40 C (–40 F) and
delivered. If an excessively rich condition is detected on 120 C (248 F).
Bank 2, the PCM will set DTC P0175. Manifold absolute pressure is between 24 kPa and 99
kPa.
The PCM’s maximum authority to control long term fuel
trim allows a range between –15%(automatic Throttle angle is steady below 95%.
transmission) or –12%(manual transmission) and +20%. Vehicle speed is below 136 km/h (85 mph).
The PCM’s maximum authority to control short term fuel Engine speed is between 400 and 6,000 RPM.
ENGINE DRIVEABILITY AND EMISSIONS 6E–167
Barometric pressure is greater than 72.5 kPa. Damaged harness – Inspect the wiring harness for
Mass air flow is between 2 g/second and 200 g/second. damage. If the harness appears to be OK, observe the
Bank 2 HO2S 1 display on the Tech 2 while moving
Ignition voltage is above 9.5 volts. connectors and wiring harnesses related to the engine
Fuel system is in “closed loop.” harness. A change in the display will indicate the
location of the fault.
Action Taken When the DTC Sets Reviewing the Failure Records Vehicle mileage since the
The PCM will illuminate the malfunction indicator lamp diagnostic test last failed may help determine how often
(MIL) after the second consecutive trip in which the the condition that caused the DTC to be set occurs. This
failure is detected. may assist in diagnosing the condition.
The PCM will store conditions which were present
when the DTC was set as Freeze Frame and in the Test Description
Failure Records data. Number(s) below refer to the step number(s) on the
Diagnostic Chart.
Conditions for Clearing the MIL/DTC
2. DTCs other than P0172 and P0175 may indicate a
DTC P0175 can be cleared by using the Tech 2 “Clear condition present which may cause a lean condition.
Info” function or by disconnecting the PCM battery If this is the case, repairing the condition which
feed. caused the other DTC will most likely correct the
DTC P0172/P0175.
Diagnostic Aids
4. If the DTC P0175 test passes while the Failure
Check for the following conditions: Records conditions are being duplicated, the rich
Poor connection at PCM – Inspect harness connectors condition is intermittent. Refer to Diagnostic Aids or
for backed -out terminals, improper mating, broken Symptoms for additional information on diagnosing
locks, improperly formed or damaged terminals, and
poor terminal-to-wire connection. intermittent problems.
6E–168 ENGINE DRIVEABILITY AND EMISSIONS

DTC P0175 – Fuel Trim System Rich Bank 2


Step Action Value(s) Yes No
1 Was the ”On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 Are any DTCs set other than P0172 and P0175? Go to the
applicable
DTC charts
and repair the
other DTCs
before
proceeding
with this
— chart. Go to Step 3
3 1. Start the engine and operate the vehicle in “closed
loop.” L.T. Fuel
2. Observe the “BANK 2 L.T. FUEL TRIM” display on Trim: –15%
the Tech 2. (auto. trans.)
Is the displayed value more negative than the specified OR –12%
value? (man. trans.) Go to Step 5 Go to Step 4
4 1. Review and record the Tech 2 Failure Records data.
2. Clear the DTC P0172/P0175 and operate the
vehicle to duplicate the Failure Records conditions.
3. Monitor the Tech 2 “DTC” info for DTC P0175 while
operating the vehicle to duplicate the Failure The rich
Records conditions. condition is
4. Continue operating the vehicle until the DTC P0175 not present.
test runs. If a
driveability
5. Note the test result. symptom still
Does the Tech 2 indicate DTC P0175 failed this exists, refer
ignition? — Go to Step 5 to Symptoms.
5 Was DTC P0172 also set? — Go to Step 6 Go to Step 15
6 Visually and physically inspect the air filter element and
replace it if necessary.
Did the air filter require replacement? — Verify repair Go to Step 7
7 Visually and physically inspect the air intake duct for
collapse or restriction and repair if necessary.
Did your inspection reveal a problem requiring repair? — Verify repair Go to Step 8
8 Inspect the MAF sensor inlet screen for damage or for
the presence of foreign objects which may partially
block air flow through the screen and correct any
problem found.
Did your inspection of the MAF sensor reveal a
condition requiring repair or replacement? — Verify repair Go to Step 9
9 Start the engine and note the idle quality.
Is a low or unsteady idle being experienced? — Go to Step 10 Go to Step 11
10 1. Turn the ignition off and physically inspect the
throttle body bore, throttle plate, and IAC passages
for coking and foreign objects.
2. If a problem was found, repair as necessary.
Did your inspection reveal a condition requiring repair? — Verify repair Go to Step 11
ENGINE DRIVEABILITY AND EMISSIONS 6E–169

DTC P0175 – Fuel Trim System Rich Bank 2


Step Action Value(s) Yes No
11 1. Disconnect the vacuum hose from the fuel pressure
regulator and inspect the hose for the presence of
fuel.
2. If fuel is present in the vacuum hose, replace the
fuel pressure regulator (refer to Fuel Metering
System).
Did the fuel pressure regulator require replacement? — Verify repair Go to Step 12
12 1. Ignition “ON,” engine “OFF.”
2. Monitor the TP Angle display on the Tech 2 while
slowly depressing the accelerator pedal.
Does the TP Angle display increase steadily and Minimum 0%
evenly from minimum value at closed throttle to Maximum
maximum value at wide-open throttle? 100% Go to Step 13 Go to Step 18
13 1. Disconnect the MAF sensor electrical connector.
2. Operate the vehicle in “closed loop” while
monitoring the “BANK 1 L.T. FUEL TRIM” and
“BANK 1 S.T. FUEL TRIM” display on the Tech 2.
Did both values change to near the specified value? 0% Go to Step 19 Go to Step 14
14 1. Perform the “Fuel System Pressure Test.”
2. If Fuel System Pressure Test isolates a problem,
repair as necessary (refer to Engine Fuel or Fuel
Metering System).
Did the Fuel System Pressure Test isolate a condition
requiring repair? — Verify repair Go to Step 16
15 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
16 1. Perform the “Injector Balance Test.”
2. If the Injector Balance Test isolates a problem,
repair as necessary (refer to Fuel Metering
System).
Did the Injector Balance Test isolate a problem
requiring repair? — Verify repair Go to Step 17
17 1. Remove and visually/physically inspect the Bank 2
HO2S 1 for silicon contamination. This will be
indicated by a powdery white deposit on the portion
of the HO2S that is exposed to the exhaust stream.
2. If contamination is evident on the Bank 2 HO2S 1, Refer to
replace the contaminated sensor. Diagnostic
Did the sensor require replacement? — Verify repair Aids
18 1. Check the TP sensor mounting screws and tighten
or replace them as necessary if they are loose or
missing.
2. If the screws are OK, replace the TP sensor.
Is the action complete? — Verify repair —
19 Replace the MAF sensor.
Is the action complete? — Verify repair —
6E–170 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit

D06RW034

Circuit Description Conditions for Clearing the MIL/DTC


The powertrain control module (PCM) has six individual DTC P0201 can be cleared by using the Tech 2 “Clear
injector driver circuits. Each controls an injector. When a Info” function or by disconnecting the PCM battery
driver circuit is grounded by the PCM, the injector is feed.
activated. The PCM monitors the current in each driver
circuit. The voltage on each driver is monitored to detect Diagnostic Aids
a fault. If the voltage is not what the PCM expects to An injector driver circuit that is open or shorted to voltage
monitor on the circuit, a DTC is set. This DTC is also set if will cause a DTC P0201 to set. It will also cause a misfire
an injector driver is shorted to voltage or if there is an open due to an inoperative injector. A misfire DTC will also be
circuit. set indicating which cylinder is inoperative.
Long term and short term fuel trims that are excessively
Conditions for Setting the DTC high or low are a good indication that an injector is faulty.
The battery voltage is more than 9 volts. Use Fuel Injector Coil Test Procedure to check for faulty
The engine is turning, determined by 58X crankshaft injectors.
position input signal.
The injector voltage does not equal the ignition voltage
Test Description
when the injector is commanded “OFF” or the injector The number(s) below refer to the step number(s) on the
voltage does not equal 0 volts when the injector is Diagnostic Chart.
commanded “ON.” 3. This step determines if DTC P0201 is the result of a
The above conditions are met for 15 seconds. hard failure or an intermittent condition.
Action Taken When the DTC Sets 5. A special injector test connector is provided so that
the injectors can be electrically tested without
The PCM will illuminate the malfunction indicator lamp removal of the manifold. On the Trooper, the
(MIL) the first time the fault is detected. special 7-way gray connector is located at the front
The PCM will store conditions which were present of the charcoal canister. The test connector can be
when the DTC was set as Freeze Frame and in the identified by the blue connector lock which is
Failure Records data. tethered to the wiring harness. If the light for
cylinder 1 is “ON” steady before cranking the engine
as well as while cranking the engine, then the
injector driver circuit is shorted to ground.
ENGINE DRIVEABILITY AND EMISSIONS 6E–171
If the test light blinks while cranking, the PCM and 7. Because the test light was “ON” steady, voltage to
the wiring to the injectors are OK. The Fuel Injector the injector is OK, but the driver circuit is grounded
Coil Test Procedure will check if the injectors are at all times. This step determines if the circuit is
faulty. shorted to ground or the PCM is faulty.
9. The reading should be about 12-14 .
10.Locating the open in the harness or in the injector
will require removal of the manifold to provide
access.

R321054

DTC P0201 – Injector 1 Control Circuit


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 Will the engine start? Go to Engine
Cranks But
Will Not Run
— Go to Step 3 chart
3 1. Install the Tech 2. Clear the DTC.
2. Idle the engine for one minute.
Does DTC P0201 reset? — Go to Step 5 Go to Step 4
4 1. Review the Freeze Frame data with the ignition
“ON” and the engine “OFF” and note the
parameters.
2. Operate the vehicle within the Freeze Frame Go to
conditions as noted. Diagnostic
Does P0201 reset? — Go to Step 5 Aids
5 1. Engine “OFF.”
2. Disconnect the injector connector.
3. Install an injector test light 5-8840-2636-0 on the
injector test connector. Go to Fuel
Injector Coil
4. Crank the engine and note the light. Test
Does the injector test light blink? — Procedure Go to Step 6
6 Note whether the injector test light for cylinder 1 was
“OFF” or “ON” steady in step 5.
Was the test light “ON” steady while cranking the
engine? — Go to Step 7 Go to Step 9
6E–172 ENGINE DRIVEABILITY AND EMISSIONS

DTC P0201 – Injector 1 Control Circuit


Step Action Value(s) Yes No
7 1. Disconnect the PCM connector for the affected
injectors.
2. With a test light connected to B+, probe the affected
injector driver circuit.
Does the test light illuminate? — Go to Step 8 Go to Step 15
8 Repair short to ground in the injector driver circuit. Go to OBD
System
Is the action complete?
— Check —
9 1. Disconnect the injector test connector.
2. At the injector side of the harness, connect an
ohmmeter between the positive wire (red with blue
tracer) and the wire for cylinder 1 (green with white
tracer).
Does the ohmmeter indicate continuity? — Go to Step 11 Go to Step 10
10 Repair the open injector harness wire or open injector.
Is the action complete? — Verify repair —
11 At the PCM side of the injector test connector, check
the green/white wire for a short to voltage.
Was there a short to voltage? — Go to Step 12 Go to Step 13
12 Repair the short to voltage.
Is the action complete? — Verify repair —
13 Check for an open circuit between the injector test
connector and the PCM.
Was there an open circuit? — Go to Step 14 Go to Step 15
14 Repair the open circuit.
Is the action complete? — Verify repair —
15 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–173

Diagnostic Trouble Code (DTC) P0202 Injector 2 Control Circuit

D06RW034

Circuit Description Conditions for Clearing the MIL/DTC


The powertrain control module (PCM) has six individual DTC P0202 can be cleared by using the Tech 2 “Clear
injector driver circuits. Each controls an injector. When a Info” function or by disconnecting the PCM battery
driver circuit is grounded by the PCM, the injector is feed.
activated. The PCM monitors the current in each driver
circuit. The voltage on each driver is monitored to detect Diagnostic Aids
a fault. If the voltage is not what the PCM expects to An injector driver circuit that is open or shorted to voltage
monitor on the circuit, a DTC is set. This DTC is also set if will cause a DTC P0202 to set. It will also cause a misfire
an injector driver is shorted to voltage or if there is an open due to an inoperative injector. A misfire DTC will also be
circuit. set indicating which cylinder is inoperative.
Long term and short term fuel trims that are excessively
Conditions for Setting the DTC high or low are a good indication that an injector is faulty.
The battery voltage is more than 9 volts. Use Fuel Injector Coil Test Procedure to check for faulty
The engine is turning, determined by 58X crankshaft injectors.
position input signal.
The injector voltage does not equal the ignition voltage
Test Description
when the injector is commanded “OFF” or the injector The number(s) below refer to the step number(s) on the
voltage does not equal 0 volts when the injector is Diagnostic Chart.
commanded “ON.” 3. This step determines if DTC P0202 is the result of a
The above conditions are met for 15 seconds. hard failure or an intermittent condition.
Action Taken When the DTC Sets 5. A special injector test connector is provided so that
the injectors can be electrically tested without
The PCM will illuminate the malfunction indicator lamp removal of the manifold. On the Trooper, the
(MIL) the first time the fault is detected. special 7-way gray connector is located at the front
The PCM will store conditions which were present of the charcoal canister. The test connector can be
when the DTC was set as Freeze Frame and in the identified by the blue connector lock which is
Failure Records data. tethered to the wiring harness. If the light for
cylinder 2 is “ON” steady before cranking the engine
as well as while cranking the engine, then the
injector driver circuit is shorted to ground.
6E–174 ENGINE DRIVEABILITY AND EMISSIONS
If the test light blinks while cranking, the PCM and 7. Because the test light was “ON” steady, voltage to
the wiring to the injectors are OK. The Fuel Injector the injector is OK, but the driver circuit is grounded
Coil Test Procedure will check if the injectors are at all times. This step determines if the circuit is
faulty. shorted to ground or the PCM is faulty.
9.The reading should be about 12-14 .
10.Locating the open in the harness or in the injector
will require removal of the manifold to provide
access.

R321055

DTC P0202 – Injector 2 Control Circuit


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 Will the engine start? Go to Engine
Cranks But
Will Not Run
— Go to Step 3 chart
3 1. Install the Tech 2. Clear the DTC.
2. Idle the engine for one minute.
Does DTC P0202 reset? — Go to Step 5 Go to Step 4
4 1. Review the Freeze Frame data with the ignition
“ON” and the engine “OFF” and note the
parameters.
2. Operate the vehicle within the Freeze Frame Go to
conditions as noted. Diagnostic
Does P0202 reset? — Go to Step 5 Aids
5 1. Engine “OFF.”
2. Disconnect the injector test connector.
3. Install an injector test light 5-8840-2636-0 on
injector connector. Go to Fuel
Injector Coil
4. Crank the engine and note the light. Test
Does the cylinder 2 test light blink? — Procedure Go to Step 6
6 Note whether the injector test light for cylinder 2 was
“OFF” or “ON” steady in step 5.
Was the test light “ON” steady while cranking the
engine? — Go to Step 7 Go to Step 9
ENGINE DRIVEABILITY AND EMISSIONS 6E–175

DTC P0202 – Injector 2 Control Circuit


Step Action Value(s) Yes No
7 1. Disconnect the PCM connector for the affected
injectors.
2. With a test light connected to B+, probe the affected
injector driver circuit.
Does the test light illuminate? — Go to Step 8 Go to Step 15
8 Repair short to ground in the injector driver circuit. Go to OBD
System
Is the action complete?
— Check —
9 1. Disconnect the injector test connector.
2. At the injector side of the harness, connect an
ohmmeter between the positive wire (red with blue
tracer) and the wire for cylinder 2 (green with orange
tracer).
Does the ohmmeter indicate continuity? — Go to Step 11 Go to Step 10
10 Repair the open injector harness wire or open injector.
Is the action complete? — Verify repair —
11 At the PCM side of the injector test connector, check
the green/orange wire for a short to voltage.
Was there a short to voltage? — Go to Step 12 Go to Step 13
12 Repair the short to voltage.
Is the action complete? — Verify repair —
13 Check for an open circuit between the injector test
connector and the PCM.
Was there an open circuit? — Go to Step 14 Go to Step 15
14 Repair the open circuit.
Is the action complete? — Verify repair —
15 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
6E–176 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0203 Injector 3 Control Circuit

D06RW034

Circuit Description Conditions for Clearing the MIL/DTC


The powertrain control module (PCM) has six individual DTC P0203 can be cleared by using the Tech 2 “Clear
injector driver circuits. Each controls an injector. When Info” function or by disconnecting the PCM battery
the driver circuit is grounded by the PCM, the injector is feed.
activated. The PCM monitors the current in each driver
circuit. The voltage on each driver is monitored to detect Diagnostic Aids
a fault. If the voltage is not what the PCM expects to An injector driver circuit that is open or shorted to voltage
monitor on the circuit, a DTC is set. This DTC is also set if will cause a DTC P0203 to set. It will also cause a misfire
an injector driver is shorted to voltage or if there is an open due to an inoperative injector. A misfire DTC will also be
circuit. set indicating which cylinder is inoperative.
Long term and short term fuel trims that are excessively
Conditions for Setting the DTC high or low are a good indication that an injector is faulty.
The battery voltage is more than 9 volts. Use Fuel Injector Coil Test Procedure to check for faulty
The engine is turning, determined by the 58X injectors.
crankshaft position input signal.
The injector voltage does not equal the ignition voltage
Test Description
when the injector is commanded “OFF” or the injector The number(s) below refer to the step number(s) on the
voltage does not equal 0 volts when the injector is Diagnostic Chart.
commanded “ON.” 3. This step determines if DTC P0203 is the result of a
The above conditions are met for 15 seconds. hard failure or an intermittent condition.
Action Taken When the DTC Sets 5. A special injector test connector is provided so that
the injectors can be electrically tested without
The PCM will illuminate the malfunction indicator lamp removal of the manifold. On the Trooper, the
(MIL) the first time the fault is detected. special 7-way gray connector is located at the front
The PCM will store conditions which were present of the charcoal canister. The test connector can be
when the DTC was set as Freeze Frame and in the identified by the blue connector lock which is
Failure Records data. tethered to the wiring harness. If the light for
cylinder 3 is “ON” steady before cranking the engine
as well as while cranking the engine, then the
injector driver circuit is shorted to ground.
ENGINE DRIVEABILITY AND EMISSIONS 6E–177
If the test light blinks while cranking, the PCM and 7. Because the test light was “ON” steady, voltage to
the wiring to the injectors are OK. The Fuel Injector the injector is OK, but the driver circuit is grounded
Coil Test Procedure will check if the injectors are at all times. This step determines if the circuit is
faulty. shorted to ground or the PCM is faulty.
9. The reading should be about 12-14 .
10.Locating the open in the harness or in the injector
will require removal of the manifold to provide
access.

R321056

DTC P0203 – Injector 3 Control Circuit


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 Will the engine start? Go to Engine
Cranks But
Will Not Run
— Go to Step 3 chart
3 1. Install the Tech 2. Clear the DTC.
2. Idle the engine for one minute.
Does DTC P0203 reset? — Go to Step 5 Go to Step 4
4 1. Review the Freeze Frame data with the ignition
“ON” and the engine “OFF” and note the
parameters.
2. Operate the vehicle within the Freeze Frame Go to
conditions as noted. Diagnostic
Does P0203 reset? — Go to Step 5 Aids
5 1. Engine “OFF.”
2. Disconnect the injector test connector .
3. Install an injector test light 5-8840-2636-0 on
injector connector. Go to Fuel
Injector Coil
4. Crank the engine and note the light. Test
Does the cylinder 3 test light blink? — Procedure Go to Step 6
6 Note whether the injector test light for cylinder 3 was
“OFF” or “ON” steady in step 5.
Was the test light “ON” steady while cranking the
engine? — Go to Step 7 Go to Step 9
6E–178 ENGINE DRIVEABILITY AND EMISSIONS

DTC P0203 – Injector 3 Control Circuit


Step Action Value(s) Yes No
7 1. Disconnect the PCM connector for the affected
injectors.
2. With a test light connected to B+, probe the affected
injector driver circuit.
Does the test light illuminate? — Go to Step 8 Go to Step 15
8 Repair short to ground in the injector driver circuit. Go to OBD
System
Is the action complete?
— Check —
9 1. Disconnect the injector test connector.
2. At the injector side of the harness, connect an
ohmmeter between the positive wire (red with blue
tracer) and the wire for cylinder 3 (green).
Does the ohmmeter indicate continuity? — Go to Step 11 Go to Step 10
10 Repair the open injector harness wire or open injector.
Is the action complete? — Verify repair —
11 At the PCM side of the injector test connector, check
the green wire for a short to voltage.
Was there a short to voltage? — Go to Step 12 Go to Step 13
12 Repair the short to voltage.
Is the action complete? — Verify repair —
13 Check for an open circuit between the injector test
connector and the PCM.
Was there an open circuit? — Go to Step 14 Go to Step 15
14 Repair the open circuit.
Is the action complete? — Verify repair —
15 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–179

Diagnostic Trouble Code (DTC) P0204 Injector 4 Control Circuit

D06RW034

Circuit Description Conditions for Clearing the MIL/DTC


The powertrain control module (PCM) has six individual DTC P0204 can be cleared by using the Tech 2 “Clear
injector driver circuits. Each controls an injector. When Info” function or by disconnecting the PCM battery
the driver circuit is grounded by the PCM, the injector is feed.
activated. The PCM monitors the current in each driver
circuit. The voltage on each driver is monitored to detect Diagnostic Aids
a fault. If the voltage is not what the PCM expects to An injector driver circuit that is open or shorted to voltage
monitor on the circuit, a DTC is set. This DTC is also set if will cause a DTC P0204 to set. It will also cause a misfire
an injector driver is shorted to voltage or if there is an open due to an inoperative injector. A misfire DTC will also be
circuit. set indicating which cylinder is inoperative.
Long term and short term fuel trims that are excessively
Conditions for Setting the DTC high or low are a good indication that an injector is faulty.
The battery voltage is more than 9 volts. Use Fuel Injector Coil Test Procedure to check for faulty
The engine is turning, determined by the 58X injectors.
crankshaft position input signal.
The injector voltage does not equal the ignition voltage
Test Description
when the injector is commanded “OFF” or the injector The number(s) below refer to the step number(s) on the
voltage does not equal 0 volts when the injector is Diagnostic Chart.
commanded “ON.” 3. This step determines if DTC P0204 is the result of a
The above conditions are met for 15 seconds. hard failure or an intermittent condition.
Action Taken When the DTC Sets 5. A special injector test connector is provided so that
the injectors can be electrically tested without
The PCM will illuminate the malfunction indicator lamp removal of the manifold. On the Trooper, the
(MIL) the first time the fault is detected. special 7-way gray connector is located at the front
The PCM will store conditions which were present of the charcoal canister. The test connector can be
when the DTC was set as Freeze Frame and in the identified by the blue connector lock which is
Failure Records data. tethered to the wiring harness. If the light for
cylinder 4 is “ON” steady before cranking the engine
as well as while cranking the engine, then the
injector driver circuit is shorted to ground.
6E–180 ENGINE DRIVEABILITY AND EMISSIONS
If the test light blinks while cranking, the PCM and 7. Because the test light was “ON” steady, voltage to
the wiring to the injectors are OK. The Fuel Injector the injector is OK, but the driver circuit is grounded
Coil Test Procedure will check if the injectors are at all times. This step determines if the circuit is
faulty. shorted to ground or the PCM is faulty.
9. The reading should be about 12-14 .
10.Locating the open in the harness or in the injector
will require removal of the manifold to provide
access.

R321057

DTC P0204 – Injector 4 Control Circuit


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 Will the engine start? Go to Engine
Cranks But
Will Not Run
— Go to Step 3 chart
3 1. Install the Tech 2. Clear the DTC.
2. Idle the engine for one minute.
Does DTC P0204 reset? — Go to Step 5 Go to Step 4
4 1. Review the Freeze Frame data with the ignition
“ON” and the engine “OFF” and note the
parameters.
2. Operate the vehicle within the Freeze Frame Go to
conditions as noted. Diagnostic
Does P0204 reset? — Go to Step 5 Aids
5 1. Engine “OFF.”
2. Disconnect the injector test connector.
3. Install an injector test light 5-8840-2636-0 on
injector connector. Go to Fuel
Injector Coil
4. Crank the engine and note the light. Test
Does the cylinder 4 test light blink? — Procedure Go to Step 6
6 Note whether the injector test light for cylinder 4 was
“OFF” or “ON” steady in step 5.
Was the test light “ON” steady while cranking the
engine? — Go to Step 7 Go to Step 9
ENGINE DRIVEABILITY AND EMISSIONS 6E–181

DTC P0204 – Injector 4 Control Circuit


Step Action Value(s) Yes No
7 1. Disconnect the PCM connector for the affected
injectors.
2. With a test light connected to B+, probe the affected
injector driver circuit.
Does the test light illuminate? — Go to Step 8 Go to Step 15
8 Repair short to ground in the injector driver circuit. Go to OBD
System
Is the action complete?
— Check —
9 1. Disconnect the injector test connector.
2. At the injector side of the harness, connect an
ohmmeter between the positive wire (red with blue
tracer) and the wire for cylinder 4 (green/red).
Does the ohmmeter indicate continuity? — Go to Step 11 Go to Step 10
10 Repair the open injector harness wire or open injector.
Is the action complete? — Verify repair —
11 At the PCM side of the injector test connector, check
the green/red wire for a short to voltage.
Was there a short to voltage? — Go to Step 12 Go to Step 13
12 Repair the short to voltage.
Is the action complete? — Verify repair —
13 Check for an open circuit between the injector test
connector and the PCM.
Was there an open circuit? — Go to Step 14 Go to Step 15
14 Repair the open circuit.
Is the action complete? — Verify repair —
15 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
6E–182 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0205 Injector 5 Control Circuit

D06RW034

Circuit Description Conditions for Clearing the MIL/DTC


The powertrain control module (PCM) has six individual DTC P0205 can be cleared by using the Tech 2 “Clear
injector driver circuits. Each controls an injector. When Info” function or by disconnecting the PCM battery
the driver circuit is grounded by the PCM, the injector is feed.
activated. The PCM monitors the current in each driver
circuit. If the voltage is not what the PCM expects to Diagnostic Aids
monitor on the circuit, a DTC is set. This DTC is also set if An injector driver circuit that is open or shorted to voltage
an injector driver is shorted to voltage or if there is an open will cause a DTC P0205 to set. It will also cause a misfire
circuit. due to an inoperative injector. A misfire DTC will also be
set indicating which cylinder is inoperative.
Conditions for Setting the DTC Long term and short term fuel trims that are excessively
The battery voltage is more than 9 volts. high or low are a good indication that an injector is faulty.
The engine is turning, determined by the 58X Use Fuel Injector Coil Test Procedure to check for faulty
crankshaft position input signal. injectors.
The injector voltage does not equal the ignition voltage
when the injector is commanded “OFF” or the injector Test Description
voltage does not equal 0 volts when the injector is The number(s) below refer to the step number(s) on the
commanded “ON.” Diagnostic Chart.
The above conditions are met for 15 seconds. 3. This step determines if DTC P0205 is the result of a
hard failure or an intermittent condition.
Action Taken When the DTC Sets
5. A special injector test connector is provided so that
The PCM will illuminate the malfunction indicator lamp the injectors can be electrically tested without
(MIL) the first time the fault is detected. removal of the manifold. On the Trooper, the
The PCM will store conditions which were present special 7-way gray connector is located at the front
when the DTC was set as Freeze Frame and in the of the charcoal canister. The test connector can be
Failure Records data. identified by the blue connector lock which is
tethered to the wiring harness. If the light for
cylinder 5 is “ON” steady before cranking the engine
as well as while cranking the engine, then the
injector driver circuit is shorted to ground.
ENGINE DRIVEABILITY AND EMISSIONS 6E–183
If the test light blinks while cranking, the PCM and 7. Because the test light was “ON” steady, voltage to
the wiring to the injectors are OK. The Fuel Injector the injector is OK, but the driver circuit is grounded
Coil Test Procedure will check if the injectors are at all times. This step determines if the circuit is
faulty. shorted to ground or the PCM is faulty.
9. The reading should be about 12-14 .
10.Locating the open in the harness or in the injector
will require removal of the manifold to provide
access.

R321058

DTC P0205 – Injector 5 Control Circuit


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 Will the engine start? Go to Engine
Cranks But
Will Not Run
— Go to Step 3 chart
3 1. Install the Tech 2. Clear the DTC.
2. Idle the engine for one minute.
Does DTC P0205 reset? — Go to Step 5 Go to Step 4
4 1. Review the Freeze Frame data with the ignition
“ON” and the engine “OFF” and note the
parameters.
2. Operate the vehicle within the Freeze Frame Go to
conditions as noted. Diagnostic
Does P0205 reset? — Go to Step 5 Aids
5 1. Engine “OFF.”
2. Disconnect the injector test connector.
3. Install an injector test light 5-8840-2636-0 on
injector connector. Go to Fuel
Injector Coil
4. Crank the engine and note the light. Test
Does the cylinder 5 test light blink? — Procedure Go to Step 6
6 Note whether the injector test light for cylinder 5 was
“OFF” or “ON” steady in step 5.
Was the test light “ON” steady while cranking the
engine? — Go to Step 7 Go to Step 9
6E–184 ENGINE DRIVEABILITY AND EMISSIONS

DTC P0205 – Injector 5 Control Circuit


Step Action Value(s) Yes No
7 1. Disconnect the PCM connector for the affected
injectors.
2. With a test light connected to B+, probe the affected
injector driver circuit.
Does the test light illuminate? — Go to Step 8 Go to Step 15
8 Repair short to ground in the injector driver circuit. Go to OBD
System
Is the action complete?
— Check —
9 1. Disconnect the injector test connector.
2. At the injector side of the harness, connect an
ohmmeter between the positive wire (red with blue
tracer) and the wire for cylinder 5 (green with black
tracer).
Does the ohmmeter indicate continuity? — Go to Step 11 Go to Step 10
10 Repair the open injector harness wire or open injector.
Is the action complete? — Verify repair —
11 At the PCM side of the injector test connector, check
the green/black wire for a short to voltage.
Was there a short to voltage? — Go to Step 12 Go to Step 13
12 Repair the short to voltage.
Is the action complete? — Verify repair —
13 Check for an open circuit between the injector test
connector and the PCM.
Was there an open circuit? — Go to Step 14 Go to Step 15
14 Repair the open circuit.
Is the action complete? — Verify repair —
15 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–185

Diagnostic Trouble Code (DTC) P0206 Injector 6 Control Circuit

D06RW034

Circuit Description Conditions for Clearing the MIL/DTC


The powertrain control module (PCM) has six individual DTC P0206 can be cleared by using the Tech 2 “Clear
injector driver circuits. Each controls an injector. When Info” function or by disconnecting the PCM battery
the driver circuit is grounded by the PCM, the injector is feed.
activated. The PCM monitors the current in each driver
circuit. The voltage on each driver is monitored to detect Diagnostic Aids
a fault. If the voltage is not what the PCM expects to An injector driver circuit that is open or shorted to voltage
monitor on the circuit, a DTC is set. This DTC is also set if will cause a DTC P0206 to set. It will also cause a misfire
an injector driver is shorted to voltage or if there is an open due to an inoperative injector. A misfire DTC will also be
circuit. set indicating which cylinder is inoperative.
Long term and short term fuel trims that are excessively
Conditions for Setting the DTC high or low are a good indication that an injector is faulty.
The battery voltage is more than 9 volts. Use Fuel Injector Coil Test Procedure to check for faulty
The engine is turning, determined by 58X crankshaft injectors.
position input signal.
The injector voltage does not equal the ignition voltage
Test Description
when the injector is commanded “OFF” or the injector The number(s) below refer to the step number(s) on the
voltage does not equal 0 volts when the injector is Diagnostic Chart.
commanded “ON.” 3. This step determines if DTC P0206 is the result of a
The above conditions are met for 15 seconds. hard failure or an intermittent condition.
Action Taken When the DTC Sets 5. A special injector test connector is provided so that
the injectors can be electrically tested without
The PCM will illuminate the malfunction indicator lamp removal of the manifold. On the Trooper, the
(MIL) the first time the fault is detected. special 7-way gray connector is located at the front
The PCM will store conditions which were present of the charcoal canister. The test connector can be
when the DTC was set as Freeze Frame and in the identified by the blue connector lock which is
Failure Records data. tethered to the wiring harness. If the light for
cylinder 6 is “ON” steady before cranking the engine
as well as while cranking the engine, then the
injector driver circuit is shorted to ground.
6E–186 ENGINE DRIVEABILITY AND EMISSIONS
If the test light blinks while cranking, the PCM and 7. Because the test light was “ON” steady, voltage to
the wiring to the injectors are OK. The Fuel Injector the injector is OK, but the driver circuit is grounded
Coil Test Procedure will check if the injectors are at all times. This step determines if the circuit is
faulty. shorted to ground or the PCM is faulty.
9. The reading should be about 12-14 .
10.Locating the open in the harness or in the injector
will require removal of the manifold to provide
access.

R321059

DTC P0206 – Injector 6 Control Circuit


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 Will the engine start? Go to Engine
Cranks But
Will Not Run
— Go to Step 3 chart
3 1. Install the Tech 2. Clear the DTC.
2. Idle the engine for one minute.
Does DTC P0206 reset? — Go to Step 5 Go to Step 4
4 1. Review the Freeze Frame data with the ignition
“ON” and the engine “OFF” and note the
parameters.
2. Operate the vehicle within the Freeze Frame Go to
conditions as noted. Diagnostic
Does P0206 reset? — Go to Step 5 Aids
5 1. Engine “OFF.”
2. Disconnect the injector test connector.
3. Install an injector test light 5-8840-2636-0 on
injector connector. Go to Fuel
Injector Coil
4. Crank the engine and note the light. Test
Does the cylinder 6 test light blink? — Procedure Go to Step 6
6 Note whether the injector test light for cylinder 6 was
“OFF” or “ON” steady in step 5.
Was the test light “ON” steady while cranking the
engine? — Go to Step 7 Go to Step 9
ENGINE DRIVEABILITY AND EMISSIONS 6E–187

DTC P0206 – Injector 6 Control Circuit


Step Action Value(s) Yes No
7 1. Disconnect the PCM connector for the affected
injectors.
2. With a test light connected to B+, probe the affected
injector driver circuit.
Does the test light illuminate? — Go to Step 8 Go to Step 15
8 Repair short to ground in the injector driver circuit. Go to OBD
System
Is the action complete?
— Check —
9 1. Disconnect the injector test connector.
2. At the injector side of the harness, connect an
ohmmeter between the positive wire (red with blue
tracer) and the wire for cylinder 6 (green with yellow
tracer).
Does the ohmmeter indicate continuity? — Go to Step 11 Go to Step 10
10 Repair the open injector harness wire or open injector
Is the action complete? — Verify repair —
11 At the PCM side of the injector test connector, check
the green/yellow wire for a short to voltage.
Was there a short to voltage? — Go to Step 12 Go to Step 13
12 Repair the short to voltage.
Is the action complete? — Verify repair —
13 Check for an open circuit between the injector test
connector and the PCM.
Was there an open circuit? — Go to Step 14 Go to Step 15
14 Repair the open circuit.
Is the action complete? — Verify repair —
15 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
6E–188 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0325 KS Module Circuit

D06RW035

Circuit Description The PCM will use a “substitute” default spark retard
value of 6 degrees to minimize knock during conditions
The knock sensor is used to detect engine detonation, when knock is likely to occur.
allowing the powertrain control module (PCM) to retard
ignition control (IC) spark timing based on the knock Conditions for Clearing the MIL/DTC
sensor (KS) signal being received. The knock sensor
produces an AC signal so that under a no knock condition DTC P0325 can be cleared by using Tech 2 “Clear Info”
function or by disconnecting the PCM battery feed.
the signal on the KS circuit measures about 0.007 V AC.
The KS signal’s amplitude and frequency depend upon Diagnostic Aids
the amount of knock being experienced. The PCM
contains a non-replaceable knock filter module called a Check for the following conditions:
signal-to-noise enhancement filter (SNEF) module. This Poor connection at PCM – Inspect the knock sensor
filter module in the PCM determines whether knock is and PCM connectors for backed-out terminals, broken
locks, and improperly formed or damaged terminals.
occurring by comparing the signal level on the KS circuit
Misrouted harness – Inspect the knock sensor harness
with the voltage level on the noise channel. The noise to ensure that it is not routed too close to high voltage
channel allows the PCM to reject any false knock signal wires such as spark plug leads.
by knowing the amount of normal engine mechanical Reviewing the Failure Records vehicle mileage since the
noise present. Normal engine noise varies depending on diagnostic test last failed may help determine how often
engine speed and load. When the PCM determines that the condition that caused the DTC to be set occurs. This
an abnormally low noise channel voltage level is being may assist in diagnosing the condition.
experienced, a DTC P0325 will set.
Test Description
Conditions for Setting the DTC
Number(s) below refer to the step number(s) on the
Engine has been running for at least 30 seconds. Diagnostic Chart.
The PCM determines that its internal signal from its 2. Ensures that the fault is present.
knock filter module indicates a continuous knocking
condition for more than 10 seconds.

Action Taken When the DTC Sets


The PCM will store conditions which were present
when the DTC was set as Freeze Frame and in the
Failure Records data.
ENGINE DRIVEABILITY AND EMISSIONS 6E–189

DTC P0325 – KS Module Circuit


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 IMPORTANT: If an engine knock can be heard, repair
the engine mechanical problem before proceeding with
this diagnostic.
1. Operate the vehicle within parameters specified
under criteria included in “Conditions for Setting the
DTC.”
2. Using Tech 2, monitor “Specific DTC” info for DTC
P0325 until the DTC P0325 test runs.
3. Note the test result.
Does Tech 2 indicate DTC P0325 failed this ignition? — Go to Step 4 Go to Step 3
3 1. Ignition “ON,” engine “OFF.”
2. Review and record Tech 2 Failure Records data for
DTC P0325.
3. Operate the vehicle within Failure Records
conditions.
4. Using Tech 2, monitor “Specific DTC” info for DTC
P0325 until the DTC P0325 test runs. Refer to
Does Tech 2 indicate DTC P0325 test failed this Diagnostic
ignition? — Go to Step 4 Aids
4 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
6E–190 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0327 KS Sensor Circuit

D06RW035

Circuit Description The PCM will store conditions which were present
when the DTC was set as Freeze Frame and in the
The powertrain control module (PCM) uses the knock Failure Records data.
sensor to detect engine detonation, allowing the PCM to
The PCM will use a calculated spark retard value to
retard ignition control (IC) spark timing based on the minimize knock during conditions when knock is likely
knock sensor (KS) signal being received. The knock to occur. The calculated value will vary based on
sensor produces an AC signal so that under a no knock engine speed and load.
condition the signal on the KS circuit measures about
0.007 V AC. The signal amplitude and frequency are Conditions for Clearing the MIL/DTC
dependent upon the amount of knock being experienced. DTC P0327 can be cleared by using Tech 2 “Clear Info”
The PCM monitors the KS signal and can diagnose the function or by disconnecting the PCM battery feed.
KS sensor and circuitry.
Diagnostic Aids
Conditions for Setting the DTC Reviewing the Failure Records vehicle mileage since the
Engine running for at least 10 seconds. diagnostic test last failed may help determine how often
The TP sensor is greater than 5%. the condition that caused the DTC to be set occurs. This
The ECT sensor is greater than 60 C (140 F). may assist in diagnosing the condition.
Engine speed is between 2000 and 4000 RPM.
Test Description
The knock sensor signal voltage is less than 0.20 volts,
or greater than 4.8 volts. Number(s) below refer to the step number(s) on the
All conditions are present for more than 15 seconds. Diagnostic Chart.
2. Ensures that the fault is present.
Action Taken When the DTC Sets 4. The knock sensor is attached to a short jumper
The PCM will illuminate the malfunction indicator lamp harness, so it can be tested without removing the
(MIL) after the second consecutive trip in which the intake manifold. A 2-wire connector for the knock
fault is detected. sensor is accessible behind the left rear fuel injector.
ENGINE DRIVEABILITY AND EMISSIONS 6E–191

DTC P0327 – KS Sensor Circuit


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 IMPORTANT: If an engine knock can be heard, repair
the engine mechanical problem before proceeding with
this diagnostic.
1. Operate the engine within the conditions specified
in diagnostic support “Conditions for Setting the
DTC.”
2. Using Tech 2, monitor “Specific DTC” info for DTC
P0327 until the DTC P0327 test runs.
3. Note the test result.
Does Tech 2 indicate DTC P0327 failed this ignition? — Go to Step 4 Go to Step 3
3 1. Ignition “ON,” engine “OFF.”
2. Review and record Tech 2 Failure Records data.
3. Operate the vehicle within Failure Records
conditions.
4. Using Tech 2, monitor “Specific DTC” info for DTC
P0327 until the DTC P0327 test runs.
Refer to
5. Note the test result. Diagnostic
Does Tech 2 indicate DTC P0327 failed this ignition? — Go to Step 4 Aids
4 1. Check for a damaged terminal at the knock sensor
connector.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 5
5 Using a test light to battery +, check the black/blue wire
(PCM side) to verify that the shield connection is good.
Did the test light illuminate? — Go to Step 7 Go to Step 6
6 Repair the open shield ground.
Is the action complete? — Verify repair —
7 1. Ignition “OFF,” disconnect the PCM.
2. Check the KS signal circuit for a poor terminal
connection at the PCM.
3. If a problem is found, replace the faulty terminal.
Was a problem found? — Verify repair Go to Step 8
8 1. Ignition “OFF,” PCM disconnected.
2. Check the KS signal circuit between the PCM and
the knock sensor connector for an open, a short to
voltage, or a short to ground.
3. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 9
9 1. Ignition “OFF,” PCM disconnected.
2. Knock sensor connected.
3. Measure the resistance of the knock sensor by
connecting the DVM between the PCM connector
and the engine block.
Is the resistance of each knock sensor near the
specified value? 100K ohms Go to Step 10 Go to Step 11
6E–192 ENGINE DRIVEABILITY AND EMISSIONS

DTC P0327 – KS Sensor Circuit


Step Action Value(s) Yes No
10 1. Ignition “OFF,” PCM disconnected.
2. Connect the DVM to monitor AC voltage between
the PCM connector and engine ground.
3. Tap on the engine lift bracket with a socket
extension while observing the signal indicated on
the DVM.
Is any signal indicated on the DVM while tapping on the
engine lift bracket? — Go to Step 12 Go to Step 11
11 Replace the knock sensor.
Is the action complete? — Verify repair —
12 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–193

Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit

D06RW032

Circuit Description Action Taken When the DTC Sets


The 58X reference signal is produced by the crankshaft The PCM will illuminate the malfunction indicator lamp
position (CKP) sensor. During one crankshaft revolution, (MIL) after the second consecutive trip in which the
58 crankshaft pulses will be produced. The powertrain fault is detected.
control module (PCM) uses the 58X reference signal to The PCM will store conditions which were present
calculate engine RPM and crankshaft position. The PCM when the DTC was set as Freeze Frame and in the
constantly monitors the number of pulses on the 58X Failure Records data.
reference circuit and compares them to the number of
camshaft position (CMP) signal pulses being received. If Conditions for Clearing the MIL/DTC
the PCM receives an incorrect number of pulses on the DTC P0336 can be cleared by using Tech 2 “Clear Info”
58X reference circuit, DTC P0336 will set. function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC Diagnostic Aids


Engine is running. An intermittent may be caused by a poor connection,
Extra or missing pulse is detected between rubbed-through wire insulation or a wire broken inside the
consecutive 58X reference pulses. insulation. Check for:
Above condition is detected in 10 of 100 crankshaft Poor connection - Inspect the PCM harness and
rotations. connectors for improper mating, broken locks,
improperly formed or damaged terminals, and poor
terminal-to-wire connection.
6E–194 ENGINE DRIVEABILITY AND EMISSIONS
Damaged harness – Inspect the wiring harness for Reviewing the Failure Records vehicle mileage since the
damage. If the harness appears to be OK, disconnect diagnostic test last failed may help determine how often
the PCM, turn the ignition on and observe a voltmeter the condition that caused the DTC to be set occurs. This
connected to the 58X reference circuit at the PCM may assist in diagnosing the condition.
harness connector while moving connectors and
wiring harnesses related to the ICM. A change in
voltage will indicate the location of the fault.

DTC P0336 – 58X Reference Signal Circuit


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 Attempt to start the engine. Go to “Engine
Cranks But
Does the engine start?
Will Not Run”
— Go to Step 3 chart
3 1. Review and record Failure Records information.
2. Clear DTC P0336.
3. Start the engine and idle for 1 minute.
Refer to
4. Observe DTCs. Diagnostic
Is DTC P0336 set? — Go to Step 4 Aids
4 1. Disconnect the PCM and CKP sensor.
2. Check for an open or a short to ground in the 58X
reference circuit between the CKP sensor
connector and the PCM harness connector.
3. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 5
5 1. Reconnect the PCM and CKP sensor.
2. Connect a DVM to measure voltage on the 58X
reference circuit at the PCM connector.
3. Observe the voltage while cranking the engine.
Is the voltage near the specified value? 2.5 V Go to Step 8 Go to Step 6
6 Check the connections at the CKP sensor and replace
the terminals if necessary.
Did any terminals require replacement? — Verify repair Go to Step 7
7 Replace the CKP sensor. Use caution to avoid any hot
oil that may drip out.
Is the action complete? — Verify repair —
8 Check connections at the PCM and replace the
terminals if necessary.
Did any terminals require replacement? — Verify repair Go to Step 9
9 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–195

Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency

D06RW032

Circuit Description Action Taken When the DTC Sets


The 58X reference signal is produced by the crankshaft The PCM will illuminate the malfunction indicator lamp
position (CKP) sensor. During one crankshaft revolution, (MIL) after the second consecutive trip in which the
58 crankshaft reference pulses will be produced. The fault is detected.
powertrain control module (PCM) uses the 58X reference The PCM will store conditions which were present
signal to calculate engine RPM and crankshaft position. when the DTC was set as Freeze Frame and in the
The PCM constantly monitors the number of pulses on Failure Records data.
the 58X reference circuit and compares them to the
number of camshaft position (CMP) signal pulses being Conditions for Clearing the MIL/DTC
received. If the PCM does not receive pulses on the 58X DTC P0337 can be cleared by using Tech 2 “Clear Info”
reference circuit, DTC P0337 will set. function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC Diagnostic Aids


No camshaft position (CMP) sensor DTCs are set. An intermittent may be caused by a poor connection,
Engine cranking. rubbed-through wire insulation or a wire broken inside the
insulation. Check for:
Crankshaft position (CKP) sensor signal is not present
between two cam pulses. Poor connection – Inspect the PCM harness and
connectors for improper mating, broken locks,
CKP reference pulse is not detected within 8 CMP improperly formed or damaged terminals, and poor
pulses. terminal-to-wire connection.
6E–196 ENGINE DRIVEABILITY AND EMISSIONS
Damaged harness – Inspect the wiring harness for Reviewing the Failure Records vehicle mileage since the
damage. If the harness appears to be OK, disconnect diagnostic test last failed may help determine how often
the PCM, turn the ignition on and observe a voltmeter the condition that caused the DTC to be set occurs. This
connected to the 58X reference circuit at the PCM may assist in diagnosing the condition.
harness connector while moving connectors and
wiring harnesses related to the ICM. A change in
voltage will indicate the location of the fault.

DTC P0337 – CKP Sensor Circuit Low Frequency


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 Attempt to start the engine.
Does the engine start? — Go to Step 3 Go to Chart 3
3 1. Review and record Failure Records information.
2. Clear DTC P0337.
3. Start the engine and idle for 1 minute.
Refer to
4. Observe DTCs. Diagnostic
Is DTC P0337 set? — Go to Step 4 Aid
4 1. Disconnect the CKP sensor.
2. Ignition “ON.”
3. Using a DVM, verify that 5 V reference and ground
are being supplied at the sensor connector (PCM
side).
Are 4-6 volts and ground available at the sensor? — Go to Step 7 Go to Step 5
5 1. Ignition “ON.”
2. With a DVM, backprobe the PCM connector 5 V
reference and ground connections.
Are 5 V reference and ground available at the PCM? — Go to Step 6 Go to Step 11
6 Check 5 V reference or ground between the CKP
sensor and PCM and repair the open circuit, short to
ground or short to voltage.
Is the action complete? — Verify repair —
7 1. Ignition “OFF.”
2. Disconnect the PCM and CKP sensor.
3. Check for an open or a short to ground in the 58X
reference circuit between the CKP sensor
connector and the PCM harness connector.
4. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 8
8 1. Reconnect the PCM and CKP sensor.
2. Connect a DVM to measure voltage on the 58X
reference circuit at the PCM connector.
3. Observe the voltage while cranking the engine.
Is the voltage near the specified value? 2.5 V Go to Step 11 Go to Step 9
9 Check the connections at the CKP sensor and replace
the terminals if necessary.
Did any terminals require replacement? — Verify repair Go to Step 10
10 Replace the CKP sensor. Use caution and avoid hot oil
that may drip out.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–197

DTC P0337 – CKP Sensor Circuit Low Frequency


Step Action Value(s) Yes No
11 Check the connections at the PCM and replace the
terminals if necessary.
Did any terminals require replacement? — Verify repair Go to Step 12
12 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
6E–198 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0341 CMP Sensor Circuit Performance

D06RW032

Circuit Description Conditions for Setting the DTC


The CMP signal is produced by the camshaft position The engine is running (1X CMP reference pulses are
(CMP) sensor pulses when the engine is running and being received).
crankshaft position (CKP) sync pulses are also being The CMP sensor signal is not detected at the correct
received. The powertrain control module (PCM) uses the interval every 6 cylinders.
CMP signal pulses to initiate sequential fuel injection. Above condition fails for 100 occurrences within 200
The PCM constantly monitors the number of pulses on test samples.
the CMP signal circuit and compares the number of CMP
pulses to the number of 58X reference pulses received. If Action Taken When the DTC Sets
the PCM receives an incorrect number of pulses on the The PCM will illuminate the malfunction indicator lamp
CMP reference circuit, DTC P0341 will set and the PCM (MIL) after the second consecutive trip in which the
will initiate injector sequence without the CMP signal with fault is detected.
a one in six chance that injector sequence is correct. The The PCM will initiate the injector sequence without the
engine will continue to start and run normally, although CMP signal with a one in six chance that the injector
the misfire diagnostic will be affected if a misfiring sequence is correct.
condition occurs. The PCM will store conditions which were present
when the DTC was set as Freeze Frame and in the
Failure Records data.
ENGINE DRIVEABILITY AND EMISSIONS 6E–199
Conditions for Clearing the MIL/DTC wiring harnesses related to the ICM and the CMP
sensor. A change in voltage will indicate the location
DTC P0341 can be cleared by using Tech 2 “Clear Info” of the fault.
function or by disconnecting the PCM battery feed. Reviewing the Failure Records vehicle mileage since the
diagnostic test last failed may help determine how often
Diagnostic Aids the condition that caused the DTC to be set occurs. This
An intermittent may be caused by a poor connection, may assist in diagnosing the condition.
rubbed-through wire insulation or a wire broken inside the
insulation. Check for: Test Description
Poor connection – Inspect the PCM harness and Number(s) below refer to the step number(s) on the
connectors for improper mating, broken locks, Diagnostic Chart.
improperly formed or damaged terminals, and poor
terminal-to-wire connection. 2. Ensures that the fault is present.
Damaged harness – Inspect the wiring harness for 12.Determines whether the fault is being caused by a
damage. If the harness appears to be OK, disconnect missing camshaft magnet or a faulty sensor. The
the PCM, turn the ignition on and observe a voltmeter voltage measured in this step should read around 4
connected to the CMP signal circuit at the PCM volts, toggling to near 0 volts when the CMP sensor
harness connector while moving connectors and interfaces with the camshaft magnet.
6E–200 ENGINE DRIVEABILITY AND EMISSIONS

DTC P0341 – CMP Sensor Circuit Performance


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Ignition “ON.”
2. Review and record Tech 2 Failure Records data.
3. Operate the vehicle within Failure Records
conditions as noted.
4. Using Tech 2, monitor “Specific DTC” info for DTC
P0341 until the DTC P0341 test runs.
Refer to
5. Note the test result. Diagnostic
Does Tech 2 indicate DTC P0341 failed this ignition? — Go to Step 3 Aids
3 1. Disconnect the CMP sensor.
2. Measure the voltage between the sensor feed
circuit and the sensor ground circuit at the CMP
sensor harness connector.
Does the voltage measure near the specified value? 4-6 V Go to Step 4 Go to Step 5
4 Measure the voltage between the CMP sensor signal
circuit and the sensor ground circuit at the CMP sensor
harness connector.
Does the voltage measure near the specified value? 4-6 V Go to Step 11 Go to Step 8
5 If the voltage measured in step 3 was less than 4-6
volts, proceed directly to step 6 without completing this
step.
If the voltage in step 3 was greater than 4-6 V, repair the
short to voltage in the CMP feed circuit.
Is the action complete? — Verify repair —
6 1. Check for poor connections at the camshaft
position sensor.
2. If a problem is found, repair it as necessary.
Was a problem found? — Verify repair Go to Step 7
7 1. Ignition “OFF,” disconnect the PCM and the CMP
sensor.
2. Check the following circuits for an open between the
ignition coil and the CMP sensor:
The sensor feed circuit.
3. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 9
8 1. Ignition “OFF,” disconnect the PCM (leave the CMP
sensor disconnected).
2. Ignition “ON,” check the following circuits:
The CMP sensor signal circuit for an open or a
short to voltage.
The CMP sensor input signal circuit for a short
to ground.
3. If a problem is found, repair it as necessary.
Was a problem found? — Verify repair Go to Step 9
9 Check for a short or open in the sensor ground circuit.
Was a problem found? — Verify repair Go to Step 10
ENGINE DRIVEABILITY AND EMISSIONS 6E–201

DTC P0341 – CMP Sensor Circuit Performance


Step Action Value(s) Yes No
10 1. Check for poor connections at the PCM.
2. If a problem is found, repair it as necessary.
Was a problem found? — Verify repair Go to Step 11
11 Backprobe the PCM connector with a DVM to monitor
voltage on the camshaft position input signal circuit
while cranking the engine with the sensor connected.
(Use rubber band, tape, or an assistant to keep the
DVM lead in contact with the sensor terminal during this
test.)
Does the voltage toggle between the specified values? 4-0 V Go to Step 15 Go to Step 12
12 1. Remove the CMP sensor from the engine front
cover (leave the sensor wiring connected).
2. Place a magnet on the CMP sensor.
(If you use a magnet that is too small to cover the face
of the sensor, test on every part of the sensor face
because only a small area will respond to this test.)
Does the DVM display a voltage near the specified
value? 0V Go to Step 13 Go to Step 14
13 Replace the faulty or missing camshaft position sensor
magnet.
Is the action complete? — Verify repair —
14 Replace the camshaft position sensor.
Is the action complete? — Verify repair —
15 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
6E–202 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0342 CMP Sensor Circuit Low

D06RW032

Circuit Description Conditions for Setting the DTC


The CMP signal produced by the camshaft position The engine is running.
(CMP) sensor pulses when the engine is running and The CMP sensor signal is not received by the PCM
crankshaft position (CKP) sync pulses are also being once every 6 cylinders.
received. The hall type CMP sensor and the CKP sensor The above condition occurs for 10 seconds.
share 5 V and ground connections at the powertrain
control module (PCM). The third wire at the sensor is a Action Taken When the DTC Sets
signal circuit to the PCM. The PCM uses the CMP signal
The PCM will illuminate the malfunction indicator lamp
pulses to initiate sequential fuel injection. The PCM (MIL) after the second consecutive trip in which the
constantly monitors the number of pulses on the CMP fault is detected.
signal circuit and compares the number of CMP pulses to The PCM will initiate injector sequence without the
the number of 58X reference pulses received. If the PCM CMP signal with a one in six chance that the injector
does not receive pulses on the CMP reference circuit, sequence is correct.
DTC P0342 will set and the PCM will initiate injector The PCM will store conditions which were present
sequence without the CMP signal with a one in six chance when the DTC was set as Freeze Frame and in the
that injector sequence is correct. The engine will continue Failure Records data.
to start and run normally, although the misfire diagnostic
will be affected if a misfiring condition occurs.
ENGINE DRIVEABILITY AND EMISSIONS 6E–203
Conditions for Clearing the MIL/DTC connected to the CMP signal circuit at the PCM
harness connector while moving connectors and
DTC P0342 can be cleared by using Tech 2 “Clear Info” wiring harnesses related to the ICM and the CMP
function or by disconnecting the PCM battery feed. sensor. A change in voltage will indicate the location
of the fault.
Diagnostic Aids
An intermittent may be caused by a poor connection, Test Description
rubbed-through wire insulation or a wire broken inside the Number(s) below refer to the step number(s) on the
insulation. Check for: Diagnostic Chart.
Poor connection – Inspect the PCM harness and 2. Ensures that the fault is present.
connectors for improper mating, broken locks,
improperly formed or damaged terminals, and poor 14.Determines whether the fault is being caused by a
terminal to wire connection. missing camshaft magnet or a faulty PCM. The
Damaged harness – Inspect the wiring harness for voltage measured in this step should read around 4
damage. If the harness appears to be OK, disconnect volts, toggling to near 0 volts when the CMP sensor
the PCM, turn the ignition on and observe a voltmeter interfaces with the camshaft magnet.

DTC P0342 – CMP Sensor Circuit Low


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Ignition “ON.”
2. Review and record Tech 2 Failure Records data.
3. Operate the vehicle within Failure Records
conditions as noted.
4. Using Tech 2, monitor “Specific DTC” information
for DTC P0342 until the DTC P0342 test runs.
Refer to
5. Note test result. Diagnostic
Does Tech 2 indicate DTC P0342 failed this ignition? — Go to Step 3 Aids
3 1. Ignition “ON.”
2. Disconnect the CMP sensor.
3. Measure the voltage between the sensor feed
circuit and the sensor ground circuit at the CMP
sensor harness connector.
Does the voltage measure near the specified value? 4-6 V Go to Step 7 Go to Step 4
4 1. Ignition “OFF,” disconnect the PCM and the CMP
sensor.
2. Check for poor connections at the camshaft
position sensor.
3. If a problem is found, repair it as necessary.
Was a problem found? — Verify repair Go to Step 5
5 1. Check for poor connections at the PCM.
2. If a problem is found, repair it as necessary.
Was a problem found? — Verify repair Go to Step 6
6 1. Check the following circuits between the PCM and
the CMP sensor:
The sensor feed circuit. Open or short to
ground?
The sensor ground circuit. Open or short to
voltage?
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair —
6E–204 ENGINE DRIVEABILITY AND EMISSIONS

DTC P0342 – CMP Sensor Circuit Low


Step Action Value(s) Yes No
7 1. Ignition “ON,” engine “OFF.”
2. Measure the voltage between the CMP sensor
signal circuit and the sensor ground circuit at the
CMP sensor harness connector.
Does the voltage measure near the specified value? 4-6 V Go to Step 8 Go to Step 9
8 1. Turn the ignition “OFF.”
2. Disconnect the PCM and connect a DVM to monitor
voltage on the camshaft position signal circuit at the
PCM connector.
3. Ignition “ON.”
4. Monitor the voltage display on the DVM while
repeatedly touching the CMP sensor signal circuit
at the CMP sensor connector with a test light to
ground.
Does the DVM voltage display switch between 0 and
approximately 5 volts when the test light is touched to
the CMP sensor signal circuit? — Go to Step 12 Go to Step 9
9 1. Ignition “OFF.”
2. Leave the PCM disconnected.
3. Ignition “ON.”
4. Probe the camshaft position signal circuit at the
PCM connector with a test light to B+.
5. If the test light is “ON,” locate and repair the short to
ground in the camshaft position input signal circuit.
Was either circuit shorted to ground? — Verify repair Go to Step 10
10 1. Ignition “OFF.”
2. Leave the PCM disconnected.
3. Ignition “ON.”
4. Probe the camshaft position signal circuit with a test
light to ground.
5. If the test light is “ON,” locate and repair the short to
voltage in the camshaft position input signal circuit.
Was the test light “ON”? — Verify repair Go to Step 11
11 1. Ignition “OFF,” disconnect the PCM (leave the CMP
sensor disconnected).
2. Ignition “ON,” check the following circuit:
The CMP sensor signal circuit for an open.
3. If a problem is found, repair it as necessary.
Was a problem found? — Verify repair —
12 1. Ignition “ON.”
2. Remove the CMP sensor from the engine front
cover (leave the sensor wiring connected).
3. Place a magnet on the CMP sensor. If you use a
magnet that is too small to cover the face of the
sensor, test on every part of the sensor face
because only a small area will respond to this test.
Does the DVM display a voltage near the specified
value? 0V Go to Step 14 Go to Step 13
13 Replace the camshaft position sensor.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–205

DTC P0342 – CMP Sensor Circuit Low


Step Action Value(s) Yes No
14 1. Reinstall the CMP sensor to the engine front cover.
2. Observe the DVM connected to monitor voltage on
the camshaft position signal circuit while cranking
the engine.
Does the voltage toggle between the specified values? 4-0 V Go to Step 15 Go to Step 16
15 Replace the PCM.
NOTE: The replacement PCM must be programmed.
Refer to UBS 98model year Immobilizer Workshop
Manual.
Is the action complete? — Verify repair —
16 Replace faulty or missing camshaft magnet.
Is the action complete? — Verify repair —
6E–206 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit

D06RW072

Circuit Description The output voltage is not equal to 5 volts when output
is “ON.”
The powertrain control module’s (PCM) control circuit 1
provides a zero-volt or a 5-volt output signal to the ignition The output voltage is not equal to 0 volts when output
is “OFF.”
coil. The normal voltage on the circuit is zero volts. When
the ignition coil receives the 5-volt signal from the PCM, it Twenty test failures occur within 40 samples of
continuous spark events.
provides a ground path for the B+ supply to the primary
side of the number 1 ignition coil. When the PCM shuts off Action Taken When the DTC Sets
the 5 volts to the ignition coil, the ignition coil turns “OFF.”
This causes the ignition coil primary magnetic field to The PCM will illuminate the malfunction indicator lamp
collapse, producing a voltage in the secondary coil which (MIL) the first time the fault is detected.
fires the spark plug. The PCM will store conditions which were present
when the DTC was set as Freeze Frame and in the
The circuit between the PCM and ignition coil is monitored Failure Records data.
for an open circuit, short to voltage, and short to ground.
When the PCM detects a problem on ignition control Conditions for Clearing the MIL/DTC
circuit 1, it will set a DTC P0351.
DTC P0351 can be cleared by using Tech 2 “Clear Info”
Conditions for Setting the DTC function or by disconnecting the PCM battery feed.
The ignition is “ON.” Diagnostic Aids
The engine is turning, determined by the 58X Check for the following conditions:
crankshaft position input signal.
ENGINE DRIVEABILITY AND EMISSIONS 6E–207
Poor connection at PCM – Inspect the harness connector and wiring related to the ignition system. A
connectors for backed-out terminals, improper mating, change in the display will indicate the location of the
broken locks, improperly formed or damaged fault.
terminals, and poor terminal-to-wire connections. Reviewing the Failure Records vehicle mileage since the
Damaged harness – Inspect the wiring harness for diagnostic test last failed may help determine how often
damage. If the harness appears to be OK, observe the condition that caused the DTC to be set occurs. This
Tech 2 display related to DTC P0351 while moving the may assist in diagnosing the condition.

DTC P0351 – Ignition 1 Control Circuit


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Ignition “ON,” engine “OFF.”
2. Review and record Tech 2 Failure Records data.
3. Operate the vehicle within Failure Record
conditions as noted.
4. Use Tech 2 to monitor the “Specific DTC”
information for DTC P0351 until the DTC P0351 test
runs.
5. Note the test result. Go to
Does Tech 2 indicate DTC P0351 failed this ignition Diagnostic
cycle? — Go to Step 3 Aids
3 Check for faulty connection at ignition coil.
Was a problem found? — Verify repair Go to Step 4
4 Check for faulty connection at PCM connector.
Was a problem found? — Verify repair Go to Step 5
5 1. Ignition “ON,” engine “OFF.”
2. Back probe the ignition control circuit 1 at the PCM
with a DVM.
Is the voltage near the specified value? 25-55 mV Go to Step 6 Go to Step 9
6 1. Ignition “ON,” engine running.
2. Back probe the ignition control circuit at the PCM for
the cylinder being tested.
Is the voltage in the specified range, rapidly toggling
back and forth to a reading 20-50 mV higher? 100-180 mV Go to Step 7 Go to Step 13
7 1. Ignition “OFF.”
2. Disconnect the 3-pin and 5-pin connectors at the
ignition coil.
3. Check ignition control circuit 1 voltage at the ignition
coil connector while cranking the engine.
Does the voltage measure between the specified
values? 200-1200 mV Go to Step 8 Go to Step 11
8 Replace the ignition coil.
Is the action complete? — Verify repair —
9 1. Ignition “OFF.”
2. Disconnect the PCM and the ignition coil.
3. Check ignition control circuit 1 for short to ground.
Was a problem found? — Verify repair Go to Step 10
10 Check ignition control circuit 1 for short to voltage.
Was a problem found? — Verify repair Go to Step 13
6E–208 ENGINE DRIVEABILITY AND EMISSIONS

DTC P0351 – Ignition 1 Control Circuit


Step Action Value(s) Yes No
11 Check for an open ignition control circuit 1.
Was the ignition control circuit open? — Go to Step 12 Go to Step 13
12 Repair the open ignition control circuit.
Is the action complete? — Verify repair —
13 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–209

Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit

D06RW072

Circuit Description The output voltage is not equal to 5 volts when output
is “ON.”
The powertrain control module’s (PCM) control circuit 2
provides a zero-volt or a 5-volt output signal to the ignition The output voltage is not equal to 0 volts when output
is “OFF.”
coil. The normal voltage on the circuit is zero volts. When
the ignition coil receives the 5-volt signal from the PCM, it Twenty test failures occur within 40 samples of
continuous spark events.
provides a ground path for the B+ supply to the primary
side of the number 2 ignition coil. When the PCM shuts off Action Taken When the DTC Sets
the 5 volts to the ignition coil, the ignition coil turns “OFF.”
This causes the ignition coil primary magnetic field to The PCM will illuminate the malfunction indicator lamp
collapse, producing a voltage in the secondary coil which (MIL) the first time the fault is detected.
fires the spark plug. The PCM will store conditions which were present
when the DTC was set as Freeze Frame and in the
The circuit between the PCM and ignition coil is monitored Failure Records data.
for an open circuit, short to voltage, and short to ground.
When the PCM detects a problem on ignition control Conditions for Clearing the MIL/DTC
circuit 2, it will set a DTC P0352.
DTC P0352 can be cleared by using the Tech 2 “Clear
Conditions for Setting the DTC Info” function or by disconnecting the PCM battery
feed.
The ignition is “ON.”
The engine is turning, determined by the 58 X Diagnostic Aids
crankshaft position input signal. Check for the following conditions:
6E–210 ENGINE DRIVEABILITY AND EMISSIONS
Poor connection at PCM – Inspect the harness connector and wiring related to the ignition system. A
connectors for backed-out terminals, improper mating, change in the display will indicate the location of the
broken locks, improperly formed or damaged fault.
terminals, and poor terminal-to-wire connections. Reviewing the Failure Records vehicle mileage since the
Damaged harness – Inspect the wiring harness for diagnostic test last failed may help determine how often
damage. If the harness appears to be OK, observe the the condition that caused the DTC to be set occurs. This
Tech 2 display related to DTC P0352 while moving the may assist in diagnosing the condition.

DTC P0352 – Ignition 2 Control Circuit


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Ignition “ON,” engine “OFF.”
2. Review and record Tech 2 Failure Records data.
3. Operate the vehicle within Failure Record
conditions as noted.
4. Use a Tech 2 to monitor the “Specific DTC”
information for DTC P0352 until the DTC P0352 test
runs.
5. Note the test result. Go to
Does the Tech 2 indicate DTC P0352 failed this ignition Diagnostic
cycle? — Go to Step 3 Aids
3 Check for faulty connection at ignition coil.
Was a problem found? — Verify repair Go to Step 4
4 Check for faulty connection at PCM connector.
Was a problem found? — Verify repair Go to Step 5
5 1. Ignition “ON,” engine “OFF.”
2. Back probe the ignition control circuit 2 at the PCM
with a DVM .
Is the voltage near the specified value? 25-55 mV Go to Step 6 Go to Step 9
6 1. Ignition “ON,” engine running.
2. Back probe the ignition control circuit at the PCM for
the cylinder being tested.
Is the voltage in the specified range, rapidly toggling
back and forth to a reading 20-50 mV higher? 100-180 mV Go to Step 7 Go to Step 13
7 1. Ignition “OFF.”
2. Disconnect the 3-pin and 5-pin connectors at the
ignition coil.
3. Check ignition control circuit 2 voltage at the ignition
coil connector while cranking the engine connector.
Does the voltage measure between the specified
values? 200-1200 mV Go to Step 8 Go to Step 11
8 Replace the ignition coil.
Is the action complete? — Verify repair —
9 1. Ignition “OFF.”
2. Disconnect the PCM and the ignition coil.
3. Check ignition control circuit 2 for short to ground.
Was a problem found? — Verify repair Go to Step 10
10 Check ignition control circuit 2 for short to voltage.
Was a problem found? — Verify repair Go to Step 13
ENGINE DRIVEABILITY AND EMISSIONS 6E–211

DTC P0352 – Ignition 2 Control Circuit


Step Action Value(s) Yes No
11 Check for an open ignition control circuit 1.
Was the ignition control circuit open? — Go to Step 12 Go to Step 13
12 Repair the open ignition control circuit.
Is the action complete? — Verify repair —
13 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
6E–212 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0353 Ignition 3 Control Circuit

D06RW072

Circuit Description The output voltage is not equal to 5 volts when output
is “ON.”
The powertrain control module’s (PCM) control circuit 3
provides a zero-volt or a 5-volt output signal to the ignition The output voltage is not equal to 0 volts when output
is “OFF.”
coil. The normal voltage on the circuit is zero volts. When
the ignition coil receives the 5-volt signal from the PCM, it Twenty test failures occur within 40 samples of
continuous spark events.
provides a ground path for the B+ supply to the primary
side of the number 3 ignition coil. When the PCM shuts off Action Taken When the DTC Sets
the 5 volts to the ignition coil, the ignition coil turns “OFF.”
This causes the ignition coil primary magnetic field to The PCM will illuminate the malfunction indicator lamp
collapse, producing a voltage in the secondary coil which (MIL) the first time the fault is detected.
fires the spark plug. The PCM will store conditions which were present
when the DTC was set as Freeze Frame and in the
The circuit between the PCM and ignition coil is monitored Failure Records data.
for an open circuit, short to voltage, and short to ground.
When the PCM detects a problem on ignition control Conditions for Clearing the MIL/DTC
circuit 3, it will set a DTC P0353.
DTC P0353 can be cleared by using the Tech 2 “Clear
Conditions for Setting the DTC Info” function or by disconnecting the PCM battery
feed.
The ignition is “ON.”
The engine is turning, determined by the 58X Diagnostic Aids
crankshaft position input signal. Check for the following conditions:
ENGINE DRIVEABILITY AND EMISSIONS 6E–213
Poor connection at PCM – Inspect the harness connector and wiring related to the ignition system. A
connectors for backed-out terminals, improper mating, change in the display will indicate the location of the
broken locks, improperly formed or damaged fault.
terminals, and poor terminal-to-wire connections. Reviewing the Failure Records vehicle mileage since the
Damaged harness – Inspect the wiring harness for diagnostic test last failed may help determine how often
damage. If the harness appears to be OK, observe the the condition that caused the DTC to be set occurs. This
Tech 2 display related to DTC P0353 while moving the may assist in diagnosing the condition.

DTC P0353 – Ignition 3 Control Circuit


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Ignition “ON,” engine “OFF.”
2. Review and record Tech 2 Failure Records data.
3. Operate the vehicle within Failure Record
conditions as noted.
4. Use a Tech 2 to monitor the “Specific DTC”
information for DTC P0353 until the DTC P0353 test
runs.
5. Note the test result. Go to
Does the Tech 2 indicate DTC P0353 failed this ignition Diagnostic
cycle? — Go to Step 3 Aids
3 Check for faulty connection at ignition coil.
Was a problem found? — Verify repair Go to Step 4
4 Check for faulty connection at PCM connector.
Was a problem found? — Verify repair Go to Step 5
5 1. Ignition “ON,” engine “OFF.”
2. Back probe the ignition control circuit 3 at the PCM
with a DVM positive lead with the negative lead to
ground.
Is the voltage near the specified value? 25-55 mV Go to Step 6 Go to Step 9
6 1. Ignition “ON,” engine running.
2. Back probe the ignition control circuit at the PCM for
the cylinder being tested.
Is the voltage in the specified range, rapidly toggling
back and forth to a reading 20-50 mV higher? 100-180 mV Go to Step 7 Go to Step 13
7 1. Ignition “OFF.”
2. Disconnect the 3-pin and 5-pin connectors at the
ignition coil.
3. Check ignition control circuit 3 voltage at the ignition
coil connector while cranking the engine.
Does the voltage measure between the specified
values? 200-1200 mV Go to Step 8 Go to Step 11
8 Replace the ignition coil.
Is the action complete? — Verify repair —
9 1. Ignition “OFF.”
2. Disconnect the PCM and the ignition coil.
3. Check ignition control circuit 3 for short to ground.
Was a problem found? — Verify repair Go to Step 10
10 Check ignition control circuit 3 for short to voltage.
Was a problem found? — Verify repair Go to Step 13
6E–214 ENGINE DRIVEABILITY AND EMISSIONS

DTC P0353 – Ignition 3 Control Circuit


Step Action Value(s) Yes No
11 Check for an open ignition control circuit 1.
Was the ignition control circuit open? — Go to Step 12 Go to Step 13
12 Repair the open ignition control circuit.
Is the action complete? — Verify repair —
13 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–215

Diagnostic Trouble Code (DTC) P0354 Ignition 4 Control Circuit

D06RW072

Circuit Description The output voltage is not equal to 5 volts when output
is “ON.”
The powertrain control module’s (PCM) control circuit 4
provides a zero-volt or a 5-volt output signal to the ignition The output voltage is not equal to 0 volts when output
is “OFF.”
coil. The normal voltage on the circuit is zero volts. When
the ignition coil receives the 5-volt signal from the PCM, it Twenty test failures occur within 40 samples of
continuous spark events.
provides a ground path for the B+ supply to the primary
side of the number 4 ignition coil. When the PCM shuts off Action Taken When the DTC Sets
the 5 volts to the ignition coil, the ignition coil turns “OFF.”
This causes the ignition coil primary magnetic field to The PCM will illuminate the malfunction indicator lamp
collapse, producing a voltage in the secondary coil which (MIL) the first time the fault is detected.
fires the spark plug. The PCM will store conditions which were present
when the DTC was set as Freeze Frame and in the
The circuit between the PCM and ignition coil is monitored Failure Records data.
for an open circuit, short to voltage, and short to ground.
When the PCM detects a problem on ignition control Conditions for Clearing the MIL/DTC
circuit 4, it will set a DTC P0354.
DTC P0354 can be cleared by using the Tech 2 “Clear
Conditions for Setting the DTC Info” function or by disconnecting the PCM battery
feed.
The ignition is “ON.”
The engine is turning, determined by the 58X Diagnostic Aids
crankshaft position input signal. Check for the following conditions:
6E–216 ENGINE DRIVEABILITY AND EMISSIONS
Poor connection at PCM – Inspect the harness connector and wiring related to the ignition system. A
connectors for backed-out terminals, improper mating, change in the display will indicate the location of the
broken locks, improperly formed or damaged fault.
terminals, and poor terminal-to-wire connections. Reviewing the Failure Records vehicle mileage since the
Damaged harness – Inspect the wiring harness for diagnostic test last failed may help determine how often
damage. If the harness appears to be OK, observe the the condition that caused the DTC to be set occurs. This
Tech 2 display related to DTC P0354 while moving the may assist in diagnosing the condition.

DTC P0354 – Ignition 4 Control Circuit


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Ignition “ON,” engine “OFF.”
2. Review and record Tech 2 Failure Records data.
3. Operate the vehicle within Failure Record
conditions as noted.
4. Use a Tech 2 to monitor the “Specific DTC”
information for DTC P0354 until the DTC P0354 test
runs.
5. Note the test result. Go to
Does the Tech 2 indicate DTC P0354 failed this ignition Diagnostic
cycle? — Go to Step 3 Aids
3 Check for faulty connection at ignition coil.
Was a problem found? — Verify repair Go to Step 4
4 Check for faulty connection at PCM connector.
Was a problem found? — Verify repair Go to Step 5
5 1. Ignition “ON,” engine “OFF.”
2. Back probe the ignition control circuit 4 at the PCM
with a DVM positive lead with the negative lead to
ground.
Is the voltage near the specified value? 25-55 mV Go to Step 6 Go to Step 9
6 1. Ignition “ON,” engine running.
2. Back probe the ignition control circuit at the PCM for
the cylinder being tested.
Is the voltage in the specified range, rapidly toggling
back and forth to a reading 20-50 mV higher? 100-180 mV Go to Step 7 Go to Step 13
7 1. Ignition “OFF.”
2. Disconnect the 3-pin and 5-pin connectors at the
ignition coil.
3. Check ignition control circuit 4 voltage at the ignition
coil connector while cranking the engine.
Does the voltage measure between the specified
values? 200-1200 mV Go to Step 8 Go to Step 11
8 Replace the ignition coil.
Is the action complete? — Verify repair —
9 1. Ignition “OFF.”
2. Disconnect the PCM and the ignition coil.
3. Check ignition control circuit 4 for short to ground.
Was a problem found? — Verify repair Go to Step 10
10 Check ignition control circuit 4 for short to voltage.
Was a problem found? — Verify repair Go to Step 13
ENGINE DRIVEABILITY AND EMISSIONS 6E–217

DTC P0354 – Ignition 4 Control Circuit


Step Action Value(s) Yes No
11 Check for an open ignition control circuit 1.
Was the ignition control circuit open? — Go to Step 12 Go to Step 13
12 Repair the open in ignition control circuit.
Is the action complete? — Verify repair —
13 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
6E–218 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0355 Ignition 5 Control Circuit

D06RW072

Circuit Description The output voltage is not equal to 5 volts when output
is “ON.”
The powertrain control module’s (PCM) control circuit 5
provides a zero-volt or a 5-volt output signal to the ignition The output voltage is not equal to 0 volts when output
is “OFF.”
coil. The normal voltage on the circuit is zero volts. When
the ignition coil receives the 5-volt signal from the PCM, it Twenty test failures occur within 40 samples of
continuous spark events.
provides a ground path for the B+ supply to the primary
side of the number 5 ignition coil. When the PCM shuts off Action Taken When the DTC Sets
the 5 volts to the ignition coil, the ignition coil turns “OFF.”
This causes the ignition coil primary magnetic field to The PCM will illuminate the malfunction indicator lamp
collapse, producing a voltage in the secondary coil which (MIL) the first time the fault is detected.
fires the spark plug. The PCM will store conditions which were present
when the DTC was set as Freeze Frame and in the
The circuit between the PCM and ignition coil is monitored Failure Records data.
for an open circuit, short to voltage, and short to ground.
When the PCM detects a problem on ignition control Conditions for Clearing the MIL/DTC
circuit 5, it will set a DTC P0355.
DTC P0355 can be cleared by using the Tech 2 “Clear
Conditions for Setting the DTC Info” function or by disconnecting the PCM battery
feed.
The ignition is “ON.”
The engine is turning, determined by the 58X Diagnostic Aids
crankshaft position input signal. Check for the following conditions:
ENGINE DRIVEABILITY AND EMISSIONS 6E–219
Poor connection at PCM – Inspect the harness connector and wiring related to the ignition system. A
connectors for backed-out terminals, improper mating, change in the display will indicate the location of the
broken locks, improperly formed or damaged fault.
terminals, and poor terminal-to-wire connections. Reviewing the Failure Records vehicle mileage since the
Damaged harness – Inspect the wiring harness for diagnostic test last failed may help determine how often
damage. If the harness appears to be OK, observe the the condition that caused the DTC to be set occurs. This
Tech 2 display related to DTC P0355 while moving the may assist in diagnosing the condition.

DTC P0355 – Ignition 5 Control Circuit


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Ignition “ON,” engine “OFF.”
2. Review and record Tech 2 Failure Records data.
3. Operate the vehicle within Failure Record
conditions as noted.
4. Use a Tech 2 to monitor the “Specific DTC”
information for DTC P0355 until the DTC P0355 test
runs.
5. Note the test result. Go to
Does the Tech 2 indicate DTC P0355 failed this ignition Diagnostic
cycle? — Go to Step 3 Aids
3 Check for faulty connection at ignition coil.
Was a problem found? — Verify repair Go to Step 4
4 Check for faulty connection at PCM connector.
Was a problem found? — Verify repair Go to Step 5
5 1. Ignition “ON,” engine “OFF.”
2. Back probe the ignition control circuit 5 at the PCM
with a DVM positive lead with the negative lead to
ground.
Is the voltage near the specified value? 25-55 mV Go to Step 6 Go to Step 9
6 1. Ignition “ON,” engine running.
2. Back probe the ignition control circuit at the PCM for
the cylinder being tested.
Is the voltage in the specified range, rapidly toggling
back and forth to a reading 20-50 mV higher? 100-180 mV Go to Step 7 Go to Step 13
7 1. Ignition “OFF.”
2. Disconnect the 3-pin and 5-pin connectors at the
ignition coil.
3. Check ignition control circuit 5 voltage at the ignition
coil connector while cranking the engine.
Does the voltage measure between the specified
values? 200-1200 mV Go to Step 8 Go to Step 11
8 Replace the ignition coil.
Is the action complete? — Verify repair —
9 1. Ignition “OFF.”
2. Disconnect the PCM and the ignition coil.
3. Check ignition control circuit 5 for short to ground.
Was a problem found? — Verify repair Go to Step 10
10 Check ignition control circuit 5 for short to voltage.
Was a problem found? — Verify repair Go to Step 13
6E–220 ENGINE DRIVEABILITY AND EMISSIONS

DTC P0355 – Ignition 5 Control Circuit


Step Action Value(s) Yes No
11 Check for an open ignition control circuit 1.
Was the ignition control circuit open? — Go to Step 12 Go to Step 13
12 Repair the open ignition control circuit.
Is the action complete? — Verify repair —
13 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–221

Diagnostic Trouble Code (DTC) P0356 Ignition 6 Control Circuit

D06RW072

Circuit Description The output voltage is not equal to 5 volts when output
is “ON.”
The powertrain control module’s (PCM) control circuit 6
provides a zero-volt or a 5-volt output signal to the ignition The output voltage is not equal to 0 volts when output
is “OFF.”
coil. The normal voltage on the circuit is zero volts. When
the ignition coil receives the 5-volt signal from the PCM, it Twenty test failures occur within 40 samples of
continuous circuit monitoring.
provides a ground path for the B+ supply to the primary
side of the number 6 ignition coil. When the PCM shuts off Action Taken When the DTC Sets
the 5 volts to the ignition coil, the ignition coil turns “OFF.”
This causes the ignition coil primary magnetic field to The PCM will illuminate the malfunction indicator lamp
collapse, producing a voltage in the secondary coil which (MIL) the first time the fault is detected.
fires the spark plug. The PCM will store conditions which were present
when the DTC was set as Freeze Frame and in the
The circuit between the PCM and ignition coil is monitored Failure Records data.
for an open circuit, short to voltage, and short to ground.
When the PCM detects a problem on ignition control Conditions for Clearing the MIL/DTC
circuit 6, it will set a DTC P0356.
DTC P0356 can be cleared by using the Tech 2 “Clear
Conditions for Setting the DTC Info” function or by disconnecting the PCM battery
feed.
The ignition is “ON.”
The engine is turning, determined by the 58X Diagnostic Aids
crankshaft position input signal. Check for the following conditions:
6E–222 ENGINE DRIVEABILITY AND EMISSIONS
Poor connection at PCM – Inspect the harness connector and wiring related to the ignition system. A
connectors for backed-out terminals, improper mating, change in the display will indicate the location of the
broken locks, improperly formed or damaged fault.
terminals, and poor terminal-to-wire connections. Reviewing the Failure Records vehicle mileage since the
Damaged harness – Inspect the wiring harness for diagnostic test last failed may help determine how often
damage. If the harness appears to be OK, observe the the condition that caused the DTC to be set occurs. This
Tech 2 display related to DTC P0356 while moving the may assist in diagnosing the condition.

DTC P0356 – Ignition 6 Control Circuit


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Ignition “ON,” engine “OFF.”
2. Review and record Tech 2 Failure Records data.
3. Operate the vehicle within Failure Record
conditions as noted.
4. Use a Tech 2 to monitor the “Specific DTC”
information for DTC P0356 until the DTC P0356 test
runs.
5. Note the test result. Go to
Does the Tech 2 indicate DTC P0356 failed this ignition Diagnostic
cycle? — Go to Step 3 Aids
3 Check for faulty connection at ignition coil.
Was a problem found? — Verify repair Go to Step 4
4 Check for faulty connection at PCM connector.
Was a problem found? — Verify repair Go to Step 5
5 1. Ignition “ON,” engine “OFF.”
2. Back probe the ignition control circuit 6 at the PCM
with a DVM positive lead with the negative lead to
ground.
Is the voltage near the specified value? 25-55 mV Go to Step 6 Go to Step 9
6 1. Ignition “ON,” engine running.
2. Back probe the ignition control circuit at the PCM for
the cylinder being tested.
Is the voltage in the specified range, rapidly toggling
back and forth to a reading 20-50 mV higher? 100-180 mV Go to Step 7 Go to Step 13
7 1. Ignition “OFF.”
2. Disconnect the 3-pin and 5-pin connectors at the
ignition coil.
3. Check ignition control circuit 6 voltage at the ignition
coil connector while cranking the engine.
Does the voltage measure between the specified
values? 200-1200 mV Go to Step 8 Go to Step 11
8 Replace the ignition coil.
Is the action complete? — Verify repair —
9 1. Ignition “OFF.”
2. Disconnect the PCM and the ignition coil.
3. Check ignition control circuit 6 for short to ground.
Was a problem found? — Verify repair Go to Step 10
10 Check ignition control circuit 6 for short to voltage.
Was a problem found? — Verify repair Go to Step 13
ENGINE DRIVEABILITY AND EMISSIONS 6E–223

DTC P0356 – Ignition 6 Control Circuit


Step Action Value(s) Yes No
11 Check for an open ignition control circuit 1.
Was the ignition control circuit open? — Go to Step 12 Go to Step 13
12 Repair the open ignition control circuit.
Is the action complete? — Verify repair —
13 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
6E–224 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0402 EGR Pintle Crank Error

D06RW106

Circuit Description Conditions for Clearing the MIL/DTC


The powertrain control module (PCM) monitors the EGR DTC P0402 can be cleared by using Tech 2 “Clear Info”
valve pintle position input to ensure that the valve function or by disconnecting the PCM battery feed.
responds properly to commands from the PCM, and to
detect a fault if pintle position is stuck open. If the PCM Diagnostic Aids
detects a pintle position signal indicates more than 21.5% Check for the following conditions:
and more than for 625 msec during cranking, the PCM will Foreign material on EGR valve between pintle and
set DTC P0402. seat may cause EGR stuck open. Inspect foreign
material in EGR valve.
Conditions for Setting the DTC Excessive carbon deposit may cause unsmooth
Ignition voltage is between 11 and 16 volts. operation of EGR valve shaft. Inspect carbon deposit
and clean up inside of carbon deposit.
Intake Air temp is more than 3 C
Poor connection or damaged harness–inspect the
At Engine revolution less than 600 RPM, EGR pintle wiring harness for damage If the harness appears to be
position indicates more than 21.5% and more than for OK, observe the EGR actual position display on Tech
625 msecs. 2 while moving connectors and wiring harnesses
related to EGR valve. A change in the display will
Action Taken When the DTC Sets indicate the location of the fault.
The PCM will illuminate the malfunction indicator lamp NOTE: If the EGR valve shows signs of excessive heat,
(MIL) after the second consecutive trip in which the check the exhaust system for blockage (possibly a
fault is detected. plugged catalytic converter) using the “Restricted
The PCM will store conditions which were present Exhaust System Check”.
when the DTC was set as Freeze Frame and in Failure
Records data.
ENGINE DRIVEABILITY AND EMISSIONS 6E–225

DTC P0402 – EGR Pintle Crank Open Error


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Ignition “ON”, engine “OFF”, review and record
Tech 2 Failure Records data.
2. Operate the vehicle within Failure Records
conditions as noted.
3. Using Tech 2, monitor “Specific DTC” info for DTC
P0402 until the DTC P0402 test runs. Note the Refer to
result. Diagnostic
Does Tech 2 indicates DTC P0402 failed this ignition? — Go to Step 3 Aids
3 1. Disconnect the EGR valve harness connector.
2. Inspect the EGR valve and connectors for damaged
pin or terminals.
Were there any damaged pins or terminals? — Go to Step 4 Go to Step 5
4 Repair the damaged pin or terminal.
Is the action complete? — Verify repair —
5 1. Remove EGR valve from Engine.
2. Inspect EGR valve whether there is any foreign
material between seat and pintle.
Was any foreign material in EGR valve? — Go to Step 6 Go to Step 7
6 1. Remove EGR valve foreign material from EGR
valve and clean up inside.
2. Visually inspect damage of pintle and seat, which
leakage may occur. Verify repair
Was there any severe damage which affects function? — Go to Step 7 Go to Step 8
7 1. Reconnect.
2. Ignition “OFF”.
3. Install Tech 2.
4. Run the engine at idle.
5. On Tech-II, select special function for EGR.
6. Use the “UP” arrow to increase the EGR from 0% to
40%.
Did EGR work properly? — — Go to Step 8
8 Replace the EGR valve.
Does DTC P0402 still fail “DTC” test on Tech 2? — Go to Step 9 Verify repair
9 Replace the EGR valve.
Is the action complete? — Verify repair —
6E–226 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0404 EGR Open Stuck

D06RW106

Circuit Description The PCM will store conditions which were present
when the DTC was set as Freeze Frame and in Failure
The powertrain control module (PCM) monitors the EGR Records data.
valve pintle position input to ensure that the valve
responds properly to commands from the PCM, and to Conditions for Clearing the MIL/DTC
detect a fault if pintle position is different from
commanded position. If the PCM detects a pintle position DTC P0404 can be cleared by using Tech 2 “Clear Info”
function or by disconnecting the PCM battery feed.
signal indicates more than 15 points different between
current and commanded and more than 15 seconds, the Diagnostic Aids
PCM will set DTC P0404.
Check for the following conditions:
Conditions for Setting the DTC Excessive carbon deposit on EGR valve shaft may
cause EGR stuck open or unsmooth operation. Those
Ignition voltage is between 11 and 16 volts. carbon deposit may occur by unusual port operation.
Intake Air temp is more than 3 C. Clean up carbon may make smooth function of EGR
Desire EGR position is more than 0. valve.
The difference between desired EGR and current EGR Poor connection or damaged harness – Inspect the
is less than 3%. wiring harness for damage. If the harness appears to
be OK, observe the EGR actual position display on
Difference EGR pintle position between current and Tech 2 while moving connectors and wiring harnesses
commanded position becomes more than 15% and related to EGR valve. A change in the display will
last more than 15 seconds, and this condition meets indicate the location of the fault.
three times in a trip. Then it trigger, the PCM lights on.

Action Taken When the DTC Sets


The PCM will illuminate the malfunction indicator lamp
(MIL) as soon as failure detected after consecutive 2nd
trip in which the fault is detected.
ENGINE DRIVEABILITY AND EMISSIONS 6E–227

DTC P0404 – EGR Open Stuck


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Ignition “ON,” engine “OFF”, review and record
Tech 2 Failure Records Data.
2. Operate the vehicle within Failure Records
conditions as noted.
3. Using Tech 2, monitor “Specific DTC” info for DTC
P0404 until the DTC P0404 test runs. Note the Refer to
result. Diagnostic
Does Tech 2 indicates DTC P0404 failed this ignition? — Go to Step 3 Aids
3 1. Disconnect the EGR valve harness connector.
2. Inspect the EGR valve and connectors for damaged
pin or terminals.
Were there any damaged pins or terminals? — Go to Step 4 Go to Step 5
4 Repair the damaged pin or terminal.
Is the action
— Verify repair complete?
5 1. Remove EGR valve from Engine.
2. Inspect EGR valve whether there is any excessive
carbon deposit on EGR shaft.
Was excessive carbon deposit 0n EGR valve shaft? — Go to Step 6 Go to Step 7
6 1. Clean up EGR valve shaft and inside of EGR valve.
2. Visually inspect damage of pintle and seat whether
there is bent, leakage may occur. Verify repair
Was there any severe damage which affects function? — Go to Step 8 Go to Step 7
7 1. Reconnect.
2. Ignition “OFF”.
3. Install Tech 2.
4. Run the engine at idle.
5. On Tech 2, select F3:Misc. Test; F2:EGR.
6. Use the “UP” arrow to increase the EGR from 0% to
40%.
Did EGR work properly? — — Go to Step 8
8 Replace the EGR valve.
Does DTC P0404 still fail “DTC” test on Tech 2? — Go to Step 9 Verify repair
9 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
6E–228 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0405 EGR Low Voltage

D06RW106

Circuit Description The PCM will store conditions which were present
when the DTC was set as Freeze Frame and in Failure
The powertrain control module (PCM) monitors the EGR Records data.
valve pintle position input to ensure that the valve
responds properly to command from the PCM. If current Conditions for Clearing the MIL/DTC
pintle position voltage indicates less than 0.1 V and last
more than 10 seconds, then the PCM will set DTC P0405. DTC P0405 can be cleared by using Tech 2 “Clear Info”
function or by disconnecting the PCM battery feed.
Conditions for Setting the DTC Diagnostic Aids
Ignition voltage is between 11 and 16 volts. Check for the following conditions:
EGR pintle position output voltage is less than 0.1 volt Poor connection or damaged harness – Inspect the
and last more than 10 sec. Action taken when the DTC wiring harness for damage. If the harness appears to
sets. be OK, observe the EGR actual position display on
Tech 2 while moving connectors and wiring harnesses
Action Taken When the DTC Sets related to EGR valve. A change in the display will
The PCM will illuminate the malfunction indicator lamp indicate the location of the fault.
(MIL) as soon as failure detected.
ENGINE DRIVEABILITY AND EMISSIONS 6E–229

DTC P0405 – EGR Low Volt


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Ignition “ON,” engine “OFF”, review and record
Tech 2 Failure Records Data.
2. Operate the vehicle within Failure Records
conditions as noted.
3. Using Tech 2, monitor “DTC” info for DTC P0405 Refer to
until the DTC P0405 test runs. Note the result. Diagnostic
Does Tech 2 indicates DTC P0405 failed this ignition? — Go to Step 3 Aids
3 1. Disconnect the EGR valve harness connector.
2. Inspect the EGR valve and connectors for damaged
pin or terminals.
Were there any damaged pins or terminals? — Go to Step 4 Go to Step 5
4 Repair the damaged pin or terminal.
Is the action complete? — Verify repair —
5 1. Disconnect the EGR harness connector.
2. Ignition “ON”.
3. At the EGR valve, use a DVM to check the voltage
at the 5 volt reference wire (RED) and ground (B).
Did the DVM indicate the specified value? 4–6 V Go to Step 6 Go to Step 7
6 1. Disconnect the EGR harness connector.
2. Measure resistance between terminal B and D.
Was resistance in range? 5–5.5 K Go to Step 10 Go to Step 17
7 1. Ignition “ON”.
2. At the PCM connector, backprobe with a DVM at the
5 volt reference for the EGR valve.
Did the DVM indicate the specified value? 4–6 V Go to Step 8 Go to Step 9
8 Repair the open 5 volt reference circuit.
Is the action complete? — Verify repair —
9 Repair the damaged sensor ground wire.
Is the action complete? — Verify repair —
10 1. Disconnect the EGR harness
2. Use an ohmmeter to measure between the pintle
position pin and the sensor ground pin on the EGR
valve.
NOTE: J-35616 Connector Test Adapter Kit may be
useful for gaining access to the recessed pins on the
valve.
Was the ohmmeter reading approximately equal to the
specified value? 1 to 1.25 K Go to Step 11 Go to Step 17
11 1. Ignition “ON”.
2. Backprobe with a DVM to measure voltage at EGR
valve pintle position pin and sensor ground pin. Less than
Was voltage in range? 0.1 V Go to Step 17 Go to Step 12
6E–230 ENGINE DRIVEABILITY AND EMISSIONS

DTC P0405 – EGR Low Volt


Step Action Value(s) Yes No
12 1. Ignition “ON”.
2. Backprobe with a DVM to measure voltage at PCM
sensor ground pin and pintle position pin. Less than
Was voltage in range? 0.1 V Go to Step 13 Go to Step 18
13 1. Ignition “OFF”.
2. Disconnect the EGR harness.
3. Check short circuit between EGR pintle position
circuit and EGR ground circuit.
Was any short circuit? — Go to Step 14 Go to Step 18
14 Locate and repair the short to ground in the pintle
position circuit
Is the action complete? — Verify repair —
15 1. Ignition “OFF”.
2. Disconnect the PCM.
3. Ignition “ON”.
4. Measure the voltage between the EGR pintle
position circuit and ground. Less than
Is the measured voltage near the specified value? 0.1 V Go to Step 17 Go to Step 16
16 Check for a short circuit between other wires and the
pintle position circuit Repair short
Was any short circuit? circuit
— Verify repair Go to Step 17
17 Replace the EGR valve.
Does DTC P1404 still fail “specific DTC test on Tech 2? — Go to Step 18 Verify repair
18 Examine the PCM pin and terminal connection.
Was there a damaged terminal? — Go to Step 4 Go to Step 19
19 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–231

Diagnostic Trouble Code (DTC) P0406 EGR High Voltage

D06RW106

Circuit Description The PCM will store conditions which were present
when the DTC was set as Freeze Frame and in Failure
The powertrain control module (PCM) monitors the EGR Records data.
valve pintle position input to ensure that the valve
responds properly to command from the PCM. If current Conditions for Clearing the MIL/DTC
pintle position voltage indicates more than 4.8 V and last
more than 10 seconds, then the PCM will set DTC P0406. DTC P0404 can be cleared by using Tech 2 “Clear Info”
function or by disconnecting the PCM battery feed.
Conditions for Setting the DTC Diagnostic Aids
Ignition voltage is between 11 and 16 volts. Check for the following conditions:
EGR pintle position output voltage is more than 4.8 volt Poor connection or damaged harness – Inspect the
and last more than 10 sec. wiring harness for damage. If the harness appears to
be OK, observe the EGR actual position display on
Action Taken When the DTC Sets Tech 2 while moving connectors and wiring harnesses
The PCM will illuminate the malfunction indicator lamp related to EGR valve. A change in the display will
(MIL) as soon as failure detected. indicate the location of the fault.
6E–232 ENGINE DRIVEABILITY AND EMISSIONS

DTC P0406 – EGR High Voltage


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Ignition “ON,” engine “OFF”, review and record
Tech 2 Failure Records Data.
2. Operate the vehicle within Failure Records
conditions as noted.
3. Using Tech 2, monitor “DTC” info for DTC P0406 Refer to
until the DTC P0406 test runs. Note the result. Diagnostic
Does Tech 2 indicates DTC P0406 failed this ignition? — Go to Step 3 Aids
3 1. Disconnect the EGR valve harness connector.
2. Inspect the EGR valve and connectors for damaged
pin or terminals.
Were there any damaged pins or terminals? — Go to Step 4 Go to Step 5
4 Repair the damaged pin or terminal.
Is the action
Is the action complete? — Verify repair complete?
5 1. Disconnect the EGR harness connector.
2. Ignition “ON”.
3. At the EGR valve, use a DVM to check the voltage
at the 5 volt reference wire (RED).
Did the DVM indicate the specified value? 4–6 V Go to Step 8 Go to Step 6
6 1. Ignition “ON”.
2. At the PCM connector, backprobe with a DVM at the
5 volt reference for the EGR valve.
Did the DVM indicate the specified value? 4–6 V Go to Step 7 Go to Step 16
7 Repair the open 5 volt reference circuit
Is the action complete? — Verify repair —
8 1. Ignition “OFF”
2. Disconnect the EGR harness.
3. Use a DVM to check for an resistance between D (5
V reference) and B (Sensor Ground) at EGR sensor
terminals.
NOTE: J-35616 Connector Test Adapter Kit may be
useful for gaining access to the recessed pins on the
valve.
Was there measured resistance in range? 5 to 5 K Go to Step 9 Go to Step 15
9 1. Ignition “OFF”.
2. Disconnect the EGR harness.
3. Use a DVM to check for an resistance between B
and C at EGR sensor terminal.
Was there open circuit? — Go to Step 15 Go to Step 10
10 1. Ignition “OFF”.
2. Disconnect the EGR harness at PCM connector.
3. Use a DVM to check for shorted wire between A1
and B7.
Was there shorted wire? — Go to Step 14 Go to Step 11
ENGINE DRIVEABILITY AND EMISSIONS 6E–233

DTC P0406 – EGR High Voltage


Step Action Value(s) Yes No
11 1. Ignition “ON”.
2. Use a DVM to backprobe at terminal C of EGR
valve for voltage. more than
Was measured voltage more than 4.8 V? 4.8 V Go to Step 12 Go to Step 12
12 1. Ignition “ON”.
2. Stay the EGR harness connected.
3. Check voltage by backproving at PCM B7 terminal.
Was voltage more than 4.8 V? 4.8 V Go to Step 16 Go to Step 13
13 1. Locate short circuit at EGR harness between RED
to RED or GREEN, RED to YEL.
2. Replace EGR harness.
Is the action complete? — Verify repair —
14 Replace EGR harness.
Is the action complete? — Verify repair —
15 Replace the EGR valve.
Does DTC P1404 still fail “specific DTC test on Tech 2? — Go to Step 16 Verify repair
16 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
6E–234 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0502 VSS Circuit Low Input

D06RW019

Circuit Description Conditions for Clearing the MIL/DTC


The vehicle speed sensor has a magnet rotated by the DTC P0502 can be cleared by using the Tech 2 “Clear
transmission output shaft. Attached to the sensor is a hall Info” function or by disconnecting the PCM battery
effect circuit the interacts with the magnetic field treated feed.
by the rotating magnet. A 12-volt operating supply for the
speed sensor hall circuit is supplied from the meter fuse. Test Description
The VSS pulses to ground the 9-volt signal sent from the Number(s) below refer to the step number(s) on the
powertrain control module (PCM) on the reference circuit. Diagnostic Chart.
The PCM interprets vehicle speed by the number of 10. To avoid backprobing the VSS and possibly
pulses to ground per second on the reference circuit. damaging a seal or terminal, the VSS output can be
tested at the point where the transmission harness
Conditions for Setting the DTC connects to the engine harness. Power and ground
Engine is running. are applied by jumpers to the VSS through the
connectors which are located just in front of the air
Engine coolant temperature is above 60 C (140 F).
cleaner assembly. The VSS signal is monitored
Engine speed is between 1800 RPM and 2500 RPM. with a DVM as the rear driveshaft turns. The
Throttle angle is between 10% and 40%. wheels can be turned to rotate the driveshaft, or in
Engine load is greater than 50 kPa. 2-wheels-drive vehicles the driveshaft can be turned
MAP sensor indicates greater than 50 kPa manifold directly.
pressure. 12. The speedometer-to-PCM VSS signal wire is
PCM detects no VSS signal for 12.5 seconds over a spliced to a wire leading to the cruise control
period of 25 seconds. module. If a short to ground or voltage is indicated
between the PCM and speedometer, it could be on
Action Taken When the DTC Sets the cruise control circuit if the vehicle is equipped
The PCM will illuminate the malfunction indicator lamp with cruise control.
(MIL) the first time the fault is detected.
The PCM will store conditions which were present
when the DTC was set as Freeze Frame and in the
Failure Records data.
ENGINE DRIVEABILITY AND EMISSIONS 6E–235

DTC P0502 – VSS Circuit Low Input


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 Does the speedometer work? — Go to Step 10 Go to Step 3
3 1. Disconnect the VSS connector.
2. Ignition “ON.”
3. Using a test light to battery +, probe the connector
ground wire.
Did the light illuminate? — Go to Step 5 Go to Step 4
4 Repair the sensor ground.
Is the action complete? — Verify repair —
5 1. Ignition “ON,” sensor disconnected.
2. Using a DVM, measure at the VSS connector
between ground and voltage supply. Battery
Was the measurement near the specified value? voltage Go to Step 7 Go to Step 6
6 Repair the open or short to ground which may have
blown the meter fuse.
Is the action complete? — Verify repair —
7 1. Ignition “ON,” VSS disconnected.
2. Using a DVM, measure at the VSS connector
between ground and the wire from the
speedometer.
Was the measurement near the specified value? 7.5-8 V Go to Step 9 Go to Step 8
8 Check for an open or short circuit between the
speedometer and the VSS.
Was an open or short circuit located? — Verify repair Go to Step 9
9 Replace the speedometer.
Is the action complete? — Verify repair —
6E–236 ENGINE DRIVEABILITY AND EMISSIONS

DTC P0502 – VSS Circuit Low Input


Step Action Value(s) Yes No
10 1. Ignition “OFF.”
2. Disconnect the MAF sensor and remove the air
cleaner assembly and filter element to gain access
to the 16-way black connector located immediately
to the rear of the left front headlamp. The connector
attaches the VSS wires from the transmission
harness to the left-side engine harness.
3. Disconnect the black 16-way connector.
4. Select a terminal adapter from kit J 35616 that can
be used with a jumper to supply B+ to the blue wire
with a yellow tracer (transmission side of the
connector).
5. Use another terminal adapter to attach a voltmeter
to the light-green wire with a while tracer (next to the
wire in the previous step.)
6. Disconnect the blue connector next to the black
16-way connector, and locate the black/red tracer
wire at one corner of the blue connector. The
black/red wire is the VSS ground. Use a terminal
adapter to attach a jumper to ground to the
black/red VSS ground wire at the transmission side
of the blue connector.
7. Raise the rear wheels off the ground with
transmission in neutral.
Does the DVM toggle back and forth between 0.6 V and
10 V as the wheels (and driveshaft) are rotated? — Go to Step 11 Go to Step 12
11 Replace the VSS.
Is the action complete? — Verify repair —
12 Check for an open or short between the PCM and the
speedometer.
Was a problem found? — Verify repair Go to Step 13
13 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–237

Diagnostic Trouble Code (DTC) P0562 System Voltage Low

D06RW020

Circuit Description Conditions for Clearing the MIL/DTC


The powertrain control module (PCM) monitors the A history DTC P0562 will clear after 40 consecutive
system voltage on the ignition feed terminal to the PCM. warm-up cycles have occurred without a fault.
A system voltage DTC will set whenever the voltage is DTC P0562 can be cleared by using the Tech 2 “Clear
below a calibrated value. Info” function or by disconnecting the PCM battery
feed.
Conditions for Setting the DTC
Diagnostic Aids
Ignition “ON.”
System voltage is below 11.5 volts for 15 minutes. If the DTC sets when an accessory is operated, check for
a poor connection or excessive current draw.
Action Taken When the DTC Sets
The PCM will not illuminate the malfunction indicator
lamp (MIL).
The PCM will store as Failure Records conditions
which were present when the DTC was set. This
information will not be stored as Freeze Frame data.
6E–238 ENGINE DRIVEABILITY AND EMISSIONS

DTC P0562 – System Voltage Low


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 Using a Tech 2, measure the battery voltage at the
Charge
battery.
battery, then
Is the battery voltage greater than the specified value? 11.5 V Go to Step 3 go to Step 3
3 1. Using a Tech 2.
2. Select “Ignition Volts” on the Tech 2.
3. Start the engine and raise the engine speed to the
specified value.
4. Load the electrical system by turning on the
headlights, high blower, etc. Go to
Is the ignition voltage approximately equal to the 2000 RPM Starting/Char
specified value? 12.8-14.1 V Go to Step 4 ging
4 1. Ignition “OFF.” Check for
2. Disconnect the PCM connector at the PCM. excessive
current draw
3. Using a DVM, measure the battery voltage at the
with ignition
PCM connector A-4.
“OFF,” engine
Is it approximately equal to battery voltage? — “OFF.” Go to Step 5
5 1. Check for faulty connections at the PCM harness
terminals.
2. Repair as necessary.
Was a repair necessary? — Verify repair Go to Step 6
6 Check for an open battery feed circuit to the PCM.
Is the action complete? — Verify repair Go to Step 7
7 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–239

Diagnostic Trouble Code (DTC) P0563 System Voltage High


Circuit Description The PCM will store as Failure Records only conditions
which were present when the DTC was set. This
The powertrain control module (PCM) monitors the information will not be stored as Freeze Frame data.
system voltage on the ignition feed terminals to the PCM.
A system voltage DTC will set whenever the voltage is Conditions for Clearing the MIL/DTC
above a calibrated value.
A history DTC P0563 will clear after 40 consecutive
Conditions for Setting the DTC warm-up cycles have occurred without a fault.
DTC P0563 can be cleared by using the Tech 2 “Clear
Ignition “ON.” Info” function or by disconnecting the PCM battery
System voltage is above 16 volts for 15 minutes. feed.

Action Taken When the DTC Sets Diagnostic Aids


The PCM will not illuminate the malfunction indicator If the DTC sets when an accessory is operated, check for
lamp (MIL). a poor connection or excessive current draw.

DTC P0563 – System Voltage High


Step Action Value(s) Yes No
1 Was the “ON-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 Using a Tech 2, measure the battery voltage at the
battery.
Is the battery voltage less than the specified value? 11.5 V Go to Step 3 Go to Step 4
3 1. Charge the battery and clean the battery terminals.
2. Clean the battery ground cable connection if
corrosion is indicated. Replace
Is the battery voltage less than the specified value? 11.5 V battery Go to Step 4
4 1. Turn “OFF” all the accessories.
2. Install a Tech 2.
3. Select the ignition voltage parameter on the Tech 2.
4. Start the engine and raise the engine RPM to the
specified value. Go to
Is the voltage more than 2.5 volts greater than the Starting/Char
measurement taken in step 2 or 3? 2000 RPM ging Go to Step 5
5 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98 model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
6E–240 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0601 PCM Memory


Circuit Description The PCM will store conditions which were present
when the DTC was set in the Failure Records data only.
The powertrain control module (PCM) used in this vehicle
utilizes an electrically erasable programmable read-only Conditions for Clearing the MIL/DTC
memory (EEPROM). The EEPROM contains program
information and the calibrations required for engine, DTC P0601 can be cleared by using the Tech 2 “Clear
transmission, and powertrain diagnostics operation. Info” function or by disconnecting the PCM battery
feed.
Unlike the PROM used in past applications, the EEPROM
is not replaceable. Diagnostic Aids
Conditions for Setting the DTC DTC P0601 indicates that the contents of the
EEPROM have changed since the PCM was
The PCM detects an internal program fault (check sum programmed. The only possible repair is PCM
error). replacement.
Action Taken When the DTC Sets
The PCM will not illuminate the malfunction indicator
lamp (MIL).

DTC P0601 – PCM Memory


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–241

Diagnostic Trouble Code (DTC) P1154 HO2S Circuit Transition Time Ratio
Bank 2 Sensor 1

060RW190

Circuit Description Above conditions are present for a 3-second


monitoring period.
The powertrain control module (PCM) monitors the
heated oxygen sensor (HO2S) activity for 90 seconds 90 seconds after “closed loop” and stoichiometric
operation have been enabled, Bank 2 HO2S 1
after “closed loop” and stoichiometric operation have transition ratio between lean to rich and rich to lean is
been enabled. During the monitor period the PCM counts less than 0.44 or greater than 3.8.
the number of times that the HO2S responds from
rich-to-lean and from lean-to-rich and adds the amount of Action Taken When the DTC Sets
time it took to complete all transitions. With this
The PCM will illuminate the malfunction indicator lamp
information, an average time for all transitions can be (MIL) after the second consecutive trip in which the
determined. The PCM then divides the rich-to-lean fault is detected.
average by the lean-to-rich average to obtain a ratio. If ”Open loop” fuel control will be in effect.
the HO2S transition time ratio is not within this range, The PCM will store conditions which were present
DTC P1154 will be set, indicating that the oxygen sensor when the DTC was set as Freeze Frame and in the
is not responding as expected to changes in exhaust Failure Records data.
oxygen content.
Conditions for Clearing the MIL/DTC
Conditions for Setting the DTC
DTC P1154 can be cleared by using Tech 2 “Clear Info”
No related DTCs. function or by disconnecting the PCM battery feed.
Engine coolant temperature (ETC) is above 50 C
(122 F) for automatic transmission; 75 C (167 F) for Diagnostic Aids
manual transmission. A multifunction in the HO2S heater ignition feed or ground
The engine is operating in “closed loop.” circuit may cause a DTC P1154 to set. Check HO2S
The engine has been running at least one minute. heater circuitry for intermittent faults or poor connections.
Canister purge duty cycle is greater than 2%. If connections and wiring are OK and DTC P1154
Engine speed is between 1500 RPM and 3000 RPM. continues to set, replace the Bank 2 HO2S 1.
Mass air flow is between 9 g/second and 42 g/second. Reviewing the Failure Records vehicle mileage since the
diagnostic test last failed may help determine how often
6E–242 ENGINE DRIVEABILITY AND EMISSIONS
the condition that caused the DTC to be set occurs. This 5. This step checks for conditions which may cause the
may assist in diagnosing the condition. heated oxygen sensor to appear faulty. Correct any
of the described conditions if present.
Test Description 8. To avoid damaging replacement sensors, correct the
Number(s) below refer to the step number(s) on the condition which caused the contamination before
Diagnostic Chart. replacing the affected sensors.
3. A condition that affects other heated oxygen sensors
indicates probable contamination. To avoid
damaging replacement sensors, correct the
condition which caused the contamination before
replacing the affected sensors.

DTC P1154 – HO2S Transition Time Ratio Bank 2 Sensor 1


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 IMPORTANT: If any other DTCs are set (except P1133
and/or P1134), refer to those DTCs before proceeding
with this diagnostic chart.
1. Idle the engine at operating temperature.
2. Operate the vehicle within parameters specified
under “Conditions for Setting the DTC” criteria
included in Diagnostic Support.
3. Using a Tech 2, monitor “Specific DTC” info for DTC
P1154 until the DTC P1154 test runs.
Refer to
Note the test result.
Diagnostic
Does Tech 2 indicate DTC failed this ignition? — Go to Step 3 Aids
3 Did Tech 2 also indicate P1133, and/or P1134 test
failed? — Go to Step 17 Go to Step 4
4 Check for leaks at the pipe joints.
Are the joints leaking? — Go to Step 5 Go to Step 6
5 Tighten the U-bolt nuts at the leaking joints.
Is your action complete? — Go to Step 2 —
6 Check for gaskets that are damaged or improperly
installed.
Are there damaged or misaligned gaskets? — Go to Step 7 Go to Step 8
7 1. Replace the damaged gaskets.
2. Align the connections.
3. Tighten the connections.
Is your action complete? — Go to Step 2 —
8 Check for loose exhaust flange connections.
Are the flange connections loose? — Go to Step 9 Go to Step 10
9 Tighten the stud nuts or bolts to specifications.
Is your action complete? — Go to Step 2 —
10 Check for burned or corroded exhaust pipes.
Are the exhaust pipes burned or corroded? — Go to Step 11 Go to Step 12
11 Replace the exhaust pipes, as required.
Is your action complete? — Go to Step 2 —
ENGINE DRIVEABILITY AND EMISSIONS 6E–243

DTC P1154 – HO2S Transition Time Ratio Bank 2 Sensor 1


Step Action Value(s) Yes No
12 Check for leaks at the exhaust manifold.
Are there leaks at the exhaust manifold? — Go to Step 13 Go to Step 14
13 Tighten the bolts to specifications or replace the
manifold if necessary.
Is your action complete? — Go to Step 2 —
14 Visually/physically inspect the following items:
Ensure that the Bank 2 HO2S 1 is securely
installed.
Check for corrosion on terminals.
Check terminal tension (at Bank 2 HO2S 1 and at
the PCM).
Check for damaged wiring.
Was a problem found in any of the above areas? — Go to Step 18 Go to Step 15
15 1. Disconnect Bank 1 HO2S 1.
2. Ignition “ON.”
3. Using a DVM at the PCM side of the HO2S 1
connector, measure the voltage between the high
signal circuit and ground.
Also measure the voltage between the low signal
circuit and ground.
Go to Step
Are both voltages in the specified range? 3-4 V 16 Go to Step 19
16 1. With Bank 1 HO2S 1 disconnected, jumper the high
and low (PCM side) signal circuits to ground.
2. Ignition “ON.”
3. Using Tech 2, monitor the Bank 2 HO2S 1 voltage.
Does the scan too indicate less than 10 mV and
immediately return to about 450 mV when the jumper is
removed? — Go to Step 21 Go to Step 22
17 Replace affected heated oxygen sensors.
NOTE: Before replacing sensors, the cause of the
contamination must be determined and corrected.
Fuel contamination.
Use of improper RTV sealant.
Engine oil/coolant consumption.
Is the action complete? — Verify repair —
18 Repair condition as necessary.
Is the action complete? — Verify repair —
19 Check for faulty PCM connections or terminal damage.
Is the action complete? — Verify repair Go to Step 20
20 Repair open, short or grounded signal circuit.
Is the action complete? — Verify repair —
6E–244 ENGINE DRIVEABILITY AND EMISSIONS

DTC P1154 – HO2S Transition Time Ratio Bank 2 Sensor 1


Step Action Value(s) Yes No
21 Replace Bank 2 HO2S 1.
Is the action complete? — Verify repair —
22 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–245

Diagnostic Trouble Code (DTC) P1171 Fuel System Lean During Acceleration

060RW193–1

Circuit Description Engine is operating in “closed loop power enrichment”


mode for 3 seconds.
The powertrain control module (PCM) internal circuitry
can identify if the vehicle fuel system is capable of Engine coolant temperature is above 60 C (140 F).
supplying adequate amounts of fuel during heavy While in “power enrichment” mode the oxygen sensor
acceleration (power enrichment). The PCM monitors the voltage remains below 400 mV for 3 seconds.
voltage of the oxygen sensor during power enrichment.
Action Taken When the DTC Sets
When a power enrichment mode of operation is
requested during “closed loop” operation (by heavy The PCM will illuminate the malfunction indicator lamp
acceleration), the PCM will provide more fuel to the (MIL) the first the fault is detected.
engine. Under these conditions the PCM should detect a The PCM will store conditions which were present
“rich” condition (high oxygen sensor voltage). If this “rich” when the DTC was set as Freeze Frame and in the
Failure Records data.
exhaust is not detected at this time, a DTC P1171 will set.
A plugged fuel filter, restricted fuel line, restricted in-tank Conditions for Clearing the MIL/DTC
filter or defective fuel pump can prevent adequate
amounts of fuel from being supplied during power DTC P1171 can be cleared by using Tech 2 “Clear Info”
enrichment mode. function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC Diagnostic Aids


No related DTCs. A restricted fuel filter or fuel line, restricted in-tank filter,
or a defective fuel pomp may supply adequate
6E–246 ENGINE DRIVEABILITY AND EMISSIONS
amounts of fuel at idle, but may not be able to supply 4. When the engine is idling or at steady cruise, the
enough fuel during heavy acceleration. HO2S voltage should vary from between
Water or alcohol in the fuel may cause low HO2S approximately 100 mV to 900 mV. It is possible to
voltage during acceleration. measure a satisfactory fuel pressure at idle even
Check for faulty or plugged fuel injector(s). though the pressure may drop at high flow
Check for low fuel. requirements. It may be necessary to watch fuel
pressure at high engine load.
Test Description 5. Wrap a shop towel around the fuel pressure
Number(s) below refer to the step number(s) on the connector to absorb any small amount of fuel
Diagnostic Chart. leakage that may occur when installing gauge.
Ignition “ON,” pump pressure should be 280-320
kPa.

DTC P1171 – Fuel System Lean During Acceleration


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 Are any component-related DTCs set? Go to
component
— DTC charts Go to Step 3
3 1. Check the vehicle’s fuel tank for an adequate
amount of fuel.
2. Add fuel to the vehicle’s fuel tank if the tank is almost
empty.
Was fuel added to the vehicle’s fuel tank? — Go to Step 4 Go to Step 5
4 1. Place the transmission in park.
2. Using Tech 2, observe HO2S 1 voltage while
running warm engine 75 C-95 C (167 F-203 F) at
1200 RPM.
3. HO2S 1 voltage should vary within the specified
range.
4. Quickly open the throttle halfway for a few seconds.
Did the voltage suddenly rise toward the high end of the Go to Chart
specified range? 100-900 mV A-7 Go to Step 5
5 1. Disconnect the fuel pump relay and crank the
engine to relieve the fuel pressure.
2. Install the fuel pressure gauge.
3. Start the engine and idle at normal operating
temperature.
4. Disconnect the vacuum line going to the fuel
pressure regulator. Go to OBD
With the engine running, is the fuel pressure within the 280-325 kPa System
specified range? (41-46 psi) Check Go to Step 6
6 Check for restricted fuel lines or restricted in-line filter.
Was a problem found? — Verify repair Go to Step 7
ENGINE DRIVEABILITY AND EMISSIONS 6E–247

DTC P1171 – Fuel System Lean During Acceleration


Step Action Value(s) Yes No
7 1. Ignition “OFF.”
2. Remove the fuel pump relay and replace it with a
fused jumper which will connect the relay’s battery
terminal to the terminal leading to the fuel pump
fuse.
3. While the fuel pump is operating, use pliers to slowly
close the return line (do not exceed the first
specified value). 414 kPa
Using the pliers to restrict the return line, can the fuel (60 psi) Go to
pressure be manipulated to exceed the second 325 kPa Diagnostic
specified value? (46 psi) Aids Go to Step 8
8 Check for:
Faulty fuel pump
Restricted fuel pump strainer (sock)
Incorrect fuel pump
Incorrect fuel being used
Hot fuel
Is the action complete? — Verify repair —
6E–248 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1380 ABS Rough Road ABS System Fault
Circuit Description Conditions for Clearing the MIL/DTC
The powertrain control module (PCM) monitors ABS fault A history DTC P1380 will clear after 40 consecutive
signal. When PCM receives fault signal, PCM will set warm-up cycles have occurred without a fault.
DTC P1380. DTC 1380 can be cleared by using Tech-2 or
disconnecting the PCM battery feed.
Conditions for Setting the DTC
Vehicle speed is more than 5 mph. Diagnostic Aids
Load is less than 99%. Check for the following conditions:
Engine revolution is less than 6250 rpm. PCM and ABS communication line short circuit to other
line may cause faulty signal. Inspect communication
PCM receives ABS fault signals from ABS unit. line.
Ignition on. Follow ABS ECU diagnosis procedure, refer to ABS
Misfire DTCs exist. procedure page.
100 test failures within 120 test samples.

Action Taken When the DTC Sets


The PCM will store DTC 1380 only, no MIL turn on.

DTC P1380 – ABS Rough Road ABS System Fault


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Ignition “ON,” engine “OFF”, review and record
Tech 2 Failure Records Data.
2. Operate the vehicle within Failure Records Refer to ABS
conditions as noted. diagnosis
3. Using a Tech 2, monitor “Specific DTC” info for DTC After inspect
P1380 and Misfire DTCs until the DTC P1380 and ABS, unit re-
peat Step 2
Misfire DTCs test runs. Note the result.
Still problem
Does the Tech 2 indicates DTC P1380 and Misfire exists, go to Clear DTC by
DTCs failed this ignition? — Step 3 Tech 2
3 Check short circuit among communication line of
PCM/ABS and others. Repair wiring
Was short circuit? — Verify repair Go to Step 4
4 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–249

Diagnostic Trouble Code (DTC) P1404 EGR Closed Stuck

D06RW106

Circuit Description The PCM will store conditions which were present
when the DTC was set as Freeze Frame and in Failure
The powertrain control module (PCM) monitors the EGR Records data.
valve pintle position input to ensure that the valve
responds properly to commands from the PCM, and to Conditions for Clearing the MIL/DTC
detect a fault if current pintle zero position is different from
the learned zero position. If the PCM detects a pintle DTC P1404 can be cleared by using the Tech 2 “Clear
Info” function or by disconnecting the PCM battery
position signal indicates more than 30 % different feed.
between current zero position and the learned zero
position and more than 5 seconds, and this condition Diagnostic Aids
meet 3 times during trip, then the PCM will set DTC
Check for the following conditions:
P1404.
Excessive carbon deposit on EGR valve shaft or/and
Conditions for Setting the DTC foreign material may cause no return to EGR valve
fully seated. Those carbon deposit may occur by
Ignition voltage is between 11 and 16 volts. unusual port operation. Remove foreign material
Intake Air temp is more than 3 C. or/and excessive carbon deposit on EGR valve shaft
may make return to EGR valve fully seated.
Desire EGR position is 0.
Poor connection or damaged harness – Inspect the
Difference EGR pintle position between current and wiring harness for damage. Same as P1406
the learned zero is more than 30 % last more than 5 description
seconds, and meet three time to the above condition Reviewing the Failure Records vehicle mileage since the
during a trip. Then it trigger the PCM lights on.
diagnostic test last failed may help determine how often
Action Taken When the DTC Sets the condition that caused the DTC to be set occurs. This
may assist in diagnosing the condition.
The PCM will illuminate the malfunction indicator lamp
(MIL) after consecutive 2nd trip in which the fault is
detected.
6E–250 ENGINE DRIVEABILITY AND EMISSIONS

DTC P1404 – EGR Closed Stuck


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Ignition “ON,” engine “OFF”, review and record
Tech 2 Failure Records Data.
2. Operate the vehicle within Failure Records
conditions as noted.
3. Using a Tech 2, monitor “DTC inf. for DTC P1404
until the DTC P1404 test runs. Note the result. Refer to
Does the Tech 2 indicates DTC P1404 failed this Diagnostic
ignition? — Go to Step 3 Aids
3 1. Disconnect the EGR valve harness connector.
2. Inspect the EGR valve and connectors for damaged
pin or terminals.
Were there any damaged pins or terminals? — Go to Step 4 Go to Step 5
4 Repair the damaged pin or terminal.
Is the action complete? — Verify repair —
5 1. Remove EGR valve from Engine.
2. Inspect EGR valve whether there is any excessive
carbon deposit on EGR shaft.
3. Inspect any foreign material inside of EGR valve.
Was excessive carbon deposit on EGR valve shaft
or/and foreign material in EGR valve ? — Go to Step 6 Go to Step 7
6 1. Clean up EGR valve shaft and inside of EGR valve.
2. Remove foreign material from EGR valve.
3. Visually inspect damage of pintle and seat whether
there is bent, leakage may occur. Verify repair
Was there any severe damage which affects function? 3–6 ohms Go to Step 8 Go to Step 7
7 1. Reconnect.
2. Ignition “OFF”.
3. Install the Tech 2.
4. Run the engine at idle.
5. On the Tech 2, select F3:Misc. Test F5:EGR.
6. Use the “UP” arrow to increase the EGR from 0% to
40%.
Did EGR work properly? — — Go to Step 8
8 1. Reset the learned zero EGR valve position.
2. Repeat step 7.
Did EGR work properly? — Verify repair Go to Step 9
9 Replace the EGR valve.
Replace the EGR valve. Does DTC P1404 still fail
“specific DTC” test on the Tech 2? — Go to Step 10 Verify repair
10 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–251

Diagnostic Trouble Code (DTC) P1508 IAC System Low RPM

T321115

Circuit Description The throttle is closed.


The powertrain control module (PCM) controls engine Engine speed is lower than desired idle.
idle speed by adjusting the position of the idle air control All of the above conditions are met for 10 seconds.
(IAC) motor pintle. The IAC is a bi-directional stepper
motor driven by two coils. The PCM applies current to the Action Taken When the DTC Sets
IAC coils in steps (counts) to extend the IAC pintle into a The PCM will illuminate the malfunction indicator lamp
passage in the throttle body to decrease air flow. The (MIL) after the second consecutive trip in which the
PCM reverses the current to retract the pintle, increasing fault is detected.
air flow. This method allows highly accurate control of idle The PCM will store conditions which were present
speed and quick response to changes in engine load. If when the DTC was set as Freeze Frame and in the
the PCM detects a condition where too low of an idle Failure Records data.
speed is present and the PCM is unable to adjust idle
speed by increasing the IAC counts, DTC P1508 will set,
Conditions for Clearing the MIL/DTC
indicating a problem with the idle control system. DTC P1508 can be cleared by using the Tech 2 “Clear
Info” function or by disconnecting the PCM battery
Conditions for Setting the DTC feed.
No Tech 2 test is being run. Diagnostic Aids
None of these DTCs are set: TP sensor, VSS, ECT, Check for the following conditions:
EGR, fuel system, MAF, MAP, IAT, canister purge,
injector control or ignition control. Poor connection at PCM or IAC motor – Inspect
harness connectors for backed-out terminals,
Barometric pressure is above 75 kPa. improper mating, broken locks, improperly formed or
Engine coolant temperature (ECT) is above 50 C damaged terminals, and poor terminal-to-wire
(120 F). connection.
Engine speed is more than 100-200 RPM lower than Damaged harness – Inspect the wiring for damage.
desired idle, based upon coolant temperature. Restricted air intake system – Check for a possible
The engine has been running for at least 125 seconds. collapsed air intake duct, restricted air filter element,
Vehicle speed is less than 1 mph. or foreign objects blocking the air intake system.
Canister purge duty cycle is above 10%. Throttle body – Check for objects blocking the IAC
Ignition voltage is between 9.5 volts and 16.7 volts. passage or throttle bore, excessive deposits in the IAC
6E–252 ENGINE DRIVEABILITY AND EMISSIONS
passage and on the IAC pintle, and excessive deposits Reviewing the Failure Records vehicle mileage since the
in the throttle bore and on the throttle plate. diagnostic test last failed may help determine how often
Large vacuum leak – Check for a condition that causes the condition that caused the DTC to be set occurs. This
a large vacuum leak, such as an incorrectly installed or may assist in diagnosing the condition.
faulty PCV valve or a disconnected brake booster
hose.

DTC P1508 – IAC System Low RPM


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Start the engine.
2. Turn all accessories “OFF”(A/C, rear defroster,
etc).
3. Using a Tech 2, command RPM up to 1500, down to
500, and the up to 1500 while monitoring the
“Engine Speed” on the Tech 2.
NOTE: This Tech 2 command may cause the engine to
“cut out” when RPM goes above 1500. If this occurs,
the “cutting out” will stop when the Tech 2 command for
the test is discontinued, or if the Tech 2 command is
changed to less than 1500 RPM. No trouble
found. Go to
Does the “Engine Speed” remain within the specified Diagnostic
value of the “Desired Idle” for each RPM command? 50 RPM Aids Go to Step 3
3 1. Disconnect the IAC.
2. Install IAC Node Light 5-8840-2312-0 or equivalent.
3. With the engine running, command RPM up to
1500, down to 500, and then up to 1500 while
observing the node light.
NOTE: This Tech 2 command may cause the engine to
“cut out” when RPM goes above 1500. If this occurs,
the “cutting out” will stop when the Tech 2 command for
the test is discontinued, or if the Tech 2 command is
changed to less than 1500 RPM.
Does each node light cycle red and green (never
“OFF”)? — Go to Step 5 Go to Step 4
4 1. Check the following circuits for an open, short to
voltage, short ground, or poor connections at the
PCM:
IAC “A” Low.
IAC “A” High.
IAC “B” Low.
IAC “B” High.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 8
ENGINE DRIVEABILITY AND EMISSIONS 6E–253

DTC P1508 – IAC System Low RPM


Step Action Value(s) Yes No
5 Visually/physically inspect for following conditions:
Restricted air intake system. Check for a possible
collapsed air intake duct, restricted air filter
element, or foreign objects blocking the air intake
system.
Throttle body. Check for objects blocking the IAC
passage or throttle bore, excessive deposits in
Refer to
the IAC passage and on the IAC pintle, and
appropriate
excessive deposits in the throttle bore and on the
section for
throttle plate.
on-vehicle
Do any of the above require a repair? — service Go to Step 6
6 1. Check for a poor connection at the IAC harness
connector.
2. If a problem is found, replace faulty terminals as
necessary.
Was a problem found? — Verify repair Go to Step 7
7 Replace the IAC valve.
Is the action complete? — Verify repair —
8 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
6E–254 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1509 IAC System High RPM

T321115

Circuit Description All of the above conditions are met for 5 seconds.
The powertrain control module (PCM) controls engine
idle speed by adjusting the position of the idle air control
Action Taken When the DTC Sets
(IAC) motor pintle. The IAC is a bi-directional stepper The PCM will illuminate the malfunction indicator lamp
motor driven by two coils. The PCM applies current to the (MIL) after the second consecutive trip in which the
IAC coils in steps (counts) to extend the IAC pintle into a fault is detected.
passage in the throttle body to decrease air flow. The The PCM will store conditions which were present
PCM reverses the current to retract the pintle, increasing when the DTC was set as Freeze Frame and in the
Failure Records data.
air flow. This method allows highly accurate control of idle
speed and quick response to changes in engine load. If Conditions for Clearing the MIL/DTC
the PCM detect a condition where too high of an idle
speed is present and the PCM is unable to adjust idle DTC P1509 can be cleared by using the Tech 2 “Clear
Info” function or by disconnecting the PCM battery
speed by increasing the IAC counts, DTC P1509 will set, feed.
indicating a problem with the idle control system.
Diagnostic Aids
Conditions for Setting the DTC
Check for the following conditions:
No Tech 2 test is being run. Poor connection at PCM or IAC motor – Inspect
None of these DTCs are set: TP sensor, VSS, ECT, harness connectors for backed-out terminals,
EGR, fuel system, MAF, MAP, IAT, canister purge, improper mating, broken locks, improperly formed or
injector control or ignition control. damaged terminals, and poor terminal-to-wire
Barometric pressure is above 75 kPa. connection.
Engine coolant temperature is above 50 C (120 F). Damaged harness – Inspect the wiring for damage.
Engine speed is more than 100-200 RPM lower than Vacuum leak – Check for a condition that causes a
desired idle, based upon coolant temperature. vacuum leak, such as disconnected or damaged
The engine has been running for at least 125 seconds. hoses, leaks at the EGR valve and the EGR pipe to the
intake manifold, leaks at the throttle body, faulty or
Vehicle speed is less than 1 mph. incorrectly installed PCV valve, leaks at the intake
Canister purge duty cycle is above 10%. manifold, etc.
Ignition voltage is between 9.5 volts and 16.7 volts.
Engine speed is lower than desired idle.
ENGINE DRIVEABILITY AND EMISSIONS 6E–255
Throttle body – Check for sticking throttle plate. Also the condition that caused the DTC to be set occurs. This
inspect the IAC passage for deposits or objects which may assist in diagnosing the condition.
keep the IAC pintle from fully extending.
Reviewing the Failure Records vehicle mileage since the
diagnostic test last failed may help determine how often

DTC P1509 – IAC System High RPM


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Start the engine.
2. Turn all accessories “OFF” (A/C, rear defroster,
etc.).
3. Using a Tech 2, command RPM up to 1500, down to
500, and then up to 1500 while monitoring “Engine
Speed” on the Tech 2.
NOTE: This Tech 2 command may cause the engine to
“cut out” when RPM goes above 1500. If this occurs,
the “cutting out” will stop when the Tech 2 command for
the test is discontinued, or if the Tech 2 command is
changed to less than 1500 RPM. No trouble
found. Go to
Does the “Engine Speed” remain within the specified Diagnostic
value of “Desired Idle” for each RPM command? 50 RPM Aids Go to Step 3
3 1. Disconnect the IAC.
2. Install IAC Node Light 5-8840-2312-0 or equivalent.
3. With the engine running, command RPM up to
1500, down to 500, and then up to 1500 while
observing the node light.
NOTE: This Tech 2 command may cause the engine to
“cut out” when RPM goes above 1500. If this occurs,
the “cutting out” will stop when the Tech 2 command for
the test is discontinued, or if the Tech 2 command is
changed to less than 1500 RPM.
Does each node light cycle red and green (never
“OFF”)? — Go to Step 5 Go to Step 4
4 1. Check the following circuits for an open, short to
voltage, short ground, or poor connections at the
PCM:
IAC “A” Low
IAC “A” High
IAC “B” Low
IAC “B” High
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 8
5 Visually/physically inspect for following conditions:
Vacuum leaks.
Throttle plate or throttle shaft for binding.
Accelerator and cruise control cables for being
misadjusted or for binding. Refer to
appropriate
Faulty, missing, or incorrectly installed PCV
section for
valve.
on-vehicle
Do any of the above require a repair? — service Go to Step 6
6E–256 ENGINE DRIVEABILITY AND EMISSIONS

DTC P1509 – IAC System High RPM


Step Action Value(s) Yes No
6 1. Check for a poor connection at the IAC harness
connector.
2. If a problem is found, replace faulty terminals as
necessary.
Was a problem found? — Verify repair Go to Step 7
7 Replace the IAC valve.
Is the action complete? — Verify repair —
8 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed, Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–257

Diagnostic Trouble Code (DTC) P1618 Serial Peripheral Interface (SPI) PCM
Interprocessor Communication Error
Circuit Description Check sum fault present for 3 out 6 seconds.
The serial peripheral interface (SPI) communication is No TCM resets for 2 seconds.
used internally by the PCM to send messages between
the engine processor and the automatic transmission Action Taken When the DTC Sets
processor. Included in each message sent between the The PCM will flash the “Check Trans” lamp the first
two-processors is a checksum of the message. Both the time the fault is detected.
engine processor and automatic transmission processor The PCM will store conditions which were present
will compare this check sum value with the calculated when the DTC was set as Freeze Frame and in the
value. If the checksums don’t match, the processor will Failure Records data.
view the new data as being corrupted and ignore the The automatic transmission will operate in the “safety
values. The processor will then use the previous mode” to protect the mechanical parts of the
transmission. Shift quality and/or gear changes may
message. The receiving processor will then send a not be normal.
message to the sending processor informing it that it’s
last message was corrupted. Conditions for Clearing the MIL/DTC
Conditions for Setting the DTC DTC P1618 can be cleared by using the Tech 2 “Clear
Info” function or by disconnecting the PCM battery
Battery voltage is above 9.0 V for 2 seconds. feed.
The PCM detects an internal program fault (check sum
of data communications error).

DTC P1618 – Serial Peripheral Interface (SPI) PCM Interprocessor


Communication Error
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 Is the EEPROM calibration the latest version
available? — Go to Step 4 Go to Step 3
3 Reprogram the PCM with the latest available
calibrations.
Does DTC 1618 re-appear when the OBD System Repair
Check is repeated? — Go to Step 4 completed
4 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
6E–258 ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset


Circuit Description
The powertrain control module (PCM) monitors
unexpected PCM reset. This will not turn on MIL light on,
only records code DTC P1625.

Conditions for Setting the DTC


Clock or COP reset.

Action Taken When the DTC Sets


The PCM will not illuminate the malfunction indicator
lamp (MIL).
The PCM will store conditions which were present
when the DTC was set as Failure Records only. This
information will not be stored as Freeze Frame data.

Conditions for Clearing the MIL/DTC


DTC P1625 can be cleared by using the Tech 2 “Clear
Info” function or by disconnecting the PCM battery
feed.

Diagnostic Aids
Check for the following conditions:
P1625 alone stored does not need diagnosis. Clear
DTC code.
ENGINE DRIVEABILITY AND EMISSIONS 6E–259

Diagnostic Trouble Code (DTC) P1640 Driver-1-Input High Voltage


Circuit Description Diagnostic Aids
Output driver modules (ODMs) are used by the Check for the following conditions:
powertrain control module (PCM) to turn “ON” many of Poor connection at PCM – Inspect harness connectors
the current-driven devices that are needed to control for backed-out terminals, improper mating, broken
various engine and transmission functions. Each ODM is locks, improperly formed or damaged terminals, and
capable of controlling up to 7 separate outputs by poor terminal-to-wire connection.
applying ground to the device which the PCM is Damaged harness – Inspect the wiring harness for
commanding “ON.” damage, If the harness appears to be OK, disconnect
Unlike the Quad Driver Modules (QDMs) used in prior the PCM, turn the ignition “ON” and observe a
voltmeter connected to the suspect driver circuit at the
model years, ODMs have the capability of diagnosing PCM harness connector while moving connectors and
each output circuit individually. DTC P1640 set indicates wiring harnesses relates to the MIL. A change in
an improper voltage level has been detected on an ODM voltage will indicate the location of the fault.
output. Poor connection at component – Examine for
Since A/C is an option, No A/C will cause the air damaged connectors, unplugged connector, or
conditioning clutch relay output to always fault. If a fault is damaged terminals at the following locations:
seen on the air conditioning clutch relay output, it will not Instrument cluster harness, canister purge solenoid,
be logged as a fault until the A/C request input interrupts a A/C clutch relay. An open ignition feed circuit at any of
these components will cause DTC P1640 to be set.
high voltage, indicating that A/C has been installed.
Reviewing the Failure Records vehicle mileage since the
Conditions for Setting the DTC diagnostic test last failed may help determine how often
the condition that caused the DTC to be set occurs. This
Ignition “ON.” may assist in diagnosing the condition.
Engine running. The following PCM pins are controlled by output driver
No DTC 1618. modules (ODMs):
Ignition voltage is above 13.2 volts for 4 seconds. A13 – “Check Engine Lamp”
Output voltage does not equal ignition voltage when A14 – SVS (”Check Trans”)
output is “OFF” or output voltage is not less than 1 volt B14 – A/C Clutch
when output is “ON.”
Above conditions occur for at least 1 second. Test Description
Number(s) below refer to the step number(s) on the
Action Taken When the DTC Sets
Diagnostic Chart.
The PCM will not illuminate the malfunction indicator 6. The Tech 2 Driver Module Status indicates the PCM
lamp (MIL).
pin that is affected.
The PCM will store conditions which were present
when the DTC was set as Failure Records only. This 11. The Tech 2 may indicate “short circuit” even when
information will not be stored as Freeze Frame data. the problem is an open circuit. The cause of an
open circuit may be in the component itself-lamp,
Conditions for Clearing the MIL/DTC purge, solenoid, or A/C compressor relay.
DTC P1640 can be cleared by using the Tech 2 “Clear 13.A short to ground on the ignition side of the
Info” function or by disconnecting the PCM battery component will blow the fuse. Since the fuse was
feed. checked in Step 4, a short to ground would be
between the affected component and the PCM.
6E–260 ENGINE DRIVEABILITY AND EMISSIONS

DTC P1640 – Driver-1-Input High Voltage


Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
— Go to Step 2 Check
2 1. Ignition “ON,”engine “OFF.”
2. Install the Tech 2.
3. Review and record Tech 2 Failure Records data.
4. Operate the vehicle within Failure Records
conditions as noted.
5. Use the Tech 2 to indicate DTC P1640.
Does the Tech 2 indicate DTC P1640? — Go to Step 3 —
3 Check the fuse for the driver circuit that was shown as
faulty.
Was the fuse blown? — Go to Step 4 Go to Step 5
4 1. Check for a short to ground between the fuse and
the affected component.
2. Replace the fuse after making any necessary
repairs.
Is the action complete? — Verify repair —
5 Disconnect the PCM connector for the affected driver
circuit.
Is there any damage to the PCM pin or connector? — Go to Step 6 Go to Step 7
6 Repair the damaged pin or terminal.
Is the action complete? — Verify repair —
7 Were either of the lamp circuits for “Check Engine” or
“Check Trans.” indicated as faulty by the Tech 2? — Go to Step 8 Go to Step 14
8 1. Leave the PCM connector for the lamp driver circuit
disconnected.
2. Ignition “ON.”
3. Using a DVM, check the voltage at the PCM
connector for the affected lamp driver circuit.
Was the voltage equal to the specified value? B+ Go to Step 16 Go to Step 9
9 1. Ignition “ON.”
2. Check for battery voltage at the fuse for the affected
lamp circuit.
Was battery voltage available at the fuse? — Go to Step 11 Go to Step 10
10 Repair the open circuit between the ignition switch and
the fuse.
Is the action complete? — Verify repair —
11 1. Ignition “OFF.”
2. Disconnect the PCM connector for the affected
driver terminal.
3. Connect an ohmmeter between a good ground and
the PCM connector for the affected driver.
Did the ohmmeter indicate continuity? — Go to Step 12 Go to Step 13
12 Repair the short to ground between the affected
component and is PCM driver terminal.
Is the action complete? — Verify repair —
ENGINE DRIVEABILITY AND EMISSIONS 6E–261

DTC P1640 – Driver-1-Input High Voltage


Step Action Value(s) Yes No
13 Repair the open circuit between the fuse and the PCM
driver terminal for the affected circuit.
Is the action complete? — Verify repair —
14 1. Connect the PCM.
2. Start the engine and let it idle.
3. Backprobe the affected terminal at the PCM with a
DVM.
Was the voltage equal to the specified value? +B Go to Step 16 Go to Step 15
15 1. Run the engine at idle.
2. Check for battery voltage at the fuse for the affected
circuit.
Was battery voltage available at the fuse? — Go to Step 11 Go to Step 10
16 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to UBS 98model year Immobilizer
Workshop Manual.
Is the action complete? — Verify repair —
6E–262 ENGINE DRIVEABILITY AND EMISSIONS

Symptom Diagnosis intermittent condition. Use the following feature to find


intermittent faults:
Using Tech 2’s “Freeze Frame” buffer or “Failure
Preliminary Checks Records” buffer can aid in locating an intermittent
Before using this section, perform the “On-Board condition. Review and record the information in the
Diagnostic (OBD) System Check” and verify all of the freeze frame or failure record associated with the
following items: intermittent DTC being diagnosed. The vehicle can be
The powertrain control module (PCM) and malfunction driven within the conditions that were present when the
indicator lamp (MIL) (Service Engine Soon lamp) are DTC originally set.
operating correctly. To check for loss of diagnostic code memory, disconnect
There are no DTC(s) stored. the MAP sensor and idle the engine until the MIL (Service
Tech 2 data is within normal operating range. Refer to Engine Soon lamp) comes on. DTC P0107 should be
Typical Scan Data Values. stored and kept in memory when the ignition is turned
Verify the customer complaint and locate the correct “OFF.” If not, the PCM is faulty. When this test is
symptom in the table of contents. Perform the completed, make sure that you clear the DTC P0107 from
procedure included in the symptom chart. memory.
An intermittent MIL (Service Engine Soon lamp) with no
Visual/Physical Check stored DTC may be caused by the following:
Several of the symptom procedures call for a careful Ignition coil shorted to ground and arcing at ignition
visual/physical check. This can lead to correcting a wires or plugs.
problem without further checks and can save valuable MIL (Service Engine Soon lamp) wire to PCM shorted
time. to ground.
This check should include the following items: Poor PCM grounds. Refer to the PCM wiring
PCM grounds for cleanliness, tightness and proper diagrams.
location. Check for improper installation of electrical options such
Vacuum hoses for splits, kinks, and proper as lights, cellular phones, etc. Route ignition coil wiring
connections, as shown on the “Vehicle Emission away from the ignition coils. Check all wires from the
Control Information” label. Check thoroughly for any PCM to the ignition coil for poor connections.
type of leak or restriction. Check for an open diode across the A/C compressor
Air intake ducts for collapsed or damaged areas. clutch and check for other open diodes (refer to wiring
diagrams in Electrical Diagnosis).
Air leaks at throttle body mounting area, mass air flow
(MAF) sensor and intake manifold sealing surfaces. If problem has not been found, refer to PCM Connector
Symptom tables.
Ignition wires for cracking, hardness, and carbon
tracking.
Wiring for proper connections, pinches and cuts.

Intermittents
IMPORTANT: An intermittent problem may or may not
turn on the malfunction indicator lamp (MIL) or store a
DTC. DO NOT use the Diagnostic Trouble Code (DTC)
charts for intermittent problems. The fault must be
present to locate the problem.
Most intermittent problems are caused by faulty electrical
connections or wiring. Perform a careful visual/physical
check for the following conditions:
Poor mating of the connector halves or a terminal not
fully seated in the connector (backed out).
Improperly formed or damaged terminal.
All connector terminals in the problem circuit should be
carefully checked for proper contact tension.
Poor terminal-to-wire connection. This requires
removing the terminal from the connector body to
check.
Road test the vehicle with a J 39200 Digital Multimeter
connected to a suspected circuit. An abnormal voltage
when the malfunction occurs is a good indication that
there is a fault in the circuit being monitored.
Use Tech 2 to help detect intermittent conditions. Tech 2s
have several features that can be used to locate an
ENGINE DRIVEABILITY AND EMISSIONS 6E–263

Hard Start Symptom


Step Action Value(s) Yes No
1 DEFINITION: Engine cranks, but does not start
for a long time. Does eventually run, or may start
but immediately stalls. Go to OBD
Was the “On-Board Diagnostic (OBD) System Check” System
performed? — Go to Step 2 Check
2 1. Perform a bulletin search.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found that addresses the symptom? — Verify repair Go to Step 3
3 Was a visual/physical check performed? Go to
Visual/Physic
— Go to Step 4 al Check
4 Check engine coolant temperature (ECT) sensor for
shift in value. After 8 hours with the hood up and the
engine not running, connect Tech 2. With the ignition
“ON” and the engine not running, compare engine
coolant temperature to intake air temperature.
Are ECT and IAT within the specified value of each
other? 5 C ( 9 F) Go to Step 8 Go to Step 5
5 1. Using Tech 2, display the engine coolant
temperature and note the value.
2. Check the resistance of the engine coolant
temperature sensor.
3. Refer to Engine Coolant Temperature Sensor
Temperature vs. Resistance chart on DTC P0118
Diagnostic Support for resistance specifications.
Is the resistance value near the resistance for the
temperature noted? — Go to Step 7 Go to Step 6
6 Replace the ECT sensor.
Is the action complete? — Verify repair —
7 Locate and repair high resistance or poor connection in
the ECT signal circuit or the ECT sensor ground.
Is the action complete? — Verify repair —
8 1. Check for a faulty, plugged, or incorrectly installed
PCV valve.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 9
9 1. Check for water- or alcohol-contaminated fuel.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 10
10 1. Perform the procedure in Fuel System Pressure
Test.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 11
11 1. Check for proper ignition voltage output with spark
tester J 26792 (ST-125). Refer to Electric Ignition
System for procedure.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 12
6E–264 ENGINE DRIVEABILITY AND EMISSIONS

Hard Start Symptom


Step Action Value(s) Yes No
12 1. Remove spark plugs. Check for wet plugs, cracks,
wear, improper gap, burned electrodes, or heavy
deposits. Refer to Electronic Ignition System.
NOTE: If spark plugs are gas or oil fouled, the cause of
the fouling must be determined before replacing the
spark plugs.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 13
13 1. Check for a loose ignition coil ground.
Refer to Electronic Ignition System.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 14
14 1. Remove the ignition coils and check the ignition
coils for cracks or carbon tracking.
2. If a problem is found, replace affected coil(s) as
necessary.
Was a problem found? — Verify repair Go to Step 15
15 1. Check IAC operation. Perform the procedure in the
DTC P0506, Step 6 diagnostic table.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 16
16 1. Check for the following engine mechanical
problems (refer to Engine Mechanical):
Low compression
Leaking cylinder head gaskets
Worn or incorrect camshaft
Camshaft drive belt slipped or stripped
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 17
17 1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:
Visual/physical inspection
Tech 2 data
Freeze Frame data/Failure Records buffer
All electrical connections within a suspected
circuit and/or system.
Contact
3. If a problem is found, repair as necessary. Technical
Was a problem found? — Verify repair Assistance
ENGINE DRIVEABILITY AND EMISSIONS 6E–265

Surges and/or Chuggles Symptom


Step Action Value(s) Yes No
1 DEFINITION:
Engine power variation under steady throttle or cruise.
Feels like the vehicle speeds up and slows down with
no change in the accelerator pedal.
Go to OBD
Was the “On-Board Diagnostic (OBD) System Check” System
performed? — Go to Step 2 Check
2 1. Perform a bulletin search.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found that addresses the symptom? — Verify repair Go to Step 3
3 Was a visual/physical check performed? Go to
Visual/Physic
— Go to Step 4 al Check
4 Be sure that the driver understands transmission
torque converter clutch and A/C compressor operation
as explained in the owner’s manual.
Inform the customer how the TCC and the A/C clutch
operate.
Is the customer experiencing a normal condition? — System OK Go to Step 5
5 1. Check the the fuel control heated oxygen sensors
(HO2S, B1S1 and B2S1). The fuel control heated
oxygen sensors (HO2S) should respond quickly to
different throttle positions. If they don’t, check them
for silicon or other contaminants from fuel or use of
improper RTV sealant. The sensors may have a
white powdery coating.
Silicon contamination causes a high but false
HO2S signal voltage (rich exhaust indication).
The PCM will then reduce the amount of fuel
delivered to the engine, causing a severe
driveability problem. For more information, refer
to Powertrain Control Module (PCM) and Sensors.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 6
6 1. Check the fuel pressure. Refer to Fuel System
Pressure Test.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 7
7 Monitor the long term fuel trim on Tech 2.
Is the long term fuel trim significantly in the negative
range (rich condition)? — Go to Step 8 Go to Step 9
8 1. Check items that can cause the engine to run rich.
Refer to Diagnostic Aids in DTC P0172 Diagnostic
Support.
2. If a problem is found, repair as necessary.
Was a problem found? — Go to Step 10 Verify repair
9 1. Check items that can cause the engine to run lean.
Refer to Diagnostic Aids in DTC P0171.
2. If a problem is found, repair as necessary.
Was a problem found? — Go to Step 10 Verify repair
6E–266 ENGINE DRIVEABILITY AND EMISSIONS

Surges and/or Chuggles Symptom


Step Action Value(s) Yes No
10 1. Check for proper ignition voltage output with spark
tester J 26792 (ST-125). Refer to Electric Ignition
System for procedure.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 11
11 1. Check for a loose ignition coil ground.
Refer to Electric Ignition System.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 12
12 1. Check the ignition coils for cracks or carbon
tracking.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 13
13 1. Remove the spark plugs and check for wet plugs,
cracks, wear, improper gap, burned electrodes, or
heavy deposits. Refer to Electronic Ignition
System.
NOTE: If spark plugs are gas or oil fouled, the cause of
the fouling must be determined before replacing the
spark plugs.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 14
14 1. Check the injector connections.
2. If any of the injector connectors are connected to an
incorrect cylinder, correct as necessary.
Was a problem found? — Verify repair Go to Step 15
15 1. Check PCM grounds for the cleanliness, tightness
and proper locations. Refer to the PCM wiring
diagrams in Electrical Diagnosis.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 16
16 1. Check MAF sensor connections.
2. If a problem is found, replace the faulty terminals as
necessary. Refer to Electrical Diagnosis for wiring
repair procedures.
Was a problem found? — Verify repair Go to Step 17
17 1. Visually/physically check vacuum hoses for splits,
kinks, and proper connections and routing as
shown on the “Vehicle Emission Control
Information” label.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 18
ENGINE DRIVEABILITY AND EMISSIONS 6E–267

Surges and/or Chuggles Symptom


Step Action Value(s) Yes No
18 1. Check the exhaust system for possible restriction:
Inspect the exhaust system for damaged or
collapsed pipes.
Inspect the muffler for heat distress or possible
internal failure.
Check for a possible plugged three-way
catalytic converter by checking the exhaust
system back pressure. Refer to Restricted
Exhaust System Check.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 19
19 1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:
Visual/physical inspection
Tech 2 data
Freeze Frame data/Failure Records buffer
All electrical connections within a suspected
circuit and/or system.
Contact
3. If a problem is found, repair as necessary. Technical
Was a problem found? — Verify repair Assistance
6E–268 ENGINE DRIVEABILITY AND EMISSIONS

Lack of Power, Sluggish or Spongy Symptom


Step Action Value(s) Yes No
1 DEFINITION:
Engine delivers less than expected power. Little or no
increase in speed when accelerator pedal is pushed
down part-way.
Go to OBD
Was the “On-Board Diagnostic (OBD) System Check” System
performed? — Go to Step 2 Check
2 1. Perform a bulletin search.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found that addresses the symptom? — Verify repair Go to Step 3
3 Was a visual/physical check performed? Go to
Visual/Physic
— Go to Step 4 al Check
4 1. Remove and check the air filter element for dirt or
restrictions. Refer to Air Intake System in
ON-Vehicle Service.
2. Replace the air filter element if necessary.
Was a repair required? — Verify repair Go to Step 5
5 1. Check for low fuel pressure. Refer to Fuel System
Pressure Test.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 6
6 1. Check for water- or alcohol-contaminated fuel.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 7
7 1. Using Tech 2, monitor the knock sensor (KS)
system for excessive spark retard activity. Refer to
Knock Sensor (KS) System.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 8
8 1. Check for proper ignition voltage output with spark
tester J 26792 (ST-125). Refer to Electronic Ignition
System for procedure.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 9
9 1. Remove the spark plugs and check for wet plugs,
cracks, wear, improper gap, burned electrodes, or
heavy deposits. Refer to Electronic Ignition
System.
NOTE: If spark plugs are gas or oil fouled, the cause of
the fouling must be determined before replacing the
spark plugs.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 10
10 1. Check the ignition coils for cracks or carbon
tracking.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 11
ENGINE DRIVEABILITY AND EMISSIONS 6E–269

Lack of Power, Sluggish or Spongy Symptom


Step Action Value(s) Yes No
11 1. Check the PCM grounds for the cleanliness,
tightness and proper locations. Refer to the PCM
wiring diagrams in Electrical Diagnosis.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 12
12 1. Check the exhaust system for possible restriction:
Inspect the exhaust system for damaged or
collapsed pipes.
Inspect the muffler for heat distress or possible
internal failure.
Check for a possible plugged three-way
catalytic converter by checking the exhaust
system back pressure. Refer to Restricted
Exhaust System Check.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 13
13 1. Check the torque converter clutch (TCC) for proper
operation. Refer to 4L30-E Transmission
Diagnosis.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 14
14 1. Check for an engine mechanical problem. Check
for low compression, incorrect or worn camshaft,
loose timing belt, etc. Refer to Engine Mechanical.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 15
15 1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:
Visual/physical inspection
Tech 2 data
Freeze Frame data/Failure Records buffer
All electrical connections within a suspected
circuit and/or system.
Contact
3. If a problem is found, repair as necessary. Technical
Was a problem found? — Verify repair Assistance
6E–270 ENGINE DRIVEABILITY AND EMISSIONS

Detonation/Spark Knock Symptom


Step Action Value(s) Yes No
1 DEFINITION:
A mild to severe ping, usually worse under acceleration.
The engine makes sharp metallic knocks that change
with throttle opening.
Go to OBD
Was the “On-Board Diagnostic (OBD) System Check” System
performed? — Go to Step 2 Check
2 1. Perform a bulletin search.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found that addresses the symptom? — Verify repair Go to Step 3
3 Was a visual/physical check performed? Go to
Visual/Physic
— Go to Step 4 al Check
4 If Tech 2 readings are normal (refer to Typical Scan
Values) and there are no engine mechanical faults, fill
the fuel tank with a known quality gasoline that has a
minimum octane rating of 87 and re-evaluate the
vehicle performance.
Is detonation present? — Go to Step 5 Verify repair
5 1. Check the transmission range switch circuit. Use
Tech 2 and be sure Tech 2 indicates that the vehicle
is in drive with the gear selector in drive or overdrive.
2. If a problem is found, diagnose and repair the
transmission range switch as necessary (refer to
4L30-E Automatic Transmission Diagnosis).
Was a problem found? — Verify repair Go to Step 6
6 1. Check TCC operation. Refer to 4L30-E
Transmission Diagnosis.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 7
7 1. Check for obvious overheating problems:
Low engine coolant.
Restricted air flow to radiator, or restricted
water flow through radiator.
Correct coolant solution should be a 50/50 mix
of approved antifreeze/coolant and water.
Refer to Engine Cooling.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 8
8 1. Check fuel pressure. Refer to Chart Fuel System
Pressure Test.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 9
9 1. Check items that can cause an engine to run lean
(long term fuel trim significantly in the positive
range). For a lean condition, refer to Diagnostic
Aids in DTC P0171 Diagnostic Support.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 10
ENGINE DRIVEABILITY AND EMISSIONS 6E–271

Detonation/Spark Knock Symptom


Step Action Value(s) Yes No
10 1. Spark plugs for proper heat range. Refer to General
Information.
2. If incorrect spark plugs are installed, replace spark
plugs as necessary.
Did any spark plugs require replacement? — Verify repair Go to Step 11
11 1. Remove excessive carbon buildup with a top engine
cleaner. Refer to instructions on the top engine
cleaner can.
2. Re-evaluate vehicle performance.
Is detonation still present? — Go to Step 12 Verify repair
12 1. Check for an engine mechanical problem. Perform
a cylinder compression check. Refer to Engine
Mechanical.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 13
13 1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:
Visual/physical inspection
Tech 2 data
Freeze Frame data/Failure Records buffer
All electrical connections within a suspected
circuit and/or system.
Contact
3. If a problem is found, repair as necessary. Technical
Was a problem found? — Verify repair Assistance
6E–272 ENGINE DRIVEABILITY AND EMISSIONS

Rough, Unstable, or Incorrect Idle, Stalling Symptom


Step Action Value(s) Yes No
1 DEFINITION:
Engine runs unevenly at idle. If severe, the engine or
vehicle may shake. Engine idle speed may vary in
RPM. Either condition may be severe enough to stall
the engine.
Go to OBD
Was the “On-Board Diagnostic (OBD) System Check” System
performed? — Go to Step 2 Check
2 1. Perform a bulletin search.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found that addresses the symptom? — Go to Step 13 Go to Step 3
3 Was a visual/physical check performed? Go to
Visual/Physic
— Go to Step 4 al Check
4 1. Check the PCM grounds for cleanliness, tightness
and proper routing. Refer to the PCM wiring
diagrams in Electrical Diagnosis.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 5
5 Observe the long term fuel trim on Tech 2.
Is the long term fuel trim significantly in the negative
range (rich condition)? — Go to Step 6 Go to Step 7
6 1. Check items that can cause the engine to run rich.
Refer to Diagnostic Aids in DTC P0172 Diagnostic
Support.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 9
7 Is the long term fuel trim significantly in the positive
range (lean condition)? — Go to Step 8 Go to Step 9
8 1. Check items that can cause the engine to run lean.
Refer to Diagnostic Aids in DTC P0171 Diagnostic
Support.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 9
9 1. Check for incorrect idle speed. Ensure that the
following conditions are present:
The engine is fully warm.
The accessories are “OFF.”
Between 10
2. Using Tech 2, monitor the IAC position. and 50
Is the IAC position within the specified values? counts Go to Step 11 Go to Step 10
ENGINE DRIVEABILITY AND EMISSIONS 6E–273

Rough, Unstable, or Incorrect Idle, Stalling Symptom


Step Action Value(s) Yes No
10 1. Visually/physically inspect for the following
conditions:
Restricted air intake system. Check for a
possible collapsed air intake duct, restricted
air filter element, or foreign objects blocking
the air intake system.
Throttle body. Check for objects blocking the
IAC passage or throttle bore, excessive
deposits in the IAC passage and on the IAC
pintle, and excessive deposits in the throttle
bore and on the throttle plate.
Large vacuum leak. Check for a condition that
causes a large vacuum leak, such as an
incorrectly installed or faulty crankcase
ventilation valve or a disconnected brake
booster hose.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 8
11 Check the injector connections. If any of the injectors
are connected to an incorrect cylinder, correct as
necessary.
Was a problem found? — Verify repair Go to Step 12
12 1. Perform the “Injector Coil/Balance Test” in Fuel
Metering System.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 13
13 1. Check for fuel in the pressure regulator vacuum
hose.
2. If fuel is present, replace the fuel pressure regulator
assembly. Refer to Fuel Metering System.
3. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 14
14 1. Check for proper ignition voltage output with spark
tester J 26792 (ST-125). Refer to Electronic Ignition
System for the procedure.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 15
15 1. Remove spark plugs. Check for wet plugs, cracks,
wear, improper gap, burned electrodes, or heavy
deposits. Refer to Electronic Ignition System.
NOTE: If spark plugs are gas or oil fouled, the cause of
the fouling must be determined before replacing the
spark plugs.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 16
16 1. Check for a loose ignition coil ground.
Refer to Electrical Ignition System.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 17
6E–274 ENGINE DRIVEABILITY AND EMISSIONS

Rough, Unstable, or Incorrect Idle, Stalling Symptom


Step Action Value(s) Yes No
17 1. Check ignition coils for cracks or carbon tracking.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 18
18 Using Tech 2, monitor the throttle position (TP) angle Refer to DTC
with the engine idling. P0123 for
further
Is the TP angle at the specified value and steady?
0% Go to Step 19 diagnosis
19 1. Check the positive crankcase ventilation (PCV)
valve for proper operation. Refer to Crankcase
Ventilation System.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 20
20 1. Check the transmission range switch circuit. Use
Tech 2 and be sure Tech 2 indicates that the vehicle
is in drive with the gear selector in drive or overdrive.
2. If a problem is found, diagnose and repair the
transmission range switch as necessary (refer to
4L30-E Automatic Transmission Diagnosis).
Was a problem found? — Verify repair Go to Step 21
21 1. Check for the following engine mechanical items.
Refer to Engine Mechanical for diagnosis
procedures:
EGR valve mounted backward. Compare with
a known-good vehicle.
Low compression
Sticking or leaking valves
Worn camshaft lobe(s)
Camshaft drive belt slipped or stripped
Incorrect valve timing
Worn rocker arms
Broken valve springs
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 22
22 1. Check for faulty motor mounts. Refer to Engine
Mechanical for inspection of mounts.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 23
23 1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:
Visual/physical inspection
Tech 2 data
Freeze Frame data/Failure Records buffer
All electrical connections within a suspected
circuit and/or system.
Contact
3. If a problem is found, repair as necessary. Technical
Was a problem found? — Verify repair Assistance
ENGINE DRIVEABILITY AND EMISSIONS 6E–275

Poor Fuel Economy Symptom


Step Action Value(s) Yes No
1 DEFINITION:
Fuel economy, as measured by an actual road test, is
noticeably lower than expected. Also, economy is
noticeably lower than it was on this vehicle at one time,
as previously shown by an actual road test.
(Non-standard tires will cause odometer readings to be
incorrect, and that may cause fuel economy to appear
poor when it is actually normal.)
Go to OBD
Was the “On-Board Diagnostic (OBD) System Check” System
performed? — Go to Step 2 Check
2 1. Perform a bulletin search.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found that addresses the symptom? — Verify repair Go to Step 3
3 Was a visual/physical check performed? Go to
Visual/Physic
— Go to Step 4 al Check
4 Check owner’s driving habits.
Is the A/C “ON” full time (defroster mode “ON”)?
Are tires at the correct pressure?
Are excessively heavy loads being carried?
Is acceleration too much, too often?
Was a problem found? — Go to Step 5 Go to Step 6
5 Review the items in Step 4 with the customer and
advise as necessary.
Is the action complete? — System OK —
6 1. Visually/physically check: Vacuum hoses for splits,
kinks, and improper connections and routing as
shown on the “Vehicle Emission Control
Information” label.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 7
7 1. Remove and check the air filter element for dirt or for
restrictions. Refer to Air Intake System.
2. Replace the air filter element if necessary.
Was a repair required? — Verify repair Go to Step 8
8 1. Remove spark plugs and check for wet plugs,
cracks, wear, improper gap, burned electrodes, or
heavy deposits. Refer to Spark Plug Replacement.
NOTE: If spark plugs are gas or oil fouled, the cause of
the fouling must be determined before replacing the
spark plugs.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 9
9 1. Check for low engine coolant level. Refer to Engine
Cooling.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 10
6E–276 ENGINE DRIVEABILITY AND EMISSIONS

Poor Fuel Economy Symptom


Step Action Value(s) Yes No
10 1. Check for an incorrect or faulty engine thermostat.
Refer to Engine Cooling.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 11
11 1. Check for low engine compression. Refer to Engine
Mechanical.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 12
12 1. Check the TCC operation. Refer to 4L30-E
Transmission Diagnosis.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 13
13 1. Check the exhaust system for possible restriction:
Inspect the exhaust system for damaged or
collapsed pipes.
Inspect the muffler for heat distress or possible
internal failure.
Check for a possible plugged three-way
catalytic converter by checking the exhaust
system back pressure. Refer to Restricted
Exhaust System Check.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 14
14 Check for proper calibration of the speedometer.
Does the speed indicated on the speedometer closely
match the vehicle speed displayed on Tech 2? — Go to Step 16 Go to Step 15
15 Diagnose and repair an inaccurate speedometer
condition as necessary. Refer to Vehicle Speed
Sensor in Electrical Diagnosis.
Was a problem found? — Verify repair —
16 1. Check the air intake system and the crankcase for
air leaks. Refer to Air Intake System and
Crankcase Ventilation System.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 17
17 1. Review all diagnostic procedures within this table.
2. When all procedures have been completed and no
malfunctions have been found, review/inspect the
following:
Visual/physical inspection
Tech 2 data
Freeze Frame data/Failure Records buffer
All connections within a suspected circuit
and/or system.
3. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 18
18 Perform the procedure in Fuel System Pressure Test. Contact
Technical
Was the fuel pressure normal?
— Assistance Verify repair
ENGINE DRIVEABILITY AND EMISSIONS 6E–277

Excessive Exhaust Emissions or Odors Symptom


Step Action Value(s) Yes No
1 DEFINITION:
Vehicle fails an emission test. Vehicle has excessive
“rotten egg” smell. (Excessive odors do not necessarily
indicate excessive emissions.)
Go to OBD
Was the “On-Board Diagnostic (OBD) System Check” System
performed? — Go to Step 2 Check
2 1. Perform a bulletin search.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found that addresses the symptom? — Go to Step 12 Go to Step 3
3 Was a thorough visual/physical check performed? Go to
Visual/Physic
— Go to Step 4 al Check
4 1. Check for vacuum leaks. Check vacuum lines,
intake manifold, throttle body, etc.
2. If a problem is found, repair as necessary.
Were any vacuum leaks located? — Go to Step 12 Go to Step 5
5 1. Check the fuel cap for proper installation.
2. Secure the fuel cap if necessary.
Was the fuel cap installed properly? — Go to Step 6 Go to Step 12
6 1. Check the fuel pressure. Perform the procedure in
Fuel System Pressure Test.
2. If a problem is found, repair as necessary.
Was a problem found? — Go to Step 12 Go to Step 7
7 1. Check for a faulty, plugged, or incorrectly installed
crankcase ventilation valve; also check the
crankcase ventilation system for plugging.
2. If a problem is found, repair as necessary.
Was a problem found? — Go to Step 12 Go to Step 8
8 1. Check the injector connections.
2. If any of the injectors are connected to an incorrect
cylinder, correct as necessary.
Was a problem found? — Go to Step 12 Go to Step 9
9 1. Perform the “Injector Coil/Balance Test” in Fuel
Metering System.
2. If a problem is found, repair as necessary.
Was a problem found? — Go to Step 12 Go to Step 10
10 1. Refer to Engine Cooling for cooling system
diagnosis.
2. If a problem is found, repair as necessary.
Was a problem found? — Go to Step 12 Go to Step 11
11 1. Remove excessive carbon buildup with a top engine
cleaner. Refer to the instructions on the top engine
cleaner can.
2. Perform the exhaust emission test.
Does the vehicle pass the test? — System OK Go to Step 13
12 Perform the exhaust emission test.
Does the vehicle pass the test? — System OK Go to Step 13
6E–278 ENGINE DRIVEABILITY AND EMISSIONS

Excessive Exhaust Emissions or Odors Symptom


Step Action Value(s) Yes No
13 Does the exhaust emission test indicate excessive CO
and HC levels or is long term fuel trim significantly in the
negative range (rich condition)? — Go to Step 14 Go to Step 15
14 1. Check items that can cause the engine to run rich.
Refer to Diagnostic Aids in DTC P0172 Diagnostic
Support. Make any necessary repairs.
2. Perform the exhaust emission test.
Does the vehicle pass the test? — System OK Go to Step 16
15 1. Check items that can cause the engine to run lean.
Refer to Diagnostic Aids in DTC P0171 Diagnostic
Support. Make any necessary repairs.
2. Perform the exhaust emission test.
Does the vehicle pass the test? — System OK Go to Step 16
16 1. Check the EGR system.
2. If a problem is found, repair as necessary.
Was a problem found? — Go to Step 12 Go to Step 17
17 1. Check for an engine mechanical problem.
Perform a cylinder compression check (refer to
Engine Mechanical).
2. If a problem is found, repair as necessary.
Was a problem found? — Go to Step 12 Go to Step 18
18 1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:
Visual/physical inspection
Tech 2 data
Freeze Frame data/Failure Records butter
All electrical connections within a suspected
circuit and/or system.
Contact
3. If a problem is found, repair as necessary. Technical
Was a problem found? — Verify repair Assistance
ENGINE DRIVEABILITY AND EMISSIONS 6E–279

Dieseling, Run-On Symptom


Step Action Value(s) Yes No
1 DEFINITION:
Engine continues to run after key is turned “OFF,” but
runs very rough. If engine runs smooth, check ignition
switch and adjustment.
Go to OBD
Was the “On-Board Diagnostic (OBD) System Check” System
performed? — Go to Step 2 Check
2 1. Perform a bulletin search.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found that addresses the symptom? — Verify repair Go to Step 3
3 Was a visual/physical check performed? Go to
Visual/Physic
— Go to Step 4 al Check
4 1. Check for a short between B+ and any of the ignition
feed circuits.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 5
5 1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:
Visual/physical inspection
Tech 2 data
Freeze Frame data/Failure Records butter
All electrical connections within a suspected
circuit and/or system
Contact
3. If a problem is found, repair as necessary. Technical
Was a problem found? — Verify repair Assistance
6E–280 ENGINE DRIVEABILITY AND EMISSIONS

Backfire Symptom
Step Action Value(s) Yes No
1 DEFINITION:
Fuel ignites in the intake manifold, or in the exhaust
system, making a loud popping noise. Go to OBD
Was the “On-Board Diagnostic (OBD) System Check” System
performed? — Go to Step 2 Check
2 1. Perform a bulletin search.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found that addresses the symptom? — Verify repair Go to Step 3
3 Was a visual/physical check performed? Go to
Visual/Physic
— Go to Step 4 al Check
4 1. Check for proper ignition voltage coil output with
spark tester 5-8840-0383-0. Refer to Electric
Ignition System for procedure.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 5
5 1. Remove spark plugs and check for wet plugs,
cracks, wear, improper gap, burned electrodes, or
heavy deposits. Refer to Electronic Ignition
System.
NOTE: If spark plugs are gas or oil fouled, the cause of
the fouling must be determined before replacing the
spark plugs. Refer to DTC P0172 to determine the
cause of a rich condition or Engine Mechanical for an oil
fouling condition.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 6
6 1. Visually/physically inspect the ignition coils for
cracks.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 7
7 1. Check for an intermittent ignition system
malfunction:
Intermittent CKP 58X signal.
Intermittent ignition feed circuit or sensor
ground circuit to the crankshaft position
sensor.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 8
8 1. Check the fuel pressure. Refer to Fuel System
Pressure Test.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 9
ENGINE DRIVEABILITY AND EMISSIONS 6E–281

Backfire Symptom
Step Action Value(s) Yes No
9 1. Check for the following engine mechanical
conditions.
Refer to Engine Mechanical for diagnosis
procedures:
Low compression
Sticking or leaking valves
Worn camshaft lobe(s)
Camshaft drive belt slipped or stripped
Incorrect valve timing
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 10
10 1. Check the intake and exhaust manifold(s) for
casting flash. Refer to Engine Mechanical.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 11
11 1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:
Visual/physical inspection
Tech 2 data
Freeze Frame data/Failure Records butter
All electrical connections within a suspected
circuit and/or system.
Contact
3. If a problem is found, repair as necessary. Technical
Was a problem found? — Verify repair Assistance
6E–282 ENGINE DRIVEABILITY AND EMISSIONS

Cuts Out, Misses Symptom


Step Action Value(s) Yes No
1 DEFINITION:
Steady pulsation or jerking that follows engine speed;
usually more pronounced as engine load increases. Go to OBD
Was the “On-Board Diagnostic (OBD) System Check” System
performed? — Go to Step 2 Check
2 1. Perform a bulletin search.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found that addresses the symptom? — Go to Step 13 Go to Step 3
3 Was a visual/physical check performed? Go to
Visual/Physic
— Go to Step 4 al Check
4 1. Check the PCM grounds for clearness, tightness
and proper routing. Refer to the PCM wiring
diagrams in Electrical Diagnosis.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 5
5 Observe the long term fuel trim on Tech 2.
Is the long term fuel trim significantly in the negative
range (rich condition)? — Go to Step 6 Go to Step 7
6 1. Check items that can cause the engine to run rich.
Refer to Diagnostic Aids in DTC P0172 Diagnostic
Support.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 9
7 Is the long term fuel trim significantly in the positive
range (lean condition)? — Go to Step 8 Go to Step 9
8 1. Check items that can cause the engine to run lean.
Refer to Diagnostic Aids in DTC P0171 Diagnostic
Support.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 9
9 1. Check for incorrect idle speed. Ensure that the
following conditions are present:
The engine is fully warm.
The accessories are “off.”
Between 5
2. Using Tech 2, monitor the IAC position. and 50
Is the IAC position within the specified values? counts Go to Step 11 Go to Step 10
ENGINE DRIVEABILITY AND EMISSIONS 6E–283

Cuts Out, Misses Symptom


Step Action Value(s) Yes No
10 1. Visually/physically inspect for the following
conditions:
Restricted air intake system. Check for a
possible collapsed air intake duct, restricted
air filter element, or foreign objects blocking
the air intake system.
Throttle body. Check for objects blocking the
IAC passage or throttle bore, excessive
deposits in the IAC passage and on the IAC
pintle, and excessive deposits in the throttle
bore and on the throttle plate.
Large vacuum leak. Check for a condition that
causes a large vacuum leak, such as an
incorrectly installed or faulty PCV valve or
brake booster hose disconnected .
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 8
11 Check the injector connections. If any of the injectors
are connected to an incorrect cylinder, correct as
necessary.
Was a problem found? — Verify repair Go to Step 12
12 1. Perform the “Injector Coil/Balance Test” in Fuel
Metering System.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 13
13 1. Check for fuel in the pressure regulator vacuum
hose.
2. If fuel is present, replace the fuel pressure regulator
assembly. Refer to Fuel Metering System.
3. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 14
14 1. Check for proper ignition voltage output with spark
tester J 26792 (ST-125). Refer to Electronic Ignition
System for the procedure.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 15
15 1. Remove spark plugs. Check for wet plugs, cracks,
wear, improper gap, burned electrodes, or heavy
deposits. Refer to Electronic Ignition System.
NOTE: If spark plugs are gas or oil fouled, the cause of
the fouling must be determined before replacing the
spark plugs.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 16
16 1. Check for a loose ignition coil ground.
Refer to Electronic Ignition System.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 17
6E–284 ENGINE DRIVEABILITY AND EMISSIONS

Cuts Out, Misses Symptom


Step Action Value(s) Yes No
17 1. Check ignition coils for cracks or carbon tracking.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 18
18 Using Tech 2, monitor the TP angle with the engine Refer to DTC
idling. P0123 for
further
Is the TP angle at the specified value and steady?
0% Go to Step 19 diagnosis
19 1. Check the PCV valve for proper operation. Refer to
Crankcase Ventilation System.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 20
20 1. Check the transmission range switch circuit. Use
Tech 2 and be sure Tech 2 indicates that the vehicle
is in drive with the gear selector in drive or overdrive.
2. If a problem is found, diagnose and repair the
transmission range switch as necessary (refer to
4L30-E Automatic Transmission Diagnosis).
Was a problem found? — Verify repair Go to Step 21
21 1. Check the following engine mechanical items.
Refer to Engine Mechanical for diagnosis
procedures:
Low compression
Sticking or leaking valves
Worn camshaft lobe(s)
Camshaft drive belt slipped or stripped
Incorrect valve timing
Worn rocker arms
Broken valve springs
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 22
22 1. Check for faulty motor mounts. Refer to Engine
Mechanical for inspection of mounts.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 23
23 1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:
Visual/physical inspection
Tech 2 data
Freeze Frame data/Failure Records butter
All electrical connections within a suspected
circuit and/or system
Contact
3. If a problem is found, repair as necessary. Technical
Was a problem found? — Verify repair Assistance
ENGINE DRIVEABILITY AND EMISSIONS 6E–285

Hesitation, Sag, Stumble Symptom


Step Action Value(s) Yes No
1 DEFINITION:
Momentary lack of response as the accelerator is
pushed down. Can occur at any vehicle speed. Usually
most pronounced when first trying to make the vehicle
move, as from a stop sign. May cause the engine to stall
if severe enough.
Go to OBD
Was the “On-Board Diagnostic (OBD) System Check” System
performed? — Go to Step 2 Check
2 1. Perform a bulletin search.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found that addresses the symptom? — Verify repair Go to Step 3
3 Was a visual/physical check performed? Go to
Visual/Physic
— Go to Step 4 al Check
4 1. Check the fuel control heated oxygen sensors
(HO2S, B1S1 and B2S1). The fuel control heated
oxygen sensors (HO2S) should respond quickly to
different throttle positions. If they don’t, check them
for silicon or other contaminants from fuel or use of
improper RTV sealant. The sensors may have a
white powdery coating.
Silicon contamination causes a high but false
HO2S signal voltage (rich exhaust indication).
The PCM will then reduce the amount of fuel
delivered to the engine, causing a severe
driveability problem. For more information, refer
to Powertrain Control Module (PCM) and Sensors.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 5
5 1. Check the fuel pressure. Refer to Fuel System
Pressure Test.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 6
6 Observe the TP angle display on Tech 2 while slowly
increasing throttle pedal.
Does the TP angle display steadily increase from 0% at
closed throttle to 100% at WOT? — Go to Step 7 Go to Step 18
7 Monitor the long term fuel trim on Tech 2.
Is the long term fuel trim significantly in the negative
range (rich condition)? — Go to Step 8 Go to Step 9
8 1. Check items that can cause the engine to run rich.
Refer to Diagnostic Aids in DTC P0172 Diagnostic
Support.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 10
9 1. Check items that can cause the engine to run lean.
Refer to Diagnostic Aids in DTC P0171 Diagnostic
Support.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 10
6E–286 ENGINE DRIVEABILITY AND EMISSIONS

Hesitation, Sag, Stumble Symptom


Step Action Value(s) Yes No
10 1. Check for proper ignition voltage output with spark
tester J 26792 (ST-125). Refer to Electronic Ignition
System for the procedure.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 11
11 1. Check for a loose ignition coil ground.
Refer to Electronic Ignition System.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 12
12 1. Check the ignition coils for cracks or carbon
tracking.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 13
13 1. Remove spark plugs and check for wet plugs,
cracks, wear, improper gap, burned electrodes, or
heavy deposits. Refer to Electronic Ignition
System.
NOTE: If spark plugs are gas or oil fouled, the cause of
the fouling must be determined before replacing the
spark plugs.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 14
14 1. Check the PCM grounds for clearness, tightness
and proper routing. Refer to the PCM wiring
diagrams in Electrical Diagnosis.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 15
15 1. Check the MAF sensor connections.
2. If a problem is found, replace the faulty terminals as
necessary. Refer to Electrical Diagnosis for wiring
repair procedures.
Was a problem found? — Verify repair Go to Step 16
16 1. Visually/physically check vacuum hoses for splits,
kinks, and proper connections and routing as
shown on the “Vehicle Emission Control
Information” label.
2. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 17
ENGINE DRIVEABILITY AND EMISSIONS 6E–287

Hesitation, Sag, Stumble Symptom


Step Action Value(s) Yes No
17 1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:
Visual/physical inspection
Tech 2 data
Freeze Frame data/Failure Records butter
All electrical connections within a suspected
circuit and/or system
Contact
3. If a problem is found, repair as necessary. Technical
Was a problem found? — Verify repair Assistance
18 Replace the TP sensor.
Is the action complete? — Verify repair —
6E–288 ENGINE DRIVEABILITY AND EMISSIONS

Default Matrix Table


Service Procedure Default Strategy
A referral strategy has been established to assist the
technician with additional information when the cause of
the failure cannot be determined. If no problem is found
after performing diagnostics, then refer to the default
matrix table for further diagnostic information.
Default Matrix Table

Strategy Based Diagnostic Charts Initial Diagnosis Default Section(s)


On-Board Diagnostic (OBD) System Vehicle does not enter diagnostics. Chassis Electrical
Check
On-Board Diagnostic (OBD) System Vehicle enters diagnostics and Ignition System Check
Check communicates with Tech 2. MIL is
“ON” in diagnostics. Engine does not
start and run.
On-Board Diagnostic (OBD) System Engine starts and runs, no PCM —
Check codes set. Customer complains of
vibration.
On-Board Diagnostic (OBD) System Engine starts and runs, no PCM Automatic Transmission
Check codes set. Customer complains of
harsh or soft shift, poor performance,
delayed or no engagement into drive
or reverse, transmission fluid leak,
transmission noise or vibration, or
improper TCC operation.
PCM Power and Ground Check On-Board Diagnostic (OBD) System Chassis Electrical
Check.
PCM Power and Ground Check On-Board Diagnostic (OBD) System Chassis Electrical
Check. PCM power and ground
circuits OK. Data link voltage
incorrect.
On-Board Diagnostic (OBD) System Engine starts and runs, no PCM Automatic Transmission
Check codes set. Customer complains of
harsh or soft shift, poor performance,
delayed or no engagement into drive
or reverse, transmission fluid leak,
transmission noise or vibration, or
improper TCC operation.

Symptoms Initial Diagnosis Default Section(s)


Intermittents 1. On-board Diagnostic (OBD) Chassis Electrical
system check.
2. Careful visual/physical
inspections.
Hard Starts 1. OBD system check. Engine Mechanical, Ignition
2. Sensors (ECT, MAP, MAF, TP) ; System Check, Exhaust System
MAP output chart. Diagnosis
3. Fuel system electrical test, fuel
system diagnosis.
4. Ignition system.
5. IAC system check.
Surges and/or Chuggles 1. OBD system check. Calibration ID “Broadcast
2. Heated oxygen sensors. Code”/Service Bulletins, Ignition
System Check, Generator
3. Fuel system diagnosis.
Output, Exhaust System
4. Ignition system. Diagnosis, 4L30-E System Test
ENGINE DRIVEABILITY AND EMISSIONS 6E–289

Symptoms Initial Diagnosis Default Section(s)


Lack of Power, Sluggish or Spongy 1. OBD system check. Refer to Exhaust System in
2. Fuel system diagnosis. Engine Exhaust, TCC Operation,
Calibration ID/Service Bulletins
3. Ignition system.
4. Knock sensor.
5. EGR operation.
6. EGR system check.
Detonation/Spark Knock 1. OBD system check. TCC operation, Cooling System,
2. Transmission range switch. Ignition System Check,
Calibration ID/Service Bulletins
3. EGR operation.
4. EGR system check.
5. TCC operation.
6. Fuel system diagnosis.
7. Ignition system.
8. Knock sensor.
Hesitation, Sag, Stumble 1. OBD system check. EGR Operation, EGR System
2. TP. Check, Generator Output
Voltage (refer to Chassis
3. MAP output check.
Electrical), Calibration ID/Service
4. Fuel system diagnosis. Bulletins, Ignition System Check
5. Fuel injector and fuel injector
balance test.
6. Ignition system.
Cuts Out, Misses 1. OBD system check. Ignition System Check
2. Cylinder balance test.
Rough, Unstable, or Incorrect Idle, 1. OBD system check. MAP Output Check, Throttle
Stalling 2. Fuel injector and fuel injector Linkage, IAC System Check,
balance test. EGR System Check, A/C Clutch
Control Circuit Diagnosis,
3. Ignition system.
Crankcase Ventilation System,
4. IAC operation. Calibration ID/Service Bulletins,
5. EGR operation. Generator Output Voltage (refer
to Chassis Electrical), Exhaust
Diagnosis
Poor Fuel Economy 1. OBD system check. TCC Operation, Exhaust System
2. Careful visual/physical inspection. (refer to Engine Exhaust)
3. Ignition system.
4. Cooling system.
Engine Cranks But Will Not Run 1. OBD system check. Fuel System Electrical
Diagnosis, Fuel System
Diagnosis, Fuel Injector and Fuel
Injector Balance Test.
Excessive Exhaust Emissions or 1. OBD system check. EGR System Check, Exhaust
Odors 2. Emission test. Diagnosis, Calibration ID/Service
Bulletins
3. Cooling system.
4. Fuel system diagnosis.
5. Fuel injector and fuel injector
balance test.
6. Crankcase ventilation system.
7. Ignition system.
8. MAP output check.
Dieseling, Run-On 1. OBD system check. —
2. Careful visual/physical inspection.
3. Fuel system diagnosis.
6E–290 ENGINE DRIVEABILITY AND EMISSIONS

Symptoms Initial Diagnosis Default Section(s)


Backfire 1. OBD system check. Exhaust System Diagnosis,
2. Ignition system. Intake Casting Flash, Ignition
System Check
3. Fuel system diagnosis.
4. Fuel injector and fuel injector
balance test.
5. EGR operation, EGR system
check.
Catalyst Monitor 1. OBD system check. Exhaust System
2. Careful visual/physical inspection.
3. Heated oxygen sensors.
Fuel Trim 1. OBD system check. Exhaust System Intake Air
2. Careful visual/physical inspection. System
3. Fuel system diagnosis.
4. Heated oxygen sensors, MAF
sensors.
Evaporative Emissions 1. OBD system check. —
2. Careful visual/physical inspection.
3. Fuel system diagnosis.
Heated Oxygen Sensors 1. OBD system check. Exhaust System
2. Careful visual/physical inspection.
ENGINE DRIVEABILITY AND EMISSIONS 6E–291

Camshaft Position (CMP) Inspection Procedure


Sensor 1. Inspect the sensor O-ring for cracks or leaks.
2. Replace the O-ring if it is worn or damaged.
Removal Procedure 3. Lubricate the new O-ring with engine oil.
1. Disconnect the negative battery cable. 4. Install the lubricated O-ring.
2. Remove the engine cover.
3. Remove the common chamber assembly. Installation Procedure
Refer to Common Chamber in Engine Mechanical. 1. Install the CMP sensor in the cylinder head.
2. Install the CMP sensor retaining bolt.
Tighten
Tighten the retaining screw to 9 Nꞏm (78 lb in.).
3. Connect the electrical connector to the CMP sensor.

014RW120

4. Disconnect the electrical connector to the CMP


sensor.

014RV053

4. Install the common chamber assembly.


Refer to Common Chamber in Engine Mechanical.

014RV053

5. Remove the CMP retaining bolt from the side of left


cylinder head.
6. Remove the CMP sensor from the cylinder head.

014RW106

5. Install the engine cover.


6. Connect the negative battery cable.
6E–292 ENGINE DRIVEABILITY AND EMISSIONS

Crankshaft Position (CKP)


Sensor
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the electrical connector to the CKP
sensor.
3. Remove one bolt and the CKP sensor from the right
side of the engine block, just behind the mount.
NOTE: Use caution to avoid any hot oil that might drip
out.

TS22909

3. Connect the electrical connector to the CKP sensor.


4. Connect the negative battery cable.
Engine Coolant Temperature
(ECT) Sensor
Removal Procedure
NOTE: Care must be taken when handling the engine
coolant temperature (ECT) sensor. Damage to the ECT
sensor will affect proper operation of the fuel injection
system.
TS22909 1. Disconnect the negative battery cable.
2. Drain the radiator coolant. Refer to Draining and
Inspection Procedure Refilling Cooling System in Engine Cooling.
1. Inspect the sensor O-ring for cracks or leaks. 3. Disconnect the electrical connector.
2. Replace the O-ring if it is worn or damaged.
3. Lubricate the new O-ring with engine oil.
4. Install the lubricated O-ring.

Installation Procedure
1. Install the CKP sensor in the engine block.
2. Install the CKP sensor mounting bolt.
Tighten
Tighten the mounting bolt to 9 Nꞏm (78 lb in.).

014RW127
ENGINE DRIVEABILITY AND EMISSIONS 6E–293
4. Remove the ECT sensor from the coolant crossover. 3. Connect the electrical connector.

014RW086 014RW085

4. Fill the radiator with coolant. Refer to Draining and


Installation Procedure Refilling Cooling System in Engine Cooling.
1. Apply sealer or the equivalent to the threads of the 5. Connect the negative battery cable.
ECT sensor.
2. Install the ECT sensor in the coolant crossover.
Heated Oxygen Sensor (HO2S)
Tighten Removal Procedure
Tighten the ECT sensor to 30 Nꞏm (22 lb ft.). 1. Disconnect the negative battery cable.
2. Locate the oxygen sensors.
Bank 1 sensor 1 is mounted on the right-hand front
exhaust pipe.

014RW086

TS22912
6E–294 ENGINE DRIVEABILITY AND EMISSIONS
Bank 2 sensor 1 is mounted on the exhaust pipe 4. Remove the sensor from the exhaust pipe.
ahead of the catalytic converter. Because of the expansion and contraction of the
metal in the exhaust system over time, this may be
difficult if the engine temperature is below 48 C
(120 F).

TS22914

3. Disconnect the pigtail from the wiring harness.

TS23739

Inspection Procedure
All two sensors are identical. Inspect each in the same
way.
1. Inspect the pigtail and the electrical connector for
grease, dirt, corrosion, and bare wires or worn
insulation.
2. Inspect the louvered end of the sensor for grease,
dirt, or other contaminations.

TS23739

IMPORTANT: The pigtail is permanently attached to


the sensor. Be careful not to pull the wires out.
NOTE: Do not use a torch to remove an HO2S unless the
sensor is being replaced. Using a torch could damage the
sensor.

TS23739
ENGINE DRIVEABILITY AND EMISSIONS 6E–295

Installation Procedure 4. Disconnect the electrical connector from the IAT


sensor.
IMPORTANT:
A special anti-seize compound, P/N 5613695, is used
on the HO2S threads. This compound consists of
glass beads suspended in a liquid graphite solution.
The graphite burns away with engine heat, but the
glass beads will remain, making the sensor easier to
remove.
New or service sensors will already have the
compound applied to the threads. If a sensor is
removed and is to be reinstalled for any reason, the
threads must have anti-seize compound applied.
1. Apply anti-seize compound or the equivalent to the
threads of the oxygen sensor, if necessary.
2. Install the oxygen sensor on the exhaust pipe in its
original position.
Tighten
Tighten the oxygen sensor to 55 Nꞏm (40 lb in.).

TS23741

5. Remove the IAT sensor from the intake air duct by


using a rocking motion while pulling the sensor.

Installation Procedure
1. Install the IAT sensor into the grommet in the intake
air duct.
2. Correct the IAT electrical connector.

TS23739

3. Connect the pigtail to the wiring harness.


4. Connect the negative battery cable.
Intake Air Temperature (IAT)
Sensor
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the engine cover TS23741

3. The IAT sensor is located in the intake air duct, behind 3. Install the engine cover.
the throttle body. 4. Connect the negative battery cable.
6E–296 ENGINE DRIVEABILITY AND EMISSIONS

Knock Sensor (KS) Installation Procedure


NOTE: Do not apply thread sealant to the sensor threads.
Removal Procedure The sensor is coated at the factory and applying
1. Disconnect the negative battery cable. additional sealant will affect the sensor’s ability to detect
2. Drain the cooling system. Refer to Draining and detonation.
Filling the Cooling System in Engine Cooling. 1. Screw the knock sensor into the engine block.
3. Remove the engine cover. Tighten
4. Remove the common chamber assembly. Tighten the knock sensor to 20 Nꞏm (177 lb in.).
Refer to Common Chamber in Engine Mechanical.

014RW103

014RW106 2. Connect the electrical connector to the knock sensor.


5. Disconnect the electrical connector from the knock 3. Install the common chamber assembly.
sensor.
Refer to Common Chamber in Engine Mechanical.

014RW103

6. Unscrew the knock sensor from the engine block. 014RW106

4. Install the engine cover.


5. Fill the cooling system.
Refer to Draining and Filling the Cooling System in
Engine Cooling.
6. Connect the negative battery cable.
ENGINE DRIVEABILITY AND EMISSIONS 6E–297

Mass Air Flow (MAF) Sensor 2. Install the intake air duct and the clamp on the MAF
sensor.
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the electrical connector from the MAF
sensor.

TS23781

3. Tighten the clamps to secure the MAF sensor to the


intake air duct and the air cleaner.
4. Connect the MAF electrical connector.
5. Connect the negative battery cable.
TS23740

3. Loosen the clamps which secure the intake air duct Manifold Absolute Pressure
and the air cleaner to the MAF sensor.
(MAP) Sensor
4. Remove the intake air duct from the MAF sensor.
5. Remove the MAF sensor from the air cleaner. Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the electrical connector from the MAP
sensor.

TS23781

Installation Procedure
1. Install the MAF sensor on the air cleaner with the 055RW005
clamp.
3. Remove the bolt securing the MAP sensor to the
mounting bracket on the common chamber.
6E–298 ENGINE DRIVEABILITY AND EMISSIONS
4. Remove the MAP sensor from the mounting bracket.

055RW005

055RW002 4. Connect the negative battery cable.

Installation Procedure Malfunction Indicator Lamp


1. Install the MAP sensor in the mounting bracket. (MIL)
Removal and Installation Procedure
Refer to Warning light bulb, indicator light valve,
illumination light bulb, A/T indicator light bulb in Meter and
Gauge.
Powertrain Control Module
(PCM)
Service Precaution
NOTE: To prevent possible electrostatic discharge
damage to the PCM, do not touch the connector pins or
soldered components on the circuit board.

Electrostatic Discharge (ESD)


Damage
Electronic components used in the control systems are
often designed to carry very low voltage. Electronic
055RW002 components are susceptible to damage caused by
2. Install the mounting bracket retaining bolt on the electrostatic discharge. Less than 100 volts of static
common chamber. electricity can cause damage to some electronic
3. Connect the MAP electrical connector. components. By comparison, it takes as much as 4,000
volts for a person to even feel the zap of a static
discharge.
There are several ways for a person to become statically
charged. The most common methods of charging are by
friction and by induction. An example of charging by
friction is a person sliding across a car seat.
Charging by induction occurs when a person with well
insulated shoes stands near a highly charged object and
momentarily touches ground. Charges of the same
polarity are drained off leaving the person highly charged
with the opposite polarity. Static charges can cause
ENGINE DRIVEABILITY AND EMISSIONS 6E–299
damage, therefore, it is important to use care when
handling and testing electronic components.
NOTE: To prevent possible Electrostatic Discharge
damage, follow these guidelines:
Do not touch the control module connector pins or
soldered components on the control module circuit
board.
Do not open the replacement part package until the
part is ready to be installed.
Before removing the part from the package, ground
the package to a known good ground on the vehicle.
If the part has been handled while sliding across the
seat, or while sitting down from a standing position, or
while walking a distance, touch a known good ground
before installing the part.
NOTE: To prevent internal PCM damage, the ignition
must be in the “OFF” position in order to disconnect or
reconnect power to the PCM (for example: battery cable,
PCM pigtail, PCM fuse, jumper cables, etc.). TS23755

IMPORTANT: When replacing the production PCM 2. Remove the transfer shift lever knob by
with a service PCM, it is important to transfer the unscrewing the knob.
broadcast code and production PCM number to the 3. Move the transmission gear selector out of the
service PCM label. This will allow positive identification of park position.
PCM parts throughout the service life of the vehicle. Do
not record this information on the metal PCM cover. 4. Lift up sharply on the back edge of the assembly.

IMPORTANT: The ignition should always be in the 5. Disconnect the seat heater switch connectors (if
“OFF” position in order to install or remove the PCM equipped).
connectors. 6. Disconnect the POWER and WINTER switch
Service of the PCM should normally consist of either re- connectors.
placement of the PCM or EEPROM programming. If the 7. Lift out the front console assembly.
diagnostic procedures call for the PCM to be replaced,
the PCM should be checked first to ensure it is the correct
part. If it is, remove the faulty PCM and install the new
service PCM.
The service PCM EEPROM will not be programmed.
DTC P0601 indicates the check sum error.

Removal Procedure
1. Disconnect the negative battery cable.
2. Block the wheels.
3. Remove the front console assembly.
1. Remove the four screws.

TS23756
6E–300 ENGINE DRIVEABILITY AND EMISSIONS
4. Disconnect the red, white, and blue electrical
connectors at the PCM.
EEPROM
5. Remove the two screws in the front of the PCM. General Description
6. Remove the one screw at the left rear of the PCM. The Electronically Erasable Programmable Read Only
7. Pull the PCM straight out from the dashboard. Memory (EEPROM) is a permanent memory that is
physically soldered within the PCM. The EEPROM
contains program and calibration information that the
PCM needs to control powertrain operation.

EEPROM Programming
1. Step-up – Ensure that the following conditions have
been met:
The battery is fully charged.
The ignition is “ON.”
The Vehicle Interface Module cable connection at
the DLC is secure.
2. Program the PCM using the latest software matching
the vehicle. Refer to up-to-date Techline equipment
user’s instructions.
3. If the PCM fails to program, Refer to UBS 98 model
year Immobilizer Workshop Manual.

TS23757
Functional Check
1. Perform the On-Board Diagnostic System Check.
Installation Procedure 2. Start the engine and run for one minute.
1. Insert the PCM into the dashboard. 3. Scan for DTCs using the Tech 2.
Line up the holes in front for the mounting screws.
2. Install the PCM with two screws in the front and one
Power Steering Pressure (PSP)
screw at the left rear. Switch
3. Plug the red, white, and blue connectors into the
appropriate sockets. General Description
The Power Steering Pressure (PSP) switch closes when
the hydraulic pressure reaches 3920 690 kPa (570
100 psi). This causes the PCM to actuate the idle air
control valve in order to prevent the additional load from
slowing down the engine. The switch opens when the
hydraulic pressure drops to 2970 560 kPa (430 80
psi).

Removal Procedure
1. Disconnect the PSP switch pigtail from the wiring
harness.
The pigtail is permanently attached to the switch.
Do not attempt to remove the wires from the
sensor.
Have a container ready to catch the power steering
fluid that leaks out of the line when the switch is
removed.

TS23757
ENGINE DRIVEABILITY AND EMISSIONS 6E–301
2. Remove the PSP switch from the power steering line. 3. Remove the bolts and the TP sensor from the throttle
Plug the line to prevent excessive loss of fluid and body.
possible contamination of the power steering
system.

TS23747

NOTE: Do not clean the TP sensor by soaking it in


TS23760 solvent. The sensor will be damaged as a result.

Installation Procedure Function Check


1. Install the PSP switch in the power steering line. Use a Tech 2 to check the TP sensor output voltage at
closed throttle.
The voltage should be under 0.85 volt.
If the reading is greater than 0.85 volt, check the
throttle shaft to see if it is binding. Check that the
throttle cable is properly adjusted, also. Refer to
Throttle Cable Adjustment.
If the throttle shaft is not binding and the throttle cable
is properly adjusted, install a new TP sensor.

Installation Procedure
1. Install the TP sensor on the throttle body with the
bolts.

TS23760

2. Connect the PSP switch pigtail to the wiring harness.


3. Check the power steering fluid level. Refer to Power
Steering.
4. Start the engine. Watch the PSP switch for signs of
fluid leakage.
Throttle Position (TP) Sensor
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the TPS electrical connector.
TS23747
6E–302 ENGINE DRIVEABILITY AND EMISSIONS
2. Connect the TP electrical connector. 4. Remove the VSS from the transfer case by wiggling it
3. Install the negative battery cable. slightly and pulling it straight out.

Vehicle Speed Sensor (VSS) Inspection Procedure


1. Inspect the electrical connector for signs of corrosion
Removal Procedure or warping. Replace the VSS if the electrical
connector is corroded or warped.
CAUTION: The VSS is located on the right side of
the transfer case just ahead of the rear propeller 2. Inspect the VSS driven gear for chips, breaks, or worn
shaft and very close to the exhaust pipes. Be sure condition. Replace the VSS if the driven gear is
that the exhaust pipes are cool enough to touch chipped, broken or worn.
before trying to remove the VSS. If the pipes are hot, 3. Inspect the O-ring for wear, nicks, tears, or
you could be burned. looseness. Replace the O-ring if necessary.
1. Disconnect the negative battery cable.
Installation Procedure
2. Disconnect the VSS electrical connector.
1. Install the VSS in the transfer case with the notch for
the connector facing the rear.
2. Secure the VSS in place with the clamp and the bolt.
Tighten
Tighten the bolt to 16 Nꞏm (12 lb ft.).

TS23748

3. Remove the bolt and the clamp securing the VSS in


place.
IMPORTANT: Have a container ready to catch any fluid
that leaks out when the VSS is removed from the transfer
case. TS23780

3. Connect the VSS electrical connector.

TS23780

TS23748
ENGINE DRIVEABILITY AND EMISSIONS 6E–303
4. Check the transfer case oil level. Add fluid if 5. Remove the retaining bolts and the air cleaner
necessary. housing from the vehicle.
5. Connect the negative battery cable.
Air Cleaner/Air Filter
Removal Procedure
1. Loosen the clamp between the air cleaner lid and the
mass air flow sensor.
2. Release the four latches securing the lid to the air
cleaner housing.
3. Remove the air cleaner lid.

130RT002

Installation Procedure
1. Install the air cleaner housing in the vehicle with the
retaining bolts.

TS23973

4. Remove the air filter element.

130RT002

TS23794
6E–304 ENGINE DRIVEABILITY AND EMISSIONS
2. Install the air filter element in the air cleaner housing.

TS23745

TS23794

3. Install the air cleaner lid on the MAF sensor and the air Cleaning, Inspection, and
cleaner housing. Measurement Procedure
Clean the IAC valve O-ring sealing surface, pintle
valve seat and air passage.
– Use carburetor cleaner and a parts cleaning brush to
remove carbon deposits. Do not use a cleaner that
contains methyl ethyl ketone. This is an extremely
strong solvent and not necessary for this type of
deposit.
– Shiny spots on the pintle are normal and do not
indicate misalignment or a bent pintle shaft.
– If the air passage has heavy deposits, remove the
throttle body for complete cleaning.

TS23973

4. Tighten the clamp and secure the four latches


between the lid and the air cleaner housing.
Idle Air Control (IAC) Valve
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the IAC electrical connector.
3. Remove the bolts and the IAC valve from the throttle
body.
NOTE: Do not clean the IAC valve by soaking it in TS23746

solvent. The valve will be damaged as a result. Inspect the IAC valve O-ring for cuts, cracks, or
distortion. Replace the O-ring if damaged.
ENGINE DRIVEABILITY AND EMISSIONS 6E–305
In order to install a new IAC valve, measure the 2. Connect the IAC valve electrical connector.
distance between the tip of the pintle and the 3. Install the negative battery cable.
mounting flange. If that measurement is 28 mm (1.1
in.) or less, the valve needs no adjustment. If the Common Chamber
measurement is greater than 28 mm (1.1 in.), apply
finger pressure and retract the valve. The force Removal and Installation Procedure
required to retract the pintle on a new valve will not
damage the valve, shaft, or pintle. Refer to Common Chamber in Engine Mechanical.

NOTE: Do not push or pull on the IAC valve pintle on IAC Accelerator Cable Assembly
valves that have been in service. The force required to
move the pintle may damage it. Removal Procedure
IMPORTANT: Use an identical replacement part in 1. Remove the engine cover.
order to replace a valve. IAC valve pintle shape and 2. Loosen the adjusting nut on the cable bracket
diameter are designed for the specific application. mounting on the common chamber.

TS23746 101RW005

3. Remove the accelerator control cable (on the throttle


Installation Procedure valve end).
1. Install the IAC valve on the throttle body with the bolts.
Tighten
Tighten the bolts to 1 Nꞏm (9 lb in.).

101RW006

TS23745
6E–306 ENGINE DRIVEABILITY AND EMISSIONS
4. Remove the accelerator control cable (on the Installation Procedure
accelerator pedal end).
1. Install the accelerator control cable.

TS23982

5. Remove the grommet. TS23983

2. Install the grommet.


6. Remove the accelerator control cable.
3. Install the accelerator control cable (on the
accelerator pedal end).

TS23983

TS23982

Inspection Procedure
Check the following items, and replace the control cable if
any abnormality is found:
The control cable should move smoothly.
The control cable should not be bent or kinked.
The control cable should be free of damage and
corrosion.
ENGINE DRIVEABILITY AND EMISSIONS 6E–307
4. Install the accelerator control cable (on the throttle Adjustment Procedure
valve end).
1. Loosen the adjusting nut and lock nut.
2. Pull outer cable closing fully the throttle valve.
3. Tighten adjusting nut and lock nut temporarily.

101RW006

5. Install the adjusting nut.

035RW004

4. Loosen adjusting nut by three turns and tighten lock


nut. Then, manually operating the throttle valve,
make sure that the valve lever returns up to the
stopper screw.
IMPORTANT: The valve lever must return up to the
stopper screw. If the valve lever does not reach the
stopper screw, repeat the procedure again from step 1.
5. It does not reach the stopper screw, repeat from step
1.

101RW007

6. Adjust the accelerator cable at the throttle body.


Refer to Accelerator Cable Adjustment.
7. Install the engine cover.

TS23782
6E–308 ENGINE DRIVEABILITY AND EMISSIONS

Accelerator Pedal Replacement 3. Disconnect the wiring harness from the kick-down
switch.
Removal Procedure
1. Disconnect the cruise control cable from the
accelerator pedal assembly.

TS24038

4. Remove the two screws from the accelerator pedal


assembly.

TS24053

2. Disconnect the accelerator pedal control cable from


the accelerator pedal assembly.

TS24055

5. Remove the accelerator pedal assembly from the


bulkhead.

TS24054
ENGINE DRIVEABILITY AND EMISSIONS 6E–309

Installation Procedure 4. Connect the accelerator pedal control cable to the


accelerator pedal assembly.
1. Install the accelerator pedal assembly on the
bulkhead.
2. Install the two screws to the accelerator pedal
assembly.

TS24054

5. Connect the cruise control cable to the accelerator


pedal assembly.

TS24055

3. Connect the wiring harness to the kick-down switch.

TS24053

TS24038
6E–310 ENGINE DRIVEABILITY AND EMISSIONS

Pedal Stroke Adjustment Procedure If high vacuum or high pressure occurs in the fuel tank,
each valve works to adjust the pressure in order to
1. Loosen the jam nut and rotate the kick-down switch prevent damage to the tank at the EGR valve.
counterclockwise.

TS23767

TS24039

2. Fully depress the pedal and hold it by hand. Rotate Inspection Procedure
the switch clockwise until the switch clicks.
NOTE: Replace the fuel filler cap with the same type of
3. Rotate the switch 1/2 turn further and lock it in this
filler cap that was originally installed on the vehicle.
position by tightening the jam nut.
Check the seal ring in the filler cap for any abnormality
and for seal condition.
Replace the filler cap if any abnormality is found.
Fuel Filter
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the fuel filler cap.

TS24040

4. Step on the accelerator pedal and make sure there is


a clicking sound at the full-stroke position.
Fuel Filter Cap
General Description
The fuel filler cap includes a vacuum valve and a pressure
valve.
041RW005
ENGINE DRIVEABILITY AND EMISSIONS 6E–311
3. Disconnect the fuel line from the fuel filter on the 6. Remove the fuel filter.
engine side.
4. Disconnect the fuel line from the fuel filter on the fuel
tank side.

041RW008

Inspection Procedure
041RW006
1. Replace the fuel filter when the following occur:
5. Remove the bolt on the fuel filter holder. Fuel leaks from the fuel filter body.
The fuel filter body is damaged.
The fuel filter is clogged with dirt or sediment.
2. If the drain hole is clogged, clean the drain.

041RW007

041RW009
6E–312 ENGINE DRIVEABILITY AND EMISSIONS

Installation Procedure 3. Connect the fuel line on the engine side.


4. Connect the fuel line on the fuel tank side.
1. Install the fuel filter in the correct direction.

041RW006
041RW008
5. Install the fuel filler cap.
2. Install the bolt on the fuel filter holder.

041RW005
041RW007
6. Connect the negative battery cable.
ENGINE DRIVEABILITY AND EMISSIONS 6E–313

Fuel Gauge Unit 5. Remove the fuel gauge unit retaining screws.
6. Remove the fuel gauge unit.
Removal Procedure Cover or plug the fuel tank to prevent dust, dirt, or
debris from entering the tank.
1. Disconnect the negative battery cable.
2. Loosen the fuel filler cap.
3. Drain the fuel from the tank.
Tighten
Tighten the drain plug to 20 Nꞏm (14 lb ft.).

TS22911

Installation Procedure
1. Install the fuel gauge unit.
2. Install the fuel gauge unit retaining screws.
TS22907

4. Disconnect the wiring connector from the fuel gauge


unit.

TS22911

TS23771
6E–314 ENGINE DRIVEABILITY AND EMISSIONS
3. Connect the wiring connector to the fuel gauge unit.

014RW164

TS23771 4. Remove the injector retainer clip.


4. Fill the fuel tank with fuel.
Tighten the fuel filler cap.
Check for leaks at the fuel gauge unit gasket.
5. Connect the negative battery cable.
Fuel Injectors
Removal Procedure
NOTE: If the fuel injectors are leaking, the engine oil may
be contaminated with fuel. Check the oil for signs of
contamination and change the oil and the filter if
necessary.
NOTE: Use care in removing the fuel injectors in order to
prevent damage to the fuel injector electrical connector
pins or the fuel injector nozzles. The fuel injector is an
electrical component and should not be immersed in any
type of cleaner as this may damage the fuel injector.
IMPORTANT: Fuel injectors are serviced as a complete 055RW009

assembly only. 5. Remove the fuel injector assembly.


1. Disconnect the negative battery cable. 6. Remove the O-ring from the fuel injector.
2. Remove the upper intake manifold. Refer to 7. Remove the O-ring backup from the fuel injector .
Common Chamber in Engine Mechanical..
3. Remove the fuel rail. Refer to Fuel Rail. Inspection Procedure
1. Inspect the O-rings for cracks or leaks.
2. Replace worn or damaged O-rings.
3. Lubricate the new O-rings with engine oil before
installation.
ENGINE DRIVEABILITY AND EMISSIONS 6E–315

Installation Procedure Fuel Pressure Regulator


1. Install the O-ring backup on the fuel injector.
2. Install the new O-ring on the fuel injector. Removal Procedure
3. Install the fuel injector on the fuel rail. CAUTION: To reduce the risk of fire and personal
injury, it is necessary to relieve the fuel system
pressure before servicing the fuel system
components.

CAUTION: After relieving the system pressure, a


small amount of fuel may be released when servicing
fuel lines or connections. Reduce the chance of
personal injury by covering the fuel line fittings with
a shop towel before disconnecting the fittings. The
towels will absorb any fuel that may leak out. When
the disconnect is completed, place the towel in an
approved container.
NOTE: Compressed air must never be used to test or
clean a fuel pressure regulator, as damage to the fuel
pressure regulator may result.
NOTE: To prevent damage to the fuel pressure regulator,
do not immerse the pressure regulator in solvent.
1. Depressurize the fuel system. Refer to Fuel Pressure
055RW009 Relief Procedure.
4. Use new fuel injector retainer clips to retain the fuel 2. Disconnect the negative battery cable.
injector to the fuel rail.
3. Remove the fuel pump relay. Refer to Fuel Pump
5. Coat the end of the fuel injector with engine oil. Relay.
6. Install the fuel rail. Refer to Fuel Rail. 4. Remove the pressure regulator hose from the fuel
pressure regulator.

014RW164

7. Install the upper intake manifold. Refer to Common 014RW110

Chamber in Engine Mechanical.


8. Install the engine cover.
9. Connect the negative battery cable.
6E–316 ENGINE DRIVEABILITY AND EMISSIONS
5. Remove the two bolts from the protector that secures Disassembly Procedure
the common chamber.
1. Remove the O-ring from the fuel pressure regulator.
2. Loosen the swivel nut.
3. Remove the fuel return line from the fuel pressure
regulator.
4. Remove the O-ring from the fuel return line.
The O-ring may be left inside the fuel pressure
regulator instead of on the fuel return line.

014RW109

6. Remove the fuel pressure regulator attaching screw.

F06RW043

Assembly Procedure
1. Install a new O-ring on the fuel return line.
2. Install the fuel return line on the fuel pressure
regulator.
NOTE: Do not over-tighten the swivel nut on the fuel
pressure regulator. The fuel pressure regulator can be
damaged and fuel may leak if the swivel nut is
over-tightened.
3. Tighten the swivel nut.
4. Install a new O-ring on the fuel pressure regulator.
F06RW043

7. Remove the fuel pressure regulator from the fuel rail.


ENGINE DRIVEABILITY AND EMISSIONS 6E–317

Installation Procedure 4. Install the pressure regulator hose to the fuel


pressure regulator.
1. Install the fuel pressure regulator attaching screw.
Tighten
Tighten the fuel pressure regulator attaching screw
to 3 Nꞏm (26 lb in.).

014RW110

5. Install the fuel pump relay. Refer to Fuel Pump Relay.


6. Connect the negative battery cable.
7. Crank the engine until it starts. Cranking the engine
F06RW043 may take longer than usual due to trapped air in the
2. Install the fuel pressure regulator on the fuel rail. fuel lines.
3. Install the two bolts to the protector that secures the
common chamber.
Fuel Metering System
Fuel Pressure Relief Procedure
CAUTION: To reduce the risk of fire and personal
injury, it is necessary to relieve the fuel system
pressure before servicing the fuel system
components.

CAUTION: After relieving the system pressure, a


small amount of fuel may be released when servicing
fuel lines or connections. Reduce the chance of
personal injury by covering the fuel line fittings with
a shop towel before you disconnect the fittings. The
towels will absorb any fuel that may leak out. When
the disconnect is completed, place the towel in an
approved container.
1. Remove the fuel cap.

014RW109
6E–318 ENGINE DRIVEABILITY AND EMISSIONS
2. Remove the fuel pump relay from the underhood Inspection Procedure
relay box. Refer to Fuel Pump Relay.
1. Inspect the fuel pump gasket for tears, cracks,
stretching, or rotting. If any of these conditions are
found, replace the fuel pump gasket.
2. Inspect the in-tank fuel filter for tears or evidence of
dirt, debris, or water in the fuel. If any of these
conditions are found, replace the in-tank fuel filter.

Installation Procedure
1. Install the fuel pump assembly.
2. Install the fuel pump assembly retaining screws.
3. Install the fuel tank assembly. Refer to Fuel Tank.
4. Fill the tank with fuel.
5. Tighten the fuel filler cap.
6. Connect the negative battery cable.

TS23976R

3. Start the engine and allow it to stall.


4. Crank the engine for 30 seconds.
5. Disconnect the negative battery cable.
Fuel Pump Assembly
Removal Procedure
1. Disconnect the negative battery cable.
2. Drain all the fuel from the tank.
3. Install and tighten the drain plug.
Tighten
Tighten the drain plug to 20 Nꞏm (14 lb ft.).
4. Remove the fuel tank. Refer to Fuel Tank. TS23795

5. Remove the retaining screws from the fuel tank.


6. Remove the fuel pump assembly from the fuel tank.
Cover the fuel pump opening in order to prevent
dust, dirt, or debris from entering the fuel tank.

TS23795
ENGINE DRIVEABILITY AND EMISSIONS 6E–319

Fuel Pump Relay Installation Procedure


1. Insert the relay into the correct place in the fuse and
Removal Procedure relay box with the catch slot facing forward.
1. Remove the fuse and relay box cover from under the 2. Press down until the catch engages.
hood. An audible “click” will be heard.
2. Consult the diagram on the cover to determine which
is the correct relay.
3. Insert a small screwdriver into the catch slot on the
forward side of the fuel pump relay.
The screwdriver blade will release the catch inside.

T321092

3. Install the fuse and relay box cover.


Fuel Rail Assembly
T321092
Removal Procedure
4. Pull the relay straight up and out of the fuse and relay NOTE:
box.
Do not attempt to remove the fuel inlet fitting on the
fuel rail. It is staked in place. Removing the fuel inlet
fitting will result in damage to the fuel rail or the
internal O-ring seal.
Use care when removing the fuel rail assembly in
order to prevent damage to the injector electrical
connector terminals and the injector spray tips.
Fittings should be capped and holes plugged during
servicing to prevent dirt and other contaminants from
entering open lines and passages.

TS23976R
6E–320 ENGINE DRIVEABILITY AND EMISSIONS
IMPORTANT: An eight-digit identification number is
stamped on the side of the fuel rail. Refer to this number
when you service the fuel rail or when a replacement part
is required.

014RW164

8. If removal of the fuel pressure regulator is necessary,


refer to Fuel Pressure Regulator.
9. If removal of the fuel injectors is necessary, refer to
TS24022 Fuel Injectors.
Before removal, the fuel rail assembly may be cleaned
with a spray type engine cleaner. Follow the spray Installation Procedure
package instructions. Do not immerse the fuel rails in
liquid cleaning solvent. 1. If the fuel injectors were removed, install them. Refer
1. Depressurize the fuel system. Refer to Fuel Pressure to Fuel Injectors.
Relief Procedure in this Section. 2. If the fuel pressure regulator was removed, install it.
2. Disconnect the negative battery cable. Refer to Fuel Pressure Regulator.
3. Remove the engine cover. 3. Install the common chamber. Refer to common
chamber in engine Mechanical.
4. Disconnect the accelerator pedal cable from throttle
body and cable bracket.
5. Disconnect the connectors from manifold absolute
pressure sensor, solenoid valve, electric vacuum
sensing valve.
6. Disconnect the vacuum hose on canister VSV and
positive crankcase ventilation hose.
7. Remove the common chamber. Refer to the common
chamber in Engine Mechanical.
1. Lift up carefully on the fuel injectors. Do not
separate the fuel injectors from the fuel rail.
2. If an injector becomes separated from the fuel
rail, the infector O-ring seals and the retainer clip
must be replaced.
3. Drain residual fuel into an approved container.

014RW164
ENGINE DRIVEABILITY AND EMISSIONS 6E–321
4. Connect the vacuum hose on Canister VSV and
positive crankcase ventilation hose.
5. Connect the connectors to manifold absolute
pressure sensor, solenoid valve, electric vacuum
sensing valve.
6. Connect the accelerator pedal cable to throttle body
and cable bracket.
7. Install the engine cover.
8. Connect the negative battery cable.
9. Crank the engine until it starts. Cranking the engine
may take longer than usual due to trapped air in the
fuel rail and in the injectors.
Fuel Tank
Removal Procedure
1. Disconnect the negative battery cable.
2. Loosen the fuel filler cap.
3. Drain the fuel from the tank into an approved TS23797

container. 9. Disconnect the wiring connector to the fuel pump.


4. Install and tighten the drain plug. 10. Disconnect the wiring connector to the fuel gauge
Tighten unit.
11. Remove the fuel gauge unit connector from the
Tighten the drain plug to 20 Nꞏm (14 lb ft.).
bracket.
5. Disconnect the fuel filler hose at the fuel tank.
12. Disconnect the EVAP vapor hose.
6. Disconnect the air breather hose at the fuel tank.
13. Disconnect the fuel supply hose.
14. Disconnect the fuel return hose.
Plug the hoses to prevent dust from entering the
hoses.

TS23796

7. Remove the undercover retaining bolts.


8. Remove the undercover.
TS23769
6E–322 ENGINE DRIVEABILITY AND EMISSIONS
15. Remove the fuel tank retaining bolts on both sides. 3. Connect the fuel return hose.
16. Remove the fuel tank. 4. Connect the fuel supply hose.
5. Connect the EVAP vapor hose.
6. Connect the wiring connector for the fuel gauge unit.
7. Connect the fuel gauge wiring connector to the
bracket.
8. Connect the wiring connector for the fuel pump.

TS23770

Installation Procedure
1. Install the fuel tank.
Place the flanges on the left and right side of the
tank on the bracket. TS23769

2. Install the fuel tank retaining bolts. 9. Install the undercover.


Tighten 10. Secure the undercover with the retaining bolts.
Tighten the fuel tank retaining bolts to 36 Nꞏm (27 lb
ft.).

TS23797

TS23770
ENGINE DRIVEABILITY AND EMISSIONS 6E–323
11. Connect the fuel filler fuse at the tank. 5. Disconnect the vacuum hose below the air horn.
12. Connect the air breather hose at the tank. 6. Remove the intake air duct clamp.
7. Disconnect the intake air duct.
8. Disconnect the coolant lines from the throttle body.
9. Remove the bolts from the common chamber.
10. Remove the throttle body from the common chamber.
11. Remove the gasket from the upper intake manifold.

TS23796

13. Fill the fuel tank with fuel.


14. Tighten the fuel filler cap.
15. Connect the negative battery cable.
Throttle Body (TB)
035RW024

Removal Procedure 12. Remove the IAC. Refer to Idle Air Control (IAC)
Solenoid.
1. Disconnect the negative battery cable.
13. Remove the TP sensor. Refer to Throttle Position
2. Drain the cooling system. Refer to Cooling System. (TP) Sensor.
3. Remove the accelerator cable assembly. Refer to
Accelerator Cable in Engine Speed Control System.. Inspection Procedure
4. Disconnect the electrical connectors:
NOTE: Do not use solvent of any type when you clean the
Throttle position (TP) sensor. gasket surfaces on the intake manifold and the throttle
Idle air control (IAC) solenoid. body assembly. The gasket surfaces and the throttle
Intake air temperature (IAT) sensor. Refer to body assembly may be damaged as a result.
Intake Air Temperature Sensor. If the throttle body gasket needs to be replaced,
remove any gasket material that may be stuck to the
mating surfaces of the manifold.
Do not leave any scratches in the aluminum casting.

Installation Procedure
1. Install the TP sensor. Refer to Throttle Position (TP)
Sensor.
2. Install the IAC. Refer to Idle Air Control (IAC)
Solenoid.
3. Install the gasket on the common chamber.
4. Install the throttle body on the common chamber.

035RW023
6E–324 ENGINE DRIVEABILITY AND EMISSIONS
5. Secure the gasket and the throttle body with the four 11. Install the accelerator cable assembly. Refer to
bolts. Accelerator Cable in Engine Speed Control System..
The vacuum lines must be properly routed under 12. Fill the cooling system. Refer to Cooling System.
the throttle body before tightening the mounting 13. Install the negative battery cable.
bolts.
Tighten Electronic Ignition System
Tighten the throttle body mounting bolts to 24 Nꞏm
(17 lb ft.).
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the electrical connector at the ignition coil.
3. Remove the two screws that secure the ignition coil to
the rocker cover.

035RW024

6. Install the coolant lines.


7. Connect all the vacuum lines.
8. Install the intake air duct.
9. Tighten the intake air duct clamp. 014RW108

4. Remove the ignition coil and the spark plug boot from
10. Connect all the electrical connectors: the spark plug.
Throttle position (TP) sensor. Twist the ignition coil while pulling it straight up.
Idle air control (IAC) solenoid.
Intake air temperature (IAT) sensor. Refer to
Intake Air Temperature Sensor.

014RW091

5. Use the spark plug socket in order to remove the


spark plug from the engine.
035RW023
ENGINE DRIVEABILITY AND EMISSIONS 6E–325

Spark Plug Gap Check


Check the gap of all spark plugs before installation.
Use a round wire feeler gauge to ensure an accurate
check.
Plugs installed with the wrong gap can cause poor
engine performance and excessive emissions.

Installation Procedure
NOTE: The plug must thread smoothly into the cylinder
head and be fully seated. Use a thread chaser if
necessary to clean the threads in the cylinder head.
Cross-threading or failure to fully seat the spark plug can
cause plug overheating, exhaust blow-by gas, or thread
damage. Do not overtighten the spark plugs. Over
tightening can cause aluminum threads to strip.
1. Install the spark plug in the engine. Use the
appropriate spark plug socket.
Tighten 014RW091

Tighten the spark plug to 18 Nꞏm (13 lb ft.). 4. Connect the electrical connector at the ignition coil.
2. Install the ignition coil and spark plug boot over the 5. Connect the negative battery cable.
spark plug.
Catalytic Converter
Removal and Installation Procedure
Refer to Engine Exhaust in Engine.
Air Conditioning Relay
Removal Procedure
1. Remove the fuse and relay box cover from under the
hood.
2. Consult the diagram on the cover to determine which
is the correct relay.
3. Insert a small screwdriver into the catch slot on the
forward side of the fuel pump relay.
The screwdriver blade will release the catch inside.

014RW108

3. Secure the ignition coil to the rocker cover with two


screws.

T321092
6E–326 ENGINE DRIVEABILITY AND EMISSIONS
4. Pull the relay straight up and out of the fuse and relay
box.
EVAP Canister
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the three hoses from the EVAP canister.

TS23986

Installation Procedure
1. Insert the relay into the correct place in the fuse and
relay box with the catch slot facing forward. 014RW145

2. Press down until the catch engages. 3. Remove the retaining two bolts on the mounting
bracket and slide the canister out of mounting
An audible “click” will be heard. bracket.
3. Install the fuse and relay box cover.

014RW146

TS23986

EVAP Canister Hoses Inspection Procedure


1. Inspect the hoses for cracks and leaks.
Service Information 2. Inspect the canister for a damaged case.
To view the routing of the EVAP canister hoses, refer to
Vehicle Emission Control Information in Diagnosis. Use
6148M or equivalent when you replace the EVAP canister
hoses.
ENGINE DRIVEABILITY AND EMISSIONS 6E–327

Installation Procedure 2. Disconnect the vacuum hoses from the EVAP


canister purge solenoid.
1. Slide the canister into mounting bracket and install
the mounting bracket two bolts.

014RW136

3. Remove the EVAP canister purge solenoid retaining


014RW146
bolt from the upper intake manifold.
2. Connect the three hoses to the EVAP canister.
4. Remove the EVAP canister purge solenoid.

014RW145
014RW137
3. Disconnect the negative battery cable.
EVAP Canister Purge Solenoid Installation Procedure
1. Install the EVAP canister purge solenoid on the upper
Removal Procedure intake manifold.
1. Disconnect the electrical connector from the EVAP 2. Install the EVAP canister purge solenoid retaining
canister purge solenoid. bolt.
6E–328 ENGINE DRIVEABILITY AND EMISSIONS
3. Connect the vacuum hoses to the EVAP canister 2. Disconnect the electrical connector at the EGR valve.
purge solenoid.

014RW139

014RW137 3. Remove the bolt and the nut from the upper intake
4. Connect the electrical connector to the EVAP canister manifold.
purge solenoid.

014RW098

014RW138 4. Remove the EGR valve from the upper intake


manifold.
Fuel Tank Vent Valve
5. Remove the gasket from the upper intake manifold.
Removal and Installation Procedure
Installation Procedure
Refer to Fuel Pump
1. Install the gasket on the upper intake manifold.
Linear Exhaust Gas 2. Install the EGR valve on the upper intake manifold.
Recirculation (EGR) Valve 3. Secure the EGR valve and the gasket with the bolt
and the nut.
Removal Procedure
1. Disconnect the negative battery cable.
ENGINE DRIVEABILITY AND EMISSIONS 6E–329
NOTE: It is possible to install the EGR valve rotated 180 2. Pull the PCV valve from the rubber grommet in the
from the correct position. Make sure that the base of the right valve cover.
valve is placed so that it aligns with the mounting flange.

014RW097

Inspection Procedure
014RW098

4. Connect the electrical connector at the EGR valve.


1. Shake the valve and listen for the rattle of the needle
inside the valve.
2. If the valve does not rattle, replace the valve.

Installation Procedure
1. Push the PCV valve into the rubber grommet in the
left valve cover.
2. Install the vacuum hose on the PCV valve and secure
the vacuum hose with the clamp.

014RW139

5. Connect the negative battery cable.


Positive Crankcase Ventilation
(PCV) Valve
Removal Procedure
1. Remove the vacuum hose at the PCV valve.
Slide the clamp back to release the hose.
014RW097
6E–330 ENGINE DRIVEABILITY AND EMISSIONS

Wiring and Connectors Wire Harness Repair: Twisted


Wiring Harness Service
Shielded Cable
The control module harness electrically connects the Removal Procedure
control module to the various solenoids, switches and
sensors in the vehicle engine compartment and 1. Remove the outer jacket.
passenger compartment. 2. Unwrap the aluminum/mylar tape. Do not remove the
Replace wire harnesses with the proper part number mylar.
replacement.
Because of the low amperage and voltage levels utilized
in powertrain control systems, it is essential that all wiring
in environmentally exposed areas be repaired with crimp
and seal splice sleeves.
The following wire harness repair information is intended
as a general guideline only. Refer to Chassis Electrical for
all wire harness repair procedures.

Connectors and Terminals


Use care when probing a connector and when replacing
terminals. It is possible to short between opposite
terminals. Damage to components could result. Always
use jumper wires between connectors for circuit
checking. NEVER probe through Weather-Pack seals.
Use an appropriate connector test adapter kit which
contains an assortment of flexible connectors used to
probe terminals during diagnosis. Use an appropriate
fuse remover and test tool for removing a fuse and to
adapt the fuse holder to a meter for diagnosis.
Open circuits are often difficult to locate by sight because 047

oxidation or terminal misalignment are hidden by the 3. Untwist the conductors.


connectors. Merely wiggling a connector on a sensor, or 4. Strip the insulation as necessary.
in the wiring harness, may temporarily correct the open
circuit. Intermittent problems may also be caused by
oxidized or loose connections.
Be certain of the type of connector/terminal before
making any connector or terminal repair. Weather-Pack
and Com-Pack III terminals look similar, but are serviced
differently.
PCM Connectors and Terminals
Removal Procedure
1. Remove the connector terminal retainer.
2. Push the wire connected to the affected terminal
through the connector face so that the terminal is
exposed.
3. Service the terminal as necessary.

Installation Procedure
1. Bend the tab on the connector to allow the terminal to
be pulled into position within the connector. 048

2. Pull carefully on the wire to install the connector


terminal retainer.
ENGINE DRIVEABILITY AND EMISSIONS 6E–331

Installation Procedure Twisted Leads


1. Splice the wires using splice clips and rosin core
solder. Removal Procedure
2. Wrap each splice to insulate. 1. Locate the damaged wire.
3. Wrap the splice with mylar and with the drain 2. Remove the insulation as required.
(uninsulated) wire.

051

049

4. Tape over the whole bundle to secure. Installation Procedure


1. Use splice clips and rosin core solder in order to splice
the two wires together.

050

052
6E–332 ENGINE DRIVEABILITY AND EMISSIONS
2. Cover the splice with tape in order to insulate it from 4. Tape the wires with electrical tape. Hold in place.
the other wires.

055

3. Twist the wires as they were before starting this


053
Weather-Pack Connector
procedure.
Tools Required
J 28742-A Weather-Pack II Terminal Remover

Removal Procedure
A Weather-Pack connector can be identified by a rubber
seal at the rear of the connector. This engine room
connector protects against moisture and dirt, which could
from oxidation and deposits on the terminals. This
protection is important, because of the low voltage and
the low amperage found in the electronic systems.
1. Open the secondary lock hinge on the connector.

054

070
ENGINE DRIVEABILITY AND EMISSIONS 6E–333
2. Use tool J 28742-A or the equivalent to remove the 2. Slip the new seal onto the wire.
pin and the sleeve terminals. Push on J 28742-A to 3. Strip 5 mm (0.2”) of insulation from the wire.
release.
4. Crimp the terminal over the wire and the seal.
NOTE: Do the use an ordinary pick or the terminal may
be bent or deformed. Unlike standard blade terminals,
these terminals cannot be straightened after they have
been improperly bent.

073

5. Push the terminal and the connector to engage the


locking tangs.

071

3. Cut the wire immediately behind the cable seal.

070

6. Close the secondary locking hinge.

072
Com-Pack III
Installation Procedure General Information
Make certain the connectors are properly seated and all The Com-Pack III terminal looks similar to some
of the sealing rings are in place when you reconnect the Weather-Pack terminals. This terminal is not sealed and
leads. The secondary lock hinge provides a backup is used where resistance to the environment is not
locking feature for the connector. The secondary lock required. Use the standard method when repairing a
hinge is used for added reliability. This flap should retain terminal. Do not use the Weather-Pack terminal tool J
the terminals even if the small terminal lock tangs are not 28742-A or equivalent. These will damage the terminals.
positioned properly.
Do not replace the Weather-Pack connections with
Metri-Pack
standard connections. Read the instructions provided
with the Weather-Pack connector and terminal packages. Tools Required
1. Replace the terminal. J 35689 Terminal Remover
6E–334 ENGINE DRIVEABILITY AND EMISSIONS

Removal Procedure Installation Procedure


Some connectors use terminals called Metri-Pack Series Metri-Pack terminals are also referred to as “pull-to-seat”
150. These may be used at the engine coolant terminals.
temperature (ECT) sensor. 1. In order to install a terminal on a wire, the wire must be
1. Slide the seal (1) back on the wire. inserted through the seal (2) and through the
2. Insert the J 35689 tool or equivalent (3) in order to connector (3).
release the terminal locking tang (2). 2. The terminal (1) is then crimped onto the wire.

060 061

3. Push the wire and the terminal out through the 3. Then the terminal is pulled back into the connector to
connector. If you reuse the terminal, reshape the seat it in place.
locking tang.
ENGINE DRIVEABILITY AND EMISSIONS 6E–335

General Description trigger the injectors in the proper sequence. The PCM
uses the CMP signal to indicate the position of the #1
piston during its power stroke. This allows the PCM to
General Description (PCM and calculate true sequential fuel injection (SFI) mode of
operation. If the PCM detects an incorrect CMP signal
Sensors) while the engine is running, DTC P0341 will set. If the
CMP signal is lost while the engine is running, the fuel
58X Reference PCM Input injection system will shift to a calculated sequential fuel
The powertrain control module (PCM) uses this signal injection mode based on the last fuel injection pulse, and
from the crankshaft position (CKP) sensor to calculate the engine will continue to run. As long as the fault is
engine RPM and crankshaft position at all engine speeds. present, the engine can be restarted. It will run in the
The PCM also uses the pulses on this circuit to initiate calculated sequential mode with a 1-in-6 chance of the
injector pulses. If the PCM receives no pulses on this injector sequence being correct.
circuit, DTC P0337 will set. The engine will not start and Refer to DTC P0341 for further information.
run without using the 58X reference signal.

A/C Request Signal


This signal tells the PCM when the A/C mode is selected
at the A/C control head. The PCM uses this to adjust the
idle speed before turning “ON” the A/C clutch. The A/C
compressor will be inoperative if this signal is not
available to the PCM.
Refer to A/C Clutch Circuit Diagnosis for A/C wiring
diagrams and diagnosis for the A/C electrical system.

Crankshaft Position (CKP) Sensor


The crankshaft position (CKP) sensor provides a signal
used by the powertrain control module (PCM) to calculate
the ignition sequence. The CKP sensor initiates the 58X
reference pulses which the PCM uses to calculate RPM
and crankshaft position.
Refer to Electronic Ignition System for additional
information.
0014

Engine Coolant Temperature (ECT) Sensor


The engine coolant temperature (ECT) sensor is a
thermistor (a resistor which changes value based on
temperature) mounted in the engine coolant stream. Low
coolant temperature produces a high resistance of
100,000 ohms at –40 C (–40 F). High temperature
causes a low resistance of 70 ohms at 130 C (266 F).
The PCM supplies a 5-volt signal to the ECT sensor
through resistors in the PCM and measures the voltage.
The signal voltage will be high when the engine is cold and
low when the engine is hot. By measuring the voltage, the
PCM calculates the engine coolant temperature. Engine
coolant temperature affects most of the systems that the
PCM controls.
Tech 2 displays engine coolant temperature in degrees.
After engine start-up, the temperature should rise steadily
to about 85 C (185 F). It then stabilizes when the
0013
thermostat opens. If the engine has not been run for
several hours (overnight), the engine coolant
Camshaft Position (CMP) Sensor and temperature and intake air temperature displays should
Signal be close to each other. A hard fault in the engine coolant
sensor circuit will set DTC P0177 or DTC P0118. An
The camshaft position (CMP) sensor sends a CMP signal intermittent fault will set a DTC P1114 or P1115.
to the PCM. The PCM uses this signal as a “sync pulse” to
6E–336 ENGINE DRIVEABILITY AND EMISSIONS

0016 0012

Electrically Erasable Programmable Read Intake Air Temperature (IAT) Sensor


Only Memory (EEPROM) The intake air temperature (IAT) sensor is a thermistor
The electrically erasable programmable read only which changes its resistance based on the temperature of
memory (EEPROM) is a permanent memory chip that is air entering the engine. Low temperature produces a high
physically soldered within the PCM. The EEPROM resistance of 100,000 ohms at –40 C (–40 F). High
contains the program and the calibration information that temperature causes low resistance of 70 ohms at 130 C
the PCM needs to control powertrain operation. (266 F) . The PCM supplies a 5-volt signal to the sensor
Unlike the PROM used in past applications, the EEPROM through a resistor in the PCM and monitors the signal
is not replaceable. If the PCM is replaced, the new PCM voltage. The voltage will be high when the incoming air is
will need to be programmed. Equipment containing the cold. The voltage will be low when the incoming air is hot.
correct program and calibration for the vehicle is required By measuring the voltage, the PCM calculates the
to program the PCM. incoming air temperature. The IAT sensor signal is used
to adjust spark timing according to the incoming air
Fuel Control Heated Oxygen Sensors density.
The fuel control heated oxygen sensors (Bank 1 HO2S 1 Tech 2 displays the temperature of the air entering the
and Bank 2 HO2S 1) are mounted in the exhaust stream engine. The temperature should read close to the
where they can monitor the oxygen content of the exhaust ambient air temperature when the engine is cold and rise
gas. The oxygen present in the exhaust gas reacts with as underhood temperature increases. If the engine has
the sensor to produce a voltage output. This voltage not been run for several hours (overnight), the IAT sensor
should constantly fluctuate from approximately 100 mV to temperature and engine coolant temperature should read
900 mV. The heated oxygen sensor voltage can be close to each other. A fault in the IAT sensor circuit will set
monitored with Tech 2. By monitoring the voltage output DTC P0112 or DTC P0113.
of the oxygen sensor, the PCM calculates the pulse width
command for the injectors to produce the proper
combustion chamber mixture.
Low HO2S voltage is a lean mixture which will result in
a rich command to compensate.
High HO2S voltage is a rich mixture which will result in
a lean command to compensate.
An open Bank 1 HO2S 1 signal circuit will set a DTC
P0134 and Tech 2 will display a constant voltage between
400-500 mV. A constant voltage below 300 mV in the
sensor circuit (circuit grounded) will set DTC P0131. A
constant voltage above 800 mV in the circuit will set DTC
P0132. Faults in the Bank 2 HO2S 1 signal circuit will
cause DTC 0154 (open circuit), DTC P0151 (grounded
circuit), or DTC P0152 (signal voltage high) to set.
ENGINE DRIVEABILITY AND EMISSIONS 6E–337
circuit or the knock sensor. If the PCM determines that an
abnormal minimum or maximum noise level is being
experienced, DTC P0325 will set.
The PCM contains a knock sensor (KS) module. The KS
module contains the circuitry which allows the PCM to
utilize the KS signal and diagnose the KS sensor and the
KS circuitry. If the KS module is missing or faulty, a
continuous knock condition will be indicated, and the
PCM will set DTC P0325.
Although it is a plug-in device, the KS module is not
replaceable. If the KS module is faulty, the entire PCM
must be replaced.

0018

Knock Sensor
Insufficient gasoline octane levels may cause detonation
in some engines. Detonation is an uncontrolled explosion
(burn) in the combustion chamber. This uncontrolled
explosion results from a flame front opposite that of the
normal flame front produced by the spark plug. The
rattling sound normally associated with detonation is the
result of two or more opposing pressures (flame fronts)
colliding within the combustion chamber. Light
detonation is sometimes considered normal, but heavy
detonation could result in engine damage. 0009

A knock sensor system is used to control detonation. This


system is designed to retard spark timing up to 20 Linear Exhaust Gas Recirculation (EGR)
degrees to reduce detonation in the engine. This allows Control
the engine to use maximum spark advance to improve The PCM monitors the exhaust gas recirculation (EGR)
driveability and fuel economy. actual position and adjusts the pintle position accordingly.
The knock sensor system has two major components: The PCM uses information from the following sensors to
The knock sensor (KS) module. control the pintle position:
The knock sensor. Engine coolant temperature (ECT) sensor.
The knock sensor, mounted in the engine block near the Throttle position (TP) sensor.
cylinders, detects abnormal vibration in the engine. The Mass air flow (MAF) sensor.
sensor produces an AC output signal of about 10
millivolts. The signal amplitude and frequency are Mass Air Flow (MAF) Sensor
dependent on the amount of knock being experienced.
The mass air flow (MAF) sensor measures the difference
The signal voltage increases with the severity of the
between the volume and the quantity of air that enters the
knock. This signal voltage is input to the PCM. The PCM
engine. “Volume” means the size of the space to be filled.
then retards the ignition control (IC) spark timing based
“Quantity” means the number of air molecules that will fit
on the KS signal being received.
into the space. This information is important to the PCM
The PCM determines whether knock is occurring by
because heavier, denser air will hold more fuel than
comparing the signal level on the KS circuit with the
lighter, thinner air. The PCM adjusts the air/fuel ratio as
voltage level on the noise channel. The noise channel
needed depending on the MAF value. Tech 2 reads the
allows the PCM to reject any false knock signal by
MAF value and displays it in terms of grams per second
indicating the amount of normal engine mechanical noise
(gm/s). At idle, Tech 2 should read between 4-7 gm/s on a
present. Normal engine noise varies depending on the
fully warmed up engine. Values should change quickly on
engine speed and load. If the voltage level on the KS
acceleration. Values should remain stable at any given
noise channel circuit is below the range considered
normal, DTC P0327 will set, indicating a fault in the KS
6E–338 ENGINE DRIVEABILITY AND EMISSIONS
RPM. A failure in the MAF sensor or circuit will set DTC
P0101, DTC P0102, or DTC P0103.

055RW004

0007 Powertrain Control Module (PCM)


The powertrain control module (PCM) is located in the
Manifold Absolute Pressure (MAP) Sensor passenger compartment below the center console. The
The manifold absolute pressure (MAP) sensor responds PCM controls the following:
to changes in intake manifold pressure (vacuum). The Fuel metering system.
MAP sensor signal voltage to the PCM varies from below Transmission shifting (automatic transmission only).
2 volts at idle (high vacuum) to above 4 volts with the
Ignition timing.
ignition ON, engine not running or at wide-open throttle
(low vacuum). On-board diagnostics for powertrain functions.
The MAP sensor is used to determine the following: The PCM constantly observes the information from
Manifold pressure changes while the linear EGR flow various sensors. The PCM controls the systems that
test diagnostic is being run. Refer to DTC P0401. affect vehicle performance. The PCM performs the
diagnostic function of the system. It can recognize
Engine vacuum level for other diagnostics.
operational problems, alert the driver through the MIL
Barometric pressure (BARO). (Service Engine Soon lamp), and store diagnostic trouble
If the PCM detects a voltage that is lower than the codes (DTCs). DTCs identify the problem areas to aid the
possible range of the MAP sensor, DTC P0107 will be set. technician in making repairs.
A signal voltage higher than the possible range of the This engine uses 2 different control modules:
sensor will set DTC P0108. An intermittent low or high IPCM-6KT for automatic transmission-equipped
voltage will set DTC P1107 or DTC P1106, respectively. vehicles.
The PCM can detect a shifted MAP sensor. The PCM
ISFI-6 for manual transmission-equipped vehicles.
compares the MAP sensor signal to a calculated MAP
based on throttle position and various engine load factors.
If the PCM detects a MAP signal that varies excessively
PCM Function
above or below the calculated value, DTC P0106 will set. The PCM supplies either 5 or 12 volts to power various
sensors or switches. The power is supplied through
resistances in the PCM which are so high in value that a
test light will not light when connected to the circuit. In
some cases, even an ordinary shop voltmeter will not give
an accurate reading because its resistance is too low.
Therefore, a digital voltmeter with at least 10 megohms
input impedance is required to ensure accurate voltage
readings. Tool J 39200 meets this requirement. The PCM
controls output circuits such as the injectors, IAC, cooling
fan relays, etc., by controlling the ground or the power
feed circuit through transistors of following device.
Output Driver Module (ODM)
ENGINE DRIVEABILITY AND EMISSIONS 6E–339
Engine Coolant Temperature
Crankshaft Position
Exhaust Oxygen Content
Electronic Ignition
Manifold Absolute Pressure
Battery Voltage
Throttle Position
Vehicle Speed
Fuel Pump Voltage
Power Steering Pressure
Intake Air Temperature
Mass Air Flow
Engine Knock
Camshaft Position

Outputs – Systems Controlled


Exhaust Gas Recirculation (EGR)
0005

Ignition Control
PCM Components Fuel Control
The PCM is designed to maintain exhaust emission levels Idle Air Control
to government mandated standards while providing Electric Fuel Pump
excellent driveability and fuel efficiency. The PCM
Air Conditioning
monitors numerous engine and vehicle functions via
electronic sensors such as the throttle position (TP) Diagnostics
sensor, heated oxygen sensor (HO2S), and vehicle – Malfunction Indicator Lamp (Service Engine Soon
speed sensor (VSS). The PCM also controls certain lamp)
engine operations through the following: – Data Link Connector (DLC)
Fuel injector control – Data Output
Ignition control module Transmission Control Module
Knock sensor Alternator Gain Control
Automatic transmission shift functions
Cruise control PCM Service Precautions
A/C clutch control The PCM is designed to withstand normal current draws
associated with vehicle operation. Avoid overloading any
PCM Voltage Description circuit. When testing for opens and shorts, do not ground
or apply voltage to any of the PCM’s circuits unless
The PCM supplies a buffered voltage to various switches
instructed to do so. These circuits should only be tested
and sensors. It can do this because resistance in the
Tech-2. The PCM should remain connected to the PCM
PCM is so high in value that a test light may not illuminate
or to a recommended breakout box.
when connected to the circuit. An ordinary shop
voltmeter may not give an accurate reading because the Reprogramming The PCM
voltmeter input impedance is too low. Use a 10-megohm
input impedance digital voltmeter (such as J 39200) to The Trooper allow reprogramming of the PCM without
assure accurate voltage readings. removing it from the vehicle . This provides a flexible and
The input/output devices in the PCM include cost-effective method of making changes in software
analog-to-digital converters, signal buffers, counters, calibrations.
and special drivers. The PCM controls most components The service programming system (SPS) will not allow
with electronic switches which complete a ground circuit incorrect software programming or incorrect calibration
when turned “ON.” These switches are arranged in changes.
groups of 4 and 7, called either a surface-mounted quad Refer to the UBS 98model year Immobilizer Workshop
driver module (QDM), which can independently control up Manual.
to 4 output terminals, or QDMs which can independently
control up to 7 outputs. Not all outputs are always used.
Throttle Position (TP) Sensor
The throttle position (TP) sensor is a potentiometer
PCM Input/Outputs connected to the throttle shaft on the throttle body. The
PCM monitors the voltage on the signal line and
Inputs – Operating Conditions Read calculates throttle position. As the throttle valve angle is
changed (accelerator pedal moved), the TP sensor signal
Air Conditioning “ON” or “OFF”
also changes. At a closed throttle position, the output of
6E–340 ENGINE DRIVEABILITY AND EMISSIONS
the TP sensor is low. As the throttle valve opens, the For more information on the transmission on the
output increases so that at wide open throttle (WOT), the transmission range switch, refer to 4L30-E Automatic
output voltage should be above 4 volts. Transmission.
The PCM calculates fuel delivery based on throttle valve
angle (driver demand). A broken or loose TP sensor may Vehicle Speed Sensor (VSS)
cause intermittent bursts of fuel from an injector and The PCM determines the speed of the vehicle by
unstable idle because the PCM thinks the throttle is converting a plusing voltage signal from the vehicle speed
moving. A hard failure in the TP sensor 5-volt reference sensor (VSS) into miles per hour. The PCM uses this
or signal circuits will set a DTC P0123. A hard failure with signal to operate the cruise control, speedometer, and the
the TP sensor ground circuit may set DTC P0123. Once TCC and shift solenoids in the transmission. For more
a DTC is set, the PCM will use an artificial default value information on the TCC and shift solenoids, refer to
based on engine RPM and mass air flow for the throttle 4L30-E Automatic Transmission.
position, and some vehicle performance will return. A
high idle may result when DTC P0123 is set. The PCM
can also detect a shifted TP sensor. The PCM monitors
throttle position and compares the actual TP sensor
reading to a predicted TP value calculated from engine
speed. If the PCM detects an out-of-range condition,
DTC P0121 will be set.

0008

Use of Circuit Testing Tools


Do not use a test light to diagnose the powertrain
electrical systems unless specifically instructed by the
diagnostic procedures. Use Connector Test Adapter Kit J
35616 whenever diagnostic procedures call for probing
0021
connectors.
Transmission Fluid Temperature (TFT) Aftermarket Electrical and Vacuum
Sensor Equipment
The transmission fluid temperature sensor is a thermistor Aftermarket (add-on) electrical and vacuum equipment is
which changes its resistance based on the temperature of defined as any equipment which connects to the vehicle’s
the transmission fluid. For a complete description of the electrical or vacuum systems that is installed on a vehicle
TFT sensor, refer to 4L30-E Automatic Transmission after it leaves the factory. No allowances have been
Diagnosis. made in the vehicle design for this type of equipment.
A failure in the TFT sensor or associated wiring will cause
DTC P0712 or DTC P0713 to set. In this case, engine NOTE: No add-on vacuum equipment should be added
coolant temperature will be substituted for the TFT to this vehicle.
sensor value and the transmission will operate normally. NOTE: Add-on electrical equipment must only be
connected to the vehicle’s electrical system at the battery
Transmission Range Switch (power and ground).
IMPORTANT: The vehicle should not be driven with the Add-on electrical equipment, even when installed to
transmission range switch disconnected; idle quality will these guidelines, may still cause the powertrain system to
be affected. malfunction. This may also include equipment not
The four inputs from the transmission range switch connected to the vehicle electrical system such as
indicate to the PCM which position is selected by the portable telephones and radios. Therefore, the first step
transmission selector lever. This information is used for in diagnosing any powertrain problem is to eliminate all
ignition timing, EVAP canister purge, EGR and IAC valve aftermarket electrical equipment from the vehicle. After
operation.
ENGINE DRIVEABILITY AND EMISSIONS 6E–341
this is done, if the problem still exists, it may be diagnosed Upshift Lamp
in the normal manner. Refer to Manual Transmission.
Electrostatic Discharge Damage
Electronic components used in the PCM are often
General Description (Air Induction)
designed to carry very low voltage. Electronic
components are susceptible to damage caused by Air Induction System
electrostatic discharge. Less than 100 volts of static The air induction system filters contaminants from the
electricity can cause damage to some electronic outside air, and directs the progress of the air as it is
components. By comparison, it takes as much as 4000 drawn into the engine. A remote-mounted air cleaner
volts for a person to feel even the zap of a static prevents dirt and debris in the air from entering the
discharge. engine. The air duct assembly routes filtered air to the
throttle body. Air enters the engine by to following steps:
1. Through the throttle body.
2. Into the common chamber.
3. Through the cylinder head intake ports.
4. Into the cylinders.

TS23793

There are several ways for a person to become statically


charged. The most common methods of charging are by
friction and induction.
An example of charging by friction is a person sliding
across a vehicle seat.
Charge by induction occurs when a person with well 055RV010

insulated shoes stands near a highly charged object


and momentary touches ground. Charges of the General Description (Fuel Metering)
same polarity are drained off leaving the person
highly charged with the opposite polarity. Static
charges can cause damage, therefore it is important
Acceleration Mode
to use care when handling and testing electronic The PCM provides extra fuel when it detects a rapid
components. increase in the throttle position and the air flow.
NOTE: To prevent possible electrostatic discharge Accelerator Controls
damage, follow these guidelines:
The accelerator control system is a cable-type system
Do not touch the PCM connector pins or soldered with specific linkage adjustments.
components on the PCM circuit board. Refer to Cable Adjustment.
Do not touch the knock sensor module component
leads. Battery Voltage Correction Mode
Do not open the replacement part package until the When battery voltage is low, the PCM will compensate for
part is ready to be installed. the weak spark by increasing the following:
Before removing the part from the package, ground The amount of fuel delivered.
the package to a known good ground on the vehicle. The idle RPM.
If the part has been handled while sliding across the Ignition dwell time.
seat, while sitting down from a standing position, or
while walking a distance, touch a known good ground CMP Signal
before installing the part.
The PCM uses this signal to determine the position of the
number 1 piston during its power stroke, allowing the
6E–342 ENGINE DRIVEABILITY AND EMISSIONS
PCM to calculate true sequential multiport fuel injection
(SFI). Loss of this signal will set a DTC P0341. If the CMP
signal is lost while the engine is running, the fuel injection
system will shift to a calculated sequential fuel injection
based on the last fuel injection pulse, and the engine will
continue to run. The engine can be restarted and will run
in the calculated sequential mode as long as the fault is
present, with a 1-in-6 chance of being correct.

Clear Flood Mode


Clear a flooded engine by pushing the accelerator pedal
down all the way. The PCM then de-energizes the fuel
injectors. The PCM holds the fuel injectors de-energized
as long as the throttle remains above 80% and the engine
speed is below 800 RPM. If the throttle position becomes
less than 80%, the PCM again begins to pulse the
injectors “ON” and “OFF,” allowing fuel into the cylinders.

Deceleration Mode
The PCM reduces the amount of fuel injected when it 0003

detects a decrease in the throttle position and the air flow.


When deceleration is very fast, the PCM may cut off fuel Fuel Metering System Components
completely for short periods. The fuel metering system is made up of the following
parts:
Engine Speed/Vehicle Speed/Fuel Disable The fuel injectors.
Mode The throttle body.
The PCM monitors engine speed. It turns off the fuel The fuel rail.
injectors when the engine speed increase above 6400
RPM. The fuel injectors are turned back on when engine The fuel pressure regulator.
speed decreases below 6150 RPM. The PCM.
The crankshaft position (CKP) sensor.
Fuel Cutoff Mode The camshaft position (CMP) sensor.
No fuel is delivered by the fuel injectors when the ignition The idle air control (IAC) valve.
is “OFF.” This prevents engine run-on. In addition, the
The fuel pump.
PCM suspends fuel delivery if no reference pulses are
detected (engine not running) to prevent engine flooding. The fuel pump relay.

Fuel Injector Basic System Operation


The sequential multiport fuel injection (SFI) fuel injector is The fuel metering system starts with the fuel in the fuel
a solenoid-operated device controlled by the PCM. The tank. An electric fuel pump, located in the fuel tank,
PCM energizes the solenoid, which opens a valve to allow pumps fuel to the fuel rail through an in-line fuel filter. The
fuel delivery. pump is designed to provide fuel at a pressure above the
The fuel is injected under pressure in a conical spray pressure needed by the injectors. A fuel pressure
pattern at the opening of the intake valve. Excess fuel not regulator in the fuel rail keeps fuel available to the fuel
used by the injectors passes through the fuel pressure injectors at a constant pressure. A return line delivers
regulator before being returned to the fuel tank. unused fuel back to the fuel tank. Refer to Section 6C for
A fuel injector which is stuck partly open will cause a loss further information on the fuel tank, line filter, and fuel
of fuel pressure after engine shut down, causing long pipes.
crank times.
Fuel Metering System Purpose
The basic function of the air/fuel metering system is to
control the air/fuel delivery to the engine. Fuel is delivered
to the engine by individual fuel injectors mounted in the
intake manifold near each intake valve.
The main control sensor is the heated oxygen sensor
(HO2S) located in the exhaust system. The HO2S tells
the PCM how much oxygen is in the exhaust gas. The
PCM changes the air/fuel ratio to the engine by controlling
the amount of time that fuel injector is “ON.” The best
mixture to minimize exhaust emissions is 14.7 parts of air
to 1 part of gasoline by weight, which allows the catalytic
converter to operate most efficiently. Because of the
ENGINE DRIVEABILITY AND EMISSIONS 6E–343
constant measuring and adjusting of the air/fuel ratio, the a constant fuel pressure at the injectors. Remaining fuel
fuel injection system is called a “closed loop” system. is then returned to the fuel tank.
The PCM monitors signals from several sensors in order
to determine the fuel needs of the engine. Fuel is
delivered under one of several conditions called “modes.”
All modes are controlled by the PCM.

Fuel Pressure Regulator


The fuel pressure regulator is a diaphragm-operated
relief valve mounted on the fuel rail with fuel pump
pressure on one side and manifold pressure on the other
side. The fuel pressure regulator maintains the fuel
pressure available to the injector at three times
barometric pressure adjusted for engine load. It may be
serviced separate.
If the pressure is too low, poor performance and a DTC
P0131, DTC P0151,DTC P0171 or DTC P1171 will be the
result. If the pressure is too high, excessive odor and/or a
DTC P0132, DTC P0152,DTC P0172 or DTC P0175 will
be the result. Refer to Fuel System Diagnosis for
information on diagnosing fuel pressure conditions.
055RW009

Idle Air Control (IAC) Valve


The purpose of the idle air control (IAC) valve is to control
engine idle speed, while preventing stalls due to changes
in engine load. The IAC valve, mounted in the throttle
body, controls bypass air around the throttle plate. By
moving the conical valve (pintle) in (to decrease air flow)
or out (to increase air flow), a controlled amount of air can
move around the throttle plate. If the RPM is too low, the
PCM will retract the IAC pintle, resulting in more air
moving past the throttle plate to increase the RPM. If the
RPM is too high, the PCM will extend the IAC pintle,
allowing less air to move past the throttle plate,
decreasing the RPM.
The IAC pintle valve moves in small steps called counts.
During idle, the proper position of the IAC pintle is
calculated by the PCM based on battery voltage, coolant
temperature, engine load, and engine RPM. If the RPM
0011 drops below a specified value, and the throttle plate is
closed, the PCM senses a near-stall condition. The PCM
Fuel Pump Electrical Circuit will then calculate a new IAC pintle valve position to
When the key is first turned “ON,” the PCM energizes the prevent stalls.
fuel pump relay for two seconds to build up the fuel If the IAC valve is disconnected and reconnected with the
pressure quickly. If the engine is not started within two engine running, the idle RPM will be wrong. In this case,
seconds, the PCM shuts the fuel pump off and waits until the IAC must be reset. The IAC resets when the key is
the engine is cranked. When the engine is cranked and cycled “ON” then “OFF.” When servicing the IAC, it
the 58 X crankshaft position signal has been detected by should only be disconnected or connected with the
the PCM, the PCM supplies 12 volts to the fuel pump relay ignition “OFF.”
to energize the electric in-tank fuel pump. The position of the IAC pintle valve affects engine start-up
An inoperative fuel pump will cause a “no-start” condition. and the idle characteristics of the vehicle. If the IAC pintle
A fuel pump which does not provide enough pressure will is fully open, too much air will be allowed into the manifold.
result in poor performance. This results in high idle speed, along with possible hard
starting and a lean air/fuel ratio. DTC P0507 or DTC
Fuel Rail P1509 may set. If the IAC pintle is stuck closed, too little
The fuel rail is mounted to the top of the engine and air will be allowed in the manifold. This results in a low idle
distributes fuel to the individual injectors. Fuel is speed, along with possible hard starting and a rich air/fuel
delivered to the fuel inlet tube of the fuel rail by the fuel ratio. DTC P0506 or DTC P1508 may set. If the IAC
lines. The fuel goes through the fuel rail to the fuel pintle is stuck part-way open, the idle may be high or low
pressure regulator. The fuel pressure regulator maintains and will not respond to changes in the engine load.
6E–344 ENGINE DRIVEABILITY AND EMISSIONS
Throttle Body Unit
The throttle body has a throttle plate to control the amount
of air delivered to the engine. The TP sensor and IAC
valve are also mounted on the throttle body. Vacuum
ports located behind the throttle plate provide the vacuum
signals needed by various components.
Engine coolant is directed through a coolant cavity in the
throttle body to warm the throttle valve and to prevent
icing.

0006

Run Mode
The run mode has the following two conditions:
Open loop
Closed loop
When the engine is first started the system is in “open
loop” operation. In “open loop,” the PCM ignores the
signal from the heated oxygen sensor (HO2S). It
calculates the air/fuel ratio based on inputs from the TP, 0019

ECT, and MAF sensors.


The system remains in “open loop” until the following General Description (Electronic
conditions are met:
Ignition System)
The HO2S has a varying voltage output showing that
it is hot enough to operate properly (this depends on
temperature). Camshaft Position (CMP) Sensor
The ECT has reached a specified temperature. As the camshaft sprocket turns, a magnet in the sprocket
A specific amount of time has elapsed since starting activates the Hall-effect switch in the CMP sensor. When
the engine. the Hall-effect switch is activated, it grounds the signal
line to the PCM, pulling the camshaft position sensor
Engine speed has been greater than a specified RPM
signal circuit’s applied voltage low. This is a CMP signal.
since start-up.
The CMP signals is created as piston #1 is approximately
The specific values for the above conditions vary with
25 after top dead counter on the power stroke. If the
different engines and are stored in the programmable
correct CMP signal is not received by the PCM, DTC
read only memory (PROM). When these conditions are
P0341 will be set.
met, the system enters “closed loop” operation. In
“closed loop,” the PCM calculates the air/fuel ratio
(injector on-time) based on the signal from the HO2S.
This allows the air/fuel ratio to stay very close to 14.7:1.

Starting Mode
When the ignition is first turned “ON,” the PCM energizes
the fuel pump relay for two seconds to allow the fuel pump
to build up pressure. The PCM then checks the engine
coolant temperature (ECT) sensor and the throttle
position (TP) sensor to determine the proper air/fuel ratio
for starting.
The PCM controls the amount of fuel delivered in the
starting mode by adjusting how long the fuel injectors are
energized by pulsing the injectors for very short times.
ENGINE DRIVEABILITY AND EMISSIONS 6E–345

0014 0013

Crankshaft Position (CKP) Sensor Ignition Coils


The crankshaft position (CKP) sensor provides a signal A separate coil-at-plug module is located at each spark
used by the powertrain control module (PCM) to calculate plug. The coil-at-plug module is attached to the engine
the ignition sequence. The sensor initiates the 58X with two screws. It is installed directly to the spark plug by
reference pulses which the PCM uses to calculate RPM an electrical contact inside a rubber boot. A three-way
and crankshaft position. Refer to Electronic Ignition connector provides 12-volt primary supply from the
System for additional information. 15-amp ignition fuse, a ground-switching trigger line from
the PCM, and a ground.
Electronic Ignition
The electronic ignition system controls fuel combustion
by providing a spark to ignite the compressed air/fuel
mixture at the correct time. To provide optimum engine
performance, fuel economy, and control of exhaust
emissions, the PCM controls the spark advance of the
ignition system. Electronic ignition has the following
advantages over a mechanical distributor system:
No moving parts.
Less maintenance.
Remote mounting capability.
No mechanical load on the engine.
More coil cooldown time between firing events.
Elimination of mechanical timing adjustments.
Increased available ignition coil saturation time.

0001

Ignition Control
The ignition control (IC) spark timing is the PCM’s method
of controlling the spark advance and the ignition dwell.
The IC spark advance and the ignition dwell are
calculated by the PCM using the following inputs:
Engine speed.
6E–346 ENGINE DRIVEABILITY AND EMISSIONS
Crankshaft position (58X reference). The knock sensor tells the PCM if there is any
Camshaft position (CMP) sensor. problem with pre-ignition or detonation. This
information allows the PCM to retard timing, if
Engine coolant temperature (ECT) sensor.
necessary.
Throttle position (TP) sensor.
Knock signal (knock sensor).
Park/Neutral position (PRNDL input).
Vehicle speed (vehicle speed sensor).
PCM and ignition system supply voltage.
The crankshaft positron (CKP) sensor sends the
PCM a 58X signal related to the exact position of the
crankshaft.

TS24037

Based on these sensor signals and engine load


information, the PCM sends 5V to each ignition coil.

TS22909

The camshaft position (CMP) sensor sends a signal


related to the position of the camshaft.

060RW015

The PCM applies 5V signal voltage to the ignition coil


requiring ignition. This signal sets on the power transistor
of the ignition coil to establish a grounding circuit for the
primary coil, applying battery voltage to the primary coil.
At the ignition timing, the PCM stops sending the 5V
signal voltage. Under this condition the power transistor
of the ignition coil is set off to cut the battery voltage to the
primary coil, thereby causing a magnetic field generated
TS22910 in the primary coil to collapse. On this moment a line of
magnetic force flows to the secondary coil, and when this
magnetic line crosses the coil, high voltage induced by
ENGINE DRIVEABILITY AND EMISSIONS 6E–347
the secondary ignition circuit to flow through the spark optimum driveability and emissions, the PCM monitors
plug to the ground. the input signals from the following components in order
to calculate spark timing:
Engine coolant temperature (ECT) sensor.
Intake air temperature (IAT) sensor.
Mass air flow (MAF) sensor.
PRNDL input from transmission range switch.
Throttle position (TP) sensor.
Vehicle speed sensor (VSS) .
Crankshaft position (CKP) sensor.

Spark Plug
Although worn or dirty spark plugs may give satisfactory
operation at idling speed, they frequency fail at higher
engine speeds. Faulty spark plugs may cause poor fuel
economy, power loss, loss of speed, hard starting and
generally poor engine performance. Follow the
scheduled maintenance service recommendations to
ensure satisfactory spark plug performance. Refer to
Maintenance and Lubrication.
TS24047
Normal spark plug operation will result in brown to
grayish-tan deposits appearing on the insulator portion of
Ignition Control PCM Output the spark plug. A small amount of red-brown, yellow, and
The PCM provides a zero volt (actually about 100 mV to white powdery material may also be present on the
200 mV) or a 5-volt output signal to the ignition control (IC) insulator tip around the center electrode. These deposits
module. Each spark plug has its own primary and are normal combustion by-products of fuels and
secondary coil module (”coil-at-plug”) located at the spark lubricating oils with additives. Some electrode wear will
plug itself. When the ignition coil receives the 5-volt signal also occur. Engines which are not running properly are
from the PCM, it provides a ground path for the B+ supply often referred to as “misfiring.” This means the ignition
to the primary side of the coil-at -plug module. This spark is not igniting the air/fuel mixture at the proper time.
energizes the primary coil and creates a magnetic field in While other ignition and fuel system causes must also be
the coil-at-plug module. When the PCM shuts off the considered, possible causes include ignition system
5-volt signal to the ignition control module, the ground conditions which allow the spark voltage to reach ground
path for the primary coil is broken. The magnetic field in some other manner than by jumping across the air gap
collapses and induces a high voltage secondary impulse at the tip of the spark plug, leaving the air/fuel mixture
which fires the spark plug and ignites the air/fuel mixture. unburned. Misfiring may also occur when the tip of the
The circuit between the PCM and the ignition coil is spark plug becomes overheated and ignites the mixture
monitored for open circuits, shorts to voltage, and shorts before the spark jumps. This is referred to as
to ground. If the PCM detects one of these events, it will “pre-ignition.”
set one of the following DTCs: Spark plugs may also misfire due to fouling, excessive
P0351: Ignition coil Fault on Cylinder #1 gap, or a cracked or broken insulator. If misfiring occurs
P0352: Ignition coil Fault on Cylinder #2 before the recommended replacement interval, locate
P0353: Ignition coil Fault on Cylinder #3 and correct the cause.
Carbon fouling of the spark plug is indicated by dry, black
P0354: Ignition coil Fault on Cylinder #4
carbon (soot) deposits on the portion of the spark plug in
P0355: Ignition coil Fault on Cylinder #5 the cylinder. Excessive idling and slow speeds under
P0356: Ignition coil Fault on Cylinder #6 light engine loads can keep the spark plug temperatures
so low that these deposits are not burned off. Very rich
Knock Sensor (KS) PCM Input fuel mixtures or poor ignition system output may also be
The knock sensor (KS) system is comprised of a knock the cause. Refer to DTC P0172.
sensor and the PCM. The PCM monitors the KS signals Oil fouling of the spark plug is indicated by wet oily
to determine when engine detonation occurs. When a deposits on the portion of the spark plug in the cylinder,
knock sensor detects detonation, the PCM retards the usually with little electrode wear. This may be caused by
spark timing to reduce detonation. Timing may also be oil during break-in of new or newly overhauled engines.
retarded because of excessive mechanical engine or Deposit fouling of the spark plug occurs when the normal
transmission noise. red-brown, yellow or white deposits of combustion by
products become sufficient to cause misfiring. In some
Powertrain Control Module (PCM) cases, these deposits may melt and form a shiny glaze on
The PCM is responsible for maintaining proper spark and the insulator around the center electrode. If the fouling is
fuel injection timing for all driving conditions. To provide found in only one or two cylinders, valve stem clearances
or intake valve seals may be allowing excess lubricating
6E–348 ENGINE DRIVEABILITY AND EMISSIONS
oil to enter the cylinder, particularly if the deposits are keep it from seating even though the proper torque is
heavier on the side of the spark plug facing the intake applied. Once spark plugs are properly seated, tighten
valve. them to the torque shown in the Specifications Table. Low
torque may result in poor contact of the seats due to a
loose spark plug. Overtightening may cause the spark
plug shell to be stretched and will result in poor contact
between the seats. In extreme cases, exhaust blow-by
and damage beyond simple gap wear may occur.
Cracked or broken insulators may be the result of
improper installation, damage during spark plug
re-gapping, or heat shock to the insulator material. Upper
insulators can be broken when a poorly fitting tool is used
during installation or removal, when the spark plug is hit
from the outside, or is dropped on a hard surface. Cracks
in the upper insulator may be inside the shell and not
visible. Also, the breakage may not cause problems until
oil or moisture penetrates the crack later.

TS23995

Excessive gap means that the air space between the


center and the side electrodes at the bottom of the spark
plug is too wide for consistent firing. This may be due to
improper gap adjustment or to excessive wear of the
electrode during use. A check of the gap size and
comparison to the gap specified for the vehicle in
Maintenance and Lubrication will tell if the gap is too wide.
A spark plug gap that is too small may cause an unstable
idle condition. Excessive gap wear can be an indication
of continuous operation at high speeds or with engine
loads, causing the spark to run too hot. Another possible
cause is an excessively lean fuel mixture.

TS23994

A broken or cracked lower insulator tip (around the center


electrode) may result from damage during re-gapping or
from “heat shock” (spark plug suddenly operating too
hot).

TS23992

Low or high spark plug installation torque or improper


seating can result in the spark plug running too hot and
can cause excessive center electrode wear. The plug
and the cylinder head seats must be in good contact for
proper heat transfer and spark plug cooling. Dirty or
damaged threads in the head or on the spark plug can TS23993
ENGINE DRIVEABILITY AND EMISSIONS 6E–349
Damage during re-gapping can happen if the gapping The PCM.
tool is pushed against the center electrode or the
insulator around it, causing the insulator to crack. A/C Request Signal
When re-gapping a spark plug, make the adjustment This signal tells the PCM when the A/C mode is selected
by bending only the ground side terminal, keeping the at the A/C control head. The PCM uses this to adjust the
tool clear of other parts. idle speed before turning on the A/C clutch. The A/C
”Heat shock” breakage in the lower insulator tip compressor will be inoperative if this signal is not
generally occurs during several engine operating available to the PCM.
conditions (high speeds or heavy loading) and may be Refer to A/C Clutch Circuit Diagnosis for A/C wiring
caused by over-advanced timing or low grade fuels. diagrams and diagnosis for A/C electrical system.
Heat shock refers to a rapid increase in the tip
temperature that causes the insulator material to
crack. General Description (Exhaust Gas
Spark plugs with less than the recommended amount of Recirculation (EGR) System)
service can sometimes be cleaned and re-gapped , then
returned to service. However, if there is any doubt about EGR Purpose
the serviceability of a spark plug, replace it. Spark plugs
with cracked or broken insulators should always be The exhaust gas recirculation (EGR) system is use to
replaced. reduce emission levels of oxides of nitrogen (NOx). NOx
emission levels are caused by a high combustion
A/C Clutch Diagnosis temperature. The EGR system lowers the NOx emission
levels by decreasing the combustion temperature.
A/C Clutch Circuit Operation
A 12-volt signal is supplied to the A/C request input of the
PCM when the A/C is selected through the A/C control
switch.
The A/C compressor clutch relay is controlled through the
PCM. This allows the PCM to modify the idle air control
position prior to the A/C clutch engagement for better idle
quality. If the engine operating conditions are within their
specified calibrated acceptable ranges, the PCM will
enable the A/C compressor relay. This is done by
providing a ground path for the A/C relay coil within the
PCM. When the A/C compressor relay is enabled,
battery voltage is supplied to the compressor clutch coil.
The PCM will enable the A/C compressor clutch
whenever the engine is running and the A/C has been
requested. The PCM will not enable the A/C compressor
clutch if any of the following conditions are met:
The throttle is greater than 90%.
The engine speed is greater than 6315 RPM. 057RW002

The ECT is greater than 119 C (246 F).


The IAT is less than 5 C (41 F). Linear EGR Valve
The throttle is more than 80% open. The main element of the system is the linear EGR valve.
The EGR valve feeds small amounts of exhaust gas back
A/C Clutch Circuit Purpose into the combustion chamber. The fuel/air mixture will be
diluted and combustion temperatures reduced.
The A/C compressor operation is controlled by the
powertrain control module (PCM) for the following Linear EGR Control
reasons:
The PCM monitors the EGR actual positron and adjusts
It improvises idle quality during compressor clutch
the pintle position accordingly. The uses information from
engagement.
the following sensors to control the pintle position:
It improvises wide open throttle (WOT) performance. Engine coolant temperature (ECT) sensor.
It provides A/C compressor protection from operation Throttle position (TP) sensor.
with incorrect refrigerant pressures.
The A/C electrical system consists of the following Mass air flow (MAF) sensor.
components:
Linear EGR Valve Operation and Results
The A/C control head.
of Incorrect Operation
The A/C refrigerant pressure switches.
The linear EGR valve is designed to accurately supply
The A/C compressor clutch. EGR to the engine independent of intake manifold
The A/C compressor clutch relay. vacuum. The valve controls EGR flow from the exhaust
6E–350 ENGINE DRIVEABILITY AND EMISSIONS
to the intake manifold through an orifice with a PCM EGR Pintle Position Sensor
controlled pintle. During operation, the PCM controls The PCM monitors the EGR valve pintle position input to
pintle position by monitoring the pintle position feedback endure that the valve responds properly to commands
signal. The feedback signal can be monitored with Tech 2 from the PCM and to detect a fault if the pintle position
as “Actual EGR Pos.” “Actual EGR Pos.” should always sensor and control circuits are open or shorted. If the
be near the commanded EGR position (”Desired EGR PCM detects a pintle position signal voltage outside the
Pos.”). If a problem with the EGR system will not allow the normal range of the pintle position sensor, or a signal
PCM to control the pintle position properly, DTC P1406 voltage that is not within a tolerance considered
will set. The PCM also tests for EGR flow. If incorrect flow acceptable for proper EGR system operation, the PCM
is detected, DTC P0401 will set. If DTCs P0401 and/or will set DTC P1406.
P1406 are set, refer to the DTC charts.
The linear EGR valve is usually activated under the
following conditions: General Description (Positive
Warm engine operation. Crankcase Ventilation (PCV) System)
Above-idle speed.
Too much EGR flow at idle, cruise or cold operation may Crankcase Ventilation System Purpose
cause any of the following conditions to occur: The crankcase ventilation system is use to consume
Engine stalls after a cold start. crankcase vapors in the combustion process instead of
Engine stalls at idle after deceleration. venting them to the atmosphere. Fresh air from the
Vehicle surges during cruise. throttle body is supplied to the crankcase and mixed with
blow-by gases. This mixture is then passed through the
Rough idle.
positive crankcase ventilation (PCV) valve into the
Too little or no EGR flow may allow combustion common chamber.
temperatures to get too high. This could cause:
Spark knock (detonation). Crankcase Ventilation System Operation
Engine overheating. The primary control is through the positive crankcase
Emission test failure. ventilation (PCV) valve. The PCV valve meters the flow at
DTC P0401 (EGR flow test). a rate that depends on the intake vacuum. The PCV valve
Poor fuel economy. restricts the flow when the inlet vacuum is highest. In
addition, the PCV valve can seal the common chamber
off in case of sudden high pressure in the crankcase.

0017

028RV002

While the engine is running, exhaust fuses and small


amounts of the fuel/air mixture escape past the piston
ENGINE DRIVEABILITY AND EMISSIONS 6E–351
rings and enter the crankcase. These gases are mixed
with clean air entering through a tube from the air intake
duct.

028RW002

During normal, part-throttle operation, the system is


designed to allow crankcase gases to flow through the
PCV valve into the throttle body to be consumed by
normal combustion.
A plugged valve or PCV hose may cause the following
conditions:
Rough idle.
Stalling of slow idle speed.
Oil leaks.
Sludge in the engine.
A leaking PCV hose would cause:
Rough idle.
Stalling.
High idle speed.
6E–352 ENGINE DRIVEABILITY AND EMISSIONS

Special Tools

901RW180

Legend (3) SAE 16/19 Adapter


(1) PCMCIA Card (4) DLC Cable
(2) RS232 Loop Back Connector (5) TECH–2
ENGINE DRIVEABILITY AND EMISSIONS 6E–353

TOOL NO. TOOL NO.


ILLUSTRATION ILLUSTRATION
TOOL NAME TOOL NAME

5-8840-0285-0
(J 39200) BT-8515
High Impedance Exhaust Back Pressure
Multimeter (Digital Tester or common tool
Voltmeter – DVM)

(1) PCMCIA Card


(2) RS232 Loop Back 5-8840-2640-0
Connector (J 39194-B)
(3) SAE 16/19 Adapter Heated Oxygen Sensor
(4) DLC Cable Wrench
(5) TECH–2

5-8840-0632-0
5-8840-0607-0 (J 35689-A)
(J 34142-B) Terminal Remover
Unpowered Test Light

5-8840-0388-0
5-8840-0385-0 (J 28742-A)
(J 35616-A/BT-8637) Weather Pack II
Connector Test Terminal Remover
Adapter Kit

5-8840-2635-0
5-8840-0383-0 (J 39021-90)
(J 26792/BT-7220-1) Injector Switch Box
Spark Tester

5-8840-0279-0 5-8840-2636-0
(J 23738-A) (J 39021-65)
Vacuum Pump with Injector Test Light
Gauge common tool
6E–354 ENGINE DRIVEABILITY AND EMISSIONS

TOOL NO. 1. 5-8840-2607-0 (J-41413)EVAP Pressure/Purge


ILLUSTRATION Diagnostic Station is a multipurpose tool which is
TOOL NAME
used to perform several diagnostic procedures for
enhanced emission testing. The station will
accommodate a nitrogen gas filled cylinder which is
used to pressurize the vehicle EVAP system for a
5-8840-2607-0 leakdown test and leak location test when a vehicle is
(J 41413) repaired for leakage in the enhanced evaporative
EVAP Pressure/Purge emission control system. It also has two additional
Diagnostic Station gauges (inches of mercury and inches of water) which
are used to measure both source vacuum and EVAP
canister purge vacuum to verify correct operation and
vapor flow within the canister purge circuit.
2. 5-8840-2608-0 (J-41416) Ultrasonic Leak Detector is
a microprocessor-based device used to detect leaks
in the enhanced evaporative emission control
system. The evaporative system is pressurized to 30
5-8840-2608-0 inches of water using the 5-8840-2607-0 (J-41413)
(J 41416) EVAP Pressure/Purge Diagnostic System. Small
Ultrasonic Leak Detector leaks in the EVAP system will emit sound at a high
frequency undetectable by a human ear but
detectable with the 5-8840-2608-0 (J-41416). The
technician traces along the evaporative system and
can pinpoint leaks due to corroded lines, cracked
hoses, or a damaged EVAP component. The
detector includes a high quality set of headphones to
block out surrounding shop noise and the LED
sensitivity meter allows a visual reference for locating
leaks in conjunction with the audio output heard
through the headphones. Powered by (1) nine volt
battery.
ENGINE EXHAUST 6F–1

ENGINE
ENGINE EXHAUST
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 6F–1 Exhaust Silencer . . . . . . . . . . . . . . . . . . . . . . . . 6F–6
General Description . . . . . . . . . . . . . . . . . . . . . 6F–2 Exhaust Silencer and Associated Parts . . . 6F–6
Front Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . 6F–4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F–6
Front Exhaust Pipe and Associated Parts . 6F–4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F–6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F–4 Rear Exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . 6F–7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F–4 Rear Exhaust pipe and Associated Parts . 6F–7
Three Way Catalytic Converter . . . . . . . . . . . . 6F–5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F–7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F–5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F–7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F–5 Main Data and Specifications . . . . . . . . . . . . . 6F–8

Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
6F–2 ENGINE EXHAUST

General Description
General export with three way catalytic converter
model

150RW060

General export with out three way catalytic


converter model

150RW059
ENGINE EXHAUST 6F–3

For Isuzu General Motors (IGM)

150RW058

When inspecting or replacing exhaust system Three Way Catalytic Converter


components, make sure there is adequate clearance The three way catalytic converter is an emission control
from all points on the underbody to prevent overheating
device added to the exhaust system to reduce pollutants
the floor pan and possible damage to the passenger
from the exhaust gas stream.
compartment insulation and trim materials.
CAUTION: The catalytic converter requires the use
Check complete exhaust system and nearby body areas of unleaded fuel only.
and rear compartment lid for broken, damaged, missing Periodic maintenance of the exhaust system is not
or mispositioned parts, open seams, holes, loose required. If the vehicle is raised for other service, it is
connections or other deterioration which could permit advisable to check the condition of the complete exhaust
exhaust fumes to seep into the rear compartment or system.
passenger compartment. Dust or water in the rear A dual bed monolith catalytic converter is used in
compartment may be an indication of a problem in one of combination with three way catalytic converter.
these areas. Any faulty areas should be corrected Catalytic Types:
immediately. Three way (Reduction/Oxidation) catalyst
Hangers The catalyst coating on the three way (reduction)
Various types of hangers are used to support exhaust converter contains platinum and rhodium which lowers
system(s). These include conventional rubber straps, the levels of nitrous oxide (NOx) as well as hydrocarbons
rubber rings, and rubber blocks. (HC) and carbon monoxide (Co).

The installation of exhaust system supports is very Gasket


important, as improperly installed supports can cause The gasket must be replaced whenever a new exhaust
annoying vibrations which can be difficult to diagnose. pipe, muffler or catalytic converter is installed.
6F–4 ENGINE EXHAUST

Front Exhaust Pipe


Front Exhaust Pipe and Associated Parts

150RW063

Legend (5) Front Exhaust Pipe LH Fixing Bolts and Nuts


(1) Front Exhaust Pipe RH Fixing Nuts (6) Front Exhaust Pipe LH
(2) Front Exhaust Pipe RH Fixing Bolts and Nuts (7) Front Exhaust Pipe RH
(3) O2 Sensor Terminal Connector (for IGM) (8) Three way Exhaust Pipe Fixing Bolts and Nuts
(4) Front Exhaust Pipe LH Fixing Nuts

Removal Installation
1. Disconnect battery ground cable. 1. Install front exhaust pipe (6)(7) and tighten three stud
2. Raise the vehicle and support with suitable safety nuts (1)(4) and nuts (2)(5)(8) to the specified torque.
stands. Torque
3. Disconnect O2 sensor harness connector (3). Stud Nuts : 67 Nꞏm (6.8 Kgꞏm/49 lb ft)
4. Remove front exhaust pipe fixing nuts and three way Nuts : 43 Nꞏm (4.3 Kgꞏm/32 lb ft)
Exhaust Pipe Fixing Bolts and Nuts (2)(5)(8). 2. Reconnect O2 sensor harness connector (3).
5. Remove front exhaust pipe fixing three stud nuts from
exhaust manifold (1)(4).
6. Remove front exhaust pipe (6)(7).
ENGINE EXHAUST 6F–5

Three Way Catalytic Converter


Removal
1. Disconnect battery ground cable.
2. Raise the vehicle and support with suitable safety
stands.
3. Remove three way exhaust pipe fixing bolts and nuts.

150RW065

Installation
1. Install three way catalytic converter between three
way exhaust pipe and silencer.
2. Tighten nuts to the specified torque.
Torque
Nuts : 43 Nꞏm (4.4 Kgꞏm/32 lb ft)
6F–6 ENGINE EXHAUST

Exhaust Silencer
Exhaust Silencer and Associated Parts

E06RW031

Legend (3) Mounting Rubber


(1) Exhaust Silencer (4) Exhaust Silencer Fixing Nuts
(2) Exhaust Silencer (5) Exhaust Silencer Fixing Bolts

Removal Installation
1. Disconnect battery ground cable. 1. Install the exhaust silencer (1)(2) chassis side and
2. Raise the vehicle and support with suitable safety tighten nuts to the specified torque.
stands. Nuts: 16 Nꞏm (1.6 Kgꞏm/12 lb ft)
3. Remove exhaust silencer fixing nuts (4) then 2. Install the exhaust silencer and tighten nuts (5) on
disconnect rear exhaust pipe from exhaust silencer. front exhaust pipe to specified torque.
4. Remove exhaust silencer fixing nuts (5) then Nuts: 43 Nꞏm (4.4 Kgꞏm/32 lb ft)
disconnect exhaust silencer from three way exhaust
pipe. 3. Install the rear exhaust pipe and tighten fixing nuts on
exhaust silencer to specified torque.
5. Remove exhaust silencer mounting nuts from
chassis side then remove exhaust silencer (1)(2). Nuts: 43 Nꞏm (4.4 Kgꞏm/32 lb ft)
ENGINE EXHAUST 6F–7

Rear Exhaust pipe


Rear Exhaust pipe and Associated Parts

E06RW033

Legend (2) Rear Exhaust Pipe


(1) Mounting Rubber (3) Rear Exhaust Pipe Fixing Nuts

Removal Installation
1. Disconnect battery ground cable. 1. Install the mounting rubber (1).
2. Raise the vehicle and support with suitable safety 2. Install the exhaust pipe (2) and tighten two nuts (3) on
stands. exhaust silencer to specified torque.
3. Remove rear exhaust pipe fixing nuts (3), then Nuts: 43 Nꞏm (4.4 Kgꞏm/32 lb ft)
disconnect rear exhaust pipe from exhaust silencer.
4. Remove mounting rubber (1).
5. Remove rear exhaust pipe (2).
6F–8 ENGINE EXHAUST

Main Data and Specifications


Torque Specifications
Nꞏm (Kgꞏm/lb ft)

E06RW047
ENGINE LUBRICATION 6G–1

ENGINE
ENGINE LUBRICATION
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 6G–1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G–10
General Description . . . . . . . . . . . . . . . . . . . . . 6G–2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G–10
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G–3 Oil Pump Oil Seal . . . . . . . . . . . . . . . . . . . . . . . 6G–12
Oil Pump and Associated Parts . . . . . . . . . . 6G–3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G–12
Oil Pump and Associated Parts . . . . . . . . . . 6G–3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G–12
Inspection and Repair . . . . . . . . . . . . . . . . . . 6G–4 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G–13
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6G–5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G–13
Oil Pan and Crankcase . . . . . . . . . . . . . . . . . . 6G–7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G–13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G–7 Main Data and Specification . . . . . . . . . . . . . . 6G–14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G–7 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G–15
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G–10

Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
6G–2 ENGINE LUBRICATION

General Description

C06RW002

Legend (10) Crankshaft


(1) Oil Strainer (11) Connecting Rod Bearing
(2) Oil Pump (12) Connecting Rod
(3) Relief Valve (13) Piston
(4) Oil Pressure Switch (14) Oil Gallery; Cylinder Head
(5) Oil Filter (15) Camshaft
(6) Safety Valve (16) Camshaft Journal
(7) Oil Pressure Unit (17) Front Journal; Camshaft Drive Gear
(8) Oil Gallery (18) Rear Journal; Camshaft Drive Gear
(9) Crankshaft Bearing (19) Oil Pan
ENGINE LUBRICATION 6G–3

Oil Pump
Oil Pump and Associated Parts

051RW005

Legend (8) Relief Valve


(1) Crankshaft Timing Pulley (9) Oil Pump Cover
(2) Crankcase with Oil Pan (10) Driven Gear
(3) Oil Pipe (11) Drive Gear
(4) Oil Strainer (12) Oil Seal
(5) Oil Pump Assembly (13) O-ring
(6) Plug (14) Oil Pump Body
(7) Spring

Oil Pump and Associated Parts 5. Remove oil pump assembly.


6. Remove plug.
1. Remove crankshaft timing pulley.
7. Remove spring.
2. Remove crankcase with oil pan.
8. Remove relief valve.
3. Remove oil pipe.
9. Remove oil pump cover.
4. Remove oil strainer.
10. Remove driven gear.
6G–4 ENGINE LUBRICATION
11. Remove drive gear.
12. Remove oil seal.
13. Remove O-ring.

Inspection and Repair


CAUTION: Make necessary correction or parts
replacement if wear, damage or any other abnormal
conditions are found during inspection.
Relief Valve (8)
Check to see that the relief valve slides freely.
The oil pump must be replaced if the relief valve does
not slide freely.
Replace the spring and/or the oil pump assembly (5) if
the spring is damaged or badly worn.

051RS004

Measure the clearance between the drive gear and


driven gear with a feeler gauge.
Standard : 0.11 mm–0.24 mm
(0.0043 in–0.0094 in)
Limit : 0.35mm (0.0138 in)

051RS002

Body (14) and Gears (10, 11)


The pump assembly must be replaced if one or more of
the conditions below is discovered during inspection.
Badly worn or damaged driven gear (10).
Badly worn drive gear (11) driving face.
Badly scratched or scored body sliding face (14) or
driven gear (10). 051RS003

Badly worn or damaged gear teeth. Measure the side clearance with a precision straight
Measure the clearance between the body and the driven edge and a feeler gauge.
gear with a feeler gauge. Clearance
Standard : 0.10 mm–0.18 mm Standard : 0.03 mm–0.09 mm
(0.0039 in.–0.0070 in) (0.0011 in–0.0035 in)
Limit : 0.20mm (0.0079 in) Limit : 0.15mm (0.0059 in)
ENGINE LUBRICATION 6G–5
6. Install the plug (6).
Torque : 8 Nꞏm (0.8 Kgꞏm/69 lb in)

051RS005

Oil Strainer
Check the oil strainer for cracking and scoring. If cracking 051RS007

and scoring are found, the oil strainer must be replaced. 7. Install oil pump assembly (5).
Carefully remove any oil from the cylinder body and
the pump. Apply sealant (TB–1207B or equivalent)
to the pump fitting face as shown in illustration. Take
care that sealant is not applied to oil port surfaces.
The oil pump assembly must be installed within 5
minutes after sealant application before the sealant
hardens.
CAUTION: Do not apply an excessive amount of
sealant to the contact surface. Applying too much
sealant will overflow the contact surfaces. This
could cause serious damage to the engine.
Attach oil pump assembly to cylinder body.
Tighten the oil pump fixing bolts.
Torque : 25 Nꞏm (2.5 Kgꞏm/18 lbꞏft)

051RS006

Reassembly
1. Install drive gear (11).
2. Install driven gear (10).
3. Install oil pump cover (9) and first, loosely tighten all of
the attaching screws. Next, tighten the attaching
screws to the specified torque.
Torque : 10 Nꞏm (1.0 Kgꞏm/89 lb in)
After installation, check that the gear rotates
smoothly.
4. Install relief valve (8) and apply engine oil to the relief
valve and spring (7).
5. Install spring (7). 051RW002
6G–6 ENGINE LUBRICATION
Tighten fixing bolts to the specified torque.
Torque : 10 Nꞏm (1.0 Kgꞏm/89 lb in)

051RW001

Legend
(1) Around Bolt Holes
013RW010
(2) Around Dowel Pin 12. Install crankshaft timing pulley.
8. Install the new oil seal (12). Apply engine oil to the oil
seal lip before installation then use 5–8840–2287–0
oil seal Installer, install oil seal.

015RS001

9. Install oil strainer (4) with O-ring (13).


Torque: 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
10. Install oil pipe (3) with O-ring (13).
Torque: 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
11. Install crankcase with oil pan (2).
Remove oil on crankcase mounting surface and dry
the surface.
Apply a proper 4.5 mm (0.7 in) wide bead of sealant
(TB1207C or equivalent) to the crankcase
mounting surface. The bead must be continuous.
The crankcase must be installed within 5 minutes
after sealant application before the sealant
hardens.
ENGINE LUBRICATION 6G–7

Oil Pan and Crankcase


Removal
1. Disconnect battery ground cable.
2. Drain engine oil.
3. Lift vehicle by supporting the frame.
4. Remove front wheels.
5. Remove oil level dipstick from level gauge tube.
6. Remove stone guard.
7. Remove radiator under fan shroud.
8. Remove suspension cross member fixing bolts, 2 pcs
each per side and remove suspension cross member.
9. Remove pitman arm and relay lever assembly, using
the 5–8840–2005–0 remover, remove pitman arm
from the steering unit and remove four fixing bolts for
relay lever assembly.
10. Remove axle housing assembly four fixing bolts from
housing isolator side and mounting bolts from wheel
side. At this time support the axle with a garage jack 013RS003
and remove axle housing assembly.
11. Remove oil pan fixing bolts.
Installation
12. Remove oil pan, using 5–8840–2153–0 sealer cutter,
remove oil pan. 1. Install crankcase.
1. Remove residual sealant, lubricant and moisture
from mounting surface, then dry thoroughly.
2. Properly apply a 4.5 mm (0.7 in) wide bead of
sealant (TB-1207C or equivalent) to mounting
surface of crankcase.
Sealant beat must be continuous.
The crankcase must be installed within 5
minutes after sealant application before the
sealant hardens.

013RS003

13. Remove crankcase fixing bolts.


14. Remove crankcase, using 5–8840–2153–0 sealer
cutter, remove crankcase.
NOTE: Do not deform or damage the flange of oil pan and
crankcase.
Replace the oil pan and/or crankcase if deformed or dam-
aged.

013RW010
6G–8 ENGINE LUBRICATION
3. Install crankcase, tighten crankcase fixing bolts 3. Install axle housing assembly and tighten fixing bolts
to the specified torque. to the specified torque.
Torque : 10 Nꞏm (1.0 Kgꞏm/89 lb in) Axle case bolts
Torque : 82 Nꞏm (8.4 Kgꞏm/60 lb ft)
Mounting bolts
Torque : 152 Nꞏm (15.5 Kgꞏm/112 lb ft)

013RW004

2. Install oil pan


1. Remove residual sealant, lubricant and moisture
from mounting surface, then dry thoroughly. 013RW005

2. Properly apply a 4.5 mm (07 in) wide bead of 4. Install relay lever assembly and tighten fixing bolts.
sealant (TB-1207C or equivalent) to mounting Torque: 44 Nꞏm (4.5 Kgꞏm/32 lb ft)
surface of oil pan.
5. Engage teeth of pitman arm and steering unit, and
Sealant beat must be continuous. tighten nut to the specified torque.
The crankcase must be installed within 5
Torque : 216 Nꞏm (22.0 Kgꞏm/159 lb ft)
minutes after sealant application befor the
sealant hardens.

013RW006

013RW003 Legend
3. Install oil pan, tighten oil pan fixing bolts to the (1) Pitman Arm
specified torque. (2) Relay Lever
Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
ENGINE LUBRICATION 6G–9
6. Install suspension cross member and tighten fixing
bolts to the specified torque.
Torque : 78 Nꞏm (8.0 Kgꞏm/58 lb ft)

013RW007

7. Install radiator under fan shroud.


8. Install stone guard.
9. Install engine oil level dipstick.
10. Fill engine oil until full level on engine oil gauge
dipstick.
6G–10 ENGINE LUBRICATION

Oil Pump
Removal Use 5–8840–2287–0 installer when installing new
oil seal.
1. Disconnect battery ground cable.
Apply engine oil to oil seal lip.
2. Drain engine oil.
3. Remove crankcase assembly. Install oil pump assembly to the cylinder block.
Refer to removal procedure for Oil Pan and NOTE: Do not damage oil seal during installation of oil
Crankcase in this manual. pump assembly.
4. Remove crankshaft pulley.
Refer to removal procedure for Crankshaft Pulley in
this manual.
5. Remove timing belt.
Refer to removal procedure for Timing Belt in this
manual.
6. Remove timing pulley from crankshaft.
7. Remove four fixing bolts from oil filter assembly.
8. Remove oil strainer fixing bolts, remove oil strainer
assembly with O-ring.
9. Remove three bolts from oil pipe and O-ring.
10. Remove eight oil pump fixing bolts, then oil pump
assembly.
11. Remove sealant from mounting surface of oil pump
assembly, cylinder block and take care not to damage
mounting surfaces of oil pump and cylinder block.

Installation 015RS001

Tighten fixing bolts to the specified torque.


1. Install oil pump assembly
Apply sealant (TB-1207B or equivalent) to the oil Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
pump mounting surfaces as shown in the
illustration.
The oil pump assembly must be installed within 5
minutes after sealant application before the sealant
hardens.
NOTE: Do not apply sealant to the oil ports.

051RW001

2. Install oil pipe with O-ring, tighten fixing bolt to the


specified torque.
Torque : 10 Nꞏm (1.0 Kgꞏm/89 lb in)
3. Install oil strainer with O-ring, tighten fixing bolt to the
specified torque.
051RW002
Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
ENGINE LUBRICATION 6G–11
4. Install oil filter assembly and tighten bolts to the
specified torque.
Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)

050RW001

Legend
(1) Oil Pump
(2) Oil Filter
(3) Oil Gallery
(4) From Oil Filter
(5) To Oil Filter

5. Install timing pulley on crankshaft.


Install timing belt.
Refer to installation procedure for Timing Belt in this
manual.
6. Install crankshaft pulley.
Refer to install procedure for Crankshaft Pulley in
this manual.
7. Install crankcase assembly.
Refer to installation procedure for Oil Pan and
Crankcase in this manual.
8. Refill engine oil until full level on engine oil dipstick.
6G–12 ENGINE LUBRICATION

Oil Pump Oil Seal


Removal
1. Disconnect battery ground cable.
2. Drain engine oil.
3. Remove crankshaft pulley.
Refer to removal procedure for Crankshaft Pulley in
this manual.
4. Remove timing belt.
Refer to removal procedure for Timing Belt in this
manual.
5. Remove timing pulley from crankshaft.
6. Remove oil pump oil seal using a sealer puller.
NOTE: Take care not to damage sealing surfaces of oil
pump and crankshaft when removing oil seal.

Installation
1. Install oil pump oil seal, apply engine oil to oil seal lip,
then install oil seal using 5–8840–2287–0 installer.

015RS001

2. Install timing pulley to crankshaft.


3. Install timing belt.
Refer to installation procedure for Timing Belt in this
manual.
4. Install crankshaft pulley.
Refer to installation procedure for Crankshaft
Pulley in this manual.
5. Refill engine oil until full level.
ENGINE LUBRICATION 6G–13

Oil Filter
Removal
1. Disconnect battery ground cable.
2. Drain engine oil.
3. Remove oil filter using 5-8840-0203-0 filter wrench.

Installation
1. Clean filter fitting surface and apply small amount of
engine oil to sealing surface.
2. Install oil filter cartridge by hand until it comes in
contact with sealing surface then rotate additional 2/3
turn to tighten using 5-8840-0203-0 filter wrench.

050RW001

Legend
(1) Oil Pump
(2) Oil Filter
(3) Oil Gallery
(4) From Filter
(5) To Filter

3. Fill engine oil until full level on dipstick.


4. Reconnect battery ground cable.
6G–14 ENGINE LUBRICATION

Main Data and Specification


General Specification
Specifications
Item
6VD1 6VE1
Oil capacity 5.3 liters

Torque Specifications
Crankcase, Oil pan, Timing belt tensioner, Timing
pulley, timing belt cover, Oil pump, Oil gallery, Oil
strainer Nꞏm (Kgꞏm/lb ft)

E06RW045
ENGINE LUBRICATION 6G–15

Special Tool
TOOL NO.
ILLUSTRATION
TOOL NAME

5–8840–2287–0
(J–39202)
Installer; Oil pump oil
seal

5–8840–2153–0
(J–37228)
Seal cutter

5–8840–2005–0
(J–29107)
Universal pitman arm
puller

5–8840–0203–0
(J–36390)
Wrench; Oil filter
ENGINE SPEED CONTROL SYSTEM 6H–1

ENGINE
ENGINE SPEED CONTROL SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 6H–1 Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . 6H–3
Accelerator Pedal Control Cable . . . . . . . . . . 6H–2 Accelerator Pedal and Associated Parts . . 6H–3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6H–2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6H–3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6H–2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6H–3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6H–2 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 6H–3
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 6H–2

Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
6H–2 ENGINE SPEED CONTROL SYSTEM

Accelerator Pedal Control Cable


Removal
1. Loosen the adjusting nut(5) on the cable bracket
mounted on the common chamber.
2. Remove cable clip(3).
3. Disconnect accelerator pedal (AP) control cable(6).
(on throttle valve side)
4. Disconnect AP control cable(1). (on AP pedal(7) side)
5. Remove molding cap(2).
6. Remove AP control cable(4).

101RW001

Adjustment
1. Loosen adjusting nut and lock nut.
2. Pull outer cable while closing fully the throttle valve.
3. Tighten adjusting nut and lock nut temporarily.
4. Loosen adjusting nut by three turns and tighten lock
nut.
Then, manually operating the throttle valve, make
sure that the valve lever returns up to the stopper
101RW001
screw.
If it does not reach the stopper screw, repeat from
Inspection step 1.
Check the following items, and replace the control cable if
any abnormality is found:
The control cable should move smoothly.
The control cable should not be bent or kinked.
The control cable should be free of damage and
corrosion.

Installation
1. Install AP control cable(4).
2. Install molding cap(2).
3. Connect AP control cable(1). (on AP side)
4. Connect AP control cable(6). (on throttle valve side)
5. Install cable clip(3).
6. Install adjusting nut(5).

035RW004

Legend
(1) Clearance
(2) Lock Nut
(3) Adjusting Nut
ENGINE SPEED CONTROL SYSTEM 6H–3

Accelerator Pedal
Accelerator Pedal and Associated Adjustment
Parts Manual Transmission:
Rotate counterclockwise to loosen the lock nut and
screw the stopper bolt in sufficiently.
Fully depress the pedal and hold it there with your
hand. Next, rotate the stopper bolt until it hits the
stopper of pedal bracket. Then, lock the stopper bolt
there.

Automatic Transmission:
Rotate counterclockwise to loosen the kickdown
switch sufficiently.
Fully depress the pedal and hold it there with your
hand. Rotate the switch clockwise and then rotate
further by 1/2 turn from the position where the switch
clicks. Lock the switch there.
Step on the accelerator pedal and make sure that you
can hear a clicking sound at the full stroke position.

035RW028

Legend
(1) Accelerator Pedal Control Cable
(2) Accelerator Pedal Assembly

Removal
1. Accelerator Pedal control cable(1).
2. Accelerator Pedal assembly(2).

Installation
1. Accelerator pedal assembly(2).
2. Accelerator pedal control cable(1).
6H–4 ENGINE SPEED CONTROL SYSTEM

MEMO
INDUCTION 6J–1

ENGINE
INDUCTION
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 6J–1
Air Cleaner Element . . . . . . . . . . . . . . . . . . . . . 6J–2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6J–2
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6J–2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6J–2
Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM
(SRS),REFER TO THE SRS COMPONENT AND
WIRING LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
6J–2 INDUCTION

Air Cleaner Element


Removal Installation
1. Remove positive ventilation hose from connector(1). 1. Install air cleaner element(5).
2. Remove intake air temperature sensor(2). 2. Attach the air cleaner duct cover (4) to the body
3. Remove air flow sensor(3). completely, then clamp it with the clip.
4. Remove air cleaner duct cover(4). 3. Install mass air flow sensor(3).
5. Remove air cleaner element(5). 4. Install air temperature sensor(2).
5. Connect positive crankcase ventilation hose to
connector(1).
For General Export Model

130RW003

Inspection
130RW003
Check the air cleaner element for damage or dust
clogging. Replace if it is damaged, or clean if it is clogged. For Isuzu General Motors (IGM) Model
Cleaning Method
Tap the air cleaner element gently so as not to damage
the paper element, or clean the element by blowing with
compressed air of about 490 kPa (71 psi) from the clean
side if it is extremely dirty.

130RW006

130RW002
ENGINE MECHANICAL (6VE1 3.5L) 6A–1

ENGINE
CONTENTS
Engine Mechanical . . . . . . . . . . . . . . . . . . . . . . 6A Driveability and Emissions . . . . . . . . . . . . . . . . 6E
Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . . 6B Engine Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . 6F
Engine Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . 6G
Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . 6D1 Engine Speed Control System . . . . . . . . . . . . 6H
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . 6D2 Induction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6J
Starting and Charging System . . . . . . . . . . . . 6D3

ENGINE MECHANICAL (6VE1 3.5L)


CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 6A–2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–38
General Description . . . . . . . . . . . . . . . . . . . . . 6A–3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–39
Engine Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 6A–4 Crankshaft and Main Bearings . . . . . . . . . . . . 6A–40
Cylinder Head Cover LH . . . . . . . . . . . . . . . . . 6A–19 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–40
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–41
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–20 Rear Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–45
Cylinder Head Cover RH . . . . . . . . . . . . . . . . . 6A–21 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–45
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–21 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–45
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–21 Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . 6A–46
Common Chamber . . . . . . . . . . . . . . . . . . . . . . 6A–22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–46
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–22 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–47
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–22 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–49
Exhaust Manifold LH . . . . . . . . . . . . . . . . . . . . . 6A–24 Cylinder Head and Associated Parts . . . . . 6A–49
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–24 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–50
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–24 Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–50
Exhaust Manifold RH . . . . . . . . . . . . . . . . . . . . 6A–25 Inspection and Repair . . . . . . . . . . . . . . . . . . 6A–50
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–25 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–51
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–25 Valve Spring, Oil Controller, Valve, Valve
Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . . 6A–26 Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–53
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–26 Valve Spring, Oil Controller, Valve, Valve
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–26 Guide and Associated Parts . . . . . . . . . . . . 6A–53
Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–27 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–53
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–27 Inspection and Repair . . . . . . . . . . . . . . . . . . 6A–54
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–28 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–57
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–32 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–60
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–32 Camshaft and Associated Parts . . . . . . . . . 6A–60
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–33 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–60
Inspection and Repair . . . . . . . . . . . . . . . . . . 6A–61
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–35
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–63
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–35
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–35 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–67
Crankshaft and Associated Parts . . . . . . . . 6A–67
Valve Stem Oil Controller , Valve Spring and
Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–37 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–67
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–37 Inspection and Repair for Bearings . . . . . . 6A–68
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–37 Inspection and Repair for Crankshaft . . . . . 6A–70
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–71
Piston, Piston Ring and Connecting Rod . . . 6A–38
6A–2 ENGINE MECHANICAL (6VE1 3.5L)
Piston and Connecting Rod . . . . . . . . . . . . . . . 6A–75 Cylinder Block and Associated Parts . . . . . 6A–82
Piston, Connecting Rod and Associate Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–82
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–75 Inspection and Repair . . . . . . . . . . . . . . . . . . 6A–83
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–75 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–84
Inspection and Repair . . . . . . . . . . . . . . . . . . 6A–76 Main Data and Specification . . . . . . . . . . . . . . 6A–87
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–80 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–93
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–82

Service Precaution CAUTION: Always use the correct fastener in the


proper location. When you replace a fastener, use
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL ONLY the exact part number for that application.
RESTRAINT SYSTEM (SRS). REFER TO THE SRS ISUZU will call out those fasteners that require a
COMPONENT AND WIRING LOCATION VIEW IN replacement after removal. ISUZU will also call out
ORDER TO DETERMINE WHETHER YOU ARE the fasteners that require thread lockers or thread
PERFORMING SERVICE ON OR NEAR THE SRS sealant. UNLESS OTHERWISE SPECIFIED, do not
COMPONENTS OR THE SRS WIRING. WHEN YOU use supplemental coatings (Paints, greases, or other
ARE PERFORMING SERVICE ON OR NEAR THE SRS corrosion inhibitors) on threaded fasteners or
COMPONENTS OR THE SRS WIRING, REFER TO fastener joint interfaces. Generally, such coatings
THE SRS SERVICE INFORMATION. FAILURE TO adversely affect the fastener torque and the joint
FOLLOW WARNINGS COULD RESULT IN POSSIBLE clamping force, and may damage the fastener. When
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR you install fasteners, use the correct tightening
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
ENGINE MECHANICAL (6VE1 3.5L) 6A–3

General Description Cylinder Block


The cylinder block is made of aluminum die–cast casting
Engine Cleanliness And Care for 75 V–type six cylinders. It has a rear plate integrated
An automobile engine is a combination of many structure and employs a deep skirt. The cylinder liner is
machined, honed, polished and lapped surfaces with cast and the liner inner diameter and crankshaft journal
tolerances that are measured in the thousandths of a diameter are classified into grades. The crankshaft is
millimeter (ten thousandths of an inch). Accordingly, supported by four bearings of which width is different
when any internal engine parts are serviced, care and between No.2, No.3 and No.1, No.4; the width of No.3
cleanliness are important. Throughout this section, it bearing on the body side is different in order to support the
should be understood that proper cleaning and protection thrust bearing. The bearing cap is made of nodular cast
of machined surfaces and friction areas is part of the iron and each bearing cap uses four bolts and two side
repair procedure. This is considered standard shop bolts.
practice even if not specifically stated.
A liberal coating of engine oil should be applied to all Cylinder Head
friction areas during assembly to protect and lubricate The cylinder head, made of aluminum alloy casting
the surfaces on initial operation. employs a pent–roof type combustion chamber with a
Whenever valve train components, pistons, piston spark plug in the center. The intake and exhaust valves
rings, connecting rods, rod bearings, and crankshaft are placed in V–type design. The ports are cross–flow
journal bearings are removed for service, they should type.
be retained in order.
At the time of installation, they should be installed in Valve Train
the same locations and with the same mating Intake and exhaust camshaft on both banks are driven
surfaces as when removed. with a camshaft drive gear by the timing belt. The valves
Battery cables should be disconnected before any are operated by the camshaft and the valve clearance is
major work is performed on the engine. Failure to adjusted to select suitable thickness shim.
disconnect cables may result in damage to wire
harness or other electrical parts. Intake Manifold
The six cylinders of this engine are identified by The intake manifold system is composed of the aluminum
numbers; Right side cylinders 1, 3 and 5, Left side cast common chamber and intake manifold attached with
cylinders 2, 4 and 6, as counted from crankshaft six fuel injectors.
pulley side to flywheel side.
Exhaust Manifold
General Information on Engine Service The exhaust manifold is made of nodular cast iron.
The following information on engine service should be
noted carefully, as it is important in preventing damage Pistons and Connecting Rods
and contributing to reliable engine performance. Aluminum pistons are used after selecting the grade that
When raising or supporting the engine for any reason, meets the cylinder bore diameter. Each piston has two
do not use a jack under the oil pan. Due to the small compression rings and one oil ring. The piston pin made
clearance between the oil pan and the oil pump of chromium steel is offset 1mm toward the thrust side,
strainer, jacking against the oil pan may cause and the thrust pressure of piston to the cylinder wall varies
damage to the oil pick–up unit. gradually as the piston travels. The connecting rods are
The 12–volt electrical system is capable of damaging made of forged steel. The connecting rod bearings are
circuits. When performing any work where electrical graded for correct size selection.
terminals could possibly be grounded, the ground
cable of the battery should be disconnected at the Crankshaft and Bearings
battery. The crankshaft is made of Ductile cast–iron. Pins and
Any time the intake air duct or air cleaner is removed, journals are graded for correct size selection for their
the intake opening should be covered. This will bearing.
protect against accidental entrance of foreign
material into the cylinder which could cause extensive
damage when the engine is started.
6A–4 ENGINE MECHANICAL (6VE1 3.5L)

Engine Diagnosis
First of all the engine diagnose to check the fuel quantity,
the engine level and the engine coolant level.

Hard Starting
1. Starting Motor Does Not Turn Over
Troubleshooting Procedure
Turn on headlights and starter switch.
Condition Possible cause Correction
Headlights go out or dim Battery run down or under charged Recharge or replace battery
considerably
Terminals poorly connected Clean battery posts and terminals
and connect properly
Starting motor coil circuit shorted Overhaul or replace
Starting motor defective Overhaul or replace
Headlights stay bright Starting motor circuit open Refer to Starting and Charging
System
Starting motor coil open Replace

2. Ignition Trouble — Starting Motor Turns Over But Engine Does Not Start
Spark Test
Disconnect an ignition coil from any spark plug. Connect
the spark plug tester (For example J–26792), start the
engine, and check if a spark is generated in the spark plug
tester. Before starting the engine, make sure that the
spark plug tester is properly grounded. To avoid electrical
shock, do not touch the part where insulation of the
ignition coil is broken while the engine is running.
Condition Possible cause Correction
Spark jumps across gap Spark plug defective Replace
Ignition timing incorrect Refer to Ignition System
Fuel not reaching fuel injector(s) or Refer to item 3 (Trouble in fuel
engine system)
Valve timing incorrect Adjust
Engine lacks compression Refer to item 4 (Engine lacks
compression)
No sparking takes place Ignition coil disconnected or broken Connect properly or replace
Ion sensing module defective Replace
Ion sensing module cable broken or Correct or raplace
poor connections
Poor connections in engine harness Correct
Powertrain Control Module cable Correct or replace
disconnected or defective
ENGINE MECHANICAL (6VE1 3.5L) 6A–5
3. Trouble In Fuel System

Condition Possible cause Correction


Starting motor turns over and spark Fuel tank empty Fill
occurs but engine does not start
start.
Water in fuel system Clean
Fuel filter clogged Replace filter
Fuel pipe clogged Clean or replace
Fuel pump defective Replace
Fuel pump circuit open Correct or replace
Evaporative Emission Control Correct or replace
System circuit clogged
Multiport Fuel Injection System faulty Refer to “Driveability and Emissions”
section

4. Engine Lacks Compression

Condition Possible cause Correction


Engine lacks compression Spark plug loosely fitted or spark Tighten to specified torque or replace
plug gasket defective gasket
Valve timing incorrect Adjust
Cylinder head gasket defective Replace gasket
Valve incorrectly seated Lap valve
Valve stem seized Replace valve and valve guide
Valve spring weakened or broken Replace
Cylinder or piston rings worn Overhaul engine
Piston ring seized Overhaul engine.

Engine Compression Test Procedure


1. Start and run the engine until the engine reaches
normal operating temperature.
2. Turn the engine off.
3. Remove all the spark plugs.
4. Remove ignition coil fuse (15A) and disable the
ignition system.
5. Remove the fuel pump relay from the relay and fuse
box.
6. Engage the starter and check that the cranking speed
is approximately 300 rpm.
7. Install cylinder compression gauge into spark plug
hole.
8. With the throttle valve opened fully, keep the starter
engaged until the compression gage needle reaches
the maximum level. Note the reading.
9. Repeat the test with each cylinder.
If the compression pressure obtained falls below the
limit, engine overhaul is necessary.
Limit; 1000 kPa (10.2 kg/cm2, 145 psi)
6A–6 ENGINE MECHANICAL (6VE1 3.5L)
Rough Engine Idling or Engine Stalling
Condition Possible cause Correction
Trouble in fuel injection system Throttle valve defective Correct or replace
Throttle position sensor circuit open Correct or replace
or shorted
Fuel injector circuits open or shorted Correct or replace
Fuel injectors damaged Replace
Fuel pump relay defective Replace
Mass Airflow Sensor circuit open or Correct or replace
poor connections
Mass Airflow Sensor defective Replace
Manifold Absolute Pressure Sensor Correct or replace
circuit open or poor connections
Manifold Absolute Pressure Sensor Replace
defective
Engine Coolant Temperature Sensor Correct or replace
circuit open or poor connections
Engine Coolant Temperature Sensor Replace
defective
Intake Air Temperature sensor circuit Correct or replace
open or poor connections
Intake Air Temperature sensor Replace
defective
Ion Sensing Module cable broken or Correct or replace
poor connections
Ion Sensing Module defective Replace
Vehicle Speed Sensor circuit open or Correct or replace
shorted
Vehicle Speed Sensor defective Replace
Trouble in emission control system Powertrain Control Module defective Replace
Exhaust Gas Recirculation Valve Correct or replace
circuit open or poor connections
Exhaust Gas Recirculation Valve Replace
faulty
Canister purge valve circuit open or Correct or replace
poor connections
Canister purge valve defective Replace
Trouble in ignition system Refer to “Hard Start”
Others Engine lacks compression Refer to “Hard Start”
Valve incorrectly seated Lap valve
Air Cleaner Filter clogged Replace filter element
Valve timing incorrect Readjust
Positive Crankcase Ventilation valve Replace
defective or clogged
ENGINE MECHANICAL (6VE1 3.5L) 6A–7
Rough Engine Running
Condition Possible cause Correction
Engine misfires periodically Ignition coil layer shorted Replace
Spark plugs fouling Clean or install hotter type plug
Spark plug(s) insulator nose leaking Replace
Ion sensing module or ION sensing Correct or replace
module circuits defective
Fuel injector(s) defective Replace
Powertrain control module faulty Replace
Engine knocks periodically Spark plugs running too hot Install colder type spark plugs
Powertrain control module faulty Replace
Ion Sensing module or ION sensing Correct or replace
module circuits defective
Engine lacks power Spark plugs fouled Clean
Fuel injectors defective Replace
Mass Airflow Sensor or Intake Correct or replace
Airflow Sensor circuit defective
Manifold Absolute Pressure (MAP) Correct or replace
Sensor or Manifold Absolute
Pressure Sensor circuit defective
Engine Coolant Temperature Sensor Correct or replace
or Engine Coolant Temperature
Sensor circuit defective
Powertrain Control Module faulty Replace
Intake Air Temperature Sensor or Correct or replace
Intake Air Temperature Sensor
circuit defective
Throttle Position Sensor or Throttle Correct circuit or replace throttle
Position Sensor circuit defective valve ASM
ION Sensing Module or ION Sensing Correct or replace
Module circuits defective
6A–8 ENGINE MECHANICAL (6VE1 3.5L)
Hesitation
Condition Possible cause Correction
Hesitation on acceleration Throttle Position Sensor adjustment Replace throttle valve assembly
incorrect
Throttle Position Sensor circuit open Correct or replace
or shorted
Mass Airflow Sensor circuit open or Correct or replace
poor connections
Mass Airflow Sensor defective Replace
Manifold Absolute Pressure (MAP) Correct or replace
Sensor circuit open or shorted
MAP Sensor defective Replace
Intake Air Temperature (IAT) Sensor Correct or replace
circuit open or poor connections
Ion Sensing Module circuit open or Correct or replace
poor connections
Ion Sensing Module defective Replace
IAT Sensor defective Replace
Hesitation at high speeds Fuel tank strainer clogged Clean or replace
(Fuel pressure too low) Fuel pipe clogged Clean or replace
Fuel filter clogged Replace
Defective fuel pump system Check and replace
Fuel Pressure Control Valve leaking Replace
Hesitation at high speeds Power supply or ground circuit for Check and correct or replace
(Fuel injector not working normally) Multiport Fuel Injection System
shorted or open
Fuel Injector defective Replace
Cable of Multiport Fuel Injection Correct or replace
System circuit open or poor
connections
ENGINE MECHANICAL (6VE1 3.5L) 6A–9

Condition Possible cause Correction


Hesitation at high speeds Powertrain Control Module defective Replace
Throttle Position Sensor cable Correct cable or replace throttle
broken or poor connections valve ASM
Throttle Position Sensor defective Replace throttle valve ASM
Engine Coolant Temperature Sensor Correct or replace
circuit open or shorted
Engine Coolant Temperature Sensor Replace
defective
Mass Airflow Sensor circuit open or Correct or replace
poor connections
Mass Airflow Sensor defective Replace
MAP Sensor cable broken or poor Correct or replace
connections
MAP Sensor defective Replace
IAT Sensor circuit open or poor Correct or replace
connections
IAT Sensor defective Replace
Ion Sensing Module circuit open or Correct or replace
poor connections
Ion Sensing Module defective Replace
Throttle valve not fully opened Check and correct or replace
Air Cleaner Filter clogged Replace filter element
Power supply voltage too low Check and correct or replace
6A–10 ENGINE MECHANICAL (6VE1 3.5L)
Engine Lacks Power
Condition Possible cause Correction
Trouble in fuel system Fuel Pressure Control Valve not Replace
working normally
Fuel injector clogged Clean or replace
Fuel pipe clogged Clean
Fuel filter clogged or fouled Replace
Fuel pump drive circuit not working Correct or replace
normally
Fuel tank not sufficiently breathing Clean or replace
due to clogged Evaporative
Emission Control System circuit
Water in fuel system Clean
Inferior quality fuel in fuel system Use fuel of specified octane rating
Powertrain Control Module supplied Correct circuit
poor voltage
Throttle Position Sensor cable Correct or replace
broken or poor connections
Throttle Position Sensor defective Replace
Mass Airflow Sensor not working Replace
normally
Manifold Absolute Pressure Sensor Replace
not working normally
Intake Air Temperature Sensor not Replace
working normally
Engine Coolant Temperature Sensor Correct or replace
circuit open or shorted
Engine Coolant Temperature Sensor Replace
defective
Powertrain Control Module defective Replace
Trouble in intake or exhaust system Air Cleaner Filter clogged Replace filter element
Air duct kinked or flattened Correct or replace
TWC defective Repair
Ignition failure ———— Refer to Hard Start Troubleshooting
Guide
Heat range of spark plug inadequate Install spark plugs of adequate heat
range
Ignition coil defective Replace
ENGINE MECHANICAL (6VE1 3.5L) 6A–11

Condition Possible cause Correction


Engine overheating Level of Engine Coolant too low Replenish
Fan clutch defective Replace
Incorrect fan installed Replace
Thermostat defective Replace
Engine Coolant pump defective Correct or replace
Radiator clogged Clean or replace
Radiator filler cap defective Replace
Level of oil in engine crankcase too Change or replenish
low or wrong engine oil
Resistance in exhaust system Clean exhaust system or replace
increased defective parts
Throttle Position Sensor adjustment Replace with Throttle Valve ASM
incorrect
Throttle Position Sensor circuit open Correct or replace
or shorted
Cylinder head gasket damaged Replace
Engine overcooling Thermostat defective Replace (Use a thermostat set to
open at 82 C (180 F))
Engine lacks compression ———— Refer to Hard Start
Others Tire inflation pressure abnormal Adjust to recommended pressures
Brake drag Adjust
Clutch slipping Adjust or replace
Level of oil in engine crankcase too Correct level of engine oil
high
Exhaust Gas Recirculation Valve Replace
defective
6A–12 ENGINE MECHANICAL (6VE1 3.5L)
Engine Noisy
Abnormal engine noise often consists of various noises
originating in rotating parts, sliding parts and other
moving parts of the engine. It is, therefore, advisable to
locate the source of noise systematically.
Troubleshooting Procedure for Crankshaft Journals or Crankshaft Bearing Noise

Condition Possible cause Correction


Noise from crank journals or from Oil clearance increased due to worn Replace crank bearings and
crank bearings crank journals or crank bearings crankshaft or regrind crankshaft and
(Faultyy crank journals
j and crank install the undersize bearing
bearings usually make dull noise that Crankshaft out of round Replace crank bearings and
becomes more evident when crankshaft or regrind crankshaft and
accelerating) install the undersize bearing
Crank bearing seized Crank bearing seized Replace crank
bearings and crankshaft or regrind
crankshaft and install the undersize
bearing

Troubleshooting Procedure for Connecting Rods or Connecting Rod Bearing Noise


Short out each spark plug in sequence using insulated
spark plug wire removers. Locate cylinder with defective
bearing by listening for abnormal noise that stops when
spark plug is shorted out.
Condition Possible cause Correction
Noise from connecting rods or from Bearing or crankshaft pin worn Replace connecting rod bearings
connecting rod bearings and crankshaft or regrind crankshaft
(Faulty
y connecting
g rods or pin and install the undersize bearing
connecting rod bearings usually Crankpin out of round Replace connecting rod bearings
make an abnormal noise slightly and crankshaft or regrind crankshaft
higher than the crank bearing noise, pin and install the undersize bearing
which becomes more evident when
engine
g is accelerated)) Connecting rod bent Correct or replace
Connecting rod bearing seized Replace connecting rod bearings
and crankshaft or regrind crankshaft
pin and install the undersize bearing

Troubleshooting Procedure for Piston and Cylinder Noise


Abnormal noise stops when the spark plug on the cylinder
with defective part is shorted out.
Condition Possible cause Correction
Piston and cylinder noise Piston clearance increased due to Replace piston and cylinder body
(Faulty piston or cylinder usually cylinder wear
makes
k a combined
bi d mechanical
h i l
Piston seized Replace piston and cylinder body
thumpingg noise which increases
when engine is suddenly accelerated Piston ring broken Replace piston and cylinder body
but diminishes gradually as the
engine warms up) Piston defective Replace pistons and others

Troubleshooting Procedure for Piston Pin Noise


Short out each spark plug and listen for change in engine
noise.
Condition Possible cause Correction
Piston pin noise Piston pin or piston pin hole worn Replace piston, piston pin and
(Piston makes noise each time it connecting rod assy
goes up and down)
ENGINE MECHANICAL (6VE1 3.5L) 6A–13
Troubleshooting Procedure for Slapping or Hitting etc Noise
The slapping sound stops when spark plug on bad
cylinder is shorted out.
Condition Possible cause Correction
Timing belt noise Timing belt tension is incorrect Replace pusher or adjust the tension
pulley or replace timing belt
Tensioner bearing defective Replace
Timing belt defective Replace
Timing pulley defective Replace
Timing belt comes in contact with Replace timing belt and timing cover
timing cover
Valve noise Valve clearance incorrect Replace adjusting shim
Valve and valve guide seized Replace valve and valve guide
Valve spring broken or weakened Replace
Valve seat off–positioned Correct
Camshaft worn out Replace
Crankshaft noise Crankshaft end play excessive Replace thrust bearing
(noise occurs when clutch is
engaged)
Engine knocking Preignition due to use of spark plugs Install Spark Plugs of adequate heat
of inadequate heat range range
Carbon deposits in combustion Clean
chambers
Fuel too low in octane rating Replace fuel
Wide Open Throttle enrichment Refer to Section 6E
system failure
Selection of transmission gear Caution operator of incorrect gear
incorrect selection
Engine overheating Refer to “Engine Lacks Power”
Others Water pump defective Replace
Exhaust system defective Repair or Replace
Drive belt slipping Replace auto tensioner or drive belt
6A–14 ENGINE MECHANICAL (6VE1 3.5L)
Abnormal Combustion
Condition Possible cause Correction
Trouble in fuel system Fuel pressure control valve defective Replace
Fuel filter clogged Replace
Fuel pump clogged Clean or replace
Fuel tank or fuel pipe clogged Clean or replace
Fuel injector clogged Clean or replace
Fuel pump relay defective Replace
Power supply cable for fuel pump Reconnect, correct or replace
broken or poor connections
Mass Airflow (MAF) Sensor circuit Correct or replace
open or defective
MAF Sensor defective Replace
Manifold Absolute Pressure Sensor Correct or replace
circuit open or shorted
Manifold Absolute Pressure Sensor Replace
defective
Engine Coolant Temperature (ECT) Correct or replace
Sensor circuit open or shorted
ECT Sensor defective Replace
Throttle Position Sensor adjustment Readjust
incorrect
Throttle Position Sensor defective Replace
Throttle Position Sensor connector Reconnect
poor connections
Vehicle Speed Sensor cable poor Correct or replace
connections or defective
Vehicle Speed Sensor loosely fixed Fix tightly
Vehicle Speed Sensor in wrong Replace
contact or defective
Powertrain Control Module cable Correct or replace
poor connections or defective
Trouble in emission control system Heated Oxygen Sensor circuit open Correct or replace
Heated Oxygen Sensor defective Replace
Signal vacuum hose loosely fitted or Correct or replace
defective
EGR Valve circuit open or shorted Correct or replace
Exhaust Gas Recirculation Valve Replace
defective
ECT Sensor circuit open or shorted Correct or replace
Canister Purge Valve circuit open or Correct or replace
shorted
Canister Purge Valve defective Replace
ECT Sensor defective Replace
Positive Crankcase Ventilation Correct or replace
(PCV) valve and hose clogged
Evaporator system Refer to Section 6E
Trouble in ignition system ———— Refer to “Engine Lacks Power”
ENGINE MECHANICAL (6VE1 3.5L) 6A–15

Condition Possible cause Correction


Trouble in cylinder head parts Carbon deposits in combustion Remove carbon
chamber
Carbon deposit on valve, valve seat Remove carbon
and valve guide
6A–16 ENGINE MECHANICAL (6VE1 3.5L)
Excessive Engine Oil Consumption
Condition Possible cause Correction
Oil leaking Oil pan drain plug loose Retighten or replace gasket
Crankcase fixing bolts loosened Retighten
Oil pan setting bolts loosened Retighten
Oil pan gasket broken Replace gasket
Front cover retaining bolts loose or Retighten or replace gasket
gasket broken
Head cover fixing bolts loose or Retighten or replace gasket
gasket broken
Oil filter adapter cracked Replace
Oil filter attachings bolt loose or Retighten or replace oil filter
rubber gasket broken
Crankshaft front or rear oil seal Replace oil seal
defective
Oil pressure unit loose or broken Retighten or replace
Blow–by gas hose broken Replace hose
Positive Crankcase Ventilation Valve Clean
clogged
Engine/Transmission coupling failed Replace oil seal
Oil leaking into combustion Valve stem oil seal defective Replace
chambers due to poor
oor seal in valve
system Valve stem or valve guide worn Replace valve and valve guide

Oil leaking into combustion Cylinders and pistons worn Replace cylinder body assembly and
chambers due to poor seal in cylinder excessively pistons
parts
t Piston ring gaps incorrectly Correct
positioned
Piston rings set with wrong side up Correct
Piston ring sticking Replace cylinder body assembly and
pistons
Piston ring and ring groove worn Replace pistons and others
Return ports in oil rings clogged Clean piston and replace rings
Positive Crankcase Ventilation Positive Crankcase Ventilation Valve Clean
System malfunctioning clogged
Others Improper oil viscosity Use oil of recommended S.A.E.
viscosity
Continuous high speed driving Continuous high speed operation
and/or severe usage such as trailer and/or severe usage will normally
towing cause increased oil consumption
ENGINE MECHANICAL (6VE1 3.5L) 6A–17
Excessive Fuel Consumption
Condition Possible cause Correction
Trouble in fuel system Mixture too rich or too lean due to Refer to “Abnormal Combustion”
trouble in fuel injection system
Fuel cut function does not work Refer to “Abnormal Combustion”
Trouble in ignition system Misfiring or abnormal combustion Refer to “Hard Start” or “Abnormal
due to trouble in ignition system Combustion”
Others Engine idle speed too high Reset Idle Air Control Valve
Fuel system leakage Correct or replace
Clutch slipping Correct
Brake drag Correct
Selection of transmission gear Caution operator of incorrect gear
incorrect selection
Excessive Exhaust Gas Refer to “Abnormal Combustion”
Recirculation flow due to trouble in
Exhaust Gas Recirculation system

Lubrication Problems
Condition Possible cause Correction
Oil pressure too low Wrong oil in use Replace with correct engine oil
Relief valve sticking Replace
Oil pump not operating properly Correct or replace
Oil pump strainer clogged Clean or replace strainer
Oil pump worn Replace
Oil pressure gauge defective Correct or replace
Crankshaft bearing or connecting Replace
rod bearing worn
Oil contamination Wrong oil in use Replace with correct engine oil
Oil filter clogged Replace oil filter
Cylinder head gasket damage Replace gasket
Burned gases leaking Replace piston and piston rings or
cylinder body assembly
Oil not reaching valve system Oil passage in cylinder head or Clean or correct
cylinder body clogged

Engine Oil Pressure Check 4. Install an oil pressure gauge.


1. Check for dirt, gasoline or water in the engine oil. 5. Start the engine and allow the engine to reach normal
operating temperature (About 80 C).
a. Check the viscosity of the oil.
6. Measure the oil pressure.
b. Check the viscosity of the oil.
Oil pressure should be:
c. Change the oil if the viscosity is outside the
specified standard. 390–550 kPa (4.0–5.6 kg/cm2, 57–80 psi) at 3000
d. Refer to the “Maintenance and Lubrication” section rpm.
of this manual. 7. Stop the engine.
2. Check the engine oil level. 8. Remove the oil pressure gauge.
The level should fall somewhere between the “ADD” 9. Install the oil pressure unit.
and the “FULL” marks on the oil level dipstick. 10. Start the engine and check for leaks.
If the oil level does not reach the “ADD” mark on the
oil level dipstick, engine oil must be added.
3. Remove the oil pressure unit.
6A–18 ENGINE MECHANICAL (6VE1 3.5L)
Malfunction Indicator Lamp
The instrument panel “CHECK ENGINE” Malfunction
Indicator Lamp (MIL) illuminates by self diagnostic
system when the system checks the starting of engine, or
senses malfunctions.
Condition Possible cause Correction
“CHECK ENGINE” MIL does not Bulb defective Replace
illuminate at the starting of engine
MIL circuit open Correct or replace
Command signal circuit to operate Correct or replace
self diagnostic system shorted
Powertrain Control Module (PCM) Correct or replace
cable loosely connected,
disconnected or defective
PCM defective Replace
“CHECK ENGINE” MIL illuminates, Deterioration of heated oxygen Replace
and stays on sensor internal element
Heated oxygen sensor connector Reconnect properly
terminal improper contact
Heated oxygen sensor lead wire Correct
shorted
Heated oxygen sensor circuit open Correct or replace
Deterioration of engine coolant Replace
temperature sensor internal element
Engine coolant temperature sensor Reconnect properly
connector terminal improper contact
Engine coolant temperature sensor Correct
lead wire shorted
Engine coolant temperature sensor Correct or replace
circuit open
Throttle position sensor open or Correct or replace
shorted circuits
Deterioration of crankshaft position Replace
sensor
Crankshaft position sensor circuit Correct or replace
open or shorted
Vehicle speed sensor circuit open Correct or replace
Manifold absolute pressure sensor Correct or replace
circuit open or shorted
Intake air temperature sensor circuit Correct or replace
open or shorted
Fuel injector circuit open or shorted Correct or replace
PCM driver transistor defective Replace PCM
Malfunctioning of PCM RAM Replace PCM
(Random Access Memory) or ROM
(Read Only Memory)
ENGINE MECHANICAL (6VE1 3.5L) 6A–19

Cylinder Head Cover LH


Removal
1. Disconnect battery ground cable.
2. Remove engine cover from the dowels on the
common chamber.

060R200199

Legend
(1) Ignition Coil Connector
(2) Bolt
(3) Ignition Coil Assemblies
F06RY001

3. Disconnect positive crankcase ventilation hose. 6. Disconnect fuel injector harness connector then
4. Remove ground cable fixing bolt on cylinder head remove fuel injector harness bracket bolt.
cover. 7. Remove eight fixing bolts, then the cylinder head
5. Ignition coil connector and ignition coil. cover.
Disconnect the three connectors from the ignition
coils.
Remove harness bracket bolt on cylinder head
cover.
Remove fixing bolts on ignition coils.

010R200001

NOTE: Where do you refer the tech in case of bolt


removal difficulties.
6A–20 ENGINE MECHANICAL (6VE1 3.5L)

Installation
1. Install cylinder head cover.
Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and sealing
materials completely.
Apply sealant (TB-1207B or equivalent) of bead
diameter 2-3 mm at eight place of arched area of
camshaft bearing cap on front and rear sides.
The cylinder head cover must be installed with in 5
minutes after sealant application to prevent
hardening of sealant.
Tighten bolts to the specified torque.
Torque : 9 Nꞏm (0.9 kgꞏm/78 lb in)

060R200199

Legend
(1) Ignition Coil Connector
(2) Bolt
(3) Ignition Coil Assembly

CAUTION: Ignition coil assembly #6 is different


from ignition coil assembly from #1 to #5. Ignition
coil assembly #6 is short type. So, note it when
installing ignition coil assembly of #6.

010R200002

2. Install fuel injection harness bracket and tighten bolt


to the specified torque.
Torque : 9 Nꞏm (0.9 kgꞏm/78 lb in)
3. Connect ignition coil connector and ignition coil, then
tighten bolt to the specified torque.
Torque : 4 Nꞏm (0.4kgꞏm/35 lb in)

060RY00002

Legend
(1) Long Type Ignition Coil Assemblies (# 1 # 5)
(2) Short Type Ignition Coil Assembly (# 6)

4. Connect ground cable and tighten bolts to the


specified torque.
Torque : 9 Nꞏm (0.9 kgꞏm/78 lb in)
5. Install positive crankcase ventilation hose.
6. Install engine cover mating with the dowels.
ENGINE MECHANICAL (6VE1 3.5L) 6A–21

Cylinder Head Cover RH


Removal Installation
1. Disconnect battery ground cable. 1. Install cylinder head cover.
2. Remove engine cover from the dowels on the Clean the sealing surface of cylinder head and
common chamber. cylinder head cover to remove oil and sealing
materials completely.
Apply sealant (TB-1207B or equivalent) bead
(diameter 2-3 mm) at eight places of arched areas
of camshaft bracket on front and rear sides.

F06RY001

3. Disconnect ventilation hose from cylinder head cover.


4. Disconnect three ignition coil connectors from ignition
coils and remove harness bracket bolts on cylinder
head cover then remove ignition coil fixing bolts on 014RW019

ignition coils and remove ignition coils. The cylinder head cover must be installed within 5
minutes after sealant application to prevent
5. Disconnect fuel injector harness connector then
premature hardening of sealant.
remove fuel injector harness bracket bolt.
6. Remove eight fixing bolts then the cylinder head Tighten bolts to the specified torque.
cover. Torque : 9 Nꞏm (0.9 kgꞏm/78 lb in)
2. Tighten fuel injector harness bracket bolts to
specified torque then reconnect fuel injector harness
connector.
Torque : 9 Nꞏm (0.9 kgꞏm/78 lb in)
3. Connect ignition coil connector and tighten ignition
coil fixing bolts to specified torque.
Torque : 4 Nꞏm (0.4 kgꞏm/35 lb in)
4. Connect ventilation hose to cylinder head.
5. Install engine cover mating with the dowels.

010RW002
6A–22 ENGINE MECHANICAL (6VE1 3.5L)

Common Chamber
Removal 9. Remove two bolts from common chamber rear side
to remove fuel hose bracket.
1. Disconnect battery ground cable. 10. Remove common chamber four bolts and four nuts
2. Remove air cleaner duct assembly. then remove the common chamber.

013RY00001 025R200001

Legend Legend
(1) Positive Crankcase Ventilation Hose Connector (1) Common Chamber
(2) Intake Air Temperature Sensor (2) Throttle Valve Assembly
(3) Air Cleaner Duct Assembly (3) Bolt
(4) Air Flow Sensor

3. Disconnect vacuum booster hose from common Installation


chamber.
4. Disconnect connector from manifold absolute 1. Install common chamber and tighten bolts and nuts to
pressure sensor, Ion sensing module, throttle the specified torque.
position sensor, solenoid valve, electric vacuum Torque :
sensing valve, and EGR valve. Bolt : 25 Nꞏm (2.5 kgꞏm/18 lb ft)
5. Disconnect vacuum hose on canister VSV and Nut : 25 Nꞏm (2.5 kgꞏm/18 lb ft)
positive crankcase ventilation hose, fuel rail
assembly with pressure control valve bracket. 2. Install fuel hose bracket and tighten bolts to specified
torque.
6. Remove ventilation hose from throttle valve and
intake duct and remove water hose. Torque : 10 Nꞏm (1.0 kgꞏm/87 lb in)
7. Remove the four throttle body fixing bolts. 3. Install exhaust gas recirculation valve assembly and
tighten bolt and nut to the specified torque.
8. Remove exhaust gas recirculation valve assembly
fixing bolt and nut on common chamber and remove Torque : 25 Nꞏm (2.5 kgꞏm/18 lb ft)
EGR valve assembly. 4. Install throttle body and tighten bolts to the specified
torque.
Torque : 25 Nꞏm (2.5 kgꞏm/18 lb ft)
5. Install ventilating hose to throttle valve and intake
duct.
6. Connect vacuum hoses on canister VSV and positive
crankcase ventilation hose. Tighten bolts for fuel rail
assembly with pressure control valve bracket.
Torque : 25 Nꞏm (2.5 kgꞏm/18 lb ft)
ENGINE MECHANICAL (6VE1 3.5L) 6A–23
7. Connect each connector.
8. Connect vacuum booster hose.
9. Connect the Ion sensing module connectors as
shown in the illustration.

060RY00111

Legend
(1) Green Connector
(2) Blue Connector
(3) Identification Mark (6VE1 Engine Only)

10. Install air cleaner duct assembly.

013RY00001

Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Mass Air Flow Sensor
6A–24 ENGINE MECHANICAL (6VE1 3.5L)

Exhaust Manifold LH
Removal Installation
1. Disconnect battery ground cable. 1. Install exhaust manifold and gasket and tighten
2. Remove transfer case skid plate. exhaust manifold fixing nuts to the specified torque
with new nuts.
3. Remove 3rd crossmember.
4. Disconnect Heated oxygen (O2) sensor connector. Torque: 52 Nꞏm (5.2 kgꞏm/38 lb ft)
5. Remove the three stud nuts from the front exhaust 2. Install heat protector.
pipe flange and two nuts from the rear exhaust pipe 3. Install exhaust front pipe’s three stud nuts and rear
flange. pipe’s two nuts to the specified torque.
Torque :
Stud nuts: 67 Nꞏm (6.8 kgꞏm/49 lb ft)
Nuts: (Exhaust front pipe LH–RH): 57 Nꞏm (5.8
kgꞏm/42 lb ft)
Nuts: (Exhaust front pipe-silencer): 43 Nꞏm (4.4
kgꞏm/32 lb ft)
4. Set A/C compressor to normal position and tighten
two bolts to the specified torque.
Torque : 40 Nꞏm (4.1 kgꞏm/30 lb ft)
5. Reconnect O2 sensor connectors.
6. Install 3rd crossmember.
7. Install transfer case skid plate.

035RX015

Legend
(1) O2 Sensors
(2) Exhaust Front Pipe LH
(3) Transfer Case Skid Plate
(4) 3rd Crossmember

6. Remove heat protector two fixing bolts then the heat


protector.
7. Remove a bolt on engine LH side for air conditioner
(A/C) compressor bracket and loosen two bolts for
A/C compressor then move A/C compressor to front
side.
8. Remove exhaust manifold eight fixing nuts and
remove exhaust manifold from the engine.
ENGINE MECHANICAL (6VE1 3.5L) 6A–25

Exhaust Manifold RH
Removal

035RX016

Legend (4) Front Propeller Shaft


(1) Exhaust Front Pipe RH (5) Transfer Case Skid Plate
(2) O2 Sensors (6) 3rd Crossmember
(3) Torsion Bar

1. Disconnect battery ground cable. Installation


2. Remove transfer case skid plate.
1. Install exhaust manifold and tighten bolts to the
3. Remove 3rd crossmember. specified torque.
4. Remove torsion bar and front propeller shaft. Refer to
Torque : 52 Nꞏm (5.3 kgꞏm/38 lb ft)
removal procedure in Front Suspension section.
5. Disconnect front Heated oxygen (O2) sensor 2. Install the EGR pipe, tighten bolts and nut on exhaust
connectors. manifold to specified torque.
6. Remove front exhaust flange pipe three stud nuts and Torque : 28 Nꞏm (2.9 kgꞏm/21 lb ft)
two rear flange nuts then disconnect exhaust pipe. Tighten nut to EGR valve to the specified torque.
7. Remove heat protector two fixing bolts then the heat Torque : 44 Nꞏm (4.5 kgꞏm/33lb ft)
protector.
Tighten the bolt for EGR pipe bracket to specified
8. Remove exhaust gas recirculation (EGR) pipe fixing torque.
bolt and nut from exhaust manifold, remove a nut
from EGR valve and a bolt from rear side of cylinder Torque : 25 Nꞏm (2.5 kgꞏm/18 lb ft)
head for bracket of EGR pipe then remove the EGR 3. Install heat protector
pipe. 4. Install front exhaust flange pipe and tighten three stud
9. Remove exhaust manifolds eight fixing nuts and the nuts and rear two nuts to the specified torque.
exhaust manifold.
Torque:
Stud nuts: 67 Nꞏm (6.8 kgꞏm/49 lb ft)
6A–26 ENGINE MECHANICAL (6VE1 3.5L)
Nuts: 57 Nꞏm (5.8 kgꞏm/42 lb ft) 7. Install front propeller shaft.
5. Reconnect O2 Sensor harness connector. Refer to installation procedue in Front suspension
6. Install the torsion bar and readjust the vehicle height. section.
Refer to installation and vehicle height adjustment 8. Install 3rd crossmember.
procedure for Front Suspension. 9. Install transfer case skid plate.

Crankshaft Pulley
Removal Legend
(1) Crankshaft Pulley
1. Disconnect battery ground cable.
(2) Cooling Fan Pulley
2. Remove air cleaner assembly. (3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Idle Pulley
(8) Driver Belt

5. Remove cooling fan assembly four fixing nuts, then


the cooling fan assembly.
6. Remove crankshaft pulley assembly using
5-8840-0133-0 crankshaft holder, hold crankshaft
pulley then remove center bolt and pulley.

Installation
1. Install crankshaft pulley using 5-8840-0133-0
crankshaft holder, hold the crankshaft pulley and
tighten center bolt to the specified torque.
Torque : 167 Nꞏm (17.0 kgꞏm/123 lb ft)
013RY00001
2. Install cooling fan assembly and tighten bolts/nuts to
Legend the specified torque.
(1) Positive Crankcase Ventilation Hose Connector Torque : 22 Nꞏm (2.2 kgꞏm/16 lb ft) for fan pulley
(2) Intake Air Temperature Sensor and fan bracket.
(3) Air Cleaner Duct Assembly
Torque : 10 Nꞏm (1.0 kgꞏm/87 lb in) for fan and
(4) Air Flow Sensor
clutch assembly.
3. Remove radiator upper fan shroud from radiator. 3. Move serpentine belt tensioner to loose side using
4. Move serpentine belt tensioner to loose side using wrench, then install serpentine belt to normal
wrench then remove serpentine belt. position.
4. Install radiator upper fan shroud.
5. Install air cleaner assembly.

850RW001
ENGINE MECHANICAL (6VE1 3.5L) 6A–27

Timing Belt
Removal 11. Remove right side timing belt cover then left side
timing belt cover.
1. Disconnect battery ground cable. 12. Remove lower timing belt cover
2. Remove air cleaner assembly. 13. Remove pusher.
3. Remove radiator upper fan shroud from radiator.
CAUTION: The pusher prevents air from entering
4. Move drive belt tensioner to loose side using wrench the oil chamber. Its rod must always be facing
then remove drive belt. upward.

850RW001
014R100020

Legend Legend
(1) Crankshaft Pulley (1) Up Side
(2) Cooling Fan Pulley (2) Down Side
(3) Tensioner (3) Direction For Installation
(4) Generator (4) Locking Pin
(5) Air Conditioner Compressor (5) Apply a force of 980 N (220 lb) when
(6) Power Steering Oil Pump compressing the pusher rod.
(7) Idle Pulley
(8) Drive Belt 14. Remove timing belt.
CAUTION:
5. Remove cooling fan assembly four nuts, then the
cooling fan assembly. 1. Do not bend or twist the belt, otherwise its core
could be damaged. The belt should not be bent at
6. Remove cooling fan drive pulley assembly. a radius less than 30 mm (1.1811 in).
7. Remove idle pulley assembly.
2. Do not allow oil or other chemical substances to
8. Remove serpentine belt tensioner assembly. come in contact with the belt. They will shorten
9. Remove power steering pump assembly. the life.
10. Remove crankshaft pulley assembly using 3. Do not attempt to pry or stretch the belt with a
5-8840-0133-0 crankshaft holder, hold crankshaft screw driver or any other tool during installation.
pulley remove center bolt, then the pulley.
4. Store timing belt in a cool and dark place. Never
expose the belt direct sunlight or heat.
6A–28 ENGINE MECHANICAL (6VE1 3.5L)

Installation 1. Install timing belt.


1. Align groove of crankshaft timing pulley (2) with
NOTE: For correct belt installation, the letter on the belt mark on oil pump (1).
must be able to be read as viewed from the front of the Align the mark on the crankshaft timing pulley (3)
vehicle. with alignment mark (white dotted line) on the tim-
ing belt (4).
Secure the belt with a double clip or equivalent
clip.
NOTE: When timing marks are aligned, No.2 piston will
be on Top Dead Center.

014RW005

Legend
(1) Crankshaft Timing Pulley
(2) RH Bank Camshaft Drive Gear Pulley
(3) Water Pump Pulley
(4) Idle Pulley 014RW003

(5) LH Bank Camshaft Drive Gear Pulley Legend


(6) Tension Pulley (1) Alignment Mark on Oil Pump
(7) Alignment Mark on Oil Pump. (2) Groove on Crankshaft Timing Pulley
(8) Alignment Mark on Timing Belt (3) Alignment Mark on Crankshaft Timing Pulley
(4) Alignment Mark on Timing Belt

2. Align the alignment mark on the RH bank


camshaft drive pulley (2) to the alignment mark of
the cylinder head cover RH (3).
The camshaft pulley is not 1:1 with the camshafts.
It is necessary to rotate the camshaft pulley until
the camshaft lobes are in the position as shown
in the diagram on page 6A–34.
The camshaft pulley alignment mark should also
align with alignment mark on the cylinder head
cover.
It may require up to four revolutions of the cam-
shaft pulley to achieve alignment of all marks.

014RW006

Legend
(1) Timing Belt
(2) Engine Rotation Direction
(3) Cylinder Head Side
ENGINE MECHANICAL (6VE1 3.5L) 6A–29
3. Align the alignment mark (white line) on the timing NOTE: It is recommended for easy installation that the
belt (1) with alignment mark on the RH bank belt be secured with a double clip or equivalent clips after
camshaft drive pulley (2) (on the left side as it is installed to each pulley.
viewed from the front of the vehicle) and put the
timing belt on the camshaft drive pulley.
Secure the belt with a double clip or equivalent
clip.

014RW00005

Legend
(1) Alignment Mark on Timing Belt (White line).
014RW00004
(2) Alignment Mark on Camshaft Drive Pulley.
(3) Alignment Mark on Cylinder Head Cover LH.
Legend
(1) Alignment Mark on Timing Belt (White line).
6. Install crankshaft pulley temporarily and tighten
(2) Alignment Mark on Camshaft Drive Pulley. center bolt by hand (do not use a wrench).
(3) Alignment Mark on Cylinder Head Cover RH.
Turn the crankshaft pulley clockwise to give some
belt slack between the crankshaft timing pulley
4. Align the alignment mark on the LH bank and the RH bank camshaft drive pulley.
camshaft drive pulley (2) to the alignment mark of 2. Install pusher and tighten bolt to the specified torque.
the cylinder head cover LH (3).
Torque : 25 Nꞏm (2.5 kgꞏm/18 lb ft)
The camshaft pulley is not 1:1 with the camshafts.
It is necessary to rotate the camshaft pulley until 1. Install the pusher while pushing the tension pulley
the camshaft lobes are in the position as shown to the belt.
in the diagram on page 6A–34. 2. Pull out pin from the pusher.
The camshaft pulley alignment mark should also
align with alignment mark on the cylinder head NOTE: When reusing the pusher, press the pusher with
cover. approximately 980 N (100 kgf/220 lb) to retract the rod,
It may require up to four revolutions of the cam- and insert a pin (1.4 mm (0.055 in) piano wire).
shaft pulley to achieve alignment of all marks.
5. Align the alignment mark (white line) on the timing
belt (1) with the alignment mark on the LH bank
camshaft drive pulley (2).
When aligning the timing marks, use a wrench to
turn the camshaft drive pulley, then set the timing
mark between timing belt and camshaft drive
pulley and put the timing belt on the camshaft
drive pulley.
Secure the belt with a double clip or equivalent
clip.
6A–30 ENGINE MECHANICAL (6VE1 3.5L)
3. Install timing belt cover.
Remove crankshaft pulley that was installed in step
1 item 5.
Tighten bolts to the specified torque.
Torque: 19 Nꞏm (1.9 kgꞏm/14 lb ft)

014R100020

Legend
(1) Up Side
(2) Down Side
(3) Direction for Installation
(4) Locking Pin
020RW004
(5) Apply a force of 980 N (100 kgf/220 lb) when
compressing the pusher rod. Legend
(1) Timing Belt Cover RH
After release the push rod from the locking pin, (2) Timing Belt Cover LH
the rod projection is approximate 5 mm (0.1969 (3) Timing Belt Cover Lower
in).

014R100032 020RW003

Legend Legend
(1) Tensioner Pulley (1) Timing Belt Cover
(2) Crankshaft Pulley Rotation Direction (2) Rubber Bushing
(3) Crankshaft Pulley (3) Sealing Rubber
(4) Pusher Assembly (4) Cylinder Body

3. Remove double clips or equivalent clips from 4. Install crankshaft pulley using 5-8840-0133-0, hold
timing belt pulleys. the crankshaft pulley and tighten center bolt to the
Turn the crankshaft pulley by six turns and check specified torque.
for timing mark alignment. Torque : 167 Nꞏm (17.0 kgꞏm/123 lb ft)
ENGINE MECHANICAL (6VE1 3.5L) 6A–31
5. Install fan pulley bracket and tighten fixing bolts to the
specified torque.
Torque : 22 Nꞏm (2.2 kgꞏm/16 lb ft)
6. Install power steering pump assembly and tighten to
the specified torque.
Torque :
M8 bolt : 22 Nꞏm (2.2 kgꞏm/16 lb ft)
M10 bolt : 46 Nꞏm (4.7 kgꞏm/34 lb ft)
7. Install cooling fan assembly and tighten bolts/nuts to
the specified torque.
Torque : 22 Nꞏm (2.2 kgꞏm/16 lb ft) for fan pulley
and fan bracket.
Torque : 10 Nꞏm (1.0 kgꞏm/87 lb in) for fan and
clutch assembly.
8. Move drive belt tensioner to loose side using wrench,
then install drive belt to normal position.

850RW001

Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Idle Pulley
(8) Drive Belt

9. Install radiator upper fan shroud.


10. Install air cleaner assembly.
6A–32 ENGINE MECHANICAL (6VE1 3.5L)

Camshaft
Removal 9. Remove three fixing bolts from camshaft drive gear
retainer, then camshaft drive gear assembly.
1. Disconnect battery ground cable.
2. Remove crankshaft pulley.
Refer to removal procedure for Crankshaft Pulley in
this manual.
3. Remove timing belt.
Refer to removal procedure for Timing Belt in this
manual.
4. Remove cylinder head cover LH.
Refer to removal procedure for Cylinder Head
Cover LH in this manual.
5. Remove cylinder head cover RH.
Refer to removal procedure for Cylinder Head
Cover RH in this manual.
6. Remove twenty fixing bolts from inlet and exhaust
camshaft bearing cap on one side bank, then
camshaft bearing cap.

014RW026

Legend
(1) Right Bank
(2) Left Bank
(3) Timing Mark on Retainer

014RW027

7. Remove camshaft assembly.


8. Remove fixing bolt for camshaft drive gear pulley.
ENGINE MECHANICAL (6VE1 3.5L) 6A–33

Installation
1. Install camshaft drive gear assembly and tighten
three bolts to the specified torque.
Torque : 10 Nꞏm (1.0 kgꞏm/87 lb in)
2. Tighten bolt for camshaft drive gear assembly pulley
to the specified torque.
Torque : 98 Nꞏm (10.0 kgꞏm/72 lb ft)
3. Tighten sub gear setting bolt.
1. Use 5-8840-2443-0 to turn sub gear to right
direction until it aligns with the M5 bolt hole
between camshaft driven gear and sub gear.
2. Tighten the M5 bolt to a suitable torque to prevent
the sub gear from moving.

014RW020

Legend
(1) Intake Camshaft Timing Gear for Right Bank
(2) Intake Camshaft Timing Gear for Left Bank
(3) Exhaust Camshaft Timing Gear
(4) Discrimination Mark
(LI: Left bank intake, RI: Right bank intake)
(LE: Left bank exhaust, RE: Right bank
exhaust)

014RW041

4. Install camshaft assembly and camshaft bearing


caps, tighten twenty bolts on one side bank to the
specified torque.
1. Apply engine oil to camshaft journal and bearing
surface of camshaft bearing caps.
2. Align timing mark on intake camshaft (one dot for
right bank, two dot for left bank) and exhaust
camshaft (one dots for right bank, two dots for left
bank) to timing mark on camshaft drive gear (one
dot).

014RW023

Legend
(1) Right Bank Camshaft Drive Gear
(2) Left Bank Camshaft Drive Gear
(3) Timing Mark on Drive Gear
(4) Dowel Pin
6A–34 ENGINE MECHANICAL (6VE1 3.5L)

014RW024

Legend (3) Alignment Mark on Camshaft Drive Gear


(1) Right Bank (4) Alignment Mark on Camshaft
(2) Left Bank (5) Alignment Mark on Retainer

3. Tighten twenty bolts on numerical order an one 5. Install cylinder head cover RH.
side bank as shown in the illustration. Refer to installation procedure for CYLINDER
Torque : 10 Nꞏm (1.0 kgꞏm/87 lb in) HEAD COVER RH in this manual.
6. Install cylinder head cover LH.
Refer to installation procedure for CYLINDER
HEAD COVER LH in this manual.
7. Install timing belt.
Refer to installation procedure for TIMING BELT in
this manual.
8. Install crankshaft pulley.
Refer to installation procedure for CRANKSHAFT
PULLEY in this manual.

014RW031
ENGINE MECHANICAL (6VE1 3.5L) 6A–35

Cylinder Head
Removal Installation
1. Remove engine hood. 1. Install cylinder head assembly to cylinder block.
2. Disconnect battery ground cable. A. Put cylinder head gasket on the cylinder block.
3. Drain radiator coolant. NOTE: There is discrimination mark “R” for right bank
4. Drain engine oil. and “L” for left bank on the cylinder head gasket as shown
5. Remove crankshaft pulley. in the illustration.
Refer to removal procedure for Crankshaft Pulley in Do not reuse cylinder head gasket.
this manual.
6. Remove timing belt.
Refer to removal procedure for Timing Belt in this
manual.
7. Remove cylinder head cover LH.
Refer to removal procedure for Cylinder Head
Cover LH in this manual.
8. Remove cylinder head cover RH.
Refer to removal procedure for Cylinder Head
Cover RH in this manual.
9. Remove common chamber.
Refer to removal procedure for Common Chamber
in this manual.
10. Remove cylinder head assembly.
1. Loosen head bolts in reverse of tightening
sequence.
2. Remove cylinder head assembly.
011RW005

B. Align dowel pin hole to dowel pin on the cylinder


block.
C. Position cylinder head on the cylinder block.
D. Tighten two bolts temporarily by hand to prevent
the cylinder head assembly from moving.
E. Using 9-8511-4209-0 cylinder head bolt wrench,
tighten bolts in numerical order as shown in the
illustration to the specified torque.

014RW028

Legend
(1) Cylinder Head
(2) Cylinder Head Bolt
(3) Camshaft
6A–36 ENGINE MECHANICAL (6VE1 3.5L)
NOTE: Do not reuse cylinder head bolts.
Do not apply any lubricant to the cylinder head bolts.
Torque :
Temporary : 29 Nꞏm (3.0 kgꞏm/22 lb ft)
Final : 64 Nꞏm (4.8 kgꞏm/47 lb ft)

014RW029

2. Install common chamber.


Refer to installation procedure for Common
Chamber in this manual.
3. Install cylinder head cover RH.
Refer to installation procedure for Cylinder Head
Cover RH in this manual.
4. Install cylinder head cover LH.
Refer to installation procedure for Cylinder Head
Cover LH in this manual.
5. Install timing belt.
Refer to installation procedure for Timing Belt in this
manual.
6. Install crankshaft pulley.
Refer to installation procedure for Crankshaft
Pulley in this manual.
ENGINE MECHANICAL (6VE1 3.5L) 6A–37

Valve Stem Oil Controller , Valve Spring and Valve Guide


Removal Installation
1. Disconnect battery ground cable. 1. Install valve guide using 5-8840-2442-0 valve guide
2. Drain engine oil. installer.
Drain engine coolant. 2. Install oil controller using 5-8840-0624-0 oil controller
installer.
3. Remove cylinder head assembly.
3. Install lower valve spring seat, valve spring and upper
Refer to removal procedure for Cylinder Head in
valve spring seat then put split collars on the upper
this manual.
spring seat, using 5-8840-2446-0 valve spring
4. Remove camshaft. compressor and 5-8840-2547-0 valve spring
Refer to removal procedure for Camshaft in this compressor adapter to install the split collars.
manual.
5. Remove tappets with shim.
NOTE: Do not damage shim surface.
6. Remove valve springs using 5-8840-2446-0 valve
spring compressor and 5-8840-2547-0 valve spring
compressor adapter then remove upper valve spring
seat and lower seat.

014RW042

4. Install tappet with shim.


5. Install camshaft assembly.
Refer to installation procedure for Camshaft in this
manual.
6. Install cylinder head assembly.
Refer to installation procedure for Cylinder Head in
014RW042 this manual.
7. Remove oil controller using 5-8840-0623-0 oil 7. Fill engine oil until full level.
controller remover, remove each valve stem oil 8. Fill engine coolant.
controller.
8. Remove valve guide using 5-8840-2549-0 valve
guide replacer.
6A–38 ENGINE MECHANICAL (6VE1 3.5L)

Piston, Piston Ring and Connecting Rod


Removal

F06RW011

Legend (4) Oil Strainer


(1) Cylinder Head (5) Oil Gallery
(2) Crankcase with Oil Pan (6) Piston with Connecting Rod Assembly
(3) Oil Pipe

1. Remove cylinder head assembly. 2. Remove crankcase with oil pan.


Refer to removal procedure for Cylinder Head in Refer to removal procedure for Oil Pan and
this manual. Crankcase in this manual.
ENGINE MECHANICAL (6VE1 3.5L) 6A–39
3. Remove oil strainer fixing bolts, remove oil strainer
assembly with O-ring.

015RW003

Legend
050RW002 (1) Piston Front Mark
Legend (2) Piston Grade
(1) Oil Pump (3) Connecting Rod Front Mark
(2) Oil Strainer
(3) Oil Gallery 2. Install oil gallery and tighten the bolts in two steps, in
(4) From Oil Filter the order shown in illustration.
(5) To Oil Filter Torque :
1st step : 29 Nꞏm (3.0 kgꞏm/22 lb ft)
4. Remove three fixing bolts, oil pipe with O-ring. 2nd step : 55 –65
5. Remove eight fixing bolts, oil gallery.
6. Remove piston with connecting rod assembly.
(before removing the bearing cap, remove carbon on
the top of cylinder bore and push piston with
connecting rod out from the top of cylinder bore.)

Installation
1. Install piston with connecting rod assembly.
Apply engine oil to cylinder bore, connecting rod
bearing and crank pin.
When installing the piston, its front mark must face
the engine front side.
The bearing cap number must be the same as
connecting rod number.
Apply engine oil to the thread and seating surface of
each nut.
Tighten nuts to the specified torque. 051RS009

Torque : 54 Nꞏm (5.5 kgꞏm/40 lb ft) 3. Install oil pipe with O-ring.
After tightening the nuts, make sure that the Torque : 10 Nꞏm (1.0 kgꞏm/87 lb in)
crankshaft rotates smoothly. 4. Install oil strainer assembly with O-ring.
NOTE: Do not apply engine oil to the bearing back faces Torque : 25 Nꞏm (2.5 kgꞏm/18 lb ft)
and connecting rod bearing fitting surfaces. 5. Install crankcase with oil pan.
Refer to installation procedure for Oil Pan and
Crankcase in this manual.
6. Install cylinder head assembly.
Refer to installation procedure for Cylinder Head in
this manual.
6A–40 ENGINE MECHANICAL (6VE1 3.5L)

Crankshaft and Main Bearings


Removal

F06RY002

Legend (8) Oil Pump Assembly


(1) Engine Assembly (9) Cylinder Body Side Bolt
(2) Crankshaft Pulley (10) Oil Gallery
(3) Timing Belt Cover (11) Flywheel
(4) Timing Belt (12) Rear Oil Seal Retainer
(5) Crankcase with Oil Pan (13) Connecting Rod Cap
(6) Oil Pipe (14) Crankshaft Main Bearing Cap
(7) Oil Strainer (15) Crankshaft and Main Bearing

1. Remove engine assembly. 3. Remove oil pan and crankcase.


Refer to removal procedure for Engine Assembly in Refer to removal procedure for Oil Pan and
this manual. Crankcase in this manual.
2. Remove timing belt. 4. Remove oil pipe with O-ring.
Refer to removal procedure for Timing Belt in this 5. Remove oil strainer assembly with O-ring.
manual.
ENGINE MECHANICAL (6VE1 3.5L) 6A–41
6. Remove oil pump assembly.
Refer to removal procedure for Oil Pump in this
manual.
7. Remove cylinder body side bolts.
8. Remove oil gallery.
9. Remove flywheel.
10. Remove rear oil seal retainer.
Refer to removal procedure for Rear Oil Seal in this
manual.
11. Remove connecting rod caps.
12. Remove crankshaft main bearing caps.
13. Remove crankshaft and main bearings.

Installation
1. Install crankshaft and main bearings.
Install main bearing in the cylinder block and main
bearing cap respectively. 015RS013

Apply new engine oil to upper and lower main 2. Install crankshaft main bearing caps.
bearings. Apply engine oil to the thread and seating surface of
each bearing cap fixing bolt.
NOTE:
NOTE:
Do not apply engine oil to the bearing back faces.
Do not apply engine oil to the bearing back faces.
Make sure that main bearings are in correct position.
Install bearing caps, starting with cylinder block front
Install crankshaft with care. side.
Apply engine oil to the thrust washer. Tighten main bearing fixing bolts to the specified
Install thrust washer on No.3 journal. torque.
Oil grooves in thrust washer must face the Torque : 39 Nꞏm (4.0 kgꞏm/29 lb ft)
crankshaft.
After tightening the bolts, make sure that the
crankshaft rotates smoothly.
3. Install connecting rod caps.
The cap number must be same as connecting rod
number.
Apply engine oil to the thread and seating surface of
each nut.
Tighten nuts to the specified torque.
Torque : 54 Nꞏm (5.5 kgꞏm/40 lb ft)
After tightening the nuts, make sure that the
crankshaft rotates smoothly.
4. Install rear oil seal retainer.
Remove oil on cylinder block and retainer fitting
surface.
Apply sealant (TB1207B or equivalent) to retainer
fitting surface as shown in illustration.
015RS012
The oil seal retainer must be installed within 5
minutes after sealant application to prevent
premature hardening of sealant.
6A–42 ENGINE MECHANICAL (6VE1 3.5L)

015RW002 015RS018

Legend 6. Install oil gallery.


(1) Around Bolt Holes Clean contact surface of oil gallery and main
(2) Around Dowel Pin bearing cap.
Apply engine oil to oil gallery fixing bolts and tighten
the bolts in two steps, in the order shown.
Apply engine oil to oil seal lip and align a dowel pin
hole in the cylinder block with that in the retainer. Torque :
Tighten retainer fixing bolts to the specified torque. 1st step : 29 Nꞏm (3.0 kgꞏm/22 lb ft)
2nd step : 55 –65
Torque : 18 Nꞏm (1.8 kgꞏm/13 lb ft)
7. Install cylinder body side bolts and tighten bolts in
order to the specified torque.
Torque : 39 Nꞏm (4.0 kgꞏm/29 lb ft)
NOTE: Do not apply the oil to the bolts.

015RW001

5. Install flywheel.
Clean tapped holes in the crankshaft.
Remove oil on crankshaft and flywheel fitting
surface. 012RS007

8. Install oil pump assembly.


NOTE:
Remove oil on cylinder block and oil pump mounting
Do not reuse the bolts. surface.
Do not apply oil or thread lock to the bolts. Apply sealant (TB1207B or equivalent) to the oil
Tighten fixing bolts to the specified torque. pump mounting surface.
Torque : 54 Nꞏm (5.5 kgꞏm/40 lb ft) The oil pump assembly must be installed within 5
minutes after sealant application to prevent
premature hardening of sealant.
ENGINE MECHANICAL (6VE1 3.5L) 6A–43
Apply engine oil to oil seal lip. Properly apply a 4.5 mm (0.7 in) wide bead of
sealant (TB1207C or equivalent) to the crankcase
Install oil pump in the cylinder block and tighten
mounting surface. The bead must be continuous.
fixing bolts to the specified torque.
The crankcase must be installed within 5 minutes
Torque : 25 Nꞏm (2.5 kgꞏm/18 lb ft)
after sealant application to prevent premature
hardening of sealant.
Tighten fixing bolts to the specified torque.
Torque : 10 Nꞏm (1.0 kgꞏm/87 lb in)

051RW002

Legend
(1) Around Bolt Holes
(2) Around Dowel Pin
013RW010

013RW004
051RW001

9. Install oil strainer with O-ring, tighten to the specified 12. Install oil pan
torque. Remove oil on oil pan mounting surface and dry the
Torque : 25 Nꞏm (2.5 kgꞏm/18 lb ft) surface.
10. Install oil pipe with O-ring, tighten fixing bolts to the Properly apply a 4.5 mm (0.7 in) wide bead of
specified torque. sealant (TB1207C or equivalent) to the oil pan
mounting surface. The bead must be continuous.
Torque : 25 Nꞏm (2.5 kgꞏm/18 lb ft)
The oil pan must be installed within 5 minutes after
11. Install crankcase. sealant application to prevent premature hardening
Remove oil on crankcase mounting surface and dry of sealant.
the surface.
6A–44 ENGINE MECHANICAL (6VE1 3.5L)
Tighten fixing bolts to the specified torque.
Torque : 25 Nꞏm (2.5 kgꞏm/18 lb ft)

013RW003

013RW002

13. Install timing belt.


Refer to installation procedure for Timing Belt in this
manual.
14. Install engine assembly.
Refer to installation procedure for Engine
Assembly in this manual.
ENGINE MECHANICAL (6VE1 3.5L) 6A–45

Rear Oil Seal


Removal
1. Remove transmission assembly.
See Transmission section in this manual.
2. Remove flywheel.
3. Remove rear oil seal using a seal remover.
NOTE: Take care not to damage the crankshaft or oil seal
retainer when removing oil seal.

Installation
1. Apply engine oil to oil seal lip and install oil seal using
5-8840-2286-0.

015RS018

3. Install transmission.
See Transmission section in this manual.
CAUTION: When assembling the engine and
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side.
NOTE: Take care that dowel positions are different
between the manual transmission and the automatic
transmission.
Otherwise, the transmission may be damaged.

015RS017

2. Install flywheel.
Clean tapped holes in the crankshaft.
Remove oil on the crankshaft and flywheel
mounting surface.
Tighten fixing bolts to the specified torque.
NOTE: Do not reuse the bolts and do not apply oil or
thread lock to the bolts.
Torque : 54 Nꞏm (5.5 kgꞏm/40 lb ft)

012RS009
6A–46 ENGINE MECHANICAL (6VE1 3.5L)

Engine Assembly
Removal

035RY00001

1. Disconnect battery ground and positive cable. 23. Move drive belt tensioner to loose side using wrench
2. Remove battery. then remove drive belt.
3. Make alignment mark on the engine hood and hinges 24. Remove power steering pump fixing bolts, then
before removal in order to return the hood to original power steering pump. Place the power steering pump
position exactly. along with piping on the body side.
4. Remove engine hood. 25. Remove air conditioning compressor fixing bolts from
bracket and place the compressor along with piping
5. Drain radiator coolant.
on the body side.
6. Disconnect Ion sensing module harness connectors,
26. Remove four O2 sensor harness connectors (two
and manifold absolute pressure sensor harness
each bank) from exhaust front pipe.
connectors from sensor on common chamber.
27. Remove three exhaust pipe fixing nuts from each
7. Disconnect throttle position sensor harness
bank.
connectors from throttle body.
28. Remove two exhaust pipe fixing nuts from each
8. Disconnect air duct with air cleaner cover.
exhaust pipe, then move exhaust pipe to rear side of
9. Remove air cleaner assembly. vehicle.
10. Disconnect canister vacuum hose. 29. Remove flywheel dust covers.
11. Disconnect vacuum booster hose. 30. Disconnect two heater hoses from engine.
12. Disconnect three engine harness connectors. 31. Disconnect fuel hoses from right side of transmission.
13. Disconnect harness connector to transmission (left
CAUTION: Plug fuel pipes on engine side and fuel
front side of engine compartment), disconnect shift
hoses from fuel tank.
on the fly harness connector from front side of front
axle and remove transmission harness bracket from 32. Remove transmission assembly. Refer to
engine left side. Transmission section in this manual.
14. Disconnect ground cable between engine and frame. 33. Support the engine by engine hoist.
15. Disconnect bonding cable connector on the back of 34. Remove two left side engine mount fixing bolts from
right dash panel. engine mount on chassis side.
16. Disconnect bonding cable terminal on the left bank. 35. Remove two right side engine mount fixing bolts from
engine mount on chassis side.
17. Disconnect starter harness connector from starter.
36. Remove engine assembly.
18. Disconnect generator harness connector from
generator.
19. Disconnect coolant reserve tank hose from radiator.
20. Remove radiator upper and lower hoses.
21. Remove upper fan shroud.
22. Remove cooling fan assembly four fixing nuts, then
the cooling fan assembly.
ENGINE MECHANICAL (6VE1 3.5L) 6A–47

Installation
CAUTION: When assembling the engine and
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side.
NOTE: Take care that dowel positions are different
between the manual transmission and the automatic
transmission.
If the engine is assembled in the condition that the dowels
have not been mounted in the specified positions, the
transmission may be damaged.

035RW005

Legend
(1) Exhaust Front Pipe RH
(2) O2 Sensor

012RS009

1. Install engine assembly. Tighten engine mount fixing


bolts to frame to the specified torque.
Torque: 41 Nꞏm (4.2 kgꞏm/30 lb ft)
2. Reconnect fuel hose to fuel pipe on engine.
3. Install transmission assembly. Refer to Transmission
section in this manual.
4. Reconnect two heater hoses to engine.
5. Install flywheel dust covers.
6. Install exhaust pipe and temporally tighten two (each
bank) rear exhaust flange nuts then tighten three stud 035RW016

nuts (each bank) between exhaust manifold and


exhaust pipe, finally tighten rear side nuts to the Legend
specified torque. (1) O2 Sensor
(2) Exhaust Front Pipe LH
Torque:
Nuts: (Exhaust front pipe LH–RH): 57 Nꞏm (5.8 7. Reconnect O2 sensor connector.
kgꞏm/42 lb ft)
8. Install cooling fan assembly and tighten bolts/nuts to
Nuts: (Exhaust front pipe pipe–silencer): 43 Nꞏm the specified torque.
(4.4 kgꞏm/32 lb ft)
Torque : 22 Nꞏm (2.2 kgꞏm/16 lb ft) for fan pulley
Stud nuts: 67 Nꞏm (6.8 kgꞏm/49 lb ft) and fan bracket.
Torque : 10 Nꞏm (1.0 kgꞏm/87 lb in) for fan and
clutch assembly.
6A–48 ENGINE MECHANICAL (6VE1 3.5L)
9. Install air conditioner compressor to engine and 24. Install air cleaner assembly.
tighten to the specified torque. 25. Reconnect air duct.
Torque : 26. Reconnect throttle position sensor harness
M8 bolts : 22 Nꞏm (2.2 kgꞏm/16 lb ft) connector.
M10 bolts : 43 Nꞏm (4.4 kgꞏm/32 lb ft)
10. Install power steering pump, tighten fixing bolt to the
specified torque.
Torque :
M8 bolts : 22Nꞏm (2.2 kgꞏm/16 lb ft)
M10 bolts : 46 Nꞏm (4.7 kgꞏm/34 lb ft)
11. Move drive belt tensioner to loose side using wrench,
then install drive belt to normal position.

035R200004

Legend
(1) Throttle Position Sensor Connector
(2) Throttle Valve Assembly

27. Reconnect manifold absolute pressure sensor


harness connectors.
28. Reconnect ion sensing module connectors as shown
in the illustration.
850RW001

Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Idle Pulley
(8) Drive Belt

12. Install upper fan shroud.


13. Reconnect radiator upper and lower hoses.
14. Reconnect coolant reserve tank hose to radiator.
15. Reconnect generator harness connector.
16. Reconnect starter harness connector.
17. Reconnect bonding cable terminal on left bank
18. Reconnect bonding cable terminal on the back of right 060RY00111
dash panel.
Legend
19. Reconnect ground cable between engine and
(1) Green Connector
chassis.
(2) Blue Connector
20. Reconnect harness connector to transmission and
install transmission harness bracket on engine left (3) Identification Mark (6VE1 Engine Only)
side.
29. Install engine hood to the original position.
21. Reconnect three engine harness connectors.
Refer to installation procedure for Body section in
22. Reconnect vacuum booster hose. this manual.
23. Reconnect canister vacuum hose.
ENGINE MECHANICAL (6VE1 3.5L) 6A–49

Cylinder Head
Cylinder Head and Associated Parts

011RW008

Legend (8) Camshaft Intake


(1) Spark Plug (9) Retainer Fixing Bolt
(2) Cylinder Head Bolt (10) Retainer Assembly
(3) Camshaft Drive Gear Pulley Fixing Bolt (11) Tappet with Shim
(4) Camshaft Drive Gear Pulley (12) Split Collar
(5) Camshaft Bearing Cap Fixing Bolt (13) Valve Spring and Spring Upper Seat
(6) Camshaft Bearing Cap (14) Valve
(7) Camshaft Exhaust
6A–50 ENGINE MECHANICAL (6VE1 3.5L)

Disassembly Inspection and Repair


NOTE: 1. Inspect cylinder head gasket and mating surfaces for
leaks, corrosion and blow–by. If the gasket has failed,
During disassembly, be sure that the valve train
determine the cause.
components are kept together and identified so that
they can be reinstalled in their original locations. – Insufficient torque on head bolts
Before removing the cylinder head from the engine – Improper installation
and before disassembling the valve mechanism, – Loose or warped cylinder head
perform a compression test and note the results. – Missing dowel pins
1. Remove camshaft drive gear pulley fixing bolt (3), – Warped case surface
then pulley (4). 2. Inspect cylinder head for cracks, especially between
2. Remove camshaft bearing cap fixing bolt (5), valve seats and in the exhaust ports.
camshaft bearing cap (6), then camshaft exhaust (7), 3. Inspect cylinder head deck for corrosion, sand
and intake side (8). particles in head and porosity.
3. Remove tappet with shim (11).
CAUTION:
4. Use the 5-8840-2446-0 valve spring compressor and
5-8840-2547-0 valve spring compressor adapter to Do not attempt to weld the cylinder head. Replace
remove the split collar (12), valve spring with upper it.
seat (13) and valve (14). Do not reuse cylinder head bolts.
4. Inspect cylinder head deck, common chamber and
exhaust manifold mating surfaces for flatness. These
surfaces may be reconditioned by milling. If the
surfaces are “out of flat” with “round” by more than
specification, the surface should be ground to within
specifications. Replace the head if it requires
machining beyond the repairable limit.
Head surface and manifold surface
Standard: 0.05 mm (0.002 in) or less
Warpage limit: 0.2 mm (0.0079 in)
Maximum Repairable limit: 0.2 mm (0.0079 in)
Head height
Standard height : 133.2 mm (5.2441 in)
Warpage limit : 0.2 mm (0.0079 in)
Maximum Repairable limit : 133.0 mm (5.2362 in)

014RW042

5. Remove spark plug (1).


CAUTION: Do not remove the spark plugs when the
head and plugs are hot. Clean dirt and debris from
spark plug recess areas before removal.

Clean
Cylinder head
Carefully remove all varnish, soot and carbon from the
bare metal. Do not use surface conditioning disc on any
gasket sealing surface.

011RW019

5. Water jacket sealing plugs seating surfaces.


ENGINE MECHANICAL (6VE1 3.5L) 6A–51

Reassembly
1. Install Spark plug and tighten all the spark plugs to
specified torque.
Torque: 18 Nꞏm (1.8 kgꞏm/13 lb ft)
2. Tighten sub gear setting bolt.
1. Use 5-8840-2443-0 gear spring lever to turn sub
gear to right direction until the M5 bolt aligns with
the hole between camshaft driven gear and sub
gear.
2. Tighten the M5 bolt to a suitable torque to prevent
the sub gear from moving.

014RW020

Legend
(1) Intake Camshaft Timing Gear for Right Bank
(2) Intake Camshaft Timing Gear for Left Bank
(3) Exhaust Camshaft Timing Gear
(4) Discrimination Mark
LI: Left Bank Intake
RI: Right Bank Intake
LE: Left Bank Exhaust
RE: Right Bank Exhaust

014RW041

3. Install camshaft drive gear assembly and tighten


three bolts to the specified torque.
Torque: 10 Nꞏm (1.0 kgꞏm/87 lb in)
4. Install camshaft assembly and camshaft bearing cap,
tighten twenty bolts on one side bank to the specified
torque.
1. Apply engine oil to camshaft journal and bearing
surface of camshaft bearing cap.
2. Align timing mark on intake camshaft (one dot for
right bank, two dots for left bank) and exhaust
camshaft (one dot for right bank, two dots for left
bank) to timing mark on camshaft drive gear (one
dot).

014RW023

Legend
(1) Right Bank Camshaft Drive Gear
(2) Left Bank Camshaft Drive Gear
(3) Timing Mark on Drive Gear
(4) Dowel Pin
6A–52 ENGINE MECHANICAL (6VE1 3.5L)

014RW024

Legend (3) Alignment Mark on Camshaft Drive Gear


(1) Right Bank (4) Alignment Mark on Camshaft
(2) Left Bank (5) Alignment Mark on Retainer

3. Tighten twenty bolts in numerical order on each


bank as shown in the illustration.
Torque: 10 Nꞏm (1.0 kgꞏm/87 lb in)

014RW031

5. Tighten bolt for camshaft drive gear assembly pulley


to the specified torque.
Torque: 98 Nꞏm (10.0 kgꞏm/72 lb ft)
ENGINE MECHANICAL (6VE1 3.5L) 6A–53

Valve Spring, Oil Controller, Valve, Valve Guide


Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts

014RW039

Legend (7) Spring Upper Seat


(1) Camshaft Bearing Cap Fixing Bolts (8) Valve Spring
(2) Camshaft Assembly Inlet (9) Oil Controller
(3) Camshaft Assembly Exhaust (10) Spring Lower Seat
(4) Shim (11) Valve Guide
(5) Tappet (12) Valve
(6) Split Collar

Disassembly 3. Remove camshaft assembly (Exhaust side).


4. Remove shim (4) and tappet (5).
1. Remove camshaft bearing cap fixing bolts (1).
2. Remove camshaft assembly (intake).
6A–54 ENGINE MECHANICAL (6VE1 3.5L)
5. Use the 5-8840-2446-0 valve spring compressor and 2. Measure the valve spring squareness with a steel
5-8840-2547-0 valve spring compressor adapter to square and replace the valve springs if the measured
remove split collar. value exceeds the specified limit.
Limit : 2 mm (0.079 in)

014RW042

6. Remove valve spring.


014RS005

7. Remove valve. 3. Using a spring tester to compress the springs to the


8. Remove oil controller and spring lower seat. installed height, measure the compressed spring
9. Remove the valve guide using the 5-8840-2442-0 tension, and replace the springs if the measured
valve guide replacer. tension is below the specified limit.
At installed height: 35.0 mm (1.38 in)
Inspection and Repair Standard: 196 N (20.0 kgf/44 lb)
Limit: Less than 181 N (18.5 kgf/41 lb)
Valve Spring
CAUTION: Visually inspect the valve springs and
replace them if damage or abnormal wear is evident.
1. Measure the free height of the springs. The springs
must be replaced if the free height is below the
specified limit.
Standard : 44.6 mm (1.756 in)
Limit : 43.6 mm (1.717 in)

014RS006

Valve Guide
CAUTION: Take care not to damage the valve seat
contact surface, when removing carbon adhering to
the valve head. Carefully inspect the valve stem for
scratches or abnormal wear. If these conditions are
present, the valve and the valve guide must be
replaced as a set.
014RS004
ENGINE MECHANICAL (6VE1 3.5L) 6A–55
1. Measure the valve stem diameter with a micrometer. Valve Guide Replacement
If the valve stem diameter is less than the specified
limit, the valve and the valve guide must be replaced 1. Using Valve guide replacer: 5-8840-2442-0, drive out
as a set. the valve guide from the combustion chamber side.
Diameter of Valve Stem
Intake
Standard : 5.977 mm–5.959 mm
(0.2353 in–0.2346 in)
Limit : 5.90 mm (0.2323 in)
Exhaust
Standard : 5.952 mm–5.970 mm
(0.2343 in–0.2350 in)
Limit : 5.90 mm (0.2323 in)

014RS008

2. Apply engine oil to the outside of the valve guide.


Using valve guide replacer 5-8840-2442-0, drive in a
new valve guide from the camshaft side, and check
the valve guide height.
Valve guide upper end height: 13.0 mm (0.5118
in)
(Measured from the cylinder head upper face)

014RS007

2. Measure the inside diameter of the valve guide with a


micrometer. Subtract the measured outer diameter of
the valve stem from the measured inner diameter of
the valve guide. If the value exceeds the specified
limit, the valve and the valve guide must be replaced
as a set.
Inside Diameter of the Vale Guide
Inlet clearance
Standard : 0.023 mm–0.056 mm
(0.0009 in–0.0002 in)
Limit : 0.20 mm (0.00787 in)
Exhaust clearance
Standard : 0.030 mm–0.063 mm
(0.0012 in–0.0025 in)
Limit : 0.20 mm (0.00787 in) 014RW046

3. Check the clearance. If the clearance is less than the


specified value, ream the inside diameter of valve
guide. Using a sharp 6 mm reamer, ream the valve
guide to obtain the specified clearance.
6A–56 ENGINE MECHANICAL (6VE1 3.5L)
Valve Seat Contact Surface Angle on Valve Seat on
1. Measure the protrusion of the valve stem when a new Valve
valve is installed in the cylinder head. If the protrusion 1. Measure contact surface angle on valve seat.
of the valve stem exceeds the limit, replace the valve 2. If the measured value exceeds the limit, replace
seat insert or the cylinder head assembly. valve, valve guide and valve seat as a set.
Protrusion of valve stem Valve contact surface angle: 45
Intake
Standard: 39.32 mm (1.5480 in)
Limit: 39.47 mm (1.5539 in)
Exhaust
Standard: 39.3 mm (1.5472 in)
Limit: 39.45 mm (1.5531 in)

014RS012

Valve Seat Insert Correction


1. Remove the carbon from the valve seat insert
surface.
2. Use a valve cutter to minimize scratches and other
014RW047
rough areas. This will bring the contact width back to
2. Measure the valve seat contact width. Make the the standard value. Remove only the scratches and
necessary corrections if the seat contact surface is rough areas. Do not cut away too much. Take care not
damaged or rough or if the contact width wear to cut away unblemished areas of the valve seat
exceeds the limit. surface.
Valve seat contact width Valve seat angle degree: 90
Standard: 1.1 mm (0.0433 in)
Limit: 1.7 mm (0.0669 in)

014RW059

014RS011
ENGINE MECHANICAL (6VE1 3.5L) 6A–57
3. Apply abrasive compound to the valve seat insert 4. Carefully clean the valve seat press–fit section on the
surface. cylinder head side.
4. Insert the valve into the valve guide. 5. Heat the press–fit section with steam or some other
5. Turn the valve while lapping it to fit the valve seat means to cause expansion. Cool the valve seat with
insert. dry ice or some other means.
6. Check that the valve contact width is correct. 6. Insert the press–fit section into the valve seat
horizontally.
7. Check that the valve seat insert surface is in contact
with the entire circumference of the valve. Standard fitting interference: 0.14 mm–0.09 mm
(0.0055 in–0.0035 in)
7. After insertion, use a seat grinder to grind finish the
seating face. Carefully note the seating angle, the
contact width, and the depression.
8. Lap the valve and the seat.

Reassembly
1. Install valve guide (1) to cylinder head. Apply engine
oil to the outside of the valve guide. Using valve guide
replacer 5-8840-2442-0, drive in a new valve guide
from the camshaft side.
2. Install oil controller (3) and spring lower seat (2).
Using oil controller replacer 5-8840-0623-0, drive in a
new oil controller.

014RS014

Valve Seat Insert Replacement


1. Arc weld the rod at several points. Be careful not to
damage the aluminum section.
2. Allow the rod to cool for a few minutes. This will cause
the valve seat to shrink.
3. Strike the rod and pull it out.

014RW058

014RS015
6A–58 ENGINE MECHANICAL (6VE1 3.5L)
3. Install valve to valve guide. Before installing valve Valve Clearance Adjustments
guide apply engine oil to the outside of the valve stem.
4. Install valve spring to cylinder head. Attach the valve NOTE: To adjust valve clearance, apply engine oil to the
spring to the lower spring seat. The painted area of cam as well as to the adjusting shim (2) with the cylinder
the valve spring should be facing downward. head built on the cylinder block, give a few turns to the
camshaft by means of timing pulley tightening bolt, and
measure valve clearance when the nose of cam is just
opposite of maximum cam lift (1) as shown in illustration
below.

014RS020

5. Install lower valve spring seat, valve spring and upper


valve spring seat then put split collars on the upper
spring seat, using the 5-8840-2446-0 valve spring
compressor and 5-8840-2547-0 valve spring 014RW081

compressor adapter to install the split collars. Legend


(1) Cam
(2) Shim
(3) Tappet

Valve Clearance Standard Value (cold)


Intake: 0.23 mm–0.33 mm
(0.0091 in–0.0130 in)
Exhaust: 0.25 mm–0.35 mm
(0.0098 in–0.0138 in)

Selection of Adjusting Shim


Shim to be selected = (Thickness of removed shim) +
(Valve clearance measurement – Standard value)
Based on the above formula, the best suited shim should
be selected from 41 types of shim (differently thick at
0.02mm (0.0008 in) intervals from 2.40mm (0.0945 in)
through 3.2mm (0.1260 in) thick). Install the shim and
014RW042
check valve clearance.
6. Install tappet with shim.
7. Install camshaft assembly.
Refer to installation procedure for Camshaft in this
manual.
ENGINE MECHANICAL (6VE1 3.5L) 6A–59
Replacement of Shim
Let the cam push down the edge of tappet by using
5-8840-2444-0 valve clearance adjusting tool and push
out the shim with a flat blade screw driver as shown in
illustrations below.

014RW084

014RW082

014RW083
6A–60 ENGINE MECHANICAL (6VE1 3.5L)

Camshaft
Camshaft and Associated Parts

014R100028

Legend (6) Camshaft Drive Gear Pulley


(1) Camshaft Bracket Fixing Bolt (7) Retainer Fixing Bolt
(2) Camshaft Bracket (8) Retainer
(3) Camshaft Assembly Intake (9) Camshaft Drive Gear
(4) Camshaft Assembly Exhaust (10) Oil Seal
(5) Pulley Fixing Bolt (11) O–ring

Disassembly
1. Remove fixing bolt (5) for camshaft drive gear pulley
using the 5-8840-2447-0 universal holder.

014RW060
ENGINE MECHANICAL (6VE1 3.5L) 6A–61
2. Remove twenty fixing bolts from intake and exhaust Inspection and Repair
camshaft bracket on one side bank, then camshaft
brackets (2). 1. Use a micrometer to measure the cam lobe height
and uneven wear. Replace the camshaft if either the
lobe height or the uneven wear exceeds the specified
limit.
Lobe height : 44.709 mm (1.7602 in)
Uneven wear : 0.05 mm (0.0020 in)

014RW027

3. Remove camshaft assembly (3), (4) with camshaft


end plug.
4. Remove three fixing bolts (7) from camshaft drive
gear retainer (8), then camshaft drive gear assembly.
5. Use the snap ring pliers to remove the snap ring(1). 014RW043

6. Remove the wave washer(2), sub gear(3) and spring 2. Use a micrometer to measure the diameter and the
camshaft gear(4) from the camshaft assembly(5). uneven wear of the camshaft journals.
Replace the camshaft if the diameter or the uneven
wear exceeds the specified limit.
Journal Diameter
Standard : 25.972 mm–25.993 mm
(1.0225 in–1.0233 in)
Limit : 25.8 mm (1.0157 in)
Uneven wear : 0.05 mm (0.0020 in)

014R100018

Legend
(1) Snap Ring
(2) Wave Washer
(3) Sub Gear
(4) Spring; Camshaft Gear
(5) Camshaft Assembly
014RS023
6A–62 ENGINE MECHANICAL (6VE1 3.5L)
3. Place the camshaft on V–blocks. 2. Subtract the camshaft outside diameter from the
Slowly rotate the camshaft and measure the runout camshaft bracket housing inside diameter.
with a dial indicator. Oil Clearance
Replace the camshaft if the runout exceeds the Standard : 0.027 mm–0.078 mm
specified limit.
(0.0011 in–0.0031 in)
Runout Limit : 0.11 mm (0.0043 in)
Limit : 0.1 mm (0.0039 in)

014RW037

014RW044 5. Replace the cylinder head and/or camshaft if the


4. Measure the camshaft journal oil clearance. measured oil clearance exceeds the specified limit.
1. Measure the camshaft bracket housing inside 1. Carefully clean the camshaft journal, the
diameter. camshaft bracket, and the cylinder head.
NOTE: Tighten camshaft bracket (2) to specified torque 2. Install camshaft assembly and camshaft brackets
before measuring the camshaft bracket inside diameter. (2), tighten twenty bolts (1) on one side bank to
the specified torque.
Torque : 10 Nꞏm (1.0 kgꞏm/87 lb in)
Torque: 10 Nꞏm (1.0 kgꞏm/87 lb in)

014RW031

014RW031
ENGINE MECHANICAL (6VE1 3.5L) 6A–63
3. Measure the camshaft thrust clearance with a dial 3. Align the dowel pin on the sub gear to the clearance of
indicator. Replace the camshaft and/or the the spring ; camshaft gear made in step 2 and install
cylinder head if the camshaft thrust clearance the sub gear (3).
exceeds the specified limit. 4. Install the wave washer (2). Use snap ring pliers to
Camshaft thrust Clearance install the snap ring (1).
Standard : 0.03 mm–0.08 mm
(0.0012 in.–0.0031 in.)
Limit : 0.12 mm (0.0047 mm)

014R100018

5. Tighten sub gear setting bolt.


a. Use 5-8840-2443-0 gear spring lever to pre-load
the sub gear. Turn the sub gear in a clockwise
014RW035
direction until the M5 bolt hole aligns with the hole
in the camshaft driven gear.
Reassembly b. Install the M5 bolt and tighten to a suitable torque to
prevent the sub gear from moving.
1. Install camshaft drive gear assembly and tighten
three bolts to specified torque.
Torque: 10 Nꞏm (1.0 kgꞏm/87 lb in)
2. Install the spring ; camshaft gear(1) into the camshaft
assembly.
Ensure the clearance is between the right side of the
spring; camshaft gear (1) and the dowel pin (2).

014RW041

6. Align the timing mark on the retainer and dowel pin of


the camshaft drive gear.
7. Install camshaft assembly and camshaft brackets,
tighten twenty bolts on one side bank to the specified
torque.

014R100017
6A–64 ENGINE MECHANICAL (6VE1 3.5L)
a. Apply engine oil to camshaft journal and bearing
surface of camshaft bracket.
b. Align timing mark on intake camshaft (one dot for
right bank, two dots for left bank) and exhaust
camshaft (one dot for right bank, two dots for left
bank) to timing mark on camshaft drive gear (one
dot).

014R100026

Legend
(1) Alignment Mark for Left Bank (Two Dots)
(2) Discrimination Mark for Left Bank Intake
Camshaft Gear
(3) Camshaft Timing Gear for Left Bank Intake

014R100016

Legend
(1) Alignment Mark on the Camshaft Gear
(2) Alignment Mark on the Camshaft Drive Gear

014R100027

Legend
(1) Discrimination Mark
LE : Left Bank Exhaust
RE : Right Bank Exhaust
014R100025
(2) Alignment Mark
Legend One Dot for Right Bank
(1) Discrimination Mark for Right Bank Intake Two Dots for Left Bank
Camshaft Gear (3) Camshaft Timing Gear for Exhaust
(2) Alignment Mark for Right Bank (One Dot)
(3) Camshaft Timing Gear for Right Bank Intake
ENGINE MECHANICAL (6VE1 3.5L) 6A–65

014R100023 014RW031

Legend 8. If the oil seal requires replacement, use the


5-8840-2445-0 to install the oil seal.
(1) Timing Mark on the Camshaft Drive Gear for
Right Bank Exhaust Camshaft
(2) Timing Mark on the Camshaft Drive Gear for
Right Bank Intake Camshaft
(3) Dowel Pin

014RW034

014R100024

Legend
(1) Timing Mark on the Camshaft Drive Gear for
Left Bank Intake Camshaft
(2) Timing Mark on the Camshaft Drive Gear for
Left Bank Exhaust Camshaft
(3) Dowel Pin

c. Tighten twenty bolts in numerical order on one side


bank as shown in the illustration.
Torque: 10 Nꞏm (1.0 kgꞏm/87 lb in)
6A–66 ENGINE MECHANICAL (6VE1 3.5L)
9. If the camshaft end plug requires replacement, use
the 5-8840-2445-0 to install the camshaft end plug.

014R100031

10. Tighten bolt for camshaft drive gear pulley to the


specified torque using the 5-8840-2447-0 universal
holder.
Torque: 98 Nꞏm (10.0 kgꞏm/72 lb ft)

014RW060
ENGINE MECHANICAL (6VE1 3.5L) 6A–67

Crankshaft
Crankshaft and Associated Parts

013RW009

Legend (8) Piston and Connecting Rod Assembly


(1) Cylinder Head Assembly (9) Flywheel
(2) Crankcase with Oil Pan (10) Rear Oil Seal Retainer and Oil Seal
(3) Oil Pipe and O-ring (11) Main Bearing Cap
(4) Oil Strainer and O-ring (12) Crankshaft
(5) Oil Pump Assembly (13) Main Bearing Cap Fixing Bolts
(6) Cylinder Block Side Bolts (14) Oil Gallery Fixing Bolts
(7) Oil Gallery

Disassembly CAUTION: Take care not to damage or deform the


sealing flange surface of crankcase.
1. Remove cylinder head assembly (1). Refer to 3. Remove oil pipe and O-ring (3).
“Cylinder Head” in this manual.
4. Remove oil strainer and O-ring (4).
2. Remove crankcase with oil pan (2). Refer to “Oil Pan
and Crankcase” in this manual. 5. Remove oil pump assembly (5).
6. Remove crankcase side bolts (6).
6A–68 ENGINE MECHANICAL (6VE1 3.5L)
7. Remove oil gallery (7).
8. Remove piston and connecting rod assembly (8).
Refer to “Piston, Piston Ring and Connecting Rod” in
this manual.
9. Remove flywheel (9).
10. Remove rear oil seal retainer (10).
11. Remove main bearing cap (11).
12. Remove crankshaft (12).

Inspection and Repair for Bearings


1. Inspect Crankshaft
Set the dial indicator as shown in the illustration and
measure the crankshaft thrust clearance. If the thrust
clearance exceeds the specified limit, replace the
thrust bearings as a set.
Thrust Clearance
Standard : 0.06 mm–0.24 mm 015RS004

(0.0024 in–0.0094 in) 3. Remove the crankshaft.


Limit : 0.30 mm (0.0118 in) Remove the main bearings.
4. Clean the upper and lower bearings as well as the
crankshaft main journal.
5. Check the bearings for damage or excessive wear.
The bearings must be replaced as a set if damage or
excessive wear is discovered during inspection.
6. Set the upper bearings and the thrust washers to their
original positions.
Carefully install the crankshaft.
7. Set the lower bearings to the bearing cap original
position.
8. Apply plastigage to the crankshaft journal unit as
shown in the illustration.
NOTE: Do not set the plastigage on the oil hole.

015RS003

Main Bearing Clearance


1. Remove the bearing caps and measure the oil
clearance.
2. Remove the main bearing cap fixing bolts in the
sequence shown in the illustration.
Arrange the removed main bearing caps in the
cylinder number order.
Remove the main bearings.

015RS005
ENGINE MECHANICAL (6VE1 3.5L) 6A–69
9. Install main bearing caps, oil gallery and crank case 11. Measure the plastigage width and determine the oil
bolts in the order shown, and tighten each bolt to the clearance. If the oil clearance exceeds the specified
specified torque. limit, replace the main bearings as a set and/or
replace the crankshaft.
NOTE: Do not apply engine oil to the crank case side
bolts. Standard : 0.019 mm–0.043 mm
(0.0007 in–0.0017 in)
Main bearing cap bolts.
Limit : 0.08 mm (0.0031 in)
Torque: 39 Nꞏm (4.0 kgꞏm/29 lb ft)
Oil gallery fixing bolts.
Torque:
1st step: 29 Nꞏm (3.0 kgꞏm/22 lb ft)
2nd step 55 65
Crank case side bolts
Torque : 39 Nꞏm (4.0 kgꞏm/29lb ft)
NOTE: Do not allow the crankshaft to rotate.

015RS008

12. Clean the plastigage from the bearings and the


crankshaft.
Remove the crankshaft and the bearings.

Crankshaft Inspection
Inspect the surface of the crankshaft journal and crank
pins for excessive wear and damage. Inspect the oil seal
fitting surfaces for excessive wear and damage. Inspect
015RS006
the oil ports for obstructions.
10. Remove the main bearing caps in the sequence
shown in the illustration.

015RS004
6A–70 ENGINE MECHANICAL (6VE1 3.5L)

Inspection and Repair for Crankshaft Crankshaft Bearing Selection


1. Carefully set the crankshaft on the V–blocks. Slowly When installing new crankshaft bearings or replacing
rotate the crankshaft and measure the runout. If the bearings, refer to the selection table below. Select and
crankshaft runout exceeds the specified limit, the install the new crankshaft bearings, paying close
crankshaft must be replaced. attention to the cylinder block journal hole.
Runout : 0.04 mm (0.0016 in) 1. Diameter size mark (1) and the crankshaft journal.

015RS010

2. Diameter size mark (1).


015RS007

2. Measure the diameter and the uneven wear of main


journal and crank pin. If the crankshaft wear exceeds The diameter size marks are stamped on the No.1
the specified limit, crankshaft must be replaced. crankshaft balancer as shown in the illustration.
Main journal diameter : 63.918 mm–63.933 mm
(2.5165 in–2.5170 in)
Crank pin diameter : 53.922 mm–53.937 mm
(2.1229 in.–2.1235 in.)
Uneven wear limit : 0.005 mm (0.0002 in)

015R200005

NOTE: Take care to ensure the bearings are positioned


correctly.

015RS009
ENGINE MECHANICAL (6VE1 3.5L) 6A–71
Legend
(1) Number 1 and 4 main bearing upper and lower
(2) Number 2 and 3 main bearing upper
(3) Number 2 and 3 main bearing lower
(4) Size mark paint
(5) Tab

015R200006

Crank
Size Mark Crank Shaft Shaft Crank Shaft
Main Bearing Size Mark Oil Clearance
(Cylinder Main Journal Bearing Bearing
Bore Diameter (Crankshaft) (Reference)
block) Diameter Size Mark Thickness
paint
63.918-63.925 mm 2.527-2.530 mm
(2.5165-2.5167 in)
2 Blue (0.0995-0.0996 in)
68.994-69.000 mm
1
(2.7163-2.7165 in) 63.926-63.933 mm
(2.5168-2.5170 in)
1
2.524-2.527 mm
Brown (0.0994-0.0995 in)
63.918-63.925 mm
(2.5165-2.5167 in)
2
68.987-68.993 mm 0.019-0.043 mm
2
(2.7160-2.7163 in) 63.926-63.933 mm (0.0007-0.0017 in)
(2.5168-2.5170 in)
1
2.521-2.524 mm
Green (0.0993-0.0994 in)
63.918-63.925 mm
(2.5165-2.5167 in)
2
68.980-68.986 mm
3
(2.7157-2.7160 in) 63.926-63.933 mm 2.518-2.521 mm
(2.5168-2.5170 in)
1 Yellow (0.0991-0.0993 in)

Reassembly
1. Crankshaft (12)
Install the main bearings to the cylinder block and
the main bearing caps.
Be sure that they are positioned correctly.
Apply new engine oil to the upper and lower main
bearing faces.
NOTE: Do not apply engine oil to the main bearing back
faces.

015RS012
6A–72 ENGINE MECHANICAL (6VE1 3.5L)
Carefully mount the crankshaft. Apply engine oil to the oil seal lip.
Apply engine oil to the thrust washer. Align the cylinder block dowel pin holes with the rear
retainer dowel pins.
Assemble the thrust washer to the No.3 bearing
journal. The oil grooves must face the crankshaft. Tighten the rear retainer fixing bolts. New bolts
should be used when installing rear retainer.
Torque: 18 Nꞏm (1.8 kgꞏm/13 lb ft)
NOTE: Be very careful not to disengage the oil seal garter
spring during installation of the rear retainer.
If the seal was removed from retainer for
replacement, apply engine oil to the oil seal lip and
install the oil seal using 5-8840-2286-0 oil seal
installer.

015RS013

2. Rear oil seal (10)


Remove the oil from the cylinder block and the
retainer mounting surface.
Apply sealant (TB–1207B or equivalent) to the
retainer mounting surface, following the pattern
shown in the illustration.
The retainer must be installed within 5 minutes after
sealant application to prevent premature hardening
of sealant.
015RW001

015RS017

015RW002 3. Flywheel (9)


Legend 1. Thoroughly clean and remove the oil from the
(1) Around Bolt Holes threads of crankshaft.
(2) Around Dowel Pin 2. Remove the oil from the crankshaft and flywheel
mounting faces.
3. Mount the flywheel on the crankshaft and then
install the washer.
ENGINE MECHANICAL (6VE1 3.5L) 6A–73
4. Hold the crankshaft to prevent from rotating then Insert the piston/connecting rod assemblies into
install the bolts in the order shown to the specified each cylinder with the piston ring compressor. The
torque. front marks must be facing the front of the engine.
Torque: 54 Nꞏm (5.5 kgꞏm/40 lb ft) Match the numbered caps with the numbers on the
connecting rods. Align the punched marks on the
NOTE: Do not reuse the bolt and do not apply oil or thread connecting rods and caps.
lock to the bolt.
Apply engine oil to the threads and seating faces of
the nuts.
Tighten the nuts.
Torque: 54 Nꞏm (5.5 kgꞏm/40 lb ft)
After tightening the cap nuts, check to see that the
crankshaft rotates smoothly.
NOTE: Do not apply engine oil to the bearing back faces.

015RS018

4. Piston and connecting rod assembly (8)


Apply engine oil to the cylinder bores, the
connecting rod bearings and the crankshaft pins.
Check to see that the piston ring end gaps are
correctly positioned.

015RS020

5. Install oil gallery (7) and tighten the bolts in 2 steps, in


the order shown.
1st step: 29 Nꞏm (3.

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